What part of NC are you in? If you are somewhere central, I will be glad to help you figure the machine out. The gear swaps are confusing at first but once you figure it out it is a piece of cake.
I am in Cary, ill post my procedure to make sure I am not doing something wrong. I might need to take you up one that. Ill send Matt an email this morning as well.
The problem is caused by 2 things as far as I can tell: every time I swap the gear couplers, the shafts on the square bolts don't fit anymore. When I tighten the gears onto the quadrant and put the e-clips on, the e-clips bind to the gear causing the nut and clip to rotate with the gear, and tightening it until they lock in place completely.
Here is what I did:
1. Open gear cover
2. Loosen and swing out the quadrant
3. Loosen and remove the square bolts and remove top two gear sets
4. Using a piece of aluminum tap out the gear couplers
5. Using the same piece of aluminum tap the coupler into the new gear then tap the next gear onto the coupler
6. Try to insert square bolts, they don't fit
7. Tap bolts into place, use wrench to rotate them until they can spin freely. This took about 20 minutes each time (3 gear changes total)
8. Put washer between quadrant and gear assembly, install gear on quadrant and tighten down
9. 85% of the time, it would bind. Anytime I tightened it, the bolt would tighten as the gears turned until they were completely locked into place.
10. Read manual again to see if I missed anything, nope nothing there to miss.
Anything there look wrong? Are the gears and couplers supposed to be so tight they have to be tapped out?