412-MM-CH63 (1) Tren de Potencia

BHT-412-MM-6
CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM
TABLE OF CONTENTS
Paragraph Chapter/Section Page

Number Title Number Number
MAIN ROTOR DRIVE SYSTEM
63-1 Main Rotor Drive ............................................................................ 63-00-00 11

63-2 Metal Particle Contamination.................................................... 63-00-00 11
63-3 Metal Particle Contamination — Inspection ...................... 63-00-00 11
63-4 Metal Particle Contamination — Identification .................. 63-00-00 11
ENGINE-TO-TRANSMISSION (MAIN) DRIVESHAFT
63-5 Engine-to-Transmission (Main) Driveshaft..................................... 63-00-00 15

63-6 Engine-to-Transmission (Main) Driveshaft —
Troubleshooting ........................................................................ 63-00-00 15
63-7 Engine-to-Transmission (Main) Driveshaft — Maintenance ..... 63-00-00 15
63-8 Engine-to-Transmission (Main) Driveshaft — Removal .... 63-00-00 15
63-9 Engine-to-Transmission (Main) Driveshaft — Cleaning .... 63-00-00 16
63-10 Engine-to-Transmission (Main) Driveshaft — Inspection.. 63-00-00 16
63-11 Engine-to-Transmission (Main) Driveshaft — Repair ....... 63-00-00 22
Lubrication ........................................................................ 63-00-00 22
Installation......................................................................... 63-00-00 22
63-14 Engine-to-Transmission (Main) Driveshaft — Balancing .. 63-00-00 23
63-15 Engine-to-Driveshaft Curvic Coupling Adapter ......................... 63-00-00 23
63-16 Engine-to-Driveshaft Curvic Coupling Adapter —
Removal............................................................................ 63-00-00 23
Inspection.......................................................................... 63-00-00 26
Repair ............................................................................... 63-00-00 26
Installation......................................................................... 63-00-00 26
MAIN ROTOR MAST
63-20 Main Rotor Mast............................................................................. 63-00-00 29

63-21 Main Rotor Mast — Maintenance ............................................. 63-00-00 29
63-22 Main Rotor Mast — Removal ............................................ 63-00-00 29
63-23 Main Rotor Mast — Cleaning............................................ 63-00-00 32
63-24 Main Rotor Mast — Inspection and Repair ....................... 63-00-00 32
63-25 Main Rotor Mast — Installation......................................... 63-00-00 32
63-26 Torque Tube Assembly Alignment............................................ 63-00-00 35
TRANSMISSION
63-27 Transmission.................................................................................. 63-00-00 37

63-28 Transmission — Troubleshooting ............................................. 63-00-00 37
63-00-00
ECCN EAR99 1 MAY 2012 Rev. 15 Page 1
BHT-412-MM-6
TABLE OF CONTENTS (CONT)

63-29 Transmission — Maintenance .................................................. 63-00-00 37

63-30 Transmission — Removal................................................. 63-00-00 37
63-31 Transmission — Inspection............................................... 63-00-00 42
63-32 Transmission — Build-up.......................................................... 63-00-00 42
63-33 Transmission — Installation.............................................. 63-00-00 49
63-34 Transmission — Alternate Run-in Procedures.................. 63-00-00 50
TRANSMISSION OIL SYSTEM COMPONENTS
63-35 Electric Chip Detectors .................................................................. 63-00-00 53

63-36 Mast Bearing Electric Chip Detector......................................... 63-00-00 53
63-37 Mast Bearing Electric Chip Detector — Removal ............. 63-00-00 53
63-38 Mast Bearing Electric Chip Detector — Inspection ........... 63-00-00 53
63-39 Mast Bearing Electric Chip Detector — Cleaning ............. 63-00-00 53
63-40 Mast Bearing Electric Chip Detector — Installation .......... 63-00-00 53
63-41 Main Input Gear Quill Electric Chip Detector ............................ 63-00-00 56
63-42 Main Input Gear Quill Electric Chip Detector —
Removal............................................................................ 63-00-00 56
Inspection.......................................................................... 63-00-00 56
Cleaning............................................................................ 63-00-00 56
Installation......................................................................... 63-00-00 56
63-46 Sump Case Electric Chip Detector ........................................... 63-00-00 56
63-47 Sump Case Electric Chip Detector — Removal................ 63-00-00 56
63-48 Sump Case Electric Chip Detector — Inspection ............. 63-00-00 59
63-49 Sump Case Electric Chip Detector — Cleaning................ 63-00-00 59
63-50 Sump Case Electric Chip Detector — Installation............. 63-00-00 59
63-51 Transmission Oil System Components.......................................... 63-00-00 61
63-52 Planetary Oil Jets...................................................................... 63-00-00 61
63-53 Planetary Oil Jets — Removal .......................................... 63-00-00 61
63-54 Planetary Oil Jets — Inspection........................................ 63-00-00 61
63-55 Planetary Oil Jets — Cleaning .......................................... 63-00-00 61
63-56 Planetary Oil Jets — Repair.............................................. 63-00-00 61
63-57 Planetary Oil Jets — Installation ....................................... 63-00-00 61
63-58 Oil Jet No. 1 .............................................................................. 63-00-00 63
63-59 Oil Jet No. 1 — Removal .................................................. 63-00-00 63
63-60 Oil Jet No. 1 — Inspection ................................................ 63-00-00 63
63-61 Oil Jet No. 1 — Cleaning .................................................. 63-00-00 63
63-62 Oil Jet No. 1 — Repair ...................................................... 63-00-00 63
63-63 Oil Jet No. 1 — Installation ............................................... 63-00-00 63
63-64 Oil Jet No. 2 .............................................................................. 63-00-00 63
63-68 Oil Jet No. 2 — Repair ...................................................... 63-00-00 63
63-00-00
Page 2 Rev. 15 1 MAY 2012 ECCN EAR99
BHT-412-MM-6

63-70 Oil Jet No. 3 .............................................................................. 63-00-00 66

63-74 Oil Jet No. 3 — Repair ...................................................... 63-00-00 66
63-76 Oil Jet No. 4 .............................................................................. 63-00-00 66
63-80 Oil Jet No. 4 — Repair ...................................................... 63-00-00 66
63-82 Oil Jet No. 5 .............................................................................. 63-00-00 69
63-86 Oil Jet No. 5 — Repair ...................................................... 63-00-00 69
63-88 Oil Jet No. 6 .............................................................................. 63-00-00 69
63-92 Oil Jet No. 6 — Repair ...................................................... 63-00-00 69
63-94 Oil Jet No. 7 .............................................................................. 63-00-00 72
63-98 Oil Jet No. 7 — Repair ...................................................... 63-00-00 72
63-100 Oil Pressure Regulating Valve.................................................. 63-00-00 72
63-101 Oil Pressure Regulating Valve — Removal ...................... 63-00-00 72
63-102 Oil Pressure Regulating Valve — Cleaning ...................... 63-00-00 75
63-103 Oil Pressure Regulating Valve — Inspection .................... 63-00-00 75
63-104 Oil Pressure Regulating Valve — Repair .......................... 63-00-00 75
63-105 Oil Pressure Regulating Valve — Installation ................... 63-00-00 75
63-106 Oil Temperature Manifold ......................................................... 63-00-00 75
63-107 Oil Temperature Manifold — Removal.............................. 63-00-00 75
63-108 Oil Temperature Manifold — Installation........................... 63-00-00 77
63-109 Oil Pressure Transmitter........................................................... 63-00-00 77
63-110 Oil Pressure Transmitter — Removal ............................... 63-00-00 77
63-111 Oil Pressure Transmitter — Inspection ............................. 63-00-00 77
63-112 Oil Pressure Transmitter — Installation ............................ 63-00-00 77
63-113 Oil Pressure Switch .................................................................. 63-00-00 79
63-114 Oil Pressure Switch — Removal ....................................... 63-00-00 79
63-115 Oil Pressure Switch — Inspection..................................... 63-00-00 79
63-116 Oil Pressure Switch — Installation.................................... 63-00-00 79
63-00-00
BHT-412-MM-6

63-117 Oil Pressure Manifold ............................................................... 63-00-00 79

63-118 Oil Pressure Manifold — Removal.................................... 63-00-00 79
63-119 Oil Pressure Manifold — Cleaning.................................... 63-00-00 79
63-120 Oil Pressure Manifold — Inspection.................................. 63-00-00 79
63-121 Oil Pressure Manifold — Repair ....................................... 63-00-00 82
63-122 Oil Pressure Manifold — Installation................................. 63-00-00 82
63-123 Filler Neck, Scupper, and Mounting Bracket ............................ 63-00-00 82
63-124 Filler Neck, Scupper, and Mounting Bracket —
Removal............................................................................ 63-00-00 82
Cleaning............................................................................ 63-00-00 82
Inspection.......................................................................... 63-00-00 82
Installation......................................................................... 63-00-00 82
63-128 Oil Pump ................................................................................... 63-00-00 84
63-129 Oil Pump — Removal ....................................................... 63-00-00 84
63-130 Oil Pump — Installation .................................................... 63-00-00 84
63-131 Oil Pump Inlet Screen............................................................... 63-00-00 86
63-132 Oil Pump Inlet Screen — Removal ................................... 63-00-00 86
63-133 Oil Pump Inlet Screen — Inspection ................................. 63-00-00 86
63-134 Oil Pump Inlet Screen — Cleaning ................................... 63-00-00 86
63-135 Oil Pump Inlet Screen — Installation ................................ 63-00-00 86
63-136 Sump Case Internal Filter ......................................................... 63-00-00 89
63-137 Sump Case Internal Filter — Removal ............................. 63-00-00 89
63-138 Sump Case Internal Filter — Inspection ........................... 63-00-00 89
63-139 Sump Case Internal Filter — Cleaning ............................. 63-00-00 89
63-140 Sump Case Internal Filter — Installation .......................... 63-00-00 93
63-141 Full Flow Debris Monitor ........................................................... 63-00-00 93
63-142 Full Flow Debris Monitor — Removal ............................... 63-00-00 93
63-143 Full Flow Debris Monitor — Inspection ............................. 63-00-00 93
63-144 Full Flow Debris Monitor — Cleaning ............................... 63-00-00 93
63-145 Full Flow Debris Monitor — Installation ............................ 63-00-00 93
63-146 Sight Glasses............................................................................ 63-00-00 95
63-147 Sight Glasses — Removal ................................................ 63-00-00 95
63-148 Sight Glasses — Cleaning ................................................ 63-00-00 95
63-149 Sight Glasses — Inspection.............................................. 63-00-00 95
63-150 Sight Glasses — Installation ............................................. 63-00-00 95
TRANSMISSION OIL COOLING SYSTEM
63-151 Transmission Oil Cooling System .................................................. 63-00-00 97

63-152 External Oil Filter ...................................................................... 63-00-00 97
63-153 External Oil Filter — Removal........................................... 63-00-00 97
63-154 External Oil Filter — Inspection ........................................ 63-00-00 97
63-155 External Oil Filter — Cleaning........................................... 63-00-00 97
63-156 External Oil Filter — Installation........................................ 63-00-00 99
63-00-00
BHT-412-MM-6

63-157 Thermal Bypass Valve.............................................................. 63-00-00 99

63-158 Thermal Bypass Valve — Removal .................................. 63-00-00 99
63-159 Thermal Bypass Valve — Cleaning .................................. 63-00-00 99
63-160 Thermal Bypass Valve — Installation ............................... 63-00-00 101
63-161 Oil Drain Valves ........................................................................ 63-00-00 101
63-162 Oil Drain Valves — Removal ............................................ 63-00-00 101
63-163 Oil Drain Valves — Cleaning ............................................ 63-00-00 101
63-164 Oil Drain Valves — Inspection .......................................... 63-00-00 101
63-165 Oil Drain Valves — Installation ......................................... 63-00-00 101
63-166 Transmission Oil Cooler and Blower ........................................ 63-00-00 103
TRANSMISSION QUILLS
63-167 Transmission Quills........................................................................ 63-00-00 105

63-168 Main Input Quill......................................................................... 63-00-00 105
63-169 Main Input Quill — Removal ............................................. 63-00-00 105
63-170 Main Input Quill — Cleaning ............................................. 63-00-00 105
63-171 Main Input Quill — Inspection ........................................... 63-00-00 105
63-172 Main Input Quill — Repair................................................. 63-00-00 107
63-173 Main Input Quill — Installation .......................................... 63-00-00 107
63-174 Main Input Quill Magnetic Seal (412-040-111) ......................... 63-00-00 111
63-175 Main Input Quill Magnetic Seal — Removal
(Helicopters Prior to S/N 36020 not Modified by
412-570-001-103 or Pre BHT-412-SI-74
(412SP to 412HP Upgrade)) ............................................. 63-00-00 111
63-176 Main Input Quill Magnetic Seal — Removal
(Helicopters S/N 36020 and Subsequent and
Helicopters Modified by 412-570-001-103 or
Post BHT-412-SI-74 (412SP to 412HP Upgrade)) ........... 63-00-00 117
63-177 Main Input Quill Magnetic Seal — Cleaning ..................... 63-00-00 118
63-178 Main Input Quill Magnetic Seal — Inspection ................... 63-00-00 118
63-179 Main Input Quill Magnetic Seal — Repair ......................... 63-00-00 118
63-180 Main Input Quill Magnetic Seal — Installation
(Helicopters Prior to S/N 36020 not Modified by
412-570-001-103 or Pre BHT-412-SI-74
(412SP to 412HP Upgrade)) ............................................. 63-00-00 118
63-181 Main Input Quill Magnetic Seal — Installation
(Helicopters S/N 36020 and Subsequent and
Helicopters Modified by 412-570-001-103 or
Post BHT-412-SI-74 (412SP to 412HP Upgrade)) ........... 63-00-00 120
63-182 Main Input Quill Lip Seal (2820-33655) .................................... 63-00-00 121
63-183 Main Input Quill Lip Seal — Removal ............................... 63-00-00 121
63-184 Main Input Quill Lip Seal — Cleaning ............................... 63-00-00 123
63-185 Main Input Quill Lip Seal — Inspection ............................. 63-00-00 123
63-186 Main Input Quill Lip Seal — Repair................................... 63-00-00 123
63-187 Main Input Quill Lip Seal — Installation ............................ 63-00-00 123
63-188 No. 1 Hydraulic Pump Drive Quill ............................................. 63-00-00 125
63-189 No. 1 Hydraulic Pump Drive Quill — Removal.................. 63-00-00 125
63-00-00
BHT-412-MM-6

63-190 No. 1 Hydraulic Pump Drive Quill — Cleaning.................. 63-00-00 127

63-191 No. 1 Hydraulic Pump Drive Quill — Inspection ............... 63-00-00 127
63-192 No. 1 Hydraulic Pump Drive Quill — Repair ..................... 63-00-00 127
63-193 No. 1 Hydraulic Pump Drive Quill — Installation............... 63-00-00 129
63-194 No. 2 Hydraulic Pump Drive Quill ............................................. 63-00-00 129
63-195 No. 2 Hydraulic Pump Drive Quill — Removal.................. 63-00-00 129
63-196 No. 2 Hydraulic Pump Drive Quill — Cleaning.................. 63-00-00 131
63-197 No. 2 Hydraulic Pump Drive Quill — Inspection ............... 63-00-00 131
63-198 No. 2 Hydraulic Pump Drive Quill — Repair ..................... 63-00-00 131
63-199 No. 2 Hydraulic Pump Drive Quill — Installation............... 63-00-00 131
63-200 Rotor Tachometer Generator.................................................... 63-00-00 131
63-201 Rotor Tachometer Generator — Removal ........................ 63-00-00 133
63-202 Rotor Tachometer Generator — Cleaning ........................ 63-00-00 133
63-203 Rotor Tachometer Generator — Inspection...................... 63-00-00 133
63-204 Rotor Tachometer Generator — Repair............................ 63-00-00 133
63-205 Rotor Tachometer Generator — Installation ..................... 63-00-00 133
63-206 Tail Rotor Drive Quill................................................................. 63-00-00 134
63-207 Tail Rotor Drive Quill — Removal ..................................... 63-00-00 134
63-208 Tail Rotor Drive Quill — Inspection................................... 63-00-00 134
63-209 Tail Rotor Drive Quill — Cleaning ..................................... 63-00-00 136
63-210 Tail Rotor Drive Quill — Repair......................................... 63-00-00 136
63-211 Tail Rotor Drive Quill — Installation .................................. 63-00-00 136
63-212 Rotor Brake Quill ...................................................................... 63-00-00 137
63-213 Rotor Brake Quill — Removal........................................... 63-00-00 137
63-214 Rotor Brake Quill — Cleaning........................................... 63-00-00 137
63-215 Rotor Brake Quill — Inspection......................................... 63-00-00 137
63-216 Rotor Brake Quill — Repair .............................................. 63-00-00 139
63-217 Rotor Brake Quill — Installation........................................ 63-00-00 139
TRANSMISSION QUILL PORT COVERS
63-218 Transmission Quill Port Covers ..................................................... 63-00-00 141

63-219 Transmission Quill Port Covers — Removal ............................ 63-00-00 141
63-220 Transmission Quill Port Covers — Installation ......................... 63-00-00 141
TRANSMISSION MOUNTS
63-221 Transmission Mounts..................................................................... 63-00-00 143

63-222 Aft Isolation Mount and Friction Dampers................................. 63-00-00 143
63-223 Aft Isolation Mount and Friction Dampers — Removal ..... 63-00-00 143
63-224 Transmission Mounts — Inspection.................................. 63-00-00 143
63-225 Aft Mount Friction Dampers — Inspection ........................ 63-00-00 143
63-226 Aft Isolation Mount and Friction Dampers — Installation .. 63-00-00 146
63-227 Forward Isolation Mounts ......................................................... 63-00-00 146
63-227A Forward Isolation Mounts — Removal.............................. 63-00-00 146
63-228 Forward Isolation Mounts — Inspection............................ 63-00-00 146
63-229 Forward Isolation Mounts — Installation........................... 63-00-00 146
63-00-00
BHT-412-MM-6

63-230 Lift Link ..................................................................................... 63-00-00 148

63-231 Lift Link — Removal.......................................................... 63-00-00 148
63-232 Lift Link — Cleaning.......................................................... 63-00-00 148
63-233 Lift Link — Inspection and Repair ..................................... 63-00-00 148
63-234 Lift Link — Installation....................................................... 63-00-00 148
63-235 Lift Link Fitting........................................................................... 63-00-00 151
63-236 Lift Link Fitting — Removal ............................................... 63-00-00 151
63-237 Lift Link Fitting — Cleaning ............................................... 63-00-00 151
63-238 Lift Link Fitting — Inspection and Repair .......................... 63-00-00 151
63-239 Lift Link Fitting — Installation ............................................ 63-00-00 151
SERVICEABILITY CHECKS
63-240 Serviceability Checks — Transmission, Tail Rotor Gearbox,

and Intermediate Gearbox ............................................................. 63-00-00 153
63-241 Serviceability Check — Transmission ...................................... 63-00-00 153
63-242 Serviceability Check — Intermediate or Tail Rotor Gearbox .... 63-00-00 153
ROTOR BRAKE SYSTEM
63-243 Rotor Brake System....................................................................... 63-00-00 155

63-244 Rotor Brake System Troubleshooting....................................... 63-00-00 155
63-245 Bleeding.................................................................................... 63-00-00 158
63-246 Bleeding — Brake Assembly P/N 9450103 ...................... 63-00-00 158
63-247 Bleeding — Brake Assembly P/N 9450103-1 ................... 63-00-00 158
63-248 Rotor Brake System Component ................................................... 63-00-00 159
63-249 Master Cylinder......................................................................... 63-00-00 159
63-250 Master Cylinder — Removal ............................................. 63-00-00 159
63-251 Master Cylinder — Inspection........................................... 63-00-00 159
63-252 Master Cylinder — Repair................................................. 63-00-00 159
63-253 Master Cylinder — Installation .......................................... 63-00-00 159
63-254 Brake Assembly........................................................................ 63-00-00 159
63-255 Brake Assembly — Removal (P/N 9450103) .................... 63-00-00 163
63-256 Brake Assembly — Removal (P/N 9450103-1)................. 63-00-00 163
63-257 Brake Assembly — Inspection .......................................... 63-00-00 163
63-258 Brake Assembly — Repair................................................ 63-00-00 166
63-259 Brake Assembly — Installation (P/N 9450103) ................. 63-00-00 166
63-260 Brake Assembly — Installation (P/N 9450103-1).............. 63-00-00 167
63-261 Rotor Brake Disc....................................................................... 63-00-00 168
63-262 Rotor Brake Disc — Removal ........................................... 63-00-00 168
63-263 Rotor Brake Disc — Inspection......................................... 63-00-00 168
63-264 Rotor Brake Disc — Installation ........................................ 63-00-00 168
63-265 Flange Adapter ......................................................................... 63-00-00 171
63-266 Flange Adapter — Removal.............................................. 63-00-00 171
63-267 Flange Adapter — Installation........................................... 63-00-00 171
63-00-00
BHT-412-MM-6
FIGURES
Figure Page
Number Title Number
63-1 Drive System Chip Detector Debris — Analysis ................................................. 12

63-2 Engine-to-Transmission (Main) Driveshaft.......................................................... 17
63-3 Main Driveshaft — Damage Limits ..................................................................... 19
63-4 Engine-to-Driveshaft Curvic Coupling Adapter ................................................... 24
63-5 Engine-to-Driveshaft Curvic Coupling Wrench Set — Tool Application.............. 25
63-6 Engine-to-Driveshaft Curvic Coupling Adapter (S/N 33001 and Subsequent
and 36001 through 36019) — Damage Limits .................................................... 27
63-6A Engine-to-Driveshaft Curvic Coupling Adapter (S/N 36020 and Subsequent)
— Damage Limits ............................................................................................... 28
63-7 Main Rotor Mast.................................................................................................. 30
63-8 Mast Driving Adapter to Transmission Top Case Dimension Requirements ...... 34
63-9 Transmission....................................................................................................... 38
63-10 Transmission Removal and Installation .............................................................. 40
63-11 Transmission Assembly ...................................................................................... 43
63-12 Transmission Build-up ........................................................................................ 45
63-13 Mast Bearing Electric Chip Detector ................................................................... 54
63-14 Electric Chip Detector (Typical) — Damage Limits............................................. 55
63-15 Main Input Gear Quill Electric Chip Detector ...................................................... 57
63-16 Sump Case Electric Chip Detector ..................................................................... 58
63-17 Sump Case Electric Chip Detector — Damage Limits........................................ 60
63-18 Planetary Oil Jet.................................................................................................. 62
63-19 Oil Jet No. 1 ........................................................................................................ 64
63-20 Oil Jet No. 2 ........................................................................................................ 65
63-21 Oil Jet No. 3 ........................................................................................................ 67
63-22 Oil Jet No. 4 ........................................................................................................ 68
63-23 Oil Jet No. 5 ........................................................................................................ 70
63-24 Oil Jet No. 6 ........................................................................................................ 71
63-25 Oil Jet No. 7 ........................................................................................................ 73
63-26 Oil Pressure Regulator Valve.............................................................................. 74
63-27 Oil Temperature Manifold ................................................................................... 76
63-28 Oil Pressure Transmitter ..................................................................................... 78
63-29 Oil Pressure Switch............................................................................................. 80
63-30 Oil Pressure Manifold.......................................................................................... 81
63-31 Filler Neck, Scupper, and Mounting Bracket....................................................... 83
63-32 Transmission Oil Pump....................................................................................... 85
63-33 Oil Pump Inlet Screen ......................................................................................... 87
63-34 Oil Pump Inlet Screen — Damage Limits ........................................................... 88
63-35 Sump Case Internal Filter (Pre TB 412-91-94) ................................................... 90
63-36 Sump Case Internal Filter ................................................................................... 91
63-37 Sump Case Internal Filter — Damage Limits...................................................... 92
63-38 Full Flow Debris Monitor ..................................................................................... 94
63-39 Sight Glass.......................................................................................................... 96
63-40 Transmission External Oil Filter .......................................................................... 98
63-41 Thermal Oil Bypass Valve................................................................................... 100
63-42 Oil Drain Valve .................................................................................................... 102
63-43 Main Input Quill ................................................................................................... 106
63-44 Main Input Quill Assembly .................................................................................. 108
63-45 Pusher Set (T101586-5) Application................................................................... 110
63-46 Main Input Quill Magnetic Seal ........................................................................... 112
63-00-00
BHT-412-MM-6
FIGURES (CONT)
Figure Page
Number Title Number
63-47 Tool Application .................................................................................................. 114

