BHT 205a1 Cro 1

BHT-205A1 -CR&O-1
COMPONENT REPAIR
AND
OVERHAUL MANUAL
NOTICE
The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins and other
directions issued by Bell Helicopter Textron and Airworthiness Directives issued by the Federal Aviation
Administration, must be strictly followed.
COPYRIGHT NOTICE
COPYRIGHT 2004
BELL ®HELICOPTER TEXTRON INC.
AND BELL HELICOPTER TEXTRON A Textron Company
CANADA LTD. POST OFFICE BOX 482 * FORT WORTH, TEXAS 76101
ALL RIGHTS RESERVED
24 JULY 1990
REVISION 3 15 JANUARY 2004
BHT-205A1-CR&O-1
A Textron Company
PROPRIETARY RIGHTS NOTICE

These data are proprietary to Bell Helicopter Textron Inc. Disclosure, reproduction, or use of
these data for any purpose other than helicopter operation and/or maintenance is forbidden
without prior written authorization from Bell Helicopter Textron Inc.
Additional copies of this publication may be obtained by contacting:

Commercial Publication Distribution Center
Bell Helicopter Textron Inc.
P.O. Box 482
Fort Worth, Texas 76101-0482
PN Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
A Textron Company
WARNING
THIS MANUAL APPLIES ONLY TO HELICOPTERS AND COMPONENTS
MAINTAINED IN ACCORDANCE WITH BELL HELICOPTER TEXTRON
(BELL) APPROVED PROCEDURES USING BELL APPROVED PARTS.
ALL INSPECTION, REPAIR AND OVERHAUL PROCEDURES PUBLISHED

BY BELL, INCLUDING PART RETIREMENT LIFE, ARE BASED SOLELY ON
THE USE OF BELL PARTS THAT HAVE BEEN MAINTAINED USING BELL
APPROVED DATA. THE DATA PUBLISHED HEREIN OR OTHERWISE SUP-
PLIED BY BELL IS NOT APPLICABLE TO NON-BELL PARTS OR PARTS
THAT HAVE BEEN REPAIRED USING DATA AND/OR PROCESSES NOT AP-
PROVED BY BELL.
BELL IS NOT RESPONSIBLE FOR ANY PART OTHER THAN THOSE THAT
IT HAS APPROVED.
BEFORE PERFORMING ANY PROCEDURE CONTAINED IN THIS MANUAL

YOU MUST INSPECT THE AFFECTED PARTS AND RECORDS FOR EVI-
DENCE OF ANY MANUFACTURE, REPAIR, REWORK OR USE OF A PRO-
CESS NOT APPROVED BY BELL.
IF YOU IDENTIFY OR SUSPECT THE USE OF PARTS NOT AUTHORIZED BY

BELL, EITHER REMOVE THE AFFECTED ITEM FROM THE AIRCRAFT OR
OBTAIN INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FROM THE
MANUFACTURER OR THE ORGANIZATION THAT APPROVED THE RE-
PAIR.
15 JAN 2004 Rev. 3 Warning

BHT-205A1-CR&O-1
A Textron Company
LIST OF EFFECTIVE PAGES
On a revised page, the portion of the text, wiring diagram, and illustration affected by the latest revision is indicated
by a vertical line. Suffix letters O and I are not used in added paragraphs, figures, or page numbers.
Original ....... ...... 01 FEB 1978 Revision........5 ..... 30 OCT 1981 Reissue........ 0..... 24 JUL 1990
Revision ....... 1 ...... 20 MAR 1979 Revision........6 ..... 18 DEC 1981 Revision ....... 1 ..... 03 FEB 1995
Revision ....... 2......01 FEB 1980 Revision ........ 7 ...... 01 FEB 1982 Revision ....... 2 ..... 01 MAY 1996
Revision ....... 3...... 16 JUN 1980 Revision........8 ..... 16 MAY 1983 Revision ....... 3 ..... 15 JAN 2004
Revision ....... 4.....15 AUG 1981 Revision ....... ..... 01 NOV 1984
Page Revision Page Revision Page Revision

No. No. No. No. No. No.
Cover .............. ......... 3 65-18A/65-18B ............... 2 65-96 ......................... 3

Title ....................... .3 65-19-65-20 .................. 2 65-97 - 65-99 .................. .0
P N ........................... 3 65-20A/65-20B ................. 2 65-100 ....................... 3
Warning ....................... 3 65-21 ........................ 2 65-101 ........................ 0
A - B ........................ 3 65-22 ........................ 0 65-102 ........................ 2
Help ......................... 3 65-22A/65-22B ................. 2 65-102A- 65-102B .............. 2
Customer Feedback ............. 3 65-23 ........................ 2 65-103- 65-122 ................. 0
Helicopter Sale Notice ............ 3 65-24 ........................ 0 65-123 ...................... 2
W arranty ............... ..... 3 65-25 - 65-26 .................. 2 65-124- 65-130 ................. 0
1-1/1-2 ......... ............. 0 65-26A/65-26B ................. 2 65-131 - 134 ................... 3
1-3/1-4 ....................... 0 65-27 - 65-29 .................. 0 65-135 ........................ 2
20-1/20-2 ..................... 0 65-30 ................. ..... 2 65-136- 65-137 ................. 3
27-1 - 27-2 ................... .2 65-31 ........................ 0 65-138 ........................ 0
27-3 .......................... 3 65-32 ........................ 3 65-139/65-140 .................. 3
27-4- 27-20 ......... .......... 0 65-33 ........................ 0 66-1 - 66-2 ..................... 2
27-21 ......................... 3 65-34 ............... ..... 2 66-3 - 66-4 ..................... 3
27-22 - 27-45 .................. .0 65-35 - 65-36 .................. 0 66-4A/66-4B .................. .2
27-46 ......................... 2 65-37 - 65-38 .................. 2 66-5 .......................... 3
27-47 ........................ 0 65-39 - 65-41 .................. 0 66-6 .......................... 2
27-48 ......................... 3 65-42 - 65-45 .................. 2 66-7 ......................... 0
27-48A - 27-48D ................ 2 65-46 ........................ 0 66-8 .......................... 2
27-49 ......................... 0 65-47 - 65-48 .................. 2 66-8A - 66-8B ................. 2
27-50 ......................... 2 65-48A - 65-48B .............. 2 66-9- 66-13 .................... 2
27-51 - 27-52 ................. .0 65-48C/65-48D ............... 2 66-14 ........................ 0
27-53/27-54 .................... 0 65-49 ........................ 2 66-15- 66-20 ................. .2
28-1 - 28-2 ..................... 0 65-50 ........................ 3 66-20A/66-20B ................. 2
28-3/28 4 ...................... 0 65-50A/65-50B ................. 2 66-21/66-22....................0
29-1 .......................... 2 65-51 - 65-52 .................. 2 66-23 ......................... 0
29-2- 29-4 ................... .0 65-52A/65-52B ................. 2 66-24 ......................... 2
29-5 - 29-7 ..................... 2 65-53 - 65-56 .................. 2 66-24A - 66-24B ................ 2
29-8- 29-19 ................... 0 65-57 - 65-59 ..... .......... 0 66-24C/66-24D ................. 2
29-20 ......................... 2 65-60 ........................ 2 66-25/66-26 .................... 0
29-21 - 29-23 ................. .0 65-61 - 65-67 .................. 0 66-27/66-28 ......... ......... 0
29-24 ......................... 2 65-68 ........................ 2 66-29 ........................ 3
29-25 - 29-30 .................. .0 65-68A - 65-68B ................ 2 66-30 - 66-32 .................. .0
29-31 - 29-32 ................... 2 65-69 - 65-74 ..... .......... 0 66-33 ......................... 3
32-1 .......................... 2 65-74A - 65-74B ................ 3 66-34 - 66-35 .................. .0
32-2 - 32-5 ................... .0 65-75 ........................ 2 66-36 ......................... 3
32-6- 32-18 .................. .2 65-76 ........................ 3 66-36A/66-36B ................. 3
65-1 - 65-3 ................... .3 65-76A - 65-76B ................ 3 66-37 - 66-39 .................. .0
65-4 - 65-6 ..................... 0 65-77 ........................ 3 66 40 ....................... 2
65-7 - 65-8 Deleted .............. 0 65-78 - 65-85 .................. 0 66-40A/66-40B ................. 2
65-9 - 65-14 ................... 0 65-86 ................ ..... 3 66-41 - 66-45 .................. 0
65-14A- 65-14D ................ 2 65-87 - 65-88 .................. 2 66-46 ......................... 2
65-15- 65-16 .................. 2 65-89 - 65-92 .................. 0 66-46A/66-46B ................. 2
65-16A/65-16B ................. 2 65-93 ........................ 2 66-47 - 6648...................2
65-17- 65-18 ................... 2 65-94 - 65-95 .............. . 0 66-49 ........................ 0
15 JAN 2004 Rev. 3 A

BHT-205A1-CR&O-1
A Textron Company
LIST OF EFFECTIVE PAGES (CONT)
Page Revision Page Revision Page Revision

No. No. No. No. No. No.
66-50 ........................ 2 66-142 ................ .... 2 66-207 ....................... 0
66-50A/66-50B ................. 2 66-143 - 66-147 ................ 0 66-208 ....................... 2
66-51 - 66-52 .................. 0 66-148- 66-150 ................ 2 66-209- 66-212 ................ 0
66-53 ........................ 3 66-150A/66-150B ............... 2 66-212A- 66-212B .............. 2
66-54 - 66-56 .................. 0 66-151- 66-152 ................ 0 66-213- 66-214 ................ 2
66-56A/66-56B ................. 2 66-153-66-154 ................ 2 66-215 ....................... 0
66-57 ......................... 2 66-154A-66-154B .............. 2 66-216 ....................... 2
66-58 - 66-61 ................. .0 66-155-66-160 ................ 0 66-216A/66-216B ............... 2
66-62 ......................... 3 66-161-66-162 ................ 2 66-217- 66-220 ............ 0
66-63 - 66-68 .................. 0 66-162A - 66-162B .............. 2 66-220A - 66-220B .............. 2
66-69 ........................ 3 66-163- 66-164 ................ 2 66-221 ........................ 2
66-70 ......................... 2 66-164A - 66-164D ............. 2 66-222 ........................ 0
66-71 - 66-101 .................. 0 66-165- 66-166 ................ 2 66-223 ....................... 2
66-102 ....................... 2 66-167- 66-170 ................ 0 66-224 - 66-225 ................ 0
66-103- 66-104 ................ 0 66-171 -66-172 ................ 2 66-226 ....................... 2
66-105........................3 66-172A/66-172B ............... 2 66-226A/66-226B ............... 2
66-106........................2 66-173 ................ .... 0 66-227- 66-229 ................. 0
66-106A- 66-106D .............. 2 66-174 ................. 3 66-230 ....................... 2
66-106E/66-106F ............... 2 66-175-66-176................ 0 66-230A - 66-230B .............. 2
66-107 ....................... 2 66-176A/66-176B ............... 2 66-231 - 66-232 ................ 2
66-108 ....................... 0 66-177- 66-180 ................ 2 66-232A/66-232B ............... 2
66-108A- 66-108B .............. 3 66-180A/66-180B ............... 2 66-233 - 66-241 ................. 0
66-109- 66-113 ................ 0 66-181-66-183 ................ 0 66-242 ........................ 2
66-114 -66-116 ................. 2 66-184 - 66-186 ................ 2 66-243 ....................... 0
66-117 ........................ 0 66-186A/66-186B ............... 2 66-244 ....................... .2
66-118- 66-119 ................. 2 66-187 ................ .... 0 66-244A/66-244B ............... 2
66-120- 66-124 ................ 0 66-188 ................ .... 2 66-245 - 66-248 ................ 0
66-125........................3 66-189- 66-191 ................ 0 66-249 - 66-250 ................ 2
66-126- 66-130 ................ 0 66-192 ................ .... 2 71-1 .......................... 3
66-131 -66-132 ................. 2 66-193- 66-195 ................ 0 71-2- 71-12 ................... 0
66-132A/66-132B .............. 2 66-196 ................ .... 2 71-13/71-14 .................... 0
66-133........................2 66-196A/66-196B ............... 2 71-15 - 71-16 ................... 3
66-134 ........................ 0 66-197 - 66-202 ................ 0 71-17/71-18 .................. .3
66-134A/66-134B ............... 2 66-202A - 66-202B .............. 2 79-1 - 79-2 ................... .0
66-135- 66-138 ................ 2 66-203 ................ .... 2 79-3/79-4 ..................... 0
66-138A- 66-138B .............. 2 66-204 ................ .... 0 Index 1 - Index 2 ................ 0
66-138C/66-138D ............... 2 66-205 - 66-206 ................ 2 Index 3/Index 4 ................. 0
66-139-66-141 .................. 0 66-206A/66-206B ............... 2
B Rev. 3 15 JAN 2004

HELP
E VALUATE
LOGISTICS
P UBLICATIONS
Have you found something wrong with this manual - an

error, an inconsistency, unclear instructions, etc.? Although
we strive for accuracy and clarity, we may make errors on
occasion. If we do and you discover it, we would appreciate
your telling us about it so that we can change whatever is
incorrect or unclear. Please be as specific as possible.
Your complaint or suggestion will be acknowledged and we

will tell you what we intend to do.
You may use the enclosed Customer Feedback form, as

applicable, to inform us where we have erred.
Your assistance is sincerely appreciated.

A Textron Company
CUSTOMER FEEDBACK
RETURN VIA FAX TO PRODUCT SUPPORT ENGINEERING (450) 433-0272
Manual Title:
Manual Number (if assigned):
Date of Issue:
Date of Last Revision:
Section, Chapter, Paragraph Affected:
Your Feedback:
Now Reads:
Should Read:
Your Name:
Address:
Position: Telephone No.:

Company: Fax No.:
Reference No. (your initials and date):
(If you choose to mail this form, fold in thirds, with address exposed, tape and mail.)
TAPE HERE
From
POSTAGE
NECESSARY
ATextron Company,
Product Support Engineering
12,800 rue de I'Avenir
Mirabel, Quebec, Canada, J7J 1R4
FOLD ON DOTTED LINES AND TAPE
TAPE HERE
IMPORTANT
HELICOPTER SALE NOTICE
Please complete this Form and return by Mail or FAX (817-280-3224, Attention: CPDC)
to Bell Helicopter Textron. This will ensure that the New Owners receive updates to
their Bell Helicopter Technical Manuals and Bulletins.
Model of Helicopter Sold or Purchased
Bell Serial Number
Registration Number
Company or Individual who purchased Helicopter
Address
City
State
Zip Code
Country
FAX No. Telephone No.

TAPE HERE
From
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS REPLY MAIL

FIRST CLASS PERMIT NO. 1744 FORT WORTH, TEXAS
A Textron Company
ASubsidiary of Textron Inc.
COMMERCIAL PUBLICATION DISTRIBUTION CENTER

P.O. BOX 482
FORT WORTH, TEXAS 76101-0482
FOLD ON DOTTED LINES AND TAPE
TAPE HERE
BHT-205A1-CR&O-1
WARRANTY
Spare Parts
WARRANTY AND REMEDY: Seller warrants each new helicopter part or helicopter part reconditioned by
seller to be free from defect in material and workmanship under normal use and service. Seller's sole obligation
under this warranty is limited to replacement or repair of parts which are determined to Seller's reasonable
satisfaction to have been defective within 1,000 hours of operation or one (1) year after installation, whichever
occurs first and reimbursement of reasonable freight charges. After 200 hours of use, there will be a prorated
charge to the Purchaser for replacement parts (prorating the hours of total use against the then applicable part
life or 2,000 hours, whichever is the lesser). Defective parts must be reported in writing to the Seller's Warranty
Administration within 90 days of being found defective. Warranty adjustment is contingent upon the Purchaser
complying with the Seller's Warranty Administration disposition instructions for defective parts. Failure to com-
ply with all of the terms of this paragraph may, at Seller's sole option, void this warranty.
THIS WARRANTY IS GIVEN AND ACCEPTED IN PACE OF (i) ALL OTHER WARRANTIES OR CONDI-
TIONS, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR
CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND (ii) ANY OB-
LIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR IN TORT (DELICT), INCLUDING
PRODUCT LIABILITIES BASED UPON STRICT LIABILITY, NEGLIGENCE, OR IMPLIED WARRANTY IN
LAW.
This warranty is the only warranty made by Seller. The Purchaser's sole remedy for a breach of this war-
ranty or any defect in a part is the repair or replacement of helicopter parts and reimbursement of reasonable
freight charges as provided herein. Seller excludes liability, whether as a result of a breach of contract or war-
ranty, negligence or strict product liability, for incidental or consequential damages, including without limitation,
damage to the helicopter or other property, costs and expenses resulting from required changes or modifica-
tions to helicopter components and assemblies, changes in retirement lives and overhaul periods, local cus-
toms fees and taxes, and costs or expenses for commercial losses or lost profits due to loss of use or
grounding of helicopters or otherwise.
Seller makes no warranty and disclaims all liability in contract or in tort (delict), including, without limitation,
negligence and strict tort (delictual) liability, with respect to work performed by third parties at Purchaser's re-
quest and with respect to engines, engine accessories, batteries, radios, and avionics, except Seller assigns
each manufacturer's warranty to Purchaser to the extent such manufacturer's warranty exists and is assign-
able.
This warranty shall not apply to any helicopter part which has been repaired or altered outside Seller's fac-
tory in any way so as, in Seller's judgement, to affect its stability, safety or reliability, or which has been subject
to misuse, negligence or accident, or which has been installed in any aircraft which has been destroyed unless
that helicopter has been rebuilt by Bell. A list of destroyed aircraft is obtainable from Bell Product Support. Re-
pairs and alterations which use or incorporate parts and components other than genuine Bell parts or parts
approved by Bell for direct acquisition from sources other than Bell itself are not warranted by Bell, and this
warranty shall be void to the extent that such repairs and alterations, in Seller's sole judgment, affect the sta-
bility, safety or reliability of the helicopter or any part thereof, or damage genuine Bell or Bell-approved parts.
No person, corporation, or organization, including Bell Customer Service Facilities, is authorized by Seller to
assume for it any other liability in connection with the sale of its helicopters and parts.
January 1, 1996
A Textron Company
POST OFFICE BOX 482 ·FORT WORTH. TEXAS 76101
BHT-205A1-CR&O-1
INTRODUCTION
LIST OF CHAPTERS
Chapter Subject
1 INTRODUCTION
20 STANDARD PRACTICES
27 FLIGHT CONTROLS
28 FUEL SYSTEM
29 HYDRAULIC SYSTEM
32 LANDING GEAR
65 ROTOR SYSTEM
66 POWER TRAIN
71 POWER PLANT
79 ENGINE OIL SYSTEM
INDEX 1 ALPHABETICAL INDEX
1-1/1-2
BHT-205A 1-CR&O-1
INTRODUCTION
1-1. SCOPE OF MANUAL. required data is most likely to appear or find the item
in the Alphabetical Index.
This component repair and overhaul manual provides
data for repair and overhaul of components and 2. Use the tab guides, turn to the desired chapter,
assemblies of the 205A-1 helicopter. The removal and check the chapters Table of Contents.
and installation procedures for components and
assemblies contained in this manual are provided in 3. The Table of Contents lists the name and page
BHT-205A1-MM-1 Maintenance Manual. The number which contains the desired information.
standard practices referred to in this component
repair and overhaul manual are provided in 4. The Alphabetical Index, the last chapter of this
BHT-ALL-SPMStandard Practices Manual. manual, lists all primary headings with
cross-indexing.
1-2. ALERT SERVICE BULLETINS. 5. The removal and installation procedures for
components and assemblies in this manual are in the
same chapter and section number of the
A list of Alert Service Bulletins issued against the BHT-205A1-MM-1.
model 205A-1 helicopter is recorded in the Bell
205A-1 Alert Service Bulletin index. 1-4. CONSUMABLE MATERIALS.
COMPLIANCE WITH ALL ALERT SERVICE
BULLETINS IS MANDATORY. Consumable materials required while performing
maintenance are listed in text by name and item
number such as "MEK (C-309)". The number refers
1-3. USE OF MANUAL. to consumable item 309 in Appendix A of
BHT-ALL-SPMmanual. This table provides full
1. Consult the List of Chapters in the front of this nomenclature, specifications applicable, and a
manual and determine the chapter in which the recommended source.
1-2 1-3/1-4
BHT-205A1-CR&O-1
CHAPTER 20
STANDARD PRACTICES
NOTE
Chapter 20 has been deleted in its entirety. For standard maintenance practices
applicable to all Bell helicopters, refer to the Standard Practices manual
(BHT-ALL-SPM)
20-1/20-2
BHT-205A1-CR&O-1
FLIGHT CONTROLS
TABLE OF CONTENTS
Paragraph Page
Number Title Number
27-1 Flight control bearings ........................................................ 27-3

27-5 Collective minimum friction clamp .............................................. 27-3
27-7 Pilot collective stick ........................................................... 27-6
27-11 Collective jackshaft ........................................................... 27-20
27-13 Collective pitch control linkage ................................................. 27-20
27-15 Pilot cyclic stick and support .................................................. 27-21
27-19 Cyclic pitch control linkage .................................................... 27-21
27-21 Anti-torque pedal and support .................................................. 27-28
27-26 Anti-torque pedal adjuster ..................................................... 27-35
27-30 Anti-torque control linkage ..................................................... 27-37
27-32 Force gradient ............................................................... 27-37
27-34 Flight controls tubes ............................................ 27-38
27-36 Anti-torque control tube sleeves ...... ..... ............................. 27-38
27-37A Pitch change components .................................... ............... 27-48A
27-38 Synchronized elevator control tube sleeves ...................................... 27-49
27-40 Synchronized elevator controls ................................... ........... 27-49
* LIST OF TABLES
Table Page
Number Title Number
27-1 Control tube wall thickness .................................................... 27-39
LIST OF FIGURES
Figure Page
Number Title Number
27-1 Universal assembly damage and repair limits ................................... 27-4

27-2 Universal bearing replacement ................................................. 27-5
27-3 Pilot collective stick .................................... ..................... 27-7
27-4 Collective control components damage and repair limits ........................... 27-10
27-5 Cyclic control stick ............................................................ 27-22
27-6 Cyclic control components damage and repair limits .............................. 27-23
27-7 Anti-torque pedal and support .................................... ............ 27-28
27-8 Anti-torque control components damage and repair limits ......................... 27-29
27-9 Anti-torque pedal adjuster ..................................................... 27-36
27-10 Force gradient ............................................................... 27-38
27-11 Control tube damage and repair limits ................................... ..... 27-40
27-12 Anti-torque control tube sleeve location ......................................... 27-48
27-12A Pitch change components damage and repair limits .............................. 27-48B
Rev. 2 27-1
BHT-205A1-CR&O-1 Bell Helicopter
TABLE OF CONTENTS (Cont)
LIST OF FIGURES (Cont)
Figure Page
Number Title Number
27-12B Lever bushing replacement .................................. ........... 27-48C

27-12C Pitch change control tube repair............................................ 27-48D
27-13 Synchronized elevator control tube sleeve location ............................... 27-49
27-14 Elevator component damage and repair limits .................................... 27-50
27-2 Rev. 2
BHT-205A1-CR&O-1
27-1. FLIGHT CONTROL BEARINGS. Cleanliness of universal bores is especially important

to ensure full bonding strength of retaining compound
27-2. UNIVERSAL BEARING REPLACEMENT when new bearings are installed. There are no
(205-076-175 AND 205-076-381). solvents available to dissolve cured anaerobic
retaining compound. Therefore, any residual cured
NOTE: Refer to figure 27-1 for damage and repair compound in bores may have to be carefully worn
limits. away using nylon web abrasive pads (C-407).
1. Press out RDW-5T-3V-1 bearing. Ensure that CAUTION: DO NOT ALLOW SOLVENT TO ENTER
universal body is positioned perpendicular to the BEARINGS.
bearing during bearing removal operation.
4. Clean outside diameter of bearings with MEK
2. Check housing bore for corrosion and cracks (C-309).
(refer to figure 27-1).
3. Apply a light coat of primer (C-201 or C-204) CAUTION: DO NOT ALLOW RETAINING
to OD of replacement bearing and insert bearing in COMPOUND TO ENTER BEARINGS.
universal assembly.
5. Apply anaerobic retaining compound (C-352)
4. Secure T101886-1 roller staking tool in drill to completely coat outer diameter of bearings and
press and position bearing on holding fixture. bores of universal housing.
5. Set drill press at 200 to 225 rpm. Stake 6. Press bearings into universal housing.
bearing in place by applying sufficient hand-pressure Bearings shall be centered equally from each side of
to drill press, in 10-second intervals, so the rollers of universal. Wipe off excessive retaining compound.
the spinning tool roll without interruption around the
pregrooved outer races. (Refer to figure 27-2).
7. Allow retaining compound in assembled
6. Repeat step 5. until bearing is completely universal to cure at 70-85°F (21.1 -29.4°C) for eight to
staked. Maximum clearance between bearing and ten hours. Accelerated curing may be accomplished at
housing after stake is 0.008 inch. a temperature not to exceed 200°F (93.3°C) 15 to 20
minutes.
7. Repeat steps 1. through 6. for opposite
bearing replacement. 8. After retaining compound has completely
cured, proof load bonded bearings in universal. Apply
8. Check rotational torque of bearing, after side load of 200 pounds to each bearing by pressing
staking. Rotational torque should be from one to six against outer race. Acceptable installation shall give
inch-pounds. no evidence of permanent deformation, loosening, or
damage.
27-3. Deleted
9. Check bearings by feel for smooth operation.
27-4. UNIVERSAL BEARING REPLACEMENT
(412-076-620).
27-5. COLLECTIVE MINIMUM FRICTION
1. Using press and pressing work aids, remove CLAMP.
unserviceable bearings from universal housing.
Ensure that the universal is positioned perpendicular 27-6. REPLACEMENT - FRICTION CLAMP
to bearing during bearing removal operation. LINER
2. Inspect universal housing for damage, 1. Remove all old friction liner material and
corrosion, and cracks (refer to BHT-ALL-SPM adhesive from clamp halves using abrasive cloth or
manual). paper (C-423). Rinse clamp in water and air dry.
3. Clean all surfaces of universal housing using 2. Cut new friction liner material to proper size.
MEK (C-309). Wipe dry before solvent evaporates. (Two pieces each approximately 1.0 x 3.0 inches).
15 JAN 2004 Rev. 3 27-3

BHT-205A 1-CR&O-1
UNIVERSAL ASSEMBLY (TYPICAL)
DAMAGE AREA REPAIR SYMBOLS
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
MECHANICAL AND
CORROSION
(After cleanup) 0.005 in.
MAXIMUM AREA PER

NONOVERLAPPING FULL
DEPTH REPAIR 0.10 sq. in.
NUMBER OF
NONOVERLAPPING
REPAIRS One per segment
°
EDGE CHAMFER 0.030 in. by 45
BEARING WEAR Bearing load for radial play 5 Pounds

Bearing load for axial play 5 Pounds
Allowable radial play 0.006 in.
Allowable axial play 0.015 in.
NOTES:
1. Bore damage not to exceed 0.001 inch for one-fourth circumference. Limit one repair per bore.
2. No cracks allowed.
Figure 27-1. Universal assembly damage and repair limits
27-4
BHT-205A 1-CR&O-1
T101886-1 X 205-076-381
TOOL KIT UNIVERSAL
ASSEMBLY
RDW-5V-1 BEARING
MAXIMUM CLEARANCE AFTER

RDW-5T-3V-1 BEARING
Figure 27-2. Universalbearing replacement
27-5
BHT-205A 1 -CR&O- 1
3. Lightly abrade dacron (pink) surface of liner 7. Remove nut (16) and washer (17) from tube
material with 180 grit abrasive cloth or paper (C-423) assembly (18).
in preparation for bonding to the clamp halves. (Note:
The teflon (dark) surface is friction side of material). 8. Remove bearings (15) from inside throttle grip
(14).
4. Apply adhesive, (C-363) to both the bonding
surfaces on the clamp and to the dacron (pink) 9 Removebearings(19)andring(20).
surface of liner.
5. Position liner on clamp and secure clamp 10.. Removeretainingring(21)andnutassembly

assembly around a suitable cylindrical work aid to (22) from tube assembly (24).
ensure an even bonding pressure during adhesive
curing. Remove adhesive squeeze-out. Adhesive will 11. Slip drag link assembly off of pin at bottom of
cure in 24 hours at 75°F (24°C). tube assembly (6) and slide tube assembly (6) off of
tube assembly (18).
6. After complete cure, remove clamp assembly
from work aid and scuff friction surface (dark side) 12. Remove bushing (25) from tube assembly
with 180 grit abrasive cloth or paper (C-423) (6).
followed by abrasive pad (C-407) until it has a
uniform moleskin finish. After scuffing, the clamp 13. Remove guide (26) from drive assembly (27).
assembly shall be washer in soap and water followed
by MEK (C-309) to remove grit and other foreign 14. Removenut(28),washer(29),andshim(31)
material. attaching pinion gear (30) to drive assembly (27).
27-7. PILOT COLLECTIVE STICK. 15. Remove drive assembly (27) from elbow (37)
and remove key (32) from drive assembly (27).
The pilot collective stick consists of a throttle grip and
a switch box mounted on top. The pilot collective
stick is connected to a jackshaft tube mounted
laterally under the cabin floor.
17. Remove roll pin (44) and pin (41).
27-8. DISASSEMBLY - PILOT COLLECTIVE STICK.
18. Remove bearings (43) and sleeves (38) from
1. Release clamps (1, figure 27-3) at bottom of elbow (37).
tube (6) and unscrew nut to release electrical cable
(2) from bracket on tube (6). 19. Remove nuts (39), washers (40), and bolts
(45) attaching housing assembly (42) to support
2. Remove three screws attaching cover (3) on assembly (62).
switch box (4). Push electrical cable upward to allow
cover to be moved without disconnecting electrical 20. Remove housing assembly (42) from elbow
wiring. (37).
3. From outside switch box (4), drive out pin (5)

and lift switch box from the tube assembly (24).
4. Remove washers (7 and 8). 22. Slide tube assembly (24) down through
elbow (37).
5. Remove retaining ring (9), washer (10), and
packing (11). 23. Remove bearing and sleeve (46) from support
assembly (62).
6. Remove throttle friction nut (12) and pin (13)
from throttle grip (14) and slide throttle grip off of 24. Remove nut (58), washers (59), and shim
tube assembly (24). (53).
27-6
BHT-205A1-CR&O-1
1. Clamp 25. Bushing

2. Cable 26. Guide
3. Cover 27. Drive
4. Switch box 28. Nut
5. Pin 29. Washer
6. Tube 30. Pinion
7. Washer 31. Shim
8. Washer 32. Key
9. Retaining ring
10. Washer
11. Packing
12. Throttle friction nut
13. Pin
14. Throttle grip
15. Bearings
16. Nut
17. Washer
18. Tube
19. Bearings
20. Ring
21. Retaining ring
22. Nut
23. Nut
24. Tube
Figure 27-3. Pilot collective stick (Sheet 1 of 2)
27-7
BHT-205A 1-CR&O-1
33. Cotter Pins 48. Clevis

34. Pin 49. Lever
35. Linkage 50. Shaft
36. Brake Shoes 51. Nut
37. Elbow 52. Washer
38. Sleeves 53. Shim
39. Nuts 54. Nut
40. Washers 55. Washer
41. Pin 56. Spirolox
42. Housing 57. Bearing
43. Bearings 58. Nut
44. Roll Pin 59. Washer
45. Bolts 60. Bearings
46. Sleeve 61. Sleeves
47. Screw 62. Support
Figure 27-3. Pilot collective stick (Sheet 2 of 2)
27-8
BHT-205A1-CR&O-1
25. Remove nut (54), washer (55), and spirolox 27-10. REASSEMBLY - PILOT COLLECTIVE
(56). STICK.
26. Remove bearing (57) from lever assembly 1. Install sleeves (61, figure 27-3) and bearings
(49). (60) in support assembly (62). (Refer to
BHT-ALL-SPM manual).
27. Remove nut (51), washer (52), and screw
(47). 2. Install bearing (43) and sleeve (38) in support
assembly (62). Insert short end of elbow into bearing
28. Remove shaft (50) from lever assembly (49). (43) in support assembly (62).
29. Remove sleeves (61) and bearings (60). 3. Position tube assembly (24) up through elbow
(37). Install nut (23) and secure with lockwire
27-9. INSPECTION AND REPAIR - PILOT (C-405).
COLLECTIVE STICK.
4. Insert drive assembly (27) through elbow (37)
1. Inspect all components of pilot collective stick and bearing in support assembly (62). Place shim
for corrosion, nicks, scratches, dents, broken or (31) on drive assembly (27). Install key (32) in recess
damaged tubing and frayed or broken cabling. (Refer of drive assembly. Install pinion (30), washer (29),
to figure 27-4). and nut (28). Thickness ofshim (31) may have to be
changed when step 7. is completed.
2. Repair acceptable corrosion and mechanical
damage. Polish steel parts only to a depth sufficient 5. Install bearing (57) in lever assembly (49) and
to remove traces of corrosion and clean aluminum
parts twice depth of deepest pit not to exceed limits manual).
of figure 27-4. Use fine to medium grade abrasive pads
6. Insert clevis (48) through bearing (57) and
(C-407), and final polish to a scratch-free finish with (4)
crocus cloth (C-409). Score marks on bushing ID may secure with washer (55) and nut (54). Torque nut 50
be polished if damaged and subsequent repair does
not exceed 0.002 inch depth. Apply brush cadmium 7. Position lever assembly (49) and shim (53)
(C-108) to repairs on cadmium plated surfaces and between bearings (60) and insert shaft through
apply chemicalapply
film (C-100)
chemicalto aluminum
(C-100)to
film aluminum surfaces.
surfaces. bearings (60), shim (53), and lever assembly (49).
Align hole in lever assembly and shaft and install
3. Inspect friction mechanism on pilot collective
. screw (47), washer (52) and nut (51). Install washer
stick for
for general
stick general condition.
condition. Inspect
Inspect brake
brake shoes
shoes (36,
(36, (59), and nut (58) on shaft. Check for a 0.50 to 1.50
figure 27-3) for condition and secure bonding to
pounds pull at end of lever assembly (49), to rotate
lever. Add or remove shims (31 and 53), as required,
to provide for 0.50 to 1.50 pounds friction. Secure
4. Refer to BHT-ALL-SPMmanual for fluorescent
nut (58) with cotter pin (33).
penetrant inspection requirements.
8. Position sleeve (38) and bearing (43) on elbow
5. Bond lining to housing assembly (42) by
installing rivets and using epoxy resin (C-219). Apply
moderate pressure, using three small C clamps and a 9. Position brake shoes (36) between lugs of
strip of metal or equivalent method. Countersink so elbow (37). Align holes in brake shoes with hole in
rivet head is 0.030 inch below surface of lining, elbow and install pin (41), drilled end in first. Install
roll pin (44) through elbow (37) and hole in pin (41).
6. Replace switches on switch box (4) if
inoperative or damaged. 10. Position linkage assembly (35), with center
link up, over brake shoes (36). Align holes and install
7. Replace throttle grip (14) if worn or damaged. pins (34). Secure pins (34) with cotter pins (33).
27-9
BHT-205A1-CR&O-1
204-001-194
TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH
MECHANICAL
(After repair) 0.010 in. 0.020 in.
CORROSION
(Before repair) 0.005 in. 0.010 in.
MAXIMUM AREA PER

NONOVERLAPPING FULL
DEPTH REPAIR 0.04 sq. in. 0.10 sq. in.
NUMBER OF
NONOVERLAPPING
REPAIRS One per segment Not critical
°
EDGE CHAMFER 0.030 in. by 45 0.050 in. by 45 °
NOTES:
1. Bore damage not to exceed 0.002 inch for one-fourth circumference.
Figure 27-4. Collective control components damage and repair limits (Sheet 1 of 10)
27-10
BHT-205A1-CR&O-1
204-001-601
DAMAGE LOCATION SYMBOLS
MECHANICAL
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
DEPTH REPAIR 0.10 sq. in. Not critical
NUMBER OF
NONOVERLAPPING
REPAIRS One per lug Not critical
° °
EDGE CHAMFER 0.040 in. by 45 0.060 in. by 45
NOTES:
27-11
BHT-205A 1-CR&O- 1
Typical both
surfaces of
bothlugs
204-001-195
MECHANICAL
(After repair) 0.010 in. 0.016 in. 0.040 in.
CORROSION
(Before repair) 0.005 in. 0.008 in. 0.020 in.
MAXIMUM AREA PER

NONOVERLAPPING FULL
DEPTH REPAIR 0.10 sq. in. 0.10 sq. in. 0.25 sq. in.
NUMBER OF
NONOVERLAPPING
REPAIRS One per lug One per area Not critical
° ° °
EDGE CHAMFER 0.015 in. by 45 0.025 in. by 45 0.060 in. by 45
NOTES:
1. Bearing bore damage not to exceed 0.001 inch for one-fourth circumference. Limit one repair per bore.
2. Bolt bore damage not to exceed 0.002 inch for one-fourth circumference. Limit one repair per bore.
27-12
BHT-205A 1-CR&O-1
Typical both
surfaces of
both lugs
204-001-178
MECHANICAL
(Before and
after repair) 0.010 in. 0.020 in.
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
° °
NOTES:
1. Bore damage not to exceed 0.002 inch for full circumference.
2. Bushing bore damage not to exceed 0.001 inch for one-fourth circumference.
3. Bushing bores shall be in line and perpendicular to adjacent surface within 0.007 inch.
27-13
BHT-205A 1 -CR&O- 1
0o0 0
204-001-184
DAMAGE LOCATION
MECHANICAL
(Before and
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS One per lug Two per part
° °
NOTES:
1. Bore damage not to exceed 0.003 inch for one-fourth circumference. Limit one repair per bore.
27-14
BHT-205A 1-CR&O- 1
204-001-185
MECHANICAL
(Before and
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS One per area Two per area
EDGECHAMFER 0.030 in. by 45 ° 0.060 in. by 45 °
NOTES:
2. Bolt hole and bushing bore damage not to exceed 0.002 inch for one-fourth circumference. Limit one
repair per bore.
27-15
BHT-205A 1-CR&O-1
Typical both
surfaces of
four lugs
204-001-330
MECHANICAL
(Before and
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS One per segment Not critical
NOTES:
27-16
BHT-205A 1 -CR&O- 1
205-001-109 CLAMP ASSEMBLY
MECHANICAL AND
CORROSION
(Before and
after repair) 0.010 in.
NUMBER OF
NONOVERLAPPING
REPAIRS One
MAXIMUM AREA PER

NONOVERLAPPING FULL
EDGE CHAMFER 0.015 x 450
MAXIMUM BORE 0.002 on 25% of the circumference

DAMAGE (INTERNAL) One damage area per bore
NOTE:
27-17
BHT-205A1-CR&O-1
MECHANICAL
(After repair) 0.005 in.
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS One per area
NOTES:
No thread damage is acceptable.
27-18
BHT-205A1-CR&O-1
204-001-102 204-001-603 204-001-148

SUPPORT LEVER ASSEMBLY BELLCRANK
MECHANICAL (Before
and after repair) 0.005 in. 0.010 in. 0.015 in.
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
DEPTH REPAIR 0.10 sq. in. 0.0 sq. in. 1 sq. in.
NUMBER OF
NONOVERLAPPING
REPAIRS One per area One per area One per area
EDGECHAMFER 0.04 in. by 45 ° 0.05 in. by 45 ° 0.05 in. by 45 °
BOREDAMAGE 0.002 inch for one-fourth circumference
NOTE
27-19
BHT-205A1-CR&O-1
11. Install housing assembly (42) on elbow (37). 27-11. COLLECTIVE JACKSHAFT.
12. Install washers (40), nuts (39), and bolts (45) 27-12. INSPECTION AND REPAIR
to attach housing assembly (42) and support COLLECTIVEJACKSHAFT.
assembly (62). Torque nuts and bolts 20 to 25
1. Inspect and repair jackshaft for wear and
inch-pounds. inch-pounds. damage (refer to figure 27-4). Apply brush cadmium
(C-108) to repairs of cadmium plated surfaces and
13. Slip guide (26) on drive assembly (27). apply chemical film (C-100) to repairs of aluminum
surfaces.
14. Slide tube assembly (18) inside tube 2. Polish out scratches, not in excess of 0.010
assembly (6). Turn tube assembly (18) to interlock inch in depth. In accordance with following step.
with drive assembly (27).
3. Remove all scratches that are within
limitations with wet or dry sandpaper (C-423), 400 or
15. Install retaining ring (21) and nut assembly
finger, to obtain a smooth scratch-free surface. Apply
(22) on tube assembly (24).
two coats of primer (C-204) to repaired area.
16. Install bearings (15) in top and bottom of NOTE: No limitations apply to length or direction of
throttle grip (14). Place ring (20) between bearings scratches. Scratches should be blended out to extend
(19) and place inside top of throttle grip (14), and over a minimum two inch area.
slide throttle grip on tube assembly (18).
4. Replace jackshaft assembly details as
required.
17. Install washer (17) and nut (16) on tube
assembly (18). 27-13. COLLECTIVE PITCH CONTROL
LINKAGE.
18. Align hole in throttle grip (14) with hole in Linkage between collective pitch control jackshaft
tube (18) and install pin (13) through throttle grip (14) and collective lever consists of push-pull tubes,
and tube (18). bellcranks, and hydraulic servo actuator.
27-14. INSPECTION AND REPAIR - COLLECTIVE

19. Install throttle friction nut (12) on tube (18).
PITCH CONTROL LINKAGE.
20. Install packing (11), washer (10), and 1. Inspect linkage parts for wear, elongated bolt
retaining ring (9) to secure top portion of conduit to holes, cracks, nicks or damage. Inspect bearings for
switch box (4). wear or roughness. (Refer to BHT-ALL-SPM manual).
Maximum allowable elongation to a bushing or clevis

21. Position washer (8) between washers (7) and hole in the control system is 0.003 inch.
place inside throttle friction nut (12).
3. Inspect control tubes for damage in excess of
the limits specified in paragraph 27-34.
22. Position switch box (4) on tube assembly
(24). Align hole in base of switch box (4) with hole in a. Repair of nicks and dents on the threads shall
tube (24). Install roll pin (5). not exceed one third of thread depth. Length of each
repair should not exceed 0.25 inch. Threads may
23. Install screws attaching cover (3) to switch have two repair areas.
box (4).
b. Repair of mechanical damage shall not
exceed original damage depth and width of repair
24. Install clamps (1) at bottom of tube (6) to areas at any section shall not exceed one third of the
secure electrical cable. tube circumference.
27-20
BHT-205A1-CR&O-1
c. Depth of repair of corrosion damage should be b. Apply adhesive primer (C-317) to new friction
to twice the depth of corrosion damage but shall not material (C-445) and install in bell (24).
exceed mechanical damage limits for depth or width.
4. Replace support (15) if worn or damaged.
4. Remove all mechanical and corrosion damage
that is within limits with wet or dry sandpaper (C-423),
5. Replace gimbal (16) if worn or damaged.
400 or finer, to obtain a smooth scratch free surface.
Apply two coats of primer (C-204) to repaired area.
6. Repair lever (5) to damage limits shown in
5. Inspect all bellcranks, levers, and supports for figure 27-6.
wear and damage limits. (Refer to figure 27-4).
27-18. REASSEMBLY - PILOT CYCLIC STICK
6. Any wear in excess of limits is cause for AND SUPPORT.
replacement.
1. Attach gimbal (16, figure 27-5) to lever
assembly (5) by installing two bearings (21), shims
27-15. PILOTS CYCLIC STICK AND SUPPORT. (22) and inserting bolts (20), heads inboard. Shim, as
required, to center line bore of 204-001-357 lever
27-16. DISASSEMBLY - PILOT CYCLIC STICK within 0.005 inch. Install washer (19) and nuts (18).
AND SUPPORT. Torque nuts 50-70 inch-pounds and secure with cotter
pins (17).
1. Remove screw (1, figure 27-5), lockwasher (2)
and clamp (3) attaching electrical cable (4) to lever
assembly (5). 2. Attach gimbal (16) to support assembly (15)
by installing two bearings (21), shims (22), and
inserting bolts (14), heads outboard. Shim, as
2. Remove cotter pin (6), nut (7), washer (8) and
required, to center line bore of 204-001-357 lever
bolt (9) attaching stick assembly (10) and lever
within 0.005 inch. Install washers (13) and nuts (12).
assembly (5) and separate parts.
Torque nuts 50-70 inch-pounds and secure with cotter
pins (11).
3. Remove two nuts (12), washers (13), and
bolts (14) attaching support (15) to gimbal (16) and
separate parts. 3. Place stick assembly (10) through support
assembly (15) into lever assembly (5) so the fore and
4. Remove nuts (18), washers (19) and bolts (20) aft control tube attachment point is aft. Insert bolt (9),
attaching gimbal (16) to lever assembly (5) and washers (8), one under bolt head and one under nut
separate parts. (7). Torque nut 30 to 40 inch-pounds and secure with
cotter pin (6).
5. Remove four bearings (21) and shims (22).
4. Position electrical wiring (4) and secure with
27-17. INSPECTION AND REPAIR - PILOT clamp (3) by installing screw (1) with lockwasher (2).
CYCLIC STICK AND SUPPORT.
27-19. CYCLIC PITCH CONTROL LINKAGE.
1. Replace bearings if worn, rough, or damaged.
(Refer to BHT-ALL-SPM manual).
27-20. REPAIR - CYCLIC CONTROL LINKAGE.
2. Replace electrical wires if frayed or broken. 1. Repair control tubes to limits of paragraph 27-
34.
3. Replace friction material (25, figure 27-5) in
bell assembly (24), if worn or damaged, as follows: 2. Remove all mechanical and corrosion damage
that is within limits, with wet or dry sandpaper (C-423),
a. Scrape old friction material out of bell and 400 or finer, to obtain a smooth scratch free
clean with MEK (C-309).
15 JAN 2004 Rev. 3 27-21

BHT-205A 1-CR&O-1
1. Screw 14. Bolt

2. Lock Washer 15. Support Assembly
3. Clamp 16. Gimbal
4. Electrical Wiring 17. Cotter Pin
5. Lever Assembly 18. Nut
6. Cotter Pin 19. Washer
7. Nut 20. Bolt
8. Washer 21. Bearing
9. Bolt 22. Shims
10. Stick Assembly 23. Rivet
11. Cotter Pin 24. Bell
12. Nut 25. Friction Material
13. Washer 26. Collar
Figure 27-5. Cyclic control stick
27-22
BHT-205A 1-CR&O-1
204-001-357
MECHANICAL
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
EDGECHAMFER 0.015 in. by 45° 0.025 in. by 45° 0.060 in. by 45°
NOTES:
Figure 27-6. Cyclic control components damage and repair limits (Sheet 1 of 5)
27-23
BHT-205A 1-CR&O-1
Both surfaces
204-001-358
of inboard lug
204-001-332 204-001-356 only
MECHANICAL (Before
and after repair) 0.020 in. 0.040 in.
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS One per area Two per area
° °
BOREDAMAGE 0.001 inch for 1/4 circumference
NOTE:
27-24
BHT-205A1-CR&O-1
BOTH LUGS
204-001-559 BELLCRANK
204-001-514 SUPPORT
MECHANICAL DAMAGE
(Before and
after repair) 0.005 in. 0.010 in. 0.015 in.
CORROSION DAMAGE
(Before reapir) 0.0025 in. 0.005 in. 0.0075 in.
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
EDGE CHAMFER 0.04 in. by 45 ° 0.05 in. by 45 °
BORE DAMAGE 0.002 inch for 1/4 circumference
NO CRACKS ALLOWED
27-25
BHT-205A1-CR&O-1
LUGS OF SUPPORT
205-001-301
MIXIMNG LEVERASSEMBLY
MECHANICAL DAMAGE
(Before and
CORROSION DAMAGE
(Before cleanup) 0.0025 in. 0.005 in. 0.0075 in.
(After cleanup) 0.005 in. 0.010 in. 0.015 in.
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
EDGE CHAMFER None 0.04 in. by 45 ° 0.05 in. by 45 °
NOTE:
1. No cracks allowed
27-26
BHT-205A1-CR&O-1
1.25
205-001-307
MECHANICAL (Before
and after repair) 0.010 in. 0.020 in.
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
° °
SLEEVEAND BORES 0.001 inch for one-fourth circumference
NOTE:
27-27
BHT-205A1 -CR&O-1
surface. Apply two coats of primer (C-204) to

repaired area.
NOTE: Maximum allowable elongation to a bushing

or clevis hole in the control system is 0.003 inch.
3. Polish out damage , to limits of paragraph

27-34.
4. Lubricate applicable parts of linkage before

assembling linkage. (Refer to BHT-205A1-MM-1
manual).
27-21. ANTI-TORQUE PEDAL AND SUPPORT.
27-22. DISASSEMBLY - ANTI-TORQUE PEDAL

AND SUPPORT.
1. Remove bolts (7, figure 27-7), aluminum

washers (3), and self-locking nuts (8) to separate arm
(6) from lever (9).
2. Remove close tolerance bolt (10), aluminum

washers (3), and castellated nut (11 ) to separate lever
from support (12).
3. Remove clevis bolt (2), shear nut (4),

aluminum washers (3), and separate pedal from arm
(6).
27-23. INSPECTION - ANTI-TORQUE PEDAL AND

SUPPORT.
1. Inspect pedals, arms, levers and support for

cracks, dents, corrosion, or other damage. (Refer to
figure 27-8).
2. Inspect bearings (13, figure 27-7) in support

for roughness and wear.
3. Inspect bushings in lever (9) for wear,

elongation, and looseness. Bushing wear of 0.002
inch maximum over 1/4 of circumference of the bore
is allowable. 1. Pedal Pad 8. Self-Locking Nut
2. Clevis Bolt 9. Lever
4. Replace parts that do not meet inspection 3.
4. Washers
Shear Nut 10.
11. Close Tolerance
Castellated Nut Bolt
requirements. 5. Cotter Pin 12. Support
6. Arm 13. Bearing
27-24. REPAIR/REPLACEMENT - ANTI-TORQUE 7. Bolt 14. Sleeve
PEDAL AND SUPPORT.
1. Remove minor damage from parts using

abrasive pads (C-407). Apply two coats of primer
(C-201 or C-204) to repaired area. (Refer to
BHT-ALL-SPMmanual for application of primer).
Figure 27-7. Anti-torque pedal and support
27-28
BHT-205A1-CR&- 1
Two surfaces of lug

and machined flat on
1.25 in. barrel
Both surfaces of
two lugs
204-001-757
REPAIR TYPEOF
DAMAGE
DAMAGE
AND
MAXIMUM
MECHANICAL
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
NOTES:
Figure 27-8. Anti-torque control components damage and repair limits (Sheet 1 of 6)
27-29
BHT-205A1-CR&O-1
204-001-700
MECHANICAL
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
NOTES:
27-30
BHT-205A 1-CR&O- 1
204-001-762 204-001-762
ADJUSTER ASSEMBLY ADJUSTER ASSEMBLY
MECHANICAL DAMAGE
CORROSION DAMAGE
(Before cleanup) 0.0025 in. 0.05 in.
0.0075
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
° ° °
BOREDAMAGE 0.002 inch for one-fourth circumference
NO CRACKS ALLOWED
27-31
BHT-205A 1-CR&- 1
205-001-704
204-001-855 LEVER
LEVER
1.0 in
MECHANICAL DAMAGE
CORROSION DAMAGE
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
° °
EDGE CHAMFER 0.05 in. by 45 0.04 in. by 45 0.060 in. by 45 °
BORE DAMAGE 0.002 inch for 1/4 circumference
NO CRACKS ALLOWED
27-32
BHT-205A 1-CR&O-1
IDLER 209-011-711
LEVER
CONTROL TUBE 209-011-712
209-011-710
MECHANICAL DAMAGE
(After cleanup) 0.002 in. 0.005 in. 0.010 in. 0.020 in.
CORROSION
(After cleanup
- steel) 0.002 in. 0.005 in. 0.005 in. 0.010 in.
(Before cleanup - AL.) 0.0025 in. 0.0025 in. 0.005 in.

(After cleanup - AL.) 0.005 in. 0.005 in. 0.010 in.
AREA OF
FULL
NONOVERLAPPING 0.05 0.05 0.100 0.25
DEPTH REPAIR sq. in. sq. in. sq. in. sq. in.
NUMBER OF
NONOVERLAPPING One per Two One per One per
REPAIRAREAS tang segment segment
EDGE CHAMFER 0.010 in. 0.020 in. 0.030 in. 0.060 in.
by 45 by 45 by 45 ° by 45 °
THREAD DAMAGE:
Depth: One-Third of thread
Length: One-Tenth inch
Number: Two
NOTE:
27-33
BHT-205A 1-CR&O-1
212-011-713
STOP
DAMAGE REPAIR LIMIT
TYPE OF DAMAGE
MECHANICAL
(Before and after repair) 0.002 in 0.005 in 0.01 in
CORROSION
(Before and after repair) 0.002 in 0.005 in 0.01 in
MAXIMUM AREA NONOVERLAPPING

FULL DEPTH REPAIR 0.05 Sq. in. 0.057 Sq. in. 0.10 Sq. in.
NUMBER OF NONOVERLAPPING
REPAIRS 1 1 1
EDGE CHAMFER ° ° °
0.005 in. by 45 0.010 in. by 45 0.010 in. by 45
SPLINE DAMAGE 1/3 OF SPLINE

1/3 OF DEPTH
2 SPLINES
NOTE:
27-34
BHT-205A1-CR&O-1
2. Replace defective bushings in lever (9, figure 12. Remove bearing and bushing (3) and
27-7). bushings (6 and 46) from bellcrank assembly (47).
3. Replace defective bearings in support (12) 13. Remove nut (19) and washer (20).
(Refer to BHT-ALL-SPM manual).
14. Remove bolt (9) and washer (10).
27-25. REASSEMBLY - ANTI-TORQUE PEDAL
AND SUPPORT. 15. Remove plate assemblies (11 and 17) and
spacer (16).
1. Assembly pedal (1, figure 27-7) to arm (6)
using bolt (2), washers (3) and shear nut (4). Install 16. Remove bushings (12, 13, and 18).
cotter pin (5).
17. Remove screws (14 and 38) from nut (23).
2. Assembly arm (6) to lever (9) using bolts (7),
heads aft, washers (3) and self-locking nuts (8). 18. Remove roll pin (22), pin (15) and link (21)
Torque bolts 20 to 25 inch-pounds. from screw (14).
3. Assemble lever (9) to support (12) as shown 19. Slide retainer (43) or (45), and gear (44) to
on figure 27-7, using close tolerance bolt (10), one side of shaft (42).
washers (3), and castellated nut (11). Position bolt
heads on outboard side. Torque bolts 160 to 190 20. Remove pin (41).
inch-pounds and install cotter pin (5). 21. Remove nut (23) and shaft (42) from support
4. Repeat steps 1., 2., and 3., for opposite pedal. assembly (24).
27-26. ANTI-TORQUE PEDAL ADJUSTER. .22. Remove retainers (43 and 45) and gear (44)
from shaft (42).
27-27. DISASSEMBLY - ANTI-TORQUE PEDAL
ADJUSTER. 27-28. INSPECTION/REPAIR - ANTI-TORQUE
PEDAL ADJUSTER.
NOTE: Disassembly only to extent necessary.
1. Remove nut (28, figure 27-9), washer (29), 1. Inspect chain (35,figure 27-9) for wear,
and bolt (34). damaged links, and corrosion.
2. Remove chain (35). 2. Inspect sprockets (30 and 32) for wear and
chipped or missing teeth.
3. Remove sprocket (30) and key (33) from bolt
(34). 3. Inspect keys (33 and 36) for wear.
4. Remove nut (5), washer (4), bolt (1), and 4. Inspect bushings in bellcrank assembly (47),
washer (2). upper plate assembly (11) lower plate assembly (17),
and support assemblies (24 and 25) for wear,
5. Repeat procedure for opposite side. elongation or looseness. Bushing wear of 0.002 inch
6. Remove roll pin (8) from gear (7). maximum over one-fourth circumference of bore is
allowable.
7. Remove nut (27) and washer (26).
5. Inspect pedal adjuster for corrosion and
8. Remove bolt (37) and separate support damage. (Refer to figure 27-8).
assemblies (24 and 25) from bellcrank assembly
(47). 6. Remove minor damage from parts using
9. Remove gear (7). abrasive pad (C-407).
10. Remove sprocket (32) and key (36) from bolt 7. Apply two coats of primer (C-201 or C-204) to
(37). repaired area. (Refer to BHT-ALL-SPM manual).
11. Remove bearing and bushing (31) from 8. Replace parts that do not meet inspection
support assembly (25). requirements.
27-35
BHT-205A 1 -CR&O- 1
1. Bolt 13. Bushing 25. Support assembly 35. Chain 47. Bellcrank
2. Washer 14. Screw 26. Washer 36. Key assembly
3. Bearing and bushing 15. Pin 27. Nut 37. Bolt
4. Washer 16. Spacer 28. Nut 38. Screw
5. Nut 17. Plate assembly 29. Washer 39. Bushing
6. Bushing 18. Bushing 30. Sprocket 40. Spacer
7. Gear 19. Nut 31. Bearing 41. Pin
8. Roll pin 20. Washer and 42. Shaft
9. Bolt 21. Link bushing 43. Retainer
10. Washer 22. Roll Pin 32. Sprocket 44. Gear
11. Plate assembly 23. Nut 33. Key 45. Retainer
12. Bushing 24. Support assembly 34. Bolt 46. Bushing
Figure 27-9. Anti-torque pedal adjuster
27-36
BHT-205A 1-CR&O-1
27-29. REASSEMBLY - ANTI-TORQUE PEDAL 15. Install key (33) and sprocket (30) on bolt
ADJUSTER. (34).
1. Replace bearings and bushings if rough or 16. Install chain (35).

worn.
17. Install bolt (34), washer (29), and nut (28).
2. Temporarily place retainer (43, figure 27-9)
and gear (44) on one end of shaft (42) leaving hole in 27-30. ANTI-TORQUE CONTROL LINKAGE.
shaft exposed.
27-31. REPAIR - ANTI-TORQUE CONTROL
3. Install retainer (45) on shaft (42). LINKAGE.
NOTE: Ensure nut is installed with 45 degree 1. Repair control tubes that exceed damage limits
chamfer on opposite side of arm on bellcrank in paragraph 27-34.
assembly (47).
2. Repair wear sleeves (refer to paragraph
4. Align shaft (42) with holes of support 27-36).
assembly (24) while sliding nut (23) into place.
3. Inspect levers, counterweight link, pitch link,
5. Install pin (41) in shaft (42) and nut (23). counterweight support, bellcrank, and cross head for
damage in accordance with figure 27-8.
6. Slide gear (44) over pin (41) and lock retainers
(43 and 45) into place. 4. Inspect the tail rotor pitch change link rod end
bearings for wear. A maximum of 0.020 inch radial
7. Install link (21), pin (15) and roll pin (22) on and/or axial play is allowed.
screws (14 and 38). Roll pin (15) shall be punch
staked into place 0.025 in from hole on each side of 27-32. FORCEGRADIENT.
screw (14 and 38).
27-33. ADJUSTMENT - FORCE GRADIENT.
8. Install screws (14 and 38) in nut (23) and
tighten screws until contact is made with pin (41). NOTE: The three force gradient assemblies utilized
in the flight control system are functionally similar,
9. Install bushings (12, 13, and 18) on plate but not identical. Ensure that parts are not intermixed
assemblies (11 and 17). when two or more force gradient assemblies are
disassembled at one time.
10. Install spacer (16), plate assemblies (11 and
17), bolt (9), washer (10 and 20) and nut (19). 1. Cutlockwireandremovecap(2,figure27-10).
Remove shaft (1), spring (6), and guides (7) from
11. Place gear (7) in bellcrank assembly (47) and cylinder (8).
attach bellcrank assembly to support assembly (24)
with bolt (1), washer (2 and 4) and nut (5). 2. Disassembly spring assembly by removing
nuts (3 and 4), guides (5 and 7) washers (10), spring
12. Install key (36) and sprocket (32) on bolt (6), and washer (9) from shaft (1). Visually inspect all
(37). parts for evidence of wear, corrosion and mechanical
damage. Check spring (6) for correct and
13. Attach support assembly (25) to bellcrank uncompressed free length:
assembly (47) with bolt (37), washer (26), and nut
4.49 inches.
b. Foreand aft force gradient (540-001-029) -

4.96 to 4.84 inches.
27-37
BHT-205A 1-CR&O-1
1. Shaft 6. Spring
2. Cap 7. Guide
3. Nut 8. Cylinder
4. Nut 9. Washer
5. Guide 10. Washers (212-001-045 only)
(TYPICAL)
Figure 27-10. Force gradient
c. Directional force gradient (204-001-045) - all noticeable end play of spring assembly is
4.50 to 4.62 inches. eliminated. Secure cap (2) with lockwire (C-405) as
shown.
NOTE: If spring length of 204-001-045 force
gradient assembly is 4.31 inches or less, install 27-34. FLIGHT CONTROL TUBES.
washers (10) at each end of spring (6). If spring
length is 4.31 to 4.37 inches, install one washer (10)
at one end of spring (6). 27-35. REPAIR - FLIGHT CONTROL TUBES.
3. Reassemble washer (9), spring (6), and guides 1. Replace any tube that is cracked or exceeds
(5 and 7) on shaft (1). damage limits in figure 27-11.
a. Adjust tension of spring (6) on lateral force 2. Polish out acceptable damage using abrasive
gradient assembly and directional force gradient paper (C-423), 400 grit or finger to obtain a scratch
assembly (204-001-045) as follows. free surface.
(1) Apply a force of 2.5 to 3.0 pounds on 3. Dents that are within limits shall be filled and
guide (5) to compress spring. smoothed using adhesive (C-313). Reinspect after
100 hours operating time.
(2) Adjust nuts (3 and 4) to hold guide in
position and maintain spring tension.
4. Refer to table 27-1 for a list of control tubes
b. Adjust tension on spring (6) on forward and used on this helicopter, and their wall thickness.
aft force gradient assembly (540-001-029) as
follows: 5. Refer to BHT-ALL-SPMmanual for finishing.
(1) Apply a force of 5.5 to 6.5 pounds on 27-36. ANTI-TORQUE CONTROL TUBE
guide (5) to compress spring. SLEEVES.
(2) Adjust nuts (3 and 4) to hold guide in 27-37. REPAIR - ANTI-TORQUE CONTROL TUBE
position and maintain spring tension. SLEEVES.
4. Position shaft (1) with assembled spring and 1. Remove worn sleeves, avoid scratching the
guides in cylinder (8). Install cap (2) and screw in until
tube surface.
27-38
BHT-205A1-CR&O-1
Table 27-1. Control Tube Wall Thickness
Part Number (TubeAssy) Wall Thickness (inch)
Collective: 204-001-027-023 0.049

204-001-109-001 0.049
204-001-190-001 0.049
204-001-212-001 0.134
204-001-602-001 0.035
204-001-663-001 0.035
205-001-011-017 0.049
205-001-021-007 0.049
205-001-055-007 0.049
205-076-164-005 0.083
Cyclic: 204-001-011-013 0.049

204-001-016-013 0.049
204-001-027-005 0.049
204-001-326-011 0.049
205-001-014-001 0.049
205-001-029-005 0.035
205-001-053-007 0.035
205-001-053-011 0.035
205-001-055-001 0.049
205-001-055-013 0.049
Anti-Torque 204-001-014-007 0.049

205-001-011-005 0.049
205-001-011-009 0.049
205-001-028-001 0.035
205-001-029-001 0.035
205-001-033-001 0.049
205-001-044-001 0.035
205-001-044-101 0.035
209-001-061-009 0.035
212-001-052-001 0.035
212-001-052-101 0.035
212-001-055-001 0.035
212-001-055-101 0.035
Elevator: 204-001-957-001 0.050

205-001-036-001 0.049
205-001-037-001 0.035
205-001-038-001 0.035
205-001-038-101 0.035
205-001-039-001 0.035
205-001-040-001 0.049
205-001-041-001 0.049
205-001-054-001 0.049
205-001-054-007 0.049
27-39
BHT-205A 1-CR&O-1
GUIDEDAMAGE
MECHANICAL AND
CORROSION
(Before and after repair) 0.005 in.
MAXIMUM AREA PER

NONOVERLAPPING
FULL DEPTH REPAIR 0.010 sq. in. 0.10 sq. in
NUMBER OF
NONOVERLAPPING
REPAIR AREAS One per clevis 4
°
BORE DAMAGE 0.002 in. for

one-fourth
circumference
THREAD DAMAGE:
Depth: One-third of thread
Length: 0.25 in.
Number: Two per segment
GUIDE DAMAGE 0.008 in. maximum wear depth

CRACKS NONE
NOTES:
The width of repair at any section shall not exceed one-third of the tube circumference.
The mechanical damage to the surface of the control tube shall not exceed 10% of the tube wall
thickness. Corrosion damage shall not exceed 5% of the tube wall thickness before cleanup and 10%
after cleanup. Listed below are the control tubes and wall thickness.
205-001-039-1 0.035
205-001-040-1 0.049
205-001-041-1 0.049 A
205-001-044-1 0.035
The smaller diameter of tube and approximately 0.5 in. of swaged section are critical, and no damage
or repair is permitted.
Elevator controls.
Anti-torque controls.
Figure 27-11. Control tube damage and repair limits (Sheet 1 of 8)
27-40
BHT-205A 1-CR&O-1
-- j [-0.5IN. ----- >T[- __ _^ 0.5IN .

_--, --
GUIDEDAMAGE
MECHANICAL AND
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING
FULL DEPTH REPAIR 0.010 sq. in. 0.10 sq. in.
NUMBER OF A
NONOVERLAPPING One per clevis 4
REPAIR AREAS or bearing
EDGE CHAMFER 0.010 in. by 45 °

one-fourth
circumference

CRACKS NONE
NOTES:
205-001-028-1 0.035
209-001-061-9 0.035
204-001-014-7 0.049
27-41
BHT-205A1-CR&O-1
GUIDE DAMAGE
MECHANICAL AND
CORROSION
MAXIMUM AREA PER
FULL DEPTH REPAIR 0.010 sq. in. 0.10sq. in
NUMBER OF
NONOVERLAPPING
REPAIR AREAS One per bearing
EDGE CHAMFER 0.020 in. by 45°

one-fourth
circumference

CRACKS NONE
NOTES:
205-001-014-1 0.049
204-001-602-1 0.035
Cyclic controls.
Collective controls.
27-42
BHT-205A1-CR&O-1
-1.0 IN. GUIDE DAMAGE

TYP.
MECHANICAL AND
CORROSION A
MAXIMUM AREA PER

NONOVERLAPPING
FULL DEPTH REPAIR 0.010 sq. in. 0.10 sq. in.
NUMBER OF
NONOVERLAPPING

one-fourth
circumference
THREAD DAMAGE:
DEPTH One-third
LENGTH 0.25 in.
NUMBER Two per segment

CRACKS NONE
NOTES:
205-001-029-1 0.035
205-001-029-5 0.035
The smaller diameter of tube and approximately 0.5 in. of swaged section is critical, and no damage or
repair is permitted.
Damage limits in parentheses for cyclic system only.
Cyclic controls.
The smaller diameter of tube and approximately 1.0 inch of the swaged section is critical, and no
damage or repair is permitted.
27-43
BHT-205A 1-CR&O- 1
1.0 IN. GUIDEDAMAGE

TYP.
MECHANICAL AND
CORROSION
(Before and 0.005 in.
and after repair) 0.010 in. 0.010
MAXIMUM AREA PER

NONOVERLAPPING
FULL DEPTH REPAIR 0.010 sq. in. 0.10 sq.in.
NUMBER OF
NONOVERLAPPING
EDGECHAMFER 0.010 in. by 45° 0.020)

one-fourth
circumference

CRACKS NONE
NOTES:
204-001-011-13 0.049 205-001-011-5 0.049
204-001-016-13 0.049 205-001-011-9 0.049
204-001-027-5 0.049
204-001-027-23 0.049
205-001-011-17 0.049
Damage limits in parentheses for cyclic and collective system only.
Cyclic controls.
27-44
BHT-205A1-CR&O-1
0.5IN.
GUIDEDAMAGE
MECHANICAL AND
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING
FULL DEPTH REPAIR 0.010 sq. in. 0.10 sq.in
NUMBER OF
NONOVERLAPPING

one-fourth
circumference

CRACKS NONE
NOTES:
204-001-957-1 0.050 212-001-052-1 0.035
205-001-036-1 0.049 212-001-052-101 0.035
205-001-037-1 0.035 212-001-055-1 0.035
205-001-038-1 0.035 212-001-055-101 0.035
205-001-038-101 0.035,
Elevator controls.
27-45
BHT-205A1-CR&O-1
GUIDEDAMAGE
MECHANICAL AND
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING
FULL DEPTH REPAIRS 0.010 sq. in. 0.10sq.in.
NUMBER OF
NONOVERLAPPING One per clevis 4
REPAIR AREA or bearing

one-fourth
circumference
THREAD DAMAGE:
Depth: One-third
Length: 0.25 in.

CRACKS NONE
NOTES:
205-001-021-7 0.049
205-001-053-7 0.035
205-001-053-11 0.035
Cyclic controls.
205A1-R-27-11-7
Figure 27-11. Control tube damage and repair limits (Sheet 7)
27-46 Rev. 2
BHT-205A 1-CR&O-1
GUIDE DAMAGE
MECHANICAL AND
CORROSION
after repair) 0.010 in. 010
MAXIMUM AREA PER

NONOVERLAPPING
FULL DEPTH REPAIR 0.010 sq. in.
NUMBER OF
NONOVERLAPPING
REPAIR AREAS One per clevis

one-fourth
circumference
THREAD DAMAGE:
Length: 0.25 in.

CRACKS NONE
NOTES:
after cleanup. Listed below are the control tubes used in the collective pitch system with the control
tube and wall thickness.
205-001-054-1 0.049
205-001-054-101 0.049
205-001-055-1 0.049
205-001-055-7 0.049
205-001-055-13 0.049
Damage limits in parentheses for cyclic and collective system only.
Elevator controls.
Cyclic controls.
27-47
BHT-205A1 -CR&O-1
NOTE: The quality of bond depends on the 4. Mix adhesive (C-331) per manufacturers
cleanliness and preparation procedure. instructions, ensure proper amount (by weight) of base
resin to hardener or catalyst if used.
2. Prepare tube, in sleeve area, with abrasive
pad (C-407), and MEK (C-309). Remove primer and 5. Apply adhesive (C-331) to cleaned areas on
apply chemical film (C-100). Clean with MEK or tubes as shown on figure 27-12, and inside diameter
aliphatic naphtha (C-305). of sleeve.
3. Prepare sleeve inside diameter bonding

surface (if necessary) as follows: 6. Install sleeves, on applicable tube, at locations
shown in figure 27-12. Hold in place with masking
(C-418) or secure sleeves in place with hi-shrink tape
a. Blast with a slurry of 30 to 50 percent abrasive (C-487) (use masking tape (C-426) on ends). Apply
3/0 inspected grade flint quartz in water. Blast heat to tape (C-487) with heat gun evenly to ensure
uniformly at 30 to 80 psi, or use abrasive pad (C-407). uniform shrinkage.
b. Rinse with clean water. Do not allow abrasive
slurry to dry on sleeves. 7. Cure time for adhesive (C-331) is 24 hours at
65 to 85°F (18 to 29°C).
c. Preform sleeve by inserting an aluminum tube
approximate diameter of control tube and heat in oven 8. Prime external surface of tube with primer (C-
at 275°F (135°C) for 15 minutes. 204). Overlap each end of sleeve by 0.20 to 0.40 inch.
Figure 27-12. Anti-torque control tube sleeve location
27-48 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
27-37A. PITCH CHANGE COMPONENTS. b. Inspect bushing bores in lever for damage.
Replace lever if damage exceeds 0.002 inch for
one-fourth of circumference.
27-37B. INSPECTION - PITCH CHANGE
COMPONENTS. c. Coat replacement bushings with unreduced
primer (C-201). Press bushings into lever while primer
1. Inspect components for mechanical or corrosion is still wet.
damage. (Refer to figure 27-12A.)
d. Line ream bushings 0.3125 to 0.3130 inch as
2. Inspect idler and leverfor cracks using fluorescent shown on figure 27-12B.
penetrant method. (Refer to BHT-ALL-SPM.)
e. Machine faces of bushings equally to obtain
3. Inspect bearings in idler and lever for roughness 0.938 to 0.940 inch dimension shown on figure 27-12B.
and wear. Replace bearings if rough or worn Faces of bushings shall be perpendicular to centerline
excessively. (Refer to BHT-ALL-SPM.) of bushings within 0.001 inch after machining.
4. Inspect bushings in lever for looseness and wear. 8. Metallize pitch change control tube as follows:
Replace lever if bushings are loose. Replace bushings
if inside diameter exceeds 0.3135 inch or if elongation a. Remove tool marks, uneven surface, and/or
exceeds 0.002 inch. a. Remove tool marks, uneven surface, and/or
corrosion by machining to a diameter not less than 0.735
inch. Runout of machined area shall not exceed 0.010
27-37C REPAIR PITCH CHANGE inch total indicator reading and runout of entire
COMPONENTS assembly shall not exceed 0.020 inch with the assembly
mounted on centers. Surface finish of 16 microinches or
better is required. Refer to figure 27-12C for repair area.
1. Repair pitch change components in accordance
with limits shown in figure 27-12A. b If reworked diameter (not less than 0.736 inch)
is less than the undercut at the intersection of the 60
2. Remove all mechanical and corrosion damage degree conic and repair area, blend reworked diameter
within limits with abrasive cloth or paper (C-423) to into fillet radius at the base of the conic using a 0.25 inch
obtain a smooth scratch-free surface. radius. Ensure area is free of sharp edges or corners
and is limited to fillet radius area at the intersection of the
3. Mask off bushing bores and slider portion of 60 degree conic and basic tube.
control tube.
c. Prepare surface and apply nickel XHB solution
4. Apply two spray coats of primer (C-204) to to reworked area per MIL-STD-865C in accordance with
repaired area. Selectrons Ltd. Instruction Manual.
5. Replace any cracked components. d. Remove excessive amount of nickel buildup by

machine turning outside diameter to a dimension of
6. Replace any components that exceeds .7500/.7490 inch with a minimum surface finish of 16
mechanical or corrosion limits. microinches or better. Runout limits shall not exceed
0.010 inch total indicator reading or 0.020 inch with the
7. Replace bushings in lever as follows: assembly mounted on centers.
a. Press bushings from lever. Clean aged primer e. Apply brush cadmium plate to adjacent
from bushing bores in lever. surfaces. Refer to BHT-ALL-SPM.
Rev. 2 27-48A
BHT-205A1-CR&O-1
IDLER
209-011-711
LEVER
CONTROLTUBE
209-011-712
209-011-710
AREA A AREA B AREA C AREA D
AREA A AREA B AREA C AREA D
TYPE DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH
NICKS, SCRATCHES, 0.010 in. 0.020 in. 0.005 in. 0.002 in.
AND CORROSION
CORROSION 0.005 in. 0.010 in. 0.005 in. 0.002 in.
AREA OF 0.25 sq. in. 0.50 sq. in. 0.05 sq. in. 0.05 sq. in.
FULL DEPTH REPAIR
NUMBER OF REPAIR One per segment One per segment Two One per tang
AREAS
THREAD DAMAGE:
DEPTH: One-third of thread
LENGTH: One-tenth inch
NUMBER: Two
205A1 -R-27-12A-1
Figure 27-12A. Pitch change components damage and repair limits (Sheet 1 of 2)
27-48B Rev. 2
BHT-205A1-CR&O-1
GEARBOX HOUSING
209-011-720
MECHANICAL 0.010 in.
CORROSION 0.005 in. before repair
0.010 in. after repair
MAXIMUM AREA FOR 0.01 sq. in.

FULL DEPTH REPAIR
NUMBER OF REPAIRS Not critical 205A1-R-27-12A-2
Figure 27-12A. Pitch change components damage and repair limits (Sheet 2)
0.938 TO 0.940 IN.
0.3125TO 0.3130 IN.
205A 1-R-27-12B
Figure 27-12B. Lever bushing replacement
Rev. 2 27-48C
BHT-205A1-CR&O-1
REPAIR AREA
205A1-R-27-12C
Figure 27-12C. Pitch change control tube repair
27-48D Rev. 2
BHT-205A1-CR&O-1
27-38. SYNCHRONIZED ELEVATOR 6. Install sleeves, on applicable tube, at locations

CONTROL TUBE SLEEVES. shown in figure 27-13. Hold in place with masking
(C-418) or secure sleeves in place with hi-shrink tape
27-39. REPAIR - SYNCHRONIZED ELEVATOR (C-487) (use masking tape (C-426) on ends). Apply
CONTROLTUBE SLEEVES. heat to tape (C-487) with heat gun evenly to ensure
uniform shrinkage.
1. Remove worn sleeve, avoid scratching the tube
surface. 7. Cure time for adhesive (C-313) is 24 hours at
65 to 85°F, (18 to 29°C).
NOTE: The quality of bond depends on the
cleanliness and preparation procedure. 8. Prime external surfaces of tube with primer
(C-204). Overlap each end of sleeve by 0.20 to 0.40
2. Prepare tube, in sleeve area, with abrasive pad inch.
(C-407), and MEK (C-309). Remove primer and apply
chemical film (C-100). Clean with MEK or aliphatic 27-40. SYNCHRONIZED ELEVATOR
naphtha (C-305). CONTROLS.
3. Prepare sleeve inside diameter bonding surface 27-41. REPAIR - SYNCHRONIZED ELEVATOR
(if necessary) as follows: CONTROL COMPONENTS.
a. Blast with a slurry of 30 to 50 percent 1. Repair components in accordance with figure

abrasive 3/0 inspected grade flint quartz in water. 27-14.
Blast uniformly at 30 to 80 psi, or use abrasive pad
(C-407). 2. Remove all mechanical and corrosion damage
(within limits) with abrasive paper (C-423), 400 grit
b. Rinse with clean water. Do not allow or finer, to obtain a smooth scratch-free surface.
abrasive slurry to dry on sleeves. Apply two coats of primer (C-204) to repaired area.
c. Preform sleeve by inserting an aluminum 3. Replace any components that are cracked.
tube approximate diameter of control tube and heat in
oven at 275°F (135°C) for 15 minutes. 4. Replace any components that exceed
mechanical or corrosion limits.
4. Mix adhesive (C-313) per manufactures
instructions, ensure proper amount (by weight) of 5. Replace any component if bearings are rough
base resin to hardener or catalyst if used. or excessively worn.
5. Apply adhesive to cleaned areas on tubes as 6. Replace component if elongation to bushing or

shown on figure 27-13, and inside diameter of sleeve. clevis exceeds 0.003 inch.
62.75
205-001-038
Figure 27-13. Synchronized elevator control tube sleeve location
27-49
BHT-205A1-CR&O-1
ELEVATOR ASSY
INDEX HEAT
NO. ITEM TYPE MATERIAL SPECIFICATION TREAT
1. Rib Al Aly 6013 AMS 4347 T6

2. Flange Al Aly 6013 AMS 4347 T42
3. Spar Al Aly 2024 WW-T-700/3 T3
4. Support Al Aly Forging 2014 QQ-A-367 T6
5. Horn Al Aly Casting A356 MIL-A-21180
6. Trailing Edge Al Aly 2024 QQ-A-250/5 T3
7. Cap Rubber, Silicone 299-947-095 Black
8. Doubler Al Aly 6013 AMS 4347 T6
9. Doubler Hard Cres Steel 301 1/4 299-947-133 125
10 Stiffener Al Aly 6013 AMS 4347 T6
205A1-R-27-14-1
Figure 27-14. Elevator component damage and repair limits (Sheet 1 of 4)
27-50 Rev. 2
BHT-205A1-CR&O-1
DAMAGE 0.005 INCH

ELEVATOR OUTLINE (0.127 mm) DEEP (MAX) CRITICAL AREAS (TYPICAL)
SPAR TUBE
NOTE
The entire elevator spar tube is a critical fatigue area. The area where the elevator attaches
to the horn and the radii adjacent to the rib lands are especially critical because these are
the points where loads are transferred to the spar. If an elevator sustains damage, the
elevator skin must be removed for inspection of the spar prior to repair of the internal
damage.
LIMITS - REPAIRABLE DAMAGE
Scratch and scoring damage is limited to 0.005 inch (0.127 mm) depth after clean-up with
400 grit of smoother abrasive paper (C-423) to a polished smiith surface. Scratch and
scoring damage is further limited as follows:
0.50 in. (12.7 mm) Radially

1.00 in. (25.4 mm) Longitudinally
No dents which result in visible tube wall depressions are permitted. The allowable limit on
pit corrosion is 10% of wall thickness. No corrosion is permitted after clean-up.
NOTE
Apply two coats of polyamide eqoxy primer (C-204) to spar in clean-up areas, but do not
apply primer to portion of spar which fits inside horn.
27-51
BHT-205A 1-CR&O-1
DETAIL A
CRACKS ALLOWED None
MECHANICAL DAMAGE None 0.010 in. 0.015 in.

(0.254 mm) (0.381 mm)
CORROSION DAMAGE None

BEFORE REPAIR 0.005 in. 0.0075 in.
(0.127 mm) (0.190 mm)
AFTER REPAIR 0.010 in. 0.015 in.

(0.254 mm) (0.381 mm)
MAXIMUM AREA PER

NONOVERLAPPING 0.10 sq. in. 1 sq. in.
FULL DEPTH REPAIR (64.52 sq. mm) (645.2 sq. mm)
NUMBER OF
NONOVERLAPPING
REPAIRS 1 per area 1 per area
° °
EDGE CHAMFER 0.04 in. by 45 0.05 by 45
(1.02 by 45 ° ) (1.27 by 45 ° )
BOREDAMAGE 0.002 in. (0.051 mm) for 1/4 bore circumference
BEARING WEAR Radial 0.012 in. (0.305 mm)

Axial 0.030 in. (0.762 mm)
NOTE:
1 No cracks allowed
27-52
BHT-205A1-CR&O-1
BUSHING
MAXIMUM CLEARANCE AFTER

STAKING 0.005 INCH
MECHANICAL DAMAGE 0.008 in. 0.012 in.

(0.203 mm) (0.305 mm)
CORROSION DAMAGE
BEFORE REPAIR 0.006 in. 0.010 in.
(0.152 mm) (0.254 mm)
AFTER REPAIR 0.008 in. 0.012 in.
(0.203 mm) (0.305 mm)
MAXIMUM AREA PER
NONOVERLAPPING 0.10 sq. in. 0.16 sq. in.
FULL DEPTH REPAIRS (64.5 sq. mm) (103.2 sq. mm)
NUMBER OF
NONOVERLAPPING
REPAIR 4 6
BORES Bolt holes 0.002 in. (0.051 mm) for one-fourth circumference
BUSHING DAMAGE None
CRACKS ALLOWED None
27-53/27-54
BHT-205A1-CR&O-1
FUEL SYSTEM
TABLE OF CONTENTS
Paragraph Page
Number Title Number
28-1 Fuel cells ..................................... ..............

... 28-2
28-1
BHT-205A 1 -CR&O-1
28-1. FUEL CELLS. patch. Use a roller or blunt instrument to press patch
down. Place a fifty pound shot bag on patch with a
Two forward fuel tank cells are laminated fabric and piece of cellophane between shot bag and fuel cell.
rubber self-sealing type, with molded-type metal Do not disturb for six hours.
fittings at openings, and passages for internal
components and hoses. Each cell has a vent port on e. Seal coat one-half inch wide strip around
the upper inboard side, interconnecting ports on edge of patch with one coat of adhesive (C-325 or
forward and aft ends, a drain port, and a large opening C-444). Allow to dry thoroughly.
for the sump assembly on the lower side.
2. Repair inside surface of cell (nonself-sealing)
Three aft fuel tank cells are bladder type, of laminated as follows:
fabric and synthetic rubber, with inserted metal
flange-type fittings at openings and integral hangers a. Repair inside surfaces of fuel cell only after
around upper ends for nylon cord suspension in damaged area on outside surface has been repaired.
cavities.
b. Cut a patch of synthetic rubber nylon
28-2. INSPECTION-FUEL
CELLSsandwich material (C-443) large enough to cover
damage with a two-inch overlap in any direction.
1. Inspect fuel cell visually for deterioration,
evidence of seepage and mechanical damage. Apply patch in same manner as described for outside
patch in step 1. b through d.
2. Inspect fuel cell for damage which may have

occurred during crating or removal from shipping c. Coat patch and one-half inch wide strip
container. underlapping patch with two coats of adhesive
(C-325 or C-444). Allow first coat to dry one hour or
28-3. REPAIR- FUELCELLS. more. After second coat is dry, wipe patch and
cemented area with clean lubrication oil (C-009) to
1. Repair outside surface of cell (nonself-sealing) prevent patch from sticking to other parts of the cell.
as follows:
d. To repair scuffed fabric on fuel cell. buff area
CAUTION: FIELD REPAIRSTO ANY RADIUS, ANY of scuff damage with garnet paper (abrasive paper
FITTING AREA, OR ANY CUT OR TEAR LONGER with garnet as abrasive). Wash with MEK (C-309) to
THAN ONE INCH ARE PROHIBITED. CELLS WITH remove buffing dust.
SUCH DAMAGE SHALL BE RETURNED TO AN
AUTHORIZED REPAIR CENTER FOR REPAIR.
e. Apply two coats of cement (C-444) to
buffed area. Allow ten minutes drying time between
a. Cut a patch of synthetic rubber coated fabric
coats.
(C-441) outside repair material large enough to cover
damage with a two inch overlap in any direction.
3. Repair self-sealing type fuel cell as follows:
b. Buff patch and cell area to be repaired with
garnet paper (abrasive paper with garnet as abrasive). CAUTION: MAKE NO REPAIRS ON THE RADIUS OF
Wash with MEK (C-309) to remove buffing dust. A CELL OR IN THE FITTING AREA OF A CELL. CELLS
WITH SUCH DAMAGE SHALL BE RETURNED TO AN
c. Apply two coats of adhesive (C-325 or AUTHORIZED REPAIR CENTER FOR REPAIRS. NO
C-444) to buffed area of fuel cell and patch. Allow DAMAGED AREA LARGER THAN TWO INCHES
each coat to dry 10 to 15 minutes. SHOULD BE REPAIRED IN THE FIELD.
d. Apply MEK (C-309) to cemented area of fuel a. Use a piece of synthetic rubber coated fabric
cell. While still tacky, apply edge of patch to edge of (C-442) large enough to cover damage at least two
cemented area; hold opposite edge of patch off fuel inches from cut in any direction. Buff this material
cell. Roll the patch down in one-half inch wide strip lightly and thoroughly with fine sandpaper (C-423)
increments to avoid trapping air between fuel cell and and wash with MEK (C-309) to remove buffing dust.
28-2
BHT-205A 1-CR&O- 1
b. Cement buffed side of patch with two coats k. Buff cell area to be patched lightly and
of black rubber cement (C-444). Allow each coat to thoroughly with fine sandpaper (C-423) and then
dry 10 to 15 minutes. wash off buffing dust with MEK (C-309).
c. Buff cell with area to be patched lightly and l. Coat buffed area with two coats of black
thoroughly with fine sandpaper (C-423) and wash rubber cement (C-444) and allow each coat to dry 10
with MEK (C-309) to remove buffing dust. to 15 minutes.
d. Cement buffed area with two coats of m. Freshen cemented area of patch and
cement (C-444). Allow each coat to dry 10 to 15 cemented area of cell with MEK (C-309).
minutes.
n. While still tacky, apply edge of patch to edge
e. Freshen cemented area of patch and of cemented area, centering patch over cut in cell.
cemented area of cell with MEK (C-309). Hold part of patch off the cemented area and roll or
press it down a half-inch to an inch across at a time so
f. While still tacky, apply edge of patch to edge as not to trap air between patch and cell.
of cement area on cell. With a roller or blunt
instrument, roll or press patch to cemented area on o. Remove red fabric from patch by moistening
cell. Hold part of patch off cemented area and roll or with MEK (C-309).
press it down a half-inch to an inch across at a time so
as not to trap air between patch and cell. p. Seal coat patch and area one-half inch from
edge of patch with two coats of cement (C-444).
g. Seal coat edge of patch one-half inch with Allow the first coat to dry 15 minutes and the second
one coat of cement (C-444) and allow the patch to coat to dry 12 hours or more.
remain undisturbed for six hours.
h. After the damaged area has been patched on 28-4. STORAGE - FUEL CELLS.
the outside of the cell and the repair allowed to stand
a minimum of six hours, the cell is then ready to have 1. When a cell which has contained fuel is to
the patch applied on the inside of the cell. remain empty for more than three days, the inner
surface of the cell should be fogged with light
i. Lightly and thoroughly buff a piece of Buna N lubricating oil (C-009) to prevent deterioration caused
nylon sandwich material (C-443) large enough to by drying out. Do not leave the cell collapsed. If it is
cover damage at least two inches from cut in any not to be replaced in the helicopter immediately, the
direction. Wash buffing dust off patch with MEK cell should be installed in a stand or a container such
(C-309). as is normally used for shipping. Restore cell to
normal shape.
j. Cement patch, opposite red fabric side, with
two coats of black rubber cement (C-444) and allow 2. Do not store fuel cells where they will be
each coat to dry 10 to 15 minutes. subjected to heat or extremes of humidity.
28-3/28-4
BHT-205A1-CR&O-1
HYDRAULIC SYSTEM
TABLE OF CONTENTS
Paragraph Page
Number Title Number
29-1 Hydraulic system ......... ........... .. ....................... 29-2

29-2 Hydraulic accumulator (single system) .......................................... 29-2
29-7 Hydraulic accumulator (dual system) ............................................ 29-4
29-12 Dual hydraulic servo actuator mounting bracket .................................. 29-5
29-14 Seal replacement - cyclic hydraulic servo actuator ............................... 29-5
29-15 Seal replacement - collective hydraulic servo actuator ........................... 29-20
29-16 Seal replacement - anti-torque hydraulic servo actuator .......................... 29-24
29-17 Rotor brake master cylinder ................................................... 29-25
29-23 Hydraulic reservoir ........................................................... 29-31
LIST OF FIGURES
Figure Page
Number Title Number
29-1 Accumulator hydraulic (single system) ......................................... 29-3

29-2 Accumulator hydraulic (dual system) ............................................ 29-4
29-3 Hydraulic accumulator limits chart (dual system) ................................. 29-5
29-4 Dual hydraulic actuator mounting bracket damage limits ........................... 29-6
29-5 Seal replacement - cyclic hydraulic servo actuator ............................... 29-8
29-6 Procedural steps ............................................................. 29-9
29-7 Work aids ...................................... 29-10
29-8 Channel seal installation tool ................................ 29-12
29-9 Seal installation .............................................................. 29-13
29-10 Test block work aid ........................................................... 29-15
29-11 Hydraulic test set up .................. ....................... 29-16
29-12 Seal positioning ............................................................. 29-17
29-13 Actuator ......................................................... 29-18
29-14 Collective servo actuator ...................................................... 29-21
29-15 Anti-torque servo actuator ..................................................... 29-26
29-16 Rotor brake master cylinder .................................... ............. 29-28
29-17 Damage limits - rotor brake assembly master cylinder ........................... 29-30
Rev. 2 29-1
BHT-205A 1-CR&O-1
29-1. HYDRAULIC SYSTEM. Figure and

Item Number Nomenclature
When repairs, overhaul, special tools, spare parts, or
service manuals for the module assembly, main 29-1, 1 Cap
hydraulic actuators (cyclic and collective), or 29-1,7 Cartridge
anti-torque actuator are required, contact the 29-1, 10 Piston
following for nearest approved service facility.
Hydraulic Research Textron 29-5. REPAIR - HYDRAULIC ACCUMULATOR.

Valencia, California 91355
CAUTION: CLEANING OF ACCUMULATOR OR
29-2. HYDRAULIC ACCUMULATOR (SINGLE OTHERHYDRAULICSYSTEMCOMPONENTS SHALL
SYSTEM). BE ACCOMPLISHED USING SOLVENT, P-D-680,
TYPE II (C-304) ONLY.
29-3. DISASSEMBLY - HYDRAULIC
1. Remove minor nicks and scratches with (300
ACCUMULATOR.
to 400 grit) aluminum oxide cloth (C-406).
1. Remove lockwire.
2. After completion of repair, clean parts with
2. Remove cap (1, figure 29-1) and shims (2). solvent (C-304).
NOTE: Shims should be kept in groups for 3. Repair damage to anodized finish by applying a
reinstallation in same position. protective chemical film (C-100).
3. Remove springs (3 and 4) and piston (10)from

4. Replace all parts that cannot be reworked to
cartridge(7). meet repair criteria. (Refer to figure 29-3.)
4. Remove shims (5) from piston (10). 5. Discard all packings at overhaul regardless of
condition.
5. Remove packing (8) and packing retainer (9)
6. Replace parts if thread damage exceeds 50%
from piston (10). of one thread.
6. Clean and inspect for corrosion and other

visible damage. 29-6. REASSEMBLY - HYDRAULIC
ACCUMULATOR.
ACCUMULATOR.
29-4. INSPECTION - HYDRAULIC 1. Install new packing (8, figure 29-1) and
ACCUMULATOR. packing retainer (9) on piston (10).
1. Inspect all surfaces and threaded areas for 2. Apply a light coat of hydraulic fluid (C-002) or
damage, galling, burrs, excessive wear, and petrolatum (C-008) to packing and retainer. Insert
corrosion. piston into cartridge (7).
NOTE: Excessive wear shall be defined as any 3. Install shims (5) on piston (10).
obvious deformation or deterioration of parts which
may render the accumulator inoperative. 4. Install springs (3 and 4) on piston (10).
2. Inspect the following parts by fluorescent 5. Place shims (2) in cap (1) and install cap.
penetrant method.
6. Torque cap (1) 40 to 50 inch-pounds.
NOTE: Refer to BHT-ALL-SPM manual for approved
fluorescent penetrant material (Post Emulsified 7. Secure cap (1) to lower end of cartridge (7)
Penetrant System). with lockwire (C-405).
29-2
BHT-205A 1-CR&O-1
1. Cap
2. Shim
3. Spring
4. Spring
5. Shim
6. Plate, Ident
7. Cartridge
8. Packing Preformed MS28775-212
9. Retainer, Packing MS28875-212
10. Piston
Figure 29-1. Accumulator hydraulic (single system)
29-3
BHT-205A 1-CR&O-1
29-7. HYDRAULIC ACCUMULATOR (DUAL 29-10. REPAIR- HYDRAULICACCUMULATOR.

SYSTEM).
1. Remove minor nicks and scratches with 600 to
The hydraulic accumulator consists of a 800 grade aluminum oxide cloth (C-406).
spring-loaded piston enclosed in a cylindrical body.
Purpose is to prevent entry of air into servo actuators 2. After completion of repair, clean parts with
when operating manually, by supplying fluid to make solvent (C-304).
up any leakage past seals.
3. Repair damage to anodized finish by applying a
29-8. DISASSEMBLY - HYDRAULIC protective chemical film (C-100).
ACCUMULATOR.
1. Remove lockwire between cap (figure 29-2)

and lock (6).
2. Back off nut (5) until lock is free of cap. 1. Cap

2. Spring
3. Piston
3. Remove cap (1). 4. Packing
4. Packing
5. Nut
4. Remove spring (2) and piston (3) from body. 6. Lock
Remove packing (4) from piston. 7. Body
29-9. INSPECTION - HYDRAULIC

ACCUMULATOR.
CAUTION: CLEANING OF ACCUMULATOR OR

OTHER HYDRAULIC SYSTEM COMPONENTS SHALL
BE ACCOMPLISHED USING SOLVENT, P-D-680,
TYPE II (C-304) ONLY.
1. Inspect all surfaces and threaded areas for

damage, galling, burrs, excessive wear, and
corrosion.
NOTE: Excessive wear is defined as any

deformation or deterioration of parts which render the
unit inoperative.
2. Inspect the following parts by fluorescent

penetrant method.

fluorescent penetrant material (Post Emulsified
Penetrant System).
Figure and
Item Number Nomenclature
29-2, 1 Cap
29-2, 3 Piston
29-2, 5 Nut
29-2, 7 Body Figure 29-2. Hydraulic accumulator (dual system)
29-4
BHT-205A1-CR&O-1
4. Replace all parts that cannot be reworked to meet 29-12. DUAL HYDRAULIC SERVO
repair criteria. (Refer to figure 29-3.) ACTUATOR MOUNTING BRACKET.
5. Discard all packing at overhaul regardless of 2913. INSPECTION AND REPAIR - DUAL
condition.
HYDRAULIC SERVO ACTUATOR MOUNTING
6. Replace parts if thread damage exceeds 50% of BRACKET.
one thread.
1. Inspect mounting bracket for mechanical and
2-11. REASSEMBLY HYDRAULIC corrosion damage. (Refer to figure 29-4 for damage
ACCUMULATOR. limits.
2. Apply two coats of primer (C-204) to all surfaces
1. Lubricate packing with hydraulic fluid (C-002) or 2 two coats primer(C-204)to all surfaces
1. Lubricat packing with hydraulic fluid (C-002) or of mounting bracket and bearing nut except for threads
petrolatum (C-008), place packing (4, figure 29-2) on and mounting holes. Refer to BHT-ALL-SPM
piston (3), lubricate piston. Insert piston (3) into body.
2. Coat spring2.(2)Coatspring(2)with
with grease(C-001orC-007)and
grease (C-001 or C-007) and 3. Fill mounting bracket with corrosion preventive
place over end of piston inside body (7). compound (C-104) prior to installing bearing boot.
3. Assemble nut (5) and lock (6) on body (7). Turn 29-14. SEAL REPLACEMENT CYCLIC
nut far enough onto threads to keep lock (6) clear of cap HYDRAULIC SERVO ACTUATOR.
(1) during installation.
TOOLS REQUIRED
4. Thread cap (1) on body (7) until bottomed out,
then back off until nearest key slot aligns with lock (6). T41000470-19 Tool Kit
Turn nut toward cap (1) until lock (6) is in slot.
5. Torque nut (5) 100 to 200 inch-pounds. Secure NOTE: All new seals shall be lubricated upon
cap (1) to lock (6) with lockwire (C-405). installation, with hydraulic fluid (C-002).
ACCUMULATOR BODY ACCUMULATOR PISTON
MIN. MAX
ITEM NOMENCLATURE INCHES
1. Accumulator Body Piston Bore 1.116 1.120
2. Accumulator Piston 1.113 1.115
3. Accumulator Piston Guide 1.495 1.497
Figure 29-3. Hydraulic accumulator limits chart (dual system)
Rev. 2 29-5
BHT-205A1-CR&O-1
AREA C FINISH ALL SURFACES AREA C

EXCEPT THREADS
DRILL EXISTING AREA

HOLE TO 0.125 AREA C
INCH DIAMETER
AREA B
TYP 4 PLACES
212-076-116
AREA A AREA B AREA C
NICKS SCRATCHES, DENTS 0.005 In. 0.020 In. 0.002 In.

AND CORROSION
MAXIMUM AREA PER 0.05 Sq. In. 0.50 Sq. In. 0.05 Sq. In.
FULL DEPTH REPAIR
NUMBER OF REPAIR AREAS One Two One
EDGE CHAMFER 0.010 In. 0.020 In.
205A1-R-29-4
Figure 29-4. Dual hydraulic actuator mounting bracket damage limits
29-6 Rev. 2
BHT-205A1-CR&O-1
CAUTION: REPAIR SERVO ACTUATOR IN A I. Position retainer plate (9) with countersunk
CLEAN DUST-FREE AREA. ENSURE THAT holes outboard and secure to upper cap assembly (1)
POLISHED ACTUATOR SURFACES AND LAPPED with the three screws.
SERVO AND BYPASS VALVES DO NOT INCUR
DAMAGE DURING REPAIR PROCEDURE. m. Remove and replace channel seal (11) and
preformed packing (12) in groove in smaller ID of upper
CAUTION: EXTERNAL CLEANING OF ACTUATOR cap assembly (1). Ensure that preformed packing is
OR OTHER HYDRAULIC SYSTEM COMPONENTS inside of OD of channel and that edges of seal are in
SHALL BE ACCOMPLISHED USING SOLVENT, grooves of upper cap assembly.
P-D-680, TYPE II (C-304) ONLY.
n. Remove and replace preformed packing (13) in
CAUTION: INTERNAL CLEANING OF ACTUATOR groove in the larger ID of upper cap assembly (1).
COMPONENTS SHALL BE ACCOMPLISHED USING
METHYLENE CHLORIDE. REFER TO A.S.B.
205-88-29 AND A.S.B. 205-88-30. cylinder assembly (6).
1. Replace seal in upper cap assembly (1, figure .p. Tighten upper cap assembly (1) until it bottoms
29-5) as follows:
a. Position servo cylinder in a suitable fixture to q. Screw retainer nut (7) with lock key (8) against
prevent damage during the following operations. (Refer the upper cap assembly (1).
to figure 29-6.) Suitable work aids may be made as
shown in figure 29-7. NOTE: The lock key must fit into a slot in the upper cap
assembly; therefore, the upper cap assembly may be
b. Remove sealant from clevis (2, figure 29-5) and rotated (backed-off) to closest slot until the lock key is in
jamnut (3). proper position.
c. Remove lockwire from jamnut (3) and lock key r. Holding upper cap assembly (1) with a suitable
(4). tool, tighten retainer nut (7) with spanner wrench and
torque to 250 to 300 inch-pounds against upper cap
d. Loosen jamnut (3) and unscrew clevis (2) from assembly (1).
upper piston (5).
s. Secure retainer nut (7) and lock key (8) with
e. Remove lockwire from retainer nut (7) and lock lockwire (C-405).
key (8).
t. Install clevis (2) with lock key (4) and jamnut (3)
f. Hold upper cap assembly (1) and, using a in upper piston (5).
spanner wrench, loosen retainer nut (7). Back off
retainer nut sufficiently so that lock key will be clear of u. Adjust clevis (2) to a 1.625 inch dimension
slot in upper cap assembly. measured from center of clevis bolt hole to top of upper
piston (5).
g. Place suitable container in position to receive
any hydraulic fluid retained in upper cylinder assembly. v. Tighten jamnut (3) with lock key (4) and torque
jamnut (3) to 600 to 780 inch-pounds.
h. Remove upper cap assembly (1) from upper
cylinder assembly (6). w. Securejamnut (3) and lock key (4) with lockwire
(C-405) and apply adhesive (C-308) around threads of
i. Seal open end of upper cylinder assembly to clevis (2), lock key (4), and jamnut (3). Cure adhesive 12
prevent contamination by foreign matter. hours prior to installation.
j. Remove three screws securing retainer plate (9) 2. Replace seal in upper cylinder assembly (6, figure
to upper cap assembly (1). 29-5) as follows:
k. Remove and replace scraper ring (10) in upper a. Position servo cylinder in a suitable fixture to
cap assembly (1). prevent damage during assembly.
NOTE: Position collar of scraper ring outboard. b. Remove upper cap assembly. (Refer to step 1.)
Rev. 2 29-7
BHT-205A1-CR&O-1
1. Upper Cap Assembly 11. Channel Seal (S12562-120) 21. Preformed Packing (MS28775-212) (3 reqd) 31. Preformed Packing (MS28775-125) 41. Link
2. Clevis 12. Preformed Packing (MS28775-120) 22. Retaining Plate 32. Channel Seal (S12562-120) 42. Spool Valve Linkage
3. Jam Nut 13. Preformed Packing (MS28775-224) 23. Jam Nut 33. PreformedPacking (MS28775-120) 43. IrreversibleAssembly
4. Lock Key 14. Retaining Nut 24. Scraper Ring (S1 1065-9-T) 34. Lower Piston 44. Cap Screws
5. Upper Piston 15. Servo Head Assembly 25. Channel Seal (S12562-120) 35. Lower Cylinder Assembly 45. Channel Seal (S12562-120)
6. Upper Cylinder Assembly 16. Shoulder Screw 26. Preformed Packing (MS28775-120) 36. Deleted 46. PreformedPacking (MS28775-120)
7. Retainer Nut 17. Nut 27. Lower Cylinder End Cap 37. PreformedPacking (7124MR972P4) 47. PreformedPacking (MS28775-125)
8. Lock Key 18. Clip 28. Cap Screws 38. Connecting Cylinder Assembly 48. Rod End Bearing
9. Retainer Plate 19. Deleted 29. Retainer Plate 39. Nut 49. Lock Key
10. Scraper Ring (S11065-9-T) 20. Preformed Packing (7124MR972P4) 30. Scraper Ring (S11065-9-T) 40. ShoulderScrew 50. Jam Nut
Figure 29-5. Seal replacement - cyclic hydraulic servo actuator
29-8
BHT-205A1-CR&O-l
step 1 step 2
step 3 STEP4
Figure 29-6. Procedural steps
c. Remove lock wire from retaining nut (14) and temporary installation of shoulder screw (16) to retain
using a wrench, loosen retaining nut (14). connecting cylinder assembly (38) and servo head
assembly (15).
d. Remove cotter pin from shoulder screw (16).
nut (17),and clip (18).
g. Tighten retaining nut (14) finger tight to limit
CAUTION: ENSURE THAT SERVO HEAD movement of servo head assembly (15) and complete
ASSEMBLY DOES NOT ROTATE OR MOVE AFT removal of upper piston (5) and uppar cylinder
WHEN LOOSENED AS DAMAGE TO SPOOL VALVES assembly (6) as a unit.
COULD RESULT.
NOTE: Handle unit with care as upper piston is loose
e. Remove shoulder screw (16). and can easily fall out.
f. Unscrew upper piston rod 15) in a h. Remove upper piston (5) from upper cylinder
counterclockwise direction sufficiently to allow assembly (6).
29-9
BHT-205A1-CR&O-1
29-10 Holding Blocks

MATERIAL:
WOODOR EQUIVALENT
MATERIAL:
DUPONT PLASTIC TRADE NAME "DELRIN"
OR ANY NON-METALLIC MATERIAL
Channel Seal Remover
Figure 29-7. Work aids
29-10
BHT-205A1-CR&O- 1
i. Remove and replace preformed packing (20) s. Continue to install (turn clockwise) upper
in groove of dam on upper piston (5). piston (5) until it bottoms out on retaining nut (14).
j. Remove three screws securing retaining plate t. Back off retaining nut (14) and continue to
(22) to jamnut (23). install upper piston (5) until the three holes (servo
head (1 5), connecting cylinder (38), and upper piston
k. Remove and replace scraper ring (24) in (5)) are in alignment.
jamnut (23). Position collar of scraper ring outboard.
l. Position retainer plate (22) with countersunk NOTE: Holes in servo head, connecting cylinder
holes outboard and secure to jamnut (23) with the assembly and upper piston must be aligned in order to
three screws. install shoulder screw (16).
m. Remove and replace channel seal (25) and u. Installshoulder screw (16), clip (18), and nut
preformed packing (26) in groove of ID of upper
cylinder (6). If difficulty is encountered during the
installation of channel seal (25), fabricate a tool as
follows: v. Tighten retaining nut (14) and torque
205-076-036-1 nut 200 to 250 inch-pounds and
(1) Fabricate a special tool per figure 29-8. lockwire (C-405). Torque 205-076-036-3, -5, -7, and
Wrap a strip of 1/4 inch masking tape (C-426) around -9 nut to 500 to 550 inch-pounds and lockwire
tool 7/16 inch from blunt end as shown in figure 29-9. (C405)
(2) Insert the blunt end of tool into cylinder as 3. Replace seal in lower cylinder end cap (27),
shown in figure 29-9. Bend channel seal as shown in and lower piston (34) as follows:
figure 29-9 and slide seal into bottom of cylinder and
place in seal slot. (Tool will provide stop so seal will a. Position servo cylinder in a suitable holding
not slide past groove.) Press seal into groove with fixture.
finger. Remove tool.
b. Remove lockwire and four cap screws (28)
(3) Insert taper end of tool into lower portion with washers which secure lower cylinder end cap
of cylinder and rotate until seal is seated properly. (27) to lower cylinder assembly (35).
(Refer to figure 29-9.)
c. Remove lower cylinder end cap (27) from
n. Install upper piston (5, figure 29-5) in upper lower cylinder assembly (35). Place suitable
cylinder assembly (6). container to receive any hydraulic fluid retained in
lower cylinder assembly.
o. Install upper cap assembly on upper cylinder
assembly. (Refer to step 1.) d. Remove three screws securing retainer plate
(29) to lower cylinder end cap (27).
p. Remove and replace three preformed
packings (21) in grooves 1,3, and 5 in servo head e. Remove and replace scraper ring (30) in
assembly (15). lower end cap assembly (27).
NOTE: Groove 2 and 4 are fluid grooves and remain

open. NOTE: Position collar of scraper ring outboard.
q. Position upper piston (5), with upper cylinder f. Position retainer plate (29) with countersunk
assembly (6) and upper cap assembly (1), in place in holes outboard and secure to lower cylinder end cap
servo head assembly (15). (27) with the three previously removed screws.
r. Back off upper piston (5) enough to allow g. Remove and replace preformed packing (31)
removal of shoulder screw (16). from OD groove of lower end cap (27).
29-11
BHT-205A1-CR&O-1
0.25 RADIUS
DIA
0.9985 D IA 0.50 DIA
0.980DIA 0.9975
2.66
(REF)
6.0
(DIM. FOR 0.9985-0.9975 DIA)
11.75
MATERIAL: DUPONTPLASTIC, TRADENAME"DELRIN"
OR SIMILARMATERIAL
1. Channel Seal (Glyd. Ring)

2. Servo Actuator Cylinder
3. Channel Seal Insert Tool
Figure 29-8. Channel seal installation tool
29-12
BHT-205A 1-CR&O-1
UPPER
CYLINDER
CHANNELSEAL
7/16"
O' RING
CHANNEL PUSH AND
IS SEATED
PROPERLY
Figure 29-9. Seal installation
h. Remove and replace channel seal (32) and m. Secure lower cylinder end cap (27) in place
preformed packing (33) from ID groove of lower end with four cap screws (28) and washers. Torque
cap (27). screws 50 to 60 inch-pounds.
NOTE: Ensure that preformed packing is inside of n. Secure four cap screws (28) with lockwire
OD of channel seal and that edges of seal are in (C-405).
grooves of lower cylinder end cap. 4. Replace seal in connecting cylinder assembly
i. Remove lower piston (34) from lower cylinder (38) as follows:
assembly. Remove port plugs temporarily in order to a. Position servo cylinder in a suitable fixture.
relieve air lock, then replace.
b. Secure spool valve linkage with 1/4 tape
j. Remove and replace preformed packing (37) around irreversible valve. (Refer to step 3, figure
from OD groove in dam of lower piston (34). 29-6.)
k. Install lower piston (34) in place in lower c. Remove cotter pin from nut (39, figure
cylinder assembly (35). 29-5), washer, shoulder screw (40), and four teflon
washers securing link (41) to connecting cylinder
I. Install lower cylinder end cap (27) in place on (38) and two servo valve spool linkages (42) of
lower cylinder assembly (35). irreversible assembly (43).
29-13
BHT-205A1-CR&O-1
CAUTION: ENSURE THAT THE SERVO VALVE p. Remove 1/4 inch tape used to hold servo
SPOOL LINKAGE DOES NOT BECOME DISENGAGED valve linkage.
AS DAMAGE TO INTERNAL SPOOL VALVES COULD
RESULT. 5. Replace seal in valves as follows:
d. Remove lockwire and four cap screws (44)

securing connecting cylinder (38) to lower cylinder NOTE: It is recommended that customers having
assembly (35). machine shop facilities at their disposal make up a
test block work aid to assure that there is no leakage
e. Move lower piston (34) to extended position. to spool valves prior to installation. (Figure to figure
Remove port plugs temporarily installed to relieve air 29-10.) A Hydraulic Test Set Up can also be
lock. Replace after lower piston is extended. constructed locally as shown in figure 29-11. Ensure,
however, that the pump has a shut-off feature to
f. Separate connecting cylinder (38) from lower ensure that pressure can be depleted prior to
cylinder assembly (35). Place suitable container to removing sleeve from test block. A 204/205 ground
receive any hydraulic fluid retained in assembly. handling wheel pump is an example of the type of
pump desired.
CAUTION: HANDLE LOWER CYLINDER ASSEMBLY a. Place actuator assembly on a clean work
AND LOWER PISTON WITH CARE. LOWER PISTON IS surface that is well lighted. Bleed residual pressure at
FREE IN THE LOWER CYLINDER ASSEMBLY AND indicated points shown in figure 29-12. Protect
CAN EASILY FALL OUT. removed parts from damage by placing parts in clean
individual plastic bags.
g. Remove and replace channel seal (45) and
preformed packing (46) from first ID groove in b. Lubricate all preformed packings with
connecting cylinder assembly (38). hydraulic fluid (C-002) or petrolatum (C-008).
Identify all reusable parts.
NOTE: Inboard ID groove is an open groove. c. Clean all parts thoroughly with solvent
(C-304).
h. Remove and replace preformed packing (47)
in OD groove of connecting cylinder assembly (38). 6. Replace seal in the lower cylinder bypass valve
as follows:
i. Reinstall connecting cylinder assembly (38)
in lower cylinder assembly (35). a. Remove shoulder bolt and four teflon
spacers. (Refer to figure 29-13.) Turn pivot link away
j. Align dowel pin with hole in connecting from actuator assembly. Note the position of the
cylinder assembly. (-1 actuators only.) teflon spacers for reinstallation after seal
replacement.
k. Secure with four cap screws (44). Torque to
50to 60 inch-pounds. NOTE: The spool and sleeve have matching serial
numbers and must not be interchanged. Be sure to
I. Lockwire four cap screws (44). tag before removal.
m. Position
two servothevalve linkages (42) b. Remove the six spool valve retaining screws,
and link (41) in place on connecting cylinder (38). slide boot in direction of linkage and remove retainer
plate.
n. Install four teflon washers one on each side
of servo links. (1) Insert T41105920-8 tool into lower
irreversible cylinder at the bottom side of spool valve.
o. Install
screwshoulder
(40), washer and nut ith a mallet, tap on lower end of tool to remove
(39). Tighten and install cotter pin. spool and sleeve. Ensure that the sleeve is guided to
prevent damage to spool and sleeve on removal.
29-14
BHT-205A 1-CR&O-1
MS33514-4
FOR TEST PURPOSES

INSTALLINBOARDAND
OUTBOARD O-RINGSONLY
MAKE FROM PLASTIC OR

SIMILARMATERIAL
MAKE FROM CRES
/ 4------
MS33649-4
0.31
TYP
DIAMETER
TO BE
CONCENTRIC
WITHIN 0.001 T I R.
Figure 29-10. Test block work aid
29-15
BHT-205A1-CR&O-1
Figure 29-11. Hydraulic test set up
(2) Remove opposite spool and sleeve c. Slide the T41000470-20-001 tool with seal
assembly in same manner as step 6.b.(1). installed over valve assembly until bottomed. Slide
the seal into position on the spool (link end of
c. Remove the spool valve assemblies from the assembly). Remove spool assembly from tool. Install
sleeve assemblies. T41105950-10 seal sizing tool, to reform seal, hold
tool compressed for about one minute, remove sizing
CAUTION: DO NOT ADJUST JAMNUTS. IF THE tool. Install spool assembly in its matched sleeve.
LOCK TORQUE SEAL IS BROKEN, THE SERVO Push spool sufficiently to allow end of spool to
ASSEMBLY MUST BE RETURNED TO AN protrude from end of sleeve until the inner land of seal
AUTHORIZED OVERHAUL FACILITY FOR VALVE groove is exposed. (Refer to figure 29-12.)
TIMING.
CAUTION: DO NOT EXPOSE MORE THAN THE
d. Remove spool from sleeve. Remove and FULL WIDTH OF THE LAND AS THIS WILL CAUSE
discard MS28775-015 packing from sleeve (four DAMAGE TO THE FIRST SEA INSTALLED ON THE
packings per sleeve) bag sleeve and identify location. OPPOSITE SIDE.
Carefully remove and discard seal from spool (two
d. Position T41000470-24 seal installation
each per spool). Bag assembly of spool, wire drive, tool on the protruding spool to the middle of the first
support, boot, and link, identify with mating sleeve land and install one T41000727 Jo seal, using
(these are a matched lapped set). 41105940-9 tool, push Jo seal into groove with
pressure cavity facing other seal. Remove tool from
7. Reassemble spool and sleeve as follows:
spool assembly.
a. Install M28775-015 packing (four Install T41105950-10 seal sizing tool with
required) on bypass sleeves. pilot end (flanged) of tool toward sleeve, compress
sizing tool, hold for about one minute and retract
b. Install T41000470-21 loader into end of spool into sleeve until end of spool is approximately
T41000470-20-001 seal installation tool, being flush with sleeve. Remove sizing tool.
certain loader is bottomed. Place one 41000727 Jo
seal on loader end of installation tool with pressure f. To test seals prior to inserting spool valve and
cavity face (exposed O-ring) of seal towards sleeve assembly into cylinder assembly the following
installation tool (figure 29-12). Use T41105950-9 procedures are recommended:
tool to push seal into load area of the seal installation
tool. After seal is in place, remove the loader end of (1) Install only the outboard O-rings on the
tool. sleeve for testing purposes.
29-16
BHT-205A1-CR&O-1
BLEED RESIDUAL
PRESSUREBEFORE
BEGINNING DISASSEMBLY
DUSTER CAP AND

RETAINER RINGS
REMOVE SERVO HEAD

RETAINING BOLTS
UPPERVALVE BODY
* SEAL POSITION FOR

ALL VALVES
SPOOL
VALVE
RETAINER
SLEEVE RETAINER CAP SCREWS
LEVER SHOULDER BOLT
SHOULDER BOLT
DO NOT EXPOSEMORE THAN

THE FULL WIDTH OF THE SHOULDER BOLT
LAND AS THIS COULD CAUSE
DAMAGE TO OPPOSITESEAL.
Figure 29-12. Seal positioning
29-17
BHT-205A 1-CR&O-1
LINK ASSEMBLY
TEFLON SPACERS
(4 EACH)
SHOULDER BOLT
VALVE LINKAGE
RETAINING NUTS
RETAINING SCREWS
BYPASS LINKAGE
RETAINER PLATE
LOWER ACTUATOR
Figure 29-13. Actuator
(2) Insert the sleeve and valve assembly into CAUTION: DO NOT ALLOW SPOOL POSITION TO
the test block. CHANGE WITH TOOL IN PLACE, INSTALL SPOOL
AND SLEEVE ASSEMBLY INTO THE BORE FROM
NOTE: Ensure that the valve does not move in WHICH THE ASSEMBLY WAS REMOVED. SLIDE
relation to the sleeve as damage to the seals could BOOT AND RETAINER BACK TO CLEAR SUPPORT.
occur. TAP LIGHTLY WITH A SMALL MALLET TO INSTALL
ASSEMBLY. REMOVE PIN AND CAREFULLY REMOVE
(3) Apply 1200 to 1500 pounds of pressure INSTALLATION TOOL. DO NOT MOVE VALVE
to test block and check for any leakage. ASSEMBLY AFTER INSTALLATION INTO HOUSING.
(4) Deplete pressure and remove sleeve and b. Repeat all substeps of step 7. and step a.,
valve assembly from test block utilizing fabricated
above, for second spool and sleeve assembly.
tool as noted in figure 29-10.
(5) Install remaining two O-rings following c. Reinstall sleeve retainer plate using six
completion of test. screws.
8. Install spool and sleeve assembly into housing d. Thread T41105950-6 alignment tool onto
as follows: shoulder bolt and reinstall teflon spacers, working
with shoulder bolt until all washers are installed.
a. Attach 41000470-18 spool and sleeve Remove T41105950-6 tool. Install nut and cotter
installation tool to spool and sleeve assembly. key. Ensure that bolt is able to rotate after installation.
29-18
BHT-205A1-CR&O-1
9. Disassemble servo head, servo and bypass i. Remove from the spool and sleeve assembly
spool, and sleeve assemblies as follows: and discard MS28775-015 packing from sleeve. Bag
sleeve and identify position. Carefully remove and
NOTE: Prior to removal of any parts, identify for discard 41000392 seal and 41000598 compression
reinstallation. Note the direction and location of bolts ring from spool (two each per spool). Bag spool
and spacers for reinstallation. assembly, valve assembly, support, boot and link,
identify with mating sleeve (these are a matched
a. Remove the three shoulder bolts (figure serial numbered lapped set).
29-13) and teflon spacers which secure the lever
assembly to the interconnect cylinder.
10. Reassemble servo head, servo and bypass
b. Position cylinder to upper end of actuator spool, and sleeve assemblies as follows:
rod.
a. Sleeve seals:
c. Remove two servo head retaining bolts,
nearest lever, from valve body. (1) Servo sleeves. Install MS28775-015
packing (six required).
d. Remove the two retaining rings and dust
caps on top of valve body. (2) Bypass sleeves. Install MS28775-015
packing (four required).
e. Remove the six screws that secure the
sleeve retainer plate. Slide boot toward the link b. Servo spool and bypass spool:
assembly and remove retainer plate.
(1) Install T41000470-21 loader into end of
f. Using T411059520-8 sleeve extractor tool, T41000470-20-001 seal installation tool being
carefully remove the servo spool and sleeve assembly certain loader is bottomed. Place one 41000727 Jo
by inserting through the top of valve body. seal assembly on loader end of installation tool with
pressure cavity face (exposed O-ring) of seal towards
CAUTION: UNDER NO CIRCUMSTANCES, SHALL installation tool. Use T41105950-9 to push seal onto
THE JAMNUTS BE ADJUSTED IN THE FIELD. IF THE load area of the seal installation too. After seal is in
LOCK TORQUE SEAL IS BROKEN, THE SERVO place, remove loader end of tool.
ASSEMBLY MUST BE RETURNED FOR VALVE
TIMING. (2) Position spool assembly in seal
installation tool by bottoming. Slide the seal into the
g. Remove spool from sleeve. Remove and groove of spool (link end of assembly). Remove spool
discard MS28775-015 packing from sleeve (six assembly from tool. Install T41105950-10 seal
packings per sleeve) bag sleeve and identify position. sizing tool to reform seal, hold tool compressed for
Carefully remove and discard 41000392 seal and about one minute, remove tool. Position spool
41000598 compression ring from the spool (two assembly in its matched sleeveand allow end of spool
each per spool). Bag assembly of spool, valve to protrude from end of sleeve until the inner land of
assembly, support, boot and link, identify with seal groove is exposed.
mating sleeve (these are a matched serial number
lapped set).
CAUTION: DO NOT EXPOSE MORE THAN THE
h. Using T41105920-8 sleeve extractor tool, FULL WIDTH OF THE LAND AS THIS COULD CAUSE
carefully remove, as an assembly, the bypass spool DAMAGE TO THE FIRST SEAL INSTALLED ON
and sleeve assembly. OPPOSITE END.
CAUTION: UNDER NO CIRCUMSTANCES, SHALL (3) Position T41000470-24 seal installation

THE JAMNUTS BE ADJUSTED IN THE FIELD. IF THE tool on the protruding spool to the middle of the first
LOCK TORQUE SEAL IS BROKEN, THE SERVO land and install one 41000727 Jo seal assembly into
ASSEMBLY MUST BE RETURNED FOR VALVE groove with pressure cavity facing other seal.
TIMING. Remove tool from spool assembly.
29-19
BHT-205A1-CR&O-1
(4) Install T41105950-10 seal sizing tool with externalleakage. Disassembleonlytodepthrequiredto

pilot end (flanged) of tool toward sleeve, compress replace seal(s) which are leaking; i.e., do not remove
sizing tool approximately one minute and retract spool piston rod assembly (33, figure 29-14) if only the seals
into sleeve until end is approximately flush with sleeve. associated with cylinder cap (27) are defective. Perform
Remove sizing tool. only the steps applicable for replacement of faulty seals.
(5) If tools are available, test for leakage, refer CAUTION: REPAIR SERVO ACTUATOR IN A
to step 7.f. CLEAN, DUST-FREE AREA. ENSURE THAT
POLISHED ACTUATOR SURFACES AND LAPPED
11. Install spool and sleeve assembly into housing SERVO AND BYPASS VALVES DO NOT INCUR
DAMAGE DURING REPAIR PROCEDURE.
a. Attach T41000470-18 spool and sleeve

installation tool to spool and sleeve assembly. CAUTION: EXTERNAL CLEANING OF ACTUATOR
OR OTHER HYDRAULIC SYSTEM COMPONENTS
CAUTION: DO NOT ALLOW SPOOL POSITION TO SHALL BE ACCOMPLISHED USING SOLVENT,
CHANGE WITH TOOL IN PLACE. INSTALL SPOOL P-D-680, TYPE II (C-304) ONLY.
AND SLEEVE ASSEMBLY INTO THE BORE FROM
WHICH THE ASSEMBLY WAS REMOVED. TAP CAUTION: INTERNAL CLEANING OF ACTUATOR
LIGHTLY WITH A SMALL MALLET TO INSTALL COMPONENTS SHALL BE ACCOMPLISHED USING
ASSEMBLY. TO REMOVE THE INSTALLATION TOOL, METHYLENE CHLORIDE. REFER TO A.S.B.
FIRST REMOVE THE PIN THEN ROTATE THE 205-88-29 AND A.S.B. 205-88-30.
INSTALLATION TOOL SO THAT IT LIES OVER THE
LINK AND WIRE DRIVE AND CAREFULLY 1. Remove control tube assembly (22) from
WITHDRAW THE INSTALLATION TOOL AWAY FROM actuator.
THE SERVO HEAD.
b. Bypass spool and sleeve assembly: 2. Cut lockwire and loosen cylinder locknut (17)
sufficiently to disengage key lock (16). Remove cylinder
(1) Repeat step a. above. cap (27). Remove screws (23), retainer plate (24) and
rod wiper (21). Remove packings (18 and 19) and
(2) Reinstall sleeve retaining plate using six channel seal (20).
screws previously removed.
3. Cut lockwire and loosen jamnut (42). Remove
(3) Thread T41105950-6 alignment tool onto shoulder screw (40). Turn piston rod assembly (33) to
shoulder bolt and reinstall teflon spacers and shoulder disengage from yoke (43) and withdraw piston rod
bolts. Remove the T41105950-6 tool. Install nuts and assembly from hydraulic servo housing assembly (39).
cotter key. Ensure that bolts are able to rotate after Remove packings (34, 36, and 38).
installation.
4. Remove three screws (32), retainer plate (31),
(4) Reinstall upper dust covers, snap rings and and rod wiper (30). Remove retainer nut (29) and tab
dust boots. washer (8). Remove housing (10), bushing set (11), and
bearing (9). Remove cylinder (28) from piston rod
(5) Reinstall the two valve body bolts. assembly (33). Remove packing (12) and channel seal
(13). Remove seal cap (26).
29-15. SEAL REPLACEMENT - COLLECTIVE 5. Install new packing (12) and channel seal (13) in
HYDRAULIC SERVO ACTUATOR. cylinder (28). Lubricate packing with hydraulic fluid
(C-002) or petrolatum (C-008) to prevent damage to
Repair of servo actuator is limited to replacement of seal during installation. Fabricate and use work aid
damaged packings which cause external leakage. A illustrated infigure29-8to install channel seal (13, figure
functional check is required after repair. 29-14). Install new seal cap (26) and seal ring (25) on
piston rod assembly (33); lubricate lightly with hydraulic
NOTE: This procedure is applicable for replacement fluid (C-002) or petrolatum (C-008). Position piston rod
of all seals associated with actuator which may cause assembly (33) in cylinder (28).
29-20 Rev. 2
BHT-205A1-CR&O-1
SECTION A-A
1. Actuating Lever 17. Cylinder Lock Nut 33. Piston Rod

2. Bolt 18. Packing (MS28775-224) 34. Packing (MS28775-212)
3. Link Assembly 19. Packing (MS28775-120) 35. Flow Groove
4. Nut 20. Channel Seal (S12562-120) 36. Packing (MS28775-212)
5. Torque Lacquer 21. Rod Wiper (S11065-9-T) 37. Flow Groove
6. Servo Valve 22. Tube Assembly 38. Packing (MS28775-212)
7. Accumulator 23. Screw 39. Housing Assembly
8. Tab Washer 24. Retainer Plate 40. Shoulder Screw
9. Bearing 25. Deleted 41. Washer
10. Housing 26. Seal Cap (7125MR972P4) 42. Jam Nut
11. Bushing Set 27. Cylinder Cap 43. Yoke
12. Packing (MS28775-120) 28. Cylinder 44. Shoulder Screw
13. Seal (S12562-120) 29. Retainer Nut 45. Nut
14. Nut 30. Rod Wiper (S11065-9-T) 46. Nut
15. Boot 31. Retainer Plate 47. Plug and Bleeder
16. Key Lock 32. Screw
Figure 29-14. Collective servo actuator (Sheet 1 of 3)
29-21
BHT-205A1-CR&O-1
52 53
48. By-Pass Valve

49. Packing (200260-18)
50. Packing (200260-18)
51. By-Pass Spool Sleeve
52. Retainer
53. Spring
54. Spring
55. Ring
56. Packing (MS2875-020)
57. Piston
58. Packing (MS2875-113)
59. Packing (MS28775-015)
29-22
BHT-205A1-CR&O-1
PRESS
6. Install packing (19), channel seal (20), and inch-pounds and secure to tab washer (8) with
packing (18) in cylinder cap (27). Install cylinder cap lockwire (C-405). Install rod wiper (30) and retainer
on cylinder; bottom the threads and back off to first plate (31) with three screws (32). Assemble housing
keyway to permit engagement of cylinder locknut (10), bushing set (11), and nut (14). Lubricate with
(17) and key lock (16); torque 250 to 300 grease (C-007) and adjust nut (14) so that 25 to 50
inch-pounds and secure with lockwire (C-405). inch-pounds force is required to move bearing
Install retainer plate (24) and rod wiper (21) with through its travel
three screws (23).
7. Position boot (15), nut (14), housing (10), 8. Install packings (34, 36, and 38) in housing
bushing set (11), bearing (9), and tab washer (8) on assembly (39); use light coat of hydraulic fluid
cylinder. Install retainer nut (29). Torque 150 to 200 (C-002) or petrolatum (C-008) on packings.
29-23
BHT-205A1-CR&O-1
CAUTION: ENSURE THAT PACKINGS ARE IN INSTALLED IN ITS CORRECT POSITION. AVOID
CORRECT POSITION; DO NOT INSTALL IN FLOW FORCING THE SPOOL INTO POSITION. THE
GROOVES (35 AND 37). SPOOLS AND THEIR MATING SLEEVES ARE A
LAPPED FIT; DAMAGE TO THE SPOOL SLEEVES OR
9. Assemble piston rod assembly (33) in housing PACKINGS MAY OCCUR IF CARE IS NOT TAKEN
(39). Engage threads of piston rod assembly (33) and DURING INSTALLATION.
yoke (43) to full bottoming depth; back off minimum
amount until shoulder screw (40) can be installed. Install d. Rotate actuating lever (1) into position and
shoulder screw (40) and nut (46); secure with cotter pin. install shoulder screw (44) to attach both link assemblies
Ensure washer (41) is installed; torque jamnut (42) 200 (3) to actuating lever and yoke. Nut (45) is a castellated,
to 250 inch-pounds; secure with lockwire (C-405). self-locking type; install washer and adjust nut (45) to
eliminate end play but loose enough to permit shoulder
10. Install control tube (22). screwto be rotated by hand. Install cotter pin. Check bolt
(40) to ensure that it will also rotate by hand and that it
11. Replace leaking seals in servo and bypass is properly secured with a cotter pin.
valves as follows:
a. Remove shoulder screw (44) and rotate 2916. SEAL REPLACEMENT - ANTITORQUE
actuating lever assembly (1) upward to permit removal HYDRAULIC SERVO ACTUATOR.
of servo valve spool and/or bypass valve spool for
replacement of faulty seals. NOTE: The following instructions cover repair and
seal replacement for the 205-076-031 servo actuator.
CAUTION: IF BOTH SPOOLS REQUIRE When repair is required on the 212-076-004 servo
REPLACEMENT OF SEALS, ENSURE THAT COLOR actuator, contact Hydraulic Research Textron, Valencia,
CODE IS PRESENT OR IDENTIFY THE SPOOLS California 91355 for latest repair bulletin or nearest
FOR REPLACEMENT IN THE SAME LOCATION overhaul facility.
FROM WHICH REMOVED. IT IS POSSIBLE TO
INSTALL SERVO VALVE SPOOL IN BYPASS VALVE Repair of the anti-torque servo actuator is limited to
SPOOL SLEEVE AND TO INSTALL BYPASS VALVE replacement of damaged packings which cause
SPOOL IN SERVO VALVE SLEEVE. external leakage. A functional check is required after
repair.
b. Carefully withdraw servo valve spool (6) and/or
bypass valve spool from servo housing assembly (39) CAUTION: REPAIR SERVO ACTUATOR IN A
with link assembly (3) attached. CLEAN, DUST-FREE AREA. ENSURE THAT
POLISHED ACTUATOR SURFACES AND LAPPED
CAUTION: DO NOT BREAK TORQUE LACQUER SERVO AND BYPASS VALVES DO NOT INCUR
OR DISTURB NUT (4). THE ADJUSTMENT OF THE DAMAGE DURING REPAIR PROCEDURE.
LINK ASSEMBLY (3) ON THE SPOOL MUST NOT BE
CHANGED. CAUTION: EXTERNAL CLEANING OF ACTUATOR
OR OTHER HYDRAULIC SYSTEM COMPONENTS
NOTE: Packings (49 and 50) shown in section C-C for SHALL BE ACCOMPLISHED USING SOLVENT,
bypass valve, are also typical of servo valve spool (6) P-D-680, TYPE II (C-304) ONLY.
shown in section A-A.
CAUTION: INTERNAL CLEANING OF ACTUATOR
c. Remove two packings (49 and 50) from spool. COMPONENTS SHALL BE ACCOMPLISHED USING
Clean spool and install two new packings. Lubricate METHYLENE CHLORIDE. REFER TO A.S.B.
packings with a light coat of hydraulic fluid (C-002) or 205-88-29 AND A.S.B. 205-88-30.
petrolatum (C-008). Carefully install spool in its correct
sleeve in housing. If spool is not to be reinstalled 1. Replace leaking seals in the actuator as follows:
immediately, package to prevent corrosion or
mechanical damage. NOTE: This procedure is applicable for replacement
of all seals associated with actuator which may cause
CAUTION: ENSURE THAT SERVO VALVE SPOOL external leakage. Disassemble only to depth required to
OF BYPASS VALVE SPOOL, AS APPLICABLE, IS replace seal(s) which are leaking; i.e., do not
29-24 Rev. 2
BHT-205A 1-CR&O- 1
remove piston rod assembly (33, figure 29-15) from i. Install new packings (28, 30, and 32) in
hydraulic housing assembly (34) if only seals hydraulic servo housing assembly; use light coat of
associated with the cylinder housing assembly are hydraulic fluid (C-002) or petrolatum (C-008) on
defective. Perform only the steps_applicable to packings.
replacement of the-faulty-seal(s)
CAUTION: ENSURE THAT PACKINGS ARE IN
a. Remove control tube assembly (15), from CORRECT POSITION; DO NOT INSTALL PACKINGS
actuator. IN FLOW GROOVES (29 AND 31).
b. Cut lockwire and loosen cylinder locknut j. Assemble piston rod assembly (33) into
(23) sufficiently to disengage key lock (12). Separate housing (34). Engage piston rod assembly and yoke
cylinder cap (24) from cylinder housing assembly (35) to full bottoming depth; back off until shoulder
(22). Remove three screws (16), rod wiper retainer screw (37) can be installed. Install shoulder screw
plate (17) and rod wiper (18). Remove cylinder (37), washer (38), and nut (39); safety with cotter
housing from piston rod (33). Remove packing (14) pin.
and channel seal (13).
k. Install control tube (15).
c. Remove shoulder screw (37). Pull piston rod
assembly (33) to disengage from yoke (35) and 29-17. ROTOR BRAKE MASTER CYLINDER.
withdraw piston rod assembly from hydraulic servo
housing assembly. Remove packings (28, 30, and 29-18. DISASSEMBLY- ROTOR BRAKEMASTER
32). CYLINDER.
d. Remove three screws (27), rod wiper 1. Remove filler cap (9, figure 29-16) and draw
retainer plate (26), and rod wiper (25). Remove fluid from cylinder.
cylinder cap assembly (24) from piston rod assembly.
Remove packing (11). 2. Remove handle pivot bolt (15). Remove handle
and piston assembly (11) as a nut.
e. Remove packing (19).
3. Remove link (14) from handle and piston.
f. Clean and inspect all parts. If servo actuator
is not to be reassembled immediately, package to
prevent corrosion and mechanical damage. CAUTION: EXERCISE CARE WHEN REMOVING
CAP (13). SPRING (10) EXERTS APPROXIMATELY
g. Install new packing (14) and channel seal 250 POUNDS OF FORCE ON CAP.
(13) in cylinder housing assembly (22). Install new
rod wiper (18) and rod wiper retainer plate (17) on 4. Position piston assembly (11) in arbor press
cylinder housing assembly with three screws (16). with cap (13) up. Apply sufficient pressure to relieve
Install new packing (19) on piston. Install new pressure on retaining ring (12).
packing (11), channel seal (10) and packing (9) in
cylinder cap (24). Install rod wiper (25) and rod wiper 5. Carefully remove retaining ring (12) and relieve
retainer plate (26) on cylinder cap with three screws pressure on cap.
(27).
6. Apply approximately 35 pounds of pressure to
h. Lubricate seals installed in step g. with a light sleeve (5), remove retaining ring (25) and relieve
coat of hydraulic fluid (C-002) or petrolatum (C-008) pressure on sleeve.
and assemble the piston rod assembly (33), cylinder
housing assembly (22) and cylinder cap (24). Ensure 7. Remove sleeve (5) and springs (18 and 20).
that cylinder cap bottoms on cylinder housing Check for washers at base of spring (18).
assembly; then back off until key lock (12) can be
engaged; torque cylinder locknut 300 to 400 8. Remove retainer (19), spring (21), and poppet
inch-pounds and secure with lockwire (C-405). valve (23).
29-25
BHT-205A1-CR&O-1
1. Lever Assembly 21. Identification Plate

