BHT-206B3-CR&O-4

CHAPTER 65 — TAIL ROTOR DRIVE SYSTEM

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

SEGMENTED TAIL ROTOR DRIVESHAFTS

65-1 Tail Rotor Drive System............................................................. 65-00-00 5

65-2 Tail Rotor Driveshafts ........................................................... 65-00-00 5
65-3 Cleaning........................................................................ 65-00-00 5

FORWARD AND AFT SHORT SHAFTS

65-4 Forward Short Shaft .................................................................. 65-00-00 7

65-5 Forward Short Shaft — Maintenance ................................... 65-00-00 7
65-6 Forward Short Shaft — Inspection and Repair ............. 65-00-00 7
65-7 Aft Short Shaft ........................................................................... 65-00-00 7
65-8 Aft Short Shaft — Maintenance ............................................ 65-00-00 7
65-9 Aft Short Shaft — Inspection and Repair...................... 65-00-00 7

SEGMENTED TAIL ROTOR DRIVESHAFTS

65-10 Segmented Tail Rotor Driveshaft .............................................. 65-00-00 11

65-11 Segmented Tail Rotor Driveshaft — Maintenance ............... 65-00-00 11
65-12 Segmented Tail Rotor Driveshaft — Disassembly........ 65-00-00 11
65-13 Segmented Tail Rotor Driveshaft — Inspection and
Repair ........................................................................... 65-00-00 11
65-14 Segmented Tail Rotor Driveshaft — Fluorescent
Penetrant Inspection..................................................... 65-00-00 18
65-15 Segmented Tail Rotor Driveshaft — Magnetic Particle
Inspection ..................................................................... 65-00-00 18
65-16 Assembly ...................................................................... 65-00-00 19
65-17 Corrosion Protective Coating........................................ 65-00-00 20

DISC ASSEMBLY

65-18 Disc Assembly ........................................................................... 65-00-00 23

65-19 Disc Assembly — Maintenance............................................ 65-00-00 23
65-20 Disc Assembly — Cleaning .......................................... 65-00-00 23
65-21 Disc Assembly — Inspection ........................................ 65-00-00 23

OIL COOLER BLOWER

65-22 Oil Cooler Blower....................................................................... 65-00-00 25

65-23 Oil Cooler Blower — Maintenance ....................................... 65-00-00 25
65-24 Oil Cooler Blower — Disassembly................................ 65-00-00 25
65-25 Oil Cooler Blower — Cleaning ...................................... 65-00-00 25
65-26 Oil Cooler Blower — Inspection.................................... 65-00-00 25
65-27 Assembly ...................................................................... 65-00-00 31
65-28 Static Balance of Impeller and Shaft Assembly ............ 65-00-00 33

65-00-00
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BHT-206B3-CR&O-4

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

TAIL ROTOR GEARBOX (206-040-400)

65-29 Tail Rotor Gearbox (206-040-400) ............................................ 65-00-00 35

65-30 Maintenance ......................................................................... 65-00-00 35
65-31 Disassembly ................................................................. 65-00-00 35
65-32 Cleaning ....................................................................... 65-00-00 46
65-33 Inspection and Repair................................................... 65-00-00 47
65-34 3000 Hour Inspection ................................................... 65-00-00 51
65-35 Fluorescent Penetrant Inspection ................................. 65-00-00 51
65-36 Magnetic Particle Inspection......................................... 65-00-00 52
65-37 Corrosion Damage Inspection ...................................... 65-00-00 52
65-38 Corrosion Removal and Repair .................................... 65-00-00 53
65-39 Assembly ...................................................................... 65-00-00 57
65-40 Backlash Check ............................................................ 65-00-00 64
65-41 Painting......................................................................... 65-00-00 64
65-42 Preservation ................................................................. 65-00-00 67

TAIL ROTOR GEARBOX (206-040-402)

65-43 Tail Rotor Gearbox 206-040-402 ............................................... 65-00-00 69

65-44 Maintenance ......................................................................... 65-00-00 69
65-45 Disassembly ................................................................. 65-00-00 69
65-46 Cleaning ....................................................................... 65-00-00 76
65-47 Inspection and Repair................................................... 65-00-00 77
65-48 3000 Hour Inspection ................................................... 65-00-00 84
65-49 Fluorescent Penetrant Inspection ................................. 65-00-00 84
65-50 Magnetic Particle Inspection......................................... 65-00-00 86
65-51 Corrosion Damage Inspection ...................................... 65-00-00 86
65-52 Corrosion Removal and Repair .................................... 65-00-00 87
65-53 Assembly ...................................................................... 65-00-00 91
65-54 Tail Rotor Gearbox 206-040-402 — Backlash Check... 65-00-00 97
65-55 Painting......................................................................... 65-00-00 99
65-56 Preservation ................................................................. 65-00-00 101

FIGURES

Figure Page
Number Title Number

65-1 Forward Short Shaft Damage Limits .............................................................. 8

65-2 Aft Short Shaft Damage Limits ....................................................................... 9
65-3 Segmented Tail Rotor Driveshaft ................................................................... 12
65-4 Segmented Tail Rotor Driveshaft (Bonded) — Wear Limits ........................... 12A
65-5 Coupling Adapter Damage Limits ................................................................... 14

65-00-00
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 BHT-206B3-CR&O-4

FIGURES (CONT)

Figure Page
Number Title Number

65-6 Hanger Damage Limits ................................................................................... 15

65-7 Segmented Tail Rotor Driveshaft (Bonded) — Damage Limits ...................... 16
65-7A Segmented Tail Rotor Driveshaft (Riveted) — Wear and Damage Limits...... 16B
65-8 Bearing Hanger Spacer .................................................................................. 21
65-9 Coupling Disc Packs — Inspection and Repair .............................................. 24
65-10 Oil Cooler Blower............................................................................................ 26
65-11 Oil Cooler Impeller Shaft Wear Limits............................................................. 28
65-12 Forward Bearing Hanger Repair..................................................................... 30
65-13 Oil Cooler Blower Impeller Shaft and Bearing Hanger Wear Limits ............... 32
65-14 Tail Rotor Gearbox 204-040-400 .................................................................... 37
65-15 Input Pinion Inner Nut Tool Application .......................................................... 39
65-16 Output Shaft Inner Nut Tool Application ......................................................... 40
65-17 Tail Rotor Gearbox Mounting Workaid ........................................................... 41
65-18 Input Pinion Outer Nut Tool Application ......................................................... 42
65-19 Input Pinion Tool Application .......................................................................... 43
65-20 Duplex Bearing and Input Pinion Tool Application ......................................... 44
65-21 Output Shaft Tool Application ......................................................................... 45
65-22 Output Shaft Outer Nut Tool Application ........................................................ 46
65-23 Tail Rotor Gearbox Limits 206-040-400.......................................................... 48
65-24 Gear Wear Pattern (206-040-400).................................................................. 50
65-25 Output Shaft Runout Inspection (206-040-400).............................................. 54
65-26 Tail Rotor Gearbox Corrosion Damage Areas (206-040-400) ........................ 55
65-27 Tail Rotor Gearbox 206-040-400 Stud Heights .............................................. 56
65-28 Tail Rotor Gearbox Backlash Checks (206-040-400) ..................................... 59
65-29 Output Shaft Bearing Workaid ........................................................................ 60
65-30 Input Pinion Bearing Pressing Workaid .......................................................... 62
65-31 Tail Rotor Gearbox Backlash Tool Application ............................................... 65
65-32 Tail Rotor Gearbox Painting (206-040-400).................................................... 66
65-33 Tail Rotor Gearbox 206-040-402 .................................................................... 71
65-34 Input Pinion Inner Nut Tool Application, T101511 and MS8514-1.................. 73
65-35 Output Shaft Inner Nut and T101511 and T101513 Tool ............................... 74
65-36 Tail Rotor Gearbox Mounting Workaid ........................................................... 75
65-37 Input Pinion Outer Nut and T101512 Tool ...................................................... 76
65-38 Input Pinion and T101507 Tool with Owatonna 927 and 927A Tools ............ 77
65-39 Duplex Bearing and Input Pinion and Owatonna 630-3 and 951 Tools.......... 78
65-40 Removal of Output Shaft Tool Application...................................................... 79
65-41 Output Shaft Outer Nut Tool Application T101512 and Mounting Workaid .... 80
65-42 Tail Rotor Gearbox 206-040-402 Wear Limits ................................................ 81
65-43 Gear Wear Pattern (206-040-402).................................................................. 85
65-44 Output Shaft Runout Inspection (206-040-402).............................................. 86
65-45 Tail Rotor Gearbox 206-040-402 Damage Limits ........................................... 88
65-46 Tail Rotor Gearbox 206-040-402 Stud Replacement ..................................... 90
65-47 Tail Rotor Gearbox 206-040-402 Backlash Checks ....................................... 93
65-48 Output Shaft Bearing Pressing Cylinder Workaid........................................... 94
65-49 Input Pinion Bearing Pressing Cylinder Workaid ............................................ 96
65-50 Tail Rotor Gearbox Backlash Using T101511 and T102093 Tools ................ 98
65-51 Tail Rotor Gearbox 206-040-402 Painting ...................................................... 100

65-00-00
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BHT-206B3-CR&O-4

TABLES

Table Page
Number Title Number

65-1 Tail Rotor Driveshaft Fluorescent Penetrant Overhaul Inspection

Requirements ................................................................................................. 18
65-2 Tail Rotor Driveshaft Magnetic Particle Overhaul Inspection Requirements .. 19
65-3 Tail Rotor Gearbox 206-040-400 Fluorescent Penetrant Overhaul Inspection
Requirements ................................................................................................. 52
65-4 Tail Rotor Gearbox 206-040-400 Magnetic Penetrant Overhaul Inspection
Requirements ................................................................................................. 52
65-5 Tail Rotor Gearbox 206-040-400 Painting Requirements .............................. 67
65-6 Tail Rotor Gearbox 206-040-402 Fluorescent Penetrant Overhaul Inspection
Requirements ................................................................................................. 86
65-7 Tail Rotor Gearbox 206-040-402 Magnetic Particle Overhaul Inspection
Requirements ................................................................................................. 86
65-8 Tail Rotor Gearbox 206-040-402 Painting Requirements .............................. 99

65-00-00
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 BHT-206B3-CR&O

TAIL ROTOR DRIVE SYSTEM

65-1. TAIL ROTOR DRIVE SYSTEM. 1. Clean all tail rotor driveshaft parts with
solvent (C-304), except tail rotor driveshaft
bearings. Wipe exterior surfaces of bearings
65-2. TAIL ROTOR DRIVESHAFTS. clean with clean dry cloths using caution not
to wipe dirt or expelled lubricant under
The following paragraphs provide overhaul bearing seal and into bearing.
and repair instructions applicable to the tail
rotor driveshaft system. 2. Dry parts with filtered compressed air and
clean cloths.
NOTE
3. Remove paint from metal parts using
Any portion of tail rotor driveshaft paint remover (C-436).
system may be disassembled, as
required, to accomplish component
r e p a i r to a p a rt i c u l a r p a r t o r
assembly.

65-3. Cleaning.

MATERIALS REQUIRED

NUMBER NOMENCLATURE

C-304 Solvent
C-436 Paint Remover

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 BHT-206B3-CR&O-4

FORWARD AND AFT SHORT SHAFTS

65-4. FORWARD SHORT SHAFT 4. Each overhaul inspect forward short shaft and
mating splined adapters by magnetic particle
inspection method (paragraph 65-15).
65-5. FORWARD SHORT SHAFT —
MAINTENANCE
5. Inspect mating splined adapters for chips, cracks,
and damaged splines. Inspect splines for wear (Figure
65-6. Forward Short Shaft — Inspection and 65-5).
Repair
6. Inspect mating disc assemblies
(BHT-206A/B-SERIES-MM).
MATERIALS REQUIRED
65-7. AFT SHORT SHAFT
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE 65-8. AFT SHORT SHAFT — MAINTENANCE

C-108 Cadmium Plating 65-9. Aft Short Shaft — Inspection and Repair
Solution

C-204 Epoxy Polyamide

Primer MATERIALS REQUIRED

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

C-464 India Stone NUMBER NOMENCLATURE

C-100 Chemical Film Material

1. Thoroughly clean forward short shaft (paragraph
C-423 Abrasive Paper
65-3).
C-464 India Stone
2. Visually inspect forward short shaft for
mechanical and corrosion damage (Figure 65-1). 1. Thoroughly clean aft short shaft (paragraph
65-3).
a. Polish out acceptable damage with 400 or 600
grit abrasive paper (C-423) or India stone (C-464). 2. Visually inspect aft short shaft for mechanical and
corrosion damage (Figure 65-2).
b. Apply cadmium plating solution (C-108) or
epoxy polyamide primer (C-204) to all repaired or bare a. Polish out acceptable damage with 400 to 600
steel surfaces (BHT-ALL-SPM). grit abrasive paper (C-423).

b. Apply chemical film material (C-100) to all

3. Inspect adapter flanges on each end of shaft for
distortion. Check runout at a point on outboard side of
adapter flange 1.0 inch (25.4 mm) from centerline of
shaft. If flange is not square within 0.004 inch
(0.102 mm) TIR, replace shaft. Inboard surfaces of
adapter flanges must be parallel with outboard
surfaces within 0.005 inch (0.127 mm) (Figure 65-1,
notes 1 and 2).
repaired aluminum surfaces (BHT-ALL-SPM).
3. Inspect adapter flanges on each end of driveshaft
for distortion. Check runout at a point on outboard side
of adapter flange, 1.0 inch (25.4 mm) from centerline
of driveshaft. If flange is not square within 0.002 inch
(0.051 mm) TIR, replace driveshaft (Figure 65-2,
note 1).

65-00-00
ECCN 9E991 31 MAR 2010 Rev. 2 Page 7
BHT•206B3-CR&O

� I�-,------

0
0

206-040-325 FORWARD SHORT SHAFT (STEEL)

DAMAGE LOCATION SY MBOLS

1-B-I
TYP E OF DAMAGE MAXIMUM DAMAGE AND REPAIR D EPTH

MECHANICAL Mechanical damage up to 0.002 inch (0.051 mm) deep around entire
circumference shall be polished out, provide that stock removal does not
exceed 0.003 inch (0.076 mm).
Mechanicai damage up to 0.005 inch (0.127 mm) deep, axial or
circumferential but not longer than 25 percent of circumference, shall be
polished out, provided that stock removal does not exceed 0.006 inch
(0.152mm).

CORROSION When corrosion dama�s removed from diameter l

-C-! and
surfaces !
-A-! and � , caution must be used to ensure that
0.002 to 0.004 inch (0.051 to 0.102 mm) (T.I.R.) runout of surface is not
exceeded.
Corrosion damage shall be polished out, provided that stock removal does
not exceed 0.006 inch (0.152 mm).

EDGE CHAMFE R Edge damage shall be removed from surfaces I

-A-! and l
-B- ! by
using a chamfer of 0.030 inch (0.762 mm) by 40 to 50 degrees, whose
total length when polished to existing surface shall not exc_.Jd 0.50 inch
(12.70 mm) provided that no more than two such repairs are located in the
same quadrant of the flange adapter.

NOTES

&,. Surfaces ! -A-l must be square with centerline of driveshaft within 0.004 inch (0.102 mm)
T.I.R.

£ Surfaces I -B- ! must be parallel with surfaces l -A- l within 0.005 inch (0.127 mm).

206B3-R-65-1

Figure 65-1. Forward short shaft damage limits

65-00-00
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 BHT-206B3-CR&O-4

DETAIL D
(2 PLACES)

AREA E
AREA F
END STOPPER
(2 PLACES)

DAMAGE LOCATION SYMBOLS

- A- - B- - C-

MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL Mechanical damage up to 0.002 inch (0.051 mm) deep around entire
circumference shall be polished out, provided that stock removal does not
exceed 0.003 inch (0.076 mm).

Mechanical damage up to 0.005 inch (0.127 mm) deep, axial or

circumferential but not longer than 25% of circumference, shall be
polished out provided that stock removal does not exceed 0.006 inch
(0.152 mm).

CORROSION When corrosion damage is removed from diameter - C- and surfaces

- A- and - B- , caution must be used to ensure that 0.004 inch
(0.102 mm) (TIR) runnout of surface is not exceeded.

Corrosion damage shall be polished out provided that stock removal does
not exceed 0.006 inch (0.152 mm).

EDGE CHAMFER Edge damage shall be removed from surfaces - A- and - B- by using a
chamfer of 0.030 inch (0.762 mm) by 40 to 50°, whose total length, when
polished to existing surface, shall not exceed 0.50 inch (12.70 mm)
provided that no more than two such repairs are located in the same
quadrant of the flange adapter.

BOND LINE AND Cracked or missing adhesive, or evidence of corrosion is not allowed.
END STOPPERS

NOTES
1 Surfaces - A- must be square with centerline of driveshaft within 0.002 inch (0.051 mm) TIR.

2 Surface - B- runout must be within 0.003 inch (0.076 mm) TIR.

3 Aft short shaft 206-040-330 does not have end stoppers.

206AB_MM_65_0008+

Figure 65-2. Aft Short Shaft Damage Limits

65-00-00
ECCN 9E991 31 MAR 2010 Rev. 2 Page 9
BHT-206B3-CR&O-4
4. Inspect driveshaft inboard of each adapter flange
for distortion. Check runout at a point within 1.0 inch
(25.4 mm) of adapter flanges. If driveshaft runout is
not within 0.003 inch (0.076 mm) TIR, replace
driveshaft (Figure 65-2, note 2).
5. Inspect mating slip adapter for chips, cracks, and
damaged or worn splines (1, Figure 65-11). Polish out
minor burrs and nicks with a fine India stone (C-464).
65-00-00
Page 10 Rev. 2 31 MAR 2010
6. At each overhaul, inspect aft short shaft by
fluorescent penetrant inspection method (paragraph
65-14).
7. At each overhaul, inspect mating splined adapter
by magnetic particle inspection method (paragraph
65-15).
8. Inspect mating disc assembly (paragraph 65-21).
9. Apply corrosion protective coating to aft short
shaft (paragraph 65-17).
ECCN 9E991
 BHT-206B3-CR&O-4

SEGMENTED TAIL ROTOR DRIVESHAFTS

65-10. SEGMENTED TAIL ROTOR MATERIALS REQUIRED

DRIVESHAFT
Refer to BHT-ALL-SPM for specifications.
65-11. SEGMENTED TAIL ROTOR DRIVESHAFT
— MAINTENANCE NUMBER NOMENCLATURE

C-001 1 Grease
65-12. Segmented Tail Rotor Driveshaft —
Disassembly C-100 Chemical Film Material

1. Disassemble each segment by removing nut (2, C-108 Cadmium Plating

Figure 65-3), washer (15), and plate (3) from forward Solution
end of driveshaft (7). Pull coupling adapter (4) from
driveshaft. C-423 Abrasive Paper

2. Press hanger (6) and sealed bearing (5) from C-464 India Stone
driveshaft (7). Ensure pressure is only applied to
bearing inner race during pressing operations. NOTE:

3. Remove nut (10), spacer (11), and spring (12)
from clinch bolt (13) in hanger (6). Do not remove
clinch bolt from hangers as damage to hanger will
result.
4. Rotate sealed bearing (5) 90° to align with slots in
hanger (6), and then remove bearing.
1 Replaced with grease (C-172) as an
alternative, use corrosion preventive
compound (C-104).
1. Thoroughly clean segmented tail rotor driveshaft
parts (Paragraph 65-3).

65-13. Segmented Tail Rotor Driveshaft — NOTE

Inspection and Repair Limit charts are provided to show the
required fit between mating parts. It is not
intended that all dimensions listed on limit
SPECIAL TOOLS REQUIRED charts be checked as a prescribed overhaul
procedure; however, parts that show
evidence of wear or physical damage must
NUMBER NOMENCLATURE be checked dimensionally.

T101511 Spline Wrench 2. Inspect plate (3, Figure 65-3), coupling adapter
(4), sealed bearing (5), hanger (6), spacer (11), and
Commercial Hypodermic Needle spring (12) dimensionally and replace parts that do not
fall within inspection limits (Figure 65-4).
Commercial Stud Remover and
Setter Tool 3. If driveshaft (7, Figure 65-3) is a bonded
segment, inspect for wear, mechanical damage, and
Commercial Vee Blocks (Qty 2) corrosion damage (Figure 65-4 and Figure 65-7).
Replace driveshaft if it does not fall within inspection
Commercial Veterinary Syringe or repair limits.

4. If driveshaft (7, Figure 65-3) is a riveted segment,

inspect for wear, mechanical damage, and corrosion
damage (Figure 65-7A). Replace driveshaft if it does
not fall within inspection or repair limits.

5. Visually inspect coupling adapter (4, Figure 65-3)

and hanger (6) for mechanical and corrosion damage
(Figure 65-5 and Figure 65-6).

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BHT-206B3-CR&O

3
2 I
I fa.8
� I 15

1. Tail rotor driveshaft segment (5) 7. Driveshaft 13. Clinch bolt

2. Nut 8. Disc assembly (Thomas coupling) 14. Bushing
3. Plate 9. Adapter - slip 15. Thin steel washer
4. Adapter - coupling 10. Nut 16. Screw
5. Bearing - sealed 11. Spacer
6. Hanger 12. Spring
206B3-R-65-3

Figure 65-3. Segmented tail rotor driveshaft

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 BHT-206B3-CR&O-4

5 5

2
6 5

BONDED SEGMENTED SHAFT

(206-040-931/206-040-365)

206AB_MM_65_0014a_c01+

Figure 65-4. Segmented Tail Rotor Driveshaft (Bonded) — Wear Limits (Sheet 1 of 2)

65-00-00
ECCN 9E991 31 MAR 2010 Rev. 2 Page 12A/12B
 BHT-206B3-CR&O-4

NOTES
1 Before measuring inside spherical diameter of hanger, set expansion gap at 0.0600 to 0.0605 inch
(1.5240 to 1.5367 mm).

2 2.161 inches (54.889 mm) for shaft assembly 206-040-931 and 2.059 inches (52.299 mm) for shaft
assembly 206-040-365.

3 Mount driveshaft in Vee blocks between the two indicated areas. Runout of bearing seat, bearing seat
shoulder, and adapter flange are not to exceed specified limits.

4 Runout measurement of flanges to be taken 1.0 inch (25.4 mm) from centerline.

5 Inspect bond line using 10X magnifiying glass. If bond line area shows damage such as cracked or
missing adhesive, or evidence of corrosion, the shaft shall be considered unserviceable and
non-repairable.

