BHT-206L3-MM-6

CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

63-1 Main Rotor Drive System ............................................................... 63-00-00 5

63-2 Allowable Leakage Rates for Main Rotor Drive System
Components ............................................................................. 63-00-00 5
63-3 Troubleshooting Main Rotor Drive System .................................... 63-00-00 5
63-4 Troubleshooting Transmission System..................................... 63-00-00 5
63-5 Troubleshooting Transmission Mounts..................................... 63-00-00 10
63-6 Troubleshooting Main Driveshaft .............................................. 63-00-00 10
63-7 Troubleshooting Freewheeling Assembly................................. 63-00-00 10
63-8 Oil Contamination .......................................................................... 63-00-00 10
63-9 Identification of Foreign Material............................................... 63-00-00 11
63-10 Transmission Oil Contamination............................................... 63-00-00 11
63-11 Freewheeling Unit Oil Contamination ....................................... 63-00-00 12
63-12 Transmission System Oil Servicing Drain Hoses........................... 63-00-00 12
63-13 Serviceability Check....................................................................... 63-00-00 15
63-14 Transmission Serviceability Check ........................................... 63-00-00 15
63-15 Freewheeling Assembly Serviceability Check .......................... 63-00-00 16

GREASE LUBRICATED MAIN DRIVESHAFT

63-16 Grease Lubricated Main Driveshaft ............................................... 63-00-00 17

63-17 Grease Lubricated Main Driveshaft — Removal ...................... 63-00-00 17
63-17A Grease Lubricated Main Driveshaft — Cleaning ...................... 63-00-00 17
63-18 Grease Lubricated Main Driveshaft — Inspection .................... 63-00-00 17
63-19 Grease Lubricated Main Driveshaft — Installation ................... 63-00-00 18E

ENGINE TO TRANSMISSION DRIVESHAFT

206L3+ IGW UPGRADE

63-19A Engine to Transmission Driveshaft — KAflex ................................ 63-00-00 18G

63-19B KAflex Driveshaft — Removal .................................................. 63-00-00 18G
63-19C KAflex Driveshaft — Cleaning .................................................. 63-00-00 18I
63-19D KAflex Driveshaft — Inspection ................................................ 63-00-00 18L
63-19E KAflex Driveshaft — Repair ...................................................... 63-00-00 18L
63-19F KAflex Driveshaft — Installation ............................................... 63-00-00 18M
63-20 Main Rotor Mast............................................................................. 63-00-00 19
63-21 Main Rotor Mast — Removal.................................................... 63-00-00 19
63-22 Main Rotor Mast — Cleaning.................................................... 63-00-00 19
63-23 Main Rotor Mast — Inspection and Repair............................... 63-00-00 21
63-24 Main Rotor Mast — Installation................................................. 63-00-00 21
63-25 Transmission.................................................................................. 63-00-00 22
63-26 Transmission — Removal......................................................... 63-00-00 22
63-27 Transmission — Cleaning......................................................... 63-00-00 24
63-28 Transmission — Inspection and Repair.................................... 63-00-00 24
63-29 Transmission — Installation...................................................... 63-00-00 25
63-30 Transmission — Operational Check ......................................... 63-00-00 27
63-31 Tachometer Generator................................................................... 63-00-00 27

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 1
BHT-206L3-MM-6

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-32 Tachometer Generator — Removal.......................................... 63-00-00 27

63-32A Tachometer Generator — Inspection ....................................... 63-00-00 27
63-32B Tachometer Generator — 600-Hour/12-Month Inspection
and Lubrication Interval ............................................................ 63-00-00 30C
63-33 Tachometer Generator — Installation....................................... 63-00-00 30F
63-34 Transmission Oil System ............................................................... 63-00-00 30F
63-35 Oil Pump ........................................................................................ 63-00-00 30G
63-36 Oil Pump — Removal ............................................................... 63-00-00 30G
63-37 Inspection and Repair............................................................... 63-00-00 32
63-38 Installation................................................................................. 63-00-00 32
63-39 Oil Pump Inlet Screen .................................................................... 63-00-00 33
63-40 Oil Pump Inlet Screen — Removal ........................................... 63-00-00 33
63-41 Oil Pump Inlet Screen — Inspection......................................... 63-00-00 33
63-42 Oil Pump Inlet Screen — Installation ........................................ 63-00-00 33
63-43 Electric Chip Detectors .................................................................. 63-00-00 33
63-44 Electric Chip Detectors — Removal ......................................... 63-00-00 33
63-45 Electric Chip Detectors — Inspection ....................................... 63-00-00 34
63-46 Electric Chip Detectors — Installation ...................................... 63-00-00 34
63-47 Transmission Oil Level Sight Gauge.............................................. 63-00-00 34
63-48 Transmission Oil Level Sight Gauge — Removal..................... 63-00-00 34
63-49 Transmission Oil Level Sight Gauge — Inspection .................. 63-00-00 34
63-50 Transmission Oil Level Sight Gauge — Installation.................. 63-00-00 35
63-51 Transmission Oil Jets..................................................................... 63-00-00 35
63-52 Transmission Oil Jets — Removal............................................ 63-00-00 35
63-53 Transmission Oil Jets — Inspection ......................................... 63-00-00 35
63-54 Transmission Oil Jets — Installation......................................... 63-00-00 35
63-55 Transmission Oil Pressure Regulating Valve................................. 63-00-00 37
63-56 Transmission Oil Pressure Regulating Valve — Removal........ 63-00-00 37
63-57 Transmission Oil Pressure Regulating Valve — Inspection ..... 63-00-00 37
63-58 Transmission Oil Pressure Regulating Valve — Installation..... 63-00-00 37
63-59 Transmission Oil Pressure Regulating Valve — Adjustment.... 63-00-00 37
63-60 Transmission Oil Filter And Housing Assemblies .......................... 63-00-00 38
63-61 Transmission Oil Filter And Housing Assemblies — Removal . 63-00-00 38
63-62 Transmission Oil Filter and Housing Assemblies — Inspection 63-00-00 38
63-63 Transmission Oil Filter and Housing Assemblies — Installation 63-00-00 38
63-64 Transmission Oil Filter ................................................................... 63-00-00 40
63-65 Transmission Oil Filter — Removal .......................................... 63-00-00 40
63-66 Transmission Oil Filter — Cleaning and Inspection.................. 63-00-00 40
63-67 Transmission Oil Filter — Installation ....................................... 63-00-00 40
63-68 Transmission Oil Temperature Bulb .............................................. 63-00-00 40
63-69 Transmission Oil Temperature Bulb — Removal ..................... 63-00-00 40
63-70 Transmission Oil Temperature Bulb — Inspection ................... 63-00-00 41
63-71 Transmission Oil Temperature Bulb — Installation .................. 63-00-00 41
63-72 Transmission Oil Bypass Valve ..................................................... 63-00-00 41
63-73 Transmission Oil Bypass Valve — Removal ............................ 63-00-00 41
63-74 Transmission Oil Bypass Valve — Inspection .......................... 63-00-00 41
63-75 Transmission Oil Bypass Valve — Installation ......................... 63-00-00 43
63-76 Transmission Oil Thermostat ......................................................... 63-00-00 43

63-00-00
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 BHT-206L3-MM-6

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-77 Transmission Oil Thermostat — Removal ................................ 63-00-00 43

63-78 Transmission Oil Thermostat — Installation ............................. 63-00-00 43
63-79 Transmission Oil Filter Bypass Indicator........................................ 63-00-00 43
63-80 Bypass Indicator — Removal ................................................... 63-00-00 44
63-81 Bypass Indicator — Inspection ................................................. 63-00-00 44
63-82 Bypass Indicator — Installation ................................................ 63-00-00 44
63-83 Transmission Oil Thermoswitch..................................................... 63-00-00 44
63-84 Transmission Oil Thermoswitch — Removal............................ 63-00-00 45
63-85 Transmission Oil Thermoswitch — Inspection.......................... 63-00-00 45
63-86 Transmission Oil Thermoswitch — Installation......................... 63-00-00 45
63-87 Transmission Oil Fittings................................................................ 63-00-00 45
63-88 Transmission Oil Fittings — Removal....................................... 63-00-00 45
63-89 Transmission Oil Fittings — Installation.................................... 63-00-00 45
63-90 Transmission Oil System Hoses and Tube Assemblies ................ 63-00-00 46
63-91 Hoses and Tube Assemblies — Removal ................................ 63-00-00 46
63-92 Hoses and Tube Assemblies — Cleaning and Inspection........ 63-00-00 46
63-93 Hoses and Tube Assemblies — Installation .................................. 63-00-00 46
63-94 Transmission Oil Pressure Lines — Bleeding .......................... 63-00-00 48
63-95 Transmission Oil Pressure System................................................ 63-00-00 48
63-96 Transmission Oil Pressure Switch — Removal ........................ 63-00-00 48
63-97 Transmission Oil Pressure Switch — Inspection ...................... 63-00-00 48
63-98 Transmission Oil Pressure Switch — Installation ..................... 63-00-00 48
63-99 Transmission Oil Cooler................................................................. 63-00-00 49
63-100 Transmission Oil Cooler — Removal........................................ 63-00-00 49
63-101 Transmission Oil Cooler — Cleaning and Inspection ............... 63-00-00 49
63-102 Transmission Oil Cooler — Installation..................................... 63-00-00 51
63-103 Freewheeling Assembly................................................................. 63-00-00 52
63-104 Freewheeling Assembly — Removal........................................ 63-00-00 52
63-105 Freewheeling Housing — Removal .......................................... 63-00-00 52
63-106 Freewheeling Assembly — Inspection and Repair ................... 63-00-00 54
63-107 Freewheeling Assembly — Installation..................................... 63-00-00 54
63-108 Freewheeling Assembly — Operational Check ........................ 63-00-00 56A

FREEWHEEL ASSEMBLY 406-040-500

206L3+ IGW UPGRADE

63-108A Freewheel Assembly 406-040-500 ................................................ 63-00-00 56C

63-108B Freewheel Assembly 406-040-500 — Removal ....................... 63-00-00 56C
63-108C Freewheel Assembly 406-040-500 — Cleaning ....................... 63-00-00 56H
63-108D Freewheel Assembly 406-040-500 — Inspection and Repair .. 63-00-00 56H
63-108E Freewheel Assembly 406-040-500 — Installation .................... 63-00-00 56J
63-108F Freewheel Assembly 406-040-500 — Operational Check........ 63-00-00 56K

TRANSMISSION MOUNTS — NODAL BEAM

63-109 Transmission Mounts..................................................................... 63-00-00 57

63-110 Transmission Mounts — Cleaning............................................ 63-00-00 57
63-111 Link Attachments ........................................................................... 63-00-00 57

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 16 Page 3
BHT-206L3-MM-6

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-112 Link Attachments — Removal .................................................. 63-00-00 57

63-113 Link Attachments — Inspection and Repair.............................. 63-00-00 58
63-114 Link Attachments — Installation ............................................... 63-00-00 58
63-115 Link Assemblies ............................................................................. 63-00-00 61
63-116 Link Assemblies — Removal .................................................... 63-00-00 61
63-117 Link Assemblies — Inspection and Repair ............................... 63-00-00 61
63-118 Elastomeric Bearings — INspection ......................................... 63-00-00 62
63-119 Elastomeric Components — Sealing ........................................ 63-00-00 62
63-120 Link Assemblies — Installation ................................................. 63-00-00 62
63-121 Arm and Flexure Assembly............................................................ 63-00-00 63
63-122 Arm and Flexure Assembly — Removal................................... 63-00-00 63
63-123 Arm and Flexure Assembly — Inspection And Repair.............. 63-00-00 63
63-124 Arm and Flexure Assembly — Installation................................ 63-00-00 64
63-125 Support Assemblies ....................................................................... 63-00-00 67
63-126 Support Assemblies — Removal .............................................. 63-00-00 67
63-127 Support Assemblies — Inspection and Repair ......................... 63-00-00 67
63-128 Support Assemblies — Installation ........................................... 63-00-00 69
63-129 Transmission Restraint .................................................................. 63-00-00 70
63-130 Transmission Restraint — Removal ......................................... 63-00-00 70
63-131 Transmission Restraint — Inspection and Repair .................... 63-00-00 71
63-132 Transmission Restraint — Installation ...................................... 63-00-00 71
63-133 Isolation Support ............................................................................ 63-00-00 71
63-134 Isolation Support — Removal ................................................... 63-00-00 72
63-135 Isolation Support — Inspection and Repair .............................. 63-00-00 72
63-136 Isolation Support — Installation ................................................ 63-00-00 72
63-137 Stop Mounts................................................................................... 63-00-00 72
63-138 Stop Mounts — Removal.......................................................... 63-00-00 73
63-139 Stop Mounts — Inspection and Repair ..................................... 63-00-00 73
63-140 Stop Mounts — Installation....................................................... 63-00-00 74
63-141 Drag Pins and Up Stops ................................................................ 63-00-00 75
63-142 Drag Pins and Up Stops — Removal ....................................... 63-00-00 75
63-143 Drag Pins and Up Stops — Inspection And Repair .................. 63-00-00 75
63-144 Drag Pins and Up Stops — Installation .................................... 63-00-00 75

FIGURES

Figure Page
Number Title Number

63-1 Transmission System Troubleshooting............................................................... 6

63-2 Grease Lubricated Main Driveshaft — Troubleshooting ..................................... 9
63-3 Freewheeling Assembly Troubleshooting ........................................................... 10
63-4 Corrective Action for Contamination Found in Transmission.............................. 13
63-5 Grease Lubricated Main Driveshaft .................................................................... 18
63-5A Engine-to-transmission KAflex Driveshaft — Installation/Removal..................... 18H
63-5B KAflex Driveshaft Tool Set — Installation/Removal ............................................ 18J
63-6 Main Rotor Mast.................................................................................................. 20

63-00-00
Page 4 Rev. 16 25 FEB 2011 ECCN EAR99
 BHT-206L3-MM-6

FIGURES (CONT)

Figure Page
Number Title Number

63-7 Pylon ................................................................................................................... 23

63-8 Transmission Oil Pump, Screen, and Electrical Chip Detectors ......................... 28
63-8A Tachometer Generator Driveshaft — Inspection ................................................ 30A
63-8B Interconnect Adapter — Inspection..................................................................... 30B
63-8C Tachometer Generator Driveshaft — Removal/Installation ................................ 30D
63-9 Transmission Oil System Schematic .................................................................. 30H
63-10 Transmission Oil Pump Removal Tool application ............................................. 32
63-11 Transmission Oil Jets and Relief Valve .............................................................. 36
63-12 Transmission Oil Filter and Housing ................................................................... 39
63-13 Transmission Oil Filter Housing and Fittings ...................................................... 42
63-14 Transmission Oil System .................................................................................... 47
63-15 Transmission Oil Cooler...................................................................................... 50
63-16 Freewheeling Assembly...................................................................................... 53
63-17 Freewheeling Clearances and Torques (206L3 Only) ........................................ 56
63-17A Freewheel Assembly 406-040-500 ..................................................................... 56D
63-17B Seal Cap, Clutch, and Shaft Assembly — Inspection ......................................... 56I
63-18 Transmission Link Assembly and Attachment .................................................... 59
63-19 Transmission Arm and Flexure .......................................................................... 65
63-20 Transmission Restraint ....................................................................................... 68

TABLES

Table Page
Number Title Number

63-1 Maximum Allowable Leakage for Main Rotor Drive System Components.......... 5
63-2 Oil Servicing Drain Hose Usage ......................................................................... 15

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 16 Page 4A/4B
 BHT-206L3-MM-6

MAIN ROTOR DRIVE SYSTEM

63-1. MAIN ROTOR DRIVE SYSTEM
The main rotor drive system provides a means of
transmitting power from the engine to the main rotor.
The main rotor drive system includes the following
components: transmission, main rotor mast, main
driveshaft, and freewheeling assembly.
Refer to Volume 2, Chapter 12 and to the
BHT-206L3-FM-1 (BHT-206L4-FM-1 for
206L3+ IGW Upgrade) for the approved
specifications and recommended use of
oils.
63-2. ALLOWABLE LEAKAGE RATES FOR MAIN
ROTOR DRIVE SYSTEM COMPONENTS

NOTE Table 63-1 presents a measurement of allowable

Certain steps within the chapter specify the leakage rates that may be used in conjunction with
use of lubricating oil MIL-PRF-7808, main rotor drive system troubleshooting.
MIL-PRF-23699, or DOD-PRF-85734
(C-010, C-011, or C-030).

Table 63-1. Maximum Allowable Leakage for Main Rotor Drive System Components

COMPONENTS TYPE LEAKAGE RATE

Transmission and Freewheeling Assembly S Input quill leakage shall not exceed 5 drops
per minute. Total transmission leakage at all
sources, including freewheeling assembly,
must not exceed 10 drops per minute.
Transmission and Freewheeling Assembly D One quart per three hours of operating time.
Tail Rotor Gearbox S Input quill leakage shall not exceed 2 drops
per minute. Total leakage at all sources must
not exceed 6 drops per minute.
Tail Rotor Gearbox D 50% of normal sight gauge oil level indication
per 3 hours of operating time.
NOTES:
D – Dynamic
S – Static

63-3. TROUBLESHOOTING MAIN ROTOR checks, and other detailed procedures in this and other
DRIVE SYSTEM chapters of the manual.

Figure 63-1 through Figure 63-3 provide 63-4. TROUBLESHOOTING TRANSMISSION

troubleshooting procedures for the main rotor drive
system. They include indication of troubles, probable
causes, and corrective actions to be taken. The
troubleshooting tables should be used along with the
general information and other sources of information
such as: transmission oil system schematic, electrical
wiring diagrams, operational checks, serviceability
SYSTEM
The transmission troubleshooting procedures (Figure
63-1) are a brief summary of oil system transmission
troubles which may be encountered. Conditions
involving obvious major damage are omitted, as are
those which would require evaluation by a competent
authority.

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 5
BHT-206L3-MM-6

Remove and replace pressure switch.

(Volume 10, Chapter 96). Perform
ground run for functional check.
(BHT-206L-3-FM)
(BHT-206L4-FM-1 for 206L3+ IGW upgrade)

206L3_MM_63_0001a

Figure 63-1. Transmission System Troubleshooting (Sheet 1 of 2)

63-00-00
Page 6 Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

Check wiring system for

continuity and for grounding.
Replace faulty wiring. Remove
and replace thermoswitch.
(Volume 10, Chapter 96). Perform
ground run for functional check.
(BHT-206L-3-FM)
(BHT-206L4-FM-1 for 206L3+ IGW upgrade)

206L3_MM_63_0001b

Figure 63-1. Transmission System Troubleshooting (Sheet 2 of 2)

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 7
BHT-206L3-MM-6

Bypass red indicator

in extended position.

0
YES Replace oil filter element
and perform serviceability
check.

YES

NO
YES
EE3
3/
Push red indicator in
and resume operation.
j
Replace red
indicator.

206L3-63-1-3

Figure 63-1. Transmission system troubleshooting (Sheet 3)

63-00-00
Page 8
 BHT-206L3-MM-6

Figure 63-2. Grease Lubricated Main Driveshaft — Troubleshooting

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 9
BHT-206L3-MM-6
Figure 63-3. Freewheeling Assembly Troubleshooting
63-5. TROUBLESHOOTING TRANSMISSION
MOUNTS
The vibration isolation system is designed to isolate
the fuselage from the main rotor vibration that occurs
twice per rotor revolution. This vibration has
components both in the vertical direction and in the
plane of the rotor. The inplane isolation is controlled by
the link geometry and spring rate of the pylon restraint
spring, neither of which is adjustable. The vertical
isolation is controlled by the nodal beam spring rate
and the amount of tuning weights added. All nodal
beams tested have been tuned for optimum 2/rev
isolation by adding 4 pounds of weight to each nodal
beam arm. Therefore, no tuning should be required for
the vibration isolation system. If there is a deterioration
in the isolation of the 2/rev vibration, the following
components should be checked for bond separation:
• Nodal beam support assemblies
• Pylon restraint spring
• Nodal beam flexure assemblies
• Pylon restraint support bushings
63-00-00
Page 10 Rev. 10 20 JUL 2009
63-6. TROUBLESHOOTING MAIN DRIVESHAFT
See Figure 63-2 for troubleshooting main driveshaft.
63-7. TROUBLESHOOTING FREEWHEELING
ASSEMBLY
See Figure 63-3 for troubleshooting freewheeling
assembly. Take corrective action for oil contamination
and metal particles, and make serviceability checks
(paragraph 63-13 and paragraph 63-17).
63-8. OIL CONTAMINATION
Particles of foreign material found in the transmission
or tail rotor gearbox electric chip detectors,
transmission filter, freewheeling unit electric chip
detector, or in oil drained from the systems may
indicate that one or more parts have failed. These
particles are not necessarily an indication that the
component is no longer serviceable (Figure 63-4). The
quantity, source, form, and type of material found, and
the service history of the component must be taken
into consideration. The service time accumulated
since new or overhaul, previous failures, and the type
of operation are important factors in determining the
further serviceability of the component. The particles
ECCN EAR99
 BHT-206L3-MM-6

may be steel, silver, aluminum, magnesium, bronze, or lubricant for gear meshing and, therefore, is
phenolic. Refer to paragraph 63-9 for identification of not detrimental to transmission.
foreign material.
4. Place a small quantity of 50% nitric acid (C-432)
solution in a test tube and add a particle of material to
MATERIALS REQUIRED be tested. If particle does not dissolve, warm solution
slightly. If particle dissolves after warming, add a few
Refer to BHT-ALL-SPM for specifications. drops of 5% sodium chloride (C-501) solution. If white
precipitate forms in the test tube, the particle being
NUMBER NOMENCLATURE
tested is silver. Use of any chemical product to remove
C-010 Lubricating Oil silver plating is not permitted. Remove loose silver
plating using nylon web abrasive pad (C-407).
C-011 Lubricating Oil
C-030 Lubricating Oil 5. Place a small amount of hydrochloric acid
(C-431) in a test tube and add a particle of the material
C-407 Abrasive Pad
to be tested. If the solution releases bubbles rapidly,
C-431 Hydrochloric Acid the particle disintegrates, and a black residue forms,
the particle being tested is probably aluminum or
C-432 Nitric Acid
magnesium. Place a small amount of nitric acid
C-501 Sodium Chloride (C-432) in a test tube and add a second particle of the
same material. If there is no reaction with the nitric
acid, the particle is probably aluminum.
63-9. IDENTIFICATION OF FOREIGN MATERIAL
6. Differentiate between copper, bronze, and
1. Inspect particles visually. If particles cannot be
magnesium as follows: Place a small amount of nitric
recognized by color and hardness, perform tests
acid (C-432) in a test tube and add a particle of the
outlined in step 2 through step 6.
material to be tested. If a bright green color is formed
in the acid, the particle is copper or bronze. If there is a
2. the following equipment is required to perform
rapid emission of bubbles when the particle is dropped
test:
into the acid, the particle is probably magnesium.

• Permanent magnet
NOTE
• 50% by volume nitric acid (C-432) and water Phenolic and aluminum do not react
solution noticeably with nitric acid (C-432).

• 5% by weight sodium chloride (C-501) and 63-10. TRANSMISSION OIL CONTAMINATION

water solution

• Hydrochloric acid (C-431) WARNING

• Test tube
3. Check particles with permanent magnet. The
magnet will attract steel particles only.
NOTE
Silver plating flakes found in filter during
inspection is not cause for rejection of
transmission. If silver flakes are found,
change oil, change filter, clean oil screen,
flush transmission, and fill with lubricating
oil (Volume 2, Chapter 12). Silver plating is
a soft material used as an additional
WHEN FOREIGN PARTICLES ARE
LARGE ENOUGH TO BE IDENTIFIED AS
A PART OF A COMPONENT OF THE
TRANSMISSION OR MAST BEARING,
RE PL ACE TH E T RA NSM IS SIO N O R
MAST BEARING AS INDICATED BY THE
LOCATION OF THE PARTICLE.
The transmission is equipped with a collector
pan and chip detector immediately under the upper
mast bearing and a second chip detector in the sump.
As a result, it is possible to isolate the source of the
metal particles to either the transmission or the

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 11
 FiT-2061-3- -6

mast assembly. If chips are found on the 63-11. FREEWHEELING IT IL

upper chip detector but not on the lower, a CONTAMINATION.
mast bearing problem is indicated. If chips
are found on the lower chip detector but not
on the upper, a transmission problem is
indicated.
WHEN FOREIGN PARTICLES ARE

Ill
®®®o®o®®®®o®ooooo
LARGE ENOUGH TO BE

®-i
3
{ TI IDENTIFIED AS A PART OF A
ooo®®®®®®®®o®®oo
C O M P O N E N T OF T H E
FREEWHEELING UNIT, REPLACE

Ill
WHEN TRANSMISSION OIL IS THE FREEWHEELING UNIT
CONTAMINATED, THE OIL (PARAGRAPH 63-103).
COOLER AND FREEWHEELING
UNIT MAY ALSO E
CONTAMINATED. THE
TRANSMISSION OIL FILTER WILL
NORMALLY PRECLUDE THIS, BUT
IF FOREIGN PARTICLES ARE

5-<mmm
mmz

®Zm
IF THE OIL FILTER HAS CLOGGED
ENOUGH TO CAUSE BYPASSING, DISCOVERED IN THE
THEN CONTAMINATION OF THE FREEWHEELING UNIT, THE
ABOVE COMPONENTS AND TRANSMISSION MAY OR MAY
NOT BE CONTAMINATED.
ASSOCIATED OIL LINES CAN
OCCUR. 1. Identify foreign particles found in the

0
®-q
freewheeling assembly oil (paragraph
paragraph 63-9).
63-9
1. Identify foreign particles found in the
transmission oil (paragraph 63-9).
paragraph 63-9 2. For corrective action to be taken for
contamination of freewheeling unit, see figure
figure
63-4.
63-4
. For corrective action to be taken for
contamination of transmission, see figure 63-
figure 63-
-°°

44.
63-12. TRANSMISSION SYSTEM II-
SERVICING AI HOSES.
Operators who wish to obtain oil drain hoses
®3°--.
3. Remove and replace oil cooler and for the transmission and/or freewheeling unit
®°0
>0)o

identify removed oil cooler as being
contaminated (paragraph 63-166 and 63-162).
4. Thoroughly flush all oil lines leading to
and from oil cooler and freewheeling unit
which are to be reused. Clean restrictor in oil
supply line.
should obtain part number from table
table 63-2
63-2
and determine the length desired in inches.
Order drain hoses directly from the following
manufacturer:
Technical Development Company
Glenoiden, PA 19036
Attention: Sales Department

. Disassemble and clean oil filter housing

and install new filter element (paragraph 63-
paragraph 63-
65, 63-6,
65 63-6 and 63-67).
63-67
axe

6. Disassemble and clean freewheeling

assembly (paragraph 63-163).
paragraph 63-103

63-6®-Q6
Page 12
 BI-IT-2061-3-MM-6
STEEL CONTAMINATION

STEEL Detail A STEEL

Fuzz, fine hair-like particles.

