LIS:CLr~I:I Lycomlng M AN DATO RY

Reciprocating Engine Divisionl

Subsidiary of Textron Inc.
652 Oliver Street
SERVICE BULLETIN
Williamsport,PA 17701 U.S.A.

DATE: August 18, 1993 Service Bulletiri No. 439A

(Supersedes Service Bulletin No. 439)
Engineering Aspects are
FAA Approved

SUBJECT: Inspection of Connecting Rods for Fretting and/or Galling and Repair of
Fretting.

MODELS AFFECTED: All Textron Lycoming aircraft engines.

TIME OF COMPLIANCE: During inspection and regrinding of connection rods at overhaul.

The following procedure pertains to inspecting and insert shown in Figure 2 represents a typical case of
grinding the cI-ankpin bearing bsre of all connecting rods galling; while the connecting rod bearing bore shown
listed in the charts of this publication, .010 inch over is an example of severe galling and indicative of immi-
size; for the use of oversize bearings. Conclusive results nent failure of the connecting rod.
in the field have dictated that all connecting rods may
be reworked providing there is no fretting on the rod The seriousness of
galling is illustrated in Figure 3.
and cap faces and/or galling in the critical areas. In ad- This picture was made from an unretouched photo-
dition to the usual dimensional inspection procedures micrograph of an unetched section of metal removed
performed on connecting rods during overhaul, it is from a cracked connecting rod. The gall mark that caus-
necessary to make a very thorough visual check for ed the crack can be seen on the magnified view of the
fretting and galling. bearing surface.

Fretting occurs between the connecting rod parting Inspection for galling must be accomplished on all
´•face and cap face due to motion between the mating connecting rods during overhaul. The rods and bear-
surfaces. See Figure i. If this condition exists, the con- ing inserts must be thoroughly clean and examination
necting rod must be scrapped. During manufacturing, carried out with the aid of a 6 power magnifying glass
the contact faces of the rod and cap are ground very (minimum) or bench microscope. Do not mistake stains
precisely. Fretting on this surface can induce bending or discolo~-ation for galling’; surface blemishes are easily

in the bolt which could result in failure of the bolt and/or removed with a fine abrasive cloth, chemical cleaner
the connecting rod. or steel wool while galling cannot be removed. Galling
is a distortion in the metal and is compar~able to corro-
Galling, as shown in
Figure 2, is caused by a move- sion in the manner in which it weakens the metallic

ment between the surfaces of the bearing insert and structure of the connecting rod. When magnified, gall
the connecting rod
during periods loading
of high such marks will have a surface appearance similar to the
as is
produced during overspeed or excessive manifold magnified view in Figure 3. However, the spots vary
pressure operation. The visual evidence produced by in size and shape some have been found as small as

galling appears as if particles of metal from one con- pin heads; while in shape, they vary from circular or

tacting surface had welded to the other. The bearing oval to thin, rodlike marks.

General Aviation
Manufachners Association 1 of 6
Page
 Service Bulletin No. 4~39A

FRETTING IN THIS AREA

IS REASON FOR REJECTION

Figure i. Connecting Rod and Cap Showing Damage by Fretting

It has been found that the location of galling determines I-beam of the rod. Do not scrap a rod because of galling that
if the rod is
or is not likely to fail. Galling marks in the bear- is confined to this area; but also do not reuse a rod having
ing bore are critical except for the area directly under the gall marks in the critical area as shown in Figure 4.

ORIGINAL
As Received By
ATP

CONNECTING ROD BEARING BORE

SHOWING SEVERE GALLING

CONNECTING ROD BEARING

SHOWING MODERATE GALLING
INSERTt. -2

Figure 2. Bearing Insert and Conneding Rod Showing Damage by Galling

Page 2 of 6
 ORlGINAb
As Received By
A’6P Service Bulletin No. 4391\

GALLED CONNECTING ROD

i~
SECTION OF ROD REMOVED
FOR PHOTOMICROGRAPHY

PHOTOMICROGRAPH OF GALLED SECTION

Figure 3. Photo-Micrograph of Gall Mark on Connecting Rod Surface

CRITICAL AREA (DARKENED) RODS WITH GALLING IN THIS AREA

ARE NOT ACCEPTABLE FOR REWORK

GALLING ACCEPTABLE IN THIS AREA PROVIDED IT CAN BE

REMOVED BY GRINDING NOT EXCEEDING .010 INCH

----Htt~-------

IF ANY EVIDENCE OF FRETTING IS APPARENT ON THE MATING

SURFACES OF THE ROD AND CAP IT IS NOT ACCEPTABLE FOR REWORK.

