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You do have some wear I see on the "Ring gear" though the "pattern" on the pinion is a good one. How are the bearings ? You should be able, by using a flashlight to look at the bearing races and see if there is any grooves or other wear patterns on them. If there is then don't use it.

Take it back then. Tell them your concerns and show them what you're talking about. If you don't trust your differential, you will not have good travelling experiences as you will be worrying about the differential blowing up. That kind of nagging feeling can ruin any road trip.

If you had worked in the industry you would know that the factory says this to prevent the gear set from "singing" (making noise). Most customers of light vehicles do not like noise coming from their differential. Now big trucks owners like longevity over noise. Setting the gearset to a...

Recommended by who ? In all the rebuild shops I worked in, gearsets are set by the gear pattern. Not some arbitrary number. You use the backlash as a "guide" , not the "be-all end-all" . Thats the difference between "book" learning and "real life experiance" .

Actually I've seen backlash measurements of .016" to .020" on older gear sets that only needed the bearings tightened up a bit and the backlash reset. You will get small amounts of wear on larger bearings like .001" to .002" due to normal wear. So figure your gearset has run 100,000 miles. Thats...

If your gears look OK and the bearings are OK, run it.

When I was rebuilding differentials on a daily basis, I never went past .016" for backlash. Even on the most worn gears. Anything past .016" just brings problems down the road with the gears "slamming" into each other when shifting manual transmissions or going back and forth between reverse and...