2. Link Assembly 22. Cylinder Housing
3. Nut 23. Cylinder Lock Nut
4. Torque Lacquer 24. Cylinder Cap
5. Servo Spool 25. Rod Wiper (205000-A)
6. Packing (200260-18) 26. Retainer Plate
7. Packing (200260-18) 27. Screw
8. Servo Sleeve 28. Packing (MS28775-116)
9. Packing (MS28775-116) 29. Flow Groove
10. Channel Seal (S12562-116) 30. Packing (MS28775-116)
11. Packing (MS28775-217) 31. Flow Groove
12. Key Lock 32. Packing (MS28775-116)
13. Channel Seal (S12562-116) 33. Piston Rod
14. Packing (MS28775-116) 34. Housing Assembly
15. Tube Assembly 35. Yoke
16. Screw 36. Shoulder Screw
17. Retainer Plate 37. Shoulder Screw
18. Rod Wiper (205000-A) 38. Nut
19. Packing (7117MR972P4) 39. Nut
20. Deleted
Figure 29-15. Anti-torque servo actuator (Sheet 1 of 2)
29-26
BHT-205A1-CR&O-1
40. By-pass Spool

41. Bolt
42. Torque Lacquer
43. Servo Spool
44. By-pass Spool
45.Packing (200260-18
46. Packing (200260-18)
47. By-pass Sleeve
SECTIONB B
Figure 29-15. Anti-torque servo actuator (Sheet 2 of 2)
29-27
BHT-205A1-CR&O-1
ALTERNATECONFIGURATION
1. Plug 16. Stop

2. Retaining Ring 17. Adjustment Washer
3. Plug 18. Spring
4. Packing 19. Retainer
5. Sleeve 20. Spring
6. Spring 21. Spring
7. Main Housing 22. Packing
8. Piston 23. Adjustable Poppet Valve
9. Filler Cap 24. Poppet Valve
10. Spring 25. Retaining Ring
11. Piston Assembly 26. Handle
12. Retaining Ring 27. Spring Pin
13. Cap 28. Washer
14. Link 29. Spring
15. Pivot Bolt 30. Pin
VIEW A - A 204076-2000
Figure 29-16. Rotor brake master cylinder
29-28
BHT-205A1-CR&O-1
9. Apply approximately five pounds pressure to 9. Install link (14) and handle (26) on piston
piston (8) and remove stop (16). Remove piston along assembly (11).
with spring (6).
10. Install piston assembly in housing and install
10. Remove retaining ring (2) and plug (1). handle pivot bolt (15) and cotter pin.
NOTE: Do not remove pin (30) unless damaged or 11. Install plug (1) and retaining ring (2).
excessively worn.
12. Install plug (3) and filler cap (9).
11. Remove and discard all packings and glyd
rings except packings (4 and 22). Discard packings (4 13. Install pin (30), spring (29), washer (28), and
and 22) only if damaged. spring (27) if these parts were removed during
disassembly.
29-19. ASSEMBLY - ROTOR BRAKE MASTER
CYLINDER. 29-20. INSPECTION - ROTOR BRAKE MASTER
CYLINDER.
1. Install spring (6, figure 29-16) and piston (8) in
housing (4). CAUTION: CLEANING OF MASTER CYLINDER OR
OTHER HYDRAULIC SYSTEM COMPONENTS SHALL
CAUTION: USE CARE WHEN HANDLING OR BE ACCOMPLISHED USING SOLVENT, P-D-680,
INSTALLING PACKINGS AND GLYD RINGS TO AVOID TYPE II (C-304) ONLY.
NICKS, CUTS, OR OTHER DAMAGE.
1. Clean all components using solvent (C-304).
2. Install packing on stop (16). Compress piston
(8) sufficiently to clear hole for stop. Install and 2. Inspect all parts for cracks or other damage.
tighten stop. No cracks are allowed.
NOTE: Apply a light coat of hydraulic fluid (C-002) 3. Inspect springs for condition.
or petrolatum (C-008) to surfaces of all internal
components. 4. Inspect housing and components for
serviceability (figure 29-17).
3. Install poppet valve (23), spring (21), and
retainer (19) into poppet valve (24). Turn retainer (19) 5. Glyd ring and packing working surfaces shall
clockwise until outer surface of retainer is flush with be free from pitting or other imperfections and shall
end of poppet valve. conform to a finish of 15 RHR.
4. Install springs (18 and 20) in piston (11). 6. Inspect bolts for excessive wear and thread
damage.
5. Install poppet assembly from step 3. in sleeve
(5). 29-21. REPAIR - ROTOR BRAKE MASTER
CYLINDER.
6. Install poppet and sleeve assembly in piston
(11). While compressing sleeve into piston, install TOOLS REQUIRED
retaining ring (25).
Repair Kit 204-1653-1
7. Install spring (10) and cap (13) in piston
assembly (11). NOTE: The components of the master cylinder are
not repairable. Unserviceable components shall be
8. Position piston assembly in an arbor press with replaced with like serviceable items.
cap (13) up. Apply sufficient force (approximately
250 pounds) to compress spring and install retaining 1. Replace cracked or otherwise unserviceable
ring (12). components.
29-29
BHT-205A 1-CR&O-1
2 Sleeve ID 0.438 0.441

3 Main Piston OD 1.308 1.311
4 Cylinder Housing ID 1.313 1.316
5 Main Piston ID 0.875 0.878
6 Sleeve OD 0.872 0.874
7 8 Piston
Main Piston (204-076-315) OD 2.495
2.450 2.498
2.480PISTON
9 Cylinder Housing ID 2.500 2.503
10 Main Piston ID 2.125 2.128
11 PlugAssembly OD 2.109 2.115
12
13 Plug Bushing
Link Bushings ID
ID 0.250
0.250 0.255
0.265
14 Figure 29-17.
Handle Bushing
Damage limits - rotor ID assembly
brake master
0.250 cylinder
13 Link Bushings 0.250 0.256
ID 0.265
14 Handle Bushing ID 0.250 0.256
15
15 Handle PivotPoint
Handle Pivot Point ID
ID 0.250
0.250 0.257
0.257
16
16 Handle
Handle Pivot
Pivot Bolt
Bolt Bushings
Bushings ID
ID 0.87250
0.250 0.256
0.256
OD
2.450
2.42001
2040766-315)
204076-2001
Figure 29-17. Damage limits-rotor brake assembly master cylinder

BHT-205A1-CR&O-1
LANDING GEAR
TABLE OF CONTENTS
Paragraph Page
Number Title Number
32-1 Skid landing gear ............................................................. 32-2

32-3 Skid shoes - landing gear ................... ................................. 32-3
32-5 Crosstubes - landing gear.................................................... 32-6
32-7 Ground handling gear (204-050-200) ........................................... 32-9
32-10 Wheel and tire assembly ................... ................................... 32-9
32-12 Tubeless tire ................................................................. 32-9
32-15 Tube type tire ........................................................ ... 32-11
32-19 Ground handling gear hydraulic pump ........................................ 32-11
32-22 Ground handling gear hydraulic ram and trunnion ................................ 32-13
32-26 Ground handling gear (212-050-200) ........................................ 32-13
32-29 Wheel and tire assembly .................................................... 32-15
32-31 Tubeless tire ......... ........................ ........................... 32-15
32-34 Tube type tire ................................................. .. ....... 32-15
32-38 Ground handling gear hydraulic pump ........................................ 32-16
32-41 Ground handling gear hydraulic ram and trunnion ................................ 32-16
32-44 Ground handling gear axle ............ ................................. 32-17
32-47 Ground handling gear fixed forward pin ........................................ 32-17
32-50 Ground handling gear bushing ................................................. 32-17
LIST OF FIGURES
Figure Page
Number Title Number
32-1 Skid tube repair limits ........................................................ 32-2

32-2 Landing gear skid tube repair ............................................... 32-3
32-3 Repair of landing gear skid shoes .............................................. 32-4
32-4 Crosstube supports ........................................................... 32-7
32-5 Crosstube supports damage and repair limits ......... ................... 32-8
32-7 Ram/Pump assembly repair kits ......... ..................... 32-12
32-9 Ground Handling wheel axle drilling (212-050-200) ............................... 32-18
Rev. 2 32-1
BHT-205A 1-CR&O-1
32-1. SKID LANDING GEAR. d. Position and secure patch in place on skid
tube. Drill rivet holes. Remove patch and deburr as
necessary.
32-2. REPAIR - SKID TUBE.
e. Remove paint and dirt from damaged area
and both sides of patch.
1. Patch repair skid tubes as follows:
f. Apply a coat of primer (C-201 or C-204) to
NOTE: Patch repairs are limited to the top of skid patch area and to both sides of patch. Allow primer to
tube in areas as shown in figure 32-1. dry. Coat faying surface of skid tube patch with
adhesive (C-308).
a. Polish out scratches and dents. Trim and g. Position patch and use CR2248-6-3 rivets to
smooth rough edges of holes. rivet in place.
b. Fabricate a patch of 0.095 wall thickness h. Apply a coatof primer (C-201 orC-204)over
2024-T3 aluminum alloy tube, WW-T-700/3, or repaired area. When dry, apply two coats of paint, to
equivalent. Rivet pattern shall be as shown in figure match original finish.
32-2.
i. Apply two coats of walkway coating (C-223)
c. Verify that patch fits skid tube contour and to front steps (pilot and copilot). Apply second coat
lay out rivet hole pattern. after 30 minutes drying time.
PATCH MAY EXTEND
NOTE
No patches are allowed
under skid shoes.
NOTE
No patches are allowed under skid shoes.
Figure 32-1. Skid tube repair limits
32-2
BHT-205A1-CR&O-1
MINIMUM OF 4 ROWS
ONE ROWOF
NAS 1738B-6-3
EQUALLY SPACED @ 4 x
RIVET DIA MAX
TYPICAL PATCHREPAIR
Figure 32-2. Landing gear skid tube repair
32-3. SKID SHOES - LANDING GEAR. 2. Repair damaged skid shoe tabs as follows:
32-4. REPAIR - SKID SHOES. a. Cut off damaged tab parallel to skid tube, or,
CAUTION: PRIOR TO ANY WELDING REPAIR, if damaged tab can be straightened, reshape to
REMOVE SKID SHOE FROM SKID TUBE TO AVOID original configuration, figure 32-3, details A and B.
DAMAGE TO THE ALUMINUM SKID TUBE DUE TO b. If damaged tab has been cut from shoe,
EXCESSIVEHEAT. fabricate a similar tab from normalized 4130 steel,
NOTE: Excessive dents in attaching skid shoe tab MIL-S-18729, 0.050 inch thickness. Butt weld per,
may be hot reformed or reshaped, provided dents do MIL-W-8611, fabricated tab along cut line of shoe.
not exist within a minimum distance of 2.0 inches of Grind weld smooth on side adjacent to skid tube.
any borium weld beads.
c. If damaged tab has been reshaped to original
1. Repair elongated hole in attaching tabs of configuration, fabricate a doubler from same material
shoe, exceeding 0.030 inch, as follows: in preceding step b. Position doubler over existing tab
and weld all around contact area of doubler and shoe,
a. Fabricate an appropriate circular or figure 32-3, detail A.
elongated doubler of 4130 steel 0.050 inch
thickness, normalized per MIL-S-18729, as shown in 3. Check bottom of skid shoes for evidence of
figure 32-3, details C and D. weld bead. Do not use skid shoes that have weld
NOTE: On all repairs requiring welding, remove beads completely worn off. (Referto figure 32-2.)
cadmium plating from both surfaces prior to welding.
NOTE: Transverse cracks across weld beads are
b. Secure doubler to shoe tab by welding per permissible and should not be cause for repair or
MIL-W-861 1 around entire periphery of doubler. replacement of skid shoes.
32-3
BHT-205A1-CR&O-1
Note 1 Note 2
Fabricate doubler of normalized Fabricate doubler of normalized 4130

4130 steel, MIL-S-18729, 0.050 steel, MIL-S-18729, and of same
inch thickness and of same configuration as removed tab. Grind
configuration as damaged tab. weld smooth on side adjacent to skid
tube.
WELD DOUBLER SEVERELY DAMAGED TAB
TO DAMAGED SKID MAY BE CUT OFF AND
SHOE TAB AS SHOWN REPLACED BY BUTT
(SEE NOTE 1) WELDING DOUBLER TO SKID
SHOE AS SHOWN (SEE TAB (REF)
2)TAB
NOTE
BUTT WELD
0.30" 0.30"
(MINIMUM)T
SKID SKID
SHOE SHOE (REF)
DETAIL A DETAIL B
(TAB REPAIR) (TAB REPLACEMENT)
SKID SHOE REPAIR/REPLACEMENT (TYPICAL)
WELD DOUBLER TO
TAB AS SHOWN
(SEE NOTE 1)
0.30"R- 0.62"R
0.182"
SKID SHOE - SKID SHOE
DETAIL C DETAIL D
(CIRCULAR DOUBLER REPAIR) (ELONGATED DOUBLER REPAIR)
ELONGATED HOLE REPAIR
Figure 32-3. Repair of landing gear skid shoes (Sheet 1 of 2)
32-4
BHT-205A1-CR&O- 1
I
Figure 32-3. Repair of landing gear skid shoes (Sheet 2 of 2)
32-5
BHT-205A1-CR&O-1
4. Reform bead as follows: c. Apply a coat of primer (C-204) over repaired

area. When dry, apply two coats of paint to match
f. Remove cadmium plating from skid shoes in original finish. Refer to BHT-ALL-SPM manual.
accordance with step 5.
g. Weld beads 0.06 to 0.10 inch high along skid 32-6. CROSSTUBES- SUPPORT
shoe using acetylene and 0.125 inch hard facing REPLACEMENT.
(borium) weld tube (C-484) or DT 600 HM 0.125 inch
hard facing weld tube (C485). 1. Replace forward and aft crosstube supports as
follows:
h. Hot reform skid shoe, as required, to fit contour
of skid tube. a. Measure the distance between outboard edges
of ribs on top support (2, figure 32-4). Distance should
i. Apply a coat of primer (C-204) to skid shoe. be 28 inches. Verify that one support is located 14
When dry, apply two or three coats of lacquer (C-203) to inches from the center of crosstube to outboard edge of
match original finish. rib.
5. Removecadmiumplatingfromskidshoespriorto b. Remove nut (5 or 10) and washer (4 or 9).

welding repair as follows: Remove U-bolt (1 or 6) attaching supports (2 and 3 or 7
and 8) to crosstube.
CAUTION: STRIPPED PARTS ARE VERY

SUSCEPTIBLE TO CORROSION AND SHALL CAUTION: DO NOT EXCEED 250°F (121°C) WHEN
IMMEDIATELY BE REPAIRED AND PRIMED. HEATING SUPPORTS.
a. Mix a solution of 16 ounces of ammonium c. Heat and remove supports (2 and 3 or 7 and 8).
nitrate per gallon of water.
CAUTION: DO NOT USE METAL TOOLS OR
b. Maintain solution at a temperature of 120°F OBJECTS TO REMOVE SUPPORTS OR SEALANT
(49°C). Immerse skid shoes into solution until all FROM CROSSTUBE.
cadmium plating has been removed. Rinse shoes in
clear water and air dry. d. Remove sealant from crosstube and supports
with MEK (C-309) and a stiff bristle brush.
c. After repair and cleanup of weld deposits, apply
brush cadmium plating (C-108), or two coats of primer e. Apply a thin coat of sealant (-308) on supports
(C-204). When dry, apply two or three coats of lacquer (2 and 3 or 7 and 8) and support area of crosstubes.
(C-203) to match original finish.
f. Locate supports to dimensions in step a.
32-5. CROSSTUBES - LANDING GEAR. NOTE: Torque must be applied within five minutes of
sealant application.
32-5A. CROSSTUBES - SUPPORT REPAIR. g. Install U-bolts (1 or 6), washers (4 or 9) and nuts
(5 or 10). Torque nuts 100 inch-pounds.
1. Repair crosstube supports (2, 3, 7, and 8, figure
32-4) as follows: h. Allow twenty-five minutes for wet sealant to
squeeze out, then retorque nuts (5 or 10) 100
a. Damage may be worked out, using emory cloth, inch-pounds.
and polished out with 400 grit abrasive cloth or paper or
abrasive pad to smooth out all scratches and to i. Coat remaining bare areas with primer (C-204)
eliminate abrupt thickness changes. Cleanup shall not and allow to dry.
exceed damage limits of figure 32-5.
j. Apply a bead of sealant (C-308) around edge of
b. Where anodized surface is removed by repairs, supports (2 and 3 or 7 and 8). Allow to cure at room
restore finish with chemical film treatment (C-100). temperature for 72 hours. Refinish reworked area with
Refer to BHT-ALL-SPM manual. lacquer (C-203).
32-6 Rev. 2
BHT-205A1-CR&O-1
1 U-bolt - wd 6 U-bolt - aft

2. Support - fwd upper 7. Support - aft upper
3. Support - fwd lower 8. Support - aft lower
4. Washer 9. Washer
5. Nut 10. Nut
NOTE
Apply a bead of adhesive (C-308) around entire
periphery of supports.
Figure 32-4. Crosstube supports
Rev. 2 32-7
BHT-205A1-CR&O-1
205-050-132-001
205-050-133-001
CROSSTUBE - FWD
205-050-132-003
205-050-133-003
CROSSTUBE - AFT
MECHANICAL 0.020 In.
CORROSION 0.020 In.
MAXIMUM AREA FOR 1.00 Sq. In.

FULL DEPTH REPAIR
NUMBER OF REPAIRS 2
EDGE CHAMFER 0.050 In.
BORE DAMAGE 0.020 In. for 1/4 circumference

205A1-R-32-5
Figure 32-5. Crosstube supports damage and repair limits
32-8 Rev. 2
BHT-205A1-CR&O-1
32-7. GROUND HANDLING GEAR (30) is serviced properly, cause is probably internal
(204-050-200). hydraulic leak in hydraulic pump (30).
32-8. REMOVAL - GROUND HANDLING GEAR. 32-10. WHEEL AND TIRE ASSEMBLY.
1. Retract wheels individually, lower helicopter to 32-11. REMOVAL-WHEELANDTIRE

skid by turning T-handle of hydraulic pump valve. ASSEMBLY.
2. If installed, remove pin (24, figure 32-6) of lanyard

(27) from release pin (25). WARNING: IF INSTALLED, DEFLATE TIRE PRIOR
TO REMOVING NUT (2, FIGURE 32-6). IF WHEEL
3. Push release pin (26) to disengage spring-loaded THROUGH BOLTS ARE NOT PROPERLY
support pin (21) from eyebolt. INSTALLED, AN INFLATED TIRE MAY CAUSE
WHEEL HALVES TO SEPARATE WHEN NUT (2) IS
4. Remove ground handling gear from skid gear. REMOVED.
NOTE: The following procedures are applicable to

32-9. INSPECTION - GROUND HANDLING both wheel and tire assemblies of the ground handling
GEAR. gear.
1. Inspect tire and wheel assemblies (4, figure 32-6) 1. Deflate tire.
for tire damage and deterioration when tires are
installed. Check both tires for inflation to 45 psi. Inspect 2. Remove cotter pin (1, figure 32-6), nut (2), retainer
wheel for corrosion, cracks, and secure installation on (3), and wheel bearing.
axles.
3. Remove tire and wheel assembly (4).
2. Inspect hydraulic pump (30) for proper servicing,
corrosion, obvious mechanical damage, and secure 32-12. TUBELESS TIRE
installation on cradle assembly (19).
3. Inspect hydraulic ram (16) exterior for scratches 32-13. REMOVAL -TUBELESS TIRE.
or nicks. Scratches or nicks exceeding 0.005 inch in
depth are cause for replacement. Polish out minor NOTE: The ground handling wheel tires may be of the
scratches with fine India stone (C-464). Inspect threads tube type or tubeless type.
for damage.
1. With ground handling gear removed from skid,
4. Inspect structureforlooseand missing bolts, nuts, remove wheel assembly (4, figure 32-6) from axle by
and general condition. removing cotter pin (1), nut (2) and retainer (3), and
wheel bearing.
5. Inspect support pin (18) and spring pin (14) to
ensure they are not sheared and are adequately 2. Remove valve core from valve stem.
secured.
WARNING: ENSURE THAT TIRE IS DEFLATED
6. Inspect lubrication fitting (28) for secure PRIOR TO REMOVING WHEEL THROUGH BOLTS IN
installation and for damage. FOLLOWING STEP
7. Perform functional check of ground handling gear. 3. After airflow has stopped, remove nut from wheel
Install ground handling gear on helicopter landing gear through bolts and separate wheel halves.
skid and raise helicopter.
4. Remove valve stem, if required.
8. Inspect for hydraulic leaks. If ground handling
gear will not raise helicopter, and the hydraulic pump 5. Remove and discard wheel seal.
Rev. 2 32-9
BHT-205A1-CR&O-1
1. Cotter pin 17. Tee and elbow fitting

2. Nut 18. Support pin
3. Retainer 19. Cradle assembly
4. Wheel assembly 20. Spring
5. Axle 21. Support pin
6. Support rod 22. Nicopress sleeve
7. Ball-lock pin 23. Lanyard
8. Lubricator pin 24. Pin
9. Clevis 25. Release pin
10. Setscrew 26. Release pin
11. Washer 27. Connecting pin
12. Nut 28. Lubrication fitting
13. Trunnion 29. Ram arm
14. Spring pin 30. Hydraulic pump
15. Hose 31. Setscrew
16. Hydraulic ram 32. U-Bolt
205A1-R-32-6
Figure 32-6. Ground handling gear (204-050-200)
32-10 Rev. 2
BHT-205A1-CR&O-1
32-14. INSTALLATION - TUBELESS TIRE. 32-18. INSTALLATION - WHEEL AND TIRE

ASSEMBLY.
1. Place new wheel seal on inboard machined
surface of wheel half. NOTE: The following procedures are applicable to
both wheel and tire assemblies of the ground handling
2. Install new valve stem, if required. gear.
1. Apply a bead of grease (C-001) around axle shaft

3. Place tire on wheel half. Place opposite wheel half and wheel bearing.
on tire and align through bolt hole and valve stem.
2. Place wheel and tire assembly (4, figure 32-6) on
4. Place a steel washer on each through bolt and axle. Place wheel bearing and retainer (3) on axle and
install through wheel halves. Install steel washer and nut install nut (2). Secure nut (2) with cotter pin (1).
on each bolt. Torque nuts 125 to 150 inch-pounds.
3. Service hydraulic pump and hydraulic rams with
5. Inflate tire to 45 psi. hydraulic fluid (C-002).
32-19. GROUND HANDLING GEAR

32-15. TUBE TYPE TIRE. HYDRAULIC PUMP.
32-16. REMOVAL -TUBE TYPE TIRE. 32-20. REMOVAL - GROUND HANDLING GEAR
HYDRAULIC PUMP.
1. With ground handling gear removed from skid, 1. Place suitable vessel to catch fluid. Disconnect
remove wheel assembly (4, figure 32-6) from axle by hose (15, figure 32-6) from tee and elbow fitting (17).
removing cotter pin (1), nut (2), retainer (3), and wheel Cap or plug open hose and fitting.
bearing.
2. Remove four nuts (12) and washers (11) from two
2. Remove valve core from tube valve stem. U-bolts (32).
3. After air flow has stopped, remove nuts from 3. Remove hydraulic pump (30) and U-bolts (32)
wheel through bolts and separate wheel halves. from cradle assembly (19).
Remove tire and tube.
4. Remove tee and elbow fitting (17) from hydraulic
pump (30).
32-17. INSTALLATION - TUBE TYPE TIRE. 5. Refer to figure 32-7 for proper repair kit for
overhaul of hydraulic pump (30, figure 32-6).
1. Insert tube into tire. Place tire and tube on wheel
half and feed valve stem through hole in inner flange of
wheel. 32-21. INSTALLATION - GROUND HANDLING
GEAR HYDRAULIC PUMP.
2. Place opposite wheel half on tire and align valve 1. Apply tape (C-448) to pipe threads of tee and
stem and through bolt holes. elbow fitting (17, figure 32-6) and install tee and elbow
fitting in hydraulic pump (30). Position tee and elbow
3. Place a steel washer on each through bolt and fitting (17) horizontal to hydraulic pump (30).
install through wheel halves. Install steel washer and nut
on each bolt. Torque nut 125 to 150 inch-pounds. 2. Position hydraulic pump (30) on cradle assembly
(19), with tee and elbow fitting (17) forward and secure
4. Inflate tire to 45 psi. with two U-bolts (32), washers (11) and nuts (12).
Rev. 2 32-11
BHT-205A1-CR&O-1
1.625-12UN-2A
1/4-18 NPT 204-050-170 REF
0.750-16UNF-2B
0.75 FULL THD 3.00 TRAVEL
6.00 MAX
6.38 MAX
7.86 MAX (OVERALL LENGTH RETRACTED)
RAM REPAIR KITS

BHT Part Number Vendor Vendor Part No. Consumables
214-050-104-001 Porter Ferguson BU0955 P/N 330729 Backup Ring
(H.K. Porter)
Somerville, MA P/N 330730 Packing
508-774-1629
214-050-104-101 C.F. Hein-Werner SDO-1651-011 P/N 82070 Repair Kit
Waukesha, WI
414-464-0538
214-050-104-103 A Fort Worth TX SKR214 P/N SKI-214 Repair Kit
817-551-1967
May be purchased from BHT or vendor.
Alternate assembly for -001 and -101.
Purchase from vendor only.

PUMP ASSEMBLY KITS
Dash No. Mfg. Pump RAM Assembly Notes
Effectivity Assembly
-003 28001-28070 BU0953B 214-050-104-001 A Part of P/N 214-706-104-001
Aux. Equipment Kit
-103 Alternate SDO-3032-006 A 214-050-104-101 Uses new pump, ram, and
for -003 release pin
-105 Supersedes BU0953B 214-050-104-001 Similar to -003 with new
-003 forward pin
-107 Alternate SDO-3032-006 214-050-104-101 Similar to -103 with new
for -105 forward pin
Use P/N RBU0953 repair kit; available from BHT or vendor.
See ram repair kit information.
Use P/N 82068 repair kit; available from vendor only. 205A1-R-32-7
Figure 32-7. Ram/Pump assembly repair kits
32-12 Rev. 2
BHT-205A1-CR&O-1
32-22. GROUND HANDLING GEAR 7. Insert hydraulic ram (16) and trunnion (13) into
HYDRAULIC RAM AND TRUNNION. cradle assembly (19).
32-23. REMOVAL- GROUND HANDLING GEAR 32-25. INSTALLATION - GROUND HANDLING

HYDRAULIC RAM AND TRUNNION. GEAR.
1. Drain hydraulic fluid. 1. If necessary, service ground handling gear.
2. Disconnect hose (15, figure 32-6) from tee and 2. Lubricate wheels, actuating arms and cradle
elbow fitting (17). Cap or plug open hoses and fittings. assemblies with grease (C-001).
3. Remove lubricator pin (8) and washers. 3. Check tire pressure.
4. Remove teeand elbow fitting (17)from hydraulic 4. Service hydraulic pump (30, figure 32-6) with
ram (16). hydraulic fluid (C-002) by holding ground handling gear
assembly so that hydraulic pump (30) is in vertical
5. Remove clevis (9) from hydraulic ram (16). position and filling hydraulic pump to filler hole level.
6. Loosen setscrew (31) and remove hydraulic ram 5. Position ground handling gear assembly, with
(16) from trunnion (13). hydraulic pump handle forward, over landing gear skid
tube between eyebolts, and align with eyebolts.
7. Remove piston from hydraulic ram (16).
6. Insert support pin (18) in forward eyebolt and
8. Remove and discard packing and backup ring-loaded support pin (19) in rear eyebolt.
9. Remove trunnion (13) from cradle assembly (19).

NOTE: On helicopters 30554 and subsequent, pull pin
(24) then release pin (25). Engage release pin (25) then
32-24. INSTALLATION - GROUND HANDLING install pin (24) after installing ground handling gear.
GEAR HYDRAULIC RAM AND TRUNNION.
7. Actuate hydraulic pump handle to lower wheels
1. Position trunnion (13, figure 32-6) in cradle and lift skid gear clear of surface.
assembly (19).
NOTE: Refer to figure 32-7 for correct repair kit for 32-26. GROUND HANDLING GEAR
hydraulic ram (16, figure 32-6). (212-050-200).
2. Install packing and backup ring.

32-27. REMOVAL - GROUND HANDLING GEAR.
3. Install piston in hydraulic ram (16).
1. Retract wheels individually, lower helicopter to
4. Screw hydraulic ram (16) into trunnion (13) until it skid by turning T-handle of hydraulic pump valve.
bottoms, then back out until hydraulic outlet is pointing
outboard. 2. Remove pin (5, figure 32-8) from cradle assembly
(29).
5. Install and tighten setscrew (31).
3. Pull fixed forward pin (34) from eyebolt, remove
6. Screw clevis (9) into hydraulic ram (16). ground handling gear from skid gear.
Rev. 2 32-13
BHT-205A1-CR&O-1
1. Wheel assembly
2. Cotter pin
3. Nut
4. Retainer
5. Pin
6. Washer
7. Nut
8. Axle
9. Lubricator pin
10. Cotter pin
11. Washer
12. Clevis
13. Trunnion
14. Elbow
15. Hydraulic ram
16. Tee
17. Hose
18. Setscrew
19. Bolt
20. Washer
21. Washer
22. Setscrew
23. Retainer
24. Bushing
25. Bushing
26. Bushing
27. Nut
28. Washer
29. Cradle assembly
30. Washer
31. Nut
32. Spring pin
33. Bushing
34. Fixed forward pin
35. U-Bolt
36. Hydraulic pump
37. U-Bolt
38. Bolt
39. Washer
40. Axle
41. Washer
42. Nut
205A1-R-32-8
Figure 32-8. Ground handling gear (212-050-200)
32-14 Rev. 2
BHT-205A1-CR&O-1
32-28. INSPECTION - GROUND HANDLING 32-31. TUBELESS TIRE.

GEAR.
GEAR.
1. Inspect tires for proper 32-32. REMOVAL- TUBELESS TIRE.
inflation, cuts and
excessive wear.
NOTE: The ground handling wheel tires may be of the
2. Check hydraulic pump (36, figure 32-8) for proper tube type or tubeless type.
operation. 1. With ground handling gear removed from skid,
remove wheel assembly (1, figure 32-8) from axle by
3. Inspect hydraulic ram (15) exterior for scratches removing cotter pin (2), nut (3) retainer (4) and wheel
or nicks. Scratches or nicks exceeding 0.005 inch depth bearing.
are cause for replacement. Polish out minor scratches
with fine India stone (C-464). Inspect threads for 2. Remove valve core from valve stem.
damage.
WARNING: ENSURE THAT TIRE IS DEFLATED
4. Inspect structure for loose and missing bolts, nuts, PRIOR TO REMOVING WHEEL THROUGH BOLTS IN
and general condition. FOLLOWING STEP.
5. Inspect lubrication fittings for secure installation 3. Afterairflowhasstopped, remove nutfrom wheel
and for damage. through bolts and separate wheel halves.
6. Performfunctionalcheckofgroundhandlinggear. 4. Remove valve stem, if required.

Install ground handling gear on helicopter landing gear 5. Remove and discard wheel seal.
skin and raise helicopter.
7. Inspect for hydraulic leaks. If ground handling 32-33. INSTALLATION-TUBELESS TIRE.

gear will not raise helicopter, and the hydraulic pump
(36) is serviced properly, cause is probably internal 1. Place new wheel seal on inboard machined
hydraulic leak in hydraulic pump (36). surface of wheel half.
2. Install new valve stem, if required.

32-29. WHEEL AND TIRE ASSEMBLY 3. Place tire on wheel half. Place opposite wheel half
on tire and align through bolt hole and valve stem.
32-30. REMOVAL - WHEEL AND TIRE 4. Place a steel washer on each through bolt and
ASSEMBLY. install through wheel halves. Install steel washer and nut
on each bolt. Torque nuts 125 to 150 inch-pounds.
WARNING: IF INSTALLED, DEFLATE TIRE PRIOR
TO REMOVING NUT (3, FIGURE 32-8). IF WHEEL 5. Inflate tire to 75 psi, inflate12.5 x 4.5 tire to 90 psi.
THROUGH BOLTS ARE NOT PROPERLY
INSTALLED, AN INFLATED TIRE MAY CAUSE 32-34. TUBE TYPE TIRE
WHEEL HALVES TO SEPARATE WHEN NUT (3) IS
REMOVED.
32-35. REMOVAL - TUBE TYPE TIRE.
NOTE: The following procedures are applicable to 1. With ground handling gear removed from skid,
both wheel and tire assemblies of the ground handling
gear. remove wheel assembly (1, figure 32-8) from axle by
removing cotter pin (2), nut (3), retainer (4) and wheel
1. Deflate tire. bearing.

2. Remove valve core from tube valve stem.
2. Remove cotter pin (2), nut (3), retainer (4), and
wheel bearing. 3. After air flow has stopped, remove nuts from
wheel through bolts and separate wheel halves.
3. Remove tire and wheel assembly (1). Remove tire and tube.
Rev. 2 32-15
BHT-205A1-CR&O-1
32-36. INSTALLATION - TUBE TYPE TIRE. 3. Remove hydraulic pump (36) and U-bolts (35 and
37) from cradle assembly (29).
1. Insert tube into tire. Place tire and tube on wheel
half and feed valve stem through hole in inner flange of 4. Remove tee (16) from hydraulic pump (36).
wheel.
5. Refer to figure 32-7 for proper repair kit for
2. Place opposite wheel half on tire and align valve overhaul of hydraulic pump (36, figure 32-8).
stem and through bolt holes.
32-40. INSTALLATION-GROUND HANDLING
on each bolt. Torque nut 125 to 150 inch-pounds.

1. Apply tape (C-448) to pipe threads of tee (16,
figure 32-8) and install tee (16) in hydraulic pump (36).
2. Position hydraulic pump (36) on cradle assembly
NOTE: The following procedures are applicable to

both wheel and tire assemblies of the ground handling 32-41. GROUND HANDLING GEAR
gear. HYDRAULIC RAM AND TRUNNION.
1. Apply a bead of grease (C-001) around axle shaft

and wheel bearing. 32-42. REMOVAL- GROUND HANDLING GEAR
HYDRAULIC RAM AND TRUNNION.
2. Place wheel and tire assembly (1, figure 32-8) on
axle. Place wheel bearing and retainer (4) on axle. 1. Drain hydraulic fluid.
Install nut (3) and secure with cotter pin (2).
2. Disconnect hose (17, figure 32-8) elbow (14). Cap
3. Service hydraulic pump and hydraulic rams with or plug open hoses and fittings.
hydraulic fluid (C-002).
3. Remove cotter pin (10) from lubricator pin (9) and
remove lubricator pin (9) and washers (11 and 21).
32-38. GROUND HANDLING GEAR
HYDRAULIC PUMP. 4. Remove elbow (14) from hydraulic ram (15).
5. Remove clevis (12) from hydraulic ram (15).

32-39. REMOVAL-GROUND HANDLING GEAR
HYDRAULIC PUMP. 6. Loosen setscrew (18) and remove hydraulic ram
(15) from trunnion (13).
1. Place suitable vessel to catch fluid. Disconnect
hose (17, figure 32-8) from tee (16). Cap or plug open 7. Remove piston from hydraulic ram (15).
hose and fitting.
8. Remove and discard packing and backup ring.
2. Remove nuts (27 and 31) and washers (28 and
30) from two U-bolts (35 and 37). 9. Remove trunnion (13) from cradle assembly (19).
32-16 Rev. 2
BHT-205A1-CR&O-1
32-43. INSTALLATION - GROUND HANDLING 2. Adjust both clevis (12) with ram fully extended, to
GEAR HYDRAULIC RAM AND TRUNNION. hold both axes at 1.98 inch dimension (view B, figure
32-9). Adjust set screw (22, figure 32-8) to contact axle
1. Position trunnion (13, figure 32-8) in cradle and allow lubricator pin (9) to be installed. Install
assembly (29). lubricator pin (9). Position arm on axles (view A, figure
32-9), and line drill axles 0.316 to 0.322 inch. Remove
NOTE: Refer to figure 32-7 for correct repair kit for axle (8, figure 32-8) and remove aluminum chips.
hydraulic ram (15, figure 32-8). Reinstall axle (8).
2. Install packing and backup ring. 3. Align holes in retainer (23), axle (8), and axle (40).
3. Install piston in hydraulic ram (15). Install bolts (19 and 38), with washers (20 and 39).
Install washers (6 and 41) and nuts (7 and 42).
4. Screw hydraulic ram (15) into trunnion (10) until it
bottoms, then back out until hydraulic outlet is pointing
32-47. GROUND HANDLING GEAR FIXED
FORWARD PIN.
5. Install and tighten setscrew (18).
6. Screw clevis (12) into hydraulic ram (15). 32-48. REMOVAL-GROUND HANDLING GEAR
FIXED FORWARD PIN.
7. Insert hydraulic ram (15) and trunnion (13) into
cradle assembly (29). 1. Remove spring pin (32, figure 32-8).
32-44. GROUND HANDLING GEAR AXLE. 2. Remove fixed forward pin (34) from cradle
assembly (29).
32-45. REMOVAL--GROUND HANDLING GEAR

AXLE. 32-49. INSTALLATION - GROUND HANDLING
GEAR FIXED FORWARD PIN.
1. Remove lubricator pin (9, figure 32-8).
1. Place fixed forward pin (34, figure 32-8), with
2. Remove nut (42), washers (39 and 41), and bolt bevel facing down, in cradle assembly (29).
(38).
2. Align holes in cradle assembly (29), with hole in
3. Remove nut (7), washers (6 and 20), and bolt(19). fixed forward pin (34), and install spring pin (32).
4. Remove axle (8) and retainer (23) from cradle

assembly (29). Remove axle (40) from cradle assembly 32-50. GROUND HANDLING GEAR
(29). BUSHINGS.
32-46. INSTALLATION -GROUND HANDLING

GEAR AXLE. 32-51. REMOVAL - GROUND HANDLING
GEAR BUSHINGS.
1. Insert axle (40, figure 32-8) into cradle assembly
(29) from right side. Position retainer (23) on exposed 1. Remove wheel assembly (1, figure 32-8), axles
end of axle (40), with larger dimension from bolt hole and forward fixed pin, as required, for access to
inboard. Insert axle (8) into axle (40). bushings.
NOTE: Step 2 provides procedure to drill axle (8). If 2. Heat cradle assembly (29) and press or pull
axle is already drilled, proceed to step 3. Axle (40) and bushings (24,25,26, and 33) from cradle assembly (29).
retainer (23) are predrilled. Refer to BHT-ALL-SPM manual.
Rev. 2 32-17
BHT-205A1-CR&O-1
5.214 IN.
NOTE
VIEW B
Line A-B is 90 degrees to ground handling wheel attaching pins.
205A1-R-32-9
Figure 32-9. Ground handling gear wheel axle drilling (212-050-200)
32-52. INSTALLATION- GROUND HANDLING 7. Check pin (5) for slip fit in bushings (24, 25, and
GEAR BUSHINGS. 26) and that pin (5) will lock.
1. Press in bushing (33, figure 32-8) into cradle 32-53. INSTALLATION - GROUND HANDLING
assembly (29). Face of bushing to be flush with surface GEAR.
of cradle assembly (29).
1. Lubricate wheels, actuating arms and cradle
2. Ream ID of bushing (33) 0.4995 to 0.5005 inch. assembly with grease (C-001).
2. Check tire pressure.

3. Press bushing (24) into cradle assembly (29).
Bushing face shall be flush with surfaces of cradle 3. Service hydraulic pump (36, figure 32-8) with
assembly (29). hydraulic fluid (C-002) by holding ground handling gear
assembly so that pump is in vertical position and filling
4. Press bushing (25) into cradle assembly (29). pump to filler hole level.
Bushing outboard face shall be flush with surface of
cradle assembly (29). 4. Position ground handling gear assembly, with
pump handle forward, over landing gear skid tube
5. Press bushing (26) into cradle assembly (29). between eyebolts, and align with eyebolts.
Bushing outboard face shall be flush with surface of 5 Insertfixedforwardpin(34)inforwardeyeboltand
cradle assembly (29). There will be approximately 0.125 place cradle assembly (29) over rear eyebolt and install
inch space between bushing (26) and bushing (27). locking pin (45) in cradle assembly (29).
6. Line ream bushing (24, 25, and 26) 0.5000 to 6. Actuate pump handle to lower wheels and lift skid
0.5100 inch. gear clear of surface.
32-18 Rev. 2
BHT-205A1-CR&O-1
ROTOR SYSTEM
TABLE OF CONTENTS
Paragraph Page
Number Title Number
65-1 Main rotor system .......................................................................................................... 65-4

65-2 Main rotor hub end blades............................................................................................ 65-4
65-7 Main rotor blades .......................................... ............................................................. 65-9
65-10 Main rotor blade 12 months or 1000 hour inspection .................................................... 65-14
65-11 Main rotor blade splice cover......................................................................................... 65-15
65-13 Main rotor hub ............................................................................................................... 65-15
65-21 Main rotor grip seals ...................................................................................................... 65-58
65-23 Main rotor controls........................................................................................................ 65-60
65-24 Stabilizer bar.................................................................................................................. 65-61
65-33 Pitch change link overhaul............ ....................................... ......... ................ 65-74
65-35.1 Pitch change components ............................................................................................. 65-74A
65-35A Control tube overhaul .................................................................................................... 65-74A
65-36 Scissors and sleeve overhaul ...................................... .............................................. 65-74B
65-43 Swashplate and support overhaul ................................................................................. 65-89
65-51 Collective lever.............................................................................................................. 65-104
65-53 Tail rotor hub and blade system .................................................................................... 65-106
65-54 Tail rotor hub and blades (212-010-701)....................................................................... 65-106
65-60 Tail rotor hub overhaul (212-010-701) ........................................................................... 65-110
65-68 Tail rotor hub and blades (212-011-701) ....................................................................... 65-117
65-75 Tail rotor hub overhaul (212-011-701) ........................................................................... 65-121
65-83 Pitch Horn ......................................................................... .... ............. 65-129
65-86 Crosshead assem bly..................................................................................................... 65-131
65-88 Tail rotor blades (212-010-750)..................................................................................... 65-134
LIST OF TABLES
Table Page
Number Title Number
65-1 Main rotor hub configuration ............................................................................................. 65-48

65-2 Stabilizer bar assem bly configuration ............................................................................... 65-68
65-3 Swashplate and support assembly ..................................................................... 65-102
LIST OF FIGURES
Figure Page
Number Title Number
65-1 Main rotor hub and blade.................................................................................................. 65-4

65-2 Main rotor blade retention bolt extracting fixture............................................................... 65-5
65 -3 Dele te d .............................................................................................................................
65 -4 De lete d .............................................................................................................................
65-5 Grip positioning link........................................................................................................... 65-9
65-6 Main rotor blade alignment ............................................................................................... 65-10
65-7 Main rotor blade ............................................................................... 65-11
15 JAN 2004 Rev. 3 65-1

BHT-205A1-CR&O-1
Figure Page
Number Title Number
65-8 M ain rotor blade repair.................................................................................................... 65-13

65-8A Grip modification ............................................................................................................... 65-14C
65-8B Plate fabrication ................................................................................................................ 65-14D
65-8C Liner modification ............................................................................................................. 65-14D
65-8D Grip disc fabrication .......................................................................................................... 65-15
65-8E Pillow block seal lip modification ....................................................................................... 65-15
65-9 M ain rotor hub................................................................................................................... 65-16
65-10 M ain rotor hub outboard section ....................................................................................... 65-17
65-11 Yoke.................................................................................................................................. 65-19
65-12 Yoke disassem bly tool ...................................................................................................... 65-20
65-13 Grip ................................................................................................................................... 65-21
65-14 Grip disassembly tool ....................................................................................................... 65-22
65-15 M ain rotor trunnion and pillow block ................................................................................. 65-23
65-16. Tool application ................................................................................................................ 65-24
65-16A Spindle journal wear step limits ........................................................................................ 65-26A
65-17 Blade bolt dam age and repair limits ................................................................................. 65-29
65-18 M ain rotor hub wear limits................................................................................................. 65-30
65-19 Drag brace dam age limits ................................................................................................. 65-31
65-20 Pitch horn dam age lim its ................................................................................................. 65-35
65-21 Outboard fitting, inboard fitting, and pillow block damage limits ....................................... 65-36
65-22 Yoke assembly dam age and repair limits .................................................................. 65-37
65-23 Grip assem bly dam age and repair limits........................................................................... 65-39
65-24 Trunnion assembly dam age and repair limits ................................................................... 65-40
65-25 Trunnion limits chart ..................................................................................................... 65-41
65-26 Main rotor yoke refinishing area ....................................................................................... 65-43
65-26A M ain rotor hub grip bushing replacem ent ......................................................................... 65-46
65-27 Pillow block buffer............................................................................................................. 65-48
65-28 Collective pitch retention strap adjustm ent ....................................................................... 65-49
65-29 Seal installation (new style) ............................................................................................. 65-49
65-30 Drag brace ........................................................................................................................ 65-51
65-31 Centering trunnion on hub ................................................................................................ 65-52
65-32 Main rotor grip positioning ................................................................................................ 65-54
65-33 M ain rotor hub balancing .................................................................................................. 65-55
65-34 Balancing kit ..................................................................................................................... 65-56
65-35 Balancing m ain rotor (alternate procedures) .................................................................... 65-57
65-36 M ain rotor grip seal replacem ent ...................................................................................... 65-59
65-37 Stabilizer bar................................................................................................................... 65-62
65-38 Stabilizer bar mixing lever and support dam age limits...................................................... 65-64
65-39 Stabilizer bar tube and fram e dam age limits .................................................................... 65-65
65-40 Lever damage limits.......................................................................................................... 65-69
65-41 Stabilizer damper, adapter, and damper link tube damage limits ..................................... 65-70
65-42 Shimm ing procedure for 212-010-302 mixing lever .......................................................... 65-71
65-43 Tube assembly (540-011-319).......................................................................................... 65-73
65-44 Stabilizer bar balancing .................................................................................................... 65-74
65-45 Pitch change link dam age and repair limits ...................................................................... 65-75
65-45A Pitch change com ponents dam age and repair limits ........................................................ 65-76
65-45B Control tube damage and repair limits ......................................................... 65-76B
65-46 Drive plate wear check ..................................................................................................... 65-77
65-47 Scissors and sleeve .......................................................................................................... 65-78
65-48 Scissor and drive link damage limits..................................................... 65-82
65-49 Hub and sleeve dam age limits.......................................................................................... 65-83
65-2 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
Figure Page
Number Title Number
65-50 Bearing and liner assembly damage limits ....................................................................... 65-84

65-51 Scissors and sleeve wear limits........................................................................................ 65-85
65-52 Swashplate and support ................................................................................................... 65-90
65-53 Trunnion removal and installation work aid....................................................................... 65-92
65-54 Swashplate inner and outer ring damage limits ................................................................ 65-94
65-55 Swashplate support damage limits ................................................................................... 65-95
65-56 Swashplate and support wear limits ................................................................................. 65-97
65-57 Inner ring and support bushing replacement dimensions ................................................. 65-98
65-58 Collective lever.................................................................................................................. 65-104
65-59 Collective lever damage limits .......................................................................................... 65-105
65-60 Collective lever wear limits................................................................................................ 65-106
65-61 Tail rotor hub and blades (212-010-701) .......................................................................... 65-107
65-62 Tail rotor hub and blade balancing.................................................................................... 65-109
65-63 Tail rotor hub (212-010-701) ............................................................................................. 65-111
65-64 Tail rotor yoke and trunnion damage and repair limits...................................................... 65-112
65-65 Bearing wear indications .................................................................................. 65-114
65-66 Tail rotor yoke bearing replacement ................................................................................. 65-115
65-67 Tool for staking tail rotor trunnion bearings (212-010-723, -768, -762) ............................ 65-116
65-68 Tool for staking tail rotor blade retention bearings (205-012-710, 212-010-731) .............. 65-116
65-69 Tail rotor hub and blades (212-011-701) ................................................. .................... 65-118
65-70 Tail rotor hub and blade (212-011-701) balancing............................................................ 65-120
65-71 Tail rotor hub (212-011-701) ............................................................................................ 65-122
65-72 Tail rotor trunnion housing damage limits......................................................................... 65-124
65-73 Tail rotor trunnion damage limits....................................................................................... 65-125
65-74 Tail rotor yoke damage limits............................................................................................ 65-126
65-75 Tool for staking tail rotor blade retention bearings............................................................ 65-127
65-76 Tail rotor yoke blade bearing replacement........................................................................ 65-128
65-77 Tail rotor trunnion centering tool ....................................................................................... 65-130
65-78 Tail rotor pitch horn damage limits (212-010-716) ............................................................ 65-132
65-79 Tail rotor pitch horn dam age limits (212-011-701) ............................................................ 65-133
65-80 Pitch horn bushing replacement ....................................................................................... 65-134
65-81 Crosshead components damage and repair limits............................................................ 65-135
65-82 Deleted............................................................................................................................. 65-136
65-83 Tail rotor blade butt sealing............................................................................................... 65-138
65-84 Tail rotor blade refinishing................................................................................................. 65-139
15 JAN 2004 Rev. 3 65-3

BHT-205A1-CR&O-1
65-1. MAIN ROTOR SYSTEM. Secure shims to brace or to blade for use in
reassembly.
The main rotor system incorporates a stabilizer bar
and dampers, swashplate and support, scissors and 3. Remove screw (9) with nut and washer to
sleeve, and connecting linkage to transmit flight unlock nut (10). Remove nut (10) and washer (11)
control movements to the main rotor head. from lower end of blade retaining bolt (4) using
T101414 wrench.
65-2. MAIN ROTOR HUB AND BLADES.
4. Gently raise tip of blade until blade retaining
TOOLS REQUIRED bolt (4) can be readily removed. Remove blade from
T101402 Grip Positioning Links grip.
T101414 Wrench
CAUTION: BLADES ARE PRECONED AND
ELEVATION IS NECESSARY TO FREE BOLTS. IF
65-3. DISASSEMBLY - MAIN ROTOR HUB AND DIFFICULTY IS ENCOUNTERED IN REMOVING
BLADES. BOLTS, USE BOLT EXTRACTING FIXTURE WHICH
CAUTION: ENSURE THAT T101402 GRIP MAY BE FABRICATED AS SHOWN ON FIGURE 65-
POSITIONING LINKS ARE INSTALLED. 2.
1. Support main rotor hub on stand. Support NOTE: Do not change adjustment of drag brace.
each main rotor blade (5, figure 65-1) to remove all Identify blade retaining bolts for reassembly in grips
droop. from which removed.
2. Remove drag brace bolt (7) with shims (6), 5. Remove opposite blade using same
washers, and nut to detach drag brace (8) from blade. procedure.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Figure 65-1. Main rotor hub and blade
65-4
BHT-205A1 -CR&O-1
SEEDETAIL B
1. Puller Rod Assembly 4130 (or better), 1.0 O.D - 15.0 Long
2. 3 Hex Nuts 0. 875 NF (14) Thread
3. Bearing (Thrust) Inner Race 1.0 I.D.
4. Plate or Washer, Steel or Aluminum, 4.050-4.125 0. D., 1.125 I.D., 0.250 Thick
5. Plate or Washer, Steel or Aluminum, 3.750 O.D., 1.125 I.D., 0.250 Thick
6. Tube, Steel or Aluminum, Wall Thickness 0.083 - 0.125
NOTE
All Dimensions Shown Are In Inches.
Figure 65-2. Main rotor blade retention bolt extracting fixture
65-5
BHT-205A 1-CR&O-1
65-4. INSPECTIONAND REPAIR - MAIN ROTOR 5. Align clevis of drag brace (8) to blade drag plate
HUB AND BLADECOMPONENTS. hole. Install shims (6) top, bottom, or equally,
depending on existing gap location between clevis
NOTE: If records or physical appearance indicate and drag plate. Shim for 0.000 to 0.005 inch
hub has been involved in an accident or incident, refer clearance. Install drag brace bolt (7) with two
to BHT-205A1-MM-1 manual. washers next to nut.
6. Be sure that T101402 grip positioning link

Inspect and repair detail parts of hub and blade (refer to figure 65-5) is installed between pitch horn
assembly in accordance with appropriate and stud on pillow block.
maintenance paragraphs.
7. Install opposite blade in same manner.
8. Torque nuts on drag brace bolts (7, figure 65-1)

100 to 120 foot-pounds.
9. Torque nut on each blade retaining bolt 260 to

300 foot-pounds, using T101414 wrench. Secure
65-5. REASSEMBLY - MAIN ROTOR HUB AND each nut by installing a screw (9) through aligned
BLADES. holes on nut (10) and blade retaining bolt (4). Secure
with nut and washer.
NOTE: After drag braces are properly adjusted,
blades should be installed in original position. To avoid 10. Torque nuts on drag brace (8) inboard bolts
disturbing rotor balance, reinstall blade retaining bolts 125 to 150 foot-pounds.
in grips from which removed.
NOTE: If blade alignment is required, refer to
1. Support main rotor hub on a suitable stand. paragraph 65-6.
2. Apply corrosion preventive compound (C-101) 65-6. ALIGNMENT - MAIN ROTORBLADES.

to blade-retaining bolt holes in hub grips, to blade
butts, and to drag brace and drag brace bolt holes. TOOLS REQUIRED
CAUTION: FOREIGN MATERIAL OR T101356 Build-up Bench

MISALIGNMENT OF BOLT HOLES WILL RESULT IN T101400 Scope Support
DAMAGED PARTS. T101401 Scope Assembly
T101402 Grip Positioning Links
3. Insert main rotor blade (5, figure 65-1) into T101865 Flap Stop
grip, observing color coding. Apply a thin coat of
corrosion preventive compound (C-104) on bolt (4) CAUTION: INSTALL T101402 GRIP POSITIONING
on shank but not on threads. Align holes and insert LINKS BEFORE HANDLING HUB AND BLADE
bolt through grip and blade from top. To find best ASSEMBLY.
alignment, gently move tip of blade up and down
while inserting bolt. Support end of installed blade. 1. Level T101356 build-up bench assembly.
Position main rotor with hub trunnion supported on
CAUTION: WHEN INSTALLING WASHER (11) ON bench. Place alignment cradles or other suitable
BLADE RETAINING BOLT (4), ENSURE WASHER supports under both blades to position blades
RECESSED SURFACE IS TOWARD BLADE GRIP straight at normal preconed angle throughout blade
BUSHING, AND FLAT SURFACE IS TOWARD NUT length.
(10).
2. Install two T101865 flap stops. Attach with
4. Install washer (11) and nut (10) on blade bolts and washers to each side of hub trunnion at
retaining bolt (4). lower set of holes.
65-6 Pages 65-7 and 65-8, including figures 65-3 and 65-4, deleted.
BHT-205A1-CR&O-1
alignment with third target mark. Repeat procedure

until alignment is satisfactory.
6. Sight through scope and align with screw (2),

located near leading edge strip, and tip on upper
surface of either blade. Center of screw head should
align on vertical crosshair within 0.100 inch forward
and 0.400 inch aft. Adjust blade drag brace as
necessary, for alignment.
GRIP
POSITIONING NOTE: Blade alignment point (screw head) (2) will
LINK vary in its location, and is to be used for reference
only during blade alignment.
7. Reverse scope in support. Repeat step 6. to

align opposite blade. Blade-to-blade difference shall
not exceed 0.050 inch.
8. When alignment is correct, remove scope and

Figure 65-5. Grip positioning link support assemblies. Paint a reference line across drag
brace barrel and lock nut to indicate original
3. Adjust T101402 grip positioning links to set alignment position for use in vibration
hub grips at zero pitch angle. Measure with a troubleshooting.
propeller protractor placed across outboard machined
surface on each grip.
65-7. MAIN ROTOR BLADES.
NOTE: Failure to support blades properly at
preconed angle (2-3/4 degrees) and to set zero grip 65-8. INSPECTION- MAIN ROTORBLADES.
angle will result in blade misalignment.
4. Position support assembly, T101400 (4, figure NOTE: Main rotor blades must be returned to an
65-6) across hub pillow blocks and secure with two authorized Bell Helicopter Textron blade repair shop
1/4-28 bolts, 2-1/4 inches long. Place T101401 for bushing replacement.
scope assembly (5) in support.
1. Check main retention bolt hole (3, figure 65-7)
5. Check scope for zero adjustment: and drag plate bolt hole for corrosion, pitting,
elongation, and size.
a. Sight through scope at a surface
approximately 50 feet away. Draw a straight vertical 2. Main retention bushing must be replaced if I.D.
mark on surface aligned with vertical cross hair. exceeds 2.505 inches.
b. Loosen clamp screws on scope mount,

rotate scope 180 degrees on tube axis, and tighten 3. Drag plate bushing must be replaced if .D.
screws. Take another sight to check that vertical exceeds 0.877 inch.
crosshair aligns with target mark.
4. Any corrosion or pitting of either bushing I.D.
c. If vertical crosshair fails to align with target in excess of replacement dimension after polishing is
mark, make a second target mark at new alignment of cause for removal. Local polishing in excess of
vertical crosshair. Make a third mark midway between replacement dimension is acceptable.
first and second target marks. Adjust screw marked L
on side of scope to align vertical crosshair with third 5. Refer to BHT-205A1-MM-1 manual for
mark. Rotate scope 180 degrees and recheck additional inspection data.
65-9
BHT-205A1-CR&O-1
STA
288.00
STA
5.110
REF ONLY,
ALIGNMENT POINT
WILL VARY IN
LOCATION
1. Pitch Change Axis

2. Blade Alignment Point (Screw Head)
3. Trunnion Axis
4. T101400 Support Assembly
5. T101401 Scope Assembly
204410-2000
Figure 65-6. Main rotor blade alignment
65-10
1 Butt cover
2. Ballast weights 7. Nose block 12. Leading edge
3. Main retention bolt hole 8. Honeycomb core 13. Trim tab
4. Drag link bolt hole 9. Skin 14. Ballast weights
5. Drag plates 10. Trailing edge extrusion 15. Tip cover
6. Grip plates 11. Main spar 16. Splice cover
BHT-205A 1-CR&O- 1
65-9. REPAIR - DAMAGED ROTOR BLADE SKINS. 4. Remove all paint from around the hole in the
area using clean rags dampened with MEK (C-309).
NOTE: Scratches, nicks, gouges, tears, holes, etc. Do not allow any MEK to enter the blade. Remove
in the skins that exceed the limits specified in super-koropon primer by sanding in a spanwise
BHT-205A1-MM-1 manual, that do not touch or direction using 300 grit or finer sandpaper (C-423).
damage in any way the trailing edge extrusion or the
spar (box beam), or that do not come within 1 inch of .
the doublers, may be repaired locally. This is 5. Prepare a patch of 2024-T3 aluminum alloy
may be repaired locally. 0.020 inch thick. The patch must be large enough to
accomplished by patching as described in this
paragraph and returned to service. The limits (figure overlap the hole at least 0.75 inch around the
65-8) must be met after the hole is cleaned up for perimeter, except as shown on figure 65-8. Deburr
patching. For patch limits to extreme trailing edge,
refer to figure 65-8.
6. Sand the mating surfaces of the blade and the
patch using 400 grit paper (C-423). Wipe both
CAUTION: REPAIRS DESCRIBED IN THIS surfaces clean with a rag wet with MEK (C-309) and
PARAGRAPH, INBOARD OF STATION 234.0, SHALL dry with a clean cloth.
BE INSPECTED DAILY FOR CRACKS.
1. Cut out the skin around the damaged area. CAUTION: THE AREA TO BE BONDED MUST BE
This may be accomplished by using a hole saw or CLEAN, DRY, AND FREE OF GREASE, OIL, WAX,
scribing through the skin with a sharp instrument. ETC.
7. Apply adhesive (C-317) to the bond areas of

NOTE: If a circular hole is cut out to remove the the patch and the blade.
damaged area, it must not exceed 2.0 inches in
diameter. However, it is permissible to cut out an
oblong
oblong hole
hole ifif the
the general
general direction
direction of
of the
the long
long 8. Apply
slightly backthe patch
and to the
forth blade
under moving to
pressure theseat
patch
it
dimension of the hole is within 15 degrees to the slightly back and forth under pressure to seat it
leading or trailing edge of the blade. Maximum size of properly and to expell air pockets in the adhesive.
the oblong hole shall not exceed 1 inch in width by 4 Blend out excess adesive around the edges.
inches in length. The ends of the hole must have a
minimum radius of 0.25 inch. 9. The patch may be held in place while curing
with rubber bands made from an inner tube or other
It is not necessary to cut a hole, if the defect can be mechanical means with cellophane sheet inserted
polished smooth without leaving the skin in the area between holding device and blade. If adhesive
so thin that it can be dented with fingernail pressure. (C-317) is used, cure at 75F ,21 °C) minimum for 5
In these cases, the area must have a patch applied in days or at 180°F (82°C) for 60 minutes. If using
the same manner as though a hole existed. Maximum adhesive (C-313), cure at 70 to 90F (21 to 32°C)
diameter of a patch of this type is to be 4.0 inches for 24 hours or at 140 ° to 1 55F (60 to 68°C) for 30
with at least 0.75 inch of bonded area around the minutes.
perimeter of the dent, except adjacent to trailing edge
skins as shown in figure 65-8. 10. Brush patch and bare areas around the patch,
using chemical conversion coating (C-100).
2. Remove the skin in the cut out area disturbing
the core as little as possible. It is desirable to heat the
cut out disc to 200°F (max) (93C) and lift out the 11 (C-424 to fill and fair around the
disc of skin while heated. patch.
3. Deburr the edges of the hole making sure the 12. Refinish repair area. Refer to
skin is free of scratches and nicks. BHT-205A1-MM-1 manual.
65-12
BHT-205A1-CR&O-1
Note
°
1 X 4 OBLONG WITHIN 15 OF
Patching limitations apply to upper and lower LEADINGEDGEORTRAILING
blade surfaces independently of each other. EDGEOFBLADE
288.00
AREAS OF REPAIR ON MAIN ROTOR BLADES
AND VIEW OF ROOT END OF BLADE
SECTION AT TRIM TAB LOCATION
Figure 65-8. Main rotor blade repair
65-13
BHT-205A 1-CR&O- 1
65-10. MAIN ROTOR BLADE 12 MONTHS OR detected by a change in sound from that of the
1000 HOUR INSPECTION. surrounding area. If voids are found, a maximum of
0.5 inch may be removed from the outboard tips of
1. Perform following inspection and repair on the grip plate, drag plate, or doublers to eliminate the
main rotor blades each 12 months or each 1000 void. The pattern of the cut, when removing material,
hours, whichever occurs first. should be approximately the same radius as the
original tip with no sharp edges or corners. Use
extreme care during cutting to avoid damage to
a. Inspect main rotor blades as follows: adjacent surfaces.
(1) Clean blade from an area starting at the b. Refinish main rotor blade as follows:
butt end of the blade to several inches outboard of the
doublers on both upper and lower blade surfaces
using aliphatic naphtha (C-305) or any good NOTE: If the rework performed has removed a large
degreasing solvent. amount of the original paint finish, it is recommended
that the top two coats of acrylic lacquer be removed
from an area starting at the butt end of the blade to
(2) Inspect main rotor blade grip pads, grip several inches outboard of the doublers on both upper
plates, doublers, drag plates and adjacent surfaces and lower blade surfaces and a complete refinish be
for voids, edge voids, corrosion, cracks, and accomplished.
condition of adhesive squeeze-out along bond lines.
(Refer to BHT-205A1-MM-1 manual for inspection (1) All edges around grip pads, grip plates,
criteria and repair limits unless otherwise stated doublers, and drag plates should have a smooth fillet
herein.) of adhesive squeeze-out. A bulge or lump of adhesive
could be mistaken for a bulge caused by corrosion.
CAUTION: DURING TRIMMING AND SANDING Sand down all spots of protruding adhesive
OPERATIONS, DO NOT NICK, SCRATCH OR GOUGE squeeze-out using 280 grit abrasive paper (C-423).
METAL SURFACES OR EDGES. DO NOT FEATHER
EDGES. (2) After all sanding has been completed,
scrub exposed metal surfaces using nylon web
(3) To inspect for corrosion under loose abrasive pad (C-407) and cleaning compound
adhesive squeeze-out, trim loose squeeze-out by (C-318) to remove traces of sanding residue and
cutting or scraping. Take care not to damage adjacent other contamination. Rinse with distilled or
surfaces. The trimmed area must be sanded smooth demineralized water and wipe dry.
using 280 grit or finer abrasive paper (C-423).
(3) Apply brush chemical film treatment
(C-100) to bare metal surfaces. The solution should
(4) Determine depth and length of any edge remain on the blade until the characteristic golden
void by using a 0.00 15 feeler gage. (Refer to iridescent to brown color develops, usually 30
BHT-205A1-MM-1 manual for limits of edge void.) seconds to 2 minutes. Rinse by wiping with cloth
saturated with distilled or demineralized water.
(5) Remove pin holes in squeeze-out by
cutting or scraping, taking care not to damage (4) Fill any remaining pin holes, grooves,
adjacent surfaces. The trimmed area must be sanded seams or trimmed edges, which may trap moisture,
smooth using 280 grit or finer abrasive paper around grip plates, grip pads, drag plates and doubler
(C-423). edges with adhesive (C-317 or C-322). A tongue
depressor should be used to produce a smooth
(6) A crack in the paint finish which follows application, free of lumps and bulges. Allow adhesive
the doubler tip outline may indicate a possible void. to harden overnight.
Carefully tap the upper surface of blade several
inches outboard of the doubler with a heavy coin or a (5) Spray one light coat of polyamide epoxy
small tapping hammer. A void can be primer (C-204) to all surfaces that have been sanded
to bare metal. Allow to air dry 30 minutes to 4 hours.
65-14
BHT-205A1-CR&O-1
(6) Mix adhesive as follows: 4. Wipe area with a clean cloth dampened with MEK
(C-309). Repeat with successive clean cloths and MEK
(a) Mix adhesive (C-322) per until the cloth remains clean after wiping. Wipe dry with
manufacturer's instructions. Then mix 13% to 15% (by a final clean cloth.
weight) of epoxy primer (C-204) into adhesive (C-322).
5. Remove peel ply from inside of cover assembly.
(b) Thin to a spray consistency by adding Lightly sand composite bonding adhesive on inside of
MEK (C-309) not to exceed 50% by volume of the mixed cover with 320 grit or finer abrasive paper (C-423). Wipe
adhesive. Approximately 35% by volume will produce a area with a clean cloth dampened with MEK (C-309).
sprayable consistency. Pot life of the thinned adhesive Wipe dry with a clean cloth.
is approximately 3 hours.
6. Apply adhesive (C-317) to inside of cover and to
(7) Spray three light coats of adhesive mixture blade surface. Rub adhesive around on blade and cover
to all surfaces that had been sanded to bare metal. Allow to assure complete wetting of the contact surfaces.
to dry 45 to 60 minutes between coats. After application
of final coat, allow to air dry at room temperature for 16 7. Position cover on blade and move slightly back
to 24 hours or for 1 hour at room temperature followed and forth to expel air pockets. Wipe off excessive
by 2 hours at 150 to 170°F (66 to 77°C). adhesive. Fair in edges of cover with adhesive.
(8) Spray one thin coat of polyamide epoxy 8. Hold cover in place with heavy rubber bands or
primer (C-204) over the adhesive mixture applied in step bungee cords.
(7) and over all adjacent areas where the original primer
was exposed during the rework and sanding operations. 9. Allow adhesive to cure for 24 hours at room
Allow primer to dry for 30 minutes minimum, 4 hours temperature or for 1 hour at 170 to 190°F (77 to 88°C).
maximum. It is necessary to cover the entire area Apply heat locally only and do not exceed the maximum
because the finish coats of lacquer or polyurethane will temperature.
not adhere to primer that has dried more than 4 hours.
10. Refinish blade as required.
(9) Spray two top finish coats of lacquer
(C-203) to match original finish. Allow to air dry 1 to 24 11. Perform the same on other blade.
hours between coats. Following final top coat, allow the
lacquer finish to air dry 48 hours or one hour at room
temperature plus one hour at 150°F (41°C).
NOTE: If rotor grip seals regularly allow oil to migrate

65-11.
ROTRMAIN
B E SPCE COVER past hub assembly inboard seals, customer may opt to
modify main rotor hub grips to grease-lubricated
65-12. INSTALLATION - MAIN ROTOR BLADE configuration. Refer to following paragraph for
SPLICE COVER. modification instructions.
1. Position cover (16, figure 65-7) on blade so 65-13A. MAIN ROTOR HUB ASSEMBLY,
inboard end of cover is two inches from the scarf joint at
204-012-101-(ALL D ASH NUMBERS),
the extreme leading edge. Pencil mark around the cover MODIFICATION TO GREASE LUBRICATION.
outline.
1. Remove and disassemble main rotor hub. Refer
2. Remove all paint and prime to bare metal in area to paragraph 65-14
receiving cover. Extend removal area 0.50 inch over the
cover outline. Use 180 grit or finer abrasive paper 2. Clean parts as specified in disassembly
procedures.
3. Prior to installation of cover, inspect scarf joint for 3
filler erosion and evidence of corrosion. If corrosion is follows:
present, contact Bell Helicopter Textron Product
Support Department, or an authorized blade repair a. Parts required to accomplish modification are
station for shipping instructions. as follows:
Rev. 2 65-14A
BHT-205A1-CR&O-1
PART NUMBER NOMENCLATURE QUANTITY procedures used shall be based on hub assembly
configuration.
AN4-H3A Bolt 6
AN960-416 Washer 6 Steps pertaining to grease-lubricated hub assembly
MS15001-4 Lubrication fitting 2 shall be designated as such.
MS15001-4 Lubrication fitting 2
MS20002C4 Washer 2 TOOLS REQUIRED
NAS516-1A Fitting 2
205-612-001-101 Bolt 2 T101356 Buildup Bench
T101363 Jaws (2 required)
b. Modify grips as specified in figure 65-8A. Drill or
through grip wall (1) with 40 (0.098 inch) drill using bolt T101454
(2) as guide. Vibro-etch letter "G" after part number on T101400 Support
identification plate (4) to identify modification to grease T101402 Grip Positioning Link
lubrication. Apply chemical film material (C-100) to T101405 Plate
reworked area. (Refer to BHT-ALL-SPM.) T101406 Plate
c. Fabricate two plates as specified in figure T101421 Adapter Plate
65-8B. Apply chemical film material (C-100), apply T101450 Arbor
primer (C-204), and paint plates with acrylic lacquer T101458 Main Rotor Balance Set
(C-203). (Refer to BHT-ALL-SPM.) T101559 Grip Spacing Tool
d. Modify two liners as specified in figure 65-8C. T101865 Flap Stop
Apply chemical film material (C-100) to reworked area. 8063 Step Plate
Vibro-etch letter "G" adjacent to fitting to identify 1107 Legs (2 required)
modification to grease lubrication. Refer to 1104 Legs (2 required)
BHT-ALL-SPM. 938 Push Puller
1151 Pulling Attachment
e. Fabricate two discs as specified in figure 65-8D. 1124 Pulling Attachment
Apply chemical film material (C-100) to disc, apply 1106 Legs (2 required)
primer, and paint disc. (Refer to BHT-ALL-SPM.)
NOTE: Review Mandatory Retirement Schedule in
CAUTION: TO AVOID DAMAGE TO SEALING BHT-205A1-MM-1 manual and retire all items
SURFACE, CARE SHALL BE EXERCISED WHILE scheduled for retirement. If main rotor hub is being
TRIMMING LIP OF PILLOW BLOCK SEAL. disassembled for replacement of part(s) instead of
overhaul, disassemble only to extent necessary to
NOTE: Trimming of seal lip allows grease to purge out replace part(s).
before disassembly.
NOTE: Pillow block seal shall be reversed during 1. Position T101421 adapter plate on T101356
installation. buildup bench assembly, with flat surface of adapter
plate down.
g. Annotate modification of main rotor hub in 2. Place main rotor hub on buildup bench, cut
appropriate historical records. lockwire, remove drain plug (16, figure 65-10) and drain
oil from grip (11).
h. Assemble main rotor hub. Refer to paragraph 3. Remove relief fitting (12) on inboard side of plate
after draining.
65-14. DISASSEMBLY- MAIN ROTOR HUB. 4. Remove grip as follows:
NOTE: Grease-lubricated hub assembly is packed NOTE: Procedure for removal of one grip is outlined.
with grease (C-001). Excess grease shall be removed Opposite grip removal is identical and opposite grip
as required during disassembly. should be removed at same time.
Procedures for grease-lubricated hub assembly are not a. Remove nut (18) and washer (17). Remove bolt
the same as those for oil-lubricated hub assembly. The (9), and washer (10), and drag brace (35) from grip (11).
65-14B Rev. 2
BHT-205A1-CR&O-1
1. Grip wall
3. Reworked area
4. Identification plate
SECTION C-C
205A1-R-65-8A
Figure 65-8A. Grip modification
Rev. 2 65-14C
BHT-205A1-CR&O-1
0.25
TYP
MAT'L: 2024-T3 OR T4 ALUM/ANY SPEC
205A1-R-65-8B
Figure 65-8B. Plate fabrication
0.03
0.02
205A1-R-65-8C
Figure 65-8C. Liner modification
65-14D Rev. 2
BHT-205A1-CR&O-1
0.10
MAT'L: 2024T3 OR T4 ALUM/ANY SPEC
MICROFINISH: 63
205A1-R-65-8D
Figure 65-8D. Grip disc fabrication
205A1-R-65-8E
Figure65-8E. Pillows block seal lip modification
Rev. 2 65-15
BHT-205A1-CR&O-1
205A1-R-65-9
Figure 65-9. Main rotor hub
65-16 Rev. 2
BHT-205A1-CR&O-1
64 TO 79 FT-LB
TORQUE
Figure 65-10. Main rotor hub outboard section (Sheet 1 of 2)
Rev. 2 65-16A/65-16B
BHT-205A1-CR&O-1
1. Blade bolt 11. Grip 21. Lock 027. Key

2. Strap 12. Relief fitting 22. Clamp *28. Pin
3. Shield assembly 013. Plate 23. Washer 29. Packing
04. Pillow block 014. Pitch horn 23A. Steelwasher 30. Fitting
5. Bushing 15. Bolt 23B. Chamfered washer 31. Nut
6. Bolt 16. Drain plug 24. Bolt 32. Barrel
7. Washer 17. Washer 24A. Bolt 33. Nut
8. Nut 18. Nut 24B. Fitting 34. Clevis
9. Bolt 19. Washer 25. Outboard fitting 35. Drag brace
10. Washer 20. Nut 26. Nut
NOTES:
Apply corrosion preventive compound (C-104)on all unthreaded internal faying

surfaces marked with prior to installation.
Apply primer (C-204)to faying surfaces marked with o and install while
primer is still wet.
Apply corrosion preventive compound (C-101)to external surfaces of bolts,

nuts, and washers marked with after installation.
Seal around pillow block bushings, boltheads, nuts, and washers with
adhesive (C-308).
Apply primer (C-204)between faying surfaces of pillow block and yoke. Apply primer to pillow
block bushing and to yoke and pillow block surfaces faying with bushing.
Applies only to grease-lubricated hub assembly.
205A1 -R-65-10-2
Figure 65-10. Main rotor hub outboard section (Sheet 2 of 2)
Rev. 2 65-17
BHT-205A1-CR&O-1
b. Remove nut (20), washer (19), and blade bolt static stop (2) from bottom of yoke assembly (4).
(1). Remove yoke from buildup bench. Tap outboard end of
strap (7) inboard with nonmetallic hammer until inboard
c. Remove bolts (15) and washers. Tap pitch horn strap fitting (8) is centered in yoke opening. Slide backup
(14) with a nonmetallic hammer to disengage bushings ring (9) outboard to clear pin (10). Push pin out of strap
from grip. fitting (8). Remove strap fitting (8), packing (11), and
backup ring (9) from center of yoke assembly (4). Pull
d. Remove bolt (24), washer (23), clamp (22), and strap (7) through outboard end of spindle.
lock (21). Remove nut (26) and key (27).
b. Pull seal sleeve (12) with packing (14 and 16)
e. Grease-lubricated hub assembly: remove and channel seal (15) from yoke spindle. Separate seal
fitting (24B), bolt (24A), chamfered washer (23B), steel sleeve (12), packings, and seal. Place yoke (4) on
washer (23A), clamp (22), and lock (21). Remove nut buildup bench.
(26) and key (27). c. Remove screws (17) and lock plate (18) from
yoke spindle. Use nut (26, figure 65-10) as a wrench and
NOTE: Rotating grip 90 degrees is not required for remove nut (19,figure 65-11). Using T101406 plate and
removal if radius ring (3) or place (13) does not have standard puller, remove bearing inner race (20), sleeve
safety locks. (21), bearing inner race (22) and shield assembly (23)
from yoke. (Refer to figure 65-12 for tool usage.)
f. Push pin (28) out of outboard fitting (25) and Remove packing (24, figure 65-11) from shield
remove fitting. Separate packings (29) from outboard assembly.
fitting (25). Press grip (11) inboard and rotate
approximately 90 degrees counterclockwise to 8. Disassemble grip as follows:
disengage from shield assembly (3). Support grip and
pull outboard to remove. a. Remove bolts (20, figure 65-13), washers (21)
and plate (22) from end of grip (1). Remove packing
5. Disassemble drag brace (35) as follows: (26), shims (25), and seal (19) from plate (22). Remove
bolt (13), spring washers (14), washers (15 and 16), and
a. Back off nuts (31 and 33). packing (17) from center of cover (10). Remove cover,
packings (7 and 9), and sight glass (8). Remove filler
b. Remove fitting (30) and clevis (34). Remove plug (12) and packing (11) from cover (10). Remove
nuts (31 and 33) from barrel (32). relief plug (18) and drain plug (24), with packing (23),
from plate (22).
NOTE: Clevis end of drag brace has coarse threads b. Grease-lubricated hub assembly: remove bolts
and fitting end has fine threads. (20), washers (21), and plate (22) from end of grip (1).
Remove packing (26), shims (25), and seal (19) from
6. Remove pillow blocks and trunnion as follows: plate (22). Remove bolt (13A) and washer (15A) from
center of disc (10A) and remove packing (9A) and disc
a. Remove four nuts (8), washers (7), and bolts (6) (1 A).
from pillow blocks (4).
c. Position T101405 bearing removal plate in
b. Use a non-metallic drift and tap bushings (5) outboard end of grip (1) and press bearing (2), spacer
from yoke and pillow blocks (4). (4), and bearing (6) from grip. (Refer to figure 65-14 for
tool usage.) Remove packings (3 and 5, figure 65-13)
c. Lift pillow blocks and trunnion assembly from from spacer (4).
yoke. Release relief fitting and separate pillow blocks
from trunnion. 9. Disassemble trunnion and pillow blocks as
follows:
NOTE: Be prepared for oil drainage from each pillow NOTE: Procedure is given for one spindle only.
block. Opposite spindle is identical and should be
disassembled at same time.
7. Disassemble yoke as follows:
a. Remove nut (1, figure 65-15) and washer (2).
a. Remove screws and washers (5, figure 65-11) Pull lock (9) and packing (8) from spindle (4). Separate
and aligning bracket (6) from static stop (2). Remove packing from lock.
65-18 Rev. 2
BHT-205A1-CR&O-1
TORQUE
85 TO 170 FT-LB
205A1-R-65-11-1
Figure 65-11. Yoke (Sheet 1 of 2)
Rev. 2 65-18A/65-18B
BHT-205A1-CR&O-1
1. Bolt and washer 14. Packing

o 2. Static stop 15. Channel seal
3. Stop 16. Packing
4. Yoke assembly 17. Screws (2 reqd)
5. Screw and washer 18. Lock plate
6. Aligning bracket 19. Nut
7. Strap assembly 20. Bearing inner race
8. Strap fitting 21. Sleeve
9. Backup ring 22. Bearing inner race
10. Pin 23. Shield assembly
11. Packing 24. Packing
12. Seal sleeve 25. End cap
13. Seal sleeve assembly
NOTES:
1. Apply corrosion preventivecompound (C-104)on faying surfaces markedwith prior to installation.

2. Apply primer (C-204)to faying surfaces marked with o and install while primer is still wet.
Apply a bead of sealant (C-328)to yoke spindle and shield assembly (23) faying surfaces.
Apply corrosion preventive compound (C-101) to external surfaces of bolts and washers (1) after
installation.
205A1-R-65-11-2
Figure 65-11. Yoke (Sheet 2 of 2)
Rev. 2 65-19
BHT-205A1-CR&O-1
g. Grease-lubricated hub assembly: remove nuts

(32), washers (33), bolts (11), and washers (12) from
liner (27A) and pillow block (24). Remove liner (27A),
shims (26), and packings (36) from pillow block (24).
938 Push Puller Remove retainer ring (34) and modified seal (35A) from
less 1106 Legs liner. Refer to figure 65-16 for tool usage and use puller
jaws T101454 to pull bearing (25) from liner. Remove
thrust washer (10, figure 65-15).
65-15. INSPECTION - MAIN ROTOR HUB.
NOTE: If records or physical appearance of hub

indicate assembly has been subjected to an accident or
1104 Legs incident outside the realm of normal usage, perform
conditional inspection, paragraph 65-16. If the hub does
not require conditional inspection, proceed with normal
overhaul inspection, paragraph 65-17.
1124 Pulling 65-16. Conditional Inspection - Main Rotor Hub.

Attachment
NOTE: If the following evaluation necessitates

Removal of radius ring, replacement of any part, also replace both retention
bearinginner racesand
inner spacerfrom yoke strapsand four strappins.
1. Carefully inspect all detail parts visually for any
apparent damage or abnormal appearance. Visual
defects that are cause to replace the entire hub are:
a. Yoke obviously bent outside limits established

Figure 65-12. Yoke disassembly tool in this manual.
b. Use standard puller and remove bearing inner b. Pitch horn pulled from grip.
race (7), packing (6), and radius ring (5) from trunnion
spindle (4). (Refer to figure 65-16 for tool usage). c. A segment of sheared mast attached to
trunnion.
c. Remove bolts (16, figure 65-15) spring washers
(15), washers (13 and 14), cover (20), packing (21), d. Obvious deformation of any other detail part
reservoir (22) and packing (23) from pillow block (24). within hub assembly would cause only the part
Remove filler plug (18) and relief fitting (17). deformed to be replaced along with parts defined in
NOTE above.
d. Grease-lubricated hub assembly: remove bolts
(16A), washers (15A), and plate (22A) from pillow block. 2. Any detail part within the hub assembly which
has sustained surface damage shall also be subject to
e. Remove bolt (31), balance washers (29) and surface damage inspection as outlined in paragraph
balance weight (28) from liner (27). 65-17, and repair as outlined in paragraph 65-18.
Surface damage in excess of overhaul limits will
f. Remove nuts (32), washers (33), bolts (11) and require replacing only the damaged part along with
washers (12) from liner (27) and pillow block (24). both retention straps and four strap pins.
Remove liner (27), shims (26), and packings (36) from
pillow block (24). Remove seal (35) and retainer ring 3. Dimensionally check for indications of
(34) from liner (27). Use T101454 puller jaws and pull permanent deformation or damage to the parts
bearing (25) from liner. (Refer to figure 65-16 for tool specified below. A dimensional discrepancy of any
usage). Remove thrust washer (10, figure 65-15.) part will cause only that part to be replaced along
65-20 Rev. 2
BHT-205A1-CR&O-1
205A1-R-65-13-1
Figure 65-13. Grip (Sheet 1 of 2)
Rev. 2 65-20A/65-20B
BHT-205A1-CR&O-1
1. Grip 13A. Bolt

2. Bearing 14. Spring washer
3. Packing 15. Washer
4. Spacer 15A. Washer
6. Bearing 17. Packing
7. Packing 18. Relief fitting
8. Sight glass 19. Seal
9. Packing 20. Bolt
9A. Packing 21. Washer
10. Cover 22. Plate
10A. Disc 23. Packing
11. Packing 24. Drain Plug
12. Filler plug 25. Shim
13. Bolt 26. Packing
NOTES:
A Apply primer (C-204)to faying surfaces of shim (25), plate (22) and grip (1).
Install while primer is still wet.
A Apply a film of sealant (C-328) to faying surface at seal (19) and plate (22).
A Applies only to grease-lubricated hub assembly.
A Apply bead of adhesive (C-308)to edge of disc (10A)after installation.
205A1-R-65-13-2
Figure 65-13. Grip (Sheet 2 of 2)
Rev. 2 65-21
BHT-205A 1-CR&O- 1
with parts defined in NOTE above unless stated

otherwise in that particular evaluation procedure.
a. Grip.
(1) A new bolt should fit through the

bushings such that it can be turned with the fingers.
Check for a 4.502 to 4.506 inch dimension between
inner faces of the grip tangs. Use a small screw jack, if
necessary, but under no circumstances should the
tangs be forced apart greater than 4.506 inches. If a
bolt will not fit through both bushings simultaneously,
the entire hub assembly shall be replaced. Removal of bearing
outer races and outer
spacer from grip
204011-229
(2) A new bolt should fit freely through the Figure65-14. Grip disassemblytool
drag brace hole. If the bolt will not fit through both
bushings simultaneously, or if the bushing is loose in (2) The flat center section of the yoke must
the grip, the entire hub assembly shall be replaced. be checked for flatness. Even if the precone is within
limits, should the flat center sections show curvature
in excess of 0.0015 inch, the yoke must be replaced.
b. Yoke. If the yoke exceeds precone limits and the center
section is not flat within above limit, then entire hub
(1) The precone angle and the spanwise assembly must be scrapped.
straightness must be checked with a propeller
protractor or clinometer. Measurement must be taken (3) The pillow block bushing bores must be
from the outboard bearing surfaces. Precone angles round within 0.001 inch. If 0.001 inch out-of-round
must be equal within 0°6 ' . The following chart lists is exceeded, cadmium plate should be removed and
the disposition of the yoke for the measured precone the bore remeasured. Elongation in excess of 0.002
and spanwise straightness. inch is cause to scrap entire hub assembly.
PRECONE
REUSE SCRAP YOKE SCRAP HUB
'
2°3'/300 Within 2 ° 15'/2°30 '
If less than 2 ° 1 5'
or
°
Within 3°00'/3 1 5' If greater than 3 ° 1 5'
SPANWISE STRAIGHTNESS
REUSE SCRAP YOKE SCRAP HUB
°
0°00'/006' 0°06'/0 18' Greater than 0 ° 18'
65-22
BHT-205A1-CR&O-1
Figure 65-15. Main rotor trunnion and pillow block (Sheet 1 of 2)
Rev. 2 65-22A/65-22B
205A1-R-65-15-1
Rev. 2 65-22A/65-22B
BHT-205A1-CR&O-1
1. Nut 19. Packing

2. Washer 20. Cover
3. Trunnion 21. Packing
4. Spindle 22. Reservoir
5. Radius ring 22A. Plate
7. Bearing inner race 24. Pillow block
8. Packing 25. Bearing
9. Lock 26. Shim
10. Thrust washer 27. Liner
11. Bolt 27A. Liner
12. Washer 28. Balance weight
13. Washer 29. Balance washer
14. Washer 30. Washer
15. Spring washer 31. Bolt
15A. Washer 32. Nut
16. Bolt 33. Washer
16A. Bolt 34. Retainer ring
17. Relief fitting 35. Seal
18. Filler plug 35A. Modified seal
36. Packing
NOTES:
1. Apply corrosion preventive compound (C-101)on faying surface marked with after installation.
2. Apply primer (C-204)to faying surfaces marked with and install while primer is still wet.
3. Apply corrosion preventive compound (C-104)on all unthreaded internal faying surfaces marked
with * prior to installation.
Applies only to grease-lubricated hub assembly.
Seal around inboard end of radius ring (5) with adhesive (C-308)prior to installation of pillow block
bolts.
205A1-R-65-15-2
Rev. 2 65-23
BHT-205A 1 -CR&O- 1
c. Main bolt.
(1) Measure diameter of bolt in six or eight

different locations. The dry film lubricant must be
removed before measurement. Lubricant can be
938 Push Puller removed by scrubbing with MEK (C-309). Diameters
should not vary over 0.0005 inch.
(2) Check bolt on a surface plate for

indications of curvature. Center line of bolt shall be in
line throughout length of shank within 0.001 5 inch. If
this dimension is exceeded on either bolt, both bolts
1151PullingAttachment must be replaced.
T101454
d. Drag brace bolt.
(1) Roll drag brace bolt on a flat table to

check for curvature.
1104 Legs
(2) Any indication of curvature is reason to

scrap the bolt.
1124 PullingAttachment e. Strapfittings.
of pillow
Removal (1) Strap pin hole should be round within
block bearingouter 0.001 inch.
race fromliner
(2) Egging in excess of 0.0015 inch with

larger diameter in spanwise direction is cause for
replacing entire hub assembly.
f. Trunnion.
less 1106 Legs
(1) Trunnion bearing surfaces must be
concentric within 0.002 inch T.I.R. Concentricity
8063 Step Plate should be checked by mounting the trunnion in
V-blocks with V-block touching only the outer 0. 100
inch of bearing surfaces. A dial indicator should be
mounted at inboard edge of each trunnion bearing
124 Pulling Attachment surface. With rotation of trunnion, neither indicator
should read in excess of 0.0005 inch T.I.R.
(2) The base surface of trunnion should be

Removalof ring and
bearing inner race checked for flatness on a surface plate. A deviation
from trunnion from flat in excess of 0.001 inch will require replacing
trunnion.
g. Drag brace.
(1) An unworn bolt must be free fitting

Figure 65-16. Toolapplication through the clevis bushings.
65-24
BHT-205A1-CR&O-1
(2) With the aid of a straight edge, check the 2. Inspect the following parts by magnetic particle
inner surfaces of clevis tangs and surface surrounding (Code M) or fluorescent penetrant (Code F) as
holes for indications of curvature. Any distinct deviation applicable. Magnetic particle inspection shall be made
from flat is cause to replace the drag brace. using wet continuous method. Useof fluorescent coated
particles with ultraviolet light is mandatory. The length of
h. Pitch horn. any indication shall be determined by the residual
method of magnetization.
(1) Any unworn bolt must be free fitting through NOTE: Refer to BHT-ALL-SPM manual for approved
the pitch link bushings. A bind is reason to scrap the fluorescent penetrant material.
pitch horn.
The following general formula shall be used for
(2) With a straight edge, check the flat machine determining amperage (meter). Ampere turns is number
surfaces surrounding the pitch link joint for deformation. of coil turns (on coil nameplate) - Amperage (meter).
Deviations from flat, in excess of 0.001 inch, are cause
to scrap the pitch horn. EXAMPLE: For a 5 turn coil, 11,000 ampere turns =
2200 amperes.
(3) The pitch horn to grip surface must be NOTE: If ac magnetic particle inspection equipment is
checked on a surface plate. This surface should be flat used, use 60 percent of dc amperes specified
within 0.001 inch. If necessary, remove interfering
bushings. Figure and
Index No. Nomenclature Code
(4) Proceed with Normal Inspection of parts 65-10 1 Bolt M(referto
which comply with above requirements. step 6)
i. Inspect for unapproved pins (10, figure 65-11). 65-10, 5 Bushing M

(Refer to A.S.B. 205-91-42.) 65-10,6 Bolt M
4. Accomplish Normal Inspection, paragraph 65-17. 65-10, 14 Pitch horn F
65-10, 20 Nut F
65-17. Normal Inspection - Main Rotor Hub. 65-10, 25 Outboard fitting M (refer to
step 5)
NOTE: Grease-lubricated hub assembly is packed 65-10,26 Nut M
with grease (C-001). Excess grease shall be removed
as required during inspection. 65-10, 28 Pin M (refer to
step 41)
Procedures for grease-lubricated hub assembly are not 65-10, 30 Fitting M (refer to
the same as those for oil-lubricated hub assembly. The step 9)
procedures used shall be based on hub assembly
configuration. 65-10,32 Barrel M (refer to
step 11)
Steps pertaining to grease-lubricated hub assembly 65-10, 33 Nut M (refer to
shall be designated as such. step 13)
1. Inspect parts dimensionally and replace parts that

65-10, 34 Clevis M (refer to
step 12)
do not fall within inspection limits. Dimensionally inspect
parts, if required, as specified in subsequent steps. 65-11,4 Yoke F (refer to
step 3)
NOTE: Wear limits are provided to show the required 65-11, 8 Inboard strap M (refer to
fit between mating parts. It is not intended that all fitting step 5)
dimensions be checked as a prescribed overhaul
procedure; however, parts that show evidence of wear 65-11, 10 Pin M (refer to
or physical damage shall be checked dimensionally. step 41)
Rev. 2 65-25
BHT-205A1-CR&O-1
Figure and 4. Magnetic particle inspection of trunnion (3, figure

Index No. Nomenclature Code 65-15). The trunnion must be inspected by all of the
following steps:
65-13, 1 Grip F
a. Thoroughly degrease trunnion.
65-15, 3 Trunnion M (refer to
step4) b. Magnetize trunnion by placing it so that trunnion
65-15, 24 Pillow block F arms contact gauze heads of inspection equipment.
Pass 2500 amperes dc through trunnion.
3. Perform fluorescent penetrant inspection of yoke c. Inspect trunnion completely for indications.
(4, figure 65-11). (Refer to BHT-ALL-SPM).
d. Place trunnion in a coil with long axis (trunnion
a. through m. Deleted. spindles) approximately 90 degrees to direction of
current flow in coil. Magnetize trunnion using 15,000
n. Clean yoke bushing bores with MEK (C-309) ampere-turns.
and visually inspect for cracks and corrosion, especially
pitting type. Any crack, verified by fluorescent penetrant e. Inspect trunnon completely for indications.
inspection or any mechanical or corrosion damage
beyond specified limits, are cause for rejection of yoke.
(1) Indications interpreted as cracks are cause
NOTE: Shield assembly does not have to be removed for rejection regardless of length or location.
for yoke bearing journal inspection.
(2) Indication of stringers or nonmetallic
3A. Clean yoke spindles and inspect bearing inclusions will be acceptable provided they do not
journals for evidence of step wear and journal diameter exceed the following limits:
limits. Refer to figure 65-16A for limits.
(a) Indications of defects parallel within 15
3B. Refer to Chapter 5 for yoke assembly recurring degrees to the long axis of the trunnion arms are
inspection requirements. Yoke journal inspection is acceptable provided they do not exceed 0.5 inch in
recommended in conjunction with tension torsion strap length and do not extend into the radius. The total length
change. of all inclusions shall not exceed 1.5 inches.
65-26 Rev. 2
BHT-205A1-CR&O-1
TOP
AFT FORWARD
212-011-102
FORWARDSIDE OF WEAR AREASON BEARING
SHOT PEENEDAREA WEAR AREA
SECTION A-A
ITEM NOMENCLATURE MAXIMUM WEAR STEP
1. Outboard journal 0.008

2. Inboard journal 0.003 (FWD side)
0.0045 (Top and/or bottom)
0.006 (AFT side)
NOTE:
Minimum diameter per figure 65-18 applies to

wear step (maximum wear step cannot violate
minimum diameter). 205A1-R-65-16A
Figure 65-16A. Spindle, journal wear step limits
Rev. 2 65-26A/65-26B
BHT-205A1-CR&O-1
(b) Indication of defects parallel to the long d. Rotate outboard fitting 180 degrees on the
axis within 15 degrees of the trunnion arms, which central conductor and repeat steps b. and c.
extend into the radius, are cause for rejection.
e. Place a one inch diameter central conductor
(c) Indications of defects in the trunnion through the in-line holes in outboard fitting. Place
arms, that are more than 15 degrees from the long central conductor between the contact heads of
axis, transverse, or circumferential are cause for inspection equipment. Pass 2000 amperes dc
rejection. through the central conductor.
(d) Indications of defects on the outer f. Inspect outboard fitting completely for
section of the trunnion (excluding the trunnion indications.
spindles) are acceptable provided residual particle
buildup does not indicate cracks. g. Place outboard fitting in the coil such that
the longitudinal axis of outboard fitting is
(e) Indications which are caused by a sharp perpendicular to plane of coil. Magnetize outboard
change in section are acceptable. fitting using 15,000 ampere turns.
h. Inspect outboard fitting completely for

(f) Strong magnetic indications where indications.
indications.
considerable build-up of particles are present,
indicating the defect has considerable depth and/or
cross section shall be cause for rejection regardless of i. Inspect outboard fitting 180 degrees about
length, size, or direction. its axis and repeat step g.
(g) Indications of defects extending into or j. Inspect outboard fitting thoroughly for
in slots, internal splines, or the threaded holes (1/4 indications.
inch or 3/8 inch diameter) are cause for rejection.
k. Acceptance criteria. Magnetic indications
interpreted as cracks, seams, laps or shuts are cause
g. After completion of inspection demagnetize
for rejection.
trunnion and check with pocket field indicator or
compass to assure demagnetization.
(2) After completion of inspection,
demagnetize the fitting and check with a field
5. Magnetic particle inspection of outboard indicator or compass to assure demagnetization.
fitting (25, figure 65-10) and inboard strap fitting (8,
figure 65-11). The outboard and inboard strap fittings
must be inspected by all of the following steps: strapI.fitting
Perform steps 65-11).
(8 figure 5.b. through 5.k. on inboard
strap fitting (8, figure 65-11).
a. Remove end cap (25) from inboard strap

Bond end cap (25) to inboard strap fitting (8)
fitting (8). Thoroughly degrease outboard and with sealant (C-308)
inboard strap fittings.
b. Place a 1-3/4 inches diameter central 6. Magnetic particle inspection of blade bolt (1,
conductor (copper or aluminum bar) through figure 65-10). The blade bolt must be inspected by all
of the following steps:
rectangular hole in outboard fitting. Place central
conductor between the contact heads of inspection
equipment. Pass 3000 amperes dc through central a. Thoroughly degrease blade bolt.
conductor.
b. Magnetize blade bolt by placing blade bolt
between contact heads of inspection equipment.
c. Inspect outboard fitting completely for
indications. Pass approximately 1500 amperes dc through blade
65-27
BHT-205A1-CR&O-1
bolt longitudinally, thus developing a circular (5) Strong magnetic indications where
magnetic field. considerable build-up is present, indicating the defect
has considerable depth and/or cross section shall be
c. Inspect blade bolt completely for indications, cause for rejection regardless of length, section, or
location.
d. Place blade bolt inside coil such that long
axis of the blade bolt is approximately 90 degrees in g. After completion of inspection, demagnetize
direction of current flow in the coil. Magnetize blade blade bolt and check with pocket field indicator, or
bolt using approximately 9400 ampere turns compass, to assure demagnetization.
magnetizing force dc.
7. Inspect blade bolt (1, figure 65-10) for
e. Inspectbladeboltcompletely for indications. mechanical and corrosion damage. (Refer to figure
65-17.) If visual indications of wear are present,
f. Acceptance criteria: dimensionally inspect bolt. (Refer to figure 65-18.)
Inspect bolt for damage and scratches in dry lubricant
(1) Magnetic indications interpreted as film.
cracks, seams, laps, shuts, or busts are cause for
rejection regardless of size or location. 8. Inspect drag brace (35, figure 65-10), for
cracks, nicks, scratches, corrosion and damaged
threads (refer to figure 65-19). Inspect fitting and
(2) Magnetic indications of stringers or
clevis for wear of protective paint on mating surfaces.
non-metallic inclusions will be acceptable if they are
within the following limits. Indications below 1/64
inch are not considered rateable. 9. Remove gray lacquer finish from drag brace
(35, figure 65-10) using thinner (C-206) and
disassemble.
(a) Indications parallel to the long axis (±
15 ° ) are acceptable provided they do not exceed 1/2
10. Magnetic particle inspection of drag brace
inch
inch in
in length.
length. Not
Not more
more than
than two such indications
two such indications are
are fitting (30, figure 65-10). The drag brace fitting must
allowed in any 1.0 square inch of surface area. The
be inspected by all of the following steps:
total aggregate length of multiple small indications
shall not exceed 1-1/2 inches in any 1.0 square inch
ofsurface area. a. Thoroughly degrease drag brace fitting.
of surface area.
b. Place drag brace fitting longitudinally
(b) Indications that are more than ± 15° between contact heads of the inspection equipment.
off the long axis are rejectable regardless of size or
Pass 2500 amperes dc through drag brace fitting.
location.
c. Inspect drag brace fitting completely for
(c) Indications that terminate at edges, indications.
slots, threads, and fillets are not acceptable.
d. Place a 3/4 inch diameter central conductor
(d) Indications of surface discontinuities (copper or aluminum bar) through bolt hole of the
which break over corners or run into fillets are not drag brace fitting. Place central conductor between
acceptable. contact heads of inspection machine. Pass 1000
amperes dc through central conductor.
(e) Indication of subsurface discontinuities
which break a transverse face, are cause for rejection. e. Inspect drag brace fitting completely for
indications.
(3) Indication caused by a change in section
thickness are acceptable. f. Place drag brace fitting in coil such that the
longitudinal axis of drag brace fitting is perpendicular
(4) Indications in internal or external threads to plane of the coil. Magnetize drag brace fitting using
are not acceptable. 15,000 ampere-turns.
65-28
BHT-205A 1-CR&O-1
BLADE BOLT
MECHANICAL
(Before and after repair) 0.005 in. 0.010 in.
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS Two Not critical
EDGE CHAMFER Not applicable 0.030 in. by 450
THREAD DAMAGE:
Length: One-half inch
Number: One
NOTE:
Figure 65-17. Blade bolt damage and repair limits
65-29
BHT-205A1-CR&O-1
ITEM NOMENCLATURE MIN. MAX.
1. Liner ID 5.624 5.631 Avg

2. Liner ID 5.374 5.381 Avg
3. Grip (width) 4.492 4.516
4. Bushing ID 2.500 2.504
5. Bolt (blade retaining) OD 2.4982 2.4999
6. Bushing (drag brace) ID 0.8745 0.8770
Width 2.874 2.876
7. Spindle (yoke) OD 4.493 4.4985
8. Spindle (yoke) OD 4.743 4.7485
8A. Journal (yoke, 212-011-102) OD 4.4910 4.4999
8B. Journal (yoke, 212-011-102) OD 4.7430 4.7499
9. Plate (measure from unworn sur- 0.125
face)
205A1 -R-65-18
Figure 65-18. Main rotor hub wear limits
65-30 Rev. 2
BHT-205A 1-CR&O-1
DRAG BRACE
TYPE OF DAMAGE MAXIMUM DEPTH AND REPAIR AREAS ALLOWED
MECHANICAL
(Before and after repair) 0.010 in. 0.020 in. 0.030 in.
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
DEPTH REPAIR 0.010 sq. in. 0.20 sq. in. Not critical
NUMBER OF
NONOVERLAPPING
REPAIRS One per tang Two per segment Not critical
EDGE CHAMFER 0.030 in. by 45 ° 0.030 in. by 45 ° 0.060 in. by 45 °
BOLT HOLE
DAMAGE: * 0.001 inch for 1/4 circumference
NOTE:
Figure 65-19. Drag brace damage limits (Sheet 1 of 2)
65-31
BHT-205A1-CR&O-1
CREST
1/3 THREAD HEIGHT ZONE 1- CREST
THREAD HEIGHT ZONE 2 - FLANK
2/3 THREAD HEIGHT ZONE 3-ROOT
ROOT
(ENLARGED)
EXTERNAL THREADS
TYPE/LOCATION OF DAMAGE THREAD REPAIR
MECHANICAL DAMAGE
MAXIMUM DEPTH AFTER REPAIR:
Zone 1 0.010 In., A=45, 2 occurences per thread, 1/3 total no. thread
Zone 2 0.005 In., A=45, 1 occurence per thread, 1/4 total no. thread
Zone 3 None allowed
CORROSION DAMAGE
MAXIMUM DEPTH AFTER REPAIR:
Zone 1 0.010 In., A=45, 2 occurences per thread, 1/3 total no. thread
Zone 2 0.005 In., A=45°, 1 occurence per thread, 1/4 total no. thread
Zone 3 0.002 In., A=45, 2 occurences per thread, 1/2 total no. threads
(maintain original root radius, blend to flank)
CRACKS: None allowed
INTERNAL THREADS
Any Internal superficial corrosion, which cannot be removed with

cleaner (C-344), abrasive pad (C-407) or steel wool (C-411), Is
cause for rejection.
205A1CRO 65000_00190_002
Figure 65-19. Drag brace damage limits (Sheet 2 of 2)
65-32 Rev. 3 15 JAN 2004

BHT-205A 1-CR&O-1
g. Inspect drag brace fitting completely for c. Inspect drag brace clevis completely for
indications. indications.
h. Acceptance Criteria. Magnetic particle d. Place a 3/4 inch diameter central conductor
indications interpreted as cracks are cause for (copper or aluminum bar) through clevis holes. Place
rejection. central conductor between contact heads of
inspection equipment. Pass 1000 amperes dc
i. After inspection, demagnetize drag brace
through central conductor.
fitting and check with pocket field indicator or
compass to assure demagnetization.
e. Inspect drag brace clevis completely for
j. Inspect internally for corrosion. Any internal indications.
superficial corrosion which cannot be removed with
cleaner (C-344), abrasive pad (C-407) or steel wool is f. Place drag brace clevis in the coil such that
cause for rejection. the longitudinal axis of drag brace clevis is
perpendicular to plane of the coil. Magnetize drag
11. Magnetic particle inspection of drag brace brace clevis using 15,000 ampere-turns.
barrel (32, figure 65-10). The drag brace barrel must
be inspected by all of the following steps. g. Inspect drag brace clevis completely for
indications.
a. Thoroughly degrease drag brace barrel.
h. Acceptance Criteria. Magnetic particle
b. Place drag brace barrel longitudinally indications interpreted as cracks are rejectable.
between contact heads of inspection equipment.
Pass 1000 amperes dc through drag brace barrel.
i. After completion of inspection demagnetize
c. Inspect drag brace barrel completely for drag brace clevis and check with pocket field
indications. indicator or compass to assure demagnetization.
d. Place drag brace barrel in coil such that the 13. Magnetic particle inspection of drag brace
longitudinal axis of drag brace barrel is perpendicular nut (33). The drag brace nut must be inspected by all
to plane of the coil and equal lengths of drag brace of the following steps:
barrel protrude from each end of coil. Magnetize drag
brace barrel using 11,000 ampere-turns. a. Thoroughly degrease drag brace nut.
e. Inspect drag brace barrel completely for b. Place a 1-1/4 inch diameter central
indications. conductor (copper or aluminum bar) through the drag
brace nut and central conductor between contact
f. Acceptance Criteria. Magnetic particle heads of inspection equipment. Pass 1500 amperes
indications interpreted as cracks are rejectable. dc through central conductor.
g. After completion of inspection demagnetize c. Inspect drag brace nut completely for
drag brace barrel and check with pocket field indications.
indicator or compass to assure demagnetization.
12. Magnetic particle inspection of drag brace d. Place drag brace nut in coil such that the
clevis (34). The drag brace clevis must be inspected diameter of drag brace nut is concentric with the coil
by all of the following steps: diameter.
a. Thoroughly degrease drag brace clevis. e. Magnetize drag brace nut using 15,000
ampere-turns.
b. Place drag brace clevis longitudinally
between contact heads of inspection equipment and f. Inspect drag brace nut completely for
pass 2000 amperes dc through the drag brace clevis. indications.
65-33
BHT-205A1-CR&O-1
g. Rotate drag brace nut 180 degrees around its d. Delamination of the urethane coating from the
diameter and repeat steps d. thru f. bushings is acceptable. Delamination in any other area
is cause for rejection.
h. Acceptance Criteria. Magnetic particle
indications interpreted as cracks are rejectable. e. A permanent set in twist may occur and is not
i. After completion of inspection demagnetize
drag brace nut and check with pocket field indicator or f. Strap stiffness can vary when flexed in an
compass to ensure demagnetization. unloaded condition and is not cause for rejection.
14. Inspect pitch horn (14, figure 65-10) for cracks,

dents, nicks, and corrosion to limits of figure 65-20. g. Oil contamination resulting in swelling of the
Inspect bushings for looseness and elongation of bolt urethane coating is cause for rejection. If oil has come
holes. in contact with the strap but swelling has not occurred,
the strap assembly shall be cleaned with denatured
alcohol (C-326) to remove all traces of oil.
15. Inspect nut (26, figure 65-10) for cracks, dents,
damage, and corrosion. Inspect threads on nut (26) for
galling and damage. Inspect outboard fitting (25) for h. Displacement of the urethane wedgesbetween
damage. (Refer to figure 65-21.) the bushings and inner surface of the wire bundle is
16. Inspect all attaching hardware for damage,
deformation, and crossed or damaged threads. Inspect i. Cracks in the strap bushings are cause for
strap pins (28, figure 65-10) and (10, figure 65-11) for rejection. Inspect using a ten power glass.
damage and corrosion. Inspect bonded washers for
security.
j. Inspect bushings for fretting corrosion. A
maximum of 0.005 inch in depth for 25 percent total area
17. Inspect static stop (2, figure65-11)forelongation is allowed on the bushing flange surfaces. A maximum
of bolt holes and damage on surface of contact with of 0.002 inch in depth is allowed for 1/4 of the total
mast. bushing bore surfaces.
18. Inspect yoke (4) for scratches and corrosion.

(Refer to figure 65-22.) Inspect bearing seats on 20. Inspect inboard strap fitting (8, figure 65-11) for
spindles (7 and 8, figure 65-18) to limits of figure 65-18 nicks damage, and corrosion. (Refer to figure 65-21.)
if visual inspection indicates wear. Inspect threads for
galling and damage. (Refer to figure 65-22.) 21. Inspect backup ring (9, figure 65-11) for cracks,
nicks, damage, and distortion.
19. Visually inspect strap (7, figure 65-11) as follows:
22. Inspect sleeve (21) for corrosion.
a. A total of 25 broken wires (50 loose ends)
protruding through the urethane coating at any one of
23. Inspect nut (19) for cracks, corrosion, and
the 8 outside corners is cause for rejection. A total of 400
loose ends found over the entire strap surface is cause
for rejection.
24. Inspect bearing inner races (20 and 22) for
b. Strap bulge in excess of 0.06 inch above the evidence of spalling on outerdiameterand discoloration
normal straight contour is cause for rejection. Bulging of due to overheat.
the strap cross section in any area 4 inches from the
ends of the strap inboard is normal and not cause for 25. Inspect shield assembly (23)in seal contact area
rejection. for signs of grooving. Grooving depth should not exceed
0.020 inch. Inspect rings for cracks and corrosion
c. Cracks in urethane coating are not permitted. damage (none allowed). Inspect for broken bond and
Delamination between urethane wedges and spools is torn or damaged shield. Inspect end cap (25) for tears,
acceptable. bonding or other damage.
65-34 Rev. 2
BHT-205A 1-CR&O-1
PITCH HORN
MECHANICAL
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS Two per segment Four
° °
BOLT HOLE
NOTE:
Figure 65-20. Pitch horn damage limits
65-35
BHT-205A 1-CR&O-1
FITTING FITTING PILLOW BLOCK
MECHANICAL
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS One per segment One inside Not critical
One outside

THREAD DAMAGE:
Depth: One-quarter of thread
Number: One
BOLT HOLE
DAMAGE: 0.001 inch for 1/4 circumference
STRAP PIN
HOLE: 1 0.0005 inch for 1/4 circumference
NOTE:
Figure 65-21. Outboard fitting, inboard fitting, and pillow block damage limits
65-36
BHT-205A1-CR&O-1
(TYPICAL)
SOLID FILM YOKEASSEMBLY
LUBRICATE
THIS AREA
DAMAGE AREA REPAIRS SYMBOLS
MECHANICAL 0.002 In. 0.005 In. 0.010 In.