Figure 4. Diagram of Connecting Rod Showing Area of Critical Galling

i. Check connecting rod by magnetic particle necting rods obsolete and limited the repair of
method to determine if rod is suitable for reuse. others. Do not reuse or perform the procedure
(See latest edition of S.I. 1285.) If magnetic par- herein described on any connecting rod unless
tide check indicateS rod is cracked, do not reuse. specifically permitted in the chart found at the

If rod bore is galling is evident as shown

worn or rear of this publication.
in Figure 4; and upon inspection it is found to
be reworkable, it may be reworked by grinding a. Assemble the rod and cap using arbor
the crankpin bore of the rod .010 inch oversize, ST-236 or ST-237 and applicable slave bolts
Product improvements have made certain con- (see Figure 5). The rod is placed over the

Page 3 of 6
 Service Bulletin No. 439A

arbor with the hats perpendicular to the CRANKPIN BORE AND ACCELERATE
axis; lubricate the slave bolts and tighten STONE WEAR.
each bolt to its correct torque length. (See
latest edition of Service Table of Limits.) A d. Dimensional inspections are made with dial
Slave bolt is made by grinding sufficient bore gage, and measurements are taken at
material ~-om the side of the bolt to provide a minimum of two positions 90 degrees apart

clearance in the bearing area (see Figure 5). in that particular plane being measured.

b. Remove the arbor from the rod and stone e. To insure proper bore size crankpin bore
both sides of rod to remove a~ burrs. Then must not be out-of-round more than .0005
secure the rod on a suitable face plate of an inch. Thrust faces on large end must be
internal grinding machine with the crankpin
square with crankpin bore within .002 total
bore in the center of the face plate. indicator reading.

NOTE f. Twist between piston pin bore and crankpin

bore must not exceed .007 in 10 inches.
Be careful not to distort bore of rod while
securing rod to face plate.
g. Piston pin bore and crankpin bore must be
c. Proceed to grind the inside diameter of pa~allel with each other within .005 in 10
inches.
crankpin bore .010 inch o/s as indicated in
Figure 6. Surface finish of the
ground bore
2. If it is not necessary to grind the connecting rod
must be 80 micro-inches maximum. A grin-
ding wheel, 2 x 1-1/8 x 5/8, Baystate bearing bore, assemble the rod and cap using
arbor ST-236 ST-237 The rod is placed over the
A60K5V72K or equivalent is satisfactory for
arbor with the flats perpendicular to the axis;
this purpose.
lubricate the bolts and tighten each to its cor-
rect torque or stretch length; then remove the
CAUTION
arbor from the rod. See latest edition of Ser-
THE CORRECT.SPINDLE SPEED FOR vice Table of Limits.
GRINDING THE CRANKPIN BORE IS
12, 250 RPM WITH CONNECTING ROD 3. Check bearing bore diameter as described in
ROTATING AT 100 RPM. EXCESSIVE paragraph l-d, e, f and g. Diameter should be
SPEED COULD CAUSE OVERSIZE within limits shown for bore. See Figure 6.

DRESS GRINDING WHEEL TO APPROXIMATE

2" RADIUS, AND GRIND BOLT AT THIS
LOCATION TO 5/64 INCH DEPTH. NOTE
o./ I LOCATION OF GROUND AREA I~ RELATION
c~P/ I TO CHAMFER ON BOLT HEAD.

