407-MM-Chapter 65 - Tail Rotor Drive System

BHT-407-MM-7
CHAPTER 65 — TAIL ROTOR DRIVE SYSTEM
TABLE OF CONTENTS
Paragraph Chapter/Section Page

Number Title Number Number
TAIL ROTOR DRIVE SYSTEM
65-1 Tail Rotor Drive .............................................................................. 65-00-00 7

65-2 Tail Rotor Drive System — Operational Check ........................ 65-00-00 9
65-3 Tail Rotor Drive System — Operational Check —
Procedures........................................................................ 65-00-00 9
65-4 Tail Rotor Drive System — Inspection for Condition and
Security..................................................................................... 65-00-00 10
65-5 Tail Rotor Drive System — Inspection .............................. 65-00-00 10
65-6 Tail Rotor Drive System — Scheduled Condition and
Security Inspection............................................................ 65-00-00 18
65-7 Tail Rotor Gearbox — Torque Check ....................................... 65-00-00 19
65-8 Tail Rotor Gearbox — 10 to 25 Hours After Installation
Torque Check ................................................................... 65-00-00 19
65-9 Tail Rotor Gearbox — 300 Hour Torque Check................ 65-00-00 19
65-10 Coupling Disc Pack — Torque Check............................... 65-00-00 19
65-11 Tail Rotor Drive System — Conditional Inspection................... 65-00-00 19
65-12 Conditional Inspection — Hard Landing ........................... 65-00-00 19
65-13 Conditional Inspection — Sudden Stoppage .................... 65-00-00 23
65-14 Conditional Inspection — Overspeed ............................... 65-00-00 23
65-15 Conditional Inspection — Overtorque ............................... 65-00-00 23
65-16 Conditional Inspection — Lightning Strike ........................ 65-00-00 23
65-17 Tail Rotor Gearbox — 60 Month Interim Scheduled
Inspection.......................................................................... 65-00-00 24
65-18 Tail Rotor Drive System — Leakage Limits .............................. 65-00-00 24
65-19 Tail Rotor Drive System — Serviceability Check...................... 65-00-00 27
65-20 Unwanted Particles — Visual Identification .............................. 65-00-00 27
65-21 Unwanted Particles — Chemical Identification ......................... 65-00-00 31
65-22 Tail Rotor Driveshaft Bearings — Serviceability Check ............ 65-00-00 32
65-23 Tail Rotor Drive System Components............................................ 65-00-00 33
65-24 Forward Short Shaft Assembly ................................................. 65-00-00 33
65-25 Forward Short Shaft Assembly — Removal ..................... 65-00-00 33
65-26 Forward Short Shaft Assembly — Cleaning ..................... 65-00-00 39
65-27 Forward Short Shaft Assembly — Paint Removal and
Application ........................................................................ 65-00-00 39
65-28 Forward Short Shaft Assembly — Inspection and Repair. 65-00-00 41
65-29 Forward Short Shaft Assembly — Installation .................. 65-00-00 41
65-30 Oil Cooler Blower...................................................................... 65-00-00 48
65-31 Oil Cooler Blower — Removal .......................................... 65-00-00 48
65-32 Oil Cooler Blower — Disassembly .................................... 65-00-00 54
65-33 Oil Cooler Blower — Cleaning .......................................... 65-00-00 56
65-34 Oil Cooler Blower — Inspection and Repair ..................... 65-00-00 56
65-35 Oil Cooler Blower Shaft — Stripping and Painting ............ 65-00-00 59
65-36 Impeller — Assembly and Balance ................................... 65-00-00 71
65-37 Oil Cooler Blower — Assembly......................................... 65-00-00 73
65-38 Oil Cooler Blower — Installation ....................................... 65-00-00 74
65-00-00
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BHT-407-MM-7
TABLE OF CONTENTS (CONT)

65-39 Oil Cooler Blower Shaft — Alignment ............................... 65-00-00 76

65-40 Oil Tank and Oil Cooler — Installation.............................. 65-00-00 81
65-41 Aft Short Shaft Assembly.......................................................... 65-00-00 84
65-42 Aft Short Shaft Assembly — Removal .............................. 65-00-00 84
65-43 Aft Short Shaft Assembly — Cleaning .............................. 65-00-00 85
65-44 Aft Short Shaft Assembly — Inspection and Repair ......... 65-00-00 85
65-45 Aft Short Shaft Assembly — Stripping and Painting ......... 65-00-00 85
65-46 Aft Short Shaft Assembly — Installation ........................... 65-00-00 90
65-47 Tail Rotor Driveshaft Segment Assembly ................................. 65-00-00 91
65-47A Tail Rotor Driveshaft Segment Assembly —
Configuration and Upgrade............................................... 65-00-00 91
65-48 Tail Rotor Driveshaft Segment Assembly — Removal ..... 65-00-00 92C
65-49 Tail Rotor Driveshaft Segment Assembly — Disassembly 65-00-00 93
65-50 Tail Rotor Driveshaft Segmented Shaft Assembly —
Cleaning............................................................................ 65-00-00 96
65-51 Tail Rotor Driveshaft Segmented Shaft Assembly —
Inspection and Repair ....................................................... 65-00-00 96
65-52 Tail Rotor Driveshaft Segmented Shaft Assembly and
Adapter — Stripping and Painting..................................... 65-00-00 102
65-53 Tail Rotor Driveshaft Segment Assembly — Assembly .... 65-00-00 106
65-54 Tail Rotor Driveshaft Segment Assembly — Installation .. 65-00-00 106
65-55 Tailboom Bearing Hanger Support and Bearing Hanger
— Shimming ..................................................................... 65-00-00 107
65-56 Tail Rotor Driveshaft Segment Assembly Bearing —
Alignment .......................................................................... 65-00-00 110
65-57 Tail Rotor Driveshaft Segment Assembly — Alignment.... 65-00-00 110
65-58 Coupling Disc Packs................................................................. 65-00-00 112
65-59 Coupling Disc Packs — Inspection ................................... 65-00-00 112
65-60 Coupling Disc Pack — Torque Sequence......................... 65-00-00 112
65-61 Tail Rotor Gearbox ................................................................... 65-00-00 114
65-62 Tail Rotor Gearbox — Removal........................................ 65-00-00 116
65-63 Tail Rotor Gearbox — Cleaning........................................ 65-00-00 116
65-64 Tail Rotor Gearbox — Inspection...................................... 65-00-00 116
65-65 Tail Rotor Gearbox — Installation..................................... 65-00-00 119
65-66 Tail Rotor Gearbox Inspection Plug.......................................... 65-00-00 125
65-67 Tail Rotor Gearbox Inspection Plug — Removal .............. 65-00-00 125
65-68 Tail Rotor Gearbox Inspection Plug — Cleaning .............. 65-00-00 125
65-69 Tail Rotor Gearbox Inspection Plug — Inspection ............ 65-00-00 125
65-70 Tail Rotor Gearbox Inspection Plug — Installation ........... 65-00-00 125
65-71 Tail Rotor Gearbox Breather and Breather Tube...................... 65-00-00 125
65-72 Tail Rotor Gearbox Breather and Breather Tube —
Removal............................................................................ 65-00-00 125
Cleaning............................................................................ 65-00-00 125
Inspection.......................................................................... 65-00-00 127
Installation......................................................................... 65-00-00 127
65-00-00
Page 2 Rev. 38 4 OCT 2013 Export Classification C, ECCN EAR99
BHT-407-MM-7
TABLE OF CONTENTS (CONT)

65-76 Chip Detector and Self-Closing Valve ...................................... 65-00-00 127

65-77 Chip Detector and Self-Closing Valve — Removal........... 65-00-00 127
65-78 Chip Detector and Self-Closing Valve — Cleaning ........... 65-00-00 127
65-79 Chip Detector and Self-Closing Valve — Inspection......... 65-00-00 127
65-80 Chip Detector and Self-Closing Valve — Installation ........ 65-00-00 127
65-81 Tail Rotor Gearbox Oil Sight Glass........................................... 65-00-00 130
65-82 Tail Rotor Gearbox Oil Sight Glass — Removal ............... 65-00-00 130
65-83 Tail Rotor Gearbox Oil Sight Glass — Cleaning ............... 65-00-00 130
65-84 Tail Rotor Gearbox Oil Sight Glass — Inspection............. 65-00-00 130
65-85 Tail Rotor Gearbox Oil Sight Glass — Installation ............ 65-00-00 130
65-86 Tail Rotor Gearbox Filler Cap ................................................... 65-00-00 130
65-87 Tail Rotor Gearbox Filler Cap — Removal ....................... 65-00-00 130
65-88 Tail Rotor Gearbox Filler Cap — Cleaning ....................... 65-00-00 130
65-89 Tail Rotor Gearbox Filler Cap — Inspection ..................... 65-00-00 130
65-90 Tail Rotor Gearbox Filler Cap — Installation .................... 65-00-00 133
65-91 Tail Rotor Gearbox Output Cap ................................................ 65-00-00 133
65-92 Tail Rotor Gearbox Output Cap — Removal .................... 65-00-00 133
65-93 Tail Rotor Gearbox Output Cap — Cleaning .................... 65-00-00 133
65-94 Tail Rotor Gearbox Output Cap — Inspection .................. 65-00-00 133
65-95 Tail Rotor Gearbox Output Cap — Installation ................. 65-00-00 140
65-96 Tail Rotor Gearbox Output Seal ............................................... 65-00-00 140
65-97 Tail Rotor Gearbox Output Seal — Removal.................... 65-00-00 140
65-98 Tail Rotor Gearbox Output Seal — Installation................. 65-00-00 142
65-99 Tail Rotor Gearbox Input Seal .................................................. 65-00-00 142
65-100 Tail Rotor Gearbox Input Seal (All) — Removal ............... 65-00-00 142
65-101 Tail Rotor Gearbox Input Seal (All) — Inspection and
Repair ............................................................................... 65-00-00 143
65-102 Tail Rotor Gearbox Carbon Type Input Seal —
Installation......................................................................... 65-00-00 146
65-103 Tail Rotor Gearbox Lip Type Input Seal — Installation ..... 65-00-00 161
FIGURES
Figure Page
Number Title Number
65-1 Tail Rotor Drive System ...................................................................................... 8

65-2 Tail Rotor Drive System — Trouble No. 1........................................................... 11
65-9 Spiral Bevel Pinion Inspection ............................................................................ 25
65-10 Unwanted Material on the Tail Rotor Chip Detector ........................................... 28
65-11 Forward Short Shaft Assembly — Removal/Installation ..................................... 34
65-00-00
Export Classification C, ECCN EAR99 4 OCT 2013 Rev. 38 Page 3
BHT-407-MM-7
FIGURES (CONT)
Figure Page
Number Title Number
65-12 Coupling Disc Packs — Inspection and Repair .................................................. 40

65-13 Forward Short Shaft — Inspection...................................................................... 42
65-14 Splined Flywheel Adapter — Inspection ............................................................. 44
65-15 Oil Cooler Blower ................................................................................................ 49
65-16 Bearing Hanger — Inspection............................................................................. 58
65-17 Bearing — Inspection.......................................................................................... 60
65-18 Oil Cooler Blower Hanger/Bracket Link — Inspection ........................................ 61
65-19 Oil Cooler Blower Shaft — Inspection................................................................. 62
65-20 Oil Cooler Blower Impeller — Inspection ............................................................ 65
65-21 Oil Cooler Blower Housing — Inspection............................................................ 66
65-22 Brackets — Inspection ........................................................................................ 67
65-23 Splined Adapter — Inspection ............................................................................ 69
65-24 Oil Cooler Blower Shaft — Tool Application ....................................................... 72
65-25 Oil Cooler Blower Shaft — Aft Alignment............................................................ 77
65-26 Oil Cooler Blower Shaft — Forward Alignment................................................... 79
65-27 Oil Cooler Blower Shaft — Centering ................................................................. 80
65-28 Aft Short Shaft Assembly — Removal/Installation .............................................. 82
65-29 Aft Short Shaft Assembly — Inspection .............................................................. 86
65-30 Driveshaft and Adapters — Organic Finish Application ...................................... 88
65-31 Tail Rotor Driveshaft Segment Assemblies ........................................................ 92
65-32 Tail Rotor Driveshaft Segment Assembly — Disassembly/Assembly................. 94
65-33 Tail Rotor Driveshaft Segmented Shaft Assembly — Inspection and Repair ..... 97
65-34 Tail Rotor Driveshaft Segment Assembly Bearing Hanger —
Inspection and Repair ......................................................................................... 100
65-35 Tail Rotor Driveshaft Segment Assembly Adapter — Inspection and Repair ..... 103
65-36 Coupling Washer — Inspection and Repair........................................................ 105
65-37 Shimming Procedure .......................................................................................... 108
65-38 Tail Rotor Driveshaft Segment Assembly Bearing — Alignment ........................ 111
65-39 Tail Rotor Driveshaft Segment Assembly — Alignment...................................... 113
65-40 Tail Rotor Gearbox.............................................................................................. 115
65-41 Tail Rotor Gearbox Workaid — Field Fabricated ................................................ 117
65-42 Tail Rotor Gearbox — View Looking Up ............................................................. 118
65-43 Tailboom Support — View Looking Down .......................................................... 120
65-44 Tail Rotor Gearbox — View Looking Aft ............................................................. 121
65-45 Tail Rotor Gearbox Housing — Inspection ......................................................... 122
65-46 Tail Rotor Gearbox Inspection Plug — Inspection .............................................. 126
65-47 Breather — Inspection ........................................................................................ 128
65-48 Self-Closing Valve — Inspection......................................................................... 129
65-49 Oil Sight Glass — Inspection .............................................................................. 131
65-50 Cap Assembly (Nonvented) — Inspection .......................................................... 132
65-51 Tail Rotor Gearbox Output Cap — Removal/Installation .................................... 134
65-52 Output Shaft — Inspection.................................................................................. 136
65-53 Cap Assembly — Inspection............................................................................... 138
65-54 Output Seal — Removal/Installation ................................................................... 141
65-55 Tail Rotor Gearbox Input Components — Removal/Installation ......................... 144
65-56 Tail Rotor Gearbox Input Carbon Seal — Removal/Installation.......................... 147
65-57 Tail Rotor Gearbox Input Lip Seal — Workaids .................................................. 148
65-58 Tail Rotor Gearbox Input Lip Seal — Removal/Installation................................. 150
65-59 Carbon Seal — Inspection .................................................................................. 151
65-00-00
BHT-407-MM-7
FIGURES (CONT)
Figure Page
Number Title Number
65-60 Input Duplex Bearing Nut — Inspection.............................................................. 155

65-61 Input Adapter Nut — Inspection.......................................................................... 156
65-62 Input Adapter — Inspection ................................................................................ 157
65-63 Plug — Inspection............................................................................................... 159
65-64 Tail Rotor Gearbox Input Adapter/Wear Sleeve — Installation/Removal ........... 163
65-65 Tail Rotor Gearbox Input Seal — Installation Workaid ....................................... 165
TABLES
Table Page
Number Title Number
65-1 Non-Destructive Test —Tail Rotor Drive............................................................. 20

65-2 Magnetic Particle Inspection — Procedures ....................................................... 21
65-3 Maximum Permitted Leakage Rates for Tail Rotor Drive System....................... 24
65-4 Unwanted Particles — Visual Identification ........................................................ 30
65-5 Tail Rotor Driveshaft Segment Assembly Versus Helicopter Serial Number ..... 92C
65-6 Tail Rotor Driveshaft Segment Assembly — Configuration ................................ 92D
65-00-00
Export Classification C, ECCN EAR99 4 OCT 2013 Rev. 38 Page 5/6
BHT-407-MM-7
TAIL ROTOR DRIVE SYSTEM
65-1. TAIL ROTOR DRIVE holds the engine and transmission oil coolers. The oil
cooler blower shaft is held by two bearing hangers (8),
Power to operate the tail rotor comes through the tail one on the forward end and one on the aft end. These
rotor drive system, from the engine freewheel unit. are bolted to the helicopter structure. The oil cooler
blower shaft is connected to the forward short shaft (1)
The engine freewheel unit turns the forward short shaft with a splined adapter, (S/N 53443 and subsequent or
(1, Figure 65-1) and supplies power to the oil cooler S/N 53000 through 53442 Post BHT-407-II-30), or a
blower assembly (2). The power then goes through the splined flywheel adapter, (S/N 53000 through 53442
aft short shaft (3) and the four tail rotor driveshaft Pre BHT-407-II-30), and to the aft short shaft (3) with a
segment assemblies (4) to the tail rotor gearbox (5). splined adapter. The splined adapters or the splined
The tail rotor gearbox changes the direction of the flywheel adapter (6) can slide fore and aft on the oil
power 90° and reduces the speed by a ratio of 2.53 to cooler blower shaft splines. Balance plates may also
1. The tail rotor drive system turns at 6317 RPM and be installed on each end of the oil cooler blower shaft
the tail rotor gearbox output shaft turns at 2500 RPM. to allow for dynamic balancing. The balance plates are
only used with the splined adapter configuration. The
Major components of the tail rotor drive system are: impeller is covered by a housing that is attached to the
helicopter structure.
• forward short shaft assembly
Helicopters that have an environmental control system
• splined flywheel adapter (if installed) use the oil cooler blower shaft to operate the air
conditioner compressor. One of the weights (7) is
removed when the tail rotor drive is equipped with a
• oil cooler blower assembly
compressor.
• aft short shaft assembly
The aft short shaft assembly (3) is an aluminum shaft.
• tail rotor driveshaft segment assemblies The forward end is connected to the oil cooler blower
by a coupling disc pack and a sliding splined adapter.
The aft end is fixed. It is connected to a coupling disc
• the tail rotor gearbox assembly
pack (9) on the first tail rotor driveshaft segment
assembly (4).
The forward short shaft assembly (1) is a steel shaft.
The forward end is fixed. It is connected to a coupling
disc pack on the freewheel output adapter. The aft end The four tail rotor driveshaft segment assemblies (4)
is connected to the oil cooler blower assembly (2) by a are installed along the top of the tailboom. The tail
coupling disc pack and a sliding splined adapter, (S/N rotor driveshaft segment assemblies are accessed
53443 and subsequent or S/N 53000 through 53442 through the removal of two tailboom fairings. The four
Post BHT-407-II-30). A splined flywheel adapter (6), tail rotor driveshaft segment assemblies are
(S/N 53000 through 53442 Pre BHT-407-II-30), is connected by coupling disc packs (9) that make
used to change the tail rotor drive shaft natural allowance for tailboom movement. Each of the four tail
tortional frequencies. rotor driveshaft segment assemblies are the same and
are interchangeable. Each tail rotor driveshaft
The oil cooler blower assembly (2) is part of the tail segment assembly is aluminum, and has an aluminum
rotor drive system. The impeller is attached to the adapter flange. The bearing hangers (8) hold the tail
shaft. For S/N 53443 and subsequent or S/N 53000 rotor driveshaft segment assemblies aligned. The
through 53442 Post BHT-407-II-30 two weights (7) are most aft tail rotor driveshaft segment assembly is
attached, along with the impeller, to the shaft. The attached to the tail rotor gearbox input adapter through
weights (7) are positioned aft of the impeller. The shaft a coupling disc pack (9). The tail rotor gearbox input
is steel and drives the aft short shaft. The oil cooler adapter is part of the tail rotor gearbox (5). Allowance
blower shaft is splined at both ends. The oil cooler for tail rotor gearbox movement is through the coupling
blower assembly (2) is installed aft of the aft firewall. It disc pack.
65-00-00
BHT-407-MM-7
1 6 2
7 5
3 8 4
9 4
8 9
8 9 9
8 9
1. Forward short shaft

2. Oil cooler blower assembly
3. Aft short shaft
4. Tail rotor driveshaft segment assembly
5. Tail rotor gearbox
6. Splined flywheel adapter (S/N 53000 through 53442 Pre BHT-407-II-30), splined adapter (S/N 53443 and
subsequent or S/N 53000 through 53442 Post BHT-407-II-30)
7. Weights (quantity 2) (S/N 53443 and subsequent or S/N 53000 through 53442 Post BHT-407-II-30)
8. Bearing hanger
9. Coupling disc pack
407MM_65_0042
Figure 65-1. Tail Rotor Drive System
65-00-00
Page 8 Rev. 23 7 NOV 2006
BHT-407-MM-7
All bearing hangers (8) can be lubricated through a 65-3. Tail Rotor Drive System — Operational
grease fitting. They can be shimmed to align the tail Check — Procedures
rotor driveshaft.
Do a 20 minute ground-run operational check
The coupling disc packs (9) join the different following the interim inspection of the tail rotor
components of the tail rotor driveshaft to each other. gearbox, installation of a repaired or overhauled tail
The coupling disc packs (9) are made of 9 to 12 rotor gearbox, repair of a tail rotor driveshaft segment
separate steel discs. The disc circumference has two assembly, or oil cooler blower assembly. This check
index flats, parallel to the grain of the steel. These should also be performed anytime an operational
index flats are an aid to ensure that the grain of the discrepancy is suspected and not yet identified.
steel is alternated with each disc (each disc is turned
90° from the previous disc).
The tail rotor gearbox (5) contains an input pinion and CAUTION
a spiral bevel gear set that changes the direction of the
drive 90°. The speed is reduced by a ratio of 2.53 to 1
at these gears. The tail rotor gearbox housing is made ONLY AN APPROVED PERSON MUST
of magnesium and is attached to the tailboom. The tail BE AT THE HELICOPTER CONTROLS
rotor gearbox assembly includes a filler cap, oil sight DURING THIS PROCEDURE.
glass, a breather and rigid line, and a combination
electrical chip detector/self-closing valve. The tail rotor
NOTE
gearbox (5) also gives the support for the tail rotor
pitch change control system (Chapter 67). For all operations, follow the instructions in
the flight manual (BHT-407-FM).
The tail rotor chip detector/self-closing valve and oil
sight glass help during maintenance. The self closing 1. Prepare the helicopter for the ground-run.
valve makes it possible to examine the electric chip
detector for metal particles without draining the oil.
The self-closing valve also serves as a drain plug for
the tail rotor gearbox (5). The oil sight glass makes it CAUTION
possible to visually examine the quantity of oil in the
tail rotor gearbox (5).
MAINTENANCE PERSONNEL
The breather assembly permits the lubricating oil and OBSERVING THE OPERATION OF THE
the air in the tail rotor gearbox (5) to expand and HELICOPTER SHALL IMMEDIATELY
contract due to changes in temperature and altitude. NOTIFY THE PERSON AT THE
The tail rotor gearbox (5) will not pressurize because CONTROLS OF DISCREPANCIES
the breather assembly vents to the atmosphere. REQUIRING THE STOPPING OF THE
OPERATIONAL CHECK. REPAIR ANY
DISCREPANCIES PRIOR TO THE
65-2. TAIL ROTOR DRIVE SYSTEM — CONTINUATION OF THE OPERATIONAL
OPERATIONAL CHECK CHECK.
The operational check procedure makes sure the tail

rotor drive system operates correctly. The NOTE
troubleshooting charts give the means to find and Corrective actions for discrepancies that
correct the majority of the faults that can occur in the are identified during the Operational Check
tail rotor drive system. are referenced in the following locations:
When you do troubleshooting on an unserviceable • If an unusual vibration originates from forward

system, do an operational check first. The results will or aft short shaft, refer to Trouble No. 1,
indicate if the system operation is normal. Figure 65-2.
65-00-00
BHT-407-MM-7
• If an unusual vibration originates from the oil 3. If after five minutes, no discrepancies are found,
cooler blower assembly, refer to Trouble No. the engine and transmission oil pressures and
2, Figure 65-3. temperatures are stabilized within limits, slowly
increase the NR and NP RPM to 100% (FLY position
on throttle) and check for the following:
• If an unusual vibration originates from the tail
rotor driveshaft segment assemblies, refer to
Trouble No. 3, Figure 65-4. a. Unusual vibrations.
• If an unusual vibration originates from the tail b. Tail rotor driveshaft hanger bearings that are
rotor gearbox, refer to Trouble No. 4, running hot.
Figure 65-5.
c. Leaks in the tail rotor gearbox area.
• If a tail rotor driveshaft bearing temperature is
suspected of being high, examine the bearing d. Illumination of the tail rotor chip detector (T/R
with a surface pyrometer. Black colored CHIP) segment in the caution/warning and advisory.
grease that is being purged from the bearing
indicates an overtemperature operation. The 4. After 20 minutes of ground run with no indication
maximum operating temperature after the of discrepancies, reduce NG to idle RPM for the
break-in period is 185°F (85°C). A new required engine cool down. Shut down the engine.
bearing may run as hot as 275°F (135°C) for
the first 15 or 20 hours of operation. If the 65-4. TAIL ROTOR DRIVE SYSTEM —
bearing temperature does not stabilize under INSPECTION FOR CONDITION AND
185°F (85°C) during this time, discard the SECURITY
bearing. The bearing will also run hot after
servicing. Refer to Chapter 12 for the correct
servicing procedure. 65-5. Tail Rotor Drive System — Inspection
These paragraphs give the instructions for:

• If the caution/warning and advisory panel (T/R
CHIP) annunciator segment illuminates, refer
to Trouble No. 5, Figure 65-6. 1. The scheduled condition and security inspection.
2. The tail rotor gearbox torque check (Special

• If there is an oil leak in the tail rotor gearbox
Inspection).
area, refer to Trouble No. 6, Figure 65-7.
3. The examination of the condition identified in

• If the tail rotor gearbox chip detector is
Chapter 5, or for damage after one or more of the
contaminated, refer to Trouble No. 7,
following:
Figure 65-8.
• hard landing
2. Start the engine, stabilize the RPM at idle and
immediately check for the following:
• sudden stoppage
a. Unusual vibrations. • overspeed
b. Tail rotor driveshaft hanger bearings that are • overtorque

running hot.
• lightning strike
c. Leaks in the tail rotor gearbox area or
illumination of the tail rotor chip detector (T/R CHIP) 4. The 60 month interim scheduled inspection for
segment in the caution/warning and advisory. the tail rotor gearbox.
65-00-00
Page 10 Rev. 23 7 NOV 2006
BHT-407-MM-7
TROUBLE NO. 1
THE VIBRATION ORIGINATES

FROM FORWARD OR AFT
SHORT SHAFT.
CHECK FOR LOOSE BOLTS

AND INCORRECT INSTALLATION.
YES NO
INSTALL SERVICEABLE CHECK THE COUPLING DISC

PART AND HARDWARE. PACKS FOR EXCESSIVE GAP AND
ENSURE CORRECT INSTALLATION. CONDITION. REFER TO THE
APPLY TORQUE. PROCEDURE IN THIS CHAPTER.
YES NO
CHECK SPLINED ADAPTER,

INSTALL SERVICEABLE SPLINED FLYWHEEL ADAPTER
DISC PACK AND AND OIL COOLER BLOWER
SHAFT FOR WEAR.
APPLY TORQUE.
REFER TO THE TOLERANCE
IN THIS CHAPTER.
YES NO
GAPS IN THE DISC PACK

MAY INDICATE OIL COOLER
BLOWER SHAFT, ENGINE AND/OR
SEGMENTED SHAFT
AND MISALIGNMENT.
REFER TO THE ALIGNMENT
PROCEDURE IN THIS CHAPTER.
INSTALL SERVICEABLE CHECK THE SHAFT

OIL COOLER BLOWER FOR STRAIGHTNESS.
SHAFT, SPLINED ADAPTER AND REFER TO THE PROCEDURE
SPLINED FLYWHEEL ADAPTER. IN THIS CHAPTER.
YES NO
INSTALL SERVICEABLE
SHAFT. ROTATING THE SHAFT 180
DEGREES END FOR END MAY
REDUCE THE UNUSUAL VIBRATION
TO AN ACCEPTABLE LEVEL.
NO
CHECK BALANCE OF
SHAFT AND SPLINED FLYWHEEL
ADAPTER (IF INSTALLED).
407MM_65_0043
Figure 65-2. Tail Rotor Drive System — Trouble No. 1
65-00-00
7 NOV 2006 Rev. 23 Page 11
BHT-407-MM-7
TROUBLE NO.2
VIBRATION ORIGINATES
FROM THE OIL COOLER BLOWER.
EXAMINE THE IMPELLER FOR

CLEANLINESS OR DAMAGE.
YES NO
CLEAN THE IMPELLER OR CHECK FOR LOOSENESS

REPLACE WITH A IN THE ATTACHING HARDWARE.
SERVICEABLE IMPELLER.
YES NO
REPLACE THE DAMAGED PARTS CHECK THE BEARINGS FOR

WITH SERVICEABLE PARTS ROUGHNESS AND LOOSENESS
AND TORQUE HARDWARE. IN HANGER. PERFORM TAIL ROTOR
DRIVESHAFT BEARINGS -
SERVICEABILITY CHECK.
YES NO
INSTALL A SERVICEABLE CHECK THE OIL COOLER

BEARING. BLOWER SHAFT
ALIGNMENT.
YES NO
ALIGN OIL COOLER CHECK BALANCE OF

BLOWER SHAFT SHAFT AND IMPELLER.
REFER TO THE OIL
COOLER BLOWER SHAFT
ALIGNMENT PROCEDURE.
407MM_65_0044
65-00-00
Page 12 Rev. 23 7 NOV 2006
BHT-407-MM-7
65-00-00
7 NOV 2006 Rev. 23 Page 13
BHT-407-MM-7
TROUBLE NO. 4
VIBRATION ORIGINATES
FROM THE TAIL ROTOR GEARBOX.
CHECK CHIP DETECTOR

FOR UNWANTED MATERIAL.
YES NO
SEND GEARBOX TO AN CHECK THE TAIL ROTOR GEARBOX

AUTHORIZED OVERHAUL FACILITY. ATTACHMENT POINT.
YES NO
IF NO DAMAGE IS EVIDENT MEASURE MOVEMENT OF THE

ON THE STUD, DOWEL PIN OUTER SHAFT BY INSTALLING
OR STRUCTURE, A DIAL INDICATOR, ONE INCH
TORQUE THE NUTS. OUTBOARD OF GEARBOX OUTPUT
SEAL. TOTAL RADIAL MOVEMENT
OF THE SHAFT, WHEN MOVED UP
AND DOWN, SHALL NOT EXCEED
0.003 INCH (0.076 mm)
AT THIS POINT.
THE MOVEMENT SHOULD BE
PERFORMED BY APPLYING THUMB
AND INDEX FINGER TO THE
OUTBOARD END OF SHAFT AND
ENOUGH UP AND DOWN
PRESSURE TO CHECK THE
ACTUAL LOOSENESS.
YES NO
AXIAL MOVEMENT OF
IF THE MOVEMENT IS IN EXCESS
THE OUTPUT SHAFT.
OF 0.003 INCH (0.076 mm),
SEND THE GEARBOX TO AN
AUTHORIZED OVERHAUL FACILITY.
SEND GEARBOX TO AN
AUTHORIZED OVERHAUL FACILITY.
407MM_65_0046
65-00-00
Page 14 Rev. 23 7 NOV 2006
BHT-407-MM-7
TROUBLE NO. 5
TAIL ROTOR GEARBOX CHIP

DETECTOR LIGHT IS ON.
CHECK THE CHIP DETECTOR

FOR METAL CONTAMINATION.
YES NO
REFER TO TROUBLE NO. 7. REFER TO CHAPTER 96

FOR CHIP DETECTOR
OPERATIONAL TEST.
407MM_65_0047
65-00-00
7 NOV 2006 Rev. 23 Page 15
BHT-407-MM-7
TROUBLE NO. 6
OIL LEAK IN TAIL ROTOR

GEARBOX AREA.
CHECK THE TAIL ROTOR

GEARBOX INPUT AND OUTPUT
SEAL FOR LEAKAGE.
YES NO
REFER TO THE LEAKAGE TABLE EXAMINE THE FOLLOWING

FOR PERMITTED PARTS FOR LEAKAGE:
LEAKAGE RATE. - INSPECTION PORT
- CHIP DETECTOR
- SIGHT GLASS
- FILLER CAP
- BREATHER
- PLUG
REPLACE THE AFFECTED
SEAL OR PACKING.
YES NO
REPLACE THE UNSERVICEABLE CHECK THE TAIL ROTOR

PART OR PACKING WITH A GEARBOX HOUSING
SERVICEABLE UNIT. FOR CRACKS.
SEND THE TAIL ROTOR

GEARBOX TO AN AUTHORIZED
FACILITY FOR OVERHAUL.
407MM_65_0048
65-00-00
Page 16 Rev. 23 7 NOV 2006
BHT-407-MM-7
TROUBLE NO. 7
TAIL ROTOR GEARBOX

CHIP DETECTOR CONTAMINATED.
CHIP LIGHT ON.
YES NO
REFER TO THE UNWANTED

MATERIAL TABLE IN THIS CHAPTER REFER TO CHAPTER 96
FOR FOREIGN MATERIAL FOR OPERATIONAL TEST OF THE
IDENTIFICATION AND ACTION CAUTION LIGHT PANEL.
REQUIRED.
IF IT IS DETERMINED THAT THE
TAIL ROTOR GEARBOX MAY
REMAIN IN SERVICE, DO A
SERVICEABILITY CHECK.
REFER TO THE PROCEDURE
IN THIS CHAPTER.
407MM_65_0049
65-00-00
7 NOV 2006 Rev. 23 Page 17
BHT-407-MM-7
65-6. Tail Rotor Drive System — Scheduled g. Examine the bearing hanger retaining ring for
Condition and Security Inspection security.
1. Examine the forward and the aft short shafts as 3. Examine the four tail rotor driveshaft segment
follows: assemblies as follows:
a. Examine the shafts for corrosion and a. Examine the shaft for corrosion and
mechanical damage. mechanical damage.
b. Examine the shafts for loose hardware. b. Examine the bearing hanger for loose
hardware.
c. Make sure that the number, location, and
direction of the coupling washers (2, 8, 13, and 18,
c. Examine the bearing hanger for cracks,
Figure 65-11) and (3, 5, 10, 15, and 20, Figure 65-28)
corrosion, and mechanical damage.
are correct. Make sure the number of coupling
washers installed 180° opposite of each other are the
same. d. Examine the bearing hanger retaining ring for
security.
d. Examine the coupling disc packs for condition,
security, and gaps between the discs (paragraph e. Examine the bearing for black colored grease
65-59). around the seal. Refer to paragraph 65-22 for bearing
serviceability check.
e. Examine the rivets that hold the shaft adapters
to the shaft for looseness. f. Ensure that the number, location, and
direction of the coupling washers is correct. Make sure
f. Examine the splines of the splined adapter (5, the number of coupling washers that are installed 180°
Figure 65-11) or the splined flywheel adapter (23) (if opposite of each other are the same.
installed), and the splined adapter (17, Figure 65-28)
for condition. g. Examine the coupling disc packs for condition,
security, and gaps between the discs (paragraph
2. Examine the oil cooler blower assembly as 65-59).
follows:
h. Examine the rivets that hold the shaft adapters
a. Examine the oil cooler blower shaft for to the shaft for looseness.
corrosion and mechanical damage.
4. Examine the tail rotor gearbox as follows:
b. Make sure the impeller is clean (Chapter 12)
and examine for corrosion, mechanical damage, and
a. Examine the tail rotor gearbox for corrosion,
cracks.
mechanical damage, and cracks.
c. Examine the housing and covers for
corrosion, cracks, and mechanical damage. b. Examine the tail rotor gearbox for leaks
(Table 65-3).
d. Examine the impeller, housing, and bearing
hangers for loose hardware. c. Examine the tail rotor gearbox for looseness
at the attachment points.
e. Examine the bearing hangers for cracks,
corrosion, and mechanical damage. d. Examine the tail rotor gearbox for the correct
oil level.
f. Examine the bearings for black colored
grease around the seal. Refer to paragraph 65-22 for e. Make sure the filler cap and the chip detector
bearing serviceability check. are correctly installed.
65-00-00
Page 18 Rev. 23 7 NOV 2006
BHT-407-MM-7
65-7. TAIL ROTOR GEARBOX — TORQUE 2. If the fastener(s) moved and this is the first check
CHECK after the initial installation, apply the correct torque to
the fastener(s) (paragraph 65-60).
65-8. Tail Rotor Gearbox — 10 to 25 Hours After
Installation Torque Check 3. If the fastener(s) moved during a different
scheduled torque check inspection, do the steps that
1. Apply the minimum torque required for the follow:
fastener. If the fastener does not move, the test is
complete. a. Remove the coupling disc pack and examine
the bolts, nuts and washers for damage. Discard the
damaged parts.
2. If one or more of the fasteners move, apply
maximum torque to the fastener(s).
b. Examine the coupling disc pack for condition
(paragraph 65-59).
3. Do the torque check procedure again each 10 to
25 flight hours until the torque is stable. 65-11. TAIL ROTOR DRIVE SYSTEM —
CONDITIONAL INSPECTION
65-9. Tail Rotor Gearbox — 300 Hour Torque
Check 65-12. Conditional Inspection — Hard Landing
1. Apply the minimum torque required for the

fastener. If the fastener does not move, the test is MATERIALS REQUIRED
complete.
Refer to BHT-ALL-SPM for specifications.
2. If the fastener moved, do the following: NUMBER NOMENCLATURE
a. Examine the tail rotor gearbox studs, dowel C-355 Detergent

pins and the face of the tail rotor gearbox that mates
with the tailboom for condition (BHT-407-CR&O). 1. Remove and disassemble: the forward short shaft
(paragraph 65-25), the aft short shaft (paragraph
b. Examine the tailboom holes, the dowel pin 65-42), the oil cooler blower assembly (paragraph
bores and the face of the tailboom that mates with the 65-32) and the tail rotor driveshaft segment
tail rotor gearbox for condition (BHT-LIGHT-SRM). assemblies (paragraph 65-49).
c. If you find damage, repair the damage to the 2. Examine the forward short shaft (paragraph
tail rotor gearbox and/or the tailboom as required by 65-28), the aft short shaft (paragraph 65-44), the oil
the applicable manual and torque the fasteners again. cooler blower assembly (paragraph 65-34) and the tail
rotor driveshaft segment assemblies (paragraph
d. If you do not find damage, install the parts that 65-51).
were removed and torque the fasteners again.
3. Do a straightness check on all of the shafts and
e. Do the tail rotor gearbox torque check adapters.
(paragraph 65-7) again at the same scheduled interval
(Chapter 5). 4. Examine the coupling disc packs for condition
(paragraph 65-59).
65-10. Coupling Disc Pack — Torque Check
5. Examine the attachment hardware for condition.
1. Apply the minimum torque required for the
fasteners. If the fasteners do not move the check is 6. Magnetic Particle Inspect (MPI) the parts listed in
complete. Table 65-1.
65-00-00
7 NOV 2006 Rev. 23 Page 19
BHT-407-MM-7
Table 65-1. Non-Destructive Test —Tail Rotor Drive
FLUORESCENT
MAGNETIC PARTICLE
PART NUMBER NOMENCLATURE PENETRANT
INSPECTION
INSPECTION
406-040-315 Forward Short Shaft X
407-040-316 Splined Flywheel X

