I was finally able to pull the govenor out of the transmission.  As expected, the plastic teeth were ground off of the gear.  The "lands" of the govenor body look great - very smooth. I took the gear off, oiled up the govenor body and slide it back in, to see how easily it turns.  I don't see any problems with it.  However, I remember when I installed the first time that I tapped on the center of the cover with a hammer to get it to seat fully.  After a little reading, I now believe the cover is what keeps the govenor in place and I'm thinking that I may have bent the cover in ever so slightly, so that there was no clearance between it and the govenor, causing too much drag and causing the gear teeth to break.  What do you guys think?

My currrent plan is to get a bronze replacement gear and to "work on" the cover a little to get a little clearance (or buy a new cover).  Problem is, when it's installed, there is no way to measure clearance.  Does anyone have other suggestions for me?

If you knock the center of the gov. cover in too far, it will bend the end of the gov., by the weights, which would be obvious. There should be some end play in the gov, but it's not really critical.

I didn't go back and look at your original post, but, was the gear ever damaged before? If so, unless the old pieces were removed, they can float around back there, and get caught up in the new gear, and damage it.

Take a good look at the end of the gov by the weights, and see if it is bent inward. If so, then you might have distorted it enough for the weights to hit the cover as they spin outward. Check the inside of the cover for scratch marks from the weights.
Check HERE

I would still recommend going back to the orig. weight/spring set-up, if for no other reason than to eliminate that as the source of these problems.     Adams' Apple38907.8471412037

Thanks Adam.

Any ideas on the best way to clean out any teeth particles that might still be in the tranny?  I thought I would drop the pan and change the ATF, but while the pan was off, I would spay a bucn of carb cleaner into the governor opening, followed by a bunch of ATF, to hopefully wash everything out of there.  The problem is, I have no idea whether the cleaner/ATF I spray into there would take the particles to the pan (good) or lead them to another part of the tranny that would be more detrimental.  Anyone know or have better ideas on how to go about this?

Unfortunately, the only way to get any remaining shrapnel out of there is to remove the tailhousing! Sorry!
There is a small opening back there in the case that will allow smaller "parts" to wind up in the pan, but the gear pieces normally won't fit thru the hole.