More than 10 flakes not exceeding
1/64 inch (0.39 mm) in diameter and 1/4
inch (6.35-mm) in length found on
the upper chip detector only.
W
DETAIL A
Ly1

i i
Result
or normal
wear may have YES
exaggerated Replace mast bearing and

<,0
appearance perform serviceability check.
because
of oil. e

DETAIL B Detail B&C

Particles in splinter or More than 10 flakes not exceeding

X330

))<

coo
granular form. 1/64 inch (0.39 mm) in diameter and 1 /4
inch (6.35 mm) in length found on
any chip detector.
L\YJ

i
LWJ

Perform serviceability check.

Replace transmission/
freewheeling unit if YES

'1°
Replace transmission/

X90
necessary. freewheeling unit as
DETAIL C
applicable.

Detail D
Thin flakes not exceeding 1/64 inch (0.39 mm)
in thickness and 1/16 inch (1.58 mm) in
length. Quantity not to exceed 10
flakes.

CAUTION
Avi
DETAIL D
WHEN SMALL AMOUNTS OF METAL PARTICLES ARE FOUND IN
TRANSMISSION OR FREEWHEELING ASSEMBLY COMPONENTS, OR
THERE IS SOME DOUBT ABOUT THE SUITABILITY OF THE COMPONENT
Perform serviceability check. FOR CONTINUED SERVICE, A SERVICEABILITY CHECK SHALL BE

Own
Replace transmission/freewheeling CONDUCTED. SERVICEABILITY CHECKS ARE A SPECIFIC REQUIREMENT
unit if necessary. WHEN DIRECTED IN THE TROUBLESHOOTING PROCEDURES OR THIS
FIGURE.
206L3-63-4-1

Figure 63-4. Corrective action for contamination found in transmission (Sheet 1 of 2)

63.00.00

-46
Page 13
 Ell-IT-2061-3-MM-6

ALUMINUM OTHER METALS CONTAMINATION COPPER

MAGNESIUM
Particles in granular form.
7
Particles in granular form or
resembling miniature lathe turnings.

May
indicate
excessive YES Replace transmission. Disassembly
,May,

MCP
wear of bearing will be required to determine
be result cages as a result extent of damage.
of use of these of bearing
materials as mallets YES A failure.
or drifts during Perform serviceability check.
assembly. May indicate Replace transmission if necessary.
wear of oil pump
indicate wear
interior
surfaces. ,

Small amount in flake form.

SILVER
byj
Small amount of silver flakes.

L Vi
/Perform serviceability check.

YES

PHENOLIC

Silver flakes with other metals. Perform inspection for source.

LEI

206L3-63-4-2

Figure 63-4. Corrective action for contamination found in transmission (Sheet 2)

63-00.00
Page 14
 BHT-206L3-MM-6

63-13. SERVICEABILITY CHECK 6. If gross contamination of the filter element and

63-14. TRANSMISSION SERVICEABILITY CHECK
1. Drain lubricating oil from transmission and collect
oil in a clean container (Volume 2, Chapter 12).
indication of filter bypass are found, remove and
replace the oil cooler and identify them as being
contaminated. Thoroughly flush all oil lines leading to
and from oil cooler and freewheeling unit which are to
be reused. Remove and inspect freewheeling lube
restrictor on the left side of the cabin roof.

7. If only minor contamination of the filter element is

2. Inspect, clean, and reinstall electric chip detector
and self-closing valve (paragraph 63-43).
3. Inspect drained oil for metal particles. If any
particles are found, identify them (paragraph 63-9).
Perform corrective action (Figure 63-4).
4. Inspect oil filter bypass indicator for bypass
indication.
5. Remove and inspect oil filter element to
determine the extent of entrapped contaminants and
for damage to element.
found, and bypassing of the filter is not indicated, then
the procedures outlined in step 6 are not required.
Install a new filter element. Remove and inspect the oil
jets and freewheeling lube restrictor on the left side of
the cabin roof.
8. Remove, inspect, clean, and reinstall oil screen
(paragraph 63-40, paragraph 63-41, and paragraph
63-42).
9. Fill transmission to proper level (Volume 2,
Chapter 12).

Table 63-2. Oil Servicing Drain Hose Usage

CHIP DETECTOR PART NO. COMPONENT DRAIN HOSE PART NO.

B-3188B Main Transmission 1 DB-3188

B-3225C Freewheeling Unit 1 DB-3225
B-4213-1 Freewheeling Unit H4713
NOTES:

1 The drain hoses listed are equipped with a standard hose length of 24 inches (610 mm). A longer length
drain hose may be obtained when ordering by adding a dash number to the drain hose part number that
equals the length of hose desired in inches. Example: A DB-3188-50 drain hose would be 50 inches
(1300 mm) in length.

10. Prepare helicopter for ground run-up. Ground run
the helicopter for 1 hour (BHT-206L3-FM-1
(BHT-206L4-FM-1 for 206L3+ IGW Upgrade)) and
accomplish the following at completion of run:
a. Remove electric chip detectors and inspect for
metal particles.
b. Drain lubricating oil from transmission and
collect oil in a clean container.
c. Inspect lubricating oil for foreign material.
d. If this inspection is being conducted because
of metal particle contamination and the number of
metal particles has increased or if any particles are
found which are large enough to be identified as chips
from a gear or bearing, replace the transmission. If the
number of particles has decreased and only minute
particles are found, perform step 1 through step 10c
again. If particles are found, remove transmission and
freewheeling unit and repair or overhaul as required
(BHT-206L-CR&O).

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 15
BHT-206L3-MM-6

63-15. FREEWHEELING ASSEMBLY 5. Thoroughly flush return line from freewheeling

SERVICEABILITY CHECK assembly to transmission. Flush hose with clean
lubricating oil (Volume 2, Chapter 12).
1. Drain lubricating oil from freewheeling assembly
6. Fill transmission to proper level with lubricating oil
and collect oil in a clean container (Volume 2,
(Volume 2, Chapter 12).
Chapter 12).
7. Prepare helicopter for ground run-up. Ground run
helicopter for 1 hour (BHT-206L3-FM-1
(BHT-206L4-FM-1 for 206L3+ IGW Upgrade) and
CAUTION accomplish the following at completion of run:

a. Remove electric chip detector and inspect for

IF F OREIGN PARTICLES ARE
DISCOVERED IN THE FREEWHEELING
ASSEMBLY, THE TRANSMISSION AND
MAST BEARING MAY OR MAY NOT BE
CONTAMINATED.
metal particles (step 2 and step 3).
b. Drain one quart (0.9 L) of lubricating oil from
freewheeling housing and collect oil in a clean
container (Volume 2, Chapter 12).

2. Inspect, clean, and reinstall electric chip detector c. Inspect lubricating oil for foreign material
and self-closing valve (paragraph 63-45). (step 3).

d. If this inspection is being conducted because

3. Inspect drained oil for metal particles. If any
particles are found, identify them (paragraph 63-9).
Perform corrective action (Figure 63-4).
4. Inspect transmission oil filter for metal particles. If
any particles are found, identify them (paragraph
63-9). Perform corrective action (Figure 63-4).
of metal particle contamination, and the number of
metal particles has increased or if any particles are
found which are large enough to be identified as chips
from bearing, clutch, or shaft, replace the freewheeling
assembly. If the number of particles has decreased
and only minute particles are found, add lubricating oil
to freewheeling housing (Volume 2, Chapter 12), and
release the helicopter for continued operation.

63-00-00
Page 16 Rev. 10 20 JUL 2009 ECCN EAR99

GREASE LUBRICATED MAIN DRIVESHAFT
63-16. GREASE LUBRICATED MAIN
DRIVESHAFT
The main driveshaft consists of flexible splined
couplings installed between the freewheel assembly
and the transmission input drive adapter flange.
Flexible couplings accommodate movement between
transmission and freewheel assembly. A spring in
each coupling assists centering of driveshaft during
operation.
63-17. GREASE LUBRICATED MAIN
DRIVESHAFT — REMOVAL
1. Remove cowling and fairings for access to main
driveshaft (Volume 9, Chapter 71).
2. Remove screws (9, Figure 63-5) and washers (8)
from cover (7).
CAUTION
COMPRESS OUTER AFT AND OUTER
FORWARD COUPLINGS (14 AND 16)
ONLY ENOUGH TO RELEASE FROM
MATING ADAPTER FLANGES. IF OUTER
COUPLINGS ARE COMPRESSED MORE
THAN REQUIRED TO RELEASE FROM
MAT ING ADA PT ER FLA NGES , IT IS
RECOMMENDED THAT THE MAIN
DRIVESHAFT BE DISASSEMBLED,
INSPECTED, AND LUBRICATED
(BHT-206L-CR&O).
3. Remove four nuts (2), steel washers (3), and
bolts (4).
4. Remove four nuts (12), steel washers (11), and
bolts (10).
5. Push aft on main driveshaft (15) to compress
spring in aft outer couplings (14) and obtain clearance
between forward outer coupling (16) and input adapter
flange. Move forward end of main driveshaft (15)
outboard to clear input adapter flange. Move main
driveshaft (15) aft through opening and remove from
helicopter.
ECCN EAR99
BHT-206L3-MM-6
63-17A. GREASE LUBRICATED MAIN
DRIVESHAFT — CLEANING
Clean exterior surfaces of main driveshaft (15,
Figure 63-5) (BHT-206L-CR&O).
63-18. GREASE LUBRICATED MAIN
DRIVESHAFT — INSPECTION
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-204 Epoxy Polyamide
Primer
C-423 Abrasive Paper
C-464 India Stone
1. Visually inspect main driveshaft (15, Figure 63-5)
for damage, corrosion, and surface damage. Check
for freedom and smoothness of axial movement.
2. Visually inspect main driveshaft (15) input area
for evidence of oil leakage and outer couplings (14
and 16) for overheating or grease leakage.
3. Inspect outer couplings (14 and 16) with
overtemperature indicator (TEMP-PLATE) as follows:
a. Overtemperature indicator dots on the
TEMP-PLATE are white or light gray and turn black
when exposed to an overtemperature condition.
Chemical contamination can also cause the indicating
dots to turn black.
b. TEMP-PLATES have a shelf life of 2 years
from date of manufacture when stored under the
following conditions: 40 to 80°F (4 to 27°C). Relative
humidity: 50% maximum. Storage under other
conditions may result in reduced shelf life of the
TEMP-PLATES. Use of TEMP-PLATES with expired
shelf life may result in false coupling overtemperature
indications. TEMP-PLATES must be installed and
actively enter helicopter service before expiration of
shelf life. Refer to BHT-206L-CR&O for TEMP-PLATE
replacement procedures.
63-00-00
20 JUL 2009 Rev. 10 Page 17
BHT-206L3-MM-6

17

1. Transmission
2. Nut
3. Steel washer
4. Bolt
5. Forward firewall
6. Gasket
7. Cover
8. Washer
9. Screw
10. Bolt
11. Steel washer
12. Nut
13. Freewheel assembly
14. Coupling (outer, aft) 17
(TYPICAL)
15. Main driveshaft
16. Coupling (outer, forward)
17. Overtemperature TEMP-PLATE

50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)
206L1_MM_66_0001

Figure 63-5. Grease Lubricated Main Driveshaft (Sheet 1 of 5)

63-00-00
Page 18 Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

SEE VIEW C
D

SEE VIEW B

VIEW B VIEW C

D-D.

206L1_MM_66_0003

Figure 63-5. Grease Lubricated Main Driveshaft (Sheet 2 of 5)

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 18A
BHT-206L3-MM-6

SECTION D-D

206L1_MM_66_0004

Figure 63-5. Grease Lubricated Main Driveshaft (Sheet 3 of 5)

63-00-00
Page 18B Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

206L1_MM_66_0010

Figure 63-5. Grease Lubricated Main Driveshaft (Sheet 4 of 5)

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 18C
BHT-206L3-MM-6

4
5 6

206L1_MM_66_0011

Figure 63-5. Grease Lubricated Main Driveshaft (Sheet 5 of 5)

63-00-00
Page 18D Rev. 10 20 JUL 2009 ECCN EAR99

c. TEMP-PLATE serviceability check:
TEMP-PLATES must not show evidence of
overtemperature, deterioration, debonding, or
discoloration of the epoxy coating that prevents
interpretation of the indicating dots (Figure 63-5).
d. If only one TEMP-PLATE of a given color is
missing, and no dot on any other TEMP-PLATE (on
the same coupling) is discolored or shows mechanical
damage or degradation of the epoxy overcoating, the
helicopter may be returned to service.
e. The discrepant TEMP-PLATE should be
replaced as soon as practical. If any indicator dot on
any red or yellow bordered 6000-1 or 6000-3
TEMP-PLATE has changed color to black, refer to
Figure 63-5 for probable cause and required action.
f. Check TEMP-PLATES for evidence of
elevated temperature indication (Figure 63-5).
g. Check for deteriorated, debonded, or missing
TEMP-PLATES (Figure 63-5).
h. Check for excessive discoloration of the epoxy
overcoating.
i. Inspect parts for nicks and scratches.
Maximum limits are 0.002 inch (0.051 mm) deep
around entire circumference, or 0.005 inch (0.127 mm)
deep around axial or circumferential, but not longer
than 25% of circumference.
j. Dress out acceptable nicks and scratches with
abrasive paper (C-423), or an India stone (C-464), as
required. Apply epoxy polyamide primer (C-204) to
external repaired areas.
63-19. GREASE LUBRICATED MAIN
DRIVESHAFT — INSTALLATION
CAUTION
COMPRESS OUTER AFT AND OUTER
FORWARD COUPLINGS (14 AND 16,
FIGURE 63-5) ONLY ENOUGH TO
INSERT DRIVESHAFT BETWEEN
ECCN EAR99
BHT-206L3-MM-6
MATING ADAPTER FLANGES. IF OUTER
COUPLINGS ARE COMPRESSED MORE
THAN REQUIRED FOR INSTALLATION,
IT IS RECOMMENDED THAT THE MAIN
DRIVESHAFT BE DISASSEMBLED,
INSPECTED, AND RELUBRICATED
(BHT-206L-CR&O).
1. Place main driveshaft (15, Figure 63-5) through
opening in forward firewall (5), and position in place
between input pinion flange on transmission (1) and
flange on freewheel assembly (13).
2. Align attachment bolt holes of aft outer coupling
(14) and flange of freewheel assembly (13). Install four
bolts (10) with heads inboard through aft outer
coupling (14) into flange on freewheel assembly (13).
Install two steel washers (11) on shank of each bolt
(10) with nuts (12). Hold heads of bolts (10) and torque
nuts (12) 50 to 70 inch-pounds (5.65 to 7.91 Nm).
3. Secure forward outer coupling (16) to input pinion
flange on transmission (1) in the same manner as
step 2.
CAUTION
ENSURE COVER (7) IS NOT DEFORMED
AND THERE IS CLEARANCE BETWEEN
IT AND MAIN DRIVESHAFT (15).
4. Install cover (7) and serviceable gasket (6) on
forward side of forward firewall (5), and secure with
screws (9) and washers (8).
5. Install cowling and fairings (Volume 9,
Chapter 71).
6. Following installation of a new main driveshaft, or
one that has been disassembled for inspection,
ground-run the helicopter for 20 minutes (refer to
applicable Flight Manual). Inspect the driveshaft and
the structure around both of the driveshaft couplings
for evidence of grease leakage. If evidence of leakage
is found, disassemble driveshaft and inspect to
determine cause of the leakage.
63-00-00
20 JUL 2009 Rev. 10 Page 18E/18F

ENGINE TO TRANSMISSION DRIVESHAFT
206L3+ IGW UPGRADE
63-19A.ENGINE TO TRANSMISSION
DRIVESHAFT — KAFLEX
NOTE
KAflex driveshaft is only applicable
to 206L3+ IGW Upgrade helicopters when
BHT-206-SI-2052 has been accomplished.
The engine to transmission driveshaft (KAflex) (6,
Figure 63-5A) is made up of four flex frames that are
attached with bolts to each other and to each end of
the shaft. The two flange adapters are attached to the
flex frame with bolts. One flange adapter is attached to
the transmission input adapter. The other flange
adapter is attached to the rotor disc and to the
freewheel adapter. If the rotor brake kit is not installed,
a spacer is used instead of the rotor disc.
The engine to transmission driveshaft turns at 6016
RPM and transmits the power from the engine to the
transmission. The engine to transmission driveshaft is
designed to flex and permit a certain misalignment
between the engine and the transmission that is
caused by the movement of the transmission.
63-19B. KAFLEX DRIVESHAFT — REMOVAL
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
206-240-003-101FM or Driveshaft Tool Set
206-240-003-101FM-1
407-240-009-101
407-240-009-101FM
407-240-009-121
WARNING
DRIVESHAFT ASSEMBLY IS NOT TO BE
TAKEN APART AND FASTENERS ARE
ECCN EAR99
BHT-206L3-MM-6
NOT TO BE DISTURBED. DISASSEMBLY
OR DISTURBING FASTENERS IS CAUSE
FOR REPLACEMENT.
NOTE
KAflex driveshaft is only applicable
to 206L3+ IGW Upgrade helicopters when
BHT-206-SI-2052 has been accomplished.
1. Remove the transmission cowling and the engine
air inlet cowling (Volume 9, Chapter 71) to get access
to the engine to transmission driveshaft (6,
Figure 63-5A).
2. Remove the screws (8), washers (9), and cover
(7) from the forward firewall (12).
3. Remove the left-hand and right-hand brake
calipers (14) if the rotor brake kit is installed
(BHT-206-SI-2044).
NOTE
Prior to cleaning the driveshaft flex frame
bolted joints, visually inspect per paragraph
63-19D.
4. Remove the nuts (17), washers (16), and bolts
(15) that attach the aft adapter flange of the engine to
transmission driveshaft (6) to the spacer (13) or rotor
brake disc (14), if installed, and freewheel adapter
(21).
NOTE
The transmission input seal housing has a
notch at the 12 o’clock position, which you
can use to remove the bolts that attach the
driveshaft forward adapter flange to the
transmission input quill adapter.
5. Remove the nuts (4), washers (3), and bolts (1)
that attach the driveshaft end fitting (5) of the engine to
transmission driveshaft (6) to the adapter (2).
63-00-00
20 JUL 2009 Rev. 10 Page 18G
BHT-206L3-MM-6

12

19

TORQUE
50 TO 70 IN-LBS 7
(5.65 TO 7.91 Nm)

4
3

18 1

9
8 11
6
10
5
2

1. Bolt
2. Adapter
3. Washer
4. Nut
5. Driveshaft adapter
6. Engine-to-transmission
driveshaft
7. Cover 20
8. Screw 21
9. Washer 13
10. Screw
11. Washer
12. Forward firewall
13. Spacer
14. Rotor brake kit (optional) 15
15. Bolt
16. Washer
17. Nut 16
18. Transmission assembly 17
TORQUE
19. Cover 50 TO 70 IN-LBS
20. Freewheel assembly 14
(5.65 TO 7.91 Nm)
21. Freewheel adapter

206L1_MM_66_0002+

Figure 63-5A. Engine-to-transmission KAflex Driveshaft — Installation/Removal

63-00-00
Page 18H Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

7. Tighten the turnbuckle (3) of the tool set while you

NOTE hold the hex nut on the cable and remove the engine
to transmission driveshaft (6).
As you evenly tighten the compressing
tools on both sides of the engine to
transmission driveshaft, it is possible that 8. Remove the applicable tool set.
the driveshaft assemblies do not detach at
both ends. If this occurs, decrease the 63-19C. KAFLEX DRIVESHAFT — CLEANING
tension on the compressing tool and permit
the driveshaft to return to its installed
position. Two bolts must be installed in MATERIALS REQUIRED
diametrically opposed locations through
both end adapters of the driveshaft and the Refer to BHT-ALL-SPM for specifications.
adapters of the transmission input quill and
the freewheel assembly. Install four nuts on NUMBER NOMENCLATURE
the four bolts, finger tight only. The limited
free play in these temporary bolts will force C-304 Drycleaning Solvent
the detachment of the driveshaft from the
adapters on both ends, as you apply
pressure with the compressing tool.
CAUTION
6. Install the tool set bracket (1, Figure 63-5B) in the
groove of the flexframe (7). Connect the two brackets
DO NOT PRESSURE WASH OR CLEAN
(1) and cable assemblies (2) together with the
BY IMMERSING THE ENGINE TO
turnbuckle (3).
TRANSMISSION DRIVESHAFT IN FLUIDS
OR CLEANERS.

DO NOT DISTURB OR TAKE APART THE

CAUTION FA S T E NE RS O N T HE DRI VE S HA F T
A S S E M B LY. T A M P E R I N G W I T H
ASSEMBLY FASTENERS WILL REQUIRE
THE ENGINE TO TRANSMISSION
REPLACEMENT OF THE ENGINE TO
DRIVESHAFT MUST BE COMPRESSED
TRANSMISSION DRIVESHAFT
ONLY ENOUGH TO PERMIT REMOVAL
ASSEMBLY.
OF THE DRIVESHAFT. TIGHTEN EACH
TURNBUCKLE TO EVENLY COMPRESS
BOTH SIDES. NOTE
KAflex driveshaft is only applicable
to 206L3+ IGW Upgrade helicopters when
BHT-206L-SI-2052 has been
CAUTION accomplished.

1. Clean the engine to transmission driveshaft (6,

EXERCISE CARE NOT TO DAMAGE THE Figure 63-5A) with drycleaning solvent (C-304). Dry
DRIVESHAFT DURING REMOVAL. with a clean cloth before the solvent evaporates.

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 18I
BHT-206L3-MM-6

1
3
1
2

5
4

SEE VIEW A

SEE DETAIL C

7
5

SEE VIEW B 1
LUG
VIEW A 3
1 1
2

LUG

VIEW B
206L3_MM_63_0002a

Figure 63-5B. KAflex Driveshaft Tool Set — Installation/Removal (Sheet 1 of 2)

63-00-00
Page 18J Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

3
2 2
4
1 1

FWD SEE VIEW D

DETAIL C
TOOL SET INSTALLATION (TYP. BOTH SIDES)

1. Bracket
2. Cable assembly
3. Turn buckle
4. Wire
5. End-adapter fitting
6. Engine-to-transmission
driveshaft 1
7. Flexframe

NOTES
1 Install the bracket (1) in the adapter groove 1
with the bracket radius close to the
adapter lug.

2. Only tighten the tool sufficiently

to permit the shaft to be removed.
Compress the driveshaft by only VIEW D
0.375 inch (9.525 mm).

CAUTION
DO NOT INSTALL THE BRACKET
BETWEEN THE FLEXFRAMES (7)

206L3_MM_63_0002b

Figure 63-5B. KAflex Driveshaft Tool Set — Installation/Removal (Sheet 2 of 2)

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 18K
BHT-206L3-MM-6

63-19D. KAFLEX DRIVESHAFT — INSPECTION 4. Wipe the flex frame at the 16 bolted joints with a
clean cloth and acetone (C-316).

MATERIALS REQUIRED 5. Visually check the 16 flex frame bolted joints on

the forward and aft end of the driveshaft with a bright
Refer to BHT-ALL-SPM for specifications. light and a 10X magnifying glass as follows:
NUMBER NOMENCLATURE
a. Make sure that the 16 bolted joints are
C-316 Acetone inspected.

b. Visually inspect the flex frame for evidence of

NOTE
cracks over the full circumference (360°) around the
KAflex driveshaft is only applicable bolt head and washer side and over the full
to 206L3+ IGW Upgrade helicopters when circumference (360°) around the nut and washer side.
BHT-206L-SI-2052 has been
accomplished.
c. Visually inspect the four inside and outside
corner radii and radii edges for evidence of cracks on
1. Visually examine the engine to transmission
each flex frame. Inspect the corner radii edges on both
driveshaft (6, Figure 63-5B) for corrosion, surface
sides of the flex frame.
damage, and cracked flexures. Refer to
BHT-206L-CR&O for the damage limits.
d. Visually inspect each shaft end-fitting flange
for evidence of cracks over the full circumference
NOTE (360°) around the nut and washer side.
Do not clean the driveshaft flex frame
bolted joints at this time. e. Visually inspect the interconnect adapter
flange for evidence of cracks over the full
circumference (360°) around the nut and washer side.
CAUTION
f. If a crack is found, remove the driveshaft from
service.
DO NOT DISTURB OR TIGHTEN THE
FLEX FRAME BOLTED JOINTS. 6. If a driveshaft is found with a loose bolt or nut, or
red colored powder is observed, or if a crack is found,
2. Visually check the torque witness mark at the 16 contact Product Support Engineering.
bolted joints to ensure that the nuts and bolts have not
moved. If it is determined that a nut or bolt has moved,
remove the driveshaft from service. 63-19E. KAFLEX DRIVESHAFT — REPAIR

3. Visually check the 16 bolted joints for evidence of

wear or looseness. Metal wear will appear as red MATERIALS REQUIRED
colored powder (rust debris). If rust debris is found,
remove the driveshaft from service. Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE

CAUTION C-201 Zinc Chromate Primer

C-406 Abrasive Cloth

DO N OT SP RA Y OR IMM ERS E THE
DRIVESHAFT IN ACETONE.

63-00-00
Page 18L Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

1. Install the tool set bracket (1, Figure 63-5B) in the

NOTE
KAflex driveshaft is only applicable
to 206L3+ IGW Upgrade helicopters when
BHT-206L-SI-2052 has been
accomplished.
NOTE
Minimize the removal of the protective coat
during the repair.
1. Use aluminum oxide abrasive cloth (C-406) to
remove the corrosion and damage. Do not exceed
damage limits of engine to transmission driveshaft (6,
Figure 63-5B) provided in BHT-206L-CR&O.
2. Touch up the protective coat with zinc chromate
primer (C-201).
groove of the flexframe (7). Connect the two brackets
(1) and cable assemblies (2) together with the
turnbuckle (3).
CAUTION
COMPRESS THE ENGINE TO
TRANSMISSION DRIVESHAFT ONLY TO
THE LENGTH NECESSARY TO PERMIT
THE INSTALLATION.
2. Turn the turnbuckle (3) while you hold the hex
nuts on the tool set to evenly compress the engine to
transmission driveshaft (6) approximately 0.375 inch
(9.525 mm).

3. Apply a top coat of SermeTel 1122. The SermeTel

1122 can be applied using conventional spray, brush,
or swab. The top coat must be cured in an oven at CAUTION
300°F (163°C) for 15 minutes.
EXERCISE CARE NOT TO DAMAGE THE
For information contact: DRIVESHAFT DURING INSTALLATION.
SERMATECH INT'L INC. 3. Put the engine to transmission driveshaft (6,
155 S LIMERICK RD. Figure 63-5A) in position between the adapter (2), the
LIMERICK, PA 19468 spacer (13) or rotor brake disc (14), if installed, and
TEL: (610) 948- 2872 freewheel adapter (21).
FAX: (610) 948-2771.

