412CRO412CROCH63

BHT-412-CR&O-3
CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM
TABLE OF CONTENTS
Paragraph Chapter/Section Page

Number Title Number Number
MAIN DRIVESHAFT
63-1 Main Driveshaft (212-040-005-103)........................................... 63-00-00 11

63-2 Main Driveshaft — Disassembly........................................... 63-00-00 11
63-3 Main Driveshaft — Cleaning................................................. 63-00-00 14
63-4 Main Driveshaft — Inspection............................................... 63-00-00 14
63-5 Main Driveshaft — Conditional Inspection............................ 63-00-00 14
63-6 Main Driveshaft — Normal Inspection .................................. 63-00-00 14
63-7 Main Driveshaft — Repair .................................................... 63-00-00 25
63-8 Main Driveshaft — Lubrication ............................................. 63-00-00 29
63-9 Main Driveshaft — Assembly ............................................... 63-00-00 29
63-10 Main Driveshaft (Helicopters S/N 36020 and Subsequent,
to Include S/N 46400 Through 46499, and Helicopters
Modified by 412-570-001-103 or Post BHT-412-SI-74
(412SP to 412HP Upgrade)) ..................................................... 63-00-00 31
63-11 Main Driveshaft — Disassembly........................................... 63-00-00 31
63-12 Main Driveshaft — Cleaning................................................. 63-00-00 34
63-13 Main Driveshaft — Inspection............................................... 63-00-00 34
63-14 Main Driveshaft — Conditional Inspection............................ 63-00-00 34
63-15 Main Driveshaft — Normal Inspection .................................. 63-00-00 43
63-16 Main Driveshaft — Repair .................................................... 63-00-00 46
63-17 Main Driveshaft — Lubrication ............................................. 63-00-00 50
63-18 Main Driveshaft — Assembly ............................................... 63-00-00 50
TRANSMISSION MAIN ROTOR MAST
63-18A Mast Assembly — Configuration ............................................... 63-00-00 52A

63-19 Transmission Main Rotor Mast Assemblies
(412-040-366-103 and -105) ..................................................... 63-00-00 53
63-20 Transmission Main Rotor Mast Assembly — Disassembly .. 63-00-00 53
63-21 Transmission Main Rotor Mast Assembly — Cleaning ........ 63-00-00 62
63-22 Transmission Main Rotor Mast Assembly — Inspection ...... 63-00-00 62
63-23 Transmission Main Rotor Mast Assembly — Repair ............ 63-00-00 62
63-24 Transmission Main Motor Mast Assembly — Assembly....... 63-00-00 68
63-25 Transmission Main Rotor Mast Assemblies (412-040-366-109
and Subsequent) (S/N 36020 through 36999, S/N 37002
through 37999, S/N 46400 through 46499, and Helicopters
Modified by 412-570-001-103 or Post BHT-412-SI-74 (412SP
to 412HP Upgrade)) .................................................................. 63-00-00 74
63-26 Transmission Main Rotor Mast Assembly — Disassembly .. 63-00-00 74
63-27 Transmission Main Rotor Mast Assembly — Cleaning ........ 63-00-00 85
63-28 Transmission Main Rotor Mast Assembly — Inspection ...... 63-00-00 86
63-29 Transmission Main Rotor Mast Assembly — Repair ............ 63-00-00 100
63-30 Transmission Main Rotor Mast Assembly — Assembly ....... 63-00-00 102
63-00-00
Export Classification C, ECCN EAR99 28 FEB 2020 Rev. 12 Page 1
BHT-412-CR&O-3
TABLE OF CONTENTS (CONT)

TRANSMISSION
63-31 Transmission (412-040-002 and 412-040-004) ......................... 63-00-00 107

63-32 Transmission — Disassembly .............................................. 63-00-00 107
63-33 Transmission — Cleaning .................................................... 63-00-00 135
63-34 Transmission — Inspection .................................................. 63-00-00 135
63-35 Transmission — Conditional Inspection ............................... 63-00-00 136
63-36 Transmission — Normal Inspection ..................................... 63-00-00 136
63-37 Transmission — Repair ........................................................ 63-00-00 142
63-38 Transmission — Assembly ................................................... 63-00-00 144
63-39 Transmission — Run-in and Test ......................................... 63-00-00 160
63-40 Transmission — Sealing and Painting ................................. 63-00-00 160
TRANSMISSION CASES
63-41 Transmission Case.................................................................... 63-00-00 163

63-42 Transmission Top Case (212-040-059-101) ........................ 63-00-00 163
63-43 Transmission Top Case — Disassembly...................... 63-00-00 163
63-44 Transmission Top Case — Cleaning ............................ 63-00-00 163
63-45 Transmission Top Case — Inspection.......................... 63-00-00 163
63-46 Transmission Top Case — Repair................................ 63-00-00 163
63-47 Transmission Top Case — Assembly........................... 63-00-00 173
63-48 Transmission Main Bevel Gear Case (212-040-053-009) .... 63-00-00 173
63-49 Transmission Main Bevel Gear Case — Disassembly . 63-00-00 173
63-50 Transmission Main Bevel Gear Case — Cleaning ....... 63-00-00 173
63-51 Transmission Main Bevel Gear Case — Inspection ..... 63-00-00 178
63-52 Transmission Main Bevel Gear Case — Repair ........... 63-00-00 178
63-53 Transmission Main Bevel Gear Case — Assembly ...... 63-00-00 179
63-54 Transmission Main Support Case
(212-040-054-013 and -109) ................................................ 63-00-00 180
63-55 Transmission Main Support Case — Disassembly....... 63-00-00 180
63-56 Transmission Main Support Case — Cleaning............. 63-00-00 180
63-57 Transmission Main Support Case — Inspection........... 63-00-00 180
63-58 Transmission Main Support Case — Repair ................ 63-00-00 196
63-59 Transmission Main Support Case — Assembly ........... 63-00-00 196A
PLANETARY RING GEAR, UPPER PLANETARY, AND LOWER PLANETARY ASSEMBLIES
63-60 Planetary Ring Gear, Upper Planetary, and Lower Planetary

Assemblies ................................................................................ 63-00-00 197
63-61 Planetary Ring Gear (205-040-231-009).............................. 63-00-00 197
63-62 Planetary Ring Gear — Disassembly ........................... 63-00-00 197
63-63 Planetary Ring Gear — Cleaning ................................. 63-00-00 197
63-64 Planetary Ring Gear — Inspection ............................... 63-00-00 197
63-65 Planetary Ring Gear — Repair ..................................... 63-00-00 197
63-66 Planetary Ring Gear — Assembly ................................ 63-00-00 197
63-00-00
Page 2 Rev. 12 28 FEB 2020 Export Classification C, ECCN EAR99
BHT-412-CR&O-3

63-67 Upper Planetary Assembly (204-040-360-005, -103

and -105) .............................................................................. 63-00-00 201
63-68 Upper Planetary Assembly — Disassembly ................. 63-00-00 201
63-69 Upper Planetary Assembly — Cleaning ....................... 63-00-00 201
63-70 Upper Planetary Assembly — Inspection ..................... 63-00-00 205
63-71 Upper Planetary Assembly — Repair ........................... 63-00-00 209
63-72 Upper Planetary Assembly — Assembly ...................... 63-00-00 209
63-73 Lower Planetary Assembly ................................................... 63-00-00 210
63-74 Lower Planetary Assembly — Disassembly ................. 63-00-00 210
63-75 Lower Planetary Assembly — Cleaning ....................... 63-00-00 214
63-76 Lower Planetary Assembly — Inspection ..................... 63-00-00 215
63-77 Lower Planetary Assembly — Repair ........................... 63-00-00 215
63-78 Lower Planetary Assembly — Assembly ...................... 63-00-00 218
MAIN INPUT GEAR QUILL
63-79 Main Input Gear Quill (204-040-362-103).................................. 63-00-00 221

63-80 Main Input Gear Quill — Disassembly.................................. 63-00-00 221
63-81 Main Input Gear Quill — Cleaning........................................ 63-00-00 221
63-82 Main Input Gear Quill — Inspection...................................... 63-00-00 223
63-83 Main Input Gear Quill — Repair ........................................... 63-00-00 228
63-84 Main Input Gear Quill — Assembly ...................................... 63-00-00 232
63-85 Main Input Gear Quill (412-040-362-101 and -103) (S/N
36020 and Subsequent to Include S/N 46400 through 46499
and Helicopters Modified by 412-570-001-103 or
Post BHT-412-SI-74 (412SP to 412HP Upgrade)) .................... 63-00-00 235
63-86 Main Input Gear Quill — Disassembly.................................. 63-00-00 235
63-87 Main Input Gear Quill — Cleaning........................................ 63-00-00 237
63-88 Main Input Gear Quill — Inspection...................................... 63-00-00 237
63-89 Main Input Gear Quill — Repair ........................................... 63-00-00 247
63-90 Main Input Gear Quill — Assembly ...................................... 63-00-00 247
MAIN INPUT QUILL
63-91 Main Input Quill (212-040-263-107)........................................... 63-00-00 253

63-92 Main Input Quill — Disassembly........................................... 63-00-00 253
63-93 Main Input Quill — Cleaning................................................. 63-00-00 257
63-94 Main Input Quill — Inspection............................................... 63-00-00 257
63-95 Main Input Quill — Repair .................................................... 63-00-00 270
63-96 Main Input Quill — Assembly ............................................... 63-00-00 271
63-97 Main Input Quill (212-040-263-101)........................................... 63-00-00 280
63-98 Main Input Quill — Disassembly........................................... 63-00-00 280
63-100 Main Input Quill — Inspection............................................... 63-00-00 282
63-00-00
BHT-412-CR&O-3

63-103 Main Input Quill (412-040-263-ALL) (S/N 36020 and

Subsequent to Include S/N 46400 through 46499
and Helicopters Modified by 412-570-001-103 or
Post BHT-412-SI-74 (412SP to 412HP Upgrade)) .................... 63-00-00 286
63-104 Main Input Quill — Disassembly .......................................... 63-00-00 286
63-106 Main Input Quill — Inspection .............................................. 63-00-00 290
GENERATOR (OR SYS 2 HYDRAULIC PUMP) DRIVE QUILL
63-109 Generator (or SYS 2 Hydraulic Pump) Drive Quill

(204-040-379-003 and -101) ..................................................... 63- 00-00 309
63-110 Generator (or SYS 2 Hydraulic Pump) Drive Quill —
Disassembly ......................................................................... 63- 00-00 309
Cleaning ............................................................................... 63- 00-00 309
Inspection ............................................................................. 63- 00-00 311
Repair................................................................................... 63- 00-00 311
Assembly.............................................................................. 63-00-00 319
OFFSET ACCESSORY DRIVE QUILL
63-115 Offset Accessory Drive Quill (212-040-208-003 and -101)........ 63-00-00 321
63-116 Offset Accessory Drive Quill — Disassembly....................... 63-00-00 321
63-117 Offset Accessory Drive Quill — Cleaning ............................. 63-00-00 323
63-118 Offset Accessory Drive Quill — Inspection........................... 63-00-00 323
63-119 Offset Accessory Drive Quill — Repair ................................ 63-00-00 326
63-120 Offset Accessory Drive Quill — Assembly ........................... 63-00-00 326
ACCESSORY AND TAIL ROTOR DRIVE AND SUMP ASSEMBLY
63-121 Accessory and Tail Rotor Drive and Sump Assembly

(212-040-365-105, -109, and -111) ........................................... 63-00-00 329
63-122 Accessory and Tail Rotor Drive and Sump Assembly —
Disassembly ......................................................................... 63-00-00 329
63-123 Accessory and Tail Rotor Drive And Sump Assembly —
Cleaning ............................................................................... 63-00-00 336
Conditional Inspection .......................................................... 63-00-00 336
Normal Inspection ................................................................ 63-00-00 336
63-00-00
BHT-412-CR&O-3


Repair ................................................................................... 63-00-00 337
Assembly .............................................................................. 63-00-00 341
63-128 Rotary Oil Pump ........................................................................ 63-00-00 345
63-129 Rotary Oil Pump — Disassembly ......................................... 63-00-00 345
63-130 Rotary Oil Pump — Cleaning ............................................... 63-00-00 345
63-131 Rotary Oil Pump — Inspection ............................................. 63-00-00 345
63-132 Rotary Oil Pump — Repair ................................................... 63-00-00 347
63-133 Rotary Oil Pump — Assembly .............................................. 63-00-00 347
63-134 Oil Filter (Internal) (02W101633) ............................................... 63-00-00 348
63-135 Oil Filter (Internal) — Disassembly....................................... 63-00-00 348
63-136 Oil Filter (Internal) — Cleaning ............................................. 63-00-00 348
63-137 Oil Filter (Internal) — Inspection........................................... 63-00-00 348
63-138 Oil Filter (Internal) — Repair................................................. 63-00-00 348
63-139 Oil Filter (Internal) — Assembly............................................ 63-00-00 348
63-140 Full Flow Debris Monitor (212-040-122-101) ............................. 63-00-00 348
63-141 Full Flow Debris Monitor — Disassembly............................. 63-00-00 348
63-142 Full Flow Debris Monitor — Cleaning ................................... 63-00-00 351
63-143 Full Flow Debris Monitor — Inspection................................. 63-00-00 351
63-144 Full Flow Debris Monitor — Repair....................................... 63-00-00 351
63-145 Full Flow Debris Monitor — Assembly.................................. 63-00-00 351
63-146 Accessory and Tail Rotor Drive Quill
(212-040-365-023 and -115) ..................................................... 63-00-00 351
63-147 Accessory and Tail Rotor Drive Quill — Disassembly.......... 63-00-00 351
63-148 Accessory and Tail Rotor Drive Quill — Cleaning ................ 63-00-00 353
63-149 Accessory and Tail Rotor Drive Quill — Inspection.............. 63-00-00 353
63-150 Accessory and Tail Rotor Drive Quill — Repair.................... 63-00-00 354
63-151 Accessory and Tail Rotor Drive Quill — Assembly............... 63-00-00 358
63-152 Tail Rotor Drive Quill (212-040-365-025)................................... 63-00-00 359
63-153 Tail Rotor Drive Quill — Disassembly .................................. 63-00-00 359
63-154 Tail Rotor Drive Quill — Cleaning......................................... 63-00-00 360
63-155 Tail Rotor Drive Quill — Inspection ...................................... 63-00-00 363
63-156 Tail Rotor Drive Quill — Repair ............................................ 63-00-00 368
63-157 Tail Rotor Drive Quill — Assembly ....................................... 63-00-00 371
63-158 Tail Rotor Drive Quill (S/N 36020 and Subsequent to
Include S/N 46400 through 46499 and Helicopters Modified
by 412-570-001-103 or BHT-412-SI-74
(412SP to 412HP Upgrade)) ..................................................... 63-00-00 376
63-159 Tail Rotor Drive Quill — Disassembly .................................. 63-00-00 376
63-160 Tail Rotor Drive Quill — Cleaning......................................... 63-00-00 378
63-161 Tail Rotor Drive Quill — Inspection ...................................... 63-00-00 378
63-162 Tail Rotor Drive Quill — Repair ............................................ 63-00-00 381
63-163 Tail Rotor Drive Quill — Assembly ....................................... 63-00-00 382
63-164 Single Boost (or System 1) Hydraulic Drive Quill
(212-040-365-103)..................................................................... 63-00-00 385
63-00-00
BHT-412-CR&O-3

63-165 Single Boost (or System 1) Hydraulic Drive Quill —

Disassembly ......................................................................... 63-00-00 385
Cleaning ............................................................................... 63-00-00 387
Inspection ............................................................................. 63-00-00 387
Repair................................................................................... 63-00-00 389
Assembly.............................................................................. 63-00-00 390
ROTOR BRAKE DRIVE QUILL
63-170 Rotor Brake Drive Quill (412-040-123-101 and -103)................ 63-00-00 393
63-171 Rotor Brake Drive Quill — Disassembly............................... 63-00-00 393
63-172 Rotor Brake Drive Quill — Cleaning ..................................... 63-00-00 393
63-173 Rotor Brake Drive Quill — Inspection................................... 63-00-00 395
63-174 Rotor Brake Drive Quill — Repair ........................................ 63-00-00 395
63-175 Rotor Brake Drive Quill — Assembly ................................... 63-00-00 408
TRANSMISSION MOUNTING
63-176 Transmission Mount Friction Damper........................................ 63-00-00 409

63-177 Transmission Mount Friction Damper — Inspection ............ 63-00-00 409
63-178 Transmission Mount Friction Damper — Repair .................. 63-00-00 409
63-179 Transmission Mount Friction Damper — Test ...................... 63-00-00 410
63-180 Transmission Lift Link ................................................................ 63-00-00 410
63-181 Transmission Lift Link — Inspection..................................... 63-00-00 410
63-182 Transmission Lift Link — Repair .......................................... 63-00-00 410
63-183 Transmission Lift Link Fitting ................................................ 63-00-00 413
63-184 Pylon Isolation Mount Bolt ......................................................... 63-00-00 413
63-185 Pylon Isolation Mount Bolt — Inspection .............................. 63-00-00 413
63-186 Pylon Isolation Mount Bolt — Repair.................................... 63-00-00 413
FIGURES
Figure Page
Number Title Number
63-1 Main Driveshaft Assembly (212-040-005-103) ............................................... 12

63-2 Wrench (T101306), Wrench Set (T101588), and Extension Bar (L-122) —
Tool Application .............................................................................................. 13
63-3 Main Driveshaft (212-040-686-001) and Nut (204-040-184-001)
— Damage Limits ........................................................................................... 15
63-4 Main Driveshaft Outer Coupling (212-040-005-103) — Damage Limits ......... 17
63-00-00
BHT-412-CR&O-3
FIGURES (CONT)
Figure Page
Number Title Number
63-5 Main Driveshaft Inner Coupling (212-040-005-103) — Damage Limits.......... 22

63-6 Main Driveshaft (212-040-005-103) — Paint Area ......................................... 27
63-7 Main Driveshaft Assembly (412-040-005-101 and -103) ................................ 32
63-8 Wrench (T101306) — Tool Application........................................................... 33
63-9 Main Driveshaft Outer Coupling (214-040-659-005) — Damage Limits ......... 35
63-10 Main Driveshaft Inner Coupling (214-040-657-003) — Damage Limits.......... 39
63-11 Main Driveshaft and Nut (412-040-005-101) — Damage Limits..................... 44
63-12 Main Driveshaft (412-040-005-101 and -103) — Painted Area ...................... 48
63-13 Transmission Rotor Mast Assembly (412-040-366-103 and -105) ................. 55
63-14 Transmission Main Rotor Mast Assembly/Disassembly Tool
(412-040-366-103 and -105) — Tool Application ........................................... 59
63-15 Transmission Main Rotor Mast Assembly (412-040-366-103 and -105) —
Damage Limits................................................................................................ 63
63-16 Main Rotor Mast (412-040-366-103 and -105) — Cadmium Plating Areas.... 69
63-17 Transmission Main Rotor Mast Assembly ...................................................... 76
63-18 Main Rotor Mast Assembly/Disassembly Tools — Tool Application .............. 80B
63-19 Torque Tube Nut Removal — Tool Application .............................................. 83
63-20 Torque Tube Plug Removal — Tool Application............................................. 84
63-21 Transmission Main Rotor Mast (412-040-366-109 and -111) —
Damage Limits................................................................................................ 87
63-22 Plug (412-040-512-101) — Wear and Damage Limits ................................... 93
63-23 Tube Assembly (412-040-510-103) — Wear and Damage Limits.................. 94
63-24 Plug (412-040-514-101) — Wear and Damage Limits ................................... 96
63-25 Nut (412-040-515-101) (S/N 36020 Through 36096) — Wear and
Damage Limits................................................................................................ 97
63-26 Rotor (412-040-519-101) (S/N 36020 Through 36096) — Wear and
Damage Limits................................................................................................ 98
63-27 Transmission Main Rotor Mast — Cadmium Plating Areas............................ 101
63-28 Mast Assembly (412-040-366-113, -117, -121, -123, -127, and -129)
— Rotor Installation ........................................................................................ 106A
63-30 Transmission Assembly Stand — Application ................................................ 108
63-31 Transmission Maintenance Transportation Stand — Application ................... 109
63-32 Transmission Electrical Cable — Installation.................................................. 111
63-33 Neck, Scupper, and External Oil Hoses — Installation................................... 113
63-34 Breather and Planetary Oil Jet Tubes — Installation...................................... 114A
63-35 Oil Pressure and Temperature Regulating and Indicating Components —
Installation ...................................................................................................... 116
63-36 Oil Jets No. 1, No. 2, No. 3, No. 5, and Planetary Jet — Installation.............. 117
63-37 Oil Temperature and Oil Pressure Manifolds — Installation........................... 119
63-38 Top Case — Installation ................................................................................. 122
63-39 SYS 2 Hydraulic Pump and Rotor Brake Drive Quill — Installation................ 124
63-40 Main Input Quill — Installation (Typical) ......................................................... 125
63-41 Upper and Lower Planetary — Installation ..................................................... 128
63-42 Ring Gear and Jet Housing — Installation ..................................................... 130
63-43 Main Input Gear Quill and Main Case — Installation...................................... 132
63-44 Accessory and Tail Rotor Drive and Sump — Installation .............................. 134
63-45 Transmission Gears, Bearings, and Liners — Damage Limits ....................... 137
63-00-00
Export Classification C, ECCN EAR99 12 JAN 2021 Rev. 13 Page 7
BHT-412-CR&O-3
FIGURES (CONT)
Figure Page
Number Title Number
63-46 Roller Bearing — Wear Patterns .................................................................... 140

63-47 Transmission Sun Gear — Wear Patterns ..................................................... 141
63-48 Pusher Set (T101586) — Application ............................................................. 147
63-49 Dial Indicator Support Workaid ....................................................................... 151
63-50 Mast Driving Adapter To Transmission Top Case — Dimension
Requirements ................................................................................................. 156
63-51 Main Input Quill Grease Retainer — Installation (Typical).............................. 161
63-52 Sealing Compound and Sealant Application .................................................. 162
63-53 Transmission Top Case.................................................................................. 164
63-54 Transmission Top Case — Damage Limits and Repair ................................. 165
63-55 Transmission Main Case ................................................................................ 174
63-56 Main Bevel Gear Case — Damage Limits ...................................................... 175
63-57 Main Support Case (212-040-054-013) and Lift Link Fitting —
Damage Limits................................................................................................ 181
Damage Limits................................................................................................ 186
Damage Limits................................................................................................ 191
63-60 Planetary Ring Gear — Damage and Wear Limits ......................................... 198
63-61 Upper Planetary Assembly ............................................................................. 202
63-62 Upper Planetary Assembly — Wear Limits .................................................... 206
63-63 Upper Planetary Pinion — Wear Patterns ...................................................... 207
63-64 Bearing Retainer — Damage Limits ............................................................... 208
63-65 Lower Planetary Assembly ............................................................................. 211
63-66 Lower Planetary Assembly — Wear Limits .................................................... 216
63-67 Lower Planetary Assembly — Wear Patterns ................................................ 217
63-68 Main Input Gear Quill (204-040-362-103)....................................................... 222
63-69 Main Input Gear Quill Case (204-040-386-001) — Damage Limits................ 224
63-70 Spiral Bevel Gear Mounting Holes (204-040-701) — Damage Limits ............ 226
63-71 Main Input Gear Quill (204-040-386-001) — Wear Patterns .......................... 227
63-72 Main Input Gear Quill Shaft — Magnetic Inspection Areas ............................ 229
63-73 Main Input Gear Quill — Wear Limits ............................................................. 230
63-74 Main Input Gear Quill (204-040-362-103) — Shimming ................................. 233
63-75 Main Input Gear Quill (412-040-362-101 and -103) ....................................... 236
63-76 Main Input Gear Quill Case (412-040-385-101) — Damage Limits................ 238
63-77 Main Input Gear Quill (412-040-701-101) — Damage Limits ......................... 241
63-78 Main Input Gear Quill — Magnetic Inspection Areas...................................... 246
63-79 Main Input Gear Quill — Wear Limits ............................................................. 248
63-80 Main Input Gear Quill (412-040-362-101) — Shimming ................................. 251
63-81 Main Input Quill (212-040-263-107)................................................................ 254
63-82 Wrench Set (T101588) — Application ............................................................ 255
63-83 Plate Set (T101912) — Application ................................................................ 256
63-84 Main Input Drive Quill Pinion — Damage Limits............................................. 258
63-85 Main Input Drive Quill Sleeve — Damage Limits............................................ 259
63-86 Main Input Quill Cap Assembly — Damage Limits ......................................... 260
63-87 Main Input Quill Seal Retainer — Damage Limits .......................................... 261
63-88 Main Input Quill Curvic Coupling Adapter — Damage Limits ......................... 262
63-00-00
Page 8 Rev. 13 12 JAN 2021 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
FIGURES (CONT)
Figure Page
Number Title Number
63-89 Magnetic Seal — Damage Limits ................................................................... 264

63-90 Seal Case and Carbon Sealing Element (412-040-111-105) —
Damage Limits................................................................................................ 265
63-91 Magnetic Seal (412-040-111-105) — Damage Limits .................................... 268
63-92 Main Input Quill Pinion — Copper Plating Area.............................................. 272
63-93 Main Input Quill Processing Requirements..................................................... 273
63-94 Pinion and Triplex Bearing Etching ................................................................ 276
63-95 Main Input Quill Assembly (212-040-263-101) ............................................... 281
63-96 Main Input Quill Assembly (412-040-263-101) ............................................... 287
63-97 Wrench Set (412-240-001-101) — Application............................................... 288
63-98 Bearing Removal Tool Set (412-240-009-101) — Application........................ 289
63-99 Main Input Quill Pinion — Damage Limits ...................................................... 291
63-100 Main Input Quill Sleeve — Damage Limits ..................................................... 293
63-101 Main Input Quill Cap Assembly — Damage Limits ......................................... 295
63-102 Main Input Quill Seal Retainer — Damage Limits .......................................... 296
63-103 Input Adapter (412-040-136-101) — Damage Limits...................................... 297
63-104 Main Input Quill Assembly — Wear Limits...................................................... 298
63-105 Main Input Quill Pinion — Copper Plating Area.............................................. 302
63-106 Main Input Quill Processing Requirements..................................................... 303
63-107 Generator (or SYS 2 Hydraulic Pump) Drive Quill.......................................... 310
63-108 Generator (or SYS 2 Hydraulic Pump) Drive Quill — Wear Limits ................. 312
63-109 Generator (or SYS 2 Hydraulic Pump) Drive Quill Pinion Assembly —
Damage Limits................................................................................................ 313
63-110 Generator (or SYS 2 Hydraulic Pump) Drive Quill Sleeve — Damage Limits 315
63-111 Offset Accessory Drive Quill ........................................................................... 322
63-112 Offset Accessory Drive Quill — Wear Limits .................................................. 324
63-113 Offset Accessory Drive Quill Gear — Wear Pattern ....................................... 325
63-114 Accessory and Tail Rotor Drive and Sump Assembly .................................... 330
63-115 Accessory and Tail Rotor Drive Case Assembly ............................................ 335
63-116 Accessory and Tail Rotor Drive Case Assembly — Damage Limits............... 338
63-117 Rotary Oil Pump ............................................................................................. 346
63-118 Oil Filter (Internal) ........................................................................................... 349
63-119 Full Flow Debris Monitor ................................................................................. 350
63-120 Accessory and Tail Rotor Drive Quill Assembly ............................................. 352
63-121 Accessory and Tail Rotor Drive and Sump Assembly — Damage Limits....... 355
63-122 Tail Rotor Drive Quill Assembly ...................................................................... 361
63-123 Tail Rotor Drive Quill Sleeve — Damage and Wear Limits ............................ 364
63-124 Tail Rotor Drive Coupling — Damage Limits .................................................. 369
63-125 Seal (204-040-611) Installation Workaid ........................................................ 374
63-126 Lubrication of Tail Rotor Driveshaft Coupling Workaid ................................... 375
63-127 Tail Rotor Drive Quill Assembly ...................................................................... 377
63-128 Tail Rotor Drive Quill (212-040-365-113) — Damage Limits .......................... 379
63-129 Single Boost (or System 1) Hydraulic Drive Quill Assembly........................... 386
63-130 Single Boost (or System 1) Hydraulic Drive Quill — Damage Limits.............. 388
63-131 Rotor Brake Drive Quill ................................................................................... 394
63-132 Rotor Brake Quill — Wear Limits.................................................................... 396
63-133 Rotor Brake Disc Inspection Arbor ................................................................. 398
63-00-00
BHT-412-CR&O-3
FIGURES (CONT)
Figure Page
Number Title Number
63-134 Rotor Brake Quill Sleeve — Rework Limits .................................................... 400

63-135 Rotor Brake Quill Retainer — Rework Limits ................................................. 403
63-136 Rotor Brake Quill Flange — Rework Limits .................................................... 405
63-137 Transmission Mount Friction Damper Assembly ............................................ 411
63-138 Transmission Lift Link — Damage Limits ....................................................... 412
63-139 Pylon Isolation Mount Bolt — Damage Limits ................................................ 414
TABLES
Table Page
Number Title Number
63-1 Mast Assembly Versus Helicopter Serial Number .......................................... 52A

63-1A Mast Assembly — Configuration .................................................................... 52B
63-1B Mast Assembly — Configuration .................................................................... 52E
63-1C Mast Pole Assembly — Configuration ............................................................ 52G
63-1D Mast Pole Assembly — Configuration ............................................................ 52H
63-1E Main Bevel Gear Case — Required Dimensions ........................................... 180
63-2 Chip Detector Boss Measurements and Machining Requirements ................ 340
63-3 Magnetic Particle Inspection........................................................................... 415
63-00-00
BHT-412-CR&O-3
MAIN DRIVESHAFT
63-1. MAIN DRIVESHAFT (212-040-005-103) 4. Insert the wrench (T101306) in the nut (3,
Figure 63-2).
NOTE
5. Install the wrench set (T101588) on the outer
For helicopters S/N 36020 and subsequent coupling (8) and install the two washers (6) and the
to include S/N 46400 through 46499 and nuts (7).
helicopters modified by 412-570-001-103,
refer to paragraph 63-10. 6. Insert the extension bar (L-122) through the plate
of the wrench set (T101588) and engage the wrench
63-2. MAIN DRIVESHAFT — DISASSEMBLY (T101306). Hold the wrench set (T101588) and loosen
the nut (3).
SPECIAL TOOLS REQUIRED 7. Remove the tools.
NUMBER NOMENCLATURE 8. Remove the nut (6, Figure 63-1) and the spring
retainer (7).
L-122 Extension Bar,
3/4 Drive
NOTE
T101306 Wrench The recording of coupling serial numbers to
facilitate reassembly is no longer required.
T101588 Wrench Set
It is a recommended maintenance practice
to match the serial numbers of the
couplings in order to reassemble couplings
NOTE
into original position.
If the main driveshaft is being
disassembled for replacement of parts, 9. Remove the inner coupling (8) and the outer
instead of overhaul, disassemble only to coupling (9), as an assembly, and separate the
the extent necessary to replace the parts. couplings.
1. Place the driveshaft in a suitable support. 10. Remove the eight bolts (13), thin aluminum
washers (12), boot assembly (11), and packing (10).
2. Remove the retaining ring (1, Figure 63-1), Discard the packing.
retainer plate (2), packing (3), and centering spring (4).
Discard the packing. 11. Remove the outer coupling (17) and associated
parts in the same manner outlined in step 1 through
3. Remove the locking spring (5) from the nut (6). step 10.
63-00-00
Export Classification C, ECCN EAR99 16 JUN 2017 Rev. 11 Page 11
BHT-412-CR&O-3
17
16 A
13 T 1
15
14
11 12
9 10
8
6 T 2
5 7
4
3
2
1 9
A 11
16
1. Retaining ring
2. Retainer plate SECTION A-A
3. Packing
4. Centering spring
5. Locking spring
6. Nut
7. Spring retainer
8. Inner coupling
9. Outer coupling
10. Packing
11. Boot assembly
12. Thin aluminum washer SYSTEM LUBRICANT (C-015)
13. Bolt
14. Serial and part number nameplate
50 TO 70 IN-LBS
15. Optional location for serial number T 1 (5.65 TO 7.91 Nm)
and part number nameplate
16. Driveshaft
100 TO 200 FT-LBS
17. Outer coupling T 2 (136 TO 271 Nm)
412_CRO_63_0001
Figure 63-1. Main Driveshaft Assembly (212-040-005-103)
63-00-00
BHT-412-CR&O-3
10
3 T
9 4
8
5
7 6
1. Extension bar (L-122)

2. Wrench (T101306)
3. Nut
4. Inner coupling
5. Wrench set (T101588)
6. Steel washer
7. Nut
8. Outer coupling
9. Rubber boot
10. Main driveshaft
100 TO 200 FT-LBS

T (136 TO 271 Nm)
412_CRO_63_0002_c01
Figure 63-2. Wrench (T101306), Wrench Set (T101588), and Extension Bar (L-122) — Tool Application
63-00-00
BHT-412-CR&O-3
63-3. MAIN DRIVESHAFT — CLEANING 63-5. MAIN DRIVESHAFT — CONDITIONAL

INSPECTION
MATERIALS REQUIRED 1. Visually inspect the driveshaft for external

damage.
Refer to BHT-ALL-SPM for specifications.
2. Visually inspect the inner and outer couplings for
NUMBER NOMENCLATURE
chipped, dented, or cracked teeth or for galling caused
C-304 Drycleaning Solvent by excessive misalignment. Superficial damage on the
coupling teeth is permitted if not detected with a
C-516 Clean Cloth 0.020-inch (0.51-mm) spherical radius inspection
probe. Galling damage and/or evidence of overheating
is cause to replace both the inner and outer couplings
on that end of driveshaft.
CAUTION
3. With the inner and outer couplings (8 and 9,
Figure 63-1) removed from both ends of the shaft,
DO NOT USE DRYCLEANING SOLVENT mount the shaft on centers and check shaft runout.
(C-304) INSIDE ASSEMBLED COUPLING. Runout shall not exceed 0.020 inch (0.51 mm) Total
I F A L L T R A C E S O F D RY C L E A N I N G Indicated Runout (TIR) at the mid-point of the shaft or
SOLVENT ARE NOT REMOVED FROM
0.010 inch (0.25 mm) TIR when checked at 7.0 inches
PARTS, THE SOLVENT RESIDUE MAY
(178 mm) from either end.
PREVENT LUBRICANT FROM
ADHERING TO PARTS. CONTAMINATION
OF BOOTS WITH DRYCLEANING NOTE
SOLVENT WILL REQUIRE THE BOOTS
TO BE REPLACED. Any evidence of yielding exceeding the
limits of step 3, renders the entire main
1. Clean the driveshaft parts, except the boots, with driveshaft unserviceable and
drycleaning solvent (C-304). nonrepairable.
2. Dry the parts with dry filtered compressed air. 4. If no evidence of conditions of step 1 through
step 3 is found, accomplish the normal inspection
(paragraph 63-6).
3. Clean the boot assemblies (11, Figure 63-1) with
a clean cloth (C-516).
63-6. MAIN DRIVESHAFT — NORMAL
INSPECTION
4. Remove all traces of drycleaning solvent residue
from the inner and outer couplings (8 and 9) with a
clean cloth (C-516).
MATERIALS REQUIRED
63-4. MAIN DRIVESHAFT — INSPECTION
NOTE NUMBER NOMENCLATURE
If records or physical appearance of the C-464 India Stone

main driveshaft indicate that the assembly
has been subjected to an accident or
incident outside the realm of normal usage, 1. Inspect the driveshaft (16, Figure 63-1) in
perform a conditional inspection (paragraph accordance with Figure 63-3.
63-5). If the driveshaft does not require a
conditional inspection, proceed with the 2. Inspect the outer couplings (9 and 17,
normal inspection (paragraph 63-6). Figure 63-1) in accordance with Figure 63-4.
63-00-00
BHT-412-CR&O-3
ALTERNATE LOCATION
FOR NAMEPLATE
NAMEPLATE
B B
NUT
(204-040-184-001)
SEE DETAIL A SEE DETAIL A
DRIVESHAFT
(212-040-686-001)
USE 0.1920 IN. (4.877 mm)

DIAMETER PINS
E
B A C
3.290 TO 3.295 IN.
(83.57 TO 83.70 mm) C A B
D
NUT
SECTION B-B
DETAIL A
NOTES
1. Mechanical and corrosion damage limits on shaft are defined as follows:
EXTERNAL SURFACES:
Nicks and scratches Not exceeding 0.004 inch (0.10 mm) in depth are acceptable without repair.
running parallel to, or
within 15° of parallel to Not exceeding 0.008 inch (0.20 mm) in depth or 1.5 inches (38 mm) in length are
shaft axis. acceptable if polished out, provided total polished area does not exceed 10%
of circumference at any point.
Nicks and scratches not Not exceeding 0.004 inch (0.10 mm) in depth are acceptable on up to 100% of
running within 15° of the circumference of shaft if polished out.
shaft axis.
Not exceeding 0.008 inch (0.20 mm) in depth or 1.5 inches (38 mm) in length are
acceptable provided the total polished area does not exceed 10% of the
circumference at any point.
Corrosion pitting Not exceeding 0.008 inch (0.20 mm) in depth is acceptable provided it is
polished out. Maximum length of rework at any point must not exceed
1.5 inches (38 mm) nor cover more than 10% of the circumference at any point.
The maximum acceptable total reworked area is 4.0 square inches (2581 mm2).
412_CRO_63_0003a
Figure 63-3. Main Driveshaft (212-040-686-001) and Nut (204-040-184-001) — Damage Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
INTERNAL SURFACES:
Corrosion pitting Not exceeding 0.005 inch (0.13 mm) on inside diameter in area designated “A” on
Section B-B are acceptable without polishing out. Pits exceeding 0.005 inch (0.13 mm)
are acceptable if completely polished out and depth after polishing out does not
exceed 0.010 inch (0.25 mm). Minimum radius in rework area(s) is 0.50 inch (12.7 mm).
Surface finish rework area must be 63 RHR (Roughness Height Rating) or better.
Corrosion pitting Not exceeding 0.010 inch (0.25 mm) on inside diameter in area designated “B” on
Section B-B are acceptable without polishing out. Pits exceeding 0.010 inch (0.25 mm)
are acceptable if completely polished out and minimum wall thickness after rework is
0.060 inch (1.52 mm). Rework must completely clean up pits. Minimum radius in
rework area(s) is 0.090 inch (2.29 mm). Surface finish in rework area must be 63 RHR
or better.
Corrosion pitting Not exceeding 0.030 inch (0.76 mm) on inside diameter in area designated “C” on
Section B-B are acceptable without polishing out. This area is the last two threads.
Superficial corrosion Only superficial corrosion which can be removed by hand polishing with an abrasive
pad (C-407) or with fine steel wool is allowed in area “D”.
Corrosion pitting on nut Not exceeding 0.030 inch (0.76 mm) on nut in area designated “E” on Section B-B is
acceptable.
2. Thread damage:
Depth: 1/4 of thread
Length: 0.50 inch (12.7 mm)
Number: One
3. Spline wear/damage limits:
The spline wear limits are provided to show the required fit between the driveshaft and inner couplings. It is
not intended that spline wear be measured as a prescribed overhaul procedure. Inspect splines for wear and
damage visually. If there is evidence of wear, measure dimension over pins as shown in Detail A. Spline
wear in excess of limit shown on Detail A and/or spline damage such as chipped spline teeth is not
acceptable. Very small nicks and dents are acceptable if polished out with fine India stone (C-464).
4. Inspect two nameplates for secure installation and legible markings. Only one nameplate should have
markings. The second nameplate should be installed face down 180° opposite the nameplate with markings.
5. Inspect driveshaft by magnetic particle method. Refer to BHT-ALL-SPM. No cracks are acceptable.
6. Contact Bell Helicopter Textron Product Support Engineering (PSE) if corrosion damage is in excess of
established limits.
412_CRO_63_0003b
Figure 63-3. Main Driveshaft (212-040-686-001) and Nut (204-040-184-001) — Damage Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
SEE DETAILS A, B, WIRE FEELER GAUGE

E, F and G MAXIMUM 0.0055 IN.
(0.140 mm)
POSITION METAL STRAIGHT
EDGE PERPENDICULAR TO FACE
SPLINE TEETH OF TOOTH BEING INSPECTED
WEAR AREA
0.1728 IN. 4.7657 TO 4.7703 IN.

(4.389 mm) (121.049 TO 121.166 mm)
PINS
DETAIL A
DETAIL B
SEE DETAIL D
1.081 IN. (27.46 mm)
REF (4TH GROOVE)
6000-1 TEMP-PLATE (RED BORDER)
2 REQUIRED 180° APART (LOCATED 90° FROM
THE 6000-2 TEMP-PLATES)
SLIGHT LIFTING
OF TEMP-PLATE IS
DETAIL D ACCEPTABLE IN
THIS AREA ONLY
6000-2 TEMP-PLATE (YELLOW BORDER)

2 REQUIRED-180° APART
(LOCATED 90° FROM THE 6000-1 TEMP-PLATES)
VIEW C
412_CRO_63_0004a
Figure 63-4. Main Driveshaft Outer Coupling (212-040-005-103) — Damage Limits (Sheet 1 of 4)
63-00-00
BHT-412-CR&O-3
PITTING
PEENING
CONTACT AREA
DETAIL E DETAIL F
SHOWS MAXIMUM ALLOWABLE PITTING OF THIS CONDITION IS ACCEPTABLE ON NOT MORE THAN 15
CONTACT AREA. REJECT FOR PITTING OF THIS CONSECUTIVE TEETH OF 35 TEETH TOTAL. MAXIMUM
TYPE DETECTABLE BY 0.020 INCH (0.51 mm) ACCEPTABLE DEPTH OF PEENING OR WEAR
RADIUS PROBE IN 0.0005 INCH (0.013 mm)
D H
A
E
F
G B C
OUTBOARD
LAND
DETAIL G
412_CRO_63_0004b
63-00-00
BHT-412-CR&O-3
CAUTION
COUPLING SHALL BE MASKED TO PREVENT BEAD IMPINGEMENT ON ANY SPLINE TOOTH SURFACE AND
CURVIC TOOTH SURFACE AND TO PREVENT REMOVAL OF CADMIUM PLATING OUTER REPAIR AREA.
NOTES
1. Perform over-temp inspection in accordance with applicable Maintenance and CR&O manuals and the following
instructions. Scrap affected male and female couplings if any of the conditions listed below exist or if required
by applicable CR&O manual inspection criteria.
a. The cadmium plating on the outer coupling is discolored (circumferential tan or light brown band) or
blistered.
b. The gear teeth of either coupling are discolored (brown or blue) in the normally bright contact patterns.
c. Under 5x to 10x magnification, the surfaces of the gear teeth of either the inner or the outer coupling exhibit
signs of metal smearing or tearing in the contact patterns.
d. The grease is very viscous (thick) and has a strong pungent odor.
e. If none of the above conditions exist the coupling may be reassembled in accordance with the applicable
CR&O manual and returned to service following replacement of the “TEMP-PLATE”.
2. Inspect area where retaining ring contacts outer coupling. Damage that could cause lubricant leakage is not
acceptable.
3. Inspect outer coupling by magnetic particle method (BHT-ALL-SPM). No cracks are acceptable.
4. Spline teeth wear/damage limits:
The spline teeth wear limits are provided to show required fit between outer coupling and inner coupling. It is
not intended that spline wear be measured as prescribed overhaul procedure if there are no visual indications
of wear. Inspect splines for wear and damage visually. Use a white card or similar material to reflect light. If
there is evidence of wear, measure dimension between pins as shown on Detail A and/or Detail B as indicated
by appearance of splines. Spline wear in excess of limit shown on Detail A, or wear in excess of limit shown on
Detail B, and/or spline damage is not acceptable. If outer coupling is not acceptable, mating inner coupling may
also not be acceptable.
Inspect spline area (Area A, Detail G) for corrosion and spalled, chipped, pitted or dented teeth. Using a
0.020 inch (0.51 mm) radius probe, inspect coupling teeth faces. Flaws exceeding 0.015 inch (0.38 mm) across in
any direction or which can be detected with probe are cause for rejection. Small defects, which cannot be felt
with probe, are acceptable on not more than three consecutive teeth or total of six teeth. Light corrosion or
corrosion staining which can be removed by hand using abrasive pad (C-407) is acceptable. Do not chemically
remove corrosion products. Refer to Details E and F.
Inspect Area B (Detail G) for corrosion and mechanical damage. Light corrosion and scratches are acceptable
provided damage does not exceed 0.002 inch (0.05 mm) nor affect more than 25% of total surface area after
clean up. Rework damaged areas by hand using 400 grit abrasive cloth (C-423).
Surface finish after rework shall be 63 RMS or better.
412_CRO_63_0004c
63-00-00
BHT-412-CR&O-3
NOTES
4. Spline teeth wear/damage limits (continued)
Inspect Area C for corrosion, pitting, wear, and mechanical damage. Light corrosion is permitted providing it does
not exceed 0.002 inch (0.05 mm) in depth nor affect more than 40% of surface area after clean up.
Remove corrosion from Area C by glass bead blasting affected surface in a dry process.
Inspect edges of retaining ring groove to ensure edge radius or corner break does not exceed 0.010 inch (0.25 mm)
after rework. Light scratches 0.010 inch (0.25 mm) or less in depth are acceptable across narrow and outboard of
retaining groove. Remove raised material from around acceptable scratches using fine India stone (C-464).
Inspect Area D for corrosion and mechanical damage. Light fretting corrosion is acceptable provided it does not
exceed 0.002 inch (0.05 mm) in depth nor affects more than 50% of surface area between any two threaded holes.
Remove acceptable corrosion from Area D by glass-bead blasting affected surface in a dry process.
Allowable mechanical damage in Area D is limited to nicks, dents, and scratches at flange outer diameter which do
no exceed 0.010 inch (0.25 mm) in depth nor more than 0.5 inch (13 mm) in width after repairs. Polish out acceptable
damage using 0.125 inch (3.18 mm) minimum fillet radii. Maintain surface finish at 63 RMS or better. Damage
occurring more than once in any 2.0 inches (51 mm), or more than eight places around circumference is cause for
rejection of coupling. Remove any acceptable raised material around circumference by hand using India stone
(C-464). Maintain surface finish at 63 RMS or better.
Inspect Area E for corrosion and mechanical damage. No corrosion or mechanical damage is allowed.
Inspect washer seat areas surrounding each bolt hole. Corrosion not exceeding 0.002 inch (0.05 mm) in depth is
acceptable providing it is removed.
Inspect fillet area at coupling cylinder intersection for indentations at bolt hole locations. Any such indications are
unacceptable and are cause for rejection of coupling.
Repair acceptable corrosion damage around bolt holes by glass-bead blasting the affected surface in a dry process.
Inspect Area F for corrosion and mechanical damage. Allowable mechanical damage in Area F is limited to nicks,
dents, and scratches at flange outer diameter which do not exceed 0.010 inch (0.25 mm) in depth nor more than
0.5 inch (13 mm) in width after repairs. Polish out acceptable damage using 0.125 inch (3.18 mm) minimum fillet
radii. Maintain surface finish at 63 RMS or better. Damage occurring more than once in any 2.0 inches (51 mm), or
more than eight places around circumference is cause for rejection of coupling. Remove any acceptable raised
material around circumference by hand using fine India stone (C-464). Maintain surface finish at 63 RMS or better.
Visually inspect curvic coupling (Area G) for spalled, chipped, pitted, dented or corroded teeth. Only light corrosion
or corrosion staining which can be removed by hand using abrasive pads (C-407) is acceptable.
Inspect Area H for corrosion and mechanical damage. No damage is permitted.
Inspect bolt holes for corrosion. Corrosion pitting which does not exceed 0.010 inch (0.25 mm) in depth or affect
more than 20% of wall area after clean up is acceptable.
Inspect threaded holes for damage. No damage allowed.
Inspect entire coupling for cracks using magnetic particle inspection. No cracks allowed.
412_CRO_63_0004d
63-00-00
BHT-412-CR&O-3
3. Inspect the inner coupling (8, Figure 63-1) and 9. Inspect the retaining ring (1) and the similar
the similar coupling at the opposite end of the retaining ring at the opposite end of the driveshaft for
driveshaft in accordance with Figure 63-5. deformation. Any damage that can be detected
visually is not permitted.
4. Inspect the nut (6, Figure 63-1) and the similar
nut at the opposite end of the driveshaft in accordance 10. Inspect the spring retainer (7) for corrosion
with Figure 63-3. damage. Pits to a maximum depth of 0.010 inch
(0.25 mm) are permitted. Chemically remove
corrosion products. Do not polish out.
NOTE
It is recommended that the boot assembly NOTE
(11, Figure 63-1) be replaced each 1200
The following procedure is to be
hours of operation.
accomplished in conjunction with the
2500-hour or 3000-hour overhaul and
5. Inspect the boot assembly (11) and the similar
conditional inspection. This procedure is
boot assembly at the opposite end of the driveshaft for not required if the driveshaft is
cracks, tears, wrinkles, and bands of heavy wear disassembled for lubrication only.
against the shroud. No defects are permitted.
11. Inspect the retainer plate (2), centering spring (4),
6. Inspect the packing groove on the retainer plate and spring retainer (7) with the fluorescent penetrant
(2) and the surface in the outer couplings (9 and 17) method (BHT-ALL-SPM).
contacted by the packing for nicks or burrs. Remove
any such defects with a fine India stone (C-464). 12. Inspect the following parts by magnetic particle
Carefully remove any foreign material. If nicks deep inspection. Demagnetize the parts after the magnetic
enough to permit passage of grease are found, particle inspection. Refer to Table 63-3 and the
replace the defective part. Inspect the area that BHT-ALL-SPM for the procedure.
contacts the retaining ring (1) for excessive wear.
7. Inspect the locking spring (5) and the similar FIGURE 63-1
spring at the opposite end of the driveshaft for NOMENCLATURE CODE
INDEX NO.
deformation. Any damage that can be detected
visually is not permitted. 6 Nut M
8 Inner Coupling M
8. Inspect the centering spring (4) and the similar
spring at the opposite end of the driveshaft for 9 Outer Coupling M
visually is not permitted. 16 Driveshaft M
63-00-00
BHT-412-CR&O-3
GEAR TEETH
AREA A
AREA D AREA C
0.1440 IN. (3.658 mm) PINS

SPLINE TEETH 5.1680 IN. TO 5.1841 IN.
AREA B (131.267 TO 131.676 mm)
SEE DETAIL C
A A
2.8427 TO 2.8464 IN.
(72.205 TO 72.298 mm)
SURFACE E 0.1440 IN. (3.658 mm) PINS

WITH FLAT GROUND TO
SECTION A-A 0.115 IN. (2.92 mm)
VIEW B
A. Typical acceptable wear pattern on the

inner coupling, engine end.
B. Typical acceptable wear pattern on the

inner coupling, transmission end.
C. Typical unacceptable wear pattern on the

inner coupling, transmission or engine
end.
DETAIL C
412_CRO_63_0005a_c01
Figure 63-5. Main Driveshaft Inner Coupling (212-040-005-103) — Damage Limits (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3
DIMENSIONS
MINIMUM MAXIMUM
INSPECTION INCH INCH
AREA CHARACTERISTIC METHOD (millimeters) (millimeters)
A Gear teeth wear Measure over 0.1440 inch 5.1680 5.1841

(3.658 mm) diameter pins (131.267) (131.6761)
A Indentations, pitting Visual/feel See Note 1a

scratches and
scoring
B Spline teeth wear Measure between 0.1440 2.8427 2.8464

inch (3.6576 mm) diameter (72.2046) (72.2986)
pins (see text)
A, B Corrosion Visual See Note 1b
A, B Chip, broken or Visual None allowed

missing teeth
mechanical damage
C, D Corrosion pitting or Visual/measure See Note 1c

mechanical damage
E Mechanical damage Visual See Note 1e
Undesignated Corrosion pitting or Visual None allowed

areas mechanical damage
All Cracks Magnetic particle None allowed
412_CRO_63_0005b
63-00-00
Export Classification C, ECCN EAR99 17 SEP 2014 Rev. 9 Page 23
BHT-412-CR&O-3
NOTE
1. Spline teeth and gear teeth wear/damage limits:
The spline teeth and gear teeth wear limits are provided to show required fit between inner coupling, outer
coupling, and driveshaft. It is not intended that spline teeth and gear teeth wear be measured as prescribed
overhaul procedure. Inspect teeth for wear and damage visually. Use white card or similar material to reflect
light. If there is evidence of wear on gear teeth, measure dimension over pins as shown on Detail B. Also
compare wear patterns with patterns shown on Detail C. If there is evidence of wear on inner splines, measure
dimensions between pins as shown on Detail B. Wear in excess of limits shown on Detail B is not acceptable.
Very small nicks and dents are acceptable if polished out with fine India stone (C-464).
a. Using a 0.020 inch (0.51 mm) radius probe, inspect coupling teeth faces (Area A) for indentations, pitting,
scratches, or scoring. Flaws exceeding 0.015 inch (0.38 mm) across in any direction or which can be
detected with probe, are cause for rejection. Small defects, which cannot be felt with probe, are acceptable
on not more than three consecutive teeth or six total teeth. Inspect coupling teeth for non-corrosion pits,
indentations, or scratches. Pits and indentations no larger than 0.030 inch (0.76 mm) across the largest
dimension and scratches not wider than 0.015 inch (0.38 mm) with only one of the damage per tooth.
b. Inspect areas A and B for corrosion. Light corrosion or corrosion staining which can be removed by hand
using abrasive pad (C-407) is acceptable. Do not chemically remove corrosion deposits.
c. Using a 0.1440 inch (3.658 mm) diameter pin with a flat side, ground to 0.1150 inch (2.921 mm) (see Detail B),
measure spline wear (Area B).
d. Inspect areas C and D for corrosion pitting and mechanical damage. Damage shall not exceed 0.005 inch
(0.13 mm) in depth and not affect more than 10% of the total area of any surface after clean up. Polish out
acceptable damage to 0.250 inch (6.35 mm) minimum fillet and blend radii.
Surface finish in reworked areas shall be 63 rms or better.
e. Inspect surface E. Nicks and dents which do not exceed 0.005 inch (0.13 mm) in depth nor are located within
90° apart are acceptable. Remove raised material with fine India stone (C-464) until flush with surrounding
surface.
f. Inspect coupling by magnetic particle method. No cracks are permitted.
412_CRO_63_0005c
63-00-00
Page 24 Rev. 9 17 SEP 2014 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
63-7. MAIN DRIVESHAFT — REPAIR deformed, or corrosion pitting is beyond the permitted
limits.
MATERIALS REQUIRED 7. Replace the parts that exceed the wear limits of
Figure 63-3, Figure 63-4, and Figure 63-5.
8. With abrasive cloth or paper (C-406), polish out
NUMBER NOMENCLATURE mechanical and corrosion damage on the driveshaft
(16, Figure 63-1) that is within the limits shown in
C-108 Cadmium Plating
Figure 63-3. Blend the repaired area to a minimum
Solution
radius of 0.50 inch (12.7 mm). The finished repair
C-208 Epoxy/Zinc Coating must be 32 RHR or better (BHT-ALL-SPM).
C-304 Drycleaning Solvent
C-309 MEK CAUTION
C-318 Cleaning Compound

DO NOT ALLOW CADMIUM PLATING
C-406 Abrasive Cloth or SOLUTION TO CONTACT ANY SPLINE
Paper TOOTH SURFACE. DO NOT APPLY ANY
S U P P L E M E N TA R Y C H R O M AT E
C-407 Abrasive Pad TREATMENT.
C-426 Masking Tape 9. Touch up repair areas with cadmium plating
solution (C-108). Use only the brush cadmium plating
C-464 India Stone
procedure defined in the BHT-ALL-SPM.
C-516 Clean Cloth
10. Polish out very small nicks and dents on the
driveshaft spline teeth with a fine India stone (C-464).
1. Replace all the parts that fail the magnetic
particle inspection.
11. Replace missing or illegible nameplates (14 or
15, Figure 63-1). Refer to the BHT-ALL-SPM for
2. Replace all the parts that have damaged threads. nameplate bonding instructions.
3. Replace the inner and outer couplings (8 and 9, a. Stamp the required information on a new
Figure 63-1) if evidence of overheating is found. nameplate. Bond the nameplate to the driveshaft.
b. Bond the unmarked nameplate, face down, to

NOTE
the driveshaft, 180° apart from the marked nameplate
It is recommended that the boot assembly for balance purposes.
(11) be replaced each 1200 hours of
operation. 12. Polish out very small nicks and dents on the
spline teeth of the outer couplings with a fine India
4. Replace the boot assembly (11) if cracked, torn, stone (C-464).
wrinkled, or excessive wear with the shroud is noted.
5. Dress off burrs on the retainer plate (2) with spline teeth of the inner couplings with a fine India
abrasive cloth or paper (C-406) to ensure proper stone (C-464).
packing seat.
14. Paint the inside of the driveshaft (Figure 63-6,
6. Replace the retaining ring (1), spring retainer (7), View A) only if the existing finish has been damaged.
centering spring (4), and locking spring (5) if damaged, Comply with the following:
63-00-00
BHT-412-CR&O-3
a. Clean the inside of the driveshaft with inside surface. Drain excess coating material from the
drycleaning solvent (C-304). driveshaft.
b. Allow solvent to dry.

NOTE
c. Prepare epoxy/zinc coating (C-208) as The material drained from the driveshaft
follows: into a clean container may be used on
other parts if the 8-hour pot life is not
exceeded.
NOTE
The epoxy/zinc coating material is supplied f. Keep the driveshaft vertical for 1 hour after
in a three-component kit. coating to prevent coating from puddling on one side.
(1) Measure an adequate volume of base g. The coating will reach final cure in 72 hours at
material to paint the number of driveshafts that can be ambient temperature.
painted in 8 hours or less.
h. The coating may be heat cured as follows:
(2) Add an equal volume of the accelerator/
thinner and mix thoroughly. (1) Dry at ambient conditions for 2 hours.
(3) Weigh the mixed material.
(2) Cure at 150 to 160°F (66 to 71°C) for a
minimum of 1 hour.
(4) Calculate the required amount of zinc
powder to produce 20 to 25% (weight) of the mixed
i. Remove the masking tape.
material. For instance, each 100 grams of base/
thinner mixture requires 20 to 25 grams of zinc
powder. j. Touch up small areas that may have been
inadvertently missed during initial application.
(5) Weigh out the required amount of zinc
powder and add to the base/thinner mixture with k. The coating, after drying, must be free of pits,
constant stirring to achieve a uniform mixture. mud cracking, craters, blisters, and other surface
irregularities. The metallic filler must be evenly
(6) Allow the mixed material to set for a dispersed to present a relatively uniform gray
minimum of 1 hour at room temperature prior to use. appearance. Some dark streaks in coatings applied by
Discard the mixed material if not used within 8 hours the fill and drain process caused by heavier zinc
after mixing. concentration are permitted.
d. Mask off areas of the driveshaft outside 15. Replace the visual over temperature indicator
Area A (Figure 63-6) with masking tape (C-426). (TEMP-PLATES) on the coupling (Figure 63-4) if
mutilated or discolored, as follows:
e. Apply one coat of epoxy/zinc coating (C-208)
to Area A. Seal or plug one end of the driveshaft. Flow a. Remove damaged TEMP-PLATES with MEK
epoxy/zinc mixture into the hollow driveshaft while you (C-309) and a clean cloth (C-516). Wipe dry with a
turn the driveshaft. Make sure to fully coat the entire clean cloth (C-516) before MEK evaporates.
63-00-00
BHT-412-CR&O-3
PAINT IS REQUIRED
ON INSIDE DIAMETER
IN AREA A
AREA A
DIAMETER DIAMETER
B C
412_CRO_63_0006
Figure 63-6. Main Driveshaft (212-040-005-103) — Paint Area
63-00-00
BHT-412-CR&O-3
WORKING WITH TEMP-PLATES. DO NOT

PRESS OR RUB THE TEMP-PLATE WITH
CAUTION
BARE FINGERS DURING INSTALLATION
ON COUPLING AS THIS WILL
CONTAMINATE SURFACE.
BONDING SURFACE AND TEMP-PLATES
MUST BE FREE OF ALL
a. Remove the protective backing from the
C O N TA M I N AT I O N . ANY
TEMP-PLATE and carefully position onto the prepared
CONTAMINATION COULD ALLOW THE
surface.
T E M P - P L AT E S T O C O M E O F F O R
INDICATE FALSE TEMPERATURES.
b. With a clean cloth (C-516), work the
b. Prepare the coupling surface for bonding by TEMP-PLATES into the contour of the coupling. Make
scrubbing the area with a clean cloth (C-516) sure the TEMP-PLATES are in full contact with the
moistened with MEK (C-309). Wipe dry before MEK coupling surface.
evaporates. The surface should be at least 0.050 inch
(1.27 mm) larger than the TEMP-PLATE.
NOTE
c. Accomplish a water break free test on the Apply epoxy coating to the TEMP-PLATES
prepared bonding surface by applying distilled or immediately following the installation of the
demineralized water from a suitable dispenser TEMP-PLATES on each coupling.
(squeeze bottle). The water must flow into a
continuous film without gathering into distinct water 17. Install epoxy coating over the TEMP-PLATES as
droplets within 25 seconds after application. Wipe dry follows:
with a clean cloth (C-516). If the coupling bonding
surface does not meet the water break free test and
you have ensured the cleaning materials are not
contaminated, clean the coupling bonding surfaces as CAUTION
follows:
THE USE OF ANY EPOXY ADHESIVE

NOTE OTHER THAN SPECIFIED IS NOT
Follow the manufacturer’s AUTHORIZED.
recommendations for proper water
mixtures. a. Mix epoxy coating per manufacturer
recommendations.
(1) Scrub the coupling bonding surface with
a clean cloth (C-516) and cleaning compound (C-318). b. With a soft bristled brush (artist brush),
Follow the cleaning with a thorough water rinse. vigorously mix the epoxy. A few drops of
recommended thinner may be added during mixing to
(2) Thoroughly dry the coupling surface and reduce the viscosity to a level that permits uniform
repeat the water break free test as stated in step 15, brush application of the mixture and will not run when
substep c. applied to a vertical surface. The final viscosity of the
mixture should be similar to a heavy bodied paint.
16. Install the TEMP-PLATES as follows:
CAUTION
CAUTION
TOO THIN OF AN EPOXY COATING MAY

IN ORDER TO PREVENT SEEP INTO TEMP-PLATE CAUSING
C O N TA M I N AT I O N O F T E M P - P L AT E INDICATOR DOTS TO TURN BLACK, IN
ADHESIVE BACK, MAKE SURE HANDS WHICH EVENT, TEMP-PLATE MUST BE
ARE THOROUGHLY CLEANED BEFORE REPLACED.
63-00-00
BHT-412-CR&O-3
c. Uniformly apply epoxy coating over the 19. Treat repaired cadmium plated surfaces with
TEMP-PLATE to a thickness of approximately 0.002 to cadmium plating solution (C-108). Refer to the
0.004 inch (0.05 to 0.10 mm). The coating should BHT-ALL-SPM for procedures.
totally cover the surface of TEMP-PLATE and extend
approximately 0.250 inch (6.35 mm) beyond the 63-8. MAIN DRIVESHAFT — LUBRICATION
edges of the TEMP-PLATE.
The inspection of driveshaft couplings and the internal
18. Cure the epoxy coating as follows: inspection of the driveshaft for corrosion is required
when the driveshaft is lubricated at the interval
designated in the BHT-412-MM-2, Chapter 5. Refer to
paragraph 63-2 through paragraph 63-4, paragraph
CAUTION 63-8, and paragraph 63-9 for instructions to
disassemble, clean, inspect, lubricate, and assemble
the driveshaft.
DO NOT EXPOSE EPOXY COATING TO
OIL, GREASE, CLEANING SOLVENTS,
63-9. MAIN DRIVESHAFT — ASSEMBLY
OR OTHER CHEMICALS DURING CURE.
a. Allow the epoxy coating to cure at room

temperature (60 to 100°F (16 to 38°C)) for a minimum SPECIAL TOOLS REQUIRED
of 6 hours prior to helicopter operation. For best
results, allow to cure overnight.
NUMBER NOMENCLATURE
b. The epoxy coating total curing time can be
L-122 Extension Bar,
accelerated by allowing the epoxy coating to cure at
3/4 Drive
room temperature for 1 hour, then place the coupling
in a temperature controlled oven for 1 to 2 hours at a T101306 Wrench
temperature of 150 to 180°F (66 to 82°C). An alternate
source of heat can be used if the temperature does T101588 Wrench Set
not exceed 180°F (82°C).
NOTE MATERIALS REQUIRED

Following the cure, the TEMP-PLATE
should conform to the contour of the Refer to BHT-ALL-SPM for specifications.
coupling and be free of lifted edges.
NUMBER NOMENCLATURE
Indicating dots on the TEMP-PLATE must
remain the original white or light gray with C-015 Lubricant (Tube Pack)
no or partial black discoloration. Some
lifting at the extreme ends of C-405 Lockwire
TEMP-PLATES installed on grooved
couplings is permitted (Figure 63-4,
View A). Lifting is permitted only at the 1. Lubricate a new packing (10, Figure 63-1) with
bottom, as shown, and should not exceed lubricant (tube pack) (C-015) and install in the groove
0.030 inch (0.76 mm). in the boot assembly (11).
c. After curing time, accomplish an adhesion test

NOTE
by pressing a 1.0-inch (25-mm) wide strip of high
adhesion tape over each TEMP-PLATE and beyond The recording of coupling serial numbers to
the edge of the epoxy overcoat. Grasp one end of the facilitate reassembly is no longer required.
tape and remove the tape in one abrupt motion. Lifting It is a desirable maintenance practice to
or peeling of the epoxy coating or TEMP-PLATE is not match the serial numbers of the couplings
permitted and requires replacement of the in order to reassemble couplings into
TEMP-PLATE. Repeat step 15 through step 18. original position.
63-00-00
BHT-412-CR&O-3
2. Select the outer coupling (9) and inner coupling 11. Insert the extension bar (L-122) (1) through the
(8) that are to be assembled. wrench set (T101588) (5) and engage the wrench
(T101306) (2). Torque the nut (3) 100 to
3. Position the outer coupling (9) on the boot 200 foot-pounds (136 to 271 Nm).
assembly (11). Install the eight bolts (13) and the
washers (12). Torque the bolts 50 to 70 inch-pounds 12. Remove the tools.
(5.65 to 7.91 Nm). Secure the bolt heads together with
lockwire (C-405). Position the coupling with the boot 13. Install the locking spring (5, Figure 63-1). Make
assembly down on the work bench. sure that the tang of the locking spring is fully engaged
in the hole in the nut (6) and the slot in the driveshaft
4. Squeeze 1/2 tube of lubricant (tube pack) (C-015) (16). Check the boot assembly (11) for wrinkles. If
into the boot assembly (11) and the outer coupling (9).
wrinkles are found, loosen and retorque the nut.
Hand pack the lubricant evenly over the coupling and
behind the dam in the boot, as shown in View A. 14. Squeeze one tube of lubricant (tube pack)
(C-015) into the outer coupling (9). Spread the
5. Put the inner coupling (8) into the outer coupling
lubricant evenly over the splines of the outer coupling.
(9). Make sure that the inner coupling is installed into
Install the centering spring (4) on the spring
the lip of the boot assembly (11).
retainer (7).
6. Lightly coat the spring retainer (7), locking spring
15. Lightly coat the new packing (3) with lubricant
(5), centering spring (4), nut (6), and the threads and
(tube pack) (C-015).
splines of the driveshaft (16) with lubricant (tube pack)
(C-015).
16. Install the packing (3) on the retainer plate (2) and
7. Place the driveshaft (16) in a suitable support. install into the outer coupling (9).
Install the inner and outer couplings (8 and 9) on the
driveshaft. NOTE
After the installation of the new packing (3),
8. Position the spring retainer (7) in the driveshaft
check that no rubber slivers are present
(16). Install the nut (6) finger tight.
indicating the packing was damaged during
installation.
9. Position the wrench (T101306) (2, Figure 63-2) in
the nut (3). 17. Install the retaining ring (1) in the groove of the
outer coupling (9). Inspect the ring for proper seating
10. Position the wrench set (T101588) (5) on the
in the groove.
outer coupling (8).
18. Install the outer coupling (17) and associated
parts in the same manner outlined in step 1 through
CAUTION step 17.
THE TEETH OF INNER COUPLING (4) 19. Inspect the boot assembly (11) for damage that
SHALL FULLY ENGAGE SPLINES OF may have occurred during assembly. Wrinkles are
OUTER COUPLING (8) BEFORE NUT (3) caused by misindexing coupling teeth. Tears are
IS TORQUED. usually caused during torquing of the nut (6).
63-00-00
BHT-412-CR&O-3
63-10. MAIN DRIVESHAFT (HELICOPTERS that the teeth of one coupling are in contact
S/N 36020 AND SUBSEQUENT, TO with the same teeth of the mating coupling.
INCLUDE S/N 46400 THROUGH 46499, To meet these objectives, suitable
AND HELICOPTERS MODIFIED BY non-permanent markings should be applied
412-570-001-103 OR POST to the driveshaft couplings during the

disassembly process.
BHT-412-SI-74 (412SP TO 412HP
UPGRADE)) 1. Place the driveshaft in a suitable support.
2. Remove the retaining ring (1, Figure 63-7),

SPECIAL TOOLS REQUIRED packing (3), retainer plate (2), and centering spring (4).
Discard the packing.
NUMBER NOMENCLATURE
3. Remove the locking spring (5) from the nut (6).
L-122 1 Extension Bar,
3/4 Drive
T101306 Wrench the nut (3).
T103063 Wrench Set
NOTE: outer coupling (8) and install two steel washers (6) and
1 The extension bar (L-122) is part of the the nuts (7).
wrench set (T103063).
6. Insert the extension bar (L-122) (1) through the
63-11. MAIN DRIVESHAFT — DISASSEMBLY plate of the wrench set (T103063) (5) and engage the
wrench (T101306) (2). Hold the wrench set (T103063)
NOTE and loosen the nut (3).
If the engine-to-transmission driveshaft is
being disassembled for replacement of 7. Remove the tools.
parts, instead of overhaul, disassemble

8. Remove the nut (6, Figure 63-7) and the spring
only to the extent necessary to replace the
retainer (7).
parts.
9. Remove the inner coupling (8) and the outer
To maximize the service life of the
coupling (9) as an assembly, and separate the
driveshaft couplings and to aid in the
couplings.
diagnoses of driveshaft problems, it is
recommended the couplings be reinstalled
10. Remove the six bolts (14), washers (13), nuts
with their original mates at their original
(12), boot assembly (11), and packing (10). Discard
ends (transmission end or engine end) of
the packing.
the driveshaft. To maximize coupling gear
and propagation of any driveshaft coupling 11. Remove the outer coupling (17) and associated
tooth damage, it is also recommended the parts in the same manner outlined in step 1 through
inner and outer couplings be installed such step 10.
63-00-00
BHT-412-CR&O-3
OVER FULL LENGTH OF GEAR TEETH 1

FOR -103
2
0.15 TO 0.25 IN. 3
(3.8 TO 6.3 mm) 6 T 2
4
5
8 7
1
DETAIL A 9
9
10
11
15
12
SEE DETAIL A
13
16
14 T 1 1
17
1. Retaining ring
2. Retainer plate
3. Packing
4. Centering spring SYSTEM LUBRICANT (C-015)
5. Locking spring
6. Nut 70 TO 90 IN-LBS
7. Spring retainer T 1 (7.91 TO 10.17 Nm)
8. Inner coupling
9. Outer coupling 150 TO 200 FT-LBS
10. Packing T 2 (204 TO 271 Nm)
11. Boot assembly
12. Nut
13. Washer
14. Bolt
NOTE
15. Serial and part number nameplate 1 Add running torque of bolt (14) to the actual torque.
16. Driveshaft
17. Outer coupling
412_CRO_63_0008_c03
Figure 63-7. Main Driveshaft Assembly (412-040-005-101 and -103)
63-00-00
BHT-412-CR&O-3
1 1
3 T
10 9 4
8
5
7 6
1. Extension bar (L-122)

2. Wrench (T101306)
3. Nut
4. Inner coupling
5. Wrench set (T103063)
6. Steel washer
7. Nut
8. Outer coupling
9. Rubber boot
10. Engine-to-transmission driveshaft
150 TO 200 FT-LBS

T (204 TO 271 Nm)
NOTE
1 The extension bar (L-122) is part of wrench set (T103063).
412_CRO_63_0009_c02
Figure 63-8. Wrench (T101306) — Tool Application
63-00-00
BHT-412-CR&O-3
63-12. MAIN DRIVESHAFT — CLEANING has been subjected to an accident or

incident outside the realm of normal usage,
perform the conditional inspection
MATERIALS REQUIRED
(paragraph 63-14). If the driveshaft does
Refer to BHT-ALL-SPM for specifications. not require a conditional inspection,
proceed with the normal inspection
NUMBER NOMENCLATURE (paragraph 63-15).
63-14. MAIN DRIVESHAFT — CONDITIONAL
C-516 Clean Cloth INSPECTION
1. Visually inspect the driveshaft for external

damage.
CAUTION
2. Visually inspect the inner and outer couplings for
DO NOT USE DRYCLEANING SOLVENT chipped, dented, or cracked teeth and for scoring of
(C-304) INSIDE ASSEMBLED COUPLING. the teeth caused by excessive misalignment. Refer to
IF ALL TRACES OF SOLVENT ARE NOT Figure 63-9 and Figure 63-10 for the coupling damage
R E M O V E D F R O M PA R T S , T H E
limits.
DRYCLEANING SOLVENT RESIDUE MAY
PREVENT LUBRICANT FROM
ADHERING TO PARTS. NOTE
1. Clean the driveshaft parts except the boots with Any evidence of yielding, or exceeding the
drycleaning solvent (C-304). following limits, renders the entire main
driveshaft unserviceable and
2. Dry the parts with dry, filtered compressed air.
nonrepairable.
3. Clean the boot assembly (11, Figure 63-7) with a 3. With the inner and outer couplings (8 and 9,
clean cloth (C-516).
Figure 63-7) removed from both ends of the shaft,
mount the shaft on the centers and check shaft runout.
4. Remove all traces of solvent residue from the
inner and outer couplings (8 and 9) with a clean cloth Runout shall not exceed 0.020 inch (0.51 mm) Total
(C-516). Indicated Runout (TIR) at the mid-point of the shaft or
0.010 inch (0.25 mm) TIR when checked at 7.0 inches
63-13. MAIN DRIVESHAFT — INSPECTION (178 mm) from either end.
NOTE 4. If no evidence of the conditions of step 1 through

If records or the physical appearance of the step 3 is found, accomplish the normal inspection
main driveshaft indicate that the assembly (paragraph 63-15).
63-00-00
BHT-412-CR&O-3
WIRE FEELER GAUGE

C MAXIMUM 0.0055 IN.
(0.140 mm)
POSITION METAL STRAIGHT
EDGE PERPENDICULAR TO FACE
OF TOOTH BEING INSPECTED
SEE DETAILS WEAR AREA

A, B and E
SPLINE TEETH
0.250 IN.
6 (6.35 mm) 5.4997 IN. (139.692 mm) MAXIMUM
PINS
DETAIL B
DETAIL A
SEE DETAIL D 1.360 IN. (34.54 mm)

REF (4TH GROOVE)
6000-2 TEMP-PLATE (YELLOW BORDER)

2 REQUIRED-180° APART
(LOCATED 90° FROM THE 6000-1 TEMP-PLATES)
LOCATE 6000-1 AND 6000-2 TEMP-PLATES
EQUALLY SPACED WITHIN 0.300 IN. (7.62 mm)
WEAR MEASURING
TOOL USAGE
VIEW C
0.19 TO 0.25 IN. RAD.
6000-1 TEMP-PLATE (RED BORDER) (4.8 TO 6.4 mm)
2 REQUIRED 180° APART LOCATE 6000-1 AND
6000-2 TEMP-PLATES EQUALLY SPACED 60°
0.100 TO 0.125 IN.
WITHIN 0.300 IN. (7.62 mm) (2.54 TO 3.18 mm)
30°
0.28 TO 0.34 IN.
SLIGHT LIFTING
(7.1 TO 8.6 mm)
OF TEMP-PLATE IS
ACCEPTABLE IN
THIS AREA ONLY DETAIL E
DETAIL D (COUPLING SPLINE WEAR GAUGE) 7 8
412_CRO_63_0007a
63-00-00
BHT-412-CR&O-3
NOTES
1. Perform over-temp inspection in accordance with applicable Maintenance and CR&O manuals and the
following instructions. Scrap affected male and female couplings if any of the conditions listed below exist
or if required by applicable CR&O manual inspection criteria.
a. The cadmium plating on the outer coupling is discolored (circumferential tan or light brown band) or
blistered.
b. The gear teeth of either coupling are discolored (brown or blue) in the normally bright contact patterns.
c. Under 5x to 10x magnification, the surfaces of the gear teeth of either the inner or the outer coupling
exhibit signs of metal smearing or tearing in the contact patterns.
d. The grease is very viscous (thick) and has a strong pungent odor.
e. If none of the above conditions exist, the coupling may be reassembled in accordance with the
applicable CR&O manual and returned to service following replacement of the “TEMP-PLATE”.
2. Couplings that show evidence of wear on spline teeth shall be inspected in accordance with Detail A and
Detail B. If teeth are worn only on one side, or if teeth are worn on both sides as a result of coupling
reversals in past maintenance, they shall be inspected only in accordance with Detail B. Maximum depth of
wear is 0.005 inch (0.13 mm). If coupling teeth are worn to 0.005 inch (0.13 mm) depth on one side and are
relatively unworn on opposite side, coupling may be reversed during installation so that it may be continued
in service.
3. Couplings that exhibit surface fatigue-type pitting in active areas of teeth on one side may be reversed
during installation so that they may be continued in service if: (a) largest pit does not exceed 0.006 inch
(0.15 mm) at its largest dimension and, (b) other side of teeth is in serviceable condition.
4. Inspect coupling for mechanical damage and corrosion in accordance with inspections per Areas A, B, C, D,
E, and F.
5. Inspect coupling for cracks by magnetic particle method (BHT-ALL-SPM). No cracks are acceptable.
6 Maximum length of 0.250 inch (6.35 mm) for 0.2160 inch (5.486 mm) diameter pins. Pins should be placed in
area of coupling tooth-face visually indicating greatest wear.
7 Manufacture from 0.005 inch (0.13 mm) thick metal gauge or from common thickness gauge set.
8 Remove any burrs from reworked edges of gauge using a fine sharpening stone.
412_CRO_63_0007b
63-00-00
BHT-412-CR&O-3
G G
B C B
B
F F B
D D
E E
AREAS
AREA A:
Visually inspect spline area for spalled, chipped, pitted, dented, or corroded teeth. Only extremely light corrosion
or corrosion staining which can be readily removed by hand polishing with fine steel wool or abrasive pad (C-407)
is acceptable.
Mechanical damage in the form of nicks, dents, scratches, and pits which can be detected with a probe having a
0.020 inch (0.51 mm) spherical radius is cause for rejection unless the criteria of items 2 or 3 on sheet 2 applies to
allow coupling reversal on installation.
AREA B:
Light fretting corrosion is acceptable provided it does not exceed 0.002 inch (0.05 mm) depth and covers no more
than 50% of the surface area between any two bolt holes. Do not polish out the pitting, but remove corrosion
deposits in accordance with note 2.
Allowable mechanical damage is limited to nicks, dents, and scratches which do not exceed 0.050 inch (1.27 mm)
in depth, 0.05 inch (1.3 mm) in length and occur no more than once in any 2.0 inches (51 mm) of circumferential
flange length. Do not polish out the damage but remove any raised material in accordance with note 1.
Corrosion pitting is acceptable in bolt holes provided the pitting is no deeper than 0.010 inch (0.25 mm) and covers
no more than 20% of the surface area of the hole. See limits on hole size below. Do not polish out the pitting but
remove corrosion deposits in accordance with note 2.
AREA C:
Light corrosion is permitted in Area C provided the depth of the corrosion does not exceed 0.002 inch (0.05 mm)
and covers no more than 20% of the area of any surface. No corrosion is acceptable in undercuts F except that
which can be readily removed by hand polishing with fine abrasive mat of steel wool. Remove any residual
corrosion deposits in accordance with note 2.
Nicks, dents and scratches are acceptable provided they do not exceed 0.010 inch (0.25 mm) in depth,
0.50 inch (12.7 mm) in length, and occur no more than 2.0 inches (51 mm) of circumference. Polish out damage on
cylindrical surfaces and fillet radii. Refer to note 1 for rework. Damage on the sides of the convolutions need not
be polished out but remove any raised material flush with surrounding surfaces.
412_CRO_63_0007c
63-00-00
BHT-412-CR&O-3
AREA D:
Very light corrosion or mechanical damage in the form of scratches in acceptable provided the depth does not
exceed 0.002 inch (0.05 mm) and covers no more than 25% of the area of the surface. Rework by hand
polishing with fine abrasive pad (C-407).
AREA E:
Light corrosion pitting is acceptable provided the depth does not exceed 0.002 inch (0.05 mm) and covers no
more than 40% of the area of any surface. Rework by hand polishing with fine abrasive pad (C-407).
Remove any residual corrosion deposits in accordance with note 2.
Light scratches are acceptable across the narrow land outboard of the retaining ring groove provided they do
not exceed 0.010 inch (0.25 mm) in depth and the diameter measures no greater than 6.083 inches (154.51 mm)
at any point following rework. Rework only to remove any raised material flush with surrounding surface using
fine India stone (C-464).
AREA F:
Light corrosion pitting is acceptable provided the depth does not exceed 0.005 inch (0.13 mm). Do not polish
out the pitting but remove corrosion deposits in accordance with note 2.
Allowable mechanical damage is limited to nicks, dents, and scratches which are no deeper than 0.005 inch
(0.13 mm), no longer than 0.50 inch (12.7 mm) and occur no more than once in any 2.0 inches (51 mm) of
circumference. Polish out mechanical damage in accordance with notes 1 and 5.
NOTES
1. Polish out mechanical damage using a fine India stone (C-464). Blend repair areas with a minimum fillet
radius of 0.125 inch (3.18 mm) except where noted otherwise and 63 RMS or better surface finish. Remove
any raised material flush with surrounding surface by hand polishing with fine India stone (C-464).
2. Where specified, remove corrosion deposits in Areas B, C, E and G using chemical corrosion cleaner (C-344)
for ferrous parts. Apply corrosion cleaner using a cotton swab. DO NOT allow cleaner to run into Area A.
3. Touch up cad plate in reworked areas and in non-reworked damaged areas (BHT-ALL-SPM) except in Area A.
Omit supplementary chromate treatment.
4. Dimensional limits on damage apply after any specified rework has been accomplished.
5. Where material is removed from Area G to repair mechanical damage, the same amount of material must be
removed from the outer edge of the flange at a point 180° from the original damage site in order to maintain
part balance.
412_CRO_63_0007d
63-00-00
BHT-412-CR&O-3
A 0.2057 IN. (5.225 mm)

PINS
MINIMUM
D 6.0532 IN.
C G MAXIMUM (153.751 mm)
F E
2.7574 IN. (70.038 mm)
B
0.1728 IN. (4.389 mm) PINS

DETAIL A
AREA NOMENCLATURE CHARACTERISTIC INSPECTION LIMIT

METHOD
A, B Gear teeth, spline Chipped, broken or Visual None allowed

missing teeth,
mechanical damage
A, B Gear teeth, spline Corrosion Visual 1
A Gear teeth Wear Measure over 6.0532 inches (153.751 mm) minimum 6 7
0.2057 inch (see Detail A).
(5.225 mm)
diameter pins
A Gear teeth Pitting Visual/ None that can be felt. If it can be felt with a 5
(not due to corrosion) measure probe having a 0.020 inch (0.51 mm)
and indentations spherical radius except if the pit or
indentation is no larger than 0.030 inch
(0.76 mm) across its largest dimension with
only one pit or indentation per tooth.
A Gear teeth Scratches Visual/ As a general requirement, a scratch on the

measure face of any tooth is not acceptable if it can
be felt with a probe having a 0.020 inch
(0.51 mm) spherical radius except when the 5
scratch is no wider than 0.015 inch
(0.38 mm) with only one scratch per tooth.
412_CRO_63_0010a_c01
Figure 63-10. Main Driveshaft Inner Coupling (214-040-657-003) — Damage Limits (Sheet 1 of 4 )
63-00-00
BHT-412-CR&O-3
AREA NOMENCLATURE CHARACTERISTIC INSPECTION LIMIT

METHOD
A Gear teeth “Scoring” (surface of Visual None allowed.

tooth face appears
“smeared” under
magnification)
Pitting, scoring Visual/measure None that can be felt with a

indentations, 0.020 inch (0.51 mm) spherical
scratches radius probe and are more than
0.015 inch (0.38 mm) across.
B Spline Wear Measure between 2.7574 inches (70.038 mm) maximum

0.1728 inch (see Detail A).
(4.389 mm)
diameter pins
C, D Web Corrosion/mechanical Visual/measure 3

damage
E, F End surfaces Mechanical Visual/measure 2
G Hub Corrosion/mechanical Visual/measure 3

damage
All Undesignated Corrosion/mechanical Visual None allowed.

surfaces
All Coupling Cracks Magnetic particle None allowed.
NOTES
1 Only extremely light corrosion or corrosion staining which can be readily removed via light abrading by
hand with the fine abrasive pad (C-407) is acceptable.
2 Mechanical damage in the form of nicks and dents is acceptable on Surface E and F provided the damage
does not exceed 0.005 inch (0.13 mm) in depth and spacing between damage sites is no less than 90°.
Remove any raised material flush with the surrounding surface(s) using a fine India stone (C-464).
3 Corrosion pitting is acceptable in Areas C, D and G provided the damage does not exceed 0.005 inch
(0.13 mm) in depth or covers more than 20% of any 1.0 square inch (645 mm2) of surface or 10% of the total
area of any surface after rework. Corrosion is not permitted in the web holes or their associated
end-chamfers and rework of the hole areas is not permitted. Remove corrosion pitting by polishing to
0.250 inch (6.35 mm) minimum fillet and blend radii. Surface finish in reworked areas to be 63 RMS or better.
Mechanical damage in the form of nicks, dents, and scratches is acceptable in Areas C, D and G provided it
is no deeper than 0.005 inch (0.13 mm), no longer than 0.40 inch (10.2 mm) and the separation between
damage sites is no less than 2.0 inches (51 mm) (1.0 inch (25 mm) in Area G). Polish out mechanical
damage to 0.25 inch (6.4 mm) minimum fillet and blend radii. Surface finish in reworked areas to be 63 RMS
or better.
4. Dimensional limits for damage apply after all specified repairs have been performed.
5 No repairs are allowed on the faces of coupling gear teeth. Do not attempt to polish out damage.
412_CRO_63_0010b_c01
63-00-00
BHT-412-CR&O-3
DETAIL B
NOTES
6 Typical maximum wear pattern for transmission-end coupling. The central section of the pattern (tiger-eye)
may not be present. Pattern size will vary somewhat between different couplings at the same relative
position due to variations in service time, initial misalignment and aircraft operating conditions. If the edge
of either end of the pattern extends to within 0.050 inch (1.27 mm) of the adjacent end of the tooth, a check
of engine-to-transmission alignment and an inspection of elastomeric pylon mounts should be performed
(see Detail B).
7 On new couplings received from BHTI, a pattern will already exist on the teeth as a result of acceptance
testing of the coupling or driveshaft assembly. Care must be taken during evaluation of coupling patterns
so as to distinguish between the service pattern and any underlying test pattern. The patterns are most
easily distinguished by viewing the teeth obliquely using adequate lighting and a white card inserted
between the teeth. The acceptance test pattern will generally be larger than the service pattern and may
actually exceed the maximum recommended size given above. Samples of acceptance test patterns are
given in Detail B.
412_CRO_63_0010c
63-00-00
Export Classification C, ECCN EAR99 17 SEP 2014 Rev. 9 Page 41
BHT-412-CR&O-3
DETAIL C
8. Typical maximum wear pattern for engine-end coupling. Pattern size will vary somewhat between different
couplings at the same relative position due to variations in service time, initial misalignment and aircraft
operating conditions. If the pattern is significantly wider than that shown, a check of
engine-to-transmission alignment should be performed (see Detail C).
9. On new couplings received from BHTI, a pattern will already exist on the teeth as a result of acceptance
testing of the coupling or driveshaft assembly. A third pattern may also exist if the coupling has seen
previous service at the transmission end of the driveshaft. Care must be taken during evaluation of
coupling patterns so as to distinguish between the engine end service pattern and any larger underlying
pattern. The patterns are most easily distinguished by viewing the teeth obliquely using adequate lighting
and a white card inserted between the teeth. The photograph of Detail C depicts a rather large rectangular
engine-end pattern superimposed on a typical transmission-end pattern.
DETAIL D
10. This area is the central bright area of the tooth normally called the “Tiger Eye”. Pitting normally will
originate in this area. Pattern only visible under good lighting conditions. Best viewing of the tooth face is
from a slight angle.
11. Under normal operating conditions this is the “steady state” (operational wear) area.
12. A very faint pattern is seen at this location and will only exist if the maximum misalignment is less than the
green-run pattern. This pattern may not always be visible.
13. The outer most pattern normally indicates the green-run pattern. This pattern can be overwritten by the
pattern indicated in note 2 and 3.
412_CRO_63_0010d
63-00-00
Page 42 Rev. 9 17 SEP 2014 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
63-15. MAIN DRIVESHAFT — NORMAL completing the entire inspection procedure