Adapter (If Installed)
406-040-316 Adapter X
406-040-320 Shaft X
407-040-320 Shaft X
206-061-432 Impeller X
407-040-325 Aft Short Shaft X

407-040-321 Forward Bracket X
406-040-323 Aft Bracket X
407-040-323 Aft Bracket X
406-040-318 Link X
407-040-311 Link X
406-040-322 Hanger X
407-040-322 Hanger X
406-040-317 Hanger X
406-040-328 Adapter X
407-040-330 Shaft X
406-040-327 Washer X
a. All aspects of the MPI process shall be

NOTE
performed in accordance with BHT-ALL-SPM, Chapter
Personnel performing NDI must meet the 6, Nondestructive Inspection, ASTM E1444 and in
Qualification Requirements as stated in conjunction with the following information and
BHT-ALL-SPM, Chapter 6, Nondestructive instructions.
Inspection.
b. Clean the parts to make sure the surfaces are
NOTE free of dirt, oil, corrosion, or other surface conditions
that could hide defects or give incorrect results. The
It is not necessary to remove the organic method you use to clean the parts must not cause
finish from the interior of the forward short corrosion or hydrogen embrittlement. Refer to the
shaft to do the Magnetic Particle BHT-ALL-SPM for the cleaning procedures.
Inspection.
7. Fluorescent Penetrant Inspect (FPI) the parts
listed in Table 65-1.
65-00-00
Page 20 Rev. 23 7 NOV 2006
BHT-407-MM-7
Table 65-2. Magnetic Particle Inspection — Procedures
NOMENCLATURE METHOD OF MAGNETIZATION ACCEPTANCE CONDITIONS
Flywheel adapter (if installed) Head Shot Parts that give the indication of
407-040-316 Place the part on a 1 inch (25.4 cracks, laps, seams, cold shunts
mm) diameter central conductor. or bursts are cause for rejection.
Current for small diameter: Parts that give the indication of

Magnetize at 758 amperes. inclusions that break over edges,
or extend into radii, reliefs or
Current for larger diameter: undercuts are cause for rejection.
Magnetize at 5060 amperes. Inclusions that are turned more
than ±15° from the longitudinal
5 Turn coil shot axis are cause for rejection.
Lay the part flat in the bottom of
the coil. Shoot at 3000 amperes. Parts that give the indication of
Turn the part 1/4 turn and do the non-metallic inclusions are
shot again. permitted if the maximum length
of each indication is less than 1/8
inch (3.175 mm), and ratable
indications are less than 1/4 inch
(6.35 mm) from each other. All
indications 1/64 inch (0.397 mm)
or greater are ratable.
Adapter 406-040-316 Head Shot Parts that give the indication of
Put the part over a 1 inch (25.4 cracks, laps, seams, cold shunts

Current for larger diameter: or extend into radii, reliefs or
Magnetize at 2100 amperes. undercuts are cause for rejection.
Inclusions that are turned more
5 Turn Coil Shot than ±15° from the longitudinal
This part has a short length to axis are cause for rejection.
diameter ratio. Do not do the 5 Parts that give the indication of
Turn Coil Shot. non-metallic inclusions are
permitted if the maximum length
of each indication is less than 1/8
inch (3.175 mm), and ratable
indications are less than 1/4 inch
(6.35 mm) from each other. All
indications 1/64 inch (0.397 mm)
or greater are ratable.
65-00-00
7 NOV 2006 Rev. 23 Page 21
BHT-407-MM-7
Table 65-2. Magnetic Particle Inspection — Procedures (Cont)
NOMENCLATURE METHOD OF MAGNETIZATION ACCEPTANCE CONDITIONS
Shaft 406-040-320 or Head Shot Parts that give the indication of

407-040-320 Put the part over a 1 inch (25.4 cracks, laps, seams, cold shunts

Current for larger diameter: or extend into radii, reliefs, or
Magnetize at 2150 amperes. undercuts are cause for rejection.
Inclusions that are turned more
5 Turn Coil Shot than ±15° from the longitudinal
Put the part in the bottom of the axis are cause for rejection.
coil, with the long axis parallel to Parts that give the indication of
the coil axis. Shoot at 1810 non-metallic inclusions that are
amperes. 1/64 inch (0.397 mm) long or
greater are cause for rejection.
You can remove the adhesive used to bond

NOTE
the stoppers in the end face of the adapters
Personnel performing NDI must meet the by PMB.
Qualification Requirements as stated in
BHT-ALL-SPM, Chapter 6, Nondestructive
b. Remove the organic finish from the aft short
Inspection.
shaft and the four tail rotor driveshaft segment
a. All aspects of the FPI process shall be assemblies with PMB. Refer to BHT-407-CR&O for the
performed in accordance with BHT-ALL-SPM, Chapter PMB procedures. Do not remove the organic layer by
6, Nondestructive Inspection, ASTM E1417 and in sand blasting, glass beading or mechanical sanding.
conjunction with the following information and
instructions. c. Clean the parts to make sure the surfaces are
free of dirt, oil, corrosion products or other surface
conditions that could hide defects or give incorrect
CAUTION results. The method you use to clean the parts must
not cause corrosion or hydrogen embrittlement. Refer
to the BHT-ALL-SPM for the cleaning procedures.
DO NOT USE CHEMICAL PRODUCTS TO
REMOVE THE ORGANIC FINISH FROM 8. If any of the specified items in the Chapter 5,
THE SHAFTS. YOU CAN NOT RINSE THE “Conditional Inspection for Hard Landing”, are
CHEMICAL PAINT REMOVER FULLY
identified, do an overhaul of the tail rotor gearbox.
FROM THE GAP BETWEEN THE
Refer to the BHT-407-CR&O manual for the
RIVETED ADAPTER AND THE SHAFT.
procedures.
THE MECHANICAL RIVETS CAN START
TO CORRODE IN A WAY THAT CAN NOT
BE DETECTED. a. Do a straightness check of the tail rotor
gearbox output shaft.
NOTE
Do not Plastic Media Blast (PMB) the end b. Do a straightness check of the tail rotor
face of the adapters riveted to the shaft. gearbox input adapter.
65-00-00
Page 22 Rev. 23 7 NOV 2006
BHT-407-MM-7
65-13. Conditional Inspection — Sudden All signs of deformation of the bore (bolt hole) is cause
Stoppage for rejection.
1. Examine the tail rotor driveshaft. Do the steps 65-14. Conditional Inspection — Overspeed
that follow:
1. Examine the tail rotor driveshaft as follows: do the
inspection for condition and security (paragraph 65-4).
a. Do the conditional inspection for a hard
landing (paragraph 65-12).
2. Examine the tail rotor gearbox as follows:
b. Measure the attachment hardware bolt hole
and bores on the components that follow. Any sign of a. If the chip detector shows signs of unwanted
bore deformation is cause for rejection of that material (metal particles), do an overhaul of the tail
component. rotor gearbox. Refer to the BHT-407-CR&O manual for
the procedures.
• forward short shaft
b. Do a straightness check of the output shaft.
• aft short shaft
65-15. Conditional Inspection — Overtorque
• splined flywheel adapter (if installed)
1. Examine the tail rotor driveshaft as follows:
• splined adapter
2. Do the inspection for condition and security
• oil cooler blower shaft (paragraph 65-4).
• impeller
3. If you find damage when you do the inspection for
condition and security, do the conditional inspection
• tail rotor driveshaft segment assemblies for sudden stoppage (paragraph 65-13).
• tail rotor driveshaft segment assemblies

adapters 4. Examine the tail rotor gearbox as follows:
c. Examine the coupling disc packs for signs of a. If the chip detector shows signs of unwanted
deformation. Discard the coupling disc pack if one disc material (metal particles), do an overhaul of the tail
shows signs of deformation. Replacement of the rotor gearbox. Refer to the BHT-407-CR&O manual for
deformed disc is not permitted. the procedures.
2. Examine the tail rotor gearbox. Refer to the steps b. Measure the bore (bolt hole) for the
that follow: attachment hardware on the adapters for deformation.
All signs of deformation of the bore (bolt hole) is cause
a. Do an overhaul of the tail rotor gearbox. Refer for rejection.
to the BHT-407-CR&O manual for the procedures.
65-16. Conditional Inspection — Lightning Strike
b. Do a straightness check of the output shaft. If
the output shaft is found to be unserviceable, the 1. Examine the tail rotor driveshaft as follows:
complete tail rotor gearbox assembly is considered
unrepairable and must be discarded. a. Disassemble the tail rotor driveshaft.
c. Do a straightness check of the tail rotor b. Examine all of the components for signs of
gearbox input adapter. electric arc burns. If you find signs of electric arc burns
on any one component, discard all of the driveshafts
d. Measure the bore (bolt hole) for the and bearings. Do not discard the oil cooler impeller
attachment hardware on the adapters for deformation. and housing.
65-00-00
7 NOV 2006 Rev. 23 Page 23
BHT-407-MM-7
c. Examine the oil cooler impeller for signs of 2. Examine the housing where it comes together
damage and electric arc burns. If you find electric arc with the tailboom for condition (BHT-407-CR&O).
burns, discard the oil cooler impeller.
3. Remove the output cap (paragraph 65-92) and do
2. Examine the tail rotor gearbox as follows: the steps that follow:
a. Examine the spiral bevel gearback face and

a. If you see signs of arc burns on any tail rotor,
shaft for corrosion (Figure 65-9).
tail rotor pitch change component, or tail rotor
driveshaft component, do an overhaul of the tail rotor
b. Examine the cap and housing where they
gearbox. Refer to the BHT-407-CR&O manual for the
come together for condition (BHT-407-CR&O).
procedures.
4. Remove the oil sight glass (paragraph 65-82) and
b. Carefully examine the bearing balls, inner and do the steps that follow:
outer race contact point and the pinion and spiral
bevel gear tooth contact point. If a part shows signs of a. Examine the spiral bevel gear with a mirror for
electric arc burns, discard the part. condition and security.
65-17. Tail Rotor Gearbox — 60 Month Interim b. Examine the housing for condition.
Scheduled Inspection
5. Remove the inspection plug (paragraph 65-67)
and examine the spiral bevel gear teeth and pinion
NOTE teeth for condition (Figure 65-9).
Do this inspection if an overhaul inspection
has not been accomplished within the past 65-18. TAIL ROTOR DRIVE SYSTEM — LEAKAGE
60 months. LIMITS
1. Remove the tail rotor gearbox (paragraph 65-62) Table 65-3 shows the permitted leakage rates that you
and examine the studs and dowel pins that attach the can use together with the tail rotor gearbox
tail rotor gearbox to the tailboom for condition and troubleshooting charts.
security (BHT-407-CR&O).
Table 65-3. Maximum Permitted Leakage Rates for Tail Rotor Drive System
COMPONENT TAIL ROTOR DRIVE STATUS LEAKAGE RATE
Tail rotor gearbox Static — not operating Input quill leakage will not exceed
(0% rotor RPM) two drops per minute. Total
leakage at all sources must not be
more than six drops per minute.
Dynamic — operating 50% of normal oil sight glass oil

(100% rotor RPM) level indication per 3 hours of
operation.
65-00-00
Page 24 Rev. 23 7 NOV 2006
BHT-407-MM-7
H
I B
G C
K
J F A E
SPIRAL BEVEL PINION (406-040-420-103)

MATERIAL: ALLOY STEEL
REF INSPECTION
NO. LTR CHARACTERISTIC METHOD LIMIT
1 A Spline wear Measure above Minimum 1.4267 inches (36.2 mm).

0.120 inch
(3.05 mm)
diameter pins
2 A Corrosion/scratches Measure Maximum 0.004 inch (0.102 mm).
Depth 1/3 of tooth surface, 2 teeth
maximum. Finish to be 32 RMS with a
0.1 inch (2.54 mm) minimum radius. 7
3 B Packing groove Visual None permitted.
damage
4 C Corrosion/mechanical Measure 0.005 inch (0.127 mm) maximum
depth.
5 D Corrosion, nicks, Measure 0.010 inch (0.254 mm) maximum
dents, scratches depth, 0.25 inch (6.35 mm), maximum
length, two for each quadrant. Finish
to be 32 RMS with a 0.1 inch
(2.54 mm) minimum radius.
6 E Thread damage Visual/measure One thread pitch, 1/3 thread depth,

0.250 inch (6.35 mm) maximum
length.
7 F Inside diameter Measure Maximum 0.010 inch (0.254 mm) for

corrosion 180 degrees of circumference. 6
407MM_65_0050
Figure 65-9. Spiral Bevel Pinion Inspection (Sheet 1 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 25
BHT-407-MM-7
REF INSPECTION
8 G Corrosion/mechanical Visual None permitted. 4
9 H Chipped, missing teeth Visual None permitted. 2
10 I Indentation or cuts on Feel If you find indentations or cuts on the 5

face of teeth faces of the teeth that can be felt
with a probe that has a 0.020 inch
(0.508 mm) radius spherical point,
replace the part.
11 J Duplex bearing journal Measure Minimum diameter 1.3782 inches

(35.0 mm). 1
12 K Roller bearing journal Measure Light circumferential scratches that 3

can be felt with a probe that has a
0.010 inch (0.254 mm) radius spherical
point are permitted. Axial scratches
are not permitted.
NOTES
1 The shaft journal is harder than the bearing inner ring. The inner ring can creep and/or fret and keep excess
material on the journal. The material deposit can cause some galling or tearing of the journal surface when the
bearing is removed. If there are signs of movement or damage, the dimension is given to make the local
rework easier. Remove only the raised material from the surface of the journal. Polish/blend all axial scratches
that are galling. Make them smooth with the initial journal surface or to a maximum width of 0.010 inch (0.254
mm), length of 0.100 inch (2.54 mm) and a radius of 0.010 inch (0.254 mm). No more than one rework for each
adjacent quadrant in a 0.5 inch (12.7 mm) length of journal or four for each shaft journal is permitted.
2 In areas where the tooth contact pattern extends to the top edge of the tooth, remove nicks from the top edge
of the teeth that extend to a maximum of 0.020 inch (0.508 mm) into the pattern. In areas outside the tooth
contact pattern, remove nicks from the top edge of the teeth that extend to a maximum of 0.050 inch
(1.27 mm) onto the face of the tooth. Do the rework with a fine India stone. Finish to be 32 RMS with a
0.1 inch (2.54 mm) radius.
3 No rework is permitted on the active bearing surface. Nicks or indentations on the race lead in chamfer can be
reworked by removal of the raised material. This can show damage to the bearing roller or retainer, it is
recommended that you discard the bearing if you find these signs.
4 Axial scratches to the raised surface edge because of bearing removal and installation is permitted. Blend the
scratches with a 400 grit aluminum oxide paper with a minimum diameter of 1.378 inches (35.0 mm).
5 The tooth pattern that shows pitting, scoring and spalling is cause for rejection. Pitting that causes patchy
wear to the contact zone of the tooth can be identified as micropitting and is cause for rejection.
6 Rework evenly to prevent balance problems. After the rework, fill with primer (C-204), drain and put in a
vertical position to dry.
7 Remove the wear step between the worn and unworn areas of the spline teeth with an India stone. This makes
a smooth change.
407MM_65_0051_c1
Figure 65-9. Spiral Bevel Pinion Inspection (Sheet 2 of 2)
65-00-00
Page 26 Rev. 25 29 SEP 2008
BHT-407-MM-7
65-19. TAIL ROTOR DRIVE SYSTEM — 11. Drain the lubricating oil through filter paper into a
SERVICEABILITY CHECK clean container (Chapter 12).
Do this test when the T/R CHIP annunciator comes a. Examine the filter paper for contaminants.
on, or when required by this manual. Refer to paragraph 65-20 and Table 65-4 for
identification of contaminants and for corrective action.
1. Remove the tail rotor chip detector and examine it
for metal particles. Refer to Figure 65-10 for the 12. If the number of metal particles has increased, or
identification of contaminants. If you find if the particles are large enough to be identified as part
contaminants, continue with the next steps. of a gear or bearing, overhaul the tail rotor gearbox. If
the number of particles is less, the tail rotor gearbox is
2. Remove the inspection plug (paragraph 65-67). serviceable.
Examine the pinion and the spiral bevel gear teeth for
condition (Figure 65-9). If the pinion or gear teeth are 13. Service the tail rotor gearbox (Chapter 12).
damaged, overhaul the tail rotor gearbox
(BHT-407-CR&O). If you do not find damage, continue 65-20. UNWANTED PARTICLES — VISUAL
with the next steps. IDENTIFICATION
3. Install the inspection plug (paragraph 65-70).

NOTE
4. Drain the lubricating oil through filter paper into a When you find metal particles, or if you are
clean container (Chapter 12). not sure of the serviceability of the tail rotor
gearbox, do a serviceability check
(paragraph 65-19).
5. Examine the filter paper for contaminants. Refer
to paragraph 65-20 and Table 65-4 for identification of
1. The tail rotor chip detector is installed in the tail
contaminants and for corrective action.
rotor gearbox. It will give a visual alarm on the caution/
warning/advisory panel when some ferrous particles
6. Flush the tail rotor gearbox with the system are trapped in it. Figure 65-40 shows the location of
lubricant (Chapter 12). the tail rotor chip detector.
7. Service the tail rotor gearbox (Chapter 12). 2. If you find a small quantity of metal particles in the
tail rotor gearbox, this can indicate normal wear. When
8. Do a tail rotor drive system operational check the particles are large enough to be identified as part
(paragraph 65-3). of a component, replace the gearbox. Paragraph
65-21 will help you to chemically identify particles that
9. Shut down the helicopter. are too small to identify visually.
10. Remove and examine the tail rotor chip detector 3. Table 65-4 can be used to identify unwanted
for metal particles. Refer to Figure 65-10 for the material collected from the filter paper after the
identification of contaminants. serviceability check. Figure 65-10 can be used to
identify unwanted material collected from the tail rotor
gearbox chip detector.
65-00-00
Export Classification C, ECCN EAR99 10 DEC 2012 Rev. 35 Page 27
BHT-407-MM-7
MATERIAL (STEEL) FOUND ON THE CHIP DETECTORS

DETAIL DESCRIPTION SIGNIFICANCE CORRECTIVE ACTION
Tiny whisker-like particles. Insignificant debris. If the component has several

Groups of dark microscopic Generally microscopic wear hundred operating hours, no
particles. Chips disappear particles caused by normal maintenance is necessary.
into a large black smudge wear within the drive system Clean and install the chip
when removed. The common components. The particles detector. If the component is
term for this condition is are often grouped by the relatively new or recently
sludge or fuzz. magnetic field of the chip overhauled, do a
detector magnet and take on serviceability check.
the shape of apparently
larger chips.
Spiral curls or Insignificant debris. The The same procedure as

comma-shaped particles. particles are fragments of above if you find the
Under magnification, the chips or shavings caused by particles within the first 50
particles are often smooth machining of ferrous metal hours of operation of a new
and shiny on their convex components. Such or overhauled component. If
surfaces and quite rough on contamination is often you find the particles after
other surfaces and edges. introduced into the drive the first 50 hours of
The color of the particles is system components on the operation, do a serviceability
usually dull gray on the tools at the compressed air check.
rough surfaces. The dust operations within the
common term for this component assembly area.
condition is manufacture
debris.
Hair-like ferrous debris. Insignificant debris. This The same procedure as

Subject debris can have a debris is normally scrap above.
rectangular or triangular that is made as the
cross section gradually components are
reaching 0.080 inch (2.03 interference fitted together
mm) or less in thickness. at the assembly of the drive
The length can range from system components. The
0.10 inch (2.54 mm) to over debris of this general shape
1.0 inch (25.4 mm). The color is also made after a long
of the debris is usually light term operation at the
gray, although one or more corners of the wear
sides can have a black surfaces. This type of
appearance. The common debris can also be made at
name for this condition is the opening of lubrication
hairs. oil cans and can be
introduced into the
components at the fill
procedure.
407MM_65_0052
Figure 65-10. Unwanted Material on the Tail Rotor Chip Detector (Sheet 1 of 2)
65-00-00
Page 28 Rev. 23 7 NOV 2006
BHT-407-MM-7
MATERIAL (STEEL) FOUND ON THE CHIP DETECTORS

DETAIL DESCRIPTION SIGNIFICANCE CORRECTIVE ACTION
Irregular shaped ferrous Insignificant debris. The The same procedure as
metal particles. The particles particles of this type are above.
are usually triangular in commonly a result of tool
cross section. The particles slippage at assembly of the
are often spike-like in drive system components.
appearance. Under
magnification, one side of a
triangular section will
usually look sheared. The
color of the particles can be
silver gray or black with one
or more silver sides.
Existence of two or more
particles of this type on the
chip detector at one time is
rare. The common name for
this condition is manufacture
debris.
Irregular shaped ferrous Significant debris. Existence Repair or replace the

chunks of different sizes and of this type of debris shows component.
shapes. Under magnification, that the gear and/or bearing
one or more sides of the is damaged within the drive
particles look rough and system components.
grainy. The color of the
particles is often silvery gray
with one or more black
sides. No common term for
this condition.
Few moderately sized and/or Significant debris. The Repair or replace the
numerous small nearly flat particles of this description component.
pieces. Under magnification, are classic signs of the
one side of the flake appears rolling element bearing
very smooth. The flakes are failure. They are also less
silvery in color with black common signs of gear tooth
sides. The common name for spalling.
this condition is flakes.
407MM_65_0053
Figure 65-10. Unwanted Material on the Tail Rotor Chip Detector (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 29
BHT-407-MM-7
Table 65-4. Unwanted Particles — Visual Identification
MATERIAL YOU CAN FIND IN THE FILTER PAPER
NECESSARY
MATERIAL DESCRIPTION CAUSE
PROCEDURE
Aluminum and The particles are in If the quantity is small This can be the result of
magnesium granular form or look like and you find it at the first use of these materials
miniature lathe turnings. inspection after the as mallets or drifts at
overhaul or major assembly. It can also
maintenance, no show wear of the oil
corrective action is pump interior surfaces or
necessary. If you find unusual interference.
particles at the
subsequent inspection
or if the quantity is large,
replace the component.
Silver Small flakes or powder. If you find it during the This can be result from
first 100 hours of wear of the silver plated
operation, at overhaul, components such as
or at first inspection, no bearing cages and input
corrective action is pinion gear teeth. The
necessary. If you find it quantity can be relatively
after the first inspection large until the
of the first 100 hours and components fully
the quantity is large, "break-in".
replace the component.
Copper (bronze) The particles are in If the quantity is large, This can be an indication
granular form. replace the component. of too much wear to the
bearings.
Copper (bronze) Chips. None. Results from the use of

mallets or drifts at
assembly.
Phenolic Chips, flakes or powder. None. Results from the use of

mallets or drifts at
assembly.
Rubber Different shapes and None. Material cut from the
sizes, usually have one packings at assembly.
rounded side.
65-00-00
Page 30 Rev. 23 7 NOV 2006
BHT-407-MM-7
65-21. UNWANTED PARTICLES — CHEMICAL ADDED TO ACID, A VIOLENT CHEMICAL

IDENTIFICATION REACTION CAN OCCUR AND CAUSE
INJURIES TO PERSONS.
SPECIAL TOOLS REQUIRED a. Mix a solution of 50% by volume of nitric acid

(C-432) and 50% of water in a test tube.
NUMBER NOMENCLATURE b. Mix a solution of 5% by weight of sodium

chloride (C-501) and 95% of water in a second test
Commercial Test Tubes (Qty 2) tube.
c. Add a particle of the material to be tested to

MATERIALS REQUIRED the nitric acid solution. If the particle does not dissolve,
slightly warm the solution.
d. When the particle dissolves, add a few drops
NUMBER NOMENCLATURE of the sodium chloride solution to the nitric acid
solution.
C-431 Hydrochloric Acid
C-432 Nitric Acid e. If a white precipitate forms, the particle is

silver.
C-501 Sodium Chloride
2. Empty the two test tubes and rinse with water
until they are clean.
NOTE
The process of a chemical identification 3. To identify a copper or bronze particle, do the
allows to identify minute particles that are following:
too small to be examined for color and
hardness.
a. Put a small quantity of nitric acid (C-432) in a
test tube.
NOTE
Identification of silver plate flakes in the oil b. Add a particle of the material to be tested to
is not a cause for replacement of the tail the nitric acid (C-432).
rotor gearbox.
c. If a green precipitate forms, the particle is
Silver plate is a soft material that is used as copper or bronze.
an additional lubricant for gear meshing.
Therefore it is not critical to the tail rotor 4. Empty the test tube and rinse with water until it is
gearbox. clean.
When evidence of unwanted particles
occurs, drain and service the tail rotor 5. To identify an aluminum particle, do the following:
gearbox with lubrication oil (Chapter 12).
a. Put a small quantity of Hydrochloric acid
1. To identify a silver particles, do the following: (C-431) in a test tube.
b. Add a particle of the material to be tested to

WARNING the Hydrochloric acid (C-431).
c. If the particle gradually disintegrates with a

ALWAYS ADD ACID TO WATER. NEVER rapid emission of bubbles and forms a black residue
ADD WATER TO ACID. IF WATER IS (aluminum chloride), then it is aluminum.
65-00-00
7 NOV 2006 Rev. 23 Page 31
BHT-407-MM-7
6. Empty the test tube and rinse with water until it is bearings 407-340-339-107 have an orange elastomer
clean. seal.
7. To identify a magnesium particle, do the 3. Rotate the main rotor to turn the tail rotor drive
following: system. While it is turning, check for indication of
bearing roughness at each hanger assembly
a. Put a small quantity of nitric acid (C-432) in a supporting each segmented shaft. You can detect
test tube. indications of abnormal roughness by feel, by placing
your hand on the bearing hanger as the segmented
shafts are turning.
b. Add a particle of the material to be tested to
the nitric acid (C-432).
4. Examine the accumulated grease that has been
expelled from around the seal during the operation for
NOTE a change in color. Bearings 406-040-339-ALL and
If the particle is aluminum, there will be no 407-340-339-107 use Mobil 28 grease (C-001) that is
effect with the nitric acid (C-432). normally red-purple as it is injected in the bearing, but
turns black when the bearing is damaged.
c. If a rapid emission of bubbles occurs, the
particle is magnesium.
5. Examine the grease for indication of visible metal
particles.
8. Empty the test tube and rinse with water until it is
clean.
6. If no indication of roughness is detected, the
expelled grease has not turned black, you see no
65-22. TAIL ROTOR DRIVESHAFT BEARINGS — metal in the expelled grease, and the bearing seal is
SERVICEABILITY CHECK intact, the bearing is acceptable for return to service.
Do the roughness check of the bearings installed on

the oil cooler blower and segmented driveshaft, as 7. If you detect or suspect roughness of a bearing:
follows:
a. For the oil cooler blower, disconnect the
forward and aft short shaft to confirm the bearing
NOTE
roughness.
It is not necessary to disconnect any shaft
to do this check.
b. For the segmented driveshaft, remove the
affected segmented driveshaft and rotate the bearing
1. Remove the cowling to get access to the oil manually to confirm the bearing roughness.
cooler blower and segmented driveshaft hanger
bearings.
8. If the bearing is rough, a seal is torn, the expelled
grease has turned black, or you see metal particles in
the expelled grease, replace the affected bearing
WARNING (paragraph 65-32), and contact:
DO NOT TOUCH HANGER BEARINGS Product Support Engineering

IMMEDIATELY AFTER ENGINE Bell Helicopter Textron
SHUTDOWN. WAIT A SHORT PERIOD E-mail: [email protected]
OF TIME, AND THEN EXERCISE
Fax: 450-433-0272
CAUTION TO AVOID BURNS.
Phone: USA 800-363-8023
2. Inspect for tears in the bearing seals. Bearings Canada 800-361-9305
406-040-399-ALL have a brown elastomer seal and International (call collect) 450-437-2862
65-00-00
Page 32 Rev. 24 2 OCT 2007
BHT-407-MM-7
65-23. TAIL ROTOR DRIVE SYSTEM

COMPONENTS CAUTION
The tail rotor drive system includes the components

that follow: S U P P O RT T H E F O R WA R D S H O R T
SHAFT TO PREVENT DAMAGE TO THE
COUPLING DISC PACKS.
• forward short shaft assembly with the splined
flywheel adapter (if installed) THE SURFACE CONDITION OF THE
FORWARD SHORT SHAFT ASSEMBLY IS
• oil cooler blower assembly VERY IMPORTANT TO FLIGHT SAFETY.
THE SURFACE OF THE SHAFT MUST BE
SMOOTH AND UNMARRED. THE
• aft short shaft assembly SURFACE MUST NOT BE DAMAGED
DURING REMOVAL OR HANDLING. BE
• tail rotor driveshaft segment assemblies VERY CAREFUL DURING REMOVAL
AND WHEN YOU HOLD THE FORWARD
SHORT SHAFT ASSEMBLY.
• coupling disc packs
2. Loosen the nuts (21, Figure 65-11) that attach the
• tail rotor gearbox coupling disc pack (19) to the forward short shaft (11)
until they are finger tight.
65-24. FORWARD SHORT SHAFT ASSEMBLY
NOTE
The forward short shaft assembly (11, Figure 65-11) is Complete step 3, step 4, or step 5 as it
a steel shaft. The forward end is fixed. It is connected applies to the helicopters configuration.
to a coupling disc pack (19) on the freewheel output
adapter (16). The aft end of the forward shaft 3. For helicopters without a balance plate (24)
assembly is connected to the oil cooler blower by a installed, remove the nuts (10), the flat washers (9),
coupling disc pack (22) and a splined adapter (5) or the coupling washers (8), the spacer (7) (if installed),
the splined flywheel adapter (23). and the bolts (6) that attach the coupling disc pack
(22) to the forward short shaft assembly (11).
65-25. Forward Short Shaft Assembly — Removal
4. For helicopters without air conditioning and with a
balance plate (24) installed, remove the nuts (10), the
flat washers (9), the coupling washers (8), and the
MATERIALS REQUIRED bolts (6).

