TASK 70-35-26-300-501 Replace Damaged Unified Thinwall Self Lock Inserts

DMC:V2500-00-70-35-26-00A-920A-D|Issue No:002.00|Issue Date:2019-02-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 70-35-26-300-501 Replace Damaged Unified Thinwall Self Lock Inserts

General

This repair gives the procedure for the removal/installation of thinwall self-lock inserts.

Install thinwall self-lock inserts when specified in the inspection check and or repair scheme.

Insert and tapped hole data

For data on the tapped hole refer to the engineering detail drawings.

For data on the thinwall insert (part number and dimensions) refer to Step Table 1.

For data on the insert part number in relation to the serration contour (if applicable) refer to Step Table 2 and Figure.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Standard workshop toolsLOCALStandard workshop tools
Thinwall self-lock insert removal/installation toolsLOCALThinwall self-lock insert removal/installation tools

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 04-004 JOINTING COMPOUND, LIGHT GRADELOCALCoMat 04-004

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 70-35-26-350-001 Replacement of Thinwall Self-Lock Inserts

      1. CAUTION

        YOU MUST NOT DAMAGE THE THREADS OR SERRATIONS IN THE HOLE.

        Removal procedure.

      1. You can remove the insert with the removal of the swaged lock device.

      2. For the correct size of the removal cutter to be used refer to StepTable and Figure.

      3. Screw the removal tool into the insert. The tool will begin to cut through the counter bore of the insert. This will start to remove the swaged lock device. Continue to cut until the tool touches the bottom of the counterbore. Remove the tool.

      4. Screw the insert out of the tapped hole in a counterclockwise direction. Use the applicable drive tool.

      5. Make sure that all parts of the insert are removed.

      6. Inspect the counterbore, tapped hole and serrations (if applicable) of the component for damage and unwanted material.

      7. Use a thread gauge to examine the thread.

      2. Installation data.

      1. Examine and make sure the tapped hole, counterbore and serrations (if applicable) have no burrs, unwanted particles, grease and oil.

      2. Examine and make sure the insert is clean and has no grease on it.

      3. Apply a thin layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE externally on to the insert if it is to be installed in aluminium or magnesium components (this prevents electrolytic corrosion).

      4. Allow the insert to air dry for a minimum of 10 minutes before installation.

      3. Installation procedure.

        1. Screw the insert into the tapped hole in a clockwise direction with the applicable tool (refer to Step Table 3 and Figure). The insert must be installed 0.40 mm to 0.65 mm (0.0157 in. to 0.0256 in.) below the surface of the component (Refer to Figure).

        1. Ensure that the tool is held firmly down on the insert. Stop turning the tool when the tool face touches the surface of the component.

        2. If you continue turning the installation tool the insert will be too far down the threaded hole. Use hand pressure only to turn the tool.

        3. If hand pressure is not sufficient to install the insert to depth, discard it and use a new insert.

      2. Check that the insert is smooth with or just below the bottom of the chamfer.

      4. Swage the insert.

      1. The mating component must be put on a strong heavy surface before the insert can be correctly installed.

      2. Where a serrated counterbore is used (this is optional) you must ensure that the serrations line up at the 0.40 mm to 0.65 mm (0.0157 in. to 0.0256 in.) installation depth (Refer to Figure).

      3. To lock the insert, sufficient force must be applied to the approved swage tool (Refer to Step Table 4 and Figure) with a pneumatic gun or if this is not available a mechanical press (Fly press) or manual method (Hammer). This must be done until the nylon stop washer of the tool touches the surface of the component. The insert must now be examined to make sure it is correctly swaged and locked (refer to Figure).

      4. During the swage operation do not use too much force. This can cause damage to the component.

      5. Inspection.

      1. After the insert has been swaged and the nylon stop washer has touched the surface of the component, the swaged insert must agree with the specified dimensions (refer to Step Table 5 and Figure).

      2. As an alternative to the applicable after swage check gage in Step Table 5, it is permitted to use the after swage check gauge that the insert manufacturer specifies for the installed insert.

      3. After the insert has been swaged, examine the insert and the adjacent material for damage. Flaking or damage to the silver layer is permitted in the counterbore only, but loose flakes of silver must be removed and must not be permitted to touch the mating surfaces of the component.

