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well started to mess around this evening. my software was having a problem generating a Pressure angle of 20 with 28 teeth Module 1 trying to match your clearance (backlash) it was making the software bug out. i guess you must of manually closed off the gear backspacing to add strength to the diff gear which is why the software refused to create the gear profile correctly.

well i decided to try out a 29T diff gear with pressure angle of 20 and module 1 with some backfill to strength the teeth, so i'm running it out and see if the mesh is too tight or not.