Several studies were made on the effects of gear faults on vibrations and noise. Fault signatures were defined and procedures for fault detection were proposed. Now, the question is to define fault thresholds. As an experimental determination does not appear simple, thresholds can be defined by comparing the dynamic tooth root stress due to a fault to a fatigue limit of the gear material and by relating the type and the depth of the fault to the vibration levels and tooth root stress increase. The experimental study of the gear fault effect on bearing vibrations enables us to define descriptors which indicate the presence of fault and its nature, the experimental study will be shortly summed up, then a numerical model will be developed involving validation with respect to previous experimental studies. The dynamic tooth load and tooth root stress with and without fault will be presented and the risks of tooth failure due to stress fluctuations were discussed.