A method for remanufacturing pinion member of large-sized skew bevel gears using a CNC machining center and respecting an existing gear member is proposed. For this study, first the tooth surface forms of skew bevel gears are modeled mathematically. Next, the real tooth surfaces of the existing gear member are measured using a coordinate measuring machine and the deviations between the real and theoretical tooth surface forms are formalized using polynomial expression. Moreover, the tooth contact pattern and trans…