TASK 72-00-60-020-003-002 External Gearbox Module - Remove The External Gearbox Module - Method 2, Removal-004

DMC:V2500-A0-72-00-6000-03A-520B-B|Issue No:005.00|Issue Date:2020-05-01

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 72-00-60-020-003-002 External Gearbox Module - Remove The External Gearbox Module - Method 2, Removal-004

General

Fig./item numbers in parentheses in the procedure agree with those used in the IPC. Only the primary Fig/item numbers are used. For the service bulletin alpha variants refer to the IPC.

For all parts identified in a different Chapter/Section/Subject, the applicable Chapter/Section/Subject comes before the Fig./item number.

Lubricate all threads and abutment faces of nuts and bolts. Refer to SPM TASK 70-64-00-640-001.

Seal all openings when tubes are disconnected, to prevent contamination from unwanted material.

Remove and discard the lockwire before parts are disconnected or removed.

Discard all rubber seal rings, cotter pins and seal washers removed in this procedure.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 1F10011 Handling fixture0AM53IAE 1F100112
IAE 1F10021 Storage stand0AM53IAE 1F100211
IAE 1F10022 Hydraulic jack0AM53IAE 1F100221
IAE 1F10023 Gearbox adapter0AM53IAE 1F100231
IAE 1F10026 Hydraulic hand pump0AM53IAE 1F100261
IAE 1F10292 Puller0AM53IAE 1F102921
IAE 1F10293 Puller0AM53IAE 1F102931
IAE 1F10294 Puller0AM53IAE 1F102941
IAE 1F10412 Puller0AM53IAE 1F104121
IAE 1J12082 Holding CapLOCALIAE 1J120821
Container - Minimum capacity of about 10 USgal (38 l)LOCAL
Removal/Installation ToolLOCALS888IDG1

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-147 LOCKWIRELOCALCoMat 02-147

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-60-020-057 Drain the Engine Oil System

      1. WARNING

        DO NOT GET ENGINE OIL ON YOUR SKIN, IN YOUR MOUTH OR IN YOUR EYES. ENGINE OIL IS POISONOUS AND CAN GO THROUGH YOUR SKIN AND IN TO YOUR BODY. FLUSH ENGINE OIL FROM YOUR EYES, MOUTH OR SKIN WITH WATER. GET MEDICAL AID IF YOU GET ENGINE OIL IN YOUR EYES OR MOUTH.
        DO NOT REMOVE THE OIL TANK PRESSURIZATION VALVE FOR FIVE MINUTES AFTER THE ENGINE STOPS TO LET THE TANK PRESSURE BLEED OFF.

        CAUTION

        DO NOT LET THE ENGINE MOTOR WHEN THE OIL IS DRAINED.

        Drain the oil tank.

      1. Loosen the oil filler cap.

      2. Release and remove the drain oil plug ENGINE-MAIN GEARBOX CASE AND FITTINGS (72-60-21, 01-120) from the front flange of the main gearbox casing, below the oil pressure pump.

      3. Discard the packing from the plug.

      4. NOTE

        Let the engine oil drain for a minimum of 10 minutes.

        Drain the oil in to a container.

      2. Drain the external gearbox.

      1. Put a clean container below the external gearbox to catch the drained oil.

      2. Remove the Left-Hand Gearbox magnetic chip detector (MCD). Refer to TASK 72-00-00-050-001 (REMOVAL-001).

      3. Remove the MCD housing Magnetic Chip Detector (79-22-45, 01-120).

      4. Unscrew and remove the MCD housing. Discard the lockwire. Let the oil drain into a container.

      5. Remove and discard the seal ring Magnetic Chip Detector (79-22-45, 01-140) from the MCD housing.

      6. Repeat Step thru Step for the Right-Hand Gearbox magnetic chip detector and the Angle Gearbox magnetic chip detector.

      3. Drain the pressure and scavenge oil filters.

      1. Release and remove the plugs from the bottom of the pressure and scavenge oil filters. Drain the oil in to a container.