(Before or after repair) (Restore to RHR 125)
(Restore to RHR 16) 0.005 In.
CORROSION 0.002 In. 0.005 In. 0.010 In.
(Before or after repair) (Restore to RHR 125)
(Restore to RHR 16) 0.005 In.
MAXIMUM AREA PER
NONOVERLAPPING
REPAIRS Two per side dia-
metrically opposed Four Four
EDGE CHAMFER 0.030 In. by 45° 0.040 In.
Material removal not to exceed mechanical damage repair limit.
THREAD DAMAGE
BOLT HOLE 0.002 Inch for 1/4 circumference

DAMAGE:
CRACKS None allowed for any trunnion damage/repair zone

NOTES:
Main rotor yokes equipped with inner races P/N 212-311-009-101 and 212-311-010-101.
Maximum depth repair to journals limited by maximum wear step allowance (figure 65-16A)
and by minimum diameter limitations (figure 65-18). Repair depth is not additive to maximum
wear step.
205A1-R-65-22
Figure 65-22. Yoke assembly damage and repair limits
Rev. 2 65-37
BHT-205A1-CR&O-1
26. Inspect plate (22, figure 65-13) for cracks, b. Any cracks discovered in pillow blocks are
elongated bolt holes, and distortion. cause for scrapping and replacement. I
27. Inspect lower plate (9, figure 65-18) for wear. 38. Inspect liner (27 or 27A, figure 65-15) for cracks,
warpage, and damage. Inspect helicoil insert for
28. Inspect shims (25, figure 65-13) for curled or looseness and damaged threads.
damaged laminations.
39. Inspect bearing (25) for spalling and
29. Inspect reservoir cover (10) and sight glass (8) discoloration due to overheat. Check for broken rollers
for cracks and damage. and for roughness of operation.
29A. Grease-lubricated hub assembly: inspect disc 40. Inspect lock (21, figure 65-10), clamp (22), and
(10A) for cracks and damage. key (27) for cracks and damage. Inspect lock (9, figure
65-15) and thrust washers (10) for damage.
30. Inspect grip assembly (1) surfaces for
mechanical and corrosion damage. (Refer to figure 40A. Grease-lubricated hub assembly: inspect
65-23 for limits.) Inspect for worn or chipped protective fitting (24B), bolt (24A), lock (21), clamp (22), and key
paint on inside surface of grip tangs. Inspect grip upper (27) for cracks and damage. Inspect lock (9, figure
bushing for correct edge chamfer. Inspect rosan inserts 65-15) and thrust washers (10) for damage.
for security and damaged threads. Inspect main rotor 41. Magnetic particle inspection of pins (28, figure
bolt hole, drag brace bushings, width between grip 65-10) and (10, figure 65-11). Each pin shall be
tangs, and bearing liner inside diameterto limits of figure inspected by all of the following steps:
65-18 if visual evidence of wear is present.
a. Remove washers from each end of pin (10).
31. Inspect spacer (4, figure 65-13) for cracks,
corrosion, and damage. b. Check pin (10) and washers for pin serial
number vibro etched on surface. Vibro etch number on
32. Inspect bearings (2 and 6) for broken rollers and for end of pin or on one surface of new washers installed
spalling of outer race inside surface. Check for roughness after magnetic particle inspection.
of operation and discoloration due to overheating.
c. Thoroughly degrease pins.
33. Inspect trunnion (3, figure 65-15) for nicks,
damage, and corrosion. (Referto figure 65-24 for limits.) d. Place pin longitudinally between contact heads
Inspect dry-lube film on spindles for scratches and of machine. Pass 1000 amperes dc through pin.
trunnion wear. (Refer to figure 65-25.) e. Completely inspect pin for indications.
34. Inspect bearing inner race (7, figure 65-15) for f. Place pin in coil such that longitudinal axis is
evidence of spalling and for discoloration due to perpendicular to plane of coil. Magnetize pin using
overheat. Check for signs of race turning on trunnion (3). 15,000 ampere turns.
35. Inspect radius ring (5) for worn outer surface, g. Completely inspect pin for indications.
corrosion, cracks, and damage. h. Acceptance criteria. Magnetic particle
36. Inspect reservoir (22) and cover (20) for cracks indications interpreted as cracks are not acceptable and
and damage. the pin must be scrapped.
(2) If pin (10) is found cracked then replace the
36A. Grease-lubricated hub assembly: inspect plate mating strap fitting.
(22A) for cracks and damage.
(3) After completion of inspection, demagnetize
37. Inspect pillow block (24) for damage and pin and check with field indicator or compass to assure
corrosion. (Refer to figure 65-21.) demagnetization.
NOTE: 204-011-108-005 pillow block assemblies i. Clean ends of pin and two AN960JD816L
shall be inspected and identified prior to further use. washers using a nylon web abrasive pad and MEK
Refer to A.S.B. 205-92-51. (C-309). Wipe dry with a clean cloth.
a. Inspect pillow block assemblies for evidence of j. Bond one AN960JD816L washer to each end of
cracks using fluorescent penetrant. (Refer to pin. Use adhesive (C-313) to bond washers.
BHT-ALL-SPM). Allow adhesive to cure for 24 hours at room
65-38 Rev. 2
BHT-205A1-CR&O-1
GRIP
MECHANICAL DAMAGE
(Before and after
clean up) 0.020 in. 0.040 in.
CORROSION
(Before clean up) 0.010 in. 0.020 in.
(After clean up) 0.020 in. 0.040 in.
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS Two per lug Five

BOLT HOLE
NOTES:
A Area of repair on surfaces mating with blade or drag brace shall not exceed one-half of any quadrant.
2 No cracks allowed.
Figure 65-23. Grip assembly damage and repair limits.
65-39
BHT-205A1-CR&O-1
TRUNNION ASSEMBLY
MECHANICAL DAMAGE
(Before and
CORROSION DAMAGE
(Before and)
(after repair) 0.010 in. 0.020 in. 0.020 in.
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS One per segment Four Two per ear
BORE DAMAGE
SPLINEDAMAGE: Depth: One-third of spline

Length: 2.0 inches
Number: Two splines
THREAD DAMAGE:
Length: One-quarter inch
Number: One per segment
BOLTHOLE DAMAGE: 0.002 inch for 1/4 circumference
NOTE:
Figure 65-24. Trunnion assembly damage and repair limits
65-40
BHT-205A1-CR&O-1
temperature or for 30 minutes at a temperature of 6. If bonding between washer and ends of strap
145 to 180°F (63 to 82°C). retaining pins is broken, bond washer in place as
follows:
65-18. REPAIR - MAIN ROTOR HUB.
a. Lightly abrade surfaces to be bonded with
1. Replace all packings and seals. Replace 400 grit abrasive paper or cloth (C-423). Do not
self-locking nuts and unserviceable attaching remove cadmium plating from sides and chamfer of
hardware. pin.
b. Mix adhesive in accordance with following
2. Replace parts that fail magnetic particle or note. Apply adhesive to faying surface of pin and
fluorescent penetrant inspection. washer. Locate washer on pin centerline within 0.010
inch. Apply firm pressure to bond and cure bond in
3. Replace parts having mechanical or corrosion accordance with following note.
damage that exceed repair limits of figures 65-17,
65-19, 65-20, 65-21, 65-22, 65-23, and 65-24. NOTE: Mix adhesive (C-317) 33 parts B to 100
parts A. Ensure firm contact between parts and allow
4. Replace parts that exceed wear limits of to cure at 70 to 95°F (21 to 35°C) for 24 hours.
figures 65-18 and 65-25. (Maximum strength in 6 to 7 days at room
temperature.) Alternate curing may be accomplished
5. Replace shims if laminations are curled or by heating area 175 to 1900 F (79 to 88°C) for 60
damaged. minutes.
1. Bushing OD 0.9980 0.9990

2. Pillow Block ID 3.7500 3.7520
3. Liner ID 3.4992 3.5010
4. Spindle (After Coating) OD 2.2490 2.2505
Figure 65-25. Trunnion limits chart
65-41
BHT-205A1-CR&O-1
7. Replace shield assembly (23, figure 65-11) if (2) Outboarddragbracebolt .8721 inch.
damage penetrates hard anodized finish or if groove in
seal area exceeds 0.020 inch in depth. If shield is torn 9. Blade bolt (1, figure 65-10).
or damaged, replace as follows: a. Polish out minor scratches, score marks and
a. Remove damaged shield and clean off aged damage with crocus cloth. (Refer to figure 65-17 for
adhesive. limits.)
b. Vapor degrease shield and ring. b. Replace blade bolts if scored, corroded orworn
in excess of limits in figure 65-17 and 65-18.
c. Apply adhesive (C-301) to mating surfaces of
the shield and ring and to inside diameter of shield. Mix c. Coat repaired areas with LHE solution (C-108).
and cure adhesive to specifications listed on container. (Refer to BHT-ALL-SPM manual for prescribed
cadmium plating method.) Replace solid film lubricant
d. Position shield on radius ring and apply sealant (C-005) by spray or dip method if damaged or removed
(C-328) to bridge gap between shield and machined for inspection. Apply 0.0002 to 0.0005 inch thick on all
breakout of ring (two places). Apply light pressure to the exterior surfaces. (Refer to BHT-ALL-SPM.)
assembly and cure for 24 hours at 160°F (71 °C), or five
days at 70 to 95°F (21 to 35°C). 10. Pitch horn (14, figure 65-10).
8. Repair drag brace (35, figure 65-10) as follows: a. Polish out minor nicks, dents, and scratches
with crocus cloth.
a. Externally.
b. Coat repaired areas with brush alodine (C-100).
(1) Polish out minor nicks, scratches and dents
with crocus cloth. (Refer to figure 65-19.) Coat repaired c. Replace pitch horn if cracked, or if damaged or
areas with LHE solution (C-108). (Refer to corrosion exceeds limits of figure 65-20.
BHT-ALL-SPM manual for prescribed cadmium plating d. Replace bushings that are loose or
method.) Replace parts if damage or corrosion exceeds out-of-round, as follows:
limits of figure 65-19.
(1) Press out bushing in horn base (surface
NOTE: Allow enamel to air dry approximately 30 mating with grip). Replace pitch horn if diameter of hole
minutes prior to elevated temperature curing. in horn base exceeds 0.688 inch.
(2) Apply two coats, as required, inside tang (2) Bushings in control end of pitch horn:
surfaces of clevis (34, figure 65-10) and outboard flat
surfaces of fitting (30) with epoxy enamel (C-207). Allow (a) Press out single bushing first, then use
enamel to cure at 70 to 95°F (21 to 35°C) for 30 minutes. a drift to remove one of the dual bushings.
b. Internally. (b) Press out remaining bushing. Replace
pitch horn if diameter of hole in control end of pitch horn
(1) Remove internal superficial corrosion from exceeds 0.5005 inch.
fitting (30) with cleaner (C-344), abrasive pad or steel (3) Thoroughly clean pitch horn with solvent
wool. If corrosion cannot be removed by above method, (-304). Apply wet unreduced primer (C-201) to hole in
replace fitting. pitch horn and outside diameter of bushing spindle.
(2) Treat area of corrosion removal by Apply heat lamp to pitch horn and press in bushing.
assembling fitting to barrel (32). Fill and drain fitting and (4) Line ream bushings in control end of pitch
barrel with primer (C-204). Do not allow primer on horn 0.3743 to 0.3748 inch after installation. Bushings
threads of barrel or fitting. in base do not require line reaming.
c. Polish damaged areas of drag brace bolts (9)

blending edges of damage into surrounding surface to 11. Nut (26, figure 65-10) and pin (28).
a smooth contour, using crocus cloth. Damage area a. Polish out minor nicks and scratches.
shall not exceed one-fourth of bolt circumference after
clean-up. Replace bolts if outside diameter is below the b. Replace part if cracked, damaged or corroded.
following dimension.
12. Static stop (2, figure 65-11). Replace static stop if
(1) Inboard drag brace bolt 0.8730 inch. bolt holes are elongated or cracked or if part is distorted.
65-42 Rev. 2
BHT-205A1-CR&O-1
13. Yoke (4). e. In yoke spindle area outboard of inboard journal

diameter, repairdefects by blending and/or polishing out
NOTE: Rework of bearing journals shall exhibit no more than 0.005 inch depth of material. Reparable
evidence of polishing to a bright, smooth finish. Polished defects may be removed with 600 grit or finer abrasive
area shall blend smoothly into fully shot-peened area. cloth or crocus cloth until evidence of defect is removed.
Width of blended area shall be approximately 0.5 inch
wide and is not critical. See figure 65-22 for acceptable f. Rework in other areas of yoke requires Bell
size limits. Local rework of journals to improve surface Helicopter-Textron authorization.
finish is not recommended.
g. Refinish yoke as follows:

a. Repair by polishing and/or blending, defects
(scratches, abrasions, or dents) to no more than 0.002 (1) First overhaul interval for yokes not
inch depth of material. Reparable defects shall be previously painted
removed with 600 grit or finer abrasive cloth, or crocus
cloth, until no evidence of defect remains.
CAUTION: ALCOHOLIC PHOSPHORIC CLEANER
b. Refer to figure 65-22 for repair limits, area of SHALL BE APPLIED TO EFFECT REMOVAL OF ANY
repair, and other repair criteria. CORROSION PRESENT.
c. Longitudinal scratches on spindle, not in excess
of 0.002 inch, deep may not require complete removal. (a). Apply cleaner (C-344) to areas A, B,
Surface burrs shall be removed using crocus cloth, and C, figure 65-26 using a clean cloth. Rub briskly for
Clean up minor damage to threads. approximately 30 to 60 seconds.
d. Replace yoke if cracked, if bearing journal step
wear greater than limits outlined in figure 65-16A or if (b) Rinse thoroughly with clean flowing
damaged beyond limits outlined in figure 65-22. distilled water and wipe dry with a clean cloth.
Figure 65-26. Main rotor yoke refinishing area
Rev. 2 65-43
BHT-205A1-CR&O-1
(c) Touch up any cadmium plating as NOTE: If oven equipment necessary to bake solid film
required in areas B and C using brush LHE solution lubricant (C-005) is not available, solid film lubricant
(C-108). (Referto BHT-ALL-SPM manual for prescribed (C-006) may be used which can be cured (150°F) (66°C)
cadmium plating method.) by heat lamps or heat gun.
(d) Apply minimum thickness of 0.0004 inch (e) Lightly buff primed areas (areas B and C)
of solid film lubricant (C-005) to area A (spindles). (Refer with abrasive pad. Apply one coat of primer (C-202) to
to BHT-ALL-SPM manual.) Do not apply solid film areas where primer was removed and one mist coat to
lubricant to area B (spindle radius). areas where primer is intact. Allow to dry at least one
hour but no more than four hours.
NOTE: If oven equipment necessary to bake solid film
lubricant (C-005) is not available, solid film lubricant (f) Applytwospraycoatsoflacquer(C-203),
(C-006) may be used which can be cured (150°F) (66°C) light gull gray (color 36440), to all primed surfaces of
by heat lamps or heat gun. areas B and C, except pillow bushing holes. Spray coats
applied to area B (spindle radius) should be thin. Allow
(e) Apply one spray coat of primer (C-202) to air dry one hour minimum between coats.
to all surfaces of area C, except the seating bore area
for the inboard strap fitting. Apply one spray coat of 14. Strap assembly (7, figure65-11)
primerto area B (spindle radius). Allowto airdryat least a. Replace strap if inspection limits listed in
one hour but no more than four hours. paragraph 65-17, step 19 are exceeded.
NOTE: Acrylic lacquer will not adhere to primer b. Loose ends shall be snipped off flush with
(C-202) that has dried more than four hours. urethane coating and the number found entered in hub
historical record.
CAUTION: ACRYLICLACQUERTHICKNESSMUST c. If subsequent inspection reveals additional
BE UNIFORM WITH 0.001 INCH MAXIMUM loose ends, this number shall be added to entry in hub
ACCUMULATION PER COAT ON TOP SURFACE OF record to determine disposition of strap.
YOKE (AREA C).
(f) Applytwospraycoatsoflacquer(C-203), 15. Inboard strap fitting (8, figure 65-11) and
light gull gray (color 36440), to all primed surfaces of outboard fitting (25, figure 65-10).
areas B and C except pillow block bushing holes. Spray
coats applied to area B (spindle radius) should be thin.
Allow to air dry one hour minimum between coats. b. Replace fitting if cracked or badly corroded.
(2) Refinish procedures for second and 16. Back-upring(9,figure65-11)
subsequent overhauls (first refinish procedures for
painted yokes). a. Polish out minor nicks, scratches and dents.
(a) Apply cleaner (C-344) to area A, B, and b. Replace ring if cracked or distorted.
C, figure 65-26, using a clean cloth. Rub briskly for
approximately 30 to 60 seconds. 17. Replace pin (10) or sleeve (21) if corroded or
cracked.
(b) Rinse thoroughly with clean flowing
distilled water and wipe dry with a clean cloth.
a. Clean up minor damage to outer surface.
(c) Touch up any exposed surface in areas
B and C where primer and cadmium plating has been b. Replace if cracked, damaged, or corroded.
removed using brush LHE solution (C-108). (Refer to
BHT-ALL-SPM manual for prescribed cadmium plating 19. Replace shield assembly (23) if cracked,
method.) corroded, damaged, or if outside diameter is less than
5.488 inches.
(d) Apply minimum thickness of 0.0004 inch
of solid film lubricant (C-005) to area A (spindles). (Refer 20. Replace bearings (2 and 6, figure 65-13) and
to BHT-ALL-SPM manual.) Do not apply solid film inner races (20 and 22, figure 65-11) if spalled or
lubricant to area B (spindle radius). discolored due to overheating.
65-44 Rev. 2
BHT-205A1-CR&O-1
21. Replace plate (22, figure 65-13) if cracked, (1) Remove insert by drilling through lockring
distorted, or if bolt holes are elongated, or if shield with a drill bit which will just clean up serrations on inside
contact area on plate reservoir drain port exceeds a diameter. Use a square extractor and remove insert.
depth of 0.150 inch. Collapse any remaining lockring and remove.
22. Replace shims (25) if laminations are curled or (2) Inspect and clean threads and counterbore.
damaged. If threads are worn or hole is badly deformed, use next
oversize insert, with original inside thread.
23. Replace cover (10) and sight glass (8) if cracked
or damaged. (3) Coat mating surfaces with primer (C-201 or
204) and screw insert into grip (using installation tool),
23A. Grease-lubricated hub assembly: replace disc while wet, until top of serrations are 0.010 to 0.020 inch
(10A) if cracked or damaged. below surface of grip. Place lockring over insert,
engaging serrations on inside diameter with serrations
24. Grip repair. on insert, and drive flush with top of insert.
a. Polish out nicks, dents, and corrosion on outer d. Replace blade bolt bushings if inside diameter
surface of grip (1). (Refer to figure 65-23 for repair areas exceeds limits of figure 65-18.
and limits.) Treat repairs with chemical film (C-100). (1) Support tang of grip (2, figure 65-26A) and
press out blade bolt bushings (1).
b. Clean and coat all external surfaces of grip with
one coat of primer (C-204). Omit paint from all holes, (2) Inspect bushing bores in grip for damage.
bores, bushings, flanges, and nameplate. Replace grip if damage exceeds 0.002 inch for
one-fourth of circumference.
(1) Vapor degrease grip using trichloroethane
(C-334) at 188 to 193°F (87 to 89°C) and abrasive pad. (3) Install bushing (1) in grip (2) using thermal
After cleaning apply a film of water to surface and check fit procedures in BHT-ALL-SPM. Do not stress relieve.
for water break free surface. If a flashout occurs within (4) Check for gap between flange of bushing
25 seconds after flow of water stops, repeat cleaning (1) and surface of grip (2). Maximum gap of 0.0025 inch
and testing. permitted.
(2) Apply brush coat of chromic acid (C-103) to (5) Place a gage block 4.504 inches thick
surface. Rinse grip with clean water and dry with between tangs of grip (2) inboard of bushings (1) to
cheesecloth or tack rag. prevent misalignment while reaming.
(3) Applyprimer(C-204)tosurface. Primeshall (6) Line ream bushings (1) 2.500 - 2.501
be overcoated in not less than one hour and not more inches.
than eight hours. If primer was applied at elevated
temperatures, apply overcoat in not less than 30 e. Replace drag brace bolt bushings if inside
minutes and not more than three hours. diameter exceeds limits of figure 65-18.
NOTE: Lacquer surfaces not overcoated within one (1) Support drag brace tang and press out
hour require being wiped and with a tack rag prior to bushings (3, figure 65-26A).
application of next coat. (2) Inspect bushing bores for damage. Replace
grip if damage exceeds 0.002 inch for one-fourth of
(4) Apply lacquer (C-203) within time limits of circumference.
step (3). Apply a second coat of lacquer after a minimum
of 30 minutes drying time. (3) Install bushings (3) in grip (2) using thermal
fit procedures in BHT-ALL-SPM. Do not stress relieve.
(5) Cure by air drying for one hour and baking (4) Check for gap between flange of bushing
at 160°F (71°C) for one hour. Alternate cure is to air dry
at 65 to 85°F (18 to 29°C) for four to six hours.
(3) and surface of grip (2). Maximum gap of 0.0025 inch
permitted.
c. Replace inserts in grip if loose or threads are (5) Line ream bushings (3) 1.1245 to 1.1255
damaged. inches.
Rev. 2 65-45
BHT-205A1-CR&O-1
SEEVIEW B
SEE VIEW A
1.1245-
2.500-2.501 IN. 1. Blade Bolt Bushing

2. Grip
3. Drag Brace Bushing
VIEW A
Figure 65-26A. Main rotor hub grip bushing replacement
65-46
BHT-205A1-CR&O-1
(6) Machine faces of bushings (3) equally to 29. Replace reservoir (22) and cover (20) if cracked
obtain 2.872 to 2.876 inches shown in view B, figure or damaged.
65-26A. Faces of bushings (3) must be parallel with drag
brace tangs within 0.0005 inch after machining. 29A. Grease-lubricated hub assembly: replace
cover (22A) if cracked or damaged.
f. Replace grip if dimensions of bearing liners,
bushings, or grip tangs exceed limits shown in figure
65-18. a. Polish out minor nicks and scratches in pillow
block with crocus cloth. (Refer to figure 65-21.)
25. Replace bearings (2 and 6, figure 65-13) if rollers
are broken, if spalling or brinelling is evident, if b. Coat repaired areas with brush magnesium
discolored due to overheating or rough in operation or alloy chemical film treatment. (Refer to BHT-ALL-SPM)
inner races are replaced.
c. Replace pillow block if cracked or damaged
26. Trunnion repair. beyond limits shown in figure 65-21.
a. Polish out minor nicks and scratches on surface 31. Replace buffer (1, figure 65-27) if torn or worn
of trunnion (3, figure 65-15) with crocus cloth without through.
exceeding limits of figure 65-24.
existing buffer.
b. Coat repaired areas with LHE solution (C-108).
(Referto BHT-ALL-SPM for prescribed cadmium plating a. Remove remaining material and adhesive on
method.) the pillow blocks by carefully peeling and scraping with
a plastic scraper. Wipe clean with MEK (C-309).
c. Clean up minor nicks, burrs, and scratches on
splines with fine india stone. b. New buffer should be lightly sanded using 320
grit or finer abrasive paper. Wipe clean with MEK
d. Replace trunnion if cracked, damaged, or if (C-309).
corrosion limits of figure 65-24 are exceeded.
c. Cut bond spacer (3) (C-486) one-half inch
e. Clean using cloth moistened with MEK (C-309). larger than pillow block.
Apply solid film lube (C-005) to trunnion spindle outside d. Spread adhesive (C-363) on buffer and pillow
diameter, 0.0002 to 0.0004 inch thick. (Refer to block faying surfaces.
BHT-ALL-SPM) block faying surfaces.
e. Place bond spacer between buffer and pillow

NOTE: Allow film lube to dry 30 minutes at room block. Clamp pillow block and buffer in a locally
temperature, then heat to 350° ± 15°F (177 ± 90C) fabricated fixture. Cure for one hour at 175 to 190°F (79
for 60 minutes. to 88°C).
(1) Spindle diameter, after coating to be 2.2490 f. When cured, trim around base of pillow block.
to 2.2505 inches.
g. If required, remove face of buffer to achieve
(2) Apply corrosion preventive compound dimensional requirement of figure 65-27 without
(C-101) to trunnion spindle inside diameter. (Refer to penetrating fabric.
BHT-ALL-SPM for prescribed cadmium plating
cracked, warped or damaged. Replace helicoil insert if
27. Replace bearing inner race (7, figure 65-15) if loose or damaged.
spalled or discolored due to overheating. Replace 33. Replace bearing (25, figure 65-15) if spalled,
bearing inner race (7) and trunnion (3) if damaged due discolored due to overheating, roller is broken or is
to race turning on spindle (4). rough in operation.
is 28. Replace radius ring (5) if outer surface is worn, 34. Replace any part if defects are found for which
corroded, damaged, or cracked. no damage limits are established.
Rev. 2 65-47
BHT-205A1-CR&O-1
1. Buffer P/N 150-022-1

2. Pillow block
3. Bond spacer cerex 3607-21
Figure 65-27. Pillow block buffer
NOTE: Upgrade of main rotor hub assembly to later configuration requires incorporation
of parts listed in table 65-1. Parts retained for further service shall be subjected to normal
overhaul inspections to determine serviceability.
Table 65-1. Main rotor hub configuration
Part Number Item Quantity Configuration Remarks
204-012-101- Hub assembly 1 -005 Not procurable

-027 Not procurable
-145 Not procurable
-149
204-010-191-001 Reservoir 2 X X X X
204-010-506-005 Sight glass 2 X X X X
204-010-526-001 Lock 2 X X X X
204-010-529-001 Cover 2 X X X X
204-011-102-017 Yoke 1 X X Not procurable
204-011-102-021 Yoke 1 X Not procurable
204-011-102-125 Yoke 1 X X Replaced by
212-011-102-105
212-011-102-105 Yoke 1 X
204-011-105-001 Trunnion 1 X X X X
204-012-116-001 Radius ring 2 X Replaced by
116-107
204-012-116-003 Radius ring 2 X X Replaced by
116-107
204-012-116-005 Radius ring 2 X X Replaced by
116-107
204-012-116-107 Shield assembly 2 X
204-010-507-001 Cover 2 X X X X
65-48 Rev. 2
BHT-205A1-CR&O-1
Table 65-1. Main rotor hub configuration (Cont)
204-012-101 Hub assy 1 -005 -027 -145 Not procurable

-149
204-011-108-001 Pillow block 2 X Not procurable
204-011-108-003 Pillow block 2 X Not procurable
204-011-108-005 Pillow block 2 X Replaced by
108-113
204-011-108-113 Pillow block 1 X Replaced 108-ALL
204-011-110-001 Bearing 2 X Replaced by
110-003
204-011-110-003 Bearing 2 X X X X Replaced by
111-103
204-011-110-005 Bearing 2
204-011-111-001 Bearing 2 X X X Replaced by
111-103
204-011-111-003 Bearing 2
212-011-111-103 Bearing 2 X Replaced
111-ALL
204-011-112-001 Bearing 2 X X X Replaced by
112-103
204-011-112-003 Bearing 2
212-011-112-103 Bearing 2 X Replaced 112-ALL
204-011-116-001 Nut 2 X X X X
204-011-120-005 Pitch horn 2 X X X X
204-011-121-001 Grip 2 X Replaced by
121-005
204-011-121-005 Grip 2 X X X X
204-011-122-001 Liner 2 X X X X
204-011-123-001 Back-up ring 2 X X X X
204-011-125-001 Plate 2 X X Replaced by
125-005
204-011-125-005 Plate 2 X X Use in pairs
204-011-131-005 Seal 2 X X Replaced by
131-107
204-011-131-107 Seal 2 X X
204-011-132-001 Seal 2 X X X X
204-011-133-001 Thrust washer 2 X X X X
204-011-134-001 Lock 2 X X X X
204-011-135-003 Bushing 4 X X X Replaced by
135-105
204-011-135-105 Bushing 4 X
204-011-140-001 Drag brace 2 X X X X
204-011-147-001 Shim 8 X X X X
204-011-148-001 Radius ring 2 X X X X
204-011-149-001 Clamp 2 X X X X
204-011-150-001 Weight 16 X X X X
204-011-151-001 Blade bolt 2 X X X X
204-011-152-001 Washer 2 X X X X
204-011-153-001 Nut 2 X X X X
204-011-158-003 Key 2 X X X X
Rev. 2 65-48A
BHT-205A1-CR&O-1
Table 65-1. Main rotor hub configuration (Cont)
204-012-101 Hub assy 1 -005 -027 -145 -149

204-011-159-001 Outer spacer 2 X X X X
204-011-160-001 Inner spacer 2 X X X X
204-011-161-001 Grip align brkt 2 X X X X
204-011-162-001 Shim 8 X X X X
204-011-166-003 Bolt 2 X Not procurable
204-011-166-009 Bolt 2 X X X Not procurable
204-011-171-003 Bolt 4 X X Replaced by
20-057-10-48
20-057-10-48 Bolt 4 X
204-012-102-005 Inbd fitting 2 X X Replaced by
102-009
204-012-102-009 Inbd fitting 2 X X
204-012-103-001 Otbd fitting 2 X X X X
204-012-104-005 Pin 4 X X X X
204-012-105-001 Static stop 2 X X X X
204-012-106-001 Nut 2 X X X X
204-012-107-001 Seal sleeve 2 X X X X
204-012-108-001 Stop 2 X X X X
204-012-112-005 TT strap 2 X X Replaced by
204-012-122-001
204-012-122-001 TT strap 2 X Replaced by
122-005
204-012-122-005 TT strap 2 X X
204-310-101-101 TT strap 2 Alternate
204-012-113-003 Lockplate 2 X X X X
S12561-341 Channel seal 2 X X Replaced by
S32979-341 G99
S32979-341G99 Channel seal 2 X X
65-19. ASSEMBLY--MAIN ROTOR HUB. surfaces of parts specified in figures 65-10, 65-11,
65-13, and 65-15, and install while primer is still wet.
NOTE: Procedures for grease-lubricated hub (Refer to BHT-205A-1-MM-1).
assembly are not the same as those for oil-lubricated
hub assembly. The procedures used shall depend on All torque values are standard unless otherwise
hub assembly configuration being maintained. specified. (Refer to BHT-ALL-SPM).
Grease-lubricated hub assembly is packed with grease 1. Assembe yoke as follows:

(C-001). During assembly all bearings and all cavities
requiring grease shall be handpacked. NOTE: The following procedure is for one side of yoke
only. Opposite side is identical and shall be assembled
at the same time.
Steps pertaining to grease-lubricated hub assembly
shall be designated as such. a. Position yoke assembly (4, figure 65-11) on
edge and temporarily install static stop (2).
Apply corrosion preventive compound (C-101) or
corrosion preventive compound (C-104) to faying b. Positon T101421 adapter plate, flat surface
surfaces of parts specified in figures 65-10, 65-11, and down, on T101356 build-up bench. Place yoke on
65-15 during assembly. Apply primer (C-204) to faying build-up bench and on plate.
65-48B Rev. 2
BHT-205A1-CR&O-1
NOTE: Coat inside diameter of yoke assembly with (22) and install on spindle against shield assembly (23).
corrosion preventive compound (C-101 or 127). Slide sleeve (21) on spindle with stepped end outboard.
Install outer bearing inner race (20) next to sleeve. Note
c. Install shield assembly (23) as follows: direction of race installation (chamfer) on bearing races
(20 and 22).
(1) Clean inboard side of shield assembly and
spindle radius with a cloth dampened with denatured CAUTION: BEARING MATERIAL OR TEFLON
alcohol (C-326). COATING SHALL NOT BE REMOVED TO EASE
INSTALLATION OF BEARINGS.
(2) Install packing (24) in shield assembly (23).
e. Grease-lubricated hub assembly: apply grease
(3) Place shield assembly under heat lamp for (C-001) to inner diameter of bearing inner races (20 and
approximately 30 minutes prior to installation. 22) and yoke spindle bearing seats. Heat bearing inner
race (22) to 150 to 200°F and install on spindle against
(4) Apply a bead of sealant (C-328) to yoke shield assembly (23). Slide sleeve (21) on spindle with
spindle radius. stepped end outboard. Install outer bearing inner race
(20) next to sleeve. Note direction of chamfer on bearing
(5) Position shield assembly on yoke and tap races (20 and 22).
lightly using a nonmetallic drift to ensure seating on yoke
spindle radius. Fair sealant squeeze out to ensure that f. Using nut (26, figure 65-10), as a wrench, install
no sealant voids exist between shield assembly and nut (19, figure 65-11) on spindle. Torque nut 85 to 170
adjacent yoke surfaces. foot-pounds. Tap nut with a nonmetallic hammer to seat
bearing races, sleeve and radius ring. Retorque nut 85
NOTE: Inboard bearing inner race (22) and outboard to 170 foot-pounds. Back off nut (19) to give 0.005 to
bearing inner race (20) shall be installed with both race 0.015 inch clearance between nut and inner race of
serial numbers facing outboard. Bearings shall be bearing.
installed with chamfer in same direction as inner race.
Use inner races 212-311-009-101 and g. Install lock plate (18) and secure with two
212-311-010-101. Refer to A.S.B. 205-94-60. screws (17), secure screws with lockwire.
d. Apply lubricant (C-017) to inner diameter of NOTE: Lock plate may be installed on spindle of yoke
bearing inner races (20 and 22) and to yoke spindle with either face of lock plate next to spindle to allow
bearing seats. Apply heat lamp to bearing inner race alignment with screw holes in spindle end.
Rev. 2 65-48C/65-48D
BHT-205A1-CR&O-1
h. Remove static stop (2). Insert strap (7) through l. Establish initial setting of the opposite main rotor
spindle from outboard end. Place backup ring (9) over grip strap in the same manner.
strap end in center of yoke with flat surface inboard.
Install packing (11) on strap fitting (8) and install fitting NOTE: It may be necessary to make further
on inboard end of strap (7) with tabs on fitting down. adjustment of main rotor grip straps after flight test.
Insert pin (10) and slide backup ring (9) on strap fitting
(8) tight against shoulderof fitting. Press fitting and strap m. Assemble seal sleeve assembly,
assembly into cavity of yoke spindle. S32979-341G99, as follows:
NOTE: Establish initial setting of main rotor grip straps (1) Install expander (3, figure 65-29) in groove
when main rotor hub is assembled and/or when initial of sleeve (1) and position toward pressure side of
setting has been lost on both sides of hub due to groove.
inadvertent loosening of bolts (7, figure 65-28).
(2) Fold seal ring (2) and install in groove on low
pressure side of expander (3).
i. Install static stop assembly (5) and adjusting bolt
(4) with two bolts (7). Tighten bolts (7) to ensure NOTE: This seal does not require sealant.
engagement of bolt (4) with inboard strap fitting (3) but
loose enough to permit adjustment of adjusting bolt (4). n. Assemble seal sleeve assembly (13, figure
65-11), S12561-341, as follows:
j. Adjust bolt (4) so that dimension A from top of
yoke to tab on the leading edge of inboard strap fitting (1) Clean seal seeve (12) groove with MEK
(3) is 0.200 inch greater than dimension B on the trailing (C-309), and packing (14) with denatured alcohol.
edge side. (Refer to figure 65-28.)
(2) Clean channel seal (15) with acetone
(C-316) or MEK (C-309). Treat with tetra-etch (C-368)
NOTE: Do not turn adjusting bolt (4) more than four and rinse with acetone (C-316) or MEK (C-309).
turns.
(3) Coat sleeve internal groove and packing
k. Tighten bolts (7) and lockwire. (14) and channel seal (15) faying surfaces with
adhesive (C-308).
ROTATION
SYSTEM
PRESSURE
VIEW LOOKING OUTBOARD 1 Sleeve

1. Main Rotor Yoke 6. Aligning Bracket 2. Sealring
2. Tab (Trailing Edge) 7. Bolt 3. Expander
3. Inboard Strap Fitting 8. Gear-Adjusting Unit
4. Bolt 9. Tab (Leading Edge)
5. Static Stop Assembly
Figure 65-28. Collective pitch retention strap

adjustment Figure 65-29. Seal installation (New style)
Rev. 2 65-49
BHT-205A1-CR&O-1
(4) Install packing (14, figure 65-11) and packing (26) and shims (25) to give 0.003 to 0.007
channel seal (15) in sleeve (12). Wipe off excess inch clamp-up on bearings.
sealant with acetone (C-316) or MEK (C-309).
CAUTION: SEALANT SHALL NOT COVER
(5) Cure at 65 to 85°F (18 to 29°C) for 72 LUBRICATION PORTS IN PLATE ASSEMBLY (22).
hours minimum with outboard strap fitting or simulated
fitting engaged. Alternate cure 170 to 180°F (77 to d. Clean OD of seal (19) with MEK (C-309).
82°C) for two hours minimum. Install seal (19) in inboard side of plate (22) with bead
of sealant (C-328) around outside diameter of seal.
o. Install packing (16) on seal sleeve (12). Reinstall plate assembly and secure with bolts (20)
and washers (21). Install drain plug (24) with packing
p. Coat external surface of seal sleeve assembly (23) and relief plug (18). Secure drain plug and two
(13) and internal mating surface of spindle with bottom bolts (20) together with lockwire. Lockwire
lubricant (C-017). Install seal sleeve assembly (13) remaining bolts (20) in pairs.
into yoke spindle.
NOTE: Bolts, washers, and nuts shall be replaced with
q. Grease-lubricated hub assembly: coat new hardware. Further replacement will depend on
external surface of seal sleeve assembly (13) mating condition of hardware. To prevent unnecessary
surface of spindle with grease (C-001). Install seal replacement, sealant integrity shall be inspected
sleeve assembly (13) into yoke spindle. during daily inspections.
r. Bond seal sleeve assembly (13) and packing Bearing inner races (20 and 22, figure 65-11) shall be
(16) into yoke with adhesive MIL-S-8802, Class B2 (C- installed with chamfer facing outboard. Both inner
308). races and bearings (2 and 6, figure 65-13) shall be
installed in same direction.
2. Oil-lubricated hub assembly: assemble grip as
follows: 2A. Grease-lubricated hub assembly: assemble
grip as follows:
NOTE: Bearing inner races (20 and 22, figure 65-11)
CAUTION: SOLVENT USED TO CLEAN BEARING
shall be installed with chamfer facing outboard. Both
inner races and bearings (2 and 6, figure 65-13) must SHALL BE THOROUGHLY REMOVED BY
be installed in the same direction. COMPRESSED AIR OR AIR DRY BEFORE
PACKING WITH GREASE.
a. Position grip (1) on a suitable bench with a. Position grip assembly (1), tangs down, on
tangs down. Clean preservative from bearings (2 and
suitable bench. Clean bearings (2 and 6) with solvent
6) with clean solvent (C-304). Lubricate bearings (2 (C-304). Handpack bearings with grease (C-001) and
and 6) with approved oil and press bearing (6) into grip press bearing (6) into grip (1). Place packing (5) on
(1). Place packing (5) on outboard end and packing (3)
outboard end and packing (3) on inboard end of
on inboard end of spacer (4). Slide spacer (4) into grip
spacer (4). Slide spacer (4) into grip (1) firmly against
(1) firmly against outboard bearing. Press bearing (2) outboard bearing. Press bearing (2) into grip firmly
into grip firmly against spacer (4).
against spacer (4).
b. Position plate (22), flat side down, on bench. b. Position plate (22), flat side down, on bench.
Place packing (7) on reservoir surface of plate. Install Place packing (9A) on surface of grip plate. Place disc
packing (9) on cover (10). Place sight glass (8) on (10A) on plate (22) and install washer (15A) and bolt
plate. Place cover on sight glass. Place two spring (13A). Torque bolt 50 to 70 inch-pounds. Lockwire
washers (14), a thin steel washer (15), aluminum alloy bolthead with lockwire.
washer (16), and packing (17) on bolt (13). Install bolt
(13) in cover (10) and torque bolt until spring washers c. Install plate (22) on grip with six bolts (20) and
(14) are completely compressed. Back bolt off one full six washers (21). Tighten bolts snug and measure gap
turn (6 plus or minus 1/2 wrench flats). Install filler plug between grip and plate face. Remove plate and install
(12) and packing (11) in cover (10) and secure plug to packing (26) and shims (25) to provide 0.003 to 0.007
bolt (13) with lockwire. inch clampup on bearings.
c. Install plate (22) on grip with six bolts (20) and CAUTION: SEALANT SHALL NOT COVER GRIP
washers (21). Tighten bolts snug and measure gap ASSEMBLY LUBRICATION FITTING OR PLATE
between grip and plate face. Remove plate and install ASSEMBLY RELIEF FITTING.
65-50 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
d. Clean outside diameter of seal (19) with MEK order: two spring washers (15), one thin steel washer
(C-309). Install seal (19) in inboard side of plate (22) with (14), and one aluminum alloy washer (13). Install bolts
bead of sealant (C-328) around outside diameter of and torque bolts until spring washers (15) are
seal. Install plate (22) and secure with bolts (20) and completely compressed. Back bolt off one full turn (6
washers (21). Lockwire bolts (20) in pairs with lockwire. plus or minus 1/2 wrench flats).
Install relief fitting (18).
f. Install filler plug (18) with packing (19) and relief
3. Oil-lubricated hub assembly: assemble fitting (17) in cover (20).
trunnion and pillow block as follows:
3A. Grease-lubricated hub assembly: assemble
NOTE: The following procedure is for one side of
trunnion and one pillow block only. Opposite side is
identical and should be assembled at same time.
NOTE: The following procedure is for one side of
a. Install packing (6, figure 65-15) in radius ring (5) trunnion and pillow block only. Opposite side is identical
and press ring on trunnion (4) spindle. Apply lubricant and should be assembled at same time.
(C-017) to spindle (4) OD and bearing inner race (7) ID
and press bearing inner race (7) (smooth face inboard) a. Install packing (6, figure 65-15) in radius ring (5)
on trunnion tight against ring. Place packing (8) on lock and press ring on trunnion (4) spindle. Handpack
(9) and install in trunnion (3) spindle. Install washer (2) bearing inner race (7) inner diameter with grease
and nut (1) and torque 100 to 140 inch-pounds. Clean (C-001) and press bearing inner race (7) (smooth face
spindle in area of radius ring (5) in seal contact area with inboard) on trunnion tight against ring. Place packing (8)
MEK (C-309). Apply a bead of adhesive (C-308) or on lock (9) and install in trunnion (3) spindle. Install
equivalent to outside diameter of trunnion spindle, and washer (2) and nut (1) and torque 100 to 140
inboard side of radius ring (5). inch-pounds. Clean spindle in area of radius ring (5) in
seal contact area with MEK (C-309). Apply a bead of
b. Clean preservation from bearing (25). Press adhesive (C-308) or equivalent to outside diameter of
bearing (25) into liner (27). Secure with retainer ring (34) trunnion spindle and inboard side of radius ring (5).
and install seal (35). Check that seal is installed 0.22
inch below outboard surface of liner (27). Position b. Clean preservative from bearing (25). Press
packings (36) in pillow block (24) and press liner into bearing (25) into liner (27A). Secure with retainer ring
pillow block with lubrication holes aligned with holes in (34) and install modified seal (35A). Position packings
pillow block (24). Install four bolts (11), with washers (12) (36) in pillow block (24) and press liner into pillow block
under heads and nuts (32). Install nuts (32) and washers with lubrication holes aligned with holes in pillow block
fingertight. (24). Install four bolts (11), with washers (12) under
heads and nuts (32). Install nuts (32) and washers (33)
NOTE: Shims (26) will not be installed until trunnion fingertight.
centering operation, step 5. Use new shims at
installation. c. Install grease fitting (if removed) in liner (27A).
c. Position pillow block (24) outboard side down,

drop thrust washer (10) through liner bearing. NOTE: Shims (26) will not be installed until trunnion
centering operation, step 5. Use new shims at
d. Press trunnion assembly into liner. installation.
e. Install packings (23), reservoir (22), packing d. Position pillow block (24) outboard side down,
(21) and cover (20). Place washers on bolts (16) in this drop thrust washer (10) through liner bearing.
Rev. 2 65-50A/65-50B
BHT-205A1-CR&O-1
e. Press trunnion assembly into liner.
f. Install plate (22A) in place of reservoir assembly

with bolts (16A) and washers (15A). Torque bolts 50 to
70 inch-pounds and secure boltheads with lockwire.
4. Main rotor hub final assembly.
a. Install grip on yoke as follows:
NOTE: Procedure is given for one side only. Opposite

side is identical and should be installed at same time. FITTING
All torque values are standard, unless specified.

NUT
(1) Position yoke on T101356 buildup bench.

Position grip (11, figure 65-10) on yoke spindle with
tangs of grip approximately vertical. Press grip inboard
and rotate approximately 90 degrees to lock grip to
shield assembly (3).
NOTE: Rotating grip 90 degrees is not required for

installation, if shield assembly or grip plate does not BARREL
have safety lock.
(2) Place packings (29) on outboard fitting (25) 19.02

and install on outboard end of strap (2) with keyway of
fitting and grip aligned. Secure outboard fitting (25) with
pin (28). Apply a bead of adhesive (C-308)
approximately 0.06 inch diameter around each end of
pin (28). Insert key (27) into aligned keyway of grip and
fitting and install nut (26). (Final setting of nut (26) will be
accomplished in step 6.) Install blade bolt (1), washer
(19), with counterbored side against grip bushing, and NUT
nut (20). Tighten nut fingertight.
5.3
(3) Apply corrosion preventive compound
(C-101), to inner diameter and threaded parts of drag
brace assembly (35). Assemble nuts (31 and 33) on 0.620
barrel (32). Note that threads on barrel must match that
particular nut. Install clevis (34) on data plate end of
barrel and fitting (30) on opposite end. Adjust drag brace
length to a 19.02 inch dimension between hole centers
in clevis and fitting. Check for 0.620 inch thread
exposure at clevis end of drag brace. This is initial
setting only. (Refer to figure 65-30.)
(4) Attach drag brace (35, figure 65-10) to grip +

(11) with bolt (9), washer (10), washer (17) and nut (18).
Torque nut 125 to 150 foot-pounds.
(5) Apply primer (C-204) to faying surfaces of

pitch horn (14) and grip (11). Position pitch horn (14) on
grip (11) and secure with bolts (15) and washers. Torque
bolts and secure bolt heads with lockwire. Figure 65-30. Drag brace
Rev. 2 65-51
BHT-205A1-CR&O-1
b. Install pillow block and trunnion assembly on 5. Center trunnion as follows:

yoke as follows:
a. Remove hub assembly from T101356 buildup
(1) Apply primer (C-204) to following areas: stand. Turn T101421 adapter plate so the flat surface is
up and replace hub on stand. (Refer to figure 65-31.)
(a) Inside and outside diameters of bushing
(5). b. Position T101450 arbor in center of trunnion with
nut and washer removed. Place T101400 support on
(b) Bottom surface of pillow block (4) and pillow blocks and secure trunnion arbor to support. Adjust
pillow block bushing bores. pillow block liners (27 or 27A, figure 65-15) to permit tools
to align. Bolts (11) may be loose to permit alignment.
(c) Top surface of yoke which contacts
pillow blocks.
(2) Coat shank of bolts (6) with corrosion

preventive compound (C-104).
NOTE: Bolts, washers, and nuts shall be replaced with

new hardware at next removal of pillow block. Further
replacement requirement will depend on wear and
damage limits. To preclude unnecessary replacement of
hardware, sealant integrity shall be inspected during
daily crack inspection of yoke center section.
c. While primer is still wet, hold assembly securely,

and mount on yoke with bushings (5), bolts (6), washers
(7), and nuts (8). Torque nuts 64 to 79 foot-pounds.
d. Wipe following areas clean with cloth

dampened with denatured alcohol and apply a bead of
adhesive (C-308) to following areas:
(1) Pillow block bushing (5) flanges and
adjacent pillow block surface.
(2) Bolt heads (6) and adjacent bushing
surface.
(3) Perimeter of pillow block (4) and yoke
mating surface.
(4) Pillow block bolt nuts (8) and adjacent yoke
surface. \
NOTE: Retorque pillow block bolt nuts (8) after 25 to
30 flight hours.
1. T101402 Link
e. Tighten nut (26) until grip (11) is inboard as far as 2. T101400 Support
it will go. Striking outboard end of grip, with a plastic mallet, Assembly
while nut is being tightened will aid in seating parts. 3. T101450 Arbor
4. T101421 Adapter
f. Fill both grip and pillow block reservoirs with Plate
approved oil to show one-half full in the sight glass. Work 5. T101356 Build-up
out air as oil is added. Bench
g. Grease-lubricated hub assembly: purge
lubricate both pillow blocks with grease (C-001) until
grease purges past trunnion seals. Figure 65-31. Centering trunnion on hub
65-52 Rev. 2
BHT-205A1-CR&O-1
c. Install shims (26) between liner (27 or 27A) and a. Position hub on level T101356 buildup bench
pillow block (24) to provide a pinch fit of 0.000 to 0.004 (8, figure 65-32). With T101865 flap stops installed, use
inch on trunnion. This can be accomplished by bubble protractor to check for zero degree flap.
tightening eight bolts (11) and nuts (32) until the thrust Determine if the top surface of trunnion is parallel to the
washers (10) contact the trunnion without distortion of spanwise top surface of the yoke.
the liner. Measure the clearance between each liner and
pillow block with a feeler gage. Prepare shims of the b. Install T101402
positioning
grip links. Place a
same thickness less 0.002 inch. This will provide a 0.004
inch preload on the trunnion. The trunnion centerline bubble
establishprotractor
referencechordwise
plane, then top surface
on
chordwise of yoketo
on grip top
must coincide with the yoke spindle axis within 0.003
surface just outboard of blade bolt bushing. Adjust links
inch. Tighten nuts (32), except the bolt and nut with
T101402 link attached.
to position grips to zero degree angle.
d. Remove arbor, support, and main rotor hub NOTE: When positioning protractor on the grip
from buildup stand. Reverse T101421 adapter plate (flat surface, ensure that the protractor is parallel to the
surface down) on main rotor hub. protractor's position on the yoke surface. Orient
protractor in same direction on grips as it was on yoke
6. Adjust main rotor grips as follows: when the reference plane was determined.
Rev. 2 65-52A/65-52B
BHT-205A1-CR&O-1
c. Tighten nut (13) until hub grip is fully seated (4) Secure grease fitting (12A) to lock (9) with
inboard and then back-off nut (13) one full turn. Tap lockwire.
grip outboard using a heavy plastic mallet to aid in
seating hub parts. Repeat on opposite side of hub.
(5) Purge lubricate grips (1, figure 65-13) with
grease (C-001) until grease purges past grip seals (19)
d. Insert T101559 plug (3) in trunnion bore and and through relief fitting (18).
back off knurled bolt (4) to secure plug in trunnion. Set
adjustable end of T101559 grip spacing gage (2) to the
2.0 inch dimension shown in detail A. Position gage on i. Install blade bolt (1, figure 65-10), washer (19)
plug and secure gage to plug at hole marked with counterbored side against grip bushing, and nut
204-012-101. Locate the adjustable end of gage on (20) on each end of grip. Do not torque nut (20). Remove
grip bushing flange and position blade bolt (1) as grip spacing tools.
shown in figure 65-32.
7. Balance main rotor hub in accordance with
NOTE: Ifthe0.062withT101559gage(or0.176with paragraph 65-20.
T101474 gage) inch dimension cannot be obtained or
grip binding occurs, a gap up to 0.162 with T101559
gage (or 0.276 with T101474 gage) is acceptable. BALANCING-MAINROTORHUB.
Ensure grip spacing is the same on both grips within
0.002 inch. Refer to figure 65-32.
e. Check dimension between tip of T101559 gri p NOTE: If desired at this time to balance the main rotor
spacing gage (2) and barrel of blade bolt (1). Be sure hub, accomplish the following procedures, otherwise,
trunnion rotation does not occur during spacing with hub balancing must be accomplished at the time main
T101559 gage. Adjust nut (13) until gap between gage rotor blades are installed.
and bolt is 0.062 inch with T101559 gage or 0.176 inch
with T101474 gage. Tap grip outboard after each Procedures for grease-lubricated hub assembly are not
adjustment and recheck dimension. the same as those for oil-lubricated hub assembly. The
procedures used shall be based on hub assembly
f. Rotate T101559 grip spacing gage (2) and configuration.
T101559 plug (3) to the opposite grip and accomplish
steps d. and e. Steps pertaining to grease-lubricated hub assembly
shall be designated as such.
g. Install lock (9), clamp (10), washer (11), and bolt
(12) to secure nut (13) on each grip. Lockwire bolts (12).
Step 1. contains balancing procedures for Bell
Helicopter balancing tools. Step 2. is an alternate
h. For grease-lubricated hub assembly perform procedure using Marvel balancing tools.
the following:
1. Main rotor hub balancing using Bell Helicopter
(1) Install grease fitting (12A) in bolt (12B). Textron balancing tools.
Torque 50 to 70 inch-pounds.
a. Install grip positioning links (6, figure 65-32) on

NOTE: Chamfered washer shall be installed with each side of hub.
chamfered side toward bolthead and grease fitting.
(2) Install lock (9), clamp (10), chamfered b. Install flap stops (1, figure 65-33) on each side
washer (11 A), and bolt (12B) to secure nut (13) on each of trunnion.
grip.
c. Position T101458 balancing set on T101356
(3) Add steel washer (11B) as required to adjust buildup stand, with stud of T101458-5 plug (6) in socket
angle of fitting (12A) for ease of lubrication. on top of buildup stand.
Rev. 2 65-53
BHT-205A1-CR&O-1
0.176 TO 0.276 IN.

GAP AS REQUIRED
0.062 TO 0.162 IN.

GAP AS REQUIRED
TORQUE
DETAIL B DETAIL B
1. Blade bolt 7. T101421 adapter plate 11B. Steel washer

2. T101559 grip spacing gage 8. T101356 buildup bench 12. Bolt
3. T101559 plug 9. Lock 12A. Grease fitting
4. Knurled bolt 10. Clamp 12B. Bolt
5. T101865 flag stop 11. Washer 13. Nut
6. T101402 grip positioning link 11A. Chamfered washer 14. T101474 grip spacing gage
NOTE:
Applies only to grease-lubricated hub assembly. 205A1-R-65-32
Figure 65-32. Main rotor grip positioning
65-54 Rev. 2
BHT-205A1-CR&O-1
1. T101865 Flap Stop 4. Hub Assembly

2. Level, Bull's-Eye (810550) 5. T101356 Build-Up Bench
3. T101458-3 Socket and T101458-7 Spacer 6. T101458-5 Plug
Figure 65-33. Main rotor hub balancing
d. Using a plastic mallet, tap on heads of blade h. Position hub assembly on T101458 balancing
retention bolts to seat grips in their outward positions. set.
i. Place a Bulls eye spirit level (2) on top surface

e. Position drag braces to symmetrical angular of T101458 balancing set. Balance hub spanwise by
positions (equal angles relative to grips by measuring inserting lead weight into cavity of the appropriate blade
from blade retention bolt to blade drag brace bolt hole). bolt, as required, to center bubble in spirit level. Install
plugs in blade bolts and secure with lockwire.
f. Fill reservoirs with approved oil. An equal level
of oil should be in each grip. j. Balance hub assembly chordwise by attaching
balance weights (28, figure 65-15) (16 maximum)
and/or AN960-6 balance washers (29) (16 maximum),
g. Grease-lubricated hub assembly: purge lubricate as required, to bolt in center of liner (27 or 27A). Use
both grips and pillow blocks with grease (C-001) until bolts (31) of sufficient length and washer (30) to secure
grease purges past grip seals and trunnion seals. weights and washers without bottoming of bolt in liner.
Rev. 2 65-55
BHT-205A1-CR&O-1
k. Color code the parts for correct reassembly

after subsequent disassembly.
l. Remove hub from balancing stand. Remove flap

stops and grip positioning links.
2. Main rotor hub balancing using Marvel balancing

tools. (Alternate procedure.)
a. Assemble 7A050 hoist support structure kit with

2769 tube assembly instead of 2288 tube assembly to
provide additional hoist arm length. (Refer to figure
65-34.)
b. Center fixture (1, figure 65-35) on 7A050 work

stand kit.
c. Install sleeve (2) over top of fixture (1) and seat

sleeve on upper shoulder of fixture central projection.
d. Install adapter (3), heavy end downward, over

top of fixture (1) and seat on top of sleeve (2). Lock
adapter in this position by tightening adapter setscrew
(4).
e. Before positioning hub on fixture, alternately

hold grips down to bleed air from grip. Continue filling
reservoir and bleed until grips are filled, thereby
equalizing oil in both grips. Secure filler plugs with
lockwire.
Figure 65-34. Balancing kit
f. Carefully lower rotor hub assembly (8) over h. Place a block of wood against the heads of
fixture (1) aligning inside diameter of splined trunnion rotor blade retention bolts, tap the block moving the
withpilotingdiameterofadapter(3),andensuringthat grips in radially outward direction to ensure blade
cone surface of splined trunnion seats firmly on cone grips are fully seated in their radially outward position.
surface of adapter (3).
NOTE: Spot clean hub with solvent (C-304).
g. Install T101402 pitch positioning links and
adjust blade grips to symmetrical pitch positions. To i. Install yoke (5), legs downward, over top end of
accomplish this, place a bubble protractor on flat top balancing arbor (6) and positioned so that the top
surface of rotor hub across the grip pitch axis; adjust surface of its locking collar (sensitivity setting reference)
protractor to center bubble. Transfer protractor, aligns with arbor scale (7) at 14.75 inches. Lock yoke (5)
keeping it in same transverse position, to bottom firmly in this position on arbor with its collar screws,
inside surface of either blade grip fork and align using a 3/16 inch hex wrench.
protractor base with the transverse milled line in the
fork surface. Adjust grip pitch only to again center j. Install balancing arbor (6) downward through
protractor bubble. Transfer protractor in same rotor trunnion and fixture (1) assembly, seating both
transverse position to opposite grip fork and repeat yoke(5) legsfirmlyon flattop surface of rotor hub, in line
grip pitch adjustment. with blade grip pitch axis.
65-56 Rev. 2
BHT-205A 1-CR&O-1
1. Fixture
(2337, 7HEL054 Kit)
2. Sleeve
(2467, 7HEL054 Kit)
3. Adapter
(2528, 7HEL061 Kit)
4. Adapter Set Screw
5. Yoke
(2589, 7HEL061 Kit)
6. Balancing Arbor
(2259, 7A050 Kit)
7. Arbor Scale
8. Rotor Hub Assembly
9. Spacer (7A050 Kit)
10. Drag Strut
11. Drag Strut Position
Gage (2486, 7HEL061
Kit)
12. Gage Inner Position
13. Gage Outer Position SEEVEW A
14. Handwheel
(2215, 7A050 Kit)
15. Stand Table SENSITIVITY
(7A050 Kit) SETTING VIEW
REFERENCE BALANCE INDICATION
WITHIN EXCEEDS
BALANCED LIMITS LIMITS
Figure 65-35. Balancing main rotor (alternate procedures
main rotor
Figure65-35. (alternate procedures)
Balancing
65-57
BHT-205A1-CR&O-1
k. Install spacer (9) (7A050 kit) over lower end 65-22. REPLACEMENT - MAIN ROTOR GRIP
of balancing arbor (6). Install handwheel (14) in SEALS.
bottom end of arbor and tighten to clamp yoke (5)
firmly against top surface of rotor hub.
NOTE: Replace grip seals if, during a two hour
. Using drag strut position gage (11) as flight, the grip reservoir becomes empty or after a 24
illustrated, adjust rotor hub drag brace struts (10) for hour period when the helicopter is not operated, the
a symetrically angular position. Also, use outer oil level is not visible in the grip reservoir.
position gage (13). Remove gage from rotor assembly
during balance check. NOTE: The following procedure describes the
replacement of seals of one side of main rotor hub.
m. Install quick-disconnect assembly with Replace seals on opposite side in same manner if
3/16 inch cable on balancing arbor (6). Suspend rod required.
end and engage cable in lifting plate of hydraulic
pump assembly. Hoist entire assembly approximately 1 356 build-up bench
1/4 inch off work stand. Check to ensure that to workbench.
suspended assembly is free from interference with
conditions indicated by black indicator disc at top end surface down on T101356 build-up bench.
of arbor. (Refer to view A.)
3. Position main rotor hub assembly on T101356
build-up bench and T101421 adapter. Secure in
NOTE: To ensure hand wheel is free of interference place.
within the inside diameter of table, it may be
necessary to adjust level of stand by installing 4. Remove lockwire and drain plug (1, figure
suitable wood blocks or spacers under the two 65-36) with preformed packing from grip plate (2).
tubular stand legs.
NOTE: Each grip holds approximately one quart of
n. Balance hub spanwise by inserting lead into oil; therefore, position a suitable container to receive
cavity of blade retention bolt to achieve balance the oil.
within limits.
5. Remove relief fitting (3) in reservoir of grip
o. Balance hub chordwise by attaching weights plate (2) to relieve vacuum while draining oil. Replace
and/or small washers, as required, to pillow block relief fitting (3) after oil has drained.
liner. A maximum of sixteen weights may be attached
with an AN bolt of sufficient length to secure weights 6 Remove horn assembly (4) from grip assembly
without bottoming
without bottoming bolt in liner. (5) by removing lockwire and two bolts (6) and two
washers.
p. Install and lockwire plugs in blade bolts. 7. Remove grip assembly (5) from yoke assembly
(7) as follows:
q. Color-band parts to maintain their respective
positions. a. Cut lockwire from bolt (8) and remove
washer, clamp (9), and lock (10) from grip assembly.
r. Remove main rotor hub from balancing stand. b.Remove
b.Remove retention
retention nut and key12)from
nut (11) and key (12) from
grip assembly.
65-21. MAIN ROTOR GRIP SEALS.
c. Remove pin (13) from outboard fitting (14)
TOOLS REQUIRED and strap assembly (16).
T101356 Build-up Bench d. Remove outboard fitting (14) from grip

T101421 Adapter Plate assembly.
65-58
1. Drain Plug 11. Retention Nut
2. Grip Plate 12. Key
3. Relief Fitting 13. Pin
4. Horn Assembly 14. Outboard Fitting
5. Grip Assembly 15. Preformed Packing
6. Bolts 16. Strap Assembly
7. Yoke Assembly 17. Bolt
8. Bolt 18. Shims
9. Clamp 19. Seal
10. Lock 20. Preformed Packing
I O® fB=y 't
BHT-205A1-CR&O-1
NOTE: Rotating grip 90 degrees is not required for NOTE: Two bolts and washers are temporarily
removal if radius ring or grip platedoes not have safety installed until after readjustment of main rotor grips
locks. when using grip spacing tool.
e. Press grip assembly (5) inboard and rotate 10. Assemble grip assembly to yoke assembly as
90 degrees (looking inboard) and pull outboard. follows:
NOTE: Grip assembly is secured to yoke assembly

by a channel in the radius ring and the lip of the cover CAUTION: USE EXTREME CARE WHEN
plate until rotated. INSTALLING GRIP ASSEMBLY ON YOKE
ASSEMBLY TO PREVENT DAMAGE TO BEARINGS
8. Disassemble grip as follows: WHEN MATING WITH INNER RACE.
a. Remove lockwire, six bolts (17), and six NOTE: Apply approved oil liberally to mating parts.
washers securing grip plate (2) to grip assembly (5).
Remove grip plate (2).
NOTE: Rotating grip 90 degrees is not required for
b. Remove shims (18) and identify for installation, if radius ring or grip plate does not have
reinstallation. safety locks.
c. Remove seal (19) and preformed packing a. Slide grip assembly (5) inboard with care on
(20) from grip plate (2). spindle of yoke assembly (7) (drag brace up). Align
slot in outboard fitting with slot in grip assembly.
Rotate 90 degrees to lock in place.
d. Clean all parts with solvent (C-304) and finish
cleaning with MEK (C-309).
b. Install two preformed packings (15) in
grooves of outboard fitting (14).
e. Apply adhesive (C-325) to O.D. of seating
surface of a new seal (19) and install in grip plate c. Slide outboard fitting(14)in place over strap
(2) with lip of seal (19) inboard in grip plate.
assembly (16) and lock in place with pin (13). Apply
adhesive (C-308) (approximately 0.06 inch diameter)
CAUTION: MAKE SURE THAT FILLER HOLE AND around end of pin (13).
DRAIN HOLE ARE NOT FILLED WITH EXCESS
ADHESIVE. HOLES MUST BE OPEN.
d. Install key (12) in slot and temporarily screw
retention nut (11) onto outboard fitting (14). Apply
f. Lubricate seal (19) liberally with oil. primer (C-201) to key, and to slot in outboard fitting
and grip assembly.
g. Install preformed packing (20) in groove in
grip plate (2). e. Fill both grip reservoirs with approved oil to
show one-half full in sight glass. Work out air as oil
9. Assemble grip assembly as follows: is added.
a. Measure and record thickness of shims (18). 11. Adjust spacing of main rotor grip. (Refer to
paragraph 65-19, step 6.)
NOTE: The two shims should measure within 0.002
inch in thickness to each other and for each grip
assembly. 65-23. MAIN ROTOR CONTROLS.
b. Position shims (18) and grip plate (2) on grip

assembly. The main rotor controls covered in this section are:
stabilizer bar, pitch change links, control tubes,
c. Install bolts (17) and washers in grip scissors and sleeve, swashplate and support, and
assembly. collective levers.
65-60 Rev. 2
BHT-205A1-CR&O-1
65-24. STABILIZER BAR. 65-27. Conditional Inspection - Stabilizer Bar.
65-25. DISASSEMBLY- STABILIZERBAR. 1. Apparent deformation of a tube assembly is

cause for scrapping the stabilizer bar assembly.
NOTE: Review Mandatory Retirement Schedule,
BHT-205A1-MM-1, and retire all items scheduled for 2. If there is no evidence of tube deformation,
retirement. accomplish Normal Inspection, paragraph 65-28.
If stabilizer bar is being disassembled for replacement

of parts instead of overhaul, disassemble only to 65-28. Normal Inspection- StabilizerBar.
extent necessary to replace parts.
1. Visually inspect parts for obvious defects that
Overhaul of stabilizer bars 204-011-326 and would render the part unserviceable.
212-010-300 is the same except where noted in text
or illustration. 2. Inspect parts for mechanical and corrosion
damage. (Refer to figures 65-38 and 65-39.)
1. Remove nuts (14, figure 65-37), bolts (25) and
washers (15). Remove support assemblies (22).
2. Remove 204-011-301 mixing levers (32) by a. Corrosion and mechanical damage on cable
removing nuts (33), washers (34), bolts (30) and end fittings shall not exceed 0010 inch depth after
shim washers (29). Remove mixing levers (32). cleanup.
3. Remove 212-010-302 mixing levers (35) by b. Replace ssembly f crimped excessive

removing nuts (33), washers (34), bolts (30), corrosion damage, or frayed wires are found on cable.
bushing (37), special washer (36) and shim washers
(29). Remove mixing lever (33) and special washers
4. Inspect the following parts by magnetic
(40). particle (Code M) or fluorescent penetrant (Code F),
as applicable. Demagnetize parts after magnetic
particle inspection. Index numbers are keyed to figure
4. Remove tube assembly (12) from each end of
centerframe (19) by removing bolts (23), washers
(24) and nuts (18).
NOTE: Magnetic particle inspection shall be
5. Cut lockwire, back off nut (10) from weight (9) performed using the wet, continuous, fluorescent
until key type lock (11) is free from weight. Remove method. The length of any indications may be
nuts (5), retainer (6), bushing (7), and washer (8) determined by the residual method of magnetization.
from cable assembly (3). Remove weight (9) and nut
(10) from tube assembly (12). The following general formula shall be used for
determining ampere-turns: number of coil turns (on
6. Remove bolt (4), stat-o-seals (2), nut (1) and coil plate) x amperage (meter).
pull cable assembly (3) from tube. Cut lockwire and
remove screws (13), bearing retainer (16) and bearing Refer to BHT-ALL-SPM manual for approved
(17). fluorescent penetrant material.
65-26. INSPECTION - STABILIZER BAR. Index No. Nomenclature Code
NOTE: If records or physical appearance indicate 12 Tube M (See

that the stabilizer bar has been subjected to an step 8)
accident or incident outside the realm of normal 19 Centerframe F
usage, perform Conditional Inspection, paragraph 22 Support F
65-27. If stabilizer bar does not require the 32 Lever (204-011-301) F
Conditional Inspection, proceed with Normal 35 Lever(212-010-302) F
Inspection, paragraph 65-28.
65-61
BHT-205A1-CR&O-1
TORQUE
60 TO 85 IN-LB---
TORQUE
3. Cable assembly 14. Nut 25. Bolt 36. Special washer

4. Bolt 15. Washer 26. Bushing 37. Bushing
5. Nut 16. Retainer, bearing 27. Bearing 38. Cotter pin
6. Retainer 17. Bearing 28. Bushing 39. Bushing
7. Bushing 18. Nut 29. Washer/s (shim) 40. Special washer (212-010-310)
8. Washer 19. Centerframe 30. Bolt 41. Stabilizer (212-010-300)
9. Weight 20. Bushing31. Bearing 42. Stabilizer (204-011-326)
10. Nut 21. Bushing 32. Mixing lever (204-011-301)
11. Lock, key type 22. Support assembly 33. Nut
Figure 65-37. Stabilizer bar (Sheet 1 of 2)
65-62
BHT-205A 1-CR&O-1
MINIMUM TUBE ENGAGEMENT
TORQUE 1 TO 40 IN-LB
TORQUE
1600 TO 1900
IN-LBS
SEALANT
DETAIL A
0·t~~~~~~~~ ~~~ASSEMBLY DIMENSION PRIOR TO BALANCE
DETAIL B
Figure 65-37. Stabilizer bar (Sheet 2 of 2)
5. Inspect bushing ID for scoring not to exceed 7. Visually inspect retainer (6), bushing (7),
0.002 maximum depth. Inspect bushing ID for wear. washer (8), weight (9), key type lock (11), and
Refer to the following table for wear limits. Bushing bearing retainer (16) for damage.
index numbers are keyed to figure 65-37.
8. Conduct magnetic particle inspection of
Bushing stabilizer bar tube assembly (12). The stabilizer bar
Index No. Minimum Maximum tube must be inspected by all of the following steps
using wet continuous method. Use of fluorescent
20 0.2495 0.2520 coated particles with ultra violet light is mandatory.
21 0.3745 0.3770 The length of any indication shall be determined by
26 0.6242 0.6267 residual method of magnetization.
28 0.3744 0.3767
39 0.3745 0.3767 NOTE: If ac magnetic particle inspection equipment
is used, use 60 percent of dc amperes specified:
6. Inspect lube fittings in centerframe (19) and
mixing lever (32 or 35) for security and damage. a. Thoroughly degrease stabilizer bar tube.
65-63
BHT-205A1-CR&O-1
MIXING LEVER(TYPICAL) SUPPORT
AREA A AREA B AREA C
TYPE OF DAMAGE MAXIMUM DEPTHS ALLOWED
NICKS, SCRATCHES, 0.010 in. before and 0.035 in. before and 0.035 in. before and
SHARP DENTS after repair after repair after repair
CORROSION 0.005 in. before repair 0.017 in. before repair 0.017 in. before repair
0.010 in. after repair 0.035 in. after repair 0.035 in. after repair
AREA OF FULL 0.10 sq. in. 0.25 sq. in. 0.25 sq. in.
DEPTH REPAIR
NUMBER OF REPAIR One/segment One/segment Two

AREAS
NOTE:
1. All edges may be radiused or chamfered 0.060 inch to remove nicks and dents.
Figure 65-38. Stabilizer bar mixing lever and support damage limits
65-64
BHT-205A1-CR&O-1
FRAME
TYPE OF DAMAGE
MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
NICKS, SCRATCHES, 0.005 In. 0.010 In. See Note

DENTS AND
CORROSION 0.035 In. 0.020 In.
(For Mech. (For Mech.
Damage) Damage)
0.017 Before Repair 0.010 Before Repair

0.035 After Repair 0.020 After Repair
(For Corrosion (For Corrosion
Damage) Damage)
MAXIMUM AREA PER 0.25 Sq. In. 0.050 Sq. In.
FULL DEPTH REPAIR 0.75 Sq. In. 0.50 Sq. In.
NUMBER OF REPAIRS Two Not Critical
Not Critical Two Per Segment

EDGE CHAMFER Not Applicable 0.030 In.
0.100 In. 0.050 In.

THREAD DAMAGE: Depth: One-Third of Thread
Length: One-Quarter Inch
Number: Two
NOTE: Small nicks and dents may be suitably treated by coating with zinc chromate.
Figure 65-39. Stabilizer bar tube and frame damage limits
65-65
BHT-205A1-CR&O-1
b. Place stabilizer bar tube longitudinally m. After completion of inspection demagnetize

between contact heads of the inspection equipment stabilizer bar tube and check with pocket field
and pass 1000 amperes of dc current through indicator or compass to assure demagnetization.
stabilizer bar tube.
65-29. REPAIR - STABILIZER BAR.
c. Inspect completely for indications.
1. Repair mechanical and corrosion damage by
polishing out the damage and blend repair smoothly
d. With stabilizer bar tube placed as in step b.,rounding
into surrounding area.
area. Do not exceed depth and area
Do not exceed depth and area
pass 3000 amperes of dc current through stabilizer limits of figures 65-38 and 65-39.
limits of figures 65-38 and 65-39.
bar tube.
CAUTION: IN ALL REPAIRS, REMOVE ONLY
e. Inspect fitting end of stabilizer bar tube NECESSARY MATERIAL REQUIRED TO
completely for indications. ACCOMPLISH REPAIRS DESCRIBED ABOVE. DO
NOT USE STEEL WOOL ON ALUMINUM PARTS. USE
f. Place stabilizer bar tube in the coil with OF GRINDING WHEELS, PATCHING, OR PLUGGING
longitudinal axis of stabilizer bar tube perpendicular OF HOLES IS NOT ALLOWED.
to the plane of the coil and fitting end of stabilizer bar
tube protruding approximately two inches from coil. 2. Coat repaired areas on aluminum parts with
Magnetize stabilizer bar tube using 10,000 chemical treatment film (C-100) and apply LHE
ampere-turns. solution (C-108) to repair areas where cadmium
plating was removed. (Refer to BHT-ALL-SPMmanual
g. Inspect stabilizer bar tube completely for for prescribed cadmium plating method.)
indications.
3. Treat internal surface of tube assembly (12,
figure 65-37) to prevent corrosion as follows:
h. Reposition stabilizer bar tube in coil with
fitting end of stabilizer bar tube protruding from the a.
a. Degrease tube assembly (12) with
coil approximately 17 inches. Magnetize stabilizer bar
trichloroethane (C-334) or equivalent.
tube using 10,000 ampere-turns.
b. Mix epoxy/zinc coating (C-208) in
i. Inspect stabilizer bar tube completely for accordance with instructions of manufacturer. Do not
indications. thin the material.
j. Reposition stabilizer bar tube in coil with CAUTION: COMPLY WITH POT LIFE LIMIT SET
threaded end of stabilizer bar tube protruding from FORTH BY MANUFACTURER.
coil approximately seven inches. Magnetize stabilizer
bar tube using 10,000 ampere-turns. c. Thoroughly agitate the material prior to each
application to keep the zinc evenly dispersed.
k. Inspect stabilizer bar tube completely for
indications. d. Plug one end of stabilizer bar tube and bolt
(4, figure 65-37) hole. Fill the tube approximately 3/4
I. Acceptance
criteria.partical
Magnetic
I. Acceptance criteria. Magnetic particle
and rotate until surfaces are coated. Remove plugs
indications interpreted as cracks are rejectable. and allow the excess material to flow out.
and allow the excess material to flow out.
e. Allow minimum of one hour air dry time then

NOTE: A broad hazy circumferential indication, repeat step d. and allow to air dry for 24 to 48 hours.
located approximately 5-1/2 inches from fitting end
of stabilizer bar tube, will normally be detected. This 4. Replace parts found defective by magnetic
broad hazy indication is acceptable. particle or fluorescent penetrant inspection.
65-66
BHT-205A 1-CR&O- 1
5. Replace bearing (17), stat-o-seals (2), and c. Clean lever bore and sleeve with solvent
self-locking nuts. (C-304). Inspect bore for scoring. Score marks shall
not exceed 0.002 inch depth after cleanup nor
6. Replace parts if mechanical or corrosion one-fourth the circumference.
damage exceeds repairable limits.
d. Apply primer (C-201) to mating surfaces of
7. Replace defective bushings (20, 21, 26, 28, sleeve and bore of lever.
and 39) as follows:
e. Press sleeve into lever while primer is still
a. Place part on suitable support and press wet. Check that sleeve extends approximately 0.015
bushing out. Inspect bore for scoring. Score marks to 0.020 inch on each side of lever bore.
shall not exceed 0.002 inch depth after cleanup and
not to exceed 1/4 circumference.
CAUTION: ENSURE FITTING HOLE IS NOT
b. Coat mating surfaces of replacement ENLARGEDDURING DRILLING.
bushing and part with primer (C-201).
f. Remove lube fitting from lever. Using lube
c. Support part and press bushing in place fitting hole as a guide, drill a 0.090 inch hole through
while primer is still wet. sleeve. Install lube fitting.
d. Ream bushing ID to the following g. Ream sleeve 1.2485 to 1.2490 inches

dimensions, as applicable. Bushing index numbers diameter. Clean sleeve thoroughly.
are keyed to figure 65-37.
h. Apply primer (C-201) to mating surface of
bearing and sleeve. Press bearing into sleeve while
Index No. Bushing ID primer is still wet.
Index No. Bushing ID
i. Select a staking tool to accomplish a ring

20 0.2495 to .2500 Inch stake. (Refer to BHT-ALL-SPM manual.) Ring stake
sleeve both sides.
21 0.3745 to 0.3750 Inch
(Line Ream Bushings) j. Support lever on a suitable support and proof
load bearing 500 to 800 pounds in each direction.
26 0.6242 to 0.6247 Inch Ensure load is applied to outer race of bearing. Check
bearing for smooth operation.
28 0.3744 to 0.3747 Inch
(Line Ream Bushings) 9. Replace bearings (27, figure 65-37). Apply
coat of unreduced primer (C-201) to mating surface
39 0.3745 to 0.3750 Inch of new bearing and liner and install bearing while
(Line Ream Bushings) primer is still wet.
8. Replace bearing (31) as follows: 10. Paint support assembly (22), mixing lever (32
or 35), and centerframe (19) as follows:
a. Support lever on suitable support having
clearance for bearing and sleeve. Press bearing and a. Apply chemical film treatment (C-100) as
sleeve out of lever. required. (Refer to BHT-205A1-MM-1 manual.)
b. Remove any visible burrs from replacement b. Prime all surfaces and holes with one coat of
sleeve with 320 or finer abrasive paper (C-423). primer (C-204). Overcoat shall be applied in not less
Ensure edges are not rounded or chamfered by than one hour nor more than eight hours. (Refer to
sanding. BHT-205A1-MM-1 manual.)
65-67
BHT-205A1-CR&O-1
c. Paint all surfaces with two coats of lacquer 1. Inspect dampers as described in
(C-203) light gull gray, except bearing bores, BHT-205A1-MM-1.
lubrication fittings, bushings, and holes. (Refer to
BHT-ALL-SPM.) 2. Repair lever arm to limits of figure 65-40.
65-30. INSPECTION AND REPAIR - STABILIZER 3. Repairdamper,adapter,anddamperlinktubeto

BAR DAMPERS. limits of figure 65-41.
NOTE: Upgrading stabilizer bar assembly to later configuration will require

incorporating parts as shown in table 65-2. All parts to be retained in service
shall be required normal overhaul inspection to determine serviceability.
Table 65-2. Stabilizer bar assembly configuration
Part Number Item Quantity Configuration Notes
204-011-326 Stabilizer bar assembly 1 -001 -007 -013 -015 N/P

212-010-300 Stabilizer bar assembly 1 -001
204-011-301-001 Mixing lever 2 X X 1
212-010-302-001 Mixing lever 2 X X X 2
212-010-302-105 Mixing lever 2 Replaces mixing lever 212-010-302-001
204-011-303-007 Weight 2 X X X X 3
212-010-306-001 Weight 2 X
204-011-304-001 Support assembly 2 X X X X X 4
204-011-304-105 Support assembly 2 Replaces support 204-011-304-001
204-011-307-001 Center frame 2 X X X X X 5
204-011-307-105 Center frame 2 Replaces frame 204-011-307-001
204-011-308-001 Bearing retainer 2 X X X X X
204-011-310-001 Bearing set 2 X X X X X
204-011-311-001 Washer 2 X
204-011-328-001 Tube assembly 2 X X 6
204-011-328-011 Tube assembly 2 X X 3
540-011-319-001 Tube assembly 2 X
212-010-311-101 Tube assembly 2 Alternate for Tube P/N 540-010-319-001
204-011-312-001 Tie rod 2 X
204-011-329-001 Cable assembly 2 X X X X
204-011-332-001 Washer 2 X X X
204-011-333-001 Bushing 2 X X X X
204-011-334-001 Retainer 2 X X X X
212-010-303-001 Bushing 4 X X X
212-010-304-001 Washer 4 X X
212-010-310-001 Washer 4 X X X
540-011-322-001 Bushing 2 X
AN315-4L Check nut - 4
MS17826-6 Nut - 4 4 4 7
MS17826-10 Nut - 2 7
AN320-10 Nut - 2 2 2 8
AN320-6 Nut - 4 4 9
65-68 Rev. 2
BHT-205A1-CR&O-1
Table 65-2. Stabilizer bar assembly configuration (Cont)

204-011-326 Stabilizer bar assembly 1 -001 -007 -013 -015 N/P

212-010-300 Stabilizer bar assembly 1 -001
AN960-416 Washer - 4
AN960-616 Washer - AR AR AR 12
AN960-616L Washer - AR AR AR 4
AN960-1016 Washer - 4 4 4 2
MS24665-283 Cotter pin - 4
MS24665-300 Cotter pin - 4 4 4 4
MS24655-353 Cotter pin - 2
MS24665-370 Cotter pin - 2 2 2 2
MS29513-119 Packing - 2
NAS464-6-20 Bolt - 4 4 10
20-057-6S20D Bolt - Replaces NAS464-6-20
NAS464P6-23 Bolt - 4 11
20-057-6S23D Bolt - Replaces NAS464P6-23 4
20-057-6S24D Bolt - 4
NAS464-10-27 Bolt - 2 2 2 12
20-057-10S27D Bolt - Replaces NAS64-10-27 2
20-057-10S29D Bolt - 2
NAS509-12 Nut - 2 2 2 2
NAS509-24 Nut - 2
NAS559-5 Lock - 2 2 2 2
NAS559-9 Lock - 2
140-007-25S36B4 Washer - 4
140-007-41 S38C4 Washer - 2
NOTES:
1. For spare replacement use lever 212-010-302-001/-105, bushing 212-010-303-001, washer

212-010-304-001, washer 212-010-310-001, and bolt 20-057-6S23D.
2. Inactive for future procurement, use lever 212-010-302-105.
3. For spare replacement use two tubes 540-011-319-001 or 212-010-311-101, weights 212-010-306-001, locks
NAS559-9, nuts NAS 509-24, bushing 540-011-322-001, and packings MS29513-119.
4. For spare part replacement, use support 204-011-304-105.
5. For spare part replacement, use center frame 204-011-307-105.
6. Inactive for future procurement, use tube assembly 204-011-328-011.
7. MS17826 series nuts have been superseded by MS14144L series nuts.
8. Inactive for future procurement this application, use nut MS17826-10.
9. Inactive for future procurement this application, use nut MS17826-6.
10. Replaced by bolt 20-057-6S20D. Refer to ASB 205-76-13.
Rev. 2 65-68A
BHT-205A1-CR&O-1
65-31. ASSEMBLY - STABILIZER BAR. b. Install nut (33) on one bolt and tighten enough
to secure bearing (27) against bushing (21) in
NOTE: Apply corrosion preventive compound centerframe (19).
(C-104) to shanks only of all bolts prior to installation
and corrosion preventive compound (C-101) to bolt c. Move mixing lever (32) in direction of side
heads and nuts after installation. with loose bolt (30) and bushing (21), to ensure no
gap exists between bolt head (30) and bearing (27).
With mixing lever (32) in this position, measure gap
1. Wash preservative from bearing (17, figure between bearing (27) and bushing (21) in
65-37) with solvent (C-304) and air dry. Hand pack centerframe.
bearings with grease (C-007).
d. Determine number of washers (AN960-616
and/or AN960-616L) required to fill gap. Divide
2. Installbearing(17)incenterframe(19).Position washers into two groups equal in depth within one
bearing retainer (16) and install screws (13). Secure AN960-616L washer. AN960-616 washers are 0.063
screw heads with lockwire. Install opposite bearing plus or minus 0.010 inch thick. AN960-616L washers
set in same manner. are 0.032 plus or minus 0.010 inch thick.
3. Assemble centerframes (19) and tube e. Remove nut (33) and bolts (30).
assemblies (12) with bushings (20) in centerframes
down, and keyway in threaded portion of outer tube f. Install bolt (30) through bearing (27) in mixing
assemblies down. Install bolts (23) with one washer lever (32) with one group of washers between bearing
under bolt head and one washer under nuts (18). (27) and bushing (21). Repeat installation on opposite
Install AN175-11A bolts in inboard positions and side with remaining group of washers. Install nuts on
AN 175-1 OAbolts in outboard positions. Ensure that a the mixing lever bolts with one AN960-616 washer
minimum of one thread on bolts is exposed after (34) under each nut. Torque nuts (33) 95 to 110
tightening nuts. inch-pounds and install cotter pins (38).
4. Place washer (15) on bolt (25) and insert g. Perform steps a. through f. on opposite mixing
through inboard side of support assembly (22) and lever.
through bearing (17). Position support on inboard side
of centerframe (19). Install washer (15) and nut (14) 6 Install212-010-302 mixing lever(35)as follows:
on bolt. Install cotter pins after balancing has been
accomplished. a. Install stabilizer bar on a trunnion to establish
5.200 inch dimension between inboard faces of
support assemblies (22).
5. Install 204-011-301 mixing lever (32) as follows:
b. Install nylatron washer (11, figure 65-42) over
a. Install stabilizer bar on a trunnion or other shouldered bushing (10) in centerframe.
suitable fixture to establish a 5.200 inch dimension
between inboard faces of support assemblies (22). c. Position mixing lever (3), grease fitting up,
Position mixing lever (32) between centerframes with between centerframes.
lubrication fittings up and install bolts (30) through
bearings (27) in mixing lever and through bushings d. Install bolt (7), washer (6) and bushing (8)
(21) in centerframe (19). through one bearing (5) in mixing lever (3) to engage
65-68B Rev. 2
BHT-205A1-CR&O-1
LEVER
MECHANICAL
(Before and
CORROSION
AREA OF
NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIR AREAS One per segment Not critical
° °
SPLINE DAMAGE:
Depth: 1/3 of spline
Length: 1/2 of spline
Number: Three
NOTE:
Figure 65-40. Lever damage limits
65-69
BHT-205A1-CR&O-1
DAMPER ADAPTER DAMPER LINK TUBE
MECHANICAL
(Before and
CORROSION
(Before repair) 0.005 in.
AREA OF
NONOVERLAPPING
DEPTH REPAIR 0.10 square inch
NUMBER OF
NONOVERLAPPING
REPAIR AREAS Not critical
Two per tube
Two per rod end
THREADS:
Depths: One-third of thread
Length: One-fourth of circumference
Number: Two
NOTE:
Figure 65-41. Stabilizer damper, adapter, and damper link tube damage limits
65-70
BHT-205A1 -CR&O-1
SHIM WASHERS TO
3. Mixing Lever 8. Bushing 12. Washer

4. Liner 9. Bolt 13. Cotter Pin
5. Bearing
Figure 65-42. Shimming procedure for 212-010-302 mixing lever
shouldered bushing (10). Install nut (1) and tighten Remove and divide washers/shims into two groups to
enough to secure inner race stack against bushing fill equal space on each side of mixing lever (3) within
(10) in centerframe (2). Refer to detail A. one thin washer/shim.
e. Arrange opposite side of lever as follows: f. Remove bolt (7), washer (6), bushings (8)
and positioning bolt (9). Install bolts (7) with washers
(1) Install 3/8 inch positioning bolt (9) (6), bushings (8) and measured group of
through centerframe (2) from outside. Install bushing washers/shims through bearings (5). Push bolts (7)
(8) through bearing (5) in mixing lever (3). Refer to through bushings (8) in centerframes (2). Install
detail B. washers (12) and nuts (1). Torque nuts (1) 95 to 100
inch-pounds, and install cotter pins (13).
NOTE: Slightly reducing outside diameter of
(AN960-616 and -16L or AN960-516 and -516L) NOTE: When properly shimmed and with hardware
washers/shims may be required to allow them to slide torqued, there should be no free movement (float) of
through bearing (5). mixing lever (3) relative to centerframe (2).
(2) While holding mixing lever (3) against g. Perform steps a. through f. for opposite
centerframe (2), slide floating bushing (8) against mixing lever (35, figure 65-37).
fixed bushing (10) in centerframe (2). Insert threaded
end of a 3/8 inch diameter positioning bolt (9) flush 7. Position cable assembly (3) in tube assembly
with inside race of bearing (5). Measure space by (12) with cable threads outboard. Align holes on
placing washers/shims flat against bushing (8) to fill cable fitting of cable assembly (3) and tube assembly
space between bushing (8) and flush with inner race (12) and install bolt (4) with one stat-o-seal (2) under
of bearing (5) (tolerance is +0.000 inch, -0.032 inch). bolt (4) head and one under nut (1). Install bolt with
65-71
BHT-205A 1-CR&O- 1
head up and through hole in cable assembly. Install 12. Balance stabilizer bar. (Refer to paragraph
opposite cable assembly in same manner. 65-22.)
8. Clean weight (9) ID, outboard end fitting of

cable assembly (3) and outboard end of tube 65-32. BALANCING - STABILIZERBAR.
assembly (12) ID with MEK (C-309).
1. Remove support assemblies (21, figure 65-37)
9. Install nut (10) and key type lock (11) on each from centerframes. Insert a round bar, smaller than
end of tube assembly (12) with lock in keyway and inside diameter of pivot bearing (17), through center
pierced end inboard. Thread nut (10) past middle of of bearings and support bar on a reasonably level
tube threads. Thread weight (9) on each end of tube surface in such a manner that the stabilizer bar is
with slotted side inboard until 52.8 inch dimension is suspended. (Refer to figure 65-44.)
obtained as shown in detail B. Check that end of
tubes are flush with shoulder in weight within 0.03 NOTE: There is too much friction in the support
inch as shown in detail A. bearings to properly balance the bar while resting on
the supports; therefore, a rod smaller than the bearing
10. Turn nuts (10) outboard and engage key type inside diameter must be used.
locks (11) in slot of weights. Install washer (8),
bushing (7), retainer (6) and nuts (5) on each end of 2. Support the lever assemblies by inserting bolts
tube. Finger torque nuts (5). Torque nuts (10) 1600 to of equal length through the outboard bearings and
1900 inch-pounds and secure nuts to key type locks resting the bolts on the centerframes. (Refer to figure
(11) with lockwire (C-405). Lubricate stabilizer bar 65-44.)
with grease (C-007) at all lube fittings.
3. Check balance of 204-011-326 stabilizer bar
11. Install weight on 540-011-319 tube assembly and if necessary adjust as follows:
assembly as follows:
a. Cut lockwire (if installed), back off nut from
a. Clean internal threads of weight (1, figure weight, adjust weights (9, figure 65-37) until balance
65-43), external thread of cable (4), and outboard is obtained at nearest lock position. Maintain
end of tube (12) with MEK (C-309). minimum tube engagement shown in detail A.
b. Install nut (9) and lock (11) on end of tube b. Leave bar at rest for a few minutes to
(12) with lock in keyway and lockwire end of lock determine if it will remain level. Torque nut (10) 133
inboard. Turn nut (9) past center of tube threads. to 158 foot-pounds. Secure nut to lock with lockwire
Install weight (1) on tube with slotted end inboard. (C-405).
Adjust weight to 51.8 inches from center of bolt.
(Referto detail A.) c. Apply adhesive (C-308) to outboard ends of
stabilizer bar as follows:
c. Turn nut (9) outboard and engage lock (11)
into nearest slot of weight (1). Install O-ring (8) on
bushing (7), slide bushing (7) onto cable (4) and into NOTE: Adhesive has a pot life of two hours and will
tube (12) as shown in detail A. Install bushing (2) cure at room temperature in 72 hours. An accelerated
onto cable (4) until it is against bushing (7). Install cure may be obtained by allowing one hour drying at
retainer (3) onto cable (4) until it covers bushing (2). room temperature and then applying 167 to 173°F
Install nut (6). Torque nut (6) 1 to 40 inch-pounds. (75 to 78°C) heat for two hours.
Install nut (5), torque 60 to 85 inch-pounds. Torque
nut (9) 133 to 158 foot-pounds and secure with (1) Remove nuts (5), retainer (6), bushing
lockwire (C-405) to lock (11). (7), and washer (8). Ensure that location of weights
(9) is not disturbed. Apply adhesive (C-308) to inside
d. Lubricate stabilizer bar bearings with grease of weights at shoulder of weight and end of tube and
(C-007) at all lubrication fittings. in the gap between cable fitting and tube ID.
65-72
BHT-205A 1-CR&O- 1
212-010-311 TUBE
OR SEE DETAIL A
51.8 INCH
ASSEMBLY DIMENSION
EXCEPTOPPOSITE PRIOR TO STATIC BALANCE 212-010-306 WEIGHT
MINIMUM TUBE ENGAGEMENT IN WEIGHT TO BE

FLUSH WITH SHOULDER WITHIN 0.03 INCH.
DETAIL A
TORQUE 133
TO 158 FT-LB
1. Weight
3. Retainer
4. Cable
5. Nut
6. Nut
7. Bushing
8. O ring
9. Nut
10. Lockwire
11. Lock
12. Tube
NOTES:
Tubes 212-010-311 and 540-011-319-1 must be installed in pairs.
Omit epoxy/zinc coating and coat with corrosion preventive compound (C-101).
Omit primer and paint.
Figure 65-43. Tube assembly (540-011-319)
65-73
BHT-205A 1-CR&O-1
Figure 65-44. Stabilizer bar balancing
(2) Assemble washer (8), bushing (7), b. With stabilizer bar balanced, leave for two to
retainer (6), and nuts (5) on stabilizer bar. Insert a three minutes to determine if it is actually balanced.
screwdriver in slotted end of cable to prevent cable
from twisting and torque inboard nut (5), 1 to 40
inch-pounds and torque outboard nut 60 to 85
c. Torque nut (9) 133 to 158 foot-pounds.
inch-pounds. Maintain 0.005 inch minimum gap Secure nut (9) to lock (11) with lockwire (C-405).
between retainer (6) and weight (9). Refer to detail A.
Recheck static balance and correct balance as
required by using AN960-516 and/or AN960-516L
washers between nuts (5) and retainer (6). d. Back off nut (5) one turn and check torque on
nut (6) to be 1 to 40 inch-pounds. Bring nut (5)
(3) Place washer on bolt (23) and insert against nut (6), torque nut (5) 60 to 85 inch-pounds.
through inboard side of support assembly. Position
support on inboard side of centerframe (19). Install
washer (15) and nut (14) on bolt. Torque nut 500 to
700 inch-pounds and install cotter pin (38). 65-33. PITCH CHANGE LINK OVERHAUL.
4. Check balance of 212-010-300 stabilizer bar
as follows:
65-34. INSPECTION - PITCH CHANGE LINK.
a. Remove lockwire, back off nut (9, figure
65-43) from weight (1). Adjust weight (1) to the 1. Check universal bearings for a maximum
closest locking position. Turn nut (9) outboard and looseness of 0.017 inch axial and 0.0085 inch radial.
engage locks (11) in weight slots.
65-74
BHT-205A1-CR&O-1
2. Check rod end bearings for a maximum 6. Mask threaded areas, fill and drain barrel and
looseness of 0.010 inch axial and radial. The 0.010 drilled hole in clevis with primer (C-202) (refer to BHT-
inch can be extended to 0.020 inch, provided ALL-SPM manual).
excessive vertical vibration does not occur in main
rotor operation. 7. Apply a coating of primer (C-202) to all
repaired surfaces which have had plating removed
3. Inspect pitch change links for corrosion, (refer to BHT-ALL-SPM manual).
cracks, and scratches. Refer to figure 65-45 for
damage and repair limits. Perform magnetic inspection 65-35.1.PITCH CHANGE COMPONENTS.
on cadmium plated parts (BHT-ALL-SPM). Perform
fluorescent penetrant inspection on non-cadmium 65-35.2. INSPECTION - PITCH CHANGE
plated parts (BHT-ALL-SPM). COMPONENTS
4. Inspect thread and shoulder area of clevis for 1. Inspect components for mechanical or
cracks using a 5X magnifying glass. corrosion damage (figure 65-45A).
5. If clevis is suspected of having cracks, inspect 2. Inspect idler and lever for cracks using
using wet continuous magnetic particle inspection fluorescent penetrant method (BHT-ALL-SPM).
method consisting of:
3. Inspect tail rotor retaining nut for cracks using
magnetic particle inspection method (BHT-ALL-SPM).
a. A head shot of 1000 amps.
4. Inspect bearings in idler and lever for

b. A coil shot of 1500 amps.
roughness and wear.
6. Inspect for cracks using a 10X magnifying
5. Inspect bushings in lever for looseness and
glass and a black light. No cracks are permissible. If
wear. Replace lever if bushings are loose. Replace
no cracks are found, demagnetize and clean part.
bushings if inside diameter exceeds 0.3135 inch or if
elongation exceeds 0.002 inch.
7. Inspect for any bent, dented, or distorted link
parts, or any parts having cracks. 6. Inspect threaded rod of pitch link assembly for
cracks using particle inspection method (BHT-ALL-
65-35. REPAIR - PITCH CHANGE LINK. SPM).
1. Polish out acceptable damage. Refer to figure 65-35A.CONTROL TUBE OVERHAUL.

65-45.
65-35B.INSPECTION - CONTROL TUBE.
2. Use 400 to 600 grit abrasive cloth or paper to
remove damage to a scratch-free surface. Do not 1. Inspect control tube for foreign object damage
attempt repairs by using a grinding wheel. and adequate bolt shank clearance at scissor arm
attachment point.
3. No thread or surface damage is acceptable if
repair will interfere with thread engagement. 2. Inspect control tube for corrosion, nicks,
dents, and bore damage. Refer to figure 65-45B for
damage and repair limits.
4. Replace any bent, dented, or distorted link
parts, or any parts having cracks.
65-35C.REPAIR - CONTROL TUBE.
5. Apply brush cadmium plate to repaired NOTE: Edges may be radiused or chamfered to
surfaces which have plating removed (refer to BHT- remove nicks or dents within limits shown on figure 65-
ALL-SPM manual). 45A.
15 JAN 2004 Rev. 3 65-74A

BHT-205A1 -CR&O-1
1. Polish out acceptable damage using fine replacement of part(s) instead of overhaul,
grade abrasive cloth or paper. Refer to figure 65-45A. disassemble only to extent necessary to replace
part(s).
2. Touch up reworked area with chemical film
treatment for aluminum alloys (refer to BHT-ALL-SPM
1. Check spline wear of driveplate (6, figure 65-
manual).
46) prior to disassembly, as follows:
3. Apply coating of primer (C-204) to repaired
surfaces (refer to BHT-ALL-SPM manual). Do not a. Install scissors and sleeve assembly onto a
prime bushings. suitable mast, engaging drive plate splines with
splines of mast.
4. Apply two coats of acrylic lacquer (C-203)
color light gull gray No. 36440 per FED-STD-595 (refer
to BHT-ALL-SPM manual). Do not paint bushings. b. Attach dial indicator (2) to mast with indicator
probe (4) in contact with a flat of bolt head (3). Chuck
hub assembly (5), in plane of rotation, and measure
65-36. SCISSORS AND SLEEVE OVERHAUL.
amount of radial play present. Maximum radial play
TOOLS REQUIRED allowed between mast (1) and drive plate (6) is 0.040
Support inch at point of measurement.
T101369 (2)
T101382 Ram Adapter
T101392 Wrench 2. Remove nut (34, figure 65-47), washer (31
T101424 Bar and 33), bolt (30) and remove link (32) from scissor.
T101493 Wrench Remove shim (28), housing assembly (27) and thrust
washer (29). Remove inner race (20).
65-37. DISASSEMBLY - SCISSORS AND
SLEEVE. 3. Remove nut (17) and washers (18) and
remove cover plate (16). Remove nut (19) and spacer
BHT-205A1-MM-1 manual, and retire all items (14) from bolt (5 or 6). Support scissor assembly (3 or
scheduled for retirement. 8) and remove bolt (5 or 6) with washer (26) and
special washer (7) or roller bearing inner race (4).
Check all pivot joints for binding before disassembly. If Remove scissor from hub assembly (1), removing
severe binding exists, scrap the entire assembly. If spacer (21) as it is released. Remove bearing (25)
scissors and sleeve are being disassembled for from scissor assembly (8).
65-74B Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
- UNIVERSAL
BEARING, ROD END CLEVIS
NICKS, SCRATCHES,
AND SHARP DENTS 0.005 in. 0.010 in. 0.020 in.
CORROSION 0.005 in. 0.010 in. 0.020 in.
AREA PER
NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIRS Two per zone Two per zone One per zone
° ° °
THREAD DAMAGE:
Depth: One-thrid of thread
NOTES:
1. The width of repair at any section shall not exceed one-third of the circumference.
2. Damage limits in drilled hole of clevis shank are 0.010 inch.
3. Apply epoxy-zinc protective coating (C-208) to internal surface of barrel and clevis.
Figure 65-45. Pitch change link damage and repair limits
Rev. 2 65-75
BHT-205A1-CR&O-1
NICKS, SCRATCHES, 0.010 IN. 0.020 IN.

AND CORROSION (0.254 mm) (0.508 mm)
CORROSION 0.005 IN. 0.010 IN.

(0.127 mm) (0.254 mm)
AREA OF 0.25 SQ. IN. 0.50 SQ. IN.

FULL DEPTH REPAIR (16.13 SQ. mm) (322.6 SQ. mm)
NUMBER OF REPAIR AREAS One per segment One per segment
EDGE CHAMFER 0.030 IN. 0.060 IN.

(0.762 mm) (1.524 mm)
THREAD DAMAGE:
DEPTH: One-third of thread
LENGTH: One-tenth Inch (0.254 mm)
NUMBER: Two
205A1CRO_65000_0045A 001
Figure 65-45A. Pitch change components damage and repair limits (sheet 1 of 2)
65-76 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
GEARBOX HOUSING
209-011-720
MECHANICAL 0.010 IN. (0.254 mm)
CORROSION 0.005 IN. (0.127 mm) before repair
0.010 IN. (0.254 mm) after repair
MAXIMUM AREA FOR 0.01 SQ. IN. (6.45 SQ. mm)

FULL DEPTH REPAIR
NUMBER OF REPAIRS Not critical
205A1CRO 65000_0045A_002
Figure 65-45A. Pitch change components damage and repair limits (sheet 2)
15 JAN 2004 Rev. 3 65-76A

BHT-205A1-CR&O-1
NICKS AND DENTS 0.005 In. 0.005 In.
CORROSION
Before repair 0.0025 In. 0.0025 In.
After repair 0.005 In. 0.005 In.
AREA OF FULL DEPTH REPAIR 0.10 Sq. In. 0.50 Sq. In.
NUMBER OF REPAIR AREAS One per lug Two per segment
BORE DAMAGE 0.001 For 1/4 Circumference
NOTE:
1. The width of repair at any section of tube should not exceed one-third of
the circumference.
205A1CRO 65000_0045 001
Figure 65-45B. Control tube damage and repair limits
65-76B Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
4. Remove bolts (44), washers (43) and remove 7. Place sleeve on a press with T101369 support
flange (45) and drive plate (46). Remove screws (50) halves under lower bearing set (39). Place small end
and remove lockplate (49). of T101382 ram adapter in upper end of sleeve and
press sleeve from bearing set (39) and spacer set
(38). Remove seal (41) from nut (40) with T101382
5. Install T101392 wrench on nut (37). Invert hub ram.
and sleeve and secure wrench in a vise. Using
T101493 wrench turn nut (40) out of hub (48). Remove
CAUTION: ENSURE THAT BEARINGS WILL CLEAR
tools from assembly. T101369 SUPPORTS DURING PRESSING
OPERATION.
6. Remove pin (36), install T101392 wrench with
pins engaged in holes of nut (37). Insert T101424 bar 8. Place assembly upright on a press with
in holes at lower end of sleeve. Hold bar and remove T101369 support halves located under hub (48). Place
left-hand threaded nut (37). small end of T101382 ram adapter in top of collective
sleeve (2) and press sleeve out of hub. Remove seal
(47) and shoulder ring (42).
9. Remove liner (9) from scissors assembly. Use

T101424 bar and press out shims (10 and 12), bearing
set (11) and spacer (13) from liner (9).
10. Use T101424 bar to remove bearings (24 and

22) and spacer (23) from scissors.
65-38. INSPECTION - SCISSORS AND SLEEVE.
NOTE: If records or physical appearance indicate that

the scissors and sleeve assembly have been
subjected to an accident or incident, perform
Conditional Inspection, paragraph 65-39. If assembly
does not require conditional inspection, accomplish
Normal Inspection, paragraph 65-40.
65-39. Conditional Inspection - Scissors and

Sleeve.
1. Carefully inspect the assembled component

visually for any apparent damage or abnormal
appearance. Obvious defects which are cause to
scrap the entire assembly are:
a. Binding in any of the pivot joints.
1. Mast
2. Dial Indicator b. Binding between the hub and sleeve.
3. Bolt Head
4. Indicator Probe
5. Hub Assembly 2. Any detail part within the scissors and sleeve
6. Drive Plate assembly which has sustained surface damage shall
7. Magnet
be subject to surface damage inspection as outlined in
205A1CRO_65000 00460 001 paragraph 65-40 (Normal Inspection). Surface
damage that exceeds limits, will require scrapping only
Figure 65-46. Driveplate wear check the damaged part.
15 JAN 2004 Rev. 3 65-77

BHT-205A 1-CR&O-1
26 AS REQD FOR 0.010 IN

MINIMUM GAP BETWEEN
7AND
DETAIL B
SHIM FOR 0.000

SEAL TO 0.002GAP
DETAIL A
1. Hub assembly 9. Liner 17. Nut 25. Bearing 33. Washer
2. Collective Sleeve 10. Shim 18. Washer 26. Washer 34. Nut
3. Scissor assembly (212-010-407) 11. Bearing set 19. Nut 27. Housing assembly 35. Cotter pin
4. Roller bearing inner race 12. Shim 20. Inner race 28. Shim
5. Bolt (212-010-411-1) 13. Spacer 21. Spacer 29. Thrust washer
6. Bolt (NAS464P8-90) 14. Spacer 22. Bearing (with seal) 30. Bolt
7. Special washer 15. Cotter pin 23. Spacer 31. Washer
8. Scissor assembly (204-011-406) 16. Cover plate 24. Bearing 32. Link
Figure 65-47. Scissors and sleeve (Sheet 1 of 3)
65-78
BHT-205A 1-CR&O-1
38. Spacer Set

39. Bearing Set
40. Nut
41. Seal
42. Shoulder Ring
43. Washer
44. Bolt
45. Flange
46. Drive Plate
47. Seal
48. Hub
49. Lockplate
50. Screw
DETAIL E
Figure 65-47. Scissors and sleeve (Sheet 2 of 3)
65-79
BHT-205A1-CR&O-1
TYP BEFORE
STAKING 0.655
DETAIL F
DETAIL G
51. Bearing
65-80
BHT-205A1-CR&O-1
3. An unworn bolt must fit freely through the 5. Inspect roller bearing inner race (4), inner race
bushings in the drive link. Any bind is cause for (20), and thrust washer (29). If other than a smooth,
scrapping the drive link. unscored surface is found, replace parts as required.
4. With a straight edge, check the cylindrical 6. Inspect spacers (13, 14, 21 and 23) and liner
portion of the collective sleeve for deformation. (9) for cracks, corrosion, and wear.
Warpage in excess of 0.005 inch in a 5.0 inch length
is reason to scrap the sleeve. 7. Inspect drive plate (46) for spline damage.
5. All machined flat surfaces surrounding lugs, 8. Inspect collective sleeve (2) and hub (48) for
holes and bushings in the entire assembly should be thread damage. (Refer to figure 65-39.)
checked with a straight edge for deformation.
Deviations from flat in excess of 0.002 inch will 9. Inspect flange (45, figure 65-47), lockplate
require scrapping only the damaged part. (49), shoulder ring (42), housing assembly (27),
cover plate (16), and pin (36) for damage or
6. Accomplish Normal Inspection, paragraph deformation.
65-40.
10. Score marks on the ID of holes and bushings,
65-40. Normal Inspection- Scissorsand Sleeve. not to exceed 0.002 inch, are acceptable.
1. Inspect parts for mechanical or corrosion 11. Inspect studs in scissor assembly (3 or 8) for
damage. (Refer to figures 65-48, 65-49, and 65-50.) looseness or damaged threads.
2. Inspect bearing set (39, figure 65-47) and 12. Inspect the following parts by magnetic
spacer set (38) as follows: particle method (code M) or fluorescent penetrant
method (code F). Index numbers are keyed to figure
a. Inspect bearings for roughness and 65-47.
brinelling.
NOTE: Any brinelling visible under a 5 power NOTE: Refer to BHT-ALL-SMPmanual for approved
magnification or of sufficient depth to cause fluorescentpenetrantmaterial.
roughness when the bearing is rotated, shall be cause
Index No. Nomenclature Code
for rejection.
2 Sleeve M
b. Inspect for galled or flaked area on balls and
3 or 8 Scissors F
raceways under a strong light. Inspect for broken or
32 Link F
fractured retainers.
37 Nut M
40 Nut M
c. Inspect spacer set (38) for damage and
corrosion. 48 Hub M
3. Inspect bearing set (11), and bearings (25 and

51) for smooth operation and damaged seals or 13. Inspect parts dimensionally and replace parts
shield. Inspect bearing (51) and liner for looseness. that are not within limits. (Referto figure 65-51.)
Any looseness will require removal of liner and
checking the mating hole. Egging of the hole not to
exceed 0.001 inch for 30 degrees is acceptable. NOTE: Wear limits are provided to show the required
fit between mating parts. It is not intended that all
4. Inspect bearings (22 and 24) for smooth dimensions be checked as a prescribed overhaul
operation. Inspect rollers for looseness due to wear, procedure; however, parts that show evidence of
flaked or flat spots, pitting or scoring. Inspect seals wear or physical damage shall be checked
for damage. dimensionally.
65-81
BHT-205A 1 -CR&O- 1
SCISSORSASSEMBLY
DRIVE LINK
NICKS, SCRATCHES.
AND SHARP DENTS 0.005 in. 0.010 in. 0.020 in. 0.035 in.
CORROSION 0.0025in. 0.005 in. 0.010 in. 0.0175in.
AREA OF FULL
DEPTH REPAIR 0.10 sq. in. 0.10 sq. in. 0.25 sq. in. 0.40 sq. in.
NUMBER OF
REPAIRAREAS One One per lug Not critical Not critical
BOREDAMAGE: * 0.002 inch for 1/4 circumference for 1/2 bore lenth
Figure 65-48. Scissor and drive link damage limits
65-82
BHT-205A 1-CR&- 1
HUB
SLEEVE
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREA ALLOWED
NICKS, SCRATCHES,
SHARP DENTS AND
CORROSION 0.010 in. 0.010 in. 0.020 in.
AREA OF FULL
NUMBER OF
REPAIRAREAS One per lug Not critical Not critical
EDGEOF CHAMFER 0.020 in. 0.020 in. 0.040 in.
THREAD DAMAGE:
Depth: One-thrid of thread
Figure 65-49. Hub and sleeve damage limits
65-83
BHT-205A 1-CR&O-1
BEARING AND LINER ASSEMBLY
BEARING AND LINER ASSEMBLY
NICKS, SCRATCHES,
AND SHARP DENTS 0.010 in.
CORROSION 0.010 in.
AREA OF FULL
NUMBER OF
REPAIR AREAS Not critical
Figure 65-50. Bearing and liner assembly damage limits
65-41. REPAIR- SCISSORSAND SLEEVE. 65-48, 65-49, and 65-50. Use fine to medium grade
abrasive pad (C-407) and final polish to a scratch-free
1. Replace seals (41 and 47, figure 65-47) and finish with crocus cloth (C-409). Score marks on
seal in housing assembly (27). bushing ID may be polished if damaged and
subsequent repair does not exceed 0.002 inch depth.
2. Replace parts on hub and sleeve if wear limits Apply LHE solution (C-108) to repairs on cadmium
of figure 65-49 are exceeded. plated surfaces. (Refer to BHT-ALL-SPM manual for
prescribed cadmium plating method.) Apply chemical
3. Replace parts that fail magnetic particle or film treatment (C-100) on aluminum surfaces.
penetrant inspection.
8. Replace link bushings (55 and 56, figure
4. Replace bolts (5 or 6 and 30, figure 65-47), 65-47) if wear limits are exceeded, as follows:
nuts (19 and 34) and washers.
a. Properly support tangs of link and press out
5. Replace parts having nonreparable thread bushings (55 and 56), as required.
damage. (Referto figure 65-51.)
b. Coat mating surfaces with primer (C-201).
6. Replace unserviceable bearings. Bearing set
(11, figure 65-47) must be replaced as a serialized Support tang and press in new bushing while primer is
still wet.
set.
7. Repair acceptable corrosion and mechanical c. Line ream two bushings (56) 0.3120 to
damage. Polish steel parts only to a depth sufficient 0.3125 inch after installation.
to remove corrosion and clean aluminum parts twice
depth of deepest pit, not to exceed limits of figures d. Line ream two bushings (55) 0.4995 to
0.5000 inch after installation.
65-84
BHT-205A1-CR&-1
NOMENCLATURE MIN MAX

1 Hub ID 5.2496 5.2520
2 Hub Bolt Hole 0.4995 0.5015
3 Sleeve Bearing Seat OD 4.2480 4.2507
4 Link Bushing ID 0.4995 0.5010
5 Inner Race ID 0.4995 0.5010
6 Bearing Liner ID 1.1249 1.1270
7 Link Bushing ID 0.3120 0.3140
Figure 65-51. Scissors and sleeve wear limits.
65-85
BHT-205A1-CR&O-1
9. Replace defective scissors bearing (51) as a. Support scissor tang and press housing
follows: assembly out.
a. Position scissors over a suitable support b. Remove all traces of adhesive from scissor
having clearance for bearing and sleeve. Press bore with a plastic scraper. Clean bore with MEK (C-
bearing and sleeve out of scissors lever. 309) and blot dry with a clean cheesecloth.
b. Clean lever bore with MEK (C-309). Inspect c. Abrade faying surface of housing assembly
bore for scoring. Depth of score shall not exceed 0.002 and scissor with 180 grit abrasive paper (C-423) and
inch after cleanup. wipe dry with a dry, clean cloth to remove sanding
residue.
c. Apply primer (C-201) to mating surfaces of
replacement sleeve and scissors bore. Support d. Mix adhesive (C-363) in accordance with
scissors and press sleeve into scissors bore. (Refer to instructions of manufacturer and apply adhesive to
detail F,figure 65-47.) faying surfaces of housing assembly and scissor bore.
Press housing assembly into scissor with grease fitting
d. Remove lube fitting from lever and using lube up. Cure at 180°F (82°C) for one hour or room
fitting hole as a guide,.drill 0.092 to 0.098 inch hole in temperature for 24 hours.
sleeve. Exercise caution not to increase fitting hole
size. Press new lube fitting in lever. Ream sleeve e. Press roller bearing (53) into housing
1.2488 to 1.2493 inch diameter. Clean sleeve bore assembly (52). Press bearing on marked end. Press
with MEK (C-309). flush to 0.010 below surface. (Refer to detail G.)
e. Apply primer (C-201) to mating surfaces of 12. Repair nuts (37 and 40) as follows:
bearing and sleeve. Press bearing into sleeve.
a. Nicks, scratches, sharp dents, and corrosion
f. Ring stake sleeve both sides. (Refer to detail may be polished out to maximum depth of 0.005 inch.
F.) Proof load ring staking of bearing to 500 pounds in
each direction. Apply load to outer race of bearing b. Maximum area of full depth repair is 0.25
only. Check bearing for freedom of movement. square inch.
c. Maximum of two repairs per nut.

g. Check scissors for cracks.
d. Edge chamfer 0.020 inch.
10. Replace defective bearing sleeve (54) in
scissor assembly (8) as follows: e. Thread damage: Maximum of two with a
length of 1/4 inch and a depth of 1/3 of a thread.
a. Support scissors and press sleeve out.
65-42. ASSEMBLY - SCISSORS AND SLEEVE.
b. Remove all traces of adhesive from scissors
bore with a plastic scraper. Clean bore with MEK (C- NOTE: Apply corrosion preventive compound (C-104)
309) and wipe dry with a clean cheesecloth. to shanks only of all bolts prior to installation and
corrosion preventive compound (C-101) to bolt heads
c. Abrade the sleeve OD with 180 grit abrasive and nuts after installation.
paper (C-423) and wipe with a dry, clean cloth to
remove sanding residue. 1. Assemble scissor assembly (3 or 8, figure 65-
47) as follows:
d. Mix adhesive (C-363) per instructions of
manufacturer and apply adhesive to faying surfaces of a. Remove preservative from bearing set (11)
sleeve and scissors bore. Install sleeve in scissors and and bearings (22 and 24) with clean solvent (C-304).
cure at 180°F for one hour or at room temperature for Air dry and hand pack bearings with grease (C-007).
24 hours.
b. Use a T101424 bar and press bearing (24),
11. Replace defective housing assembly (52) in spacer (23) and bearing (22) (seal side outboard) into
scissor assembly (3) as follows: scissor liner.
65-86 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
c. Install shim (10) and bearing set (11) (V mark (39). Place shoulder ring (42) on upper bearings (39)
on outer races pointing inboard) into liner (9). Install and press hub down over bearings.
liner in scissors and check for a dimension of 3.990
to 4.000 inches between inner race of bearing set f. Install T101392 wrench on top of hub. Invert
(11) and inside face of short leg of scissors. (Refer the hub and sleeve and secure T101392 wrench in
to detail A.) Peel shim (10) as required to accomplish a vise. Start nut (40) into hub and using T101493
correct dimension. wrench torque nut 400 to 500 foot-pounds. Install
lockplate (49) with tabs engaged in nut (40). Install
two screws (50) and lockwire heads together. Turn
d. Install shim (12) and spacer (13) in liner (9). assembly upright and remove tools.
Check that spacer (13) extends 0.003 to 0.009 inch
beyond outer face of liner (9). (Refer to detail A.) Peel
shim (12), as required, to obtain desired dimension NOTE: If lockplate(49)doesnotalign,secureanew
plate and drill two holes, 0.198 to 0.204 inch diameter
to match the two holes in hub (48).
e. Accomplish steps a. through d. on opposite
scissor. g. Install driveplate (46) and flange (45) on top
of hub and secure with bolts (44) and washers (43).
2. Assemble collective sleeve (2) on hub (48) as Secure bolt heads in sets of three with lockwire.
follows:
3. Install scissors assembly as follows:
a. Install new seal (41) in nut (40) using T101382
ram adapter. Place nut (slotted side down) on a. Install 204-011-406 scissor assembly (8) as
collective sleeve (2), below shoulder. Apply coat of follows:
corrosion preventive compound (C-101) to threads
of nut. (1) Position bearing (25) in short arm of
scissor assembly (8).
b. Clean bearing set (39) with solvent (C-304),
air dry and hand pack bearing with grease (C-007). NOTE: Bearing(25) isintendedtohave a loose fitin
Assemble bearing set and spacer set (38) with V-mark sleeve (54).
on bearing races aligned and pointing up. (Refer to
detail E.) Use a T101382 ram adapter and press two
lower bearing sets (39) on collective sleeve (2). Press (2) Position special washer (7) and standard
spacer set (38) and upper two bearings on sleeve. or thin steel washer 26), as required, to provide a
Ensure that V-mark is pointing up. 0.010 inch minimum gap between scissor assembly
(8) and special washer (7). (Refer to detail B.)
c. Applycoatofcorrosion preventivecompound (3) Position scissor assembly (8) on hub

(C-101) to nut (37) threads. Start nut (37) (left-hand assembly (1) with spacer (21) between bearing set
thread) on collective sleeve (2). Install T101392 (11) and hub assembly (1). Insert bolt (6), washer(s)
wrench with pins engaged in holes of nut. Hold (26) and special washer (7) through scissor and hub
collective sleeve (2) with T101424 bar and torque nut assembly.
(37) 150 to 200 foot-pounds. Align holes of nut and
sleeve (one location) and install pin (36). (Refer to
detail D.) Install lockwire through hole in pin in space (4) Install spacer(14) and nut(19). Torque nut
between nut and sleeve. (Refer to detail D.) (19) 200 to 400 inch-pounds and install cotter pin (15).
(5) Check that nut (19) has not bottomed out

d. Press new seal (47) (lip of seal up) into top on bolt (6) and that scissors to hub clamp-up is correct
of hub (48) with T101382 adapter. Press seal flush as follows:
with or slightly below top surface of hub seal bore.
(a) Use a torque wrench on head of bolt (6)
e. Place collective sleeve (2) on a suitable press and attempt to turn clockwise. Bolt should not rotate
with T101369 support halves under lower bearing set at less than 180 inch-pounds.
Rev. 2 65-87
BHT-205A1-CR&O-1
(b) If bolt rotates at less than 180 (b) If bolt rotates at less than 180
inch-pounds, remove cotter pin and nut (19). inch-pounds, remove cotter pin and nut (19).
(c) Place one AN960-816 washer on bolt (c) Place one AN960-816 washer on bolt
(6) and reinstall nut (19). Torque nut 200 to 400 (5) and reinstall nut (19). Torque nut 200 to 400
inch-pounds and install cotter pin. inch-pounds and install cotter pin.
(d) Repeat step (a) to ensure bolt (6) will (d) Repeat step (a) to ensure bolt (5) will
not rotate at less than 180 inch-pounds. If bolt still not rotate at less than 180 inch-pounds. If bolt still
rotates at less than 180 inch-pounds, remove scissors rotates atless than 180 inch-pounds, remove scissors
from hub and reinstall, following step 3.(a). from hub and reinstall, following step 3.b.
(6) Install cover plate (16) and secure with (7) Install cover plate (16) and secure with
washers (18) and nuts (17). washers (18) and nuts (17).
(7) Accomplish steps 3.a. through 3.a.(6) on (8) Accomplish steps 3.b. through 3.b.(7) on
opposite scissor. opposite scissor.
NOTE: Scissors assembly 204-011-406-9 may be 4. Install link (32) on scissors (3 or 8) as follows:
replaced with scissors assembly 204-011-406-15 or
212-010-407-1 provided both scissors are replaced.
Scissors assembly, 204-011-406-15 and a. Install inner race (20), thrust washer (29) and
212-010-407-1 have an unlimited service life. If housing assembly (27), between tangs of link (32).
scissors assembly, 212-010-407-1 is used, two new Retain parts in place with bolt (30). Hold assembled
pivot bolts, 212-010-411-1 must also be used. parts against opposite side of link and measure gap
between housing assembly (27) and tang of link (32).
b. Install 212-010-407 scissor assembly (3) as
follows: b. Peel shim (28) to dimension of gap measured
in step a. within 0.000 to 0.002 inch. (Refer to detail
(C.) Remove bolt (30) and assembled parts from link
(1) Deleted.(32).
(2) Place roller bearing inner race (4) on bolt c. Deleted.
(5).
scissor assembly (3) on hub

(3 Position d. Insert inner race (20) in outboard end of
assembly (1) with spacer (21) between bearing set scissors
scissors (3
(3 or
or 8).
8). Position
Position link
link (32) on scissor with
(32)onscissor with
(11) and hub assembly (1). thrust washer (29), housing assembly (27) and shim
(28), of previously determined thickness, between
forward tang of link and scissor. Install bolt (30) with
(4) Insertbolt(5)withrollerbearinginnerrace washer (31) under head. Install washer (33) and nut
(4) through scissor assembly and hub assembly. (34). Torque nut (34) 200 to 400 inch-pounds, install
cotter pin (35).
(5) Install spacer(14) and nut(19). Torque nut
(19) 200 to 400 inch-pounds and install cotter pin (15).
NOTE: If end play exceeds 0.090 inch, replace
(6) Check that nut (19) has not bottomed out thrust washer (29).
on bolt (5) and that scissors to hub clamp-up is correct
as follows: e. Accomplish steps a. through d. to install link
on opposite scissor.
(a) Use a torque wrench on head of bolt (5)
and attempt to turn clockwise. Bolt should not rotate 5. Lubricate scissors and hub through lube fittings
at less than 180 inch-pounds. with grease (C-007).
65-88 Rev. 2
BHT-205A1-CR&O-1
6. Check scissors and hub for free operation. CAUTION: CARE SHOULD BE EXERCISED WHEN
REMOVING TRUNNION BEARINGS TO PREVENT
65-43. SWASHPLATE AND SUPPORT DAMAGE. EXCESSIVE SPREADING OF THE
OVERHAUL. TRUNNION CLAMP AREA OF THE RINGS COULD
CAUSE DAMAGE THAT MAY INITIATE A FATIGUE
65-44. DISASSEMBLY - SWASHPLATE AND CRACK.
SUPPORT. NOTE: For steps 6. and 7., fabrication of a work aid
is recommended to allow removal of trunnions with
NOTE: Review Mandatory Retirement Schedule in less possibility of damage to swashplate rings. (Refer
BHT-205A1 -MM-1 manual; and retire all items to figure 65-53.) Excessive spreading of the trunnion
scheduled for retirement. clamp area of the ring could cause a crack resulting in
loss of rotor control. After removing bolts and plates,
If swashplate and support are being disassembled for
insert tangs of tool into slot and tighten screw until
replacement of part(s) instead of overhaul, trunnion can just be pulled out. Immediately release
disassemble only to extent necessary to replace screwtension and remove work aid.
part(s).
6. Remove two trunnion assemblies (30, figure
CAUTION: REFERTO CONDITIONAL INSPECTION, 65-52) from outer ring by removing bolts (29) with
PARAGRAPH 65-47, PRIOR TO DISASSEMBLY. nuts and washers.
1. Detach swashplate assembly (3, figure 65-52) 7. At each of three control horns of inner ring (28,
from gimbal ring assembly (4) by removing two bolts figure 65-52), remove trunnion assemblies using
(2), with cotter pins, nuts, washers, and special work aid shown in figure 65-53).
washers (1). Secure bushings (17) to swashplate 65-45. CLEANING - SWASHPLATE AND
inner ring. SUPPORT.
CAUTION: BOLTS (2 AND 9) ARE DIFFICULT TO 1. Clean parts with solvent (C-304). Dry with
REMOVE DUE TO RETAINING COMPOUND AND filtered, compressed air.
MUST BE DRIVEN OUT. SUPPORT THE LUGS OF
INNER RING (28) AND SUPPORT (15) TO PREVENT NOTE: Do not immerse shielded or sealed bearings
DAMAGE DURING BOLTREMOVAL. in solvent. Wipe clean with solvent dampened cloth.
2. Remove fingerprints or similar contamination
2. Detach gimbal ring assembly (4) from support
from bearing surfaces and steel liners or sleeves with
(15) by removing two bolts (9) with cotter pins, nuts,
fingerprint remover (C-105) and final rinse with
and special washers (10). Secure bushings (12) to
swashplate support.
3. Clean bearing liners on inner and outer rings by
3. Remove each of four bearing and liner blasting with glass beads after inspection.
assemblies (6 and 7) with shims (5) from gimbal ring
by removing lockwire and screws (8). Press bearing 4. Protect bearings from contamination.
from each liner. 65-46. INSPECTION - SWASHPLATE AND
SUPPORT.
4. Remove 24 nuts and washers from studs at top
of swashplate. Lift off cover (19), outer cap (23), NOTE: If records or physical appearance of
inner cap (20), and two shim sets (21 and 24). swashplate and support indicate that the assembly
Remove seal (22) from outer cap. has been subjected to an accident or incident outside
the realm of normal usage, perform the Conditional
5. Lift outer ring (26) and thrust bearing (25) from Inspection, paragraph 65-47. If the assembly does
inner ring (28). Remove bearing and lower seal (27) not require a conditional inspection, accomplish
from outer ring. Normal Inspection, paragraph 65-48.
65-89
BHT-205A1-CR&O-1
TORQUE
VIEW
VIEW
VIEW C
1. Special chamfered washer (204-011-457-3)
2. Bolt
3. Swashplate assembly TORQUE
4. Gimbal ring assembly TO 120
5. Shim
6. Liner
7. Bearing
8. Screw SEE VIEW C
9. Bolt
10. Special washer (204-011-457-1)
11. Special chamfered washer (204-011-457-3)
12. Bushing (slip bushing)
13. Bushing
14. Washer VIEW A
15. Support NOTES
16. Bushing A Used in swashplate which use slip
17. Bushing (slip bushing) bushings.
18. Bushing
Install with chamfer toward bolthead.
Washer 204-011-457-3 may be used as an

alternate for washer 204-011-457-1
provided chamfer on washer is installed
toward lug of support away from nut.
Figure 65-52. Swashplate and support (Sheet 1 of 2)
65-90
BHT-205A 1 -CR&O- 1
19. Cover 31. Bolt

20. Inner cap 32. Plate
21. Shim set 33. Trunnion
22. Seal 34. Plate
23. Outer cap 35. Spacer
24. Shim set 36. Bolt
25. Thrust bearing 37. Bolt
26. Outer ring 38. Plate
27. Seal 39. Spacer
28. Innerring 40. Trunnion
29. Bolt 41. Bracket
30. Trunnion 42. Bolt
50-70 IN LB
TYPICAL ALL TRUNIONS
DETAIL FOR
AFT HORN ONLY
ETCHED ARROWS
DETAIL B
Figure 65-52. Swashplate and support (Sheet 2 of 2)
65-91
BHT-205A 1-CR&O-1
0.45 IN. 0.85 IN.
0.25 IN. 0.30 IN.
Figure 65-53. Trunnion removal and installation work aid
65-92
BHT-205A1-CR&O-1
65-47. Conditional Inspection - Swashplate and (1) The bearing liner ID shall be round within
Support. 0.002 inch.
1. Carefully inspect the assembled component (2) Check

Check several
several segments
segments around
around the top
the top
visually for any apparent damage or abnormal for flatness with a straight edge. Not more than two
appearance. Obvious defects which are cause to studs
studs should
should be
be outboard
outboard ofof the
the straight
straight edge
edge when
when
scrap the entire assembly are: performing a check. The ring should be flat within
0.001 inch over the length measured.
a. Binding in any of the pivot joints. 4. Accomplish Normal Inspection, paragraph
65-48.
b. Binding of outer ring on inner ring.
65-48. Normal Inspection - Swashplate and
2. Any detail part which has sustained surface Support.
damage shall be subject to surface damage
inspection as outlined in paragraph 65-48. Surface 1. Inspect surfaces of parts for mechanical
damage that exceeds limits will require scrapping only damage (scratches and nicks) and corrosion damage.
the damaged part. Reject parts if surface damage cannot be polished out
within the following limits:
3. Inspect the swashplate support, inner ring and
outer ring as follows: a. Maximum depths of surface damage before
and after repair on swashplate inner and outer rings
and support are shown on figure 65-54 and 65-55.
a. Swashplate support.
b. Score marks on inside surface of holes of
NOTE: Ensure no oversized bushings and flanges bushings may be polished out if not more than 0.002
are installed on the gimbal ring support lugs. Refer to inch deep.
A.S.B. 205-91-45.
2. Inspect parts dimensionally and replace parts
(1) An unworn bolt must fit freely in both that do not fail within inspection limits. (Refer to figure
gimbal support and collective lever support bushings.
Any bind is cause for scrapping the support. NOTE: Limit charts are provided to show the
required fit between mating parts. It is not intended
(2) With the aid of a straight edge, check flat that all dimensions listed on limits chart be checked as
areas of gimbal support lugs for deformation. a prescribed overhaul procedure; however, parts that
Deviations from flat in excess of 0.002 inch are cause show evidence of wear or physical damage must be
to scrap the support. checked dimensionally.
(3) The base surface of the support shall be 3. Inspect thrust bearing (25, figure 65-52) for
flat within 0.001 inch. dents, deformation, cracks, corrosion, signs for
overheating, and looseness due to wear. Check by
b. Inner ring. feel for indications of internal damage (brinelling,
spalling, and cracked or broken balls) by placing
cleaned thrust bearing flat on a clean surface and
(1) An unworn bolt (9, figure 65-52) and bushing applying even pressure with palms and heels of hands
(12) must fit freely in gimbal ring and bushing. Any bind while turning bearing slowly.
is cause for scrapping the inner ring.
CAUTION: RAPID OR CONTINUED ROTATION
(2) With the aid of a straight edge check flat WILL SCORE RACES OF UNLUBRICATED
areas of gimbal support lugs for deformation. BEARING.
Deviations from flat in excess of 0.002 inch are cause
to scrap the inner ring. 4. Inspect trunnions for general condition. Check
for axial play, not to exceed 0.019 inch.
(3) Top surface must be flat within 0.002 inch. NOTE: The trunnion bearings are different from
other bearings, which normally can be feel-checked
c. Outer ring. for roughness and ease of rotation. The trunnion
Rev. 2 65-93
BHT-205A1-CR&O-1
204-011-402
INNER RING
TRUNNION BORE 0.002 IN.
204-011-403
OUTER RING TRUNNION BORE 0.002 IN.
NICKS, SCRATCHES
AND SHARP DENTS 0.010 in. 0.020 in. 0.020 in. 0.030 in.
CORROSION
(Before repair) 0.005 in. 0.010 in. 0.010 in. 0.015 in.
(After repair) 0.010 in. 0.020 in. 0.020 in. 0.030 in.
MAXIMUM AREA PER

FULL DEPTH REPAIR 0.10 sq. in. 0.50 sq. in. See Note 1 Not Critical
NUMBER OF
REPAIR AREAS Two Per Lug Two Per Arm See Note 1 Not Critical
EDGECHAMFER 0.030 in. 0.100 in. See Note 1 0.100 in.
THREAD DAMAGE
DEPTH: One-Third of Thread
LENGTH: One Quarter of Circumference
NUMBER: One
Note:
1. Surface corrosion may be cleaned up over the entire surface of the liner. Corrosion requiring
full depth repair is limited to one-fourth of the total area. Segments of full depth repair should not
exceed 2.0 inches in length and should maintain 0.50 inch minimum separation.
Figure 65-54. Swashplate inner and outer ring damage limits
65-94
BHT-205A1-CR&O-1
NICKS, SCRATCHES
AND SHARP DENTS 0.010 in. 0.020 in. 0.035 in.
CORROSION
MAXIMUM AREA PER

FULL DEPTH REPAIR 0.10 sq. in. 0.25 sq. in. 0.50 sq. in.
NUMBER OF
REPAIR AREAS One Per Lug Not Critical Not Critical
EDGECHAMFER 0.040 in. 0.060 in. 0.100 in.
BORE DAMAGE
0.002 Inch in Depth
for One Quarter
Circumference
Figure 65-55. Swashplate support damage limits
65-95
BHT-205A1-CR&O-1
bearings are preloaded into the cylinder portion of the c. Treat repaired anodized area with chemical
trunnion with a 0.0005-inch tight to 0.0005-inch loose film treatment (C-100). (Refer to BHT-ALL-SPM
tolerance. The bearings are roller type, with no manual.)
separated roller cages and angular-faced inner and
outer races. The normal feel of this assembly is one of
d. Where cadmium plating is removed by repairs,
tightness, due mainly to the 0.0005-inch tight
restore finish with LHE solution (C-108). (Refer to
tolerance. The feeling of roughness is due to the
BHT-ALL-SPM manual for prescribed cadmium plating
preloaded and the angular faces of the inner and outer
method.)
races. When grease is applied to the assembly, as
required, the normal bearing feel does not exist. The
conditions described are inherent in the trunnion 2. Replace defective bushing in inner ring as
bearing assembly. Checking the bearing assembly for follows: (Refer to figure 65-57, sheet 1.)
tightness should be accomplished by hand movement
only of the barrel and the crosshead.
NOTE: Three different part number inner rings are in
use on 205A-1 helicopters. The different bushings
5. inspect the following parts by magnetic
installations are covered in the following steps and are
particle (Code M) or fluorescent penetrant method
shown on figure 65-57.
(Code F). Index numbers are keyed to figure 65-52.
Demagnetize parts after magnetic particle inspection.
a. Heat inner ring with a heat lamp and tap or
press out bushings.
fluorescent penetrant material.
b. Check bores in inner ring for scoring and
Index No. Nomenclature Code cracks. Maximum depth of scores after cleanup shall
not exceed 0.002 inch.
4 Gimbal Ring M
15 Support F
26 Outer Ring F c. Install bushings in 204-011-402-17 inner ring
28 Inner Ring F as follows: (Refer to figure 65-57, detail A.)
6. Inspect studs of inner and outer rings for

looseness and damage. Replace loose studs. Inspect
thread damage in accordance with figure 65-54.
NOTE: The latest replacement bushings for the 204-
011-402-17 inner ring have an inside diameter of
0.3125 - 0.3135 inch and do not require reaming
I
after installation. After installation these bushings, 204-
011-464-1 and 204-011-464-3, may be lapped or
7. Inspect bushings (9) for wear (figure 65-56). honed, if required, to obtain 0.312 - 0.313 inch inside
diameter.
65-49. REPAIR - SWASHPLATE AND SUPPORT.
(1) Heat inner ring with a heat lamp.
1. Corrosion and mechanical damage repair.
(2) Coat replacement bushings and inner

a. Using fine to medium grades of abrasive cloth ring bores with primer (C-201). While primer is still wet
(C-406) or a fine india stone (C-464), remove no more press the longer bushing in each end of the outboard
material than necessary. Polish to a smooth scratch- holes and press the shorter bushing (flange facing
free surface. No surface shall be repaired by use of outboard) into hole in lug. Ensure that bushings are full
grinding wheel, plugging or patching. seated. (Refer to detail A.)
b. Corrosion damage, on aluminum only, should

(3) Line ream bushings to 0.312 - 0.313
be polished out to twice depth of pit, but mechanical inch.
damage should be polished out only deep enough to
remove damage. Do not exceed limits of figure 65-55
and 65-56. (4) Inspect inner ring for cracks.
65-96 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
MIN. MAX.
1 Outer Ring ID 10.250 10.254

2 Bearing OD 10.246 10.250
3 Bearing ID 8.999 9.003
4 Inner Ring OD 8.996 8.999
5 Gimbal Ring ID 1.3750 1.377
6 Bearing Liner OD 1.373 1.3748
7 Bearing Liner ID 1.2490 1.2505
8 Bushing (Support or Inner Ring) ID 0.3120 0.3150
9 Bushing (204-010-496-1) Floating OD 0.4988 0.4998
10 Bushing (204-010-497-1) Fixed ID 0.5000 0.5010
11 Bushing (204-010-495-1) Fixed ID 0.3120 0.3180
12 Bushing (204-010-496-3) Floating OD 0.4363 0.4373
13 Bushing (204-010-497-3) Fixed ID 0.4375 0.4385
14 Bushing (204-010-495-3) Fixed ID 0.3120 0.3180
Indicates average dimension.
Used on swashplate with 204-011-402-21 inner ring and 204-011-404-17 support (slip
bushing type).
Used on all other swashplates.
Figure 65-56. Swashplate and support wear limits
65-97
BHT-205A 1-CR&O-1
0.3120 - 0.3130
INCH DIA.' SIX
0.4375 TO 0.4380
INCH DIA., FOUR
HOLES IN LINE
0.313 DIA. HOLE.
DETAILA
SECTIONAL VIEW
INNERRING ASSY
204-011-402-21
0.312 TO 0.313
INCH DIA., TWO
HOLES IN LINE
0.0675- 0.0685 INCH

REF. 2 PLACES
SECTIONAL VIEW
INNERRINGASSY 0.558 - 0.560
204-011-402-127 INCH 2 PLACES
Figure65-57. Inner ring and support bushing replacement dimensions (Sheet 1 of 2)
65-98
BHT-205A 1-CR&O-1
0.312 TO 0.313 INCH 0.558 - 0.560 INCH

DIA., TWO HOLES 2 PLACES
INLINEWITH 0.0675 - 0.0685 INCH
0. 5000 TO 0.5005 REF.2 PLACES
0.5000 TO0.5005
INCH DIA., TWO
HOLES IN LINE
WITH 0.312 TO 0.313
INCH DIA. HOLE
DETAILD DETAILE
0.3120 - 0.3130
INCH DIA.
FOUR HOLES
IN LINETO
BETRUE TO
SURFACEA
5.868
5.870
SEEDETAIL D
FOR -17 SUPPORT
SEEDETAIL E FOR
-121 AND -125 SUPPORT
0.4995 - 0.5005 INCHDIA.
TWO HOLESIN LINE
TO BE TRUETO SURFACE
A WITHIN 0.002 PERINCH
9.250 0.010
SUPPORTASSY
SURFACE A
Figure 65-57. Inner ring and support bushing replacement dimensions (Sheet 2 of 2)
65-99
BHT-205A1-CR&O-1
d. Install bushings in 204-011-402-21 inner ring (8) Inspect inner ring for cracks.
as follows: (Refer to figure 65-57, detail B.)
3. Replace defective collective lever attachment
(1) Heat inner ring with heat lamp. bushings in support as follows: (Refer to figure 65-57,
sheet 2.)
(2) Coat replacement flanged bushings and
bores with primer (C-201). While primer is still wet, a. Warm support with heat lamp. Using a suitable
press the flanged bushings (flange facing outboard) support, back up tang and press or tap out bushing.
into hole in lug. Ensure that bushings are full seated. Inspect bores for cracks and scoring. Scoring not to
exceed 0.002 inch depth after cleanup.
(3) Line ream flanged bushing to 0.3120 -
0.3130 inch. b. Coat new bushings and hole ID with primer
(C-201). Apply heat lamp to support and insert
(4) Coat replacement flangeless bushing and bushings. Ensure bushings are fully seated.
bores with primer (C-201). Press flangeless bushings
into each end of outboard holes until bushing is flush c. Check dimension between faces of outboard
to 0.005 inch below surface. bushings in support arms. Mill bushings flanges an
equal amount to establish 5.868 to 5.870 inch
(5) Ream flangeless bushings to 0.4375 - dimensions as shown.
0.4380 inch in line with 0.3120- 0.3130 holes.
d. Line ream bushings 0.4995 to 0.5005 inch.
(6) Inspect inner ring for cracks. Check that bushing ID is true to surface A within 0.002
per inch.
e. Install bushings in 204-011-402-127 inner ring
4. Replace defective gimbal ring attachment
as follows: (Refer to figure 65-57, detail C.)
bushings as follows: (Refer to figure 65-57, sheet 2.)
(1) Heat inner ring with heat lamp. NOTE: Four different part number supports are used
on 205A-1 helicopters. They are 204-011-404-13, 204-
(2) Coat replacement bushings and bores 011-404-17, 204-011-404-121, and 204-011-404-125.
with primer (C-201). The different bushing installations are covered in the
following steps and shown on figure 65-57, sheet 2.
(3) Press shortest bushing, 204-011-464-105
(flange facing outboard) into hole in lug. a. Heat support with heat lamp. Use a suitable
support and back up tang. Press out bushings.
(4) Press bushing with thickest flange, 204- b. Inspect bores for cracks and scores.
011-464-107, into inboard end of hole. Maximum depth of scores after cleanup shall not
exceed 0.002 inch.
(5) Press other bushing, 204-011-464-3 into
outboard end of hole. c. Install bushings in 204-011-404-13 support as
follows:
(6) Ensure all bushings are fully seated.
(1) Coat replacement bushing and bores
NOTE: These bushings are manufactured with an with primer (C-201). Support tang and press bushings
inside diameter of 0.3125 - 0.3135 inch and do not into support while primer is still wet. Install bushing
require reaming. After installation these bushings may with thickest flange in outboard tang as shown on
be lapped or honed, if required, to obtain 0.312 - figure 65-57, sheet 2.
0.313 inch inside diameter.
(2) Line ream bushing to 0.1320 - 0.1330
(7) Machine flange of bushing 204-011-464- inch diameter.
107, as required to obtain 0.558 - 0.560 inch
dimension shown in detail C. (3) Inspect support for cracks.
65-100 Rev. 3 15 JAN 2004

BHT-205A1 -CR&O-1
d. Install bushings in 204-011-404-17 support NOTE: These instructions are applicable to the
as follows: studs which have a serrated locking ring. The locking
ring inner teeth engage a serrated collar of the stud.
(1) Coat replacement flanged bushings and The locking ring outer teeth broach into the material
inboard bores of support with primer (C-201). of the case. Special tools for removal/installation are
Support tang and press bushings into support while available from the manufacturer of the studs. When
primer is still wet. Install bushings in inboard bores as such tools are not available, replacement can be
shown on detail D. accomplished with other tools provided that careful
workmanship is applied.
(2) Line ream flanged bushing to 0.3120 -
0.3130 inch diameter. c. Removal of stud: Select a hollow mill with
outside diameter 1/64 inch less than root diameter of
(3) Coat replacement flangeless bushing and outer serrations of locking ring. Mill to depth equal to
outboard bores of support with primer (C-201). Press ring thickness. Remove stud and remaining portion of
flangeless bushings into support, while primer is still ring. If a hollow mill is not available, saw stud off and
wet, until bushing is flush to 0.005 inch below use drill and extractor.
surface.
d. Check condition of tapped hole and
(4) Ream flangeless bushings 0.5000 - counterbore. Holes are tapped with a standard class 3
0.5005 inch in line with 0.3120 - 0.3130 inch tap and the counterbore has a 90 degree shoulder. If
holes. necessary, clean up minor damage but avoid
enlargement of holes.
(5) Inspect support for cracks.
e. Coat portion of new stud, which will be in
e. Install bushings in 204-011-404-121 or contact with case, with primer (C-201) and install
204-011-404-125 support as follows: into tapped hole until top surface of serrated collar is
0.010 to 0.020 inch below surface of parent metal.
NOTE: Bushings used in supports Driving torque for stud is 50 to 95 inch-pounds.
204-011-404-121 and 204-011-404-125 have an
inside diameter of 0.3125 - 0.3135 inch and do not g. Coat new locking ring with primer (C-201)
require reaming after installation. Bushings may be and position on stud or insert with teeth aligned.
honed, if required, to obtain 0.312 - 0.313 inch Drive ring into case flush with top of stud collar.
inside diameter after installation.
6. Apply lacquer (C-203) on all exterior surfaces
of three arms on inner ring, from tips inboard a
(1) Coat replacement bushings and bores
with primer (C-201). Support tang and press minimum of four inches as follows:
bushings into support while primer is still wet. Install
bushings with thickest flange in outboard tang as a. Thoroughly clean surfaces with cloth
shown in detail D. saturated with toluene (C-306) or MEK (C-309). Wipe
surface dry with clean cloth before solvent
(2) Machine flange of outboard bushing as evaporates.
required to obtain 0.558 - 0.560 inch dimension
shown in detail D. b. Mask inside surfaces of trunnion holes and
bolt hole, and other surfaces not to be coated.
(3) Inspect support for cracks.
WARNING: AVOID BREATHING COATING VAPORS
5. Replace loose or damaged studs in the inner
AND EXPOSURE TO OPEN FLAME.
and outer ring as follows:
c. Spray apply a set coat of protective coating
a. Measure height of stud to be replaced.
(C-203) to exterior surface of three control arms, to
include areas one inch inboard of large holes in tops
b. Remove loose or damaged stud.
and bottoms of arms.
65-101
BHT-205A1-CR&O-1
d. Air dry at room temperature for 30 minutes 7. Replacegimbal ringbearings,seals, bolts, nuts,
minimum. and cotter pins on reassembly. Replace all
unserviceable parts.
e. Apply second coat. 8. Lubricate the following parts before assembly.
f. Cure by one of the following methods: a. Hand pack thrust bearing (25, figure 65-52)
with grease (C-007). After reassembly of swashplate,
use a suitable gun at two lube fittings on outer ring
(1) Air dry 48 hours minimum at room and purge grease past seals to ensure bearing
temperature. lubrication.
b. After reassembly, trunnions will be purge

(2) Air dry 15 minutes; bake at 150°F (67°C) lubricated with hand gun through fittings provided on
for one hour. each rod end and swashplate horn.
NOTE: Upgrading swashplate and support assembly to later configuration will

require incorporating parts as shown in table 65-3. All parts to be retained in
service shall require normal overhaul inspections to determine serviceability.
Table 65-3. Swashplate and support assembly configurations
204-011-400 Swashplate and 1 -013 -017 -025 -127 N/P

support assembly 1 -129
204-010-404-001 Gimbal ring 1 X X X X X
204-011-402-017 Inner ring 1 X X 1
204-011-402-021 Inner ring 1 X 2
204-011-402-127 Inner ring 1 X X
204-011-403-001 Outer ring 1 X X X X X
204-011-404-005 Support assembly 1 X 3
204-011-404-009 Support assembly 1 9 X 4
204-011-404-125 Support assembly 1 X
204-011-426-001 Outer cap 1 X X X X X
204-011-427-001 Inner cap 1 X X X X X
204-011-428-003 Cover 1 X X X X X
204-011-429-001 Seal 2 X X X X X
204-011-430-001 Bearing 1 X X X X X
204-011-431-001 Shim 4 X X X X X
204-011-444-001 Shim 4 X X X X X
204-011-451-001 Trunnion 5 X X X X X
204-011-457-001 Washer - 6 6 2 7
204-011-457-003 Washer - 4 4 6 8
204-011-460-001 Spacer 2 X X X X X
204-011-458-003 Plate 3 X X X X X
204-011-458-007 Plate 2 X X X X X
204-011-461-001 Bolt 2 X 9
65-102 Rev. 2
BHT-205A1-CR&O-1
Table 65-3. Swashplate and support assembly configuration (Cont)
204-011-400 Swashplate and 1 -013 -017 -025 -127 N/P

support assembly 1 -129
204-011-463-001 Bolt 2 X X X
204-011-463-003 Bolt 2 X X X
204-010-496-001 Bushing 2 X
204-010-496-003 Bushing 2 X
205-011-304-001 Bracket 1 X X X X X
212-001-273-001 Bracket 1 alternate for 205-011-304-001
AN320-5 Nut 4 X replaced by MS17826-5 nut
MS17826-5 Nut 4 X X X X X 10
NAS464-5-20 Bolt 2 X 11
NAS464-5-39 Bolt 2 X X 12
AN4-22A Bolt 3 X X X X X
AN4-23A Bolt 4 X X X X X
AN960JD416 Washer 32 X X X X X
AN960-516 Washer - 2 2 4 2 2
NAS679A4 Nut 28 X X replaced by MS21042L4 nut
MS21042L4 Nut 28 X X X
NOTES:
1. Replaced by inner ring 204-011-402-021.
2. Replaced by inner ring 204-011-402-127.
3. Replaced by support 204-011-404-009.
7. Washer 204-011-457-003 may be used as an alternate.
8. Install chamfer towards bolt head. When used under nut, install chamfer towards lug.
9. Replaced by 204-011-463-003. Refer to A.S.B. 205-76-13.
10. MS17826 series nuts have been replaced by MS14144 series nuts.
11. Inactive for future procurement, use bolt 204-011-463-003.
12. Replaced by 204-011-463-001. Refer to A.S.B. 205-76-13.
65-50. ASSEMBLY - SWASHPLATE AND 1. Apply adhesive (C-325) on outside diameter of

