To date, plastic gears are continuing to displace metal gears in a widening arena of applications. Plastic gears are presently not just being used for light-stacked applications but also in automotive starter gears, turbo actuators, and electronic throttle control. Despite of the benefits of plastic gears including noiseless operation, low weight, and working without lubrication, the occurrence of wear in plastic gears limit its application particularly in higher contact force during the operation. Therefore, in this study an attempt has been made to study the applicability and practical ability of using glass fiber in plastic gear in order to reduce the wear failure in plastic gear. The integration of Taguchi Method and Principal Component Analysis (PCA) optimization were implemented to investigate the effects of controlled parameters (gear combinations, speed, running time and load) on the wear behavior, tooth thickness and addendum circles measurement of glass fiber reinforced plastic gear. © 2021 Author(s).