We have bought several of these over the years and most recent one bought about 6 months ago started skipping horizonatal areas of the incoming fax. It makes part of the fax unreadable due to some sectioned being eliminated and running together.
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Although it fit the broken fuser, it does not mean it's ok.
1-they must have the same number of teeth ( diif. gears have diff. amounts of teeth)
2-it must be the same diameter ( so they can mesh together, otherwise it's touching the tip of hte teeth and may be skipping.
But I'm not sure the double image is coming from there, it would jam the paper because the timing is off.
Anyway you need to eliminate the obvious then see what happens, I think you said you had another tonertry putting that in, if it doesn't work then change the gear for the correct one.
I have a brother intellifax 770 and I bought it used so their for I do not have the owners manual and I am having trouble setting it up and getting it to work. I can fax out but I just can't recieve faxes I can fax my daughter but when she faxes me she gets an error of 388 but she is able to fax and recieve faxes so we know her end is not the problem.
It sounds like the CIS (scanner) has failed in both machines. Its no generally not a common problem. I would change one every six months if I was lucky.
It may point to something in your environment. I have have seen rust build up on the contacts of the scanner cause this problem. So if you have high moisture or are close to the ocean this maybe a problem.