63-19F. KAFLEX DRIVESHAFT — INSTALLATION NOTE

To aid in bolt hole alignment, you can install
a bolt through the driveshaft fittings and the
SPECIAL TOOLS REQUIRED
adapter and the freewheel adapter before
you remove the tool set.
NUMBER NOMENCLATURE
4. Turn the turnbuckle (3, Figure 63-5B) while you
206-240-003-101FM or Driveshaft Tool Set hold the hex nuts on the tool set to release the
206-240-003-101FM-1 driveshaft tool set. Remove the tool set from the
407-240-009-101 engine to transmission driveshaft (6).
407-240-009-101FM
407-240-009-121 5. Install the bolts (1, Figure 63-5A), washers (3),
and the nuts (4) that attach the forward driveshaft
adapter (5) of the engine-to-transmission driveshaft (6)
NOTE to the transmission input quill adapter (2). Torque the
KAflex driveshaft is only applicable nuts T .
to 206L3+ IGW Upgrade helicopters when
BHT-206L-SI-2052 has been 6. Install the bolts (15), washers (16), and the nuts
accomplished. (17) that attach the aft adapter of the driveshaft (6) to

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 18M
BHT-206L3-MM-6

the forward freewheel adapter (21). Torque the 7. If the rotor brake kit is installed, install the left-side
nuts T . and right-side calipers, as applicable, on the freewheel
cap assembly.

8. Install the cover (19) to the forward firewall (12)

CAUTION with screws (10) and washers (11).

9. Install the cover (7) to the forward firewall (12)

MAKE SURE THE COVERS ARE NOT with screws (8) and washers (9).
DAMAGED AND THAT THERE IS
CLEARANCE BETWEEN THE COVERS 10. Install the transmission fairing and the engine air
AND DRIVESHAFT. inlet cowling (Volume 9, Chapter 71).

63-00-00
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 BHT-206L3-MM-6

63-20. MAIN ROTOR MAST 4. Remove swashplate from mast (Volume 8,

The main rotor mast is attached to the transmission by
a mast locking plate and studs in top of transmission
case.
SPECIAL TOOLS REQUIRED
Chapter 67).
5. Remove studs and washers (1, Figure 63-6).
6. Temporarily install main rotor mast nut on main
rotor mast (Volume 6, Chapter 62). Attach T101897
lifting eye clevis to eye in main rotor mast nut. Attach
hoisting cable to lifting eye clevis and hoist.

NUMBER NOMENCLATURE 7. Lift main rotor mast from transmission top case
(2, Figure 63-6) and transmission.
Commercial Hoist, 600 Pound (272
kg) Capacity, Minimum 8. Place main rotor mast on suitable support.
Remove hoisting cable and lifting eye clevis. Remove
Commercial Hoisting Cable, 600
main rotor mast nut (Volume 6, Chapter 62).
Pound (272 kg)
Capacity, Minimum
9. Cover opening in top of transmission with
T101897 Lifting Eye Clevis T103141 hoisting ring (206-240-001-101 lift and cover
plate for 206L3 S/N 51308 and subsequent, and
T103141 Hoisting Ring 206L3+ IGW Upgrade) to prevent entrance of foreign
(206L3 S/N 51001 material or for hoisting transmission.
Through 51307)
63-22. MAIN ROTOR MAST — CLEANING
206-240-001-101 Lift and Cover Plate
(206L3 S/N 51308 and
Subsequent, and
MATERIALS REQUIRED
206L3+ IGW Upgrade)
Refer to BHT-ALL-SPM for specifications.
63-21. MAIN ROTOR MAST — REMOVAL
NUMBER NOMENCLATURE

NOTE C-304 Drycleaning Solvent

Main rotor mast may be removed from

transmission while transmission is mounted
on the helicopter. CAUTION

1. Remove cowling for access to transmission

(Volume 9, Chapter 71). IF MAIN ROTOR MAST IS REMOVED, DO
NOT ALLOW BEARINGS TO SPIN.
2. Remove main rotor hub and blade (Volume 6,
DO NOT ALLOW SOLVENT TO CONTACT
Chapter 62).
LIP SEAL.

3. Disconnect collective and cyclic flight controls 1. Clean main rotor mast with drycleaning solvent
from swashplate (Volume 8, Chapter 67). (C-304) and dry with filtered compressed air.

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 19
BHT-206L3-MM-6

1. Stud nut and washer

2. Transmission top case
3. Seal bearing plate

100 TO 140 IN-LBS

T (11.3 TO 15.8 Nm)

1 T

3
2

206L3_MM_63_0003a

Figure 63-6. Main Rotor Mast (Sheet 1 of 2)

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Page 20 Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

O-RING

O-RINGS

SECTION A-A
206L3+ IGW UPGRADE AND
206L3 S/N 51308 AND SUBSEQUENT
SHOWN

206L3_MM_63_0003b

Figure 63-6. Main Rotor Mast (Sheet 2 of 2)

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ECCN EAR99 20 JUL 2009 Rev. 10 Page 20A/20B
 BHT-206L3-MM-6

63-23. MAIN ROTOR MAST — INSPECTION AND 2. If a new or repaired transmission has been
REPAIR installed, pour 1 quart of lubricating oil (C-010, C-011,
or C-030) (lubricating oil (C-030) for 206L3+ IGW
Upgrade), into top of transmission to lubricate gears
MATERIALS REQUIRED and splines with a coating of oil.

Refer to BHT-ALL-SPM for specifications.

NOTE
NUMBER NOMENCLATURE
Mast 206-040-014-103 and
C-108 LHE Cadmium Plating 206-040-014-107 will require two packings:
Solution one in lower groove and one against
C-204 Epoxy Polyamide shoulder of liner. Refer to Figure 63-6.
Primer
3. Lubricate new packing with lubricating oil (C-010,
C-411 Steel Wool C-011, or C-030) (lubricating oil (C-030) for 206L3+
IGW Upgrade) and install on mast bearing liner
C-423 Abrasive Paper (Figure 63-6, Sheet 2).
C-464 India Stone
4. Prepare for lifting main rotor mast (paragraph
1. Visually inspect main rotor mast for mechanical 63-21, step 6).
damage and corrosion (BHT-206A/B/L-Series-CR&O).
5. Install assembled main rotor mast through
a. Polish out mechanical damage with fine opening in top of transmission. Line up lower mast
abrasive paper (C-423) and fine India stone (C-464). spline teeth with spline teeth in the planetary carrier.

b. Remove surface corrosion using fine steel

wool (C-411).
2. After cleanup, the exterior surfaces of main rotor
mast above seal bearing plate (3, Figure 63-6) should
be plated with cadmium plating solution (C-108)
(BHT-ALL-SPM). If surfaces cannot be cadmium
plated, apply two coats of epoxy polyamide primer
(C-204) for corrosion protection until plating can be
accomplished. Do not use primer below seal bearing
plate.
63-24. MAIN ROTOR MAST — INSTALLATION
6. Carefully guide lower end of main rotor mast into
lower mast bearing and position seal bearing plate (3,
Figure 63-6) over studs on transmission top case (2).
Press main rotor mast and seal bearing plate in place.
7. Remove hoisting cable and T101897 lifting eye
clevis. Remove main rotor mast nut (Volume 6,
Chapter 62).
8. Install swashplate over main rotor mast and align
with studs in top case. Ensure collective flight control
linkage (Volume 8, Chapter 67).

MATERIALS REQUIRED 9. Install new washers and new stud nuts (1) on
each stud of transmission top case (2) and torque 100
Refer to BHT-ALL-SPM for specifications. to 140 inch-pounds (11.30 to 15.82 Nm).

NUMBER NOMENCLATURE 10. Complete installation of swashplate and collar set

C-010 Lubricating Oil (Volume 8, Chapter 67).

C-011 Lubricating Oil

11. Install main rotor hub and blades (Volume 6,
C-030 Lubricating Oil Chapter 62).

1. Remove T103141 hoisting ring or cover from top 12. Connect collective and cyclic flight control to
of transmission. swashplate (Volume 8, Chapter 67).

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BHT-206L3-MM-6

13. Service main transmission to proper level

(Volume 2, Chapter 12).
14. Reinstall cowling (Volume 9, Chapter 71).
63-25. TRANSMISSION
The transmission provides a two-stage reduction of
15.23 to 1.0 (6000 to 394 RPM). The first stage is a
bevel gear arrangement with 3.26 to 1.0 reduction; the
second stage reduction is obtained with a planetary
gear train providing 4.67 to 1.0 reduction. A complete
hydraulic system power pack is mounted forward of
the transmission and the hydraulic pump is driven by
the transmission accessory gear. The accessory drive
gear provides a 1.42 to 1.0 reduction. The
transmission is mounted on the cabin roof and
incorporates nodal beam suspension and
transmission restraint. The transmission is mounted
on two nodes and the normal vibrations and vertical
movement are absorbed by a flexure assembly.
63-26. TRANSMISSION — REMOVAL
SPECIAL TOOLS REQUIRED
NOTE
Transmission may be removed with
swashplate and support and the mast
installed. If this procedure is to be used,
omit step 4 and step 5 at this time.
4. Remove collar set and idler (4) with boot,
swashplate, and support (5) (Volume 8, Chapter 67).
5. Remove mast (2) (paragraph 63-21).
6. Install T103141 hoisting ring (or 206-240-001-101
lift and cover plate for 206L3+ IGW Upgrade) on top
case studs of transmission (26) and secure or reinstall
mast nut if mast is installed. Attach suitable hoist and
clevis to lifting device (Volume 2, Chapter 7). Align
hoist with centerline of mast or transmission. Remove
all slack from hoist.
7. Remove main driveshaft (paragraph 63-17).
8. Disconnect cyclic control tubes (6 and 31) and
collective control tube (32) from bellcranks mounted
on forward side of transmission (26) (Volume 8,
Chapter 67).

NUMBER NOMENCLATURE
9. Disconnect electrical wiring harness from oil
Commercial Hoist, 600 Pound (272 temperature bulb (8), oil thermoswitch (10), lower and
kg) Capacity, Minimum upper electric chip detectors (30 and 34), and from
hydraulic pump tachometer generator (29). Separate
Commercial Hoisting Cable, 600 electrical cabling and clamps from attachment points
Pound (272 kg) on transmission. Relocate electrical cabling to prevent
Capacity, Minimum interference during transmission (26) removal.
T102102 Dehydrator
T103141 Hoisting Ring 10. Remove lower electric chip detector (30) from
transmission (26) and drain lubricating oil (Volume 2,
206-240-001-101 Lift and Cover Plate Chapter 12).
(206L3+ IGW
Upgrade)
11. Remove hydraulic pump – tachometer generator
(29) separately or together (paragraph 63-32 and
1. Disconnect battery and remove external power, if Volume 4, Chapter 29). It is recommended that the
used. hydraulic pump be removed with hydraulic hoses
attached to prevent draining hydraulic system. Discard
2. Remove fairings and cowling to gain access to all gaskets if parts are separated.
work area (Volume 9, Chapter 71).
12. Disconnect transmission oil inlet and outlet hoses
3. Remove main rotor hub and blade (1, from two unions (7) on oil filter and housing (9). Install
Figure 63-7) and pitch links (3) (Volume 6, protective caps and plugs to prevent system
Chapter 62). contamination.

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 BHT-206L3-MM-6

16
(ALTERNATE)

T 2 1

T 1

NOTE
36 TO 204 IN-LBS 1 With nodal arms in down
T 1 (4.1 TO 23 Nm) position.
260 TO 390 IN-LBS
T 2 (29.3 TO 44 Nm)

206L3_MM_63_0004

Figure 63-7. Pylon

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 23
BHT-206L3-MM-6

13. Disconnect oil pressure outlet hose from oil 63-27. TRANSMISSION — CLEANING
pressure outlet reducer (17) located on left rear of
transmission (26). Disconnect freewheeling return oil
hose from freewheeling oil return union (18) located MATERIALS REQUIRED
just inboard of left stop mount (23). Install protective
caps and plugs to prevent system contamination. Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE
14. Check hoist alignment with vertical centerline of
transmission (26). Remove all slack from hoist and C-304 Drycleaning Solvent
provide sufficient tension to support transmission (26).

15. Disconnect transmission restraint (16) from

isolation support on transmission deck by removing CAUTION
nut (15), washers (12, 13, and 14), and bolt (11).

E X E R CI S E CA U T I O N TO P RE V E N T
16. Remove nuts (19) and stops (20) from two drag SOLVENT FROM CONTACTING FLIGHT
pins (28). CONTROL SYSTEM SEALED BEARINGS.

Clean transmission with drycleaning solvent (C-304)

17. Disconnect the four link assemblies (27) from the
and soft bristle brush. Dry with filtered compressed air.
four link attachments (25) by removing nuts (21) and
support washers (22).
63-28. TRANSMISSION — INSPECTION AND
REPAIR
18. Adjust tension on hoist and transmission (26) and
pull four link assemblies (27) outboard from link
attachments (25); disconnect transmission (26) from
MATERIALS REQUIRED
helicopter. Check that all attachments between
transmission and helicopter have been disconnected.
Refer to BHT-ALL-SPM for specifications.

19. Carefully hoist transmission (26) from helicopter NUMBER NOMENCLATURE

while providing adequate clearance for the two stop C-100 Chemical Film Material
mounts (23) to clear drag pins (28).
C-423 Abrasive Paper
20. Place transmission (26) on work bench or other
suitable support.
NOTE
Total static or dynamic input quill leakage
NOTE shall not exceed 10 drops per minute. Total
transmission leakage at all sources must
An appropriate log book entry must be
not exceed 15 drops per minute.
made upon installation of dehydrator.

1. Inspect lower and upper electric chip detectors (6

21. Remove and store oil filler cap, with lanyard and 26, Figure 63-8) for metal particles and their
attached, in a sealed plastic bag. Install dehydrator self-closing valves for leakage.
(T102102) while transmission is removed.

22. If transmission is removed for extended NOTE

maintenance, shipping, or storage, perform For damage exceeding the following limits,
preservation (BHT-206L-CR&O and BHT-ALL-SPM). refer to the BHT-206L-CR&O.

63-00-00
Page 24 Rev. 10 20 JUL 2009 ECCN EAR99

2. Inspect upper and lower cases of transmission
(10) for nicks, scratches, and damage. Damage not
exceeding 0.010 inch (0.254 mm) on the aluminum top
case and 0.020 inch (0.508 mm) on the magnesium
lower case may be blended out with No. 400 abrasive
paper (C-423).
a. Touchup treatment on magnesium parts shall
be restricted to small areas that have the dichromate
coating removed due to damage and minor rework.
b. Apply chemical film material (C-100) to
repaired aluminum and magnesium areas and a
protective paint finish (BHT-ALL-SPM).
3. Visually inspect all studs, attachments, hoses,
and electrical cabling for condition and security.
4. Visually inspect external components on
transmission for evidence of oil leakage and damage.
5. Visually inspect components of the transmission
mounts (nodal beam) and transmission restraint (16,
Figure 63-7) for condition and security.
6. Visually inspect flight control bellcranks and
supports for condition and security (Volume 8,
Chapter 67).
63-29. TRANSMISSION — INSTALLATION
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
T103141 Hoisting Ring
206-240-001-101 Lift and Cover Plate
(206L3+ IGW
Upgrade)
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-002 Hydraulic Fluid
C-010 Lubricating Oil
ECCN EAR99
BHT-206L3-MM-6
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-011 Lubricating Oil
C-030 Lubricating Oil
C-405 Lockwire
NOTE
Remove dehydrator (T102102) if installed
and reinstall filler cap.
1. Install T103141 hoisting ring (206-240-001-101
lift and cover plate for 206L3+ IGW Upgrade) to top
case studs on transmission or reinstall mast and mast
nut and attach suitable hoisting clevis. Attach hoist to
hoisting ring or clevis and carefully lift transmission
into position for installation in helicopter.
2. Install transmission restraint (16, Figure 63-7) to
stop mounts (23), if removed (paragraph 63-144).
3. Check bore of two stop mounts (23) to ensure
that serviceable packings are bonded in the lower
radius groove.
4. Insert a bearing washer (24) on shank of each
link attachment (25). Carefully lower transmission (26),
guiding stop mounts (23) over drag pins (28), and
transmission restraint (16) into isolation support.
Lower transmission until the four link assemblies (27)
may be positioned on spindles of the four link
attachments.
5. Secure the four link assemblies (27) to link
attachments (25) with support washers (22) and nuts
(21). Torque nuts 36 to 204 inch-pounds (4.1 to 23.0
Nm) and secure with cotter pins (20).
6. Align transmission restraint (16) to isolation
support. Install bolt (11) with special washer (12) under
bolt head, using up to three special washers (13) to fill
gap between isolation support and restraint. Then,
install two steel washers (14) and nut (15). Torque nut
260 to 390 inch-pounds (29.3 to 44.0 Nm) with nodal
arms in down stop position.
7. Disconnect hoist from hoisting ring or clevis.
63-00-00
20 JUL 2009 Rev. 10 Page 25
BHT-206L3-MM-6
8. Position stops (20) on spindles of drag pins (28).
Install nuts (19) and turn until contact is made with
stops then turn nuts an additional 90 to 120°.
9. Remove protective caps and plugs. Connect
freewheeling oil return hose to freewheeling oil return
union (18) located by the stop mount (23). Clamp
freewheel hose to left arm of transmission
restraint (16).
10. Connect oil pressure outlet hose to oil pressure
outlet reducer (17) located above left stop mount (23)
and aft of pressure relief valve.
11. Connect oil inlet and outlet hoses to unions (7) on
oil filter and housing (9). Ensure oil inlet hose is
connected to forward union and outlet hose to aft
union. Clamp inlet and outlet hoses to right aft link
assembly (27).
12. Install hydraulic pump – tachometer generator
(29) (paragraph 63-33 and Volume 4, Chapter 29).
13. Route electrical cabling from under hydraulic
pump – tachometer generator (29) up along external
oil tube to top case of transmission (26). Clamp
electrical cabling at three equally spaced locations
along external oil tube.
a. Connect D1B20 and D2B20N electrical wires
to oil temperature bulb (8) on oil filter and housing (9).
Secure connector with lockwire (C-405) to oil
temperature bulb.
b. Connect D3G20 electrical lead to oil
thermoswitch (10) on oil filter and housing (9). Torque
nut on thermoswitch 6 inch-pounds (0.56 Nm).
c. Connect W62C20 electrical lead to upper
electric chip detector (34) and W62D20 electrical lead
to lower electric chip detector (30).
14. Remove T103141 hoisting ring (206-240-001-101
lift and cover plate for 206L3+ IGW Upgrade) from top
of transmission (26), if used, and pour 1 quart (0.9 L)
of lubricating oil (C-010, C-011, C-030) (lubricating oil
(C-030) for 206L3+ IGW Upgrade) into transmission
for initial lubrication of upper gears and bearings. If
mast was not removed from transmission, omit this
step and step 15.
15. Install mast (2) in top of transmission (26)
(paragraph 63-26).
63-00-00
Page 26 Rev. 10 20 JUL 2009
16. Install oil filler cap lanyard and bracket to
swashplate mounting stud; install swashplate and
support (5) and collar set and idler (4) (Volume 8,
Chapter 67).
17. Connect cyclic control tubes (6 and 31) and
collective control tube (32) to bellcranks mounted on
forward side of transmission (26). Connect collective
link (33) to collective lever and swashplate and
support (5) (Volume 8, Chapter 67).
18. Install main rotor hub and blades (1) and pitch
links (3) (Volume 6, Chapter 62).
19. Install main driveshaft (paragraph 63-19 or
paragraph 66-19F (206L3+ IGW Upgrade)).
20. Service transmission (26) to proper level and
hydraulic reservoir to proper level (Volume 2,
Chapter 12).
21. Check rigging of collective and cyclic flight control
systems (Volume 8, Chapter 67).
22. Check transmission (26) for correct installation of
all parts, mounting hardware, clamping, and safety
devices.
23. Prepare helicopter for ground run-up. Ground run
helicopter (BHT-206L3-FM-1 (BHT-206L4-FM-1 for
206L3+ IGW Upgrade)) and accomplish the following:
a. Transmission oil pressure. Verify that TRANS
OIL PRESS caution segment light is out with
increasing pressure at 38 PSI (260 kPa) and ON with
decreasing pressure at 30 ±2 PSI (210 ±14 kPa)
operating pressure in green arc.
b. Cyclic and collective flight control system
operation normal with HYD BOOST ON.
c. Check transmission (26) for oil leaks and
driveshaft for slinging grease.
d. If a new or overhauled transmission has been
installed, perform run-in checks and inspection
(paragraph 63-30).
24. Reinstall fairings and cowling (Volume 9,
Chapter 71).
ECCN EAR99
 BHT-206L3-MM-6

63-30. TRANSMISSION — OPERATIONAL 2. Remove nuts (15) and washers (13), and remove
CHECK tachometer generator (21) and hydraulic pump (19)
from transmission (10).
NOTE
Perform this operational check after each 3. Remove nuts (18) and washers (16). Remove
installation of a new, overhauled, or tachometer generator (21) from hydraulic pump (19).
repaired transmission. Remove and discard gaskets (20 and 22).

1. Perform ground run-in cycle for 20 minutes

(BHT-206L3-FM-1 (BHT-206L4-FM-1 for 206L3+ IGW 4. If tachometer generator (21) and hydraulic pump
Upgrade)). Monitor indicators to ensure oil pressure (19) are not to be reinstalled, secure oil pump (12) to
and temperature stabilize and remain within limits. transmission (10) with spacers or extra washers (13)
Adjust pressure as required (Figure 63-1). and washers (16), and nuts (15 or 18).

2. After shutdown, accomplish the following 63-32A. TACHOMETER GENERATOR —

requirements: INSPECTION

a. Remove and inspect electric chip detectors for

1. Inspect the tachometer generator (21,
metal particles. If metal particles are found, investigate
Figure 63-8) for general condition.
to determine cause (Figure 63-4).

b. Remove and inspect oil filter for metal
particles.
c. Remove and inspect No. 1 and No. 2 oil jets
and freewheeling lube restrictor (two restrictors on
206L3+ IGW Upgrade) on left side cabin roof. Visually
inspect jets for distortion, cracks, cut packings, and
foreign material.
d. Visually inspect oil at sight gauge for
discoloration and contamination.
2. On S/N 51001 through 51612 Pre TB
206L-03-211, inspect the transmission oil pump shaft
splines and tachometer generator splines for wear and
damage. For damage limits, refer to BHT-206L-CR&O,
Chapter 63.
3. On S/N 51001 through 51612 Post TB
206L-03-211, and 206L3+ IGW Upgrade, inspect as
follows:

e. Inspect transmission and attached a. Inspect the transmission oil pump shaft
components for oil leaks. splines for wear and damage. For damage limits, refer
to BHT-206L-CR&O, Chapter 63.
63-31. TACHOMETER GENERATOR
b. Remove the retaining ring (37, Figure 63-8)
A tachometer generator for the main rotor RPM and the adapter (36) from the tachometer generator
indicating system is mounted on the transmission oil driveshaft.
pump and hydraulic pump.

c. Inspect the tachometer generator driveshaft

63-32. TACHOMETER GENERATOR —
for wear and damage (Figure 63-8A).
REMOVAL

1. Disconnect electrical leads to tachometer d. Inspect the adapter (36, Figure 63-8) for wear
generator (21, Figure 63-8). and damage (Figure 63-8B).

63-00-00
ECCN EAR99 30 APR 2010 Rev. 14 Page 27
BHT-206L3-MM-6

30
31

1
29 HELICOPTER S/N 51001 THROUGH 51307
WITH VENTED CAP

28 2
3

4
5 SEE DETAIL B
OIL LEVEL SIGHT GAUGE LOCATED
RIGHT SIDE MAIN TRANSMISSION
LOWER CASE
DETAIL A
1. Lanyard
2. Vented plug
3. Packing SEE DETAIL A
4. Strainer
5. Packing
6. Electric chip detector
7. Packing
8. Self-closing valve
9. Packing
10. Transmission
11. Packing 17
14
12. Oil pump 27
13. Aluminium washer
14. Packing
15. Nut
16. Aluminium washer
25
17. Retaining ring 26 24
18. Nut 23
19. Hydraulic pump
20. Gasket
T 2
21. Tachometer generator
22. Gasket 10
23. Packing 11
24. Self-closing valve 9
22
25. Packing
26. Electric chip detector 8
27. Screen assembly 21
28. Sight gauge
12 T 2 7
29. Plate 20
30. Screw 13
31. Thin steel 6
washer 19
16 15 SEE DETAIL C 50 TO 70 IN-LBS
T 1 (5.7 TO 7.9 Nm)
18 T 1
75 TO 125 IN-LBS
T T 2 (8.5 TO 14.1 Nm)
1
206L3_MM_63_0008a

Figure 63-8. Transmission Oil Pump, Screen, and Electrical Chip Detectors (Sheet 1 of 3)

63-00-00
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 BHT-206L3-MM-6

DETAIL B
BREATHER
HELICOPTER S/N 51308 AND SUBSEQUENT
AND 206L3+ IGW UPGRADE

206L3_MM_63_0008b

Figure 63-8. Transmission Oil Pump, Screen, and Electric Chip Detectors (Sheet 2 of 3)

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 16 Page 29
BHT-206L3-MM-6

Figure 63-8. Transmission Oil Pump, Screen, and Electric Chip Detectors (Sheet 3 of 3)

63-00-00
Page 30 Rev. 16 25 FEB 2011 ECCN EAR99
 BHT-206L3-MM-6

A
C
B

TACHOMETER GENERATOR
(206-076-373-001 AND 206-375-202-101)

REF INPSECTION
NO. LTR CHARACTERISTIC METHOD LIMIT

1. A Corrosion/mechanical Visual/measure

2. B Corrosion/mechanical Visual/measure 0.002 inch (0.05 mm)

maximum depth.

3. B Spline wear Visual/measure Permitted if damage or wear 1

cannot be felt with a 0.020 inch
(0.508 mm) spherical radius probe.

4. C Corrosion/mechanical Visual/measure 0.002 inch (0.05 mm)

maximum depth.

5. C Corrosion/mechanical Measure between 0.2258 inch (5.7353 mm) 1

0.0360 inch (0.9144 mm) maximum.
diameter pins.

6. D Corrosion/mechanical Visual/measure 0.002 inch (0.05 mm)

maximum depth.

7. D Corrosion/mechanical Measure between 0.040 0.3192 inch (8.1076 mm)

inch (1.016 mm) minimum.
diameter pins.

