Front Sprocket on 07 Avenger

[glen1971]

So while cleaning up my chains after this year's first hunting trip, I found a couple of issues...
I heard a noticeable "clunking" sound while up north. While in the bush I attributed it to several stiff chain links. I worked them as free as I could and managed to finish up the hunt.. While removing the chains to clean them, I naturally dropped half the master link in the bottom, so I gabbed a magnet to pick it up. I grabbed it and a half moon piece of metal. After scratching my head as to where it may go, I found where it actually came from. Apparently a couple of years ago, when I replaced the chains from the 2nd to the 3rd wheels (first single 60), I went with the cheaper route on chain (verified by receipts) and the rollers had split. Upon checking, I lost 5 rollers.. I checked and I musta done both sides with the same chain.. I'll be replacing them with the heavy duty chain that I used when I did the remainder of the chains (Tsubaki)..
Then after I pulled the front chain, the sprocket looked a little shinier than the rest. I looked at it, and each set of teeth are about as wide as my son's mountain bike gears.. After going through the maintenance books, I pulled the axle (what a fun one that is) and removed the sprocket - it's toast... I'll be ordering one tomorrow, and was wondering:
1) What may have caused this? I thought I read somewhere that this sprocket is supposed to be floating, to help with chain tension. Is that true? If it is, should I even bother re-installing the set screw?
2) Should I order a new idler shaft? The teeth don't look damaged, but I don't want to get stranded in the middle of no where.
3) The bearings look good and I should know better tomorrow morning when I clean up the axle. I didn't damage the seals when I took the axle out. Do I need to look at replacing any of them while I'm at it? Are any of them a "one shot" deal?

TIA....

[JoeMeg]

The sprocket on the jackshaft that is supposed to "float" slid over and got stuck causing some strange popping noises in my Conquest. Here was the result. This is my brake rotor that needed replaced.

[glen1971]

UPDATE...
So this morning I checked to see if I needed anything else, before ordering the sprocket.. I noticed that the Idler Shaft seemed to move a lot in and out in the bearings on the same side I was having front sprocket issues. Also I found the Idler Sprocket moving a lot in and out on the shaft. I decided to pull the shaft and found one of the outboard bearing set screws had almost fallen out. I checked and didn't see either of the retaining clips on the Idler Shaft for the sprocket. This would explain some of the markings I saw on the brake disc. I checked the other side and the shaft is tight, but the clips don't seem to be there either..
So after talking to Argyll, I have a new brake disc, front sprocket, Idler Shaft, Idler Sprocket, bearings and clips coming.. Not sure how the retaining clips broke off, but they aren't on either side now.. Since I have to pull it and install the clips, I figured I'd replace the bearings on the other side at the same time, then clean them up and keep for a spare if needed.. If the new shaft comes in and looks the same as the original, I think I'll keep the original as a spare.. Might get me out of a bind some day, but I hope to never have to do this again..

On a side note.. The repair manuals are AWESOME and spot on for directions.. When they say to do something, follow it, or else close the doors and windows, cuz you'll be frustrated.. The only thing I found was to remove the front axle, if I had taken the bolt and bracket off for the bilge pump first, I wouldn't have fought with it until the end..

[glen1971]

So today I got the parts I needed, including a new idler shaft, which is more of a "just in case".. According to what I've seen, the Idler sprocket is free floating. The new shaft has 4 grooves on it for the snap rings to lock it in place. The manual I saw shows the Right shaft using grooves 2 and 4 (1 is closest to the spline) and the Left shaft uses 1 and 3. Comparing my two older shafts to the new, it looks like I have grooves #2 and 3. So from this, can I conclude that the older shafts only utilize one snap ring per shaft, with the Right shaft being on the inboard groove and the left on the outboard? This would put the snap rings on the smaller diameter of the sprocket in both cases..

[glen1971]

Update:
Shafts and sprockets are back in... Original left shaft was toast, as the sprockets to the front chain were worn.. Chains, clutch, belt, and brakes going in tomorrow, then take it for a short test run down the street. Woulda been done today, but I learned two things while re-assembling... Start the set screws in the bearings before installing them.. And dry fit/test fit everything before installing.. Cost me some time and nylock nuts to learn these ones. It's been a good learning, but hopefully this is the last time for awhile to do all this!

[glen1971]

Got 'er done in time for round 2 of hunting season.. Took it over to a gravel parking lot to give it a listen and it seems to run as good as new! Learned a couple more things. The screw holes on my brake fan shroud aren't slotted as described, but I could move it enough by loosening. Don't put the outboard snap ring into place on the left side until after the brake disc goes in. I always forget how "fun" the idler chain master links are until I do them.