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1) We had to use a 3-4 ft lever arm to remove the chuck from the rest of the gearbox. IIRC, we chucked up a large hex bolt, grabbed a wrench and a really long lever arm, and started turning. It eventually broke loose.
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The chuck/gearbox shaft isn't threaded, correct? I attempted the long lever trick this morning, and broke a Craftsman ratchet.

I'll have to try again with a regular wrench or a stronger ratchet.
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we have used this with direct drive and we have been extremely happy with this system.
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What size wheels are you using? Do you have any other gearing? What speed does this make the robot go?
We have thought about this, as it would elimate a lot of weight, as well as some of the problems with chain and sprockets.