6 Inspect end stopper using 10X magnifiying glass. If end stopper area shows damage such as cracked or
missing adhesive, or evidence of corrosion, the shaft shall be considered unserviceable and
non-repairable.

206AB_MM_65_0014b_c01+

Figure 65-4. Segmented Tail Rotor Driveshaft (Bonded) — Wear Limits (Sheet 2 of 2)

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ECCN 9E991 31 MAR 2010 Rev. 2 Page 13
BHT-20683-CR&O

COUPLING ADAPTER
206-040-363

DAMAGE LOCATION SYMBOLS

I-A-I i-B-1
TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL Scratches up to 0.005 inch (0.127 mm) deep around the entire
circumference may be polished out provide stock removal does not exceed
0.007 inch (0.178 mm).
Scratches up to 0.010 inch (0.254 mm) deep, axial or circumferential, not
longer than 25 percent of circumference may be polished out provided
stock removal does not exceed 0.012 inch (0.305 mm).
CORROSION When corrosion damage is removed from surfaces i-A-1 and i-B-!
caution must be used to ensure that 0.002 to 0.004 inch (0.051 to 0.102
mm) (T.1.R.) runout of flange surfaces is not exceeded.
Corrosion damage shall be polished out, provided maximum depth of stock
removal for cleanup shall not exceed 0.010 inch (0.254 mm).
ED GE CHAMFER Damage shall be removed from corners using a chamfer of 0.030 inch
(0.762 mm) by 40 to 50 degrees, whose total length, when polished to
existing surface shall not exceed 0.50 inch (12.70 mm) provided that no
more than two such repairs are located in the same quadrant on the
adapter.
206B3-R-65-5

Figure 65-5. Coupling adapter damage limits

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 BHT-206B3-CR&O

HANGER
206-040-344-5

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR

MECHANICAL Mechanical damage up to 0.003 inch (0.076 mm) deep located on the
spherical (ID) surface of the hanger shall be polished out, provided that
stock removal does not exceed 0.004 inch (0.102 mm).
CORROSION Corrosion damage shall be removed from the exterior surfaces of the
hanger, provided that stock removal does not exceed 0.010 inch (0.254
mm).
ED GE CHAMFER Edge damage shall be removed from corners and edges using a chamfer of
0.030 inch (0.762 mm) by 40 to 50 degrees, whose total length, when
polished to the existing surface shall not exceed 0.50 inch (12.70 mm)
provided that no more than two such repairs are located in the same
quadrant of the hanger.
206B3-R-65-6

Figure 65-6. Hanger damage limits

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BHT-206B3-CR&O-4

- A-
- C-

- B-
TAIL ROTOR DRIVESHAFT
(206-040-931 AND 206-040-365)

DAMAGE LOCATION SYMBOLS

- A- - B- - C-

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL Mechanical damage up to 0.002 inch (0.051 mm) deep around entire circumference
may be polished out, provided stock removal does not exceed 0.003 inch (0.076 mm)
and TIR runout limits are not exceeded (Figure 65-4).

Mechanical damage up to 0.005 inch (0.127 mm) deep, axial or circumferential,

not longer than 25% of the circumference shall be polished out, provided
that stock removal does not exceed 0.006 inch (0.152 mm) and TIR runout limits
are not exceeded (Figure 65-4).

CORROSION When corrosion damage is removed from diameter - A- , and surfaces - B- and
- C- , caution must be used to ensure that TIR runout limits of surfaces are
not exceeded (Figure 65-4).

Corrosion damage shall be polished out, provided maximum depth of stock

removal for cleanup does not exceed 0.006 inch (0.152 mm).

EDGE CHAMFER Damage shall be removed from corners using a chamfer of 0.030 inch (0.762 mm)
by 40 to 50°, whose total length, when polished to the existing surface, shall
not exceed 0.50 inch (12.70 mm), provided that no more than two such repairs are
located in the same quadrant of the shaft.

206B3_CRO_65_0007a

Figure 65-7. Segmented Tail Rotor Driveshaft (Bonded) — Damage Limits (Sheet 1 of 2)

65-00-00
Page 16 Rev. 2 31 MAR 2010 ECCN 9E991
 BHT-206B3-CR&O-4

NOTES
1. Polish out acceptable damage with 400 to 600 grit abrasive paper (C-423) or India stone (C-464).

2. Apply chemical film material (C-100) treatment to all repaired and bare aluminum surfaces (BHT-ALL-SPM).

3. When damage is removed from driveshaft bearing seat, mating shoulder area, or flanges, caution must be
used to ensure that runout of surfaces does not exceed limits specified in Figure 65-4.

4 Inspect stud for damaged threads, distortion, or looseness. If stud requires replacement, secure T101511
spline wrench in shop vise as a holding fixture. Install driveshaft adapter into fixture and remove stud
using a stud remover and setter tool.

a. If stud or stud hole damage is noted, install next oversize stud (provided 0.003 inch (0.076 mm)
increments), but not exceeding a stud AN125963 through AN125968 (BHT-206A/B-SERIES-IPB).

CAUTION

CORROSION DAMAGE TO STUDS AND DRIVESHAFT MAY BE CRITICAL

AND COULD AFFECT FUNCTION AND STRUCTURAL INTEGRITY.

b. After removal of damaged stud, examine the threaded stud hole and the stud for corrosion.
No corrosion is permitted past first thread. Discard the shaft if corrosion is present in the
threaded stud hole. Discard the stud if it is corroded.

c. Set replacement stud with zinc chromate primer (C-201). Using a stud remover and setter tool,
torque stud 50 to 95 inch-pounds (6 to 10 Nm) with a projection of 2.161 inches (54.889 mm)
for shaft assembly 206-040-931 and 2.059 inches (52.299 mm) for shaft assembly 206-040-365
from inboard flange of sealed bearing inner race (Figure 65-4, 2 ).

206B3_CRO_65_0007b

Figure 65-7. Segmented Tail Rotor Driveshaft (Bonded) — Damage Limits (Sheet 2 of 2)

65-00-00
ECCN 9E991 31 MAR 2010 Rev. 2 Page 16A
BHT-206B3-CR&O-4

3 B F B
12 PL
I H
D
J

K
4 PL

E
G

C
9 9

A 1 1
1.7 IN. 1.7 IN.
(43.2 mm) (43.2 mm)

RIVETED SEGMENTED SHAFT

(206-040-385)

NO REF DESCRIPTION CHARACTERISTIC INSPECTION LIMITS

LTR METHOD

1. A Bearing journal Corrosion Only superficial corrosion,

removable with abrasive pad (C-407).
2. A Bearing journal Mechanical Measure 0.005 inch (0.127 mm) up to
0.250 inch (6.35 mm) long
must be polished to remove
all raised material.
3. A Bearing journal Wear Measure 1.1803 inches (29.979 mm)
minimum. Signs of bearing
spinning are not acceptable.
4. B Adapter external Corrosion/ Measure 0.005 inch (0.127 mm) up to
diameter mechanical 50% of the circumference.

5. B Adapter flange Corrosion/ Measure Maximum chamfer to remove the

mechanical damage is 0.030 inch (0.762 mm)
X 40 to 45° up to 0.50 inch
(12.700 mm) (no more than two per
quadrant).

6. C Spline relief Corrosion Only superficial corrosion,

removable with abrasive pad (C-407).

NO OBJECT BEYOND THIS POINT 206AB_MM_65_0018a

Figure 65-7A. Segmented Tail Rotor Driveshaft (Riveted) — Wear and Damage Limits (Sheet 1 of 3)

65-00-00
Page 16B Rev. 2 31 MAR 2010 ECCN 9E991
 BHT-206B3-CR&O-4

NO REF DESCRIPTION CHARACTERISTIC INSPECTION LIMITS

LTR METHOD
7. C Spline relief Mechanical Measure 0.002 inch (0.051 mm) may be
blended smooth.

8. D Shoulder Corrosion/mechanical Measure 0.001 inch (0.025 mm) up to

25% of the circumference.

9. E Spline adapter Corrosion/mechanical Measure 0.010 inch (0.254 mm),

end face remove all raised material.

10. F Tube outside Corrosion/mechanical Measure 0.005 inch (0.127 mm) to

2
diameter 25% of the circumference.
0.002 inch (0.051 mm) up to
100% of the circumference.

11. G Flange adapter Corrosion Only superficial corrosion,

end face removable with abrasive pad.

12. G Flange adapter Mechanical Measure 0.002 inch (0.051 mm) up to

end face 25% of area.

13. G Adapter faces TIR Measure TIR done with the shaft mounted 1
on V-blocks. Maximum of
0.004 inch (0.102 mm).

14. H Rivet spotface Corrosion/mechanical Visual None adjacent to rivet head.

0.005 inch (0.127 mm) of the
remaining spotface.

15. I Rivets Loose rivets None allowed. 7

16. J Spline-measure Wear Measure 1.107 inches (28.117 mm) 5

over 0.1200 inch minimum.
(3.048 mm)
diameter pin

17. J Spline-sides, roots, Corrosion/mechanical Visual Light, superficial that can be 6

and ends of teeth polished out by hand with the
use of a fine stainless steel
wool or abrasive pad (C-407).

18. K Fastener hole Wear Measure Maximum of 0.2530 inch

(6.426 mm) diameter.

NO OBJECT BEYOND THIS POINT 206AB_MM_65_0018b

Figure 65-7A. Segmented Tail Rotor Driveshaft (Riveted) — Wear and Damage Limits (Sheet 2 of 3)

65-00-00
ECCN 9E991 31 MAR 2010 Rev. 2 Page 16C
BHT-206B3-CR&O-4

NOTES
1 Prior to mounting the shaft on V-blocks at the two indicated areas, paint must be removed from
those areas. Measure the TIR at the bearing seat shoulder and the adapter flange. The shaft
must be discarded if the measurement exceeds one of the dimensions that follow :

A Bearing seat 0.001 inch (0.025 mm) TIR

D Bearing seal shoulder 0.004 inch (0.102 mm) TIR
G Adapter flange 0.004 inch (0.102 mm) TIR

2 Surface of the tube must be smooth and unmarred. Scratches can be polished out so the minimum
outside diameter is not less than 1.235 inches (31.370 mm).
3 Replace a stud that is distorted, loose, or with threads that are damaged. If the stud is loose,
replace it with an oversize stud. Examine the threaded stud hole and the stud for corrosion. No
corrosion is permitted past first thread. Discard the shaft if corrosion is present in the threaded
stud hole. Discard the stud if it is corroded. Install the replacement stud with unreduced zinc chromate
primer (C-201) or epoxy polyamide primer (C-204). The height of the stud as measured
in the figure is 2.049 to 2.069 inches (52.045 to 52.553 mm) when it is torqued at 50 to 95 inch-pounds
(5.65 to 10.74 Nm).
4. Refer to BHT-ALL-SPM for the procedures to chemically film treat
the repaired area.
5 Examine the spline teeth for signs of a wear step. Discard the shaft if you can feel a wear step
with a 0.030 inch (0.762 mm) spherical radius probe.
6 Refer to the CSSD-PSE-87-001 to do the repairs.
7 Replacement of the rivets is not permitted.
8. Make repairs with a 0.25 inch (6.35 mm) minimum radius and a 32 RMS surface finish.

9 When damaged material must be removed from the balancing rim, remove an equal amount of
material on the same rim, at 180° opposite to the repair area.
10. Remove two times the depth of the corrosion to repair a corroded surface. The limits shown are
after the repair is completed.

NO OBJECT BEYOND THIS POINT 206AB_MM_65_0018c

Figure 65-7A. Segmented Tail Rotor Driveshaft (Riveted) — Wear and Damage Limits (Sheet 3 of 3)

65-00-00
Page 16D Rev. 2 31 MAR 2010 ECCN 9E991

6. Repair acceptable damage to coupling adapter
(4, Figure 65-3), hanger (6), and driveshaft (7) as
follows:
a. Polish out acceptable damage with 400 or 600
grit abrasive paper (C-423).
b. Apply chemical film material (C-100)
treatment to all repaired and bare aluminum surfaces
(BHT-ALL-SPM).
c. Apply brush cadmium plating solution (C-108)
to repaired steel surfaces (BHT-ALL-SPM).
7. Inspect sealed bearings (5) as follows:
a. Inspect sealed bearing (5) for evidence of
overheating and excessive grease leakage. Signs of
overheating are discoloration, damage to seals, and
black grease ejected or liquified from the bearing.
b. If installed, inspect sealed bearings (5) for
roughness after a flight while bearings are warm.
Roughness may be felt with light hand pressure
applied to shafts while turning tail rotor and driveshaft
by hand. If shaft has been disassembled from
helicopter, roll bearings by hand and check for smooth
rotation without excessive play. Replace bearings if
they are still rough after 5 hours of operation whether
they show signs of overheating or not.
c. Visually inspect non-removable rubber seal for
deterioration. Seals torn at four lubrication points that
allow excessive grease to squeeze out should be
replaced. Bearings with rotating seals should be
replaced.
d. If there is any doubt of bearing serviceability,
replace bearing.
e. Lubricate bearings that are to remain in
service using a 6 cubic centimeter (cc) LC veterinary
syringe and 18 gauge hypodermic needle. Inject 0.5 to
0.7 cc of grease (C-001) into one of the holes in
bearing seal plate. If hypodermic needle does not fully
enter seal and bearing, remove needle and rotate
ECCN 9E991
BHT-206B3-CR&O-4
inner race of bearing to clear bearing ball cage and
reinsert and inject bearing. Needle should be purged
prior to each use and external surface of needle
lubricated to prevent unnecessary tearing of seal.
Wipe excess grease from exterior of bearing.
8. Inspect inside spherical diameter of bearing
hangers (6) and bushings (14) for wear or damage as
follows:
a. Check expansion gap on hangers (6) for a
dimension of 0.0600 to 0.0605 inch (1.5240 to
1.5367 mm) (Figure 65-4, 1 ). If expansion gap is
less than 0.0600 inch (1.5240 mm), insert a 0.0600 to
0.0605 inch (1.5240 to 1.5367 mm) shim. If gap is
greater than 0.0605 inch (1.5367 mm), reinstall spring
(12, Figure 65-3), spacer (11), and nut (10). Tighten
nut until dimension at expansion gap is set to 0.0600
to 0.0605 inch (1.5240 to 1.5367 mm).
b. Inside spherical diameter of hangers (6) is not
to exceed 2.1670 inches (55.0418 mm).
c. Any damage through hard anodize finish on
bushings (14) or which exceeds wear limits in
Figure 65-4 requires bushing replacement.
9. Inspect slip adapter (9, Figure 65-3) for chips,
cracks, and damaged splines. Inspect splines for wear
(Figure 65-11). Polish out minor burrs and nicks with a
fine India stone (C-464).
10. Inspect coupling disc packs (Figure 65-9).
11. At each overhaul, inspect coupling adapter (4),
hanger, (6) and driveshaft (7) by fluorescent penetrant
inspection method (paragraph 65-14).
12. At each overhaul, inspect adapter washer (3,
figure 65-3) and splined slip adapter (9) by magnetic
particle inspection method (paragraph 65-15).
13. Refinish segmented tail rotor driveshaft parts
(paragraph 65-17).
65-00-00
31 MAR 2010 Rev. 2 Page 17
BHT-206B3-CR&O-4

65-14. Segmented Tail Rotor Driveshaft —

Fluorescent Penetrant Inspection

1. Refer to Table 65-1 for tail rotor driveshaft

fluorescent penetrant overhaul inspection
requirements.

Table 65-1. Tail Rotor Driveshaft Fluorescent Penetrant Overhaul Inspection Requirements

SPECIAL ACCEPTANCE
DESCRIPTION REFERENCE
REQUIREMENTS

Aft Short Shaft Figure 65-2 None

Forward Hanger 4, Figure 65-10 None

Housing 20, Figure 65-10 None

Impeller 21, Figure 65-10 None

Aft Hanger 28, Figure 65-10 None

Coupling Adapter 4, Figure 65-3 None

Hanger 6, Figure 65-3 None

Driveshaft 7, Figure 65-3 None

2. Those parts listed in Table 65-1 shall be
inspected in accordance with Special Acceptance
Requirements of the stated reference, and fluorescent
penetrant inspection procedure contained in the
BHT-ALL-SPM, Chapter 6.
65-15. Segmented Tail Rotor Driveshaft —
Magnetic Particle Inspection
1. Refer to Table 65-2 for tail rotor driveshaft
magnetic particle overhaul inspection requirements.

65-00-00
Page 18 Rev. 2 31 MAR 2010 ECCN 9E991
 BHT-206B3-CR&O

Table 65-2. Tail rotor driveshaft magnetic particle overhaul inspection requirements
DESCRIPTION REFERENCE SPECIAL ACCEPTANCE
REQUIREMENTS

Forward Short figure 65-1 None

Driveshaft

Slip Adapters (Four) 9, figure 65-3 None

Fan Shaft 24, figure 65-10 Refer to paragraph 65-26, step 10.

Plate 3, figure 65-3 None I

2. Those parts listed in table 65-2 shall be
inspected in accor d ance with Special
Acceptance Requirements o f the stated
reference, and magnetic particle inspection
procedure contained in BHT-A LL-SPM.
2. Hold sealed bearings (5) 90 degrees to
hangers (6) and insert halfway into hanger
through slots. Rotate sealed bearing into
plane with hanger.

65-16. Assembly. I WARNING'

MATERIALS REQUIRED VE R I FY T H A T CO R R E C T
SPACERS ARE INSTALLED ON
NUMBER NOMENCLATURE HANGERS. USE ONLY 206-040-
351-1 SPACERS (SHANK L ENGTH
C-101 Corrosion Preventive 0.545 TO 0.550 IN. (13.843 TO
Compound 13.970 MM)). USING INCORRECT
SPACERS MAY RESULT IN TAIL
C-104 Corrosion Preventive ROTOR DRIVESHAFT FAILURE.
Compound (FIGURE 65-8.)
C-452 Antiseize Compound
3. Insert springs (12, figure 66-3) on spacers
(11) and install on clinch bolts (13) in hangers
1. Ap p l y a t hi n c o a t i n g of c o r r o s i o n (6). Install and torque nuts (10) 50 to 70 in.lb.
preventive compound (C-101) o r corrosion (6 to 8 Nm).
preventive compound (C-104) to the following
parts. 4. Ap p l y a thin c o a t i n g of c o r r o s i o n
preventive compound ( C - 1 0 4 ) to inside
a. Inside diameter of hangers (6, figure diameter of sealed bearings (5) and to outer
65-3) corrosion preventive compound (C-104) diameter of bearing seat on driveshaft (7).
and to exposed shank of clinch bolts (13)
corrosion preventive compound (C-101) . 5. Press hangers (6) and sealed bearings
(5) onto driveshafts (7) until firmly seated.
b. Outer diameter of sealed bearings (5), Install hangers so that nuts (10), spacers
corrosion preventive compound (C-104) (11), and springs (12) are to the left side, and
compound must not contact rubber seals. only apply pressure to inner race of sealed
bearings.
c. Spacers (11), springs (12} and inboard
surface of p l ate (3) corrosion preventive 6. Apply a light film of antiseize compound
compound (C-101) . (C-452) to splines of coupling adapters (4)
and splines of driveshaft (7).

65-00-00
Page 19
BHT-206B3-CR&O

7. Install adapters (4) on shaft adapter (7)
and seat with hand pressure. Insert plates (3)
onto driveshaft stud with corrosion preventive
compound (C-101) inboard. Install thin steel
washers (15) and nuts (2), torque nuts 30 to
50 in.lb. (3 to 6 Nm).
8. Apply corrosion protective treatment to all
driveshaft segments (paragraph 65-17).
65-17. Corrosion protective coating.
1. Surface preparation. Thoroughly clean
driveshafts receiving coating with a cloth
saturated with aliphatic naphtha (C-305) .
Wipe surface dry with a clean cloth before
solvent evaporates.
2. Masking preparation. Mask all bearings
and disc assemblies with tape (C-426) .
3. Application of coating. Mix 1 part of clear
acrylic lacquer (C-203) to 1.5 to 2 parts clear
lacquer (C-216) and apply as follows:

MATERIALS REQUIRED a. Spray. Apply a wet spray coat from

c omp a r a t i v e l y c l o s e t o t h e s u r f a c e
(approximately 6 to 8 in. (152 to 203 mm).
NUMBER NOMENCLATURE After 15 to 30 minutes drying time, apply a
second coat in the same manner as the first
C-101 Corrosion Preventive coat was applied.
Compound
C-203 Lacquer b. Brush. Apply using a fine hair brush
(camel or ox hair, not nylon) and brush
C-216 Lacquer lacquer coating quickly over the surface
overlapping the previous strokes, but not
C-305 Aliphatic Naphtha reworking the entire coat in the same manner
as the first coat was applied.
C-423 A b r a sive Cloth or
Paper 4. Curing. Curing of protective coating may
C-426 Tape be accomplished as follows:

a. Air dry. After second coat is applied full

cure can be obtained in approximately 48
SPECIAL TOOLS REQUIRED
hours at 70 to 80 °F (21 to 27 °C).

NUMBER NOMENCLATURE b. Heat dry. After second coat is applied,

Fi n e H a i r Bru s h
(Camel or Ox Hair, not
Nylon)
Heat Lamp
NOTE
The tail rotor driveshaft shall receive
two coats of the corrosion protective
coating. The anodized aluminum
p a r t s of t h e d r i v e s h a f t s h o u l d
receive the protective coating after
assembly or installation on the
helicopter. The cadmium plated steel
parts of the driveshaft shall receive
the protective coating prior to
reassembly.
accelerated curing can be accomplished by
air drying for 30 minutes, then heat lamp bake
at 150 °F (66 °C) for 2 hours.
c. Remove masking tape.
5. Inspection. After curing, the coating shall
be smooth and uniform over entire surface
with no area of shafting uncoated. Coating
shall have a dry film thickness of 0.0012 to
0.0020 in. (0.0305 to 0.0508 mm) (1.2 mils to
2.0 mils). Areas found to be uncoated may be
repaired (step 6).
6. Spot repair. Isolated areas of non­
adhesion shall be refinished by feathering the
isolated areas with 400 to 600 grit abrasive
cloth or paper (C-423) . Wipe areas with

65-00-00
Page 20
 BHT-206B3-CR&O

-1 I 0.060±0.010 IN.
-(1.524±0.254mm)

-1
0.550TO0.545 IN.
- I 13.970TO 13.843mm)

-3
0.710TO0.7051N.
--(18.034TO17.907mm)

206-040-351-1, -3, SPACER 206B3-R-65-8

Figure 65-8. Bearing hanger spacer

aliphatic naphtha (C-305) and refinish (step
3).
7. Apply corrosion preventive compound (C-
101) to seam where hanger bearing outer
race contacts hanger. Do not allow corrosion
preventive compound to contact bearing
seals.