INSPECTION and the couplings have been determined
serviceable.
MATERIALS REQUIRED 2. Inspect the outer couplings TEMP-PLATES

(Figure 63-9) for deterioration, debonding, or
Refer to BHT-ALL-SPM for specifications. discoloration. Replace the TEMP-PLATES in
accordance with the procedures in paragraph 63-16.
NUMBER NOMENCLATURE
C-464 India Stone 3. Inspect the driveshaft (16, Figure 63-7) for
damage limits in accordance with Figure 63-11.
NOTE 4. Inspect the outer couplings (9 and 17,

Overtemperature indicator dots on the Figure 63-7) for damage limits in accordance with
temperature indicator TEMP-PLATES are Figure 63-9.
of a white or light gray color and turn black
when exposed to an overtemperature 5. Inspect the inner coupling (8, Figure 63-7) and
condition. Chemical contamination can also the similar coupling at the opposite end of the
cause indicating dots to turn black. driveshaft for damage limits in accordance with
Figure 63-10.
1. Inspect the outer couplings (9 and 17,
Figure 63-7) TEMP-PLATES for evidence of
overtemperature indication. If overtemperature 6. Inspect the nut (6, Figure 63-7) and the similar
indication is noted, perform the coupling nut at the opposite end of the driveshaft for damage
overtemperature inspection as follows: limits in accordance with Figure 63-11.
a. Inspect the outer coupling cadmium plating for 7. Inspect the boot assembly (11, Figure 63-7) and
discoloration (circumferential). If a tan or light brown the similar boot at the opposite end of the driveshaft as
band or blistering is found, replace the outer and inner follows:
coupling.
a. Inspect the boot assembly (11) and the similar
b. Inspect the gear teeth of the outer coupling boot at the opposite end of the driveshaft for cracks in
and inner couplings for discoloration (brown or blue) in the metallic components and cracks, tears, wrinkles,
normal bright contact patterns. If discoloration is and evidence of chemical damage in the elastomeric
found, replace the outer and inner couplings. portion of the boot. Defects of this type are not
permitted.
c. Inspect the outer coupling and inner coupling
under a 5X to 10X magnifying glass for teeth exhibiting b. Visually inspect the outer surface of the
signs of metal smearing or tearing in contact patterns.
elastomeric portion of the boot for areas (bands) of
If smearing or tearing is found, replace the outer and
wear caused by contact with the conical boot retainer
inner couplings (Figure 63-9).
in the presence of abrasive material. Damage of this
type having the appearance of depth or thinning of the
d. Inspect the grease from the outer and inner
couplings. If the grease is very viscous (thick) and has boot is not permitted.
a strong pungent odor, replace the outer and inner
couplings. c. Support the outer ring of the boot on the
blocks and slowly displace the inner ring axially, by
hand, to upper and lower limits of travel. Replace the
NOTE boot if the elastomeric portion does not roll smoothly
If the TEMP-PLATES are to be replaced, or exhibits permanent flats, wrinkles, or any other
replace the TEMP-PLATES after major deformities as it flexes.
63-00-00
BHT-412-CR&O-3
ALTERNATE LOCATION
FOR NAMEPLATE
NAMEPLATE
B B
NUT
(204-040-184-001)
SEE DETAIL A SEE DETAIL A
DRIVESHAFT
(212-040-686-001)
USE 0.1920 IN. (4.877 mm)

DIAMETER PINS
E
B A C
3.2909 TO 3.2952 IN.
(83.589 TO 83.698 mm) C A B
D
NUT
SECTION B-B
DETAIL A
NOTES
1. Mechanical and corrosion damage limits on shaft are defined as follows:
EXTERNAL SURFACES:
Nicks and scratches Not exceeding 0.004 inch (0.10 mm) in depth are acceptable without repair.
running parallel to, or
within 15° of parallel to Not exceeding 0.008 inch (0.20 mm) in depth or 1.5 inches (38 mm) in length are
shaft axis. acceptable if polished out, provided total polished area does not exceed 10%
of circumference at any point.
Nicks and scratches not Not exceeding 0.004 inch (0.10 mm) in depth are acceptable on up to 100% of
running within 15° of the circumference of shaft if polished out.
shaft axis.
Not exceeding 0.008 inch (0.20 mm) in depth or 1.5 inches (38 mm) in length are
acceptable provided the total polished area does not exceed 10% of the
circumference at any point.
Corrosion pitting Not exceeding 0.008 inch (0.20 mm) in depth is acceptable provided it is
polished out. Maximum length of rework at any point must not exceed
1.5 inches (38 mm) nor cover more than 10% of the circumference at any point.
The maximum acceptable total reworked area is 4.0 square inches (2581 mm2).
412_CRO_63_0011a
Figure 63-11. Main Driveshaft and Nut (412-040-005-101) — Damage Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
INTERNAL SURFACES:
Corrosion pitting Not exceeding 0.005 inch (0.13 mm) on inside diameter in area designated “A” on
Detail B are acceptable without polishing out. Pits exceeding 0.005 inch (0.13 mm) are
acceptable if completely polished out and depth after polishing out does not exceed
0.010 inch (0.25 mm). Minimum radius in rework area(s) is 0.50 inch (12.7 mm). Surface
finish rework area must be 63 RHR (Roughness Height Rating) or better.
Corrosion pitting Not exceeding 0.010 inch (0.25 mm) on inside diameter in area designated “B” on
Detail B are acceptable without polishing out. Pits exceeding 0.010 inch (0.25 mm) are
acceptable if completely polished out and minimum wall thickness after rework is
0.060 inch (1.52 mm). Rework must completely clean up pits. Minimum radius in
rework area(s) is 0.090 inch (2.29 mm). Surface finish in rework area must be 63 RHR
or better.
Corrosion pitting Not exceeding 0.030 inch (0.76 mm) on inside diameter in area designated “C” on
Detail B are acceptable without polishing out. This area is the last two threads.
Superficial corrosion Only superficial corrosion which can be removed by hand polishing with an abrasive
pad (C-407) or with fine steel wool is allowed in area “D”.
Corrosion pitting on nut Not exceeding 0.030 inch (0.76 mm) on nut in area designated “E” on Detail B is
acceptable.
2. Thread damage:
Depth: 1/4 of thread
Length: 0.50 inch (12.7 mm)
Number: One
The spline wear limits are provided to show the required fit between the driveshaft and inner couplings. It is
not intended that spline wear be measured as a prescribed overhaul procedure. Inspect splines for wear and
damage visually. If there is evidence of wear, measure dimension over pins as shown in Detail A. Spline
wear in excess of limit shown on Detail A and/or spline damage such as chipped spline teeth is not
acceptable. Very small nicks and dents are acceptable if polished out with fine India stone (C-464).
4. Inspect two nameplates for secure installation and legible markings. Only one nameplate should have
markings. The second nameplate should be installed face down 180° opposite the nameplate with markings.
5. Inspect driveshaft by magnetic particle method. Refer to BHT-ALL-SPM. No cracks are acceptable.
6. Contact Bell Helicopter Textron Product Support Engineering (PSE) if corrosion damage is in excess of
established limits.
412_CRO_63_0011b
Figure 63-11. Main Driveshaft and Nut (412-040-005-101) — Damage Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
8. Inspect the retainer plate (2) as follows:
FIGURE 63-7
a. Inspect the packing groove in the retainer NOMENCLATURE
INDEX NUMBER
plate (2) and the surface in the outer couplings (9 and
17) contacted by the packing for nick or burrs. 6 Nut
b. Remove any nicks or burrs with an India stone 8 Inner Coupling

(C-464). Carefully remove any foreign material.
9 Outer Coupling
c. If nicks deep enough to permit passage of 16 Driveshaft

grease are found, replace the defective part.
63-16. MAIN DRIVESHAFT — REPAIR
d. Inspect the area that contacts the retaining
ring (1) for excessive wear.
MATERIALS REQUIRED
9. Inspect the locking spring (5) and the similar
spring at the opposite end of the driveshaft for Refer to BHT-ALL-SPM for specifications.
visually, is not permitted. NUMBER NOMENCLATURE
10. Inspect the centering spring (4) and the similar C-108 Cadmium Plating
Solution
spring at the opposite end of the driveshaft for
deformation. Any damage that can be detected C-208 Epoxy/Zinc Coating
visually, is not permitted.
C-298 Epoxy Adhesive
11. Inspect the retaining ring (1) and the similar
retaining ring at the opposite end of the driveshaft for C-304 Drycleaning Solvent
C-309 MEK
visually, is not permitted.
C-318 Cleaning Compound
12. Inspect the spring retainer (7) for corrosion
damage. Pits to a maximum depth of 0.010 inch C-406 Abrasive Cloth or
(0.25 mm) are permitted. Remove corrosion products Paper
with a wire brush.
C-426 Masking Tape
C-464 India Stone

NOTE
The following procedure is to be done in C-516 Clean Cloth
conjunction with an overhaul and
conditional inspection. This procedure is
1. With abrasive cloth or paper (C-406), polish out
not required if disassembly is for
relubrication only. mechanical and corrosion damage on the driveshaft
(16, Figure 63-7) that is within the limits shown in
13. Inspect the retainer plate (2), centering spring (4), Figure 63-11. Blend the repaired area to a minimum
and spring retainer (7) with the fluorescent penetrant radius of 0.50 inch (12.7 mm). The finished repair
method (BHT-ALL-SPM).
must be 32 RHR or better (BHT-ALL-SPM).
14. Inspect the following parts by magnetic particle

2. Touch up the repair areas with cadmium plating
inspection. Demagnetize the parts after the magnetic
particle inspection. Refer to Table 63-3 and the solution (C-108). Use only the brush cadmium plate
BHT-ALL-SPM for the procedure. procedure defined in the BHT-ALL-SPM.
63-00-00
BHT-412-CR&O-3
3. Polish the nicks and dents in the spline teeth of (3) Weigh the mixed material.
the driveshaft splines, only to remove any raised
material, with a fine India stone (C-464). (4) Calculate the required amount of zinc
powder to produce 20 to 25% (weight) of the mixed
4. Replace missing or illegible nameplates (15, material. For instance, each 100 grams of base/
Figure 63-7) as follows: thinner mixture requires 20 to 25 grams of zinc
powder.
a. Remove the illegible nameplate.
(5) Weigh out the required amount of zinc
b. Stamp the required information on a new powder and add to the base/thinner mixture with
nameplate and bond the plate on the driveshaft as per constant stirring to achieve a uniform mixture.
instructions in the BHT-ALL-SPM.
(6) Allow the mixed material to set for a
c. Bond an unmarked nameplate, face down to minimum of 1 hour at room temperature prior to use.
the driveshaft, 180° apart from the marked nameplate Discard the mixed material if not used within 8 hours
for balance purposes (BHT-ALL-SPM). after mixing.
5. Polish out small nicks and dents, not exceeding d. Mask off the areas of the driveshaft outside
0.030 inch (0.76 mm) across the largest dimension, at Area A (Figure 63-12) with masking tape (C-426).
the corners at the ends of the inner and outer gear
teeth with a fine India stone (C-464). Do not attempt to e. Apply one coat of epoxy/zinc coating (C-208)
polish out the damage on the face of the coupling gear to Area A. Seal or plug one end of the driveshaft. Flow
teeth. the epoxy/zinc mixture into the hollow driveshaft and
slosh as needed to coat the entire surface. Drain
6. Polish nicks and dents in the teeth of the internal excess coating material from the driveshaft.
spline of the inner couplings with a fine India stone
(C-464), only to remove any raised material.
NOTE
7. Paint the inside of the driveshaft in Area A The material drained from the driveshaft
(Figure 63-12) only if the existing finish has been into a clean container may be used on
damaged. Comply with the following: other parts if the 8-hour pot life is not
exceeded.
a. Clean the inside of the driveshaft with
f. Keep the driveshaft vertical for 1 hour after
drycleaning solvent (C-304).
coating to prevent the coating from puddling on one
side.
b. Allow the solvent to dry.
g. The coating will reach final cure in 72 hours at
c. Prepare the epoxy/zinc coating (C-208) as
ambient temperature.
follows:
h. The coating may be heat cured as follows:
NOTE
The epoxy/zinc coating material is supplied (1) Dry at ambient conditions for 2 hours.
in a three-component kit.
(2) Cure at 150 to 160°F (66 to 71°C) for a
(1) Measure an adequate volume of base minimum of 1 hour.
material to paint the number of driveshafts that can be
painted in 8 hours or less. i. Remove the masking tape.
(2) Add an equal volume of the accelerator/ j. Touch up the small areas that may have been
thinner and mix thoroughly. inadvertently missed during the initial application.
63-00-00
BHT-412-CR&O-3
PAINT IS REQUIRED
ON INSIDE DIAMETER
IN AREA A
AREA A
DIAMETER DIAMETER
B C
412_CRO_63_0012
Figure 63-12. Main Driveshaft (412-040-005-101 and -103) — Painted Area
63-00-00
BHT-412-CR&O-3
k. The coating, after drying, must be free of pits, (1) Scrub the coupling bonding surface with
mud cracking, craters, blisters, and other surface a clean cloth (C-516) and cleaning compound (C-318).
irregularities. The metallic filler must be evenly Follow the cleaning with a thorough water rinse.
dispersed to present a relatively uniform gray
appearance. Some dark streaks in coatings applied by (2) Thoroughly dry the coupling surface and
the fill and drain process caused by heavier zinc repeat the water break free test as stated in step 8,
concentration are permitted. substep c.
8. Replace the visual over temperature indicator 9. Install the TEMP-PLATES as follows:
TEMP-PLATES on the coupling (Figure 63-9) if
CAUTION
a. Remove the damaged TEMP-PLATES with
MEK (C-309) and a clean cloth (C-516). Wipe dry with
a clean cloth (C-516) before MEK evaporates. IN ORDER TO PREVENT
CONTAMINATION OF THE TEMP-PLATE
ADHESIVE BACK, MAKE SURE THAT
WORK AREA AND HANDS ARE
CAUTION T H O R O U G H LY C L E A N E D B E F O R E
WORKING WITH TEMP-PLATES. DO NOT
PRESS OR RUB THE TEMP-PLATE WITH
T H E B O N D IN G S U R FA C E A N D T H E
BARE FINGERS DURING INSTALLATION
TEMP-PLATES MUST BE FREE OF ALL
ON COUPLING AS THIS WILL
CONTAMINATE SURFACE.
CONTAMINATION COULD ALLOW THE
T E M P - P L AT E S T O C O M E O F F O R a. Remove the protective backing from the
INDICATE FALSE TEMPERATURES. TEMP-PLATE and carefully position onto the prepared
surface.
b. Prepare the coupling surface for bonding by
scrubbing the area with a clean cloth (C-516) b. With a clean cloth (C-516), work the
moistened with MEK (C-309). Wipe dry before MEK TEMP-PLATES into the contour of the coupling. Make
evaporates. The surface should be at least 0.050 inch sure the TEMP-PLATE is in full contact with the
(1.27 mm) larger than the TEMP-PLATE. coupling surface.
c. Accomplish a water break free test on the

prepared bonding surface by applying distilled or NOTE
demineralized water from a suitable dispenser Apply epoxy adhesive (C-298) to the
(squeeze bottle). The water must flow into a TEMP-PLATES immediately following the
continuous film without gathering into distinct water installation of the TEMP-PLATES on each
droplets within 25 seconds after application. Wipe dry coupling.
with a clean cloth (C-516). If the coupling bonding
surface does not meet the water break free test and 10. Install epoxy adhesive (C-298) over the
you have ensured the cleaning materials are not TEMP-PLATE as follows:
contaminated, clean the coupling bonding surface as
follows:
CAUTION
NOTE
Follow the manufacturer's THE USE OF ANY EPOXY ADHESIVE
recommendations for proper water OTHER THAN SPECIFIED IS NOT
mixtures. AUTHORIZED.
63-00-00
BHT-412-CR&O-3
a. Mix epoxy adhesive (C-298) per manufacturer

NOTE
recommendations.
Following the cure, the TEMP-PLATE
b. With a soft bristled brush (artist brush), should conform to the contour of the
vigorously mix the epoxy. A few drops of coupling and be free of lifted edges.
recommended thinner may be added during mixing to Indicating dots on the TEMP-PLATES must
reduce the viscosity to a level that permits uniform remain the original white or light gray with
brush application of the mixture and will not run when no or partial black discoloration.
applied to a vertical surface. The final viscosity of
Some lifting at the extreme ends of the
mixture should be similar to a heavy bodied paint.
TEMP-PLATES installed on grooved
couplings is permitted (Figure 63-9,
View A). Lifting is permitted only at the
CAUTION bottom, as shown, and should not exceed
0.030 inch (0.76 mm).
TOO THIN OF AN EPOXY COATING MAY c. After curing, accomplish an adhesion test by
SEEP INTO THE TEMP-PLATE CAUSING pressing a 1.0-inch (25-mm) wide strip of high
adhesion tape over each TEMP-PLATE and beyond
THE INDICATOR DOTS TO TURN BLACK,
the edge of the epoxy overcoat. Grasp one end of the
IN WHICH EVENT, THE TEMP-PLATE
tape and remove the tape in one abrupt motion. Lifting
MUST BE REPLACED.
or peeling of the epoxy coating or TEMP-PLATE is not
permitted and requires replacement of the
c. Uniformly apply the epoxy coating over the
TEMP-PLATE. Repeat step 8 through step 11.
TEMP-PLATE to the thickness of approximately 0.002
to 0.004 inch (0.05 to 0.10 mm). The coating should
12. Treat the repaired cadmium surfaces with
totally cover the surface of the TEMP-PLATE and cadmium plating solution (C-108). Refer to the
extend approximately 0.250 inch (6.35 mm) beyond BHT-ALL-SPM for procedures.
the edges of the TEMP-PLATE.
63-17. MAIN DRIVESHAFT — LUBRICATION
11. Cure the epoxy coating as follows:
The inspection of the driveshaft couplings and the
internal inspection of the driveshaft for corrosion is
required when the driveshaft is lubricated at the
CAUTION
interval designated in the BHT-412-MM-2, Chapter 5.
Refer to paragraph 63-11 through paragraph 63-13,
paragraph 63-17, and paragraph 63-18 for instructions
DO NOT EXPOSE THE EPOXY COATING
to disassemble, clean, inspect, lubricate, and
TO OIL, GREASE, CLEANING
assemble the driveshaft.
SOLVENTS, OR OTHER CHEMICALS
DURING CURE.
63-18. MAIN DRIVESHAFT — ASSEMBLY
temperature (60 to 100°F (16 to 38°C)) for a minimum
of 6 hours prior to helicopter operation. For best SPECIAL TOOLS REQUIRED
results, allow epoxy to cure overnight.
NUMBER NOMENCLATURE
b. The epoxy coating total curing time can be
accelerated by allowing the epoxy coating to cure at L-122 Extension Bar,
room temperature for 1 hour, then place the coupling 3/4 Drive
in a temperature controlled oven for 1 to 2 hours at a
temperature of 150 to 180°F (66 to 82°C). An alternate T101306 Wrench
source of heat can be used if temperature does not
T103063 Wrench Set
exceed 180°F (82°C).
63-00-00
BHT-412-CR&O-3
6. Lightly coat the spring retainer (7), locking spring

MATERIALS REQUIRED (5), centering spring (4), nut (6), and threads and
splines of the driveshaft (16) with lubricant (tube pack)
Refer to BHT-ALL-SPM for specifications. (C-015).
NUMBER NOMENCLATURE 7. Place the driveshaft (16) in a suitable support.

Install the inner and outer couplings (8 and 9) on the
C-015 Lubricant (Tube Pack)
driveshaft.
1. Lubricate a new packing (10, Figure 63-7) with 8. Position the spring retainer (7) in the driveshaft
lubricant (tube pack) (C-015) and install in the groove (16). Install the nut (6) finger tight.
in the boot assembly (11).
NOTE the nut (3).
The recording of the coupling serial

numbers to facilitate reassembly is no
outer coupling (8).
longer required. It is a desirable
maintenance practice to match the serial
numbers of the couplings in order to
reassemble the couplings into the original CAUTION
position.
2. Select the outer coupling (9) and the inner THE TEETH OF INNER COUPLING (4)
coupling (8) that are to be assembled. SHALL FULLY ENGAGE SPLINES OF
OUTER COUPLING (8) BEFORE NUT (3)
IS TORQUED.
NOTE
Add running torque of bolt (14) to the actual 11. Insert the extension bar (L-122) (1) through the
plate of the wrench set (T103063) (5) and engage the
torque.
wrench (T101306) (2). Torque the nut (3) 150 to
3. Position the outer coupling (9) on the boot 200 foot-pounds (204 to 271 Nm).
assembly (11). Install the six bolts (14), washers (13),
and nuts (12). Torque the bolts 70 to 90 inch-pounds 12. Remove the tools used in step 9, step 10, and
(7.91 to 10.17 Nm). Position the coupling with the boot step 11.
assembly down on the work bench.
13. Install the locking spring (5, Figure 63-7). Make
sure that the tang of the locking spring is fully engaged
NOTE in the hole in the nut (6) and the slot in the driveshaft
In the step 4, completely coat the inner and (16). Check the boot assembly (11) for wrinkles. If
outer coupling teeth with lubricant (tube wrinkles are found, loosen and retorque the nut.
pack) (C-015).
14. Hand pack the lubricant (tube pack) (C-015) over
4. Lubricate the inner coupling (8) with lubricant the full length of the gear teeth to a depth of 0.15 to
(tube pack) (C-015). Hand pack the lubricant (tube 0.25 inch (3.8 to 6.4 mm) over the outer coupling (9)
pack) (C-015) evenly over the full length of the gear spline teeth (View A).
teeth of the outer coupling (9).
15. Lightly coat the new packing (3) with lubricant
5. Position the inner coupling (8) into the outer (tube pack) (C-015).
coupling (9). Make sure the inner coupling is installed
into the lip of the boot assembly (11). 16. Install the packing (3) on the retainer plate (2).
63-00-00
BHT-412-CR&O-3
17. Put the centering spring (4) in position on the 19. Install the outer coupling (17) and associated
retainer plate (2) and install them on the outer parts in the same manner as outlined in step 1 through
step 17. Make sure the mounting holes in the flange of
coupling (9).
the outer coupling (9) are aligned with the ones on the
outer coupling (17) within 2.0°.
CAUTION 20. Inspect the boot assembly (11) for damage that
may have occurred during the assembly. Wrinkles are
caused by misindexing the coupling teeth. Tears are
A F T E R I N S TA L L AT I O N O F N E W usually caused during torquing of the nut (6).
PACKING (3), CHECK THAT NO RUBBER
SLIVERS ARE PRESENT INDICATING 21. If not previously accomplished, apply the
TEMP-PLATES to the driveshaft outer couplings in
PA C K I N G WA S D A M A G E D D U R I N G
accordance with the procedures in paragraph 63-16.
INSTALLATION.
22. The driveshaft assembly shall be tagged with the
18. Install the retaining ring (1) in the groove of the date of lubrication if the main driveshaft assembly is to
outer coupling (9). Inspect the ring for proper seating be returned to stock and an entry made in the
in the groove. component historical record.
63-00-00
Page 52 Rev. 11 16 JUN 2017 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
TRANSMISSION MAIN ROTOR MAST
63-18A.MAST ASSEMBLY — CONFIGURATION configurations. For the mast assembly to be

correctly configured, all the parts listed in a
The Model 412 helicopters are delivered with the mast selected column must be assembled
assembly configurations shown in Table 63-1. together.
1. Use the information in Table 63-1A and A partial upgrade does not qualify for a data
Table 63-1B, as applicable, to verify the configuration
plate or Historical Service Record (HSR)
or to upgrade the mast assembly. The components
listed below an assembly dash number are included in identification change.
that specified configuration.
4. Use the information in Table 63-1C and
2. Any noted mast assembly can be upgraded to a Table 63-1D, as applicable, to verify the configuration
newer configuration. When an assembly is upgraded, of the mast pole assembly. The components listed
all applicable Alert Service Bulletins (ASB) and below an assembly dash number are included in that
Technical Bulletins (TB) must be incorporated specified configuration.
(Table 63-1A and Table 63-1B), as applicable.
5. Following an upgrade of the mast assembly,
3. Identify the upgraded mast assembly with the
make an entry in the HSR of the mast assembly to
correct configuration dash number that you defined in
step 1 as follows: show:
a. Use a vibrating tool to mark the data plate of • The new part number (P/N)
the mast assembly. The depth of the vibroetch must
not exceed 0.005 inch (0.13 mm). • The new component inspection interval, as
applicable
Example: 412-040-366-113 -121FM
• The new retirement life of the mast assembly
parts, as applicable
NOTE
Table 63-1A and Table 63-1B, as • That the configuration of the mast assembly
applicable, lists all the mast assembly was upgraded
Table 63-1. Mast Assembly Versus Helicopter Serial Number
MAST ASSEMBLY PART NUMBER HELICOPTER SERIAL NUMBER
412-040-366-103 S/N 33001 through 33036
S/N 33037 through 33213

412-040-366-105 S/N 34001 through 34024
S/N 36001 through 36019
S/N 36020 through 36029

412-040-366-109 S/N 36031 and 36032
S/N 36034 through 36039
S/N 36030 and 36033

412-040-366-111
S/N 36040 through 36096
63-00-00
Export Classification C, ECCN EAR99 28 FEB 2020 Rev. 12 Page 52A
BHT-412-CR&O-3
Table 63-1. Mast Assembly Versus Helicopter Serial Number (Cont)
MAST ASSEMBLY PART NUMBER HELICOPTER SERIAL NUMBER
S/N 34025 through 34036

412-040-366-113
S/N 36097 through 36494
412-040-366-115 S/N 46400 through 46458
412-040-366-117 S/N 46459 through 46499
412-040-366-119 Spare (before S/N 36020)
412-040-366-121 S/N 36495 through 36670
412-040-366-123 Spare (S/N 46400 through 46499)
412-040-366-125 1 Spare (before S/N 36020)
412-040-366-127 2 Spare (S/N 46400 through 46499)
S/N 36671 through 36999

412-040-366-129 3
S/N 37002 through 37999
NOTES:
1 Latest spares configuration for helicopters not equipped with the mast torque indicating system.
2 Latest spares configuration.
3 Latest production configuration for helicopters equipped with the mast torque indicating system.
Table 63-1A. Mast Assembly — Configuration
MAST ASSEMBLY
412-040-366
NOMENCLATURE PART NUMBER NOTES -103 -105 -109 -111 -113 -115 -117
1 2 1 3 4 5 4 6 4 7 25 26 27
21 24
Mast Pole 412-040-101-105 8 X

Assembly
412-040-101-109 8 X
412-040-101-121 8 X
412-040-101-125 8 X
412-040-101-129 8 X
412-040-101-133 8 X
412-040-101-135 8 X
Lock Ring 412-040-108-101 X X X X X X X
63-00-00
Page 52B Rev. 11 16 JUN 2017 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
Table 63-1A. Mast Assembly — Configuration (Cont)
MAST ASSEMBLY
412-040-366
1 2 1 3 4 5 4 6 4 7 25 26 27
21 24
Sleeve 29810-8056 9 28 X X X X X X
536841 10 X
Seal 29940-2023B 11 X X X X X
29990-2082 11 12 X
412-340-001-101 11 X
Nut 412-040-104-101 13 X X X X X
412-040-104-103 13 X X
Plate Assembly 412-040-103-101 X X X X X X X
Bearing 214-040-125-003 14 X X X X X
214-040-125-101 X X
Liner 412-040-102-101 15 X X X X X X X
Oil Slinger 412-040-105-101 X X X X X X X
Race 204-040-270-005 16 X
204-040-270-101 17 X X X X X X
Nut 204-040-309-001 18 X
204-040-309-101 19 X X X X
412-040-524-101 20 X X
Rivet CR4523-4-04 X X
Ring M27426-3162C X X X
Lock Ring 412-040-516-101 X X X
Nut 412-040-515-101 X X X
Ring M27426-3174C X X X
Plug 412-040-514-101 X X X
Rotor 412-040-519-101 22 X X X
412-040-525-101 23 X X
63-00-00
Export Classification C, ECCN EAR99 16 JUN 2017 Rev. 11 Page 52C
BHT-412-CR&O-3
MAST ASSEMBLY
412-040-366
1 2 1 3 4 5 4 6 4 7 25 26 27
21 24
NOTES:
1 Used on helicopters with no mast torque indicating system.
2 Replaced by 412-040-366-105.
3 Replaced by 412-040-366-119.
4 Used on helicopters with mast torque indicating system.
5 Used with monopole sensor 412-375-004-105. Can be upgraded to -111 configuration for use with
monopole sensor 412-375-004-109. Refer to TB 412-01-179.
6 Replaced by 412-040-366-113.
7 Replaced by 412-040-366-121.
8 For configuration details refer to Table 63-1C.
9 Used with seals 29940-2023B or 29990-2082.
10 Used with seals 412-340-001-101 or 412-340-012-101.
11 Replaced by seal 412-340-012-101.
12 Seal 29990-2082 has no production effectivity. Sold in spares only.
13 Nut 412-040-104-101 replaced by nut 412-040-104-103. The torque applied on the -103 nut is lower than
the torque applied on the -101 nut. Refer to the BHT-412-MM.
14 Replaced by 214-040-125-101.
15 Replaced by liner 412-040-102-103 and packing 412-340-011-101 as a unit. Refer to TB 412-08-218 or

TB 412CF-08-90.
16 Race 204-040-270-005 has a width of 0.750 inch (19.05 mm).
17 Race 204-040-270-101 has a width of 1.500 inches (38.1 mm).
18 Nut 204-040-309-001 has standard right hand threads.
19 Nut 204-040-309-101 has left hand threads.
20 Nut 412-040-524-101 has left hand threads. Used with riveted type rotor.
21 Can be converted to 412-040-366-117FM for use with the 412-704-012 Slope Landing Retrofit Kit
(BHT-412-SI-62).
22 This rotor is bonded to the mast.
23 This rotor is riveted to the mast.
63-00-00
Page 52D Rev. 12 28 FEB 2020 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
MAST ASSEMBLY
412-040-366
1 2 1 3 4 5 4 6 4 7 25 26 27
21 24
NOTES (CONT):
24 Can be upgraded to -129 provided that TB 412-14-231 is done.
25 Replaced by 412-040-366-117.
26 Replaced by 412-040-366-123.
27 Can be upgraded to -127 provided that TB 412CF-14-103 is done.
28 Used with seal 29990-2082, applicable to helicopters S/N 46400 through 46499.
Table 63-1B. Mast Assembly — Configuration
MAST ASSEMBLY
412-040-366
NOMENCLATURE PART NUMBER NOTES -119 -121 -123 -125 -127 -129
1 13 3 15 2 17 1 3
14 16
Mast Pole 412-040-101-127 4 X X

Assembly
412-040-101-129 4 X X
412-040-101-133 4
412-040-101-135 4 X X
Lock Ring 412-040-108-101 X X X X X X
Sleeve 536841 5 X X X X X X
Seal 412-340-001-101 6 X X X
412-340-012-101 X X X
Nut 412-040-104-103 7 X X X X X X
Plate Assembly 412-040-103-101 X X X X X X
Packing 412-340-011-101 8 X X X X X X
Bearing 214-040-125-101 X X X X X X
Liner 412-040-102-103 8 X X X X X X
63-00-00
Export Classification C, ECCN EAR99 28 FEB 2020 Rev. 12 Page 52E
BHT-412-CR&O-3
Table 63-1B. Mast Assembly — Configuration (Cont)
MAST ASSEMBLY
412-040-366
1 13 3 15 2 17 1 3
14 16
Oil Slinger 412-040-105-101 X X X X X X
Race 204-040-270-101 9 X X X X X X
Nut 204-040-309-101 10 X X
412-040-524-101 11 X X X X
Rivet CR4523-4-04 X X X X
Rotor 412-040-525-101 12 X X X X
NOTES:
2 Replaced by 412-040-366-127.
4 For configuration details refer to Table 63-1C.
5 Used with seals 412-340-001-101 or 412-340-012-101.
6 Replaced by 412-340-012-101.
7 Nut 412-040-104-101 replaced by nut 412-040-104-103. The torque applied on the -103 nut is lower
than the torque applied on the -101 nut. Refer to BHT-412-MM.
8 Packing 412-340-011-101 is used with liner 412-040-102-103. Refer to TB 412-08-218 or

TB 412-CF-08-90.
9 Race 204-040-270-101 has a width of 1.500 inches (38.1 mm).
10 Nut 204-040-309-101 has left hand threads.
11 Nut 412-040-524-101 has left hand threads. Used with riveted type rotor.
12 This rotor is riveted to the mast.
13 Replaced by 412-040-366-125.
15 Replaced by 412-040-366-129.
17 Can be upgraded to -127 provided that TB 412CF-14-103 is done.
63-00-00
Page 52F Rev. 12 28 FEB 2020 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
Table 63-1C. Mast Pole Assembly — Configuration
MAST POLE ASSEMBLY

412-040-101
1 2 1 3 1 4 1 4 6 7 6 9
5 8
Mast 412-040-101-107 X
412-040-101-111 X
412-040-101-115 X
412-040-101-119 X
412-040-101-123 X X
Plate 100-024-1 X X X X
100-099-1 X
100-141-1 X
Plug 412-040-113-101 1 10 X X X X
NOTES:
2 Replaced by 412-040-101-113.
3
Replaced by 412-040-101-117.
4 Spares configuration.
5 Replaced by 412-040-101-127.
7 Used with monopole sensor 412-375-004-105. Refer to TB 412-01-179.
8 Can be replaced by 412-040-101-125, if TB 412-01-179 is done.
9 Used with monopole sensor 412-375-004-109. Refer to TB 412-01-179.
10 Plug 412-010-113-101 has major outside diameter of 2.88 inches (73.2 mm) and the 412-010-113-103
has a major outside diameter of 2.93 inches (74.4 mm).
63-00-00
Export Classification C, ECCN EAR99 28 FEB 2020 Rev. 12 Page 52G
BHT-412-CR&O-3
Table 63-1D. Mast Pole Assembly — Configuration
MAST POLE ASSEMBLY

412-040-101
NOMENCLATURE PART NUMBER NOTES -127 -129 -133 -135

1 2 3
Mast 412-040-101-123 X X
412-040-101-131 3
X X
Sleeve 412-040-110-101 X X
Plate 100-140-1 X
100-141-1 X X X
Plug 412-040-113-103 1 4 X
NOTES:
3
Lower section has rivet holes for installation of riveted rotor 412-040-525-101.
4 Plug 412-010-113-101 has major outside diameter of 2.88 inches (73.2 mm) and the
412-010-113-103 has a major outside diameter of 2.93 inches (74.4 mm).
5 Can be converted to 412-040-101-135FM. Use with Slope Landing Retrofit Kit (BHT-412-SI-62).
63-00-00
Page 52H Rev. 12 28 FEB 2020 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
63-19. TRANSMISSION MAIN ROTOR MAST SPECIAL TOOLS REQUIRED (Cont)

ASSEMBLIES (412-040-366-103 AND
-105) NUMBER NOMENCLATURE
T103192 Sleeve Protector

NOTE
T103260-121 Rod Set (Qty 2)
For helicopters S/N 36020 through 36999,
S/N 37002 through 37999, S/N 46400
through 46499, and helicopters modified by
412-570-001-103, refer to paragraph MATERIALS REQUIRED
63-25.
63-20. TRANSMISSION MAIN ROTOR MAST NUMBER NOMENCLATURE

ASSEMBLY — DISASSEMBLY
C-426 Masking Tape
SPECIAL TOOLS REQUIRED 1. Refer to the Airworthiness Limitations Schedule

in the applicable Maintenance Manual for
airworthiness life on the mast assembly components.
NUMBER NOMENCLATURE Identify the components that have accumulated hours
for retirement.
204-010-481-001 Mast Nut
204-011-178-001 Clevis Assembly

CAUTION
AN960-1016 Washer (Qty 2)
T100965 Power Wrench Kit DO NOT TOUCH PORTION OF MAST

T H AT IS N O R M A L LY INSIDE
T100968 Anchor Plate
TRANSMISSION WITH BARE HANDS.
T101456 or Wrench
412-240-027-101
CAUTION
T101901 Plate Assembly
T101937 Bearing Installation WHEN LIFTING MAST WITH HOIST, USE

and Removal Tool MAST NUT (204-010-481-001) AND
CLEVIS ASSEMBLY (204-011-178-001).
T101939 Rod Connector (Qty 2)
DO NOT USE CAP ASSEMBLY THAT IS
T101941 Bolt Assembly (Qty 2) USED TO SECURE MAIN ROTOR HUB
TO MAST WHEN MAST AND HUB ARE
T103163 Tie Rod Spacer (Qty 2) INSTALLED IN HELICOPTER.
T103164 Tie Bolt (Qty 2)

NOTE
T103165 Splined Adapter If the main rotor mast is being
disassembled for replacement of parts and
T103166 Screw and Plate Set not for overhaul, disassemble only to the
extent required to replace the parts.
T103167 Thrust Plate
2. If not previously done, remove the main rotor
T103178 Socket Wrench
mast assembly (BHT-412-MM-6, Chapter 63).
63-00-00
BHT-412-CR&O-3
3. Hoist the mast assembly (1, Figure 63-13) into h. Remove two cotter pins from the bearing race
position over a work bench equipped with padded retention nut (8). Discard the cotter pins.
V-blocks. Place the mast in the V-blocks in a horizontal
position (Figure 63-14).
NOTE
4. Place a layer of protective paper on the mast and Determine whether the bearing race
secure with masking tape (C-426) to avoid scratching retention nut (8) has right-hand or left-hand
the mast during the disassembly procedures. threads. Refer to Figure 63-13, Detail B, for
a description of the type of threads used on
the two masts.
5. For helicopters Post TB 412-14-231, remove the
sealant from the top of the lock ring (4, Figure 63-13)
i. Position the wrench (T101456 or
with a plastic scraper.
412-240-027-101) (9, Figure 63-14) on the bearing
race retention nut (8).
6. Cut and remove lockwire from the screws (3).
j. Position the torque wrench (10) on the wrench
7. Remove four screws (3). Cut sealant around the (T101456 or 412-240-027-101) (9) and loosen the
lock ring (4) with a plastic scraper. Remove the lock bearing race retention nut (8). Remove the torque
ring. wrench and the wrench. Remove the nut and the
bearing race.
8. Remove four screws (24). Remove the mast
bearing retaining plate (11) and the shim (12). If the k. Position the torque wrench (13) on the power
same parts are to be reinstalled on the mast assembly wrench kit (T100965) (5). Operate the power wrench
(1), index the shim for reinstallation. to turn the socket wrench (T103178) (6) and loosen
the mast bearing retention nut (2).
9. Cut the sealant around the seal (6) with a plastic
scraper. Remove the seal from the mast bearing l. Remove all the tools installed in step a
retaining plate (11) and discard the seal. through step k.
11. Remove the bearing (26) from the mast as

10. Remove the mast bearing retention nut (2,
follows:
Figure 63-14) as follows:
a. Position the sleeve protector (T103192) (7) on NOTE

Refer to Figure 63-14, Detail C and
Detail D, to install tools on the mast for
b. Position the socket wrench (T103178) (6) on bearing removal.
a. Position the bearing installation and removal
c. Put the power wrench kit (T100965) (5) on the tool (T101937) (24) on the main rotor mast (1).
socket wrench (T103178) (6).
b. Position the plate assembly (T101901) (22) on
d. Position the anchor plate (T100968) (4) on the the main rotor mast (1).
power wrench kit (T100965) (5).
c. Install two bolt assemblies (T101941) (23).
e. Position the splined adapter (T103165) (3) on
the main rotor mast (1). Make sure that the splined d. Assemble the rod set (T103260-121) (21), tie
adapter fully engages the splines of the mast and the bolt (T103164) (19), rod connector (T101939) (20), tie
splines of the anchor plate (T100968) (4). rod spacer (T103163) (17), washer (AN960-1016)
(16), and nut (5/8-11 UNC) (15). Make sure that equal
f. Tighten the two thumb screws (11). thread engagement of the two rods is obtained in the
rod connector. Assemble the opposite rods and
g. Position the steel bar (12) as illustrated. connector in the same manner.
63-00-00
BHT-412-CR&O-3
29 3 SEE DETAIL A
23
4 24
25
20
21 7 T 2 T 3
19 8
22 9
18
10
17
11 S2
16 SEE DETAIL A 26
12
T 1
27
13
14 28 SEE DETAIL B
15
412_CRO_63_0013a_c01
Figure 63-13. Transmission Rotor Mast Assembly (412-040-366-103 and -105) (Sheet 1 of 4)
63-00-00
BHT-412-CR&O-3
1.55 IN.
(39.4 mm)
0.55 IN.
(14.0 mm)
3 29
DETAIL A
(PRE TB 412-14-231)
SEALING COMPOUND AND GREASE APPLICATION AREAS
4 11 6
5 23
25
1
1.55 IN. S1 4
(39.4 mm) 10
0.55 IN.
(14.0 mm)
ANNULAR GROOVE
7
3 29
DETAIL A
(POST TB 412-14-231)
412_CRO_63_0013b_c01
63-00-00
BHT-412-CR&O-3
MAST ASSEMBLY 412-040-101-105 MAST ASSEMBLY 412-040-101-109

HAS RIGHT HAND THREADS ON HAS LEFT HAND THREADS ON
BEARING RACE RETENTION NUT BEARING RACE RETENTION NUT
26 27
COTTER PIN 6 COTTER PIN 6
DETAIL B
1. Mast assembly 16. Threaded insert

2. Hub adapter wear sleeve 17. Threaded insert
3. Screw 18. Packing
4. Lock ring 19. Jet No. 8
5. Wear sleeve 20. Cap
6. Seal 21. Screw
7. Mast bearing retention nut 22. Threaded insert
8. Nut 23. Bearing liner
9. Thin steel washer 24. Screw
10. Aluminum washer (AN960PD516) 25. Oil slinger
11. Mast bearing retaining plate 26. Bearing race
12. Shim 27. Nut
13. “V” mark on inner race 28. Cotter pin
14. Bearing 29. Cork plug
15. “V” mark on outer race
250 TO 300 FT-LBS

LOCKWIRE (C-405) T 1 (339 TO 406 Nm)
900 TO 1100 FT-LBS 2
S1 SEALANT (C-251) T 2 (1220 TO 1491 Nm)
1400 TO 1900 FT-LBS 1
S2 SEALANT (C-328) T 3 (1898 TO 2576 Nm)
412_CRO_63_0013c_c02
63-00-00
BHT-412-CR&O-3
NOTES
1 For mast bearing nut 412-040-104-101.
3 Install with shellac varnish (C-211).
4 After installation of seal in plate, apply a bead of sealant (C-328) to indicated area.
5 Fill area between the two seal lips with grease (C-001) before installation of plate on mast.
6 After described torque is applied to bearing race retention nut, install two cotter pins. Select holes for cotter
pins that will result in each cotter pin being positioned on nut castellation to prevent nut loosening. The
position will be opposite for the right hand and left hand threaded nuts. Install cotter pins with heads inside
mast as shown and bend both tangs to avoid damage to mast threads.
7 Apply a coat of epoxy primer coating (C-246) to the annular groove before you install the bearing and the nut.
The epoxy primer coating shall not extend the bearing journal or past the first thread of the threaded area.
8 Apply a light coat of grease (C-172) to the bearing journal and to the first three threads of the threaded area.
Fill the annular groove area between the nut and the mast bearing journal with grease. After bearing
installation, remove any excess of grease from the lower side of the bearing and make sure that the annular
groove and the first three threads of the threaded area have grease.
9 Apply a coat of epoxy primer coating (C-246) and one coat of polyurethane coating (C-245) to the area.
10 Apply a light coat of sealant (C-251) to the nut side of the lock ring (4) and a bead of sealant on the thread
adjacent to the nut face before lock ring installation. After the lock ring installation, fill the four holes in the
lock ring with sealant and apply a bead of sealant to cover the exposed threads and to the edge of the lock
ring. Apply sealant to create a slope, to make sure the water drains off.
412_CRO_63_0013d
63-00-00
BHT-412-CR&O-3
SEE DETAIL B, C AND D
2
1 SEE DETAIL A
1 4
3 6
7
8 9
11
10
12
DETAIL A
BEARING RACE RETENTION NUT REMOVAL/INSTALLATION
412_CRO_63_0014a_c01
Figure 63-14. Transmission Main Rotor Mast Assembly/Disassembly Tool (412-040-366-103 and -105) —
Tool Application (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3
1
3
4
11
12 DETAIL B
BEARING RETENTION NUT REMOVAL/INSTALLATION
13
23
22
21 E 24
19 20
17
16
15
18
1 E
14
DETAIL C
BEARING REMOVAL
412_CRO_63_0014b
63-00-00
BHT-412-CR&O-3
1 24
22
18
21
E 17
16
15
23
14
DETAIL D
BEARING INSTALLATION
22 24 1. Main rotor mast

2. Mast bearing retention nut
3. Splined adapter (T103165)
23 4. Anchor plate (T100968)
5. Power wrench kit (T100965)
1 6. Socket wrench (T103178)
7. Sleeve protector (T103192)
8. Bearing race retention nut
9. Wrench (T101456)
10. Torque wrench
11. Thumb screw
12. Steel bar
13. Torque wrench
14. Screw and plate set (T103166)
15. Nut (5/8-11 UNC)
16. Washer (AN960-1016)
17. Tie rod spacer (T103163)
18. Thrust plate (T103167)
19. Tie bolt (T103164)
20. Rod connector (T101939)
21. Rod set (T103260-121)
27 26 22. Plate assembly (T101901)
25
23. Bolt assembly (T101941)
24. Bearing installation and removal tool (T101937)
SECTION E-E 25. Oil slinger
SECTIONAL VIEW OF REMOVAL/INSTALLATION 26. Bearing
TOOLS MOUNTED ON MAST BEARING 27. Liner
412_CRO_63_0014c
63-00-00
BHT-412-CR&O-3
e. Place the thrust plate (T103167) (18) on the 2. Inspect the following parts by magnetic particle
end of the mast. Position both tie bolts (T103164) (19) inspection. Demagnetize the parts after the magnetic
in the slots of the screw and plate set (T103166) (14) particle inspection. Refer to Table 63-3 and the
and tighten the nuts (5/8-11 UNC) (15). Tighten the BHT-ALL-SPM for the procedure.
large screw in the center of the plate set to pull the
bearing (26) from the mast. When the bearing is clear
of the journal on the mast, remove the tools installed in
step a through step d. Remove the oil slinger (25), FIGURE 63-13
bearing, and liner (27) from the main rotor mast (1). NOMENCLATURE
INDEX NUMBER
12. Use a hollow, cylindrical sleeve to support the 1 Mast Assembly

outer race of the bearing (26). Position a similar sleeve
on the liner (27) and press the liner off the bearing. 4 Lock Ring
7 Mast Bearing Retention

13. Remove the cork plug (29, Figure 63-13). Discard Nut
the cork plug.
23 Bearing Liner
63-21. TRANSMISSION MAIN ROTOR MAST 25 Oil Slinger
ASSEMBLY — CLEANING
27 Nut
MATERIALS REQUIRED 3. Inspect the mast bearing retaining plate (11,

Figure 63-13) by the fluorescent penetrant method
Refer to BHT-ALL-SPM for specifications. (BHT-ALL-SPM).
NUMBER NOMENCLATURE
63-23. TRANSMISSION MAIN ROTOR MAST
C-304 Drycleaning Solvent ASSEMBLY — REPAIR
C-309 MEK
C-516 Clean Cloth MATERIALS REQUIRED

1. Remove old sealant from the mast bearing
retainer plate (11, Figure 63-13) with a plastic scraper NUMBER NOMENCLATURE
and a clean cloth (C-516) moistened with MEK
(C-309). C-108 Cadmium Plating
Solution
2. Clean all the mast assembly components with C-406 Abrasive Cloth or
drycleaning solvent (C-304). If jet No. 8 (19) is Paper
clogged, determine the source of the material that is
clogging the jet. C-464 India Stone
3. Dry the parts with low pressure, filtered

1. Inspect the mast for the word REWORKED on
compressed air. Do not allow the bearings to spin
flange E as illustrated in Figure 63-15. If the word
while drying.
REWORKED is on the flange and there is corrosion or
mechanical damage on the mast that requires
63-22. TRANSMISSION MAIN ROTOR MAST polishing out, reject the mast. Rework on the mast is
ASSEMBLY — INSPECTION permitted one time only. This restriction is not
applicable to the mast bearing retaining plate and liner
1. Inspect the main rotor mast in accordance with or to superficial corrosion in Area A and Area F that
Figure 63-15. can be removed with steel wool.
63-00-00
BHT-412-CR&O-3
SEE DETAIL A
SEE DETAIL A
0.100 IN.
(2.54 mm)
DETAIL A
MAIN ROTOR MAST ASSEMBLY
412-040-101-105 AND 412-040-101-109
(THESE ASSEMBLIES DO NOT INCLUDE MAST BEARING RETAINING PLATE,
MAST BEARING, AND BEARING RACE ON LOWER END OF MAST)
TRANSMISSION MAIN ROTOR MAST ASSEMBLY

412-040-366-103 AND 412-040-366-105
(THESE ASSEMBLIES INCLUDE MAST BEARING RETAINING PLATE,
MAST BEARING, AND BEARING RACE ON LOWER END OF MAST)
412_CRO_63_0015a_c02
Figure 63-15. Transmission Main Rotor Mast Assembly (412-040-366-103 and -105) — Damage Limits
(Sheet 1 of 5)
63-00-00
BHT-412-CR&O-3
NOTES
1. Inspect mast for the word "REWORKED" on flange E. If the word "REWORKED" is on the flange and there is
corrosion or mechanical damage on the mast that requires polishing out, reject the mast. Rework is permitted
one time only. This restriction is not applicable to mast bearing retaining plate and liner damage limits. Refer
to note 5 for plate and liner damage limits. The restriction is also not applicable to superficial corrosion in
area A, area F, area S, and area T that can be removed with steel wool (C-411).
2. Inspect all mast assembly components for cracks. No cracks are acceptable.
3. Mechanical and corrosion damage (other than superficial corrosion) on mast outside diameters that is within
limits stated below is acceptable if damage is completely removed by polishing out with fine India stone (C-464)
to a finish of 32 RMS or better. Mast must be treated for corrosion protection after rework. Word "REWORKED"
must be marked on flange E if damage is polished out.
MAST CORROSION AND MECHANICAL DAMAGE LIMITS
OUTSIDE DIAMETERS: Areas A, B, C, D, F, and G.
MAXIMUM ALLOWABLE DEPTH OF REWORK
AREA A INCLUDING THREADS AND SPLINES:

Surface corrosion: Only superficial corrosion that can be removed by steel wool (C-411) is acceptable. If
wear can be visually detected on spline O, comply with note 11.
AREA B: 0.002 inch (0.05 mm)
AREA C: 0.015 inch (0.38 mm)
AREA D: 0.020 inch (0.51 mm)
AREA F, INCLUDING THREADS:

Surface corrosion. Only superficial corrosion that can be removed by wire brush or steel wool (C-411).
AREA F is 2.1 inches (53 mm) long on mast 412-040-101-109.
AREA F is 1.4 inches (35 mm) long on mast 412-040-101-105.
AREA G, EXCEPT THREADS AND SPLINES:

0.010 inch (0.25 mm) local clean up.
AREA G THREADS:
Length - 1/4 inch (6.35 mm)
Depth - 1/3 of thread
Number - 1
AREA G SPLINES: (spline K and spline M)

Corrosion and mechanical damage:
Depth - 0.003 inch (0.08 mm)
Length - 0.500 inch (12.70 mm)
One repair per surface with a maximum of five surface.
Superficial corrosion that can be removed by wire brush or steel wool (C-411) is acceptable. Repairs may not
extend into the root. Damage in the root is cause for rejection, the root starts at 0.100 inch (2.54 mm) inch
below crest, see Detail A. If wear can be detected on spline K and M, comply with note 11.
AREA G MAST HUB ADAPTER WEAR SLEEVE:

In addition to 0.010 inch (0.25 mm) damage limit noted above, inspect for wear sleeve-to-mast bonding
failure. No bonding failures are acceptable.
412_CRO_63_0015b_c01
(Sheet 2 of 5)
63-00-00
BHT-412-CR&O-3
INSIDE DIAMETERS Areas H, I and J
AREA H:
Refer to the following table for maximum acceptable inside diameters in Area H for various outside
diameters measured in inches unless otherwise specified from top of mast.
INCHES (mm) INCHES (mm) INCHES (mm)
If outer diameter measures 3.545 (90.04) 3.550 (90.17) 3.555 (90.30)
Maximum acceptable inside 2.815 (71.50) 2.828 (71.83) 2.831 (71.91)

diameter at station 0 to 7.0 is

diameter at station 7.0 to 14.0 is

AREA I:
Maximum acceptable inside diameter is 2.805 inches (71.25 mm).
AREA J:
Maximum acceptable depth of damage is 0.005 inch (0.13 mm) or to a maximum diameter of 2.815 inches
(71.50 mm).
5. Mechanical and corrosion damage on mast bearing retaining plate and linear within limits stated below is
acceptable if polished out with varying grades of aluminum oxide paper to a finish of 63 RMS or better, and
rework areas are treated for corrosion protection. Pitting must be completely removed within allowable cleanup
depth for mast bearing retaining plate and linear to be acceptable. Inspect 13 threaded inserts in mast bearing
retaining plate for secure installation and damaged threads. Damaged, loose and/or missing inserts are not
acceptable.
AREA R:
Maximum depth after cleanup is 0.020 inch (0.51 mm).
Maximum area of rework is 40% of total surface area.
Maximum area of rework is 50% of any 1.0 square inch (645 mm2).
Minimum blend radius of rework is 0.5 inch (13 mm).
AREA Q:
Superficial marks on inner diameter and outer diameter of bearing liner in Area Q are acceptable without
repair. Damage in excess of superficial is not acceptable. If there is evidence of wear, comply with note 12.
6. When mast bearing retaining plate and duplex bearing are removed from mast, inspect slinger, shim, nut, and
sleeve for mechanical and corrosion damage. Damage to any of these parts in excess of superficial is not
acceptable.
412_CRO_63_0015c
(Sheet 3 of 5)
63-00-00
BHT-412-CR&O-3
7. Inspect duplex bearing in Area Q as follows:
CAUTION
DO NOT HANDLE BEARING BALLS AND RACES WITH

BARE HANDS AS THE BODY ACIDS MAY CAUSE ETCHING
OF THE SURFACE RESULTING IN EARLY FAILURES.
ALWAYS OIL BEARINGS AFTER INSPECTIONS AND PLACE
IN A CLEAN PLASTIC BAG OR PROTECTIVE PAPER.
a. Inspect bearing for evidence of debris damage (indentations) in the inner and outer races of both upper
and lower bearings. Debris damage will eventually result in bearing failure therefore is cause for
replacement of bearing.
b. Inspect the inner and outer races for evidence of microspalling, in the loaded ball path. Microspalling is
cause for replacement of bearing. Microspalling will appear as small pits or blisters in the ball path. Use a
4X power glass to observe this area to determine whether condition exists. Micropalling is a progressive
failure mode and will eventually result in a spalling failure of the race.
c. Inspect the balls of the bearings for cuts which may indicate excessive angle. If the balls exhibit cuts it will
likely result in premature bearing failure and is cause for replacement of bearing.
d. Bearing races that show signs of corrosion in the ball path are still considered usable if the corrosion is
limited to stains that exhibit no visible depth when viewed with a 4X power glass. Corrosion that is outside
the loaded ball path is acceptable if; it is limited to less than 10% of the total bearing surface, cannot be
felt with a probe having an end radius of 0.020 inch (0.51 mm), is removed with abrasive pad (C-407).
Polishing of the balls or load area of the races is prohibited.
e. Inspect bearing for brinelling damage. Brinelling damage as evidenced by indications in the races that
correspond to ball spacing is cause for replacement. False brinelling is visually evidenced by minute
scratches along the bore axis of the races and usually is caused by vibration during shipment. Unless this
brinelling shows signs of noticeable depth which can be felt with a probe having a 0.030 inch (0.76 mm).
radius it is not cause for replacement.
8. Inspect oil jet No. 8 (not illustrated) as follows:
a. Inspect for clogging. If jet passages are clogged, determine source of material that is clogging jet.
b. Inspect for corrosion. Superficial corrosion damage on jet plate on exterior of transmission is acceptable
if products of corrosion are removed.
c. Inspect for mechanical damage. Cracks and distortion are not acceptable.
9. Bearing race at lower end of mast is illustrated in Area S and Area T for masts 412-040-366-103 and
412-040-366-105, respectively. Mechanical and corrosion damage such as spalling, scoring, pitting,
brinelling, and flaking that can be detected visually on race is not acceptable.
10. Inspect name (data) plate for legibility and secure installation on mast. Loose and/or illegible data plates are
not acceptable.
412_CRO_63_0015d_c01
(Sheet 4 of 5)
63-00-00
BHT-412-CR&O-3

It is not intended that spline wear limits be measured as a prescribed overhaul procedure. Measure splines only
if there is visual evidence of wear:
MIN MAX
INCHES (mm) INCHES (mm)
SPLINE K OVER PINS 4.0760 (103.530) 4.0961 (104.041)

(Use 0.1920 inch (4.877 mm) diameter pins
SPLINE M OVER PINS 4.0760 (103.530) 4.0961 (104.041)

SPLINE O OVER PINS 4.9860 (126.644) 4.9913 (126.779)

12. Wear on mating surfaces of duplex ball bearing, mast, and linear:
It is not intended that wear on bearing, mast, and linear mating surfaces be measured as a prescribed overhaul
procedure. Measure only if there is visual evidence of wear.
MIN MAX
BEARING ID 4.3302 (109.987) 4.3307 (110.000)
BEARING OD 6.6922 (169.982) 6.6929 (170.000)
LINER ID 6.6919 (169.974) 6.6928 (169.997)
13. MAST DISTORTION (BENDING)
It is not intended that mast run-out be measured as a prescribed overhaul procedure. The run-out inspection is
required when mast records and/or mast appearance indicate that mast has been involved in an accident or
incident that requires conditional inspection. Refer to BHT-412-MM-1 for accidents and/or incidents which
require conditional inspection.
Mount mast on centers in a lathe or suitable fixture. Measure run-out on Surfaces L, N, and P. Maximum
acceptable total indicator readings (TIR) are:
SURFACE L (TOP) N (MIDDLE) P (BOTTOM)
MAX TIR 0.0035 inch (0.089 mm) 0.003 inch (0.08 mm) 0.002 inch (0.05 mm)
412_CRO_63_0015e
(Sheet 5 of 5)
63-00-00
BHT-412-CR&O-3
2. Dress out small burrs, nicks, and scratches on 63-24. TRANSMISSION MAIN MOTOR MAST
spline O, Figure 63-15, with a fine India stone (C-464). ASSEMBLY — ASSEMBLY
3. Polish out mechanical and corrosion damage on

the mast in the areas other than Area A and Area F. SPECIAL TOOLS REQUIRED
Also polish out damage on the bearing retaining plate
with fine to medium abrasive cloth or paper (C-406) or
NUMBER NOMENCLATURE
a fine India stone (C-464). If damage after a complete
cleanup exceeds the limits of Figure 63-15, the mast is T101456 or Wrench
not repairable. Final polish the repair area to a surface 412-240-027-101
roughness of 32 RMS or better.
NOTE MATERIALS REQUIRED

If corrosion must be polished out on the
mast inside diameter, comply with Note 4 in Refer to BHT-ALL-SPM for specifications.
Figure 63-15.
NUMBER NOMENCLATURE
NOTE C-001 Grease
Cleanup limited to external surface C-172 Grease

corrosion, which can be removed with steel
wool, does not require the mast to be C-204 Epoxy Polyamide
marked REWORKED. Primer
C-211 Shellac Varnish

4. If damage was polished out on areas of the mast
other than Area A, Area F, or the mast bearing C-245 Polyurethane Coating
retaining plate, mark the word REWORKED on
flange E with a vibrating stylus. C-246 Epoxy Primer
Coating 1
5. Touch up the rework areas where cadmium
C-251 Sealant
plating was removed as follows:
C-309 MEK
a. If field repair is being accomplished, do not
C-317 Adhesive
apply cadmium plating solution (C-108) on the inside
diameter of the mast beyond the 6.0-inches (152-mm)
C-328 Sealant
limit noted at step 4 in Figure 63-15.
C-426 Masking Tape
b. Use only the cadmium plating procedures
noted in the BHT-ALL-SPM. C-452 Anti-seize Thread
Compound
c. Apply cadmium plating solution (C-108) only C-516 Clean Cloth
in the areas indicated in Figure 63-16
(BHT-ALL-SPM). NOTE:
1 Epoxy Polyamide Primer (C-204) can be

6. Replace missing or illegible nameplates
used as an alternate.
(BHT-ALL-SPM).
63-00-00
BHT-412-CR&O-3
AREA W
0.62 IN. BEARING JOURNAL

(15.7 mm)
SPLINE M SPLINE O
1.05 IN.
SPLINE K (26.7 mm)
MAST, HUB ADAPTER

WEAR SLEEVE
NOTE
Areas enclosed by dash lines are cadmium plated at time of mast manufacture, Area W on wear sleeve,
Spline M, and all mast external surface below top of bearing journal are not cadmium plated.
412_CRO_63_0016
Figure 63-16. Main Rotor Mast (412-040-366-103 and -105) — Cadmium Plating Areas
63-00-00
BHT-412-CR&O-3
c. Place the previously prepared shim (12) in the

bearing liner (23) on the outer race of the upper
CAUTION
bearing (14). Install the mast bearing retaining plate
(11) on the mast with care to avoid damaging the seal
on the mast splines. Secure the bearing liner to the
DO NOT TOUCH PORTION OF MAST
retaining plate with four screws (24). Measure and
record the gap between the bearings and the plate.
The shim should be equal to, or 0.001 to 0.003 inch
(0.03 to 0.08 mm) thicker than, the recorded
dimension. If the shim thickness is not within the limits,
CAUTION prepare a shim of the correct dimensions.
d. Remove four screws (24) and separate the

WHEN LIFTING MAST WITH HOIST, USE
bearing liner (23) from the mast bearing retaining plate
MAST NUT (204-010-481-001) AND
(11).
USED TO SECURE MAIN ROTOR HUB
NOTE
TO MAST.
Refer to Figure 63-14, Detail D for a
1. Place a layer of protective paper on the mast sectional view of the bearings, oil slinger,
assembly and secure with masking tape (C-426) to and liner installed on the mast.
avoid scratching the mast during the assembly
procedures. e. Position the bearing installation and removal
tool (24, Figure 63-14) on the main rotor mast (1).
2. Before you install the bearing (14, Figure 63-13)
and the mast bearing retention nut (7), apply a coat of
f. Position the oil slinger (25), bearings (26), and
epoxy primer coating (C-246) to the annular groove
liner (27) on the main rotor mast (1).
only. Do not apply primer to the bearing journal or to
the threaded area.
g. Position the plate assembly (T101901) (22) on
the main rotor mast (1) and install the two bolt
3. Apply grease (C-172) to the mast bearing journal
assemblies (T101941) (23).
and to the first three threads of the threaded area. Fill
the annular groove with grease.
h. Put the thrust plate (T103167) (18), screw and
4. Install the new cork plug (29) inside the mast plate set (T103166) (14), two rod sets (T103260-121)
assembly (1) with shellac varnish (C-211). (21), two tie rod spacers (T103163) (17), two washers
(AN960-1016) (16), and two nuts (5/8-11 UNC) (15) on
the main rotor mast (1). Tighten the nuts.
5. Install the bearing (14) on the mast assembly (1)
as follows:
i. Carefully tighten the large screw in the screw
a. Position the bearing (14) with the V-marks and plate set (T103166) (14) to pull the bearing (26)
(13) on the bearing inner races aligned and the apex into position on the main rotor mast (1). When the
pointing toward the top of the mast. Align the V-marks bearing is fully seated against the shoulder on the
(15) on bearing outer races with the apex pointing mast, remove the tools installed in step e through
toward the bottom of the mast. step h.
b. Position a hollow cylindrical metal sleeve of 6. Make sure that after the bearing (14,
the correct size to contact the bearing outer race on Figure 63-13) installation, the annular groove is filled
the bearings (14) and press the bearing into the with grease (C-172). Make sure that the first three
bearing liner (23). Rotate the bearing inner race to threads of the threaded area have grease. Remove
check for freedom of operation during seating any excess grease from the lower side area of the
procedure. bearing.
63-00-00
BHT-412-CR&O-3
c. Position the sleeve protector (T103192) (7) on

NOTE
Depending on the helicopter configuration,
a mast bearing retention nut (7) d. Position the socket wrench (T103178) (6) on
412-040-104-101 or -103 may be the mast bearing retention nut (2).
applicable for installation. The primary
difference between the mast bearing e. Position the power wrench kit (T100965) (5)
retention nuts 412-040-104-101 and -103 is on the main rotor mast (1) with the lugs and thumb
that the threads of the retention nut -103 screws (11) toward the top of the mast.
are coated with solid film lubricant. Prior to
installation of a retention nut -103, make f. Position the anchor plate (T100968) (4) on the
sure the threads have a coating of solid film main rotor mast (1). Engage the anchor plate on the
lubricant. If the solid film lubricant coating is lugs of the power wrench kit (T100965) (5). Tighten
damaged or missing, refer to the the two thumb screws (11).
BHT-ALL-SPM for application procedures.
The application of solid film lubricant is g. Position the splined adapter (T103165) (3) to
directly related to the nut -103 torque value engage the splines on the main rotor mast (1) with the
specified in the following assembly splines on the anchor plate. Make sure that the splines
instructions. are fully engaged.
7. Install the mast bearing retention nut (7) as h. For the mast bearing retention nut (2)
follows: 412-040-104-101, inspect the data plate on the power
wrench kit (T100965) (5) or refer to Figure 63-13 and
determine what torque should be applied with the
NOTE torque wrench (13, Figure 63-14).
Refer to Figure 63-14, Detail B, for a view
of the installed bearing retention nut i. For the mast bearing retention nut (2)
removal/installation tools and Figure 63-13, 412-040-104-103, inspect the data plate on the power
Detail A for the sealing and grease wrench kit (T100965) (5) or refer to Figure 63-13 and
application. determine what torque should be applied with the
torque wrench (13, Figure 63-14).
a. Make sure that the mast bearing retention nut
(2, Figure 63-14) has a wear sleeve bonded to the nut j. Position the steel bar (12) in the anchor
prior to installation. Thread the nut onto the main rotor plate (T100968) (4).
mast (1) with the splined end of the nut next to the
bearing. k. Position the torque wrench (13) on the power
wrench kit (T100965) (5).
b. If the wear sleeve is damaged, install a new
wear sleeve on the mast bearing retention nut (2) as l. For the mast bearing retention nut (2)
follows: 412-040-104-101, make sure that the splines on the
tools, mast, and nut are fully engaged and torque the
nut to the lowest torque value T with the torque
(1) Protect the bearing from contamination
wrench (13). Rotate the outer race of the bearing to
and carefully remove the wear sleeve.
check for freedom of operation.
(2) Remove the adhesive from the mast m. For the mast bearing retention nut (2)
bearing retention nut (2) and clean with a clean cloth 412-040-104-103, make sure that the splines on the
(C-516) moistened with MEK (C-309). tools, mast, and nut are fully engaged and torque the
nut to the lowest torque value T with the torque
(3) Apply adhesive (C-317) to the outside wrench (13). Rotate the outer race of the bearing to
diameter of the mast bearing retention nut (2) and check for freedom of operation.
install a new wear sleeve.
n. Remove the tools installed in the preceding
(4) Clean off excess adhesive as required. steps.
63-00-00
BHT-412-CR&O-3
8. Position the lock ring (4, Figure 63-13) on the c. Clean the surfaces where the sealant is to be
mast bearing retention nut (7) and check whether the applied with a clean cloth (C-516) moistened with MEK
holes for the screws (3) are aligned. If the holes are (C-309). Wipe dry with a clean cloth (C-516) before
not aligned, rotate the lock ring to different splines on the solvent evaporates.
the mast. If the holes for all four screws are still not
accessible, reinstall the tools and tighten the retention d. Mix the sealant (C-328) in accordance with
nut. Repeat as required until the four screws (3) can the manufacturer’s instructions on the container, or
be installed, but do not exceed the torque limits noted mix 100 parts by weight of base material to 12 parts by
in step h and step i. Do not install the lock ring at this weight of accelerator. Mix thoroughly. The pot life of
time. mixed sealant is 2 hours. Tack free time after
applications is 12 to 24 hours.
9. After the holes are aligned for the four screws (3),
install the tools as outlined in step c through step k. e. Locate four 0.125 inch (3.18 mm) drain holes
These tools are used to hold the mast during the in the mast bearing retaining plate (11). Do not allow
installation of the bearing race (26) and nut (27). the sealant to obstruct these four holes. Apply sealant
(C-328) to the area indicated in Figure 63-13.
10. Install the bearing race (26) and nut (27) as
follows: 12. Fill the area between the two lips of the new seal
(6) with grease (C-001) (Detail A).
a. Examine the mast and determine which of the
two bearing race and bearing race retention nut 13. Place the previously prepared shim (12) in the
configurations are required. Also, determine whether bearing liner (23) on the outer race of the upper
the threads are right-hand or left-hand (Figure 63-13, bearing.
Detail B).
14. Clean the faying surfaces of bearing liner (23)
b. Position the bearing race (26) on the mast and mast bearing retaining plate (11) with denatured
assembly (1). alcohol (C-326).
c. Apply anti-seize thread compound (C-452) to

the threads of the mast assembly (1) and nut (27).
Thread the nut on the mast.
CAUTION
d. Position the wrench (T101456 or

IF THE MAST ASSEMBLY IS NOT TO BE
412-240-027-101) (9, Figure 63-14) and torque the
I N S TA L L E D I N A T R A N S M I S S I O N
wrench (10) on the nut (27, Figure 63-13). Torque the
WITHIN 30 MINUTES OF SEALANT
nut to the low side of the torque T . Remove the
APPLICATION, CLAMP THE LINER TO
wrenches and determine whether the two new cotter
THE P L AT E A S S E M B LY A N D
pins (28) can be installed. If necessary, apply more
RETIGHTEN THE 4 SCREWS
torque to the nut, but do not exceed the high side limit.
(MS24693-S271). THIS OPERATION
MUST BE COMPLETED WITHIN 30
e. Install the two new cotter pins (28) and bend
MINUTES OF SEALANT APPLICATION.
as described in Figure 63-13.
THE MAST ASSEMBLY MAY THEN BE
STORED UNTIL IT IS REQUIRED.
f. Remove the tools that were installed in step 9.
a. Apply a thin coating of sealant (C-328) to the
11. Apply sealant (C-328) to the mast bearing lower surface of mast bearing retaining plate (11)
retaining plate (11) and the new seal (6) as follows: flange.
a. Install the new seal (6) in the mast bearing b. Attach bearing liner (23) to mast bearing
retaining plate (11), as shown in Detail A. retaining plate (11) with four screws (24), ensuring
proper seating of seal (6) and shims (12). Lightly coat
b. Refer to Figure 63-13 for the definition of the area between seal lips with grease (C-001) (Mobile
area where the sealant is to be applied. 28).
63-00-00
BHT-412-CR&O-3
c. Immediately prior to installing mast into 18. Fill the four holes of the lock ring (4) with sealant
transmission, clean the faying surfaces of bearing liner (C-251) and apply sealant to cover the exposed
(23) flange and top of case assembly threads and the lock ring screws up to the edge of the
(212-040-059-101) with denatured alcohol (C-326) lock ring.
and apply a thin coating of sealant (C-328) to the case
assembly. 19. After the lock ring (4) installation, apply one coat
of epoxy primer coating (C-246) and one coat of
15. Position jet No. 8 (19) in the mast bearing polyurethane coating (C-245) from the outboard edge
retaining plate (11) with the new packing (18) and of the lock ring up to the mast assembly (1) (Detail A).
install the screw (21). Install the cap (20).
20. Apply a bead of sealant (C-251) to cover the
16. Clean the lock ring (4) and apply a light coat of exposed threads up to the edge of the lock ring (4).
sealant (C-251) to the nut side and a bead of sealant Apply sealant to create a slope to ensure the water
on the thread adjacent to the nut face. dissipates (Figure 63-13).
17. Position the lock ring (4) on the mast assembly

(1) and install four screws (3). Secure the four screws
with lockwire (C-405).
63-00-00
BHT-412-CR&O-3
SPECIAL TOOLS REQUIRED (Cont)

ASSEMBLIES (412-040-366-109 AND
SUBSEQUENT) (S/N 36020 THROUGH NUMBER NOMENCLATURE
36999, S/N 37002 THROUGH 37999,
S/N 46400 THROUGH 46499, AND T101939 Rod Connector (Qty 2)
HELICOPTERS MODIFIED BY
T101941 Bolt Assembly (Qty 2)
412-570-001-103 OR POST
BHT-412-SI-74 (412SP TO 412HP T103163 Tie Rod Spacer (Qty 2)
UPGRADE))
T103164 Tie Bolt (Qty 2)
NOTE T103165 Splined Adapter

Mast assembly 412-040-366-109 shall be T103166 Screw and Plate Set
returned to Bell Helicopter Textron (BHT)
for rework. Mast assemblies T103178 Socket Wrench
412-040-366-111 and -115 may be returned
to BHT for rework. T103192 Sleeve Protector
63-26. TRANSMISSION MAIN ROTOR MAST T103260-121 Rod Set (Qty 2)

ASSEMBLY — DISASSEMBLY
MATERIALS REQUIRED
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE NUMBER NOMENCLATURE
204-010-481-001 Mast Nut C-426 Masking Tape
204-011-178-001 Clevis Assembly
412-240-003-101 Wrench Assembly CAUTION

412-240-004-101 Socket
412-240-005-101 Puller Set DO NOT TOUCH PORTION OF MAST

412-240-026-101 Thrust Plate TRANSMISSION WITH BARE HANDS.
AN960-1016 Washer (Qty 2)
T100965 Power Wrench Kit CAUTION

T100968 Anchor Plate Assembly
WHEN LIFTING MAST WITH HOIST, USE
T101456 or Wrench
412-240-027-101 MAST NUT (204-010-481-001) AND
T101901 Plate Assembly DO NOT USE CAP ASSEMBLY THAT IS
USED TO SECURE MAIN ROTOR HUB
T101937 Bearing Installation TO MAST WHEN MAST AND HUB ARE
and Removal Tool
INSTALLED IN HELICOPTER.
63-00-00
BHT-412-CR&O-3
d. Attach the wrench assembly

NOTE (412-240-003-101) (1, Figure 63-19).
If the main rotor mast is being

disassembled for replacement of parts and e. Install the socket (412-240-004-101) (3)
through the wrench assembly (412-240-003-101) (1)
not for overhaul, disassemble only to the
and remove the nut (35, Figure 63-17) from the
extent required to replace the parts.
rotor (32).
NOTE
NOTE
Refer to Mandatory Airworthiness
The bolt used in the torque tube plug
Limitations Schedule in the
removal is a 0.500 X 13 UNC 2.4 inches
BHT-412-MM-2, Chapter 4 for
(61 mm) long.
airworthiness life on mast assembly
components. Identify the components that
f. With a 0.500 X 13 UNC-2B die, extend the
have accumulated hours for retirement. threads up the shank of the bolt (3, Figure 63-20) to
within 0.50 inch (12.7 mm) of the bolt head.
1. Hoist the mast assembly (4, Figure 63-17) into
position over a work bench equipped with padded
g. Install the puller set (412-240-005-101) (6) on
V-blocks. Place the mast in the V-blocks in a horizontal the lower end of the mast assembly. Thread the
position (Figure 63-18). bolt (3) into the nut (4). Tighten the bolt on the shoe (5)
to remove the plug (1) from the rotor (32,
2. Place a layer of protective paper on the mast and Figure 63-17). Remove the retaining ring (33).
secure with masking tape (C-426) to avoid scratching
the mast during disassembly procedures. h. Cool the lower end of the mast with dry ice to
loosen the adhesive holding the rotor (32) in the mast
assembly (4). Pull the rotor from the mast with a
suitable puller.
CAUTION
i. Carefully remove the rotor assembly from the
mast assembly (4).
USE CARE WHEN REMOVING
T O R Q U E M E T E R T U B E A S S E M B LY
4. Remove the sealant from the top of the lock ring
FROM MAST TO PREVENT DAMAGE TO
(7) with a plastic scraper.
CADMIUM PLATING OF MAST INSIDE
DIAMETER.
5. Remove the four screws (6). Cut the sealant
3. Remove the torquemeter tube as follows: around the lock ring (7) with a plastic scraper. Remove
the lock ring.
a. Remove the Iockwire and three bolts (1,

6. Remove the four screws (24). Remove the mast
Figure 63-17) from the plug (2) and the torquemeter
bearing retaining plate (14), packing (47), as
tube assembly (3). Discard the lockwire.
applicable, and the shim (15). If same parts are to be
reinstalled on the mast assembly (4), index the shim
b. Using three jackscrews, remove the plug (2) for reinstallation.
from the torquemeter tube assembly (3).
7. Cut the sealant around the seal (8) with a plastic
c. Remove the retaining ring (37) and the lock scraper. Remove the seal from mast bearing retaining
ring (36) from the rotor (32) and the nut (35). plate (14). Discard the seal.
63-00-00
BHT-412-CR&O-3
29 30 S2 11
28 31 14
12
27
13
1 26
2 A 25 47 (POST TB 412-08-218)
3 15
SEE DETAIL A
16
17
2
18
4 3
19
5 38 4
24
20 32 A
6
33
34
39 T 2 4
7 S1
40 4
8 S2
4 A 35 T 1
36
9 SEE DETAIL C
21
37
10 T 3 T 4
5 6 22
23
SEE DETAIL B
412_CRO_63_0017a_c02
Figure 63-17. Transmission Main Rotor Mast Assembly (Sheet 1 of 6)
63-00-00
BHT-412-CR&O-3
E E
DETAIL A
(PRE TB 412-14-231)
7 S1
10 2
1 S2
9
41
42
14 S2
43 7 8
9
44 45 19
SEE DETAIL D ANNULAR

20
GROOVE
4 A
DETAIL A
(POST TB 412-14-231)
412_CRO_63_0017b_c02
63-00-00
BHT-412-CR&O-3
4 A
39 4
40 4
COTTER PIN 3 38 4
MAST ASSEMBLY 412-040-101-121
HAS LEFT HAND THREADS ON
BEARING RACE RETENTION NUT 3.5 IN. (89 mm) MIN.
OVER RIVET HEADS
DETAIL B DETAIL C
47
14 S2
19
DETAIL D
(POST TB 412-08-218)
412_CRO_63_0017c_c03
63-00-00
BHT-412-CR&O-3
14
S2 11
SECTION E-E
46
EDGE OF CHAMFER
IN TOP CASE
SEE DETAIL F
0.10 IN. (2.5 mm)
MAXIMUM
ALL AROUND
12 S3
DETAIL F
412_CRO_63_0017d_c02
63-00-00
BHT-412-CR&O-3
1. Bolt (3 reqd) 25. Threaded insert

2. Plug 26. Threaded insert
3. Torquemeter tube assembly 27. Packing
4. Mast assembly 28. Jet No. 8
5. Hub adapter wear sleeve 29. Cap
6. Screw (4 reqd) 30. Screw
7. Lock ring 31. Threaded insert
8. Seal 32. Rotor
9. Wear sleeve 33. Retaining ring
10. Mast bearing retention nut 34. Plug
11. Nut 35. Nut
12. Thin steel washer 36. Lock ring
13. Aluminum washer 37. Retaining ring
14. Mast bearing retaining plate 38. Rotor
15. Shim 39. Nut
16. V marks 40. Rivet (2 reqd)
17. Bearing 41. Bolt (10 reqd)
18. V marks 42. Washer (10 reqd)
19. Bearing liner 43. Washer (20 reqd)
20. Oil slinger 44. Washer (10 reqd)
21. Bearing race 45. Nut (10 reqd)
22. Cotter pin 46. Transmission case assembly
23. Nut 47. Packing (Post TB 412-08-218)
24. Screw (4 reqd)
A ADHESIVE (C-317) S2 SEALANT (C-328)
ASSEMBLY FLUID (C-024) S3 SEALANT (C-308)
ANTI-SIEZE COMPOUND (C-452) WET UNREDUCED PRIMER (C-246)
GREASE (C-001) 600 TO 700 IN-LBS

1 T 1 (68 TO 79 Nm)
GREASE (C-172) 250 TO 300 FT-LBS
2 T 2 (339 TO 406 Nm)
900 TO 1100 FT-LBS 6
LOCKWIRE (C-405) T 3 (1220 TO 1491 Nm)
1400 TO 1900 FT-LBS 5
S1 SEALANT (C-251) T 4 (1898 TO 2576 Nm)
NOTES
1 After installation of the seal in the plate, apply a bead of sealant (C-328) to indicated area.
2 Lightly lubricate the seal lips and mating sleeve outside diameter with grease (C-001) before installation of
the plate on the mast.
3 After prescribed torque is applied to the bearing race retention nut, install the two cotter pins. Select holes
for the cotter pins that will result in each cotter pin being positioned on the nut castellation to prevent the
nut from loosening. This position will be opposite for the right and left threaded nuts. Install the cotter pins
with the heads inside the mast, as shown, and bend both tangs to avoid damage to the mast threads.
412_CRO_63_0017e_c01
63-00-00
BHT-412-CR&O-3
NOTES (CONT.)
4 Rotor (38), nut (39), and rivets (40) applicable to 412-040-366-113/-117 transmission main rotor mast assembly
only.
6 For mast bearing nut 412-040-104-103 and subsequent.
7 Apply a coat of epoxy primer coating (C-246) to the annular groove before you install the bearing and the nut.
The epoxy primer coating shall not extend the bearing journal or pass the first thread of the threaded area.
8 Apply a light coat of grease (C-172) to the bearing journal and to the first three threads of the threaded area.
Fill the annular groove area between the nut and the mast bearing journal with grease. After bearing
installation, remove any excess grease from the lower side of the bearing and make sure that the annular
groove and the first three threads of the threaded area have grease.
9 Apply a coat of epoxy primer coating (C-246) and one coat of polyurethane coating (C-245) to the area.
10 Apply a light coat of sealant (C-251) to the nut side of the lock ring (7) and a bead of sealant on the thread
adjacent to the nut face before lock ring installation. After the lock ring installation, fill the four holes in the
lock ring with sealant and apply a bead of sealant to cover the exposed threads and to the edge of the lock
ring. Apply sealant to create a slope, as shown, to make sure the water dissipates.
11 Apply a thin coating of sealant (C-328) to the lower surface mast bearing retaining plate (14).
12 Immediately prior to mast installation, apply a thin uniform coating of sealant (C-308) to the indicated area.
412_CRO_63_0017f_c01
63-00-00
BHT-412-CR&O-3
SEE DETAIL B, C AND D
2
1 SEE DETAIL A
1 4
3 6
7
8 9
11
10
12
DETAIL A
BEARING RACE RETENTION NUT REMOVAL/INSTALLATION
412_CRO_63_0018a_c01
Figure 63-18. Main Rotor Mast Assembly/Disassembly Tools — Tool Application (Sheet 1 of 3)
63-00-00
Page 80B Rev. 12 28 FEB 2020 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
1
3
4
11
12 DETAIL B
BEARING RETENTION NUT REMOVAL/INSTALLATION
13
23
22
21 E 24
19 20
17
16
15
18 18A
1 E
14
DETAIL C
BEARING REMOVAL
412_CRO_63_0018b
63-00-00
BHT-412-CR&O-3
1 24
22
18
21
E 17
16
15
23
14
DETAIL D
BEARING INSTALLATION
22 24 1. Main rotor mast

2. Mast bearing retention nut
3. Splined adapter (T103165)
23 4. Anchor plate (T100968)
5. Power wrench kit (T100965)
1 6. Socket wrench (T103178)
7. Sleeve protector (T103192)
8. Bearing race retention nut
9. Wrench (T101456)
10. Torque wrench
11. Thumb screw
12. Steel bar
13. Torque wrench
14. Screw and plate set (T103166)
15. Nut (5/8-11 UNC)
16. Washer (AN960-1016)
17. Tie rod spacer (T103163)
18. Thrust plate (412-240-026-101)
18A. Thrust plate (412-240-032-101)
19. Tie bolt (T103164)
20. Rod connector (T101939)
27 26 21. Rod set (T103260-121)
25
22. Plate assembly (T101901)
23. Bolt assembly (T101941)
SECTION E-E 24. Bearing installation and removal tool (T101937)
SECTIONAL VIEW OF REMOVAL/INSTALLATION 25. Oil slinger
TOOLS MOUNTED ON MAST BEARING 26. Bearing
27. Liner
412_CRO_63_0018c
63-00-00
BHT-412-CR&O-3
1. Wrench assembly (412-240-003-101)

2. Rotor
3. Socket (412-240-004-101)
4. Nut
412_CRO_63_0019_c01
Figure 63-19. Torque Tube Nut Removal — Tool Application
63-00-00
BHT-412-CR&O-3
1
2
0.50 IN. (12.7 mm)
6 5
7
1. Plug
2. Sleeve
3. Bolt
4. Nut
5. Shoe
6. Puller set (412-240-005-101)
7. Mast
412_CRO_63_0020
Figure 63-20. Torque Tube Plug Removal — Tool Application
63-00-00
BHT-412-CR&O-3
8. Remove the mast bearing retention nut (2,

NOTE
Refer to Figure 63-18, Detail C and
a. Put the sleeve protector (T103192) (7) on the Detail D to install the tools on the mast for
mast bearing retention nut (2). the bearing removal.
a. Put the bearing installation and removal tool

b. Put the socket wrench (T103178) (6) on the
(T101937) (24) on the main rotor mast (1).
mast bearing retention nut (2).
b. Put the plate assembly (T101901) (22) on the
c. Put the power wrench kit (T100965) (5) on the
main rotor mast (1).
socket wrench (T103178) (6).
c. Install two bolt assemblies (T101941) (23).
d. Put the anchor plate assembly (T100968) (4)
on the power wrench kit (T100965) (5).
d. Assemble the rod set (T103260-121) (21), tie
bolt (T103164) (19), rod connector (T101939) (20), tie
e. Put the splined adapter (T103165) (3) on the rod spacer (T103163) (17), washer (AN360-1016)
main rotor mast (1). Make sure that the splined (16), and nut (5/8-11 UNC) (15). Make sure that equal
adapter fully engages the splines of the mast and the thread engagement of the two rods is obtained in the
splines of the anchor plate (T100968) (4). rod connector. Assemble the opposite rods and
connector in the same manner.
f. Tighten the two thumb screws (11).
e. Put the thrust plate (412-240-026-101) (18) on
g. Position the steel bar (12) as illustrated. the end of the mast. Put both tie bolts (T103164) (19)
in the slots of the screw and plate set (T103166) (14)
h. Remove the two cotter pins from the bearing and tighten the nuts (5/8-11 UNC) (15). Tighten the
race retention nut (8). Discard the cotter pins. large screw in the center of the plate set to pull the
bearing (26) from the mast. When the bearing is clear
of the journal on the mast, remove the tools installed in
NOTE
step a through step d. Remove the oil slinger (25),
Refer to Figure 63-17, Detail B for a bearing (26), and liner (27) from the main rotor mast
description of the type of threads used on (1).
the mast 412-040-101-121.
10. Use a hollow, cylindrical sleeve to support the
i. Put the wrench (T101456 or outer race of the bearing (26). Put a similar sleeve on
412-240-027-101) (9, Figure 63-18) on the bearing liner (27) and press the liner off the bearing.
race retention nut (8).
j. Put the torque wrench (10) on the wrench ASSEMBLY — CLEANING
(T101456 or 412-240-027-101) (9). Loosen the
bearing race retention nut (8). Remove the torque
wrench and the wrench. Remove the bearing race
MATERIALS REQUIRED
retention nut.
k. Put the torque wrench (13) on the power
wrench kit (T100965) (5). Operate the power wrench NUMBER NOMENCLATURE
to turn the socket wrench (T103178) (6) and loosen
the mast bearing retention nut (2). C-304 Drycleaning Solvent
l. Remove all the tools installed in the preceding C-309 MEK

step a through step k.
C-516 Clean Cloth
9. Remove the bearing (26) from the mast as
follows:
63-00-00
BHT-412-CR&O-3
1. Remove the old sealant from the mast bearing 2. Inspect and repair the plug (2, Figure 63-17),
retaining plate (14, Figure 63-17) with a plastic scraper torquemeter tube assembly (3), rotor (32), plug (34),
and a clean cloth (C-516) moistened with MEK and nut (35). Refer to Figure 63-22 through
(C-309). Figure 63-26.