63-48 Main Input Quill Curvic Coupling Adapter and Magnetic Seal Assembly............ 116
63-49 Main Input Quill Lip Seal (28203-3655) .............................................................. 122
63-50 No. 1 Hydraulic Pump Drive Quill ....................................................................... 126
63-51 No. 1 Hydraulic Pump Drive Quill Assembly....................................................... 128
63-52 No. 2 Hydraulic Pump Drive Quill ....................................................................... 130
63-53 Rotor Tachometer Generator.............................................................................. 132
63-54 Tail Rotor Drive Quill........................................................................................... 135
63-55 Rotor Brake Quill................................................................................................. 138
63-56 Quill Port Covers................................................................................................. 142
63-57 Transmission Aft Isolation Mounts and Friction Dampers................................... 144
63-58 Isolation Mount Inspection Work Aid — Tool Application ................................... 145
63-59 Forward Isolation Mounts.................................................................................... 147
63-60 Transmission Lift Link ......................................................................................... 149
63-61 Lift Link Fitting..................................................................................................... 150
63-62 Rotor Brake System............................................................................................ 156
63-63 Rotor Brake Assembly ........................................................................................ 160
63-64 Rotor Brake Assembly — Damage Limits........................................................... 164
63-65 Rotor Brake Disc................................................................................................. 169
63-66 Rotor Brake Disc Inspection Arbor...................................................................... 170
TABLES
Table Page
Number Title Number
63-1 Engine-to-Transmission (Main) Driveshaft — Troubleshooting .......................... 15

63-2 Main Driveshaft TEMP-PLATE Condition and Corrective Action........................ 21
63-3 Rotor Brake System — Troubleshooting ............................................................ 155
63-00-00
ECCN EAR99 1 MAY 2012 Rev. 15 Page 9/10
BHT-412-MM-6
MAIN ROTOR DRIVE SYSTEM
63-1. MAIN ROTOR DRIVE FRAGMENTS OF TRANSMISSION

PARTS SUCH AS GEARS, HARDWARE,
This chapter contains maintenance instructions for the BEARINGS, LOCKWIRE, OR OTHER
drive system components, which transmit power from INTERNAL COMPONENTS, REPLACE
the engine to the main rotor assembly and to TRANSMISSION, MAST ASSEMBLY, OIL
transmission mounted accessories. This includes the COOLER, AND EXTERNAL OIL FILTER
engine-to-transmission (main) driveshaft, transmission ELEMENTS. CLEAN AND THOROUGHLY
and related components, and main rotor mast FLUSH ALL OIL LINES WITH OPERATING
assembly. OIL (CHAPTER 12).
63-2. METAL PARTICLE CONTAMINATION Visual inspection of color and hardness may identify
particles. When a particle cannot be positively
63-3. Metal Particle Contamination — identified by visual means, perform the following tests
Inspection with a permanent magnet, concentrated hydrochloric
acid, and concentrated nitric acid.
Metal particles found in transmission oil, screens,
filters, or accumulated on chip detectors may indicate 1. STEEL — Isolate steel particles with a permanent
impending failure of an internal part of the magnet.
transmission. The presence of metal particles is not
necessarily an indication the transmission, or 2. ALUMINUM — Identify aluminum particles by
component part, is no longer serviceable (paragraph reaction to hydrochloric acid. When a particle of
63-158). The quantity, source, form, and type of metal, aluminum is immersed into hydrochloric acid, the
together with the service history of the particular solution will fizz vigorously and the particles will
component, must be taken into consideration. The gradually disintegrate. A black residue will remain.
time accumulated since the gearbox was new or
overhauled, previous failures, and type of operation
NOTE
are important factors in determining further
serviceability. The particles found may be steel, Magnesium and aluminum react similarly in
aluminum, magnesium, or phenolic in various shapes hydrochloric acid. When in doubt, drop
and quantities. Refer to Figure 63-1 for disposition of particle in nitric acid. Aluminum does not
metal particle contaminated transmissions. react noticeably in nitric acid while
magnesium does.
63-4. Metal Particle Contamination —
Identification 3. COPPER OR BRONZE — Particles of copper or
bronze will form a bright green cloud in nitric acid.
CAUTION
W H E N PA R T I C L E S F O U N D A R E
R E A D I LY IDENTIFIABLE AS
63-00-00
30 MAR 2007 Rev. 11 Page 11
BHT-412-MM-6
Figure 63-1. Drive System Chip Detector Debris — Analysis (Sheet 1 of 3)
63-00-00
BHT-412-MM-6
63-00-00
BHT-412-MM-6
63-00-00
BHT-412-MM-6
ENGINE-TO-TRANSMISSION (MAIN) DRIVESHAFT
63-5. ENGINE-TO-TRANSMISSION (MAIN) 63-7. ENGINE-TO-TRANSMISSION (MAIN)

DRIVESHAFT DRIVESHAFT — MAINTENANCE
The main driveshaft is installed between an adapter on The following paragraphs provide maintenance
the engine combining (reduction) gearbox and input instructions for the main driveshaft. Vibration analysis
drive quill on the transmission. The driveshaft is a and balancing is contained in Chapter 18.
steel tube with grease lubricated, spherical, splined
coupling assemblies on either end to provide flexibility.
63-8. Engine-to-Transmission (Main) Driveshaft
— Removal
63-6. ENGINE-TO-TRANSMISSION (MAIN)
DRIVESHAFT — TROUBLESHOOTING
1. Remove left and right air inlet fairings.
Refer to Table 63-1.
2. Open left engine top cowling. Disconnect fire
detector leads at firewall. Disconnect left starter
generator air hose from vent in engine cowl.
3. Remove left engine top cowling.
Table 63-1. Engine-to-Transmission (Main) Driveshaft — Troubleshooting
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
High frequency vibration Improperly assembled driveshaft. Remove, disassemble, inspect,

and assemble driveshaft
(BHT-412-CR&O).
Loss of grease from coupling. Remove, disassemble, inspect,

assemble, and install coupling
(BHT-412-CR&O).
Loose engine adapter or adapter Remove, inspect, and install

bolt. engine adapter.
Dirt or burr on mounting diameters Remove, inspect, clean, and

of driveshaft. install driveshaft.
Loose coupling bolt(s). Loosen, then retighten coupling

bolts in sequence.
Driveshaft out of balance. Balance driveshaft (Chapter 18).
Improperly assembled driveshaft Remove, disassemble, inspect,

coupling. assemble, and install coupling
(BHT-412-CR&O).
Grease leakage Faulty packings or seals. Replace packings or seals
(BHT-412-CR&O).
Over-temperature indicator Possible overheat condition and/or Refer to paragraph 63-10.

(TEMP-PLATE) shows component degradation.
discoloration (from white to black)
63-00-00
30 MAR 2007 Rev. 11 Page 15
BHT-412-MM-6
4. For helicopters S/N 33001 and subsequent, and 1. Prior to cleaning, inspect driveshaft
36001 through 36019, do the steps that follow: (4, Figure 63-3) for lubricant leakage.
a. If applicable, put a mark to identify the

locations of the balancing weights (2 and 8, CAUTION
Figure 63-2).
b. Hold the driveshaft (6) and remove nuts (4 DO NOT IMMERSE DRIVESHAFT IN
and 11), washers (3 and 10), bolts (1 and 7), and DRYCLEANING SOLVENT (C-304) OR
balancing weights (2 and 8), if installed. ANY CLEANING AGENTS.
c. Put a mark on the flexible couplings for 2. Clean driveshaft parts, except boots (3 and 5),
installation in the same position. with a clean, lint-free cloth dampened with drycleaning
solvent (C-304).
d. Push the driveshaft (6) forward until the aft
end is free. 3. Dry driveshaft (4) with filtered, compressed air.
e. Remove the driveshaft (6). 4. Clean boots (3 and 5) with a clean, dry, lint-free
cloth.
5. For helicopters S/N 36020 and subsequent and
helicopters modified by 412-570-001-103 or Post 63-10. Engine-to-Transmission (Main) Driveshaft
BHT-412-SI-74 (412SP to 412HP Upgrade), do the — Inspection
steps that follow:
1. Inspect driveshaft in accordance with
Figure 63-3.
a. Put marks to identify the location of the
balancing weights (13 and 19). 2. Refer to the BHT-412-CR&O Manual for detailed
inspection information.
b. Hold the driveshaft (17) and remove the nuts
(12 and 18), balancing weights (13 and 19) (where 3. Perform serviceability check of over-temperature
applicable), washers (15 and 20), and bolts (14 indicator (TEMP-PLATE) (7) as follows:
and 21).
a. Over-temperature indicators (TEMP-PLATE)
(7) must not show evidence of over-temperature,
c. Put a mark on the flexible couplings for
deterioration, debonding, or discoloration of the epoxy
installation in the same position.
coating that prevents interpretation of the indicating
dots. If any of these conditions exist, proceed to
d. Push the driveshaft (17) forward until the aft step b.
end is free.
e. Remove the driveshaft (17). b. If only one over-temperature indicator

(TEMP-PLATE) (7) of a given color is missing, and no
63-9. Engine-to-Transmission (Main) Driveshaft dot on any other over-temperature indicator
— Cleaning (TEMP-PLATE) (on the same coupling) is discolored
or shows mechanical damage or degradation of the
epoxy overcoating, the helicopter may be returned to
service. The discrepant over-temperature indicator
MATERIALS REQUIRED (TEMP-PLATE) should be replaced as soon as
practical.
Refer to BHT-ALL-SPM for specifications.
c. If any indicator dot on either the red or yellow
NUMBER NOMENCLATURE bordered over-temperature indicator (TEMP-PLATE)
(7) has changed color to black, see Table 63-2 for
C-304 Drycleaning Solvent
probable cause and required corrective action.
63-00-00
BHT-412-MM-6
3 4
FLEXIBLE 2
COUPLING
SEE VIEW A 2
1
7
8
FLEXIBLE
9
COUPLING
14
10 13 1
S/N 33001 THROUGH SUBSEQUENT AND
S/N 36001 THROUGH 36019 11
2
15
12
FLEXIBLE
COUPLING 16
22
17
1
5 4
18
FLEXIBLE 2 3
19 COUPLING 6
20 VIEW A 1
21 BOLT TORQUE SEQUENCE
S/N 36020 THROUGH SUBSEQUENT AND 1
HELICOPTERS MODIFIED BY 412-570-001-103
412_MM_63_0011
Figure 63-2. Engine-to-Transmission (Main) Driveshaft (Sheet 1 of 2)
63-00-00
30 MAR 2007 Rev. 11 Page 17
BHT-412-MM-6
1. Bolt
2. Balancing weight
3. Washer
4. Nut
5. Engine-to-driveshaft curvic coupling adapter
6. Driveshaft
7. Bolt
8. Balancing weight
9. Main input quill curvic coupling adapter
10. Washer
11. Nut
12. Nut
13. Balancing weight
14. Bolt
15. Washer
17. Driveshaft
18. Nut
19. Balancing weight
20. Washer
21. Bolt
22. Main input quill curvic coupling adapter
70 TO 90 IN-LBS
1 (7.91 TO 10.16 Nm)
100 TO 140 IN-LBS

2 (11.30 TO 15.81 Nm)
NOTE
1 Torque bolts in three steps; 1/3 full torque, 2/3 full torque, and full torque respectively.
Tighten bolts in sequence as shown in Detail A. Repeat sequence at each torque step.
412_MM_63_0019
Figure 63-2. Engine-to-Transmission (Main) Driveshaft (Sheet 2 of 2)
63-00-00
Page 18 Rev. 11 30 MAR 2007
BHT-412-MM-6
Figure 63-3. Main Driveshaft — Damage Limits (Sheet 1 of 2)
63-00-00
30 MAR 2007 Rev. 11 Page 19
BHT-412-MM-6
NOTES
1. Evidence of lubricant leakage at couplings (2) or (6) is cause for overhaul evaluation of driveshaft.
Refer to BHT-412-CR&O manual.
2. Mechanical and corrosion damage limits on driveshaft (4) are defined as follows:
MECHANICAL/CORROSION LIMITS
DAMAGE
Nicks and scratches running Not exceeding 0.004 inch (0.101 mm) in depth are acceptable without
parallel to, or within 15° of repair.
parallel to shaft axis.
Not exceeding 0.008 inch (0.203 mm) in depth or 1.5 inches (38 mm) in
length are acceptable if polished out, provided the total polished area
does not exceed 10% of circumference at any point.
Nicks and scratches not Not exceeding 0.004 inch (0.101 mm) in depth are acceptable on up to
running within 15° of shaft 100% of the circumference of shaft, if polished out.
axis.
Not exceeding 0.008 inch (0.203 mm) in depth or 1.5 inches (38 mm) in
length are acceptable provided the total polished area does not
exceed 10% of circumference at any point.
Corrosion pitting. Not exceeding 0.008 inch (0.203 mm) in depth is acceptable provided
it is polished out. Maximum length of rework at any point must not
exceed 1.5 inches (38 mm) nor cover more than 10% of the
circumference at any point. The maximum acceptable total reworked
area is 4.0 square inches (2580 mm2).
3. Mechanical and/or corrosion damage on retainer plate (1) or similar plate in couplings (6) that could
result in lubricant leakage is not acceptable.
4. Mechanical and/or corrosion damage on boots (3 and 5) that could result in lubricant leakage is not
acceptable.
5. Superficial mechanical damage on couplings (2 and 6) is acceptable without repair. Mechanical

damage in excess of superficial and/or corrosion damage is cause for overhaul evaluation of driveshaft
(4). Refer to the BHT-412-CR&O.
6. Visual over-temperature indicator (TEMP-PLATES) for discoloration and overheat condition. A change
in color of TEMP-PLATES dots from white to black will indicate a possible overheat condition and/or
component degradation, and cause of indicator (TEMP-PLATES) dots’ discoloration should be
determined prior to condition operation. Refer to the BHT-412-CR&O for Inspection and Lubrication
procedures.
Figure 63-3. Main Driveshaft — Damage Limits (Sheet 2 of 2)
63-00-00
Page 20 Rev. 11 30 MAR 2007
BHT-412-MM-6
Table 63-2. Main Driveshaft TEMP-PLATE Condition and Corrective Action
ONE YELLOW OTHER YELLOW ONE RED OTHER RED PROBABLE SEE
TEMP-PLATE TEMP-PLATE TEMP-PLATE TEMP-PLATE CAUSE NOTE
Good Black Good Good Defect/Instl. 1
Black Black Good Good Elevated Temp. 2
Good Good Black Good Defect/Instl. 1

Good Good Black Black Defect/Instl. 4
Black Black Black Black Overtemp 3
Part Black Good Good Good Chem. Contamination 1
Part Black Part Black Good Good Chem. Contamination 1
Good Good Part Black Good Chem. Contamination 1
Good Good Part Black Part Black Chem. Contamination 4
Missing Good Good Good Defect/Instl. 1
Missing Missing Good Good Possible Elevated 2

Temperature
Good Good Missing Good Defect/Instl. 1
Good Good Missing Missing Defect/Instl. 4
Missing Missing Missing Missing Possible Overtemp 3
NOTES:
1. Resume operation. In the event of defective TEMP-PLATE or improper installation, replace defective
TEMP-PLATE as soon as practical in accordance with the BHT-412-CR&O.
2. Elevated coupling temperature is indicated. Determine probable cause of elevated temperature indication and
take corrective action prior to continued operation. Accomplish checks in step a and step b. If probable cause
is not revealed from step a or step b, perform step c and step d. It is recommended that the affected
TEMP-PLATE be replaced in accordance with the BHT-412-CR&O prior to resuming operation.
a. Check the driveshaft coupling for any sign of grease leakage. If leakage is detected, the coupling must be
serviced prior to returning the helicopter to service.
b. Review current helicopter operating conditions to determine the probable cause of elevated coupling
temperature, such as extended operation at CG limits, extended operation at high power, repeated heavy lift,
or high ambient temperature. Make appropriate adjustment to correct condition.
c. Inspect engine mounts and transmission pylon mounts for condition.
d. Verify engine-to-transmission alignment.
3. Coupling overtemperature condition is very likely. Remove driveshaft and perform overtemperature inspection
in accordance with the BHT-412-CR&O.
4. Same as Note 1 except during operations before TEMP-PLATE replacement, a yellow-bordered

TEMP-PLATE indication shall be considered as an overtemperature indication and Notes 2 and 3 must be
accomplished.
63-00-00
30 MAR 2007 Rev. 11 Page 21
BHT-412-MM-6
63-11. Engine-to-Transmission (Main) Driveshaft Use the marks from the removal to help put
— Repair the flexible couplings in the initial position.
b. Put the flexible couplings in the correct

MATERIALS REQUIRED position on the main input quill curvic coupling adapter
(9) and the engine-to-driveshaft curvic coupling
Refer to BHT-ALL-SPM for specifications. adapter (5).
NUMBER NOMENCLATURE
NOTE
C-204 Epoxy Polyamide Use the marks from the removal to put the
Primer balancing weights in the initial position.
c. If necessary, install the balancing weights (2

1. Polish out acceptable defects on driveshaft
and 8) where applicable.
(4, Figure 63-3). Use minimum radius of 0.500 inch
(1.270 mm) in polishing out surface damage. Ensure
damage limits are not exceeded. d. Install bolts (1 and 7), washers (3 and 10), and
nuts (4 and 11).
2. Refinish polished area with two coats of epoxy
polyamide primer (C-204). NOTE
Refer to Figure 63-2 for torque sequence.
3. Replace over-temperature indicator
(TEMP-PLATE) (7) if mutilated or discolored e. Torque nut (4 and 11) T .
(BHT-412-CR&O).
63-12. Engine-to-Transmission (Main) Driveshaft helicopters modified by 412-570-001-103 or Post
— Lubrication BHT-412-SI-74 (412SP to 412HP Upgrade), do the
steps that follow:
Refer to the BHT-412-CR&O for coupling lubrication
instructions. a. Put the driveshaft (17) in position in the center
firewall.
63-13. Engine-to-Transmission (Main) Driveshaft
— Installation
NOTE
The two ends of the driveshaft can be It is necessary to push the flexible
installed forward. It is recommended that couplings inboard to accomplish the step
the flexible coupling with the identification that follows. If possible, compress the
plate be installed in the forward position. flexible couplings equally to avoid moving
the lubricant inside.
1. For helicopters S/N 33001 and subsequent, and
36001 through 36019, do the steps that follow: Use the marks from the removal to help put
the flexible couplings in the initial position.
a. Put the driveshaft (6, Figure 63-2) in position
in the center firewall. b. Put the flexible couplings in the correct
couplings in the correct position on the main input quill
curvic coupling adapter (22) and the
NOTE engine-to-driveshaft curvic coupling adapter (16).
It is necessary to push the flexible
couplings inboard to accomplish the step
NOTE
that follows. If possible, compress the
flexible couplings equally to avoid moving Use the marks from the removal to put the
the lubricant inside. balancing weights in the initial position.
63-00-00
BHT-412-MM-6
c. Install bolts (14 and 21), washers (15 and 20), 63-14. Engine-to-Transmission (Main) Driveshaft
balancing weights (13 and 19) (where applicable), and — Balancing
nuts (12 and 18).
NOTE
NOTE For helicopters S/N 36020 and subsequent
Refer to Figure 63-2 for torque sequence. and helicopters modified by
412-570-001-103 or Post BHT-412-SI-74
d. Torque bolts (14 and 21) T . (412SP to 412HP Upgrade), perform main
driveshaft balancing whenever driveshaft is
removed and reinstalled.
3. Connect the starter generator air hose and the
fire detector leads.
Refer to Chapter 18 for balancing procedures.
4. Install the air inlet fairings and the engine top 63-15. ENGINE-TO-DRIVESHAFT CURVIC
cowling. COUPLING ADAPTER
NOTE 63-16. Engine-to-Driveshaft Curvic Coupling

Adapter — Removal
Ground run and leak check must be
performed following installation of new, SPECIAL TOOLS REQUIRED
repaired, or relubricated driveshaft flexible
couplings.
NUMBER NOMENCLATURE
5. Perform ground run of helicopter for
approximately 5 minutes at 100% rotor RPM T101588 Wrench Set – Curvic
(BHT-412-FM). Coupling, or
T103063 Wrench Set

6. After the rotor is stopped, inspect the flexible (S/N 36020 and
coupling and surrounding structure for signs of grease Subsequent and
leakage. Helicopters Modified
by 412-570-001-103 or
7. If there is leakage, remove the driveshaft (6 or Post BHT-412-SI-74
17) and inspect as per BHT-412-CR&O. (412SP to 412HP
Upgrade))
NOTE 1. Remove main driveshaft (paragraph 63-8).