5. For helicopters with air conditioning and with a
balance plate (24) installed, remove nuts (32,
NUMBER NOMENCLATURE
Figure 65-11, Sheet 4), washers (31), bevel washers
C-405 Lockwire (30), bevel washers (29), and bolts (28).
6. Remove the nuts (21, Figure 65-11), the flat

washers (20), the coupling washers (18) and the bolts
NOTE
(17) that attach the coupling disc pack (19) to the
To help minimize rebalance procedures forward short shaft assembly (11).
following reinstallation, note installed
position of all items prior to removal. 7. Push the splined adapter (5) or the splined
flywheel adapter (23) aft and remove the forward short
1. Gain access to the forward short shaft assembly shaft assembly (11). If applicable, also remove the
(Chapter 53). balance plate (24).
65-00-00
7 NOV 2006 Rev. 23 Page 33
BHT-407-MM-7
I.D.chamfer side must

face the bolt head
1 23 7
11 6
1 7
DETAIL A
22
8 Bevelled side must face
4 coupling disc pack
SEE DETAIL B 3
SEE DETAIL B
SEE DETAIL C
2
2 6
1 8
5 DETAIL B
4
SEE DETAIL C 20 21
22 2
SEE DETAIL A 8
18
18 19 9
17
11 10
4
SEE DETAIL B 3
12
13 SEE DETAIL C 2
13 SEE DETAIL B 2
16 1
14 6
25 8
15 26
27 5 4
21 22
20
SEE DETAIL C 8
SEE DETAIL A 9
18
19
18 24 3 5
17 3
11 10
SEE VIEW D OR G
16 12 NON AIR CONDITIONING SHOWN
13
14 VIEW D - NON AIR CONDITIONING
13
15 SEE DETAIL B VIEW G - AIR CONDITIONING
407MM_65_0054
Figure 65-11. Forward Short Shaft Assembly — Removal/Installation (Sheet 1 of 5)
65-00-00
Page 34 Rev. 23 7 NOV 2006
BHT-407-MM-7
19 22
INDEX FLATS
DETAIL C
S/N 53292 AND SUBSEQUENT OR POST TB 407-99-18/POST TB 407-02-35
19 22 INDEX FLATS
DETAIL C
S/N 53000 THROUGH 53291 OR PRE TB 407-99-18/PRE TB 407-02-35
407MM_65_0055
65-00-00
7 NOV 2006 Rev. 23 Page 35
BHT-407-MM-7
SEE DETAIL E
FWD
VIEW D
6 8 10 14
F 24
5 4
5 25 26 27
11
5
1 2 3 4 24
22
F SECTION F-F
DETAIL E
407MM_65_0057
65-00-00
Page 36 Rev. 23 7 NOV 2006
BHT-407-MM-7
SEE DETAIL H
5 4
FWD
VIEW G
24
34 31 30 29 31 33
SECTION J-J
J
3 5 24
3 5 25 26 27
11
32
A/C PULLEY
31 30 22 29 28 6 5 (STC SR00222DE) REF 6
DETAIL H
407MM_65_0058
65-00-00
7 NOV 2006 Rev. 23 Page 37
BHT-407-MM-7
1. Bolt 19. Coupling disc pack

2. Coupling washer 20. Flat washer
3. Flat washer 21. Nut
4. Nut 22. Coupling disc pack
5. Splined adapter 23. Splined flywheel adapter
6. Bolt 24. Balance plate
7. Spacer 25. Screw
8. Coupling washer 26. Washer
9. Flat washer 27. Nut
10. Nut 28. Bolt
11. Forward short shaft assembly 29. Bevel washer (S-3526EC-7)
12. Bolt is 0.035 inch (0.89 mm) thick.
13. Coupling washer 30. Bevel washer (S-3526EC-5)
14. Flat washer is 0.077 inch (1.95 mm) thick.
15. Nut 31. Flat washer
16. Freewheel output adapter 32. Nut
17. Bolt 33. Bolt
18. Coupling washer 34. Nut
150 TO 180 IN-LBS (16.9 TO 20.3 Nm)
NOTES
1 Helicopters S/N 53000 through 53442 Pre BHT-407-II-30.
2 Helicopters S/N 53443 through 53497 Pre TB 407-02-35.
3 Helicopters S/N 53000 through 53442 Post BHT-407-II-30, S/N 53443 through 53497 Post TB 407-02-35
and S/N 53498 through subsequent. Refer to view D for non-air conditioning and view G for air
conditioning.
4 Flanges of forward splined adapter (5, Figure 65-11) and aft splined adapter (17, Figure 65-28) must be
positioned 90° to each other within spline tolerances. Ensure that each adapter slides freely on blower
shaft splines prior to installation. To facilitate sliding, remove dry lubricant coating from top of shaft
splines.
5 Initial hardware setup on all four balance screw locations, is one NAS1351-3-14 screw, one
NAS1149F0363P washer and one MS21042L3 nut. For balancing, use a maximum of seven (7) washers
(NAS1149F0363P) or any combination of varying thickness washers (NAS1149F03( )( )P) provided that a
minimum of two threads extend past the nut. It is permissible to remove one or more screws
(NAS1351-3-14) to obtain proper balance. If screw is installed, one washer (NAS1149F0363P) and one nut
(MS21042L3) must be installed. Until such time that chapter 18 is updated, refer to BHT-407-II-30 part VII
for balancing procedures.
6 Configuration shown in detail H applies to helicopters equipped with Air Comm air conditioner kit. Refer
to AIRCOMM STC SR00222DE, drawing 407EC-300 and AIRCOMM Service Bulletin SB 407-3526 Rev A
for information on air conditioning installation and maintenance.
7 For information on flywheel (23) balancing and balance hardware installation, refer to TB 407-02-35 or
Chapter 18.
407MM_65_0056
65-00-00
Page 38 Rev. 23 7 NOV 2006
BHT-407-MM-7
8. Slide the splined adapter (5) or the splined 65-27. Forward Short Shaft Assembly — Paint
flywheel adapter (23) off the oil cooler blower shaft. Removal and Application
MATERIALS REQUIRED
CAUTION
MAKE SURE THAT THE ORDER IN NUMBER NOMENCLATURE
W HIC H T HE D IS C S EG M E NTS A RE
STACKED DOES NOT CHANGE AFTER C-208 Epoxy/Zinc Coating
THE COUPLING DISC PACK HAS
OPERATED. FIGURE 65-12 CONTAINS C-305 Aliphatic Naphtha
INSTRUCTIONS FOR MAINTENANCE
AND REPAIR. C-309 MEK
9. Put lockwire (C-405) through an empty bolt hole C-344 Alcoholic Phosphoric
in the coupling disc pack (22) to make sure that the Cleaner
order of the discs are not changed.
C-436 Paint Remover
NOTE
NOTE
Complete step 10 or step 11 as it applies to
the helicopters configuration. You do not need to remove the primer from
the inside of the shaft to do the inspection.
10. For helicopters without air conditioning, remove
the nuts (4), the flat washers (3), the coupling washers 1. If the primer is damaged or if necessary, remove
(2), and the bolts (1) that attach the coupling disc pack the primer from the inside of the shaft with paint
(22) to the splined adapter (5) or the splined flywheel remover (C-436). Refer to the BHT-ALL-SPM for the
adapter (23). procedures.
11. For helicopters with air conditioning and with a 2. To paint the inside of the shaft, do the steps that
balance plate (24), remove the nuts (34, Figure 65-11, follow:
sheet 4), the flat washers (31), the bevel washers (30
and 29), the flat washers (31) and the bolts (33). a. Clean the inside of the shaft with aliphatic
naphtha (C-305) or MEK (C-309).
12. Put lockwire (C-405) through an empty bolt hole
in the coupling disc pack (19, Figure 65-11) to make b. Treat the shaft surface with alcoholic
sure the order of the discs are not changed. phosphoric cleaner (C-344). Refer to the
BHT-ALL-SPM for the procedures.
13. Remove the nuts (15), the flat washers (14), the
coupling washers (13), and the bolts (12) that attach c. Install a tapered nonmetallic plug in one end
the coupling disc pack (19) to the freewheel output of the shaft. Flow epoxy/zinc coating (C-208) along the
adapter (16). inside of the shaft while you turn the shaft. Make sure
the internal surface has a full layer of epoxy/zinc
coating (C-208).
65-26. Forward Short Shaft Assembly — Cleaning
d. Put the shaft in a vertical position and remove
1. To clean the forward short shaft assembly (11, the tapered plug. Permit the epoxy/zinc coating
Figure 65-11), refer to the BHT-ALL-SPM. (C-208) to drain out. Two layers of epoxy/zinc coating
(C-208) are required. The shaft must stay in a vertical
2. To clean the coupling disc packs (22), refer to position to stop the formation of epoxy/zinc coating
Figure 65-12. (C-208) puddles and to keep dynamic balance.
65-00-00
7 NOV 2006 Rev. 23 Page 39
BHT-407-MM-7
Figure 65-12. Coupling Disc Packs — Inspection and Repair
65-00-00
Page 40 Rev. 25 29 SEP 2008
BHT-407-MM-7
65-28. Forward Short Shaft Assembly — MAKE SURE THAT THE ORDER IN
Inspection and Repair W HIC H T HE D IS C S EG M E NTS A RE
STACKED DOES NOT CHANGE AFTER
1. Examine the forward short shaft assembly (11, THE COUPLING DISC PACK HAS
Figure 65-11) for condition. Refer to Figure 65-13 for OPERATED. FIGURE 65-12 CONTAINS
damage limits and repair instruction. INSTRUCTIONS FOR MAINTENANCE
AND REPAIR.
2. Examine the splined flywheel adapter (23,
Figure 65-11) (if installed) for condition. Refer to INDIVIDUAL COUPLING WASHERS ARE
Figure 65-14 for damage limits and repair instruction. TO BE INSTALLED WITH THE BEVELED
EDGE AGAINST THE COUPLING DISK
PACK AND THE FLAT SIDE AGAINST
3. Examine the sliding adapter (5, Figure 65-11) (if THE ADAPTER FLANGE. IF TWO
installed) for condition. Refer to Figure 65-23 for COUPLING WASHERS ARE INSTALLED
damage limits and repair instructions. TO GETHER, REFER FIGURE 65-11,
D E TA I L A A N D D E TA I L B F O R TH E
4. Examine the discs of the coupling disc packs for C O R R E C T I N S TA L L AT I O N O F T H E
condition (paragraph 65-59). COUPLING WASHERS.
5. Examine the balance plate (24, Figure 65-11) for NOTE

condition.
Hold the bolt stationary and turn the nut
only. If you turn the bolt, gaps in the
65-29. Forward Short Shaft Assembly —
coupling disc pack may occur.
Installation
Make sure bolt lengths are equal. Ensure

that only the grip portion (unthreaded
MATERIALS REQUIRED
portion) of the bolt is in contact with the
coupling disc pack.
NUMBER NOMENCLATURE To maintain balance, reinstall items in same

position as noted prior to disassembly.
C-405 Lockwire
C-525 Grease 1. For helicopters without air conditioning, install the

coupling disc pack (22, Figure 65-11) on the splined
C-561 Grease adapter (5) or splined flywheel adapter (23) with the
bolts (1), coupling washers (2, Figure 65-11, Detail B),
flat washers (3), and nuts (4). Tighten the nuts until
they lightly contact. The bolts must remain loose
CAUTION enough so that they can be turned by hand.
2. For helicopters with air conditioning, install the

THE SURFACE CONDITION OF THE coupling disk pack (22) on the splined adapter (5) with
FORWARD SHORT SHAFT ASSEMBLY IS the bolts (33, Figure 65-11), flat washers (31), bevel
VERY IMPORTANT TO FLIGHT SAFETY. washers (29 and 30), flat washer (31), and nuts (34).
THE SURFACE OF THE SHAFT MUST BE Tighten the nuts until they lightly contact. The bolts
SMOOTH AND UNMARRED. THE must remain loose enough so that they can be turned
SURFACE MUST NOT BE DAMAGED by hand.
DURING INSTALLATION OR HANDLING.
BE VERY CAREFUL DURING THE
I N S TA L L AT I O N O F T H E F O RWA R D 3. Remove the lockwire (C-405) from the coupling
SHORT SHAFT ASSEMBLY. disc pack (22).
65-00-00
ECCN EAR99 8 APR 2011 Rev. 30 Page 41
BHT-407-MM-7
B C B
E
A A
D (4 PLACES)
(8 PLACES) F
FACE G FACE G
FORWARD SHORT SHAFT (406-040-315)

MATERIAL: CRES STEEL
REF
LTR DESCRIPTION TYPE OF DAMAGE LIMIT
A Adapter end face Corrosion/mechanical 0.001 inch (0.025 mm), up to 100%

of area.
B Adapter external Corrosion/mechanical 0.005 inch (0.127 mm) up to 100%

diameter circumference.
C Tube outside Corrosion/mechanical 0.005 inch (0.127 mm) up to

diameter 1 square inch (645.200 mm ²).
0.005 inch (0.127 mm) up to
25% of circumference.
0.850 inch (21.590 mm) wide.
0.002 inch (0.051 mm) up to
100% of circumference.
0.210 inch (0.533 mm) wide. 2
407MM_65_0060
Figure 65-13. Forward Short Shaft — Inspection (Sheet 1 of 2)
65-00-00
Page 42 Rev. 23 7 NOV 2006
BHT-407-MM-7
REF
D Bore Wear 0.315 inch (8.001 mm)

diameter maximum.
Corrosion/mechanical 0.001 inch (0.025 mm) up to

100% of the area.
A, B, C Number of repairs Five maximum.
Adapter flange Corrosion/mechanical The maximum chamfer to remove

damage is 0.030 inch (0.762 mm)
x 40-45° up to 0.500 inch
(12.700 mm) (No more than two per
quadrant).
E Balance weight Missing Balance weight must be replaced.
F Rivet Loose rivets None allowed.
C Shaft tube Straightness Using a 12 inch (304.8 mm)

straight edge, the maximum gap is
0.010 inch (2.565 mm).
G Adapter end face Total indicator runout Total indicator runout done with
the shaft mounted on centers,
0.004 inch (0.102 mm).
NOTES
1. Remove two times the depth of the corrosion to repair the corroded surface. The limits shown are for
after the repair is completed.
2 Scratches can be polished out so the wall thickness is not less than 0.044 inch (1.118 mm) and the
minimum outside diameter is not less than 1.240 inches (31.496 mm).
3. Refer to the BHT-ALL-SPM or CSSD-PSE-87-001 to do the repairs.
4. Repair the damage with a 0.25 inch (6.35 mm) minimum radius and a 32 RMS surface finish.
407MM_65_0061
Figure 65-13. Forward Short Shaft — Inspection (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 43
BHT-407-MM-7
Figure 65-14. Splined Flywheel Adapter — Inspection (Sheet 1 of 3)
65-00-00
Page 44 Rev. 23 7 NOV 2006
BHT-407-MM-7
REF
A Spline Wear 1.2257 inches (31.1328 mm) 1

Measure over a maximum diameter.
0.108 inch (2.743 mm)
diameter pin
Spline Corrosion/mechanical Light, superficial, that you can

The side and root polish out with fine stainless steel
of the teeth wool or Scotchbrite.
B Spline Wear 1.3185 inches (33.4899 mm)

Minor diameter maximum diameter.
Spline Corrosion/mechanical 0.010 inch (0.254 mm) maximum 5

Top and end of teeth up to 0.025 inch (0.635 mm)
long on all teeth. One area of
damage per tooth.
C Spline Wear 1.4389 inches (36.5481 mm)

Major diameter. maximum diameter.
D Fastener hole. Wear 0.315 inch (8.001 mm)

maximum diameter.
E Bore Corrosion/damage 0.715 inch (18.161 mm)

maximum diameter.
Bore Edge damage Chamfer to a 0.025 inch (0.635 mm)

radius x 0.025 inch (0.635 mm)
length x 0.005 inch (0.127 mm)
depth (Maximum two repairs per hole).
F Surface Corrosion/mechanical 0.001 inch (0.025 mm) deep,

maximum area per full depth repair
is 0.025 square inch (16.13 mm ²).
G Rim Corrosion/mechanical 0.005 inch (0.127 mm) deep,

is one square inch (645.2 mm ²).
Rim Edge damage Chamfer to 0.025 inch (0.635 mm) 3 4

radius x 0.025 inch (0.635 mm)
length x 0.005 inch (0.127 mm)
depth (Maximum two repairs
per edge quadrant).
H Surface Corrosion/mechanical 0.005 inch (0.127 mm) deep,

is one square inch (645.2 mm ²).
TIR 0.004 inch (0.102 mm) maximum. 6
407MM_65_0063
65-00-00
7 NOV 2006 Rev. 23 Page 45
BHT-407-MM-7
NOTES
1 Examine the splines for signs of a wear step. If you can feel a wear step
with a 0.020 inch (0.508 mm) spherical radius probe, discard the flywheel adapter.
2. Repair damage with a 0.25 inch (6.35 mm) minimum radius and a 63 RMS
surface finish.
3 When you remove damaged material from the flywheel adapter, remove an equal
amount of material 180° opposite the repaired area to maintain balance.
4 The flywheel adapter is dynamically balanced at the factory. Material is removed
from the inner diameter of the flywheel adapter rim. Permitted repairs to these
edges are in addition to the material removed for the dynamic balance procedure.
5 Remove small nicks, dents and scratches from spline teeth edges with a fine India
Stone. Remove the raised material until it makes a continuous surface on all sides.
6 Measure Total Indicator Runout (TIR) with the flywheel adapter installed on the
oil cooler blower shaft. Install the shaft on V blocks at the bearing journal.
7. Refer to the BHT-ALL-SPM or CSSD-PSE-87-001 for the repair procedures.
8. Remove two times the depth of the corrosion to repair a corroded surface. The limits
shown are for after the repair is completed.
9. Refer to the BHT-ALL-SPM for the procedures to brush cadmium plate the repaired
areas.
407MM_65_0064
65-00-00
Page 46 Rev. 23 7 NOV 2006
BHT-407-MM-7
8. Install the bolts (17), coupling washers (18)

(Figure 65-11, Detail A), flat washers (20), and nuts
CAUTION
(21) that attach the coupling disc pack (19) to the
forward end of the forward short shaft. Tighten the
nuts until they lightly contact. The bolts must remain
FORWARD AND AFT OIL COOLER
loose enough so that they can be turned by hand.
BLOWER SHAFT SLIDING SPLINED
ADAPTERS MUST SLIDE FREELY ON
ENDS OF BLOWER SHAFT. IF NOTE
REQUIRED TO ATTAIN THIS RESULT, IT
Depending on helicopter configuration,
MAY BE NECESSARY TO REMOVE THE
DRY LUBRICANT FROM TOP OF SHAFT perform step 9, step 10, or step 11.
SPLINES. IF ADAPTERS DO NOT SLIDE
9. For helicopters with a flywheel (23), install the
FREELY, DAMAGE TO BEARINGS MAY
bolts (6), spacers (7), coupling washers (8)
OCCUR DUE TO PRELOADING.
(Figure 65-11, Detail B), flat washers (9), and nuts (10)
that attach the coupling disc pack (22) to the forward
NOTE short shaft (11). Tighten the nuts until they lightly
contact. The bolts must remain loose enough so that
Flanges of forward splined adapter (5, they can be turned by hand.
Figure 65-11) and aft splined adapter (17,
Figure 65-28) must be positioned 90° to 10. For helicopters with a splined adapter (5), with or
each other within spline tolerance. without a balance plate (24) and without air
conditioning, install the bolts (6), coupling washers (8),
4. Apply grease (C-525) or grease (C-561) to the flat washers (9), and nuts (10) that attach the coupling
splines of the adapter (5). Slide the splined adapter or disc pack (22) to the forward short shaft (11). Tighten
the splined flywheel adapter (23) (if installed) onto the the nuts until they lightly contact. The bolts must
oil cooler blower shaft. remain loose enough so that they can be turned by
hand.
5. Install the coupling disc pack (19) on the
freewheel output adapter (16) with the bolts (12), 11. For helicopters with a splined adapter (5), with a
coupling washers (13, Figure 65-11, Detail B), flat balance plate (24) and with air conditioning, install the
washers (14), and nuts (15). Tighten the nuts until they bolts (28, Figure 65-11), bevel washers (29 and 30),
lightly contact. The bolts must remain loose enough so flat washers (31), and nuts (32). Tighten the nuts until
that they can be turned by hand. they lightly contact. The bolts must remain loose
enough so that they can be turned by hand.
6. Remove the lockwire from the coupling disc 12. Apply torque T to all the nuts (Figure 65-11) on
pack (19). the coupling disc packs. Make sure that you follow the
torque sequence (paragraph 65-60).
CAUTION
CAUTION
DURING INSTALLATION, SUPPORT THE

FORWARD SHORT SHAFT TO PREVENT DUE TO A VARIATION IN HMU
DA M A GE TO T H E CO UP LI N G D I S C CASTINGS A POSSIBILITY EXISTS THAT
PACKS. CONTACT CAN OCCUR BETWEEN THE
COUPLING DISC PACK HARDWARE
AND THE HMU. THIS IS NOT DESIRABLE
7. Put the forward short shaft assembly (11) in AND MUST NOT BE ALLOWED.
position on the helicopter. If applicable, position the
balance plate (24) over the aft end of the short shaft, 13. Measure the clearance between the
prior to putting it in position. hydromechanical unit (HMU) and the flange on the
65-00-00
ECCN EAR99 8 APR 2011 Rev. 30 Page 47
BHT-407-MM-7
forward end of the forward short shaft assembly. 65-31. Oil Cooler Blower — Removal
Measure the clearance between the hardware that
attaches the HMU and the hardware that attaches the
forward flange to the coupling disc pack. If either of MATERIALS REQUIRED
these measurements is less than 0.070 inch
(1.778 mm), examine the forward short shaft assembly
for correct installation of the coupling disc packs and NUMBER NOMENCLATURE
attachment hardware. If the installation is correct the
C-428 Caps and/or Plugs
HMU must be removed and replaced until the
minimum clearance is met.
1. Gain access to the oil cooler blower (Chapter 53).
14. Perform an operational check (paragraph 65-3). 2. Drain the engine and transmission oil cooler
Refer to BHT-II-30, part VII for balancing procedures. lines, the oil cooler, and the oil tank (Chapter 12).
If flywheel (23, Figure 65-11) is installed, refer to TB
407-02-35 for flywheel balancing procedures.
CAUTION
65-30. OIL COOLER BLOWER
MAKE SURE THAT YOU INSTALL CAPS

The oil cooler blower assembly is installed aft of the aft AND/OR PLUGS (C-428) ON ALL OF THE
firewall. It is bolted to the helicopter structure and OPEN PORTS, TUBES, AND HOSES.
holds the engine and transmission oil coolers. The oil THIS PREVENTS CONTAMINATION OF
cooler blower shaft (51, Figure 65-15) is supported by THE SYSTEM.
two bearing hangers, one on the forward end (27) and
3. Disconnect the oil inlet and outlet lines on the
one on the aft end (7). Each hanger has a sealed engine (Chapter 79) and transmission (Chapter 63) oil
bearing with a grease fitting and a pivot support for coolers.
alignment. The oil cooler blower shaft (51) has
lubricant applied to the shaft splines. It is connected to 4. Remove the screws (21, Figure 65-15) and
the forward and aft short shaft with a splined adapter, washers (22) that attach the oil cooler transition duct
(S/N 53443 and subsequent or S/N 53000 through to the oil cooler blower assembly. Remove the oil
cooler and transition duct as an assembly (Chapter
53442 Post BHT-407-II-30, without air conditioning), or
79).
a splined flywheel adapter, (S/N 53000 through 53442
Pre BHT-407-II-30), on the forward end, and a splined 5. Remove the forward short shaft (paragraph
adapter on the aft end. The splined flywheel adapter (if 65-25).
installed) or the splined adapter(s) can slide fore and
aft on the oil cooler blower shaft splines. The oil cooler 6. Remove the oil tank (Chapter 79).
impeller (49) is bolted to the oil cooler blower shaft
with four bolts. On helicopters S/N 53443 and 7. Remove the aft short shaft (paragraph 65-42).
subsequent or S/N 53000 through 53442 Post
BHT-407-II-30, two weights (54 and 55) are bolted 8. Remove the forward short shaft covers on the aft
along with the impeller (49) to the oil cooler blower firewall (Chapter 53).
shaft. The oil cooler blower shaft is part of the tail rotor
9. Remove the nut (13), washers (3), and bolt (1)
drive system. It is made of steel and drives the
from the bearing hanger (7).
aluminum aft short shaft and the oil cooler impeller.
Balance plates may also be installed at each end of 10. Remove the nut (16), washers (4), bolt (2), and
the oil cooler blower shaft. The balance plates permit links (5 and 12) from the aft bearing hanger bracket
dynamic balancing. (19).
65-00-00
BHT-407-MM-7
SEE DETAIL C
11
6
53 6
5 1
D 52 1 8
48 3 7
5
10
SEE DETAIL A 2 9
4 12
6 1 55 3
13
5
SEE DETAIL B 1 54 14
15
51 59 4
3 16
50 5
49
19
48 17
5
47
18
20
46
21
45 22
43 44
3
SEE DETAIL C
42
3 59
32
41 1 27
33 23
3
28 24
25 SINGLE TAB
29 26 25 10 30
30
33
34
5
35 36
40 5
37
31 39
6
38
5 DETAIL B
37 (TYPICAL)
DETAIL A
407MM_65_0065a
Figure 65-15. Oil Cooler Blower (Sheet 1 of 5)
65-00-00
BHT-407-MM-7
57
56
51
58
DETAIL C
PARTS OMITTED FOR CLARITY
407MM_65_0065b
65-00-00
BHT-407-MM-7
INSTALLED ORIENTATION INSTALLED ORIENTATION

8 OF HANGER FLANGE 8 OF HANGER FLANGE
FWD
27 7
31 11
E F
30 10
S/N 53000 THROUGH 53442 SHOWN, PRE TB 407-II-30/POST ASB 407-02-54

(WITH FLYWHEEL INSTALLED)
INSTALLED ORIENTATION 7 INSTALLED
7 OF HANGER FLANGE ORIENTATION OF
FWD 54 1 HANGER FLANGE
55 1 6
59 3
27 59 3
7
31 11
G H
30 10
3
3
S/N 53519 AND SUBSEQUENT OR S/N 53000 THROUGH 53518 IF ALL THREE OF THE
FOLLOWING HAVE BEEN COMPLETED: BHT-407-II-30/TB 407-02-35/ASB 407-02-54
VIEW D
407MM_65_0065c
65-00-00
BHT-407-MM-7
6 5
63 4 2
27 4 63
32 7
2 5 60
4
61 62
60
4
61
S/N 53000 THROUGH 53442 POST BHT-407-II-30 S/N 53000 THROUGH 53442 POST BHT-407-II-30
VIEW E VIEW F
FORWARD BEARING AFT BEARING
(LOOKING AFT) (LOOKING FORWARD)
63 4 32 5
27 2
63 4 6 5
2
7
60
4
60
4
61
61
S/N 53000 THROUGH 53442 POST TB 407-02-35 S/N 53000 THROUGH 53442 POST TB 407-02-35
AND S/N 53443 AND SUBSEQUENT AND S/N 53442 AND SUSBEQUENT
VIEW G VIEW H
FORWARD BEARING AFT BEARING
(LOOKING AFT) (LOOKING FORWARD) 407MM_65_0065d
65-00-00
BHT-407-MM-7
1. Bolt 22. Washer 43. Screw

2. Bolt 23. Screw 44. Screw
3. Washer 24. Washer 45. Oil cooler blower housing
4. Washer 25. Shim 46. Screw
5. Link 26. Inlet cover 47. Bolt
6. Grease fitting 27. Bearing hanger 48. Washer
7. Bearing hanger 28. Bearing 49. Impeller
8. Bearing 29. Retaining ring 50. Inlet cover
9. Retaining ring 30. Locking washer 51. Oil cooler blower shaft
10. Locking washer 31. Spanner nut 52. Washer
11. Spanner nut 32. Grease fitting 53. Nut
12. Link 33. Washer 54. Primary weight
13. Nut 34. Nut 55. Secondary weight
14. Cotter pin 35. Cotter pin 56. Adapter
15. Cotter pin 36. Screw 57. Spanner assembly (T103216-101)
16. Nut 37. Washer 58. Spanner wrench (AN8515-1)
17. Screw 38. Bolt 59. Airflow shield
18. Washer 39. Shim 60. Adapter
19. Aft bearing 40. Forward bearing 61. Lockwire (C-405)
hanger bracket hanger bracket 62. Insulation (130-005-1-3)
20. Shim 41. Bolt 63. Washer
21. Screw 42. Bracket
5 TO 10 IN-LBS 20 TO 30 IN-LBS
1 (0.56 TO 1.13 Nm) 4 (2.3 TO 3.4 Nm)
2 (1.7 TO 2.3 Nm) 5 (5.7 TO 7.9 Nm)
3 (2.3 TO 2.8 Nm) 6 (22.6 TO 33.9 Nm)
NOTES
1 S/N 53443 and subsequent, or S/N 53000 through 53442 Post BHT-407-II-30.
2 Airflow shield (59) omitted for clarity.
3 Airflow shield (59) installed on S/N 53108 and 53519 and subsequent or on
S/N 53000 through 53518 Post ASB 407-02-54.
4 On S/N 53443 and subsequent, or S/N 53000 through 53442 Post BHT-407-II-30 or Post
TB 407-02-35, additional washer under adapter may be required if grease fitting (MS15001) needs
rotational adjustment to aid greasing operation. Use washer (NAS1149F0463P),
(NAS1149F0432P) or (NAS1149F0416P) as required. Maximum total washer thickness not
to exceed 0.085 inch (2.15 mm). One washer minimum required.
5 On S/N 53443 and subsequent, or S/N 53000 through 53442 Post BHT-407-II-30 or Post
TB 407-02-35, existing grease fitting (MS15001-1) may be reused. As alternates, grease
fittings (MS15001-3 or -4) may be used to obtain most practical access for greasing.
6 Secondary weight (55) not used with air conditioning installation.

Refer to AIR COMM STC SR00222DE.
7 Orientation of hanger flange applies to S/N 53443 and subsequent or S/N 53000
through 53442 Post TB 407-02-35.
8 Orientation of hanger flange applies to S/N 53000 through 53442 Pre TB 407-02-35 and
S/N 53000 through 53442 Post BHT-407-II-30.
407MM_65_0065e
65-00-00
BHT-407-MM-7
11. Remove the screws (46) and the inlet cover (50) SPECIAL TOOLS REQUIRED (Cont)
from the oil cooler blower housing (45).
NUMBER NOMENCLATURE
12. Remove the nut (34), washers (33), and bolt (41)
from the forward bearing hanger bracket (40). OTC1025 Bearing Puller or
Equivalent
13. Remove the oil cooler blower shaft (51), impeller
(49), bearing hanger (27), and bearing hanger (7) as OTC8059 Step Plate Adapter
an assembly, from the oil cooler blower housing (45). or Equivalent
OTC8062 Step Plate Adapter or

NOTE Equivalent
The shims (20, 25, and 39) are installed T103216-101 Spanner Assembly
under the oil cooler blower housing and
hanger brackets (19 and 40). The brackets Workaid No. 2 Workaid,(Figure 65-31)
align the oil cooler blower housing to the
impeller, and the oil cooler blower shaft to
the tail rotor drive system. Be very careful
MATERIALS REQUIRED
not to move the shims during removal of
the oil cooler blower assembly.
After the oil cooler blower housing (45) and NUMBER NOMENCLATURE
the hanger brackets (19 and 40) are
removed, install the screws (17, 23, 36, and C-326 Denatured Alcohol
43) and the bolt (38) to keep the shims in
position.
1. Removal of the forward and aft bearing hangers
14. Remove the screws (17), washers (18), and aft and bearing are the same. The forward procedure is
bearing hanger bracket (19) from the helicopter shown. Use the same procedure to remove the aft
structure. bearing hanger and bearing. Remove the bearing
hanger (7 or 27, Figure 65-15) and bearing (8 or 28)
as follows:
15. Remove the screws (23 and 43), washers (24),
and bracket (42).
a. Lift the tang of the locking washer (10 or 30)
from the slot in the spanner nut (11 or 31).
16. Remove the oil cooler blower housing (45).
b. Attach the spanner assembly, T103216-101
17. Remove the screws (44) and the inlet cover (26). (57), to the adapter (56).
18. Remove the screws (36), bolts (38), washers c. Install the adapter (56) on the oil cooler blower
(37), and forward bearing hanger bracket (40) from the shaft (51).
helicopter structure.
d. Hold the splines of the oil cooler blower shaft
(51) with the spanner assembly, T103216-101 (57),
65-32. Oil Cooler Blower — Disassembly and remove the spanner nut (11 or 31) with the
spanner wrench AN8515-1 (58).
SPECIAL TOOLS REQUIRED e. Remove and discard the locking washer (10
or 30).
NUMBER NOMENCLATURE 2. Remove the bearing (8 or 28) and the bearing

hanger (7 or 27), as an assembly, from the shaft using
AN8515-1 Spanner Wrench
Method A or Method B. If you want to reuse the
65-00-00
BHT-407-MM-7
bearing (8 or 28) and you do not have to remove the e. Place a cardboard or other adequate shield
bearing (8 or 28) from the bearing hanger (7 or 27), material, as required, to cover the bearing face on the
use Method A. If you intend to replace the bearing spline side of the oil cooler blower shaft (51). This
hanger (7 or 27) or bearing (8 or 28), use Method B. shield must be designed to protect the bearing inner
Due to the stress applied to the bearing (8 or 28),
race from any refrigerant that may spill or boil over the
which could cause undetectable damage, it is
recommended that any time Method B is used, the end of the shaft during the next step.
bearing (8 or 28) be discarded.
METHOD A: WARNING
Remove the forward and aft bearings and hangers as

an assembly from the shaft as follows: USE ADEQUATE PERSONAL
PROTECTION INCLUDING GLOVES AND
SAFETY FACE SHIELD WHEN
NOTE MANIPULATING SOLUTIONS. THE COLD
Bearing 407-340-339-107 can be removed ALCOHOL -109°F (-78°C) MAY BOIL ON
from the blower shaft and reused again, CONTACT WITH THE BLOWER SHAFT
only if the following procedure and CAUSING IT TO FLOW OVER THE
restrictions are observed while removing SHAFT AND ONTO THE BEARING FACE.
the bearing from the shaft.
f. Place a piece of approximately one cubic inch
a. Using a clean rag, lightly coat the inside and (16 cm3) of dry ice in 10 ounces (296 ml) of denatured
outside of the oil cooler blower shaft (51) with turbine alcohol (C-326). Stir the dry ice and alcohol for a
oil.
minimum of two minutes. A small amount of dry ice
must still be present in the solution after stirring; this
NOTE ensures that alcohol is as cold as it can get. Carefully
pour the alcohol into the fan shaft bore until the level
Suggested cork size: small end 1 inch
inside of the shaft is above the bearing face.
(25.4 mm) diameter, large end 1.2 inch
(30.5 mm) diameter.
b. Insert a cork into the fan shaft bore to a CAUTION

distance of 0.5 inch (12.7 mm) below the bearing to be
removed.
DO NOT EXCEED 2000 POUNDS (8896
c. Mount the bearing and shaft assembly into a N) OF PRESSING FORCE. IF PRESSING
press capable of a 5,000 pound force (22,241 N). FORCE EXCEEDS 2,000 POUNDS (8896
Configure the press to push the shaft through the N), BEARING SHALL BE DISCARDED.
bearing bore while restraining the bearing at the outer
ring. Use a soft metal bar or plate to press against the
end of the shaft. Monitoring the press force is NOTE
essential. Provide support under the shaft.
Most presses are equipped with a gauge
graduated in pounds. If your press has
d. Using a heat gun, warm up the bearing (28 or gauge graduated in pounds per square inch
8) and oil cooler blower shaft (51) near the bearing
or kilopascals, you will need to know the
until the temperature of the blower shaft adjacent to
the bearing reaches 150 ±20°F (66 ±10°C). Rotate the area of the piston in the cylinder in order to
shaft as required to achieve a uniform shaft apply the proper force on the bearing.
temperature. Do not exceed a temperature of 285°F Usually this figure is printed somewhere on
(140°C) on the hanger housing. the press itself.
65-00-00
BHT-407-MM-7
28) and the bearing hanger (7 or 27) from the oil

g. Use this formula to calculate the maximum cooler blower shaft (51).
pressure allowed on the gauge in order not to exceed
2000 pounds (8896 N) of force.
If required, remove the bearing (8 or 28) from the
bearing hanger (7 or 27) as follows:
2000 pounds (8896 N) = pressure (PSI) (kPa)
a. Remove the grease fitting (6 or 32), and if
Piston area (sq. in.) (cm2) applicable, adapter (60).
b. Remove the retaining ring (9 or 29).
CAUTION c. Use an arbor press, step plate OTC8062, and

workaid No. 2 (12, Figure 65-32) and press the
bearing (28 or 8, Figure 65-15) from the bearing
REMOVE THE BEARING QUICKLY hanger (7 or 27). If installed, remove airflow shield
AFTER POURING THE ALCOHOL (59).
S O L U T I O N IN T O T H E O IL C O O L E R
B L O W E R S H A FT ( 5 1 ) . T H E F O R C E
REQUIRED TO REMOVE THE BEARING NOTE
(28 AND 8) SIGNIFICANTLY INCREASES
WITH TIME IN THE REMOVAL It is recommended to discard the bearing
PROCESS. IF PRESSING FORCE each time that it is removed. The stress
EXCEEDS 2000 POUNDS (8896 N), applied to the bearing’s inner race when
BEARING SHALL BE DISCARDED. pressing on the outer race may cause
damage to the bearing that is not
detectable through normal visual
h. Within 30 seconds of pouring the alcohol into inspection.
the oil cooler blower shaft (51), press the bearing (28
or 8) off the shaft with a steady motion. If installed, d. Discard bearing (8 or 28).
remove airflow shield (59). Provide support under the
shaft.
3. Remove the impeller (49) and the weights (54
and 55), if installed, from the oil cooler blower shaft
(51) as follows:
CAUTION
a. Remove the nut (53), washers (48 and 52),
and bolt (47).
ALCOHOL MAY BE HARMFUL OR FATAL
IF SWALLOWED. b. Remove the impeller (49) and the weights (54
and 55) from the oil cooler blower shaft (51).
i. Properly dispose of the alcohol in the shaft
bore and remove the cork. 65-33. Oil Cooler Blower — Cleaning
j. Use a heat gun to bring all components of the 1. Refer to the BHT-ALL-SPM and clean the oil
oil cooler blower shaft (51) and bearing (28 and 8) cooler blower parts.
assembly to room temperature. Remove any
condensation that may have accumulated.
2. Clean only the outside surface of the bearings (8
and 28, Figure 65-15), with a clean cloth. Apply a light
METHOD B: pressure so that the dirt and expelled grease is not
forced back into the bearing.
Use step plate adapter, OTC8059, or a suitable plug to
protect the end of the oil cooler blower shaft (51) and 3. To clean the oil cooler blower while installed on
the bearing puller OTC1025. Remove the bearing (8 or the helicopter, refer to Chapter 12.
65-00-00
BHT-407-MM-7
65-34. Oil Cooler Blower — Inspection and Repair 4. If no indication of roughness is detected, if the
expelled grease has not turned black, if you see no
1. Refer to Figure 65-16 through Figure 65-23 and metal in the expelled grease, and if the bearing seal is
do the inspection and repair of the oil cooler blower intact, the bearing is acceptable for return to service.
parts.
5. If you detect or suspect roughness of a bearing,
2. Gain access to bearing hangers (Chapter 53). disconnect the forward and aft short shaft and rotate
the blower shaft manually to confirm the bearing
roughness. If the bearing is rough, if a seal is torn, if
the expelled grease has turned black, or if you see
WARNING metal particles in the expelled grease, replace the
affected bearing (paragraph 65-32) and contact
Product Support Engineering.
OPERATING BEARINGS ARE HOT. IF
YOU DO THIS CHECK A SHORT TIME 6. Visually inspect forward and aft spanner nuts (31
AFTER SHUTDOWN, EXERCISE and 11, Figure 65-15) for evidence of corrosion
CAUTION TO AVOID BURNS. (TB 407-09-89). If surface or pitting corrosion is found,
replace the nut.
NOTE
65-35. Oil Cooler Blower Shaft — Stripping and
Refer to Figure 65-17 for additional Painting
inspection information.
MATERIALS REQUIRED
NOTE
It is not necessary to disconnect any shaft
to do this check. NUMBER NOMENCLATURE
3. Inspect oil cooler blower assembly bearings as C-208 Epoxy/Zinc Coating

follows:
C-305 Aliphatic Naphtha
a. Visually inspect bearing seals for tears. C-309 MEK
C-344 Alcoholic Phosphoric

b. Rotate the main rotor to turn the tail rotor drive Cleaner
system. While it is rotating, check for indications of
bearing roughness by placing a hand on the bearing C-436 Paint Remover
hanger at each bearing location.
NOTE
c. Visually check for accumulated grease that You do not have to remove the primer from
has expelled from around the seal during operation for the internal diameter of the oil cooler blower
color change. shaft (51, Figure 65-15) to do the
inspection. Shaft 407-040-320 does not
have primer.
NOTE
Bearing 407-340-339-107 installed on S/N 1. If the primer is damaged or if necessary, remove
53000 through 53579 Post ASB 407-04-63 the primer from the internal diameter of the oil cooler
and S/N 53580 and subsequent has an blower shaft (51) with paint remover (C-436). Refer to
orange elastomer seal and uses Mobil 28 the BHT-ALL-SPM.
grease (C-001) that is normally red-purple.
The grease will turn black if the bearing is 2. The outside diameter of the oil cooler blower
damaged. shaft (51) is not painted. Use Brush Cadmium Plate on
repaired areas of the oil cooler blower shaft outside
d. Visually check grease for metal particles. diameter. Refer to the BHT-ALL-SPM.
65-00-00
BHT-407-MM-7
A D B D
B B
A A
C E C E
A B
F SECTION A-A F SECTION B-B
AFT BEARING HANGER- OIL COOLER BLOWER FWD BEARING HANGER- OIL COOLER BLOWER
(406-040-317-101) (406-040-322-101/407-040-332-101)
MATERIAL: CRES STEEL MATERIAL: CRES STEEL
REF
A Bearing bore. Wear 2.6775 inches (68.0085 mm)
maximum diameter.
B Internal diameter Corrosion 0.003 inch (0.076 mm) deep.
and surface. 25% of any one circumferential
inch (25.4 mm) of surface.
Mechanical Axial and circumferential scratches

