This paper presents an approach for the determination of conjugate pinion tooth surfaces of hypoid drives and the analysis of pinion mismatch. The conjugate pinion tooth surface is compared with the tooth surface of the pinion manufactured by the machine tool settings obtained by the local contact synthesis. The analysis of the mismatch provides a quantitative verification of the pinion surface modifications and complements the existing tooth contact analysis. A numerical example is included in the paper to demonstrate the analysis of pinion mismatch and tooth contact.

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