What is a sign of improper gearing alignment in a hypoid gear set?

In a hypoid gear set, improper gearing alignment is often indicated by excessive face contact. This condition occurs when the gear teeth do not engage properly, leading to increased surface contact area that can cause premature wear and potential failure. When the gears are misaligned, the load is not distributed evenly across the teeth, which can create hot spots and lead to excessive wear patterns.

Excessive face contact can result in higher friction, increased heat generation, and ultimately, shortened lifespan for the gearing system. This highlights the importance of precise alignment in maintaining not only the performance of the gear set but also its durability and reliability over time.

Even wear across the teeth, for instance, would suggest that the alignment and contact pattern are appropriate, while whining noises might indicate issues related to lubrication or other mechanical failures. Low resistance when rotating might suggest that there is insufficient contact, which can also lead to different types of wear or inefficiencies, rather than implying that excessive contact is occurring.