0.003 inch (0.076 mm) deep.
Remove raised material.
C Faces Mechanical Remove the raised material until
it makes a continuous surface on
all sides.
All External diameter Corrosion 0.010 inch (0.254 mm) deep.
and surface. Shoulder 25% of any one square inch
internal diameter. (645.2 mm²) of surface.
Hanger flange. Mechanical Nicks, dents and scratches

0.010 inch (0.254 mm) deep,
0.50 inch (12.70 mm) long.
Edge damage 0.030 inch (0.762 mm) x 45º
chamfer, 0.50 inch (12.70 mm)
total length, two repairs per quadrant.
D Threaded hole. Corrosion/mechanical None past the first thread pitch.
407MM_65_0067
Figure 65-16. Bearing Hanger — Inspection (Sheet 1 of 2)
65-00-00
BHT-407-MM-7
E Bolt hole Wear 0.269 inch (6.833 mm)

maximum diameter.
(406-040-317 and -322)
0.260 inch (6.604 mm)
maximum diameter
(407-040-322)
Corrosion 0.010 inch (0.254 mm) deep.
25% of the wall area.
F Mount Wear
406-040-317-101 2.410 inches (61.265 mm)
minimum dimension
406-040-322-101 2.400 inches (60.96 mm)
minimum dimension
407-040-322-101 2.414 inches (61.316 mm)

minimum dimension
NOTES
1. The limits shown are for after the repair is completed.
2. Refer to the BHT-ALL-SPM or CSSD-PSE-87-001 for the repair procedures.
3. Repair the damage that have a 0.25 inch (6.35 mm) minimum radius and a 32 RMS
surface finish.
4. Refer to the BHT-ALL-SPM for the procedures to brush cadmium plate the repaired areas.
Do not apply brush cadmium plating in the bolt holes and in the threaded holes.
407MM_65_0068
Figure 65-16. Bearing Hanger — Inspection (Sheet 2 of 2)
65-00-00
BHT-407-MM-7
BEARING (406-040-339/407-340-339)
REF
A Internal diameter Scratches 1.575 inches (40.005 mm) maximum. 1

B Outside diameter Scratches 2.6767 inches (67.988 mm) minimum. 1
C Index marks Seal cap Make sure that the index marks on the bearing 2
spinning outer race and the seal cap match. Discard the
bearing if the index marks do not match.
NOTES
1 This dimension is given only as a reference to help remove the raised material until it
makes a continuous surface on all sides.
2 Replace the bearing if the seal cap is distorted or if the seal material is torn, cut or worn
where it is in contact with the inner race.
3. Examine the bearing for roughness. Hold the outer race and turn the inner race. If the
bearing is rough or binds, discard the bearing.
4. Examine the bearing races for signs of an overheat condition. An overheat of the
bearing can be identified by the discoloration of the races and heat damage to the seal.
Discard the bearing if signs of an overheat condition are present.
5. Refer to the operational test in this chapter to find out if the bearing runs too hot.
6. Evidence of black grease pushed out from bearing is cause for rejection. Normal colored
grease (red-purple for Mobil 28) that is pushed out from the bearing seal is not cause for
rejection.
7. Do not wash, clean or spray the bearing or the bearing hanger with any type of solution.
Use only clean cloths to clean the grease from the bearing seal face. Apply a light pressure
so that expelled grease is not forced back into the bearing.
407MM_65_0069
Figure 65-17. Bearing — Inspection
65-00-00
Page 60 Rev. 23 7 NOV 2006
BHT-407-MM-7
LINK-OIL COOLER BLOWER HANGER / BRACKET

406-040-318-101/-103
MATERIAL: ALUMINIUM
406-040-318-105/-107 AND 407-040-311
REF
A Fastener holes Wear Maximum of 0.269 inch (6.833 mm).
(406-040-318)
Maximum of 0.260 inch (6.604 mm).
(407-040-311)
B All surfaces Corrosion None allowed.
Mechanical Nicks, dings, dents, and scratches up to

0.010 inch (0.254 mm) deep and 0.250
inch (6.35 mm) long.
Remove the raised material until it
Edges Corrosion/mechanical None allowed.
NOTE
Refer to the BHT-ALL-SPM to do the brush cadmium plating after repair. Do not apply brush cadmium
plating in the bolt holes and threaded holes.
407MM_65_0070
Figure 65-18. Oil Cooler Blower Hanger/Bracket Link — Inspection
65-00-00
7 NOV 2006 Rev. 23 Page 61
BHT-407-MM-7
A C A
B G G G G B
TYPICAL
9 F I J BOTH
ENDS
8 8
E E H
1
D
7
1.78 IN. 1.77 IN.
(45.21 mm) (44.96 mm)
OIL COOLER BLOWER SHAFT (406-040-320/407-040-320)

REF
A Bearing journals. Wear Minimum diameter of

1.5743 inches (39.9997 mm).
A Bearing journals Corrosion Light, superficial corrosion that

shoulders. you can remove by hand.
Polish with a fine stainless steel
wool or Scotchbrite.
Mechanical None that can be felt with a

0.020 inch (0.508 mm)
spherical radius tip probe.
B Spline-measure Wear Minimum diameter of

over a 0.1200 inch 1.5470 inches (39.2938 mm).
(3.0480 mm)
diameter pin.
B Spline-sides and Corrosion/mechanical Light, superficial corrosion that

roots of teeth. you can remove by hand.
Spline-tops and Corrosion/mechanical Maximum of 0.010 inch (0.254 mm), 4

ends of teeth. up to 0.25 inch (6.35 mm)
long on all teeth.
0.001 inch (0.025 mm) 4

maximum up to 100% of
the surface of all the teeth.
407MM_65_0071
Figure 65-19. Oil Cooler Blower Shaft — Inspection (Sheet 1 of 3)
65-00-00
Page 62 Rev. 23 7 NOV 2006
BHT-407-MM-7
REF
C Diameters and faces Corrosion Light, superficial corrosion that

you can remove by hand.
Mechanical 0.005 inch (0.127 mm) 4
deep, two per quadrant.
D Fastener hole Wear Maximum diameter of
0.287 inch (7.290 mm).
E Threads Corrosion/mechanical One thread pitch. 1/4 thread
depth, 0.25 inch (6.35 mm)
over the total length.
F Inside diameter Corrosion Clean up to 1.110 inches (28.194 mm) 9
maximum inside diameter.
G Shaft body- Corrosion/mechanical 0.005 inch (0.127 mm) deep local

outside diameter clean up in a one square inch
(645.2 mm²) area to a minimum
outside diameter of 1.245 inches
(31.623 mm).
H Spline-major Wear 1.4350 inches (36.4490 mm) minimum
diameter diameter.
I Shoulder Wear 1.842 inches (46.787 mm) minimum

diameter.
J Shoulder Wear Minimum diameter of
1.842 inches (46.787 mm).
(406-040-320)
1.8325 inch (46.5455 mm).
(407-040-320)
All Slots, thread relief, Corrosion 0.005 inch (0.127 mm) deep local
not designed areas. clean up. 25% of any one surface.
Mechanical 0.005 inch (0.127 mm) deep, 4

four per any surface.
NOTES
1 Measure the total indicator runout. 0.001 inch (0.025 mm) maximum on the pilot diameter, and 0.005 inch
(0.127 mm) maximum on the face with the shaft mounted on V blocks at the bearing journals.
2. Examine the spline teeth for signs of a wear step. If you can feel a wear step with the use of a 0.020 inch
(0.508 mm) spherical radius tip probe, the shaft must be discarded.
3. Make repairs with a 0.25 inch (6.35 mm) minimum radius and a 32 RMS surface finish unless shown
differently.
4 Remove nicks, dents, and scratches with the use of a fine India stone. Remove the raised material until it
407MM_65_0072
65-00-00
7 NOV 2006 Rev. 23 Page 63
BHT-407-MM-7
7 Refer to the BHT-ALL-SPM to do the brush cadmium plating after the

repair. Do not apply brush cadmium plating in the bolt holes and threaded holes.
8 Apply a solid film lubricant, solid film (C-021) (Aerosol) to the splines. The solid film lubricant must
overlap the cadmium plating by 0.150 inch (3.810 mm). Shaft P/N 406-040-320 only.
9 Polish the shaft to remove the corrosion. Make sure to remove the material constantly around the
diameter of the shaft. It is not necessary to apply brush cadmium plating to the internal diameter of the
shaft after the repair. It is necessary to apply the Epoxy Zinc coating to the internal diameter of the shaft.
Refer to the procedures in this chapter for the removal and application of Epoxy Zinc coating.
407MM_65_0073
65-00-00
Page 64 Rev. 23 7 NOV 2006
BHT-407-MM-7
NOTES
1. Examine the impeller flanges and blades for cracks, dents, or bends. Carefully examine the
mounting flanges and individual blades. Discard the impeller if a blade or flange is cracked,
has dents, or is bent.
2. Examine the impeller for deformation. Discard the impeller if deformation is found. Measure
the balance of the impeller before the disassembly (the impeller must be clean) to find
deformation.
3. No repairs are permitted on the impeller.
4. Refer to the BHT-ALL-SPM or CSSD-PSE-87-001 for corrosion prevention treatment.
407MM_65_0074
Figure 65-20. Oil Cooler Blower Impeller — Inspection
65-00-00
7 NOV 2006 Rev. 23 Page 65
BHT-407-MM-7
NOTES
1. Examine the blower housing and inlet covers for cracks, dents, or bends and for loose rivets
and nutplates.
2. Loose rivets and nutplates can be replaced with the use of standard sheet metal procedures.
4. Apply zinc chromate primer (C-201) to the repaired area.
407MM_65_0075
Figure 65-21. Oil Cooler Blower Housing — Inspection
65-00-00
Page 66 Rev. 23 7 NOV 2006
BHT-407-MM-7
G
A A A A
A A
A A
C
FWD BEARING HANGER BRACKET- OIL COOLER BLOWER (407-040-321-101/-103)

MATERIAL: ALUMINUM ALLOY
H F
A A
A A
A A
C
AFT SUPPORT BRACKET- OIL COOLER BLOWER (406-040-323-101/407-040-323-101)

407MM_65_0076
Figure 65-22. Brackets — Inspection (Sheet 1 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 67
BHT-407-MM-7
REF
A Machined surfaces Corrosion/mechanical 0.010 inch (0.254 mm) deep. 5

Maximum of 25% of any surface.
B Cast surfaces Corrosion/mechanical 0.010 inch (0.254 mm) deep 50% of any
square inch (645.2 mm²) of the surface.
ALL Fastener holes Corrosion 0.010 inch (0.254 mm) up to 25% of the
wall surface.
Mechanical Axial scratches 0.010 inch (0.254 mm) deep,

full length of the hole wall. Random nicks, dents,
scratches around edges 0.010 inch (0.254 mm)
deep, 0.050 inch (1.27 mm) long/wide.
Edge chamfer to Corrosion/mechanical 0.030 inch (0.762 mm) x 40 to 45°

remove damage for 0.50 inch (12.7 mm).
C Fastener holes Wear Maximum of 0.289 inch (7.341 mm).
D Machined faces Wear Maximum of 0.240 inch (6.096 mm). 1
E Fastener holes Wear Maximum of 0.269 inch (6.833 mm).

(407-040-321-101)
(407-040-321-103)
F Fastener holes Wear Maximum of 0.269 inch (6.960 mm).

(406-040-323-101)
(407-040-323-101)
G Mounting width Wear Maximum width 2.406 inches (61.468 mm).

(407-040-321-101)
Maximum width 2.420 inches (61.112 mm).
(407-040-321-103)
H Mounting width Wear Minimum width 2.418 inches (61.417 mm).

(406-040-323-101)
Minimum width 2.414 inches (61.316 mm).
(407-040-323-101)
NOTES
1 It is permitted to machine the surface A to the minimum shown. The upper and lower surfaces must be
parallel within 0.005 inch (0.127 mm). The machine surfaces at the pivot points cannot be machined.
2. Remove two times the depth of the corrosion to repair the corroded surface. The limits shown are for
after the repair is completed.
4. Repair the damage with a 0.25 inch (6.35 mm) minimum radius and a 32 RMS surface finish.
5 Rework nicks, dents, and scratches only to remove the raised material until it makes a continuous
surface on all sides.
6. Refer to the BHT-ALL-SPM to treat the repaired areas chemically.
407MM_65_0077
Figure 65-22. Brackets — Inspection (Sheet 2 of 2)
65-00-00
Page 68 Rev. 23 7 NOV 2006
BHT-407-MM-7
B
A
A
SECTION A-A
ADAPTER (406-040-316)
REF
A Faces Corrosion/mechanical 0.001 inch (0.025 mm) deep, maximum

area per full depth repair is 0.250
square inch (161.3 mm ²).
B Outside diameter Corrosion/mechanical 0.005 inch (0.127 mm) deep, maximum

A, B Number of repair Two per area.
ALL Edge Corrosion/mechanical Maximum edge chamfer to remove

damage is 0.030 inch (0.762 mm) x
40 to 45° up to 0.50 inch
(12.70 mm). No more than two per
quadrant.
C Spline - measure over Wear Maximum diameter of 1.2257 inches

0.108 inch (2.743 mm) (31.1328 mm).
diameter pin.
407MM_65_0078
Figure 65-23. Splined Adapter — Inspection (Sheet 1 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 69
BHT-407-MM-7
REF
C Spline - sides and Corrosion/mechanical Light, superficial that can be

root of teeth polished out by hand with a
fine stainless steel wool or scotchbrite.
Spline - tops and Corrosion/mechanical Maximum of 0.010 inch (0.254 mm), up 2

ends of teeth to 0.25 inch (6.35 mm) long on all
teeth.
Maximum of 0.001 inch (0.025 mm), up 2

to 100% of the surface of
all teeth.
D Fastener hole Wear 0.315 inch (8.001 mm)

maximum diameter.
NOTES
1. Examine the spline teeth for sign of a wear step. If you can feel a wear step with a 0.020 inch (0.508 mm)
spherical radius probe, the shaft must be discarded.
2 When you remove nicks, dents and scratches, only remove the raised material until it is flush with all
sides of the surface. Use a fine India stone.
3 Total indicator runout is not to exceed a maximum of 0.004 inch (0.102 mm) when measured, installed,
on the oil cooler blower shaft mounted on V blocks at the bearing journals.
5. Repair the damage to a 0.25 inch (6.35 mm) minimum radius and a 32 RMS surface finish.

7. Refer to the BHT-ALL-SPM for the procedures to brush cadmium plating to repaired area.
407MM_65_0079
Figure 65-23. Splined Adapter — Inspection (Sheet 2 of 2)
65-00-00
Page 70 Rev. 23 7 NOV 2006
BHT-407-MM-7
1. Install the impeller (49, Figure 65-15) and

NOTE
weights, S/N 53443 and subsequent or 53000 through
Primer may be applied to the inside 53442 Post BHT-407-II-30 (54 and 55) on the oil
diameter of the oil cooler blower shaft cooler blower shaft (51) with the bolts (47), washers
407-040-320. (48), and nuts (53). Tighten, but do not torque the nuts
at this time.
3. Paint the oil cooler blower shaft inside diameter
as follows: 2. Balance the impeller (49), weights (54 and 55), if
installed, and oil cooler blower shaft (51) as follows:
a. Clean the oil cooler blower shaft (51) internal
diameter with aliphatic naphtha (C-305) or MEK a. Put the impeller (5, Figure 65-24), weights (if
(C-309). installed), and oil cooler blower shaft (4) on a leveled
knife edge (1) type balancer with the knife edges
b. Treat the inside surface with alcoholic positioned inboard of the keyway slots (2) on the
phosphoric cleaner (C-344). Refer to the bearing journal (3) surfaces.
BHT-ALL-SPM for the correct procedures.
NOTE
c. Install a non-metallic tapered plug in one end
of the oil cooler blower shaft (51). Flow the epoxy/zinc Use a maximum of seven washers
coating (C-208) into the bore while you turn the oil NAS1149F0432P (or an equivalent
cooler blower shaft. Make sure the epoxy/zinc coating thickness of washers NAS1149F0463P),
(C-208) covers the complete inside surface of the oil (52, Figure 65-15) in addition to the existing
cooler blower shaft. washers to obtain balance.
b. Balance the shaft and impeller assembly by

d. Put the oil cooler blower shaft (51) in the adding the washer NAS1149F0432P (52,
vertical position. Remove the non-metallic tapered Figure 65-15) to the bolt (47) on the light side of the
plug and drain the epoxy/zinc coating (C-208). Two impeller.
applications of epoxy/zinc coating (C-208) are
required. The oil cooler blower shaft must stay in the c. Balance is achieved when the two situations
vertical position for a minimum of one hour after each that follow occur:
application of epoxy/zinc coating (C-208) to prevent
puddles and the loss of dynamic balance. Refer to (1) You add an NAS1149F0463P washer to
BHT-ALL-SPM. the light side of the assembly and you see a change in
the balance.
65-36. Impeller — Assembly and Balance
(2) You add an NAS1149F0432P washer to
the light side of the assembly and you do not see a
NOTE
change in the balance.
Secondary weight (55) is not used with air
conditioning installation. Refer to AIR d. When the balance is achieved, tighten the
COMM STC, SR00222DE. nuts (53) T .
65-00-00
BHT-407-MM-7
5 4
2
3
1 3
2
KNIFE EDGE SHAFT BALANCE
2.5 IN.
(63.5 mm)
1.6 IN.
(40.64 mm)
1.8 IN.
(45.72 mm)
1
BEARING PRESSING WORKAID
1. Knife edge
2. Keyway slots
3. Bearing journal
4. Oil cooler blower shaft
5. Impeller
NOTE
1 Vibroetch mark "OIL COOLER BLOWER SHAFT BEARING PRESSING WORKAID".
407MM_65_0080
Figure 65-24. Oil Cooler Blower Shaft — Tool Application
65-00-00
Page 72 Rev. 23 7 NOV 2006
BHT-407-MM-7
65-37. Oil Cooler Blower — Assembly 27) T or into adapter (60) T . Install lockwire
(C-405) to adapter (60) and forward bearing housing.
Install lockwire (C-405) and insulation (62) to adapter
SPECIAL TOOLS REQUIRED (60) and aft bearing housing.
b. Apply a thin layer of corrosion preventive

NUMBER NOMENCLATURE compound (C-104) to the inner diameter of the bearing
hanger (7 or 27) and to the outer diameter of the
AN8515-1 Spanner Wrench bearing (8 or 28).
OTC8068 Step Plate Adapter c. Heat bearing hanger (7 or 27) to 200°F (93°C)
and press the bearing (8 or 28) into the bearing hanger
T103216-101 Spanner Assembly
(7 or 27) with an arbor press and the step plate
Bearing Pressing adapter OTC8068. Do not exceed 285°F (140.5°C) on
Sleeve Workaid the hanger.
(Figure 65-24)
d. Install the retaining ring (9 or 29) that holds the
bearing (8 or 28) in the bearing hanger (7 or 27).
MATERIALS REQUIRED NOTE

Installation of the forward and the aft
bearing hangers and bearings on the oil
NUMBER NOMENCLATURE cooler blower shaft are the same. The
procedure for the forward bearing hanger
C-104 Corrosion Preventive and bearing is shown.
Compound
2. Install the forward bearing hanger and bearing as
C-204 Epoxy Polyamide follows:
Primer
C-405 Lockwire
CAUTION
1. Assembly of the forward and aft bearing hangers
and bearings are the same. The forward procedure is THERE ARE DIFFERENT
shown. Use the same procedure to assemble the aft CONFIGURATIONS CONCERNING THE
bearing hanger and bearing. INSTALLED DIRECTION OF THE
BEARING HANGER FLANGES.
TO ENSURE THAT BEARING HANGER

CAUTION FLANGES ARE ORIENTED PROPERLY,
SEE FIGURE 65-15, SHEET 3 FOR
PROPER INSTALLATION.
DO NOT PERMIT CORROSION
PREVENTIVE COMPOUND (C-104) TO
CONTACT THE BEARING SEAL. THE
CORROSION PREVENTIVE COMPOUND CAUTION
( C - 1 0 4 ) C A U S E S D A M A G E TO T H E
BEARING SEAL.
ON HELICOPTERS S/N 53000 THROUGH
a. If applicable, install the washer (63, 53442 PRE TB 407-02-35, ENSURE THE
Figure 65-15) and the adapter (60) into the bearing FLANGE ON THE INNER DIAMETER OF
hanger (7 or 27) T . Apply a layer of epoxy polyamide BOTH HANGERS ARE INSTALLED
primer (C-204) to the grease fitting threads (6 or 32). FACING THE BEARING FLANGE ON THE
Install the grease fitting in the bearing hanger (7 or O I L C O O L E R B L O W E R S H A FT . O N
65-00-00
BHT-407-MM-7
HELICOPTERS S/N 53443 AND PART WILL NOT BE LOCKED

SUBSEQUENT OR POST TB 407-02-35, CORRECLTY.
ENSURE THE FLANGE ON THE INNER
DIAMETER OF THE HANGER IS h. Hold the aft end of the oil cooler blower shaft
INSTALLED FACING THE OIL COOLER (51) with the spanner assembly T103216-101 (57).
BLOWER SHAFT BEARING RETAINING Install the spanner nut (11 or 31) and tighten with the
NUT. spanner wrench AN8515-1 (58) T .
a. Apply a thin layer of corrosion preventive i. Bend one tang (minimum) of the locking
compound (C-104) to the inner diameter of the bearing washer (10 or 30) into the castellation of the spanner
(8 or 28) and to the bearing journals of the oil cooler nut (11 or 31). If possible, bending two tangs of the
blower shaft (51). locking washer is preferred.
b. Make sure to install the bevel of the bearing 65-38. Oil Cooler Blower — Installation
airflow shield (59) in the correct direction.
c. Using the bearing pressing sleeve workaid

MATERIALS REQUIRED
(Figure 65-24), and ensuring correct orientation of
flange on inner diameter of hangers, (ref.
Figure 65-15, Sheet 3), press against the inner race of
the bearing (8 or 28, Figure 65-15). Press the bearing NUMBER NOMENCLATURE
hanger (7 or 27) on the oil cooler blower shaft (51),
until the bearing hanger is fully seated. C-405 Lockwire
d. Make sure the bearing airflow shields (59) are

not loose. If the bearing airflow shield can be moved, it NOTE
indicates that the bearing (8 and 28) is not fully seated.
Shims (20, 25, and 39, Figure 65-15) are
installed under the oil cooler blower
NOTE housing and brackets. They are for the
On the locking washer (10), there is a alignment of the blower housing to the
single tab that is located at one place only. impeller and the alignment of the oil cooler
This single tab is to be installed in the slot blower shaft to the tail rotor drive system.
of the oil cooler blower shaft. Be very careful not to move the shims
during installation of the oil cooler blower
e. Install the locking washer (10 or 30) on the oil assembly.
cooler blower shaft (51). Make sure that the single tab
stays aligned and seated in the slot of the oil cooler 1. If not installed, install the aft bearing hanger
blower shaft at all times, as shown in Figure 65-15. bracket (19) as follows:
f. Install adapter (56) on the oil cooler blower a. Remove the screw (17) holding the shim (20)
shaft (51). to the helicopter structure.
g. Install spanner assembly T103216-101 (57) b. Place the aft bearing hanger bracket (19) over
on adapter (56). the shims (20).
c. Install the washers (18) and the screws

CAUTION (17) T .
d. The lockwire (C-405) is installed after shaft

MAKE SURE THE SINGLE TAB ON THE alignment verification.
LOCKING WASHER IS STILL SEATED IN
THE SLOT OF THE OIL COOLER 2. If not installed, install the forward bearing hanger
BLOWER SHAFT. OTHERWISE THE bracket (40) as follows:
65-00-00
BHT-407-MM-7
a. Remove the screws (36) and the bolts (38) a. Install the bolt (1) through the washers (3),
holding the shims (39). links (5 and 12), and bearing hanger (7). Install the nut
(13). Tighten nut finger tight.
b. Place the forward bearing hanger bracket (40)
over the shims (39). b. Insert the oil cooler blower shaft (51), impeller
(49), weights (54 and 55), if installed, and bearing
c. Install the washers (37), screws (36), and hangers (7 and 27) through the oil cooler blower
bolts (38) T . housing (45).
c. Place the inlet cover (50) over the oil cooler

d. The lockwire (C-405) is installed after shaft
blower shaft (51) forward of the bearing hanger (7).
alignment verification.
d. Insert the bolt (41) through the washers (33),
3. If not installed, install the oil cooler blower forward bearing hanger bracket (40), and bearing
housing (45) as follows: hanger (27). Install the nut (34). Tighten nut finger
tight.
a. Place the inlet cover (26) on the oil cooler
blower housing (45). e. Insert the bolt (2) through the washers (4), aft
bearing hanger bracket (19), and links (5 and 12).
b. Install the screws (44). Install the nut (16). Tighten nut finger tight.
c. Remove the screws (23 and 43) holding the NOTE

shims (25) on the helicopter structure.
Use the following procedure to center the
oil cooler blower bearing hangers (7 and
d. Place the oil cooler blower housing (45) over 27). The purpose is to set the bearing
the shims (25). hangers perpendicular to the oil cooler
blower shaft (51) and to allow the presence
NOTE of normal bearing axial play. The goal is to
avoid axial bearing preloading, which can
Final tightening of screws 23 and 43 is part reduce the service life of the bearings.
of OIL COOLER BLOWER SHAFT —
ALIGNMENT paragraph 65-39. The 5. Center the oil cooler blower bearing hangers for
requirement to complete paragraph 65-39 helicopter S/N 53000 through 53442 Pre TB
is called out in step 11. 407-02-35 as follows:
e. Install the screws (23 and 43), washers (24),

and bracket (42). Make sure the bracket is installed as NOTE
shown in Figure 65-15. Do not tighten the screws (23 The bolt holes of the links (5 and 12),
and 43). bearing hangers (7 and 27), forward
bearing hanger bracket (40), and aft
4. Install the oil cooler blower shaft (51), impeller bearing hanger bracket (19) have a loose
(49), weights (54 and 55), if installed, and bearing fit.
hangers (7 and 27) as an assembly as follows:
a. While pushing down on the oil cooler blower
shaft (51), and ensuring that it is resting down on the
links (5 and 12), forward bearing hanger bracket (40),
CAUTION and aft bearing hanger bracket (19), rock the forward
bearing hanger (27) fore and aft. Maintain the hanger
in the midpoint position and tighten the bracket bolt nut
WRAP THE SHAFT TO PROTECT IT. (34). Do not install the cotter pin at this time.
DAMAGE CAN OCCUR IF THE SHAFT
RUBS AGAINST THE OIL COOLER b. Rock the aft bearing hanger (7) fore and aft.
BLOWER INLET COVER. Maintain the hanger in the midpoint position and
65-00-00
BHT-407-MM-7
tighten the two bracket bolts and nuts (13 and 16). Do 8. Install screws (46).
not install the cotter pin at this time.
9. Install the aft short shaft assembly (paragraph
c. Take the oil cooler blower shaft (51) one hand 65-46).
on each end. Move the shaft fore and aft. Some axial
play, however slight, must be felt. This indicates that 10. Install the forward short shaft assembly
bearings are not loaded axially. (paragraph 65-29).
d. Repeat step a through step c until axial play of

11. Do an oil cooler blower shaft alignment
the shaft is felt.
(paragraph 65-39).
e. Torque all three bracket bolts and nuts (13, 16
12. Install the engine oil tank and oil cooler
and 34). Install cotter pins T .
(paragraph 65-40).
f. Lubricate bearings (8 and 28) as required
(Chapter 12). 13. Install the forward short shaft covers on the aft
firewall (Chapter 53).
g. Complete the installation of the blower
assembly. 65-39. Oil Cooler Blower Shaft — Alignment
6. Center the oil cooler blower bearing hangers for NOTE

helicopter S/N 53443 and subsequent or S/N 53000
through 53442 Post TB 407-02-35, Part 1 as follows: Make sure that the special tools specified
are used for the procedure.
a. Rock the forward bearing hanger (27) fore and
aft. Maintain the hanger in the midpoint position and
SPECIAL TOOLS REQUIRED
tighten the bracket bolt nut (34). Do not install the
cotter pin at this time.
NUMBER NOMENCLATURE
b. Rock the aft bearing hanger (7) fore and aft.
Maintain the hanger in the midpoint position and T103388-103 Bolt
tighten the two bracket bolts and nuts (13 and 16). Do
not install the cotter pin at this time. T103388-105 Post
c. Take the oil cooler blower shaft (51), one hand 196B Starrett Dial Indicator
on each end. Move the shaft fore and aft. Some axial
196K Holding Sleeve
play, however slight, must be felt. This indicates that
bearings are not loaded axially.
d. Repeat step a through step c until axial play of MATERIALS REQUIRED

the shaft is felt.
e. Torque all three bracket bolts and nuts (13, 16
and 34). Install cotter pins T . NUMBER NOMENCLATURE
f. Lubricate oil cooler blower hanger bearings (8 C-317 Adhesive

and 28) as required (Chapter 12).
C-405 Lockwire
g. Complete the installation of the blower
assembly. 1. Make sure that the alignment of the tail rotor
driveshaft segment assemblies are correct (paragraph
7. Place the inlet cover (50) on the oil cooler blower 65-57) before performing the oil cooler blower shaft
housing (45). alignment.
65-00-00
BHT-407-MM-7
2. Do the oil cooler blower shaft alignment, if

required, by conditional inspection, or if for any reason
CAUTION
you think that the shaft is out of horizontal plane
alignment.
INSTALL THE COUPLING WASHERS
3. Measure the alignment of the oil cooler blower aft WITH THE BEVELLED SIDE AGAINST
bearing hanger bracket as follows: THE COUPLING DISC PACK.
b. Install the bolt (2) T103388-103, coupling

a. Remove one nut (7, Figure 65-25), the flat washers (3), flat washer (6), and nut (7) T . Make
washer (6), the coupling washers (3), and the bolt (1). sure the short end of the bolt (2) faces forward.
65-00-00
Export Classification C, ECCN EAR99 4 OCT 2013 Rev. 38 Page 76A/76B
BHT-407-MM-7
6
1 3 3
2
11
10 7
5
0.100 IN. 4
12 (2.54 mm)
9
4
90°
1. Bolt
2. Bolt, T103388-103
8 3. Coupling washer
5. Aft short shaft
6. Flat washer
12 O'CLOCK POSITION, 3 7. Nut
6 O'CLOCK 180° 8. Dial indicator
OPPOSITE 9. Oil cooler blower shaft
10. Dial indicator holding sleeve
11. Post, T103388-105
12. Splined adapter
150 TO 180 IN-LBS

(16.95 TO 20.34 Nm)
NOTES
1. Maximum total indicator reading 0.035 inch (0.89 mm) for S/N 53000 through 53554. 6 7
Nominal total indicator reading 0.024 inch (0.61 mm) for S/N 53000 through 53554.
2. Maximum total indicator reading 0.035 inch (0.89 mm) for S/N 53555 and subsequent. 6
Nominal total indicator reading 0.031 inch (0.79 mm) for S/N 53555 and subsequent.
3 The dial indicator is shown at this location for clarity. Take readings at the 6 and 12
o'clock positions.
4 Shield not shown for clarity.
5. Balance plate (if installed) not shown for clarity. Refer to Figure 65-28 for installed
position of balance plate.
6 The allowable tolerance is dictated by the maximum value shown. Nominal value is
provided for reference only.
7 If tailboom P/N 407-030-801-205 or subsequent is installed on helicopter S/N 53000 through
53554, use indicator values applicable to S/N 53555 and subsequent.
407MM_65_0081_c1
Figure 65-25. Oil Cooler Blower Shaft — Aft Alignment
65-00-00
29 SEP 2008 Rev. 25 Page 77
BHT-407-MM-7
c. If the disc pack gap exceeds 0.015 inch (0.381

mm), or if the other bolts are loose, tighten all the bolts
CAUTION
(paragraph 65-60).
d. Install the post (11) T103388-105, and the

INSTALL THE COUPLING WASHERS
196K dial indicator holding sleeve (10).
WITH THE BEVELLED SIDE AGAINST
THE COUPLING DISC PACK.
e. Remove the threaded tip from the Starrett
196B dial indicator (8). b. Install the bolt (8), T103388-103, the coupling
washers (10), the flat washer (11), and the nut (1) T .
f. Install the Starrett 196B dial indicator (8) on Make sure the short end of the bolt (8) faces forward.
the dial indicator holding sleeve (10) as shown in
Figure 65-25. c. If, after you tighten the disc pack, the gap
exceeds 0.015 inch (0.381 mm), or if the other bolts
g. Set the travel of the Starrett 196B dial are loose, tighten all the bolts and nuts (paragraph
indicator (8) so that it has a minimum range of ±0.04 65-60).
inch (±1.02 mm) and does not reach the end of travel
in that range. d. Install the Post (7), T103388-105, and the
Starrett dial indicator holding sleeve (6), 196K, on the
bolt (8).
CAUTION
e. Install the Starrett 196B dial indicator (5) on
the holding sleeve (6) as shown in Figure 65-26.
ENSURE THAT THE MAIN ROTOR
BLADES AND THE TAIL ROTOR BLADES f. Set the travel of the Starrett 196B dial
ARE CLEAR BEFORE YOU ROTATE THE indicator (5) so that it has a range of ±0.04 inch (±1.02
OIL COOLER BLOWER SHAFT. IF THE mm) and does not reach the end of travel in that
BLADES HIT AN OBJECT, THEY CAN BE range.
DAMAGED.
h. Use an inspection mirror to read the Starrett

