206 MM CH63

BHT-206A/B-SERIES-MM-6
CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM
TABLE OF CONTENTS
Paragraph Chapter/Section Page

Number Title Number Number
MAIN ROTOR DRIVE SYSTEM
63-1 Main Rotor Drive System ............................................................... 63-00-00 5

63-1A Main Rotor Drive System — Pylon Whirl Inspection................. 63-00-00 5
63-2 Main Rotor Drive System — Troubleshooting .......................... 63-00-00 5
63-3 Main Rotor Drive System — Leakage Rates ............................ 63-00-00 5
63-4 Main Rotor Drive System — Major Changes............................ 63-00-00 6
63-5 Oil Contamination of Transmission Drive System
Components ............................................................................. 63-00-00 14
63-6 Identification of Foreign Materials............................................. 63-00-00 14
63-7 Oil Contamination of Transmission ................................................ 63-00-00 20
63-8 Oil Contamination of Freewheel Assembly............................... 63-00-00 20
63-9 Transmission Serviceability Check ........................................... 63-00-00 21
63-10 Freewheel Assembly Serviceability Check ............................... 63-00-00 21
63-11 Main Driveshaft .............................................................................. 63-00-00 22
63-12 Main Driveshaft — Removal ..................................................... 63-00-00 22
63-13 Main Driveshaft — Cleaning ..................................................... 63-00-00 22
63-14 Main Driveshaft — Inspection................................................... 63-00-00 24
63-15 Main Driveshaft — Installation .................................................. 63-00-00 24
63-16 Main Rotor Mast............................................................................. 63-00-00 26
63-17 Main Rotor Mast — Removal.................................................... 63-00-00 26
63-18 Main Rotor Mast — Cleaning.................................................... 63-00-00 31
63-19 Main Rotor Mast — Inspection ................................................. 63-00-00 31
63-20 Main Rotor Mast — Installation................................................. 63-00-00 31
63-21 Transmission.................................................................................. 63-00-00 32
63-22 Transmission — Removal......................................................... 63-00-00 32
63-23 Transmission — Cleaning......................................................... 63-00-00 36
63-24 Transmission — Inspection ...................................................... 63-00-00 36
63-25 Transmission — Installation...................................................... 63-00-00 36
63-26 Transmission — Bleeding Oil Pressure Hose........................... 63-00-00 38
63-27 Transmission — Operational Check ......................................... 63-00-00 38
63-28 Transmission Oil System ............................................................... 63-00-00 38
63-29 Oil Pump ........................................................................................ 63-00-00 39
63-30 Oil Pump — Removal ............................................................... 63-00-00 39
63-31 Oil Pump — Inspection ............................................................. 63-00-00 39
63-32 Oil Pump — Installation ............................................................ 63-00-00 39
63-33 Oil Pump Inlet Screen .................................................................... 63-00-00 43
63-34 Oil Pump Inlet Screen — Removal ........................................... 63-00-00 43
63-35 Oil Pump Inlet Screen — Inspection......................................... 63-00-00 43
63-36 Oil Pump Inlet Screen — Installation ........................................ 63-00-00 43
63-37 Chip Detectors ............................................................................... 63-00-00 43
63-38 Chip Detectors — Removal ...................................................... 63-00-00 43
63-39 Chip Detectors — Cleaning and Inspection.............................. 63-00-00 44
63-40 Chip Detectors — Installation ................................................... 63-00-00 45
63-41 Oil Level Sight Glass...................................................................... 63-00-00 45
63-42 Oil Level Sight Glass — Removal............................................. 63-00-00 45
63-00-00
Export Classification C, ECCN EAR99 10 APR 2020 Rev. 17 Page 1
TABLE OF CONTENTS (CONT)
Paragraph Chapter/Section Page

Number Title Number Number
63-43 Oil Level Sight Glass — Inspection .......................................... 63-00-00 45

63-44 Oil Level Sight Glass — Installation.......................................... 63-00-00 45
63-45 Oil Jets ........................................................................................... 63-00-00 46
63-46 Oil Jets — Removal .................................................................. 63-00-00 46
63-47 Oil Jets — Cleaning and Inspection.......................................... 63-00-00 46
63-48 Oil Jets — Installation ............................................................... 63-00-00 46
63-49 Oil Pressure Regulating Valve ....................................................... 63-00-00 46
63-50 Oil Pressure regulating Valve — Removal ............................... 63-00-00 46
63-51 Oil Pressure Regulating Valve — Inspection............................ 63-00-00 47
63-52 Oil Pressure regulating Valve — Installation ............................ 63-00-00 47
63-53 Transmission Oil Pressure Adjustment..................................... 63-00-00 47
63-54 Transmission Oil Filter (Transmission Assemblies
206-040-002-005/-015) — Servicing ........................................ 63-00-00 47
63-55 Transmission Oil Filter (Transmission Assemblies
206-040-002-013/-025 and Subsequent) — Servicing ............. 63-00-00 48
63-56 Oil Cooler ....................................................................................... 63-00-00 48
63-57 Oil Cooler — Removal .............................................................. 63-00-00 48
63-58 Oil Cooler — Cleaning and Inspection...................................... 63-00-00 48
63-59 Oil Cooler — Installation ........................................................... 63-00-00 49
63-60 Pylon Support Links ....................................................................... 63-00-00 49
63-61 Pylon Support Links — Removal .............................................. 63-00-00 49
63-62 Pylon Support Links — Inspection............................................ 63-00-00 49
63-63 Pylon Support Links — Installation ........................................... 63-00-00 51
63-64 Isolation Mount............................................................................... 63-00-00 51
63-65 Isolation Mount — Removal...................................................... 63-00-00 51
63-66 Isolation Mount — Inspection ................................................... 63-00-00 52
63-67 Isolation Mount — Installation................................................... 63-00-00 52
63-68 Freewheel Assembly...................................................................... 63-00-00 52
63-69 Freewheel Assembly — Removal............................................. 63-00-00 53
63-70 Freewheel Assembly — Cleaning............................................. 63-00-00 57
63-71 Freewheel Assembly — Inspection .......................................... 63-00-00 57
63-72 Freewheel Assembly — Installation.......................................... 63-00-00 57
63-73 Freewheel Assembly — Operational Check ........................... 63-00-00 59
FIGURES
Figure Page
Number Title Number
63-1 Main Rotor Drive System Components............................................................... 7

63-2 Transmission System Troubleshooting............................................................... 8
63-3 Main Driveshaft Troubleshooting ........................................................................ 11
63-4 Freewheel Assembly Troubleshooting................................................................ 13
63-5 Pylon Whirl Inspection ........................................................................................ 15
63-6 Corrective Action for Contamination Found on Oil Monitor/Chip Detectors........ 18
63-7 Main Driveshaft Assembly .................................................................................. 23
63-8 Main Driveshaft Overtemperature Indicators ...................................................... 27
63-00-00
Page 2 Rev. 17 10 APR 2020 Export Classification C, ECCN EAR99
FIGURES (CONT)
Figure Page
Number Title Number
63-9 Main Rotor Mast Assembly ................................................................................. 30

63-10 Transmission Assembly ...................................................................................... 33
63-11 Transmission Oil System Schematic .................................................................. 40
63-12 Transmission System Components .................................................................... 41
63-13 Pylon Support Links and Isolation Mount............................................................ 50
63-14 Freewheel Assembly........................................................................................... 54
63-15 Freewheel Assembly Dimensional Check........................................................... 60
TABLES
Table Page
Number Title Number
63-1 Maximum Allowable Leakage Rates for Main Rotor Drive System
Components........................................................................................................ 5
63-2 Main Rotor Drive System Major Changes........................................................... 6
63-3 TEMP-PLATE Condition and Corrective Action.................................................. 25
63-4 Chip Detector Strength ....................................................................................... 44
63-00-00
ECCN EAR99 27 SEP 2010 Rev. 9 Page 3/4
MAIN ROTOR DRIVE SYSTEM
63-1. MAIN ROTOR DRIVE SYSTEM 63-2. MAIN ROTOR DRIVE SYSTEM —
TROUBLESHOOTING
The main rotor drive system provides a means of
transmitting power from the engine to the main rotors. Figure 63-2 through Figure 63-5 provide
The main rotor drive system consists of a troubleshooting procedures for the main rotor drive
transmission, main rotor mast, main driveshaft, system components. These troubleshooting
freewheel assembly, and oil cooler (Figure 63-1). The procedures are a brief summary of troubles that may
freewheel assembly is mounted on the engine be encountered. They include indication of troubles,
accessory gear case. It connects the engine to the probable causes, and corrective actions to be taken.
transmission through the main driveshaft on the The troubleshooting data should be used along with
forward side, and the tail rotor gearbox through related other sources of information such as transmission oil
shafting on the aft side. This provides simultaneous system schematics, electrical wiring diagrams,
rotation of main and tail rotors and permits free operational checks, serviceability checks, and other
rotation of both rotors when the engine is not detailed procedures in this manual, and in conjunction
operating. with Table 63-2.
63-1A. MAIN ROTOR DRIVE SYSTEM — PYLON 1. For troubleshooting of transmission system, refer
WHIRL INSPECTION to Figure 63-2.
2. For troubleshooting of main driveshaft, refer to

NOTE Figure 63-3.
Perform pylon whirl inspection following
pilot report or evidence of abnormal 3. For troubleshooting of freewheel assembly, refer
landing, excessive slope landing, operation to Figure 63-4.
in severe turbulence, low rotor RPM during
flight (power ON or OFF), rapid and 63-3. MAIN ROTOR DRIVE SYSTEM —
extreme cyclic input, excessive spike LEAKAGE RATES
knock, or main driveshaft contact with
isolation mount. Table 63-1 presents a measurement of allowable
leakage rates that may be used in conjunction with
For pylon whirl inspection, refer to Figure 63-5. main rotor drive system troubleshooting.
Table 63-1. Maximum Allowable Leakage Rates for Main Rotor Drive System Components
COMPONENT TYPE LEAKAGE RATE
Transmission and freewheel Static Input quill leakage shall not exceed 10 drops per
assembly minute. Total transmission leakage at all sources
including freewheel assembly must not exceed 15
drops per minute.
Dynamic 1 quart per 3 hours of operating time.
63-00-00
ECCN EAR99 27 SEP 2010 Rev. 9 Page 5
63-4. MAIN ROTOR DRIVE SYSTEM — MAJOR helicopters main rotor drive system components. Due
CHANGES to the interchangeability of components, maintenance
instructions in this section shall include the component
Table 63-2 outlines the major changes and part number in the paragraph titles and illustrations, as
improvements that have occurred on the designated applicable.
Table 63-2. Main Rotor Drive System Major Changes
HELICOPTER S/N COMPONENT AND PART NUMBER MAJOR CHANGE
4 through 583 Transmission 206-040-002-005 Original, with five changes
584 through 913 Transmission 206-040-002-015 Main case with two chip detectors
914 through 1251 Transmission 206-040-002-013 Filter assembly – cartridge type
1252 and subsequent Transmission 206-040-002-025 Four pinion planetary and electric chip
detectors
Spares Transmission 206-040-002-029 Grease lubricated sun gear and magnetic

carbon input seal
4 through 517 Freewheel assembly 206-040-230-013 Original
518 through 913 Freewheel assembly 206-040-230-019 Non-vented
914 through 1413 Freewheel assembly 206-040-230-025 Housing with union and drain plug, and
improved sprag clutch from S/N 989
through 1413
1414 and subsequent Freewheel assembly 206-040-270-003 Increased cap size for rotor brake installation
and incorporation of electric chip detector
63-00-00
Page 6 Rev. 9 27 SEP 2010 ECCN EAR99
206AB_MM_63_0001
Figure 63-1. Main Rotor Drive System Components
63-00-00
ECCN EAR99 27 SEP 2010 Rev. 9 Page 7
Figure 63-2. Transmission System Troubleshooting (Sheet 1 of 3)
63-00-00
Page 8 Rev. 6 7 DEC 2009 ECCN EAR99
63-00-00
ECCN EAR99 7 DEC 2009 Rev. 6 Page 9
206AB_MM_63_0002c
63-00-00
Figure 63-3. Main Driveshaft Troubleshooting (Sheet 1 of 2)
63-00-00
Figure 63-3. Main Driveshaft Troubleshooting (Sheet 2 of 2)
63-00-00
206AB_MM_63_0004
Figure 63-4. Freewheel Assembly Troubleshooting
63-00-00
63-5. OIL CONTAMINATION OF TRANSMISSION 2. Check for steel particles with permanent magnet.
DRIVE SYSTEM COMPONENTS The magnet will attract steel particles only.
Particles of foreign material found in transmission chip 3. Check for silver particles as follows:
detectors, oil monitor magnetic plug, transmission
filter, freewheel assembly chip detector, or in oil
drained from the system may indicate that one or more
NOTE
parts have failed. These particles are not necessarily
an indication that the component is no longer Use of any chemical product to remove
serviceable. The quantity, source, form, types of silver plating is not permitted. Remove
material found, and the service history of the loose silver plating using abrasive pad
component must be considered. The service time (C-407).
accumulated since new or overhaul, previous failures,
and the type of operation are important factors in a. Place a small quantity of the 50% nitric acid
determining the further serviceability of the (C-432) and water solution in a test tube, then add a
component. The particles may be steel, silver, particle of material to be tested. If particle does not
aluminum, magnesium, bronze, or phenolic. Refer to dissolve, warm solution slightly. If particle dissolves
paragraph 63-6 for identification of foreign materials. after warming, add a few drops of the 5% sodium
chloride (C-501) and water solution. If white precipitate
63-6. IDENTIFICATION OF FOREIGN forms in the test tube, the particle being tested is
MATERIALS silver.
b. Silver plating flakes found in filter during

