TASK 72-60-21-300-060 Main Gearbox Casing - Repair The Crank Cover Stud Holes By Oversize Stud, Repair-060 (VRS5713)

DMC:V2500-A0-72-60-2101-40A-664A-C|Issue No:001.00|Issue Date:2021-08-01

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 72-60-21-300-060 Main Gearbox Casing - Repair The Crank Cover Stud Holes By Oversize Stud, Repair-060 (VRS5713)

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

SYMBOL

MATERIAL

Casing, Main Angle Gearbox

A357/T61 (AMS4219)

Aluminum alloy

General

This repair can be performed on a Gearbox Casing in either the fully disassembled piece-part level or as part of an assembled Gearbox Assembly. When at piece-part level, a milling machine must be used to machine the Gearbox Casing. When installed in a Gearbox Assembly, the IAE 3P16628 Guide, Drill must be used to machine the Gearbox Casing.

For the removal of lock rings and studs, refer to Repair, VRS5255 TASK 72-60-21-300-004 (REPAIR-004), SUBTASK 72-60-21-320-054 and SUBTASK 72-60-21-350-057. For the installation of studs and lock rings, refer to Repair, VRS5255 TASK 72-60-21-300-004 (REPAIR-004), SUBTASK 72-60-21-350-058 and SUBTASK 72-60-21-350-059.

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 3P16628 Guide, Drill0AM53IAE 3P16628
Drive ToolLOCALSF5902-3D
WrenchLOCALR1105W
Removal toolLOCALSM101-18
Magnifying GlassLOCALMagnifying Glass
Vibration peen equipmentLOCALVibration peen equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-031 ACETONE (CH3)2COLOCALCoMat 01-031
CoMat 01-459 AQUEOUS WIPE CLEANER71410CoMat 01-459
CoMat 02-002 ADHESIVE TAPE GENERALPURPOSE PAPERLOCALCoMat 02-002
CoMat 07-028 CHROMATE CONVERSION COATING FOR ALUMINUMLOCALCoMat 07-028
CoMat 10-077 APPROVED ENGINE OILSX333XCoMat 10-077

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
STUD96906MS51992C503-11
STUD96906MS51992C643-11
RING - LOCKING96906MS51997E103P

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-60-21-220-200 Examine the Repair Area

    1. Refer to Figure.

      2. This repair cannot be done if you find a threaded bushing at the repair location. Examine each stud location separately.

      1. Reference Repair, VRS5679 TASK 72-60-21-300-053 (REPAIR-053).

    2. SUBTASK 72-60-21-380-004 Mask the Gearbox Casing

      1. Apply a mask or maskants to all bores, holes, and passage ways in the proximity of the repair area.

    3. SUBTASK 72-60-21-350-221 Remove the Stud, if Necessary

      NOTE

      Only remove one stud at a time. An installed stud is necessary opposite the repair area to properly locate the IAE 3P16628 Guide, Drill.

      1. Mill through the serrations of the MS51997E103P RING - LOCKING. Use Removal tool.

      1. Lift tool frequently to permit clearing metal chips from the cutting teeth.

      2. It is not necessary to mill fully through the MS51997E103P RING - LOCKING. Only milling through the serrations is necessary.

      2. Apply the removal torque to the stud.

      1. Continuous pressure of withdrawn stud must cause lock ring to be forced out from its location.

    4. SUBTASK 72-60-21-320-177 Machine the Gearbox Casing (When Gearbox Casing is Installed on Milling Machine)

    1. Refer to Figure, Figure, and Figure.

    2. Machine the gearbox casing to accept the oversize stud and lock ring.

    5. SUBTASK 72-60-21-320-178 Machine the Gearbox Casing using the IAE 3P16628 Drill Guide (Assembled Gearbox Module Method)

    1. Refer to Figure.

    2. Set the Detail 8 Drill and the Detail 7 Drill Stop to produce the applicable depth tap drill hole. See Figure.

    3. Set the Detail 9 Drill and the Detail 6 Drill Stop to produce the applicable depth counterbore. See Figure.

    4. Remove the tape from the crank port that was applied before.

    5. Install the Detail 4 Bushing to the Detail 1 Base. Lock in place with the Detail 5 Lock Screw.

    6. Install the Detail 2 packing onto the Detail 1 Base.

    7. Attach the Detail 1 Base to the gearbox casing at the manual crank pad location, use the Detail 13 Coupling Nut. Align the drill bushing end of the drill guide over the hole to be repaired. Make sure the conical end of the coupling nut mates with the countersink feature of the base.