NOTE
1 Nicks on ends of the splines not exceeding 0.010 inch (0.2 mm) deep may be polished smooth with a
fine India stone.
206LS_MM_63_0008

Figure 63-8A. Tachometer Generator Driveshaft — Inspection

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 16 Page 30A
BHT-206L3-MM-6

S/N 51001 THROUGH 51612

POST TB 206L-03-211
AND 206L3+ IGW UPGRADE

INTERCONNECT ADAPTER (407-340-108-101)

NO. CHARACTERISTIC INSPECTION LIMIT

METHOD

1 Spline wear and Visual/measure Permitted if damage or

mechanical wear cannot be felt with
a 0.020 inch (0.508 mm)
spherical radius probe.

206L3_MM_63_0007_c1

Figure 63-8B. Interconnect Adapter — Inspection

63-00-00
Page 30B Rev. 16 25 FEB 2011 ECCN EAR99
 BHT-206L3-MM-6

63-32B. TACHOMETER GENERATOR —

600-HOUR/12-MONTH INSPECTION AND CAUTION
LUBRICATION INTERVAL

DO NOT PERMIT SOLVENT TO ENTER

SPECIAL TOOLS REQUIRED T H E I N T E R N A L P O RT I O N O F T H E
TACHOMETER GENERATOR. SOLVENT
CAN DAMAGE THE BEARINGS AND
NUMBER NOMENCLATURE ELECTRICAL COMPONENTS.

Item No. 1 Workaid 3. Taking care to ensure the solvent does not enter
the tachometer generator (3), clean the internal
Item No. 2 Workaid splines with drycleaning solvent (C-304) and a small
brush. Clean the mating splines of the driveshaft (1)
NOTE: with drycleaning solvent (C-304) and a small brush.
Dry the splines with low pressure filtered compressed
For Item No. 1 and No. 2, refer to Figure 63-8C.
air.

4. Inspect the internal splines of the tachometer

MATERIALS REQUIRED generator (3) and the splines of the driveshaft (1)
(Figure 63-8A).
Refer to BHT-ALL-SPM for specifications.
a. If the internal splines of the tachometer
NUMBER NOMENCLATURE
generator (3, Figure 63-8C) are damaged beyond
C-304 Drycleaning Solvent limits, the tachometer generator can be returned to
Bell Helicopter Textron for repair. Refer to
C-561 Grease IL GEN-04-98.

b. If the splines of the driveshaft (1) are damaged

1. Remove the tachometer generator (21, beyond limits, replace the driveshaft.
Figure 63-8) (paragraph 63-32).
5. Install the driveshaft (1) into the tachometer
generator (3) as follows:
CAUTION
a. Install the retaining clip (2) on the
driveshaft (1).
DO NOT USE HYDRAULIC PRESS TO
REMOVE THE DRIVESHAFT. b. Lubricate the internal splines of the
EXCESSIVE PRESSURE CAN DAMAGE tachometer generator (3) and the mating driveshaft (1)
THE TACHOMETER GENERATOR splines with grease (C-561).
HOUSING.
c. Insert the driveshaft (1) in the tachometer
2. Using an arbor press or equivalent and workaids generator (3).
No. 1 and No. 2, remove the driveshaft (1,
Figure 63-8C) from the tachometer generator (3). The 6. Install the tachometer generator (3) (paragraph
retaining clip (2) can be reused if serviceable. 63-33).

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 16 Page 30C
BHT-206L3-MM-6

ARBOR PRESS

WORKAID NO. 1
SEE DETAIL A

WORKAID NO. 2
SEE DETAIL B

1
1

2 2
3 3

(VESPEL ADAPTER NOT

SHOWN FOR CLARITY)

TACHOMETER GENERATOR TACHOMETER GENERATOR

(206-076-373-001) (206-375-202-101)

206LS_MM_63_0010a

Figure 63-8C. Tachometer Generator Driveshaft — Removal/Installation (Sheet 1 of 2)

63-00-00
Page 30D Rev. 16 25 FEB 2011 ECCN EAR99
 BHT-206L3-MM-6

1.49 IN.
(37.85 mm)

0.80 IN.
(20.32 mm)

0.25 IN. 1.00 IN.

(6.25 mm) (25.40 mm)

WORKAID NO. 1
MATERIAL: ALUMINUM

DETAIL A

3.00 IN.
(76.20 mm)
1.60 IN.
(40.64 mm)

0.84 IN.
(21.34 mm)

WORKAID NO. 2
MATERIAL: ALUMINUM

DETAIL B

1. Driveshaft
2. Retaining clip
3. Tachometer generator

GREASE (C-561)

206LS_MM_63_0010b

Figure 63-8C. Tachometer Generator Driveshaft — Removal/Installation (Sheet 2 of 2)

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 16 Page 30E
BHT-206L3-MM-6
63-33. TACHOMETER GENERATOR —
INSTALLATION
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-002 Hydraulic Fluid
C-561 Grease
1. Remove nuts (15, Figure 63-8) and washers (13),
or spacers securing oil pump (12) to transmission (10).
2. Apply a thin coating of grease (C-561) to mating
shaft and splines of tachometer generator (21) and
hydraulic pump (19).
3. On S/N 51001 through 51612 Pre TB
206L-03-211, apply a thin coating of grease (C-561) to
mating shaft and splines of tachometer generator (21)
and oil pump (12).
NOTE
Do not apply any lubricant to the internal or
external splines of the adapter (36,
Figure 63-8). The use of grease lubricant
can result in deterioration of the adapter.
4. On S/N 51001 through 51612 Post TB
206L-03-211, and 206L3+ IGW Upgrade, install the
adapter (36, Figure 63-8) and the retaining ring (37) in
the tachometer generator shaft splines.
5. Position new gasket (22) on studs at installed oil
pump (12) and install tachometer generator (21) with
electrical connector pointing inboard. Install electrical
cable bracket and clamp on lower outboard stud,
ground wire terminal to lower inboard stud and secure
with thin aluminum washers (13) and nuts (15). Torque
nuts 50 to 70 inch-pounds (5.65 to 7.90 Nm).
NOTE
Make sure hydraulic pump case is full of
hydraulic fluid (C-002) before installation.
63-00-00
Page 30F Rev. 16 25 FEB 2011
6. Position new gasket (20) on studs of tachometer
generator (21). Install hydraulic pump (19) to
tachometer generator (21). Align shafts as parts are
mated. Tachometer generator shaft may be rotated by
rotating main rotor hub and blade assembly. Secure
hydraulic pump (19) with thin aluminum washers (16)
and nuts (18). Torque nuts 50 to 70 inch-pounds (5.65
to 7.91 Nm).
7. On first ground run-up, check main rotor RPM
indicator to ensure proper functioning. Also check
transmission oil pressure indicator for normal pressure
indication and that hydraulic pump (19) is providing
boost to cyclic and collective control systems.
63-34. TRANSMISSION OIL SYSTEM
Lubrication is provided by a system which includes an
oil pump, pressure regulating valve, oil cooler, filter
element, and spray oil jets No. 1 and No. 2
(Figure 63-9). The oil pump is a constant volume type,
driven by the accessory gear that delivers oil under
pressure externally to the oil filter and housing
assembly, oil cooler, and then returns oil to the main
transmission and spray jets for lubricating internal
parts. An oil level sight gauge is located on the right
side of main transmission lower case where it can be
easily inspected. A breather-type filler cap is located
on the main transmission top case.
The transmission oil system also provides lubrication
for the freewheeling assembly mounted in the engine
accessory gear case.
Oil pressure for lubrication of the freewheeling
assembly and to the transmission oil pressure gauge
on the instrument panel is taken from a tee-fitting
installed in the pressure line.
Oil temperature indications are provided by an oil
temperature bulb located in the outlet side of the oil
filter housing and a high oil temperature switch which
is connected to TRANS OIL TEMP caution segment.
The TRANS OIL PRESS caution segment light is
connected to the transmission oil pressure switch
located in the oil pressure line below and forward of
the instrument panel.
ECCN EAR99
 BHT-206L3-MM-6

63-36. OIL PUMP — REMOVAL

63-35. OIL PUMP
The oil pump, tachometer generator and hydraulic
pump are mounted together on forward side of the
transmission and all are driven by the accessory drive
gear. Both the hydraulic pump and tachometer
generator must be removed to gain access to the oil
pump.
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
1. Drain lubricating oil from transmission.
2. Remove hydraulic pump (19, Figure 63-8) and
tachometer generator (21) (paragraph 63-32 and
Volume 4, Chapter 29).
3. Using heat lamp, heat transmission case at boss
for oil pump (12). After transmission case has warmed
up, install slide hammer puller to face of oil pump (12)
with two 10-32 bolts or cap screws and remove oil
pump (12).

NUMBER NOMENCLATURE

C-010 Lubricating Oil

C-011 Lubricating Oil

C-030 Lubricating Oil

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 16 Page 30G
BHT-206L3-MM-6

THERMOBULB
CLOG FILTER INDICATOR

HIGH TEMPERATURE FILTER BYPASS VALVE

WARNING SWITCH OIL COOLER THERMO
MAST ASSEMBLY BYPASS VALVE
OIL COOLER

MAST BEARING
MAGNETIC CHIP
DETECTOR

CHIP COLLECTOR
OIL JET NO. 2
PAN
BLOWER ASSEMBLY

FILTER ELEMENT
PLANETARY
ASSEMBLY 1 RESTRICTOR IN FITTING

PRESSURE
REG VALVE
OIL PUMP
FILTER
4.5 TO 5 GPM
(17 TO 19 IPM) FREEWHEEL UNIT
OIL JET NO. 1 ENGINE
INTERNAL JETS TO
DRAIN PLUG AND SUN GEAR AND PLANETARY
MAGNETIC DRAIN PLUG AND MAGNETIC
CHIP DETECTOR CHIP DETECTOR
206L3 HELICOPTERS

LUBRICATING OIL

FLOW OF OIL
UNDER PRESSURE

NOTE
1 To pilot panel oil pressure gauge and low pressure warning switch.

206L3_MM_63_0009a

Figure 63-9. Transmission Oil System Schematic (Sheet 1 of 2)

63-00-00
Page 30H Rev. 16 25 FEB 2011 ECCN EAR99
 BHT-206L3-MM-6

THERMOBULB
CLOG FILTER INDICATOR

HIGH TEMPERATURE FILTER BYPASS VALVE

WARNING SWITCH OIL COOLER THERMO
MAST ASSEMBLY BYPASS VALVE
OIL COOLER

MAST BEARING
MAGNETIC CHIP
DETECTOR

CHIP COLLECTOR
OIL JET NO. 2
PAN
BLOWER ASSY

FILTER ELEMENT
PLANETARY
ASSEMBLY 1 RESTRICTOR IN FITTING
RESTRICTOR IN FITTING
PRESSURE
REG VALVE
OIL PUMP
FILTER
4.5 TO 5 GPM
(17 TO 19 IPM) FREEWHEEL UNIT
OIL JET NO. 1 ENGINE
INTERNAL JETS TO
DRAIN PLUG AND SUN GEAR AND PLANETARY
MAGNETIC DRAIN PLUG AND MAGNETIC
CHIP DETECTOR CHIP DETECTOR

LUBRICATING OIL
NOTE
1 To pilot panel oil pressure gauge and FLOW OF OIL
low pressure warning switch. UNDER PRESSURE

206L3+ IGW UPGRADE HELICOPTERS

206L3_MM_63_0009

Figure 63-9. Transmission Oil System Schematic (Sheet 2 of 2)

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 31
BHT-2061.3- -6

(See figure 63-10 for tool application). 6-35. INSTALLATION.

(Y3
figure 63-10
-s.
Remove slide hammer puller form oil pump.
1. Using heat lamp, heat case of

a)0
4. Remove and discard packing (11, figure
figure transmission (10, figure 63-3) at boss for oil

._-
figure 63-3
63-3) from oil pump (12). Cover ports in oil
63-3
(f)

pump (12).
pump (12) and opening in transmission (10)
0.U

case to prevent entry of foreign material. 2. Lubricate new packing (11) with
lubricating oil (C-010)
C-010 and position on oil
63-37. INSPECTION A REPAIR. pump.

1. Rotate shaft of oil pump (12, figure 63-3)

figure 63-3 After case of transmission (10) is warm,
(!b

.
and check for freedom and smoothness of install oil pump (12) into case with slot in
rotation. pump pointing down. Rotate oil pump (12)

-4CD
0)a)
slightly if necessary to engage splines with
2. Visually check spline teeth of pump shaft
0_0

accessory drive gear. If tachometer generator

®-a
(both ends) for wear, chips, or cracks. (21) and hydraulic pump (19) are not to be

3. Visually inspect ports in body of oil pump
(12) for damage to gerotor.
. Inspect outboard oil seal for excessive
'-'
installed at this time, install spacers or
additional aluminum washers (13) with nuts
(15) to secure oil pump (12).
4. Install tachometer generator (21) and

-o-

((5
"ca
leakage.
hydraulic pump (19) (paragraph 63-33 and
paragraph 63-33
Volume 4, Chapter 29
29).

5. Service transmission to proper level

LSD

0
(Volume 2, Chapter 12).
Chapter 12

1. Belts or cap screws - 10-32 threads

2. Slide hammer puller
3. Oil pump 2®6L3-63-1®

Figure 63-10. Transmission oil pump removal tool application

63-00-00
Page 32
 BHT-206L3-MM-6

6. On first helicopter ground run-up, check oil pump 63-42. OIL PUMP INLET SCREEN —
for oil leaks and correct indication of oil pressure. INSTALLATION
Adjust oil pressure as required in accordance with
paragraph 63-59.
MATERIALS REQUIRED
63-39. OIL PUMP INLET SCREEN Refer to BHT-ALL-SPM for specifications.

The oil pump inlet screen assembly is located in a NUMBER NOMENCLATURE

boss adjacent to the oil pump of the transmission
C-010 Lubricating Oil
lower case, and filters lubricating oil prior to entering
the oil pump. Screen material is 16 X 16 mesh, C-011 Lubricating Oil
number 23 gauge steel screening that is brazed to an
inlet sleeve and plug. C-030 Lubricating Oil

63-40. OIL PUMP INLET SCREEN — REMOVAL 1. Lubricate new packing (28, Figure 63-8) with
lubricating oil (C-010, C-011, C-030) (lubricating oil
(C-030) for 206L3+ IGW Upgrade) and position on
1. Drain lubricating oil from transmission.
screen assembly (27).

2. Remove retaining ring (17, Figure 63-8). 2. Insert screen assembly (27) into boss in lower
case transmission and secure with retaining ring (17).
3. Withdraw screen assembly (27) from
transmission (10). Immediately inspect screen 3. Service transmission (10) to proper level (Volume
assembly for foreign material. If any particles are 2, Chapter 12).
found, place them in a clean container for inspection.
4. Inspect for oil leaks on first ground run-up.

4. Remove and discard packing (14).

63-43. ELECTRIC CHIP DETECTORS

63-41. OIL PUMP INLET SCREEN — INSPECTION The electric chip detectors consist of a self-locking
bayonet type probe with a permanent ceramic magnet
at the end. In the event metal particles should become
free in the oil, the magnet will attract the metal
MATERIALS REQUIRED particles. When sufficient metal is attracted to
complete a circuit between pole and ground, the
Refer to BHT-ALL-SPM for specifications. applicable yellow caution segment on the caution
panel will illuminate (Volume 10, Chapter 96).
NUMBER NOMENCLATURE

C-304 Drycleaning Solvent 63-44. ELECTRIC CHIP DETECTORS —

REMOVAL

1. If any particles are found, identify and perform

corrective action (paragraph 63-9 and Figure 63-4).
CAUTION

2. Clean screen assembly (27, Figure 63-8) with

drycleaning solvent (C-304). ROUGH HANDLING OF CHIP
DETECTORS AND THE ELECTRICAL
CONNECTOR IS THE MAJOR CAUSE OF
3. Inspect screen assembly (27) for cracks and FAILURE AND FALSE INDICATIONS IN
distortion. Inspect retaining ring (17) for distortion. THE CAUTION LIGHT SYSTEM.

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 33
BHT-206L3-MM-6

1. Disconnect electrical leads from terminal studs on self-closing valves (8 and 24). Lubricate packings with
end of electric chip detectors (6 and 26, Figure 63-8). a film of lubricating oil (C-010, C-011, C-030)
(lubricating oil (C-030) for 206L3+ IGW Upgrade).
2. Press electric chip detector in, turn
counterclockwise and remove from self-closing valve. 2. Install self-closing valves (8 and 24) in upper and
Check detector for metal particles. If any particles are lower cases of transmission (10). Torque self-closing
found, place them in a clean container and retain until valves 75 to 125 inch-pounds (8.47 to 14.12 Nm) and
inspection is completed. secure to transmission with lockwire (C-405).

3. Inspect self-closing valves (8 and 24) for leakage 3. Insert electric chip detectors (6 and 26) into
after electric chip detectors are removed. self-closing valves (8 and 24) and turn clockwise to
lock in place. Connect electrical leads to electric chip
4. Drain lubricating oil from component. detectors.

5. Cut and remove lockwire from self-closing valves 4. Service transmission to proper level (Volume 2,
(8 and 24), remove valves, and discard packings (9 Chapter 12).
and 23). Discard packings (7 and 25) from electric chip
detectors (6 and 26). 5. Check for oil leaks on first ground run-up.

63-45. ELECTRIC CHIP DETECTORS —

63-47. TRANSMISSION OIL LEVEL SIGHT
INSPECTION
GAUGE

1. Inspect electric chip detectors (6 and 26, Figure Transmission oil level sight gauge is located on the
63-8) for metal particles. If any particles are found, right side of the transmission and provides a visual
identify in accordance with paragraph 63-9. Perform indication of oil level.
corrective action required by Figure 63-4.
63-48. TRANSMISSION OIL LEVEL SIGHT
2. Inspect for worn or damaged bayonet pins on GAUGE — REMOVAL
electric chip detectors (6 and 26) and self-closing
valves (8 and 24).
1. Drain lubricating oil from transmission (Volume 2,
Chapter 12).
63-46. ELECTRIC CHIP DETECTORS —
INSTALLATION
2. Cut and remove lockwire from eight screws (30,
Figure 63-8, Detail A) on sight gauge (28).

MATERIALS REQUIRED
3. Remove eight screws (30) and washers (31) from
Refer to BHT-ALL-SPM for specifications. sight gauge (28). Carefully remove sight gauge from
transmission case to prevent damage to bonded
NUMBER NOMENCLATURE gasket, if still serviceable, with plate (29).

C-010 Lubricating Oil 63-49. TRANSMISSION OIL LEVEL SIGHT

GAUGE — INSPECTION
C-011 Lubricating Oil

C-030 Lubricating Oil 1. Inspect sight gauge (28, Figure 63-8) for crazing,
discoloration, and cracking. Replace sight gauge if
C-405 Lockwire crazed or discolored to extent it will be difficult to see
lubricating oil or determine oil level.
1. Install new packings (7, 9, 23, and 25, Figure
63-8) on electric chip detectors (6 and 26) and 2. Inspect plate (29) for cracking and damage.

63-00-00
Page 34 Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

63-50. TRANSMISSION OIL LEVEL SIGHT 2. Remove screws (24 and 25) and remove oil jet
GAUGE — INSTALLATION No. 1 (23) from transmission (27). Remove and
discard packings (19, 20, 21, and 22) and sealing
washer (26).
MATERIALS REQUIRED
3. Cover or plug open ports in transmission to
Refer to BHT-ALL-SPM for specifications. prevent entry of foreign material.

NUMBER NOMENCLATURE
63-53. TRANSMISSION OIL JETS — INSPECTION
C-010 Lubricating Oil

C-011 Lubricating Oil

MATERIALS REQUIRED
C-030 Lubricating Oil
Refer to BHT-ALL-SPM for specifications.
C-304 Drycleaning Solvent
NUMBER NOMENCLATURE
C-405 Lockwire
C-304 Drycleaning Solvent

1. Clean surface of gasket on sight gauge (28,

Figure 63-8) and mating surface of transmission (10) 1. Clean oil jet No. 2 (6, Figure 63-11) and oil jet
with drycleaning solvent (C-304). No. 1 (23) with drycleaning solvent (C-304) and dry
with filtered compressed air.

2. Position sight gauge (28) to transmission (10)

and loosely install lower five screws (30) and thin steel 2. Inspect oil jets No. 2 and No. 1 (6 and 23) for
washers (31). Position plate (29) to sight gauge and clogged passages, cracks, dents, distortion, and
install remaining three screws (30) and thin steel corrosion.
washers (31).
63-54. TRANSMISSION OIL JETS —
3. Tighten screws (30) evenly and secure heads INSTALLATION
together with lockwire (C-405), as shown in Detail A.

4. Service transmission to proper level (Volume 2, MATERIALS REQUIRED

Chapter 12).
Refer to BHT-ALL-SPM for specifications.
5. Inspect for oil leaks on first ground run-up. NUMBER NOMENCLATURE

63-51. TRANSMISSION OIL JETS C-010 Lubricating Oil

C-011 Lubricating Oil

Two oil jets are incorporated in the transmission. The
No. 1 oil jet directs a lubricating oil spray to the bevel C-030 Lubricating Oil
gears of the transmission and the No. 2 oil jet
lubricates planetary pinions and mast bearing. C-405 Lockwire

63-52. TRANSMISSION OIL JETS — REMOVAL
1. Remove screws (8 and 9, Figure 63-11) and
remove oil jet No. 2 (6) from oil filter and housing (1)
and transmission (27). Remove and discard packings
(2, 3, 4, and 5), and sealing washer (7).
1. Lubricate new packings (2, 3, 4, and 5,
Figure 63-11) with lubricating oil (C-010, C-011,
C-030) (lubricating oil (C-030) for 206L3+ IGW
Upgrade) and position on oil jet No. 2 (6). Install oil jet
No. 2 into oil filter and housing (1) and transmission
(27).

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 35
BHT-206L3-MM-6

200 TO 300 IN-LBS

T (22.6 TO 33.9 Nm)

206L3_MM_63_0011

Figure 63-11. Transmission Oil Jets and Relief Valve

63-00-00
Page 36 Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

2. Align tab on oil jet No. 2 (6) and install screws (8 3. If evidence of an oil leak is noted around
and 9) and new sealing washer (7). Tighten screws adjusting screw (12), or piston (15) is binding, repair
and secure together with lockwire (C-405). valve assembly in accordance with the
BHT-206L-CR&O.
3. Lubricate new packings (19, 20, 21, and 22) for
oil jet No. 1 (23) and install in same manner as step 1 63-58. TRANSMISSION OIL PRESSURE
and step 2. REGULATING VALVE — INSTALLATION

4. Inspect for oil leaks on first ground run-up.

MATERIALS REQUIRED
63-55. TRANSMISSION OIL PRESSURE
REGULATING VALVE Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE
The transmission oil pressure regulating valve is
located on the left rear corner of the transmission C-010 Lubricating Oil
lower case. The regulating valve is used to adjust
transmission oil pressure to normal operating limits C-011 Lubricating Oil
and relieves excess oil pressure back into the
transmission case. C-030 Lubricating Oil

C-405 Lockwire
63-56. TRANSMISSION OIL PRESSURE
REGULATING VALVE — REMOVAL
1. Lubricate new packings (17 and 18, Figure 63-11)
1. Cut and remove lockwire from oil pressure with lubricating oil (C-010, C-011, C-030) (lubricating
regulating valve body (11, Figure 63-11). oil (C-030) for 206L3+ IGW Upgrade).

2. Use wrench on hexagonal shoulder of valve body
(11) to loosen and remove valve assembly from
transmission lower case. Remove and discard
packings (17 and 18).
63-57. TRANSMISSION OIL PRESSURE
REGULATING VALVE — INSPECTION
1. Inspect valve body (11, Figure 63-11) for scored
areas and damaged threads. Using a nonmetallic
blunt rod, check piston (15) for freedom of movement
by pushing it into the valve body several times.
2. Position packing (17) next to head of valve body
(11) and packing (18) on end of valve body.
3. Carefully thread valve body (11) into boss on
lower case of transmission (27). Torque valve body
200 to 300 inch-pounds (22.6 to 33.9 Nm) and secure
to adjacent oil transfer dowel tube with lockwire
(C-405).
4. Inspect for oil leaks and adjust transmission oil
pressure on first ground run-up (paragraph 63-59).

63-59. TRANSMISSION OIL PRESSURE

REGULATING VALVE — ADJUSTMENT
CAUTION

LOOSENING NUT (10) OR TURNING CAUTION

ADJUSTING SCREW (12) WILL REQUIRE
ADJUSTMENT OF TRANSMISSION OIL
PRESSURE.
2. Inspect valve body (11) for evidence of oil leaks
and nut (10) for loss of locking tension.
ADJUSTMENT OF TRANSMISSION OIL
PRESSURE REGULATING VALVE MUST
BE ACCOMPLISHED IMMEDIATELY ON
GROUND RUN-UP.

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 37
BHT-206L3-MM-6

1. Transmission oil pressure limits are 30 to 70 PSI housing (13) to transmission (1). Remove complete
(210 to 480 kPa). Maximum oil temperature is 110°C assembly from transmission.
(230°F). Do not exceed these limits.
63-62. TRANSMISSION OIL FILTER AND
2. If transmission oil pressure is not within the HOUSING ASSEMBLIES — INSPECTION
specified range, hold adjusting screw (12,
Figure 63-11) with a flat tip screwdriver and loosen nut
(10). To obtain correct pressure, turn adjusting screw 1. Inspect tube assembly (6, Figure 63-12) for nicks,
clockwise to increase pressure and counterclockwise scratches, damage, and oil leaks. Check tube nuts for
to decrease pressure. Adjust oil pressure to 45 to 55 security and clamp installation for proper mounting.
PSI (310 to 380 kPa) (50 to 55 PSI (345 to 380 kPa) Check electrical harness, clamped to tube assembly,
for 206L+3 IGW Upgrade) at 100% N2 RPM. Tighten for chafing and deterioration.
nut after oil pressure is adjusted.
2. Inspect oil filter housing (13) and housing (16) for
3. When transmission oil temperature has security, damage, and oil leaks.
stabilized, recheck transmission oil pressure and
make additional adjustments, as required.
63-63. TRANSMISSION OIL FILTER AND
HOUSING ASSEMBLIES —
63-60. TRANSMISSION OIL FILTER AND INSTALLATION
HOUSING ASSEMBLIES

The transmission oil filter and housing assembly is

mounted to the aft side of the transmission and MATERIALS REQUIRED
incorporates a disposable filter element, bypass
indicator, bypass valve, thermostat, temperature bulb, Refer to BHT-ALL-SPM for specifications.
and a thermoswitch.
NUMBER NOMENCLATURE

63-61. TRANSMISSION OIL FILTER AND C-010 Lubricating Oil

HOUSING ASSEMBLIES — REMOVAL
1. Drain lubricating oil from transmission and oil
cooler assembly (Volume 2, Chapter 12).
2. Remove tube assembly (6, Figure 63-12) from
two elbows (7) and clamping installation on
transmission (1). If elbows are to be removed, loosen
nuts (8) and unscrew elbows from oil filter housing
(13) and lower case of transmission. Remove and
discard packings (9).
3. Disconnect oil hose assemblies to inlet union (3)
and outlet union (4). Install protective plugs in oil hose
assemblies to prevent entry of foreign material.
Remove inlet union, outlet union, and discard
packings (2 and 5).
4. Remove transmission oil jet No. 2 (paragraph
63-52).
5. Remove three nuts (10) and thin steel washers
(11) and aluminum washers (12), securing oil filter
C-011 Lubricating Oil
C-030 Lubricating Oil
C-304 Drycleaning Solvent
C-308 Sealant
1. Clean the mating flange surfaces of the oil filter
housing (13, Figure 63-12) and transmission (1) with
drycleaning solvent (C-304).
2. Position oil filter housing (13) on studs of
transmission top case. Install oil jet No. 2 (6), to align
housing and top case, in accordance with paragraph
63-54. Install an aluminum washer (12), thin steel
washer (11), and nut (10) on each of the three studs.
Torque nuts 50 to 70 inch-pounds (5.65 to 7.91 Nm).
3. Apply a bead of sealant (C-308) to mating edge
surfaces around oil filter housing (13) and
transmission (1).