.680
.690

64

2.248
2.249

Figure 5. Method of Modifying Connecting Rod Bolt to Serve As Slave Bolt

For Use With LW-10646 Rods Only

Page 4 of 6
 Service Bulletii~ No. 439A

NOTE PEEN PART NUMBERS, OR ANY

OTHER IDENTIFICATION ON THE
Again check rod by magnetic particle CONNECTING ROD.
method.
5. Rods that have beenreground .010 o/s must be
4. Identify rods that have been ground .010 inch weighed and the correct weight identification let-
oversize by electrochemical or acid etching the ter code added to the part number on the rod.
suffix P10 on the part number. See Figure 6. See the following charts for correct code letter.
Depth of the etch should not exceed .0005 inch. Rods should be selected for replacement by
weight as described in the overhaul inanual;
CAUTION however, rods,in ’’s’’ weight group may be us-
ed for individ~ial rod replacement-in any group
DO NOT METAL STAMP OR VIBRO- with the same part number.

CONNECTING ROD PERMISSIBLE REPAIR

PART NUMBERS DESCRIPTION AND REPLACEMENT

75059 Phosphate coated rod. Do not repair. Do not reuse. Replace with
LW-10646 rods.
75548 Phosphate coated rod. Do not repair. Do not reuse. Replace with
77450 rods.
77450 Tongue and grooved rod, Grind oversize and identify as n450-P10.
not phosphate coated. Mandatory replacement for 75548.
LW-10776 Tongue and grooved rod, Grind oversize and identify as 77450-P10.
phosphate coated.
LW-10646 Tongue and grooved rod, Grind oversize and identify as LW-10646-P10.
not phosphate coated, large
bore.
LW-19332 Tongue and grooved rod, Grind -oversize and identify as LW-19332-P10.
not, phosphate coated, large
bore.

On all other connecting rods listed in the chart below and reworkable identify rework in accordance
with paragraph 4.

LENGTH BETWEEN CONNECTING ROD BEARING CENTERS

ARE SHOWN IN THE FOLLOWING CHART.
DIA. A

-t ----Ctt (tt-- -t

PART NUMBER, SIZE AND WEIGHT

IDENTIFICATION TO BE ETCHED ON
THIS SIIRFACE.’ SEE PAR. 4 AND 5.

Figure 6. Diagram of Connecting Rod Bushing Bore Diameter

Page 5 of 6
 i

Service Bulletin No. 439A

CONNECTING ROD WEIGHT CODES AND WEIGHT

Connecting Rod Bore biameter Bore Diameter Weight

P/N "A" Standard "A" .010" o/s Code 010" o/s Length

LW-ll457, 2.2870 2.2970 A 2 .121-2.160 6.7485

LW-ll750, 2.2875 2.2975 *S 2.161-2.180 6.7515
LW-13937 E 2.181-2.220

77450 2.2870 2.2970 A 2 .360-2 .380 6.7485

LW-13422 2.2875 2.2975 *S 2 .381-2 .390 6.7515
E 2.391-2.410

78030 2.2870 2.2970 A 1.890-1.970 6.4985

2.2875 2 .2975 *S 1.971-2 .010 6.5015
E 2.011-2.090

78029 2.2870 2.2970 None 2 .015-2 .045 6.4985

2.2875 2.2975 6.5015

78028 2.2870 2.2970 None 1.965-1.995 6.4985

2.2875 2.2975 6.5015

LW-10646 2 .4205 2 .4305 A 2.220-2 .240 6.7485

LW-19332 2 .4210 2 .4310 *S 2 .241-2 .250 6.7515
E 2.251-2.270

LW-13865 2.2870 2.2970 A 1.924-1.975 6.7485

2.2875 2.2975 *S 1.976-2 .001 6.7515
E 2.002-2.053

LW-15288 2.2870 2.2970 A 1.936-1;987 6.7485

2.2875 2.2975 *S 1.988-2 .013 6.7515
E 2.014-2.065

Rods in "s" (Service) group may be used individually.

Acid etched in accordance with AS478-6Aor 7A1. Code letter after P/N on rod with figures .25 high.
-1Pound 454 Grams

SPECIAL SERVICE TOOLS

Tool No. Tool Description

ST-236 Connecting Rod Assembly Use with large bearing bore rods.

ST-237 Connecting Rod Assembly Use with small bearing bore rods.

22306, 23988, 24264, 24264A, 24264B These numbers for Textron Lycoming reference only.

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