gearing design calculation question

[caffel]

487 stripped a cluster gear in the Atwood gearbox.
Its not clear why, but we'd like some advice on the design.
We used the old motors and the plastic housing from the Atwood jack. We took the 80 tooth steel gear and welded it onto a new output shaft. This gives a free speed of 450 RPM.
This new 5/8" output shaft goes straight to the wheel.
We may or may not have adequate alignment and spacing of the shafts and we are worried because its too late to change it.
Basic Transmission design question:
Using the Atwood 'copper' cluster gear, there is 11 nm torque coming in to the cluster gear's 16 tooth output. (2.2 x 44/9)
The 80 tooth spur gear is mated to the 16 tooth on the cluster gear and that increases the final output torque to 55 nm.
The steel spur gear has a face width of approx .375".
Question: Based in using the 'coppery' cluster gear (rated at 90,000 psi) and the stock spur gear 32 dp, hardened steel, 80 teeth, 3/8" face width, are we overloading this step in the gearing?
If we could get 1/2" face width, would that put us over the top?
We must replace the stripped shaft/gear assembly, but we'd like to make the new one more reliable.

Thanks, Charlie Affel, Team 487