2. Clean all the mast assembly components with
inspection. Demagnetize the parts after the magnetic
drycleaning solvent (C-304). If jet No. 8 (28) is
particle inspection. Refer to Table 63-3 and the
clogged, determine the source of the material that is
BHT-ALL-SPM for the procedure.
clogging the jet.
3. Dry the parts with low pressure, filtered

compressed air. Do not allow the bearings to spin FIGURE 63-17
NOMENCLATURE
while drying. INDEX NUMBER
3 Torquemeter Tube
63-28. TRANSMISSION MAIN ROTOR MAST Assembly
ASSEMBLY — INSPECTION
4 Mast Assembly
1. Inspect the main rotor mast in accordance with 7 Lock Ring
Figure 63-21.
10 Mast Bearing Retention
Nut
19 Bearing Liner
CAUTION
20 Oil Slinger
IT IS MANDATORY TO REPLACE THE 21 Bearing Race

FOLLOWING PARTS. 23 Nut
32 Rotor
FIGURE 63-17
NOMENCLATURE 34 Plug
INDEX NUMBER
35 Nut
6 Screw
8 Seal 4. Fluorescent penetrant inspect the mast bearing

retaining plate (14, Figure 63-17) in accordance with
15 Shim the BHT-ALL-SPM. Linear and non-linear indications
22 Cotter Pin shall be interpreted. Linear indications determined to
be cracks and nonlinear indications determined to be
24 Screw corrosion pitting or pitting caused by chemical
processing that exceed the repair limits given in
27 Packing Figure 63-21 shall be cause for rejection.
30 Screw
33 Retaining Ring
37 Retaining Ring
63-00-00
BHT-412-CR&O-3
SEE DETAIL B
SEE DETAIL B
0.100 IN.
(2.54 mm)
DETAIL B
MAIN ROTOR MAST ASSEMBLY
412-040-101-121 OR 412-040-101-125
(THESE ASSEMBLIES DO NOT INCLUDE MAST BEARING RETAINING PLATE, MAST BEARING,
AND BEARING RACE ON LOWER END OF MAST, OR ROTOR, PLUG AND NUT)
TRANSMISSION MAIN ROTOR MAST ASSEMBLY

412-040-366-109 AND 412-040-366-111
(THESE ASSEMBLIES INCLUDE MAST BEARING RETAINING PLATE, MAST BEARING,
AND BEARING RACE ON LOWER END OF MAST AND ROTOR, PLUG AND NUT)
412_CRO_63_0021a_c02
Figure 63-21. Transmission Main Rotor Mast (412-040-366-109 and -111) — Damage Limits (Sheet 1 of 6)
63-00-00
BHT-412-CR&O-3
NOTES
1. Inspect mast for the word “REWORKED” on flange E. If the word “REWORKED” is on the flange and there is
corrosion or mechanical damage on the mast that requires polishing out, reject the mast. Rework is permitted
one time only. This restriction is not applicable to mast bearing retaining plate and liner damage limits. Refer to
note 5 for plate and linear damage limits. The restriction is also not applicable to superficial corrosion in Areas
A, F, S, and T that can be removed with steel wool (C-411).
2. Inspect all mast assembly components for cracks. No cracks are acceptable.
3. Mechanical and corrosion damage on mast outside diameters that is within limits stated below is acceptable if
damage is completely removed by polishing out with fine India stone (C-464) to a finish of 32 RMS or better.
Mast must be treated for corrosion protection after rework. Word “REWORKED” must be marked on Flange E if
damage is polished out.
MAST CORROSION AND MECHANICAL DAMAGE LIMITS
OUTSIDE DIAMETERS: Areas A, B, C, D, F, and G.
MAXIMUM ALLOWABLE DEPTH OF REWORK
Area A INCLUDING THREADS AND SPLINES:

Surface corrosion: Only superficial corrosion that can be removed by steel wool (C-411) is acceptable. If
wear can be visually detected on Spline O visually, comply with note 11.
Area B: 0.002 inch (0.05 mm)
Area C: 0.015 inch (0.38 mm)
Area D: 0.020 inch (0.51 mm)
Area F, INCLUDING THREADS:

Surface corrosion. Only superficial corrosion that can be removed by wire brush or steel wool (C-411).
Area F is 2.15 inches (54.6 mm) long on mast 412-040-101-109 and 412-040-101-111.
Area G, EXCEPT THREADS AND SPLINES:

0.010 inch (0.25 mm) local clean up.
Area G THREADS:
Length - 1/4 inch (6.35 mm)
Depth - 1/3 of thread
Number - 1
Area G SPLINES: (splines K and M)

Corrosion and mechanical damage:
Depth - 0.003 inch (0.08 mm)
Length - 0.500 inch (12.70 mm)
One repair per surface with a maximum of five surfaces.
Superficial corrosion that can be removed by wire brush or steel wool (C-411) is acceptable. Repairs may
not extend into the root. Damage in the root is cause for rejection, the root starts at 0.100 inch (2.54 mm)
below crest, see Detail B. If wear can be detected on spline K and M, comply with note 11.
Area G MAST HUB ADAPTER WEAR SLEEVE:

In addition to 0.010 inch (0.25 mm) damage limit noted above, inspect for wear sleeve-to-mast bonding
failure. No bonding failures are acceptable. 412_CRO_63_0021b_c01
63-00-00
BHT-412-CR&O-3
4. Corrosion damage on mast inside diameters that is within limits stated below is acceptable provided cleanup is
accomplished by honing or similar method so material removed is uniform around diameter and a surface finish
of 63 RMS maximum is obtained. Field repair on mast inside diameters is authorized only in area from top of
mast down to a point 6.0 inches (152 mm) from top of mast and in area from bottom of mast up to a point 6.0
inches (152 mm) from bottom. If damage is present on mast inside diameter deeper than 6.0 inches (152 mm)
from top and/or bottom of mast, request instructions from Bell Helicopter Textron Product Support Engineering
(PSE). Mast must be treated for corrosion protection after rework. Request corrosion protection instructions
from Bell Helicopter Textron PSE.
INSIDE DIAMETERS Areas H, I, J, T and U.
Area H:
Refer to the following table for maximum acceptable inside diameters in area H for various outside
diameters measured in inches unless otherwise specified from top of mast.
INCHES (mm) INCHES (mm) INCHES (mm)
If outer diameter measures 3.545 (90.04) 3.550 (90.17) 3.555 (90.30)



Area I:
Maximum acceptable inside diameter is 2.805 inches (71.25 mm).
Area J:
Maximum acceptable depth of damage is 0.005 inch (0.13 mm) or to a maximum diameter of 2.815 inches
(71.50 mm).
Area T:
Surface corrosion. Only superficial corrosion that can be removed by wire brush or steel wool.
Area U:
Surface corrosion. Only superficial corrosion that can be removed by wire brush or steel wool.
5. Mechanical and corrosion damage on mast bearing retaining plate and linear within limits stated below is
acceptable if polished out with varying grades of aluminum oxide paper to a finish of 63 RMS or better, and
rework areas are treated for corrosion protection. Pitting must be completely removed within allowable cleanup
depth for mast bearing retaining plate and linear to be acceptable. Inspect 13 threaded inserts in mast bearing
retaining plate for secure installation and damaged threads. Damaged, loose and/or missing inserts are not
acceptable.
Area R:
Maximum depth after cleanup is 0.020 inch (0.51 mm)
Maximum area of rework is 40% of total surface area.
Maximum area of rework is 50% of any 1.0 square inch (645 mm2).
Minimum blend radius of rework is 0.5 inch (13 mm).
Area Q:
Superficial marks on inner diameter and outer diameter of bearing liner in Area Q are acceptable without
repair. Damage in excess of superficial is not acceptable. If there is evidence of wear, comply with note 12.
412_CRO_63_0021c
63-00-00
BHT-412-CR&O-3
6. When mast bearing retaining plate and duplex bearing are removed from mast, inspect slinger, shim, nut, and
sleeve for mechanical and corrosion damage. Damage to any of these parts in excess of superficial is not
acceptable. Inspect seal wear sleeve for wear. The maximum acceptable depth of wear is 0.002 inch (0.05 mm) in
measured from unworn area of sleeve diameter.
7. Inspect duplex bearing in area Q as follows:
CAUTION
DO NOT HANDLE BEARING BALLS AND RACES

WITH BARE HANDS AS THE BODY ACIDS MAY
CAUSE ETCHING OF THE SURFACE RESULTING
IN EARLY FAILURES. ALWAYS OIL BEARINGS
AFTER INSPECTIONS AND PLACE IN A CLEAN
PLASTIC BAG OR PROTECTIVE PAPER.
a. Inspect bearing for evidence of debris damage (indentations) in the inner and outer races of both upper and
lower bearings. Debris damage will eventually result in bearing failure therefore is cause for replacement of
bearing.
b. Inspect the inner and outer races for evidence of microspalling, in the loaded ball path. Microspalling is cause
for replacement of bearing. Microspalling will appear as small pits or blisters in the ball path. Use a 4X power
glass to observe this area to determine whether condition exists. Microspalling is a progressive failure mode
and will eventually result in a spalling failure of the race.
c. Inspect the balls of the bearings for cuts which may indicate excessive angle. If the balls exhibit cuts the
damage will likely result in premature bearing failure and is cause for replacement of bearing.
d. Bearing races that show signs of corrosion in the ball path are still considered usable if the corrosion is
limited to stains that exhibit no visible depth when viewed with a 4X power glass. Corrosion that is outside the
concave race surfaces is acceptable if; it is limited to less than 10% of the total bearing surface, cannot be felt
with a probe having an end radius of 0.020 inch (0.51 mm) and is readily removable by lightly hand polishing
with fine Scotch Brite. Polishing of the balls or load area of the races is prohibited.
e. Inspect bearing for brinelling damage. Brinelling damage as evidenced by indications in the races that
correspond to ball spacing is cause for replacement. False brinelling is visually evidenced by minute
scratches along the bore axis of the races and usually is caused by vibration during shipment. Unless this
brinelling shows signs of noticeable depth which can be felt with a probe having a 0.030 inch (0.76 mm).
radius it is not cause for replacement.
8. Inspect oil jet No. 8 (not illustrated) as follows:
CAUTION
CLEAN THE JET USING A SOFT BRISTLE BRUSH AND

SOLVENT. DRY USING FILTERED COMPRESSED AIR.
DO NOT INSERT ANY HARD MATERIAL INTO THE JET
ORIFICE TO REMOVE OBSTRUCTIONS.
412_CRO_63_0021d
63-00-00
BHT-412-CR&O-3
a. Inspect for clogging. If jet passages are clogged determine source of material that is clogging jet.
b. Inspect for corrosion. Superficial corrosion damage on jet plate on exterior of transmission is acceptable if
products of corrosion are removed.
c. Inspect for mechanical damage. Cracks and distorsion are not acceptable.
9. Bearing race at lower end of mast is illustrated in Area S. Visually examine the bearing race for scratches, dings,
dents, scuffing, micropitting, spalling, brinelling, and corrosion pitting.
a. A burnished or polished condition in the roller path is acceptable provided the condition is uniform over the
entire circumference of the race.
b. Scratches, dings, dents and scuffs which can be felt with an 0.020 inch (0.51 mm) spherical radius probe are
cause for rejection.
c. Micropitting, spalling, brinelling, and corrosion pitting are cause for rejection.
Refer to Detail A. With bearing race mounted on mast, measure the size of the race at three locations as follows:
Instrument must be capable of reliability measuring to four decimal place accuracy.
a. Measure and record diameter at locations A and B in areas of no wear.
b. Measure and record diameter at location C in area of heaviest wear in roller path.
c. Calculate and record the arithmetic average of diametral measurements A and B.
d. Reject the race if the difference between the calculated average of measurements A and B and measurement
C is greater than 0.0002 inch (0.005 mm), or if the diameter at location C measures 3.8568 inches
(97.963 mm) or less with the race installed on the mast.
If measuring instrument of the required accuracy is not available, check the bearing race for evidence of a
wear step using a probe having 0.020 inch (0.51 mm) spherical radius point. A wear step at either end of the
roller path which can be felt with a probe is cause for rejection of the race.
10. Inspect name (data) plate for legibility and secure installation on mast. Loose and/or illegibile data plates are not
acceptable.

It is not intended that spline wear limits be measured as a prescribed overhaul procedure. Measure splines only
if there is visual evidence of wear:
MIN MAX
SPLINE K OVER PINS 4.0760 (103.530) 4.0961 (104.041)

SPLINE M OVER PINS 4.0760 (103.530) 4.0961 (104.041)

SPLINE O OVER PINS 4.9860 (126.644) 4.9913 (126.779)

412_CRO_63_0021e
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BHT-412-CR&O-3
12. Wear on mating surfaces of duplex ball bearing, mast, and liner:
It is not intended that wear on bearing, mast, and liner mating surfaces be measured as a prescribed overhaul
procedure. Measure only if there is visual evidence of wear.
MIN MAX
BEARING ID 4.3302 (109.987) 4.3307 (110.000)
BEARING OD 6.6922 (169.982) 6.6929 (170.000)
LINER ID 6.6919 (169.974) 6.6928 (169.997)
13. MAST DISTORTION (BENDING)

It is not intended that mast run-out be measured as a prescribed overhaul procedure. The run-out inspection
is required when mast records and/or mast appearance indicate that mast has been involved in an accident
or incident that requires conditional inspection. Refer to BHT-412-MM-1 for accidents and/or incidents which
require conditional inspection.
The center countersinks at each end of the mast must be inspected for damage and repaired as required
before performing run-out inspections. Remove any paint on the countersinks using a soft cloth moistened
with MEK (C-309). Remove any localized raised material using an India stone (C-464) by hand.
Mount mast on centers in a lathe or suitable fixture. Measure run-out on Surfaces L, N, and P. Maximum
acceptable total indicator readings (TIR) are:
SURFACE L (TOP) N (MIDDLE) P (BOTTOM)
MAX TIR 0.0035 inch (0.089 mm) 0.003 inch (0.08 mm) 0.002 inch (0.05 mm)
412_CRO_63_0021f
63-00-00
BHT-412-CR&O-3
F B
A E
D
C
NO. REF CHARACTERISTIC INSPECTION LIMIT

LTR METHOD
1. A Mechanical Visual/measure 1
2. B, C Mechanical Visual/measure 2
3. D Mechanical Visual/measure 2
4. E Mechanical Visual/measure 2
5. F Mechanical Visual/measure 3
6. All Corrosion Visual 4
7. All Cracks Magnetic particle None allowed

(BHT-ALL-SPM)
NOTES
1 Light axial scratches are acceptable on Surface A provided damage does not exceed 0.002 inch (0.05 mm) in
depth. Rework only to remove any raised material flush with surrounding surface.
2 Mechanical damage in the form of nicks, dents, and scratches is acceptable on Surfaces B, C, E and in D up
to 0.010 inch (0.25 mm) in depth after rework. Polish out damage on Surfaces B, C and E to produce
minimum radii of 0.25 inch (6.4 mm) with a surface finish of 63 RMS or better. Do not polish out damage in
hole D but remove any raised material flush with surrounding wall.
3 Mechanical damage in threads is limited to one thread pitch. Damage may not exceed 1/4 thread depth nor
0.250 inch (6.35 mm) combined length after rework. Inspect threads for burrs and galled material.
4 Only light superficial corrosion which may be readily removed by hand polishing with fine steel wool (C-411)
or abrasive pads (C-407) is acceptable.
412_CRO_63_0022
Figure 63-22. Plug (412-040-512-101) — Wear and Damage Limits
63-00-00
BHT-412-CR&O-3
AREA J AREA C
B AREA J
A
F
DIA DIA
B H A
I
AREA D AREA D SPLINE E
3.0 IN. 3.0 IN.
(76 mm) (76 mm)
G
11
TUBE ASEMBLY
(412-040-510-103)

LTR METHOD
1. A Wear Measure 2.117 inches (53.77 mm)

(B/P 2.1173 to 2.1177 inches)
(53.779 to 53.790 mm)
3. B Mechanical Visual/measure 1
4. C Warpage/distorsion Measure straightness 2
5. D Warpage/distorsion Measure runout
7. F Mechanical Visual/measure 1
8. G Mechanical Visual/measure 5
9. H Mechanical Visual/measure 6
10. I Mechanical Visual/measure 7
11. ALL Corrosion Visual 8
12. ALL Cracks Magnetic particle 9

(BHT-ALL-SPM)
13. J Mechanical Visual 10
412_CRO_63_0023a_c01
Figure 63-23. Tube Assembly (412-040-510-103) — Wear and Damage Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
NOTES
1 Light axial scratches are acceptable in Areas A, B, and F provided damage does not exceed 0.002 inch
(0.05 mm). Rework only to remove any raised material flush with surrounding surface.
2 Using an 18.0 inches (457 mm) straight edge, check straightness of tube in Area C. Maximum gap
between tube and straight edge is 0.018 inch (0.46 mm).
3 DELETED
4 Mechanical damage in the form of nicks and dents and light scratches on the outboard ends of the teeth
of Spline E is acceptable provided damage does not exceed 0.002 inch (0.05 mm) in depth. No damage is
acceptable on the spline tooth tip edges. Rework spline only to remove any raised material flush with the
surrounding surface.
5 Light circumferential scratches are acceptable in Areas A, B, and F provided damage does not exceed
0.002 inch (0.051 mm) in depth. Rework only to remove any raised material flush with surrounding
surface.
6 Mechanical damage in the form of nicks, dents, and scratches is acceptable on Surface H up to
0.010 inch (0.25 mm) in depth and 25 percent of the area of the surface. Polish out damage to produce
minimum radii of 0.25 inch (6.4 mm) with a surface finish of 63 RMS of better.
7 Mechanical damage in threads is limited to one thread pitch. Damage may not exceed 1/4 thread depth
nor 0.250 inch (6.35 mm) combined length after rework. Inspect threads for burrs and galled material.
8 Only light superficial corrosion which may be readily removed by hand polishing with fine steel wool
(C-411) or abrasive pads (C-407) is acceptable.
9 Indications to 1/8 inch (3.18 mm), no closer than 1/4 inch (6.35 mm) are acceptable. Process per
BHT-ALL-SPM, Chapter 3 except for maintenance criteria.
10 Brazed joints check for integrity and cracks. Porosity is acceptable.
11 Area is cadmium plated. Touch up bare areas per BHT-ALL-SPM, Chapter 3 (except threads).
412_CRO_63_0023b_c01
Figure 63-23. Tube Assembly (412-040-510-103) — Wear and Damage Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
AREA D
AREA B
AREA C
AREA A

LTR METHOD
1. A, B Mechanical Visual/measure 1
2. C Mechanical Visual/measure 2

(BHT-ALL-SPM)
NOTES
1 Light axial scratches are acceptable in Areas A and B provided damage does not exceed 0.002 inch
(0.05 mm) in depth. Rework only to remove any raised material flush with surrounding surface.
Maintain 32 RMS or better surface finish in Area B.
2 Uniform circumferential wear on Area C may not exceed 0.002 inch (0.05 mm) in depth.
3 Mechanical damage in the form of nicks, dents, and scratches is acceptable in Area D provided damage
does not exceed 0.010 inch (0.25 mm) in depth after rework. Polish out mechanical damage to produce
0.060 inch (1.52 mm) fillet radii with a surface finish of 63 RMS or better. Maintain 0.005 to 0.015 inch
(0.13 to 0.38 mm) edge break at corners E.
412_CRO_63_0024_c01
Figure 63-24. Plug (412-040-514-101) — Wear and Damage Limits
63-00-00
BHT-412-CR&O-3
AREA A
AREA B
AREA C

LTR METHOD
2. B Mechanical Visual/measure 2 3

(BHT-ALL-SPM)
NOTES
1. Scratches and sharp nicks and dents no deeper than 0.005 inch (0.13 mm) need not be polished out.
Polish out mechanical damage deeper than 0.005 inch (0.13 mm) to produce 0.060 inch (1.52 mm)
minimum fillet radii with a surface finish of 63 RMS or better.
2 Mechanical damage in the form of nicks, dents, and scratches is acceptable in Area A and on Area B
provided the damage does not exceed 0.010 inch (0.25 mm) in depth after rework. Scratches on the
spline teeth need not be reworked but remove all raised material flush with surrounding surface.
3 Uniform circumferential wear on Area B may not exceed 0.002 inch (0.05 mm) in depth.
4 Allowable mechanical damage in threads in Area C is limited to one thread pitch. Thread damage may not
exceed 1/4 thread depth nor more than 0.25 inch (6.4 mm) combined total length after rework. Inspect
threads for burrs and galled material.
412_CRO_63_0025
Figure 63-25. Nut (412-040-515-101) (S/N 36020 through 36096) — Wear and Damage Limits
63-00-00
BHT-412-CR&O-3
DIA A SPLINE D
MINOR DIA
C
E

LTR METHOD
1. A Wear Measure 2.8435 TO 2.8445 inches 1

(72.225 TO 72.250 mm)
3. B Mechanical Visual/measure 3
5. D Roundness Measure runout 4

(BHT-ALL-SPM)
412_CRO_63_0026a
Figure 63-26. Rotor (412-040-519-101) (S/N 36020 through 36096) — Wear and Damage Limits
(Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
NOTES
1 Measure diameter in four places 45° apart (between slots). Measurements must be within range specified.
2 Light axial scratches are acceptable provided damage does not exceed 0.001 inch (0.03 mm). Rework only
to remove any raised material flush with surrounding surface.
3 Light axial scratches are acceptable provided damage does not exceed 0.002 inch (0.05 mm). Rework only
4 Measure runout of minor diameter of spline while part is mounted on Diameter A. Runout must be within
0.001 inch (0.03 mm).
5 Mechanical damage in the form of nicks and dents and light scratches on the ends of the teeth is
acceptable provided damage does not exceed 0.002 inch (0.05 mm) In depth.
Light longitudinal scratches are acceptable on the faces of the spline teeth provided the scratches do not
exceed 0.002 inch (0.05 mm) in depth and do not break over the tooth tip edges.
No damage is acceptable on the tip edges of the spline teeth.
Rework spline only to remove any raised material flush with surrounding surface.
6 Mechanical damage in threads is limited to one thread pitch. Damage may not exceed 1/4 thread depth nor
0.25 inch (6.4 mm) collected length after rework. Inspect threads for burrs and galled material.
412_CRO_63_0026b
Figure 63-26. Rotor (412-040-519-101) (S/N 36020 through 36096) — Wear and Damage Limits
(Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
63-29. TRANSMISSION MAIN ROTOR MAST cleanup exceeds the limits of Figure 63-21, the mast is
ASSEMBLY — REPAIR not repairable. Final polish repair the area to a surface
roughness of 32 RMS or better.
MATERIALS REQUIRED
NOTE
Refer to BHT-ALL-SPM for specifications. If corrosion must be polished out on the
mast inside diameter, comply with Note 4 in
NUMBER NOMENCLATURE Figure 63-21.
4. Polish out superficial corrosion damage in areas
Solution
A, F, T, and U (Figure 63-21) with steel wool (C-411) or
C-406 Abrasive Cloth or with a wire brush only. Removal of superficial
Paper corrosion from areas A, F, T, and/or area U does not
require marking the word REWORKED on flange E.
C-411 Steel Wool
5. If damage was polished out on areas of the mast
C-464 India Stone
other than areas A, F, T, and U, or the mast bearing
retaining plate, mark the word REWORKED on
1. Inspect the mast for the word REWORKED on flange E with vibrating stylus.
the flange E illustrated in Figure 63-21. If the word
REWORKED is on the flange and there is corrosion or 6. Touch up rework areas where cadmium plating
mechanical damage on the mast that requires was removed as follows:
polishing out, reject the mast. Rework on the mast is
permitted one time only. This restriction is not
applicable to the mast bearing retaining plate, liner, a. If field repair is being accomplished, do not
rotor, plug, and nut or to superficial corrosion in areas apply brush cadmium plating on the inside diameter of
A, F, T, and U that can be removed with steel wool the mast beyond the 6.0-inches (152-mm) limits noted
(C-411). at step 4 in Figure 63-21.
2. Dress out small burrs, nicks, and scratches on b. Use only the brush cadmium plating
the spline O (Figure 63-21) with a fine India stone procedures noted in the BHT-ALL-SPM.
(C-464).
c. Apply cadmium plating solution (C-108) only
3. Polish out mechanical and corrosion damage on in the areas indicated in Figure 63-27
the mast in areas other than areas A, F, T, and U. Also, (BHT-ALL-SPM).
polish out damage on the bearing retaining plate. Use
a fine to medium abrasive cloth or paper (C-406) or a 7. Replace missing or illegible nameplate
fine India stone (C-464). If damage after a complete (BHT-ALL-SPM).
63-00-00
BHT-412-CR&O-3
AREA W
BEARING JOURNAL
0.62 IN.
(15.7 mm) SPLINE O
SPLINE K 1.05 IN. SPLINE M
(26.7 mm)
MAST, HUB ADAPTER

WEAR SLEEVE
AREA V
NOTE
Areas enclosed by dash lines are cadmium plated at time of mast manufacture. Area W on wear sleeve,
spline M, and all mast external surfaces below top of bearing journal are not cadmium plated.
Area V is primed with (C-204) internally.
412_CRO_63_0027
Figure 63-27. Transmission Main Rotor Mast — Cadmium Plating Areas
63-00-00
BHT-412-CR&O-3
MATERIALS REQUIRED (Cont)

ASSEMBLY — ASSEMBLY
NUMBER NOMENCLATURE
C-246 1 Epoxy Primer Coating

NUMBER NOMENCLATURE
C-251 Sealant
412-240-003-101 Wrench Assembly
C-305 Aliphatic Naphtha
412-240-004-101 Socket
C-309 MEK
412-240-026-101 Thrust Plate
C-317 Adhesive
412-240-031-101 Wrench Assembly
C-326 Denatured Alcohol
T100965 Power Wrench Kit
C-328 Sealant
T100968 Anchor Plate Assembly
C-405 Lockwire
C-426 Masking Tape
T101937 Bearing Installation
and Removal Tool C-452 Anti-seize Compound
T101941 Bolt Assembly C-516 Clean Cloth
T103163 Tie Rod Spacer NOTE:
T103165 Splined Adapter As an alternate, use epoxy polyamide
1
primer (C-204)
T103166 Screw and Plate Set
T103178 Socket Wrench
T103192 Sleeve Protector CAUTION
T103260-121 Rod Set

DO NOT TOUCH PORTION OF MAST
MATERIALS REQUIRED

CAUTION
NUMBER NOMENCLATURE
C-001 Grease WHEN LIFTING MAST WITH HOIST, USE

MAST NUT (204-010-481-001) AND
C-024 Assembly Fluid CLEVIS ASSEMBLY (204-011-178-001).
C-172 Grease USED TO SECURE MAIN ROTOR HUB
TO MAST.
C-204 Epoxy Polyamide
Primer 1. Place a layer of protective paper on the mast and
secure with masking tape (C-426) to avoid scratching
C-245 Polyurethane Coating
the mast during the assembly procedures.
63-00-00
BHT-412-CR&O-3
2. Before you install the bearing (17, Figure 63-17) g. Put the bearing installation and removal tool
and the mast bearing retention nut (10), apply a coat (T101937) (24, Figure 63-18) on the main rotor mast
of epoxy primer coating (C-246) to the annular groove (1).
only. Do not apply primer to the bearing journal or to
the threaded area. Let dry. h. Put the oil slinger (25), bearings (26), and liner
(27) on the main rotor mast (1).
3. Apply grease (C-172) to the mast bearing journal
and to the first three threads of the threaded area. Fill i. Put the plate assemblies (T101901) (22) on
the annular groove with grease. the mast and install two bolt assemblies
(T101941) (23).
4. Install the bearing on the mast as follows:
j. Put the thrust plate (412-240-026-101) (18),
a. Put the bearing (17) with the V-marks (16) on screw and plate set (T103166) (14), two rod sets
the bearing inner races aligned and the apex pointing (T103260-121) (21), two tie rod spacers (T103163)
toward the top of the mast. Align the V-marks (18) on (17), two washers (AN960-1016) (16), and two nuts
the bearing outer races with the apex pointing toward (5/8-11 UNC) (15) on the mast. Tighten the nuts.
the bottom of the mast.
k. Carefully tighten the large screw in the screw
b. Put a hollow cylindrical metal sleeve of the and plate set (T103166) (14) to pull the bearing into
correct size to contact the bearing outer race on the position on the mast. When the bearing is fully seated
bearings (17) and press the bearing into the bearing against the shoulder on the mast, remove the tools
liner (19). Rotate the bearing inner race to check for installed in step g through step j.
freedom of operation during the seating procedure.
5. Make sure that after the bearing (17,
c. Place a shim (15) of sufficient thickness to Figure 63-17) installation, the annular groove is filled
create a gap between the flange of the bearing liner with grease (C-172). Make sure that the first three
(19) and the flange of the mast bearing retainer plate threads of the threaded area have grease. Remove
(14). any excess grease from the lower side area of the
bearing.
d. Install the mast bearing retainer plate (14) on
the mast assembly (4) with care to avoid damaging the
seal on the mast splines. Secure the bearing liner with NOTE
four new screws (24).
Depending on the helicopter configuration,
a mast bearing retention nut (2,
e. Measure and record the gap between the Figure 63-18) 412-040-104-101 or -103
bearing liner (19) and the retainer plate (14). To obtain may be applicable for installation. The
the proper shim (15) thickness, subtract the previously primary difference between the mast
recorded dimension from the shim installed in step c bearing retention nuts 412-040-104-101
and add 0.001 to 0.003 inch (0.03 to 0.08 mm) to the and -103 is that the threads of the -103
total shim thickness. This will result in a 0.001 to retention nut are coated with solid film
0.003 inch (0.03 to 0.08 mm) pinch on the lubricant. Prior to the installation of a
bearing (17). retention nut -103, make sure the threads
have a coating of solid film lubricant. If the
f. Remove the four screws (24) and separate solid film lubricant coating is damaged or
the bearing liner (19) from the mast bearing retaining missing, refer to the BHT-ALL-SPM for
plate (14). application procedures. The application of
solid film lubricant is directly related to the
nut -103 torque value specified in the
NOTE following assembly instructions.
Refer to Figure 63-18, Detail D, for the
sectional view of the bearings, oil slinger, 6. Install the mast bearing retention nut (2) as
and liner installed on the mast. follows:
63-00-00
BHT-412-CR&O-3
i. For the mast bearing retention nut (2)

NOTE
412-040-104-103, inspect the data plate on the power
Refer to Figure 63-18, Detail B for the view wrench kit (T100965) (5) and determine what torque
of the installed bearing retention nut should be applied with the torque wrench (13) to the
removal/installation tools. nut T .
a. Make sure that the mast bearing retention nut j. Put the steel bar (12) in the anchor plate
(2) has a wear sleeve bonded to the nut prior to (T100968) (4).
installation. Thread the nut onto the mast with the
splined end of the nut next to the bearing. k. Put the torque wrench (13) on the power
wrench kit (T100965) (5).
b. If the wear sleeve is damaged, install a new
wear sleeve on the mast bearing retention nut (2) as l. For the mast bearing retention nut (2)
follows: 412-040-104-101, make sure that the splines on the
(1) Protect the bearing from contamination nut to the lowest torque value T with the torque
and carefully remove the wear sleeve. wrench (13). Rotate the outer race of the bearing to
check for freedom of operation.
(2) Remove the adhesive from the mast
bearing retention nut (2) and clean with a clean cloth m. For the mast bearing retention nut (2)
(C-516) moistened with MEK (C-309). 412-040-104-103, make sure that the splines on the
(3) Apply adhesive (C-317) to the outside nut to the lowest torque value T with the torque
diameter of the mast bearing retention nut (2) and wrench (13). Rotate the outer race of the bearing to
install a new wear sleeve. check for freedom of operation.
(4) Clean off excess adhesive, as required. n. Remove the tools installed in the preceding
steps.
c. Put the sleeve protector (T103192) (7) on the
mast bearing retention nut (2). 7. Put the lock ring (7, Figure 63-17) on the mast
bearing retention nut (10) and check whether the holes
d. Put the socket wrench (T103178) (6) on the for the screws (6) are aligned. If the holes are not
mast bearing retention nut (2). aligned, rotate the lock ring to different splines on the
mast. If the holes for all four screws are still not
e. Put the power wrench kit (T100965) (5) on the accessible, reinstall the tools and tighten the mast
mast with the lugs and thumb screws (11) toward the bearing retention nut (2, Figure 63-18). Repeat, as
top of the mast. required, until the four screws (6, Figure 63-17) can be
installed, but do not exceed the torque limits noted in
step h and step i. Do not install the lock ring at this
f. Put the anchor plate (T100968) (4) on the
time.
mast. Engage the anchor plate on the lugs of the
power wrench kit (T100965) (5). Tighten the two
thumb screws (11). 8. After the holes are aligned for the four screws (6),
install the tools as outlined in step c through step k.
g. Put the splined adapter (T103165) (3) to These tools will be used to hold the mast during the
engage the splines on the mast with the splines on the installation of the bearing race (21) and the nut (23).
anchor plate (T100968) (4). Make sure that the splines
are fully engaged. 9. Install the bearing race (21) and the nut (23) as
follows:
h. For the mast bearing retention nut (2)
412-040-104-101, inspect the data plate on the power
NOTE
wrench kit (T100965) (5) and determine what torque
should be applied with the torque wrench (13) to the The bearing race retention nut has
nut T . left-hand threads.
63-00-00
BHT-412-CR&O-3
a. Put the bearing race (21) on the mast g. If the mast torque tube is to be installed at this
assembly (4). time, refer to the BHT-412-MM-6 for installation and
alignment instructions.
b. Apply anti-seize thread compound (C-452) to
the threads of the mast and nut (23). Thread the nut 11. For the mast assemblies 412-040-366-113, -117,
on the mast. -121, -123, -127, and -129, install the rotor (4,
c. Put the wrench (T101456 or
412-240-027-101) (9, Figure 63-18) and torque the
a. Install the rotor (4) on the mast assembly (1)
torque wrench (10) on the nut. Torque the nut to the
with any two diametrically opposed tabs centered on
lowest torque value T . Remove the wrenches and
the spotfaced mast pilot holes within 0.030 inch
determine whether the two cotter pins (22,
(76 mm).
Figure 63-17) can be installed. If necessary, apply
more torque to the nut, but do not exceed the high side
limit. b. With the rotor (4) firmly seated against the
shoulder, line drill the mast and rotor tabs at the two
spotfaced pilot holes.
d. Install the two new cotter pins (22) and bend
as described in Figure 63-17.
c. Edge break holes after reaming to remove
e. Remove the tools that were installed in step 8. burrs, maximum edge break 0.003 inch (0.08 mm).
d. Install the two rivets (3) with the manufactured

NOTE head outboard in any two diametrically opposed mast
The mast assembly 412-040-366-109 must holes positioned in the slots of the fully torqued nut (2),
be returned to BHT for calibration of the except hole for rivet to be 0.129 to 0.130 inch (3.28 to
torquemeter tube assembly whenever the 3.30 mm) diameter.
mast assembly has had the torquemeter
tube or mast lower rotor disassembled or e. After rivet installation, use wrench assembly
repositioned. (412-240-031-101) and apply a test torque of
100 inch-pounds (11.30 Nm) in the clockwise and
10. For the mast assemblies 412-040-366-111 and counterclockwise directions to the rotor (4). No relative
-115, install the rotor (32) as follows: motion between the mast and rotor is allowed.
a. Apply adhesive (C-317) to the faying surfaces f. If the mast torque tube is to be installed at this
of the rotor (32) and mast assembly (4). time, refer to the BHT-412-MM-6 for installation and
alignment instructions.
b. Install the rotor (32) in the mast assembly (4).
Wipe off excess adhesive and install the retaining
12. Apply sealant (C-328) to the mast bearing
ring (33).
retaining plate (14, Figure 63-17) and the seal (8) as
follows:
c. Install the plug (34) and the nut (35).
d. Attach the wrench assembly a. Install the new seal (8) in the mast bearing
(412-240-003-101) to the rotor (32). Install the socket retaining plate (14), as shown in Detail A.
(412-240-004-101) through the wrench assembly.
Torque the nut (35) T within one hour of application b. Refer to Figure 63-17 for the definition of the
of adhesive (C-317) for installation of rotor. area where the sealant is to be applied.
e. Line up the tabs on the lock ring (36) with the c. Clean the surfaces where the sealant is to be
notches in the nut (35) and install the lock ring. applied with a clean cloth (C-516) moistened with MEK
(C-309). Wipe dry with a clean cloth (C-516) before
f. Install the new retaining ring (37). the solvent evaporates.
63-00-00
BHT-412-CR&O-3
d. Mix sealant (C-328) in accordance with the 19. Attach the bearing liner (19) to the mast bearing
manufacturer’s instructions on the container, or mix retaining plate (14) with four screws (24). Ensure
100 parts by weight of base material to 12 parts by proper seating of the seal (8), packing (47), as
weight of accelerator. Mix thoroughly. The pot life of applicable, and shims (15).
mixed sealant is 2 hours. Tack-free time after
application is 12 to 24 hours.
CAUTION
e. Locate four 0.125 inch (3.18 mm) drain holes
in the mast bearing retaining plate (14). Do not allow
sealant to obstruct these four holes. Apply sealant I F M AS T A SS EM BLY I S NO T TO B E
(C-328) to the area indicated in Figure 63-17. FULLY INSTALLED IN A TRANSMISSION
WITHIN 30 MINUTES OF SEALANT
A P P L I C AT I O N , S T E P 2 0 M U S T B E
NOTE
DONE.
Do not pack grease in the cavity between
the seal lips. 20. Install the bolts (41), washers (42, 43, and 44),
and nuts (45) to clamp the bearing liner (19) to the
13. Lightly lubricate the new seal (8) lips and mating mast bearing retaining plate (14), as shown in
sleeve outside diameter with grease (C-001). Figure 63-17, Detail A. Torque the nuts 100 to
140 inch-pounds (11.3 to 15.8 Nm). Tighten the
14. Clean the faying surfaces of the bearing liner (19) screws (24), again.
and the mast bearing retaining plate (14) with aliphatic
naphtha (C-305) or denatured alcohol (C-326).
NOTE
15. Apply a thin coating of sealant (C-328) to the Store the mast assembly (4) until it is
lower surface of the mast bearing retaining plate (14) required. If the mast assembly is being
flange, as shown in Figure 63-17, Detail A. installed in the transmission, then step 21
shall be completed within 30 minutes of
sealant (C-308) application.
16. Put the shim (15) in position on top of the bearing
(17).
21. Immediately before installing the main rotor mast
assembly (4) into the transmission assembly
NOTE (BHT-412-MM-6), clean the mating surfaces of the
bearing liner (19) flange and the top of the
The step 17 is applicable to helicopters S/N
transmission case assembly (46) with aliphatic
36495 through 36999, S/N 37002 through
naphtha (C-305) or denatured alcohol (C-326). Apply
37999, and mast assemblies Post TB
412-08-218. a thin coating of sealant (C-308) to the transmission
case assembly (46, Detail F).
17. Install the packing (47). A light coat of assembly
fluid (C-024) may be used to correctly position the 22. Put the jet No. 8 (28) in the mast bearing retaining
packing. Make sure the assembly fluid application plate (14) with the new packing (27) and install the
contacts only the packing, bearing liner (19) surfaces, screw (30). Install the cap (29).
and mast bearing retaining plate (14).
23. Clean the lock ring (7) and apply a light coat of
18. Put the mast bearing retaining plate (14) in sealant (C-251) to the nut side and a bead of sealant
position on the bearing liner (19). on the thread adjacent to the nut face.
63-00-00
BHT-412-CR&O-3
3 1
2 T
1
3.51 IN. (89.2 mm) MIN.

OVER RIVET HEADS
1. Mast assembly (412-040-101-129)

2. Nut (412-040-524-101)
3. Rivet (CR4523-4-04) 2 Reqd
4. Rotor (412-040-525-101)
250 TO 300 FT-LBS

T (339 TO 406 Nm)
NOTE
1 Install rivets (3) with manufactured head outboard in any two diametrically opposed mast holes
positioned in the slots of the fully torqued nut (2).
412_CRO_63_0028
Figure 63-28. Mast Assembly (412-040-366-113, -117, -121, -123, -127, and -129) — Rotor Installation
63-00-00
BHT-412-CR&O-3
24. Put the lock ring (7) on the mast and install the 26. After the lock ring (7) installation, apply one coat
four new screws (6). Secure the four screws with of epoxy primer coating (C-246) and one coat of
lockwire (C-405). polyurethane coating (C-245) from the outboard edge
of the lock ring up to the mast assembly (Detail A).
25. Fill the four holes of the lock ring (7) with sealant 27. Apply a bead of sealant (C-251) to cover the
(C-251) and apply sealant to cover the exposed exposed threads up to the edge of the lock ring (7).
threads and the lock ring screws up to the edge of the Apply sealant to create a slope to ensure water
lock ring. dissipates, as shown in Figure 63-17, Detail A.
63-00-00
Page 106B Rev. 12 28 FEB 2020 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
TRANSMISSION
63-31. TRANSMISSION (412-040-002 AND 1. If a conditional inspection is required, accomplish

412-040-004) the conditional inspections, such as check for binding
of internal parts, prior to disassembly (paragraph
63-34 and paragraph 63-35).
1. Prior to disassembly, inspect the transmission
and the transmission records for evidence of accident
or incident outside the realm of normal usage. If such NOTE
evidence is present, comply with the instructions in If the transmission is being disassembled
paragraph 63-34. for replacement of parts, instead of
overhaul, disassemble only to the extent
necessary to replace the parts.
2. Refer to the Mandatory Airworthiness Schedule in
the applicable Maintenance Manual and determine 2. If not previously accomplished, remove the main
whether any transmission components have been rotor mast (BHT-412-MM).
assigned mandatory maximum hours life before
retiring from service. If any transmission components 3. Install the cover and lift plate assembly
have been assigned maximum hours life, identify (T103211-101) on the transmission.
these components for retirement.
NOTE
63-32. TRANSMISSION — DISASSEMBLY
The transmission assembly/overhaul stand
(Figure 63-30) is the preferred stand to
support the transmission during
SPECIAL TOOLS REQUIRED maintenance procedures, which include
removal/installation of tail rotor drive and
sump assembly; however, it is possible to
NUMBER NOMENCLATURE use the transmission maintenance/
transportation stand Figure 63-31.
412-240-006-101 Backlash Tool Set
4. Assemble the stand that will be used to support
SWE13832-21 Mount Assembly
the transmission (Figure 63-30 and Figure 63-31).
SWE13852-40 Adapter
5. If the transportation stand illustrated in
SWE13855B Maintenance Stand Figure 63-31 is to be used, remove the accessory and
tail rotor drive and sump assembly prior to removal of
SWE13875 Maintenance the top case. Refer to step 66 for the removal
Transportation Stand procedure.
SWE13875-60 Adapter
6. Hoist the transmission into position and secure
T100929 Jackscrew Set the transmission in the stand assembled in step 4.
T101308 Screw Set
T101338 Jackscrew Set
T103211-101 Cover and Lift Plate

Assembly
63-00-00
BHT-412-CR&O-3
1. Engine and transmission stand (SWE13855B)

2. Transmission adapter (SWE13852-40)
412_CRO_63_0030
Figure 63-30. Transmission Assembly Stand — Application
63-00-00
BHT-412-CR&O-3
Figure 63-31. Transmission Maintenance Transportation Stand — Application
63-00-00
Export Classification C, ECCN EAR99 21 MAR 2013 Rev. 7 Page 109
BHT-412-CR&O-3
l. Remove the clamps (21) from the

transmission electrical cable assembly (22).
CAUTION
m. Remove the transmission electrical cable
assembly (22) from the transmission (1).
DO NOT USE ANY METALLIC DRIFTS
FOR DISASSEMBLY OR ASSEMBLY OF
COMPONENTS, SUCH AS BEARINGS, 8. Remove the neck and scupper assembly (1,
RACEWAYS, SLEEVES, ETC. Figure 63-33) as follows:
7. Remove the transmission electrical cable as a. Remove the screws (16), washers (13),
follows (Figure 63-32): nuts (12), and clamps (15). Discard the clamps.
a. Disconnect the electrical terminal and nipple b. Loosen the nuts (10) and remove the hose
(14) from the upper mast electrical chip detector (15). assembly (11).
b. Remove the electrical terminal and nipple (19) c. Loosen the nut (21) and remove the elbow
from the planetary electrical chip detector (18). and packing (19). Discard the packing.
c. Remove the electrical connector (17) from the d. Remove the screw (18), washer (28), and
rotor tachometer generator (16). nut (29) from the clamp (14) and bracket (8). Discard
the clamp.
d. Remove the electrical terminal and nipple (13)
from the oil thermostatic switch (12). e. Loosen the nut (20) and remove the tube (17)
from the union. Remove the union and packing (25).
e. Remove the electrical connector (5) from the Discard the packing.
oil pressure switch (4).
f. Loosen the nuts (6) and remove the tube (7).
f. Remove the electrical connector (3) from the
oil pressure transmitter (2). g. Loosen the nut (4) and remove the elbow (5),
nut, and packing (3). Discard the packing.
g. Remove the electrical connector (7) from the
oil temperature transmitter (8). h. Remove the four nuts (22) and washers (23
and 24).
h. Remove the electrical terminal and nipple (11)
from the sump electrical chip detector (10). i. Remove the neck and scupper assembly (1)
from the neck and scupper support bracket (2).
NOTE
Transmissions with oil filters have three NOTE
ground wires. Transmissions with full flow
Remove the neck and scupper support
debris monitors have four ground wires.
bracket (2) with the ring gear in step 53 of
i. Remove the four wires for the rotor brake (20) this procedure.
from the rotor brake, if installed.
8A. Remove the filler oil cap adapter (9) as follows:
j. Remove the ground wires (23).
a. Remove the tube (7) from the filler oil cap
adapter (9) and the elbow (5).
NOTE
For transmissions with a full flow debris NOTE
monitor installed, perform step k.
In order to lock the filler oil cap adapter (9)
k. Remove the electrical terminal and nipple from the inside, fabricate a workaid that will
(11B) from the full flow debris monitor (11A). simulate a filler cap assembly.
63-00-00
BHT-412-CR&O-3
b. Remove the filler oil cap adapter (9). 9. Remove the plug (1, Figure 63-34) and the
packing (2). Discard the packing.
c. Gain access to the filler adapter (30) on the
main support case. 10. Loosen the nuts (22) and remove the tube (4).
d. Apply heat to the filler adapter (30). Heat

should not exceed 200°F (93°C). 11. Loosen the nut (6).
e. Unscrew the filler adapter (30) from the main 12. Remove the elbow and packing (5) and the
support case with the workaid or equivalent. nut (6). Discard the packing.
63-00-00
Export Classification C, ECCN EAR99 28 FEB 2020 Rev. 12 Page 110A/110B
BHT-412-CR&O-3
11A 1
11B
DETAIL B
14
15 18
1
19
2
13 SEE DETAIL C
16
3
17
D
FW
4
12 5
7 6
8
9
D
FW
10
11
SEE DETAIL B
VIEW A
412_CRO_63_0032a
Figure 63-32. Transmission Electrical Cable — Installation (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
24 14
19
4 25 26
13 9
2 20 27
23 3 31
5
7 28
SEE DETAIL D 23
29
1 11B 30
22
DETAIL D
6 GROUND WIRES INSTALLATION (TYPICAL)
17
21
11
DRIP LOOP
DETAIL C
1. Transmission 16. Rotor tachometer generator

2. Oil pressure transmitter 17. Electrical connector
3. Electrical connector 18. Planetary electrical chip detector
4. Oil pressure switch 19. Electrical terminal and nipple
5. Electrical connector 20. Wiring for rotor brake
6. Electrical connector 21. Clamps
7. Electrical connector 22. Transmission electrical cable assembly
8. Oil temperature transmitter 23. Ground wires
9. Oil manifold 24. Electrical connector (24P3) (for Chadwick
10. Sump electrical chip detector magnetic pickup on swashplate)
11. Electrical terminal and nipple 25. Nut
11A. Full flow debris monitor 26. Lockwasher
11B. Electrical terminal and nipple 27. Aluminum washer
12. Oil thermostatic switch 28. Aluminum washer
13. Electrical terminal and nipple 29. Aluminum washer
14. Electrical terminal and nipple 30. Screw
15. Upper mast electrical chip detector 31. Bracket
NOTE
1 Transmission with full flow debris monitors installed in place of oil filters.
412_CRO_63_0032b_c01
Figure 63-32. Transmission Electrical Cable — Installation (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
FWD 25
24
21 23
19
29
18
20 T 22 3
17
10 4
28
14 5
8 7 6
13 12
16 6
16 9
13
15 12
11 SEE DETAIL A
10
26
27
412_CRO_63_0033a
Figure 63-33. Neck, Scupper, and External Oil Hoses — Installation (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
30
DETAIL A
1. Neck and scupper assembly 16. Screw

2. Neck and scupper support bracket 17. Tube
3. Packing 18. Screw
4. Nut 19. Elbow and packing
5. Elbow 20. Nut
6. Nut 21. Nut
7. Tube 22. Nut
8. Bracket 23. Washer
9. Filler oil cap adapter 24. Washer
10. Nut 25. Union and packing
11. Hose assembly 26. Elbow
12. Nut 27. Hose assembly
13. Washer 28. Washer
14. Clamp 29. Nut
15. Clamp 30. Filler adapter
50 TO 70 IN-LBS
T (5.65 TO 7.91 Nm)
412_CRO_63_0033b
Figure 63-33. Neck, Scupper, and External Oil Hoses — Installation (Sheet 2 of 2)
63-00-00
Page 114 Rev. 11 16 JUN 2017 Export Classification C, ECCN EAR99
BHT-412-CR&O-3
1 T 2
2 22
TO AUXILIARY
OIL JET
18 T 1 20 3
23
19
17
4
16
15 22
14 5
13 6
12 21
1. Plug TO AUXILIARY
2. Packing OIL JET
3. Transmission
4. Tube
7
5. Elbow and packing
6. Nut
7. Tube 11
Elbow 8
8.
9. Nut 10 9
10. Packing
11. Oil pressure manifold
12. Spacer
13. Union and packing
14. Jet housing
15. Packing
16. Nut
17. Elbow
18. Tube
19. Elbow and two packings
20. Banjo bolt
21. Nut
22. Nut
23. Nut
LOCKWIRE (C-405)
40 TO 65 IN-LBS
T 1 (4.5 TO 7.3 Nm)
80 TO 120 IN-LBS
T 2 (9.0 TO 13.6 Nm)
412_CRO_63_0034_c01
Figure 63-34. Breather and Planetary Oil Jet Tubes — Installation
63-00-00
BHT-412-CR&O-3
13. Remove the banjo bolt (20) and the elbow and No. 5 (36). Remove and discard the packings (37 and
two packings (19). Discard the packings. 38) and the gasket.
14. Remove the oil pressure transmitter (5, 28. Loosen the nut (51).
Figure 63-36) and the packing (2). Discard the
packing. 29. Remove the elbow (52), nut (51), and packing
(50). Discard the packing.
15. Remove the oil pressure switch (7) and the
30. Remove the screw (49).
16. Remove the union (4) and the packing (3).

31. Remove the auxiliary oil jet (48) and the packing
17. Loosen the nuts (21, Figure 63-34) and remove

the tube (7). 32. Loosen the nut (45).
18. Loosen the nut (9). 33. Remove the elbow (46), nut (45), and packing
19. Remove the elbow (8), packing (10), and nut (9).
Discard the packing. 34. Remove the screw (43).
20. Loosen the nuts (23) and remove the tube (18). 35. Remove the auxiliary oil jet (42) and the packing
21. Loosen the nut (16).
36. Remove the pressure regulating valve (10,
22. Remove the elbow (17) and the packing (15). Figure 63-35) and the packing (9). Discard the
Discard the packing. packing.
23. Remove the screw (6, Figure 63-36), gasket (4) 37. Remove the thermostatic switch (12) and the
and the thin steel washer (5). Remove the screw (7) packing (11). Discard the packing.
and the oil jet No. 6 (8). Remove and discard the
packings (1, 2, and 3) and the gasket. 38. Remove the thermobulb (9, Figure 63-37) and the
24. Remove the screw (15), gasket (13), and thin
steel washer (14). Remove the bolt (16), thin steel 39. Remove the screw (20) and the steel washer
washer (17), bracket (18), and the oil jet No. 3 (12). (19). Remove the screw (15), seal (16), and the oil jet
Remove and discard the packings (9, 10, and 11) and No. 7 (13). Discard the seal.
the gasket.
40. Remove and discard the packings (17 and 18).
25. Remove the screw (24), gasket (22), and thin
steel washer (23). Remove the screw (25) and the oil
41. Remove the bolt (10), thin steel washer (11), and
jet No. 2 (21). Remove and discard the packings (19
bracket (12).
and 20) and the gasket.
26. Remove the screw (27), thin steel washer (28), 42. Remove the oil temperature manifold (14).
and gasket (29). Remove the screw (26) and the oil jet
No. 1 (30). Remove and discard the packings (31 and 43. Remove the gasket (5) and the packings (6 and
32) and the gasket. 7). Discard the gasket and the packings.
27. Remove the screw (33), thin steel washer (34), 44. Remove the oil transfer tube (3) and the packings
and gasket (35). Remove the screw (39) and the oil jet (2 and 4). Discard the packings.
63-00-00
BHT-412-CR&O-3
12
11 FWD
10 T 2
8
2
T 1
7
T 1
5

2. Packing
3. Packing
4. Union
5. Oil pressure transmitter
6. Packing LOCKWIRE (C-405)
7. Oil pressure switch
8. Oil temperature manifold 50 TO 65 IN-LBS
9. Packing T 1 (5.7 TO 7.3 Nm)
10. Pressure regulating valve
11. Packing 150 TO 180 IN-LBS
12. Thermostatic switch T 2 (16.9 TO 20.3 Nm)
412_CRO_63_0036_c01
Figure 63-35. Oil Pressure and Temperature Regulating and Indicating Components — Installation
63-00-00
BHT-412-CR&O-3
SEE DETAIL A
39
38
33
34
35
36
37
19
32 20
21
31 25
30 22
23
29 24
28
27
26 18
17 9 1
T 16 10
11 2
12
13 3
15 14
7 4
412_CRO_63_0035a_c01
Figure 63-36. Oil Jets No. 1, No. 2, No. 3, No. 5, and Planetary Jet — Installation (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
40
46 52
TO HOUSING TO HOUSING
45 51
DETAIL A
44 50
41 47
43 42 48 49
1. Packing 19. Packing 37. Packing

2. Packing 20. Packing 38. Packing
3. Packing 21. Oil jet No. 2 39. Screw
4. Gasket 22. Gasket 40. Transmission
5. Thin steel washer 23. Thin steel washer 41. Packing
6. Screw 24. Screw 42. Auxiliary oil jet
7. Screw 25. Screw 43. Screw
8. Oil jet No. 6 26. Screw 44. Packing
9. Packing 27. Screw 45. Nut
10. Packing 28. Thin steel washer 46. Elbow
11. Packing 29. Gasket 47. Packing
12. Oil jet No. 3 30. Oil jet No. 1 48. Auxiliary oil jet
13. Gasket 31. Packing 49. Screw
14. Thin steel washer 32. Packing 50. Packing
15. Screw 33. Screw 51. Nut
16. Bolt 34. Thin steel washer 52. Elbow
17. Thin steel washer 35. Gasket
18. Bracket 36. Oil jet No. 5
50 TO 70 IN-LBS
LOCKWIRE (C-405) T (5.7 TO 7.9 Nm)
412_CRO_63_0035b_c01
Figure 63-36. Oil Jets No. 1, No. 2, No. 3, No. 5, and Planetary Jet — Installation (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
SEE DETAIL B
5
14
13
6
7
12
8
11
9 T 2
T 1
10
SEE DETAIL A
412_CRO_63_0037a_c01
Figure 63-37. Oil Temperature and Oil Pressure Manifolds — Installation (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
14
18
17
13
16
15
19
20
DETAIL A 1. Transmission
2. Packing
3. Oil transfer tube
4. Packing
5. Gasket
6. Packing
7. Packing
8. Packing
9. Thermobulb
1 10. Bolt
11. Thin steel washer
12. Bracket
13. Oil jet No. 7
14. Oil temperature manifold
15. Screw
16. Seal
21 17. Packing
18. Packing
22 19. Steel washer
20. Screw
23 21. Data plate
22. Spacer
24. Aluminum washer
25. Steel washer
26. Nut
28 27. Union
28. Packing
27
LOCKWIRE (C-405)
50 TO 70 IN-LBS
24 T 1 (5.7 TO 7.9 Nm)
25 15 TO 20 IN-LBS
T 2 (1.7 TO 2.2 Nm)
26 T 1
DETAIL B 412_CRO_63_0037b_c01
Figure 63-37. Oil Temperature and Oil Pressure Manifolds — Installation (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
45. Remove the union (27) and the packing (28).

CAUTION
46. Remove the nut (26), aluminum washer (24), and

steel washer (25). WHEN JACKSCREWS ARE USED TO
REMOVE QUILLS, MAKE SURE THAT
ALL SEALANT IS REMOVED FROM
47. Remove the oil pressure manifold (23) and the THREADED HOLES PRIOR TO
spacer (22) from the transmission (1). INSTALLATION OF JACKSCREWS.
48. Remove the top case (20, Figure 63-38) as a. If installed, remove the brake assembly (3A)
follows: and the disc (3) (BHT-412-MM-6, Chapter 63).
b. Remove the bolts (14) and the washers (15

a. Remove the upper mast electrical chip and 16).
detector (1).
c. With the screw set (T101308), remove the
b. Remove and discard the packing (2). rotor brake drive quill (13) from the transmission (1).
d. Remove and discard the packing (17).

c. Cut the sealant at the mating flange of the top
case (20) and the ring gear (11) with a plastic scraper.
50. Remove the hydraulic pump drive quill (4) as
follows:
d. Remove the bolt (3), washers (4 and 7), nut
(8), and bracket (5). a. If installed, remove the nuts (11),
washers (10), cover (9), and gasket (8). Discard the
e. Remove the 15 bolts (21), washers (10, 15, gasket.
and 16), and nuts (9).
b. Cut the sealant around the hydraulic pump
f. Remove the three screws (19) and the drive quill (4) with a plastic scraper and remove
aluminum washers (18). sealant from the jackscrew holes.
c. Remove the bolts (7) and the washers (5

g. Install three jackscrew sets (T100929) in the and 6).
holes where the screws (19) were removed. Equally
turn the jackscrews clockwise to pull the top case (20) d. Install three screw sets (T101308) in the
from the ring gear (11). threaded holes in the hydraulic pump drive quill (4).
Equally turn the jackscrews clockwise to pull the quill
h. Remove the top case (20) and remove the from the transmission (1).
jackscrews from the case.
e. Remove and discard the packing (12).
i. Remove the oil transfer tube (13) and the
packings (12 and 14). Discard the packings. 51. Remove the main input quill (6, Figure 63-40) as
follows:
j. Remove and discard the packing (17).

a. Loosen the nut (24) and remove the tube (seal
drain) (21).
NOTE
b. Remove the union (22) and the packing (23).
Perform a backlash check, if desired. Discard the packing.
49. Remove the rotor brake drive quill (13, c. Remove the plug (15) and the packing (16).
Figure 63-39) as follows: Discard the packing.
63-00-00
BHT-412-CR&O-3
21
1 T 1
20
19 2
18
17
3
16
4
15
14 5
13
12
10 11
T 2 9
7
8 T 2
412_CRO_63_0038a_c01
Figure 63-38. Top Case — Installation (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
1. Upper mast electrical chip detector

2. Packing
3. Bolt
5. Bracket
6. Main input quill
7. Steel washer
8. Nut
9. Nut
10. Steel washer
11. Ring gear
12. Packing
13. Oil transfer tube
14. Packing
15. Washer
17. Packing
18. Aluminum washer
19. Screw
20. Top case
21. Bolt
LOCKWIRE (C-405)
30 TO 108 IN-LBS
T 1 (3.4 TO 12.2 Nm)
230 TO 250 IN-LBS
T 2 (26 TO 28 Nm)
412_CRO_63_0038b_c01
Figure 63-38. Top Case — Installation (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
13
1
17
2
16
15
14 T
SEE DETAIL A
DETAIL A
3
12
D
FW
5 3A
10 6
8
11
9
7 T
1. Transmission 9. Cover
2. Main input quill 10. Steel washer
3. Disc 11. Nut
3A. Brake assembly 12. Packing
4. Hydraulic pump drive quill 13. Rotor brake drive quill
5. Washer 14. Bolt
6. Steel washer 15. Washer
7. Bolt 16. Washer
8. Gasket 17. Packing
160 TO 190 IN-LBS

T (18 TO 21 Nm)
412_CRO_63_0039_c01
Figure 63-39. SYS 2 Hydraulic Pump and Rotor Brake Drive Quill — Installation
63-00-00
BHT-412-CR&O-3
8
10
6 7 9
2
11 T
1 3
5
12 T
4 13
14
15
16
17 23
18
22
19
20
24 21
WA
R NIN
G
412_CRO_63_0040a_c01
Figure 63-40. Main Input Quill — Installation (Typical) (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
25 1
26 3
33
27
2.033 IN.
(51.64 mm)
32 2
30
29
31 28
1. Transmission 12. Nut 23. Packing
2. Bearing 13. Thin steel washer 24. Nut
3. Work aid (rubber plug) 14. Aluminum washer 25. Pin
4. Packing 15. Plug 26. Backlash tool set -101
5. Packing 16. Packing 27. Plate assembly -103
6. Main input quill 17. Set screw 28. Washer (2 reqd) and nuts (2 reqd)
7. Aluminum washer 18. Packing 29. Screw (2 reqd)
8. Screw 19. Oil transfer tube 30. Pinion (ref)
9. Aluminum washer 20. Packing 31. Gear assembly (ref)
10. Clip 21. Tube (seal drain) 32. Case assembly (ref)
11. Nut 22. Union 33. Ring gear assembly (ref)
160 TO 190 IN-LBS
T (18 TO 21 Nm)
LOCKWIRE (C-405)
NOTES
1 Force fit in -109 bracket slip fit through eye bolt.
2 Read 0.010 to 0.018 inch (0.25 to 0.46 mm) backlash.
3 The 412-240-006-101 backlash tool set - input bevel gears, main transmission - used to check backlash
between 412-040-700 pinion (30) and 412-040-701 gear assembly (31) to 205-040-231 ring gear assembly (33).
412_CRO_63_0040b
Figure 63-40. Main Input Quill — Installation (Typical) (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
d. Remove the nut (11), aluminum washer (9), 53. Remove the ring gear (5, Figure 63-42) and the
and clip (10). three jet housings as follows:
e. Remove the six nuts (12) and the washers (13 a. Remove the bolts (1), washers (2, 3, 23, and
and 14). 24), and nuts (22).
f. Cut the sealant around the edge of the quill b. Remove the neck and scupper support
where it contacts the transmission case with a plastic bracket (4).
scraper.
c. Remove the bolt (6), washers (18, 19, 44), nut
g. Remove the three screws (8) and the
(17), and bracket (7).
washers (7).
d. Remove the bolts (8), washers (9, 14, and 15),
h. Install three screw sets (T101308) in the holes
and nuts (16).
where the screws (8) were removed.
i. Equally turn the jackscrews clockwise and e. Cut the sealant between the ring gear (5) and
carefully pull the quill from the transmission case. the main case assembly (13) with a plastic scraper.
j. Remove the three jackscrews and f. Remove the ring gear (5) from main case
immediately install the three screws (8) and the assembly (13). If necessary, tap on the ring gear lightly
washers (7) to secure the cap to the quill sleeve. with a plastic or a rawhide mallet to separate it from
Tighten the screws. main case. Remove the ring gear and packing (10).
k. Remove the oil transfer tube (19).
g. Remove and discard the cotter pins (25).
l. Remove and discard the packings (18 and
20). h. Remove the bolts (28), washers (27, 27A, 29,
30, and 31), and nuts (26).
m. Remove and discard the packings (4 and 5).
i. Remove the oil jet housing (32) and the
52. Remove the upper planetary (2, Figure 63-41) as gasket (33). Discard the gasket.
follows:
j. Remove and discard the cotter pins (35).
a. Remove the upper planetary (2), mast driving
adapter (3), extension (4), upper bearing (5), and liner k. Remove the bolts (43), washers (37, 37A, 40,
(outer) (6) out of the ring gear (15) as a unit. 41, and 42), and nuts (36).
b. Remove the retaining ring (1) and separate l. Remove the oil jet housing (39) and the
the mast driving adapter (3), upper bearing (5), and gasket (38). Discard the gasket.
liner (outer) (6).
m. Remove the oil jet housing (34) in same
c. Remove the upper sun gear (7) and the oil manner outlined for the oil jet housing (39).
deflector (9) as a unit.
54. Remove the lower planetary (10, Figure 63-41)
d. Remove the retaining ring (8) and the oil from the transmission.
deflector (9) from the upper sun gear (7).
55. Remove the liners (11 and 13) and the lower
NOTE bearing (12). Separate the liners and the bearing.
The lower planetary (10) and the remaining
components will be removed after the ring 56. Remove the lower sun gear (14) from the main
gear is removed. input gear quill (16).
63-00-00
BHT-412-CR&O-3
SEE DETAIL A
412_CRO_63_0041a
Figure 63-41. Upper and Lower Planetary — Installation (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
Figure 63-41. Upper and Lower Planetary — Installation (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
1 5 SEE DETAIL A
2
4
3
6 44
10
11
12
13
24
23
T 2
22
14
WD
19
F
15
18
21
16 T 2
17 T 2
20
412_CRO_63_0042a_c01
Figure 63-42. Ring Gear and Jet Housing — Installation (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
28
29
27A 30
31
5
32
27
T 1 26 33
25
TOOLING HOLE (REF)
41
38
40 39 35 34
42
43
37A 37
36 T 1
DETAIL A
1. Bolt 16. Nut 30. Aluminum washer

2. Thin steel washer 17. Nut 31. Thin aluminum washer
3. Washer 18. Thin steel washer 32. Oil jet housing
4. Neck and scupper 19. Washer 33. Gasket
support bracket 20. Planetary electrical 34. Oil jet housing
5. Ring gear chip detector 35. Cotter pin
6. Bolt 21. Packing 36. Nut
7. Bracket 22. Nut 37. Thin steel washer
8. Bolt 23. Thin steel washer 37A. Washer
9. Thin steel washer 24. Washer 38. Gasket
10. Packing 25. Cotter pin 39. Oil jet housing
11. Main input gear quill 26. Nut 40. Thin aluminum washer
12. Main input quill 27. Thin steel washer 41. Steel washer
13. Main case assembly 27A. Washer 42. Thin steel washer
14. Washer 28. Bolt 43. Bolt
15. Thin steel washer 29. Thin steel washer 44. Washer
50 TO 70 IN-LBS
T 1 (5.7 TO 7.9 Nm)
230 TO 250 IN-LBS

T 2 (26 TO 28 Nm)
412_CRO_63_0042b_c01
Figure 63-42. Ring Gear and Jet Housing — Installation (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
12
1
13 T 2
14
15
2
3
4 T 3
5
11
6
10
7 16
17
25 23
22 T 3 21
24
18
T 1 20
1. Main input gear quill

2. Packing
3. Main case
4. Nut
5. Thin steel washer 19
6. Washer
7. Plug 26
8. Packing
9. Lower mast bearing 27 D
FW
10. Mast guide ring
11. Retaining ring
T 3
28
12. Cotter pin

13. Nut
14. Steel washer
15. Offset accessory drive quill 22. Nut
16. Washer 23. Washer
17. Bolt 24. Bracket
18. Support case 25. Packing
19. Dowel pin 26. Washer
20. Planetary electric chip detector 27. Thin steel washer
21. Packing 28. Nut
30 TO 108 IN-LBS 50 TO 70 IN-LBS 230 TO 250 IN-LBS

T 1 (3.4 TO 12.2 Nm) T 2 (5.7 TO 7.9 Nm) T 3 (26 TO 28 Nm)
LOCKWIRE (C-405)
412_CRO_63_0043_c02
Figure 63-43. Main Input Gear Quill and Main Case — Installation
63-00-00
BHT-412-CR&O-3
57. Remove the main input gear quill (1, 60. Remove the cotter pins (12), six nuts (13), and
Figure 63-43) as follows: washer (14). Discard the cotter pins.
a. Make sure that the oil temperature manifold 61. Remove the offset accessory drive quill (15) with
(14, Figure 63-37) is removed. the jackscrew set (T101338).
b. Remove the planetary electric chip detector 62. If not previously accomplished, remove the tail
(20, Figure 63-43) and the packing (21). Discard the rotor drive quill adapter (2, Figure 63-44).
packing.
63. Remove the retaining ring (11, Figure 63-43),
c. Cut the sealant between the main input gear mast guide ring (10), and lower mast bearing (9).
quill (1) and the main case (3) with a plastic scraper.
64. Remove the bolt (17) and the washer (16).
NOTE
65. Push the plug (7) upward out of the support case
For the transmission 412-040-004 use the (18).
screw set (T101308).
66. Remove the accessory and tail rotor drive and
d. Install the jackscrew set (T100929) or the sump assembly (7, Figure 63-44) as follows:
screw set (T101308) in three threaded holes in the
main input gear quill (1) and tighten evenly to separate
a. If the transmission is supported on the
the gear quill from the case (3).
transportation stand illustrated in Figure 63-31, hoist
the transmission clear of the stand and proceed to
e. Remove the main input gear quill (1) and the step c.
packing (2) from the main case (3). Discard the
packing. b. If the transmission is supported on the
transmission stand illustrated in Figure 63-30, rotate
58. Remove the main case (3) as follows: the transmission 90° to the horizontal position.
a. Remove the nut (22), bracket (24), and c. Remove the nut (8, Figure 63-44), thin steel
washer (23). washer (9), and bracket (10).
b. Remove the twelve nuts (4) and the washers d. Remove the twelve nuts (6) and the washers
(5 and 6). (4 and 5).
e. Remove the accessory and tail rotor drive and

c. Remove the eight nuts (28), and the washers
sump assembly (7) from the support case (1). Use a
(26 and 27).
plastic or a rawhide mallet to tap the sump assembly
and separate it from the support case.
d. Cut the sealant between the main case (3)
and the support case (18) with a plastic scraper.
f. Remove the gasket (3). Discard the gasket.
e. Install the screw set (T101308) and tighten g. Remove the four cotter pins (11), nuts (12),
evenly to separate the main case (3) from the support and steel washers (13). Discard the cotter pins.
case (18). Remove the lift link fitting (14).
f. Remove the main case (3) and the packing h. If the transmission is to be supported on the
(25). Discard the packing. transportation stand illustrated in Figure 63-31, install
the transmission in the stand.
59. Inspect the four dowel pins (19) for evidence of
shearing. If more than one dowel pin is sheared and i. If the transmission is supported on the
torsional overload is indicated, the entire transmission transmission stand illustrated in Figure 63-30, rotate
is non-airworthy and nonrepairable. the transmission 90° to the vertical position.
63-00-00
BHT-412-CR&O-3
D
FW
14
1
13
1 T 1
12
2
2 T 2 11 3
10
T 3
8
4
1. Support case 6 T 3
2. Tail rotor drive quill adapter
3. Gasket
4. Aluminum washer
5. Thin steel washer 7
6. Nut
7. Accessory and tail rotor drive and sump assembly
8. Nut
10. Bracket
11. Cotter pin
12. Nut
13. Steel washer
14. Lift link fitting
37 TO 42 FT-LBS 40 TO 58 FT-LBS 50 TO 70 IN-LBS

T 1 (50.2 TO 56.9 Nm) T 2 (54.2 TO 78.6 Nm) T 3 (5.7 TO 7.9 Nm)
NOTES
1 7/16 inch (11.1 mm) studs.
2 1/2 inch (12.7 mm) studs.

412_CRO_63_0044
Figure 63-44. Accessory and Tail Rotor Drive and Sump — Installation
63-00-00
BHT-412-CR&O-3
63-33. TRANSMISSION — CLEANING 4. Coat the bearings with corrosion preventive

compound (C-105) immediately after cleaning. Refer
to step 10 for the procedure.
MATERIALS REQUIRED
5. Remove the sealant from the cases and the
Refer to BHT-ALL-SPM for specifications. sleeves with a plastic scraper.
NUMBER NOMENCLATURE 6. Clean all the parts except the bearings by vapor
degreasing with solvent (C-334).
C-105 Corrosion Preventive
Compound 7. Remove the paint from all the painted parts
except the manifolds (1 and 8, Figure 63-35) and oil jet
housing (32, Figure 63-42) with paint remover (C-436).
C-334 Solvent
8. Rinse the parts with water and dry with filtered
C-436 Paint Remover compressed air.
C-516 Clean Cloth 9. Apply a coat of lubricating oil of the type used in
the transmission to all the transmission parts except
1. Prior to cleaning, inspect the cases and sleeves the bearings. Refer to the following step for bearing
for corrosion damage to threaded holes and for treatment.
corrosion damage to studs. If corrosion damage is
present, refer to the inspection paragraph for the NOTE
affected component to determine whether the damage
is within permitted limits. Parts treated per the following step may be
left covered in indoor storage for
approximately 150 hours without being
2. Clean the parts of the disassembled transmission affected by corrosion.
with drycleaning solvent (C-304) Use a non-metallic,
soft bristle brush to dislodge deposits. 10. Immediately after cleaning bearings with
drycleaning solvent (C-304), gently agitate the
3. Dry the parts with a clean cloth (C-516) or filtered bearings in corrosion preventive compound (C-105)
compressed air. Do not allow bearings to spin when and allow to drain dry. Apply a coat of lubricating oil of
drying with compressed air. the type used in the transmission to the bearings.
63-34. TRANSMISSION — INSPECTION
CAUTION 1. Inspect the transmission and the transmission

records to determine whether the transmission has
been subjected to an accident or incident outside the
DO NOT HANDLE UNOILED BEARINGS realm of normal usage, which would require a
WITH BARE HANDS. conditional inspection. Refer to the BHT-412-MM, for
the definition of accidents or incidents, which require
that a conditional inspection be conducted.
NOTE
The parts treated per the following step 2. If a conditional inspection is required, conduct the
may be left covered in indoor storage for inspection in accordance with paragraph 63-35. If a
approximately 150 hours without being conditional inspection is not required, proceed with the
affected by corrosion. normal inspection (paragraph 63-36).
63-00-00
BHT-412-CR&O-3
(1) Inspect the support case for yielding in

63-35. TRANSMISSION — CONDITIONAL
accordance with Figure 63-58.
INSPECTION
(2) Inspect the accessory and tail rotor drive
NOTE and sump case for damage to the bore of the tail rotor
drive quill and the bore of the accessory and tail rotor
If a conditional inspection is required due to drive quill. Refer to paragraph 63-122 for the bore
engine clutch misengagement, refer to the diameter limits.
BHT-412-MM, for instructions to conduct
the inspection. If a conditional inspection is (3) Replace the following parts:
required for a reason other than engine
clutch misengagement, comply with the
instructions in this paragraph.
NOMENCLATURE PART NUMBER
1. Inspect the external surfaces of the transmission
for cracks, distortion, dents, and other damage. Pay Accessory and Drive Quill 212-040-150
particular attention to the main support case for cracks Pinion
and/or distortion. A cracked, broken, or yielded arm on
the main support case may result from a hard landing Tail Rotor Quill Gear 212-040-151
and does not necessarily indicate excessive torsional Offset Accessory and Tail 212-040-201
loads. If there is no evidence that the main rotor Rotor Drive Quill Gear
drivetrain has been overloaded torsionally, a cracked,
broken or yielded arm on the main support case is not Offset Accessory and Tail 212-040-202
cause to declare the entire transmission unserviceable Rotor Drive Quill Pinion
and nonrepairable. Refer to step 3 for instructions to
determine whether the transmission has been
63-36. TRANSMISSION — NORMAL INSPECTION
overloaded torsionally.
2. Rotate the main input quill manually and check NOTE

for binding of the internal transmission parts. If any Limits charts are provided to show the
binding is evident, determine the cause when the required fit between mating parts. It is not
transmission is disassembled. intended that all dimensions listed on the
limits charts be checked as a prescribed
3. Disassemble the transmission (paragraph 63-32). overhaul procedure; however, parts that
show evidence of wear or physical damage
must be checked dimensionally.
4. Determine whether the main rotor drivetrain has
been overloaded torsionally by accomplishing the 1. Visually inspect the parts shown in Figure 63-45.
following inspections: If any parts show evidence of wear or physical
damage when inspected during the subsequent steps,
a. Inspect the dowel pins in the main support measure the dimensions to determine whether the
case at the mating surface of the main case for part is permitted. Damage limits are shown in
shearing. If more than one dowel pin is sheared, Figure 63-45.
torsional overload is indicated and the entire
transmission is non-airworthy and nonrepairable. 2. Inspect the mast driving adapter (3, Figure 63-41)
for corrosion damage and wear and damaged spline
5. Inspect all gears and pinions visually and by teeth.
magnetic particle method (BHT-ALL-SPM). If any
cracked or broken gears in the main rotor drivetrain 3. Inspect the planetary support upper and lower
are found, torsional overload is indicated and the bearings (5 and 12) for roughness, spalling, scoring,
entire transmission is non-airworthy and pitting, brinelling, corrosion damage, cracked or
nonrepairable. If any cracked or broken gears in the broken retainers, and for wear. Damage that can be
tail rotor drivetrain are found, accomplish the following: detected visually or by feel is not permitted.
63-00-00
BHT-412-CR&O-3
UPPER PLANETARY
2 ASSEMBLY
3
8 15 16
TOP CASE
7 1
5 17 18
10
RING GEAR 11 12
19 20
BEVEL GEAR
SUPPORT CASE LOWER PLANETARY
ASSEMBLY
MAIN BEVEL
GEAR CASE
SUPPORT
CASE
21 22
13
14
412_CRO_63_0045a
Figure 63-45. Transmission Gears, Bearings, and Liners — Damage Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
NUMBER DESCRIPTION
1. Ring gear teeth between pins 13.6830 TO 13.6890 inches

(use 0.2160 inch (5.486 mm) diameter pins) (347.548 TO 347.001 mm)
2. Adapter gear over pins 6.4174 TO 6.4269 inches

3. Adapter spline between pins 4.4532 TO 4.4666 inches

4. Sun gear teeth over pins 7.0059 TO 7.0120 inches

5. Sun gear spline over pins 6.9964 TO 7.0120 inches

6. Outer liner ID 5.5113 TO 5.5124 inches

(139.987 TO 140.015 mm)
7. Bearing OD 5.5112 TO 5.5118 inches
(139.985 TO 140.000 mm)
ID 4.3302 TO 4.3308 inches
(109.987 TO 110.002 mm)
8. Extension OD 4.3298 TO 4.3309 inches
(109.977 TO 110.005 mm)
9. Inner liner OD 4.3298 TO 4.3309 inches
(109.977 TO 110.005 mm)
10. Outer liner ID 5.5113 TO 5.5124 inches
(139.987 TO 140.015 mm)
11. Sun gear spline between pins 4.3400 TO 4.3441 inches
12. Sun gear teeth over pins 7.0059 TO 7.0120 inches

13. Liner ID 4.9987 TO 5.0003 inches

(126.967 TO 127.008 mm)
14. Bearing OD 4.9984 TO 4.9990 inches
(126.959 TO 126.975 mm)
15. Top case OD 14.7990 TO 14.8020 inches
(375.895 TO 375.971 mm)
16. Ring gear ID 14.7980 TO 14.8020 inches
(375.869 TO 375.971 mm)
17. Ring gear ID 14.7980 TO 14.8020 inches
(375.869 TO 375.971 mm)
18. Bevel gear support case OD 14.7980 TO 14.8020 inches
(375.869 TO 375.971 mm)
19. Main bevel gear case ID 13.7500 TO 13.7540 inches
(349.250 TO 349.352 mm)
20. Bevel gear support case OD 13.7480 TO 13.7510 inches
(349.199 TO 349.275 mm)
21. Support case ID 14.7510 TO 14.7550 inches
(374.675 TO 374.777 mm)
22. Main bevel gear case OD 14.7480 TO 14.7520 inches
(374.599 TO 374.701 mm)
412_CRO_63_0045b
Figure 63-45. Transmission Gears, Bearings, and Liners — Damage Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
4. Inspect the lower mast bearing (9, Figure 63-44) 8. Inspect the hose assemblies (11 and 27,
and the input quill support bearing (2, Figure 63-41) as Figure 63-33) and related fittings for damaged
follows: threads, distortion, and deterioration.
a. Inspect for spalling, scoring, pitting, brinelling, 9. Inspect the tubes (7 and 17) and related fittings
for damaged threads, distortion, and cracks.
flaking, corrosion damage on rolling elements or
races, and cracked or broken retainers. Those
damages are not permitted. Superficial corrosion is 10. Inspect the neck and scupper assembly (1) and
permitted. Corrosion damage in excess of superficial the neck and scupper support bracket (2) for cracks
is not permitted. and distortion.
b. Inspect the bearing rollers for nicks, cuts and 11. Inspect the following tubes and related fittings for
scratches. Nicks, cuts and scratches on the bearing damaged threads, distortion, and cracks:
rollers are permitted provided they are too small to be
felt with a 0.020-inch (0.51-mm) spherical radius
inspection probe and provided the total affected area
does not exceed 10% of the contact area at any point. NOMENCLATURE FIGURE
Tube (4, Figure 63-34)

c. Inspect the bearing rollers and races for
Tube (7, Figure 63-34)
circumferential scratches. Minor circumferential
scratches are permitted on the rollers and races Tube (18, Figure 63-34)
provided they cannot be felt with a 0.020-inch
(0.51-mm) spherical radius inspection probe and Oil transfer tube (3, Figure 63-37)
provided the affected area does not exceed 10% of Oil transfer tube (13, Figure 63-38)
the contact area at any point.
Oil transfer tube (19, Figure 63-40)
d. Inspect the bearing rollers for wear pattern.
Refer to Figure 63-46 for examples of acceptable and 12. Inspect the pressure regulating valve assembly
unacceptable wear patterns. (10, Figure 63-35), thermostatic switch (12), oil
pressure switch (7), oil pressure transmitter (5), and
thermobulb (9, Figure 63-37) for damaged threads and
5. Inspect the liners (6, 11, and 13, Figure 63-42) for mechanical damage.
wear and distortion. Wear and/or damage in excess of
superficial is not permitted.
13. Visually inspect all the parts for damage and
excessive wear. Inspect the gears and the splines for
6. Inspect the manifolds (1 and 8, Figure 63-35), chipped, broken, or worn teeth. Check the bearings for
and oil jet housings (32, 34, and 39, Figure 63-42) for smooth operation and for indications of failure or
corrosion, mechanical damage, and damaged excessive wear. If metal particles were found in the
threads. transmission at disassembly or if there is evidence of
metal particles going through the gear meshes,
carefully examine the gear teeth and the bearings for
7. Inspect all oil jets for bends, mechanical damage, dents and cuts. Inspect the cases and the sleeves for
and corrosion. Pay particular attention to the area of corrosion damage, excessive wear, and loose or
the slots. Inspect the jets for cracks by magnetic damaged bearing liners.
particle method (BHT-ALL-SPM). No cracks are
permitted. When inspecting the jets by magnetic 14. Inspect the upper sun gear (7, Figure 63-41) and
particle method, a single indication of a straight line the lower sun gear (14) for chipped, dented, pitted,
crack across the inner end of the oil jet may be a false spalled, or scuffed gear teeth. Refer to Figure 63-47
indication termed a smudge line, which is typical of the for examples of acceptable and unacceptable gear
method of manufacture. wear patterns.
63-00-00
BHT-412-CR&O-3
Figure 63-46. Roller Bearing — Wear Patterns
63-00-00
BHT-412-CR&O-3
Figure 63-47. Transmission Sun Gear — Wear Patterns
63-00-00
BHT-412-CR&O-3
15. Inspect the following parts by magnetic particle 21. Refer to paragraph 63-94, paragraph 63-100, and
inspection. Demagnetize the parts after the magnetic paragraph 63-106 for the inspection of the main input
particle inspection. Refer to Table 63-3 and the quill.
BHT-ALL-SPM for the procedure.
22. Refer to paragraph 63-112 for the inspection of
the generator (or system 2 hydraulic pump) drive quill.
FIGURE AND
NOMENCLATURE 23. Refer to paragraph 63-118 for the inspection of
INDEX NUMBER
the offset accessory drive quill.
3, Figure 63-41 Mast driving adapter
4, Figure 63-41 Extension 24. Refer to paragraph 63-173 for the inspection of
the rotor brake drive quill.
6, Figure 63-41 Liner (outer)
7, Figure 63-41 Upper sun gear 63-37. TRANSMISSION — REPAIR
11, Figure 63-41 Liner (outer)
13, Figure 63-41 Liner (inner) MATERIALS REQUIRED
14, Figure 63-41 Lower sun gear Refer to BHT-ALL-SPM for specifications.
5, Figure 63-42 Ring gear NUMBER NOMENCLATURE

2, Figure 63-44 Tail rotor drive quill C-103 Chromic Acid
adapter Treatment

NOTE Primer
Limits charts are provided to show the
required fit between the mating parts. It is C-464 India Stone
not intended that all dimensions listed on
the limits charts be checked as a
prescribed overhaul procedure; however,
parts that show evidence of wear or CAUTION
physical damage must be checked
dimensionally.
DUPLEX BEARINGS ARE MARKED WITH
16. Inspect the parts dimensionally as required SERIAL NUMBERS AND MUST BE
(Figure 63-45). REPLACED IN MATCHED PAIRS.
17. Refer to paragraph 63-45, paragraph 63-51, and NOTE

paragraph 63-57 for the inspection of the top, main,
and support cases. All the parts reworked or repaired shall be
inspected prior to use or assembly.
18. Refer to paragraph 63-64 for the inspection of the
planetary ring gear, upper planetary, and lower 1. Replace all seals, gaskets, preformed packings,
planetary assemblies. cork plugs and cotter pins on reassembly.
19. Refer to paragraph 63-124 for the inspection of 2. Replace parts that are cracked, broken, warped,
the accessory and tail rotor drive and sump assembly. distorted, or have malformed threads.
20. Refer to paragraph 63-82 and paragraph 63-88 3. Replace all the parts that exceed allowable
for the inspection of the main input gear quill. tolerances given in applicable limits charts.
63-00-00
BHT-412-CR&O-3
4. Replace corroded, nicked, pitted, scratched, or d. Treat the tapped hole with chromic acid
dented parts that cannot be repaired in accordance treatment (C-103) brush-on treatment
with the repair procedures set forth in this manual. (BHT-ALL-SPM).
NOTE
CAUTION The top four threads of the Rosan insert are
expanded to provide interference fit.
ROLLER BEARING INNER AND OUTER e. Make an insert from a Rosan insert
RACE MUST BE A MATCHED SET WITH (H2R-205SC-7). Machine the overall length to
THE SAME SERIAL NUMBER ON BOTH 0.250 inch (6.35 mm) by removing materials from end
RACES. where the external threads are cut back. Treat the
insert with chromic acid treatment (C-103)
5. Assemble the roller bearing inner and outer races (BHT-ALL-SPM).
with matched or the same serial numbers.
f. Apply epoxy polyamide primer (C-204) to the
external threads of the insert modified in step e. Install
6. The serial number on the ground shim plate must
the insert in the manifold while the primer is wet with a
conform to the serial number on the sleeve or the
hex wrench. Install the insert 0.030 inch (0.76 mm)
case.
below the surface of the manifold.
9. Replace all bearings that show evidence of

CAUTION spalling, scoring, pitting, brinelling, flaking, or
corrosion damage on the roller elements or races, or
that have cracked or broken retainers, or that do not
B E A R I N G S PA C E R S M U S T B E A roll smoothly.
MATCHED SET WITH THE SAME SERIAL
NUMBER ON BOTH SPACERS. 10. Replace roller bearings that show evidence of
spalling, scoring, pitting, brinelling, or large corrosion
7. The bearing spacers are finished ground together pitting damage on the rolling elements or races, or that
as a matched set and serialized for replacement. have cracked or broken retainers. Minor nicks, cuts, or
scratches are permitted on rollers provided they are
too small to be felt with a probe having an end radius
8. Repair the oil temperature manifold (14, of 0.030 inch (0.76 mm), and provided the total
Figure 63-37) as follows: affected area does not exceed 10% of the contact area
at any point. Minor circumferential scoring is permitted
on rollers and races provided it cannot be felt with a
NOTE probe having end radius of 0.030 inch (0.76 mm) and
Repair of the manifold is limited to the provided the affected area does not exceed 10% of
removal of the damaged helicoil and the the contact area at any point (Figure 63-46).
installation of a modified Rosan insert.
11. Replace bevel gears that are spalled or scuffed or
a. Remove the damaged helicoil used for the oil that have improper wear patterns. Replace spur gears
jet No. 7 (13) retention screw. that are spalled or that are scuffed beyond the limits
shown in Figure 63-47. If metal particles are found in
the transmission during disassembly, or if there is
b. Drill out the hole where the helicoil was evidence of metal particles going through gear
removed with a letter size F twist drill to 0.335 inch meshes, the gear teeth should be carefully examined
(8.51 mm) maximum depth. for indentions and cuts. Repair minor nicks, scratches,
and burrs on the splines and gear teeth by dressing
c. Tap the 5/16-18 UNC-3B threads to 0.280 inch with a fine India stone (C-464) in accordance with the
(7.11 mm) full thread depth. inspection requirements.
63-00-00
BHT-412-CR&O-3
12. Touch up the transmission parts where corrosion SPECIAL TOOLS REQUIRED
protective chemical film has been removed. Refer to the
BHT-ALL-SPM for the procedure to accomplish the
corrosion protective treatment for localized areas. NUMBER NOMENCLATURE
13. Refer to paragraph 63-46, paragraph 63-52, and 205-040-300-1GIF-1 Backlash Tool
paragraph 63-58 for the repair of the top case, main bevel
gear case, and main support case. T101586 Pusher Set
14. Refer to paragraph 63-65, paragraph 63-71, and T102064 Jacking Screw Set
paragraph 63-77 for repair of planetary ring gear, upper
planetary assembly, and lower planetary assembly. T103211-101 Cover and Lift Plate
Assembly
15. Refer to paragraph 63-126 for the repair of the
accessory and tail rotor drive and sump assembly.
16. Refer to paragraph 63-83 and paragraph 63-89 for the MATERIALS REQUIRED
repair of the main input gear quill.
17. Refer to paragraph 63-95, paragraph 63-101, and
paragraph 63-107 for the repair of the main input quill. NUMBER NOMENCLATURE

Compound
generator (or system 2 hydraulic pump) drive quill.
19. Refer to paragraph 63-119 for the repair of the offset Compound
accessory drive quill.
C-201 Zinc Chromate Primer
20. Refer to paragraph 63-132 for the repair of the rotary
oil pump. C-304 Drycleaning Solvent
21. Refer to paragraph 63-150 for the repair of the C-308 Sealant
accessory tail rotor drive quill.
C-309 MEK
22. Refer to paragraph 63-156 and paragraph 63-162 for
C-328 Sealant
the repair of the tail rotor drive quill.
C-405 Lockwire
hydraulic drive quill.
24. Refer to paragraph 63-174 for the repair of the rotor

CAUTION
brake drive quill.
63-38. TRANSMISSION — ASSEMBLY DO NOT HANDLE UNOILED BEARINGS WITH

BARE HANDS.
SPECIAL TOOLS REQUIRED NOTE

Use new preformed packings, gaskets,
seals, and cotter pins when assembling
NUMBER NOMENCLATURE transmission.
212-040-001-3 GIF-1 Backlash Tool
212-040-001-19 GIF-1 Backlash Tool
63-00-00
BHT-412-CR&O-3
11. Return the support case (18) to the upright

NOTE
position.
Immediately prior to installing the parts,
coat the packings and mating surfaces with
12. Install the lower mast bearing (9) in the liner of
the same oil used in the transmission.
the support case (18).
1. If not previously accomplished, assemble the
stand (Figure 63-30 or Figure 63-31) that will be used 13. Install the mast guide ring (10) on the lower mast
to support the transmission during the assembly bearing (9) and secure with the retaining ring (11).
procedures. The stand illustrated in Figure 63-30 is
the preferred stand to use for the transmission
14. Heat the support case (18) at the port for offset
assembly.
accessory drive quill (15) with a heat lamp. Coat the
mating surfaces of the accessory drive sleeve and the
2. Make sure that the shims of the proper case with the same oil used in the transmission.
dimensions have been installed. Refer to paragraph
63-53, paragraph 63-84, paragraph 63-90, paragraph
63-96, paragraph 63-102, paragraph 63-108,
paragraph 63-114, and paragraph 63-127 for CAUTION
information on the required shim thickness.
3. Clean all the parts with drycleaning solvent D O N O T TA P O N T H E G E A R O R

(C-304) and drain. Make sure that all the parts that DAMAGE TO THE GEAR WILL OCCUR.
were coated with corrosion preventive compound
(C-105) (fingerprint remover) are thoroughly cleaned. 15. Install the offset accessory drive quill (15). If
Coat the parts with the same oil used in the necessary tap on the quill to seat it in the case but do
transmission after cleaning. not tap on the gear.
4. Install the support case (18, Figure 63-43) in the 16. Install the six steel washers (14) and the nuts
stand (Figure 63-30 or Figure 63-31). (13). Torque the nuts 50 to 70 inch-pounds (5.65 to
7.91 Nm) and secure with the new cotter pins (12).
5. Remove any particles of magnesium from the
case that might become detached, and clean the case 17. Lubricate a new packing (25) with the same oil
thoroughly. used in the transmission.
6. If the adjustable stand illustrated in Figure 63-30 18. Install the new packing (25) on the main case (3).
is being used, invert the case in the stand.
19. Heat the support case (18) with a heat lamp.