SUPPORT. upper seal (22, figure 65-52). Press seal, with lip of
seal pointing up, into top of cap (16), until flush with
NOTE: Apply corrosion preventive compound surface outer cap. Remove any excess adhesive.
(C-104) to shanks only of all bolts prior to installation
and corrosion preventive compound (C-101) to bolt 2. In same manner, install lower seal (27) with lip
heads and nuts after installation. pointing down, into lower side of outer ring (26).
Rev. 2 65-102A
BHT-205A1-CR&O-1
3. Install a trunnion (30) in each of two mounting b. Assemble on horn (refer to detail A), plate
points in outer ring as follows: (38), and bracket (41). Install two bolts (37) with
washers under bolt head and nut. At lower hole insert
a. Lightly coat outside of trunnion barrel with spacer (39) between faces of horn and install bolt
corrosion preventive compound (C-101) and insert (42) with bolt head outboard. Install nuts and torque
into outer ring. evenly 50 to 70 inch-pounds.
NOTE: Use of work aid illustrated in figure 65-53 is c. Assemble on horn (referto detail B) two plates
recommended to allow installation of trunnions with (34), spacer (35), and bolts (36) with one washer
less possibility of damage to swashplate rings. underbolthead and nut. Install nutsand torqueevenly
Excessive spreading of the trunnion clamp area of the 50 to 70 inch-pounds.
ring could cause a crack resulting in loss of rotor
control. Insert tang of tool in slot and tighten screw d. Position plates (32) on aft horn (refer to detail
until trunnion can just be installed. C) and install bolt (31) in lower hole with washer under
bolt head and nut. At the two upper holes, measure
b. Align bolt grooves and holes. Coat bolts (29, the gap both sides between the plates and horn. Shim
figure 65-52) with primer (C-201). Install two bolts the gap with AN960PD416L washers, as required,
with a washer next to each bolt head and nut. Release to obtain a 0.000 to 0.016 inch maximum clamp-up
screw tension on work aid and remove work aid. on each side. Install bolts (31) with washers under
Torque nuts 50 to 70 inch-pounds. bolt head and nut. Torque nuts evenly 50 to 70
inch-pounds.
4. Install trunnion assemblies and attaching parts
in three control horns of inner ring (28).
5. Press four bearings (7, figure 65-52) into liners
a. Apply a light coat of corrosion preventive (6).
compound (C-101) to trunnion barrel and insert a
trunnion into each of three horns of inner ring. Align 6. Fit bearing liner assemblies to gimbal ring and
trunnion bolt grooves with holes in horn. mating parts to determine shims required to center
bearings between bushings of mounting points.
NOTE: Apply a primer (C-201) on all bolt shanks and
on inner faces of all plates and brackets before a. Placetwoliners(6)inoppositesidesofgimbal
installing. ring assembly (4) without shims or retaining screws.
65-102B Rev. 2
BHT-205A1-CR&O-1
b. Mount gimbal ring on support (1 5) with bolts through support and bearings. Install special washers
(9) inserted through support bushings and gimbal (10) and nuts. Torque nuts 90 to 120 inch-pounds,
bearings. Tap gimbal ring to one side of support. Use and install cotter pins.
feeler gage at opposite side to measure clearance
between gimbal ring and bearing liner flange. b. Position inner ring (28) over support with
control horns located as illustrated and gimbal ring
c. Prepare two shims (5), each shim one-half as bearings aligned in mounting points of inner rings.
thicktotal
as measured
clearance. Make sure that elevator horn (aft horn of inner ring) is
d. Match-mark gimbal ring and support at one located farthest away from collective lever mounting
place. Remove gimbal ring. bosses of support (15). Install two bolts (2), with
special washers (1) next to heads, from inboard
e. Remove both bearing liner assemblies. Apply through bearing and inner ring. Install washers (14)
corrosion preventive compound (C-101) to liner and nuts. Torque nuts 90 to 120 inch-pounds, and
surface which will touch gimbal ring, and reinstall install cotter pins.
with shims in place and retaining screws (8). Secure
screws, in pairs, with lockwire (C-405). 9. Install swashplate assembly (3), and gimbal
ring assembly (4) to support (15) as follows:
f. In the same manner, fit and install the
remaining two bearing liners in gimbal ring, with a. Position gimbal ring to mounting points of
shims peeled, as required, to center bearings in support, observing match-marks. Install bushings
mounting points of inner ring (28). (12) in support (15). Install bolts (9) with washers
7. Prepare parts for final assembly: (11), next to heads, from inboard through support
and bearings. Install washer (14) and nuts. Torque
a. Thoroughly clean shanks of four bolts (2 and nuts 90 to 120 inch-pounds and install cotter pins.
9), and inside diameters of gimbal ring bearings and
bushings in mounting points of inner ring and support b. Position inner ring (28) over support, with
with MEK (C-309). control horns located as illustrated and gimbal ring
bearings aligned in mounting points of inner ring.
CAUTION: KEEP SOLVENTS AND RETAINING Make sure that elevator horn (aft horn of inner ring) is
COMPOUNDS OUT OF WORKING PARTS OF located farthest away from collective lever mounting
BEARINGS. bosses of support (15). Install two bushings (17) in
b. Apply
(C-335)
sealant
sparingly
but
evenly inner ring. Install two bolts (2), with special washer
on ID surfaces of bushings and bearing inner races. (11 ), next to heads, from inboard through bearing and
Place a special washer (10) on bolt (9) and special inner ring. Install washers (14) and nuts Torque nuts
washer (1) on bolt (2) with chamfer toward bolt head 90 to 120 inch-pounds, and installcotter pins.
and apply sealant to bolt shanks. Do not allow sealant
to contact bushings (12 and 17) outer diameter or NOTE: After 30 minutes curing time, tilt swashplate
their faying surface. all in
directions to ensure there is no binding caused
by retaining compound entering gimbal bearings.
NOTE: Accomplish step 8. when assembling Sealant shall cure 12 hours at 75°F (24°C) before
swashplates which attach support and inner ring to service use.
gimbal ring without using slip bushings. Accomplish
step 9. when assembling swashplates which use slip 10. Apply light coatings of corrosion preventive
bushings when attaching support and inner ring to compound (C-101) on inside and outside diameters
gimble ring. of thrust bearing (25) and on mating surfaces of outer
ring liner (26) and liner on inner ring (28). Hand pack
8. Install swashplate assembly (3), and gimbal thrust bearing (25) with grease (C-007).
ring assembly (4) to support (15) as follows:
a. Position gimbal ring to mounting points of 11. Seat outer ring assembly over inner ring,
support, observing match-marks. Install two bolts (9) taking care that lower seal passes undamaged over
with special washers (10) next to heads, from inboard shoulder on inner ring sleeve.
65-103
BHT-205A 1-CR&O-1
12. Align etched arrows on outer race of thrust 18. Lubricate thrust bearing (25) with grease
bearing (25). Install bearing between inner and outer (C-007) applied with hand gun through fittings on
rings, and tap evenly until seated. outer ring. Purge grease past seals to ensure
lubrication. Purge lubricate trunnions through fittings
13. Determine height of bearing outer race above on rod-ends and on control horns.
top surface of outer ring, either by using a depth gage
or by placing outer race cap on bearing and measuring 19. Check swashplate assembly for freedom of
gap with a feeler gage. Peelfour-section shim set (17) movement.
0.009 to 0.012 inch thinner than measured
dimension, to provide clamp-up on bearing race. 65-51. COLLECTIVE LEVER.
14. Determine height of bearing inner race above 65-52. REPAIR- COLLECTIVELEVER.
top surface of inner ring, by methods similar to step
(20). Peel four-section shim set (21) 0.009 to 0.012 NOTE: Replace bearing in collective lever if axial or
inch thinner than measured dimension. radial looseness exceeds 0.005 or if bearing feels
rough when inner race is rotated.
15. Place prepared shim on inner ring studs. Fill
gaps between shim sections with corrosion 1. Remove bearing as follows:
preventive compound (C-101). Place inner cap (20)
on studs. a. Place collective lever (2, figure 65-58) on a
suitable support having clearance for bearing.
16. Place prepared shim on outer ring studs.
Apply corrosion preventive compound (C-101) to fill Press lever bearing (3) from lever. Press on
gaps between ends of shim sections. Install outer cap outer race.
(23) with 12 washers and nuts on studs. Tighten nuts
2. Repair inside of bearing liner not to exceed
depth of 0.0020 inch for mechanical or corrosion
17. Install cover (19) with washers and nuts on damage. Repaired liner ID not to exceed 1.1245 inch
inner ring studs. Tighten nuts evenly.
1. Pin
2. Collective lever
3. Lever bearing
4. Liner
Figure 65-58. Collective lever
65-104
BHT-205A1-CR&O- 1
3. Install bearing as follows: b. Press pin from lever. Do not drive pin by
impact.
a. Apply corrosion preventive compound
(C-101) to new lever bearing (3) and liner (4).
5. Repair collective lever (2) in accordance with
b. Place collective lever (2) on a suitable damage and repair limits shown on figures 65-59 and
support. 65-60.
c. Press lever bearing (3) into liner (4). Press

into lever (2). 6. Install pin (1, figure 65-58) in collective lever
NOTE: Pin should not be removed unless (2) as follows:

mechanical or corrosion damage exceeds damage
limits shown on figure 65-59. a. Apply corrosion preventive compound
(C-101) to collective lever (2) and pin (1).
4. Remove pin (1, figure 65-58) as follows:
b. Place lever on a suitable support.
a. Place collective lever (2) on a suitable
support having clearance for pin (1). c. Press new pin (1) into collective lever (2).
Bottom pin in lever.
TYPE OF DAMAGE MAXIMUM DAMAGE DEPTHS
NICKS, SCRATCHES,
SHARP DENTS 0.010 in. 0.020 in.
CORROSION
MAXIMUM AREA PER

NONOVERLAPPING FULL
NUMBER OF
NONOVERLAPPING
REPAIR AREAS One per segment 4
EDGE CHAMFER
° °
OR RADIUS 0.030 in. by 45 0.060 in. by 45
BORE DAMAGE 0.001 inch for 1/4 of

circumference
NOTES:
Figure 65-59. Collective lever damage limits
65-105
BHT-205A1-CR&O-1
ITEM NOMENCLATURE MIN. INCH MAX. INCH
1 Pin 0.6243 0.6250
Figure 65-60. Collective lever wear limits
65-53. TAIL ROTOR HUB AND BLADE If tail rotor hub and blades are being disassembled for
SYSTEM. replacement of defective part(s) instead of overhaul,
disassemble only to extent necessary to replace
The tail rotor hub and blade system components defective part(s).
covered in this section are: tail rotor hub and blade,
tail rotor hub, and tail rotor blades. Identify bolts, washers, balance washers, blades,
and nuts at location from which removed. However, if
65-54. TAIL ROTOR HUB AND BLADES parts replacement or repairs are required, the hub and
(212-010-701). blade assembly will require balancing. Disassemble
hub and blade only to extent required to accomplish
The 212-010-701-21 tail rotor hub and blades is inspection and parts replacement.
equipped with a dynamic balance arm. The 1. Remove nuts (2, figure 65-61), balance
212-010-701-25 tail rotor hub and blades is
washers (3), chamfered washers (4), and bolts (9).
equipped with a dynamic balance arm and a trunnion
bearing wear indicator.
2. Remove blade (5) from hub (1).
TOOLS REQUIRED 3. Repeat steps 1. and 2. for opposite side.
7HEL075A Balancing Kit 4. Remove nuts (12), washers (11), bolts (10)
or and pitch horn (6).
7HEL087 Balancing Kit
5. Cut lockwire and remove balance bolt (7) and
65-55. DISASSEMBLY - TAIL ROTOR HUB AND balance washers (8).
BLADES. 65-56. INSPECTION - TAIL ROTOR HUB AND
BLADES.
BHT-205A1-MM-1 manual, and retire all items 1. Refer to paragraph 65-62 for tail rotor hub
scheduled for retirement. inspection.
65-106
BHT-205A1-CR&O-1
1. Hub
2. Nut TORQUE 500 IN-LB
3. Balance washer
4. Chamfered washer
5. Blade
6. Pitch horn
7. Balance bolt
8. Balance washer
9. Bolt
10. Bolt
11. Washer
12. Nut TORQUE60 IN-LB
13. Bolt holes
14. Bearings
TORQUE 50 TO 70 IN-LB
Figure 65-61. Tail rotor hub and blades (212-010-701)
2. Refer to paragraph 65-89 for tail rotor blade NOTE: Installation of balance washers (3 and 8),
inspection. balance bolt (7), and torquing of nut (2), will be
accomplished during the balancing of hub and blade.
3. Refer to paragraph 65-84 for pitch horn
inspection. 3. Position pitch horn (6) between blade grips and
install bolts (10), washers (11), and nuts (12). Torque
65-57. REASSEMBLY - TAIL ROTOR HUB AND nuts 60 inch-pounds.
4. Balance tail rotor hub and blades. (Refer to
paragraph 65-58.)
1. Position blade grips over hub (1, figure 65-61)
with data plate on same side as data plate on yoke. 65-58. BALANCING - TAIL ROTOR HUB AND
BLADES.
NOTE: Bolts (9) may be installed with heads inboard
or outboard. However all four shall be installed the NOTE: Modification of balancing kit by the addition
same. of new pilot bushing 3285 is required. Reidentify
balancing kit as 7HEL075-A.
2. Align hub bearings (14) with bolt holes (13) in
blade and install bolts (9), chamfered washers (4) and 1. Prepare for balancing as follows:
nuts (2). Bolts (9) may be installed with heads either a. Provide a work bench or flat top stand in a
inboard or outboard but all four bolts shall be installed draft free area. Providea hoist or other suitable means
the same.
65-107
BHT-205A 1-CR&O- 1
of suspension above the bench or in the immediate 7. With rotor resting on support blocks, adjust
area. trunnion position to visually align arbor vertically.
Maintain blade contact with blocks for pitch
b. Place two support blocks approximately five positioning.
inches high by eight inches long on bench top. Space
parallel, eighteen inches apart. 8. Install base (6), hub extension downward, on
arbor lower end. Align length of base with rotor span
c. Remove balance indicating arbor (2, figure axis. Install upward along arbor to position posts (7)
65-62) from 7HEL075-A kit case and stand in a approximately 1/16 inch below blade root and secure
vertical position supported in bore of kit case block, by evenly tightening both setscrews (8).
d. Clean oil accumulation, if present, from top
tissue.
cloth or tissue.
soft cloth
with soft coupling with hoist hook and suspend assembly clear
of all obstructions without causing change to blade
pitch or trunnion position.
(11), if tightened, and depress indicator downward
against light spring pressure to position bottom 10. Loosen pilot bushing (3), setscrews (4), and
surface approximately 0.005 inch above black firmly reseat bushing in cone of trunnion. Maintain
indicator disk (10). Lightly tighten the setscrew. seating pressure and secure by moderately tightening
both setscrews (4).
f. Check that indicator collar does not contact
the indicator disk during balancing. 11. Recheck position of bushing top surface so
that arbor scale setting is maintained. Reseat both
NOTE: Prior to storing arbor in kit case after use, pilot bushings, if necessary, to maintain arbor setting
release setscrew and allow internal spring-loaded and firm seating in trunnion.
damping oil seal to move upward and seat. Do not
retighten setscrew. 1 2. Check that blades maintain clearance with
posts of base. If friction of pitch change bearings
2. Clean trunnion bore and cone seat surfaces of cannot maintain blade position and post clearance,
rotor and position to locate data plates of hub allowbothbladestopitchtrailingedgedownwardand
upward. Place rotor on support blocks with blocks rest on the trailing posts.
contacting blade roots on flat outboard from blade
bolts. Adjust blade pitch to seat evenly on blocks.
13. Stabilize movements of suspended rotor and
observe balance indicated by concentricity
3. Remove pilot bushing (13)fromstorage position
of arbor shaft with indicator collar (11). Acceptable
balance is indicated when indicator collar remains
arbor to align arbor
to..
top surfae
to align
surface (sensitivity setting
within the edge limits of the black indicator disk.
(Referto view A.)
reference surface) with the 5-3/8 inch arbor scale
position. Temporarily secure with its setscrews (4).
14. Check that balance indications are not
5. Insert arbor downward through trunnion bore affected by interference from surrounding objects, air
and seat bushing in cone of trunnion. drafts, or movement of nearby personnel.
6. Install pilot bushing (1), large end downward, 15. Chordwise balance is accomplished by
on arbor lower end. Position upward along arbor to adding weight on bolt (13). An alternate method is to
engage trunnion bore and seat in cone of trunnion. add weight to dynamic balance arm, if installed. If
Secure by evenly tightening both setscrews (5). weight is to be added on bolt (13), proceed to step a.
65-108
BHT-205A1-CR&O-1
212-010-777 BALANCE ARM
1. Pilot Bushing (P/N 2529)

2. Balance Indicating Arbor (P/N 3165)
3. Pilot Bushing (P/N 3285)
4. Setscrews
5. Setscrews
6. Base (P/N 3152)
7. Post
8. Setscrews
9. CableLoop
10. Indicator Disk
11. Indicator Collar
12. Washers, Chordwise Balance
13. Bolt
14. Washers, Spanwise Balance
15. Bolts, Blade Attaching
16. Balance Arm for 212-010-701-23 WITHIN EXCEEDS
Hub and Blade Assembly
Figure 65-62. Tail rotor hub and blade balancing
65-109
BHT-205A1-CR&O-1
If weight is to be added to dynamic balance arm, 2. Separate trunnion halves (5and 10)from yoke
proceed to step b. (7).
a. Balance hub and blade chordwise using NOTE: Trunnion halves are serialized and shall be
combination of AN970-4 and AN960-416 washers replaced or retained as a matched set.
as required (maximum of ten in any combination).
Length of bolt (13) to be AN4H-4A to AN4H-1OA as 65-62. INSPECTION- TAIL ROTORHUB.
necessary to accommodate balance washers. When
bolt (13) is installed at least one washer is required NOTE: If records or physical appearance of tail rotor
under head. Torque bolt (13) 50 to 70 inch-pounds
and lockwire to pitch horn (C-405). hub indicate that assembly has been subjected to an
accident or incident outside realm of normal usage,
perform Conditional Inspection, paragraph 65-63. If
b. Addand
AN970-4
AN960-416 washers, as tail rotor hub does not require conditional inspection
required, (maximum of ten any combination) to bolt in proceed with Normal Inspection, paragraph 65-64.
dynamic balance arm. Install washers equally under
head of bolt and under nut. Bolt to be AN4-4A to
AN4-10A with MS21042L4 nut. Bolt and nut can be 65-63. Conditional Inspection - Tail Rotor Hub.
installed in each end of balance arm if necessary.
Torque nut 60 inch-pounds. 1. Carefully inspect all detail parts visually for any
apparent damage or abnormal appearance.
NOTE: If bolt is installed, at least one washer is
required under bolt head. 2. Inspect parts for surface damage. (Refer to
paragraph 65-64.)
16. Balance hub and blades spanwise by using
combination of AN960-816, AN960-816L, 3. Visually check yoke for indications of
AN970-8 and 212-101-764-1 spanwise balance permanent deformation. Replace hub assembly for
washers (14), as required. Assemble with heaviest any deformations.
balance washer next to chamfered washer. Length of
blade attaching bolt (15) to be NAS1308-34 to 4. Inspect for bent flexure by measuring the
NAS1308-36, as required, to accommodate balance precone angle in the following manner:
washers. Refer to view A for balance indications.
Torquenut 500 inch-pounds. a. Clamp one end of yoke (7, figure 65-63) on
surface plate. If necessary, use equal thickness
17. Recheck balance of hub and blades according
spacer blocks to allow room to clear trunnion bore
to steps 13 and 14.
area.
65-59. DELETED.
b. On opposite end, immediately inboard of
65-60. TAIL ROTOR HUB OVERHAUL inboard bearing, place a pencil mark. Place another
pencil mark at point 4.75 inches outboard of first
mark. Second mark should be immediately outboard
of outboard bearing.
TOOLS REQUIRED
T101 577-1 Staking Tool c. Measure heights of these two points above
surface plate. Difference in heights must be between
0.124 and 0.207 inch. If difference exceeds these
limits, scrap yoke.
65-61. DISASSEMBLY- TAIL ROTORHUB. limits, scrap yoke.
1. Remove nuts (13, figure 65-63), washers (2 5. Inspect trunnion retention bolts and blade
and 12) and bolts (1). If installed, remove indicator retention bolts for indication of shear offset. Reject
(3), shims (4) and balance arm (11). hub assembly if any bolts show shear offset.
65-110
BHT-205A1-CR&O-1
1. Bolt
5. Trunnion Half
6. Bearing
7. Yoke
8. Bearing
9. Data Plate
10. Trunnion Half
11. Balance Arm
12. Washer
13. Nut
Figure65-63. Tail rotor hub (212-010-701)
65-111
BHT-205A1-CR&O-1
TRUNNION SET
YOKE ASSEMBLY A
(TYPICAL)
MECHANICAL AND
CORROSION
(Before and
MECHANICAL AND
CORROSION
(Before and
0.010 in.
MAXIMUM AREA PER 0.10 sq. in. 0.15 sq. in.

FULL DEPTH REPAIR:
0.05 sq. in 0.10sq. in.
NUMBER OF One per segment Not critical

REPAIR AREAS
One per lug Two
EDGE CHAMFER 0.010 in. 0.020 in.
0.010 in. 0.020 in.
BORE DAMAGE 0.002 in. for 1/4 circumference
SPLINE DAMAGE Depth: One-third of spline

Length: One-half of spline
Number: Three
NOTES:
1 Repair area must be coated with brush cadmium (C-108).
2 Repair area must be coated with primer (C-201).

Figure 65-64. Tail rotor yoke and trunnion damage and repair limits
65-112
BHT-205A 1 -CR&O-1
6. Inspect bearing races for looseness in yoke. 65-65. REPAIR - TAIL ROTOR HUB.
Reject yoke if bearings are loose.
1. Repair damage to yoke or trunnion as follows:
7. Perform Normal Inspection, paragraph 65-64. a. Polish out mechanical and corrosion damage
using fine to medium abrasive cloth (C-406) and
65-64. Normal Inspection - Tail Rotor Hub. crocus cloth (C-409) to obtain a smooth scratch-free
surface. Repairs must not exceed the limits of figure
1. Inspect trunnion set to limits shown on figure 65-64.
65-64. Replace both halves of set if limits are exceed
b. Coatall repaired areas except trunnion
on either half. splines with brush cadmium (C-108).
2. Inspect yoke to limits shown on figure 65-64. 2. Inspect trunnion bearings (6, figure 65-63) and
Replace yoke if limits are exceeded. blade retention bearings (8) in yoke for play. Replace
bearings if axial play of bearings exceed 0.01 5 inch.
NOTE: Refer to BHT-ALL-SPMmanual for approved Bearing wear indications on hubs equipped with
fluorescent penetrant material. (Post Emulsified indicator (3) are shown on figure 65-65.
Penetrant System.)
3. Replace trunnion and blade retention bearings
as follows:
3. Perform a fluorescent penetrant inspection of
trunnion set. NOTE: Blade retention bearing (8, figure 65-63)
205-012-710-1 supersedes bearing 212-010-731-1
4. Perform a magnetic particle inspection, wet for further procurement. All four bearings must be
continuous method, of yoke as follows: same part number, intermixing is not authorized.
a. Support yoke on a suitable surface having
a. If yoke is being inspected during overhaul clearance for bearing and press out bearing. Clean
remove bearings prior to inspection. (Refer to primer from yoke bores and inspect bores for scoring.
paragraph 65-65, step 3.a.) If yoke is being inspected Clean up to a maximum depth of 0.002 inch and not
at other than overhaul, bearing should be masked to exceed 1/4 total circumference. Inspect yoke for
using sealing wax or equivalent. cracks using the magnetic particle method.
NOTE: Magnetic particle inspection may be b. Apply unreduced primer, (C-201), to mating
surfaces of bearing and yoke and insert new bearing
conducted using either ac or dc current. When using
ac, use only 60% of dc amperes. in yoke. Clean off excess primer and avoid primer
contaminating bearing.
b. Magnetize yoke by placing between c. Roll stake bearing as follows:
contacts and passing 2500 amperes through the long CAUTION THE FIRST STAKING OPERATION
axis of yoke. Inspect under black light for indications. SHALL BE PERFORMED WITH DATA PLATE
(PRECONED) SIDE OF YOKE UP AND FLANGED SIDE
c. Place the yoke in the coil so that the long axis OF THE STAKING ANVIL DOWN. (REFER TO DETAIL
of yoke is 90 degrees to direction of current flow A, FIGURE65-66.)
through the coil. Magnetize the yoke using 12,500
ampere turns magnetizing force (for a 5 turn coil this NOTE: Stake trunnion bearings using a
is 2500 amperes). Inspect under black light for T101577-17 housing and a T101577-19 backstop.
indications. Repeat this inspection at 8 inch Stake blade retention bearings using a T101577-11
increments to assure an adequate inspection. housing and T101577-13 backstop.
(1) Assemble staking tool as shown on figure

d. Demagnetize yoke and clean thoroughly.
65-67 to stake trunnion bearings. Assemble staking
tool as shown on figure 65-68 to stake blade
e. Remove masking material from bearings. retention bearings. Lubricate staking tool rollers and
65-113
BHT-205A 1-CR&O- 1
INDICATES BEARING HAS

REACHED APPROXIMATELY INDICATES BEARING WEAR
50% OF ITS WEAR ALLOWANCE TOLERANCE HAS BEEN REACHED
Figure 65-65. Bearing wear indications
install tool in a hand fed, stand type drill press. Set (7) Check bearing for proper location by
drill press at 250 to 350 rpm maximum. measuring between the flat surface of bearing end
and the adjacent flat surface of yoke. Bearings shall
be located in yoke to the dimensions shown in detail
(2) Place anvil on drill press (flat side up) B.
(refer to detail A, figure 65-66) and position bearing
on anvil. Feedthe spindle of the staking tool into the d. Paint areas of yoke contacted by bearing
bearing to ensure alignment of the tool rollers with the wear indicator with primer (C-201).
bearing groove.
65-66. REASSEMBLY - TAIL ROTOR HUB.
(3) Start drill press and apply steady hand 1. Position trunnion half (5, figure 65-63) on data
pressure for a minimum of 10 seconds to allow the
tool to roll the outer lip of bearing over the yoke
opposite side. Align master tooth splines in trunnion
chamfer.
set.
(4) Reposition anvil with flanged side up and 2. If used, install shims (4) and indicator (3) over
roll stake opposite side of bearing. trunnion half (5). Adjust shims (4) to provide 0.024 to
0.026 inch clearance between tabs of indicator (3)
and yoke (7).
(5) After staking, the gap between the
staked lip and yoke chamfer shall not exceed 0.008 3. Install bolts (1), washers (2 and 12), balance
inch. (Refer to detail B, figure 65-66.) arm (11), if used, and nuts (13), Torque nuts 500
inch-pounds.
(6) Rotate bearing and check for smooth
operation. Check that outer lip of bearing (two sides) 65-67. PAINTING - TAIL ROTORHUB.
is rolled smoothly onto the yoke chamfer and that the
inner lip and ball were not scored by the staking tool. 1. Clean surface with naphtha (C-305) and dry
(light sanding is permissible).
65-114
BHT-205A 1-CR&O-1
STAKINGTOOL
(ARBOR, HOUSING
AND ROLLERS)
FIRST OPERATION
DATA PLATE UP
HUB
STAKINGTOOL
(BACKSTOP)
FIRST OPERATION
FLANGED SIDE OF BACKSTOP
DOWN (TYPICAL)
DETAIL A
TOOLAPPLICATION
GAP BETWEEN YOKE
STAKING REQUIREMENTS THIS SIDE OF YOKE
Figure 65-66. Tail rotor yoke bearing replacement
65-115
BHT-205A 1 -CR&O- 1
ARBOR T101577-3
WOODRUFF KEY NO. 213
HOUSING, T101577-17
Figure 65-67. Tool for staking tail rotor trunnion bearings (212-010-723,
-768. -762)
ARBOR, T101577-3
HOUSING, T101577-11
ROLLER, T101577-7
BUSHING, T101577-5 - RETAINER, T101577-9

WASHER, AN960-10
SCREW,NAS1351-3-6
BACKSTOP, T101577-13
Figure 65-68. Tool for staking tail rotor blade retention bearings (205-012-710.
212-010-731)
65-116
BHT-205A 1-CR&O-1
2. Apply a mist coat of primer (C-204) to all 65-70. INSPECTIONAND REPAIR- TAIL ROTOR
surfaces, except bearing. HUB AND BLADES.
3. Paint all surfaces, except bearings, with two NOTE: If records or physical appearance of tail rotor
coats of lacquer (C-203). hub and blade assembly indicates the assembly was
subject to an accident or incident outside realm of
normal usage, perform conditional inspection of tail
65-68. TAIL ROTOR HUB AND BLADES rotor hub and conditional inspection of tail rotor
(212-011-701). blades. Refer to BHT-205A1-MM-1 manual for
definition of accidents or incidents that require
The 212-011-701 tail rotor hub assembly has grease conditional inspection be conducted.
lubricated roller element flapping bearings.
1. Refer to paragraph 65-77 for tail rotor hub
inspection.
TOOLS REQUIRED
2. Refer to paragraph 65-89 for tail rotor blade
7HEL087 Balancing Kit inspection.
3. Refer to paragraph 65-84 for pitch horn

65-69. DISASSEMBLY - TAIL ROTOR HUB AND inspection.
BLADES.
65-71. REMOVAL - PITCH HORN.
BHT-205A1-MM-1 manual, and retire all items 1. Remove bolt (21, figure 65-69) and balance
scheduled for retirement. washers (19 and 20).
If tail rotor hub and blades are being disassembled for 2. Remove two bolts (13).
replacement of defective parts instead of overhaul,
disassemble only to extent necessary. 3. Remove pitch horn (18).
65-72. INSTALLATION
Identify bolts, washers, balance washers, blades, 65-72 INSTALLATION-- PITCH
PITCH HORN.
HORN.
and nuts at location from which removed. However, if
parts replacement or repairs are required, the hub and 1. Position pitch horn (18, figure65-69 between
blade assembly will require balancing. Disassemble blade grips.
hub and blades only to extent required to accomplish
inspection and parts replacement. 2. Install two bolts (13), washers (14 and 22) and
nuts (23). Torque nuts (23) 150 inch-pounds.
1. Remove nuts (1 and 29, figure 65-69), 3. Install bolts (21) and balance washers (19 and
washers, and bolts (10 and 12). 20), as required. Torque bolt (21) 50 to 70
inch-pounds. Lockwire bolt (21) to pitch horn (18).
2. Remove pitch horn (18) from rotor blade
(paragraph 65-71). 65-73. REASSEMBLY - TAIL ROTOR HUB AND
BLADES.
3. Remove blade (7) from hub (15).
1. Install pitch horn (18, figure 65-69) on each tail
4. Repeat steps 1. through 3. for opposite side. rotor blade (paragraph 65-72).
5. Cut lockwire and remove balance bolt (21) and 2. Position blade grips over hub (15) with data
balance washers. plate on blades outboard and yoke inboard.
65-117
BHT-205A1-CR&O-1
1. Nut 10. Bolt

3. Washer 12. Bolt
4. Washer 13. Bolt
TORQUE500 TO 550IN -LB . Washer 14. Washer
6. Washer 15. Tail rotor hub
7. Tail rotor blade 16. Tail rotor bearing
8. Buffer 17. Tail rotor balance bracket
9. Washer 18. Tail rotor pitch horn
19. Washer
20. Washer
21. Bolt
22. Washer
24. Washer
25. Washer
26. Washer
27. Washer
28. Washer
29. Nut
NOTE
NOTES:
Refer to BHT-205A1-MM-1 manual for

instructions to install weights for tail
rotor chordwise balancing with CHAMFEREDSIDE OF
Chadwick-Helmuth Vibrex equipment WASHERTOWARD HEAD
(dynamic method). OF BOLT.
Bracket is an installation component.
Figure 65-69. Tail rotor hub and blades (212-011-701)
65-118
BHT-205A1-CR&O-1
NOTE: Bolts (10 and 12) may be installed with 2. Provide a work bench or flat top stand in a draft
heads inboard or outboard. However, all four shall be free area. Provide a suitable means to suspend arbor
installed the same. (3, figure 65-70) and tail rotor above work bench.
Arbor must be supported at cable loop (1).
3. Align hub blade bearings (16) with blade bolt
holes. Install bolts (10 and 12), chamfered washers 3. Loosen retaining setscrew in indicator collar
(9 and 11), with bolt heads facing inboard. Install (2). Depress indicator downward against light spring
chamfered washers (5 and 24) with nuts (1 and 29). pressure to position bottom surface approximately
0.005 inch above black indicator disc (18). Lightly
NOTE: Installation of balance washers and torque of tighten setscrew. Ensure indicator collar (2) does not
nuts (1 and 29) will be accomplished during contact indicator disc.
balancing of hub and blades.
4. Balance tail rotor hub and blades. (Refer to 4. Clean tail rotor hub (1 5) trunnion bore and cone
paragraph 65-74.) seat surfaces with soft cloth or tissue.
65-74. BALANCING - TAIL ROTOR HUB AND 5. Place two parallel wooden blocks on work
BLADES(STATICMETHOD). bench to support tail rotor hub and blade assembly.
Place tail rotor hub and blade assembly on wooden
1. Prepare balance kit for use as follows:
blocks with flat surface of blades outboard of blade
a. Immediately prior to use of balance kit, retention bolts in contact with wooden blocks and
carefully wipe all external and internal mating with heads of rotor blade retention bolts (7) facing
surfaces with lint-free cloth or paper cleansing tissue down. Adjust blade pitch to cause blades to rest
to remove old oil and accumulations of fine dust or evenly on blocks. Tail rotor hub name (data) plate
other foreign matter. Coat components (except should be facing down.
spherical bearings) with oil (C-031). This procedure
will facilitate installation of close-fitting pilot 6. Install pilot bushing (4) and plate (17) on arbor
adapters, cones, and bushings on balancing arbors. (3). Do not tighten setscrews (5) at this time.
Seizing of cones and bushings on the arbors is usually
caused by fine particles of dirt or other foreign matter, 7. Position cone (16) on balance indicating arbor
or by improper lubrication. (3) with top of cone (16) at 5.125 inch mark on arbor
(3). This is marked "Sensitivity Setting Reference
b. Should excessive oscillation of balance Surface" on illustration. Tighten setscrews (6).
indicator occur due to inadvertent loss of arbor
dashpot oil, or should change of dashpot oil become
necessary, fill balance arbor dashpot with low 8. Position arbor (3) in hub and blade assembly
viscosity oil (3-in-1 light machine oil or equivalent).
One oil hole is located in side of arbor approximately
1-11/16 inches below indicator bushing; another is 9. Install adapter (12) on arbor (3) and seat
located in opposite side approximately 2-1/2 inches adapter on tail rotor hub trunnion.
from lower end of arbor. Remove both oil hole screws,
using 1/16-inch hexwrench. Using positive pressure, 10. Install base (13) on arbor (3). Tighten
pump action oil can, pump oil into lower arbor oil hole setscrews (14).
until oil appears at level of upper arbor oil hole. Install
lower and upper filler hole screws. If 11. Seat plate (17) against hub and blade
positive-press-type can is not available, arbor assembly. Seat pilot bushing (4) against plate (17)
dashpot may be filled through upper hole only. Leave and tighten setscrews (5). Install pitch horn bushing
lower screw installed in arbor. In this case, repeat (20) in pitch horn. Install post (19) on base (13) and
filling operation two or three times at 10-minute pitch horn (11). Adjust pitch horn height on post to
intervals to ensure small air spaces are completely set rotor blade at 0 degrees pitch. Install opposite
filled. Ensure that filler hole screws are installed post in same manner. Ensure that both rotor blades
following filling or draining operation. are at 0 degrees pitch.
65-119
BHT-205A1-CR&O-1
1-5/16 IN.
DETAIL B
5-1/8 INCH
SENSITIVITY SETTING
REFERENCE
1. Cable loop 11. Pitch horn

2. Indicator collar 12. Adapter (3378) (7HEL087Kit)
3. Arbor (3165) (7HEL087Kit) 13. Base (3152) (7HEL087Kit)
4. Pilot bushing (2533) (7HEL087Kit) 14. Setscrews
5. Setscrews 15. Tail rotor hub and blade assembly
6. Setscrews 16. Cone (3380) (7HEL087Kit)
7. Blade attaching bolt 17. Plate (2586) (7HEL087Kit)
8. Spanwise balance washers 18. Indicator disc
9. Chordwise balance washers 19. Post (2939) (7HEL087Kit)
10. Bolt 20. Pitch horn bushing
Figure 65-70. Tail rotor hub and blade (212-011-701) balancing
65-120
BHT-205A1-CR&O-1
12. Carefully engage cable loop (1) with hoist 20. Remove two posts (19, figure 65-70). Secure
hook and suspend assembly clear of all obstructions floating bushings (20) to pitch horns (11).
without causing change to blade pitch or trunnion
position on arbor. 21. Loosen setscrews (14). Remove base (13)
and adapter (12).
13. Loosen setscrews (5) and firmly reseat plate
(17) on hub assembly. Maintain seating pressure and 22. Remove arbor (3) from tail rotor hub and
secure by moderately tightening setscrew (5). blade.
14. Recheck position of cone (16) to ensure that 23. Loosen setscrews (6) and remove cone (16).
sensitivity setting of 5.125 inches that was set at
step 7 has not changed. If setting has changed and/or 23. Loosen setscrews (5) and remove pilot
if arbor is not firmly seated on rotor hub trunnion, bushing (4) and plate (17).
repeat steps 5 through 13. 25. Loosen setscrew in indicator collar (2) and
15. Stabilize movements of suspended rotor and allow internal, spring-loaded damping oil seal to move
observe balance indicated by concentricity upward and seat. Do not tighten setscrew.
relationship of black indicator disk (18) in top surface 26. Place all balance kit components in storage
of arbor shaft with indicator collar (2). Acceptable case. Position storage case in storage so that arbor is
balance is indicated when indicator collar remains
upright to prevent seepage of oil around indicator.
within the edge limits of the black indicator disk. See
view A, figure 65-70. 65-75. TAIL ROTOR HUB (212-011-701).
16. Check that balance indications are not 65-76. DISASSEMBLY- TAILROTORHUB.
affected by interference from surrounding objects, air
drafts, or movements of nearby personnel. 1. Remove four bolts (1, figure 65-71).
17. Install washers (19 and 20, figure 65-69) to 2. Remove trunnion housing (5).
balance hub and blade assembly chordwise. Use a
maximum of ten washers (19 and 20) of any 3. Remove thrust plug (9).
combination. Use bolts (21) of correct length to
accommodate washers and obtain proper thread 4. Remove shim (10).
engagement. Bolts (21) may be AN4H4A through
AN4H10A. A minimum of one washer (19 or 20) 5. Remove bearing (6).
must be under head of bolts (21), after chordwise and
spanwise balance is within limits. Torque bolts (21) 6. Remove seal (7)
50 to 70 inch-pounds. Lockwire (C-405) two bolts
7. Remove similar parts from opposite side of
(21) to pitch horns (18). yoke (12).
18. Install washers (5, 9, 11, and 24) next to

8. Remove trunnion (11).
rotor blades. Install washers (2, 3, 4, 6, 25, 26, 27
and 28) as needed to obtain spanwise balance, 9. Remove inner races (8) from trunnion (11).
starting with heaviest washers next to washers (5
and 24). Use bolts (10 and 12) of correct length to 65-77. INSPECTION - TAILROTORHUB.
accommodate washers and obtain proper thread
engagement. Bolts (10 and 12) may be NAS 1308-34 NOTE: If records or physical appearance of tail rotor
through NAS 1308-36. hub indicate that assembly has been subjected to an
accident or incident outside realm of normal usage,
19. When balance indication (figure 65-70, view perform Conditional Inspection, paragraph 65-78. If
A) is within limits, torque nuts (1 and 29, figure tail rotor hub does not require Conditional Inspection,
65-69) 500 to 550 inch-pounds. proceed with Normal Inspection, paragraph 65-79.
65-121
BHT-205A1-CR&O-1
1. Bolt
2. Steel washer
3. Tail rotor balance bracket
4. Lubrication fitting
5. Trunnion bearing housing
12.
9. Yoke
Thrust plug
10. Shim
11. Trunnion
12. Yoke
13. Blade retention bearing
Figure 65-71. Tailrotor hub (212-011-701)
65-122
BHT-205A1-CR&O-1
65-78. Conditional Inspection - Tail Rotor Hub. b. Place trunnion in five turn coil with long axis
parallel to coil axis; apply 4200 amperes. Inspect
1. Carefully inspect all detail parts visually for any surface for indications.
apparent damage or abnormal appearance.
c. Demagnetize trunnion and clean trunnion
2. Inspect parts for surface damage. (Refer to thoroughly.
figures 65-72, 65-73, and 65-74.)
3. Perform a magnetic particle inspection, wet
3. Visually check yoke for indications of continuous method on yoke, as follows:
deformation. Replace entire hub assembly if any
deformation is found. Inspect for bent flexure by a. If yoke is beings inspection during
overhaul,
angle in the following manner:
the
measuring
precone remove blade bearings prior to inspection. If yoke is
being inspected at other than overhaul, bearings
should be masked using sealing wax or equivalent.
a. Clamp one end of yoke (12, figure 65-71) on
surface plate. If necessary, use equal thickness NOTE: Magnetic particle inspection may be
spacer blocks to allow room to clear trunnion bore
conducted using either ac or dc current. When using
area. ac, use only 60% of dc amperes.
b. On opposite end, immediately inboard of b. Magnetize yoke by placing between contacts

inboard bearing, place a pencil mark. Place another and passing 2500 amperes through long axis of yoke.
pencil mark at point 4.75 inches outboard of first mark. Inspect under black light for indications.
Second mark should be immediately outboard of
outboard bearing. c. Place yoke in coil so long axis of yoke is 90
degrees to direction of current flow through coil.
c. Measure heights of these two points above Magnetize yoke using 12,500 ampere turns
surface plate. Difference in heights must be between magnetizing force (for a 5 turn coil this is 2500
0.124 and 0.207 inch. If difference exceeds these amperes). Inspect under black light for indications.
limits, replace yoke. Repeat this inspection at 8 inch increments to assure
an adequate inspection.
4. Inspect blade retention bolts for indication of
shear offset. Replace hub and blade assembly if any d. Demagnetize yoke and clean thoroughly.
bolts show shear offset.
e. Remove masking material from bearings.
5. Inspect blade bearing races for looseness in
yoke. Replace yoke if bearings are loose. 4. Inspect flat raised portion of trunnion bearing
housing (5) that contacts thrust plug (9) for thickness.
6. Accomplish Normal Inspection, paragraph If less than 0.060 inches, replace trunnion bearing
65-79. housing (5) and notify product support.
65-80. REPAIR - TAIL ROTOR HUB.

65-79. Normal Inspection - Tail Rotor Hub.
1. Polish out acceptable mechanical and
1. Inspect bearing (6, figure 65-71) and race (8) for corrosion damage as follows:
condition. (Refer to BHT-ALL-SPM manual.)
a. Repair tail rotor trunnion housing to limits
2. Perform a magnetic particle inspection of shown on figure 65-72.
trunnion as follows:
b. Repair tail rotor trunnion to limits shown on
a. Using one inch diameter central conductor figure 65-73.
through splines, place conductor between contact
heads and pass 1100 amperes through conductor. c. Repairtailrotoryoketolimitsshownonfigure
Inspect under black light for indications. 65-74.
Rev. 2 65-123
BHT-205A1-CR&O-1
THIS DAMAGE
LIMIT APPLICABLE
TO BOTH OUTSIDE
AND INSIDE DIAMETERS.
BOTH ENDS
TRUNNION HOUSING
212-011-709
CRACKS ALLOWED None None None
0.002 in. 0.005 in. 0.010 in.

MECHANICAL DAMAGE
CORROSIONDAMAGE 0.002 in. 0.005 in. 0.010 in
0.10 sq. in. 0.10 sq. in. 0.10 sq. in.

MAXIMUM AREA PER
NONOVERLAPPING FULL
DEPTH REPAIR:
One per segment One per segment One per segment

NUMBER OF
NONOVERLAPPING
REPAIR AREAS
BORE DAMAGE 0.002 in. for one-fourth

circumference
°
EDGECHAMFER 0.030 in. by 45
NO DAMAGE TO LUBRICATION FITTING

IS ACCEPTABLE
NOTE:
Repairs in this area must be made uniformly around the bolt hole (not to exceed limits) so that bolt
head has a flat and square bearing surface.
Figure 65-72. Tail rotor trunnion housing damage limits
65-124
BHT-205A 1-CR&O-1
TRUNNION ASSEMBLY
212-011-704
CRACKS ALLOWED None None
CORROSION DAMAGE 0.002 in. 0.010 in.

NONOVERLAPPING FULL
DEPTH REPAIR:
NUMBER OF One per segment One per segment

NONOVERLAPPING
REPAIR AREAS
SPLINE DAMAGE
Depth one-third of spline
Length one-half of spline
Number Three splines
Figure 65-73. Tail rotor trunnion damage limits
65-125
BHT-205A 1-CR&O- 1
YOKE ASSEMBLY
212-0011-702
CORROSIONDAMAGE 0.002 in. 0.005 in.

NONOVERLAPPING FULL
DEPTH REPAIR:
NUMBER OF One per segment

NONOVERLAPPING
REPAIR AREAS
° °
BOREDAMAGE 0.002 in. for one-fourth

circumference
THREAD DAMAGE
Depth one-third of thread
Length 0.25 in.
Number One per segment
NOTE:
Maximum acceptable axial play in blade retention bearings is 0.015 inch. Bearing looseness in yoke is not
acceptable.
Figure 65-74. Tail rotor yoke damage limits
65-126
BHT-205A 1-CR&O- 1
2. Inspect retention bearings (13, figure 65-71) in NOTE: Stake blade retention bearings using a
yoke for play. Replace bearings if axial play of T101577-11 housing and T10115-13 backstop.
bearings exceed 0.01 5 inch.
(1) Assemble staking tool as shown on figure
3. Replace bearings (13)as follows: 65-75 to stake blade retention bearings. Lubricate
staking tool rollers and install tool in a hand feed,
stand type drill press. Set drill press at 250 to 350
NOTE: All four bearings must be same part number, rpm maximum.
intermixing is not authorized.
(2) Place backstop on drill press (flat side up)
a. Support yoke on a suitable surface having (refertodetailA,figure65-76andpositionbearingon
clearance for bearing and press out bearing. Clean backstop. Feedspindle of staking tool into bearing to
primer using MEK (C-309) from yoke bores and ensure alignment of tool rollers with bearing groove.
inspect bores for scoring. Clean up to a maximum
depth of 0.002 inch and not exceeding one-fourth (3) Start drill press and apply steady hand
total circumference. pressure for a minimum of 10 seconds to allow tool to
roll outer lip of bearing over yoke chamfer.
b. Apply primer (C-201 or C-204) to mating
surfaces of bearing and yoke and insert new bearing (4) Reposition anvil with flanged side up and
in yoke. Clean excess primer and avoid primer roll stake opposite side of bearing.
contaminating bearing.
(5) After staking, gap between staked lip and
c. Roll stake bearing as follows: yoke chamfer shall not exceed 0.008 inch. (Refer to
detail B, figure 65-76.)
CAUTION: THE FIRST STAKING OPERATION
SHALL BE PERFORMEDWITH PRECONED SIDE OF (6) Rotate bearing and check for smooth
YOKE UP AND FLANGED SIDE OF THE STAKING operation. Check that outer lip of bearing (two sides)
BACKSTOP DOWN. is rolled smoothly onto yoke chamfer and inner lip and
ball were not scored by staking tool.
Figure 65-75. Tool for staking tail rotor blade retention bearings
65-127
BHT-205A 1-CR&O-1
STAKING TOOL
(ARBOR, HOUSING
AND ROLLERS)
FIRST OPERATION
PRECONEUP
HUB
STAKINGTOOL
(BACKSTOP)
FIRST OPERATION
FLANGED SIDE OF BACKSTOP
DOWN (TYPICAL)
DETAIL A
TOOL APPLICATION
GAP BETWEEN YOKE

YOKE AND STAKED LIP NOT
CHAMFER STAKED LIP TO EXCEED 0.005 IN.
1-0.154
0.149
DETAIL B TYPICALFOURLOCATIONS
STAKING REQUIREMENTS THIS SIDE OF YOKE
Figure 65-76. Tail rotor yoke blade bearing replacement
65-128
BHT-205A1-CR&O-1
(7) Check bearing for proper location by b. Place work aid on bench with pins (2) facing
measuring between flat surfaces of bearing inner race up. Remove insert (3).
in adjacent flat surface of yoke. Bearings shall be
located in yoke to dimensions shown in detail B. c. Position yoke on work aid with pins (2)
through two inboard blade retention bearings.
4. Install races (8, figure 65-71) on each end of
trunnion (11) using thermal fit method in d. Loosen eight bolts (1,figure 65-71) to allow
BHT-ALL-SPM,omit stress relief. trunnion to move. Position insert (3, figure 65-77)
through trunnion and into hole in plate (1).
65-81. PAINTING-TAIL ROTOR HUB.
1. Clean hub with aliphatic naphtha (C-305). Do e. Tighten eight bolts (figure 65-71) to snug
not allow naphtha to contaminate bearings. position but do not torque at this time.
2. Mask off bearings. f. Measure gap between housing (5) and yoke
(12) with feeler gage and record the dimension.
3. Apply a mist coat of primer (C-204).
g. Remove bolts (1), washers (2), housing (5),
4. Paint with lacquer (C-203). thrust plug (9), and shim (10). Measure and record
shim thickness. Peel laminations from shim (10) to
5. Remove masking tape. reduce thickness by 0.000 to 0.002 inch less then
gap dimension recorded in step f. This will provide a
65-82. REASSEMBLY - TAIL ROTOR HUB. pinch fit on trunnion when installed.
1. Prior to assembly, wash bearings (6, figure h. Position shim (10), prepared in preceeding
65-76) with solvent (C-304) and air dry. Hand pack
bearings with grease (C-001). step, same thrust plug (9), and same housing (5) on
same side of yoke with lubrication fitting (4)
2. Install new seal (7) and new bearings (6), with positioned as illustrated. Install washers (2) and bolts
(1). Torque bolts 30 to 40 inch-pounds.
stamped end of bearing visible in each housing (5).
i. Prepare shim (10) for opposite end of
3. Ensure that races (8) are securely installed on
trunnion (11). trunnion (11) and install in same manner outlined in
steps f. through h.
4. Position housing (5) on yoke (12). Position
housing and lubrication fitting (4) as illustrated.
Install bolts (1) and washers (2). Tighten bolts (1) to
remove all gap in joint between housing and yoke. k. Remove hub from work aid.
k. Remove hub from work aid.
5. Position new shim (10) and thrust plug (9) on
Position
thrustnew
plug
5.
shim
(9)
(10)on
and NOTE: Bracket (3) will be installed at tail rotor
one end of trunnion (11). Position trunnion (11) in installation.
yoke (12). installation.
6. Install new shim (10), thrust plugs (9) and 8. Lubricate hub two places at fittings (4) with
housing (5) on opposite end of trunnion (11). Install
grease (C-001). Clean excess grease from hub.
bolts (1) and washers (2). Tighten bolts (1) to snug 65-83. PITCH HORN (212-010-716 AND
position.
212-011-708).
7. Center trunnion using work aid.
Two different type pitch horns are used in the tail rotor
a. If not previously accomplished, fabricate assembly. The 212-010-716 pitch horn is used with
work aid as shown on figure 65-77. the 212-010-701 tail rotor hub. The 212-011-708
65-129
BHT-205A1-CR&O-1
12.00 INCH
6.00 INCH
5.5020 INCH
11.0040 INCH
1. PLATE 3/4 x 4.5 x 12 INCH

4130 STEEL
2. PIN, STEEL ROD

0.4985 TO 0.4990
INCH DIAMETER
4130 STEEL
3. INSERT, STEEL ROD
1.2180 TO 1.2185 INCH
DIAMETER, 4130 STEEL
Figure 65-77. Tail rotor trunnion centering tool
65-130
BHT-205A1-CR&O-1
pitch horn is used with the 212-011-701 tail rotor hub. 4. Replace fixed bushing in pitch horn as follows:
Both pitch horns are covered in the following
paragraphs. Where inspection or repair procedures a. Press bushing from pitch horn.
differ they are explained in the text and illustrations.
b. Inspect bushing bore in pitch horn for damage.
65-84. INSPECTION - PITCH HORN. If damage exceeds 0.002 inch for one-fourth of
circumference replace pitch horn.
NOTE: Refer to BHT-ALL-SPM for approved
fluorescent penetrant material. c. Coat replacement bushing with primer (C-
201). Press bushing into pitch horn while primer is still
1. Inspect pitch horn for cracks using fluorescent wet.
penetrant method. Replace if cracked.
d. Ream bushing 0.3120 to 0.3125 inch.
2. Inspect pitch horn threads for corrosion or
damage. Replace if threads are damaged or corroded.
e. Pitch horn 212-010-716; machine face of
3. Inspect pitch horn, 212-010-716 as follows: bushing to obtain dimensions shown in View A, figure
65-80.
a. Inspect for damage or corrosion as shown on
figure 65-78. Replace if limits are exceeded. f. Pitch horn 212-011-708; machine face of
bushing to obtain dimensions shown in View B, figure
b. Inspect hole for floating bushing for corrosion 65-80.
and wear. Replace pitch horn if corroded or if inside
diameter of hole exceeds 0.5005 inch. 65-86. CROSSHEAD ASSEMBLY.
c. Inspect fixed bushing for looseness and wear. 65-86A.INSPECTION - CROSSHEAD ASSEMBLY.
Replace pitch horn if bushing is loose. Replace
bushing if inside diameter exceeds 0.313 inch. 1. Inspect crosshead assembly for mechanical
and corrosion damage (figure 65-81).
4. Inspect pitch horn, 212-011-708 as follows:
2. Inspect crosshead assembly for cracks using
a. Inspect for damage or corrosion as shown on magnetic particle inspection method (BHT-ALL-SPM).
figure 65-79. Replace if limits are exceeded.
65-87. REPAIR - CROSSHEAD ASSEMBLY.
b. Inspect hole for floating bushing for corrosion
and wear. Replace pitch horn if corroded or if inside 1. Repair crosshead assembly components in
diameter of hole exceeds 0.438 inch. accordance with figure 65-81.
c. Inspect fixed bushing for looseness and wear. 2. Remove all mechanical and corrosion damage
Replace pitch horn if bushing is loose. Replace that is within limits with sandpaper (C-423) to obtain a
bushing if inside diameter exceeds 0.313 inch. smooth scratch-free surface.
65-85. REPAIR - PITCH HORN.
3. Apply two coats of primer (C-204) to repaired
1. Polish out allowable mechanical damage or area.
corrosion using fine to medium grades of abrasive
cloth (C-406). Remove corrosion damage twice the 4. Replace any components that cracked.
depth of pit. Polish out mechanical damage deep
enough to remove traces of damage. Do not exceed 5. Replace any components that exceeds
limits of figures 65-78 and 65-79. mechanical or corrosion damage limits.
2. Apply chemical film treatment to repaired 6. Replace pitch link bearing if radial play
areas. Refer to BHT-ALL-SPM. exceeds 0.007 inch or if axial play of bearing exceeds
0.015 inch. (Refer to BHT-ALL-SPM.)
3. Refinish repaired areas with one coat of
primer (C-204) and one coat of light gray acrylic 7. Replace counterweight link if axial or radial
lacquer. play of bearing exceeds 0.020 inch.
15 JAN 2004 Rev. 3 65-131

BHT-205A1-CR&O-1
212-010-716
PITCH HORN

MECHANICAL
(Before and
after repair) 0.010 In. 0.020 In.
CORROSION
(Before Repair) 0.005 In. 0.010 In.
(After repair) 0.010 In. 0.020 In.
MAXIMUM AREA PER
NONOVERLAPPING
FULL DEPTH REPAIR 0.050 sq. In. 0.100 sq. In.
NUMBER OF
NONOVERLAPPING
REPAIR AREAS One One per surface
BUSHING BORE
DAMAGE
NOTES:
Maximum acceptable dimension for hole for sliding bushing Is 0.5005 Inch.
Maximum acceptable dimension for sliding bushing outside diameter Is 0.4995
Inch.
Inspect fixed bushing for secure Installation. A loose bushing Is not
acceptable.
Inspect threaded Insert for secure Installation and damage.
Any defect Is unacceptable.
Blade attachment holes damage not to exceed 0.002 inch for 1/4 circumference,
one place per hole. Size not to exceed 0.253 Inch excluding
1/4 circumference repair.
Barrel nut hole damage not to exceed 0.002 inch for 1/4 circumference,
one place. Size not to exceed 0.599 Inch excluding 1/4 circumference
repair.
205A1CRO 65000_00780 001
Figure 65-78. Tail rotor blade pitch horn damage limits (212-010-716)
65-132 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
PITCH HORN
212-011-708

MECHANICAL DAMAGE 0.010 in. 0.020 In.
CORROSION DAMAGE
(Before repair) 0.005 In. 0.010 In.
(After repair) 0.010 in. 0.020 In.
MAXIMUM AREA PER

NONOVERLAPPING
FULL DEPTH REPAIR 0.050 sq. In. 0.10 sq. In.
NUMBER OF
NONOVERLAPPING
REPAIRS One One per surface
BUSHING BORE DAMAGE 0.002 Inch for 1/4 circumference
BUSHING WEAR:
NOTES:
Maximum acceptable dimension for hole for sliding bushing Is 0.4380 Inch.
Minimum acceptable dimension for sliding bushing outside diameter is
0.4369 Inch.
Inspect fixed bushing for secure Installation. A loose bushing Is

not acceptable.
Inspect threaded Insert for secure Installation and damage. Any defect
is unacceptable.
Blade attachment holes damage not to exceed 0.002 inch for 1/4
circumference, one place per hole. Size not to exceed 0.253 Inch excluding
Barrel nut hole damage not to exceed 0.599 Inch excluding

205A1CRO_65000_00790_001
Figure 65-79. Tail rotor blade pitch horn damage limits (212-011-708)
15 JAN 2004 Rev. 3 65-133

BHT-205A1-CR&O-1
--- -- 0.645 - 0.647 IN.
-- - 0.750 IN.
212-010-716 PITCH HORN

VIEW
A
a. Check for bond separation anywhere on the

blade. If there is any, replace the blade.
65-89. INSPECTION - TAIL ROTOR BLADE.
b. If any movement of root end weights has
NOTE: If records and/or physical appearance of the occurred, replace the blade.
tail rotor blade indicate that the tail rotor blade has
been subjected to an accident or incident outside the c. If one blade has been damaged badly enough
realm of normal usage, perform Conditional that metal has been torn or any bond lines have been
Inspection, paragraph 65-90, as applicable. If separated, both blades must be replaced.
assembly does not require Conditional Inspection,
accomplish Normal Inspection, paragraph 65-91. d. If one blade has been damaged slightly by
denting, it should be scrapped, rather than returned to
an authorized overhaul facility. The other blade may be
65-90. Conditional Inspection - Tail Rotor Blade.
continued in service after inspection and after any
necessary repair by an authorized overhaul facility.
1. Major overspeed inspection.
3. Accomplish Normal Inspection, paragraph 65-
a. Check for bond separation anywhere on the 91.
blade. If any separations exist, replace the blade.
65-91. Normal Inspection - Tail Rotor Blade.
b. If any movement of the tip or root end balance
weights has occurred, replace the blade. 1. Check for looseness of blade bolt bushing.
Any looseness of blade bolt bushing is cause for blade
replacement. Check blade bushing ID. If ID exceeds
c. Check the retention bushings for evidence of 0.5005 inch, bushing shall be replaced by an
looseness. If any bushing is loose, replace the blade. authorized blade overhaul facility.
d. If a blade passes the above inspection 2. Inspect buffer pads around blade bolt holes for
requirements and no other discrepancies exist, then wear, tears, or debonding.
the blade is serviceable.
3. Refer to BHT-205A1-MM-1 manual for
2. Sudden stoppage or hard landing inspection. additional inspection requirements.
65-134 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
COUNTERWEIGHT LINK
PITCH LINK
COUNTERWEIGHT SUPPORT
BELLCRANK
CROSSHEAD
TYPICAL
MECHANICAL
(Before and
after repair) 0.005 In. 0.010 In. 0.002 In.
CORROSION
(Before and
after repair) 0.005 In. 0.010 In. 0.002 In.
MAXIMUM AREA PER
NONOVERLAPPING FULL
DEPTH REPAIR 0.05 Sq. In. 0.10 Sq. In. 0.05 Sq. In.
NUMBER OF
NONOVERLAPPING
REPAIRS One per lug One One per segment
° °
EDGE CHAMFER 0.010 In. by 45 0.020 In. by 45
BORE DAMAGE 0.002 for 1/4 circumference
THREAD: SPLINE:
Depth: One-third of thread Depth: One-third of spline
Length: One-quarter inch Length: One-third of spline
Number: One per segment Number: Two
CRACKS None
PITCH LINK
BEARING PLAY
Axial: 0.015 In.
Radial: 0.007 In. 205A1-R-65-81
Figure 65-81. Crosshead components damage and repair limits
Rev. 2 65-135
BHT-205A1-CR&O-1
Figure 65-82. Deleted
65-92. REPAIR - TAIL ROTOR BLADES. direction only with 400 grit abrasive cloth or paper (C-
423) to achieve a surface finish of 32 RMS or better.
MATERIALS REQUIRED
b. Wipe area around hole with a clean cloth
Refer to BHT-ALL-SPM for specifications and source. dampened with MEK (C-309), then wipe dry with clean
cloth.
NUMBER NOMENCLATURE
c. Install new buffer pad centered around hole,
C-339 Alcohol one pad at each hole. Bond buffer pads to blade using
adhesive (C-317). Apply 5 to 10 PSI pressure to buffer
C-363 Adhesive pads.
C-423 Abrasive Cloth or Paper
d. Cure under pressure at 75°F (24°C) for 24
1. Repair rotor blade minor damage. Refer to

hours or one hour at 180°F (82°C). I
BHT-205A1-MM for procedure. 65-93. TAIL ROTOR BLADE BUTT SEALING.
2. Blades with one or more holes in the skin, or MATERIALS REQUIRED

that otherwise do not meet the inspection limits
described in BHT-205A1-MM, may be sent to an Refer to BHT-ALL-SPM for specifications and source.
authorized blade repair facility for evaluation of
possible repair. NUMBER NOMENCLATURE
C-309 Methyl-Ethyl-Ketone
3. Replace buffer pads around blade bolt holes (MEK)
as follows:
C-313 Adhesive
a. Remove damaged or worn buffer pad with a
putty knife or similar instrument. Do not gouge blade. 1. Inspect all butt area bond lines placing
Sand off adhesive to bare metal in a spanwise emphasis on those areas illustrated in figure 65-83.
65-136 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
CAUTION: DO NOT ALLOW ANY MEK TO ENTER 2. Thoroughly wipe surface to be repainted with
BLADE. DO NOT SATURATE THE BOND LINES solvent (C-386). Allow solvent to wet area for a few I
WITH MEK. MEK WILL SOFTEN ADHESIVE. minutes, then wipe dry with clean cheesecloth.
2. If cracks are suspected, remove paint in
3. Thoroughly sand area to be painted with 400
suspected areas using a clean cloth dampened with
MEK (C-309). grit or finer abrasive cloth or paper (C-423) until a
uniform matte finish is obtained.
I
3. Dry exposed sections of the butt block with a
clean cloth. 4. Wash sanded surface using nylon web I
abrasive pads (C-407) and cleaning compound (C-
4. Apply a thin film of adhesive (C-313) to 318) to obtain a water break-free surface. Rinse with
bondlines depicted on figure 65-83, view C-C, Areas A
water. Repeat steps 2. through 4. as required to obtain
and B. a water break-free surface.
5. Apply a small bead of adhesive (C-313) to
inner channel bondlines. NOTE: From completion of this step through final
paint, surface of blades that are to be painted shall not
6. Swab inside diameter of leading edge drain be handled with bare hands.
hole with a thin film of adhesive (C-313) to ensure
adequate sealing exists. 5. If bare metal is exposed, prepare area to be
NOTE: Cure time for adhesive (C-313) at 70°F (21°C) painted by applying a brush or spray coating of cleaner
to 90 F (32°C) is 24 hours. The cure may be (C-344). Allow cleaner to remain in contact with metal
accelerated by applying heat at 145°F (63°C) to 155°F surfaces for one to three minutes, then thoroughly
(68°C) for 30 minutes. rinse with water and verify a water break-free surface.
7. Refinish the reworked area of the tail rotor 6. Apply one spray coat of primer (C-204) to
blade. Refer to BHT-205A1-MM-1 manual. I
cover sanded area.
NOTE: The blades shall be balanced with the tail rotor
hub and blade assembly prior to helicopter installation. NOTE: Primer shall be overcoated between one and
eight hours. If eight hours is exceeded, repeat steps 2.
65-94. REFINISHING - TAIL ROTOR BLADES. through 6.
MATERIALS REQUIRED 7. Apply one to two light spray coats of

polyurethane coating (C-245). Allow 30 minutes to
Refer to BHT-ALL-SPM for specifications and source. eight hours air drying time between coats. If eight
NUMBER NOMENCLATURE hours is exceeded, the initial coat shall be sanded and
reprimed with urethane compatible primer prior to
C-204 Primer overcoating.
C-245 Polyurethane Coating
C-318 Cleaning Compound 8. After air drying for a minimum of six hours,
C-344 Cleaner mask areas (figure 65-84) not to be painted with
C-386 Solvent masking tape.
C-407 Abrasive Pad
C-420 Tape NOTE: If topcoat air dries for longer than eight hours
at room temperature, all topcoated surfaces to be
C-423 Abrasive Cloth or Paper striped shall be thoroughly sanded with 400 grit or finer
C-486 Cheese Cloth
I
abrasive cloth or paper (C-423) and reprimed with
urethane compatible primer (C-234) prior to striping.
Refinish tail rotor blades as follows:
9. Stripe by applying one or two light spray coats
1. Protect blade bearings and data plate with of polyurethane coating (C-245). Allow 30 minutes to
masking tape. eight hours air dry between coats.
15 JAN 2004 Rev. 3 65-137

BHT-205A 1-CR&-1
LEADING EDGE
DRAIN HOLE
BOND LINES
(TYPICAL)
APPLY
-- A
R AREA B
Figure 65-83. Tail rotor blade butt sealing
65-138
BHT-205A1 -CR&O-1
FEATHER EDGES OF PAINT

(LINES IN FEATHERED EDGES
OMIT PAINT IN THIS AREA FORMED BY LAYERS OF
TOPCOAT ARE PERMISSIBLE)
10. After air drying for a minimum of eight hours, 12. Remove masking tape from blades.
feather out paint lines on leading edge with 400 grit or
finer abrasive cloth or paper (C-423) to assure a NOTE: Only tail rotor blades with the same paint
smooth transition from metal to paint. scheme shall be utilized in the tail rotor hub and blade
assembly.
11. Stencil the following on both sides of tail rotor
blade tip using urethane coating gloss black No. 13. Static balance tail rotor hub and blade
17038. The letters shall be 0.250 inch high. Spacing assembly.
between lines shall be 0.062 inch.
DO NOT USE
FOR HANDLING
HELICOPTER
15 JAN 2004 Rev. 3 65-139/65-140

BHT-205A1-CR&O-1
POWER TRAIN
TABLE OF CONTENTS
Paragraph Page
Number Title Number
66-1 Main driveshaft .............................................................. 66-4A

66-2 Lubrication and inspection - main driveshaft (205-040-004-003, -011 and -103) ..... 66-4A
66-3 Overhaul - main driveshaft (205-040-004-003, -011 and -103) .................... 66-8B
66-11 Lubrication and inspection - main driveshaft (205-040-004-017) ................... 66-17
66-12 Overhaul - main driveshaft (205-040-004-017) .................................. 66-19
66-19 Main rotor mast .............................................................. 66-24C
66-28 Transmission ................................................................ 66-37
66-39 Transmission cases .......................................................... 66-61
66-48 Upper transmission planetary .................................................. 66-80
66-55 Lower transmission planetary .................................................. 66-85
66-62 Transmission ring gear ........................................................ 66-93
66-69 Input driven quill ............................................................. 66-96
66-76 Main input quill ............................................................... 66-105
66-89 Hydraulic pump drive quill ..................................................... 66-121
66-96 Offset accessory drive quill .................................... .............. 66-125
66-103 Accessory drive and sump ..................................................... 66-131
66-110 Transmission oil pump ........................................................ 66-137
66-116A Oil filter (internal) ............................................................ 66-138
66-116G Full flow debris monitor ....................................................... 66-138A
66-117 Accessory case input quill ..................................................... 66-138C
66-130 Tail rotor drive quill ........................................................... 66-147
66-137 Hydraulic pump and tachometer drive quill ....................................... 66-154B
66-144 Rotor brake drive quill ......................................................... 66-161
66-151 Rotor brake disc and flange assembly ......................................... 66-164D
66-156 Transmission mount friction damper ............................................ 66-166
66-160 Tail rotor driveshaft hanger .................................................... 66-167
66-170 Intermediate gearbox ......................................................... 66-177
66-191 Intermediate gearbox input quill ................................................ 66-191
66-208 Intermediate gearbox output quill ............................................... 66-213
66-225 Tail rotor gearbox ............................................................. 66-230A
66-236 Tail rotor gearbox input quill .................................................... 66-243
LIST OF TABLES
Table Page
Number Title Number
66-1 Main driveshaft (205-040-004-003, -011, and -103) damage limits .................. 66-16
66-2 Main case required dimensions ................................................ 66-70
66-3 Chip detector boss measurement and machining requirements ..................... 66-134A
Rev. 2 66-1
BHT-205A1-CR&O-1
LIST OF FIGURES
Figure Page
Number Title Number
66-1 Lubrication - main driveshaft (205-040-004-003, -011 and -103) ................... 66-6
66-2 Main driveshaft coupling wear patterns .......................................... 66-7
66-3 Main driveshaft coupling TEMP-PLATE installation ............................... 66-8
66-4 Main driveshaft (205-040-004-003, -011 and -103) ................................ 66-9
66-5 Main driveshaft wear limits (205-040-004-003, -011 and -103) ...................... 66-15
66-6 Main driveshaft painting ....................................................... 66-17
66-7 Deleted
66-8 Main driveshaft lubrication (205-040-004-017) ................................... 66-18
66-9 Deleted
66-10 Main driveshaft (205-040-004-017) ............................................. 66-20
66-11 Main driveshaft wear limits (205-040-004-017) ................................... 66-21
66-11A Main driveshaft assembly (204-040-433-101) .................................... 66-24A
66-11B Main driveshaft damage limits .................................................. 66-24B
66-12 Main driveshaft seal installation tool ............................................ 66-25
66-13 Main rotor mast .............................................................. 66-27
66-14 Mast liner bearing removal work aid ............................................ 66-30
66-15 Main rotor mast wear limits .................................................... 66-33
66-16 Liner wear limits .............................................................. 66-34
66-17 Main rotor mast damage limits ................................................. 66-36
66-18 Upper mast bearing shimming ................................................. 66-37
66-19 Mast liner and bearing installation work aid ...................................... 66-38
66-20 Transmission external components ............................................. 66-41
66-21 Transmission oil jets .......................................................... 66-43
66-22 Transmission electrical (prior to 212-040-001-133) ................................ 66-45
66-23 Transmission electrical (212-040-001-133 and subsequent) ........................ 66-46
66-24 Transmission ................................................................. 66-47
66-25 Transmission case special inspection ........................................... 66-51
66-26 Transmission internal component wear limits ..................................... 66-52
66-27 Roller bearings inspection criteria .............................................. 66-54
66-28 Sun gear wear pattern ........................................................ 66-55
66-29 Input drive quill installation work aid ............................................. 66-58
66-30 Upper planetary adapter installation ............................................ 66-59
66-31 Sealant application ........................................................... 66-60
66-32 Transmission main case ...................................................... 66-62
66-33 Transmission main support case bushing replacement ............................ 66-64
66-34 Transmission top case ........................................................ 66-65
66-35 Transmission case inspection .................................................. 66-66
66-36 Transmission case corrosion areas ............................................. 66-67
66-37 Main case center web (204-040-353) ........................................... 66-71
66-38 Transmission main support case repair limits .................................... 66-73
66-39 Lift link fitting damage limits .................................................... 66-79
66-40 Upper transmission planetary .................................................. 66-81
66-41 Upper transmission planetary wear limits ........................................ 66-83
66-42 Upper transmission planetary pinion wear pattern ................................ 66-84
66-43 Upper transmission planetary lockwiring ......................................... 66-86
66-44 Lower transmission planetary ................. ........................ 66-87
66-45 Lower transmission planetary wear limits ........................................ 66-90
66-46 Lower transmission planetary pinion wear pattern ................................ 66-91
66-47 Lower transmission planetary bearing installation ................................. 66-92
66-48 Lower transmission planetary lockwiring ......... ........................... 66-92
66-2 Rev. 2
BHT-205A1-CR&O-1
LIST OF FIGURES (CONT)

Figure Page
Number Title Number
66-49 Planetary ring gear............................................................................................................ 66-94

66-50 Main input driven quill ........................................ ............................. 66-98
66-51 Input driven quill corrosion damage areas ........................................................................ 66-98
66-52 Input driven quill wear pattern........................................................................................... 66-99
66-53 Input gear quill shaft magnetic inspection areas ............................................................... 66-100
66-54 Input driven quill wear limits ...................... ....................................... .................................
66-101
66-55 Main input driven gear quill shimming (204-040-362-103)................................................ 66-103
66-56 Main input driven quill shimming (204-040-362-103)........................................................ 66-104
66-57 Input drive quill.................................................................................................................. 66-106
66-57A C lutch assem bly................................................................................................................ 66-106C
66-58 Input drive quill wear limits ............................................... ......................... ..... .... 66-108
66-58A Main case assembly (204-040-353) input bore damage and wear limits.......................... 66-108A
66-58B Main case assembly (212-040-053) input bore damage and wear limits .......................... 66-108B
66-59 Input drive quill pinion wear pattern .................................................................................. 66-109
66-60 S eal kit .............................................................................................................................. 6 6-11 2
66-61 Input quill seal wear ring work aid................................................................................ 66-114
66-62 Input drive quill (205-040-263-101) ............................................................. ................. 66-116
66-63 Main input quill wear pattern ........................................ .............................. 66-117
66-64 Main input quill wear limits (205-040-263-101)................................................................. 66-119
66-65 Hydraulic pump drive quill.................................................................. ............................... 66-123
66-66 Hydraulic pump drive quill wear limits ......... ............................... ..............................
66-124
66-67 Offset accessory drive quill............................................................................................... 66-127
66-68 Offset accessory drive quill wear limits ........................................ ............................. 66-128
66-69 Offset accessory drive quill pinion and spur gear wear pattern ........................................ 66-129
66-70 Spur gear inspection areas ....................................................................... ......... .. 66-130
66-71 Accessory drive and sump................................................................................................ 66-132
66-72 Accessory drive and sump inspection areas....................................................... ............... 66-134
66-72A Accessory drive and sump damage limits......................................................................... 66-133
66-73 Transmission oil pump ...................................................................................................... 66-137
66-73A Oil filter assembly (internal) ........................................ ................................ 66-138A
66-73B Full flow debris monitor (internal)...................................................................................... 66-138B
66-74 Accessory case input quill (204-040-206)......................................................................... 66-139
66-75 Accessory case input quill wear limits (204-040-206)....................................................... 66-141
66-76 Accessory case input quill pinion wear pattern ................................................................. 66-142
66-77 Pinion gear work area................................................................................................... 66-142
66-78 Accessory case input quill (212-040-365) ......................................................................... 66-144
66-79 Accessory case input quill wear limits (212-040-365) ....................................................... 66-145
66-80 T ail rotor drive quill............................................................................................................ 66-148
66-81 Seal (204-040-611) installation workaid............................................................................ 66-150
66-82 Tail rotor drive quill wear limits.......................................................................................... 66-151
66-83 Tail rotor drive couplings wear patterns ...................................................................... 66-152
66-84 Tail rotor drive quill overtemperature indicator TEMP-PLATE .......................................... 66-154
66-85 Workaid for lubrication of tail rotor drive coupling ............................................................. 66-155
66-86 Hydraulic pump and tachometer drive quill ...................................................................... 66-156
66-87 Hydraulic pump and tachometer drive quill wear limits ........................... ......................... 66-158
66-88 Hydraulic pump and tachometer drive quill inspection areas ............................................ 66-159
66-89 Rotor brake drive quill (412-040-123) .................................................... ................... 66-162
66-90 Rotor brake drive quill (412-040-123) damage limits ........................................................ 66-162A
66-91 Rotor brake drive quill (412-040-123) sleeve rework limits .............................................. 66-164
15 JAN 2004 Rev. 3 66-3

BHT-205A1-CR&O-1
LIST OF FIGURES (CONT)
Figure Page
Number Title Number
66-91A Rotor brake quill (412-040-123) retainer assembly rework limits ..................................... 66-164C
66-92 Rotor brake disc and flange assembly.................................................... ......................... 66-165
66-93 Rotor brake disc inspection arbor..................................................................................... 66-167
66-94 Rotor brake drive quill support flange rework limits .......................................................... 66-168
66-95 Transmission mount friction damper assembly................................................................. 66-170
66-96 Tail rotor driveshaft hanger............................................................................................... 66-171
66-97 Tail rotor driveshaft coupling wear pattern ................................................................... 66-173
66-98 Tail rotor driveshaft wear limits ................................................................... 66-174
66-99 Overtemperature indicator TEMP-PLATE......................................................................... 66-176A
66-100 Intermediate gearbox (204-040-003) ........................................ ........................... 66-179
66-101 Intermediate gearbox (204-040-003) case inspection area .............................................. 66-180A
66-102 Intermediate gearbox (204-040-003) case repair ............................................................. 66-181
66-103 Intermediate gearbox pinion identification ................................................................... 66-182
66-104 Intermediate gearbox (212-040-003) ............................................... .. 66-186
66-105 Intermediate gearbox (212-040-003) ................................................................................ 66-187
66-106 Deleted
66-107 Intermediate gearbox (212-040-003) ................................. ........................................... 66-190
66-108 Intermediate gearbox (204-040-003) input quill ............................................................... 66-192
66-109 Gear and pinion wear patterns ........................................................................................ 66-194
66-110 Intermediate gearbox (204-040-003) input quill wear limits .............................................. 66-197
66-111 Coupling teeth wear patterns ........................................ ........................... 66-198
66-112 Roller bearing wear pattern .............................................................................................. 66-199
66-113 Intermediate gearbox (204-040-003) input and output quill processing requirements ...... 66-199
66-114 Intermediate gearbox (204-040-003) input and output quill sleeve damage limits ........... 66-200
66-115 Intermediate gearbox input and output quill overtemperature indicator TEMP-PLATE .... 66-202B
66-116 Intermediate gearbox (212-040-003) input quill ................................................................ 66-205
66-117 Intermediate gearbox (212-040-003) input quill wear limits .............................................. 66-207
66-118 Intermediate gearbox (212-040-003) input sleeve damage limits ..................................... 66-209
66-119 Intermediate gearbox (212-040-003) input quill sleeve processing requirements ............ 66-210
66-120 Intermediate gearbox (204-040-003) output quill .............................................................. 66-214
66-121 Intermediate gearbox (204-040-003) output quill wear limits ............................................ 66-217
66-122 Gear teeth patterns........................................................................................................... 66-218
66-123 Intermediate gearbox (212-040-003) output quill.............................................................. 66-223
66-124 Intermediate gearbox (212-040-003) output quill wear limits............................................ 66-225
66-125 Tail rotor gearbox.............................................................................................................. 66-231
66-126 Tail rotor gearbox wear limits............................................................................................ 66-234
66-127 Tail rotor gearbox corrosion damage limits....................................................................... 66-235
66-128 Tail rotor gearbox output shaft damage limits................................................................... 66-236
66-129 Gear and pinion wear pattern ........................................................................................... 66-237
66-130 Tail rotor gearbox input quill ........................................ ........................... 66-242
66-131 Sleeve damage limits........................................................................................................ 66-245
66-132 Tail rotor gearbox input quill wear limits............................................................................ 66-246
66-133 Coupling teeth wear patterns............................................................................................ 66-247
66-4 Rev. 3 15JAN2004

BHT-205A1-CR&O-1
66-1. MAIN DRIVESHAFT. 4. Visually inspect splines and teeth of couplings (5

and 8) for obvious damage and wear. (Refer to figure
66-2).
66-2. LUBRICATION AND INSPECTION - MAIN
DRIVESHAFT (205-040-004-003, -011, AND -103). a. Visually inspect outer coupling (5, figure 66-1)
and inner coupling (8) for chipped or cracked teeth, or
1. Remove retaining ring (1, figure 66-1) and retainer for galling caused by excessive misalignment.
(3) with packing (2), discard packing. Remove spring
(4). b. Deleted.
2. Set driveshaft upright, push outer coupling (5) c. Visually inspect driveshaft boot (6) for cracks,
down to expose inner coupling (8). tears, or wrinkles. No defects permitted.
CAUTION: DO NOT WASH ELASTOMERIC BOOT d. Inspect packing groove in retainer (3) and
OR ASSEMBLED DRIVESHAFT IN SOLVENT. surface in outer coupling (5) packing contact area for
nicks or burrs. If nicks are deep enough to permit
3. Dry coupling teeth and splines using a clean cloth. passage of lubricant, replace defective part(s).
Rev. 2 66-4A/66-4B
BHT-205A1-CR&O-1
NOTE: Overtemperature dots on overtemperature NOTE: If 205-040-176-001/-003/-005/-009 boots are

indicator TEMP-PLATES are of a white or light gray installed, two tubes of lubricant (C-015) are necessary
color and turn black when exposed to an for lubricating driveshaft couplings on 205-040-004-
overtemperature condition. Chemical contamination 003/-011 driveshaft. If 205-040-176-101 boots are
can also cause indicating dots to turn black. installed, three tubes of lubricant (C-015) are required.
NOTE: Three tubes of lubricant (C-015) are required
4A. Inspect outer coupling (5, figure 66-1)
for lubricating driveshaft couplings on 205-040-004-
overtemperature indicator TEMP-PLATES for
103 driveshaft.
evidence of overtemperature indication. If
overtemperature indication is noted, perform coupling
b. Lubricate outer coupling splines and boot as
overtemperature inspection as follows:
follows:
a. Inspect outer couplings cadmium plating for (1) Squeeze one-fourth tube of lubricant (C-
being discolored (circumferential tan or light brown 015) into boot (6) and outer coupling (5) of 205-040-
band) or blistered. If cadmium plate discoloration or 004-011 main driveshaft. Spread lubricant to coat inner
blistering is found, replace outer coupling and inner surface of boot (6).
coupling.
(2) Squeeze one-half of lubricant (C-015)
b. Inspect gear teeth of outer coupling and inner into boot (6) and outer coupling (5) of 205-040-004-
coupling for being discolored (brown or blue) in 103 main driveshaft. Handpack lubricant evenly over
normally bright contact patterns. If discoloration is coupling (8) and behind dam in boot (6).
found, replace outer coupling and inner coupling.
c. Cut a section of corrugated cardboard 8 x 16
inches and wrap around shaft (7) to hold couplings
c. Inspect outer coupling and inner coupling extended. Secure with masking tape (C-426).
under 5X to 10X magnification for teeth exhibiting
signs of metal smearing or tearing in contact patterns. d. Apply lubricant to inside couplings as follows:
If smearing or tearing is found, replace outer coupling
and inner coupling. (1) Spread remaining three-fourths tube of
lubricant (C-015) into outer coupling (5) of 205-040-
d. Inspect grease from couplings for being very 004-011 main driveshaft. Spread lubricant evenly over
viscous (thick) and having a strong pungent odor. If coupling splines.
grease is found to be viscous (thick) and having a
strong pungent odor, replace outer coupling and inner (2) Spread one tube of lubricant (C-015) into
coupling. outer coupling (5) of 205-040-004-103 main driveshaft.
Spread lubricant evenly over coupling splines.
NOTE: If TEMP-PLATES are to be replaced, replace
TEMP-PLATES after completing entire inspection e. Coat new packing (2) with lubricant and install
procedure and couplings have been determined on retainer (3).
serviceable and prior to lubricating couplings.
f. Install driveshaft spring (4) and retainer (3) in
4B. Inspect outer coupling (5, figure 66-1) outer coupling (5).
deterioration, debonding or discoloration of epoxy g. Ensure that packing (2) was not damaged
coating that prevents interpretation of indicating dots. If during installation.
deterioration, debonding, or discoloration of epoxy is
found, replace TEMP-PLATES in accordance with step h. Install and ensure retaining ring (1) is properly
8. seated in outer coupling groove.
i. Remove cardboard from shaft (7) and clean all

5. Lubricate main driveshaft couplings as traces of grease from exterior surfaces of shaft with a
follows: clean dry cloth.
a. Set driveshaft on end. Push outer coupling (5) 6. For lubrication of other end of driveshaft,
down from inner coupling (8). invert driveshaft and accomplish steps 1. through 5.
15 JAN 2004 Rev. 3 66-5

BHT-205A1-CR&O-1
I
1. Retaining ring
2. Packing
4. Spring
5. Outer coupling
6. Boot
7. Shaft
8. Inner coupling
NOTE: Location of overtemperature indicator TEMP-PLATE.
205A1-R-66-1
Figure 66-1. Lubrication - main driveshaft (205-040-004-003, -011 and -103)
66-6 Rev. 2
BHT-205A1-CR&O-l
DETAIL A
Details A end B show typical acceptance patterns of

wear on spherical teeth of male coupling. Patterns will DETAIL F
very due to differences in time in service, alignment, Conditions shown in Detail E or F are not acceptable.
end extent of operation at high power. This type of failure has only been found when an
improper lubricant had been used. These photos show
that the entire tooth surface has been spelled.
All, or at least 30 of the 60 teeth. will exhibit this failure.

Check for the proper kind of lubricant, and be sure the
proper amount of lubricant is installed.
Normally if the male coupling is as shown in Details E.

F, or G the surface of the female will be damaged and
should be scrapped.
DETAIL c
Small defects as shown in Detail C can occur in either

Detail A or B. This type of defect is not detrimental to
the coupling.
DETAIL D DETAIL G
Grooves, es shown in Detail D, of any length are Detail G shows a group of teeth from a coupling which
acceptable on not more than two consecutive teeth or was run with an improper lubricant (the type of failure
four teeth total. as shown in Details E end F).
66-7
BHT-205A1-CR&O-1
7. Touch up exposed cadmium plated surfaces of c. Perform a water break-free test on the prepared
the external coupling with brush LHE solution (C-108). bonding surface by applying distilled or demineralized
water from a suitable dispenser (squeeze bottle). Water
8. Replace overtemperature indicator must flow into a continuous film without gathering into
TEMP-PLATES as follows: distinct water droplets within 25 seconds after application
to the surface. Wipe dry with a clean cloth. Ensure
a. Remove epoxy coating and TEMP-PLATES bonding surfaces are not subsequently contaminated.
(figure 66-3) using paint remover (C-436). Repeat
process until no trace of epoxy is present. d. If the coupling bonding surface will not meet the
water break-free test requirements and ensure cleaning
CAUTION: BONDING SURFACE AND materials are not contaminated; clean coupling bonding
TEMP-PLATES MUST BE FREE OF ALL surfaces as follows:
CONTAMINATION. ANY CONTAMINATION COULD
ALLOW TEMP-PLATES TO COME OFF OR INDICATE
FALSE TEMPERATURES. NOTE: Followthe manufacturer recommendations for
proper mixtures.
b. Prepare outer coupling surface for bonding by
scrubbing surface using clean cloths wetted with a (1) Using a cleaning compound (C-318) and
cleaning solvent MEK (C-309). Remove all cloth, scrub coupling bonding surface clean. Follow
contamination and before MEK dries, wipe the surface
cleaning with a thorough water rinse.
dry with clean cloth. The cleaned surface area should be
minimum 0.50 inch larger than area of TEMP-PLATES
on outer coupling. (2) Thoroughly dry coupling surfaces.
6000-1 TEMP-PLATE(RED BORDER)

°
2 REQD 180 APART
SEEVIEW A 1.081 IN. 2 REQD 180 ° APART
SEE AVIEW REF
1 (4TH GROOVE) (LOCATED90 FROM THE 6000-2 TEMP-PLATES)
(4TH
REF GROOVE)\ LOCATE6000-1 TEMP-PLATES AND
6000-2 TEMP-PLATES
EQUALLYSPACEDWITHIN 0.25 IN.
SLIGHT TEMP-PLATE
LIFT-OFF ACCEPTABLE
VIEW A THIS AREA ONLY.
LIFTING SHOULD
NOT EXCEED 0.030 IN.
ESTIMATED
6000-2 TEMP-PLATE(YELLOW BORDER)

2 REQD 180 APART
°
(LOCATED 90 FROM THE 6000-1 TEMP-PLATES)
LOCATE6000-2 TEMP-PLATESAND
6000-1 TEMP-PLATES
EQUALLYSPACED WITHIN 0.25 IN. 205A1-R-66-3
Figure 66-3. Main driveshaft coupling TEMP-PLATE installation
66-8 Rev. 2
BHT-205A1-CR&O-1
(3) Repeat water break-free test as stated be removed and replaced). Working time forthe mixture
above. is approximately 15 minutes.
CAUTION: TO PREVENT CONTAMINATION OF i. Using a soft-bristled brush, uniformly apply

THE TEMP-PLATES ADHESIVE BACKING, ENSURE epoxy coating over TEMP-PLATES to a thickness of
THAT WORK AREA AND HANDS ARE THOROUGHLY approximately 0.002 to 0.004 inch (similar to a coat of
CLEANED BEFORE WORKING WITH TEMP-PLATES. paint). Coating should be uniform in appearance, totally
cover surface of TEMP-PLATES, and extend
DO NOT PRESS OR RUBTEMP-PLATES WITH BARE approximately 0.25 inch beyond edges of
FINGERS DURING INSTALLATION ON COUPLING. TEMP-PLATES.
THIS WILL CONTAMINATE SURFACES. APPLY
EPOXY COATING TO TEMP-PLATES IMMEDIATELY CAUTION: DO NOT EXPOSE EPOXY COATING TO
FOLLOWING INSTALLATION OF TEMP-PLATES ON OIL, GREASE, CLEANING SOLVENT OR OTHER
COUPLING. CHEMICALS DURING CURE.
e. Carefully form overtemperature indicator j Allow epoxy coating to cure at room

TEMP-PLATES to match V contour of coupling surface. temperature, approximately 60 to 100°F, for a minimum
Do not crease TEMP-PLATES sharply. of six hours prior to operating helicopter. For best
results, allow epoxy to cure overnight prior to operating
NOTE: Working one TEMP-PLATE at a time, repeat helicopter or exposing to oil or grease.
steps f and g until all TEMP-PLATES are installed on
coupling. NOTE: An alternate source of heat can be used if the
temperature does not exceed 180°F.
f. Remove protective backing from TEMP-PLATE
and carefully position onto surface prepared in step b.
k. After one hour epoxy curing time at room
g. Using clean cloth or cotton swab, work temperature, the epoxy coating total curing time can be
TEMP-PLATE into contour of coupling. A thoroughly accelerated by placing the coupling in a temperature
cleaned firm rubber (edge of a block type eraser) controlledovenforonetotwohoursat a temperatureof
workaid may be utilized to work TEMP-PLATE into full 150 to 180°F.
contact with coupling surface. Ensure the TEMP-PLATE
is in full contact with coupling surface. Do not press or NOTE: Some lifting at extreme ends of
rub TEMP-PLATE with bare fingers. TEMP-PLATES installed on grooved couplings is
acceptable. Refer to figure 66-3, view A for acceptable
NOTE: UseofanyepoxyadhesiveotherthanDevcon lifting limits. Lifting is permitted only as shown and
2-Ton (C-298) is not authorized. should not exceed 0.030 inch estimated.
h. Prepare Devcon2-Ton epoxy adhesive (C-298) l. Following the cure, TEMP-PLATES should
as follows: conform to the contour of the coupling and be free of
lifted edges except as in note above. Indicating dots on
(1) Pour equal amounts of epoxy Part A and TEMP-PLATES must remain original white or light gray
Part B into a solvent proof container. with not full or partial black discoloration.
(2) Vigorously mix Part A and Part B with a m. Perform an adhesion test on each
brush such as an artist brush. TEMP-PLATE installation. Press a one inch wide strip of
high adhesion tape onto TEMP-PLATE and epoxy
(3) A few drops of thinner, such as MEK overcoat. Tape should extend beyond edge of epoxy
(C-309), may be added to epoxy during mixing overcoat. Grasp one end of tape at approximately 90
operation to reduce viscosity to a level that permits degrees from the surface and remove tape in one abrupt
uniform brush application of epoxy mixture. Do not thin motion. Lifting or peeling of epoxy coating or
this mixture such that it runs when applied to a vertical TEMP-PLATE is not acceptable. If lifting or peeling is
surface. The final viscosity of epoxy should be similarto detected, remove and replace TEMP-PLATE by
heavy bodied paint. Too thin a mixture may seep into repeating procedure.
overtemperature TEMP-PLATE and cause indicator
dots to turn black (in which event, TEMP-PLATE must n. Repeat procedure for opposite coupling.
Rev. 2 66-8A
BHT-205A1-CR&O-1
66-3. OVERHAUL - MAIN DRIVESHAFT 4. Remove centering spring (detail C).

(205-040-004-003, -011 and -103).
5. Remove grease from coupling with a stiff bristle
TOOLS REQUIRED brush. Remove locking spring (9), detail D. Break torque
on splined nut (10) with T101306 splined wrench, detail
T101306 Splined Wrench F. Do not remove nut.
T101420 Holding Fixture
6. Remove clamp set to free driveshaft from
T101420 holding fixture. Reinstall grease retainer
NOTE: Refer to paragraph 66-12 for overhaul of removed in step 3 without retaining ring. Invert main
205-040-004-017 main driveshaft. driveshaft and reinstall in T101420 holding fixture.
Repeat steps 2. through 5. to break torque of nut on
opposite end of driveshaft.
66-4. DISASSEMBLY - MAIN DRIVESHAFT.
7. Remove driveshaft from holding fixture and
NOTE: If main driveshaft is being disassemblied for complete disassembly as follows:
replacement of part(s) instead of overhaul, disassemble
only to extent necessary to replace part(s). a. Remove grease retainer (7). Remove both
splined nuts (10). Remove both spring retainers (11).
1. Clean exterior surface of main driveshaft. Use a (Refer to details G and H).
clean cloth dampened with solvent (C-304).
b. Remove inner and outer couplings from shaft.
2. Install T101420 holding fixture in a vise and Carefully separate couplings. (Refer to detail J).
position main driveshaft on the holding fixture (detail E,
figure 66-4). Secure driveshaft to holding fixture with NOTE: Only separate boot from outer coupling if
coupling clamp set (4). replacement is required.
3. Remove retaining ring (5) from upper end of c. Remove bolts (16) to separate driveshaft boot
driveshaft (detail A). Remove grease retainer (7) by (15) and packing (14) from outer coupling (13).
pressing down on outer (spherical) coupling (13) with
fingersundercouplingandthumbsonretainer(detailB). d. Disassemble other end of driveshaft by
Do not push outer coupling off inner coupling. repeating steps a. through c.
66-8B Rev. 2
BHT-205A1-CR&O-1
3. Nut 13. Outer (Spherical) Coupling
8. Driveshaft Spring 18. Adapter Retaining Bolt
10. Splined Nut 20. Engine Driveshaft Adapter
Figure 66-4. Main driveshaft (205-040-004-003, -011 and -103) (Sheet 1 of 4)
Rev. 2 66-9
BHT-205A1-CR60-1
Figure 66-4. Main driveshaft
Rev. 2
BHT-205Al-CR&O-1
-
Figure 66-4. Main drIveshaft (205-040-004-003; -011 and -103) (Sheet 3 of 4)
Rev. 2
BHT-205A1-CR&O-1
,
Figure 66-4. Main driveshaft (201-040 -003,-011
(Sheet
and-103)
4 of 4)
66-12 Rev. 2
BHT-205A1-CR&O-1
66-5. CLEANING - MAIN DRIVESHAFT. 1. Inspect outer coupling (5, figure 66-1)
overtemperature indicator TEMP-PLATES for evidence
1. Clean driveshaft parts, except boots, with solvent of overtemperature indication. If overtemperature
(C-304). indication is noted, perform coupling overtemperature
inspection as follows:
2. Dry parts with filtered compressed air.
a. Inspect outer coupling cadmium plating for
being discolored (circumferential tan or light brown
3. Cleandriveshaft boots (15,figure66-4)with clean
band) or blistered. If cadmium plate discoloration or
dry cloth. blistering is found, replace outer coupling and inner
coupling.
66-6. INSPECTION - MAIN DRIVESHAFT.
b. Inspect gear teeth of outer coupling and inner
NOTE: If records or physical appearance of main coupling for being discolored (brown or blue) in normally
driveshaft indicate that assembly has been subjected to bright contact patterns. If discoloration is found, replace
an accident or incident outside the realm of normal outer coupling and inner coupling.
usage, perform Conditional Inspection, paragraph 66-7.
c. Inspect outer couplingand inner coupling under
If it does not require conditional inspection, proceed with
to 10X magnification for teeth exhibiting signs of
5X
66-8. paragraph Normal Inspection, metal smearing or tearing in contact patterns. If
smearing or tearing is found, replace outer coupling and
66-7. CONDITIONAL INSPECTION - MAIN inner coupling.
DRIVESHAFT.
d. Inspect grease from couplings for being very
1. If records and/or physical appearance of viscous (thick) and having a strong pungent odor. If
driveshaft indicate that it has been involved in an grease is found to be viscous and having a strong
accident or incident, or has been subjected to loads pungent odor, replace outer coupling and inner coupling.
outside the realm of normal usage, accomplish the
following evaluation: NOTE: If TEMP-PLATES are to be replaced, replace
TEMP-PLATES after completing entire inspection
a. Visually inspect driveshaft assembly for procedure and couplings have been determined
external damage. serviceable and prior to lubricating couplings.
1A. Inspect outer coupling (5) overtemperature

b. Visually inspect inner coupling (12, figure 66-4) indicatorTEMP-PLATES for deterioration, debonding or
and outer coupling (13) for chipped or cracked teeth, or discoloration of epoxy coating that prevents
for galling caused by excessive misalignment. interpretation of indicating dots. If deterioration,
debonding, or discoloration of epoxy is found, replace
c. Remove couplings and mount shaft (17) on 60 TEMP-PLATES in accordance with step 8.
degree centers to check for yielding. Maximum
acceptable run-out on outer diameter of shaft is 0.005 2. Inspect inner coupling (12) and outer coupling
inch TIR. (13) for chipped, pitted, galled, or worn teeth. Use a
white card or other suitable material to reflect light,
d. If run-out of shaftexceedsacceptable limits, the detail K. If defects are found on either coupling, the
entire driveshaft assembly must be rejected. If run-out other coupling will also be damaged. Refer to figure
is within acceptable limits, accomplish Normal 66-2 for acceptable wear pattern.
Inspection, paragraph 66-8.
3. Inspect packing groove in grease retainer (7,
66-8. NORMAL INSPECTION - MAIN figure 66-4) and surface in outer coupling contacted by
DRIVESHAFT. packing, for nicks or burrs. If nicks deep enough to
permit passage of grease are found, replace defective
part.
NOTE: Overtemperature dots on overtemperature
indicator TEMP-PLATES are of a white or light gray 4. Inspect driveshaft boot (15) for cracks, tears, or
color and turn black when exposed to an wrinkles. No defects permitted.
overtemperature condition. Chemical contamination
can also cause indicating dots to turn black. 5. Visually inspect threaded parts for damage.
Rev. 2 66-13
BHT-205A1-CR&O-1
6. Inspect the following parts by magnetic 10. Inspect the diameter of driveshaft for
particle method. Index numbers are keyed to figure corrosion pitting. (Refer to table 66-1.) Shaft found
66-4. (Refer to BHT-ALL-SPMmanual). with corrosion pitting beyond the specified limits may
be returned to Bell Helicopter Textron for repair.
INDEX NO. NOMENCLATURE
66-9. REPAIR- MAIN DRIVESHAFT.
4 Coupling
Coupling Clamp
Clamp Set
Set 1. Polish out acceptable defects on driveshaft. Do
10 Splined Nut
12 Inner not exceed main driveshaft damage limits given in
13 Inner Coupling table 66-1. Touch up repaired areas with LHE solution
17 OuterCoupling (C-108). (Refer to BHT-ALL-SPM for prescribed
18 Adapter Retaining Bolt cadmium plating method.)
20 Engine Driveshaft Adapter NOTE: Minimum radius used in polishing shall be
0.5 inch. Surface finish in reworked areas must be 32
7. Inspect parts dimensionally and replace parts RHR (Roughness Height Rating) or better. Maximum
that do not fall within inspection limits. (Refer to permissible length of rework is 1.5 inches and
figure 66-5). maximum permissible total cumulative length of
rework is 4.0 inches.
NOTE: Wear limits are provided to show the required
fit between mating parts. It is not intended that all 2. Replace parts exceeding wear limits of figure
dimensions be checked as a prescribed overhaul 66-5.
procedure; however, parts that show evidence of
wear or physical damage must be checked 3. Dress small nicks or burrs on spline teeth with
dimensionally. fine india stone (C-464).
4. Replace inner coupling (12,
Replace inner coupling figure 66-1) and
8. Inspect inside of shaft (17, figure 66-4) for (12, figure 66-1) and
evidence of rust under paint, and for cracked, outer coupling (13), if evidence of overheating is
chipped, or peeling paint. found.
5. Replace driveshaft boot (15), if cracked, torn,
9. Inspect the outer surface of the main or wrinkled.
driveshaft for nicks and scratches to the following
limits: 6. Remove burrs on grease retainer (7) with
abrasive cloth (C-406) to ensure proper packing seat.
a. Nicks and scratches, running within 15
degrees of shaft axis, which are not in excess of 7. Replace packings (6 and 14).
0.005 inch in depth are permissible without polishing
out. 8. Replace retaining ring (5), driveshaft spring
(8), and locking spring (9) if damaged or deformed.
b. Nicks and scratches, running with 15
degrees of shaft axis, which are not in excess of 9. Replace all parts failing magnetic particle
0.010 inch in depth, are permissible if polished out, inspection.
provided total polished area does not exceed 20
percent of circumference of shaft any point. 1 damaged threads.
11. Install data plate as follows:
c. Nicks and scratches not running within 15
degrees of shaft axis must be polished out. A NOTE: Bond two data plates on driveshaft, 180
maximum depth of 0.005 inch may be polished out degrees apart, for balance purpose.
on 100 percent of shaft circumference. A maximum
depth of 0.010 inch may be polished out provided the a. Stamp correct information on one data plate.
total polished area does not exceed 20 percent of Data plate on opposite side to be unmarked and
shaft circumference at any point. installed face down.
66-14
BHT-205A1-CR&O-1
DETAILA
DETAIL B
MIN MAX
1 Outer Coupling - Internal Spline
2 Inner Coupling - Spherical Teeth Over Pins 5.1549 5.1841

(Use 0.1440 In. Dia. Pins) (See Detail A)
3 Inner Coupling - Internal Spline Between 2.8427 2.8464

(Use 0.1440 In. Dia. Pins) (See Detail B) Pins
4 Shaft - Spline (Use 0.1920 In. Dia. Pins) Over Pins 3.2909 3.2952
5 Adapter - Spline (Use 0.1200 In. Dia. Pins) Over Pins 1.8017 1.8088
NOTES:
Maximum allowable detph of wear 0.0055,

measure from unworn face of tooth.
Use pins with one side ground flat to

0.115 inch to provide clearance
between pins and root of spline teeth.
Figure 66-5. Main driveshaft wear limits (205-040-004-003, -011 and -103)
Rev. 2 66-15
BHT-205A1-CR&O-1
Table 66-1. Main driveshaft (205-040-004-003, -011, and -103) damage limits
DAMAGE REPAIR
Nicks and scratches Not exceeding 0.005 inch in depth are permitted without
running parallel to polishing out.
or within 15 degrees of
parallel to shaft axis. Not exceeding 0.010 inch in depth are permissible
if polished out, provided total polished area does
not exceed 20 percent of circumference at any point.
Nicks and scratches not Not exceeding 0.005 inch in depth are permissible
running with 15 on up to 100 percent of the circumference of
degrees of shaft axis shaft if polished out.
must be polished out. Not exceeding 0.010 inch in depth are permissible
provided the total polished area does not exceed
20 percent of the circumference at any point.
Corrosion pitting. Not exceeding 0.010 inch is permissible provided

it is polished out. Maximum rework at any point must not
exceed more than 20 percent of the circumference at any point.
b. Position data plate on shaft and form to have 66-6 for area to be painted (Refer to BHT-ALL-SPM
contact with shaft over its entire bonding surface. manual for application of epoxy/zinc coating.)
c. Clean the data plate and shaft in the area

where the data plate will be bonded by abrading lightly 6-10. REASSEMBLY-MAINDRIVESHAFT.
with 400 abrasive paper (C-423). Remove residue
with clean cloth moistened with aliphatic naphtha CAUTION: ENSURE THAT ALL PARTS ARE
(C-305). THOROUGHLY CLEAN AND DRY AND THAT
LUBRICANT IS NOT CONTAMINATED DURING
d. Mix adhesive (C-317) 33 parts B to 100 parts ASSEMBLY OF MAIN DRIVESHAFT.
A. Mix the two parts thoroughly. (Pot life is 30 to 50
minutes after mixing.) Apply a thin coat of adhesive to 1. Position boot (15, figure 66-4) in outer coupling
the data plate and shaft in the area where the data (13) using new packing (14). Align large holes in boot
plate will be bonded. Place a four mil thread in the with threaded holes in coupling. Install bolts (16) with
adhesive on the data plate. Two pieces of thread washers. Torque bolts 50 to 70 inch-pounds and
positioned lengthwise on the data plate serves as a secure with lockwire.
spacer, and controls bondline thickness.
NOTE: Check serial number of inner and outer

e. Position data plate on shaft. Use a fixture or coupling. Refer to serial numbers recorded during
rubber bands to maintain approximately 10psipressure disassembly. Carefully assemble correctly paired
on data plates. inner and outer couplings.
f. Cure bond at 70 to 95°F (21 to 35°C) for 24 2. Position couplings on shaft (17). Install spring
hours. Alternate curing may be accomplished by retainers (11) and install splined nuts (10), fingertight.
heating 170 to 190°F (77 to 88°C) for 60 minutes.
3. Temporarily install driveshaft spring (8) and
12. Paint inside of driveshaft (17, figure 66-4)with grease retainer (7) in one coupling. Attach this end of
one coat of epoxy/zinc coating (C-208). Refer to figure
66-16 Rev. 2
BHT-205A1-CR&O-1
NOTE:
Apply epoxy/zinc coating (C-208) to inside area of

driveshaft as indicated.
Figure 66-6. Main driveshaft painting
driveshaft to T101420 holding fixture with clamp set (4). 9. The main driveshaft shall be tagged with date of
Secure holding fixture in a vise, detail E. lubrication and an entry made in component historical
record, if driveshaft is to be returned to stock.
CAUTION: ENSURE THAT OUTER AND INNER
COUPLING TEETH ARE FULLY ENGAGED PRIORTO 10. When main driveshaft is installed on helicopter,
TORQUING SPLINED NUTS (10) TO PREVENT an entry shall be made in helicopter log and flex
DAMAGE TO DRIVESHAFT BOOTS (15). couplings lubrication log in BHT-205A1-MM-1 manual
with data of lubrication.
4. Torque splined nut (10) 100 to 200 foot-pounds.

Use T101306 splined wrench detail F. Install locking 66-11. LUBRICATION AND INSPECTION -
spring (9). Ensure that locking spring tang engages MAIN DRIVESHAFT (205-040-004-017).
mating holes in nut and shaft.
1. Remove retaining ring (1, figure 66-8) and retainer
(3) with packing (2), discard packing. Remove spring
5. Repeat steps 2. and 3. to torque opposite nut. (4)
6. Apply lubricant to inside of couplings (refer to 2. Set driveshaft upright, push outer coupling (5)
paragraph 66-2). down to expose inner coupling (7).
3. Dry coupling teeth and splines using a clean cloth.
7. Inspect coupling boots for damage that may have
occurred during assembly, Wrinkles are caused by 4. Visually inspect splines and teeth of couplings (5
misindexing of coupling teeth. Tears may be caused by and 7) for obvious damage and wear. (Refer to figure
tightening retaining nuts when inner and outer coupling 66-2).
teeth are not engaged.
a. Visually inspect outer coupling (5) and inner
coupling (7) for chipped or cracked teeth, or for galling
8. Replace overtemperature indicator caused by excessive misalignment.
TEMP-PLATES if mutilated or discolored (refer to
paragraph 66-2). b. Deleted.
Figure 66-7 deleted.
Rev. 2 66-17
BHT-205A1-CR&O-1
1. Retaining ring
2. Packing
3. Retainer
4. Spring
5. Outer coupling
6. Shaft
7. Inner coupling
NOTE: A Location of overtemperature indicator TEMP-PLATE.
205A1-R-66-8
Figure 66-8. Main driveshaft lubrication (205-040-004-017)
c. Inspect packing groove, in grease retainer (3) a. Inspect outer coupling cadmium plating for
and surface in outer coupling (5) packing contact area being discolored (circumferential tan or light brown
for nicks or burrs. If nicks are deep enough to permit band) or blistered. If cadmium plate discoloration or
passage of lubricant, replace defective part/s. blistering is found, replace outer coupling and inner
coupling.
indicator TEMP-PLATES are of a white or light gray b. Inspect gear teeth of outer coupling and inner
color and turn black when exposed to an coupling for being discolored (brown or blue) in normally
overtemperature condition. Chemical contamination bright contact patterns. If discoloration is found, replace
can also cause indicating dots to turn black. outer coupling and inner coupling.
4A. Inspect outer coupling (5, figure 66-8) c. Inspectoutercouplingandinnercouplingunder

overtemperature indicator TEMP-PLATES for evidence 5X to 10X magnification for teeth exhibiting signs of
of overtemperature indication. If overtemperature metal smearing or tearing in contact patterns. If
indication is noted, perform coupling overtemperature smearing ortearing isfound, replace outercoupling and
inspection as follows: inner coupling.
66-18 Rev. 2
BHT-205A1-CR&O-1
d. Inspect grease from couplings for being very 66-13. DISASSEMBLY- MAIN DRIVESHAFT.
viscous (thick) and having a strong pungent odor. If
grease is found to be viscous and having a strong NOTE: If main driveshaft is being disassembled for
pungent odor, replace outer coupling and inner replacement of parts instead of overhaul, disassemble
coupling. only to extent necessary to replace part(s).
NOTE: are to be replaced, replace

If TEMP-PLATES 1. Clean the exterior surface of the main driveshaft.
TEMP-PLATES after completing entire inspection Use a clean cloth dampened with solvent (C-304).
procedure and couplings have been determined 2. Install T101420 holding fixture in a vise and
serviceable and prior to lubricating couplings. position main driveshaft on the holding fixture. Secure
driveshaft to holding fixture with a coupling clamp.
4B. Inspect outer coupling (5) overtemperature
indicatorTEMP-PLATES fordeterioration, debonding or 3. Remove retaining ring (1, figure 66-10) from
discoloration of epoxy coating that prevents upper end of driveshaft. Remove grease retainer (3) by
interpretation of indicating dots. If deterioration, pressing down on outer coupling (11)with fingers under
debonding, or discoloration of epoxy is found, replace coupling and thumbs on retainer. Do not push outer
TEMP-PLATES in accordance with step 8. coupling off inner coupling.
5. Lubricate main driveshaft couplings as follows: 4. Remove centering spring.
a. Set driveshaft on end. Push outer coupling (5) 5. Remove grease from coupling with a stiff bristle
down from inner coupling (7). brush. Remove locking spring (5). Break torque on
splined nut (6) with T101306 splined wrench. Do not
NOTE: Two tubes of lubricant (C-015) are necessary remove nut.
for lubricating driveshaft couplings on 205-040-004-017 6. Remove coupling clamp to free driveshaft from
d riveshaft. T101420 holding fixture. Reinstall grease retainer (3)
removed in step 3. Do not install retaining ring (1). Invert
b. Squeeze one-fourth tube of lubricant (C-015) main driveshaft and reinstall in T101420 holding fixture.
into outer coupling (5). Repeat steps 2. through 5. to break torque of nut on
opposite end of driveshaft.
c. Cut a section of corrugated cardboard 8x16
inches and wrap around shaft (6) to hold couplings 7. Remove driveshaft from holding fixture and
extended. Secure with masking tape. completely disassemble as follows:
Remove grease retainer (3). Remove both
a.
6. Touch up exposed cadmium plated surfaces of a. greaseboth
Remove retainers
spring ( 9).
the external coupling with brush LHE solution (C-108). splined nuts (6). Remove both spring retainers (9).
Refer to BHT-ALL-SPM manual for application b. Remove inner and outer coupling (10 and 11)
procedures. from shaft. Carefully separate couplings. Record serial
numbers of mating inner and outer couplings.
7. Replace overtemperature indicator
TEMP-PLATES, if mutilated or discolored (refer to NOTE: Only separate housing (13) and ring (16) if
paragraph 66-2.) parts replacement is required.
c. Remove bolts (8) and washer (7) to separate

66-12. OVERHAUL - MAIN DRIVESHAFT housing (13) and ring (16) from outer coupling (11).
(205-040-004-017). Remove sleeve (17) from seal (15). Discard packings
(12 and 14) and discard seal (15).
TOOLS REQUIRED d. Disassemble other end of driveshaft by
repeating steps a. through c.
T101306 Splined Wrench
T101420 Holding Fixture e. Clean driveshaft parts with solvent (C-304).
Figure 66-9 deleted.
Rev. 2 66-19
BHT-205A1-CR&O-1
1. Retaining ring
2. Packing
3. Retainer
4. Spring
5. Locking spring
7. Washer
8. Bolt
9. Retainer
10. Inner coupling
11. Outer coupling
12. Packing
13. Housing
14. Packing
15. Seal
17. Sleeve
18. Shaft
NOTE: Location of overtemperature indicator TEMP-PLATE.

205A1-R-66-10
Figure 66-10. Main driveshaft (205-040-004-017)
66-14. INSPECTION - MAIN DRIVESHAFT. incident, or has been subjected to loads outside the
realm of normal usage, accomplish the following
NOTE: If records of physical appearance of main evaluation:
driveshaft indicate that assembly has been subjected to
an accident or incident outside the realm of normal 1. Visually inspect driveshaft assembly for external
usage, perform Conditional Inspection paragraph damage.
66-15. If it does not require conditional inspection,
proceed with Normal Inspection, paragraph 66-16. 2. Visually inspect inner coupling (10, figure 66-10)
and outer coupling (11) for chipped or cracked teeth, or
for galling caused by excessive misalignment.
66-15. CONDITIONAL INSPECTION - MAIN
DRIVESHAFT. 3. Remove couplings and mount shaft (18) on 60
degree centers to check for yielding. Maximum
If records and/or physical appearance of driveshaft acceptable run-out on outer diameter of shaft is 0.005
indicate that it has been involved in an accident or inch TIR.
66-20 Rev. 2
BHT-205A1-CR&O-1
4. If run-out of the shaft exceeds acceptable limits, procedure and couplings have been determined
the entire driveshaft assembly shall be rejected. If serviceable and prior to lubricating couplings.
run-out is within acceptable limits, accomplish Normal
Inspection, paragraph 66-16. 1A. Inspect outer coupling (11) overtemperature
indicatorTEMP-PLATES for deterioration, debonding or
discoloration of epoxy coating that prevents
66-16. NORMAL INSPECTION - MAIN interpretation of indicating dots. If deterioration,
DRIVESHAFT. debonding, or discoloration of epoxy is found, replace
TEMP-PLATES in accordance with step 8.
indicator TEMP-PLATES are of a white or light gray 2. Inspect inner coupling (10, figure 66-10) and outer
color and turn black when exposed to an coupling (11) for chipped, pitted, galled, or worn teeth.
overtemperature condition. Chemical contamination Use a white card or other suitable materialto reflect light.
can also cause indicating dots to turn black. If defects are found on either coupling, the other
coupling will also be damaged. (Refer to figure 66-11 for
1. Inspect outer coupling (11, figure 66-10) allowable wear limits.)
of overtemperature indication. If overtemperature 3. Inspect packing groove in grease retainer (3) and
indication is noted, perform coupling overtemperature surface in outer coupling (11)contacted by packing, for
inspection as follows: nicks or burrs. If nicks deep enough to permit passage
of grease are found, replace defective part.
being discolored (circumferential tan or light brown 4. Visually inspect threaded parts for damage.
blistering is found, replace outer coupling and inner
5. Inspect the following parts by magnetic particle
method. Index numbers are keyed to figure 66-10.
b. Inspect gear teeth of outer coupling and inner (Referto BHTALL-SPM manual)
coupling for being discolored (brown or blue) in normally
bright contact patterns. If discoloration is found, replace INDEX NO. NOMENCLATURE
outer coupling and inner coupling. 6 Nut
8 Bolt
c. Inspect outercouplingand innercoupling under Inner Coupling
5X to 10X magnification for teeth exhibiting signs of Outer Coupling
metal smearing or tearing in the contact patterns. If
smearing or tearing is found, replace outer coupling and 16
inner coupling.
d. Inspect grease from couplings for being very 6. Inspectpartsdimensionallyand replace partsthat
viscous (thick) and having a strong pungent odor. If donotfallwithininspectionlimits.(Refertofigure66-11.)
grease is found to be viscous and having a strong
pungent odor, replace outer coupling and inner NOTE: Wear limits are provided to show the required
coupling. fit between mating part. It is not intended that all
NOTE: If TEMP-PLATES are to be replaced, replace procedure; however, parts that show evidence of wear
TEMP-PLATES after completing entire inspection or physical damage must be checked dimensionally.
Rev. 2 66-20A/66-20B
BHT-205A 1-CR&O- 1
* P7
SEE DETAIL
SEE DETAIL A
SEE DETAIL B
SEE
DETAIL B
0.115 IN.
MIN. MAX.
1. Outer Coupling - Internal Spline Between Pins 4.8757 4.8852

(Use 0.1440 in. Dia. Pins) (Detail B)
2. Inner Coupling - Spherical Teeth Over Pins 5.1549 5.1841

(Use 0.1440 in. Dia. Pins) (Detail A)
3. Inner Coupling - Internal Spline Between Pins 2.8427 2.8464

(Use 0.1440 in. Dia. Pins) (Detail B)
4. Shaft - Spline (Use 0.1920 in. Dia. Pins) Over Pins 3.2909 3.2952
5. Adapter - Spline (Use 0.1200 in. Dia. Pins) Over Pins 1.8017 1.8088
6. Sleeve 2
NOTES
Use pins with one side ground flat to a 0.115 inch dimension to provide clearance between
pins and root of spline teeth.
Maximum allowable depth of wear is 0.010 inch with no sharp edges or scratches in seal
wear area. Part may be polished to clean up.
Figure 66-11. Main driveshaft wear limits (205-040-004-017) 66-21/66-22

66-21/66-22
BHT-205A 1-CR&O-1
7. Inspect the outer surface of the main 4. Replace inner coupling (10, figure 66-10) and
driveshaft for nicks and scratches to the following outer coupling (11), if evidence of overheating is
limits. found.
a. Nicks and scratches, running within 15 5. Remove burrs on grease retainer (3) with
degrees of shaft axis, which are not in excess of abrasive cloth (C-406) to ensure proper packing seat.
0.005 inch in depth are permissible without polishing
out. 6. Replace packings (2, 12, and 14).
b. Nicks and scratches, running within 15 7. Replace retaining ring (1), spring (4), and
degrees of shaft axis, which are not in excess of locking spring (5), if damaged ordeformed.
0.010 inch in depth, are permissible if polished out,
provided total polished area does not exceed 20
percent of circumference of shaft at any point. 8. Replace all parts failing magnetic particle
inspection.
c. Nicks and scratches not running within 15

degrees of shaft axis must be polished out. A
maximum depth of 0.005 inch may be polished out
on 100 percent of shaft circumference. A maximum 10. Install data plate (refer to paragraph 66-9).
depth of 0.010 inch may be polished out provided the
total polished area does not exceed 20 percent of 66-18. REASSEMBLY- MAIN DRIVESHAFT.
shaft circumference at any point.
CAUTION: ENSURE THAT ALL PARTS ARE

8. Inspect the inside diameter of driveshaft for THOROUGHLY CLEAN AND DRY AND THAT
corrosion pitting. (Refer to table 66-1.) Shaft found LUBRICANT IS NOT CONTAMINATED DURING
with corrosion pitting beyond the specified limits may ASSEMBLYOF MAIN DRIVESHAFT.
be returned to Bell Helicopter Textron for repair.
NOTE: When SKC 4703 seal is used,
66-17. REPAIR- MAIN DRIVESHAFT. 205-040-188-3 ring and 205-040-189-3 housing
must be used.
1. Polish out acceptable defects on driveshaft. Do

not exceed main driveshaft damage limits given in 1. Place outer coupling (11, figure 66-10) on
table 66-1. Touch up repaired areas with LHE solution bench with teeth side down.
(C-108). (Refer to BHT-ALL-SPMmanual.)
2. Place packing (12) in groove of housing (13).
NOTE: Position packing (14) and seal (15) in ring (16).
NOTE:radius
Minimum
used in polishing shall be Assemble housing (13) and ring (16) together with
0.5 inch. Surface finish in reworked areas must be 32 packing 14) and seal (15) between parts.
RHR (Roughness Height Rating) or better. Maximum
permissible length of rework is 1.5 inches and
maximum permissible total cumulative length of CAUTION: PACKING(14) AND PACKING (12)ARE
rework is 4.0 inches. LOOK-A-LIKE ITEMS EXCEPT PACKING (14) IS
SLIGHTLY THICKER. DO NOT REVERSE OR
SUBSTITUTE THEIR LOCATION IN THE ASSEMBLY
2. Replace parts exceeding wear limits of figure OR LOSS OF COUPLING GREASE WILL RESULT.
66-11.
3. Place assembled housing and ring on outer
3. Dress small nicks or burrs on spline teeth with coupling (11) and align bolt holes. Install bolts (8)
fine india stone (C-464). with washers (7). Torque bolts 50 to 70 inch-pounds.
66-23
BHT-205A1-CR&O-1
Ensure that seal (15) is not pinched and is free to float 66-18A. OVERHAUL - MAIN DRIVESHAFT
between housing and ring after bolts are torqued. (204-040-433-101).
Secure bolts in pairs with lockwire.
66-18B. DISASSEMBLY- MAIN DRIVESHAFT.

4. Check serial numbers of inner and outer
couplings to ensure correct couplings are being CAUTION: DO NOT ATTEMPT TO LOOSEN OR
matched. Refer to serial numbers recorded during TIGHTEN ANY HARDWARE ON DRIVESHAFT
disassembly. ASSEMBLY. ANY REASON FOR PART REMOVAL IS
CAUSE FOR SHAFT REPLACEMENT.
5. Place inner coupling (10) on bench with teeth side
down. Place sleeve (17) on top in internal coupling with
external bevel of sleeve upward. Place tool, fabricated 66-18C. CLEANING-MAIN DRIVESHAFT.
as shown on figure 66-12, in sleeve with tapered end of
1. Clean shaft assembly and attaching parts with
tool upward. solvent (C-304) or MEK (C-309).
6. Lubricate lips of seal (15, figure 66-10), outside of 2. Dry with filtered compressed air or clean cloth.
sleeve (17), and tool with grease (C-015).
66-18D. INSPECTION - MAIN DRIVESHAFT.

7. Work assembled outer coupling (11) down over
tool until seal (15 is positioned on sleeve (17). NOTE: Black residue developing around flex plates is
not a cause for rejecting the driveshaft.
8. Remove tool and inner coupling (10) from
assembled outer coupling. Check inside of assembled 1. Inspect internal fail-safe diameters for evidence of
outer coupling to ensure lips of seal (15) are positioned contact (figure 66-11A). If contact is noticed, driveshaft
correctly and not rolled under. must be replaced.
2. Visually inspect driveshaft for obvious mechanical

9. Place outer coupling on bench with seal side damage, flexplate looseness, corrosion, and/or fretting
down. Squeeze one-quarter tube grease (C-015) into at flexplate bolted joints. Refer to figure 66-11B for
coupling. Carefully assemble paired inner and outer damage limits. Repair in accordance with paragraph
couplings. 66-18E.
10. Position assembled couplings on shaft (18). 66-18E. REPAIR - MAIN DRIVESHAFT.
Install retainer (9) and install nut (6) fingertight.
1. Superficial scratches not exceeding 0.002 inch in
11. Assemble coupling on other end of shaft in depth or well-rounded dents on part edges not
accordance with steps 1. through 10. exceeding 0.005 inch in depth do not require repair.
2. Scratches in metal deeper than 0.002 inch or with

12. Temporarily install spring (4, figure 66-10) and sharp notches shall be blended into surrounding area so
grease retainer (3) in one coupling. Attach this end of sharp indentations or edges remain. Repair must be
driveshaft to T101420 holding fixture with coupling within limits specified in figure 66-11B. Accomplish
clamp set. Secure holding fixture in a vise. repair by careful hand filing or stoning, using fine emery
cloth for final polishing. Minimize removal of protective
13. Torque nut (6) 100 to 200 foot-pounds. Use coating during repair.
T101306 splined wrench. Install locking spring (5).
Ensure that locking spring tang engages mating holes 3. Damage to the protective coating (removal to
in nut and shaft. base metal) which exceeds 0.25 inch in width shall be
touched up with polyurethane topcoat (C-218) for
14. Repeat steps 12. and 13. to torque opposite nut. aluminum colored appearance and minimal protection
from corrosion. Smaller areas left bare will not corrode
due to sacrificial properties of the original protective
15. Lubricate coupling (refer to paragraph 66-11). coating.
66-24 Rev. 2
BHT-205A1-CR&O-1
TORQUE
100 TO 130
INDEX MARK
ALIGN GAP TO INDEX MARK
TORQUE 100 TO 130 IN-LBS
TORQUE360 TO 400 IN-LBS 6. Thin steel washer 12. Adapter
205A1-R-66-11A
Figure 66-11A. Main driveshaft assembly (204-040-433-101)
Rev. 2 66-24A
BHT-205A1-CR&O-1
INTERCONNECTZONE 3
(CENTERAREA)
ZONE 2
TYP ALL ADAPTER
Zone 1 Zone 2 Zone 3 Zone 4

THICK SECTION
NICKS, SCRATCHES, 0.002 In. 0.005 In. 0.010 In. 0.040 In.
CORROSION
EDGE DENTS, NICKS 0.005 In. 0.010 In. N/A 0.060 In.
MAXIMUM AREA PER 0.05 Sq. In. 0.10 Sq. In. Not critical
FULL DEPTH REPAIR (local area only)
NUMBER OF REPAIRS 2 Max per plate one per lug Not critical (not to overlap)
1-inch minimum one per plate
separation
205A1-R-66-11B
Figure 66-11B. Main driveshaft damage limits
66-24B Rev. 2
BHT-205A1-CR&O-1
66-19. MAIN ROTOR MAST. 66-21. DISASSEMBLY - MAIN ROTOR MAST.

BHT-205A1-MM-1 and retire all items scheduled for
66-20. OVERHAUL - MAIN ROTOR MAST. retirement.
If main rotor mast is being disassembled, for

TOOLS REQUIRED replacement of part/s instead of overhaul, disassemble
only to extent necessary to replace part/s.
T100965 Power Wrench
T100968 Anchor Plate 1. Support mast assembly in a suitable stand.
T101303 Socket Remove cover nut (1, figure 66-13) from mast (2), when
T101304 Adapter necessary, but keep in place whenever possible to
T101456 Wrench protect mast threads.
Rev. 2 66-24C/66-24D
BHT-205A1-CR&O-1
3.550 DIA.
32 RHR
FINISHED
SURFACE
0.20
MATERIAL- ALUMINUM OR MICA
Figure 66-12. Main driveshaft seal installation tool
66-25/66-26
BHT-205A 1-CR&O-1
1. Cover nut
2. Mast
3. Shield
4. Seal
5. Retainer plate
6. No. 8 oil jet
7. Shim
8. Upper bearing
9. Liner
10. Retaining nut
11. Lockring
12. Lower bearing inner race
13. Retaining nut
PEELSHIM FOR
0.001 TO 0.004 PINCH FIT
ON BEARING
2000 TO 2500 FT-LB

TORQUE
250 TO 300 FT-LB

TORQUE
Figure 66-13. Main rotor mast
66-27/66-28
BHT-205A1-CR&O-1
2. Remove shield (3), with two screws, from 2. Use a sharp edged plastic tool to scrape
upper bearing retainer plate (5). Remove four sealant from retainer plate (5, figure 66-13) and liner
countersunk screws to detach retainer plate (5) from (9). Do not scratch retainer plate.
upper bearing liner (9). Carefully lift plate assembly off
mast (2). Press out seal (4). Remove shims (7) and
66-23. INSPECTION - MAIN ROTOR MAST.
keep with plate. Remove No. 8 oil jet (6) with attaching
screws.
NOTE: If records and/or physical appearance of main
rotor mast indicate that assembly has been subjected
3. At lower end of mast (2), remove two cotter to an accident or incident outside realm of normal
pins and use T101456 wrench to remove bearing usage, perform Conditional Inspection, paragraph 66-
retaining nut (13). Pull or use a soft drift and carefully 24. If main rotor mast does not require conditional
tap lower bearing inner race (12) from lower end of inspection, proceed with Normal Inspection, paragraph
mast. Re-install retaining nut (13) finger tight to protect 66-25.
threads.
66-24. CONDITIONAL INSPECTION - MAIN
4. Remove lockwire and remove two screws and ROTOR MAST.
lockring (11) from bearing retaining nut (10). Position
T101304 adapter over mast drive splines, and 1. Visually inspect for damage, with particular
T101303 socket on nut. Use T100965 power wrench attention given to that area of the mast that would be
assembly with T100968 anchor plate to break nut contacted by main rotor static stops. There should be
torque. Remove tools and nut. no yielding or deformation.
5. If mast bearing removal tool is not available, 2. Mount mast on centers and inspect as follows:
fabricate one in accordance with figure 66-14, and use Refer to figure 66-15.
as follows:
a. Check for yielding. Runout at lower bearing
a. Install bearing puller plate on mast from top of journal should not exceed 0.0025. Runout at upper
mast with collar down against inner race of bearing. bearing journal should not exceed 0.006. Runout at
groove in upper set of splines (the split cone seat)
b. Position bearing holding plate from bottom of should not exceed 0.0045.
mast over bearing and races. Install bolts and nuts and
pull up snug to hold bearing together during removal. b. Check for twist. Splines (D, E, and F, figure 66-
15) on 204-011-450 mast must be in line radially with
c. Remove retaining nut (13, figure 66-13) and 1/2 degree.
place plug in lower end of mast and install puller.
3. Inspect liner (9, figure 66-13) for deformation.
d. Engage legs of puller in slots of bearing puller Surfaces B and C (figure 66-16) shall be square with
plate and tighten threaded bolt. Use wrench to turn diameter A within 0.001 inch TIR, and there should be
bolt to pull bearing. no evidence of coning.
e. Use suitable wrench to tighten bolt until upper 4. Inspect mast and bearing liner for cracks by
bearing assembly (8) is removed from seat. magnetic particle method.
I
5. Nonconformance to the requirements above is
6. Press bearing outer race from liner (9). cause for rejection of the mast assembly.
63-22. CLEANING - MAIN ROTOR MAST. 6. Replacement of the mast thrust bearing is
mandatory if component was involved in an accident
1. Clean all parts of mast assembly with solvent or incident or was subjected to loads or conditions
(C-304) and dry with filtered compressed air. outside the realm of normal operation.
15 JAN 2004 Rev. 3 66-29

BHT-205A1-CR&O-1
CL BOLT
4.75 TYP--
CLEAR WELD TO 4.733 DIA
ALLOW DETAIL 3
TO CONTACT 0.32 PULLER
DETAIL 1 FULL PLATE
0.03 X 45° MAX 5.00
BEARING
HOLDING BEARING
PLATE
PULLER
LEGS
26.625
_ 2.960 DIA
+0.000
-0.005
3.00 TYP
PLUG DIA
Note
1. Break all sharp edges. 0.24
2. Match so as to be symmetrical TYP
about center line for balanced pull.
3. Cad plate all steel details.
TY P
DRILL 5 8 DIA ALTER
THREADED BOLT-
THREADED
BOLT AS PULLER
Figure 66-14. Mast liner and bearing removal work aid (Sheet 1 of 3)
66-30
BHT-205A1-CR&O-1
PULLER
0.5625
0.28 DIA THRU

HOLE(2 PLACES)
BEARINGHOLDING
PLATE (REF)
VIEW A-A
LOOKING DOWN
66-31
BHT-205A 1-CR&O-1
VIEW C-C
LOOKING UP
DET REQ'D MATERIAL SIZE REMARKS
1 1 Al Plates 1 1/2 x 6 1/4 x 12 1/4

2 2 Weld Assy of Det's 3 & 4
3 1 C.R.S 1/2 Dia x2 1/8 Lg.
4 1 C.R.S. 1/2 Dia x 26 3/4 Lg.
5 1 H.R.S. 4 Dia x 2 5/8 Lg.
6 1 H.R.S. 2 Dia x 2 1/8 Lg.
7 1 H.R.S. 3/4 x 2 x 7 1/8
8 1 Weld Assy of Det's 6 & 7
9 2 STD 1/4 Dia x 1 1/2 Lg Hon. Dowel
10 1 STD 1/2 - 13 x 4 Lg Hex Hd Mach Bolt
11 1 A1Al 3/4 x 9x 9
12 2 STD 1/4 - 20 x 3 1/4 Hx Hd Mach Bolt
13 2 STD 1/4 - 20 Hx Hd Nut
306 -3A
204040-
Note
1. Break all sharp edges.
2. Match so as to be symmetrical
about center line for balanced pull.
3. Cad plate all steel details.
66-32
BHT-205A1-CR&O-1

INCHES
1 Liner - Thrust Bearing ID 6.6919 6.6929
2 Mast - Bearing Seat OD 4.3307 4.3315
3 Liner - Roller Bearing ID 4.9987 5.0003
4 Bearing - Roller OD 4.9984 4.9990
ID 3.4995 3.5001
5 Mast- Bearing Seat OD 3.5003 3.5012
6 Splines - Drive (Use 0.1920 Dia. Pins) Over Pins 4.2908 4.2956
7 Splines - Rotor (Use 0.1920 Dia. Pins) Over Pins 4.0906 4.0955
8 Snap Ring Groove OD 3.625 3.655
9 Wear Sleeve OD 3.575 3.605
C Cone Groove OD 3.587 3.591
NOTE
TIR run-out check not required at normal overhaul, but

Is required If crash damage, overtorque, overspeed or
hard landing Is recorded, suspected or evident.
Run-out limits using lathe, mast supported on mast

centers:
Surface = A B C
Max. TIR = 0.0025 0.006 0.0045
205A1CRO 66000 00150 001
Figure 66-15. Main rotor mast wear limits
15 JAN 2004 Rev. 3 66-33

BHT-205A 1-CR&O-1
DIAMETER "A" SURFACE "B"
SURFACE "C"
204-040-307 LINER
Figure 66-16. Liner wear limits.
7. Accomplish Normal Inspection, refer to 7. Inspect parts dimensionally and replace parts
paragraph 66-25. that do not fall within inspection limits. (Refer to
figure 66-15.)
66-25. NORMAL INSPECTION- MAIN ROTOR NOTE: Limit charts are provided to show the
MAST. required fit between mating parts. It is not intended
that all dimensions be checked as a prescribed
1. Inspect parts visually for signs of wear or overhaul procedure; however, parts that show
damage. evidence of wear or physical damage must be
checked dimensionally.
2. Inspect lower bearing inner race (12, figure
8. Inspect parts by magnetic particle (M), or
brinelling, or corrosion damage. fluorescent penetrant (F), as indicated. Index
numbers are keyed to figure 66-13. Reject any part
that reveals evidence of a crack.
CAUTION: TO PREVENT CORROSION DAMAGE NOTE: Refer to BHT-ALL-SPM manual for approved
AVOID
UNOILED
HANDLING
BEARINGS. fluorescent penetrant material. (Post Emulsified
Penetrant System.)
3. Inspect mast (2) visually for yielding or INDEX NO. NOMENCLATURE CODE
deformation, with particular attention given to the
area contacted by the main rotor static stops. 1 Cover Nut M
2 Mast M
4. Inspect mast visually for nicks, dents, 5 RetainerPlate F
scratches, or corrosion damage to the limits given in 9 Liner M
table 66-1. Particular attention shall be given to the 10 Retaining Nut M
radius and adjacent area just above the upper bearing, 13 Retaining Nut M
and to the tapered section below the upper bearing.
5. Inspect retainer plate (5, figure 66-13) for 66-26. REPAIR OR REPLACEMENT - MAIN
corrosion or pitting in area contacted by the oil seal. ROTORMAST.
Inspect for nicks, dents, or scratches. Inspect the
four drain holes (running from just above the oil seal 1. Replace all parts that do not meet inspection
seat) for clogging, requirements.
2. Dress splines with fine india stone (C-464) if
6. Inspect the No. 8 oil jet (6) for deformation or
other damage. Check that jet is clean and oil hole necessary, to blend out burrs, small nicks or
scratches.
unobstructed.
66-34
BHT-205A1-CR&O-1
3. Polish out scratches, nicks, dents, and 66-27. REASSEMBLY- MAIN ROTORMAST.
corrosion to limits shown in figure 66-11, blending
reworked areas to a finish of 32 RHR. NOTE: To avoid corrosion damage, avoid handling
unoiled bearings. Coat upper bearing (8, figure
NOTE: A roughness value of 32 RHR can be 66-13) and lower bearing inner race (12) with
attained by carefully honing with a fine india stone approved transmission oil (refer to BHT-205A1-MM-1
removing all surface imperfections other then those manual) before assembly.
left by the stone.
1. Coat inner surface of liner (9) with approved oil
4. Replace mast if depth of damage exceeds and press outer race of upper bearing (8) into liner (9).
limits shown in figure 66-17.
2. Determine thickness of shim (7) required
5. Replace retainer plate (5, figure 66-13) if between outer race and lip of retainer plate (5) to
corrodedor pitted in seal seat area. provide 0.001 to 0.004 inch pinch fit when
assembled as follows:
6. On areas above upper bearing apply spray coat
of primer (C-201 or C-204) to repaired area, followed a. With a depth gage, measure dimension from
by a thin coat of aluminum lacquer (C-215), or LHE mounting face of liner to top of bearing outer race.
solution (C-108) (Refer to BHT-ALL-SPM manual for (Refer to dimension A, figure 66-18.)
prescribed cadmium plating method.)
b. Measure dimension from mounting face of
7. Removesuperficial corrosion from lower end of retainer plate to bottom of lip which will extend into
mast using steel wool in area A, figure 66-1 7. liner when assembled. (Refer to dimension B, figure
66-18.)
8. Remove corrosion from mast in other areas by
c. Subtract dimension B from dimension A and
polishing with fine india stone (C-464) to the
add 0.001 to 0.004 inch for pinch fit. Peel shim to
dimensions shown in figure 66-17.
required thickness and keep with retainer plate for
NOTE: Honed area must have a generous radius assemby.
blending into the surrounding areas and be finished to
32 RHR 3. With
bearing mast suitably
journal supported,
and threads with coat mast
approved
CAUTION: MAST MAY BE REWORKED ONE TIME transmission oil (refer to BHT-205A1-MM-1 manual).
ONLY, IF REWORK WAS NOT LIMITED TO REMOVAL 4. If not available, fabricate bearing installation
OF SURFACE CORROSION WITH STEEL WOOL. tool in accordance with figure 66-19. Use tool to
CHECK FORWORD, "REWORKED", VIBRO-ETCHED install upper bearing (8, figure 66-13) as follows:
ON FLANGE FOR LOWER BEARING. IF MAST IS
MARKED IT IS NOT SUITABLE FOR REWORK. a. Assemble bearing and place on mast. Hold
bearing up against bearing seat on mast.
9. Identify a mast that has been reworked by
marking the word "REWORKED", on the mast flange NOTE: Keep parts of upper bearing in matched set
adjacent to the lower bearing race using a electric by serial numbers etched on outer race, on ball
pencil, unless rework was limited to removal of retainer, and on both halves on inner race. The two
surface corrosion with steel wool (C-411). inner race halves must be installed so that the
stamped 0 (or dull burr mark) on each half is aligned.
10. Replace all unserviceable parts.
b. Install threaded cap with stud over lower end
NOTE: Keep parts of upper bearing in matched set of mast. (Refer to figure 66-19.)
by serial number etched on outer race on ball retainer,
and on both halves on inner race. Lower bearings is c. Install pressing tool over mast and seat
not serialized and inner race may be interchanged on against inner race of bearing, with the three
mast without having to change the other part of the spring-loaded bolts contacting liner on bearing outer
bearing in the transmission. race.
66-35
BHT-205A1-CR&O-1
10.6 TO 10.8 IN.

