So, I'll just be running with a missing tooth?
I appreciate the help.
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ok, if it were me, I`d repair/build it better now than later. going with a newer 08+ axle assy.
BUT, if you absolutely have to get it back on the road now, and need a bandaid at least change the cross shaft pin, and clean it up.
but you won`t know the extent of the damage until you get into it. so there is going to be down time no matter what you do. if you discover your ring gear and pinion are toast from metallic wear, it is not a matter of if, it`s a matter of when.
Yes, you will be operating with a small 1/8" corner off the tooth. I did the same thing to remove my CS pin, or your looking at removing the whole carrier, removing the ring gear and starting over setting everything up.
so you need to decide how, and what you want out of the truck and proceed. This is a well known issue with Titans, especially the early ones.
My spyders were shedding metal at a very young age. I didn`t waste anytime looking in to it and taking care of it.
by the time you realize what will fix it for the long term, you`ll be changing the diff or axle assy for sure...
since your 4wd, mine wouldn`t work for you with the 2.94 ratio.