7. Lubricate a new packing (8, Figure 63-43) with
the same oil used in the transmission.
20. Install the main case (3) on the support case (18)
8. Put the new packing (8) on the plug (7) and install then tap the main case down into position and make
the plug in the support case (18) with the hole aligned sure that the packing (25) is properly seated and not
for the bolt (17). damaged.
9. Install the bolt (17) and the washer (16). Make 21. Install the washers (23), bracket (24), and nut
sure that the bolt head contacts the support case (18) (22) on the stud, as shown in Figure 63-43. Torque the
before the threaded end bottoms on the plug (7). nut 230 to 250 inch-pounds (25.99 to 28.25 Nm).
Tighten the bolt.
22. Install the washers (6), thin steel washers (5), and
10. Secure the plug (7) to the support case (18) with nuts (4) on all the upper studs. Torque the nuts 230 to
lockwire (C-405). 250 inch-pounds (25.99 to 28.25 Nm).
63-00-00
BHT-412-CR&O-3
23. Install the washers (26), thin steel washers (27), to Figure 63-48 for a sectional view of the installed
and nuts (28) on the lower studs. Torque the nuts 230 workaid.
to 250 inch-pounds (25.99 to 28.25 Nm).
e. Heat the case in the area of the quill port with
24. Heat the upper portion of the main case (3) with a a heat lamp or a 250 watt light bulb. The heating time
heat lamp. will vary, but heat the case until the area near the quill
port is hot to touch.
25. Lubricate a new packing (2) and the mating
surface of the main input gear quill (1) with the same f. Lubricate new packings (18 and 20,
oil used in the transmission. Figure 63-40) with the same oil used in the
transmission.
26. Install the new packing (2) on the main input gear
quill (1). g. Install the new packings (18 and 20) on the oil
transfer tube (19). Put the tube in the transmission
case.
27. Align the FWD arrow on the main input gear quill
(1) with the forward side of the main case (3). Carefully
install the gear quill in the main case. Make sure that h. Lubricate new packings (4 and 5) with the
the gearshaft engages the roller bearing and the spline same oil used in the transmission.
in the offset accessory drive quill (15). Rotate the
gearshaft of the quill slightly to engage the splines.
CAUTION
NOTE
As a alternate, you can use the backlash MAKE SURE TO LEAVE THE CENTER
tool set 412-240-006-101. GROOVE OPEN FOR OIL CIRCULATION
OR DAMAGE TO TRANSMISSION MAY
28. For transmission 412-040-002, put the backlash OCCUR.
tool 204-040-001-17 PAT 1, on the main input gear
quill (1). Install four bolts to secure the tool to the quill i. Install the new packing (5) in the groove
and the main case (3). Tighten the clamp on the nearest the flange of the main input quill (6) and install
backlash tool to prevent the shaft from turning in quill. the new packing (4) in the groove nearest the pinion.
Leave the center groove open for oil circulation.
29. Install the main input quill (6, Figure 63-40) as
follows:
CAUTION
a. Make sure the bearing (2) is installed.
b. Remove the set screws (17) from the studs on MAKE SURE THE OIL TRANSFER TUBE
the transmission case. I S I N S TA L L E D O R D A M A G E T O
TRANSMISSION MAY OCCUR.
c. Remove the three nuts (11, Figure 63-48)
from the pusher set studs (T101586-5) (12). Install the j. Put the input quill pinion (6, Figure 63-48) on
three studs (12) in holes where set screws were the pusher set stud (T101586-5) (12) with the union for
removed. Refer to Figure 63-48 for view of installed the drain tube at the bottom.
studs.
k. Carefully slide the quill into the transmission
d. Pass through the rotor brake quill port and case. Align the input quill pinion (6) teeth with the input
install the workaid plug (2) to hold the rollers of the gear quill (5) teeth. Align the front of the input quill
bearing (3) against the outer race of the bearing. Refer pinion with the bearing rollers (3).
63-00-00
BHT-412-CR&O-3
Figure 63-48. Pusher Set (T101586) — Application
63-00-00
BHT-412-CR&O-3
v. Put the opposite end of the tube (seal drain)

(21) to drain into the scupper adjacent to the internal
CAUTION
oil filter on the transmission sump.
WORKAID PLUG MUST BE REMOVED w. Tighten the nut (24).

BEFORE FULLY SEATING THE QUILL.
OTHERWISE, THE PLUG COULD BE
x. Install the clamp on the tube (seal drain) (21).
FORCED AGAINST THE OIL JET NO. 6
AND CAUSE DAMAGE. Secure the clamp to the bracket (10, Figure 63-44).
l. Install the three nuts (11) and tighten evenly to 30. Install the hydraulic pump drive quill (4,
keep the quill aligned. When the quill is started into the Figure 63-39) as follows:
bearing, remove the workaid plug (2), through the rotor
brake quill port, to prevent pushing workaid into oil jet
No. 6, if installed.
CAUTION
m. Continue tightening the nuts (11) to fully seat
the quill. When the quill is fully seated, loosen the nuts
and remove the pusher set studs (T101586-5) (12). THE SPIRAL BEVEL PINION IN THE
HYDRAULIC PUMP DRIVE QUILL
n. Install the set screws (17, Figure 63-40) on ASSEMBLY 204-040-379-003 HAS SIX
the studs at 3, 7 and 11 o'clock positions. HOLES IN THE WEB AND SHALL BE
I N S TA L L E D I N T R A N S M I S S I O N S
o. Install the aluminum washer (9), clip (10), and 412-040-002. THE SPIRAL BEVEL PINION
nut (11) on lower right stud (5 o'clock position). Install IN THE HYDRAULIC PUMP DRIVE QUILL
the six aluminum washers (14), six thin steel washers ASSEMBLY 204-040-379-101 HAS FOUR
(13), and six nuts (12) on the remaining studs. Torque HOLES IN THE WEB AND SHALL BE
the nuts (11 and 12) 160 to 190 inch-pounds (18 to I N S TA L L E D I N T R A N S M I S S I O N S
21 Nm). 412-040-004. SEVERE DAMAGE TO THE
TRANSMISSION WILL RESULT IF THIS
p. Rotate the curvic adapter on the outboard end CAUTION IS NOT FOLLOWED.
of the main input quill (6) by hand. Check for a small
amount of backlash. A small amount of backlash must
be evident.
CAUTION
q. Lubricate a new packing (16) with the same oil
used in the transmission and install on the plug (15).
E X E R C I S E C A U T I O N TO P R E V E N T
DAMAGE TO HYDRAULIC PUMP DRIVE
r. Install the plug (15) in the main input quill (6).
QUILL PINION AND SPIRAL BEVEL
Tighten the plug and secure with lockwire (C-405).
GEAR TEETH. ROTATE QUILL PINION
SLIGHTLY AS THE QUILL IS BEING
s. Install the three aluminum washers (7) and the INSTALLED TO PERMIT MESHING OF
screws (8). Tighten the screws and secure to the quill GEARS.
a. Heat the transmission main case in the area of

t. Put the same oil used in the transmission on
the threads of the union (22) and the new packing the quill port with a heat lamp until the case is too hot
(23). Install the new packing on the union and install to touch.
the union on the main input quill (6).
b. Lubricate a new packing (12) with the same oil
u. Install the tube (seal drain) (21) on the union used in the transmission and install on the hydraulic
(22). pump drive quill (4).
63-00-00
BHT-412-CR&O-3
ROTATE QUILL PINION SLIGHTLY AS

THE QUILL IS BEING INSTALLED TO
CAUTION
PERMIT MESHING OF GEARS.
MAKE SURE THE OIL HOLE IN THE a. Clean oil, sealant, and other residue from the
QUILL SLEEVE IS UP OR DAMAGE TO mounting surface and the rotor brake bore.
THE QUILL MAY OCCUR.
b. Heat the main case in the area of the rotor
c. Carefully insert the hydraulic pump drive brake bore with a heat lamp until the case is too hot to
quill (4) into the transmission case with the oil hole in touch.
the quill sleeve up. Exercise caution to prevent
damage to the quill teeth. Rotate the quill pinion c. Verify that the correct rotor brake drive quill is
slightly to permit gear meshing. Align the holes and being installed in the transmission per the previous
install the six washers (5), steel washers (6), and caution.
bolts (7). Torque the bolts 160 to 190 inch-pounds (18
to 21 Nm). d. Lubricate a new packing (17) with the same oil
used in the transmission and install on the rotor brake
d. Install the cover (9) and the new gasket (8) drive quill (13).
with the six steel washers (10) and the nuts (11).
Tighten the nuts. e. Apply corrosion preventive compound (C-128)
to the rotor brake drive quill (13) and the transmission
case as follows:
31. If previously removed, install the rotor brake drive
quill (13, Figure 63-39) as follows:
(1) Mix the corrosion preventive compound
(C-128) with MEK (C-309) to obtain a brushable
consistency.
CAUTION
(2) Apply a thin even coat of corrosion
preventive compound (C-128) to the rotor brake drive
THE SPIRAL BEVEL PINION IN THE quill (13) from the edge of the packing groove, nearest
R O T O R B R A K E Q U I L L A S S E M B LY the quill flange, to the outer edge of the flange.
412-040-123-101 HAS SIX HOLES IN THE
WEB AND SHALL BE INSTALLED IN
(3) Apply a thin even coat of corrosion
TRANSMISSIONS 412-040-002. THE
preventive compound (C-128) to the transmission
SPIRAL BEVEL PINION IN THE ROTOR case from the edge of the bore that mates with the
BRAKE QUILL A S S E M B LY rotor brake drive quill (13) to the outer edge of the
412-040-123-103 HAS FOUR HOLES IN case shim.
THE WEB AND SHALL BE INSTALLED IN
TRANSMISSIONS 412-040-004. SEVERE
DAMAGE TO THE TRANSMISSION WILL
R E S U LT I F T H I S C A U T I O N I S N O T CAUTION
FOLLOWED.
DURING ROTOR BRAKE QUILL

INSTALLATION DO NOT STRIKE END OF
CAUTION PINION SHAFT OR FLANGED ADAPTER.
IF NECESSARY, DRIVE QUILL INTO
PLACE BY LIGHTLY TAPPING AROUND
E X E R C I S E C A U T I O N TO P R E V E N T THE QUILL SLEEVE FLANGE NEAR THE
DAMAGE TO ROTOR BRAKE PINION OUTER EDGES WITH A RUBBER
AND SPIRAL BEVEL GEAR TEETH. MALLET.
63-00-00
BHT-412-CR&O-3
b. Put the cover on the transmission main case.

CAUTION
c. Install the six bolts with aluminum washers
next to the cover and the steel washers next to the bolt
MAKE SURE THE OIL HOLE IN THE heads. Torque the bolts 160 to 190 inch-pounds (18 to
QUILL SLEEVE IS UP OR DAMAGE TO 21 Nm).
THE QUILL MAY OCCUR.
33. For transmission 412-040-002, check the
f. Carefully insert the rotor brake drive quill (13) backlash on the main input quill (6, Figure 63-40) as
into the transmission case with the oil hole in the quill follows:
sleeve up. Exercise caution to prevent damage to the
quill teeth. Rotate the quill pinion slightly to permit gear
meshing. Align the holes and install the six bolts (14)
with the washers (15 and 16). Torque the bolts 160 to CAUTION
190 inch-pounds (18 to 21 Nm).
g. Check the backlash as follows: DO NOT ALTER SHIM PLATE ON MAIN

CASE OR QUILL SLEEVE TO OBTAIN
(1) Install a dial indicator on the BACKLASH. IF BACKLASH IS NOT
transmission (1). WITHIN LIMITS, PA R T S A R E
IMPROPERLY ASSEMBLED OR ARE
DIMENSIONALLY INCORRECT.
(2) Install the backlash tool
205-040-300-1GIF-1 on the rotor brake disc. With the
drive quill stationary, measure the backlash of the rotor a. Remove the retaining ring (1, Figure 63-51),
brake disc with the tool. grease retainer (2), and lock spring (4).
(3) If the tool is not available, measure the b. Install the backlash tool (212-040-001-19
backlash tangentially at a distance of 1.421 inches GIF-1) on the main input quill (5).
(36.09 mm) out from center of the rotor brake disc.
c. If not previously accomplished, make the
(4) The backlash limit for the rotor brake quill workaid for the dial indicator support (Figure 63-49).
assembly 412-040-123-101 is 0.012 to 0.020 inch
(0.30 to 0.51 mm). d. Install the dial indicator support (Figure 63-49)
on one of the main input quill studs. Install the dial
(5) The backlash limit for the rotor brake quill indicator on the support and put a dial indicator to
assembly 412-040-123-103 is 0.010 to 0.020 inch contact the marked spot on the backlash tool.
(0.25 to 0.51 mm).
e. Take the backlash reading at three places
h. Install the rotor brake disc (3) and brake 120° apart around the gear. Record the backlash
assembly (3A) (BHT-412-MM). values. The backlash limit for the main input quill is
0.012 to 0.019 inch (0.31 to 0.48 mm) for the
transmission 412-040-002.
NOTE
The following procedure applies if the rotor
brake is not installed. NOTE
If the backlash tools previously listed are
32. Install the cover (not illustrated) on the rotor brake not available, other tools that can measure
drive quill port as follows: backlash at a distance (radius) of
2.070 inches (52.58 mm) from the input
a. Lubricate a new packing with the same oil quill gear center may be substituted.
used in the transmission and install the packing on the Permitted backlash values are the same as
cover. stated in step e.
63-00-00
BHT-412-CR&O-3
Figure 63-49. Dial Indicator Support Workaid
63-00-00
BHT-412-CR&O-3
f. Remove the backlash tools from the main e. Remove the backlash tool plate assembly
input quill, but leave the tools installed in the main from the main quill adapter, but leave the tools
input gear quill. installed on the ring gear and the main input gear quill.
g. Install the lock spring (4, Figure 63-51). Make 35. Check the backlash on the hydraulic pump drive
sure that the tang on the lock spring is fully seated in quill (4, Figure 63-39) as follows:
the groove.
h. Lubricate and install the new packing (3) on CAUTION

the grease retainer (2).
i. Install the grease retainer (2) and the retaining DO NOT ALTER SHIM PLATE ON MAIN
ring (1). CASE OR QUILL SLEEVE TO OBTAIN
BACKLASH. IF BACKLASH IS NOT
34. For the transmission 412-040-004, check the WITHIN LIMITS, PA R T S A R E
backlash on the main input quill (6, Figure 63-40) as IMPROPERLY ASSEMBLED OR ARE
follows: DIMENSIONALLY INCORRECT.
a. Install the backlash tool (212-040-001-3

NOTE GIF-1, Detail 4) on the hydraulic pump drive quill (4).
Make sure that the ring gear (5, b. If not previously accomplished, make the
Figure 63-42) is installed prior to installation workaid for the dial indicator support (Figure 63-49).
of the backlash tool set 412-240-006-101.
c. Install the dial indicator support (Figure 63-49)
a. Install the plate assembly 412-240-006-103 on one of the hydraulic pump drive quill studs. Install
on the main input adapter, as shown in Figure 63-40. the dial indicator on the support and put a dial indicator
to contact the dowel pin in the backlash tool.
b. If not previously accomplished, make the
workaid for the dial indicator support per Figure 63-49. d. Take the backlash reading at three places
120° apart around the gear. Record the backlash
c. Install the dial indicator support (Figure 63-49) values. The backlash limit for the hydraulic pump drive
on one of the main input quill studs. Install the dial quill is 0.010 to 0.018 inch (0.25 to 0.46 mm) for the
indicator on the support and put a dial indicator to transmissions 412-040-002. A permitted backlash
contact the marked spot on the backlash tool. value for the hydraulic pump drive quill is 0.010 to
0.020 inch (0.25 to 0.51 mm) for the transmissions
412-040-004.
CAUTION
NOTE
If the backlash tools previously listed are
DO NOT ALTER SHIM PLATE ON MAIN not available, other tools that can measure
CASE OR QUILL SLEEVE TO OBTAIN backlash at a distance (radius) of
BACKLASH. IF BACKLASH IS NOT 1.774 inches (45.06 mm) from the hydraulic
WITHIN LIMITS, PA R T S A R E pump drive gear center may be substituted.
IMPROPERLY ASSEMBLED OR ARE Permitted backlash values are the same as
DIMENSIONALLY INCORRECT. stated in step d.
d. Take the backlash reading at three places e. Remove the backlash tools from the hydraulic
120° apart around the gear. Record the backlash pump drive quill.
values. The backlash limit for the main input quill is
0.010 to 0.018 inch (0.25 to 0.46 mm) for the f. Remove the backlash tools from the main
transmission 412-040-004. input gear quill that were installed in step 29.
63-00-00
BHT-412-CR&O-3
36. Verify the existence of backlash on the rotor n. Install the thermostatic switch (12) in the oil
brake drive quill if installed. A measurement is not temperature manifold (8). Tighten the switch.
required.
o. Lubricate a new packing (9) with the same oil
37. Install the oil temperature manifold (14, used in the transmission and install the packing on the
Figure 63-37) and the oil jets as follows: pressure regulating valve (10).
p. Install the pressure regulating valve (10) in the

a. Lubricate new packings (6 and 7) with the
oil temperature manifold (8). Torque the pressure
same oil used in the transmission and install the
regulating valve 150 to 180 inch-pounds (16.9 to
packings and the new gasket (5) on the oil
20.3 Nm).
temperature manifold (14).
q. Secure the pressure regulating valve (10) to
b. Put the oil temperature manifold (14) on the
the thermostatic switch (12) with lockwire (C-405).
main case and install the bracket (12) with the bolt (10)
and the thin steel washer (11). Torque the bolt 50 to
r. Lubricate a new packing (8, Figure 63-37) with
70 inch-pounds (5.65 to 7.91 Nm).
the same oil used in the transmission and install the
packing on the thermobulb (9).
c. Lubricate new packings (17 and 18) with the
same oil used in the transmission and install the
s. Install the thermobulb (9) in the oil
packings on the oil jet No. 7 (13).
temperature manifold (14). Torque the thermobulb 15
to 20 inch-pounds (1.69 to 2.25 Nm).
d. Put the oil jet No. 7 (13) in the oil temperature
manifold (14). t. Secure the thermobulb (9) to the pressure
regulating valve (10, Figure 63-35) with lockwire
e. Install the screw (20) and the steel washer (C-405).
(19). Tighten the screw.
f. Install the new seal (16) and the screw (15). NOTE
Tighten the screw. Refer to Figure 63-41, Detail A for a
sectional view of the installed planetary
g. Secure the screw (15) to the screw (20) with gears, sun gears, and adapting parts when
lockwire (C-405). accomplishing step 38 through step 42.
h. Lubricate new packings (9, 10, 11, 38. Put the lower sun gear (14, Figure 63-41) on the
Figure 63-36) with the same oil used in the main input gear quill shaft (16) with the longer inner
transmission and install the packings on the oil jet shoulder down.
No. 3 (12).
39. Assemble the lower bearing (12), outer liner (11),
i. Put the oil jet No. 3 (12) in the manifold. and inner liner (13) with the thrust (non-counterbored)
side of the outer race of the bearing against the
j. Install the bracket (18) with the bolt (16) and shoulder in the outer liner until fully seated. Install the
the thin steel washer (17). Torque the bolt 50 to assembled parts on the main input gear quill shaft (16)
70 inch-pounds (5.65 to 7.91 Nm). above the lower sun gear (14). Make sure that the
bearing liner and sun gear are positioned, as shown in
k. Install the screw (15), new gasket (13), and the sectional view, Detail A.
thin steel washer (14). Tighten the screw.
40. Install the lower planetary (10) with the pinions
l. Secure the screw (15) to the bolt (16) with engaged with the lower sun gear (14). When the lower
lockwire (C-405). planetary is properly installed, the splined section of
the lower planetary will be seated on the flange of the
m. Lubricate a new packing (11, Figure 63-35) outer liner (11). Only for the lower planetary
with the same oil used in the transmission and install 204-040-784 with the spider 412-040-785 installed,
packing on the thermostatic switch (12). the three equally spaced slots must engage the three
63-00-00
BHT-412-CR&O-3
tangs of the liner and must be lined up with the three e. Install the bolts (28), with the thin steel washer
chamfered teeth on the lower side of the spider. (29) under the bolt heads, with the head outboard.
Install the aluminum washer (30) and the thin
aluminum washer (31), as required, next to the oil jet
41. Put the oil deflector (9) on the upper sun gear (7),
housing (32) and one washer (27A) and one thin steel
as shown in the sectional view, Detail A. Install the
washer (27) under the nuts (26). Torque the nuts 50 to
retaining ring (8). Make sure that the retaining ring is
70 inch-pounds (5.65 to 7.91 Nm) and secure with the
fully seated in the retaining ring groove.
new cotter pins (25).
42. Put the assembled upper sun gear (7) and the oil
deflector (9) into the lower planetary (10). Engage the NOTE
notches in the lower side of the sun gear with the
The procedures for the oil jet housing (34
tangs on the outer liner (11).
and 39) are the same, therefore only the
procedure for the oil jet housing (39) is
43. Install the oil jet housing on the ring gear (5, given.
f. Put the new gasket (38) and the oil jet housing
a. Put the ring gear (5) on the work bench with (39) on the ring gear (5) with the hole for the oil jet
the wider gear teeth up. screw toward the oil jet housing (32), as shown in
Figure 63-42.
g. Install the bolts (43) with the thin steel washer

CAUTION
(42) under the bolt heads, with the heads outboard.
Install the steel washer (41) and the thin aluminum
washers (40), as required, next to the oil jet housing
DO NOT ALLOW SEALANT COATED
(39). Install the washers (37A) and the thin steel
GASKETS TO COME IN CONTACT WITH
washers (37) under the nuts (36). Torque the nuts 50
TRANSMISSION OIL FOR AT LEAST
to 70 inch-pounds (5.65 to 7.91 Nm) and secure with
24 HOURS AFTER SEALANT HAS BEEN
the new cotter pins (35).
APPLIED.
44. Install the ring gear (5) as follows:

NOTE
Put the jets through the jet housings and
a. Lubricate new packings (2 and 4,
the ring gear to ensure correct alignment
Figure 63-37) with the same oil used in the
during installation of each jet housing.
transmission and install the packings on the oil
transfer tube (3).
b. Locate the tooling hole on the lower flange of
the ring gear (5). A second tooling hole may be located
in the upper flange. b. Install the oil transfer tube (3) in the oil
temperature manifold (14).
c. Clean the mating surfaces of the oil jet
housing (32) and the ring gear (5) with MEK (C-309). c. Lubricate a new packing (10, Figure 63-42)
Apply a thin coating of sealant (C-308), 0.010 to with the same oil used in the transmission and install
0.020 inch (0.25 to 0.51 mm) thick, to both sides of the the packing on the main input gear quill (11).
new gasket (33). Apply sealant (C-308) to the inside
edges of the gasket holes with a cotton swab to
ensure complete coverage. NOTE
If a run-in test stand is available per
d. Put the new gasket (33) and the oil jet housing BHT 77-003, it is permitted to omit sealant
(32) on the ring gear (5) on the first set of holes on the mating surface until such time the
counterclockwise from the tooling hole(s), as shown in qualification inspection is complete and
Figure 63-42. ready for assembly.
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BHT-412-CR&O-3
d. Apply a thin coat of sealant (C-328) to the 46. Install the upper planetary (2) in the ring gear (15)
mating flange of the ring gear and the main input gear with pinion teeth engaged in the ring gear and the
quill. upper sun gear (7). Engage projections on the outer
liner (6) with the notches in the outer liner (11). The
e. Put the ring gear (5) on the main input gear upper bearing (5) and the lower bearing (12) should
quill (11) with the oil jet housing (32) aligned with the now be back-to-back.
tube installed in step a and carefully mesh the spline
teeth. Insert the tube into the housing. Tap the ring 47. Spray the inside of the transmission with the
gear with a rawhide or a plastic mallet until fully same oil used in the transmission.
seated.
f. Put the neck and scupper support bracket (4) 48. Install the top case (20, Figure 63-38) as follows:
on the lower flange of the ring gear on the right side of
the transmission. The forward hole in the bracket must a. Lubricate new packings (12 and 14) with the
be positioned at the first hole in the ring gear (5) flange same oil used in the transmission and install on the oil
aft of the oil jet housing (39). Install the four bolts (1), transfer tube (13). Insert the tube into the oil jet
to secure the bracket to the transmission with the thin housing installed on the ring gear (11) in step 43.
steel washer (2) under the bolt head, the washer (3)
next to the bracket, the washer (24) next to the main b. Lubricate a new packing (17) with the same oil
case and the thin steel washer (23) with the nut (22). used in the transmission and install on the top
Do not torque the nut at this time. case (20).
g. Put the bracket (7) on the lower flange of the c. Put the top case (20) on the ring gear (11) and
ring gear (5) at the first hole aft of the planetary simultaneously insert the oil transfer tube (13) into the
electrical chip detector (20). Install the bolt (6), port on the top case. Tap the top case lightly with a
washers (19 and 18), and nut (17). Do not torque the rawhide or plastic mallet to seat the top case on the
nut at this time. ring gear.
h. Install the four additional brackets (7) and the

d. Install the bolt (3), thin steel washer (4), and
bolts at the alternate holes on the left side of the ring
bracket (5) at the first hole aft of the port for the upper
gear in the same manner as outlined in the preceding
mast electrical chip detector (1). Install the steel
step. The five brackets will support the electrical wiring
washer (7) and the nut (8). Do not torque the nut at
from above and slightly right of the center of the main
this time.
input quill, around the left side of the ring gear, to the
planetary electrical chip detector (20).
e. Install the 15 bolts (21), washers (16, 15, and
i. Install the 11 bolts (8), washers (9, 14, and 10), and nuts (9). Torque the nuts (8 and 9) 230 to
15), and nuts (16) in the remaining holes in the ring 250 inch-pounds (26 to 28 Nm).
gear (5) lower flange. Torque the nuts (16, 17, and 22)
230 to 250 inch-pounds (25.99 to 28.25 Nm). f. Measure the distance from the top of the mast
driving adapter (3, Figure 63-50) to the top of the top
45. Assemble the upper bearing (5, Figure 63-41), case as illustrated. If the dimension is less than
outer liner (6), mast driving adapter (3), and extension 2.226 inches (56.54 mm), the transmission is not
(4), if applicable, with the thrust (non-counterbored) assembled properly. Inspect the outer liners (6 and 11,
side of the bearing outer race against the shoulder in Figure 63-41) to ensure that the projections on the
the outer liner. Insert these parts from the lower side of outer liner (6) are engaged with the notches in the
the upper planetary (2) and install the retaining ring outer liner (11).
(1). Make sure that the retaining ring is fully seated.
g. Install the cover and lift plate assembly
(T103211-101) on the top case (20, Figure 63-38).
NOTE
To help the installation, use two jacking h. Install the three screws (19) and the aluminum
screw sets (T102064) installed at opposite washers (18). Secure the screws to the adjacent holes
sides on the upper planetary (2). in the top case with lockwire (C-405).
63-00-00
BHT-412-CR&O-3
2.226 IN. (56.54 mm)

MINIMUM ON TRANSMISSION
412-040-002-103
412_CRO_63_0050
Figure 63-50. Mast Driving Adapter To Transmission Top Case — Dimension Requirements
63-00-00
BHT-412-CR&O-3
i. Install the upper mast electrical chip detector top case adjacent to the port for the mast with lockwire
(1) and the new packing (2). Torque the chip detector (C-405).
30 to 108 inch-pounds (3.4 to 12.2 Nm). Secure the
chip detector at the hole in the top case adjacent to the 51. Put the spacer (22, Figure 63-37) and the oil
port for the mast with lockwire (C-405). pressure manifold (23) on the transmission (1). Install
the aluminum washer (24), steel washer (25), and nut
49. Install the accessory and tail rotor drive and sump (26) in two places. Torque the nuts 50 to
assembly (7, Figure 63-44) as follows: 70 inch-pounds (5.65 to 7.91 Nm).
a. If the transmission is supported on the 52. Apply the same oil used in the transmission to the
transportation stand, as illustrated in Figure 63-31, threads of the union (27) and the new packing (28).
hoist the transmission clear of the stand and proceed Install the union and the packing in the oil pressure
to step c. manifold (23). Tighten the union.
b. If the transmission is supported on the
transmission stand, as illustrated in Figure 63-30, 53. Apply the same oil used in the transmission to the
rotate the transmission 90° to the horizontal position. threads of the elbow and new packing (5,
Figure 63-34). Install the elbow and packing (5) and
c. Put the tail rotor drive quill adapter (2, the nut (6) in the oil pressure manifold (23,
Figure 63-44) in the accessory drive quill in the Figure 63-37), but do not torque the nut at this time.
support case (1).
54. Apply the same oil used in the transmission to the
d. Put the new gasket (3) on the support case threads of the banjo bolt (20, Figure 63-34) and the
(1). two new packings on the elbow and two packings (19).
Put the elbow on the transmission with one packing
e. Put the accessory and tail rotor drive and next to the transmission and one packing on top of the
sump assembly (7) on the support case (1) with the tail elbow. Install the banjo bolt, but do not torque at this
rotor drive quill on the aft side of the case. Secure the time.
sump with aluminum washers (4) next to the sump,
thin steel washers (5), and nuts (6) on each of the 13 55. Apply the same oil used in the transmission to the
studs with one exception; omit the aluminum washer threads of the elbow and the new packing on the
and install the bracket (10), thin steel washer (9), and elbow and packing (5). Install the tube (4). Tighten the
nut (8), on the stud directly above the magnetic chip nut (6) and the banjo bolt (20). Torque banjo bolt 40 to
detector in the sump. Torque the nuts (6 and 8) 50 to 65 inch-pounds (4.5 to 7.3 Nm).
70 inch-pounds (5.65 to 7.91 Nm).
56. Lubricate new packings (31 and 32,
f. Put the lift link fitting (14) on the support case
(1) as illustrated. Install the four steel washers (13),
transmission and install the packings on the oil jet
nuts (12). Torque the nuts 37 to 42 foot-pounds (50.16
No. 1 (30). Put the jet in the transmission (40). Install
to 56.94 Nm) for the transmission 412-040-002.
the screw (26). Install the screw (27), thin steel washer
Torque the nuts 40 to 58 foot-pounds (54.23 to
(28), and new gasket (29). Secure the screws (26 and
78.64 Nm) for the transmissions 412-040-004. Secure
27) together with lockwire (C-405).
the nuts with new cotter pins (11).
g. If the transmission is to be supported on the 57. Lubricate new packings (19 and 20) with the
transportation stand illustrated in Figure 63-31, install same oil used in the transmission and install the new
the transmission in the stand. If the transmission is packings on the oil jet No. 2 (21). Put the jet in the
supported in the transmission stand illustrated in transmission. Install the screw (25). Install the screw
Figure 63-30, rotate the transmission 90° to the (24), thin steel washer (23), and new gasket (22).
vertical position. Secure the screws (24 and 25) together with lockwire
(C-405).
50. Install the plug (1, Figure 63-34) and the new
packing (2). Torque the plug 80 to 120 inch-pounds 58. Lubricate new packings (1, 2, and 3) with the
(9.04 to 13.56 Nm). Secure the plug to the hole in the same oil used in the transmission and install the
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BHT-412-CR&O-3
packings on the oil jet No. 6 (8). Put the jet in the 70. Secure the oil pressure transmitter (5) to the oil
transmission (40). Install the screw (7). Install the pressure manifold (1) with lockwire (C-405).
screw (6), new gasket (4), and thin steel washer (5).
Secure the screws (6 and 7) together with lockwire
71. Lubricate new packings (37 and 38,
(C-405).
transmission and install the packings on the oil jet
59. Put the auxiliary oil jet (48) and the new packing No. 5 (36). Put the jet in the transmission and install
(47) in the jet housing on the ring gear. Install the the screw (39). Install the screw (33) with the thin steel
screw (49). Coat the threads of the elbow (52) and the washer (34) and the new gasket (35). Secure the
new packing (50) with the same oil used in the screws (33 and 39) together with lockwire (C-405).
transmission. Install the nut (51), packing (50), and
elbow (52) in the auxiliary oil jet. Do not tighten the nut
at this time. 72. Lubricate the new packing (21, Figure 63-43) with
the same oil used in the transmission and install the
planetary electrical chip detector (20) and the packing.
60. Coat the threads of the elbow (17 and 8,
Torque the chip detector 30 to 108 inch-pounds (3.4 to
Figure 63-34) and the threads on the nuts at both ends
12.2 Nm). Secure the chip detector to the adjacent
of the tubes (18 and 7) with the same oil used in the
hole in the case with lockwire (C-405).
transmission. Install the elbows, new packings (15 and
10), and nuts (16 and 9) in the jet housing (14). Do not
tighten the nuts at this time. 73. Lubricate a new packing with the same oil used in
the transmission and install the union and packing (25,
61. Install the tube (18) on the elbow (17). Install the Figure 63-33) on the neck and scupper assembly (1).
opposite end of the tube on the elbow (52, Tighten the union.
Figure 63-36). Tighten the nuts on both elbows.
74. Put the neck and scupper assembly (1) in
62. Install the auxiliary oil jet (42) and the tube (7, position on the neck and scupper support bracket (2)
Figure 63-34) in the same manner as outlined in with the union and packing (25) facing aft.
step 60, step 61, and step 62.
75. Install the neck and scupper assembly (1) on the
63. Secure the screw (43, Figure 63-36) to the elbow neck and scupper support bracket (2) with four
(46) with lockwire (C-405). washers (24) between the scupper and the bracket.
Install the washers (23) and the nuts (22) on the
64. Secure the screw (49) to the elbow (52) with scupper at four places, securing the scupper to the
lockwire (C-405). bracket. Torque the nuts 50 to 70 inch-pounds (5.65 to
7.91 Nm).
65. Lubricate new packing (3, Figure 63-35) with the
same oil used in the transmission and install the 76. Coat the threads of the elbow and new packing
packing on the union (4). (19) with the same oil used in the transmission. Install
the elbow and packing and the nut (21).
66. Install the union (4) on the oil pressure manifold
(1). Tighten the union.
77. Install the hose assembly (11) on the elbow and
packing (19) and tighten the nuts (10 and 21).
67. Install the oil pressure switch (7) and the new
packing (6) on the union (4). Torque the oil pressure
switch 50 to 65 inch-pounds (5.65 to 7.34 Nm). 78. Install the new clamps (15) with the screws (16),
washers (13), and nuts (12). Tighten the nuts.
68. Secure the oil pressure switch (7) to the oil
pressure manifold (1) with lockwire (C-405). 79. Put the tube (17) on the transmission and attach
the nut (20) to the union and new packing (25). Put the
69. Install the oil pressure transmitter (5) and the new opposite end of the tube to drain into the scupper
packing (2). Torque the oil pressure transmitter 50 to adjacent to the internal oil filter on the transmission
65 inch-pounds (5.65 to 7.34 Nm). sump. Tighten the nut.
63-00-00
BHT-412-CR&O-3
80. Install the screw (18), washer (28), and nut (29) a. Put the transmission electrical cable assembly
to secure the new clamp (14) to the bracket (8). (22) on the transmission (1).
Tighten the nut.
b. Stow the electrical connector (24P3) (24).
81. If applicable, remove the cap from the neck and
scupper assembly (1). c. Connect the electrical terminal and nipple (14)
to the upper mast electrical chip detector (15). Do not
82. Install the filler oil cap adapter (9) as follows: overtorque the terminal stud nut on the electrical chip
detector.
a. If a new filler adapter (30) is installed on the d. Connect the electrical terminal and nipple (19)
transmission support case, remove and discard the to the planetary electrical chip detector (18). Do not
existing safety chain. overtorque the terminal stud nut on the electrical chip
detector.
b. Apply wet zinc chromate primer (C-201) to the
threads of the filler adapter (30). e. Connect the electrical connector (17) to the
rotor tachometer generator (16).
c. Install the filler adapter (30) into the
transmission support case (Figure 63-33). Hand f. Connect the electrical terminal and nipple (13)
tighten the adapter. to the oil thermostatic switch (12). Do not exceed
6 inch-pounds (0.68 Nm) torque on the terminal stud
nut.
NOTE
In order to lock the filler oil cap adapter (9) g. Connect the electrical connector (5) to the oil
from the inside, fabricate a workaid that will pressure switch (4).
simulate a filler cap assembly.
h. Connect the electrical connector (3) to the oil
d. Install the filler oil cap adapter (9) on the filler
pressure transmitter (2).
adapter (30). Tighten the filler oil cap adapter.
i. Connect the electrical connector (7) to the oil
e. Deleted. temperature transmitter (8).
83. Apply the same oil used in the transmission to the j. Connect the electrical terminal and nipple (11)
threads of the elbow (5), new packing (3), and to the sump electrical chip detector (10). Make drip
tube (7). loop in wire, as shown in Figure 63-32.
84. Install the elbow (5), nut (4), and new packing (3) k. Connect the four wirings for rotor brake (20) to
on the neck and scupper assembly (1). Tighten the the rotor brake, as shown in Detail B. If the rotor brake
nut. is not installed, stow the wiring for the rotor brake.
85. Install the tube (7) on the elbow (5) and the l. Connect the three or four ground wires (23),
extension cap (9). Tighten the nuts (6). as applicable, to the bracket (31) with the screw (30),
aluminum washers (27, 28, and 29), lockwasher (26),
and nut (25). Tighten the nut.
86. If previously removed, install the cap on the neck
and scupper assembly (1). Tighten the cap.
NOTE
87. Clamp the lower end of the tube (17) to the If the transmission with a full flow debris
bracket (10, Figure 63-44). monitor is installed, perform step m.
88. Install the transmission electrical cable assembly m. Connect the electrical terminal and nipple
(22, Figure 63-32) as follows: (11B) to the full flow debris monitor (11A).
63-00-00
BHT-412-CR&O-3
n. Secure the clamps (21) to the brackets (7, 1. Apply sealing compound and sealant prior to
Figure 63-42) and all other similar brackets on the painting the transmission.
transmission.
2. Install the protective covers at the following
89. Cap or plug all open hoses and ports to prevent locations:
the entry of foreign materials.
a. Tachometer generator mounting flange.
90. Run-in and test the transmission (paragraph
63-39). b. Hydraulic pump mounting flange adjacent to
the tachometer generator.
91. Apply sealant and paint the transmission
(paragraph 63-40). c. Hydraulic pump mounting flange on the main
case.
63-39. TRANSMISSION — RUN-IN AND TEST
d. Rotor brake quill on the main case.
1. If a run-in stand is available, run-in and test the
transmission in accordance with the BHT-PUB 77-003, e. Port in the main case on the right side
Run-In and Test Manual. opposite the rotor brake quill.
2. If a run-in stand is not available, use an alternate 3. Remove the external lines and hoses to facilitate
Run-In and Test Procedure outlined in the painting. Cap or plug all openings.
BHT-412-MM-6. This is the minimum acceptable test
for an overhauled transmission. 4. Touch up areas on the magnesium cases where
chemical film has been removed with chromic acid
63-40. TRANSMISSION — SEALING AND treatment (C-103) (BHT-ALL-SPM, Chapter 3).
PAINTING
5. Mask the transmission for primer and paint.
MATERIALS REQUIRED 6. Clean the areas of the transmission that are to be

painted with clean cheesecloth (C-486) moistened
Refer to BHT-ALL-SPM for specifications. with aliphatic naphtha (C-305). Wipe dry with a clean
cheesecloth before naphtha evaporates.
NUMBER NOMENCLATURE
C-103 Chromic Acid 7. Apply one coat of epoxy polyamide primer

Treatment (C-204) 5 to 8 mil thickness (BHT-ALL-SPM, Chapter
4).
Primer 8. Apply a coat of polyurethane coating (C-245) not
less than 30 minutes and not more than 4 hours after
C-245 Polyurethane Coating the epoxy primer is applied (color No. 36440 per
FED-STD-595) (BHT-ALL-SPM, Chapter 4).
C-305 Aliphatic Naphtha
C-486 Cheesecloth 9. Install the SERVICE TRANSMISSION decal on

the main support case below and to the left of the oil
filler cap to indicate the type of oil to be used.
NOTE
Make sure that the transmission is 10. Identify the transmission by the part number on
assembled and has been run-in and tested the top case. Use stamp ink or stencil.
prior to sealing and painting (paragraph
63-39). 11. Install the hoses and the lines removed in step 3.
63-00-00
BHT-412-CR&O-3
4
3
2
1
1. Retaining ring
2. Grease retainer
3. Packing
4. Lock spring
5. Main input quill
412_CRO_63_0046_c01
Figure 63-51. Main Input Quill Grease Retainer — Installation (Typical)
63-00-00
BHT-412-CR&O-3
Figure 63-52. Sealing Compound and Sealant Application (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
13. Main case and support case 3
412_CRO_63_0052b
Figure 63-52. Sealing Compound and Sealant Application (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
TRANSMISSION CASES
63-41. TRANSMISSION CASE 5. If the top case is corroded, remove the corrosion
by chromic acid treatment (C-103) pickle process for
cleaning magnesium parts (BHT-ALL-SPM).
This section contains instructions to overhaul the top
case, main bevel gear case, and main support case.
63-45. Transmission Top Case — Inspection
63-42. TRANSMISSION TOP CASE 1. Inspect the top case (1, Figure 63-53) for yielding
(212-040-059-101) and the stud threads for damage and looseness.
63-43. Transmission Top Case — Disassembly 2. Inspect the top case (1) for corrosion and
damage in accordance with Figure 63-54.
Remove the cotter pins (5, Figure 63-53), nuts (4),
washers (3), and collector (2) from top case (1). 3. Inspect the top case (1, Figure 63-53) by
Discard the cotter pins. fluorescent penetrant method (BHT-ALL-SPM).
63-44. Transmission Top Case — Cleaning 63-46. Transmission Top Case — Repair
MATERIALS REQUIRED
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
C-100 Chemical Film Material
C-103 Chromic Acid
Treatment C-308 Sealant

1. Replace loose or damaged threaded inserts with
C-334 Solvent new threaded inserts (BHT-ALL-SPM).
C-436 Paint Remover 2. If the top case is corroded in the area adjacent to
the studs or if the studs are corroded, rework as
C-516 Clean Cloth
follows:
1. Clean all the parts with drycleaning solvent

NOTE
(C-304). Use soft bristle brush to dislodge stubborn
deposits. All parts may be cleaned with solvent When corrosion has not penetrated past
(C-334) by vapor degreasing if desired. the first thread, rework as outlined in step a
through step d.
2. Dry the parts with a clean cloth (C-516) or dry a. Measure and record the height of the stud.
filtered compressed air.
b. Remove the stud from the corrosion damaged
area.
3. Remove the sealant with a plastic scraper.
c. If the corrosion has affected more than one

4. Remove the paint with paint remover (C-436). complete thread, the case is non-airworthy and
Rinse with water and dry with filtered compressed air. nonrepairable.
63-00-00
BHT-412-CR&O-3
4 T
5
1. Top case
2. Collector
3. Washer
4. Nut
5. Cotter pin
12 TO 15 IN-LBS
T (1.4 TO 1.7 Nm)
412_CRO_63_0053
Figure 63-53. Transmission Top Case
63-00-00
BHT-412-CR&O-3
AREA
H
J A
D
C
VE
NT
AREA
H
J
O
IL
P
R
E
S
D
S
RN
O AREA K
SE
(TYPICAL 19 PLACES)
TOP CASE ASSEMBLY

(212-040-059-101)
412_CRO_63_0054a
Figure 63-54. Transmission Top Case — Damage Limits and Repair (Sheet 1 of 7)
63-00-00
BHT-412-CR&O-3
SURFACE E
1.17 to 1.37 IN.

(29.7 TO 34.7 mm)
SURFACE G
AREA DIAMETER DIAMETER

T B A
AREA
P
SURFACE
F
AREA
R
SECTION A-A
412_CRO_63_0054b_c01
63-00-00
BHT-412-CR&O-3
AREA
M
SECTION B-B
AREA
N
SECTION C-C
412_CRO_63_0054c
63-00-00
BHT-412-CR&O-3
DIAMETER
DIAMETER D1
C2
SURFACE E
DIAMETER AREA
C1 H
AREA
L
DIAMETER SECTION J-J

D2
SECTION D-D
DIAMETER NEW PART DIMENSION REPLACE

MINIMUM MAXIMUM
A 14.800 inches 14.802 inches 14.799 inches

(375.92 mm) (375.97 mm) (375.89 mm)
B 7.060 inches 7.061 inches 7.062 inches

(179.32 mm) (179.35 mm) (179.37 mm)
C1 0.812 inch 0.814 inch 0.815 inch

(20.62 mm) (20.68 mm) (20.70 mm)
C2 0.615 inch 0.635 inch 0.636 inch

(15.62 mm) (16.13 mm) (16.15 mm)
D1 0.438 inch 0.440 inch 0.441 inch

(11.13 mm) (11.18 mm) (11.20 mm)
D2 0.375 inch 0.377 inch 0.378 inch

(9.53 mm) (9.58 mm) (9.60 mm)
412_CRO_63_0054d_c01
63-00-00
BHT-412-CR&O-3
NOTES
1. Where rework is specified, repair dents, nicks, scratches, and corrosion by polishing with a fine India stone
(C-464) to a minimum radius of 0.12 inch (3.0 mm) unless otherwise noted. Remove any raised material flush
with surrounding surface. Surface finish of repaired areas to be 63 RMS or better.
Corrosion pitting or repairs on any plane surface may not extend radially inward across more than 75% of the
width of the surface nor more than 50% of the distance from any hole to an outside edge, unless otherwise
noted.
2. Mechanical damage in the form of fine axial scratches is acceptable on Diameter A, provided such scratches
do not exceed 0.003 inch (0.08 mm) in depth. Do not polish out such scratches but remove any raised material
flush with surrounding surface using a fine India stone (C-464).
3. Fine axial scratches are acceptable in Diameter B, provided the depth of such scratches does not exceed
0.002 inch (0.05 mm) after polishing with a 400 grit aluminum oxide paper (C-406). The circumferential
length of such may not exceed 1.5 inches (38 mm) and the circumferential spacing between repair sites shall
be no less than 3.0 inches (76 mm). See wear limits.
4. No corrosion pitting or mechanical damage permitted in Diameters C and D. See wear limits.
5. Corrosion pitting or mechanical damage is acceptable on Surface E, provided the corrosion or mechanical
damage does not exceed 0.010 inch (0.25 mm) in depth, and covers no more than 20% of the area within any
1.0 square inch (645 mm2) or 10% of the total area of the surface. Corrosion or mechanical damage
must not extend closer than 0.060 inch (1.52 mm) from edge of holes or edges of transfer tube bore entry
chamfers.
Corrosion or mechanical damage may extend no closer than 0.150 inch (3.81 mm) from Diameter A. Remove
any raised material flush with the surrounding surface using a fine India stone (C-464).
Light fretting erosion on Surface E commonly covers large areas, particularly on outer edges. This condition is
acceptable provided the fretting extends no closer than 0.400 inch (10.16 mm) from edges of bolt holes and
transfer tube holes and does not exceed 0.0015 inch (0.038 mm) in depth at any point.
Corrosion pitting on the inside of bolt holes on Surface B may not exceed 0.020 inch (0.51 mm) in depth nor
cover more than 20% of total wall area inside the hole.
6. Corrosion pitting is acceptable on Surfaces F and G provided the corrosion does not exceed 0.010 inch
(0.25 mm) in depth, and covers no more than 20% of the area within any 1.0 square inch (645 mm2) or
10% of the total area of the surface. Corrosion may extend no closer than 0.100 inch (2.54 mm) from the edge
of washer seats and threaded stud holes on Surface F, or from threaded inserts on Surface G. Do not polish out
such pitting but remove any raised material flush with the surrounding surface using a fine India stone (C-464).
Mechanical damage in the form of nicks, dents, and scratches is acceptable on Surfaces F and G, provided the
damage is no greater than 0.010 inch (0.25 mm) in depth, 0.500 inch (12.70 mm) in length and extends no closer
than 0.100 inch (2.54 mm) from the edge of washer seats and threaded stud holes on Surface F or threaded
inserts on Surface G. Do not polish out such damage but remove any raised material flush with the
surrounding surface using fine India stone (C-464).
Mechanical damage to threaded holes for studs in Surface F is acceptable, provided damage does not extend
past the first thread.
Mechanical or corrosion damage at threaded inserts and washer seats is not acceptable.
7. Corrosion pitting is acceptable in Areas H provided the pitting does not exceed 0.010 inch (0.25 mm) in depth
and covers no more than 20% of the total area of the corroded surface. Corrosion pitting may extend no closer
than 0.100 inch (2.54 mm) from edges of bore entry chamfer, dowel pin, and threaded insert. Do not polish out
such pitting but remove any raised material flush with surrounding surface using a fine India stone (C-464).
Mechanical damage in the form of nicks, dents, and scratches is acceptable in Areas H provided damage is no
greater than 0.010 inch (0.25 mm) in depth, 0.250 inch (6.35 mm) in length and extends no closer than
0.100 inch (2.54 mm) from the edges of bore entry chamfer, dowel pin, and threaded insert. Remove any raised
material flush with surrounding surface using a fine India stone (C-464).
No corrosion or mechanical damage acceptable in jet bores and associated entry chamfers, threaded inserts,
or on dowel pins.
412_CRO_63_0054e_c01
63-00-00
BHT-412-CR&O-3
8. Corrosion pitting or mechanical damage is acceptable on spot face Areas K provided damage or corrosion
does not exceed 0.020 inch (0.51 mm) in depth and covers no more than 25% of total area of surface, nor more
than 15% of the area under the mating washer. Corrosion or mechanical damage may extend no closer than
0.060 inch (1.52 mm) from the edges of holes. Do not polish out pitting or mechanical damage but remove any
raised material flush with surrounding surface using a fine India stone (C-464).
9. Corrosion pitting or mechanical damage is acceptable on Areas L provided corrosion or mechanical damage
does not exceed 0.010 inch (0.25 mm) in depth, and covers no more than 15% of total area of surface.
Corrosion or mechanical damage must not extend closer than 0.100 inch (2.54 mm) from the edge of threaded
holes. Do not polish out pitting or mechanical damage but remove any raised material flush with surrounding
surface using a fine India stone (C-464).
Mechanical damage to threaded holes for studs in Areas L is acceptable, provided damage does not extend
past first thread.
10. Corrosion pitting is acceptable in Areas M and N provided it is no more than 0.010 inch (0.25 mm) in depth and
covers no more than 20% of the total area of the surface. Corrosion must not extend closer than
0.060 inch (1.52 mm) from edge of boss entry chamfer.
Mechanical damage in the form of nicks, dents, and scratches is acceptable provided they do not exceed
0.005 inch (0.13 mm) in depth, nor more than 0.250 inch (6.35 mm) in length and extends no closer than
0.060 inch (1.52 mm) from the edge of boss entry chamfer.
No corrosion or mechanical damage is acceptable in boss bores or entry chamfers and threads.
11. Light corrosion pitting is acceptable in Area P provided such corrosion does not exceed 0.002 inch
(0.05 mm) in depth after removal of corrosion products. Do not polish out corrosion pitting.
12. No corrosion or mechanical damage is acceptable in packing Area R.
13. Corrosion pitting is acceptable on unspecified cast surfaces provided it is no more than 0.030 inch (0.76 mm)
deep and covers no more than 40% of any one square inch nor more than 10% of the total area of surface
involved after rework. Corrosion pitting 0.020 inch (0.51 mm) or less in depth need to be reworked. Rework to
0.250 inch (6.35 mm) minimum fillet radii with 63 RMS maximum surface finish. Areas reworked in prior
overhauls may not be reworked again to remove corrosion pitting.
Mechanical damage in the form of nicks, dents, and scratches is acceptable on unspecified cast surfaces
provided the damage does not exceed 0.030 inch (0.76 mm) in depth nor more than 0.75 inch (19.1 mm) in
length after rework. Rework to 0.250 inch (6.35 mm) fillet radii with 63 RMS maximum surface finish. Remove
any raised material flush with surrounding surface using a fine India stone (C-464). Areas reworked in prior
overhauls may not be reworked again to remove mechanical damage.
14. Liquid penetrant inspect per MIL-I-6866 for indications of cracks. No such indications are permitted.
15. A case with corrosion damage within acceptable limits must be treated by immersion in a hot chromic acid
bath. Refer to BHT-ALL-SPM for procedures.
Corrosion removal process must be controlled to ensure machined dimensions are maintained and that
cadmium plating is not removed from studs. After chromic acid bath, rinse case with water to remove chromic
acid and dry with filtered compressed air. Apply sealant (C-320) to counterdrilled area around studs.
16. Treat case assembly in accordance with chemical film (chromic acid) immersion treatment if case was
completely stripped of paint. Small, localized repairs performed after application of primer shall be treated in
accordance with chemical film (chromic acid) brush on treatment. Refer to BHT-ALL-SPM for procedures.
17. Prime case with two coats of polyamide epoxy primer (C-204). Refer to BHT-ALL-SPM for procedure. Omit
primer from indicated areas (see sheet 7, note 1).
18. Apply corrosion preventive compound (C-127).

412_CRO_63_0054f
63-00-00
BHT-412-CR&O-3
TOP CASE ASSEMBLY

(212-040-059-101)
412_CRO_63_0054g
63-00-00
Export Classification C, ECCN EAR99 12 JAN 2021 Rev. 13 Page 171/172
BHT-412-CR&O-3
d. If the corrosion has affected less than one 3. Remove the screws (29) and the shim plate set
complete thread, rework case as follows: (1). Mark the shim plate set for installation at the same
location on the same case.
(1) In Area T (Figure 63-54, Section A-A),
counter drill stud holes 0.327 to 0.334 inch (8.31 to
4. Remove the screws (5) and shim plate (7). Mark
8.48 mm) in diameter and a maximum depth of
the shim plate for installation at the same location on
0.110 inch (2.79 mm). Break all sharp edges, except in
the same case.
the threaded area.
(2) In Area L (Figure 63-54, Section J-J), 5. Remove the screws (15) and shim plate (16).
counter drill stud holes 0.327 to 0.334 inch (8.31 to Mark the shim plate for installation at the same
8.48 mm) in diameter and a maximum depth of location on the same case.
0.110 inch (2.79 mm). Break all sharp edges, except in
the threaded area.
6. Remove the screws (22) and shim plate (21).
Mark the shim plate for installation at the same
(3) After drilling, treat the surfaces with location on the same case.
magnesium alloy chromic acid brush-on treatment
(BHT-ALL-SPM).
7. Remove the screws (26) and shim plate (25).
(4) Install a new stud in reworked hole. Use Mark the shim plate for installation at the same
wet primer on mating parts. Torque the stud 100 to location on the same case.
130 inch-pounds (11 to 14 Nm).
63-50. Transmission Main Bevel Gear Case —
(5) Fill the counterdrilled holes with sealant Cleaning
(C-308) flush with the top case.
3. Touch up all areas on the case where chemical

film has been removed with chemical film material MATERIALS REQUIRED
(C-100) for the aluminum brush-on treatment
(BHT-ALL-SPM). Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
63-47. Transmission Top Case — Assembly
C-103 Chromic Acid
1. Install the collector (2, Figure 63-53) on the top Treatment
case (1) with the washers (3) and the nuts (4).
2. Torque the nuts (4) 12 to 15 inch-pounds (1.36 to C-436 Paint Remover
1.69 Nm). Safety the nuts with new cotter pins (5).
63-48. TRANSMISSION MAIN BEVEL GEAR CASE 1. Prior to cleaning, Inspect the Area J
(212-040-053-009) (Figure 63-56) and all the studs in the case for
corrosion. Refer to Figure 63-56 for the inspection
63-49. Transmission Main Bevel Gear Case — procedure.
Disassembly
2. Clean the main bevel gear case with drycleaning
1. If not previously accomplished, remove the solvent (C-304) and dry with filtered compressed air.
retaining ring (4, Figure 63-55) and the input pinion
bearing (3).
2. If not previously accomplished, remove the
retaining ring (19) and the input gear shaft bearing 4. Remove the paint with paint remover (C-436).
(20). Rinse with water and dry with filtered compressed air.
63-00-00
BHT-412-CR&O-3
4
1 3
29 31
2 5
30
28
6 7
26
8
27 9
25
24
10 11
23
12
13
14
18 17
21
22 20 16
15
19
1. Shim plate set 9. Lock ring 17. Stud 25. Shim plate
2. Washer seat 10. Stud 18. Washer seat 26. Screw
3. Input pinion bearing 11. Set screw 19. Retaining ring 27. Insert
4. Retaining ring 12. Clinch nut 20. Input gear shaft bearing 28. Lock ring
5. Screw 13. Lock ring 21. Shim plate 29. Screw
6. Washer seat 14. Insert 22. Screw 30. Liner
7. Shim plate 15. Screw 23. Washer seat 31. Liner
8. Insert 16. Shim plate 24. Main case
412_CRO_63_0055_c01
Figure 63-55. Transmission Main Case
63-00-00
BHT-412-CR&O-3
13.750 TO 13.752 IN. DIA

(349.25 TO 349.30 mm)
LINER
5.000 TO 5.002 IN. DIA

(127.00 TO 127.05 mm) LINER
5.000 TO 5.002 IN. DIA

(127.00 TO 127.05 mm)
TRANSMISSION MAIN BEVEL GEAR CASE

(212-040-053-009)
UP
AREA
A
SURFACE T SURFACE T
14.750 TO 14.752 IN. DIA
(374.65 TO 374.70 mm)
VIEW A
412_CRO_63_0056a_c01
Figure 63-56. Main Bevel Gear Case — Damage Limits (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3
AREA IJ
AREAJJ
AREA
AREAP
AREA J 0.060 IN. (1.52 mm) AREA M
MAX. DEPTH OF
CLEANUP
AREAG
AREA J
204-040-168-001 LINER AN385-2P6 PIN
VIEW B
NOTES
1. No cracks are acceptable anywhere on main case except the aluminum boss at the three bearing liner taper
pins shown at Area M on View B. Cracks in Area M are acceptable if polished out and the area inspected by
fluorescent penetrant method as outlined in main case “repair” paragraph.
2. Corrosion damage on studs or on case immediately adjacent to studs must be inspected as follows:
a. Measure and record stud height.
b. Remove stud. Refer to main case “repair” paragraph for procedure.
c. If corrosion damage has affected more than one complete thread, the case is not repairable.
d. If corrosion damage has affected less than one thread, the case is repairable. Refer to main case “repair”
paragraph for procedure.
3. Inspect all studs, threaded inserts, and washer seats for secure installation in case. Damaged or loose studs,
inserts, and/or washer seats are not acceptable. Refer to main case “repair” paragraph for stud replacement
procedure.
4. Inspect three bearing liners for secure installation in case and for evidence of corrosion between liner and
case. Loose liners and/or corrosion between liner and case render the main case nonrepairable.
5. Inspect shim plates for damaged cadmium plating.
412_CRO_63_0056b
63-00-00
BHT-412-CR&O-3
6. Inspect two bearings, removed from main case at main case “disassembly” paragraph, for spalling, scarring,
pitting, brinelling, corrosion, cracked or broken retainers, and for excessive wear. Damage in excess of
superficial is not acceptable.
7. Critical areas shown in Views A and B. Corrosion within following limits is acceptable if cleaned up, as
described in main bevel gear case “repair” paragraph:
a. Maximum depth of pitting in area P is 0.020 inch (0.51 mm) and no more than 20% of the area within
any 1.0 square inch (645 mm2), nor 10% of total surface may be pitted. Washers must still make
contact with case for entire 360° around each bolt for at least 50% of washer width. No more
than 10% of normal area contacted by washer may be pitted.
b. Inspect area J carefully prior to any corrosion removal for evidence of corrosion between the inserts and
the case. Any evidence of corrosion here is cause for rejection of the case.
c. Maximum depth of pitting in area I or J is 0.020 inch (0.51 mm) and no more than 40% of area within
any 1.0 square inch (645 mm2), nor 20% of total area of any surface or diameter may be pitted. See
step d for additional limits on chamfers.
d. Maximum depth of pitting in areas A, I, and J on all internal chamfers is 0.060 inch (1.52 mm) on no more
than 20% of the diameter. In area I, the maximum allowable pitting depth on the surface, four places
only, between the ends of the shim plates is 0.060 inch (1.52 mm).
e. Maximum depth of pitting in area A and area G is 0.020 inch (0.51 mm) provided no more than 40% of
any 1.0 square inch (645 mm2) and 20% of the total surface area is corroded.
f. Maximum depth of pitting inside mounting flange bolt holes is 0.020 inch (0.51 mm) and no more than
40% of the area of the wall of the hole may be pitted except isolated pits to a maximum depth of
0.060 inch (1.52 mm) are acceptable provided that the pitting in excess of 0.020 inch (0.51 mm) in depth
does not exceed 10% of the area of the wall of the hole, and provided that the total area pitted does not
exceed 40% of the area of the wall of the hole.
g. Corrosion on main case outside designated areas described above is not acceptable if structural or
functional integrity of case is affected.
8. Distortion/yielding limit measurement dimensions are given in “conditional inspection” paragraph.
412_CRO_63_0056c
63-00-00
BHT-412-CR&O-3
5. If the main bevel gear case is corroded, remove d. If the corrosion has affected less than one
corrosion by chromic acid treatment (C-103) pickle complete thread, rework the case as follows:
process for cleaning magnesium parts
(BHT-ALL-SPM). (1) Counter drill the stud holes 0.452 to
0.459 inch (11.48 to 11.66 mm) in diameter and a
63-51. Transmission Main Bevel Gear Case — maximum depth of 0.156 inch (3.96 mm). Break all
Inspection sharp edges, except in the threaded area.
(2) After drilling, treat surfaces with chemical

1. Inspect the main bevel gear case by fluorescent
film material (C-100) for aluminum brush-on treatment
penetrant method (BHT-ALL-SPM).
(BHT-ALL-SPM).
2. Inspect the main bevel gear case in accordance (3) Install a new stud in reworked hole
with Figure 63-56. (BHT-ALL-SPM).
63-52. Transmission Main Bevel Gear Case — (4) If the stud below the input quill bore was
Repair replaced, fill the top of the stud hole flush with the
input quill bore with adhesive (C-363). Do not allow the
adhesive to obstruct the bore for the input quill.
MATERIALS REQUIRED
(5) Fill all counterdrilled holes with sealant
Refer to BHT-ALL-SPM for specifications. (C-308) flush with top of case.
NUMBER NOMENCLATURE 4. If any cracks are present in the aluminum boss at

the three bearing liner taper pins, shown in Area M
C-100 Chemical Film Material (Figure 63-56, Detail B), rework the case as follows:
C-308 Sealant a. File out the crack(s) with a rotary file. The
minimum fillet radius after rework is 0.125 inch
C-363 Adhesive
(3.18 mm). The maximum allowable depth of cleanup
C-406 Abrasive Cloth or is 0.060 inch (1.52 mm), measured from the original
Paper cast surface shown in Area M.
b. Inspect the reworked cases by fluorescent

1. Replace loose or damaged threaded inserts penetrant method (BHT-ALL-SPM). If all indications of
(BHT-ALL-SPM). crack(s) cannot be polished out within the limits noted
in step a, the case is non-airworthy and nonrepairable.
2. Replace loose or missing washer seats.
c. Treat the rework area for corrosion protection
as outlined in step 3 (BHT-ALL-SPM).
3. If the main bevel gear case is corroded in the
area adjacent to the studs, or if the studs are corroded,
5. Rework Area I to remove corrosion damage as
rework as follows:
follows:
a. Measure and record the height of the stud. a. Polish out corrosion damage, at four locations
between the ends of the shim plates. Radius rework
b. Remove the stud from the corrosion damaged the area within 1/2 (0.50)-inch (12.7-mm) radius. If the
area. If a stud is removed below the input quill bore, corrosion extends into the shim area or seal area and/
also remove the filler from the top of the hole. or exceeds the depth limit noted in Figure 63-56, the
case is non-airworthy and nonrepairable.
complete thread, the case is non-airworthy and b. Polish the rework area with 400 grit abrasive
nonrepairable. cloth or paper (C-406).
63-00-00
BHT-412-CR&O-3
6. Touch up all areas on the case where chemical d. If the required shim plate is missing, subtract
film has been removed with chemical film material the value recorded in step a from the required
(C-100) for aluminum brush-on treatment dimension value listed in Table 63-1E. The resulting
(BHT-ALL-SPM). value is the required thickness of the shim plate.
7. Touch up cadmium plate on the shim plates (7, e. Procure shim plate(s) of the correct
16, 21, and 25, Figure 63-55) (BHT-ALL-SPM). dimension, as determined in the previous steps, from
Bell Helicopter Textron, Attn: CPR Dept. Include all the
63-53. Transmission Main Bevel Gear Case — pertinent information relative to the shim location and
Assembly the referenced dimensions used in calculating the
shim thickness.
1. Inspect the shim plates (7, 16, 21, and 25,
Figure 63-55) to ensure cadmium plate is intact prior 3. Visually inspect the main case (24) to ensure that
to installation. the washer seats (2, 6, 18, and 23), inserts (8, 14, and
27), and clinch nuts (12) are properly installed.
2. Inspect the shim plates (7, 16, 21, and 25) and
the main case (24) in the area where the shim plate is 4. Install the shim plate set (1) on the top flange of
to be installed for an etched serial number. The same the main case (24) and secure with screws (29).
serial number must be on both parts. If the existing
shim plates parts cannot be identified by serial
5. Put the shim plate (7) on the main case and
number, determine the required dimension of the
install three screws (5).
shims as outlined in step a through step c. If a new
shim plate is required, comply with step d and step e.
a. Inspect the main case (24) for a reference install three screws (15).
dimension, which should be metal stamped or
vibro-etched on the case adjacent to the mounting 7. Put the shim plate (21) on the main case and
surface. Record this dimension and where it is located install three screws (22).
on the case.
b. If a shim plate of the correct part number is install three screws (26).
available, but without a serial number, measure the
thickness and record.
9. Put the input gear shaft bearing (20) in the case
c. Add the shim plate thickness to the reference and install retaining ring (19).
dimension found on the main case. The resulting value
must fall within the required dimension provided in 10. Put the input pinion bearing (3) in the case and
Table 63-1E. install retaining ring (4).
63-00-00
BHT-412-CR&O-3
Table 63-1E. Main Bevel Gear Case — Required Dimension
REQUIRED DIMENSION
LOCATION SHIM PLATE
MINIMUM MAXIMUM
INCHES (MM) INCHES (MM)
Main Case, Top 212-040-053-017 6.1240 (155.5496) 6.1250 (155.5750)

212-040-053-101
Main Case, Top 212-040-053-017 6.1340 (155.8036) 6.1350 (155.8290)

212-040-053-009
Main Case, Rear Port 212-040-053-015 8.6420 (219.5068) 8.6425 (219.5195)
Main Case, Front Port 212-040-053-013 7.4715 (189.7761) 7.4720 (189.7888)
Main Case, Left Port 212-040-053-013 7.4715 (189.7761) 7.4720 (189.7888)
Main Case, Right Port 212-040-053-013 7.4715 (189.7761) 7.4720 (189.7888)
63-54. TRANSMISSION MAIN SUPPORT CASE 1. Prior to cleaning, inspect all the studs in the
(212-040-054-013 AND -109) support case for corrosion. Refer to Figure 63-57 or
Figure 63-58 or Figure 63-59 for the inspection
63-55. Transmission Main Support Case — procedure.
Disassembly
2. Clean the main support case with drycleaning
1. Remove the cotter pins (4, Figure 63-57 or
solvent (C-304) and dry with filtered compressed air.
Figure 63-58 or Figure 63-59), nuts (3), steel washers
(2), and the lift link fitting (5) from the main support
case (7). Discard the cotter pins. 3. Remove the sealant with a plastic scraper.
2. Remove the screws (8) and washers (9 and 10) 4. Remove the paint with paint remover (C-436).
from the top and bottom main support case (7) lateral Rinse with water and dry with filtered compressed air.
mounts.
63-56. Transmission Main Support Case — 5. If the main support case is corroded, remove the
Cleaning corrosion by chromic acid treatment (C-103) pickle
process for cleaning magnesium parts
(BHT-ALL-SPM).
MATERIALS REQUIRED
63-57. Transmission Main Support Case —
Refer to BHT-ALL-SPM for specifications. Inspection
NUMBER NOMENCLATURE
1. Inspect the main support case (7, Figure 63-57 or
C-103 Chromic Acid Figure 63-58 or Figure 63-59) by fluorescent penetrant
Treatment method (BHT-ALL-SPM).
C-304 Drycleaning Solvent 2. Inspect the main support case (7) in accordance
with Figure 63-57 or Figure 63-58 or Figure 63-59, as
C-436 Paint Remover
applicable.
63-00-00
BHT-412-CR&O-3
9 11
1
4 PL
10 B
7
6
8
SEE DETAIL A
SEE DETAIL C
5
2
MAIN SUPPORT CASE

212-040-054-013, -101, AND -105
LIFT LINK FITTING

212-040-106-001 AND -105
412_CRO_63_0057a_c01
Figure 63-57. Main Support Case (212-040-054-013, -101, -105) and Lift Link Fitting — Damage Limits
(Sheet 1 of 5)
63-00-00
BHT-412-CR&O-3
DETAIL A
412_CRO_63_0057b_c01
(Sheet 2 of 5)
63-00-00
BHT-412-CR&O-3
SURFACE G
(MATING SURFACE FOR MAIN CASE)
2.260 TO 2.270 IN.

(57.40 TO 57.66 mm)
DIMENSION LINE
(LOWER SURFACE OF STEEL BUSHING)
D VIEW B
F F
212-040-106-001 FOR -013 SUPPORT CASE VIEW D

212-040-106-105 FOR -109 SUPPORT CASE
DETAIL C
DETAIL E SECTION F-F

412_CRO_63_0057c_c01
(Sheet 3 of 5)
63-00-00
BHT-412-CR&O-3
VIEW G VIEW H
1. Dowel pin
2. Steel washer
3. Nut
4. Cotter pin
6. Bearing liner
7. Main support case
8. Screw
9. Washer (204-040-236-001)
10. Washer (204-040-736-001)
11. Bushing
NOTES
1. Damage limits stated in notes 3, 4, and 5 are based on minimum wall thickness of case.
2. No cracks are acceptable anywhere on the main support case (7).
3. Critical areas shown on Detail A:
Minor scratches in the critical areas, but not on the radii, up to 0.010 inch (0.25 mm) in depth and/or
1.0 inch (25 mm) in length, and other mechanical damage located on the radii up to 0.030 inch (0.76 mm) in
depth and 2.0 inches (51 mm) in length are acceptable if polished out.
4. Crosshatched areas shown on Detail A:
Mechanical damage in the crosshatched areas, but not on the radii, up to 0.040 inch (1.02 mm) in depth,
and mechanical damage on the radii up to 0.060 inch (1.52 mm) in depth is acceptable if polished out.
5. Hatched areas shown on Detail A:
Mechanical damage in the hatched areas, both on the radii and not on the radii, up to 0.060 inch (1.52 mm)
in depth is acceptable if polished out.
6. Mechanical and corrosion damage in areas not specifically detailed in preceding notes up to
0.010 inch (0.25 mm) is acceptable if polished out.
7. Area F and Area G on Detail A:
Corrosion pitting up to 0.020 inch (0.51 mm) in depth is acceptable provided no more than 40% of any
1.0 square inch (645 mm2), and no more than 20% of the total surface area is corroded. Also areas of
corrosion which exceed one half the width of the mounting surface are not acceptable.
412_CRO_63_0057d_c01
(Sheet 4 of 5)
63-00-00
BHT-412-CR&O-3
b. Remove stud. Refer to support case “repair” paragraph for procedure.
c. If corrosion damage has been affected more than one complete thread, the case is not repairable.
d. If corrosion damage has affected less than one thread, the case is repairable. Refer to support case “repair”
9. Inspect all studs on case for secure installation in case. No loose studs are acceptable. Refer to support case
“repair” paragraph for stud replacement procedure.
10. Inspect dowel pins on Surface G on View B for shearing and for secure installation. No loose and/or sheared
dowel pins are acceptable. More than one sheared dowel pin is indicative of transmission torsional overload,
renders the entire transmission nonairworthy and nonrepairable.
11. Distorsion/yielding limit measurement dimensions are shown on View B. Additional limits are given in
“conditional inspection” paragraph.
12. Maximum acceptable diameter for Diameter L on Detail C is 0.7525 inch (19.114 mm). Maximum acceptable
diameter for Diameter M is 1.0025 inches (25.464 mm).
13. Area A shown on Detail C:
1.0 square inch (645 mm2), and no more than 10% of the total surface area is corroded. Washers must make
contact with fitting for entire 360 degrees around each bolt for at least 50% of washer width. No more than
10% of normal area contacted by washer may be pitted.
14. Area B shown on Detail C:
1.0 square inch (645 mm2), and no more than 20% of the total surface area is corroded, except Area E, View D.
15. Area C shown on Detail C:
Mechanical damage in either Area C, but not on the radii, up to 0.010 inch (0.25 mm) in depth and no more than
20% of the total surafce area. Mechanical damage on the radii up to 0.020 inch (0.51 mm) in depth and no more
than 30% of the total surface area is permitted. Polish out damage.
16. Area D shown on Detail C:
1.0 square inch (645 mm2), and no more than 40% of the total surface area is corroded. Minor damage on blend
radii shall be blended out to a maximum depth of 0.010 inch (0.25 mm) and maximum length of 1.0 inch (25 mm).
17. Area E shown on View D:
Surface corrosion only is permitted. Surface corrosion is that which can be removed with wire brush or steel
wool.
412_CRO_63_0057e_c01
(Sheet 5 of 5)
63-00-00
BHT-412-CR&O-3
9 11
1
4 PL
10 B
7
6
8
SEE DETAIL A
SEE DETAIL C
5
2
MAIN SUPPORT CASE

212-040-054-109
LIFT LINK FITTING

212-040-106-105
412_CRO_63_0134a_c01
Figure 63-58. Main Support Case (212-040-054-109) and Lift Link Fitting — Damage Limits (Sheet 1 of 5)
63-00-00
BHT-412-CR&O-3
412_CRO_63_0134b_c01
63-00-00
BHT-412-CR&O-3
SURFACE G
2.260 TO 2.270 IN.

(57.40 TO 57.66 mm)
DIMENSION LINE
D VIEW B
F F
VIEW D
212-040-106-005 FOR -109 SUPPORT CASE
DETAIL C
DETAIL E SECTION F-F 412_CRO_63_0134c_c01
63-00-00
BHT-412-CR&O-3
VIEW G VIEW H
1. Dowel pin
2. Steel washer
3. Nut
4. Cotter pin
6. Bearing liner
8. Screw
9. Washer (204-040-236-001)
10. Washer (204-040-736-001)
11. Bushing
NOTES
412_CRO_63_0134d_c01
63-00-00
BHT-412-CR&O-3
wool.
412_CRO_63_0134e_c01
63-00-00
BHT-412-CR&O-3
9 11
1
4 PL
10 B
7
6
8
SEE DETAIL A
SEE DETAIL C
5
2
MAIN SUPPORT CASE

212-040-054-117
LIFT LINK FITTING

212-040-106-005
412_CRO_63_0135a_c01
63-00-00
BHT-412-CR&O-3
DETAIL A
412_CRO_63_0135b_c01
63-00-00
BHT-412-CR&O-3
SURFACE G
2.260 TO 2.270 IN.

(57.40 TO 57.66 mm)
DIMENSION LINE
D VIEW B
F F
VIEW D
212-040-106-005 FOR -117 SUPPORT CASE
DETAIL C
DETAIL E SECTION F-F 412_CRO_63_0135c_c01
63-00-00
BHT-412-CR&O-3
VIEW G VIEW H
1. Dowel pin
2. Steel washer
3. Nut
4. Cotter pin
6. Bearing liner
8. Screw
9. Washer (204-040-236-001)
10. Washer (204-040-736-001)
11. Bushing
NOTES
412_CRO_63_0135d_c01
63-00-00
BHT-412-CR&O-3
wool.
412_CRO_63_0135e_c01
63-00-00
BHT-412-CR&O-3
3. Inspect the screws (8) for corrosion and thread

NOTE
damage. Replace the screw(s) if you find corrosion or
thread damage. If you return the part to Bell Helicopter
Textron (BHT), refer to General Information
Letter (IL) GEN-04-98 for applicable
4. Inspect the top and bottom washers (9 and 10) shipping information and to obtain a Return
for corrosion and pitting. Replace the washer(s) if Material Authorization (RMA) number.
corrosion or pitting is more than 10% of any surface or
is deeper than 0.01 inch (0.3 mm). 1. Replace a sheared dowel pin, if the damage is
within the limits shown in Figure 63-57 or Figure 63-58
or Figure 63-59, as applicable. If the limits are
5. Inspect the installed case bushings (11) for exceeded, send the part to Bell Helicopter Textron
corrosion and pitting. The corrosion or pitting inside (BHT) for evaluation and possible repair.
the bushing bore must not be more than 10% of the
surface or 0.005 inch (0.13 mm) deep. The corrosion 2. If the main support case is corroded in the area
or pitting on bushing flange or chamfer must not be adjacent to the studs, or if the studs are corroded,
more than 10% of the surface or 0.01 inch (0.3 mm) rework as follows:
deep. If the limits are exceeded, contact Product
Support Engineering (PSE) for possible repairs. a. Measure and record the height of the stud.
b. Remove the stud from the corrosion damaged

6. Inspect the main support case (7) lateral mounts,
area.
top and bottom machined surfaces under or adjacent
to the washers (9 and 10) for pitting and the screw
holes for thread damage. Maximum depth of pitting complete thread, the case is non-airworthy and
must not be more than 0.03 inch (0.8 mm). Affected nonrepairable.
area must not be more than 0.75 square inch
(483.87 mm2) total for each pad surface or 50% of any d. If the corrosion has affected less than one
0.50 inch (12.7 mm) diameter. Damage to the complete thread, rework the case as follows:
threaded holes (8-32 NC-2B x 0.62 deep) must not
exceed 1 thread depth maximum. Replace the main (1) In Area F, counterdrill the stud holes
support case if the specified damage limits are 0.327 to 0.334 inch (8.31 to 8.48 mm) in diameter and
exceeded. a maximum depth of 0.125 inch (3.18 mm). Break all
sharp edges, except in the threaded area.
63-58. Transmission Main Support Case — Repair (2) In Area G, counter-drill stud holes 0.452
to 0.459 inch (11.48 to 11.66 mm) in diameter and a
maximum depth of 0.156 inch (3.96 mm). Break all
MATERIALS REQUIRED sharp edges, except in the threaded area.
Refer to BHT-ALL-SPM for specifications. (3) After drilling, treat the surfaces with
chromic acid treatment (C-103) (BHT-ALL-SPM).
NUMBER NOMENCLATURE
(4) Install a new stud in the reworked hole
C-103 Chromic Acid (BHT-ALL-SPM).
Treatment
(5) Fill all counterdrilled holes flush with the
C-204 Epoxy Polyamide top of the case with sealant (C-308).
Primer
3. Polish out mechanical and corrosion damage on
C-308 Sealant the support case and the lift link fitting that is within the
limits noted in Figure 63-57 or Figure 63-58 or
C-406 Abrasive Cloth or
Figure 63-59. Finish polish the rework area with 400
Paper
grit abrasive cloth or paper (C-406).
63-00-00
BHT-412-CR&O-3
4. Touch up all areas on the case where chemical 63-59. Transmission Main Support Case —
film has been removed with chromic acid treatment Assembly
(C-103) (BHT-ALL-SPM).
MATERIALS REQUIRED
5. Inspect all areas on the main case that were
reworked in step a through step d by fluorescent Refer to BHT-ALL-SPM for specifications.
penetrant method. Refer to Table 63-1E and
NUMBER NOMENCLATURE
BHT-ALL-SPM for procedure.
C-201 Zinc Chromate Primer
6. Repair the washers (9 and 10) if corrosion or
pitting is below the specified limits. Remove the C-308 Sealant
corrosion or pitting with a polishing pad or a fine sand
paper. Touch up all the bare areas per BHT-ALL-SPM.
1. Install the lift link fitting (5, Figure 63-57 or
Figure 63-58 or Figure 63-59) on the main support
7. Repair the bushing(s) (11) if corrosion or pitting is
case (7) with the steel washers (2) and the nuts (3).
below the specified limits. Remove the corrosion or
pitting with a polishing pad or a fine sand paper. Touch
2. For studs that are size 7/16 (0.4375) inch
up all the bare areas per BHT-ALL-SPM. If the
(11.113 mm), torque the nuts (3) 37 to 42 foot-pounds
damage limits are exceeded, contact Product Support
(50.17 to 56.94 Nm). Safety the nuts with new cotter
Engineering (PSE) for possible repair.
pins (4).
8. Repair the support case lateral mounts if pitting or
screw holes damages are below the specified limits. 3. For studs that are size 1/2 (0.50) inch (12.7 mm),
Blend out all the pitting in the machined corner radius torque the nuts (3) 40 to 58 foot-pounds (54.24 to
(bottom flange surfaces (4 places)). Do not blend out 78.63 Nm). Safety the nuts with new cotter pins (4).
the pitting on the flange faces unless it is within
0.03 inch (0.8 mm) of the flange edge. Remove all the 4. Apply zinc chromate primer (C-201) and install
loose corrosion debris and touch up the magnesium the washers (9) and screws (8) on the top portion of
alloy surface treatment per BHT-ALL-SPM. After the main support lateral mounts (4 places).
treatment, fill in all the affected areas with epoxy
polyamide primer (C-204). 5. Apply zinc chromate primer (C-201) and install
the washers (10) and screws (8) on the bottom portion
of the main support lateral mounts (4 places). Apply a
bead sealant (C-308) sealant to outside diameter (OD)
of washers in the joint where it meets the case and to
the area between bushing (11) flange and washer,
where water entrapment can occur. Make sure the
sealant (C-308) does not extend above surface of
washers or interfere with inside diameter (ID) of
bushings.
63-00-00
BHT-412-CR&O-3
PLANETARY RING GEAR, UPPER PLANETARY, AND LOWER PLANETARY ASSEMBLIES
63-60. PLANETARY RING GEAR, UPPER 2. Clean the ring gear with drycleaning solvent
PLANETARY, AND LOWER (C-304) and a soft bristle brush.
PLANETARY ASSEMBLIES
3. Dry the part with a clean cloth (C-516) or dry,
filtered, compressed air.
This section contains instructions to overhaul the
planetary ring gear, upper planetary, and lower
planetary assemblies. 4. Remove the sealant with a plastic scraper.
63-64. Planetary Ring Gear — Inspection

63-61. PLANETARY RING GEAR
(205-040-231-009)
1. Inspect the ring gear (Figure 63-60) by magnetic
particle method. Demagnetize parts after the magnetic
particle inspection. Refer to Table 63-3 and the
SPECIAL TOOLS REQUIRED BHT-ALL-SPM for the inspection procedures.
2. Inspect the ring gear teeth for wear patterns.

NUMBER NOMENCLATURE Replace the gear if it exceeds wear and damage limits
(Figure 63-60).
204-040-009-1 PAT-2D Backup Ring
T101332 Guide Pin 63-65. Planetary Ring Gear — Repair
T101572 Alignment Fixture

MATERIALS REQUIRED
T101574 Shaft Guide
63-62. Planetary Ring Gear — Disassembly NUMBER NOMENCLATURE
1. If not previously accomplished, remove three jet C-464 India Stone

housings from the planetary ring gear (paragraph
63-32). 1. Polish out minor damage on the ring gear teeth
that is within limits (paragraph 63-64) with a fine India
stone (C-464).
63-63. Planetary Ring Gear — Cleaning
63-66. Planetary Ring Gear — Assembly
MATERIALS REQUIRED 1. Install the three jet housings on the ring gear
(paragraph 63-38).
NUMBER NOMENCLATURE
C-436 Paint Remover
C-516 Clean Cloth
1. Remove paint from the surface with paint

remover (C-436).
63-00-00
Export Classification C, ECCN 9E991 21 MAR 2013 Rev. 7 Page 197
BHT-412-CR&O-3
I
SURFACE G
C
F E B
D
SURFACE H
I
SECTION A-A
412_CRO_63_0064a
Figure 63-60. Planetary Ring Gear — Damage and Wear Limits (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3

LTR METHOD
1. A Wear Measure between 0.2160 inch 13.689 inches (347.70 mm) MAX.
(5.486 mm) diameter pins
Corrosion/mechanical Visual/measure 1
2. B Corrosion/mechanical Visual/measure 2 7
3. C, D Wear Measure 14.802 inches (375.95 mm) MAX. 5
4. E Corrosion Visual/measure 0.010 inch (0.25 mm) depth

20% of the wall 7
5. F Corrosion Visual 6
6. G, H Corrosion/mechanical Visual/measure 3 7
7. I Corrosion/mechanical Visual/measure 4
8. All Cracks Magnetic particle per None allowed

BHT-ALL-SPM
NOTES
1 Visually inspect gear teeth in area A for spalled, scuffed, pitted, or scratched surfaces or chipped teeth.
Any spalling, scuffing, or pitting that can be detected with a probe having a 0.020 inch (0.51 mm) spherical
radius is unacceptable.
Polish out minor damage in tops or ends of teeth with fine lndia stone (C-464). No corrosion pitting is
permitted on any gear tooth surface.
No corrosion or mechanical damage is permitted in the area between the gear root diameter and the rim
inside diameter.
2 Light corrosion pitting is acceptable in area B provided the pitting, after rework, is no deeper than
0.005 inch (0.13 mm) and covers no more in than 40% of any 1.0 square inch (645 mm2) of surface nor, as
cumulative total, cover more than 10% of the total area of any surface.
Mechanical damage in the form of nicks, dents, and scratches is acceptable in area B provided the
damage after rework is no deeper than 0.005 inch (0.13 mm), nor longer than 0.500 inch (12.70 mm) with
1.50 inches (38.1 mm) minimum separation between the reworked areas.
412_CRO_63_0064b
63-00-00
BHT-412-CR&O-3
63-00-00
Page 200 Rev. 7 21 MAR 2013 Export Classification C, ECCN 9E991
BHT-412-CR&O-3
63-67. UPPER PLANETARY ASSEMBLY 8. Separate the thrust washers (4 and 9), bearing
(204-040-360-005, -103 AND -105) rollers (6), bearing retainer (7), and bearing inner race
(5) from the pinion gear (8). Keep the bearing rollers
63-68. Upper Planetary Assembly — Disassembly together as a matched set.
9. Remove the seven remaining pinion gears (8) in

the same manner outlined in step 2 through step 9.
NUMBER NOMENCLATURE
NOTE
T101332 Guide Pin
The spider assembly (2) consists of a plate
T101574 Shaft Guide and web that are assembled prior to final
machining at time of manufacture.
1. Cut and remove the lockwire.