      4. CAUTION

        YOU MUST NOT CLEAN THE INTERNAL THREAD OF THE INSERT WITH A TAP. IF YOU DO DAMAGE TO THE INSERT WILL OCCUR.

        The insert thread must be examined for damage from the swaging procedure. The thread must be examined with the correct thread gauge or bolt (See Table 1 for nominal bolt size). This gauge or bolt must be screwed into the insert with the hand until it gets to the lock thread. Then remove the gauge or bolt. If the thread gauge or bolt does not go into the insert easily, then the insert must be removed. A new insert must then be installed.

      5. If it is necessary to remove the insert this must be done as specified in the removal procedure.

  2. SUBTASK 70-35-26-300-002 Table 1 (Bolt sizes, thinwall insert part numbers and dimensions)

    Bolt thread diameter

    Short inserts

    Length +/- 0.25mm (0.0098in.)

    Long inserts

    Length +/- 0.30 mm (0.0118in.)

    Tapped hole diameter

    0.1900-32 UNJF

    AS52760

    7.37

    (0.290)

    AS52790

    12.07 (0.475)

    0.2500-28 UNJF

    0.2500-28 UNJF

    AS52761

    9.65

    (0.380)

    AS52791

    15.11 (0.595)

    0.3125-24 UNJF

    0.3125-24 UNJF

    AS52762

    11.94 (0.470)

    AS52792

    18.29 (0.720)

    0.3750-24 UNJF

    0.3750-24 UNJF

    AS52763

    14.22 (0.560)

    AS52793

    22.22 (0.875)

    0.4375-20 UNJF

    0.4375-20 UNJF

    U760329

    25.40 (1.000)

    0.5000-20 UNJF

    0.5000-20 UNJF

    U760330

    28.57 (1.124)

    0.5625-24 UNJEF

  3. SUBTASK 70-35-26-300-003 Table 2 (Thinwall insert part numbers and bolt thread diameter in relation to the serration contour)

    BOLT THREAD DIAMETER

    SHORT INSERT

    AA mm (in.)

    DIA AB mm (in.)

    DIA AC mm (in.)

    AD mm (in.)

    ANGLE AE

    0.1900-32 UNJF

    AS52760

    0.305 (0.012)

    6.77 (0.266)

    6.57 (0.258)

    0.08 (0.003)

    80.3

    0.2500-28 UNJF

    AS52761

    0.300 (0.0118)

    8.55 (0.337)

    8.32 (0.327)

    0.09 (0.0035)

    82.0

    0.3125-24 UNJF

    AS52762

    0.360 (0.014)

    10.22 (0.402)

    9.90 (0.389)

    0.10 (0.0039)

    83.5

    0.3750-24 UNJF

    AS52763

    0.383 (0.015)

    11.67 (0.459)

    11.39 (0.448)

    0.10 (0.0039)

    84.5

  4. SUBTASK 70-35-26-300-004 Table 3 (Thinwall insert part numbers and tool dimensions)

    Short insert

    Long insert

    A mm (in.)+/-

    0.125 mm (0.0049)

    B max

    mm (in.)

    AS52760

    AS52790

    3.775 (0.147)

    4.52 (0.178)

    AS52761

    AS52791

    5.175 (0.204)

    5.77 (0.227)

    AS52762

    AS52792

    6.575 (0.259)

    6.76 (0.266)

    AS52763

    AS52793

    8.075 (0.318)

    8.41 (0.331)

    U760329

    9.375 (0.369)

    8.94 (0.352)

    U760330

    10.975 (0.432)

    10.67 (0.420)

  5. SUBTASK 70-35-26-300-005 Table 4 (Thinwall insert part numbers and tool dimensions)

    Short insert

    Long insert

    DIA B mm (in.) +/-0.015 mm (0.0006 in.)

    C mm (in.) +/-0.127mm (0.005 in.)

    DIA D mm (in.) +/-0.25 mm (0.0098 in.)

