Preliminary Requirements

Procedure

1. SUBTASK 70-35-08-860-001 Equipment and Material

   1. Standard equipment.

      Approved workshop equipment.

   2. Consumable materials.

      CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE	Jointing compound
      CoMat 10-059 ENGINE LUBRICATING OIL	Engine lubricating oil
      NOTE To identify the consumable materials refer to the PCI. NOTE These tools are approved hand tools and can be obtained from Supplier Code IAE00.

   3. Special tools.

      For the special tools required, refer to Step.

2. SUBTASK 70-35-08-860-002 General

   1. 

      WARNING

      IT IS THE RESPONSIBILITY OF THE OPERATOR TO OBTAIN AND OBSERVE THE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS. THESE CONTAIN INFORMATION SUCH AS, HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL MEASURES AND ALSO TO TAKE LOCAL REGULATIONS INTO CONSIDERATION.

      NOTE

      Unless approved by an International Aero Engines AG repair, do not install wire thread inserts.

      This TASK gives instructions for the replacement of damaged inserts and the repair of damaged threads with the use of new inserts. It also gives instructions for the installation and repair of inserts in light alloy materials.

   2. When a new insert is damaged during assembly, a new insert can be installed. This will have no effect on disassembly, when the removal and insertion tools are changed; as shown in Figure and Figure.

   3. Install screw lock inserts only when specified in the Illustrated Parts Catalog.

   4. Types of inserts:

      1. Screw lock inserts - one coil is bent to permit self-locking.

      2. Free running inserts - this has no self-locking property.

      3. Repair insert - a solid insert into which a wire thread insert is installed.

3. SUBTASK 70-35-08-350-001 Remove the Wire Thread Insert

   1. Remove the damaged insert. Refer to Figure and Step or Figure and Figure.

4. SUBTASK 70-35-08-325-001 Machine the Hole

   1. Drill the hole to permit installation of the insert (if not previously installed). Refer to Figure, Figure and Step.

   2. Clean and examine the hole. Refer to Step.

5. SUBTASK 70-35-08-380-001 Apply Protection

   1. Apply protection to the threads of magnesium components. Refer to the applicable Manual Repair Scheme.

6. SUBTASK 70-35-08-350-002 Install the Wire Thread Insert

   1. After selection of the applicable insert apply a layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to the threads; also apply a layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to the threads of magnesium components. Refer to Figure.

   2. Install the wire thread insert. Refer to Figure, Figure and Step or Figure and Figure.

   3. Remove the tang. Refer to Figure and Step.

7. SUBTASK 70-35-08-230-001 Do a Crack Test on the Repaired Area

   1. Do a crack test on the repaired area. Refer to the SPM TASK 70-23-01-230-501, SPM TASK 70-23-04-230-501, SPM TASK 70-23-03-230-501 or SPM TASK 70-23-02-230-501.

8. SUBTASK 70-35-08-220-001 Do an Inspection of the Wire Thread Inserts

   1. Examine the wire thread insert. Refer to Figure, Figure and Step.

   2. Do a check on the torque of the screw lock inserts. Refer to Figure and Step.

   3. Vibration engrave VRSXXXX near to part number. Do not engrave VRSXXXX when you replace an insert.

9. SUBTASK 70-35-08-220-002 Do an Inspection on the Repair Insert for Machining and Installation

   1. Do a dimensional inspection on the component to make sure boss proportions are sufficient for machining. Refer to Figure.

10. SUBTASK 70-35-08-325-002 Machine the Hole

    1. Drill the hole for the repair insert. Refer to Figure and Step.

    2. Tap the hole for the repair insert. Refer to Step.

    3. Clean and examine the hole. Refer to Figure and Figure.

11. SUBTASK 70-35-08-380-002 Apply Protection after Machining the Hole

    1. Apply protection to the threads of magnesium components. Refer to the applicable Manual Repair Scheme.

12. SUBTASK 70-35-08-350-003 Install the Repair Inserts

    1. After selection of the applicable insert apply a layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to threads; also apply a layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to the threads of magnesium components. Refer to Figure.

    2. Install the repair insert. Refer to Figure and Step.

    3. Do a visual inspection of the insert. Refer to Figure.

13. SUBTASK 70-35-08-350-004 Install the Wire Thread Insert

    1. After selection of the applicable insert apply a layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to threads; also apply a layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to the threads of magnesium components. Refer to Figure.

    2. Install the wire thread insert. Refer to Figure, Figure and Step or Figure and Figure.

    3. Remove the tang. Refer to Figure and Step.

14. SUBTASK 70-35-08-230-002 Do a Crack Test on the Repaired Area

    1. Do a crack test on the repaired area. Refer to the SPM TASK 70-23-01-230-501, SPM TASK 70-23-03-230-501, SPM TASK 70-23-04-230-501 or SPM TASK 70-23-02-230-501.