10. Do not disassemble the spider assembly (2).
2. Remove the nut (3, Figure 63-61) with the socket

wrench square adapter. 63-69. Upper Planetary Assembly — Cleaning
3. Put the planetary on the backup ring

(204-040-009-1 PAT-2D). MATERIALS REQUIRED
4. Thread the shaft guide (T101574) into the pinion Refer to BHT-ALL-SPM for specifications.
shaft (1).
NUMBER NOMENCLATURE

CAUTION Compound

USE CARE WHEN REMOVING PINION
C-334 Solvent
FROM SPIDER TO PREVENT DAMAGE.
C-516 Clean Cloth
5. Press the pinion shaft (1) out of the spider
assembly (2).
(C-304). Use a soft bristle brush to dislodge stubborn
deposits. If desired, all the parts other than bearings
CAUTION
may be cleaned with solvent (C-334) by vapor
degreasing.
PLANETARY BEARING ROLLERS (6)
FROM EACH PINION ARE A MATCHED
SET AND MUST NOT BE INTERMIXED.
CAUTION
6. Put the guide pin (T101332) through the bearing
inner race (5) where the pinion shaft (1) was removed.
DO NOT ALLOW BEARINGS TO SPIN
7. Tap pinion gear (8) out of the side opening of the WHILE DRYING.
spider assembly (2). Hold the thrust washers (4 and 9)
in place to prevent bearing rollers (6) from falling out of 2. Dry the parts with a clean cloth (C-516) or dry
the bearing retainer (7). filtered compressed air.
63-00-00
BHT-412-CR&O-3
4 A
6
2
A
8
3 T
9
AREA OF ALLOWABLE PITTING
SECTION A-A
412_CRO_63_0059a
Figure 63-61. Upper Planetary Assembly (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3
VIEW B
LOCKWIRE PATTERN FOR UPPER SURFACE
VIEW C
LOCKWIRE PATTERN FOR LOWER SURFACE
412_CRO_63_0059b_c01
63-00-00
BHT-412-CR&O-3
SHAFT GUIDE (T101574) BACKUP RING (111345953)
GUIDE PIN (T101332)
1. Pinion shaft
2. Spider assembly
3. Nut
4. Thrust washer (204-040-134-005)
5. Bearing inner race
6. Bearing roller
7. Bearing retainer
8. Pinion gear
9. Thrust washer (204-040-134-005)
LOCKWIRE (C-405)
60 TO 80 FT-LBS
T (81 TO 108 Nm)
412_CRO_63_0059c_c01
63-00-00
BHT-412-CR&O-3
3. Inspect the teeth on pinion gears (8,

CAUTION Figure 63-61) and splines on spider assembly (2) for
nicks and dents, chipped and/or broken and worn
teeth. Any anomalies felt with a 0.020-inch (0.51-mm)
DO NOT HANDLE UNOILED BEARINGS spherical radius probe are unacceptable. Minor
WITH BARE HANDS. damage that can be polished out with a fine India
stone (C-464) is permitted if polished out.
NOTE
Parts treated per the following step may be
left covered in indoor storage for CAUTION
affected by corrosion.
THE SPIDER ASSEMBLY (2) CONSISTS
3. Immediately after cleaning parts with solvent, OF A PLATE AND WEB, WHICH ARE A
gently agitate parts in corrosion preventive compound MATCHED SET. DO NOT SEPARATE
(C-105) and allow to drain dry. DURING MAGNETIC INSPECTION.
63-70. Upper Planetary Assembly — Inspection 4. Inspect the following parts by magnetic particle
inspection. Demagnetize parts after magnetic particle
inspection. Refer to Table 63-3 and the BHT-ALL-SPM
for the procedure.
MATERIALS REQUIRED
NUMBER NOMENCLATURE FIGURE 63-61

NOMENCLATURE
INDEX NUMBER
C-464 India Stone
1 Pinion Shaft
2 Spider Assembly
NOTE
3 Nut
Limits charts are provided to show the
required fit between mating parts. It is not 5 Bearing Inner Race
intended that all dimensions listed on limits
charts be checked as a prescribed overhaul 7 Bearing Retainer
(214-040-110 and
procedure; however, parts that show
412-040-133)
evidence of wear or physical damage must
be checked dimensionally. 8 Pinion Gear
1. Inspect the parts shown in Figure 63-62. Inspect

5. Inspect the bearing retainer (7) 204-040-129-001
all threaded parts for damaged threads. If any parts
and 205-340-001-101 for chips, cracks, wear, or
show evidence of wear or physical damage when
inspected during subsequent steps, measure damage, as shown in Figure 63-64.
dimensions to determine whether the part is within
limits. 6. Inspect the bearing retainers (7), all part
numbers, for embedded bearing chips or other steel
2. Inspect the wear pattern in the teeth of all upper particles in the tang on the retainers. Retainers with
planetary pinions. Refer to Figure 63-63 for examples embedded chips and/or mechanical damage that can
of acceptable and unacceptable wear patterns. be detected visually are not permitted.
63-00-00
BHT-412-CR&O-3
(SEE VIEW A) 1 2 3
(SEE VIEW B) 7
UPPER PLANETARY ASSEMBLY
(204-040-360-105)
PIN DIAMETER
PIN DIAMETER 0.2160 IN. (5.486 mm)
0.2160 IN. (5.486 mm)
VIEW B
VIEW A PINION TEETH
SPLINE TEETH
ITEM NOMENCLATURE MINIMUM MAXIMUM
INCH INCH
(millimeters) (millimeters)
1. Spider - spline between pins 5.7986 5.8143

(use 0.2160 inch (5.486 mm) diameter pins) (147.284) (147.683)
2. Spider - shaft bore inner diameter 1.3750 1.3758

(34.925) (34.945)
3. Pinion shaft outer diameter 1.3752 1.3760

(34.930) (34.950)
4. Pinion gear inner diameter 2.6969 2.6976

(68.501) (68.519)
5. Inner race inner diameter 1.3750 1.3758

(34.925) (34.945)
6. Inner race outer diameter 1.8297 1.8303

(46.474) (46.490)
7. Pinion - gear teeth over pins 3.9705 3.9793 1

NOTE
1 Limit not peculiar to 204-040-360-105 planetary assembly but to any planetary using
205-040-233-001, -101, or -105 pinions.
412_CRO_63_0061
Figure 63-62. Upper Planetary Assembly — Wear Limits
63-00-00
BHT-412-CR&O-3
Figure 63-63. Upper Planetary Pinion — Wear Patterns
63-00-00
BHT-412-CR&O-3
VIEW A
BEARING RETAINER (204-040-129-001/205-340-001-101)

MATERIAL: NYLON
REF INSPECTION
NO. LTR CHARACTERISTIC METHOD LIMIT
1. A Chip Visual/measure 0.020 inch (0.508 mm)
maximum.
2. Blistered Visual None permitted. 1

missing plating
3. Mechanical Visual None permitted except

usual wear.
NOTE
1 Burnishing or polishing of plating on the inner diameter and on the roller pockets is usual and permitted.
NO OBJECT BEYOND THIS POINT 412_CRO_63_0060
Figure 63-64. Bearing Retainer — Damage Limits
63-00-00
BHT-412-CR&O-3
7. Inspect the spider assembly (2, Figure 63-61) for a. If the spider assembly (2) is not free of oil,
corrosion pitting. Pitting is permitted on the top surface grease, and other similar contaminates, clean the
in the area shown in Figure 63-61, Section E-E, spider with drycleaning solvent (C-304).
except for the area contacted by the flange of the
pinion shafts (1), provided damage is polished out and b. Mix 1 part cleaner (C-344) with 3 parts water.
the maximum depth after polishing does not exceed
0.010 inch (0.25 mm) and no more than 20% of any
1.0 square inch (645.2 mm2) is affected. c. Apply cleaner prepared in step b to the
corroded areas of the spider. Do not apply to
non-corroded areas. Apply the cleaner with a brush or
8. Inspect the bearing inner races (5) and bearing
swab. Avoid getting cleaner in the joints between the
rollers (6) for spalling, scoring, pitting, brinelling,
spider halves, in the pinion shaft holes, or in threaded
indentations, and corrosion. Damage that can be
holes. Leave the cleaner in contact with metal for 1 to
detected visually and with a 0.020-inch (0.51-mm)
3 minutes.
spherical radius probe is not permitted. Light scoring
on the bearing inner races in the area contacted by the
bearing retainers (7) is permitted. d. Rinse the cleaner off the spider thoroughly
with clean water.
63-71. Upper Planetary Assembly — Repair
e. Repeat step c and step d, if necessary, to
remove corrosion.
MATERIALS REQUIRED
f. Dry the planetary spider in an oven at 150°F
Refer to BHT-ALL-SPM for specifications. (66°C) maximum. If an oven is not available, use a
clean cloth (C-516) or filtered compressed air.
NUMBER NOMENCLATURE
C-105 Corrosion Preventive 4. Immediately after cleaning the spider, immerse

Compound the spider in corrosion preventive compound (C-105).
Agitate the spider to ensure complete coverage. Place
C-304 Drycleaning Solvent the spider on a rack and allow to drip dry. Apply a coat
of approved lubricating oil used in the transmission.
C-344 Cleaner
C-406 Abrasive Cloth or 63-72. Upper Planetary Assembly — Assembly

Paper
C-464 India Stone

C-516 Clean Cloth
NUMBER NOMENCLATURE
1. Polish out minor damage in the tops or ends of
the teeth of the pinion gears (8, Figure 63-61) and the T101332 Guide Pin
splines of the spider assembly (2) with a fine India
T101574 Shaft Guide
stone (C-464). Polishing is not permitted on the face of
the teeth.
2. Polish out corrosion pitting damage on the spider MATERIALS REQUIRED

assembly (2) that is within limits (paragraph 63-68)
with fine grit abrasive cloth or paper (C-406). Refer to BHT-ALL-SPM for specifications.
3. Remove the superficial corrosion from the spider NUMBER NOMENCLATURE

assembly (2) that was not cleaned in the step 2 as
C-405 Lockwire
follows:
63-00-00
BHT-412-CR&O-3
7. Torque the nut (3) on all the pinions 60 to

80 foot-pounds (81 to 108 Nm).
CAUTION
8. Rotate each pinion gear (8) manually and check
MAKE SURE THAT BEARING ROLLERS for binding in the spider. If the pinions do not turn
( 6 ) A R E A M AT C H E D S E T. A L L T H E freely, check the bearing retainer (7) for burrs. Check
ROLLERS IN A SET MUST BE FROM for foreign material in the bearing. No binding is
S A M E M A N U FA C T U R E R . C H E C K permitted. If necessary, disassemble the planetary to
MANUFACTURER'S IDENTIFICATION determine the cause of binding.
MARK ON END OF EACH ROLLER.
ALSO, INDIVIDUAL ROLLERS ARE NOT 9. Measure the distance between the ends of each
INTERCHANGEABLE. IF ONE OR MORE bearing roller (6) and the thrust washers (4 and 9) with
R O L L E R S O F A S E T FA I L TO PA S S a feeler gauge. The minimum permitted clearance is
INSPECTION, THE ENTIRE SET MUST 0.001 inch (0.03 mm). The maximum permitted
BE REPLACED. ROLLER SETS WITH clearance is 0.0027 inch (0.069 mm).
DIFFERENT DASH NUMBERS MAY BE
U S E D I N T H E S A M E P L A N E TA R Y
10. Secure the pinion shafts (1) with lockwire
ASSEMBLY, BUT ALL THE ROLLERS IN A
(C-405), as shown in View A.
SET FOR ONE PLANETARY PINION
MUST BE OF SAME DASH NUMBER.
11. Secure the nuts (3) with lockwire (C-405), as
1. Put the spider assembly (2, Figure 63-61) on the shown in View B.
backup ring (204-040-009 PAT-2D).
63-73. LOWER PLANETARY ASSEMBLY
2. Install the shaft guide (T101574) in the pinion
63-74. Lower Planetary Assembly — Disassembly
shaft (1).
NOTE SPECIAL TOOLS REQUIRED
Chamfer of thrust washers (4 and 9) is to

be installed away from the bearing rollers NUMBER NOMENCLATURE
(6).
T101332 Guide Pin
3. Assemble the pinion gear (8), bearing retainer
(7), bearing inner race (5), bearing rollers (6), and
thrust washers (4 and 9) on the guide pin (T101332). T101573 Holding Fixture
Hold the parts together and put in the spider assembly
(2). T101574 Shaft Guide
4. Align the pinion with the spider and press the 1. Cut and remove lockwire.
pinion shaft (1) into position through the pinion gear
(8). The guide pin (T101332) will be pressed out the
2. Install the holding fixture (T101573) in a vise. Put
lower side of the spider. Make sure that the pinion
the lower planetary on the holding fixture, as shown in
shaft is seated. Remove the shaft guide (T101574)
Figure 63-65.
from the pinion shaft.
3. Remove the four nuts (10).

5. Install the nut (3), but do not torque at this time.
4. Loosen the four nuts (9) but keep the nuts tight
6. Install the remaining seven pinion gears (8) in the enough to hold the planetary rigid during removal of
same manner outlined in step 2 through step 5. the shafts (17).
63-00-00
BHT-412-CR&O-3
17
VEE MARK
16
4
0.020 IN. (0.51 mm)

15 MAX. CHIP 5
6
14
7
13
12 8
11
T 1
9
T 2
10
VEE MARK
412_CRO_63_0062a_c01
Figure 63-65. Lower Planetary Assembly (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3
10 9
12
17
1
HOLDING FIXTURE (T101573) APPLICATION

POSITION FOR REMOVAL/INSTALLATION OF NUTS (9 AND 10)
PUNCH
(T101572-9)
GUIDE
(T101572-5)
BASE
(T101572-3)
4 5
ALIGNMENT FIXTURE (T101572) APPLICATION

POSITION FOR REMOVAL OF BEARING (5)
DRIVE
(T101572-7)
GUIDE
(T101572-5)
BASE
(T101572-3)
4
5
ALIGNMENT FIXTURE (T101572) APPLICATION

POSITION FOR INSTALLATION OF BEARING (5)
412_CRO_63_0062b
63-00-00
BHT-412-CR&O-3
SHAFT GUIDE (T101574) BACKUP RING (111345953)
GUIDE PIN (T101332)

1. Bolt
2. Plate
3. Spacer
4. Spider
5. Bearing
6. Retaining ring
7. Spacer
8. Plate
9. Nut
10. Nut
11. Thrust washer (204-040-134-005)
12. Pinion gear
13. Retainer
14. Roller
15. Inner race
16. Thrust washer (204-040-134-005)
17. Shaft
LOCKWIRE (C-405)
35 TO 45 FT-LBS
T 1 (47 TO 61 Nm)
60 TO 80 FT-LBS
T 2 (81 TO 108 Nm)
412_CRO_63_0062c_c01
63-00-00
BHT-412-CR&O-3
5. Remove the planetary from the holding fixture. 15. Remove the four retaining rings (6).
6. Put the planetary on the backup ring 16. Put the spider (4) in the base of the alignment
(204-040-009-1 PAT-2D). fixture (T101572), as shown in Figure 63-65
7. Thread the shaft guide (T101574) into the shaft 17. Put the guide (T101572-5) and the punch
(17). (T101572-9) in position, as shown in Figure 63-65
8. Press the shaft (17) out of the planetary. Hold the 18. Press the bearing (5) out of the spider (4).
pinion gear (12) to prevent it from falling out of the Discard the bearing.
planetary.
19. Remove and discard the three remaining
9. Put the guide pin (T101332) into the inner race bearings (5) in the same manner outlined in step 17
(15). Remove the shaft (17) from the shaft guide. and step 18.
10. Tap the pinion gear (12), with a rubber mallet, out 20. Remove the spider (4) from the alignment fixture
of the side opening between the plates (2 and 8). Hold (T101572).
the thrust washers (11 and 16) in place to prevent the
rollers (14) from falling out. 63-75. Lower Planetary Assembly — Cleaning
MATERIALS REQUIRED
CAUTION
BEARING ROLLERS ARE A MATCHED NUMBER NOMENCLATURE
S E T. M A K E S U R E T H E Y A R E K E P T
TOGETHER. C-105 Corrosion Preventive
Compound
11. Remove the thrust washers (11 and 16), rollers
(14), retainer (13), and inner race (15) from the pinion C-304 Drycleaning Solvent
gear (12). Keep the rollers together as a matched set.
C-334 Solvent
12. Remove the three remaining pinion gears (12) in C-516 Clean Cloth
the same manner outlined in step 7 through step 11.
CAUTION deposits if desired. All parts other than the bearings
may be cleaned with solvent (C-334) by vapor
degreasing.
PLATES ARE A MATCHED SET AND NOT
INTERCHANGEABLE. MAKE SURE THEY
ARE KEPT TOGETHER.
CAUTION
13. Remove the four nuts (9) and the bolts (1).
Separate the plates (2 and 8) and the spider (4). Keep
the plates together as a matched set.
WHILE DRYING.
14. Tap all the spacers (3 and 7) out of the plates (2 2. Dry the parts with a clean cloth (C-516) or dry
and 8) with a rubber mallet. filtered compressed air.
63-00-00
BHT-412-CR&O-3
FIGURE 63-65
CAUTION NOMENCLATURE
INDEX NUMBER
1 Bolt
DO NOT HANDLE UNOILED BEARINGS
WITH BARE HANDS. 2 Plate
4 Spider
NOTE 7 Spacer
8 Plate
approximately 150 hours without being 9 Nut
10 Nut
3. Immediately after cleaning parts with solvent, 12 Pinion Gear
gently agitate the parts in corrosion preventive
compound (C-105) and allow to drain dry. 13 Retainer
15 Inner Race
63-76. Lower Planetary Assembly — Inspection
17 Shaft
NOTE 5. Inspect the retainer (13) 204-040-133 by

Limits charts are provided to show the fluorescent penetrant method (BHT-ALL-SPM).
required fit between mating parts. It is not
intended that all dimensions listed on the 6. Inspect the retainers (13), all part numbers, for
limits charts be checked as in prescribed embedded bearing chips or other steel particles in the
overhaul procedure; however, parts that tang on the retainers. Retainers with embedded chips
show evidence of wear or physical damage and/or mechanical damage that can be detected
must be checked dimensionally. visually are not permitted. Retainers that are chipped
up to 0.020 inch (0.51 mm) in depth in the area shown
1. Visually inspect the parts shown in Figure 63-66. in Figure 63-65 are permitted.
If any parts show evidence of wear or physical
damage when inspected during subsequent steps,
measure the dimensions to determine whether the 7. Inspect the inner races (15) and rollers (14) for
part is permitted. spalling, scoring, pitting, and brinelling, indentations,
and corrosion. Damage that can be detected visually,
and with a 0.020-inch (0.51-mm) spherical radius
2. Inspect the wear pattern in the teeth of all lower probe, is not permitted. Light scoring on the inner
planetary pinions. Refer to Figure 63-67 for examples races in the area contacted by the retainers (13) is
of acceptable and unacceptable wear patterns. permitted.
3. Inspect the teeth on the pinion gears (12, 63-77. Lower Planetary Assembly — Repair
Figure 63-65) and the splines on the spider (4) for
nicks, dents, chipped, and/or broken, and worn teeth.
Any anomaly felt with a 0.020-inch (0.51-mm)
MATERIALS REQUIRED
spherical radius probe is unacceptable.
inspection. Demagnetize parts after magnetic particle NUMBER NOMENCLATURE
inspection. Refer to Table 63-3 and the BHT-ALL-SPM
C-464 India Stone
for the procedure.
63-00-00
BHT-412-CR&O-3
SEE VIEW A 3
4
1 5
6
2 7
8
10 11 9
SEE VIEW B
LOWER PLANETARY ASSEMBLY (204-040-784-109 OR -111)

MINIMUM INCH(ES) MINIMUM INCH(ES)
ITEM NOMECLATURE (millimeters) (millimeters)
1 Spider arm ID 1.1245 1.1250

(28.562) (28.575)
2 Spacer OD 1.3752 1.3758
(34.930) (34.945)
ID 0.5650 0.5663
(14.351) (14.848)
3 Spider spline between pins 6.3523 6.3682
4 Spider shaft bore ID 1.3750 1.3758
(34.925) (34.945)
5 Pinion shaft OD 1.3752 1.3760
(34.930) (34.950)
6 Pinion gear ID 2.6969 2.6976
(68.501) (68.519)
7 Inner race OD 1.8297 1.8303
(46.474) (46.490)
8 Inner race ID 1.3750 1.3758
(34.925) (34.945)
9 Pinion gear teeth over pins 3.9705 3.9793 1
10 Nut OD 1.3752 1.3760
(34.930) (34.950)
11 Bolt OD 0.5590 0.5620
(14.199) (14.275)
NOTE
1 Limit not peculiar to 204-040-784-109 or -111 planetary assembly but to any planetary assembly using
205-040-233-001, -101, or -105 pinions.
412_CRO_63_0063_c01
Figure 63-66. Lower Planetary Assembly — Wear Limits
63-00-00
BHT-412-CR&O-3
Figure 63-67. Lower Planetary Assembly — Wear Patterns
63-00-00
BHT-412-CR&O-3
1. Polish out minor damage in the teeth of the pinion 1. Inspect the new bearings (5, Figure 63-65) for
gear (12, Figure 63-65) and the splines of the spider sharp edges at the outer diameter of the chamfer.
(4) with a fine India stone (C-464). Polish sharp edges lightly with fine abrasive cloth or
paper (C-406). Make sure you don’t damage the
2. If not previously accomplished, remove the four bearings. Clean the bearings with drycleaning solvent
bearings (5) from the spider (4). Discard the old (C-304). Coat the bearings with the type of oil used in
bearings. Polish out any minor mechanical damage in the transmission and allow to drain.
the bore where the bearings were removed from the
spider. If damage after cleanup exceeds 0.020 inch
(0.51 mm) in depth and/or damage extends over more
than 20% of the area of the bore, the spider is CAUTION
non-airworthy and nonrepairable.
DO NOT EXCEED THE MAXIMUM

3. Remove superficial corrosion from the spider (4)
ALLOWABLE TEMPERATURE WHEN
by the same general procedure outlined in paragraph
YOU HEAT A PART OR DAMAGE TO THE
63-71.
PART MAY OCCUR.
63-78. Lower Planetary Assembly — Assembly 2. Put the spider (4) in the base (T101572-3) of the
alignment fixture (T101572), as shown in View C. Heat
the spider to 200°F (93°C) maximum.
3. Put the new bearing (5), drive (T101572-7), and
NUMBER NOMENCLATURE guide (T101572-5) on the spider (4). Press the bearing
into position. Press the remaining three bearings into
T101332 Guide Pin the spider.

4. Install the four retaining rings (6).
T101573 Holding Fixture
5. Press the four spacers (3) into alternate holes in
T101574 Shaft Guide the plate (2). Support the plate set in the area adjacent
to the hole during pressing operations.
MATERIALS REQUIRED 6. Locate the V-mark on the plates (2 and 8). These
marks must be aligned when the planetary is
Refer to BHT-ALL-SPM for specifications. assembled. Index the four holes in the plate (8) to
match the holes in the plate (2) where the spacers (3)
NUMBER NOMENCLATURE were installed at the preceding step.

7. Press the four spacers (7) into the plate (8) in the
C-405 Lockwire intended holes. Support the plate in the areas
adjacent to the hole during the pressing operations.
Paper
8. Put the plate (8) with flange down as illustrated.
Put the spider (4) on the plate (8). Put the plate (2) on
the spider (4) with flange up as illustrated. Align the
V-marks.
CAUTION
9. Apply the same oil as used in the transmission

DO NOT HANDLE UNOILED PARTS WITH under the heads and on the threads of the four
BARE HANDS. bolts (1).
63-00-00
BHT-412-CR&O-3
10. Install the four bolts (1) and the nuts (9). Tighten shaft into position. Catch the guide pin (T101332) as it
snugly, but do not torque at this time. is pushed out the bottom. Make sure that shaft is fully
seated on the plate (2).
11. Put the planetary parts assembled in the
preceding steps on the backup ring (204-040-009-1 15. Remove the shaft guide (T101574) from the
PAT-2D). shaft (17).
16. Install the three remaining pinion gears (12) in the

CAUTION same manner outlined in step 12 through step 15.
17. Apply the same oil as used in the transmission on

MAKE SURE THAT BEARING ROLLERS the threads of the four nuts (10). Install the nuts on the
(14) ARE A MATCHED SET. ALL THE shafts (17). Do not torque the nuts at this time.
ROLLERS IN A SET MUST BE FROM
S A M E M A N U FA C T U R E R . C H E C K 18. Remove the planetary from the backup ring
MANUFACTURER'S IDENTIFICATION (204-040-009-1 PAT-2D).
MARK ON END OF EACH ROLLER.
ALSO, INDIVIDUAL ROLLERS ARE NOT
INTERCHANGEABLE. IF ONE OR MORE 19. Install the holding fixture (T101573) in a vise. Put
ROLLERS OF A SET FAILS TO PASS the planetary on the holding fixture, as shown in
INSPECTION, THE ENTIRE SET MUST View A.
BE REPLACED. ROLLER SETS WITH
DIFFERENT DASH NUMBERS MAY BE 20. Torque the four nuts (9) 35 to 45 foot-pounds (47
U S E D I N T H E S A M E P L A N E TA R Y to 61 Nm) in diametrical sequence.
ASSEMBLY, BUT ALL THE ROLLERS IN A
SET FOR ONE PLANETARY PINION 21. Torque the four nuts (10) 60 to 80 foot-pounds (81
MUST BE OF SAME DASH NUMBER. to 108 Nm) in diametrical sequence.
12. Assemble the pinion gear (12), retainer (13),
inner race (15), rollers (14), and thrust washers (11 22. Rotate the four pinion gears (12) manually and
and 16) on the planetary guide pin (T101332). check for binding. Binding that can be detected by feel
is not permitted.
13. Install the shaft guide (T101574) in the shaft (17).
23. Secure the nuts (9 and 10) in pairs with lockwire
14. Put the pinion gear (12) and parts assembled in (C-405).
step 12 in the planetary. Align the holes for the shaft
(17). Make sure the planetary is properly supported on 24. Secure the bolts (1) and the shaft (17) in pairs
the backup ring (204-040-009-1 PAT-2D). Press the with lockwire (C-405).
63-00-00
Export Classification C, ECCN EAR99 28 FEB 2020 Rev. 12 Page 219/220
BHT-412-CR&O-3
MAIN INPUT GEAR QUILL
63-79. MAIN INPUT GEAR QUILL

(204-040-362-103) CAUTION
NOTE B E A R I N G S ( 8 ) M U S T B E R I G I D LY
For helicopters S/N 36020 and subsequent SUPPORTED ON THE INNER RACE
to include S/N 46400 through 46499 and AROUND THE FULL CIRCUMFERENCE
helicopters modified by 412-570-001-103, SO THAT THE OUTER RACES ARE NOT
refer to paragraph 63-85. LOADED DURING BEARING REMOVAL.
INADEQUATE SUPPORT WILL RESULT
IN DAMAGED BEARINGS AND/OR
63-80. MAIN INPUT GEAR QUILL —
SHAFT.
DISASSEMBLY
CAUTION
BEARINGS ARE A MATCHED SET AND

NUMBER NOMENCLATURE
MUST BE RETAINED OR REPLACED IN
T100965 Power Wrench Kit PAIRS.
T100968 Anchor Plate 9. Support the duplex bearings (8) on the inner race
and press the shaft out of the bearing. Keep the
T101303 Socket bearings together as a matched set. Mark the bearings
for assembly.
1. Remove the 24 bolts (1, Figure 63-68) and the

10. Remove the bearing retainer plate (9).
washers (14).
11. Remove the 32 bolts (10) from the flange of

2. Carefully tap the gear support case (2) to remove shaft (11).
it from the collector (13).
12. Carefully tap or press the spiral bevel gear (12)
3. Remove the shims (3 and 4) and mark the shims out of the shaft.
for installation at the same location.
63-81. MAIN INPUT GEAR QUILL — CLEANING
4. Remove the collector (13).
MATERIALS REQUIRED
5. Remove the screws (5) and the lockring (6).
6. Put the socket (T101303) on the nut (7). NUMBER NOMENCLATURE

7. Install the anchor plate (T100968) and the power
Compound
wrench kit (T100965) on the shaft (11) and loosen the
nut (7). C-304 Drycleaning Solvent
C-516 Clean Cloth

8. Remove the tools and the nut (7).
63-00-00
BHT-412-CR&O-3
1 T 2 T 1
10
1 T 3
14
11
5 12
7 T 4
1. Bolt 8. Duplex bearing
2. Gear support case 9. Bearing retainer plate
8 3. Shim 10. Bolt
4. Shim 11. Shaft
5. Screw 12. Spiral bevel gear
6. Lockring 13. Collector
7. Nut 14. Washer
390 IN-LBS
T 1 (44 Nm)
13
300 TO 325 IN-LBS
T 2 (34 TO 37 Nm)
9 20 TO 25 IN-LBS
T 3 (2.3 TO 2.8 Nm)
150 TO 200 FT-LBS

T 4 (203 TO 271 Nm)
LOCKWIRE (C-405)
NOTE
1 Torque all bolts (10) to T 1 . Individually break torque at each bolt (10) and retorque to T 2.
412_CRO_63_0065_c01
Figure 63-68. Main Input Gear Quill (204-040-362-103)
63-00-00
BHT-412-CR&O-3
1. Inspect the parts for corrosion damage to holes 1. Inspect all the parts visually for damage and
before cleaning. No structural damage to holes is excessive wear.
permitted.
2. Inspect the gear support case (2, Figure 63-68)
2. Remove the sealant from the gear support case for corrosion and for a loose bearing liner as follows:
with a plastic scraper.
a. The maximum permitted depth of pitting in
3. Clean the quill parts with drycleaning solvent Area A (Figure 63-69) is 0.020 inch (0.51 mm), except
(C-304). Use a soft bristle brush to dislodge deposits. as defined in step b. No more than 40% of the area
All parts except bearings may be cleaned with solvent within any 1.0 square inch (645.2 mm2) or 20% of total
(C-334) by vapor degreasing. area of any surface or diameter may be pitted. Inspect
Area B carefully prior to any corrosion removal for
evidence of corrosion in the bolt holes and between
the bearing liner and case. Any evidence of corrosion
CAUTION in the bolt holes or between the liner and case is
cause for rejection of the part.
DO NOT ALLOW BEARINGS TO SPIN b. The maximum permitted depth of pitting on

WHILE DRYING. the lower flange only, in area 1/32 (0.03125) inch
(0.7938 mm) below radius to the packing groove in
4. Dry the parts with a clean cloth (C-516) or dry Area A (Figure 63-69), is 0.030 inch (0.76 mm) and is
filtered compressed air. limited to no more than 40% of the area within any
1.0 square inch (645.2 mm2) or 20% of the total area.
Isolated pits in Area A are permitted to a maximum
depth of 0.060 inch (1.52 mm), provided the total area
CAUTION pitted in excess of 0.030 inch (0.762 mm) does not
exceed 2% of the area within any 1.0 square inch
(645.2 mm2) or 0.50% of the total area of any surface
DO NOT HANDLE UNOILED BEARINGS or diameter.
WITH BARE HANDS.
3. Inspect the nut (7, Figure 63-68) for damaged
threads.
NOTE
Parts treated per the following step may be 4. Inspect the duplex bearings (8) for spalling,
left covered in indoor storage for scoring, flaking, corrosion, and roughness when
approximately 150 hours without being rotated.
5. Inspect the bearing retainer plate (9) for damaged
5. Coat the bearings with corrosion preventive threads.
compound (C-105) immediately after cleaning
(BHT-ALL-SPM). 6. Inspect the shaft (11) for spalling, scoring, pitting,
flaking, corrosion, and indentations on the bearing
63-82. MAIN INPUT GEAR QUILL — INSPECTION contact surfaces. Inspect the splines for pitted,
chipped, or excessively worn teeth. Inspect the
threads for defects. The maximum permitted depth of
NOTE nicks, dents, and scratches on the spline teeth is
Wear limits are provided to show the 0.030 inch (0.76 mm) and is limited to no more than
required fit between mating parts. It is not 10% of the tooth within 20% of the tooth length. The
intended that all dimensions be checked as tooth length is the one that contacts the mating
a prescribed overhaul procedure; however, surface.
parts that show evidence of wear or
physical damage must be checked 7. Inspect the spiral bevel gear (12) for spalled,
dimensionally. scuffed, chipped, or dented teeth.
63-00-00
BHT-412-CR&O-3
Figure 63-69. Main Input Gear Quill Case (204-040-386-001) — Damage Limits
63-00-00
BHT-412-CR&O-3
8. Inspect the mating surfaces of the shaft (11) and e. Bottom of the holes shall be free of burrs,
the spiral bevel gear (12) for fretting damage. The tears, gouges, or compacted chips. The disposition
maximum permitted depth of fretting (pitting) is shall be determined by visual comparison of the spiral
0.0005 inch (0.013 mm). Pitting of measurable depth bevel gear holes with Figure 63-70.
is permitted only in the area on the gear or the shaft
surface outside of the diameter of the bolt holes and is 10. Inspect the following parts by magnetic particle
not permitted within 0.10 inch (2.5 mm) of the edge of inspection (Code M) or fluorescent penetrant
a bolt hole. inspection (Code F), as applicable. Demagnetize parts
after magnetic particle inspection. Refer to Table 63-3
9. Inspect the spiral bevel gear (12) for pitting or and the BHT-ALL-SPM for the procedure.
corrosion damage as follows:
a. Pitting of any magnitude resulting from FIGURE 63-68

NOMENCLATURE CODE
surface fatigue during operation is not permitted. This INDEX NUMBER
may appear as only a fine line of pin holes near the
2 Gear Support Case F
pitch diameter and be detectable only with a side light
source and a probe point of approximately 0.001 inch 7 Nut M
(0.03 mm) radius. A more severe example of this is
shown in Figure 63-71, Detail B. Minor pitting resulting 9 Bearing Retainer M
from corrosion is permitted within following limits: Plate
11 Shaft M
(1) No more than 0.001 inch (0.03 mm)
deep, and no more than 0.040 inch (1.02 mm) wide, or 12 Spiral Bevel Gear M
0.080 inch (2.03 mm) long.
NOTE
(2) No more than 0.002 inch (0.05 mm) deep
and no more than 0.040 inch (1.02 mm) wide or Refer to step 11 and step 12 for special
0.100 inch (2.54 mm) long and located on the outer inspection procedures for the shaft (11).
(i.e., adjacent to the heel) half of the face of the tooth
and above the pitch line, or located outside of the wear 11. Inspect the shaft (11, Figure 63-68) by magnetic
pattern and outside of the root radius. particle method. The shaft must be inspected by all of
the following steps using wet continuous method. The
b. Surface roughness detectable by drawing a use of fluorescent coated particles with ultra violet light
probe along the tooth in a profile direction is cause for is mandatory. The length of any indication shall be
rejection if pitting occurred on the mating member. determined by the residual method of magnetization.
c. Any grinding scratches around which pitting or

NOTE
other damage occurs are not permitted.
If AC magnetic particle inspection
equipment is used, use 60% of DC amps
d. Nicks, cuts, or dents caused by handling or by
specified.
foreign material going through mesh during operation
are permitted provided they are no more than
0.003 inch (0.08 mm) deep and are not more than a. Thoroughly degrease the gear.
0.020 inch (0.51 mm) across in any direction, and
cannot be felt with a 0.020-inch (0.51-mm) spherical b. Magnetize the gear by placing the shaft
radius probe. between the contact heads of the inspection
equipment. Pass approximately 2000 amps of DC
current through the gear.
NOTE
The following visual evaluation shall use c. Inspect the gear completely, inside and
supplemental lighting. outside, for indications.
63-00-00
BHT-412-CR&O-3
DIM A DIM A
DIM B DIM B
PRIMARY CONFIGURATION OF THREADED HOLES OPTIONAL CONFIGURATION OF THREADED HOLES
PART NO. DIM A DIM B PART NO DIM A DIM B
204-040-701-ALL 0.510 IN. MAX 0.616 IN. MAX 204-040-701-ALL 0.510 IN. MAX 0.580 IN. MAX
(12.95 mm) (15.65 mm) (12.95 mm) (14.73 mm)
NOTE
Hole depth measurements for gears which were drilled and tapped but have optional true-bored configuration.
412_CRO_63_0066
Figure 63-70. Spiral Bevel Gear Mounting Holes (204-040-701) — Damage Limits
63-00-00
BHT-412-CR&O-3
Figure 63-71. Main Input Gear Quill (204-040-386-001) — Wear Patterns
63-00-00
BHT-412-CR&O-3
d. Place the gear inside the coil such that the (4) Indications more than 15° off the long
long axis of the gear is approximately 90° to the axis, transverse or circumferential to the long axis, are
direction of the current flow in the coil. Magnetize the permitted in the spline areas provided they do not
gear with approximately 1000 amps of DC current. exceed 0.125 inch (3.18 mm) in length. Not more than
one indication is allowed per tooth, and not more than
e. Inspect the shaft completely for indications. six to each spline area. All other indications in the
spline area are cause for rejection.
f. After completion of the inspection,

(5) Indications in the threaded sections are
demagnetize the shaft and check with a compass or
cause for rejection regardless of size or location in
equivalent to ensure demagnetization.
Area A (Figure 63-72).
12. Evaluate the defects noted during the magnetic (6) Indications of subsurface discontinuities
particle inspection of the shaft (11) as follows that break a transverse face shall not exceed
(Figure 63-72): 0.031 inch (0.79 mm) in length or cross section.
a. Indications interpreted as cracks are cause for (7) Indications or surface discontinuities that
rejection regardless of size or location. break over corners or run into fillets, splines, or
threads, are cause for rejection.
b. Surface or subsurface indications or stringers,
shunts, non-metallic inclusions, bursts, laps, or seams (8) Indications caused by a change in the
are permitted provided they are within all the following section are permitted.
limits:
(9) Strong magnetic indications where
(1) Indications of defects parallel (±15°) to considerable buildup is present, indicating that defect
the long axis of the shaft are permitted, provided the has considerable depth and/or cross section, shall be
length of the indication does not exceed 0.125 inch cause for rejection regardless of location.
(3.18 mm) and provided other limitations herein are
not exceeded. Not more than two such indications 13. Inspect the parts dimensionally and replace parts
allowed in any 2.0 square inches (1290.3 mm2) of that do not fall within the inspection limits
surface area. (Figure 63-73).
(2) Circumferential indications, or indications 63-83. MAIN INPUT GEAR QUILL — REPAIR
more than 15° off the long axis of the shaft are
permitted in Area B (Figure 63-72) provided the length
of the indications does not exceed 0.25 inch (6.4 mm).
Not more than two such indications shall be allowed in MATERIALS REQUIRED
any 1.0 square inch (645.2 mm2) of surface area.
Indications on the bearing journal, in Area B, are Refer to BHT-ALL-SPM for specifications.
permitted if the length of the indication does not
NUMBER NOMENCLATURE
exceed 0.0625 inch (1.588 mm) in length and provided
the indication is 0.125 inch (3.18 mm) or more from C-464 India Stone
the end of the bearing journal. Indications within
0.125 inch (3.18 mm) of the end of the bearing journal
or that break over the end of the bearing journal are 1. If small nicks, burrs, or scratches are visible,
cause for rejection. No more than four indications dress the splines and the gear with a fine India stone
within the above limits, are allowed on each bearing (C-464) (Figure 63-73).
journal.
2. Repair minor damage to the bevel gears by lightly
(3) Circumferential indications, or indications polishing with a fine India stone (C-464) to remove any
that are more than 15° of the long axis of the shaft in material that protrudes above the original ground
Area A (Figure 63-72), are cause for rejection. surface.
63-00-00
BHT-412-CR&O-3
AREA A AREA B
412_CRO_63_0068
Figure 63-72. Main Input Gear Quill Shaft — Magnetic Inspection Areas
63-00-00
BHT-412-CR&O-3
1 2 3 4
6 5
10 7
9 8

INCHES INCHES
1. Bearings inner diameter 4.7232 4.7236

(119.969) (119.979)
outer diameter 6.6923 6.6929
(169.984) (170.000)
2. Spline
(use 0.1920 inch (4.877 mm) diameter pins) over pins 4.7894 4.7938
(121.651) (121.763)
3. Shaft bearing seat outer diameter 4.7250 4.7255

(120.015) (120.028)
4. Support case liner inner diameter 6.6919 6.6931

(169.974) (170.005)
5. Gear inner diameter 7.6000 7.6008

(193.040) (193.060)
6. Shaft gear seat outer diameter 7.6007 7.6015

(193.058) (193.078)
412_CRO_63_0067a
Figure 63-73. Main Input Gear Quill — Wear Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3

INCHES INCHES
7. Shaft bearing race outer diameter 5.1537 5.1545

(130.904) (130.924)
8. Spline over pins 4.8948 4.8993

9. Bearing outer diameter 6.4983 6.4990

(165.057) (165.075)
10. Main case liner inner diameter 6.4980 6.4990

(165.049) (165.075)
412_CRO_63_0067b
Figure 63-73. Main Input Gear Quill — Wear Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
3. Replace the bevel gear support case that has

corrosion damage that would affect its function or
CAUTION
structural integrity. Remove the corrosion in Area A
(Figure 63-69) by acid bath (BHT-ALL-SPM).
I T I S E S S E N T I A L T H AT U T M O S T
4. Blend the spline areas of the shaft (11, PRECISION BE USED WHEN
Figure 63-68) with a 0.060 inch (1.52 mm) minimum ASSEMBLING THIS QUILL.
radius. After rework, measure the spline wear, as
3. Put the spiral bevel gear (12, Figure 63-68) on
shown in Figure 63-73. Also, polish the transferred
the shaft (11) with the holes aligned. Tap or press the
material on the sun gear splines with a fine India stone gear on the flange.
(C-464).
4. Install the bolts (10) into the shaft (11) and spiral
63-84. MAIN INPUT GEAR QUILL — ASSEMBLY bevel gear (12). Torque all the bolts evenly to
390 inch-pounds (44 Nm), then individually break the
bolt torque, and retorque to 300 to 325 inch-pounds
(34 to 37 Nm).
5. Secure the bolt heads in pairs with lockwire
(C-405) around the heads, not over the tops.
NUMBER NOMENCLATURE
T100965 Power Wrench Kit 6. Check the duplex bearings (8) to confirm that the
serial number is the same on both bearings. Hold the
T100968 Anchor Plate bearings back-to-back, measure the width of the outer
races and record as Dimension C (Figure 63-74).
T101303 Socket
7. Determine the thickness of the shims (2 and 3,
Figure 63-74) for the main input quill as follows:
MATERIALS REQUIRED
NOTE
Determine the thickness of the shim (3)
NUMBER NOMENCLATURE between the bearing and liner as outlined in
step a through step c.
a. Record the following dimensions.
C-405 Lockwire
Dim C — Measure width of bearing outer
races (step 6).
(C-304) and drain. Dim X — Etched on support case.
Dim Y — Etched on support case.
Dim R — Etched on shaft.
NOTE
Dim S — 0.0330 inch (0.838 mm) actual
Refer to the BHT-412-MM for approved measured dimension.
lubricants.
Dim T — Etched on bearing retainer plate.
2. Coat all the parts with the same oil used in the Dim B — Given: 3.0610 to 3.0630 inches
transmission and drain. (77.749 to 77.800 mm)
63-00-00
BHT-412-CR&O-3
Y C X
B
S R T
2
1. Collector Measure actual thickness
2. Shim Shim to obtain 0.001 to 0.005 inch

(0.03 to 0.13 mm) pinch on bearing
3. Shim Shim to obtain Dimension B
412_CRO_63_0070_c01
Figure 63-74. Main Input Gear Quill (204-040-362-103) — Shimming
63-00-00
BHT-412-CR&O-3
b. Typical example: Pinch required, +0.0030 inch (+0.076 mm)

0.001 to
I. 0.005 inch
(0.025 to
Dim B (average) 3.0620 inches (77.775 mm)
0.127 mm)
Dim Y +1.4543 inches (+36.939 mm)
Dimension: 1.7340 inches
Dimension: 4.5163 inches (44.044 mm)
(114.714 mm)
VI.
II.
Dim IV (above) 1.7548 inches (44.572 mm)
Dim R 1.3095 inches (33.261 mm)
Dim V (above) -1.7340 inches (-44.044 mm)
Dim C +1.7248 inches (+43.810 mm)
Required Dimension: 0.0208 inch
Dim X +1.4520 inches (+36.881 mm) thickness for (0.528 mm)
Dimension: 4.4896 inches the shim (2) (use 0.021 shim)
(114.036 mm) 0.0208 inch
(0.528 mm)
III.
Dim I (above) 4.5163 inches (114.714 mm) e. Recheck computation of shim thickness.
Dim II (above) -4.4863 inches (-113.952 mm)
Required Dimension: 0.0300 inch
thickness for the (0.762 mm)
CAUTION
shim
(3, Figure 63-74)
M A K E S U R E T H AT B E A R I N G S A R E
c. Recheck computation of shim thickness.
PROPERLY INSTALLED BACK-TO-BACK.
MAKE SURE THAT SHIMS (3 AND 4,
NOTE FIGURE 63-68) ARE NOT DAMAGED
DURING INSTALLATION OF BOLTS.
Determine thickness of the shim (2)
between the case and bearing retainer as MAKE SURE THAT BOLTS (1 AND 10)
outlined in step d through step e. ARE PROPERLY SECURED.
d. Typical example: 8. Put the shim (3, Figure 63-68) in the liner of the
gear support case (2).
IV.
Shim 0.0300 inch (0.762 mm) 9. Put the duplex bearings (8) in the back-to-back
determined at position over the gear support case (2).
III
Dim C +1.7248 inches (+43.810 mm) 10. Press the duplex bearings (8) into the gear
Dimension: 1.7548 inches support case (2).
(44.572 mm)
V. 11. Put the shim (4) in position and install the
Dim T 0.2440 inch (6.198 mm) collector (13) and the bearing retainer plate (9) with
the bolts (1) and the washers (14) under the bolt
Dim S +0.0330 inch (+0.838 mm) heads.
Dim Y +1.4540 inches (+36.932 mm)
12. Torque the bolts (1) evenly 20 to 25 inch-pounds
(2.3 to 2.8 Nm) and secure in pairs with lockwire
(C-405).
63-00-00
BHT-412-CR&O-3
approximately 90° apart. The measurements must be

NOTE
3.0610 to 3.0630 inches (77.749 to 77.800 mm). If the
The etched marks placed on the bearings dimension is not obtained, a damaged shim or a shim
by the bearing manufacturer mark the high of incorrect thickness may be the cause. Repeat
point of the race runout. step 6 through step 21.
13. Put the gear support case (2) on the shaft (11).
22. Check the bearings for free rotation.
Align vibro-etched 0 on ends of the inner races with
index marks on shaft.
63-85. MAIN INPUT GEAR QUILL
(412-040-362-101 AND -103) (S/N 36020
NOTE AND SUBSEQUENT TO INCLUDE
If the shaft (11) is being replaced, S/N 46400 THROUGH 46499 AND
vibro-etch the index mark on the new shaft HELICOPTERS MODIFIED BY
the same as on the old shaft. 412-570-001-103 OR POST
BHT-412-SI-74 (412SP TO 412HP
14. Press the duplex bearings (8) on the inner races UPGRADE))
to seat against the shoulder of the shaft (11).
63-86. MAIN INPUT GEAR QUILL —
15. Install the nut (7). DISASSEMBLY
16. Put the socket (T101303) and the power wrench

kit (T100965) over the nut (7). SPECIAL TOOLS REQUIRED
17. Install the anchor plate (T100968) on the shaft.

NUMBER NOMENCLATURE
18. Torque the nut (7) to the low side of 150 to
T100965 Power Wrench Kit
200 foot-pounds (203 to 271 Nm). This is 13.5 to
18 foot-pounds (18.3 to 24 Nm) on torque wrench
when using the power wrench kit (T100965).
T101303 Socket
19. Remove the tools as necessary to install the lock
ring (6) on the nut (7). Adjust the torque, if necessary, T101921 Plate Set
by tightening within the torque limits until the screw
holes line up.
1. Remove the 24 bolts (4, Figure 63-75) and the
washers (5).
20. Install the two screws (5) at opposite sides of the
shaft and secure each to a hole in the edge of the lock
2. Carefully tap the gear support case (6) to remove
ring (6) with lockwire (C-405).
it from the collector (9).
3. Remove the shims (7) and mark the shims for

CAUTION installation at the same location.
4. Remove the collector (9).

I T I S I M P E R AT I V E TO O BTA I N T H E
PROPER DIMENSION AS FAILURE TO
DO SO WILL CAUSE IMPROPER
NOTE
BACKLASH AND GEAR WEAR PATTERN.
Shims (10) are installed on top of the
21. Check the assembly on the surface plate with a collector (9) on configuration
vernier height gauge and dial indicator. Measure 412-040-362-103, and under the collector
Dimension B (Figure 63-74) at several points (9) on configuration 412-040-362-101.
63-00-00
BHT-412-CR&O-3
1
9
2
T 2
3
T 1
4
2 10
11
12
7
1 10
LOCKWIRE (C-405)
1. Screw 5. Washer 9. Collector
2. Locking 6. Gear support case 10. Shim
3. Nut 7. Shim 11. Bearing retainer plate 20 TO 25 IN-LBS
4. Bolt 8. Duplex bearing 12. Gear assembly
T 1 (2 TO 3 Nm)
150 TO 200 FT-LBS
T 2 (203 TO 271 Nm)
NOTES
1 Install shim (10) on top of collector (9) on configuration 412-040-362-103.
2 Install shim (10) under of collector (9) on configuration 412-040-362-101.
412_CRO_63_0071_c02
Figure 63-75. Main Input Gear Quill (412-040-362-101 and -103)
63-00-00
BHT-412-CR&O-3
5. Remove the shims (10) and mark the shims for intended that all dimensions be checked as
installation at the same location. a prescribed overhaul procedure; however,
6. Remove the screws (1) and the lockring (2). physical damage must be checked
dimensionally.
7. Put the socket (T101303) on the nut (3).
1. Inspect all the parts visually for damage and
8. Install the anchor plate (T100968) and the power excessive wear.
wrench kit (T100965) on the shaft of the gear
assembly (12) and loosen the nut (3). 2. Inspect the gear support case (6, Figure 63-75)
for corrosion and for a loose bearing liner
9. Remove the tools and the nut (3). (Figure 63-76).
3. Inspect the nut (3, Figure 63-75) for damaged

CAUTION threads.
B E A R I N G S ( 8 ) M U S T B E R I G I D LY 4. Inspect the duplex bearings (8) for spalling,

SUPPORTED ON THE INNER RACE scoring, flaking, corrosion, and roughness when
AROUND THE FULL CIRCUMFERENCE rotated.
SO THAT THE OUTER RACES ARE NOT
LOADED DURING BEARING REMOVAL. 5. Inspect the bearing retainer plate (11) for
INADEQUATE SUPPORT WILL RESULT damaged threads.
IN DAMAGED BEARINGS AND/OR
SHAFT.
6. Inspect the gear assembly (12), as shown in
Figure 63-77.
CAUTION
inspection (Code M) or fluorescent penetrant
BEARINGS ARE A MATCHED SET AND inspection (Code F), as applicable. Demagnetize parts
MUST BE RETAINED OR REPLACED IN after magnetic particle inspection. Refer to Table 63-3
PAIRS. and the BHT-ALL-SPM for procedure.
10. Support the duplex bearings (8) on the inner race
with the plate set (T101921) and press the shaft out of FIGURE 63-75
NOMENCLATURE CODE
the bearing. Keep the bearings together as a matched INDEX NUMBER
set. Mark the bearings for assembly.
3 Nut M
11. Remove the bearing retainer plate (11). 6 Gear Support Case F
63-87. MAIN INPUT GEAR QUILL — CLEANING 11 Bearing Retainer M

Plate
Refer to paragraph 63-81 for the cleaning procedure of
12 Gear Assembly M
the main input gear quill.
63-88. MAIN INPUT GEAR QUILL — INSPECTION

NOTE
NOTE Refer to step 8 and step 9 for special
inspection procedures for the shaft (11).
Wear limits are provided to show the
63-00-00
BHT-412-CR&O-3
Figure 63-76. Main Input Gear Quill Case (412-040-385-101) — Damage Limits (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3
D
G
J F
SURFACE
A
E SURFACE
H
B
SECTION A-A
NO. SURFACE/AREA CHARACTERISTIC INSPECTION LIMIT

METHOD
1. A, D Corrosion/mechanical Visual 1
2. B Wear Measure 13.748 inches

(349.20 mm)
minimum
Corrosion/mechanical Visual 2
3. C Wear Measure 14.798 inches

(375.87 mm)
minimum
4. E Corrosion/mechanical Visual 3
5. F, G Corrosion/mechanical Visual None

allowed
6. H Corrosion/mechanical Visual 4
7. J Wear Measure 6.6926 inches

(169.992 mm)
maximum
Corrosion/mechanical Visual
5
412_CRO_63_0072b_c01
63-00-00
BHT-412-CR&O-3
NOTES
1 Corrosion pitting or mechanical damage is acceptable on Surface A provided corrosion or mechanical
damage does not exceed 0.010 inch (0.25 mm) in depth, and covers no more than 20% of the area
within any 1.0 square inch (645 mm2) or 10% of the total area of the surface. Corrosion or
mechnical damage must not extend closer than 0.060 inch (1.52 mm) from the edge of holes and clinch
nuts. Corrosion or mechanical damage may extend no closer than 0.150 inch (3.81 mm) from Diameters C
and B. Remove any raised material flush with the surrounding surface using a fine India stone (C-464).
Light fretting erosion on Surface A and Area D commonly covers large areas, particularly on the outer
edges. This condition is acceptable provided the fretting extends no closer than 0.400 inch (10.16 mm)
from the edges of bolt holes.
Corrosion pitting on inside of bolt holes on Surface A, shall not exceed 0.020 inch (0.51 mm) in depth
nor cover more than 20% of the total wall area inside the hole.
Mechanical or corrosion damage at threaded insert and washer seats not acceptable.
2 Mechanical damage in the form of fine axial scratches is acceptable on Diameters B and C provided such
scratches do not exceed 0.003 inch (0.08 mm) in depth. Do not polish out such scratches but remove
any raised material flush with surrounding surface using a fine India stone (C-464).
3 Corrosion pitting is acceptable in Area E, provided the pitting does not exceed 0.010 inch (0.25 mm) in
depth and covers no more than 20% of the total area of the surface. Corrosion pitting may extend no
closer than 0.100 inch (2.54 mm) from the edges of bore entry chamfer. Do not polish out such pitting but
remove any raised material flush with the surrounding surface using a fine India stone (C-464).
Mechanical damage in the form of nicks, dents, and scratches is acceptable in Area E provided the damage
is no greater than 0.010 inch (0.25 mm) in depth, 0.250 inch (6.35 mm) in length and extends no closer
than 0.100 inch (2.54 mm) from the edges of bore entry chamfer. Remove any raised material flush with
the surrounding surface using a fine India stone (C-464).
No corrosion or mechanical damage is acceptable in jet bores and associated entry chamfers.
4 Corrosion pitting or mechanical damage is acceptable on Surface H, provided the corrosion or mechanical
damage does not exceed 0.010 inch (0.25 mm) in depth, and covers no more than 20% of the area
within any 1.0 square inch (645 mm2) or 10% of the total area of the surface. Corrosion or
mechanical damage must not extend closer than 0.060 inch (1.52 mm) from the edge of holes. Remove
any raised material flush with surrounding surface using a fine India stone (C-464).
Light fretting erosion on Surface H commonly covers a large area, particularly on outer edges. This
condition is acceptable provided the fretting extends no closer than 0.150 inch (3.81 mm) from edges of
bolt holes.
Corrosion pitting on the inside of bolt holes on Surface H, may not exceed 0.020 inch (0.51 mm) in depth
nor cover more than 20% of the total wall area inside the hole.
5 Only light superficial corrosion, easily removable with steel wool is allowed.
412_CRO_63_0072c
63-00-00
BHT-412-CR&O-3
SPLINE
E
M
THREAD
G
DUPLEX BEARING
B
JOURNAL
H B
J
ROLLER RACE
C
A
N
C
D ROLLER RACE
D
L SPLINE
F
412_CRO_63_0073a_c01
Figure 63-77. Main Input Gear Quill (412-040-701-101) — Damage Limits (Sheet 1 of 4)
63-00-00
BHT-412-CR&O-3

LTR METHOD
1. A Corrosion/mechanical Visual 1
2. B Wear Measure 4.7250 inches (120.015 mm) min.
3. C, D Wear Measure 3
4. E Wear Measure over 4.7894 inches (121.651 mm) min.

0.1920 inch
(4.877 mm)
diameter pins
5. F Wear Measure over 4.8968 inches (124.379 mm) min.

0.1920 inch
(4.877 mm)
diameter pins
6. G Corrosion/mechanical Visual 5
7. H, J, K Corrosion/mechanical Visual 6
8. L, M Corrosion/mechanical Visual None allowed
9. N Corrosion/mechanical Visual 7
10. All Cracks Magnetic None allowed

particle per
BHT-ALL-SPM
NOTES
1 Visually inspect gear teeth, area A, for spalled, scored, pitted, dented, or scratched surfaces. Any such
condition which can be felt with a probe having a spherical end radius of 0.020 inch (0.51 mm) is cause
for rejection. No corrosion pitting is permitted on any gear tooth surface.
No corrosion pitting or mechanical damage is allowed in the region between gear root diameter and rim
inside diameter.
2 Light superficial corrosion which may be readily removed by hand polishing with fine steel wool (C-411) or
fine abrasive pad (C-407) is acceptable in area B, spline E, and spline F. See wear limits for bearing journal
and spline teeth.
No mechanical damage is permitted on the above surfaces.
412_CRO_63_0073b_c01
63-00-00
BHT-412-CR&O-3
3 Accurately measure size of roller races C and D at three axial locations.
NOTE
The following measurements must be made under stabilized temperature conditions
using an instrument having at least 0.000050 inch (0.00127 mm) measuring accuracy.
a. Measure and record diameter at location 1 in area of no wear to five decimal places.
b. Measure and record diameter at location 2 in area of no wear to five decimal places.
c. Measure and record diameter at location 3 in area of maximum wear in roller path to
five decimal places.
d. Calculate and record arithmetic average of diametral measurements at location 1 and 2.
e. Reject the part if difference between the calculated average of diameters 1 and 2 and
the measurement at location 3 is greater than 0.0003 inch (0.008 mm) or, if the diameter
at location 3 is less than 4.5547 inches (115.689 mm) for roller race C and, if the diameter at
location 3 is less than 5.1537 inches (130.904 mm) for roller race D .
4 Visually examine the roller race C and D for evidence of black oxide removal, scratches, dings, dents,
scuffing, micro pitting, spalling and corrosion pitting.
a. A burnished or polished condition of the black oxide treatment in the roller path is acceptable provided
the condition is uniform over the entire circumference of the race.
b. Scratches, dings, dents and scuffs which can be felt with a 0.020 inch (0.51 mm) spherical radius
probe are cause for rejection.
c. Micro pitting, spalling, and corrosion pitting are cause for rejection.
5 Allowable damage in thread Area G is limited to one thread pitch. Damage on the thread pitch may not
exceed 1/4 thread depth nor more than 0.25 inch (6.4 mm) in aggregate total length after rework to
remove the damage. Inspect for burrs and galled metal in threads. No corrosion pitting is permitted.
6 Corrosion pitting or mechanical damage is acceptable in Areas H and J provided the corrosion or damage
is polished out and the reworked area does not exceed 0.005 inch (0.13 mm) in depth and covers no more
than 10% of the total area of any surface. Remove material during rework to produce minimum radii
of 0.250 inch (6.35 mm) with a surface finish of 63 RMS or better.
Gearshafts on which material was polished out in previous overhauls to remove corrosion or mechanical
damage in Areas H and J may not be reworked to remove additional corrosion or mechanical damage on
the previously reworked surfaces.
Existence of an etched triplex ball bearing index mark on the indicated cylindrical surface is acceptable
provided mark is no deeper than 0.010 inch (0.25 mm) nor longer than 0.250 inch (6.35 mm). Remove any
raised material at corner formed by the intersection of the cylindrical surface and gearshaft bearing shoulder.
fine abrasive pad (C-407) is acceptable in Area N.
412_CRO_63_0073c
63-00-00
BHT-412-CR&O-3
Main input driven gear quill wear pattern.
A Spiral Bevel Gear, Input Driven Gear Quill.

Typical acceptable wear pattern.
B Spiral Bevel Gear, Input Driven Gear Quill.

Gear is spalled on the face of the tooth.
Any spalling of this type is unacceptable,
and both the gear and mating pinion
should be replaced even though mating
pinion may not be spalled.
C Input Pinion.
Input drive quill wear pattern showing
a non-uniform wear pattern with a band
of heavy wear in the flank. This is the
maximum acceptable for this condition.
412_CRO_63_0073d
63-00-00
BHT-412-CR&O-3
8. Inspect the gear assembly (12, Figure 63-75) by (2) Circumferential indications, or indications
magnetic particle method. The shaft must be more than 15° off the long axis of the gear are
inspected by all of the following steps using the wet permitted in Area B (Figure 63-78) provided the length
continuous method. The use of fluorescent coated of the indications does not exceed 0.25 inch (6.4 mm).
particles with an ultraviolet light is mandatory. The Not more than two such indications shall be allowed in
length of any indication shall be determined by the any 1.0 square inch (645.2 mm2) of surface area.
residual method of magnetization.
(3) Indications on the bearing journal, in
Area B, are permitted if the length of the indication
NOTE
does not exceed 0.0625 inch (1.588 mm) and
If AC magnetic particle inspection provided the indication is 0.125 inch (3.18 mm) or
equipment is used, use 60% of DC amps more from the end of the bearing journal. Indications
specified. within 0.125 inch (3.18 mm) of the end of the bearing
journal or that break over the end of the bearing
a. Thoroughly degrease the gear. journal are cause for rejection. No more than four
indications within the above limits, are allowed on
b. Magnetize the gear by placing the shaft each bearing journal.
between the contact heads of the inspection
equipment. Pass approximately 2000 amps of DC (4) Circumferential indications or indications
current through the gear. that are more than 15° of the long axis of the gear in
Area A (Figure 63-78) are cause for rejection.
c. Inspect the gear completely, inside and
outside, for indications. (5) Indications more than 15° off the long
axis, transverse or circumferential to the long axis, are
d. Place the gear inside the coil such that the permitted in the spline areas provided they do not
long axis of the gear is approximately 90° to the exceed 0.125 inch (3.18 mm) in length. Not more than
direction of current flow in the coil. Magnetize the gear one indication is allowed per tooth, and not more than
with approximately 1000 amps of DC current. six to each spline area. All other indications in the
spline area are cause for rejection.
e. Inspect the gear completely for indications.
(6) Indications in the threaded sections are
f. After completion of the inspection,
cause for rejection regardless of size or location in
demagnetize the gear and check with a compass or
Area A (Figure 63-78).
equivalent to ensure demagnetization.
9. Evaluate the defects noted during the magnetic (7) Indications of subsurface discontinuities
particle inspection of the gear (12) as follows that break a transverse face shall not exceed
(Figure 63-78): 0.031 inch (0.79 mm) in length or cross section.
a. Indications interpreted as cracks are cause for (8) Indications or surface discontinuities that
rejection regardless of size or location. break over corners or run into the fillets, splines, or
threads, are cause for rejection.
b. Surface or subsurface indications or stringers,
shunts, non-metallic inclusions, bursts, laps or seams (9) Indications caused by a change in
are permitted provided they are within all the following section are permitted.
limits:
(10) Strong magnetic indications where
(1) Indications of defects parallel (±15°) to considerable buildup is present, indicating that defect
the long axis of the gear are permitted, provided the has considerable depth and/or cross section shall be
length of the indication does not exceed 0.125 inch cause for rejection regardless of location.
(3.18 mm) and provided other limitations herein are
not exceeded. Not more than two such indications 10. Inspect the parts dimensionally and replace parts
allowed in any 2.0 square inches (1290 mm2) of that do not fall within the inspection limits
surface area. (Figure 63-79).
63-00-00
BHT-412-CR&O-3
AREA A AREA B
412_CRO_63_0074
Figure 63-78. Main Input Gear Quill — Magnetic Inspection Areas
63-00-00
BHT-412-CR&O-3
63-89. MAIN INPUT GEAR QUILL — REPAIR

NOTE
Refer to the BHT-412-MM for approved
MATERIALS REQUIRED lubricants.
Refer to BHT-ALL-SPM for specifications. 2. Coat all the parts with the same oil used in
transmission and drain.
NUMBER NOMENCLATURE
C-464 India Stone

CAUTION
1. If small nicks, burrs, or scratches are visible,
dress the splines and the gear with a fine India stone
(C-464) (Figure 63-79). I T I S E S S E N T I A L T H AT U T M O S T
PRECISION BE USED WHEN
2. Repair minor damage to bevel gears by lightly ASSEMBLING THIS QUILL.
polishing with a fine India stone (C-464) to remove any
material that protrudes above the original ground 3. Check the duplex bearings (8, Figure 63-75) to
surface. confirm that the serial number is the same on both
bearings. Hold the bearings back-to-back, measure
63-90. MAIN INPUT GEAR QUILL — ASSEMBLY the width of the outer races, and record as
Dimension C (Figure 63-80).
CAUTION
NUMBER NOMENCLATURE
T100965 Power Wrench Kit THE SAME SHIMS (7 AND 10,

FIGURE 63-75) THAT WERE REMOVED
S H A L L B E R E I N S TA L L E D I F N O T
T101303 Socket DAMAGED.
MATERIALS REQUIRED CAUTION

IF SHIM(S) (7 AND/OR 10) ARE
NUMBER NOMENCLATURE DAMAGED, NOTIFY BELL HELICOPTER
TEXTRON, CPR DEPARTMENT AND
C-304 Drycleaning Solvent GIVE DIMENSION C, DIMENSION L,
D I M E N S I O N S , D I M E N S I O N T,
C-405 Lockwire
DIMENSION X, AND DIMENSION Y
(FIGURE 63-80 AND STEP 4). SHIM
1. Clean all the parts with drycleaning solvent THICKNESS WILL BE CALCULATED AND
(C-304) and drain. APPROPRIATE SHIM WILL BE SENT.
63-00-00
BHT-412-CR&O-3
Figure 63-79. Main Input Gear Quill — Wear Limits
63-00-00
BHT-412-CR&O-3
4. Determine the thickness of shims (7 and 10,

IV.
Figure 63-75 for the main input quill as follows:
Actual shim at III Total dimension of I and II
a. Record the following dimensions. Dim C + Dimension C
Total dimension of C and III

Dim C — Measure width of bearing outer V.
races.
Dim T Dimension T
Dim X — Etched on support case.
Dim S + Dimension S
Dim Y — Etched on support case.
Dim Y + Dimension Y
Dim R — Etched on shaft.
Pinch required, +0.0030 inch (+0.076 mm)
Dim S — Oil collector thickness. 0.001 to 0.005
Dim T — Etched on bearing retainer plate. inch (0.03 to
0.13 mm)
Dim A — 1.752 inches (44.50 mm)
Given: 1.7510 to 1.7530 inches = Total dimension
(44.475 to 44.526 mm) VI.
Dim IV (above) Dimension IV

b. Determine the thickness of the shim (3)
between the bearing and the liner as follows: Dim V (above) - Dimension V
Required = Total dimension

thickness for ±0.002 inch (±0.05 mm)
I. shim (2)
Dim A 1.752 inches (44.50 mm) Dim B Dimension B
Dim Y + Dimension Y Measure from
lower surface of
= Dimension I gear shaft
support case to
II. upper surface of
Dim C Dimension C bevel gear.
Dim X + Dimension X Dim R - Dimension R
= Dimension II Dim B - R should = 1.751 to 1.753 inches

(44.48 to 44.53 mm)
III.
Dim I (above) Total dimension of A and Y
Dim II (above) - Total dimension of C and X

CAUTION
Required = Shim (3) thickness

thickness for ±0.001 inch (±0.03 mm) M A K E S U R E T H AT B E A R I N G S A R E
shim PROPERLY INSTALLED BACK-TO-BACK.
(3, Figure 63-80) MAKE SURE THAT SHIMS (7 AND 10)
ARE NOT DAMAGED DURING
INSTALLATION OF BOLTS. MAKE SURE
c. Determine the thickness of the shim (2) T H AT B O LT S ( 4 ) A R E P R O P E R LY
between the case and the bearing retainer as follows: SECURED.
63-00-00
BHT-412-CR&O-3
5. Put the shim (7, Figure 63-75) in the liner of the 12. Install the nut (3).
gear support case (6).
13. Put the socket (T101303) and the power wrench
6. Put the duplex bearings (8) in the back-to-back kit (T100965) over the nut (3).
position over the gear support case (6).
14. Install the anchor plate (T100968) on the shaft.
7. Press the duplex bearings (8) into the gear
support case (6). 15. Torque the nut (3) to the low side of 150 to
200 foot-pounds (203 to 271 Nm). This is 13-1/2 to
18 foot-pounds (18 to 24 Nm) on the torque wrench
NOTE when using the power wrench kit (T100965).
Shims (10) are installed on top of collector
(9) on configuration 412-040-362-103, and 16. Remove the tools as necessary to install the
under the collector (9) on configuration lockring (2) on the nut (3). Adjust torque, if necessary,
412-040-362-101. by tightening within the torque limits until the screw
holes line up.
8. Put the shim (10) in position and install the
collector (9) and the bearing retainer plate (11) with the 17. Install the two screws (1) at opposite sides of the
bolts (4) and the washers (5) under the bolt heads. shaft and secure each to a hole in the edge of the
lockring (2) with lockwire (C-405).
9. Torque the bolts (4) evenly 20 to 25 inch-pounds
(2 to 3 Nm) and secure in pairs with lockwire (C-405).
CAUTION
NOTE
The etched marks placed on the bearings I T I S I M P E R AT I V E TO O BTAI N T H E
by the bearing manufacturer mark the high PROPER DIMENSION AS FAILURE TO
point of the race runout. DO SO WILL CAUSE IMPROPER
BACKLASH AND GEAR WEAR PATTERN.
10. Put the gear support case (6) on the shaft of the
gear assembly (12). Align the vibro-etched 0 on the 18. Check the assembly on the surface plate with a
ends of the inner races with the index marks on the vernier height gauge and dial indicator. Measure
shaft. Dimension B (Figure 63-80) at several points
approximately 90° apart. Subtract Dimension L,
etched on the side of the shaft from Dimension B. This
NOTE result is Dimension A and shall be 1.751 to
If the gear assembly (12) is being replaced, 1.753 inches (44.48 to 44.53 mm). If the dimension is
vibro-etch index mark on a new shaft the not obtained, a damaged shim or a shim of incorrect
same as on the old shaft. thickness may be the cause. Refer to paragraph 63-90
for shim replacement if Dimension A tolerance is not
11. Press the duplex bearings (8) on the inner races achieved.
to seat against the shoulder of the shaft on the gear
assembly (12). 19. Check the bearings for free rotation.
63-00-00
BHT-412-CR&O-3
X Y T
A C
B
S L
Dimension A - given: 1.751 to 1.753 inches (44.48 to 44.53 mm).

Dimension C - measure width of outer races.
Dimension X - etched on support case.
Dimension Y - etched on support case.
Dimension L - etched on gear shaft.
Dimension S - 0.0330 inch (0.838 mm).
Dimension T - etched on bearing retainer plate.
Dimension B - measure after assembly.
1. Collector Measure actual thickness (dimension)
2. Shim Shim to obtain 0.001 to 0.005 inch (0.03 to 0.13 mm) pinch on bearing
3. Shim Shim to obtain Dimension A
412_CRO_63_0076_c01
Figure 63-80. Main Input Gear Quill (412-040-362-101) — Shimming
63-00-00
BHT-412-CR&O-3
MAIN INPUT QUILL
63-91. MAIN INPUT QUILL (212-040-263-107) 9. Remove the six screws (11) and the six washers
(10) from the cap assembly (9).
NOTE 10. Remove the cap assembly (9) from the sleeve
For helicopters S/N 36020 and subsequent (2). Discard the shim (4).
to include S/N 46400 through 46499 and
helicopters modified by 412-570-001-103, 11. Install the plate set (T101912) (1, Figure 63-83)
refer to paragraph 63-103. on the pinion (1, Figure 63-81) between the gear and
the sleeve (2).
63-92. MAIN INPUT QUILL — DISASSEMBLY
12. Support the bearing inner race and press the
pinion (1) out of the triplex bearings (5).
NUMBER NOMENCLATURE CAUTION
T101588 Wrench Set

RETAIN BEARINGS AS A MATCHED
T101912 Plate Set SET.
13. Support the sleeve (2) and press the triplex

1. Remove the retaining ring (27, Figure 63-81) and bearings (5) out of the sleeve by pressing on the outer
the plate (26). race. Keep the bearings together as a matched set.
2. Remove and discard the packing (25). 14. Remove the packing (3) from the sleeve (2).
3. Remove the lock spring (24).
15. Remove the cap (6) with the union (7) and
packing (8) from the cap assembly (9). Discard the
4. Install the wrench set (T101588) on the quill, as
packing.
shown in Figure 63-82.

5. Secure a 3/4 (0.750)-inch (19.05-mm) square bar
vertically in a vise and put the quill on the bar with the
17. Remove the plug (13) with the packing (14) from
pinion engaged on the bar.
the cap assembly (9). Discard the packing.
6. Loosen the nut (23, Figure 63-81). 18. Remove the retaining ring (21).
7. Remove the wrench set (T101588) and the 19. Remove the seal retainer (20) from the cap
nut (23). assembly (9).
8. Remove the curvic coupling adapter (22) from the 20. Remove the packings (18 and 19) from the seal
pinion (1). retainer (20). Discard the packings.
63-00-00
BHT-412-CR&O-3
16
12 15
11
10
9
8 A
7
0.055 TO 0.085 IN. 6
(1.40 TO 2.16 mm)
A
5 13
SECTION A-A 4
3
2
14
27
26
25
1
24
T 23
22
21
20
19
18
11. Screw
12. Alignment pin
17
13. Plug
14. Packing
15. Packing
16. Carbon ring
17. Magnetic ring
1. Pinion 18. Packing
2. Sleeve 19. Packing
3. Packing 20. Seal retainer
4. Shim 21. Retaining ring
5. Triplex bearing 22. Curvic coupling adapter
6. Cap 23. Nut
7. Union 24. Lock spring
350 TO 400 FT-LBS
T (475 TO 542 Nm)
8. Packing 25. Packing
9. Cap assembly 26. Plate
10. Washer 27. Retaining ring
LOCKWIRE (C-405)
412_CRO_63_0077_c01
Figure 63-81. Main Input Quill (212-040-263-107)
63-00-00
BHT-412-CR&O-3
Figure 63-82. Wrench Set (T101588) — Application
63-00-00
BHT-412-CR&O-3
412_CRO_63_0079
Figure 63-83. Plate Set (T101912) — Application
63-00-00
BHT-412-CR&O-3
2. Dry the parts with a clean cloth (C-516) or dry

CAUTION
MAGNETIC SEAL IS MADE UP OF TWO CAUTION

PARTS, THE MAGNETIC RING AND THE
CARBON RING. KEEP THEM TOGETHER
AS A MATCHED SET. DO NOT HANDLE UNOILED BEARINGS
WITH BARE HANDS.
CAUTION NOTE
DO NOT HANDLE THE PARTS WITH
BARE HANDS.
21. Remove the carbon ring (16) and the magnetic 3. Coat the bearings with corrosion preventive
ring (17), as a unit, from the cap assembly (9). compound (C-105) immediately after cleaning
(BHT-ALL-SPM).
22. Remove and discard the packing (15).
63-94. MAIN INPUT QUILL — INSPECTION
63-93. MAIN INPUT QUILL — CLEANING

NOTE
Wear limits are provided to show required
MATERIALS REQUIRED fit between mating parts. It is not intended
that all dimensions be checked as a
Refer to BHT-ALL-SPM for specifications. prescribed overhaul procedure, however,
NUMBER NOMENCLATURE physical damage must be checked
dimensionally.
Compound 1. Inspect the pinion (1, Figure 63-81) in
C-334 Solvent 2. Inspect the sleeve (2, Figure 63-81) in

C-516 Clean Cloth
3. Inspect the triplex bearing (5, Figure 63-81) for
spalling, scoring, pitting, brinelling, corrosion damage,
1. Clean all the quill parts with drycleaning solvent cracked or broken retainers, and roughness when
(C-304). Use a soft bristle brush to dislodge deposits. rotated. Any defect is cause for rejection.
All parts except bearings may be cleaned with solvent
(C-334) by vapor degreasing.
4. Inspect the cap assembly (9) in accordance with
Figure 63-86.
CAUTION 5. Inspect the seal retainer (20, Figure 63-81) in

DO NOT ALLOW BEARINGS TO SPIN 6. Inspect the curvic coupling adapter (22,
WHILE DRYING. Figure 63-81) in accordance with Figure 63-88.
63-00-00
BHT-412-CR&O-3
3.2928 TO 3.2952 IN.

(83.637 TO 83.698 mm)
SEE DETAIL B
PINION
VIEW A
(204-040-700-101)
Main input quill teeth wear pattern showing a

non-uniform wear pattern with a band of heavy
wear in the flank. This is the maximum
acceptable for this condition.
DETAIL B
NOTES
1. Inspect pinion teeth for chipping, dents, spalling, scuffing, and pitting. Pitting of any magnitude resulting
from surface fatigue during operation is not acceptable on teeth of pinion. This may appear as only a fine line
of pin holes near pitch diameter and be detectable only with a side light source and a probe with a point of
approximately 0.001 inch (0.03 mm) radius. Minor pitting resulting from corrosion is acceptable within
following limits:
a. No more than 0.001 inch (0.03 mm) deep and no more than 0.040 inch (1.02 mm) wide or 0.080 inch
(2.03 mm) long.
b. No more than 0.002 inch (0.05 mm) deep and no more than 0.040 inch (1.02 mm) wide or 0.100 inch
(2.54 mm) long and located on the outer (i.e. adjacent to the heel). half of the face of the tooth and
above the pitch line; or located outside of the wear pattern and outside of the root radius.
c. Surface roughness detectable by drawing probe along tooth in profile direction is cause for rejection
if pitting occurred on mating member.
d. Grinding scratches. Any scratches around which pitting or other damage occurs are not acceptable.
e. Nicks, cuts, or dents caused by handling or by foreign material going through mesh during operation
are acceptable provided they are no more than 0.003 inch (0.08 mm) deep and are no more than
0.020 inch (0.51 mm) across in any direction, and cannot be felt with a probe having end radius of
0.020 inch (0.51 mm).
2. Inspect wear pattern on teeth in accordance with Detail B for maximum acceptable non-uniform wear pattern.
3. Inspect front of pinion that contacts roller bearing inside transmission for mechanical and corrosion damage.
Damage that can be detected visually is not acceptable.
4. If necessary, check pinion spline wear limits as shown in View A.

412_CRO_63_0080_c01
Figure 63-84. Main Input Drive Quill Pinion — Damage Limits
63-00-00
BHT-412-CR&O-3
A
INPUT QUILL SLEEVE
(214-040-097-003)
6.3662 TO 6.3667 IN.

(161.702 TO 161.714 mm)
6.7495 TO 6.7500 IN.

5.9047 TO 5.9052 IN. (171.438 TO 171.450 mm)
(149.980 TO 149.992 mm)
SECTION A-A
NOTE
In Area A, light oxide coating is not a cause for rejection, provided not more than 40% of any
1.0 square inch (645 mm2) or 20% of the total area of any surface is affected.
412_CRO_63_0082
Figure 63-85. Main Input Drive Quill Sleeve — Damage Limits
63-00-00
BHT-412-CR&O-3
Figure 63-86. Main Input Quill Cap Assembly — Damage Limits
63-00-00
BHT-412-CR&O-3
A
AREA
A A
AREA B
SECTION A-A
SEAL RETAINER
(212-040-126-101)
NOTES
IN AREA A:
1. Light oxide coating is not cause for rejection provided not more than 40% of any
1.0 square inch (645 mm2) or 20% of total area of any surface is affected.
2. Nicks and dents are acceptable provided they do not exceed 0.030 inch (0.76 mm) depth.
IN AREA B:
Maximum acceptable depth of pitting is 0.030 inch (0.76 mm), provided no more than 40%
of any 1.0 square inch (645 mm2) or 20% of total area of any surface is affected.
412_CRO_63_0087
Figure 63-87. Main Input Quill Seal Retainer — Damage Limits
63-00-00
BHT-412-CR&O-3
Figure 63-88. Main Input Quill Curvic Coupling Adapter — Damage Limits
63-00-00
BHT-412-CR&O-3
7. Inspect the retaining rings (21 and 27, than 0.020 inch (0.51 mm) deep. Zones of porosity
Figure 63-81) and the lock spring (24) for obvious shall not extend more than 1/4 of the way across any
defects and deformation. surface and shall not extend to within 0.070 inch
(1.78 mm) of any edge.
8. Inspect the nut (23) for thread damage and
obvious defects. (2) Edge chips on the inside diameter and
the outside diameter of the back face are permitted if
9. Inspect the plate (26) for corrosion damage and they are less than 0.0625 inch (1.588 mm) long and
nicks or burrs in the seal groove, which could cause 0.020 inch (0.51 mm) wide.
leakage.
(3) No cracks are permitted.
e. Inspect the outside diameter surface of the

CAUTION magnetic ring (17) as follows:
(1) Zones of porosity shall not extend more

THE SEAL INSPECTION PROCEDURE than 1/4 of the way across any surface and shall not
MUST BE ACCOMPLISHED UNDER extend to within 0.070 inch (1.78 mm) of any edge.
CLEAN CONDITIONS. WEAR WHITE
COTTON GLOVES WHILE HANDLING (2) Porosity holes are permitted if less than
SEAL. DO NOT SLIDE MAGNETIC SEAL 0.020 inch (0.51 mm) in diameter and less than
ON MAGNETIC RING. DO NOT ALLOW 0.020 inch (0.51 mm) deep.
C A R B O N S E A L I N G S U R FA C E O R
SEALING RING ON MAGNETIC RING TO (3) Edge chips are permitted if less than
CONTACT ANY OTHER OBJECT. DO 0.0312 inch (0.793 mm) long and 0.0156 inch
NOT ALLOW ANY FOREIGN PARTICLES (0.396 mm) wide.
TO CONTACT SEAL.
(4) No cracks are permitted.
NOTE
f. Inspect the sealing face of the magnetic ring
The magnetic seal is made up of two parts, (17) as follows:
the magnetic ring (17) and the carbon ring
(16), which is bonded to the seal case. (1) The sealing ring is defined as the ring
which coincides with the mating carbon sealing
10. Inspect the magnetic seal as follows: surface plus an additional 0.020 inch (0.51 mm) per
side allowance. Chips, nicks, and scratches are not
a. Measure the gap between the magnetic ring allowed on the sealing ring.
and seal case with a clean, non-metallic feeler gauge
(Figure 63-89, Figure 63-90, and Figure 63-91, as (2) The sealing ring shall be free of porosity
applicable). holes and pits unless they are within the limits per
Figure 63-89 and Figure 63-90, as applicable. Pits and
b. Separate the magnetic ring (17, Figure 63-81) porosity holes must be clean and free of foreign
from the carbon ring (16) by carefully pulling directly matter. No two pits and/or porosity holes may be
away from each other. aligned radially across the sealing ring.
c. Inspect the magnetic ring (17) with a high (3) Porosity holes outside the sealing ring
intensity light for scratches, nicks, and cracks. A are permitted if less than 0.020 inch (0.51 mm) in
cracked ring is nonrepairable and must be replaced. diameter and less than 0.016 inch (0.41 mm) deep.
Zones of porosity shall not extend more than 1/4 of the
d. Inspect the back face and the inside diameter way across any surface and shall not extend within
surface conditions of the magnetic ring (17) as follows: 0.070 inch (1.78 mm) of any edge.
(1) Porosity holes and voids under (4) Scratches outside the sealing ring are
0.020 inch (0.51 mm) in diameter are permitted if less permitted.
63-00-00
BHT-412-CR&O-3
0.025 IN. (0.64 mm)

MINIMUM MEASURE 4
WITH FEELER GAUGE NOT ACCEPTABLE
BETWEEN SEAL CASE
AND MAGNETIC RING
MINIMUM
ACCEPTABLE = A
1 2
SEAL CASE MAGNETIC RING
SEGMENT OF CARBON RING

CARBON RING
PIT LIMITS
SIZE NUMBER AND LIMITS
Up to 0.010 inch (0.25 mm) 2 per 1.0 inch (25 mm) minimum of 0.0625 inch (1.588 mm) apart 4
maximum diameter
Up to 0.006 inch (0.15 mm) 3 per 1.0 inch (25 mm) minimum of 0.0625 inch (1.588 mm) apart 4
maximum diameter
NUMBER OF CHIPS MAXIMUM LENGTH OF CHIP MAXIMUM PROTRUSION INTO SEALING RING
1 maximum 0.050 inch (1.27 mm) 0.016 inch (0.41 mm) seal face width
3 maximum 0.050 inch (1.27 mm) 0.008 inch (0.20 mm) seal face width
More than 4 0.050 inch (1.27 mm) 0.004 inch (0.10 mm) seal face width
NOTES
1 Dimension A denotes width of sealing area surface.
2 No chip may be closer than “A” to another chip.
3. Edges of carbon sealing surface may be chamfered. Chamfer protrusion into sealing surface cannot exceed
5% of carbon sealing surface width.
4 Not acceptable, if two pits align in radial direction.
5. All dimensions are in inches (millimeters) unless otherwise specified.
412_CRO_63_0086_c01
Figure 63-89. Magnetic Seal — Damage Limits
63-00-00
BHT-412-CR&O-3
A CARBON SEALING ELEMENT REF
SEAL CASE
A MAGNETIC RING
SECTION A-A
412_CRO_63_0132a_c01
Figure 63-90. Seal Case and Carbon Sealing Element (412-040-111-105) — Damage Limits (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3
B
B
A
B
B
CARBON SEALING
ELEMENT REF
SEAL CASE
SECTION B-B

LTR METHOD
1. A Chips or nicks Visual None allowed
2. A Pitting Visual None allowed
3. B Chips or nicks Visual/measure 2
4. All Mechanical/corrosion None allowed except as noted
412_CRO_63_0132b_c01
63-00-00
BHT-412-CR&O-3
CAUTION
AVOID TOUCHING SEALING SURFACE OF CARBON

SEALING ELEMENT WITH BARE FINGERS AND/OR
MEASURING INSTRUMENTS.
NOTES
1. All dimensions are in inches (millimeters).
2 Nicks or chips allowable at edges of sealing surface:

All protrusion dimensions are taken from surfaces normal to the sealing surface.
a. If chip or nick protrudes into sealing ring by a maximum of 0.019 inch (0.48 mm) and is no longer than
0.050 inch (1.27 mm), only one such defect is allowed.
b. If chip or nick protrudes into sealing ring by a maximum of 0.0095 inch (0.241 mm) and is no longer than
0.050 inch (1.27 mm) three such defects are allowed.
c. If chip or nick protrudes into sealing ring by a maximum of 0.005 inch (0.13 mm) and is no longer than
0.050 inch (1.27 mm), the number of such defects is unlimited provided the requirements of note “e” are
satisfied.
d. Each edge of the sealing ring may have been chamfered. Chamfer may not protrude into the sealing
ring more than 0.005 inch (0.13 mm).
e. No two chips or nicks may be aligned along a radial line closer than 0.100 inch (2.54 mm)
(measured circumferentially).
412_CRO_63_0132c_c01
63-00-00
BHT-412-CR&O-3
0.130 IN. (3.30 mm)
A A B
G F
E
C
F
D
SECTION A-A

LTR METHOD
1. All Cracks Visual None allowed
2. A Pitting Visual/measure 2
3. B Pitting/crazing Visual/measure Pits up to 0.060 inch (1.52 mm)

diameter X 0.015 inch (0.38 mm)
deep are acceptable.
Porosity of a crazing type is
acceptable.
4. B Scratches Visual/measure Circumferential scratches up

to 0.015 inch (0.38 mm) deep
are acceptable.
5. C Pitting Visual/measure 3
6. D Pitting, holes, voids, crazing Visual/measure 4
7. E Cold faults, pitting, holes, voids, crazing Visual/measure 5
8. F Chips or nicks Visual/measure 6
9. G Chips or nicks Visual/measure 7
10. All Mechanical/corrosion None allowed except as noted.
412_CRO_63_0133a_c01
Figure 63-91. Magnetic Seal (412-040-111-105) — Damage Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
CAUTION
AVOID TOUCHING THE SEALING SURFACE

OF THE MAGNET RING WITH FINGERS
AND/OR MEASURING INSTRUMENTS.
2 Pitting allowed in magnet ring sealing ring:
a. Up to 0.006 inch (0.15 mm) diameter occurring no more frequently than three per circumferential
inch and spaced no closer than 0.062 inch (1.57 mm) from each other or the edge defects
in Area G. Pits must be clean and free of foreign matter.
b. Up to 0.010 inch (0.25 mm) diameter occurring no more frequently than two per circumferential
inch and spaced no closer than 0.062 inch (1.57 mm) from each other or the edge defects
in Area G. Pits must be clean and free of foreign matter.
c. No two pits may be aligned along a radial line closer than 0.100 inch (2.54 mm)(measured
circumferentially).
3 Pitting and porosity is acceptable if no longer larger than 0.010 inch (0.25 mm) diameter.
4 a. Porosity of a crazing type is acceptable.
b. Porosity holes and voids are acceptable if no greater than 0.125 inch (3.18 mm) diameter or
0.032 inch (0.81 mm) deep.
5 a. Cold faults are acceptable providing they do not extend to the sealing ring (Area A) or back face (Area D).
b. Porosity of a crazing type is acceptable.
c. Porosity holes and voids are acceptable if no greater than 0.125 inch (3.18 mm) diameter or
0.032 inch (0.81 mm) deep.
6 Edge chipping is acceptable if less than 0.062 inch (1.57 mm) long and 0.032 inch (0.81 mm) wide and
are spaced no closer than 0.250 inch (6.35 mm).
7 Edge chipping is acceptable if less than 0.062 inch (1.57 mm) long, does not protrude onto the
sealing ring (Area A) more than 0.005 inch (0.13 mm), and are spaced no closer than 0.250 inch (6.35 mm).
412_CRO_63_0133b_c01
Figure 63-91. Magnetic Seal (412-040-111-105) — Damage Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
(5) Chipping on the inside diameter and the

outside diameter edges is permitted provided it is FIGURE 63-81
NOMENCLATURE CODE
outside the sealing ring and is less than 0.0625 inch INDEX NUMBER
(1.588 mm) long and 0.020 inch (0.51 mm) wide.
22 Curvic Coupling M
Adapter
g. Inspect the seal case and the carbon ring
assembly under a high intensity light. Minor scratches 23 Nut M
and nicks are permitted on the seal case. The sealing
surface of the carbon must show no visible scratches
or pits when viewed under a high intensity light. 63-95. MAIN INPUT QUILL — REPAIR
Damage on the edges of the carbon sealing surface is
allowable if no two damaged areas are aligned with
one another in the radial direction and if the number MATERIALS REQUIRED
and size of the damaged areas are within the carbon
seal edge damage limits shown in Figure 63-89 and Refer to BHT-ALL-SPM for specifications.
Figure 63-90, as applicable.
NUMBER NOMENCLATURE
h. Inspect the packing groove and remove any
foreign particles. The groove shall not have any burrs C-201 Zinc Chromate Primer
that might damage the packing.
Paper
CAUTION C-407 Abrasive Pad
C-464 India Stone

D O N O T S L I D E S E A L M AT I N G
SURFACES AGAINST EACH OTHER AT
1. Polish out minor dents and nicks on the sleeve (2,
ANY TIME. DO NOT TOUCH EITHER
Figure 63-81) flange top surface with a fine India stone
S E A L I N G S U R FA C E W I T H A N Y
(C-464). Blend the repaired area into the flat surface
FOREIGN OBJECT.
with a minimum radius of 0.12 inch (3.0 mm). The
finished repair must be 32 RHR (Roughness Height
i. Assemble the seal by lining up the two seal
Rating) or better. The maximum depth, after repair,
halves to their final assembled position and carefully
must not exceed 0.030 inch (0.76 mm).
allow the two halves to pull together into their
assembled position.
2. Polish out minor dents, nicks, and scratches on
11. Inspect the following parts by magnetic particle the exterior surfaces of the cap assembly (9) with
inspection (Code M) or fluorescent penetrant abrasive cloth or paper (C-406). Replace a loose or
inspection (Code F), as applicable. Demagnetize parts deformed alignment pin (12). Coat the pin with zinc
after magnetic particle inspection. Refer to Table 63-3 chromate primer (C-201) immediately prior to
and the BHT-ALL-SPM for the procedure. installation.
3. Polish out minor nicks, dents, and scratches on

the curvic coupling adapter (22) with a fine India stone
FIGURE 63-81 (C-464).
NOMENCLATURE CODE
INDEX NUMBER
1 Pinion M 4. Polish out minor nicks, dents, and scratches on

the seal retainer (20) with abrasive cloth or paper
2 Sleeve M (C-406).
9 Cap Assembly F
20 Seal Retainer F the plate (26) with abrasive cloth or paper (C-406).
63-00-00
BHT-412-CR&O-3
(2) The outside diameter of the triplex

NOTE
bearing journal should be 3.1501 to 3.1503 inches
If you return the part to Bell Helicopter (80.013 to 80.017 mm) before the copper plating and
Textron (BHT), refer to General Information 3.1511 to 3.1515 inches (80.038 to 80.048 mm) after
Letter (IL) GEN-04-98 for applicable the copper plating. The copper plating shall be 0.0003
shipping information and to obtain a Return to 0.0007 inch (0.008 to 0.017 mm) thick after plating
Material Authorization (RMA) number. (Figure 63-92).
6. Repair of the magnetic seal by the user is not

8. Refinish parts (except pinion) after repair in
permitted. If there is evidence of damage, return the
part to the manufacturer, one of its authorized service
centers, or BHT for evaluation and possible repair.
63-96. MAIN INPUT QUILL — ASSEMBLY
7. Repair the pinion (1) as follows:
a. Repair minor nicks, burrs, or scratches on SPECIAL TOOLS REQUIRED

non-contact surfaces of the gears of the splines with a
fine abrasive pad (C-407).
NUMBER NOMENCLATURE
b. Repair nicks, dents, and scratches on the
spline teeth by smoothing out with a fine abrasive pad T101588 Wrench Set
(C-407). Do not exceed the limits defined in
Figure 63-84.
MATERIALS REQUIRED
CAUTION Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
DO NOT STRIP GEAR TEETH OR
SPLINES DURING COPPER STRIPPING C-024 Assembly Fluid
OPERATION. MASK GEAR TEETH AND
SPLINES TO PREVENT ACCUMULATION C-464 India Stone
OF COPPER DEPOSITS DURING
COPPER PLATING OPERATIONS. 1. Make sure that all the parts have been cleaned
(paragraph 63-93).
c. Strip and replace the copper plating as follows
(BHT-ALL-SPM):
2. Coat the triplex bearings (5, Figure 63-81), sleeve
(1) Strip the copper plating on the triplex (2), and pinion (1) with approved transmission
bearing journal (Figure 63-92). lubricating oil and allow parts to drain.
63-00-00
BHT-412-CR&O-3
COPPER PLATING AREA 4
SPLINES
2.0091 TO 2.0096 IN.
(51.032 TO 51.043 mm)
COPPER PLATING
IN GRIND RELIEF
AREA IS OPTIONAL
NOTES
1. Copper plate indicated area 0.0003 to 0.0007 inch (0.008 to 0.017 mm) thick.
2. Accomplish embrittlement relief within one hour after plating. Temperature to be 260°F (127°C) for
four to five hours.
3. Black oxide coating is not allowed in plated area.
4 The outside diameter of the triplex bearing journal should be 3.1501 to 3.1503 inches
(80.013 to 80.017 mm) before the copper plating and 3.1511 to 3.1515 inches (80.038 to 80.048 mm)
after the copper plating.
412_CRO_63_0081_c02
Figure 63-92. Main Input Quill Pinion — Copper Plating Area
63-00-00
BHT-412-CR&O-3
1
AREA A
(FLANGE)
NOTE
1 Apply brush cadmium plate to Area A of sleeve where

original cadmium plate has been removed.
Refer to BHT-ALL-SPM for cadmium plating procedures.
INPUT SLEEVE
(214-040-097-003)
A
NOTES
1. Apply one coat of primer (C-204) except as noted at note 2.