      2. Discard the packings from the plugs.

    2. SUBTASK 72-00-60-020-058 Remove the Gearbox Dressings

    1. V2500-A1 Remove the tubes and the electrical harness from the external gearbox, refer to TASK 72-00-60-020-002-A00.

    2. V2500-A5 Remove the tubes and the electrical harness from the external gearbox, refer to TASK 72-00-60-020-002-B00.

    3. SUBTASK 72-00-60-050-051 Remove the Oil Scavenge Filter Housing Assembly and the Oil Feed Tubes (180 and 179)

    1. Refer to Figure.

    2. Remove the three bolts, the one washer, and the bracket that attach the tube (180) to the oil tank.

    3. Remove the three bolts and the three washers which attach the oil tube (179) to the oil scavenge pump.

      4. Remove the scavenge oil filter housing assembly with the oil tubes (180 and 179) as follows:

      1. CAUTION

        HOLD THE WEIGHT OF THE SCAVENGE FILTER DURING THE REMOVAL OF THE BOLTS.

        Hold the scavenge oil filter housing assembly.

      2. Remove the three bolts and washers which attach the scavenge oil filter housing assembly to the oil tank.

      3. Carefully move the scavenge oil filter housing assembly to disengage the flange of the oil feed tube (180) from the flange on the oil tank.

      4. Disengage the flange of the oil tube (179) from the flange on the oil scavenge pump.

      5. Remove the scavenge oil filter housing assembly with oil tubes (180) and (179).

      6. Remove and discard the two packings.

    5. Remove the six bolts and the six washers which attach the tubes (171) and the oil feed tube (180) to the oil filter housing assembly.

    6. NOTE

      The parts of the oil scavenge filter must have their maintenance completed, as given in the Component Maintenance Manual, Pub.ref. CMM-MECH-V2500-1IA.

      Remove and discard the packings.

    4. SUBTASK 72-00-60-050-063 Remove the Oil Tank

    1. Refer to Figure.

    2. CAUTION

      HOLD THE WEIGHT OF THE OIL TANK DURING THE REMOVAL OF THE NUTS.

      Remove the six nuts and two washers which attach the oil tank and the brackets to the gearbox casing. Remove the brackets.

    3. Remove the oil tank from the gearbox casing.

    4. NOTE

      The parts of the oil tank filter must have their maintenance completed, as given in the Component Maintenance Manual, Pub.ref. CMM-MECH-V2500-1IA.

      Discard the packing.

    5. SUBTASK 72-00-60-050-064 Remove the Oil Scavenge Pump

    1. Remove the oil scavenge pump, refer to TASK 72-00-60-050-007, SUBTASK 72-00-60-050-105 .

    6. SUBTASK 72-00-60-050-065 Remove the Fuel Metering Unit

    1. Remove the fuel metering unit. Refer to TASK 72-00-60-050-002, SUBTASK 72-00-60-050-058 .

    7. SUBTASK 72-00-60-050-066 Remove the Fuel Pump and the Adapter Housing

    1. Refer to Figure.

    2. Remove the fuel pump. Refer to TASK 72-00-60-050-008, SUBTASK 72-00-60-050-097 .

      3. Remove the adapter housing.

      1. Remove the nuts and the washers.

      2. Remove the bracket.

      3. Remove the adapter housing.

      4. Remove and discard the sealing ring.

    8. SUBTASK 72-00-60-050-067 Remove the Integrated Drive Generator

    1. Refer to Figure.

      2. Install the IDG removal/installation tool (S888IDG).

      1. Put the IDG Removal/Installation tool, S888IDG, in to position below the IDG.

      2. Lift the attachment cradle to the IDG with the hydraulic pump on the IDG Removal/Installation Tool.

      3. Attach the tool to the IDG.

      3. CAUTION

        HELP THE IDG OUT IN A STRAIGHT LINE. THE INPUT SHAFT CAN CATCH AND CAUSE DAMAGE TO THE INPUT SEAL.

        CAUTION

        DO NOT USE EXTERNAL PARTS OR TOOLS TO PULL THE IDG FROM THE GEARBOX. THEY CAN CAUSE DAMAGE.

        Remove the IDG.

      1. Cut and remove the lockwire from the QAD coupling.

      2. NOTE

        If the coupling does not fully open, lightly hit the coupling circumference to help it to open.

        Loosen the QAD coupling and align the two OPEN marks.

      3. Carefully pull the IDG rearwards from the gearbox and remove it.

      4. Remove and discard the packings.

    4. Put applicable covers/caps/plugs on to all the exposed openings and the electrical connections.

    9. SUBTASK 72-00-60-050-068 Remove the IDG QAD Coupling

    1. Refer to Figure.

    2. CAUTION

      DO NOT HIT THE PUNCH TOO HEAVILY, THIS CAN CAUSE DAMAGE TO THE SCREWS.

      NOTE

      The screws can be very tight and should be hit heavily to loosen them. You may use an impact driver as an alternative to a punch.

