Front pinion replacement.

[Monkeypirate]

Hello Everyone! When I disassembled my M2 years ago, I found a broken tooth on my front pinion. The ring was intact. I had ordered a new pinion at the time and have finally gotten around to putting the front axle together, Or trying to at least.  I have a problem with the engagement of the gears. When i took the diff apart there was 3 shims on the pinion carrier totaling 0.010". After installing the new pinion with new bearings and cups, I could not bolt the axle half together due to ring being to close to the pinion. I had to shift the ring 0.055" away from the pinion to get the correct back lash. the problem is that when I check the tooth engagement it is only contacting on the very tip of  the heel on the drive side and the toe on the coast side. I tried adjusting the pinion location to get a better contact but in order to move the contact closer to the center of the ring gear I have had to add 0.130" of spacers. This seams like its extreme to me and even with this much space I still don't have the best engagement.  So the question I have is has any one had any issues replacing the pinion  and should I just go ahead and run it with  the odd contact or put the 0.130" of spacers on the pinion? I don't think it will be to much of an issue being as the front drive will most likely never be used.  Id just like an opinion of some one with a little experience dealing with these axles. 
Thanks,
Will.

[Monkeypirate]

Here is a look at the pattern. The first 2 picks are with the pinion spaced out 0.031" the 3rd picture is with the pinion spaced out 0.130". Im thinking it should be fine to run with the first patern as im not going to be doing any off roading with it.  But any advice and opinions are welcome.

[8683jb]

I think it's a grenade. Those gears will eat themselves alive in pretty short order. And there's so little contact that another broken tooth is almost a certainty. I'd do whatever it takes to set it up properly while it's out and apart. You may not plan to run the front end much, but the next guy might!

Jon

[Jesse]

I would ask around and see if any of the dealers have a matched set.

[Monkeypirate]

Definitly want to getit right. Its been expensive to get it to this point , id hate to trash it over a poor adjustment. If it cant be  brought into spec I will probably just leave the 3rd member and axles out. Later i can find a used set of gears. I dont think there is going to be a new set available anywhere for what i would consider a reasonable price.

[Monkeypirate]

So after talking to many people aboutthis im going to try to locate another pinion. If anyone has one let me know. Good used or whatever. The one i installed has a number on it but not sure if it means anything. Looks like 6Q157 and 3-43 below it.i was thinking a part number and date maybe?

[Torque]

The first 2 pictures you are checking the pattern on the wrong side of the teeth. Well, maybe not depending on which side you are looking at.

[Monkeypirate]

Yea, pics are not the best angle. Just wanted to show the drive and coast sides. But either way the gears only contact on the heel and toe, nothing in the center no mater how i move the pinion. Fairly sure i have the wrong ratio pinion. I will just get another pinion and see what happens.