MATERIALS REQUIRED inspection is not cause for rejection of transmission. If
silver flakes are found, change oil, change filter, clean
Refer to BHT-ALL-SPM for specifications. oil screen, flush transmission and fill with approved
transmission oil (Chapter 12). Silver plating is a soft
NUMBER NOMENCLATURE material used as an additional lubricant for gear
meshing and, therefore, is not detrimental to
C-407 Abrasive Pad transmission.
C-431 Hydrochloric Acid
4. Check for aluminum particles as follows:
C-432 Nitric Acid
C-501 Sodium Chloride a. Place a small amount of hydrochloric acid

(C-431) in a test tube and add a particle of the material
to be tested. If the solution releases bubbles rapidly,
1. Inspect particles visually (Figure 63-6). If particles the particle disintegrates, and a black residue forms,
cannot be recognized by color and hardness, perform the particle being tested is probably aluminum or
tests outlined in step 2 through step 5. The following magnesium.
equipment is required to perform tests:
b. Place a small amount of nitric acid (C-432)
• Permanent magnet solution in a test tube and add a second particle of the
same material. If there is no reaction with the nitric
• 50% by volume nitric acid (C-432) and water acid, the particle is probably aluminum.
solution
5. Differentiate between copper and bronze by
• 5% by weight sodium chloride (C-501) and placing a small amount of nitric acid (C-432) solution
water solution in a test tube and adding a particle of the material to
be tested. If a bright green color is formed in the acid,
• Hydrochloric acid (C-431) particle is copper or bonze. If there is a rapid emission
of bubbles when particle is dropped into the acid, the
• Test tube particle is probably magnesium.
63-00-00
PYLON WHIRL INSPECTION

EXAMINE DRAG PIN FOR DAMAGE
PILOT REPORTS ANY OF THE AND SECURITY OF ATTACHMENT.
1
FOLLOWING CONDITIONS:
2
AN ABNORMAL LANDING
EXCESSIVE SLOPE LANDING

IS THE DRAG PIN DAMAGED? 2
THE HELICOPTER WAS
OPERATED IN SEVERE YES NO
TURBULENCE IF DRAG PIN IS DAMAGED OR
LOW ROTOR RPM DURING ATTACHING HARDWARE IS
LOOSE, REMOVE DRAG PIN AND
FLIGHT
PERFORM MPI TO DRAG PIN PER
APPLICATION OF EXTREME AND BHT-ALL-SPM, CHAPTER 6.
RAPID CYCLIC CONTROL INPUT
EXAMINE ISOLATION MOUNT FOR
OR DAMAGE CAUSED BY CONTACT
IF ANY OF THE DRAG PIN FROM MAIN DRIVESHAFT.
VISUAL EXAMINATION REVEALS ATTACHMENT STUDS ARE
SUPPORT 206-031-510 MAY BE DAMAGED BEYOND LIMITS,
DAMAGED FROM CONTACT WITH REPLACE ALL 4 STUDS. REFER IS ISOLATION MOUNT DAMAGED?
DRAG PIN (“SPIKE KNOCK”) TO BHT-206B3-CR&O.
MAIN DRIVESHAFT COUPLING YES NO
HAS CONTACTED THE
ISOLATION MOUNT
IF DRAG PIN ATTACHMENT STUD IS ISOLATION MOUNT DAMAGED
THREADS IN LOWER CASE ARE BEYOND LIMITS? EXAMINE MAIN ROTOR PITCH
DAMAGED, CONTACT BELL
YES NO LINKS FOR CONTACT WITH THE
HELICOPTER PRODUCT SUPPORT
READ OPERATIONS SAFETY COWLING.
ENGINEERING TO DETERMINE
NOTICE 206-84-13. THE POSSIBILITY OF REPAIR.
OVERHAUL THE MAIN
DRIVESHAFT. IS CONTACT WITH COWLING
EXAMINE SUPPORT 206-031-510 EVIDENT?
FOR DAMAGE FROM CONTACT YES NO
WITH DRAG PIN.
2
FOR GREASE COUPLING MAIN FOR US ARMY MODEL TH-67 FOR GREASE COUPLING MAIN FOR US ARMY MODEL
DRIVESHAFTS, PAY PARTICULAR TRAINING HELICOPTERS WITH DRIVESHAFTS, DISASSEMBLE TH-67 TRAINING IF CONTACT WITH COWLING IS CONTINUE ON
ATTENTION FOR HARD CONTACT KAFLEX MAIN DRIVESHAFT MAIN DRIVESHAFT ASSEMBLY. HELICOPTERS WITH EVIDENT, PERFORM THE SHEET 2
IS SUPPORT DAMAGED? 2 MARKS (INDENTATIONS) AND OR INSTALLED, REFER TO KAMATICS KAFLEX MAIN FOLLOWING:
CHIPPED TEETH ON THE INNER CORPORATION INSTRUCTIONS DRIVESHAFT INSTALLED,
OVERHAUL BOTH PITCH
YES NO AND OUTER DRIVESHAFT FOR CONTINUED REFER TO KAMATICS
PERFORM AN MPI ON THE CORPORATION LINKS.
COUPLINGS. AIRWORTHINESS (ICA).
REFER TO BHT-206B3-CR&O. FORWARD OUTER COUPLING INSTRUCTIONS FOR OVERHAUL SWASHPLATE
PER BHT-ALL-SPM, CHAPTER 6. CONTINUED
ASSEMBLY. (VERIFY THAT
AIRWORTHINESS (ICA).
REPAIR OR REPLACE THE SWASHPLATE OUTER
IF THE KAFLEX DRIVESHAFT IS RING EARS ARE IN
SUPPORT 206-031-510 OR INSTALLED AND CONTACT IS
ADJACENT PARTS IN ARE HARD CONTACT MARKS VISUALLY INSPECT REMAINING ALIGNMENT WITH EACH
MADE WITH THE ISOLATION DRIVESHAFT ASSEMBLY AND OTHER).
ACCORDANCE WITH (INDENTATIONS) AND/OR MOUNT CAUSING DAMAGE TO
BHT-206-SRM-1. CHIPPED TEETH IDENTIFIED? REASSEMBLE.
THE ISOLATION MOUNT AND TO OVERHAUL SWASHPLATE
REFER TO BHT-206B3-CR&O.
YES NO THE SERMETAL COATING ON THE DRIVE ASSEMBLY (COLLAR
KAFLEX DRIVESHAFT, OVERHAUL SET, IDLER LEVER, AND
THE FREEWHEEL ASSEMBLY. IDLER LINK). REFER TO
REFER TO BHT-206B3-CR&O. BHT-206B3-CR&O.
OVERHAUL THE FREEWHEELING
ASSEMBLY.
REFER TO BHT-206B3-CR&O.
IF PITCH LINK CLEVISES
CONTACTED THE OUTER RING
OR COWL:
REMOVE CLEVISES.
EXAMINE FOR DAMAGE.
PERFORM FPI PER

BHT-ALL-SPM, CHAPTER 6.
206A/B_MM_63_0005a
Figure 63-5. Pylon Whirl Inspection (Sheet 1 of 3)
63-00-00
CONTINUED FROM SHEET 1
EXAMINE SWASHPLATE FOR

CONTACT OF INNER RING TO THE
SLEEVE.
HAS NR TACH GENERATOR MADE
CONTACT WITH THE
TRANSMISSION DECK OR THE
IS THERE CONTACT WITH THE
LEFT-HAND CYCLIC BELLCRANK
SLEEVE?
SUPPORT?
YES NO YES NO
IF THE INNER RING CONTACTED EXAMINE THE MAST FOR IF APPLICABLE, REPAIR EXAMINE MAST FOR SEVERE
THE SLEEVE CAUSING CONTACT WITH THE UPPER TRANSMISSION DECK IN CONTACT WITH MAIN ROTOR
DEFORMATION OF THE SLEEVE, INSIDE DIAMETER OF THE ACCORDANCE WITH HUB STATIC STOPS.
THE SWASHPLATE SLEEVE IS SWASHPLATE SUPPORT. BHT-206-SRM-1. 3
CONSIDERED UNSERVICEABLE
AND SHALL BE DISCARDED.
OVERHAUL THE SWASHPLATE IS CONTACT WITH SWASHPLATE IF APPLICABLE, PERFORM AN FPI
ASSEMBLY. REFER TO SUPPORT EVIDENT? ON THE LEFT-HAND CYCLIC IS THERE ANY DAMAGE TO
BHT-206B3-CR&O. YES NO BELLCRANK SUPPORT THE MAST? 3
206-001-544 PER BHT-ALL-SPM,
CHAPTER 6. REFER TO YES
BHT-206A/B-SERIES-MM. NO
IF MAST CONTACTED THE IF SEVERE CONTACT IS

EXAMINE ALL FLIGHT CONTROLS REMOVE AND EXAMINE NR TACH
SWASHPLATE SUPPORT, THE IDENTIFIED, DISASSEMBLE MAST
FROM THE HYDRAULIC SERVOS GENERATOR AND HYDRAULIC
SWASHPLATE SUPPORT IS ASSEMBLY. VISUALLY INSPECT EXAMINE MAIN ROTOR BLADES
TO THE SWASHPLATE FOR PUMP FOR CONDITION.
CONSIDERED UNSERVICEABLE AND PERFORM A FOR DAMAGE, VOIDS,
CONDITION. REFER TO EXAMINE ACCESSIBLE PART OF
AND SHALL BE DISCARDED. TOTAL INDICATED RUN-OUT (TIR) DELAMINATION, OR
BHT-206A/B-SERIES-MM. TRANSMISSION OIL PUMP FOR
REFER TO BHT-206B3-CR&O. OF THE MAST POLE. DEFORMATION. PAY PARTICULAR
DAMAGE AND SECURITY OF REFER TO
ATTACHMENT. ATTENTION TO THE DOUBLERS
BHT-206A/B/L-SERIES-CR&O. FOR SEPARATION.
REPLACE DAMAGED PARTS IN
DISASSEMBLE MAST ASSEMBLY. ARE THERE ANY DAMAGED ACCORDANCE WITH
VISUALLY INSPECT AND FLIGHT CONTROLS ? BHT-206A/B-SERIES-MM.
IS THE MAST POLE BEYOND TIR IS THERE ANY DAMAGE TO THE
PERFORM A TOTAL INDICATED LIMITS? MAIN ROTOR BLADES?
YES NO
RUN-OUT (TIR) OF THE
MAST POLE. YES NO YES NO
REFER TO
BHT-206A/B/L-SERIES-CR&O.
THE MAST POLE IS CONSIDERED IF DAMAGE IS BEYOND THE CONTINUE
OVERHAUL THE MAST
UNSERVICEABLE AND LIMITS STATED IN ON SHEET 3
ASSEMBLY.
SHALL BE SCRAPPED. BHT-206A/B-SERIES-MM
REFER TO
REFER TO CHAPTER 62, CONTACT A BELL
BHT-206A/B/L-SERIES-CR&O.
REPLACE ALL AFFECTED PARTS BHT-206A/B/L-SERIES-CR&O. HELICOPTER APPROVED ROTOR
THAT ARE DAMAGED BEYOND BLADE REPAIR FACILITY
LIMITS. REFER TO FOR REPAIR.
BHT-206A/B-SERIES-MM. OVERHAUL THE MAST
ASSEMBLY.
REFER TO
BHT-206A/B/L-SERIES-CR&O. CONTINUE
ON SHEET 3
OVERHAUL TRANSMISSION
ASSEMBLY.
REFER TO
BHT-206B3-CR&O.
206A/B_MM_63_0005b_c01
63-00-00
Page 16 Rev. 12 1 JUN 2012 ECCN EAR99
CONTINUED FROM SHEET 2
EXAMINE AFT FUSELAGE

