A) Yes, the new WRX tranny still uses a gear. I wish I had a picture.
B) Hmm, odd that he's having trouble stuffing the gears in. Maybe it's the whole main shaft setup that drops into our transmissions? I remember hearing that the internals would drop in, didn't know if it was the gears or the shaft set.
C) The WRX gears are not stronger than ours. If it's true that our gears are shot-peened, then we are already another step ahead. No WAY could a stock WRX transmission handle 300awhp, not a chance in HELL. They can't even handle STOCK power.
I really think everyone is overestimating the strength of the WRX gears, and underestimating the driver skill of said gearbox. The gears are TINY.
If you take advantage of the stock power levels of the WRX (and the advertised 5.4 second 0-60), you'll risk blowing the tranny. My friend did, and nearly sued SOA for not covering it under warranty.
Look at this picture. A comparison of the RA gears and the stock WRX gears.
The RA set is on the right (and broken), and the stock is on the right (with a chipped first gear drive tooth). Look at the tininess of the gears!
Now, a little Transmission 101: No chipping teeth actually occurs. It's sheering teeth that actually happens. The gears are always meshed, always spinning. The gears are stationary on the shafts always engaged, and when you move the shifter it just engages a collar against a gear. On the lay-shaft (constantly spinning as long as the clutch is out) the gears are fixed. They don't move. The gears on the main shaft are sitting on bearings. This is what allows all of the gears to be constantly meshed. Using dog teeth, it simply meshes with the gear and engages that specific gear. Now, dog teeth are STRONG. When you grind a gear, that's what's grinding, not the gear itself. I won't get into synchro's, as they don't have much to do with the strength of the gears in a box.
A grinding transmission means the dog teeth are being abused and hurt, not the drive teeth.
SO, breaking gears, really is all a factor of the gear itself, not so much the driver. While you CAN butcher the shifting enough to do some real damage to the gear, the synchro's usually prevent you from shifting so fast to do that. Flat shifting the transmission (barely lifting the clutch and burrying the gas to the floor) will hurt stuff, but even still.
Synchro's get in the way of breaking lots of stuff. Trannys without synchros (called dog boxes, because they are just the dog teeth engaging without any help), are built with strong enough gears to handle the shock associated with a flat shift.
So you see, a broken gear is 95% the result of a weak gear, not driver mishap. The biggest load a gear will see, is when the dog teeth engage, and even that is pretty fluid thanks to synchro's, the clutch, and proper driving technique. 99% of the shift-induced drivetrain shocks are when there is no throttle applied after the shift. Like when you do a WOT pull through 2nd gear, shift to 3rd and don't give it gas when you let off the clutch, that kind of shock. A WOT pull kind of shock comes from dumping the clutch on a shift or flat shifting. No one in their right mind would flatshift a car they want to be able to drive home, and dumping the clutch on a shift still doesn't shock TO much, unless not enough throttle is applied, again.
The stock clutch is pretty forgiving on a WRX, so lots of those shocks (like the WOT clutch dump shift) are absorbed by clutch slippage.
The gears are just tiny and weak, and that sucks

. The case is nice though!
Sorry for the long reply.