Originally Posted by SierraHawk
The two teeth were not broken off near the edge of the tooth were I would have expected if the damage was caused by abuse. I am 62, retired and, like most of you, do not drive my van in an aggressive or abusive manner.
It looks like the base of the pinion teeth were stressed so severely that they literally pulled steel out of the pinion body. Did the wrong set up on the pinion cause so much force on the body of the tooth that over time the steel fatigued and caused the tooth to literally pull steel out of the pinion body at the base of the gear? Or is there another explanation like the gear itself was flawed?
The wear at the inboard edge of the ring gear teeth tells me setup was off, or something moved. The bearing marks on the pinion shaft lead me to think the setup changed, probably because the pinion nut wasn't tight enough.
The pinion teeth were point-loaded by the edge of the ring gear teeth.
When my pinion gear broke (on my 4.30 set) it was from a hard impact, after I had already weakened them by severely overheating them.