65-00-00
Page 21/22
 BHT-206B3-CR&O-4

DISC ASSEMBLY

65-18. DISC ASSEMBLY 2. Soak disc in cleaner (C-344) (Figure 65-9,

note 4).
65-19. DISC ASSEMBLY — MAINTENANCE
3. Clean light fretting and pitted areas by scrubbing
NOTE with a soft rubber eraser. If disc cannot be cleaned it
must be discarded.
The following instructions are applicable to
the tail rotor driveshaft disc assembly (8,
Figure 65-3). The disc assembly (Thomas 65-21. Disc Assembly — Inspection
coupling) is bolted between driveshaft
segments in seven places. Refer to
1. Inspect disc for cracks, nicks, and scratches
BHT-206A/B-SERIES-MM for removal and
(Figure 65-9).
installation procedures.

65-20. Disc Assembly — Cleaning 2. Inspect disc for fretting and corrosion
(Figure 65-9).

MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications. CAUTION

NUMBER NOMENCLATURE
THE GRAIN OF EACH DISC RUNS
C-304 Drycleaning Solvent PARALLEL TO THE INDEXING FLAT
E DG E S . W HE N A SS E MB L IN G D IS C
C-344 Cleaner
PACK ASSEMBLY, IT IS NECESSARY TO
A LT E R N AT E I N D E X I N G F L AT S T O
OBTAIN ALTERNATE GRAIN DIRECTION.
CAUTION
3. The disc pack should be kept as an assembly.
However, unserviceable discs may be replaced with
DO NOT USE ABRASIVE CLEANING new discs, as required, provided the assembled disc
MATERIALS. pack is within 0.115 to 0.127 inch (2.921 to 3.226 mm)
thick. The disc assemblies vary between 9 to 12 plates
1. Clean grease and oil from each disc using and each plate varies between 0.010 to 0.014 inch
drycleaning solvent (C-304). (0.254 to 0.356 mm) thick.

65-00-00
ECCN 9E991 31 MAR 2010 Rev. 2 Page 23
BHT-206B3-CR&O-4

INDEX FLATS 1 0.50 IN.

8 7
(12.7 mm)
ONLY 4 DISC SEGMENTS DIA.
SHOWN FOR CLARITY

DISC ASSEMBLY

CAUTION

MAKE SURE THAT THE ORDER IN WHICH THE DISC SEGMENTS ARE STACKED
DOES NOT CHANGE AFTER THE COUPLING DISC PACK HAS OPERATED.

NOTES
1 The grain of the disc segment is parallel to the index flats. Make sure that the index flats on each disc segment
are turned 90° from the disc segment before and the disc segment after in the disc pack.

2. A coupling disc pack is 0.115 to 0.127 inch (2.92 to 3.22 mm) thick. A coupling disc pack has 9 to 12 disc
segments. Each disc segment is 0.010 to 0.014 inch (0.254 to 0.355 mm) thick.

3. Use solvent (C-304) to clean grease and oil from each disc segment.

4. Soak the coupling disc pack in cleaner (C-344), or use a soft rubber eraser to clean fretting corrosion.

5. Cracks, nicks, and scratches are not permitted.

6 No fretting damage is permitted in less than 0.050 inch (1.270 mm) from an edge.

7 Discard disc segments that have fretting corrosion of more than 0.001 inch (0.025 mm) deep and on more than
40% of the area (4 places each side). Damage of 0.001 inch (0.025 mm) can be felt with a 0.010 inch (0.254 mm)
spherical radius probe.

8 Random light fretting corrosion is permitted if corrosion is not on more than 5% of each quadrant, and each
pitted area is not more than 0.005 inch (0.127 mm) in diameter and 0.001 inch (0.025 mm) in depth. Damage of
0.001 inch (0.025 mm) can be felt with a 0.010 inch (0.254 mm) spherical radius probe.

9. The only repair possible on the coupling disc packs is the replacement of the disc segment(s).
Replace a damaged disc segment as follows:
a. Replace an unserviceable disc segment with a new disc segment.
A new disc segment is a segment that has not been operated on a helicopter.
b. You can replace more than one of the disc segments.
c. To replace a disc segment, put the new disc(s) in the center of the disc pack.
Do not put the new disc(s) at the ends of the disc pack.
1
10. When disc assembly is installed, check for gaps between discs. Gaps of more than 0.005 inch (0.13 mm)
are not acceptable. If gaps are excessive, loosen nuts and rotate disc assembly back and forth,
and uniformly tighten nuts to required torque. If any gaps exist which exceed 0.005 inch (0.127 mm), replace
disc assembly.

NO OBJECT BEYOND THIS POINT 206AB_MM_65_0009

Figure 65-9. Coupling Disc Packs — Inspection and Repair

65-00-00
Page 24 Rev. 2 31 MAR 2010 ECCN 9E991
 BHT-206B3-CR&O-4

OIL COOLER BLOWER

65-22. OIL COOLER BLOWER 1. Clean all parts with drycleaning solvent (C-304).

65-23. OIL COOLER BLOWER — MAINTENANCE 2. Dry with filtered, compressed air.

65-24. Oil Cooler Blower — Disassembly

65-26. Oil Cooler Blower — Inspection

SPECIAL TOOLS REQUIRED

MATERIALS REQUIRED

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

T101511 Spline Wrench NUMBER NOMENCLATURE

C-100 Chemical Film Material

1. Straighten tangs on lockwashers (10 and 34,
Figure 65-10) and remove bearing retaining nuts (9 C-204 Primer
and 35). Hold oil cooler shaft (24) with spline wrench
(T101511) and remove nuts with a 2 inch spanner C-304 Drycleaning Solvent
wrench.
C-423 Abrasive Cloth or
Paper
2. Press bearings (11 and 33) and bearing hangers
(4 and 28) from oil cooler shaft (24) as an assembly.
1. Visually inspect bearing hangers for scratches,
3. Remove nuts (5 and 32), spacers (6 and 31), and dents, nicks, cracks, or other physical damage.
springs (7 and 30) from bearing hangers (4 and 28).
Rotate bearings (11 and 33) 90° and align with 2. Inspect bearings for roughness and signs of
notches in bearing hangers, then remove bearings overheating. Replace as required.
(Detail A and Detail B).

3. Inspect impeller shaft for wear or physical

4. Remove four screws (23) attaching impeller inlet damage. (See Figure 65-11 for maximum total
cover (22) to blower housing (20) and remove inlet indicator reading (TIR)).
cover.

4. Inspect impeller for cracks and other physical

5. Remove impeller (21) and oil cooler shaft (24)
damage, particularly at mounting flange and individual
from blower housing (20). Remove four mounting bolts
blades. If any blades are damaged or missing, replace
(27), thin steel washers (26), and nuts (25). Remove
cooler blower assembly.
impeller (21).

65-25. Oil Cooler Blower — Cleaning 5. Inspect oil cooler impeller as follows:

a. Clean four spoke radius areas on impeller rear

MATERIALS REQUIRED mounting plate using drycleaning solvent (C-304).
Remove all dirt, grease, and oil residue and wipe dry.
Refer to BHT-ALL-SPM for specifications.
b. As applicable to P/N 206-061-432-031, dye
NUMBER NOMENCLATURE penetrant inspect impeller mounting plate paying
special attention to radius areas around spokes for
C-304 Drycleaning Solvent
crack indications as shown in Figure 65-10, Detail C.

65-00-00
ECCN 9E991 31 MAR 2010 Rev. 2 Page 25
 BHT-206B3-CR&O

1. Bearing cover 25. Nu t

2. G asket 26. T hin steel washer
3. Aft f irewall 27. Bolt
4. Forw ard b earing hang er 28. Aft b earing hang er
5. Nu t 29. Clinc h bolt
I::...
Spac er ili
6. 30. Spring
7. Spring 1
3 . Spac er
;::...
ili
8. Clinc h bolt 2
3 . Nu t
9. Bearing ret ainer nu t 3 .3 B earing
10. 13
I
Lockwasher 43 . Lockw asher
11. Bearing 53 . B earing ret ainer nu t 11 12
'

I �,
12. asher 6 3 . Bolt � I
WN u t 3 _
10 j,

I
1 .3 7 T hin steel washer 9 _ � 1
14. Bolt 8 3 · Aluminum washer

l_/�� )'
15. Thin st eel w asher 4 , ·
16. inumwasher
2
A
:��.;"
17.
3
1
I /
� �

I�
18. St eel washer 2
19. Al uminum washer 14

�J·-......../1/
20. Blowerho u sing

-\x '\
5
21.
22.
I pell er
m
I peller inl et cover
m
£,t< ,, s ,,,,.
J
1
2 .3 Screw ,- & _,,,,

@)'I
24. Oil cooler shaft
✓ 1 �{" � ·
SEEDETAILA ,,,- 16
�1tr•' "

" &

fl·�. ·,. .-1 -�

•,1 ,r. .
.
;·, '�-:!_,_..,:i,J. �\ 1
1,
�
11

,. - - - ,. . - .:i-
,,u,,-_-. ,• .11
•;:.,,,," •...•,,,.,,
I
-ty I 2
1
26 25

//
35

,,,,
IH
I �
34

I)@�
33

28
I
I

,-36

®-37
-
SHIMS �-38
SEEDETAILB 20683-R-65-10-1

Figure 65-10. Oil cooler blower (sheet 1 of 2)

65-00-00
Page 26
 BHT-206B3-CR&O

FORWARD BEARING HANGER AFT BEARING HANGER

DETAIL A DETAILB

&
NOTES

Perform dye penetrant inspection (BHT-ALL-SPM) this

area in four places. Pay special attention to radius areas.

£ Applicable to helicopter S/N 2212 through 3967 with

impeller P/N 206-061-432-031.

.& Use P/N 206-040-351-3 spacer measuring 0.7050 to

0.7100 (17.9070 to 18.0340 mm) from flanged end
only. DETAILC

206B3-R-65-10-2

Figure 65-10. Oil cooler blower (sheet 2)

65-00-00
Page 27
BHT-206B3-CR&O-4

2 2

inch

inch 1

NOTES
1 Dress out wear step between worn and unworn areas of spline teeth with fine India stone (C-464), or
equivalent, to form a smooth transition.

2 Mechanical damage up to 0.002 inch (0.050 mm) deep shall be polished out, provided that material
removal does not exceed 0.003 inch (0.076 mm).

Corrosion damage shall be polished out, provided that material removal does not exceed 0.002 inch
(0.050 mm).

206AB_MM_65_0006

Figure 65-11. Oil Cooler Impeller Shaft Wear Limits

65-00-00
Page 28 Rev. 2 31 MAR 2010 ECCN 9E991

c. If no crack indications, clean inspection
materials from impeller.
d. Inspect impeller blades for cracks,
nicks, and straightness. Give special attention
to area where impeller attaches to blower
shaft and to individual vanes.
e. If any cracks are detected replace
impeller.
6. Inspect finish on impeller and if impeller
requires refinishing, clean thoroughly and
apply a very thin coat of primer (C-204) .
NOTE
It is important to maintain dynamic
balance of impeller wheel. Do not do
anything that will disturb balance. In
applying very thin uniform coat of
primer (C-204) , exercise care that
primer does not run into corners and
form thick deposits that disturb
dynamic balance of impeller. Static
balance impeller and oil cooler shaft
(paragraph 65-28).
7. Inspect hangers and shaft for cracks or
damage. Apply protective coating as required.
8. Inspect and repair forward bearing hanger
(figure 65-12).
a. Damage to hanger lugs not to exceed
0.015 in. (0.381 mm) in depth.
b. Damage to hanger cross brace not to
exceed 0.030 in. (0.762 mm) in depth.
c. Replace hanger if damage per step a.
and/or b. is exceeded.
d. If damage per step a. and/or b. is not
exceeded blend out damaged surfaces, using
180 grit or finer abrasive cloth or paper (C-
423) . Remove sharp edges and provide
blended radii or chamfer.
e. Apply brush chemical film material (C-
100) to bare metal surfaces.
f. Apply two coats of primer (C-204) to
reworked surfaces.
BHT-20683-CR&O
9. Visually inspect splined adapters and
flexible couplings for damage and wear.
10. Inspect oil cooler shaft (24, figure 65-10) I
in accordance with the following special
acceptance standards.
a. Acceptance - Magnetic Particle
Inspection.
(1) Ma g n e t i c p a r t i c l e i n d i c a t i o n s
interpreted as cracks, seams, laps, or other
metal voids are cause for rejection.
(2) Indications which are not interpreted
as discontinuities, but rather are caused by
driveshaft (13) geometry, are acceptable.
b . Pro c e d u r e M a g n e t i c Pa r t i c l e
Inspection.
(1) Oil cooler shaft ( 2 4 ) shall be I
inspected by all the following steps using the
wet continuous method. The length of any
indication shall be determined by the residual
method.
(2) Magnetize the oil cooler shaft (24) I
by placing the ends in contact with the gauze
contact heads of the machine and pass 1500
amperes current in the shaft. Inspect shaft
completely for indications.
(3) Place the oil cooler shaft (24) in the I
coil with the long axis of the shaft
perpendicular (90 ° ) to the direction of current
flow through the coil. Magnetize the shaft
using 9000 ampere-turns magnetizing force,
or 1800 amperes current for a five turn coil.
Inspect the shaft completely for indications.
(4) After completion of inspection,
demagnetize the oil cooler shaft (24) and I
check with a field indicator to ensure removal
of residual fields.
11. Perform fluorescent penetrant inspection
(BHT-ALL-SPM) of following. Parts are
indexed to figure 65-10.
65-00-00
Page 29
BHT-206B3-CR&O

A A
ON SIDE OF LUG, BLEND OUT DAMAGE.
0.015 IN. 10.381 mml MAX MAT"L REMOVAL.
[

206-040-346
k=J==::t;'"-----�-�
BREAK EDGE

REMOVE SHARP
V 0.005 TO 0.020 IN.
(0.127 T00.508mm)R
EDGE. BLEND WITH OR CHAMFER
0.010 TO 0.020 IN. I\
(0.254 TO 0.508mm)RADIUS 0.030 IN. (0.762 mm) MAT'L
REMOVAL PERMITTED BLEND SMOOTH
BREAK EDGES 0.010 TO 0.025 IN.
(0.254 TO 0.635 mm)RADIUS

-+-
I
VIEWA-A
FORWARD BEARING HANGER

206B3-R-65-12

Figure 65-12. Forward bearing hanger repair

65-00-00
Page 30
 BHT-206B3-CR&O

INDEX NO. NOMENCLATURE SPECIAL TOOLS REQUIRED

4 Bearing Hanger, Forward

20 Blower Housing
21 Impeller
28 Bearing Hanger, Aft
12. Inspect oil cooler shaft in accordance
with following acceptance criteria:
a. Magnetic particle indications interpreted
as cracks, seams, laps, or other metal voids
are cause for rejection.
b. Indications caused by part geometry,
not interpreted as discontinuities, are
acceptable.
13. A f t e r c o m p l e t i o n o f i n s p e c t i o n ,
demagnetize oil cooler shaft and check with
field indicator to ensure removal of residual
fields.
14. Inspect parts dimensionally and replace
parts that do not fall within inspection limits
(figure 65-13).
NOTE
Wear limits are provided to show the
required fit between mating parts. It
is not intended that all dimensions
be checked as a prescribed overhaul
procedure; however, parts exhibiting
e v i d e n c e of w e a r o r p h y s i c a l
damage must be checked
NUMBER NOMENCLATURE
T101511 Spline Wrench
Two Inch Spanner
Wrench
1. Position impeller (21, figure 65-10) on oil
cooler shaft (24) and secure with four bolts
(27), thin steel washers (26), and nuts (25).
Ensure thin steel washers (26) are placed
under boltheads and nuts.
NOTE
After static balance of impeller and
s h a f t , bolt length a n d w a s h e r
quantities may vary (paragraph 65-
28).
2. Position impeller and shaft in blower
housing (20, figure 65-10) and install impeller
inlet cover (22). Secure with four screws (23).
3. A p p l y a t h i n c o a t i n g of c o r r o s i o n
preventive compound (C-104) t o the inner
diameter of forward and aft bearing hangers
(4 and 28) and the outer race of bearings (11
and 33). Do not allow compound to contact
bearing seals. Also apply a thin coating of
corrosion preventive compound (C-101) to
shanks and threads of bolts (8 and 29),
springs (7 and 30), and spacers (6 and 31)
(details A and B).

I
dimensionally.

15. Replace worn or damaged parts.

WARNING -

65-27. Assembly. E NSURE TH AT 2 0 6-040 -3 5 1-3

SPACERS (6 AND 31) MEASURING
MATERIALS REQUIRED
0.7050 TO 0.7100 IN. (17.9070 TO
18.0340 mm) FROM FLANGED END
A RE USE D I N 2 0 6- 0 40 - 3 46
NUMBER NOMENCLATURE FORWARD BEARING HANGER (4)
AND IN 206-040-355 AFT BEARING
C-1 01 Corrosion Preventive H A N GER (2 8 ) . MIXI NG OF
Compound SPACERS MAY RESULT IN TAIL
ROTOR DRIVESHAFT FAILURE
C-104 Corrosion Preventive (FIGURE 65-9).
Compound

65-00-00
Page 31
BHT-206B3-CR&O

0 0 0

NOMENCLATURE MINIMUM MAXIMUM

IN. mm IN. mm
1 Forward bearing hanger 2.1649 54.99 2.1670 55.04
Spherical ID with 0.0600 to 0.0605 IN.
(1.52 to 1.54 mm) space at split
2 Bearing (both hangers) 2.1637 54.96 2.1657 55.01
Spherical OD
3 Bearing (both hangers) ID 1.1807 29.99 1.1815 30.01
4 Shaft (each end) OD 1.1803 29.98 1.1816 30.01
5 Aft bearing hanger
Spherical ID with 0.0600 to 0.0605 IN. ID 2.1649 54.99 2.1670 55.04
(1.52 to 1.54 mm) space at split
6 Shaft spline (each end)
(Use 0.1200 IN. (3.05 mm) dia. pins) over pins 1.1025 28.00&,.
7 Splined Adapter between pins 0.7414 18.83
(use 0.1200 IN. (3.05 mm) dia. pins)
8 Disc assembly (typical 7 places)

.&
NOTE

Dress out wear step between worn and unworn areas of spline teeth with fine India stone, or equivalent, to
form a smooth transition.
206B3-R-65-13

Figure 65-13. Oil cooler blower impeller shaft and bearing hanger wear limits

65-00-00
Page 32

4. If bearing hanger was disassembled,
install springs (7 and 30), spacers (6 and 31),
and nuts (5 and 32). Do not torque nuts (5
and 32) at this time.
5. Hold bearings (11 and 33) 90° to notches
in bearing hangers (4 and 28) and insert
bearings halfway through hangers, then rotate
bearings into plane of bearing hangers.
Torque nuts (5 and 32) 50 to 70 in.lb. (6 to 8
Nm).
6. Press bearings {11 and 33) with forward
and aft bearing hanger (4 and 28) into
position on oil cooler shaft {24).
NOTE
When installing bearings on oil
cooler shaft, observe that forward
bearing hanger firewall mounting
flange is to forward end of the oil
cooler shaft, and for the aft bearing
hanger assembly, the side with the
longest height dimension is to the
forward end of the shaft.
I 7. Position new lockwashers (1O and 34) on
oil cooler shaft (24) and install nuts (9 and
35). Hold shaft with T101511 spline wrench
and torque nuts (9 and 35), using a 2.0 in.
(50.8 mm) spanner wrench, 200 to 300 in.lb.
{23 to 34 Nm). Lock bearing retainer nuts (9
and 35) by bending tab of lock-washers (1O
and 34) into lugs on nuts.
65-28. Static balance of impeller and
shaft assembly.
To preclude high frequency vibration as a
r e s u l t o f either instal ling a new or
BHT-206B3-CR&O
replacement oil cooler impeller shaft and/or a
new or replacement impe l l e r or any
combination thereof, static balance complete
assembly prior to installation as follows:
1. Disassemble impeller and shaft assembly I
(paragraph 65-24).
2. Mount shaft and impeller on knife edge
balancer, inboard of the key-way slots on the
bearing journal surface.
3. Using AN 960-416 and AN 960-416L
washers (26), balance assembly to within one
thin steel AN960-416L washer. Longer AN4-
6A bolts {27) may be required due to
additional balance washers. Torque nuts {25)
50 to 70 in.lb. (6 to 8 Nm).
1·················1
t CAUTION
i•••••••••••••••••
WHEN CHANGING AN4-5A BOLT
LENGTH, ENSURE THAT NUTS DO
NOT BOTTOM ON SHANK OF
BOLT BEFORE PROPER TORQUE
IS OBTAINED.
4. Completely assemble impeller and shaft I
assembly (paragraph 65-27).
65-00-00
Page 33/34
 BHT-20683-CR&O

TAIL ROTOR GEARBOX (206-040-400)

I
65-29. TAIL ROTOR GEARBOX (206-040- inspection, perform backlash check
400). ( P a r ag r a p h 65-40 ). Re c o r d
backlash readings for comparison
after inspection is complete.
65-30. MAINTENANCE.

The following paragraphs provide overhaul, SPECIAL TOOLS REQUIRED

repair, and 3000 hour inspection instructions
applicable to the tail rotor gearbox. NUMBER NOMENCLATURE

AN8514-1 Spanner Wrench, 2 in.

