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You must have got a bad one. I have torqued on mine pretty hard and never had this issue. Don't get me wrong I'm not a fan of new star but this particular part isn't absolutely horrible.
I had a few new star seals that didn't really want to slide over the spindle. Had to hit the inside of it with a file. I have had them make the outer bearing hot because they were warped. So far I haven't had the key tab break off.
Unfortunately, new star is about the only option with...
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