For helicopters prior to S/N 36020 not
modified by 412-570-001-103 or Pre 2. Straighten tang of washer (3, Figure 63-4) to
BHT-412-SI-74 (412SP to 412HP permit removal of nut (4).
Upgrade), the step that follows is optional
and not necessary for component life or 3. Position plate assembly (7, Figure 63-5) on
serviceability requirements. adapter (1) and install nut (4).
4. Install extension bar (6). Hold plate assembly (7)

For helicopters S/N 36020 and subsequent and turn extension bar to loosen retaining nut (5).
and helicopters modified by
412-570-001-103 or Post BHT-412-SI-74 5. Remove extension bar (6), plate assembly (7),
(412SP to 412HP Upgrade), the driveshaft and retaining nut (5).
must be balanced anytime it has been
removed (Chapter 18). 6. Remove engine-to-driveshaft curvic coupling
adapter (2, Figure 63-4).
8. If necessary, balance the driveshaft (6 or 17)
(paragraph 63-14). 7. Discard washer (3).
63-00-00
BHT-412-MM-6
2
INITIAL TORQUE
3
250 TO 275 FT-LBS
(339 TO 373 N-m)
4
FINAL TORQUE
125 TO 200 FT-LBS
(170 TO 271 N-m)
1. Engine
3. Washer
4. Nut
412_MM_63_0020
Figure 63-4. Engine-to-Driveshaft Curvic Coupling Adapter
63-00-00
Page 24 Rev. 11 30 MAR 2007
BHT-412-MM-6
Figure 63-5. Engine-to-Driveshaft Curvic Coupling Wrench Set — Tool Application
63-00-00
30 MAR 2007 Rev. 11 Page 25
BHT-412-MM-6
63-17. Engine-to-Driveshaft Curvic Coupling

Adapter — Inspection MATERIALS REQUIRED
For helicopters S/N 33001 and subsequent, 36001 Refer to BHT-ALL-SPM for specifications.
through 36019, and helicopters not modified by
412-570-001-103 or Pre BHT-412-SI-74 (412SP to NUMBER NOMENCLATURE
412HP Upgrade), inspect the engine-to-driveshaft
curvic coupling adapter as per information in C-001 Grease
Figure 63-6.
C-007 Bearing Grease
For helicopters S/N 36020 and subsequent and

helicopters modified by 412-570-001-103 or Post 1. Position engine-to-driveshaft curvic coupling
BHT-412-SI-74 (412SP to 412HP Upgrade), inspect adapter (2, Figure 63-4) on engine (1). Lubricate
the engine-to-driveshaft curvic coupling adapter as per threads and mating face of nut (4) lightly with grease
(C-001) or bearing grease (C-007). Keep mating faces
information in Figure 63-6A.
of washer (3) and engine-to-driveshaft curvic coupling
adapter dry.
63-18. Engine-to-Driveshaft Curvic Coupling
Adapter — Repair
2. Install washer (3) and nut (4) on engine hand
tight. Using suitable marker, mark an index line on
outer lock washer tang and adapter to enable
MATERIALS REQUIRED verification that lock washer does not rotate during
torquing.
3. Position plate assembly (7, Figure 63-5) on
NUMBER NOMENCLATURE
adapter (1) and install nut (4). Position extension bar
C-464 India Stone (6) in retaining nut (5).
4. Torque retaining nut (5) to 250 to 275 foot-pounds

Repair of adapter is restricted to polishing out minor (339 to 373 Nm) for initial torque. Loosen retaining nut
damage on face which contacts driveshaft. Polish out (5), then torque to 125 to 200 foot-pounds (170 to 271
repairable damage with a fine India stone (C-464). Nm).
63-19. Engine-to-Driveshaft Curvic Coupling 5. Remove extension bar (6) and plate
Adapter — Installation assembly (7).
6. Inspect washer (3, Figure 63-4) to ensure tang

SPECIAL TOOLS REQUIRED indexed in step 2 has not rotated. If inspection reveals
washer has rotated, replace washer and repeat step 1
through step 5 above.
NUMBER NOMENCLATURE
7. Bend single tab of washer (3) into slot of nut (4).
T101588 Wrench Set – Curvic
Coupling or
T103063 Wrench Set

(S/N 36020 and
Subsequent and
Helicopters Modified
by 412-570-001-103 or
Post BHT-412-SI-74
(412SP to 412HP
Upgrade))
63-00-00
BHT-412-MM-6
Figure 63-6. Engine-to-Driveshaft Curvic Coupling Adapter (S/N 33001 and Subsequent
and 36001 through 36019) — Damage Limits
63-00-00
27 FEB 2009 Rev. 12 Page 27
BHT-412-MM-6
B K (6 PLACES) I
F
E
H C
B
A
J (6 PLACES)
B
SECTION B-B
VIEW A
ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER (209-040-618)

MATERIAL: STEEL
412_MM_63_0023
Figure 63-6A. Engine-to-Driveshaft Curvic Coupling Adapter (S/N 36020 and Subsequent)
— Damage Limits (Sheet 1 of 3)
63-00-00
Page 28 Rev. 12 27 FEB 2009
BHT-412-MM-6
REF INSPECTION
NO. LTR CHARACTERISTIC METHOD LIMIT
1. A Spline wear Measure 1.6687 inches (42.385 mm)

between maximum diameter
0.1080 inch
(2.743 mm)
diameter
pins
2. A Mechanical damage Visual None permitted.
3. B Mechanical damage Visual/measure 0.005 inch (0.13 mm) maximum 1

depth, 0.500 inch (12.70 mm)
maximum length, and 1.50 inches
(38.1 mm) minimum spacing
between damage.
4. B Wear Measure 6.0795 inches (154.419 mm)

minimum diameter.
5. C Mechanical damage Visual/measure 0.005 inch (0.13 mm) maximum 1

depth, 0.500 inch (12.70 mm)
maximum length, and 0.750 inches
(19.05 mm) minimum spacing
between damage.
6. D Nicks, dents, Visual/measure 0.005 inch (0.13 mm) maximum 1

scratches depth.
7. D Circular wear Visual/measure 0.002 inch (0.05 mm) maximum 1

grooves depth.
8. E Mechanical damage Visual/measure Fine axial scratches of 0.001 inch

(0.03 mm) maximum depth.
9. A, B, Corrosion damage Visual Only superficial corrosion 2

C, D, permitted.
E
10. F Corrosion damage Visual/measure 0.002 inch (0.05 mm) maximum 3

depth and no more than 50%
of total surface area between two
holes.
11. G, H Mechanical damage Visual None permitted.
12. G, H Corrosion damage Visual Only superficial corrosion 2

permitted.
13. I Corrosion damage Visual/measure 0.003 inch (0.08 mm) maximum

depth.
412_MM_63_0023a
63-00-00
27 FEB 2009 Rev. 12 Page 28A
BHT-412-MM-6
REF INSPECTION
NO. LTR CHARACTERISTIC METHOD LIMIT
14. I Mechanical damage Visual/measure 0.010 inch (0.25 mm) maximum

depth and 0.500 inch (12.70 mm) 2 3
maximum length.
15. J Corrosion damage Visual/measure 0.010 inch (0.25 mm) maximum

depth and no more than 50% 3
of total wall area.
16. J Bore Wear Measure 0.275 inch (6.98 mm) maximum

diameter.
17. J Elongation Measure 0.279 inch (7.08 mm) maximum

diameter.
18. K Corrosion damage Visual/measure 0.002 inch (0.05 mm) maximum

depth and 0.50 inch (12.7 mm)
maximum distance around each
hole.
19. Cracks MPI None permitted.
NOTES
1 Polish with a fine india stone (C-464) to remove any raised material.
2 Polish with a fine steel wool (C-411) or abrasive pad (C-407).
3 Remove corrosion with abrasive glass beads (C-470). Refer to the CSSD-PSE-87-001,
Chapter 20 for procedure.
4. Brush cadmium plate reworked areas per BHT-ALL-SPM.
5. All dimensions, wear, and damage limits provided are limits required after repair except where indicated.
6. Driveshaft applicable to helicopters S/N 36020 and subsequent and helicopters modified by
412-570-001-103 or post BHT-412-SI-74 (412SP to 412HP upgrade).
412_MM_63_0023b_c01
63-00-00
Page 28B Rev. 15 1 MAY 2012 ECCN EAR99
BHT-412-MM-6
MAIN ROTOR MAST
63-20. MAIN ROTOR MAST REQUIRE THE TORQUE TUBE TO BE

REALIGNED AT BELL HELICOPTER.
The main rotor mast (2, Figure 63-7) is a tubular steel HELICOPTERS WITH A 412-375-004-109
shaft which includes a bearing and plate for MONOPOLE SENSOR INSTALLED MAY
attachment to top of transmission. A bearing race is HAVE TORQUE TUBE ALIGNED USING
installed on lower end of mast which mates with a 412-240-028-101 MAST TORQUEMETER
roller bearing located in transmission. ALIGNMENT TOOL. AFTER A MAST IS
INSTALLED INTO THE TRANSMISSION,
63-21. MAIN ROTOR MAST — MAINTENANCE A ZE R O TO R Q U E CA L I B RATI O N IS
REQUIRED (CHAPTER 96).
The following paragraphs provide maintenance
information for the main rotor mast. NOTE
Hub and sleeve assembly may be removed
63-22. Main Rotor Mast — Removal
with swashplate and support assembly as a
unit. Care must be exercised to prevent
damage to mast and hub spline.
SPECIAL TOOLS REQUIRED
2. Remove hub sleeve assembly (Chapter 62).
NUMBER NOMENCLATURE
3. Remove swashplate and support assembly
T101581 Hoist or Equivalent (Chapter 62).
T103211-101 Cover Lift Plate

WARNING
204-010-481-001 Mast Nut
204-011-178-001 Clevis
DO NOT LIFT MAST (2, FIGURE 63-7)
Commercial Slide Hammer with 1/4 WITH MAST CAP (412-010-160-103). USE
X 20 UNC Threaded MAST NUT (1) (204-010-481-001).
Shaft
4. Install mast nut (1, Figure 63-7). Attach clevis
(204-011-178-001) to mast nut. Attach hoist to clevis.
1. Remove main rotor hub and blade assembly
(Chapter 62).
helicopters modified by 412-570-001-103 or Post
BHT-412-SI-74 (412SP to 412HP Upgrade), remove
CAUTION monopole sensor assembly (13) from bottom of
transmission and mast (2) as follows:
HELICOPTERS S/N 36020 AND

S UB S E Q UE N T A N D H E L IC O P T E RS NOTE
MODIFIED BY 412-570-001-103 OR POST Some oil will be trapped behind monopole
B H T- 4 1 2 - S I - 7 4 ( 4 1 2 S P T O 4 1 2 H P sensor assembly (13).
UPGRADE) HAVE A TORQUEMETER
ASSEMBLY (TORQUE TUBE ASSEMBLY) a. Cut and remove lockwire from four screws
I N S TA L L E D I N S I D E T H E M A S T. (16) and remove screws with washers (15).
R E M O VA L O F P L U G A N D T U B E
ASSEMBLY REQUIRES REALIGNMENT. b. Remove sealant from around base of
HELICOPTERS WITH A 412-375-004-105 monopole sensor assembly (13) using a sharp plastic
M O N O P O L E S E N S O R I N S TA L L E D scraper.
63-00-00
BHT-412-MM-6
1
FLANGE S
1 17 WARNING
1 18
C
DO NOT LIFT MAST (2) WITH MAST
2
CAP (412-010-160-103). USE MAST
1 19
NUT (1) (204-010-481-001).
19
C
2
10 11
SEE DETAIL A
SECTION C-C
8
1 12
9
13
14
3 T
15
1. Mast nut 4
2. Mast
Nut 16 4
3. 6
4. Steel washer 5
5. Temperature bulb clamp bracket
6. Aluminum washer 1
7. Wire clamp bracket
8. Mast bearing retaining plate
9. Lower bearing race
10. Hose 7
11. Transmission
12. Packing
13. Monopole sensor assembly D
14. Spacer
6 FW
15. Washer
16. Screw
17. Bolt
18. Plug
19. Torque tube DETAIL A
NOTE
100 TO 140 IN-LBS 1 S/N 36020 and subsequent and helicopters modified by 412-570-001-103 or
T (11.3 TO 15.8 Nm) post BHT-412-SI-74 (412SP to 412HP upgrade).
412_MM_63_0013_c01
Figure 63-7. Main Rotor Mast (Sheet 1 of 2)
63-00-00
BHT-412-MM-6
B B
VIEW LEFT SIDE
FWD
VIEW B-B
412MM_63_0022
Figure 63-7. Main Rotor Mast (Sheet 2 of 2)
63-00-00
30 MAR 2007 Rev. 11 Page 31
BHT-412-MM-6
63-23. Main Rotor Mast — Cleaning

CAUTION
MATERIALS REQUIRED
DO NOT USE JACKSCREW(S) TO PULL
SENSOR FROM CASE. DO NOT ALLOW Refer to BHT-ALL-SPM for specifications.
PULLER TO BOTTOM OUT IN
NUMBER NOMENCLATURE
THREADED HOLE OF SENSOR.
c. Install slide hammer with 1/4 x 20 UNC
threaded shaft in outboard holes of monopole sensor
assembly (13). Pull sensor and spacer (14) from
support case. Remove and discard packing (12).
CAUTION
6. Remove nuts (3), washers (4 and 6), temperature
bulb clamp bracket (5), and wire clamp bracket (7)
DO NOT ALLOW SOLVENT TO ENTER
from mast bearing retaining plate (8). Remove sealant
MAST BEARINGS.
from around base of mast bearing retaining plate with
a sharp plastic scraper. 1. Clean main rotor mast (2, Figure 63-7) with a
clean, lint-free cloth damp with drycleaning solvent
7. Disconnect mast bearing oil hose (10) from mast (C-304).
bearing retaining plate (8). Cap or plug oil jet and
hose. 2. Dry mast with filtered, compressed air.
63-24. Main Rotor Mast — Inspection and Repair

CAUTION
Inspect and repair mast in accordance with the
BHT-412-CR&O.
D O N O T TO U C H T HE S E C T I O N O F
MAST INSTALLED IN TRANSMISSION 63-25. Main Rotor Mast — Installation
WITH BARE HANDS.
NOTE SPECIAL TOOLS REQUIRED
Heating top case of transmission with a

heat lamp will aid in mast removal. NUMBER NOMENCLATURE
8. Carefully lift mast (2) from transmission. T103211-101 Cover Plate

Immediately after removal, install cover lift plate
(T103211-101). 204-010-481-001 Mast Nut
204-011-178-001 Clevis
9. Position mast (2) on padded stand to prevent
damage to mast. Place protective cover on lower
bearing race (9). Remove clevis (204-011-178-001).
Leave mast nut (1) installed to protect threads. MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 Adhesive Sealant
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Page 32 Rev. 11 30 MAR 2007
BHT-412-MM-6
MATERIALS REQUIRED 3. Install mast nut (1, Figure 63-7). Attach clevis
(204-011-178-001) to mast nut. Attach hoist to clevis.
NUMBER NOMENCLATURE
CAUTION
C-328 Sealing Compound
C-405 Lockwire HELICOPTERS S/N 36020 AND

S UB S E Q UE N T A N D H E L I CO P T E RS
1. Remove cover plate from transmission. MODIFIED BY 412-570-001-103 OR POST
B H T- 4 1 2 - S I - 7 4 ( 4 1 2 S P T O 4 1 2 H P
2. Perform dimensional check of transmission to UPGRADE) HAVE A TORQUEMETER
prevent damage to upper planetary assembly as ASSEMBLY INSTALLED IN MAST (2,
follows: FIGURE 63-7). FAILURE TO REMOVE
MONOPOLE SENSOR ASSEMBLY (13)
BEFORE INSTALLING MAST CAN CAUSE
a. Place straight edge (1, Figure 63-8) on
DAMAGE TO TORQUEMETER
transmission top case (2). Measure from top of mast
ASSEMBLY.
driving adapter (3) to straight edge and record
dimension. If dimension is less than 2.226 inches
(56.54 mm), comply with step b through step d.
NOTE
Heating transmission top case with a heat
lamp will aid in installation.
WARNING
4. Lower mast (2) carefully into transmission (11).
Guide lower bearing race (9) of mast into lower
HANDLE MAST DRIVING ADAPTER (3,
bearing of transmission.
F I G U R E 6 3 - 8 ) C A R E F U L LY W H E N
INDEXING BEARING LINERS. INJURY TO
FINGERS MAY RESULT. 5. Align mast bearing retaining plate (8) with studs
in top of transmission (11).
b. Inspect upper and lower bearing liners (5 and
6) to determine whether tangs are disengaged. If 6. Apply a coat of sealing compound (C-328) to
tangs are disengaged, a gap of approximately mating surfaces of mast bearing retaining plate (8) and
0.25 inch (6.0 mm) will be evident. top of transmission (11) before allowing mast bearing
retaining plate to seat.
c. Insert hands back-to-back through mast
driving adapter (3). Lift mast driving adapter slightly
7. Lower mast (2) until mast bearing retaining plate
and rotate upper bearing liner (5) until tabs on upper
(8) is in contact with transmission (11) top case.
bearing liner align with slots in lower bearing liner (6)
and drop into position.
8. Install temperature bulb clamp bracket (5) next to
d. Repeat measurements described in step a. mast bearing retaining plate (8). Install steel washer
(4) and nut (3). Install wire clamp bracket (7) with one
aluminum washer (6) under L bracket and one above
bracket and one steel washer (4) under nut (3). Torque
WARNING nuts to 100 to 140 inch-pounds (11.3 to 15.8 Nm).
9. Connect oil hose (10) to mast bearing oil jet.

DO NOT LIFT MAST (2, FIGURE 63-7)
WITH MAST CAP (412-010-160-103). USE
ONLY MAST NUT (204-010-481-001) TO 10. Rotate transmission input quill by hand to ensure
LIFT MAST. there is no unusual noise or binding.
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BHT-412-MM-6
Figure 63-8. Mast Driving Adapter to Transmission Top Case Dimension Requirements
63-00-00
Page 34 Rev. 11 30 MAR 2007
BHT-412-MM-6
11. Remove clevis and mast nut (1). Use mast cap 15. Install main rotor hub (Chapter 62).
assembly for final installation.
a. For helicopters S/N 36020 and subsequent helicopters modified by 412-570-001-003 or Post
and helicopters modified by 412-570-001-003 or Post BHT-412-SI-74 (412SP to 412HP Upgrade), calibrate
BHT-412-SI-74 (412SP to 412HP Upgrade), mast torque system (Chapter 96).
accomplish torque tube assembly alignment in
accordance with paragraph 63-26. Alignment is only
required if torque tube was removed or disturbed 17. Install blade assembly (Chapter 62).
during mast removal or installation.
63-26. TORQUE TUBE ASSEMBLY ALIGNMENT
NOTE
Replacement monopole sensor assemblies
(13) will have spacer (14) temporarily
attached with hardware for shipping. NUMBER NOMENCLATURE
Remove shipping hardware and retain
spacer for installation with monopole T103222 Jackscrews
sensor.
412-240-028-101 Mast Torquemeter
12. For helicopters S/N 36020 and subsequent and (Only Used with Mast Alignment Tool
helicopters modified by 412-570-001-003 or Post Assemblies
BHT-412-SI-74 (412SP to 412HP Upgrade), install 412-040-366-111 and
monopole sensor assembly (13) in bottom of Subsequent)
transmission (11) as follows:
a. Lubricate new packing (12) with transmission MATERIALS REQUIRED

oil (Chapter 12) and install on monopole sensor
assembly (13). Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
b. Clean transmission support case free of oil
and adhesive residue using plastic scrapper and a C-308 Sealant
clean cloth dampened with drycleaning solvent
(C-304). C-339 Ethyl Alcohol
c. Apply light coat of transmission oil (Chapter C-405 Lockwire

12) to bore in support case.
d. Insert monopole sensor assembly (13), with NOTE

spacer (14) installed, into support case and align
The following procedure is applicable to
monopole sensor assembly screw holes with holes in
helicopters S/N 36020 and subsequent and
support case of transmission (arrow pointing forward).
helicopters modified by 412-570-001-003
or Post BHT-412-SI-74 (412SP to 412HP
e. Install four screws (16) with washers (15). Upgrade) that have a 412-375-004-109
Secure screws with lockwire (C-405). monopole sensor assembly (13,
Figure 63-7 and 412-040-366-111 or -113
f. Apply a bead of sealant (C-308) around mast assembly. For helicopters with
mating surface of sensor. 412-375-004-105 monopole sensor
assembly and 412-040-366-109 mast
13. Install swashplate and support assembly assembly installed (pre TB 412-01-179),
(Chapter 62). torque tube alignment for transmissions
shall be accomplished at Bell Helicopter
14. Install hub and sleeve assembly (Chapter 62). only.
63-00-00
BHT-412-MM-6
1. Remove monopole sensor assembly (13, 6. Clean the mating surfaces of the torque tube (19)
Figure 63-7) (paragraph 63-22). and the mast (2).
2. Remove torque tube (19) from mast (2) as 7. Apply sealant (C-308) on top of the mast (2).
follows:
8. Install torque tube (19) into mast (2) carefully.
Rotate torque tube slightly, if required, to engage
a. Remove mast nut (1).
upper spline of alignment tool (412-240-028-101).
Continue installation until fully seated at top of mast.
b. Using a sharp plastic scraper, remove sealant
from torque tube (19) and mast (2). 9. Ensure slots of torque tube flange are filled with
sealant (C-308).
c. Cut and remove lockwire from bolts (17) and
remove bolts from plug (18). 10. Remove any excess sealant from flange and top
of mast.
d. Remove plug (18) using jackscrews
(T103222). 11. Rotate torque tube counterclockwise (looking
down from top of mast) as far as alignment tool will
e. Insert a wooden rod (broom stick) inside allow. Torque tube may be rotated by gently tapping on
torque tube (19) through the opening in the bottom of split flange with soft metal bar and mallet. Hold
mast (2). alignment tool counterclockwise with upward pressure
while tube is lowered. If alignment tool is pushed down
f. Using a hammer, lightly tap the wooden rod while lowering torque tube, this is an indication of
against the top of torque tube (19). misalignment. Rotate torque tube gently until
alignment tool rises. This indicates the alignment tool
g. When torque tube (19) breaks loose, remove has engaged both the signal and reference gears.
it from mast (2).
12. Install plug (18) into torque tube (19). Install bolts
3. Clean surface of rotor in mast assembly which (17) and torque to 50 to 70 inch-pounds (5.65 to
contacts with torque tube (19). Apply light coat of 7.90 Nm) in symmetrical manner.
transmission oil to surface. Verify surface is smooth
and clean. 13. Loosen bolts on alignment tool. Verify tool can be
rotated slightly and fits loosely in splines of mast (2)
and torque tube (19). If tool cannot be rotated, repeat
CAUTION step 11 and step 12.
14. Remove alignment tool by pulling tool past torque

DO NOT ROTATE ANY DRIVE SYSTEM tube spline, rotating tool a few degrees, and pulling
COMPONENTS WHILE TOOL IS tool out past mast spline.
INSTALLED.
15. Install monopole sensor assembly (13)
4. Insert alignment tool (412-240-028-101) in (paragraph 63-25).
bottom of transmission support case. Work top and
bottom splines of tool up through spline of rotor 16. Secure torque tube plug (18) with lockwire
assembly in bottom of mast (2). Rotate tool (C-405). Apply ethyl alcohol (C-339) to mating
counterclockwise (looking up at bottom of mast) until surfaces of torque tube (19).
splined teeth of tool are bottomed out against teeth of
rotor in mast assembly. Hold tool in place with four 17. Install mast nut (1) (Chapter 62).
screws and washers. Leave screws loose enough to
allow 1/4 inch movement of tool. 18. Perform mast torque system zero torque
calibration (Chapter 96).
5. Clean outer bearing surface of torque tube (19).
Verify surface is smooth. Use care to keep bearing 19. Perform mast torque system flight check
surface clean during installation. (Chapter 96).
63-00-00
BHT-412-MM-6
TRANSMISSION
63-27. TRANSMISSION 63-30. Transmission — Removal
The transmission (Figure 63-9) is a mechanical

reduction gearbox attached to the fuselage structure SPECIAL TOOLS REQUIRED
by four isolation mounts at corners of transmission
support case and by lift link, which is the main load
bearing component. The two aft isolation mounts NUMBER NOMENCLATURE
attach to the helicopter structure and also to the
friction dampers. The lift link is attached to the AN100036 Cover
transmission support case and helicopter lift beam.
SWE13860 Adapter
63-28. TRANSMISSION — TROUBLESHOOTING SWE13875 Stand
T101581 Hoist
In analysis of transmission oil system troubles,
consider the following characteristics of the system: T102118-101 Dehydrator Assembly
1. Low oil level will not cause low oil pressure 204-010-481-001 Mast Nut
indications provided sump contains sufficient oil to
cover pump inlet. Oil temperature may rise. 204-040-929-101 Cover and Lift Plate
204-011-178-001 Clevis
2. Effects of an oil leak will depend on location of
leak within system and rate of fluid loss. Do not
exceed 10 drops per minute from any single source. 1. If transmission is not to be reinstalled, accomplish
Do not exceed 15 drops per minute from all sources transmission preservation by one of the following
on the transmission. An external leak can allow sump methods:
to be pumped dry, causing internal failure of
transmission. While any oil remains in sump, the a. If helicopter and transmission are operational,
pressure relief valve will tend to maintain normal perform a 10 minute ground run (BHT-412-FM) prior to
system pressure. This applies especially to leaks removal of transmission.
between pump and relief valve. Leaks occurring
beyond the relief valve could cause indications of low b. If transmission and engine cannot be ground
oil pressure. Leaks in the interior of transmission will run, accomplish preservation after transmission is
not affect oil level but may starve downstream removed as follows:
lubrication areas and may also affect indicated oil
pressure and temperature.
(1) Remove mast assembly (paragraph
63-22).
3. Cumulative clogging of oil filters will not show as
a gradual drop in oil pressure because the pressure (2) Spray inside of transmission through top
relief valve maintains normal system pressure. The opening of transmission with 4 quarts of transmission
external filter has a visual indicator which will extend oil (Chapter 12). Rotate gears by hand while spraying
when filter bypass conditions are impending. This oil.
indicator should be checked during all normal
inspections.
(3) Install cover and lift plate
(204-040-929-101) or install mast assembly.
63-29. TRANSMISSION — MAINTENANCE
(4) Cut and remove lockwire from plug and
The following paragraphs provide maintenance remove plug (AN814-6DL) from top case and install
information for the transmission. dehydrator assembly (T102118-101).
63-00-00
30 MAR 2007 Rev. 11 Page 37
BHT-412-MM-6
Figure 63-9. Transmission
63-00-00
Page 38 Rev. 11 30 MAR 2007
BHT-412-MM-6
2. Remove hub and blade assembly (Chapter 62). 10. Disconnect oil outlet hose (23).
11. Disconnect oil sump drain line (22).

