Rear drive vehicles transfer power to the rear wheels through the Gear Carrier Assembly, which is fit at the central section of the Rear Axle. The Gear Carrier Assembly includes hypoid ring and pinion gears, set at the heart of the system. However, one of the common issues with hypoid gears is gear scoring and whine noise, both of which can seriously affect durability and reduce the overall performance of a vehicle. In this study, the focus is on design changes as well as process improvements to address these problems and at the same time improve gear reliability. On the design side, changes such as refining the macro geometry, upgrading materials, and modifying the heat treatment cycle were carried out. These helped in improving properties like contact stress resistance, bending and impact strength, and also reduced motion transmission error (MTE). From the process point of view, careful control over carburizing, hardening, and quenching temperatures, along with adjustments in quenching pressure, played a major role in improving hardness distribution and the quality of the microstructure. Finishing steps after lapping, like vibro-deburring and manganese phosphating, were also introduced to achieve surface finishes that were very close to ground gears. With these combined measures, noticeable improvements were seen, MTE was reduced, the contact pattern shifted from being center-biased to diagonal-biased, drivetrain losses came down, NVH performance improved, and durability increased. Overall, the study highlights the steps taken to tackle scoring and noise issues in hypoid gears, with the aim of making them more reliable and efficient in operation.