that is the second OPDA gear that I am aware of that has failed in exactly the same way
makes me think that something is creating abnormal strain on the gear, possibly the bearings in the unit seizing or lacking lube
I spent a bit of money bringing a brand new Rev E unit to a machinist for disassembly...
Bottom bushing requires oil to defy gravity and flow upward through 4 very small channels, which would work if it was set in some kind of pressurized cavity, however it isn't.
There is a seal in between bushings, so even if oil managed to get into the bottom bushing, it would never make it to the top.
Top bushing has zero chance of lubrication. There is a galley where lubrication is placed from the factory, but the Rev E unit doesn't have a pathway to the inside of the bushing. My machinist removed the top bushing drilled a hole in it that lined up with the galley, and installed a zerk.
Ultimately this is what I would like to see:
1.) A seal at the end of the bottom bushing where the gear attaches.
2.) A seal at the top of the top bushing where the pickup wheel is.
3.) Middle seal removed.
4.) Oil passages at around the bottom bushing sealed.
5.) Zerk with hole in top bushing as described above.
This would create a completely sealed system that is self lubricated. The next problem of course is making sure the cam/OPDA gears are properly lubricated themselves, enter Hesco's high volume oil pump with axillary lubrication tube.