AbstractHeavily loaded machine elements, such as gears, usually operate in the mixed lubrication regime. Surface roughness has a significant effect on the pressure distribution, the subsurface stress field, and the friction coefficient. Based on the superposition of a dry rough and a fully flooded smooth contact, a mixed lubrication model has been developed. The roughness profile is assumed to be known. Surface deformation is calculated by taking into account the pressure distribution that is built up by asperity contacts, asperity interactions, and lubricant flow. Thermal and sliding effects are incorporated into the analysis. Non‐Newtonian lubricant behaviour is considered by using a power‐law rheological model. The pressure distribution, subsurface stress field, and friction coefficient were calculated from the model at several points along the contact path for an FZG type C gear pair. It was shown that a significant part of the load is carried by the contacting asperities. The position of the maximum shear stress is very close to the surf