FOR WRINKLES, WAVINESS,
DISTORTION, AND LOOSE
FASTENERS.
VERIFY THE FIT OF THE EXAMINE TAIL ROTOR HUB AND
TAILBOOM ACCESS DOOR. BLADE ASSEMBLY FOR
EXAMINE TAILBOOM, CONDITION.
PAY PARTICULAR ATTENTION TO
VERTICAL FIN, STINGER
THE BUMPER, STATIC STOP,
AND HORIZONTAL
AND YOKE.
STABILIZER FOR
DISTORTION, COMPRESSION
WRINKLES, OR OTHER
DAMAGE. IS BUMPER STATIC STOP OR
YOKE DAMAGED?
YES NO
IS THERE ANY DAMAGE
IDENTIFIED ON THE AFT
FUSELAGE OR TAILBOOM?
YES NO
REMOVE TAIL ROTOR HUB AND EXAMINE LANDING GEAR
BLADE ASSEMBLY FROM THE CROSSTUBES, CROSSTUBE
TAIL ROTOR GEARBOX. ATTACHMENTS, AND
ATTACHMENT AREA ON THE
REMOVE TAILBOOM AND EXAMINE TAIL ROTOR GEARBOX SKIDS AND AIRFRAME FOR
EXAMINE THE ATTACHMENT AND PERFORM A TORQUE CHECK DAMAGE OR DISTORTION.
FITTINGS ON THE FUSELAGE AND REMOVE TAIL ROTOR BLADES
ON THE GEARBOX ATTACHMENT
TAILBOOM FOR CRACKS AND FROM THE YOKE ASSEMBLY.
NUTS. REFER TO
LOOSE FASTENERS. REFER TO BHT-206A/B-SERIES-MM.
BHT-206A/B-SERIES-MM.
CLEAN AND EXAMINE THE TAIL IS THERE ANY DAMAGE
ROTOR HUB ASSEMBLY AND TAIL IDENTIFIED?
ARE ANY OF THE GEARBOX ROTOR BLADES FOR CONDITION.
REMOVE UPPER ACCESS COVER ATTACHMENT NUTS LOOSE? YES NO
REFER TO
IN THE BAGGAGE
YES NO BHT-206A/B-SERIES-MM.
COMPARTMENT AND INSPECT
BOTH UPPER LONGERONS IN THE
IF DAMAGE TO THE AIRFRAME IS IF NO DAMAGE IS IDENTIFIED,
AREA OF THE ENGINE MOUNTS.
FOUND, REPAIR IN ACCORDANCE THE PYLON WHIRL INSPECTION
REFER TO REMOVE TAIL ROTOR GEARBOX
WITH THE BHT-206-SRM-1. IS COMPLETE.
BHT-206A/B-SERIES-MM. AND INSPECT FOR DAMAGED OR
LOOSE STUDS AND PINS.
REPLACE ALL DAMAGED STUDS
OR PINS. REFER TO
IF DAMAGE TO ANY CROSSTUBE
REPAIR DAMAGE IN BHT-206A/B-SERIES MM AND
IS FOUND, PERFORM THE
ACCORDANCE WITH BHT-206B3-CR&O.
CROSSTUBE DEFLECTION
BHT-206-SRM-1.
INSPECTION IN ACCORDANCE
WITH
BHT-206A/B-SERIES-MM,
INSPECT TAIL ROTOR GEARBOX CHAPTER 32.
ATTACHMENT AREA ON THE
TAILBOOM FOR DAMAGE. REFER
TO BHT-206B3-CR&O AND
BHT-206-SRM-1. IF DAMAGE TO ANY CROSSTUBE
IS BEYOND LIMITS, PERFORM A
HARD LANDING INSPECTION IN
NOTES ACCORDANCE WITH
1 Pilot may also report intermittent noises and/or vibrations. BHT-206A/B-SERIES-MM,
CHAPTER 5.
2 Slight paint or cadmium removal is not considered damage.
3 Paint or cadmium removal damage is not considered severe contact. Any distortion of the parent material is considered
severe contact. THE PYLON WHIRL INSPECTION
IS COMPLETE.
206A/B_MM_63_0005c
63-00-00
Figure 63-6. Corrective Action for Contamination Found on Oil Monitor/Chip Detectors (Sheet 1 of 2)
63-00-00
Figure 63-6. Corrective Action for Contamination Found on Oil Monitor/Chip Detectors (Sheet 2 of 2)
63-00-00
63-7. OIL CONTAMINATION OF

NOTE
TRANSMISSION
For special inspection and cleaning of
restrictor (206-040-244-001 or 206-040-
254-001), and filter (50-075-1), refer to part-
WARNING
III of ASB 206-14-132.
4. Thoroughly flush all oil lines leading to and from

IF FOREIGN PARTICLES ARE LARGE oil cooler and freewheel assembly that are to be
ENOUGH TO BE IDENTIFIED AS PART reused. Inspect and clean oil filter (50-075-1) in supply
OF A COMPONENT OF THE line to freewheel assembly (located in fluid fitting at
TRANSMISSION OR MAST BEARING, transmission). Clean restrictor in oil supply line.
R E P L A C E T H E T R A NS M I SS I O N O R
MAST BEARING AS INDICATED BY THE 5. Disassemble and clean oil filter housing (BHT-
LOCATION OF THE PARTICLE. 206A/B-M&O or BHT-206B3-CR&O), and install new
filter element (paragraph 63-54 and paragraph 63-55).
Remove, clean, and install oil monitor magnetic plug
CAUTION (paragraph 63-38 through paragraph 63-40).
6. Disassemble and clean freewheel assembly

WHEN TRANSMISSION OIL IS (BHT-206A/B-M&O or BHT-206B3-CR&O).
CONTAMINATED, THE OIL COOLER AND
FREEWHEEL ASSEMBLY MAY ALSO BE 63-8. OIL CONTAMINATION OF FREEWHEEL
CONTAMINATED. THE TRANSMISSION ASSEMBLY
OIL FILTER WILL NORMALLY PRECLUDE
THIS, B U T I F T H E O I L F I LT E R H A S
C L O G G E D E N O U G H TO C A U S E
BYPASSING, THEN CONTAMINATION OF WARNING
THESE COMPONENTS AND
ASSOCIATED OIL LINES CAN OCCUR.
IF FOREIGN PARTICLES ARE LARGE
Some transmissions are equipped with a collector pan ENOUGH TO BE IDENTIFIED AS PART
and chip detector immediately under the upper mast OF A COMPONENT OF THE
bearing, and a second chip detector in the sump. As a FREEWHEEL ASSEMBLY, REPLACE THE
result, it is possible to isolate the source of metal FREEWHEEL ASSEMBLY (PARAGRAPH
particles to either the transmission or the main rotor 63-69 THROUGH PARAGRAPH 63-72).
mast assembly. If chips are found on the upper chip
detector, but not on the lower, a mast bearing problem
is indicated. If chips are found on the lower chip CAUTION
detector, but not on the upper, a transmission problem
is indicated.
I F F O R E I G N PA R T I C L E S A R E
1. Identify foreign particles found in transmission oil DIS COVE RED IN THE FREE WHE EL
(paragraph 63-6). ASSEMBLY, THE TRANSMISSION MAY
OR MAY NOT BE CONTAMINATED.
2. Take corrective action for contamination of
transmission system (Figure 63-2).
NOTE
3. Remove and replace oil cooler, and identify For special inspection and cleaning of
removed oil cooler as being contaminated (paragraph restrictor (206-040-244-001 or 206-040-
63-57). 254-001), and filter (50-075-1), refer to part-
III of ASB 206-14-132.
63-00-00
1. Identify particles found in the freewheel assembly a. Remove, inspect, clean, and install chip
oil (paragraph 63-6). detectors and oil monitor magnetic plug
(paragraph 63-38 through paragraph 63-40).
2. Take corrective action for contamination of
freewheel assembly (Figure 63-4). b. Drain lubricating oil from transmission into a
clean and, if possible, clear container (Chapter 12).
63-9. TRANSMISSION SERVICEABILITY CHECK

c. Inspect lubricating oil for foreign material
(paragraph 63-6).
1. Drain lubricating oil from transmission into a
clean and, if possible, clear container (Chapter 12).
d. If this inspection is being conducted because
of metal particle contamination and the number of
2. Remove, inspect, clean, and install chip detectors metal particles has increased, or if any particles are
and oil monitor magnetic plug (paragraph 63-38 found which are large enough to be identified as chips
through paragraph 63-40). from a gear or bearing, replace the transmission
(paragraph 63-22 through paragraph 63-25). If the
3. Inspect drained oil for metal particles. Identify any number of particles has decreased and only minute
particles found (paragraph 63-6). Perform corrective particles are found, repeat step 1 through step 8. If
action (Figure 63-2). particles are found, remove transmission and
freewheel assembly and repair or overhaul as required
4. Remove and inspect transmission oil filter (BHT-206A/B-M&O or BHT-206B3-CR&O).
element (paragraph 63-54 and paragraph 63-55) to
determine the extent of entrapped contaminants, and 63-10. FREEWHEEL ASSEMBLY
for damage to element. SERVICEABILITY CHECK
a. If gross contamination of filter element is 1. Drain lubricating oil from freewheel assembly and
found, replace oil cooler (paragraph 63-57) and collect in a clean and, if possible, clear container
identify as being contaminated. Thoroughly flush all oil (Chapter 12).
lines, leading to and from oil cooler and freewheel
assembly, that are to be reused. Remove and inspect
freewheel tube restrictor on left side of cabin roof.
CAUTION
b. If only minor contamination of filter element is
found, the procedures outlined in step a are not I F F O R E I G N PA R T I C L E S A R E
required. Install new filter element. Remove, inspect, DISCOVERED IN THE FREEWHEEL
and reinstall oil jets (paragraph 63-46, ASSEMBLY, THE TRANSMISSION AND
paragraph 63-47, and paragraph 63-48) and MAST BEARING MAY OR MAY NOT BE
freewheel tube restrictor on left side of cabin roof. CONTAMINATED.
5. Remove, inspect, clean, and reinstall oil pump 2. Remove, inspect, clean, and install chip detector
inlet screen (paragraph 63-34 through (paragraph 63-38 through paragraph 63-40).
paragraph 63-36).
3. Inspect drained oil for metal particles. Identify any
particles found (paragraph 63-6). Perform corrective
6. Remove, inspect, clean, and reinstall filter
action (Figure 63-4).
(50-075-1) located at oil pressure outlet on
transmission at pressure regulator boss.
4. Inspect transmission oil filter for metal particles.
Identify any particles found (paragraph 63-6). Perform
7. Fill transmission to proper level with approved corrective action (Figure 63-4).
transmission oil (Chapter 12).
5. Thoroughly flush return hose from freewheel
8. Do an operational check (Paragraph 63-27). assembly to transmission. Flush return hose with
Accomplish the following at completion of run: clean, approved lubricating oil (Chapter 12).
63-00-00
6. Fill transmission to proper level with approved MAINTENANCE ON ANOTHER

lubricating oil (Chapter 12). C O M P O N E N T, L U B R I C AT I O N O F
A S S E M B LY I S N O T R E Q U I R E D .
7. Do an operational check (Paragraph 63-73). COMPRESS OUTER SPHERICAL
Accomplish the following after completion of run: C O U P L I N G S O N LY E N O U G H T O
RELEASE FROM MATING ADAPTER
FLANGES.
a. Remove, inspect, clean, and install chip
detector (paragraph 63-38 through paragraph 63-40).
4. Remove nuts (6), steel washers (5), and bolts (4)
attaching forward outer coupling (8 or 9) to
b. Drain 1 quart (0.9 L) of lubricating oil from
transmission adapter flange.
freewheel assembly and collect in a clean and, if
possible, clear container (Chapter 12).
5. Remove nuts (6), steel washers (5), and bolts (4)
c. Inspect drained oil for metal particles. Identify attaching aft outer coupling (8 or 9) to freewheel
any particles found (paragraph 63-6). Perform assembly (7).
corrective action (Figure 63-4).
6. Push aft on main driveshaft (10) to compress
d. If this inspection is being conducted because spring in aft outer coupling (8 or 9) and obtain
of metal particle contamination and the number of clearance between forward outer coupling (8 or 9) and
metal particles has increased, or if any particles are transmission adapter flange. Move forward end of
found which are large enough to be identified as chips main driveshaft outboard to clear transmission adapter
from a bearing, clutch, or shaft, replace freewheel flange. Move main driveshaft forward, passing aft
assembly (paragraph 63-69 through outer coupling through opening and remove main
paragraph 63-15). If the number of particles has driveshaft from helicopter.
decreased and only minute particles are found, fill
transmission to proper level with approved 7. If main driveshaft (10) does not require
transmission oil (Chapter 12), and release helicopter disassembly, cut strips of cardboard or wood of
for continued operation. sufficient length to fit between the two outer couplings
(8 or 9). Place material on shaft and secure with
63-11. MAIN DRIVESHAFT masking tape. This will aid in preventing the collapse
of outer couplings.
A driveshaft with splined couplings is installed
between the freewheel assembly and the adapter 63-13. MAIN DRIVESHAFT — CLEANING
flange on transmission input quill.
63-12. MAIN DRIVESHAFT — REMOVAL MATERIALS REQUIRED
1. Remove cowling for access to main driveshaft Refer to BHT-ALL-SPM for specifications.
(10, Figure 63-7) (Chapter 71).
NUMBER NOMENCLATURE
2. Remove main driveshaft cover (3). C-304 Drycleaning Solvent
3. Remove main driveshaft door (2) from aft side of C-516 Clean Cloth
forward firewall (1).
1. Clean exterior metal surfaces of main driveshaft

(10, Figure 63-7) with drycleaning solvent (C-304).
CAUTION
2. Dry parts with filtered, compressed air.
IF MAIN DRIVESHAFT IS BEING
REMOVED TO FA C I L I TAT E 3. Clean rubber seals with a clean cloth (C-516).
63-00-00
206AB_MM_63_0006
Figure 63-7. Main Driveshaft Assembly
63-00-00
Export Classification C, ECCN EAR99 7 DEC 2009 Rev. 6 Page 23
63-14. MAIN DRIVESHAFT — INSPECTION damage or degradation of the epoxy overcoating, the
helicopter may be returned to service.
MATERIALS REQUIRED e. The discrepant TEMP-PLATE should be

replaced as soon as practical (BHT-206B3-CR&O). If
Refer to BHT-ALL-SPM for specifications. any indicator dot on any red or yellow bordered 6000-1
or 6000-3 TEMP-PLATE has changed color to black,
NUMBER NOMENCLATURE refer to Table 63-3 for probable cause and required
action.
C-204 Epoxy Polyamide
Primer f. Check TEMP-PLATES for evidence of
elevated temperature indication (Table 63-3).
C-464 India Stone
g. Check for deteriorated, debonded, or missing
1. Visually inspect main driveshaft (10, Figure 63-7) TEMP-PLATES (Figure 63-8).
for damage, corrosion, and surface damage. Check
for freedom and smoothness of axial movement. h. Check for excessive discoloration of the epoxy
overcoating.
2. Visually inspect main driveshaft (10) input area
for evidence of oil leakage and outer coupling (8 or 9) i. Inspect parts for nicks and scratches.
for overheating or grease leakage. Maximum limits are 0.002 inch (0.051 mm) deep
around entire circumference, or 0.005 inch (0.127 mm)
deep around axial or circumferential but not longer
3. Inspect outer couplings (8 or 9) with
than 25% of circumference.
overtemperature indicator (TEMP-PLATE) as follows:
j. Dress out acceptable nicks and scratches with

a. Overtemperature indicator dots on the abrasive cloth or paper, or an India stone (C-464), as
TEMP-PLATE are of a white or light gray and turn required. Apply epoxy polyamide primer (C-204) to
black when exposed to an overtemperature condition. external repaired areas.
Chemical contamination can also cause the indicating
dots to turn black.
63-15. MAIN DRIVESHAFT — INSTALLATION
b. TEMP-PLATES have a shelf life of 2 years

