Assembly Instructions
This assembly guide was updated in October 2024.
Teams should choose their preferred orientation of their motors prior to assembly. Images that detail the various options can be found here: Motor Orientation
Reference the MAXSwerve Pack Contents Guide for help identifying the Bearings, Spacers, and Hardware from your kit!
1/8" Hex Key - Button Head Hex Drive Screws #10-32 screws
5/32" Hex Key - Socket Head Screws #10-32
2.5mm Hex Key - M3 Socket Head Cap Screws
2mm Hex Key - M3 Button Head Screws
3/8" Socket Wrench or Combination Wrench - #10-32 Low Profile Nylon Lock Nuts
Several of the below steps call for the use of threadlocker with certain screws. We recommend LOCTITE® Threadlocker Blue 242 or an equivalent threadlocker.
When assembling the 3in MAXSwerve Module we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using White Lithium Grease or Red Tacky Grease will provide sufficient lubrication.
When applying the grease of your choice, add a small amount to the gearbox’s gears, ensuring that it gets evenly distributed throughout the system.
If your MAXSwerve Module Kits do not contain the 3in MAXSwerve Module V1 to V1.1 Upgrade Kit, please start at the MAXSwerve V1.0 - Top Plate Subassembly
The below instructions are for Top Plate Subassembly of a MAXSwerve Module with a NEO Vortex using the Vortex Shaft - MAXSwerve Integrated Key. The continuation of this assembly guide will show images of MAXSwerve Module assembled with a NEO Brushless Motor v1.1 as the next steps are identical across all motors.
Some 3in MAXSwerve Module Wheel Axles may not be a slip fit. Please see our MAXSwerve Assembly Tips section for a solution: Wheel Axle - Tight Fit
The Steering UltraPlanetary Subassembly is dependent on which orientation (left hand or right hand) was chosen during Top Plate Subassembly.
Some of the UltraPlanetary Cartridges have a mounting hole that is partially closed. Please see our guide on how to fix this: UltraPlanetary Mounting Holes Fix
If you forgot to apply threadlocker during the assembly of the UltraPlanetary Subassembly you can use a Wicking Grade Threadlocker to apply threadlocker to the pre-assembled gearbox.
For instructions see our MAXSwerve Assembly Tips section
Once you assemble your MAXSwerve Modules onto your Drivetrain, check out the following sections for help to start moving!
The materials listed below will attach the SPARK MAX Mounting Bracket for ONE MAXSwerve Module
| Item & SKU | QTY |
|---|---|
The MAXSwerve SPARK MAX Mounting Bracket is reversible and can be used on any corner of your MAXSwerve Drivetrain
The SPARK MAX Mounting Bracket has an optional fourth hole that teams can use to secure the Mounting Bracket directly to their MAXSwerve module!
Teams can use #10-32 3/8in Button-Head Socket Cap Screws to attach this Mounting Bracket to the module, as pictured below. We recommend using threadlocker on this screw.
When assembling their 3in MAXSwerve Module, teams have a choice of either left-hand or right-hand assembly, meaning teams can choose which direction their motors' wires face.
Depending on the choice the team makes, your layout of the MAXSwerve may look like either of these, at various stages of the assembly process.
In our 3in MAXSwerve Drivetrain example we chose two Left-Hand and two Right-Hand orientations to allow for clean wire management and a balanced drivetrain.
| Left-Hand Orientation | Right-Hand Orientation |
|---|---|
If you are assembling the MAXSwerve Module with a NEO Vortex make sure to follow the NEO Vortex MAXSwerve Shaft Top Plate Subassembly instructions.
| Left-Hand Orientation | Right-Hand Orientation |
|---|---|
| Left-Hand Orientation | Right-Hand Orientation |
|---|---|
If you encounter any problems while assembling your MAXSwerve Module(s) please contact support@revrobotics.com
Making sure your screws are secure is important when building your MAXSwerve Modules. Here is a video with some best practices to keep in mind while applying Loctite or a similar thread locker to your screws.
To use, apply the Wicking Loctite to the top of the UltraPlanetary Gearbox Assembly where the screw tips are showing. The Loctite will wick between the engaged threads using capillary action to secure your screws.
We recommend using superglue to ensure that the key stays securely in place
When placing the MAXSwerve Motor Key (REV-21-3005-P10) you need to pay close attention to two areas of the key, these are marked as A and B in the image below. For area A at the end of the motor's output shaft, make sure that the key is placed close to the end of the motor shaft for the notch in the key to rest slightly above the lip of the encoder bridge. Area B of the key will need to sit as flush as possible with the NEO's Keyway so that it does not catch inside the encoder bridge and get pulled out. Use superglue to secure the motor key once you have placed it in the correct location.
