Abstract: The main objective of this project is to design and develop a 2-Stage- Reduction gearbox for all terrain vehicles application. Gearbox is a mechanical unit consisting of series of gears within a housing (casing) or a simple gear train. It is the main component of the powertrain system as it provides speed and torque conversions from the Engine or CVT to the wheels. The gears inside of gearbox can be any one of a number of different types of the gear that are available in the market

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... ., from spur gears to worm gears and planetary gears as well. In this report the gearbox is made from a helical gear train. This report focuses on selection of overall reduction ratio of the gearbox, material selection, selection of gear dimensions, selection of shaft dimension, design of key and bearing selection from SKF bearing catalogue. The bending and wear strengths are calculated to determine factor of safety and later, Finite element analysis is performed to validate the results. Keywords: Geartrain, Shaft Design, SKF Bearings, Solidworks, FEA