- Joined
- Aug 19, 2001
- Messages
- 10,904
- City
- So. Calif (SFV)
- Vehicle Year
- 1990
- Engine
- 2.9 V6
- Transmission
- Manual
- Tire Size
- 35x12.50R15
I ground my 5.13 8.8 gear. It was probably between 1/16 - 3/32" that I had to take off the very tip of two teeth. You could probably go as much as 1/8" before you'd start getting into the tooth contact area.
As for it causing a stress riser, there's no load placed on the tips of the teeth, so how could it be stressed there?
Also, there are two styles of notched pins (one is "stepped" (usually factory), the other has a center cutout (aftermarket)). Neither is as strong as a solid pin. Stress is put on the entire length of that shaft, no matter where it's notched.
As for it causing a stress riser, there's no load placed on the tips of the teeth, so how could it be stressed there?

Also, there are two styles of notched pins (one is "stepped" (usually factory), the other has a center cutout (aftermarket)). Neither is as strong as a solid pin. Stress is put on the entire length of that shaft, no matter where it's notched.