Owatonna 630-3 Step Plate Adapter,
1¼ X 1 in. (31.75 X 25
IF T HERE IS EVI D ENC E OF mm)
ACC I D ENT O R I N C I D E NT Owatonna 927 Puller
DA M A G E , CH EC K FO R
MEC HA NI C A L D AMAG E T O Owatonna 927A Puller legs, 6¼ in.
EXTERNA L SURF ACES OF (171.45 mm) long
GEARBOX AND CHECK FOR FREE
ROT ATIO N OF T AIL ROT O R Owatonna 951 B e a r i ng P u l l i ng
GEARBOX INPUT PINION AND Attachment
P RO P ER BA C KL A S H IN
ACCORDANCE WITH PARAGRAPH T10130 8 Jackscrew Set
65-40 PRIOR TO DISASSEM BLY. T101507 Pinion Installation and
Removal Set
NOTE T101511 Spline Wrench
The ta il r otor gea r b ox may be
T101512 Gearbox Wrench
d i s a s s e m bl e d, as r equ i r e d, to
accomplish component repair to a T101513 O u t p u t S h a f t Nu t
particular part or assembly. Wrench
Figure 65-17 Fabricated Tail Rotor
65-31. Disassembly. G e a r b ox Mo u n t i ng
Workaid
MATERIALS REQUIRED
1/2 In. Breaker Bar

NUMBER NOMENCLATURE Heat Lamp

C-309 Methyl-Ethyl-Ketone Hydraulic Press

( MEK)
Offset Screwdriver (2)
C-407 Abrasive Pad
Plastic Mallet
Plastic Scraper

I
NOTE
I f d i s a s s emb l y i s b e i n g
accomplished to perform 3000 hour

65-00-00
Page 35
 BHT-206B3-CR&O
SPECIAL TOOLS REQUIRED (CONT)
NUMBER NOMENCLATURE
Round Pressing Plug
(Maxim u m OD 0 .98
in.) (24.89 mm)
NOTE
R eview Mandato r y R etir em ent
Schedule in BHT-206B3-MM and
r e t i r e a ll i t e m s s c h e d u l e d for
retirement . If tail rotor gearbox is
being disassembled for replacement
of part(s) inst ead of overhaul,
d i s a s s e m b le o n ly t o ext e n t
necessary to replace part(s).
1. Dra i n o i l from t a i l rotor gearbox b y
I removing electric chip detector (21, figure 65-
14) and self-closing valve (19). Remove and
discard packings (18 and 20).
2. Cut and remove lockwire from input
pinion, outer nut (40) and case assembly (17).
3. Using two offset screwdrivers, lift the two
opposing locking tangs of lockwasher (43).
Force lockwasher outboard to free it from nut
( 4 2) a n d i n p u t p i n i o n ( 46 ) . D i s c a r d
lockwasher.
4. Clamp T101511 spline wrench with 15
teeth spline opening exposed in a sturdy shop
vise and position splined end of input pinion
(46) in wrench. Loosen input pinion inner nut
(42) with AN8514-1 spanner wrench, then
remove gearbox from splined wrench and
remove nut (figure 65-15).
5. Reverse T101511 spline wrench in shop
v i s e so that 32 t eeth spline o p ening is
exposed. Position splined end of output shaft
( 2 8 , figure 65-14) in spline wrench and
remove cotter pin (2) from output shaft inner
nut (3) and output shaft. Position T1 O 1513
output shaft nut wrench with 1/2 in. breaker
bar and remove output shaft inner nut (figure
6 5 - 16). Remove tai l roto r gearbox and
wrenches from shop vise.
65-00-00
Page 36
6. Fabricate tail rotor gearbox mounting
workaid (figure 65-17).
7. Clamp mounting workaid (figure 65-17) in
shop vise. Secure tail rotor gearbox to the
workaid with four washers and nuts and
accomplish the following:
a. Remove sealant from around input
pinion outer nut (40, figure 65-14) and case
assembly (17), using a plastic scraper.
b. Position T101512 gearbox wrench with
1/2 in. breaker bar to input pinion outer nut
(40) and remove from case assembly (17)
(figure 65-18).
c. Remove packing (39, figure 65-14) from
input pinion outer nut (40) and press out seal
(41). Discard packing and seal. Leave case
assembly (17) secured to fabricated mounting
workaid. Do not remove spacer (38) at this
time.
8. Remove input pinion (46) from case
assembly (17) using T101507 pinion
installation and removal set as follows: Refer
to figure 65-19 for tool application).
a. Thread T101507-5 base into case
assembly (17, figure 65-14).
b. Thread T101507-7 adapter on input
pinion (46) until in firm contact with spacer
(38).
c. Assemble and install Owatonna 927
puller and 927 A puller legs to installed
T101507-5 base and T101507-7 adapter as
shown in figure 65-19. Ensure puller nut is on
outboard side of puller bar.
d. Apply heat lamp to case assembly (17,
figure 65-14) and heat in area of duplex
bearings (44).
e. Operate puller and remove input pinion
(46) and duplex bearings (44) from case
assembly (17). Disassemble and remove
puller and pinion removal tools.
 BHT-206B3-CR&O

TORQUE650
13-0
TO BOO IN-LB

. I I tI J
2 21
SEE DETAIL A

18
19
20
I
·,
,ii,
;1t;1 . : � I 4 9-. I� . 1
,
� 22
I 23

25 i ,l�
16 2
6-·
10-cb
I 11)
,
I��
!�
,
I /\]� -
26 27
I I

206B3-R-65-14-1

Figure 65-14. Ta1·1 rotor gearbox 206-040-400 (sheet 1 of 2)

65-00-00
Page 37
BHT-206B3-CR&O

44
TRIM ONE TANG
FLUSH TO 0.025 IN.
(0.635 mm) RECESSED
FROM END OF NUT

3 \._ INSTALL BEARINGS

DETAIL A DETAIL 8 BACK TO BACK

1. Output shaft outer nut 27. Spiral bevel gear

2. Cotter pin 28. Output shaft
3. Output shaft inner nut 29. Seal
4. Duplex bearing 30. Wear sleeve
5. Shim ring 31. Nut
6. Retainer ring 32. Thin steel washer
7. Washer 33. Aluminum washer
8. Aluminum wool packing 34. Cap assembly
9. Plug 35. Packing
10. Packing 36. Roller bearing
11. Spring assembly 37. Retainer ring
12. Oil filler cap 38. Spacer
13. Retainer ring 39. Packing
14. Pin 40. Input pinion outer nut
15. Chain 41. Seal
16. Pin 42. Input pinion inner nut
17. Case assembly 43. Lockwasher
18. Packing 44. Duplex bearing
19. Self-closing valve 45. Packing
20. Packing 46. Input pinion
21. Electric chip detector 47. Retainer ring
22. Retainer ring 48. Roller bearing
23. Packing 49. Shim ring
24. Sight glass 50. Data plate
25. Oil level indicator 51. Adapter
26. Bolt

206B3-R-65-14-2

Figure 65-14. Tail rotor gearbox 206-040-400 (sheet 2)

65-00-00
Page 38

T101511
SPLINE
WRENCH
Figure 65-15. Input pinion inner nut tool application
DO NOT REMOVE SHIM RINGS (5
AND 49) FROM CASE ASSEMBLY
(17) EXCEPT FOR INSPECTION
AND CLEANING OF SHIM RING
GROOVE IN BEARING LINERS. IT
I S MANDATORY T H A T S H I M
RINGS BE KEPT WITH THE CASE
ASSEMBLY TO OBTAIN CORRECT
GEAR MESH.
9. Remove duplex bearings (44) from input
pinion (46) using Owatonna 951 bearing
pulling attachment as follows: (See figure 65-
20 for tool application).
NOTE
A s an a l tern a te m e t h o d 9 2 7
Owatonna puller, Owatonna 927A
puller legs and Owatonna 630-3 step
plate adap t er may be u s ed to
remove duplex bearings (44, figure
65-14).
BHT-206B3-CR&O
20683-R-65- 1 5
a. Position 951 Owatonna bearing pulling
attachment around input pinion (46) between
gear teeth and duplex bearing (44). Adjust
puller to contact inner race of duplex bearing
i. . . . . . . . .l
only.
CAUTION
.................
DO NOT ALLOW 951 OWATONNA
BEARING PULLING ATTACHMENT
TO APPLY PRESSURE TO OUTER
RACE OF DUPLEX BEARINGS (44)
OR TO SCORE INPUT PINION (46)
DURING PRESSING OPERATION.
b. Using hydraulic press and 630-3
Owatonna step plate adapter on end of input
pinion (46), press spacer (38) and duplex
bearings (44) from pinion. Remove and
discard packing (45).
1 O. Remove output shaft (28) and cap
assembly (34) from case assembly (17) as
follows:
65-00-00
Page 39
BHT-206B3-CR&O
Figure 65-16. Output shaft inner nut tool application
a . R emove nuts (31) and thin steel
washers (32), and a�uminum washers (33)
from studs at cap assembly (34). Thread two
T101308 jackscrews in cap assembly until
cap is free of output shaft (28). Remove cap
from output shaft.
b. Position and support assembly (17)
with output shaft (28) pointing downward
t h r o u g h opening in su pport p l ates o n
hydraulic press. Output shaft must not contact
su pport plate du ring pressing operations
(figure 65-21).
c. Place a round pressing plug (maximum
outer diameter 0.98 in.) (24.89 mm) against
inner end of output shaft (28, figure 65-14)
and slowly press from case assembly (17).
Check that output shaft does not bind or
contact support plates du ring pressing
operations, and that pressing plug does not
bind on duplex bearings (4).
d. When output shaft (28) has been
pressed from case assembly (17), remove
from hydraulic press.
65-00-00
Page 40
11. Remove seal (29) and roller bearing (36)
from cap assembly (34) as follows:
a. Remove packing (35) and retainer ring
(37) from cap assembly. Discard packing.
b. App l y h e at l a m p t o face o f c a p
assembly (34). When heated, t a p cap
assembly on hard wood su rface to remove
roller bearing (36).
c. Press seal (29) from cap assembly (34)
using pressing plug and hydraulic press. Do
not permit pressing plug to contact liner in
cap assembly.
12. Remove spiral bevel gear (27) from
output shaft (28) as follows:
a. Clamp T101511 spline wrench in shop
vise so that 32 teeth spline opening is
exposed. Position output shaft (28) in spline
wrench and remove bolts (26).
b. Using plastic mallet, lightly tap spiral
bevel gear (27) from output shaft (28).
 BHT-206B3-CR&O

6.0IN.
1152.4mm)
: :
' :
'' ''
: :

WELD 0.501N.
BEAD 112.70mm)
3.0TO 4.0IN.
176.2TO 101.6mm)

0.501N.
112.70mml-
ENDVIEW

4.75±0.010IN.
2.3751N. 1120.65±0.254mm)
160.325mm)

2.125±0.0101N.
153.975±0.254mm)

4.25±0.010IN.
1107.95±0.254mm)

TOP VIEW

MATERIAL: 0.50 inch (12.70 mm) aluminum, brass or steel stock

USE: Mounting tail rotor gearbox to shop vise for assembly, disassembly,
repairs, and backlash check.

20683-R-65-17

Figure 65-17. Tail rotor gearbox mounting workaid

65-00-00
Page 41
BHT-206B3-CR&O
Figure 65-18. Input pinion outer nut tool application
13. Inspect wear sleeve (30) on output shaft
(28) for evidence of wear. If wear sleeve is
grooved it must be replaced.
a. Cut a groove across wear sleeve (30)
with a file or small power grinder. Do not cut
completely through wear sleeve.
b. Insert a blunt wedge-shaped instrument
in groove and strike with a light hammer until
wear sleeve (30) splits; then remove from
output shaft (28).
c. Remove sealant from output shaft (28)
in area of removed wear sleeve (30) using
MEK (C-309) and fine abrasive pad (C-407) .
d. Insert output shaft (28) in area of
removed wear sleeve (30) for damage.
Damage will require replacement of output
shaft.
14. Remove output shaft outer nut (1) and
o i l level indicator (25) using fabricated
mounting workaid and T101512 gearbox
wrench as follows: (See figure 65-22, for tool
application).
65-00-00
Page 42
" ""'
i
,F::::/:(:\?' :::,:��i
a. Position T101512 gearbox wrench with
1/2 in. breaker bar into output shaft outer nut
(1, figure 65-14) and remove.
b. Remove retainer ring (22) and push
sight glass (24) from case assembly (17) by
reaching inside case assembly and pressing
sight glass and oil level indicator (25) from
case assembly.
c. Remove and discard packing (23) from
sight glass (24).
15. Remove oil filler cap (12) and disconnect
chain (15) at pin (16) as follows:
a. Remove pin (14) and retainer ring (13)
from oil filler cap (12).
b. Remove retainer ring (6), washer (7),
aluminum wool packing (8), packing (10), and
spring assembly (11) from plug (9). Discard
aluminum wool packing and packing.
c. Remove case assembly (17) from
fabricated mounting workaid.
 BHT-20683-CR&O

T101507-5 OWATONNA NO. 927A

BASE PULLER LE GS

T101507-7
ADAPTER

NUT MUST BE
OUTBOARD FOR
PULLING INPUT
PINION GE AR

Figure 65-19. Input pinion tool application

65-00-00
Page 43
BHT-206B3-CR&O

Figure 65-20. Duplex bearing and input pinion tool application

65-00-00
Page 44
 BHT-206B3-CR&O

Figure 65-21. Output shaft tool application

65-00-00
Page 45
BHT-206B3-CR&O

FABRICATED
MOUNTING __....,_
WORK AID

Figure 65-22. Output shaft outer nut tool application

16. Apply heat lamp to case assembly (17) 65-32. Cleaning.

in area of duplex bearings (4). When case
assembly is heated, tap case on hard wood
surface to remove duplex bearings. Do not
MATERIALS REQUIRED
r emove shim ring (5), refer to Caution
statement in step 8. NUMBER NOMENCLATURE
17. Remove roller bearing (48) from case C-010 Lubricating Oil
assembly (17) as follows:
C-105 Corrosion Preventive
a. Remove retainer rings (47) from both C-304 Solvent
sides of roller bearing (48).
C-415 Corrosion Preventive
b. Apply heat lamp to case assembly (17)
in area of roller bearing (48). When case C-436 Paint Remover
assembly is heated, press roller bearing from
case.
1. Clean all tail rotor gearbox parts with
solvent (C-304).

DO NOT ALL OW BEARINGS TO

SPIN. DO NOT HANDLE BLACK

65-00-00
Page 46

OXIDE PARTS WITH BARE
HANDS.
2. Dry parts with filtered compressed air and
lint free clean cloths.
3. Remove paint from metal parts using
paint remover (C-436) .
4. After parts are cleaned, the following
corrosion prevention treatment should be
accomplished.
a. Wash all ferrous parts in a clean rinse
of solvent (C-304) .
b. Gently agitate parts in corrosion
preventive (C-105) , then drain the parts.
NOTE
Normally parts treated in accordance
with steps a. and b. may be left
c o v e r e d in i n d o o r s t o r a g e f o r
approximately 150 hours without
being affected by corrosion. If parts
are not assembled within prescribed
time, comply with step d.
c. Immediately prior to assembly of parts,
the treatment specified in steps a. and b.
shall be repeated if the parts are
contaminated with dust, dirt, or foreign matter.
d. Each part shall be covered with a
I protective coating of corrosion preventive (C-
415)
5. Immediately prior to assembly, clean
parts with solvent (C-304) and coat with
lubricating oil (C-010) . Do not handle or
assemble un-oiled parts.
65-33. Inspection and repair.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-423 Abrasive Cloth or
Paper
C-435 Paint Remover
BHT-206B3-CR&O
MATERIALS REQUIRED (CONT)
NUMBER NOMENCLATURE
C-464 India Stone
1. Inspect tail rotor gearbox visually and
review accompanying records to determine
whether gearbox has been subjected to an
accident or incident outside the realm of
normal usage.
a. If there is no evidence of accident or
incident damage, proceed with normal
component repair or overhaul, as required.
b. If there is evidence of accident or
incident damage, accomplish the following
before disassembly.
(1) Check for mechanical damage to
external surfaces of gearbox.
(2) Check for free rotation of tail rotor
gearbox input pinion and proper backlash
(paragraph 65-40).
2. Parts, components, or assemblies found
worn or defective beyond reparable limits
shall be scrapped.
3. Inspect parts dimensionally and replace
parts that do not fall within inspection limits
(figure 65-23).
NOTE
Limit charts are provided to show
required fit between mating parts. It
is not intended that all dimensions
listed on limits chart are checked as
a prescribed overhaul procedure;
however, parts exhibiting evidence
of wear or physical damage shall be
checked dimensionally.
4. Inspect surfaces of spiral bevel gear (27,
figure 65-14) and input pinion (46) for
chipped, broken, or worn gear teeth. Inspect
gear wear patterns (figure 65-24). Polish out
acceptable damage using fine India stone (C-
464) or 320 to 400 grit abrasive cloth or paper
(C-423) .
65-00-00
Page 47
BHT-206B3-CR&O-4

Figure 65-23. Tail Rotor Gearbox Limits 206-040-400 (Sheet 1 of 2)

65-00-00
Page 48 Rev. 7 28 FEB 2020 Export Classification C, ECCN 9E991
 BHT-20683-CR&O

ITEM NOMENCLATURE MINIMUM MAXIMUM

IN. mm IN. mm
1. Duplex bearing - input pinion ID 1.1809 29.99 1.1812 30.00
2. Duplex bearing - input pinion OD 2.4404 61.99 2.4409 62.00

&.
3. Splines - input pinion OD 1.1025 28.00
(use 0.1200 inch (3.05 mm) 4
diameter pin)

&.
4. Duplex bearing seat - input pinion OD 1.1814 30.01 1.1819 30.02
&
5. Roller bearing inner race - input pinion OD 0.5505 13.98 0.5510 14.00
6. Roller bearing - input pinion OD 1.1807 29.99 1.1811 30.00
7. Shim ring - gearbox case output 2

£
8. Duplex bearing - output shaft ID 0.9841 25.00 0.9844 25.00
9. Duplex bearing - output shaft OD 1.8500 46.99 1.8504 47.00

&
10. Liner duplex bearing seat - ID 1.8497 46.98 1.8505 47.00
gearbox case output 5
11. Liner roller bearing seat - ID 1.1805 29.98 1.1813 30.01
gearbox case input 5
12. Bearing cap seat - gearbox case ID 4.5005 114.31 4.5013 114.33

&.
13. Output shaft seat - spiral bevel gear ID 1.2500 31.75 1.2506 31.77
14. Duplex bearing seat - output shaft OD 0.9846 25.01 0.9851 25.02
15. Spiral bevel gear seat - output shaft OD 1.2500 31.75 1.2506 31.77
16. Roller bearing inner race - OD 2.0010 50.83 2.0015 50.84
output shaft
17. Wear sleeve seat - output shaft OD 1.7490 44.42 1.7510 44.48
18. Splines - output shaft OD 1.0883 27.64 1.0898 27.68
(use 0.060 inch (1.52 mm)
diameter pins)

&
19. Mounting seat - output shaft OD 4.4997 114.29 4.5010 114.33
bearing cap
20. Liner roller bearing seat - ID 2.6766 67.99 2.6774 68.01

&
output shaft bearing cap 5
21. Roller bearing - output shaft OD 2.6767 67.99 2.6772 68.00
22. Liner duplex bearing seat - ID 2.4402 61.98 2.4410 62.00
gearbox case input 5
23. Shim ring - gearbox case inpu
24. Pin hole - pitch change shaft � 3 ID 0.1945 4.94

NOTES

&Maximum allowable wear on the diameter is 0.0002 inch (0.01 mm) determined by measuring the difference in the diameter in the

A Output shim ring (item 7) is ground specifically for each tail rotor gear case to properly space duplex bearings and output shaft in gear
worn and unworn area.
ill
case to obtain correct gear mesh of output spiral bevel gear and input pinion. Keep this shim with its own case. The control dimension
for each case is etched on side of case adjacent to short end of output shaft. Shim ring dimension is gained by using the factor 1.0140
to 1.0145 inches (25.76 to 25.77 mm) minus the etched control dimension. This new dimension is the thickness required for the shim

A ring and must be included on your order to Bell Helicopter Textron.

fillnput shim ring (23) is ground specifically for each tail rotor gear case to properly space duplex bearings and input pinion in gear case to
obtain correct gear mesh of input pinion and output spiral bevel gear. Keep this shim with its own case. The control dimension for each
case is etched on input side of case. Shim ring dimension is gained by using the factor of 2.3400 to 2.3405 inches (59.44 to 59.45
mm) minus the etched control dimension. This new dimension is the thickness required for the shim ring and must be included on your

A order to Bell Helicopter Textron.

ffiDress out wear step between worn and unworn areas of spline teeth with India stone or equivalent to form a smooth transition.
Corrosion rework limit on I.D. of input pinion is 0.010 inch (0.25 mm) maximum per side. Rework I.D. evenly to prevent balancing
A problems. After rework, fill and drain using suitable primer to prevent corrosion.
fillf liners are excessively worn, case or cap assembly shall be returned to Bell Helicopter Textron for liner replacement.
206B3-R-65-23-2

Figure 65-23. Tail rotor gearbox limits 206-040-400 (sheet 2)

65-00-00
Page 49
BHT-206B3-CR&O

TOP

C:

TOE ......................... ..........__ -........__

HEEL

FLANK

SPIRAL BEVEL GEAR

VIEW A

INPUT PINION
VIEW B
DESIRED GEAR WEAR PATTERN FOR GEAR AND PINION

t ----- ------ -------------- -------

SPIRAL BEVEL GEAR

VIEW C
ACCEPTABLE WEAR PATTERN FOR GEAR
CHECK GEAR WEAR PATTERN ON CONVEX SIDE OF GEAR AND
CONCAVE SIDE OF PINION. WEAR PATTERN MUST BE WITHIN THE
FOLLOWING LIMITS:

DESIRED PATTERN: The desired pattern Is PROFILE PATTERN: The pattern shall be
shown In views A and B. Note that the pattern positioned on the tooth In a profile direction
touches at the toe and has a total length In such that when observing the gear, the pattern
excess of 0.60 Inch. The pattern does not touch may touch top of gear but must not extend over
the top of tooth of gear or pinion. A sllght bright the top. See view C. The pattern may extend over
llne at top of pattern on gear and In flank of the top of pinion providing no sign of distress Is
pinion Is characteristic. evident In flank of gear.
MINIMUM LENGTH: The minimum length of the In addition to pattern size and location, examine
pattern shall be 0.60 Inch and may not touch the drive face of all gear teeth for the following
heel. See view C. unacceptable defects: noncleanup, grinding
scratches, pitting, corroclon, cuts, nicks, dents,
MAXIMUM LENGTH: The maximum length of the grinding flats or barber poling (evidenced by
contact wear pattern Is such that It must not diagonal streaks In the wear pattern), scuffing,
extend beyond the heel of the tooth but may scaring, and Inclusions. Pitting of any
extend beyond the toe providing that no hard magnitude resulting from surface fatigue Is not
bright llne or tooth distress Is evident at this permlsslble.
point. 206B-65-24
C0002

Figure 65-24. Gear wear pattern (206-040-400)

65-00-00
Page 50

5. Visually inspect duplex bearings (44,
Figure 65-14) and roller bearings (36 and 48) for
roughness, spalling, scoring, pitting, flaking, broken or
damaged retainers, and for evidence of overheating
and corrosion.
6. Visually inspect retainer rings (6, 22 and 37) and
shim rings (5 and 49) for wear, damage and distortion.
7. Visually inspect studs and dowels in case
assembly (17) for security and damage. Replace
damaged studs (Paragraph 65-38).
8. Inspect case assembly (17) and cap
assembly (34) for corrosion and damage (Paragraph
65-37).
9. Inspect sight glass (24, Figure 65-14) for
cracking, crazing, or any condition that may obscure
level or color of oil. Inspect oil level indicator (25) for
discoloration, paint peeling and evidence of a plastic
film on the painted side. If plastic film exists, it must be
removed.
10. Visually inspect nuts (1, 3, 40, and 42) for cracks,
distorted tangs and thread damage.
11. At each overhaul, inspect nuts (1 and 40), case
assembly (17), and cap assembly (34) by fluorescent
penetrant inspection method per MIL-STD-6866 and
BHT-ALL-SPM (Paragraph 65-35). Remove paint
finish with paint remover (C-435) prior to inspection.
12. Perform runout inspection on output shaft (28)
(Figure 65-25).
Export Classification C, ECCN 9E991
BHT-206B3-CR&O-4
13. At each overhaul, inspect nut (3), spiral bevel
gear (27), output shaft (28), spacer (38), and input
pinion (46) by magnetic particle inspection method per
MIL-STD-1949 and BHT-ALL-SPM (Paragraph 65-36).
65-34. 3000 Hour inspection.
1. Perform backlash check (Paragraph 65-40).
Record readings.
2. Perform inspection steps 4, 5, 7, 8, and 9.
3. Assemble tail rotor gearbox (Paragraph 65-39).
4. Perform backlash check (Paragraph 65-40).
Backlash readings shall be within 0.001 inch
(0.0254 mm) of original readings unless input pinion or
spiral bevel gear were replaced. Backlash readings
shall be within overhaul limits (Paragraph 65-40).
5. Refinish tail rotor gearbox (Paragraph 65-41).
6. Make an entry in historical records that the
3000 hour inspection has been performed.
65-35. Fluorescent Penetrant Inspection.
1. Refer to Table 65-3 for tail rotor gearbox
fluorescent penetrant overhaul inspection
requirements.
2. Those parts listed in Table 65-3 shall be
inspected in accordance with Special Acceptance
Requirements of the stated reference, and fluorescent
penetrant inspection MIL-STD-6866 procedure
contained in BHT-ALL-SPM.
65-00-00
28 FEB 2020 Rev. 7 Page 51
BHT-206B3-CR&O-4

Table 65-3. Tail Rotor Gearbox 206-040-400 Fluorescent Penetrant Overhaul Inspection
Requirements

SPECIAL ACCEPTANCE
DESCRIPTION REFERENCE
REQUIREMENTS

Nut-Output Shaft Outer 1, Figure 65-14 None

Case Assembly 17, Figure 65-14 None

Cap Assembly 34, Figure 65-14 None

Nut-Input Pinion Outer 40, Figure 65-14 None

65-36. Magnetic Particle Inspection. 2. Those parts listed in Table 65-4 shall be
inspected in accordance with Special Acceptance
1. Refer to Table 65-4 for tail rotor gearbox Requirements of the stated reference, and magnetic
magnetic particle overhaul inspection requirements. particle inspection MIL-STD-1949 procedure
contained in BHT-ALL-SPM.

