TASK 72-60-21-300-053 Main Gearbox Casing - Repair The Crank Cover Stud Holes By Bushing, Repair-053 (VRS5679)

DMC:V2500-A0-72-60-2101-35A-664A-C|Issue No:001.00|Issue Date:2014-08-01

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 72-60-21-300-053 Main Gearbox Casing - Repair The Crank Cover Stud Holes By Bushing, Repair-053 (VRS5679)

Effectivity

FIG/ITEM

PART NO.

02-050

4B0053

02-050

4B0054

02-050

4B0055

02-050

4B0057

02-050

4B0400

02-050

4B0402

02-050

4B0423

Material of component

DESCRIPTION

RR

SYMBOL

MATERIAL

Casing, Main Angle Gearbox

A357/T61 (AMS4219)

Aluminium alloy

Bushing

A357-T61 Spec. AMS4219,

or AMS 4120 (type 2024 T4fT351)

Aluminium alloy, Beryllium free

General

Price and availability - None

The practices and processes referred to in the procedure by the TASK numbers are in the SPM.

For the removal of lock rings and studs, refer to (VRS5255) TASK 72-60-21-300-004, SUBTASKS 72-60-21-320-054 and 72-60-21-350-057.

For the installation of studs and lock rings, refer to (VRS5255) TASK 72-60-21-300-004, SUBTASKS 72-60-21-350-058 and 72-60-21-350-059.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Standard Workshop EquipmentLOCALStandard Workshop Equipment
FPI EquipmentLOCALFPI Equipment
Workshop Inspection Equipment0AM53Workshop Inspection Equipment
Magnifying GlassLOCALMagnifying Glass
Vibration peen equipmentLOCALVibration peen equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-459 AQUEOUS WIPE CLEANER71410CoMat 01-459
CoMat 07-028 CHROMATE CONVERSION COATING FOR ALUMINUMLOCALCoMat 07-028
CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)LOCALCoMat 06-063
CoMat 02-002 ADHESIVE TAPE GENERALPURPOSE PAPERLOCALCoMat 02-002

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-60-21-350-001 Mask the Gearbox Casing

      1. Mask all bores, holes, passage ways in the proximity of the repair area.

    2. SUBTASK 72-60-21-320-001 Machine the Damaged Holes of the Gearbox Casing

    1. Refer to Figure.

      2. Inspect the damaged holes.

      1. Inspect the holes to find if this repair was done before.

      2. If it is not there, go to operation Step.

      3. CAUTION

        Use appropriate drilling equipment to remove the pin first, then remove the bushing. Make sure that you do not damage the gearbox casing.

        If it is there, it must be removed by machining. Go to Step.

      3. Drill the damaged holes.

      1. Refer to Figure and Figure.

      2. Use a drilling tool with flat head. The diameter of the hole must be 0.439 - 0.449 in. (11. 160 - 11. 400 mm). Drill to a depth of 0.745 - 0.752 in. (18.900 - 19.100 mm).

      4. Drill the counterbores.

      1. Use a drilling tool with flat head. The diameter must be 0.599 - 0.602 in. (15.200 - 15.300 mm). Drill to depth of 0.252 - 0.259 in. (6.400 - 6.600 mm).

      5. Inspect the holes for cracks.

      1. Use a magnifying glass. As an alternative, do a local fluorescent penetrant inspection.

      3. Cracks are not allowed.

      6. Tap the holes.

      1. Tap the hole. The thread must be .500- UNJC. The depth of the thread must be 0.709 - 0.728 in. (18.000 - 18.500 mm) from the surface of the gearbox casing.

    3. SUBTASK 72-60-21-220-001 Examine the Gearbox Casing

      1. Locally degrease the repaired area.

      1. Use CoMat 01-031 or similar.

      2. Inspect the gearbox casing for cracks in the area of the bore.

      3. Locally restore the surface protection.

      1. Refer to SPM TASK 70-38-02-300-503.

    4. SUBTASK 72-60-21-320-002 Produce a Bushing

    1. Refer to Figure.

      2. Machine the bushing.

      1. Use the specified types of Aluminium alloy. Do not use other types of material. Refer to Figure.

      2. Make sure you comply with dimensions and tolerances.

        NOTE

        A convenient fixture to torque the bushing into its position in the main gearbox casing can be machined on the external flat surface.

      3. Apply the chromate conversion coating to the bushing.

      1. Refer to SPM TASK 70-38-02-300-503.

    5. SUBTASK 72-60-21-350-002 Install the Bushing into the Machined Hole of the Gearbox Casing

      1. Screw the bushing in.

      1. Torque the bushing in the threaded hole of the casing. Make sure that the bushing reaches the bottom. Do not exceed 220 lbf-in. (25 Nm).

      2. Machine the bushing.

      1. Machine the bushing end flush with the casing surface.

    6. SUBTASK 72-60-21-350-003 Install an Anti-Rotation Pin

    1. Refer to Figure.

      2. Drill the pin hole.

      1. Drill a hole axially across the counter bore between the gearbox casing and the bushing. The diameter of the hole must be between 0.077 - 0.079 in. (1.950 - 2.000 mm). The tolerance for the perpendicularity of the hole axis is the same as for the previous drilling. Hole depth is 0.193 - 0.200 in. (4.900- 5.100 mm).

