[Jack21]

Factory engines do go 100k+ miles without distributor gear problems, but the gears and cams are matched at the factory. Aftermarket hydraulic roller cams for street motors is when this distributor gear construction became an issue. Ford 302's began using hydraulic rollers in '85, and in 351W's in '93. Used the factory steel distributor gear for a roller motor and have had little trouble.

After 14,000 miles, the gear is showing more than normal wear, so I'm replacing it anyway and check it once a year.

Do like your idea of honing out gear so that it's a slight interference fit rather than a press fit, and use same pin hole, and that's how I'll do replacement.

The initial swap, I heated gear on stove, put distributor in freezer, slid the gear on quickly and it worked.