Table 65-4. Tail Rotor Gearbox 206-040-400 Magnetic Penetrant Overhaul Inspection
Requirements

SPECIAL ACCEPTANCE
DESCRIPTION REFERENCE
REQUIREMENTS

Nut-Output Shaft Inner 3, Figure 65-14 None

Spiral Bevel Gear 27, Figure 65-14 None

Output Shaft 28, Figure 65-14 None

Input Pinion 46, Figure 65-14 None

65-37. Corrosion Damage Inspection.
1. Replace case assembly (17, Figure 65-14) and
cap assembly (34) if bearing liners are loose or if
threads for studs are structurally damaged and
impractical to repair.
2. Replace case assembly (17) and cap
assembly (34) which have corrosion damage under
bearing liners, in critical areas which would affect
function or structural integrity of part, or if damage
exceeds limits for areas designated on Figure 65-26.
3. Areas of tail rotor gearbox most frequently
damaged by corrosion are shown in Figure 65-26.
Acceptable depth limits for pitting and percentage of
area pitting (i.e., the percentage of area in which the
original machined surface has been removed by
corrosion) are as follows:
a. Case Assembly (1 7, Figure 65-14). Areas A,
B and D, Figure 65-26, should be inspected carefully
prior to any corrosion removal for evidence of
corrosion in threads between case and studs. Any
corrosion on threads is cause for rejection of part. In
areas A through D, the maximum depth of corrosion
pitting is 0.030 in. (0.762 mm) and no more than 40%
of the area of any one sq.in. (645.2 mm) square nor
20% of the total

65-00-00
Page 52 Rev. 7 28 FEB 2020 Export Classification C, ECCN 9E991
 BHT-206B3-CR&O

area of any surface or diameter should be touchup solution from running into areas
pitted. where it is not needed.

b. Cap A ssembly. Remove corrosion c. Scrub area to be treated with fine

damage and repair (paragraph 65-38). abrasive pad (C-407) , or fine aluminum wool
(C-422) . Abrade to clean bare metal. Fresh
machined surfaces may be treated without
65-38. Corrosion removal and repair. abrading.

MATERIALS REQUIRED d. Flush areas with cleaning compound

(C-318) mixed four ounces (113 g) per gallon
(four liters) of water, as required, to ensure a
NUMBER NOMENCLATURE water-break free surface.
C-116 Chromic Acid e. Rinse with clean water and repeat
C-120 Calcium Sulfate steps c. and d., as required, to provide a
clean surface.
C-201 Primer
2. Prepare magnesium touchup treatment
C-309 Methyl- Ethyl- Ketone solution by mixing 1.3 ounce (1 0 grams)
(MEK) chromic acid (C-116) , and 1 ounce (7. 5
grams) calcium sulfate (C-120 ) per gallon
C-318 Cleaning Compound (four liters) of water.
C-319 Chlorothene
NOTE
C-407 Abrasive Pad
The calcium sulfate will not go into
C-418 Tape
solution.
C-422 Aluminum Wool
a. Apply touchup solution with a brush or
C-423 A b rasive C l o t h or swab to repaired areas. Allow solution to
Paper react for at least one minute, reapply solution,
as required, to keep the area wet. Excess
solution should be clearly marked, dated, and
NOTE stored at room temperature in a glass jar. Do
not store touchup solution where
Removal of corrosion products is temperatures may vary to extremes, or in
mandatory prior to subsequent contact with direct sunlight. Do not use a
r e p a i r or corro s i o n protect ive touchup solution older than three months from
treatment. date of mixing.

1. The u s e o f t h e magnesium touchup b. Rinse thoroughly with clean water to

t r e a t m e n t is r e s t r i c t e d to p a r t s a n d
assemblies that have small areas of the
dichromate coating removed by scratches,
a b r a s i o ns o r m i n o r r e w o r k . Pa r t s o r
assemb lies that require touchup shall b e
treated as follows:
a . R e m o ve o i l a n d gr e a s e w i t h a
chlorothene (C-319) or MEK (C-309) .
b. Masking is not required; however, it
should be used, as required, to prevent
remove excess solution. The treatment should
produce a brassy colored film, if required,
repeat application of touchup solution until a
brassy colored film is obtained. Rinse, un
mask and rerinse to ensure solution removal.
All rinsing shall be accomplished using room
temperature water.
c. Dry with filtered compressed air and dry
cloths.

65-00-00
Page 53
BHT-206B3-CR&O-4
Figure 65-25. Output Shaft Runout Inspection (206-040-400)
d. Parts that require painting as the next
operation shall be painted as soon as practicable after
drying, preferably within 24 hours (Paragraph 65-41).
Bare steel parts shall be oiled immediately after drying
to prevent corrosion.
3. Rework or repair case assembly (17,
Figure 65-14) and cap assembly (34) as follows:
a. Corrosion in areas A through F, Figure 65-26,
or on the walls of bolt holes should be removed by
immersion in hot chromic acid bath rather than by
mechanical means so that effective position of the
original surfaces is not changed. It is mandatory that
all corrosion products be removed (step 4).
b. In area G, Figure 65-26, if no pitting is present
in the area contacted by the washers, corrosion may
be removed by immersion in a hot chromic acid bath
(step 4). If area is pitted, then the surface may be
machined. Minimum dimension after repair at point X
is 0.238 inch (6.045 mm).
65-00-00
Page 54 Rev. 7 28 FEB 2020
c. Magnesium parts which will be reused must
have all sharp edges polished out with 400 to 600 grit
abrasive cloth or paper (C-423).
4. Prepare hot chromic acid bath by mixing 20 to
24 ounces (567 to 680 g) of chromic acid (C-116) per
gallon (four liters) of water. Bath temperature should
be maintained at a temperature of 200°F (93°C). Parts
should be treated in the bath for as long as is required
to completely remove corrosion products. The
corrosion removal process must be controlled to
ensure that machined dimensions are maintained and
that cadmium plating is not removed from plated parts.
Plated parts should be masked with plating tape
(C-434).
5. Remove broken, bent, damaged, or loose studs
(1 and 2, Figure 65-27) in case assembly (3) as
follows:
a. Inspect threaded stud for damage. If holes are
damaged, repair or replace case assembly, as
required. Stud retaining holes
Export Classification C, ECCN 9E991
 BHT-206B3-CR&O

AREAD

AREAG

AREAC

AREAE

AREAA

CASE ASSEMBLY
(MAGNESIUM ALLOY
CASTING) CAP ASSEMBLY
(MAGNESIUM ALLOY CASTING)

B
T YPICAL 4 PLACES

DIMENSIONX

0.238 IN.
(6.045mm) G
T YPICAL
5PLACES
206B3-R-65-26

Figure 65-26. Tail rotor gearbox corrosion damage areas (206-040-400)

65-00-00
Page 55
BHT-20683-CR&O

r
-0.751N.(19.05mm) A
3PLACES ill
0.88 IN. (22.35 mm) A
3PLACES ill
. .---,-.

.
2

L 0.75 IN. (19.05mm)

4PLACES
A
ill

1. Stud AN125999 thru AN126002 oversize AN126003 thru AN126004.

2. Stud AN126011 thru AN126014oversize AN126015 thru AN126016-
3. Case assembly.

NOTE

Set studs with unreduced primer (C-201).

20683-R-65-27

Figure 65-27. Tail rotor gearbox 206-040-400 stud heights

65-00-00
Page 56
 BHT-206B3-CR&O-4

must be tapped to a sufficient depth so no imperfect SPECIAL TOOLS REQUIRED (Cont)

threads can be engaged.

NUMBER NOMENCLATURE
b. Clean out small vent hole in bottom of stud
holes, as required. Apply unreduced primer (C-201) to T101507 Pinion Installation and
threads of replacement stud and install to the depth Removal Set
shown in Figure 65-27. Torque studs 50 to
95 inch-pounds (6 to 11 Nm). T101511 Spline Wrench

T101512 Gearbox Wrench

65-39. Assembly.
T101513 Output Shaft Nut
Wrench
MATERIALS REQUIRED
T102103 Dehydrator
Refer to BHT-ALL-SPM for specifications. Figure 65-17 Fabricated Tail Rotor
Gearbox Mounting
NUMBER NOMENCLATURE
Workaid
C-001 1 Grease
Figure 65-29 Output Shaft Bearing
C-010 Lubricating Oil Pressing Cylinder
Workaid
C-011 Lubricating Oil
Figure 65-30 Input Pinion Bearing
C-021 Lubricant Pressing Cylinder
Workaid
C-309 Methyl-Ethyl-Ketone
(MEK) — Heat Lamp

C-317 Adhesive — Hydraulic Press

C-328 Sealing Compound — Plastic Mallet

C-405 Lockwire

C-422 Aluminum Wool 1. Install sight glass (24, Figure 65-14) and oil level
indicator (25) as follows:
NOTE:
a. Insert oil level indicator (25) in case
1 Replaced with grease (C-172) as an assembly (17) so that notch in indicator aligns with
alternative, use corrosion preventive notch in case assembly.
compound (C-104).
b. Apply a film of lubricating oil (C-010) to new
packing (23) and outer diameter of sight glass (24).
Position packing in groove on sight glass and insert in
case assembly (17).
SPECIAL TOOLS REQUIRED
c. Secure sight glass (24) in case assembly (17)
NUMBER NOMENCLATURE with retainer ring (22).

Owatonna 927 Puller

Owatonna 927A Puller Legs, 6¾ Inch

(171.45 mm) Long

65-00-00
Export Classification C, ECCN 9E991 28 FEB 2020 Rev. 7 Page 57
BHT-206B3-CR&O-4

KEPT WITH CASE ASSEMBLY (17) TO

CAUTION
E N S U R E T H AT T H E S A M E S H I M
RINGS (5 AND 49) ARE INSTALLED IN
C A S E A S S E M B LY ( 1 7 ) . I T I S
MANDATORY THAT SHIM RINGS BE
OBTAIN CORRECT GEAR MESH.
2. Check to ensure that shim rings (5 and 49) are
installed in case assembly (17).
3. Install duplex bearings (4) in case assembly (17)
as follows:

65-00-00
Page 57A/57B Rev. 7 28 FEB 2020 Export Classification C, ECCN 9E991
BHT-206B3-CR&O
NOTE
Du plex bearings (4) must be a
matched part and serial numbered
set.
a. Locate burr or etch marks on inner
races of duplex bearings (4) and make a mark
across inside of inner races in line with
marks. Apply film of lubricating oil (C-010) to
duplex bearings and to bearing liner in case
assembly (17).
WHEN USIN G HEAT LAMP DO
NOT EXCEED A TEMPERATURE
OF 200 ° F (93 ° C) FOR DAMAGE
TO PACKINGS MAY OCCUR.
b. Apply heat lamp to case assembly (17)
in area of bearing liner for duplex bearing (4).
c. When case assembly (17) is heated,
press duplex bearings (4) in bearing liner one
at a time, face-to-face , with pencil mark
aligned (figure 65-14).
4. Apply a film of lubricating oil (C-010) to
threads of output shaft outer nut (1) and
install in case assembly (17) finger tight.
Output shaft outer nut will be torqued in a
later step.
5. Install retainer rings (47) and roller
bearing (48) in case assembly (17) as follows:
a. Apply a film of lubricating oil (C-010) to
roller bearing (48) and bearing liner in case
assembly (17).
b. Install one retainer ring (47) in bearing
liner in case assembly (17) on inboard side.
c. Apply heat lamp to case assembly (17)
in area of bearing liner for bearing (48).
d. When case assembly (17) is heated,
press roller bearing (48) in bearing liner with
Bell Helicopter Textron, Inc. part number
outboard. Secure roller bearing with second
retainer ring (47).
65-00-00
Page 58
6. Assemble spiral bevel gear (27) and
output shaft (28) as follows:
a. Clamp T101511 spline wrench in shop
vise with 32 spline teeth opening exposed
and insert output shaft (28).
b. Position spiral bevel gear (27) on
output shaft (28). Align bolt holes and tap in
place with a plastic mallet.
c. Install ten bolts (26) and uniformly
torque 100 to 125 in.lb. (11.3 to 14.1 Nm).
Ensure spiral bevel gear (27) is square and
i· · · · · · · · · 1
flush to flange on output shaft (28).
CAUTION
•••••••••••••••••
CUT L OCKWIR E TAILS S HOR T
A ND TUCK INTO BOLT (26) HEAD
TO PREVENT CO NTACT WITH
INBOARD BEARING HOUSING OF
INPUT PINION.
d. Safety bolts (26) in pairs with lockwire
(C-405) .
7. Apply a film of lubricating oil (C-010) to
new wear sleeve (30) and to output shaft
(28). Apply heat lamp to wear sleeve until
heated, then press on output shaft until firmly
seated, (O.D. of chamfer pointing outboard). I
8. Install spiral bevel gear (27) and output
shaft (28) in case assembly (17) as follows:
a. Apply a film of lubricating oil (C-010) to
installed duplex bearings (4) and to bearing
seat on output shaft (28).
b. Position outboard end of output shaft
(28) on support plates in hydraulic press.
Position case assembly (17) over upper end
of output shaft and spiral bevel gear (27) with
end of shaft starting through inner race of
duplex bearings (4).
c. Fabricate output shaft bearing pressing
cylinder workaid (figure 65-29).
d. Position fabricated bearing pressing
cylinder against inner race of duplex bearings
 BHT-206B3-CR&O

r INPUT PINION GEAR

BACKLASH MUST
BE WITHIN
0.003 TO 0.011 IN.
(0.076 TO 0.279 mm)
MUST NOT VARY MORE
THAN 0.002 INCH
(0.051 mm) AT THREE
DIFFERENT LOCATIONS

TRIM ONE TANG

FLUSH TO 0.025 IN.
(0.635 mm) RECESSED
FROM END OF NUT

DUPLEX BEARINGS
CAP ASSEMBLY
INSTALL FACE-TO
-FACE
CASE ASSEMBLY

VIEW A-A

206B3-R-65-28

Figure 65-28. Tail rotor gearbox backlash checks (206-040-400)

65-00-00
Page 59
BHT-206B3-CR&O-4

Figure 65-29. Output Shaft Bearing Workaid

(4). Operate hydraulic press, pressing duplex bearings
firmly on output shaft (28, Figure 65-14).
9. Install seal (29) and roller bearing (36) in cap
assembly (34) as follows:
a. Apply a film of lubricating oil (C-010) to roller
bearing (36) and to bearing liner in cap assembly (34).
Apply heat lamp to cap assembly.
seals, fill groove between lips with a coating of grease
(C-001) or solid film lubricant (C-021), then apply a
coating to lip of seal and wear sleeve (30) on output
shaft (28).
e. Apply a film of lubricating oil (C-010) to new
packing (35) and install in groove on inboard side of
cap assembly (34).

b. When cap assembly (34) is heated, press

roller bearing (36), in bearing liner of cap with part
CAUTION
numbered side next to retainer ring (37). Secure
bearing with retainer ring.
EXERCISE CAUTION WHEN PLACING
c. Clean outer diameter of new seal (29) and
SEAL (29) ON WEAR SLEEVE (30), OR
mating inner surface in cap assembly (34) with cloth
DAMAGE TO SEAL MAY RESULT.
dampened with MEK (C-309). Wipe surfaces dry.
Apply a thin film of sealing compound (C-328) to outer
diameter of seal and mating inner surface of cap 10. Position cap assembly (34) over output shaft
assembly. (28), wear sleeve (30), and on studs of case assembly
(17). Press cap assembly in case assembly and install
d. Press seal (29) in cap assembly (34) until aluminum washers (33), thin steel washers (32), and
firmly seated, then remove excess sealing compound. new nuts (31). Torque nuts uniformly 50 to 70
Ensure lip of seal is pointing inboard. On double-lip inch-pounds (6 to 8 Nm).

65-00-00
Page 60 Rev. 2 31 MAR 2010 ECCN 9E991

11. Install and torque output shaft inner nut
(3) to output shaft (28) as follows:
a. Clamp up T101511 spline wrench in a
sturdy shop vise with 32 teeth spline opening
exposed. Insert output shaft into spline
w r e n c h . (Se e f i g u r e 6 5 - 1 6 f o r t o o l
application).
b. Apply a film of lubricating oil (C-010) to
threads on output shaft (28, figure 65-14) and
output shaft inner nut (3).
c. Using T101513 output shaft nut wrench
torque output shaft inner nut (3) 31O to 350
in.lb. (35 to 40 Nm).
d. Temporarily remove output shaft outer
nut (1) and install cotter pin (2) with head in
slot through output shaft (28) and body
through nut (3). Trim cotter pin so that
outboard tang is flush to 0.025 in. (0.635 mm)
recessed from inner nut. Bend inboard tang in
opposite direction (figure 65-28).
e. Install output shaft outer nut (1, figure
65-14) finger tight in case assembly (17), nut
will be torqued in a later step. Remove output
shaft (28) from spline wrench.
f. Rotate output shaft (28), by hand, to
check that bearings roll smoothly and shaft is
free to turn.
12. Install duplex bearings (44) and spacer
(38) on input pinion (46) as follows:
a. Apply a film of lubricating oil (C-010) to
input pinion (46), packing (45), duplex
bearings (44), and spacer (38).
b. Fabricate input pinion bearing pressing
cylinder workaid (figure 65-30).
c. Position fabricated bearing pressing
cylinder on support plates in hydraulic press.
Stack duplex bearings (44, figure 65-14) back
to back and place on hydraulic press support
plates. Insert duplex bearings one at a time
on input pinion (46) and position in bearing
pressing cylinder, then press firmly on gear.
BHT-206B3-CR&O
d. Install packing (45) on input pinion (46)
in second groove from outboard side of
installed duplex bearings (44).
e. Press spacer (38) over packing (45)
and on input pinion (46) until flush with inner
race of installed duplex bearings (44). If
s p a c e r c a n n o t be i n s t a l l e d w i t h h a n d
pressure, use T101507-7 adapter threaded on
input pinion to press spacer in position.
13. Install input pinion (46) and duplex
bearings (44) in case assembly (17) using
T101507 pinion installation and removal as
f o l l o w s : ( S ee f i g u r e 6 5 - 1 9 , f o r t o o l
application).
a. Mount and secure case assembly (17,
figure 65-14) in fabricated mounting workaid
and clamp up in shop vise.
b. Thread T101507-5 base in case
assembly (17).
c. Thread T101507-7 adapter on input
pinion (46) until in firm contact with spacer
(38).
d. Assemble and install Owatonna 927
puller and 927 A puller legs to installed
T101507-5 base and T101507-7 adapter as
shown in figure 65-19, except that puller nut
[·· · · · · · · ·1
must be on the inboard side of puller bar.
CAUTION
................
WHEN USING HEAT LAMP, DO
NOT EXCEED A TEMPERATURE
OF 200 °F (93 °C) FOR DAMAGE
TO PACKINGS MAY OCCUR.
e. Apply heat lamp to case assembly (17,
figure 65-14) and heat in area of duplex
i.... . . ... . . i
bearings (44).
CAUTION
.................
ENSURE THAT NOSE OF INPUT
PINI ON A LI GNS WITH INNER
RACE OF ROLLER BEARING AND
65-00-00
Page 61
 BHT-206B3-CR&O

I
1.6IN. 1.2 ± 0.010IN.