1. Place main driveshaft (10, Figure 63-7) through
from date of manufacture when stored under the
opening in forward firewall (1) and position in place
following conditions: 40 to 80°F (4 to 27°C). Relative
between transmission adapter flange and freewheel
humidity: 50% maximum. Storage under other
assembly (7).
conditions may result in reduced shelf life of the
TEMP-PLATES. Use of TEMP-PLATES with expired
shelf life may result in false coupling overtemperature 2. Align attachment bolt holes of aft outer coupling
indications. TEMP-PLATES must be installed (8 or 9) and flange of freewheel assembly (7). Install
(BHT-206B3-CR&O) and helicopter returned to bolts (4) with heads inboard through outer coupling
service before expiration of shelf life of into freewheel assembly. Install two steel washers (5)
TEMP-PLATES. on shank of each bolt (4). Install nuts (6) T .
c. TEMP-PLATE serviceability check: 3. Secure forward outer coupling (8 or 9) to

TEMP-PLATES must not show evidence of transmission adapter flange in the same manner as
overtemperature, deterioration, debonding, or step 2.
discoloration of the epoxy coating that prevents
interpretation of the indicating dots (Table 63-3).
NOTE
d. If only one TEMP-PLATE of a given color is If main driveshaft cover is deformed, it
missing, and no dot on any other TEMP-PLATE (on could contact driveshaft seal. Ensure
the same coupling) is discolored or shows mechanical proper clearance.
63-00-00
Page 24 Rev. 6 7 DEC 2009 Export Classification C, ECCN EAR99
Table 63-3. TEMP-PLATE Condition and Corrective Action
ONE YELLOW OTHER YELLOW ONE RED OTHER RED

PROBABLE CAUSE
TEMP-PLATE TEMP-PLATE TEMP-PLATE TEMP-PLATE
1 Good Black Good Good Defect/installation
2 Black Black Good Good Elevated Temperature
1 Good Good Black Good Defect/installation
4 Good Good Black Black Defect/installation
3 Black Black Black Black Overtemperature
1 Part Black Good Good Good Chemical

contamination
1 Part Black Part Black Good Good Chemical

contamination
1 Good Good Part Black Good Chemical

contamination
4 Good Good Part Black Part Black Chemical

contamination
1 Missing Good Good Good Defect/installation
2 Missing Missing Good Good Possible elevated

temperature
1 Good Good Missing Good Defect/installation
NOTES:
1 Resume operation. Defective TEMP-PLATE or improper installation, replace defective TEMP-PLATE as

soon as practical (BHT-206B3-CR&O).
2 Elevated coupling temperature is indicated. Determine probable cause of elevated temperature indication
and take corrective action before continued operation. Accomplish checks in step a and step b. If
probable cause is not revealed from step a and step b, perform step c and step d. Replace affected
TEMP-PLATE (BHT-206B3-CR&O).
a. Check driveshaft coupling for any sign of grease leakage. If leakage is detected, the coupling must be
serviced before returning to service.
b. Review current operating conditions to determine probable cause of elevated coupling temperature. For
example: extended operation at CG limits, extended operation at high power, repeated heavy lift, or high
ambient temperature. Make appropriate adjustment to correct condition.
c. Examine engine mounts (Chapter 71) and transmission mounts (Chapter 63) for condition and security.
d. Verify engine-to-transmission alignment by comparing original Bell Helicopter shim stack-up of

transmission and engine mounts with installed shims. (Use shim values determined by the repair station if
a fixture restoration has been accomplished).
63-00-00
Table 63-3. TEMP-PLATE Condition and Corrective Action (Cont)
NOTES: (CONT)
3 Coupling overtemperature condition is very likely. Remove main driveshaft or outer couplings, and
perform overtemperature inspection (BHT-206B3-CR&O). Scrap affected male and female couplings if
any of the following conditions exist, or if required by the manual inspection criteria (BHT-206B3-CR&O):
• Cadmium plating on the outer coupling is discolored (circumferential tan or light brown band) or
blistered.
• Gear teeth of either coupling are discolored (brown or blue) in normally bright contact patterns.
• Under 5 to 10X magnifying glass, the surfaces of the gear teeth of either the inner or the outer coupling
exhibit signs of metal smearing or tearing in the contact patterns.
• Grease is very viscous (thick) and has a strong pungent odor.
• If none of the preceding conditions exist, the coupling may be reassembled (BHT-206B3-CR&O) and
returned to service following replacement of the TEMP-PLATES.
4 Same as 1 , except during operations before TEMP-PLATE replacement, a yellow bordered

TEMP-PLATE indication shall be considered as an overtemperature indication and 2 and 3
shall be accomplished.
4. Install main driveshaft door (2) and main helicopter, the main rotor mast assembly
driveshaft cover (3) on aft side of forward firewall (1) may be removed after transmission is
and secure with screws. removed.
5. Install cowling (Chapter 71). 1. Remove cowling for access to transmission and
flight controls (Chapter 71).
6. Following installation of a new main
driveshaft (10), or one that has been disassembled for 2. Remove main rotor assembly (Chapter 62).
inspection, ground run the helicopter (refer to
applicable JetRanger Flight Manual) for 20 minutes
3. Remove flight controls from main rotor mast
and inspect main driveshaft and structure around both
assembly (6) (Chapter 62).
of the outer couplings (8 or 9) for evidence of grease
leakage. If evidence of leakage is found, disassemble
the driveshaft (BHT-206B3-CR&O) and inspect to 4. Remove nuts (5), lanyard bracket (4),
determine the cause of the leakage (Figure 63-3). spacers (3), and washers (2) attaching transmission
mast plate and liner and top case (8).
63-16. MAIN ROTOR MAST
5. Remove swashplate assembly from main rotor
The main rotor mast drives the rotor and support mast assembly (6) (Chapter 62).
components required for directional changes.
6. Lift main rotor mast assembly (6) from
63-17. MAIN ROTOR MAST — REMOVAL transmission.
NOTE 7. Remove packing (7) from groove in transmission

Main rotor mast assembly (6, Figure 63-9) top case (8). Discard packing.
may be removed from transmission while
transmission is mounted on helicopter. 8. Cover opening in transmission top case (8) to
When transmission is to be removed from prevent foreign matter from falling into transmission.
63-00-00
Figure 63-8. Main Driveshaft Overtemperature Indicators (Sheet 1 of 3)
63-00-00
63-00-00
206AB_MM_63_0007c
63-00-00
Figure 63-9. Main Rotor Mast Assembly
63-00-00
63-18. MAIN ROTOR MAST — CLEANING MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.

MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-328 Sealant
NUMBER NOMENCLATURE
1. Remove cover from transmission top case (8,
C-304 Drycleaning Solvent Figure 63-9).
1. Clean all parts of main rotor mast assembly (6, 2. Thoroughly inspect internal area of transmission
Figure 63-9) and splines with drycleaning solvent for any foreign material.
(C-304).
3. Apply sealant (C-328) to all faying surfaces,
2. Dry with filtered compressed air.
lubricate packing (7) with approved transmission oil
(Chapter 12) and position in groove in bearing
63-19. MAIN ROTOR MAST — INSPECTION liner (3).
MATERIALS REQUIRED NOTE
Refer to BHT-ALL-SPM for specifications. Before installing main rotor mast assembly,
pour one quart of approved transmission oil
NUMBER NOMENCLATURE (Chapter 12) (bathing entire top of
planetary gear) into top of transmission to
C-464 India Stone lubricate gears and splines with a thin
coating of oil.
1. Visually inspect all parts of the main rotor mast
4. Position main rotor mast assembly (6) through
assembly (6, Figure 63-9) for wear and damage
opening in transmission top case (8). Line up lower
(BHT-206A/B/L-Series-CR&O).
mast spline teeth with spline teeth in planetary spider.
Guide end of mast into lower mast bearing and
2. Inspect splines for chipping, cracks, or wear.
position upper mast bearing liner (3) over mounting
Dress splines with India stone (C-464), if necessary, to
studs in transmission top case. Apply sealant (C-308)
remove burrs or scratches.
around periphery of the mast plate and liner and the
transmission top case. If transmission and mast
3. For overhaul procedure, refer to the
assembly is assembled for storage (with swashplate
BHT-206A/B/L-Series-CR&O.
uninstalled), secure main rotor mast assembly with
washers (2), spacers and nuts (5). Use spacers to
4. Inspect the transmission top case (8)
avoid breaks of studs. Torque the nuts T .
206-040-151, whenever an oil leak is found in the area
of the top case, refer to TB 206-04-73-1.
5. Install swashplate assembly (Chapter 62).
63-20. MAIN ROTOR MAST — INSTALLATION
6. Install flight controls (Chapter 67).
MATERIALS REQUIRED 7. Install main rotor assembly (Chapter 62).

8. Service transmission to proper level with
NUMBER NOMENCLATURE approved transmission oil (Chapter 12).
C-308 Sealant
9. Install cowling (Chapter 71).
63-00-00
63-21. TRANSMISSION tachometer generator, and hydraulic oil

pump installed.
The transmission provides a two-stage reduction of
15.23 to 1.0 (6000 to 394 RPM). The first stage is a 1. Disconnect battery and remove external power, if
bevel gear arrangement with 3.26 to 1.0 reduction. used.
The second-stage reduction is obtained with a
planetary gear train providing 4.67 to 1.0 reduction. A 2. Remove cowling for access to transmission
complete hydraulic system power pack is mounted on (Chapter 71).
the forward side of the transmission case and is driven
by a transmission accessory drive gear. The 3. Remove main rotor assembly (Chapter 62).
accessory drive gear provides 1.42 to 1.0 reduction.
The transmission is mounted on the cabin roof deck, 4. Remove flight controls from main rotor mast
forward of the power plant. The main rotor mast is assembly (Chapter 62).
secured in top of the transmission by the mast
bearing, bearing liner, and seal plate, and is isolated
from the airframe by a system composed of two pylon 5. Remove swashplate assembly (Chapter 62).
support links (one on each side), and a drag link
secured to the bottom of the transmission and 6. Drain lubricating oil from transmission
connected to the rubber isolation support mount on (Chapter 12).
the airframe. A cylindrical boss extends downward
from the forward end of drag link and fits loosely in a 7. Disconnect oil pressure hose (5, Figure 63-10)
hole in the pylon stop mounted on the airframe, from reducer (6) and disconnect oil return hose (9)
providing a positive limit of travel of the pylon. from union (8).
63-22. TRANSMISSION — REMOVAL 8. Remove collective control bellcrank (34)

(Chapter 62).
SPECIAL TOOLS REQUIRED 9. Remove air ducts (1) with clamps (2) from oil
cooler (3).
NUMBER NOMENCLATURE
NOTE
T102102 Dehydrator
Tachometer generator and hydraulic pump
T103140 Cover and Lift may be removed together as a unit.
Assembly
10. Remove tachometer generator (28) and hydraulic
Commercial Clevis oil pump (29) (Chapter 29).
Commercial Hoist 11. If main rotor mast assembly has not been
removed from transmission, perform step a. If main
rotor mast assembly has been removed, perform
MATERIALS REQUIRED step b.
Refer to BHT-ALL-SPM for specifications. a. Install mast nut on top of main rotor mast
assembly. Attach clevis, with bolt, to eye of mast nut
NUMBER NOMENCLATURE and attach hoist.
C-428 Cap and/or Plugs b. Install cover and lift assembly (T103140) to
top of transmission and attach hoist.
NOTE
12. Take up slack in hoist cable and apply only
The transmission may be removed with the sufficient tension to support transmission when pylon
main rotor mast assembly, flight controls, supports and drag pin are disconnected.
63-00-00
SEE DETAIL A
1 T1
T 3
36 T 1
37
35
34
10
T 5
T 2
T 7
APPLICABLE TO
TRANSMISSION
ASSEMBLIES
206-040-002-005 AND -015
T 4
T 6
206AB_MM_63_0009a
Figure 63-10. Transmission Assembly (Sheet 1 of 3)
63-00-00
48 T 5
47
34
APPLICABLE ONLY TO TRANSMISSION ASSEMBLY

206-040-002-005
49 38
50 T 3
39 T 3
51 40
46 35
44 37
45 T 1 34
36 T 1 34
APPLICABLE ONLY TO TRANSMISSION ASSEMBLIES APPLICABLE ONLY TO TRANSMISSION ASSEMBLIES

206-040-002-013 AND -015 206-040-002-025 AND -029
DETAIL A
206AB_MM_63_0009b
63-00-00
1. Air duct 18. Pylon mount 35. Electric chip detector (B-3188B)
2. Clamp 19. Washer 36. Self-closing valve
3. Oil cooler 20. Bolt 37. Packing
4. Main driveshaft 21. Bolt 38. Electric chip detector (B-3182B)
5. Oil pressure hose 22. Washer 39. Self-closing valve
6. Reducer 23. Pylon drag pin assembly 40. Packing
7. Pylon support spindle 24. Pylon stop 41. Electric chip detector (B-551)
8. Union 25. Washer 42. Self-closing valve
9. Oil return hose 26. Nut 43. Packing
10. Radius washer 27. Cotter pin 44. Packing
11. Isolation mount 28. Tachometer generator 45. Self-closing valve
12. Cotter pin 29. Hydraulic oil pump 46. Magnetic chip detector (B-3659)
13. Spindle nut 30. Magnetic plug 47. Packing
14. Radius washer 31. Oil monitor 48. Drain plug (B-148/B-734)
15. Pylon support link 32. Packing 49. Magnetic chip detector (B-3181)
16. Nut 33. Oil pump 50. Self-closing valve
17. Washer 34. Collective control bellcrank 51. Packing
20 TO 60 IN-LBS
T 1 (2.26 TO 6.78 Nm)
30 TO 45 IN-LBS
T 2 (3.39 TO 5.08 Nm)
30 TO 108 IN-LBS
T 3 (3.39 TO 12.20 Nm)
50 TO 290 IN-LBS
T 4 (5.65 TO 32.76 Nm)
75 TO 125 IN-LBS
T 5 (8.47 TO 14.12 Nm)
468 TO 516 IN-LBS

