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I have an idler gear that looks good but the shafts show they have some wear when you put a micrometer across them. The unworn area is 0.750” with 0.0005” loss of diameter on the long side and 0.0015 on the short. Is usable or just bin fodder? What would you say are the limits of acceptable?

D

They are readily available so ditch it.
Idler gears/bearings take a lot of abuse and don't half make a mess when it all goes wrong.