A Refer to BHT-ALL-SPM for procedure to apply primer.
2 Do not prime indicated areas.
CAP ASSEMBLY
(209-040-142-001) 2 (ALL HOLES AND SPOT FACES)
2 2
2 (DRAIN BOSS AND HOLE)
SECTION A-A
412_CRO_63_0093a
Figure 63-93. Main Input Quill Processing Requirements (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
CURVIC COUPLING ADAPTER

(212-040-190-101)
AREA B
NOTE
1 Apply brush cadmium plate to Area B of sleeve where

AREA B
SECTION B-B
NOTE
Touch-up areas where chemical film has been removed.

Use chemical film treatment for aluminum alloy. Refer to
BHT-ALL-SPM for procedure to apply chemical film.
PLATE
(212-040-187-001)
412_CRO_63_0093b
63-00-00
BHT-412-CR&O-3
3. Assemble the triplex bearing (5) and the sleeve c. With a feeler gauge, measure the gap
(2) as follows: between the cap assembly (9) and the sleeve (2) at a
minimum of three approximately equally spaced
locations.
CAUTION d. Peel the shim (4) 0.001 to 0.004 inch (0.03 to

0.10 mm) less than the gap measured in step c. This
will provide a 0.001 to 0.004 inch (0.03 to 0.10 mm)
DO NOT PRESS ON THE BEARING pinch on the outer race of the triplex bearing.
INNER RACES DURING INSTALLATION
OR DAMAGE TO THE BEARING WILL e. Remove the cap assembly (9) from the
OCCUR. sleeve (2).
4. Install the pinion (1) in the triplex bearing (5) as

NOTE follows:
A dull burr mark approximately 0.125 inch
(3.18 mm) in diameter is placed on an end NOTE
face of each bearing inner race member by
Index marks are etched on the inner races
the bearing manufacturer to mark the high
of inboard and outboard members of the
point of the race runout. Bearings shall be
triplex bearing (5) and on the pinion (1) to
installed with the inner races of the three
provide a means of detecting inner race
member bearings positioned with the dull
slippage on the pinion. Quill assemblies are
burr marks aligned. Before installing the
inspected for bearing slippage following
bearings, with a non-permanent marker,
bench acceptance testing during original
mark an axial line across the inner diameter
manufacture and during 3100 hour special
of each member bearing aligned with the
inspections of the helicopter.
dull burr mark. The marks shall be used to
align the bearing inner races when the a. If the pinion (1) is being replaced and the
pinion (1) is installed. replacement part has index marks applied, proceed to
step b. If the part has not been index marked, proceed
a. Align the V-marks on the outer races of the as follows:
triplex bearing (5). Support the sleeve (2) and press
the bearings into the sleeve with the apex of the (1) With a vibrating stylus, etch a line across
V-mark pointing as shown in Figure 63-81. the pinion outer diameter, as shown in Figure 63-94.
(2) Remove all raised material at the edges

NOTE of the etched line with a fine India stone (C-464).
Make sure the bearing outer races are fully
b. If the bearing (5) is being replaced and
seated against the shoulder in the sleeve. replacement the part has index markings, proceed
directly to step c. If the part has no etch index marks
b. With the sleeve (2) and the triplex bearing (5) on the faces of the end bearing inner races, proceed
resting on the inboard end of the sleeve, put the cap as follows:
assembly (9) in position with the cap lip resting on the
face of the triplex bearing outer race. Apply 30 to (1) Mask the inboard member bearing and
50 pounds (133.44 to 222.4 N) axial force uniformly to sleeve (2) with a suitable tape so that only the inboard
the end of the cap until fully seated against the outer face and bore of the bearing are exposed
race of the triplex bearing. (Figure 63-94).
63-00-00
BHT-412-CR&O-3
ETCHED AXIAL (-) LINE

ACROSS THIS SURFACE
ENSURE NO RAISED MATERIAL

REMAINS AT THIS CORNER
PINION
0.260 IN.
(6.60 mm) BEARING CAGE
MINIMUM ETCHED LINE
BEARING INNER RACE
SLEEVE
TRIPLEX BEARING
412_CRO_63_0094
Figure 63-94. Pinion and Triplex Bearing Etching
63-00-00
BHT-412-CR&O-3
NOTE
CAUTION
The replacement pinion (1) or triplex
bearing (5) may have etched index marks
DO NOT DAMAGE BEARING CAGE only at the inboard ends at this point.
WHILE PERFORMING THE FOLLOWING
STEP (2) AND STEP (3). f. Align the inner races of the three member
bearings of the triplex bearing (5) so that the axial lines
marked in step 3 are in alignment.
NOTE
The location of the etched line relative to
the bearing dull burr marks is not important.
CAUTION
(2) With a vibrating stylus, etch a short radial
line on the face of the bearing inner race, as shown in
Figure 63-94. DO NOT MISALIGN BEARING BURR
MARKS IN AN EFFORT TO IMPROVE
(3) With a fine India stone (C-464), remove ALIGNMENT OF INBOARD AND
all raised material at the edges of the etched line flush OUTBOARD INDEX MARKS. EXACT
with the surrounding surface. ALIGNMENT OF INDEX MARKS IS NOT
N E C E S S A RY. A N Y M I S A L I G N M E N T
AFTER ASSEMBLY WILL BE RECORDED
CAUTION IN STEP K AND STEP L
g. Put the pinion (1) in position so that the index

REMOVE ALL DEBRIS FROM MASKING mark on the pinion shoulder is aligned with the index
MATERIAL AND SURROUNDING AREAS mark on the face of the bearing inner race as closely
BEFORE REMOVING MASKING as possible. For previously used pinions and bearings
M AT E R I A L . D E B R I S C A N D A M A G E it is also necessary to align the index mark on the
BEARING. pinion spline with the corresponding mark on the face
of the outboard member bearing as closely as
(4) Remove all masking material from the possible.
triplex bearing (5, Figure 63-81) and the sleeve (2).
h. Press the pinion through the bearing until

pinion shoulder is firmly seated against the inner race
CAUTION of the inboard bearing.
DO NOT EXCEED THE MAXIMUM i. Apply and hold 18 to 20 tons (160,136 to

ALLOWABLE TEMPERATURE WHEN 177,928 N) of seating pressure on the pinion until the
YOU HEAT A PART OR DAMAGE TO THE assembly has cooled to room temperature.
PART MAY OCCUR.
j. If an index mark exists on the outboard
c. Heat the sleeve (2) with the triplex bearing (5)
(splined) end of the pinion (1) or the outboard face of
uniformly to 230 to 250°F (110 to 121°C).
the bearing inner race, proceed to step k. If an index
mark does not exist, proceed as follows:
d. Wipe the bore of the triplex bearing (5) and
the mating journal of the pinion (1) free of oil.
(1) With suitable tape, mask the outboard
e. Put the sleeve (2) with the triplex bearing (5) member of the triplex bearing (5) and the sleeve (2) so
in a suitable press so that the assembly is uniformly that only the face of the bearing inner race and the
supported on the inner race of the outboard bearing. splined end of the pinion are exposed.
63-00-00
BHT-412-CR&O-3
CAUTION CAUTION
DO NOT DAMAGE BEARING CAGE IF BEARINGS ARE REMOVED FROM

WHILE PERFORMING FOLLOWING PINION FOR ANY REASON AFTER
STEP (2) THROUGH STEP (4). INSTALLATION, STRIP AND REAPPLY
COPPER P L AT E TO PINION
(PARAGRAPH 63-95).
(2) If the triplex bearing (5) is not marked but
the pinion (1) has an etched mark, mark the face of the 5. Lubricate the new packing (3) with approved
bearing inner race with a short radial line aligned with transmission oil and install in the groove of the
the pinion mark, with a vibrating stylus. Mark a line, as sleeve (2).
shown in Figure 63-94, for inboard end marking.
6. Lubricate the new packings (18 and 19) and the
mating grooves of the seal retainer (20) with assembly
(3) If the triplex bearing (5, Figure 63-81) has fluid (C-024).
an index mark but the pinion (1) is not marked, mark
an approximately 0.19 inch (4.8 mm) long axial line on 7. Install the packings (18 and 19) on the seal
the pinion diameter, outboard of the pinion journal. retainer (20).
With a vibrating stylus, etch mark adjacent to the
bearing aligned with the index mark on the bearing. 8. Align the slot of the seal retainer (20) with the
alignment pin (12) in the cap assembly (9) and install
(4) If both pinion (1) and triplex bearing (5) the seal retainer in the cap assembly.
are not marked, etch index marks on both parts in
9. Install the retaining ring (21).
accordance with the previous step (2) and step (3).
CAUTION
CAUTION
DO NOT TOUCH SEALING FACES OF

REMOVE ALL DEBRIS FROM MASKING CARBON RING (16) OR MAGNETIC RING
MATERIAL AND FROM SURROUNDING (17) WITH BARE FINGERS. HANDLE THE
AREAS BEFORE REMOVING MASKING SEAL COMPONENTS WITH CLEAN
M AT E R I A L . D E B R I S C A N D A M A G E COTTON GLOVES.
BEARING.
k. Measure and record in the quill maintenance CAUTION

record the amount and direction that the outboard
bearing index mark is offset from the index mark on
KEEP SEAL IN ORIGINAL PACKAGING
the pinion shank. Make an evaluation while viewing UNTIL READY FOR INSTALLATION.
the bearing from the splined end of the pinion. WHEN SEAL PACKAGE IS OPENED,
S E PA R AT E S E A L B Y P U L L I N G
l. Measure and record in the quill maintenance MAGNETIC RING AND CARBON RING
STRAIGHT AWAY FROM EACH OTHER.
record the amount and direction that the inboard
SLIDING BETWEEN SEAL HALVES MAY
bearing index mark is offset from the index mark on DAMAGE MATING SURFACES. DO NOT
the pinion outer diameter at the bearing shoulder. PLACE MAGNETIC RING OR CARBON
Make an evaluation while viewing the bearing from the R I N G I N A R E A W H E R E M E TA L
gear head end of the pinion. PA R T I C L E S M AY B E AT T R A C T E D .
63-00-00
BHT-412-CR&O-3
INSTALL SEAL BY HAND PRESSING 16. Carefully lower the pinion (1) with the sleeve (2)
ONLY. PRIOR TO INSTALLATION OF and the triplex bearing (5) onto the curvic coupling
S E A L , L U B R I C AT E PA C K I N G S A N D adapter (22) while engaging the pinion and adapter
MATING DIAMETERS SPARINGLY WITH splines.
ASSEMBLY FLUID (C-024). DO NOT
ALLOW ASSEMBLY FLUID (C-024) TO 17. Align the screw holes of the cap assembly (9)
CONTACT CARBON SEALING SURFACE. with the threaded holes in the flange of the sleeve (2)
and install the washers (10) and the screws (11). Do
NOTE not tighten the screws at this time.
The magnetic seal is made of two parts, the 18. Uniformly force the cap assembly (9) against the
carbon ring (16) and the magnetic ring (17). triplex bearing (5) outer race by hand and while
holding in position, use a feeler gauge to check for
10. Lubricate a new packing (15) and the mating 0.001 to 0.004 inch (0.03 to 0.10 mm) clearance
groove of the carbon ring (16) with assembly fluid between the cap assembly and the shims (4).
(C-024) and install the packing in the carbon ring.
11. Install the magnetic ring (17) into the seal retainer
(20). Make sure the part number on the magnetic ring CAUTION
points to the flange of the seal retainer and the ring
points to the bearing.
DO NOT ALLOW CURVIC COUPLING
ADAPTER (22) TO SLIP OUTWARD ON
12. Put the curvic coupling adapter (22), flanged end PINION (1) WHEN QUILL ASSEMBLY IS
down, on a clean surface and apply a light coating of T U R N E D O V E R . S L I P PA G E O F
assembly fluid (C-024) to the outer diameter at the ADAPTER MAY SEPARATE MAGNETIC
uppermost end. RING (17) FROM CARBON RING (16).
SHOULD ADAPTER SLIP OUTWARD,
13. Install the cap assembly (9) with the magnetic REMOVE ADAPTER, SEAL, CAP
ring (17), seal retainer (20), new packing (19), and SUBASSEMBLY FROM PINION, SLEEVE,
retaining ring (21) over the curvic coupling adapter BEARING SUBASSEMBLY AND PLACE
(22). THE ADAPTER, SEAL, CAP
SUBASSEMBLY ON WORK BENCH WITH
ADAPTER FLANGED END DOWN, THEN
14. Carefully install the carbon ring (16) with the new
REPEAT STEP 14 THROUGH STEP 18.
packing (15) on the upper end of the curvic coupling
adapter (22) with the carbon seal facing down. Slide
the seal down on the adapter so that the upper surface NOTE
of the ring is 0.30 to 0.35 inch (7.6 to 8.9 mm) from the Should removal of the adapter, seal, or cap
upper end of the adapter. subassembly from the pinion be required,
the carbon ring (16) must be returned to the
starting position of step 14 before step 15
NOTE
through step 18 are repeated.
Allow the previously assembled curvic
coupling adapter (22) with the cap 19. Hold the curvic coupling adapter (22) against the
assembly (9) and the seal components to triplex bearing (5) in the sleeve (2) and turn the quill
remain on the work bench with the flanged over so that the inboard end of the pinion (1) is down.
end down through the assembly (step 18). Provide a suitable support for the assembly to stabilize
This will prevent the carbon ring (16) from it in this position.
sliding off the adapter during the assembly
of the quill. 20. Tighten the screws (11) and secure with lockwire
(C-405) to anchor the holes in the cap assembly (9).
15. Place a new shim (4) that was sized in step 3 Make sure the screws do not protrude beyond the
substep d on the flange face of the cap assembly (9). mounting face of the sleeve (2). If the screws protrude,
63-00-00
BHT-412-CR&O-3
a thin steel washer may be added under the head of 32. Install the union (7) in the cap assembly (9).
the screw. Install the cap (6) on the union.
21. Install the nut (23) on the pinion (1) and hand 33. Lubricate a new packing (14) with approved
tighten the nut. transmission oil and install the packing on the plug
(13). Install the plug in the cap assembly (9).
22. Install the wrench set (T101588) onto the curvic
coupling adapter (22) with the splined extension 34. Tighten the plug (13) and secure with lockwire
outboard. (C-405) to the anchor hole of the cap assembly (9).
23. Install the 3/4 (0.750)-inch (19.05-mm) drive,

63-97. MAIN INPUT QUILL (212-040-263-101)
12.0 inches (305 mm) extension bar (L-122) into the
wrench set (T101588).
24. Make sure the square drive of the extension bar
(L-122) engages with the square drive of the
pinion (1). SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
CAUTION
T101588 Wrench Set
T101912 Plate Set

Q U I L L A S S E M B LY M U S T B E W E L L
PADDED AND SUITABLY SUPPORTED
ON WORK BENCH DURING FOLLOWING 1. Remove the retaining ring (25, Figure 63-95) and
TORQUING OPERATIONS TO AVOID the plate (24).
DAMAGE TO QUILL.
2. Remove and discard the packing (23).
25. Install the torque wrench with the 3/4 (0.750)-inch
(19.05-mm) square drive into the 3/4 (0.750)-inch
(19.05-mm) square drive of the wrench set (T101588) 3. Remove the lock spring (22).
and torque the nut (23) 350 to 400 foot-pounds (474 to
542 Nm). 4. Install the wrench set (T101588) on the quill, as
26. Remove the extension bar (L-122) and the
wrench set (T101588). 5. Secure a 3/4 (0.750)-inch (19.05-mm) square bar
vertically in a vise and put the quill on the bar with the
27. Install the lock spring (24). Make sure the lock pinion engaged on the bar.
spring is fully seated in the groove in the splines of the
pinion (1). 6. Loosen the nut (21, Figure 63-95).
28. Lubricate the new packing (25) and the mating

surface of the plate (26) with approved transmission NOTE
oil.
The wear sleeve (19) is bonded to the
adapter (20). Do not attempt to remove the
29. Install the packing (25) on the plate (26). wear sleeve unless the wear or damage
limits are exceeded. Refer to paragraph
30. Install the plate (26) and secure with the retaining 63-100 for inspection and paragraph
ring (27). 63-101 for repair.
31. Lubricate a new packing (8) with approved 7. Remove the wrench set (T101588) and the
transmission oil and install on the union (7). nut (21).
63-00-00
BHT-412-CR&O-3
11 SEAL LIP
12 DIRECTION
10
19 20
9 B
8
7
B
6
3
SECTION A-A
4 5
14
2 15
25
1
24
23
22
21
20
19
18 0.055 TO 0.085 IN.
A (1.40 TO 2.16 mm)
17
16
13
SECTION B-B
1. Pinion 10. Washer 19. Wear sleeve

2. Sleeve 11. Screw 20. Adapter
3. Packing 12. Seal 21. Nut
4. Shim 13. Pin 22. Lock spring
5. Triplex bearing 14. Plug 23. Packing
6. Dust cap 15. Packing 24. Plate
7. Union 16. Packing 25. Retaining ring
8. Packing 17. Sleeve
LOCKWIRE (C-405) 9. Cap assembly 18. Retaining ring
412_CRO_63_0088_c01
Figure 63-95. Main Input Quill Assembly (212-040-263-101)
63-00-00
BHT-412-CR&O-3
8. Remove the adapter (20) from the pinion (1). 63-99. MAIN INPUT QUILL — CLEANING
9. Remove the six screws (11) and six washers (10) 1. Clean the main input quill components with the
from the cap assembly (9). materials and the procedures provided in paragraph
63-93.
10. Remove the cap assembly (9) from the sleeve
(2). Discard the shim (4). 63-100. MAIN INPUT QUILL — INSPECTION
1. Inspect the main input quill components with the

11. Install the plate set (T101912) (1, Figure 63-83)
procedures and the limits provided in the paragraph
on the pinion (1, Figure 63-95) between the gear and
63-94, except for the following:
the sleeve (2).
a. Inspect the wear sleeve (19, Figure 63-95) on

12. Support the bearing inner race and press the
the adapter (20) for roughness or seal grooving using
pinion (1) out of the triplex bearings (5).
a probe with a point of approximately 0.020 inch
(0.51 mm) radius.
CAUTION b. Inspect the sleeve (17) for obvious damage

and excessive wear. Pay particular attention to the
packing groove.
RETAIN BEARINGS AS A MATCHED
SET. 2. Inspect the sleeve (17) by fluorescent penetrant
method (BHT-ALL-SPM).
bearings (5) out of the sleeve by pressing on the outer 63-101. MAIN INPUT QUILL — REPAIR
race. Keep the bearings together as a matched set.
14. Remove the packing (3) from the sleeve (2). MATERIALS REQUIRED
15. Remove the dust cap (6) with the union (7) and
NUMBER NOMENCLATURE
the packing (8) from the cap assembly (9). Discard the
packing. C-317 Adhesive
16. Cut and remove the lockwire. C-327 Adhesion Promoter
C-345 Grease Removing

17. Remove the plug (14) with the packing (15) from Primer
C-407 Abrasive Pad
18. Remove the retaining ring (18) and the
C-436 Paint Remover
sleeve (17).
C-486 Cheesecloth
19. Remove the packing (16) from the sleeve (17).
1. Repair the main input quill components with the
materials and the procedures provided in paragraph
20. Remove the seal (12) from the cap assembly (9). 63-94, except the parts in the steps that follow:
Discard the seal.
2. Replace the wear sleeve (19, Figure 63-95) if it is
21. Remove the pin (13) when damaged. worn or rough as follows:
63-00-00
BHT-412-CR&O-3
a. Use an end mill or hand-held grinder to cut a

groove almost through the old wear sleeve (19). Avoid WARNING
cutting through the wear sleeve and damaging the
adapter (20). Strike the wear sleeve with a rubber
mallet to break the uncut portion and remove the THE SOLVENT IN PRIMER IS TOXIC.
sleeve from the adapter. USE PRIMER IN WELL VENTILATED
AREA.
b. Clean the adhesive from the adapter (20) with
a plastic scraper and abrasive pad (C-407) or use d. Stir the primer thoroughly in its container and
apply grease removing primer (C-345) to the
paint remover (C-436). Inspect the adapter for
unmasked portion of the adapter (20) only; this step is
damage that may have occurred during the removal of
not applicable to the wear sleeve. Scrub primer into
the wear sleeve. (19).
the surface of the outer race with abrasive cloth or
paper (C-406). Use additional primer as required to
ensure that the adapter is clean.
CAUTION
e. Allow the grease removing primer (C-345) to
dry to a white powder. Remove the dry powder with a
P R E C A U T I O N S M U S T B E TA K E N clean dry cheesecloth (C-486). Wear clean white
gloves while handling parts. If the next step is not to be
DURING ACCOMPLISHMENT OF THE
accomplished immediately, wrap the adapter (20) with
FOLLOWING STEPS TO KEEP WEAR
clean Kraft paper.
SLEEVE AND ADAPTER CLEAN. WEAR
CLEAN WHITE GLOVES WHEN
H A N D L I N G PA R T S A N D C H A N G E
GLOVES WHEN THEY BECOME SOILED. WARNING
COVER WORK BENCH WITH CLEAN
KRAFT PAPER. AVOID CONTACT WITH
ALL MOLD RELEASE AGENTS SUCH AS THE ADHESION PROMOTER (C-327)
SILICONE, WAX, OIL, GREASE, ETC. USED IN FOLLOWING STEP IS HIGHLY
THE WORK AREA WHERE BONDING IS VOLATILE. USE IT IN WELL VENTILATED
AREA. KEEP PROMOTER IN
DONE MUST BE MAINTAINED AT 65° TO
NON-ABSORPTIVE CONTAINER AND
82°F (18° TO 28°C) WITH RELATIVE
KEEP LID TIGHTLY CLOSED WHEN NOT
HUMIDITY BELOW 75%. IT MUST BE
IN USE. EXPOSURE TO ATMOSPHERE
DUST FREE TO THE EXTENT THAT WILL CAUSE GRADUAL
B O N D I N G O P E R AT I O N S A R E N O T DECOMPOSITION, EXCEPT WHEN
AFFECTED. APPLIED TO PARTS AND ALLOWED TO
DRY. SEDIMENT OR BROWN RESIDUE
BONDING STEPS MUST BE IN BOTTOM OF CONTAINER INDICATES
A C C O M P L I S H E D W I T H O U T D E L AY DECOMPOSITION OF PROMOTER TO
BETWEEN STEPS. THE MAXIMUM TIME E X T E N T T H AT I T S H O U L D B E
INTERVAL BETWEEN SANDBLASTING DISCARDED. THE PH RANGE OF THE
AND THE NEXT STEP IS 4 HOURS. PROMOTER MUST BE 7 TO 8.
f. Apply adhesion promoter (C-327) to the

c. Mask the outer diameter of the new wear unmasked portion of the wear sleeve (19) and adapter
sleeve (19). Mask the adapter (20) all over except the (20) with a brush. Use a pure (hog bristle) brush with
surface that mates with the wear sleeve and the an unpainted handle. Apply only enough adhesion
adjacent 0.062-inch (1.57-mm) radius. Sandblast the promoter to wet the surfaces. Allow the promoter to
unmasked surfaces of these parts with 60 grit garnet dry for a minimum of 30 minutes at room temperature
at 5 to 10 PSI (34.5 to 69 kPa) and remove the or for 15 minutes at 150 to 160°F (66 to 71°C). If the
residue. Wrap the parts in clean Kraft paper after next step is not to be accomplished immediately, wrap
sandblasting. the parts with clean Kraft paper.
63-00-00
BHT-412-CR&O-3
g. Mix the adhesive (C-317) (33 parts B to

100 parts A). The pot life of mixed adhesive is 30 to
CAUTION
50 minutes. Coat the inside diameter of the wear
sleeve (19) and the mating surface on the adapter with
adhesive. Press the wear sleeve on the adapter with
the radiused outside diameter of the wear sleeve
UNTIL READY FOR INSTALLATION.
positioned at the outer edge of the adapter
(Figure 63-95, Detail B). Clean off excess adhesive, 2. Lubricate the packings and the parts (except the
leaving chamfer between the wear sleeve and the wear sleeve (19, Figure 63-95) and the seal (12)) with
adapter filled with adhesive. Cure at room temperature the same oil used in the transmission and allow to
for 24 hours. After bonding and prior to the assembly drain.
of the quill, make sure that all traces of adhesive are
cleaned from the area of the wear sleeve that contacts 3. Apply a film of sealant (C-328) to the outer
the seal (12). surface of the new seal (12). Press the seal into the
sleeve (17) with the seal lip facing inboard, as shown
3. Replace the pin (13) if damaged (Figure 63-95, in Figure 63-95. Remove the excess sealant.
Detail A).
4. Install the new packing (16) on the sleeve (17).
Align the slot in the sleeve with the pin (13). Install the
63-102. MAIN INPUT QUILL — ASSEMBLY sleeve in the cap assembly (9) by hand pressing.
Install the retaining ring (18).
SPECIAL TOOLS REQUIRED 5. Assemble the triplex bearing (5) and the sleeve
(2) as follows:
NUMBER NOMENCLATURE
T101588 Wrench Set CAUTION
DO NOT PRESS ON THE BEARING

MATERIALS REQUIRED INNER RACES DURING THE
INSTALLATION OR DAMAGE TO THE
Refer to BHT-ALL-SPM for specifications. BEARING WILL OCCUR.
NUMBER NOMENCLATURE NOTE

C-028 Dry Film Lubricant A dull burr mark approximately 0.125 inch
(3.18 mm) in diameter is placed on an end
C-328 Sealant face of each bearing inner race member by
the bearing manufacturer to mark the high
C-405 Lockwire point of the race runout. Bearings shall be
installed with the inner races of the three
member bearings positioned with the dull
1. Make sure that all the parts have been cleaned burr marks aligned. Before installing
(paragraph 63-99). bearings, with a non-permanent marker,
mark an axial line across the inner diameter
of each member bearing aligned with the
dull burr mark. The marks shall be used to
CAUTION align the bearing inner races when the
pinion (1) is installed.
DO NOT HANDLE UNOILED PARTS WITH a. Align the V-marks on the outer races of the
BARE HANDS. triplex bearing (5). Support the sleeve (2) and press
63-00-00
BHT-412-CR&O-3
the bearings into the sleeve with the apex of the 9. Put the new shim (4) and the cap assembly (9) on
V-mark pointing as shown in Figure 63-95. the sleeve (2).
NOTE 10. Align the screw holes and install the washers (10)
and the screws (11). Do not tighten the screws at this
Make sure the bearing outer races are fully time.
seated against the shoulder in the sleeve.
11. Make sure the screws (11) do not protrude
b. With the sleeve (2) and the triplex bearing (5)
beyond the mounting face of the sleeve (2). If the
resting on the inboard end of the sleeve, put the cap
screws protrude, a thin steel washer may be added
assembly (9) in position with the cap lip resting on the
under the head of the screw.
face of the triplex bearing outer race. Apply 30 to 50
pounds (133.44 to 222.4 N) axial force uniformly to the
end of the cap until fully seated against the outer race 12. With a feeler gauge, check for a 0.001 to
of the triplex bearing. 0.004 inch (0.03 to 0.10 mm) clearance between the
cap assembly (9) and the shim (4). Tighten the screws
c. With a feeler gauge, measure the gap (11) and secure with lockwire (C-405) to the holes in
between the cap assembly (9) and the sleeve (2) at a the cap assembly (9).
minimum of three approximately equally spaced
locations. 13. Apply dry film lubricant (C-028) to the outside
diameter of the wear sleeve (19). Exercise caution to
d. Peel the shim (4) 0.001 to 0.004 inch (0.03 to avoid coating other parts.
0.10 mm) less than the gap measured in step c. This
will provide a 0.001 to 0.004 inch (0.03 to 0.10 mm) 14. Install the nut (21) on the pinion (1) and hand
pinch on the outer race of the triplex bearing. tighten the nut.
e. Remove the cap assembly (9) from the 15. Install the wrench set (T101588) onto the
sleeve (2). adapter (20).
6. Align the inner races of the three bearings so that 16. Install the 3/4 (0.750)-inch (19.05-mm) square
the non-permanent marker line shows that three dull drive and 12.0 inches (305 mm) extension bar (L-122)
burr marks of the bearings are aligned. Put the pinion into the wrench set (T101588).
(1) in position so that the vibro-etched index marks on
the pinion shaft are aligned with the vibro-etched index
17. Make sure the square drive of the extension bar
marks on the bearing inner races.
(L-122) engages the pinion (1).
NOTE
If the bearings or the pinion were replaced, CAUTION
it will be necessary to vibro-etch index
marks (lines) on the new part the same as
on the part replaced, so that the bearings Q U I L L A S S E M B LY M U S T B E W E L L
may be checked for spinning after the test PADDED AND SUITABLY SUPPORTED
run. If the bearings are replaced, be sure ON WORK BENCH DURING FOLLOWING
that the dull burr marks on the inner races TORQUING OPERATIONS TO AVOID
are aligned when the index marks are DAMAGE TO QUILL.
vibro-etched on the races.
18. Install the torque wrench with the 3/4 (0.750)-inch
7. Install the pinion (1) on the triplex bearing (5) in (19.05-mm) square drive into the 3/4 (0.750)-inch
accordance with paragraph 63-96. (19.05-mm) square drive of the wrench set (T101588)
and torque 350 to 400 foot-pounds (475 to 542 Nm).
8. Lubricate a new packing (3, Figure 63-95) with
the same oil used in the transmission and install on the 19. Remove the extension bar (L-122) and the
sleeve (2). wrench set (T101588).
63-00-00
BHT-412-CR&O-3
20. Install the lock spring (22). Make sure the lock 2. Remove and discard the packing (24).
spring is fully seated in the groove in the splines of the
pinion (1).
3. Remove the retaining ring (23) and the
lockwasher (22).
21. Lubricate the new packing (23) and the mating
surface with the same oil used in the transmission
prior to assembly. 4. Install the holding fixture (412-240-002-101) on
the quill, as shown in Figure 63-97.
22. Install a new packing (23) on the plate (24).
5. Secure a 3/4 (0.750)-inch (19.05-mm) square bar
23. Install the plate (24) and secure with the retaining vertically in a vise and put the quill on the bar with the
ring (25). pinion engaged on the bar.
24. Lubricate a new packing (8) with the same oil 6. Loosen the nut (21, Figure 63-96) with the
used in the transmission and install on the union (7). wrench set (412-240-001-101).
25. Install the union (7) in the cap assembly (9). 7. Remove the holding fixture (412-240-002-101),
Install the cap (6) on the union. wrench set (412-240-001-101), and nut (21).
26. Lubricate a new packing (15) with the same oil 8. Remove the retaining ring (16) and remove the
used in the transmission and install the new packing seal retainer (15).
on the plug (14). Install the plug in the cap assembly
(9).
9. Remove the adapter (20) from the pinion (1).
27. Tighten the plug (14) and secure with lockwire
(C-405) to the anchor hole of the cap assembly (9). 10. Remove the screws (18) and the washers (17).
63-103.MAIN INPUT QUILL (412-040-263-ALL) 11. Remove the cap assembly (8) from the
(S/N 36020 AND SUBSEQUENT TO sleeve (3).
INCLUDE S/N 46400 THROUGH 46499
AND HELICOPTERS MODIFIED BY 12. Remove the shim (6), spacer (7), and packing (5).
412-570-001-103 OR POST Discard the packing and mark the shim.
BHT-412-SI-74 (412SP TO 412HP
UPGRADE))
13. Install the bearing removal tool set
(412-240-009-101) (1, Figure 63-98) on the pinion (1,
Figure 63-96) between the gear and the sleeve (3).
SPECIAL TOOLS REQUIRED 14. Support the bearing inner race and press the
pinion (1) out of triplex bearings (4).
NUMBER NOMENCLATURE
412-240-009-101 Bearing Removal Tool CAUTION

Set
412-240-001-101 Wrench Set RETAIN BEARINGS AS A MATCHED

SET.
412-240-002-101 Holding Fixture
1. Remove the retaining ring (26, Figure 63-96) and bearings (4) out of the sleeve by pressing on the outer
the cover plate (25). race. Keep the bearings together as a matched set.
63-00-00
BHT-412-CR&O-3
26
25
24
23
22
21
16
20
18 15
17 19 14
13
12
11
7 1
10
28
9
8
6
27
5
1
4
1. Pinion 11. Magnetic seal 21. Nut

3 2. Packing 12. Packing 22. Lockwasher
2 3. Sleeve 13. Packing 23. Retaining ring
4. Triplex bearing 14. Packing 24. Packing
5. Packing 15. Seal retainer 25. Plate
6. Shim 16. Retaining ring 26. Retaining ring
7. Spacer 17. Washer 27. Union
8. Cap assembly 18. Screw 28. Packing
LOCKWIRE (C-405) 9. Packing 19. Pin
10. Plug 20. Adapter
NOTE
1 Used on helicopters S/N 36020 through 36034 only.
412_CRO_63_0089_c01
Figure 63-96. Main Input Quill Assembly (412-040-263-101)
63-00-00
BHT-412-CR&O-3
2 3
1
8 6
1. Seal retainer
2. Curvic coupling adapter, main driveshaft
3. Holding fixture (412-240-002-101)
4. Wrench set (412-240-001-101)
5. Nut
6. Seal
7. Input quill cap assembly
8. Input quill pinion
412_CRO_63_0090_c01
Figure 63-97. Wrench Set (412-240-001-101) — Application
63-00-00
BHT-412-CR&O-3
Figure 63-98. Bearing Removal Tool Set (412-240-009-101) — Application
63-00-00
BHT-412-CR&O-3
16. Remove the packing (2) from the pinion (1). All parts except bearings may be cleaned with solvent
Discard the packing. (C-334) by vapor degreasing.

CAUTION
18. Remove the plug (10) with the packing (9) from
WHILE DRYING.
CAUTION 2. Dry the parts with a clean cloth (C-516) or dry,
MAGNETIC SEAL IS MADE UP OF TWO

PARTS, THE MAGNETIC RING AND THE
CARBON RING. KEEP THEM TOGETHER CAUTION
AS A MATCHED SET.

WITH BARE HANDS.
CAUTION
NOTE
DO NOT HANDLE THE PARTS WITH Parts treated per the following step may be
BARE HANDS. left covered in indoor storage for
19. Remove the magnetic seal (11) from the seal
retainer (15).
3. Coat the bearings with corrosion preventive
20. Remove and discard the packings (12, 13, compound (C-105) immediately after cleaning
and 14). (BHT-ALL-SPM).
21. Remove the union (27) and the packing (28) from 63-106. MAIN INPUT QUILL — INSPECTION
NOTE
63-105. MAIN INPUT QUILL — CLEANING
Wear limits are provided to show the
MATERIALS REQUIRED
intended that all dimensions be checked as
a prescribed overhaul procedure; however,
NUMBER NOMENCLATURE physical damage must be checked
dimensionally.
Compound 1. Inspect the pinion (1, Figure 63-96) in
2. Inspect the sleeve (3, Figure 63-96) in
C-334 Solvent accordance with Figure 63-100.
C-516 Clean Cloth

3. Inspect the triplex bearing (4, Figure 63-96) for
spalling, scoring, pitting, brinelling, corrosion damage,
1. Clean all the quill parts with drycleaning solvent cracked or broken retainers, and roughness when
(C-304). Use a soft bristle brush to dislodge deposits. rotated. Any defect is cause for rejection.
63-00-00
BHT-412-CR&O-3
0.1200 IN. (3.048 mm)

5 A DIAMETER PINS
3.1781 TO 3.1822 IN.

(80.724 TO 80.828 mm)
SEE DETAIL B
PINION
(412-040-700-101) VIEW A
Main input quill teeth wear pattern showing a

non-uniform wear pattern with a band of heavy
wear in the flank. This is the maximum
acceptable for this condition.
DETAIL B
A C B
INSPECTION - ROLLER RACE

412-040-700-101 PINION
NOTES
1. Inspect pinion teeth for chipping, dents, spalling, scuffing, and pitting. Pitting of any magnitude resulting
from surface fatigue during operation is not acceptable on teeth of pinion. This may appear as only a fine line
of pin holes near pitch diameter and be detectable only with a side light source and a probe with a point of
approximately 0.001 inch (0.03 mm) radius. Minor pitting resulting from corrosion is acceptable within
following limits
a. No more than 0.001 inch (0.03 mm) deep and no more than 0.040 inch (1.02 mm) wide or 0.080 inch
(2.03 mm) long.
b. No more than 0.002 inch (0.05 mm) deep and no more than 0.040 inch (1.02 mm) wide or 0.100 inch
(2.54 mm) long and located on the outer (i.e. adjacent to the heel), half of the face of the tooth and above
the pitch line; or located outside of the wear pattern and outside of the root radius.
c. Surface roughness detectable by drawing probe along tooth in profile direction is cause for rejection if
pitting occurred on mating member.
d. Grinding scratches. Any scratches around which pitting or other damage occurs are not acceptable.
e. Nicks, cuts, or dents caused by handling or by foreign material going through mesh during operation are
acceptable provided they are no more than 0.003 inch (0.08 mm) deep and are no more than
0.020 inch (0.51 mm) across in direction, and cannot be felt with a probe having end radius
0.020 inch (0.51 mm).
412_CRO_63_0092a
Figure 63-99. Main Input Quill Pinion — Damage Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
2. Inspect wear pattern on teeth in accordance with Detail B for maximum acceptable non-uniform wear pattern.
3. Inspect front of pinion that contacts roller bearing inside transmission for mechanical and corrosion damage.
Damage that can be detected visually is not acceptable.
4. If necessary, check pinion spline wear limits as shown in View A.
5 Measure the size of the roller race at three locations as follows:
Instrument must be capable of reliably measuring to four decimal place accuracy.
b. Measure and record diameter at location C in area of maximum wear in roller path.
c. Calculate and record arithmetic average of diametral measurements A and B.
d. Reject the part if the difference between the calculated average of measurements A and B and
measurement C is greater than 0.0002 inch (0.005 mm).
If a measuring instrument of the required accuracy is not available, check the roller race for evidence of a
wear step using a probe having a 0.020 inch (0.51 mm) spherical radius point. A wear step at either end of
the roller path which can be felt with the probe is cause for rejection.
412_CRO_63_0092b
Figure 63-99. Main Input Quill Pinion — Damage Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
Figure 63-100. Main Input Quill Sleeve — Damage Limits
63-00-00
BHT-412-CR&O-3
4. Inspect the cap assembly (8) in accordance with c. Inspect the magnetic ring with a high intensity
Figure 63-101. light for scratches, nicks, and cracks. A cracked ring is
nonrepairable and must be replaced.
5. Inspect the seal retainer (15, Figure 63-96) in
accordance with Figure 63-102. d. Inspect the magnetic ring back face and l.D.
surface conditions as follows:
6. Inspect the adapter (20, Figure 63-96) in
(1) Porosity holes and voids under
0.020 inch (0.51 mm) in diameter are permitted if less
than 0.020 inch (0.51 mm) deep. Zones of porosity
7. Inspect the retaining rings (16 and 23, shall not extend more than 1/4 of the way across any
Figure 63-96) and Iockwasher (22) for obvious defects surface and shall not extend to within 0.070 inch
and deformation. (1.78 mm) of any edge.
8. Inspect the nut (21) for thread damage and (2) Edge chips on the inside diameter and
obvious defects. the outside diameter of the back face are permitted if
they are less than 0.0625 inch (1.588 mm) long and
0.020 inch (0.51 mm) wide.
9. Inspect the plate (25) for corrosion damage and
nicks or burrs in the seal groove that could cause
leakage. (3) No cracks are permitted.
e. Inspect the magnetic ring outside diameter

surface as follows:
CAUTION
(1) Zones of porosity shall not extend more
than 1/4 of the way across any surface and shall not
THE SEAL INSPECTION PROCEDURE extend to within 0.070 inch (1.78 mm) of any edge.
MUST BE ACCOMPLISHED UNDER
CLEAN CONDITIONS. WEAR WHITE (2) Porosity holes are permitted if less than
COTTON GLOVES WHILE HANDLING 0.020 inch (0.51 mm) in diameter and less than
SEAL. DO NOT SLIDE MAGNETIC SEAL 0.020 inch (0.51 mm) deep.
ON MAGNETIC RING. DO NOT ALLOW
C A R B O N S E A L I N G S U R FA C E O R (3) Edge chips are permitted if less than
SEALING RING ON MAGNETIC RING TO 0.0312 inch (0.793 mm) long and 0.0156 inch
CONTACT ANY OTHER OBJECT. DO (0.396 mm) wide.
NOT ALLOW ANY FOREIGN PARTICLES
TO CONTACT SEAL. (4) No cracks are permitted.
NOTE f. Inspect the magnetic ring sealing face as

follows:
The magnetic seal is made up of two parts,
the magnetic ring and the carbon ring,
(1) The sealing ring is defined as the ring
which is bonded to the seal case.
that coincides with the mating carbon sealing surface
plus an additional 0.020 inch (0.51 mm) per side
10. Inspect the magnetic seal as follows:
allowance. Chips, nicks, and scratches are not
allowed on the sealing ring.
a. Measure the gap between the magnetic ring
and the seal case with a clean, non-metallic feeler (2) The sealing ring shall be free of porosity
gauge (Figure 63-89, Figure 63-90, and Figure 63-91, holes and pits unless they are within the limits per
as applicable). Figure 63-104 and Figure 63-90, as applicable. Pits
and porosity holes must be clean and free of foreign
b. Separate the magnetic ring from the carbon matter. No two pits and/or porosity holes may be
ring by carefully pulling directly away from each other. aligned radially across the sealing ring.
63-00-00
BHT-412-CR&O-3
A
B
A
B
INPUT QUILL CAP

(412-040-264-101)
0.610 IN. (15.49 mm)

(7 PLACES)
NAS561P4-6 PIN
0.055 TO 0.085 IN.

(1.40 TO 2.16 mm)
SECTION A-A SECTION B-B
NOTES
1 In Areas C, D and E, maximum depth of pitting is 0.030 inch (0.76 mm), provided no more than 40%
of any 1.0 square inch (645 mm2) or 20% of total area of any surface is affected.
2 In Area E, inside bolt holes, maximum depth of pitting is 0.020 inch (0.51 mm), provided no more than 20%
of wall area of any hole is affected.
3 In Area C, maximum depth of pitting is 0.010 inch (0.25 mm) in area of packing.
412_CRO_63_0101
Figure 63-101. Main Input Quill Cap Assembly — Damage Limits
63-00-00
BHT-412-CR&O-3
Figure 63-102. Main Input Quill Seal Retainer — Damage Limits
63-00-00
BHT-412-CR&O-3
Figure 63-103. Input Adapter (412-040-136-101) — Damage Limits
63-00-00
BHT-412-CR&O-3
8
7
6
5
3
2
QUILL ASSEMBLY
(412-040-263)
NO. CHARACTERISTIC INSPECTION LIMIT

METHOD
1. Bevel gear roller bearing race O.D. 2.0090 inches (51.029 mm) min.
2.0096 inches (51.044 mm) max.
2. Bevel gear ball bearing journal O.D. 1

(412-040-700-101)
If replating is required O.D. 3.1501 inches (80.013 mm) min. 2

3.1505 inches (80.023 mm) max.
Bevel gear ball bearing journal O.D. 3.1505 inches (80.023 mm) min. 3
(412-040-700-103) 3.1511 inches (80.038 mm) max.
If replating is required O.D. 3.1503 inches (80.018 mm) min. 2

3.1505 inches (80.023 mm) max.
3. Bevel gear spline. Use 0.1200 inch Over pins 3.1781 inches (80.724 mm) min.
(3.048 mm) diameter pins 3.1822 inches (80.828 mm) max.
4. Input sleeve I.D. 5.9047 inches (149.979 mm) min.

5.9054 inches (149.997 mm) max.
5. Input sleeve O.D. 6.7479 inches (171.397 mm) min.

6.7500 inches (171.450 mm) max.
412_CRO_63_0104a
Figure 63-104. Main Input Quill Assembly — Wear Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
NO. CHARACTERISTIC INSPECTION LIMIT

METHOD
6. Triplex bearing I.D. 3.1491 inches (79.987 mm) min.

3.1495 inches (79.997 mm) max.
7. Triplex bearing O.D. 5.9050 inches (149.987 mm) min.

5.9055 inches (150.000 mm) max.
8. Adapter spline, use 0.1080 inch Between pins 2.8484 inches (72.349 mm) min. 4
(2.743 mm) diameter pins 2.8530 inches (72.466 mm) max.
NOTES
1 Visually inspect copper plating. No scratches or gouges in plating which penetrate plating thickness are
permitted.
2 Measurement to be made after copper plating has been removed.
3 Plating must be replaced if worn beyond the limiting dimension given or if there are scratches or gouges
which penetrate the plating thickness.
4 Pin to be flattened on one side as shown:
0.100 IN.
(2.54 mm)
0.1080 IN. DIA.

(2.743 mm)
412_CRO_63_0104b
Figure 63-104. Main Input Quill Assembly — Wear Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
(3) Porosity holes outside the sealing ring physical damage must be checked
are permitted if less than 0.020 inch (0.51 mm) in dimensionally.
diameter and less than 0.016 inch (0.41 mm) deep.
Zones of porosity shall not extend more than 1/4 of the 11. Inspect the quill assembly parts dimensionally in
way across any surface and shall not extend within accordance with Figure 63-104 and replace parts that
0.070 inch (1.78 mm) of any edge. do not conform to the inspection limits.
(4) Scratches outside the sealing ring are 12. Inspect the following parts by magnetic particle
permitted. inspection (Code M) or fluorescent penetrant
inspection (Code F), as applicable. Demagnetize parts
(5) Chipping on the inside diameter and the after magnetic particle inspection. Refer to Table 63-3
outside diameter edges is permitted provided it is and the BHT-ALL-SPM for procedure.
outside the sealing ring and is less than 0.0625 inch
(1.588 mm) long and 0.020 inch (0.51 mm) wide.
g. Inspect the seal case and carbon ring FIGURE 63-96

NOMENCLATURE CODE
assembly under a high intensity light. Minor scratches INDEX NUMBER
and nicks are permitted on the seal case. The sealing
surface of the carbon must show no visible scratches 1 Pinion M
or pits when viewed under a high intensity light.
3 Sleeve M
Damage on the edges of the carbon sealing surface is
allowable if no two damaged areas are aligned with 8 Cap Assembly F
one another in the radial direction and if the number
and size of the damaged areas are within the carbon 15 Seal Retainer F
seal edge damage limits shown in Figure 63-89 and
20 Adapter M
Figure 63-90, as applicable.
21 Nut M
h. Inspect the packing groove and remove any
foreign particles. The groove shall not have any burrs 63-107. MAIN INPUT QUILL — REPAIR
that might damage the packing.
MATERIALS REQUIRED
CAUTION
D O N O T S L I D E S E A L M AT I N G NUMBER NOMENCLATURE
SURFACES AGAINST EACH OTHER AT
ANY TIME. DO NOT TOUCH EITHER C-201 Zinc Chromate Primer
S E A L I N G S U R FA C E W I T H A N Y
FOREIGN OBJ ECT.
Paper
i. Reassemble the seal by lining up the two seal C-464 India Stone
halves to their final assembled position and carefully
allow the two halves to pull together into their
assembled position. 1. Polish out minor dents and nicks on the sleeve (3,
Figure 63-96) flange top surface with a fine India stone
(C-464). Blend repaired area into the flat surface with
NOTE a minimum radius of 0.12 inch (3.0 mm). The finished
Wear limits are provided to show required repair must be 32 RHR or better. The maximum depth,
fit between mating parts. It is not intended after repair, must not exceed 0.030 inch (0.76 mm).
that all dimensions be checked as a
prescribed overhaul procedure; however, 2. Polish out minor dents, nicks, and scratches on
parts that show evidence of wear or the exterior surfaces of the cap assembly (8) with
63-00-00
BHT-412-CR&O-3
abrasive cloth or paper (C-406). Replace a loose or c. Strip and replace the copper plating as follows
deformed pin (19). Coat the pin with unreduced zinc (BHT-ALL-SPM):
chromate primer (C-201) immediately prior to
installation. (1) Strip the copper plating on the triplex
bearing journal (Figure 63-105).
the curvic adapter (20) with a fine India stone (C-464). (2) The outside diameter of the triplex
bearing journal should be 3.1501 to 3.1503 inches
(80.013 to 80.017 mm) before the copper plating and
3.1511 to 3.1515 inches (80.038 to 80.048 mm) after
seal retainer (15) with abrasive cloth or paper (C-406). the copper plating. The copper plating shall be 0.0003
to 0.0007 inch (0.008 to 0.017 mm) thick after plating
5. Polish out minor nicks, dents, and scratches on (Figure 63-105).
plate (25) with abrasive cloth or paper (C-406).
8. Refinish the parts (except the pinion) after repair
in accordance with Figure 63-106.
NOTE
If you return the part to Bell Helicopter 63-108. MAIN INPUT QUILL — ASSEMBLY
Textron (BHT), refer to General Information
Letter (IL) GEN-04-98 for applicable
shipping information and to obtain a Return
Material Authorization (RMA) number.
6. Repair of the magnetic seal by the user is not NUMBER NOMENCLATURE

permitted. If there is evidence of damage, return the
part to the manufacturer, one of its authorized service 412-240-001-101 Wrench Set
centers, or BHT for evaluation and possible repair.
412-240-002-101 Holding Fixture
7. Repair pinion (1) as follows:
MATERIALS REQUIRED
a. Remove any raised material on noncontact
surfaces with a fine India stone (C-464). Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
b. Repair nicks, dents, and scratches on the
spline teeth by smoothing out with a fine India stone C-001 Grease
(C-464). Do not exceed limits defined in Figure 63-99.
C-011 Lubricating Oil
C-024 Assembly Fluid

CAUTION
Compound
DO NOT STRIP GEAR TEETH OR
C-405 Lockwire
SPLINES DURING COPPER STRIPPING
OPERATION. MASK GEAR TEETH AND C-516 Clean Cloth
SPLINES TO PREVENT
A C C U M U L AT I O N S O F C O P P E R
DEPOSITS DURING COPPER PLATING 1. Make sure that all the parts have been cleaned
OPERATIONS. (paragraph 63-105).
63-00-00
BHT-412-CR&O-3
SPLINES
COPPER PLATING AREA 4
COPPER PLATING
IN GRIND RELIEF
AREA IS OPTIONAL
NOTES
1. Copper plate indicated area 0.0003 to 0.0007 inch (0.008 to 0.017 mm) thick.
2. Accomplish embrittlement relief within one hour after plating. Temperature to be

260°F (127°C) for four to five hours.
3. Black oxide coating is not allowed in plated area.
4 The outside diameter of the triplex bearing journal should be 3.1501 to 3.1503 inches
(80.013 to 80.017 mm) before the copper plating and 3.1511 to 3.1515 inches
(80.038 to 80.048 mm) after the copper plating.
412_CRO_63_0099_c01
Figure 63-105. Main Input Quill Pinion — Copper Plating Area
63-00-00
BHT-412-CR&O-3
1
AREA A
(FLANGE)
NOTE
1 Apply brush cadmium plate to Area A of sleeve where

original cadmium plate has been removed. Refer to
BHT-ALL-SPM for cadmium plating procedures.
INPUT SLEEVE
(412-040-137-101)
A
NOTES
1. Apply one coat of primer (C-204) except as noted at note 2.

A Refer to BHT-ALL-SPM for procedure to apply primer.
2 Do not prime indicated areas.
CAP ASSEMBLY
(412-040-264-101) 2 (ALL HOLES AND SPOT FACES)
2 2
2 (DRAIN BOSS AND HOLE)
SECTION A-A
412_CRO_63_0106a
63-00-00
BHT-412-CR&O-3
CURVIC COUPLING ADAPTER

(412-040-136-101)
NOTE
1 Apply brush cadmium plate to Area B of sleeve where

AREA B 1
SECTION B-B
NOTE
Touch-up areas where chemical film has been removed.

Use chemical film treatment for aluminum alloy. Refer to
BHT-ALL-SPM for procedure to apply chemical film.
PLATE
(412-040-139-101)
412_CRO_63_0106b
63-00-00
BHT-412-CR&O-3
CAUTION CAUTION
DO NOT HANDLE UNOILED PARTS WITH DO NOT EXCEED THE MAXIMUM

BARE HANDS. ALLOWABLE TEMPERATURE WHEN
YOU HEAT A PART OR DAMAGE TO THE
2. Coat the triplex bearing (4, Figure 63-96), sleeve PART MAY OCCUR.
(3), and pinion (1) with approved transmission oil and
b. Uniformly heat the triplex bearing (4)
allow to drain. Refer to the BHT-412-MM for approved
assembly 230 to 250°F (110 to 121°C).
lubricants.
c. Align the marks on the three bearing inner
3. Align the V-marks on the outer races of the triplex rings with the mark on the spline of the pinion.
bearing (4) and the sleeve (3) and press the bearings
into the sleeve with the apex of the V pointing as d. Support the triplex bearing inner races.
e. Press the pinion through the bearing until fully
seated against the bearing inner race.
CAUTION f. Hold 18 to 20 tons (160.1360 to 177.9289 N)

pressure on the pinion until the assembly has cooled
to approximately room temperature.
IF BEARINGS MUST BE REMOVED
FROM PINION FOR ANY REASON g. Wipe the triplex bearing (4) assembly and the
AFTER INSTALLATION, THE COPPER pinion (1) journal diameter free of oil.
PLATING SHALL BE INSPECTED. IF THE
PLATING IS SCRATCHED OR GOUGED, h. Lubricate the pinion (1) and the triplex bearing
IT MUST BE STRIPPED AND REPLACED (4) with the same oil used in the transmission.
BEFORE THE BEARING, OR ITS
REPLACEMENT, CAN BE INSTALLED 5. Check the pinion (1) and the triplex bearing (4) for
(PARAGRAPH 63-107). free rotation.
6. Temporarily install the cap assembly (8) on the

NOTE sleeve (3) the with spacer (7), as applicable, without
the packing (5) or the shim (6).
If the bearings or the pinion were replaced,
it is necessary to vibro-etch index marks
(lines) on a new part the same as on the 7. Support the sleeve (3) and apply light pressure to
part replaced, so that the bearings may be the flange of the cap assembly (8).
checked for spinning after the test run. If
the bearings are replaced, be sure that dull 8. With a feeler gauge, measure the clearance
burr marks on the inner races are aligned between the cap assembly (8) and the spacer (7), if
when the index marks are vibro-etched on installed, or the sleeve (3).
the races.
9. Measure the thickness of the laminated shim (6).
Peel the shims to obtain a clearance of 0.001 to
4. Install the pinion (1) in the triplex bearing (4) as
0.004 inch (0.03 to 0.10 mm) between the cap
follows:
assembly (8) and the spacer (7), if installed, or the
sleeve (3).
a. Remove the oil from the bore of the triplex
bearing (4) and the journal of the pinion (1) with a 10. Lubricate the new packing (5) with the same oil
clean cloth (C-516). used in the transmission and install on the sleeve (3).
63-00-00
BHT-412-CR&O-3
NOTE
CAUTION
Allow the previously assembled cap
assembly (8) and adapter (20) to remain on
the work bench with the large end of the
KEEP NEW MAGNETIC SEAL IN
adapter down. This will prevent the carbon
ORIGINAL PA C K A G I N G UNTIL
ring from sliding off the adapter shaft during
I N S TA L L AT IO N . I F S E A L I S N O T I N
assembly.
PACKAGE DO NOT ALLOW SLIDING
B E T W E E N S E A L H A LV E S . D O N O T
11. Lubricate the new packing (2) and the pinion (1)
PLACE SEAL IN AREA WHERE THEY
contact diameter with approved transmission oil.
MAY ATTRACT METAL PARTICLES. DO
Install the packing on the pinion.
NOT ALLOW ULTRACHEM ASSEMBLY
FLUID TO CONTACT CARBON SEALING
12. Apply a thin even coat of corrosion preventive SURFACE. INSTALL SEAL BY HAND
compound (C-128) to the mating flanges of the cap PRESSING ONLY.
assembly (8), spacer (7), shim (6), and sleeve (3).
NOTE
13. Put the new shim (6) and the spacer (7) on the
cap assembly (8) and the adapter (20) by aligning the The magnetic seal is made up of two parts,
splines of the pinion (1) with splines of the adapter. the carbon ring and the magnetic ring.
Align the screw holes and install the screws (18) and
the washers (17). Tighten the screws and secure with 16. Lubricate a new packing (12) and the mating
lockwire (C-405). diameters of the magnetic seal (11) with assembly
fluid (C-024). Install the packing in the carbon ring and
install the magnetic seal over the adapter (20) inside
the cap assembly (8).
CAUTION
17. Press the adapter (20) into the cap assembly (8)
and align the seal retainer (15) slot with the cap
alignment pin (19) and install the seal retainer on cap
UNTIL READY FOR INSTALLATION.
assembly.
WHEN SEAL PACKAGE IS OPENED,
S E PA R AT E S E A L B Y P U L L I N G
MAGNETIC RING AND CARBON RING 18. Install the holding fixture (412-240-002-101) on
STRAIGHT AWAY FROM EACH OTHER. the flange of the adapter (20) and secure in a vise.
SLIDING BETWEEN SEAL HALVES MAY
DAMAGE MATING SURFACES. DO NOT
19. Lubricate the nut (21) threads with grease
PLACE MAGNETIC RING OR CARBON
(C-001) and the nut flange with lubricating oil (C-011).
R I N G I N A R E A W H E R E T H E Y M AY
ATTRACT METAL PARTICLES. INSTALL
SEAL BY HAND PRESSING ONLY. PRIOR 20. Install the nut (21) and torque the nut 450 to
TO INSTALLATION OF SEAL, LUBRICATE 500 foot-pounds (610 to 678 Nm) with the wrench set
PACKINGS AND MATING DIAMETERS (412-240-001-101).
SPARINGLY WITH ASSEMBLY FLUID
(C-024).
21. Remove the nut (21), wipe clean, and repeat
step 19 and step 20.
14. Lubricate the new packings (13 and 14) and the
seal retainer (15) contact diameters with assembly
fluid (C-024). 22. Remove the holding fixture (412-240-002-101)
and the wrench set (412-240-001-101).
15. Install the packings (13 and 14) on the seal
retainer (15) and install the seal retainer over the 23. Install the lockwasher (22) and the retaining
adapter (20). ring (23).
63-00-00
BHT-412-CR&O-3
24. Push the seal retainer (15) down into the cap 26. Lubricate a new packing (28) with the same oil
assembly (8) and install the retaining ring (16). used in the transmission and install the packing on the
union (27). Install the union in the cap assembly (8).
25. Put the new packing (24) on the plate (25).
Lubricate the packing and the mating surface with the 27. Lubricate a new packing (9) with the same oil
same oil used in the transmission prior to assembly. used in the transmission and install the packing on the
Install the plate and secure with the retaining ring (26). plug (10). Install the plug in the cap assembly (8).
63-00-00
BHT-412-CR&O-3
GENERATOR (OR SYS 2 HYDRAULIC PUMP) DRIVE QUILL
63-109.GENERATOR (OR SYS 2 HYDRAULIC 10. Press the duplex bearing (1) and the spacer set
PUMP) DRIVE QUILL (204-040-379-003 (2) out of the sleeve (9) with the bar (T101334). Keep
AND -101) the duplex bearings and spacer set together as a set.
63-110. GENERATOR (OR SYS 2 HYDRAULIC 11. Remove the three screws (11) and the shim plate
PUMP) DRIVE QUILL — DISASSEMBLY (10). Mark the shim plate for installation on the same
sleeve.
SPECIAL TOOLS REQUIRED 63-111. GENERATOR (OR SYS 2 HYDRAULIC

PUMP) DRIVE QUILL — CLEANING
NUMBER NOMENCLATURE
T101305 Wrench Assembly MATERIALS REQUIRED
T101334 Bar Refer to BHT-ALL-SPM for specifications.

T101447 Holding Fixture NUMBER NOMENCLATURE
T101449 Wrench C-105 Corrosion Preventive
Compound
1. Place the quill in the holding fixture (T101447)
with the pinion (12, Figure 63-107) facing down. C-334 Solvent
C-516 Clean Cloth

2. Remove the nut (7) with the wrench (T101449).
3. Press the seal (8) out of the nut (7) and remove 1. Inspect the quill for corrosion damage to the
the packing (6). Discard the seal and the packing. threaded studs and stud holes before cleaning. No
structural damage to the threads or holes is permitted.
4. Remove the clip (5).
5. Remove the nut (4) with the wrench assembly (C-304). Use a soft bristle brush to dislodge stubborn
(T101305) and the back of the plate assembly deposits. All parts except the bearings may be cleaned
(T101519). with solvent (C-334) by vapor degreasing if desired.
6. Remove the washer (3).

CAUTION
7. Support the duplex bearing (1) on the inner race
with the plate assembly (T101519).
8. Press the pinion (12) out of the sleeve (9). WHILE DRYING.
9. Remove the cork (13) from the pinion (12). 3. Dry the parts with a clean cloth (C-516) or dry
Discard the cork. filtered compressed air.
63-00-00
BHT-412-CR&O-3
2
2
3
12 1 4
13
5 6
10
7
8
9
11
12 2
1. Duplex bearing
2. Spacer set
3. Washer
4. Nut
5. Clip
6. Packing
7. Nut
8. Seal
9. Sleeve
10. Shim plate
11. Screw
12. Pinion
13. Cork
NOTES
1 Quill assembly P/N 204-040-379-003 contains pinion with six holes.
2 Quill assembly P/N 204-040-379-101 contains pinion with four holes.
412_CRO_63_0107
Figure 63-107. Generator (or SYS 2 Hydraulic Pump) Drive Quill
63-00-00
BHT-412-CR&O-3
NOTE FIGURE 63-107

NOMENCLATURE CODE
Parts treated per the following step may be INDEX NUMBER
12 Pinion M
4. Inspect the sleeve (9, Figure 63-107) in
4. Immediately after cleaning the bearings with accordance with Figure 63-110.
drycleaning solvent (C-304), gently agitate the
bearings in corrosion preventive compound (C-105) 63-113. GENERATOR (OR SYS 2 HYDRAULIC
and allow to drain dry. Apply a coat of lubricating oil of PUMP) DRIVE QUILL — REPAIR
the type used in the transmission to the bearings.
5. Remove the sealant from the quill parts with a MATERIALS REQUIRED
plastic scraper.
63-112. GENERATOR (OR SYS 2 HYDRAULIC
PUMP) DRIVE QUILL — INSPECTION NUMBER NOMENCLATURE
C-103 Chromic Acid

NOTE Treatment
Wear limit dimensions shown in C-211 Shellac Varnish
Figure 63-108 are provided to show the
intended that all dimensions listed on the 1. Install the new cork (13, Figure 63-107) in the
illustration be checked as a prescribed position shown in Figure 63-108, 0.25 to 0.31 inch (6.4
overhaul procedure; however parts that to 7.9 mm) in depth from the flat surface of the gear
show evidence of wear or physical damage web and coat with shellac varnish (C-211).
must be checked dimensionally.
2. Remove the loose or damaged studs and inserts
1. Inspect the pinion (12, Figure 63-107) in
on the quill sleeve (9, Figure 63-107). Install the new
studs and/or the inserts (BHT-ALL-SPM).
2. Inspect the duplex bearings (1, Figure 63-107) for

3. Polish out mechanical and corrosion damage that
spalling, scoring, pitting, brinelling, and corrosion
is within the limits noted in Figure 63-108 through
damage. Damage that can be detected visually is not
Figure 63-110.
permitted.
3. Inspect the following parts by magnetic particle 4. Immediately after corrosion removal and/or
inspection (Code M) or fluorescent penetrant polishing out mechanical damage, apply the chromic
inspection (Code F), as applicable. Demagnetize the acid treatment (C-103) (BHT-ALL-SPM).
parts after the magnetic particle inspection. Refer to
Table 63-3 and the BHT-ALL-SPM for the procedure.
CAUTION
FIGURE 63-107
NOMENCLATURE CODE
INDEX NUMBER
C O R R O S I O N R E M O VA L P R O C E S S
4 Nut M MUST BE MONITORED TO MAKE SURE
THAT MACHINED DIMENSIONS ARE
7 Nut F M A I N TA I N E D A N D T H AT C A D M I U M
P L AT I N G I S N O T R E M O V E D F R O M
9 Sleeve F STUDS.
63-00-00
BHT-412-CR&O-3
POSITION CORK
0.25 TO 0.31 IN.
(6.4 TO 7.9 mm)
INBOARD FROM
FLAT SURFACE
OF GEAR WEB
GENERATOR (OR SYS 2 HYDRAULIC PUMP)

DRIVE QUILL
(204-040-379-003 AND -101)

LTR METHOD
1. Outer spacer O.D. 2.664 inches (67.67 mm) min.

2.674 inches (67.91 mm) max.
2. Inner spacer I.D. 1.578 inches (40.08 mm) min.

1.588 inches (40.33 mm) max.
3. Bearing I.D. 1.5746 inches (39.995 mm) min.

1.5748 inches (39.999 mm) max.
O.D. 2.6769 inches (67.993 mm) min.

2.6774 inches (68.006 mm) max.
1 and 2 Spacers Width 0.755 inch (19.18 mm) min. 1

0.775 inch (19.68 mm) max.
NOTE
1 The width difference between the spacers must not exceed 0.0002 inch (0.005 mm).
412_CRO_63_0102_c01
Figure 63-108. Generator (or SYS 2 Hydraulic Pump) Drive Quill — Wear Limits
63-00-00
BHT-412-CR&O-3
A TEETH
G
B
DIAMETER
D
F
E
SPLINE TEETH
H
I
SURFACE
C B
THREADS

LTR METHOD
1. A Wear Visual 1
2. B Wear Measure 1.5755 inches (40.018 mm) max.

1.5750 inches (40.005 mm) min.
3. C Corrosion/mechanical Visual 3
4. D Wear, corrosion/mechanical Visual/measure 4
5. E Wear Measure between 0.7300 inch (18.542 mm) max.

0.0720 inch (1.829 mm) 0.7207 inch (18.306 mm) min.
diameter pins
6. F, G Corrosion/mechanical Visual 6
8. I Corrosion/mechanical Visual 8
412_CRO_63_0103a
Figure 63-109. Generator (or SYS 2 Hydraulic Pump) Drive Quill Pinion Assembly — Damage Limits
(Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
1 Visually inspect gear teeth in Area A for spalled, scored, pitted, dented or scratched surfaces. Any such
condition which can be felt with a probe having a spherical radius 0.020 inch (0.51 mm) is cause for
rejection. No corrosion pitting is permitted on any gear tooth surface.
No corrosion or mechanical damage is allowed in the region of Area A between the gear root diameter
and the rim inside diameter.
fine abrasive pad (C-407) is acceptable in Area B. No mechanical damage is permitted in the Area B.
3 Allowable damage in thread Area C is limited to one thread pitch. Damage on the thread pitch may not
exceed one fourth thread depth nor more than 0.25 inch (6.4 mm) aggregate total length after rework to
remove the damage. Remove material to 0.063 inch (1.60 mm) fillet radii and 63 RMS maximum surface
finish. Inspect for burrs and galled metal in threads. Corrosion pitting in the thread area is unacceptable.
4 No corrosion or mechanical damage is acceptable in seal lip Area D. Maximum depth of seal wear groove
may not exceed 0.002 inch (0.05 mm).
5 Fretting erosion and corrosion pitting are acceptable on the teeth of Spline E provided the depth of
corrosion pitting does not exceed 0.003 inch (0.08 mm), and covers no more than 30 percent of the
total area of any spline tooth surface and the tabulated dimensions of Spline E remain within acceptable
limits after removal of corrosion products. Remove corrosion products in accordance with instructions
contained in BHT-ALL-SPM, CORROSION REMOVAL - STEEL PARTS, except apply the solution with a
cotton swab and prevent run off of the solution onto surfaces on which the above corrosion removal
process is not authorized.
6 Corrosion pitting or mechanical damage is acceptable in Areas F and G, provided the damage or
corrosion is polished out and the reworked areas do no exceed 0.005 inch (0.13 mm) in depth and cover
no more than 10% of area within any 1.0 square inch (645 mm2) nor more than 5%
of the total area of any surface. Remove material during rework to produce minimum radii of
0.250 inch (6.35 mm) with a surface finish of 63 RMS or finer.
Following the mechanical removal of corrosion pitting in Areas F and G, chemically treat reworked areas
in accordance with instructions contained in BHT-ALL-SPM, CORROSION REMOVAL - STEEL PARTS,
except mask the part as required using Teflon tape and apply the cleaner using a cotton swab to prevent
run-off of cleaner into areas other than Areas F and G.
7 Light superficial corrosion which may be readily removed by hand polishing with fine steel wool (C-411)
or fine abrasive pad (C-407) is acceptable in Area H. No mechanical damage is permitted in Area H.
8 Corrosion pitting or mechanical damage in the form of nicks, dents and scratches is acceptable on
surface 1 provided the damage or corrosion does not exceed 0.010 inch (0.25 mm) in depth, cover
no more than 10% of the total area of the surface and circumferential separation between damage
sites may be no less than 90 degrees. Do not polish out corrosion or mechanical damage but remove
any raised material flush with the surrounding surface using a fine lndia stone (C-464). Remove
corrosion products in accordance with instructions contained in BHT-ALL-SPM, CORROSION REMOVAL -
STEEL PARTS, except apply the solution with a cotton swab and prevent rundown of the solution onto
surfaces on which the above corrosion removal process in not authorized.
9. Apply corrosion protection particularly to worn and reworked areas in accordance with procedures
contained in BHT-ALL-SPM, CORROSION PREVENTIVE TREATMENT.
412_CRO_63_0103b_c01
Figure 63-109. Generator (or SYS 2 Hydraulic Pump) Drive Quill Pinion Assembly — Damage Limits
(Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
E (6 PLACES)
J
I
14
SEE DETAIL B
C
A
B
G
H
DETAIL B
D
DIAMETER
14
SECTION A-A
412_CRO_63_0139a
Figure 63-110. Generator (or SYS 2 Hydraulic Pump) Drive Quill Sleeve — Damage Limits (Sheet 1 of 4)
63-00-00
BHT-412-CR&O-3

LTR METHOD
2. B Corrosion/mechanical Visual 3
4. D Wear Measure 4.9989 inches (126.972 mm) min.

5.0000 inches (127.000 mm) max.
6. F Corrosion/mechanical Visual 10
7. G Corrosion/mechanical Visual None allowed
9. I Wear Measure 2.6769 inches (67.993 mm) min.

2.6774 inches (68.006 mm) max.
10. J Corrosion/mechanical Visual 4
NOTES
1. Where rework is specified repair dents, nicks, scratches and corrosion by polishing with a fine lndia stone
(C-464) to a minimum radius of 0.12 inch (3.0 mm), unless otherwise noted. Remove any raised material
flush with surrounding surface. Surface finish of repaired areas to be 63 RMS or better.
Corrosion pitting or repairs on any plane surface may not extend inward radially across more than 75% of
the width of the surface nor more than 50% of the distance from any hole to an outside edge unless
otherwise noted.
2 Corrosion pitting or mechanical damage is acceptable on as cast surfaces, provided the corrosion or
damage is polished out and the reworked areas do not exceed 0.030 inch (0.76 mm) in depth and total no
more than 40% of the area within any 1.0 square inch (645 mm2) or 20% of the total area of any surface.
For inside of bolt holes in area A, the maximum corrosion must not exceed 0.020 inch (0.51 mm) in depth
with no more than 20% of the wall area inside the hole being affected. Do not polish out such pitting but
remove corrosion deposits in accordance with instructions contained in BHT-ALL-SPM.
Corrosion pitting or mechanical damage is acceptable provided the damage or corrosion is polished out and
3 reworked areas do not exceed 0.010 inch (0.03 mm) in depth and cover no more than 20% of any
1.0 square inch (645 mm2) of surface or as an aggregate total, cover more than 20% of the total area of any
surface. Repair may not break in to packing groove.
412_CRO_63_0139b
63-00-00
BHT-412-CR&O-3
4 Very light corrosion pitting or mechanical damage in the form of scratches is acceptable provided the depth
of such damage does not exceed 0.002 inch (0.05 mm) nor cover more than 25% of total area of surface after
rework. Rework by carefully hand polishing with 400 grit or finer aluminum oxide cloth (C-406) to produce a
surface finish of 63 RMS or better.
5 Corrosion pitting is acceptable provided it is no more than 0.020 inch (0.51 mm) in depth and covers no more
than 15% of the total area of each spotface after rework. Rework areas must extend no closer than 0.060 inch
(1.52 mm) from the edge of boit holes, see Note 1 for rework instructions. The spotface areas may, however,
be repaired if corrosion exceeds these limits, by respotfacing to a 0.875 ±0.010 inch (22.23 ±0.25 mm)
diameter x 0.030 ±0.010 inch (0.76 ±0.25 mm) fillet radius to a minimum flange thickness of 0.335 inch
(8.51 mm) not including thickness of shim. Spotfaced surface must be concentric with the boit hole within
0.010 inch (0.25 mm) T.I.R. and parallel with Surface F within 0.002 inch (0.05 mm).
Mechanical damage in the form of nicks, dents and scratches is acceptable provided they do not exceed
0.010 inch (0.25 mm) in depth nor more than 0.250 inch (6.35 mm) in length after rework. Rework mechanical
damage to a 0.060 inch (1.52 mm) fillet radius. Extent of repaired areas is subject to above corrosion limits.
Refer also to Note 1.
6 Corrosion pitting is acceptable on Surface C provided the corrosion does not exceed 0.030 inch (0.76 mm) in
depth and covers no more than 20% of the area within any 1.0 square inch (645 mm2) or 10% of the total area
of the surface after removal of corrosion products. Do not polish out corrosion pitting. Corrosion pitting may
extend no closer than 0.100 inch (2.54 mm) from the edges of threaded stud holes and from the edge of the
Diameter K entry chamfer. See Note 1 for additional limitations.
Mechanical damage in the form of nicks, dents and scratches is acceptable provided the damage is no
0.100 inch (2.54 mm) from edges of threaded holes, or the entry chamfer of Diameter K. Remove any raised
material flush with surrounding surface by polishing with a fine lndia stone (C-464). Mechanical damage to
the threaded holes for shim screws is acceptable provided the damage does not extend past the first thread.
No corrosion or repair permitted in threaded holes. No loose, bent, or corroded studs permitted.
7 Consult wear limits chart for replacement dimensions. Corrosion pitting is acceptable provided it does not
exceed 0.010 inch (0.25 mm) in depth with no more than 40% of any 1.0 square inch (645 mm2) or 5% of total
area of surface being affected after removal of corrosion products. Do not polish out corrosion pitting.
No corrosion or mechanical damage permitted in lube hole for bearing.
8 Only light, superficial corrosion which can be readily removed with steel wool (C-411) or abrasive pad (C-407)
is permitted. No repairs permitted. See wear limits chart.
9 Allowable damage in thread area is limited to two thread pitches. Damage on the thread pitch may not exceed
one-fourth thread depth nor more than 0.25 inch (6.4 mm) aggregate total length after rework to remove
damage. lnspect for burrs and galled metal in the threads.
10 Corrosion pitting is acceptable on Surface F provided the corrosion does not exceed 0.010 inch (0.25 mm) in
depth and covers no more than 10% of the area within any 1.0 square inch (645 mm2) of surface or
10% of the total area of the surface after removal of corrosion products. Do not polish out corrosion pitting.
Damage must not extend closer than 0.060 inch (1.52 mm) from the edges of stud holes, threaded holes for
shim and clinch nut counter bores. Refer to Note 1 for additional limitations on extent of corrosion.
412_CRO_63_0139c
63-00-00
BHT-412-CR&O-3
10 Cont’d
0.060 inch (1.52 mm) from the edges of stud holes, threaded holes, and clinch nut counter bores. Remove
raised material flush with the surrounding surface by polishing with a fine lndia stone (C-464). Mechanical
damage to the threaded holes for shim screws is acceptable provided damage does not extend past first
thread. No loose or damaged clinch nuts are permitted.
11. Mechanical damage in the form of nicks, dents, and scratches is acceptable provided such damage is no
greater than 0.020 inch (0.51 mm) nor longer than 0.500 inch (12.70 mm) and there is 1.25 inches (31.8 mm)
minimum circumferential spacing between damage. Do not polish out such damage but remove any raised
material flush with the surrounding surface with a fine lndia stone (C-464).
12. Penetrant inspect for indications of cracks. No such indications are permitted.
13. Apply corrosion preventive treatment to sleeve assembly if sleeve was completely stripped of paint. Small,
localized repairs permitted after application of primer shall be treated.
14 Refinish external surfaces using two coats of polyamide epoxy primer (C-204). Omit primer from indicated
areas.
412_CRO_63_0139d
63-00-00
BHT-412-CR&O-3
5. Touch up the cadmium plated parts. Refer to the number on the shim plate must match the
BHT-ALL-SPM for the prescribed method. The shim serial number on the quill sleeve (9).
plate (10, Figure 63-107) thickness must be
maintained after touch-up. 3. Inspect the shim plate (10) and the sleeve (9) for
an etched serial number. If the same serial number is
on both parts and the shim plate is serviceable, install
63-114. GENERATOR (OR SYS 2 HYDRAULIC
the shim plate on the sleeve with the three
PUMP) DRIVE QUILL — ASSEMBLY
screws (11).
4. If the shim plate (10) is not serviceable or the

SPECIAL TOOLS REQUIRED serial number is missing or illegible, determine the
required dimension of the shim as follows:
NUMBER NOMENCLATURE
a. Inspect the sleeve (9) for a reference
T101305 Wrench Assembly dimension, which will be metal stamped or
vibro-etched on the part adjacent to the mounting
T101447 Holding Fixture surface. Record the dimension and where it is located
on the sleeve.
T101449 Wrench
b. Measure the thickness of the shim plate (10)
T101519 Plate Assembly and record.
c. Subtract the shim plate (10) thickness from

the reference dimension noted in step a. The resulting
MATERIALS REQUIRED
value must be within 2.2215 to 2.2200 inches (56.426
to 56.388 mm). This value includes the thickness of
the cadmium plating on the shim plate.
NUMBER NOMENCLATURE
d. Procure a shim plate (10) of the correct
C-304 Drycleaning Solvent dimension determined in step c. Install the shim plate
on the sleeve (9) with the three screws (11).
C-328 Sealant
C-405 Lockwire
CAUTION

(C-304) and drain. DUPLEX BEARING (1) SET AND SPACER
S E T ( 2 ) M U S T B E I N S TA L L E D A S
2. Coat all the parts with the same oil used in the MATCHED SETS.
5. Inspect the duplex bearing (1) set to make sure
the serial number on both bearings is the same.
Inspect the spacer set (2) to make sure the serial
CAUTION number on both spacers is the same.
6. Put the sleeve (9) with the studs facing up.

D O N O T H A N D L E U N O I L E D PA RT S
WITH BARE HANDS 7. Put one bearing of the duplex bearing (1) set on
the sleeve (9) with the thrust side of the outer race
facing up. Use a metal plug or cylinder of the correct
NOTE
outside diameter to apply force to the outer race of the
Cadmium plating on the shim plate (10, bearing during the pressing operation. Press the
Figure 63-107) must be intact and the serial bearing into the sleeve.
63-00-00
BHT-412-CR&O-3
8. Put both parts of the spacer set (2) in the 11. Put the plate assembly (T101519) in a vise with
sleeve (9). the short end of the pins up.
9. Put the second bearing of the duplex bearing (1) 12. Put the pinion (12) on the plate with the holes of
set on the sleeve (9) with the thrust side of outer race pinion engaged on the pins.
facing down so the bearing set will be installed
back-to-back. Use a metal plug or cylinder of the
13. Coat the threads with the same oil used in the
correct outside diameter to apply force to the outer
transmission and install the washer (3) and the nut (4)
race of the bearing during the pressing operation.
with the shoulder side of the nut next to the washer.
Press the bearing into the sleeve.
Torque the nut 30 to 40 foot-pounds (41 to 54 Nm)
with the wrench assembly (T101305).
CAUTION 14. Install the clip (5). Make sure that the tangs of the
clip are properly engaged.
W H E N I N S TA L L I N G P I N I O N I N T O 15. Apply a thin film of sealant (C-328) to the outer

BEARINGS, USE CARE TO ONLY APPLY surface of the new seal (8). Press the seal into the nut
PRESSURE TO THE PINION HUB AREA. (7) with the lip of the seal facing inboard. Wipe off
PRESSURE APPLIED AT GEAR TEETH excess sealant.
CAN RESULT IN CRACKS BETWEEN
THE HOLE IN THE WEB AND POSSIBLE
FAILURE OF THE PINION IN SERVICE. 16. Put a new packing (6) in the groove of the nut (7).
17. Coat the lip of the seal (8), packing (6), and
CAUTION threads of nut (7) with the same oil used in the
transmission.
MAKE SURE THE INNER SPACER OF 18. Hold the sleeve (9) with the holding fixture
T H E S PA C E R S E T I S C O R R E C T LY (T101447) and install the nut (7).
ALIGNED OR DAMAGE TO THE PARTS
MAY OCCUR. 19. Use the wrench (T101449) to torque the nut (7)
150 to 200 foot-pounds (203 to 271 Nm).
10. Use a metal cylinder of the correct diameter and
wall thickness to support the inner race of the duplex
bearing (1) set and permit passage of the bearing 20. Secure the nut (7) to the sleeve (9) with lockwire
journal part of the pinion (12). Put the parts assembled (C-405). Check the pinion (12) for free rotation.
in step 6 and step 8 on the metal cylinder. Press the
pinion into position in the bearing set and the sleeve.
63-00-00
BHT-412-CR&O-3
OFFSET ACCESSORY DRIVE QUILL
63-115.OFFSET ACCESSORY DRIVE QUILL 7. Remove the quill from the wrench assembly
(212-040-208-003 AND -101) (T101568) and place the quill on a press.
63-116. OFFSET ACCESSORY DRIVE QUILL — 8. Press the support (3) out of the bearing (5).
DISASSEMBLY Remove the retaining ring (4) from the sleeve (6).
9. Put the quill on the wrench assembly (T101568)

SPECIAL TOOLS REQUIRED with the pinion (15) teeth down, engaging the splines
of the pinion with the wrench.
NUMBER NOMENCLATURE 10. Remove the clip (9).