CAUTION
196B dial indicator (8). Adjust the dial indicator to read
zero at the 12 o’clock position (Figure 65-25, Note 3).
Turn the shaft one-half turn to the 6 o’clock position.
ENSURE THAT THE MAIN ROTOR
Record the reading off the dial indicator. Refer to
BLADES AND THE TAIL ROTOR BLADES
Figure 65-25, Notes 1 and 2, for limits.
ARE CLEAR BEFORE YOU ROTATE THE
OIL COOLER BLOWER SHAFT. IF THE
i. If the value is not within the limits shown in BLADES HIT AN OBJECT, THEY CAN BE
Figure 65-25, take no remedial action until you DAMAGED.
measure the alignment of the forward bearing hanger
bracket as specified in step 4. g. Use an inspection mirror to read the Starrett
196B dial indicator (5). Adjust the dial indictor to read
j. Remove the Starrett 196B dial indicator (8), zero at the 12 o’clock position (Figure 65-26, Note 3).
holding sleeve (10), post (11) and bolt (2). Install the Turn the shaft one-half turn to the 6 o’clock position.
bolt (1), the coupling washers (3), the flat washer (6), Record the reading off the dial indicator. Refer to
and the nut (7). Do not tighten the nut (7) at this time. Figure 65-26, Notes 1 and 2, for limits.
4. Measure the alignment of the oil cooler blower h. If both ends of the shaft are in the limits shown
forward bearing hanger bracket as follows: on Figure 65-25 and Figure 65-26, remove the Starrett
196B dial indicator (5, Figure 65-26) and the bolt (8).
a. Remove one nut (1, Figure 65-26), the flat Install the bolt (9), the coupling washers (10), the flat
washer (11), the coupling washers (10), and the bolt washer (11) and the nut (1). Do not tighten the nut (1)
(9). at this time.
65-00-00
Page 78 Rev. 23 7 NOV 2006
BHT-407-MM-7
11
10
10
9 1
4
7
2
6
0.76 IN.
(19.30 mm)
12 O'CLOCK 3
POSITION,
6 O'CLOCK
180° OPPOSITE
90°
5 3
1. Nut
2. Splined adapter (helicopter 12
S/N 53443 and subsequent, or
S/N 53000 through 53442
Post BHT-407-II-30)
10. Coupling washer
3. Forward short shaft
11. Flat washer
12. Splined flywheel adapter
5. Dial indicator
(helicopter S/N 53000 through
6. Dial indicator holding sleeve
7. Post, T103338-105 53442 Pre BHT-407-II-30)
8. Bolt, T103338-103 150 TO 180 IN-LBS
9. Bolt (16.95 TO 20.34 Nm)
NOTES
1. Maximum total indicator reading 0.039 inch (0.99 mm) for S/N 53000 through 53554. 5 6
Nominal total indicator reading 0.028 inch (0.71 mm) for S/N 53000 through 53554.
2. Maximum total indicator reading 0.035 inch (0.89 mm) for S/N 53555 through subsequent. 5
Nominal total indicator reading 0.028 inch (0.71 mm) for S/N 53555 through subsequent.
3 The dial indicator is shown at this location for clarity. Take readings at the 6 and 12
o'clock positions.
4. Balance plate (if installed) not shown for clarity. Refer to Figure 65-11 for installed
position of balance plate.
5 The allowable tolerance is dictated by the maximum value shown. Nominal value is
provided for reference only.
6 If tailboom P/N 407-030-801-205 or subsequent is installed on helicopter S/N 53000 through
53554, use indicator values applicable to S/N 53555 and subsequent.
407MM_65_0082_c1
Figure 65-26. Oil Cooler Blower Shaft — Forward Alignment
65-00-00
29 SEP 2008 Rev. 25 Page 79
BHT-407-MM-7
FWD
A A
B B
NOTE
Measure distance A and B. Difference between
A and B cannot exceed 0.030 inch (0.762 mm).
407MM_65_0083
Figure 65-27. Oil Cooler Blower Shaft — Centering
65-00-00
Page 80 Rev. 23 7 NOV 2006
BHT-407-MM-7
i. Loosen the three other nuts (1) on the 5. Following the procedures for the alignment of the
coupling disc pack (4). Torque the nuts in accordance oil cooler blower shaft, a final check is required to
with the torque sequence procedure (paragraph ensure that end (axial) play still exists:
65-60).
a. Grasp the blower shaft (51), one hand on
j. Loosen the three other nuts (7, Figure 65-25) each end. Move the shaft fore and aft. An end (axial)
play, however slight, must be felt. This indicates that
on the coupling disc pack (4). Torque the nuts in
the bearings are not loaded axially.
accordance with the torque sequence procedure
(paragraph 65-60).
b. If no end (axial) play exists, follow the
procedures in paragraph 65-38, step 5 for helicopters
S/N 53000 through 53442 Pre TB 407-02-35 or
NOTE
paragraph 65-38, step 6 for helicopters S/N 53443 and
Adjustment to the shims of the brackets (19 subsequent or S/N 53000 through 53443 Post TB
or 40, Figure 65-15) can affect the tail rotor 407-02-35.
driveshaft segment assembly. If the oil
cooler blower shims are changed, do the 6. Lockwire the screws (36) and the bolts (38) with
tail rotor driveshaft segment alignment lockwire (C-405).
(paragraph 65-57).
7. Make sure the oil cooler blower shaft (51) is
Prior to any adjustment of shims, contact vertically centered in the oil cooler blower housing inlet
Product Support Engineering. Product covers (26 and 50). The oil cooler blower shaft (51)
Support Engineering can evaluate the must not be more than 0.030 inch (0.762 mm) off
center (Figure 65-27). If the oil cooler blower shaft is
values measured and provide appropriate
more than 0.030 inch (0.762 mm), peel or replace the
recommendations. shims (25, Figure 65-15). If you replace the shims
(25), they must be bonded to the helicopter structure
k. If a measurement is less than the nominal with adhesive (C-317).
total indicator reading shown in Figure 65-25 and
Figure 65-26, the angle between the oil cooler blower a. Tighten the screws (23 and 43) T .
shaft and the next shaft segment is below average but
is acceptable. As the allowable tolerance is dictated by b. Lockwire the screws (23 and 43) with lockwire
a maximum value only, this nominal value is to be (C-405).
used as a reference only.
65-40. Oil Tank and Oil Cooler — Installation
NOTE
1. Install the oil tank (Chapter 79).
Prior to any adjustment of shims, contact
Product Support Engineering. Product
2. Install the oil cooler and transition duct
Support Engineering can evaluate the
(Chapter 79).
values measured and provide appropriate
recommendations.
3. Connect the oil inlet and outlet lines on the
transmission and engine oil coolers (Chapter 79).
l. If a measurement is greater than the
maximum total indicator reading shown on
4. Service the engine oil systems (Chapter 12).
Figure 65-25 and Figure 65-26, the angle between the
oil cooler blower shaft and the next shaft segment is
too large. Add shims under the affected bracket, or 5. Do an operational check (paragraph 65-2).
remove shims from under the bracket on the opposite
end. 6. Install the cowling (Chapter 53).
65-00-00
BHT-407-MM-7
BEVELLED SIDE MUST

FACE COUPLING DISC PACK
7
6
DETAIL A
5
4
3
2
8
1
22
20
SEE DETAIL A 21 9
20
10
19
18 11
12
13
14
1 7
15 6
16 5
4
17 3 3
2
8
1
22
20
SEE DETAIL A
21 9
20
10
11
23 12
4
18 13
14
15
2
16
SEE DETAIL B
24
25 17
26 3
407MM_65_0084
Figure 65-28. Aft Short Shaft Assembly — Removal/Installation (Sheet 1 of 2)
65-00-00
Page 82 Rev. 23 7 NOV 2006
BHT-407-MM-7
23 2 4 24 17 3
24 A 1 25
2 4 25 2 4 23
13 14 15 16 2 4
26 26
FWD
17 3 18 20 22
A
21
DETAIL B SECTION A-A
(VIEW LOOKING AFT)
1. Aft short shaft assembly 14. Flat washer

2. Bolt 15. Coupling washer
3. Coupling washer 16. Bolt
4. Coupling disc pack 17. Splined adapter
5. Coupling washer 18. Nut
6. Flat washer 19. Flat washer
7. Nut 20. Coupling washer
8. Tail rotor driveshaft segment assembly 21. Coupling disc pack
9. Bolt 22. Bolt
10. Coupling washer 23. Balance plate
11. Flat washer 24. Screw
12. Nut 25. Washer
13. Nut 26. Nut
150 TO 180 IN-LBS

(16.9 TO 20.3 Nm)
NOTES
1 Helicopters S/N 53000 through 53442 Pre BHT-407-II-30.
2 Helicopters S/N 53000 through 53442 Post BHT-407-II-30, S/N 53443 through 53497 Post TB
407-02-35 and S/N 53498 through subsequent.
3 Flanges of forward splined adapter (5, Figure 65-11) and aft splined adapter (17, Figure 65-28)
must be positioned 90° to each other within spline tolerances. Ensure that adapter slides freely on
blower shaft splines prior to installation on short shaft adapters. To facilitate sliding, remove dry
lubricant coating from top of shaft splines.
4 Initial hardware setup on all four balance screw locations, is one NAS1351-3-14 screw, one
NAS1149F0363P washer and one MS21042L3 nut. For balancing, use a maximum of seven washers
(NAS1149F0363P) or any combination of varying thickness washers (NAS1149F03()()P) provided that a
minimum of two threads extend past the nut. It is permissible to remove one or more screws
(NAS1351-3-14) to obtain proper balance. If screw is installed, one washer (NAS1149F0363P) and one nut
(MS21042L3) must be installed. Until such time that chapter 18 is updated, refer to BHT-407-II-30 part VII
for balancing procedures.
407MM_65_0085
Figure 65-28. Aft Short Shaft Assembly — Removal/Installation (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 83
BHT-407-MM-7
65-41. AFT SHORT SHAFT ASSEMBLY 2. Loosen the nuts (12, Figure 65-28) until they are
finger tight.
The aft short shaft assembly (1, Figure 65-28) is an
aluminum shaft connected to a coupling disc pack (21) 3. For helicopters without a balance plate (23)
and a splined sliding adapter (17) at the forward end. installed, remove the nuts (18), the flat washers (19),
The aft end of the aft short shaft assembly is the coupling washers (20), and the bolts (22). For
connected to a coupling disc pack (4) on the first tail helicopters with a balance plate (23) installed, remove
rotor driveshaft segment assembly (8). The aft end of the nuts (18), the coupling washers (20) and the bolts
the aft short shaft assembly (1) is fixed. The forward (22).
end is attached to the splined adapter (17) that slides
on the splined end of the oil cooler blower shaft.
coupling washers (10), and the bolts (9).
65-42. Aft Short Shaft Assembly — Removal
5. Push the splined adapter (17) forward.
MATERIALS REQUIRED 6. Remove the aft short shaft assembly (1).

7. Remove the splined adapter (17) from the oil
NUMBER NOMENCLATURE cooler blower shaft. If applicable, also remove the
balance plate (23).
C-405 Lockwire
NOTE CAUTION
To help minimize rebalance procedures
following reinstallation, note installed MAKE SURE THAT THE ORDER IN
position of all items prior to removal. W HIC H T HE D IS C S EG M E NTS A RE
STACKED DOES NOT CHANGE AFTER
1. Gain access to the aft short shaft assembly THE COUPLING DISC PACK HAS
(Chapter 53). OPERATED. FIGURE 65-12 CONTAINS
AND REPAIR.
CAUTION 8. Put lockwire (C-405) through an empty bolt hole

in the coupling disc pack (21, Figure 65-28) to make
sure the order of the disc segments are not changed.
SUPPORT THE AFT SHORT SHAFT TO
PREVENT DAMAGE TO THE COUPLING 9. Remove the nuts (13), the flat washers (14), the
DISC PACKS. coupling washers (15), and the bolts (16). Remove the
coupling disc pack (21) from the shaft (1).
THE SURFACE CONDITION OF THE AFT
SHORT SHAFT ASSEMBLY IS VERY
10. Put lockwire (C-405) through an empty bolt hole
IMPORTANT TO FLIGHT SAFETY. THE
in the coupling disc pack (4) to make sure the order of
SURFACE OF THE SHAFT MUST BE
the disc segments are not changed.
SMOOTH AND UNMARRED. THE
SURFACE MUST NOT BE DAMAGED
DURING REMOVAL OR HANDLING. BE 11. Remove the nuts (7), the flat washers (6), the
VERY CAREFUL DURING REMOVAL coupling washers (5 and 3), and the bolts (2). Remove
AND WHEN YOU HOLD THE AFT SHORT the coupling disc pack (4) from the tail rotor driveshaft
SHAFT ASSEMBLY. segment assembly (8).
65-00-00
Page 84 Rev. 23 7 NOV 2006
BHT-407-MM-7
65-43. Aft Short Shaft Assembly — Cleaning THE SHAFT. YOU CAN NOT RINSE THE
CHEMICAL PAINT REMOVER FULLY
MATERIALS REQUIRED RIVETED ADAPTER AND THE SHAFT.
THE MECHANICAL RIVETS CAN START
Refer to BHT-ALL-SPM for specifications. TO CORRODE IN A WAY THAT CAN NOT
BE DETECTED.
NUMBER NOMENCLATURE
NOTE
C-304 Drycleaning Solvent
Do not Plastic Media Blast (PMB) the end
face of the adapters riveted to the shaft.
1. To clean the aft short shaft assembly, refer to the
You can remove the adhesive used to bond
BHT-ALL-SPM. Use drycleaning solvent (C-304) to
the stoppers in the end face of the adapters
clean the shaft. Other solvents can damage the
by PMB.
organic finish.
1. Use PMB (BHT-ALL-SPM) to remove the organic
2. To clean the disc pack, refer to Figure 65-12. finish from the aft short shaft outside diameter, if it is
required to do the Non Destructive Inspection as a
65-44. Aft Short Shaft Assembly — Inspection result of a conditional inspection or some other
and Repair reason.
1. Examine the aft short shaft for condition 2. After repair on the shaft outside diameter, refer to
(Figure 65-29). the BHT-ALL-SPM and apply the chemical protection
layer to the exposed bare metal.
2. Examine the sliding adapter for condition
(Figure 65-23). 3. To apply the organic finish to the shaft outside
diameter, refer to Figure 65-30. Use the application
3. Examine the discs of the coupling disc packs for procedures of the BHT-ALL-SPM for application of the
condition (Figure 65-12). Polyamide Epoxy primer and for application of the
Polyurethane Enamel, except as otherwise specified
4. Examine the balance plate (23, Figure 65-28) for in Figure 65-30 and this paragraph.
condition.
4. Do the touch-up of the Epoxy primer and the
65-45. Aft Short Shaft Assembly — Stripping and Polyurethane Enamel layer in agreement with the
Painting instructions in the BHT-ALL-SPM.
CAUTION
DO NOT USE CHEMICAL PRODUCTS TO

REMOVE THE ORGANIC FINISH FROM
65-00-00
7 NOV 2006 Rev. 23 Page 85
BHT-407-MM-7
B D 2 B
F (16 PL)
8
A
A
6
10 10
8 H 7 C
(16 PL)
E
1.7 IN. 1.7 IN. (4 PL)
(43.2 mm) (43.2 mm)
G FACE
(2 PL)
REF
A Adapter end face Corrosion/mechanical 0.001 inch (0.025 mm) up to 100%

of area.
B Adapter external Corrosion/mechanical 0.005 inch (0.127 mm) up to 100%
diameter of the circumference.
B Adapter flange Corrosion/mechanical Maximum chamfer to remove the
40 to 45° up to 0.0500 inch
(12.700 mm) (No more than two per
quadrant).
C Rivet spotface Corrosion/mechanical None allowed.

D Shaft tube Straightness With the use of a 12 inch (304.8 mm)
0.005 inch (0.127 mm).
D Tube outside Corrosion/mechanical 0.005 inch (0.127 mm) up to one

diameter square inch (645.2 mm ²).
0.005 inch (0.127 mm) to 25% of the
circumference, 0.850 inch (21.59 mm)
wide. 0.002 inch (0.051 mm) up to
100% of the circumference, 0.210 inch
(5.334 mm) wide.
E Fastener hole Wear Maximum of 0.315 inch (8.001 mm)

diameter.
407MM_65_0086
Figure 65-29. Aft Short Shaft Assembly — Inspection (Sheet 1 of 2)
65-00-00
Page 86 Rev. 23 7 NOV 2006
BHT-407-MM-7
REF
A, B, D Number of repairs Five maximum.
F Rivets Loose rivets None allowed. 5
G Adapter end faces Total Indicator Runout Total Indicator Runout done with the
shaft mounted on V block. Maximum of
0.004 inch (0.102 mm).
H Tube interior Corrosion None allowed. 7

A Total Indicator Runout Maximum of 0.004 inch (0.102 mm) 10
at the adapter flange.
G Shaft body- Corrosion/mechanical 0.005 inch (0.127 mm) deep local clean
outside diameter up in a one square inch (645.2 mm²)
area to a minimum outside diameter
of 1.245 inch (31.623 mm).
All Slots, thread relief, Corrosion 0.005 inch (0.127 mm) deep local clean
not designated areas up. 25% of any one surface.
Mechanical 0.005 inch (0.127 mm) deep, four per 4

any one surface.
NOTES
1. Remove two times the depth of the corrosion to repair a corroded surface. The limits shown
are for after the repair is completed.
2 Surface of the tube must be smooth and unmarred. Scratches can be polished out so that
the wall thickness is not less than 0.068 inch (1.727 mm) and the minimum outside diameter
is not less than 1.738 inch (44.145 mm).
4 Make repairs with a 0.25 inch (6.35 mm) minimum radius and a 32 RMS surface finish.
5 Replacement of the rivets is not permitted.
6 Do not remove the end plug unless you think there is damage. If the end plug is damaged
or loose, replace with a new end plug, P/N 120-179-26A. Clean the tube inside diameter with
drycleaning solvent (C-304) where the plug is installed. Use adhesive, 299-947-100 TYII CL2,
to install the plug in the tube. The plug must be pushed-in far enough to leave a gap of
0.060 inch (1.524 mm) between the plug and the tube end. Fill and fair that gap with the same
adhesive that was used to install the plug.
7 Do not remove the primer from the inside diameter of the tube. Do the touch-up to the
primer with epoxy polyamide primer (C-204).
8 When damaged material must be removed from the balancing rim, remove an equal amount
of material on the same rim, at 180° opposite to the repair area.
9. Refer to the BHT-ALL-SPM for the procedures to chemically film treat the repaired area.
10 Mount the shaft on V block at the two indicated areas.
11. Refer to Figure 65-30 for the instructions to apply the organic finish.
407MM_65_0087
Figure 65-29. Aft Short Shaft Assembly — Inspection (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 87
BHT-407-MM-7
R 0.350 INCH
NON-PAINTED AREA B (8.89 mm)
8 PLACES 8 PLACES
PRIMER AND TOPCOAT AREA A
NON-PAINTED NON-PAINTED
AREA C AREA D
E E
NON-PAINTED
AREA C AND D
407-040-325 SHAFT ASSEMBLY VIEW E
R 0.350 INCH
NON-PAINTED AREA B (8.89 mm)
4 PLACES 4 PLACES
PRIMER AND TOPCOAT AREA A
NON-PAINTED
AREA C
NON-PAINTED
AREA D
407-040-328 ADAPTER LOCATION
407-040-330 SHAFT ASSEMBLY VIEW F
PRIMER AND TOPCOAT AREA A NON-PAINTED AREA B

4 PLACES R 0.350 INCH
(8.89 mm)
4 PLACES
NON-PAINTED
AREA C
G
NON-PAINTED
AREA D
407-040-328 ADAPTER VIEW G

407MM_65_0088
Figure 65-30. Driveshaft and Adapters — Organic Finish Application (Sheet 1 of 2)
65-00-00
Page 88 Rev. 23 7 NOV 2006
BHT-407-MM-7
NOTES
EPOXY PRIMER - APPLICATION
1. Apply one layer of epoxy primer (C-202) or epoxy polyamide primer (C-204) to area A of the
driveshafts and adapters (BHT-ALL-SPM). Do not apply primer to the areas B, C, and D.
2. Keep the driveshaft in a vertical position while it dries to prevent puddling of the primer
and a loss of dynamic balance.
POLYURETHANE ENAMEL TOPCOAT - APPLICATION
3. Apply two layers of the polyurethane enamel (C-245) MIL-PRF-85285, FED-STD-595,

color No. 16440 (light gray) to area A of the driveshafts and adapters (BHT-ALL-SPM). Do not apply
polyurethane enamel topcoat to areas B, C, and D.
4. The humidity must be between 50 and 90%.
5. Apply the first polyurethane enamel layer between 1 and 8 hours after the primer
is applied.
6. After each layer of the polyurethane enamel, put the driveshaft in a vertical position while
it dries to prevent puddling of the polyurethane enamel and a loss of dynamic balance.
7. The dried film thickness of the polyurethane enamel layer is to be 0.0085 to 0.00115 inch
(0.216 to 0.029 mm).
407MM_65_0089
Figure 65-30. Driveshaft and Adapters — Organic Finish Application (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 89
BHT-407-MM-7
65-46. Aft Short Shaft Assembly — Installation 2. Remove the lockwire from the coupling disc
pack (21).
MATERIALS REQUIRED

CAUTION
NUMBER NOMENCLATURE
C-525 Grease FORWARD AND AFT OIL COOLER

BLOWER SHAFT SLIDING SPLINED
C-561 Grease ADAPTERS MUST SLIDE FREELY ON
END OF BLOWER SHAFT. IF REQUIRED
TO ATTAIN THIS RESULT, IT MAY BE
NECESSARY TO REMOVE THE DRY
CAUTION L UB R I C A NT F R O M T O P O F S H A FT
SPLINES. IF ADAPTERS DO NOT SLIDE
FREELY, DAMAGE TO BEARINGS MAY
MAKE SURE THAT THE ORDER IN OCCUR DUE TO PRELOADING.
STACKED DOES NOT CHANGE AFTER NOTE
OPERATED. FIGURE 65-12 CONTAINS Flanges of forward splined adapter (5,
INSTRUCTIONS FOR MAINTENANCE Figure 65-11) and aft splined adapter (17,
AND REPAIR. Figure 65-28) must be positioned 90° to
each other.
INDIVIDUAL COUPLING WASHERS ARE
TO BE INSTALLED WITH THE BEVELED 3. Apply grease (C-525) or grease (C-561) to the
EDGE AGAINST THE COUPLING DISC splines of the adapter (17). Put the adapter and, if
PACK AND THE FLAT SIDE AGAINST applicable, the balance plate (23) on the oil cooler
THE ADAPTER FLANGE. IF TWO blower shaft. The balance plate is installed on the
COUPLING WASHERS ARE INSTALLED forward side of the adapter.
TOGETHER, REFER FIGURE 65-28,
DETAIL A FOR THE CORRECT 4. Install the coupling disc pack (4) on the other end
INS TA LLA TION OF THE COUP LING of the aft short shaft assembly (1) with the bolts (9),
WASHER STACK-UP. coupling washers (10), flat washers (11), and nuts
(12). Tighten the nut until it lightly contacts. The bolt
NOTE must remain loose enough so that it can be turned by
hand.
Do not turn the bolt when you install the
coupling disc pack. Turn the nut while you
5. Remove the lockwire from the coupling disc
hold the bolt. If the bolt turns, gaps can
pack (4).
occur between the coupling discs.
Make sure bolt lengths are equal. Permit 6. Slide the splined adapter (17) and, if applicable,
only the grip portion (unthreaded portion) of the balance plate (23) forward on the oil cooler blower
the bolt to touch the coupling disc pack. shaft.
To maintain balance, reinstall items in same

position as noted prior to disassembly.
CAUTION
1. Install the coupling disc pack (21, Figure 65-28)
on the shaft (1) with the bolts (16), coupling washers
(15), flat washers (14), and nuts (13). Tighten the nut SUPPORT THE AFT SHORT SHAFT TO
until it lightly contacts. The bolt must remain loose PREVENT DAMAGE TO THE COUPLING
enough so that it can be turned by hand. DISC PACKS.
65-00-00
Page 90 Rev. 30 8 APR 2011 ECCN EAR99
BHT-407-MM-7
7. Put the aft short shaft assembly (1) in position on fairings allow access to the tail rotor driveshaft
the helicopter. segment assemblies. The four tail rotor driveshaft
segment assemblies are connected by coupling disc
8. Attach the aft coupling disc pack (4) to the tail packs. The coupling disc packs compensate for
rotor driveshaft segment assembly (8) with the bolt (2), tailboom movement. Each of the four tail rotor
the coupling washers (3 and 5), the flat washers (6), driveshaft segment assemblies are identical and
and the nut (7). Tighten the nut until it lightly contacts. therefore interchangeable. Removal, inspection,
The bolt must remain loose enough so that it can be repair, and installation are the same for all tail rotor
turned by hand. driveshaft segment assemblies. Each tail rotor
driveshaft segment assembly is aluminum, and has an
9. On helicopters without a balance plate (23), aluminum adapter flange. The bearing hangers have a
attach the coupling disc pack (21) to the splined grease fitting (27, Figure 65-31) to lubricate the sealed
adapter (17) with the bolts (22), the coupling washers bearing. The tail rotor driveshaft segment assembly
(20), the flat washers (19), and the nut (18). Tighten (14) is attached through a coupling disc pack (21) to
the nut until it lightly contacts. The bolt must remain an adapter on the tail rotor gearbox (28).
loose enough so that it can be turned by hand.
65-47A.Tail Rotor Driveshaft Segment Assembly —
10. On helicopters with a balance plate (23), install it Configuration and Upgrade
and the coupling disc pack (21) to the splined adapter
(17) with the bolts (22), the coupling washers (20), and Model 407 helicopters were delivered with the tail rotor
the nut (18). Tighten the nut until it lightly contacts. The driveshaft segment assembly configuration shown in
bolt must remain loose enough so that it can be turned Table 65-5.
by hand.
1. Use the information in Table 65-6 to verify the
11. Apply torque T to all the nuts (Figure 65-28) on configuration or to upgrade the tail rotor driveshaft
the coupling disc packs following the torque sequence segment assembly. The components and assembly
(paragraph 65-60). dash number are included in that specified
configuration.
12. Perform an operational check (paragraph 65-3).
Refer to BHT-II-30 part VII for balancing procedures. 2. Any noted tail rotor driveshaft segment assembly
can be upgraded to a newer configuration. When an
13. Install the cowling (Chapter 53). assembly is upgraded, all applicable Alert Service
Bulletins (ASB) and Technical Bulletins (TB) must be
65-47. TAIL ROTOR DRIVESHAFT SEGMENT incorporated.
ASSEMBLY
3. Identify the upgraded tail rotor driveshaft segment
There are four tail rotor driveshaft segment assemblies assembly with the correct configuration dash number
installed along the top of the tailboom. Two tailboom that you defined in step 1.
65-00-00
ECCN EAR99 23 DEC 2009 Rev. 26 Page 91
BHT-407-MM-7
Figure 65-31. Tail Rotor Driveshaft Segment Assemblies (Sheet 1 of 2)
65-00-00
BHT-407-MM-7
Figure 65-31. Tail Rotor Driveshaft Segment Assemblies (Sheet 2 of 2)
65-00-00
Export Classification C, ECCN EAR99 4 OCT 2013 Rev. 38 Page 92A/92B
BHT-407-MM-7
Table 65-5. Tail Rotor Driveshaft Segment Assembly Versus Helicopter Serial Number
PART NUMBER NOTES HELICOPTER SERIAL NUMBER
407-040-302-101 1 S/N 53002 through 53219
407-040-302-103 1 S/N 53220 through 53292
407-040-302-105 1 S/N 53293 through 53321
407-040-302-107 1 S/N 53322 through 53442
407-040-302-109 1 S/N 53443 through 53483
407-040-302-111 1 S/N 53484 through 53519 and 53521
407-040-302-113 1 S/N 53520 and 53522 through 53579
407-040-302-115 1 S/N 53580 through 53769
407-040-302-117 2 S/N 53770 and subsequent
NOTES:
1 Tail rotor driveshaft segment assembly can be upgraded to a newer configuration (Table 65-6).
2 Tail rotor driveshaft segment assembly 407-040-302-117 is the latest production configuration and can be
used on 407 helicopters S/N 53000 and subsequent.
65-00-00
Export Classification C, ECCN EAR99 4 OCT 2013 Rev. 38 Page 92C
BHT-407-MM-7
Table 65-6. Tail Rotor Driveshaft Segment Assembly — Configuration
TAIL ROTOR DRIVESHAFT SEGMENT ASSEMBLY

407-040-302
NOMENCLATURE PART NUMBER NOTES
-101 1 2 -103 1 2 -105 1 2 -107 1 2 -109 1 2 -111 1 2 -113 1 2 -115 1 2 -117
Washer 406-040-327-101 X X X X X X X X X
Bearing 406-040-339-105 3 X
406-040-339-111 3 X X
407-340-339-101 3 X X
407-340-339-103 3 X X
407-340-339-107 X X
Bearing Hanger 406-040-322-103 4 5 X X X X
407-040-322-103 5 X X X X
407-040-322-107 X X X
Adapter 406-040-328-103 6 X X X X X X X X
406-040-328-105 X
Shaft Assembly 407-040-330-101 7 X X
407-040-330-105 8 X X X X X X
407-040-330-107 X
NOTES:
1 Replaced by tail rotor driveshaft segment assembly 407-040-302-117 2 .
2 Tail rotor driveshaft segment assembly may be upgraded to the next higher assembly or to the current production (-117) configuration, as shown in table.
3 Replaced by bearing 407-340-339-107.
4 Replaced by bearing hanger 407-040-322-103 5 .
5 Replaced by bearing hanger 407-040-322-107.
6 Apply organic coating per paragraph 65-52 and re-identify to a 406-040-328-105 with permanent ink.
7 Replaced by shaft assembly 407-040-330-107.
8 Apply organic coating per paragraph 65-52 and re-identify to a 407-040-330-107 with permanent ink.
65-00-00
Page 92D Rev. 38 4 OCT 2013 Export Classification C, ECCN EAR99
BHT-407-MM-7
65-48. Tail Rotor Driveshaft Segment Assembly — FLIGHT SAFETY. THE SURFACE OF THE
Removal SHAFT MUST BE SMOOTH AND
UNMARRED. THE SURFACE MUST NOT
BE DAMAGED DURING REMOVAL OR
MATERIALS REQUIRED HANDLING. BE VERY CAREFUL DURING
REMOVAL AND WHEN YOU HOLD THE
Refer to BHT-ALL-SPM for specifications. TAIL ROTOR DRIVESHAFT SEGMENT
ASSEMBLY.
NUMBER NOMENCLATURE
3. Put a support under the aft end of the tail rotor
C-405 Lockwire driveshaft segment assembly (14) to prevent damage
to the coupling disc pack (21).
1. Gain access to the tail rotor driveshaft segment
assemblies (Chapter 53). 4. Support the aft end of tail rotor driveshaft
segment (29) and remove the nuts (1), the flat
2. Loosen the nuts (8, Figure 65-31) that hold the washers (2), the coupling washers (3), and the
tail rotor driveshaft segment to the coupling disc bolts (4).
pack (21).
5. Remove the cotter pin (5), the nut (6), and the flat
washer (7). Discard cotter pin.
CAUTION
THE SURFACE CONDITION OF THE TAIL
ROTOR DRIVESHAFT SEGMENT 7. Remove the bolt (12), the washer (13), and the
ASSEMBLY IS VERY IMPORTANT TO shims (15).
65-00-00
Export Classification C, ECCN EAR99 4 OCT 2013 Rev. 38 Page 92E/92F
BHT-407-MM-7
8. Remove the tail rotor driveshaft segment SPECIAL TOOLS REQUIRED (Cont)
assembly (14).
NUMBER NOMENCLATURE
CAUTION OTC8068 Step Plate Adapter

(or equivalent)
MAKE SURE THAT THE ORDER IN Workaid No. 1 Figure 65-32

STACKED DOES NOT CHANGE AFTER Workaid No. 2 Figure 65-32
OPERATED. FIGURE 65-12 CONTAINS 1. Remove the nut (1, Figure 65-32), the washers (2
INSTRUCTIONS FOR MAINTENANCE and 3), and the coupling adapter (4).
AND REPAIR.
9. Put lockwire (C-405) through an empty bolt hole 2. Remove the grease fitting (5).
in the coupling disc pack (21, Figure 65-31) to make
sure the order of the disc segments are not changed.
NOTE
It is recommended that the bearing (6) be
discarded after removal. During removal,
the bearing is subjected to stress, outer
11. Remove the coupling disc pack (21).
race pressed against inner race, that may
12. Put lockwire (C-405) through an empty bolt hole cause undetectable damage.
in the coupling disc pack (26) to make sure the order
of the disc segments are not changed. 3. Place workaid No. 1 (7) over the end of the tail
rotor driveshaft segment assembly (8). The workaid
13. Remove the nuts (22), the flat washers (23), the No. 1 will protect the mounting stud and provide a
coupling washers (24), and the bolts (25). stable surface to apply the force necessary to pull the
bearing hanger (9) from the tail rotor driveshaft
14. Remove the coupling disc pack (26). segment assembly.
65-49. Tail Rotor Driveshaft Segment Assembly —

Disassembly 4. Pull the bearing hanger (9) along with the bearing
(6) from the tail rotor driveshaft segment assembly (8),
using the bearing puller OTC1025 (or equivalent).
5. Remove retaining ring (10).
NUMBER NOMENCLATURE
6. Using an arbor press (11), workaid No. 2 (12),
OTC1025 Bearing Puller
and step plate adapter OTC8062 (13), remove bearing
(or equivalent)
(6) from bearing hanger (9). Refer to Figure 65-32.
OTC8062 Step Plate Adapter
(or equivalent)
7. Discard bearing (6).
65-00-00
BHT-407-MM-7
3 8
9
5
1
10
SECTION A-A
AFTER INSTALLATION 4
A
3
2 A
1
2
0.50 IN.
(12.7 mm)
1.0 IN. 1.0 IN.

(25.4 mm) (25.4 mm)
1.25 IN.
(31.75 mm)
7
1.25 IN. MATERIAL: ALUMINUM

(31.75 mm)
WORKAID NO. 1
MATERIAL: STEEL
2.6 IN.
1.0 IN.
(66.04 mm) 13
(25.4 mm)
12
14
3.0 IN.
(76.2 mm)
WORKAID NO. 2
MATERIAL: STEEL
NO OBJECT BEYOND THIS POINT 407MM_65_0091a

Figure 65-32. Tail Rotor Driveshaft Segment Assembly — Disassembly/Assembly (Sheet 1 of 2)
65-00-00
Page 94 Rev. 35 10 DEC 2012 Export Classification C, ECCN EAR99
BHT-407-MM-7
11
6
14
13 6
9
9
12
DISASSEMBLY ASSEMBLY
1. Nut
2. Washer
3. Washer
4. Coupling adapter
5. Grease fitting
6. Bearing
7. Workaid No.1
9. Bearing hanger
10. Retaining ring
11. Arbor press
12. Workaid No.2
13. Step plate adapter, OTC 8062
14. Step plate adapter, OTC 8068
5 TO 10 IN-LBS
1 (0.56 TO 1.13 Nm)
30 TO 50 IN-LBS
2 (5.7 TO 7.9 Nm)
407MM_65_0092
Figure 65-32. Tail Rotor Driveshaft Segment Assembly — Disassembly/Assembly (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 95
BHT-407-MM-7
65-50. Tail Rotor Driveshaft Segmented Shaft

Assembly — Cleaning
CAUTION
MATERIALS REQUIRED DO NOT TOUCH HANGER BEARINGS

IMMEDIATELY AFTER ENGINE
Refer to BHT-ALL-SPM for specifications. SHUTDOWN. WAIT A SHORT PERIOD
OF TIME, AND THEN EXERCISE
NUMBER NOMENCLATURE CAUTION TO AVOID BURNS.