If you are experiencing difficulty getting the key for your motor to rest on the lip of the encoder bridge, it is possible that the key is too large for the keyway. We have received this report specifically from teams using NEO V1s and Falcon 500s with the MAXPlanetary Falcon Input Kit, as the keyways changed sizes between the NEO V1 and the NEO V1.1. To resolve this issue, we recommend sanding down the key using a jeweler's file. Start by taking off a small amount and checking the fit, then continue to remove more as needed.
Some of the UltraPlanetary Cartridges that shipped with the first batch of MAXSwerve Modules (January 2023) have a mounting hole that is partially closed. There is a small amount of plastic leftover from the manufacturing process that will need to be removed before use.
To clear the mounting hole, use a 1/8in drill bit to drill out the excess plastic. Be sure to drill from the side of the UltraPlanetary Cartridge with the output spline facing up so that the through hole does not get off center.
3in MAXSwerve Module Wheel Axles that shipped with the first batch of MAXSwerve Modules (January 2023) may have a tighter fit than expected.
We recommend using a product that is 400 grit or higher for this process
If you forgot to apply Loctite during the assembly of the UltraPlanetary Subassembly you can use a to apply thread locker to the pre-assembled gearbox
When putting together the of your MAXSwerve Module, ensure that the MAXSwerve Motor Key's notch rests slightly above the lip of the encoder bridge. If the notch is not located above the encoder bridge's lip and falls into the slot, the module will not function properly and the key will become damaged.
To help with the fit of your Wheel Axle assembly, use a fine grit emery cloth, sandpaper, or to remove a small amount of material from the axle. It is easiest to put the Wheel Axle in a drill and then sand the Axle until the bearings are a slip fit.
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The instructions are the same for the NEO Vortex Solo Adapter.
1) Insert your 2x1 MAXTube into the mounting slot on the MAXSwerve Module
2) Slide the MAXSwerve SPARK MAX Mounting Bracket over the tabs of the MAXSwerve module that you just inserted the MAXTube into
3) Secure the MAXSwerve SPARK MAX Mounting Bracket and 2x1 MAXTube to the MAXSwerve Module with 2 - 3in #10-32 Button Head Screws and Nylock Nuts
1) With the NEO motor sitting shaft upwards on a flat surface, position the Top Plate upside down on the motor boss- the small raised circle on the center of the motor. Align the motor holes for your preferred configuration, either left hand or right hand. CAD examples of those options can be found here: NEO Orientation
2) Install the Through Bore Encoder on the motor shaft, lined up with the correct holes in the motor body for your preferred configuration. Ensure that the motor shaft is perfectly centered in the hex bore of the encoder. Fasten the encoder and motor together using two 1/2in 10-32 button head screws, applying threadlocker to the screws. CAD examples of those options can be found here: NEO Orientation
3) Install the Encoder Bridge into the Through Bore Encoder so that the hex side of the bridge rotates the Through Bore Encoder.
4) Slide the Pinion Spacer over the motor shaft press it into the Encoder Bridge.
5) Install Motor Key into motor shaft keyway. The key should fit into keyway and should rest on top of the Pinion spacer
6) Install the appropriate motor pinion for the preferred speed option (low, mid, or high) onto the motor shaft, with the pinion boss facing away from the motor as shown the the second image. Set Top Plate subassembly aside.
1) With the NEO Vortex motor sitting shaft upwards on a flat surface, position the Top Plate upside down on the on the mounting surface of the SPARK Flex Motor Controller. †Align the motor holes for your preferred configuration, either left hand or right hand. CAD examples of those options can be found here: NEO Orientation
2) Install the Through Bore Encoder on the motor shaft, lined up with the correct holes in the motor body for your preferred configuration. Ensure that the motor shaft is perfectly centered in the hex bore of the encoder. Fasten the encoder and motor together using two 1/2in 10-32 button head screws, applying threadlocker to the screws. CAD examples of those options can be found here: NEO Orientation
3) Install the Encoder Bridge into the Through Bore Encoder so that the hex side of the bridge rotates the Through Bore Encoder.
4) Install the appropriate motor pinion for the preferred speed option (low, mid, or high) onto the motor shaft, with the pinion boss facing away from the motor as shown the the second image. Set Top Plate subassembly aside.
