I have always believed the gear should be more than a "light" press fit, more of a substantial press fit. That's the way I've found them when I've removed them. I also believe too light of a fit will lead to roll pin shearing. Which was the topic of another recent thread. I had "assumed" that gears that weren't tight enough had been polished by the owner/mechanic to make them easier to install, never considered they were being manufactured that way. Its stuff like that that has lead me to have the opinion I do of hot rod parts.
The polymer gear would be a good solution for Bdud so he could get that brass gear out of his engine.
Sticky #3 also has a good instruction on how to install the gear.
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