NOTE
Refer to Figure 65-17 for additional
1. Refer to the Standard Practice Manual inspection information.
(BHT-ALL-SPM) to clean the segmented shaft
assembly parts. Use drycleaning solvent (C-304) to
clean the shaft; other solvents can damage the NOTE
organic finish. It is not necessary to disconnect any shaft
to do this check.
2. Clean only the outside surface of the bearing (6, a. Inspect for tears in the bearing seals.
Figure 65-32) with a clean cloth. Apply a light pressure Bearings, 406-040-339-ALL, have a brown elastomer
so that dirt and expelled grease is not forced back into seal and bearings, 407-340-339-107, have an orange
the bearing. elastomer seal.
3. Refer to Figure 65-12 to clean the disc pack. b. Rotate the main rotor to turn the tail rotor drive
system. While it is turning, check for indication of
bearing roughness at each hanger assembly
65-51. Tail Rotor Driveshaft Segmented Shaft supporting each segmented shaft. You can detect
Assembly — Inspection and Repair indications of abnormal roughness by feel, by placing
your hand on the bearing hanger as the segmented
shafts are turning.
MATERIALS REQUIRED
c. Examine the accumulated grease that has
been expelled from around the seal during the
operation for a change in color. Bearings
NUMBER NOMENCLATURE 406-040-339-ALL and 407-340-339-107 use Mobil 28
grease (C-001) that is normally red-purple as it is
C-001 Grease injected in the bearing, but turns black when the
bearing is damaged.
C-026 Lubricant
1. Examine the segmented shaft assembly for

condition. Repair it as shown in Figure 65-33.
2. Examine the tail rotor driveshaft segment d. Examine the grease for indication of visible
assembly bearing hangers for condition. Repair them metal particles.
as shown in Figure 65-34.
e. If no indication of roughness is detected, if the
expelled grease has not turned black, if you see no
3. Inspect the segmented shaft hanger bearings as metal in the expelled grease, and if the bearing seal is
follows: intact, the bearing is acceptable for return to service.
65-00-00
Page 96 Rev. 23 7 NOV 2006
BHT-407-MM-7
3 B F B
H
(16 PL)
J 4
K
D G
8
E
I 7
C
A 1 1
10 1.7 IN. 1.7 IN. 10 L
(43.2 mm) (43.2 mm) (4 PL)
REF
A Bearing journal Corrosion/mechanical 0.001 inch (0.025 mm) up to 100%
of the circumference.
A Bearing journal Wear 1.5744 inches (39.9898 mm) minimum
diameter.
B Adapter outside Corrosion/mechanical 0.005 inch (0.127 mm) deep, up to
diameter 100% of the circumference.
B Adapter flange Corrosion/mechanical Maximum chamfer to remove damage

is to be 0.030 inch (0.762 mm) x 40 to 50º
up to 0.50 inch (12.70 mm).
No more than two per quadrant.
C Spline relief Corrosion/mechanical 0.001 inch (0.025 mm) up to 100%

D Shoulder Corrosion/mechanical 0.001 inch (0.025 mm) up to 100%

E Spline adapter Corrosion/mechanical 0.010 inch (0.250 mm) up to 100%
and face of the area.
F Tube outside Corrosion/mechanical 0.005 inch (0.127 mm) up to 1 square

diameter inch (645.2 mm ²). 0.005 inch
(0.127 mm) deep up to 25% of the
circumference, 0.850 inch (21.59 mm)
wide. 0.002 inch (0.051 mm) up to 100%
of the circumference, 0.210 inch
(5.334 mm) wide.
F Shaft tube Straightness With the use of a 12-inch (304.8 mm)

0.005 inch (0.127 mm).
G Flange adapter Corrosion/mechanical 0.001 inch (0.025 mm) up to 100%

end face of the area.
NO OBJECT BEYOND THIS POINT 407MM_65_0093a
Figure 65-33. Tail Rotor Driveshaft Segmented Shaft Assembly — Inspection and Repair (Sheet 1 of 3)
65-00-00
BHT-407-MM-7
REF
A, B, C, D Number of repairs Five per area.
E, F, G
H Rivet spotface Corrosion/mechanical None allowed.
I Tube interior Corrosion None allowed.
J Rivet Loose rivet None allowed.

K Spline - measure over Wear 1.5525 inches (39.4335 mm) minimum 5
0.120 inch (3.050 mm) diameter.
diameter pin
K Spline - sides and Corrosion/mechanical Light, superficial that can be polished

roots of teeth out by hand with the use of a fine
stainless steel wool or Scotchbrite.
K Spline - tops and Corrosion/mechanical 0.010 inch (0.254 mm) maximum up to 6
end of teeth 0.25 inch (6.35 mm) long on all teeth.
One area of damage per tooth.
0.001 inch (0.025 mm) maximum up to 6
100% of the surface of all teeth. One
area of damage per tooth.
L Fastener hole Wear 0.315 inch (8.001 mm) maximum
diameter.
NOTES
1 Mount the driveshaft in the V blocks between the two indicated areas. Measure the Total Indicator Runout
at the bearing seat shoulder and the adapter flange. The shaft must be discarded if the measurement
exceeds one of the dimensions that follow:
A Bearing seat 0.001 inch (0.025 mm) Total Indicator Runout
D Bearing seat shoulder 0.004 inch (0.102 mm) Total Indicator Runout
G Adapter flange 0.004 inch (0.102 mm) Total Indicator Runout
2. The surface of the tube must be smooth and unmarred. Scratches can be polished out so that the wall
thickness is not less than 0.068 inch (1.727 mm) and the minimum outside diameter is not less than 1.738
inch (44.145 mm).
3 Replace a stud that is distorted, loose, or with threads that are damaged. If the stud is loose, replace it with
an oversize stud. Examine the threaded stud hole and the stud for corrosion. No corrosion is permitted.
Discard the shaft if corrosion is present in the threaded stud hole. Discard the stud if it is corroded. Install
the replacement stud with unreduced zinc chromate primer (C-201) or polyamide primer (C-204). The
height of the stud as measured in the figure is 0.630 to 0.650 inch (16.00 to 16.51 mm) when it is torqued at
50 to 95 inch-pounds (5.65 to 10.74 Nm).
4 Replacement of rivet is not permitted.
5 Examine the spline teeth for signs of a wear step. Discard the shaft if you can feel a wear step with a 0.020
inch (0.508 mm) spherical radius probe.
6 When you remove nicks, dents, and scratches, only remove the raised material until it is flush with all
sides of the surface. Use a fine India stone.
NO OBJECT BEYOND THIS POINT 407MM_65_0093b
65-00-00
BHT-407-MM-7
NOTES
7 Do not remove the primer from the inside diameter of the tube. Do the touch-up to the
primer with epoxy polyamide primer (C-204).
8 Do not remove the end plug unless damage is suspected. If the end plug is damaged or
loose, replace with a new end plug, P/N 120-179-26A. Clean the tube inside diameter with
solvent (C-304) where the plug is installed. Use adhesive (C-363) to install the plug in the
tube. The plug must be pushed in far enough to leave a gap of 0.060 inch (1.524 mm)
between the plug and the tube end. Fill and fair that gap with the same adhesive that was
used to install the plug.
9. Remove two times the depth of the corrosion to repair a corroded surface. The limits shown
are for after the repair is completed.
10 When damaged material must be removed from the balancing rim, remove an equal amount
of material on the same rim, at 180º opposite to the repair area.
407_MM_65_0095_c01
65-00-00
BHT-407-MM-7
A D
E
C
A
SECTION A-A
BEARING HANGER-TAIL ROTOR DRIVESHAFT SEGMENT ASSEMBLY SHAFT
(406-040-322-103/407-040-322-103)
REF
A Bearing bore Wear 2.677 inches (67.996 mm)

maximum diameter.
B Internal diameter Corrosion 0.003 inch (0.076 mm) deep. 25%

and surface of any one circumferential inch
(25.4 mm) of surface.
Mechanical Axial and circumferential scratches

0.003 inch (0.076 mm) deep.
C Faces Mechanical Remove the raised material until

it makes a continuous surface
on all sides.
ALL External diameter Corrosion 0.010 inch (0.254 mm) of any one
and surface shoulder square inch (645.2 mm ²).
internal diameter of surface.
Adapter flange Mechanical Nicks, dents, and scratches 0.010 inch

(0.254 mm) deep, 0.50 inch
(12.70 mm) long.
Edge damage 0.030 inch (0.762 mm) x 45º

chamfer, 0.50 inch (12.70 mm) total
length, two repairs per quadrant.
407MM 65 0096
Figure 65-34. Tail Rotor Driveshaft Segment Assembly Bearing Hanger — Inspection and Repair
(Sheet 1 of 2)
65-00-00
Page 100 Rev. 23 7 NOV 2006
BHT-407-MM-7
REF
D Threaded hole Corrosion/mechanical None past the first thread pitch.
E Bolt hole Wear 0.269 inch (6.833 mm)

maximum diameter.
Corrosion 0.010 inch (0.254 mm) inch deep.

25% of the wall area.
NOTES
4. Refer to the BHT-ALL-SPM to do the brush cadmium plating after the repair. Do not apply brush cadmium
plating in the bolt holes and the threaded holes.
407MM 65 0097
Figure 65-34. Tail Rotor Driveshaft Segment Assembly Bearing Hanger
— Inspection and Repair (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 101
BHT-407-MM-7
f. If you detect, or suspect roughness of a T H E TA I L R O T O R D R I V E S H A F T

bearing, remove the affected segmented driveshaft SEGMENTED SHAFT ASSEMBLY. IT IS
and rotate the bearing manually to confirm the bearing NOT POSSIBLE TO RINSE THE
roughness. CHEMICAL PAINT REMOVER FULLY
g. If the bearing is rough, a seal is torn, the RIVETED ADAPTER AND THE SHAFT.
expelled grease has turned black, or if you see metal THE RIVETS CAN START TO CORRODE
particles in the expelled grease, replace the affected IN A WAY THAT CANNOT BE DETECTED.
bearing (paragraph 65-53) and contact:
NOTE
Product Support Engineering
Bell Helicopter Textron Do not Plastic Media Blast (PMB) the end
E-mail: [email protected] face of the adapters that are riveted to the
shaft. You can remove the adhesive that
Fax: 450-433-0272
bonds the stoppers in the end face of the
Phone: USA 800-363-8023 adapters by PMB.
Canada 800-361-9305
International (call collect) 450-437-2862 1. Use PMB (BHT-ALL-SPM) to remove the organic
finish from the shaft outside diameter. Remove the
4. Examine the segmented shaft assembly adapters organic finish from the shaft only if it is required by the
for condition. Repair them as shown in Figure 65-35. conditional inspection to do the Non Destructive
Inspection (NDI) or if the organic finish needs to be
5. Examine the coupling washers for condition. refreshed.
Repair them as shown in Figure 65-36.
2. After the repair to the shaft outside diameter, refer
6. Examine the disc segments of the coupling disc
to BHT-ALL-SPM and apply the chemical protection
packs for condition (Figure 65-12).
layer to the exposed bare metal.
65-52. Tail Rotor Driveshaft Segmented Shaft

Assembly and Adapter — Stripping and 3. Refer to Figure 65-30 and apply the organic finish
Painting to the outside diameter of the segmented shaft and
adapter. Use the application procedures from
BHT-ALL-SPM for the polyamide epoxy primer and the
polyurethane enamel application.
CAUTION
4. Refer to BHT-ALL-SPM for the instructions to do

DO NOT USE CHEMICAL PRODUCTS TO the touch up of the epoxy primer and the polyurethane
REMOVE THE ORGANIC FINISH FROM enamel layer.
65-00-00
Page 102 Rev. 23 7 NOV 2006
BHT-407-MM-7
B
A
A
SECTION A-A
ADAPTER (406-040-328)
REF
A Faces Corrosion/mechanical 0.001 inch (0.025 mm) maximum

B Outside diameter Corrosion/mechanical 0.005 inch (0.127 mm) deep, maximum

and bore area per full depth repair is 1.0
A, B Number of repair Two per area.
ALL Edges Corrosion/mechanical Maximum edge chamfer to remove

40 to 45º up to 0.50 inch
(12.70 mm). No more than two per
quadrant.
C Spline - measure over Wear 1.2257 inches (31.1328 mm) 1

0.108 inch (2.743 mm) maximum diameter.
diameter pin.
407MM_65_0098
Figure 65-35. Tail Rotor Driveshaft Segment Assembly Adapter — Inspection and Repair (Sheet 1 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 103
BHT-407-MM-7
REF
C Spline - sides and Corrosion/mechanical Light, superficial that can be

roots of teeth polished out by hand with a
fine stainless steel wool or scotchbrite.
Spline - tops and Corrosion/mechanical 0.010 inch (0.254 mm) maximum, up 2

end of teeth to 0.25 inch (6.35 mm) long on all
teeth. One area of damage per tooth.
0.001 inch (0.025 mm) maximum, up 2

to 100% of the surface of all teeth.
One area of damage per tooth.

maximum diameter.
NOTES
1 Examine the spline teeth for signs of a wear step. If you can feel a wear step with a 0.020 inch (0.508 mm)
spherical radius probe, the shaft must be discarded.
2 Remove small nicks, dents and scratches, from spline teeth edges with a fine India stone. Remove the
raised material until it makes a continuous surface on all sides.
3. Total indicator runout is not to exceed a maximum of 0.004 inch (0.102 mm) when measured, installed,
on the oil cooler blower shaft mounted on V blocks at the bearing journals.

7. Refer to the BHT-ALL-SPM for the procedures to brush cadmium plating to repaired areas.
407MM_65_0099
Figure 65-35. Tail Rotor Driveshaft Segment Assembly Adapter — Inspection and Repair (Sheet 2 of 2)
65-00-00
Page 104 Rev. 23 7 NOV 2006
BHT-407-MM-7
E D
A
B
WASHER (406-040-327) C
REF
A, B Surface Circumferential steps None allowed. If you find a step, rework

the surface to keep a minimum
thickness, C.
A, B Surface Corrosion/mechanical 0.010 inch (0.254 mm) deep 1 2

0.25 square inch (161.3 mm ²).
C Thickness Minimum thickness of 0.190 inch (4.826 mm). Surface must be

surface A and B parallel within 0.005 inch (0.127 mm).

minimum diameter.
E Outside diameter Corrosion/mechanical 1.490 inches (37.846 mm) 1
maximum diameter.
F Area Corrosion/mechanical 0.010 inch (0.254 mm) deep, 0.25

square inch (161.3 mm ²). Number of
repairs is not very important.
ALL Edge Corrosion/mechanical Maximum edge chamfer to remove 1

damage is to be 0.030 inch
(0.762 mm) x 40 to 45º.
NOTES
1 The number of repairs is not very important as long as the dimensions are kept.
2 Remove small nicks, dents and scratches, from spline teeth edges with a fine India stone. Remove the
raised material until it makes a continuous surface on all sides.
6. Refer to the BHT-ALL-SPM for the procedures to brush cadmium plating to repaired areas.
407MM_65_0100
Figure 65-36. Coupling Washer — Inspection and Repair
65-00-00
7 NOV 2006 Rev. 23 Page 105
BHT-407-MM-7

Assembly
CAUTION
SPECIAL TOOLS REQUIRED ENSURE THAT BEARING HANGERS (9)

ARE ORIENTED PROPERLY TO SHAFT
(8).
NUMBER NOMENCLATURE
5. Apply a thin layer of corrosion preventive
Workaid Bearing Pressing
compound (C-104) to the inner diameter of the bearing
Workaid, Figure 65-24
(6) and to the bearing journal on shaft (8). Using the
OTC8068 Step Plate Adapter bearing pressing workaid, Figure 65-24, press the
bearing hanger (9) and bearing (6) onto the forward
end of the tail rotor driveshaft segment assembly (8).
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications. CAUTION
NUMBER NOMENCLATURE
POSITION WASHER (3) WITH TAPERED
C-104 Corrosion Preventive SIDE FACING AWAY FROM ADAPTER (4,
Compound FIGURE 65-32, SECTION A-A).
OTHERWISE, DAMAGE TO THE PART
C-204 Epoxy Polyamide WILL OCCUR.
Primer
6. Install the coupling adapter (4), the washers (3
1. Apply a layer of epoxy polyamide primer (C-204) and 2), and the nut (1) T .
to the threads on the grease fitting (5, Figure 65-32).
Install the grease fitting (5) T . 7. Lubricate hanger bearing (6) (Chapter 12).

Installation
CAUTION
CAUTION
DO NO T PERMIT THE CO RROSION
PREVENTIVE COMPOUND (C-104) TO
TOUCH THE BEARING SEAL. IF MAKE SURE THAT THE ORDER IN
CORROSION PREVENTIVE COMPOUND W HIC H T HE D IS C S EG M E NTS A RE
(C-104) TOUCHES THE BEARING SEAL, STACKED DOES NOT CHANGE AFTER
THE SEAL WILL BE DAMAGED. THE COUPLING DISC PACK HAS
OPERATED. FIGURE 65-12 CONTAINS
2. Apply a thin layer of corrosion preventive
compound (C-104) to the inner diameter of the bearing
AND REPAIR.
hanger (9) and to the outer diameter of the bearing (6).
INSTALL COUPLING WASHERS WITH
3. Heat bearing hanger (9) to 200°F (93°C) and THE BEVELLED EDGE AGAINST THE
press the bearing (6) into the bearing hanger (9) with COUPLING DISC PACK AND THE FLAT
an arbor press and the step plate adapter OTC8068 SIDE AGAINST THE ADAPTER FLANGE.
(14). Do not exceed 285°F (142°C) on the hanger. IF T WO C OUP LING WASH ERS ARE
INSTALLED TOGETHER, THEY MUST BE
4. Install the retaining ring (10) in the bearing INSTALLED SO THE FLAT SIDES OF
hanger (9). EACH TOUCH.
65-00-00
BHT-407-MM-7
13. Perform a tail rotor driveshaft segment assembly

NOTE
bearing alignment (paragraph 65-56).
Do not turn the bolt when you install the
coupling disc pack. Turn the nut while you 14. Lubricate hanger bearings as required
hold the bolt. If the bolt turns, gaps can (Chapter 12).
occur between the coupling discs.
Make sure bolt lengths are equal. Permit 15. Do an operational check (paragraph 65-2).
only the grip portion (unthreaded portion) of
the bolt to touch the coupling disc pack. 16. Install the fairings (Chapter 53).
1. Install the coupling disc pack (26, Figure 65-31)

65-55. Tailboom Bearing Hanger Support and
on the tail rotor driveshaft segment assembly (14).
Bearing Hanger — Shimming
2. Install bolt (25), coupling washers (24), flat 1. Get access to the tail rotor driveshaft segment
washer (23), and nut (22). Tighten the nut finger tight. assemblies on the tailboom. Refer to Chapter 53 for
the removal of the aft fairing assembly and the tail
3. Remove the lockwire from the coupling disc rotor driveshaft cover.
pack (26).
4. Install the coupling disc pack (21) on the forward NOTE

tail rotor gearbox (28). The instructions to determine the amount of
shims required is the same for the four
5. Install the bolts (20), coupling washers (19), flat tailboom bearing hanger supports. Repeat
washers (18), and nuts (17). Tighten the nuts finger step 2 through step 5 for the four bearing
tight. hanger supports.
6. Remove the lockwire from the coupling disc 2. Remove the cotter pin (1, Figure 65-37) and
pack (21). loosen the nut (2). Do not remove the bolt (4).
7. Install the tail rotor driveshaft segment assembly 3. Push the bearing hanger (5) on the bolt (4) until it
(14) on the tailboom. Place a support under the aft end contacts one flange of the tailboom bearing hanger
of the tail rotor driveshaft segment assembly. support (6, 7, 8, or 9, Figure 65-37, Detail A). Using a
feeler gauge, carefully measure the free gap between
the bearing hanger (5) and the other flange of the
8. Install the bolt (12) and the washer (13) through tailboom bearing hanger support (6, 7, 8, or 9). Record
the bearing hanger support (16) and the bearing the gap width.
hanger.
4. Prepare the shims; refer to Figure 65-37, View B,

9. Perform tailboom bearing hanger support and
View C, and Notes 1 through 3.
bearing hanger shimming procedure, paragraph 65-55
step 3 through step 7.
5. Install shim(s) per View B or C of Figure 65-37.
10. Install the bolts (11), coupling washers (10), flat
washers (9), and nuts (8). Tighten the nuts finger tight. 6. Install additional washer, if necessary; see Note 3
of Figure 65-37.
11. Install the bolts (4), coupling washers (3), flat
washers (2), and nuts (1). Tighten the nuts finger tight. 7. Install the washer (3) and the nut (2). Tighten the
nut finger tight.
12. Apply torque to the bolts on the coupling disc
packs (21 and 26) following the torque sequence 8. Perform a tail rotor driveshaft segment assembly
(paragraph 65-60). bearing alignment (paragraph 65-56).
65-00-00
BHT-407-MM-7
STEP 1
REMOVE THE COTTER PIN (1),
NUT (2) AND THE WASHER (3)
STEP 2
SLIDE THE BEARING HANGER (5) ON THE
BOLT (4), AGAINST THE LEFT SIDE OF THE TAILBOOM
BEARING HANGER SUPPORT (6, 7, 8 or 9)
STEP 3
MEASURE THE FREE GAP BETWEEN THE
BEARING HANGER (5) AND THE TAILBOOM
BEARING HANGER SUPPORT (6, 7, 8 or 9)
9
STA
SEE DETAIL A 339.243
8
STA
306.199
7
STA
273.132
6 1. Cotter pin
2. Nut
STA 3. Washer
240.047 4. Bolt
5. Bearing hanger
6. Tailboom bearing hanger support
5
STEP 2
3 3 2
1
4
STEP 1
STEP 3
CAUTION
USE CARE NOT TO FORCE THE

VIEW LOOKING FORWARD TAILBOOM BEARING HANGER SUPPORT
OPEN WITH THE FEELER GAUGE
DETAIL A (TYPICAL)
407MM_65_0101
Figure 65-37. Shimming Procedure (Sheet 1 of 2)
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Page 108 Rev. 23 7 NOV 2006
BHT-407-MM-7
3 1 2
3 2
VIEW B VIEW C
LOOKING FORWARD LOOKING FORWARD
SHIM LOCATION FOR A GAP OF SHIM LOCATION FOR A GAP OF

0.010 IN. (0.254 mm) AND LESS 0.010 IN. (0.254 mm) AND GREATER
NOTES
1 If the measured gap is 0.010 inch (0.254 mm) or less, peel the shim 120-008C24E9 to the same
thickness as the measured gap within 0.002 inch (0.0508 mm) and put it between the bearing hanger
and the tailboom bearing hanger support on the nut side of the tailboom bearing hanger support.
Measured gap of 0.002 inch (0.0508 mm) or less does not require a shim.
2 If the measured gap is more than 0.010 inch (0.254 mm), peel the shim 120-008C24E9 into two shims
that have a combined thickness that is the same as the measured gap within 0.002 inch (0.0508 mm)
and their individual thicknesses are equal within 0.004 inch (0.1016 mm). Install one shim between the
bearing hanger and the tailboom bearing hanger support on the bolt head side and one between the
bearing hanger and the tailboom bearing hanger support on the nut side of the tailboom bearing
hanger support.
3 Use an additional washer NAS1149F0463P, or a maximum of two washers NAS1149F0432P as required

to align the cotter pin with the slot in the nut. Make sure that the nut does not touch the bolt grip.
407MM_65_0102
Figure 65-37. Shimming Procedure (Sheet 2 of 2)
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BHT-407-MM-7
65-56. Tail Rotor Driveshaft Segment Assembly b. Install the bearing alignment tool
Bearing — Alignment T102146-101 (5) on the bearing hanger (6). Tighten
shoulder screws (1) T .
SPECIAL TOOLS REQUIRED c. Tighten the screws (2) T .
d. Tighten the nut (8) T .

NUMBER NOMENCLATURE
e. Install the cotter pin (9).
T102146-101 Bearing Alignment Tool
f. Remove the screws (2).
1. The purpose of the procedure is to align the
hanger and the bearing outer race with the shaft and g. Remove the shoulder screws (1).
the bearing inner race.
h. Remove the bearing alignment tool
T102146-101 (5).
a. Do the bearing alignment procedure each time
you remove a tail rotor driveshaft segment assembly
i. Install the retaining ring (7) into the bearing
or when required by the conditional inspection.
hanger (6).
b. Start the bearing alignment with the most aft 65-57. Tail Rotor Driveshaft Segment Assembly —
bearing hanger. Continue by working forward. Alignment
NOTE NOTE
If the driveshaft was not completely This tail rotor driveshaft segment assembly
removed, start alignment with the most aft alignment procedure is provided for
bearing hanger replaced. verification purposes only. Only do the tail
rotor driveshaft segment assembly
2. Align the tail rotor driveshaft segment assembly alignment procedure, if required, by the
bearing as follows: conditional inspection, by a callout in this
manual, or if for any reason you think that
a. Make sure that the nut (8, Figure 65-38) is the driveshaft is out of alignment. If the
loose (finger tight). Remove the retaining ring (7) from alignment is not within limits, contact
the bearing hanger (6). Rest the retaining ring (7) on product support engineering for assistance.
the coupling adapter.
1. The tail rotor driveshaft segment assembly
alignment procedure aligns the tail rotor driveshaft
NOTE segment assembly to the horizontal plane.
Make sure the bearing alignment tool
T102146-101 (5) is in good contact with the a. Start the alignment with the most aft tail rotor
bearing inner race and coupling adapter driveshaft segment assembly replaced. Continue by
before you tighten the shoulder screws (1). working forward.
65-00-00
Page 110 Rev. 23 7 NOV 2006
BHT-407-MM-7
1
2 1 3 1 2 1 1
1 5
8
3
7
9 6
4 4
2 1 1
3 1
1. Shoulder screws
2. Screw 5 1
3. Swivel clamps
5. Bearing alignment tool
6. Bearing hanger
7. Retaining ring
8. Nut
9. Cotter pin
20 IN-LBS
1 (2.26 Nm)
30 TO 50 IN-LBS
2 (3.39 TO 5.65 Nm)
50 TO 70 IN-LBS
3 (5.7 TO 7.9 Nm)
NOTE
1 Part of alignment tool set T102146-101.
407MM_65_0103
Figure 65-38. Tail Rotor Driveshaft Segment Assembly Bearing — Alignment
65-00-00
7 NOV 2006 Rev. 23 Page 111
BHT-407-MM-7
2. Align the tail rotor driveshaft segment assembly are made of 9 to 12 separate steel discs
as follows: (Figure 65-12). The disc circumference is cut in two
places, parallel to the grain of the steel. This index flat
is an aid to make sure the grain of the steel is
alternated with each disc (each disc index is turned
CAUTION 90° from the previous disc).
65-59. Coupling Disc Packs — Inspection

MAKE SURE THE HELICOPTER IS ON A
HARD AND LEVEL SURFACE BEFORE
YOU PUT IT ON THE JACKS. 1. Examine the installed coupling disc packs as
follows:
NOTE
a. Examine the coupling disc pack for gaps of
Make sure the helicopter is stable and will more than 0.015 inch (0.381 mm) between the disc
not rock or move during the alignment segments. If you find a gap of more than 0.015 inch
procedure. (0.381 mm) loosen the nuts on the coupling disc pack
and apply torque (paragraph 65-60).
a. Put a tripod jack under the aft fuselage jack
point. Jack the helicopter enough to support the
b. Examine the coupling disc pack for cracks in
weight and prevent rocking during the alignment.
the disc segments. If you find a crack on the disc
Refer to Chapter 7.
segment go to step 2.
b. Measure the driveshaft at the four locations as
2. Examine the disassembled coupling disc pack
shown in Figure 65-39. Start the measurements at the
(Figure 65-12).
most aft shaft and work towards the front of the
helicopter.
65-60. Coupling Disc Pack — Torque Sequence
c. Use a precision inclinometer (2, Figure 65-39)
to measure the horizontal angle of the tail rotor
NOTE
driveshaft segment assemblies (3 and 5) at the
bearing hanger (1). With reference to Figure 65-39, The following procedure is for use following
subtract value "Y" from value "X" (i.e. X - Y) to obtain reassembly of any coupling disc pack. It
the angle between the adjacent driveshaft segments. does not apply for a torque check of the
If the difference between the value measured on the hardware. If a torque check is required,
shaft located aft (value "X") and forward (value "Y") of apply minimum torque as specified in
the bearing hanger (1) is greater than what is Figure 65-31 plus tare torque.
permitted, contact product support engineering for
assistance. Repeat for other 3 locations. 1. Apply torque to the nuts on the coupling disc
packs. Start with the aft coupling disc pack. Initially, the
65-58. COUPLING DISC PACKS nuts should only be tightened until they lightly contact
the adapter. The bolts should remain loose enough so
The coupling disc packs (Thomas couplings) they can be turned by hand. The torquing procedure is
(Figure 65-12) join the different components of the tail the same for all coupling disc packs. Do the steps that
rotor drive train to each other. The coupling disc packs follow:
65-00-00
Page 112 Rev. 23 7 NOV 2006
BHT-407-MM-7
SEE DETAIL A
4
4
VALUE "X" 6
1 2 2
1
DETAIL B
5
TABLE 1
VALUE "Y" S/N 53000 THROUGH 53554
ANGLE FORMED BETWEEN ADJACENT
3 DRIVESHAFT SEGMENT ("X"-"Y"=ANGLE)
1 2 2
DEGREES
LOCATION
MINIMUM ANGLE MAXIMUM ANGLE
1 0.494 0.750
2 0.516 0.750
3 0.524 0.750
SEE DETAIL B 4 0.540 0.750
DETAIL A
(TYPICAL 4 PLACES) TABLE 2
S/N 53555 AND SUBSEQUENT
1. Bearing hanger ANGLE FORMED BETWEEN ADJACENT
2. Precision inclinometer DRIVESHAFT SEGMENT ("X"-"Y"=ANGLE)
3. Tail rotor driveshaft segment assembly DEGREES
4. Tailboom bearing hanger support LOCATION
MINIMUM ANGLE MAXIMUM ANGLE
5. Tail rotor driveshaft segment assembly 1 0.494 0.520
6. Shim 2 0.520 0.600
3 0.632 0.660
NOTES 4 0.654 0.680
1 Refer to Table 1 for helicopter S/N 53000 through 53554 and Table 2 for helicopter S/N 53555 and
subsequent, except as follows: If tailboom P/N 407-030-801-205 is installed on helicopter
S/N 53000 through 53554, refer to values provided in Table 2.
2 The allowable tolerance is dictated by the maximum values shown in the tables. Minimum
values are provided for reference only.
407MM_65_0104
Figure 65-39. Tail Rotor Driveshaft Segment Assembly — Alignment
65-00-00
7 NOV 2006 Rev. 23 Page 113
BHT-407-MM-7
h. Apply 20 inch-pounds (2.26 Nm) torque to the

nut at the 9 o’clock position. Hold the bolt and apply
CAUTION
torque to the nut only. If the bolt turns, gaps can occur
in the coupling disc pack.
MAKE SURE THE MAIN ROTOR BLADES
AND THE TAIL ROTOR BLADES ARE i. Repeat step b to step h three times. Each time
CLEAR BEFORE YOU ROTATE THE OIL you repeat the steps, increase the torque by 40
COOLER BLOWER SHAFT. IF THE inch-pounds (4.5 Nm). The final time that you repeat
BLADES HIT AN OBJECT, THEY CAN BE the step, torque the nut to the specified value, refer to
DAMAGED. Figure 65-31.
a. Slowly turn the tail rotor drive system three or 2. Measure the gap between the discs in the disc
four revolutions in the clockwise direction (looking pack. If the gap is larger than 0.015 inch (0.381 mm),
forward as installed on the helicopter), with the main loosen the nuts (do not allow bolt to turn), on the
rotor, tail rotor or main driveshaft. Rotate until the two coupling disc pack and do step 1. If the gap is still
bolts with their heads facing forward are located at the larger then 0.015 inch (0.381 mm), refer to
3 and 9 o’clock positions. Figure 65-12 for replacement of damaged discs.
b. Apply 20 inch-pounds (2.26 Nm) torque to the 65-61. TAIL ROTOR GEARBOX
nut at the 9 o’clock position (looking forward). Hold the
bolt and apply torque to the nut only. If the bolt turns,
The tail rotor gearbox (4, Figure 65-40) contains an
gaps can occur in the coupling disc pack. input pinion and a spiral bevel gear set that changes
the direction of the drive 90°. The speed is reduced by
c. Slowly turn the tail rotor drive system 1/2 turn a ratio of 2.53 to 1 at these gears. The tail rotor
in the clockwise direction (looking forward as installed gearbox housing is made of magnesium and is
on the helicopter), with the main rotor, tail rotor or main attached to the tailboom with four studs, nuts (10),
driveshaft. washers (9), and two dowel pins for alignment. The tail
rotor gearbox assembly includes a filler cap (1), oil
d. Apply 20 inch-pounds (2.26 Nm) torque to the sight glass (5), a breather (18), and a combination
nut at the 9 o’clock position (looking forward). Hold the electric chip detector/self-closing valve (16 and 19).
gaps can occur in the coupling disc pack. The electric chip detector/self-closing valve (16 and
19) and the oil sight glass (5) help during
maintenance. The self-closing valve (19) makes it
e. Slowly turn the tail rotor drive system 3/4 turn
possible to examine the electric chip detector (16) for
in the clockwise direction (looking forward as installed
metal particles without draining the oil. The self-closing
on the helicopter), with the main rotor, tail rotor or main
valve also serves as a drain plug for the tail rotor
driveshaft.
gearbox. The oil sight glass (5) makes it possible to
visually examine the quantity of oil in the tail rotor
f. Apply 20 inch-pounds (2.26 Nm) torque to the gearbox.
nut at the 9 o’clock position (looking forward). Hold the
The tail rotor gearbox assembly (4) contains a
gaps can occur in the coupling disc pack. replaceable breather assembly that permits the
lubricating oil and the air in the tail rotor gearbox to
g. Slowly turn the tail rotor drive system 1/2 turn expand and contract because of the changes in
in the clockwise direction (looking forward as installed temperature and altitude. The tail rotor gearbox will not
on the helicopter), with the main rotor, tail rotor or main pressurize because the breather assembly vents to
driveshaft. the atmosphere.
65-00-00
Page 114 Rev. 23 7 NOV 2006
BHT-407-MM-7
1 SEE DETAIL B
16
17 27
SEE DETAIL A 3
19 2
1
20 30
31 3
32 21 28 4
33
18 5 3
15 1 29
6
14
7
8
10
25 2
12
11
13
26
20. Packing
21. Pitch change mechanism
1. Cap assembly 22. Packing
DETAIL A 2. Chain 23. Packing
3. Pin 24. Screw
24 4. Tail rotor gearbox 25. Pitch change lever
1
5. Sight glass 26. Pitch change control rod
6. Packing 27. Inspection plug
7. Cap assembly 28. Packing
8. Output shaft 29. Packing
2 9. Washer 30. Screw
10. Nut 31. Washer
11. Door 32. Clamp
12. Washer 33. Spacer
13. Screw
23 14. Adapter 75 TO 125 IN-LBS
15. Breather tube 1 (8.5 TO 14.1 Nm)
16. Electric chip detector 140 TO 160 IN-LBS
22 2 (15.8 TO 18.1 Nm)
17. Packing
18. Breather 250 TO 400 IN-LBS
DETAIL B 19. Self-closing valve 3 (28.3 TO 45.2 Nm)
407MM_65_0105
Figure 65-40. Tail Rotor Gearbox
65-00-00
7 NOV 2006 Rev. 23 Page 115
BHT-407-MM-7
65-62. Tail Rotor Gearbox — Removal 65-63. Tail Rotor Gearbox — Cleaning

CAUTION
NUMBER NOMENCLATURE
DO NOT LET THE SOLVENT TOUCH THE
Tail Rotor Gearbox SEALS. DAMAGE TO THE SEALS CAN
Workaid, Figure 65-41 BE CAUSED BY THE SOLVENT.
1. Refer to BHT-ALL-SPM and clean the tail rotor

1. Get access to the tail rotor gearbox (Chapter 53). gearbox.
2. Disconnect the connector 1E4P1 from the tail 65-64. Tail Rotor Gearbox — Inspection
rotor gearbox electric chip detector (16, Figure 65-40).
Remove clamps securing wire harness from the tail
1. If there is leakage from the cap assembly (1,
rotor gearbox (4).
Figure 65-40), refer to paragraph 65-89 for the
inspection and repair.
3. Remove the screw (30), washer (31), clamp (32)
and spacer (33). Disconnect the breather tube (15)
from the breather (18). 2. Examine the tail rotor gearbox (4) for leaking
seals. Refer to Table 65-3 for the permitted leakage
rates. To replace the seals that leak, refer to
4. Remove the tail rotor hub and blade assembly
paragraph 65-99 for the input seal and to paragraph
(Chapter 64).
65-96 for the output seal.
5. Remove the last tail rotor driveshaft segment

3. Examine the tail rotor gearbox electric chip
assembly (paragraph 65-48).
detector (16) for unwanted material. Refer to the
operational check (paragraph 65-2) to find the cause
6. Disconnect the pitch change control rod (26) from and the procedures for repair.
the pitch change lever (25) (Chapter 67).
4. Examine the self-closing valve (19) for leaks.
7. Drain the lubrication fluid from the tail rotor
Refer to paragraph 65-76 for the inspection and
gearbox (4) (Chapter 12).
replacement procedures.
8. Remove the screws (13), the washers (12), and

5. Examine the oil sight glass (5) for leaks. Refer to
the door (11). Access the nuts (10) and the washers
paragraph 65-81 for the inspection and replacement
(9) through the door opening.
procedures.
NOTE 6. If necessary refer to paragraph 65-91 to remove