63-00-00
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 BHT-206L3-MM-6

T 1

T 2

50 TO 70 IN-LBS 100 TO 140 IN-LBS

T 1 (5.7 TO 7.9 Nm) T 2 (11.3 TO 15.8 Nm)

206L3_MM_63_0012

Figure 63-12. Transmission Oil Filter and Housing

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 39
BHT-206L3-MM-6

4. Apply a film of lubricating oil (C-010, C-011, 3. Clean lower surface of oil filter housing (13,
C-030) (lubricating oil (C-030) for 206L3+ IGW Figure 63-12), and housing (16) with drycleaning
Upgrade) to new packings (9) and position on two solvent (C-304). Dispose of paper filter element.
elbows (7) with nuts. Install elbows in oil filter housing
(13) and lower case of transmission (1). Install tube 63-67. TRANSMISSION OIL FILTER —
assembly (6) and torque nuts (8) and nuts on tube INSTALLATION
assembly. Install electrical clamp installations on tube
assembly.
MATERIALS REQUIRED
63-64. TRANSMISSION OIL FILTER
Refer to BHT-ALL-SPM for specifications.
The transmission oil filter element is contained in the
lower housing of the oil filter housing assembly. The NUMBER NOMENCLATURE
filter element is a micronic, pleated paper element type
which is disposable. C-010 Lubricating Oil

C-011 Lubricating Oil

63-65. TRANSMISSION OIL FILTER — REMOVAL
1. Place rags or absorbent material below oil filter
housing (16, Figure 63-12) to collect residual oil.
2. Remove two nuts (18) with steel washers (17)
and pull housing (16) from oil filter housing (13). Leave
residual oil in housing for inspection.
C-030 Lubricating Oil
1. Apply a film of lubricating oil (C-010, C-011,
C-030) (lubricating oil (C-030) for 206L3+ IGW
Upgrade) to new packings (15 and 19, Figure 63-12).
Position packing (19) on oil journal in lower surface of
oil filter housing (13).

3. Remove filter element (14) from oil tube on oil 2. Position filter element (14) onto oil journal in
filter housing (13) and place in a clean container for lower surface of oil filter housing (13).
inspection.
3. Position packing (15) around flange of housing
4. Remove and discard packings (15 and 19). (16). Install housing to oil filter housing (13) and
secure with two steel washers (17) and two nuts (18).
63-66. TRANSMISSION OIL FILTER — CLEANING Torque nuts 100 to 140 inch-pounds (11.30 to
AND INSPECTION 15.82 Nm).

4. Inspect for oil leaks and that transmission oil

MATERIALS REQUIRED pressure and temperature indications are normal on
first ground run-up.
Refer to BHT-ALL-SPM for specifications.
63-68. TRANSMISSION OIL TEMPERATURE
NUMBER NOMENCLATURE BULB
C-304 Drycleaning Solvent
The transmission oil temperature bulb is located on
the forward side of the oil filter housing and is
1. Immediately upon removal of transmission oil electrically connected to oil temperature indicator on
filter element (14, Figure 63-12) and housing (16), the instrument panel.
inspect residual oil and element for foreign particles
and contamination. 63-69. TRANSMISSION OIL TEMPERATURE
BULB — REMOVAL
2. If any particles are found, identify in accordance
with paragraph 63-9. Perform corrective action 1. Remove electrical connector from temperature
required by Figure 63-4. bulb (5, Figure 63-13).

63-00-00
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 BHT-206L3-MM-6

2. Remove temperature bulb (5) from oil filter 63-72. TRANSMISSION OIL BYPASS VALVE
housing (16). Remove and discard packing (4).
The transmission oil bypass valve assembly will open
63-70. TRANSMISSION OIL TEMPERATURE when excessive back pressure is caused by a clogged
BULB — INSPECTION filter element or extreme cold temperatures. The
bypass valve will then allow lubricating oil to bypass
1. Inspect electrical connector and electrical leads the oil filter element and be directed to the thermostat
to temperature bulb (5, Figure 63-13) for chafing, and oil cooler.
damage, and correct clamping.
63-73. TRANSMISSION OIL BYPASS VALVE —
REMOVAL
2. Inspect pins and probe in temperature bulb (5) for
corrosion and damage. If installed, check for external
damage, oil leaks, and security.
CAUTION
63-71. TRANSMISSION OIL TEMPERATURE
BULB — INSTALLATION
BYPASS RETAINER IS SPRING LOADED
AT 7.6 POUNDS (3.4 N).
MATERIALS REQUIRED
1. Cut and remove lockwire from retainer (11,
Figure 63-13).
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE 2. Remove retainer (11), spring (9), and bypass

valve (8) from oil filter housing (16). Remove and
C-010 Lubricating Oil discard packing (10).

C-011 Lubricating Oil 63-74. TRANSMISSION OIL BYPASS VALVE —

INSPECTION
C-030 Lubricating Oil

C-405 Lockwire 1. Inspect bypass valve (8, Figure 63-13), spring

1. Apply a film of lubricating oil (C-010, C-011,
C-030) (lubricating oil (C-030) for 206L3+ IGW
Upgrade) to new packing (4, Figure 63-13) and
position on temperature bulb (5).
2. Install temperature bulb (5) in oil filter housing
(16). Secure oil temperature bulb to hexagon flange
and secure thermostat (2) with lockwire (C-405).
3. Attach electrical lead to oil temperature bulb (5).
4. On first ground run-up, check for oil leaks and
that transmission oil temperature increases normally
on indicator.
(9), and retainer (11) for visual evidence of wear or
damage.
2. Inspect spring (9) as follows:
a. Check spring (9) for a free length dimension of
2.780 inches ±0.010 inch (70.61 ±0.25 mm).
b. Apply a measurable amount of weight to
spring (9) and compress length to 1.300 inches,
±0.010 inch (33.02 ±0.25 mm). The amount of weight
required shall not exceed 7.6 ±0.5 pounds (3.4
±0.2 kg).
3. Visually inspect retainer (11) and port in oil filter
housing (16) for thread damage.

63-00-00
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BHT-206L3-MM-6

7
6
11

10
5 9
4 8
1 12 13

2 3

14
15
16 T
SEE DETAIL A

19
20

17
18

15
1. Transmission 14. Screw
2. Thermostat 15. Bypass indicator 16
14
3. Packing 16. Oil filter housing
4. Packing 17. Union
5. Temperature bulb 18. Packing
6. Packing 19. Reducer
7. Plug 20. Packing 25
8. Bypass valve 21. Glyd ring and packing
24
9. Spring 22. Lower magnet assembly
21 1
10. Packing 23. Spring
11. Retainer 24. Packing 22
12. Packing 25. Back-up- ring
13. Thermoswitch
23

NOTE
17 TO 19 IN-LBS
T (1.92 TO 2.15 Nm) 1 Not field replaceable. DETAIL A
206L3_MM_63_0013

Figure 63-13. Transmission Oil Filter Housing and Fittings

63-00-00
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 BHT-206L3-MM-6

63-75. TRANSMISSION OIL BYPASS VALVE — 63-77. TRANSMISSION OIL THERMOSTAT —

INSTALLATION REMOVAL

1. Cut and remove lockwire between thermostat (2,

MATERIALS REQUIRED Figure 63-13) and temperature bulb (5).

Refer to BHT-ALL-SPM for specifications. 2. Remove thermostat (2) from oil filter housing
(16). Remove and discard packing (3).
NUMBER NOMENCLATURE

C-010 Lubricating Oil 63-78. TRANSMISSION OIL THERMOSTAT —

INSTALLATION
C-011 Lubricating Oil

C-030 Lubricating Oil

MATERIALS REQUIRED
C-405 Lockwire
Refer to BHT-ALL-SPM for specifications.

1. Apply a film of lubricating oil (C-010, C-011, NUMBER NOMENCLATURE

C-030) (lubricating oil (C-030) for 206L3+ IGW
Upgrade) to a new packing (10, Figure 63-13) and C-010 Lubricating Oil
position on retainer (11).
C-011 Lubricating Oil

C-030 Lubricating Oil

CAUTION C-405 Lockwire

BYPASS VALVE (8) MAY FALL LOOSE
INSIDE HOUSING (16) DURING
INSTALLATION. INSPECT THROUGH
CENTER OIL HOLE ON BOTTOM OF
H O U S I N G F O R P R O P E R S E AT I N G
AFTER INSTALLATION.
2. Insert bypass valve (8) and spring (9) on retainer
(11) and install in oil filter housing (16). Secure retainer
to adjacent tang beside boss with lockwire (C-405).
3. Inspect for oil leaks on first ground run-up.
63-76. TRANSMISSION OIL THERMOSTAT
1. Apply a film of lubricating oil (C-010, C-011,
C-030) (lubricating oil (C-030) for 206L3+ IGW
Upgrade) to a new packing (3, Figure 63-13) and
position on thermostat (2).
2. Install thermostat (2) in oil filter housing (16).
Secure thermostat to temperature bulb (5) with
lockwire (C-405).
3. Inspect for oil leaks and that oil temperature
stabilizes on first ground run-up.
63-79. TRANSMISSION OIL FILTER BYPASS
INDICATOR

The transmission oil filter bypass indicator is located

On start up, when the transmission thermostat valve is
open, lubricating oil does not go to the cooler but
returns to the transmission. The thermostat valve
begins to close at 150°F (66°C). As the valve begins to
close, some oil flows through the cooler. At 178°F
(81°C), the thermostat valve is closed on seat, forcing
all of the oil through the cooler.
on the oil filter housing above the filter element. The
filter bypass indicator incorporates a spring loaded
magnet that is ported to the bypass valve. If the
bypass valve is opened due to a clogged filter element
or extreme cold temperature, the red indicator button
will be released to the extended position, indicating the
filter element has been bypassed.

63-00-00
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BHT-206L3-MM-6
63-80. BYPASS INDICATOR — REMOVAL
1. Remove screws (14, Figure 63-13).
2. Carefully remove top of bypass indicator (15) and
lower magnet assembly (22).
CAUTION
EXERCISE EXTREME CARE IN
HANDLING BYPASS INDICATOR (15)
AND LOWER MAGNET ASSEMBLY (22).
I F S P R I N G ( 2 3 ) I S P E R M A N E N T LY
DISTORTED, THE INDICATOR WILL NOT
O P E R AT E C O R R E C T LY. B Y PA S S
INDICATOR IS A MATCHED ASSEMBLY;
PA R T S C A N N O T B E O R D E R E D
S E PA R AT E LY AND ARE NOT
INTERCHANGEABLE. DO NOT REMOVE
GLYD RING AND PACKING (21).
3. Remove and discard packing (24) and backup
ring (25) from bypass indicator (15) sub-assembly.
4. If bypass valve is found to be defective, replace
indicator. For repair, contact:
Aircraft Porous Media
Pinellas Park, FL (34665-5798)
63-81. BYPASS INDICATOR — INSPECTION
1. Visually inspect top of bypass indicator (15,
Figure 63-13) for evidence of wear, damage, and
security.
2. If top sub-assembly of bypass indicator (15) is
removed, inspect lower magnet assembly (22) and
lower magnet spring (23) for damage and distortion.
Inspect recess in oil filter housing (16) for cleanliness
and damage.
63-00-00
Page 44 Rev. 10 20 JUL 2009
63-82. BYPASS INDICATOR — INSTALLATION
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-010 Lubricating Oil
C-011 Lubricating Oil
C-030 Lubricating Oil
C-405 Lockwire
CAUTION
E X E R C IS E E X T R E M E C A R E W H E N
HANDLING AND INSTALLING SPRING
AND LOWER MAGNET ASSEMBLY TO
PREVENT PERMANENT DISTORTION
FROM DESTROYING B Y PA S S
INDICATOR CALIBRATION.
1. Position spring (23, Figure 63-13) to lower
magnet assembly (22), as illustrated in Detail A, and
insert into port of oil filter housing (16).
2. Position new backup ring (25) and packing (24) to
top sub-assembly of bypass indicator (15). Lubricate
packing and ring with lubricating oil (C-010, C-011,
C-030) (lubricating oil (C-030) for 206L3+ IGW
Upgrade). Carefully insert top unit of bypass indicator
(15) into oil filter housing (16).
3. Install four screws (14) and torque 17 to 19
inch-pounds (1.92 to 2.15 Nm) using diagonal
sequence. Secure heads of screws in pairs with
lockwire (C-405).
4. Inspect for oil leaks and that transmission oil
temperature and pressure increases normally and
stabilizes on first ground run-up.
63-83. TRANSMISSION OIL THERMOSWITCH
The transmission oil thermoswitch is located on the oil
filter housing and is electrically connected to the
TRANS OIL TEMP caution light segment. When the
ECCN EAR99
 BHT-206L3-MM-6

transmission oil reaches a temperature of 110°C

(230°C), the thermoswitch will illuminate the caution CAUTION
light segment.

63-84. TRANSMISSION OIL THERMOSWITCH — D O N O T A P P LY M O R E T H A N 6

REMOVAL
1. Disconnect electrical terminal from thermoswitch
(13, Figure 63-13).
2. Cut and remove lockwire from thermoswitch (13)
and remove from oil filter housing (16). Remove and
discard packing (12).
INCH-POUNDS (0.68 NM) TORQUE TO
TERMINAL STUD OR 12 INCH-POUNDS
(1.36 NM) TORQUE TO HEX NUT OR
CALIBRATION MAY BE DESTROYED.
2. Install thermoswitch (13) into oil filter housing (16)
and secure to adjacent tab with lockwire (C-405).
63-87. TRANSMISSION OIL FITTINGS

Transmission oil fittings consist of unions, plugs, and a

63-85. TRANSMISSION OIL THERMOSWITCH —
reducer attaching oil hoses or tube assemblies to the
INSPECTION
transmission and oil filter housing.

1. Inspect electrical terminal post and electrical 63-88. TRANSMISSION OIL FITTINGS —
leads to thermoswitch (13, Figure 63-13) for chafing, REMOVAL
damage, and correct clamping.
1. Remove attaching hose or tube assembly
2. Inspect probe of thermoswitch (13) for damage. If connected to fitting.
installed, check for external damage, oil leaks, and
security. 2. Remove fitting and discard packing.

63-86. TRANSMISSION OIL THERMOSWITCH — 63-89. TRANSMISSION OIL FITTINGS —

INSTALLATION INSTALLATION

MATERIALS REQUIRED MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications. Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE NUMBER NOMENCLATURE

C-010 Lubricating Oil C-010 Lubricating Oil

C-011 Lubricating Oil C-011 Lubricating Oil

C-030 Lubricating Oil C-030 Lubricating Oil

C-405 Lockwire C-304 Drycleaning Solvent

C-405 Lockwire
1. Apply a film of lubricating oil (C-010, C-011,
C-030) (lubricating oil (C-030) for 206L3+ IGW 1. Clean threads on fitting and mating port with
Upgrade) to new packing (12, Figure 63-13) and drycleaning solvent (C-304). Check fittings and ports
position on thermoswitch (13). for thread damage.

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 45
BHT-206L3-MM-6

2. Apply a film of lubricating oil (C-010, C-011, 2. Inspect hoses and tube assemblies for evidence
C-030) (lubricating oil (C-030) for 206L3+ IGW of chafing, crimping, twisting, cracks, damaged
Upgrade) to new packings and position on fittings. threads, or obstruction in openings.

3. Install fittings into transmission or oil filter housing 3. Inspect hose and tube assemblies for leakage.
and connect attaching hose on tube assemblies.
Secure fittings, as required, with check nuts or
63-93. HOSES AND TUBE ASSEMBLIES —
lockwire (C-405).
INSTALLATION

63-90. TRANSMISSION OIL SYSTEM HOSES

AND TUBE ASSEMBLIES MATERIALS REQUIRED

The transmission oil system hose and tube Refer to BHT-ALL-SPM for specifications.
assemblies shown in Figure 63-14 comprise the
NUMBER NOMENCLATURE
distribution system. The tube assemblies have sleeves
and fittings which are retained by flares on tubes. C-010 Lubricating Oil

C-011 Lubricating Oil

63-91. HOSES AND TUBE ASSEMBLIES —
REMOVAL C-030 Lubricating Oil

1. Disconnect hose or tube assemblies at

connecting fittings. 1. Remove protective caps or plugs from openings
to hoses, tubes, or components.

2. Remove attaching clamps securing hose or tube

2. Install new packings on all removed fittings.
assemblies to structure and remove.
Lubricate new packings with lubricating oil (C-010,
C-011, C-030) (lubricating oil (C-030) for 206L3+ IGW
3. Remove and discard all packings on fittings. Upgrade). When installing restrictor fitting (16,
Figure 63-14) restrictor side of fitting must be installed
to tube assembly (17).
4. Install protective caps or plugs in opening to
prevent system contamination.
3. Position hose or tube assembly to supports,
clamps, and structure as required. Torque hose or
63-92. HOSES AND TUBE ASSEMBLIES — tube assemblies as required by torque chart
CLEANING AND INSPECTION (BHT-ALL-SPM).

4. Secure hose or tube assembly with required

MATERIALS REQUIRED clamp installation. Ensure that there will be no chafing
between hose or tube assemblies and components.
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE 5. Service transmission to proper level (Volume 2,

Chapter 12).
C-304 Drycleaning Solvent

6. If oil pressure lines between hose assembly (13)

1. Clean hoses and tube assemblies with on transmission and oil pressure indicator located on
drycleaning solvent (C-304) and dry with filtered pilot instrument panel are disconnected, it is
compressed air. recommended that oil lines be bled (paragraph 63-94).

63-00-00
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 BHT-206L3-MM-6

10

9
11
8
9
8

7
6
5

4
3
2
1
OIL RETURN
FROM FREEWHEEL
ASSEMBLY
12
13

14
OIL PRESSURE TO
FREEWHEEL
ASSEMBLY
21 OIL PRESSURE TO
FREEWHEEL
17 16 ASSEMBLY
20
OIL PRESSURE 15
19 18 FROM FILTER TO
PRESSURE SWITCH
AND INDICATOR 15

22

206L3+ IGW UPGRADE

OVERBOARD
1. Filter cap 12. Drain valves
DRAIN LINES
2. Transmission 13. Hose assembly
3. Lanyard 14. Hose assembly
4. Electric chip detector - upper 15. Tube assembly
5. Return oil hose 16. Restrictor fitting
6. Outlet oil hose 17. Tube assembly
7. Oil filter and housing 18. Pressure regulating valve
8. Union 19. Oil pump
9. Packing 20. Electric chip detector
10. Engine and transmission oil cooler 21. Oil screen
11. Oil cooler blower 22. Restrictor fitting
206L3_MM_63_0014

Figure 63-14. Transmission Oil System

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 47
BHT-206L3-MM-6

63-94. TRANSMISSION OIL PRESSURE LINES — PRESS caution light segment to illuminate on pilot
BLEEDING instrument panel.

63-96. TRANSMISSION OIL PRESSURE SWITCH

MATERIALS REQUIRED — REMOVAL

Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-010 Lubricating Oil
C-011 Lubricating Oil
C-030 Lubricating Oil
Anytime transmission oil pressure line is disconnected
between the transmission and the transmission oil
pressure indicator the system should be bled. This will
ensure a positive indication of oil pressure on starts
and eliminate sluggish or erratic operation.
1. Disconnect oil pressure hose assembly (14,
Figure 63-14) from reducer at transmission (2) and
place end of hose assembly in a receptacle so that
end will be covered by fluid. Station a person at
receptacle to observe when a bubble free flow has
been established.
2. Gain access to rear of instrument panel.
Disconnect pressure indicator hose assembly and
connect to a low pressure filler gun or pressure pot
serviced with lubricating oil (C-010, C-011, C-030)
(lubricating oil (C-030) for 206L3+ IGW Upgrade).
Apply pressure slowly so lines will be filled with
lubricating oil, displacing oil in line. Continue to force
lubricating oil into lines until a bubble free steady flow
is established in receptacle at transmission.
1. Gain access to transmission oil pressure switch
and remove electrical connector.
2. Place rags or absorbent material below oil
pressure switch to collect residual oil.
3. Remove tube assembly from union installed in
forward end of oil pressure switch. Install protective
plugs and caps to prevent entry of foreign material.
4. Remove clamp installation, union, nut, bushing,
and packing from oil pressure switch and remove
switch.
63-97. TRANSMISSION OIL PRESSURE SWITCH
— INSPECTION
1. Functionally check electrical circuit for
transmission oil pressure indicator and switch (Volume
10, Chapter 95).
2. Inspect transmission oil pressure switch for
cracks, wear, leakage, and for security of mounting.
Check condition of oil pressure lines and electrical
leads.
63-98. TRANSMISSION OIL PRESSURE SWITCH
— INSTALLATION
MATERIALS REQUIRED

3. Reconnect hose assemblies at transmission and Refer to BHT-ALL-SPM for specifications.

oil pressure indicator.
NUMBER NOMENCLATURE

63-95. TRANSMISSION OIL PRESSURE C-010 Lubricating Oil

SYSTEM
C-011 Lubricating Oil
The transmission oil pressure switch is located below
C-030 Lubricating Oil
the instrument panel and is connected into the
transmission oil pressure indicator oil line. During
normal operation, the oil pressure switch contacts 1. Apply a film of lubricating oil (C-010, C-011,
open at 38 PSI (260 kPa) on increasing oil pressure. C-030) (lubricating oil (C-030) for 206L3+ IGW
Contacts close at 30 ±2 PSI (210 ±14 kPa) on Upgrade) to new packing and position on union and
decreasing oil pressure and causing the TRANS OIL install in oil pressure switch.

63-00-00
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 BHT-206L3-MM-6

2. Position oil pressure switch to clamp installation 5. Remove bolts (6) and washers (7) from oil cooler
and secure with screws, nuts, and bushing. (2) and transition duct (10). Lift oil cooler from
transition duct and oil cooler.
3. Connect oil pressure line to union on oil pressure
switch. 6. Remove transition duct (21) by removing screws
(19) and thin aluminum washers (20).
4. Bleed transmission oil pressure lines (paragraph
63-94). 7. Remove unions (4, 11, and 9) and elbow (16)
from oil cooler (2). Remove and discard packings (3,
5. Inspect for oil leaks on first ground run-up check. 14, 10, and 8). Install protective plugs to prevent oil
system contamination.
63-99. TRANSMISSION OIL COOLER
63-101. TRANSMISSION OIL COOLER —
The oil cooler assembly contains two separate CLEANING AND INSPECTION
independent cores welded together. The aft core is for
the engine oil system and the forward core is for the
transmission oil system. The oil cooler assembly is MATERIALS REQUIRED
mounted to the oil cooler blower assembly by a
transition duct. The thermal bypass valve controlling Refer to BHT-ALL-SPM for specifications.
the flow of oil through the engine oil cooler core is
located on the inlet side of the oil cooler and allows oil NUMBER NOMENCLATURE
to bypass the oil cooler core when oil temperature is
low. The thermal bypass valve for the transmission oil C-304 Drycleaning Solvent
cooler is located on the transmission.
1. Clean exterior surface of oil cooler (2,
63-100. TRANSMISSION OIL COOLER —
Figure 63-15) with drycleaning solvent (C-304) and dry
REMOVAL
with filtered compressed air.
1. Open two drain valves (12, Figure 63-14) located
on back wall of the baggage compartment and drain
transmission oil cooler lines. Allow oil to drain into CAUTION
suitable container located below overboard drain lines.

2. It is not necessary to drain the engine oil tank IF OIL COOLER HAS BEEN REMOVED
unless maintenance is to be performed on the tank. FOR METAL CONTAMINATION IT SHALL
BE REPLACED. MANUFACTURER DOES
N O T R E C O M M E N D R E PA I R I N G
NOTE DAMAGED OR CLEANING
Residual engine and transmission oil will CONTAMINATED OIL COOLERS.
drain from the oil cooler and connecting
lines during removal of the oil cooler. OIL SYSTEMS WITH CONTAMINATION
Position sufficient absorbent material at oil SHALL HAVE ALL OIL TUBES, HOSES,
tubes and fittings to collect residual oil. VALVES, AND FITTINGS REMOVED,
T H O R O U G H LY C L E A N E D W I T H
3. Disconnect three engine oil tubes (1, 5, and 17, S O LV E N T, A N D F L U S H E D W I T H
Figure 63-15) from oil cooler (2) and engine oil tank. LUBRICATING OIL.
Install protective caps and plugs to prevent oil system
contamination. 2. Inspect oil cooler for damaged core and condition
of threaded parts.
4. Disconnect transmission oil inlet and outlet tube
assemblies (22 and 18) to oil cooler. Install protective 3. Inspect all oil tubes for chafing, crimping, wear,
caps and plugs to prevent oil system contamination. leakage, and condition of threaded fittings.

63-00-00
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BHT-206L3-MM-6

2
4
3 TO ENGINE OIL
TANK - VENT
TO ENGINE OIL
TANK - RETURN

7
6

10
8
11
9

13 1. Tube assembly
12 2. Oil cooler
14 3. Packing
4. Union
15 5. Tube assembly
16
8 6. Bolt
7. Thin aluminum washer
8. Packing
13 9. Union
10. Packing
18 12 11. Union
ENGINE 12. Shim
21 OIL INLET 17 13. Shim
XMSN IN
14. Packing
20
15. Nut
19
16. Elbow
17. Tube assembly
18. Tube assembly
19. Screw
XMSN OUT 20. Thin aluminum washer
21. Transition duct
22. Tube assembly
23. Oil cooler blower
22
23
NOTE
1 Apply bead of sealant (C-353) to air seal
transition duct, to oil cooler,
and to blower assembly.