      2. Measure and record the pin hole diameter.

      3. Make a Pin.

      1. Machine a pin to fit into the pin hole with an interference between 0.0004 - 0.0007 in. (0 .010 - 0.020 mm). Pin length is 0.256 in. (6.500 mm).

      4. Apply surface protection coating to the pin.

      1. Refer to SPM TASK 70-38-02-300-503.

      5. Install the anti-rotation pin.

      1. Refer to Figure.

      2. Install the anti-rotation pin within the dedicate hole. Freeze the pin up to -60°C. Use of nitrogen liquid is also allowed. Machine the pin end flush with the bushing surface.

    7. SUBTASK 72-60-21-320-002 Drill and Tap the Stud Holes in the Bushings

    1. Refer to Figure.

      2. Drill the stud holes.

      1. Use a drilling tool with flat head. The diameter of the hole must be 0.272 - 0.280 in. (6.910 - 7.100 mm). Drill to a maximum depth of 0.74 in. (18.800 mm).

      3. Drill the counterbores.

      1. Use a drilling tool with flat head. The diameter must be 0.375 - 0.378 in. (9.525 - 9.600 mm). Drill to depth of 0.141- 0.171 in. (3.580 - 4.340 mm).

      4. Inspect the holes for cracks.

      1. Use a Magnifying Glass. As an alternative, do a local fluorescent penetrant inspection. Follow SPM TASK 70-23-05-230-501, use CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY).

      2. Cracks are not allowed.

      5. Tap the holes.

      1. Tap the hole. The thread must be .3125 - 24UNJ-3B. The depth of the thread must be 0.5945 in. (15.100 mm) minimum from the surface of the gearbox casing.

    8. SUBTASK 72-60-21-350-004 Install New Studs

      1. Install the studs and locking rings.

      1. Install the studs and locking rings per VRS5255, SUBTASK 72-60-21-350-058 and 72-60-21-350-059.

      2. Apply surface protection coating.

      1. Refer to SPM TASK 70-38-02-300-503.

    9. SUBTASK 72-60-21-350-005 Identify the Repair

      1. Make a mark VRS5679 adjacent to the part number.

      1. Use vibro engraving equipment. Refer to TASK 70-09-00-400-501 and SUBTASK 70-09-00-400-001.

      2. Protect the marked area.

      1. Do the touch up process. Refer to SPM TASK 70-38-02-300-503.

    10. Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair all details and dimensions

    Repair all details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added new repair. (EA14VF806)

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:71410
Enterprise Name:HENKEL CORPORATION (WAS: TURCO PRODUCTS, INC)
BU Name:HENKEL CORPORATION (WAS: TURCO PRODUCTS, INC)
Street:32100 STEPHENSON HIGHWAY
City:MADISON HEIGHTS
State:MI
Zip Code:48071
Country:USA
Phone Number:1-248-583-9300
Fax Number:1-248-583-2976
Internet:www.aerospace.henkel.com
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:71410
Supply Number:CoMat 01-459
Type:sp01
Supply Short Name:CoMat 01-459 AQUEOUS WIPE CLEANER
Supply Name:CoMat 01-459 AQUEOUS WIPE CLEANER
Specification Groups:
Doc NumberType
SPMC 148-1TURCO 6780
Suppliers:
ManufacturerRemarks
71410
Manufacturer Code:LOCAL
Supply Number:CoMat 02-002
Type:sp01
Supply Short Name:CoMat 02-002 ADHESIVE TAPE GENERALPURPOSE PAPER
Supply Name:CoMat 02-002 ADHESIVE TAPE GENERALPURPOSE PAPER
Specification Groups:
Doc NumberType
JCR-198SCOTCH 202 PREMIUM GRADE (A-A-883 TYPE I)
OMAT: 237SCOTCH 202 PREMIUM GRADE (A-A-883 TYPE I)
Suppliers:
ManufacturerRemarks
LOCAL
94960
K0993
K6835
Manufacturer Code:X222X
Supply Number:CoMat 06-063
Type:sp01
Supply Short Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Supply Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐063 letter suffix material with other CoMat 06‐063 letter suffix materials. Where CoMat 06‐063 is specified with no suffix, use one of the CoMat 06‐063 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Supply Number:CoMat 07-028
Type:sp01
Supply Short Name:CoMat 07-028 CHROMATE CONVERSION COATING FOR ALUMINUM
Supply Name:CoMat 07-028 CHROMATE CONVERSION COATING FOR ALUMINUM
Specification Groups:
Doc NumberType
DELETED. USE COMAT 01-275
Suppliers:
ManufacturerRemarks
LOCAL
Link not Found
Manufacturer Code:LOCAL
Tool Number:Magnifying Glass
Tool Name:Magnifying Glass
Manufacturer Code:LOCAL
Tool Number:Standard Workshop Equipment
Tool Name:Standard Workshop Equipment
Manufacturer Code:LOCAL
Tool Number:Vibration peen equipment
Tool Name:Vibration peen equipment
Manufacturer Code:0AM53
Tool Number:Workshop Inspection Equipment
Tool Name:Workshop Inspection Equipment