<p>An accurate mathematical model for the tooth surface of spiral bevel gears incorporating manufacturing errors has been developed. A gear pair meshing model with consideration of assembly error has been derived. The impact of comprehensive errors of manufacturing and assembling on the tooth surface contact patterns has been investigated. A low sensitivity design method for tooth surfaces considering comprehensive errors of manufacture and assemble has been proposed. The results show that with the error changing from negative to positive, the tooth surface contact pattern of the cutter mean radius, ratio of roll, and the pinion axial displacement error move from toe-top to heel-root sides. The tooth surface contact pattern of the radial distance, horizontal, work offset error move from heel-root to the toe-top sides. For the comprehensive errors, the five parameters of the cutter mean radius, radial distance, horizontal, ratio of roll, and pinion axial displacement error have the most significant impact on the tooth surface contact pattern, directly leading to severe edge contact. With surface modification, the movement of parameters under error conditions decreases substantially, and except for a little edge contact in the ratio of rolling error, no edge contact occurs in other parameter errors.</p>