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In this research, a new differential gear assembly of an agricultural vehicle is developed by considering the manufacturing cost. A new design of the assembly together with its associated manufacturing process is proposed to minimize the machining cost and the material cost. The new design is characterized by both the pinion bevel gear having a fiat back face and the assembly case having a slot for the pinion bevel gear and a sprocket for power transmission. The preform of the assembly case is hot forged to save material loss and finally cold sized after machining. The new assembly is made and its function is verified to satisfy the basic requirement.