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I tried a few more combos of speedo-odo units and gears: Re-flowed some more solder joints, blew them out lightly with air, inspected carefully for broken bits, micro-drop of grease, checked assembled units by spinning the rotor with a pick ....
Similar results to before: one 1989 odometer works with an old 25-tooth gear, in multiple 15-tooth pods, but does not work with any of the new gears (including one not from odometergears.com) on various pods and with various rotors. This remains a mystery to me.
During these inspections I noticed something I'd overlooked: One of the odometergears.com 25-tooth gears did not have a boss* on the bottom. So the bottom of the gear was flush instead of being raised and the rotor had to turn it on this larger surface.
I exchanged emails with Dave Barton (davebarton.com) and Jeff Caplan (odometergears.com). Both were helpful. When I identified the problem with the one gear, Jeff mailed a new gear immediately no questions asked.
What I haven't done:
1. Tried the newest gear
2. Followed Ken C's suggestion that I try a matched gear set
(my test bench is installing a unit, sans case/bezel, in a car and running it on a lift)
*Boss: not sure what the right word is here. The gear should have a slight extension on the bottom that the gear rotates on.
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240 drivers / parts cars - JH, Ohio
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