Dana 18 Chipped Intermediate Gear

I have a spare intermediate gear for my Dana 18. I would like to use this gear for a tapered bearing conversion but the only problem is one gear is chipped. It's a small chip on the very top of one of the gears. Should I buy a NOS gear or can this one be repaired with a file?

 

find a better shape gear . before you spend money on machine work

 

I agree, it's not like they're uncommon. Find a good NOS or used one before you spend the $ on the conversion machine work.

 

x3 I wouldn't use that gear

 

x4. Definitely not worth putting ANY money in that one and not worth the potential risk to the transfercase running it. Lots of good used ones available.

 

I agree with the others, I'd bet if you check it with dye penetrant, inexpensive to do or have done, you will find it is cracked. If that "came from together" while the tcase was in motion- No bueno!