206L3_MM_63_0015

Figure 63-15. Transmission Oil Cooler

63-00-00
Page 50 Rev. 10 20 JUL 2009 ECCN EAR99

4. Inspect transition duct (21) for cracks. Check
screws (19) and bolts (6) for security.
5. For inspection of oil cooler blower (Volume 7,
Chapter 65).
63-102. TRANSMISSION OIL COOLER —
INSTALLATION
NOTE
Helicopter S/N 51232 and prior include oil
cooler, P/N 8543903, and duct, P/N
206-064-511-001. Replacement with oil
cooler, P/N 206-360-501-101, will require
replacement of additional parts.
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-010 Lubricating Oil
C-011 Lubricating Oil
C-030 Lubricating Oil
C-100 Chemical Film Material
C-204 Epoxy Polyamide
Primer
C-353 Sealing Compound
1. Install oil cooler blower (23, Figure 63-15), if
removed (Volume 7, Chapter 65).
2. Position transition duct (21) to top of oil cooler
blower (23) and secure with screws (19) and thin
aluminum washers (20).
3. Remove protective plugs from oil cooler (2).
Insert new packings (3, 8, 10, and 14) on unions (4, 9,
and 11) and elbow (16). Lubricate packings with
lubricating oil (C-010, C-011, C-030) (lubricating oil
(C-030) for 206L3+ IGW Upgrade). Install unions and
elbow with nut (15) in oil cooler.
4. When installing oil cooler P/N 8543909 (2),
position oil cooler on transition duct (21) and secure
with bolts (6) and thin aluminum washers (7). Torque
bolts 20 to 25 inch-pounds (2.3 to 2.8 Nm).
ECCN EAR99
BHT-206L3-MM-6
5. Cover openings in the corners of transition duct
(21) with sealing compound (C-353).
6. When installing oil cooler P/N 206-360-501-xxx
(2), shims (12 and 13) shall be utilized to fill the gap
between oil cooler (2) and transition duct (21), as
follows:
NOTE
Shims SH112777-1 and SH112996-1 are
0.050 inch thick and are not peelable.
Shims SH112777-2 and SH112996-2 are
0.10 inch (2.54 mm) thick and are peelable.
a. Place oil cooler (2) on transition duct (21) with
the transition duct centered between the attachment
flanges of the oil cooler.
b. Measure the gaps between the attachment
flanges of the oil cooler (2) and the transition duct (21).
NOTE
Shims SH112777-1 and/or SH112777-2
(13) are installed on the fore and aft
flanges. Shims SH112996-1 and
SH112996-2 (12) are installed on the left
and right flanges.
c. For gaps exceeding 0.050 inch (1.27 mm),
use non-peelable shim(s) first and peelable shims as
required for remaining gaps.
d. Following the shimming procedure, the
remaining gap shall not exceed 0.015 inch (0.38 mm).
e. Record shim (12 and 13) thickness and
location.
f. Before final assembly, remove shims (12 and
13), brush chemical film material (C-100) and apply
two coats of epoxy polyamide primer (C-204)
(BHT-ALL-SPM). Allow to dry.
7. Place oil cooler (2) on the transition duct (21).
Place shims at marked locations and secure with bolts
(6) and thin aluminum washers (7). Torque bolts 20 to
25 inch-pounds (2.3 to 2.8 Nm).
8. Cover openings in the corners of transition duct
(21) with sealing compound (C-353).
63-00-00
20 JUL 2009 Rev. 10 Page 51
BHT-206L3-MM-6
9. Install engine oil tube assemblies (1, 5, and 9)
and secure to fittings.
10. Install or connect transmission oil tube
assemblies (14 and 15) and secure to fittings.
11. Service engine and transmission oil system to
proper level (Volume 2, Chapter 12).
12. Inspect for oil leaks on first ground run-up.
Ground run helicopter (BHT-206L3-FM-1
(BHT-206L4-FM-1 for 206L3+ IGW Upgrade)) for
sufficient duration to ensure that oil pressure and
temperature stabilize and that thermal bypass valve is
operating.
63-103. FREEWHEELING ASSEMBLY
The freewheeling assembly is mounted on the engine
accessory gearbox and its shaft is splined directly to
the power takeoff gear shaft. Engine power is
transmitted to the outer race of the freewheeling
assembly, then through the sprag elements of the
assembly which couples the engine power to the
transmission driveshaft. During autorotation, the main
rotor drives the inner race shaft assembly. Under this
condition, the freewheeling assembly provides a
disconnect from the engine so the rotational forces of
the main rotor are free to drive the transmission, tail
rotor, and all transmission mounted accessories.
63-104. FREEWHEELING ASSEMBLY —
REMOVAL
NOTE
For better access to the freewheeling
assembly in the engine compartment from
right side, remove fuel filter bracket
(Volume 4, Chapter 28) from forward
firewall with fuel filter attached. Do not
break any fuel lines. Tie the complete
assembly with tie-wrap (or other suitable
means) away from area where accessibility
is required.
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
T101555 Coupling Wrench
63-00-00
Page 52 Rev. 10 20 JUL 2009
1. Remove forward short tail rotor driveshaft. This
shaft connects to the aft end of freewheel assembly
and the forward end of oil cooling fan shaft (Volume 7,
Chapter 65).
2. Remove main driveshaft (paragraph 63-17).
3. Drain oil from freewheeling assembly (Volume 2,
Chapter 12).
4. Disconnect hose assembly from reducer (22,
Figure 63-16) on housing (23).
5. Remove nut (21) and washer (20) from aft end of
inner race shaft assembly (3).
NOTE
Do not remove shims (18) from engine
accessory gear case unless a different
freewheeling assembly is to be installed.
Be careful to retain shims if the same
freewheel assembly is to be reinstalled.
6. Remove nuts (13), washers (14), washers (15),
and housing (23) with adapter (19) from aft side of
engine accessory gear case. Remove housing and
adapter as a unit.
7. Remove nuts (17) and washers (16) from cap
assembly (1) and housing assembly (11). Install three
1/4 - 28 jack screws in threaded holes in cap assembly
and remove from housing assembly. The inner race
shaft assembly (3) is an assembly of components
comprising: outer race shaft assembly (2), clutch,
bearings, and cap assembly, with seals. Remove this
assembly from housing assembly and engine
accessory case as a complete unit.
8. Remove housing assembly (11) and ring (7)
(paragraph 63-105) only if it is necessary for engine
accessory gearbox seal replacement, change of
engine, or change of freewheeling assembly.
63-105. FREEWHEELING HOUSING — REMOVAL
NOTE
Removal of freewheeling housing (11,
Figure 63-16) is not recommended unless it
is necessary for engine gearbox seal
replacement, change of engine, or change
of freewheeling assembly.
ECCN EAR99
 BHT-206L3-MM-6

12
8
11 SEE VIEW A

9 T 2

ACCESSORY
GEARBOX 7
T 1
10

VIEW A
5

4
1 6

3
2

14
13 T 1
15

1. Cap assembly
2. Outer race shaft assembly
20
21 T 3 3. Inner race shaft assembly
19
4. Packing
16 5. Packing
6. Union
T 1
17
25 7. Ring
8. Electric chip detector
9. Self-closing valve
10. Nut
11. Housing assembly
12. Gasket
13. Nut
22 14. Steel washer
15. Aluminum washer
16. Washer
23 17. Nut
24 18. Shim
50 TO 70 IN-LBS
T 1 (5.7 TO 7.9 Nm)
19. Adapter
20. Washer
75 TO 125 IN-LBS 21. Nut
18 T 2 (8.5 TO 14.1 Nm) 22. Reducer
23. Housing
225 TO 500 IN-LBS 24. Packing
T 3 (25.4 TO 56.4 Nm) 25. Cotter pin
206L3_MM_63_0016_c01

Figure 63-16. Freewheeling Assembly

63-00-00
ECCN EAR99 30 APR 2010 Rev. 14 Page 53
BHT-206L3-MM-6

1. Remove freewheeling assembly (paragraph a. Hold outer race shaft assembly (2) and inner
63-104). race shaft assembly (3) with flange end towards you.

2. Disconnect hose assembly from union (6) on
front of housing assembly (11).
3. Remove nuts (10) located inside housing
assembly (11) and remove ring (7), housing assembly,
and gasket (12). Discard gasket and nuts.
b. Rotate flange of inner race shaft assembly (3)
by hand. Freewheeling clutch assembly should drive
when turned clockwise and freewheel when turned
counterclockwise.
8. Check bearing in aft housing (23) for freedom of
movement without flat or rough spots.

63-106. FREEWHEELING ASSEMBLY —

9. Visually inspect all studs for security and
INSPECTION AND REPAIR
condition of threads.

63-107. FREEWHEELING ASSEMBLY —

MATERIALS REQUIRED
INSTALLATION
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE MATERIALS REQUIRED

C-423 Abrasive Paper
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE
1. Inspect chip detector (8, Figure 63-16) for metal
particles immediately after removal. If any particles are C-010 Lubricating Oil
found, refer to paragraph 63-9 and Figure 63-4.
C-011 Lubricating Oil
2. Inspect self-closing valve (9) and chip detector C-030 Lubricating Oil
(8) for condition and serviceability. This detector has a
ceramic magnet and is not susceptible to loss of C-204 Epoxy Polyamide
magnetic strength. Primer

C-305 Aliphatic Naphtha

3. Inspect all parts for nicks and scratches. Dress
out minor nicks and scratches with No. 320 or 400 grit C-308 Sealant
abrasive paper (C-423). Apply protective coating
where required. C-405 Lockwire

4. Visually inspect splines for wear, cracks, and

damage (BHT-206L-CR&O). NOTE
If engine assembly is removed, install
freewheeling assembly before installing
5. Inspect union (6) and reducer (22), seals, gasket,
engine assembly in helicopter, for ease of
and packings for leakage.
maintenance.

6. Replace gasket and all packings.
7. Check for free rotation of the outer race shaft
assembly (2) and inner race shaft assembly (3), and
engagement of clutch assembly as follows:
1. Install housing assembly (11, Figure 63-16) as
follows:
a. Insert gasket (12) on studs on forward side of
engine accessory gearbox.

63-00-00
Page 54 Rev. 10 20 JUL 2009 ECCN EAR99

CAUTION
NUTS (10) MAY NOT BE REUSED IF
FRICTION DRAG TORQUE OF NUTS IS
LESS THAN 8 INCH-POUNDS (0.90 NM).
b. Install ring (7) in housing assembly (11) and
align to studs on forward side of engine accessory
gearbox. Guide ring and housing assembly onto studs
and secure with nuts (10). Torque nuts 50 to 70
inch-pounds (5.7 to 7.9 Nm).
2. Stand assembled inner and outer race shaft
assemblies (3 and 2) on adapter flange and squirt
lubricating oil (C-010, C-011, C-030) (same type as
used in transmission) between inner and outer shaft
assemblies, lubricating clutch assembly, and bearings.
3. Check for freedom of movement to ensure that
cap assembly (1), clutch assembly, and bearings are
not binding.
4. Apply a light coating of lubricating oil (C-010,
C-011, C-030) to new packings (4 and 5) and install on
shaft assemblies.
5. Position inner and outer race shaft assemblies (3
and 2) in housing assembly (11) until splined end of
inner race shaft assembly protrudes through aft side of
engine accessory gear case. Rotate adapter flange on
forward end of inner race shaft assembly (3) back and
forth to align spline teeth between outer race shaft
assembly (2) and drive gear in engine accessory gear
case.
6. Push cap assembly (1) firmly into housing
assembly (11). Install washers (16) and new nuts (17).
Torque nuts 50 to 70 inch-pounds (5.7 to 7.9 Nm).
7. Apply a film of lubricating oil (C-010, C-011,
C-030) to new packings and to surfaces of bearing in
housing (23). Insert new packing on reducer (22) and
install in housing. Insert new packing (24) in groove on
inboard flange of housing.
ECCN EAR99
BHT-206L3-MM-6
CAUTION
IF THE SAME FREEWHEELING
ASSEMBLY IS BEING REINSTALLED ON
T H E S A M E E N G I N E A S S E M B LY
W I T H O U T A N Y A LT E R AT I O N O R
R E P L A C E M E N T O F PA R T S , T H E
INSTALLATION MAY BE MADE WITH THE
ORIGINAL SHIMS (18) WITHOUT
MAKING A DIMENSIONAL CHECK.
INSTALLATION OF A NEW ENGINE, NEW
F R E E W H E E L I N G A S S E M B LY, O R
REPAIR OF ORIGINAL FREEWHEELING
A S S E M B LY W I L L R E Q U I R E A
DIMENSIONAL CHECK.
8. Dimensional Check.
a. Install adapter (19) and housing (23) as a unit
on exposed aft end of the inner race shaft
assembly (3).
b. Install steel washer (20) and nut (21) on aft
end of inner race shaft assembly (3). Attach T101555
coupling wrench to adapter flange on forward end of
inner race shaft assembly and tighten nut only enough
to firmly seat bearing and adapter (19).
c. Push inner race shaft assembly (1,
Figure 63-17) aft in housing assembly (2) by applying
hand pressure to adapter flange on forward end. Using
two feeler gauges, measure at diametrically opposite
positions the gap between aft face of engine
accessory gearbox and forward face of aft housing
assembly (3).
d. Peel shim (4) to provide a shim 0.015 to 0.020
inch (0.381 to 0.508 mm) less than measured
clearance between faces to provide proper clearance
between shoulder of outer race shaft assembly (5) and
power output gear shaft.
e. Remove nut (21, Figure 63-16), washer (20),
adapter (19), and housing (23) as a unit from aft end of
inner race shaft assembly (3) and aft side of engine
accessory gearbox. Do not separate adapter and
housing.
63-00-00
20 JUL 2009 Rev. 10 Page 55
BHT-206L3-MM-6

ENGINE ACCESSORY

OBTAIN BY
0.015 TO 0.020 IN. VARYING SHIM (4)
1
(0.381 TO 0.508 mm) GAP

GEAR CASE 3 APPLY SEALANT

5
TORQUE AN310-7 NUT
ADAPTER SEE CAUTION
FLANGE

4
2
SELF-CLOSING VALVE
INSTALL ONE-WAY
CLUTCH ASSEMBLY 1
WITH ARROW POINTING
CLOCKWISE

1. Inner race shaft assembly

2. Forward housing assembly
3. Aft housing assembly
4. Shim
5. Outer race shaft assembly
6. Cotter pin

CAUTION

EYE AND TANGS OF COTTER PIN

MUST BE FLUSH OR BELOW OUTSIDE
SURFACE OF NUT.

NOTE
1 The 0.015 to 0.020 inch (0.381 to 0.508 mm) gap between the outer
race shaft (5) and power output gear shaft is obtained by adjusting shim
(4) thickness between the aft housing (3) and the aft face of engine
accessory gearbox.

206L3_MM_63_0017_c01

Figure 63-17. Freewheeling Clearances and Torques (206L3 Only)

63-00-00
Page 56 Rev. 14 30 APR 2010 ECCN EAR99

NOTE
After completing dimensional check on a
new installation or replacing a removed
installation, accomplish all the following
steps.
9. Clean mating surfaces of shim (18), housing (23),
and aft face of engine accessory gearbox and studs
with aliphatic naphtha (C-305). Wipe dry and apply a
coating of epoxy polyamide primer (C-204) to mating
surfaces and studs. Reinstall parts immediately in
accordance with the following procedures.
10. Position shim (18) on housing (23). Do not
position shim on engine accessory gearbox studs, for
possible damage to packing (24) may occur when
installing housing. Install packing on housing.
Lubricate housing and packing with lubricating oil
(C-010, C-011, C-030) (same type as used in
transmission). Install assembled parts as a unit on aft
face of engine accessory gearbox and onto inner race
shaft assembly (3). Flat surface on housing should be
at the top with reducer (22) at the 10 o'clock position.
11. Secure housing (23) with aluminum washers (15),
steel washers (14), and nuts (13). Ensure that
aluminum washers are installed next to housing and
that steel washers are under nuts. Torque nuts 50 to
70 inch-pounds (5.7 to 7.9 Nm).
12. Clean surfaces of washer (20) and threads of nut
(21) with aliphatic naphtha (C-305). Apply a ring of
sealant (C-308) to surfaces of washer and threads of
nut and install on inner race shaft assembly (3). Attach
coupling wrench (T101555) to adapter flange on
forward end of inner race shaft assembly and torque
nut 225 to 500 inch-pounds (25.4 to 56.4 Nm).
Remove coupling wrench (T101555). Install cotter
pin (25).
ECCN EAR99
BHT-206L3-MM-6
13. Apply a film of lubricating oil (C-010, C-011,
C-030) to new packings and insert one packing on
union (6) and install in lower front corner of housing
assembly (11). Insert one packing on self-closing valve
(9) and install in side of housing assembly. Torque
self-closing valve 75 to 125 inch-pounds (8.5 to 14.1
Nm) and union to standard torque (BHT-ALL-SPM).
Secure self-closing valve to case with lockwire
(C-405). Install chip detector (8) in self-closing valve.
14. Connect oil hose assemblies to union (6) and
reducer (22).
15. Install forward short tail rotor driveshaft
(Chapter 65).
16. Install main driveshaft (paragraph 63-19).
17. If a new or overhauled freewheeling assembly
has been installed, perform run-in checks and
inspection in accordance with paragraph 63-108.
63-108. FREEWHEELING ASSEMBLY —
OPERATIONAL CHECK
NOTE
Perform this operational check after each
freewheeling assembly installation.
1. Perform ground run-in cycle for 20 minutes
(BHT-206L3-FM-1).
2. After shutdown, accomplish the following
requirements:
a. Remove and inspect electric chip detector for
metal particles. If metal particles are found, investigate
to determine cause (Figure 63-3).
b. Inspect freewheeling assembly for oil leaks.
63-00-00
30 APR 2010 Rev. 14 Page 56A/56B
 BHT-206L3-MM-6

FREEWHEEL ASSEMBLY 406-040-500

206L3+ IGW UPGRADE

63-108A.FREEWHEEL ASSEMBLY
406-040-500
NOTE
The following is only applicable to 206L3+
IGW Upgrade helicopters when
BHT-206-SI-2052 has been accomplished.
Freewheel assembly is mounted on engine accessory
gearbox. Shaft of freewheel assembly is splined
directly to power takeoff gear shaft. Engine power is
transmitted to outer race of freewheel assembly, then
through sprag elements of assembly, which couples
engine power to transmission driveshaft. During
autorotation, main rotor drives inner race shaft
assembly. Under this condition, freewheel assembly
provides a disconnect from engine so rotational forces
of main rotor are free to drive transmission, tail rotor,
and all transmission mounted accessories.
63-108B.FREEWHEEL ASSEMBLY 406-040-500 —
REMOVAL
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
H4713 Drain Hose
NOTE
Replacement of freewheel assembly
carbon seal is a critical procedure. Refer to
BHT-206L-CR&O for procedures.
NOTE
For better access to freewheel assembly in
engine compartment from right side,
remove fuel filter bracket (Volume 4,
Chapter 28) from forward firewall with fuel
filter attached. Do not break any fuel lines.
Tie complete assembly with tie-wrap (or
other suitable means) away from area
where accessibility is required.
NOTE
The following is only applicable to 206L3+
IGW Upgrade helicopters when
BHT-206-SI-2052 has been accomplished.
1. Remove forward short tail rotor driveshaft. This
shaft connects to aft end of freewheel assembly and
forward end of oil cooling fan shaft (Volume 7,
Chapter 65).
2. Remove main driveshaft (paragraph 63-19B).
3. Remove electrical connector (1, Figure 63-17A)
from chip detector (4).

T101308 Jackscrew Set

4. Remove chip detector (4) from chip detector
T103306-101 Spanner Adapter house (3).

T101977 Spline Wrench 5. Install drain hose (2) H4713 into chip detector
housing (3) and drain oil into suitable container.

6. When oil is completely drained from freewheel

MATERIALS REQUIRED unit, remove drain hose and install chip detector (4)
into chip detector housing (3).
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE 7. Remove and discard cotter pin (11) from adapter
retaining nut (12).
C-426 Masking Tape
8. Install spanner assembly on output adapter (7)
C-427 Barrier Material
and secure in place with accompanying hardware.

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 56C
BHT-206L3-MM-6

3
5

6 7
2
8
9
22 11
10
21

1
4

20 12 T 4
1. Electrical connector 19
2. Drain hose
3. Chip detector housing 6
4. Chip detector
5. Aft bearing and seal cap
6. Freewheel unit shaft 5
7. Output adapter 13
8. Packing 18 14
9. Washer
17
10. Washer T 1
11. Cotter pin 16
12. Adapter retaining nut 15
13. Washer
14. Nut
15. Packing
16. Cone set spacer 23
17. Cone set
18. Groove
19. Support stud
20. Output support
21. Oil inlet line 5
22. Elbow fitting
23. Seal lip

GREASE

206L1_MM_63_0001+

Figure 63-17A. Freewheel Assembly 406-040-500 (Sheet 1 of 3)

63-00-00
Page 56D Rev. 10 20 JUL 2009 ECCN EAR99
 BHT-206L3-MM-6

31

32

30

28 29
27
26
T 1
25 33

24

45
24. Output shaft assembly 44
25. Nut
26. Steel washer
27. Aluminum washer 43
28. Forward seal cap
29. Jackscrew
30. Packing
31. Mounting stud
32. Housing assembly
33. Packing
34. Return oil line 37
35. Elbow fitting 35
36. Inlet oil line 36
37. Forward cap fitting 39 34
38. Output adapter bolt
39. Packing 42 38
40. Pin
41. Output shaft plug assembly 41
40
42. Retainer ring
43. Main drive shaft adapter
44. Threads
45. Splines

206L1_MM_63_0002+

Figure 63-17A. Freewheel Assembly 406-040-500 (Sheet 2 of 3)

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 56E
BHT-206L3-MM-6

52

51

50
48 49
47 53

T 1
46

54
55
T 2

56
57

58
59 T 3

46. Nut
47. Pilot ring
48. Packing 50 TO 70 IN-LBS
49. Packing T 1 (5.7 TO 7.9 Nm)
50. OIl transfer tube
75 TO 100 IN-LBS
51. Housing assembly T 2 (8.5 TO 11.2 Nm)
52. Packing
53. Mounting stud 75 TO 125 IN-LBS
54. Packing T 3 (8.5 TO 14.1 Nm)
55. Chip detector housing
225 TO 500 IN-LBS
56. Chip detector T 4 (25.4 TO 56.4 Nm)
57. Packing
58. Jam nut
59. Elbow fitting

206L1_MM_63_0003+

Figure 63-17A. Freewheel Assembly 406-040-500 (Sheet 3 of 3)

63-00-00
Page 56F Rev. 10 20 JUL 2009 ECCN EAR99

9. While holding output adapter (7) with spanner
assembly, remove nut (12) and washers (10) from
freewheel unit shaft (6).
10. Using plastic scraper, remove sealant from
washer (9) and output adapter (7).
11. Remove washer (9) with packing (8) from
freewheel unit shaft (6). Discard packing.
NOTE
When adapter (7) is removed, oil will drain
from aft bearing and seal cap (5) to engine
deck.
12. Remove output adapter (7) from aft bearing and
cap (5) and freewheel unit shaft (6).
13. Disconnect oil inlet line (21) from elbow fitting (22)
on aft bearing and seal cap (5).
14. Cap oil line and identify for installation location.
15. Remove nuts (14) and washers (13) from support
studs (19).
16. Remove aft bearing and seal cap (5) with packing
(15) from output support (20) with conduit pliers.
Discard packing.
CAUTION
CONE SET IS A MATCHED SET.
REMOVE AND INSTALL AS A SET.
17. Remove spacer (16) and cone set (17) from
groove (18) on freewheel unit shaft (6).
18. Remove retainer ring (42) from output adapter
bolt (38).
NOTE
A single jackscrew (29) T101308 can be
used as a tool to remove output shaft plug
assembly (41) by threading jackscrew into
plug assembly.
ECCN EAR99
BHT-206L3-MM-6
19. Remove output shaft plug assembly (41) with
packing (39). Discard packing.
20. Install input adapter spanner T103306-101 on
main driveshaft adapter (43) and secure in place.
21. While holding main driveshaft adapter (43) in
place, remove output adapter bolt (38), using external
spline wrench T101977.
22. Remove main driveshaft adapter (43) from
freewheel unit output shaft assembly (24).
23. Disconnect inlet oil line (36) from forward cap
fitting (37).
24. Disconnect return oil line (34) from elbow
fitting (35).
25. Remove nuts (25), steel washers (26), and
aluminum washers (27), securing output shaft
assembly (24) to housing assembly (32).
CAUTION
JACKSCREWS MUST BE TURNED
EVENLY WHILE REMOVING OUTPUT
SHAFT, OR DAMAGE TO OUTPUT
SHAFT OR ENGINE ACCESSORY
GEARS WILL RESULT.
26. Install three jackscrews T101308 (29) in threaded
holes in forward seal cap (28).
27. Remove output shaft assembly (24) with packings
(30 and 33) using jackscrews (29). Discard packings.
28. Place output shaft assembly (24) on suitable
surface and cover to prevent contamination.
29. Remove nuts (46) from mounting studs (53).
30. Remove housing assembly (51) and pilot ring
(47) with packing (52). Discard packing.
31. Remove pilot ring (47) and packings (48) from
housing assembly (51). Discard packing.
63-00-00
20 JUL 2009 Rev. 10 Page 56G
BHT-206L3-MM-6

32. Cover openings in engine accessory gear case

with barrier material (C-427) and secure with masking
tape (C-426).

33. Remove elbow fitting (59) from housing assembly NOTE

(51) by loosening jam nut (58) and turning elbow The following is only applicable to 206L3+
fitting. Remove and discard packing (57). IGW Upgrade helicopters when
BHT-206-SI-2052 has been accomplished.

34. Cut lockwire and remove chip detector (56) and

1. Examine all components for condition. Refer to
housing (55) with packing (54) from housing (51). BHT-206L-CR&O for the damage limits.
Discard packing.

2. Examine the splines for chipped, worn, or broken

35. Remove packing (49) from housing assembly oil teeth.
transfer tube (50). Discard packing.
3. If removed, examine the forward seal and cap for
63-108C.FREEWHEEL ASSEMBLY 406-040-500 — corrosion, scratches, nicks, and cracks.
CLEANING
4. Examine the visible portions of the inner and
outer shafts for corrosion, wear, and cracks.
MATERIALS REQUIRED
5. Turn the forward adapter (43, Figure 63-17A) or
Refer to BHT-ALL-SPM for specifications. output shaft assembly (24) by hand and verify the
clutch and bearing for smoothness and freedom of
NUMBER NOMENCLATURE rotation in the freewheel direction and lockup in the
drive direction.
C-304 Drycleaning Solvent

6. Repair all damage. Refer to BHT-206L-CR&O,

Chapter 63.
NOTE
The following is only applicable to 206L3+
7. If necessary, replace forward or aft seals. Refer to
IGW Upgrade helicopters when
BHT-206L-CR&O, Chapter 63.
BHT-206-SI-2052 has been accomplished.