AN8516-1 Spanner Wrench
11. Remove the nut (10) with the wrench assembly
T101305 Wrench Assembly (T101305).
T101568 Wrench Assembly 12. Remove the retaining ring (14) from the slot with
a small screwdriver.
Deleted 13. Remove the quill from the wrench assembly

(T101568).
1. Clamp the wrench assembly (T101568) in a vise 14. Heat the sleeve (6) with a heat lamp.
with the spline end up.
15. Press the pinion (15) and the bearing stack out of
2. Put the quill on the wrench assembly (T101568) the sleeve (6).
with the pinion (15, Figure 63-111) teeth down,
engaging the splines of the pinion with the wrench.
16. Press the bearing (5) out of the sleeve (6).
Discard the bearing.
3. Bend the locking tangs of the lockwasher (7) out
of the recess in the nut (8). 17. Install the plate assembly (T101589) on the
pinion between the spacer (12) and the duplex
4. Hold the sleeve (6) and remove the nut (8) with bearing (11).
the spanner wrench (AN8516-1).
18. Press the pinion (15) out of the duplex bearing
5. Remove the lockwasher (7). (11) using a suitable pressing plug.
6. Remove the retainer (2) from the gear (1) and the 19. Remove the spacer (12), roller bearing (13), and
support (3). Remove the gear from support. retaining ring (14) from the pinion (15).
63-00-00
BHT-412-CR&O-3
2
13
12
4
15
11
5
14
6 1. Gear
2. Retainer
3. Support
4. Retaining ring
5. Bearing
7 6. Sleeve
7. Lockwasher
8. Nut
9. Clip
10. Nut
T 8
11. Duplex bearing
9 12. Spacer
10 13. Roller bearing
14. Retaining ring
15. Pinion
50 TO 100 FT-LBS
T (68 TO 136 Nm)
412_CRO_63_0105_c01
Figure 63-111. Offset Accessory Drive Quill
63-00-00
BHT-412-CR&O-3
63-117. OFFSET ACCESSORY DRIVE QUILL — approximately 150 hours without being
CLEANING affected by corrosion.
e
MATERIALS REQUIRED compound (C-105) immediately after cleaning
(BHT-ALL-SPM).
63-118. OFFSET ACCESSORY DRIVE QUILL —
NUMBER NOMENCLATURE INSPECTION

Compound NOTE
C-304 Drycleaning Solvent Wear limits are provided to show required

fit between mating parts. It is not intended
C-309 MEK that all dimensions be checked as a
prescribed overhaul procedure, however,
C-334 Solvent parts that show evidence of wear or
C-516 Clean Cloth dimensionally.
1. Inspect the quill for corrosion damage to the

1. Clean all the quill parts with drycleaning solvent
threaded studs and the stud holes.
deposits.
2. Inspect the worn or damaged parts dimensionally
in accordance with Figure 63-112.
2. All parts except the bearings may be cleaned with
solvent (C-334) by vapor degreasing.
3. Inspect the gear (1, Figure 63-111) and pinion
(15) for spalled, scuffed, pitted, chipped, or dented
3. Remove the sealant from the sleeve with a plastic
teeth.
scraper and MEK (C-309).
4. Inspect the roller bearing (13) surface of the

pinion for spalling, scoring, pitting, brinelling, and
CAUTION corrosion damage.
5. Inspect the splines on the pinion (15) for chipped,

DO NOT ALLOW BEARINGS TO SPIN pitted, or excessively worn teeth.
WHILE DRYING.
6. Inspect the pinion (15) for damaged threads.
7. Inspect the wear pattern on the gear (1), as
CAUTION 8. Inspect the bearings (11 and 13, Figure 63-111)

for spalling, scoring, pitting, brinelling, corrosion
damage, and for cracked or broken retainers.
WITH BARE HANDS.
9. Inspect the roller bearing (13) for roughness
when rotated.
NOTE
Parts treated per the following step may be 10. Inspect the sleeve (6) for corrosion damage and
left covered in indoor storage for loose or damaged bearing liners.
63-00-00
BHT-412-CR&O-3
4 6
1 8
2 9
3 14 10
15 7
12 11
12
13
ITEM CHARACTERISTIC INSPECTION MINIMUM MAXIMUM

METHOD INCHES (millimeters) INCHES (millimeters)
1. Sleeve I.D. 5.5113 5.5120

(139.987) (140.005)
2. Bearing O.D. 5.5112 5.5118
(139.984) (140.000)
I.D. 4.3302 4.3308
(109.987) (110.002)
3. Support O.D. 4.3308 4.3314
(110.002) (110.018)
4. Gear teeth over pins 6.0005 6.0048
5. Gear splines between pins 4.4416 4.4444
6. Pinion teeth over pins 4.1895 4.1928
7. Pinion splines between pins 1.1251 1.1306
8. Sleeve I.D. 3.1489 3.1497
(79.982) (80.002)
9. Bearing O.D. 3.1492 3.1496
(79.990) (80.000)
10. Pinion O.D. 1.8691 1.8697
(47.475) (47.490)
11. Sleeve I.D. 2.6768 2.6775
(67.991) (68.009)
12. Bearing O.D. 2.6769 2.6774
(67.993) (68.006)
I.D. 1.5745 1.5749
(39.992) (40.002)
13. Pinion O.D. 1.5748 1.5755
(40.000) (40.018)
14. Sleeve O.D. 3.6252 3.6260
(92.080) (92.100)
15. Case I.D. 3.6245 3.6263
(92.062) (92.108)
412_CRO_63_0140
Figure 63-112. Offset Accessory Drive Quill — Wear Limits
63-00-00
BHT-412-CR&O-3
Figure 63-113. Offset Accessory Drive Quill Gear — Wear Pattern
63-00-00
BHT-412-CR&O-3
11. Inspect the support (3), nut (8), and nut (10) for
damaged threads.
CAUTION

inspection (Code M) or fluorescent penetrant REPLACE BEARINGS AS A MATCHED
inspection (Code F), as applicable. Demagnetize the SET.
parts after the magnetic particle inspection. Refer to
Table 63-3 and the BHT-ALL-SPM for the procedure. 2. Replace the duplex bearings as a matched
serialized set, if unserviceable.
3. Replace the parts that are cracked, broken,

FIGURE 63-111 warped, have malformed threads, or exceed wear
NOMENCLATURE CODE limits.
INDEX NUMBER
1 Gear M 4. Repair dents and nicks or the sleeve flange top

3 Support M surface by polishing with a fine India stone (C-464).
Blend the repaired area into the flat surface with a
6 Sleeve F minimum radius of 0.12 inch (3.0 mm). The finished
repair must be 63 RHR (Roughness Height Rating) or
8 Nut M better. The maximum depth, after repair, must not
10 Nut M exceed 0.030 inch (0.76 mm).
15 Pinion M 5. Refinish the parts after repair as follows

(BHT-ALL-SPM):
63-119. OFFSET ACCESSORY DRIVE QUILL —
REPAIR a. Aluminum parts: touch up with chemical film
material (C-100).
b. Magnesium parts: remove all traces of

MATERIALS REQUIRED
corrosion by immersion in chromic acid (C-116). Touch
up parts with chromic acid treatment (C-103) or treat
the entire part with dichromate treatment (C-114).
NUMBER NOMENCLATURE
c. Cadmium plated steel parts: treat rework
C-100 Chemical Film Material areas with cadmium plating solution (C-108).
C-103 Chromic Acid 63-120. OFFSET ACCESSORY DRIVE QUILL —

Treatment ASSEMBLY

Solution SPECIAL TOOLS REQUIRED
C-114 Dichromate Treatment
NUMBER NOMENCLATURE
C-116 Chromic Acid
AN8516-1 Spanner Wrench
C-464 India Stone
T101305 Wrench Assembly
1. Replace the parts that are not within the
allowable wear limits (Figure 63-112).
63-00-00
BHT-412-CR&O-3
NOTE
MATERIALS REQUIRED
To help the removal, install the end of the
Refer to BHT-ALL-SPM for specifications. retaining ring (14) in the middle of the slot.
NUMBER NOMENCLATURE 7. Install the retaining ring (14).
C-304 Drycleaning Solvent 8. Support the inner race of the bearing (5) with a
suitable sleeve and press the support (3) into the
bearing.
(C-304) and drain.
9. Heat the inner race of the duplex bearing (11)
with a heat lamp.
2. Coat all the parts with the same oil used in the
transmission and drain. 10. Support the duplex bearing (11) on the inner race
and press the pinion (15) into the sleeve (6).
11. Place the wrench assembly (T101568) in a vise,

CAUTION splined end up. Put the sleeve (6) and the pinion (15)
on the wrench assembly with pinion teeth down.
DO NOT HANDLE UNOILED PARTS WITH
12. Install the nut (10) on the pinion (15), torque the
BARE HANDS.
nut 30 to 40 foot-pounds (41 to 54 Nm) with the
wrench assembly (T101305). Safety the nut with the
3. Heat the sleeve (6, Figure 63-111) with a heat clip (9).
lamp. Put the sleeve on the press with the face up.
Press the new bearing (5) into the sleeve with the face
13. Place the gear (1) on the support (3) and install
of the bearing up. Install the retaining ring (4).
the retainer (2). Make sure that both ends of the
retainer are fully engaged in the holes in the tang of
the gear.
CAUTION
14. Install the lockwasher (7) on the support (3) with
the tangs engaged in the slots of the support.
DUPLEX BEARING MUST BE A
MATCHED SET WITH SAME SERIAL 15. Install the nut (8) with the beveled side next to the
NUMBER ON BOTH BEARINGS. lockwasher (7). With the spanner wrench (AN8516-1),
torque the nut 50 to 100 foot-pounds (68 to 136 Nm)
4. Press the duplex bearing (11) into the sleeve (6) with the two tangs of the lockwasher aligned with the
with the two bearings of the set positioned slots of the nut. Bend the tangs of the lockwasher into
back-to-back. the slots of the nut.
16. Remove the offset accessory drive quill from the

5. Install the spacer (12) with the larger diameter wrench assembly.
end up.
17. Check the pinion and the bearings for free
6. Press the roller bearing (13) into the sleeve (6). rotation.
63-00-00
BHT-412-CR&O-3
ACCESSORY AND TAIL ROTOR DRIVE AND SUMP ASSEMBLY
63-121.ACCESSORY AND TAIL ROTOR DRIVE c. Remove the set screw (24A).
AND SUMP ASSEMBLY
(212-040-365-105, -109, AND -111) d. Install a slide hammer in the threaded hole in
the center of the rotary oil pump (24). Make sure that
the slide hammer fully engages in the threads of the
NOTE rotary oil pump but does not bottom out in the
If the records or the physical appearance of threaded hole.
the accessory and tail rotor drive and sump
assembly indicates the assembly was e. Remove the rotary oil pump (24) with the slide
subject to an accident or incident outside hammer.
the realm of normal usage, perform a
conditional inspection (paragraph 63-124). f. Remove and discard the packings (23).
2. Disassemble the rotary oil pump (24) (paragraph

SPECIAL TOOLS REQUIRED 63-129).
3. Remove the hydraulic drive quill (46) as follows:

NUMBER NOMENCLATURE
a. Remove the four nuts (40) and the
T101308 Screw Set washers (41).
T101338 Jackscrew Set
b. Remove the two nuts (44) and the aluminum
washers (45).
63-122. ACCESSORY AND TAIL ROTOR DRIVE
AND SUMP ASSEMBLY — DISASSEMBLY c. Cut the sealant around the edge of the
hydraulic drive quill (46), where it contacts the
accessory and tail rotor drive case (22), with a plastic
NOTE scraper. Remove the sealant from the three threaded
If the accessory and tail rotor drive and holes in the quill. Install the screw set (T101308).
sump assembly is being disassembled for Equally turn the jackscrews clockwise and pull the quill
replacement of parts, instead of an from the case.
overhaul, disassemble only to the extent
necessary to replace the parts. d. Remove and discard the packing (47).
1. Remove the rotary oil pump (24, Figure 63-114) 4. Disassemble the hydraulic drive quill (46)
as follows: (paragraph 63-165).
a. Loosen the nuts (39A and 39B) and remove 5. Remove the accessory and tail rotor drive quill
the tube assemblies (30 and 34), nut (29), aluminum (10) as follows:
washer (28), tee (33), drain valve (63), union (69), and
attached fittings. a. Cut and remove the lockwire.
b. Remove the nuts (27 and 37), washers (26, b. Remove the six nuts (11) and steel
38, and 39), and bracket (25). washers (12).
63-00-00
BHT-412-CR&O-3
11 T 1
T 1 6 12
13 21 T 1
19
T 1
1
7 18
14
2 17
8
3 10 16 20
SEE DETAIL A
1 SEE DETAIL B 15
9
4 5
22
C
SEE DETAIL D
TO OIL FILTER 36
SCUPPER
35 23
39A
24
39A 39 24A
34 38 25
26
T 1
37 27 T 1
33 29
31 28
39B 30
32
TO OVERBOARD DRAIN
TO DRAIN VALVE
SEE DETAIL D
412_CRO_63_0108a_c01
Figure 63-114. Accessory and Tail Rotor Drive and Sump Assembly (Sheet 1 of 4)
63-00-00
BHT-412-CR&O-3
42
43 44 T
T 2
40 41 2
45 46
22
47
51
50
49
48
DETAIL A
1
2 3
8 4A
DETAIL B 1
412_CRO_63_0108b_c01
63-00-00
BHT-412-CR&O-3
22
84
83
FW 82
D 81
80
79
78
77
76
85
87 86
T 3 88
75
74 T 3 22
73
72
71
VIEW C 52
53
54
55
56
57
58
61
70
60
69
59
68
67
66 39B
65 TO TEE (33) AND OVERBOARD DRAIN

64
63 62
DETAIL D
412_CRO_63_0108c_c01
63-00-00
BHT-412-CR&O-3
1. Nut 45. Aluminum washer (AN960PD516)

2. Thin steel washer 46. Hydraulic drive quill
3. Bracket 47. Packing
4. Oil filter 48. Gasket
4A. Full flow debris monitor 49. Cover
5. Packing 50. Washer (AN960C416)
6. Nut 51. Nut
7. Thin steel washer 52. Packing
8. Bracket 53. Packing
9. Retaining ring 54. Jet No. 4
10. Accessory and tail rotor drive quill 55. Seal (NAS1598-3Y)
11. Nut 56. Thin steel washer
12. Steel washer 57. Screw
13. Retaining ring 58. Screw
14. Oil pump shaft 59. Elbow
15. Packing 60. Nut
16. Tail rotor drive quill 61. Packing
17. Aluminum washer (AN960PD416) 62. Tube assembly
18. Thin steel washer 63. Drain valve
19. Spacer 64. Nut
21. Nut 66. Elbow
22. Accessory and tail rotor drive case 67. Packing
23. Packing 68. Nut
24. Rotary Oil pump 69. Union
24A. Set screw 70. Packing
25. Bracket 71. Electrical chip detector element
27. Nut 73. Packing
28. Aluminum washer (AN960PD916) 74. Electrical chip detector self-closing valve
29. Nut 75. Gasket
30. Tube assembly 76. Retaining ring
31. Packing 77. Packing
32. Union 78. Glass
33. Tee 79. Oil level indicator (low)
34. Tube assembly 80. Retaining ring
35. Union 81. Packing
36. Packing 82. Glass
37. Nut 83. Oil level indicator (full)
38. Thin steel washer 84. Oil filter scupper
39. Thin aluminum washer (AN960PD416L) 85. Packing
39A. Nut 86. Plug
39B. Nut 87. Gasket
40. Nut 88. Pump screen
41. Washer (AN960C516)
42. Cover
43. Gasket
44. Nut
50 TO 70 IN-LBS 100 TO 140 IN-LBS 300 TO 400 IN-LBS

LOCKWIRE (C-405) T 1 (5.6 TO 7.9 Nm) T 2 (11 TO 16 Nm) T 3 (34 TO 45 Nm)
NOTE
1 Helicopters modified with a full flow debris monitor (4A).
412_CRO_63_0108d_c01
63-00-00
BHT-412-CR&O-3
c. Install the jackscrew set (T101338) in the 15. Remove the pump screen (88) and the gasket
accessory and tail rotor drive quill (10). Equally turn (87). Discard the gasket.
the jackscrews clockwise to pull the quill from
accessory and tail rotor drive case (22).
16. Remove the retaining ring (76), packing (77),
glass (78), and oil level indicator (79). Discard the
d. Remove the retaining ring (9). packing.
e. Remove the oil pump shaft (14) and the 17. Remove the retaining ring (80), packing (81),
retaining ring (13). glass (82), and oil level indicator (83). Discard the
packing.
6. Disassemble the accessory and tail rotor drive
quill (10) (paragraph 63-147). 18. Remove the nut (1), thin steel washer (2), and
bracket (3).
7. Remove the tail rotor drive quill (16) as follows:
19. Remove the three nuts (6), thin steel washers (7),
a. Remove the six nuts (21), washers (17, 18, and bracket (8).
and 20), and spacer (19).
20. Remove the oil filter (4) or the full flow debris
b. Cut the sealant around the edge of the tail monitor (4A), as applicable.
rotor drive quill (16), where it contacts the accessory
and tail rotor drive case (22), with a plastic scraper. 21. Remove and discard the packing (5).
Remove the sealant from the three threaded holes in
the quill. Install the jackscrew set (T101338). Equally
turn the jackscrews clockwise and pull the quill from 22. Disassemble the oil filter (4) (paragraph 63-135)
the case. or the full flow debris monitor (4A) (paragraph 63-141),
as applicable.
c. Remove and discard the packing (15).
8. Disassemble the tail rotor drive quill (16) CAUTION

(paragraph 63-153 or paragraph 63-159).
T H E S H I M P L AT E S ( 2 , 6 , A N D 9 ,
9. Remove the nut (60), packing (61), and elbow
Figure 63-115) MUST BE INSTALLED IN
THE SAME LOCATION ON SAME THE
CASE OR GEAR BACKLASH WILL BE
10. Remove the screw (58), packings (52 and 53), AFFECTED.
and jet No. 4 (54). Discard the packings.
23. Remove the shim plates (2, 6, and 9) as follows:
11. Remove the screw (57), thin steel washer (56),
and seal (55). Discard the seal. a. Remove the three screws (1) and the shim
plate (2). Mark the shim plate for installation at the
same location.
12. Remove the plug (86) and the packing (85).
b. Remove the three screws (5) and the shim
plate (6). Mark the shim plate for installation at the
13. Remove the electrical chip detector element (71) same location.
and the packings (72 and 73). Discard the packings.
c. Remove the three screws (10) and the shim
14. Remove the electrical chip detector self-closing plate (9). Mark the shim plate for installation at the
valve (74) and the gasket (75). Discard the gasket. same location.
63-00-00
BHT-412-CR&O-3
5 10
9
2
7
3 4
1
11
12
1. Screw
2. Shim plate
3. Stud
4. Accessory and tail rotor drive case
5. Screw
6. Shim plate
7. Stud
8. Stud
9. Shim plate
10. Screw
11. Lock ring
12. Threaded insert
412_CRO_63_0109
Figure 63-115. Accessory and Tail Rotor Drive Case Assembly
63-00-00
BHT-412-CR&O-3
63-123. ACCESSORY AND TAIL ROTOR DRIVE 63-124. ACCESSORY AND TAIL ROTOR DRIVE
AND SUMP ASSEMBLY — CLEANING AND SUMP ASSEMBLY — CONDITIONAL
INSPECTION
MATERIALS REQUIRED Refer to the BHT-412-MM, conditional inspection

section, for the definition of accidents or incidents that
Refer to BHT-ALL-SPM for specifications. require a conditional inspection of the accessory and
tail rotor drive and sump components. Inspection
NUMBER NOMENCLATURE procedures and damage limits are also included in the
conditional inspections section.
C-309 MEK 63-125. ACCESSORY AND TAIL ROTOR DRIVE

AND SUMP ASSEMBLY — NORMAL
C-334 Solvent INSPECTION
C-436 Paint Remover
C-516 Clean Cloth MATERIALS REQUIRED

NOTE
NUMBER NOMENCLATURE
Instructions for cleaning the following parts
are located in the indicated paragraphs. C-304 Drycleaning Solvent
Oil filter (paragraph 63-136), or full flow C-464 India Stone

debris monitor (paragraph 63-142).
Rotary oil pump (paragraph 63-130). NOTE

Instructions for inspecting the following
Accessory and tail rotor drive quill
parts are located in the indicated
(paragraph 63-148).
paragraphs.
Hydraulic drive quill (paragraph 63-166).

Oil filter (paragraph 63-137), or full flow
debris monitor (paragraph 63-143).
Tail rotor drive quill (paragraph 63-154 or
paragraph 63-160).
Rotary oil pump (paragraph 63-131).
1. Clean the parts illustrated in Figure 63-114,
except the parts listed in the preceding note, with Accessory and tail rotor drive quill
drycleaning solvent (C-304). Dislodge stubborn (paragraph 63-149).
deposits with a soft bristle brush. All parts except the
bearings may be cleaned with solvent (C-334) by Hydraulic drive quill (paragraph 63-167).
vapor degreasing method if vapor degreasing
equipment is available.
Tail rotor drive quill (paragraph 63-155 or
paragraph 63-161).
2. Clean sealant from the case adjacent to the quill
ports with a plastic scraper and a clean cloth (C-516)
moistened with MEK (C-309).
inspection (Code F), as applicable. Demagnetize the
3. Remove the paint from all the painted parts with parts after the magnetic particle inspection. Refer to
paint remover (C-436). Table 63-3 and the BHT-ALL-SPM for the procedure.
63-00-00
BHT-412-CR&O-3
9. Inspect the jet No. 4 (54) for distortion and

cracks. Damage that can be visually detected is not
FIGURE 63-114 permitted.
NOMENCLATURE CODE
INDEX NO.
14 Oil Pump Shaft M 10. Inspect the accessory and tail rotor drive case
(22) in accordance with Figure 63-116.
22 Accessory and Tail F
Rotor Drive Case
NOTE
2. Inspect the oil tube assemblies (30 and 34, Case wear/damage limits: the case wear
Figure 63-114) and the bracket (25) and related fittings limits are provided to show the required fit
for mechanical and corrosion damage. Superficial between the parts. It is not intended that
mechanical damage is permitted without repair. wear be measured as a required overhaul
Cracked or distorted parts are not permitted. procedure.
Superficial corrosion is permitted if polished out and
area treated for corrosion prevention. 11. Inspect the case parts for the input quill and tail
rotor drive quill. If there is evidence of wear, measure
3. Inspect the oil pump shaft (14) for mechanical the case, as shown in Figure 63-121.
and corrosion damage. Superficial damage is
permitted without repair. Inspect the splines and gear 63-126. ACCESSORY AND TAIL ROTOR DRIVE
teeth for pits, chips or excessively worn teeth. Damage AND SUMP ASSEMBLY — REPAIR
that can be detected visually is not permitted.
4. Inspect the sight glasses (78 and 82) for MATERIALS REQUIRED
discoloration and crazing. Damage that prevents
reading the indicator is not permitted. Refer to BHT-ALL-SPM for specifications.
5. Inspect the oil level indicators (79 and 83) for NUMBER NOMENCLATURE
discoloration and chipped paint. Damage that prevents
reading the indicator is not permitted. C-103 Chromic Acid
Treatment
6. Inspect the accessory and tail rotor drive quill (10) C-304 Drycleaning Solvent
for pitted, chipped, cracked, broken, and worn spline
teeth. Minor dents and nicks on the spline teeth are C-308 Sealant
permitted if polished out with a fine India stone
(C-464). More severe damage is not permitted. C-318 Cleaning Compound
C-464 India Stone

7. Inspect the oil pump screen (88) for metal
particles. Clean the screen with drycleaning solvent C-516 Clean Cloth
(C-304), and dry with compressed air. Visually inspect
the screen for distortion, cracks, and damaged
threads. Damage that can be visually detected is not 1. Repair the case with corrosion damage around
permitted. the studs as follows:
8. Inspect the electric chip detector element (71) for a. Refer to Figure 63-116 for repairable damage
metal particles. Inspect the element for damaged limits.
threads on the stud and for distorted lugs. Damage
that can be visually detected is not permitted. Inspect b. With a 0.327 to 0.334 inch (8.31 to 8.48 mm)
the electrical chip detector self-closing valve (74) for in diameter drill, counterdrill stud holes to a maximum
damaged threads, valve spring, and ball. Damage that depth of 0.125 inch (3.18 mm). Break all sharp edges,
can be visually detected is not permitted. except in the threaded area.
63-00-00
BHT-412-CR&O-3
6
5 10
9
2
7
3
4
1
8
11
12
AREA E
(204-040-355-017)
AREA C
AREA D
COUNTERSINK DIAMETER
1.110 TO 1.130 IN.
(28.19 TO 28.70 mm)
SEE DETAIL B
AREA A
14
13
AREA B
15
VIEW A
DETAIL B
412_CRO_63_0110a
Figure 63-116. Accessory and Tail Rotor Drive Case Assembly — Damage Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
1. Screw 8. Stud
2. Shim plate 9. Shim plate
3. Stud 10. Screw
4. Accessory and 11. Lock ring
tail rotor drive case 12. Threaded insert
5. Screw 13. Magnetic plug
6. Shim plate 14. Pump screen boss
7. Stud 15. Chip detector boss
NOTES
1. Inspect studs (3, 7, and 8) for thread damage, secure installation, and corrosion. If studs are loose and/or
corrosion exists on case adjacent to stud, inspect stud and case as follows:
a. Measure and record height of stud.
b. Remove stud from case.
c. Inspect threads in case.
If damaged threads are cause for loose stud, case is not repairable.
If less than first full thread is corroded, case is acceptable if repaired in accordance with paragraph titled,
"Repair - Accessory and Tail Rotor Drive and Sump Assembly". If corrosion extends past first full thread,
case is not repairable.
2. Inspect case for corrosion damage. If there is any evidence of corrosion damage under shim plates
(2, 6, or 9), mark the shim plate(s) for installation at the same location and remove shim plate(s). If corrosion
in excess of superficial corrosion in localized area is evident, clean case by chromic acid pickle process
for cleaning magnesium parts. Refer to BHT-ALL-SPM for procedure. After cleaning, inspect case for
damage in excess of the following limits:
a. In Areas C, D, and E, corrosion pitting damage is acceptable to a maximum depth of 0.020 inch (0.51 mm)
and a maximum area of 40% of any 1.0 square inch (645 mm2) and 20% of the total area.
b. Measure diameter of quill ports. Maximum acceptable dimension is 3.6265 inches (92.113 mm).
c. Measure chip detector boss entry-countersink diameter at three places, 120° apart. Refer to Detail B.
Acceptable dimension is 1.110 to 1.130 inches (28.19 to 28.70 mm). If dimension is larger than
1.130 inches (28.70 mm), refer to the repair paragraph for rework procedure.
3. Inspect Area A for fretting damage. Fretting damage in this area that does not exceed 0.070 inch (1.78 mm)
in depth and/or 2.0 square inches (1290 mm2) is acceptable if treated for corrosion protection.
4. Inspect Area B and four other threaded bosses in case for thread damage. Damage that affects fit of
components that will be installed in these bosses is not acceptable.
5. Inspect threaded insert (12) for damaged threads and for secure installation in case. Damage that would
interfere with installation of oil jet is not acceptable.
412_CRO_63_0110b
Figure 63-116. Accessory and Tail Rotor Drive Case Assembly — Damage Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
c. Treat drilled areas of the case with chromic indicator runout is no greater than 0.002 inch
acid treatment (C-103) (BHT-ALL-SPM). (0.05 mm).
d. Install a new stud in the reworked hole. Refer b. Machine the chip detector boss surface to
to the BHT-ALL-SPM for the procedure. achieve 1.130 to 1.110 inches (28.70 to 28.19 mm)
entry-countersink diameter. The machining depth shall
not exceed 0.035 inch (0.89 mm). Refer to Table 63-2
e. Fill the counterdrilled holes with sealant for the required depth of machining to achieve 1.130 to
(C-308)). 1.110 inches (28.70 to 28.19 mm) entry countersink.
The surface finish of the remachined boss face must
2. Remove the threaded insert (12) that failed to not exceed 63 RMS.
pass inspection and install a new insert
(BHT-ALL-SPM). c. Remove oil and grease with drycleaning
solvent (C-304). Clean the freshly machined face with
cleaning compound (C-318) mixed with water, to
3. Rework the chip detector boss as follows:
ensure a water- break free surface. Rinse with water
and repeat as necessary to provide a clean surface.
a. Install the sump case in a suitable machine Allow the surface to air-dry or force dry with clean,
tool such as a vertical milling machine. Use minimal filtered compressed air and a clean cloth (C-516).
clamping forces on the sump case. With a dial
indicator mounted in the machined spindle, sweep the d. Treat the reworked areas and other areas on
face of the sump case chip detector boss. Adjust the the case where chemical film has been removed with
position of sump case as required so that the total chromic acid brush-on treatment (BHT-ALL-SPM).
Table 63-2. Chip Detector Boss Measurements and Machining Requirements
COUNTERSINK DIAMETER MEASUREMENTS MACHINING DEPTH REQUIRED

INCHES (MM) INCH (MM)
1.230 (31.2420) 0.035/0.030 (0.8890/0.7620)
1.220 (30.9880) 0.032/0.027 (0.8128/0.6858)
1.210 (30.7340) 0.029/0.024 (0.7366/0.6096)
1.200 (30.4800) 0.026/0.021 (0.6604/0.5334)
1.190 (30.2260) 0.023/0.018 (0.5842/0.4572)
1.180 (29.9720) 0.020/0.015 (0.5080/0.3810)
1.170 (29.7180) 0.017/0.012 (0.4318/0.3048)
1.160 (29.4640) 0.014/0.009 (0.3556/0.2286)
1.150 (29.2100) 0.011/0.006 (0.2794/0.1524)
1.140 (29.9560) 0.008/0.003 (0.2032/0.0762)
63-00-00
BHT-412-CR&O-3
63-127. ACCESSORY AND TAIL ROTOR DRIVE b. Put a shim plate (2) of the correct thickness on
AND SUMP ASSEMBLY — ASSEMBLY the accessory and tail rotor drive case (4) and install
the three screws (1).
c. Determine the required thickness for the shim

SPECIAL TOOLS REQUIRED plate (2) for the accessory and tail rotor drive case (4)
as follows:
NUMBER NOMENCLATURE
(1) Inspect the accessory and tail rotor drive
212-040-001-3 GIF-1 Backlash Tool case (4) for the reference dimension, which should be
metal stamped or vibro-etched on the case adjacent to
the mounting surface for the shim plate (2). Record
this dimension and location on the case.
MATERIALS REQUIRED
(2) Measure the thickness of the shim plate
Refer to BHT-ALL-SPM for specifications. (2) and record.
NUMBER NOMENCLATURE (3) Add the shim plate thickness recorded in

step (2) to the reference dimension recorded in
C-100 Chemical Film Material step (1). The resulting value must fall within the
minimum/maximum dimensions listed as follows. This
C-308 Sealant is the required value for a plated shim plate.
C-328 Sealant
C-405 Lockwire MINIMUM MAXIMUM

SHIM INCHES INCHES
(MM) (MM)
1. Inspect the accessory and tail rotor drive case (4,
Figure 63-115) to make sure that it is clean and that Shim Plate (6), 4.7895 4.7900
the oil passages are not obstructed. Put the case on a Accessory and Tail (121.6533) (121.6660)
clean workbench or install in a suitable support fixture. Rotor Drive Quill
Shim Plate (9), 4.8685 4.8690

2. Install the shim plates (2, 6, and 9) as follows: Tail Rotor Drive Quill (123.6599) (123.6726)
Shim Plate (2), 4.8685 4.8690

Hydraulic Drive Quill (123.6599) (123.6726)
CAUTION
dimension determined in step c. Install the shim as
THE SHIM PLATES (2, 6, AND 9) MUST described in step b.
BE INSTALLED IN THE SAME LOCATION
ON THE SAME CASE FROM WHICH e. Install the shim plates (6 and 9) by the same
REMOVED OR GEAR BACKLASH WILL procedure outlined in step a through step d.
PROBABLY BE INCORRECT.
3. Assemble the accessory and tail rotor drive quill
a. Inspect the accessory and tail rotor drive case (10, Figure 63-114) (paragraph 63-151).
(4) and the shim plate (2) for the serial number. If the
same serial number is legible on both parts, or if the 4. Install the accessory and tail rotor drive quill (10)
shim plate was indexed at the time of removal, install as follows:
the shim plate as outlined in step b. If the shim plate
cannot be positively identified, determine the required a. Make sure that correct shim plate is installed
shim thickness as outlined in step c. on the accessory and tail rotor drive quill (10).
63-00-00
BHT-412-CR&O-3
b. Install the retaining ring (13) in the accessory out, then apply a bead of sealant (C-308) around the
and tail rotor drive quill (10). outside diameter of the set screw.
c. Put the oil pump shaft (14) in the quill and 7. Assemble the tail rotor drive quill (16) (paragraph
install the retaining ring (9). 63-157 or paragraph 63-163).
d. Heat the accessory and tail rotor drive case 8. Install the tail rotor drive quill (16) as follows:
(22) at the port for the accessory and tail rotor drive
quill (10) with a heat lamp. a. Make sure that the correct shim plate is
installed on the tail rotor drive quill (16).
e. Coat the mating surfaces of the quill with the
same oil used in the transmission. Put the quill in the b. Heat the accessory and tail rotor drive case
case and install the six steel washers (12) and the nuts (22) at the port for the tail rotor drive quill (16) with a
(11). Torque the nuts 50 to 70 inch-pounds (5.65 to heat lamp.
7.91 Nm). Secure the nuts in pairs with lockwire
(C-405). c. Lubricate the new packing (15) with the same
oil used in the transmission and install the packing on
5. Assemble the rotary oil pump (24) (paragraph the tail rotor drive quill (16).
63-133).
d. Coat the mating surfaces of the quill and the
6. Install the rotary oil pump (24) as follows: case with the same oil used in the transmission.
Carefully install the tail rotor drive quill (16) in the case.
a. Heat the accessory and tail rotor drive case Rotate the quill coupling if necessary to engage the
(22) at the port for the rotary oil pump (24) with a heat gear teeth and the accessory and tail rotor drive
lamp. quill (10).
b. Lubricate the new packings (23) with the e. Install the aluminum washers (17) next to the
same oil used in the transmission and install the tail rotor drive quill (16). Install the thin steel washers
packings on the rotary oil pump (24). (18), spacers (19), thin steel washer (20), and nuts
(21). Torque the nuts 50 to 70 inch-pounds (5.65 to
7.91 Nm).
CAUTION 9. Assemble the hydraulic drive quill (46)
(paragraph 63-169).
DO NOT APPLY EXCESSIVE FORCE ON
THE OIL PUMP OR THE RETAINING 10. Install the hydraulic drive quill (46) as follows:
RING MAY BE DISPLACED.
a. Make sure that correct shim plate is installed
c. Coat the mating surfaces of the pump and the on hydraulic drive quill (46).
case with the same oil used in the transmission. Put
the pump in the case and engage the oil pump shaft b. Heat the accessory and tail rotor drive case
(14) on the pump driveshaft. (22) at the port for the hydraulic drive quill (46) with a
heat lamp.
d. Put the bracket (25) on the stud, at the
position illustrated, and install the thin steel washer c. Remove the cover (42) and gasket (43).
(26) and the nut (27). Install the thin aluminum Discard the gasket.
washers (39), thin steel washers (38), and nuts (37) on
the two remaining studs. Torque the nuts (27 and 37) d. Lubricate the new packing (47) with the same
50 to 70 inch-pounds (5.65 to 7.91 Nm). oil used in the transmission and install the packing on
the hydraulic drive quill (46).
e. Place a small quantity of chemical film
material (C-100) in the hole center of the rotary oil e. Coat the mating surfaces of the quill and the
pump (24). Insert the set screw (24A) until it bottoms case with the same oil used in the transmission.
63-00-00
BHT-412-CR&O-3
Carefully install the hydraulic drive quill (46) in the same oil used in the transmission. Install the oil level
case. Rotate the quill gear if necessary to engage the indicator (full) (83), glass (82) and retaining ring (80).
teeth with the accessory and tail rotor drive quill (10).
17. Install the oil level indicator (low) (79) in the same
f. Install the aluminum washers (45) and the manner outlined in step 16.
nuts (44) on the two studs.
18. Lubricate the new packing (61) with the same oil
g. Torque the nuts (44) 100 to 140 inch-pounds
used in the transmission and install the elbow (59),
(11.30 to 15.82 Nm).
packing (61), and nut (60).
h. Check the gear backlash (step 22).

19. Assemble the oil filter (4) (paragraph 63-139) or
the full flow debris monitor (4A) (paragraph 63-145),
i. Put the new gasket (43) and the cover (42) on
as applicable.
the hydraulic drive quill (46).
j. Install the four washers (41) and the nuts (40) 20. Install the oil filter (4) or the full flow debris
to secure the cover (42). monitor (4A) as follows:
k. Torque the nuts (40) 100 to 140 inch-pounds a. Put the assembled oil filter (4) or full flow
(11.30 to 15.82 Nm). debris monitor (4A) in the case without the packing (5)
and check to ensure the flange of the filter seats flush
11. Lubricate the new packing (85) with the same oil on the case flange. If any burrs prevent proper
used in the transmission and install the packing on the seating, polish out the burrs.
plug (86) and install the plug in the accessory and tail
rotor drive case (22). Torque the plug 300 to
400 inch-pounds (33.89 to 45.19 Nm).
CAUTION
12. Wet install the pump screen (88) and the new
gasket (87) with sealant (C-328). Torque the pump INSTALL FULL FLOW DEBRIS MONITOR
screen 300 to 400 inch-pounds (33.89 to 45.19 Nm). (4A) WITH DATA PLATE ON TOP.
13. Wet install the electrical chip detector self-closing b. Lubricate the new packing (5) with the same
valve (74) and the new gasket (75) with sealant oil used in the transmission. Put the packing and the
(C-328). Torque the valve 300 to 400 inch-pounds oil filter (4) or full flow debris monitor (4A) on the
(33.89 to 45.19 Nm). Install the electrical chip detector accessory and tail rotor drive case (22). Put the
element (71) and the new packings (72 and 73). bracket (8) on the filter or full flow debris monitor at the
position illustrated. Install the three thin steel washers
14. Secure the pump screen (88) to the electrical chip (7) and the nuts (6).
detector self-closing valve (74) with lockwire (C-405).
Secure the plug (86) to the valve with lockwire c. Put the bracket (3) on the oil filter (4) or full
(C-405). flow debris monitor (4A) at the position illustrated.
Install the thin washer (2) and the nut (1).
15. Put two new packings (52 and 53) on the jet No. 4
(54). Coat the jet and the packings with the same oil d. Torque the three nuts (6) and nut (1) 50 to
used in the transmission. Put the jet in the accessory 70 inch-pounds (5.65 to 7.91 Nm).
and tail rotor drive case (22). Install the screw (58).
Install the new seal (55), thin steel washer (56), and 21. Install the drain valve (63) and external oil lines
screw (57). Secure the screws (57 and 58) together as follows:
a. Lubricate the new packing (31) with the same
16. Put the new packing (81) on the glass (82). oil used in the transmission and install the union (32)
Lubricate the packing and the port in the case with the and the packing in the tee (33).
63-00-00
BHT-412-CR&O-3
b. Put the tee (33) in the bracket (25) and install TO STEP 2 FOR PROCEDURE TO
the aluminum washer (28) and the nut (29). DETERMINE CORRECT SHIM
THICKNESS.
c. Lubricate the new packing (36) with the same
oil used in the transmission and install the packing and a. Install the backlash tool (212-040-001-3
the union (35) in the oil filter scupper (84). GIF-1) on top of the accessory drive sump (22) and
attach with three bolts. Tighten the clamp on the
d. Install the tube assembly (34) on the union backlash tool to secure the pinion in the accessory
(35) and the tee (33). and tail rotor drive quill (10, Figure 63-114).
b. Install the backlash tool (212-040-001-3

GIF-1, Detail 3) on the tail rotor drive quill (16). Tighten
CAUTION the backlash tool to the clamp on the inner coupling of
the tail rotor drive quill. Install the dial indicator support
on one of the tail rotor drive quill studs. Install the dial
INSTALL SHORT END OF UNION (69)
indicator on the support and position it to contact the
INTO DRAIN BOSS OF ACCESSORY
dowel pin in the backlash tool, Detail 3. Take the
AND TAIL ROTOR DRIVE CASE (22). IF
backlash reading at three places approximately 120°
LONG END OF UNION IS INSTALLED,
apart around the gear and record. Backlash on the tail
D A M A G E T O P U M P S C R E E N M AY
rotor drive quill must be within 0.004 to 0.010 inch
RESULT.
(0.10 to 0.25 mm).
e. Lubricate the new packing (70) with the same
oil used in the transmission and install the packing and c. Remove the backlash tools from the tail rotor
the union (69) in the accessory and tail rotor drive drive quill, but leave the backlash tool, Detail 2, on the
case (22). accessory case input quill.
f. Lubricate the new packing (67) with the same

NOTE
oil used in the transmission and install the nut (68),
packing, and elbow (66) on the union (69). If the backlash tool (212-040-001-3 GIF-1,
Detail 3) is unavailable, the backlash may
g. Lubricate the new packing (65) with the same be determined by an alternate method.
oil used in the transmission and install the drain valve Take backlash readings at three places
(63), nut (64), and packing on the elbow (66). approximately 120° apart around the gear
and at a distance (radius) of 1.227 inches
h. Install the tube assembly (62) on the drain (31.17 mm) from the gear center. The
valve (63) and the tee (33). backlash must be within the limits noted in
step b.
i. Tighten the nuts (39A, 39B, 64, and 68).
d. Install the backlash tool (212-040-001-3
GIF-1, Detail 4) on the pinion shaft of the hydraulic
22. Check the backlash of the sump and accessory
drive quill (46). Install the dial indicator support on one
drive assembly quills as follows:
of the hydraulic pump and tachometer drive quill studs.
Install the dial indicator on the support and position it
to contact the dowel pin in the backlash tool Detail 4.
CAUTION Take the backlash reading at three places
approximately 120° apart around the gear and record.
The backlash must be within 0.014 to 0.022 inch (0.36
DO NOT ALTER SHIM PLATES ON CASE to 0.56 mm).
O R Q U I L L S L E E V E T O O B TA I N
BACKLASH. IF BACKLASH IS NOT e. Remove the backlash tools from the hydraulic
WITHIN LIMITS, PA R T S A R E pump and tachometer drive quill. Remove the
I M P R O P E R LY A S S E M B L E D OR backlash tool from the input quill at the top of the
DIMENSIONALLY INCORRECT. REFER accessory drive sump.
63-00-00
BHT-412-CR&O-3
63-130. ROTARY OIL PUMP — CLEANING

NOTE
If the backlash tool (212-040-001-3 GIF-1,
Detail 4) is unavailable, backlash may be MATERIALS REQUIRED
determined by an alternate method. Take
backlash readings at three places Refer to BHT-ALL-SPM for specifications.
approximately 120° apart around the gear
and at a distance (radius) of 1.227 inches NUMBER NOMENCLATURE
(31.17 mm) from the gear center. The
backlash must be within the limits noted in C-105 Corrosion Preventive
step d Compound
23. Apply sealant to the required areas and paint the C-304 Drycleaning Solvent
sump in accordance with paragraph 63-40.
C-516 Clean Cloth
63-128.ROTARY OIL PUMP
63-129. ROTARY OIL PUMP — DISASSEMBLY
2. Clean all the rotary oil pump parts with
1. Remove the retaining ring (1, Figure 63-117). drycleaning solvent (C-304). Use a soft bristle brush to
dislodge stubborn deposits.

CAUTION
DO NOT REMOVE ANY PART OF PUMP

B Y F O R C E . L O O S E N PA R T S B Y CAUTION
TA P P I N G L I G H T LY W I T H A F I B E R
MALLET.
2. Remove the retainer plate (2). Do not remove the
WITH BARE HANDS.
bearing (3) from the retainer plate.
3. Remove the inner gerotor (6), shaft (7) and outer NOTE
gerotor (5). Parts treated per the following step may be
4. Remove the retaining rings (4 and 9). Discard the approximately 150 hours without being
retaining rings. affected by corrosion.
5. Remove the inner gerotor (6) and the key (8) from 4. Coat the parts with corrosion preventive
the shaft (7). Do not remove the bearing (10) or the compound (C-105) immediately after cleaning
dowel pin (11) from the body (12). (BHT-ALL-SPM).
63-131. ROTARY OIL PUMP — INSPECTION
1. Inspect the bearings (3 and 10, Figure 63-117),

shaft (7), inner and outer gerotors (6 and 5), and body
(12) for scoring or indentations. Visible damage is not
permitted.
2. Inspect the shaft (7) by magnetic particle

inspection. Demagnetize the shaft after the magnetic
particle inspection (BHT-ALL-SPM).
63-00-00
BHT-412-CR&O-3
11
14
12 13
10
8 9
6 7
5
2 4
1 3
1. Retaining ring 8. Key

2. Retainer plate 9. Retaining ring
3. Bearing 10. Bearing
4. Retaining ring 11. Dowel pin
5. Outer gerotor 12. Body
6. Inner gerotor 13. Insert
7. Shaft 14. Ring
412_CRO_63_0117_c01
Figure 63-117. Rotary Oil Pump
63-00-00
BHT-412-CR&O-3
3. Inspect the external part of the body (12) for

mechanical and corrosion damage. Superficial MINIMUM MAXIMUM
mechanical damage is permitted without repair. NOMENCLATURE INCH(ES) INCH(ES)
Cracked or distorted parts are not permitted. (MM) (MM)
Superficial corrosion is permitted if polished out and
Allowable Clearance 0.0010 0.0025
area treated for corrosion prevention.
(0.0254) (0.0635)
4. Inspect the insert (13) for damaged threads and

63-132. ROTARY OIL PUMP — REPAIR
secure installation in the body. Damaged threads and/
or a loose insert are not permitted.
Repair is limited to the replacement of non-acceptable
parts. Refer to the BHT-ALL-SPM for the procedure to
NOTE replace the insert (13, Figure 63-117).
Wear limits are provided to show the 63-133. ROTARY OIL PUMP — ASSEMBLY
intended that all dimensions be checked as
prescribed overhaul procedure; however,
parts that show evidence of wear or MATERIALS REQUIRED
dimensionally. Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
5. Inspect the following parts dimensionally. Parts
that do not fall within the inspection limits are not C-304 Drycleaning Solvent
permitted.

(C-304) and drain.
MINIMUM MAXIMUM
NOMENCLATURE INCH(ES) INCH(ES)
(MM) (MM)
CAUTION
Outer Gerotor Width 0.7080 0.7085
(17.9832) (17.9959)
Body Chamber 0.7100 0.7105 WITH BARE HANDS.
Width (18.0340) (18.0467)
Allowable Chamber 0.0015 0.0027 transmission and drain.
Face Clearance (0.0381) (0.0686)
3. Install a new retaining ring (9, Figure 63-117) in
Outer Gerotor 2.1220 2.1225
the inboard groove of the shaft (7).
Outside Diameter (53.8988) (53.9115)
Body Inside 2.1250 2.1255 4. Insert the key (8) in the shaft (7) and install the
Diameter (53.9750) (53.9877) inner gerotor (6) so that the keyway engages the key.
Allowable Clearance 0.0025 0.0040

5. Install a new retaining ring (4) on the outboard
(0.0635) (0.1016) end of the shaft (7).
Driveshaft Outside 0.4985 0.4990
Diameter (12.6619) (12.6746) 6. Install the shaft (7) in the body (12).
Bearing Inside 0.5000 0.5005

7. Install the outer gerotor (5) over the inner
Diameter (12.7000) (12.7127) gerotor (6).
63-00-00
BHT-412-CR&O-3
8. Install the retainer plate (2) on the shaft (7). Make 2. Inspect the spacers (6) for corrosion and
sure that the dowel in the body (12) engages the hole deformation. Damage in excess of superficial is not
in retainer plate (2). permitted.
9. Install the retaining ring (1) in the body (12). The 3. Inspect the screen retention nut (4) for corrosion
retaining ring has a beveled and a flat side. The flat and thread damage. Damage in excess of superficial
side must be against the plate. Make sure that the ring is not permitted.
is fully seated in the groove.
4. Inspect the filter body (8) for mechanical and

10. Rotate the shaft (7) to ensure that the internal
corrosion damage. Damage in excess of superficial is
parts turn freely.
not permitted.
63-134.OIL FILTER (INTERNAL) (02W101633)
63-138. OIL FILTER (INTERNAL) — REPAIR
63-135. OIL FILTER (INTERNAL) — DISASSEMBLY
1. Repair of oil filter (Figure 63-118) is limited to
1. Straighten the tangs on the washer (5, replacement of defective parts.
Figure 63-118).
63-139. OIL FILTER (INTERNAL) — ASSEMBLY
2. Remove the nut (4) and the washer (5).
1. Put the wafer screens (7, Figure 63-118), spacers
3. Remove the wafer screens (7), and the spacers
(6), washer (5), and nut (4) on the filter body (8).
(6) from the filter body (8). Inspect the screens for
metal particles.
2. Tighten the nut (4) just enough to prevent the
63-136. OIL FILTER (INTERNAL) — CLEANING wafer screens (7) from turning. Bend the tangs of the
washer (5) against the side of the nut (4).
MATERIALS REQUIRED 3. Put the oil filter (4, Figure 63-114) in position on
the accessory and tail rotor drive case (22) without the
Refer to BHT-ALL-SPM for specifications. packing (5). If the filter does not seat properly in the
case, the filter is not assembled properly. Remove the
NUMBER NOMENCLATURE filter from the case.
63-140.FULL FLOW DEBRIS MONITOR
1. Clean the oil filter with drycleaning solvent
(212-040-122-101)
(C-304) and dry with compressed air.
63-141. FULL FLOW DEBRIS MONITOR —
63-137. OIL FILTER (INTERNAL) — INSPECTION DISASSEMBLY
1. Inspect the wafer screens (7, Figure 63-118) for 1. Remove the debris scavenge cup/screen tube
distortion and tears. Damage that can be visually assembly (2, Figure 63-119), scupper (1), filter
detected is not permitted. element (3), and packing (4). Discard the packing.
63-00-00
BHT-412-CR&O-3
10
1
9
7
6
1. Spring
2. Ball
3. Set screw 5
4. Nut
4
5. Washer
6. Spacer
7. Wafer screens
8. Filter body
9. Nameplate
10. Housing
412_CRO_63_0112_c01
Figure 63-118. Oil Filter (Internal)
63-00-00
BHT-412-CR&O-3
6
5
4 0.100 IN. (2.54 mm)

ELECTRICAL CHIP
DETECTION GAP
(2 PLACES)
0.12 IN. (3.048 mm)

1
MIN CLEARANCE
ALL AROUND
3 2 T
1. Scupper
2. Debris scavenge cup/screen tube assembly
3. Filter element
4. Packing
5. Receptacle, electrical
6. Full flow debris monitor
22 TO 30 IN-LBS
T (2.5 TO 3.4 Nm)
412_CRO_63_0119
Figure 63-119. Full Flow Debris Monitor
63-00-00
BHT-412-CR&O-3
63-142. FULL FLOW DEBRIS MONITOR — 2. Install the filter element (3) in the full flow debris
CLEANING monitor (6).
3. Install the scupper (1) on the full flow debris

MATERIALS REQUIRED monitor (6).
Refer to BHT-ALL-SPM for specifications. 4. Install the debris scavenge cup/screen tube
assembly (2) to secure the filter element (3) and the
NUMBER NOMENCLATURE
scupper (1). Torque the debris scavenge cup/screen
C-304 Drycleaning Solvent tube assembly 22 to 30 inch-pounds (2.48 to
3.39 Nm).
C-516 Clean Cloth
63-146.ACCESSORY AND TAIL ROTOR DRIVE
1. Clean the debris scavenge cup/screen tube QUILL (212-040-365-023 AND -115)
assembly (2, Figure 63-119), filter element (3), and
scupper (1) with drycleaning solvent (C-304). Clean 63-147. ACCESSORY AND TAIL ROTOR DRIVE
the exterior surface of the magnetics with a clean cloth QUILL — DISASSEMBLY
(C-516). Dry with filtered compressed air.
63-143. FULL FLOW DEBRIS MONITOR — SPECIAL TOOLS REQUIRED

INSPECTION
NUMBER NOMENCLATURE
1. Inspect the filter element (3, Figure 63-119) for
distortion and tears. Damage that can be visually T101305 Wrench Assembly
detected is not permitted.
T101449 Wrench
2. Inspect the scupper (1) and the debris scavenge T101455 Plate Assembly
cup/screen tube assembly (2) for thread damage, T101566 Bar
physical damage, and corrosion.
T101567 Bar
3. Inspect the full flow debris monitor (6) and T101568 Wrench Assembly
electrical receptacle (5) for physical damage,
mechanical damage and corrosion.
1. Remove the clip (2, Figure 63-120).
63-144. FULL FLOW DEBRIS MONITOR — REPAIR

2. If not previously accomplished, remove the oil
pump shaft retaining ring in the base of the pinion (11).
1. Repair of the full flow debris monitor (6, Hold the pinion with the wrench assembly (T101568)
Figure 63-119) is limited to replacement of defective and remove the nut (3) with the wrench assembly
parts. (T101305). Remove the tab washer (4).
63-145. FULL FLOW DEBRIS MONITOR — 3. Press the pinion (11) out of the duplex
ASSEMBLY bearing (5).
1. Lubricate the new packing (4, Figure 63-119) with 4. Hold the tail rotor drive spiral bevel gear sleeve
the same oil used in the transmission and install the (6) with the plate assembly (T101455) and remove the
packing on the filter element (3). bearing retaining nut (1) with the wrench (T101449).
63-00-00
BHT-412-CR&O-3
1 T 1
3 T 2
4 9
5
10
11
1. Bearing retaining nut

2. Clip
3. Nut
4. Tab washer
5. Duplex bearing
6. Tail rotor drive spiral bevel gear sleeve
7. Shim plate
8. Screw
9. Roller bearing
10. Retaining ring
11. Pinion
LOCKWIRE (C-405)
100 TO 150 FT-LBS

T 1 (135 TO 203 Nm)
180 TO 200 FT-LBS

T 2 (244 TO 271 Nm)
412_CRO_63_0114_c01
Figure 63-120. Accessory and Tail Rotor Drive Quill Assembly
63-00-00
BHT-412-CR&O-3

CAUTION
deposits. All parts except the bearings may be cleaned
by vapor degreasing method (BHT-ALL-SPM,
Chapter 5).
IN STEP 5 AND STEP 6, EXERCISE
C A R E T O P R O P E R LY P O S I T I O N
BEARING REMOVAL BAR ON BEARINGS
TO AVOID DAMAGING BEARING OR
CAUTION
SLEEVE.

CAUTION WHILE DRYING.

RETAIN BEARINGS AS A MATCHED filtered compressed air.
SET.
5. Insert the bearing removal bar (T101566) through

the slot in the side of the tail rotor drive spiral bevel CAUTION
gear sleeve (6) and press the duplex bearing (5) out of
the sleeve. Keep the bearings together as a matched
set. DO NOT HANDLE UNOILED BEARINGS
WITH BARE HANDS.
6. Remove the retaining ring (10).
NOTE
7. Insert the bearing removal bar (T101567) through Parts treated per the following step may be
the slot in the side of the tail rotor drive spiral bevel left covered in indoor storage for
gear sleeve (6) and press the roller bearing (9) out of approximately 150 hours without being
the sleeve. affected by corrosion.
8. Remove the three screws (8) and the shim plate 3. Coat the bearings with corrosion preventive
(7). Mark the shim plate for installation on the same compound (C-105) immediately after cleaning
sleeve. (BHT-ALL-SPM).
63-148. ACCESSORY AND TAIL ROTOR DRIVE 63-149. ACCESSORY AND TAIL ROTOR DRIVE
QUILL — CLEANING QUILL — INSPECTION
MATERIALS REQUIRED MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications. Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE NUMBER NOMENCLATURE
C-105 Corrosion Preventive C-464 India Stone
Compound

NOTE
C-334 Solvent Quill Wear/Damage Limits: The quill wear
limits are provided to show the required fit
C-516 Clean Cloth
between parts. It is not intended that wear
63-00-00
BHT-412-CR&O-3
be measured as a required overhaul with a 0.020-inch (0.51-mm) spherical radius probe is

procedure. cause for rejection.
1. Inspect the quill parts for wear and damage. If

7. Inspect the pinion (11) for spalled, scuffed, pitted,
there is evidence of wear, measure the parts, as
chipped, or dented teeth. Inspect the roller bearing
shown in Figure 63-121. Wear in excess of the limits
surface for spalling, scoring, pitting, brinelling, and
shown is not permitted.
corrosion damage. Inspect the splines for chipped,
pitted, or excessively worn teeth. Inspect the threads
2. Inspect the following parts by magnetic particle for damage. Very small dents and nicks on the pinion
inspection (Code M) or fluorescent penetrant teeth that can be polished out with a fine India stone
inspection (Code F), as applicable. Demagnetize the (C-464)) are permitted if polished out, providing the
parts after the magnetic particle inspection. Refer to dents and nicks do not extend into the face of the gear
Table 63-3 and the BHT-ALL-SPM for the procedure. teeth.
63-150. ACCESSORY AND TAIL ROTOR DRIVE

QUILL — REPAIR
FIGURE 63-120
NOMENCLATURE CODE
INDEX NO.
1 Bearing Retaining F MATERIALS REQUIRED

Nut
3 Nut M
NUMBER NOMENCLATURE
6 Tail Rotor Drive F
Spiral Bevel Gear C-100 Chemical Film Material
Sleeve
11 Pinion M
Paper
3. Inspect the nuts (1 and 3) for damaged threads.

Damage that can be detected visually is not permitted. 1. Polish out nicks and dents on the tail rotor drive
spiral bevel gear sleeve (6, Figure 63-120) that are
within the limits noted in paragraph 63-149. Use
4. Inspect the duplex bearings (5) for spalling, abrasive cloth or paper (C-406) to polish out damage.
scoring, pitting, brinelling, corrosion damage, cracked Comply with the radius and surface finish limits noted
or broken retainers, and for roughness when rotated. in paragraph 63-149.
Damage that can be detected visually or by feel is not
permitted.
pinion (11) teeth provided the dents and nicks do not
5. Inspect the tail rotor drive spiral bevel gear sleeve extend into the face of the gear teeth.
(6) for corrosion damage, loose or damaged bearing
liner, and damaged threads. Dents and nicks on the
top surface of the flange up to 0.030 inch (0.76 mm) in 3. Touch up the areas on the tail rotor drive spiral
depth are permitted if polished out and blended into bevel sleeve (6) where chemical film was removed.
the flat surface with a minimum radius of 0.12 inch Use chemical film material (C-100) for aluminum
(3.0 mm) and surface finish of 63 RHR or better. (BHT-ALL-SPM).
Damaged bearing liner and/or damaged threads are
not permitted.
4. Polish out minor dents and nicks on the spline
teeth of the tail rotor quill adapter for the accessory
6. Inspect the roller bearing (9) for spalling, scoring, and tail rotor drive quill (10, Figure 63-114) with a fine
pitting, brinelling, corrosion damage, and cracked or India stone (C-464). Do not exceed the limits defined
broken roller retainers. Any damage that can be felt in Figure 63-121.
63-00-00
BHT-412-CR&O-3
27
12
5 13
7 28
3 8
9
10 14 15
17
11
16 18
1
2 0.03 TO 0.15 IN.
(0.8 TO 3.8 mm)
23 19
24 21 20
25 22
26
212-040-365-105
412_CRO_63_0115a_c01
Figure 63-121. Accessory and Tail Rotor Drive and Sump Assembly — Damage Limits (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3

1. Spline. oil pump shaft over pins 1.3410 1.3480

2. Spline, pinion between pins 1.0871 1.0966
3. Sleeve liner I.D. 3.1490 3.1499
(79.985) (80.007)
4. Duplex bearing O.D. 3.1491 3.1496
(79.987) (80.000)
I.D. 1.3777 1.3781
(34.994) (35.004)
5. Shaft, pinion O.D. 1.3780 1.3786
(35.001) (35.016)
6. Spline, pinion over pins 1.3410 1.3480
7. Sleeve O.D. 3.6247 3.6255*
(92.067) (92.088)
8. Case I.D. 3.6250 3.6265*
(92.075) (92.113)
9. Bearing surface, pinion O.D. 1.8692 1.8696
(47.478) (47.488)
10. Bearing O.D. 3.1492 3.1496
(79.990) (80.000)
11. Sleeve liner I.D. 3.1489 3.1497
(79.982) (80.002)
12. Nut
13. Nut
14. Sleeve liner I.D. 2.8340 2.8347
(71.984) (72.001)
15. Duplex bearing O.D. 2.8341 2.8346
(71.986) (71.999)
I.D. 1.3777 1.3781
(34.994) (35.004)
16. Shaft. gear O.D. 1.3780 1.3786
(35.001) (35.016)
17. Spline, gear over pins 1.4424 1.4465
18. Spline, inner coupling between pins 1.1465 1.1578
19. Teeth, inner coupling over pins 2.1590 2.1740
20. Splines, outer coupling between pins 1.8290 1.8360**
412_CRO_63_0115b_c01
63-00-00
BHT-412-CR&O-3

21. Sleeve O.D. 3.6247 3.6255*

(92.067) (92.088)
22. Case I.D. 3.6250 3.6265*
(92.075) (92.113)
23. Bearing surface, gear O.D. 1.8691 1.8696
(47.475) (47.488)
24. Bearing O.D. 3.1492 3.1496
(79.990) (80.000)
25. Sleeve liner I.D. 3.1489 3.1497*
(79.982) (80.002)
26. Single boost hydraulic drive quill
(see separate illustration for limits)
27. Spline, adapter over pins 1.3410 1.3480
28. Spline. adapter between pins 1.0871 1.0966
* Average dimension
** Maximum depth of wear 0.005 inch (0.13 mm) (measure from unworn face of tooth)
412_CRO_63_0115c
63-00-00
BHT-412-CR&O-3
63-151. ACCESSORY AND TAIL ROTOR DRIVE BEVEL GEAR SLEEVE (6) FROM WHICH
QUILL — ASSEMBLY REMOVED OR GEAR BACKLASH WILL
PROBABLY BE INCORRECT.
SPECIAL TOOLS REQUIRED a. Inspect the shim plate (7) and the tail rotor
drive spiral bevel gear sleeve (6) for a serial number. If
same serial number is legible on both parts, or if the
NUMBER NOMENCLATURE
shim plate was indexed at the time of removal, install
T101305 Wrench Assembly the shim plate as outlined in step b. If the shim plate
cannot be positively identified, determine the required
T101455 Holding Plate shim thickness as outlined in step c.
Assembly
T101449 Wrench b. Put a shim plate (7) of the correct thickness on

the tail rotor drive spiral bevel gear sleeve (6).
T101568 Wrench Assembly Countersink the shim plate in three places for the
screws (8). Install the three screws.
MATERIALS REQUIRED c. Determine the required thickness for the shim

plate (7) for the tail rotor drive spiral bevel gear sleeve
Refer to BHT-ALL-SPM for specifications. (6) as follows:
NUMBER NOMENCLATURE
(1) Inspect the tail rotor drive spiral bevel
C-304 Drycleaning Solvent gear sleeve (6) for the reference dimension, which
should be metal stamped or vibro-etched on the
C-405 Lockwire sleeve adjacent to the mounting surface for the shim
plate (7). Record this dimension and location on the
1. Clean all the parts with drycleaning solvent sleeve.
(C-304) and drain.
(2) Measure the thickness of the shim plate
(7) and record.
CAUTION
(3) Subtract the shim plate thickness from
the reference dimension noted in step (1). The
D O N O T H A N D L E U N O I L E D PA RT S resulting value must fall within the minimum/maximum
WITH BARE HANDS. dimensions listed as follows. This is the required value
for a plated shim plate.
3. Install the shim plate (7, Figure 63-120) as MINIMUM MAXIMUM

follows: SHIM INCH INCH
(MM) (MM)
Shim Plate (7), 0.9895 0.9905

CAUTION Tail Rotor Drive Quill (25.133) (25.158)
SHIM PLATE (7) MUST BE INSTALLED d. Procure a shim plate (7) the dimension
ON SAME TAIL ROTOR DRIVE SPIRAL determined in step c as described in step b.
63-00-00
BHT-412-CR&O-3
63-153. TAIL ROTOR DRIVE QUILL —

DISASSEMBLY
CAUTION
DUPLEX BEARING MUST BE A SPECIAL TOOLS REQUIRED

MATCHED SET WITH SAME SERIAL
NUMBER ON BOTH BEARINGS.
NUMBER NOMENCLATURE
4. Press the duplex bearing (5) into the tail rotor
drive spiral bevel gear sleeve (6), face-to-face, by
pressing on the outer race with a suitable sleeve. T101333 Bar
5. Press the roller bearing (9) into the tail rotor drive T101334 Bar
spiral bevel gear sleeve (6) with a suitable sleeve and
install the retaining ring (10). T101455 Holding Plate
Assembly
6. Support the duplex bearings (5) on the inner race
T101600 Wrench
and press the pinion (11) into the bearings.
7. Put the wrench assembly (T101568) in a vise with

the splined end up. CAUTION
8. Put the quill on the wrench assembly (T101568)
with the pinion teeth down. BLOCK THE OUTER COUPLING SO
T H AT I T W I L L R E M A I N I N T H E
9. Install the tab washer (4) and nut (3). Torque the OUTBOARD (EXTENDED) POSITION.
nut 180 to 200 foot-pounds (244.05 to 271.16 Nm) T H I S W I L L S TA B I L I Z E T H E O U T E R
with the wrench assembly (T101305). COUPLING DURING DISASSEMBLY AND
A S S E M B LY O R D A M A G E T O T H E
10. Install the nut locking clip (2) and remove the quill COUPLING MAY OCCUR.
from the wrench assembly (T101568).
1. Push the plate assembly (26, Figure 63-122)
against the centering spring (25) and remove the
11. Hold the tail rotor drive spiral bevel gear sleeve
retaining ring (27).
(6) with the holding plate assembly (T101455) and
install the bearing retaining nut (1). With the wrench
(T101449), torque the nut 100 to 150 foot-pounds 2. Remove the plate assembly (26) and the
(135.58 to 203.37 Nm). centering spring (25).
12. Secure the bearing retaining nut (1) with lockwire 3. Remove the lock spring (24).
(C-405).
4. Install a 1/4-20 UNC threaded bolt into the spring
13. Check the pinion (11) for free rotation. retainer (23) and pull on the bolt to withdraw the
retainer from the inner coupling (19).
63-152.TAIL ROTOR DRIVE QUILL
(212-040-365-025) 5. Remove the packing (22) from the spring
retainer (23). Discard the packing.
NOTE
6. Hold the outer coupling (18) with the wrench
For helicopter S/N 36020 and subsequent assembly (T101307) or hold the gear (4) with the
to include S/N 46400 through 46499 and holding plate assembly (T101455), position the square
helicopters modified by 412-570-001-103 adapter through the wrench, and remove the coupling
refer to paragraph 63-158. retaining bolt (21) and the special washer (20).
63-00-00
BHT-412-CR&O-3
7. Remove the couplings (18 and 19) from the 17. Remove the three screws (9) and the shim plate
gear (4). (8). Mark the shim plate with the sleeve serial number
for installation on the same sleeve.
8. Separate the couplings (18 and 19) and remove
the seal (17) from the outer coupling (18). Discard the 63-154. TAIL ROTOR DRIVE QUILL — CLEANING
seal.
9. Put the quill sleeve (10) in the holding plate MATERIALS REQUIRED
assembly (T101455). Remove the bearing retaining
nut (13) with the wrench (T101600). Remove the seal Refer to BHT-ALL-SPM for specifications.
(14) and the packing (12) from the nut. Discard the
seal and the packing. NUMBER NOMENCLATURE
10. Remove the spacer (16) and the packing (15). C-105 Corrosion Preventive
Discard the packing. Compound

11. Press the gear (4) out of the sleeve (10).
C-309 MEK
12. Remove the retaining ring (1), funnel (2), and
packing (3). Discard the packing. C-334 Solvent
C-516 Clean Cloth

13. Remove the cork (5) from the gear (4). Discard
the cork.
1. Remove the sealant with a plastic scraper and a
clean cloth (C-516) moistened with MEK (C-309).
CAUTION
deposits. All the parts except the bearings may be
cleaned with solvent (C-334) by vapor degreasing
C A R E T O P R O P E R LY P O S I T I O N
method.
SLEEVE (10).
CAUTION
15. Press the roller bearing (7) out of the sleeve (10) DO NOT ALLOW BEARINGS TO SPIN
with the removal bar (T101333). WHILE DRYING.
16. Press the duplex bearings (11) out of the sleeve 3. Dry the parts with a clean cloth (C-516) or dry
(10) with the bar (T101334). filtered compressed air.
63-00-00
BHT-412-CR&O-3
SEE DETAIL A
5
18 1
9
4 B
C 18A
17
3
16
B
2 C
14 15
1
T 1
13
12
11
10
27
26
25
24 0.710 TO 0.770 IN.
23 (18.04 TO 19.56 mm)
22
T 2 21
19 20
1
6000-1 TEMP-PLATE
(RED BORDER)
2 REQUIRED - 180° APART
EQUALLY SPACED WITHIN
0.300 IN. (7.62 mm)
DETAIL A
412_CRO_63_0116a_c01
Figure 63-122. Tail Rotor Drive Quill Assembly (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
WORKAID
SEAL (17) PARTIALLY SEATED SEAL (17) FULLY SEATED
18
INSTALLED INVERTED
ON INNER COUPLING (19)
INNER COUPLING (19) USED

AS BACK-UP TO PUSH LIP 18A
OF SEAL (17) UP
SECTION B-B
OIL HOLE 1. Retaining ring

5 2. Funnel
3. Packing
4. Gear
5. Cork
6. Retaining ring
7. Roller bearing
8. Shim plate
9. Screw
10. Sleeve
11. Duplex bearing
12. Packing
1.030 TO 1.150 IN. 13. Bearing retaining nut
(26.16 TO 29.21 mm) 14. Seal
4 15. Packing
SECTION C-C 16. Spacer
17. Seal
18. Outer coupling
LOCKWIRE (C-405) 18A. Internal splines
19. Inner coupling
20. Special washer
100 TO 150 FT-LBS
T 1 (136 TO 203 Nm) 21. Coupling retaining bolt
22. Packing
80 TO 100 FT-LBS 23. Spring retainer
T 2 (109 TO 135 Nm) 24. Lock spring
25. Centering spring
26. Plate assembly
NOTE 27. Retaining ring
1 Location of visual overtemperature indicator (TEMP-PLATES).
412_CRO_63_0116b_c01
Figure 63-122. Tail Rotor Drive Quill Assembly (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
3. Inspect the gear (4, Figure 63-122) for spalled,

scuffed, pitted, chipped, or dented teeth and abnormal
CAUTION
wear patterns.
DO NOT HANDLE UNOILED BEARINGS 4. Inspect the roller bearing (7) surface for spalling,
WITH BARE HANDS. scoring, pitting, brinelling, and corrosion damage. Any
damage that can be felt with a 0.020-inch (0.51-mm)
spherical radius probe is cause for rejection.
NOTE
left covered in indoor storage for 5. Inspect the splines of the gear (4) for pitted,
approximately 150 hours without being chipped, or excessively worn teeth in accordance with
affected by corrosion. Figure 63-121.
4. Coat the bearings with corrosion preventive 6. Inspect the threads on the gear (4,
compound (C-105) immediately after cleaning Figure 63-122) for damage. Any visual damage is not
(BHT-ALL-SPM). permitted.
63-155. TAIL ROTOR DRIVE QUILL — INSPECTION 7. Inspect the sleeve (10) in accordance with
Figure 63-123.
NOTE
8. Inspect the outer coupling (18, Figure 63-122)
Quill Wear/Damage Limits: The quill wear
visual over temperature indicator (TEMP-PLATES) for
damage limits are provided to show the
discoloration and overheat condition. Refer to the
required fit between parts. It is not intended
BHT-412-MM, Table 65-2 for condition and corrective
that wear be measured as a required
action of the over temperature indicators. Scrap the
overhaul procedure.
outer and inner couplings (18 and 19) if any of the
following conditions exist:
shown in Figure 63-121. Wear in excess of the limits • The cadmium plating on the outer coupling
shown is not permitted. (18) is discolored (circumferential tan or light
brown band) or blistered
inspection (Code M) or fluorescent penetrant • The gear teeth of either coupling are
inspection (Code F), as applicable. Demagnetize the discolored (brown or blue) in the normally
parts after the magnetic particle inspection. Refer to bright contact patterns
Table 63-3 and the BHT-ALL-SPM for the procedure.
• Under a 10X magnifying glass, the surface of
the gear teeth of either inner or outer coupling
exhibits signs of metal smearing or tearing in
FIGURE 63-122 the contact patterns
NOMENCLATURE CODE
INDEX NO.
4 Gear M • The grease is very viscous (thick) and has a

strong pungent odor
10 Sleeve F
18 Coupling, Outer M If none of the above conditions exist, the coupling may
be returned to service after replacement of the
19 Coupling, Inner M TEMP-PLATES.
63-00-00
BHT-412-CR&O-3
A
E (6 PLACES)
K
SEE DETAIL B BORE
A
C
SURFACE
J B
G F
SURFACE
H
D THREAD
SECTION A-A
DETAIL B
412_CRO_63_0131a
Figure 63-123. Tail Rotor Drive Quill Sleeve — Damage and Wear Limits (Sheet 1 of 4)
63-00-00
BHT-412-CR&O-3

LTR METHOD
2. B Corrosion/mechanical Visual 3
4. D Wear Measure 3.6247 inches (92.067 mm) min.

3.6255 inches (92.088 mm) max.
6. F Corrosion/mechanical Visual 11
7. G Corrosion/mechanical Visual 7
9. J Wear Measure 2.8340 inches (71.984 mm) min.

2.8347 inches (72.001 mm) max.
10. K Corrosion/mechanical Visual 4
11. L Wear Measure 3.1489 inches (79.982 mm) min.

3.1497 inches (80.002 mm) max.
412_CRO_63_0131b_c01
63-00-00
BHT-412-CR&O-3
NOTES
1 Where rework is specified repair dents, nicks, scratches and corrosion by polishing with a fine lndia
stone (C-464) to a minimum radius of 0.12 inch (3.05 mm), unless otherwise noted. Remove any
raised material flush with surrounding surface. Surface finish of repaired areas to be 63 RMS or better.
Corrosion pitting or repairs on any plane surface may not extend inward radially across more than 75%
of the width of the surface nor more than 50% of the distance from any hole to an outside
edge unless otherwise noted.
2 Corrosion pitting or mechanical damage is acceptable on cast surfaces, provided the corrosion or
damage is polished out and the reworked areas do not exceed 0.030 inch (0.76 mm) in depth and
total no more than 40% of the area within any 1.0 square inch (645 mm2) or 20% of the total area
of any surface. Refer to note 1 for rework instructions.
For inside of boit holes in Area A, the maximum corrosion must not exceed 0.020 inch (0.51 mm) in depth
with no more than 20% of the wall area inside the hole being affected. Do not polish out such pitting but
remove corrosion deposits in accordance with note 14.
3 Corrosion pitting or mechanical damage is acceptable provided the damage or corrosion is polished out
and reworked areas do not exceed 0.010 inch (0.25 mm) in depth and cover no more than 20% of
any 1.0 square inch (645 mm2) of surface or as an aggregate total, cover more than 20% of the
total area of any surface. Repair may not break into packing groove. Refer to note 1 for rework instructions.
4 Very light corrosion pitting or mechanical damage in the form of scratches is acceptable in Area K
provided the depth of such damage does not exceed 0.002 inch (0.05 mm) nor cover more than 25%
of total area of surface after rework. Rework by careful hand polishing with 400 grit or finer aluminum
oxide abrasive cloth (C-406) to produce a surface finish of 63 RMS or better.
5 Corrosion pitting is acceptable in Area E provided it is no more than 0.020 inch (0.51 mm) in depth and
covers no more than 15% of the total area of each spotface after rework. Rework areas must extend
no closer than 0.060 inch (1.52 mm) from the edge of boit holes, see note 1 for rework instructions.
The spotface areas may, however be repaired if corrosion exceeds these limits, by respotfacing to a
1.000 ± 0.010 inch(es) (25.40 ± 0.25 mm) diameter x 0.040 ± 0.010 inch (1.02 ± 0.25 mm) fillet radius to a
minimum flange thickness of 0.400 inch (10.16 mm) not including thickness of shim. Spotfaced surface
must be concentric with the boit hole within 0.010 inch (0.25 mm) T.I.R. and parallel with Surface F within
0.002 inch (0.05 mm).
Mechanical damage in the form of nicks, dents and scratches is acceptable provided they do not exceed
0.010 inch (0.25 mm) in depth nor more than 0.250 inch (6.35 mm) in length after rework.
Rework mechanical damage to a 0.060 inch (1.52 mm) fillet radius. Extent of repaired areas subject to above
corrosion limits. Refer no note 1.
6 Corrosion pitting is acceptable on Surface C provided the corrosion does not exceed 0.030 inch (0.76 mm)
in depth and covers no more than 20% of the area within any 1.0 square inch (645 mm2) or 10% of
the total area of the surface after removal of corrosion products. Do not polish out corrosion pitting.
Corrosion pitting may extend no closer than 0.100 inch (2.54 mm) from the edges of threaded stud
holes and from the edge of the Diameter K entry chamfer. See note 1 for additional limitations.
greater than 0.020 inch (0.51 mm) in depth, 0.500 inch (12.70 mm) in length and extends no closer
than 0.100 inch (2.54 mm) from edges of threaded holes, or the entry chamfer of Diameter K. Remove
any raised material flush with surrounding surface by polishing with a fine lndia stone (C-464).
Mechanical damage to the threaded holes for shim screws is acceptable provided the damage does not
extend past the first thread. No corrosion or repair permitted in thread holes.
412_CRO_63_0131c
63-00-00
BHT-412-CR&O-3
7 No corrosion or mechanical damage permitted in Area G.
8 Corrosion pitting is acceptable in Area D provided it does not exceed 0.010 inch (0.25 mm) in depth
with no more than 40% of any 1.0 square inch (645 mm2) or 5% of total area of surface being
effected after removal of corrosion products. Do not polish out corrosion pitting.
No corrosion or mechanical damage permitted in lube hole for bearing.
9 Only light, superficial corrosion, which can be readily removed with steel wool (C-411) or abrasive pad
(C-407), is permitted in Areas J and L. No repairs permitted.
10 Allowable damage in thread Area H is limited to two thread pitches. Damage on the thread pitch may
not exceed one-fourth thread depth nor more than 0.25 inch (6.4 mm) aggregate total length after
rework to remove damage. lnspect for burrs and galled metal in the threads.
11 Corrosion pitting is acceptable on Surface F provided the corrosion does not exceed 0.010 inch (0.25 mm)
in depth and covers no more than 10% of the area within any 1.0 square inch (645 mm2) of surface or 10%
of the total area of the surface after removal of corrosion products. Do not polish out corrosion pitting.
Damage must not extend closer than 0.060 inch (1.52 mm) from the edges of stud holes, threaded holes
for shim and clinch nut counter bores. Refer to note 1 for additional limitations on extent of corrosion.
0.060 inch (1.52 mm) from the edges of stud holes, threaded holes and clinch nut counter bores.
Remove raised material flush with the surrounding surface by polishing with a fine lndia stone (C-464).
Mechanical damage to the threaded holes for shim screws is acceptable provided damage does not
extend past first thread.
No loose or damaged clinch nuts are permitted.
12. Mechanical damage in the form of nicks, dents and scratches is acceptable provided such damage is no
greater than 0.020 inch (0.51 mm) nor longer than 0.500 inch (12.70 mm) and there is 1.25 inches (31.8 mm)
minimum circumferential spacing between damage. Do not polish out such damage but remove any raised
material flush with the surrounding surface using a fine lndia stone (C-464).
13. Penetrant inspect for indications of cracks. No such indications are permitted.
14. Sleeve with corrosion damage within acceptable limits must be treated by immersion in a hot chromic
acid bath. Refer to BHT-ALL-SPM for procedure. Corrosion removal process must be controlled to ensure
machined dimensions are maintained.
15. Apply corrosion-preventive treatment to sleeve assembly, in accordance with immersion method, if sleeve
was completely stripped of paint. Small localized repairs permitted after application of primer shall be
treated in accordance with brush on method. Refer to BHT-ALL-SPM for procedure.
16. Refinish external surfaces using two coats of polyamide epoxy primer (C-204).
17. Apply corrosion preventive compound (C-127) treatment.
412_CRO_63_0131d
63-00-00
BHT-412-CR&O-3
63-156. TAIL ROTOR DRIVE QUILL — REPAIR

NOTE
To ease the inspection of the outer coupling
(18) and the inner coupling (19), use a MATERIALS REQUIRED
clean piece of white paper between the
teeth of the couplings. Refer to BHT-ALL-SPM for specifications.
9. Inspect the outer coupling (18) for chipped, NUMBER NOMENCLATURE

cracked, broken, pitted, or excessively worn spline
teeth. C-100 Chemical Film Material
10. Inspect the inner coupling (19) for chipped, C-108 Cadmium Plating
cracked, broken, pitted, or excessively worn spline Solution
teeth. Refer to Figure 63-124, for acceptable wear
patterns.
C-298 Epoxy Adhesive
11. Inspect the teeth of the inner coupling (19,
Figure 63-122) for non-corrosion pits, indentations, or C-309 MEK
scratches. Make sure the pits and the indentations are
not larger than 0.030 inch (0.76 mm) across the C-318 Cleaning Compound
largest dimension. Make sure the scratches are not
wider than 0.015 inch (0.38 mm). Only one damage is C-516 Clean Cloth
permitted per tooth.
1. Replace all unserviceable parts.
12. Inspect the duplex bearings (11) for spalling,
scoring, pitting, brinelling, and corrosion damage.
Inspect the bearings for cracked or broken retainers
and for roughness when rotated. Any damage to the CAUTION
bearings that can be detected visually or by feel is not
permitted.
MAKE SURE THAT THE OIL HOLE IN
THE GEAR IS NOT OBSTRUCTED OR
13. Inspect the spacer (16) in the seal contact area
DAMAGE TO THE GEAR WILL OCCUR.
for roughness and wear. Damage that could result in
oil leakage is not permitted. Inspect the splines for 2. Replace the cork (5, Figure 63-122) in the gear
chipped, broken, and worn teeth. Damage that can be (4) as follows:
detected visually is not permitted.
a. Use a new No. 9 short cork and install the cork
14. Inspect the bearing retaining nut (13) for with shellac varnish (C-211) from 1.030 to
damaged threads and broken or rounded corners on 1.150 inches (26.16 to 29.21 mm) to the splined end
the tangs. If damage exist, replace the nut. of the gear, as shown in Figure 63-122, Section C-C.
15. Inspect the coupling retaining bolt (21) for b. Make sure that the 0.050 to 0.064 inch (1.27
damaged threads. to 1.62 mm) diameter oil hole is not obstructed.
3. Refinish the parts, after repair in accordance with

the BHT-ALL-SPM, as follows:
a. Aluminum parts: touch up with chemical film

material (C-100).
b. Cadmium plated steel parts: treat reworked

areas with cadmium plating solution (C-108)
(BHT-ALL-SPM).
63-00-00
BHT-412-CR&O-3
Figure 63-124. Tail Rotor Drive Coupling — Damage Limits
63-00-00
BHT-412-CR&O-3
4. Replace the visual over-temperature indicator

(TEMP-PLATES) on the outer coupling (18) if
CAUTION
a. Remove the damaged TEMP-PLATES with a IN ORDER TO PREVENT

plastic scraper, MEK (C-309), and a clean cloth CONTAMINATION OF TEMP-PLATES
(C-516). Wipe dry with a clean cloth (C-516) before ADHESIVE BACK, MAKE SURE THAT
MEK evaporates. WORK AREA AND HANDS ARE
T H O R O U G H LY C L E A N E D B E F O R E
WORKING WITH TEMP-PLATES.
CAUTION
DO NOT PRESS OR RUB THE
TEMP-PLATE WITH BARE FINGERS
BONDING SURFACE AND TEMP-PLATES DURING INSTALLATION ON COUPLING
MUST BE FREE OF ALL AS THIS WILL CONTAMINATE SURFACE.
CONTAMINATION COULD ALLOW THE a. Remove the protective backing from the
T E M P - P L AT E S T O C O M E O F F O R TEMP-PLATE and carefully position onto the prepared
INDICATE FALSE TEMPERATURE. surface.
b. Prepare the outer coupling (18) surface for b. With a clean cloth (C-516), work the
bonding by scrubbing the area with a clean cloth TEMP-PLATE into the contour of the coupling. Make
(C-516) moistened with MEK (C-309). Wipe dry before sure the TEMP-PLATE is in full contact with the
MEK evaporates. The surface should be at least coupling surface.
0.0500 inch (1.270 mm) larger than the TEMP-PLATE.
c. Accomplish a water break free test on the NOTE

prepared bonding surface by applying distilled or Apply epoxy coating to the TEMP-PLATE
demineralized water from a suitable dispenser immediately following installation on the
(squeeze bottle). The water must flow into a coupling.
continuous film without gathering into distinct water
droplets within 25 seconds after application. Wipe dry 6. Install the epoxy coating over the TEMP-PLATE
with a clean cloth (C-516). If the coupling bonding as follows:
surface does not meet the water break free test and
you have ensured the cleaning materials are not
contaminated, clean the coupling bonding surfaces as
follows: CAUTION
NOTE THE USE OF ANY EPOXY ADHESIVE

Follow the manufactures recommendations OTHER THAN SPECIFIED IS NOT
for proper water mixtures. AUTHORIZED.
(1) Scrub the coupling bonding surface with a. Mix epoxy adhesive (C-298) per manufacturer
a clean cloth (C-516) and cleaning compound (C-318). recommendations.
Follow the cleaning with a thorough water rinse.
b. With a soft bristled brush (artist brush),
(2) Thoroughly dry the coupling surface and vigorously mix the epoxy. A few drops of
repeat the water break test as stated in step 4, recommended thinner may be added during mixing to
substep c. reduce the viscosity to a level that permits uniform
brush application of the mixture and will not run when
5. Install the TEMP-PLATES on outer coupling (18) applied to a vertical surface. The final viscosity of the
as follows: mixture should be similar to a heavy bodied paint.
63-00-00
BHT-412-CR&O-3
adhesion tape over each TEMP-PLATE and beyond

the edge of the epoxy overcoat. Grasp one end of the
CAUTION
tape and remove the tape in one abrupt motion. Lifting
of the TEMP-PLATE is not permitted and requires
replacement of the TEMP-PLATE (step 4 through
TOO THIN OF AN EPOXY COATING MAY
SEEP INTO TEMP-PLATE CAUSING step 7).
INDICATOR DOTS TO TURN BLACK, IN
WHICH EVENT, TEMP-PLATE MUST BE 63-157. TAIL ROTOR DRIVE QUILL — ASSEMBLY
REPLACED.
c. Uniformly apply epoxy coating over the

TEMP-PLATE to a thickness of 0.002 to 0.004 inch
(0.05 to 0.10 mm). The coating should totally cover the
surface of the TEMP-PLATE and extend
NUMBER NOMENCLATURE
approximately 0.250 inch (6.35 mm) beyond the
edges of the TEMP-PLATE. T101307 Wrench Assembly
7. Cure the epoxy coating as follows: T101333 Bar
T101455 Holding Plate

Assembly
CAUTION T101599 Pressing Tool
T101600 Wrench
DO NOT EXPOSE EPOXY COATING TO
OIL, GREASE, CLEANING SOLVENTS,
OR OTHER CHEMICALS DURING CURE.
MATERIALS REQUIRED
temperature (60 to 100°F (16 to 38°C)) for a minimum Refer to BHT-ALL-SPM for specifications.
of 6 hours prior to helicopter operation. For best
results, allow epoxy to cure overnight. NUMBER NOMENCLATURE
C-015 Lubricant (tube pack)

b. The epoxy coating total cure time can be
accelerated by allowing the epoxy coating to cure at C-304 Drycleaning Solvent
room temperature for one hour, then place coupling in
a temperature controlled oven for one to two hours at C-405 Lockwire
a temperature of 150 to 180°F (66 to 82°C). An
alternate source of heat can be used if the
temperature does not exceed 180°F (82°C). 1. Clean all the parts with drycleaning solvent
(C-304) and drain.
NOTE
Following the cure time, the TEMP-PLATE
should conform to the contour of the CAUTION
coupling and be free of lifted edges.
Indicating dots on the TEMP-PLATE must
remain the original white or light gray with D O N O T H A N D L E U N O I L E D PA RT S
no partial black discoloration. WITH BARE HANDS.
c. After curing time, accomplish an adhesion test 2. Coat all the parts with the same oil used in the
by pressing a 1.0-inch (25-mm) wide strip of high transmission.
63-00-00
BHT-412-CR&O-3
CAUTION CAUTION
SHIM PLATE (8, FIGURE 63-122) MUST DUPLEX BEARING MUST BE A

BE INSTALLED ON SAME SLEEVE (10) MATCHED SET WITH SAME SERIAL
FROM WHICH REMOVED OR GEAR NUMBER ON BOTH BEARINGS.
B A C K L A S H W I L L P R O B A B LY B E
INCORRECT. 4. Press the duplex bearings (11) into the sleeve
(10), face-to-face, by pressing on the outer race with a
3. Install the shim plate (8) as follows: suitable sleeve.
a. Inspect the shim plate (8) and the sleeve (10)

5. Press the roller bearing (7) into the sleeve (10)
for the serial number. If the same serial number is
with the bar (T101333) or a suitable sleeve.
legible on both parts or if the shim plate was indexed
at the time of removal, install the shim plate as
outlined in step b. If the shim plate cannot be positively 6. Install the retaining ring (6).
identified, determine the required shim thickness as
outlined in step c.
b. Put a shim plate (8) of correct thickness on the CAUTION

sleeve (10) and install the three screws (9).
c. Determine the required thickness of the shim MAKE SURE THAT THE OIL HOLE IN
plate (8) for the sleeve (10) as follows: THE GEAR IS NOT OBSTRUCTED OR
(1) Inspect the sleeve (10) for a reference
dimension, which should be metal stamped or 7. Make sure that the cork (5) is installed in the gear
vibro-etched on the sleeve adjacent to the mounting (4) and that the oil hole, through the wall of the gear
surface for the shim plate (8). Record this dimension immediately inboard of the cork, is not obstructed.
and location on the case.
8. Support the duplex bearings (11) on the inner
(2) Measure the thickness of the shim plate race with the pressing tool (T101599) and press the
(8) and record. gear (4) into the bearings.
(3) Subtract the shim plate (8) thickness

from the reference dimension noted in step (1). The 9. Lubricate the new packing (15) with the same oil
resulting value must fall within the minimum/maximum used in the transmission.
dimensions listed as follows. This is the required value
for a plated shim plate. 10. Install the packing (15) on the gear (4).
11. Press the new seal (14) into the bearing retaining
MINIMUM MAXIMUM nut (13).
SHIM INCH INCH
(MM) (MM) 12. Put a new packing (12) in the groove of the
bearing retaining nut (13). Hold the sleeve (10), gear
Tail Rotor Drive Quill 0.9760 0.9765
down, with the holding plate assembly (T101455).
Shim Plate (8) (24.7904) (24.8031) Lubricate the packing with the same oil used in the
transmission and install the bearing retaining nut. Use
d. Procure a shim plate (8) of the correct the wrench (T101600) and torque the nut 100 to
dimension determined in step c. Install the shim as 150 foot-pounds (136 to 204 Nm). Secure with
described in step b. lockwire (C-405).
63-00-00
BHT-412-CR&O-3
13. Coat the spacer (16) with the same oil used in the (18). Insert the inner coupling (19) into the outer
transmission and install the spacer between the seal coupling with the small end through the seal (17).
(14) and the gear (4).
NOTE CAUTION
A workaid may be fabricated, as shown in
Figure 63-125, to aid the installation of the WHILE TORQUING THE INNER
seal (17, Figure 63-122). COUPLING, MAINTAIN THE VERTICAL
AND HORIZONTAL STABILITY OF THE
14. Install the new seal (17) into the outer coupling OUTER COUPLING OR DAMAGE TO THE
(18) seal groove as follows: COUPLING TEETH MAY OCCUR.
a. Apply a light coat of lubricant (tube pack) 16. Put the couplings on the splined end of the gear
(C-015) to the outer circumference of the seal (17). (4). Place the special washer (20) on the coupling
retaining bolt (21) and thread into the gear. Hold the
outer coupling (18) with the wrench assembly
b. Install the seal (17) into the outer coupling (18) (T101307) and torque the bolt 80 to 100 foot-pounds
seal groove with the lip of the seal toward the internal (108 to 136 Nm).
splines of the coupling, as shown in Figure 63-122,
Detail B.
NOTE
NOTE A 1/4-20 UNC threaded bolt may be used
to remove the spring retainer (23) from the
With the seal (17) partially seated, use the
coupling retaining bolt (21).
inner coupling (19) as a backup in reverse
(Detail B) to fully seat the outer
circumference edge of the seal into the NOTE
outer coupling (18) seal groove.
To help installation, mark the holes on the
spring retainer (23) and do not install the
c. With the inner coupling (19) as a backup and packing (22) until you obtain the correct
placed as shown in Detail B, firmly press down (hand alignment.
pressure only) on the outer coupling (18),
simultaneously tuck the outer circumference edge of
17. Place the new packing (22) on the spring retainer
the seal (17) with the workaid, or equivalent, into the
(23). Lubricate the packing with the same oil used in
outer coupling seal groove.
the transmission and insert into the coupling retaining
bolt (21). If one hole in the rim of the spring retainer
d. Continue pressing around the seal (17) with does not align with a notch of the male inner coupling
the workaid until the seal is fully seated. Remove the (19), pull the retainer free of the bolt, rotate 90°, and
inner coupling (19) from the outer coupling (18). install. Repeat if necessary to obtain alignment. When
the hole and the notch are aligned, install the lock
spring (24) through the hole in the rim of the retainer
NOTE and the notch of the coupling. Make sure that the lock
Make sure the inner coupling (19) is the spring is fully engaged in the notch.
correct size for the tail rotor drive quill; the
overall length is 2.070 to 2.080 inches 18. Extend the outer coupling (18) so that the seal
(52.58 to 52.83 mm). The overall length of (17) is out against the spherical teeth on the inner
the coupling for a 42 and 90° gearbox is coupling (19) and coat the internal splines of the outer
1.870 to 1.880 inches (47.50 to 47.75 mm). coupling with lubricant (tube pack) (C-015) to
0.12 inch (3.0 mm) in depth over the top of the spline
15. Place a small amount of lubricant (tube pack) teeth. A workaid may be fabricated, as shown in
(C-015) on the internal splines of the outer coupling Figure 63-126, to obtain the depth of the lubricant.
63-00-00
BHT-412-CR&O-3
8.0 IN. (203 mm)
1.0 IN. (25 mm)

7.0 IN. (178 mm)
2.0 IN. (51 mm)
0.125 IN. (3.18 mm)

0.25 IN.
1.0 IN. (25 mm) (6.4 mm)
NOTES
1. Make from plexiglass or similar material.
2. Remove all sharp edges.
412_CRO_63_0118
Figure 63-125. Seal (204-040-611) Installation Workaid
63-00-00
BHT-412-CR&O-3
Figure 63-126. Lubrication of Tail Rotor Driveshaft Coupling Workaid
63-00-00
BHT-412-CR&O-3
19. Place the boss of plate assembly (26, SPECIAL TOOLS REQUIRED (Cont)
Figure 63-122) on the small end of the centering
spring (25) and place the large end of the spring in the
spring retainer (23). NUMBER NOMENCLATURE
T101333 Bar
20. Install the retaining ring (27). Refer to
Figure 63-121 for a cutaway view of the installed T101334 Bar
components.
T101455 Holding Plate
21. Turn the plate assembly (T101455) with the quill Assembly
assembly installed.
T101600 Wrench
22. Install a new packing (3, Figure 63-122) on the
funnel (2). Lubricate the packing with the same oil 1. Remove the retaining ring (23, Figure 63-127).
used in the transmission and put the funnel in the gear
(4). Install the retaining ring (1). 2. Remove the lock spring (22).
23. Check the gear (4) for free rotation.