T 6 (52.88 TO 58.30 Nm)
480 TO 690 IN-LBS

T 7 (54.23 TO 77.96 Nm)
NOTE
1 Applicable only to transmission assemblies 206-040-002-027 and -115.
206AB_MM_63_0009c
63-00-00
13. Remove cotter pin (27), nut (26), washers (22

and 25), and bolt (21) securing pylon drag pin CAUTION
assembly (23) to isolation mount (11).
E X E R C I S E C A U T I O N TO P R E V E N T
14. Remove cotter pins (12), spindle nuts (13), and
SOLVENT FROM CONTACTING FLIGHT
radius washers (10 and 14) from pylon support CONTROL SYSTEM SEALED BEARINGS.
spindles (7).
1. Clean transmission with drycleaning solvent
15. Remove bolt (20) from forward leg of one pylon (C-304) and soft bristle brush. Dry with filtered
compressed air.
support link (15). Swing pylon support link outboard
from pylon mount (18), and slide pylon support
spherical bearing from pylon support spindle (7). Shift 63-24. TRANSMISSION — INSPECTION
transmission sideways away from free pylon support
link and slide pylon support spindle out of pylon 1. Inspect pylon support links (15, Figure 63-10)
support spherical bearing. (paragraph 63-62).
2. Inspect isolation mount (11) (paragraph 63-66).

16. Make sure that all flight controls, oil lines,
For detailed inspection and repair procedures, refer to
electrical wiring, and other attachments are BHT-206A/B-M&O or BHT-206B3-CR&O.
disconnected from transmission. Carefully hoist
transmission from airframe, being cautious to clear
63-25. TRANSMISSION — INSTALLATION
components installed on upper part of helicopter.
17. Install caps and/or plugs (C-428) on disconnected SPECIAL TOOLS REQUIRED
hoses and openings.
NUMBER NOMENCLATURE
NOTE
T103140 Cover and Lift
An appropriate log book entry must be Assembly
made upon installation of dehydrator
Commercial Clevis
(T102102).
Commercial Hoist
18. For long term storage, remove and store oil fill
cap and lanyard assembly (1, Figure 63-9) in a sealed
plastic bag. Install dehydrator (T102102) while NOTE
transmission is removed (BHT-ALL-SPM, Chapter 10). When replacing 206-040-002-005, -013, or
-015 transmission with a -025 or -029
63-23. TRANSMISSION — CLEANING transmission, correct helicopter weight and
balance record for the following
(Chapter 8):
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications. TRANSMISSION

WEIGHT ARM MOMENT
REPLACED
NUMBER NOMENCLATURE
206-040-002-005 +11.3 Lb 110 1243
C-304 Drycleaning Solvent (5.125 kg)
63-00-00
holding pylon support link with unattached leg, far

TRANSMISSION enough to one side to permit free movement of
WEIGHT ARM MOMENT
REPLACED transmission.
206-040-002-013 +11.1 Lb 110 1221
(5.034 kg) 8. Install radius washer (14) and spindle nut (13) on
positioned pylon support spindle (7). Tighten nut finger
206-040-002-015 +11.3 Lb 110 1243 tight.
(5.125 kg)
9. Position opposite pylon support spindle (7) in
spherical bearing of opposite pylon support link (15),
NOTE
and install radius washer (14) and spindle nut (13).
The transmission may be installed with the Tighten nut finger tight.
main rotor mast assembly, flight controls,
tachometer generator, and hydraulic oil 10. Install bolt (21), with washer (22), through pylon
pump installed. drag pin assembly (23) and isolation mount (11).
Install washer (25) and nut (26) T . Install cotter pin
1. Remove dehydrator (T102102), if installed, and
(27).
install oil fill cap and lanyard assembly (1,
Figure 63-9).
11. Position unattached leg of pylon support link (15)
into pylon mount (18) and install bolt (20), washers (17
2. If main rotor mast assembly has not been
and 19), and nut (16) T .
removed from transmission, perform step a. If main
rotor mast assembly has been removed, perform
step b. 12. Tighten spindle nuts (13) on pylon support
spindles (7) T . Install cotter pin (12).
a. Install mast nut on top of main rotor mast
assembly. Attach clevis, with bolt, to eye of mast nut 13. Install tachometer generator (28) and hydraulic oil
and attach hoist. pump (29) (Chapter 29).
b. Install cover and lift assembly (T103140) to 14. Connect oil pressure hose (5) to reducer (6).
top of transmission and attach hoist. Connect oil return hose (9) to union (8).
3. Take up slack in hoist cable and apply only 15. Connect air ducts (1) to oil cooler (3) with clamps
sufficient tension to support transmission when pylon (2).
supports and drag pin are connected.
16. Install collective control bellcrank (34)
4. Lift transmission, guiding carefully to avoid (Chapter 62).
damage, and position transmission with pylon support
spindles (7, Figure 63-10) directly above spherical
17. Install swashplate assembly (Chapter 62) and oil
bearings of pylon support links (15).
fill cap and lanyard assembly (1, Figure 63-9).
5. Place one radius washer (10), with chamfered

18. Install flight controls (Chapter 67).
face inboard, on each pylon support spindle (7).
19. Install main rotor assembly (Chapter 62).

6. Pull top of loosened pylon support link (15)
outboard. Lower the transmission to position drag link,
located on lower side of pylon drag pin assembly (23), 20. Install main driveshaft (4, Figure 63-10)
into hole in pylon stop (24). Guide pylon drag pin (paragraph 63-15).
assembly into connecting position with isolation
mount (11). 21. Service transmission to proper level with
approved transmission oil (Chapter 12).
7. Position pylon support spindle (7) in spherical
bearing of secured pylon support link (15), while 22. Reconnect battery.
63-00-00
23. Bleed oil pressure hose (5) (paragraph 63-26). 63-27. TRANSMISSION — OPERATIONAL
CHECK
24. If new or overhauled transmission has been

installed, or when top case has been removed, NOTE
perform transmission operational check Perform this operational check after each
(paragraph 63-27). transmission installation.
1. Perform ground run with helicopter light on skids

25. Install and close cowling (Chapter 71).
(refer to applicable JetRanger Flight Manual) for 20
minutes. Monitor indicators to ensure that oil pressure
26. If transmission top case was removed and and temperature stabilize and remain within limits.
reinstalled prior to installation of transmission, do a Adjust oil pressure as required (paragraph 63-53).
torque check of the top case stud nuts 100 flight hours Troubleshoot per procedures in Figure 63-2.
after installation (Chapter 5).
2. After shutdown, accomplish the following
requirements:
63-26. TRANSMISSION — BLEEDING OIL
PRESSURE HOSE a. Remove and inspect chip detectors and oil
monitor magnetic plug for metal particles
Any time a transmission oil pressure line is (paragraph 63-38 and paragraph 63-39). Reinstall
disconnected between transmission and transmission chip detectors and monitor magnetic plug
oil pressure indicator or between freewheel assembly (paragraph 63-40).
and transmission, the system should be bled. This will
ensure a positive indication of oil pressure on starts b. Remove and inspect No. 1 and No. 2 oil jets
(21 and 29, Figure 63-12) (paragraph 63-46 and
and eliminate sluggish or erratic operation of the
paragraph 63-47). Reinstall oil jets (paragraph 63-48).
transmission oil pressure indicator.
c. Visually inspect oil at sight gauge for
1. Disconnect oil pressure hose (5, Figure 63-10) discoloration and contamination.
from reducer (6) at transmission and place end of
hose assembly in a receptacle so that end will be d. Inspect transmission and attached
covered by fluid. Station a person at receptacle to components for evidence of oil leaks.
observe when a bubble-free flow has been
established. e. Remove, clean, and inspect transmission oil
filter (paragraph 63-54 and paragraph 63-55).
2. Gain access to rear of instrument panel (Chapter
63-28. TRANSMISSION OIL SYSTEM
95). Disconnect pressure indicator hose assembly
from transmission oil pressure indicator and connect
Lubrication is provided by a system that includes an oil
to a low-pressure filler gun, or pressure pot, serviced
pump, pressure regulating valve, oil cooler, filter
with approved lubricating oil. Apply pressure slowly so
element, and oil jets No. 1 and No. 2. The oil pump is a
lines will be filled with approved transmission oil, constant-volume type, driven by the accessory drive
displacing oil in line. Continue to force approved gear, that delivers oil under pressure externally to the
transmission oil into lines until a bubble-free, steady oil filter and housing assembly. The oil cooler then
flow is established in receptacle at transmission. returns oil to the main transmission and spray jets for
lubricating internal parts. An oil level sight gauge is
3. Connect oil pressure hose (5) to reducer (6) at located on the right side of the transmission lower
transmission. Connect pressure indicator hose case where it can be easily inspected. A non-vented
assembly to transmission oil pressure indicator filler cap is located on the transmission top case.
(Chapter 95).
The transmission oil system also provides lubrication
for the freewheel assembly mounted in the engine
4. Check for oil leaks on next ground run. accessory gear case. Oil pressure for lubrication of the
63-00-00
freewheel assembly and to the transmission oil 2. Visually check spline teeth of pump shaft (both
pressure gauge on the instrument panel is taken from ends) for wear, chips, or cracks.
a tee fitting installed in the pressure line.
3. Visually inspect ports in body of oil pump (43) for
Oil temperature indications are provided by an oil damage to gerotor.
temperature bulb located in the outlet side of the oil
filter housing, and a high oil temperature switch that is
4. Inspect outboard oil seal for excessive leakage.
connected to the TRANS OIL TEMP caution segment.
The TRANS OIL PRESS caution segment light is
connected to the transmission oil pressure switch, 5. For detailed inspection and repair procedures,
located in the oil pressure line below and forward the refer to BHT-206A/B-M&O or BHT-206B3-CR&O.
instrument panel. A schematic representation of the
transmission oil system is presented in Figure 63-11. 63-32. OIL PUMP — INSTALLATION
63-29. OIL PUMP

MATERIALS REQUIRED
A constant-volume 4.5 to 5 GPM transmission oil
pump is mounted in the transmission inboard of the Refer to BHT-ALL-SPM for specifications.
hydraulic pump and tachometer generator, with all
being driven by the accessory drive gear. The NUMBER NOMENCLATURE
tachometer generator and hydraulic pump must be
removed to gain access to the transmission oil pump. C-308 Sealant
63-30. OIL PUMP — REMOVAL C-328 Sealant
1. Drain lubricating oil from transmission 1. Using heat lamp, heat case of transmission at
(Chapter 12). boss for oil pump (43, Figure 63-12).
NOTE 2. Apply sealant (C-328) to all faying surfaces,

lubricate packing (42) with approved lubricating oil
Tachometer generator and hydraulic pump (Chapter 12), and position on oil pump (43).
may be removed together as a unit.
3. After case of transmission is warm, install oil
2. Remove tachometer generator (28, Figure 63-10)
pump (43) into case with slot in pump pointing down.
and hydraulic oil pump (29) (Chapter 29).
Rotate oil pump slightly, if necessary, to engage
splines with accessory drive gear.
3. Remove nuts (46, Figure 63-12) and washers (44
and 45) from oil pump (43).
4. Install washers (44 and 45) and nuts (46) on oil
pump (43). Torque the nuts T .
4. Using heat lamp, heat transmission case at boss
for oil pump (43). After transmission case has warmed,
install slide hammer puller to face of oil pump with two 5. Apply sealant (C-308) to all faying surfaces.
10-32 bolts or cap screws, and remove oil pump.
Remove slide hammer from oil pump. 6. Install tachometer generator (28, Figure 63-10)
and hydraulic oil pump (29) (Chapter 29).
5. Remove and discard packing (42) from oil pump
(43). Cover ports in oil pump and opening in 7. Service transmission to proper oil level
transmission case to prevent entry of foreign material. (Chapter 12).
63-31. OIL PUMP — INSPECTION 8. On first ground run of helicopter, check oil pump
(43, Figure 63-12) for evidence of leakage and correct
1. Rotate shaft of oil pump (43, Figure 63-12) and indication of oil pressure. Adjust oil pressure as
check for freedom and smoothness of rotation. required (paragraph 63-53).
63-00-00
NOTE
1 206-061-535-011 transducer installed on helicopters S/N 254 through 913.
206AB_MM_63_0013
Figure 63-11. Transmission Oil System Schematic
63-00-00
T 3
29
21
T 2
T 1
50
51
206AB_MM_63_0012a
Figure 63-12. Transmission System Components (Sheet 1 of 2)
63-00-00
50. Drain valve