Use the workaid shown in Figure 65-41 to and examine the output cap assembly (7).
remove the aft left hand nut that holds the
tail rotor gearbox to the tailboom. 7. Examine the tail rotor gearbox housing mating
faces (Figure 65-42) for the existence of primer and/or
9. Remove the nuts (10) and the washers (9) from paint. If primer and/or paint exist, remove with paint
the tail rotor gearbox mounting studs. remover or Plastic Media Blasting. Refer to
BHT-ALL-SPM, Chapter 4 or Chapter 3, as necessary.
10. Remove the tail rotor gearbox (4) by lifting
vertically. 8. If you removed primer and/or paint, apply
Magnesium Touchup Treatment to mating faces
11. Remove the pitch change mechanism (21) (Figure 65-42). Refer to BHT-ALL-SPM, Chapter 3,
(Chapter 67). Magnesium Touchup Treatment.
65-00-00
Page 116 Rev. 23 7 NOV 2006
BHT-407-MM-7
3/8" BOX END
0.75 IN.
(19.05 mm)
5.75 IN.
(140.09 mm)
3/8" DRIVE
SOCKET
407MM_65_0106
Figure 65-41. Tail Rotor Gearbox Workaid — Field Fabricated
65-00-00
7 NOV 2006 Rev. 23 Page 117
BHT-407-MM-7
MAKE SURE THAT ALL PRIMER IS

REMOVED FROM THESE MATING FACES.
APPLY SEALANT (C-392)
(4 PLACES)
SEALANT (C-392)
NOTE
If you removed primer or paint as per Tail Rotor Gearbox - Inspection, Paragraph 65-64, step 7,
apply magnesium touch up as per BHT-ALL-SPM, Chapter 3, prior to application of sealant (C-392).
407MM_65_0107
Figure 65-42. Tail Rotor Gearbox — View Looking Up
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Page 118 Rev. 23 7 NOV 2006
BHT-407-MM-7
9. Examine the tail rotor gearbox housing for FIGURE 65-40) WITHIN 15 MINUTES OF
mechanical and corrosion damage. Refer to APPLYING THE SEALANT (C-392).
Figure 65-45 for the inspection criteria.
4. Apply sealant (C-392) to the areas shown in
10. Examine mounting studs and dowel pins for Figure 65-42).
condition.
NOTE
65-65. Tail Rotor Gearbox — Installation
Do not use barrier tape between the mating
faces of the tail rotor gearbox and the
tailboom support.
5. Set the tail rotor gearbox (4, Figure 65-40) on the
tailboom.
NUMBER NOMENCLATURE
Tail Rotor Gearbox 6. Access the tail rotor gearbox mounting studs
Workaid, Figure 65-41 through the door (11) on the bottom of the tailboom.
Install the steel washers (9) and the nuts (10) T . Use
the tail rotor gearbox workaid, Figure 65-41, to install
the aft left hand nut (10, Figure 65-40).
MATERIALS REQUIRED
7. After one hour, apply torque again to nuts
(10) T to adjust for the movement of sealant.
NUMBER NOMENCLATURE
8. Connect the pitch change control rod (26) to the
C-204 Epoxy Polyamide pitch change lever (25) (Chapter 67).
Primer
9. Install the door (11), the washers (12), and the
C-305 Aliphatic Naphtha
screws (13).
C-392 Sealant
10. Install the last tail rotor driveshaft segment
assembly (paragraph 65-54).
1. Install the pitch change mechanism (21,
Figure 65-40) on the tail rotor gearbox (4).
11. Install the tail rotor hub and blade assembly
(Chapter 64).
2. Clean with aliphatic naphtha (C-305) the tail rotor
gearbox mating area on the tailboom. Ensure that the
four stud holes and the two dowel pin holes do not 12. Rig the tail rotor control system (Chapter 67).
have primer in them (Figure 65-43).
13. Service the tail rotor gearbox (Chapter 12).
3. Apply epoxy polyamide primer (C-204) to the two
dowel pins and the shanks of the four studs 14. Connect the connector (1E4P1) on the tail rotor
(Figure 65-44). The tail rotor gearbox must be installed electric chip detector (16). Install clamps securing wire
on the tailboom support while the primer is wet. harness to the tail rotor gearbox (4).
15. Install the breather (18) and connect the breather

tube (15). Attach it to the tail rotor gearbox (4) with a
CAUTION spacer (33), clamp (32), washer (31), and screw (30).
THE TAIL ROTOR GEARBOX MUST BE 16. Do an operational check (paragraph 65-2).
INSTALLED ON THE TAILBOOM AND
TORQUE APPLIED TO THE NUTS (10, 17. Install the fairing (Chapter 53).
65-00-00
7 NOV 2006 Rev. 23 Page 119
BHT-407-MM-7
MAKE SURE THAT THERE IS NO PRIMER

IN THE DOWEL AND STUD HOLES,
AND THAT THE HOLES ARE CLEAN
6 PLACES
407MM_65_0108
Figure 65-43. Tailboom Support — View Looking Down
65-00-00
Page 120 Rev. 23 7 NOV 2006
BHT-407-MM-7
PRIMER (C-204) 1
STUD SHANK ONLY
4 PLACES
PRIMER (C-204) 1
2 PLACES
NOTE
1 Tail rotor gearbox must be installed while primer is still wet.
407MM_65_0109
Figure 65-44. Tail Rotor Gearbox — View Looking Aft
65-00-00
7 NOV 2006 Rev. 23 Page 121
BHT-407-MM-7
S
S
AREA H
K
A C
P
AREA M
R
D F
AREA J B
E
U
T
SECTION S-S
VIEW R
4 PLACES
407MM_65_0110
Figure 65-45. Tail Rotor Gearbox Housing — Inspection (Sheet 1 of 3)
65-00-00
Page 122 Rev. 23 7 NOV 2006
BHT-407-MM-7
REF INSPECTION
1. A Bearing liner - Measure Maximum 2.0471 inches 7 8

output (52.0 mm).
2. B Bearing liner - Measure Maximum 2.8346 inches 7 8

input (72.0 mm).
3. C Cap assembly bore Measure Maximum 5.8763 inches 9

(149.0 mm).
4. D Bearing liner Measure Maximum 1.3781 inches 7 8

(35.0 mm).
5. E Packing gland area Measure Maximum 3.3143 inches (84.2 mm).
6. F, G, N Fretting Measure Maximum 0.002 inch (0.051 mm).

7. K, L Thread damage Visual Damage to the first outboard thread
corrosion/mechanical is permitted if it does not extend
after the first thread.
8. P Washer seat Visual No looseness is permitted.
9. Corrosion/mechanical Visual/measure See NOTES 1 through 6.

10. Stud/dowel pin Visual No looseness or thread damage
is permitted.
11. T Wear Measure Minimum 0.120 inch (3.05 mm).
12. U Dowel pin Measure Minimum diameter 0.250 inch
(6.35 mm).
407MM_65_0111
65-00-00
7 NOV 2006 Rev. 23 Page 123
BHT-407-MM-7
NOTES
1. The maximum permitted depth in the damaged surface F after you blend out mechanical or
corrosion damage is 0.020 inch (5.08 mm). No more than 40% of the area in less than
one square inch (645.0 mm²) or more than 20% of the total area of the surfaces is
permitted to be reworked. Damage in area J must not be more than the first thread.
The finish must be 32 RMS with a minimum radius of 0.100 inch (2.54 mm).
2. The maximum permitted depth in damage in areas H and J after you blend out mechanical
or corrosion damage is 0.005 inch (0.127 mm). No more than 40% of the area in less
than one square inch (645.2 mm²) or more than 20% of the total area of the surface
diameter is permitted to be reworked. The finish must be 32 RMS with a minimum
radius of 0.100 inch (2.54 mm).
3. Corrosion damage to the threaded holes for the studs is permitted if the damage is not
more than the first thread. Refer to the BHT-ALL-SPM or CSSD-PSE-87-001 to do the repairs.
4. Corrosion or mechanical damage in area M can be repaired to a maximum of 0.005 inch
(0.127 mm) and must not go more than the first thread. The area to be repaired must not
be more than 20% of the total area of surface or diameter. The finish must be 64 RMS
with a minimum radius of 0.250 inch (6.35 mm).
5. The maximum permitted depth in the damaged surfaces G and N after you blend out
mechanical or corrosion damage is 0.010 inch (0.254 mm). No more than 40% of the area in
less than one square inch (645.2 mm²) or more than 20% of the total area of the surfaces
is permitted to be reworked. The finish must be 32 RMS with a minimum radius of
0.100 inch (2.54 mm).
6. The maximum permitted depth of non functional cast surfaces in damaged area after you
blend out mechanical or corrosion damage is 0.040 inch (1.02 mm). The finish must be
64 RMS with a minimum radius of 0.25 inch (6.35 mm).
7 Bearing liner looseness is not permitted.
8 Remove only the raised material around the scratches or damage that resulted from the
removal/installation of the bearing.
9 This bore gives a sealing surface for the cap packing. The dimension is given as a maximum
for a local clean up. Remove only a minimum quantity of material when you remove the
scratches and the fretting damage. Blend the damage to a minimum radius of 0.25 inch
(6.35 mm).
407MM_65_0112
65-00-00
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BHT-407-MM-7
65-66. TAIL ROTOR GEARBOX INSPECTION 65-70. Tail Rotor Gearbox Inspection Plug —
PLUG Installation
65-67. Tail Rotor Gearbox Inspection Plug —

Removal SPECIAL TOOLS REQUIRED
SPECIAL TOOLS REQUIRED NUMBER NOMENCLATURE
1 5/8 inch (41 mm) Wrench

NUMBER NOMENCLATURE
1 5/8 inch (41 mm) Wrench 1. Install the packing (28, Figure 65-40) on the
inspection plug (27) and install the inspection plug (27)
in the tail rotor gearbox (4).
NOTE
The removal of the inspection plug permits 2. Use 1 5/8 inch (41 mm) wrench and tighten the
you to monitor the condition of the input inspection plug (27) T .
pinion gear and the spiral bevel gear teeth.
65-71. TAIL ROTOR GEARBOX BREATHER AND
1. To prevent contamination, make sure the area BREATHER TUBE
around the inspection plug is clean. Refer to
BHT-ALL-SPM to do the cleaning.
65-72. Tail Rotor Gearbox Breather and Breather
Tube — Removal
2. Use a 1 5/8 inch (41 mm) wrench and remove the
inspection plug (27, Figure 65-40) and packing (28).
Discard the packing (28). 1. Remove the screw (30, Figure 65-40), the washer
(31), the clamp (32) and the spacer (33). Disconnect
the breather tube (15) from the breather (18).
3. Put a cap on the inspection hole to prevent
contamination.
2. Remove the breather (18) and the packing (29).
65-68. Tail Rotor Gearbox Inspection Plug — Discard the packing (29).
Cleaning
3. Put a cap on the breather hole to prevent
1. Refer to BHT-ALL-SPM and clean the tail rotor contamination.
gearbox.
65-69. Tail Rotor Gearbox Inspection Plug — Tube — Cleaning
Inspection
1. Do the inspection of the inspection plug

(Figure 65-46). MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean the breather (18, Figure 65-40) as follows:
a. Backflush the breather (18) with drycleaning

solvent (C-304). Use air pressure of 10 to 15 PSI.
65-00-00
7 NOV 2006 Rev. 23 Page 125
BHT-407-MM-7
A
A
REF INSPECTION
1. A Head/bore Corrosion/mechanical Maximum 0.020 inch (0.508 mm)

deep. The number of repairs is not
very important.
2. B Packing groove Corrosion/mechanical None permitted.
3. Threads One thread pitch, 1/3 thread deep,

length.
407MM_65_0113
Figure 65-46. Tail Rotor Gearbox Inspection Plug — Inspection
65-00-00
Page 126 Rev. 23 7 NOV 2006
BHT-407-MM-7
b. Dry the breather (18) with filtered compressed 4. Remove the self-closing valve (19) and packing
air at 10 to 15 PSI. (20). Discard the packing (20).
65-74. Tail Rotor Gearbox Breather and Breather 65-78. Chip Detector and Self-Closing Valve —
Tube — Inspection Cleaning
1. Do the inspection of the breather (Figure 65-47). 1. Refer to BHT-ALL-SPM and clean the chip
detector and the self-closing valve.
2. Make sure the breather tube (15, Figure 65-40) is
not blocked. 65-79. Chip Detector and Self-Closing Valve —
Inspection
Tube — Installation 1. Do the inspection of the chip detector and the
self-closing valve (Figure 65-48).
1. Remove the protective cap from the tail rotor
gearbox. 2. Refer to Chapter 96 for the electrical operation of
the chip detector.
2. Install the packing (29, Figure 65-40) on the
breather (18) and install the breather (18) T in the tail 65-80. Chip Detector and Self-Closing Valve —
rotor gearbox (4). Installation
3. Using the screw (30), the washer (31), the clamp

(32) and the spacer (33), install the breather tube (15) MATERIALS REQUIRED
to the tail rotor gearbox (4).
4. Connect the breather tube (15) to the breather NUMBER NOMENCLATURE

(18).
C-405 Lockwire
65-76. CHIP DETECTOR AND SELF-CLOSING
VALVE 1. Install the packing (20, Figure 65-40) on the
self-closing valve (19) and install the self-closing valve
65-77. Chip Detector and Self-Closing Valve — (19) T in the tail rotor gearbox (4). Safety the
Removal self-closing valve (19) to the tail rotor gearbox (4) with
lockwire (C-405).
1. Disconnect the connector 1E4P1 from the tail
rotor gearbox electric chip detector (16, Figure 65-40). 2. Install the packing (17) and the electric chip
detector (16) (Chapter 96).
2. Remove the electric chip detector (16) (Chapter
96) and packing (17) from the self-closing valve (19). 3. Connect the connector 1E4P1 to the electric chip
Discard the packing (17). detector (16) (Chapter 96).
3. Drain the tail rotor gearbox (4) (Chapter 12). 4. Service the tail rotor gearbox (4) (Chapter 12).
65-00-00
7 NOV 2006 Rev. 23 Page 127
BHT-407-MM-7
A
A
BREATHER (2B265)
REF INSPECTION
1. A Corrosion/mechanical Visual None permitted.
2. Threads Visual One thread pitch, 1/3 thread depth,

length.
3. B Corrosion/mechanical Measure 0.010 inch (0.254 mm) after repair.

4. Air flow No blockage permitted.
407CRO_65_0054
Figure 65-47. Breather — Inspection
65-00-00
Page 128 Rev. 23 7 NOV 2006
BHT-407-MM-7
B
A
C C
0.035 IN.
(0.889 mm)
SEE DETAIL D MIN.
B DETAIL D
REF INSPECTION

2. B Corrosion/mechanical Visual 0.005 inch (0.127 mm) after repair.
3. Thread Visual/measure One thread pitch, 1/3 thread depth,
0.25 inch (6.35 mm) maximum length.
4. Valve leak Visual None permitted.
5. Lock pins Visual/measure Minimum diameter 0.09 inch (2.29 mm).
6. C Corrosion/mechanical Visual None permitted.
NOTES
1. No corrosion on the internal surface of the self-closing valve is permitted.
2. The permanent magnet must lift a weight of 1.15 ±2% ounces (32.48 ±2% g).
3. Refer to Chapter 96, for the electrical verification of the chip detector.
4. Replace the chip detector assembly if the locking detent is damaged.
407MM_65_0114
Figure 65-48. Self-Closing Valve — Inspection
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7 NOV 2006 Rev. 23 Page 129
BHT-407-MM-7
65-81. TAIL ROTOR GEARBOX OIL SIGHT GLASS 65-85. Tail Rotor Gearbox Oil Sight Glass —
Installation
65-82. Tail Rotor Gearbox Oil Sight Glass —
Removal

NUMBER NOMENCLATURE
NUMBER NOMENCLATURE 1 5/8 inch (41 mm) Wrench
1 5/8 inch (41 mm) Wrench

1. Install a packing (6, Figure 65-40) on the oil sight
glass (5) and install the oil sight glass (5) in the tail
1. Drain the tail rotor gearbox (4, Figure 65-40) rotor gearbox (4). Use a 1 5/8 inch (41 mm) wrench
(Chapter 12). and tighten the oil sight glass (5) T .
2. Use a 1 5/8 inch (41 mm) wrench and remove the 2. Service the tail rotor gearbox (4) (Chapter 12).
oil sight glass (5) and packing (6). Discard the packing
(6). 65-86. TAIL ROTOR GEARBOX FILLER CAP
65-83. Tail Rotor Gearbox Oil Sight Glass — 65-87. Tail Rotor Gearbox Filler Cap — Removal
Cleaning
1. Refer to BHT-ALL-SPM and clean the oil sight SPECIAL TOOLS REQUIRED
glass.
65-84. Tail Rotor Gearbox Oil Sight Glass — NUMBER NOMENCLATURE

Inspection
T102103 Dehydrator
1. Condensation on the inside of the oil sight glass

is permitted if the oil does not have a dirty or milky 1. Open the pin (3, Figure 65-40) and remove the
appearance. pin (3) and chain (2) from the tail rotor gearbox (4).
2. If you think that the oil is contaminated with water, 2. Push the cap assembly (1) in the tail rotor
then drain, flush and service the tail rotor gearbox gearbox (4). Turn it counterclockwise and pull to
(Chapter 12). remove the cap assembly (1).
3. Examine the oil sight glass for leakage, cracks, 3. Remove and discard the packings (22 and 23).
crazing and discoloration. If any of these conditions
are present, the sight glass must be replaced.
4. Install a dehydrator T102103 in the filler cap hole
on the tail rotor gearbox (4).
4. Do the inspection of the oil sight glass
(Figure 65-49).
65-88. Tail Rotor Gearbox Filler Cap — Cleaning
5. When you look through the oil sight glass the oil 1. Refer to BHT-ALL-SPM and clean the filler cap.
will appear black. This is normal. The oil sight glass is
a prism and is designed to make the oil look black for
filling purposes. A black oil sight glass is a sign that 65-89. Tail Rotor Gearbox Filler Cap — Inspection
the tail rotor gearbox is overfilled. Service the tail rotor
gearbox Chapter 12. 1. Do the inspection of the filler cap (Figure 65-50).
65-00-00
Page 130 Rev. 23 7 NOV 2006
BHT-407-MM-7
SIGHTGLASS (PS51B)
REF INSPECTION
1. Glass cracks, crazing, Visual None permitted.

discoloration
2. Thread Visual/measure One inch pitch, 1/3 thread depth,

length.
4. B Corrosion/mechanical Visual 0.005 inch (0.127 mm) after repair.
407_CRO_65_0056
Figure 65-49. Oil Sight Glass — Inspection
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7 NOV 2006 Rev. 23 Page 131
BHT-407-MM-7
B A
FILLER CAP (412-040-318-103)
REF INSPECTION
1. A Mechanical Visual None permitted.
2. Crack Visual None permitted.
3. B Pin Measure Minimum diameter
0.055 inch (1.397 mm)
NOTE
1 Do not remove the screw. The screw, plug and cap are bonded. Damage will result if you remove the screw.
407_CRO_65_0053
Figure 65-50. Cap Assembly (Nonvented) — Inspection
65-00-00
Page 132 Rev. 23 7 NOV 2006
BHT-407-MM-7
2. Examine the tail rotor gearbox filler neck for 6. Install the jackscrews, T101308, in the threaded
leakage. If the filler neck has leakage, refer to the holes in the cap assembly (6).
BHT-407-CR&O manual for the replacement
procedures.
7. Heat the tail rotor gearbox housing (1). Do not
exceed 200°F (93°C).
65-90. Tail Rotor Gearbox Filler Cap — Installation
8. Apply equal pressure to each jackscrew to
1. Remove the dehydrator T102103 from the tail remove the cap assembly (6). Make sure the cap
rotor gearbox (4, Figure 65-40). assembly (6) stays straight as you turn each of the
jackscrews.
2. Install the packings (23 and 22) on the cap

assembly (1). 9. Remove the jackscrews, T101308.
3. Push the cap assembly (1) in the tail rotor 10. Remove and discard the packing (5).
gearbox (4) and turn it clockwise and pull. The cap
must lock. 11. Refer to paragraph 65-96 for the output seal (8)
replacement.
4. Safety the pin (3) to the chain (2) and to the tail
rotor gearbox (4). 65-93. Tail Rotor Gearbox Output Cap — Cleaning
65-91. TAIL ROTOR GEARBOX OUTPUT CAP 1. Refer to BHT-ALL-SPM to do the cleaning of the
output cap.
65-92. Tail Rotor Gearbox Output Cap — Removal

2. Using a plastic scraper, remove the sealing
compound from the cap assembly and the tail rotor
gearbox housing.
65-94. Tail Rotor Gearbox Output Cap —

NUMBER NOMENCLATURE Inspection
T101308 Jackscrew (3) 1. Examine all the visible parts of the output shaft (2,
Figure 65-51) and the attached gear for damage
(Figure 65-52).
1. Get access to the tail rotor gearbox (Chapter 53).
2. Examine the sleeve (7, Figure 65-51) for wear in

2. Remove the tail rotor hub and blades (Chapter the area touched by the output seal (8). Replace the
64). sleeve (7) if it has grooves more than 0.002 inch
(0.051 mm) or if it has nicks, dents or scratches. Refer
3. Drain the tail rotor gearbox (Chapter 12). to BHT-407-CR&O for the sleeve (7) replacement
procedure.
4. Remove the nut (9, Figure 65-51) and the

washers (10 and 11). 3. Examine the tail rotor gearbox housing (1) for
condition (Figure 65-45).
5. Using a plastic scraper, remove the sealant from

4. Examine the bearing (4, Figure 65-51) for
the mating line between the cap assembly (6) and the
freedom of movement, pitting and spalling.
tail rotor gearbox housing (1), and from the jackscrew
holes in the cap assembly (6). Remove plastic screws
from jackscrew holes. 5. Examine the cap assembly (6, Figure 65-53).
65-00-00
7 NOV 2006 Rev. 23 Page 133
BHT-407-MM-7
1
7
4
5
JACKSCREW THREADS 1 2
(3 PLACES) 11
10 8
9
JACKSCREW SET
T101308
407MM_65_0115
Figure 65-51. Tail Rotor Gearbox Output Cap — Removal/Installation (Sheet 1 of 2)
65-00-00
Page 134 Rev. 23 7 NOV 2006
BHT-407-MM-7
1. Tail rotor gearbox housing

2. Output shaft
3. Retaining ring
4. Bearing
5. Packing
6. Cap assembly
7. Sleeve
8. Output seal
9. Nut
10. Thin steel washer
11. Aluminum washer
50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)
NOTES
1 Remove plastic screws prior to inserting jackscrews.
2 Tighten jackscrews evenly.
407MM_65_0116
Figure 65-51. Tail Rotor Gearbox Output Cap — Removal/Installation (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 135
BHT-407-MM-7
THREADS N AREA K DIA. F AREA L 2 SPLINES H AREA L 1

DIA. D DIA. G SPLINES J
R
Q
SURFACE A THREADS M
DIA. E THREADS P SURFACE C
2 1 2
SURFACE B
OUTPUT SHAFT (406-040-416-101/407-040-416-101)

REF INSPECTION
1. A, B, C Fretting Visual/measure No detectable depth permitted.
Remove only the raised material, make
it smooth with area that surrounds.
Use a fine India stone.
2. D Journal wear Measure Minimum diameter 0.9848 inch

(25.0 mm).
3. E Gear seat wear Measure Minimum diameter 1.6880 inches 2

(42.9 mm).
4. F Journal wear Measure Minimum diameter 2.0013 inches 3

(50.8 mm).
5. G Wear sleeve seat Measure Minimum diameter 1.7485 inches 1 4

(44.4 mm).
6. H Spline wear Measure over Minimum diameter 1.3035 inches

0.060 inch (33.1 mm).
(1.52 mm)
diameter pins
7. J Spline wear Measure over Minimum diameter 1.0851 inches

0.060 inch (27.6 mm).
(1.52 mm)
diameter pins
8. K, L 2 Corrosion/mechanical Measure Maximum depth 0.005 inch

7
(0.127 mm).
9. H, J Corrosion/mechanical Measure Do not have more than 1/3 of one

spline and on not more than two 5
splines, with a maximum depth of
0.002 inch (0.051 mm).
10. L1 Wear Measure Minimum diameter 0.918 inch (23.32 mm).
407CRO_65_0030
Figure 65-52. Output Shaft — Inspection (Sheet 1 of 2)
65-00-00
Page 136 Rev. 23 7 NOV 2006
BHT-407-MM-7
REF INSPECTION
11. L1 Corrosion/mechanical Measure Maximum depth of corrosion 0.002 inch

(0.0508 mm). Blend all marks. Nicks not
exceeding 0.002 inch (0.0508 mm) in
depth. Minimum blend radius of 0.100
inch (2.54 mm).
12. M, N, P Thread damage Visual One thread pitch, 1/3 thread depth,
0.250 inch (6.35 mm) maximum length.
13. Q Corrosion in shaft Visual If the corrosion cannot be removed 6

inside diameter with stainless steel wool, discard
the shaft.
14. R Corrosion/mechanical Measure Maximum depth of damage 0.10 inch (2.54 mm)
and 25% of surface. Remove only raised
material around damage.
NOTES
1 The damage to the shaft journal must be outside the seal zone of the shaft lip. If the damage extends
into the lip seal zone, distortion of the wear sleeve can occur and cause leakage. The maximum damage
permitted outside the seal zone is: 0.100 inch (2.54 mm) long (along the shaft axis), 0.020 inch (0.508 mm)
wide and 0.005 inch (0.127 mm) deep (only one area of damage is permitted).
2 Remove the raised material from around the scratches or damaged area. Blend the scratches to a
0.050 inch (1.27 mm) radius to clean up the full depth to the minimum permitted dimension. The length
of the scratch can be across the full width of the pilot diameter. The width of the scratch after clean up
is 0.060 inch (1.52 mm) maximum. No more than two scratches in each quadrant in less than 0.30 inch
(7.62 mm) of each other, no rework in the adjacent quadrants or more than three reworks in each pilot
journal are permitted.
3 The dimension given is for reference only. No rework is permitted on the active bearing surface. The
output shaft inner race is an active bearing surface. The surface must not show radial or axial scratches
that can be felt with a probe that has an end radius of 0.020 inch (0.508 mm). Nicks or indentations on the
race lead in the chamfer can show damage to the rollers and/or the retainer of the roller bearing. This
damage to the inactive surface can be reworked to remove the raised material, but it is recommended
that you scrap the bearing if you find these signs.
4 The wear sleeve outside diameter must be smooth and unmarred, no rework of the wear sleeve is permitted.
5 Remove the step between the worn and unworn areas of the teeth with an India stone to make a smooth
change. Refer to the repair section for the procedure to apply the dry film lubricant.
6 Refer to the paint section for the procedure to apply the primer to the shaft inside diameter.
7 The minimum diameter for areas K and L ɑ is 0.005 inch (0.127 mm) less than the diameter measured in the
same cross section.
407CRO_65_0031
Figure 65-52. Output Shaft — Inspection (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 137
BHT-407-MM-7
AREA G
AREA E
AREA H
(5 PLACES)
AREA F
AREA D
A B C
AREA H
(REF)
H
I 0.238 IN.
(6.045 mm)
CAP ASSEMBLY (406-040-408-101)
MATERIAL: MAGNESIUM ALLOY
REF INSPECTION
1. A Pilot diameter Measure Minimum diameter 5.8755 inches

(149.24 mm).
2. B Bearing liner - Measure Maximum diameter 2.6771 inches 2
inner diameter (68.0 mm).
3. C Seal retainer - Measure Maximum 2.8775 inches (73.08 mm).

inner diameter
4. E, F Corrosion/mechanical Visual/measure Maximum 0.010 inch (0.254 mm). 3
5. D, G Corrosion/mechanical Visual/measure Maximum 0.030 inch (0.762 mm). 4

6. D, E, F, G, H Maximum area as in No more than 40% of the area of
full depth repair 1 square inch (645 mm²) or no more
than 20% of the total area of the
surface or diameter can be reworked.
7. H Corrosion/mechanical Visual/measure Maximum 0.030 inch (0.762 mm). 5
outside the washer
contact surface
8. I Corrosion/mechanical Measure Minimum inside diameter 0.295 inch

fastener bore (7.49 mm).
407CRO_65_0028
Figure 65-53. Cap Assembly — Inspection (Sheet 1 of 2)
65-00-00
Page 138 Rev. 23 7 NOV 2006
BHT-407-MM-7
NOTES
1 Replace the loose or damaged clinch nut.
2 Only the corrosion that can be removed with stainless steel wool is permitted. No
mechanical damage is permitted other than the scratches made from the removal/
installation of the bearing or bearing outer race fretting. Repair by removal of the raised
material around scratches or fretting mark. This dimension is given to find out how much
clean-up is necessary to remove such material. A loose bearing liner is cause for rejection.
3 The finish must be 64 RMS with a minimum blend radius of 0.250 inch (6.35 mm).
4 No damage is permitted in the packing groove of area G.
5 If damage is on the surface and touches the washer boss, you can machine it to
0.238 inch (6.045 mm) thickness.
407CRO_65_0029
Figure 65-53. Cap Assembly — Inspection (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 139
BHT-407-MM-7
65-95. Tail Rotor Gearbox Output Cap — 6. Install the aluminum washers (11), the thin steel
Installation washers (10), and nuts (9) T .
7. Apply a bead of sealant (C-308) to the mating line

MATERIALS REQUIRED of the tail rotor gearbox housing (1) and cap assembly
(6). Install the plastic screws in the jackscrew holes
Refer to BHT-ALL-SPM for specifications. and cover with sealant (C-308).
NUMBER NOMENCLATURE 8. Service the tail rotor gearbox (Chapter 12).
C-001 Grease 9. Install the tail rotor hub and blade (Chapter 64).
C-024 Assembly Fluid
10. Do an operational check (paragraph 65-2).
C-308 Sealant
11. Install the tail rotor gearbox fairing (Chapter 53).
C-328 Sealing Compound
65-96. TAIL ROTOR GEARBOX OUTPUT SEAL
1. Lubricate a new packing (5, Figure 65-51) with
assembly fluid (C-024). Install the packing (5) in the If you find more than permitted leakage at the tail rotor
groove on the inboard side of the cap assembly (6). gearbox output seal (8, Figure 65-51) (refer to
Table 65-3), replace the output seal (8). This
paragraph gives the procedures to remove and install
2. Apply a thin layer of Mobil 28 grease (C-001) to the tail rotor gearbox output seal (8).
the space between the pressure lip and the dust lip of
the output seal (8). 65-97. Tail Rotor Gearbox Output Seal — Removal
3. Apply a thin layer of sealing compound (C-328) to

the mating surface of the cap assembly (6). SPECIAL TOOLS REQUIRED
4. Heat the tail rotor gearbox housing (1). Do not NUMBER NOMENCLATURE
exceed 200°F (93°C).
Workaid, Figure 65-54
1. Remove the cap assembly (6, Figure 65-51)

CAUTION (paragraph 65-92).
2. Remove the output seal (2, Figure 65-54).

BE VERY CAREFUL NOT TO DAMAGE
THE OUTP UT SE AL ( 8) WH EN Y O U
INSTALL THE CAP ASSEMBLY (6).
CAUTION
5. Install the cap assembly (6) on the tail rotor
gearbox housing (1). The bolt pattern of the tail rotor
gearbox cap assembly (6) is keyed. The bolt holes will DO NOT DAMAGE THE BEARING (4,
align when the tail rotor gearbox cap assembly (6) is in FIGURE 65-51) WHILE REMOVING THE
the correct position. OUTPUT SEAL (8).
65-00-00
Page 140 Rev. 23 7 NOV 2006
BHT-407-MM-7
BRASS PUNCH
WORKAID 1.75 IN.

MATERIAL: ALUMINUM (44.45 mm)
+0.0 0.250 IN.

7.5 -0.6 IN.
(6.350 mm)
(190.5 +0.0 mm)
-15.2
OUTPUT SEAL REMOVAL
2.86 IN. 0.50 IN.

(72.64 mm) (12.7 mm)
WORKAID
1 1
INBD
OUTPUT SEAL INSTALLATION

1. Cap assembly
2. Output seal
SEALANT (C-328)
1
SEALANT (C-308)
2
NO OBJECT BEYOND THIS POINT 407MM_65_0117_c01
Figure 65-54. Output Seal — Removal/Installation
65-00-00
BHT-407-MM-7
65-98. Tail Rotor Gearbox Output Seal — 3. Carefully set the tail rotor gearbox output seal (2)
Installation on the cap assembly (1) with the face of the seal
outboard. Use the workaid and an arbor press to
install the tail rotor gearbox output seal (2) until it is
seated.
4. Remove the workaid and remove all the sealing

NUMBER NOMENCLATURE compound that was pushed out.
Output Seal
Replacement Workaid, 5. Apply a small bead of sealant (C-308) to the
Figure 65-54 mating surface of the output seal (2) and the cap
assembly (1).
6. Install the cap assembly (6, Figure 65-51)

MATERIALS REQUIRED (paragraph 65-95).

65-99. TAIL ROTOR GEARBOX INPUT SEAL
NUMBER NOMENCLATURE
The input seal will be a lip type of seal or a spring
C-308 Sealant loaded carbon seal. The carbon seal is made up of a
seal and mating ring which are a matched serialized
C-328 Sealing Compound
set. Install only as a matched serial number set. If
there is more than the permitted leakage, replace the
1. Apply a thin layer of sealing compound (C-328) to seal. Refer to Table 65-3 for allowable leak rate. The
the outer diameter of the output seal (8, Figure 65-51) following paragraphs give the procedures to remove,
and the mating surface on the cap assembly (6). inspect and replace the lip or spring carbon types of
tail rotor gearbox input seals.
2. Make a workaid as shown in Figure 65-54 to

65-100. Tail Rotor Gearbox Input Seal (All) —
install the output seal (2, Figure 65-54).
Removal
CAUTION SPECIAL TOOLS REQUIRED
DO NOT ADD PRESSURE TO THE TAIL NUMBER NOMENCLATURE

ROTOR OUTPUT SE AL W HEN IT IS
SEATED. IF YOU ADD PRESSURE TO T101308 Jackscrew
THE OUTPUT SEAL, YOU CAN
T101449 Spanner Wrench
COLLAPSE THE STEEL CAGE OF THE
OUTPUT SEAL. THIS WILL RELEASE T103216-101 Spanner Assembly
T HE S EA L LI P P RES S URE O N T HE
SLEEVE AND PERMIT LEAKAGE. T103219-101 Seal Driver
6 inch Long, 1/2 inch Extension

NOTE Drive
Because it is hard to control the force
applied to the tail rotor gearbox output seal,
1. Get access to the tail rotor gearbox (Chapter 53).
do not use a hydraulic press to install the
tail rotor gearbox output seal. Use an arbor
press. 2. Drain the tail rotor gearbox (Chapter 12).
65-00-00
Page 142 Rev. 23 7 NOV 2006
BHT-407-MM-7
NOTE
CAUTION
Support the aft end of the second most aft
tail rotor driveshaft segment to prevent
damage to the shaft or the tailboom. DO NOT CONTAMINATE DUPLEX
BEARING WITH LOOSE SEALANT
3. Remove the most aft tail rotor driveshaft segment PARTICLES.
(paragraph 65-48).
13. Use a plastic scraper and remove the sealant
from the tail rotor gearbox housing (21, Figure 65-55)
4. For S/N 53000 through 53292, Pre TB 407-99-18, and the nut (9) mating line.
remove the retainer (1, Figure 65-55) and the locking
washer (2). For S/N 53000 through 53292, Post TB 14. Remove the nut (9) with the spanner wrench,
407-99-18 and S/N 53293 and subsequent, remove T101449.
the lockspring (18).
15. Remove and discard the packing (10).
5. Install a jackscrew, T101308, into the plug (3 or
16. For S/N 53000 through S/N 53391, Pre TB
19). Carefully pull out the plug (3 or 19) by hand.
407-01-31, remove the carbon seal as follows:
6. Remove the jackscrew, T101308, from the plug a. Remove and discard the input seal mating
(3 or 19). ring (13).
b. Remove and discard the packing (14) from the

7. Remove and discard the packing (4). input pinion (15).
8. For S/N 53000 through 53292, Pre TB 407-99-18, c. Using the seal driver, T103219-101, (1,
Figure 65-56), press the input seal (3) from the nut (2).
remove the retaining ring (5).
d. Discard the input seal (3).
9. Install the spanner assembly, T103216-101, on
the input adapter (8, 16, or 20). This holds the adapter 17. For S/N 53000 through S/N 53391, Post TB
while you remove the nut (6). 407-01-31 or S/N 53392 and subsequent, remove the
lip seal as follows:
10. Put a 6 inch (152 mm) long, 1/2 inch (12.7 mm) a. Remove and discard packing (14) from input
drive extension into the nut (6). Remove the nut (6). pinion (15).
11. Remove the washer (7). b. Support nut (9) on blocks and press out seal
(Figure 65-58).
12. Remove the input adapter (8, 16, or 20). 65-101. Tail Rotor Gearbox Input Seal (All) —
Inspection and Repair
a. If input adapter (16 or 20) has a wear sleeve 1. Examine all of the visible parts of the input pinion
(17) which needs to be removed, refer to Figure 65-64. (15, Figure 65-55) for damage. Refer to Figure 65-9.
Carefully machine or cut a groove along length of wear
sleeve (1, Figure 65-64), without damaging the 2. Examine the nut (9, Figure 65-55). Refer to
adapter. Strike groove with a blunt chisel to break wear Figure 65-60.
sleeve (1) along groove. Remove wear sleeve (1).
Ensure adapter has not been damaged during 3. Examine the inner nut (6, Figure 65-55). Refer to
removal procedure. Figure 65-61.
65-00-00
7 NOV 2006 Rev. 23 Page 143
BHT-407-MM-7
21
5
13 6 15
3 14
12 6
11
10
9
2
6
1
5
1
4
3 17
2
1 16 3
7
6
1 17
20
2 4
4
19
18
407MM_65_0118
Figure 65-55. Tail Rotor Gearbox Input Components — Removal/Installation (Sheet 1 of 2)
65-00-00
Page 144 Rev. 23 7 NOV 2006
BHT-407-MM-7
1. Retainer 12. Carbon seal

2. Locking washer 13. Mating ring
3. Plug 14. Packing
4. Packing 15. Input pinion (Ref)
5. Retaining ring 16. Input adapter (407-040-440-101)
6. Nut 17. Wear sleeve
7. Washer 18. Lockspring
8. Input adapter (406-040-440-101) 19. Plug
9. Input duplex bearing nut 20. Input adapter (427-042-440-103)
10. Packing 21. Tail rotor gearbox housing (Ref)
11. Lip seal
80 TO 100 FT-LBS
1 (108 TO 136 Nm)
100 TO 150 FT-LBS
2 (136 TO 203 Nm)
NOTES
1 S/N 53000 through 53292, Pre TB 407-99-18.
2 S/N 53293 and subsequent or Post TB 407-99-18.
3 Post TB 407-01-31, Part 1. 5
4 S/N 53392 and subsequent or Post TB 407-01-31, Part II.
5 Carbon seal mating ring (13) is required as part of assembly

when lip seal is installed per TB 407-01-31 Part One.
6 Input seal (12) and mating ring (13) are a matched set.
The serial numbers on each must be the same.
407MM_65_0119
Figure 65-55. Tail Rotor Gearbox Input Components — Removal/Installation (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 145
BHT-407-MM-7
4. Examine the adapter (8, 16, or 20, Figure 65-55).