1) With the NEO motor sitting shaft upwards on a flat surface, position the Top Plate upside down on the motor boss- the small raised circle on the center of the motor. Align the motor holes for your preferred configuration, either left hand or right hand. CAD examples of those options can be found here: NEO Orientation
2) Install the Through Bore Encoder on the motor shaft, lined up with the correct holes in the motor body for your preferred configuration. Ensure that the motor shaft is perfectly centered in the hex bore of the encoder. Fasten the encoder and motor together using two 1/2in 10-32 button head screws, applying threadlocker to the screws. CAD examples of those options can be found here: NEO Orientation
3) Install Motor Key into motor shaft keyway. The thinnest part of the key should be facing towards the motor. See our MAXSwerve assembly tips for additional images to help with proper key placement!
4) Align the Encoder Bridge’s clearance notch with the key in the motor shaft and insert the Encoder Bridge into the encoder. Ensure that the notch in the key rests slightly above the lip of the encoder bridge, as shown in the cross-section to the right. See our MAXSwerve Assembly Tips if you are finding this step difficult. If the notch is not above the lip and falls into the slot, the module will NOT function properly and may get damaged.
5) Install the appropriate motor pinion for the preferred speed option (low, mid, or high) onto the motor shaft, with the pinion boss facing away from the motor as shown the the second image. Set Top Plate subassembly aside.
1) Insert the main steering bearing into the Bottom Plate.
2) Install six 3/8in button head screws into the Bottom Plate to hold the main bearing in place, applying threadlocker to the screws. Set aside the Bottom Plate.
3) Take Steering Gear and insert the main Bevel Pinion bearing into the bottom side of the Steering Gear.
4) Insert Steering Gear into Bottom Plate.
5) Flip the Bottom Plate over and insert the Bevel Pinion into the Bevel Pinion bearing. Set Steering subassembly aside.
1) Insert the Wheel Hub into the MAXSwerve Wheel. Take care to align the holes in the wheel and the hub.
2) Insert the Wheel Bevel Gear into the opposite side of the wheel. Take care to align the holes in the wheel and the gear.
3) Fasten the Wheel Hub and Wheel Bevel Gear to the MAXSwerve Wheel with six 1in long 10-32 button head screws, applying threadlocker to the screws. These screws are inserted through the Wheel Hub side and are threaded into the Wheel Bevel Gear. Checkout our video on threadlocker application for tips and tricks.
4) Insert the two wheel bearings into either side of the MAXSwerve Wheel Assembly. One bearing should go into the Wheel Bevel Gear, and one bearing should go into the Wheel Hub.
5) Insert the Wheel Axle through the wheel bearings. If you struggle to put the Wheel Axle through the bearings, it may be easier to put a bearing on one side of the Axle, and then "sandwich" other the bearing onto the Axle and into the Wheel.
6) Place the two wheel spacers onto the Wheel Axle, one on either side of the MAXSwerve Wheel.
1) Install the two Bevel Pinion end bearings into the Active Fork. Set the Active Fork aside.
1) Insert the Active Fork Subassembly into the pocket on the bottom side of the Steering Gear. Ensure that the Bevel Pinion is inserted properly into the end bearings in the Active Fork.
2) Fasten the Active Fork in place with two 1in 10-32 socket head screws, applying threadlocker to the screws. Leave these screws slightly loose. Remember to come back after MAXSwerve Wheel Installation and tighten these screws in the same day to ensure the threadlocker is effective.
3) Insert the Passive Fork into the Steering Gear opposite from the Active Fork. Fasten the Passive Fork in place with two 1in 10-32 socket head screws, applying threadlocker to the screws. Leave these screws slightly loose. Remember to come back after MAXSwerve Wheel Installation and tighten these screws in the same day to ensure the threadlocker is effective.
1) Insert the MAXSwerve Wheel Subassembly between the two forks with the Wheel Bevel Gear engaged with the Bevel Pinion.
2) Apply threadlocker to a 2in 10-32 socket head screw and insert it through the Passive Fork, through the Wheel Axle, and thread it into the Active Fork. Leave this screw slightly loose.
3) Tighten the four screws holding the forks in (see the orange arrow), and tighten the Wheel Axle screw. If you have a torque wrench tight these screws to ~15 Inch-lbs Min ~19 Inch-lbs Max. Do not overtighten these screws.
1) Install the Steering Pinion bearing into the top of the Bottom Plate.
2) Insert motor shaft bearing into the top of the Steering Gear. If you are experiencing the motor shaft bearing falling out of the gear you can use two small strips of tape on two sides of the bearing to keep it in place.
