[Jeff K.]

It might've just been a defect. When our team got the kits, we never really noticed that. I believe that they also come with an extra clutch or two, so you could just use those.

But if you're talking about the square holes not lining up, that's normal. It's a clutch, it's doing its job. The clutch is the connection between the output shaft from the motor/servo to the shaft that goes to the gear or wheel. When a certain resistance is applied onto the output shaft, the clutch would disengage and the motor would not burn out or strip an internal gear or two.

That's sorta a basic explanation of what the clutch does..

Hope that helps.