Refer to Figure 65-62. If lip type seal is used, examine
CAUTION
the wear sleeve (17, Figure 65-55) for condition.
Inspect surface of wear sleeve for nicks, scratches, or
wear that may contribute to seal damage or leakage.
NEVER TOUCH THE INPUT SEAL WITH
YOUR BARE HANDS. ALWAYS WEAR
5. Examine the plug (3 or 19, Figure 65-55). Refer LINT FREE GLOVES. THE ACID IN YOUR
to Figure 65-63. SKIN WILL DAMAGE THE INPUT SEAL
AND MAKE LEAK PATHS.
6. Examine the tail rotor gearbox housing (21,
Figure 65-55). Refer to Figure 65-45. DO NOT USE EXCESSIVE SOLVENT TO
CLEAN THE INPUT SEAL. THE SOLVENT
7. Remove all the old sealant from the tail rotor WILL DAMAGE THE INPUT SEAL.
gearbox housing (21, Figure 65-55), and the nut (9).
DO NOT SOAK THE INPUT SEAL IN
8. If carbon type seal is used, inspect in accordance SOLVENT OR IN OTHER CLEANING
with Figure 65-59. AGENT.
65-102. Tail Rotor Gearbox Carbon Type Input Seal HOLD THE SEAL VERY CAREFULLY.
— Installation TOO MUCH COMPRESSION OF THE
CARBON SEAL IN THE CUP WILL
DAMAGE THE SEAL AND THE SPRING
ELEMENT.
NOTE
NUMBER NOMENCLATURE
The carbon input seal (12, Figure 65-55)
T101449 Spanner Wrench and the input seal mating ring (13) are a
matched set. Do not change the seal or the
T103216-101 Spanner Assembly seal mating ring alone.
T101308 Jackscrew To prevent contamination of the input seal,

make sure your work area is clean. Cover
T103219-101 Seal Driver
your work area with a sheet of clean paper.
6 inch Long, 1/2 inch Extension Do not use waxed paper. The wax on the
Drive waxed paper will contaminate the input
seal.
Remove the input seal from the shipping

MATERIALS REQUIRED package only when you are ready to install
it in the nut.
1. Lightly wipe the input seal (12, Figure 65-55) and
NUMBER NOMENCLATURE the mating ring (13) with a clean, lint free cloth moist
with drycleaning solvent (C-304) to clean the corrosion
C-024 Assembly Fluid
preventive oil.
2. To permit smooth axial movement of the spring
C-308 Sealant loaded carbon steel in the cup, put a few drops of the
system lubricant in the gap between the carbon ring
C-328 Sealing Compound and the seal cup, put a lint free cloth over the seal and
lightly hand compress the seal into the cup a few times
C-405 Lockwire
to make sure the seal moves freely.
65-00-00
Page 146 Rev. 23 7 NOV 2006
BHT-407-MM-7
1 1
AFT
3
CROSS SECTION OF CARBON SEAL REMOVAL
1 1
AFT
2 2
1 3 2
CROSS SECTION OF CARBON SEAL INSTALLATION

CARBON INPUT SEAL REPLACEMENT
1. Seal driver (T103219-101)

2. Nut
3. Input seal
1 SEALANT (C-328)
2 SEALANT (C-308)
NOTES
1 Use an arbor press in conjunction with seal driver to remove and install carbon seal (3).
2 Heat the nut to 200°F (93°C) to ease installation of seal.
407MM_65_0120
Figure 65-56. Tail Rotor Gearbox Input Carbon Seal — Removal/Installation
65-00-00
7 NOV 2006 Rev. 23 Page 147
BHT-407-MM-7
WALL THICKNESS APPROXIMATELY

0.50 IN. (12.7 mm)
APPROXIMATELY
3.0 IN. (76.2 mm)
O.D. 2.230 ±0.010 IN.

(56.64 ±0.25 mm)
INPUT LIP SEAL REMOVAL WORKAID NO. 1

MATERIAL: ALUMINUM 2024 or 6061
NOTE
1 Vibroetch identify: "407 T/R GBX INPUT LIP SEAL REMOVAL WORKAID".
407MM_65_0121
Figure 65-57. Tail Rotor Gearbox Input Lip Seal — Workaids (Sheet 1 of 2)
65-00-00
Page 148 Rev. 23 7 NOV 2006
BHT-407-MM-7
WALL THICKNESS
0.25 IN. (6.35 mm)
3.0 IN.
(76.2 mm)
O.D. 2.420 ±0.010 IN.

(61.47 ±0.25 mm)
INPUT LIP SEAL INSTALLATION WORKAID NO. 2

MATERIAL: ALUMINUM 2024 or 6061
NOTE
1 Vibroetch identify: "407 T/R GBX INPUT SEAL INSTALLATION WORKAID".
407MM_65_0122
Figure 65-57. Tail Rotor Gearbox Input Lip Seal — Workaids (Sheet 2 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 149
BHT-407-MM-7
2
3
SECTION A-A
ARBOR PRESS
INSTALLATION WORKAID NO. 2

SEE FIGURE 65-57
A 1
A
2
1. Seal
2. Nut
3. Felt wiper
SEALANT (C-308)
407MM_65_0123
Figure 65-58. Tail Rotor Gearbox Input Lip Seal — Removal/Installation
65-00-00
Page 150 Rev. 23 7 NOV 2006
BHT-407-MM-7
SEAL CASE
G
I AREA L
AREA
F
GROOVE AREA M
G
I
A B
AREA
E AREA N
AREA D MATING RING

CARBON RING 3
AREA C
RUNNING
NOT PERMITTED FACE FOR
CARBON RING
AREA J
GROOVE
MINIMUM PERMITTED
SPACING IS EQUAL AREA K
TO DIMENSION H OUTSIDE CARBON
RING RUNNING
FACE
DIMENSION H
VIEW G-G VIEW I-I
CARBON SEAL (406-040-453-101)

407_CRO_65_0044
Figure 65-59. Carbon Seal — Inspection (Sheet 1 of 4)
65-00-00
7 NOV 2006 Rev. 23 Page 151
BHT-407-MM-7
REF INSPECTION
1. A Seal case outside Measure Minimum 2.4383 inches (61.9 mm). 4

diameter
2. D, E Scratches, nicks Measure Remove only raised material maximum
0.002 inch (0.051 mm). 4
3. C, D, E Corrosion Visual None permitted.
4. F Cracks, scratches Visual None permitted.
5. F Heat check Visual/measure No more than 0.010 inch (0.254 mm)

(surface crack) in length. Must not extend to the
edge. None permitted in the adjacent
quadrant. Two maximum.
6. F Pits Visual/measure Maximum 0.008 inch (0.203 mm)

diameter. One for each adjacent
quadrant, maximum four.
7. F Edge chip Visual/measure View G-G.
8. B Mate ring inside Measure Maximum 1.3798 inches (35.0 mm). 6

diameter
9. J Heat check, cracks, Visual None permitted.
scratches, chips and
nicks
10. J Coking Visual Must be removed. 7
11. J Porosity holes/pits Visual/measure Permitted if clean and has no

8
unwanted material.
12. K Porosity holes/pits Visual/measure Up to 0.020 inch (0.508 mm)

diameter, 0.016 inch (0.406 mm) in
depth. Must not be more than 1/4 of
the surface width. Must not
extend to within 0.070 inch
(1.778 mm) of the carbon ring
running surface and the inside
diameter edge.
13. K Scratches Visual Permitted if they do not extend into the

carbon ring running face.
14. K Chips Measure Less than 0.063 inch (1.60 mm) long
and 0.020 inch (0.508 mm) wide.
15. L Porosity holes/pits Measure Up to 0.020 inch (0.508 mm)

diameter and 0.020 inch (0.508 mm)
in depth. None allowed within
0.070 inch (1.778 mm) of
all edges.
407CRO_65_0045
65-00-00
Page 152 Rev. 23 7 NOV 2006
BHT-407-MM-7
REF INSPECTION
16. L Chips Measure Up to 0.0625 inch (1.588 mm)

long and 0.016 inch
(0.406 mm) wide.
17. L Scratches Visual Remove only raised material.
18. L Crack Visual None permitted.
19. M Galling Visual The surface can be lapped (to remove

raised material only) on a flat surface
plate with a 600 grit aluminum oxide
paper.
20. M Crack Visual None permitted.

21. N Burr/crack Visual None permitted.
22. N Porosity holes/pits Visual/measure Up to 0.006 inch (0.152 mm) in diameter.
Must not be more than 1/4 of way across
surface. Must not extend to within
0.070 inch (1.778 mm) of all edges.
23. N Edge chip Visual/measure Up to 0.031 inch (0.787 mm) long

and 0.016 inch (0.406 mm) wide.
NOTES
1. Refer to the installation procedures for the handling instructions of the spring loaded
carbon seal.
2. Use a high intensity light to examine the carbon ring and the mating ring.
3. The carbon ring must return to the original position without sticking and binding after the
spring is lightly compressed. If it does not, lubricate the packing through the groove, then
lightly compress the carbon ring until it moves freely. If the seal still binds, discard it.
4 The seal case outside dimension is given to be applied to the local polish and rework of
scratches to area C. If the seal case outside diameter is measured in two places that
were not reworked and it is out of round by 0.002 inch (0.051 mm) or more, the seal is
distorted and must be discarded. If you measure the seal case in two places, one in a
reworked area and one in a non-reworked area, and you find it is out of round by 0.0025 inch
(0.064 mm) or more, the seal is distorted and must be discarded.
5 CHIP LIMITS:
NUMBER MAXIMUM LENGTH OF CHIP MAXIMUM PROTRUSION IN TO THE SEAL SURFACE

OF CHIPS
One maximum 0.050 inch (1.270 mm) 0.016 inch (0.406 mm) seal face width.
Three maximum 0.050 inch (1.270 mm) 0.008 inch (0.203 mm) seal face width.
More than four 0.050 inch (1.270 mm) 0.004 inch (0.102 mm) seal face width.
407MM_65_0010
65-00-00
7 NOV 2006 Rev. 23 Page 153
BHT-407-MM-7
NOTES (Cont'd)
6 The seal runner inside diameter maximum dimension is given to permit local cleanup or
polishing of the scratches, fretting and galling damage that resulted from the removal/
installation procedures. To repair and to find the maximum dimension, take measurements
across the unworn/undamaged areas and compare them to the measurement in the
adjacent area.
7 Remove the accumulation of the coking with a surface plate and 4/0 emery polishing
paper. Apply a light pressure when you lap the contact face. Do not lap the scratches.
8 POROSITY HOLES AND PITS LIMITS:
SIZE NUMBER SPACING

Up to 0.010 inch Two for each 1 inch (25.4 mm) 0.0625 inch (1.59 mm) apart minimum.
(0.254 mm)
maximum diameter
Up to 0.006 inch Three for each 1 inch (25.4 mm) 0.0625 inch (1.59 mm) apart minimum.
(0.152 mm)
maximum diameter
407CRO_65_0047
65-00-00
Page 154 Rev. 23 7 NOV 2006
BHT-407-MM-7
SURFACE E
AREA D
AREA C
AREA B
INPUT DUPLEX BEARING NUT (406-040-445)

MATERIAL: ALUMINUM ALLOY GROOVE G THREAD F
SECTION A-A
REF INSPECTION
1. F Damaged threads Visual None permitted. Examine for burrs or

galled metal in threads.
2. Broken tangs Visual None permitted.
3. Tool damage to Measure Maximum 0.020 inch (0.508 mm).

corner of slot
4. A Seal bore Measure Maximum 2.4360 inches (61.9 mm).
5. E Galling Measure Maximum 0.002 inch (0.051 mm). 1
6. Nicks, scratches and Measure Maximum 0.005 inch (0.127 mm).

sharp dents None permitted on surface E, threads
F or groove G.
7. B, C Corrosion/mechanical Measure Maximum 0.005 inch (0.127 mm).
8. D, E, F, G Corrosion/mechanical Visual None permitted.

9. Maximum area as in No more than 40% of the area of
full depth repair 1 square inch (645 mm²) or no more
than 20% of the total area of the surface
or diameter can be reworked.
10. H Wear Measure Minimum 0.090 inch (2.29 mm).
NOTE
1 Remove the raised material. Make it smooth with the original surface. Use a fine India stone
or 400 grit aluminum oxide paper and a flat surface plate. 407_CRO_65_0041
Figure 65-60. Input Duplex Bearing Nut — Inspection
65-00-00
7 NOV 2006 Rev. 23 Page 155
BHT-407-MM-7
AREA A
A D
AREA B
SURFACE C
SECTION A-A
INPUT ADAPTER NUT (406-040-443)

REF INSPECTION
1. Damaged threads Visual None permitted. No burrs or galled

metal in threads.
2. D Tool damage Measure Flat to flat 0.533 inch (13.5 mm)
0.020 inch (0.508 mm) depth.
3. Cracks NDI None permitted.
4. Nicks, scratches, and Measure Maximum 0.005 inch (0.127 mm).

sharp dents None permitted on surface C or
threads.
5. A Corrosion Measure Maximum 0.005 inch (0.127 mm).
6. B Corrosion Measure None permitted.
7. C Galling Measure Maximum 0.002 inch (0.051 mm). 1
8. Maximum area of No more than 40% of the area of

full depth repair 1 square inch (645 mm²) or no
more than 20% of the total area of
the surface or diameter can be
reworked.
9. F Total indicated runout Measure the Maximum 0.002 inch (0.051 mm).
(TIR) "V" block
mounted on
surface G
NOTE
1 Remove the raised material. Make it smooth with the original surface. Use a fine India stone or 400 grit
aluminum oxide paper and a surface plate.
407MM_65_0040
Figure 65-61. Input Adapter Nut — Inspection
65-00-00
Page 156 Rev. 23 7 NOV 2006
BHT-407-MM-7
SURFACE F SURFACE F
AREA SURFACE G AREA SURFACE G

C B C B
2 PLACES 2 PLACES
A A
D D
1
E E
INPUT ADAPTER (407-040-440) INPUT ADAPTER (406-040-440)

MATERIAL: CRES STEEL MATERIAL: CRES STEEL
REF INPSECTION
1. A Spline wear Measure between Minimum 1.100 inches (27.9 mm).

0.180 inch (4.57 mm)
diameter pins

4. C Hole diameter Measure Maximum 0.3150 inch (8.0 mm).
5. E Fretting Measure Maximum 0.002 inch (0.051 mm)
on surface E.
6. B Corrosion/mechanical Visual/measure Maximum 0.005 inch (0.127 mm).
7. Maximum area in No more than 40% of area in

each full depth repair less than 1 square inch (645 mm²).
or more than 20% of total area
of surface or diameter to be
reworked.
8. F Total indicated runout Rotate with surface Maximum 0.002 inch (0.051 mm).
(TIR) G on "V" block.
Measure surface F
9. A, D, E Corrosion/mechanical Visual/measure None permitted.
NOTE
1 Wear sleeve 427-342-415-101 not shown.
407MM_65_0032
Figure 65-62. Input Adapter — Inspection (Sheet 1 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 157
BHT-407-MM-7
SURFACE
G
A
SURFACE
AREA H
D C
2 PLACES
B
A
E
1
F
SECTION A-A
INPUT ADAPTER (427-042-440)

REF INPSECTION
1. B Spline wear Measure between Minimum 1.10 inches (27.94 mm).

0.180 inch (4.57 mm)
diameter pins
4. D Hole diameter Measure Maximum 0.3150 inch (8.0010 mm).

5. G Fretting Measure Maximum 0.002 inch (0.051 mm)
on surface G.
6. C Corrosion/mechanical Visual/measure Maximum 0.005 inch (0.127 mm).
7. Maximum area in No more than 40% of area in less
each full depth repair than 1 square inch (645 mm²)
or more than 20% of total area of
surface or diameter to be reworked.
8. G, H Total indicated runout Rotate with surface Maximum 0.002 inch (0.051 mm).
(TIR) H on "V" block.
Measure surface G
9. B, E, F Corrosion/mechanical Visual/measure None permitted.
NOTE
1 Wear sleeve 427-342-415-101 not shown.
407MM_65_0017
Figure 65-62. Input Adapter — Inspection (Sheet 2 of 2)
65-00-00
Page 158 Rev. 23 7 NOV 2006
BHT-407-MM-7
B
C
INPUT ADAPTER PLUG (406-040-442)
A
C B
INPUT ADAPTER PLUG (407-040-442)

REF INSPECTION
1. A Outside diameter Measure Minimum 1.4945 inches (38.0 mm).

2. B Nut mating flats Measure Minimum 0.483 inch (12.3 mm).
3. A, B, C Nicks, dents and Visual/measure Maximum 0.010 inch (0.254 mm).

scratches None permitted in groove C.
4. A, B, C Corrosion Visual/measure Maximum 0.005 inch (0.127 mm).

None permitted in groove C.
5. A, B Maximum area in No more than 40% of the area of
each full depth repair 1 square inch (645 mm²) or no more
than 20% of the total area of the
surface or diameter to be reworked.
407CRO_65_0039
Figure 65-63. Plug — Inspection
65-00-00
7 NOV 2006 Rev. 23 Page 159
BHT-407-MM-7
3. Apply a thin layer of sealing compound (C-328) to 9. Install the input seal mating ring (13) on the tail
the outer circumference of the input seal (3, rotor gearbox input pinion (15).
Figure 65-56).
10. Lubricate a new packing (10) with assembly fluid
(C-024) and install it on the nut (9).
CAUTION
11. Apply a layer of system lubricant to the faces of
the input seal (12) and the mating ring (13).
DO NOT TOUCH THE SEAL FACES WITH
THE SEAL DRIVER T103219-101, OR
WITH ANY OTHER OBJECT.
CAUTION
NOTE
BE VERY CAREFUL NOT TO DAMAGE
Heat the nut (2) to 200°F (93°C) if possible,
THE INPUT SEAL (12) WHEN YOU
to help with the installation.
INSTALL THE NUT (9).
4. Put the input seal (3, Figure 65-56) in the nut (2). 12. Make sure there is no dust on the input seal (12)
Make sure the seal face is as shown in Figure 65-56, and the mating ring (13). Install the nut (9) on the tail
seal installation. rotor gearbox housing (21), and tighten with the
spanner wrench T101449 T .
CAUTION 13. Safety the nut (9) to the tail rotor gearbox housing
(21) with lockwire (C-405) in two locations.
NEVER TRY TO HIT THE SEAL TO SEAT 14. Apply a bead of sealant (C-308) to the mating line
IT IN PLACE. USE THE SEAL DRIVER of the nut (9) and the tail rotor gearbox housing (21).
T103219-101 TO SEAT THE SEAL.
15. Install the input adapter (8 or 16).
NOTE
Because it is hard to control the force 16. Install the washer (7).
applied to the seal, do not use a hydraulic
press to install the tail rotor gearbox output 17. Attach the spanner assembly T103216-101 to the
seal. Use an arbor press. input adapter (8 or 16).
5. Push the seal evenly in position with the seal 18. Using a 6 inch (152 mm) long 1/2 inch (12.7 mm)
driver T103219-101. Examine the input seal (3, drive extension, install the nut (6) T . Use the
Figure 65-56) and the nut (2) to make sure the seal is spanner assembly to hold the input adapter (8 or 16)
correctly seated and is not distorted. while torquing the nut (6).
6. Use a plastic scraper and remove the sealing 19. Remove the spanner assembly T103216-101 and
compound that was pushed out. the 6 inch (152 mm) long, 1/2 inch (12.7 mm) drive
extension from the input adapter (8 or 16).
7. Apply a small bead of sealant (C-308) to the
mating line of the input seal (3) and the nut (2). Refer 20. For S/N 53000 through 53292, Pre TB 407-99-18,
to Figure 65-56 to locate the sealant. install the retaining ring (5).
8. Lubricate a new packing (14, Figure 65-55) with 21. Lubricate a new packing (4) with assembly fluid
assembly fluid (C-024). Install it in the groove on the (C-024) and install the packing (4) in the groove on the
tail rotor gearbox input pinion (15). plug (3 or 19).
65-00-00
Page 160 Rev. 23 7 NOV 2006
BHT-407-MM-7
22. Using a jackscrew, T101308, install the plug (3 or SPECIAL TOOLS REQUIRED (Cont)
19). Make sure the plug end is correctly engaged in
the nut (6).
NUMBER NOMENCLATURE
23. Remove the jackscrew from the plug (3 or 19). Workaid No. 2 Lip Seal Installation
Figure 65-57 Workaid
NOTE 6 Inch Long, 1/2 Inch Extension

Drive
For S/N 53000 through 53292, Pre TB
407-99-18, if the locking washer (2) will not
engage the plug (3) or the input adapter (8),
remove the plug (3), turn it 1/4 turn and MATERIALS REQUIRED
reinstall. Post TB 407-99-18 and S/N 53293
and subsequent, if the lockspring (18) will Refer to BHT-ALL-SPM for specifications.
not engage the plug (19) and input adapter
NUMBER NOMENCLATURE
(16 or 20), remove the plug (19), turn it 1/4
turn and reinstall. C-024 Assembly Fluid
24. For S/N 53000 through 53292, Pre TB 407-99-18, C-304 Drycleaning Solvent
install the locking washer (2) and the retainer (1). For
Post TB 407-99-18 and S/N 53293 and subsequent, C-308 Sealant
install the lockspring (18).
C-405 Lockwire
25. Service the tail rotor gearbox (Chapter 12).

NOTE
26. Install the aft tail rotor driveshaft segment Gearbox 406-040-400-115 must be
assembly (paragraph 65-53). modified to a 406-040-400-117 FM as per
TB 407-99-18 (DISK PACK COUPLING
407-340-340-101 INTRODUCTION OF)
27. Install the tail rotor gearbox fairing (Chapter 53). before you can install the lip type seal.
28. Do an operational check (paragraph 65-2). For first time installation of lip type seal on
S/N 53000 through 53391 comply with TB
407-01-31.
65-103. Tail Rotor Gearbox Lip Type Input Seal —
Installation Two different adapters can be used on the
lip seal configuration. They both require the
use of a wear sleeve.
1. Assemble the 407-040-440-101 adapter with the
wear sleeve as follows:
NUMBER NOMENCLATURE
a. Clean adapter (2, Figure 65-64) and wear
T101308 Jackscrew
sleeve (1) with drycleaning solvent (C-304).
T101449 Spanner Wrench
b. Apply a small bead of sealant (C-308) on the
T103216-101 Spanner Assembly wear sleeve (1) journal surface and on the adapter (2).
Workaid No. 1 Wear Sleeve

c. Apply heat to the sleeve (1). Heat to 200°F
Figure 65-63 Installation Workaid
(93°C).
65-00-00
7 NOV 2006 Rev. 23 Page 161
BHT-407-MM-7
d. Use an arbor press and a pressing plate d. Apply a small bead of sealant (C-308) to the
workaid No. 1, Figure 65-65 to install the wear sleeve mating line of seal (1) and the nut (2).
(1, Figure 65-64) flush to within 0.010 (0.254 mm) from
the end of adapter (2). 4. Install nut (9, Figure 65-55) and 407-040-440-101
adapter (16) onto the tail rotor gearbox as follows:
e. Remove any excess adhesive from adapter
(2).
NOTE
2. Assemble the 427-042-440-103 adapter with the
wear sleeve as follows: Ensure that the wear sleeve is installed on
the adapter.
a. Clean the adapter, 427-042-440-103 (2) and
the wear sleeve (1) with drycleaning solvent (C-304). a. Install packing (14) and carbon seal mating
ring (13) on the input pinion (15) with the larger
b. Apply a small bead of sealant (C-308) on the diameter of the seal mating ring (13) facing outboard
wear sleeve (1) journal surface and on the end of the toward the pinion (15) splines.
adapter (2).
b. Install the nut (9) with the new packing (10)
c. Apply heat to the sleeve (31). Heat to 200°F onto the tail rotor gearbox housing (21), and tighten
(93°C). with spanner wrench T101449 T .
d. Use an arbor press and workaid No. 2 c. Safety the nut (9) to the tail rotor gearbox
(Figure 65-65) to install the wear sleeve (1, housing (21) with lockwire (C-405) in two locations.
Figure 65-64) on adapter (2). Press the wear sleeve
(1) until it touches the step in adapter (2).
d. Apply a bead of sealant (C-308) to the mating
e. Remove any excess adhesive from adapter line of the nut (9) and the tail rotor gearbox housing
(2). (21).
3. Assemble the input adapter nut (2, Figure 65-58) e. Remove the seal shipping mandrel.
with the lip seal (1) as follows:
f. Lubricate the seal lips (11) and adapter (16)
with gearbox oil.
NOTE
Do not use a hydraulic press to install the
g. Install the adapter (16), washer (7) and nut
seal. Use an arbor press. Excessive
(6).
pressure can deform the seal case, distort
the sealing lip, and cause leakage to occur.
h. Attach spanner assembly T103216-101 to the
Keep the shipping mandrel installed on the input adapter (16).
seal (1) until you are prepared for the
immediate installation of the input adapter. i. Using a 6 inch (152 mm) long, 1/2 inch drive
extension, install nut (6) T . Use the spanner
a. Clean the nut (2) with drycleaning solvent assembly to hold the adapter (16) while torquing the
(C-304). nut (6).
b. Temporarily remove the shipping mandrel
from the seal (1) before pressing it in the nut (2). j. Remove the spanner assembly T103216-101
Reinstall the shipping mandrel after the seal (1) is and the 6 inch (152 mm) long 1/2 inch drive extension
pressed into the nut. from the input adapter (16).
c. Use workaid No. 2 (Figure 65-57) to press k. Lubricate a new packing (4) with assembly
seal (1, Figure 65-58) into nut (2). Install seal until fluid (C-024) and install into the groove of the plug
contact is made with internal shoulder of nut (2). (19).
65-00-00
Page 162 Rev. 23 7 NOV 2006
BHT-407-MM-7
SECTION A-A
A
ARBOR PRESS
OR
A
2
WORKAID NO. 2
REF FIGURE 65-65
1
WORKAID NO. 1
1
REF FIGURE 65-65
407MM_65_0124
Figure 65-64. Tail Rotor Gearbox Input Adapter/Wear Sleeve — Installation/Removal (Sheet 1 of 2)
65-00-00
7 NOV 2006 Rev. 23 Page 163
BHT-407-MM-7
VIBRATING STYLUS OR EQUIVALENT
4 BLUNT CHISEL
1. Wear sleeve
2. Input adapter
HEAT APPLICATION WITH A HEAT GUN

OR A HEAT LAMP (200°F/93°C MAX)
SEALANT (C-308)
NOTES
1 Use flat plate workaid (No. 1, Figure 65-65) for installation of wear sleeve on adapter
407-040-440-101. Install wear sleeve flush to within 0.010 inch (0.254 mm) from end of
adapter.
2 Use wear sleeve installation workaid (No. 2, Figure 65-65) for installation of wear sleeve on
adapter 427-342-412-101. Install wear sleeve until contact is made with step in adapter.
WEAR SLEEVE REMOVAL:
3 Mark a groove with a vibrating stylus or equivalent tool.
4 Strike with a blunt chisel.
5. If shaft is damaged during the removal of the wear sleeve, refer to the inspection figure
of the output shaft for limitation.
407MM_65_0125
Figure 65-64. Tail Rotor Gearbox Input Adapter/Wear Sleeve — Installation/Removal (Sheet 2 of 2)
65-00-00
Page 164 Rev. 23 7 NOV 2006
BHT-407-MM-7
2.00 IN.
(50.8 mm)
0.5 IN.
(12.7 mm)
WORKAID ITEM NO. 1

MATERIAL: ALUMINUM
A
I.D. 1.762 IN.
(44.75 mm)
2.00 IN.
(50.8 mm)
0.5 IN.
(12.7 mm)
WORKAID ITEM NO. 2 I.D. 1.630 TO 1.635 IN.

MATERIAL: ALUMINUM (41.40 TO 41.53 mm)
O.D.: 2.000 IN. (50.8 mm)
SECTION A-A
I.D.: 1.620 IN. (41.150 mm)
NOTE
1 Vibroetch identify: "407 T/R GBX INPUT WEAR SLEEVE INSTALLATION WORKAID NO. 1 OR NO. 2".
407MM_65_0126
Figure 65-65. Tail Rotor Gearbox Input Seal — Installation Workaid
65-00-00
7 NOV 2006 Rev. 23 Page 165
BHT-407-MM-7
l. Thread jackscrew, T101308 into plug (19). (15). If this occurs, apply heat (200°F/93°C)
Install plug (19) into adapter (16) so that at least one to adapter (20) before installation.
locking hole in the plug (19) aligns with at least one
locking hole in the adapter (16).
g. Install adapter (20), washer (7) and nut (6).
NOTE h. Attach spanner assembly T103216-101 to the

input adapter (20).
If the lockspring (18) will not engage the
plug (19) and the adapter (16), remove the
plug (19), turn it 1/4 turn, reinstall and i. Using a 6 inch (152 mm) long, 1/2 inch drive
check for engagement. Repeat until results extension, install nut (6) T . Use the spanner
are achieved. assembly to hold the adapter (20) while torquing the
nut (6).
m. Install lockspring (18) so that it engages the
plug (19) and the adapter (16) through the locking
j. Remove the spanner assembly T103216-101
holes.
and the 6 inch (152 mm) long, 1/2 inch drive extension
from the input adapter (20).
5. Install nut (9, Figure 65-55) and 427-042-440-103
adapter (20) onto the rotor gearbox as follows:
k. Lubricate a new packing (4) with assembly
fluid (C-024) and install into the groove of the plug
NOTE (19).
Ensure that the wear sleeve (17) is installed
on the adapter (20) and the seal mating l. Thread jackscrew, T101308, into plug (19).
ring (13) and the packing (14) are removed Install plug (19) into adapter (20) so that at least one
from the gearbox. locking hole in the plug (19) aligns with at least one
locking hole in the adapter (20).
a. Install new packing (14) on input pinion (15).
NOTE
b. Install nut (9) with the new packing (10) onto
the tail rotor gearbox housing (21) and tighten with If the lockspring (18) will not engage the
spanner wrench T101449 T . plug (19) and the adapter (20), remove the
plug (19), turn it 1/4 turn, reinstall and
c. Safety the nut (9) to the tail rotor gearbox check for engagement. Repeat until results
housing (21) with lockwire (C-405) in two locations. are achieved.
d. Apply a bead of sealant (C-308) to the mating m. Install lockspring (18) so that it engages the
line of the nut (9) and the tail rotor gearbox housing plug (19) and the adapter (20) through the locking
(21). holes.
e. Remove the seal shipping mandrel. 6. Service the tail rotor gearbox (Chapter 12).
f. Lubricate the seal lips (11) and adapter (20) 7. Install the aft tail rotor driveshaft segment
with gearbox oil. assembly (paragraph 65-53).
NOTE 8. Install the tail rotor gearbox fairing (Chapter 53).
A new adapter (20) with wear sleeve (17)

may fit tight over the pinion input splines 9. Do an operational check (paragraph 65-2).
65-00-00
Page 166 Rev. 23 7 NOV 2006

407-MM-Chapter 65 - Tail Rotor Drive System

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BHT-407-MM-7

CHAPTER 65 — TAIL ROTOR DRIVE SYSTEM

Paragraph Chapter/Section Page

TAIL ROTOR DRIVE SYSTEM

65-1 Tail Rotor Drive .............................................................................. 65-00-00 7

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

65-39 Oil Cooler Blower Shaft — Alignment ............................... 65-00-00 76

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

65-76 Chip Detector and Self-Closing Valve ...................................... 65-00-00 127

65-1 Tail Rotor Drive System ...................................................................................... 8

65-12 Coupling Disc Packs — Inspection and Repair .................................................. 40

65-60 Input Duplex Bearing Nut — Inspection.............................................................. 155

65-1 Non-Destructive Test —Tail Rotor Drive............................................................. 20

TAIL ROTOR DRIVE SYSTEM

1. Forward short shaft

Figure 65-1. Tail Rotor Drive System

The operational check procedure makes sure the tail

When you do troubleshooting on an unserviceable • If an unusual vibration originates from forward

These paragraphs give the instructions for:

2. The tail rotor gearbox torque check (Special

3. The examination of the condition identified in

a. Unusual vibrations. • overspeed

b. Tail rotor driveshaft hanger bearings that are • overtorque

THE VIBRATION ORIGINATES

CHECK FOR LOOSE BOLTS

INSTALL SERVICEABLE CHECK THE COUPLING DISC

CHECK SPLINED ADAPTER,

GAPS IN THE DISC PACK

INSTALL SERVICEABLE CHECK THE SHAFT

Figure 65-2. Tail Rotor Drive System — Trouble No. 1

EXAMINE THE IMPELLER FOR

CLEAN THE IMPELLER OR CHECK FOR LOOSENESS

REPLACE THE DAMAGED PARTS CHECK THE BEARINGS FOR

INSTALL A SERVICEABLE CHECK THE OIL COOLER

ALIGN OIL COOLER CHECK BALANCE OF

Figure 65-3. Tail Rotor Drive System — Trouble No. 2

Figure 65-4. Tail Rotor Drive System — Trouble No. 3

CHECK CHIP DETECTOR

SEND GEARBOX TO AN CHECK THE TAIL ROTOR GEARBOX

IF NO DAMAGE IS EVIDENT MEASURE MOVEMENT OF THE

Figure 65-5. Tail Rotor Drive System — Trouble No. 4

TAIL ROTOR GEARBOX CHIP

CHECK THE CHIP DETECTOR

REFER TO TROUBLE NO. 7. REFER TO CHAPTER 96

Figure 65-6. Tail Rotor Drive System — Trouble No. 5

OIL LEAK IN TAIL ROTOR

CHECK THE TAIL ROTOR

REFER TO THE LEAKAGE TABLE EXAMINE THE FOLLOWING

REPLACE THE UNSERVICEABLE CHECK THE TAIL ROTOR

SEND THE TAIL ROTOR

Figure 65-7. Tail Rotor Drive System — Trouble No. 6

TAIL ROTOR GEARBOX

CHIP LIGHT ON.

REFER TO THE UNWANTED

Figure 65-8. Tail Rotor Drive System — Trouble No. 7

1. Apply the minimum torque required for the

a. Examine the tail rotor gearbox studs, dowel C-355 Detergent