3. Install a 1/4-20 UNC threaded bolt into the spring
retainer (21) and pull on the bolt to withdraw the
24. Refer to Figure 63-52 and apply sealant around
retainer from the adapter (17).
the edge of the bearing retaining nut (13,
Figure 63-122) where it joins the sleeve (10).
4. Remove the packing (20) from the spring
25. The tail rotor drive quill shall be tagged with the retainer (21). Discard the packing.
date of lubrication and an entry made in the
component historical record, if the quill is to be
5. Hold the adapter (17) with the wrench
returned to stock.
(412-240-007-101), position the square adapter
through the wrench, and remove the adapter retaining
26. When the tail rotor drive quill is installed on the bolt (19) and the flat washer (18).
helicopter, an entry shall be made in the helicopter log
and the flex couplings lubrication log maintained as
shown in the BHT-412-MM, with the date of 6. Remove the adapter (17) from the gear (5).
lubrication.
7. Put the quill sleeve (9) in the holding plate
63-158.TAIL ROTOR DRIVE QUILL (S/N 36020 assembly (T101455). Remove the bearing retaining
AND SUBSEQUENT TO INCLUDE nut (13) with the wrench (T101600). Remove the seal
S/N 46400 THROUGH 46499 AND (14) and the packing (12) from the nut. Discard the
HELICOPTERS MODIFIED BY seal and the packing.
412-570-001-103 OR BHT-412-SI-74
(412SP TO 412HP UPGRADE))
8. Remove the spacer (16) and the packing (15).
63-159. TAIL ROTOR DRIVE QUILL —
DISASSEMBLY

10. Remove the retaining ring (1), funnel (2), and
NUMBER NOMENCLATURE
11. Remove the cork (4) from the gear (5). Discard
412-240-007-101 Wrench
the cork.
63-00-00
BHT-412-CR&O-3
OIL HOLE
1.030 TO 1.150 IN.

(26.16 TO 29.21 mm)
4 6
5 SECTION A-A
A 10
4
3 1. Retaining ring
2 A 2. Funnel
1 3. Packing
4. Cork
5. Gear
6. Retaining ring
7. Roller bearing
16 8. Shim plate
9. Sleeve
15
14 10. Screw
11. Duplex bearing
T 13 12. Packing
2 13. Bearing retaining nut
14. Seal
12 15. Packing
16. Spacer
11 17. Adapter
23 18. Flat washer
22 19. Bolt
21 20. Packing
21. Spring retainer
20 22. Lock spring
T 1
19 23. Retaining ring
18
17
LOCKWIRE (C-405)
80 TO 100 FT-LBS
T 1 (108 TO 136 Nm)
100 TO 140 FT-LBS

T 2 (136 TO 190 Nm)
412_CRO_63_0120_c01
Figure 63-127. Tail Rotor Drive Quill Assembly
63-00-00
BHT-412-CR&O-3
deposits. All the parts except the bearings may be

cleaned with solvent (C-334) by vapor degreasing
CAUTION
method.

C A R E T O P R O P E R LY P O S I T I O N CAUTION
SLEEVE (9). DO NOT ALLOW BEARINGS TO SPIN
WHILE DRYING.
13. Press the roller bearing (7) out of the sleeve (9) filtered compressed air.
with the removal bar (T101333).
14. Press the duplex bearings (11) out of the sleeve

(9) with the bar (T101334). CAUTION
15. Remove the three screws (10) and the shim plate
(8). Identify the shim plate with the sleeve serial DO NOT HANDLE UNOILED BEARINGS
number for installation on the same sleeve. WITH BARE HANDS.
63-160. TAIL ROTOR DRIVE QUILL — CLEANING NOTE

MATERIALS REQUIRED approximately 150 hours without being
NUMBER NOMENCLATURE compound (C-105) immediately after cleaning
(BHT-ALL-SPM).
Compound
63-161. TAIL ROTOR DRIVE QUILL — INSPECTION
C-309 MEK NOTE

Quill Wear/Damage Limits: The quill wear
C-334 Solvent
C-516 Clean Cloth between the parts. It is not intended that
wear be measured as a required overhaul
procedure.
1. Remove the sealant with a plastic scraper and a
clean cloth (C-516) moistened with MEK (C-309). 1. Inspect the quill parts for wear and damage. If
2. Clean all the quill parts with drycleaning solvent shown in Figure 63-128. Wear in excess of the limits
(C-304). Use a soft bristle brush to dislodge stubborn shown is not permitted.
63-00-00
BHT-412-CR&O-3
OIL PASSAGE 2 4
1
3 5
CORK 10
11 2
3 7 8 6 1
TAIL ROTOR DRIVE QUILL
(212-040-365-113) 9
ITEM NOMENCLATURE MINIMUM MINIMUM

inches (millimeters) inches (millimeters)
1 Sleeve liner I.D. 2.8340 2.8347

(71.984) (72.001)
2 Bearing O.D. 2.8341 2.8346.
(71.986) (71.999)
I.D. 1.3777 1.3781
(34.994) (35.004)
3 Shaft, gear O.D. 1.3780 1.3786
(35.001) (35.016)
4 Spline, gear Over pins 1.4424 1.4465
5 Spline, adapter Between pins 1.1465 1.1578

6 Sleeve O.D. 3.6247 3.6255

(92.067) 3 (92.088) 1
7 Bearing surface, gear O.D.
8 Bearing O.D. 3.1492 3.1496

(79.990) (80.000)
9 Sleeve liner I.D. 3.1489 3.1497
(79.982) (80.002)
10 Pilot diameter, adapter O.D. 3.4345 3.4360
(87.236) 2 (87.274)
11 Wear sleeve
NOTES
1 Average dimension.
2 0.002 inch (0.05 mm) maximum depth of wear. Measure from unworn area of diameter.
412_CRO_63_0121a_c01
Figure 63-128. Tail Rotor Drive Quill (212-040-365-113) — Damage Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
3 Measure the size of the roller race at three locations as follows:
C
A B
Instrument must be capable of reliably measuring to four decimal place accuracy.
b. Measure and record diameter at location C in area of maximum wear in roller path.
c. Calculate and record arithmetic average of diametral measurements A and B.
d. Reject the part if the difference between the calculated average of measurements A and B and
measurement C is greater than 0.0002 inch (0.005 mm).
If a measuring instrument of the required accuracy is not available, check the roller race for evidence of a
wear step using a probe having 0.020 inch (0.51 mm) spherical radius point. A wear step at either end of the
roller path which can be felt with the probe is cause for rejection.
SEE SHEET 1 FOR LIMITS

0.0960 IN.
(2.438 mm)
PINS
A
VIEW A
(412-040-624-101)
The spline wear limits are provided to show the required fit between the adapter and shaft. lt is not intended
that spline wear be measured as a prescribed overhaul procedure. lnspect splines for wear and damage
visually. If there is evidence of wear, measure dimension between pins on adapter as shown on view A.
Measure external splines on shaft in same manner, but use size pins shown on sheet 1 .
412_CRO_63_0121b
Figure 63-128. Tail Rotor Drive Quill (212-040-365-113) — Damage Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
2. Inspect the following parts by magnetic particle chipped, broken, and worn teeth. Damage that can be
inspection (Code M) or fluorescent penetrant detected visually is not permitted.
parts after the magnetic particle inspection. Refer to 11. Inspect the bearing retaining nut (13) for
Table 63-3 and the BHT-ALL-SPM for the procedure. damaged threads and broken or rounded corners on
the tangs. If damage exists, replace the nut.
12. Inspect the coupling retaining bolt (19) for

FIGURE 63-127 damaged threads.
NOMENCLATURE CODE
INDEX NO.
5 Gear M 63-162. TAIL ROTOR DRIVE QUILL — REPAIR
9 Sleeve F
16 Spacer M MATERIALS REQUIRED
17 Adapter M Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
3. Inspect the gear (5, Figure 63-127) for spalled,
scuffed, pitted, chipped, or dented teeth and abnormal C-100 Chemical Film Material
wear patterns.
4. Inspect the roller bearing (7) surface for spalling, Solution
scoring, pitting, brinelling, and corrosion damage. Any
damage that can be felt with a 0.020-inch (0.51-mm) C-211 Shellac Varnish
spherical radius probe is cause for rejection.
1. Replace all unserviceable parts.
5. Inspect the splines of the gear (5) for pitted,
chipped, or excessively worn teeth in accordance with
Figure 63-128.
CAUTION
6. Inspect the threads on the gear (5,
Figure 63-127) for damage. Any visual damage is not
MAKE SURE THAT THE OIL HOLE IN
permitted.
THE GEAR IS NOT OBSTRUCTED OR
7. Inspect the sleeve (9) in accordance with
Figure 63-123. 2. Replace the cork (4, Figure 63-127) in the gear
(5) as follows:
8. Inspect the adapter (17, Figure 63-127) for
chipped, cracked, broken, pitted, or excessively worn a. Use a new No. 9 short cork and install the cork
spline teeth. with shellac varnish (C-211) from 1.030 to
1.150 inches (26.16 to 29.21 mm) to the splined end
9. Inspect the duplex bearings (11) for spalling, of the gear, as shown in Figure 63-127, Section A-A.
scoring, pitting, brinelling, and corrosion damage.
Inspect the bearings for cracked or broken retainers b. Make sure that the 0.050 to 0.064 inch (1.27
and for roughness when rotated. Any damage to the to 1.62 mm) diameter oil hole is not obstructed.
duplex bearings that can be detected visually or by
feel is not permitted. 3. After repair, refinish parts in accordance with the
BHT-ALL-SPM as follows:
10. Inspect the spacer (16) in the seal contact area
for roughness and wear. Damage that could result in a. Aluminum parts: touch up with chemical film
oil leakage is not permitted. Inspect the splines for material (C-100).
63-00-00
BHT-412-CR&O-3
b. Cadmium plated steel parts: treat reworked (9) FROM WHICH REMOVED OR GEAR
areas with cadmium plating solution (C-108) B A C K L A S H W I L L P R O B A B LY B E
(BHT-ALL-SPM). INCORRECT.
63-163. TAIL ROTOR DRIVE QUILL — ASSEMBLY 3. Install the shim plate (8) as follows:
a. Inspect the shim plate (8) and the sleeve (9)

for the serial number. If the same serial number is
NUMBER NOMENCLATURE at the time of removal, install the shim plate as
outlined in step b. If the shim plate cannot be positively
412-240-008-101 Wrench identified, determine the required shim thickness as
T101455 Holding Plate outlined in step c.
Assembly
b. Put a shim plate (8) of the correct thickness on
T101599 Pressing Tool
the sleeve (9) and install the three screws (10).
T101600 Wrench
c. Determine the required thickness for the shim
plate (8) for the sleeve (9) as follows:
MATERIALS REQUIRED
(1) Inspect the sleeve (9) for the reference
Refer to BHT-ALL-SPM for specifications. dimension, which should be metal stamped or
vibro-etched on the sleeve adjacent to the mounting
NUMBER NOMENCLATURE
surface for the shim plate (8). Record this dimension
C-304 Drycleaning Solvent and location on the case.
C-405 Lockwire (2) Measure the thickness of the shim plate

(8) and record.
(C-304) and drain. (3) Subtract the shim plate (8) thickness
from the reference dimension noted in step (1). The
resulting value must fall within the minimum/maximum
CAUTION dimensions listed as follows. This is the required value
WITH BARE HANDS.
MINIMUM MAXIMUM
2. Coat all the parts with the same oil used in the SHIM INCH INCH
transmission. (MM) (MM)

Shim Plate (8) (24.7904) (24.8031)
CAUTION
SAME SHIM PLATE (8, Figure 63-127) dimension determined in step c. Install the shim as
MUST BE INSTALLED ON SAME SLEEVE described in step b.
63-00-00
BHT-412-CR&O-3
13. Coat the spacer (16) with the same oil used in the
transmission and install the spacer between the seal
CAUTION
(14) and the gear (5).
DUPLEX BEARING MUST BE A 14. Install the splined end of the adapter (17) on the
MATCHED SET WITH SAME SERIAL splined end of the gear (5). Install the flat washer (18)
NUMBER ON BOTH BEARINGS. on the bolt (19) and install in the gear. Hold the
adapter with the wrench (412-240-008-101) and
4. Press the duplex bearings (11) into the sleeve (9), torque the bolt 80 to 100 foot-pounds (108 to 136 Nm).
face-to-face, by pressing on the outer race with a
suitable sleeve.
NOTE
5. Press the roller bearing (7) into the sleeve (9) with A 1/4-20 UNC threaded bolt may be used to
the bar (T101333) or a suitable sleeve. remove spring retainer (21) from bolt (19).

NOTE
To help installation, mark the holes on the
spring retainer (21) and do not install the
CAUTION packing (20) until you obtain the correct
alignment.
MAKE SURE THAT THE OIL HOLE IN 15. Place the new packing (20) on the spring retainer
THE GEAR IS NOT OBSTRUCTED OR (21). Lubricate the packing with the same oil used in
DAMAGE TO THE GEAR WILL OCCUR. the transmission and insert into the coupling retaining
bolt (19). If one hole in the rim of the spring retainer
7. Make sure that the cork (4) is installed in the gear does not align with a notch of the adapter (17), pull the
(5) and that the oil hole, through the wall of the gear retainer free of the bolt, rotate 90°, and install. Repeat
immediately inboard of the cork, is not obstructed. if necessary to obtain alignment. When the hole and
the notch are aligned, install the lock spring (22)
8. Support the duplex bearings (11) on the inner through the hole in the rim of the retainer and notch of
race with the pressing tool (T101599) and press the the adapter. Make sure that the lock spring is fully
gear (5) into the bearings. engaged in the notch.
9. Lubricate the new packing (15) with the same oil 16. Install the retaining ring (23).
used in the transmission.
17. Turn the holding plate assembly (T101455) with
10. Install the packing (15) on the gear (5). the quill assembly installed.
11. Press the new seal (14) into the bearing retaining 18. Install a new packing (3) on the funnel (2).
nut (13). Lubricate the packing with the same oil used in the
transmission and put the funnel in the gear (5). Install
12. Put a new packing (12) in the groove of the the retaining ring (1).
bearing retaining nut (13). Hold the sleeve (9), gear
down, with the holding plate assembly (T101455). 19. Check the gear (5) for free rotation.
Lubricate the packing with the same oil used in the
transmission and install the bearing retaining nut. Use
the wrench (T101600) and torque the nut 100 to 20. Refer to Figure 63-52 and apply sealant around
140 foot-pounds (136 to 190 Nm). Secure the nut with the edge of the bearing retaining nut (13) where it joins
lockwire (C-405). the sleeve (9).
63-00-00
BHT-412-CR&O-3
63-164.SINGLE BOOST (OR SYSTEM 1) 7. Remove the clip (11).

HYDRAULIC DRIVE QUILL
(212-040-365-103) 8. Install the wrench assembly (T101305) on the nut
(12) and hold the gear (33) with the wrench
63-165. SINGLE BOOST (OR SYSTEM 1) (T101306). Remove the nut.
HYDRAULIC DRIVE QUILL —
DISASSEMBLY
CAUTION
NUMBER NOMENCLATURE
T101305 Wrench Assembly EXERCISE CARE TO AVOID DAMAGING

BEARINGS OR SLEEVE WHEN DOING
T101306 Wrench NEXT STEP. MAKE SURE REMOVAL
BARS ARE PROPERLY POSITIONED ON
T101308 Screw Set, BEARINGS.
1/4-28 UNF
T101333 Bar 10. Press the duplex bearing (13) out of the sleeve
(15) with the bar (T101334). Remove the retaining
T101334 Bar ring (32).

11. Press the roller bearing (31) out of the sleeve (15)
with the bar (T101333).
1. Remove the nuts (1, Figure 63-129), bolts (18
and 19), and washers (2, 3, 16, 17, 20, and 21).
12. Remove the four screws (29) and the shim plate
(30). Mark the shim plate for installation on the same
2. Remove the cover (4) with the screw set
sleeve.
(T101308). Lightly tap the sprocket (26) as the cover is
removed to prevent binding of the shaft. Remove the
gaskets (14 and 22). Discard the gaskets. 13. Remove the seals (5 and 28) from the cover (4).
Discard the seals.
3. Remove the sprocket (26) and the chain (6).
14. Remove the cork (24) from the sprocket (26).
4. Remove the retaining ring (7) and the Discard the cork.
sprocket (8).
5. Cut and remove the lockwire. 15. Remove the cork (34) from the gear (33). Discard
the cork.
6. Remove the six screws (25), retaining ring (9),
and shim (10). Mark the shim for installation on the 16. Remove the bearings (23 and 27) from the
same quill. sprocket (26) with the plate assembly (T101593).
63-00-00
BHT-412-CR&O-3
4 25
T 1
1
2
3
5
6 VIEW A
7 8 (COVER REMOVED)
9
10
11
A
12 T 2
25
28 13
14 16
15 17
27 18
26
24
23
29 22
31
30 32
33 21
20
19
34
1. Nut 18. Bolt
2. Steel washer 19. Bolt
3. Aluminum washer 20. Steel washer
4. Cover 21. Aluminum washer
5. Seal 22. Gasket
6. Chain 23. Bearing
7. Retaining ring 24. Cork
8. Sprocket 25. Screw LOCKWIRE (C-405)
9. Retaining ring 26. Sprocket
10. Shim 27. Bearing
50 TO 70 IN-LBS
11. Clip 28. Seal T 1 (5.7 TO 7.9 Nm)
12. Nut 29. Screw
13. Duplex bearing 30. Shim plate 80 TO 100 FT-LBS
14. Gasket 31. Roller bearing T 2 (108 TO 136 Nm)
15. Sleeve 32. Retaining ring
16. Aluminum washer 33. Gear
17. Steel washer 34. Cork
412_CRO_63_0129
Figure 63-129. Single Boost (or System 1) Hydraulic Drive Quill Assembly
63-00-00
BHT-412-CR&O-3
63-166. SINGLE BOOST (OR SYSTEM 1)

NOTE
HYDRAULIC DRIVE QUILL — CLEANING
MATERIALS REQUIRED approximately 150 hours without being
NUMBER NOMENCLATURE
compound (C-105) immediately after cleaning
C-105 Corrosion Preventive (BHT-ALL-SPM).
Compound
HYDRAULIC DRIVE QUILL — INSPECTION
C-309 MEK
C-334 Solvent NOTE
C-516 Clean Cloth Quill Wear/Damage Limits: The quill wear

between the parts. It is not intended that
1. Inspect the quill for corrosion damage to threaded wear be measured as a required overhaul
studs and stud holes before cleaning. No structural procedure.
damage to threads or holes is permitted.
2. Remove the sealant from the cover (4, there is evidence of wear, measure the parts, as
Figure 63-129) and the sleeve (15) with a plastic
shown in Figure 63-130. Wear in excess of the limits
scraper and a clean cloth (C-516) moistened with MEK
shown is not permitted.
(C-309).
3. Clean all quill parts with drycleaning solvent 2. Inspect the following parts by magnetic particle
(C-304). Use a soft bristle brush to dislodge stubborn inspection (Code M) or fluorescent penetrant
deposits. All the parts except the bearings may be inspection (Code F), as applicable. Demagnetize the
cleaned with solvent (C-334) by vapor degreasing parts after the magnetic particle inspection. Refer to
method. Table 63-3 and the BHT-ALL-SPM for the procedure.
CAUTION FIGURE 63-129

NOMENCLATURE CODE
INDEX NO.
DO NOT ALLOW BEARINGS TO SPIN 4 Cover F

WHILE DRYING. 8 Sprocket M
4. Dry the parts with a clean cloth (C-516) or dry 12 Nut M

15 Sleeve F
26 Sprocket M
CAUTION 33 Gear M
DO NOT HANDLE UNOILED BEARINGS 3. Inspect the gear (33) for spalled, scuffed, pitted,
WITH BARE HANDS. chipped, or dented teeth.
63-00-00
BHT-412-CR&O-3
3 2
4 5
1
CORK
6 7
14 13
10 9 9 10
CORK
12 11 11 12

METHOD INCH(ES) (millimeters) INCH(ES) (millimeters)
1. Pinion O.D. 1.8691 1.8696

(47.475) (47.488)
2. Bearing O.D. 3.1492 3.1496
(79.990) (80.000)
3. Sleeve liner I.D. 3.1489 3.1497
(79.982) (80.002)
4. Bearing O.D. 2.8341 2.8346
(71.986) (71.999)
5. Sleeve liner I.D. 2.8340 2.8347
(71.984) (72.001)
6. Pinion O.D. 1.3780 1.3786
(35.001) (35.016)
7. Bearing I.D. 1.3777 1.3781
(34.994) (35.004)
8. Pinion spline O.D. 0.5194 0.5248
9. Sprocket O.D. 0.5901 0.5909
(14.989) (15.009)
10. Bearing I.D. 0.5903 0.5907
(14.994) (15.004)
11. Bearing O.D. 1.2592 1.2598
(31.984) (31.999)
12. Liner I.D. 1.2598 1.2607
(31.999) (32.022)
13. Sleeve O.D. 3.6247 3.6255
(92.067) (92.088)
14. Case I.D. 3.6250 3.6265*
(92.075) (92.113)
* Average
412_CRO_63_0123
Figure 63-130. Single Boost (or System 1) Hydraulic Drive Quill — Damage Limits
63-00-00
BHT-412-CR&O-3
4. Inspect the sprockets (8 and 26, Figure 63-129) 2. Replace the chain (6, Figure 63-129) if worn or
for broken and damaged teeth, and excessive wear. elongated.
Damage that can be visually detected is not permitted.
3. Replace the corks in the gear (33) and the
sprocket (26). The gear requires a new No. 12 short
5. Inspect the chain (6) for wear and elongation.
cork (34). The sprocket requires a new No. 1 short
Damage that can be visually detected is not permitted.
cork (24). Install the corks in the position, as shown in
Figure 63-130, with shellac varnish (C-211).
6. Inspect the duplex bearing (13) and ball bearings
(23 and 27) for spalling, scoring, pitting, brinelling,
corrosion damage, cracked or broken retainers, and
for roughness when rotated. Damage that can be CAUTION
visually detected is not permitted.
REPLACE BEARINGS AS A MATCHED

7. Inspect the roller bearing (31) for spalling, SET.
scoring, pitting, brinelling, corrosion damage, and
cracked or broken roller retainers. Damage that can be 4. Replace duplex bearings (13, Figure 63-129) as
detected with a 0.020-inch (0.51-mm) spherical radius matched serialized set, if unserviceable.
probe is not permitted.
5. Repair sleeves that have damaged or loose studs
or damaged threads in the jackscrew holes.
8. Inspect the sleeve (15) and the cover (4) for
corrosion damage and for loose or damaged bearing
liners. Inspect the sleeve for damaged threads and for 6. Replace the washer seats under the shim plates
loose or damaged studs. Superficial mechanical if loose or missing.
damage is permitted without repair. Superficial
corrosion is permitted if it can be polished out and the 7. Repair the sleeves that have loose or missing
area treated for corrosion prevention. locked-in inserts or studs. Refer to the BHT-ALL-SPM
for the repair of the studs and the insert outlined in
step 5.
HYDRAULIC DRIVE QUILL — REPAIR
8. Inspect the sleeve flange top surface for dents
and nicks; if damage does not exceed 0.030 inch
(0.76 mm) in depth, polish out damage and blend the
MATERIALS REQUIRED repaired area into the flat surface with a minimum
radius of 0.12 inch (3.0 mm). The finished repair must
Refer to BHT-ALL-SPM for specifications. be 63 RHR or better. The maximum depth after repair
must not exceed 0.030 inch (0.76 mm).
NUMBER NOMENCLATURE
9. Refinish the parts after repair in accordance with
C-100 Chemical Film Material the BHT-ALL-SPM as follows:
Solution a. Aluminum parts: touch up with brush chemical
film material (C-100).
b. Cadmium plated steel parts: treat reworked
areas with cadmium plating solution (C-108)
1. Replace all unserviceable parts. (BHT-ALL-SPM).
63-00-00
BHT-412-CR&O-3
63-169. SINGLE BOOST (OR SYSTEM 1) a. Inspect the shim plate (30) and the sleeve (15)
HYDRAULIC DRIVE QUILL — ASSEMBLY for the serial number. If the same serial number is
at the time of removal, install the shim plate as
SPECIAL TOOLS REQUIRED outlined in step b. If the shim plate cannot be positively
identified, determine the required shim thickness as
outlined in step c.
NUMBER NOMENCLATURE
b. Put the shim plate (30) of the correct thickness
T101305 Wrench Assembly on the sleeve (15) and install the four screws (29).
T101306 Wrench c. Determine the required thickness for the shim

plate (30) and the sleeve (15) as follows:
T101333 Bar
T101599 Pressing Tool (1) Inspect the sleeve (15) for the reference
dimension, which should be metal stamped or
vibro-etched on the sleeve adjacent to the mounting
surface for the shim plate (30). Record this dimension
MATERIALS REQUIRED and location on the sleeve.
Refer to BHT-ALL-SPM for specifications. (2) Measure the thickness of the shim plate
(30) and record.
NUMBER NOMENCLATURE
(3) Subtract the shim plate thickness from
the reference dimension noted in step (1). The
C-405 Lockwire resulting value must fall within the minimum/maximum
dimensions listed as follows. This is the required value
(C-304) and drain.
MINIMUM MAXIMUM
SHIM INCH INCH
CAUTION (MM) (MM)

D O N O T H A N D L E U N O I L E D PA RT S Shim Plate (30) (24.3332) (24.3459)
WITH BARE HANDS.
2. Coat all the parts with the same oil used in the d. Procure a shim plate (30) of the correct
transmission. dimension determined in step c. Install the shim as
described in step b.
3. Install the shim plate (30, Figure 63-129) as

follows:
CAUTION
CAUTION DUPLEX BEARING MUST BE A

MATCHED SET WITH SAME SERIAL
NUMBER ON BOTH BEARINGS.
SHIM PLATE (30) MUST BE INSTALLED
ON SAME SLEEVE (15) FROM WHICH 4. Press the duplex bearing (13) into the sleeve
REMOVED OR GEAR BACKLASH WILL (15), face-to-face, by pressing on the outer race with a
PROBABLY BE INCORRECT. suitable sleeve.
63-00-00
BHT-412-CR&O-3
5. Press the roller bearing (31) into the sleeve (15)

with the bar (T101333) or a suitable sleeve. EXAMPLE:
Ring 0.338 inch (8.585 mm)

Sleeve -0.302 inch (-7.6708 mm)
0.036 inch (0.9144 mm)
Pinch -0.003 to 0.003 inch

CAUTION
(-0.0762 to 0.0762 mm)
Shim 0.033 to 0.030 inch

W H E N I N S TA L L I N G P I N I O N I N T O (0.8382 to 0.7620 mm)
BEARINGS USE CARE TO ONLY APPLY
PRESSURE TO THE PINION HUB AREA.
16. Put the shim (10) and the retaining ring (9) on the
PRESSURE APPLIED AT THE GEAR
sleeve (15) with the notches in the shim aligned with
T E E T H C A N R E S U LT I N C R A C K S
the oil holes in the ring, and the small hole for the
BETWEEN THE HOLES IN THE WEB
Iockwire in the ring aligned on the centerline between
A N D P O S S I B L E FA I L U R E O F T H E
the gear shaft and the tachometer drive.
PINION IN SERVICE.
7. Support the inner races of the duplex bearing (13) 17. Install the six screws (25) and tighten the screws.
with the pressing tool (T101599) and press the gear Secure with lockwire (C-405). Install the Iockwire in
(33) into the bearings. accordance with Figure 63-129.
18. Make sure the gear (33) rotates freely.

8. Make sure that the cork (34) is installed in the
gear (33).
19. Put the sprocket (8) on the gear shaft with two
projections engaged in the shaft slots.
9. Install the nut (12) on the gear (33). Hand tighten
the nut. 20. Install the retaining ring (7).
10. Install the wrench assembly (T101305) on the nut 21. Make sure that the cork (24) is installed in the
(12) and hold the gear (33) with the wrench sprocket (26).
(T101306). Torque the nut with the wrench assembly
(T101305) 80 to 100 foot-pounds (108 to 136 Nm). 22. Press the bearings (23 and 27) on the
sprocket (26).
11. Install the clip (11).
23. Make sure that the chain (6) spring-lock is
properly installed on the connecting link.
12. With a depth micrometer, measure the distance
from the outer race of the duplex bearing (13) to the
surface on the sleeve (15) where the retaining ring (9) 24. Install the chain (6) and the sprocket (26) in the
is to be installed. Record the dimension. sleeve (15) with the chain on both sprockets and with
the bearing (23) on the short end of the sprocket
seated in the sleeve.
13. Measure the height of the flange on the retaining
ring (9). Record the dimension.
25. Install the new seals (5 and 28) in the cover (4)
with the numbered sides of the seals outboard.
14. Subtract the sleeve (15) dimension from the
retaining ring (9) dimension. 26. Coat the lip of the oil seals (5 and 28) with the
same oil used in the transmission.
15. Prepare a shim (10) to provide a 0.003 to
0.006 inch (0.08 to 0.15 mm) pinch fit on the duplex 27. Put the new gaskets (14 and 22) on the sleeve
bearing (13). (15).
63-00-00
BHT-412-CR&O-3
28. Put the cover (4) in position on the sleeve (15). 30. Install the aluminum washers (3), steel washers
(2), and nuts (1). Place the aluminum washer next to
the cover. Torque the nuts 50 to 70 inch-pounds (5.65
29. Install the bolts (18 and 19), with the heads
to 7.91 Nm).
inboard (Figure 63-129), the steel washers (17 and
20) under the bolt heads, and the aluminum washers
(16 and 21) next to the sleeve (15). 31. Make sure the gear (33) rotates freely.
63-00-00
BHT-412-CR&O-3
ROTOR BRAKE DRIVE QUILL
63-170.ROTOR BRAKE DRIVE QUILL (3) Apply sufficient pressure to separate the
(412-040-123-101 AND -103) flange (1) from the disc (20).
63-171. ROTOR BRAKE DRIVE QUILL — (4) Inspect the disc (20) for warpage
DISASSEMBLY (paragraph 63-173).
4. Remove the flange (1).

NUMBER NOMENCLATURE
6. Remove the bolts (10), washers (11), retainer (8),
T101447 Holding Fixture packing (7), and shim (6). Mark the shim for
installation at the same location and discard the
T101519 Plate Assembly packing.
T101649-101 Holding Tool

7. Remove the transfer tube (16) and the packings
(15). Discard the packings.
1. Install the plate assembly (T101519) in a vise
(short studs up) and put the end of the pinion (19, 8. Press the seal (9) out of the retainer (8). Discard
Figure 63-131) on the plate assembly (T101519) or the seal.
hold the brake disc with the holding tool
(T101649-101).
9. Hold the duplex bearings (4) with the plate
assembly (T101519) and press the pinion (19) out of
2. Remove the nut (3) and the packing (2). Discard the sleeve (13).
the packing.
10. Press the bearings (4) and spacer set (5) out of
3. If installed, remove the disc (20) from the flange the sleeve (13).
(1) as follows:
11. Remove the screws (18) and the shim (17).
a. Cut and remove the lockwire. Identify the shim for installation on the same sleeve.
b. Hold the disc (20) with the holding fixture 63-172. ROTOR BRAKE DRIVE QUILL —
(T101447) and remove the bolts (21) and the CLEANING
washers (22).
c. Separate the flange (1) from the disc (20) by MATERIALS REQUIRED
hand pressure only.
d. If the disc (20) and the flange (1) cannot be
separated by hand pressure, do as follows: NUMBER NOMENCLATURE

(1) Install the bolts (21) and the washers (22)
to prevent inadvertent assembly separation.
1. Clean the parts with drycleaning solvent (C-304).
(2) Put the assembly in an arbor press and
remove the bolts (21) and the washers (22). 2. Dry the parts with filtered compressed air.
63-00-00
BHT-412-CR&O-3
20
2
3 T 2
4
22
5 21 T 1
6 1. Flange
2. Packing
3. Nut
7 4. Duplex bearing
5. Spacer set
8 6. Shim
7. Packing
8. Retainer
9. Seal
9 10. Bolt
11. Washer
12. Clinch nut
13. Sleeve
14. Insert
15. Packing
16. Transfer tube
12 11 17. Shim
10 T 1
18. Screw
19. Pinion
(TYPICAL) 19
20. Disc
18 21. Bolt
14 22. Washer
LOCKWIRE (C-405)
17
50 TO 70 IN-LBS
T 1 (5.7 TO 7.9 Nm)
15
16 125 TO 150 FT-LBS
13
15 T 2 (169 TO 203 Nm)
412_CRO_63_0124_c01
Figure 63-131. Rotor Brake Drive Quill
63-00-00
BHT-412-CR&O-3
63-173. ROTOR BRAKE DRIVE QUILL — a. Install the rotor brake disc inspection arbor
INSPECTION (Figure 63-133) in the pilot hole of the disc (20,
Figure 63-131) and install the four bolts AN4-5A and
1. Inspect the parts for damage or excessive wear the washers AN960-416.
(Figure 63-132).
b. Install the arbor and disc assembly between
2. Inspect the pinion (19, Figure 63-131) for the lathe centers.
chipped, broken, or excessively worn teeth.
c. While rotating the disc (20), measure the
runout as indicator probe is swept across full radial
width of each friction surface (front and back).
parts after the magnetic particle inspection. Refer to d. The total indicator runout shall not exceed
Table 63-3 and the BHT-ALL-SPM for the procedure. 0.010 inch (0.25 mm).
e. Measure the rim thickness of the disc (20).

The rim thickness shall not be less than 0.422 inch
(10.72 mm) at any point.
FIGURE 63-131
NOMENCLATURE CODE
INDEX NO.
63-174. ROTOR BRAKE DRIVE QUILL — REPAIR
1 Flange M
3 Nut M MATERIALS REQUIRED

5 Spacer (Outer) M
5 Spacer (Inner) M
NUMBER NOMENCLATURE
8 Retainer F
C-100 Chemical Film Material
13 Sleeve F
19 Pinion M
Primer
20 Disc M
C-309 MEK
4. Inspect the parts dimensionally (Figure 63-132). C-317 Adhesive
5. Inspect the shims (6 and 17, Figure 63-131) for C-334 Solvent
damage and corrosion.
Paper
6. Inspect the inserts (14) for corrosion or damaged
threads. C-464 India Stone
7. Inspect the pilot hole in the disc (20). The hole C-486 Cheesecloth
diameter must be 2.2478 to 2.2515 inches (57.094 to
57.188 mm). 1. If small nicks, burrs, or scratches are visible,
dress the splines and the gear teeth with an India
8. Inspect the disc (20) for warpage as follows: stone (C-464)
63-00-00
BHT-412-CR&O-3
4
4 8 1 8 12
13
14 6
11
10
2
9
ITEM NOMENCLATURE MINIMUM MAXIMUM REPLACE
1. Sleeve inside diameter 3.1491 inches 3.1495 inches 3.1497 inches

(79.987 mm) (79.997 mm) (80.002 mm)
2. Sleeve outside diameter 4.9995 inches 5.0000 inches 4.9993 inches

(126.987 mm) (127.000 mm) (126.982 mm)
3. Bearing inside diameter 1.5745 inches 1.5748 inches 1.5750 inches

(39.992 mm) (40.000 mm) (40.005 mm)
4. Bearing outside diameter 3.1492 inches 3.1496 inches 3.1490 inches

(79.990 mm) (80.000 mm) (79.985 mm)
5. Pinion outside diameter 1.5751 inches 1.5753 inches 1.5749 inches

(bearing journal) (40.008 mm) (40.013 mm) (40.002 mm)
6. Pinion spline 1.6130 inches 1.6160 inches 1.6114 inches

(measure over 0.120 inch (3.05 mm) (40.970 mm) (41.046 mm) (40.930 mm)
diameter pins)
7. Inner spacer inside diameter 1.5780 inches 1.5880 inches 1.5900 inches
(40.081 mm) (40.335 mm) (40.386 mm)
8. Outer spacer outside diameter 3.1320 inches 3.1420 inches 3.1300 inches
(79.553 mm) (79.807 mm) (79.502 mm)
9. Spacer set width 1.5224 inches 1.5264 inches

(38.669 mm) (38.771 mm) 1
412_CRO_63_0125a_c02
Figure 63-132. Rotor Brake Quill — Wear Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
ITEM NOMENCLATURE MINIMUM MAXIMUM REPLACE
10. Transfer tube outside diameter 0.4280 inch 0.4300 inch 0.4270 inch
(10.871 mm) (10.922 mm) (10.846 mm)
11. Flange spline (measure between 1.3324 inches 1.3342 inches 1.3359 inches
0.0900 inch (2.286 mm) diameter pins) (33.843 mm) (33.889 mm) (33.932 mm)
12. Flange inside diameter 1.5767 inches 1.5771 inches 1.5773 inches
(40.048 mm) (40.058 mm) (40.063 mm)
13. Flange outside diameter 2.2460 inches 2.2480 inches 2.2450 inches
(57.048 mm) (57.099 mm) (57.023 mm)
14. Seal wear outside diameter 1.8730 inches 1.8770 inches 0.001 inch depth
(47.574 mm) (47.676 mm) (0.03 mm)
NOTE
1 Minimum length of spacer set, measured at three equally spaced points on each spacer, shall be no
less than 1.5222 inches (38.664 mm). Maximum variation shall not exceed 0.0002 inch (0.005 mm)
between any of the six measurements.
412_CRO_63_0125b_c02
Figure 63-132. Rotor Brake Quill — Wear Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
412_CRO_63_0136+
Figure 63-133. Rotor Brake Disc Inspection Arbor
63-00-00
BHT-412-CR&O-3
a. Use a drift or bolt threaded into the nut to drive

CAUTION the clinch nut (12) out, being careful not to damage the
hole in the sleeve (13) flange.
DUPLEX BEARINGS (4, FIGURE 63-131) b. Clean the sleeve (13) by vapor degreasing
ARE SERIAL NUMBERED AND SHALL BE with solvent (C-334).
INSTALLED IN MATCHED PAIRS. BOTH
BEARINGS OF A PAIR SHALL BE FROM
THE SAME MANUFACTURER. c. Clean the surface of the sleeve (13) flange to
remove any raised burrs.
d. Treat the hole and any reworked areas on the

CAUTION
sleeve with chemical film material (C-100)
(BHT-ALL-SPM).
SPACER SET (5) IS FINISH GROUND
TOGETHER AND SERIAL NUMBERED e. If the clinch nut (12) was tight before removal,
AND SHALL BE REPLACED AS A coat a new nut with epoxy polyamide primer (C-204)
MATCHED SET. and drive the clink nut in place. Remove any raised
burrs on the sleeve flange face and touch up with
2. Replace all unserviceable components. chemical film material (C-100).
3. Replace the shim (17) as follows: f. If the clinch nut (12) was loose before
removal, remove the cadmium plating from the surface
of the clinch nut contacting the sleeve (13) with
a. Inspect the sleeve (13) for the reference
abrasive cloth or paper (C-406). Clean the clinch nut
dimension, which is stamped or etched adjacent to the
mounting surface. Record the dimension. and the mating surface of the sleeve with cheesecloth
(C-486) moistened with MEK (C-309). Bond the clinch
nut in the sleeve with adhesive (C-317).
b. Measure a new shim plate thickness and
subtract this measurement from the reference
dimension recorded from the sleeve. The result shall g. Clean excess adhesive from the threads and
be 2.2215 to 2.2220 inches (56.426 to 56.439 mm) the surface of the sleeve (13) flange and the hole. The
after plating. clinch nut shall be 0.010 inch (0.25 mm) minimum
below the surface of the sleeve flange.
c. If the resulting dimension is less than
2.2215 inches (56.426 mm), grind the surface of the h. Check that the side of the sleeve (13) flange
shim plate to obtain the proper dimension. After contacting the shim plate is flat and the clinch nut (12)
grinding, the surface finish of the shim plate shall be does not protrude above the surface.
63 RHR or better.
6. Repair corrosion and damage to the sleeve (13)
d. Make sure the screw mounting holes are and the retainer (8) in accordance with Figure 63-134
countersunk. Replate the ground surface of the shim and Figure 63-135.
with cadmium plating (BHT-ALL-SPM).
7. If surface nicks, burrs, or scratches are visible,

4. Replace the threaded inserts (14) as required dress the splines and threads of the flange (1,
(BHT-ALL-SPM). Figure 63-131) with a fine India stone (C-464). Refer
to Figure 63-136 for the flange rework procedures and
5. Replace the clinch nuts (12) as follows: limits.
63-00-00
BHT-412-CR&O-3
L
HOLES
F
J
D
LINER
C
LINER
A
B
K
SURFACE
H
M
E
I
SURFACE
G

LTR METHOD
1. A Wear Measure 3.1497 inches (80.002 mm) max.
2. B Wear Measure 4.9993 inches (126.982 mm) min.
3. C Corrosion Visual 1
4. D Corrosion Visual/measure 0.005 inch (0.13 mm) depth, 2 3 5

40% of any 1.0 square inch
(645 mm2) 5% of area of surface
5. D Mechanical Visual/measure 0.005 inch (0.13 mm) depth, 2 3 5

0.500 inch (12.70 mm) length
6. E Corrosion/mechanical Visual/measure 0.010 inch (0.25 mm) depth, 2 4

(645 mm2) 20% of area surface
412_CRO_63_0126a
Figure 63-134. Rotor Brake Quill Sleeve — Rework Limits (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3

LTR METHOD
7. F, K Corrosion/mechanical Visual None allowed
8. G, H Corrosion Visual/measure 0.010 inch (0.25 mm) depth, 3 5

(645 mm2) 10% of area of surface
9. G, H Mechanical Visual/measure 0.010 inch (0.25 mm) depth, 3 6

0.500 inch (12.70 mm) length
10. I Corrosion/mechanical Visual/measure 0.020 inch (0.51 mm) depth, 3 5 6 7

20% of surface
11. J Corrosion Visual/measure 0.020 inch (0.51 mm) depth, 5

20% of wall area
12. L, M Corrosion/mechanical Visual/measure 0.030 inch (0.76 mm) depth for 3 4

As-cast surface, 0.020 inch (0.51 mm)
depth for machined surface, 40% area
of 1.0 square inch (645 mm2) or 20%
of area of any surface
13. All Corrosion/mechanical Visual None allowed

on lube holes, threaded
insert holes, clinch nut
counter bore
14. All Looseness on insert, Visual None allowed

clinch nut, liner pins
15. All Mechanical on shim Visual None beyond first thread

screw holes
16. All Cracks on sleeve Flourescent None allowed

penetrant
412_CRO_63_0126b
63-00-00
BHT-412-CR&O-3
NOTES
1 Only light superfical corrosion, easily removable with steel wool (C-411) is allowed.
2 Damage or repair may not break into groove F.
3 Damage or repair may not extend closer than 0.060 inch (1.52 mm) from edges of lube holes, threaded
insert holes, threaded screw holes, clinch nut counter bores, and bolt holes.
4 Rework corrosion and mechanical damage by polishing with a fine India stone (C-464) to minimum radii
of 0.12 inch (3.0 mm) and a surface finish of 63 RMS or better. Remove any raised material flush with
surrounding surface.
5 Do not polish out corrosion pitting.
6 Rework only to remove any raised material flush with surrounding surface using a fine India stone (C-464).
7 Spotface Area I may be repaired if corrosion exceeds 0.020 inch (0.51 mm) depth by spotfacing to a
0.680 ± 0.010 inch (17.27 ± 0.25 mm) diameter with 0.030 ± 0.010 inch (0.76 ± 0.25 mm) fillet radius to a
minimum flange thickness of 0.480 inch (12.19 mm) not including thickness of shim. Spotface surface
must be concentric with bolt hole within 0.010 inch (0.25 mm) T.I.R. and parallel with Surface G within
0.002 inch (0.05 mm).
8. Remove all traces of corrosion on sleeve by immersion in hot chromic acid bath to clean up corrosion area.
All corrosion products must be removed.
9. Touch-up reworked areas with chromic acid (C-116) or treat entire sleeve with corrosion treatment. Refinish
by applying Epoxy primer (C-204) and acrylic lacquer (C-203) mask part to omit primer on mating surfaces.
412_CRO_63_0126c
63-00-00
BHT-412-CR&O-3
H A
G
SEE DETAIL A FOR THREADED BOSSES
A B
DETAIL A
D
ROTOR BRAKE QUILL RETAINER

LTR METHOD
1. All Corrosion/cracks Visual/fluorescent None allowed

penetrant
2. A Mechanical Visual/measure 0.030 inch (0.76 mm) depth 1 4
3. B Mechanical Visual None allowed
4. C Mechanical Visual None allowed
5. D Mechanical Visual None allowed
6. E, F Mechanical Visual None allowed
7. G Mechanical Visual/measure 0.005 inch (0.13 mm) depth 2 5
8. H Mechanical Visual/measure 0.010 inch (0.25 mm) depth 3 4
412_CRO_63_0127a_c01
Figure 63-135. Rotor Brake Quill Retainer — Rework Limits (Sheet 1 of 2)
63-00-00
BHT-412-CR&O-3
NOTES
1 No more than 40% of any 1.0 square inch (645 mm2) or 20% of total area, after rework,
may be damaged within limits.
2 Damage shall not extend into o-ring groove.
3 Damage shall not cover more than 20% of total area. No damage allowed in threaded holes or bolt holes.
4 Polish out mechanical damage to produce 0.12 inch (3.0 mm) minimum radii and a surface of 63 RMS or
better using a fine lndia stone (C-464). Remove any raised material flush with the surrounding surface.
5 Rework only to remove any raised material flush with surrounding surface using a fine lndia stone (C-464).
6. Passivate per QQ-P-35, Type Il. Supplement chromate treatment is not required.
412_CRO_63_0127b
Figure 63-135. Rotor Brake Quill Retainer — Rework Limits (Sheet 2 of 2)
63-00-00
BHT-412-CR&O-3
F
G
C
A B H D
N L
E
J 0.200 IN. (5.08 mm) CONSTANT
M
K

LTR METHOD
1. All Corrosion/mechanical Visual None except as noted
3. A Mechanical, seal wear groove Measure 0.001 inch (0.03 mm)

maximum depth
4. B Wear Measure 1.5773 inches (40.063 mm)

diameter maximum
5. B Fretting Visual/measure 9
6. C Corrosion Visual 2
7. D Fretting/wear Visual/measure 2.245 inches (57.02 mm) minimum 3
412_CRO_63_0128a_c01
Figure 63-136. Rotor Brake Quill Flange — Rework Limits (Sheet 1 of 3)
63-00-00
BHT-412-CR&O-3

LTR METHOD
8. E Mechanical Visual 0.010 inch (0.25 mm) max. depth,

1.0 inch (25 mm) min. separation 4
9. F Mechanical Visual/measure 0.010 inch (0.25 mm) max. depth,

1.0 inch (25 mm) min. separation 4 5 6
10. G Corrosion/mechanical Visual None allowed
11. H Mechanical/circumferential Visual/measure 0.001 inch (0.03 mm) max. depth 8

scratches
12. H Fretting Visual/measure 6
13. J Mechanical Visual/measure 0.005 (0.13 mm) max. depth,

1.0 inch (25 mm) min. separation
14. K Fretting Visual 11
15. L Corrosion/mechanical Visual None allowed
16. M Mechanical Visual/measure 5 10
17. N Wear Measure between 1.3359 inches (33.932 mm) max.

0.0900 inch (2.286 mm)
diameter pins
412_CRO_63_0128b
63-00-00
BHT-412-CR&O-3
NOTES
2 Light superficial corrosion easily removable by hand polishing with a fine abrasive mat or with fine steel
wool is acceptable.
3 Rework is acceptable if the material build-up in the fretted area can be removed by light hand polishing
with an abrasive mat without removing the chromium plating to bare metal in adjacent areas of the
surface and if Diameter "D" does not fall below minimum dimensional limits after material removal.
4 Rework mechanical damage by polishing out with a fine lndia stone (C-464) to a minimum concave radius
of 0.120 inch (3.05 mm) and a surface finish of 63 microinches AA or finer. Remove any raised material
flush with surrounding surface.
5 If chromium layer has been removed by rework, apply a single coat of primer (C-204) using a brush, to the
reworked areas. Do not allow primer to contact boss Diameter "D" or Surface "K".
Rework is acceptable if the material build-up in the fretted area can be removed by light hand polishing
6 with an abrasive mat or a fine lndia stone (C-464) without removing the chromium plating to bare metal in
adjacent areas of the surface.
Damage or repair may not extend closer than 0.060 inch (1.52 mm) to the edge of any hole, or surface
7. boundary.
Rework mechanical damage by removing any raised material flush with surrounding surface. Do not
8 polish out pits or mechanical damage. Remove raised material using a fine lndia stone (C-464).
9 with an abrasive mat and the size of Diameter "B" remains within acceptable dimensional limits after
material removal.
Rework mechanical damage by polishing out with a fine lndia stone (C-464) to a minimum concave radius
10 of 0.120 inch (3.05 mm) and a surface finish of 63 microinches AA or finer. Rework adjacent surfaces only
11 with an abrasive mat or a fine lndia stone (C-464) without removing the chromium plating to bare metal in
adjacent areas of the surface.
412_CRO_63_0128c
63-00-00
BHT-412-CR&O-3
63-175. ROTOR BRAKE DRIVE QUILL — 6. Lubricate the new packings (15) with the same oil
ASSEMBLY used in the transmission, and install the packings on
the transfer tube (16), and install the transfer tube in
the sleeve (13).
7. Coat the outside diameter (OD) of the new seal
(9) with sealant (C-328) immediately before the
NUMBER NOMENCLATURE installation.
T101519 Plate Assembly 8. Press the seal (9) in the retainer (8).
NOTE
MATERIALS REQUIRED
Maintain a 0.002 to 0.005 inch (0.05 to
0.13 mm) bearing pinch.
9. Install the retainer (8) without the packing (7) or
NUMBER NOMENCLATURE
shim (6) on the sleeve (13). Check the clearance with
C-328 Sealant a feeler gauge and peel the shim to obtain a 0.002 to
0.005 inch (0.05 to 0.13 mm) bearing pinch.
C-405 Lockwire
used in the transmission and install the packing in the
1. Put the duplex bearings (4, Figure 63-131) in groove of the retainer (8).
position, back-to-back, on each side of the spacer
set (5). 11. Install the shim (6) and the retainer (8) on the
sleeve (13) with the four bolts (10) and the four
2. Press the duplex bearings (4) and spacer set (5) washers (11). Torque the bolts 50 to 70 inch-pounds
in the sleeve (13). (5.65 to 7.91 Nm) and secure the bolts in pairs with
lockwire (C-405).
3. Install the shim (17) plate and the screws (18) on
the sleeve (13). 12. Install the flange (1) on the pinion (19).
13. If previously removed, install the disc (20) on the

4. Support the inner race of the duplex bearings (4) flange (1) with the washers (22) and the bolts (21).
with the plate assembly (T101519) or equivalent. Torque the bolts 50 to 70 inch-pounds (5.65 to
7.91 Nm).
NOTE
When lubricating components, use the used in the transmission, and install the packing on the
same oil used in the transmission. nut (3), and install the nut. Torque the nut 125 to
150 foot-pounds (169 to 203 Nm).
5. Lubricate the pinion (19) bearing contact areas
with the same oil used in the transmission and press 15. Secure the nut (3) between the bolts (21) with
the pinion in the duplex bearing (4). lockwire (C-405).
63-00-00
BHT-412-CR&O-3
TRANSMISSION MOUNTING
63-176.TRANSMISSION MOUNT FRICTION a. Fabricate suitable pressing tools (aluminum or

DAMPER steel tubing) that follow:
(1) Pressing tool or workaid with an outside

This section contains repair and test instructions for
diameter of 0.687 to 0.695 inch (17.45 to 17.65 mm)
the transmission mount friction damper.
and a minimum wall thickness of 0.125 inch
(3.18 mm).
Refurbished parts or kits to overhaul the friction
dampers can be purchased from LORD Corporation (2) Back-up support with an outside diameter
(www.lord.com). of 0.940 to 0.960 inch (23.88 to 24.38 mm) and a
minimum wall thickness of 0.125 inch (3.18 mm).
63-177. TRANSMISSION MOUNT FRICTION
DAMPER — INSPECTION b. Place the friction damper assembly under an
arbor press ram and press bearing (1) out from
damper upper flange, using care to retain bearing in
1. Inspect the bearing (1, Figure 63-137) for wear. position on the back-up support tool, to prevent
The maximum permitted radial play is 0.004 inch damage to damper.
(0.10 mm).
c. Clean and inspect bore and perform a
2. Inspect the boot (3) for holes and deterioration. fluorescent penetrant inspection of damper to
Damage that can be detected visually is not permitted. determine condition. Replace damper if crack is found.
d. Drill out and ream hole in damper flange to

3. Inspect the external surface of the housing (2) 0.8667 inch (22.014 mm) diameter.
and the inner member (4) for corrosion and
mechanical damage. Superficial mechanical damage e. Radius hole on each side 0.030 inch
is permitted without repair. Minor corrosion and (0.76 mm) at 45 degrees.
mechanical damage is permitted if polished out.
f. Trim sleeve (120-015-4KA) to 0.350 to
63-178. TRANSMISSION MOUNT FRICTION 0.357 inch (8.89 to 9.07 mm) in length and press
DAMPER — REPAIR sleeve into bearing bore and ream inside diameter to
0.7493 inch (19.032 mm).
g. Coat inside diameter of sleeve (120-015-4KA)

MATERIALS REQUIRED with zinc chromate primer (C-201).

h. Press new bearing (1) in sleeve
NUMBER NOMENCLATURE (120-015-4KA). Ensure bearing is centered in damper
flange.
Paper i. Ring stake bearing (1) in place.
1. Polish out minor mechanical and corrosion

damage on the external surfaces of the housing (2,
Figure 63-137) and the inner member (4) with 400 grit
abrasive cloth or paper (C-406).
2. Replace bearing (1) as follows:
63-00-00
BHT-412-CR&O-3
63-179. TRANSMISSION MOUNT FRICTION 63-180.TRANSMISSION LIFT LINK

DAMPER — TEST
63-181. TRANSMISSION LIFT LINK — INSPECTION
1. Install the damper in a test fixture capable of
supporting 1000 pounds (454 kg). 1. Inspect the lift link by magnetic particle
inspection. Demagnetize the shaft after the magnetic
particle inspection (BHT-ALL-SPM). No cracks are
permitted.
CAUTION
2. Inspect the link in accordance with Figure 63-138.
L I M I T M O T I O N TO A M A X I M U M O F 63-182. TRANSMISSION LIFT LINK — REPAIR

0.50 INCH (12.7 MM).
2. Load the damper to measure sliding friction SPECIAL TOOLS REQUIRED

between the damper inner member (4, Figure 63-137)
and the housing (2). Initial load may exceed
500 pounds (227 kg), but must drop to between 115 NUMBER NOMENCLATURE
and 180 pounds (52 and 82 kg) once sliding is
RST1016 Roll Staking Tool
initiated.
63-00-00
BHT-412-CR&O-3
1. Bearing
2. Housing
3 3. Boot
4. Inner member
412_CRO_63_0141
Figure 63-137. Transmission Mount Friction Damper Assembly
63-00-00
BHT-412-CR&O-3
2.50 IN. 2.50 IN.

(63.5 mm) (63.5 mm)
LIFT LINK (212-030-104-101)

MATERIAL: STEEL
DAMAGE LOCATION SYMBOLS
MAXIMUM DAMAGE AND REPAIR DEPTH
TYPE OF DAMAGE
CRACKS ALLOWED None None
MECHANICAL None 0.005 inch (0.13 mm)
CORROSION
BEFORE REPAIR None 0.005 inch (0.13 mm)
AFTER REPAIR None 0.005 inch (0.13 mm)
MAXIMUM AREA PER

FULL DEPTH REPAIR
NUMBER OF REPAIR AREAS
EDGE CHAMFER
BEARING BORE DAMAGE: 0.001 inch (0.03 mm) for 1/4 circumference
BEARING WEAR LIMITS

RADIAL 0.015 inch (0.38 mm)
AXIAL 0.030 inch (0.76 mm)
412_CRO_63_0130
Figure 63-138. Transmission Lift Link — Damage Limits
63-00-00
BHT-412-CR&O-3
7. Press the bearing into the lift link. Make sure the
MATERIALS REQUIRED bearing is centered equally from each side of the lift
link.
NUMBER NOMENCLATURE
CAUTION
Solution
DO NOT STAKE PARTS AFTER THE
C-204 Epoxy Polyamide SEALANT HAS CURED.
Primer
C-352 Sealant 8. Within 30 minutes after assembly, stake the

bearing in the lift link with the roll staking tool
C-516 Clean Cloth (RST1016) (BHT-ALL-SPM).
1. Remove the corrosion damage within the limits 9. Remove excess sealant with a clean cloth
by bead blasting or shot peening. Refinish the repaired (C-516).
area with cadmium plating solution (C-108) or apply
two coats of epoxy polyamide primer (C-204). 63-183. TRANSMISSION LIFT LINK FITTING
2. Replace the bearing as follows: 1. Refer to paragraph 63-17 for inspection criteria
for the transmission lift link fitting installed on the
transmission.
CAUTION
63-184.PYLON ISOLATION MOUNT BOLT
BEFORE PRESSING OUT A 63-185. PYLON ISOLATION MOUNT BOLT —

PREGROOVED BEARING WITH A STEEL INSPECTION
OUTER RACE, CAREFULLY CUT AWAY
AND REMOVE ROLL STAKED LIP ON 1. Inspect the bolt in accordance with
ONE SIDE OF BEARING USING A FLY Figure 63-139.
CUTTER. DO NOT CUT INTO PART.
63-186. PYLON ISOLATION MOUNT BOLT —

3. Press out the unserviceable bearings.
REPAIR
4. Mask off the lift link (except for bores) and clean
the bore by glass bead blasting. Do not peen more
MATERIALS REQUIRED
than the minimum required for cleanup. No local
abrading with any abrasive is permitted.
5. Measure the bore at three places 120° apart. The NUMBER NOMENCLATURE
bore diameter shall be within 1.4380 to 1.4383 inches
(36.525 to 36.533 mm). If the bore cannot be honed to C-406 Abrasive Cloth or
tolerance or if there are any remaining corrosion pits in Paper
the bore, the link shall be scrapped.
1. Repair the light scratches, nicks, and corrosion
6. Apply a coat of sealant (C-352) to the outer damage with a 400 grit abrasive cloth or paper
diameter of the replacement bearing and to the bore of (C-406). Surface finish in the reworked areas to be
the lift link. 63 RMS or better.
63-00-00
BHT-412-CR&O-3
2.55 IN.
(64.8 mm)
BOLT (212-030-096-001)
MATERIAL: STEEL
DAMAGE AREA REPAIR SYMBOLS
MAXIMUM DEPTHS AND REPAIR AREAS
TYPE OF DAMAGE
MECHANICAL None 0.005 inch (0.13 mm)
CORROSION
BEFORE CLEANUP None 0.025 inch (0.64 mm)
AFTER CLEANUP None 0.005 inch (0.13 mm)
MAXIMUM AREA PER None 0.06 square inch

FULL DEPTH REPAIR (38.7 mm2)
NUMBER OF REPAIR AREAS None One
EDGE CHAMFER None 0.015 inch (0.38 mm)
THREAD DAMAGE None
412_CRO_63_0137_c01
Figure 63-139. Pylon Isolation Mount Bolt — Damage Limits
63-00-00
BHT-412-CR&O-3
Table 63-3. Magnetic Particle Inspection
ITEM AND SET UP AND MAGNETIZATION

PART NUMBER NOMENCLATURE
FIGURE CURRENT REQUIREMENTS
MAST ASSEMBLY (412-040-366-109, -111, AND -113)
412-040-105-101 Oil Slinger 20, Figure 63-17 SET UP:

Place part over a 2.0-inches (51-mm)
diameter central conductor.
Current for primary diameters, magnetize at
2730 amps.
SET UP: 5 TURN COIL SHOT:
Disc-shaped portion of part: Place part in
bottom of coil.
Magnetize at 3000 amps.
Rotate part 1/4 turn and repeat.
204-040-309-101 Nut 23, Figure 63-17 SET UP:

1290 amps.
Omit coil shot.
412-040-524-101 Nut 23, Figure 63-17 SET UP:

1360 amps.
Omit coil shot.
412-040-525-101 Rotor 32, Figure 63-17 SET UP:

1840 amps.
Optional current for secondary diameters,
magnetize at 1150 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3
Table 63-3. Magnetic Particle Inspection (Cont)

HP/EP UPPER PLANETARY ASSEMBLY (204-040-360-105)
204-040-397-001 Spider Assembly 2, Figure 63-61 SET UP:

6000 amps.
Large I.D. of part, magnetize at six
approximately equally spaced radial
locations on central conductor.
Disc-shaped portion of part: place part in
bottom of coil.
Magnetize to 3000 amps.
204-040-130-005 Pinion Shaft 1, Figure 63-61 SET UP:

Place part over a 0.7-inch (18-mm)
1250 amps.
Omit coil shot.
204-040-131-001 Nut 3, Figure 63-61 SET UP:

1340 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

HP/EP UPPER PLANETARY ASSEMBLY (204-040-360-105) (CONT)
204-040-132-101 Bearing Inner 5, Figure 63-61 SET UP:

Race Place part over a 1.0-inch (25-mm)
2000 amps.
Place part in bottom of coil such that the
long axis of the part is 90° to the direction of
the current flow through the coil.
205-040-233-105 Pinion Gear 8, Figure 63-61 SET UP:

2170 amps.
Omit coil shot.
HP/EP GENERATOR (OR SYS 2 HYDRAULIC PUMP) DRIVE QUILL (204-040-379-101)
412-040-302-101 Pinion 12, Figure 63-107 SET UP:

3680 amps.
CAUTION
CENTRAL CONDUCTOR MAY

GET HOT.
Omit coil shot.
204-040-412-001 Nut 4, Figure 63-107 SET UP:

972 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

HP/EP LOWER PLANETARY ASSEMBLY (204-040-784-109 AND -111)
204-040-786-001 Plate Set 2 and 8, SET UP:

Figure 63-65 Place part over a 2.0-inches (51-mm)
4760 amps.
Large I.D. of part: Magnetize at six
SET: 5 TURN COIL SHOT:
bottom of coil.
412-040-785-101, Spider 4, Figure 63-65 SET UP:

-103 Place part over a 2.0-inch (51-mm)
diameter central conductor at four inside
locations between legs.
Current for body diameter, magnetize at
2200 amps.
SET UP:
Place part over a 2-inch (51-mm) diameter
central conductor at each leg.
Current for each leg shot, magnetize at
4800 amps.
SET UP:
Place part over 0.7-inch (18-mm) diameter
central conductor through each leg hole.
Current for each leg hole, magnetize at
1200 amps.
Place part flat in coil, legs up, with two legs
on coil axis.
Rotate part 1/4 turn and repeat coil shot.
DEMAGNETIZATION AND POST
INSPECTION CLEANING:
Carry out demagnetization and post
inspection cleaning of spider as per
BHT-ALL-SPAM, Chapter 6.
63-00-00
BHT-412-CR&O-3

HP/EP LOWER PLANETARY ASSEMBLY (204-040-784-109 AND -111) (CONT)
204-040-130-005 Shaft 17, Figure 63-65 SET UP:

1250 amps.
Omit coil shot.
204-040-131-001 Nut 10, Figure 63-65 SET UP:

1340 amps.
Omit coil shot.
204-040-132-101 Inner Race 15, Figure 63-65 SET UP:

2000 amps.
long axis of the part is 90° to the direction of
the current flow through the coil.

2170 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

HP/EP LOWER PLANETARY ASSEMBLY (204-040-784-109 AND -111) (CONT)
212-040-789-101 Spacer 3 and 7, SET UP:

Figure 63-65 Place part over a 0.5-inch (13-mm)
1100 amps.
Omit coil shot.
212-040-782-101 Bolt 1, Figure 63-65 SET UP: 5 TURN COIL SHOT:

Hold part in bottom of coil with long axis
parallel to coil axis.
212-040-783-101 Nut 9, Figure 63-65 SET UP:

1140 amps.
Omit coil shot.
HP/EP OFFSET ACCESSORY DRIVE QUILL (212-040-208-101)
212-040-201-101 Gear 1, Figure 63-111 SET UP:

2170 amps.
Omit coil shot.
204-040-252-001 Nut 8, Figure 63-111 SET UP:

1570 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

HP/EP OFFSET ACCESSORY DRIVE QUILL (212-040-208-101) (CONT)
204-040-412-001 Nut 10, Figure 63-111 SET UP:

972 amps.
Omit coil shot.

2920 amps.
Omit coil shot.
212-040-207-001 Spacer 12, Figure 63-111 SET UP:

1250 amps.
Omit coil shot.
HP/EP DRIVE AND SUMP ASSEMBLY (212-040-365-111)
212-040-365-103 Hydraulic Drive Figure 63-129

Quill Assembly
212-040-112-001 Sprocket 8, Figure 63-129 SET UP:

1030 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

HP/EP DRIVE AND SUMP ASSEMBLY (212-040-365-111) (CONT)
204-040-230-001 Nut 12, Figure 63-129 SET UP:

diameter central conductor
1120 amps.
Omit coil shot.

Place part over a 0.219-inch (5.56-mm)
1509 amps.
CAUTION
CONDUCTOR MAY GET HOT.

2690 amps.
CAUTION

GET HOT.
Omit coil shot.
212-040-365-113 Tail Rotor Drive Figure 63-127

Quill Assembly
63-00-00
BHT-412-CR&O-3


2570 amps.
Omit coil shot.

708 amps.
Omit coil shot.
412-040-624-101 Adapter 17, Figure 63-127 SET UP:

3530 amps.
Omit coil shot.
212-040-365-115 Accessory and Tail Figure 63-120

Rotor Drive Quill
Assembly
204-040-230-001 Nut 3, Figure 63-120 SET UP:

1120 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3


2550 amps.
Omit coil shot.
212-040-197-001 Oil Pump Shaft 14, Figure 63-114 SET UP:

856 amps.
CAUTION

GET HOT.

Hold part in bottom of coil with axis parallel
to coil axis.
412-040-700-101, Pinion 1, Figure 63-96 SET UP:

-103 Place part over a 1.0-inch (25-mm)
4350 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

412-040-137-101 Sleeve 3, Figure 63-96 SET UP:

3520 amps.
Large I.D. of part: Magnetize at four
Disc-shaped portion of part: Lay part flat in
bottom of coil.
412-040-136-101 Adapter 20, Figure 63-96 SET UP:

4570 amps.
bottom of coil.
63-00-00
BHT-412-CR&O-3

214-040-914-103 Nut 21, Figure 63-96 SET UP:

Current for magnetize at 1690 amps.
Omit coil shot.

3460 amps.
bottom of coil.
63-00-00
BHT-412-CR&O-3

HP/EP MAIN INPUT GEAR QUILL (412-040-362-101 AND -103)
204-040-357-007 Bearing Retainer 11, Figure 63-75 SET UP:

Plate Place part over a 2.0-inches (51-mm)
2750 amps.
Large I.D. of part: Rotate on central
conductor approximately three equally
spaced radial locations.
Disc-shaped part: Place part flat in bottom
of coil.
412-040-701-101 Gear Assembly 12, Figure 63-75 SET UP:

2010 amps.
Inspect interior and exterior.
Magnetize a second time at 6000 amps.
Inspect interior and exterior.
Hold part against inside bottom edge of coil
with long axis of part parallel to coil axis.
Inspect interior and exterior surfaces.
63-00-00
BHT-412-CR&O-3

HP/EP TRANSMISSION ASSEMBLY (412-040-004-103 AND -109)
412-040-107-101 Mast Driving 3, Figure 63-41 SET UP:

Adapter Place part over a 2.0-inches (51-mm)
2360 amps.
Large I.D. of part: Magnetize at three
Disc-shaped part: Place part in bottom of
coil.
412-040-109-101 Extension 4, Figure 63-41 SET UP:

2110 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

HP/EP TRANSMISSION ASSEMBLY (412-040-004-103 AND -109) (CONT)
412-040-230-101 Upper Sun Gear 7, Figure 63-41 SET UP:

Current for primary diameter, magnetize at
1940 amps.
bottom of coil.
204-040-338-001 Outer Liner 11, Figure 63-41 SET UP:

2370 amps.
Disc-shaped part: Lay part flat in bottom of
coil.
205-040-231-009 Ring Gear 5, Figure 63-42 SET UP:

3580 amps.
Large I.D. of part: Magnetize at seven
Omit coil shot.
63-00-00
BHT-412-CR&O-3

HP/EP TRANSMISSION ASSEMBLY (412-040-004-103 AND -109) (CONT)
205-040-229-003 Lower Sun Gear 14, Figure 63-41 SET UP:

2990 amps.
bottom of coil.
212-040-203-103 Tail Rotor Drive 2, Figure 63-44 SET UP:

Quill Adapter Place part over a 0.7-inch (18-mm)
838 amps.
HP/EP MAIN DRIVESHAFT ASSEMBLY (412-040-005-101 AND -103)
204-040-184-001 Nut 6, Figure 63-7 SET UP:

1990 amps.
214-040-657-003 Inner Coupling 8, Figure 63-7 SET UP:

3480 amps.
bottom of coil.
63-00-00
BHT-412-CR&O-3

HP/EP MAIN DRIVESHAFT ASSEMBLY (412-040-005-101 AND -103) (CONT)
212-040-686-001 Driveshaft 16, Figure 63-7 SET UP:

2000 amps.
With part supported on the conducting rod
between the contact plates, magnetize the
part by placing the coil in positions shown in
the attached diagram with magnetizing
force of 2400 amps.
214-010-659-005 Outer Coupling 9, Figure 63-7 SET UP:

1760 amps.
bottom of coil.
MAIN DRIVESHAFT ASSEMBLY (212-040-005-103)
204-040-184-001 Nut 6, Figure 63-1 SET UP:

1990 amps.
Omit coil shot.

2820 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

MAIN DRIVESHAFT ASSEMBLY (212-040-005-103) (CONT)

2590 amps.
bottom of coil.
212-040-686-001 Driveshaft 16, Figure 63-1 SET UP:

2000 amps.
With part supported on the conducting rod
between the contact plates, magnetize at
2400 amps.
MAST ASSEMBLY (412-040-366-103)
412-040-101-105 Mast Assembly 1, Figure 63-13 SET UP:

2600 amps.
Magnetize at 15.0-inches (381-mm)
intervals along mast.
412-040-102-101 Bearing Liner 23, Figure 63-13 Refer to 412 HP/EP magnetic particle.
412-040-104-101 Mast Bearing 7, Figure 63-13 Refer to 412 HP/EP magnetic particle.
Retention Nut
63-00-00
BHT-412-CR&O-3

MAST ASSEMBLY (412-040-366-103) (CONT)
412-040-105-101 Oil Slinger 25, Figure 63-13 SET UP:

2730 amps.
bottom of coil.
204-040-309-001 Nut 27, Figure 63-13 SET UP:

1290 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

LOWER PLANETARY ASSEMBLY (204-040-784-101 AND -107)
204-040-785-003 Spider 4, Figure 63-65 SET UP:

diameter central conductor at four inside
locations between legs.
2200 amps.
SET UP:
diameter central conductor at each leg.
Current for each leg shot, magnetize at
4800 amps.
SET UP:
diameter central conductor through each
leg hole.
1200 amps.
on coil axis.
63-00-00
BHT-412-CR&O-3

LOWER PLANETARY ASSEMBLY (204-040-784-101 AND -107) (CONT)
412-040-785-101 Spider 4, Figure 63-65 SET UP:

212-040-789-101 Spacer 3 and 7, diameter central conductor at four inside
Figure 63-65 locations between legs.
204-040-786-001 Plate Set 2 and 8, 2200 amps.
Figure 63-65
SET UP:
204-040-130-005 Shaft 17, Figure 63-65 Place part over a 2-inch (51-mm) diameter
central conductor at each leg.
204-040-131-001 Nut 10, Figure 63-65 Current for each leg shot, magnetize at
4800 amps.
205-040-233-001 Pinion Gear 12, Figure 63-65
SET UP:
205-040-233-101 Pinion Gear 12, Figure 63-65 Place part over 0.7-inch (18-mm) diameter
central conductor through each leg hole.
204-040-132-001 Inner Race 15, Figure 63-65
1200 amps.
on coil axis.
212-040-782-101 Bolt 1, Figure 63-65 SET UP: 5 TURN COIL SHOT:

Place part in bottom of coil with long axis
212-040-783-101 Nut 9, Figure 63-65 SET UP:

1140 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

UPPER PLANETARY ASSEMBLY (204-040-360-005, -103 AND -105)
204-040-130-005 Pinion Shaft 1, Figure 63-61 SET UP:

1250 amps.
848 amps.
Omit coil shot.
204-040-397-001 Spider Assembly 2, Figure 63-61 SET UP:

6000 amps.
bottom of coil.
204-040-131-001 Nut 3, Figure 63-61 SET UP:

1340 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

UPPER PLANETARY ASSEMBLY (204-040-360-005, -103 AND -105) (CONT)
204-040-132-001 Bearing Inner 5, Figure 63-61 SET UP:

Race Place part over a 1.0-inch (25-mm)
2000 amps.
longitudinal axis of the part is 90° to the
direction of the current flow through the coil.

2170 amps.
Omit coil shot.
LOWER PLANETARY ASSEMBLY (204-040-784-101 AND -107)
212-040-789-101 Spacer 3 and 7, SET UP:

Figure 63-65 Place part over a 0.5-inch (13-mm)
1100 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

LOWER PLANETARY ASSEMBLY (204-040-784-101 AND -107) (CONT)
204-040-786-001 Plate Set 2 and 8, SET UP:

Figure 63-65 Place part over a 2.0-inches (51-mm)
4760 amps.
bottom of coil.
ACCESSORY AND TAIL ROTOR DRIVE QUILL (212-040-365-023)
212-040-197-001 Oil Pump Shaft 14, Figure 63-114 SET UP:

856 amps.
CAUTION

GET NOT.

204-040-230-001 Nut 3, Figure 63-120 SET UP:

1120 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

ACCESSORY AND TAIL ROTOR DRIVE QUILL (212-040-365-023) (CONT)

1030 amps.
Omit coil shot.
TAIL ROTOR DRIVE QUILL ASSEMBLY (212-040-365-025)

1180 amps.
Omit coil shot.

3030 amps.
Omit coil shot.
212-040-151-009 Gear 4, Figure 63-122 Refer to 212 HP/EP magnetic particle.
HYDRAULIC DRIVE QUILL ASSEMBLY (212-040-365-103)

1030 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

HYDRAULIC DRIVE QUILL ASSEMBLY (212-040-365-103) (CONT)

1509 amps.
CAUTION
CONDUCTOR MAY GET HOT.

2690 amps.
CAUTION

GET VERY HOT.
Omit coil shot.
204-040-230-001 Nut 12, Figure 63-129 SET UP:

1120 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

GENERATOR (OR SYS 2 HYDRAULIC PUMP) DRIVE QUILL (204-040-379-003)

3680 amps.
CAUTION

GET HOT.
Omit coil shot.
204-040-412-001 Nut 4, Figure 63-107 SET UP:

972 amps.
Omit coil shot.
MAIN INPUT GEAR QUILL (204-040-362-103)
204-040-324-005 Shaft 11, Figure 63-68 SET UP:

2500 amps.
Rotate part 180° and magnetize at
2500 amps.
long axis of the part is 90° to the axis of the
coil.
63-00-00
BHT-412-CR&O-3

MAIN INPUT GEAR QUILL (204-040-362-103) (CONT)
204-040-701-103 Spiral Bevel Gear 12, Figure 63-68 SET UP:

4140 amps.
Large I.D. of part: Magnetize at five
bottom of coil.
204-040-357-007 Bearing Retainer 9, Figure 63-68 SET UP:

Plate Place part over a 2.0-inches (51-mm)
2750 amps.
bottom of coil.
MAIN INPUT QUILL (212-040-263-101 AND -107)
204-040-184-001 Nut 23, Figure 63-81 SET UP:

1990 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

MAIN INPUT QUILL (212-040-263-101 AND -107) (CONT)

4310 amps.
CAUTION

GET HOT.
Omit coil shot.
212-040-190-001 Curvic Coupling 22, Figure 63-81 SET UP:

4180 amps.
bottom of coil.

3460 amps.
bottom of coil.
63-00-00
BHT-412-CR&O-3

TRANSMISSION ASSEMBLY (412-040-002-105, -107, AND -111)
412-040-107-101 Mast Driving 3, Figure 63-41 SET UP:

2360 amps.
bottom of coil.
412-040-109-101 Extension 4, Figure 63-41 SET UP:

2110 amps.
Omit coil shot.

1560 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

TRANSMISSION ASSEMBLY (412-040-002-105, -107, AND -111) (CONT)

2370 amps.
Disc-shaped part: Lay part flat in bottom of
coil.
205-040-230-003 Upper Sun Gear 7, Figure 63-41 SET UP:

1930 amps.
coil.
205-040-229-003 Lower Sun Gear 14, Figure 63-41 SET UP:

2990 amps.
coil.
63-00-00
BHT-412-CR&O-3

TRANSMISSION ASSEMBLY (412-040-002-105, -107, AND -111) (CONT)
205-040-231-009 Ring Gear 15, Figure 63-41 SET UP:

3580 amps.
Large I.D. of part: Magnetize at seven
Omit coil shot.
212-040-206-101 Tail Rotor Drive 2, Figure 63-44 Refer to 212 HP magnetic particle
Quill Adapter inspection.
OFFSET ACCESSORY DRIVE QUILL (212-040-208-001)
204-040-252-001 Nut 8, Figure 63-111 SET UP:

1570 amps.
Omit coil shot.
204-040-412-001 Nut 10, Figure 63-111 SET UP:

972 amps.
Omit coil shot.

2170 amps.
Omit coil shot.
63-00-00
BHT-412-CR&O-3

OFFSET ACCESSORY DRIVE QUILL (212-040-208-001) (CONT)

2920 amps.
Omit coil shot.

1250 amps.
Omit coil shot.
ROTOR BRAKE DRIVE QUILL (412-040-123-101 AND -103)
209-040-176-101 Spacer Set 5, Figure 63-131 SET UP:

(two pieces) Place part over a 1.0-inch (25-mm)
Magnetize at 1000 amps, rotate 120°,
repeat twice.
Omit coil shot.

Magnetize smaller diameter at 1000 amps,
rotate 180°, repeat.
Increase current to 2000 amps for larger
diameter. Magnetize, inspect, rotate 120°,
repeat twice.
Place part centrally in coil with long axis
extending out of coil.
Apply 10,000 amp-turns (2000 amps).
63-00-00
BHT-412-CR&O-3

ROTOR BRAKE DRIVE QUILL (412-040-123-101 AND -103) (CONT)
412-040-177-101 Flange 1, Figure 63-131 SET UP:

Magnetize smaller diameter at 1000 amps,
rotate 180°, repeat.
Increase current to 1500 amps for larger
diameter. Magnetize, inspect, rotate 120°,
repeat twice.
Omit coil shot.
NOTES:
1. Magnetization currents provided are applicable to magnetic particle inspection apparatus using Direct Current
(DC). If an Alternating Current (AC) apparatus is used, adjust the current as follows: AC = 0.667 x DC.
2. Ferrous parts requiring magnetic particle inspection that are not addressed in the attached material, are to be
inspected in accordance with the general procedures outlined in ASTM E1444 standard practices
(BHT-ALL-SPM, Chapter 6).
3. Part numbers listed apply to all successive dash numbers for that component unless otherwise specified.
63-00-00

412CRO412CROCH63

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412CRO412CROCH63

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BHT-412-CR&O-3

CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM

Paragraph Chapter/Section Page

63-1 Main Driveshaft (212-040-005-103)........................................... 63-00-00 11

TRANSMISSION MAIN ROTOR MAST

63-18A Mast Assembly — Configuration ............................................... 63-00-00 52A

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-31 Transmission (412-040-002 and 412-040-004) ......................... 63-00-00 107

63-41 Transmission Case.................................................................... 63-00-00 163

PLANETARY RING GEAR, UPPER PLANETARY, AND LOWER PLANETARY ASSEMBLIES

63-60 Planetary Ring Gear, Upper Planetary, and Lower Planetary

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-67 Upper Planetary Assembly (204-040-360-005, -103

MAIN INPUT GEAR QUILL

63-79 Main Input Gear Quill (204-040-362-103).................................. 63-00-00 221

MAIN INPUT QUILL

63-91 Main Input Quill (212-040-263-107)........................................... 63-00-00 253

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-103 Main Input Quill (412-040-263-ALL) (S/N 36020 and

GENERATOR (OR SYS 2 HYDRAULIC PUMP) DRIVE QUILL

63-109 Generator (or SYS 2 Hydraulic Pump) Drive Quill

OFFSET ACCESSORY DRIVE QUILL

ACCESSORY AND TAIL ROTOR DRIVE AND SUMP ASSEMBLY

63-121 Accessory and Tail Rotor Drive and Sump Assembly

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-126 Accessory and Tail Rotor Drive and Sump Assembly —

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-165 Single Boost (or System 1) Hydraulic Drive Quill —

ROTOR BRAKE DRIVE QUILL

63-176 Transmission Mount Friction Damper........................................ 63-00-00 409

63-1 Main Driveshaft Assembly (212-040-005-103) ............................................... 12

63-5 Main Driveshaft Inner Coupling (212-040-005-103) — Damage Limits.......... 22

63-46 Roller Bearing — Wear Patterns .................................................................... 140

63-89 Magnetic Seal — Damage Limits ................................................................... 264

63-134 Rotor Brake Quill Sleeve — Rework Limits .................................................... 400

63-1 Mast Assembly Versus Helicopter Serial Number .......................................... 52A

SPECIAL TOOLS REQUIRED 7. Remove the tools.

Figure 63-1. Main Driveshaft Assembly (212-040-005-103)

1. Extension bar (L-122)

100 TO 200 FT-LBS

63-3. MAIN DRIVESHAFT — CLEANING 63-5. MAIN DRIVESHAFT — CONDITIONAL

MATERIALS REQUIRED 1. Visually inspect the driveshaft for external

NOTE NUMBER NOMENCLATURE

If records or physical appearance of the C-464 India Stone

USE 0.1920 IN. (4.877 mm)

3. Spline wear/damage limits:

SEE DETAILS A, B, WIRE FEELER GAUGE

0.1728 IN. 4.7657 TO 4.7703 IN.

6000-2 TEMP-PLATE (YELLOW BORDER)

4. Spline teeth wear/damage limits:

Surface finish after rework shall be 63 RMS or better.

Inspect Area H for corrosion and mechanical damage. No damage is permitted.

Inspect threaded holes for damage. No damage allowed.

0.1440 IN. (3.658 mm) PINS

SURFACE E 0.1440 IN. (3.658 mm) PINS

A. Typical acceptable wear pattern on the

B. Typical acceptable wear pattern on the

C. Typical unacceptable wear pattern on the

A Gear teeth wear Measure over 0.1440 inch 5.1680 5.1841