(269.24 TO 274.32 mm)
5.50 TO 5.70 IN.

(139.7 TO 144.78 mm)
E
F
34.0 IN. (863.6 mm)
36.0 IN. (914.4 mm)
BHT-205A1-CR&O-1
AREA E - 0.010 in. local cleanup.
Corrosion on spline tooth surfaces is generally limited to that which

can be removed by steel wool or Scotch Brite. Localized, more severe
corrosion and mechanical damage may be removed up to 0.010 inch depth of
rework on any surface on the spline teeth provided:
1. The sum of all reworked areas on any single spline tooth surface does
not exceed 20% of the total area of that tooth surface.
2. In snap ring grooves (4) of spline (2) and adjacent 0.100 Inch on either
side (view A):
AREA A
Repair of mechanical and corrosion damage to a depth of 0.002 Inch is
permitted. Repair to a depth of 0.005 Inch Is permitted If 50X Inspection
is performed after repair to verify cleanup and check for sharp radii
and burrs.
AREA B
Repair of mechanical and corrosion damage to a depth of 0.002 Inch is
permitted if 50X Inspection is performed after repair to verify cleanup and
check for burrs. Also verify that radii are 0.020 to 0.030 inch in
repaired area.
3. No more than two adjacent teeth on splines (1) and (3) may be reworked.
4. No more than four teeth on spline (1) may be reworked per note 1.
5. All teeth on spline (2) may be reworked per note 1 and 2.
6. No more than eight teeth on spline (3) may be reworked per note 1.
7. In cone groove on spline (1), maximum total rework area Is 0.5 square
inch; any one area Is not to exceed 0.5 Inch In length X 0.4 Inch In width
X 0.005 Inch in depth.
Thread: Maximum rework area Is 0.25 Inch in length X 1 thread wide

X 0.005 Inch In depth. Maximum of three repair areas.
Wear sleeve (6): Inspect for wear sleeve to mast bonding failure.
No bonding failures are acceptable.
INSIDE DIAMETER
AREA F - See table below:
Note
Table for maximum allowable inside diameter in area F for various outer
diameters, at stations measured in inches from the top of mast.
If outer diameter measures -- 3.545 3.550 3.555
Max. I.D. Sta. 0-10 2.980 2.988 2.996
Max. I.D. Sta. 10-20 2.976 2.982 2.988
Max. I.D. Sta. 20-34 2.970 2.976 2.982
AREA G - 2.970 In. maximum I.D.

AREA H -0.005 In. - Or to a maximum I.D. of 2.980 Inches. Provided
cleanup is accomplished by honing or similar method, so that
material removal is uniform around the diameter.
Note: The mast may be reworked one time only, unless the rework involves only
surface corrosion removal. After cleanup, mark the word "REWORKED" on the
flange at J, using a vibrating stylus. (If cleanup was limited to the
removal of surface corrosion that required only steel wool for removal,
then it is not necessary to mark the mast "Reworked".)
Note: Pitting must be completely removed within allowable cleanup depth for mast
to be acceptable. Finish reworked areas to 32 RHR.
205A1CRO 66000 00170 002
Figure 66-17. Main rotor mast damage limits (Sheet 2 of 2)
15JAN 2004 Rev. 3 66-36A/66-36B

BHT-205A1 -CR&O-1
7. Place lockring (1 1) over mast drive splines and

secure to bearing retaining nut (10) with two screws
at opposite side of mast. Secure screw heads
together with lockwire (C-405). If screw holes do not
align, repeat step 6, to tighten nut as necessary
within torque limit.
8. Apply sealant (C-308) on surfaces where seal

(4) will contact retainer plate (5). Press seal, with lip
up, into plate. Clean off excess sealant, be sure four
drain holes in retainer plate above seal remain clear.
Install No. 8 oil jet (6). Secure in place with screw.
9. Place shim (7) into liner, on outer race of upper

bearing. Coat lip of seal and seal surface on mast with
approved transmission oil (refer to
BHT-205A1 -MM-1 ). Install retainer plate assembly on
mast with care to avoid damaging seal on mast
BEARING OUTER RACE splines. Secure bearing liner to plate with four
countersunk screws.
10. Install shield (3). Secure to top of retainer

plate with two screws.
11. Install cover nut (1) on mast (2) to protect

threads.
12. Coat mast bearing journal with oil (C-010)

and carefully drive lower bearing inner race (12) on
seat at lower end of mast. Coat threads with
Figure 66-18. Upper mast bearing shimming approved transmission oil (refer to BHT-205A1 -MM-1
manual) and install retaining nut (13) with T101456
d. Install washers and nut on bolt of threaded wrench. Tighten nut to a torque of 250 to 300
cap and turn nut to press bearing onto mast. Hold foot-pounds, aligning two nut slots with holes at
assembled bearing together as it is pressed on. opposite sides of mast. Insert two cotter pins, with
splits horizontal, from inside mast. Bend both ends of
e. Remove bearing installation tool. each cotter pin down and in against mast end, to lie
below or flush with outer surface of nut.
5. Install bearing retaining nut (10, figure 66-13)
hand-tight, with splined flange down and threads 13. Check upper mast bearing for freedom of
lubricated with approved transmission oil (refer to rotation.
BHT-205A 1-MM-1).
6. Position T101304, adapter over mast drive 66-28. TRANSMISSION.

splines and T101303, socket, on bearing retainer
nut. Use T100965 power wrench kit T100968 66-29. OVERHAUL
- TRANSMISSION.
anchor plate to tighten nut and push assembled
bearing to position against mast shoulder. Continue TOOLS REQUIRED
tightening nut to low side of required 2000 to 2500
foot-pounds torque, then remove tools. T100929 Jack Screw Set
T101308 Jack Screw Set
NOTE: During seating torquing procedure, rotate T101338 Jack Screw Set
bearing outer race to check for freedom of operation. T101583 Pusher Set
66-37
BHT-205A1 -CR&-1
BEARING
CHAMFER UP ON
OUTERRACE
ARROW DOWN ON
INNER RACES
WELD
24 INCHES
1. Pressing tool
2. Plate
3. Tube
4. Collar
5. Nut
6. Washer
7. Helcal spring
8. Bolt
9. Plate
10. Nut
4.13 ID 11. Washers
12. Bolt
MAST
KNURL OUTSIDE SURFACE

3.50
0. 75
PER MIL-S-7742
0.50 HOLE
Figure 66-19. Mast liner and bearing installation work aid (Sheet 1 of 2)
66-38
BHT-205A 1-CR&O-1
1 1 Welded Assembly of
Items 2, 3 and 4
2 1 Al. Plate 1/2 X 4-1/2 Dia.
3 1 Al. Tube 4-1/2 dia. X 0.237 X

19-3/4 Ig.
4 1 Al. Cube or Rod 8 X 8X4-1/8
5 3 NAS679A4 Nut
6 9 AN960-416 Washer
7 3 MS24585 Helical Spring
8 3 AN4-30 Bolt
9 1 Corrosion Resistance Steel Plate

4" X 7/8 Welded Assy of NOTES
9 and 12
Break all sharp edges.
10 1 AN315-8 Nut
Bolt threaded full length.
11 2 1/2" Washer
12 1 AN8-33A Bolt
Figure 66-19. Mast liner and bearing installation work aid (Sheet 2 of 2)
66-39
BHT-205A1-CR&O-1
66-30. DISASSEMBLY -TRANSMISSION. g. Remove P-41 plug (7) from J-41 connector.
NOTE: Transmission 212-040-001-133 and h. Remove cable clamp at bracket (8).

subsequent incorporates a fourth quill port in the main
case, two additional chip detectors (one in the top case j.Remove P-35 connector (9) from rotor
and one in the main case), new input quill, top case, and tachometer generator (10).
support case, a lift link fitting mounted on the support
case and a collector attached to the main input driven j. Remove wire from chip detector
gear quill. k. Remove wire from chip detector (13).
If transmission is being disassembled for replacement l. Remove electrical cable (14) from transmission.
of part/s instead of overhaul, disassemble only to extent m. Deleted.
necessary to replace parts.
n. Deleted.
CAUTION: BEFORE PROCEEDING WITH
DISASSEMBLY OF TRANSMISSION, CHECK
HISTORICAL RECORDS AND PHYSICAL 2A Remove electrical cable harness
APPEARANCE FOR INDICATION OF ACCIDENT OR
(212-040-001-133 and subsequent transmissions) as
INCIDENT OUTSIDE OF NORMAL USAGE. IF SUCH
EVIDENCE IS PRESENT, REFER TO PARAGRAPH
66-32. a. Disconnect electrical terminal from upper mast
chip detector (15, figure 66-23).
DO NOT USE ANY METALLIC DRIFTS FOR
DISASSEMBLY OR REASSEMBLY OF b. Remove electrical terminal and nipple from
COMPONENTS, SUCH AS BEARINGS, RACEWAYS, planetary chip detector (12).
SLEEVES, ETC.
c. Remove electrical connector from rotor
REMOVE PAINT AND SEALANT FROM JACK SCREW tachometer generator (14).
HOLES PRIOR TO USE OF JACK SCREW SETS.
d. Remove electrical terminal and connector from
1. Remove the following externally mounted parts oil thermoswitch (9).
from transmission top case: elevator linkage bracket,
external oil lines, breathe vent, oil pressure transmitter e. Remove electrical terminal and connector from
and switch, oil jets, oil temperature bulb, tachometer oil pressure swtch (3).
generator, neck and scupper assembly. (Referto figures
f. Remove electrical connector from oil pressure
66-20 and 66-21.)
transmitter (2).
2. Remove electrical cable harness (prior to g. Remove electrical connector from oil
212-040-001-133 transmission) as follows: temperature transmitter (6).
a. Disconnect connector from transmission oil h. Remove electrical terminal and nipple from
pressure transmitter (2, figure 66-22). sump chip detector (8).
b. Disconnect connector from transmission oil i. Remove four wires (16) from rotor brake, if
pressure switch (1). installed.
c. Disconnect wires from ground stud (4). j. Remove ground wires (28).
k. Remove electrical terminal and nipple from full
d. Disconnect wire thermoswitch (3). flow debris monitor (10).
e. Remove connector from transmission oil I. Remove clamps (19) from electrical cable (21).
temperature bulb (5).
m. Remove electrical cable (21) from
f. Remove cable clamp at bracket (6). transmission (1).
66-40 Rev. 2
BHT-205A1-CR&O-1
3. Remove hydraulic pump drive quill (65, figure through tapped holes to loosen and remove top case (5).
66-24), if applicable. If cover (63) is installed, remove Remove oil tube (23) and packings (22) from jet housing
nuts, washers, cover (63), and gasket (64). Remove (24).
bolts which secure hydraulic pump drive quill (65) to
case. UseT101338jackscrewsettopullquillfromcase. 6. Lift out upper planetary (10) with mast driving
Tighten jackscrews evenly. Remove packing (66). adapter (11), upper bearing (12, and liner (13), as a unit.
4. Refertoparagraph66-90foroverhaulofhydraulic 7. Refer to paragraph 66-49 for overhaul of upper

pump drive quill. planetary.
5. Remove spring bracket (1), and bolts (2) which 8. Remove retainer ring (9) and remove mast
secure top case (5) to ring gear (25). Remove three adapter, bearing and liner as a unit. Separate mast
screws (3) and washers (4). Use T100929 screw set driving adapter (11), upper bearing (12), and liner (13).
Rev. 2 66-40A/66-40B
BHT-205A 1-CR&- 1
FWD
Figure 66-20. Transmission external components (Sheet 1 of 2)
66-41
BHT-205A1-CR&O-1
1. Neck and scupper assembly 29. Nut

2. Oil filler cap 30. Retainer ring
4. Bolt 32. Deleted
5. Steel washer 33. Spring
6. Aluminum washer 34. Plate
7. Bracket 35. Gasket
8. Aluminum washer 36. Adapter
9. Steel washer 37. Tube assembly
10. Nut 38. Nuts
11. Packing 39. Washers
12. Nut 40. Clamps
13. Elbow 41. Screw
14. Clamp, screw, nut, washer 42. Hose assembly
15. Clamp 43. Input quill drain tube
16. Clamp 44. Scupper drain tube
17. Nut 45. Screw
18. Washer 46. Clamp
19. Clamp 47. Bracket
20. Bolt 48. Washer
21. Clamp 49. Nut
22. Screws 50. Elbow
23. Clamp 51. Nut
24. Hose assembly 52. Packing
25. Deleted 53. Washer
26. Washer 54. Nut
27. Nut 55. Union
28. Washer 56. Packing
Figure 66-20. Transmission external components (Sheet 2 of 2)
9. Remove bolts from around bottom flange of 15. Remove nuts and washers from mounting
ring gear (25) case. If transmission assembly is at studs and use T101308 screw set to pull input drive
room temperature, ring gear case may be removed by quill (34) from main case (41). Remove retainer ring
tapping flange lightly. (32) and input pinion bearing (31) from main case
(41). Remove oil tube (40) and packings (37).
10. Refer to paragraph 66-63 for overhaul of ring 16. Refer to paragraph 66-77 for overhaul of
gear. input drive quill.
11.Lift planetary
lower out assembly (17). NOTE: Remove input pinion bearing (31) by using a
Remove and separate liner (18), lower bearing (19), suitable tool which provides a uniform force to outer
and bearing liner (20). Remove lower sun gear (21). race of bearing. Drive bearing inboard to outboard.
17. Remove nuts and washers from studs around
12. Refer to paragraph 66-56 for overhaul of main case mounting flange and at underside of
lower planetary assembly. support case directly below drive quill mounting
ports. Use T101308 screw set to separate main case
two Remove
13. oil jets and oil tube form oil 41) from support case (60). Remove packing (42),
manifold. Use T100929 screw set to pull input drive retainer ring (46) and gear shaft bearing (45) form
gear assembly (29) form main case (41). Remove lower end main case.
packing (42). NOTE: Shim plates must be identified for
reinstallation on the same case and port from which
14. Refer to paragraph 66-70 for overhaul of they were removed. Shim plates must be removed for
input driven gear quill. fluorescent penetrant inspection of case.
66-42
BHT-205A 1-CR&O-1
When using NAS1598 sealing washer use AN960-10L washer between screwhead and
sealing washer.
Figure 66-21. Transmission oil jets (Sheet 1 of 2)
66-43
BHT-205A1-CR&O-1
1. Breather vent 29. Nut

2. Gasket 30. Packing
3. Tube 31. Packing
4. Oil pressure switch manifold 32. Fitting
5. Nut, steel washer, aluminum washer 33. Elbow, packing, nut
6. Elbow 34. Packing
7. Nut, packing 35. Tube
8. Union, packing 36. Screws
9. Packings 37. Sealing washer
10. Oil jet 38. Oil jet
11. Sealing washer 39. Packings
12. Screw 40. Screw
13. Screw 41. Screw
14. Packings 42. Sealing washer
15. Oil jet 43. Oil jet
16. Sealing washer 44. Packings
17. Screw 45. Screw
18. Washer 46. Oil jet
19. Bracket 47. Packing
20. Bolt 48. Packing
21. Bolt 49. Nut
22. Washer 50. Elbow
23. Bracket 51. Screw
24. Manifold assembly 52. Sealing washer
25. Packing 53. Screw
26. Gasket 54. Oil jet
27. Tube 55. Packings
28. Elbow 56. Fitting
NOTE:
When using NAS1598 seal washer use AN960-10L washer between screw head
and sealing washer.
NAS1598 sealing washer or PRP110 Dyna-seal washer
Figure 66-21. Transmission oil jets (Sheet 2 of 2)
18. Remove offset accessory drive quill (47) 21. Remove nuts and washers from studs to
attaching nuts and washers from six mounting studs. remove accessory drive and sump (55), and gasket
Use T101338 screw set and remove offset accessory (56). Install accessory drive and sump assembly on a
drive quill. Remove tail rotor drive quill adapter (1 1). suitable stand.
19. Refer to paragraph 66-97 for overhaul of 22. Refer to paragraph 66-104 for overhaul of
offset accessory drive quill. accessory drive and sump.
23. Refer to paragraph 66-40 for overhaul of
20. Remove retainer ring (48) mast guide ring transmission cases.
(49), and lower mast bearing (50) from support case
(60). At underside of support case, remove set screw 66-31. CLEANING - TRANSMISSION.
(54) and washer (53). Remove plug (52) and packing
(51)from case. Apply following procedures to clean transmission
parts and to treat parts to prevent corrosion.
1. Inspect cases and sleeves for corrosion
NOTE: Remove plug (52) from bottom of damage to threaded stud holes before cleaning. No
transmission, driving plug upward. structural damage to threads is acceptable.
66-44
BHT-205A 1-CR&O-1
2. Oil Pressure Transmitter 9. P-35 Connector

3. Thermoswitch 10. Tachometer Generator
4. Ground Stud 11. Clamp
5.
6. Oil Temperature Bulb
Bracket 12.
13. ClampDetector
Chip
1. Oil Pressure Switch 8. Bracket
5. Figure66-22.
Bulb Transmission electrical (prior to Clamp
2-040-001-133)
6. Oil
7.
Temperature
P-41 Plug Bracket 12.
13.
14. Chip Detector
Electrical Cable
Figure 66-22. Transmission electrical (prior to 212-040-001-133)
66-45
BHT-205A1-CR&O-1
DETAILA
SEE DETAIL A
NOTES:
A Transmission with full flow debris monitors

installed in place of oil filters.
A Bracket and clamp (11) are installed at these locations
on upper face of ring gear case.
205A1-R-66-23-1
Figure 66-23. Transmission electrical (212-040-001-133 and subsequent (Sheet 1 of 2)
66-46 Rev. 2
BHT-205A1-CR&O-1
DETAIL A
1. Transmission 16. Ground wires for rotor brake

2. Oil pressure transmitter 17. Bracket and clamp
3. Oil pressure switch 18. Clamp
4. P-41 plug 19. Clamp assembly
5. Oil temperature bulb 20. Bracket
6. Oil temperature transmitter 21. Electrical cable
7. Oil manifold 22. Ground stud
8. Sump chip detector 23. Nut
9. Thermoswitch 24. Lockwasher
10. Full flow debris monitor 25. Aluminum washer
11. Bracket and clamp 26. Bracket
12. Planetary chip detector 27. Aluminum washer
13. P-35 connector 28. Ground wires
14. Rotor tachometer generator 29. Aluminum washer
15. Upper mast chip detector 30. Screw
205A1-R-66-23-2
Figure 66-23. Transmission electrical (212-040-001-133 and subsequent (Sheet 2)
Rev. 2 66-46A/66-46B
BHT-205A1-CR&O-1
TOOLING HOLE
1. Spring bracket 15. Retainer ring

2. Bolt 16. Oil deflector
3. Screws 17. Lower planetary assembly
4. Washers 18. Liner
5. Top case 19. Lower bearing
6. Packing 20. Bearing liner
7. Chip detector 21. Lower sun gear
9. Retainer ring 23. Oil tube
10. Upper planetary assembly 24. Jet housing
11. Mast driving adapter 25. Ring gear
12. Upper bearing 26. Jet housing
13. Liner 27. Gasket
14. Upper sun gear 28. Packing
205A1-R-66-24-1
Figure 66-24. Transmission (Sheet 1 of 3)
Rev. 2 66-47
BHT-205A1-CR&O-1
29. Input driven gear

30. Packing
31. Input pinion bearing
32. Retainer ring
33. Packings
34. Input drive quill
35. Clip
36. Drain tube
37. Packing
38. Packing
(MS3248-1-016)
39. Tube
(214-040-780)
40. Oil tube
41. Main case
42. Packing
44. Chip detector 54. Setscrew
45. Gear shaft bearing 55. Accessory drive and sump
46. Retainer ring 56. Gasket
47. Offset accessory drive 57. Lift link bushing
48. Retainer ring 58. Lift link bushings
49. Mast guide ring 59. Lift link fitting
50. Lower mast bearing (used on 212-040-054-0131
51. Packing support case)
52. Plug 60. Support case
NOTES:
Used on 212-040-001-133 and subsequent transmission.
Used on transmissions prior to 212-040-001-133.
205A1-R-66-24-2
66-48 Rev. 2
BHT-205A1-CR&O-1
VIEW B
61. Nut 67. Aluminumwasher
62. Washer 68. Steel washer
63. Cover
69. Bolt
65. Hydraulic pump drive quill 71. Cover
(used on helicopters with 72. Aluminum washer
dual hydraulic system) 73. Steel Washer
66. Packing 74. Bolt
2. Clean all parts with solvent (C-304), use NOTE: In nonferrous parts are primed with primer
nonmetalic, soft-bristle brush to dislodge stubborn (C-204) only the top coat needs to be removed.
deposits. All parts other than bearings may be
cleaned with trichloroethane (C-334) if desired. Dry 5. Treat parts to prevent corrosion, after cleaning,
parts with clean, lint-free cloths or filtered in accordancewith the followingprocedures:
compressed air. Do not allow bearings to spin when
drying with compressed air. Coat bearings with
corrosion preventive, finger print remover (C-105) NOTE: Precautionary measures must be exercised
immediately after cleaning. Do not handle unoiled at all times to prevent corrosion. Fingerprint residue,
bearings with bare hands. reactive with moisture in the air, will cause
3. Remove sealant from cases and sleeves with accelerated corrosion in the affected areas.
plastic scraper.
a. Wash all ferrous parts in solvent (C-304) and
4. Remove paint from all painted parts except drain dry.
manifold (24, figure 66-21) and jet housing (24,
figure 66-24). Use paint remover (C-436). Rinse parts b. Gently agitate parts in corrosion preventive,
with water and dry with filtered compressed. finger print remover (C-105) and drain dry.
66-49
BHT-205A1-CR&O-1
c. Apply protective coat of approved lubricating 6. Inspect gears for cracks by magnetic particle
oil, to all transmission parts. method.
NOTE: Parts treated per steps a., b., and c., while in 7. If anyone of the steps 2 through 6 reveal evidence
indoor storage, are protected from corrosion for that the main rotor drive train has experienced
approximately 150 hours. excessive torsional loads, indicated by cracked or
distorted cases or gears, the entire component shall be
66-32 INSPECTION-TRANSMISSIONconsidered unserviceable and nonrepairable. A
cracked, broken, or yielded arm on the main support
case may result from a hard landing and does not
NOTE: If records or physical appearance of necessarily indicate excessive torsional loads. If there
transmission indicate that assembly has been subjected is no evidence that the main rotor drive train has been
to an accident or incident outside realm of normal usage, overloaded torsionally, the component may be returned
perform Conditional Inspection, paragraph 66-33. If to a serviceable condition.
transmission does not require conditional inspection,
proceed with Normal Inspection, paragraph 66-34.
NOTE: All components shall be evaluated as an
NOTE: If main transmission is being overhauled due interrelated group.
to lighting strike, proceed to steps 8 through 10.
During disassembly, note any damage that could be
attributed to lightning strike.
66-33. CONDITIONAL INSPECTION
TRANSMISSION. 8. Visually inspect all detail components. Note any
damage that could be attributed to a lightning strike.
1. If upon receipt of accompanying records and/or
the physical appearance of component indicates that
the component has been subjected to an accident or 9. Utilizing data obtained during visual inspection of
incident outside the realm of normal usage, the following transmission components, evaluation of the related
evaluation criteria shall be accomplished for disposition components, and helicopter in general, determine entry
of the component. Should the component meet the and exit points of current. A magnetometer may be
requirements, proceed with normal overhaul, including helpful in determining current paths.
magnetic particle and fluorescent penetrant inspection.
Any variation from required dimensions is cause for NOTE: It may be necessary to disassemble and
rejection of the component. visually inspect selected bearings to determine current
paths. Once these bearings have been disassembled
2. Visually inspect the component for external they shall be scrapped.
damage. Particular attention should be given to the
main support case for cracks or yielding.
10. Utilizing the following guidelines, determine the
3. Check assembly for freedom and smoothness of serviceability of detail components:
bearing rotation.
a. Any component that exhibits evidence of arc,
4. Visually inspect gearteeth forcracked orchipped burning, or pitting shall be deemed unserviceable and
teeth. If cracked or chipped gear teeth are found in the scrapped.
tail rotor drive train, then all gears in the tail rotor drive
train, then all gears in the tail rotor drive train
(204-040-103, 204-040-104, 204-040-762 and b. Any component in current paths that cannot be
204-040-763) shall be replaced and cases 100 percent visually inspected, i.e., bearings that
and cases replace
204-040-763)shall
be cannot be disassembled, shall be deemed
dimensionally checked for bore alignment.
unserviceable and scrapped.
5. Dimensionally inspect the main bevel gear case
(refer to figure 66-25 for yielding. Surface T shall be flat 11. Accomplish Normal Inspection, refer to
within 0.002 inch TIR. paragraph 66-34.
66-50 Rev. 2
BHT-205A1-CR&O-1
66-34. NORMAL INSPECTION - procedure; however, parts that show evidence of wear
TRANSMISSION. or physical damage must be checked dimensionally.
3. Inspect following parts by magnetic particle (M)

1. Visually inspect all parts for damage and method as indicated. Demagnetize all parts after
excessive wear. Inspect gears and splines for chipped, magnetic inspection. Index numbers are keyed to figure
broken, or worn teeth. Check bearings for smooth 66-24.
operation and indications of excessive wear. Inspect
bearing liners liners for scoring, and for security in case INDEX NO. NOMENCLATURE CODE
openings. Inspect studs for looseness or damage.
11 Mast Driving Adapter M
13 Liner M
2. Inspect parts dimensionally and replace parts that 14 Upper - Sun Gear M
do not fall within inspection limits. (Refer to figure 18 Liner M
66-26.) 21 Lower -Sun Gear M
25 Ring Gear M

fit between mating parts. It is not intended that all 4. Replace roller bearings that show evidence of
dimensions be checked as a prescribed overhaul spalling, scoring, brinelling, flaking, or corrosion
Rev. 2 66-50A/66-50B
BHT-205A1-CR&O-1
SURFACE
SUPPORTCASE
Figure 66-25. Transmission case special inspection.
pitting on rolling elements or races, or that have of the inboard end of a jet is common and is typical of
cracked or broken retainers (Refer to figure 66-27.) the method of manufacturing. Inspect for cracks in
Minor nicks, cuts, or scratches are acceptable area of the slots.
provided they are too small to be felt with a probe
having an end radius of 0.030 inch, and provided the 66-35. REPAIR- TRANSMISSION.
total affected area does not exceed 10 percent of the
contact area at any point. Minor circumferential NOTE: All parts reworked or repaired shall be
scoring is acceptable on rollers and races provided it reinspected prior to use or assembly.
cannot be felt with a probe having an end radius of
0.030 inch and provided the affected area does not 1. Replace all seals, gaskets, performed
exceed 10 percent of the contact area at any point. packings, cork plugs and cotter pins on assembly.
5. Replace gears that are spalled or scuffed or 2. Replace parts that are cracked, broken,
have improper wear patterns. (Refer to figure 66-28.) warped, distorted, or have malformed threads.
6. Replace oil jets which are cracked or bent. An 3 Replace all parts that exceed allowable
indication which appears as a crack across the center tolerances.
66-51
BHT-205A 1-CR&O- 1
SECTION A-A
(ENLARGED) 204-040-354 CASE
212-040-054 CASE SECTION A-A
(ENLARGED)
Figure 66-26. Transmission internal component wear limits (Sheet 1 of 2)
66-52
BHT-205A 1-CR&O-1
MIN. MAX.
INCHES
1 Ring Gear Teeth Between Pins 13.683 13.6931 Av.

(Use 0.2160 In. Dia. Pins)
2 Adapter Spline Over pins 6.4172 6.4223
3 Adapter Spline Between pins 3.8429 3.8458
4 Sun Gear Teeth Over pins 7.0059 7.0120
6 Sun Gear Spline Over pins 7.0039 7.0120
6 Outer Liner ID 5.5113 5.5124 Av.
7 Bearing OD 5.5112 5.5118
ID 4.3302 4.3308
8 Adapter OD 4.3298 4.3309
9 Inner Liner OD 4.3298 4.3309
10 Outer Liner ID 5.5113 5.5124 Av.
11 Sun Gear Spline Between pins 4.3400 4.3441
12 Sun Gear Teeth Over pins 7.0059 7.0120
13 Liner ID 4.9987 5.0003
14 Bearing OD 4.9984 4.9990
15 Case - Diameter B ID 0.7495 0.7508
16 Case - DiameterC ID 0.8745 0 .8 7 5 8
17 Bushing - Diameter D ID 0.5620 0.5630
18 Bushing - Diameter E ID 0.7500 0.7508
19 Case - Diameter B ID 0.8745 0.8758
20 Case - Diameter C ID 1.1245 0.1258
21 Bushing - Diameter D ID 0.7500 0.7505
22 Bushing - Diameter E ID 1.0000 1.0008
NOTES:
If oversized refer to support case repair.
Replace at each overhaul.
Figure 66-26. Transmission internal component wear limits (Sheet 2 of 2)
4. Replace badly corroded, nicked, pitted, 8. Bearing sleeves are finished ground together
scratched or dented parts that cannot be repaired, in and serial numbered for replacement as a matched
accordance with repair procedures set forth in this set.
manual.
9. Repair manifold (24, figure 66-21) as follows:
5. Duplex bearings are marked with serial a. Inspect helicoil threads on manifold. If
numbers and must be replaced in matched pairs. damaged, rework as
6. . inner and outer races

Assemble roller bearing
outlined in steps b. through f.
with matched or same serial numbers. b. Remove old helicoil and tap drill hole 0.252
to 0.263 inch diameter to 0.335 inch maximum
7. Serial number on ground shim plate must depth. Countersink 90 degrees 0.312 to 0.342 inch
conform to serial number on sleeve or case. diameter.
66-53
BHT-205A1-CR&O-1
Acceptable Unacceptable
Figure 66-27. Roller bearings inspection criteria.
c. Tap 5/16-18 UNC-3B to 0.280 inch full entire part with magnesium alloy chemical film
thread depth. treatment. (Refer to BHT-ALL-SPMmanual.)
d. Treat reworked surfaces with chemical film c. Strip old plating from steel parts, if required,
solution (C-103). and replate using magnesium fluoride (C-115) or
touch up cadmium plating using LHE solution
e. Make an insertfrom a H2R-205-SC-7 Rosan (C-108). (Refer to BHT-ALL-SPM manual, for
(Inserto U-Tap). Machine overall length to 0.250 inch prescribed cadmium plating method.)
by removing material from end where external
threads are cut back. Apply LHE (C-108) solution to 11. Replace parts that are not within allowable
reworked area. (Refer to BHT-ALL-SPMmanual.) wear limits.
NOTE: Top four threads of insert are expanded to 66-36. REASSEMBLY- TRANSMISSION.
provide interference fit.
f. Install insert made in step e. using hex NOTE: NAS1197-616 washers shall be replaced
wrench to install insert. Apply primer (C-201 ro with 212-040-199 washers. When 212-040-199
C-204) to external threads of insert, install while washers are used, nuts shall be torqued 230 to 250
primer is still wet. Insert to be driven 0.030 inch inch-pounds. The diameter of 212-040-199 washer
below surface. is 0.708 inch. The diameter of NAS 1197-616 washer
is 0.625 inch.
10. Refinish parts on which the finish has been
damaged or removed by wear, corrosion, chipping, Coat packings, sleeves, and mating surfaces with
scoring, scratches, dents, rework procedures, etc. approved oil before reassembly.
(Refer to BHT-ALL-SPM manual for refinish
procedures.) 1. Mount support case (60, figure 66-24) in a
build up stand.
a. Touch-up aluminum parts with chemical film
treatment (C-100). NOTE: If case is a new part, visually check for
flashing and particles of magnesium that might
b. Remove all traces of corrosion on become detached. Grind off any such material and
magnesium by immersion in chromic acid (C-116). clean case thoroughly. Treat any bare magnesium
Touch up parts with chemical film (C-103) or treat surfaces with chromic acid (C-103).
66-54
BHT-205A1-CR&O-1
A Lower Sun Gear. Typical acceptable wear pattern.
Lower Sun Gear. Heavy wear along the tip of the

B tooth at the upper end. Unacceptable condition.
Upper Sun Gear. Typical acceptable wear pattern.
Upper Sun Gear. Heavy wear along the tip of the

tooth at the upper end. Unacceptable condition.
Figure 66-28. Sun gear wear pattern
66-55
BHT-205A 1-CR&O- 1
CAUTION: IF IT IS NECESSARY TO TAP OFFSET NOTE: Retainer ring must be well seated in recess of
ACCESSORY DRIVE ASSEMBLY DURING deflector ring.
INSTALLATION, DO NOT TAP ON GEAR.
10. Place upper sun gear (14) into lower
2. Heat case with heat lamp and place offset planetary (17) engaging splines and notches over
accessory drive (47) over six studs and secure with tabs on lower bearing liner (18).
washers and nuts. Secure each pair of nuts to existing
bolt head locate between studs, with lockwire 11. Install oil manifold assembly in main case as
(C-405). follows:
3. Place packing (42) in groove around lower end a. Position packings (25, figure 66-21), gasket
of main case. Turn main case upright and install over (26) and oil manifold assembly (24) on main case.
studs of support case (60). Tap cases together, with
care, so that packing is properly seated without b. Secure in place with washer (22) and bolt
damage. Install aluminum alloy washer, steel washer, (21). Position bracket (23) in place of washer (22) on
and nut on each stud, including studs at underside of left side.
support case. Tighten nuts evenly.
c. Install oil jets and packings in manifold
4. Fill the gap areas between the shim plates on assembly (24).
the main case (41) on the top flange with sealing
compound (C-328) prior to installation of input driven NOTE: When using NAS 1598 sealing washer, use
quill. AN960-1 OL washer between screw head and sealing
washer.
CAUTION: DO NOT ALLOW SEALANT ON SHIM
SURFACE. d. Secure with bolt (20), washer (18) and
bracket (19).
5. With support case upright, place packing (30)
on input driven gear (29) and lower input driven gear e. Install sealing washers (16) and screw (17)
into main case, guiding gear shaft into roller bearing in each oil jet.
and splines of offset accessory drive quill. (Exercise
care to engage splines and bearing properly to avoid f. Install elbows (28 and 33) into fitting (32)
damage.) Position input driven gear support case so using packing and nuts as shown.
word FWD and arrow are pointing forward. (Forward
is opposite side from input drive quill.) g. Position packings (31 and 34) on ends of
fitting (32) and install long end into oil manifold (24).
6. Mount lower sun gear (21) with longer inner
shoulder down over splined end of input driven quill 12. Install ring gear (25, figure 66-24) as follows:
gear shaft.
a. Place packing (28) on input driven gear (29)
7. Assemble lower bearing (19), liner (18), and case, coat packing and mating surfaces with
bearing liner (20) with thrust side of bearing race up, approved oil.
i.e. with face of bearing down. Place assembly on end
of gear shaft. b. Position ring gear (25) on top of main case
(41) with jet housing aligned to manifold fitting and
8. Install lower planetary assembly (17), tap into place.
engaging pinions with lower sun gear. Splines of
lower planetary assembly should rest on flange of NOTE: Tooling hole in ring gear will be directly over
liner (18). the main input quill port.
9. Place oil deflector (16) on upper sun gear (14) c. Position oil filler scupper bracket (7, figure
and secure with retainer ring (15). 66-20) in place (forward of oil manifold).
66-56
BHT-205A1-CR&O-1
d. Secure with bolts (4), washers (5, 6, 8, and 9), in liner (18). Upper and lower planetary support bearing
and nuts (10). should now be back to back.
NOTE: NAS1197 or 212-040-199, aluminum NOTE: Spray inside of transmission with approved
washers, must be installed next to the magnesium case. transmission oil (refer to BHT-205A1-MM-1 manual).
13. Assemble upper bearing (12, figure 66-24), 15. Install top case assembly on transmission as
outer liner (13) and mast driving adapter (11) with back follows:
or thrust side of bearing outer race down. Insert
assembly up through upper planetary assembly and a. Install packing (6) on top case (5). Install
secure with retainer ring (9) installed in groove in mast packings (22) on oil tube (23) and insert tube in jet
driving adapter (11). housing (24).
14. Install upper planetary (10) into ring gear case b. Position top case (5) in place on transmission
engaging gear teeth with teeth in ring gear and on upper assembly aligned with oil tube (23) and tap lightly into
sun gear. Engage projection on liner (13) with notches place.
Rev. 2 66-56A/66-56B
BHT-205A1-CR&O-1
c. Installretainerbolts(2)intopcaseandringgear (12) Reconnect P-36 connector to

case using aluminum washers next to top case surface transmission oil pressure switch (1).
and steel washers next to bolt heads and nuts. (Omit
aluminum washers where 205-040-131-1 bracket is (13) Install P-39 connectorto transmission oil
installed.) (Refer to figure 66-20.) pressure transmitter (2).
h. Install electrical cable (212-040-001-133 and
d. Install spring bracket (1, figure 66-24) at subsequent transmissions) as follows:
position illustrated. Tighten bolts evenly.
(1) Position cable (21, figure 66-23) on
e. Install three screws (3) with aluminum washers transmission (1).
in jackscrew holes.
(2) Connect electrical terminal and nipple to
f. Install chip detectors on 212-040-001-133 and upper mast chip detector (15). Do not overtorque
subsequent transmissions. terminal stud nut on chip detector.
(1) Place packing (43) on chip detector (44) plenetary chip detector (12). Do not overtorque terminal
and install chip detector. Secure chip detector with
stud nut on chip detector.
lockwire.
(4) Connect electrical connector to rotor
(2) Place packing (8) on chip detector (7) and tachometer generator (14).
install chip detector.
g. Install electrical cable (prior to thermoswitch (9). Do not exceed 6 inch-pounds torque
212-040-001-133 transmission) as follows: on terminal stud nut.
NOTE: Use only M83248-1 packing on chip detector. (6) Connectelectrical connectortooil pressure
switch (3).
(1) Install wire on chip detector (13, figure (7) Connectelectricalconnectortooilpressure
66-22). transmitter (2).
(2) Install cable in clamps (11 and 12) and (8) Connect electrical connector to oil
attach to brackets. temperature transmitter (6).
(3) Connect P-35 connector (9) to rotor (9) Connect electrical terminal and nipple to
tachometer generator (10). sump chip detector (8). Make drip loop in wire as
illustrated.
(4) Attach clamp to cable (14) and install on (10) Connect four wires (16) to rotor brake as
bracket (8). shown on detail B. If rotor brake is not installed, stow
wires (16).
(5) Install P-41 connector (7) on J41 connector.
(11) Connect three/four ground wires (28) as
(6) Attach clamp to cable (14) and install on applicable to bracket (26) with screw (30), aluminum
bracket (6). washers (25, 27, and 29), lockwasher (24) and nut (23).
(7) Install P-37 connector on transmission oil (12) Connect electrical terminal and nipple to
temperature bulb (5). full flow debris monitor (10).
(13) Secure clamps (19) to brackets on
(8) Install wire on thermoswitch (3). transmission (1).
(9) Install wires to ground stud (4). NOTE: When using NAS1598 sealing washer, use
AN960-10L washer between screwhead and sealing
(10) Attach cable (14) to brackets and clamps washer.
(17).
16. Install remaining oil jets, fittings, and secure with
(11) Deleted lockwire. (Refer to figure 66-21.)
Rev. 2 66-57
BHT-205A1-CR&O-1
17. Install input drive quill as follows: b. Install new packing (66) on quill (65), and
insert quill into transmission with oil hole in quill
a. Place two packings (33, figure 66-24) on sleeve up. It may be necessary to rotate pinion to
sleeve of input drive quill (34), leaving middle groove permit gear meshing.
open for oil circulation.
c. Align quill mounting holes with threaded
b. Install packings (37) on oil tube (40) and holes in transmission.
insert tube in case.
d. Install bolts (69) with steel washer (68) next
c. Cut out a wood or rubber plug the same to head and aluminum washer (67) next to quill.
diameter as the inner race of the inner bearing. (Refer Torque bolts 160 to 190 inch-pounds.
to figure 66-29.) Insert plug into bearing in case to
e. Check backlash of gears. (Refer to step
hold rollers in place. 1 7.g.) Backlash tolerance is 0.004 to 0.012 inch.
NOTE: Use a suitable heat lamp to heat main case at 19. nstall sump and accessory drive assembly on
input drive quill mounting port. (Refer to transmissionas follows:
BHT-ALL-SPM manual.)
a. Install tail rotor drive quill adapter.
d. Install input drive quill in mounting port of
main case (exercise care to engage bearing and gear b. Place gasket (56) and accessory drive and
teeth properly to avoid damage). sump (55) over lower studs of support case. If
necessary, turn tail rotor drive quill to align splined
e. Withdraw plug through mounting port for drive shafts.
hydraulic pump quill.
c. Install aluminum washer, steel washer, and
f. Secure with nuts, clip (35, figure 66-24), nut on each stud except at sump center line on right
aluminum washers (next to sleeve), and steel
washers next to nuts.
HARD RUBBER DISC. APPROX.
2 1/8 INCHES IN DIAMETER
g. Check backlash of input drive quill assembly AND 1/4 TO 1/2 INCH THICK.
as follows:
(1) Install a suitable fixture to secure input COTTER PIN

driven gear from any moment. LIGHT CHAIN, APPROX.
6 INCHES LONG.
(2) Mount pointer of dial indicator on center

of input pinion gear tooth.
(3) Rotate input driven quill. The backlash

tolerance is 0.004 to 0.012 inch. Record backlash.
(4) Take a reading at three places around the

gear 120 degrees apart, repeating steps (1), (2) and
(3). Record backlash.
APPROX. 2 FEET OF SEMI-
RIGID WIRE - 0.041 INCH
(5) Remove backlash tools. DIAMETER OR HEAVIER.
RED WARNING FLAG, STENCILED.

18. If transmission is so equipped, install REMOVE ING
BEFREFTRANSMISSIONC
hydraulic pump drive quill as follows:
a. Heat transmission main case in area of quill

Figure 66-29. Input drive quill installation work aid
port with heat lamp.
66-58
BHT-205A1-CR&O-1
side. On this stud install L-bracket (for electrical engaged in the slots of the lower liner. Repeat
harness support clip) instead of aluminum washer. dimensionally check above.
Torque all nuts evenly.
22. Rotate input coupling to input drive quill to
20. Complete installation of oil lines and fittings. ensure that parts are free to turn.
21. Dimensionally check for proper mast driving

adapter (11) installation as follows: 23. Perform run-in and test of transmission.
(Refer to paragraph 66-38.)
a. Place a straight edge across opening in top
case and measure distance from bottom surface of 66-37. SEALING AND PAINTING
straight edge to top surface of mast driving adapter. TRANSMISSION.
(Refer to figure 66-30.) Distance should be a
minimum of 2.570 inches. 1. Touch up any exposed magnesium surfaces
with chemical film (C-103); apply with brush. (Refer
b. If minimum measurements is not obtained, to figure 66-31 for sealant application.)
examine upper and lower planetary support liners to
determine if tangs of upper liner are engaged with 2. Apply adhesive (C-308) to the transmission as
mating slots of lower planetary liner. This can be indicated on figure 66-31. In addition to specific
determined by use of fingertips. If tangs are points indicated on figure, seal all open, drilled or
disengaged, a gap of approximately 1/4 inch will be tapped, holes in cases, drive quills and bosses.
evident between the two liners.
WARNING: EXERCISE CAUTION DURING 3. Mask transmission for primer and paint.
REINDEXING OF PARTS TO PREVENT THE
POSSIBILITYOF INJURY TO FINGERTIPS. 4. Apply two coats of primer (C-202) to all
exterior surfaces of transmission, if required, to areas
c. If the tangs are disengaged, reindex the that do not receive a top coat. Apply one coat of
liners by inserting the hands, back to back, through primer (C-202) to all surfaces that will receive an
the mast driving adapter. Lift the adapter slightly and exterior finish coat.
rotate the upper liner until the tangs are correctly
5. Paint transmission with two coats of acrylic
lacquer (C-203).
6. Install SERVICE TRANSMISSION decal

MINIMUM DIMENSION adjacent to filler cap.
7. Identify transmission assembly part number

(stamp ink) on top case.
8. Reinstall all external piping and accessories left

off during painting of the transmission.
66-38. RUN-IN AND TEST

TRANSMISSION.
Following overhaul, transmission should be run-in and

tested on 204-040-009-15GIS-1 run-in stand in
TRANSMISSION accordance with instructions contained in BHT-PUB
77-003 Run-in and Test manual. If stand is not
available, an alternate test run may be performed in
Upper planetary adapter installation accordance with
accordance with BHT-205A1-MM-1
BHT205A1-MM-1 manual.
manual.
Figure 66-30.
66-59
BHT-205A1-CR&O-1
NOTE
Conditions requiring application of sealing compound:

Condition Air bleed holes
No. 1 (small holes in bosses)
Condition Open drilled or tapped holes
No. 2
Condition Stud ends exposed in open holes
No. 3
Condition Steel in contact with magnesium
Condition Fillets where two magnesium

No. 5 surfaces mate
Condition Protect internal parts from
No. 6 elements
Application Condition Application of Sealer

Point Number
1 4 and 6 Between upper mast bearing retaining plate and top case around perimeter.
2 6 Around seams where planetary spacer case joins main case and top case.
3 2, 4 and 6 In three open holes and around main input quill.
4 2, 4, 5, Around seam of main support case and sump case, and around tail rotor drive quill.
and 6
5 2 In all open stud holes on base of sump case.
6 1, 2, 3, In nine air holes around hydraulic pump and tachometer drive quill, around seam of
4. and 6 quill and sump case, and in holes where screws break through. In five open holes on
face of quill and in three holes on rear of quill.
7 4 and 6 Around seam of rotor brake drivequill assembly andmain caseoraround seam of cover
assembly and main case.
8 4 and 6 Around seam of hydraulic pump drive quill and main case.
9 4 and 6 Around base of transmission oil filler neck at main support case.
10 2, 4 and 6 Around oil transfer tubes between main case and planetary spacer case, two places.
Figure 66-31. Sealant application
66-60
BHT-205A1-CR&O-1
66-39. TRANSMISSION CASES. 3. Disassemble 212-040-059-001 top case as

follows:
66-40. OVERHAUL- TRANSMISSION CASES. a. Remove nuts (4, figure 66-34) and washers
(3).
NOTE: This section outlines overhaul of the top b. Remove collector (2).
case, main case, and support case. Refer to
paragraph 66-104 for accessory drive and sump 66-42. CLEANING - TRANSMISSION CASES.
overhaul.
1. Inspect cases for corrosion damage to
threaded studs and stud holes before cleaning. No
66-41. DISASSEMBLY- TRANSMISSION CASES. structural damage to threads or holes is acceptable.
NOTE: Do not remove studs and inserts unless 2. Remove sealant with plastic scraper.
damaged.
3. Use paint remover (C-436) to remove paint
from all painted parts except manifold assemblies
1. Disassemble main transmission case as (24, figure 66-21) and jet housing (24, figure 66-24).
follows: Rinse parts with water and dry with filtered
compressed air.
a. Remove retainer ring (4, figure 66-32) and NOTE: If nonferrous parts are primed with primer
input pinion bearing (3) from main case. (C-202) only the top coat needs to be removed.
b. Remove retainer ring (20) and input gear 4. Clean all parts with solvent (C-304). Use soft
shaft bearing (21). bristle brush to dislodge stubborn deposits. All parts
except bearings may be cleaned with trichloroethane
c. Remove screws (5, 15, and 25) and remove (C-334) by vapor degreasing, if desired.
shim plates (7, 16, and 24). Identify shim plates for
5. Dry parts with clean, lint-free cloths or dry
reinstallation in same position.
filtered compressed air. Do not allow bearings to spin
d. Remove and disassemble oil manifold (38) as while drying.
follows: 6. Coat bearings with corrosion preventive
(C-105) immediately after cleaning. Do not handle
(1) Remove bolt (41), with washer (40) and unoiled bearings with bare hands.
bracket (39) securing manifold to main case.
66-43. INSPECTION - TRANSMISSION
(2) Remove bushings (33 and 34) and gasket CASES.
(35).
NOTE: If records or physical appearance of
(3) Remove thermoswitch (31), thermobulb transmission case indicate that assembly has been
(36), and oil pressure relief valve (43). Remove and subjected to an accident or incident outside realm of
discard accompanying packings (32, 37, and 42). normal usage, perform Conditional Inspection,
paragraph 66-44. If transmission case does not
2. Disassemble main support case (5, figure require Conditional Inspection proceed with Normal
66-33) as follows: Inspection, paragraph 66-45.
66-44. CONDITIONAL INSPECTION -
a. Remove left lift link bushing (3) only if TRANSMISSIONCASES.
damaged or loose.
1. Visually inspect top, main and support cases
b. Remove right lift link bushings (4) from for external damage. Particular attention shall be
support case. given to the main support case for cracks or yielding.
66-61
BHT-205A1-CR&O-1
1. Screw 10. Standard Stud 16. Shim Plate 24. Shim Plate
2. Washer Seat 0.003 Oversize Stud (204-040-353-15) (204-040-353-17)
3. Input Pinion Bearing 0.006 Oversize Stud 17. Standard or Oversize Stud 25. Screw
4. Retainer Ring 0.009 Oversize Stud 18. Standard or Oversize Stud 26. Washer Seat
5. Screw 0.012 Oversize Stud 19. Washer Seat 27. Main Case
6. Washer Seat 11. Set Screw 20. Retainer Ring 28. Insert
7. Shim Plate 12. Clinch Nut 21. Input Gear Shaft Bearing 29. Lock Ring
(204-040-353-13) 13. Lock Ring 22. Standard or Oversize Stud 30. Shim Plate Set
8. Insert 14. Insert 23. Standard or Oversize Stud (204-04355-11)
9. Lock Ring 15. Screw
205A1CRO_66000_00320_001
Figure 66-32. Transmission main case (Sheet 1of 2)
66-62 Rev. 3 15 JAN 2004

BHT-205A 1-CR&O
31. Thermoswitch Manifold 38.

32. Packing 39. Bracket
33. Bushing 40. Washer
34. Bushing 41. Bolt
36. Thermobulb 43. Relief valve
37. Packing
Figure 66-32. Transmission main case (Sheet 2 of 2)
2. If there are no visual indications of yielding or 66-45. NORMAL INSPECTION -TRANSMISSION

cracks in support case, check case dimensionally for CASES.
yielding. Check dimension from surface G, figure
66-35, to lower face of lateral mount bushing in each 1. Inspect top case for corrosion damage and
ear. Acceptable limits are 2.270 to 2.260 inches as loose or damaged studs and inserts.
illustrated; however, this dimension may be exceeded
by 0.010 inch above 2.270 or 0.010
inch below NOTE: Rework main case if cracks are found in
2.260 provided four bushing mounting faces (lower) taper pin area.
are parallel and flat within 0.003 TIR of each other 2. Inspect main case for corrosion damage and
and parallel within 0.003 TIR with surface G. loose or damaged studs and inserts. Inspect for
3. Check main case dimensionally for yielding. excessive wear and loose or damaged bearing liners.
Surface T, figure 66-35 must be flat within 0.002 Inspect all washer seats for secure installation.
inch TIR.
3. Inspect support case for corrosion damage and
4. Check top, main and support cases for loose or damaged studs and inserts. Inspect for
freedom and smoothness of bearing rotation. excessive wear and loose or damaged bearing liner.
5. Perform Normal Inspection, paragraph 66-45. Inspect lift link lugs on lower side of case around
66-63
BHT-205A1 -CR&O
1. Forward fifth mount bushings

2. Aft fifth mount bushing
3. Left lift link bushing
4. Right lift link bushings
5. Main support case (212-040-054-007)
6. Lift link fitting
7. Washer
8. Nut
9. Cotter pin
10. Main support case (212-040-054-013)
Figure 66-33. Transmission main support case bushing replacement
66-64
BHT-205A 1-CR&O
1. Top case 3. Washer

2. Collector (used on 4. Nut
212-040-059-001 top case) 5. Cotter pin
Figure 66-34. Transmission top case
bushing and in bushing bores for indication of cracks than 80 percent of the area within any one inch
or yielding and loose or damaged bushing (3, figure square within area C1 nor more than 40 percent of
66-33). the area within any one inch square within area A and
C, exclusive of area C1, may be pitted. No more than
4. Perform fluorescent penetrant inspection of 25 percent of the total area of any surface or diameter
top case, main case, and support case. (Refer to (exclusive of area C1) may be pitted. Refer to step d.
BHT-ALL-SPMmanual.) for inspection and repair of studs in area A.
5. Inspect shim plates for damaged cadmium b. Inside the bolt holes. Isolated pits to a
plating. maximum depth of 0.060 inch are acceptable
provided that the pitting in excess of 0.020 inch in
6. Inspect input pinion and input gear shaft depth does not exceed 10 percent of the area of the
bearings (3 and 21, figure 66-32) for spalling, wall of the hole, and provided that the total area pitted
scoring, pitting, brinelling, corrosion damage, does not exceed 40 percent of the area of the wall of
cracked or broken retainers, and for excessive wear. the hole. Corrosion in areasA, C or on the walls of the
bolt holes must be cleaned by immersion in a chromic
7. Inspect collector (2, figure 66-34) for dents, acid bath. (Refer to BHT-ALL-SPMmanual.) Remove
cracks, and distortion. all traces of corrosion products in areas A, C and on
the walls of the bolt holes.
66-46. REPAIR- TRANSMISSION CASES.
c. In area B the maximum depth of pitting is
1. Top case. 0.020 inch. If there is no pitting on the area contacted
by the washers, the corrosion may be removed by the
a. In areas A, C, and C1, of figure 66-36 the acid bath as in step b. above. If the area contacted by
maximum depth of pitting is 0.020 inch. No more the washer is pitted, then the surface must be
66-65
BHT-205A1-CR&O
SURFACE T SURFACE T
MAIN CASE
SURFACE G (MATING SURFACE FOR MAIN CASE)
2.270
2.260
DIMENSION LINE (LOWER

SURFACE OF STEEL BUSHING)
SUPPORT CASE
Figure 66-35. Transmission case inspection
66-66
*
BHT-205A1-CR&O
AREA
Figure 66-36. Transmission case corrosion areas
66-67
BHT-205A 1 -CR&
machined off (using a mill cutter with the same corner of the area within any one inch square, nor 10 percent
radius as originally used) to a minimum dimension D of the total surface should be pitted. Isolated pits in
or 0.530 inch, provided this will give 100 percent area P are acceptable to a maximum depth of 0.050
cleanup. inch provided the total area pitted in excess of limits
specified above does not excess (one) 1 % of the area
d. Top cases having corrosion around studs at within any one inch square or (one-tenth) 0.1 % of the
mast mounting post shall be reworked as follows: total area of the surface, and provided no two such
pits are in closer proximity than two inches. Washers
(1) When corrosion has not penetrated past
must still make contact with the case for the entire
the first tapped thread, rework as follows:
360 degrees around each bolt for at least 50 percent
(a) Using a 0.327 to 0.334 diameter drill, of the washer width. No more than 10 percent of the
counterdrill stud hole to a maximum depth of 0.125 normal area contacted by the washer may be pitted.
inch. Break all sharp edges, except in the area of the
threads. b. In area I or J the maximum depth of pitting is
threads.
0.020 inch and no more than 40 percent of the area
(b) Treat surface after drilling with within any one inch square, nor 20 percent of the
chemical film (C-103). total area of any surface or diameter should be pitted.
(c) Install one AN126363 through c. Corrosion should be removed by the acid
AN126370, stud which will provide the desired bath method as in step 1.b.
driving torque of 100 to 225 inch-pounds. Use wet.
d. Area J should be carefully inspected prior to
primer on (C-201) on mating parts.
any corrosion removal for evidence of corrosion
(d) All counterdrill holes shall be filled with between the inserts and the case. Any evidence of
adhesive (C-308) flush with top surface of case. corrosion here is cause for rejection of the case.
(2) When more than one thread has been e. In area G and figure 66-35, area A, pitting to
affected by corrosion, rework as follows: a maximum depth of 0.020 inch is acceptable
provided no more than 40 percent of any one inch
(a) Remove stud in corroded area. Drill square, and 20 percent of the total surface area is
existing hole 5/16 (0.3125) inch diameter through corroded. Case having corrosion on studs, or
case. Counterdrill hole 0.389 to 0.397 inch diameter adjacent to studs, shall be further inspected as
and 0.062 inch deep. follows:
(b) Tap 3/8-16UNC-3B modified threads (1) Measure and record height and stud.
through case. Break all sharp edges except in area of
threads. (2) Remove stud from corrosion damaged
threads.
area. If a stud is removed below the input quill bore,
(c) Treat reworked area with chemical film also remove filler from top of hole.
(C-103). (3) If corrosion has affected more than one
(d) Install one AN1 55385 through complete thread, replace case.
AN155390, stepped stud which will provide the (4) If corrosion has affected less than one
desired driving torque of 100 to 240 inch-pounds. complete thread, case shall be reworked as follows:
Use wet primer (C-201) on mating parts.
(a) Using a 0.452 to 0.459 inch diameter
(e) All counterdrill holes shall be filled with drill, counterdrill stud hole to a maximum depth of
adhesive (C-308) flush with top surface of case. 0.156 inch. Break all sharp edges, except in the
thread area.
2. Main case.
(b) Treat surfaces, after drilling, with
a. Inarea P offigure66-36themaximumdepth chemical film (C-103) or treat the entire part with
of pitting is 0.020 inch and no more than 20 percent corrosion treatment (C-114).
66-68
BHT-205A1-CR&O-1
(c) Install a new stud in reworked hole. h. Identify shim plates for installation in a specific
(Refer to BHT-ALL-SPM manual.) location and/or determine required thickness of shim
plates as follows:
(d) If stud below input quill bore was
replaced, fill top of stud hole smooth and flush with (1) Inspect shim plates and case on which
input quill bore with adhesive (C-363). Bore must be shim plate is to be installed for an etched serial
resin free. number. The same serial number must be on both
parts. If parts cannot be identified by serial number,
(e) All counterdrilled holes shall be filled with determine required dimension of shim.
adhesive (C-308) flush with top surface of case.
(2) Inspect case for a reference dimension
NOTE: In areas, I, J, figure 66-36, and area A, figure which shall be metal stamped or vibro-etched on part
66-35, the maximum allowable pitting depth on all adjacent to mounting surface. Record this dimension
internal chamfers is 0.060 inch on no more than 20 and where it is located on case.
percent of the diameter. In area I the maximum
allowable pitting depth on the surface, four places only, (3) If a shim plate of correct part number. but
between the ends of the shim plates is 0.060 inch. without a serial number is available, measure
Rework to remove pitting, staying outside shim and thickness and record. Determine whether shim plate is
seal area. Rework area to have a one-half inch correct for this particular installation. Add shim plate
minimum radius, and shall be smoothed with 400 thickness to reference dimension found on main case.
emery cloth. The resulting value must fall within required dimension
given in table 66-2. I
f. Inside the mounting flange bolt holes. Isolated
pits to a maximum depth of 0.060 inch are acceptable (4) If required shim plate is missing, repeat
provided that the pitting in excess of 0.020 inch in steps (2) and (3). Grind new blank shim plate to
depth does not exceed 10 percent of the area of the required thickness. Apply cadmium plate in
wall of the hole, and provided that the total area pitted accordance with BHT-ALL-SPM manual. Measure
does not exceed 40 percent of the area of the wall of required thickness of shim plate after plating.
the hole. Remove corrosion by acid bath. (Refer to
BHT-ALL-SPM manual.)
(5) Identify new shim plate by etching serial
number of applicable case on shim plate. Also etch
g. Main case that has cracks in the magnesium thickness (in thousandths of an inch) on shim plate.
boss at the tapered pins, area M, figure 66-36 may be Use etching ink (C-461) or equivalent. Neutralize with
reworked as follows: water and common baking soda after etching.
(1) File out the crack, using a rotary file. i. Input quill pusher set may be installed as
Minimum fillet radius after rework is 0.125 inch. follows:
Maximum allowable depth of cleanup is 0.060 inch,
measured from original cast surface as shown in detail NOTE: Modification of main case by installing three
B. Rework is permissible within these limits at all three
special studs at input quill mounting port will allow
pins locations.
T101583 pusher set to be used when installing input
quill.
fluorescent penetrant material. (1) Inspect input quill mounting studs at the
one, five, and nine o'clock position to determine if 205-
(2) Inspect reworked cases by fluorescent 040-308 special studs are installed. Special studs will
penetrant method. There must be no indication of be internally threaded on outboard end and will have a
crack after rework. set screw installed.
(3) Treat rework areas for corrosion (2) Remove standard studs at the one, five,
protection with chemical film (C-103). and nine o'clock positions.
15 JAN 2004 Rev. 3 66-69

BHT-205A1-CR&O-1
(3) Select 205-040-308 stud of size to achieve Inspect main case (figure 66-37) for cracks in center
proper stud height, when stud is installed and torqued. web above input quill port. If cracks are found which
extend deeper than 0.250 inch, the case is considered
205-040-308-3, standard. non-repairable. If cracks are found that do not exceed
0.250 inch, proceed as follows:
205-040-308-5, 0.003 inch oversized.

a. Grind out all indications of crack within limits
shown using a rotary file with minimum material
205-040-308-7, 0.006 inch oversized, removal. If all indications of crack cannot be removed
within prescribed limits, the case is considered to be
205-040-308-9, 0.009 inch oversized. non-repairable.
(4) Coat threads of studs with unreduced b. Polish reworked area to remove all sharp
primer (C-201). Start studs into holes in case. edges. Surface finish shall be 63 RHR or better.
(5) Use a suitable stud driving tool and torque c. Dye penetrant inspect reworked area to ensure
studs 175 to 250 inch-pounds, maintaining a projecting all indications of crack are removed. Minor
stud height of 1.56 to 1.60 inches. imperfections such as porosity and gas holes are
acceptable.
(6) Install NAS1081-4A, set screws, into

internal threaded end of studs. d. Treat reworked area with corrosion preventive
(C-103). Prime and paint area to match finish, except for
a one inch wide band centered on web which is to be
3. Main case center web (204-040-353) - primed only.
Table 66-2. Main case required dimensions
REQUIRED
DIMENSION
LOCATION SHIM PLATE MIN. MAX.

INCHES
FOR 204-040-353 CASE

Main Case - top 204-040-353-011 6.1240 6.1250
Main Case - rear port 204-040-353-013 8.5620 8.5625
Main Case - front port 204-040-353-015 7.4715 7.4720
Main Case - left port 204-040-353-017 7.4715 7.4720
OR 212-040-053 CASE
Main Case - top 204-040-053-017 6.1340 6.1350

Main Case - rear port 204-040-053-015 8.6420 8.6425
Main Case - front port 204-040-053-013 7.4715 7.4720
Main Case - left port 204-040-053-013 7.4715 7.4720
Main Case - right port 204-040-053-013 7.4715 7.4720
66-70 Rev. 2
BHT-205A1-CR&O
MAINCASE
MAIN INPUT
QUILLPORT
NOTES:
Measure reference dimension "X"

between surface of shim plate
and face of web before grinding.
Maximum allowable depth after
rework equals "X" plus 0.250 inch.
Prime only 1 inch wide band.

Centerof web. Do not paint.
A -A
SECTION
Figure 66-37. Main case center web (204-040-353)
66-71
BHT-205A 1-CR&O
4. Support case (204-040-354) - repair. (4) If diameter C exceeds 0.9067 inch, but
does not exceed 0.9375 inch, ream 0.9370 to
NOTE: If 204-040-354 support case requires 0.9380 inch for 22-015-47-58-34 bushing.
replacement, it may be replaced with 212-040-054
support case. Using 212-040-054 support case (5) If diameter C exceeds 0.9375 inch,
requires lift link and lift link attaching hardware be replace the case.
replaced. Refer to step 4 for repair of 212-040-054
support case. (6) After rework, diameter B must be
concentric with diameter C or E within 0.002 inch,
a. New lift link bushing (44, figure 66-33) must and surface finish in the reamed holes must be 40
be reinstalled in support case, and line reamed. RHR or better.
NOTE: All 204-040-354 cases shall be worked at (7) Treat all reworked areas immediately after
initial overhaul to accept 22H012-35-28-34 reworkwithchemicalfilm(C-103).
bushings.
The H in part number indicates the bushing is 1/32

(8) Coat mating surfaces of bushing and case
inch larger than first dash number indicates. The first
with unreduced zinc chromate primer (C-201), and
dash number indicates the size in sixteenths of an tap bushing n to seat flange against case.
inch.
(9) If new bushing was installed in diameter
b. Ream diameter B, figure 66-38, 0.7808 to B ream diameter D, 0.5620 to 0.5630 inch.
0.7817 inch, bore must be concentric with diameter
C or E within 0.002 inch. Surface finish of reamed (10) If new bushing was installed in diameter
hole must be 40 RHR or better. C, ream diameter E, 0.7500 to 0.7505 inch.
NOTE: Remove bushing (3, figure 66-33) only if (11) After reaming ID of bushings, diameter
damaged or loose. D must be concentric with diameter E within 0.001
inch TIR and surface finish in the reamed holes must
c. Check dimensions of case bore and bushing be 40 RHR or better.
(3) bore to determine the necessity and size of
replacement bushing.
f. Minor rework may be done in other area of
the case within the limits shown.
d. If bushing (3) was removed, replace with
new bushing and line ream.
g. Corrosion should be removed by the acid
e. If case bores exceed acceptable limits, bah method. (Referto BHT-ALL-SPMmanual.)
rework as follows:
NOTE: Either or both lugs on the case, i.e. diameter NOTE: Rework areas are shown in figure 66-38.
B or C, figure 66-38 may be reworked. It is not
necessary that both be reworked if only one is
discrepant. h. In critical areas rework shall be limited to
blending minor scratches, not exceeding 0.010 inch
(1) If diameter B exceeds 0.7817 inch, but deep, 1 inch in length. Radii located in critical areas
does not exceed 0.8125 inch, ream 0.8120 to having minor damage shall have damage blended out
0.8130 inch for 22-013-35-28-34 bushings. up to a maximum depth of 0.030 inch, and a
maximum length of two inches.
(2) If diameter B exceeds 0.8125 inch,
replace case. i. In hatched areas, rework shall be limited to
blending nicks, scratches, and dents not to exceed
(3) If diameter C exceeds acceptable limit, 0.040 inch in depth. Radii located in cross hatched
but does not exceed 0.9062 inch, ream 0.9057 to area having minor damage shall have damage blended
0.9067 inch for 22H014-47-58-34 bushing. out up to a maximum depth of 0.060 inch.
66-72
BHT-205A 1-CR&O
SECTIONA-A
Figure 66-38. Transmission main support case repair limits (Sheet 1 of 3)
66-73
BHT-205A 1 -CR&
LEGEND
CRITICAL AREAS
SHADED AREAS
SECTIONA-A
- (ENLARGED)
HATCHED AREAS
HATCHED AREAS
212-040-054 SUPPORT CASE
66-74
BHT-205A1-CR&O
SECTION B-B
212040-642
212-040-054 SUPPORT CASE
66-75
BHT-205A1 -CR&O
j. In cross hatched areas, rework shall be l. All cast surfaces reworked shall be finished
limited to blending nicks, scratches, and dents not to using 400 grit emery paper (C-423).
exceed 0.060 inch in depth. Radii located in shaded
areas having minor damage shall have damage m. Treat all reworked areas immediately after
blended out up to a maximum depth of 0.060 inch. rework with chemical film (C-103).
k. In areas F and G, figure 66-38, pitting to a NOTE: Refer to BHT-ALL-SPM manual for approved
maximum depth of 0.020 inch is permitted, provided fluorescent penetrant material.
no more than 40 percent of any one square inch, and
no more than 20 percent of the total surface is n. Inspect reworked areas by fluorescent
corroded. Areas of corrosion which exceed half the penetrant method.
width of the mounting surface are not permissible.
Cases having corrosion on studs or on case 5. Support case (212-040-054) - repair.
immediately adjacent to the studs shall be further
inspected to determine if rework is possible, as NOTE: All cases shall have new bushings (4, figure
follows: 66-33) installed. Refer to step c. below.
(1) Measure and record stud height. a. Rework in critical areas shown on figure
66-38 is limited to blending out minor scratches
(2) Remove stud from corrosion damaged which do not exceed 0.010 inch in depth and/or one
area. inch in length with the following exception: Minor
damage located on radii in critical areas shall be
(3) If corrosion has affected more than one blended out up to a maximum depth of 0.030 inch
complete thread, replace case. and a maximum length of two inches.
(4) If corrosion has affected less than one b. Rework in hatched areas shown on figure
complete thread, case shall be reworked as follows: 66-38 is limited it blending out nicks, scratches and
dents which do not exceed 0.060 inch in depth with
(a) In area F, use a 0.327 to 0.334 inch the following exception: Minor damage located on
diameter drill, counterdrill stud hole to a maximum radii in hatched areas shall be blended out up to a
depth of 0. 125 inch. Break all sharp edges, except in maximum depth of 0.060 inch.
area of thread.
c. Replace bushing (4, figure 66-33) as
(b) In area G, use a 0.452 to 0.459 inch follows:
diameter drill, counterdrill stud hole to a maximum
depth of 0.156 inch. Break all sharp edges, except in (1) Remove old bushing (4). If diameter C,
the area of thread. figure 66-38 exceed 0.9067 inch but does not
exceed 0.9375 inch, ream 0.9370 to 0.9380 inch for
(c) Treat surfaces after drilling with 22-015-47-33-34 bushing.
chemical film (C-103) or treat the entire part with
magnesium alloy chemical film treatment. (Refer to (2) Replace case if diameter C exceeds
BHT-ALL-SPMmanual.) 0.9380 inch.
(d) Install new stud in reworked hole. (3) After rework, diameter B must be
(Refer to BHT-ALL-SPM manual.) concentric to diameter C or E and surface finish in
reamed hole must be 40 RHR or better.
(e) All counterdrilled holes shall be filled
with adhesive (C-308), flush with top surface of (4) Treat all reworked areas immediately after
case. rework with chemical film (C-103).
NOTE: All areas not specifically detailed in figure (5) Coat mating surfaces of bushing and case
66-38 shall have damage blended out to a maximum with unreduced zinc chromate primer (C-201) and tap
of 0.010 inch depth. bushing in to seat flange against case.
66-76
BHT-205A 1-CR&O
(6) With new bushing installed in diameter B, f. In areas F and G, pitting to a maximum depth
ream diameter D, 0.7500 to 0.7505 inch. of 0.020 inch in permitted, provided no more than 40
percent of any one square inch, and no more than 20
(7) After reaming ID of bushing, diameter D percent of the total surface area is corroded. Areas of
must be concentricwith diameterEwithin 0.001 inch corrosion which exceed half the width of the
TIR and a surface finish in reamed holes must be 40 mounting surface are not permissible. Cases having
RHR or better. corrosion on studs or on case immediately adjacent to
the studs shall be further inspected to determine if
d. Replace bushing (3, figure 66-33) as rework is possible as follows:
follows:
(1) Measure and record stud height.
NOTE: Remove and replace bushing (3) only if
(2) Remove stud from corrosion damaged
damaged, loose or oversize.
area.
(1) If diameter C, figure 66-38 exceeds (3) If corrosion has affected more than one
acceptable limits, but does not exceed 1.1564 inch, complete thread, replace case.
ream 1.557 to 1.1572 inch for 22H018-63-66-42
bushing. (4) If corrosion has affected less than one
complete thread, case shall be reworked as follows:
NOTE: The H in part number indicates the bushings
is 1/32 inch larger than first dash number indicates. (a) In area F, use a 0.327 to 0.334 inch
The first dash number indicates the size in sixteenths diameter drill and counterdrill stud hole to a maximum
of an inch. depth of 0. 125 inch. Break all sharp edges, except in
area of thread.
(2) If diameter C exceeds 1.1752 inch but
does not exceed 1.1877, ream 1.1870 to 1.1885
(b) In area G, use a 0.452 to 0.459 inch
diameter drill and counterdrill stud hole to a maximum
inch for 22-019-63-66-42 bushing. depth of 0. 156 inch. Break all sharp edges, except in
(3) If diameter C exceeds 1.1885 inch, the area of thread.
replace case. (c) Treat surfaces after drilling with
chemical film (C-103) or treat the entire part with
(4) Treat all reworked areas immediately after magnesium alloy chemical film treatment. (Refer to
rework with chemical film (C-103). BHT-ALL-SPMmanual.)
(5) Coat mating surface of bushing and case (d) Install new stud in reworked hole.
with unreduced zinc chromate primer (C-201) and tap (Referto BHT-ALL-SPMmanual.)
bushing in to seat flange against case.
(e) All counterdrill holes shall be filled with
(6) With new bushing installed in diameter C, adhesive (C-308) flush with top surface of case.
ream diameter E, 1.0000 to 1.0005 inch.
g. All areas not specifically detailed on figure
(7) After reaming ID of bushing, diameter E 66-38 must have damage blended out to a maximum
must be concentric with diameter D within 0.001 depthof 0.010inch.
inch TIR and surface finish in reamed hole must be 40 h. Finish all reworked areas immediately after
RHR or better. rework with chemical film (C-103).
e. Rework in shaded areas shown on figure NOTE: Refer to BHT-ALL-SPM manual for approved
66-38 is limited to blending out nicks, scratches and fluorescent penetrant material.
dents which do not exceed 0.060 inch in depth.
Minor damage located on radii in shaded areas shall i. Inspect reworked areas by fluorescent
be blended out up to a maximum depth of 0.060 inch. penetrant method.
66-77
BHT-205A1-CR&O
6. Replace fifth mount bushings (1 and 2, figure 0.7183 to 0.7193 inch for 22H01 1-35-15-26
66-33) as follows: bushing (1, figure 66-33).
(3) If diameter H, figure 66-38, exceeds

NOTE: After rework, diameters G and H, figure 0.7193 inch but does not exceed 0.7490 inch, ream
66-38, shall be concentric with each other within 0.7495 to 0.7505 inch for 22-012-35-15-26
0.002 inch. Surface finish of reamed hole to be 40 bushing (1, figure 66-33)
RHR or better.
bushing (1,figure 66-33).
(4) If diameter H, figure 66-38, exceeds
a. Check size of diameter G, to determine size 0.7505 inch but does not exceed 0.7800 inch, ream
of replacementbushings. 0.7807 to 0.7817 inch for 22H012-35-15-26
bushing (1, figure 66-33).
(1) If diameter G does not exceed 0.9380
inch, use 22-015-51-32-40 bushing. (Refer to steps (5) If diameter H, figure 66-38, exceeds
c. thru i.) 0.7817 inch but does not exceed 0.8115 inch, ream
0.8120 to 0.8130 inch for 22-013-35-15-26
(2) If diameter G exceeds 0.9380 inch but bushing (1, figure 66-33).
0.9693 inch for 22H01 5-51-32-40bushing (2, figure (6) If diameter H, figure 66-38, exceeds
66-33). 0.8130 inch, replace case (5, figure 66-33).
NOTE: The H in part number indicates the bushing is c. Treat all reworked areas, after reaming, with
1/32 inch larger than first dash number indicates. The magnesium alloy chemical film treatment. (Refer to
first dash number indicates the size in sixteenths of BHT-ALL-SPMmanual.)
an inch.
d. Heat fifth mount lug to approximately 200 ° F
(3) If diameter G exceeds 0.9693 inch but (93°C) with a heat lamp.
1.0005 inch for 22-016-51-32-40 bushing (2, figure e. Coat faying surfaces of bushing and fifth
66-33). mount lug with unreduced zinc chromate primer
(C-201). Tap bushing in to seat flange against case
(4) If diameter G, figure 66-38, exceeds while primer is still wet.
1.0005 inch but does not exceed 1.0300 inch, ream
1.0307 to 1.0317 inch for 22H016-51-32-40 f. Ream bushing (2, figure 66-33), diameter J,
bushing (2, figure 66-33). figure 66-28, 0.8120 to 0.8125 inch.
(5) If diameter G, figure 66-38, exceeds g. Ream bushing (1, figure 66-33), diameter K,
1.0317 inch but does not exceed 1.0610 inch, ream figure 66-38, 0.5621 to 0.5625 inch.
1.0620 to 1.0630 inch for 22-017-51-32-40
h. Diameters J and K shall be concentric with
bushing (2, figure 66-33).
each other within 0.001 inch. Surface finish in
reamed hole shall be 40 RHR or better.
reamed hole shall be 40 RHR or better.
(6) If diameter G, figure 66-38, exceeds
1.0630 inch, replace case (5, figure 66-33). NOTE: Refer to BHT-ALL-SPMmanual for approved
b. Check size of diameter H, figure 66-38, to
determine size of replacement bushing. . Inspect reworked area by fluorescent
penetrant method.
(1) If diameter H does not exceed 0.6880
inch, use 22-011-35-15-26 bushing (1, figure 7. Repair fitting (6, figure 66-33) to limits in
66-33). (Refer to steps c. thru i.) figure 66-39.
(2) If diameter H, figure 66-38, exceeds 8. Replace parts that are not within allowable
0.6880 inch but does not exceed 0.7175 inch, ream wear limits.
66-78
BHT-205A1-CR&O
1. Maximum acceptable diameter for diameter L is 0.7525. Maximum

acceptable diameter for diameter M is 1.0025 inch.
2. Area A
Corrosion pitting up to 0.010 inch in depth is accetable provided no more than 20

percent of any one square inch, and no more than 10 percent of the total surface area
is corroded. Washers must make contact with fitting for entire360 degrees around
each bolt for at least 50 percent of washer width. No more than 10 percent of normal
area contacted by washer may be pitted.
3. Area B
Corrosion pitting up to 0.005 inch in depth is acceptable provided no more than 20

is corroded, except area E.
4. Area C
Mechanical damage in either area C, but not on radii, up to 0.010 inch in depth and
0.50 inch in length, and mechanical damage on the radii up to 0.020 inch in depth and
1.0 inch in length is acceptable if polished out.
5. Area D
Corrosion pitting up to 0.010 inch in depth is acceptable provided no more than 20

is corroded. Minor damage on blend radii shall be blended out to a maximum depth of
0.010 inch and maximum length of one inch.
6. Area E
Surface corrosion only is permitted. Surface corrosion is that which can be removed
with wire brush or steel wool
AREA
LIFT LINK FITTING 212-040-105-001
Figure 66-39. Lift link fitting damage limits
66-79
BHT-205A 1-CR&O
66-47. REASSEMBLY- TRANSMISSION CASES. checking for an etched serial number on both shim
and quill sleeve or case on which shim is to be
1. Reassemble support case as follows: installed. The same serial number must be on both
parts.
a. Mount support case (60, figure 66-24) in a
buildup stand. e. If the parts cannot be identified by serial
number, determine required dimension of shim as
NOTE: If case is a new part, visually check for described in paragraph 66-46, step 2.h.
flashing and particles of magnesium that might
become detached. Grind off any such material and 4. Reassemble top case as follows:
clean case thoroughly. Treat any bare magnesium
surfaces with chemical film (C-103). a. Position collector (2, figure 66-34) on top
case (1).
Coat packings and mating surfaces with approved oil
before reassembly. b. Secure collector (2) to top case (1) using
washers (3) and nuts (4). Torque nuts 10 to 15
b. Invert support case. Install plug (52) with inch-lbs.
packing (51) in center opening of support case. Align
hole and install setscrew (54) with aluminium alloy c. Install cotter pins (5).
washer (53).
66-48. UPPER TRANSMISSION PLANETARY.
c. Check that packing (51) is not damaged and
that screw tightens fully against head before 66-49. OVERHAUL- UPPERTRANSMISSION
threaded end bottoms on plug. Secure screwhead to PLANETARY.
case rib with lockwire (C-405). Rotate support case
to an upright position. TOOL REQUIRED
d. Install lower mast bearing (50) outer race in 204-040-009-1 Holding Fixture
liner at center of support case. Install mast guide ring PAT-2D
(49) on bearing race, and secure with retainer ring T101332 Planetary Installing Pin
(48) in groove of liner. T101574 Shaft Guide
2. Install lift link fitting (6, figure 66-33), washers 66-50. DISASSEMBLY- UPPER TRANSMISSION
(7) and nuts (8). Verify that no interference exists PLANETARY.
between fitting (6) and case. Torque nuts 37 to 42
foot-pounds and install cotter pins (9). 1. Remove pinion bearing shaft nuts (1, figure
66-40) using square wrench adapter.
3. Reassemble main case as follows:
2. Press one pinion shaft (3) out of spider
a. Install input pinion bearing (3, figure 66-32) assembly (2) with T101574 shaft guide.
in main case web liner, inboard of mounting port, for
input drive assembly. NOTE: Do not disassemble spider (2). The spider
consists of a plate and web which are assembled prior
b. Secure with retainer ring (4), seated in to final machining at time of manufacture.
groove of liner.
3. Position T101332 planetary installing pin
c. Prepare sleeves and cases for reassembly by through pinion bearing race (5) and tap pinion out of
touch up of cadmium plating on ground shims with side opening of spider. Hold planetary pinion bearing
LHE solution (C-108) and installing the shims in their washers (4) in place to prevent planetary pinion roller
original positions. set (6) from falling out of pinion bearing retainer (7).
d. If original shims are lost or mixed identify NOTE: Use care when removing pinion from spider
shims for installation in a specific location by to prevent damage to rollers and race.
66-80
BHT-205A 1-CR&O
AREA OF ALLOWABLE PITTING
VIEW B-B
tu
N
. 1
2. Spider Assembly
3. Pinion Shaft
4. Thrust Washer
5. Inner Race
6. Roller
7. Retainer
8. Pinion
*Nylon retainers in upper planetary assembly; bronze retainers in

lower planetary assenbly.
Figure 66-40. Upper transmission planetary
66-81
BHT-205A1-CR&O
4. Separate planetary pinion bearing washers (4), CAUTION: DO NOT HANDLE UNOILED BEARINGS.
planetary pinion roller set (6), pinion bearing retainer
(7), pinion bearing race (5) from planetary pinion (8). NOTE: Light scoring is acceptable in the center of
the races in the area contacted by the retainer.
NOTE: Planetary pinion rollers from each pinion are 4. Inspect retainers (7, figure 66-40) for damage
a matched set and must not be intermixed. and for evidence of imbeded bearing chips or other
steel particles in the tang on the retainers.
5. Remove remaining pinions in same manner
outlined in steps 2 through 4. 5. Inspect upper surface of spider and upper
planetary for corrosion.
66-51. CLEANING - UPPERTRANSMISSION 6. Inspect the following parts by magnetic

PLANETARY. particle method. Index numbers are keyed to figure
66-40. Demagnetize all parts after inspection. (Refer
to BHT-ALL-SPMmanual.)
1. Clean all planetary parts with solvent (C-304).
Use soft bristle brush to dislodge stubborn deposits. INDEX NO. NOMENCLATURE
All parts except bearings may be cleaned with
trichloroethane (C-334) by vapor degreasing, if 1 Nut
desired. 2 Spider
3 Shaft
2. Dry parts with clean, lint-free cloths or dry 5 Inner Race
filtered compressed air. Do not allow bearings to spin 8 Pinion
while drying.
that do not fall within inspection limits. (Refer to
3. Coat bearings with corrosion preventive figure 66-41.)
unoiled bearings with bare hands. NOTE: Wear limits are provided to show the required
4. Inspect parts for corrosion damage to threaded dimensions be checked as a prescribed overhaul
studs and stud holes before cleaning. No structural
wear or physical damage must be checked
damage to threads or holes is acceptable.
dimensionally.
66-52. NORMAL INSPECTION - UPPER 8. Inspect planetary gear wear pattern. (Refer to
TRANSMISSION PLANETARY. figure 66-42.) Replace gears that exceed limits.
66-53. REPAIR - UPPER TRANSMISSION

1. Inspect all parts visually for excessive wear PLANETARY.
and damage. Inspect all threaded parts for damaged
threads. 1. Rework minor chipping at ends of planetary
ring gear teeth by blending out chipped area with fine
2. Inspect pinion gears for chipped, broken, or india stone to effect a 0.01 5 inch radius. Rework area
worn teeth. must not exceed 0.020 inch from original end of
tooth.
3. Inspect bearing surfaces of rollers, races and 2. Inspect rework area by magnetic particle
pinion gears for spalling, scoring, pitting, brinelling, method. No indication of cracks are permissible.
indentations or corrosion damage. Demagnetize parts. (Refer to BHT-ALL-SPMmanual.)
66-82
BHT-205A 1-CR&O
PIN DIAMETER
PIN DIAMETER PINION TEETH
SPLINE TEETH

INCHES
1 Pinion - Gear Teeth Over Pins 3.9730 3.9793

(Use 0.2160 Diameter Pins)
2 Inner Race OD 1.8297 1.8303
3 Inner Race ID 1.3750 1.3758
4 Pinion Gear ID 2.6969 2.6976
5 Pinion Shaft OD 1.3752 1.3760
6 Spider - Shaft Bore ID 1.3750 1.3758
7 Spider - Spline Between Pins 5.7986 5.8143
Figure 66-41. Upper transmission planetary wear limits
3. Replace all unserviceable parts. b. Prepare cleaner by thoroughly mixing one

volume of alcoholic phosphoric cleaner (C-344) and
4. Blend out small nicks, burrs, and scratches on
splines with fine india stone (C-464). (Refer to figure
66-41.) c. Surfaces, which are to receive alcoholic
5. Inspect upper surface of spider for corrosion. phosphoric cleaner, must be free of oil, grease, shop
Pitting is allowable on top plate of upper planetary, in soil and paint. Preclean as required with solvent
area shown in view BB of figure 66-40, except for (C-304).
area contacted by flange of pinion shafts. Maximum
d. Apply cleaner by brushing or swabbing.
depth of pitting must not exceed 0.010 inch, and no
Leave cleaner in contact with metal surface for one to
more than twenty percent of any one inch square may
three minutes and rinse thoroughly with clean water.
be affected.
6. Remove corrosion from upper surface of spider NOTE: The procedure may be repeated as required
as follows: to remove light rust. Apply cleaner and rinse to
corroded area only. Avoid getting cleaner in joint
a. Lightly polish with fine emery cloth and clean between spider halves, in pinion shaft holes or in
and treat to prevent further corrosion. threaded holes.
66-83
BHT-205A1-CR&O
Pinion (upper planetary assembly). Typical ac-

A ceptable wear pattern for the sun gear side.
Pinion (upper planetary assembly). Typical ac-

ceptable wear pattern for the ring gear side.
Pinion (upper planetary assembly, sun gear side.

Pinion is spalled in the flank. Any spalling, scuffing,
C and pitting that can be detected with a probe having
a 0.020 inch radius is unacceptable.
Figure 66-42. Upper transmission planetary pinion wear pattern.
a. Dry planetary spider in en oven (150°F 1. Assemble planetary pinion (8, figure 66-40).
maximum), or with clean dry cloths, or use pinion bearing retainer (7), roller set (6), pinion
compressed air which has been filtered to render it oil bearing race (5) and washers (4) on T101332
and moisture free. planetary installing pin. Hold parts together and insert
into spider assembly (2).
f. Treat planetary spider for corrosion
prevention. Gently agitate part in figure print remover NOTE: Roller set (6) for one pinion assembly must
(C-105) and drain on rack. Apply protective coat of be from same manufacturer. Check manufacturers
approved lubricating oil. identification mark on end of rollers.
NOTE: Individual rollers (6) are not interchangeable

66-54. REASSEMBLY - UPPER TRANSMISSION and should not be mixed between roller sets. Rollers
PLANETARY. must be replaced as complete sets. Both dash
numbers, in complete sets, may be used in a
NOTE: Do not handle unoiled parts with bare hands. planetary assembly.
66-84
BHT-205A1-CR&O
2. Install T101574 shaft guide in pinion shaft (3). pin into pinion inner race (5) and tap pinion gear (4)
Position spider assembly (2) in 204-040-009-1 out of side opening between plates. Hold thrust
PAT-2D holding fixture, align pinion gear with holes in washers (3) in place to keep rollers (7) in retainer (6)
spider and press pinion shaft (3) into position through during removal procedure.
pinion. Catch T101332 pin as it is pressed out of
pinion. Use caution to prevent damage to shaft or 3. Separate thrust washers (3), rollers, retainer,
spider assembly. Ensure that pinion shaft (3) is inner race and T101332 planetary installing pin from
seated. Remove T101574 shaft guide from pinion pinion gear (4).
shaft.
CAUTION: ROLLERS (7) ARE A MATCHED SET. DO
3. Repeat steps 1. and 2. to install remaining NOT INTERMIX WITH ROLLERS FROM ANOTHER
pinions. Install nuts (1) on all eight pinion shafts and PINION GEAR.
torque 60 to 80 foot-pounds. Check each pinion for
free rolling in spider. Use a 0.001 inch feeler gage to 4. Remove and dissemble remaining pinion
check for minimum clearance between ends of each gears in same manner outlined in steps 2. and 3
roller (6) and thrust washers (4). Check at same 5. Remove nuts (8) and bolt (9). Separate plate
points for maximum clearance of 0.003 inch. set (12)and spider (13).
NOTE: If rollers do not turn freely, check retainer for 6. Remove cups (10) and washers (11) from plate
burrs, and check for chips and foreign material in set (12). Use T101565 washer removal nut to
bearing. Recheck parts dimensionally if necessary. remove washers. Thread nut on washer, and place a
drift through the washer and cup of washer and nut
4. Secure pinion shafts (3) and nuts (1) with
so that it is against the inner surface of the washer
lockwire (C-405). (Refer to figure 66-43.)
removal nut, and tap drift with mallet to remove
66-55. LOWER TRANSMISSION PLANETARY. washer.
7. Remove four retaining rings (14).
66-56. OVERHAUL - LOWER TRANSMISSION
PLANETARY. 8. Position spider (13) in base of alignment fixture
with guide and punch in position to press bearing (1 5)
TOOLS REQUIRED out of spider (Refer to view C). Press four bearings
out of spider.
T101332 Planetary Installing Pin
T101562 Gage Block 66-58. CLEANING - LOWER TRANSMISSION
T101565 Washer Removal Nut PLANETARY.
T101572 Alignment Fixture
T101573 Holding Fixture 1. Clean all planetary parts with solvent (C-304).
T101574 Shaft Guide Use soft bristle brush to dislodge stubborn deposits.
All parts except bearings may be cleaned with
66-57. DISASSEMBLY- LOWERTRANSMISSION trichloroethane (C-334) by vapor degreasing, if
PLANETARY. desired.
1. Mount T101573 in a bench vise and position 2. Dry parts with clean, lint-free cloths or dry
planetary on fixture. Refer to figure 66-44, view A. filtered compressed air. Do not allow bearings to spin
Remove nuts (2). Invert planetary on holding fixture while drying.
(see view B). Break high torque on bolts (9) but keep
tight to provide assembly rigidity during removal of 3. Coat bearings with corrosion preventive
shafts (1). After torque is broken on four bolts (9), (C-105 immediately after cleaning. Do not handle
remove planetary from holding fixture. unoiled bearings with bare hands.
2. Thread T101574 shaft guide into shaft (1). 4.

Inspect parts for corrosion damage to threaded
Press shaft out of planetary. Do not allow pinion to fall studs and stud holes before cleaning. No structural
out of planetary. Install T101332 planetary installing damage to threads or holes is acceptable.
66-85
BHT-205A1-CR&O
LOCKWIRE (C-405)
LOCKWIRE PATTERN FOR LOWER SURFACE
(C-405)
LOCKWIRE PATTERN FOR UPPER SURFACE
Figure 66-43. Upper transmission planetary lockwiring
66-86
BHT-205A1-CR&O
1. Shaft
2. Nut
3. Washer
4. Pinion gear
5. Inner race
6. Retainer
7. Roller
8. Nut
9. Bolt
10. Cup
11. Washer
12. Plate set
13. Spider
14. Retaining ring
15. Bearing
16. BoltA
17. Spacer
18. Nut
NOTES:
Used on 204-040-784-101 lower
planetary
Used on 204-040-784-005 lower
planetary VEE MARK
Figure 66-44. Lower transmission planetary (Sheet 1 of 2)
66-87
BHT-205A1 -CR&O
VIEW A - HOLDING FIXTURE (T101573) APPLICATION

POSITION FOR REMOVAL/INSTALLATION OF NUTS (2).
VIEW A - HOLDING FIXTURE (T101573) APPLICATION -

POSITION FOR REMOVAL/INSTALLATION OF NUTS (2).
POSITION FOR REMOVAL/INSTALLATION OF BOLTS (9).
VIEW C - ALIGNMENT FIXTURE (T101572) APPLICATION -

POSITION FOR REMOVAL OF BEARING (15).
Figure 66-44. Lower transmission planetary (Sheet 2 of 2)
66-88
BHT-205A 1-CR&O
66-59. NORMAL INSPECTION - LOWER 8. Inspect lower planetary gear wear pattern.
TRANSMISSION PLANETARY. (Refer to figure 66-46.) Replace gears that exceed
limits.
1. Inspect all parts visually for excessive wear
and damage. Inspect all threaded parts for damaged 66-60. REPAIR - LOWER TRANSMISSION
threads. PLANETARY.
2. Inspect pinion gears for chipped, broken, or

worn teeth. 1. Blend out any gouges, scratches, and nicks in
spider bearing bore. Replace spider if damage
3. Inspect bearing surfaces of rollers, races and exceeds 0.020 inch depth and/or if more than 20
pinion gears for spalling, scoring, pitting, brinelling, percent of the area of the bore is damaged.
indentations or corrosion damage.
2. Blend out small nicks, burrs, and scratches on
CAUTION: DO NOT HANDLE UNOILED BEARINGS. gear with fine india stone.
NOTE: Light scoring is acceptable in the center of

the races in the area contacted by the bronze retainer. 3. Blend out smal nicks, burrs and scratches on
splines with fine india stone (C-464). (Refer to figure
4. Inspect retainers (6, figure 66-44) for damage 66-45.)
and for evidence of imbedded bearing chips or other
steel particles in the tang on the retainers. 4. Replace all unserviceable parts.
5. Inspect upper surface of spider for corrosion. 66-61. REASSEMBLY - LOWER TRANSMISSION
PLANETARY.
6. Inspect the following parts by magnetic
particle method. Parts are indexed to figure 66-44. NOTE: Do not handle unoiled parts with bare hands.
Demagnetize all parts after inspection. (Refer to
BHT-ALL-SPMmanual. Refer to step 1 for assembly of 204-040-784-005
lower planetary and to step 2 for assembly of
INDEX NO. NOMENCLATURE 204-040-784-101 lower planetary.
1 Shaft 1. 204-040-784-005 lower planetary.

2 Nut
4 Pinion
Pinion
4 a. Obtain four new bearings (15, figure 66-44)
5 Inner Race and inspect for sharp edges at outer diameter of the
8Nut chamfer. Polish sharp edge lightly with 400 or finer
10 Cup sandpaper (C-423), if required. Exercise care to avoid
11 Washer damage to bearing. Clean bearing with solvent
12 12 Plate
Plate Set
Set (C-304) and coat with approved oil and drain.
13 Spider
16
16 Bolt
Bolt b. Heat spider (13) to 200°F (93°C), and
17 Spacer install in T101572 alignment fixture. Press bearings
into position. (Refer to figure 66-47 for illustration of
7. Inspect parts dimensionally and replace parts tool application.) Install four retaining rings (14,
that do not fall within inspection limits. (Refer to figure 66-44).
figure 66-45.)
c. Locate the V index marks on plate set (12).
NOTE: Wear limits are provided to show the required These marks must be in line when planetary is
fit between mating parts. It is not intended that all assembled. (Refer figure 66-33.) Select four holes in
dimensions be checked as a prescribed overhaul plate for installation of cups (10). Support plate
procedure; however, parts that show evidence of adjacent to hole and press cups into position. Note
wear or physical damage must be checked relative position of flange on plate set (12) and on cup
dimensionally. (10) to obtain correct installation. Install washers
66-89
BHT-205A 1-CR&O
PIN DIAMETER PIN DIAMETER
SPLINE TEETH PINION TEETH
1.3770

INCHES
1 SpiderArm ID 1.1245 1.1250

2 Cup OD 1.3752 1.3760
ID 0.5620 0.5635
3 Spider Spline Between Pins 6.3523 6.3682
4 Spider Shaft Bore ID 1.3750 1.3758
6 Pinion Gear ID 2.6969 2.6976
7 Inner Race OD 1.8297 1.8303
8 Inner Race ID 1.3750 1.3758
9 Pinion Gear Teeth Over Pins 3.9730 3.9793
10 Washer (204-040-789-1 & -3) ID1 1.3750 1.3765
Washer (204-040-789-1 & 3) ID 2 0.5650 0.5665
10 Washer (204-040-789-5 & -7) ID 1 1.3750 1.3765
Washer (204-040-789-5 & -7) ID 2 0.5690 0.5715
11 Nut OD 1.3752 1.3760
12 Plate - Shaft Bore ID 1.3750 1.3758
Figure 66-45. Lower transmission planetary wear limits
66-90
Pinion, Lower planetary assembly. Typical
side wear pattern far the ring gear
Pinion, Lower planetary assembly, sun gear

rids. Pinion is spalled in the flank. Any
spalling, scuffing. and pitting that cm be
detected with a probe having a 0.020 inch
radius is unacceptable.
BHT-205A1-CR&O
planetary installing pin, as it is pushed out through

- DRIVE the bottom. Use caution to prevent damage to shaft
(T101572-7) or plate set. Be sure that shaft (1) is seated. Remove
GUIDE T101574 shaft guide from shaft (1). Repeat for
(T101572-5)
(T 101572-5) remaining pinions. Check that pinions roll freely.
h. Apply anti-seize compound, (C-440), to

(T101572-3) thread of nuts (2) and install in shafts; do not torque
at this time.
i. Install T101573 holding fixture in a vise.

Position planetary on holding fixture as illustrated in
figure 66-44, view A. Torque nuts (2) 60 to 80
foot-pounds in diametrical sequence. Remove
planetary from holding fixture and reposition on
Figure 66-47. Lower transmission planetary holding fixture as illustrated in figure 66-44, view B.
bearinginstallation Torque bolts (9) 400 to 900 inch-pounds to obtain a
dimension of 1.3770 to 1.3780 inches between
(11) on cups with press, using a suitable hollow tool, plates adjacent to and on both sides of spider ball
so that force is applied to washer on flange surface joints. Use a T101562 gage block (go-no-go) to
adjacent to thread. check dimension.
d. Install four nuts (8) and washers (11) on j. Check with a 0.001 inch feeler gage to
lower half of plate set (12) in same manner noted in ensure that nuts (2) and shafts (1) are seated flat
step c. Be sure that nuts and washers are installed in against plates.
correct holes so that V on plates will align on NOTE: The 0.001 inch gage may slip partially
assembly and that flanges on plate set (12) are betweentheflangeofnutorshaftattheouteredgeof
outboard as illustrated. some points, but it must not go fully under the flange.
e. Position plate set (12) and spider (13) k. Check pinion gears (4) for free rotation.
together with Vee marks aligned. Apply anti-seize Check end clearance between rollers (7) and washers
compound, (C-440) under heads and on threads of (3). Clearance must be 0.001 to 0.003 inch.
bolts (9). Install bolts (9) and pull up snug but do not
torque. l. Secure nuts (2) and (8) in pairs with lockwire
(C-405), as illustrated in figure 66-48. Secure shafts
f. Assemble pinion gear (4), retainer (6), rollers (1) and bolts (9) in same manner.
(7), inner race (5) and washers (3) on T101332
planetary installing pin.
NOTE: Rollers (7) for one pinion must be from same LOCKWIRE
manufacturer. Check manufacturers identification (C-405)
mark on end of rollers.
Individual rollers (7) are not interchangeable and shall

not be mixed between roller sets. Rollers must be
replaced as complete sets. Both dash numbers, in
complete sets, may be used as a planetary assembly.
g. Install T101574 shaft guide, in shaft (1).

Position assembled planetary assembly in T101572
fixture. Position assembled pinion gear (4) in
Figure 66-48. Lower transmission planetary
planetary assembly. Press shaft (1) through plates lockwiring
and pinion gear from top and catch T101332
66-92
BHT-205A1-CR&O
2. 204-040-784-101 lower planetary. top and catch T101332 planetary installing pin, as it
is pushed out through the bottom. Use caution to
a. Obtain four new bearings (15, figure 66-44) prevent damage to shaft or plate set. Be sure that
and inspect for sharp edges at outer diameter of the shaft (1) is seated. Remove T101574 shaft guide
chamfer. Polish sharp edge lightly with 400 or finer from shaft (1). Repeat for remaining pinions. Check
sandpaper (C-423), if required. Exercise care to avoid that pinions roll freely.
damage to bearing. Clean bearing with solvent
(C-304) and coat with approved oil and drain. h. Apply anti-seize compound (C-440) to
threads of nuts (2) and install in shafts; do not torque
b. Heat spider (13) to 200°F (93°C), and atthistime.
install in T101572 alignment fixture. Press bearings
into position. (Refer to figure 66-47 for illustration of i. Install T101573 holding fixture in a vise.
tool application.) Install four retaining rings (14, Position planetary on holding fixture as illustrated in
figure 66-44). figure 66-44, view B. Torque bolts (16) 35 to 45
foot-pounds in diametrical sequence.
c. Locate the V index marks on plate set (12).
These marks must be in line when planetary is j. Remove planetary from holding fixture and
assembled. (Refer to figure 66-44.) Select four holes reposition on holding fixture as illustrated in figure
in each plate, keeping V index in line, for installation 66-44, view A. Torque nuts (2) 60 to 80 foot-pounds
of spacers (17). Support plate adjacent to hole and in diametrical sequence.
press spacers into position.
k. Check with a 0.001 inch feeler gage to
d. Install four nuts (18) and washers (17) on ensure that nuts (2) and shafts (1) are seated flat
lower half of the plate set (12) in same manner noted against plates
in step c. Be sure that nuts and washers are installed
in correct holes so that V on plates will align on NOTE: The 0.001 inchfeelergagemay slip partially
assembly and that flanges on plate set (12) are between the flange of nut or shaft at the outer edge at
outboard as illustrated. some points, but it must not go fully under the flange.
e. Position plate set (12) and spider (13) l. Check pinion gears (4) for free rotation.
together with V marks aligned. Apply anti-seize Check end clearance between rollers (7) and washers
compound (C-440) under heads and on threads of (3). Clearance shall be 0.001 to 0.003 inch.
bolts (16). Install bolts (16) and pull up snug but do
not torque. m. Secure nuts (2) and (18) in pairs with
lockwire (C-405), as illustrated in figure 66-37.
f. Assemble pinion gear (4), retainer (6), rollers Secure shafts (1) and bolts (16) in same manner.
(7), inner race (5) and washers (3) on T101332
planetary installing pin. 66-62. TRANSMISSION RING GEAR.
NOTE: Rollers (7) for one pinion must be from same 66-63. OVERHAUL - TRANSMISSION RING
manufacturer. Check manufacturers identification GEAR
mark on end of rollers.
66-64. DISASSEMBLY - TRANSMISSION RING
Individual rollers (7) are not interchangeable and GEAR.
should not be mixed between roller sets. Rollers must
be replaced as complete sets. Both dash numbers, in 1. Remove nut (11, figure 66-49), steel washer
complete sets, may be used in a planetary assembly. (12) and aluminum washer (13). Remove bolt (16)
with washers (14 and 15). Remove bushing (21) and
g. Install T101574 shaft guide, in shaft (1). gasket (19).
Position assembled planetary assembly in
204-040-009-1PAT-2D holding fixture. Position 2. Remove nut (10), steel washer (9) and
assembled pinion gear (4) in planetary assembly. aluminum washer (8). Remove bolt (3) with washers
Press shaft (1) through plates and pinion gear from (4 and 5). Remove housing (6) and gasket (7).
66-93
BHT-205A1-CR&O
1. Packing 13. Aluminum washer

2. Insert 14. Washer
3. Bolt 15. Steel washer
4. Steel washer 16. Bolt
5. Washer 17. Insert
6. Housing 18. Housing
7. Gasket 19. Gasket
8. Aluminum washer 20. Ring gear
9. Steel washer 21. Bushing
10. Nut 22. Packing
11. Nut 23. Tube
12. Steel washer
TOOL HOLE
Figure 66-49. Planetary ring gear
Remove tube (23) with packings (1 and 22) from top 3. Clean all parts with solvent (C-304). Use soft
of housing (6). bristle brush to dislodge stubborn deposits. All parts
66-65. CLEANING - TRANSMISSION RING may be cleaned with trichloroethane (C-334). Use
GEAR. vapor degreasing if desired.
1. Inspect parts for corrosion damage to stud 4. Dry parts with clean, lint-free cloths or dry
holes before cleaning. No structural damage to holes filtered compressed air.
is acceptable. is acceptable. 5. Coat parts with corrosion preventive (C-105)
2. Remove sealant from parts with plastic immediately after cleaning. Do not handle unoiled
scraper. parts.
66-94
BHT-205A 1-CR&O
66-66. NORMAL INSPECTION - TRANSMISSION 66-67. REPAIR/REPLACE - TRANSMISSION RING

RING GEAR. GEAR.
1. Visually inspect ring gear for wear or damage. 1. Rework minor chipping at ends of planetary
Inspect ring gear for chipped, broken or worn teeth. ring gear teeth if it can be accomplished within
Parts should be reoiled immediately after cleaning and following limits:
then inspected.
a. Blend out chipped area with fine india stone
2. Inspect external surface of ring gear for to effect a 0.015 inch radius. Rework area must not
corrosion. Lightly polish with fine emery cloth exceed0.020 inch from originalend of tooth.
(C-423) and clean by the following process:
2. Inspect reworked area by magnetic particle
a. Preparation of Cleaner - The cleaner shall method. No indication of cracks are permissible.
be prepared by thoroughly mixing one volume of Demagnetize planetary ring gear. (Refer to
cleaner (C-344) and three volumes of water. BHT-ALL-SPMmanual.)
b. Surface Preparation - Surfaces, which are 3. Replace parts that are not within allowable
to receive alcoholic phosphoric cleaner, shall be free wear imits.
of oil, grease, shop soil and paint. Precleaning shall be 66-68. REASSEMBLY - TRANSMISSION RING
accomplished, as required, by any acceptable
GEAR.
method.
1. Position ring gear (20, figure 66-49), 16 hole
c. Application Procedures - The cleaner shall
flange up, on work bench.
be applied to the metal surface by brushing or
swabbing (refer to Note). The cleaner shall remain in 2. Mount jet housing (18) and gasket (19) on the
contact with the metal surface for one to three first group of holes clockwise from tool hole
minutes and shall be followed by a thorough rinse. (205-040-134 housing will have jet retaining screw
hole down and aft at 5 o'clock position.) Install bolts
NOTE: The procedure may be repeated as required (16) with heads outboard, two washers (14) next to
to remove light rust. Apply cleaner to corroded area housing, an aluminum washer (13) next to inner
only, then rinse. surface of case and steel washers (12 and 15) next to
bolt head and nut (11). Prior to tightening castellated
d. Drying - Surfaces shall be dried using an nut, install the jet assembly to ensure proper
oven 150°F (66°C) maximum), clean dry rags, alignment at housing and ring gear holes. Tighten and
cloth, etc., or using compressed air which has been install cotter key. Install jet retaining screw and secure
filtered to render it oil and moisture free. with lockwire (C-405).
e. Treat per BHT-ALL-SPMmanual for corrosion 3. Install a second housing (18) and gasket (15) in
prevention. the next set of holes (clockwise). (205-040-134
housing will have jet retaining screw hole up and aft at
3. Inspect ring gear by magnetic particle method. 11 o'clock position.) Install bolts (16) with heads
Demagnetize all parts after magnetic inspection. outboard, two washers (14) next to housing, an
aluminum washer (13) next to inner surface of case
4. Inspect parts dimensionally and replace parts and steel washers (12 and 15) next to bolt head and
that do not fall within inspection limits. (Refer to nut (11). Prior to tightening castellated nut, install the
figure 66-26.) jet assembly to ensure proper alignment at housing
and ring gear holes. Tighten and install cotter key.
NOTE: Wear limits are provided to show therequired Install jet retaining screw and secure with lockwire
fit between mating parts. It is not intended that all (C-405).
dimensions be checked as prescribed overhaul
procedure; however, parts that show evidence of 4. Mount a jet housing (6) and gasket (7) on the
wear or physical damage must be checked last group of holes, clockwise from tool hole. Install
dimensionally.
66-95
BHT-205A1-CR&O-1
bolts (3) with heads outboard, washers (5) next to except bearings may be cleaned with trichloroethane
housing, aluminum washer (8) next to inner surface (C-334) by vapor degreasing, if desired.
of case and steel washers (4 and 9) next to bolt head
and nut (10). Prior to tightening castellated nut, 2. Dry parts with clean, lint-free cloths or dry
install the jet assembly to ensure proper alignment at filtered compressed air. Do not allow bearings to spin
housing and ring gear holes. Tighten and install cotter while drying.
key. Install jet retaining screw and lockwire (C-405).
3. Coat bearings with corrosion preventive
66-69. INPUT DRIVEN QUILL. (C-105) immediately after cleaning. Do not handle
unoiled bearings with bare hands.
66-70. OVERHAUL- INPUT DRIVEN QUILL.
4. Inspect parts for corrosion damage to holes
TOOLS REQUIRED before cleaning. No structural damage to holes is
acceptable.
T100965 Power Wrench Kit
T100968 Anchor Plate 66-73. NORMAL INSPECTION - INPUT DRIVEN
T101303 Socket QUILL.
66-71. DISASSEMBLY- INPUT DRIVEN QUILL. 1. Inspect all parts visually for damage and
excessive wear.
1. Remove twenty-four bolts and washers (1,
figure 66-50). 2. Inspect gear support case (2, figure 66-50) for
corrosion, and for loose bearing liner as follows:
2. Carefully tap gear support case (2) off
bearings. Remove shims (3 and 4) and identify for a. The maximum permissible depth of pitting,
reassembly. in area A, figure 66-51, is 0.020 inch except as
defined in step b. below. No more than 40 percent of
3. Remove screws (5) and lockring (6). Position area within any one inch square nor 20 percent of
T101303 socket on nut (7). Install T100968 anchor total area of any surface or diameter may be pitted.
plate and T 100965 power wrench on shaft (11) and Inspect area B carefully prior to any corrosion removal
loosen nut. Remove tools and nut (7). for evidence of corrosion in bolt holes and between
bearing liner and case. Any evidence of corrosion in
4. Support duplex bearings (8) in inner race and bolt holes or between liner and case is cause for
press out of shaft. Identify bearings for reassembly. rejection of part.
Bearings are a matched set and must be retained or
replaced in pairs. Remove bearing retainer plate (9). b. The maximum permissible depth of pitting
on lower flange only in area 1/32 inch below radius to
NOTE: Bearings (8) must be rigidly supported on the packing groove in area A, figure 66-51 is 0.030 inch
inner race around the full circumference so that the and is limited to no more than 40 percent of area
outer races are not loaded during bearing removal. within any one inch square of 20 percent of total area.
Inadequate support will result in damaged bearings Isolated pits in area A are acceptable to a maximum
and/or shaft. depth of 0.060 inch provided total area pitted in
excess of 0.030 inch does not exceed two percent of
5. Remove thirty-two bolts (10) from flange of area within any one square or 0.50 percent of total
shaft (11). Carefully tap or press spiral bevel gear (12) area of any surface or diameter.
off shaft.
3. Inspect nut (7, figure 66-50) for damaged
66-72. CLEANING - INPUT DRIVEN QUILL. threads.
1. Clean quill parts with solvent (C-304). Use soft 4. Inspect duplex bearings (8) for spalling,
bristle brush to dislodge stubborn deposits. All parts scoring, flaking, corrosion, and roughness when
rotated.
66-96
BHT-205A 1-CR&O- 1
1. Bolts and washers

2. Gear support case
3. Shim
4. Shim
5. Screws
6. Lockring
7. Nut
8. Duplex bearings
9. Bearing retainer plate
10. Bolts
11. Shaft
12. Spiral bevel gear
13. Collector
NOTE:
A Collector (13) is only used on 21 2-040-362-

103 main input gear quill.
Figure 66-50. Main input driven quill
66-97
BHT-205A 1-CR&O-1
figure 66-52, detail B. Minor pitting resulting from

corrosion is permissible within following limits:
(1) No more than 0.001 inch deep and no

more than 0.040 inch wide or 0.080 inch long.
AREA
A (2) No more than 0.002 inch deep and no
more than 0.040 inch wide or 0.100 inch long and
BEVEL GEAR SUPPORT CASE b. Surface roughness detectable by drawing a

probe along tooth in profile direction is cause for
rejection if pitting occurred on the mating member.
c. Grinding Scratches; Any scratches around

which pitting or other damage occurs are not
permissible.
Figure 66-51. Input driven quill corrosion
damage areasdamage areas d. Nicks, cuts, or dents caused by handling or
5. Inspect bearing retainer plate (9) for damaged by foreign material going through mesh during
threads. operation are permissible provided they are no more
than 0.003 inch deep and are no more than 0.020
6. Inspect shaft (1 1) for spalling, scoring, pitting, inch across in any direction, and cannot be felt with a
flaking, corrosion, and indentations on bearing probe having an end radius of 0.030 inch.
contact surfaces. Inspect splines for pitted, chipped,
or excessively worn teeth. Inspect threads for
defects. 10. Inspect the following parts by magnetic
particle (Code M) or fluorescent penetrant (Code F)
7. Inspect mating surfaces of shaft (1 1 ) and bevel
method as applicable. Demagnetize parts after
gear (12) for fretting damage. The maximum
magnetic inspection. Refer to BHT-ALL-SPMmanual.
acceptable depth of fretting (pitting) is 0.0005 inch. .
Index numbers are keyed to figure 66-50.
Pitting of measurable depth is acceptable only in the
area on the gear or shaft surface outside of the
diameter of the bolt holes and is not acceptable NOTE:
NOTE: Refer
Refer to
to steps
steps 10,
10, and
and 11.
11. for
for special
special
within 0.100 inch of the edge of the bolt hole.
inspection procedures for shaft ( 11).
8. Inspect bevel gear (12) for spalled, scuffed,
chipped, or dented teeth.
9. Inspect bevel gear (12) for pitting or corrosion INDEX NO. NOMENCLATURE CODE
damage as follows:
2 Gear Support Case F
a. Pitting of any magnitude resulting from 7 Nut M
surface fatigue during operation is not permissible.
This may appear as only a fine line of pin holes near 9 Bearing Retainer M
pitch diameter and be detectable only with a side light 11
source and a probe point of approximately 0.001 inch
radius. A more severe example of this is shown on Spiral Bevel Gear M
66-98
BHT-205A1-CR&O-1
11. Inspect shaft (11, figure 66-50) by magnetic b. Magnetize shaft by placing shaft between
particle method. The shaft must be inspected by all of contact heads of inspection equipment. Pass
the following steps using wet continuous method. approximately 2,000 amperes of dc current through
Use of fluorescent coated particles with ultraviolet shaft.
light is mandatory, The length of any indication shall
be determined by the residual method of c. Inspect shaft completely, inside and outside,
magnetization. for indications.
NOTE: If ac magnetic particle inspection equipment d. Place shaft inside coil such that long axis of
is used, use 60 percent of dc amperes specified. shaft is approximately 90 degrees to direction of
current flow in the coil. Magnetize shaft using
a. Thoroughly degrease shaft. approximately 1,000 amperes of dc current.
A Spiral Bevel Gear, Input Driven Gear Quill.

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

Gear is spalled on the face of the tooth. Any
B spalling of this type is unacceptable, and both
the gear and the mating pinion should be re-
placed - even though the meting pinion may
not be spalled.
Input Pinion. Input drive quill wear pattern showing

a non-uniform wear pattern with a band of heavy
C wear in the flank. This is the maximum accepta-
ble for this condition.
Figure 66-52. Input driven quiIl wear pattern

BHT-205A1 -CR&O-1
e. Inspect shaft completely for indications. acceptable if length of indication does not exceed
1/16 inch in length and provided indication is 1/8 inch
f. After completion of inspection, demagnetize or more from end of bearing journal. Indications
shaft and check with pocket field indicator or within 1/8 inch of end of bearing journal or that break
compass to assure demagnetization. over end of bearing journal are cause for rejection.
Not more than four indications, within above limits,
12. Evaluate defects noted during magnetic are allowed on each bearing journal.
particle inspection of shaft (11) as follows. (Refer to
figure 66-53.) (3) Circumferential indications, or
indications that are more than 15 degrees off long
a. Indications interpreted as cracks are cause axis of shaft in area AA, figure 66-53, are cause for
for rejection regardless of size or location. rejection.
b. Surface or subsurface indications or (4) Indications more than 15 degrees off long
stringers, shuts, nonmetallic inclusions, bursts, laps, axis, tranverse or circumferential to long axis, are
or seams will be acceptable provided they are within acceptable in spline areas provided they do not
all following limits: exceed 1/8 inch length. Not more than one indication
is allowed per tooth, and not more than six to each
(1) Indications of defects parallel (plus or spline area. All other indications in spline area are
minus 15 degrees) to long axis of shaft are cause for rejection.
acceptable, provided length of indication does not
exceed 1/8 inch and provided other limitations herein (5) Indications in threaded sections are
are not exceeded. Not more than two such cause for rejection regardless of size or location in
indications allowed in any two square inches of area AA, figure 66-53.
surface area.
(6) Indications of subsurface discontinuities
(2) Circumferential indications, or that break a tranverse face shall not exceed 0.031
indications more than 15 degrees off long axis of inch in length or cross section.
shaft are acceptable in area BB, figure 66-53,
provided length of indications does not exceed 1/4 (7) Indications or surface discontinuities that
inch. Not more than two such indications shall be break over corners or run into fillets, splines, or
allowed in any one square inch of surface area. threads, are cause for rejection.
Indications on bearing journal in area BB as shown are
(8) Indications caused by a change in section
are acceptable.
(9) Strong magnetic indications where

considerable buildup is present, indicating that defect
has considerable depth and/or cross section shall be
cause for rejection regardless of location.
13. Inspect parts of input driven quill

dimensionally as required. (Refer to figure 66-54.)

Figure 66-53. Input gear quill shaft magnetic dimensionally.
inspection areas
66-100
BHT-205A 1-CR&O- 1
NOMENCLATURE MIN. MAX.

INCHES
1 Bearings ID 4.7232 4.7236

OD 6.6923 6.6929
2 Spline (Use 0.1920 In. Diameter Pins) Over Pins 4.7894 4.7938
3 Shaft Bearing Seat OD 4.7250 4.7255
4 Support Case Liner ID 6.6919 6.6931
5 Gear ID 7.6000 7.6008
6 Shaft Gear Seat OD 7.6007 7.6015
7 Shaft Bearing Race OD 5.1537 5.1545
8 Spline (Use 0.1920 In. Diameter Pins) Over Pins 4.8948 4.8993
9 Bearing OD 6.4983 6.4990
10 Main Case Liner ID 6.4980 6.4990
Figure 66-54. Input driven quill wear limits
66-101
BHT-205A1-CR&O-1
66-74. REPAIR - INPUT DRIVEN QUILL. to back, measure width of outer races and record as
dimension C, figure 66-55.
1. Replace all parts that exceed inspection limits.
NOTE: To determine shim thickness for
2. Replace all unserviceable parts. 204-040-362-13 main input driven gear refer to step 5.
Refer to step 6. for 204-040-362-103 main input driven
3. Dress splines and gear with fine india stone, if gear.
small nicks, burrs, or scratches are visible. (Refer to
figure 66-54.) 5. Determine thickness of shims (1 and 2, figure I
66-55) for 204-040-362-13 main input driven quill. Refer
4. Repair minor damage to bevel gears by lightly to figure 66-55 and following substeps:
polishing with fine india stone to remove any material
which protrudes above original ground surface. a. Determine thickness of shim (1) between
bearing and liner as follows:
5. Replace bevel gear support case which has
corrosion damage that would affect its function or
structural integrity. (Refer to figure 66-51.) Remove Record following dimensions.
corrosion in area A by acid bath (Refer to BHT-ALL-SPM
manual.) Dim. C - Measure width of bearing outer races. (Refer
to step 4.)
66-75. REASSEMBLY - INPUT DRIVEN QUILL. Dim. X - Etched on support case.
1. Clean all parts with solvent (C-304) and drain.

Dim. Y - Etched on support case.
2. Coat all parts with approved transmission oil (refer
to BHT-205A1-MM-1 manual) and drain. Dim. R - Etched on shaft.
CAUTION: REQUIRED THICKNESS OF SHIMS (3 Dim. T - Etched on bearing retainer plate.