NOTE
Hub and sleeve assembly may be removed 12. If installed, disconnect rotor brake hydraulic
with swashplate and support assembly as a hoses and wiring.
unit. Care must be exercised to prevent
damage to mast and hub splines.
13. Disconnect electrical connector (5).
3. Remove hub and sleeve assembly (Chapter 62).
14. Remove hydraulic system 1 pump (Chapter 29).
4. Remove swashplate and support assembly Install cover (AN100036) (6) on pump drive quill.
(Chapter 62).
15. Remove fluid from hydraulic system 2 using a
5. Remove main driveshaft (paragraph 63-8). suction gun. Disconnect all hoses from hydraulic
system 2 pump. Do not remove pump at this time. Cap
all open ports and hoses.
CAUTION 16. Install mast nut (204-010-481-001) (3) and clevis

(204-011-178-001) (1) with pin (18). Secure pin (18)
with quick release pin (2).
WHEN REMOVING THE TAIL ROTOR
DRIVESHAFT (10, FIGURE 63-10) ON
HELICOPTERS PRIOR TO S/N 36020 NOTE
(NOT MODIFIED BY 412-570-001-103 OR
PRE BHT-412-SI-74 (412SP TO 412HP If mast is not installed, cover and lift plate
UPGRADE)), BOTH CLAMP ASSEMBLIES (204-040-929-101) shall be installed on
(9 AND 11) MUST BE REMOVED PRIOR transmission for lifting.
TO REMOVING TAIL ROTOR
DRIVESHAFT. FAILURE TO COMPLY
MAY RESULT IN DAMAGE TO FLEXIBLE CAUTION
COUPLINGS.
NOTE BEFORE USING HOIST (T101581) TO

REMOVE OR INSTALL TRANSMISSION,
Tail rotor driveshaft clamp assemblies (9 PLACE A SUPPORT UNDER TAILBOOM
and 11) are a matched set; keep in sets to TO STEADY FUSELAGE.
maintain balance. To replace one clamp
half, or if clamp halves are intermixed, each 17. If a suitable stationary or portable hoist is not
clamp half shall be re-matched with one of available, install hoist assembly (T101581).
equal weight (within 1 gram).
18. Attach hoist to clevis (204-011-178-001) (1).
6. Remove clamp assemblies (9 and 11) and
remove tail rotor driveshaft (10).
19. Remove bolts (19), washers (20), and shouldered
7. For helicopters S/N 36020 and subsequent and washers (21) from isolation mounts (24).
BHT-412-SI-74 (412SP to 412HP Upgrade), remove 20. Tie forward isolation mounts (24) into position to
tail rotor driveshaft (10) connected to transmission prevent mounts from disengaging from support case.
(Chapter 65).
21. Remove bolt (26) from lift link (31).
8. Drain oil from transmission sump (Chapter 12).
22. Install adapter (SWE13860) on stand
9. Disconnect transmission oil inlet hose (7). (SWE13875) if not previously accomplished.
63-00-00
BHT-412-MM-6
Figure 63-10. Transmission Removal and Installation (Sheet 1 of 2)
63-00-00
Page 40 Rev. 11 30 MAR 2007
BHT-412-MM-6
Figure 63-10. Transmission Removal and Installation (Sheet 2 of 2)
63-00-00
30 MAR 2007 Rev. 11 Page 41
BHT-412-MM-6
6. Inspect oil level sight glass (6) for crazing, cracks,

or staining (paragraph 63-146).
CAUTION
7. Inspect transmission for loose, missing, or

VERIFY PUMP FOR HYDRAULIC damaged bolts and studs.
SYSTEM 1 AND ALL ELECTRICAL
W I R I N G, H O S E S , L I N E S , A N D
ATTACHING HARDWARE IS REMOVED NOTE
B E F O R E AT T E M P T I N G TO L I F T
TRANSMISSION FROM HELICOPTER. Pay special attention to attaching bolts (26
and 30, Figure 63-10) for lift link (31) and
four bolts (19) securing transmission
23. Hoist transmission clear of airframe. Place
support case to structure.
transmission in support stand and secure to stand with
bolts.
8. Inspect isolation mounts (24, Figure 63-10) and
dampers (25) for secure installation and distortion.
24. If transmission is not to be reinstalled, remove
bolt assembly (30) and lift link (31).
9. Inspect transmission and attached oil lines for
leaks. If main input quill is leaking, replace magnetic
63-31. Transmission — Inspection
seal (paragraph 63-174).
1. Inspect three electric chip detectors as follows:

10. Inspect transmission for mechanical and
corrosion damage (BHT-412-CR&O).
a. Remove, inspect, and install mast bearing
electric chip detector (3, Figure 63-11) (paragraph
63-36). 11. Inspect transmission electrical wiring for secure
installation and damaged wires.
b. Remove, inspect, and install main input gear
quill electric chip detector (4) (paragraph 63-41). 12. Inspect main rotor mast (paragraph 63-24).
c. Remove, inspect, and install sump case

electric chip detector (8) (paragraph 63-46). NOTE
Additional detailed inspections of the
2. Inspect main driveshaft couplings and tail rotor transmission and component parts are
drive quill couplings over-temperature indicator found in the BHT-412-CR&O.
(TEMP-PLATE) for discoloration. A change in color
indicates a possible overheat condition and/or 63-32. Transmission — Build-up
component degradation. Determine and correct cause
of discoloration prior to continued operation.

3. Remove, inspect, and install external oil filter (9)
(paragraph 63-152).
NUMBER NOMENCLATURE
4. Remove, inspect, and install sump internal oil
SWE13860 Adapter
filter (10) (paragraph 63-136). Remove, inspect, and
install full flow debris monitor (helicopters modified by SWE13875 Stand
TB 412-91-94) (paragraph 63-141).
T101581 Hoist
5. Remove, inspect, and install oil pump inlet screen
204-040-929-101 Cover and Lift Plate
(7) (paragraph 63-131).
63-00-00
Page 42 Rev. 11 30 MAR 2007
BHT-412-MM-6
Figure 63-11. Transmission Assembly
63-00-00
30 MAR 2007 Rev. 11 Page 43
BHT-412-MM-6
6. Remove cover (14) and install hydraulic system 2

MATERIALS REQUIRED pump (Chapter 29). Cap or plug open ports on
hydraulic line.
NUMBER NOMENCLATURE NOTE

Hydraulic system 1 pump will be installed
C-405 Lockwire
after transmission is installed in helicopter.
Leave hydraulic system 1 pump drive quill
cover (26) installed at this time.
1. Install adapter (SWE13860) on stand
(SWE13875).
7. Remove cover (10) and install rotor tachometer
generator (19) (paragraph 63-205).
2. Install cover and lift plate (204-040-929-101) (3,
Figure 63-12) on transmission using steel washers (2) 8. Remove plug (24) and packing (23). Install oil
and nuts (1). pressure transmitter (40) and packing (39) (paragraph
63-112).
3. Remove transmission from shipping container
and position on stand (SWE13875). Secure 9. Remove cap (22). Install oil pressure switch (36)
and packing (38) (paragraph 63-116).
transmission to stand with bolts.
4. If transmission is to be installed in helicopter NOTE

immediately, open drain valve (8) and allow all Refer to Chapter 98 for electrical wiring
preservative oil to drain. Close valve. diagrams to confirm wire numbers.
10. Install electrical harness (32) as follows:
CAUTION a. Connect electrical connector (42) to oil

pressure switch (36).
IF ANY OIL LINES FROM A b. Connect electrical connector (41) to oil

TRANSMISSION WHICH WAS REMOVED pressure transmitter (40).
DUE TO INTERNAL FAILURE OR METAL
C O N TA M I N AT I O N A R E T O B E c. Connect ground wire to ground connection
I N S TA L L E D O N R E P L A C E M E N T (33).
TRANSMISSION, ENSURE ALL FOREIGN
PA R T I C L E S A R E C L E A N E D F R O M
d. Install six upper clamps (30) (remaining four
HOS ES . MA ST A SS EMB LIES F ROM are installed in step h).
TRANSMISSIONS DESCRIBED ABOVE
SHALL BE OVERHAULED PRIOR TO
e. Remove cover (21). Install electrical terminal
FURTHER USE.
and nipple (35) on thermoswitch (25).
NOTE f. Connect electrical terminal and nipple (37) to

main input gear quill electric chip detector (7)
If components from transmission removed (paragraph 63-45).
from helicopter are to be used for build-up
of replacement transmission, position g. Connect electrical terminal and nipple (34) to
transmissions near each other to facilitate mast bearing electric chip detector (4) (paragraph
transfer of components. 63-40).
5. Install mast in transmission (paragraph 63-25). h. Install four lower clamps (30).
63-00-00
Page 44 Rev. 11 30 MAR 2007
BHT-412-MM-6
Figure 63-12. Transmission Build-up (Sheet 1 of 4)
63-00-00
30 MAR 2007 Rev. 11 Page 45
BHT-412-MM-6
63-00-00
Page 46 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-00-00
30 MAR 2007 Rev. 11 Page 47
BHT-412-MM-6
63-00-00
Page 48 Rev. 11 30 MAR 2007
BHT-412-MM-6
i. Install electrical terminal and nipple (29) on EXTERNA L OIL FILTER, AND MAST
sump electric chip detector (27) and connect electrical ASSEMBLY.
harness to full flow debris monitor for S/N 36020 and
subsequent and helicopters modified by 1. Inspect condition of pylon structure and repair or
412-570-001-103 or Post BHT-412-SI-74 (412SP to replace any unserviceable isolation mounts (24,
412HP Upgrade) (or those modified by TB 412-91-94). Figure 63-10) and/or dampers (25) (paragraph
63-221).
j. Install electrical connector (28) on rotor
tachometer generator (19) and secure with lockwire 2. Install mast assembly (paragraph 63-25) and
(C-405). replace dehydrator assembly (T102118-101) in top
case with plug (AN814-6DL). For helicopters modified
k. If transmission is to be installed in a helicopter by TB 412-98-150, replace dehydrator assembly with
equipped with a rotor brake, remove rotor brake quill breather (A800V). Torque plug or breather to 80 to
port cover (6) and install rotor brake quill (paragraph 120 inch-pounds (9.04 to 13.56 Nm). Secure plug with
63-217). lockwire (C-405).
l. Install caps, covers, and plugs removed in 3. If not previously accomplished, position lift link
preceding steps. (31) and washer (32) between lugs of transmission lift
link fitting (36). Install bolt assembly (30), steel washer
63-33. Transmission — Installation (33), and nut (34). Torque nut to 60 to 80 foot-pounds
(81 to 108 Nm). Install cotter pin (35).
SPECIAL TOOLS REQUIRED 4. Erect hoist assembly (T101581 or equivalent).

Install clevis (204-011-178-001) (1) on mast nut
(204-010-481-001) (3). Attach hoist to clevis.
NUMBER NOMENCLATURE
T101581 Hoist Assembly

NOTE
204-010-481-001 Mast Nut If mast is not installed, cover and lift plate
(204-040-929-101) must be installed on
204-011-178-001 Clevis transmission for lifting.
204-040-929-101 Lift Plate Cover
5. Lift transmission from stand and lower into
position on isolation mounts (24) while guiding lift link
(31) into position on lift beam.
MATERIALS REQUIRED
6. Align lift link (31) with lift beam and install bolt
Refer to BHT-ALL-SPM for specifications. (26), thin steel washer (27), and nut (29). Torque nut to
108 to 125 foot-pounds (146.8 to 170 Nm). Install
NUMBER NOMENCLATURE cotter pin (28).
C-405 Lockwire
NOTE
Ensure countersunk side of washer (20) is
CAUTION toward head of bolt (19). Washer (21) is
installed with beveled side down.
IF REPLACING TRANSMISSION FOR 7. Install bolts (19), washers (20), and washers (21)
I N T E R N A L FA I L U R E O R M E TA L on isolation mounts (24). Torque bolts (19) to 90 to
PARTICLES IN OIL, CLEAN ALL OIL 105 foot-pounds (122 to 142 Nm). Remove ties
LINES AND REPLACE OIL COOLER, holding forward isolation mounts in position.
63-00-00
BHT-412-MM-6
8. For helicopters prior to S/N 36020 (and not 14. Connect transmission oil outlet hose (23) to
modified by 412-570-001-103 or Pre BHT-412-SI-74 manifold line.
(412SP to 412HP Upgrade)), install tail rotor driveshaft
(10) as follows:
15. Connect oil sump drain line (22).
NOTE 16. If equipped, connect rotor brake hydraulic hose

Clamp assemblies (9 and 11) are a and electrical wiring.
matched set. To replace one clamp half, or
if clamp halves are inadvertently mixed, 17. Connect hydraulic system 2 inlet and pressure
each clamp half shall be rematched with hoses, case drain hose, and seal drain hose to pump
one of equal weight (within 1 gram) to fittings.
maintain balance.
18. Service transmission (Chapter 12). Verify actual

a. Position tail rotor driveshaft (10) between tail
presence of oil in sight gauge.
rotor drive quill (12) and tail rotor hanger coupling (8).
19. If transmission has not been previously qualified

NOTE on run-in test stand, accomplish alternate run-in
All nuts used on a clamp shall be the same procedures in paragraph 63-34.
type and style. Nuts are self-locking and
shall not be used unless nut drag torque is 63-34. Transmission — Alternate Run-in
3.5 inch-pounds (0.40 Nm) minimum and Procedures
30 inch-pounds (3.39 Nm) maximum.
b. Install clamp assembly (9) with bolt heads in NOTE

direction of rotation. Tighten clamp assembly bolts
evenly. Torque nuts to 30 to 35 inch-pounds (3.39 to After overhaul, it is desirable that
3.95 Nm) above nut friction. Tap lightly around outer transmission be test run and inspected in
surface of clamp assembly with plastic mallet to seat accordance with publication furnished with
clamp. Repeat torquing procedure. run-in test stand. In the event a test stand is
not available, the following functional test
may be accomplished as the minimum
c. Install clamp assembly (11) with bolt heads in acceptable alternate test.
direction of rotation and with clamp joints 90° to clamp
assembly (9). Torque clamp assembly bolts in same
1. Install sufficient ballast in cabin to obtain
manner as described in step b.
maximum gross weight (BHT-412-FM).
9. For helicopters 36020 and subsequent (and

helicopters modified by 412-570-001-103 or Post 2. Verify helicopter is properly serviced and
BHT-412-SI-74 (412SP to 412HP Upgrade), install lubricated (Chapter 12). Visually inspect the following:
forward tail rotor driveshaft (Chapter 65).
a. Oil system for security and leakage.
10. Install engine-to-transmission driveshaft (13)
(paragraph 63-13). b. Fuel system for security and leakage.
11. Install hydraulic system 1 pump (Chapter 29). c. Hydraulic system for security and leakage.
12. Connect electrical connector (5) on right side of d. Flight controls for security.
transmission.
3. Inspect engine accessories and controls for
13. Connect transmission oil inlet hose (7) to oil filter. security, loose connections, and proper operation.
63-00-00
BHT-412-MM-6
9. At 100% RPM, check transmission oil pressure.

NOTE
Pressure should be between 52 and 58 PSI when oil
Throughout the entire procedure which temperature is 90° to 100°C. If pressure is not within
follows, carefully check for evidence of these limits, adjust pressure relief valve as follows:
leakage and abnormal noises.
a. Shut down helicopter.
4. Start engines (BHT-412-FM) and run at 60% RPM
for 5 minutes. Verify temperatures and pressures are
b. Loosen jamnut on adjustment screw.
within limits.
c. Turn adjustment screw clockwise to increase
5. Gradually increase RPM from 60 to 88% at the pressure, or counterclockwise to decrease pressure,
rate of 7% each 6 minutes of operation. as required.
6. Hold 88% for 2 minutes with collective applied to d. Tighten jam nut.
the maximum which can be attained without becoming
airborne or exceeding 100% torque. e. Start engines and gradually increase RPM to
100% and recheck pressure.
7. Shut down engines. Remove, inspect, clean, and
install the following components: f. Repeat step a through step e, as required, to
obtain proper oil pressure.
a. Three electric chip detectors (paragraph
63-35). 10. Operate at 100% RPM for 30 minutes with
collective applied to maximum attainable without
b. Oil pump inlet screen (paragraph 63-131). becoming airborne or exceeding 100% torque.
c. Sump case internal filter (paragraph 63-136). 11. Shut down helicopter and repeat inspections
listed in step 7.
d. External oil filter (paragraph 63-152).
12. Inspect main driveshaft couplings, tail rotor drive
e. Planetary oil jets (two) (paragraph 63-52). quill couplings, and surrounding area for evidence of
grease leakage. If there is evidence of leakage,
f. Oil jet No. 1 (paragraph 63-58) replace or repair defective components. Repeat leak
test run in step 10.
g. Oil jet No. 2 (paragraph 63-64).
13. Inspect main and tail rotor driveshaft couplings
h. Oil jet No. 3 (paragraph 63-70). over-temperature indicator (TEMP-PLATE) for
possible overheat condition. A change in color (from
i. Oil jet No. 4 (paragraph 63-76). white to black) indicates possible overheating and/or
component degradation. If overheating is indicated,
cause shall be determined and corrected prior to
j. Oil jet No. 5 (paragraph 63-82).
helicopter being released for flight. Refer to the
BHT-412-CR&O for inspection and lubrication
k. Oil jet No. 6 (paragraph 63-88). procedures for main driveshaft couplings and for tail
rotor driveshaft couplings.
l. Oil jet No. 7 (paragraph 63-94).
14. Check transmission oil level. Service as required
8. Restart engines (BHT-412-FM) and gradually (Chapter 12).
increase to 88% RPM. Operate at 88% for 6 minutes.
Move collective to the maximum position which can be
attained without becoming airborne. At the rate of 3% 15. Install engine and transmission cowling.
each 6 minutes, gradually increase RPM to 100%
without exceeding 100% torque. 16. Check for leaks at next helicopter ground run.
63-00-00
1 MAY 2012 Rev. 15 Page 51/52
BHT-412-MM-6
TRANSMISSION OIL SYSTEM COMPONENTS
63-35. ELECTRIC CHIP DETECTORS 1. Clean electric chip detector (4, Figure 63-13) with
drycleaning solvent (C-304).
63-36. MAST BEARING ELECTRIC CHIP
DETECTOR 2. Dry with filtered, compressed air.
The mast bearing electric chip detector is installed in 63-40. Mast Bearing Electric Chip Detector —
the transmission top case (Figure 63-13) to detect Installation
foreign particles in the transmission oil originating from
the main rotor mast upper bearing.
MATERIALS REQUIRED
63-37. Mast Bearing Electric Chip Detector —
Removal Refer to BHT-ALL-SPM for specifications.
1. Remove nut (1, Figure 63-13) and disconnect NUMBER NOMENCLATURE

wire from stud (2).
C-405 Lockwire
2. Push and twist chip detector (4) counterclockwise
to disengage locking lugs (3). Remove chip detector 1. Lubricate new packing (7, Figure 63-13) with
from chip detector housing (6). transmission oil (Chapter 12). Install packing on chip
detector housing (6).
3. Cut and remove lockwire from chip detector
housing (6), and remove chip detector housing from NOTE
transmission.
If a plug has been installed where the chip
detector housing (6) is normally installed,
4. Remove and discard packing (5) from chip
perform step 2.
detector (4) and, if removed, discard packing (7) from
chip detector housing (6). 2. Remove plug from top of transmission case were
chip detector housing (6) is normally located.
63-38. Mast Bearing Electric Chip Detector —
Inspection 3. Install chip detector housing (6) in top of
transmission (8).
1. Inspect chip detector (4, Figure 63-13) for
presence of metal particles. If any particles are found, 4. Torque chip detector housing (6) to 280 to 300
refer to paragraph 63-2 for required action. inch-pounds (31.7 to 33.9 Nm). Secure housing to
transmission with lockwire (C-405).
2. Inspect chip detector (4) components in
accordance with Figure 63-14. 5. Lubricate new packing (5) with transmission oil
(Chapter 12) and install new packing on chip detector
63-39. Mast Bearing Electric Chip Detector — (4).
Cleaning
6. Insert chip detector (4) into chip detector housing
(6). Push in on electric detector and twist clockwise to
MATERIALS REQUIRED engage locking lugs (3).
Refer to BHT-ALL-SPM for specifications. 7. Install electrical wire on stud (2).
NUMBER NOMENCLATURE 8. Install nut (1) on stud (2). Tighten nut to a

maximum of 4 inch-pounds (0.45 Nm) torque. Position
nipple over nut.
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30 MAR 2007 Rev. 11 Page 53
BHT-412-MM-6
Figure 63-13. Mast Bearing Electric Chip Detector
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BHT-412-MM-6
Figure 63-14. Electric Chip Detector (Typical) — Damage Limits
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BHT-412-MM-6
63-41. MAIN INPUT GEAR QUILL ELECTRIC 2. Dry with filtered, compressed air.
CHIP DETECTOR
63-45. Main Input Gear Quill Electric Chip
The main input gear quill electric chip detector Detector — Installation
(Figure 63-15) is installed to detect metal particles in
the transmission oil originating from the main input
gear quill.
MATERIALS REQUIRED
Detector — Removal
NUMBER NOMENCLATURE
1. Remove nut (2, Figure 63-15) and remove wire
from stud (3). C-405 Lockwire
2. Push in and twist electric chip detector (5)

1. Lubricate new packings (6 and 8, Figure 63-15)
counterclockwise to disengage locking lugs (4).
with transmission oil (Chapter 12). Install packing (8)
on chip detector housing (7) and packing (6) on
3. Remove electric chip detector (5) from chip electric chip detector (5).
detector housing (7).
2. Install chip detector housing (7) on transmission

4. Cut and remove lockwire from chip detector
(1). Torque housing to 280 to 300 inch-pounds
housing (7), and remove chip detector housing from
(31.7 to 33.9 Nm). Secure housing to transmission (1)
transmission (1).
with lockwire (C-405).
5. Remove and discard packing (6) from electric

3. Insert electric chip detector (5) into chip detector
chip detector (5) and, if removed, discard packing (8)
housing (7). Push in on electric chip detector and twist
from chip detector housing (7).
clockwise to engage locking lugs (4).

