I understand your frustration in striping the gears. The instruction settings are a guide. Note the instruction have no reference about what motor or surface the settings are for. You may need to go looser on the settings or to a softer motor. Why do you insist on using a 5.5t when drivers like Bayer and Savoya are using 6.5t/7.5t with success?
Personally I have not stripped a gear yet, but I am on to my third kit for the year.
I have offered to replace this gear if the new owners do strip/break it. No one has been back to me for a replacement. All these drivers do race at my home track.
Their is a new slipper pad and spring in the XB4 '14 kit. Maybe this combo may help you reduce the breaking of the gears. Something has to give or break. If you go to all metal gears, the driveshaft may break. Fix that, then the wheel hexes may stripe out. Fix that, then you start breaking teeth off the spur gear. Then people start complaining the car is too heavy.
My team mate at our home track has done a few gears over the last few meets on our new track layout (4 week old) but had not done one in the first half of the year. The track had sugar applied to the surface since our club hosted the states titles last week, so the traction is ready high. We both lap at the same speed and use the same motor/esc combo. We are putting it down to driving technique. We have two new technical sections on the track. A table top that leads in to a triple jump, then into a 180deg turn. I think this is where it is happening for him. If you over shot the triple you find yourself jamming on the brakes to make the turn. If you are landing with your brakes on and the slipper tight, then something must give.
Here is a video of the track. The traction level is a little lower from the practice days fully sugared (2-3sec faster) because of the rain we had over night.