AND 4, FIGURE 66-50) SHALL BE DETERMINED. IT
IS ESSENTIAL UTMOST PRECISION BE USED Dim. B - Given: 3.0610 to 3.0630 inch.
WHEN ASSEMBLING THIS QUILL.
(2) Typical example:
AN107607 BOLT IS NOT LONGER AUTHORIZED TO
ATTACH 204-040-701 BEVEL GEAR TO 204-040-324
SHAFT, USE 214-040-117-5 BOLT.
NOTE: During assembly of spiral bevel gear to shaft, Dim. B (average) 3.0620
ensure mating surfaces are dry. Use of any lubricant to
ease installation of gear on shaft will result in torque loss Dim Y +1.4543
of attachment bolts and subsequent fretting damage. Dim. 4.5163
3. Position spiral bevel gear (12) on shaft (11) with

holes aligned. Tap or press gear on flange. Coatthreads II.
of bolts (10) with approved lubricant and install. Torque Dim R 1.3095
all bolts evenly to 390 inch-pounds then individually
break the bolt torque and retorque to 300 to 325
inch-pounds. Secure bolt heads in pairs with lockwire Dim. C 1.7248
(C-405) around heads, not over tops.
4. Check duplex bearings (8) to confirm that serial Dim. X +1.4520

number is same on both bearings. Hold bearings back Dim. 4.4863
66-102 Rev. 2
BHT-205A 1-CR&O-1
1. Shim (Shim to obtain 0.001 to 0.005 inch

pinch on bearing)
2. Shim (shim to obtain dimension B)
Figure 66-55. Input driven quill shimming (204-040-362-103)
III. V.
Dim. I above 4.5163 Dim. T 0.2775
Dim. II above -4.4863

Required thickness for shim (3) Dim. 0.0300
(3) Recheck computation of shim thickness. Pinch required +0.0030

(0.001 to 0.005) Dim. 1.7348
b. Determine thickness of shim (2) between
case and bearing retainer as follows:
VI.
(1) Typical example:
Dim. IV above 1.7548
IV.
Shim determined at III 0.0300 Dim. V above -1.7348

Required thickness for shim (2) Dim. 0.0200
Dim. C +1.7248
Dim.1.7548 (2) Recheck computation of shim thickness.
66-103
BHT-205A 1-CR&O-1
6. Determine thickness of shims (2 and 3) for (2) Typical example:

204-040-362-103 main input driven quill. Refer to
figure 66-56 and following substeps: I.
a. Determine thickness of shim (3) between Dim. B (average) 3.0620

bearing and liner as follows: Dim. Y +1.4543
Dim. 4.5163
(1) Record the following dimensions.
II.
Dim. C - Measure width of bearing outer races. (Refer
to step 4.) Dim. R 1.3095
Dim. X - Etched on support case. Dim. C 1.7248
Dim. Y - Etched on support case. Dim. X +1.4520

Dim. 4.4863
Dim. R - Etched on shaft.
III.
Dim. S - 0.0330 (Actual measured dim.)
Dim. I above 4.5163
Dim. T - Etched on bearing retainer plate.
Dim. II above -4.4863
Dim. B - Given: 3.0610 to 3.0630 inch. Required thickness for shim (3) Dim. 0.0300
1. Collector Measure actual thickness

2. Shim Shim to obtain 0.001 to 0.005
pinch on bearing
3. Shim Shim to obtain dimension B
Used on 204-040-362-103 main input driven gear quill
Figure 66-56. Input driven quill shimming (204-040-362-103)
66-104
BHT-205A1-CR&O-1
(3) Recheck computation of shim thickness. NOTE: The etched marks placed on bearings by
bearing manufacturer to mark high point of race run
b. Determine thickness of shim (2) between
tween case out.
and bearing retainer as follows:
9. Press duplex bearings (8) inner races to seat
(1) Typical example: against shoulder of shaft (11). Install retaining nut (7).
Position T101303 socket over nut. Assemble T100968
IV. anchor plate and T100965 power wrench on shaft.
Torque bearing retaining nut to low side of 150 to 200
Shim determined at III 0.0300 foot-pounds. (This is 13-1/2 to 18 foot-pounds on
Dim. C +1.7248 torque wrench when using T100965 power wrench
Dim.1.7548 kit.)
V.
10. Remove tools as necessary to place lockring
Dim. T 0.2440 (6) on nut. Readjust torque, if necessary, by tightening
within torque limits until screw holes line up. Install two
Dim. S 0.0330 screws (5) at opposite sides of shaft and secure each
Dim. Y 1.4540 with lockwire to a hole in edge of lockring (6).
Pinch required 0.0030
(0.001 to 0.005) Dim. 1.7340
1.7340 11. Check assembly on surface plate with vernier
height gage and dial indicator. Measure dimension B,
VI. figure 66-55, at several points approximately 90
Dim. IV above degrees apart. Measurements must be between
3.0610 and 3.0630 inches. If dimension is not
Dim. V above 1.7340 obtained, a damaged shim or shim of incorrect
Required thickness for Dim. 0.0208 thickness may be the cause. Repeat steps 4 through
shim (2) (Use 0.021I shim)
shim) 11. It is imperative to obtain proper dimension, as
failure to do so will cause improper backlash and gear
(2) Recheck computation of shim thick,ness. wear pattern.
7. Place shim (3, figure 66-50) in liner of gear 12. Check bearings for free rotation.
support case (2). Install collector (13). Press bearings
into case back-to-back. Install twenty-four bolts (1),
with washers under heads, through case and shim (4) 66-76. MAIN INPUT QUILL.
into retainer plate (9). Torque bolts evenly and secure
in pairs with lockwire. 66-77. OVERHAUL - MAIN INPUT QUILL (205-
040-263-001, -003 AND -111).
CAUTION: ENSURE THAT BEARINGS ARE
PROPERLY INSTALLED BACK-TO-BACK. ENSURE TOOLS REQUIRED
THAT SHIMS (3, AND 4) ARE NOT DAMAGED T101306 Wrench, External Spline
DURING INSTALLATION OF BOLTS. ENSURE THAT T101362 Sleeve
BOLTS (1 AND 10)ARE PROPERLY LOCKWIRED.
T101885 Plate Assembly
NOTE: If the shaft (11) is being replaced, vibro etch

index mark on new shaft same as an old shaft. 66-78. DISASSEMBLY - MAIN INPUT QUILL.
8. Position gear support case (2) on shaft (11). 1. Remove retaining ring (12, figure 66-57),
Align bearing (8) vibro etched O on ends of inner races grease retainer (11), and packing (10) from outer race
with index marks on shaft. See NOTE following step 2.
15 JAN 2004 Rev. 3 66-105

BHT-205A1-CR&O-1
FREE INPUT COUPLING LOCK AND

WHEEL LOOKING INBOARD DRIVE
DRAG SPRING
VIEW B
NOTEAPEX MARKS (of "V")
1. Shield 14. Retainer

2. Bearing 15. Sleeve
3. Seal wear sleeve 16. Shim plate
4. Freewheelingclutch outer race 17. Shim
5. Freewheeling clutch inner race 18. Triplex bearing
6. Nut 19. Plate
7. Lock spring 20. Washer
8. Freewheeling clutch assembly 21. Nut
9. Bearing 22. Pinion
10. Packing 23. Plug
11. Grease retainer 24. Packing
12. Retaining ring 25. Packing
13. Seal 26. Union
205A1-R-66-57
Figure 66-57. Main input quill (205-040-263-001 and -003)
66-106 Rev. 2
BHT-205A1-CR&O-1
(4). Remove lock spring (7). Use T101306 wrench to 66-79. CLEANING - MAIN INPUT QUILL.
remove retaining nut (6) from outer end of pinion (22),
hold inner ed of pinion with 3/4 inch square drive 1. Inspect parts for corrosion damage of holes
extension. before cleaning. No structural damage of holes is
acceptable.
2. Remove freewheeling assembly from pinion (22).
2. Remove sealant with plastic scraper.
Support freewheeling clutch outer race (4) and press
freewheeling clutch inner race (5) with outboard bearing 3. Clean quill parts with solvent (C-304). Use soft
(9) and freewheeling clutch assembly (8) out of bristle brush to dislodge stubborn deposits. All parts
freewheeling clutch outer race (4). Remove outboard except bearings may be cleaned with trichloroethane
bearing, (9) and freewheeling clutch assembly (8) from (C-334) by vapor degreasing, if desired.
freewheeling clutch inner race (5). Inspect freewheeling
clutch in accordance with paragraph 66-80. 4. Dry parts with clean, lint-free cloths or dry filtered
compressed air. Do not allow bearings to spin while
3. Remove retainer (14), shield (1), and bearing (2) drying.
from freewheeling clutch outer race (4).
5. Coat bearings with corrosion preventive (C-105)
immediately after cleaning. Do not handle unoiled
4. Remove nuts (21) and washers (20). Support
sleeve (15) and remove triplex bearings (18), pinion
(22), and shim (17). Remove shim plate (16).
66-80. INSPECTION - MAIN INPUT QUILL.
NOTE: Shim plate (16) must be identified for
reinstallation on same sleeve from which it was 1. Visually inspect all parts for damage or excessive
removed. Shim plate must be removed for fluorescent wear. Inspectgearandsplinesforchipped orwornteeth.
penetrant inspection of sleeve. Inspect gear for scoring, pitting and spalling. Inspect
sleeve and seal ring for corrosion or damage. Inspect
5. Remove seal (13) from sleeve (15) using suitable bearings for chips, cracks, scoring, spalling, pitting,
3-leg gear puller (with legs turned out) and a plate marring, flaking, and corrosion.
across the outer end of the pinion.
2. Inspect the following parts by magnetic particle
(M) or fluorescent penetrant (F) method as indicated.
6. Support inner races of triplex bearings (18) with Index numbers are keyed to figure 66-57. Demagnetize
T101885 plate and press pinion shaft out of bearings. all parts after magnetic inspection.
Secure bearings together.
2A. Inspect freewheeling clutch 205-040-250
7. Remove seal wear sleeve (3) from freewheeling (Formsprag).
clutch outer race (4) as follows:
a. Visually inspect clutch assembly for wear or
damage. Use a 3X or 5X glass as required. Do not
a. Use an end mill or hand grinder to cut a groove disassemble clutch assembly during inspections of
almost through the seal wear sleeve. Avoid cutting steps a through h. Replace assembly if any of the
through the seal wear sleeve and damaging the following conditions exist.
freewheeling clutch outer race (4).
b. Inspect retainer for bent or distorted cross bars
b. Strike the seal wear sleeve with a hard rubber and flanges (figure 66-57A).
mallet to break the uncut portion and remove sleeve
from race. c. Check fit of retainer by installing clutch in outer
race. Retainer shall be round and not bind in outer race.
c. Remove old adhesive from outer race with d. Check for freedom of sprags in retainer slots.
plastic scraper and abrasive pad (C-407) or use paint Sprags shall not bind in retainer
remover (C-436).
e. Inspect retainer for wear on outer diameter and
d. Inspect outer race for damage which may have on side flanges. Wear in excess of 0.004 inch depth is
been incurred during removal of seal wear sleeve. not acceptable.
Rev. 2 66-106A
BHT-205A1-CR&O-1
f. Inspect retainer, sprags, and springs for n. Inspect garter spring outer diameter and sides for
corrosion. No corrosion pitting is acceptable. wear by viewing through empty retainer slot (figure
66-57A). Wear in excess of 0.0015 inch depth is not
g. Inspect sprags for heat discoloration, cracks, acceptable.
chips, spalling, or surface breaking which may be from
scuffing or scoring. Heat discoloration, cracks, chips,
spalling (including flanking of formchrome layer), flanges for wear. Wear in excess of 0.004 inch depth is
scuffing, or scoring are not acceptable.
not acceptable (figure 66-57A).
h. Inspect sprag inner and outer cam surfaces for
wear using a 3X or 5X glass and good light. Flat wear p. Install sprag in retainer slot by inserting notch at
bands which are observable are not acceptable, lower end of sprag over lower sprag. Pull an adjacent
regardless of width, if they extend more than 1/3 length sprag inward to uncover upper spring. Lift spring
of sprag. Light polished areas are acceptable. sufficiently to install in upper notch of sprag being
installed. Verify correct orientation of sprag to other
i. Inspect sprag inner and outer cam surfaces for sprags (figure 66-57A).
load contact pattern (figure 66-57A). An inner and/or
outer cam load contact pattern within 0.030 inch of
respective high-load edge of sprag cam is not q. Repeat sprag removal and inspection operations,
acceptable. step a. through q. on three other sprags approximately
equally spaced around retainer.
CAUTION: THE CLUTCH SHALL NOT BE

COMPLETELY DISASSEMBLED FOR INSPECTION. NOTE: Refer to BHT-ALL-SPM manual for approved
ONLY ONE SPRAG SHALL BE REMOVED AT A TIME fluorescent penetrant material.
AND BE REINSTALLED IN SAME ORIENTATION AS
REMOVED. IF MORE THAN ONE SPRAG IS
INADVERTENTLY REMOVED, REASSEMBLY SHALL ITEM NOMENCLATURE CODE
BE VERIFIED (FIGURE 66-57A).
4 Freewheeling Clutch Outer Race M
j. Degrease clutch and allow to dry. 5 Freewheeling Clutch Inner Race M
6 Nut M
k. With clutch lying on a flat surface, select one sprag 15 Sleeve F
and remove from retainer sufficiently to lift garter spring 22 Pinion M
out of sprag end notch and release sprag (figure
66-57A).
3. Inspect parts dimensionally and replace parts that
do not fall within inspection limits. (Refer to figure
I. Inspect sides of sprag for wear (figure 66-57A).
Inspect corners of sprag cam surface for chips, dents,
or loss of material. Wear in excess of 0.002 inch from
original surface, chips, or dents is not acceptable. NOTE: Wear limits are provided to show the required
m. Inspect inside notch at end of sprag for wear dimensions be checked as a prescribed overhaul
caused by garter spring. Wear in excess of 0.002 inch procedure; however, parts that show evidence of wear
depth is not acceptable. or physical damage must be checked dimensionally.
66-106B Rev. 2
BHT-205A1-CR&O-1
CLUTCH RETAINER
ARROW INDICATED
205A1-R-66-57A-1
Figure 66-57A. Clutch assembly (Sheet 1 of 4)
Rev. 2 66-106C
BHT-205A1-CR&O-1
SPRAGOUTER CAM SURFACE
0.030 IN.
RETAINERCROSSBAR
OUTERCAM SURFACE
LOAD PATTERN
P/N SIDE
HIGH LOAD CAM EDGE
INNERCAM SURFACE OVER RUNNING PATTERN

LOAD PATTERN
P/N SIDE
HIGH LOADCAM EDGE
NOTE:
Replaceclutch if contact load pattern is within 0.030 inch of
edge of sprag cam.
205A1-R-66-57A-2
Figure 66-57A. Clutch assembly (Sheet 2)
66-106D Rev. 2
BHT-205A1-CR&O-1
FREEWHEELINGCLUTCH - REMOVALOR INSTALLATIONOF SPRAG
OUTERCAM
SPRAG
WEAR CAUSED BY SPRING BUMPER
0.002 IN. MAX.
DEPTH OF WEAR
ACCEPTABLE
SPRAGBUMPER
SPRAG FRONT FLAT
MAX. DEPTH OF
WEAR ACCEPTABLE
0.002 IN. 0.002 IN. MAX.
INNERCAM DEPTH OF WEAR ACCEPTABLE
205A1-R-66-57A-3
Rev. 2 66-106E/66-106F
BHT-205A1-CR&O-1
MASKING TAPE
CROSSBAR WEAR CHECK FULL

LENGTH OF CROSSBAR BOTH SIDES
0.004 IN. MAX. CHECK ALL FOUR CORNERSOF
ACCEPTABLE DEPTH OF WEAR SPRAG POCKET WORN SHARP
CORNERIS NOTACCEPTABLE
RETAINER FLANGE WEAR CHECK
BOTH ENDS OF POCKET 0.004 IN.
MAX. ACCEPTABLE
DEPTH OF WEAR
SPRING WEAR CHECK BOTH
SPRINGS WEAR IN EXCESS OF
0.0015 IN. INTO SPRING WIRE
DIAMETER IS NOT ACCEPTABLE
MASKING TAPE
A-A-883, TYPEI
FREEWHEELINGCLUTCH - RETAINERAND SPRINGWEAR
ARROW SHOWSDIRECTION
OUTERRACEDRIVES
ARROW INDICATING
CLOCKWISELOOKING
INTO SHAFT DURING
INSTALLATION
205A1-R-66-57A-4
Rev. 2 66-107
BHT-205A1-CR&O-1
DETAIL A
MIN MAX
1 Shaft OD 3.1500 3.1505

2 Sleeve ID 5.5110 5.5117
3 Race OD 5.3538 5.3560
4 Shaft Splines (Use 0.1920 In. Dia. Pin) Over Pins 3.2917 3.2952
5 Inner Race Splines (Use 0.1440 In. Between 2.8427 2.8456
Dia. Pin) (See Detail A) Pins
6 Race ID 5.1180 5.1191
7 Bearing OD 5.1174 5.1181
8 Race OD 3.7397 3.7412
9 Bearing ID 3.7397 3.7403
10 Clutch Outer Race ID 4.8120 4.8130
(Dia. must not vary more than 0.0002 In.)
11 Clutch Inner Race OD 4.0636 4.0646
12 Bearing Inner Race ID 3.1491 3.1495
13 Bearing Outer Race OD 5.5113 5.5118
14 Case ID 6.7500 6.7521
15 Sleeve OD 6.7479 6.7500
16 Main Case Liner ID 3.5426 3.5434
17 Bearing OD 3.5428 3.5433
18 Shaft OD 2.0090 2.0096
NOTE
Use pins with one side ground flat to

0.115 inch to provide clearance
between pins and root of spline teeth.
Figure 66-58. Main input quill wear limits
66-108
BHT-205A1-CR&O-1
AREA
(OUTSIDE OF
AREA
DIA A
INSP
REF LTR CHARACTERISTIC PROCEDURE LIMIT
Dia A Wear Measure 6.7521 Inches (171.503 mm) maximum
Area B Mechanical / Visual Only superficial corrosion that can be removed by hand polishing
Corrosion Damage with abrasive pad (C-407, BHT-ALL-SPM) Is permitted.
Area C Mechanical / Visual / 0.010 inch (0.254 mm) maximum depth and no more than
Corrosion Damage Measure 50% of an area In 1 square Inch (646.161 square mm) with a
minimum of 0.5 Inch (1.27 mm) circumferential distance between
repairs and no more than 4 repairs allowed for the surface.
Maintain 0.25 Inch (6.35 mm) radius minimum and 63 AA surface
finish In the repaired areas.
Dia D Wear Measure 3.5434 Inches (90.0 mm) maximum
205A1CRO_66000_0058A 001
Figure 66-58A. Main case assembly (204-040-353) input bore damage and wear limts
15 JAN 2004 Rev. 3 66-108A

BHT-205A1-CR&O-1
C
SIDE OF
B)
DIA A
B
INSP
REF LTR CHARACTERISTIC PROCEDURE LIMIT
Dia A Wear Measure 6.7521 inches (171.503 mm) maximum
Area B Mechanical / Visual Only superficial corrosion that can be removed by hand polishing
Corrosion Damage with abrasive pad (C-407, BHT-ALL-SPM) Is permitted.
Area C Mechanical / Visual / 0.010 Inch (0.254 mm) maximum depth and no more than
Corrosion Damage Measure 50% of an area In 1 square Inch (646.161 square mm) with a
minimum of 0.5 Inch (1.27 mm) circumferential distance between
repairs and no more than 4 repairs allowed for the surface.
Maintain 0.25 Inch (6.35 mm) radius minimum and 63 AA surface
finishin the repaired areas.
Dia D Wear Measure 3.5434 Inches (90.0 mm) maximum
205A1CRO_66000 0058B_001
Figure 66-58B. Main case assembly (212-040-053) input bore damage and wear limts
66-108B Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
4. Replace pinion that has improper wear pattern. c. Any grinding scratches around which pitting
(Refer to figure 66-59.) Replace pinion that is spalled or other damage occurs are not permissible.
or that is scuffed beyond the limits shown. If metal
particles are found in the transmission during d. Nicks, cuts, or dents caused by handling or
disassembly, or if there is evidence of metal particles by foreign material going through gear meshes during
going through gear meshes, gear teeth should be operation are permissible provided they are no more
carefully examined for indentations and cuts. Replace that 0.003 inch deep and are no more than 0.020
input pinion (22, figure 66-57), if damage exceeds inch across in any direction, and cannot be felt with a
the following limits: probe having an end radius of 0.030 inch. If gear or
pinion is acceptable within these limits, the damaged
a. Pitting of any magnitude resulting from areas should be lightly polished with a fine india stone
surface fatigue during operation is not permissible. to remove any material that may protrude above the
This may appear as only a fine line of pin holes near original ground surface.
the pitch diameter and be detectable only with a side
light source and probe point of approximately 0.001 5. Visually inspect retaining ring (12 figure
inch radius. Minor pitting, resulting from corrosion, is 66-57), grease retainer (11), and retainer (14) for
permissible within the following limits: deformity.
(1) No more than 0.001 inch deep and no 6. Visually inspect bearings (2 and 9) for
more than 0.040 inch wide or 0.080 inch long. corrosion, cracked or broken retainers, and for
(2)than
No 0.002
more inch security of outer race holding rings (this bearing has a
morethan 0.040 inch wide or 0.100 inch long
more than 0.040 inch wide or 0.100 inch long and and split outer race). Check for smoothness of bearing
located on the outer (i.e. adjacent to the heel) half of rotation.
the face of the tooth and above the pitch line; or
located outside of the wear pattern and outside of the (4) 7. and
Visually inspect freewheeling clutch outer race
free wheeling clutch inner race
root radius. (4) and freewheeling clutch inner race (5) for
corrosion and excessive wear. Brinelling or
b. Surface roughness detectable by drawing a indentations on either race, which may be measured
probe along the tooth in the profile direction is cause or felt with a probe having an end radius of 0.030
for rejection if pitting occurred on the mating inch, is cause for rejection of the race and clutch.
member. Black oxide removal from inner race is not sufficient
66-81. REPAIR/REPLACE - MAIN INPUT QUILL.
1. Replace all parts that exceed dimensional

limits or which are unserviceable according to
inspection criteria.
2. Dress splines and gear with fine india stone if

small nicks, burrs, or scratches are visible.
Input Pinion. Input drive quill wear pattern
showing a nonuniform wear pattern with a band of 3. Triplex bearings used are marked with serial
heavy wear in the flank. This is the maximum numbers and must be installed in matched sets.
acceptable for this condition. Triplex bearings are installed with a mark on outer
races aligned as shown in figure 66-57.
4. Replace studs if damaged or loose. (Refer to

Figure 66-59. Main input quill pinion wear pattern BHT-ALL-SPM manual.)
66-109
BHT-205A1-CR&O-1
5. Corrosion pitting is permissible on the roller 4. If a Formsprag clutch is being used, observe
bearing surface on the main input pinion within the the following procedures during installation.
following limits:
a. Install clutch (8) with part number and drive
a. Outside of the roller path, the maximum direction arrow toward the flange side of outer race
depth of pitting is 0.010 inch, and the affected area (4).
must be no more than 0.10 inch across in any
direction, and the total affected area must not exceed b. Using a suitable size packing around the
10 percent of the circumference of the bearing outside of the clutch to hold the sprags down,
surface. position clutch between inner and outer races of
couplings.
b. If this condition exists, an inspection must
c. Using both hands, slowly rotate outer race
be accomplished after green run to determine that the
location of the roller path is such that the part is counter-clockwise while pushing clutch into position
acceptable in this build up. with thumbs. Do not force clutch in place with drift or
other mechanical means. After installation, remove
packing used to hold the spags down.
66-82. REASSEMBLY - MAIN INPUT QUILL. 5. Press outboard bearing (9) in place between
freewheeling clutch inner race (5) and freewheeling
clutch outer race (4). Install spacers of same
NOTE: Clean and coat all parts with approved thickness as grease retainer (11) and install retaining
transmission oil (refer to BHT-205A1-MM-1 manual) ring (12) temporarily to keep coupling intact during
prior to reassembly. handling.
1. Position curvic coupling end of freewheeling 6. Measure depth of bearing seat in sleeve (15)
clutch outer race (4, figure 66-57) down and press from inner face of liner flange to inboard end surface
bearing (2) into inboard end of race. (Press on outer where studs are installed. Record this dimension.
race of bearing only.) Install shield (1) and retainer
(14). 7. Hold triplex bearing (18) and measure width of
outer races of the three bearings individually and take
2. Turn flanged end of freewheeling clutch outer sum of the three. Record this dimension.
race (4) up. Press longest shoulder of freewheeling
clutch inner race (5) down through inboard bearing 8. Prepare shim (17) to provide 0.000 to 0.001
(support inner race of bearing to prevent damage). inch pinch on bearing outer races.
3. Place T101362 sleeve over outboard end of NOTE: Shims (17) consists of 0.003 and 0.002
freewheeling clutch inner race (5). Place freewheeling inch lamination on opposite sides.
clutch assembly (8), with sprag cage flanges inboard,
down over sleeve to position between inner and outer
races of coupling. Ensure that drag springs on inner Example:
cage of clutch are down past shoulder of outboard Depth of sleeve
bearing seat on freewheeling clutch inner race (5). liner 3.0709
Remove T101362 sleeve. Width of bearing 30409
0.0300 Shim for
0.000
NOTE: Do not allow freewheeling clutch assembly pinch
to slip outward on inner race during assembly. If this
occurs, drag spring will probably hold outboard +0.001
bearing off its seat, preventing installation of grease 0.031 Shim for
retainer, and will require disassembly of coupling to 0.001
correct the condition. pinch
66-110
BHT-205A1-CR&O-1
9. Position shim (17) of required thickness, in 15. Install seal wear sleeve (3) on coupling outer
sleeve (15). race (4) as follows: (Refer to figure 66-57 and 66-60.)
NOTE: Inspect and verify that triplex bearings (18) NOTE: Precautions must be taken during
are all marked with the same serial number and are accomplishment of the following steps to keep the
lined up with apex of V outboard seal wear sleeve and coupling outer race clean. If this
is not done, an unsatisfactory bond may result. Wear
10. Locate dull burr mark (on stamped letter "O") clean white gloves when handling parts and change
on inner race of each bearing. Mark a line with a felt gloves when they become soiled. Cover work bench
tip pen across the inner diameter of each bearing in with clean kraft paper which is grease, oil and wax
line with this mark. Bearings are to be installed with free. Avoid contact with mold release agents such as
mark on inner races in line. silicone, wax, oil, grease, etc. The work area where
bonding is done must be maintained at 65 ° to 82°F
11. Aling V mark on outer races of triplex bearing (18 ° to 28°C) with relative humidity below 75
(18) set as illustrated and press bearings into sleeve percent. It must be dust free to the extent that
(15). Install plate (19), washers (20), and nuts (21). bonding operations are not affected.
Secure nuts in pairs with lockwire (C-405).
12. Align felt tip pen index marks on bearing inner NOTE: Bonding steps must be accomplished
races. Locate vibro-etched mark on exposed sides of without delay between steps. Four hours is the
bearing inner races, and position pinion (22) so that maximum time between sandblasting and the
vibro-etched mark on pinion is in line with mark on succeeding steps.
bearing inner races.
a. Mask the outer diameter of a new seal wear
NOTE: These index marks are vibro-etched on parts sleeve. Mask the coupling outer race all over except
by the manufacturer at assembly and are used to the surface which mates with the seal wear sleeve
detect any movement of bearing races on pinion. and adjacent 0.062 inch radius.
These marks should be added to any replacement
parts at reassembly and should be located after b. Sandblast the unmasked surfaces of these
aligning the inner races so that the dull burr marks are parts with 60 grit garnet at 5 to 10 psi and remove
all aligned. residue. Wrap parts in barrier material (C-427) after
sandblasting.
13. Insert shaft of pinion (22) into bearings from
stud end of sleeve (15). Support inner races of triplex c. Apply grease removing primer, to the
bearings (18) and press input pinion (22) into unmasked portion of the coupling outer race only;
bearings until seated. Check pinion and bearings for steps d. through g. are not applicable to the seal wear
free rotation. sleeve.
14. Install new seal (13) in sleeve (15)as follows: d. Stir the primer (C-345) thoroughly in its
container before use.
a. Apply a film of sealing compound (C-328) to
OD of seal in area shown in figure 66-60. e. Scrub the primer (C-345) into the surface of
the coupling outer race using nylon web abrasive pad
b. Install seal, being careful not to bend or (C-407). Use additional primer as required to ensure
collapse outer case of seal. Make sure that seal is that the coupling outer race is clean.
bottomed against shoulder in sleeve.
NOTE: The solvent in primer (C-345) is
c. Wipe off excess sealant. trichloroethylene. Use primer in a well ventilated area.
d. Coat lip of seal with approved transmission f. Allow the primer (C-345) to dry to a white
oil (refer to BHT-205A 1-MM-1 manual.) powder.
66-111
BHT-205A1-CR&O-1
SLEEVE ASSY
0.30 INCH APPLY FILM OF

SEALING COMPOUND (C-328) TO
SEAL ONLY, PRIOR TO INSTALLATION,
IN AREA SHOWN. CLEAN OFF EXCESS
SEALANT.
QUILL ASSEMBLY OUTER RACE
ADHESIVE (C-317) TO BE PLACED

UNDER INSIDE DIAMETER
CHAMFER OF WEAR SLEEVE. R A D IU S
MAINTAIN 0.06 MINIMUM
OF ADHESIVE CONTOUR.
Figure 66-60. Seal kit
66-112
BHT-205A1-CR&O-1
g. Wear clean white gloves while handling part o. Clean off excess adhesive, leaving chamfer
and remove the dry powder with clean dry between seal wear sleeve and coupling outer race
cheesecloth. Wrap part in barrier material (C-427) if filled with adhesive. Maintain 0.060 inch minimum
the next steps are not to be accomplished radiusof adhesivecontour.
immediately.
p. Cure at room temperature for 24 hours.
WARNING: ADHESION PROMOTER (C-327) USED
IN THE FOLLOWING STEPS IS HIGHLY VOLATILE. q. Remove masking from seal wear sleeve and
USE IN A WELL VENTILATED AREA. KEEP from coupling outer race.
PROMOTER IN A NONABSORPTIVE CONTAINER
AND KEEP LID TIGHTLY CLOSED WHEN NOT IN USE. r. After bonding and prior to assembly of quill
EXPOSURE TO ATOMSPHERE WILL CAUSE assembly, ensure that all traces of adhesive are
GRADUAL DECOMPOSITION, EXCEPT WHEN cleaned from area of seal wear sleeve which contacts
APPLIED TO PARTS AND ALLOWED TO DRY. oil seal.
SEDIMENT OR BROWN RESIDUE IN BOTTOM OF
CONTAINER INDICATES DECOMPOSITION OF 16. Install freewheeling coupling with coupling
PROMOTER TO EXTENT THAT IT SHOULD BE inner race (5, figure 66-57) engaged on splines of
DISCARDED. THE pH RANGE OF THE PROMOTER pinion shaft and bottomed against triplex bearings.
MUST BE 7 TO 8.
17. Remove retaining ring (12) grease retainer
h. Apply adhesion promoter (C-327), to (11) and spacers previously installed.
(11)and spacers previously installed.
unmasked portions of seal wear sleeve and coupling
outer race using natural animal hair brush with an 18
unpainted handle. unpainted 18. Install coupling retaining nut (6), torque 350
handle. to 400 foot-pounds with T101306 wrench. Hold
i. Apply only enough adhesion promoter to wet input pinion with a square plug. Install lock spring (7).
the surfaces.
j. Allow promoter to dry for a minimum of 30 NOTE: Check freewheeling clutch for freewheeling
minutes at room temperature or for 15 minutes at and engagement in correct direction of drive. Check
150 ° to 160°F (66 ° to 71 °C). for smooth roll of pinion and quill.
k. Wrap parts in barrier material (C-427) if the 19. Place packing (10) on grease retainer (11).
next steps are not to be accomplished immediately. Install grease retainer and retaining ring (12).
I.I. Mix
Mix adhesive
adhesive (C-317)
(C-317) (33
(33 parts B to
p arts B to 100
100 20. Check quill assembly for freedom of rotation.
parts A). The pot life of mixed adhesive is 30 to 50 C k fg c f f a
Check freewheeling clutch for freewheeling and for
minutes. minutes. lock-and-drive in direction of drive.
m. Coat the inside diameter of seal wear sleeve
and mating surfaces on coupling outer race with 21. Identify shim plate for installation in specific
adhesive. location and/or determine required thickness.
NOTE: Work aid for installation of wear ring is a. Inspect shim plates and quill sleeve on which
shown on figure 66-61. Use of work aid will ensure shim plate is to be installed for an etched serial
that even pressure is applied around entire number. The same serial number must be on both
circumference of wear ring to avoid cocking and parts. If parts cannot be identified by serial number,
distortion. determine required dimension of shim.
n. Press seal wear sleeve on coupling outer race b. Inspect quill sleeve for a reference dimension
with spherical relief on OD of seal wear sleeve which shall be metal stamped or vibro-etched on part
positioned at outer edge of coupling outer race flush adjacent to mounting surface. Record this dimension
to 0.020 inch recessed. and where it is located on sleeve.
66-113
BHT-205A1-CR&O-1
6.495 ± 0.010"
6.470 ± 0.010"
2.00"
MATERIAL: ALUMINUM OR MICA
Figure 66-61. Main input quill seal wear ring work aid
c. If a shim plate with correct part number but 66-83. OVERHAUL - MAIN INPUT QUILL
without a serial number is available, measure thickness (205-040-263-101).
and record. Determine whether shim plate is correct for
this particular installation. Subtract shim plate thickness
from reference dimension found on sleeve. The TOOLS REQUIRED
resulting value shall fall within 2.2620 to 2.2625 inches.
T101306 Wrench
22. Refer to paragraph 66-37 for paint and sealing T101362 Sleeve
procedure. T101578 or Wrench Set
T101588 Wrench Set
23. Rotate input coupling to ensure that internal T101885 Plate
parts turn freely. T101912 Pinion Removal Plate
66-114 Rev. 2
BHT-205A1-CR&O-1
66-84. DISASSEMBLY - MAIN INPUT QUILL. 2. Dry parts with clean, lint-free cloths or dry filtered
1. Secure 3/4-inch square bar vertically in vise and drying.
position quill on bar with pinion engaged on bar.
3. Coat bearings with corrosion preventive (C-105)
immediately after cleaning. Do not handle unoiled
2. Remove retainer ring (22, figure 66-62), retainer bearings with bare hands.
(21), and packing (20). Remove lockspring (19).
Remove nut (18) with T101306 wrench and T101578 or 4. Inspect quill for corrosion damage to threaded
T101588 wrench set. Lift outer race (16) and internal studs and stud holes before cleaning No structural
parts off pinion splines. damage to threads or holes is acceptable.
3. Remove retainer ring (11) and shield (12).

Position outer race (16) on a support with flanged end 66-86. NORMAL INSPECTION - MAIN INPUT
down. Press inner race (15), and bearing (17) out of QUILL
outer race.
1. Inspect all parts visually for damage and

4. Remove bearing (17) from inner race. Remove excessive wear
bearing (13) and one way clutch (14) from outer race
(16). Inspect freewheeling clutch in accordance with
paragraph 66-80. 2. Inspect pinion (1, figure 66-62) for chipped,
dented, spalled, scuffed, and pitted teeth. Inspect roller
bearing surface for spalling, scoring, pitting, brinelling,
5. Remove wear sleeve (10) on outer race (16). Use indentations, and corrosion damage. Inspect splines for
hand-held grinder to grind almost through old wear chipped, pitted, and excessively worn teeth. Inspect
sleeve. Use caution to avoid grinding through wear threads for damage.
sleeve and damaging outer race (16). Strike wear
sleeve with hard rubber mallet to pop wear sleeve off
outer race. Clean old adhesive from outer race with a. Pitting of any magnitude resulting from surface
plastic scraper and abrasive pad (C-407). fatigue during operation is not permissible on teeth of
pinion. This may appear as only a fine line of pin holes
near pitch diameter and be detectable only with a side
6. Position T101885 plate on pinion (1) between light source and a probe with a point of approximately
gear and sleeve (2). Support sleeve and press pinion (1) 0.001 inch radius. A more severe example of this is
out of triplex bearings (4) and sleeve (2). shown on figure 66-63, detail B. Minor pitting resulting
from corrosion is permissible within following limits:
7. Remove screws (4) and washers (7), remove cap
(6) from sleeve (2). Remove shim (3). Remove packing (1) Nomorethan0.001 inchdeepandnomore
(5) from sleeve (2). than 0.040 inch wide or 0.080 inch long.
8. Support sleeve (2) press triplex bearing (4) out of (2) No more than 0.002 inch deep and no more
sleeve. Bearings must be retained as a matched set. than 0.040 inch wide or 0.100 inch long and located on
the outer (i.e. adjacent to the heel), half of the face of the
9. Remove seal (9) from cap (6). tooth and above the pitch line; or located outside of the
wear patten and outside of the root radius.
66-85. CLEANING- MAIN INPUT QUILL. b. Surface roughness detectable by drawing

probe along tooth in profile direction is cause for
rejection if pitting occurred on mating member.
1. Clean all quill parts with solvent (C-304). Use soft
bristle brush to dislodge stubborn deposits. All parts c. Grinding scratches. Any scratches around
except bearings may be cleaned with tricholorethane which pitting or other damage occurs are not
(C-334) by vapor degreasing, if desired. permissible.
Rev. 2 66-115
BHT-205A1-CR&O-1
15. Inner race 23. Packing

1. Pinion 8. Screw 16. Outer race 24. Plug
2. Sleeve 9. Seal 17. Bearing
3. Packing 10. Wear sleeve 18. Nut
4. Shim 11. Retainer ring 19. Lockspring
5. Triplex bearing 12. Shield 20. Packing
6. Cap 13. Bearing 21. Retainer
7. Washer 14. Freewheeling clutch 22. Retainer ring
Figure 66-62. Main input quill (205-040-263-101)
66-116 Rev. 2
BHT-205A1-CR&O-1
A Spiral Bevel Gear, Input Driven Gear Quill.

B Spiral Bevel Gear, Input Driven Gear Quill.

Gear is spalled on the face of the tooth. Any spalling
of this type is unacceptable, and both the gear and
the mating pinion should be replaced - even
though the mating pinion may not be spalled.
C Input Pinion.
Input drive quill wear pattern showing a
nonuniform wear pattern with a band of heavy
wear in the flank. This is the maximum acceptable
for this condition.
Figure 66-63. Main input quill wear pattern
66-117
BHT-205A1-CR&O-1
d. Nicks, cuts, or dents caused by handling or by 2. Replace all unserviceable parts.

handling or by foreign material going through mesh
during operation are permissible provided they are no 3. Replace wear sleeve (10, figure 66-62) if it is worn
more than 0.003 inch deep and are no more than 0.020 or rough as follows:
inch across in any direction, and cannot be felt with a
probe having end radius of 0.030 inch. a. Use end mill or hand-held grinder to cut a
groove almost through old wear sleeve (10); avoid
3. Inspect nut (18) for damaged threads. cutting through wear sleeve and damaging outer race
(16). Strike wear sleeve with rubber mallet to break the
uncut portion and remove sleeve from adapter.
4. Inspect sleeve (2) for corrosion damage and
damaged threads. Sleeve flange nicks or dents, that
exceed 0.030 inch depth, is cause for rejection of part. b. Clean old adhesive from outer race (16) with
plastic scraper and abrasive pad (C-407) or use paint
remover (C-436). Inspect adapter for damage which
5. Inspect triplex bearing (4) for spalling, scoring, may have been incurred during removal of wear sleeve.
pitting, brinelling, corrosion damage, cracked and
broken retainers, and for roughness when rotated.
Inspect freewheeling clutch in accordance with NOTE: Precautions must be taken during
paragraph 66-80. accomplishment of the following steps to keep wear
sleeve and adapter clean. Wear clean white gloves
6. Inspect the following parts by magnetic particle when handling parts and change gloves when they
(Code M) or fluorescent penetrant (Code F) as become soiled. Cover work bench with clean kraft
applicable. Demagnetize parts after magnetic paper. Avoid contact with all mold release agents such
inspection. Refer to BHT-205A1-MM-1. Index numbers as silicone, wax, oil, grease, etc. The work area where
are indexed to figure 66-62. bonding is done must be maintained at 65 to 82°F (18
to 28°C) with relative humidity below 75 percent. It must
be dust free to the extent that bonding operations are not
INDEX NO. NOMENCLATURE CODE affected.
1 Pinion M
2 Sleeve M Bonding steps must be accomplished without delay
6 Cap M between steps. Four hours is the maximum time interval
15 Inner race F between sandblasting and the next step.
16 Outer race M
18 Nut M
c. Mask outer diameter of new wear sleeve (10).
Mask outer race (16) all over except surface which
7. Inspect parts dimensionally and replace parts that mates with wear sleeve and adjacent 0.062 inch radius.
do not fall within inspection limits. (Refer to figure Sandblast unmasked surfaces of these parts with 60 grit
66-64.) garnet at 5 to 10 psi and remove residue. Wrap parts in
clean kraft paper after sandblasting.
fit between mating parts. It is not intended that all d. Apply grease removing primer (C-345) to
dimensions be checked as a prescribed overhaul unmasked portion of outer race (16) only; this step is not
procedure; however, parts that show evidence of wear applicable to wear sleeve. Stir primer thoroughly in its
or physical damage must be checked dimensionally. container before use. Scrub primer into surface of outer
race with abrasive pad (C-407). Use additional primer,
as required, to ensure that adapter is clean.
66-87. REPAIR - MAIN INPUT QUILL.
NOTE: The solvent in primer is trichlorethylene. Use
1. Replace all parts that exceed inspection limits. primer in well ventilated area.
66-118 Rev. 2
BHT-205A1-CR&O-1
MIN. MAX.
INCHES
1 Pinion OD 3.1500 3.1505

2 Bearing ID 3.1491 3.1495
3 Bearing OD 5.9050 5.9055
4 Sleeve liner ID 5.9047 5.9054
5 Spline, pinion Over pins 3.2917 3.2952
(Use 0.1920 in. dia. pins)
6 Spline, adapter Between pins 2.8427 2.8456
7 Sleeve OD 6.7479 6.7500
8 Pinion OD 2.0090 2.0096
NOTE
Use pins with one side ground flat to 0.115 inch to provide clearance between pins and
root of spline teeth.
Figure 66-64. Main input quill wear limits (205-040-263-101)
Rev. 2 66-119
BHT-205A1-CR&O-1
e. Allow primer (C-345) to dry to a white 6. After repair, refinish parts in accordance with
powder. Remove dry powder with clean dry BHT-ALL-SPM
manualas follows:
cheesecloth. Wear clean white gloves while handling
parts. If next step is not to be accomplished a. Aluminumparts:touchupwithchemicalfilm
immediately, wrap outer race (16) with clean kraft treatment (C-100).
paper.
b. Magnesium parts: remove all traces of
CAUTION: ADHESION PROMOTER (C-327) USED corrosion by immersion in chromic acid bath (C-116).
IN FOLLOWING STEP IS HIGHLY VOLATILE. USE IN Touch up parts with chromic acid (C-103) or treat
WELL VENTILATED AREA. KEEP PROMOTER IN entire part with corrosion treatment (C-114).
NONABSORPTIVE CONTAINER AND KEEP LID
TIGHTLY CLOSED WHEN NOT IN USE. EXPOSURE c. Cadmium plated steel parts: treat rework
TO ATMOSPHERE WILL CAUSE GRADUAL areas with LHE solution (C-108). (Refer to
DECOMPOSITION, EXCEPT WHEN APPLIED TO BHT-ALL-SPMmanual.)
PARTS AND ALLOWED TO DRY. SEDIMENT OR
BROWN RESIDUE IN BOTTOM OF CONTAINER 7. Replace parts that are not within allowable
INDICATES DECOMPOSITION OF PROMOTER TO wear limits.
EXTENT THAT IT SHOULD BE DISCARDED. THE pH
RANGE OF THE PROMOTER MUST BE 7 TO 8. 66-88. REASSEMBLY - MAIN INPUT QUILL.
f. Apply adhesion promoter (C-327) to 1. Clean all parts with solvent (C-304) and drain.
unmasked portion of wear sleeve (10) and outer race
(16) with a natural animal hair brush with an 2. Coat all parts with approved transmission oil
unpainted handle. Apply only enough adhesion (refer to BHT-205A1-MM-1 manual) and drain.
promoter to wet the surfaces. Allow promoter to dry
for minimum of thirty minutes at room temperature or
for fifteen minutes at 150 to 160°F (66 to 71 °C). If NOTE: Do not handle unoiled parts with bare hands.
next step is not to be accomplished immediately,
wrap parts with clean kraft paper.
g. 3. Install bearing (17, figure 66-62) on inner race

Mix adhesive (C-317) (33 parts B to 100
15). Press these assembled parts into flanged end of
parts A). The pot life of mixed adhesive is 30 to 50
outer race (16). Press on race of bearing that is in
minutes. Coat inside diameter of wear sleeve (10) and
contact, do not press across bearing.
mating surface on adapter with adhesive. Press wear
sleeve on outer race with spherical relief on OD of
4. Install retainer (21) in outer race without
wear sleeve positioned at outer edge of adapter.
packing (20) and install retainer ring (22). Packing
Clean off excess adhesive, leaving chamfer between
(20) will be installed in a subsequent step.
wear sleeve and adapter filled with adhesive. Cure at
room temperature for 24 hours. After bonding and
5. Turn flanged end of outer race (16) down and
prior to assembly of quill ensure that all traces of
place T101362 sleeve over inboard end of inner race.
adhesive are cleaned from area of wear sleeve which
Place freewheeling clutch (14) over sleeve with
contacts seal (9, figure 66-62).
flanged sides of cage up and drag springs down.
4. Repair minor nicks, cuts or dents on pinion (1) Position clutch between inner and outer races.
by lightly polishing with fine india stone (C-464). Remove T101362 sleeve.
5. Repair dents and nicks on sleeve (2) flange top 6. If a Formsprag clutch is being used, observe
surface by polishing with fine india stone (C-464). the following procedures during installation.
Blend repaired area into flat surface with a minimum
radius of 0.12 inch. Finished repair must be 30 RHR a. Install clutch (14) with part number and drive
(roughness height rating) or better. Maximum depth, direction arrow toward the flange side of outer race
after repair, must not exceed 0.030 inch depth. (16).
66-120
BHT-205A1-CR&O-1
b. Using a suitable size packing around the checked for spinning after test run. If bearings are
outside of the clutch to hold the sprags down, replaced, be sure that dull burr marks on inner races
position clutch between inner and outer races of are in line when index marks are vibro-etched on
couplings, races.
c. Using both hands, slowly rotate outer race 12. Support bearing inner races and press pinion
counter-clockwise while pushing clutch into position shaft into bearings. Check pinion and bearings for
with thumbs. Do not force clutch in place with drift or free rotation.
other mechanical means. After installation, remove
packing used to hold the sprags down. 13. Install packing (3) on sleeve (2). Position shim
(4) and cap (6) on sleeve (2), align screw holes, and
7. Remove retainer ring (22) and retainer (21).
install washers (7) and screws (8). Leave screws
Support inner race of bearing (17) and press bearing loose.
(13) into place between inner and outer races. Install
shield (12) and retainer ring (11). 14. Using a feeler gage, check for 0.001 to 0.004
8. Clean mating surfaces of seal (9, figure 66-62) inch clearance between cap (6) and shim (4). Tighten
and cap (6) with solvent (C-304) and dry. Apply a film screws and secure with lockwire (C-405) to anchor
of sealing compound (C-328) to seal (9) only, prior to holes in gap. Check screws (8) do not protrude
installation, in area shown in View A. Note that the lip beyond mounting face of sleeve. If screws protrude, a
of the seal must face inboard and press seal (9) into thin steel washer may be added under head of screw.
cap (6). (Refer to figure 66-62 for lip seal direction.)
15. Apply fluoro glide dry film lubricant (C-019)
9. Measure depth of bearing surface in sleeve (2) to OD of wear sleeve (10). Exercise caution to avoid
from face of flange and record. Hold triplex bearing coating parts other than wear sleeve with dry film
(5) together and measure width of outer races and lubricant.
record. Subtract bearing width from sleeve depth and
prepare a shim (4) to provide 0.001 to 0.004 inch 16. Secure a 3/4 inch square bar in vise vertically
pinch on outer race of bearings. A dull burr mark, and position quill on bar with pinion engaged on bar.
approximately 1/8 inch in diameter is placed on the Install nut (18) and torque nut 350 to 400
end face of each bearing inner race by the bearing foot-pounds with T101578 or T101588 wrench set.
manufacturer, to mark the high point of race runout. Install lockspring (19); ensure that lockspring is fully
Bearings must be installed with the inner races of the seated in groove.
three bearings positioned with the dull burr mark on
the three bearings in line. Before installing bearings, 17. Place packing (20) on retainer (21). Coat
mark a pencil line on the inner diameter of each packing (20) and mating surface with approved oil
bearing in line with the dull burr mark. Use the line to prior to assembly. Install plate and secure with
align the three bearings as they are installed on the retainer ring (22).
pinion.
66-89. HYDRAULIC PUMP DRIVE QUILL.
10. Align V marks on outer bearing races (5),
support sleeve (2) and press bearings into sleeve with 66-90. OVERHAUL - HYDRAULIC PUMP DRIVE
apex of V pointing up. (Refer to figure 66-62.) QUILL.
11. Align inner races of triplex bearing so pencil TOOLS REQUIRED

line shows that the three dull burr-marks of bearing
are in line. Position pinion (1) so vibro-etched index T101305 Wrench
marks on pinion shaft are aligned with vibro-etched T101334 Bar
index marks on bearing inner races. T101447 Holding Fixture
T101449 Wrench
NOTE: If bearings or pinion were replaced, it will be T101519 Plate
necessary to vibro-etch index marks (lines) on new or
part same as on part replaced so bearings may be T101446 Plate
66-121
BHT-205A1-CR&O-1
66-91. DISASSEMBLY - HYDRAULIC PUMP 2. Inspect pinion (12, figure 66-65) for spalled,
DRIVE QUILL. scuffed, pitted, chipped or dented teeth. Inspect
splines on pinion (12) for pitted, chipped or
1. Place quill in T101447 holding fixture with excessively worn teeth. Inspect pinion for damaged
pinion facing down. threads.
2. Removenut (7, figure 66-65) with T101449 3. Inspect duplex bearings (1) for spalling,
wrench. Press seal (8) out of nut and remove packing scoring, pitting, brinelling, corrosion damage, for
(6). cracked or broken retainers, and for roughness when
rotated.
3. Remove clip (5). Remove nut (4) with
T101305 wrench. Remove washer (3). 4. Inspect nuts (4 and 7) for damaged threads.
4. Support duplex bearings (1) on inner race with 5. Inspect sleeve (9) for corrosion damage, for
T101519 plate and press pinion (12) out of sleeve. loose or damaged bearing liner,fordamagedthreads,
Remove cork (13) from pinion.
and for loose or damaged studs.
5. UseT101334bartopressduplexbearings (1) 6. Inspect the following parts by magnetic
and spacer set (2) out of sleeve. Keep duplex bearings particle (Code M or fluorescent penetrant (Code F) as
and spacers together as a set. applicable. Index numbers are keyed to figure 66-65.
6. Remove three screws (11) and shim plate (10).
Demagnetize parts after magnetic inspection. Refer
Identify shim plate for reinstallation on same sleeve.
66-92. CLEANING - HYDRAULIC PUMP DRIVE INDEX NO. NOMENCLATURE CODE

QUILL.
4 Nut F
1. Clean all quill parts with solvent (C-304). Use 7 Nut M
soft bristle brush to dislodge stubborn deposits. All 9 Sleeve F
parts except bearings may be cleaned with 12 Pinion M
trichloroethane (C-334) by vapor degreasing if
desired. 7. Inspect parts dimensionally and replace parts
2. Dry parts with clean, lint-free cloths or dry figure 66-66.)
while drying. NOTE: Wear limits are provided to show the required
3. Coat bearings with corrosion preventive dimensions be checked as a prescribed overhaul
(C-105) immediately after cleaning. Do not handle procedure; however, parts that show evidence of
unoiled bearings with bare hands. wear or physical damage must be checked
dimensionally.
4. Inspect quill for corrosion damage to threaded
damage to threads or holes is acceptable. 66-94. REPAIR - HYDRAULIC PUMP DRIVE
QUILL.
66-93. NORMAL INSPECTION - HYDRAULIC
PUMP DRIVE QUILL. 2. Replace No. 16 short cork in pinion (12, figure
66-65). Shellac cork in position shown in figure
1. Inspect parts visually for damage and 66-66, 0.25 to 0.31 inch depth from flat surface of
excessive wear. gear web. Use shellac (C-21 1).
66-122
BHT-205A1-CR&O-1
1. Duplex Bearings
2. Spacer Set
3. Washer
4. Nut
5. Clip
6. Packing
7. Nut
8. Seal
9. Sleeve
10. Shim Plate
11. Screw
12. Pinion
13. Cork
Figure 66-65. Hydraulic pump drive quill
66-123
BHT-205A1-CR&O-1
POSITION CORK
0.25 TO 0.31 INCH
INBOARD FROM

INCHES
1 Sleeve ID 2.6768 2.6775

3 Bearings OD 2.6769 2 6774
4 Sleeve OD 4.9989 5 0000
5 Case ID 5.0000 5.0021
6 Spline Between Pins 0.7207 0 7263
Figure 66-66. Hydraulic pump drive quill wear limits
3. Replace parts that are cracked, broken, Blend repaired area into flat surface with a minimum
warped, have malformed threads. radius of 0.12 inch. Finished repair must be 63 RHR
(roughness height rating) or better. Maximum depth
4. Replace duplex bearings as matched serialized must not exceed 0.030 inch, after repair is
sets, if unserviceable. completed.
5. Repair sleeves which have damaged or loose 7. Repair sleeves which have loose or missing
studs or damaged threads. locked-in inserts or studs.
6. Repair dents and nicks on sleeve flange top NOTE: Refer to BHT-ALL-SPM manual for repair of
surface by polishing with fine india stone (C-464). studs and inserts, outlined in steps 5., 6., and 7.
66-124
BHT-205A1-CR&O-1
8. Refinish parts after repair in accordance with 4. Duplex bearings (1) must be installed as
BHT-ALL-SPM manual as outlined below: match set. Check that serial number is same on both
bearings of set. Inner and outer spacers are matched
a. Aluminum parts: touch up with chemical film set. Check that serial number is same on both
treatment (C-100). spacers.
b. Magnesium parts: remove all traces of 5. Position sleeve (9) with studs up. Press one
corrosion by immersion in chromic acid bath (C-116). bearing (1) of set into sleeve with thrust side of outer
Touch up parts with chemical film treatment (C-103) or race up. Use suitable plug when pressing bearings into
treat entire part with magnesium alloy chemical film sleeve to apply force to bearing outer race. Install
treatment. (Refer to BHT-ALL-SPM manual.) spacer set (2). Press second bearing of set into sleeve
with thrust side of outer race down so that bearings
c. Cadmium plate steel parts: refer to BHT-ALL- are installed back-to-back.
SPM manual for prescribed cadmium plating method.
9. Replace parts that are not within allowable CAUTION: WHEN INSTALLING PINION INTO
wear limits. BEARING, USE CARE TO ONLY APPLY PRESSURE
TO PINION HUB AREA. PRESSURE APPLIED AT
GEAR TEETH CAN RESULT IN CRACKS BETWEEN
66-95. REASSEMBLY - HYDRAULIC PUMP HOLES IN WEB AND POSSIBLE FAILURE OF
DRIVE QUILL.
PINION IN SERVICE.
1. Clean all parts with solvent (C-304) and drain.
6. Support bearing inner race with suitable
2. Coat all parts with approved transmission oil sleeve and press pinion (12) into bearings.
(refer to BHT-205A1-MM-1 manual) and drain.
7. Position T101519 plate in vise with short end
NOTE: Do not handle unoiled parts with bare hands. of pins up. Position pinion on plate with holes of pinion
engaged on pins. Coat threads with approved oil and
3. Install shim plate (10, figure 66-65) on sleeve install washer (3) and nut (4). Install nut with shoulder
(9) with three screws (11). Serial number of sleeve and side of nut next to washer. Torque nut 30 to 40 foot-
shim plate must be the same, or new shim plate must pounds with T101305 wrench. Install clip (5) to safety
be ground to correct thickness as follows: nut.
a. Inspect shim plate and quill sleeve on which

8. Press seal (8) into nut (7) with lip of seal facing
shim plate is to be installed for an etched serial
inboard. Position new packing (6) in groove on nut (7).
number. If parts cannot be identified by serial number,
Coat lip of seal, packing, and threads with approved
determine required dimension of shim.
oil. Hold sleeve with T101447 holding fixture and
install nut (7). Use T101449 wrench to torque nut 150
b. Inspect quill sleeve for reference dimension to 200 foot-pounds. Secure nut to sleeve with lockwire.
which shall be metal stamped or vibro-etched on part Check pinion for free rotation.
adjacent to mounting surface. Record this dimension
and where it is located on sleeve.
66-96. OFFSET ACCESSORY DRIVE QUILL.
c. If shim plate of correct part number but without
a serial number is available, measure thickness and
66-97. OVERHAUL - OFFSET ACCESSORY
record. Determine whether shim plate is correct for
DRIVE QUILL.
this particular installation as follows:
TOOLS REQUIRED
(1) Subtract shim plate thickness to
AN8516-1 Spanner Wrench
reference dimension found on quill sleeve. The
resulting value must fall within 2.2215 to 2.2220 T101305 Internal Spline - Wrench
inches. T101306 External Spline - Wrench
15 JAN 2004 Rev. 3 66-125

BHT-205A 1-CR&O-1
66-98. DISASSEMBLY - OFFSET ACCESSORY 66-100. NORMAL INSPECTION - OFFSET

DRIVE QUILL. ACCESSORY DRIVE QUILL.
1. Insert T101306 wrench in internally-splined a. Visually inspect all parts for damage or
end of shaft (13, figure 66-67) to hold assembly from excessive wear. Inspect gears for chipped, broken or
turning. worn teeth. Inspect bearing for smooth operation.
2. Bend lockwasher (2) tangs, out of retaining nut 2. Inspect following parts by magnetic particle
(1). Use a AN8516-1 spanner wrench and remove (M) or fluorescent penetrant (F) as indicated.
retaining nut (1) and lockwasher (2). Demagnetize all parts after magnetic inspection.
3. Remove gear retainer (3) and lift spur driving
gear (4) from gear support (5). Press out gear support NOTE: Refer to BHT-ALL-SPMmanual for approved
(5) from bearing (7). fluorescent penetrant material. (Post Emulsified
Penetrant System.)
4. Remove retaining plate (6) with bolts, nuts,
and washers. Press bearing (7) from sleeve (8). INDEX NO. NOMENCLATURE CODE
5. Holding shaft (13) with T101306 wrench, cut 1 Retaining Nut M

lockwire and remove retaining nut (9) with T101305 4 Spur Driving Gear M
wrench. Remove pinion gear (10). Remove retaining 5 Gear Support M
plate (11) with shim (12), bolts, nuts, and washers. 8 Sleeve F
9 Retaining Nut M
6. Press shaft (13) and duplex bearings (14) from 10 Pinion Gear M
sleeve (8). Press bearings from shaft while supporting 11 Retaining Plate F
inner race. 13 Shaft M

66-99. CLEANING - OFFSET ACCESSORYDRIVE figure 66-68.)
QUILL.
1. Inspect quill for corrosion damage to threaded fit between mating parts. It is not intended that all
studs and stud holes before cleaning. No structural dimensions be checked as a prescribed overhaul
damage to threads or holes is acceptable. procedure; however, parts that show evidence of
2. Remove sealant with plastic scraper. dimensionally.
3. Clean all quill parts with solvent (C-304). Use 4. Replace pinion gear that has improper wear
soft bristle brush to dislodge stubborn deposits. All pattern. (Refer to figure 66-69.) Replace spur gear
parts except bearings may be cleaned with that is spalled or that is scuffed beyond the limits
tricholorethane (C-334) by vapor degreasing, if shown. If metal particles are found in the
desired. transmission during disassembly, or if there is
evidence of metal particles going through gear
4. Dry parts with clean, lint-free cloths or dry meshes, gear teeth should be carefully examined for
filtered compressed air. Do not allow bearings to spin indentations and cuts.
while drying.
66-101. REPAIR/REPLACE - OFFSET
5. Coat bearings with corrosion preventive ACCESSORYDRIVE QUILL.
unoiled bearings with bare hands. 1. Replace all unserviceable parts.
66-126
BHT-205A1-CR&O-1
Figure 66-67. Offset accessory drive quill 66-127
1. Retaining Nut
2. Lock Washer
3. Gear Retainer
4. Spur Driving Gear
5. Gear Support
6. Retaining Plate
7. Bearing
8. Sleeve
9. Retaining Nut
10. Pinion Gear
11. Retaining Plate
12. Shim
13. Shaft
14. Duplex Bearings
14.
Figure 66-67. Offset accessory drive quill
66-127
BHT-205A 1-CR&O-1

INCHES
1 Shaft OD 1.3780 1.3786
2 Sleeve OD 3.6252 3.6260
3 Case ID 3.6245 3.6261
4 Pinion Teeth (Use 0.1728 in. Dia. Pins) Over Pins 4.3307 4.3341
5 Pinion Spline (Use 0.720 in. Dia. Pins) Between Pins 1.1251 1.1314
6 Shaft - Spline (Use 0.0960 in. Dia Pins) Over Pins 1.3491 1.3518
7 Bearing OD 5.5112 5.5118
ID 4.3302 4.3308
8 Support OD 4.3308 4.3314
9 Gear - Splines (Use 0.1440 in. Dia. Pins) Between Pins 4.4416 4.4444
10 Gear - Teeth (Use 0.1728 in. Dia. Pins) Over Pins 5.7231 5.7280
11 Sleeve ID 5.5113 5.5120
12 Sleeve ID 2.8340 2.8345
13 Bearings - Duplex OD 2.8341 2.8346
ID 1.3777 1.3781
14 Shaft - Splines (Use 0.0720 in. Dia. Pins) Between Pins 1.1314 1.1370
Figure66-68. Offset accessory drive quill wear limits
2. Dress splines and gears with fine india stone of 0.25 inch. If more than 50 percent of the original
(C-464) if small nicks, burrs or scratches are visible. surface D, within 180 degrees of the arc is reworked,
the entire surface D should be reworked to maintain
3. Duplex bearings are marked with serial
surface D parallel to surface E, within 0.002 inch TIR.
numbers and must be installed in matched pairs.
4. If spur driving gear (4, figure 66-67) has b. Minimum dimension B, after rework, is
indications of cracks on surface D (refer to figure 0.765 inch.
66-70) it may be reworked by stoning or grinding to c. Surface finish, after rework, must be 125
remove the indications, as follows: RHR or better.
a. Isolated indications may be removed by hand
d. If entire surface is reworked, maintain 0.030
stoning, using a stone (C-464) with minimum radius
inch radius maximum at the four tangs.
66-128
BHT-205A1-CR&O-1
A Spur driving gear, (offset accessory drive).

B Spur drive gear, (offset accessory drivel.

Scuffing in the root and at the tip of the teeth.
Maximum depth acceptable is 0.0004 inch.
Condition shown is in excess of 0.0004 inch and
is unacceptable.
C Pinion gear. (offset accessory drivel. Typical

acceptable wear pattern.
D Pinion gear, (offset accessory drive). Scuffing in

the mot and at the tip of the tooth. Maximum
depth acceptable is 0.0004 inch. Condition
shown is in excess of 0.0004 inch and is
unacceptable.
66-129
BHT-205A1 -CR&O-1
Figure 66-70. Spur gear inspection areas
e. Break sharp edges 0.015 inch by 45 degrees (numbered and flat) next to flange in sleeve liner.
or 0.015 inch radius. (Raised lip of inner race will be up; that is face of
bearing will be up.)
f. Inspect part after rework by magnetic particle
inspection. No indications or cracks are acceptable.
NOTE: Check bearings (7) and duplex bearings (14)
g. Shot peen surface D, figure 66-70, as for proper installation.
follows:
2. Install shim (12), peeled to provide 0.002 to
(1) Shot size to be 110cast shot. 0.005 inch pinch on duplex bearings and retaining
plate (11). Secure through two opposite long lugs of
(2) Intensity to be 0.006 to 0.010 A. plate with drilled-head bolts, thin steel washers, nuts
and cotter pins. Align drilled holes of bolt heads
(3) Coverage to be 200 percent. (Full parallel to common center line of gears (for later
coverage two times.) lockwiring with studs through corners of plate when
installed in transmission case).
(4) Stray shot allowed on tangs. All other
areas to be masked. 3. Press externally-splined end of shaft (13)
through duplex bearings from side opposite retaining
66-102. REASSEMBLY - OFFSET ACCESSORY plate supporting bearing inner races. Place pinion
DRIVE QUILL. gear (10) on shaft splines, with longest side of pinion
hub next to bearing. Hold shaft with T101306
NOTE: Clean and coat all parts with approved wrench in internally splined end. Install retaining nut
transmission oil (refer to BHT-205A1-MM-1 manual) (9). Torque 70 to 90 foot-pounds on threaded end of
prior to reassembly. shaft with T101305 wrench. Secure nut to pinion
through lightening holes with lockwire (C-405).
1. Check that duplex bearings (14, figure 66-67),
both have same serial number. Press bearings
back-to-back into sleeve (8). Press gear support NOTE: Preload on duplex bearings will normally
bearing (7) into sleeve and thrust side of outer race cause a light drag when rotating shaft.
66-130
BHT-205A1-CR&O-1
4. Install bearing retaining plate (6), attached to 2. Remove hydraulic pump and tachometer drive
sleeve by three bolts with washers, nuts, and cotter quill (1, figure 66-71). Remove nuts and washers from
pins. Bolt located at end of sleeve, on common center mounting studs and use T101308 screw set to pull quill
line of gears, will have drilled head. The hole should be free of case.
aligned square to center line of gears for later
lockwiring with two studs when installing assembly in 3. Refer to paragraph 66-138 for overhaul of
transmission case. hydraulic pump and tachometer drive quill.
5. Press gear support (5), into bearing while 4. Removeoilfilter(4)orfullflowdebrismonitor(4A)

supporting bearing inner race. Place spur driving gear and gasket by removing nuts and washers from studs.
(4) with four tangs in slots of gear support (5) and
install gear retainer (3) with ends through holes of
5. Remove sump input drive quill (5). Remove six
nuts and washers from studs and use T101338 screw
6. Invert assembly and use T101306 wrench to set to pull quill from sump case. Remove retaining ring
hold pinion shaft as in step 3. Place lockwasher (2) on and washer and pull pump drive shaft (6) through top of
bearing, with inner tangs in slots of gear support (5). quill.
Install retaining nut (1), with beveled side next to
lockwasher, torque 50 to 100 foot-pounds with a 6. Refer to paragraph 66-118 for overhaul of
AN8516-1 spanner wrench. Bend two lockwasher accessory case input quill.
tangs into nut slots. Check for free roll of pinion.
7. Remove tail rotor drive quill (7). Remove nuts,
7. Refer to paragraph 66-37 for painting and sealing washers, and spacers from studs. Use T101338 screw
procedures. set to pull quill from sump case.
8. Rotate input coupling to ensure that internal parts 8. Referto paragraph 66-131 for overhaul of tail rotor
turn freely. drive quill.
66-103. ACCESSORY DRIVE AND SUMP.

CAUTION: DO NOT BOTTOM OUT JACKSCREWS
IN STEP 9.
66-104. OVERHAUL - ACCESSORY DRIVE AND
SUMP.
9. Remove sump drain valve (16) and associated
TOOLS REQUIRED lines. Remove oil pump (13). Use T101338 screw set.
T101308 Jack Screw Set 10. Refer to paragraph 66-111 for overhaul of
T101338 Jack Screw Set transmission oil pump.
11. Remove oil jet (10), chip detector (17), pump

66-105. DISASSEMBLY - ACCESSORY DRIVE screen (19), oil sight gage (21), and all components from
AND SUMP. sump as shown in figure 66-71.
NOTE: Assemblies may be removed in any practical NOTE: If component has been subjected to accident,
sequence. Shim plates on sump case ports must be and gear teeth in the tail rotor drive train are found
installed at the same location. Identify each shim plate cracked or chipped, 204-040-104 pinion gear, in the
for reinstallation. drive train shall be replaced.
1. Drain residual oil from sump and remove external 12. Remove plug from bottom aft right corner of
tubes and fittings. sump case.
Rev. 2 66-131
BHT-205A1-CR&O-1
1. Hydraulic pump and

tachometer drive quill
2. Bracket
3. Bracket
4. Oil filter
4A. Full flow debris monitor
5. Sump input quill
6. Pumpdrive shaft
7. Tail rotor drive quill
8. Spacer
9. Bracket
10. Oil jet
11. Elbow
12. Sump case
13.Oil pump
14. Bracket
15. Bracket
16. Sump drain valve
17. Chip detector (Outer portion)
18. Chip detector (Inner portion)
19. Pump screen
20. Oil level indicator
21. Oil level sight glass
NOTE:
Helicopters modified with a full flow debris
monitor (4A).
205A1-R-66-71
Figure 66-71. Accessory drive and sump
66-132 Rev. 2
BHT-205A1-CR&O-1
66-106. CLEANING - ACCESSORY DRIVE 2. Inspect sump case quill ports for an average
AND SUMP. diameter of 3.6250 to 3.6265 inches.
3. Inspect following parts by magnetic particle (Code
1. Inspect case for corrosion damage of threaded M) or fluorescent penetrant (Code F) method. Index
damage
damage to threads or
or holes
to threads
holes is
is acceptable.
acceptable. numbers are keyed to figure 66-71. Demagnetize all
parts after magnetic inspection.
inspection.
2. Remove sealant with plastic scraper. NOTE: Refer to BHT-ALL-SPM manual for approved
fluorescent penetrant material. (Post Emulsified
3. Clean all case parts with solvent (C-304). Use soft Penetrant System.)
bristle brush to dislodge stubborn deposits. All part
except bearings may be cleaned with trichloroethane 6 Pump Drive - Shaft M
(C-334) by vapor degreasing, if desired. 12 Sump Case F
4. Dry parts with clean, lint-free cloths or dry filtered 4. Inspect chip detector boss as follows:
compressed air. Do not allow bearings to spin while drying.
a. Measure chip detector boss entry-countersink
5. Use paint remove (C-436) to remove paint from all diameter at three places, 120 degrees apart. Refer to
painted parts. figure 66-72A, detail A. If the countersink diameter
measures smaller than 1.130 inches, the chip detector
boss entry-countersink diameter is within limits and chip
NOTE: If nonferrous parts are primed with primer detector
detector and
and gasket
gasket may
may be
be installed
installed.
(C-202) only the top coat needs to be removed.
b. If the countersink diameter measures larger
6. Inspect oil sight gage (21, figure 66-71) for than 1.130 inches, referto paragraph 66-108 for rework.
discoloration and crazing.
66-108. REPAIR/REPLACE - ACCESSORY
66-107. NORMAL INSPECTION DRIVE AND SUMP.
ACCESSORY DRIVE
ACCESSORY DRIVE AND SUMP
AND SUMP. 1. Damage frequently occurs to the sump case in
area A, figure 66-72 by fretting with an external oil hose.
1. Visually inspect sump case and disassembled Fretting damage is acceptable in this area provided it
parts for damage or excessive wear. does not exceed 0.070 inch in depth and provided the
total affected area does not exceed two square inches.
a. In areas C, D, and E figure 66-72, pitting to a The affected area on acceptable cases should be
maximum depth of 0.020 inch is permitted provided no treated for corrosion prevention as outlined in
more than 40 percent of any one inch square and 20 BHT-ALL-SPM manual.
percent of the total area of any surface is corroded.
Cases having corrosion on studs or on case 2. Inspect area B for excessive wear in the ID of the
immediately adjacent to the studs shall be further oil passage. Case may have threaded plug or may use
inspected to determine if rework is possible as follows: plug with packing and retainer ring. If case uses retainer
ring, inspect for excessive wear. Replace case if wear is
(1) Corrosion should be removed by acid bath sufficient to prevent proper sealing of the oil by the
method. (Refer to BHT-ALL-SPM manual.) packing or proper fit of the retaining ring.
3. Ports that use retaining ring may be reworked as
(2) Measure and record height of stud. follows:
(3) If corrosion has affected more than one a. Measure wall thickness of boss (dimension C,
complete thread, replace case. figure 66-72). If minimum wall thickness is 0.140 inch or
more, case may be reworked.
(4) If corrosion has affected less than one b. Drill existing 0.812 inch diameter hole to 0.750
complete thread, case shall be reworked. inch depth. (Existing depth is 0.500 inch.)
b. Rework case in accordance with paragraph c. Machine boss to AND10050-10 boss, except
66-107. for tap drill depth.
Rev. 2 66-132A/66-132B
BHT-205A1-CR&O-1
SEE DETAIL A
1. Screw 8. Stud
2. Shim plate 9. Shim plate
3. Stud 10. Screw
4. Accessory and 11. Lock ring
tail rotor drive case 12. Threaded insert
5. Screw 13. Magnetic plug
6. Shim plate 14. Pump screen boss
7. Stud 15. Chip detector boss
COUNTERSINK DIAMETER
1.110 TO 1.130 IN.
DETAIL A
205A1-R-66-72A
Figure 66-72A. Accessory drive and sump damage limits
Rev. 2 66-133
BHT-205A1-CR&O-1
SUMPCASE
ENLARGED VIEW ENLARGED VIEW

OF SECTIONIN AREA B OF SECTION IN AREA B
BEFORE REWORK AFTER REWORK
Figure 66-72. Accessory drive and sump inspection areas
d. Measure wall thickness as shown 4. Sump cases having corrosion around studs
(dimension D, figure 66-72), minimum acceptable shall be reworked as follows:
thickness is 0.089 inch. Check minimum boss height
a. Using a 0.327 to 0.334 inch diameter drill,
(dimension E).
counterdrill stud hole to a maximum depth of 0.125
inch. Break all sharp edges, except in thread area.
e. Treat reworked areas of case with chemical b. Treat surfaces after drilling with chemical
film (C-103) or treat the entire part with magnesium film (C-103) or treat the entire part with magnesium
alloy chemical film treatment. (Refer to BHT-ALL-SPM alloy chemical film treatment. (Refer to BHT-ALL-SPM
manual.) manual.)
66-134
BHT-205A1-CR&O-1
c. Install new stud in reworked hole. (Refer to clamping forces on sump case. Using a dial indicator
BHT-ALL-SPM manual.) mounted in the machined spindle, sweep face of sump
case as required so total indicator runout is not greater
d. All counterdrilled holes shall be filled with than 0.002 inch.
adhesive (C-308) flush with top surface of case.
5. Replace unserviceable parts.

b. Machine chip detector boss surface to achieve
6. Replace studs when loose or damaged. 1.130/1.110 inches entry-countersink diameter.
Machining depth shall not exceed 0.035 inches. Refer
7. Rework chip detector boss as follows: to table 66-3 for required depth of machining to achieve
1.130/1.110 inches entry-countersink. The surface
a. Mount the sump case in a suitable machine tool finish of the remachined boss face must not exceed 63
such as a vertical milling machine. Use minimal RMS.
Table 66-3. Chip detector boss measurements and machining requirements
Countersink Diameter Machining Depth

Measurements Required
Inches Inch
1.230 0.035/0.030
1.220 0.032/0.027
1.210 0.029/0.024
1.200 0.026/0.021
1.190 0.023/0.018
1.180 0.020/0.015
1.170 0.017/0.012
1.160 0.014/0.009
1.150 0.011/0.006
1.140 0.008/0.003
Rev. 2 66-134A/66-134B
BHT-205A1-CR&O-1
c. Remove oil and grease with solvent (C-304).

Clean freshly machined face with cleaning compound MIN. MAX.
(C-318) mixed with water, to ensure a water-break-free LOCATION INCHES
surface. Rinse with water and repeat as necessary to
provide a clean surface. Allow surface to air-dry or force
dry using clean, filtered compressed air and clean dry Accessory case input quill 4.7895 4.7900
cloths.
Tail rotor drive quill 4.8685 4.8690
5. Treat reworked areas and other areas on case
where chemical film has been removed with chromic Hydraulic pump and
acid (C-103) brush-on treatment. Refer to tachometer drive quill 4.8685 4.8690
BHT-ALL-SPM for procedure.
3. Insert pump drive shaft (6) through splined end of

66-109. REASSEMBLY ACCESSORY sump input drive quill (5) so that square end seats in
DRIVE AND SUMP. gear. Secure with washer and retaining ring in shaft
groove below gear.
NOTE: Clean and coat all parts with approved 4. Use a suitable heat lamp to heat case at input quill
transmission oil (refer to BHT-205A1-MM-1 manual) mounting port. Lubricate quill and mating surfaces in
prior to reassembly. case with approved oil and start quill into case, align with
studs and insert until seated. Secure with washers and
CAUTION: WHEN INSTALLING QUILLS, EXERCISE nuts. Secure nuts in pairs with lockwire.
CARE TO PROPERLY MESH GEAR TEETH WITH
MATING GEAR, TO AVOID DAMAGE. IF NECESSARY
TO TAP QUILLS WHEN INSTALLING QUILL, DO NOT NOTE: Quill must be aligned to studs before inserting
TAP ON END OF GEAR. very far. This quill does not use a packing on sleeve.
5. Install packings on pump (13) and lubricate

1. Ensure that case is clean and that oil passages
are not
are not obstructed. Position
obstructed
Position case
case on
on clean
clean work
work bench
bench packings and case bore with approved oil. Heat case at
oil pump mounting port and install pump. Spline of pump
or install in suitable support fixture.
drive must be aligned to pump drive shaft (6) to avoid
disengagement of retaining ring at lower side of sump
2. Install shim plates on sump case (12, figure input quill (5). Install brackets (14 and 15) and oil pump
66-71) with screws. The serial number of the case and attaching nuts and washers
shim plates must be the same or new shim plates must
be ground to the correct thickness.
6. Lubricate tail rotor drive quill, sleeve, and mating
bore in case with approved transmission oil (refer to
a. Inspect shim plate and accessory case on
BHT-205A1-MM-1 manual). Heat case at mounting port
which shim plate is to be installed for an etched serial BHT205-A1-MM-1 manual. Heat case at mounting port
and install quill. Exercise care to engage gear teeth
properly to avoid damage. On each stud, install thin
determine required dimension of shim. aluminum washer, steel washer, spacer, steel washer,
and nut, except delete one washer at mounting studs for
b. Inspect accessory case for reference bracket (9). Torque nuts evenly.
dimension which shall be metal stamped or
vibro-etched on part adjacent to mounting surface.
Record this dimension and where it is located on case.
NOTE: Procedures for checking gear backlash for all
c. If ashimplateofcorrectpartnumberbutwithout three sump quills is in step 9.
record. Subtract shim plate thickness from reference 7. Install new packing on sleeve of hydraulic pump
dimension found on accessory case. The resulting and tachometer drive quill (1). Lubricate packing,
value must fall within min. - max dimension listed sleeve, and mating bore in case with approved
below. transmission oil (refer to BHT-205A1-MM-1
Rev. 2 66-135
BHT-205A1-CR&O-1
manual). Heat case at mounting port and install quill with d. Install 212-040-001-3G1F-1, backlash tool,
tachometer generator drive forward. Exercise care and detail 4 on pinion shaft of hydraulic pump and
engage teeth properly to avoid damage. Secure with tachometer drive quill (1). Install dial indicator support
thin aluminum and steel washers and nuts on top and on one of hydraulic pump and tachomete drive quill
bottom studs. studs. Install dial indicator on support and position it
to contact dowel pin in backlash tool, detail 4. Take
8. Install new packing on tail rotor drive quill. backlash reading at three places approximately 120
Lubricate sleeve, packing, and mating bore in case with degrees apart around the gear and record. Backlash
approved transmission oil (refer to BHT-205A1-MM-1 must be within 0.004 to 0.010 inch for
manual). Heat case at mounting port and install quill. 212-040-365-007 and -011 and 0.014 to 0.022 inch for
Exercise care to engage gear teeth properly to avoid 212-040-365-103. Backlash for 204-040-367 or
damage. On each stud install thin aluminum washer, 204-040-800 quill assembly shall be within 0.005 to
steel washer, spacer, steel washer, and nut, except 0.012 inch. Remove backlash tools from hydraulic
delete on washer at mounting studs for bracket (9). pump and tachometer drive quill. Remove backlash
Torque nuts evenly. tool from input quill at top of accessory drive sump.
9. Check backlash of sump and accessory drive

assembly quills as follows: NOTE: If backlash tool 212-040-001-3G1 F-l, detail 4
is unavailable, backlash may be determined by an
CAUTION: DO NOT ALTER SHIM PLATES ON CASE
OR QUILL SLEEVE TO OBTAIN BACKLASH. IF gear and at a distance (radius) of 1.227 inches from the
BACKLASH IS NOT WITHIN LIMITS, PARTS ARE gearcenter. Backlash must be within 0.004 to 0.010 inch
IMPROPERLY ASSEMBLED OR ARE for 212-040-365-007 and -011 and 0.014 to 0.022 inch
DIMENSIONALLYINCORRECT, REFER TO STEP 2.a. for212-040-365-103.
a. Install 212-040-001-3G1F-1 backlash tool,

detail 2, on top of accessory drive sump and attach
with three bolts. Tighten clamp on backlash tool to 10. Install plug with new packing in opening in
secure pinion in acessory case input quill (5, figure bottom of sump case at aft right corner. Install oil jet (10)
with new packings. Install packing on each oil level sight
glass and lubricate packing and port with approved
transmission oil (refer to BHT-205A1-MM-1 manual).
b. Install 212-040-001-3G1F-1, backlash tool, Position oil level indicator (20) in each port, install sight
detail 3 on tail rotor drive quill (7). Tighten backlash tool glass and retainer.
to clamp on inner coupling of tail rotor drive quill. Install
dial indicator support on one of tail rotor drive quill studs.
Install dial indicator on support and position it to contact
dowel pin in backlash tool, detail 3. Tack backlash
reading at three places, approximately 120 degrees packing. Torque 300 to 400 inch-pounds. Install chip
apart, around the gear and record. Backlash must be detector (innner
portion) (18) withtwo new packings.
within 0.004 to 0.010 inch.
NOTE: If backlash tool 212-040-001-3G1F-1, detail 3 NOTE: The center portion of the chip detector (18)
is unavailable, backlash may be determined by an has a hole provided for electric wiring in one side
alternate method. Take backlash readings at three adjacent to the terminal. This hole should face down.
places approximately 120 degrees apart around the If the hole does not face down on initial installation,
gear and at a distance (radius) of 1.227 inches from the remove chip detector (18), rotate 180 degrees and
gear center. Backlash must be within 0.004 to 0.010 reinstall.
inch.
c. Remove backlash tool from tail rotor drive quill, 12. Install pump screen (19) with new gasket and
but leave backlash tool, detail 2, on accessory case torque 300 to 400 inch-pounds. Secure to chip detector
input quill. (17) with lockwire.
66-136 Rev. 2
BHT-205A1-CR&O-1
CAUTION: INSTALL SHORT END OF UNION INTO CAUTION: DO NOT REMOVE ANY PART OF PUMP
CASE BELOW PUMP SCREEN (19). IF LONG END OF BY FORCING OR PRYING. LOOSEN PARTS BY
UNION IS INSTALLED, DAMAGE TO PUMP SCREEN TAPPING LIGHTLY WITH A FIBER MALLET.
MAY RESULT.
2. Remove retainer plate (2). Do not remove bearing
13. Install sump drain valve (16) and associated (3) from retainer plate.
lines.
3. Remove inner gerotor (6) and shaft (7) and outer
14. Install oil filter (4) or full flow debris monitor (4A) gerotor (5)
with gasket or packing, as applicable. Place brackets (2
and 3) over mounting studs and a thin aluminum alloy
washer on other stud. Install thin steel washers and nuts 4 Remove retainer rings(4 and 9). Remove inner
on all studs. Tighten nuts evenly to seat filter body gerotor and key (8) from shaft Donot remove bearing
against sump case. Torque nuts evenly 50 to 70 (10) or dowel pin (14) from body (11).
inch-pounds.
5. If damaged, remove insert (12) and ring (13).
15. Refer to paragraph 66-37 for painting and
sealing procedures.
66-113. CLEANING-TRANSMISSION OIL PUMP.
66-110. TRANSMISSION OIL PUMP.
1. Clean all pump parts with solvent (C-304). Use
soft bristle brush to dislodge stubborn deposits. All parts
66-111. OVERHAUL TRANSMISSION OIL PUMP. except bearings may be cleaned with trichloroethane
(C-334) by vapor degreasing, if desired.
66-112. DISASSEMBLY - TRANSMISSION OIL
PUMP. 2. Dry parts with clean, lint-free cloths or dry filtered
1. Remove retainer ring (1, figure 66-73). drying.
1. Retainer Ring 8. Key

2. Retainer Plate 9. Retainer Ring
3. Bearing 10. Bearing
4. Retainer Ring 11. Body
5. Outer Gerotor 12. Insert
6. Inner Gerotor 13. Ring
7. Shaft 14. Dowel Pin
Figure 66-73. Transmission oil pump
Rev. 2 66-137
BHT-205A1-CR&O-1
3. Coat bearings with corrosion preventive (C-105) 2. Coat all parts with approved transmission oil (refer
immediately after cleaning. Do not handle unoiled to BHT-205A1-MM-1 manual) and drain.
bearings with bare hands.
NOTE: Do not handle unoiled parts with bare hands.
3. Install new retainer ring (9, figure 66-73) in
66-114. NORMAL INSPECTION - inboard groove on shaft (7).
TRANSMISSION OIL PUMP. 4. Insert key (8) in shaft (7) and install inner gerotor
(6) so that key way engages key. Install new retainer ring
1. Inspect parts for damage. (4) on outboard end of shaft (7).
2. Inspect bearings (3 and 10, figure 66-73), shaft 5. Install shaft (7) in body (11). Install outer gerotor
(7), inner and outer gerotors (6 and 5), and body (11) for (5) over inner gerotor (6).
scoring or indentations.
6. Install retainer plate (2) on shaft (7). Ensure that
3. Inspect shaft (7) by magnetic particle inspection. dowel in body (11) engages hole in plate (2).
Demagnetize shaft after magnetic particle inspection.
(Refer to BHT-ALL-SPM manual.) 7. Install retainer ring (1) in body (11). Retainer ring
has a beveled and flat side. Flat side must be against
4. Inspect parts for corrosion damage and for plate. Ensure that ring is fully seated in groove.
excessive wear. Inspect parts dimensionally as
required. 8. Rotate shaft (7) to ensure that internal parts turn
freely.
MIN. MAX.
LOCATION INCHES 66-116A. OIL FILTER (INTERNAL).
Outer Gerotor Width 0.780 0.7085

Body Chamber Width 66-116B. DISASSEMBLY -OIL FILTER
0.7100 0.7105 INTERNAL
Allowable Chamber 0.0015 0.0027
Face
Face Clearance
Clearance 1. Straighten tangs on washer (5, figure 77-73A) and
Outer Gerotor OD 2.1220 2.1225
remove nut (4) and washer (5).
Body ID 2.1250 2.1255
AllowableClearance 0.0025 0.0040 2. Remove wafer screens (7) and spacers (6) from
Driveshaft OD 0.4985 0.4990 filter body (8). Inspect screens for metal particles.
Bearing ID 0.5000 0.5005
Allowable Clearance 0.0010 0.0025 CAUTION: USE CARE IN REMOVING SETSCREW
(3) BECAUSE SPRING (1) IS UNDER TENSION.
66-115. REPAIR -TRANSMISSION OIL PUMP. 3. Remove setscrew (3), ball (2) and spring (1).
1. Replace worn or damaged parts.

66-116C. CLEANING - OIL FILTER (INTERNAL).
2. Replace pump if housing, bushings, or gerotor are
excessively worn or scored. 1. Clean filter with solvent (C-304).
3. Replace parts that are not within allowable wear 2. Dry with compressed air.
limits.
66-116D. INSPECTION -OIL FILTER (INTERNAL).

66-116. REASSEMBLY - TRANSMISSION OIL
PUMP. 1. Inspect wafer screens (7, figure 66-73A) for
distortion, and tears. Damage that can be visually
1. Clean all parts with solvent (C-304) and drain. detected is not acceptable.
66-138 Rev. 2
BHT-205A1-CR&O-1
1. Spring
2. Ball
3. Setscrew
4. Nut
5. Washer
6. Spacer
7. Wafer screens
8. Filter body
9. Name plate
10. Housing
205A1-R-66-73A
Figure 66-73A. Oil filter assembly (internal)
2. Inspectspacers(6)forcorrosionanddeformation. 2. Position wafer screens (7), spacers (6), washer

Damage in excess of superficial is not acceptable. (5) and nut (4) on filter body (8).
3. Inspect screen retention nut (4) for corrosion and 3. Tighten nut (4) just enough to prevent screens (7)
thread damage. Damage in excess of superficial is not from turning. Bend washer (5) tangs against side of nut
acceptable. (4)
4. Inspect spring (1), ball (2) and setscrew (3) for

corrosion
4. and thread damage. Damage in excess of 4. Position oil filter (4, figure 66-71) on case (12)
superficial is not acceptable. without packing. If filter does not seat properly in case,
filter is not assembled properly.Remove filter from case.
5. Inspect filter body (8) for mechanical and
corrosion damage. Damage in excess of superficial is 66-116G. FULL FLOW DEBRIS MONITOR
not acceptable. (INTERNAL).
(INTERNAL).
66-116E. REPAIR - OIL FILTER (INTERNAL).

66-116H. DISASSEMBLY - FULL FLOW DEBRIS
Repair of oil filter (figure 66-73A) is limited to MONITOR
replacement of defective parts.
1. Remove debris scavenge cup/screen tube

66-116F. ASSEMBLY - OIL FILTER (INTERNAL). assembly (2, figure 66-73B), scupper (1), filter element
(3), and packing (4).
1. Install spring (1, figure 66-73A), ball (2) and
setscrew (3) in body (8). 2. Discard packing
Rev. 2 66-138A
BHT-205A1-CR&O-1
0.100 IN.
ELECTRICAL CHIP
1. Scupper
2. Debris scavenge cup/screen tube assembly
3. Filter element
4. Packing
5. Receptacle, electrical
6. Full flow debris monitor
205A1-R-66-73B
Figure 66-73B. Full flow debris monitor (internal)
66-138B Rev. 2
BHT-205A1-CR&O-1
66-1161. CLEANING - FULL FLOW DEBRIS 66-116L. ASSEMBLY - FULL FLOW DEBRIS
MONITOR. MONITOR.
1. Clean debris scavenge cup/screen tube 1. Coat packing (4, figure 66-73B) with approved oil
assembly (2, figure 66-73B), filter element (3), and used in transmission and install packing (4) on filter
scupper (1) with solvent (C-304). Clean exterior surface element (3).
of magnetics with a clean cloth.
2. Install filter element (3) in full flow debris monitor
2. Dry with filtered compressed air. (6).
3. Install scupper (1) on full flow debris monitor (6).

66-116J. INSPECTION - FULL FLOW DEBRIS
MONITOR. 4. Install debris scavenge cup/screen tube
assembly (2) to secure filter element (3) and scupper
1. Inspect filter element (3, figure 66-73B) for (1). Torque debris scavenge cup/screen tube assembly
distortion and tears. Damage that can be visually 22 to 30 inch-pounds
detected is not acceptable.
2. Inspect scupper (1), debris scavenge cup/screen 66-117. ACCESSORY CASE INPUT QUILL.
tube assembly (2) for thread damage, physical damage,
and corrosion.
66-118. OVERHAUL-ACCESSORY CASE INPUT
3. Inspect full flow debris monitor (6), and electrical QUILL (204-040-206).
receptacle (5) for physical, mechanical and corrosion
damage.
TOOLS REQUIRED
66-116K. REPAIR - FULL FLOW DEBRIS T101305 InternalSplineWrench

MONITOR. TT101333 Bar
T101334 Bar
Repair of full flow debris monitor (6, figure 66-73B) is T101336 Wrench
limited to replacement of defective parts. T101455 Plate Assembly
Rev. 2 66-138C/66-138D
BHT-205A 1-CR&O-1
66-119. DISASSEMBLY - ACCESSORY CASE 3. Press gear and bearing inner race (6) and
INPUT QUILL. spacer (7) from sleeve assembly. Remove spacer and
inner race from pinion gear (5).
1. Cut lockwire from nut (1, figure 66-74). Hold
assembly with pins of T101455 plate engaged CAUTION: IN STEP 4 AND 5 EXERCISECARE TO
through sleeve flange. Use T101336 wrench to ENSURE THAT BAR DOES NOT CATCH ON LINER
remove nut. FLANGE.
2. Remove locking-clip (2). Use T101305 wrench 4. Remove retaining ring (8) from end of sleeve
to remove nut (3), with washer (4), while holding (11). Insert T101333 bar through hole in side of
pinion gear (5) on a square 3/4 inch adapter. sleeve, and press out roller bearing (9).
1. Nut 6. Bearing inner race 11. Sleeve

2. Locking-clip 7. Spacer 12. Shim plate
3. Nut 8. Retaining ring 13. Screws
4. Washer 9. Roller bearing
5. Pinion gear 10. Duplex bearing
Figure 66-74. Accessory case input quill (204-040-206)
66-139
BHT-205A1-CR&O-1
5. Use T101334 bar to press duplex bearings 3. Inspect parts dimensionally and replace parts
(10) from upper end of sleeve (11). that do not fall within inspection limits. (Refer to
figure 66-75.)
6. Remove ground shim plate (12) from sleeve
(11). NOTE: Wear limits are provided to show the required
NOTE: Ground shim plate must be identified for dimensions be checked as a prescribed overhaul
reinstallation on the same sleeve from which it was procedure; however, parts that show evidence of
removed. Ground shim plate must be removed for wear or physical damage must be checked
fluorescent penetrant inspection of sleeve, dimensionally.
66-120. CLEANING - ACCESSORY CASE INPUT 4. Replace pinion gear that has improper wear
QUILL. pattern. (Refer to figure 66-76.) Replace pinion gear
that is spalled or that is scuffed beyond the limits
1. Remove sealant with plastic scraper. shown. If metal particles are found in the
transmission during disassembly, or if there is
2. Clean all quill parts with solvent (C-304). Use evidence of metal particles going through gear
soft bristle brush to dislodge stubborn deposits. All meshes, gear teeth should be carefully examined for
parts except bearings may be cleaned with indications and cuts.
trichloroethane (C-334) by vapor degreasing, if
desired.
66-122. REPAIR/REPLACE - ACCESSORY CASE
3. Dry parts with clean, lint-free cloths or dry INPUT QUILL.
while drying. 1. Replace all unserviceable parts.
4. Coat bearings with corrosion preventive 2. Dress splines and gear with fine india stone
(C-105) immediately after cleaning. Do not handle (C-464) if small nicks, burrs, or scratches, are visible.
66-121. NORMAL INSPECTION - ACCESSORY numbers and must be installed in matched pairs.
CASE INPUT QUILL.
4. Bearing inner and outer races must have same
1. Visually inspect all parts for damage or serial numbers.
excessive wear. Inspect gear for chipped, broken, or
worn teeth. Inspect bearings for smooth operation. 5. If pinion gear has indications of cracks on the
internal chamfer at the splined end it may be reworked
2. Inspect following parts by magnetic particle by stoning or grinding to remove the indications as
(M) or fluorescent penetrant (F) method as indicated. follows:
Demagnetize all parts after magnetic inspection. a. Isolated indications may be removed by hand
stoning using a stone (C-464) with a minimum radius
NOTE: Refer to BHT-ALL-SPMmanual for approved of 0.25 inch. If indications cover a large area on the
fluorescent penetrant material. (Post Emulsified chamfered surface, it may be reworked by grinding
Penetrant System.) the entire chamfer. Grinding should be done parallel to
the original surface (i.e. 30 degrees off rotating axis).
INDEX NO. NOMENCLATURE CODE (Refer to figure 66-77.)
5 Pinion Gear M b. Maximum depth of rework from original

11 Sleeve F surface is 0.060 inch.
66-140
BHT-205A 1-CR&-1
MIN. MAX.
1 Shaft Spline (Use 0.0960 in. Over Pins 1.341 1.348

Diameter Pins)
2 Bearing OD 2.8341 2.8346
3 Bearing ID 1.3777 1.3781
4 Sleeve ID 2.8340 2.8347
5 Shaft OD 1.3780 1.3786
6 Sleeve OD 3.6247 3.6255 Average
7 Case ID 3.6250 3.6265 Average
8 Bearing OD 3.1491 3.1496
9 Bearing ID 1.5745 1.5749
10 Sleeve ID 3.1489 3.1497
11 Shaft OD 1.5752 1.5758
Figure 66-75. Accessory case input quill wear limits (204-040-206)
c. Surface finish after rework must be 63 RHR 66-123. REASSEMBLY - ACCESSORY CASE
or better. INPUT QUILL.
d. If flat surface on the end of the gear is less NOTE: lean and coat all parts with approved
than 0.040 inch wide at the root of the spline, the end transmission oil (refer to BHT-205A1 -MM-1 manual)
should be faced off to obtain 0.040 inch width prior to reassembly. Do not handle unoiled parts with
minimum. Maximum depth of rework on the end is bare hands.
0.060 inch. If only isolated indications were removed Inspect for bearings being positioned face to face
from the chamfer by hand stoning, the end may also before installing.
be reworked by hand stoning locally only as required
to maintain a minimum face width of 0.040 inch. 1. Install shim plate (12, figure 66-74) on sleeve
Minimum radius in reworked area is 0.25 inch. (11) with screws (13). The serial number of the
sleeve and the shim plate must be the same, or a new
e. Break sharp edges 0.015 inch by 45 degrees shim plate must be ground to correct thickness as
or 0.015 inch radius. follows:
f. Inspect part by magnetic particle method. a. Inspect shim plate and quill sleeve on which
Indications of cracks are not acceptable. shim plate is to be installed for an etched serial
66-141
BHT-205A1-CR&O-1
5. Support duplex bearing inner races and press

gear shaft through bearings. Install washer (4) and nut
(3) on upper end of shaft, with nut shoulder against
washer. Hold gear on a 3/4 inch square plug. Use
T101305 wrench to torque nut 80 to 100 foot-pounds.
Install locking-clip (2) over nut spline and in shaft
groove.
6. Secure sleeve in T101455 plate assembly. Install

nut (1) in sleeve, torque 100 to 150 foot-pounds with
T101336 wrench. Secure nut to hole in end of sleeve
with lockwire. Check for free, smooth roll of gears.
NOTE: This quill does not use a seal around nut nor
on outside of sleeve.
7. Refer to paragraph 66-37 for painting and sealing

Pinion gear typical acceptable wear pattern. procedures.
Figure 66-76. Accessory case input quill pinion 8. Rotate input coupling to ensure that internal parts
wear pattern turn freely.
number, if parts cannot be identified by serial number,

determine required dimension of shim plate.
b. Inspect quill sleeve for reference dimension

which shall be metal stamped or vibro-etched on part
adjacent to mounting surface. Record this dimension
c. If a shim plate of correct part number but without

record. Determine whether shim plate is correct for this
particular installation as follows:
d. Subtract shim plate thickness from reference

dimension found on quill sleeve. The resulting value
must be 0.9760 inch minimum to 0.9765 inch maximum.
.060 INCH MAX.
DEPTH OF WORK
2. Check that duplex bearings (10, figure 66-74)

both have the same serial numbers and press bearings
face to face into upper end of sleeve (11), using
T101334 bar.
CAUTION: CHECK THAT SERIAL NUMBER ON

INNER RACE OF ROLLER BEARINGS IS SAME AS
THAT ON OUTER RACE.
3. Press roller bearing (9) into lower end of sleeve.

Install retaining ring (8) in sleeve groove.
4. Press bearing inner race (6) of roller bearing on

shaft of pinion gear (5). Place spacer (7) next to bearing
race. Figure 66-77. Pinion gear work area
66-142 Rev. 2
BHT-205A1-CR&O-1
66-124. OVERHAUL- ACCESSORY

CASEINPUT 3. Coat bearings with corrosion preventive
QUILL (212-040-365). (C-105) immediately after cleaning. Do not handle
TOOLS REQUIRED
T101305 Wrench
T101449 to T101660 Wrench
T101455 Plate 66-127. NORMAL INSPECTION - ACCESSORY
T101566 Bar CASE INPUT QUILL.
T101567 Bar
T101568 Wrench 1. Inspect all parts visually for damage and
excessive wear.
66-125. DISASSEMBLY - ACCESSORY CASE
INPUT QUILL. 2. Inspect nuts (1, and 3, figure 66-78) for
damaged threads.
1. Remove nut locking clip (2, figure 66-78). If
not previously accomplished, remove oil pump shaft 3. Inspect duplex bearings (5) for spalling
retaining ring in base of pinion (11). Hold pinion with scoring, pitting, brinelling, corrosion damage,
T101568 wrench and remove bearing retaining nut cracked or broken retainers, and for roughness when
(3) with T101305 wrench. Remove washer key (4). rotated.
2. Press pinion (11) out of sleeve. 4. Inspect sleeve (6) for corrosion damage, loose
or damaged bearing liner, and damaged threads.
3. Hold sleeve (6) with T101455 plate and
remove bearing retaining nut (1) with T101449 5. Inspect roller bearing (9) for spalling, scoring,
wrench. pitting, brinelling, corrosion damage, and cracked or
broken roller retainers.
NOTE: In steps 4. and 5., exercise care to properly
position bearing removal bar on bearings to avoid 6. Inspect pinion (11)for spalled, scuffed, pitted,
damaging bearing or sleeve. chipped, or dented teeth. Inspect roller bearing
surface for spalling, scoring, pitting, brinelling, and
4. Remove retainer ring (10). Insert T101567 corrosion damage. Inspect splines for chipped, pitted
bearing removal bar through slot in side of sleeve (6) or excessively worn teeth. Inspect threads for
and press roller bearing (9) out of sleeve. damage.
6. Remove three screws (8) and shim plate (7). 7. Inspect the following parts by magnetic
Identify shim plate for reinstallation on same sleeve. particle (Code M) or fluorescent penetrant (Code F) as
applicable. Demagnetize parts after magnetic particle
66-126. CLEANING - ACCESSORY CASE INPUT inspection. (Refer to BHT-ALL-SPM manual.) Parts are
QUILL. indexed to figure 66-78.
1. Clean all quill parts with solvent (C-304). Use INDEX NO. NOMENCLATURE CODE
soft bristle brush to dislodge stubborn deposits. All
parts except bearings amy be cleaned with 1 Nut F
trichlorethylene (C-334) by vapor degreasing, if 3 Nut M
desired. 6 Sleeve F
11 Pinion M
2. Dry parts with clean, lint-free cloths or dry
filtered compressed air. Do not allow bearings to spin 8. Inspect parts of accessory case input quill
while drying. dimensionally as required. Refer to figure 66-79.
66-143
BHT-205A1-CR&O-1
1. Nut Bearing Retaining

2. Clip, Nut Locking
3. Nut. Bearing Retaining
4. Washer. Key
5. Duplex Bearings
6. Sleeve
7. Shim Plate
8. Screw
9. Roller Bearing
10. Retainer Ring
11. Pinion
Figure 66-78. Accessory case input quill (212-040-365)
66-144
BHT-205A1-CR&0-1

INCHES
1 Spline, Oil Pump Shaft Over Pins 1.3410 1.3480

2 Spline, Pinion Between Pins 1.0871 1.0966
3 Sleeve Liner ID 3.1490 3.1499
4 Bearing OD 3.1491 3.1496
ID 1.3777 1.3781
5 Shaft, Pinion OD 1.3780 1.3786
6 Spline, Pinion Over Pins 1.3410 1.3480
7 Sleeve OD 3.6247 3.6255*
8 Case ID 3.6250 3.6265*
9 Bearing Surface, Pinion (212-040-150-1) OD 1.8691 1.8696
Bearing Surface, Pinion (212-040-150-3) OD 1.8692 1.8693
10 Bearing OD 3.1492 3.1496
11 Sleeve Liner ID 3.1489 3.1497*
12 Nut
13 Nut
14 Spline, Adapter Over Pins 1.3410 1.3480
15 Spline Adapter Between Pins 1.0871 1.0966
* Average Dimension
* * Maximum depth of wear 0.005 inch (measure from unworn face of tooth)
Figure 66-79. Accessory case input quill wear limits (212-040-365)
66-145
BHT-205A1-CR&O-1
66-128. REPAIR - ACCESSORY CASE INPUT and the shim plate must be the same, or a new shim
QUILL. plate must be ground to the correct thickness as
follows:
a. Inspect shim plate and quill sleeve on which
2. Replace pinion (11, figure 66-78) if worn or shim plate is to be installed for an etched serial
excessive pitting exists. number. If parts cannot be identified by serial number,
determine required dimension of shim plate.
3. Replace duplex bearings as matched,
serialized set, if unserviceable.
4. Inspect sleeve flange top surface for dents and which shall be metal stamped or vibro-etched on part
nicks. If damage does not exceed 0.030 inch depth, adjacent to mounting surface. Record this dimension
polish out damage and blend repaired area into flat and where it is located on sleeve.
surface with a minimum radius of 0.12 inch. The
finished repair must be 63 RHR or better. The c. If a shim plate of correct part number but
maximum depth after repair must not exceed 0.030 without a serial number is available, measure
inch. thickness and record. Determine whether shim plate
is correct for this particular installation as follows:
5. Refinish parts, after repair, in accordance with
BHT-ALL-SPMmanual as outlined below: (1) Subtract shim plate thickness from
reference dimension found on quill sleeve.
a. Aluminum parts: Touch up with brush
alodine (C-100). (2) The resulting value must be 0.9895 inch
minimum to 0.9900 inch maximum.
b. Magnesium parts: Remove all traces of
corrosion by immersion in chromic acid bath. (Refer
to BHT-ALL-SPM manual.) Touch up parts with 4. Press duplex bearings (5) into sleeve, (6),
chromic acid (C-103) or treat entire part with face-to-face, using suitable sleeve. Duplex bearings
magnesium chemical film treatment. (Refer to must be a matched set with same serial number on
BHT-ALL-SPMmanual.) both bearings.
c. Cadmium plates steel parts: Strip old plating 5. Press roller bearing (9) into sleeve (6) using
and replace using LHE solution (C-108). (Refer to suitable sleeve and install retainer ring (10).
BHT-ALL-SPM manual.) Apply supplementary
cadmium chromate conversion coating (C-1 12). 6. Support duplex bearings on inner race and
press pinion (11) into bearings.
6. Replace parts that are not within allowable
wear limits.
7. Position T101568 wrench in a vise with
splined end up. Position quill on wrench with pinion
66-129. REASSEMBLY - ACCESSORY CASE teeth down. Install key washer (4) and bearing
INPUT QUILL. retainer nut (3). Torque nut 180 to 200 foot-pounds
with T101305 wrench. Install nut locking clip (2).
1. Clean all parts with solvent (C-304) and drain. Remove quill from T101568 wrench.
2. Coat all parts with approved oil and drain. 8. Hold sleeve (6) with T101455 plate and install
bearing retaining nut (1). Use T101449 wrench to
NOTE: Do not handle unoiled parts with bare hands. torque nut 100 to 150 foot-pounds. Secure nut with
lockwire (C-405).
3. Install shim plate (7, figure 66-78) on sleeve (6)
with three screws (8). The serial number of the sleeve 9. Check pinion (11) for free rotation.
66-146
BHT-205A1-CR&O-1
66-130. TAIL ROTOR DRIVE QUILL. NOTE: Press epoxy plug or cork plug (25) out of
gear end of pinion, if metal-set plug is installed,
66-131. OVERHAUL- TAIL ROTORDRIVE QUILL. identified by a dark gray color, do not attempt
removal.
TOOLS REQUIRED
CAUTION: EXERCISE CARE TO POSITION BAR ON
T101307 Wrench Assembly BEARINGS SO THAT IT DOES NOT CATCH ON
T101333 Bar FLANGE OF LINER.
T101334 Bar
5. Remove retaining ring (22). Insert T101333
T101336- orT 600 bar through hole in side of sleeve and press roller
T101455 Plate Assembly
T101599 Pressing Tool bearing assembly (21) from inner end of sleeve (20).
Use T 101334 bar to press duplex bearings (18) from
NOTE: Press epoxy plug or cork plug (25, figure outer end of sleeve.
outer end of sleeve.
66-80) out of gear end of pinion, if metal-set plug is NOTE: Ground shim plate must be identified for
installed, identified by a dark gray color, do not reinstallation in the same sleeve from which it was
attempt removal. removed. Ground shim plate must be removed for
fluorescent penetrant inspection of sleeve.
66-132. DISASSEMBLY - TAIL ROTOR DRIVE 6. Remove ground shim plate (19) from sleeve
QUILL. (20).
NOTE: For ease of maintenance, block the outer NOTE: Ground shim plate must be identified for
coupling so that it will remain in the outboard reinstallation in the same sleeve from which it was
(extended) position. This will stabilize the outer removed. Ground shim plate must be removed for
coupling during disassembly and assembly. fluorescent penetrant inspection of sleeve.
1. Remove retaining ring (1, figure 66-80), seal 66-133. CLEANING - TAIL ROTOR DRIVE QUILL.
plate (2), and centering spring (3). Remove retainer
plug (5) with packing (6) and lock spring (4) using a 1. Remove sealant with plastic scraper.
1/4 x 20 UNC threaded bolt. Remove packing and
2. Clean all quill parts with solvent (C-304). Use
parts except bearings may be cleaned with
2. Hold sleeve (20) in T101455 plate assembly, trichloroethane (C-334) by vapor degreasing, if
with pins engaged through sleeve flange. Hold outer desired.
coupling (10) with T101307 wrench assembly while
using a square adapter to remove bolt (7) with washer 3. Dry parts with clean, lint-free cloths or dry
(8) from end of pinion (26). Remove and separate filtered compressed air. Do not allow bearings to spin
inner coupling (9), outer coupling (10) and grease seal while drying.
(12).
4. Coat bearing with corrosion preventive
3. Cut lockwire and use T101336 wrench to (C-105) immediately after cleaning. Do not handle
remove nut (15). Remove oil seal (14) and packing unoiled bearings with bare hands.
(16) from nut. Pull spacer (13) from pinion. Remove
packing (17) from pinion. 66-134. NORMAL INSPECTION - TAIL ROTOR
DRIVE QUILL.
4. Press pinion (26) with roller bearing inner race
(24) and spacer (23) out of sleeve assembly. Remove 1. Visually inspect parts for damage or excessive
spacer (23) and press roller bearing inner race (24) wear. Inspect gear for chipped, broken, or worn teeth.
from pinion. Inspect bearings for smooth operation. Inspect seal
bearing surfaces for wear or roughness.
66-147
BHT-205A1-CR&O-1
-TORQUE
80 TO 100
FT-LBS
SEE
DETAIL B
SEE VIEW A
VIEW A
205A1-R-66-80-1
Figure 66-80. Tail rotor drive quill (Sheet 1 of 2)
66-148 Rev. 2
BHT-205A1-CR&O-1
SEAL (12) PARTIALLYSEATED SEAL (12) FULLYSEATED
INTERNAL OUTERCOUPLING
SPLINES(11 ) (10)INSTALLED
INNERCOUPLING (9) USED INVERTEDON INNER
AS BACK-UP TO PUSH LIP COUPLING
OF SEAL (12) UP
DETAIL B
1. Retaining ring 11. Internal splines 21. Roller bearing

2. Seal plate 12. Grease seal 22. Retaining ring
3. Centering spring 13. Spacer 23. Spacer
4. Lock spring 14. Oil seal 24. Inner race
5. Retainer 15. Nut 25. Cork plug
6. Packing 16. Packing 26. Pinion
7. Bolt 17. Packing 27. Packing
8. Washer 18. Duplex bearings 28. Funnel
9. Inner coupling 19 Shim plate 29. Retainer ring
10. Outer coupling 20. Sleeve
NOTES:
Used on 212-040-365-005 and subsequent.
Apply sealant MIL-S-8802. Class B2, around nut (15) and sleeve (20) after
assembly.
Location of overtemperature indicator TEMP-PLATE.
205A1-R-66-80-2
Figure 66-80. Tail rotor drive quill (Sheet 2 of 2)
Rev. 2 66-149
BHT-205A1-CR&O-1

8 INCHES coupling.

INCHES coupling for being discolored (brown or blue) in normally
bright contact patterns. If discoloration is found, replace
7 INCHES outer coupling and inner coupling.
c. Inspectoutercoupling and innercoupling under

INCH 0.25 5X to 10X magnification for teeth exhibiting signs of
metal smearing or tearing in contact patterns. If
NOTES: 1. Make from plexiglass or similar material. inner coupling.
2. Remove all sharp edges.

grease is found to be viscous (thick) and having a strong
Figure 66-81. Seal (204-040-611) installation pungent odor, replace outer coupling and inner
workaid coupling.
2. Inspect following parts by magnetic particle (M) or NOTE: If TEMP-PLATES are to be replaced, replace
fluorescent penetrant (F) method as indicated. Index TEMP-PLATES after completing entire inspection
numbers are keyed to figure 66-80. Demagnetize all procedure and couplings have been determined
parts after magnetic inspection. serviceable and prior to lubricating couplings.
NOTE: Refer to BHT-ALL-SPM manual for approved 4B. Inspect outer coupling (10, figure 66-80)
fluorescent penetrant material. (Post Emulsified overtemperature indicator TEMP-PLATES for
Penetrant System.) deterioration, debonding, or discoloration of epoxy
coating that prevents interpretation of indicating dots. If
INDEX NO. NOMENCLATURE CODE deterioration, debonding, or disoloration of epoxy is
M found, replace TEMP-PLATES in accordance with
9 Inner Coupling
10 Outer Coupling M paragraph 66-136.
26 Pinion M
20 Sleeve F NOTE: Wear limits are provided to show the required
3. Inspect parts dimensionally and replace parts that procedure; however, parts that show evidence of wear
do not fall within inspection limits. (Refer to figure or physical damage shall be checked dimensionally.
66-82.)
NOTE: Overtemperature dots on overtemperature 66-135. REPAIR/REPLACE -TAIL ROTOR DRIVE

indicator TEMP-PLATES are of a white or light gray QUILL
color and turn black when exposed to an
overtemperature condition. Chemical contamination
can also cause indicating dots to turn black. 1. Replace all unserviceable parts.
4. Inspect outer coupling (10, figure 66-80) 2. Duplex bearings are marked with serial numbers
overtemperature indicator TEMP-PLATES for evidence and must be installed in matched pairs.
of overtemperature indication. If overtemperature
indication is noted, perform coupling overtemperature 3. Assemble roller bearing inner and outer races
inspection as follows: with same serial numbers.
66-150 Rev. 2
BHT-205A1-CR&O-1
4. Replace epoxy plug in pinion as shown in figure area. Seal groove wear no more than 0.002 inch deep
66-82 with resin (C-219), if cork plug is used install with and to a minimum diameter of 1.587 inch is acceptable
shellac (C-211). Check that oil hole is open and that if the groove is uniform and smooth. More severe
threaded area is free of resin, shellac or cork. damage in the seal area may be reworked by grinding
providing it gives 100 percent cleanup when reworked
5. Repair pinion shaft in accordance with paragraph as follows:
66-122, step 5. as necessary.
a. Grind coupling OD to a minimum diameter of
6. Replace tail rotor drive coupling if cracked, 1.587 inches. The reground diameter should not extend
chipped, excessively worn, or pitted in excess of the more than 0.40 inch from inner end of coupling and
limits shown. (Refer to figure 66-83.) should blend with original surface with a minimum radius
of 0.12 inch.
7. Inspect seal surface on inner coupling for nicks,
scratches, and excessive wear. b. Reground diameter should be concentric with
pitch diameter of internal spline within 0.002 inch TIR.
8. Repair nicks, dents, scratches and wear in the
seal area of inner coupling (9, figure 66-80) by polishing c. Surface finish on reground diameter should be
to remove damage and blending into the surrounding 16 RHR or better.
Rev. 2 66-150A/66-150B
BHT-205A1-CR&O-1
3.68 0.875 FROMENDOF GEAR
MIN MAX
1 Shaft - Roller Bearing Seat OD 1.5752 1.5758

2 Roller Bearing ID 1.5745 1.5749
3 Roller Bearing OD 3.1491 3.1496
4 Sleeve - Roller Bearing Seat ID 3.1489 3.1497
6 Case ID 3.6250 3.6265
7 Shaft - Duplex Bearing Seat OD 1.3780 1.3786
8 Duplex Bearing ID 1.3777 1.3781
9 Duplex Bearing OD 2.8341 2.8346
10 Sleeve - Duplex Bearing Seat ID 2.8340 2.8347
11 Shaft Splines (Use 0.0960 In. Dia. Pins) Over Pins 1.3481 1.3518
12 Inner Coupling Splines (Use 0.0720 In. Dia. Between
Pins) Pins 1.1251 1.1336
13 Teeth - Inner Coupling (Use
0.1080 In. Dia. Pins) Over Pins 2.1590 2.1740
14 Splines- Outer Coupling (Use Between
0.1309 In. Dia. Pins) Pins 1.829 1.836
15 Seal Lip Wear - Spacer OD 1.590 1.597
NOTES:
Maximum depth of wear is 0.005 inch measured from unworn face of tooth.
Maximum depth of seal lip wear is 0.001 inch measured from unworn surface.
Figure 66-82. Tail rotor drive quill wear limits
66-151
BHT-205A1-CR&O-1
A Acceptable pattern typical of low operating time.
B Acceptable pattern typical of couplings which have

operated with normal misalignment for a longer
period of time than that shown in A.
C Acceptable pattern denoting operation at higher

torque than that shown in A and B.
D Acceptable pattern showing a pitted tooth. This

condition is acceptable on all teeth.
Pattern shows a more severe condition of tooth

pitting than that shown in D. There is no metal
projecting above the normal face of the tooth, in-
E dicating that the pitted area is polishing over.
This condition may exist On all teeth. Couplings
with pits larger than 1/32 inch diameter should
be replaced.
Figure 66-83. Tail rotor drive quill couplings wear patterns
66-152
BHT-205A1-CR&O-1
d. Cadmium plate area using LHE cadmium 5A. Press inner race (24) of roller bearing on shaft of
plating solution (C-108). Plating thickness to be 0.0001 pinion gear (26). Place spacer (23) next to bearing race.
to 0.0003 inch. Do not exceed 0.0003 inch plating
thickness in seal area. Do not plate external spline teeth. 6. Check that cork if used, is installed in pinion (26)
(Refer to BHT-ALL-SPM manual for approved method.) and check oil hole through wall of pinion (26)
immediately inboard of cork to ensure that it is not
obstructed. Support duplex bearings (18) on inner race
66-136. REASSEMBLY - TAIL ROTOR DRIVE and press pinion (26) into sleeve.
QUILL.
7. Press oil seal (14) into nut (15). Position new
1. Clean all parts with solvent (C-304) and drain. packing (16) in groove of nut (15). Hold sleeve (20) with
T101455 plate. Coat packing with transmission oil (refer
2.allCoat
parts withapproved transmission oil(refer to BHT-205A1-MM-1 manual) and install nut (15); use
T101600 wrench to torque nut 100 to 150 foot-pounds.
to BHT-205A1-MM-1 manual).
Secure nut with lockwire.
NOTE: Do not handle unoiled parts with bare hands. NOTE: Slotinspacerandgrooveinpiniongearshould
be installed in line.
Refer to BHT-205A1-MM-1 manual for approved
lubricants. 8. Coat packing (17) with transmission oil (refer to
BHT-205A1-MM-1 manual) and install packing (17) and
3. Install shim plate (19, figure 66-80) on sleeve (20) spacer (13) on pinion (26).
with three screws. The serial number of the sleeve and
the shim plate must be the same, or a new shim plate NOTE: A workaid may be fabricated, as shown in
must be ground to the correct thickness as follows: figure 66-81 to aid installation of seal (12, figure 66-80).
a. Inspect shim plate and quill sleeve on which 9. Install seal (12) into outer coupling (10) seal
shim plate is to be installed for an etched serial number. groove as follows:
If parts cannot be identified by serial number, determine
required dimension of shim plate. a. Apply a light coat of grease (C-015) to outer
circumference of seal (12).
which shall be metal stamped or vibro-etched on part b. Install seal (12) into outer coupling (10) seal
adjacent to mounting surface. Record this dimension groove, with lip of seal toward internal splines (11) of
and where it is located on sleeve. coupling, as shown in figure 66-80, detail B.
c. If a shim plate of correct part number but without NOTE: Seal (12) will be partially seated and the inner
a serial number is available, measure thickness and coupling (9) will be used in reverse as a backup (see
record. Determine whether shim plate is correct for this detail B) to fully seat the outer circumference edge of
particular installation as follows: seal into outer coupling (10) seal groove.
(1) Subtract shim plate thickness from c. Using inner coupling (9) as a backup, and
reference dimension found on quill sleeve. Resulting placed, as shown in detail B, firmly press down (hand
value must be 0.9760 inch minimum to 0.9765 inch pressure only) on outer coupling (10), simultaneously
maximum. tuck outer circumference edge of seal (12) using
workaid, into outer coupling (10) seal groove.
4. Press duplex bearings (18) into sleeve (20)
face-to-face using T101599 pressing tool. Duplex d. Continue pressing around seal (12) using
bearings must be a matched set with same serial workaid until seal is fully seated.
number on both bearings.
NOTE: Ensure innercoupling (9) is correct fortail rotor
5. Press roller bearing (21) into sleeve (20) using drive quill, overall length is 2.070 to 2.080 inches.
T101333 removal bar, or suitable sleeve. Install retainer Overall length of coupling for 42 and 90 degree gearbox
ring (22). is 1.870 to 1.880 inches.
Rev. 2 66-153
BHT-205A1-CR&O-1
10. Place a small amount of grease (C-015), in coat internal splines of outer coupling (10) with grease,
internal splines of outer coupling (10). Insert inner (C-015) to 0.12 inch depth over top of spline teeth. A
coupling (9) into outer coupling (10) with small end workaid may be fabricated as shown in figure 66-85, to
through seal (12). obtain depth of greasel.
11. Position couplings on splined end of pinion (26). 14. Place small end of centering spring (3) on boss
Place washer (8) on coupling retaining bolt (7) and of seal plate (2). Install plateand spring in outercoupling
thread into gear. Hold outer coupling (10) with T101307 (10) and install retainer ring (1).
wrench and use a square extension to torque bolt (7) 80
to 100 foot-pounds. 15. 212-040-365-)005 and subsequent quills.
12. Place packing (6) on retainer plug (5). Coat a. Install new packing (27) on funnel (28). Coat
packing with approved transmission oil (refer to packing with approved transmission oil (refer to
BHT-205A1-MM-1 manual) and insert into coupling BHT-205A1-MM-1 manual), and position funnel in
retaining bolt (7). If one hole in rim of retainer plug (5) pinion (26)
does not align with notch of inner coupling (9), pull
retainer free of bolt, rotate ninety degrees and reinstall.
Repeat as necessary to obtain alignment. When hole
and notch are aligned, install lock spring (4) through hole
in rim of retainer and notch of coupling. Ensure lock 16. Check gear (26) forfree rotation.
spring is fully engaged in notch.
NOTE: A 1/4-20 threaded bolt may be used to remove TEMP-PLATES as follows:
retainer plug (5) from bolt (7).
a. Remove epoxy coating and TEMP-PLATES
13. Extend outercoupling (10) sothatseal (12) isout (figure 66-84) using paint remover (C-436). Repeat
against the spherical teeth on inner coupling (9) and process until no trace of epoxy is present.
0.74 ± 0.030 INCH
6000-1 TEMP-PLATE (RED BORDER)

2 REQD -180 DEGREES APART
EQUALLY SPACED WITHIN 0.300 INCH
205A1-R-66-84
Figure 66-84. Tail rotor drive quill overtemperature indicator TEMP-PLATE
66-154 Rev. 2
BHT-205A1-CR&O-1
CAUTION: BONDING SURFACE AND NOTE: Working one TEMP-PLATE at a time, repeat
TEMP-PLATES MUST BE FREE OF ALL steps f and g until all TEMP-PLATES are installed on
CONTAMINATION. ANY CONTAMINATION COULD coupling.
ALLOW TEMP-PLATES TO COME OFF OR INDICATE
FALSE TEMPERATURES. f. Remove protective backing from TEMP-PLATE
scrubbing surface using clean cloths wetted with a g. Using clean cloth or cotton swab, work
cleaning solvent MEK (C-309). Remove all TEMP-PLATE into contour of coupling. A thoroughly
contamination and before MEK dries, wipe the surface cleaned firm rubber (edge of a block type eraser)
dry with clean cloth. The cleaned surface area should be workaid may be utilized to work TEMP-PLATE into full
minimum 0.500 inch larger than area of TEMP-PLATES contactwith coupling surface. Ensure the TEMP-PLATE
on outer coupling. is in full contact with coupling surface. Do not press or
rub TEMP-PLATE with bare fingers.
c. Perform a water break-free test on the prepared NOTE: Use of any epoxy adhesive other than Devcon
bonding surface by applying distilled or demineralized (C-298) is not authorized.
must flow into a continuous film without gathering into h. Prepare Devcon 2-Ton epoxy adhesive (C-298)
distinct water droplets within 25 seconds after as follows:
application to the surface. Wipe dry with a clean cloth.
Ensure bonding surfaces are not subsequently (1) Pour equal amounts of epoxy Part A and
contaminated. Part B into a solvent proof container.
d. If thecoupling bonding surface will not meet the (2) Vigorously mix Part A and Part B with a
water break-free test requirements and ensure cleaning brush such as an artist brush.
materials are not contaminated; clean coupling bonding
surfaces as follows: (3) A few drops of thinner, such as MEK
(C-309), may be added to epoxy during mixing
NOTE: Followthemanufacturerrecommendationsfor operation to reduce viscosity to a level that permits
proper mixtures. uniform brush application of epoxy mixture. Do not thin
this mixture such that it runs when applied to a vertical
(1) Using a celaning compound (C-318) and surface. The final viscosity of epoxy should be similar to
cloth, scrub coupling bonding surface clean. Follow heavy bodied paint. Too thin a mixture may seep into
cleaning with a thorough water rinse, temperature indicator TEMP-PLATE and cause
indicator dots to turn black (in which event,
(2) Thoroughly dry coupling surfaces. TEMP-PLATE must be removed and replaced).
Working time for the mixture is approximately 15
(3) Repeat water break-free test as stated minutes.
above. i. Using a soft-bristled brush, uniformly apply
epoxy coating over TEMP-PLATES to a thickness of
approximately 0.002 to 0.004 inch (similar to a coat of
THE TEMP-PLATES ADHESIVE BACKING, ENSURE
THAT WORK HANDS ARE THOROUGHLY paint). Coating should be uniform in appearance, totally
cover surface of TEMP-PLATES and extend
CLEANED BEFORE WORKING WITH TEMP-PLATES. approximately
approximately 025 inch beyond
0.25 inch beyond edges of
TEMP-PLATES.
DO NOT PRESS OR RUB TEMP-PLATES WITH BARE
FINGERS DURING INSTALLATION ON COUPLING. CAUTION: DO NOT EXPOSE EPOXY COATING TO
THIS WILL CONTAMINATE SURFACES. APPLY OIL, GREASE, CLEANING SOLVENT OR OTHER
EPOXY COATING TO TEMP-PLATES IMMEDIATELY CHEMICALS DURING CURE.
FOLLOWING INSTALLATION OF TEMP-PLATES ON
COUPLING. j. Allow epoxy coating to cure at room
temperature, approximately 60 to 100°F, fora minimum
e. Carefully form temperature indicator of six hours prior to operating helicopter. For best
TEMP-PLATES to match V contour of coupling surface. results, allow epoxy to cure overnight prior to operating
Do not crease TEMP-PLATES sharply. helicopter or exposing to oil or grease.
Rev. 2 66-154A
BHT-205A1-CR&O-1
NOTE: An alternate source of heat can be used if the n. Repeat procedure for opposite coupling.
temperature does not exceed 180°F.
18. The tail rotor drive quill shall be tagged with date
k. After one hour epoxy curing time at room of lubrication and an entry made in component historical
temperature, the epoxy coating total curing time can be record, if quill is to be returned to stock.
accelerated by placing the coupling in a temperature
controlled oven for one to two hours at a temperature of
150 to 180°F. 19. When tail rotor drive quill is installed on
helicopter, an entry shall be made in helicopter log and
NOTE: Some lifting at extreme ends of flex couplings lubrication log in BHT-205A1-MM-1
TEMP-PLATES installed on grooved couplings is manualwith dateof lubrication.
acceptable lifting limits. Lifting is permitted only as
shown and should not exceed 0.030 inch estimated. 66-137 HYDRAULIC PUMP AND
l. Following the cure, TEMP-PLATES should TACHOMETER DRIVE QUILL.

conform to the contour of the coupling and be free of
lifted edges except as in note above. Indicating dots on
TEMP-PLATES must remain original white or light gray 66-138. OVERHAUL - HYDRAULIC PUMP AND
with not full or partial black discoloration. TACHOMETER DRIVE QUILL.
m. Perform an adhesion test on each

TEMP-PLATE installation. Press a one inch wide strip of TOOLS REQUIRED
high adhesion tape onto TEMP-PLATE and epoxy
overcoat. Tape should extend beyond edge of epoxy T01305 rench Assembly
overcoat. Grasp one end of tape at approximately 90 T101306
degreesfromthesurfaceand removetape in one abrupt T101308 Jackscrews1/4 X 28UNF
motion. Lifting or peeling of epoxy coating or T101333 Removal Bar
TEMP-PLATE is not acceptable. If lifting or peeling is T101334 Removal Bar
detected, remove and replace TEMP-PLATE by T101592 Pressing Tool
repeating procedure. T101593 Bearing Plate Set
66-154B Rev. 2
BHT-205A1-CR&O-1
HANDLE LENGTH IS OPTIONAL
0.120
Figure 66-85. Workaid for lubrication of tail rotor drive coupling
66-139. DISASSEMBLY - HYDRAULIC PUMP 4. Press pinion (18), with roller bearing inner race
AND TACHOMETERDRIVE QUILL. (19), and spacer (20) on shaft, out of sleeve
assembly. Remove spacer and press bearing race off
1. Remove three bolts and use T101308 pinion using T101592 pressing tool or equivalent.
jackscrews to remove housing cover (1, figure 66-86) Remove cork plug (21) from pinion.
from housing sleeve (24).
NOTE: Tap end of sprocket (9) lightly as cases NOTE Exercise care to position bar on roller
separate to eliminate binding of shaft in case and to bearings (23) and duplex bearings (26) properly to
prevent damage to chain (6). Remove gaskets (2 and
prevent bar from catching on flange of liner.
3) from sleeve studs. Press seals (4 and 5) from cover.
2. Lift out tachometer drive sprocket (9) and 5. Removeretainingring(22),anduseT101334

chain (6). Using T101 593 plate set press of bearings bar to press duplex bearings (26) from outer end of
(10 and 11) from sprocket. Remove cork plug (12) housing sleeve (24). Retain bearings (26) from outer
from sprocket shaft. Remove retaining ring (7) and end of housing sleeve (24). Retain bearings as
sprocket (8) from end of pinion (18). matched set. UseT101333 barto press roller bearing
(23) from housing sleeve (24). Retain bearing inner
3. Cut lockwire and remove six screws (13) to race (19) and roller bearing (23) as a serialized bearing
remove bearing retainer ring (14) and shim (15). assembly.
Remove locking-clip (16). Hold pinion (18) with
T101306 wrench while using T101305 wrench to 6. Remove shim plate (25) from housing sleeve
remove nut (17). (24).
66-155
BHT-205A 1-CR&O-1
4. Seal 17. Nut

1. Housing cover 14. Bearing retainer VIEW - COVER REMOVED
END ring
2. Gasket 15. Shim
3. Gasket 16. Locking-clip
4. Seal 17. Nut
5. Seal 18. Pinion
6. Chain * 19. Bearing inner race
7. Retaining ring 20. Spacer
8. Sprocket 21. Cork plug * Serialized Matched Set
9. Sprocket 22. Retaining ring
10. Bearing *23. Roller bearing
11. Bearing 24. Housing sleeve
12. Cork plug 25. Shim plate
13. Screws *26. Duplex bearings
Figure 66-86. Hydraulic pump and tachometer drive quill
66-156
BHT-205A1-CR&O-1
66-140. CLEANING - HYDRAULIC PUMP AND 3. Inspect parts dimensionally and replace parts
TACHOMETERDRIVE QUILL. that do not fall within inspection limits. (Refer to
figure 66-87.)
2. Inspect quill for corrosion damage of threaded fit between mating parts. It is not intended that all
studs and stud holes before cleaning. No structural dimensions be checked as a prescribed overhaul
damage to threads or holes is acceptable. procedure; however, parts that show evidence of
3. Clean all quill parts with solvent (C-304). Use dimensionally.
parts except bearings may be cleaned with - HYDRAULICPUMP
66-142. REPAIR/REPLACE
trichloroethane (C-334) by vapor degreasing, if AND TACHOMETERDRIVE QUILL.
desired.
1. Replace magnesium parts that have corrosion
4. Dry parts with clean, lint-free cloths or dry damage in critical area which would affect the
filtered compressed air. Do not allow bearings to spin function or structural integrity of the part, or if
while drying. damage exceeds the following limits for the areas.
The areas of the quill assembly most frequently
5. Coat bearings with corrosion preventive damaged by corrosion are those shown on figure
(C-105) immediately after cleaning. Do not handle 66-88.The acceptable limitsfordepth of pitting and
unoiled bearings with bare hands. for percent of area pitted (i.e. the percent of area in
which the original machined surface has been
removed by corrosion ) are as follows:
66-141. NORMAL INSPECTION - HYDRAULIC
PUMPAND TACHOMETER
DRIVE QUILL. The maximum allowable depth of pitting is
PUMP AND TACHOMETER DRIVE QUILL.
PUMP*A A T0.030 inch in area A or B, 0.040 inch in area C, 0.005
.i Visuayt al p s fr d e or inch in area D or E, 0.030 inch in area F, and 0.030
1. Visually inspect all parts for damage or inch on all nonfunctional internal surfaces not
excessive wear. Inspect gear, splines and sprockets incuded in designated areas.
for chipped, broken, or worn teeth. Inspect chain for
wear, elongation or looseness. Inspect bearings for b. No more than 40 percent of the area within
evidence of spalling, scoring, pitting, brinelling, any one inch square nor 20 percent of the total area of
flaking, or corrosion on rolling elements or races, and any surface or diameter may be pitted.
for cracked or broken retainers. Check for
smoothness of rotation. Inspect sleeve and cover for 2. Pits on external surfaces of sleeves in areas
corrosion damage. that will be painted or pits that might trap washer
must either be stoned out, use fine india stone
2. Inspect following parts by magnetic particle (C-464), to blend with the undamaged surface or be
(M) or fluorescent penetrant (F) method as indicated, filled. If pits are stoned out, the maximum depth of
Index numbers are keyed to figure 66-86. rework must not exceed allowable depth specified for
Demagnetize all parts after magnetic inspection. pits. Reworked areas must be blended with original
surface by effecting no radii smaller than 0.25 inch
NOTE: Refer to BHT-ALL-SPMmanual for approved and maintaining surface finish as good as the original
fluorescent penetrant material. (Post Emulsified unpitted surface. If pits are filled the following
Penetrant System.) procedure must be followed:
a. Isolate the area to be repaired by masking.