Detector — Inspection 4. Install electrical wire on stud (3).
1. Inspect electric chip detector (5, Figure 63-15) for 5. Install nut (2) on stud (3). Tighten nut to a
presence of metal particles. If any particles are found, maximum of 4 inch-pounds (0.45 Nm) torque. Position
refer to paragraph 63-2 for required action. nipple over nut.
2. Inspect electric chip detector (5) components in 63-46. SUMP CASE ELECTRIC CHIP DETECTOR
accordance with Figure 63-14.
The sump case electric chip detector (4, Figure 63-16)
63-44. Main Input Gear Quill Electric Chip is installed to detect metal particles which collect in
Detector — Cleaning sump.
63-47. Sump Case Electric Chip Detector —

MATERIALS REQUIRED Removal

NOTE
NUMBER NOMENCLATURE The sump case electric chip detector (4,
Figure 63-16) may be removed for
inspection without draining sump. However,
if the electric chip detector self-closing
1. Clean electric chip detector (5, Figure 63-15) with valve (2) is to be removed, the sump must
drycleaning solvent (C-304). be drained (Chapter 12).
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BHT-412-MM-6
1 2
SEE DETAIL A
8
DETAIL A
1. Transmission
2. Nut
3. Stud
4. Locking lugs
5. Electric chip detector
6. Packing
7. Chip detector housing
8. Packing
LOCKWIRE (MS20995C32)
280 TO 300 IN-LBS

(31.7 TO 33.9 Nm)
412_MM_63_0021
Figure 63-15. Main Input Gear Quill Electric Chip Detector
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BHT-412-MM-6
Figure 63-16. Sump Case Electric Chip Detector
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BHT-412-MM-6
1. Remove oil level access door on right side of 1. Clean electric chip detector (4, Figure 63-16) with
pylon. drycleaning solvent (C-304).
2. Move nipple (7, Figure 63-16) back on wire

2. Dry with filtered, compressed air.
terminal (5) to expose nut (6). Remove nut and wire
terminal from electric chip detector (4).
3. Push in and twist electric chip detector (4) Installation
counterclockwise to disengage from locking detents.
4. Remove electric chip detector (4) from electric MATERIALS REQUIRED

chip detector self-closing valve (2).
5. Remove and discard packings (3) from electric
chip detector (4). NUMBER NOMENCLATURE
C-405 Lockwire
6. If the electric chip detector self-closing valve (2) is
being removed, perform the following steps:
1. If the electric chip detector self-closing valve (2,
a. Drain transmission sump case (Chapter 12). Figure 63-16) was removed, perform the following
steps:
b. Cut and remove lockwire from electric chip
detector self-closing valve (2), pump screen (8), and
plug (9). a. Lubricate new gasket (1) with transmission oil
(Chapter 12). Install gasket on electric chip detector
c. Remove electric chip detector self-closing self-closing valve (2).
valve (2) from transmission sump case.
b. Install electric chip detector self-closing valve
d. Remove gasket (1) from electric chip detector (2) on transmission sump case and torque to 300 to
self-closing valve (2). 400 inch-pounds (33.9 to 45.2 Nm).

c. Secure electric chip detector self-closing valve
Inspection
(2) to pump screen (8) and plug (9) with lockwire
(C-405).
1. Inspect electric chip detector (4, Figure 63-16) for
presence of metal particles. If any particles are found,
refer to paragraph 63-2 for required action. 2. Lubricate new packings (3) with transmission oil
(Chapter 12). Install packings (3) on electric chip
2. Inspect electric chip detector (4) components in detector (4).
accordance with Figure 63-17.
3. Insert electric chip detector (4) into electric chip
63-49. Sump Case Electric Chip Detector — detector self-closing valve (2). Push in on electric chip
Cleaning detector and turn clockwise to engage the locking
detents.
MATERIALS REQUIRED
4. Install wire terminal (5) on electric chip
detector (4).
NUMBER NOMENCLATURE 5. Install nut (6) on electric chip detector (4). Tighten
nut to a maximum of 4 inch-pounds (0.45 Nm) torque.
Position nipple (7) over nut.
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27 FEB 2009 Rev. 12 Page 59
BHT-412-MM-6
Figure 63-17. Sump Case Electric Chip Detector — Damage Limits
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BHT-412-MM-6
63-51. TRANSMISSION OIL SYSTEM 63-55. Planetary Oil Jets — Cleaning

COMPONENTS
63-52. PLANETARY OIL JETS MATERIALS REQUIRED

Two planetary oil jets (8, Figure 63-18) are installed in
the planetary gear case of the transmission to provide NUMBER NOMENCLATURE
positive lubrication to planetary gearing.
63-53. Planetary Oil Jets — Removal

1. Clean planetary oil jets (8, Figure 63-18) using
NOTE
The planetary oil jet on the forward side of
transmission is shown in Figure 63-18.
Maintenance procedures for the planetary 63-56. Planetary Oil Jets — Repair
oil jet on the left side of transmission are
similar. Repair of planetary jets (8, Figure 63-18) is limited to
removal of corrosion products from plate at base of jet
on exterior of transmission.
1. Disconnect tube (2, Figure 63-18) from fitting (4).
63-57. Planetary Oil Jets — Installation
2. Cut and remove lockwire from screw (7) and
remove screw.
MATERIALS REQUIRED
3. Remove planetary oil jet (8).
4. Disassemble planetary oil jet (8) as follows: NUMBER NOMENCLATURE
C-405 Lockwire
a. Loosen nut (5) and remove fitting (4) with
packings (6).
1. Lubricate new packing (1, Figure 63-18) with
transmission oil (Chapter 12). Install packing on
b. Remove and discard packings (1 and 6). planetary oil jet (8).
63-54. Planetary Oil Jets — Inspection 2. Install nut (5) on fitting (4), and install fitting on
planetary oil jet (8).
1. Inspect planetary oil jet (8) for clogging. If

passages are clogged, determine source(s) of material 3. Lubricate new packing (6) with transmission oil
and install on fitting (4).
(paragraph 63-3).
4. Insert planetary oil jet (8) into transmission

2. Inspect for corrosion. Superficial corrosion housing and install screw (7). Secure screw (7) on
damage on plate on exterior of transmission is planetary oil jet with lockwire (C-405).
acceptable if removed.
5. Connect tube (2) and tighten nut (3).
3. Inspect for mechanical damage. Cracks and
distortion are not acceptable. 6. Check for oil leaks at next helicopter ground run.
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BHT-412-MM-6
Figure 63-18. Planetary Oil Jet
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BHT-412-MM-6
63-58. OIL JET NO. 1 63-64. OIL JET NO. 2
63-59. Oil Jet No. 1 — Removal 63-65. Oil Jet No. 2 — Removal
1. Cut and remove lockwire from screw (9, 1. Cut and remove lockwire from screw
Figure 63-19) and screw (3), and remove screw (9). (1, Figure 63-20), and remove screw from oil jet
No. 2 (4).
2. Remove oil jet No. 1 (6) from housing in top case
(2) on transmission (1). 2. Remove oil jet No. 2 (4) from housing (8) on
transmission.
3. Remove screw (3) and washers (4 and 5).
3. Remove screw (7) and washers (5 and 6).
4. Remove and discard packings (7 and 8).
63-60. Oil Jet No. 1 — Inspection
Refer to paragraph 63-54.
63-61. Oil Jet No. 1 — Cleaning
63-62. Oil Jet No. 1 — Repair
Refer to paragraph 63-56. Refer to paragraph 63-56.
63-63. Oil Jet No. 1 — Installation 63-69. Oil Jet No. 2 — Installation
MATERIALS REQUIRED MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications. Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE NUMBER NOMENCLATURE
C-405 Lockwire C-405 Lockwire
1. Install screw (3, Figure 63-19) with washers (4 1. Install screw (7, Figure 63-20) with washers (5
and 5) on oil jet No. 1 (6). and 6) on oil jet No. 2 (4).
2. Lubricate new packings (7 and 8) with 2. Lubricate new packings (2 and 3) with
transmission oil (Chapter 12) and install in grooves of transmission oil (Chapter 12) and install in grooves of
oil jet No. 1 (6). oil jet No. 2.
3. Carefully insert oil jet No. 1 (6) into housing in top 3. Carefully insert oil jet No. 2 (4) into housing (8) on
case (2). transmission.
4. Install screw (9). Secure screw (9) to screw (3) 4. Install screw (1). Secure screw (1) to screw (7)
using lockwire (C-405). using lockwire (C-405).
5. Check for oil leaks at next helicopter ground run. 5. Check for oil leaks at next helicopter ground run.
63-00-00
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BHT-412-MM-6
Figure 63-19. Oil Jet No. 1
63-00-00
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BHT-412-MM-6
63-00-00
30 MAR 2007 Rev. 11 Page 65
BHT-412-MM-6
63-70. OIL JET NO. 3 5. Secure bolt (1) to screw (10) using lockwire
(C-405).
63-71. Oil Jet No. 3 — Removal
6. Check for oil leaks at next helicopter ground run.
1. Cut and remove lockwire from bolt (1,
Figure 63-21) and screw (10).
63-76. OIL JET NO. 4
2. Remove bolt (1), thin steel washer (2), and 63-77. Oil Jet No. 4 — Removal
bracket (3) from oil jet No. 3 (7).
1. Remove access door on left side of pylon support
3. Remove oil jet No. 3 (7) with packing (4, 5, and in cabin.
6).
2. Cut and remove lockwire from screw (8,
4. Remove screw (10) and washers (8 and 9). Figure 63-22) and screw (7). Remove screw (8).
5. Remove and discard packings (4, 5, and 6).

NOTE
63-72. Oil Jet No. 3 — Inspection When removing oil jet No. 4 (4) from sump
case (1), make sure packings (2 and 3) are
Refer to paragraph 63-54. extracted with the oil jet.
63-73. Oil Jet No. 3 — Cleaning 3. Remove oil jet No. 4 (4) with packings (2 and 3)
from sump case (1).
4. Remove screw (7) and washers (5 and 6) from oil
63-74. Oil Jet No. 3 — Repair jet No. 4 (4).

63-75. Oil Jet No. 3 — Installation
MATERIALS REQUIRED Refer to paragraph 63-54.
Refer to BHT-ALL-SPM for specifications. 63-79. Oil Jet No. 4 — Cleaning
NUMBER NOMENCLATURE Refer to paragraph 63-55.
C-405 Lockwire 63-80. Oil Jet No. 4 — Repair
1. Carefully install screw (10, Figure 63-21) with Refer to paragraph 63-56.
washers (8 and 9) on oil jet No. 3 (7).
2. Lubricate new packings (4, 5, and 6) with
transmission oil (Chapter 12) and install in grooves of
oil jet No. 3 (7). MATERIALS REQUIRED
3. Carefully insert oil jet No. 3 (7) into manifold (11). Refer to BHT-ALL-SPM for specifications.
4. Install bolt (1), thin steel washer (2), and bracket NUMBER NOMENCLATURE
(3). Torque bolt (1) to 50 to 70 inch-pounds (5.7 to
C-405 Lockwire
7.9 Nm).
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BHT-412-MM-6
63-00-00
30 MAR 2007 Rev. 11 Page 67
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BHT-412-MM-6
1. Install screw (7, Figure 63-22) with washers (5 1. Install screw (5, Figure 63-23) with washers (6
and 6) on oil jet No. 4 (4). and 7) on oil jet No. 5 (3).
2. Lubricate new packings (2 and 3) with 2. Lubricate new packings (1 and 2) with
transmission oil (Chapter 12) and install in grooves of transmission oil (Chapter 12) and install in grooves of
oil jet No. 4 (4). oil jet No. 5 (3).
3. Carefully insert oil jet No. 4 (4) into sump case 3. Carefully insert oil jet No. 5 (3) into transmission
(1). case.
4. Install screw (4), and secure screw (5) to screw

4. Install screw (8) to secure oil jet No. 4 (4) into
(4) using lockwire (C-405).
sump case (1). Secure screw (8) to screw (7) using
lockwire (C-405).
63-82. OIL JET NO. 5 63-89. Oil Jet No. 6 — Removal
63-83. Oil Jet No. 5 — Removal 1. Cut and remove lockwire from screw (7,
Figure 63-24) and screw (6), and remove screw (7).
1. Cut and remove lockwire from screw (4,
Figure 63-23) and screw (5). Remove screw (4). 2. Remove oil jet No. 6 (8) with packings (1, 2, and
3).
2. Carefully remove oil jet No. 5 (3) with packing (1
and 2). 3. Remove screw (6) and washers (4 and 5).
3. Remove screw (5) and washers (6 and 7) from oil 4. Remove and discard packings (1, 2, and 3).
jet No. 5 (3).
MATERIALS REQUIRED
MATERIALS REQUIRED NUMBER NOMENCLATURE
Refer to BHT-ALL-SPM for specifications. C-405 Lockwire
NUMBER NOMENCLATURE
1. Install screw (6, Figure 63-24) with washers (4
C-405 Lockwire
and 5) on oil jet No. 6 (8).
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2. Lubricate new packings (1, 2, and 3) with 63-99. Oil Jet No. 7 — Installation
oil jet No. 6 (8).
MATERIALS REQUIRED
3. Carefully insert oil jet No. 6 (8) into transmission
case. Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
4. Install screw (7). Secure screw (7) to screw (6)
with lockwire (C-405). C-405 Lockwire

1. Install screw (9, Figure 63-25) with new seal (10).

2. Lubricate new packings (3, 4, and 5) with
63-95. Oil Jet No. 7 — Removal oil jet No. 7 (6).
1. Cut and remove lockwire from oil pressure 3. Carefully insert oil jet No. 7 (6) into transmission
regulating valve (1, Figure 63-25), thermoswitch (11), case.
and thermobulb (12).
4. Install screw (8) and thin steel washer (7). Secure

2. Remove oil pressure regulating valve screw (8) to screw (9) with lockwire (C-405).
(1, Figure 63-25) with packing (2). Discard packing.
5. Lubricate new packing (2) with transmission oil

3. Cut and remove lockwire from screw (8) and (Chapter 12) and install on oil pressure regulating
screw (9), and remove screw (8) and thin steel valve (1).
washer (7).
6. Install oil pressure regulating valve (1) in

4. Remove oil jet No. 7 (6) with packings (3, 4, and manifold.
5).
7. Secure oil pressure regulating valve (1) to

5. Remove screw (9) and seal (10). Discard seal.
thermoswitch (11) and thermobulb (12) with lockwire
(C-405).
6. Discard packings (3, 4, and 5).
63-100. OIL PRESSURE REGULATING VALVE
63-101. Oil Pressure Regulating Valve — Removal
1. Cut and remove lockwire from oil pressure

Refer to paragraph 63-55. regulating valve (1, Figure 63-26), thermoswitch (3),
and thermobulb (4).
2. Remove oil pressure regulating valve (1) and
Refer to paragraph 63-56. packing (2). Discard packing.
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BHT-412-MM-6
Figure 63-26. Oil Pressure Regulator Valve
63-00-00
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BHT-412-MM-6
63-102. Oil Pressure Regulating Valve — Cleaning 1. Lubricate new packing (2, Figure 63-26) with
transmission oil (Chapter 12), and install packing on oil
pressure regulating valve (1).
MATERIALS REQUIRED
2. Install oil pressure regulating valve (1) in manifold
Refer to BHT-ALL-SPM for specifications. (Detail A).
NUMBER NOMENCLATURE
3. Secure oil pressure regulating valve (1) to
C-304 Drycleaning Solvent thermoswitch (3) and thermobulb (4) with lockwire
(C-405).
63-106. OIL TEMPERATURE MANIFOLD

CAUTION
63-107. Oil Temperature Manifold — Removal

DO N O T IM M ER S E O IL P R E S SU RE
REGULATING VALVE IN SOLVENT. 1. Cut and remove lockwire from bolt (16,
Figure 63-27) and screw (15).
1. Wipe oil pressure regulating valve (1,
Figure 63-26) with clean cloth dampened with
drycleaning solvent (C-304). 2. Remove bolt (16), thin steel washer (17), and
bracket (18).
2. Dry using filtered, compressed air.
3. Remove oil jet No. 3 (14) and packings (11, 12,
and 13). Discard packings.
63-103. Oil Pressure Regulating Valve —
Inspection
4. Cut and remove lockwire from electrical
Inspect oil pressure regulating valve (1, Figure 63-26) connector and disconnect electrical connector from
for damaged threads and for mechanical or corrosion thermobulb (6).
damage. Damage in excess of superficial is
unacceptable. Corrosion damage shall be removed.
5. Disconnect hose (9) from elbow (8).
63-104. Oil Pressure Regulating Valve — Repair

6. Identify and tag electrical wire installed on
thermoswitch (23), and disconnect electrical wire from
Repair of oil pressure regulating valve (1,
thermoswitch.
Figure 63-26) is limited to removal of superficial
corrosion from areas exposed on exterior of
transmission. 7. Identify and tag electrical wires installed on
bracket (21). Remove electrical wires from bracket.
63-105. Oil Pressure Regulating Valve —
Installation
8. Remove bolt (19), thin steel washer (20), and
bracket (21).
MATERIALS REQUIRED
9. Cut sealant from around tube (2) using a sharp
plastic scraper.
NUMBER NOMENCLATURE 10. Carefully work oil manifold (24) loose and remove
manifold with tube (2), packings (1, 3, 4, and 5), and
C-405 Lockwire
gasket (25). Discard packings and gasket.
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BHT-412-MM-6
Figure 63-27. Oil Temperature Manifold
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BHT-412-MM-6
63-108. Oil Temperature Manifold — Installation 10. Install hose (9) on elbow (8). Tighten nut (7).
MATERIALS REQUIRED 11. Connect electrical plug to thermobulb (6) and

secure with lockwire (C-508).
12. Connect electrical wire to thermoswitch (23).
NUMBER NOMENCLATURE
C-308 Sealant 13. Install electrical wires on bracket (21). Remove

identification tag.
C-405 Lockwire
14. Apply a bead of sealant (C-308) around each end
C-508 Lockwire of tube (2) at mating joint.
1. If removed, install nut (7, Figure 63-27) on elbow 15. Check for oil leaks at next helicopter ground run.
(8), coat new packing (10) with transmission oil
(Chapter 12) and install on elbow. Install elbow, nut 63-109. OIL PRESSURE TRANSMITTER
and packing on manifold. Do not tighten nut at this
time.
63-110. Oil Pressure Transmitter — Removal
2. Lubricate new packings (1 and 3) with 1. Cut and remove lockwire from electrical
transmission oil and install on tube (2). Install tube in connector (5, Figure 63-28), and disconnect electrical
oil manifold (24). connector.
3. Lubricate new packings (4 and 5) with 2. Cut and remove lockwire securing oil pressure
transmission oil and install in oil manifold (24). transmitter (4).
Lubricate new gasket (25) with transmission oil and
install on oil manifold.
3. Remove oil pressure transmitter (4) with packing
(3). Discard packing.
4. Carefully work oil manifold (24) into position on
transmission case. Ensure tube (2) is seated in oil
4. Cap or plug exposed cavity in oil pressure switch
manifold. Ensure bushings on oil manifold are seated
and pressure transmitter manifold (2).
on transmission case.
63-111. Oil Pressure Transmitter — Inspection

5. Install bolt (19) with thin steel washer (20) and
bracket (21). Do not torque bolt at this time.
Inspect oil pressure transmitter (4, Figure 63-28) and
electrical connector for bent pins, damaged threads,
6. Lubricated new packings (11, 12, and 13) and dents, or other mechanical damage rendering
install packings on oil jet No. 3 (14). transmitter unserviceable.
7. Carefully install oil jet No. 3 (14) in oil manifold 63-112. Oil Pressure Transmitter — Installation
(24) and install bolt (16) with thin steel washer (17)
and bracket (18).
MATERIALS REQUIRED
8. Torque bolt (16) to 50 to 70 inch-pounds (5.6 to Refer to BHT-ALL-SPM for specifications.

7.9 Nm). Secure bolt to screw (15) with lockwire
(C-405). NUMBER NOMENCLATURE
9. Torque bolt (19) to 50 to 70 inch-pounds (5.6 to C-405 Lockwire

7.9 Nm). Secure bolt to thermoswitch (23) and
C-508 Lockwire
thermobulb (6) with lockwire (C-405).
63-00-00
30 MAR 2007 Rev. 11 Page 77
BHT-412-MM-6
Figure 63-28. Oil Pressure Transmitter
63-00-00
Page 78 Rev. 11 30 MAR 2007
BHT-412-MM-6
1. Lubricate packing (3, Figure 63-28) with 1. Lubricate packing (3, Figure 63-29) with
transmission oil (Chapter 12). transmission oil (Chapter 12), and install packing on oil
pressure switch (4).
2. Install packing (3) on oil pressure transmitter (4).
2. Install oil pressure switch (4) in oil pressure
switch and pressure transmitter manifold (2), and
3. Install oil pressure transmitter (4) in oil pressure
secure oil pressure switch with lockwire (C-405).
switch and pressure transmitter manifold (2). Secure
oil pressure transmitter with lockwire (C-405).
3. Install electrical connector (5). Secure connector
with lockwire (C-508).
4. Install electrical connector (5) and secure
electrical connector with lockwire (C-508).
4. Perform operational check of oil pressure switch
(4) (Chapter 96) and check for oil leaks at next
5. Perform operational check of oil pressure helicopter ground run.
transmitter (4) (Chapter 96) and check for oil leaks at
next helicopter ground run. 63-117. OIL PRESSURE MANIFOLD
63-113. OIL PRESSURE SWITCH 63-118. Oil Pressure Manifold — Removal
63-114. Oil Pressure Switch — Removal 1. Remove oil pressure switch (paragraph 63-114).
1. Cut and remove lockwire from electrical 2. Remove oil pressure transmitter (paragraph
connector (5, Figure 63-29), and disconnect electrical 63-110).
connector.
3. Remove tube assembly (2, Figure 63-30).
2. Cut and remove lockwire from oil pressure switch
(4), and remove oil pressure switch with packing (3). 4. Remove nuts (7) and washers (5 and 6), securing
Discard packing. oil manifold (4). Remove oil manifold and spacer (3)
from transmission (1).
3. Cap or plug cavity in oil pressure switch and