51. Oil monitor
50 TO 70 IN-LBS
T 1 (5.65 TO 7.91 Nm)
100 TO 140 IN-LBS

T 2 (11.30 TO 15.82 Nm)
100 TO 200 IN-LBS

T 3 (11.30 TO 22.60 Nm)
206AB_MM_63_0012b
Figure 63-12. Transmission System Components (Sheet 2 of 2)
63-00-00
63-33. OIL PUMP INLET SCREEN 2. Insert oil pump inlet screen (49) into boss in lower
case of transmission (41) and secure with retaining
The oil pump inlet screen is located in a boss, next to ring (47).
the oil pump on the transmission lower case, and
filters the lubricating oil before entering the oil pump. 3. Service transmission to proper oil level
Screen material is 16 x 16 mesh, 23-gauge steel that (Chapter 12).
is brazed to an inlet sleeve and plug.
4. Inspect for evidence of oil leakage on first ground
63-34. OIL PUMP INLET SCREEN — REMOVAL run.
1. Drain lubricating oil from transmission 63-37. CHIP DETECTORS

(Chapter 12).
NOTE
2. Remove retaining ring (47, Figure 63-12).
Prior to Service Letter 206-133,
transmissions will contain magnetic chip
3. Withdraw oil pump inlet screen (49) from
detectors. Subsequent transmissions
transmission (41). Immediately inspect oil pump inlet
incorporate electric chip detectors. Some
screen for foreign material (paragraph 63-35).
transmissions will have two chip detectors
and some will have three.
4. Remove and discard packing (48).
NOTE
63-35. OIL PUMP INLET SCREEN — INSPECTION
The oil monitor (31, Figure 63-10) is also a
chip detector. Located on the transmission
oil filter head, it consists of the oil monitor
MATERIALS REQUIRED and a removable magnetic plug (30).
Refer to BHT-ALL-SPM for specifications. The chip detector is made up of the self-closing valve
and the chip detector. The self-closing valve also
NUMBER NOMENCLATURE serves as a drain plug for the component. The chip
detector consists of a self-locking bayonet probe with
C-304 Drycleaning Solvent
a permanent magnet at the end. If metal particles
become free in the oil, the magnet will attract the metal
1. Inspect oil pump inlet screen (49, Figure 63-12) particles, allowing for inspection. If the chip detector is
for foreign material. If any particles are found, identify electric, when sufficient metal is attracted to complete
(paragraph 63-6) and perform corrective action the circuit between pole and ground, the appropriate
(Figure 63-2). TRANS CHIP detector segment on the caution panel
will illuminate.
2. Clean oil pump inlet screen (49, Figure 63-12)

63-38. CHIP DETECTORS — REMOVAL
with drycleaning solvent (C-304).
3. Inspect oil pump inlet screen (49) for cracks and

distortion. Inspect retaining ring (47) for distortion. CAUTION
63-36. OIL PUMP INLET SCREEN — ROUGH HANDLING OF CHIP

INSTALLATION DETECTORS AND ELECTRICAL
CONNECTORS IS THE MAJOR CAUSE
1. Lubricate new packing (48, Figure 63-12) with O F FA I L U R E A N D O F FA L S E
approved lubricating oil (Chapter 12) and position on INDICATIONS IN THE CAUTION LIGHT
oil pump inlet screen (49). SYSTEM.
63-00-00
63-39. CHIP DETECTORS — CLEANING AND

NOTE
INSPECTION
A drain hose is available for use in draining
oil from the transmission and/or freewheel
assembly (Chapter 12). NOTE
This procedure is applicable to all
transmission and freewheel assembly chip
NOTE
detectors.
This procedure is applicable to all
transmission chip detectors (35, 38, and
41, Figure 63-10) and freewheel assembly MATERIALS REQUIRED
chip detector (29, Figure 63-14). Electric
chip detector (35) is used for convenience. Refer to BHT-ALL-SPM for specifications.
1. Remove chip detector (35, Figure 63-10) as NUMBER NOMENCLATURE

follows:
a. If chip detector (35) is electrical, disconnect
electrical lead. 1. If chip detector is nonelectric type, perform
step a. If chip detector is electric type, perform step b.
b. Press chip detector (35) in, turn
counterclockwise, and remove from self-closing valve a. Inspect magnetic chip detector (nonelectric)
(36). Immediately inspect chip detector for metal for loss of magnetic strength (Table 63-4). This
particles. If particles are found, identify condition is rare, but can occur if chip detectors have
(paragraph 63-6) and take corrective action been dropped on floor or exposed to strong electrical
(Figure 63-2 or Figure 63-4). fields.
c. Inspect self-closing valve (36, Figure 63-10) b. Inspect electric chip detector for condition and
for evidence of leakage while still installed, but after serviceability. This type of chip detector has a ceramic
removal of chip detector (35). magnet not subject to loss of magnetic strength.
2. Remove magnetic plug (30) from oil monitor (31)

as follows:
a. Using wrench, turn magnetic plug (30) Table 63-4. Chip Detector Strength
counterclockwise and remove from oil monitor (31).
Immediately inspect magnetic plug for metal particles. PART NUMBER STRENGTH (SHOULD LIFT)
If particles are found, identify (paragraph 63-6) and
AN758R 0.75 inch (19.05 mm)
take corrective action (Figure 63-2).
diameter steel ball
b. Inspect oil monitor (31, Figure 63-10) for B-148 0.75 inch (19.05 mm)
evidence of leakage while still installed, but after diameter steel ball
removal of magnetic plug (30).
B-3181 0.75 inch (19.05 mm)
diameter steel ball
3. Remove self-closing valve (36) or oil monitor (31)
as follows: B-3182B 15 - 0.125 inch (3.18 mm)
steel balls
a. Remove lockwire. Remove self-closing valve
(36) or oil monitor (31). Be prepared to catch oil that
will drain from the component.
b. Remove packing (32) and discard.
63-00-00
Table 63-4. Chip Detector Strength (Cont) a. Insert chip detector (35) into self-closing valve
(36) and turn clockwise to lock in place.
PART NUMBER STRENGTH (SHOULD LIFT)
b. If chip detector (35) is electrical, attach
B-3188B 20 - 0.125 inch (3.18 mm)
electrical lead.
steel balls
B-3225C 15 - 0.125 inch (3.18 mm) 3. Insert magnetic plug (30) into oil monitor (31).
steel balls Torque the magnetic plug T .
B-3659 0.75 inch (19.05 mm)
diameter steel ball 4. Fill component to proper oil level (Chapter 12).
2. Inspect chip detector for stripped or damaged 5. Inspect for evidence of oil leakage on first ground
bayonet pins. run.
3. Inspect self-closing valve for damage. 63-41. OIL LEVEL SIGHT GLASS
4. Clean parts with drycleaning solvent (C-304). The oil level sight glass is located on the right side of
transmission and provides visual indication of oil level.
63-40. CHIP DETECTORS — INSTALLATION

63-42. OIL LEVEL SIGHT GLASS — REMOVAL
1. Drain lubricating oil from transmission

MATERIALS REQUIRED (Chapter 12).
2. Remove retaining ring (1, Figure 63-12).
NUMBER NOMENCLATURE
3. Remove indicator (4) and sight glass (2). Remove
C-405 Lockwire and discard packing (3).
63-43. OIL LEVEL SIGHT GLASS — INSPECTION

NOTE
This procedure is applicable to all 1. Inspect sight glass (2, Figure 63-12) for evidence
transmission chip detectors (35, 38, and of crazing, discoloration, and cracking.
41, Figure 63-10) and freewheel assembly
chip detector (29, Figure 63-14). Electric 2. Replace sight glass if crazed or discolored to the
chip detector (35) is used for convenience. extent it will be difficult to see oil or determine oil level.
1. Install self-closing valve (36, Figure 63-10) or oil 63-44. OIL LEVEL SIGHT GLASS —
monitor (31) as follows: INSTALLATION
a. Lubricate packing (32) with approved 1. Lubricate packing (3, Figure 63-12) with
lubricating oil (Chapter 12) and position on self-closing approved transmission oil (Chapter 12) and install on
valve (36) or oil monitor (31). sight glass (2).
b. Install self-closing valve (36) or oil monitor 2. Insert oil level indicator (4) in side of transmission
(31). Torque the value T . Secure with lockwire case.
(C-405).
3. Insert sight glass (2) in transmission case and
2. Install magnetic chip detector (35) as follows: secure with retaining ring (1).
63-00-00
1. Clean oil jets (21 and 29, Figure 63-12) with

4. Service transmission to proper oil level
drycleaning solvent (C-304) and dry with filtered,
(Chapter 12).
compressed air.
63-45. OIL JETS 2. Inspect oil jets (21 and 29) for clogged passages,
cracks, dents, distortion, and corrosion.
Two oil jets are incorporated in the main transmission.
Oil jet No. 1 is installed in the transmission main case 63-48. OIL JETS — INSTALLATION
and directs a lubricating spray to the spiral bevel gear
and input pinion of the transmission. Oil jet No. 2 is
installed in the transmission top case and lubricates
MATERIALS REQUIRED
the planetary pinions and mast bearing.
NOTE
NUMBER NOMENCLATURE
Maintenance procedures are applicable to
either oil jet. C-405 Lockwire
63-46. OIL JETS — REMOVAL 1. Lubricate new packings (22 through 25,
Figure 63-12) with approved transmission oil and
install on oil jet (21 or 29).
MATERIALS REQUIRED
2. Align tab on oil jet (21 or 29) and install new
Refer to BHT-ALL-SPM for specifications. Dyna-Seal (20) with screws (18 and 19). Tighten
screws and secure together with lockwire (C-405).
NUMBER NOMENCLATURE
3. Inspect for evidence of oil leakage on first ground
C-428 Caps and/or Plugs
run.
1. Cut lockwire from screws (18 and 19, 63-49. OIL PRESSURE REGULATING VALVE
Figure 63-12).
The transmission oil pressure regulating valve is
2. Remove screws (18 and 19) and Dyna-Seal (20). located on the left aft corner of the transmission lower
Discard Dyna-Seal. case, just aft of the oil filter. The regulating valve is
used to adjust transmission oil pressure to normal
operating limits and relieves excess oil pressure back
3. Remove oil jet (21 or 29) and discard packings
into the transmission case.
(22 through 25).
63-50. OIL PRESSURE REGULATING VALVE —
4. To prevent entry of foreign material, plug open REMOVAL
ports in transmission with caps and/or plugs (C-428).
1. Cut and remove lockwire from oil pressure
63-47. OIL JETS — CLEANING AND INSPECTION regulating valve (26, Figure 63-12).
MATERIALS REQUIRED CAUTION

LOOSENING LOCKNUT OR TURNING
NUMBER NOMENCLATURE ADJUSTING SCREW WILL REQUIRE
ADJUSTMENT OF TRANSMISSION OIL
PRESSURE.
63-00-00
2. Use wrench on hexagonal shoulder of oil 3. Carefully thread and tighten oil pressure
pressure regulating valve (26) to loosen and remove regulating valve (26) into boss on transmission lower
oil pressure regulating valve from transmission case. case. Secure oil pressure regulating valve to oil
Remove and discard packings (27 and 28). transfer dowel tube with lockwire (C-405).
63-51. OIL PRESSURE REGULATING VALVE — 4. Inspect for evidence of oil leakage, and adjust
INSPECTION transmission oil pressure (paragraph 63-53) on first
ground run.
1. Inspect body of oil pressure regulating valve (26,
Figure 63-12) for scored areas and damaged threads. 63-53. TRANSMISSION OIL PRESSURE
Using a nonmetallic blunt rod, check piston for ADJUSTMENT
freedom of movement by pushing it into the valve body
several times.
CAUTION
CAUTION ADJUSTMENT OF TRANSMISSION OIL

PRESSURE REGULATING VALVE MUST
BE ACCOMPLISHED IMMEDIATELY ON
LOOSENING LOCKNUT OR TURNING GROUND RUN.
ADJUSTING SCREW WILL REQUIRE
ADJUSTMENT OF TRANSMISSION OIL 1. To adjust oil pressure, loosen locknut and turn
PRESSURE. adjusting screw IN to increase pressure, OUT to
decrease pressure. Adjust pressure to 45 PSI
2. Inspect oil pressure regulating valve (26) for (310.26 kPa) at 100% NR flat pitch, and tighten
evidence of oil leaks, and locknut for loss of locking locknut.
tension.
2. When transmission oil temperature has
3. If evidence of a leak is noted around adjusting stabilized, recheck transmission oil pressure and
screw, or if piston is binding, repair oil pressure make additional adjustments, as required.
regulating valve (26) (BHT-206A/B-M&O or
BHT-206B3-CR&O). 63-54. TRANSMISSION OIL FILTER
(TRANSMISSION ASSEMBLIES
63-52. OIL PRESSURE REGULATING VALVE — 206-040-002-005/-015) — SERVICING
INSTALLATION
1. Drain lubricating oil from transmission oil filter
housing (Chapter 12).
MATERIALS REQUIRED
2. Service filter assembly (30, Figure 63-12) on filter
head (32) as follows:
NUMBER NOMENCLATURE a. Loosen wing nut on clamp (31). Remove and

properly dispose of filter assembly (30).
C-405 Lockwire
b. Lubricate seal of new filter assembly (30) with
system oil.
1. Lubricate packings (27 and 28, Figure 63-12) with
approved transmission oil (Chapter 12). c. Screw filter assembly (30) on filter head (32)
plus 1/8 turn and secure with clamp (31).
2. Position packing (27) next to head of oil pressure
regulating valve (26), and packing (28) on end of oil 3. Service transmission to proper oil level
pressure regulating valve. (Chapter 12).
63-00-00
63-55. TRANSMISSION OIL FILTER

