It would have been helpful if the OP had gotten back on this thread and updated on the results of getting and installing the new parts PM were sending him.
I have been extremely busy. It did help, but it doesn’t solve the chunkiness. As others have mentioned, this is going to happen with use, taking too deep a cut and stopping the lathe, or the gears not being properly meshed and it jumping out of gear. Unless the gear sets are bored and a nice replaceable bearing material could be inserted in the gear bore, it’s going to happen again. In the name of transparency, I had a crash the first year I owned it. Did this cause it? I’m not sure, but the problem got a whole lot worse rather suddenly with no crash, or abuse.
The gears are not made, or assembled nice enough to have a forever fix. It’s going to be up to us as machinist to either upgrade the gear set and shaft, or be very careful and understand it will take some finesse to get the gears to mesh properly.
The problem is absolutely the gear set bores are too large and possibley not concentric, or both. The easiest fix would be to turn a new shaft and cut a keyway that fits better.
I will be sure to measure the old parts and the new parts and report my findings. I have acquired a mill. I will do better about trying to come up with a fix that we all can achieve without replacing parts. It should be simple for the pros here. I believe I can accomplish it and I’m far from a pro.
Give me some time to measure and document everything. I will disassemble and compare it all.
I will try to get the old parts to work like new in my lathe. I have learned a lot since this thread. Once I achieve a fix I will gladly post it here. I wouldn’t order new parts, unless yours is 100 percent non working. All gear head lathes are like this to some degree.