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I have never seen a sprocket failure on a power feeder.
I have seen gear failures internally.
That roller is really dried out, no wonder you had an issue with it.
You'll really like your new polyurethane rollers..............Regards, Rod.
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Are the tires providing inconsistent pressure as they turn? Some things that could cause it;
1. Bad bearings.
2. Bent shaft
3. Out of round tires
4. Tires softer on one side
You should be able to set up a dial indicator against the tires and run them. Check high, low and center.
To check for softness tap with a small ball peen hammer.
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