INDEX NO. NOMENCLATURE CODE
NOTE: Ensure that plating is not removed from
1 Housing Cover F cadmium plated parts. Use suitable masking to
18 Pinion M prevent removal during chromic acid cleaning.
24 Housing Sleeve F
66-157
BHT-205A1-CR&O-1
MIN. MAX.
1 Pinion - Shaft OD 1.5752 1.5758

2 Bearing - Roller ID 1.5745 1.5749
OD 3.1491 3.1496
3 Sleeve ID 3.1489 3.1497
4 Pinion - Shaft OD 1.3780 1.3786
5 Bearings- Duplex ID 1.3777 1.3781
OD 2.8341 2.8346
6 Sleeve ID 2.8340 2.8347
7 Bearings ID 0.5903 0.5907
OD 1.2592 1.2598
8 Sleeve - Bearing Liner ID 1.2598 1.2607
9 Sprocket Shaft OD 0.5901 0.5909
10 Sleeve OD 3.6247 3.6255
Figure 66-87. Hydraulic pump and tachometer drive quill wear limits
66-158
BHT-205A1-CR&O-1
i BE AAREA
AREA
COVER ASSEMBLY SLEEVE ASSEMBLY
Figure 66-88. Hydraulic pump and tachometer drive quill inspection areas
b. Sandblast the affected area lightly. 66-143. REASSEMBLY- HYDRAULICPUMP AND

TACHOMETER DRIVE QUILL.
c. Immediately after sandblasting, apply
adhesive (C-317) or equivalent to the area, maximum 1. Check that oil passages are free of foreign
thickness 1/8 inch. material and that cover and sleeve are clean.
d. Allow part to dry for 24 hours. 2. Verify that serial numbers are the same on
duplex bearings (26, figure 66-86).
numbers and must be retained in matched pairs. 3. Verify that serial numbers are the same on
bearing inner race (19) and roller bearing (23).
4. Assemble roller bearing inner and outer races
with same serial numbers. 4. Press duplex bearings (26) face to face into
inner side of housing sleeve (24), using T101334 bar.
5. Serial number on ground shim plate must Press roller bearing (23), without inner race, into
confirm with serial number on sleeve. outer end of sleeve with T101333 bar. Install
retaining ring (22) in sleeve groove.
6. Replace cork plug in pinion shaft and
tachometer drive sprocket. Install new plug with NOTE: Inspect for duplex bearings being positioned
shellac (C-211) seated against internal shoulder of face to face and bottomed in liner and verify correct
bolt shaft and sprocket. (Refer to figure 66-87.) installation of roller bearings and retaining ring.
66-159
BHT-205A1-CR&O-1
5. Press bearing inner race (19) of roller bearing 13. Press bearings (10 and 11) on each end of
on pinion (18) shaft, with serial numbered side same sprocket (9). Install chain (6) on sprockets (8) and (9)
direction as that of outer race when assembled. Place with connecting link secured by spring lock. Seat
spacer (20) on pinion shaft. Press sleeve assembly bearing on short end of sprocket (9) in liner of sleeve
down over pinion shaft, pressing against inner race of housing.
duplex bearing with suitable pressing tool.
14. Install seals (4 and 5) in housing cover (1),
CAUTION: WHEN INSTALLING PINION INTO with numbered sides of seals outboard. Place gaskets
BEARING, USE CARE TO ONLY APPLY PRESSURE TO (2 and 3) on housing sleeve studs. Coat lip of seals
PINION HUB AREA. PRESSURE APPLIED AT GEAR and mating seal surface with approved transmission
TEETH CAN RESULT IN CRACKS BETWEEN HOLES oil (refer to BHT-205A1-MM-1 manual).
IN WEB AND POSSIBLE FAILURE OF THE PINION IN
SERVICE. 15. Position housing cover (1) on housing sleeve
(24) and install three bolts through spot faced holes in
6. Start nut (17) on pinion shaft, with shoulder of housing sleeve (24) and cover flanges, with bolt
nut against bearing. Hold shaft with T101306 heads inboard. Use aluminum washers next to sleeve
wrench while tightening nut 80 to 100 foot-pounds and cover, and steel washers under bolt heads and
with T101305 wrench. nuts. Torque nuts 50 to 70 inch-pounds.
7. Install locking-clip (16) over nut spline and in 16. Install shim plate (25, figure 66-86) on
beveled groove of shaft. housing sleeve (24) with screws. Serial number of
sleeve and shim plate must be same, or a new shim
8. Shimming requirements are as follows: plate must be grounded to correct thickness as
follows:
a. With a depth gage, measure from outer race
of duplex bearing to surface of sleeve where shim a. Inspect shim plate and quill sleeve on which
(15) is to be installed. shim plate is to be installed for an etched serial
b. Measure height of flange on bearing retainer determine required dimension of shim plate.
ring (14).
c. Subtract sleeve dimension from ring which shall be metal stamped or vibro-etched on part
dimension. adjacent to mounting surface. Record this dimension
d. Subtract 0.003 to 0.006 inch from
difference to determine thickness of shim (15) c. If a shim plate of correct part number but
required to provide a pinch fit on bearing. without a serial number is available, measure
thickness and record. Determine whether shim plate
9. Install bearing retainer ring (14) and shim (15)
with six screws (13). Align index notches in shim
with oil holes in ring. Position ring so that screw hole (1) Subtract shim plate thickness from
which has an adjacent small hole for lockwire is on reference dimension found on quill sleeve. Resulting
center line location. Secure screws with lockwire value must fall within min. - max. dimension below:
(C-405) as shown in figure 66-86.
LOCATION MIN. MAX.
10. Check for free, smooth movement of pinion INCHES
gear.
11. Check installation of cork in pinion (18) and Hydraulic pump and
sprocket (9). tachometer drive quill sleeve.
204-040-306-11 0.9760 0.9765
12. Place sprocket (8) over end of pinion shaft,
with two projections inserted in shaft slots. Install 204-040-306-101 0.9580 0.9585
retaining ring (7) in groove around shaft.
66-160
BHT-205A1-CR&O-1
17. Rotate pinion (18) to ensure that internal parts 2. Inspect pinion (19, figure 66-89) for chipped,
turn freely. broken, or excessively worn teeth.
66-144. ROTOR BRAKE DRIVE QUILL. 3. Inspect the following parts by magnetic particle
inspection (Code M) or fluorescent penetrant inspection
66-145. DISASSEMBLY - ROTOR BRAKE DRIVE (Code F) methods:
QUILL.
TOOLS REQUIRED
1 Flange M
T101519 Plate Assembly 3 Nut M
Commercial Arbor Press Spacer (outer) M
5 Spacer (inner) M
5 Spacer (inner) M
NOTE: For disassembly and overhaul of rotor brake 8 Retainer F
disc and flange assembly, refer to paragraph 66-152. 13 Sleeve F
19 Pinion M
1. Cut lockwire and remove nut (3, figure 66-89) and 20 Disc M
packing (2) from flange (1). Discard packing (2).
2. Remove flange (1) from pinion (19). 4. Inspect parts dimensionally (figure 66-90).
3. Cut lockwire and remove bolts (10) and washers 5. Inspect shims (6 and 17, figure 66-89) for damage
(11). Remove retainer (8), packing (7), and shim plate and corrosion.
(6). Mark shim plate for reinstallation. Remove bushing
(16) and packings (15). Discard packings (7 and 15). 6. Inspect insert (14) for corrosion or damaged
threads.
4. Using arbor press, press seal (9) from retainer (8).
Discard seal.
66-148. REPAIR - ROTOR BRAKE DRIVE QUILL.
5. Hold duplex bearings (4) using T1011519 plate
assembly and press pinion (19) from sleeve (13).
1. Dress splines and gear teeth with fine India stone
(C-464) if surface nicks, burrs, or scratches are visible.
6. Remove bearings (4) and spacer set (5) from
sleeve (13).
CAUTION: DUPLEX BEARINGS (4, FIGURE 66-89)
NOTE: Do not remove ground shim (17) from sleeve ARE SERIAL NUMBERED AND SHALL BE INSTALLED
(13) unless damaged. IN MATCHED PAIRS. BOTH BEARINGS OF A PAIR
SHALL BE FROM SAME MANUFACTURER.
7. Remove screws (18) and shim plate (17). Identify
shim plate for reinstallation. BEARING SPACERS (5) ARE FINISH-GROUND
TOGETHER AND SERIAL NUMBERED AND SHALL
66-146. CLEANING - ROTOR BRAKE DRIVE BE REPLACED AS MATCHED SET.
QUILL.
1. Clean parts with solvent (C-304). 2. Replace all unserviceable components.
2. Dry with filtered, compressed air. 3. If shims (6 and 17) are damaged, return rotor
brake drive quill to Bell Helicopter Textron CPR for
evaluation and repair.
66-147. INSPECTION - ROTOR BRAKE DRIVE
QUILL. 4. Replace threaded inserts (14) as required. (Refer
to BHT-ALL-SPM manual.)
1. Visually inspect parts for excessive wear or
damage (figure 66-90). 5. Replace clinch nuts (12) if damaged or loose.
Rev. 2 66-161
BHT-205A1-CR&O-1
1. Flange
2. Packing
3. Nut
4. Duplex bearing
5. Spacer set
6. Shim
7. Packing
8. Retainer
9. Seal
10. Bolt
TORQUE
125-130 FT-LBS
11. Washer
12. Clinch nut
13. Sleeve
14. Insert
15. Packing
16. Bushing
17. Shim
18. Screw
19. Pinion
20. Disc
21. Bolt
22. Washer 205A1-R-66-89
Figure 66-89. Rotor brake drive quill (412-040-123)
66-162 Rev. 2
BHT-205A1-CR&O-1
MINIMUM MAXIMUM REPLACE
1. Sleeve ID 3.1491 3.1495 3.1497

2. Sleeve OD 4.9995 5.0000 4.9992
3. Bearing ID 1.5745 1.5748 1.5750
4. Bearing OD 3.1492 3.1496 3.1490

5. Pinion OD 1.5751 1.5753 1.5749
(Brg Journal)
6. Pinion spline 1.6130 1.6160 1.6114

(measure over 0.120 inch
diameter pins)
7. Spacer set ID 1.5780 1.5880 1.5900
NOTE:
All dimensions are shown in inches.
205A1-R-66-90-1
Figure 66-90. Rotor brake quill (412-040-123) damage limits (Sheet 1 of 2)
Rev. 2 66-162A
BHT-205A1-CR&O-1
MINIMUM MAXIMUM REPLACE
8. Spacer set OD 3.1320 3.1420 3.1300

9. Spacer set width 1.5224 1.5264
10. Bushing OD 0.4280 0.4300 0.4270

11. Flange Spline 1.3324 1.3342 1.3359
(Measure between
0.0900 inch
diameter pins)
12. Flange ID 1.5767 1.5771 1.5773
13. Flange OD 2.2460 2.2480 2.2450
14. Seal Wear OD 1.8730 1.8770 0.001 depth
NOTE:
Minimum length of spacer set, measuredat three equally spaced points

on each spacer, shall be no less than 1.5222 inches. Maximum variation
shall not exceed 0.0002 inch between any of the six measurements.
205A1-R-66-90-2
Figure 66-90. Rotor brake quill (412-040-123) damage limits (Sheet 2)
66-162B Rev. 2
BHT-205A1-CR&O-1
a. Use a drift or bolt threaded into nut to drive 66-150. ASSEMBLY - ROTOR BRAKE DRIVE
clinch nut out, being careful notto damage hole in sleeve QUILL.
flange.
TOOLS REQUIRED
b. Clean sleeve by vapor degreasing with 1.1.1 -
trichloroethane (C-334). Plate Assembly
Commercial Arbor Press
205-040-300-1G1 F-1 Backlash Tool
c. Clean up surface of sleeve flange to remove
any raised burrs.
d. Treat hole and any reworked areas on sleeve 1. Install duplex bearings (4, figure 66-89) and
with chemical film material (C-100). (Refer to spacer set (5) in sleeve (13).
BHT-ALL-SPM manual).
NOTE: Bearings (4) are assembled back-to-back on

e. If clinch nut was tight before removal, coat new each side of spacer set (5).
nut with unreduced primer (C-204) and drive nut (12) in
place. Remove any raised burrs on sleeve flange face,
and touch up with chemical film material (C-100). 2. Support inner race of duplex bearings (4) with
T101591 plate assembly and press pinion (19) in
bearings (4) using arbor press.
f. If clinch nut was loose before removal, remove
cadmium plating from surfaces of clinch nut contacting
sleeve with abrasive cloth of paper. Clean clinch nut (12) 3. Install packings (15) on bushing (16) and install
and mating surface of sleeve (13) with cheesecloth bushing (16) in sleeve (13).
dampened with MEK (C-309). Bond clinch nut (12) in
sleeve (13) with adhesive (C-317). 4. Using arbor press, press seal (9) in retainer (8).
Install packing (7) in groove on retainer (8).
g. Clean excess adhesive from threads and
surface of sleeve flange and hole. Clinch nut shall be 5. Install retainer (8) and shim (6) on sleeve (13).
0.010 inch minimum below surface of sleeve flange. Install four bolts (10) and washers (11). Torque bolts 50
to 70 inch pounds. Secure bolts using 0.032 inch
h. Verify side of sleeve flange contacting shim diameter lockwire.
plate is flat and clinch nut does not protrude above
surface. 6. Check backlash as follows:
6. Repair corrosion and damage to sleeve (13) and a. Install quill assembly in transmission.
retainer (8) in accordance with figures 66-91 and
66-91 A.
b. Mount dial indicator on transmission.
c. Mount backlash tool 205-040-300-1G1F-1 on

66-149. LUBRICATION - ROTOR BRAKE DRIVE rotor brake disc. With drive quill stationary, measure
QUILL. backlash of rotor brake disc with tool.
d. If tool is not available, measure backlash

1. Lubricate bearings, gear, and mating surfaces tangentially at a distance of 1.421 inches out from center
with a light coat of approved transmission oil. (Refer to of rotor brake disc.
BHT-205A1-MM-1 manual.)
2. Apply corrosion preventive compound (C-104) on NOTE: Backlash for 412-040-123-101 quill assembly
threads. is 0.012 to 0.020 inch.
Rev. 2 66-163
BHT-205A1-CR&O-1
ITEM/ TYPE OF NOMENCLATURE INSPEC- LIMIT

AREA DAMAGE TION
METHOD
A Wear Liner ID Measure 3.1497 Inches max.
B Wear Pilot diameter Measure 4.9993 Inches min.
C Corrosion Liner Visual
D Corrosion Pilot diameter Visual/ 0.005 Inch

measure depth
40% of any one
square inch
5% of area of surface
D Mechanical Pilot diameter Visual/ 0.005 Inch depth
measure 0.500 Inch length
AA
E Corrosion/ Pilot diameter Visual/ 0010 Inch
mechanical measure depth
20% of any one
square inch
20% of area surface
205A1-R-66-91-1
Figure 66-91. Rotor brake quill (412-040-123) sleeve assembly rework limits (Sheet 1 of 3)
66-164 Rev. 2
BHT-205A1-CR&O-1
ITEM/ TYPE OF NOMENCLATURE INSPECTION LIMIT

AREA DAMAGE METHOD
F,K Corrosion/ Packing groove & Visual None allowed
mechanical sealing diameter
G,H Corrosion Shimming surface Visual/measure 0.010 Inch depth

10% of any one
square inch
10% of area
of surface
G,H Mechanical Shimming surface Visual/measure 0.010 Inch depth
0.500 inch
length
I Corrosion/ Mounting pad Visual/measure 0.020 Inch
mechanical depth
20%of surface
J Corrosion Bolt holes Visual/measure 0.020Inch

depth
20% of wall area
L,M Corrosion/ Al-cast and Visual/measure 0.030 Inch depth

mechanical machined surface for Al-cast surface,
0.020 inch depth
for machined surface
40% area of one
square inch or 20%
of area of any
surface
ALL Corrosion/ Lube holes, threaded Visual None allowed

mechanical insert holes, clinch
nut counter bore
ALL Looseness Insert, clinch nut, Visual None allowed
liner pins
ALL Mechanical Shim screw holes Visual None beyond

first thread
ALL Cracks Sleeve Fluorescent None allowed

penetrant
205A1-R-66-91-2
Figure 66-91. Rotor brake quill (412-040-123) sleeve assembly rework limits (Sheet 2)
Rev. 2 66-164A
BHT-205A1-CR&O-1
NOTES:
Only light superficial corrosion, easily removable with steel wool, is allowed.
Damage or repair may not break into packing groove F.
Damageor repair maynot extend closer than 0.060inch from edges of lube holes, threaded
insert holes, threaded screw holes, clinch nut counter bores, and bolt holes.
Reworkcorrosion and mechanical damageby polishing with a fine India stone to minimum
radii of 0.12inch and a surface finish of 63 RMSor better. Removeany raised material flush
with surrounding surface.
Do not polish out corrosion pitting.
Rework only to remove any raised material flush with surrounding surface using a fine
India stone.
Spotface area I may be repaired if corrosion exceeds 0.020 inch depth by spotfacing to a
0.680 ± 0.010 inch diameter with 0.030 ± 0.010 inch fillet radius to a minimum flange
thickness of 0.480 inch not including thickness of shim. Spotface surface must be
concentric with bolt hole within 0.010 inch T.I.R.and parallel with surface G within 0.002
inch.
8. Removeall traces of corrosion on sleeve by immersion in hot chromic acid bath to clean
up corrosion area. All corrosion products must be removed.
9. Touch up reworked areas with chromic acid or treat entire sleeve with corrosion treatment.
Refinish by applying epoxy primer and acrylic lacquer, mask part to omit primer on mating
surfaces.
205A1-R-66-91-3
Figure 66-91. Rotor brake quill (412-040-123) sleeve assembly rework limits (Sheet 3)
66-164B Rev. 2
BHT-205A1-CR&O-1
VIEW A
ITEM/ TYPE OF NOMENCLATURE INSPECTION LIMIT

AREA DAMAGE METHOD
ALL Corrosion/ N/A Visual / None allowed
cracks fluorescent
penetrant
A Mechanical Outer surface Visual/measure 0.030 Inch A
depth
B Mechanical Seal seat Visual None allowed
C Mechanical Packing groove Visual None allowed
D Mechanical Seat/race Visual None allowed
E,F Mechanical Oil hole/transfer Visual None allowed
tube bore
G Mechanical Seat Visual/measure 0.005 Inch A A
depth
H Mechanical Surface Visual/measure 0.010 Inch
depth
205A1-R-66-91A.1
Figure 66-91A. Rotor brake quill (412-040-123) retainer assembly rework limits (Sheet 1 of 2)
Rev. 2 66-164C
BHT-205A1-CR&O-1
NOTES:
No more than 40 percent of any one square inch or 20 percent of total area, after rework,
may be damaged within limits.
Damage shall not extend into packing groove.
Damage shall not cover more than 20 percent of total area. No damage allowed in threaded
holes or bolt holes.
Polish out mechanical damage to produce 0.12 inch minimum radii and a surface of 63 RMS
or better using a fine india stone. Remove any raised material flush with the surrounding
surface.
Rework only to remove any raised material flush with surrounding surface using a fine
india stone.
6. Passivate per QQ-P-35, Type II. Supplement chromate treatment is not required.
205A1-66-R-91A-2
Figure 66-91A. Rotor brake quill (412-040-123) retainer assembly rework limits (Sheet 2)
66-151. ROTOR BRAKE DISC AND FLANGE NOTE: Using an arbor press, or equivalent, to
ASSEMBLY. separate flange from disc requires disc be inspected for
warpage.
66-152. DISASSEMBLY - ROTOR BRAKE DISC a. Reinstall bolts (2) and washers (3) to prevent
AND FLANGE ASSEMBLY. inadvertent assembly separation.
b. Place assembly in arbor press and remove

TOOLS REQUIRED bolts (2) and washers (3).
Commercial Arbor Press c. Apply sufficient pressure to separate flange

from disc.
1. Cut lockwire and remove bolts (2, figure 66-92) 66-153. INSPECTION - ROTOR BRAKE DISC
and washers (3). AND FLANGE ASSEMBLY.
2. Using hand pressure only, separate flange (4) 1. Inspect pilot hole in disc. Hole diameter shall be
from disc (1). 2.2478 to 2.2515 inches.
2. Inspect disc (1, figure 66-92) and flange (4) using

3. If disc and flange cannot be separated by hand the magnetic particle inspection method. No cracks
pressure, proceed as follows: allowed.
66-164D Rev. 2
BHT-205A1-CR&O-1
1. Disc
2. Bolt
3. Washer
4. Flange
Figure 66-92. Rotor brake disc and flange assembly
3. Inspect disc for warpage as follows: 66-154. REPAIR - ROTOR BRAKE DISC AND
FLANGE ASSEMBLY.
a. Install inspection arbor (figure 66-93) in pilot 1 Remove scratches and light surface corrosion
hole for disc. Install four bolts (AN4-5A) and washers from disc (1, figure 66-92) using 400 to 600 grit abrasive
from disc (1, figure 66-92) using 400 to 600 grit abrasive
(AN960-416). cloth or paper. No further repairs are allowed. Do not
exceed limits.
b. Install arbor and disc assembly between lathe
centers. 2. Dress splines and threads of flange (4) with fine
India stone (C-464) is surface nicks, burrs, or scratches
are visible (figure 66-94).
c. While rotating disc, measure runout as indicator
probe is swept across full radial width of each friction 3. Refertofigure66-94forflangereworkprocedures
surface (front and back). and limits.
d. Totalindicatordeflectionshallnotexceed .010 66-155. ASSEMBLY-ROTOR BRAKE DISC AND

FLANGE ASSEMBLY.
e. Measure rim thickness of disc. Rim thickness 1. Install flange (1, figure 66-89) on splined end of
shall not be less than 0.422 inch at any point. pinion (19).
2. Install packing (2) on nut (3) and install nut (3) on

f. Inspect flange (4) for mechanical and corrosion
pinion (19). Torque nut 125 to 150 foot pounds.
damage.
3. Install disc (20) using washers (22) and bolts (21).
g. Inspect splines. Dimensions between 0.090 Secure nut (3) between bolts (21) using 0.032 inch
inch diameter pins shall be 1.3324 to 1.3342 inches. diameter lockwire.
Rev. 2 66-165
BHT-205A1-CR&O-1
66-156. TRANSMISSION MOUNT FRICTION 3. Inspect external surfaces of housing (2) and inner
DAMPER. member (4) for corrosion and mechanical damage.
Superficial mechanical damage is acceptable without
repair. Minor corrosion and mechanical damage is
66-157. INSPECTION - TRANSMISSION MOUNT acceptable if polished out.
FRICTION DAMPER.
1. Inspect bearing (1, figure 66-95) for wear. 66-158. REPAIR - TRANSMISSION MOUNT
Maximum acceptable radial play is 0.004 inch. FRICTION DAMPER.
2. Inspect boot (3) for holes and deterioration. Polish out minor mechanical and corrosion damage on
Damage that can be detected visually is not external surfaces of housing (2) and inner member (4)
acceptable. with 400 grit abrasive paper (C-423).
66-166 Rev. 2
BHT-205A1-CR&O-1
0.250-28 UNF-3B THRU

°
COUNTERSINK90 X 0.260 DIA
0.125 2 PLACES LACESEQ SPACED
CHAMFER
0.060 X 45 2 PLACES
CHAMFER 0.32 0.125 2 PLACES
0.12 x 45 2 PLACES
3002 PLACES
1.00DIA 1.50 DIA 2.2465

2 PLACES 2 PLACES 2.2460 DIA
0.75 2 PLACES 3.60 2.875
0.19 R 2 PLACES
2.5 - 2.5 0.500 DIA TO DEPTHSHOWN
0.310
0.310
NOTES:
1. MATERIAL: AISI 4340 STEELPER MIL-S-5000. HEAT TREAT TO RC36-40

IN ACCORDANCE WITH MIL-H-6875.
2. SURFACE FINISH 125 RMS UNLESS OTHERWISE NOTED.
3. BREAK EDGES 0.015R OR 0.015 x CHAMFER UNLESS OTHERWISE NOTED.
4. ALL DIMENSIONS ARE IN INCHES.
Figure 66-93. Rotor brake disc inspection arbor
66-159. TEST - TRANSMISSION MOUNT 66-160. TAIL ROTOR DRIVESHAFT HANGER.

FRICTION DAMPER.
1. Install damper in test fixture capable of

supporting 1000 pounds. 66-161. OVERHAUL TAIL ROTOR DRIVESHAFT
CAUTION: LIMIT MOTION TO A MAXIMUM OF HANGER.
0.500 INCH.
2. Load damper to measure sliding friction
The following procedures may be used to overhaul
housing (2). Initial load (may exceed 500 pounds) the 204-040-600 hanger assembly or the
must drop to between 115 pounds and 180 pounds 212-040-600
212-040-600 hanger
hanger assembly. Differences in
assembly. Differences in
once sliding is initiated.
once sliding is initiated. overhaul procedures are noted in text.
66-167
BHT-205A 1-CR&O-1
ITEM NOMENCLATURE
A Effective area where rework allowed.
B Pilot diameter for rotor brake disc.
C Mating surface of flange with threaded hole for disc retaining

bolt. Typical four places.
D Flange sealing surface.
E Circumference of flange with radiused expanded dimension for

threaded hole to accommodate disc retaining bolt. Typical four
places.
F Inner flange diameter for support on pinion gear.
G Flange circumference other than radiused areas with threaded

holes.
Figure 66-94. Rotor brake drive quill support flange rework limits (Sheet 1 of 2)
66-168
BHT-205A 1-CR&O-1
ITEM REWORK INSTRUCTIONS
A Remove corrosion, nicks, and scratches using file, grinder, or

abrasive paper (C-423) as applicable. Do not use chemicals.
Polish or buff surface of reworked areas to a smooth,
scratch-free finish. Protect reworked area with epoxy
polyamide primer (C-204) and lacquer (C-203), except where
restricted in following instructions. Brush cadmium plating is
permitted over reworked area in lieu of primer and paint. LHE
Cadmium solution (C-108) must be used, or part must be
baked within one hour after plating to relieve hydrogen
embrittlement.
B Diameter B rework limited to 0.010 inch depth, but no more

than 50% of effective pilot diameter in any half-inch length
around circumference. Do not paint pilot diameter.
C Area C rework limited to 0.010 inch depth, but no more than

50% of mating surface around hole, typical four places. Polish
reworked area to smooth, scratch-free finish with minimum
radius of 0.19 inch. Do not paint reworked mating surface.
Brush cadmium plating (C-108) may be applied.
D No damage or rework allowed in seal area. Minor damage

outside sealing area may be reworked to 0.010 inch depth.
E Circumference E rework limited to 0.010 inch depth on

radiused outer surface of flange around hole, typical four
places. Take care to remove an equal amount of material from
flange 180° from reworked area to maintain balance of part.
F No rework allowed. Check for wear. Reject flange if a

measurable step of 0.0005 inch or more is evident.
G Rework of flange in area G limited to 0.020 inch depth. Use

care to remove an equal amount of material from flange 180 °
from reworked area to maintain balance of part. Minimum
acceptable diameter of flange after rework is 2.81 inches.
Figure 66-94. Rotor brake drive quill support flange rework limits (Sheet 2 of 2)
66-169
BHT-205A1-CR&O-1
3. Slide rear coupling (14) from splined shaft

(10). Remove inner and outer couplings (7 and 8)
from forward end of splined shaft. Remove seal (9)
from outer coupling (8).
4. Support inner race of bearing (12) and press

out shaft (10).
5. Remove retainer ring (11), and press bearing

from hanger (13).
6. Discard bearing at overhaul.
66-163. CLEANING - TAIL ROTOR DRIVESHAFT

HANGER.
1. Wash all parts except bearings, with solvent

(C-304). Dry with filtered compressed air.
2. Clean bearing by wiping with dry, lint-free

cloth. Do not allow bearings to spin while drying.
1. Bearing NOTE: If hanger is primed with (C-204) only the top

2. Housing coat needs to be removed.
3. Boot
4. Inner member
3. Remove paint from hanger with paint remover
(C-436). (Refer to BHT-ALL-SPMmanual.) Rinse with
clean water.
Figure 66-95. Transmission mount friction damper
assembly 66-164. INSPECTION - TAIL ROTOR
DRIVESHAFT HANGER.
66-162. DISASSEMBLY - TAIL ROTOR
DRIVESHAFT HANGER. NOTE: If records or physical appearance of hanger
NOTE: If records and/or physical appearance of tail indicate component was subjected to an accident or
rotor driveshaft hanger indicate that assembly has incident outside realm of normal usage, perform
been subjected to an accident or incident outside Conditional Inspection, paragraph 66-165. If no
realm of normal usage, perform Conditional evidence is found, proceed to Normal Inspection,
Inspection, paragraph 66-165. paragraph 66-166.
If hanger is being disassembled for replacement of 66-165. Conditional Inspection - Tail Rotor
parts, instead of overhaul, disassemble only to extent DriveshaftHanger.
necessary to replace parts.
NOTE: For ease of maintenance, block the outer 1. Visually inspect curvic faces of outer and rear
coupling so that it will remain in the outboard couplings (8 and 14, figure 66-96) for distortion or
(extended) position. This will stabilize the outer evidence of overheating.
coupling during disassembly and assembly.
2. Visually inspect mounting ears of hanger (13)
1. Remove retainer ring (1, figure 66-96) plate for cracks or distortion.
(2), and spring (3) from outer coupling (8).
3. Visually inspect teeth of spherical faces of
2. Remove nut (15) with washers (5), bolt (4), inner and outer couplings (7 and 8) for cracks or
washer (5) and retainer plates (6). galling.
66-170
BHT-205A1-CR&O-1
TORQUE
50TO 70
IN-LB
GREASE GROOVES IN
204-040-623-003 BEARING
SEE DETAIL A
INTERNAL
SPLINES
SEAL (9) PARTIALLY SEATED SEAL (9) FULLY SEATED
INTERNAL OUTER COUPLING

SPLINES (8) INSTALLED
INNER COUPLING (7) USED INVERTED ON INNER
OF SEAL (9) UP
DETAIL A
1. Retainer ring 7. Inner coupling 12. Bearing

2. Plate 8. Outer coupling 13. Hanger
3. Spring 9. Seal 14. Rear coupling
4. Bolt 10. Shaft 15. Nut
5. Washer 11. Retainer ring
6. Retainer plate
NOTE: A Location of overtemperature indicator TEMP-PLATE(S).
205A1-R-6-96
Figure 66-96. Tail rotor driveshaft hanger
Rev. 2 66-171
BHT-205A1-CR&O-1
4. Check bearing (12) for freedom and smoothness overtemperature condition. Chemical contamination
of rotation. can also cause indicating dots to turn black.
5. Inspect detail parts forcracks by magnetic particle 5. Inspect outer coupling (8, figure 66-96)
or fluorescent penetrant methods as applicable. (Refer overtemperature indicator TEMP-PLATES for evidence
to paragraph 66-166.) of overtemperature indication. If overtemperature
indication is noted, perform coupling overtemperature
NOTE: If inspection reveals cracks or distortion inspection as follows:
indicative of excessive loads in any one detail part, the
entire assembly shall be considered unserviceable and a. Inspect outer coupling cadmium plating for
nonreparable. being discolored (circumferential tan or light brown
6. Perform Normal Inspection. (Refer to paragraph blistering is found, replace outer coupling and inner
66-166.) coupling.

66-166. Normal Inspection - Tail Rotor Driveshaft coupling for being discolored (brown or blue) in normally
Hanger. bright contact patterns. If discoloration is found, replace
outer coupling and inner coupling.
1. Visually inspect all parts for damage or excessive
wear. c. Inspect outer coupling and inner coupling under
5X to 10X magnification for teeth exhibiting signs of
2. Inspect inner coupling (7, figure 66-96) for metal smearing or tearing in contact patterns. If
acceptable wear patterns as shown in figure 66-97. smearing or tearing is found, replace outer coupling and
inner coupling.
3. Inspectfollowingpartsbymagneticparticle(Code d. Inspect grease from couplings for being very
M) or fluorescent penetrant (Code F), as applicable.
Index numbers are keyed to figure 66-96. Demagnetize
greaseis found to be viscous and having a strong
parts after magnetic inspection.
pungent odor, replace outer coupling and inner
fluorescent penetrant material. NOTE: If TEMP-PLATES are to be replaced, replace
INDEX NO. NOMENCLATURE CODE TEMP-PLATES after completing entire inspection
procedure and couplings have been determined
4 Bolt M serviceable and prior to lubricating couplings.
6 Retainer Plate F
7 Inner Coupling M 5A. Inspect outer coupling (8) overtemperature
8 Outer Coupling M indicator TEMP-PLATES for deterioration, debonding,
10 Shaft M or discoloration of epoxy coating that prevents
13 Hanger F/M interpretation of indicating dots. If deterioration,
14 Rear Coupling M debonding, or discoloration of epoxy is found, replace
TEMP-PLATES in accordance with paragraph 66-169.
NOTE: Perform fluorescent penetrant inspection on 6. Inspect hanger (13) for overheat condition. A
magnesium hangers (13) and magnetic particle multicolor appearance of hanger which darkens
inspection on steel hangers (13). adjacent to the bearing indicates a possible overheat
condition. The cause shall be determined and corrected
4. Inspect parts dimensionally and replace parts that prior to continued operation.
66-98.) NOTE: Wear limits are provided to show the required
NOTE: Overtemperature dots on overtemperature dimensions be checked as a prescribed overhaul
indicator TEMP-PLATES are of a white or light gray procedures; however, parts that show evidence of wear
color and turn black when exposed to an or physical damage must be checked dimensionally.
66-172 Rev. 2
BHT-205A1-CR&O-1
66-167. REPAIR/REPLACE - TAIL ROTOR 3. Polish nicks, burrs and scratches on exterior
DRIVESHAFT HANGER. surfaces with crocus cloth.
4. Treat repaired cadmium plated surfaces with LHE

1. Replace all unserviceable parts on reassembly. cadmium plating solution (C-108). (Refer to
BHT-ALL-SPM manual for prescribed cadmium plating
method.)
2. Dress splines of inner and outer couplings (7 and
8, figure 66-96) with fine India stone (C-464) as 5. Replace parts that are not within allowable wear
necessary to blend out burrs, small nicks and scratches. limits.
Rev. 2 66-172A/66-172B
BHT-205A 1-CR&O-1
B Acceptable pattern typical of couplings which have




E dicating that the pitted area is polishing over.
This condition may exist on all teeth. Couplings
be replaced.
204040-181
Figure 66-97. Tail rotor driveshaft hanger coupling wear pattern
66-173
BHT-205A1-CR&O-1

(Inches)
1 Outer Coupling - Internal Spline Between 1.8290 1.8360

(Use 0.1309 Inch Diameter Pins Pins
2 Inner Coupling - External Spline Over Pins. 2.1590 2.1740

(Use 0.1080 Inch Diameter Pins)
3 Inner Coupling and Rear Between 1.1251 1.1336

Coupling - Internal Splines Pins
4 Shaft - External Spline Over Pins 1.3502 1.3518

5 Shaft - Bearing Seat 1.3776 1.3784
6 Bearing - Inside Diameter 1.3775 1.3781
7 Bearing - Outside Diameter 2.4403 2 4409
8 Hanger - Inside Diameter 2.4401 2.4409
OTE
Maximum depth of wear 0.005 inch measured from unworn face of tooth.
Figure 66-98. Tail rotor driveshaft hanger wear limits (Sheet 1 of 2)
66-174
BHT-205A 1-CR&O-1

(Inches)
1 Outer Coupling - Internal Spline Between Pins 1.8290 1.8360

(Use 0.1309 In Diameter Pins)
2 Inner Coupling - External Spline Over Pins 2.1590 2.1740

3 Inner Coupling and Rear Between Pins 1.1465 1.1578

Coupling - Internal Splines
4 Shaft - External Spline Over Pins 1.4424 1.4465

5 Shaft - Bearing Seat

(212-040-602-1 and 5) 1.3776 1.3784
(212-040-602-3 and 7) 1.3476 1.3484
6 Bearing - Inside Diameter

(212-040-623-1 and 5) 1.3775 1.3781
(212-040-623-3) (Regreasable) 1.3477 1.3481
7 Bearing - Outside Diameter 2.4403 2.4409
8 Hanger - Inside Diameter 2.4401 2.4409
NOTE
Maximum depth of wear 0.005 inch measured from unworn face of tooth.
212-040-600
Figure 66-98. Tail rotor driveshaft hanger wear limits (Sheet 2 of 2)
66-175
BHT-205A1-CR&O-1
66-168. REASSEMBLY - TAIL ROTOR d. Continue pressing around seal (9) using
DRIVESHAFT HANGER. workaid, until seal is fully seated.
CAUTION: IF COUPLING SHAFT (10, FIGURE 4. Apply a small quantity of lubricant (C-015) to
66-96), FORWARD INNER COUPLING (7), OR REAR splines of outer coupling (8) on inboard side of seal
COUPLING (14) IS TO BE REPLACED, ENSURE THAT (9).
MESHING SPLINES OF THESE PARTS HAVE 26
SPLINESAND NOT 24 SPLINES. 5. Install inner coupling (7), with small end
through seal (9). Bottom out inner coupling against
THE 212-040-602-001, -005 SHAFTS ARE NOT seal.
INTERCHANGEABLEWITH THE.212-040-602-003,
-007 SHAFTS. THE 212-040-602-003, -007 6. Hand pack internal splines of outer coupling (8)
SHAFTS ARE LONGER AND HAVE A SMALLER with lubricant (C-015) to 0.12 inch deep over top of
OUTSIDE DIAMETER TO ACCOMMODATE THE internal splines for full length of exposed splines. A
204-040-623-003 BEARING. workaid may be fabricated, as shown on figure
66-85, to obtain depth of grease.
1. Support inner race of bearing (12, figure
66-96) and press shaft (10) into bearing. 7. Assemble inner and outer couplings (7 and 8,
figure 66-96), retainer plate (6), rear coupling (14)
NOTE: Bearing journal of shaft (10) must be onto splined ends of inner shaft (10). Install bolt (4),
centered on inner race of bearing (12) within 0.003 to bolthead toward flexible coupling end, with washers
0.016 inch. (5) and nut (15). Torque nut 50 to 70 inch-pounds and
secure with cotter pin.
2. Support hanger (13) and press bearing and
shaft into hanger. Secure bearing with retainer ring 8. Place spring (3) onto alignment probe on rear
(11). side of cover plate (2). Position spring and cover on
outer coupling (8), compress spring and install
NOTE: A workaid may be fabricated, as shown in retainer ring (1). Ensure retainer ring is fully seated.
figure 66-81 to aid installation of seal (9, figure
66-96). 9. Paint tail rotor driveshaft hanger in accordance
with paragraph66-169.
3. Install seal (9) into outer coupling (8) seal
groove as follows: 10. The tail rotor hanger shall be tagged with date
of lubrication and an entry made in component
a. Apply a light coat of grease (C-015) to outer historical record, if hanger is to be returned to stock.
11. When tail rotor hanger is installed on
b. Install seal (9) into outer coupling (8) seal helicopter, an entry shall be made in helicopter log
groove with lip of seal toward internal splines of and flex couplings lubrication log in
coupling (8), as shown in figure 66-96, detail A. BHT-205A1 -MM-1 with date of lubrication.
NOTE: Seal (9) will be partially seated and the inner 66-169. PAINTING - TAIL ROTOR DRIVESHAFT
coupling (7) will be used as a backup in reverse (see HANGER.
detail A) to fully seat the outer circumference edge of
seal into outer coupling (8) seal groove. 1. Touch up exposed magnesium surfaces on
hanger (13, figure 66-96) with chemical film (C-103).
c. Using inner coupling (7) as a backup, and
placed, as shown in detail A, firmly press down (hand 2. Mask off bearing, seal and couplings. Clean
pressure only) on outer coupling (8), simultaneously hanger in area to be painted with clean cheesecloth
tuck outer circumference edge of seal (9) using wetted with aliphatic naphtha (C-305). Wipe dry with
workaid, into outer coupling (8) seal groove. clean cheesecloth before naphtha evaporates. Apply
66-176
BHT-205A1-CR&O-1
one coat of primer (C-202) to a 0.4 to 0.9 mil thickness, to the surface. Wipe dry with a clean cloth. Ensure bonding
if primer was removed, to hanger. Air dry epoxy primer surfaces are not subsequently contaminated.
for 30 minutes before applying top coat.
d. If the coupling bonding surface will not meet the
3. Apply two orthree coats (1.0 to 1.5 mils) of lacquer water break-free test requirements and ensure cleaning
(C-203), color 36231 (gull gray). materials are not contaminated; clean coupling bonding
surfaces as follows:
TEMP-PLATES as follows: NOTE: Follow the manufacturer recommendations for
proper water mixtures.
(figure 66-99) using paint remover (C-436). Repeat (1) Using a cleaning compound (C-318) and
process until no trace of epoxy is present. cloth, scrub coupling bonding surface clean. Follow
cleaning with a thorough water rinse.
CAUTION: BONDING SURFACE AND TEMP-PLATES
MUST BE FREE OF ALL CONTAMINATION. ANY (2) Thoroughly dry coupling surfaces.
COMBINATION COULD ALLOW TEMP-PLATES TO
COME OFF OR INDICATE FALSE TEMPERATURES. (3) Repeat water break-free test as stated
above.
scrubbing surface using clean cloths wetted with a CAUTION: TO PREVENT CONTAMINATION OF
cleaning solvent MEK (C-309). Remove all comtamination THE TEMP-PLATES ADHESIVE BACKING, ENSURE
and before MEK dries, wipe the surface dry with clean THAT WORK AREA AND HANDS ARE THOROUGHLY
cloth. The cleaned surface area should be minimum 0.50 CLEANED BEFORE WORKING WITH TEMP-PLATES.
inch larger than area of TEMP-PLATES on outer coupling.
c. Perform a water break-free test on the prepared FINGERS DURING INSTALLATION ON COUPLING.
bonding surface by applying distilled or demineralized THIS WILL CONTAMINATE SURFACES. APPLY
water from a suitable dispenser (squeeze bottle). Water EPOXY COATING TO TEMP-PLATES IMMEDIATELY
must flow into a continuous film without gathering into FOLLOWING INSTALLATION OF TEMP-PLATES ON
distinct water droplets within 25 seconds after application COUPLING.
HANGER
6000-1 TEMP-PLATE (RED BORDER)

2 REQD-180 DEGREES APART
EQUALLY SPACED WITHIN 0.3 IN.
INDENTIFICATION
PLATE
205A1-R-66-99
Figure 66-99. Overtemperature indicator TEMP-PLATE
Rev. 2 66-176A/66-176B
BHT-205A1-CR&O-1
e. Carefully form overtemperature indicator of six hours prior to operating helicopter. For best
TEMP-PLATES to match V contour of coupling surface. results, allow epoxy to cure overnight prior to operating
Do not crease TEMP-PLATES sharply. helicopter or exposing to oil or grease.
NOTE: Working one TEMP-PLATE at a time, repeat NOTE: An alternate source of heat can be used if the
steps f and g until all TEMP-PLATES are installed on temperature does not exceed 180°F.
coupling.
k. After one hour epoxy curing time at room
f.
f. Remove
Remove protective
protective backing
backing from
from TEMP-PLATE
TEMP-PLATE temperature,
the our epoxytal curing time can be
and carefully position onto surface prepared in step b. temperature the epoxy coating total curing time can be
accelerated by placing the coupling in a temperatue
Using clean
g.g. Using cloth or
clean cloth cotton swab,
or cotton work
swab, work controlled oven for one to two hours at a temperature of
TEMP-PLATE into contour of coupling. A thoroughly
cleaned firm rubber (edge of a block type eraser) NOTE: Some lifting at extreme ends of
workaid may be utilized to work TEMP-PLATE into full TEMP-PLATES installed on grooved couplings is
contactwith coupling surface. Ensure theTEMP-PLATE acceptable. Refer to figure 66-3, view A for acceptable
is in full contact with coupling surface. Do not press or lifting limits. Lifting is permitted only as shown and
lifting limits. Lifting is permitted only as shown and
rub TEMP-PLATE with bare fingers. should not exceed 0.030 inch estimated.
NOTE: Use of any epoxy adhesive other than Devcon

2-Ton (C-298) is not authorized. I. Following the cure, TEMP-PLATES should
h. Prepare Devcon 2-Ton epoxy adhesive (C-298) lifted edges except as in note above Indicating dots on
as follows: TEMP-PLATES must remain original white or light gray
with no full or partial black discoloration.
(1) Pour equal amounts of epoxy Part A and
Part B into a solvent proof container. m. Perform an adhesion test on each TEMP-PLATE
installation. Press a one inch wide strip of high adhesion
(2) Vigorously mix Part A and Part B with a tape onto TEMP-PLATE and epoxy overcoat. Tape should
brush such as an artist brush. extend beyond edge of epoxy overcoat. Grasp one end of
tape at approximately 90 degrees from the surface and
(3) A few drops of thinner, such as MEK (C-309), remove tape in one abupt motion. Lfting or peeling of
may be added to epoxy during mixing operation to reduce epoxy coating or TEMP-PLATE
TEMP-PLATE is
is not
not acceptable.
acceptable If lifting
lifting
viscosity to a level that permits uniform brush application or peeling detected remove and replace TEMP-PLATE
of epoxy mixture. Do not thin this mixture such that it runs by repeating procedure.
when applied to a vertical surface. The final viscosity of
epoxy should be similar to heavy bodied paint. Too thin a n. Repeat procedure for opposite coupling.
mixture may seep into overtemperature indicator
TEMP-PLATE and cause indicator dots to turn black (in 66-170. INTERMEDIATE GEARBOX.
which event, TEMP-PLATE must be removed and
replaced). Working time for the mixture is approximately
15 minutes. 66-171. OVERHAUL - INTERMEDIATE GEARBOX
(204-040-003).
i. Using a soft-bristled brush, uniformly apply epoxy
coating over TEMP-PLATES to a thickness of TOOLS REQUIRED
approximately 0.002 to 0.004 inch (similar to a coat of T101307 Wrench
paint). Coating should be uniform in appearance, totally T101333 Bar
cover surface of TEMP-PLATES and extend approximately T101334 Bar
0.25 inch beyond edges of TEMP-PLATES. T101336 Wrench
CAUTION: DO NOT EXPOSE EPOXY COATING TO or

OIL, GREASE, CLEANING SOLVENT, OR OTHER T101600 Wrench
CHEMICALS DURING CURE. T101338 Jackscrew Set
T101350 Clamp Assembly
j. Allow epoxy coating to cure at room T101455 Plate Assembly
temperature, approximately 60 to 100°F, for a minimum T102030-3 Clamp Assembly
Rev. 2 66-177
BHT-205A1-CR&O-1
66-172. DISASSEMBLY - INTERMEDIATE 6. Inspect outer coupling (15, figure 66-100)

GEARBOX. overtemperature indicator TEMP-PLATES for evidence
of overtemperature indication. If overtemperature
NOTE: If records and/or physical appearance of indication is noted, perform coupling overtemperature
intermediate gearbox indicate that assembly has been inspection as follows:
subjected to an accident or incident outside realm of
normal usage, perform Conditional Inspection, a. Inspect outer coupling cadmium plating for
paragraph 66-175. being discolored (circumferential tan or light brown
If intermediate gearbox is being disassembled, for coupling.
replacement of parts instead of overhaul, disassemble
only to extent necessary to replace parts.
coupling for being discolored (brown or blue) in normally
1. Cut lockwire and remove vent (1, figure 66-100) bright contact patterns. If discoloration is found, replace
and gasket (2). outer coupling and inner coupling.
2. Remove chip detector (21) and gasket (20) and c. Inspect outer coupling and inner coupling under
drain oil from case assembly. 5X to 10X magnification for teeth exhibiting signs of
3. Release pin (27), turn filler cap assembly (29) smearing or tearing is found, replace outercoupling and
counterclockwise and remove from case. Remove inner coupling.
preformed packing (30).
4. Remove twelve nuts (16), steel washers (17) and viscous (thick) and having a strong pungent odor. If
washers (18) (each end). grease is found to be viscous and having a strong
CAUTION: WHEN USING JACKSCREWS TO coupling.
REMOVE INPUT AND OUTPUT QUILL, THE
MUST BE SCREWEDIN EVENLY
JACKSCREWS NOTE: If TEMP-PLATES are to be replaced, replace
EQUAL PRESSURE ON QUILL
EXERTING SLEEVE TEMP-PLATES after completing entire inspection
TO PREVENT DAMAGETO FLANGES, DO NOT USE
FORCE BY TRYING TO REMOVE QUILL. IN THE serviceable and prior to lubricating couplings.
EVENT QUILL CANNOT BE REMOVED USING THIS
PROCEDURE, HEAT CASE (WITH HEAT LAMP)
THEN USE JACKSCREWS. DO NOT USE TORCH OR overtemperature indicator TEMP-PLATES for
OPEN FLAME TO HEAT CASE. deterioration, debonding or discoloration of epoxy
NOTE: Remove sealant and/or nylon setscrews (14) found, replace TEMP-PLATES in accordance with
from jackscrew holes prior to using tool. paragraph 66-199.
5. Cut sealant between case assembly (8) and drive 7. Overhaul input quill. (Refer to paragraph 66-192.)
and driven quill assemblies (13 and 3). Use three
T101338 jackscrews through threaded holes of 8. Overhaul input quill. (Refer to paragraph 66-209.)
mounting flange. Turn jackscrews evenly to pull drive
and driven quill assemblies (13 and 3) from case 9. Remove screws (5) and remove shim plates (6
assembly (8). Remove preformed packing (12) from and 10). Identify shim plates for installation.
each sleeve.
10. Remove retaining ring (26), sight glass (25) and
NOTE: Overtemperature dots on overtemperature indicator oil plate (26). Remove and discard packing
indicator TEMP-PLATES are of a white or light gray (24).
overtemperature condition. Chemical contamination NOTE: Strip (19) is not required on helicopters that
can also cause indicating dots to tum black. have push-pull anti-torque control system.
66-178 Rev. 2
BHT-205A1-CR&O-1
66-173. CLEANING - INTERMEDIATE GEARBOX. 3. Visually inspect all detail components. Note any
damage that could be attributed to a lightning strike.
1. Clean all parts with solvent (C-304).
4. Utilizing data obtained during visual inspection of
2. Dry parts with low pressure filtered air or intermediate gearbox components, evaluation of other
cheesecloth. related components, and helicopter in general,
determine entry and exit points of current. A
3. Remove sealant from gearbox case assembly (8, magnetometer may be helpful in determining current
figure 66-100) with plastic scraper. paths.
NOTE: Parts that have an acrylic lacquer top coat and NOTE: It may be necessary to disassemble and
primer (C-202) need only to have the top coat removed visually inspect selected bearings to determine current
for fluorescent penetrant inspection. paths. Once these bearings have been disassembled
they shall be scrapped.
4. Remove all paint and primer from gearbox case
using paint remover (C-436). 5. Utilizing the following guidelines, determine the
serviceability of detail components.
5. If ferrous parts are not used immediately after
cleaning, gently agitate parts in corrosion preventive a. Any component that exhibits evidence of arc,
(C-105) and air dry. Apply protective coat of approved burning, or pitting shall be deemed unserviceable and
gearbox oil (refer to BHT-205A1-MM-1 manual). scrapped.
b. Any component in current paths that cannot be

66-174. INSPECTION - INTERMEDIATE 100 percent visually inspected, i.e., bearings that
cannot be disassembled, shall be deemed
NOTE: If records and/or physical appearance of
gearbox indicate that assembly has been subjected to 66-176. Normal Inspection - Intermediate
an accident or incident outside realm of normal usage, Gearbox.
perform, Conditional Inspection, paragraph 66-175. If
gearbox does not require conditional inspection 1. Visually inspect all parts for damage and
proceed with Normal Inspection, paragraph 66-176. excessive wear. Inspect bearing liners for scoring, and
for security in case openings. Inspect studs for
looseness or damage. Refer to BHT-ALL-SPM manual
66-175. Conditional Inspection - Intermediate for stud replacement
Gearbox.
2. Inspect case by fluorescent penetrant method.
NOTE: If intermediate gearbox is being overhauled (Referto BHT-ALL-SPM manual)
due to lightning strike, proceed to steps 3 through 5.
NOTE: If inspection reveals cracks or distortions
1. Inspect case, couplings, gears and sleeves by indicative of excessive loads, then the entire component
fluorescent penetrant methods. shall be considered unserviceable and nonreparable.
2. If step 1. reveals cracks or distortion indicative of 3. Inspect gearbox case quill ports for 3.6250 inch to
excessive loads, then the entire component shall be 3.6265 inch inside diameter.
considered unserviceable and nonreparable. If this
condition does not exist, then perform Normal 4. Inspect sight glass (25, figure 66-100) for crazing
Inspection in accordance with paragraph 66-176. or discoloration.
NOTE: All components shall be evaluated as an 5. Inspect oil indicator plate (9) for condition and
interrelated group. peeling paint.
During disassembly, note any damage that could be 6. Visually inspect shim plates (6 and 10) for
attributed to lightning strike, distortion.
Rev. 2 66-179
BHT-205A1-CR&O-1
I \$
@>(
@)
^
it
ia--^«^^^^\
\\ \\ 1fi
\ t J. ELONGATION
(TYPICAL)
1. Vent 16. Nut

2. Gasket 17. Steelwasher
3. Output quill 18. Washer
4. Output quill coupling 19. Strip
5. Screw 20. Gasket
6. Shim 21. Chip detector
7. Plate 22. Adapter
8. Case 23. Indicator plate
9. Screw 24. Packing
10. Shim 25. Sight glass
11. Stud 26. Retaining ring
12. Packing 27. Pin
13. Input quill 28. Chain
14. Nylon setscrew 29. Cap
15. Input quill coupling 30. Packing
NOTES:
Location of overtemperature indicator TEMP-PLATE(S).
Apply grease (C-001)to jackscrew hole prior
to inserting setscrew (14).
205A1-R-66-100
Figure 66-100. Intermediate gearbox (204-040-003)
66-180 Rev. 2
BHT-205A1-CR&O-1
7. Inspect area A of case shown in figure 66-101. 4. Replace gear case assembly (8, figure 66-100) if
Maximum depth of pitting acceptable is 0.030 inch and corrosion damage exceeds allowable limits, or if thread
no more than 40 percent of area within any one inch damage in any hole for studs (11) extends past top
square and no more than 20 percent of the total area A thread in the case or if gearbox attachment hole
at either bore should be pitted. Affected area must be elongation exceeds 0.292 inch. Corrosion pitting on the
inspected prior to corrosion removal for evidence of upper machined face at the four mounting bolt
corrosion in threads between studs and case. Structural
damage to threads in case are not acceptable. Inspect
sleeves for security of liners. Inspect shim plates for
damage to cadmium plating. (Refer to paragraph
66-177 for rework instructions.)
66-177. REPAIR - INTERMEDIATE GEARBOX.
1. Perform corrosion corrective action in accordance

with BHT-ALL-SPM manual.
NOTE: Parts having damage not covered by

limitations may be further evaluated by contacting
Product Support, Bell Helicopter Textron.
2. Replace all parts that exceed allowable

tolerances.
3. Remove broken, bent; damaged or loose studs.

Inspect threaded hole in case. If stud hole threads of
case show damage, repair or replace case as required. Figure 66-101. Intermediate gearbox
(Refer to BHT-ALL-SPM manual.) (204-040-003) case inspection area
Rev. 2 66-180A/66-180B
BHT-205A 1-CR&O-1
holes is acceptable provided it is no more than 0.020 66-178. ASSEMBLY- INTERMEDIATEGEARBOX.

inch deep and no more than 20 percent of the total
surface area is pitted, and no more than 20 percent of
the area under the washer is pitted, and the minimum 1. Prepare case by touching up cadmium plating
thickness of the flange in the unpitted area is no less on ground shim plate and install shims in original
than 0.300 inch. Cases having damage exceeding positions. If original ground shim plates are lost or
these limits may be reworked by machining off the mixed, determine required dimension of shim plate as
upper face to a minimum flange thickness of 0.280 follows:
(dimension B, figure 66-102) provided this leaves no
pits in excess of 0.010 inch deep and the affected a. Examine case for reference dimension which
area does not exceed the limits given above, and should be metal stamped or vibro-etched on part
provided dimension C and D are within limits. Rework adjacent to applicable mounting surface.
by using a cutter that will maintain the same 0.125
radius and effect a surface finish of 63 RHR or better. b. Subtract dimension etched on case from
Cases with corrosion damage within acceptable 3.8745 to 3.8750 inch for required shim thickness,
limits must be treated by immersion in chromic acid after plating.
bath, in accordance with BHT-ALL-SPMmanual.
c. Grind new blank shim to required thickness
and apply cadmium plate (C-108). Identify new shim
5. Remove oil filler cap adapter (22, figure
late by etching serial number of appliciable case on
66-100) if damaged or worn. Install new oil filler cap
shim plate. Also etch thickness (in thousandths of an
adapter with reduced primer (C-201).
inch) on shim plate. Use etching ink (C-461) or
equivalent. Neutralize ink after marking by wiping
6. Replace cadmium plated shim plates (6 and with a rag soaked with oil (C-109).
10, figure 66-100) if plating is damaged or worn
through. Required thickness must be met after d. Position shim plates on proper ports and
plating. (Refer to paragraph 66-178, step 1.) secure with previously removed screws.
0.125 R TRUE (TYP)
Figure 66-102. Intermediate gearbox (204-040-003) case repair
66-181
BHT-205A1-CR&O-1
2. Install quills in gear case as follows: (Refer to NOTE: Verify that quills are installed in proper
figure 66-100.) location. Use care to engage gear teeth properly to
avoid damage.
a. Coat studs of case assembly with primer
C-201).
NOTE: Teeth of pinion on input quill and output quill e. Press quill assemblies into case, aligning
are cut opposite each other. (Refer to figure 66-103.) holes in flange with studs of case.
b. Use a heat lamp and heat the forward port of

the gearbox case. Position preformed packing (12, f. Secure the quills to the gear case with
figure 66-100) on input quill, lubricate packing and aluminum washers (18) next to sleeve and steel
mating surfaces of sleeve and case with approved washers (17) under nut (16). Tighten nuts evenly.
gearbox oil (refer to BHT-205A1-MM-1 manual) and
insert quill into forward port of case.
c. Use heat lamp and heat aft port of the gear g. Mount T101350 clamp assembly to outer
case. coupling and to stud on case. Mount backlash set to
the outer coupling, mount dial indicator to case.
d. Position preformed pecking (12) on output Check for backlash of 0.004 to 0.010 inch. Check in
quill sleeve, lubricate packing and mating surfaces of three places, approximately 120 degrees apart,
sleeve and case with approved gearbox oil (refer to record readings. In any one assembly backlash
BHT-205A1-MM-1 manual). Check that oil collector reading must be within 0.002 inch range. A greater
is installed on this quill and insert into aft port of gear range would indicate warped gear. Reject out of
case. tolerance parts.
INPUT OUTPUT
Figure 66-103. Intermediate gearbox pinion identification l
66-182
BHT-205A 1-CR&O-1
CAUTION: DO NOT ALTER SHIM PLATES ON CASE 1. Clean external surfaces of case and quill sleeve
OF QUILL SLEEVES TO OBTAIN BACKLASH. IF flanges with MEK (C-309) and clean cloths. Do not
BACKLASH IS NOT WITHIN LIMITS, PARTS ARE allow cleaning agent to contact oil or grease seal.
IMPROPERLY ASSEMBLED OR ARE
DIMENSIONALLY INCORRECT. 2. Place a small quantity of grease (C-001) in
each jackscrew hole.
h. Install preformed packing (30) on cap
assembly (29) and secure on adapter. Secure with pin 3. Install nylon setscrews (14) in jackscrew
(27). Cap assembly (29) is a nonbreather type. Do not holes.
install a breather type on this case.
i. Place prefromed packing (24) on sight glass NOTE: Mix sealing compound according to
(25) and lubricate with approved gearbox oil (refer to directions on container and apply to gearbox with
BHT-205A1-MM-1 manual). Insert oil indicator plate pressure gun or wood spatula. If necessary, smooth
(23) (tang fits notch in gear case) and sight glass (25) sealant with bare finger wetted with water.
in case recessed side inboard. Secure with retaining
ring (26). 4. Apply adhesive (C-308) between case and
quill sleeves, around bearing retaining nuts, and
j. Place gasket (20) on chip detector (21) and around exposed end of setscrews (14). Allow to cure
screw into case. Torque 120 to 150 inch-pounds. for 72 hours at room temperature.
Place gasket (2) on vent (1). Install into case and
5. Remove oil filler cap. Mask filler cap adapter,
torque
inch-pounds.
30 to 40 chip detector, oil level sight glass, couplings and seals
CAUTION: CHIP DETECTOR (21) WILL BE at outboard end of quills, and data plate.
LOCKWIRED TO ADJACENT MOUNTING BOLT HEAD
WHEN GEARBOX IS INSTALLED ON HELICOPTER. 6. Spray gearbox with one coat, 0.4 to 0.8 mils
thickness of primer (C-202). Air dry epoxy primer for
k. Fill gearbox with one cup of approved 30 minutes before applying top coat.
gearbox oil (refer to BHT-205A1-MM-1 manual).
NOTE: The epoxy primer (C-202) does not have to
I. Install oil cap assembly (29) (nonbreather)
be removed for fluorescent penetrant inspection.
identified with black dot. Tumble gearbox to
distribute oil over internal parts. 7. Apply two or three coats (1.0 to 1.5 mils) of
lacquer (C-203), color 36231 (gull gray).
m. Check for free rotation of gear and pinion by
manually turning input shaft, verify existence of gear 8. Use brush to apply 1/2 inch diameter dot of
backlash. white paint-(C-210) to oil cap and to gearbox case.
Dot on case should be placed on boss below oil cap
3. Seal and paint gearbox. (Refer to paragraph adapter and directly above chip detector.
66-1 79.)
4. Perform run-in and test of gearbox. (Refer to 66-180. RUN-IN AND TEST - INTERMEDIATE
paragraph 66-180.) GEARBOX.
It is recommended that intermediate gearbox, after

66-179. SEALING AND PAINTING - overhaul, be test run, and inspected in accordance
INTERMEDIATE GEARBOX. with Bell Helicopter Textron Publication BHT-PUB
77-003, for qualification for flight. In the event a
NOTE: If intermediate gearbox is to be run-in on a run-in stand is not available, the functional test
run-in stand, skip painting and sealing, until after specified in BHT-205A1-MM-1 manual, may be
run-in inspection. (Refer to paragraph 66-180.) accomplished as minimum acceptable alternate test.
66-183
BHT-205A1-CR&O-1
66-181. OVERHAUL-INTERMEDIATE GEARBOX overtemperature condition. Chemical contamination

(212-040-003). can also cause indicating dots to turn black.
6. Inspect outer coupling (14 and 29, figure 66-104)

TOOLS REQUIRED overtemperature indicator TEMP-PLATES for evidence
T101307 Wrench of overtemperature indication. If overtemperature
T101308 Jackscrew indication is noted, perform coupling overtemperature
T101333 Pressing Bar inspection as follows:
T101334 Pressing Bar
T1101350
T101350 Backlash Clamp a. Inspect outer coupling cadmium plating for

66-182. DISASSEMBLY INTERMEDIATE coupling for being discolored (brown or blue) in normally
GEARBOX. bright contact patterns. If discoloration is found, replace
outer coupling and inner coupling.
NOTE: If records and/or physical appearance of c. Inspect outer coupling and inner coupling under
intermediate gearbox indicate that assembly has been 5X to 10X magnification for teeth exhibiting signs of
subjected to an accident or incident outside realm of metal smearing or tearing in the contact patterns. If
normal usage, perform Conditional Inspection, smearing or tearing is found, replace outer coupling and
paragraph 66-185. inner coupling.
If intermediate gearbox is being disassembled, for d. Inspect grease from couplings for being very
replacement of parts instead of overhaul, disassemble viscous (thick) and having a strong pungent odor. If
only to extent necessary to replace parts. grease is found to be viscous and having a strong
1. Remove chip detector (19, figure 66-104) and coupling.
drain oil from case. Remove packing (18) from chip
detector. NOTE: If TEMP-PLATES are to be replaced, replace
2. Release pin (25), which secures chain to case, procedure and couplings have been determined
and remove cap (27). serviceable and prior to lubricating couplings.
3. Remove retainer ring (20), glass (22), and

6A. Inspect outer coupling
6A coupling (14
(14 and
and 29,
29 66-104)
66-104)
(23). Use suitable tool to remove
indicator indicator
(23)
remove glass.
glass.
Remove
(21) from
packing
gass deterioration, debonding, or discoloration of epoxy
glass
Remove
packing(21)
from coating that prevents interpretation of indicating dots. If
4. Remove six nuts (15) and washers (16). Cut found, replace TEMP-PLATES in accordance with
sealant between case (6) and input quill (17). Remove paragraph 66-199.
sealant and/or nylon setscrews (13) from three
jackscrew holes and install three T101308 jackscrews, CAUTION: SHIM PLATE MUST BE REINSTALLED
in threaded holes in sleeve of quill. Turn jackscrews IN SAME LOCATION ON SAME CASE OR QUILL.
evenly to pull input quill from case.
7. Remove three screws (5) and shim plate (4).
5. Remove output quill (1) by same procedure Remove three screws (11) and remove shim plate (10).
described in step 4. Remove packing (12) from quills. Identify shim plates for reinstallation in same location.
Shim plates must be removed for fluorescent penetrant
NOTE: Overtemperature dots on overtemperature inspection.
indicator TEMP-PLATES are of a white or light gray
color and turn black when exposed to an 8. Refertoparagraph66-200forinputquilloverhaul.
66-184 Rev. 2
BHT-205A1-CR&O-1
9. Refer to paragraph 66-217 for output quill 3. Visually inspect all detail components. Note any
overhaul. damage that could be attributed to a lightning strike.
4. Utilizing data obtained during visual inspection of

66-183. CLEANING - INTERMEDIATE GEARBOX. transmission components, evaluation of other related
components, and helicopter in general, determine entry
1. Clean all parts with solvent (C-304). and exit points of current. A magnetometer may be
helpful in determining current paths.
2. Dry parts with low pressue filtered air or
cheesecloth. NOTE: It may be necessary to disassemble and
visually inspect selected bearings to determine current
3. Remove sealant from case (6, figure 66-104) with paths. Once these bearings have been disassembled
plastic scraper. they shall be scrapped.
4. Remove all paint and primerfrom case using paint 5. Utilizing the following guidelines, determine the
remover (C-436). serviceability of detail components:
5. If/ferrous parts are not used immediately after a. Any component that exhibits evidence of arc,
cleaning, gently agitate parts in corrosion preventive burning, or pitting shall be deemed unserviceable and
(C-105) and air dry. Apply protective coat of approved scrapped.
b. Any component in current paths that cannot be
100 percent visually inspected, i.e., bearings that
66-184. INSPECTION - INTERMEDIATE cannot be disassembled, shall be deemed
GEARBOX. unserviceable and scrapped.
NOTE: If records and/or physical appearance of 6. Perform Normal Inspection. (Refer to paragraph
gearbox indicate that assembly has been subjected to 66-186.)
an accident or incident outside realm of normal usage,
perform Conditional Inspection, paragraph 66-185. If
gearbox does not require conditional inspection 66-186. Normal Inspection - Intermediate
proceed with Normal Inspection, paragraph 66-186. Gearbox.
If intermediate gearbox is being overhauled due to

lightning strike, proceed to steps 3 through 5. 1. Inspect case (6, figure 66-104) for obvious
damage that would cause it to be nonserviceable or
nonreparable.
65-185. Conditional Inspection - Intermediate
Gearbox. 2. Inspect studs and washer seats for looseness,
damage, and corrosion.
1. Check gearbox for free rotation and backlash of
gears. Backlash should not vary more than 0.002 inch, 3. Inspect case quill ports for 4.410 inch to 4.415
when checked at different points around gear. inch inside diameter.
2. Perform fluorescent penetrant inspection of 4. Inspect oil filler cap (27) and oil filter adapter (24)
gearbox. Refer to BHT-ALL-SPM manual for approved for damage and wear.
fluorescent penetrant materials.
5. Inspect oil level sight glass (22) for cracks,
NOTE: If inspection reveals cracks or distortion, which crazing, scratches, or discoloration and inspect
indicate excessive loads, gearbox shall be considered indicator (23) for stained or peeled paint.
unserviceable and nonreparable. All components shall
be evaluated as an interrelated group. 6. Inspect chip detector (19) for obvious damage.
During disassembly, note any damage that could be 7. Inspect case for corrosion and for elongated
attributed to lightning strike. mounting bolt holes. (Refer to figure 66-105.)
Rev. 2 66-185
BHT-205A1-CR&O-1
1. Output quill 26. Packing

2. Nut 27. Cap
3. Washer (2) 28. Chain
4. Shim plate 29. Coupling
5. Screw
6. Case
7. Data plate
8. Washer seat
9. Stud
10. Shim plate
11. Screw
12. Packing
13. Nylon setscrew
14. Coupling
15. Nut
16. Washer (2)
17. Input quill
18. Packing
22. Sight glass

23. Indicator
24. Oil filler adapter
25. Pin
Location of overtemperature indicator TEMP-PLATE(S).

to inserting setscrew (13).
205A1-R-66-104
Figure 66-104. Intermediate gearbox (212-040-003)
66-186 Rev. 2
BHT-205A1-CR&O-1
8. Performfluorescent penetrant inspection of case. (1) Machineordrill outdamagedthread. Do not

(Refer to BHT-ALL-SPM manual for approved exceed depth of one thread. The clean out diameter
fluorescent penetrant materials.) must equal major thread diameter.
9. Inspect shim plates (4 and 10, figure 66-104) for (2) Break all sharp edges, except in area of
damage and wear. threads. Clean out small vent hole on bottom of
threaded hole. Treat bare surfaces with chemical film
(C-103).
66-187. REPAIR - INTERMEDIATE GEARBOX.
NOTE: Replace case if structural damage to stud (3) Replace stud. (Refer to BHT-ALL-SPM
threads or mounting bolt holes are elongated so that manual.)
they exceed repair limits.
(4) Fill all counterdrilled holes with adhesive
1. Replace parts that are not within allowable wear (C-308) flush with top of case.
limits.
c. Repair minor scratches, nicks, and pits on
2. Repair corrosion damage on the case as follows: noncritical surfaces with crocus cloth.
a. Flange repair. Machine off upper face to a d. Cases with corrosion damage within
minimum flange thickness of 0.400 inch (refer to acceptable limits must be treated by immersion in a
dimension B, figure 66-105) provided this leaves no pits chromic acid bath in accordance with BHT-ALL-SPM
in excess of 0.010 inch deep and the affected area does manual. (Refer to figure 66-105.) Corrosion removal
notexceed inspection limits. Reworkcase using a0.875 process must be controlled to ensure that machined
inch diameter spotface with 0.062 inch corner radius. dimensions are maintained and that cadmium plating is
Machined surface finish must be 63 RHR or better. not removed from studs. After chromic acid bath, rinse
case with water to remove chromic acid and dry with
b. Stud hole damage. Remove damaged or loose filtered compressed air and apply magnesium alloy
studs. Use suitable tool to grip stud and turn out slowly chemical film treatment in accordance with
and evenly to avoid seizure and breakage. If stud hole BHT-ALL-SPM manual.
threads are damaged, repair or replace case as
required. If corrosion or other damage has not 3. Replace unserviceable oil filler cap adapter (22,
penetrated past first thread, rework case as follows: figure 66-104). Install new adapter coated with
(Refer to BHT-ALL-SPM manual.) unreduced primer (C-201).
Rev. 2 66-186A/66-186B
BHT-205A1-CR&O-1
SEE VIEW A
SIDE VIEW VIEW LOOKING AFT

0.290 INCH
MAXIMUM ACCEPTABLE
ELONGATION OF
MOUNTING BOLT HOLES
NOTES:
1. Corrosion pitting on upper machined face at four mounting bolt holes is acceptable provided
it is no more 0.020 inch deep, no more than 20 percent of total area is pitted, no more than 10
percent of the area under washer is pitted and minimum thickness of flange in pitted area is
no less than 0.430 inch.
2. Cases having damage exceeding inspection limits may be reworked by machining off upper
face to a minimum flange thickness of 0.400 inch (see dimension B above) provided this
leaves no pits in excess of 0.010 inch deep and affected area does not exceed limits given
above.
3. Rework case using a 0.875 inch diameter spot face with 0.062 corner radius. Machined
surface finish must be 63 rhr or better.
4. Corrosion pitting in area A is acceptable provided it is no more than 0.030 inch deep and no
more than forty percent of area within any one inch square nor twenty percent of total areaA
at either bore is pitted. Structural damage to threaded holes for studs is acceptable provided
damage does not extend past first thread.
Figure 66-105. Intermediate gearbox (212-040-003) case damage limits
Figure 66-106. Deleted 66-187

BHT-205A1-CR&O-1
4. If original cadmium plating on case shim plates (4 8. All parts repaired shall be reinspected priorto use.
and 10) has worn through, replate using LHE cadmium Replace all parts that are cracked, broken, warped,
plating solution (C-108). (Refer to BHT-ALL-SPM distorted, have malformed threads or which cannot be
manual for prescribed cadmium plating method.) (Refer repaired. Replace all seals, gaskets, packings, standard
to step 5. for shim thickness after plating.) hardware, and all locking devices, on reassembly.
5. If original shim plate is missing or mixed with other 9. After repair, parts on which finish has been
shim plates, determine required dimensions of removed by wear, chipping, scoring, scratches, or dents
replacement shim plate as follows: shall be refinished as follows:
a. Examine case for reference dimension which a. Aluminum parts shall be touched up with
should be metal stamped or vibro-etched on the part chemical film (C-100) as required.
adjacent to the applicable mounting surface.
b. Magnesium parts shall be touched up with
b. Subtract 3.4670 to 3.4675 inches from chemical film (C-103) or apply magnesium alloy
dimension stamped on case for required shim chemical film treatment to entire part. (Refer to
thickness, after plating, for case. BHT-ALL-SPM manual).
c. Grind new blank shim to required thickness c. Steel parts shall be touch up brush cadmium
and apply LHE cadmium plate solution (C-108). plated with LHE cadmium plating solution (C-108).
(Refer to BHT-ALL-SPM manual for prescribed (Refer to BHT-ALL-SPM manual for approved
cadmium plating method.) Identify new shim plate by method.)
etching serial number of applicable sleeve or shim
plate. Also etch thickness (in thousandths of an inch)
on shim plate using etching ink (C-461) or equivalent.
Neutralize ink, after marking, by wiping with a rag 66-188. ASSEMBLY - INTERMEDIATE
soaked with oil (C-109). GEARBOX.
6. Repair oil cap as follows: 1. Position original shim plates (4 and 10, figure
66-104) or replacement shim plates on case (6). Install
a. Remove lock ring and washer at base of oil cap each shim plate with three screws (11).
(27, figure 66-104). Remove aluminum wool packing,
and discard. Remove packing (24) and discard. 2. Use heat lamp at each input and output port to
heat gearbox case (6).
b. Clean oil cap (27) in solvent (C-304). Inspect
cap, without further disassembly,for wear and damage. NOTE: Teeth of pinion on input quill and output quill
Replace cap if defects are noted which would affect are cut opposite to each other. (Refer to figure 66-103.)
function of cap.
3. Place packing (12, figure 66-104) on sleeve of

c. Install new aluminum wool (C-422) in base of each quill. Coat packing and mating surfaces of quill
cap. The correct amount of aluminum wool is in place sleeves and gear case with approved gearbox oil (refer
when the washer can be depressed 0.06 inch from its to BHT-205A1-MM-1 manual). Insert input quill (17) in
normal position and will spring back to its normal forward port.
position. When correct amount of aluminum wool is in
place, secure washer with lock ring.
NOTE: Only the output quill has an oil collector cone.
d. Install new packing (26) on oil cap.
4. Install washers (16) and nuts (15) on studs and
7. Repair oil level sight glass (22), if cracked, crazed, tighten evenly. Ensure that only aluminum washers (16)
scratched or discolored. Replace indicator (23), if are in contact with quill sleeve. Torque 50 to 70
stained or if paint is peeled. inch-pounds.
66-188 Rev. 2
BHT-205A1-CR&O-1
5. Install output quill (1) in same manner. Exercise a. Data plate information shall include initials of
care to engage gear and pinion teeth when installing facility performing overhaul or modification, date of
second quill to avoid damage. overhaul or modifications, and part number. Total
operating time since helicopter was new shall be
NOTE: Check backlash when gearbox stabilizes at included, if applicable. Stamp date on overhaul or
room temperature. modification in area adjacent to manufacturer's data.
In event that there is no sufficient space to stamp new
6. Check for backlash using T101350 clamp and
6. Check for backlash using T101350 clamp and data on old plate, make new data plate and transfer
T102030-3 clamp. Takereading from center of dowel
pertinent data from old to new plate.
pin in T102030 clamp (pin location is marked 212).
Backlash shall be 0.004 to 0.010 inch. Check in three
b. If required, locally manufacture replacement
places approximately 120 ° apart, and record
places approximately
120 data plate from 0.032 inch thick, soft aluminum
readings. In any one assembly, backlash reading must sheet condition QQ-A-250/8B. Make plate one
not vary more than 0.002 inch when checked at three
sheet, condition O, QQ-A-250/8B. Make plate one
inch wide and two inches long.
places around gear. A greater variation would indicate
a warped gear. Check gears and reject out of
tolerance parts. tolerance parts. 11. Install data plate (7) as follows:
CAUTION: DO NOT ALTER SHIM PLATES ON CASE
OR QUILL SLEEVES TO OBTAIN BACKLASH. IF a. Position data plate on gearbox and form data
BACKLASH IS NOT WITHIN LIMITS, PARTS ARE plate to have contact with gearbox over entire
IMPROPERLY ASSEMBLED, OR THEY ARE lower surface.
DIMENSIONALLY INCORRECT.
b. Clean data plate and gearbox in area where
NOTE: A half-inch diameter white dot on cap (27) plate will be bonded by abrading lightly with 400 grit
and on case (6) denotes that vented cap must be abrasive paper (C-423). Remove residue with clean
installed cloth moistened with aliphatic naptha (C-305). After
cleaning, wear clean, dry, white gloves, when
7. Install packing (26) on cap (27) and install oil handling parts to prevent contamination.
filler adapter (24). Secure chain (28) to case with pin
(25). c. Mix adhesive (C-317), 33 parts B to 100
parts A. Mix the two parts thoroughly. Pot life is 30 to
NOTE: If gearbox is to be tested immediately after
50 minutes after mixing. Apply thin coat of mixed
assembly, install oil temperature thermocouple adhesive to plate and to gearbox in area where plate
assembly, install oil temperature thermocouple
instead of oil sight glass.
will be bonded. Place four mil thread in adhesive on
8. Place packing (21) on sight glass (22) and data plate. Two pieces of thread positioned
lubricate with approved gearbox oil (refer to lengthwise on plate serve as spacer, and control
BHT-205A1-MM-1 manual). Position indicator (23) in bondline thickness.
case with tang in notch. Install sight glass (22) with
recessed side inboard. Install ring (20). d. Position plate on gearbox. Use fixture and
rubber bands to maintain approximately ten psi
9. Place packing (18) on chip detector (19) and pressure on plate during cure period of 24 hours.
install in case. Torque 120 to 150 inch-pounds. Clean off any adhesive outside bond region with
cheesecloth moistened with MEK (C-309) before
NOTE: Chip detector will be lockwired to adjacent adhesive cures.
mounting bolt head when gearbox is installed on
helicopter.
12. Seal and paint intermediate gearbox. (Refer
10. Prepare data plate (7) for installation.
to paragraph
paragraph 66-189.)
66-189.)
CAUTION: STAMPING DIRECTLY ON THE SURFACE
OF INSTALLED DATA PLATE ON ANY ASSEMBLY OR 13. Perform run-in and test of intermediate
ITEM EQUIPMENT IS PROHIBITED. gearbox. (Refer to paragraph 66-190.)
66-189
BHT-205A 1 -CR&O-1
66-189. SEALING AND PAINTING - 4. Apply adhesive (C-308) between case and
INTERMEDIATEGEARBOX. quill sleeves, around bearing retaining nuts, and
around exposed end of setscrews (13). Allow
NOTE: If intermediate gearbox is to be run-in on a
adhesive
to to cure for 72 hours at room temperature.
run-in stand, skip painting and sealing, until after
run-in inspection. Refer to paragraph 66-190. 5. Remove oil filler cap. Mask filler cap adapter,
chip detector, oil level sight glass, couplings, and
1. Clean external surfaces of case and quill sleeve seals at outboard ends of quills, and data plate.
flanges with MEK (C-309), and clean cloths. Do not
allow cleaning agent to contact oil or grease seal. 6. Spray paint gearbox with primer (C-202), coat
0.4 to 0.8 mils, if required. Air dry epoxy primer for
2. Place a small amount of grease (C-001) in each 30 minutes before applying top coat (refer to figure
jackscrew hole. 66-107).
3. Install nylon setscrews (13) in jackscrew 7. Apply two or three coats (1.0 to 1.5 mils) of
holes. lacquer (C-203), color 36231 (gull gray).
NOTE: Mix adhesive compound according to

8. Use brush to apply 1/2 inch diameter dot of
directions on container and apply to gearbox with
pressure gun or wood spatula. If necessary, smooth
white paint (C-201) to oil cap and to gearbox case.
adhesive with bare finger moistened with water. Dot on case should be placed on boss below oil cap
adapter and directly above chip detector.
VIEW A
B A VIEW B
Epoxy primer (C-202) and lacquer (C-203) will be applied to exterior area not covered by
Note 2.
Primer and final finish will not be applied to this area.
Figure 66-107. Intermediate gearbox (212-040-003) processing requirements
66-190
BHT-205A1-CR&O-1
66-190. RUN-IN AND TEST - INTERMEDIATE 4. Separate inner and outer couplings (14 and 13)
GEARBOX. and remove seal (12).
It is recommended that intermediate gearbox, after 5. Position T101564 holding fixture on sleeve (5)
overhaul, be test run, and inspected in accordance with T101600 wrench, positioned on nut (10).
with Bell Helicopter Textron Publication BHT-PUB Remove packing (9) and press seal (11) out of nut.
77-003, for qualification for flight. In the event that a
run-in stand is not available, the functional test 6. Press gear (10) out of sleeve (5). Remove
specified in BHT-205A1-MM-1 manual, may be retaining ring (2).
accomplished as minimum acceptable alternate test.
7. Press roller bearing (3) and spacer (4) using
66-191. INTERMEDIATE GEARBOX INPUT T101333 pressing bar. Press duplex bearing (6) out
QUILL. of sleeve using T101334 pressing bar. Press inner
race of bearing (3) from gear (1).
66-192. OVERHAUL - INTERMEDIATE GEARBOX
(204-040-003) INPUT QUILL. NOTE: Duplex bearings are a matched set; both
bearings have same serial number. Keep duplex
bearings together as a set.
T101307 Wrench
Wrench 8. Remove three screws (8) and shim plate (7).
T101333 Pressing Bar Identify shim plate.
T101564 Holding Fixture 66-194. CLEANING - INTERMEDIATEGEARBOX
T101600 Wrench INPUT QUILL.
66-193. DISASSEMBLY - INTERMEDIATE 1. Clean quill parts with solvent (C-304) with
GEARBOX INPUT QUILL.
exception of bearings which are cleaned with
NOTE: If input quill is being disassembled for trichlorethane (C-334).
replacement of parts instead of overhaul
replacement
of parts instead of 2. Use clean lint-free cloth or low pressure
disassemble only to extent necessary to replace
filtered, compressed air to dry parts. Do not let
bearings spin while drying.
NOTE: For ease of maintenance, block the outer
coupling so that it will remain in the outboard corrosion
(extended) position. This will stabilize the outer bearings with approved oil. To prevent corrosion
coupling during disassembly and assembly. damage avod handling unoiled bearings.
1. Remove retainer ring (22, figure 66-108), plate 4. Remove sealant from quill sleeve with plastic
(21), centering spring (20), and lock spring (19). scraper.
Remove retainer (18); a 1/4-20 threaded bolt may be
used to facilitate removal of retainer (18). Install bolt NOTE: Parts that have a lacquer top coat and primer
in center of retainer and pull on bolt to withdraw need only to have the top coat removed for
retainer from inner coupling. Remove packing (17) fluorescent penetrant inspection.
from retainer.
5. Remove paint from quill sleeve with paint
2. Hold outer coupling (13) with T101307 remover (C-436) and rinse with clean water.
wrench; position square adapter through wrench and
remove coupling retaining bolt (16). Remove washer 6. If ferrous parts are not used immediately after
(15).cleaning, gently agitate parts in corrosion preventive
(C-105) and air dry. Apply protective coat of approved
3. Remove inner and outer couplings(14 and 13). gearboxoil(refertoBHT-205A1-MM-1 manual).
66-191
BHT-205A1-CR&O-1
TORQUETORQUE
1.Gear
0.1 Nut 18. Retainer
) 2. Retainer ring
3. Roller bearing 11. Seal 19. Lock spring
4. Spacer 12. Seal 20. Spring
Sleeve
5. 13. Outer coupling 21. Plate
6. Duplex bearing 14. Inner coupling 22. Retainer ring
7. Shim plate 15. Washer
8. Screw 16. Bolt
NOTES: Location of overtemperature indicator TEMP-PLATE.

Apply sealant, MIL-S-8802, Class B2, around nut (10) and
sleeve (5) after assembly.
205A1-R-66-108-1
Figure 66-108. Intermediate gearbox (204-040-003) input quill (Sheet 1 of 2)
66-192 Rev. 2
BHT-205A 1-CR&O- 1
WORKAID

OF SEAL (12) UP
DETAIL A
66-195. INSPECTION - INTERMEDIATE Cracked or chipped teeth in the outer coupling (13,
GEARBOXINPUT QUILL. figure 66-108) resulting from static loads, with no
other indications of damage, does not render the
NOTE: If records and/or physical appearance of component nonreparable.
input quill indicate that assembly has been subjected
to an accident or incident outside realm of normal 66-197. Normal Inspection - Intermediate
usage, perform Conditional Inspection, paragraph Gearbox Input Quill.
66-196. If input quill does not require conditional
inspection proceed with Normal Inspection, 1. Visually inspect all parts for damage and
paragraph 66-197. excessive wear. Inspect gear and splines for chipped,
broken, and worn teeth. (Refer to figure 66-109) for
66-196. Conditional Inspection - Intermediate pinion wear pattern.) Check bearings for smooth
GearboxInput Quill. operation and indications of excessive wear. Inspect
bearing for scoring, and for security in case openings.
1. Visually inspect couplings for cracked or
chipped teeth. 2. Inspect following parts by magnetic particle
(M) or fluorescent penetrant (F) methods as
2. Inspect bearings for roughness of brinelling. indicated. Index numbers are keyed to figure 66-108.
Demagnetize all parts after magnetic inspection.
3. Inspect couplings, gears, and sleeves by
magnetic particle or fluorescent penetrant methods. NOTE: Refer to BHT-ALL-SPMmanual for approved
NOTE: If any of steps 1. through 3. reveal cracks or
distortion indicative of excessive loads, then the INDEX NO. NOMENCLATURE CODE
entire component shall be considered unserviceable
and nonreparable. If this condition does not exist, 1 Gear M
then accomplish Normal Inspection in accordance 5 Sleeve F
with paragraph 66-197. 13 Outer Coupling M
14 Inner Coupling M
66-193
BHT-205A1-CR&O-1
Acceptable wear pattern on pinion Acceptable wear pattern on gear

(touching toe) (touching toe)
View D View E
Figure 66-109. Gear and pinion wear patterns (Sheet 1 of 2)
66-194
BHT205A1-CR&O-1

View F View G
1. Wear Pattern Inspection: Observe the visible gear contact wear pattern on the concave
side of the pinion teeth and an the convex side of the gear teeth. The teeth an the pinion
have a left spiral and the teeth on the gear have a right spiral.
2. The desired wear pattern is shown in View A and B. A speckled or mottled appearance in
the flank of the pinion or top of the gear due to dulite removal is permissible. The wide and
not too well defined toe pattern is characteristic of this gear set. The area of the wear
pattern In the flank of the gear is very faint and proper lighting must be used in order to see it.
3. Acceptable wear patterns are shown in views D, E, F, and G. These views show various to
and heel locations, and different severities of thespeckled or mottled appearance in the flank
of the pinion and top of gear.
4. Pattern Limits at Toe: The pattern may touch the toe or be a maximum of 1/8 inch from toe
on gear (sea View C). Usually the pattern will touch the toe in the flank of the pinion and at
the top of the gear as shown in Views D and E. If the pattern touches the toe but is more than
1/8 inch from heel on gear member. then the pattern is off the toe and is not
acceptable. This method of inspection must be used, due to the wide toe pattern, to
determine whether the pattern is just touching the toe or is running off the toe. Pattern
variation at the toe must not exceed 1/32 inch.
5. Pattern Limits at Heel: The pattern may touch the heel or be a maximum of 1/8 inch from
heel on gear member (see View C). Pattern variation at the heel must not exceed 1/32 inch.
5. Pattern Profile: The pattern in the profile direction must touch or extend over the top of the
pinion as shown by Views A. D and F. On the gear. the pattern may be 1/32 inch from the
top or may extend over the tap. Most of the gear patterns will extend over the top as shown
by views 8, E and G. A bright line occurring at the top of pinion or in flank of the gear is
7. Unacceptble Defects: In addition to pattern size and location. examine the drive face of
all gear teeth for the following defects which are not acceptable if they can be felt with a
scribe having a 0.002 inch radius spherical point:
a. nonclean up g. dents
b. grinding scratches h. grinding flats or barber paling
c. pitting (evidenced bydiagonal streaks in the pattern)
d. corrosion i. scuffing
e. cuts i. scoring
f. nicks k. inclusions
Figure 66-109. Gear and pinion wear patterns (Sheet 2 of 2)
66-195
BHT-205A1-CR&O-1
3. Inspect parts dimensionally and replace parts found, replace TEMP-PLATES in accordance with
that do not fall within inspection limits. (Refer to figure paragraph 66-199.
66-110.)
5. Inspect coupling wear patterns. (Refer to figure
NOTE: Wear limits are provided to show the required 66-111.) Replace couplings if cracked, chipped, or pitted
fit between mating parts. It is not intended that all more than limits shown. Inspect the surface of the inner
dimensions be checked as a prescribed overhaul coupling that is contacted by the oil seal (11, figure
procedure; however, parts that show evidence of wear 66-108) for excessive wear and for nicks, cuts, and
or physical damage shall be checked dimensionally. scratches. A groove worn by the seal is acceptable to a
minimum diameter of 1.587 inches provided the depth
NOTE: Overtemperature dots on overtemperature does not exceed 0.002 inch. If the groove is smooth, the
indicator TEMP-PLATES are of a white or light gray part may be reworked in accordance with paragraph
color and turn black when exposed to an 99-198. Nicks, cuts, and scratches which would affect
overtemperature condition. Chemical contamination the function of the oil seal are not acceptable. Parts may
can also cause indicating dots to turn black. be reworked in accordance with paragraph 66-198 to
the limits specified.
4. Inspect outer coupling (13, figure 66-108)
overtemperature indicator TEMP-PLATES for evidence 6. Inspect bearing balls or rollers and races for
of overtemperature indication. If overtemperature roughness. Replace ball bearings that show evidence of
indication is noted, perform coupling overtemperature spalling, scoring, pitting, brinelling, flaking, or corrosion
inspection as follows: on rolling elements or races, or that have cracked or
broken retainers, or that do not roll smoothly. Replace
a. Inspect outer coupling cadmium plating for roller bearings that show evidence of spalling, flaking, or
being discolored (circumferential tan or light brown corrosion pitting on rolling elements or races, or that
band) or blistered. If cadmium plate discoloration or have cracked or broken retainers (figure 66-112). Minor
blistering is found, replace outer coupling and inner nicks, cuts, or scratches are acceptable provided they
coupling. are too small to be felt with a probe having an end radius
of 0.030 inch, and provided the total affected area does
b. Inspect gear teeth of outer coupling and inner not exceed 10 percent of the contact area at any point.
coupling for being discolored (brown or blue) in normally Minor circumferential scoring is acceptable on rollers
bright contact patterns. If discoloration is found, replace and races provided it cannot be felt with a probe having
outer coupling and inner coupling. an end radius of 0.030 inch and provided the affected
area does not exceed 10 percent of the contact area at
c. Inspect outercoupling and innercoupling under any point.
7. Inspect retaining bolt (16, figure 66-108) and nut
(10) for damaged threads.
inner coupling. 8. Inspect sleeve (5) for corrosion as follows:
d. Inspect grease from couplings for being very a. Corrosion pitting or mechanical surface
viscous (thick) and having a strong pungent odor. If damage in area A, exclusive of spotface area, is
grease is found to be viscous and having a strong acceptable for repair if it is within the following limits:
pungent odor, replace outer coupling and inner (Refer to figure 66-114.)
coupling.
(1) Maximum acceptable depth is 0.030 inch.
TEMP-PLATES after completing entire inspection (2) No more than 40 percent of the area within
procedure and couplings have been determined any one inch square, nor 20 percent of total area of any
serviceable and prior to lubricating couplings. surface or diameter may be pitted.
4A. Inspect outer coupling (13, figure 66-108) b. Corrosion pitting or mechanical surface
overtemperature indicator TEMP-PLATES for damage on spotfaced surface at attaching holes is
deterioration, debonding, or discoloration of epoxy acceptable provided is within the following limits:
deterioration, debonding, or discoloration of epoxy is (1) Maximum acceptable depth is 0.020 inch.
66-196 Rev. 2
BHT-205A1-CR&O-1
(2) No more than 20 percent of total spotfaced 1. Replace parts that are not within allowable wear
area at any hole may be pitted. limits.
(3) No more than 20 percent of total area

(3) No more than 20 percent of total area 2. Replace roller bearing (3, figure 66-108) and
normallycontacted by washer may be pitted. duplex bearing (6) that show evidence of brinelling,
(4)
than50
No percent
more spalling, discoloration from overheating, corrosion on
(4) No more than 50 percent of the width of area
rollingelements, cracked or broken retainers, or that do
normally contacted by washer may be pitted at any point
around hole. around hole. not operate smoothly.
3. Replace all seals, preformed packings, standard

66-198. REPAIR/REPLACE - INTERMEDIATE hardware, and all safety locking devices at time of
GEARBOX INPUT QUILL. reassembly.
Rev. 2 66-196A/66-196B
BHT-205A 1-CR&O- 1

INCHES
1. Duplex bearing ID 1.3777 1.3781
OD 2.8341 2.8346
2. Gearshaft OD 1.3780 1.3786
3. Roller bearing OD 3.1491 3.1496
4. Gear shaft OD 1.5752 1.5758
5. Sleeve ID 3.1489 3.1497
6. Sleeve OD 3.6247 3.6255
7. Sleeve ID 2.8340 2.8347
8. Spline - gear Over Pins 1.3481 1.3518
(Use 0.0960 diameter pins)
9. Spline - inner coupling Between Pins 1.1251 1.1336
10. Teeth - inner coupling Over Pins 2.1590 2.1740
11. Spline - outer coupling
NOTE:
Maximum allowable depth of wear 0.005 (measure from unworn face of tooth).
Figure 66-110. Intermediate gearbox (204-040-003) input quill wear limits
66-197
BHT-205A 1-CR&O-1
Acceptable pattern typical of couplings which have

C Acceptable pattern d e not i n g operation at higher

Acceptable pattern showing a pitted tooth. This


E projecting above the normal face of the tooth, indi-
cating that the pitted area is polishing over. This
condition may exist on all teeth. Couplings with pits
larger than 1/32 inch diameter should be replaced.
Figure 66-111. Coupling teeth wear patterns
66-198
BHT-205A1-CR&O-1
Acceptable Unacceptable
Figure 66-112. Roller bearing wear pattern
INNER COUPLING OUTER COUPLING SLEEVE
Cadmium plate will be applied to this area only.

Do not apply cadmium plate in hole.
3 Epoxy primer (C-204) and acrylic lacquer (C-203) will be applied to this area only.
Figure 66-113. Intermediate gearbox (204-040-003) input and output quill processing requirements
66-199
BHT-205A1-CR&O-1
AREA C
AREA B ARE
NOTES:
1. Corrosion pitting or mechanical surface damage in area A, exclusive of area B, is acceptable

provided it is within the following limits:
a. Maximum acceptable depth of rework to completely remove damage is 0.030 inch.
b. No more than 40 percent of the area within any one inch square, nor 20 percent of the
total area of any surface or diameter may be pitted.
2. Corrosion pitting or mechanical surface damage on the spot faced surface at the attaching
holes, area B, is acceptable provided it is within the following limits:
b. No more than 20 percent of the total spot faced area at any hole may be pitted.
c. No more than 20 percent of the total area normally contacted by the washer may be
pitted.
d. No more than 50 percent of the width of the area normally contacted by the washer may
be pitted at any point around the hole.
3. Corrosion pitting or mechanical surface damage to area C is permissible provided it is within

the following limits:
b. Sharp corners which may damage packing are not permissible.
c. No more than 20 percent of the total area and no more than 30 percent of any one inch
square may be damaged.
Figure 66-114. Intermediate gearbox (204-040-003) input and output quill sleeve damage limits
66-200
BHT-205A1-CR&O-1
4. Repair minor scratches, nicks, and pits on 9. Repair sleeve (5) as follows:
noncritical surfaces with crocus cloth (C-409).
a. If damaged or loose, replace clinch nuts.
5. Repair minor nicks, scratches, and burrs on
splines and gear (1) using fine india stone (C-464). (1) Use a drift or bolt threaded into nut to
drive clinch nut out; being careful not to damage hole
6. Repair inner coupling (14) and outer coupling in sleeve flange.
(13) as follows:
(2) Clean sleeve by vapor degreasing with
a. Repair minor nicks, dents or scratches in the trichloroethane (C-334).
seal contact area on the inner couplings by polishing
with fine india stone (C-464) to remove damage. (3) Clean up surface of sleeve flange to
Blend into surrounding area. Seal groove wear no remove any raised burrs.
more than 0.002 inch deep and minimum diameter of
1.587 inch is acceptable if groove is uniform and (4) Treat hole and any reworked areas on
smooth. sleeve with chemical film (C-103).
b. Cadmium plate inner and outer couplings (14 (5) If clinch nut was not loose, coat new nut
and 13, figure 66-108) using LHE solution (C-108). with unreduced primer (C-201) and drive nut into
Plating thickness to be 0.0001 to 0.0003 inch. Do place. Remove any raised burrs on sleeve flange face,
not exceed 0.0003 inch plating thickness in seal and touch up with chemical film (C-103).
contact area. Do not plate external spline teeth on
inner coupling. Do not plate internal splines on outer (6) If nut was loose, remove cadmium plating
coupling. Apply plating tape (C-434) to areas not to from surfaces of clinch nut that contact the sleeve,
be plated. Refer to figure 66-113 for plating with abrasive paper (C-423). Wipe clinch nut and
dimensions and BHT-ALL-SPM manual for prescribed mating surfaces of the sleeve clean with MEK (C-309)
cadmium plating methods. on clean cheesecloth. Bond clinch nut in place with
adhesive (C-317). Clean excess adhesive from
7. If original cadmium plating on sleeve shim plate threads and surface of sleeve flange and hole. Clinch
(7, figure 66-108) has worn through, replate using nut must be at least 0.010 inch below surface of
LHE solution (C-108). (Refer to BHT-ALL-SPM manual sleeve flange.
for prescribed cadmium plating method.) (Refer to
step 8. for shim thickness after plating.) (7) Check that side of sleeve flange that
contacts shim plate is flat and that clinch nut does not
8. If original sleeve shim plate is missing or mixed protrude above surface.
protrude above surface.
with other shim plates, determine required
dimensions of replacement shim plate as follows: d. Repair mechanical and corrosion damage on
a. Examine sleeve for reference dimension sleeve as follows; (Refer to figure 66-108.)
which should be metal stamped or vibro-etched on
(1) If damage to spot faced surfaces, area B,
part adjacent to applicable mounting surface. exceeds inspection limits, surface may be reworked
b. Subtract 0.9760 to 0.9765 inch from by machining off surface to a minimum flange
dimension stamped or etched on sleeve for required thickness, dimension C, of 0.310 inch. Machining
shim thickness, after plating. must be done with a 0.688 inch diameter spotface
cutter, with a 0.060 inch corner radius. After
c. Grind new blank shim to required thickness cleanup, pitting is acceptable provided it is no more
and apply LHE solution (C-108). Identify new shim than 0.010 inch deep. Surface finish of unpitted
plate by etching serial number of applicable sleeve on reworked surface must be 63 RHR (roughness height
shim plate. Also etch thickness (in thousandths of an rating) or better.
inch) on shim plate. Use etching ink (C-461) or
equivalent. Neutralize ink, after marking, by wiping (2) Sleeves with corrosion damage within
with a rag soaked with oil (C-109). acceptable limits must be reworked by smoothing out
any sharp edges that might damage packing during
66-201
BHT-205A1-CR&O-1
assembly. Nicks, dents or pits in area A, figure 1. Pressduplexbearing(6,figure66-108)faceto

66-114, within allowable limits, must be reworked to face, into outboard end of sleeve (5) using T101334
blend into surrounding area. Minimum radius in bar. Both duplex bearings must have matching serial
reworked areas is 0.25 inch and surface finish must numbers and must be installed in matched pairs.
be 63 RHR or better.
2. Press roller bearing (3), without inner race, into
(3) Sleeves with corrosion damage within inboard end of sleeve (5) using T101333 bar. Secure
acceptable limits must be treated by immersion in a bearing with retainer ring (2) in groove of sleeve.
hot chromic acid bath consisting of 20 to 24 ounces
of chromic acid (C-116) per gallon of water at 200F 3. Press inner race of roller bearing (3) on gear (1).
(93°C) for as long as corrosion is present. It is Serial number of inner and outer races of bearing
mandatory that all corrosion products be removed. must be the same. Place spacer (4) on pinion next to
Corrosion removal process must be controlled to bearing inner race.
ensure that machined dimensions are maintained and
NOTE: Gear (1) does not have an oiling hole or
that cadmium plating is not removed. After chromic
acid bath, rinse sleeve with water to remove chromic
acid and dry with filtered compressed air and apply 4. Insert gear assembly throughrollerbearinginto
magnesium alloy chemical film treatment. (Refer to sleeve
sleeve assembly. Press gear assembly into
assembly. Press gear assembly into place by
place by
BHT-ALL-SPM manual.) supporting gear so as to avoid damaging gear teeth
and pressing on inner race of duplex bearing (6).
e. Perform fluorescent penetrant inspection of
sleeve. (Refer to BHT-ALL-SPM manual.) 5. Apply adhesive (C-308) to faying surface of
seal (11) and nut (10). Press seal (11) into nut (10)
10. Repair
10. Repair minor
minor nicks,
nicks, scratches,
scratches, and
and burrs
burrs on
on with open side inboard. Install packing (9) on nut.
pinion splines and teeth by dressing with fine india Coat lip of oil seal, packing, and threads with
approved gearbox oil (refer to BHT-205A1-MM-1
manual) and screw nut into sleeve (5). Hold sleeve
11. After repair during overhaul, parts on which
flange with T101455 plate assembly, and torque nut
finish has been removed by wear, chipping, scoring,
foot-pounds with
150 foot-pounds T101336 wrench.
scratches, or dents shall be refinished as follows: 100 to
100 to 150 with T101336 wrench.
(Refer to BHT-ALL-SPM manual.) Secure nut to sleeve with lockwire (C-405).
NOTE: A workaid may be fabricated, as shown in

a. Aluminum parts shall be touched up with
brush alodine (C-100) or entire part anodize as
required. 66-108).
b. Magnesium parts shall be touched up with 6. Install seal (12) into outer coupling (13) seal
groove as follows:
chemical film (C-103) or magnesium alloy chemical groove as follows:
film treatment applied to entire part. (Refer to a. Apply a light coat of grease (C-015) to outer
BHT-ALL-SPM manual.) circumference of seal (12).
c.
c. Steel
Steel parts
parts shall
shall be
be cadmium
cadmium plated
plated with
with LHE
LHE b. Install seal (12) into outer coupling (13) seal
solution (C-108). (Refer to BHT-ALL-SPM manual for groove with lip of seal toward internal splines of outer
prescribed cadmium plating method.) coupling (13), as shown in figure 66-108, detail A.
66-199. ASSEMBLY - INTERMEDIATE GEARBOX NOTE: Seal (12) will be partially seated and the
INPUT QUILL. inner coupling (14) will be used as a backup in reverse
CAUTION: SAME SHIM PLATE THAT WAS (see detail A) to fully seat the outer circumference
REMOVED FROM SLEEVE MUST BE REINSTALLED edge of seal into outer coupling (13) seal groove.
OR A NEW SHIM PLATE OF SAME THICKNESS c. Using inner coupling (14) as a backup, and
MUST BE MADE. placed as shown in detail A, firmly press down (hand
66-202
BHT-205A1-CR&O-1
pressure only) on outer coupling (13) while a. Remove epoxy coating and TEMP-PLATES
simultaneously tucking outer circumference edge of (figure 66-115) using paint remover (C-436). Repeat
seal (12) using workaid into outer coupling (13) seal process until no trace of epoxy is present.
groove.
d. Continue pressing around seal (12) using MUST BE FREE OF ALL CONTAMINATION. ANY
workaid until seal is fully seated. CONTAMINATION COULD ALLOW TEMP-PLATES TO
COME OFF OR INDICATE FALSE TEMPERATURES.
7. Place a small amount of grease (C-015) in internal
splines of outer coupling. Insert inner coupling (14) in
outer coupling (13) with small end through seal (12). b. Prepare outer coupling surface for bonding by
scrubbing surface using clean cloths wetted with a
8. Position coupling assembly on splined end of gear cleaning solvent MEK (C-309). Remove all comtamination
shaft. Place washer (15) on bolt (16) and insert bolt and before MEK dries, wipe the surface dry with clean
through inner coupling (14) to engage threads of gear cloth. The cleaned surface area should be minimum 0.50
(1). Hold sleeve assembly with T101455 plate inch larger than area of TEMP-PLATES on outer coupling.
assembly. Hold outer coupling with T101307 wrench
assembly. Use a square extension to torque bolt 80 to c. Perform a water break-free test on the prepared
100 foot-pounds. bonding surface by applying distilled or demineralized
9. Coatpacking (17)with approved gearboxoil(refer must flow into a continuous film without gathering into
to BHT-205A1-MM-1 manual) and place on retainer distinct water droplets within 25 seconds after application
(18). Insert retainer into bolt (16). to the surface. Wipe dry with a clean cloth. Ensure bonding
surfaces are not subsequently contaminated.
CAUTION: RECESS IN RETAINER (18) IS 1.130
INCH DEEP FOR INPUT DRIVE QUILL AND 0.818 d. Ifthecouplingbondingsurfacewillnotmeetthe
INCH FOR OUTPUT QUILL. DO NOT INSTALL IN water break-free test requirements and ensure cleaning
WRONG QUILL. materials are not contaminated; clean coupling bonding
10. Align hole in rim of retainer (18) with a notch of
inner coupling (13). Install lock spring (19).
NOTE: Followthe manufacturer recommendations for
11. Extend outer coupling (13) so that seal (12) is proper mixtures.
against the spherical teeth on inner coupling (14), and
pack internal spline in outer coupling with grease (1) Using a cleaning compound (C-318) and
(C-015) to a depth of 0.12 inch over tops of internal cloth, scrub coupling bonding surface clean. Follow
spline teeth. A workaid may be fabricated, as shown in cleaning with a thorough water rinse.
figure 66-85, to obtain depth of grease.
(2) Thoroughly dry coupling surfaces.
12. Place small end of centering spring on boss of
seal plate (21, figure 66-108). Install plate and spring in (3) Repeat water break-free test as stated
outer coupling (13) inserting large end of spring into above.
retainer (18) and install retainer ring (22).
13. Test quill assembly by holding sleeve and turning CAUTION: TO PREVENT CONTAMINATION OF
coupling and gear assembly. There should be a very THE TEMP-PLATES ADHESIVE BACKING, ENSURE
light drag of the gear in the sleeve caused by preload of THAT WORK AREA AND HANDS ARE THOROUGHLY
the duplex bearings and drag of oil seal, but the gear CLEANED BEFORE WORKING WITH TEMP-PLATES.
should turn smoothly.
14. Position shim plates on sleeve and secure with FINGERS DURING INSTALLATION ON COUPLING.
screws (8). THIS WILL CONTAMINATE SURFACES. APPLY
EPOXY COATING TO TEMP-PLATES IMMEDIATELY
15. Replace overtemperature indicator FOLLOWING INSTALLATION OF TEMP-PLATES ON
TEMP-PLATES as follows: COUPLING.
Rev. 2 66-202A
BHT-205A1-CR&O-1
0.74± 0.030 IN.
6000-1 TEMP-PLATE(RED BORDER)

2 REQD - 180 DEGREESAPART
EQUALLYSPACEDWITHIN 0.300 IN.
205A1-R-66-115
Figure 66-115. Intermediate gearbox input and output quill overtemperature indicator TEMP-PLATE
66-202B Rev. 2
BHT-205A1-CR&O-1
e. Carefully form temperature indicator approximately 0.25 inch beyond edges of

TEMP-PLATES to match V contour of coupling surface. TEMP-PLATES.
Do not crease TEMP-PLATES sharply.
CAUTION: DO NOT EXPOSE EPOXY COATING TO

OIL, GREASE, CLEANING SOLVENT OR OTHER
NOTE: Working one TEMP-PLATE at a time, repeat CHEMICALS DURING CURE.
steps f and g until all TEMP-PLATES are installed on
coupling.
j. Allow epoxy coating to cure at room
temperature, approximately 60 to 100°F, for a minimum
f. Remove protective backing fromTEMP-PLATE of six hours prior to operating helicopter. For best
and carefully position onto surface prepared in step b. results, allow epoxy to cure overnight prior to operating
helicopter or exposing to oil or grease.
g. Using clean cloth or cotton swab, work
TEMP-PLATE into contour of coupling. A thoroughly NOTE: An alternate source of heat can be used if the
cleaned firm rubber (edge of a block type eraser) temperaturedoesnotexceed 180°F.
workaid may be utilized to work TEMP-PLATE into full
contact with coupling surface. Ensure the TEMP-PLATE
is in full contact with coupling surface. Do not press or k. After one hour epoxy curing time at room
rub TEMP-PLATE with bare fingers. temperature, the epoxy coating total curing time can be
NOTE: Use of any epoxy adhesive other than Devcon 150 to 180°F.
2-Ton (C-298) is not authorized.
I. Following the cure, TEMP-PLATES should

h. Prepare Devcon 2-Ton epoxy adhesive (C-298) conform to the contour of the coupling and be free of
as follows: lifted edges. Indicating dots on TEMP-PLATES must
remain original white or light gray with not full or partial
black discoloration.
Part B into a solvent proof container.
m. Perform an adhesion test on each TEMP-PLATE
(2) Vigorously mix Part A and Part B with a tape onto TEMP-PLATE and epoxy overcoat. Tape should
brush such as an artist brush. extend beyond edge of epoxy overcoat. Grasp one end of
(3) A few drops of thinner, such as MEK(C-309), remove tape in one abrupt motion. Lifting or peeling of
may be added to epoxy during mixing operation to reduce epoxy coating or TEMP-PLATE is not acceptable. If lifting
viscosity to a level that permits uniform brush application or peeling is detected, remove and replace TEMP-PLATE
of epoxy mixture. Do not thin this mixture such that it runs by repeating procedure.
epoxy should be similar to heavy bodied paint. Too thin a
mixture may seep into overtemperature indicator n. Repeat procedure opposite coupling.
TEMP-PLATE and cause indicator dots to turn black (in
which event, TEMP-PLATE must be removed and 16. The tail rotor intermediate gearbox input quill
replaced). Working time for the mixture is approximately shall be tagged with date of lubrication and an entry
15 minutes. made in component historical record, if intermediate
gearbox input quill be returned to stock.
i. Using a soft-bristled brush, uniformly apply epoxy
coating over TEMP-PLATES to a thickness of 17. When tail rotor intermediate gearbox input quill
approximately 0.002 to 0.004 inch (similar to a coat of is installed on helicopter, an entry shall be made in
paint). Coating should be uniform in appearance, totally helicopter log and flex couplings lubrication log in
cover surface of TEMP-PLATES and extended BHT-205A1-MM-1 manual with date of lubrication.
Rev. 2 66-203
BHT-205A1-CR&O-1
66-200. OVERHAUL - INTERMEDIATE 6. Press pinion (24) out of sleeve (17). Remove
GEARBOX (212-040-003) INPUT QUILL. retaining ring (25) and roller bearing (26) using
T101333 pressing bar. Press duplex ball bearing (16)
out of sleeve using T101334 pressing bar.
TOOLS REQUIRED
NOTE: Duplex bearings are a matched set; both
bearings have same serial number. Keep duplex
T101307 Wrench bearings together as a set.
T101334 Pressing Bar 7. Remove retainer ring (21) and plug (22) from
T101564 Holding Fixture pinion (24). Remove packing (23).
T101600 Wrench.
8. Removethree screws (20) and shim plate (19).
Identify shim plate.
66-201. DISASSEMBLY - INTERMEDIATE
GEARBOX INPUT QUILL. 66-202. CLEANING - INTERMEDIATE GEARBOX
INPUT QUILL.
NOTE: If input quill is being disassembled for
replacement of parts instead of overhaul, 1. Clean quill parts with solvent (C-304) with
disassemble only to extent necessary to replace exception of bearings which are cleaned with
parts. trichloroethane (C-334).
2. Use clean lint-free cloth or low pressure filtered

NOTE: For ease of maintenance, block the outer compressed air to dry parts. Do not let bearings spin
coupling so that is will remain in the outboard while drying.
(extended) position. This will stabilize the outer
coupling during disassembly and assembly. 3. If not used immediately after cleaning, coat
bearings with approved gearbox oil (refer to
1. Remove retainer ring (9, figure 66-116), plate BHT-205A1-MM-1 manual). To prevent corrosion
(8), centering spring (7), and lock spring (6). Remove damage avoid handling unoiled bearings.
spacer (5). Remove retainer (4); a 1/4-20 threaded
bolt may be used to facilitate removal of retainer (4). 4. Remove sealant from quill sleeve with plastic
Install bolt in center of retainer and pull on bolt to scraper.
withdraw retainer from inner coupling. Remove
packing (3) from retainer. NOTE: Parts that have lacquer top coat and primer
(C-202) need only to have the top coat removed for
2. Hold outer coupling (11) with T101307 fluorescent penetrant inspection.
wrench; position square adapter through wrench and
remove coupling retaining bolt (2). Remove washer 5. Remove paint from quill sleeve with paint
(1). remover (C-436) and rinse with clean water.
3. 3.Remove inner and

Remove inner and outer couplings (110
outer couplings and 11)
(10 and 11) 6. If ferrous parts are not used immediately after
from pinion (24). cleaning, gently agitate parts in corrosion preventive
4. Separate inner and outer couplings (10 and 11) gearbox oil (refer to BHT-205A1-MM-1 manual).
and remove seal (12) from outer coupling (11). 66-203. INSPECTION - INTERMEDIATE
GEARBOX INPUT QUILL.
5. Position T101564 holding fixture on sleeve
(17) with T101600 wrench, positioned on nut (14). NOTE: If records and/or physical appearance of
Remove nut (14). Remove packing (15) and press input quill indicate that assembly has been subjected
seal (13) out of nut. to an accident or incident outside realm of normal
66-204
BHT-205A1-CR&O-1
1. Washer 10. Inner coupling 19. Shim plate

2. Retaining bolt 11. Outer coupling 20. Screw
3. Packing 12. Seal 21. Retainer ring
4. Retainer 13. Seal 22. Plug
5. Spacer
Spacer 14. Nut
Nut 23.
23. Packing
Packing 205A1-R-66-116-1
6. Lock spring
Lockspring 15. Packing 24.
24. Pinion
Pinion
7. Centering spring 16.
16. Duplex ball bearing
Duplex 25.
25. Retaining ring
Retaining ring
8. Plate 17. Sleeve
Sleeve 26.
26. Roller bearing
Roller bearing
9. Retainer ring 18. Clinch nut
NOTES:
NOTES: overtemperature indicator
Location of overtemperature
Location TEMP-PLATE.
indicator TEMP-PLATE.
Apply
Apply sealant, MIL-S-8802,
MIL-S-8802,Class B2, around (14) and
nut (14)
around nut and
sleeve (17)
sleeve (17)after assembly.
after assembly.
205A1-R-66-116-1
Figure 66-116. Intermediate gearbox (212-040-003) input quill (Sheet 1of 2)
Rev. 2 66-205
BHT-205A1-CR&O-1

INNER COUPLING (10) USED rINVERTED ON INNER
OF SEAL (12) UP
DETAIL A
usage, perform Conditional Inspection, paragraph NOTE: If steps 1. through 5. reveal cracks or
66-204. If input quill does not require conditional distortion, indicative of excessive loads, then input quill
inspection proceed with Normal Inspection, paragraph shall be considered unserviceable and nonreparable.
66-205.
6. Accomplish Normal Inspection. (Refer to
paragraph 66-205.)
66-204. Conditional Inspection - Intermediate
Gearbox Input Quill.
66-205. Normal Inspection - Intermediate
1. Visually inspect pinion (24, figure 66-116) teeth for
damageof
damage and evidence and
of overload
overload pattern.
evidence
pattern. Inspect parts dimensionally and replace parts that
2. Visually inspect inner and outer couplings (10 and 66-117.)
11) for cracked or chipped teeth.
3. Inspect bearings for roughness or surface fit between mating parts. It is not intended that all
impressions produced by a heavy blow or pressure of dimensions be checked as a prescribed overhaul
rollers skidding. procedure; however, parts that show evidence of wear
or physical damage must be checked dimensionally.
4. Perform magnetic particle inspection of pinion
(24) and inner and outer couplings (10 and 11). (Refer 2. Inspect pinion and splines for chipped, broken or
to BHT-ALL-SPM manual.) worn teeth.
5. Perform fluorescent penetrant inspection of 3. Inspect pinion teeth and pinion (24, figure 66-116)
sleeve (17). (Refer to BHT-ALL-SPM manual for for excessive wear, scoring, scuffing, and wear pattern.
approved fluorescent penetrant material.) (Refer to figure 66-109.)
66-206 Rev. 2
BHT-205A1-CR&O-1
NOTE: Overtemperature dots on overtemperature c. Inspectoutercouplingandinnercouplingunder

indicator TEMP-PLATES are of a white or light gray 5X to 10X magnification for teeth exhibiting signs of
color and turn black when exposed to an metal smearing or tearing in the contact patterns. If
overtemperature condition. Chemical contamination smearing or tearing is found, replace outer coupling and
can also cause indicating dots to turn black. inner coupling.

4. Inspect outer coupling (11, figure 66-116) viscous (thick) and having a strong pungent odor. If
overtemperature indicator TEMP-PLATES for evidence grease is found to be viscous and having a strong
of overtemperature indication. If overtemperature pungent odor, replace outer coupling and inner
indication is noted, perform coupling overtemperature coupling.
a. Inspect outer coupling cadmium plating for TEMP-PLATES after completing entire inspection
being discolored (circumferential tan or light brown procedure and couplings have been determined
band) or blistered. If cadmium plate discoloration or serviceable and prior to lubricating couplings.
coupling. 4A. Inspect outer coupling (11, 66-116)
deterioration, debonding or discoloration of epoxy
b. Inspect gear teeth of outer coupling and inner coating that prevents interpretation of indicating dots. If
coupling for being discolored (brown or blue) in normally deterioration, debonding, or discoloration of epoxy is
bright contact patterns. If discoloration is found, replace found, replace TEMP-PLATES in accordance with
outer coupling and inner coupling. paragraph 66-207.
Rev. 2 66-206A/66-206B
BHT-205A1-CR&O-1

INCHES
1 Spline - Outer Coupling

2 Teeth - Inner Coupling Over Pins 2.1590 2.1740
3 Spline - Inner Coupling Between Pins 1.1465 1.1578
4 Spline - Gear Over Pins 1.4424 1.4465
5 Sleeve ID 2.8340 2.8347
6 Sleeve OD 4.4097 4.4105
7 Sleeve ID 3.1489 3.1497
8 Gear Shaft OD 1.8691 1.8696
10 Pinion OD 1.3780 1.3786
OD 2.8341 2.8346
*Maximum allowable depth of wear 0.005 (measure from unworn face of tooth).
Figure 66-117. Intermediate gearbox (212-040-003) input quill wear limits
66-207
BHT-205A1-CR&O-1
5. Inspect inner and outer couplings (10 and 11, 10. Inspectsleeve(17,figure66-116)forcorrosion
figure 66-116). damage. (Refer to figure 66-118.)
a. Inspect for chipped, pitted, cracked or 11. Perform fluorescent penetrant inspection of
excessively worn teeth. sleeve. (Refer to BHT-ALL-SPM manual.)
12. Inspect shim plate (19, figure 66-116) for

b. Check wear patterns to criteria shown on figure damage and wear.
66-111.
13. Inspect plate (8) for damaged seals.

c. Inspect surfaces of inner couplings that are
contacted by seals (13, figure 66-116 for excessive 14. Inspect coupling retaining bolts (2)visually for
wear, nicks and scratches. A groove worn by seal is damaged threads. Replace bolts that have malformed
acceptable to a minimum diameter of 1.587 inches threads.
provided depth does not exceed 0.002 inch. If groove is
smooth, part may be reworked.
15. Inspect nuts (14) visually for damaged
threads. Replace nuts that have malformed threads.
6. Perform magnetic particle inspection of following
parts. Index numbers are keyed to figure 66-116.
Demagnetize all parts after inspection. 66-206. REPAIR - INTERMEDIATE GEARBOX
INPUT QUILL.
INDEX NO. NOMENCLATURE 1. Replace parts that are not within allowable wear
10 Inner Coupling limits.
11 Outer Coupling
24 Pinion 2. Replace duplex ball bearings (16, figure 66-116)
and roller bearing (26) that show evidence of
brinelling, spalling, discoloration from overheating,
7. Check duplex ball bearings (16) and roller bearing corrosion on rolling elements, cracked or broken
(26) for smooth operation and indications of excessive retainers, or that do not operate smoothly.
wear. Inspect bearing races for roughness.
3. Replace all seals, packings, standard
hardware, and all safety locking devices at time of
8. Inspect bearing liners for scoring and security of
mounting in sleeve (17). reassemby.
4. Repair minor scratches, nicks, and pits on

9. Inspect bearings for spalling, scoring, pitting, noncritical surfaces with crocus cloth.
brinelling, flaking, corrosion on rolling elements, and
cracked or broken retainers. (Refer to figure 66-112.)
splines and pinion (24) using fine India stone.
a. Minor nicks, cuts, or scratches are acceptable
provided they are too small to be felt with a probe 6. Repair inner coupling (10) and outer coupling
having an end radius of 0.030 inch, and provided that (11) as follows:
the total affected area does not exceed 10 percent of
the contact area at any point.
a. Repair minor nicks, dents or scratches in the
b. Minor circumferential scoring is acceptable with fine India stone (C-464) to remove damage,
on rollers and races provided that is cannot be felt with Blend into surrounding area. Seal groove wear of no
a probe having an end radius of 0.030 inch and more than 0.002 inch deep and minimum diameter of
provided that the affected area does not exceed 10 1.587 inches is acceptable if groove is uniform and
percent of the contact area at any point. smooth.
66-208 Rev. 2
BHT-205A 1-CR&O- 1
AREA A
AREA B
DIM. C
NOTES:
is acceptable
1. Corrosion pitting or mechanical surface damage in area A, exclusive of area B.
provided it is within the following limits:
a. Maximum acceptable depth is 0.030 inch.

of the
b. No more than 40 percent of the area within any one inch square, nor 20 percent
total area of any surface or diameter may be pitted.
attaching
2. Corrosion pitting or mechanical surface damage on the spot faced surface at the
holes, area B, is acceptable provided it is within the following limits:
a. Maximum acceptable depth is 0.020 inch.
b. No more than 20 percent of the total spot faced area at any hole may be pitted.
be
c. No more than 20 percent of the total area normally contacted by the washer may
pitted.
may
d. No more than 50 percent of the width of the area normally contacted by the washer
be pitted at any point around the hole.
Figure 66-118. Intermediate gearbox (212-040-003) input quill sleeve damage limits
66-209
BHT-205A 1-CR&O-1
b. Touch up brush cadmium plate inner and b. Subtract 0.3910 to 0.3915 inch from
outercouplings (10and 11,figure66-116)usingLHE reference dimension stamped on sleeve to give
solution (C-108). Plating thickness to be 0.0001 to required shim thickness, after plating, for sleeve.
0.0003 inch. Do not exceed 0.0003 inch plating
thickness in seal contact area. Do not plate internal c Grind new blank shim to required thickness
spline teeth on inner and outer coupling (10 and 11) ad apply LHE solution (C-108). (Refer to
and gear teeth of inner coupling. Apply plating tabe BHT-ALL-SPMmanual for prescribed cadmium plating
(C-434) to areas not to be plated. (Refer to figure method.) Identify new shim plate by etching serial
66-119 for plating areas and BHT-ALL-SPM manual number of applicable sleeve on shim plate. Also etch
for prescribed cadmium plating method.) thickness (in thousandths of an inch) on shim plate.
Use etching ink (C-461) or equivalent. Neutralize ink,
7. If original cadmium plating on sleeve shim plate after marking, by wiping with a rag soaked with oil
(19, figure 66-116) has worn through, replate using (C-109).
LHE solution (C-108). (Refer to BHT-ALL-SPM manual
for prescribed cadmium plating method.) Refer to 9. Repair sleeve (17) as follows:
step 8. for shim thickness after plating. a. If damaged or loose replace clinch nuts (18)
as follows:
8. If original sleeve shim plate (19) is missing or
mixed with other shim plates, determine required (1) Use a drift or bolt threaded into nut to
dimensions of replacement shim plate as follows: drive clinch nut out; being carefull not to damage hole
in sleeve flange.
a. Examine sleeve for reference dimension
which should be metal stamped or vibro-etched on (2) Clean sleeve by vapor degreasing with
part adjacent to applicable mounting surface. trichloroethane (C-334).
INNER COUPLING OUTER COUPLING SLEEVE

204-040-603 204-040-604 212-040-502
Cadmium plate will be applied to this area only.
Do not apply cadmium plate in hole.
Epoxy primer (C-204) and lacquer (C-203) will be applied to this area only.
Figure 66-119. Intermediate gearbox (212-040-003) input quill sleeve processing requirements
66-210
BHT-205A1-CR&O-1
(3) Clean up surface of sleeve flange to Corrosion removal process must be controlled to
remove any raised burrs. ensure that machined dimensions are maintained and
that cadmium plating is not removed. After chromic
(4)
(4) Treat
Treat hole
hole and
and any
any reworked
reworked areas
areas on
on acid bath, rinse sleeve with water to remove chromic
sleeve with chemical film (C-103). acid and dry with filtered compressed air and apply
(5) If clinch nut was not loose, coat new nut magnesium alloy chemical film treatment. (Refer to
with unreduced primer (C-201) and drive clinch nut BHT-ALL-SPMmanual.)
(18) into place. Remove any raised burrs on sleeve
c. Perform fluorescent penetrant inspection of
flange face, and touch up with chemical film (C-103).
sleeve. (Refer to BHT-ALL-SPMmanual for approved
(6) If nut was loose, remove cadmium plating fluorescent penetrant materials.)
from surfaces of clinch nut that contact the sleeve
with abrasive paper (C-423). Wipe clinch nut and 10. Repair minor nicks scratches, and burrs on
mating surfaces of the sleeve clean with MEK (C-309) pinion splines and teeth by dressing with fine india
and clean cheesecloth. Bond clinch nut in place with stone (C-464).
abrasive (C-317). Clean excess adhesive from
threads and surface of sleeve flange and hole. Clinch 11. Parts on which finish has been removed by
wear, chipping, scoring, scratches, dents shall be
nut must be at least 0.010 inch below surface of
refinished as follows: (Refer to figure 66-119 or
sleeve flange.
processing requirements.)
(7) Check that side of sleeve flange that
contacts shim plate is flat and that clinch nut does not a. Aluminum parts shall be touched up with
protrude above surface. chemical film (C-100) as required.
b. Repair mechanical and corrosion damage on b. Magnesium parts shall be touched up with
sleeve as follows: (Refer to figure 66-118.) chemical film (C-103) or apply corrosion treatment
(C-1 4) to entire part.
(1) If damage to spot faced surfaces, area B,
exceeds inspection limits, surface may be reworked c. Touch up brush cadmium plate steel parts.
by machining off surface to a minimum flange (Referto BHT-ALL-SPMmanual for approved method)
thickness, dimension C, of 0.310 inch. Machining
must be done with a 0.688 diameter spotface cutter, 66-207. ASSEMBLY - INTERMEDIATEGEARBOX
with a 0.060 corner radius. After cleanup, pitting is INPUT QUILL.
acceptable provided it is no more than 0.010 inch
deep. Surface finish of unpitted reworked surface CAUTION: SAME SHIM PLATE THAT WAS
must be 63 RHR (roughness height rating) or better. REMOVED FROM SLEEVE MUST BE REINSTALLED
OR A NEW SHIM PLATE OF SAME THICKNESS
(2) Sleeves with corrosion damage within MUST BE MADE.
acceptable limits must be reworked by smoothing out
any sharp edges that might damage packing during 1. Coat all parts with approved gearbox oil (refer
assembly. Nicks, dents or pits in area A, figure to BHT-205A1-MM-1 manual) prior to starting
66-118, within allowable limits, must be reworked to reassembly procedure.
blend into surrounding area. Minimum radius in
reworked areas in 0.25 inch and surface finish must 2. Position original shim plate (19, figure 66-116)
be 63 RHR or better. or new shim plate on sleeve (17) and install three
screws (20).
(3) Sleeves with corrosion damage within
acceptable limits must be treated by immersion in a 3. Press duplex ball bearing (16) into sleeve (17)
hot chromic acid bath consisting of 20 to 24 ounces using T101334 pressing bar. The duplex bearing
of chromic acid (C-116) per gallon of water at 200°F must have matching serial numbers, be installed in
(93°C) for as long as corrosion is present. It is pairs, and be installed face-to-face.
mandatory that all corrosion products be removed.
66-211
BHT-205A 1-CR&O-1
4. Press roller bearing (26) into sleeve (17) using 8. Place small amount of lubricant (C-015) in
T101333 pressing bar. Install retaining ring (25). internal splines of outer coupling (11). Insert inner
coupling (10) into outer coupling (11) with small end
5. Press pinion (24) into sleeve while supporting through seal.
inner race of duplex ball bearing (16). Avoid damage
to teeth to pinion. 9. Position inner and outer couplings (10 and 11)
on splined end of pinion (24).
6. Apply adhesive (C-308) to faying surface of
seal (13). Press new seal (13) into nut (14) with lip of 10. Coat threads of coupling retaining bolt (2)
seal facing inboard. Install new packing (15) on nut with approved gearbox oil (refer to BHT-205A 1-MM-1
(14). Position T101 564 holding fixture on sleeve (17) manual).
with pins engaged through holes in sleeve flange.
11. Place washer (1) on bolt and thread bolt into
Coat packing and threads of nut (14) with approved
Install nut in sleeve and torque 100 to 150 12. Hold outer coupling (11) with T101307
foot-pounds using T101600 wrench. Secure nut to wrench. Use a square extension to torque bolt (2) 80
sleeve with lockwire (C-405). to 100 foot-pounds.
NOTE: A workaid may be fabricated, as shown in 13. Place packing (3) on retainer (4).
66-116). 14. Coat packing and retainer with approved
gearbox oil (refer to BHT-205A1-MM-1 manual) and
7. Install seal (12) into outer coupling (11) seal insert retainer into bolt (2). If one hole in rim of
groove as follows: retainer (4) does not align with notch of inner
coupling (10), pull retainer free of bolt. Rotate ninety
a. Apply a light coat of grease (C-015) to outer degrees and reinstall. Repeat if necessary to obtain
circumference of seal (12). alignment. When hole and notch are aligned, install
lock spring (6) through hole in rim of retainer and
b. Install seal (12) into outer coupling (11) seal notch of inner coupling (10).
groove with lip of seal toward internal splines of outer
coupling (11), as shown in figure 66-116, detail A. 15. Extend outer coupling (11) so that seal (12) is
against teeth of inner coupling. Coat internal splines
NOTE: Seal (12) will be partially seated and the of outer coupling (11) with lubricant (C-015) to 0.12
inner coupling (10) will be used as a backup, in inch depth over top of spline teeth. A workaid may be
reverse, (see detail A) to fully seat the outer fabricated, as shown in figure 66-85, to obtain depth
circumference edge of seal into outer coupling (11) of grease.
seal groove.
16. Place small end of centering spring (7, figure
c. Using inner coupling (10) as a backup, and
66-116) on boss of seal plate (8).
placed, as shown in detail A, firmly press down (hand 17. Install plate (8), spacer (5), and centering
pressure only) on outer coupling (11), simultaneously spring (7) into coupling and install retainer ring (9).
tuck outer circumference edge of seal (12) using
workaid, into outer coupling (11) seal groove. 18. Place new packing (23) on plug (22). Coat
packing and plug with approved gearbox oil (refer to
d. Continue pressing around seal (12) using BHT-205A1-MM-1 manual), and insert plug into
workaid, until seal is fully seated. pinion (24). Install retainer ring (21).
NOTE: Ensure inner coupling (10) is correct for 19. Test quill by holding sleeve and turning
intermediate and tail rotor gearbox, overall length is coupling. There should be a very light drag caused by
1.870 to 1.880 inch. Tail rotor driveshaft hanger oil seal and preload of the duplex bearings, but
coupling overall length is 2.070 to 2.080 inch. coupling and pinion should turn smoothly.
66-212
BHT-205A1-CR&O-1
20. Replace overtemperature indicator EPOXY COATING TO TEMP-PLATES IMMEDIATELY

TEMP-PLATES as follows: FOLLOWING INSTALLATION OF TEMP-PLATES ON
COUPLING.
(figure 66-115) using paint remover (C-436). Repeat e. Carefully form overtemperature indicator
process until no trace of epoxy is present. TEMP-PLATES to match V contour of coupling surface.
MUST BE FREE OF ALL CONTAMINATION. ANY NOTE: Working one TEMP-PLATE at a time, repeat
CONTAMINATION COULD ALLOW TEMP-PLATES TO steps f and g until all TEMP-PLATES are installed on
COME OFF OR INDICATE FALSE TEMPERATURES. coupling.
b. Prepare outer coupling surface for bonding by f. Remove protective backing from TEMP-PLATE
scrubbing surface using clean cloths wetted with a and carefully position onto surface prepared in step b.
cleaning solvent MEK (C-309). Remove all comtamination
and before MEK dries, wipe the surface dry with clean g. Using clean cloth or cotton swab, work
cloth. The cleaned surface area should be minimum 0.50 TEMP-PLATE into contour of coupling. A thoroughly
inch larger than area of TEMP-PLATES on outer coupling, cleaned firm rubber (edge of a block type eraser)
workaid may be utilized to work TEMP-PLATE into full
c. Perform a water break-free test on the prepared contact with coupling surface. Ensure the TEMP-PLATE
bonding surface by applying distilled or demineralized is in full contact with coupling surface. Do not press or
water from a suitable dispenser (squeeze bottle). Water rub TEMP-PLATE with bare fingers.
must flow into a continuous film without gathering into
distinct water droplets within 25 seconds after application NOTE: Use ofanyepoxy adhesive otherthanDevcon
to the surface. Wipe dry with a'clean cloth. Ensure bonding 2-Ton (C-298) is not authorized.
surfaces are not subsequently contaminated.
d. If the coupling bonding surface will not meet the h. Prepare Devcon 2-Ton epoxy adhesive (C-298)
water break-free test requirements and ensure cleaning as follows:
materials are not contaminated, clean coupling bonding (1) Pour equal amounts of epoxy Part A and
NOTE: Followthemanufacturerrecommendationsfor (2) Vigorously mix Part A and Part B with a

proper mixtures. brush such as an artist brush.
(1) Using a cleaning compound (C-318) and (3) A few drops of thinner, such as MEK (C-309),
cloth, scrub coupling bonding surface clean. Follow may be added to epoxy during mixing operation to reduce
cleaning with a thorough water rinse. viscosity to a level that permits uniform brush application
of epoxy mixture. Do not thin this mixture such that it runs
(2) Thoroughly dry coupling surfaces. when applied to a vertical surface. The final viscosity of
(3)Repeat water break-free test as stated mixture may seep into overtemperature indicator
above. TEMP-PLATE and cause indicator dots to turn black (in
which event, TEMP-PLATE must be removed and
CAUTION: TO PREVENT CONTAMINATION OF 15 minutes.
THAT WORK AREA AND HANDS ARE THOROUGHLY i. Using a soft-bristled brush, uniformly apply epoxy
CLEANED BEFORE WORKING WITH TEMP-PLATES. coating over TEMP-PLATES to a thickness of
DO NOT PRESS OR RUB TEMP-PLATES WITH BARE paint). Coating should be uniform in appearance, totally
FINGERS DURING INSTALLATION ON COUPLING. cover surface of TEMP-PLATES and extended
THIS WILL CONTAMINATE SURFACES. APPLY approximately 0.25 inch beyond edges of TEMP-PLATES.
Rev. 2 66-212A
BHT-205A1-CR&O-1
CAUTION: DO NOT EXPOSE EPOXY COATING TO k. After one hour epoxy curing time at room
OIL, GREASE, CLEANING SOLVENT OR OTHER temperature, the epoxy coating total curing time can be
CHEMICALS DURING CURE. accelerated by placing the coupling in a temperature
j. Allow epoxy coating to cure at room 150 to 180 °F.
of six hours prior to operating helicopter. For best
results, allow epoxy to cure overnight prior to operating l. Following the cure, TEMP-PLATES should
helicopter or exposing to oil or grease. conform to the contour of the coupling and be free of
lifted edges except as in note above Indicating dots on
NOTE: An alternate source of heat can be used if the TEMP-PLATES must remain original white or light gray
temperature does not exceed 180°F. with not full or partial black discoloration.
66-212B Rev. 2
BHT-205A1-CR&O-1
m. Perform an adhesion test on each TEMP-PLATE position. This will stabilize the outer coupling during
installation. Press a one inch wide strip of high adhesion disassembly and assembly.
tape onto TEMP-PLATE and epoxy overcoat. Tape should
epoxy coating or TEMP-PLATE is not acceptable. If lifting

or peeling is detected, remove and replace TEMP-PLATE
by repeatingprocedure. 2. Hold outer coupling (10) with T101307 wrench.
Usinga square adapterthrough wrench, remove bolt (7)
and washer (8).
n. Repeat procedure for opposite coupling.
3. Remove both inner and outer couplings (9 and 10)
21. The tail rotor intermediate gearbox input quill from splines of gear (22).
shall be tagged with date of lubrication and an entry
made in component historical record, if driveshaft is to 4. Remove inner coupling (9) from large end of
be returned to stock. coupling (10) and remove seal (11)from outer coupling.
22. When tail rotor intermediate gearbox input quill 5. Remove retainer ring (25) and oil collector
is installed on helicopter, an entry shall be made in assembly (23) from inboard end of gear. Remove
helicopter log and flex couplings lubrication log in packing (24) from oil collector assembly.
BHT-205A1-MM-1 manual, with date of lubrication.
6. Hold sleeve (16) with T101455 plate assembly
with pins engaged through sleeve flange. Cut lockwire
66-208. INTERMEDIATE GEARBOX OUTPUT and with T101336 wrench, remove nut (13). Remove
QUILL. seal (12) and packing (14) from nut.
7. Press gear (22) with inner race of roller bearing

66-209. OVERHAUL- INTERMEDIATE GEARBOX (20) and spacer (19) from sleeve (16). Remove spacer
(204-040-003) OUTPUT QUILL. and inner race of bearing from gear.
TOOLS REQUIRED CAUTION: EXERCISE CARE TO POSITION BAR

ON DUPLEX BEARING (15) AND ROLLER BEARING
T101307 Wrench assembly (20) SO THAT IT DOES NOT CATCH ON FLANGE OF
T101333 Bar LINER.
T101334 Bar
T101336 Wrench 8. Remove retainer ring (21). Use T101333 bar
T101455 Plate assembly and press roller bearing (20) from inboard end of
sleeve (16).
9. Use T101334 bar and press duplex bearing (15)

GEARBOX OUTPUT QUILL.
10. Remove screws (18) and shim plate (17).

