Thanks for the comments.
The gears were not spaced apart. However we did grease/oil them. We greased them about once a regional.
The transmissions were sealed pretty well from leakage. They were not full of oil but if FIRST saw a little oil on the carpet the wouldnt like it... And yes our robot was uprighted several times and we never found any oil spots on the carpet
The non-engaged ball bearings didnt seem to cause much friction at all. The only time the ball bearings could accually enter the slots in the gears is when one hole is |- | upside down like this, so gravity can pull it out.
Even then |O| both the slots and the holes would have to do so at the same time. As soon as that would occur the ball bearings would just be forced back up in the shaft. I have easily pushed the robot along the floor when the robot is in neutral.
The transmissions are still working great! So far the robot's transmissions have been through 2 regionals, nationals, and 3 minis. We have only had to oil them and check set screws! Never even had to change a CIM motor!
The only drivetrain related problem we had this year was a shattered 4 wheel drive sprocket. Not a big deal considering we still made it up to the top platform with 3 wheel drive and it was just a practice round...
Next year we are going to make it even better!
www.tigertrons.com/2004/transmission222 Link includes Powerpoint,white paper, and Chiefdelphi Links.