Here is an update on what I have done...
1.) Purchased new OPDA.
2.) Brought new OPDA to machine shop where it was dissembled and analyzed. As others have discovered, at the factory lube hole for the upper bushing there was lube. However, in my case and in others, there was no way for that lube to EVER enter the busing. Machinist removed the upper bushing and drilled a hole in it that lines up with the reservoir cavity that surrounds the bushing. He reinstalled the busing so that the new bushing hole was on the opposite side of the new zerk, so that the reservoir would fill up with grease.
3.) Machinist compared the stock rev E gear to a Napa Eschlin gear and said they were the same, same hardness, same weight. So he just reinstalled the stock gear.
4.) On the new OPDA, there was quite a bit of play 1/8 or so between the gear and the assembly. I didn't even take the plastic key out before I gave it to the machinist. It was almost as if there was the same amount of play as those who have posted pictures with a replaced gear. However, this was with the stock gear. Rev B OPDA does not have this much play at the gear.
5.) Installed new re-engineered OPDA and took it to the stealership for syncing. I just wanted to make sure...
6.) Purchased Hesco high volume pump with auxiliary oiling tube pointing directly at the gear. Plan to install this next weekend.
7.) The only real concern that remains is the oiling of the bottom bushing. Engine oil is supposed to get sucked up through 4 little passage ways up, around, and over the top of the lower bushing. The machinist thought that the lower busing must sit in a pressurized oil cavity to force oil up through those passages, but that isn't the case. Perhaps the Hesco pump's active oiling of the gear will cover this thing in oil enough that oil will get sucked in for the lower bushing...
If this doesn't fix it, F the heep... I will take pictures of it on the bottom of a lake and post!!!!
Last edited by speed_phreak; 09-14-2010 at 10:23 PM.