15. SUBTASK 70-35-08-220-003 Do an Inspection on the Wire Thread Insert

    1. Examine the insert. Refer to Figure, Figure and Step.

    2. Do a check on the torque of the screwlock inserts. Refer to Figure and Step.

    3. Vibration engrave VRSXXXX near to part number. Do not engrave VRSXXXX when you replace an insert.

16. SUBTASK 70-35-08-860-003 Approved Hand Tools

    Table 3. Table 1 Approved Hand Tools by Size Number

    		Specified Unified Thread
    		No. 4		No. 6		No. 8		No. 10		Item
    Threads/in.		40		32		36		32
    Extraction tool		2R19579		2R19579		2R19579		2R19605		1
    Insertion tool (pre-wind type)		2R19580		2R19590		2R19597		2R19606		2
    Tang removal tool		2R19581		2R19591		2R19598		2R19607		3
    Roughing tap		2R19582		2R19592		2R19599		2R19608		4
    Plug tap		2R19583		2R19593		2R19600		2R19609		5
    Bottoming tap		2R19584		2R19594		2R19601		2R19610		6
    Special gage for tapped hole		2R19585		2R19595		2R19602		2R19611		7
    Cross thread gage		NIL		NIL		2R19603		2R19612		8
    Torque check plug		2R19586		2R19596		2R19604		2R19613		9
    Torque adapter		2R19587		2R19587		2R19587		2R19587		10
    Torquemaster		2R19588 (all threads)								11
    Torque setting rig		2R19589		2R19589		2R19589		2R19589		12

    Table 4. Table 2A Approved Hand Tools by Dimension (0.25 in. to 0.4375 in.)

    		Specified Unified Thread
    		0.250 in.		0.3125 in.		0.375 in.		0.4375 in.		Item
    Threads/in.		28		24		24		20
    Extraction tool		2R19616		2R19616		2R19634		2R19643		1
    Insertion tool (pre-wind type)		2R19617		2R19625		2R19635		2R19644		2
    Tang removal tool		2R19618		2R19626		2R19636		2R19645		3
    Roughing tap		2R19619		2R19627		2R19637		2R19646		4
    Plug tap		2R19620		2R19628		2R19638		2R19647		5
    Bottoming tap		2R19621		2R19629		2R19639		2R19648		6
    Special gage for tapped hole		2R19622		2R19630		2R19640		2R19649		7
    Cross thread gage		2R19623		2R19631		2R19641		2R19650		8
    Torque check plug		2R19624		2R19632		2R19642		2R19651		9
    Torque adapter		2R19587		2R19587		2R19587		2R19587		10
    Torquemaster		2R19588 (all threads)								11
    Torque setting rig		2R19589		2R19589		2R19589		2R19589		12

    Table 5. Table 2B Approved Hand Tools by Dimension (0.500 in.)

    		Specified Unified Thread
    		0.500 in.		Item
    Threads/in.		20
    Extraction tool		2R19643		1
    Insertion tool (pre-wind type)		2R19652		2
    Tang removal tool		2R19653		3
    Roughing tap		2R19654		4
    Plug tap		2R19655		5
    Bottoming tap		2R19656		6
    Special gage for tapped hole		2R19657		7
    Cross thread gage		NIL		8
    Torque check plug		2R19658		9
    Torque adapter		2R19587		10
    Torquemaster		2R19588 (all threads)		11
    Torque setting rig		2R19589		12

    Table 6. Table 3 Approved Hand Tools

    		Insert Thread
    		No. 10		0.250 in.		0.3125 in.		0.375 in.		Item
    Threads/in.		32		28		24		24
    Special drill		1R19697		1R19706		1R19716		1R19725		9
    Counterbore tool (cutter)		1R19698		1R19707		1R19717		1R19726		10
    Tap		1R19699		1R19708		1R19718		1R19727		11
    Insert driver		1R19700		1R19709		1R19719		1R19728		12

    Table 7. Table 4 Tools Used To Cut By Hand

    		Insert Thread
    		No. 10		0.250 in.		0.3125 in.		0.375 in.		Item
    Threads/in.		32		28		24		24
    Pilot Screw		1R19701		1R19710		1R19720		1R19729		13
    Counterbore tool (cutter)		1R19702		1R19711		1R19721		1R19730		14
    Counterbore stop		1R19703		1R19712		1R19722		1R19731		15
    Hollow cutter		1R19704		1R19713		1R19723		1R19732		16
    Radius cutter		1R19705		1R19714		1R19724		1R19733		17

Figure: Wire thread insert dimensions

Wire thread insert dimensions



Figure: Threaded hole dimensions for wire thread inserts

Threaded hole dimensions for wire thread inserts



Figure: Threaded hole dimensions for wire thread inserts

Threaded hole dimensions for wire thread inserts



Figure: Dimensions of assembled inserts

Dimensions of assembled inserts



Figure: Removal of the inserts

Removal of the inserts



Figure: Installation procedure

Installation procedure



Figure: Installation procedure

Installation procedure



Figure: Removal of the insert tang

Removal of the insert tang



Figure: Changes to tools to make them fit wire thread inserts in assembled parts

Changes to tools to make them fit wire thread inserts in assembled parts



Figure: Changes to tools to make them fit wire thread inserts in assembled parts

Changes to tools to make them fit wire thread inserts in assembled parts



Figure: Tool dimensions to fit wire thread inserts in assembled parts

Tool dimensions to fit wire thread inserts in assembled parts



Figure: Torque check of screw lock inserts

Torque check of screw lock inserts



Figure: Dimensions for inserts in light alloy materials

Dimensions for inserts in light alloy materials



Figure: Dimensions for inserts in light alloy materials

Dimensions for inserts in light alloy materials



Figure: Dimensions for inserts in light alloy materials

Dimensions for inserts in light alloy materials



Figure: Dimensions for inserts in light alloy materials

Dimensions for inserts in light alloy materials



Figure: Dimensions for inserts in light alloy materials

Dimensions for inserts in light alloy materials



Figure: Repair inserts

Repair inserts



Figure: Repair inserts

Repair inserts



Figure: Wire thread inserts

Wire thread inserts



Figure: Wire thread inserts

Wire thread inserts