[les chortos]

We had similar issues - but we found as the gear boxes were shifted more and used more -some of the rough "machining " burrs and such came off and they worked pretty consistant. From what I saw you need about 1-2 hours of driving on the chassis and a lot of up and down shifting to "break them in" - also the battery issue caused us grief. - you definitely need lots of juice if you want them to shift 10-20 times during a match. - we also programmed a slight delay 100 milliseconds 1/10 th second from the time the shift button was pressed to the time the gear would shift. - this would remove the load from the 2 gears in mesh and give the servo an easier - lesser load - to overcome when shifting. Basically if you were in a tough pushing match (low gear) and wanted to shift to high gear- the servos need to over come the gear loads- it would be very hard to do. - but by adding a delay in the motor power- it relieves the gears loads and thien slips into gear smoothly. - try it.- ask your programmer- to add a .100 second delay in power to the drive motors. pwm=127 or "0 rpm" . shift servos- then add power again. it should slip into gear within 1 or 2 eye blinks and go - it will appear to be seamless and not slow you down much- if at all.

good luck!