_l
(40.6mm) (30.5 ± 0.254mm)

l
0.2 TO 0.3IN. (5.1 TO 7 .6mm)
.------- 4.0IN.------• 45° RADIUS - BOTH ENDS .
(101.6mm)

MATERIAL; 4130 Steel (MIL-S-6758)

NOTE: Heat treatment and paint finish not required.

USE: Press tail rotor gearbox duplex bearings onto input pinion gear.
206B3-R-65-30

Figure 65-30. Input pinion bearing pressing workaid

I THAT GEAR TEETH CORRECTLY

MESH.
f. Operate puller and install input pinion
( 46) and duplex bearings (44) in case
assembly (17). Duplex bearings must seat
firmly in case assembly bearing liner.
Disassemble and remove puller and pinion
installation tools.
g. Rotate input pmIon (46), by hand, to
ensure that duplex bearings (44) roll smoothly
and that input pinion is correctly meshed with
spiral bevel gear (27).
14. Install new seal (41) and input pinion
outer nut (40) in case assembly (17) as
follows:
b. Press seal (41) in input pinion outer nut
(40) until firmly seated and remove excess
sealing compound. Ensure lip of seal is
pointing inboard. On double-lip seals, fill the
groove between the lips with a coating of
grease (C-001) or lubricant, solid film (C-021)
and apply a coating to lip of seal and outer
diameter of spacer (38) on input pinion (46). I
c. Apply a film of approved lubricating oil
(C-011) to new packing (39) and to threads of
input pinion outer nut (40). Place packing in
groove on nut and screw in case assembly
(17) until seated against duplex bearings (44)
with hand pressure. Nut will be torqued in a
later step.

I
a. Clean outer diameter of new seal (41)
and mating inner surface of input pinion outer
15. Install input pmIon inner nut (42) and
lockwasher (43) on input pinion (46) as
follows:

1 nut (40) with a cloth dampened with MEK (C-

309) . Wipe surfaces dry. Apply a thin film of
sealing compound (C-328) to outer diameter
a. Apply a film of lubricating oil (C-011) to
threads on input pinion (46) and install input
pinion inner nut (42).
of seal and mating inner surface of nut.
b. Clamp T101511 spline wrench in shop
vise with 15 teeth spline opening exposed.

65-00-00
Page 62

Position splined end of input pinion (46) in spline
wrench. (See Figure 65-15 for tool application.)
c. Torque input pinion inner nut (42, Figure
65-14) 360 to 400 inch-pounds (41 to 45 Nm) using
spanner wrench (AN8514-1).
d. Install new lockwasher (43) on input pinion
(46). Use a plastic mallet to force lockwasher against
input pinion inner nut (42) and engage two locking
tangs into nut.
16. Torque output shaft outer nut (1) and input pinion
outer nut (40) to case assembly (17) as follows:
a. Clamp fabricated mounting workaid in shop
vise and secure case assembly (17) to workaid with
washers and nuts. (See Figure 65-18 for tool
application.)
b. Torque input pinion outer nut (40, Figure
65-14) 100 to 150 foot-pounds (136 to 203 Nm) using
gearbox wrench (T101512) and 1/2 inch socket
adapter. Secure outer nut to tab on case assembly
(17) with lockwire (C-405). (See Figure 65-28 for
lockwire application.)
c. Torque output shaft outer nut (1, Figure 65-14)
650 to 800 inch-pounds (73 to 90 Nm) using gearbox
wrench (T101512) and 1/2 inch socket adapter.
Secure outer nut to tab on case assembly (17) with
lockwire (C-405).
d. Rotate output shaft (28), by hand, to ensure
smooth rotation and freedom from binding. Do not
remove case assembly (17) from mounting workaid
and shop vise.
17. Assemble and install oil filler cap (12) as follows
NOTE
Proper quantity of aluminum wool will
cause washer to fully spring back after
being depressed 0.06 inch (1.52 mm).
a. Form a ball of aluminum wool (C-422) and
insert in bottom of plug (9) and install washer (7) and
retainer ring (6).
ECCN 9E991
BHT-206B3-CR&O-4
b. Apply a film of lubricating oil (C-011) to new
packing (10) and install in groove on plug (9).
c. Position spring assembly (11) on spindle of
plug (9), press on oil filler cap (12), and secure with
retainer ring (13).
d. Form a closed loop on one end of pin (14) and
attach required length of chain (15). Rotate oil filler cap
(12) and plug (9) aligning holes for pin. Insert pin
through cap and plug until closed loop of pin is firmly
against cap, then bend end of pin down against cap
0.15 inch (3.81 mm). Trim end of pin so that it does not
extend below edge of cap.
e. Install oil filler cap (12) to adapter (51) on case
assembly (17), and secure chain (15) to case with
pin (16).
18. Apply film of lubricating oil (C-011) to new
packings (18 and 20) and position on self-closing
valve (19) and electric chip detector (21). Install
self-closing valve in case assembly (17) and torque 20
to 60 inch-pounds (2.26 to 6.78 Nm). Secure
self-closing valve to tab on case assembly with
lockwire (C-405). Install electric chip detector in
self-closing valve.
19. Stamp overhaul information on data plate (50),
then bond to case assembly (17) with adhesive
(C-317). Cure adhesive for 24 hours at 75°F (24°C)
(full cure 5 to 7 days), or for 60 minutes at 170 to
190°F (77 to 88°C).
NOTE
An appropriate log book entry must be
made upon installation of dehydrator.
20. Remove and store cap assembly (12) and install
dehydrator (T102103), when tail rotor gearbox is
removed from helicopter or stored for an
undetermined length of time.
21. Perform tail rotor gearbox backlash check
(paragraph 65-40).
22. Paint tail rotor gearbox (paragraph 65-41).
65-00-00
31 MAR 2010 Rev. 2 Page 63
BHT-20683-CR&O

23. Preserve tail rotor gearbox (paragraph 6. Total amount of movement (backlash)
65-42). must be between 0.003 to 0.011 in. (0.076 to
0.279 mm) and must not vary more than
0.002 in. (0.051 mm) when checked at three
65-40. Backlash check. different locations. Remove backlash check
tools.
SPECIAL TOOLS REQUIRED
65-41. Painting.

NUMBER NOMENCLATURE
MATERIALS REQUIRED
T101511 Spline Wrench
T102093 Anchor Assembly NUMBER NOMENCLATURE
Figure 65-17 Fabricated Tail Rotor C-203 Lacquer
Ge a r b o x M o u n t i n g
C-204 Primer
Workaid
C-308 Adhesive
Dial Indicator
C-426 Tape

1. Clam p tail rotor gearbox fabricated

mounting workaid to shop vise. Install and NOTE
secure tail rotor gearbox to mounting workaid
(figure 65-17). For a p p l i cation of paints and
primers, refer to BHT-ALL-SPM.

1. Touchup all exposed bare magnesium

2. Position T102093 anchor assembly over
output shaft. Ensure anchor assembly has
stamped outboard side facing outboard.
Thread anchor assembly bolt in threaded
o p ening in cap a s s e m b l y and t i g h t e n
clamping bolt.
3. Install T101511 spline wrench on input
pinion in horizontal position and tighten
setscrew.
surfaces (paragraph 65-38).
2. Mask areas of tail rotor gearbox not
requiring painting with tape (C-426) (figure
65-32).
3. Prime all damaged or repaired areas on
tail rotor gearbox with one coat of primer (C-
204) . Minimum coating thickness after drying
is 0.4 mil (0.0004 in.) (0.0102 mm) (Table 65-
6).

4. Clamp dial indicator and support to tail

rotor gearbox and mounting workaid with
large C-clamp shown in figure 65-31. Position
pointer of dial indicator to contact step on
T101511 spline wrench at stamped V-mark.

5. With dial indicator pointer preloaded and

gage zeroed, rotate T101511 spline wrench to
limits of travel and record reading.

65-00-00
Page 64
 BHT-206B3-CR&O

TAIL ROTOR
GEARBOX MOUNTED
TO FABRICATED MOUNTING
WORKAIDAND
SHOP VISE.

20683-R-65-31

Figure 65-31. Tail rotor gearbox backlash tool application

65-00-00
Page 65
BHT-206B3-CR&O

- Orange - yellow, color no. 13538

acrylic lacquer (C-203)

D Epoxy polyamide primer (C-204) and

aluminum, color no. 17178 acrylic
lacquer (C-203)

�. Unpainted

CT] Apply bead of class B-2 sealant

(C-308) to mating edges

VIEWA-A 206B3-R-65-32

Figure 65-32. Tail rotor gearbox painting (206-040-400)

65-00-00
Page 66
 BHT-206B3-CR&O

Table 65-5. Tail rotor gearbox 206-040-400 painting requirements

ITEM NAME PAINT TYPE AND METHOD OF NO. OF NOTES

SPECIFICATION APPLICATION COATS

Tail rotor Epoxy Polyamide Primer Spray 1 0.4 Mils

Gearbox (two part kit) (C-204) (0.0102 mm)
Minimum

Acrylic Lacquer, Aluminum Spray 2

Color No. 17178 (C-203)

Oil Filler Acrylic Lacquer, Orange­ Spray or brush 2

Cap Yellow Color No. 135388
(C-203)

4. Apply a film of adhesive (C-308) to outer MATERIALS REQUIRED (CONT)

edge mating surfaces in the following areas if
not previously accomplished (figure 65-32).
NUMBER NOMENCLATURE
a. A dap ter oil cap assemb l y to case
assembly. C-426 Tape

b. Vent holes for case studs. C-427 Barrier Material

c. Radius groove between wear sleeve

and output shaft.
d. Between input pinion outer nut and
case assembly.
5. Final prime tail rotor gearbox with one
spray coat of primer (C-204) .
1. Preserve tail rotor gearbox internally with
lubricating oil (C-010) . Fill to correct oil level.
2. Appl y a fil m of corrosion preventive
compound (C-101) to all bare metal, uncoated
and unpainted surfaces.
3. Enc lose tail rotor gearbox in barrier

I 6. Finish paint tail rotor gearbox with two

spray coats of gloss silver/aluminized lacquer
(C-203), color No. 17178.
material (C-427) and seal with tape (C-426) .

4. Sec urely pack tail rotor gearbox in a

metal or wooden sh ipping container with
7. Finish paint oil filler cap with two spray c u s h io n i n g a n d h a r d w a r e to p r e v e n t

I coats of gloss orange-yellow lacquer (C-203) ,

color No. 13538.
movement during handling and transit. Install
desiccant and seal container.

5. For long term storage, refer to BHT-

65-42. Preservation. 206B3-MM.

MATERIALS REQUIRED

NUMBER NOMENCLATURE

C-010 Lubricating Oil

C-101 Corrosion Preventive
Compound

65-00-00
Page 67/68
 BHT-206B3-CR&O

TAIL ROTOR GEARBOX 206-040-402

65-43. TAIL ROTOR GEARBOX 206-040- SPECIAL TOOLS REQUIRED (CONT)

402.
NUMBER NOMENCLATURE
65-44. MAINTENANCE.
Owatonna No. 927 Puller
The f o l lowing p a r ag r aphs p r o v i de the Owatonna No. 927A Puller legs, 6¾ in .
overhaul, repair, and 3000 hour inspection (171.45 mm) long
inst ructions applicable to the tail rotor
gearbox. Owatonna No. 951 B e a r i n g P u 11 i n g
Attachment
NOTE T101308 Jackscrew Set
The t a i l r otor gearbox may be T101507 Pinion Installation and
dis asse mbled, as r equi r e d, t o Removal Set
accomplish component repair to a
particular part or assembly. T101511 Spline Wrench

T101512 Gearbox Wrench

65-45. Disassembly.
T101513 O utput S ha f t Nut
Wrench
MATERIALS REQUIRED
Figure 65-36 Fabricated Tail Rotor
NUMBER NOMENCLATURE Ge a rbo x Moun t i ng
Workaid
C-309 Methyl-E thyl-Ketone
(MEK) Figure 65-48 Output Shaft Bearing
P r essing C y l i n de r
C-407 Abrasive Pad Workaid

Figure 65-49 Input Pinion Bearing

Pressing Workaid
NOTE
1/2 Inch Breaker Bar
I f d i s a s s e mb l y i s be i ng
accomplished to perform 3000 hour Dial Indicator
inspection, perform backlash check
(P a r ag r a p h 6 5 - 4 3 ). Record Heat Lamp
backlash readings for comparison
after inspection is complete. Offset Screwdriver (2)

Plastic Mallet
SPECIAL TOOLS REQUIRED
Plastic Scraper

NUMBER NOMENCLATURE P r e s s i n g P l ug
(Maximum OD 0.98
MS8514-1 Spanner Wrench, 2 in. in.) (24.89 mm)
(51 mm)

Owatonna No. 630-3 Step Plate Adapter,

1¼ X 1 in. (31.75 X 25
mm)
65-00-00
Page 69
BHT-206B3-CR&O
NOTE
Revi e w Mandat o r y Ret i r e m ent
Schedule in BHT-206B3-MM and
reti r e all i t e m s s c h e d u l e d f o r
retirement. If tail rotor gearbox is
being disassembled for replacement
of part(s) instead of overhaul,
disassemble only to ext ent
necessary to replace part(s).
1. Drain oil from tail rotor gearbox by
removing electric chip detector (21, figure 65-
33) and self closing valve (19). Remove and
discard packings (18 and 20).
2. Cut and remove lockwire from input
pinion, outer nut (40) and case assembly (17).
3. Using two offset screwdrivers, lift the two
opposing locking tangs of lockwasher (43).
Force lockwasher outboard to free it from nut
( 4 2 ) a n d i n p u t p i n i o n (46 ) . Di s c a r d
lockwasher.
4. Clamp T101511 spline wrench with 15
teeth spline opening exposed in a sturdy shop
vise and position splined end of input pinion
(46) in wrench. Loosen input pinion inner nut
(42) with MS8514-1 spanner wrench, then
remove gearbox from splined wrench and
remove nut. ( See figure 65-34 for tool
application).
5: Reverse T101511 spline wrench in shop
vise so that 32 teeth spline opening is
exposed. Position splined end of output shaft
(28, figure 65-33) in spline wrench and
remove cotter pin (2) from output shaft inner
nut (3) and output shaft. Position T101513
output shaft nut wrench with 1/2 inch breaker
bar and remove output shaft inner nut (See
figure 65-35, tool application). Remove tail
rotor gearbox and wrenches from shop vise.
6. Fabricate tail rotor gearbox mounting
workaid (figure 65-36).
7. Clamp mounting workaid in shop vise.
Secure tail rotor gearbox to the workaid with
four washers and nuts and accomplish the
following: (Figure 38).
65-00-00
Page 70
a. Remove sealant from around input
pinion outer nut (40, figure 65-34) and case
assembly (17), using a plastic scraper.
b. Position T101512 gearbox wrench with
a 1/2 inch breaker bar to input pinion outer
nut (40) and remove from case assembly (17)
(figure 65-33).
c. Remove packing (39, figure 65-33) from
input pinion outer nut (40) and press out seal
(41). Discard packing and seal. Leave case
assembly (17) secured to fabricated mounting
workaid. Do not remove spacer (38) at this
time.
8. Remove input pinion (46) from case
a s s e m b l y ( 1 7 ) u s i n g T1 0 15 0 7 p i n i o n
installation and removal set (figure 65-38) as
follows:
a. Thread T1015 0 7- 5 b a s e i n c a s e
assembly (17, figure 65-33).
b. Thread T101507-7 adapter on input
pinion (46) until in firm contact with spacer
(38).
c. Assemble and install Owatonna No.
927 puller and No. 927A puller legs to
installed T101507-5 base and T101507-7
adapter as shown in figure 65-38. Ensure
puller nut is on outboard side of puller bar.
d. Apply heat lamp to case assembly (17,
figure 65-33) and heat in area of duplex
bearings (44).
e. Operate puller and remove input pinion
(46) and duplex bearings (44) from case
assembly (17). Disassemble and remove
puller and pinion removal tools.
DO NOT REMOVE SHIM RINGS (5
AND 49) FROM CASE ASSEMBLY
(17) EXCEPT FOR INSPECTIO N
A ND C L EA NING OF SHIM RING
GROOVE IN BEARING LINERS. IT
IS MA ND A T O R Y T H A T SHIM
RINGS BE KEPT WITH THE CASE
 BHT-20683-CR&O

12
14

11�\
10--c.5 \
21
�
19
8
I ()

22
/x 23
24
50 5 25

26 27
,

\
49
\
48 4\[
47 �

�J
I ,� ,
.
I

I
'
'

,r l
.\ I

44 45 28

j� I
' I

(� V 39
40
6� 3
/

�) 36
41 ,(!J)
v

34 30 ',
3 �
�� 32 31 29
� 206B3-R-65-33-1

Figure 65-33. Tail rotor gearbox 206-040-402 {sheet 1 of 2)

65-00-00
Page 71
BHT-206B3-CR&O

1. Output shaft outer nut 18. Packing 35. Packing

2. Cotter pin 19. Self-closing valve 36. Roller bearing
3. Output shaft inner nut 20. Packing 37. Retainer ring
4. Duplex bearing 21. Electric chip detector 38. Spacer
5. Shim ring 22. Retainer ring 39. Packing
6. Retainer ring 23. Packing 40. Input pinion outer nut
7. Washer 24. Sight glass 41. Seal
8. Aluminum wool packing 25. Oil level indicator 42. Input pinion inner nut
9. Plug 26. Bolt 43. Lockwasher
10. Packing 27. Spiral bevel gear 44. Duplex bearing
11. Spring assembly 28. Output shaft 45. Packing
12. Oil filler cap 29. Seal 46. Input pinion
13. Retainer ring 30. Wear sleeve 47. Retainer ring
14. Pin 31. Nut 48. Roller bearing
15. Chain 32. Thin steel washer 49. Shim ring
16. Pin 33. Aluminum washer 50. Data plate
17. Case assembly 34. Cap assembly 51. Adapter
20683-R-65-33-2

Figure 65-33. Tail rotor gearbox 206-040-402 {sheet 2)

ASSEMB LY TO OBTAIN CORRECT AT T AC HM E N T T O APPLY

GEAR MESH.
9. Remove duplex bearings (44) from input
pinion (46) using Owatonna No. 951 bearing
pulling attachments (figure 65-39) as follows:
NOTE
As an alternate method Owatonna
No. 927 puller, No. 927 A puller legs
and No. 630-3 step plate adapter
may be used to remove duplex
bearings (44, figure 65-33).
a. Position Owatonna No. 951 bearing
pulling attachment around input pinion (46)
between gear teeth and duplex bearing (44).
Adjust puller to contact inner race of duplex
bearing only.
PRES SURE TO OUTER RAC E OF
DUPLEX B EARINGS (44) OR TO
S C O R E I N PUT PI N I O N ( 4 6 )
DURING PRES SING OPERATION .
b. Using hydraulic press and Owatonna
No. 630-3 step plate adapter on end of input
pinion (46), press spacer (38) and duplex
bearings (44) from pinion. Remove and
discard packing (45).
1 O. Remove output shaft (28) and cap
assembly (34)_ from case assembly (17) as
follows:
a. Remove nuts (31) and washers (32 and
33) from studs at cap assembly (34). Thread
two T101308 jackscrews in cap assembly
until cap is free on output shaft (28). Remove
cap from output shaft.

b. Position and support case assembly

(17) on studs with output shaft (28) pointing
downward through opening in support plates
on hydraulic press. Output shaft must not
D O NOT ALLOW OWATONNA NO.
9 5 1 BE A R ING P U L L ING

65-00-00
Page 72

_ BREAKER BAR AND
MS8514-1 SPANNERWRENCH .--�,.-,,--...
Tl 01511
SPLINE
WRENCH
Figure 65-34. Input pinion inner nut tool application, T101511 and MS8514-1
contact support plate d u r i n g pressing
operations (figure 65-40).
c. Place a round pressing plug (maximum
outside diameter 0 .98 inch {24.89 mm)
against inner end of output shaft {28, figure
65-33) and slowly press from case assembly
(17). Check that output shaft does not bind or
contact support plates during pressing
operations, and that pressing plug does not
bind on duplex bearings (4).
d. When output shaft {28) has been
pressed from case assembly (17), remove
from hydraulic press.
11. Remove seal (29) and roller bearing (36)
from cap assembly (17) as follows:
a. Remove packing (35) and retainer ring
(37) from cap assembly. Discard packing.
b. App l y heat l a m p to face o f cap
assembly (17). When heated, tap cap
assembly on hard wood surface to remove
roller bearing (36).
BHT-206B3-CR&O
20683-R-65• 34
c. Press seal (29) from cap assembly (17)
using pressing plug and hydraulic press. Do
not permit pressing plug to contact liner in
cap assembly.
12. Remove spiral bevel gear (27) from
output shaft (28) as follows:
a. Clamp T101511 spline wrench in shop
vise so that 32 teeth spline opening is
exposed. Position output shaft (28) in spline
wrench and remove bolts (26).
b. Using plastic mallet, lightly tap spiral
bevel gear (27) from output shaft (28).
13. Inspect wear sleeve (30) on output shaft
(28) for evidence of wear. If wear sleeve is
grooved it must be replaced.
a. Cut a groove across wear sleeve (30)
with a file or small power grinder. Do not cut
completely through wear sleeve.
b. Insert a blunt wedge-shaped instrument
in groove and strike with a light hammer until
65-00-00
Page 73
BHT-20683-CR&O
Figure 65-35. Output shaft inner nut and T101511 and T101513 tool
wear sleeve (30) splits; then remove from
output shaft (28).
c. Remove sealant from output shaft (28)
in area of removed wear sleeve (30) using
MEK (C-309) and fine abrasive pad (C-407) .
d. Inspect output shaft (28, figure 65-33)
in area of removed wear sleeve (30) for
damage. Damage will require replacement of
output shaft.
14. Remove output shaft outer nut (1) and
oil level indica tor (25) using fa bricated
mounting workaid and T101512 gearbox
wrench (figure 65-41) as follows:
a. Position T101512 gearbox wrench with
1/2 inch breaker bar into output shaft outer
nut (1, figure 65-33) and remove.
b. Remove retainer ring (22) and· push
sight glass (24) from case assembly (17) by
reaching inside case assembly and pressing
sight glass and oil level indicator (25) from
case assembly.
65-00-00
Page 74
c. Remove and discard packing (23) from
sight glass (24).
15. Remove oil filler cap (12) and disconnect
chain (15) at pin (16) as follows:
a. Remove pin (14) and retainer ring (13)
from oil filler cap (12).
b. Remove retainer ring (6), washer (7),
aluminum wool packing (8), packing (10), and I
spring assembly (11) from plug (9). Discard
aluminum wool packing and packing.
c. Remove case assembly (17) from
fabricated mounting workaid.
16. Apply heat lamp to case assembly (17)
in area of duplex bearings (4). When case
assembly is heated. tap case on hard wood
surface to remove duplex bearings. Do not
remove shim ring (5), refer to Ca ution
statement in step 8.
17. Remove roller bearing (48) from case
assembly (17) as follows:
 BHT-206B3-CR&O

------- 6.0 IN.