3) Fasten the Drive Spur Gear onto Bevel Pinion shaft with one 3/8in 10-32 button head screw, applying threadlocker to the screw. If you are having difficultly tightening the screw, we recommend firmly gripping the MAXSwerve wheel and the Forks at the same time.
1) Install one of the two Steering Pinion bearings into the UltraPlanetary Block.
2) Install the Steering Pinion into the UltraPlanetary Block. Set the UltraPlanetary Block aside.
1) Install the UltraPlanetary 550 Motor Pinion onto the NEO 550. See our documentation on the NEO 550 Product Page for more information about pressing pinions onto NEO 550s and using NEO 550s with UltraPlanetary Gearboxes.
2) Install the UltraPlanetary Motor Plate on the NEO 550 with two 8mm M3 button head screws, applying threadlocker to the screws. Ensure that you orient the motor based on the configuration chosen. CAD examples of those NEO 550 orientations can be found here: NEO 550 Orientation Options
3) Stack the 4:1 UltraPlanetary Cartridge onto the UltraPlanetary Motor Plate, followed by the 3:1 Cartridge, and the UltraPlanetary Block (with steering pinion). Ensure that these components are oriented to allow alignment features to interlock, and that they provide the correct wire orientation for your configuration. CAD examples of those wire configurations can be found here: NEO 550 Orientation Options Ensure that the pinion is fully engaged with the UltraPlanetary Cartridge output spline and fully inserted into the bearing in the UltraPlanetary Block.
4) Install and tighten two 25mm M3 socket head screws, applying threadlocker to the screws, into the notched side of the UltraPlanetary Block, through the UltraPlanetary stack, and into the UltraPlanetary Motor Plate. Take care not to over-tighten the gearbox housing screws. Hand tight is enough to keep the gearbox assembled.
1) Install the UltraPlanetary stack on the top of the Bottom Plate. The end of the Steering Pinion should be inserted into the Steering Pinion bearing.
2) We recommend applying more threadlocker than you normally would in this step. Install and tighten four 60mm M3 socket head screws, applying threadlocker to the screws, through the Bottom Plate, through the UltraPlanetary stack, and into the UltraPlanetary Motor Plate. Take care not to overtighten the screws. We recommend applying threadlocker then tighten all screws until the screw heads are touching the output plate or the outermost metal.
Tighten screws in a star pattern (see photo) a 1/4 turn each at a time until the gearbox becomes noticeably harder to spin by hand then back out the screws 1/2 turn.
Let the threadlocker cure for a full 24 hours before use.
3) Spin the fork and wheel assembly by hand to check that it moves freely. It should move easily and quickly coast to stop, continuing to rotate with some inertia, in both directions. The torque required to spin it should be uniform through an entire rotation. If significant resistance is felt, check that the leads from the NEO 550 aren't touching each other, as this can produce an artificial braking effect.
1) Set the Top Plate Subassembly upside down on a flat surface.
2) Place the three structural standoffs into their respective pockets in the inverted Top Plate.
3) Retrieve the Bottom Plate Subassembly. Place it upside down, and drop three 2in long 10-32 socket head screws into the appropriate holes in the bottom plate. If you are having issues with these screws issues with these screws falling out, we recommend placing a small amount of tape over the screw holes in the bottom plate. If you are experiencing the motor shaft bearing falling out of the gear you can use two small strips of tape on two sides of the bearing to keep it in place.
4) Carefully lower the Bottom Plate Subassembly down on top of the inverted Top Plate Subassembly. Ensure that the screws line up with (and slide inside) the structural standoffs. It may be necessary to rotate the MAXSwerve Wheel Subassembly to properly line up the four holes in the Steering Gear with the four pegs on the Encoder Bridge.
5) Insert three Nylock Nuts into the pockets on the Top Plate, and thread the 2in socket head screws into them. Tighten down the screws.
6) Test spin the module by hand, both rolling the wheel and rotating the steering. It should move easily and quickly coast to stop, continuing to rotate with some inertia, in both directions. The torque required to spin it should be uniform through an entire rotation.
A MAXSwerve Motor Key properly seated in the NEO's keyway with the notch resting slightly above the lip of the encoder bridge | Blue Edge: MAXSwerve Motor Key Orange Edge: Encoder Bridge |
MAXSwerve SPARK MAX Mounting Bracket (REV-21-2998)
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1 piece for attaching the MAXSwerve Bracket, More will be needed for assembling a whole MAXSwerve Drivetrain
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