ORIGINAL: Flyojumper
So raz54, what did you do? Did you revert to the plastic diff gear and kept the aluminium idler? Did it fix your problem and no stripping since?
Also, did you measure the alum idler versus the plastic idler by any chance? (is the aluminium slightly smaller?) What were the exact dimensions of both diff gears when you measured them? Did you notice the difference I was talking about on sharp pointy teeth for plastic versus more rounded less "meshy" for the aluminium? (even when new)
Phew, I know it's a quite a few questions but I'd really like to get to the bottom of this... If anyone has some input on this, please post.
I didn't notice the difference in the teeth till you pointed it out but yes the metal gears teeth are shorter and rounded looking. I put a new metal idler gear and the old stock diff gear in and have not had any problems since. The stock diff gear measures 26.50 mm and the metal one is 26.30 mm, probably because of the rounded teeth.