NOTE
(TRANSMISSION ASSEMBLIES
206-040-002-013/-025 AND SUBSEQUENT) Residual oil will drain from oil cooler and
— SERVICING connecting lines during removal of oil
cooler. Position sufficient absorbing
1. Service filter element (38, Figure 63-12) on head material at oil tubes and fittings to collect
assembly (40) as follows: residual oil.
1. Disconnect air ducts (1, Figure 63-10), with

a. Remove the center plug of the drain valve (50) clamps (2), from duct (8, Figure 63-12) mounted on
and drain oil into a suitable container by depressing the oil cooler (11).
the interval valve with a small diameter rod.
2. Disconnect oil tube (17) from oil cooler (11).

b. Remove nuts (34) and washer (35 and 36),
and pull filter housing (33) from head assembly (40).
3. Remove bolt (16), packings (13 and 15), and
gasket (12). Discard packings and gasket. Plug
c. Remove and inspect filter element (38)
opening in transmission from which bolt was removed
(paragraph 63-5). Discard filter element and packings
with caps and/or plugs (C-428).
(37 and 39).
d. Lubricate new packings (37 and 39) with 4. Remove bolts (5 and 9) and washers (6 and 10)
system oil and install on filter element (38). attaching bottom of oil cooler (11) to bracket (7).
e. Install new filter element (38) on head 5. Remove oil cooler (11) from transmission top
assembly (40). case and plug lower end of oil transfer tube (14) with
caps and/or plugs (C-428).
f. Install filter housing (33) and secure with
washers (35 and 36) and nuts (34). Torque the 63-58. OIL COOLER — CLEANING AND
nuts T . INSPECTION
g. Service transmission to proper oil level

(Chapter 12). MATERIALS REQUIRED

63-56. OIL COOLER
NUMBER NOMENCLATURE
The oil cooler contains a single core and is mounted to
the top aft side of transmission. The thermal bypass C-304 Drycleaning Solvent
valve controlling flow of oil through the oil cooler core
is located on outlet side of the oil cooler and allows oil
1. Clean exterior surface of oil cooler (11,
to bypass the oil cooler when oil temperature is low.
Figure 63-12) with drycleaning solvent (C-304) and dry
with filtered compressed air.
63-57. OIL COOLER — REMOVAL
CAUTION
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications. IF OIL COOLER HAS BEEN REMOVED

DUE TO METAL CONTAMINATION, IT
NUMBER NOMENCLATURE
SHALL BE REPLACED. REPAIRING OR
C L E A N I N G C O N TA M I N AT E D O I L
COOLERS IS NOT AUTHORIZED.
63-00-00
63-60. PYLON SUPPORT LINKS

CAUTION
63-61. PYLON SUPPORT LINKS — REMOVAL
OIL SYSTEMS WITH CONTAMINATION 1. Remove transmission (paragraph 63-22).

SHALL HAVE ALL OIL TUBES, HOSES,
VALVES, AND FITTINGS REMOVED, 2. Remove bolts (2, Figure 63-13), nuts (11), and
T H O R O U G H LY C L E A N E D W I T H washers (1 and 12) attaching pylon support links (3) to
DRYCLEANING SOLVENT (C-304), AND forward and aft support mounts (19 and 7).
FLUSHED WITH APPROVED
TRANSMISSION OIL.
CAUTION
2. Inspect oil cooler (11) for damaged core and
condition of threaded parts.
DO NOT REMOVE SHIMS UNDER
3. Inspect all oil tubes for chafing, crimping, wear, PYLON MOUNTS. IF SHIMS ARE NOT
BONDED, IDENTIFY FOR
leakage, and condition of threaded fittings.
REINSTALLATION IN SAME LOCATION.
LOSS OR MIXING OF SHIMS WILL
63-59. OIL COOLER — INSTALLATION REQUIRE TRANSMISSION ALIGNMENT
IN A BELL APPROVED FIXTURE.
MATERIALS REQUIRED C O N TA C T P R O D U C T S U P P O R T
ENGINEERING FOR PRODUCTION SHIM
Refer to BHT-ALL-SPM for specifications. RECORDS.
NUMBER NOMENCLATURE 3. Remove bolts (20), nuts (10), and washers (6 and
9) securing forward pylon mount (19) to roof structure.
C-405 Lockwire Remove forward pylon mounts.
4. Remove bolts (4 and 5), nuts (10), and washers

1. Install bolts (5 and 9, Figure 63-12) and washers (6 and 9) securing aft pylon mount (7) to roof structure.
(6 and 10), as required, to attach bottom of oil cooler Remove aft pylon mounts (7).
(11) to bracket (7).
63-62. PYLON SUPPORT LINKS — INSPECTION
2. Lubricate packings (13 and 15) with approved
transmission oil.
MATERIALS REQUIRED
3. Install packing (15) on bolt (16), insert bolt into oil Refer to BHT-ALL-SPM for specifications.
transfer tube (14), and install gasket (12) (next to oil
transfer tube) and packing (13). Position oil transfer NUMBER NOMENCLATURE
tube on transmission top case and install bolt. Torque
the bolt T . Secure bolt heads together by wrapping C-204 Epoxy Polyamide
lockwire (C-405) around oil transfer tube. Primer
4. Connect oil tube (17) to oil cooler (11). 1. Inspect pylon support links (3, Figure 63-13) for
nicks, scratches, and damage. Dress out minor nicks
and scratches. Touch up bare spots with epoxy
5. Connect air ducts (1, Figure 63-10), with clamps polyamide primer (C-204). For detailed inspection and
(2), to duct (8, Figure 63-12) mounted on oil repair procedures, refer to BHT-206A/B-M&O or
cooler (11). BHT-206B3-CR&O.
63-00-00
Figure 63-13. Pylon Support Links and Isolation Mount
63-00-00
2. Inspect pylon mounts (7 and 19) for nicks, and maximum strength is obtained in 6 to
scratches, cracks, and damage. For detailed 7 days.
inspection and repair procedures, refer to BHT-206A/
B-M&O or BHT-206B3-CR&O. 2. Install forward pylon mounts (19) with bolts (20),
washers (6 and 9), and nuts (10). Torque the nuts T
and apply a bead of sealant (C-308) around the
3. Inspect spherical bearings in pylon support
periphery of the pylon mounts.
links (3) and pylon mounts (7 and 19) for smoothness
and security. For detailed inspection and repair
procedures, refer to BHT-206A/B-M&O or 3. Install aft pylon mounts (7) with bolts (4 and 5),
BHT-206B3-CR&O. washers (6 and 9), and nuts (10). Torque the nuts T
and apply a bead of sealant (C-308) around the
periphery of the pylon mounts.
63-63. PYLON SUPPORT LINKS —
INSTALLATION
NOTE
Position short leg of support links (3) facing
MATERIALS REQUIRED forward.
Refer to BHT-ALL-SPM for specifications. 4. Attach pylon support links (3) with bolts (2),
washers (1 and 12), and nuts (11). Torque the
NUMBER NOMENCLATURE nuts T .
5. Install transmission (paragraph 63-25).
C-305 Aliphatic Naphtha
63-64. ISOLATION MOUNT
C-308 Sealant
C-309 MEK NOTE

If isolation mount is replaced due to
C-317 Adhesive
bondline separation or loss of integrity of
C-423 Abrasive Paper flexing element, the main driveshaft shall
be removed (paragraph 63-12),
disassembled, and inspected (BHT-206A/
1. If shims (8 and 18, Figure 63-13) are found not to B-M&O or BHT-206B3-CR&O).
be bonded during removal of pylon mounts (7 and 19),
perform following step a through step c.
NOTE
a. Clean surfaces to be bonded with aliphatic For installation, removal and inspection of
naphtha (C-305) or MEK (C-309). 206-030-539-005 and -101 isolation mount
assembly, refer to TB 206-79-28.
b. Abrade surfaces lightly with 120 grit abrasive 63-65. ISOLATION MOUNT — REMOVAL
paper (C-423). Remove sanding residue with
drycleaning solvent (C-304), and wipe parts dry with a 1. Install lift hook or clevis on main rotor mast nut
clean cloth before solvent evaporates. and support transmission with hoist to prevent tipping
of transmission.
c. Mix adhesive (C-317) by adding 8 parts
activator A to 100 parts of base resin. Apply mixture to 2. Remove cotter pin (27, Figure 63-10), washers
shims (8 and 18) and fuselage surface. (22 and 25), nut (26), and bolt (21) which passes
through pylon drag pin assembly (23) and isolation
mount (11).
NOTE
Adhesive pot life is 15 to 30 minutes. Cure 3. Remove isolation mount bolts (13, Figure 63-13)
time is 12 hours at 70 to 90°F (21 to 32°C) and washers (14).
63-00-00
ensure the two washers are in place before

installation of the mount.
CAUTION
1. If shims (15 and 16, Figure 63-13) are found not
to be bonded during removal of isolation mount (17),
DO NOT REMOVE SHIMS UNDER
perform step a through step c.
ISOLATION MOUNT. IF SHIMS ARE NOT
BONDED, IDENTIFY FOR
REINSTALLATION IN SAME LOCATION. a. Clean surfaces to be bonded with aliphatic
LOSS OR MIXING OF SHIMS WILL naphtha (C-305) or MEK (C-309).
REQUIRE TRANSMISSION ALIGNMENT
IN A BELL APPROVED FIXTURE. b. Abrade surfaces lightly with 120 grit abrasive
C O N TA C T P R O D U C T S U P P O R T paper (C-423). Remove sanding residue with
ENGINEERING FOR PRODUCTION SHIM drycleaning solvent (C-304), and wipe parts dry with a
RECORDS. clean cloth before solvent evaporates.
4. Remove isolation mount (17) from cabin roof. c. Mix adhesive (C-317) by adding 8 parts
activator A to 100 parts of base resin. Apply mixture to
63-66. ISOLATION MOUNT — INSPECTION shims (15 and 16) and fuselage surface.
1. Remove isolation mount (17, Figure 63-13) cover. NOTE

Inspect isolation mount for condition of rubber and for
security. Replace mount if deterioration is evident. Adhesive pot life is 15 to 30 minutes. Cure
time is 12 hours at 70 to 90°F (21 to 32°C)
and maximum strength is obtained in 6 to
2. For detailed inspection and repair procedures,
7 days.
refer to BHT-206A/B-M&O or BHT-206B3-CR&O.
2. Install isolation mount (17) on cabin roof with
63-67. ISOLATION MOUNT — INSTALLATION washers (14) and bolts (13) in existing nutplates.
Torque the bolts T .
MATERIALS REQUIRED 3. Insert bolt (21, Figure 63-10) through pylon drag
pin assembly (23) and isolation mount (11). Install
Refer to BHT-ALL-SPM for specifications. washers (22 and 25) and nut (26). Torque the nuts T
and install cotter pin (27).
NUMBER NOMENCLATURE
C-304 Drycleaning Solvent 63-68. FREEWHEEL ASSEMBLY
C-305 Aliphatic Naphtha A shaft from the power turbine drives the engine
power takeoff gearshaft through the engine accessory
C-309 MEK gear case. The freewheel assembly is mounted on the
engine accessory gear case and the inner race shaft
C-317 Adhesive
assembly is splined directly to the engine power
C-423 Abrasive Paper takeoff gearshaft. Engine power is transmitted to the
outer race of the freewheel assembly, then through the
full phasing sprag elements which couple the engine
power to the transmission driveshaft. The forward
NOTE
short tail rotor driveshaft connects, through a flexible
Two configurations of the isolation mount coupling, to a splined adapter on the aft end of the
are currently in service. Early model inner race shaft assembly that passes through the
mounts have two washers bonded on the engine accessory gear case. During autorotation, the
inside of the clevis. Later model mounts main rotor drives the power input shaft. Under this
have bosses machined on the inside of the condition, the freewheel assembly provides a
clevis. On early configuration mounts, disconnect from the engine so that the rotational
63-00-00
forces of the main rotor are free to drive the different freewheel assembly is to be
transmission, tail rotor, and all transmission-mounted installed.
accessories. Refer to Figure 63-14 for different
configurations of freewheel assemblies. 6. Remove nuts (20), steel washers (19), and
aluminum washers (18) securing housing (17) to aft
63-69. FREEWHEEL ASSEMBLY — REMOVAL end of engine accessory gear case. Remove adapter
(21) and housing as a unit.
SPECIAL TOOLS REQUIRED NOTE

Freewheel assembly 206-040-230 uses
NUMBER NOMENCLATURE aluminum washers (28) between steel
washers (27) and cap assembly (3).
T101308 Jackscrew Set
7. Remove nuts (26, Detail A), steel washers (27),
T101555 Face Coupling Wrench
and aluminum washers (28) securing cap assembly
(3) to housing assembly (12).
MATERIALS REQUIRED
NOTE
Refer to BHT-ALL-SPM for specifications. Heat may be applied to housing assembly
(12) to accomplish the following steps, if
NUMBER NOMENCLATURE needed.
8. Install jackscrew (T101308) set in cap assembly
(3) to remove freewheel assembly from housing
1. Remove forward short tail rotor driveshaft assembly (12). The inner race shaft assembly (1) is an
(Chapter 65). assembly of components comprising the outer race
shaft assembly (8), clutch assembly (6), bearings (2,
5, and 7), and cap assembly (3) with packings (4
2. Remove main driveshaft (paragraph 63-12). and 9). Remove the inner race shaft assembly from
housing assembly, and engine accessory case, as a
3. Drain lubricating oil from freewheel assembly complete unit.
(Chapter 12).
9. Remove housing assembly (12) and ring (11) only
if it is necessary for accessory gearbox packing
4. Disconnect oil pressure hose (5, Figure 63-10) at
replacement, change of engine, or change of
reducer (25, Figure 63-14) on housing (17), and oil
freewheel assembly.
return hose (9, Figure 63-10) at union (32,
Figure 63-14) on housing assembly (12), if not
previously accomplished during draining. 10. Remove housing assembly (12) as follows:
5. Remove cotter pin (24), nut (23), and steel a. Remove freewheel assembly.
washer (22) from aft end of inner race shaft assembly
(1), using face coupling wrench (T101555). b. Remove nuts (10) located inside housing
assembly (12) and remove ring (11), housing
assembly, and gasket (13). Discard gasket.
NOTE
Do not remove shims (16) from aft face of 11. Install caps and/or plugs (C-428) on hoses and
engine accessory gear case unless a fittings.
63-00-00
T 1
10
T 1
206AB_MM_63_0015a
Figure 63-14. Freewheel Assembly (Sheet 1 of 3)
63-00-00
63-00-00
50 TO 70 IN-LBS
T 1 (5.65 TO 7.91 Nm)
20 TO 60 IN-LBS
T 2 (2.2 TO 6.7 Nm)
120 TO 150 IN-LBS