8. Touch up all damaged surface protection. Refer

1. Clean all components with wiping rag dampened
to BHT-206L-CR&O, Chapter 63.
with drycleaning solvent (C-304).

2. Dry all components with wiping rag.

63-108D.FREEWHEEL ASSEMBLY 406-040-500 —

INSPECTION AND REPAIR

63-00-00
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 BHT-206L3-MM-6

206L1_MM_63_0004

Figure 63-17B. Seal Cap, Clutch, and Shaft Assembly — Inspection

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 56I
BHT-206L3-MM-6

2. Install packing (54) on chip detector housing (55)

and install in housing assembly (51).

3. Torque chip detector housing (55) 75 to 100

inch-pounds (8.5 to 11.2 Nm).

4. Secure chip detector housing (55) to housing

assembly (51) with lockwire (C-405). Install chip
detector (56).

5. Install jam nut (58) and packing (57) on elbow

fitting (59) and install elbow fitting in housing
assembly (51).

6. Torque jam nut (58) 75 to 125 inch-pounds (8.5 to

14.1 Nm).

7. Install packing (52) on housing assembly (51) and

install housing assembly on mounting studs (53).
63-108E.FREEWHEEL ASSEMBLY 406-040-500 —
INSTALLATION
8. Install packings (48) on mounting studs (53).

9. Install pilot ring (47) in housing assembly (51) and

MATERIALS REQUIRED
on mounting studs (53).
Refer to BHT-ALL-SPM for specifications.
10. Install nuts (46) on mounting studs (53) inside
NUMBER NOMENCLATURE housing assembly.
C-001 Grease
11. Torque nuts (46) 50 to 70 inch-pounds (5.7 to
C-030 Lubricating Oil 7.9 Nm).
C-308 Sealant
12. Lubricate packings (30 and 33) with lubricating oil
C-405 Lockwire (C-030).

13. Install packing (30) in groove of forward seal cap

NOTE
If engine assembly is removed, install
freewheel assembly before installing
engine assembly in helicopter, for ease of
maintenance.
(28), and packing (33) in groove on aft end of output
shaft assembly (24).
14. Install output shaft assembly (24) into housing
assembly (32) and on mounting studs (31).

NOTE 15. Install aluminum washers (27) on mounting studs

(31) and against forward seal cap (28).
The following is only applicable to 206L3+
IGW Upgrade helicopters when
BHT-206-SI-2052 has been accomplished. 16. Install steel washer (26) and nuts (25) on
mounting studs (31).
1. Install packing (49, Figure 63-17A) on housing
assembly oil transfer tube (50). Lubricate packing with 17. Torque nuts (25) 50 to 70 inch-pounds (5.7 to
lubricating oil (C-030). 7.9 Nm).

63-00-00
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 BHT-206L3-MM-6

NOTE

CAUTION If output adapter (7) is moved, check cone

ENSURE THAT BOTH HALVES OF CONE
S E T A R E P R O P E R LY S E AT E D I N
G R O O V E O F TA I L R O T O R D R I V E
O U T P U T S H A F T A N D T H AT T H E
SPACER IS FULLY SEATED ON CONE
SET. DAMAGE TO ACCESSORY DRIVE
GEARS AND OUTPUT SHAFT COULD
R E S U LT I F C O N E S E T B E C O M E S
UNSEATED. CONE SET IS A MATCHED
SET. REMOVE AND INSTALL AS A SET.
18. Install cone set (17) in groove (18) on aft end of
freewheel shaft (6).
19. Install spacer (16) on freewheel shaft (6) and
mate with cone set (17).
20. Install packing (15) on aft bearing and seal cap
(5) and lubricate packing with lubricating oil (C-030).
21. Fill area between lips of seal (23) with grease
(C-001).
set for seated condition. Check of cone set
may require removal of aft bearing and seal
cap.
25. Install output adapter (7) on aft end of freewheel
shaft (6).
26. Install packing (8) on washer (9) and install
washer with packing on freewheel shaft (6). Apply
sealant (C-308) to mating edges of output adapter (7)
and washer (9).
27. Install washers (10) and retaining nut (12).
28. Install spanner assembly T103216-101 on output
adapter (7).
29. Torque retaining nut (12) 225 to 500 inch-pounds
(25.4 to 56.4 Nm) and install cotter pin (11).
30. Install forward short tail rotor driveshaft (Volume
7, Chapter 65).
31. Install main driveshaft (paragraph 63-19F).

32. If a new or overhauled freewheel assembly has

22. Install aft bearing and seal cap (5) on support
been installed, perform run-in checks and inspection
studs (19). Use hand pressure to seat aft bearing and
(paragraph 66-108F).
seal cap in output support (20).

63-108F.FREEWHEEL ASSEMBLY 406-040-500 —

23. Install washers (13) and nuts (14) on support OPERATIONAL CHECK
studs (19). Torque nuts 50 to 70 inch- pounds (5.7 to
7.9 Nm).
NOTE

24. Connect oil inlet line (21) to elbow fitting (22). Perform this operational check after each
freewheel assembly installation.

NOTE
CAUTION
The following is only applicable to 206L3+
IGW Upgrade helicopters when
DO NOT REMOVE OUTPUT ADAPTER (7) BHT-206-SI-2052 has been accomplished.
O N C E I T H A S B E E N I N S TA L L E D .
MOVEMENT (IN OR OUT) OF OUTPUT 1. Perform ground run-in cycle for 20 minutes
ADAPTER MAY CAUSE CONE SET TO (BHT-206L4-FM-1).
BE U N S E AT E D . DAMAGE TO
ACCESSORY DRIVE GEARS AND 2. After shutdown, accomplish following
OUTPUT SHAFT MAY RESULT. requirements:

63-00-00
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BHT-206L3-MM-6

a. Remove and inspect electric chip detector for b. Inspect freewheel assembly for oil leaks.
metal particles. If metal particles are found, investigate
to determine cause (Figure 63-3).

63-00-00
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 BHT-206L3-MM-6

TRANSMISSION MOUNTS — NODAL BEAM

63-109. TRANSMISSION MOUNTS transmission restraint are fuel and oil

The transmission with the mast and main rotor hub
and blade assembly is supported by, and isolated
from, the fuselage by the transmission mounts (nodal
beam) and transmission restraint. This is
accomplished by use of four link attachments and two
stop mounts bolted to the transmission. Attached to
these are four link assemblies incorporating spherical
bearings, which are secured to the four support
assemblies and the flexure assemblies. The support
assemblies are bolted to the cabin roof shell and cabin
roof beam, and contain elastomeric bearing and
bushing members to isolate and balance vibration
inputs from the rotor into the flexure assemblies. The
flexure assemblies are the primary vibration isolating
components that provide for a vibration free ride
throughout the helicopters speed range.
resistant, it is recommended that they be
kept clean and free of solvents, fuels, and
oil.
1. Clean components of the transmission mounts
and transmission restraint with drycleaning solvent
(C-304).
2. Dry with filtered compressed air.
63-111. LINK ATTACHMENTS
The four nodal beam link attachments are steel
forgings and are attached to the transmission top
case. The spindles provide a mounting point for the
transmission to the nodal beam mounting installation.

The transmission restraint restrains movement of the 63-112. LINK ATTACHMENTS — REMOVAL
transmission through the use of an elastomeric
bearing and bushing member, which is secured to the
transmission restraint support. The support is bolted to SPECIAL TOOLS REQUIRED
the cabin roof shell and cabin roof beam along with
two drag pins. The two stop mounts, which are bolted
to the transmission, are installed over the drag pins. NUMBER NOMENCLATURE
The up stops mounted on the drag pins restrict the up
movement of the transmission and all oscillatory Commercial Hoist, 600 Pound (272
movement. kg) Capacity, Minimum

Commercial Hoisting Cable, 600

Tuning weights are bolted to the arm and flexure Pound (272 kg)
assemblies and provide for the fine tuning and balance Capacity, Minimum
of the transmission mounting system.
T100220 Main Rotor Hoisting
63-110. TRANSMISSION MOUNTS — CLEANING Sling

T103141 Hoisting Ring

MATERIALS REQUIRED 206-240-001-101 Lift and Cover Plate
(206L3+ IGW
Refer to BHT-ALL-SPM for specifications. Upgrade)
NUMBER NOMENCLATURE

C-304 Drycleaning Solvent MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications.

NOTE
Although the elastomeric bearing and NUMBER NOMENCLATURE
bushing members in the transmission
C-309 MEK
mount support assemblies and

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 57
BHT-206L3-MM-6

1. Remove transmission fairing (Volume 9, 1. Visually inspect link attachments (2,

Chapter 71).
2. Support transmission in helicopter with suitable
hoist and hoisting device. This may be accomplished
by the use of a clevis attached to the main rotor mast
nut, T100220 main rotor hoisting sling, or T103141
hoisting ring (206-240-001-101 lift and cover plate for
206L3+ IGW Upgrade) when mast assembly is
removed.
3. Disconnect link assemblies (7, Figure 63-18)
from link attachment (2) by removing nut (10), support
washer (9), and bearing washer (5).
4. Remove nuts (4) and steel washers (3), and
remove link attachment (2) from transmission (1). It
may be necessary to use a plastic mallet to free link
attachment from transmission case due to sealing
compound between mating surfaces.
WARNING
Figure 63-18) for nicks, scratches, dents, and
corrosion damage.
a. Maximum depth of nicks, scratches, and dents
is 0.005 inch (0.127 mm) in bolt holes, 0.02 inch (0.51
mm) at spot face for bolt holes, and 0.05 inch (1.3 mm)
all other areas.
b. Maximum depth of corrosion is 0.003 inch
(0.076 mm) in bolt holes, 0.01 inch (0.25 mm) at spot
face for bolt holes, and 0.025 (0.635 mm) inch all other
areas.
2. Blend out acceptable damage with No. 320 or
400 grit abrasive paper (C-423). Touch up repaired
areas with epoxy polyamide primer (C-204). Do not
apply primer to spindle portion of link attachment
(BHT-ALL-SPM).
3. Inspect bearing surfaces on spindles of link
attachments (2) for removal of solid film lubricant.
Touchup repairs of solid film lubricant (C-005) may be
accomplished in accordance with the BHT-ALL-SPM.
63-114. LINK ATTACHMENTS — INSTALLATION

MEK IS FLAMMABLE AND TOXIC. USE IN

W E L L V E N T I L AT E D A R E A . AV O I D MATERIALS REQUIRED
PROLONGED BREATHING OF TOXIC
VAPORS AND CONTACT WITH SKIN Refer to BHT-ALL-SPM for specifications.
AND EYES.
NUMBER NOMENCLATURE

5. Remove old sealing compound and sealant with C-308 Sealant

a plastic scraper and MEK (C-309).
C-309 MEK

63-113. LINK ATTACHMENTS — INSPECTION C-328 Sealing Compound

AND REPAIR

WARNING
MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications. MEK IS FLAMMABLE AND TOXIC. USE IN

W E L L V E N T I L AT E D A R E A . AV O I D
NUMBER NOMENCLATURE PROLONGED BREATHING OF TOXIC
VAPORS AND CONTACT WITH SKIN
C-005 Solid Film Lubricant AND EYES.
C-204 Epoxy Polyamide 1. Clean mating surfaces of transmission (1,
Primer Figure 63-18) and link attachment (2) with MEK
(C-309). Ensure all old sealing compound has been
C-423 Abrasive Paper
removed.

63-00-00
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 BHT-206L3-MM-6

1 2

3
4 T 3
8
7
5
6
2

13

T 1
10

1
12

14 12
11 T 2
15

206L3_MM_63_0018a

Figure 63-18. Transmission Link Assembly and Attachment (Sheet 1 of 2)

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 59
BHT-206L3-MM-6

1. Transmission 6. Bearing 11. Nut

2. Link attachment 7. Link assembly 12. Thin aluminum washer
3. Steel washer 8. Bearing 13. Bolt
4. Nut 9. Support washer 14. Aft arm assembly
5. Bearing washer 10. Nut 15. Forward arm assembly

36 TO 204 IN-LBS
T 1 (4.1 TO 23 Nm)
120 TO 780 IN-LBS
T 2 (13.6 TO 88.1 Nm)
160 TO 190 IN-LBS
T 3 (18.1 TO 21.4 Nm)

NOTES
1 Apply film of sealing compound (C-328) between mating flanges.

2 After installation of parts, apply bead of sealant (C-308) to mating edge of parts and transmission.

206L3_MM_63_0018b

Figure 63-18. Transmission Link Assembly and Attachment (Sheet 2 of 2)

63-00-00
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 BHT-206L3-MM-6

2. Apply a film of sealant (C-328) to mounting area SPECIAL TOOLS REQUIRED

on transmission (1) of link attachment (2).

NUMBER NOMENCLATURE
3. Position link attachment (2) onto studs of
transmission (1) and secure with washers (3) and nuts T103141 Hoisting Ring
(4). Torque nuts 160 to 190 inch-pounds (18.1 to 21.4
Nm). 206-240-001-101 Lift and Cover Plate
(206L3+ IGW
Upgrade)
4. Apply a bead of sealant (C-308) to mating edge
surfaces of link attachment (2) and transmission (1).
1. Remove transmission fairing (Volume 9,
Remove excess sealing compound and sealant.
Chapter 71).

5. Position bearing washers (5) on spindles of link 2. Support transmission (1, Figure 63-18) in
attachments (2). Then position link assemblies (7), helicopter with suitable hoist and hoisting device. This
support washers (9), and nuts (10) onto link may be accomplished by the use of a clevis attached
attachments. Torque nuts 36 to 204 inch-pounds (4.1 to the main rotor mast nut, or T100220 main rotor
to 23.0 Nm). hoisting sling, or T103141 hoisting ring
(206-240-001-101 lift and cover plate for 206L3+ IGW
Upgrade) after mast assembly is removed.
6. Disconnect and remove hoist and hoisting device.

3. Remove nuts (10), support washers (9), and

7. Reinstall transmission fairing (Volume 9, bearing washers (5).
Chapter 71).
4. Remove nuts (11), washers (12), and bolts (13).
63-115. LINK ASSEMBLIES Lift link assemblies (7) from arm assemblies (14
and 15).

The four nodal beam link assemblies are aluminum 63-117. LINK ASSEMBLIES — INSPECTION AND
alloy forgings and contain two elastomeric bearings. REPAIR
The link assemblies attach the transmission to the arm
assemblies and flexure of the nodal beam mounting
installation. MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications.

63-116. LINK ASSEMBLIES — REMOVAL
NUMBER NOMENCLATURE

C-100 Chemical Film Material

SPECIAL TOOLS REQUIRED
C-204 Epoxy Polyamide
Primer
NUMBER NOMENCLATURE
C-423 Abrasive Paper
Commercial Hoist, 600 Pound (272
kg) Capacity, Minimum
1. Visually inspect link assemblies (7, Figure 63-18)
Commercial Hoisting Cable, 600 for nicks, scratches, dents, and corrosion damage.
Pound (272 kg)
Capacity, Minimum a. Maximum depth of nicks, scratches, and dents
is 0.005 inch (0.127 mm) on the contoured surfaces
T100220 Main Rotor Hoisting
surrounding elastomeric bearings (6 and 8) and 0.01
Sling
inch (0.25 mm) on all other surfaces. Full depth repairs

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BHT-206L3-MM-6

are not allowed on same or opposite sides of flanges INSPECTION OF COMPONENT FOR
within 1.0 inch (25 mm) spacing. SEPARATION OF STRUCTURAL
DETERIORATION.
b. Maximum depth of corrosion damage is 0.003
inch (0.076 mm) on the contoured surfaces
NOTE
surrounding elastomeric bearings (6 and 8) and 0.005
inch (0.127 mm) on all other surfaces. Many elastomeric components will be
severely damaged if they are allowed to
2. Blend out acceptable damage with No. 320 or remain in contact with oil. Oil contaminants
400 grit abrasive paper (C-423). Apply chemical film should be removed on a regular basis,
material (C-100) to repaired areas and touch up with using mild liquid detergent (C-355) and
epoxy polyamide primer (C-204) (BHT-ALL-SPM). warm water.

63-118. ELASTOMERIC BEARINGS — The elastomer in component is covered

INSPECTION with a thin, oil resistant rubber coating. If
this coating cracks, peels, or becomes
Inspection of elastomeric bearings is feasible only with loose on elastomer, it should be replaced
the link assembly removed from the helicopter. Once per step 1 through step 4.
the link assembly has been removed, inspect for the
following: 1. Scrub elastomeric components used in main
rotor, swashplate, nodal beam pylon support, and
1. Elastomeric degradation. Use a 0.005 inch (0.127 airframe with mild liquid detergent (C-355) and water.
mm) feeler gauge and a magnifying glass. Note Rinse with water and dry with clean cloths.
maximum depth and arc in degrees of damage (Figure
63-18). 2. Rinse both metal and rubber elastomeric
component surfaces with aliphatic naphtha (C-305).
2. Inspect lower bearing for cracked shims. Confirm Wipe dry with clean cloths.
cracks by running firm thin object (fingernail) along
shim edge. Replace link assembly if shim crack is 3. Apply adhesive (C-307) to prepared surface in
detected. uniform thickness 1/64 to 1/16 inch (0.39 to 1.58 mm).
To obtain full contact, use a stiff brush or spatula.
63-119. ELASTOMERIC COMPONENTS — Silicone adhesive forms a trackfree skin within twenty
SEALING minutes. Discontinue use of tools and remove any
masking tape, approximately ten minutes, before
adhesive begins to harden.
MATERIALS REQUIRED
4. Allow component to cure undisturbed at room
Refer to BHT-ALL-SPM for specifications. temperature for 24 hours.
NUMBER NOMENCLATURE
63-120. LINK ASSEMBLIES — INSTALLATION
C-305 Aliphatic Naphtha
1. Insert end of link assemblies (7, Figure 63-18)
C-307 Adhesive with large elastomeric bearing (8) into forward and aft
arm assemblies (14 and 15). Align bearings with
C-355 Mild Liquid Detergent
bushings in arm assemblies and install bolts (13), thin
aluminum washers (12), and nuts (11). Install bolts
with heads inboard and torque nuts 120 to 780
CAUTION inch-pounds (13.56 to 88.13 Nm).

2. Position bearing washers (5) with chamfered ID

REPLACEMENT COATING THICKNESS against spindle shoulder of link attachment (2), then
SHOULD NOT PREVENT PROPER position link assemblies (7), support washer (9), and

63-00-00
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 BHT-206L3-MM-6

nut (10). Torque nuts 36 to 204 inch-pounds (4.1 to 1. Remove transmission fairing (Volume 9,
23.0 Nm). Chapter 71).

3. Disconnect and remove hoist and hoisting device.
4. Reinstall transmission fairing (Volume
Chapter 71).
63-121. ARM AND FLEXURE ASSEMBLY
The arm and flexure assembly is the primary nodal
beam component that isolates main rotor and
transmission vibrations from the fuselage. The nodal
beam installation develops a standing wave form to
reduce fuselage vibrations throughout the helicopter
speed range to below the level of perception. The arm
assemblies are manufactured from aluminum alloy
forgings and are bushing mounted to the fore and aft
support assemblies. The flexure assembly, located
between the two arm assemblies, consists of a
laminated elastomer flexure, shims, and shear pads
bonded into metal brackets. Tellurium lead tuning
weights are located on the end of the arm assemblies
adjacent to the flexure and provide a method for tuning
the nodal beam installation.
NOTE
The arm and flexure assembly should not
be disassembled except in accordance with
the BHT-206L-CR&O. No tuning weight
adjustments are authorized.
2. Support transmission in helicopter with suitable
hoist and hoisting device. This may be accomplished
9, by the use of a clevis attached to the main rotor mast
nut, or T100220 main rotor hoisting sling or equivalent,
or T103141 hoisting ring (206-240-001-101 lift and
cover plate for 206L3+ IGW Upgrade) when mast
assembly is removed.
3. Remove link assemblies (7, Figure 63-18) from
transmission (1) and forward and aft arms (24 and 5,
Figure 63-19) (paragraph 63-116).
4. From aft arm (5) and aft support (16), remove bolt
(1), washer (2), up stop (3), spacer (4), and down
stop (17).
5. From forward arm (24) and forward support
assembly (20), remove bolt (1), washer (2), up stop
(3), spacer (4), and down stop (17).
6. Remove nuts (10), washers (9), and bolts (21)
from forward and aft arms (24 and 5) and from froward
and aft supports (20 and 16).
7. Remove nuts (11), washers (12), washers (23),
and bolts (22) from forward and aft supports (20 and
16). Lift forward and aft arm and flexures from
supports.

63-122. ARM AND FLEXURE ASSEMBLY — 63-123. ARM AND FLEXURE ASSEMBLY —
REMOVAL INSPECTION AND REPAIR

SPECIAL TOOLS REQUIRED MATERIALS REQUIRED

NUMBER NOMENCLATURE Refer to BHT-ALL-SPM for specifications.

Commercial Hoist, 600 Pound (272 NUMBER NOMENCLATURE

kg) Capacity, Minimum
C-100 Chemical Film Material
Commercial Hoisting Cable, 600
Pound (272 kg) C-204 Epoxy Polyamide
Capacity, Minimum Primer
T100220 Main Rotor Hoisting
C-423 Abrasive Paper
Sling
T103141 Hoisting Ring
206-240-001-101 Lift and Cover Plate NOTE
(206L3+ IGW For a detailed inspection, refer to the
Upgrade) BHT-206L-CR&O.

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 63
BHT-206L3-MM-6
1. Visually inspect forward and aft arms (24 and 5,
Figure 63-19) for nicks, scratches, dents, and
corrosion damage.
a. Maximum acceptable depth of nicks,
scratches, and dents is 0.008 inch (0.203 mm) and
0.04 inch (1.0 mm) in length. Full depth repairs are not
allowed on same or opposite sides of flanges within
1.0 inch (25 mm) spacing.
b. Maximum acceptable depth of corrosion
damage is 0.004 inch (0.102 mm).
c. Maximum acceptable depth of scratches in
bushings (6, 7, and 8) is 0.008 inch (0.203 mm) or
maximum acceptable width is 0.05 inch (1.3 mm).
Cracks or corrosion in bushings requires bushing
replacement.
2. Blend out acceptable damage with No. 320 or
400 grit abrasive paper (C-423). Apply chemical film
material (C-100) to repaired areas and touch up with
epoxy polyamide primer (C-204).
3. Check tuning weights (25) for security to aft and
forward arms (5 and 24).
4. Inspect flexure (18) for security to forward and aft
arms (24 and 5) and damage to elastomeric material
covering.
5. Visually inspect flexure assembly end housings
for nicks, scratches, dents, bond separation, and
corrosion damage.
a. Maximum acceptable depth of nicks,
scratches, and dents is 0.008 inch (0.203 mm) and
maximum acceptable length is 0.040 inch (1.02 mm)
on housings bolted to either end of flexure (18).
b. Maximum acceptable depth of corrosion
damage is 0.004 inch (0.102 mm).
c. Blend out acceptable damage in accordance
with step 2.
6. Visually inspect down stops and up stops (17 and
3) for nicks, scratches, dents, and corrosion damage.
a. Maximum depth of nicks, scratches, and dents
on cadmium plated surfaces is 0.05 inch (1.3 mm).
63-00-00
Page 64 Rev. 10 20 JUL 2009
Nicks, scratches, and dents less than 0.01 inch (0.25
mm) in depth need not be repaired.
b. Nicks, scratches, and dents in bore of down
stop (17) of 0.01 inch (0.25 mm) or less may be
repaired by deepening counterbore a maximum of
0.010 inch (0.254 mm).
c. Maximum acceptable area of bond separation
for elastomeric material on down and up stops (17 and
3) is 0.6 inch2 (400 mm2). Maximum acceptable depth
of flex cracks is 0.1 inch (2.5 mm).
d. Blend out acceptable damage in accordance
with step 2.
63-124. ARM AND FLEXURE ASSEMBLY —
INSTALLATION
NOTE
On the 206L3+ IGW Upgrade, the arm and
flexure assembly differs from the 206L3 in
the areas where it contacts the up stops.
1. Position forward and aft arms (24 and 5,
Figure 63-19) and flexure (18) into aft and forward
supports (20 and 16).
2. Align bushings (7) in forward and aft arms (24
and 5) with elastomeric bearing and bushing members
(13 and 19). Loosely install bolts (22), aluminum
washers (12), thin aluminum washer (23), and nuts
(11). Install bolts with heads inboard.
3. Align tangs on elastomeric bearing and bushing
members (13 and 19) with bushings (6) in forward and
aft arms (24 and 5). Install bolts (21), heads inboard,
with thin aluminum washers (9) and nuts (10).
4. Check that barrel nuts (14) and retainers (15) are
installed and aligned with bolt holes in aft support
assembly (16) and support located inside cabin and
below forward support (20).
NOTE
Washer (2) is optional, as required, to
obtain thread engagement. The maximum
permissible exposed threads through the
barrel nut is two.
ECCN EAR99
 BHT-206L3-MM-6

1 T 3

2
21 3 5

9 4

7
22
8

23
9
T 3
1 10 T 1

2 25
3
4
17
24 18
22
INB 16
23
D 12
17 13 11 T 2
15
FWD
14
14 15 SEE VIEW B
21 12
9
20
19
SEE VIEW A 9
10 T 1
11 T 2

LEFT-HAND SIDE SHOWN

(RIGHT-HAND SIDE OPPOSITE)

206L3_MM_63_0019a

Figure 63-19. Transmission Arm and Flexure (Sheet 1 of 2)

63-00-00
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BHT-206L3-MM-6

3 31 26 1. Bolt
2. Washer
3. Up stop
27 29 1 2 27 4. Spacer
5. Aft arm
26 INB 6. Bushing
D
7. Bushing
8. Bushing
27
9 D 9. Aluminum washer
FW 10. Nut
11. Nut
12. Aluminum washer
13. Elastomeric bearing and
bushing member
MOUNTING SURFACE
14. Barrel nut
15. Retainer
16. Aft support
20 17. Down stop
18. Flexure
9 19. Elastomeric bearing and
bushing member
T 1 10 20. Forward support
9 21. Bolt
T 1
10
22. Bolt
9 23. Aluminum washer
10 T 1 24. Forward arm
VIEW A
(LEFT-HAND SIDE SHOWN) 25. Tuning weight
26. External wrenching bolt
28 27. Special washer
28 28. External wrenching bolt
29. Bolt
27 28 30. Bolt
27 31. External wrenching bolt
28 27
27
75 TO 95 IN-LBS
27 30 1 2 T 1 (8.5 TO 10.7 Nm)
INB 240 TO 1500 IN-LBS
D T 2 (27.1 TO 169.4 Nm)
9
468 TO 516 IN-LBS
FW
D T 3 (52.8 TO 58.3 Nm)
MOUNTING
SURFACE

16 9 NOTES
1 When replacing NAS1304 or NAS6604 bolts
9
10 T 1 with MS21250 bolts, MS14155-4 washer must
9
be used under bolthead and AN960JD416L
T 1 10 9 washer must be used under nut (all locations).
10 T 1
MOUNTING SURFACES 2 206L3 helicopters S/N 51001 through 51249.
T 1
10
3 206L3 helicopters S/N 51250 and subsequent
VIEW B
and 206L3+ IGW Upgrade.
(LEFT-HAND SIDE SHOWN)
206L3_MM_63_0019b

Figure 63-19. Transmission Arm and Flexure (Sheet 2 of 2)

63-00-00
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 BHT-206L3-MM-6

a. Through aft arm (5) and aft support (16), SPECIAL TOOLS REQUIRED
loosely install bolt (1), washer (2), up stop (3), spacer
(4), and down stop (17), engaging barrel nut (14) in aft
support assembly (16). NUMBER NOMENCLATURE
T100220 Main Rotor Hoisting
b. Through forward arm (24) and forward support Sling
(20), loosely install bolt (1), washer (2), up stop (3),
spacer (4), and down stop (17), engaging barrel nut T103141 Hoisting Ring
(14). Down stop is inserted between forward arm and
206-240-001-101 Lift and Cover Plate
structure, aligning spacer with counterbore in down
(206L3+ IGW
stop.
Upgrade)

NOTE 1. Remove transmission fairing (Volume 9,

It is permissible to use a maximum of seven Chapter 71).
additional thin aluminum washers to obtain
torque range. 2. Support transmission in helicopter with suitable
hoist and hoisting device. This may be accomplished
c. Torque bolts (1) 468 to 516 inch-pounds (52.8 by the use of a clevis attached to the main rotor mast
to 58.3 Nm). nut, or T100220 main rotor hoisting sling, or T103141
hoisting ring (206-240-001-101 lift and cover plate for
d. Torque nuts (11) 240 to 1500 inch-pounds 206L3+ IGW Upgrade) when mast assembly is
(27.1 to 169.4 Nm). removed.
5. Install link assemblies (7, Figure 63-20)
(paragraph 63-120). 3. Remove link assemblies (7, Figure 63-18) from
transmission (paragraph 63-116).
6. Disconnect and remove hoist and hoisting device.
4. Remove forward and aft arms (24 and 5,
7. Reinstall transmission fairing (Volume 9, Figure 63-19) with flexure (18) from forward and aft
Chapter 71). supports (20 and 16) (paragraph 63-121).