63-119. Oil Pressure Manifold — Cleaning
pressure transmitter manifold (2).
63-115. Oil Pressure Switch — Inspection MATERIALS REQUIRED
Inspect oil pressure switch (4, Figure 63-29) and Refer to BHT-ALL-SPM for specifications.
electrical connector for bent pins, damaged threads,
dents, or other mechanical damage which would NUMBER NOMENCLATURE
render switch unserviceable.
63-116. Oil Pressure Switch — Installation
1. Wipe oil manifold (4, Figure 63-30) with clean
cloth dampened with drycleaning solvent (C-304).
MATERIALS REQUIRED
63-120. Oil Pressure Manifold — Inspection
NUMBER NOMENCLATURE
Inspect oil manifold (4, Figure 63-30) for damaged
C-405 Lockwire threads and for mechanical or corrosion damage.
Damage in excess of superficial is unacceptable.
C-508 Lockwire
Corrosion damage shall be removed.
63-00-00
30 MAR 2007 Rev. 11 Page 79
BHT-412-MM-6
Figure 63-29. Oil Pressure Switch
63-00-00
Page 80 Rev. 11 30 MAR 2007
BHT-412-MM-6
Figure 63-30. Oil Pressure Manifold
63-00-00
30 MAR 2007 Rev. 11 Page 81
BHT-412-MM-6
63-121. Oil Pressure Manifold — Repair 63-125. Filler Neck, Scupper, and Mounting
Bracket — Cleaning
Repair of oil manifold (4, Figure 63-30) is limited to
removal of superficial corrosion from areas exposed
on exterior of transmission. MATERIALS REQUIRED
63-122. Oil Pressure Manifold — Installation Refer to BHT-ALL-SPM for specifications.
1. Position spacer (3, Figure 63-30) and oil manifold NUMBER NOMENCLATURE
(4) on transmission (1).
2. Install aluminum washers (5) next to oil manifold
(4), then install steel washers (6) and nuts (7). 1. Wipe all parts with clean cloth dampened with
3. Install tube assembly (2).
4. Install oil pressure transmitter (paragraph 63-112)
and oil pressure switch (paragraph 63-116). 63-126. Filler Neck, Scupper, and Mounting
Bracket — Inspection
5. Perform operational check of oil pressure switch
and transmitter (Chapter 96) and check for oil leaks at 1. Inspect scupper (1, Figure 63-31) and oil filler cap
next helicopter ground run. for cracks and distortion or other damage rendering
either component unserviceable. A loose fitting cap
63-123. FILLER NECK, SCUPPER, AND and/or cracked or distorted scupper is not acceptable.
MOUNTING BRACKET Unserviceable components shall be replaced.
Superficial damage such as dents, nicks, or scratches
63-124. Filler Neck, Scupper, and Mounting not affecting serviceability are acceptable without
Bracket — Removal repair. Light surface corrosion is acceptable provided it
is removed and original surface finish restored.
1. Disconnect hose assembly (16, Figure 63-31)
from elbow (18). 2. Inspect bracket (5) and tube (13) for damage
such as distortion and cracks. Loose fitting, cracked,
2. Remove nut (24), washer (25), and screw (17). and/or severely distorted parts are unacceptable and
shall be replaced. Superficial dents, nicks, and
3. Disconnect tube assembly (19). scratches not affecting serviceability are acceptable
without repair.
4. Loosen and remove nut (14) from extension cap
(15), and loosen nut (12) from elbow (11) and nut (14) 63-127. Filler Neck, Scupper, and Mounting
from extension cap (15). Remove tube (13). Bracket — Installation
5. Loosen nut (10) and remove elbow (11) with 1. Install aluminum washers (22, Figure 63-31) on
packing (9). Discard packing. scupper assembly (1). Position scupper assembly on
bracket (5).
6. Remove nuts (20) and aluminum washers (21).
Remove scupper assembly (1) from bracket (5) and 2. Install aluminum washers (21) and nuts (20).
remove aluminum washers (22) from bracket. Torque nuts (20) to 50 to 70 inch-pounds (5.6 to
7.9 Nm).
7. Remove nuts (8) and washers (6 and 7) from
bolts (2), and remove bracket (5). 3. Install nut (10) on elbow (11).
8. Remove bolts (2) and washers (3 and 4) from 4. Lubricate packing (9) with transmission oil
bracket (5). (Chapter 12). Install packing on elbow (11).
63-00-00
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BHT-412-MM-6
Figure 63-31. Filler Neck, Scupper, and Mounting Bracket
63-00-00
30 MAR 2007 Rev. 11 Page 83
BHT-412-MM-6
5. Install elbow (11) on scupper assembly (1). Do 4. Remove tubes (11 and 16).
not tighten nut (10) at this time.
5. Remove nut (9) and steel washer (8). Remove
6. Position bracket (5) on transmission and install bracket (10), tee connection (15), nut (12), and washer
bolts (2) with thin steel washers (3) under bolt heads (13) together as an assembly.
and thin aluminum washers (4) next to bracket (5).
6. Clean sealant from puller hole in bottom center of
7. Install aluminum washers (6) next to transmission pump (4) using a sharp plastic scraper.
case with thin steel washer (7) next to nuts (8). Torque
nuts (8) to 230 to 250 inch-pounds (25.9 to 28.2 Nm).
8. Install tube (13) on elbow (11). Tighten nuts (12 CAUTION

and 14) and tighten nut (10).
9. Connect tube assembly (19) to fitting (23). DO NOT USE JACKSCREWS TO

REMOVE PUMP (4). DO NOT ALLOW
10. Install screw (17), washer (25), and nut (24). PULLER BOLT TO BO T TOM OUT IN
THREADED HOLE OF PUMP.
11. Connect hose assembly (16) to elbow (18).
7. Install slide hammer type puller equipped with 1/4
X 28 UNF threads into center of pump base.
NOTE
Extension cap (15) may be installed by 8. Loosen jamnut on drain valve (14) and rotate
inserting cap on transmission, pressing counterclockwise.
down on cap, and twisting clockwise to
engage lock. 9. Remove remaining nuts (7) with washers (5 and
6) and remove pump (4) with packings (2 and 3).
12. Check for leaks at next helicopter ground run.
63-128. OIL PUMP
63-129. Oil Pump — Removal 63-130. Oil Pump — Installation
SPECIAL TOOLS REQUIRED MATERIALS REQUIRED

NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
Commercial Slide Hammer with 1/4
X 28 UNF Threaded C-405 Lockwire
Shaft
1. Lubricate packings (2 and 3, Figure 63-32) and
1. Remove access door in front of pylon support in mating surfaces of pump (4) and transmission sump
cabin area. assembly (1) with transmission oil (Chapter 12). Install
packings on pump.
2. Drain transmission oil (Chapter 12) from
transmission sump assembly (1, Figure 63-32).
NOTE
3. Cut and remove lockwire securing oil pump The main rotor can be manually rotated, as
screen (18) and remove oil pump screen with packing necessary, to obtain alignment of oil pump
(17). Discard packing. shaft.
63-00-00
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BHT-412-MM-6
Figure 63-32. Transmission Oil Pump
63-00-00
30 MAR 2007 Rev. 11 Page 85
BHT-412-MM-6
2. Warm sump case port with a heat lamp and insert 63-133. Oil Pump Inlet Screen — Inspection
pump into mounting port. Align pump shaft with
internal splines of transmission shaft (19). Use a 1. Inspect oil pump inlet screen (Figure 63-34) for
flashlight to verify engagement of pump and shaft (19) metal particles. If metal particles are present, refer to
through open port of oil pump screen (18). paragraph 63-3.
3. Install bracket (10), tee connection (15), washer 2. Inspect inlet oil pump inlet screen (1,
(13), and nut (12) on pump mounting stud. Figure 63-33) for damage in accordance with
Figure 63-34.
4. Install steel washer (8) and nut (9). Position drain

63-134. Oil Pump Inlet Screen — Cleaning
valve (14), as required, and tighten jamnut.
5. Install washers (5), steel washers (6), and nuts MATERIALS REQUIRED
(7). Torque nuts (7) and nut (9) to 50 to 70
inch-pounds (5.6 to 7.0 Nm). Refer to BHT-ALL-SPM for specifications.
6. Connect tubes (11 and 16). NUMBER NOMENCLATURE

7. Lubricate packing (17) with transmission oil
(Chapter 12). Install packing on oil pump screen (18).
1. Rinse inlet oil pump screen (1, Figure 63-33) with
8. Install oil pump screen (18) and torque oil pump
screen to 300 to 400 inch-pounds (33.9 to 45.1 Nm). 2. Dry using filtered, compressed air.
9. Secure oil pump screen (18) to electric chip 63-135. Oil Pump Inlet Screen — Installation
detector base with lockwire (C-405).
10. Service transmission (Chapter 12). MATERIALS REQUIRED

11. Install access door.
NUMBER NOMENCLATURE
12. Check for oil leaks at next helicopter ground run. C-405 Lockwire
63-131. OIL PUMP INLET SCREEN 1. Lubricate new gasket (2, Figure 63-33) with
transmission oil (Chapter 12). Install packing on oil
63-132. Oil Pump Inlet Screen — Removal pump inlet screen (1).
1. Drain transmission oil sump (Chapter 12). 2. Install oil pump inlet screen (1) on transmission
sump assembly (3).
2. Cut and remove lockwire from oil pump inlet

3. Torque oil pump inlet screen (1) to 300 to 400
screen (1, Figure 63-33).
inch-pounds (33.9 to 45.1 Nm).
3. Remove oil pump inlet screen (1) from 4. Secure oil pump inlet screen (1) to transmission
transmission sump assembly (3). sump assembly (3) with lockwire (C-405).
4. Remove and discard gasket (2). 5. Check for oil leaks at next helicopter ground run.
63-00-00
BHT-412-MM-6
1 T
DETAIL A
SEE DETAIL A
1. Screen
2. Gasket
3. Transmission sump assembly
300 TO 400 IN-LBS

T (33.9 TO 45.1 Nm)
412_MM_63_0033
Figure 63-33. Oil Pump Inlet Screen
63-00-00
BHT-412-MM-6
Figure 63-34. Oil Pump Inlet Screen — Damage Limits
63-00-00
Page 88 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-136. SUMP CASE INTERNAL FILTER 63-139. Sump Case Internal Filter — Cleaning
The following procedures apply to helicopters S/N

33001 to 33214, not modified by TB 412-91-94. For MATERIALS REQUIRED
maintenance procedures applicable to helicopters
modified by subject TB (installation of full flow debris Refer to BHT-ALL-SPM for specifications.
monitor), refer to paragraph 63-141.
NUMBER NOMENCLATURE
63-137. Sump Case Internal Filter — Removal
1. Remove access door on right side of pylon
support in cabin area.
NOTE
2. Remove nuts (1, 11, and 13, Figure 63-35) with Perform step 1 and step 2 if it is not
washers (2, 10, and 12). Remove bracket (3). possible to sufficiently clean the filters while
assembled.
3. Remove nut (9) with washers (7 and 8).
Perform step 3 and step 4 if it is possible to
4. Remove filter assembly (4). sufficiently clean the filters while
assembled.
5. Remove and discard packing (5) from filter
1. To disassemble filter, proceed as follows:
assembly (4).
a. Straighten tangs on washer (2, Figure 63-36)

6. Cap or cover filter mounting port in sump
and remove nut (1).
case (6).
b. Remove washer (2), spacers (3), and wafer
63-138. Sump Case Internal Filter — Inspection
screens (4).
NOTE c. Wash wafer screens (4) with drycleaning

solvent (C-304). Dry wafer screens with filtered,
If the sump case internal filter must be
compressed air.
disassembled for inspection, refer to
paragraph 63-139 and perform step 1a and
step 1b. 2. To assemble filter, proceed as follows:
1. Inspect filter for metal particles and/or other a. Install 10 spacers (3) and 10 wafer screens
material. If metal particles are found, refer to (4). Starting with spacer, alternately install spacers and
paragraph 63-3. wafer screens.
2. Inspect wafer screens (4, Figure 63-36) for b. Install eleventh spacer (3), washer (2), and
distortion or tears. Damage that can be detected nut (1).
visually is not acceptable.
c. Tighten nut (1) until wafer screens (4) will not
3. Inspect spacers (3) for corrosion and rotate when turned by hand.
deformation. Damage in excess of superficial is not
acceptable. d. Bend one tang of thin steel washer (2) over a
flat side of nut (1).
4. Inspect nut (1) for corrosion and thread damage.
Damage in excess of superficial is not acceptable. 3. Wash filter assembly (4, Figure 63-35) with
5. Inspect filter body (5) for mechanical and
corrosion damage (Figure 63-37). 4. Dry with filtered, compressed air.
63-00-00
30 MAR 2007 Rev. 11 Page 89
BHT-412-MM-6
Figure 63-35. Sump Case Internal Filter (Pre TB 412-91-94)
63-00-00
Page 90 Rev. 11 30 MAR 2007
BHT-412-MM-6
Figure 63-36. Sump Case Internal Filter
63-00-00
30 MAR 2007 Rev. 11 Page 91
BHT-412-MM-6
Figure 63-37. Sump Case Internal Filter — Damage Limits
63-00-00
Page 92 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-140. Sump Case Internal Filter — Installation material. If metal particles are found, refer to
paragraph 63-2.
transmission oil (Chapter 12). Install packing on filter 2. Inspect chip detectors (9) and screen tube (10)
assembly (4). for distortion or tears. Damage which can be detected
visually is not acceptable.
2. Insert filter assembly (4) in mounting port of sump
case (6). 3. Inspect nuts (5) for corrosion and thread damage.
In excess of superficial is not acceptable.
3. Position bracket (3) over filter assembly (4) and
studs on sump case (6). 63-144. Full Flow Debris Monitor — Cleaning
4. Install washers (2, 10, and 12) and nuts (1, 11,
and 13). MATERIALS REQUIRED
5. Install thin aluminum washer (7) next to filter Refer to BHT-ALL-SPM for specifications.
housing and thin steel washer (8) adjacent to nut (9).
NUMBER NOMENCLATURE
6. Install nut (9). Torque nuts (1, 9, 11, and 13) to 50
to 70 inch-pounds (5.6 to 7.9 Nm). C-304 Drycleaning Solvent
7. Check for oil leaks at next helicopter ground run. 1. Wash chip detectors (9, Figure 63-38) and screen
tube (10) with drycleaning solvent (C-304).
63-141. FULL FLOW DEBRIS MONITOR
The following procedures are applicable to helicopters
S/N 36020 and subsequent, and helicopters modified 63-145. Full Flow Debris Monitor — Installation
by 412-570-001-103 or Post BHT-412-SI-74 (412SP to
412HP Upgrade), and earlier numbered helicopters 1. Lubricate new packings (6 and 11, Figure 63-38)
modified by TB 412-91-94. with transmission oil (Chapter 12).
63-142. Full Flow Debris Monitor — Removal

2. Install packings (6 and 11) on debris monitor.
1. Remove access door on right side of pylon
support in cabin area (Chapter 52). 3. Install screen tube (10), scupper (7), and cap (8)
on debris monitor.
2. Disconnect electrical harness (2, Figure 63-38).
4. Torque cap (8) to 22 to 30 inch-pounds (2.5 to
3. Remove nuts (5), washers (4), and brackets (1 3.4 Nm).
and 3).
5. Perform operational check (Chapter 96).
4. Remove debris monitor from sump case.
6. Install debris monitor in transmission sump case
5. Remove cap (8), scupper (7), and screen with connector at bottom.
tube (10).
7. Install brackets (1 and 3) using washers (4) and
6. Remove and discard packings (6 and 11). nuts (5).
63-143. Full Flow Debris Monitor — Inspection 8. Torque nuts (5) to 50 to 70 inch-pounds (5.6 to
7.0 Nm).
1. Inspect chip detectors (9, Figure 63-38) and
screen tube (10) for metal particles and/or other 9. Install electrical harness (2).
63-00-00
BHT-412-MM-6
Figure 63-38. Full Flow Debris Monitor
63-00-00
Page 94 Rev. 11 30 MAR 2007
BHT-412-MM-6
10. Install access door on right side of pylon support 1. Wipe components with a clean cloth dampened
in cabin area. with drycleaning solvent (C-304).

63-146. SIGHT GLASSES
63-149. Sight Glasses — Inspection
NOTE
1. Inspect glass (3, Figure 63-39) for cracks,
The following maintenance procedures are
crazing, and stains which would prevent an accurate
detailed for indicator (4, Figure 63-39).
determination of oil level. If any of these conditions are
Maintenance procedures for indicator (6)
present, replace glass.
are similar.
63-147. Sight Glasses — Removal 2. Inspect indicator (4) for stains that might present
a false oil level reading. If such a condition exists,
1. Drain transmission oil as necessary (Chapter 12) replace indicator.
to a level below sight gauge.
2. Remove retainer ring (1, Figure 63-39). 3. Inspect retainer ring (1) for distortion, cracks, tool
marks, and insufficient tension. If any of these
conditions exist, replace retainer.
3. Carefully remove glass (3) with packing (2).
4. Remove indicator (4). 63-150. Sight Glasses — Installation
5. Remove and discard packing (2). 1. Lubricate new packing (2, Figure 63-39) with
transmission oil (Chapter 12). Install indicator (4) in
6. Cover opening in transmission sump case (5). sump.
63-148. Sight Glasses — Cleaning

2. Install new packing (2) on sight glass (3) and
insert glass in sump over indicator (4).
MATERIALS REQUIRED
3. Install retainer ring (1).
NUMBER NOMENCLATURE 4. Service transmission (Chapter 12).

63-00-00
BHT-412-MM-6
Figure 63-39. Sight Glass
63-00-00
Page 96 Rev. 11 30 MAR 2007
BHT-412-MM-6
TRANSMISSION OIL COOLING SYSTEM
63-151. TRANSMISSION OIL COOLING c. Remove bolts (3), thin aluminum washers (4),
SYSTEM and spacers (24) from filter bracket (25). Remove filter
head (13).
The transmission oil cooling system detailed in this
chapter consists of an external oil filter, thermal oil 7. Cap or plug all open lines and hoses to prevent
bypass valve, two drain valves, and connecting tubes contamination.
and hoses. Maintenance procedures applicable to the
oil cooler and blower is described in Chapter 79. 63-154. External Oil Filter — Inspection
63-152. EXTERNAL OIL FILTER

NOTE
The external oil filter (Figure 63-40) is located inside Inspect oil filter components both before
the right pylon support below the sump case and is and after cleaning.
connected to an oil cooler outlet line. The filter element
is replaceable and is made of pleated paper. The filter 1. Inspect oil filter element (17, Figure 63-40) for
head includes a bypass valve to assure oil flow in the contamination. If metal particles are present, refer to
event of filter clogging. If a bypass condition is paragraph 63-3. Do not reuse element.
impending, a red indicator button extends to provide a
positive visual indication.
2. Inspect flange areas of external oil filter body (19)
and filter head (13) for cracks. If cracks are found,
63-153. External Oil Filter — Removal replace part.
1. Remove access door on front of pylon support in 3. Inspect area contacted by packing (15) for
cabin area. Place container under external oil filter damage such as distortion and sharp edges. Minor
body (19, Figure 63-40) to catch oil spillage. surface irregularities may be removed. Distortion or
sharp edges necessitates replacement.
2. Cut and remove lockwire from v-band clamp (14)
and open v-band clamp. Remove external oil filter 63-155. External Oil Filter — Cleaning
body (19).
3. Remove filter element (17) and make a visual MATERIALS REQUIRED

check for evidence of contamination of metal particles.
4. Remove packing (16) from center boss under
filter head (13). Remove packing (18) from boss inside NUMBER NOMENCLATURE
bottom of external oil filter body (19). Discard packings
(16) and (18).
5. Remove and discard packing (15). NOTE

Inspect oil filter components both before
6. If it is necessary to remove the filter head (13), and after cleaning.
perform the following:
1. Wipe components with a clean cloth damp with
a. Disconnect inlet tube (20) and outlet hose (5). drycleaning solvent (C-304).
b. Cut and remove lockwire from bolts (3). 2. Dry with filtered, compressed air.
63-00-00
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BHT-412-MM-6
Figure 63-40. Transmission External Oil Filter
63-00-00
Page 98 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-156. External Oil Filter — Installation valve is located in oil lines between transmission and
oil cooler. The assembly consists of a valve body and
a thermostat. The thermostat will be completely open
MATERIALS REQUIRED when transmission oil temperature is 130°F (55°C) or
below, causing oil to bypass cooler and flow directly to
Refer to BHT-ALL-SPM for specifications. transmission. The thermostat partially closes at
temperatures between 130 and 175°F (55 and 79°C),
NUMBER NOMENCLATURE passing some oil through oil cooler while allowing
remainder to bypass directly to transmission. At higher
C-405 Lockwire
temperatures, all oil flow is directed through oil cooler
before being routed to transmission.
1. If removed, install filter head (13, Figure 63-40)
with outlet port aft. Install spacers (24) between filter
63-158. Thermal Bypass Valve — Removal
bracket (25) and filter head (13). Install bolts (3), thin
aluminum washers (4), and secure with lockwire
(C-405).
NOTE
Thermostat (1, Figure 63-41) may be
2. Remove plugs or caps and install inlet tube (20)
removed without removing valve body (3).
from thermal bypass valve to reducer (21) in filter inlet.
1. Disconnect tubes (7, 10, 11, and 16) from valve

3. Install outlet hose (5) to fitting (6) in filter outlet.
body (3).
4. Lubricate packings (15, 16, and 18) with

transmission oil (Chapter 12). 2. Remove screws and washers (4) and remove
valve body (3) from bulkhead.
5. Place packing (18) on boss inside bottom of

external oil filter body (19). Insert new filter element 3. Remove unions (6, 9, 12, and 15) with packings
(17) and seat firmly on boss. Place large packing (15) (5, 8, 13, and 14) and discard packings.
around upper lip of external oil filter body (19) next to
flange.
4. Cut and remove lockwire from thermostat (1).
Remove thermostat and aluminum gasket (2) from
6. Install packing (16) around center boss under
valve body (3) and discard gasket.
filter head (13). Insert external oil filter body (19) into
filter head while pressing upward until seated.
63-159. Thermal Bypass Valve — Cleaning
7. Install v-band clamp (14) around mating flanges
of head and body. While tapping v-band clamp lightly
to aid in seating, torque nut on clamp to MATERIALS REQUIRED
50 inch-pounds (5.7 Nm). Secure v-band clamp with
lockwire (C-405). Refer to BHT-ALL-SPM for specifications.
8. Service transmission (Chapter 12). NUMBER NOMENCLATURE

1. Wipe components with a clean cloth damp with

63-157. THERMAL BYPASS VALVE
The thermal oil bypass valve (Figure 63-41) is installed

on the rear bulkhead of cargo hook compartment. The 2. Dry with filtered, compressed air.
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BHT-412-MM-6
Figure 63-41. Thermal Oil Bypass Valve
63-00-00
Page 100 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-160. Thermal Bypass Valve — Installation 3. Disconnect tubes (2, 9, and 15). Cap or plug
tubes to prevent contamination.
MATERIALS REQUIRED 4. Remove tee (12) with drain valve (3) as an

assembly.
NUMBER NOMENCLATURE 5. Complete disassembly by loosening nut (4) and

removing drain valve (3) and packing (5). If required,
C-405 Lockwire remove bushing (6) with packing (7), union (10) with
packing (11), and union (14) with packing (13).
1. Lubricate new aluminum gasket (2, Figure 63-41)
and new packings (5, 8, 13, 14) with transmission oil 6. Discard packings (5, 7, 11, and 13).
(Chapter 12).
63-163. Oil Drain Valves — Cleaning
2. Install thermostat (1) with aluminum gasket (2) in
valve body (3). Tighten thermostat sufficiently to
prevent leakage. Secure thermostat with lockwire MATERIALS REQUIRED
(C-405).
3. Install unions (6, 9, 12, and 15) with new packings
(5, 8, 13, and 14). NUMBER NOMENCLATURE

