Is the gear attached to a metal shaft? If so, the hole in the plastic is slightly undersized, which is why it cracked.
To fix: Note how the gear fits on the shaft (pictures are good!) then pull the gear off the shaft. Apply epoxy to the crack and clamp it shut. (Don't get any epoxy on the teeth! Allow plenty of time to harden. Then file off the excess. Determine the diameter of the shaft. A micrometer or drill index comes handy here. Enlarge the hole to the determined size. I would use the appropriate size drill bit for this, as opposed to filing it bigger. Slip the gear back on the shaft and epoxy it in place. Again, allow sufficient time to harden and then file off only what is necessary to allow proper operation. Put the shell back on and you are done.
BTW John, I agree with your assessment: More will follow. This is a design and assembly issue, not a one-off.
Chris
LVHR