    AS52760

    AS52790

    5.375 (0.212)

    1.829 (0.072)

    0.65 (0.0256)

    AS52761

    AS52791

    7.125 (0.281)

    1.778 (0.070)

    0.80 (0.0315)

    AS52762

    AS52792

    8.775 (0.345)

    1.702 (0.067)

    1.00 (0.0394)

    AS52763

    AS52793

    10.375 (0.408)

    2.311 (0.091)

    1.10 (0.043)

    U760329

    11.955 (0.471)

    2.413 (0.095)

    1.10 (0.043)

    U760330

    13.625 (0.536)

    2.413 (0.095)

    1.10 (0.043)

  6. SUBTASK 70-35-26-300-006 Table 5 (Thinwall insert part numbers and specified dimensions)

    Short insert

    Long insert

    DIA A min mm (in.)

    B depth min mm (in.)

    After swage check gauge

    AS52760

    AS52790

    5.36 (0.211)

    1.702 (0.067)

    726016*

    AS52761

    AS52791

    7.11 (0.279)

    1.651 (0.065)

    726588*

    AS52762

    AS52792

    8.76 (0.344)

    1.575 (0.062)

    726009*

    AS52763

    AS52793

    10.36 (0.407)

    2.185 (0.086)

    726592*

    U760329

    11.94 (0.471)

    2.286 (0.09)

    726030*

    U760330

    13.61 (0.535)

    2.286 (0.09)

    726033*

    *As an alternative, it is permitted to use the after swage check gauge that the insert manufacturer specifies for the installed insert.

  7. SUBTASK 70-35-26-300-007 Table 6 (Cutter dimensions for thinwall insert removal)

    Short insert

    Long insert

    Cutter thread diameter W (BS1580)

    Major dia. inches

    Pitch dia. inches

    Dia X mm(in.)

    Tol m6

    Y mm(in.) Tol +/- 0.3 mm

    AS52760

    AS52790

    0.1870-32 UNS-3A

    0.1870 0.1810

    0.1667 0.1644

    6.37

    (0.25)

    8.00 (0.315)

    AS52761

    AS52791

    0.2470-28 UNS-3A

    0.2470 0.2405

    0.2238 0.2212

    7.96

    (0.313)

    9.50 (0.374)

    AS52762

    AS52792

    0.3095-24 UNS-3A

    0.3095 0.3023

    0.2824 0.2796

    9.53

    (0.375)

    12.50 (0.492)

    AS52763

    AS52793

    0.3720-24 UNS-3A

    0.3720 0.3648

    0.3449 0.3420

    11.00 (0.433)

    14.50 (0.570)

    U760329

    0.4345-20 UNS-3A

    0.4345 0.4264

    0.4020 0.3989

    12.73 (0.501)

    16.00 (0.629)

    U760330

    0.490-20 UNS-3A

    0.4970 0.4889

    0.4645 0.4613

    14.25 (0.561)

    18.50 (0.728)

    8. Figure: Bolt Thread diameter in relation to serration contour (Refer also to table 2)

    Bolt Thread diameter in relation to serration contour (Refer also to table 2)

    Figure: Installation Tool Data (Refer also to Table 3)

    Installation Tool Data (Refer also to Table 3)

    Figure: Installation Depth

    Installation Depth

    Figure: Aligned Serrations

    Aligned Serrations

    Figure: Swage Tool Data (Refer also to Table 4)

    Swage Tool Data (Refer also to Table 4)

    Figure: Swaged Thinwall Insert and Tool

    Swaged Thinwall Insert and Tool

    Figure: Dimensions Required (Refer also to Table 5)

    Dimensions Required (Refer also to Table 5)

    Figure: Removal of a Thinwall Insert (Refer also to Table 6)

    Removal of a Thinwall Insert (Refer also to Table 6)

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to update text and references. (18VC491)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 04-004
Type:sp01
Supply Short Name:CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE
Supply Name:CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE
Specification Groups:
Doc NumberType
OMAT: 4/46 (REF RR)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
JCR-025 (JAEC REF)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
MSRR 9055 (RR REF)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
Suppliers:
ManufacturerRemarks
LOCAL
460Y4
CJ731
K3237
Manufacturer Code:LOCAL
Tool Number:Standard workshop tools
Tool Name:Standard workshop tools
Manufacturer Code:LOCAL
Tool Number:Thinwall self-lock insert removal/installation tools
Tool Name:Thinwall self-lock insert removal/installation tools