4. Install valve body (3) on bulkhead bracket with
screws and washers (4).
1. Wipe components with a clean cloth dampened
5. Service transmission (Chapter 12). with drycleaning solvent (C-304).
6. Check for oil leaks and proper operation at next 2. Dry with filtered, compressed air.
helicopter ground run.
63-164. Oil Drain Valves — Inspection
63-161. OIL DRAIN VALVES
1. Inspect components for cracks and thread
Two ball type drain valves (one for inlet and one for damage. No cracks or thread damage is permissible.
outlet oil) are installed in lowest part of oil system
(Figure 63-42) between thermal oil bypass valve and
transmission oil cooler. The valves are provided to 2. Inspect drain valve (3, Figure 63-42) for proper
drain oil trapped in lines of oil cooler to transmission operation.
system.
3. Discard components that are not serviceable.
NOTE
63-165. Oil Drain Valves — Installation
Maintenance procedures for drain valves
are identical. The procedures for inlet drain
1. Lubricate new packings (5, 7, 11, and 13,
valve are provided.
Figure 63-42) with transmission oil (Chapter 12).
63-162. Oil Drain Valves — Removal
2. Install unions (10 and 14) with new packings (11
1. Place a container beneath drain valve and 13) into side ports of tee (12).
(3, Figure 63-42) to catch oil spillage.
3. Install packing (7) on bushing (6) and install
2. Open drain valve (3) and drain oil. bushing in lower port of tee (12).
63-00-00
30 MAR 2007 Rev. 11 Page 101
BHT-412-MM-6
SEE DETAIL A
15
14
13
12
11
10
16
9
6
5
8 4
2
1. Grommet
1 2. Drain valve tube
3. Drain valve
4. Nut
5. Packing
STA 6. Bushing
BL 169.00 7. Packing
9.50 BL 8. Tee to by-pass valve tube
11.05 9. Tee to by-pass valve tube
10. Union
COVER, DRAIN VALVES, MAIN
11. Packing
TRANSMISSION COOLERS
12. Tee
DETAIL A 13. Packing
14. Union
15. Tee to cooler outlet tube
16. Tee to cooler inlet tube
412_MM_63_0042
Figure 63-42. Oil Drain Valve
63-00-00
Page 102 Rev. 12 27 FEB 2009
BHT-412-MM-6
4. Install drain valve (3) with packing (5) and nut (4) 7. Service transmission (Chapter 12).
in bushing (6). Tighten nut sufficiently to prevent
leakage. 8. Check for oil leaks and proper operation at next
helicopter ground run.
5. Place tee and drain valve assembly in position in
helicopter after removing protective cover/caps from 63-166. TRANSMISSION OIL COOLER AND
lines, hoses, and ports. BLOWER
Refer to Chapter 79 for maintenance procedures

6. Install tubes (9 and 15) and install drain valve applicable to the combination reduction gearbox oil
tube (2) with new grommet (1) (if required) on lower and transmission oil cooler and combination engine oil
portion of valve. and transmission oil cooler blower assemblies.
63-00-00
30 MAR 2007 Rev. 11 Page 103/104
BHT-412-MM-6
TRANSMISSION QUILLS
63-167. TRANSMISSION QUILLS 9. After main input quill (6) has completely
separated from case, remove jackscrews and install
The transmission quills consist of main input quill, three screws (8) with aluminum washers (7) to secure
hydraulic system 2 drive quill, hydraulic system 1 and cap to quill sleeve.
tachometer drive quill, rotor brake quill, and tail rotor
drive quill. 10. Position main input quill (6) at right angle for
clearance, and remove from transmission pylon cavity.
63-168. MAIN INPUT QUILL
The main input quill provides the means for the engine
to provide power to the transmission through the main 12. Remove oil transfer tube (17) with packings (16
driveshaft. and 18). Discard packings.
63-169. Main Input Quill — Removal 13. Install cover (paragraph 63-220) over main input
quill port of transmission (1).
SPECIAL TOOLS REQUIRED 63-170. Main Input Quill — Cleaning
NUMBER NOMENCLATURE
MATERIALS REQUIRED
T101308 Jackscrew Set
1. Open engine and transmission cowling. NUMBER NOMENCLATURE

2. Remove main driveshaft (paragraph 63-8).
3. Disconnect drain tube (24, Figure 63-43). NOTE

Inspect quill for evidence of leakage prior to
4. Remove nut (11) with clip (10) from lower right cleaning. The cause of any leakage shall
stud on transmission (1). be corrected prior to further use. For a
definition of acceptable leakage, refer to
paragraph 63-171.
5. Remove nuts (12).
1. Wipe external surfaces of main input quill
6. Using a sharp plastic scraper, cut sealant around (6, Figure 63-43) with a clean cloth dampened with
edge of quill. drycleaning solvent (C-304).
7. Cut and remove lockwire from screws (8) and 2. Dry with filtered, compressed air.
remove screws.
63-171. Main Input Quill — Inspection
8. Using a heat lamp or a 250 watt light bulb, heat
case of the transmission (1) in area of quill until it is hot 1. Inspect main input quill (6, Figure 63-43) for
to the touch with bare hands. Install three jackscrews evidence of leakage. External leakage around seals is
(T101308) in holes where screws (8) were removed. not acceptable. A small amount of seepage, however,
Tighten jackscrews evenly and carefully to separate is acceptable. A continuous flow of droplets is
main input quill (6) from transmission (1). considered leakage.
63-00-00
30 MAR 2007 Rev. 11 Page 105
BHT-412-MM-6
Figure 63-43. Main Input Quill
63-00-00
Page 106 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-172. Main Input Quill — Repair

CAUTION
MATERIALS REQUIRED
THIS COMPONENT IS DYNAMICALLY
BALANCED. S I G N I F I C A N T LY Refer to BHT-ALL-SPM for specifications.
REWORKED DAMAGED AREAS MAY
NUMBER NOMENCLATURE
CAUSE HIGH FREQUENCY VIBRATIONS
AFTER INSTALLATION. C-204 Epoxy Polyamide
Primer
2. Inspect visible portion of main driveshaft curvic
coupling adapter (4, Figure 63-44). Superficial C-423 Abrasive Cloth or
damage is permissible without rework. Paper
3. Inspect visible portions of input quill cap C-464 India Stone

assembly (3). Maximum depth of pitting is 0.030 inch
(0.76 mm), provided no more than 40% of any 1.0
1. Repair quills that have leakage by installing a
square inch (645.15 mm2) or 20% of total area of any
new seal (paragraph 63-180 or paragraph 63-181, as
surface is affected. Repair acceptable damage in
applicable).
accordance with paragraph 63-172.
2. Polish out acceptable corrosion and mechanical

4. Inspect visible portion of input sleeve (2). Light
damage (as defined in paragraph 63-171) using a fine
oxidation is permitted provided no more than 40% of
India stone (C-464) and 600 grit abrasive cloth or
any 1.0 square inch (645.15 mm2) or 20% of total area
paper (C-423).
of any surface is affected. Remove acceptable
oxidation as described in paragraph 63-172.
3. Touch-up repaired areas that were previously
painted using epoxy polyamide primer (C-204).
5. Inspect teeth on quill pinion (1) for abnormal gear
wear pattern (BHT-412-CR&O). Abnormal gear wear
pattern is not acceptable and is cause to inspect 63-173. Main Input Quill — Installation
mating gear in transmission.
6. Inspect bearings inside quill by rotating main SPECIAL TOOLS REQUIRED

driveshaft curvic coupling adapter (4) while holding
input sleeve (2). Bearing roughness which can be
detected by feel is not acceptable. If bearings exhibit NUMBER NOMENCLATURE
roughness, refer to the BHT-412-CR&O for overhaul
T101586-5 Pusher Set
procedures.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 Sealant
C-405 Lockwire
C-452 Anti-seize Thread

Compound
63-00-00
30 MAR 2007 Rev. 11 Page 107
BHT-412-MM-6
Figure 63-44. Main Input Quill Assembly
63-00-00
Page 108 Rev. 11 30 MAR 2007
BHT-412-MM-6
1. Remove setscrews (15, Figure 63-43) from studs teeth with input gear quill (5) teeth. Align front of input
in transmission (1). quill pinion with bearing rollers (3).
10. Slide spacers (11) over studs and install nuts (12)
NOTE on studs.
If rotor brake quill is installed, remove cover
from port on opposite side of transmission 11. Tighten nuts (12) evenly to keep quill aligned.
(paragraph 63-219). If this port is removed, When quill is started into bearing, remove work aid
it will be necessary to remove oil jet No. 6 plug (2) to prevent pushing work aid into oil jet No. 6 (if
(paragraph 63-89) to allow clearance for installed).
work and plug.
2. Remove cover (20) (paragraph 63-219). 12. Continue tightening nuts (12) to fully seat quill.
When quill is fully seated, loosen nuts (12) and
remove studs (13) and spacers (11).
3. Reach through port where cover was removed
and position work aid (3, Figure 63-43 and 2,
Figure 63-45) to hold rollers of bearing (2, NOTE
Figure 63-43) against outer race of bearing.
In the following steps, for aluminum
washers (7 and 14, Figure 63-43), use only
4. Using a heat lamp or a 250 watt light bulb, heat AN960JD616 (aluminum) washer next to
transmission (1) case in area of quill port until it is hot transmission case. Do not substitute any
to the touch with bare hands. other type (including NAS1197).
13. Install aluminum washer (9), clip (10), and nut

5. Lubricate new packings (16 and 18) with
(11) on lower right stud. Install six aluminum washers
transmission oil (Chapter 12) and install on oil transfer
(14) (next to transmission case), six thin steel washers
tube (17). Position tube in transmission case.
(13) (under nut), and six nuts (12) on remaining studs.
Torque nuts (11 and 12) to 160 to 190 inch-pounds
6. Lubricate new packings (4 and 5) with (18.1 to 21.4 Nm).
transmission oil (Chapter 12). Install packing (5) in
groove of main input quill (6) nearest flange and
14. Rotate main driveshaft curvic coupling adapter (4,
packing (4) in groove nearest pinion. Leave center
Figure 63-44) on outboard end of main input quill (6,
groove open.
Figure 63-43) by hand. Check for binding and verify
presence of backlash. Any binding or roughness is not
acceptable.
CAUTION
15. Place a small amount of anti-seize thread
compound (C-452) on threads of union (25).
THE CENTER GROOVE IS AN OIL
PASSAGE. IT MUST STAY OPEN. 16. If removed, lubricate a new packing (26) with
transmission oil (Chapter 12), and install on union
7. Position main input quill (6) into port with drain (25). Install union in main input quill (6) and install tube
tube union (15, Figure 63-45) for drain tube at bottom. (24) in union.
8. Install the three pusher set studs (13) in holes 17. Install three aluminum washers (7) (AN960JD616
where setscrews (15, Figure 63-43) were removed in only) on screws (8) and install screws. Secure screws
step 1. to main input quill (6) with lockwire (C-405).
9. Carefully slide input quill pinion (6, Figure 63-45) 18. Install three setscrews (15) into studs on
into transmission case. Align main input quill pinion transmission case.
63-00-00
30 MAR 2007 Rev. 11 Page 109
BHT-412-MM-6
Figure 63-45. Pusher Set (T101586-5) Application
63-00-00
Page 110 Rev. 11 30 MAR 2007
BHT-412-MM-6
1. Open engine and transmission cowling.

NOTE
If port cover opposite cover (20) was 2. Remove main driveshaft (paragraph 63-8).
removed, install oil jet No. 6 (paragraph
63-93) and cover (paragraph 63-220).
3. Remove retainer ring (1, Figure 63-46), plate (2),
and packing (3). Discard packing.
19. Lubricate new packing (19) with transmission oil
(Chapter 12), and install packing on cover (20).
4. Remove lock-spring (4).
NOTE 5. Insert T101306 splined wrench (9, Figure 63-47)

in nut (5). Install T101588 wrench (3) on main
Aluminum washers (21) are installed next
driveshaft curvic coupling adapter (1) so splines on
to transmission case and steel washers
wrench (3) engage splines of wrench (9). Tighten wing
(22) are installed directly under heads of
nuts (2) to lock wrench (3) to main driveshaft curvic
bolt (23).
coupling adapter.
20. Install steel washers (22) and then aluminum
washers (21) under heads of bolt (23). 6. Insert extension bar (4) through wrench (3) and
engage wrench (9).
21. Install bolts (23) on cover (20). Torque bolts to

7. Hold wrench (3) and loosen nut (5) so it can be
160 to 190 inch-pounds (18.1 to 21.4 Nm).
removed by hand. Leave nut installed. Remove
extension bar (4), wrench (3), and wrench (9).
22. Apply a bead of sealant (C-308) around flange of
quill and cover which was removed where there is
8. Remove retainer ring (7, Figure 63-46).
contact with case.
9. Remove nut (5, Figure 63-47).

23. Install main driveshaft (paragraph 63-13).
10. Use two screwdrivers to remove adapter and
24. Close engine and transmission cowling. magnetic seal assembly (12, Figure 63-46) as an
assembly. Position two screwdrivers 180° apart and
engage groove in seal retainer (8). Pry against input
25. Perform engine ground run (BHT-412-FM) and
quill cap assembly (9) to remove adapter and
check for proper operation and leakage.
magnetic seal assembly (12). Carefully place
assembly on bench with main driveshaft curvic
63-174. MAIN INPUT QUILL MAGNETIC SEAL coupling adapter (8, Figure 63-48) facing down.
(412-040-111)
63-175. Main Input Quill Magnetic Seal — Removal CAUTION

(Helicopters Prior to S/N 36020 not
Modified by 412-570-001-103 or Pre
BHT-412-SI-74 (412SP to 412HP Upgrade))
MAGNETIC RING (3) AND CARBON SEAL
(2) MUST BE KEPT CLEAN IF THEY ARE
TO BE REINSTALLED. STORE THESE
SPECIAL TOOLS REQUIRED PA R T S I N A C L E A N P L A S T I C B A G
IMMEDIATELY AFTER REMOVAL TO
P R E V E N T M E TA L PA R T I C L E S O R
NUMBER NOMENCLATURE OTHER MATERIAL FROM COLLECTING.
T101306 Wrench 11. Remove carbon seal (2) and seal retainer (6) and
magnetic ring (3) from main driveshaft curvic coupling
T101588 Wrench Set
adapter (8) as an assembly (Detail B).
63-00-00
BHT-412-MM-6
D
FW
10
7 8
5 6
T 1 11
3 4
2 12
1
HELICOPTERES PRIOR TO S/N 36020 AND NOT MODIFIED

BY 412-570-001-103 OR PRE BHT-412-SI-74 (412SP TO 412HP UPGRADE)
412_MM_63_0014a
Figure 63-46. Main Input Quill Magnetic Seal (Sheet 1 of 2)
63-00-00
BHT-412-MM-6
23
29
22
24
25
26
20 21
T 2 18 19
16 17 28
14 13 27
15
HELICOPTERS S/N 36020 AND SUBSEQUENT AND

HELICOPTERS MODIFIED BY 412-570-001-103 OR
POST BHT-412-SI-74 (412SP TO 412HP UPGRADE)
1. Retainer ring 16. Retainer ring 350 TO 400 FT-LBS

2. Plate 17. Lockwasher T 1 (476 TO 542 Nm)
3. Packing 18. Nut
4. Lock-spring 19. Main driveshaft adapter 450 TO 500 FT-LBS
5. Nut 20. Retainer ring T 2 (610.12 TO 677.91 Nm)
6. Main driveshaft curvic coupling 21. Seal retainer
7. Retainer ring 22. Input quill cap assembly
8. Seal retainer 23. Transmission
9. Input quill cap assembly 24. Input quill pinion
10. Transmission 25. Packing
11. Input quill pinion 26. Packing
12. Adapter and magnetic seal assembly 27. Packing
13. Retainer ring 28. Magnetic seal
14. Plate 29. Packing
15. Packing
412_MM_63_0014b
Figure 63-46. Main Input Quill Magnetic Seal (Sheet 2 of 2)
63-00-00
BHT-412-MM-6
TRIPLEX
BEARINGS
HELICOPTERS PRIOR TO S/N 36020 AND

NOT MODIFIED BY 412-570-001-103 OR
PRE BHT-412-SI-74 (412SP TO 412HP UPGRADE)
412_MM_63_0015a
Figure 63-47. Tool Application (Sheet 1 of 2)
63-00-00
BHT-412-MM-6
TRIPLEX
BEARINGS
10 12
11
13
14
15
17
16
HELICOPTERS S/N 36020 AND SUBSEQUENT AND

HELICOPTERS MODIFIED BY 412-570-001-103 OR POST BHT-412-SI-74 (412SP TO 412HP UPGRADE)
1. Main driveshaft curvic coupling adapter 10. Retainer ring

2. Wing nut (MS35426-14) 11. Main driveshaft adapter
3. Wrench set (T101588) 12. Wrench set 412-240-002-101
4. Extension bar (L-122) 13. Wrench 412-240-001-101
5. Nut 14. Nut
6. Seal retainer 15. Seal retainer
7. Input quill cap assembly 16. Input quill cap assembly
8. Input quill pinion 17. Input quill pinion
9. Tool (T101306)
412_MM_63_0015b
Figure 63-47. Tool Application (Sheet 2 of 2)
63-00-00
BHT-412-MM-6
Figure 63-48. Main Input Quill Curvic Coupling Adapter and Magnetic Seal Assembly
63-00-00
Page 116 Rev. 11 30 MAR 2007
BHT-412-MM-6
7. Install the wrench (412-240-001-101) on the nut

(18, Figure 63-46).
CAUTION
8. Loosen the nut but leave it installed.
MAGNETIC RING (3) AND CARBON SEAL
(2) SHALL BE SEPARATED BY PULLING 9. Remove the wrench (412-240-001-101) and the
HALVES STRAIGHT AWAY FROM EACH wrench set (412-240-001-101) (Figure 63-47).
OTHER. ALLOWING HALVES TO SLIDE
AGAINST EACH OTHER MAY DAMAGE 10. Remove the retainer ring (20, Figure 63-46).
MATING SURFACES.
11. Remove the nut (18).
12. Remove carbon seal (2) from seal retainer (6).
13. Remove packing (1) from carbon seal (2). NOTE

Discard packing.
Adapter and magnetic seal assembly
consists of all parts shown in Figure 63-46.
14. Remove magnetic ring (3) from seal retainer (6) These parts may be removed as an
(Detail C). assembly.
15. Remove packings (4 and 5) from seal retainer (6). 12. Use two screwdrivers to remove the main
Discard packings. driveshaft adapter (19) and the magnetic seal (28) as
an assembly.
63-176. Main Input Quill Magnetic Seal — Removal
(Helicopters S/N 36020 and Subsequent 13. Position two screwdrivers 180° apart and engage
and Helicopters Modified by them in the grooves of the seal retainer (21).
412-570-001-103 or Post BHT-412-SI-74
(412SP to 412HP Upgrade)) 14. Apply a force against the input quill cap assembly
(22) to remove the main driveshaft adapter (19) and
the magnetic seal (28).
15. Put the assembly on a bench with the adapter
(19) face down.
NUMBER NOMENCLATURE
412-240-001-101 Wrench 16. Remove and discard the packing (29) from the
input quill pinion (24).
412-240-002-101 Wrench Set
1. Open the engine and transmission cowling. CAUTION
2. Remove the main driveshaft (paragraph 63-8).

MAGNETIC RING (3, FIGURE 63-48) AND
3. Remove the retainer ring (13, Figure 63-46) and CARBON SEAL (2) MUST BE KEPT
the plate (14). CLEAN IF THEY ARE TO BE
REINSTALLED. STORE THESE PARTS IN
A CLEAN PLASTIC BAG IMMEDIATELY
4. Remove and discard the packing (15).
AFTER REMOVAL TO PREVENT METAL
PARTICLES OR OTHER MATTER FROM
5. Remove the retainer ring (16) and the lockwasher ADHE RING TO MAGNETIC AND/OR
(17). CARBON SEAL.
6. Install the wrench set (412-240-002-101) 17. Remove carbon seal (2, Figure 63-48), seal
(Figure 63-47). retainer (6), and magnetic ring (3) from the main
63-00-00
BHT-412-MM-6
driveshaft curvic coupling adapter (8) as an assembly. 63-179. Main Input Quill Magnetic Seal — Repair
Refer to Detail B.
Polish out nicks and burrs on seal retainer (6,
Figure 63-48) which could damage packings.
CAUTION 63-180. Main Input Quill Magnetic Seal —

Installation (Helicopters Prior to S/N 36020
not Modified by 412-570-001-103 or Pre
MAGNETIC RING (3) AND CARBON SEAL BHT-412-SI-74 (412SP to 412HP Upgrade))
(2) MUST BE SEPARATED BY PULLING
HALVES AWAY FROM EACH OTHER.
SLIDING THE SEAL HALVES CAN
DAMAGE THE MATING SURFACES.
18. Remove the carbon seal (2) from the seal NUMBER NOMENCLATURE
retainer (6).
T101306 Wrench
19. Remove the packing (1) from the carbon seal (2). T101588 Wrench Set
20. Remove the magnetic ring (3) from the seal

retainer (6).
MATERIALS REQUIRED
21. Remove the packing (4 and 5) from the seal Refer to BHT-ALL-SPM for specifications.
retainer (6).
NUMBER NOMENCLATURE
63-177. Main Input Quill Magnetic Seal — C-001 Grease
Cleaning
C-024 Assembly Fluid
MATERIALS REQUIRED 1. Assemble adapter and magnetic seal assembly

(12, Figure 63-46) as follows:
NUMBER NOMENCLATURE
CAUTION
1. Clean seal retainer (6, Figure 63-48) and main LEAVE SEAL IN PACKAG ING UNTIL
driveshaft curvic coupling adapter (8) with drycleaning R E A D Y F O R I N S TA L L AT I O N . S E A L
solvent (C-304). CAVITY SHALL BE CLEAN AND FREE OF
B U R R S O N PA C K I N G C O N TA C T
DIAMETERS. WHEN SEAL PACKAGE IS
2. Dry with filtered, compressed air. OPENED, SEAL SHALL BE SEPARATED
BY PULLING HALVES DIRECTLY AWAY
63-178. Main Input Quill Magnetic Seal — F R O M E A C H O T H E R TO P R E V E N T
Inspection D A M A G E TO M AT I N G S U R FA C E S .
INSTALL SEAL BY HAND PRESSURE
ONLY.
1. Inspect main driveshaft curvic coupling adapter
(8, Figure 63-48) (paragraph 63-17).
a. Coat packings (4 and 5, Figure 63-48) and
seal retainer (6) contact diameters with assembly fluid
2. Inspect seal retainer (6) (BHT-412-CR&O). (C-024).
63-00-00
BHT-412-MM-6
b. Install packing (5) in inner groove of seal 6. Locate groove in edge of seal retainer (8). Rotate
retainer (6). Install magnetic ring (3) in seal retainer. retainer to align groove with pin at upper side of input
quill cap assembly (9), then push main driveshaft
curvic coupling (6) in against triplex bearings. Refer to
c. Install packing (4) on outer groove of seal
Figure 63-47 for a sectional view of installed adapter
retainer (6).
and magnetic seal assembly.
d. Coat packing (1) sparingly with assembly fluid

(C-024) and install in inner groove of carbon seal (2)
as shown in Detail B. CAUTION
DO NO T S E AT S E A L RE TA I N ER ( 6 ,
CAUTION FIGURE 63-47) INTO INPUT QUILL CAP
ASSEMBLY (7) AT THIS TIME.
DO NOT SLIDE SEAL HALVES ON EACH

7. Install nut (5, Figure 63-46) finger tight to hold
OTHER DURING ASSEMBLY. adapter and magnetic seal assembly (12) in place.
e. Place carbon seal (2) on magnetic ring (3)

very carefully. Align so magnetic seal assembly may 8. Install wrench set (T101306) and (T101588) as
be installed on main driveshaft curvic coupling adapter described in paragraph 63-175. Torque nut (5) to 350
to 400 foot-pounds (475 to 542 Nm).
(8) (Detail A).
2. Position retaining ring (7) on main driveshaft 9. Install lock-spring (4). Ensure tang on lock-spring
curvic coupling adapter (8) (Detail A). fully engages nut (5) and input quill pinion (11).
3. Position seal retainer (6), and parts assembled in 10. Using hand pressure only, seat seal retainer (6,
step 1, on main driveshaft curvic coupling adapter (8) Figure 63-47) in groove on input quill cap assembly
(Detail A). (7). Ensure seal retainer is fully seated.
4. Coat outer diameter of packing (4) and contact 11. Install retainer ring (7, Figure 63-46) in groove on
area of seal retainer (6) with assembly fluid (C-024). input quill cap assembly (9). Ensure seal retainer (6,
Figure 63-47) is fully seated.
12. Install packing (3, Figure 63-46) on plate (2).