    8. Drill the hole with the Detail 8 Drill, Detail 7 Drill Stop, and a hand drill.

    9. Remove the Detail 4 Bushing from the Detail 1 Base and install the Detail 3 Bushing.

    10. Drill the counterbore for the lock ring with the Detail 9 Drill, Detail 6 Drill Stop, and a hand drill.

    11. Tap the hole with the Detail 10 Plug Tap and Detail 12 Tap Handle.

    12. Tap the hole with the Detail 11 Bottoming Tap and Detail 12 Tap Handle.

    13. Remove any machining debris from the hole and the drill guide.

    14. Remove the Detail 13 Coupling Nut and remove the Detail 1 Base from the gearbox casing.

    15. Apply tape to the crank port to prevent debris entering the gearbox.

    6. SUBTASK 72-60-21-220-201 Examine the Repair Area

      1. Locally degrease the repaired area.

      2. Examine the gearbox casing for cracks in the repair area.

      1. Use a 10X Magnifying Glass. Refer to SPM TASK 70-21-00-220-501.

      2. Cracks are not permitted.

      3. Examine for break-through into the internal cavity of the gearbox casing.

      1. Break-through is not permitted.

      4. Locally repair the surface protection.

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

    7. SUBTASK 72-60-21-350-222 Install the Oversize Stud

    1. Refer to Figure.

      2. Lubricate the larger threads of the stud.

      3. Install the stud.

      1. The depth is given in Figure.

      2. Use the Wrench.

    8. SUBTASK 72-60-21-350-223 Install the Lock Ring

    1. Refer to Figure.

      1. Align the staking serrations in the directions having the most wall thickness to the edge of the boss.

      1. Seat the new MS51997E103P RING - LOCKING to depth given in Figure.

      2. Use the Drive Tool.

    9. SUBTASK 72-60-21-350-224 Identify the Repair

      1. Make a mark VRS5713 adjacent to the part number.

      1. Use vibro engraving equipment. Refer to Repair, VRS5679 TASK 70-09-00-400-501 (REPAIR-053) 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 Location

    Repair Location

    Figure: Stud Position

    Stud Position

    Figure: Hole Preparation

    Hole Preparation

    Figure: Threading

    Threading

    Figure: Installation Of Stud

    Installation Of Stud

    Figure: Drill Guide

    Drill Guide

    Drill Guide

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added new repair. (20VF829)

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:96906
Enterprise Name:MILITARY STANDARDS MANUAL 4120 3-M
BU Name:MILITARY STANDARDS MANUAL 4120 3-M
Street:NONE
City:NONE
Country:USA
Phone Number:NONE
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X333X
Enterprise Name:REFER TO V2500 SB ENG-79-0108
Part Number:MS51992C503-11
Part Name:STUD
Manufacturer Code:96906
Part Number:MS51992C643-11
Part Name:STUD
Manufacturer Code:96906
Part Number:MS51997E103P
Part Name:RING - LOCKING
Manufacturer Code:96906
Manufacturer Code:LOCAL
Supply Number:CoMat 01-031
Type:sp01
Supply Short Name:CoMat 01-031 ACETONE (CH3)2CO
Supply Name:CoMat 01-031 ACETONE (CH3)2CO
Specification Groups:
Doc NumberType
OMAT: 150 (RR REF)COMMERCIAL GRADE O-A-51
PMC 9008 (PW REF)COMMERCIAL GRADE O-A-51
JCR-041 (JAEC REF)COMMERCIAL GRADE O-A-51
MTH 169 (98%) (MTU REF)COMMERCIAL GRADE O-A-51
Suppliers:
ManufacturerRemarks
LOCAL
K6835
81348
K3504
U1185
24853
70657
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: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
Manufacturer Code:X333X
Supply Number:CoMat 10-077
Type:sp01
Supply Short Name:CoMat 10-077 APPROVED ENGINE OILS
Supply Name:CoMat 10-077 APPROVED ENGINE OILS
Specification Groups:
Doc NumberType
For V2500-A1/A5/D5 models - Refer to V2500 Service Bulletin ENG-79-0108
For V2500-E5 model - Refer to Service Bulletin E5-79-0001
Suppliers:
ManufacturerRemarks
X333X
Link not Found
Manufacturer Code:LOCAL
Tool Number:Magnifying Glass
Tool Name:Magnifying Glass
Manufacturer Code:LOCAL
Tool Number:R1105W
Tool Name:Wrench
Manufacturer Code:LOCAL
Tool Number:SF5902-3D
Tool Name:Drive Tool
Manufacturer Code:LOCAL
Tool Number:SM101-18
Tool Name:Removal tool
Manufacturer Code:LOCAL
Tool Number:Vibration peen equipment
Tool Name:Vibration peen equipment