      Use a flat headed punch to loosen the screws that attach the QAD coupling and the gasket to the gearbox accessory mounting pad.

    3. If the screws still do not turn, loosen them with a punch that has a point. Use the punch at an angle to turn the screws counter-clockwise.

    4. Remove the screws.

    5. Remove the coupling and the gasket.

    6. Discard the gasket.

    7. Put the applicable covers/caps/plugs on the gearbox accessory mounting pad.

    10. SUBTASK 72-00-60-050-158 Remove the IDG Cooling Tubes Overflow, Pressure Couplings, Overflow Drain Valves and Pressure-Fill Valve

    1. Refer to Figure.

    2. Make a note of the couplings ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-110) and ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-502). They must be put in the same positions on installation.

    3. Remove the couplings ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-110) and ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-502). Remove and discard the packings ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-114) and ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-506).

    4. Remove the overflow drain valve ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-050) and the pressure-fill valve ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-060). Remove and discard the packings ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-045) and V2500-A5-21-24-51-01A-941A-D (21-24-51, 01-058).

    5. Put applicable covers/caps/plugs on to all exposed openings.

    11. SUBTASK 72-00-60-050-069 Remove the Oil Pressure Pump and Filter Assembly

    1. Remove the oil pressure pump and filter assembly. Refer to TASK 72-00-60-050-003, SUBTASK 72-00-60-050-100 .

    12. SUBTASK 72-00-60-050-070 Remove the Hydraulic Pump

    1. Refer to Figure.

    2. CAUTION

      HOLD THE WEIGHT OF THE HYDRAULIC PUMP DURING THE REMOVAL OF THE NUTS.

      Loosen the four nuts and turn the pump to put the nuts in the large holes.

    3. Remove the hydraulic pump.

    4. Discard the gasket and the seal.

    5. Put the applicable covers/caps/plugs on the gearbox accessory mounting pad.

    13. SUBTASK 72-00-60-050-071 Remove the Dedicated Alternator Stator

    1. V2500-A1 Remove the Dedicated Alternator Stator, Ref. TASK 72-00-60-050-001-A00.

    2. V2500-A5 Remove the Dedicated Alternator Stator, Ref. TASK 72-00-60-050-001-B00.

    14. SUBTASK 72-00-60-050-072 Remove the Starter

    1. Remove the starter, Ref. TASK 72-00-60-050-009.

    15. SUBTASK 72-00-60-020-059 Install the External Gearbox Support Tooling

    1. Refer to Figure.

    2. Install the IAE 1F10011 Handling fixture 2 off on the ground handling bosses on the bottom of the external gearbox.

      Refer to Figure.

    3. If necessary, install IAE 1F10026 Hydraulic hand pump 1 off on IAE 1F10022 Hydraulic jack 1 off and connect the hose.

    4. Install IAE 1F10023 Gearbox adapter 1 off on the plate of the hydraulic jack. Make sure the adjustable support of the hydraulic jack is in lowered position.

    5. Move the hydraulic jack with the handling adapter below the engine. Operate the hydraulic pump to lift the hydraulic jack until the handling adapter is at about 2.75 in. (70 mm) from the gearbox.

    6. Turn clockwise the knob on the front of the hydraulic jack base to prevent any accidental lowering of the hydraulic jack.

    7. Align the holes on the shock absorber of the handling adapter with the two handling pins. Align the angle gearbox support with the angle gearbox.

    8. Turn clockwise the handwheel of the adjustable support of the hydraulic jack. Lift the handling adapter until the handling pins are fully in to the holes of the shock absorbers. Make sure the angle gearbox support touches the angle gearbox.

    9. Install the two safety pins in to the hole of the handling pin.

    10. Put the two locking rods in position on the bosses of the angle gearbox. Safety with the knobs.

    11. Turn clockwise the handwheel of the adjustable support to remove the weight of the external gearbox from the link.

    16. SUBTASK 72-00-60-020-060 Disconnect the External Gearbox from the Intermediate Case

    1. Refer to Figure.

      2. Disconnect the right hand link on the front of the gearbox.

        Refer to Figure.

      1. Remove the two bolts that safety the bonding strap and the pins. Remove the bonding strap. Install again the bolts and tighten by hand.

      2. Remove the two nuts, washers and bolts which attach the two brackets to the intermediate case flange.

    3. Disconnect the left hand link on the front of the gearbox. Do the Step and.

      Refer to Figure.

