<p> Back-taper gear is an essential element in the power-transfer system of dual-clutch transmission(DCT). It has recently attracted increased interest because of its fuel-efficient characteristic. During the manufacture of a mono-type back-taper gear by cold forging, however, repeated excessive forming loads have frequently resulted in die failure. To address this issue, the cold forging processes were examined , and improved die profile using the finite element analysis(FEA) adopting high-strain flow curve and the artificial neural network method (ANN). These improvements make effective stress in first cold forging process die reduced from 1,710 MPa to 1,501 MPa and significantly enhance the die life for the first cold forging process, while it is impossible to change the die profile of second cold forging due to its unconventional structure that forms back-taper tooth profile. Consequently, replacement of the die material is proposed as an additional method to improve die life. The five die materials selected in this study were evaluated to extend the fatigue and wear life at least twice compared to the existing material.</p>