Finite element analyses of the dial-dop index gear assembly were conducted to quantify deflection and identify failure initiation sites across three critical studies: attachment point necking, beam deflection under spring pressure, and custom mounting point integrity under multi-point contact loading. Advanced meshing techniques, boundary condition calibration, and linear static solver implementation enabled precise evaluation of sub-micron displacements (10⁻⁸ to 10⁻³ mm range) at stress concentrations. These simulations demonstrate proficiency in geometric preprocessing, contact pressure modeling, and failure mode prediction, confirming robust structural performance without tool dependency.