      4. Disconnect the rear link.

      1. Remove the two nuts, washers and bolts which attach the brackets of the rear link to the intermediate case flange.

      5. CAUTION

        DO NOT PUT LOAD ON THE CENTER LINK AND BRACKETS WITH THE WEIGHT OF THE GEARBOX DURING THE SUBSEQUENT OPERATION.

        NOTE

        Do the subsequent operation to easy the access at the center link of the gearbox.

        Disconnect the front center link.

        Refer to Figure.

      1. Turn counterclockwise the handwheel of the adjustable support to move the external gearbox away from the engine until the link is in vertical position.

      2. Remove the two nuts, washers and bolts which attach the brackets to the intermediate case flange.

    17. SUBTASK 72-00-60-020-061 Remove the External Gearbox from the Intermediate Case

    1. Lower the hydraulic jack and remove the external gearbox from the intermediate case.

    2. Move the external gearbox from the engine.

      3. Put the assemblies adapter gearbox/external gearbox on IAE 1F10021 Storage stand 1 off.

      1. Move the hydraulic jack to the front of the opened side of the storage stand.

      2. If necessary, lift the hydraulic jack until the handling adapter is higher than the storage stand.

      3. Move the hydraulic jack and align the handling adapter with the support of the storage stand.

      4. Slowly lower the hydraulic jack until the handling adapter touch the support of the storage stand. Safety with the quick release pins. Remove the hydraulic jack from the storage stand.

    18. SUBTASK 72-00-60-020-139 Install Holding Cap on to the Oil Seal Tube to Hold the PTO Shaft

    1. Refer to Figure.

    2. Remove two of the four bolts (01-160) to replace them with the two bolts of the holding cap. Refer to Figure for the positions of the bolts to be replaced.

    3. Turn the cap screw (part of IAE 1J12082 Holding Cap 1 off) counterclockwise fully to move it out of the cap.

    4. Align the four boltholes in the cap (part of the holding cap) with the two bolts and the two holes in the oil seal tube.

    5. Attach the cap to the oil seal tube and safety with the two washers, spring washers and bolts (part of the holding cap). Tighten the bolts.

    6. Turn the cap screw clockwise until the sheet touches the PTO shaft.

    7. Safety the cap screw with CoMat 02-147 LOCKWIRE. Refer to SPM TASK 70-42-05-400-501.

    8. Install the two nuts (part of the holding cap) on to the two bolts (01-160) that were removed before. Install the bolts in to the threaded holes in the cap and tighten the nuts.

      NOTE

      The holding cap is removed from the oil seal. The two bolts (01-160) are moved from the cap to the oil seal tube in TASKS which install the external gearbox to the fan case.

    19. SUBTASK 72-00-60-020-062 Remove the Support Link Assemblies from the External Gearbox

    1. Refer to Figure.

      2. Remove the right hand link with IAE 1F10292 Puller 1 off.

        Refer to Figure.

      1. Remove the bolt that safeties the pin to the lug.

      2. Remove the hexagonal head screw from the puller support (if installed).

      3. Put the puller against the gearbox lugs. Align and install the rod of the pusher in to the hole on the lug adjacent the pin.

      4. Put the driver bolt through the smaller hole of the puller support and install in to the bolt hole of the pin.

      5. Put the hexagonal head screw through the larger hole of the puller support and through the internal hole of the pin. Install the special nut on the threaded end of the hexagonal head screw and turn against the pin.

      6. Turn the hexagonal head screw with a standard wrench until the pin is removed from the lugs.

      7. Remove the driver bolt and the pusher from the gearbox lug. Remove the special nut and remove the pin from the hexagonal head screw.

    3. Remove the left hand link with IAE 1F10293 Puller 1 off. Do the Step thru Step.

      Refer to Figure.

      4. Remove the center link with IAE 1F10294 Puller 1 off.

        Refer to Figure.

      1. Remove the bolt that safeties the pin to the lug.

      2. Remove the hexagonal head screw from the puller support (if installed).

      3. Put the puller against the gearbox lug.

      4. Put the driver bolt through the smaller hole of the puller support and install in to the bolt hole of the pin.

      5. Put the hexagonal head screw through the larger hole of the puller support and through the internal hole of the pin. Install the special nut on the threaded end of the hexagonal head screw and turn against the pin.

      6. Turn the hexagonal head screw with a standard wrench until the pin is removed from the lugs.

      7. Remove the driver bolt and the pusher from the gearbox lug. Remove the special nut and remove the pin from the hexagonal head screw.

