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The homoclinic bifurcation and transition to chaos in gear systems are studied both analytically and numerically. Applying Melnikov analytical method, the threshold values for the occurrence of chaotic motion are obtained. The influence of system parameters on the character of vibration is studied. The numerical simulation of the system including bifurcation diagram, phase plane portraits, Fourier spectra, and time histories is considered to confirm the analytical predictions for the occurrence of homoclinic bifurcation and chaos in nonlinear gear systems.