63-125. SUPPORT ASSEMBLIES 5. Remove forward and aft supports (20 and 16) by
removing bolts (26, 28, 29, 30, and 31), washers (9),
washers (27), and nuts (10). It may be necessary to
The forward and aft support assemblies contain
trim sealant from the mating edges of support and
bonded elastomeric bearing and bushings members to
structure to remove part.
isolate the arm and flexure assemblies from the
fuselage. Support assemblies are manufactured from
aluminum alloy forgings. 63-127. SUPPORT ASSEMBLIES — INSPECTION
AND REPAIR
63-126. SUPPORT ASSEMBLIES — REMOVAL

MATERIALS REQUIRED
SPECIAL TOOLS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE NUMBER NOMENCLATURE
Commercial Hoist, 600 Pound (272 C-204 Epoxy Polyamide
kg) Capacity, Minimum Primer
Commercial Hoisting Cable, 600 C-309 MEK
Pound (272 kg)
Capacity, Minimum C-423 Abrasive Paper

63-00-00
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BHT-206L3-MM-6

1 2 TIGHTEN NUT UNTIL CONTACT IS MADE

WITH STOP, THEN TIGHTEN NUT
3 AN ADDITIONAL 90 TO 120°.
4 SEE DETAIL A

5 7
6 8
9 2 7
(ALTERNATE)
11
12 10

14 13 T 6 20 T 2
1 6
AREAS NOTED MUST BE
15 T 1 21 23
FREE OF ADHESIVE 18 22
12 24
16 19
0.12 IN.
(3.0 mm) 17
34
BOND PACKING
USING ADHESIVE 33
(C-311) 35
25 T 3
0.10 IN. 32 21
(2.5 mm) 4 29
28
DETAIL A
32 30 27 26 T 5
T 4
31

1. Transmission
31 T 4
32
2. Nut
3. Up stop
4. Packing 14. Steel washer 25. Nut
5. Bolt 15. Nut 26. Nut
6. Aluminum washer 16. Bolt 27. Steel washer
7. Transmission restraint 17. Special washer 28. Bolt
8. Restraint spring 18. Torsional (elastomeric) bearing 29. Torsional (elastomeric) bushing
9. Special washer 19. Torsional (elastomeric) bushing 30. Torsional (elastomeric) bearing
(140-009H25S40) 20. Nut 31. Nut
10. Bearing 21. Thin aluminum washer 32. Thin aluminum washer
11. Bushing 22. Isolation support 33. Bolt
12. Stop mount 23. Bolt 34. Drag pin
13. Nut 24. Thin aluminum washer 35. Bolt

NOTES
1 Permissible to use a maximum of four 15 TO 90 IN-LBS 120 TO 160 IN-LBS
additional washers (6), as required, to obtain
T 1 (1.7 TO 10.1 Nm) T 4 (13.5 TO 18.0 Nm)
torque range for cotter pin installation. 30 TO 40 IN-LBS 260 TO 390 IN-LBS
T 2 (3.4 TO 4.5 Nm) T 5 (29.3 TO 44.0 Nm)
2 Permissible to use a maximum of three
75 TO 95 IN-LBS 444 TO 502 IN-LBS
washers (9) between isolation support
and transmission restraint.
T 3 (8.5 TO 10.7 Nm) T 6 (50.1 TO 56.7 Nm)

206L3_MM_63_0020

Figure 63-20. Transmission Restraint

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Page 68 Rev. 10 20 JUL 2009 ECCN EAR99

1. Inspect cabin roof shell and cabin roof beam for
evidence of damage in area of forward and aft
supports (20 and 16, Figure 63-19). Remove aged
sealant or sealing compound with MEK (C-309) and
plastic scraper.
2. Visually inspect forward and aft supports (20 and
16) for nicks, scratches, dents, and corrosion damage.
a. Maximum acceptable depth of nicks,
scratches, and dents is 0.005 inch (0.127 mm) in bolt
holes. Maximum acceptable damage in all other areas
is 0.008 inch (0.203 mm) in depth and 0.040 inch (1.01
mm) in length.
b. Maximum acceptable depth of corrosion
damage is 0.003 inch (0.076 mm) in bolt holes and
0.004 inch (0.102 mm) in all other areas.
3. Blend out acceptable damage with No. 320 or
400 grit abrasive paper (C-423). Touch up repaired
areas with epoxy polyamide primer (C-204).
4. Visually inspect elastomeric bearing and bushing
members (13 and 19) for evidence of cuts, flex cracks,
and bond separation.
a. Maximum area of metal-to-rubber bond
separation not to exceed a total of 0.6 inch2 (400
mm2).
b. Maximum acceptable depth of flex cracks or
surface failure of rubber due to flexing not to exceed
0.1 inch (2mm).
c. Inspect bore of elastomeric bearing and
bushing for evidence of scratches, cracks, or
corrosion. Maximum acceptable depth of scratches is
0.008 inch (0.203 mm) or maximum acceptable length
is 0.05 inch (1.27 mm). Cracks or corrosion are not
permitted in bushing.
5. Inspect barrel nuts (14) and retainers (15) for
cracks, distortion, and thread damage.
ECCN EAR99
BHT-206L3-MM-6
63-128. SUPPORT ASSEMBLIES —
INSTALLATION
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-308 Sealant
1. Install barrel nuts (14, Figure 63-19) and retainers
(15) in aft support (16) and in support structure inside
cabin for forward support (20), if removed.
2. On 206L3 helicopters S/N 51001 through 51249,
install forward and aft support assemblies (20 and 16)
to cabin roof shell as follows:
a. Apply sealant (C-308) to faying surfaces of
cabin roof shell and aft and forward support
assemblies (16 and 20).
b. Position forward support (20) in place. Secure
inboard side with two MS21250-04014 12-point
external wrenching bolts (26), special washers (27),
aluminum washers (9), and nuts (10). Locate washers
as shown in View A. Secure center and outboard side
with three NAS6604-12 bolts (29), aluminum washers
(9), and nuts (10). Locate washers as shown in View
A. Torque nuts (10) 75 to 95 inch-pounds (8.5 to 10.7
Nm).
c. Position aft support (22) in place. Secure
inboard side with four MS21250-04012 12-point
external wrenching bolts (28), special washers (27),
aluminum washers (9), and nuts (10). Locate washers
as shown in View B. Secure center and outboard side
with six NAS6604-11 bolts (30), aluminum washers
(9), and nuts (10). Locate washers as shown in View
B. Torque nuts (10) 75 to 95 inch-pounds (8.5 to 10.7
Nm).
d. After sealant (C-308) has cured, torque check
all attaching nuts.
3. On 206L3 helicopters S/N 51250 and subsequent
and 206L3+ IGW Upgrade, install forward and aft
support assemblies (20 and 16) to cabin roof shell as
follows:
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BHT-206L3-MM-6

a. Apply sealant (C-308) to faying surfaces of 63-130. TRANSMISSION RESTRAINT —

cabin roof shell and aft and forward support REMOVAL
assemblies (16 and 20).

b. Position forward support (20) in place. Secure SPECIAL TOOLS REQUIRED

inboard side with two MS21250-04014 12-point
external wrenching bolts (26), special washers (27),
NUMBER NOMENCLATURE
aluminum washers (9), and nuts (10). Locate washers
as shown in View A. Secure center and outboard side Commercial Hoist, 600 Pound (272
with three MS21250-04012 12-point external kg) Capacity, Minimum
wrenching bolts (31), special washers (27), aluminum
washers (9), and nuts (10). Locate washers as shown Commercial Hoisting Cable, 600
in View A. Torque nuts (10) 75 to 95 inch-pounds (8.5 Pound (272 kg)
Capacity, Minimum
to 10.7 Nm).
T100220 Main Rotor Hoisting
c. Position aft support (16) in place. Secure with Sling
ten MS21250-04012 12-point external wrenching bolts
T103141 Hoisting Ring
(28), special washers (27), aluminum washers (9), and
nuts (10). Locate washers as shown in View B. Torque 206-240-001-101 Lift and Cover Plate
nuts (10) 75 to 95 inch-pounds (8.5 to 10.7 Nm). (206L3+ IGW
Upgrade)
d. After sealant (C-308) has cured, torque check
all attaching nuts. 1. Remove transmission fairing (Volume 9,
Chapter 71).
4. Install forward and aft arms (24 and 5) and flexure
(18) (paragraph 63-124). 2. Support transmission in helicopter with suitable
hoist and hoisting device. This may be accomplished
5. Install four link assemblies (7, Figure 63-18) by the use of a clevis attached to the main rotor mast
(paragraph 63-120). nut, or T100220 main rotor hoist sling, or T103141
hoisting ring (206-240-001-101 lift and cover plate for
206L3+ IGW Upgrade) when mast assembly is
6. Disconnect and remove hoist and hoisting device. removed. Hoist transmission sufficiently to allow
removal of hardware from transmission restraint.
7. Install transmission fairing (Volume 9,
Chapter 71). 3. Remove main driveshaft (paragraph 63-17 or
paragraph 63-19B (206L3+ IGW Upgrade).
63-129. TRANSMISSION RESTRAINT
4. Disconnect hose clamps on left arm of
The transmission restraint is an elastomeric spring transmission restraint (7, Figure 63-20) for
assembly enclosed in a steel housing. The restraint is freewheeling oil return hose.
secured in an isolation support that is mounted to the
cabin roof beam and restrains transmission movement 5. Disconnect transmission restraint (7) from
both fore and aft and laterally. The forward arms of the isolation support (22) by removing nut (26), washers
restraint contain teflon lined spherical bearings that (27), bolt (16), and washers (9 and 17). Adjust hoist
are attached to the stop mounts which are secured to tension to allow free removal of bolt.
the transmission. The transmission is further
restrained through the stop mounts by the up stops 6. Remove nuts (15), washers (6), and bolts (5).
and drag pins. Remove transmission restraint (7) from helicopter.

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 BHT-206L3-MM-6

63-131. TRANSMISSION RESTRAINT — a. Maximum acceptable area of metal-to-rubber

INSPECTION AND REPAIR bond separation is a total of 0.6 inch2 (60 mm2).

b. Maximum acceptable area of flex cracks or

MATERIALS REQUIRED surface failure of rubber due to flexing is 0.1 inch2 (400
mm2).
Refer to BHT-ALL-SPM for specifications.
c. Inspect bore of torsional bearings (19 and 29)
NUMBER NOMENCLATURE for evidence of scratches, cracks, or corrosion.
Maximum acceptable depth of scratches is 0.008 inch
C-204 Epoxy Polyamide (0.203 mm) and maximum acceptable width is 0.05
Primer inch (1.3 mm). Cracks or corrosion are not permitted in
bushing.
C-423 Abrasive Paper
63-132. TRANSMISSION RESTRAINT —
1. Visually inspect transmission restraint (7, INSTALLATION
Figure 63-20) for nicks, scratches, dents, and
corrosion damage. 1. Position transmission restraint (7, Figure 63-20)
into stop mount (12) and isolation support (22). Install
a. Maximum depth of nicks and scratches is bolt (16) with special washers (9 and 17) through
0.008 inch (0.203 mm) and dents 0.040 inch (1.02 isolation support (22) and through transmission
mm). Full depth repairs are not allowed on same or restraint using steel washers (27) as necessary to fill
opposite sides of transmission restraint (7) within 1.0 gap between isolation support and transmission
inch (25 mm) spacing. restraint. Install nut (26). Torque nut 260 to 390
inch-pounds (29.3 to 44.0 Nm) and secure with cotter
b. Maximum depth of corrosion is 0.004 inch pin.
(0.102 mm).
NOTE
2. Blend out acceptable damage with No. 320 or
400 grit abrasive paper (C-423). Touch up repaired It is permissible to use a maximum of four
areas and bare spots with epoxy polyamide primer additional washers to obtain torque range
(C-204). and install cotter pins.

2. Adjust hoist tension and position transmission

3. Inspect bearings (10) in arms of transmission assembly to allow installation of bolts (5), washers (6),
restraint (7) for smoothness of movement, looseness, and nuts (15). Torque nuts 15 to 90 inch-pounds (1.69
and general condition. to 10.17 Nm) and secure with cotter pin.

a. Maximum acceptable depth of scratches is 3. Disconnect and remove hoist and hoisting device.
0.008 inch (0.203 mm) and maximum acceptable
width is 0.05 inch (1.3 mm). Cracks or corrosion on
4. Install main driveshaft (paragraph 63-19 or
bearing (10) will require bearing replacement.
paragraph 63-19F for 206L3+ IGW Upgrade).
b. Maximum allowable axial wear of bearing (10)
is 0.007 inch (0.178 mm). 5. Secure hose clamp installation to left arm of
transmission restraint (7).
c. Check both sides of bearings (10) for
evidence of teflon fabric liner deterioration which 6. Reinstall transmission fairing (Volume 9,
would require bearing replacement Chapter 71).
(BHT-206L-CR&O).
63-133. ISOLATION SUPPORT
4. Visually inspect restraint spring (8) in
transmission restraint (7) for evidence of cuts, flex The isolation support is an aluminum alloy forging and
cracks, or bond separation. is secured to the upper cabin roof shell and cabin roof

63-00-00
ECCN EAR99 20 JUL 2009 Rev. 10 Page 71
BHT-206L3-MM-6

beam. The isolation support provides a fixed structure b. Maximum acceptable depth of corrosion is
support for the transmission restraint, limiting 0.002 inch (0.051 mm) in bolt holes, 0.003 inch (0.076
transmission movement through elastomeric bearings. mm) in bushing area, and 0.01 inch (0.25 mm) on
other surfaces.
63-134. ISOLATION SUPPORT — REMOVAL
3. Blend out acceptable damage with No. 320 or
1. Remove transmission fairing (Volume 9, 400 grit abrasive paper (C-423). Apply chemical film
Chapter 71). material (C-100) to repaired areas and touch up with
epoxy polyamide primer (C-204).
2. Remove transmission restraint (7, Figure 63-20)
(paragraph 63-130). 4. Inspect bore of bushings (19 and 29) for
scratches, cracks, and corrosion. Maximum
3. Remove isolation support (22) from structure by acceptable depth of scratches not to exceed 0.008
removing bolts (23 and 28), washers (24 and 21), and inch (0.203 mm) or 0.05 inch (1.3 mm) in length.
nuts (25 and 20). Cracks or corrosion are not permitted in bushing
(BHT-206L-CR&O).
63-135. ISOLATION SUPPORT — INSPECTION
AND REPAIR 63-136. ISOLATION SUPPORT — INSTALLATION

1. Position isolation support (22, Figure 63-20) to

MATERIALS REQUIRED cabin roof shell and align bolt holes.

Refer to BHT-ALL-SPM for specifications. 2. Insert bolts (28) from bottom and bolts (23) from
top with thin aluminum washers (21 and 24) through
NUMBER NOMENCLATURE isolation support (22), cabin roof shell, and cabin roof
beam. Bolts (28) are the longest and are installed in
C-100 Chemical Film Material
the four forward locations. If necessary, install
C-204 Epoxy Polyamide additional thin aluminum washers on each bolt and
Primer secure with nuts (20 and 25). Torque nuts (20) 30 to 40
inch-pounds (3.39 to 4.52 Nm) and install cotter pins.
C-423 Abrasive Paper Torque nuts (25) 75 to 95 inch-pounds (8.47 to 10.73
Nm).
1. Inspect cabin roof shell and cabin roof beam for
evidence of damage in area of isolation support (22, 3. Install transmission restraint (7) (paragraph
Figure 63-20). 63-132).

2. Visually inspect isolation support (22) for nicks, 4. Install transmission fairing (Volume 9,
scratches, dents, and corrosion damage. Chapter 71).

a. Maximum acceptable depth of nicks, 63-137. STOP MOUNTS

scratches, and dents is 0.003 inch (0.076 mm) in bolt
holes, 0.005 inch (0.127 mm) in bushing area, and
0.02 inch (0.408 mm) on other surfaces. Full depth
repairs are not allowed on same or opposite sides of
isolation support within 1.0 inch (25 mm) spacing.
The two stop mounts are steel forgings and are
attached to the lower aft portion of the transmission
lower case. The stop mounts limit vertical and
oscillatory movement of the transmission.

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 BHT-206L3-MM-6

63-138. STOP MOUNTS — REMOVAL 5. Disconnect the four link assemblies in

accordance with paragraph 63-116, and hoist
transmission (1) only enough to allow removal of bolts
(33) after the stop mounts (12) and drag pins (34)
SPECIAL TOOLS REQUIRED
have been disconnected. Use extreme caution during
hoisting not to apply tension to connected control
NUMBER NOMENCLATURE tubes, hose assemblies, and electrical cabling.

Commercial Hoist, 600 Pound (272 6. Remove nuts (2) and up stops (3) from drag pins
kg) Capacity, Minimum (34) and stop mounts (12). Remove bolts (33 and 35),
washers (32), nuts (31), and washers (14). Remove
Commercial Hoisting Cable, 600 stop mounts (12) and drag pins (37). It may be
Pound (272 kg) necessary to use a plastic mallet to free stop mounts
Capacity, Minimum from transmission lower case due to sealing
compound applied between mating surfaces.
T100220 Main Rotor Hoisting
Sling
7. Remove aged sealant and sealing compound
T103141 Hoisting Ring with a plastic scraper and MEK (C-309).
(206L3 S/N 51001
Through 51307) 63-139. STOP MOUNTS — INSPECTION AND
REPAIR
206-240-001-101 Lift and Cover Plate
(206L3 S/N 51308 and
Subsequent, and MATERIALS REQUIRED
206L3+ IGW Upgrade)
Refer to BHT-ALL-SPM for specifications.

MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-309 MEK
1. Remove transmission fairings (Volume
Chapter 71).
2. Remove main driveshaft (paragraph 63-17 or
paragraph 63-19B for 206L3+ IGW Upgrade).
3. Support transmission in helicopter with suitable
hoist and hoisting device. This may be accomplished
by the use of a clevis attached to the main rotor mast
nut, or T100220 main rotor hoist sling, or T100089
hoisting ring (206-240-001-101 lift and cover plate
206L3 S/N 51308 and subsequent, and 206L3+ IGW
Upgrade) when mast assembly is removed.
NUMBER NOMENCLATURE
C-204 Epoxy Polyamide
Primer
C-423 Abrasive Paper
1. Visually inspect stop mounts (12, Figure 63-20)
for nicks, scratches, dents, and corrosion damage.
9,
a. Maximum acceptable depth of nicks,
scratches, and dents is 0.005 inch (0.127 mm) on lugs
for bushings (11) and bolt holes, 0.02 inch (0.51 mm)
in radius groove for packings (4), and 0.05 inch (1.3
mm) on other surfaces.
b. Maximum acceptable depth of corrosion is
0.003 inch (0.076 mm) on lugs for bushings (11) and
bolt holes, 0.01 inch (0.25 mm) in radius groove for
packings (4), and 0.025 inch (0.635 mm) on other
surfaces. Full depth repairs are not allowed on same
or opposite sides of lugs within a 0.50 inch (13 mm)
spacing.

4. Remove transmission restraint (7, Figure 63-20) c. Inspect bushings (11) for scratches, cracks,
(paragraph 63-130). corrosion, and security. Maximum acceptable depth of

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BHT-206L3-MM-6

scratches is 0.008 inch (0.203 mm) and 0.05 inch (1.3
mm) in length. No cracks or corrosion are allowed in
bushings.
2. Blend out acceptable damage with No. 320 or
400 grit abrasive paper (C-423). Touch up repaired
areas with epoxy polyamide primer (C-204).
4. Insert drag pin (34) into stop mount (12) and
position assembly to studs on transmission (1) and
structure of helicopter. Ensure that spindle of drag pin
is tilted forward, then secure to structure with bolts (33
and 35), thin aluminum washers (32), and nuts (31).
Torque nuts 120 to 160 inch-pounds (13.50 to 18.08
Nm).

63-140. STOP MOUNTS — INSTALLATION 5. Secure stop mount (12) to transmission (1) with
steel washers (14) and nuts (13). Torque nuts 444 to
502 inch-pounds (50.1 to 56.7 Nm).
MATERIALS REQUIRED
6. Apply a bead of sealant (C-308) to mating edge
Refer to BHT-ALL-SPM for specifications. surfaces of stop mount (12) and transmission (1).
Remove excess sealing compound and sealant.
NUMBER NOMENCLATURE
7. Reconnect link assemblies in accordance with
C-308 Sealant paragraph 63-114.
C-309 MEK
8. Install transmission restraint (7) (paragraph
C-311 Adhesive 63-132).

C-328 Sealing Compound
1. Clean mating surfaces of transmission (1,
Figure 63-20 and stop mount (12) with MEK (C-309).
Ensure all aged sealing compound has been removed.
2. Ensure packing (4) is serviceable or new packing
is properly bonded to stop mount (12) with adhesive
(C-311) (Detail A).
9. Remove all tension from transmission and install
up stops (3) on spindle of drag pins (34) and secure
with nuts (2). Tighten nuts until contact is made with up
stops, then tighten nuts an additional 90 to 120°.
10. Disconnect and remove hoist and hosting device.
11. Install main driveshaft (paragraph 63-19 or
paragraph 63-19F for 206L3+ IGW Upgrade).

3. Apply a film of sealant (C-328) to mounting area 12. Install transmission fairing (Volume 9,
on transmission (1) for stop mount (12). Chapter 71).

63-00-00
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 BHT-206L3-MM-6

b. Maximum acceptable depth of corrosion is

63-141. DRAG PINS AND UP STOPS
Two drag pins are steel forgings and are attached to
the upper cabin roof shell and cabin roof beam. The
drag pins limit the oscillatory movement of the
transmission through the stop mounts. Vertical
restraint is limited by the up stops, which consist of
bonded upper and lower disk in contact with the stop
mounts.
63-142. DRAG PINS AND UP STOPS — REMOVAL
0.025 inch (0.635 mm) on top surface and 0.002 inch
(0.051 mm) on lower (disc) surface.
2. Blend out acceptable damage with No. 320 or
400 grit abrasive paper (C-423). Touch-up repaired
areas and bare spots with epoxy polyamide primer
(C-204).
3. Visually inspect drag pins (34) for nicks,
scratches, dents, and corrosion damage.

1. Remove transmission fairing (Volume 9, a. Maximum depth of nicks, scratches, and dents
Chapter 71). is 0.005 inch (0.127 mm) in bolt holes and 0.05 inch
(1.27 mm) on all other surfaces. Nicks, scratches, and
dents on drag pins less than 0.01 inch (0.25 mm) need
2. Remove nuts (2, Figure 63-20) from up stops (3) not be repaired.
and drag pins (34). Lift up stops from spindle of drag
pins.
b. Maximum depth of corrosion is 0.003 inch
(0.076 mm) in bolt holes and 0.025 inch (0.635 mm)
3. For removal of drag pins (34) with transmission on all other surfaces.
(1) installed (paragraph 63-138), it will be necessary to
remove stop mounts (12) with the drag pins and the
c. Blend out acceptable damage in accordance
transmission partially hoisted.
with step 2.

63-143. DRAG PINS AND UP STOPS —

63-144. DRAG PINS AND UP STOPS —
INSPECTION AND REPAIR
INSTALLATION

1. For installation of drag pins (34, Figure 63-20)

MATERIALS REQUIRED
with transmission (1) installed (paragraph 63-140), it
will be necessary to install drag pins (34) and stop
Refer to BHT-ALL-SPM for specifications.
mounts (12) together with transmission hoisted.
NUMBER NOMENCLATURE

C-204 Epoxy Polyamide 2. Install drag pins (34) with spindle tilted forward,
Primer and secure with bolts (33 and 35), thin aluminum
washers (32), and nuts (31). Torque nuts 120 to 160
C-423 Abrasive Paper inch-pounds (13.56 to 18.08 Nm).

1. Visually inspect up stops (3, Figure 63-20) for 3. With stop mounts (12) installed and all tension
nicks, scratches, dents, and corrosion damage. removed from transmission, insert up stops (3) on
spindle of drag pins (34) and install nuts (2). Tighten
nuts until contact is made with up stop, then tighten
a. Maximum depth of nicks, scratches, and dents
nuts an additional 90 to 120°.
is 0.05 inch on the top surface and 0.004 inch on the
lower (disc) surface. Nicks, scratches, and dents on
the top surfaces less than 0.01 inch in depth need not 4. Reinstall transmission fairing (Volume 9,
be repaired. Chapter 71).

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