' (152.4mm)

Ii --r
________........-+ 0.50IN.
WELD_/ (12.70mm)
BEAD

_J
3.0TO 4.0IN.
(76.2TO 101.6mm)

0.50IN.-i--­
(12.70mm)

END VIEW

4.75±0.010IN.
2.375IN. (120.65±0.254mm)
(60.325mm)
. /. -- 4HOLES

--- l
+ � 0.312TO 0.318IN.
(7.925TO 8.077mm)
0 j j -0-

I:
2.125±0.010IN.

l
\__2HOLES � (53.975±0.254mm)
0.375IN. :

.. ...
4.25±0.010IN. (9.525mm) : :
:+:
.. . l
(107.95±0.254mm)
'
1.56±0.010IN.
(39.62±0.254mm)

- 0

TOP VIEW

MATERIAL: 0.50 inch (12.70 mm) aluminum, brass or steel stock

NOTE: Heat treatment or paint finish not required.

USE: Mounting tail rotor gearbox to shop vise for assembly, disassembly,
repairs, and backlash check.
206B3-R-65-36

Figure 65-36. Tail rotor gearbox mounting workaid

65-00-00
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BHT-206B3-CR&O

Figure 65-37. Input pinion outer nut and T101512 tool

a. Remove retainer rings (47) from both

sides of roller bearing (48).

b. Apply heat lamp to case assembly (17)

in area of roller bearing (48). When case DO NOT ALLOW BEARINGS TO
assembly is heated, press roller bearing from SPIN. DO NOT HANDLE BLACK
case. OXIDE D PART S WITH BARE
HANDS.

65-46. Cleaning. 2. Dry parts with filtered compressed air and

lint-free clean cloths.
MATERIALS REQUIRED 3. Remove paint from metal parts using
paint remover (C-436) .
NUMBER NOMENCLATURE
4. After parts are cleaned, the following
C-011 Lubricating Oil corrosion prevention treatment should be
accomplished.
C-105 Corrosion Preventive
a. Wash all ferrous parts in a clean rinse
C-109 Protective Oil
of solvent (C-304) .
C-304 Solvent
b. Gently agitate parts in c orrosion
C-436 Paint Remover preventive (C-105) , then drain the parts.

1. Clean all tail rotor gearbox parts with

solvent (C-304) .

65-00-00
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 BHT-206B3-CR&O

T101507-5 OWATONNA NO. 927A

BASE PULLER LEGS

OWATONNA NO. 927

PULLER

NOTE 65-47. Inspection and repair.

Normally parts treated in accordance
with steps a. and b. may be left MATERIALS REQUIRED
covered i n i ndoor s t orage f o r
approximately 1 50 hours without
NUMBER NOMENCLATURE
being affected by corrosion. If parts
are not reassembled within C-423 Ab r a s ive C l o t h o r
prescribed time, comply with step d. Paper
c. I mmediately prior to reassembly of C-436 Paint Remover
parts, the treatment specified in steps a. and
b . shall be r e p e a t e d if the p a r t s are C-464 India Stone
contaminated with dust, dirt, or foreign matter.

d. Each part shall be covered with a
protective coating of protective oil (C-109)
5. Immediately prior to reassembly, clean
parts with solvent (C-304) and coat with
lubricating oil (C-011) . Do not handle or
assemble un-oiled parts.
1. Inspect tail rotor gearbox visually and
review accompanying records to determine
whether gearbox has been subjected to an
accident or incident outside the realm of
normal usage.
2. Parts, components, or assemblies found
worn or defective beyond repairable limits
shall be scrapped.

3. Inspect parts dimensionally and replace

parts that do not fall within inspection limits
(figure 65-42).

65-00-00
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BHT-20683-CR&O

Figure 65-39. Duplex bearing and input pinion and Owatonna 630-3 and 951 tools

65-00-00
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 BHT-206B3-CR&O

Figure 65-40. Removal of output shaft tool application

65-00-00
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BHT-206B3-CR&O

Figure 65-41. Output shaft outer nut tool application T101512 and mounting workaid

65-00-00
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 BHT-20683-CR&O

CONTROL DIMENSION

□
FOR SHIM RING 1221
ETCHED HERE
7-
CONTROL DIMENSION �
ETCHED HERE -----------.

t..---�:-;- CENTERLINES
CASE ASSEMBLY

13

14
1.0145 TO 1.01401N.
(25.7683 TO 25.7556 mm)

1
�

l+
17

DETAILA
I A MAX OD 0.1945 IN. (4.9403 mm)
P/N 206-040-425-7 SHIM RINGill
2.4603 TO 2.4598 IN.
(62.4916 TO 62.4789 mm)

DETAILB A
P/N 206-040-425-5 SHIM RING ill
206B3-R-65-42-1

Figure 65-42. Tail rotor gearbox 206-040-402 wear limits (sheet 1 of 3)

65-00-00
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BHT-206B3-CR&O

NUMBER DESCRIPTION LOCATION MINIMUM MAXIMUM

IN. mm IN. mm
1.
2.
Spacer
Bearing - duplex
ID
ID 1.1809 29.9949
&
1.1812 30.0025
OD 2.4404 61.9862 2.4409 61.9989
3. Input pinion gear -
splines (over 0.1200 IN.
OD 1.1025 28.0035
&
(3.05 mm) diameter pins)
4. Input pinion gear - OD 1.1814 30.0076 1.1819 30.0203
duplex bearing seat
5. Input pinion gear - roller OD 0.5505 13.9827 0.5510 13.9954&
bearing race
6. Bearing - roller OD 1.1807 29.9898 1.1811 29.9999
7. Bearing - duplex ID 0.9841 24.9961 0.9844 25.0038
OD 1.8500 46.9900 1.8504 47.0002
8. Case assembly - ID 1.8497 46.9824 1.8505 47.0027
bearing liner
9. Case assembly - ID 1.1805 29.9847 1.1813 30.0050
bearing liner
10. Case assembly - ID 2.4402 61.9811 2.4410 62.0014
bearing liner
11. Case assembly - ID 4.5005 114.3127 4.5013 114.3330
cap assembly seat
12. Spiral bevel gear - ID 1.2500 31.7500 1.2506 31.7652
output shaft seat
13. Output shaft - duplex OD 0.9846 25.0088 0.9851 25.0215
bearing seat
14. Output shaft - spiral OD 1.2500 31.7500 1.2506 31.7652
bevel gear seat
15. Output shaft - roller OD 2.0010 50.8254 2.0015 50.8381&
bearing seat
16. Output shaft - wear OD 1.749 44.425 1.751 44.475

&
sleeve seat
wear sleeve (not shown) OD
17. Output shaft - splines OD 1.0883 27.6428 1.0898 27.6809
(over 0.0600 IN. (1.52 mm)
diameter pins)
18. Bearing - roller OD 2.6767 67.9882 2.6772 68.0009
19. Cap assembly - OD 4.4997 114.2924 4.5010 114.3254
mounting seat
20. Cap assembly - ID 2.6766 67.9856 2.6774 68.0060
bearing liner
206B3-R-65-42-2

Figure 65-42. Tail rotor gearbox 206-040-402 wear limits (sheet 2)

65-00-00
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 BHT-206B3-CR&O

NUMBER DESCRIPTION LOCATION MINIMUM MAXIMUM

IN. mm IN. mm
21. Cap assembly
22. Shim ring - bearing liner
23. Shim ring - bearing liner

&
N OT ES

Spacer (1 l having a seal groove depth greater than 0.002 inch (0.051 mm) must
be replaced or reversed. Spacer may only be reversed one time.

&. M aximum allowable wear 0.0002 inch (0.0051 mm) determined by measuring the
difference in the worn and unworn areas.

£. Wear sleeve (16) outside diameter must be smooth and unmarred. Wear sleeve
shall be replaced at each overhaul.

& Shim rings (22 and 23) are specifically ground for each case assembly to properly
space bearings and obtain correct gear mesh. Shim rings must be kept with the
case assembly for which they were ground, and should only be removed for
inspection and cleaning of groove in bearing liner. To replace an unserviceable shim
ring return case assembly to Bell Helicopter Textron.

.£ Dress out wear step between worn and unworn areas of spline teeth with india
stone or equivalent to form a smooth transition. Corrosion rework limit on I.D. of
input pinion is 0.010 inch (0.254 mm) per side allowable. R ework evenly to prevent
balance problems. After rework fill and drain with primer (C-201, C-202 or C-204)
to prevent corrosion.

.£ If liners are excessively worn, case or cap assembly must be returned to Bell
Helicopter Textron for liner replacement.

206B3-R-65-42-3

Figure 65-42. Tail rotor gearbox 206-040-402 wear limits (sheet 3)

65-00-00
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BHT-206B3-CR&O-4
NOTE
Limit charts are provided to show the
required fit between mating parts. It is not
intended that all dimensions listed on limits
chart be checked as a prescribed overhaul
procedure; however, parts that show
evidence of wear or physical damage must
be checked dimensionally.
4. Inspect surfaces of spiral bevel gear (27,
Figure 65-33) and input pinion (46) for chipped,
broken, or worn gear teeth. Inspect gear wear patterns
(Figure 65-43).
5. Polish out acceptable damage using fine India
stone (C-464), or 320 to 400 grit abrasive cloth or
paper (C-423).
6. Visually inspect duplex bearings (44,
Figure 65-33) and roller bearings (36 and 48) for
roughness, spalling, scoring, pitting, flaking, broken or
damaged retainers, and for evidence of overheating
and corrosion.
7. Visually inspect retainer rings (6, 22 and 37) and
shim rings (5 and 49) for wear, damage and distortion.
8. Visually inspect studs and dowel pins in case
assembly (17) for security and damage. Replace
damaged studs or dowel pins (Paragraph 65-52).
9. Inspect case assembly (17, Figure 65-33) and
cap assembly (34) for corrosion and damage
(Paragraph 65-51).
10. Inspect sight glass (24, Figure 65-33) for
cracking, crazing, or any condition that may obscure
level or color of oil. Inspect oil level indicator (25) for
discoloration, paint peeling, and evidence of a plastic
film on painted side. If there is evidence of a plastic
film, it must be removed.
65-00-00
Page 84 Rev. 7 28 FEB 2020
11. Visually inspect nuts (1, 3, 40, and 42) for cracks,
distorted tangs and thread damage.
12. At each overhaul, inspect nuts (1 and 40), case
assembly (17), and cap assembly (34) by fluorescent
penetrant inspection method (Paragraph 65-49).
Remove paint finish with paint remover (C-436) prior
to inspection.
13. Perform runout inspection on output shaft (28)
(Figure 65-44).
14. At each overhaul, inspect nut (3, Figure 65-33),
spiral bevel gear (27), output shaft (28), spacer (38),
and input pinion (46) by magnetic particle inspection
method (Paragraph 65-50).
65-48. 3000 Hour Inspection.
1. Perform backlash check (Paragraph 65-54).
Record readings.
2. Perform inspection steps 4, 6, 8, 9, and 10,
paragraph 65-47.
3. Assemble tail rotor gearbox (Paragraph 65-53).
4. Perform backlash check (Paragraph 65-54).
Backlash readings shall be within 0.001 inch
(0.0254 mm) of original readings unless input pinion or
spiral bevel gear were replaced. Backlash readings
shall be within overhaul limits (Paragraph 65-54).
5. Refinish tail rotor gearbox (Paragraph 65-55).
6. Make an entry in historical records that the
3000 hour inspection has been performed.
65-49. Fluorescent Penetrant Inspection.
1. Refer to Table 65-6 for tail rotor gearbox
fluorescent penetrant overhaul inspection
requirements.
Export Classification C, ECCN 9E991
 BHT-206B3-CR&O

TOP

<
TOE ......... ------ ........__ ------ HEEL

FLANK

SPIRAL BEVEL GEAR

VIEWA

INPUT PINION
VIEW B
DESIRED GEAR WEAR PATTERN FOR GEAR ANO PINION

f ---- ----- --- ---- ----- ----

SPIRAL BEVEL GEAR
VIEW C
ACCEPTABLE WEAR PATTERN FOR GEAR
CHECK GEAR WEAR PATTERN ON CONVEX SIDE OF GEAR ANO
CONCAVE SIDE OF PINION. WEAR PATTERN MUST BE WITHIN THE
FOLLOWING LIMITS:

DESIRED PATTERN: The desired pattern Is
shown In views A and B. Note that the pattern
touches at the toe and has a total length In
excess of 0.60 Inch. The pattern does not touch
the top of tooth of gear or pinion. A slight bright
line at top of pattern on gear and In flank of the
pinion Is characteristic.
PROFILE PATTERN: The pattern shall be
positioned on the tooth In a profile direction
such that when observing the gear, the pattern
may touch top of gear but must not extend over
the top. See view C. The pattern may extend over
top of pinion providing no sign of distress Is
evident In flank of gear.

MINIMUM LENGTH: The minimum length of the In addition to pattern size and location, examine
pattern shall be 0.60 Inch and may not touch the drive face of all gear teeth for the following
heel. See view C. unacceptable defects: noncleanup, grinding
scratches, pitting, corrocion, cuts, nicks, dents,
MAXIMUM LENGTH: The maximum length of the grinding flats or barber poling (evidenced by
contact wear pattern Is such that It must not diagonal streaks In the wear pattern), scuffing,
extend beyond the heel of the tooth but may scaring, and Inclusions. Pitting of any
extend beyond the toe providing that no hard magnitude resulting from surface fatigue Is not
bright llne or tooth distress Is evident at this permissible.
point. 206B3-R-65-43
C0002

Figure 65-43. Gear wear pattern (206-040-402)

65-00-00
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BHT-206B3-CR&O-4

Table 65-6. Tail Rotor Gearbox 206-040-402 Table 65-7. Tail Rotor Gearbox 206-040-402
Fluorescent Penetrant Overhaul Inspection Magnetic Particle Overhaul Inspection
Requirements Requirements

DESCRIPTION REFERENCE DESCRIPTION REFERENCE

Nut-Output Shaft Outer 1, Figure 65-33 Nut-Output Shaft Inner 3, Figure 65-33

Case Assembly 17, Figure 65-33 Spiral Bevel Gear 27, Figure 65-33

Cap Assembly 34, Figure 65-33 Output Shaft 28, Figure 65-33

Nut-Input Pinion Outer 40, Figure 65-33 Input Pinion 46, Figure 65-33

2. Those parts listed in Table 65-7 shall be

2. Those parts listed in Table 65-6 shall be inspected in accordance with Special Acceptance
inspected in accordance with fluorescent penetrant Requirements of the stated reference, and magnetic
inspection procedure contained in BHT-ALL-SPM. particle inspection procedure contained in
BHT-ALL-SPM.

65-50. Magnetic Particle Inspection.

65-51. Corrosion Damage Inspection.

1. Refer to Table 65-7 for tail rotor gearbox 1. Replace case and cap assembly if bearing liners
magnetic particle overhaul inspection requirements. are loose or if threads for studs

Figure 65-44. Output Shaft Runout Inspection (206-040-402)

65-00-00
Page 86 Rev. 7 28 FEB 2020 Export Classification C, ECCN 9E991
 BHT-206B3-CR&O

are structurally damaged and impractical to MATERIALS REQUIRED (CONT)

repair.

2. Replace case and cap assembly that NUMBER NOMENCLATURE

have corrosion damage under bearing liners, C-318 Cleaning Compound
in critical areas which would affect the
function or structural integrity of the part, or if C-31 9 Chlorothene
d a m a g e e x c e e d s the l i m i t s for areas
designated on figure 65-45. C-407 Abrasive Pad

3. Areas of tail rotor gearbox most frequently
damaged by corrosion are shown in figure 65-
45. Acceptable depth limits for pitting and
p e r c e n t age o f a r e a p i t t i n g (i .e ., t h e
percentage o f area i n which the original
machined surface has been removed by
corrosion) are as follows:
a. Case Assembly. Areas A, B, and D,
figure 65-45, should be inspected carefully
prior to any corrosion removal for evidence of
corrosion in threads between case and studs.
Any cor rosion on threads is cause for
rejection of part . In areas A through D, the
maximum depth of corrosion pitting is 0.030
in. 0.762 mm) and no more than 40 percent of
the area of any 1.0 in. (645.2 mm) square nor
20 percent of the total area of any surface or
diameter should be pitted.
b. Cap assembly. In areas E, F, and G,
the maximum depth of pitting is 0.030 in.
(0.762 mm) and no more than 40 percent of
the area in any 1.0 in.sq. (645.2 mm) square
nor 20 percent of the total area of any surface
or diameter should be pitted.
4. R e m o v e c o r r o s i o n da ma ge a n d
accomplish repairs (paragraph 65-5 2).
C-418 Tape
C-422 Aluminum Wool
C-423 Abrasive Cloth or
Paper
NOTE
Removal of corrosion products is
mandatory prior to subsequent
repair or corrosion p r o t ective
treatment.
1. The use o f the magnesium touchup
t r e a t m e n t i s r e s t r i c t e d to p a r t s a n d
assemblies that have small areas o f the
dichromate coating removed by scratches,
a br a s i o n s o r m i n o r r e w o r k . P a r t s o r
assemblies that require touchup shall be
treated as follows:
a. Re m o ve o i l a n d g r e a s e w i t h
chlorothene (C-31 9) or MEK (C-309) .
b. Masking is not required; however it
should be used, as required, to prevent
touchup solution from running into areas
where it is not needed.

c. Scrub the area to be treated with fine

65-52. Corrosion removal and repair.
abrasive pad (C-407) , or fine aluminum wool
(C-422) . Abrade to clean to bare metal.
MATERIALS REQUIRED Fresh machined surfaces may be treated
without abrading.
NUMBER NOMENCLATURE d. Flush areas with cleaning compound
(C-318) mixed 4 ounces per gallon (30 grams
C-1 1 6 Chromic Acid
per liter) of water, as required, to ensure a
C-1 20 Calcium Sulfate water-break free surface.

C-201 Primer e. Rinse with clean water and repeat

steps c. and d. as required, to provide a clean
C-309 Methyl-Ethyl-Ketone surface.
(MEK)

65-00-00
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BHT-206B3-CR&O

AREAD

. AREAG

AREAC

AREAE

AREAA

CASE ASSEMBLY
(MAGNESIUM ALLOY
CASTING) CAP ASSEMBLY
(MAGNESIUM ALLOY CASTING)

B
T YPICAL 4 PLACES

0.238 IN.
(6.045mm) G
T YPICAL
206B3-R-65-45
5 PLACES

Figure 65-45. Tail rotor gearbox 206-040-402 corrosion damage limits

65-00-00
Page 88

2. Prepare magnesium touchup treatment
solution by mixing 1.3 ounce (1 0 grams)
chromic acid (C-116) , and 1 ounce (7 .5
grams) calcium sulfate (C-120) per gallon (3.8
liters) of water.
NOTE
The calcium sulfate will not go into
solution.
a. Apply touchup solution with a brush or
swab to repaired areas. Allow solution to
react for at least one minute, reapply solution,
as required, to keep the area wet. Excess
solution should be clearly marked, dated, and
stored at room temperature in a glass jar. Do
n o t sto r e t o u c h u p s o l u t i o n w h e r e
temperatures may vary to extremes, or in
contact with direct sunlight. Do not use a
touchup solution older than three months from
date of mixing.
b. Rinse thoroughly with clean water to
remove excess solution. The treatment should
produce a brassy colored film, if required,
repeat application of touchup solution until a
brassy colored film is obtained. Rinse,
demask and re-rinse to ensure solution
removal. All rinsing shall be accomplished
using room temperature water.
c. Dry with filtered compressed air and dry
cloths.
d. Parts that require painting as the next
operation shall be painted as soon as
practicable after drying, preferably with 24
hours (paragraph 65-55). Bare steel parts
shall be oiled immediately after drying to
prevent corrosion.
3. Rework or repair case and cap assembly
as follows:
a. Corrosion in areas A through F, figure
65-45, or on the walls of bolt holes should be
removed by immersion in hot chromic acid
bath rather than by mechanical means so that
effective position of the original surfaces is
not changed. It is mandatory that all corrosion
products be removed (Step 4.).
BHT-206B3-CR&O
b. In area G, if no pitting is present in the
area contacted by the washers, corrosion may
be removed by immersion in a hot chromic
acid bath (step 4). If area is pitted, then the
surface may be machined. Minimum
dimension after repair at point X is 0.238 in.
(6.045 mm).
c. Magnesium parts which will be reused
must have all sharp edges polished out with
400 to 600 grit abrasive cloth or paper (C-
423) .
4. Prepare hot chromic acid bath by mixing
20 to 24 oz. (567 to 680 g.) of chromic acid
(C-116) per gallon (3.8 I.) of water. Bath
temperature should be maintained at a
temperature of 200 °F (93 °C). Parts should
be treated in the bath for as long as is
required to completely remove corrosion
products. The corrosion removal process
must be controlled to ensure that machined
dimensions are maintained and that cadmium
plating is not removed from plated parts.
Plated parts should be masked with tape (C-
418) .
5. Remove broken, bent, damaged, or loose
studs (1 and 2, figure 65-46) and dowel pins
(3) in case assembly (4) as follows:
a. Inspect threaded stud or dowel pin hole
in case assembly for damage. If holes are
damaged, repair or replace case assembly,
as required. Stud retaining holes must be
tapped to a sufficient depth so no imperfect
threads can be engaged.
b. Clean out small vent hole in bottom of
stud or dowel pin holes, as required. Apply
unreduced primer (C-201) to threads of
replacement stud or shank of dowel pin and
install to the depth shown in figure 65-46.
Torque studs 50 to 96 in.lb. (6 to 11 Nm).
c. In the event an oversized dowel pin is
required for replacement, use NAS607-5-7P
dowel pin and machine the length to be
exposed (0.360 to 0.390 in.) (9.144 to 9.906
mm) to a diameter of 0.250 in. (6.350 mm).
Rework case assembly dowel pin holes to a
diameter of 0.3110 to 0.3120 in. (7.8994 to
7.92488 mm) and a depth of 0.500 to 0.530
in. (12. 700 to 13.462 mm). Remove drill
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BHT-20683-CR&O

-I
-- 0.75 IN. (19.05 mm) /\
3PLACES ill
0.88 IN. (22.35 mm) /\

----,- ill
3PLACES

L
L
0.360TO0.390IN.
3 (9.144TO9.906 mm) /\
0.75 IN. (19.05 mm) /\ 2PLACES ill
4PLACES ill

1. Stud AN 125999 thru AN 126002 oversize AN126003 thru AN126004

2. Stud AN126011 thru AN 126014 oversize AN126015 thru AN126016
3. Pin - dowel NAS607-4-7P oversize NAS607-5-7P
4. Case assembly

NOTES

& Set studs and pin with unreduced primer (C-201).

