[jhautz]

sounds like your slipper is set too loose and its slipping to much. the excess slip creates heat and that heat softens the spur gear and the spur gear gets trashed.

Just to be clear... your not tripping the teeth off of the gear. You are melting the center out of the gear where the slipper plates meet the gear.

If thats the case you just need to tighten it more. The stock slipper from the old emaxxes was not really adequate for the power of brushless systems and thats whey Strobe slippers were so popular. Now the newer Revo and new emaxx slippers are much beeter suited to handle the power.

I say just get a new gear and tighten it down more this time and it should keep it from melting. The long term solution is to get a slipper clutch that can handle the power.