BL Revo tranny - DIY

I’m in the middle of building a ground-up E. Revo – a “kit build” if you will. :027:
I wanted to use the stock Revo transmission for my conversion for overall simplicity; to retain the stock drive shafts, mechanical brake, chassis mounting locations, etc. I locked the shifting mechanism (eliminating reverse), to use the electric motor’s ability to switch rotation and reverse the entire gear train.

(refer to the exploded view of the Revo tranny for part numbers).
I know others have done this in different way, but my conversion eliminates first gear, and the lower reverse gear. It locks second gear directly to the Primary shaft (5393), by pinning it directly to the aluminum Primary Clutch assembly (5390).

How to:
Disassemble tranny halves and remove the top input shaft (5366) assembly.
Remove the Primary Shaft assembly.
Remove the first gear (5386) that rides on the one-way bearing (OWB) (5393) from the Primary Shaft. Remove the E-clip from the OWB and remove the first gear. Set the OWB aside for now.
Next, to pin the aluminum Primary Clutch assembly to the second gear, it’s easiest to remove them from the Primary shaft.
First, remove the 3x13.75mm screw pin from the white Primary gear, remove primary gear from shaft;
remove Second gear from the Primary clutch, and off the shaft;
push the pin out that holds the Primary Clutch to the shaft and remove the aluminum assembly.
Put the 10x15mm bearing (5119) from second gear back on the Primary Clutch and place it bearing up on the worksurface. Mark and drill a .089 dia. hole (#43 drill bit) through the aluminum Primary clutch, right next to the bearing. Don’t worry about scratching the bearing, it will simply become a spacer.
I also removed the set screw, spring and ball to release the cam in the Primary Clutch, and used a piece of wire to jam the cam open (to increase holding power).
Place the Second gear back on the Primary clutch and turn the clutch until the cam engages one of the pins in the Second gear. Hold it in this position and drill a .089 dia. hole through the previous hole, down into the Second gear. Run a 4-40 tap through the entire assembly to thread the holes.
Place the Primary clutch back on the Primary shaft and pin in place. Place Second gear back on the Primary clutch and turn the clutch until the cam engages one of the pins in the Second gear. Hold it in this position and insert a 4-40 setscrew through both to secure them together (use loctite).
Reassemble the Primary gear with the screw pin; place the OWB back on the Primary shaft as a spacer in place of first gear.

Note: in this section, the Forward gear is closest to the brake end of transmission. It is thinner than the reverse gear.
Outside the tranny, remove the reverse spring linkage (5392) from the reverse yoke shaft; pull the shaft all the way out to engage forward gear. Slide a wheel collar on the shaft to lock it in place.
Inside the tranny, remove the Reverse gear from the Output Shaft (5369) assembly; press the 6x10mm needle roller bearing (NRB) from the reverse gear; place the bearing back on the Output Shaft as a spacer in place of the Reverse gear.
Reassemble the shafts into the transmission – noting the location of all shims (thrust washers).

That’s it!
You now have the advantage of the Revo spur and slipper clutch set-up, the ability to use motor reverse to spin the drivetrain in reverse (if your controller allows), and the ability to use a mechanical brake.

I am working on locking the connection between the drive dog and forward output gear (5395) by pinning or screwing these two together. This would eliminate the drag of the shift yoke in the drive dog, and tighten the drivetrain.
Here's a link to pics:
http://community.webshots.com/album/548981601lQvCMa

Sorry for being long-winded.