& Use of oversize dowel pin will require that exposed portion be machined to a
diameter 0.250 inch (6.350 mm) to match tailboom assembly.

206B3-R-65-46

Figure 65-46. Tail rotor gearbox 206-040-402 stud replacement

65-00-00
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 BHT-206B3-CR&O-4

filings and clean vent holes to ensure they are clear. SPECIAL TOOLS REQUIRED (Cont)
Apply magnesium touchup treatment to reworked
areas (step 1 and step 2). Install new machined dowel
pin (step 5b). NUMBER NOMENCLATURE

65-53. Assembly. Figure 65-48 Fabricated Output

Shaft Bearing Pressing
Cylinder Workaid
MATERIALS REQUIRED
Figure 65-49 Fabricated Input Pinion
Refer to BHT-ALL-SPM for specifications. Bearing Pressing
Cylinder Workaid
NUMBER NOMENCLATURE
— Heat Lamp
C-001 1 Grease
— Plastic Mallet
C-011 Lubricating Oil
1. Install sight glass (24, Figure 65-33) and oil level
C-309 Methyl-Ethyl-Ketone indicator (25) as follows:
(MEK)
a. Insert oil level indicator (25) in case
C-328 Sealing Compound assembly (17) so that notch in indicator aligns with
notch in case assembly.
C-405 Lockwire
b. Apply a film of lubricating oil (C-011) to new
C-422 Aluminum Wool packing (23, Figure 65-33) and outer diameter of sight
glass (24). Position packing in groove on sight glass
NOTE: and insert in case assembly (17).
1 Replaced with grease (C-172) as an
c. Secure sight glass (24) in case assembly (17)
alternative, use corrosion preventive
with retainer ring (22).
compound (C-104).

CAUTION
SPECIAL TOOLS REQUIRED

NUMBER NOMENCLATURE E N S U R E T H AT T H E S A M E S H I M
RINGS (5 AND 49) ARE INSTALLED IN
Owatonna No. 927 Puller C A S E A S S E M B LY ( 1 7 ) . I T I S
MANDATORY THAT SHIM RINGS BE
Owatonna No. 927A Puller legs, 6¼ inch KEPT WITH CASE ASSEMBLY (17) TO
OBTAIN CORRECT GEAR MESH.
(171.45 mm) long
2. Check to ensure that shim rings (5 and 49) are
T101507 Pinion Installation and installed in case assembly (17).
Removal Set
3. Install duplex bearings (4) in case assembly (17)
T101511 Spline Wrench as follows:
T101512 Gearbox Wrench

T101513 Output Shaft Nut CAUTION

Wrench

DO NOT USE A PENCIL TO MARK INNER

S U R FA C E O F B E A R I N G S . P E N C I L
MARKS CAUSE CORROSION.

65-00-00
Export Classification C, ECCN 9E991 28 FEB 2020 Rev. 7 Page 91
BHT-206B3-CR&O
NOTE
Duplex bearings (4) must be a
matched part and serial numbered
set.
a. Locate inner races (figure 65-47) of
duplex bearings (4) and make a mark across
inside of inner races in line with marks. Apply
film of lubricating oil (C-011) to duplex
b e a r ings a n d to b e a r i ng l i n e r in c a s e
assembly (17).
WHEN USING HEAT LAMP DO
NOT EXCEED A TEMPERATURE
OF 200 °F (93 °C) OR DAMAGE TO
PACKINGS MAY OCCUR.
b. Apply heat lamp to case assembly (17)
in area of bearing liner for duplex bearing (4).
c. When case assembly (17) is heated,
press duplex bearings (4) into bearing liner
one at a time, face to face, with mark aligned
(figure 66-47).
4. Apply a film of lubricating oil (C-011) to
threads of output shaft outer nut (1) and
install in case assembly (17) finger tight.
Output shaft outer nut will be torqued in a
later step.
5. Install retainer rings (47) and roller
bearing (48) in case assembly (17) as follows:
a. Apply a film of lubricating oil (C-011) to
roller bearing (48) and bearing liner in case
assembly (17).
b. Install one retainer ring (47) in bearing
liner in case assembly (17) on inboard side.
c. Apply heat lamp to case assembly (17)
in area of bearing liner for roller bearing (48).
d. When case assembly (17) is heated,
press roller bearing (48) into bearing liner
with part number outboard. Secure roller
bearing with second retainer ring (47).
65-00-00
Page 92
6. Assemble spiral bevel gear (27) and
output shaft (28) as follows:
a. Clamp up T101511 spline wrench in
shop vise with 32 spline teeth opening
exposed and insert output shaft (28).
b. Position spiral bevel gear (27) on
output shaft (28). Align bolt holes and tap in
place with a plastic mallet.
c. Install ten bolts (2 6) and uniformly
torque 100 to 125 inch-pounds (11 to 14 Nm).
Ensure spiral bevel gear (27) is square and
flush to flange on output shaft (28).
d. Secure bolts (26) in pairs with lockwire
(C-405) .
7. Apply a film of lubricating oil (C-011) to
new wear sleeve (30) and to output shaft
(28). Apply heat lamp to wear sleeve until
heated, then press on output shaft until firmly
seated.
8. Install spiral bevel gear (27) and output
shaft (28) in case assembly (17) as follows:
a. Apply a film of lubricating oil (C-011) to
installed duplex bearings (4) and to bearing
seat on output shaft (28).
b. Position outboard end of output shaft
(28) on support plates in hydraulic press.
Position case assembly (17) over upper end
of output shaft and spiral bevel gear (27) with
end of shaft starting through inner race of
duplex bearings (4).
c. Fabricate output shaft bearing pressing
cylinder workaid (figure 65-48).
d. Position fabricated bearing pressing
cylinder against inner race of duplex bearings
(4, figure 65-33). Operate hydraulic press,
pressing duplex bearings firmly on output
shaft (28).
9. Install seal (29) and roller bearing (36) in
cap assembly (34) as follows:
a. Apply a film of lubricating oil (C-011) to
roller bearing (36) and to bearing liner in cap
 BHT-206B3-CR&O

INPUT PINION GEAR

DUPLEX BEARINGS
INSTALL BACK-TO
BACKLASH MUST -BACK
BE WITHIN
0.003 T00.011 IN.
(0.076 TO 0.279 mm)
MUST NOT VARY MORE
THAN 0.002 INCH
(0.051 mm) AT THREE
DIFFERENT LOCATIONS

TRIM ONE TANG

FLUSH TO 0.025 IN.
(0.635 mm) RECESSED
FROM END OF NUT

DUPLEX BEARINGS
CAP ASSEMBLY
INSTALL FACE-TO
-FACE
CASE ASSEMBLY

VIEW A-A

LOCKWIRE

206B3-R-65-47

Figure 65-47. Tail rotor gearbox 206-040-402 backlash checks

65-00-00
Page 93
BHT-206B3-CR&O

I
1.4IN.
(35.6 mm)
1
1.02±0.010IN.
(25.91±0.254 mm)

_I
"- I
I - 2.0IN. (50.8 mm) -
OR LONGER A
I 0.2 TO 0.3IN.
(5.1 TO 7 .6 mm)
45 0 RADIUS -
BOTH ENDS

&
�

MATERIAL: 4130 Steel (MIL-S-6758)

NOTES

& Length will depend upon height of tail rotor gearbox output shaft
support plates and stroke length of hydraulic press.

£. Heat treatment or paint finish not required.

USE: Pressing tail rotor gearbox duplex bearings and case assembly on
output shaft. 206B3-R-65-48

Figure 65-48. Output shaft bearing pressing cylinder workaid

a s sembly (34). Apply heat lamp to cap
assembly.
b. When cap assembly (34) is heated,
press roller bearing (36), in bearing liner of
cap with part and serial numbered side next
to retainer ring (37). Secure bearing with
retainer ring.
c. Clean outside diameter of new seal
(29) and mating inside surface in cap
assembly (34) with cloth dampened with MEK
(C-309) . Wipe surfaces dry. Apply a thin film
of sealing compound (C-328) to outside
diameter of seal and mating inside surface of
cap assembly.
d. Press seal (29) in cap assembly (34)
until firmly seated, then remove excess
sealing compound. Ensure lip of seal is
pointing inboard. On double-lip seals fill the
groove between the lips with grease (C-001) ,
and coat lip of seal and wear sleeve (30) on
output shaft (28).
e. Apply a film of lubricating oil (C-011) to
new packing (35) and install in groove on
inboard side of cap assembly (34).
10. Position cap assembly (34) over output
shaft (28) and on studs of case assembly
(17). Exercise care to aid seal (29) on wear
sleeve (30), or damage to seal may result.
Press cap assembly in case assembly and
install aluminum washers (33), thin steel
washers (32) and new nuts (31). Torque nuts
(31) uniformly 50 to 70 in.lb. (6 to 8 Nm) plus
friction drag of nuts.
11. Install and torque output shaft inner nut
(3) to output shaft (28) as follows:
a. Clamp T101511 spline wrench in a
sturdy shop vise with 32 teeth spline opening
exposed. Insert output shaft into spline
wrench (figure 65-35).
b. Apply a film of lubricating oil (C-011) to
threads on output shaft (28, figure 65-33) and
output shaft inner nut (3).

65-00-00
Page 94

c. Using T101513 output shaft nut wrench
torque output shaft inner nut (3) 31o to 350
in.lb. (35 to 40 Nm).
d. Temporarily remove .output shaft outer
nut (1) and install cotter pin (2) with head
inboard through output shaft (28) and output
shaft inner nut (3). Trim cotter pin so that
outboard tang is flush to 0.025 in. (0.635 mm)
recessed from inner nut. Bend inboard tang in
opposite direction (figure 65-47).
e. Reinstall output shaft outer nut (1,
figure 65-33) finger tight in case assembly
(17) nut will be torqued in a later step.
Remove output shaft (28) from spline wrench.
f. Rotate output shaft (28), by hand, to
check that bearings roll smoothly and shaft is
free to turn.
12. Install duplex bearings (44) and spacer
(38) on input pinion (46) as follows:
a. Apply a film of lubricating oil (C-011) to
input pinion (46), packing (4 5), duplex
bearings (44), and spacer (38).
b. Fabricate input pinion bearing pressing
cylinder workaid (figure 65-49).
c. Position fabricated bearing pressing
cylinder on support plates in hydraulic press.
Stack duplex bearings (44, figure 65-33)
back-to-back and place on hydraulic press
support plates. Insert duplex bearings one at
a time on input pinion (46) and position in
bearing pressing cylinder, then press firmly on
gear.
d. Install packing (45) on input pinion (46)
in second groove from outboard side of
installed duplex bearings (44).
e. Press spacer (38) over packing (45)
and on input pinion (46) until flush with inner
race of installed duplex bearings (44). If
s p a c e r can n o t be i n s t a lled with hand
pressure, use T101507-7 adapter threaded on
input pinion to press spacer in position.
13. Install input pinion (46) and duplex
bearings (44) in case assembly (17) using
BHT-206B3-CR&O
T101507 pmIon installation and removal set
(figure 65-38) as follows:
a. Mount and secure case assembly (17,
figure 65-33) in fabricated mounting workaid
and clamp up in shop vise.
b. T hr ead T101507 -5 base in case
assembly (17).
c. Thread T101507-7 adapter on input
pinion (46) until in firm contact with spacer
(38).
d. Assemble and install Owatonna No.
927 puller and No. 927A pu ller legs to
installed T101507-5 base and T101507-7
adapter as shown in figure 65-38, except that
puller nut must be on the inboard side of
i· · · · · · · · ·1
puller bar.
CAUTION
•••••••••••••••••
WHEN USING HEAT LAMP DO
NOT EXCEED A TEMPERATURE
OF 200 °F (93 °C). DAMAGE TO
PACKINGS MAY OCCUR.
e. Apply heat lamp to case assembly (17,
figure 65-33) and heat in area of duplex
bearings (44).
f. Operate puller and install input pmIon
(46) and dup lex bearings (44) in case
assembly (17). Exercise care to ensure that
nose of input pinion aligns with inner race of
roller bearing (4 8) and that gear teeth
correctly mesh. Duplex bearings must seat
firmly in case assembly bearing liner.
Disassemble and remove puller and pinion
installation tools.
g. Rotate input pinion (46), by hand, to
ensure that duplex bearings (44) roll smoothly
and that input pinion is correctly meshed with
spiral bevel gear (27).
14. Install new seal (41) and input pinion
outer nut (40) in case assembly (17) as
follows:
65-00-00
Page 95
BHT-20683-CR&O
-
1 1.2±0.0101N.
-+-------4.0IN.-------+-
MATERIAL: 4130 Steel (MIL-S-6758)
NOTE
Heat treatment and paint finish not required.
USE: Press tail rotor gearbox duplex bearings onto input pinion.
Figure 65-49. Input pinion bearing pressing cylinder workaid
a. Clean outside diameter of new seal
(41) and mating inside surface of input pinion
outer nut (40) with a cloth dampened with
MEK (C-309) . Wipe surfaces dry. Apply a
thin film of sealing compound (C-328) to
outside nut.
b. Press seal (41) in input pinion outer nut
(40) until firmly seated and remove excess
sealing compound. Ensure lip of seal is
pointing inboard. On double-lip seals, fill
groove between lips with grease (C-001) and
coat lip of seal and outer diameter of spacer
(38) on input pinion (46).
c. Apply a film of lubricating oil (C-011) to
new packing (39) and to threads of input
pinion outer nut (40). Place packing in groove
on nut and screw in case assembly (17) until
seated against duplex bearings (44) with hang
pressure. Nut will be torqued in a later step.
15. Install input pinion inner nut (42) and
lockwasher (43) on input pinion (46) as
follows:
65-00-00
Page 96
(30.5 ±0.254 mm)
i
0.2 TO 0.3IN.
(5 .1 TO 7.6 mm)
45 ° RADIUS
BOTH ENDS.
20683-R- 65-49
a. Apply a film of lubricating oil (C-011) to
threads on input pinion (46) and install input
pinion inner nut (42).
b. Clamp T101511 spline wrench in shop
vise with 15 teeth spline opening exposed.
Position splined end of input pinion (46) in
spline wrench (figure 65-34).
c. Torque input pinion inner nut (42, figure
65-34) 360 to 400 in.lb. (41 to 45 Nm) using
MS8514-1 spanner wrench.
d. Install new lockwasher (43) on input
pinion (46). Use a plastic mallet to force
lockwasher against input pinion inner nut (42)
and engage two locking tangs into nut.
16. Torque output shaft outer nut (1) and
input pinion outer nut (40) to case assembly
(17) as follows:
a. Clamp fabricated mounting workaid in
shop vise and secure case assembly (17) to
workaid with washers and nuts (figure 65-36).
 BHT-206B3-CR&O-4

b. Torque input pinion outer nut (40,
Figure 65-33) 100 to 150 foot-pounds (136 to 204 Nm)
using gearbox wrench (T101512) and 1/2 inch socket
adapter. Secure outer nut to tab on case assembly
(17) with lockwire (C-405). (See Figure 65-47 for
lockwire application.)
self-closing valve to tab on case assembly with
lockwire (C-405). Install electrical chip detector in
self-closing valve.
19. Perform tail rotor gearbox backlash check
(paragraph 65-54).

c. Torque output shaft outer nut (1, Figure 65-33)

650 to 800 inch-pounds (73 to 90 Nm) using gearbox 20. Paint tail rotor gearbox (paragraph 65-55).
wrench (T101512) and 1/2 inch socket adapter.
Secure outer nut to tab on case assembly (17) with
21. Preserve tail rotor gearbox (paragraph 65-56).
lockwire (C-405).

d. Rotate output shaft (28), by hand, to ensure 65-54. Tail Rotor Gearbox 206-040-402 —
smooth rotation and freedom from binding. Do not Backlash Check
remove case assembly (17) from mounting workaid
and shop vise.
SPECIAL TOOLS REQUIRED
17. Assemble and install oil filler cap (12) as follows:

NUMBER NOMENCLATURE
a. Form a ball of aluminum wool (C-422) and
insert in bottom of plug (9) and install washer (7) and T101511 Spline Wrench
retainer ring (6). Proper quantity of aluminum wool will
cause washer to fully spring back after being T102093 Backlash Anchor
depressed 0.06 inch (1.52 mm). Assembly

Figure 65-36 Fabricated Tail Rotor

b. Apply a film of lubricating oil (C-011) to new Gearbox Mounting
packing (10) and install in groove on plug (9). Workaid

c. Position spring assembly (11) on spindle of
plug (9), press on cap (12), and secure with retainer
ring (13).
d. Form a closed loop on one end of pin (14) and
attach required length of chain (15). Rotate cap (12)
and plug (9) aligning holes for pin. Insert pin through
cap and plug until closed loop of pin is firmly against
cap, then bend end of pin down against cap 0.15 inch
(3.81 mm). Trim end of pin so that it does not extend
below edge of cap.
– Dial Indicator
1. Clamp tail rotor gearbox fabricated mounting
workaid to shop vise. Install and secure tail rotor
gearbox to mounting workaid (Figure 65-36).
2. Position anchor assembly (T102093) over output
shaft. Ensure anchor assembly has stamped outboard
side facing outboard. Thread anchor assembly bolt in
threaded opening in cap assembly and tighten
clamping bolt.

e. Install cap assembly to adapter on case

assembly (17) and secure safety chain (15) to case 3. Install spline wrench (T101511) on input pinion in
with pin (16). horizontal position and tighten setscrew.

18. Apply film of lubricating oil (C-011) to new
packings (18 and 20) and position on self-closing
valve (19) and electric chip detector (21). Install
self-closing valve in case assembly (17) and torque 20
to 60 inch-pounds (2.26 to 6.78 Nm). Secure
4. Clamp dial indicator and support to tail rotor
gearbox and mounting workaid with large C-clamp as
shown in Figure 65-50. Position pointer of dial
indicator to contact step on spline wrench (T101511)
at stamped V-mark.

65-00-00
ECCN 9E991 31 MAR 2010 Rev. 2 Page 97
BHT-206B3-CR&O

T102093
T101511
ANCHOR TOOL
SPLINE WRENCH

OUTPUT SHAFT

TAIL ROTOR
GEARBOX MOUNTED
TO FABRICAT ED MOUNTING
WORKAID AND SHOP VISE

20683-R-65-50

Figure 65-50. Tail rotor gearbox backlash using T101511 and T102093 tools

65-00-00
Page 98
 BHT-206B3-CR&O

5. With dial indicator pointer preloaded and MATERIALS REQUIRED (CONT)

gage zeroed, rotate T101511 spline wrench to
limits of travel and record reading.
NUMBER NOMENCLATURE

6. Total amount of movement (backlash)

must be between 0.003 to 0.011 in. (0.076 to
0.279 mm) and must not vary more than
0.002 in. (0.051 mm) when checked at three
different locations. Remove backlash check
tools.
65-55. Painting.
C-426 Tape
1. Touchup all exposed bare magnesium
surfaces (paragraph 65-52).
2. Mask areas of tail rotor gearbox not
requiring painting with tape (C-426) (figure
65-51).

MATERIALS REQUIRED 3. Prime all damaged or repaired areas on

tail rotor gearbox with one spray coat of I
primer (C-204) . Minimum coating thickness
NUMBER NOMENCLATURE after drying is 0.4 mil (0.0004 in.) (0.0102
mm). (Table 65-9).
C-203 Lacquer

C-204 Primer

C-308 Adhesive

Table 65-8. Tail rotor gearbox 206-040-402 painting requirements

ITEM NAME PAINT TYPE AND METHOD OF NO. OF NOTES

SPECIFICATION APPLICATION COATS

Tail rotor Epoxy Polyamide Primer Spray 1 0.4 Mils

Gearbox (two part kit) (C-204) (0.0102 mm)
Minimum

Acrylic Lacquer, Silver/ Spray 2

Aluminum Color No. 17178
(C-203)

Oil Filler Acrylic Lacquer, Orange- Spray or brush 2

Cap Yellow Color No. 13538
(C-203)

4. Apply a film of adhesive (C-308) to outer
edge mating surfaces in the following areas if
not previously accomplished (figure 65-51).
a. Cap assembly to case assembly.
d. Between input pinion outer nut and
case assembly.
5. Final prime tail rotor gearbox with one
coat of primer (C-204) .

b. Vent holes for case studs. 6. Finish paint tail rotor gearbox with two

c. Radius groove between wear sleeve

and output shaft.
coats of gloss silver/aluminized lacquer (C-
203), color No. 17178 . . I
65-00-00
Page 99
BHT-20683-CR&O

- Orange - yellow, color no. 13538

acrylic lacquer (C-203)

D Epoxy polyamide primer (C-204) and

aluminum, color no. 17178 acrylic
) lacquer (C-203)

�
� Unpa·1nted

[TI Apply bead of class B-2 sealant

(C-308) to mating edges

VIEW A-A
206B3-R-65-51

Figure 65-51. Tail rotor gearbox 206-040-402 painting

65-00-00
Page 100
 BHT-20683-CR&O

7. Finish paint oil filler cap with two coats of 1. Preserve tail rotor gearbox internally with

I gloss orange yellow lacquer (C-203), color

No. 13538.
lubricating oil (C-011) . Fill to correct oil level.

2. Apply a film of corrosion p reventive

compound (C-101) to all bare metal, uncoated
65-56. Preservation.
and unpainted surfaces.

I
MATERIALS REQUIRED 3. Enclose tail rotor gearbox in barrier
material (C-427) and seal with tape (C-426) or
tape (C-430)
NUMBER NOMENCLATURE
C-011 Lubricating Oil 4. Sec urely pack tail rotor gearbox in a
metal or wooden shipping container with
C-101 Corrosion Preventive c u s hion i n g a n d ha r d wa r e t o p r e v e n t
Compound movement during handling and transit. Install
desiccant and seal container.
C-426 Tape
5. For long term storage requirements, refer
C-427 Barrier Material to BHT-206B3-MM.
C-430 Tape

65-00-00
Page 101/102