      5. Remove the rear link from the angle gearbox support.

      1. Remove the bolt and washer which attach the rear pin to the lug.

        2. Prepare the IAE 1F10412 Puller 1 off. Refer to Figure.

        1. Remove the bolt from the puller.

      3. Put the two blocks of IAE 1F10412 Puller 1 off equally spaced between the two lugs of the Angle Gearbox Support.

      4. Install the bolt through the puller and into the threaded bolthole in the pin.

      5. Rotate the two screws at the same time until the pin is free.

      6. Remove the pin.

      7. Remove the puller from the lugs.

      6. Remove the brackets and the pins from the three front links.

      1. Remove the brackets from the free ends of the three pins.

      2. Remove the bolts which attach the pins to the brackets.

      3. Remove the pins from the three links. Use a soft drift.

      4. Remove the remaining brackets from the pins.

      7. Remove the brackets and the pin from the rear link.

      1. Remove the two brackets from the ends of the pin.

      2. Remove the pin from the rear link. Use a soft drift.

        .

    20. Figure: Removal of the Oil Scavenge Filter

    Removal of the Oil Scavenge Filter

    Figure: Removal of the Oil Tank Tooling

    Removal of the Oil Tank Tooling

    Figure: Removal of the Fuel Pump

    Removal of the Fuel Pump

    Figure: Removal of the Integrated Drive Generator

    Removal of the Integrated Drive Generator

    Figure: Removal of the IDG QAD Coupling

    Removal of the IDG QAD Coupling

    Figure: Removal of the Hydraulic Pump

    Removal of the Hydraulic Pump

    Figure: Removal of the Gearbox Support Tooling

    Sheet 1

    Legend
    Removal of the Gearbox Support Tooling

    Sheet 1

    Close

    Figure: Removal of the Gearbox Support Tooling

    Sheet 2

    Legend
    Removal of the Gearbox Support Tooling

    Sheet 2

    Close

    Figure: Removal of the External Gearbox from the Intermediate Case

    Sheet 1

    Legend
    Removal of the External Gearbox from the Intermediate Case

    Sheet 1

    Close

    Figure: Removal of the External Gearbox from the Intermediate Case

    Sheet 2

    Legend
    Removal of the External Gearbox from the Intermediate Case

    Sheet 2

    Close

    Figure: Removal of the External Gearbox from the Intermediate Case

    Sheet 3

    Legend
    Removal of the External Gearbox from the Intermediate Case

    Sheet 3

    Close

    Figure: Removal of the Support Link Assembly from the External Gearbox

    Sheet 1

    Legend
    Removal of the Support Link Assembly from the External Gearbox

    Sheet 1

    Close

    Figure: Removal of the Support Link Assembly from the External Gearbox

    Sheet 2

    Legend
    Removal of the Support Link Assembly from the External Gearbox

    Sheet 2

    Close

    Figure: Install The Holding Cap On To The PTO Shaft To Hold The PTO Shaft

    Install The Holding Cap On To The PTO Shaft To Hold The PTO Shaft

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added new subtask and figure. (19VC647)

Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 02-147
Type:sp01
Supply Short Name:CoMat 02-147 LOCKWIRE
Supply Name:CoMat 02-147 LOCKWIRE
Specification Groups:
Doc NumberType
AIA/NAS NASM20995 Part Number MS20995C32 (0,8 MM)
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:0AM53
Tool Number:IAE 1F10011
Tool Name:IAE 1F10011 Handling fixture
Manufacturer Code:0AM53
Tool Number:IAE 1F10021
Tool Name:IAE 1F10021 Storage stand
Manufacturer Code:0AM53
Tool Number:IAE 1F10022
Tool Name:IAE 1F10022 Hydraulic jack
Manufacturer Code:0AM53
Tool Number:IAE 1F10023
Tool Name:IAE 1F10023 Gearbox adapter
Manufacturer Code:0AM53
Tool Number:IAE 1F10026
Tool Name:IAE 1F10026 Hydraulic hand pump
Manufacturer Code:0AM53
Tool Number:IAE 1F10292
Tool Name:IAE 1F10292 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1F10293
Tool Name:IAE 1F10293 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1F10294
Tool Name:IAE 1F10294 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1F10412
Tool Name:IAE 1F10412 Puller
Link not Found
Manufacturer Code:LOCAL
Tool Number:S888IDG
Tool Name:Removal/Installation Tool
Link not Found