NOTE: If output quill is being disassembled for Identify shim plate.
replacement of parts instead of overhaul, disassemble
only to extent necessary to replace parts.
NOTE: When ground shim plate (17) is removed from
sleeve, it must be identified to ensure that shim is
NOTE: For ease of maintenance, block the outer reinstalled on same sleeve. Shim plate must be
coupling so that it will remain in the outboard (extended) removed for fluorescent penetrant inspection.
Rev. 2 66-213
BHT-205A1-CR&O-1
1. Retainer ring 10. Outer coupling 19. Spacer

2. Plate 11. Seal 20. Roller bearing
3. Spring 12. Seal 21. Retainer ring
4. Lock spring 13. Nut 22. Gear
5. Retainer 14. Packing 23. Oil collector
6. Packing 15. Duplex bearing 24. Packing
7. Bolt 16. Sleeve 25. Retainer ring
8. Washer 17. Plate
9. Inner coupling 18. Screw
NOTES: Location of overtemperature indicator TEMP-PLATE.

Apply sealant, MIL-S-8802, Class B2, around nut (13) and
sleeve (16) after assembly.
205A1-R-66-120-1
Figure 66-120. Intermediate gearbox (204-040-003) output quill (Sheet 1 of 2)
66-214 Rev. 2
BHT-205A 1-CR&O-1

OF SEAL (12) UP
DETAIL A
Figure 66-120. Intermediate gearbox output quill (204-040-003) (Sheet 2 of 2)
66-211. CLEANING - INTERMEDIATEGEARBOX 66-212. INSPECTION - INTERMEDIATE

OUTPUT QUILL. GEARBOX OUTPUT QUILL.
1. Clean quill parts with solvent (C-304) with NOTE: If records and/or physical appearance of
exception of bearings which are cleaned with output quill indicate that assembly has been
trichloroethane (C-334). subjected to an accident or incident outside realm of
normal usage, perform Conditional Inspection,
2. Use clean lint-free cloth or low pressure filtered paragraph 66-213. If input quill does not require
compressed air to dry parts. Do not let bearings spin Conditional Inspection proceed with Normal
while drying. Inspection, paragraph 66-214.
3. If not used immediately after cleaning, coat 66-213. Conditional Inspection - Intermediate
bearings with approved gearbox oil (refer to GearboxOutput Quill.
BHT-205A1-MM-1 manual) to prevent corrosion
damageunoiled bearings
damage. Avoid handling chipped teeth. inspect couplings for cracked or
Visually
chipped teeth.
4. Remove sealant from quill sleeve with plastic
2. Inspect bearings for roughness or brinelling.
scraper.
3. Inspect case couplings, gear and sleeves by
NOTE: Parts that have lacquer top coat and primer
(C-202)
(C-202) need
need only
only to
to have
have the
the top
top coat
coat removed
removed for
for magnetic particle or fluorescent penetrant methods.
fluorescent penetrant inspection. 4. Accomplish Normal Inspection, refer to
paragraph 66-214.
5. Remove paint from quill sleeve with paint
remover (C-436) and rinse with clean water. 66-214. Normal Inspection - Intermediate
Gearbox Output Quill.
cleaning, gently agitate parts in corrosion preventive 1. Visually inspect all parts for damage and
(C-105) and air dry. Apply protective coat of approved excessive wear. Inspect gears and splines for
oil.
66-215
BHT-205A1-CR&O-1
chipped, broken, or worn teeth. Check bearings for bright contact patterns. If discoloration is found, replace
smooth operation and indications of excessive wear. outer coupling and inner coupling.
Inspect bearing liners for scoring, and for security in
case openings. Inspect studs for looseness or damage. c. Inspectoutercouplingandinnercouplingunder
2. Inspectfollowingpartsbymagneticparticle(Code metal smearing or tearing in the contact patterns. If
M) or fluorescent penetrant (Code F) methods as smearing or tearing is found, replace outer coupling and
indicated. Index numbers are keyed to figure 66-120. inner coupling.
Demagnetize all parts after magnetic inspection. d. Inspect grease from couplings for being very
NOTE: Refer to BHT-ALL-SPM manual for approved grease is found to be viscous and having a strong
fluorescent penetrant material. pungent odor, replace outer coupling and inner
coupling.
9 Inner Coupling M TEMP-PLATES after completing entire inspection
10 Outer Coupling M procedure and couplings have been determined
16 Sleeve F serviceable and prior to lubricating couplings.
22 Gear M 5A. Inspect outer coupling (11,66-116) temperature
indicator TEMP-PLATES for deterioration, debonding,
3. Inspect parts dimensionally and replace parts that or discoloration of epoxy coating that prevents
do not fall within inspection limits. (Refer to figure interpretation of indicating dots. If deterioration,
66-121.) debonding, or discoloration of epoxy is found, replace
TEMP-PLATES in accordance with paragraph 66-216.
fit between mating parts. It is not intended that all 6. Inspect coupling wear patterns to criteria shown in
dimensions be checked as a prescribed overhaul figure 66-111. Replace couplings if cracked, chipped or
procedure; however, parts that show evidence of wear pitted more than limits shown. Inspect the surface of the
or physical damage shall be checked dimensionally. inner coupling, that is contacted by the oil seal (12, figure
66-120), for excessive wear and for nicks, cuts, and
4. Inspect wear patterns of gears (22, figure 66-120). scratches. A groove worn by the seal is acceptable to a
minimum diameter of 1.587 inches provided the depth
Figure 66-122 illustrates typical patterns. Replace gears
if wear patterns are not within limits shown. does not exceed 0.002 inch. If the groove is smooth, the
part may be reworked in accordance with paragraph
66-215. Nicks,cuts, and scratches which would affect the
NOTE: Overtemperature dots on overtemperature function of the oil seal are not acceptable. Parts may be
reworked in accordance with paragraph 66-215, the
overtemperature condition. Chemical contamination limits specified.
can also cause indicating dots to turn black. 7. Inspect bearing balls and rollers and races for
roughness. Replace ball bearings that show evidence of
5. Inspect outer coupling (10, figure 66-110) spalling, scoring, pitting, brinelling, flaking, or corrosion on
overtemperature indicator TEMP-PLATES for evidence rolling elements or races, or that have cracked or broken
of overtemperature indication. If overtemperature retainers, or that do not roll smoothly. Replace roller
indication is noted, perform coupling overtemperature bearings that show evidence of spalling, flaking, or
inspection as follows: corrosion pitting on rolling elements or races, or that have
cracked or broken retainers (figure 66-112). Minor nicks,
a. Inspect outer coupling cadmium plating for cuts, or scratches are acceptable provided they are too
being discolored (circumferential tan or light brown small to be felt with a probe having an end radius of 0.030
band) or blistered. If cadmium plate discoloration or inch, and provided the total affected area does not exceed
blistering is found, replace outer coupling and inner 10 percent of the contact area at any point. Minor
coupling. circumferential scoring is acceptable on rollers and races
provided if cannot be felt with a probe having an end radius
b. Inspect gear teeth of outer coupling and inner of 0.030 inch and provided the affected area does not
coupling for being discolored (brown or blue) in normally exceed 10 percent of the contact area at any point.
66-216 Rev. 2
BHT-205A1-CR&O-1
8. Inspect retainer bolt (7, figure 66-120) and nut 66-215. REPAIR - INTERMEDIATE GEARBOX
(13) for damaged threads. OUTPUT QUILL.
9. Inspect sleeve (16) for corrosion in accordance 1. Replace parts that are not within allowable wear
with figure 66-114. limits.
10. Perform fluorescent penetrant inspection of 2. Replace duplex bearings (15, figure 66-120)
sleeve. (Refer to BHT-ALL-SPM manual for approved and roller bearing (20) that show evidence of
fluorescent penetrant material.) brinelling, flaking, spalling, discoloration from
Rev. 2 66-216A/66-216B
BHT-205A1-CR&O-1

INCHES
1 Gear shaft OD 1.5752 1.5758
2 Sleeve ID 3.1489 3.1497
3 Sleeve OD 3.6247 3.6255
4 Sleeve ID 2.8340 2.8347
5 Spline - gear Over pins 1.3481 1.3518
6 Spline - inner coupling Between pins 1.1251 1.1336
7 Teeth - inner coupling Over pins 2.1590 2.1740
8 Spline - outer coupling
9 Duplex bearing ID 1.3777 1.3781
OD 2.8341 2.8346
10 Gear shaft OD 1.3780 1.3786
11 Roller bearing OD 3.1491 3.1496
NOTE
Maximum allowable depth of wear is 0.005 inch (measure from unwornfaceof tooth).
205040-2039
Figure 66-121. Intermediate gearbox (204-040-003) output quill wear limits
66-217
BHT-205A1-CR&O-1
Typical shape, size, and location of 204-040-500

gear/pinnion tooth pattern. Acceptable pattern.
2 Pattern is back from toe, bearing a little heavy at top.

204-040-500 gear/pinion tooth. Acceptable pattern.
3 Pattern too far back towards heel 204-040-500

gear/pinion tooth pattern. Not acceptable pattern.
4 Pattern is running off top, slight scoring near toe. 204-

040-500 gear/pinion tooth pattern. Not acceptable
pattern.
5 Running off top of tooth 204-040-500 gear/pinion

tooth pattern. Not acceptable pattern.
Figure 66-122. Gear teeth patterns
66-218
BHT-205A1-CR&O-1
overheating, corrosion on rolling elements, cracked or c. Grind new blank shim to required thickness
broken retainers or that do not operate smoothly. and apply LHE solution (C-108). (Refer to
BHT-ALL-SPMmanual for prescribed cadmium plating
3. Replace all seals, preformed packings, method.) Identify new shim plate by etching serial
standard hardware, and all locking devices at time of number of applicable sleeve on shim plate. Also etch
reassembly. thickness (in thousandths of an inch) on shim plate.
Use etching ink (C-461) or equivalent. Neutralize ink,
4. Repair minor scratches, nicks, and pits on after marking, by wiping with a rag soaked with oil
noncritical surfaces with crocus cloth (C-409). (C-109).
5. Repair minor nicks, scratches, and burrs on 9. Repair sleeve (16, figure 66-120) as follows:
splines and gear (22) using fine india stone (C-464).
a. If damaged or loose, replace clinch nuts.
6. Repair inner coupling (9) and outer coupling
(10) as follows: (1) Use a drift or bolt threaded into nut to
drive clinch nut out; being careful not to damage hole
a. Repair minor nicks, dents or scratches in the in sleeve flange.
with fine india stone (C-464) to remove damage. (2) Clean sleeve by vapor degreasing with
Blend into surrounding area. Seal groove wear no trichloroethane (C-334).
more than 0.002 inch deep and minimum diameter of
1.587 inch is acceptable if groove is uniform and (3) Clean up surface of sleeve flange to
smooth. remove any raised burrs.
b. Cadmium plate inner and outer couplings (9 (4) Treat hole and any reworked areas on
and 10, figure 66-120) using LHE solution (C-108). sleeve with chemical film (C-103).
(Refer to BHT-ALL-SPM manual for prescribed
cadmium plating method.) Plating thickness to be (5) If clinch nut was not loose, coat new nut
0.0001 to 0.0003 inch. Do not exceed 0.0003 inch with primer and drive nut into place. Remove any
plating thickness in seal contact area. Do not plate raised burrs on sleeve flange face, and touch up with
external spline teeth on inner coupling. Do not plate chemical film (C-103).
internal splines on outer coupling.
(6) If nut was loose, remove cadmium plating
7. If original cadmium plating on sleeve shim plate from surfaces of clinch nut that contact the sleeve
(17) has worn through, replate using LHE solution with abrasive paper. Wipe clinch nut and mating
(C-108). (Refer to BHT-ALL-SPM manual for surfaces of the sleeve clean with MEK (C-309) on
prescribed cadmium plating method.) (Referto step 8 clean cheesecloth. Bond clinch nut in place with
for shim thickness after plating.) adhesive (C-317). Clean excess adhesive from
threads and surface of sleeve flange and hole. Clinch
8. If original sleeve shim plate is missing or mixed nut must be at least 0.010 inch below surface of
with other shim plates, determine required sleeveflange.
dimensions of shim plate as follows:
(7) Check that side of the sleeve flange that
a. Examining sleeve for reference dimension contacts shim plate is flat and that clinch nut does not
which should be metal stamped or vibro-etched on protrude above surface.
part adjacent to applicable mounting surface.
b. Repair mechanical and corrosion damage on
b. Subtract 0.9760 to 0.9765 inch from sleeveas follows:
dimension stamped or etched on sleeve for required
shim thickness, after plating. (1) If damage to spotfaced surfaces, area B,
exceeds inspection limits (figure 66-114), surface
66-219
BHT-205A1 -CR&O-1
may be reworked by machining off surface to a 66-216. ASSEMBLY - INTERMEDIATEGEARBOX

minimum flange thickness, dimension C, of 0.310 OUTPUT QUILL.
inch. Machining must be done with a 0.688 diameter
spotface cutter, with a 0.060 corner radius. After
cleanup, pitting is acceptable provided it is no more CAUTION: SAME SHIM PLATE THAT WAS
than 0.010 inch deep. Surface finish of unpitted REMOVED FROM SLEEVE MUST BE REINSTALLED
reworked surface must be 63 RHR or better. OR A NEW SHIM PLATE OF SAME THICKNESS
MUST BE MADE.
(2) Sleeves with corrosion damage within

acceptable limits must be reworked by smoothing out 1. Press duplex bearing (15, figure 66-120), face
any sharp edges that might damage packing during to face, into outboard end of sleeve (16) using
assembly. Nicks, dents or pits in area A, within T101334 bar. Both duplex bearings must have
allowable limits, must be reworked to blend into matching serial numbers and must be installed in
surrounding area. Minimum radius in reworked areas pairs.
is 0.25 inch and surface finish must be 63 RHR or
better.
NOTE: Verify correct installation of bearings. Make
sure that the serial number is the same on both
(3) Sleeves with corrosion damage within bearings of the duplex set.
acceptable limits must be treated by immersion in a
hot chromic acid bath consisting of 20 to 24 ounces 2. Check oiling hole and groove in gear shaft (22)
of chromic acid (C-116) per gallon of water at 200°F for burrs or obstructions.
(93°C) for as long as corrosion is present. It is
mandatory that all corrosion products be removed. 3. Press roller bearing (20), without inner race,
Corrosion removal process must be controlled to into inboard end of sleeve (16) using T101333 bar.
ensure that machined dimensions are maintained and Secure roller bearing with retaining ring (21) in groove
that cadmium plating is not removed. After chromic of sleeve.
acid bath, rinse sleeve with water to remove chromic
acid and dry with filtered compressed air and apply 4. Press inner race of roller bearing (20) on gear
magnesium alloy chemical film treatment. (Refer to (22). Serial number of inner and outer races of bearing
BHT-ALL-SPM manual.) must be the same. Place spacer (19) on gear shaft
next to bearing inner race.
10. After repair, parts on which finish has been 5. Insertgearassemblythroughrollerbearinginto

removed by wear, chipping, scoring, scratches, or sleeve assembly. Press gear assembly into place by
dents shall be refinished as follows: (Refer to supporting gear so as to avoid damaging gear teeth
BHT-ALL-SPM manual.) and pressing on inner race of bearing (15).

a. Aluminum parts shall be touched up with seal (12) and nut (13). Install seal (12) into nut (13)
chemical film (C-100) as required. with open side inboard. Install packing (14) on nut.
Coat lip of oil seal, packing, and threads with
b. Magnesium parts shall be touched up with manual) and screw nut into sleeve (16). Hold sleeve
chemical film (C-103) or apply magnesium alloy flange with T101455 plate assembly and torque nut
chemical film treatment to entire part. (Refer to 100 to 150 foot-pounds with T101336 wrench.
BHT-ALL-SPMmanual.) Secure nut to sleeve with lockwire (C-405).
NOTE: A workaid may be fabricated, as shown in

c. Steel parts shall be touch up brush cadmium
plated with LHE solution (C-108). (Refer to 66-120)
BHT-ALL-SPMmanual for approved method.)
66-220
BHT-205A1-CR&O-1
7. Install seal (11) into outer coupling (10) seal (10) inserting large end of centering spring into retainer
groove as follows: (5) and install retainer ring (1).
a. Apply a light coat of rease (C-015) to outer 14. Position packing (24) on oil collector (23).
circumference of seal (11). Lubricate packing and inside diameter of gear (22) with
b. Install seal (11) into outer coupling (10) seal manual) and insert oil collector in gear. Secure with
groove with lip of seal toward internal splines of retainer ring (25) in groove of gear.
coupling, as shown in figure 66-120, detail A. 15. Testquillassemblybyholdingsleeveandturning
coupling and gear assembly. There should be a very
NOTE: Seal (11) will be partially seated and the inner light drag of the gear in the sleeve caused by the preload
coupling (9) will be used as a backup in reverse (see of the duplex bearings and drag of oil seal, but the gear
detail A) to fully seat the outer circumference edge of should turn smoothly.
seal into outer coupling (10) seal groove.
16. Position plate (17) on sleeve (16) and secure
c. Using inner coupling (9) as a backup, and with screws (18).
placed, as shown in detail A, firmly press down (hand
pressure only) on outer coupling (10), simultaneously TEMP-PLATES as follows
tuck outer circumference edge of seal (11) using
workaid, into outer coupling (10) seal groove. a. Remove epoxy coating and TEMP-PLATES
(figure 66-115) using paint remover (C-436). Repeat
d. Continue pressing around seal (11) using process until no trace of epoxy is present.
workaid, until seal is fully seated.
CAUTION: BONDING SURFACE AND
8. Place a small amount of grease (C-015) in internal TEMP-PLATES MUST BE FREE OF ALL
splines of outer coupling. Insert inner coupling (9) in CONTAMINATION. ANY CONTAMINATION COULD
outer coupling with small end through seal. ALLOW TEMP-PLATES TO COME OFF OR INDICATE
FALSE TEMPERATURES.
9. Position coupling assembly on splined end of gear
(22). Place washer (8) on bolt (7) and insert bolt through b Prepare outer coupling surface for bonding by
inner coupling to engage threads of gear shaft. Hold
cleaning solvent MEK (C-309). Remove
all all
sleeve assembly with T101455 plate assembly. Hold cleaning solvent MEK (C-309). Remove
outer coupling with T101307 wrench assembly. Use a contamination and before MEK dries, wipe the surface
dry with clean cloth. The cleaned surface area should be
square extension to torque bolt 80 to 100 foot-pounds.
minimum 0.50 inch larger than area of TEMP-PLATES
10. Coat packing (6) with approved gearbox oil (refer on outer coupling.
to BHT-205A1-MM-1 manual) and place on retainer (5). c. Perform a water break-free test on the prepared
Insert retainer into bolt (7). bonding surface by applying distilled or demineralized
CAUTION: RECESS IN RETAINER(5)IS 0.818 INCH must flow into a continuous film without gathering into
FOR OUTPUT QUILL AND 1.130 INCH FOR INPUT distinct water droplets within 25 seconds after
QUILL. DO NOT INSTALL IN WRONG QUILL. application to the surface. Wipe dry with a clean cloth.
Ensure bonding surfaces are not subsequently
11. Align hole in rim of retainer with a notch of inner contaminated.
coupling (9). Install lock spring (4).
12. Extend outer coupling (10) so that seal (11) is waterbreak-freetestrequirementsandensurecleaning
against the spherical teeth on inner coupling (9), and materials are not contaminated; clean coupling bonding
pack internal spline in outer coupling with grease surfaces as follows:
(C-015) to a depth of 0.12 inch over tops of internal NOTE: Followthemanufacturerrecommendationsfor
spline teeth. A workaid may be fabricated, as shown in
proper mixtures.
figure 66-85 to obtain depth of grease.
(1) Using a cleaning compound (C-318) and
13. Place small end of centering spring (3) on boss cloth, scrub coupling bonding surface clean. Follow
of seal plate (2). Install plate and spring in outer coupling cleaning with a thorough water rinse.
Rev. 2 66-220A
BHT-205A1-CR&O-1
(2) Thoroughly dry coupling surfaces. THAT WORK AREA AND HANDS ARE THOROUGHLY
CLEANED BEFORE WORKING WITH TEMP-PLATES.
(3) Repeat water break-free test as stated DO NOT PRESS OR RUB TEMP-PLATES WITH BARE
above. FINGERS DURING INSTALLATION ON COUPLING.
CAUTION: TO PREVENT CONTAMINATION OF FOLLOWING INSTALLATION OF TEMP-PLATES ON
THE TEMP-PLATES ADHESIVE BACKING, ENSURE COUPLING.
66-220B Rev. 2
BHT-205A1-CR&O-1
e. Carefully form temperature indicator CAUTION: DO NOT EXPOSE EPOXY COATING TO

TEMP-PLATES to match V contour of coupling surface. OIL, GREASE, CLEANING SOLVENT OR OTHER
Do not crease TEMP-PLATES sharply. CHEMICALS DURING CURE.
NOTE: Working one TEMP-PLATE at a time, repeat j. Allow epoxy coating to cure at room
steps f and g until all TEMP-PLATES are installed on temperature,approximately 60 to 100°F, for a minimum
coupling. of six hours prior to operating helicopter. For best
results, allow epoxy to cure overnight prior to operating
f. Remove protective backing from TEMP-PLATE helicopter or exposing to oil or grease.
NOTE: An alternate source of heat can be used if the

g. Using clean cloth or cotton swab, work
TEMP-PLATE into contour of coupling. A thoroughly temperature does not exceed 180°F.
cleaned firm rubber (edge of a block type eraser)
workaid may be utilized to work TEMP-PLATE into full k. After one hour epoxy curing time at room
contact with coupling surface. Ensure the TEMP-PLATE temperature, the epoxy coating total curing time can be
is in full contact with coupling surface. Do not press or accelerated by placing the coupling in a temperature
rub TEMP-PLATE with bare fingers. controlled oven for one to two hours at a temperature of
150 to 180°F.
NOTE: Use of any epoxy adhesive other than Devcon
2-Ton (C-298) is not authorized. I. Following the cure, TEMP-PLATES should
lifted edges except as in note above Indicating dots on
TEMP-PLATES must remain original white or light
gray with no full or partial black discoloration.

Part B into a solvent proof container. m. Perform an adhesion test on each
TEMP-PLATE installation. Press a one inch wide strip
of high adhesion tape onto TEMP-PLATE and epoxy
(2) Vigorously mix Part A and Part B with a overcoat. Tape should extend beyond edge of epoxy
brush such as an artist brush. overcoat. Grasp one end of tape at approximately 90
degrees from the surface and remove tape in one
(3) A few drops of thinner, such as MEK abrupt motion. Lifting or peeling of epoxy coating or
(C-309), may be added to epoxy during mixing TEMP-PLATE is not acceptable. If lifting or peeling is
operation to reduce viscosity to a level that permits detected, remove and replace TEMP-PLATE by
uniform brush application of epoxy mixture. Do not repeating procedure.
thin this mixture such that it runs when applied to a
vertical surface. The final viscosity of epoxy should be
similar to heavy bodied paint. Too thin a mixture may n. Repeat procedure for opposite coupling.
seep into overtemperature indicator TEMP-PLATE
and cause indicator dots to turn black (in which event,
TEMP-PLATE must be removed and replaced).
Working time for the mixture is approximately 15 18. Thetailrotorintermediategearboxoutputquill
minutes. shall be tagged with date of lubrication and an entry
made in component historical record, if driveshaft is to
be returned to stock.
i. Using a soft-bristled brush, uniformly apply
epoxy coating over TEMP-PLATES to a thickness of
paint). Coating should be uniform in appearance, 19. When tail rotor intermediate gearbox output
totally cover surface of TEMP-PLATES and extended quill is installed on helicopter, an entry shall be made
approximately 0.25 inch beyond edges of in helicopter log and flex couplings lubrication log in
TEMP-PLATES. BHT-205A1-MM-1 manual, with date of lubrication.
Rev. 2 66-221
BHT-205A1-CR&O-1
66-217. OVERHAUL - INTERMEDIATE 8. Position T101564 holding fixture on sleeve

GEARBOX (212-040-003) OUTPUT QUILL. (17) with pins engaged through sleeve flange.
Remove nut (14) with T101600 wrench.
TOOLS REQUIRED 9. Remove packing (15), and press seal (13) out
of nut (14).
T101307 Wrench 10. Press gear (23) out of sleeve (17). Remove
T101333 Bar retaining ring (22) and roller bearing (21).
T101334 Bar
T101564 Holding Fixture 11. Press duplex ball bearing (16) out of sleeve.
T101600 Wrench
NOTE: Duplex bearings must be retained or
replaced as a matched serialized set.
66-218. DISASSEMBLY - INTERMEDIATE
GEARBOX OUTPUT QUILL. 12. Remove retainer ring (28), oil collector sleeve
(27), and oil collector cone (25).
NOTE: If output quill is being disassembled for 13. Remove packings (24 and 26).
replacement of parts instead of overhaul,
disassemble only to extent necessary to replace 14. Remove three screws (20) and shim plate
parts. (19). Identify shim plate for reinstallation on same
sleeve.
NOTE: For ease of maintenance, block the outer

coupling so that it will remain in the outboard 66-219. CLEANING- INTERMEDIATE
GEARBOX
(extended) position. This will stabilize the outer OUTPUT QUILL.
coupling during disassembly and assembly.
1. Clean quill parts with solvent (C-304) with
1. Remove retainer ring (1, figure 66-123), plate exception of bearings which are cleaned with
(2), centering spring (3) and lock spring (4). trichloroethane (C-334).
2. Remove spacer (5). 2. Use clean lint-free cloth or low pressure filtered
compressed air to dry parts. Do not let bearings spin
3. Remove retainer (6). A 1/4-20 threaded bolt while drying.
may be used to facilitate removal of retainer (6).
Install bolt in center of retainer and pull on bolt to 3. If not used immediately after cleaning, coat
withdraw retainerfrom innercoupling, bearings with approved gearbox oil (refer to
BHT-205A1-MM-1 manual). To prevent corrosion
4. Remove packing (7) from retainer (6). damage avoid handling unoiled bearings.
5. Hold outer coupling (11) with T101307 4. Remove sealant from quill sleeve with plastic
wrench. Position square adapter through wrench and scraper.
seat in coupling retaining bolt (8). Remove bolt (8)
and washer (9).
NOTE: Parts that have a lacquer top coat and primer
6. Remove inner and outer couplings (10 and 11) (C-202) need only to have the top coat removed for
from gear (23). fluorescent penetrant inspection.
7. Separate inner and outer couplings (10 and 5. Remove paint from quill sleeve with paint
11), and remove seal (12) from outer coupling (11). remover (C-436) and rinse with clean water.
66-222
BHT-205A1-CR&O-1
TORQUE
1. Retainer ring
2. Plate
3.Centering spring
4.Lock spring
5.Spacer 11. Outer coupling 17. Sleeve 23. Gear
6.Retainer 12. Seal 18. Clinch nut 24. Packing
7. 13
Packing . Seal 19. Shim plate 25. Cone
8.Bolt 14. Nut 20. Screw 26. Packing
9.Washer 15. Packing 21. Roller bearing 27. Sleeve
10.Inner coupling 16. Duplex bearing 22. Retaining ring 28. Retainer ring
NOTES:

Apply sealant, MIL-S-8802, Class B2, around nut (14) and sleeve (17)
after assembly. 205A1-R-66-123-1
Rev. 2 66-223
BHT-205A1-CR&O-1
SEAL (12) PARTIALLY SEATED

OF SEAL (12) UP
DETAIL A
6. If ferrous parts are not used immediately after 3. Inspect bearings for roughness or surface
cleaning, gently agitate parts in corrosion preventive impressions produced by a heavy blow or pressure of
(C-105) and air dry. Apply protective coat of approved rollers skidding.
gearbox oil (refer to BHT-205A1 -MM-1 manual).
4. Perform magnetic particle inspection of gear
(23) and inner and outer couplings (10 and 11). (Refer
66-220. INSPECTION - INTERMEDIATE to BHT-ALL-SPMmanual.)
GEARBOX OUTPUT QUILL.
5. Perform fluorescent penetrant inspection of
sleeve (27). (Refer to BHT-ALL-SPM manual for
NOTE: If records and/or physical appearance of approved fluorescent penetrant material.)
output quill indicate that assembly has been
subjected to an accident or incident outside realm of
normal usage, perform Conditional Inspection, NOTE: If steps 1 through 5 above reveal cracks or
paragraph 66-221. If input quill does not require distortion indicative of excessive loads, then output
conditional inspection proceed with Normal quill shall be considered unserviceable and
Inspection, paragraph 66-222. nonreparable.
6. Perform Normal Inspection. (Refer to

66-221. Conditional Inspection - Intermediate paragraph 66-222.)
Gearbox Output Quill.
66-222. Normal Inspection - Intermediate
1. Visually inspect gear (23, figure 66-123) teeth Gearbox Output Quill.
for damage and evidence of overload pattern.
2. Visually inspect inner and outer couplings (10 that do not fall within inspection limits. (Refer to
and 11) for cracked or chipped teeth. figure 66-124.)
66-224
BHT-205A1-CR&O-1
MIN. MAX.
INCHES
1 Gear shaft OD 1.8691 1.8696

2 Sleeve ID 3.1489 3.1497
3 Sleeve OD 4.4097 4.4105
4 Sleeve ID 2.8340 2.8347
5 Spline - gear Over pins 1.4424 1.4465
6 Spline - inner coupling Between pins 1.1465 1.1578
7 Teeth - inner coupling Over pins 2.1590 2.1740
8 Spline - outer coupling
9 Duplex bearing ID 1.3777 1.3781
OD 2.8341 2.8346
10 Gear shaft OD 1.3780 1.3786
11 Roller bearing OD 3.1492 3.1496
NOTE
Maximum allowable depth of wear is 0.005 inch (measure from unwornfaceof tooth).
Figure 66-124. Intermediate gearbox (212-040-003) output quill wear limits
66-225
BHT-205A1-CR&O-1
NOTE: Wear limits are provided to show the required or discoloration of epoxy coating that prevents *
fit between mating parts. It is not intended that all interpretation of indicating dots. If deterioration,
dimensions be checked as a prescribed overhaul debonding, or discoloration of epoxy is found, replace
procedure; however, parts that show evidence of wear TEMP-PLATES in accordance with paragraph 66-224. |
or physical damage must be checked dimensionally.
5. Inspect inner and outer couplings (10 and 11,
2. Inspect gear and splines for chipped, broken or figure 66-123).
worn teeth.
a. Inspect for chipped, pitted, cracked or
3. Inspect gear teeth and gear (11,figure 66-123) for excessively worn teeth.
excessive wear, scoring , scuffing, and wear pattern.
(Refer to figure 66-109.) b. Check wear patterns to criteria shown on figure
66-111.
indicator TEMP-PLATES are of a white or light gray c. Inspect surfaces of inner couplings that are
color and turn black when exposed to an contacted by seals (13, figure 66-123) for excessive
overtemperature condition. Chemical contamination wear, nicks and scratches. A groove worn by seal is
can also cause indicating dots to turn black. acceptable to a minimum diameter of 1.587 inches
provided depth does not exceed 0.002 inch. If groove is
4. Inspect outer coupling (11, figure 66-123) smooth, part may be reworked.
of overtemperature indication. If overtemperature 6. Perform a magnetic particle inspection of
indication is noted, perform coupling overtemperature following parts. Index numbers are keyed to figure
inspection as follows: 66-123. Demagnetize all parts after inspection.
a. Inspect outer coupling cadmium plating for INDEX NO. NOMENCLATURE

band) or blistered. If cadmium plate discoloration or 10 Inner Coupling
blistering is found, replace outer coupling and inner 11 Outer Coupling
coupling. 23 Gear

coupling for being discolored (brown or blue) in normally 7. Check duplex bearing (16, figure 66-123) and
bright contact patterns. If discoloration is found, replace roller bearing (21) for smooth operation and indications
outer coupling and inner coupling. of excessive wear. Inspect bearing races for roughness.
c. Inspect outercoupling and innercoupling under 8. Inspect bearing liners for scoring and security of
5X to 10X magnification for teeth exhibiting signs of mounting in sleeve (27).
smearing or tearing is found, replace outer coupling and 9. Inspect bearings for evidence of spalling, scoring,
inner coupling. pitting, brinelling, flaking, corrosion on rolling elements,
and cracked or broken retainers. (Refer to figure
d. Inspect grease from couplings for being very 66-112.)
grease is found to be viscous and having a strong a. Minor nicks, cuts, or scratches are acceptable
pungent odor, replace outer coupling and inner provided they are too small to be felt with a probe having
coupling, an end radius of 0.030 inch, and provide the total
affected area does not exceed 10 percent of the contact
NOTE: If TEMP-PLATES are to be replaced, replace area at any point.
procedure and couplings have been determined b. Minor circumferential scoring is acceptable on
serviceable and prior to lubricating couplings. rollers and races provided that it cannot be felt with a
probe having an end radius of 0.030 inch and provided
4A. Inspect outer coupling (5) overtemperature that the affected area does not exceed 10 percent of the
indicator TEMP-PLATES for deterioration, debonding, contact area at any point.
66-226 Rev. 2
BHT-205A1-CR&O-1
10. Inspect sleeves (17, figure 66-123) for corrosion b. Corrosion pitting or mechanical surface
as follows: damage on spotfaced surface at attaching holes is
acceptable provided that it is within the following limits:
a. Corrosion pitting or mechanical surface
damage in area A, exclusive of spotface area, is
acceptable for repair if it is within the following limits: 1) Maxmum acceptable depth is 0.020 inch.
(2) No more than 20 percent of total spotfaced
(1) Maximum acceptable depth is 0.030 inch. area at any hole may be pitted.
(2) No more than 40 percent of the area within

any one inch square, nor 20 percent of total area of any (3) No more than 20 percent of total area
surface or diameter may be pitted. normally contacted by washer may be pitted.
Rev. 2 66-226A/66-226B
BHT-205A1-CR&O-1
(4) No more than 50 percent of the width of Blend into surrounding area. Seal groove wear no
area normally contacted by washer may be pitted at more than 0.002 inch deep and minimum diameter of
any point around hole. 1.587 inch is acceptable, if groove is uniform and
smooth.
11. Perform fluorescent penetrant inspection of
sleeve. (Refer to BHT-ALL-SPM manual for approved b. Touch up brush cadmium plate inner and
fluorescent penetrant material.) outer couplings (10 and 11, figure 66-123) using LHE
solution (C-108). Plating thickness to be 0.0001 to
12. Inspect shim plate (19, figure 66-123) for 0.0003 inch. Do not exceed 0.0003 inch plating
damage and wear. thickness in seal contact area. Do not plate external
spline teeth on inner coupling. Do not plate internal
13. Inspect plate (2) for damaged seals. splines on outer coupling. Apply plating tape (C-434)
to areas not to be plated. (Refer to figure 66-119 for
14. Inspectoilcollectorcone(25)andsleeve(27) plating areas and BHT-ALL-SPM manual for
for damage. prescribed cadmium plating methods.)
15. Inspect-coupling retaining bolts (8) visually 7 Iforiginalcadmiumplatingonsleeveshimplate

for damaged threads. Replace bolts that have (19, figure 66-123) has worn through, replate using
malformed threads. LHE solution (C-108). (Referto BHT-ALL-SPMmanual
for prescribed cadmium plating method.) Refer to
16. Inspect nuts (14) visually for damaged step 8. for shim thickness after plating.
threads. Replace nuts that have malformed threads. s
8. If original sleeve shim plate (19) is missing or
66OUTPUTRPQUILL.
OUTPUT QUILL. dimensions of replacement shim plate as follows:

1. Replace parts that are not within allowable which should be metal stamped or vibro-etched on
wear limits. part adjacent to applicable mounting surface.
2. Replace duplex bearing (16, figure 66-123) b. Subtract 0.3910 to 0.3915 inch from
and roller bearing (21) that show evidence of reference dimension stamped on sleeve to give
brinelling, flaking, spalling, discoloration from required shim thickness, after plating, for sleeve.
overheating, corrosion on rolling elements, cracked or
broken retainers or that do not operate smoothly. c. Grind new blank shim to required thickness
and apply LHE solution (C-108). (Refer to
3. Replace all seals, preformed packings, BHT-ALL-SPMmanual for prescribed cadmium plating
standard hardware, and all locking devices at time of method.) Identify new shim plate by etching serial
reassembly. number of applicable sleeve on shim plate. Also etch
thickness (in thousandths of an inch) on shim plate.
4. Repair minor scratches, nicks, and pits on Use etching ink (C-461) or equivalent. Neutralize ink,
noncritical surfaces with crocus cloth (C-409). after marking, by wiping with a rag soaked with oil
(C-109).
splines and gear (23) using fine india stone. 9. Repair sleeve (17) as follows: (Refer to figure
66-118.)
6. Repair inner coupling (10) and outer coupling a. If damaged or loose replace clinch nuts (18,
(11) as follows: figure 66-123).
a. Repair minor nicks, dents or scratches in the (1) Use a drift or bolt threaded into nut to
seal contact area on the inner couplings by polishing drive clinch nut out; being careful not to damage hole
with fine india stone (C-464) to remove damage. in sleeve flange.
66-227
BHT-205A1-CR&O-1
(2) Clean sleeve by vapor degreasing with hot chromic acid bath consisting of 20 to 24 ounces
trichloroethane (C-334). of chromic acid (C-1 6) per gallon of water at 200°F
(93°C) for as long as corrosion is present. It is
(3) Clean up surface of sleeve flange to mandatory that all corrosion products be removed.
remove any raised burrs. Corrosion removal process must be controlled to
ensure that machined dimensions are maintained and
(4) Treat hole and any reworked areas on that cadmium plating is not removed. After chromic
sleeve with chemical film (C-103). acid bath, rinse sleeve with water to remove chromic
acid and dry with filtered compressed air and apply
(5) If clinch nut was not loose, coat new nut magnesium alloy chemical film treatment. (Refer to
with unreduced primer (C-201) and drive clinch nut BHT-ALL-SPMmanual.)
(18) into place. Remove any raised burrs on sleeve
flange face, and touch up with chemical film (C-103). 10. Repair minor nicks, scratches, and burrs on
gear (23, figure 66-123) splines and teeth by
(6) If nut was loose, remove cadmium plating dressing with fine india stone (C-464).
from surfaces of clinch nut that contact the sleeve
with abrasive paper (C-423). Wipe clinch nut and 11. After repair or during overhaul, parts on
mating surfaces of the sleeve clean with MEK (C-309) which finish has been removed by wear, chipping,
on clean cheesecloth. Bond clinch nut in place with scoring, scratches, dents shall be refinished as
adhesive (C-317). Clean excess adhesive from follows: (Refer to BHT-ALL-SPMmanual.)
threads and surface of sleeve flange and hole. Clinch
nut must be at least 0.010 inch below surface of a. Aluminum parts shall be touched up with
sleeve flange. chemical film (C-100) or anodize entire part as
required.
(7) Check that side of the sleeve flange that
contacts shim plate is flat and that clinch nut does not b. Magnesium parts shall be touched up with
chemical film (C-103) or apply corrosion treatment
protrudeabove surface. (C-114) to entire part.
b. Repair mechanical and corrosion damage on NOTE: Use only LHE solution (C-108) for cadmium
sleeve as follows: (Refer to figure 66-118.)
plating of steel parts.
(1) If damage to spotfaced surfaces, area B,
exceeds inspection limits, surface may be reworked c. Steel parts shall be touch up brush cadmum
by machining off surface to a minimum flange plated with LHE solution (C-108). (Refer to
thickness, dimension C, of 0.310 inch. Machinning BHT-ALL-SPM
method.) manual for prescribed cadmium plating
must be done with a 0.688 inch diameter spotface
cutter, with a 0.060 inch corner radius. After
cleanup, pitting is acceptable provided that it is no 66-224. ASSEMBLY - INTERMEDIATEGEARBOX
more than 0.010 inch deep. Surface finish of unpitted
reworked surface must be 63 RHR or better. CAUTION: SAME SHIM PLATE THAT WAS
(2) Sleeves with corrosion damage within REMOVED FROM SLEEVE MUST BE REINSTALLED
acceptable limits must be reworked by smoothing out OR A NEW SHIM PLATE OF SAME THICKNESS
any sharp edges that might damage packing during MUST BE MADE.
assembly. Nicks, dents or pits in area A, figure
1. Coat all parts with approved gearbox oil (refer
66-118 within allowable limits, must be reworked to
blend into surrounding area. Minimum radius in
reworked areas is 0.25 inch and surface finish must reassembly procedure.
be 63 RHR or better.
2. Position original shim plate (19, figure 66-123)
(3) Sleeves with corrosion damage within or new shim plate on sleeve (17) and install three
acceptable limits must be treated by immersion in a screws (20).
66-228
BHT-205A1-CR&O-1
3. Press duplex bearing (16) into sleeve (17) d. Continue pressing around seal (12) using
using T101334 bar. The duplex bearing must have workaid, until seal is fully seated.
matching serial numbers, be installed in pairs, and be
installed face-to-face. NOTE: Ensure inner coupling (10) is correct for
intermediate and tail rotor gearbox, overall length is
4. Press roller bearing (21) into sleeve (17) using 1.870 to 1.880 inch. Tail rotor driveshaft hanger
T101333 bar. Install retaining ring (22). coupling overall length is 2.070 to 2.080 inch.
5. Press gear (23) into sleeve while supporting 8. Place small amount of grease (C-015) in
inner race of duplex bearing (16). Avoid damage to internal splines of outer coupling (11). Insert inner
gear teeth. coupling (10) into outer coupling (11) with small end
through seal.
seal (13) and nut (14). Press new seal (13) into nut 9. Position inner and outer couplings (10 and 11)
(14) with lip of seal facing inboard. Install new on splined end of gear (23).
packing (15) on nut (14). Position T101564 holding
fixture on sleeve (17) with pins engaged through 10. Coat threads of coupling retaining bolt (8)
holes in sleeve flange. Coat packing and threads of with approved gearbox oil (referto BHT-205A1-MM-1
nut (14) with approved gearbox oil (refer to manual).
BHT-205A1-MM-1 manual). Install nut in sleeve and
torque 100 to 150 foot-pounds using T101600 11. Place washer (9) on bolt and thread bolt into
wrench. Secure nut to sleeve with lockwire (C-405). gear.
12. Hold outer coupling (11) with T101307

NOTE: A workaid may be fabricated, as shown in wrench. Use a square extension to torque bolt (8) 80
figure 66-81 to aid installation of seal (12, figure to 100 foot-pounds.
66-123).
13. Place packing (7) on retainer (6).
7. Install seal (12) into outer coupling (11) seal 14. Coat packing and retainer with approved
groove as follows: gearbox oil (refer to BHT-205A1-MM-1 manual) and
insert retainer into bolt (8). If one hole in rim of
a. Apply a light coat of grease (C-015) to outer retainer (6) does not align with notch of inner
circumference of seal (12). coupling (10), pull retainer free of bolt, rotate ninety
degrees and reinstall. Repair if necessary to obtain
b. Install seal (12) into outer coupling (11) seal alignment. When hole and notch are aligned, install
groove with lip of seal toward internal splines of outer lock spring (4) through hole in rim of retainer and
coupling (11), as shown in detail A. notch of inner coupling (10).
15. Extend outer coupling (11) so that seal (12) is

NOTE: Seal (12) will be partially seated and the against teeth of inner coupling. Coat internal splines
inner coupling (10) will be used as a backup, in of outer coupling (11) with grease (C-015) to 0.12
reverse, (see detail A) to fully seat the outer inch depth over top of spline teeth. A workaid may be
circumference edge of seal into outer coupling (11) fabricated, as shown in figure 66-85, to obtain depth
seal groove. of grease.
c. Using inner coupling (10) as a backup, and 16. Place small end of centering spring (3, figure
placed, as shown in detail A, firmly press down (hand 66-123) on boss of seal plate.
pressure only) on outer coupling (11), simultaneously
tuck outer circumference edge of seal (12) using 17. Install plate (2), spacer (5), and centering
workaid, into outer coupling (11) seal groove. spring (3) into coupling and install retainer ring (1).
66-229
BHT-205A1-CR&O-1
18. Place new packing (24) on cone (25). Coat (3) Repeat water break-free test as stated
packing and cone with approved gearbox oil (refer to above.
BHT-205A1-MM-1 manual) and insert cone into gear
(23). Install retainer ring (28). CAUTION: TO PREVENT CONTAMINATION OF
19. Test quill by holding sleeve and turning coupling. THAT WORK AREA AND HANDS ARE THOROUGHLY
There should be a very light drag caused by oil seal and LEANED BEFORE WORKING WITH TEMP-PLATES.
preload of the duplex bearings, but coupling and pinion DO NOT PRESS OR RUB TEMP-PLATES WITH BARE
should turn smoothly. FINGERS DURING INSTALLATION ON COUPLING.
20. Replace overtemperature indicator EPOXY COATING TO TEMP-PLATES IMMEDIATELY
TEMP-PLATES as follows: FOLLOWING INSTALLATION OF TEMP-PLATES ON
COUPLING.
(figure 66-115) using paint remover (C-436). Repeat e. Carefully form temperature indicator
process until no trace of epoxy is present. TEMP-PLATES to match V contour of coupling surface.
CAUTION: BONDING SURFACE AND
TEMP-PLATES MUST BE FREE OF ALL NOTE: Working one TEMP-PLATE at a time, repeat
CONTAMINATION. ANY CONTAMINATION COULD steps f and g until all TEMP-PLATES are installed on
ALLOW TEMP-PLATES TO COME OFF OR INDICATE coupling.
FALSE TEMPERATURES. f. Remove protective backing from TEMP-PLATE
scrubbing surface using clean cloths wetted with a g. Using clean cloth or cotton swab, work
cleaning solvent MEK (C-309). Remove all TEMP-PLATE into contour of coupling. A thoroughly
contamination and before MEK dries, wipe the surface cleaned firm rubber (edge of a block type eraser)
dry with clean cloth. The cleaned surface area should be workaid may be utilized to work TEMP-PLATE into full
minimum 0.50 inch larger than area of TEMP-PLATES contact with coupling surface. Ensure the TEMP-PLATE
on outer coupling. is in full contact with coupling surface. Do not press or
rub TEMP-PLATE with bare fingers.
c. Perform a water break-free test on the prepared
bonding surface by applying distilled or demineralized NOTE: Use of any epoxy adhesive otherthan Devcon
water from a suitable dispenser (squeeze bottle). Water 2-Ton (C-298) is not authorized.
must flow into a continuous film without gathering into
distinct water droplets within 25 seconds after h. Prepare Devcon 2-Ton epoxy adhesive (C-298)
application to the surface. Wipe dry with a clean cloth. as follows:
Ensure bonding surfaces are not subsequently
contaminated.
d. If thecoupling bonding surface will not meet the (2) Vigorously mix Part A and Part B with a
water break-free test requirements and ensure cleaning brush such as an artist brush.
materials are not contaminated; clean coupling bonding
surfaces follows: (3) A few drops of thinner, such as MEK (C-309),
may be added to epoxy during mixing operation to reduce
viscosity to a level that permits uniform brush application
NOTE: Followthe manufacturer recommendations for
of epoxy mixture. Do not thin this mixture such that it runs
proper water mixtures. when applied to a vertical surface. The final viscosity of
(1) Using a cleaning compound (C-318) and mixture may seep into overtemperature indicator
cloth, scrub coupling bonding surface clean. Follow TEMP-PLATE and cause indicator dots to turn black (in
cleaning with a thorough water rinse. which event, TEMP-PLATE must be removed and
(2) Thoroughly dry coupling surfaces. 15 minutes.
66-230 Rev. 2
BHT-205A1-CR&O-1
i. Using a soft-bristled brush, uniformly apply epoxy an entry shall be made in helicopter log in
coating over TEMP-PLATES to a thickness of BHT-205A1-MM-1 manual, with date of lubrication.
paint). Coating should be uniform in appearance, totally
cover surface of TEMP-PLATES and extended 66-225. TAIL ROTOR GEARBOX.
approximately 0.25 inch beyond edges of TEMP-PLATES.
CAUTION: DO NOT EXPOSE EPOXY COATING TO 66-226. OVERHAUL - TAIL ROTOR GEARBOX
OIL, GREASE, CLEANING SOLVENT OR OTHER (212-040-004).
CHEMICALS DURING CURE.
j. Allow epoxy coating to cure at room TOOLS REQUIRED

temperature, approximately 60 to 100 °F, for a minimum
of six hours prior to operating helicopter. For best T101305 Wrench
results, allow epoxy to cure overnight prior to operating T101308 Jackscrew Set
helicopter or exposing to oil or grease. T101350 Backlash Clamp
T101561 Wrench
NOTE: An alternate source of heat can be used if the T101563 Holding Fixture
temperature does not exceed 180 °F. T101566 Bar
T101599 Pressing Tool
k. After one hour epoxy curing time at room T101872 Backlash Arm
temperature, the epoxy coating total curing time can be
150 to 180 °F. 66-227. DISASSEMBLY - TAIL ROTOR
GEARBOX.
I. Following the cure, TEMP-PLATES should
conform to the contour of the coupling and be free of NOTE: If records and/or physical appearance of tail
lifted edges. Indicating dots on TEMP-PLATES must rotor gearbox indicate that assembly has been
remain original white or light gray with not full or partial subjected to an accident or incident outside realm of
black discoloration. normal useage, perform Conditional Inspection,
paragraph 66-230.
m. Perform an adhesion test on each TEMP-PLATE
tape onto TEMP-PLATE and epoxy overcoat. Tape should 1. Remove chip detector (24, figure 66-125) and
extend beyond edge of epoxy overcoat. Grasp one end of gasket (19). Drain oil from gearbox.
remove tape in one abrupt motion. Lifting or peeling of 2. Release pin (7) and remove oil cap (4). Remove
epoxy coating or TEMP-PLATE is not acceptable. If lifting packing (8) from cap
by repeating procedure.
3. Remove retaining ring (23), sight glass (22) and
for
Repeat
n. Repeat procedure procedure
for opposite
opposite coupling
coupling. indicator (20). Remove packing (21) from glass.
21. The intermediate gearbox output quill shall be 4. Remove nuts (35) and spacers (34). Cut sealant
tagged with date of lubrication and an entry made in between case (9) and input quill (33). Remove sealant
component historical record, If driveshaft is to be and/or nylon set screws (36) from three jackscrew
returned to stock. holes. Install three T101308 jackscrews. Turn jackscrew
holes. Install three T101308 jackscrews. Turn
22. When intermediate gearbox output quill is jackscrews equally to pull quill from case. Remove
installed on helicopter log and flex couplings lubrication, packing (32) from quill.
Rev. 2 66-230A
BHT-205A1-CR&O-1
5. Remove nuts (41) and washers (39 and 40). Cut 8. Remove bolts (2) and gear (3) from shaft.
sealant between case (9) and sleeve (37). Remove
sealant from three jackscrew holes and install three
T101308 jackscrews. Turn jackscrews evenly to pull 9. Support case (9) in flat areas between studs (11)
quill from case. Carefully remove sleeve from shaft to and press duplex bearings (25) out of case using
avoid damage to roller bearing. Remove packing (36) T101566 bar.
from sleeve.
6. Remove clips (27 and 29). Install T101563 NOTE: Duplex bearings are a matched set. Both
holding fixture. Remove nut (28) using T101561 bearings have the same serial number and must be kept
wrench. Remove nut (26) using T101305 wrench. together as a set.
Remove holding fixture.
7. Support case (9) in flat areas between studs (13) 10. Remove shim (18) from case with snap ring
and press shaft (1) out of case. pliers.
66-230B Rev. 2
Location
Location of
of overtemperature
overtemperature indicator
indicator
TEMP-PLATE.

to inserting setscrew (36). 0
BHT-205A1-CR&O-1
1. Shaft 13. Stud 25. Duplex bearing 37. Coupling

2. Bolt 14. Washer seat 26. Nut 38. Packing
3. Gear 15. Screw 27. Clip 39. Clinch nut
4. Cap 16. Stud 28. Nut 40. Sleeve
5. Pin 17. Shim plate 29. Clip 41. Washer
6. Safety chain 18. Shim 30. Bearing 42. Washer
7. Pin 19. Gasket 31. Retaining ring 43. Nut
8. Packing 20. Indicator 32. Packing 44. Bearing
9. Case 21. Packing 33. Input quill 45. Data plate
10. Oil cap adapter 22. Sight glass 34. Spacer 46. Retaining ring
11. Stud 23. Retaining ring 35. Nut 47. Seal
12. Bushing 24. Chip detector 36. Nylon setscrew
Figure 66-125. Tail rotor gearbox (Sheet 2 of 2)
11. Remove seal (44) from sleeve (37). Remove 5. If parts are not used immediately after cleaning,
retaining ring (43). Heat case and remove bearing (42). gently agitate parts in corrosion preventive compound
12. Remove retaining ring (31). Heat case and gearbox oil (refer to BHT-205A1-MM-1).
remove bearing (30).
13. Remove screws (15) and shim plate (17) from

case. 66-229. INSPECTION - TAIL ROTOR GEARBOX.
NOTE: Shim plate must be removed for fluorescent NOTE: If records or physical appearance of gearbox
penetrant inspection of case. Shim plate must be indicates assembly has been subjected to an accident
identified to ensure its installation on the same case or incident outside realm of normal usage, perform
from which it was removed. Conditional Inspection, paragraph 66-230. If it does not
require conditional inspection, proceed with Normal
66-228. CLEANING - TAIL ROTOR GEARBOX. Inspection, paragraph 66-231.
1. Clean parts with solvent (C-304). Dry parts with NOTE: If tail rotor gearbox is being overhauled due to
clean lint-free cloths or filtered compressed air. Do not lightning strike, proceed to steps 4 through 6.
allow bearings to spin when drying with air. Protect
cleaned bearings with corrosion preventive fingerprint 66-230. Conditional Inspection - Tail Rotor
remover (C-105) and wrap with barrier material (C-427). Gearbox.
2. Inspect case (9, figure 66-125) for corrosion

damage to threads. No structural damage to threads is 1. Check gearbox for freedom of rotation and for
acceptable. proper backlash of gears. Backlash should not vary
more than 0.002 inch when checked at different points
3. Remove sealant from gearbox case with plastic around the gear.
scraper.
2. Inspect gearbox output shaft for yielding. With
NOTE: If nonferrous parts are primed with primer gearbox still assembled, rotate output shaft and check
(C-202) only the top coat needs to be removed. runout of pitch diameter of splines by indicating on a
0.0600 diameter pin laid in the spline. Maximum
4. Remove paint with paint remover (C-436). Rinse acceptable runouts is 0.012 TIR on the small diameter
with clean water. spline or 0.010 TIR on the large spline.
66-232 Rev. 2
BHT-205A1-CR&O-1
3. If steps 1. or 2. reveal cracks or distortion, NOTE: It may be necessary to disassemble and

indicative of excessive loads, then the entire component visually inspect selected bearings to determine current
shall be considered unserviceable and nonreparable. paths. Once these bearings have been disassembled
they shall be scrapped.
NOTE: All components shall be evaluated as an
interrelated group. 6. Utilizing the following guidelines, determine the
serviceability of detail components:
During disassembly, note any damage that could be component that exhibits evidence of
a. Any component that exhibits evidence of
attributed to lightning strike. arcing, burning, or pitting shall be deemed
4. Visually inspect all detail components. Note any
damage that could be attributed to a lightning strike. b. Any component in current paths that cannot the
100 percent visually inspected, i.e., bearings that
5. Utilizing data obtained during visual inspection of cannot be disassembled, shall be deemed
transmission components, evaluation of other related unserviceable and scrapped.
components, and helicopter in general, determine entry
and exit points of current. A magnetometer may be 7. Perform Normal Inspection. (Refer to paragraph
helpful in determining current paths. 66-231.)
Rev. 2 66-232A/66-232B
BHT-205A 1-CR&O-1
66-231. Normal Inspection - Tail Rotor Gearbox. 7. Inspect oil filer cap (4) for damage.
1. Inspect all parts of gearbox for obvious 8. Inspect shim plate (17) for damage and wear.
damage that would make part non-reparable or
non-serviceable.
9. Inspect duplex bearings (25), bearing (30), and
2. Inspect gears and splines for chipped, broken, bearing (42) for roughness, spalling, scoring, pitting,
or worn teeth. Check bearings for smooth operation brinneling, flaking, and corrosion on rolling element or
and for indications of excessive wear. Inspect bearing races and for cracked or broken retainers. Refer to
liners for scoring, and for security of mounting in case figure 66-112. Minor nicks, cuts, or scratches are
and sleeve. Inspect studs and washer seats for acceptable provided they are too small to be felt with
looseness, damage, and corrosion. a probe having an end radius of 0.030 inch, and
provided the total affected area does not exceed 10
3. Inspect following parts by magnetic particle percent of the contact area at any point. Minor
(Code M) or fluorescent penetrant (Code F) method, circumferential scoring is acceptable on rollers and
as applicable. Index numbers are keyed to figure races provided it cannot be felt with a probe having an
66-125. Demagnatize parts after magnetic particle
inspection. (Referto BHT-ALL-SPMmanual.) end radius of 0.030 inch and provided the affected
area does not exceed 10 percent of the contact area
at any point.
10. Inspect nuts (26 and 28, figure 66-125)

1 Shaft M visually for damaged threads. Replace nuts that have
3 Gear M malformed threads.
9 Case F
40 Sleeve F 11. Inspect output shaft (1) visually for damaged
threads. Replace shaft if threads are malformed. If it
4. Inspect parts dimensionally and replace parts is suspected that shaft has been damaged, make
that do not fall within inspection limits. (Refer to runout inspection. Inspect output shaft for nicks,
figure 66-126.) dents, scratches, pits and wear. Refer to figure
66-128.
fit between mating parts. It is not intended that all 12. Inspect wear pattern of gear teeth. (Refer to
dimensions be checked as a prescribed overhaul figure 66-129.)
dimensionally. 13. Inspect oil level sight glass (22, figure
66-125) for cracks, crazing, scratches and
5. Inspect case (9, figure 66-125) and output discoloration.
quill sleeve (37) for corrosion damage. (Refer to figure
66-127.) 14. Inspect chip detector (24) for obvious
damage.
a. Maximum permissible depth of pitting in all
areas is 0.030 inch and no more than 40 percent of
area within one inch square or more than 20 percent 15. Inspect for bent studs (11, 13, and 16) or
of total area of any surface or diameter. damaged threads.
b. Structural damage to threaded holes for 16. If ferrous parts are not used immediately after
studs is acceptable provided damage does not extend cleaning, gently agitate parts in corrosion preventive
past first thread. compound (C-105) and air dry. Apply protective coat
of approved gearbox oil (refer to BHT-205A1-MM-1
6. Inspect oil filler cap adapter (10, figure manual).
66-125) for damage and wear.
66-233
BHT-205A 1-CR&O-1

INCHES
1 Spline, Shaft Over Pins 1.1530 1.1560

(Use 0.060 Dia. Pins)
2 Spline, Shaft Over Pins 1.3370 1.3401
(Use 0.060 Dia. Pins)
3 Shaft (Seal Contact Area) OD 1.4320 1.4400
4 Shaft (Bearing Contact Area) OD 1.4748 1.4756
6 Sleeve, Shaft OD 7.7489 Average 7.7510
7 Shaft (Gear Contact Area) OD 4.1255 4.1263
10 Shaft (Bearing Contact Area) OD 1.5751 1.5757
11 Case ID 3.5000 3.5020
14 Liner, Gearbox Case ID 3.1490 3.1497
15 Liner, Gearbox Case ID 2.0464 2.0473
16 Gear ID 4.1250 4.1255
18 Liner, Output Sleeve ID 2.4402 2.4410
Figure 66-126. Tail rotor gearbox wear limits
66-234
BHT-205A1-CR&O-1
AREA AREA
NOTES
1. The maximum permissible depth of pitting in areas A, B, C, and D is 0.030 inch and no more
than forty percent of the area within one inch square or more than twenty percent of the total
area of any surface or diameter may be pitted.
2. Structural damage to the threaded holes for the studs is acceptable provided the damage
does not extend past the first thread.
Figure 66-127. Tail rotor gearbox corrosion damage limits
66-232. REPAIR - TAIL ROTOR GEARBOX. 6. Replace gearbox cases which have corrosion
damage in excess of limits. (Refer to figure 66-1 27.)
1. Replace parts that are not within allowable
wear limits. 7. Replace cases with structural damage in
2. Replace all seals, gaskets, preformed threads exceeding repair limits.
packings, and standard hardware on reassembly.
8. Repair minor scratches, nicks and pits on
3. Replace parts that are cracked, broken, non-critical surfaces with crocus cloth (C-409).
warped, distorted, have malformed threads or fail to
pass inspection. 9. Repair minor nicks, scratches and burrs on
splines and gear teeth by dressing with fine india
4. Replace all parts that exceed allowable
tolerances given in figure 66-126.
5. Replace cases and output sleeves having loose 10. Replace oil level sight glass (22, figure
liners or that have corrosion between steel liner and 66-125) if cracked, crazed, scratched or discolored.
magnesium case or sleeve. Replace indicator (20) if paint is peeled.
66-235
BHT-205A 1-CR&O-1
DIAMETER A DIAMETER B
(SEAL CONTACT AREA) (ROLLER BEARING SURFACE)
SPLINE N AREA
SPLINE
AREA E
Notes
1. Run-Out Inspection:
a. Mount shaft on 60° centers.
b. Indicate run-out on diameter B. Maximum acceptable run-out is 0.001 inch T.LR.
2. Damage limit for area C, the outer diameter of the portion of the shaft outside the gear box between
the diameter for the oil seal and the shoulder adjacent to the splines, is 0.005 inch.
3. Damage limit for area D, the outer diameter of the portion of the shaft inside the gear box between
the two diameters for the bearings, is 0.010 inch.
4. Damage limit for diameter A, the shaft oil seal diameter, is 0.002 inch or to a minimum diameter
of 1.430 inch.
Figure 66-128. Tail rotor gearbox output shaft damage limits
11. Replace bearings that are spalled, scored, 14. Repair case (9), if corrosion is within
brinnelled, pitted, discolored from overheating, that allowable limits, as follows: (Refer to figure 66-127.)
have damaged or broken retainers, or that do not roll
smoothly. a. Polish out, within acceptable depth limits,
any sharp edges that might damage packings, using
12. Repair damaged stud holes by drilling out 400 abrasive cloth (C-423). Finish with crocus cloth
damaged thread. Clean out diameter shall not exceed (C-409).
major thread diameter of internal threads. Break all
sharp edges, except in thread areas, clean out small
vent hole in bottom of threaded hole. Treat repaired b. Immerse corroded case
(Referto BHT-ALL-SPMmanual.)in chromic acid bath.
surfaces with chemical film (C-103).
13. Repair damaged studs. (Refer to 15. If originalcadmiumplatingonshimplate(17,

BHT-ALL-SPM manual.) Stud height, prior to figure 66-125) has worn through, replate using LHE
installation of shim plate on input quill port, must be solution (C-108). (Refer to BHT-ALL-SPMmanual for
1.450 inch (minimum). Stud height on output port prescribed cadmium plating method.) (Refer to step
must be 0.850 inch (minimum). Stud height on pitch 16, for shim thickness after plating.)
change port must be 0.785 inch (minimum).
66-236
BHT-205A1-CR&O-1
Desired wear pattern an pinion

View A
Pattern tolerances at toe and heel on gear and pinion

View C
Acceptable wear pattern on gear
Figure 66-129. Gear and pinion wear pattern (Sheet 1 of 2)
66-237
BHT-205A1-CR&O-1

(5/32 inch from toe)
View F View G

(touching heel and 5/32 from toe)
View H View I
Notes
1. Wear Pattern Inspection: Observe the visible gear contact wear pattern an the concaVe
side of the pinion teeth and on the convex side of the gear teeth. Sketch the wear pattern of
the gear on the inspection sheet in the space provided.
2. The desired mar pattern is shown in views A and B. A slight bright line at top of pattern on
gear and in flank of pinion is permissible.
3. Acceptable wear patterns are shown in views 0, E, F, G, H and I. View C is furnished to

further define wear limits.
4. Pattern Limits at Toe: The wear pattern may touch theta or may be a maximum of 5/32
inch from the toe (see views C,D,G and I). Pattern variation at the toe must not exceed 1/32
inch. Normally. the pattern will touch the toe on the pinion but will not touch the toe on the
gear (see views D and E). It is permissible for the pattern to touch the toe on the gear if the
pattern does not go off the toe of the pinion.
5. Pattern Limits at Heel: The wear pattern may touch the heel or may be a maximum of 5/32
inch from the heel. (See views C and I.) Pattern variation at the heel must not exceed 1/32
inch. The heel positions shown in views A, 6, D, E, F, G, H and I are within these limits.
6. Pattern Profile: The pattern must be positioned on the tooth in a profile direction such that
the pattern extends over the top of the pinion and is 1/32 to 1/16 inch from the top of the
gear (see views A. B, D. E. F, G, Hand I).Apatternwhichdoesnatextendoverthetopofthe
pinion or touches the tap of the gear shall be rejected. A bright line occuring at the top of the
pinion or in the flank of the gear is also cause for rejection.
7. Unacceptable defects: In addition to pattern size and location, examine the drive face of all
gear teeth for the following defectswhich are not acceptable if they can be felt with ascribe
having a 0.002 inch spherical point:
a. non clean up h. grinding flats or barber poling

b. grinding scratches (evidenced by diagonal streaks in
pitting the wear pattern)
d. corrosion i. scuffing
e. cuts i. scoring
f. nicks k. inclusions
g. dents
Figure 66-129. Gear and pinion wear pattern (Sheet 2 of 2)
66-238
BHT-205A 1-CR&O-1
16. If original shim plate (17) is missing or mixed b. Replace sleeves which have excessive
with other shim plates, determine required dimension corrosion damage. (Refer to figure 66-127.)
of replacement shim plate as follows:
c. Repair sleeves, which do not exceed
a. Examine case for reference dimension which allowable corrosion damage limits, as follows:
should be metal stamped or vibro-etched on part
adjacent to applicable mounting surface. (1) Polish out, within acceptable depth limits,
any sharp edges that might damage packings using
abrasive cloth (C-423) and finish with crocus cloth
b. Subtract reference dimension noted above
from 5.2498 to 5.2503 inch to give required shim
thickness, after plating, for case.
(2) Immerse corroded sleeve in chromic acid
bath. (Refer to BHT-ALL-SPMmanual.)
c. Grind new blank shim to required thickness.
Countersink three holes 100 ° x 0.250 to 0.260 inch 19. Repair oil filler cap (4) as follows:
diameter and apply LHE solution (C-108). (Refer to
BHT-ALL-SPMmanual for prescribed cadmium plating a. Remove lock ring and washer at base of oil
method.) After plating, the sides of the shim plate cap. Remove aluminum wool packing and discard.
must be parallel within 0.0002 inch inside 4.600 Remove packing (8) and discard.
diameter, but the plate may taper 0.0000 to 0.0005
inch on either or both sides outside the 4.600 inch b. Clean oil cap in solvent (C-304). Inspect cap,
diameter. Identify new shim plate by etching serial without further disassembly, for wear and damage.
number of applicable case on shim plate. Also etch Replace cap if defects are noted which would affect
thickness (in thousandths of an inch) on shim plate. function of cap.
Use etching ink (C-461) or equivalent. After marking,
neutralize by wiping with a rag soaked with oil c. Install new aluminum wool (C-422) in base
(C-109). of cap. The correct amount of aluminum wool is in
place when the washer can be depressed 0.06 inch
17. If original shim (18) is missing or mixed with and will spring back to its normal position. When
other shim plates, determine required dimension of correct amount of aluminum wool is in place, secure
replacement shim as follows: washer with lock ring.
d. Install new packing (8) on oil cap.

which should be metal stamped or vibro-etched on 20. Repair output shaft (1) as follows:
part adjacent to applicable mounting surface.
a. Mechanical and corrosion damage within
b. Subtract 0.3542 to 0.3546 inch from limits specified in figure 66-128 should be polished
reference dimension stamped on sleeve to give out with 400 abrasive cloth (C-423) to blend with
required shim thickness for sleeve. surrounding area and to effect a bottom radius of 0.5
inch.
c. Grind new blank shim to required thickness. b. No rework is required in the oil seal contact
Sides of shim must be parallel within 0.0002 inch. Do area if the depth of wear does not exceed 0.002 inch
not cadmium plate shim (18). and the groove is uniform and smooth. More severe
damage may be reworked as follows, providing that it
18. Repair sleeve (40) as follows: gives 100 percent clean up: Grind seal diameter to a
minimum diameter of 1.430 inch. (Refer to figure
66-128.) Reground area must not extend into
a. Replace clinch nuts (39) if damaged or loose. existing 0.062 inch radius and must blend into
66-239
BHT-205A1 -CR&O-1
existing diameter with a minimum radius of 0.062 6. Pressduplexbearing (25), usingT101566bar,

inch. Finished diameter must be concentric with into case. The duplex bearings must have matching
diameter for roller bearings within 0.0015 inch TIR serial numbers, be installed in pairs, and be installed
(total indicator reading) and surface finish must be 16 face-to-face.
RHR or better.
7. Support inner race of duplex bearing (25), with
c. Inspect shaft by magnetic particle T101599 pressing tool, and press shaft (1) into case
inspection. Demagnetize shaft after magnetic (9).
particle inspection.
8. Position case (9) in T101563 holding fixture
d. Apply LHE solution (C-108) to reworked and install nut (26). Use T101305 wrench to torque
areas on the portion of the shaft between the nut 360 to 480 inch-pounds.Installclip (27).
diameter for the roller bearing and the shoulder
adjacent to the splines. (Refer to BHT-ALL-SPM 9. Install nut (28) and use T101561 wrench to
manual.) torque nut 1800 to 2400 inch-pounds. Install clip
(29). Remove T101563 holding fixture. Turn shaft
e. Apply solid film lubricant (C-005) to shaft in and check that bearings roll smoothly and that there
area E. (Refer to figure 66-128.) Minimum thickness is a light drag caused by the preload of the bearings.
of film must be 0.0002 inch. Bake shaft in an oven at
a temperature of 265°F (129°C) for two hours.
10. Heat sleeve (40), install roller bearing (44) in
sleeve (40) and secure with retaining ring (46). Press
seal (47) into sleeve with lip of seal facing inboard.
66-233. ASSEMBLY
TAIL ROTORGEARBOX. (Refer to figure 66-126 for cutaway view of installed
components.) Install new packing (38, figure
NOTE: NAS1197 washers shall be replaced with new packing (38 figure
66-125) on sleeve.
AN960PD washers.
1. Clean all parts with cleaning solvent (C-304) 11. Coat packing
11.Coat packing (38),
(38), lip
lip of
of oil
oil seal
seal (47)
(47) and
and
coat approved oil. Do not handle dry
andwith mounting port of case (9) with approved oil. Heat
bearings with bare
hands. mounting port of case with a heat lamp and install
sleeve (40) on case and secure with washers (41 and
42) and nuts (43). Torque 50 to 70 inch-pounds.
2. Position gear (3, figure 66-125) on shaft (1) Ensure that only aluminum washers (41) are in
and install bolts (2). Safety bolts with lockwire contact with magnesium case. Turn shaft (1) by hand
(C-405). and check for light drag caused by oil seal and by
preload in duplex bearings.
NOTE: The same shim plate (17) that was removed
from the case must be reinstalled or a new shim plate 12. Heat input quill port in case (9) with heat
of the same thickness must be made. (Refer to lamp. Install new packings (32) on input quill (33).
paragraph 66-232, step 15.) Lubricate packing and mating surface of input quill
with approved oil. Install quill in gearbox. Exercise
care to keep quill aligned as it is installed so that the
3. Ensure that all six washer seats (14) are nose of the pinion enters the roller bearing and the
properly installed on gearbox case. Position shim gear teeth mesh properly. Align quill on studs so that
plate (17) on case (9) and secure with three screws the flats on gearbox case and quill sleeve flange are
(15). aligned. Install spacers (34) and nuts (35).
4. Install shim (18) in case (9). 13. Check that the gearbox turns smoothly by
turning the input pinion by hand. Check backlash
5. Heat case (9) and press bearing (30) into case between input quill pinion and gear in three places
(9) and install retaining ring (31). 120 degrees apart. Use T101350 backlash clamp
66-240
BHT-205A 1-CR&O-1
and T101872 backlash arm. (Use outboard dowel.) around exposed end of setscrew (36). Allow to cure
Backlash must be 0.005 to 0.011 inch. Record for 72 hours at room temperature.
backlash.
NOTE: Adhesive (C-308) is procurable as two-part
CAUTION: DO NOT ALTER SHIM PLATE (17) OR kit. Mix according to directions on container and
SHIM (18) TO OBTAIN REQUIRED BACKLASH. IF apply to gearbox with pressure gun or wood spatula.
BACKLASH IS NOT WITHIN LIMITS, PARTS ARE NOT If necessary, smooth sealant with bare finger wetted
DIMENSIONALLY CORRECT OR ARE NOT with water.
CORRECTLY ASSEMBLED.
5. Remove plywood block and gasket from pitch
14. Install oil level indicator (20). Place packing
change quill port. Remove oil filler cap. Mask the
(21) on sight glass (22), lubricate packing and case
following areas to prepare for painting.
port with approved oil, and insert sight glass into
case. Install retaining ring (23). a. Oil cap adapter (10, figure 66-125).
15. Place new gasket (19) on chip detector (24) b. Chip detector (24).
and install in case. Torque 120 to 150 inch-pounds
and secure with lockwire (C-405). c. Input quill (33).
NOTE: Half inch diameter white dot on cap denotes d. Oil level sight glass (22).
vented cap. Half inch diameter white dot on case
denotes vented cap must be installed on case.
f. Data plate (45).
16. Place new packing (8) on oil cap (4) and
install oil cap on case. Attach pin (7) to case. g. Bushings (12).
1 7. Install 1/2 inch thick plywood block and cork h. Case port adjacent to studs (11).
gasket on pitch change quill mounting port.
i.Seals (47, figure 66-125 and 13, figure
18. Prepare data plate (45) for installation and 66-130) at outboard end of sleeve and quill.
bond to sleeve. (Refer to BHT-ALL-SPMmanual.) 6. Apply one coat of primer (C-202), 0.4 to 0.8
mils. Air dry primer 30 minutes before applying top
66-234. SEALING AND PAINTING - TAIL ROTOR coat
GEARBOX.
7. Apply two or three coats (1.0 to 1.5 mils) of
NOTE: If tail rotor gearbox is to be run-in on run-in lacquer (C-203), color 36211 (gull gray).
stand, skip painting and sealing, until after run-in
inspection. (Refer to paragraph 66-235.) 8. Use brush to apply 1/2 inch diameter dot of
white paint (C-210) to oil cap and to gearbox case
1. Clean external surfaces of case and quill sleeve boss below oil cap adapter.
with MEK (C-309) and clean cloths. Do not allow
cleaning agent to contact seals. 66-235. RUN-IN AND TEST - TAIL ROTOR
GEARBOX.
2. Place a small amount of grease (C-001) in each
jackscrew hole. It is recommended that tail rotor gearbox, after
overhaul, be test run, and inspected in accordance
3. Install nylon setscrews (36, figure 66-125) in with Bell Helicopter Textron Publication BHT-PUB
jackscrew holes. 77-003 for qualification for flight. In the event that a
run-in stand is not available, the functional test
4. Apply adhesive (C-308) between case and specified in BHT-205A1-MM-1 manual may be
quill sleeves, around bearing retaining nuts, and accomplished as minimum acceptable alternate test.
66-241
BHT-205A1-CR&O-1
INTERNAL
SPLINES
INSTALL WEAR SLEEVE WITH SEE

ROUNDED END AS SHOWN DETAIL B
DETAIL A
TORQUE
100 TO 150
FT-LBS
1. Retainer ring 9. Washer 17. Wear sleeve

2. Plate 10. Inner coupling 18. Duplex bearing
3. Spring centering 11. Outer coupling 19. Sleeve
4. Spring lock 12. Seal .20. Pinion
5. Spacer 13
. Seal 21. Cork plug
6. Packing 14. Nut
8. Bolt 16. Spacer
NOTES:
Apply sealant, MIL-S-8802, Class B2 around nut (14) and sleeve (19)
after assembly.
205A1-R-66-130-1
Figure 66-130. Tail rotor gearbox input quill (Sheet 1 of 2)
66-242 Rev. 2
BHT-205A 1-CR&O- 1
SEAL (12) PARTIALLY SEATED

SEAL (12) FULLY SEATED

OF SEAL (12) UP
DETAIL B
Figure 66-130. Tail rotor gearbox input quill (Sheet 2 of 2)
66-236. TAIL ROTOR GEARBOX INPUT remove coupling retaining bolt (8). Remove washer
QUILL. (9).
66-237. OVERHAUL - TAIL ROTOR GEARBOX 3. Remove inner and outer couplings (10 and 11)
(212-040-004) INPUT QUILL. from pinion.
TOOLS REQUIRED 4. Separate couplings and remove seal (12) from
outer coupling (11).
T101307 Wrench 5. Hold sleeve (19) with T101560 holding
T101 560 Holding Fixture fixture, and use T101600 wrench to remove nut (14).
T101566 Bar Remove seal (13) and packing (15) from nut.
T101599 Pressing Tool
T101600 Wrench NOTE: Wear sleeve (17) should be replaced any
T101880 Sleeve Tool time gearbox is overhauled or seal (13) is replaced.
TAIL ROTOR GEARBOX

66-238. DISASSEMBLY 6. Remove spacer (16) and press pinion (20) out
INPUT QUILL. of sleeve (19). Use suitable plug to press on outer
INPUT QUILL.
race of duplex bearings (18) to remove bearings from
sleeve. Tap wear sleeve (17) with a mallet to loosen
1. Remove retaining ring (1, figure 66-130), plate
bonding. Press wear sleeve (17) with a mallet to
(2), centering spring (3) and spacer (5). Thread a
1/4-20 bolt into center of retainer (6) and pull retainer loosen bonding. Press wear sleeve (17) off of spacer
(16) with T101880 sleeve tool.
with lock spring (4) and packing (7) from inner
coupling (10). Remove lockspring and packing from 66-239. CLEANING - TAIL ROTOR GEARBOX
retainer. INPUT QUILL.
NOTE: For ease of maintenance, block the outer 1. Clean parts with solvent (C-304). Dry parts
coupling so that it will remain in the outboard with clean lint-free cloths or filtered compressed air.
(extended) position. This will stabilize the outer Do not allow bearings to spin when drying with air.
coupling during disassembly and assembly. Protect cleaned bearings with corrosion preventive
2. Hold outer coupling (11) with T101307 fingerprint remover (C-105) and wrap with barrier
wrench and use square adapter through wrench to maerial (C-427).
66-243
BHT-205A1-CR&O-1
2. Inspect sleeve (19, figure 66-130) for corrosion smearing ortearing is found, replaceoutercouplingand
damage to threads. No structural damage to threads is inner coupling.
acceptable.
3. Remove sealant from quill with plastic scraper. viscous (thick) and having a strong pungent odor. If
grease is found to be viscous and having a strong
4. Clean primer from spacer (16) with a plastic pungent odor, replace outer coupling and inner
scraper and abrasive pad. coupling.
5. Remove paint with paint remover (C-436). Rinse NOTE: If TEMP-PLATES are to be replaced, replace
with clean water. TEMP-PLATES after completing entire inspection
6. If ferrous parts are not used immediately after serviceable and prior to lubricating couplings.
cleaning, gently agitate parts in corrosion preventive
compound (C-105) and air dry. Apply protective coat of 3A. Inspect outer coupling (5) overtemperature
approved gearbox oil (refer to BHT-205A1-MM-1 indicator TEMP-PLATES for deterioration, debonding,
manual). or discoloration of epoxy coating that prevents
interpretation of indicating dots. If deterioration,
debonding, or discoloration of epoxy is found, replace
66-240. NORMAL INSPECTION - TAIL ROTOR TEMP-PLATES in accordance with paragraph 66-224.
QUILL.
GEARBOX INPUTGEARBOX INPUT 4. Inspect the inner coupling (10), outer coupling
1. Inspect all parts of input quill for obvious damage
that would make part nonreparable or nonserviceable. method. (Refer to BHT=ALL-SPMmanual.)
5. Inspect input sleeve (19) for damage limits. (Refer
2. Inspect gears and splines for chipped, broken or figure 66-131.)
worn teeth. Check bearings for smooth operation and
indications of excessive wear. 6. Inspect parts dimensionally and replace parts that
NOTE: Overtemperature dots on overtemperature 66-132.)
color and turn black when exposed to an NOTE: Wear limits are provided to show the required
overtemperature condition. Chemical contamination fit between mating parts. It is not intended that all
can also cause indicating dots to turn black. dimensions be checked as a prescribed overhaul
procedure; however, parts that show evidence of wear
3. Inspect outer coupling (11, figure 66-130) of physical damage must be checked dimensionally.
of overtemperature indication. If overtemperature 7. Inspect teeth on pinion (20, figure 66-130) for
indication is noted, perform coupling overtemperature excessive wear, scoring, spalling, and scuffing.
8. Inspect inner and outer couplings (10 and 11,
a. Inspect outer coupling cadmium plating for figure 66-130) for chipped, pitted, cracked, and
being discolored (circumferential tan or light brown excessively worn teeth. (Refer to figure 66-133.)
blistering is found, replace outer coupling and inner 9. Inspect duplex bearing (18, figure 66-130) for
coupling. roughness, spalling, scoring, pitting, brinnelling, flaking
and corrosion on rolling elements or races and for
b. Inspect gear teeth of outer coupling and inner cracked or broken retainers. (Refer to figure 66-112.)
coupling for being discolored (brown or blue) in normally Minor nicks, cuts, or scratches are acceptable provided
bright contact pattems. If discoloration is found, replace they are too small to be felt with a probe having an end
outer coupling and inner coupling. radius of 0.030 inch, and provided the total affected area
does not exceed 10 percent of the contact area at any
c. Inspectoutercouplingandinnercouplingunder point. Minor circumferential scoring is acceptable on
5X to 10X magnification for teeth exhibiting signs of rollers and races provided it cannot be felt with a probe
metal smearing or tearing in the contact patterns. If having an end radius of 0.030 inch and provided the
66-244 Rev. 2
BHT-205A1-CR&O-1
affected area does not exceed 10 percent of the contact 1. Replace parts that are not within allowable wear
area at any point. limits.
10. Inspect coupling retaining bolt (8, figure 66-130) 2. Replace all seals, gaskets, and preformed
visually for damaged threads. Replace bolts with packings on reassembly.
malformed threads.
3. Replace parts that are cracked, broken, warped,
cleaning, gently agitate parts in corrosion preventive
compound (C-105) and air dry. Apply protective coat of
manual). 4. Repair minor scratches, nicks and pits on
non-critical surfaces with crocus cloth.
66-241. REPAIR -TAIL ROTOR GEARBOX INPUT 5. Repair minor nicks, scratches and burrs on
QUILL. splines and gear teeth by dressing with fine India stone.
Rev. 2 66-244A/66-244B
BHT-205A 1-CR&O-1
AREA
A. Corrosion and mechanical damages are permissible provided no more than 20 percent
of the total area, and no more than 30 percent of any one square inch is affected.
B. No corrosion or mechanical damage is allowed other than small dents and nicks
in the chamfers.
C. Corrosion and mechanical damages are permissible provided no more than 40 percent
of the total area and no more than 60 percent of any one square inch is affected.
D. Corrosion and mechanical damages are permissible provided no more than 20 percent
of the total areaand no more than 40 percent of any one square inch is affected. Also no
more than 20 percent of the bearing surface for each washer may be damaged.
E. Corrosion and mechanical damages are permissible provided no morethan 5 percent of

the total area and no more than 10 percent of any one square inch is affected.
F. Corrosion and mechanical damages are permissible provided no more than 20 percent
of the total area and no more than 30 percent of any one square inch is affected.
Figure 66-131. Sleeve damage limits
66-245
BHT-205A1-CR&O-1

INCHES
1 Pinion (Bearing Contact Area - OD 1.2395 1.2399

Diameter must not vary more
than 0.0001 over entire length)
2 Pinion (Bearing Contact Areas) OD 1.5751 1.5758
4 Sleeve, Input OD 3.5597 3.5605
Average
5 Spline, Pinion Over Pins 1.4424 1.4465
6 Spline, Inner Coupling Between Pins 1 .1465 1.1578
7 Teeth, Inner Coupling Over Pins 2.1590 2.1740
8 Spline, Outer Coupling Between Pins 1.8290 1.8360
9 Spline, Spacer Between Pins 1.1780 1.1810
10 Spacer, Splined 1.7470 1.7510
(Seal Contact Area)
11 Sleeve, Input ID 3.1492 3.1499
Maximum depth of wear 0.005 inch. Measure from unworn face of tooth.
Figure 66-132. Tail rotor gearbox input quill wear limits
6. Replace wear sleeve (17, figure 66-130) on prescribed cadmium plating method.) Plating
reassembly or when seal is replaced. thickness to be 0.0001 to 0.0003 inch. Do not
exceed 0.0003 inch plating thickness in seal contact
7. Replace bearings that are spalled, scored, area. Do not plate external spline teeth on inner
brinnelled, pitted, discolored from overheating, that coupling (10), and do not plate internal spline teeth on
have damaged or broken retainers, or that do not roll outer coupling (11). Tape area not to be plated with
smoothly. tape (C-426). (Refer to BHT-ALL-SPMmanual.)
8. Apply LHE solution (C-108) to couplings (10 9. Repair pinion (20) by dressing out minor nicks,
and 11). (Refer to BHT-ALL-SPM manual for scratches, and burrs with fine india stone (C-464).
66-246
BHT-205A1 -CR&O-1
Acceptable pattern typical of couplings which have




dicating that the pitted area is polishing over.
This condition may exist On all teeth. Couplings
be replaced.
Figure 66-133. Coupling teeth wear pattern
66-247
BHT-205A1-CR&O-1
10. Repair sleeve if damaged areas are within 5. Coat mating surfaces of wear sleeve (17) and
limits specified in figure 66-131 as follows: spacer (16) with unreduced primer (C-201). Place
wear sleeve on spacer, with unchamfered end toward
shouldered end of spacer. Press wear sleeve onto
a. In areas A and D, rework damaged area using spacer as shown in detail A, figure 66-130, using
a fine abrasive cloth (C-423) or india stone (C-464). T101880 sleeve tool. Remove excess primer. Coat
Maximum depth of rework in area A is 0.020 inch and wear sleeve with approved gearbox oil (refer to
area D is 0.010 inch, minimum blend radius 0.5 inch. BHT-205A1-MM-1 manual) and install spacer on
pinion (20).
b. In area B, rework damaged area using a fine
india stone to remove all traces of damage. Maximum
depth of rework is 0.010 inch, minimum blend radius 6. Press new seal (13) into nut (14) with lip of
is 0.5 inch. No damage or rework is acceptable that seal facing inboard. Install new packing (15) on nut.
would affect sealing of packing. Lubricate seal lip, packing and threads of nut with
c. In area C, rework damaged area using a fine manual). Position T101560 holding fixture on sleeve
abrasive cloth (C-423) or india stone (C-464). (19) and install nut (14). Use T101600 wrench to
Maximum depth of rework is 0.040 inch, minimum torque nut (14) 100 to 150 foot-pounds and secure
blend radius is 0.5 inch. with lockwire (C-405).
d. In area E, rework damaged area using a fine

abrasive cloth (C-423) or india stone (C-464). NOTE: A workaid may be fabricated, as shown in
Maximum depth of rework is 0.001 inch. Gouges and figure 66-81 to aid installation of seal (12, figure
dents up to 0.005 inch deep may be reworked by 66-130).
stoning off raised material.
e. In area F, rework damaged area using a fine 7. Install seal (12) into outer coupling (11) seal
abrasive cloth (C-423) or india stone (C-464). groove follows:
Maximum depth of rework is 0.010 inch, minimum
blend radius is 0.5 inch. a. Apply a light coat of grease (C-015) to outer
66-242. REASSEMBLY - TAIL ROTOR GEARBOX
INPUT QUILL.
b. Install seal (12) into outer coupling (11) seal
1. Clean all parts with cleaning solvent (C-304) groove with lip of seal toward internal splines of outer
and coat with approved gearbox oil (refer to coupling (11) as shown in figure 66-130, detail B.
BHT-205A1-MM-1 manual). Do not handle dry
NOTE: Seal (12) will be partially seated and the
2. Install new cork plug (21, figure 66-130) in inner coupling (10) will be used as a backup, in
pinion (20). Use a No. 9 short cork. Use Shellac reverse, (see detail B) to fully seal the outer
(C-211) to install cork in pinion as shown in figure circumference edge of seal into outer coupling (11)
66-131. seal groove.
3. Press duplex bearing (18) into sleeve (19) c. Using inner coupling (10) as a backup, and
using T101566 bar. The duplex bearings must have placed, as shown in detail B, firmly press down (hand
matching serial numbers, be installed in pairs and be pressure only) on outer coupling (11), simultaneously
installed face-to-face. tuck outer circumference edge of seal (12) using
workaid, into outer coupling (11) seal groove.
4. Support inner race of duplex bearings with
T101599 pressing tool and press pinion (20) into
sleeve (19); exercise care to avoid damage to teeth of d. Continue pressing around seal (12) using
pinion. workaid, until seal (12) is fully seated.
66-248
BHT-205A1-CR&O-1
8. Place a small amount of grease (C-015) in internal b. Prepare outer coupling surface for bonding by
spline of outer coupling (11). Insert inner coupling (10) scrubbing surface using clean cloths wetted with a
into outer coupling (11) with small end through seal. cleaning solvent MEK (C-309). Remove all
contamination and before MEK dries, wipe the surface
NOTE: Ensure inner coupling (10) is correct for drywith clean cloth. The cleaned surface area should be
intermediate and tail rotor gearbox, overall length is minimum 0.50 inch larger than area of TEMP-PLATES
1.870 to 1.880 inches. Tail rotor driveshaft hanger on outer coupling.
coupling overall length is 2.070 to 2.080 inches.
c. Perform a water break-free test on the prepared
bonding surface by applying distilled or demineralized
9. Position assembled couplings (10 and 11) on water from a suitable dispenser (squeeze bottle). Water
splined end of pinion. Coat threads of coupling retaining
bolt (8) with approved gearbox oil (refer to distinct water droplets within 25 seconds after
BHT-205A1-MM-1 manual). Place washer (9) on bolt application to the surface. Wipe dry with a clean cloth.
and thread bolt into pinion. Hold outer coupling (11)with Ensure
Ensure bonding
bonding surfaces
surfaces are
are not subsequently
not subsequently
T101307 wrench. Position square adapter through contaminated
wrench and torque bolt (8) 80 to 100 foot-pounds.
10. Place packing (7) on retainer (6). Coat packing water break-free test requirements and ensure cleaning
and retainer with approved gearbox oil (refer to materials are not contaminated; clean coupling bonding
BHT-205A1-MM-1 manual) and insert retainer into bolt surfaces as follows:
(8). If one hole in rim of retainer does not align with notch
of inner coupling, pull retainer out, rotate it ninety NOTE: Followthemanufacturerrecommendationsfor
degrees and reinstall. Repeat if necessary to obtain proper water mixtures.
alignment. Install lock spring (4).
(1) Using a cleaning compound (C-318) and
11. Extend outer coupling (11) so that seal (12) is cloth, scrub coupling bonding surface clean. Follow
against the teeth of inner coupling (10). Coat internal cleaning with a thorough water rinse.
splines of outer coupling with grease (C-015) to 0.12 inch
depth over top of spline teeth. A workaid may be (2) Thoroughly dry coupling surfaces.
fabricated, as shown in figure 66-85, to obtain depth of (
grease. 3) Repeat water break-free test as stated
above.
12. Place small end of centering spring (3, figure CAUTION: TO PREVENT CONTAMINATION OF
66-130) on boss of plate (2). Install plate, spacer (5) and THE TEMP-PLATES ADHESIVE BACKING, ENSURE
spring into coupling and install retaining ring (1). THAT WORK AREA AND HANDS ARE THOROUGHLY
CLEANED BEFORE WORKING WITH TEMP-PLATES.
13. Test quill as follows: Hold sleeve and turn
coupling. There should be a very light drag caused by DO NOT PRESS OR RUB TEMP-PLATES WITH BARE
the preload of the oil seal and the duplex bearings, but FINGERS DURING INSTALLATION ON COUPLING.
the coupling and pinion should turn smoothly. THIS WILL CONTAMINATE SURFACES. APPLY
14. Replace over temperature indicator FOLLOWING INSTALLATION OF TEMP-PLATES ON
TEMP-PLATES as follows: COUPLING.
e. Carefully form overtemperature indicator

a. Remove epoxy coating and TEMP-PLATES TEMP-PLATES to match V contour of coupling surface.
(figure 66-115) using paint remover (C-436). Repeat Do not crease TEMP-PLATES sharply.
process until no trace of epoxy is present.
NOTE: Working one TEMP-PLATE at a time, repeat
CAUTION: BONDING SURFACE AND steps f and g until all TEMP-PLATES are installed on
TEMP-PLATES MUST BE FREE OF ALL coupling.
CONTAMINATION. ANY CONTAMINATION COULD
ALLOW TEMP-PLATES TO COME OFF OR INDICATE f. Remove protective backing from TEMP-PLATE
FALSE TEMPERATURES. and carefully position onto surface prepared in step b.
Rev. 2 66-249
BHT-205A1-CR&O-1
g. Using clean cloth or cotton swab, work k. After one hour epoxy curing time at room
TEMP-PLATE into contour of coupling. A thoroughly temperature, the epoxy coating total curing time can be
cleaned firm rubber (edge of a block type eraser) accelerated by placing the coupling in a temperature
workaid may be utilized to work TEMP-PLATE into full controlled oven for one to two hours at a temperature of
contact with coupling surface. Ensurethe TEMP-PLATE 150 to 180 °F.
is in full contact with coupling surface. Do not press or
rub TEMP-PLATE with bare fingers. Following
l. the cure, TEMP-PLATES should
NOTE: Use of any epoxy adhesive otherthan Devcon lifted edges. Indicating dots on TEMP-PLATES must
2-Ton (C-298) is not authorized. remain original white or light gray with not full or partial
black discoloration.
h. Prepare Devcon 2-Ton epoxy adhesive (C-298)
as follows: m. Perform an adhesion test on each TEMP-PLATE
(1) Pour equal amounts of epoxy Part A and tape onto TEMP-PLATE and epoxy overcoat. Tape should
Part B into a solvent proof container. extend beyond edge of epoxy overcoat. Grasp one end of
(2) Vigorously mix Part A and Part B with a remove tape in one abrupt motion. Lifting or peeling of
brush such as an artist brush. epoxy coating or TEMP-PLATE is not acceptable. If lifting
(3) A few drops of thinner, such as MEK (C-309), by repeating procedure.
may be added to epoxy during mixing operation to reduce
viscosity to a level that permits uniform brush application
of epoxy mixture. Do not thin this mixture such that it runs n. Repeat procedure for opposite coupling.
mixture may seep into overtemperature indicator 15. The tail rotor gearbox input quill shall be tagged
TEMP-PLATE and cause indicator dots to turn black (in with date of lubrication and an entry made in component
which event, TEMP-PLATE must be removed and historical record, if driveshaft is to be returned to stock.
15 minutes.
16. When tail rotor gearbox input quill is installed on
i. Using a soft-bristled brush, uniformly apply epoxy helicopter, and entry shall be made in helicopter log and
coating over TEMP-PLATES to a thickness of flex couplings lubrication log in BHT-205A1-MM-1 with
approximately 0.002 to 0.004 inch (similar to a coat of date of lubrication.
paint). Coating should be uniform in appearance, totally
cover surface of TEMP-PLATES and extended
approximately 0.25 inch beyond edges of TEMP-PLATES. 66-243. PAINTING - TAIL ROTOR GEARBOX
INPUT QUILL.
CAUTION: DO NOT EXPOSE EPOXY COATING TO
OIL, GREASE, CLEANING SOLVENT OR OTHER
CHEMICALS DURING CURE. 1. Clean external surfaces of input quill sleeve with
MEK (C-309) and clean cloths. Do not allow MEK to
contact seals.
j. Allow epoxy coating to cure at room
of six hours prior to operating helicopter. For best 2. Maskseal(13,figure66-130)atoutboardendof
results, allow epoxy to cure overnight prior to operating quill.
helicopter or exposing to oil or grease.
NOTE: An alternate source of heat can be used if the 3. Refer to paragraph 66-234 for painting and
temperature does not exceed 180°F. sealing instructions applicable to input quill.
66-250 Rev. 2
BHT-205A1-CR&O-1
POWER PLANT
TABLE OF CONTENTS
Paragraph Page
Number Title Number
71-1 Power plant.................................................................................................................... 71-2

71-2 Build-up - pow er plant ................................................................................................. 71-2
71-3 Engine mount bearing replacement............................................................................... 71-15
LIST OF FIGURES
Figure Page
Number Title Number
71-1 Basic engine and shipping container ................................................................................ 71-3

71-2 Basic engine (T5313A) ..................................................................... 71-4
71-3 Pow er plant (right side)..................................................................................................... 71-5
71-4 Power plant (left side) ..................................................................... 71-6
71-5 Power plant hose and electrical harness .......................................................................... 71-8
71-6 Pow er plant electrical harness.......................................................................................... 71-11
71-7 Engine m ount bearing replacem ent.................................................................................. 71-16
71-8 Engine mount bearing replacement - dimensional requirements ................................... 71-17
15 JAN 2004 Rev. 3 71-1

BHT-205A1-CR&O-1
71-1. POWER PLANT. k. Torque pressure transmitter bracket.
I. Engine fittings and tubes (power governor).

71-2. BUILD-UP POWER PLANT.
m. Oil pressure transmitter.
1. Remove engine from shipping container in
accordance with the following: n. Oil pressure switch.
a. Release air pressure from engine shipping o. Engine tubing (oil pressure transmitter).
container.
p. Starter-generator.
b. Remove container lid attaching bolts around
center of shipping container. q. Gas producer tachometer generator.
c. Attach suitable sling to engine lifting lugs (1, r. Torque pressure transmitter and tubes.
figure 71-1).
s. Flexible hoses.
d. Attach cable hoist to engine lifting sling.
t. Electrical harness.
e. Remove mounting bolts (4) retaining engine
u. Output driveshaft adapter.
adapter mounts to shipping container.
NOTE: Inspect lines thoroughly for evidence of
f. Lift engine free of shipping container. (Refer
leaking, contamination, chafing, or heat damage.
to figure 71-2). Remove lockwire and shipping adapter
mounts (3, figure 71-1) from engine.
3. Install parts on new engine as follows:
g. Remove drain plug from lower section of fuel
control and allow to drain. a. Install firewall (14, figure 71-3) as follows:
h. Install engine in suitable build-up stand. (1) Position firewall (14) on rear of engine
combustion section. Position band clamp (15) and bolt
at bottom center line of engine.
2. Remove from the old engine the following
parts for reinstallation of the new engine. (2) While tapping around band clamp with
mallet, torque clamp nut 100 to 130 inch-pounds.
a. Firewall.
b. Install tailpipe (13) as follows:
b. Tailpipe.
(1) Position tailpipe (13) onto rear of
c. Igniters. combustion section. Align dowel pins on rear face of
combustion section to matching indents in face of
d. Bleed air adapter. mounting flange of tailpipe. Locate band clamp and
bolt to bottom centerline of engine.
e. Engine mount fitting.
(2) While tapping around band clamp with
f. Trunnion, cambox, and bracket. mallet, torque clamp nut 100 to 130 inch-pounds.
g. Throttle governor lever. c. Install igniters (11) as follows:
h. Fuel control arm. (1) Connect four igniter leads to respective

igniter plugs (11).
i. Linear actuator.
(2) Tighten and secure with shear wire (C-
j. Power turbine tachometer generator. 414).
71-2
BHT-205A1-CR&O-1
1. Lifting Lugs
2. Shipping Container
3. Shipping Adapter Mounts
4. Mounting Bolts
5. Lid Attachment Bolt Provision
Figure 71-1. Basic engine and shipping container
d. Install bleed air adapter (1) as follows: (3) Position bleed air adapter (1) on bleed air
tuba with hose coupling nipple facing front of engine.
(1) Remove four bolts attaching bleed air

(4) Install four washers and four bolts.
adapter cover and remove cover.
(5) Secure bolts in pairs with lockwire

(2) Install gasket supplied on engine. (C-405).
71-3
A
BHT-205A1-CR&O-1
1. Shipping Plug
Figure 71-2. Basic engine (T5313A)
e. Install engine mounting fittings (1, figure (5) Position the bearing on the engine mount
71-4) as follows: fitting. Install washer and nut.
(1) Install mount fitting (1) on left rear side of
(6) Torque nut 160 to 190 inch-pounds.
engine.
(2) Install four washers and four bolts (7) Install procedures for right side mount
securing the fitting to the engine. fitting (12, figure 71-3) are identical to left fitting.
Install the right fitting using steps (11 through (3).
(3) Torque bolts 160 to 190 Inch-pounds and
lockwire (C-405).
f. Install trunnion, cambox, and bracket (6,
(4) Check trunnion mount bearings prior to figure 7 l-4) as follows:
installation for 0.010 inch maximum axial play
between ball end race. If bearings play is greater than (1) Paint mating surfaces of trunnion and
these values, replace bearings. engine with primer (C-201 or C-204).
BHT-205A1-CR&O-1
1. Bleed air adapter 9. Starter-generator

2. Bleed air valve solenoid 10. Starter-generator cable assembly
3. Anti-ice tube 11. Igniter plug (Typical 4 places)
4. Tachomater generator 12. Side mount fitting
6. Torque pressure transmitter and bracket 13. Tailpipe
6. Torque pressure tuba assembly 14. Firewall
7. Engine breather hose 15. Band clamp
8. Engine oil inlet hose
Figure 71-3. Power plant (right side)
(2) Place trunnion (6) into position on lower (5) Install two lower bolts with washers
left side of engine. through bracket and trunnion.
(3) Position oil pressure transmitter and (6) Position cambox (6) on trunnion, aligning
bracket (5) on trunnion, the transmitter mounting mounting holes on cambox with upper mounting
hole provision facing aft of engine. holes of trunnion. Install two bolts with two washers.
(4) Align lower bolt holes of bracket and (7) Torque mounting bolts 480 to 560
trunnion with mounting holes of engine. inch-pounds.
BHT-205A1-CR&O-1
1. Mount Fitting 7. Governor Bleed Tube

2. Power Lever 6. Linear Actuator
3. Shipping Plug 9. Tachometer Generator
4. Engine Oil Pump Outlet Port 10. Anti-Icing System Pressure Switch
5. Oil Pressure Transmitter and Bracket 11. Governor Lever
6. Trunnion and Cambox
Figure 71-4. Power plant (left side)
(8) Secure bolt heads in pairs with lockwire (3) Install bolt in lever and lockwire (C-405).
(C-405).
h. Install fuel control arm (power lever) (2) as
g. Install throttle governor lever (11) as follows: follows:
(1) Position governor shaft at mid point (1) Install arm on power lever (2) control
between stops. shaft of fuel control.
(2) Install governor lever (11) on shaft splines (2) Install locking screw and lockwire
vertical to engine center line. (C-405).
71-6
BHT-205A1-CR&O-1
i. Install linear actuator (8) as follows: (2) Install T fitting with locking nut and
packing into fuel pump seal drain port located on
(1) Attach linear actuator (8) rod end bearing lower side, forward on fuel control.
to governor lever (11) using bolt, washer, nut, and
cotter pin. (3) Install tube assembly between fittings
installed in steps (1) and (2).
(2) Connect clevis end of linear actuator rod
to cambox rod end with bolt head up. Insert spring (4) Install restrictor fitting with locking nut
washer inside clevis beneath cambox rod end. Install and packing into oil filter located on lower side of
washer and nut on bolt. engine.
(3) Tighten nut finger tight plus one (5) Installtwofuelpressureswitches(5)with

castellation, if necessary, to facilitate installation of packing into the two pressure taps on lower section of
cotter pin. fuel control. Secure with shearwire (C-414).
(6) Remove shipping plugs from fuel control

j. Install power turbine tachometer generator inlet pressure taps (1, figure 71-2) and
(9) as follows: starter-generator pad on lower side.
(1) Remove cover for turbine tachometer (7) Install plugs with packing into ports.
generator (9), located on governor and turbine Tighten securely and lockwire (C-405).
generator gearbox on left upper side of engine
(8) Install reducer fitting with packing into
(2) Clean splines of tachometer generator starter-generator pad drive seal drain port located on
and drive splines with solvent (C-304). Pack drive lower side forward of starter-generator.
splines with lubricant (C-012).
(9) Install elbow fitting with packing into
(3) Install gasket using engine supplied outlet port of engine oil pump (4, figure 71-4).
hardware; install turbine tachometer generator with Position fitting outlet 90 degrees down from engine
electrical receptacle toward top of engine. center line and torque locking nut 300 to 325
inch-pounds.
k. Install torque pressure transmitter bracket (10) Install fitting with packing into inlet port
(5, figure 71-3) as follows: of oil pump.
(1) Position bracket (5) on mounting provided (11) Install union fitting with packing into
on forward right side of inlet housing of engine. engine breather port located on ower right side of
inlet housing of engine.
(2) Align transmitter mounting hole in
facing aft
of engine.
bracket (12) Install elbow fitting with locking nut and
packing into engine torque pressure vent pad, located
(3) Install four mounting bolts with four adjacent to starter-generator drive pad.
washers.
(13) Install torque pressure restrictor fitting
(4) Torque bolts 480to 560
480to bolts
(4) Torque 560 inch-pounds and
inch-pounds and into pressure port located on right side forward of
secure in pairs with lockwire (C-405). engine inlet
(14) Remove snap-ring, plug and packing
I. Install engine fittings and tube as follows:
from anti-icing system pressure switch (10)
(1) Install reducer fitting with packing in provision on top of engine inlet housing.
mounting
governor seal drain hose (7, figure 71-5), located on
(15) Install pressure switch in existing port
forwardtop section of power governor.
section of power governor
forward.top using engine furnished hardware and packing.
71-7
BHT-205A 1-CR&O-1
1. Igniter Box 8. Starter Generator Seal Drain Hose

2. Power Governor 9. Governor Bleed Hose
3. Engine Bleed Air Hose 10. Engine Oil Outlet Hose
4. Combustion Chamber Drain Hose 11. Oil Pressure Switch
5. Fuel Pressure Switches 12. Electrical Cable Assembly
6. Fuel Inlet Hose 13. Engine Electrical Connector (J91)
7. Governor Seal Drain Hose 14. Bleed Air Actuator Valve
Figure 71-5. Power plant hose and electrical harness
m. Install oil pressure transmitter (5, figure n. Install oil pressure switch (11, figure 71-5)
71-5) as follows: as follows:
(1) Position oil pressure transmitter on
mounting bracket (5) with electrical receptacle (1) Position oil pressure switch on oil
toward the front of the engine. pressure transmitter mounting bracket with electrical
receptacle vertical to engine center line.
(2) Tighten lock nut and lockwire (C-405).
(3) Install T fitting, lock-nut and packing on (2) Mount switch to bracket with clamp,
pressure port of transmitter. screw, washer, and nut.
71-8
BHT-205A1-CR&O-1
o. Install engine tubing as follows: (7) Secure starter-generator mounting nuts

and torque 160-to 190 inch-pounds.
(1) Install oil tube assembly between oil
pressure transmitter T fitting and elbow fitting on oil (8) Position cooling air intake shroud over air
pressure port at oil strainer. inlet ports on starter-generator and secure with two
bolts.
(2) Install tube assembly between oil
pressure switch and oil transmitter T fitting. q. Install gas producer tachometer generator
(4, figure 71-3) as follows:
(3) Install tube assembly between governor
bleed elbow fitting on power governor and union (1) Clean splines of tachometer generator
fitting connection to lower governor bleed hose (7, and drive splines with solvent (C-304). Pack drive
figure 71-4). Position shroud over connection and splines with lubricant (C-012).
secure with clamp.
(2) Install tachometer generator (4) using
(4) Attach clamp support on the top left case engine supplied hardware and gasket, on drive pad,
bolt of the accessory drive gearbox. Secure governor position electrical receptacle to the right side of
bleed tube assembly to support using clamp, screw, engine.
nut, and washer.
(3) Install four mounting nuts and torque 50
(5) Attach clamp support to lower outboard to 70 inch-pounds.
mounting bolt of turbine tachometer generator.
Secure governor bleed tube assembly to clamp r. Install torque pressure transmitter and tubes
support using clamp, nut, washer, and screw. (5, figure 71-3) as follows:
p. Install starter-generator (9, figure 71-3) as (1) Install torque pressure transmitter (5) in
follows: bracket with electrical receptacle toward front of
engine.
(1) Using existing hardware and gasket for
installation. (2) Lock into position with locking nut and
lockwire (C-405).
(2) Install cooling air exhaust shroud on rear
of starter generator. Position flat side of shroud down (3) Install elbow fitting in vent port on rear of
in respect to engine center line for maximum transmitter.
clearance of the tail rotor driveshaft housing. Tighten
locking screws and lockwire. (4) Install elbow fitting in pressure port on
front of transmitter.
(3) Install cooling air inlet shroud on
starter-generator with the flanged side toward the (5) Connect torque pressure tube assembly
mounting flange of the generator. Move shroud to rear (6) between torque pressure transmitter pressure
of generator to expose the elongated mounting holes port fitting and torque pressure fitting on engine inlet
in the flange of the starter-generator. housing section.
(4) Clean splines of starter-generator and (6) Install tube assembly between vent port
drive splines with solvent (C-304). Pack drive splines elbow fitting of transmitter and engine vent pad
with lubricant (C-01 2). elbow fitting located on forward lower right side.
(5) Place starter-generator (9) on splines of s. Install flexible hose as follows:

drive pad and mounting studs; rotate to position
terminal connectors to extreme left side of engine. (1) Connect combustion chamber drain hose
(4, figure 71-5) to drain fitting located on the bottom
(6) Lower starter-generator onto splines, of engine combustion chamber.
mounting bolts and nuts. Turn generator
counterclockwise to lock in end of elongated flange (2) Connect governor seal drain hose (7) to T
mounting holes. fitting located on lower forward side of fuel control.
71-9
BHT-205A 1-CR&O-1
(3) Connect the 45 degree fitting of the (3) Locate plug for bleed air valve. Route plug
starter-generator seal drain hose (8) to fitting on pad and attached wiring behind and inboard of fuel
drain positioned aft of engine center line. control and associated tubing.
(4) Connect power governor bleed hose (9) (4) Install bleed air wiring section of harness
to union fitting at lower end of governor bleed tube. as near inboard to engine case as possible, routing
Position shroud over connection and secure with clear of all movable engine controls and components.
clamp. Connect plug to bleed air valve solenoid (2, figure
71-3).
(5) Connect engine bleed air hose (3) elbow
fitting to bleed air adapter located at top of engine, (5) Route plug and main bundle of wiring
forward of the combustion chamber. Route the hose harness between anti-icing pressure switch and
assembly aft and downward across the combustion turbine tachometer generator (9, figure 71-4) located
chamber. Secure hose to combustion chamber on forward left side of inlet housing section. Install
section using engine supplied hardware and clamps. two clamp supports bolted together to form
horizontal clamp attachment on forward top left
(6) Connect engine breather hose (7, figure turbine tachometer generator drive bolt. Position
71-3), end fitting to engine breather port union clamp around main wire harness and attach to clamp
fitting, located at lower right side of engine support approximately 24 inches aft of plug.
compressor section.
(6) Connect plug from starter-generator
(7) Connect tank to engine oil inlet hose (8), connector to engine connector (13, figure 71-5),
to union fitting in inlet port of engine oil pump located located on bracket on left side of engine adjacent to
at lower right side of the compressor section of turbine tachometer generator.
engine. (7) Route engine torque pressure connector
and torque pressure transmitter plug over top of
(8) Connect engine oil outlet hose (10, figure
engine and under anti-icing tube (3, figure 71-3).
71-5), to the elbow fitting in the outlet port of the
engine oil pump located at lower side of the engine Clamp as shown in figure 71-6. Route exhaust
thermocouple connector (15, figure 71-6) and wiring
compressor section. Torque hose-to-fitting locking
nut 750 to 850 inch-pounds. Position shroud over
connection and secure with clamp. (8) Pull all slack of harness to right side of
engine over top of compressure section and secure
(9) Connect fuel inlet hose (6) elbow fitting clamps. Do not allow wiring to contact engine case.
to fuel inlet port union fitting of fuel control. Position Attach two clamp supports to engine combustion
shroud over connection and secure with clamp. chamber on lower right side and one clamp support to
lower case bolt of bleed air actuator valve. Refer to
(10) Connect tailpipe drain hose to lower sheet 2 of figure 71-6. Route EGT thermocouple
fitting of tailpipe. wires along lower side of combustion chamber
rearward to firewall plug mounting. Install three
t. Install electrical harness as follows: clamps (14) and clamp (13). Attach clamps to
supports.
(1) Install electrical cable assembly (10,
figure 71-3), for starter-generator. Connect marked (9) Locate wire number W16A18 in wire
terminal leads of harness to corresponding terminals bundle routed to lower forward section of engine.
of starter-generator terminal block. Install insulating cover over terminal wire end and
connect wire terminal to oil chip detector plug located
(2) Place electrical cable assembly (1 2, on lower section of starter-generator drive gearbox.
figure 71-5), on engine, locating receptacles for
tagged harness plugs. Identify and connect plug to (10) Locate oil pressure switch plugs of
anti-icing system pressure switch (10, figure 71-4) wiring harness. Route both plugs and attached wires
located on the forward top inlet housing section of the behind linear actuator (8, figure 72-4), down left side
engine. of engine alongside fuel control drain lines.
71-10
BHT-205A1-CR&O-1
FWD
1. Anti-icing system pressure switch 7. Fuel pump pressure switch

2. Harness connector 8. Starter-generator cable connector
3. Cover 9. Main cable connector
4. Oil pressure switch 10. Air filter solenoid valve connector
5. Bleed air valve connector 11. Wire, fuel filter bypass switch
6. Oil pressure transmitter
Figure 71-6. Power plant electrical harness (Sheet 1 of 2)
71-11
BHT-205A 1-CR&O-1
SEE DETAIL E
OVERSPEED
12. Torquemeter pressureswitch
14. Clamps
15. Exhaust thermocouple
connector
Figure71-6. Power plantelectrical harness (Sheet 2 of 2)

71-12
BHT-205A1-CR&O-1
(11) Install clamp on wire bundle adjacent to (19) Locate bleed air valve connector and
turbine tachometer generator drive pad and connect connected wiring. Route wires aft long center line of
to engine provided clamp support located inboard of engine left side. Place clamp around wire group and
tachometer generator drive pad. secure with two clamp supports provided on engine
compressor section. Installclamp on wire group and
(12) Connect electrical plug to oil pressure connect to clamp support provided on base of igniter
transmitter (5, figure 71-4). exciter box (1, figure 71-5). Route wires around and
below combustion chamber. Secure wire bundle with
(13) Connect electrical plug to oil pressure clamp to clamp support provided on lower left side of
switch (11, figure 71-5). combustion section.
(14) Locate wires numbered Q45C18,

Q46C18, and Q47B18 with terminal ends. Route (20) Locate wire number G1518. Route wire
wires along bundle wires of the oil pressure switch. along fuel drain tube assembly of power governor (7).
Install clamp on located wires and connect to clamp Clamp wire to fuel drain tube. Connect wire terminal
support located on lower outboard mounting bolt of end to fuel pressure switch, using engine-supplied
turbine tachometer generator. Position wire bundle hardware. Install jumper wire between two fuel
when installing clamps so that no contact or chaffing pressure switches (5).
occurs with the engine case, accessories, or
associatedtubing. (21) Connect plug to torque pressure
transmitter receptacle. Secure wires of plug to
(15) Remove cover (3, figure 71-6) from transmitter mounting bracket using clamp. Connect
terminal block of linear actuator.
plug to torque pressure switch, located adjacent to
(16) Connect terminal ends of wires as torque pressure transmitter.
follows:
(22) Install clamps between rotor
Q45C18 - To terminal E of actuator tachometer generator leads and torque pressure
transmitter leads as near to transmitter as possible.
Q46C 18 - To terminal R of actuator
Q47B18 - To center terminal of actuator (23) Connect engine overspeed control plug
to complete connection to overspeed governor trip
(17) Replace terminal block cover on switch.
actuator.
(18) Connect plug to turbine tachometer u. Install output driveshaft adapter. (Refer to
generator (9). Chapter 66.)
71-13/71-14
BHT-205A1 -CR&O-1
71-3. ENGINE MOUNT BEARING 71-5. ENGINE MOUNT BEARING

REPLACEMENT. INSPECTION.
1. Remove rod end(s) (2) and inspect inner and

MATERIALS REQUIRED outer surfaces of mount tube(s) for corrosion and
Refer to BHT-ALL-SPM for specifications and source. mechanical damage.
NUMBER NOMENCLATURE NOTE: Internal or external mechanical damage or

C-204 Epoxy Polyamide Primer corrosion in excess of 0.003 inch in depth after clean-
up is cause for rejection. A surface area affected in
C-215 Aluminized Lacquer excess of 0.5 square inch is cause for rejection.
C-309 Methyl-Ethyl-Ketone (MEK)
C-317 299-947-100, TY2, CL2 2. Remove loose adhesive from mount tube bore
Adhesive with bristle brush and MEK (C-309).
Bipod/Tripod - MS20613-6C14 Rivets (1) 3. Inspect rivet (1) holes for elongation. Rivet
Mounts: *-HL32PB8-11 Rivet (1) size may be increased to next larger size. Do not
& HL86KP-8 Collar exceed max size specified in material list.
- RE4H6-2 Rod End
NOTE: A bent mount tube is cause for rejection.
Bearing (2)
ALT-204-001-064-003
71-6. ENGINE MOUNT BEARING - ASSEMBLY.
-MS21152-2
Tube Assy.: Upper - MS20613-5C12 Rivet (1) 1. Establish rod end (2) position and ensure
- HL32PB6-8 Rivet (1) mount dimensions are in accordance with attached
& HL86KP-6 Collar figures prior to drilling rivet (1) holes. Rod ends (2) to
- BRE 6950 Rod End be oriented in-line and parallel to fittings. Drill holes
Bearing (2) undersize and line ream to within 0.001 inch of rivet (1)
ALT-KBE6-32 size.
-REPH-6N-1
-205-060-101-1
2. Deburr rivet (1) holes on both inside and
Lower - MS20613-5C14 Rivet (1) outside surfaces of tube and rod end (2).
*- HL32PB6-11 Rivet (1)
& HL86KP-6 Collar 3. Flush internal surface of mount tube(s) with
- 204-001-058-3 Rod End MEK (C-309) and allow to air dry.
Bearing (2)
ALT-204-001-064-3
4. Apply a coat of polyamide epoxy primer (C-
* Alternate Fastener- HI-LOK - Max Rivet Size 204) to inside of mount tube(s) and allow to air dry.
Increase.
5. Apply a coat of aluminized lacquer (C-215) to
71-4. ENGINE MOUNT BEARING - inside of mount tube(s) and allow to air dry.
DISASSEMBLY.
6. Using MEK (C-309), remove aluminized
1. Remove rivets (1) securing rod end bearing(s) lacquer (C-215) and epoxy polyamide primer (C-204)
(2) to mount. from mount tube internal faying surface. Clean faying
surface of rod end (2) using MEK (C-309).
2. Apply heat to mount/rod end in bonded area,
to facilitate removal of rod end (2). Do not exceed 7. Apply adhesive (C-317) to faying surface of
300°F (149°C). mount tube and rod end bearing. Fill rod end bearing
internal cavity with adhesive (C-317) and install rod
end (2).
8. Secure rod end(s) (2) using appropriate rivets

(1).
15 JAN 2004 Rev. 3 71-15
BHT-205A1-CR&O-1
0.75 In.
TYPICAL - BIPOD/TRIPOD MOUNT
Figure 71-7. Engine mount bearing replacement
71-16 Rev. 3 15 JAN 2004

BHT-205A1-CR&O-1
A -17.497 In.
B - 20.240 in.
C -13.280 in.
D -19.074 In.
1. Blpod assembly
2. Tripod assembly
3. Tube assembly
205A1CRO 71000 00080 001
Figure 71-8. Engine mount bearing replacement - dimensional requirements
15 JAN 2004 Rev. 3 71-17/71-18

BHT-205A 1-CR&O- 1
ENGINE OIL SYSTEM
TABLE OF CONTENTS
Paragraph Page
Number Title Number
79-1 Oil cooler turbine fan ......... ..... ............................... 79-2
LIST OF FIGURES
Figure Page
Number Title Number
79-1 Oil cooler turbine fan .............................................. 79-3
79-1
BHT-205A 1 -CR&O- 1
79-1. OIL COOLER TURBINE FAN. 8. Visually inspect aluminum parts for nicks,
scratches, dents, and weldment cracks.
79-2. BEARING REPLACEMENT - OIL COOLER
TURBINE FAN. 9. Remove minor scratches or nicks with crocus
cloth (C-409). Replace part/s if damage cannot be
1. Remove bolts (1, figure 79-1), nuts (11), and removed with crocus cloth.
washers (9) from cover assembly (2) and remove
cover assembly from housing (18). 10. Finish repair area with aluminum conversion
2. Using spanner wrench, remove locknut (14) coating, (C-100), as required.

and washer (13) from aft end of shaft (8).
11. Press bearing liners (19 and 11) in housing
3. Remove locknut (3) and washer (4) from shaft, (18).
and remove fan and turbine assembly (5) from shaft.
12. Install new bearings (7 and 12) on shaft (8).
4. Cut lockwire and remove four screws (21) and
retainer (6) from housing. 13. Install assembled shaft into housing (18).
5. Carefully pull shaft, with bearings (7 and 12)

14. Position retainer (6) and secure with four
a unit.
housing
from as screws (21) and secure with lockwire (C-405).
6. Using suitable bearing puller, remove bearings
(7 and 12) from shaft. 15. Position fan and turbine assembly (5) and
secure with washer (24) and locknut (3).
7. Press bearing liners (19 and 11) from housing
(18). 16. Install washer (13) and locknut (14) on aft
end of shaft (8) and secure.
NOTE: Do not remove identification plate (17) or
directional arrows (16) unless damaged, or unless 17. Install cover assembly (2) in place and secure
housing replacement is required. with bolts (1), washers (9), and nuts (10).
79-2
BHT-205A 1-CR&-1
2. Cover assembly 13. Washer

3. Locknut 14. Locknut
4. Washer 15. Rivet
5. Fan and turbine assembly 16. Directional arrow
6. Retainer 17. Identification plate
7. Front bearing 18. Housing
8. Shaft 19. Liner front bearing
9. Washer 20. Key
10. Nut 21. Screw
11. Liner rear bearing
Figure 79-1. Oil cooler turbine fan
79-3/79-4
BHT-205A-1-CR&O-1
ALPHABETICAL INDEX
Paragraph, Paragraph,
Subject Figure, Table Subject Figure, Table
Number Number
A Driveshaft Hanger, Tail Rotor ........... .66-160

Driveshaft, Main ....................... 66-1
Accessory Case Input Quill ............. 66-1 17 Dual Hydraulic Servo Actuator
Accessory Drive and Sump ............ 66-103 Mounting Bracket .................... 29-12
Accumulator (Dual Hydraulic System) ....... 29-7
Accumulator (Single Hydraulic System) ...... 29-2 E
Adjuster, Anti-Torque Pedals ............. 27-26
Anti-Torque Control Linkage ............. 27-30
Anti-Torque Pedal Adjuster .............. 27-26 F
Anti-Torque Pedal and Support ........... 27-21
Alert Service Bulletins ................... .1-2 Fan, Oil Cooler Turbine .................. 79-1
Flight Control Bearings .................. 27-1
Flight Control Tubes ................... 27-34
Force Gradient ...................... 27-32
Friction Clamp, Collective ............... .27-5
Bearing Replacement, Flight Controls ........ 27-1
Blades,
Main Rotor.........65-7 Friction Damper, Transmission ........... 66-156
Blades, Main Rotor ..................... 65-7 .
Fuel Cells ............................ 28-1
Build-up, Power Plant .................. 71-2 Fuel Cells
C
Gearbox,Intermediate ... ............ 66-170
Collective Friction Clamp . .............. 27-5 Gearbox, Tail Rotor . ............ 66-225
Collective Jackshaft . ................. 27-11
CollectiveLever . .................... 65-51
Collective Pitch Control Linkage .......... 27-13
CollectiveStick, Pilot ................. . .27-7
Conditional Inspection, Main Rotor Mast .... 66-24 Huband Blades,Main Rotor 65-2
Hub and Blades, Main Rotor .............. 65-2
Conditional Inspection,Transmission
Conditional Inspection, Transmission ...... ......
.66-33
66-33 Hub and Blade, Tail Rotor (212-010-700) ... .65-54
Cooler Fan, Oil ................... ..... 79-1
,Hub, Main Rotor ...................... 65-13
Consumable Materials ................... .. 1-4
Control consumable
Material Hydraulic Accumulator (Dual System) ....... 29-7
Control Linkage, Anti-Torque ............. 27-30
Control
Anti-Torque
Linkage, Hydraulic Accumulator (Single System) ..... 29-2
Control Tube Sleeves, Anti-Torque ........ 27-36
Hydraulic Pump and Tachometer
Control Tube Sleeves, Synchronized
Drive Quill ........................ 66-137
Elevator.......................... 27-38
Crosshead
Crosshead Assembly ..................
Assembly ................. . .65-86
65-86 Hydraulic
Crosstubes ..........
......................... 65-86
32-5 HydraulicPump Drive
System Quill..............
...................... 66-89
29-1
Cyclic Pitch Control Linkage ............ 27-19
Cyclic Stick and Support, Pilot ........... 27-15
D Input Driven Quill ..................... 66-69

Input Quill, Intermediate Gearbox ........ 66-191
Damper, Transmission Mount Friction ..... .66-156 Input Quill, Tail Rotor Gearbox ........... 66-236
Drive Quill, Hydraulic Pump .............. 66-89 Intermediate Gearbox ................. 66-170
Drive Quill, Offset Accessory ............ 66-96 Intermediate Gearbox Input Quill ......... 66-191
Drive Quill, Tail Rotor ................ .66-130 Intermediate Gearbox Output Quill ........ 66-208
Index 1
BHT-205A-1-CR&O-1
Number Number
J Pitch Horn .......................... 65-83

Power Plant .......................... 71-1
Jackshaft, Collective .................. 27-11
Q
K
Quill, Accessory Case Input ........... .66-117
L Quill, Hydraulic Pump and
Tachometer Drive .................. 66-137
Landing Gear . ....................... 32-1 Quill, Hydraulic Pump Drive .............. 66-89
Lever, Collective . .......... ... 65-51 Quill, Input Driven ................... 66-69
Lower Transmission Planetary ........... .66-55 Quill, Intermediate Gearbox Input ........ 66-191
Quill, Intermediate Gearbox Output ....... 66-208
Quill, Main Input ...................... 66-76
Quill, Rotor Brake Drive ............... .66-144
66-1 Quill, Tail Rotor Drive ................ .66-130
Main Driveshaft .......................
Main Input Quill ...................... 66-76 Quill, Tail Rotor, Gearbox Input .......... 66-236
Main Rotor Blades ..................... 65-7
Main Rotor Blade Splice Cover ........... .65-11 R
Main Rotor Blade 12 Months or
1000 Hour Inspection ................. 65-10 Ring Gear, Transmission ................ 66-62
Main Rotor Controls .................. .65-23 Rotor Brake Drive Quill ............... 66-144
Main Rotor Grip Seals ................. .65-21 Rotor Brake Master Cylinder ............ .29-17
Main Rotor Hub ...................... 65-13
Main Rotor Hub and Blades ............... 65-2
Main Rotor Mast ..................... 66-19
Main Rotor Mast Conditional Inspection .... .66-24
Scissors and Sleeve ................. .65-36
Main Rotor System .................. 65-1
Seal
Seal Replacement,
Replacement, Cyclic
Cyclic Hydraulic
Hydraulic
Master Cylinder, Rotor Brake ............ 29-17
Actuator .......................... 29-14
Mast, Main Rotor ............. ..... ...66-19
Servo Actuator Seal Replacement ......... 29-14
Skid Landing Gear .................... 32-1
Skid Shoes .......................... 32-3
Sleeves, Anti-Torque Control Tube ........ 27-36
Sleeves, Synchronized Elevator
ControlTube ................ .... 27-38
Offset Accessory Drive Quill ............. 66-96
StabilizerBar ....................... .65-24
Oil Cooler Turbine Fan .................. .79-1
Sump and Accessory Drive ............. 66-103
Oil Pump, Transmission ................ 66-110
Swashplate and Support Overhaul ......... 65-43
Output Quill, Intermediate Gearbox ....... 66-208
Synchronized Elevator Controls .......... .27-40
P
T
Pedal and Support, Anti-Torque ........... 27-21
Pilot Collective Stick ................... .27-5 Tachometer Drive Quill ............... .66-137
Pilot Cyclic Stick and Support ............ 27-15 Tail Rotor Blades (212-010-750) .......... 65-88
Pitch Change Link Overhaul ............. 65-33 Tail Rotor Drive Quill ................. 66-130
Pitch Control Linkage, Collective .......... 27-13 Tail Rotor Driveshaft Hanger ............ 66-160
Pitch Control Linkage, Cyclic ............. 27-19 Tail Rotor Gearbox ................... 66-225
Index 2
BHT-205A- 1 -CR&O-1
Number Number
Tail Rotor Gearbox Input Quill ........... 66-236 U

Tail Rotor Hub and Blades (212-010-701) ... .65-54
Tail Rotor Hub and Blades (212-011-701) ... .65-68 Upper Transmission Planetary ............ 66-48
Tail Rotor Hub and Blade System .......... 65-53
Tail Rotor Hub Overhaul (212-010-701) .... 65-60
Tail Rotor Hub Overhaul (212-011-701) .... 65-75
Tail Rotor Pedal and Support ............. 27-21
Transmission ........................ 66-28 W
Transmission Cases ................... 66-39
Transmission Lower Planetary ............ 66-55
Transmission Mount Friction Damper ...... 66-1 56
Transmission Oil Pump ................ 66-110
Transmission Ring Gear ................. 66-62 Y
Transmission Upper Planetary ............ 66-48
Tubes, Flight Control ................... 27-34
Index 3/Index 4

BHT 205a1 Cro 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BHT 205a1 Cro 1

Uploaded by

Copyright:

Available Formats

BHT-205A1 -CR&O-1

PROPRIETARY RIGHTS NOTICE

Additional copies of this publication may be obtained by contacting:

PN Rev. 3 15 JAN 2004

ALL INSPECTION, REPAIR AND OVERHAUL PROCEDURES PUBLISHED

BEFORE PERFORMING ANY PROCEDURE CONTAINED IN THIS MANUAL

IF YOU IDENTIFY OR SUSPECT THE USE OF PARTS NOT AUTHORIZED BY

15 JAN 2004 Rev. 3 Warning

LIST OF EFFECTIVE PAGES

Page Revision Page Revision Page Revision

Cover .............. ......... 3 65-18A/65-18B ............... 2 65-96 ......................... 3

15 JAN 2004 Rev. 3 A

LIST OF EFFECTIVE PAGES (CONT)

Page Revision Page Revision Page Revision

B Rev. 3 15 JAN 2004

Have you found something wrong with this manual - an

Your complaint or suggestion will be acknowledged and we

You may use the enclosed Customer Feedback form, as

Your assistance is sincerely appreciated.

RETURN VIA FAX TO PRODUCT SUPPORT ENGINEERING (450) 433-0272

Position: Telephone No.:

FOLD ON DOTTED LINES AND TAPE

Model of Helicopter Sold or Purchased

Bell Serial Number

Company or Individual who purchased Helicopter

FAX No. Telephone No.

BUSINESS REPLY MAIL

COMMERCIAL PUBLICATION DISTRIBUTION CENTER

FOLD ON DOTTED LINES AND TAPE

27-1 Flight control bearings ........................................................ 27-3

27-1 Control tube wall thickness .................................................... 27-39

27-1 Universal assembly damage and repair limits ................................... 27-4

TABLE OF CONTENTS (Cont)

LIST OF FIGURES (Cont)

27-12B Lever bushing replacement .................................. ........... 27-48C

27-1. FLIGHT CONTROL BEARINGS. Cleanliness of universal bores is especially important

15 JAN 2004 Rev. 3 27-3

UNIVERSAL ASSEMBLY (TYPICAL)

DAMAGE AREA REPAIR SYMBOLS

TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED

MAXIMUM AREA PER

BEARING WEAR Bearing load for radial play 5 Pounds

Figure 27-1. Universal assembly damage and repair limits

MAXIMUM CLEARANCE AFTER

Figure 27-2. Universalbearing replacement

5. Position liner on clamp and secure clamp 10.. Removeretainingring(21)andnutassembly

3. From outside switch box (4), drive out pin (5)

1. Clamp 25. Bushing

Figure 27-3. Pilot collective stick (Sheet 1 of 2)

33. Cotter Pins 48. Clevis

Figure 27-3. Pilot collective stick (Sheet 2 of 2)

DAMAGE AREA REPAIR SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MAXIMUM AREA PER

1. Bore damage not to exceed 0.002 inch for one-fourth circumference.

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MAXIMUM AREA PER

1. Bore damage not to exceed 0.002 inch for one-fourth circumference.

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MAXIMUM AREA PER

DAMAGE LOCATION SYMBOLS