T 3 (13.56 TO 16.95 Nm)
NOTE
1 Freewheel assembly installations 206-040-270 and 206-040-230-001/-011/-023
require 225 to 500 inch-pounds (25.50 to 56.00 Nm). Freewheel assembly
installation 206-040-230-003 requires 150 to 300 inch-pounds (16.95 to 33.60 Nm).
206AB_MM_63_0015c_c01
63-00-00
63-70. FREEWHEEL ASSEMBLY — CLEANING procedures, refer to BHT-206A/B-M&O or

BHT-206B3-CR&O.
MATERIALS REQUIRED 4. Inspect union and reducer fittings, seals, gaskets,

and packings for condition.
5. Check for free rotation of the shaft assemblies
NUMBER NOMENCLATURE and engagement of clutch as follows:

a. Hold outer race shaft assembly (8) and inner
C-309 MEK race shaft assembly (1) with flange end facing inward.
b. Rotate flange of inner race shaft assembly (1)

1. Clean all parts with drycleaning solvent (C-304) by hand. Freewheel clutch should drive when turned
and dry with filtered compressed air. Do not allow clockwise, and freewheel when turned
bearings to spin while drying. counterclockwise.
2. Inspect parts immediately after cleaning. 6. Roll bearing in housing (17) to check for freedom
Exercise care to avoid corrosion and fingerprints on of movement without flat or rough spots.
bearings and machined surfaces. If parts cannot be
inspected immediately, lubricate all parts with 7. Visually inspect all studs for security and
approved transmission oil (Chapter 12). condition of threads.
3. Remove old sealant from threads on aft end of 8. For detailed inspection and repair procedures,
inner race shaft assembly (1, Figure 63-14), adapter refer to BHT-206A/B-M&O or BHT-206B3-CR&O.
(21), steel washer (22), and nut (23) with a plastic
scraper and MEK (C-309). On steel parts, light 63-72. FREEWHEEL ASSEMBLY —
brushing with a wire brush may be used. INSTALLATION
63-71. FREEWHEEL ASSEMBLY — INSPECTION

SPECIAL TOOLS REQUIRED
MATERIALS REQUIRED NUMBER NOMENCLATURE
Refer to BHT-ALL-SPM for specifications. T101555 Face Coupling Wrench
NUMBER NOMENCLATURE
C-423 Abrasive Paper MATERIALS REQUIRED

1. Remove, inspect, clean, and install chip detectors
(29 or 34, Figure 63-14, Detail B) (paragraph 63-38 NUMBER NOMENCLATURE
through paragraph 63-40).
C-018 Lubricant
2. Inspect all parts for nicks and scratches. Dress C-201 Zinc Chromate Primer
out minor nicks and scratches with No. 320 or 400 grit
abrasive paper (C-423). Apply protective coating C-304 Drycleaning Solvent
where required.
C-305 Aliphatic Naphtha
3. Visually inspect splines for wear, cracks, and
C-308 Sealant
damage. For detailed inspection and repair
63-00-00
NOTE NOTE
If engine is removed, install freewheel Freewheel assembly 206-040-230 uses
assembly before installing engine in aluminum washers (28) between steel
helicopter. washers (27) and cap assembly (3).
1. Install housing assembly (12, Figure 63-14), if 6. Push cap assembly (3) firmly in place into
removed, as follows: housing assembly (12). Install steel washers (27) and
nuts (26). Torque the nuts T .
a. Insert gasket (13) onto studs on forward side

7. Apply a film of approved transmission oil to
of engine accessory gear case.
packing (15) and to surfaces of bearing (14) in housing
(17). Insert packing in groove on inboard flange of
housing.
CAUTION
N U T S ( M S 2 1 0 4 3 - 4 ) M AY N O T B E
CAUTION
REUSED IF TARE TORQUE OF NUTS IS
LESS THAN 8 INCH-POUNDS (0.90 NM)
IF THE SAME FREEWHEEL ASSEMBLY
(BHT-ALL-SPM, CHAPTER 2). IS BEING INSTALLED ON THE SAME
E NG I N E A SS E M BLY W I T H O U T AN Y
b. Install ring (11) in housing assembly (12) and ALTERATION OR REPLACEMENT OF
align to studs on forward side of engine accessory PARTS, THE INSTALLATION MAY BE
gear case. Guide ring and housing assembly onto MADE WITH THE ORIGINAL SHIMS (13)
studs and install the nuts (10). Torque the nuts T . WITHOUT PERFORMING A
DIMENSIONAL CHECK. INSTALLATION
OF A NEW ENGINE, NEW FREEWHEEL
2. Stand assembled inner and outer race shaft ASSEMBLY, OR REPAIR OF ORIGINAL
assemblies (1 and 8) on adapter flange and apply FREEWHEEL ASSEMBLY WILL REQUIRE
approved transmission oil (Chapter 12) between inner A DIMENSIONAL CHECK. SHIPPING
and outer race shaft assemblies to lubricate clutch GASKET MUST BE REMOVED FROM
assembly (6) and bearings (5 and 7). NEW ENGINE.
3. Check for freedom of movement to ensure that 8. Perform dimensional check as follows:
cap assembly (3), bearing (2), clutch assembly (6),
and bearings (5 and 7) are not binding. a. Apply a film of lubricant (C-018) to shank of
adapter (21), lip of seal in housing (17), and to packing
(15). Install adapter into housing using a thimble, if
4. Apply light coating of approved transmission oil
available, exercising extreme care not to damage seal.
(Chapter 12) to packings (4 and 9) on inner and outer
race shaft assemblies (1 and 8).
b. Install adapter (21) and housing (17) as a unit
on exposed aft end of the inner race shaft
5. Position inner and outer race shaft assemblies (1 assembly (1).
and 8) in housing assembly (12) until splined end of
inner race shaft assembly (1) protrudes through aft c. Install steel washer (22) and nut (23) on aft
side of engine accessory gear case. Rotate adapter end of inner race shaft assembly (1). Attach face
flange on forward end of inner race shaft assembly coupling wrench (T101555) to adapter flange on
back and forth to align gear teeth between outer race forward end of inner race shaft assembly and tighten
shaft assembly (8) and drive gear in engine accessory nut only enough to firmly seat bearing (14) and
gear case. adapter (21).
63-00-00
d. Push inner race shaft assembly (1, surface and apply a ring of sealant (C-308) on
Figure 63-15) aft into forward housing assembly (2) by surfaces of steel washer and threads of nut and install
applying hand pressure to adapter flange on forward on aft end of inner race shaft assembly (1). Attach face
end. Using two feeler gauges, measure at coupling wrench (T101555) to adapter flange on
diametrically opposite positions the gap between the forward end of inner race shaft assembly and torque
aft face of engine accessory gear case and forward nut T . Remove face coupling wrench (T101555).
face of aft housing assembly (3). If there is no gap, the
outer race shaft is not seated on the inner race shaft.
12. Secure nut (23) with cotter pin (24), with eye and
tangs below outside surface of nut.
e. Peel shim (4) to provide a shim 0.015 to
0.020 inch (0.381 to 0.508 mm) less than measured 13. Remove caps and plugs and connect oil pressure
clearance between shoulder of outer race shaft hose (5, Figure 63-10) to reducer (25, Figure 63-14)
assembly (5) and engine accessory gear case. on housing (17), and oil return hose (9, Figure 63-10)
to union (32, Figure 63-14) on housing assembly (12).
f. Remove nut (23, Figure 63-14) and steel
washer (22). Remove adapter (21) and housing (17) 14. Install forward short tail rotor driveshaft
as a unit from aft end of inner race shaft assembly (1). (Chapter 65).
Do not separate adapter from housing.
15. Install main driveshaft (paragraph 63-15).

g. Clean mating surfaces of shim (16), housing
(17), and aft face of engine accessory gear case and
studs with aliphatic naphtha (C-305). Wipe dry and 16. Service transmission to proper oil level
apply a coating of unreduced zinc chromate primer (Chapter 12).
(C-201) to mating surfaces and studs. Immediately
complete remaining procedures. 17. Bleed transmission oil pressure hose
(paragraph 63-26).
CAUTION 18. Perform freewheel assembly operational check

(paragraph 63-15).
DO NOT POSITION SHIM ON ENGINE 63-73. FREEWHEEL ASSEMBLY —

ACCESSORY CASE STUDS FIRST OR OPERATIONAL CHECK
POSSIBLE DAMAGE TO PACKING (15)
M AY O C C U R W H E N I N S TA L L I N G
HOUSING. NOTE
Perform this operational check after each
9. Position shim (16) onto housing (17) and adapter freewheel assembly installation.
(21). Install assembled parts as a unit on aft face of
engine accessory gear case and onto inner race shaft 1. Perform ground run for 20 minutes (refer to
assembly (1). Reducer (25) on housing must be applicable JetRanger Flight Manual).
located at the 10 o'clock position as viewed from the
aft side.
2. After shutdown, accomplish the following
requirements:
10. Secure housing (17) with aluminum washers (18),
steel washers (19), and nuts (20). Ensure aluminum a. Remove, clean, inspect, and install chip
washers are installed next to housing, and that steel detector (29 or 34, Figure 63-14) (paragraph 63-38
washers are under nuts. Torque the nuts T . through paragraph 63-40).
11. Clean surfaces of steel washer (22) and threads b. Inspect freewheel assembly for oil leakage
of nut (23) with aliphatic naphtha (C-305). Dry the (paragraph 63-71).
63-00-00
Figure 63-15. Freewheel Assembly Dimensional Check
63-00-00

206 MM CH63

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CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM

Paragraph Chapter/Section Page

MAIN ROTOR DRIVE SYSTEM

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

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-43 Oil Level Sight Glass — Inspection .......................................... 63-00-00 45

63-1 Main Rotor Drive System Components............................................................... 7

63-9 Main Rotor Mast Assembly ................................................................................. 30

MAIN ROTOR DRIVE SYSTEM

2. For troubleshooting of main driveshaft, refer to

COMPONENT TYPE LEAKAGE RATE

Table 63-2. Main Rotor Drive System Major Changes

HELICOPTER S/N COMPONENT AND PART NUMBER MAJOR CHANGE

4 through 583 Transmission 206-040-002-005 Original, with five changes

914 through 1251 Transmission 206-040-002-013 Filter assembly – cartridge type

Spares Transmission 206-040-002-029 Grease lubricated sun gear and magnetic

4 through 517 Freewheel assembly 206-040-230-013 Original

518 through 913 Freewheel assembly 206-040-230-019 Non-vented

Figure 63-1. Main Rotor Drive System Components

Figure 63-2. Transmission System Troubleshooting (Sheet 1 of 3)

Figure 63-2. Transmission System Troubleshooting (Sheet 2 of 3)

Figure 63-2. Transmission System Troubleshooting (Sheet 3 of 3)

Figure 63-3. Main Driveshaft Troubleshooting (Sheet 1 of 2)

Figure 63-3. Main Driveshaft Troubleshooting (Sheet 2 of 2)

Figure 63-4. Freewheel Assembly Troubleshooting

b. Silver plating flakes found in filter during

C-501 Sodium Chloride a. Place a small amount of hydrochloric acid

PYLON WHIRL INSPECTION

EXCESSIVE SLOPE LANDING

EXAMINE FOR DAMAGE.

PERFORM FPI PER

Figure 63-5. Pylon Whirl Inspection (Sheet 1 of 3)

PYLON WHIRL INSPECTION

CONTINUED FROM SHEET 1

EXAMINE SWASHPLATE FOR

IF MAST CONTACTED THE IF SEVERE CONTACT IS

Figure 63-5. Pylon Whirl Inspection (Sheet 2 of 3)

PYLON WHIRL INSPECTION

CONTINUED FROM SHEET 2

EXAMINE AFT FUSELAGE

Figure 63-5. Pylon Whirl Inspection (Sheet 3 of 3)

63-7. OIL CONTAMINATION OF

4. Thoroughly flush all oil lines leading to and from

6. Disassemble and clean freewheel assembly

63-9. TRANSMISSION SERVICEABILITY CHECK

6. Fill transmission to proper level with approved MAINTENANCE ON ANOTHER

63-12. MAIN DRIVESHAFT — REMOVAL MATERIALS REQUIRED

1. Clean exterior metal surfaces of main driveshaft

Figure 63-7. Main Driveshaft Assembly

MATERIALS REQUIRED e. The discrepant TEMP-PLATE should be

j. Dress out acceptable nicks and scratches with

b. TEMP-PLATES have a shelf life of 2 years

c. TEMP-PLATE serviceability check: 3. Secure forward outer coupling (8 or 9) to

Table 63-3. TEMP-PLATE Condition and Corrective Action

ONE YELLOW OTHER YELLOW ONE RED OTHER RED

1 Good Black Good Good Defect/installation

2 Black Black Good Good Elevated Temperature

1 Good Good Black Good Defect/installation

4 Good Good Black Black Defect/installation

3 Black Black Black Black Overtemperature