CAUTION Install plate on main driveshaft curvic coupling (6).
DO NOT PUSH ON SEAL RETAINER (6) 13. Install retainer ring (1). Ensure retainer ring is
WHILE INSTALLING MAGNETIC SEAL fully seated.
AND ADAPTER ASSEMBLY. CARBON
SEAL (2) MAY BE PUSHED OFF EDGE 14. Install main driveshaft (paragraph 63-13).
OF ADAPTER.
15. Close and secure engine and transmission

5. Align splines of main driveshaft curvic coupling
cowling.
(6, Figure 63-46) with splines of input quill pinion (11).
Using hand pressure only, push main driveshaft curvic
coupling inward to obtain contact with splines of 16. Perform engine ground run (BHT-412-FM) to
pinion. check for operation and leaks.
63-00-00
BHT-412-MM-6
63-181. Main Input Quill Magnetic Seal — c. Install the magnetic ring (3) in the seal
Installation (Helicopters S/N 36020 and retainer (6).
Subsequent and Helicopters Modified by
412-570-001-103 or Post BHT-412-SI-74 d. Install the packing (4) on the outer groove of
(412SP to 412HP Upgrade)) the seal retainer (6).
e. Lightly apply assembly fluid (C-024) to the

SPECIAL TOOLS REQUIRED packing (1).
f. Install the packing (1) in the inner groove of

NUMBER NOMENCLATURE
the carbon seal (2). Refer to Detail B.
412-240-001-101 Wrench
412-240-002-101 Wrench Set

CAUTION
MATERIALS REQUIRED DO NOT SLIDE SEAL HALVES ON EACH

OTHER DURING ASSEMBLY.
g. Very carefully, put the carbon seal (2) in
NUMBER NOMENCLATURE position on the magnetic ring (3).
C-001 Grease
h. Align to make sure that the magnetic seal
C-024 Assembly Fluid assembly can be installed on the main driveshaft
curvic coupling adapter (8) (Detail A).
1. Assemble the magnetic seal (28, Figure 63-46) 2. Put the retainer ring (7) in position on the main
and the main driveshaft adapter (19) as follows: driveshaft curvic coupling adapter (8) (Detail A).
3. Put the seal retainer (6) and the assembly from

CAUTION step 1 in position on the main driveshaft curvic
coupling adapter (8) (Detail A).
LEAVE THE SEAL IN PACKAGING UNTIL

4. Apply assembly fluid (C-024) to the outside
READY FOR INSTALLATION. THE SEAL
diameter of the packing (4) and to the contact area of
CAVITY MUST BE CLEAN AND FREE OF
the seal retainer (6).
BURRS ON PACKING CONTACT
DIAMETER. WHEN THE SEAL PACKAGE
IS OPEN, THE SEAL MUST BE 5. Install a new packing (29, Figure 63-46) on the
S E PA R A T E D B Y P U L L I N G H A L V E S input quill pinion (24).
AWAY FROM EACH OTHER TO
PREVENT DAMAGE TO MATING
SURFACES. INSTALL THE SEAL BY
HAND PRESSURE ONLY. CAUTION
a. Apply assembly fluid (C-024) to the packings

(4 and 5, Figure 63-48) and the seal retainer (6) DO NOT PUSH THE SEAL RETAINER (6,
contact diameter. FIGURE 63-48) WHILE INSTALLING THE
ADAPTER AND MAGNETIC SEAL. THE
b. Install the packing (5) in the inner groove of CARBON SEAL (2) CAN BE PUSHED OFF
the seal retainer (6). THE EDGE OF THE ADAPTER.
63-00-00
BHT-412-MM-6
6. Align the splines of the main driveshaft adapter 21. Make sure that the seal retainer (6) is installed
(19, Figure 63-46) with the splines of the input quill against the input quill cap assembly (7).
pinion (24).
22. Install the retainer ring (20, Figure 63-46) in the
7. With your hands, push on the main driveshaft groove of the input quill cap assembly (22).
adapter (19) to get in contact with the splines of the
input quill pinion (24). 23. Make sure that the seal retainer (6, Figure 63-47)
continues to be in the correct position.
8. Find the groove in the edge of the seal
retainer (21). 24. Install the packing (15, Figure 63-46) on the
plate (14).
9. Rotate the seal retainer (21) to align the groove
with the pin at the upper side of the input quill cap 25. Install the plate (14) on the main driveshaft
assembly (22). adapter (19).
26. Install the retainer ring (13).

10. Push the main driveshaft adapter (19) against the
triplex bearings (refer to Figure 63-47 for a sectional
view of the assembly). 27. Make sure that the retainer ring (13) is in the
correct position.
11. Apply a thin layer of grease (C-001) to the

28. Install the main driveshaft (paragraph 63-13).
threads of the nut (18) and transmission oil to the
flange face (Chapter 12).
29. Close and safety the engine and transmission
cowling.
12. Install the wrench set (412-240-002-101)
(Figure 63-47).
30. Do an engine ground run (BHT-412-FM) to
examine for leaks and operation.
13. With the wrench (412-240-001-101), install the
nut (18, Figure 63-46).
63-182. MAIN INPUT QUILL LIP SEAL (2820-33655)
14. Torque the nut (18) T .
63-183. Main Input Quill Lip Seal — Removal
15. Remove and clean the nut (18).

16. Repeat step 11, step 13, and step 14.
NUMBER NOMENCLATURE
17. Clean all excess grease from the threads and
around the flange of the nut (18). T101306 Wrench
T101588 Wrench Set

18. Remove the wrench (412-240-001-101)
(Figure 63-47) and the wrench set (412-240-002-101). Commercial Grinder, Handheld
19. Install the lockwasher (17, Figure 63-47) and the 1. Remove retaining ring (12, Figure 63-49) and
retainer ring (16). plate (11) with packing (10). Discard packing.
20. With hand pressure only, push the seal retainer 2. Remove lock-spring (9). Remove nut (8) using
(17, Figure 63-47) in the groove of the input quill cap wrench (T101306) and wrench set (T101588)
assembly (7). (paragraph 63-175).
63-00-00
27 FEB 2009 Rev. 12 Page 121
BHT-412-MM-6
Figure 63-49. Main Input Quill Lip Seal (28203-3655)
63-00-00
Page 122 Rev. 11 30 MAR 2007
BHT-412-MM-6
3. Inspect packing grooves in cap (3, Figure 63-49)

and plate (11) for sharp nicks and distortion.
CAUTION
4. Inspect threaded components for thread damage.
WHEN CUTTING THROUGH OLD WEAR No thread damage is allowed.
SLEEVE IN THE FOLLOWING STEP, USE
EXTREME CARE TO AVOID DAMAGING 5. Inspect retaining rings (5 and 12) for distortion.
ADAPTER (7). No distortion is allowed.
3. Remove adapter (7). Using a handheld grinder, 63-186. Main Input Quill Lip Seal — Repair
cut a groove almost through wear sleeve (6). Strike
wear sleeve with a rubber mallet to break uncut
portion of wear sleeve. Remove and discard wear
MATERIALS REQUIRED
sleeve.
4. Remove retaining ring (5) and sleeve (4) from cap
(3). Remove and discard packing (1). NUMBER NOMENCLATURE
5. Remove seal (2) from sleeve (4) by pressing C-407 Abrasive Pad
inboard.
Remove light surface corrosion from adapter (7,
63-184. Main Input Quill Lip Seal — Cleaning Figure 63-49) and sleeve (4) with a plastic scraper and
abrasive pad (C-407).
MATERIALS REQUIRED 63-187. Main Input Quill Lip Seal — Installation

NUMBER NOMENCLATURE
C-304 Drycleaning Solvent NUMBER NOMENCLATURE
C-407 Abrasive Pad T101306 Wrench
T101588 Wrench Set

1. Clean disassembled components with an
abrasive pad (C-407). Commercial Brush, Hog Bristle,
Unpainted Handle
2. Clean adapter (7, Figure 63-49) and sleeve (4)
with a plastic scraper and an abrasive pad (C-407) to
remove foreign matter.
MATERIALS REQUIRED
3. Rinse adapter (7) and sleeve (4) with drycleaning Refer to BHT-ALL-SPM for specifications.
solvent (C-304).
NUMBER NOMENCLATURE
4. Dry parts using filtered, compressed air.
C-028 Dry Film Lubricant
63-185. Main Input Quill Lip Seal — Inspection C-317 Adhesive
1. Inspect parts for excessive wear and corrosion. C-327 Adhesion Promoter
C-328 Sealing Compound

2. Inspect parts for cracks. No cracks are allowed.
63-00-00
30 MAR 2007 Rev. 11 Page 123
BHT-412-MM-6
MATERIALS REQUIRED (7) only. Scrub primer into surface of adapter with
abrasive pad (C-407). Repeat scrubbing as required to
Refer to BHT-ALL-SPM for specifications. ensure adapter is clean.
NUMBER NOMENCLATURE
5. Allow degreaser residue to dry to a white powder.
C-345 Grease Removing Remove residue from adapter (7) with a clean, dry
Primer cheesecloth.
C-407 Abrasive Pad
C-427 Barrier Material CAUTION
KEEP ADHESION PROMOTER (C-327) IN

CAUTION A COVERED, NON-ABSORPTIVE
CONTAINER AND KEEP LID TIGHTLY
CLOSED WHEN NOT IN USE.
BONDING SHALL BE ACCOMPLISHED EXPOSURE TO AT M O S P H E R E
WITHOUT DELAY BETWEEN STEPS. WILL CAUSE DECOMPOSITION.
T H E M A X I M U M T I M E I N T E R VA L SEDIMENT OR BROWN RESIDUE IN
BETWEEN SANDBLASTING AND THE BOTTOM OF CONTAINER INDICATES
NEXT STEP IS 4 HOURS. DECOMPOSITION OF PROMOTER TO
THE EXTENT IT SHALL BE DISCARDED.
NOTE PROMOTER PH RANGE SHALL BE
MAINTAINED BETWEEN 7.0 AND 8.0.
Precautions shall be taken when
accomplishing the following steps to keep
wear sleeve and adapter clean. Wear clean NOTE
white gloves when handling parts and If the next step is not to be accomplished
change gloves when soiled. Cover work immediately, wrap adapter (7) with clean
bench with clean white paper. Avoid any barrier material (C-427).
contact with mold release agents such as
silicone, oil, waxes, grease, etc. Area
6. Apply adhesion promoter (C-327) to unmasked
where work is performed shall be
portion of wear sleeve (6) and adapter (7) with a pure
maintained at 64 to 82°F (18 to 28°C) with
hog bristle brush with an unpainted handle. Apply only
relative humidity below 75%. Area shall be
enough promoter to wet the surfaces.
dust-free to the extent that bonding
operations are not affected.
7. Allow promoter to dry for a minimum of 30
1. Mask outer diameter of new wear sleeve (6, minutes at 65 to 85°F (18 to 29°C) or for 15 minutes at
Figure 63-49). 150 to 160°F (66 to 71°C).
2. Mask all surfaces of adapter (7) except those

surfaces which mate with wear sleeve (6). NOTE
If the next step is not to be accomplished
3. Sandblast unmasked surfaces of wear sleeve (6) immediately, wrap parts with clean barrier
and adapter with 60 grit garnet at 5 to 10 PSI and material (C-427).
remove residue. If there is to be any delay before
accomplishing the next step, wrap parts in clean 8. Mix adhesive (C-317) 33 parts B to 100 parts A.
barrier material (C-427) after sandblasting. The pot life of mixed adhesive is 30 to 50 minutes.
4. Stir grease removing primer (C-345) thoroughly in 9. Coat inside diameter of wear sleeve (6) and
its container and apply to unmasked portion of adapter mating surface on adapter (7) with mixed adhesive.
63-00-00
Page 124 Rev. 11 30 MAR 2007
BHT-412-MM-6
10. Press wear sleeve (6) on adapter (7) until inner 21. Perform engine ground run (BHT-412-FM) and
shoulder of wear sleeve contacts adapter. check for proper operation and leakage.
11. Clean excess adhesive from wear sleeve (6) 63-188. NO. 1 HYDRAULIC PUMP DRIVE QUILL
thoroughly and remove all protective masking
material. Allow adhesive to cure at 65 to 85°F (18 to The No. 1 hydraulic system pump and tachometer
29°C) for 24 hours. drive quill is located on the forward right side of the
transmission sump assembly.
63-189. No. 1 Hydraulic Pump Drive Quill —

CAUTION
Removal
ENSURE NO EXCESSIVE BONDING

MATERIAL REMAINS BETWEEN WEAR SPECIAL TOOLS REQUIRED
SLEEVE (6) AND COUPLING RACE.
BONDING MATERIAL WILL BECOME
HARD AND FLAKE OFF. THIS FLAKING NUMBER NOMENCLATURE
BETWEEN SEAL LIP AND WEAR RING
WILL CAUSE LEAKAGE. T101308 Jackscrew Set
12. Apply a film of sealing compound (C-328) to 1. Remove access door on right side of pylon
outside diameter of new seal (2). Press seal into support in cabin area.
sleeve (4) until bottomed out. Remove excess sealant.
2. Using a sharp plastic scraper, cut sealant at

13. Lubricate packing (1) with transmission oil mating flanges of tachometer generator
(Chapter 12). Install packing on sleeve (4). Align (13, Figure 63-50), hydraulic pump (3), and quill (8).
cutout in sleeve with pin in cap (3) and install sleeve in Remove sealant from jackscrew holes.
cap by pressing with hand pressure. Install retaining
ring (5).
3. Remove tachometer generator (13) (paragraph
63-201).
14. Spray wear sleeve (6) with dry film lubricant
(C-028). Position adapter (7) on quill pinion.
4. Remove hydraulic pump (3) (Chapter 29).
15. Install wrench (T101306) and wrench set

(T101588) as described in paragraph 63-175. Torque 5. Install jackscrews (T101308) on quill (8).
nut (8) to 350 to 400 foot-pounds (475 to 542 Nm).
16. Install lockspring (9) in hole of nut that is in line CAUTION

with slot in pinion.
17. Lubricate new packing (10) with transmission oil TIGHTEN JACKSCREWS CAREFULLY
(Chapter 12). Install packing on plate (11). Install plate AND EVENLY TO KEEP QUILL ALIGNED
in adapter (7). DURING REMOVAL.
6. Use a heat lamp or a 250 watt light bulb to heat

18. Install retaining ring (12) in adapter (7).
sump (10) in area of quill (8). Heat area until hot to the
touch with bare hands. Remove quill by tightening
19. Install main driveshaft (paragraph 63-13). jackscrews evenly. Cover open mounting port.
20. Close engine and transmission cowling. 7. Remove and discard packing (9) from quill (8).
63-00-00
30 MAR 2007 Rev. 11 Page 125
BHT-412-MM-6
Figure 63-50. No. 1 Hydraulic Pump Drive Quill
63-00-00
Page 126 Rev. 11 30 MAR 2007
BHT-412-MM-6

Cleaning MATERIALS REQUIRED

MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
C-304 Drycleaning Solvent 1. The quill (8, Figure 63-50) shall be replaced as an
assembly when inspection requirements are not met.
Seals, however, may be replaced as required.
1. Clean sealant residue from both quill (8) and
transmission mounting port using a sharp plastic
scraper. 2. Replace seals (2 and 9, Figure 63-51) as follows:
2. Clean external surfaces of parts using a. Remove nuts (12), washers (11 and 10), and
drycleaning solvent (C-304). bolt (5) with washers (6 and 8) and bracket (7).

NOTE
63-191. No. 1 Hydraulic Pump Drive Quill — As sleeve assembly (4) and cover (1)
Inspection separate, tap splined end of gear shafts
(not shown) where they protrude through
1. Visually inspect all accessible parts for damage. seals (2 and 9) to prevent binding of shaft
bearing in sleeve assembly.
2. Rotate quill gear and check bearings for smooth
operation. Roughness that can be detected by feel is b. Using jackscrew (T101308) carefully and
unacceptable. evenly remove cover (1) from sleeve assembly (4).
3. Inspect gear teeth for nicks, dents, cracks, and c. Remove and discard gasket (3) from sleeve
abnormal wear pattern. Any such damage that can be assembly (4) studs.
detected visually is unacceptable.
4. Inspect seals for evidence of leakage, damage, d. Press seals (2 and 9) from cover (1).
and abnormal wear. Leaking, damaged, or worn seals
are unacceptable. e. Clean seal housing in cover (1) with
drycleaning solvent (C-304) and dry using filtered,
5. For additional, detailed inspection criteria, refer to compressed air.
the BHT-412-CR&O Manual.
f. Install seals (2 and 9) on cover (1) with
63-192. No. 1 Hydraulic Pump Drive Quill — numbered side of seals outboard.
Repair
g. Coat lip of seals (2 and 9) with transmission oil
(Chapter 12).
h. Position new gasket (3) on sleeve assembly

NUMBER NOMENCLATURE (4) studs.

i. Install cover (1) on sleeve assembly (4).
63-00-00
BHT-412-MM-6
Figure 63-51. No. 1 Hydraulic Pump Drive Quill Assembly
63-00-00
Page 128 Rev. 11 30 MAR 2007
BHT-412-MM-6
9. Install rotor tachometer generator (paragraph

NOTE
63-205).
Bracket (7) replaces steel washer (6) at
12 o'clock position only. 10. Apply a bead of sealant (C-308) around mating
surfaces of quill (8), hydraulic pump (3), and
j. Install bolt (5) with aluminum washers (8) next tachometer generator (13).
to quill housing and steel washers (6), or bracket (7),
next to bolt head.
11. Install access door on right side of pylon support
in cabin area.
k. Install nuts (12) with aluminum washers (10)
next to cover (1) and steel washers (11) next to nut.
12. Perform engine ground run (BHT-412-FM) and
check for proper operation of hydraulic system No. 1
63-193. No. 1 Hydraulic Pump Drive Quill — and for leakage.
Installation
63-194. NO. 2 HYDRAULIC PUMP DRIVE QUILL
MATERIALS REQUIRED The No. 2 hydraulic system pump is driven by a quill

located on forward side of transmission.
NUMBER NOMENCLATURE
Removal
C-308 Sealant

transmission oil (Chapter 12). Install packing in groove
around quill (8) sleeve. NUMBER NOMENCLATURE

2. Use a heat lamp or 250 watt light bulb to heat
sump mounting port until unit is hot to the touch.
1. Open transmission forward cowling.
3. Coat mating surfaces of quill (8) and sump (10)
with transmission oil (Chapter 12). 2. Remove hydraulic system No. 2 pump
(Chapter 29).
4. Position quill (8) on mounting port with

tachometer generator pad forward. 3. Using a sharp plastic scraper, cut sealant from
around flange of quill assembly (1, Figure 63-52).
Clean sealant from jackscrew holes (5).
5. Insert quill (8) into sump (10). Mesh gears
carefully and guide sleeve flange over mounting studs.
4. Remove bolts (8) and washers (6 and 7).
6. Install aluminum washers (7), steel washers (6), 5. Install jackscrews (T101338) in holes on quill
and nuts (5) on two drive quill mounting studs (11). assembly (1). Tighten jackscrews carefully and evenly
Torque nuts to 100 to 140 inch-pounds (11.3 to to remove quill assembly from transmission (4) case.
11.7 Nm).
6. Remove and discard packing (3).

7. Check quill (8) to verify presence of backlash.
7. Cover open mounting port to prevent foreign
8. Install hydraulic system No. 1 pump (Chapter 29). objects from entering transmission (4) case.
63-00-00
BHT-412-MM-6
Figure 63-52. No. 2 Hydraulic Pump Drive Quill
63-00-00
Page 130 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-196. No. 2 Hydraulic Pump Drive Quill — 1. Lubricate packing (3, Figure 63-52) with
Cleaning transmission oil (Chapter 29) and install on quill
assembly (1).
MATERIALS REQUIRED 2. Lubricate mating surfaces of quill assembly (1)

and transmission mounting port with transmission oil.
NUMBER NOMENCLATURE 3. Use a heat lamp or 250 watt light bulb to heat
sump mounting port until unit is hot to the touch.
4. Position quill assembly (1) with oil hole (2)
1. Clean sealant residue from both quill and straight up. Insert quill assembly into transmission (4)
transmission mounting port using a sharp plastic while simultaneously rotating pinion to permit gear
scraper. meshing.
2. Clean external surfaces of parts using NOTE

Install aluminum washers AN960JD616 (6)
next to quill sleeve. Do not substitute any
3. Dry with filtered, compressed air. other type washer (including NAS1197).
63-197. No. 2 Hydraulic Pump Drive Quill — 5. Install bolts (8) with steel washers (7) under bolt
Inspection heads and aluminum washers adjacent to quill flange.
Torque bolts to 160 to 190 inch-pounds (18.1 to
21.5 Nm).
1. Inspect quill assembly (1, Figure 63-52) for
obvious mechanical and corrosion damage
(BHT-412-CR&O). 6. Check quill pinion for freedom of rotation and
existence of backlash.
2. Rotate pinion in sleeve and check for rough
bearings. Bearing roughness that can be detected by 7. Fill gap between flange on quill assembly (1) and
feel is not acceptable. flange on transmission (4) with sealant (C-308). Also
fill jackscrew holes (5) with same sealant. Allow to
cure.
Repair
8. Install hydraulic system No. 2 pump (Chapter 29).
For repair and overhaul instructions, refer to the
BHT-412-CR&O Manual. 9. Perform engine ground run (BHT-412-FM) and
check for proper operation of hydraulic system No. 2
63-199. No. 2 Hydraulic Pump Drive Quill — and for leakage.
Installation
63-200. ROTOR TACHOMETER GENERATOR
MATERIALS REQUIRED The rotor tachometer generator (5, Figure 63-53) is

driven by a chain-and-sprocket offset drive from the
Refer to BHT-ALL-SPM for specifications. hydraulic pump and tachometer generator drive quill
(2), which also drives the system No. 1 hydraulic pump
NUMBER NOMENCLATURE (1). The hydraulic pump and tachometer generator
drive quill are located on the transmission sump
C-308 Sealant
case (3).
63-00-00
BHT-412-MM-6
(System No. 1)
Figure 63-53. Rotor Tachometer Generator
63-00-00
Page 132 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-201. Rotor Tachometer Generator — Removal MATERIALS REQUIRED (Cont)
1. Disconnect electrical connector from rotor Refer to BHT-ALL-SPM for specifications.

tachometer generator (5, Figure 63-53).
NUMBER NOMENCLATURE
2. Remove nuts (7) and steel washers (6).
C-407 Abrasive Pad
3. Using a sharp plastic scraper, cut sealant from

flange of rotor tachometer generator (5). 1. Remove any surface corrosion using abrasive
pad (C-407).
4. Remove rotor tachometer generator (5) and
gasket (4). Discard gasket. 2. Remove residue by wiping area with a clean cloth
dampened with drycleaning solvent (C-304).
63-202. Rotor Tachometer Generator — Cleaning
MATERIALS REQUIRED 63-205. Rotor Tachometer Generator —

Installation
NUMBER NOMENCLATURE
MATERIALS REQUIRED
1. Clean sealant residue from both quill and mating NUMBER NOMENCLATURE
surface of offset drive using a sharp plastic scraper.
C-007 Bearing Grease
2. Clean external surfaces of parts using
C-308 Sealant
1. Clean mating surfaces of rotor tachometer

63-203. Rotor Tachometer Generator — Inspection
generator (5, Figure 63-53) and hydraulic pump and
tachometer generator drive quill (2) with drycleaning
1. Inspect rotor tachometer generator (5,
solvent (C-304).
Figure 63-53) for mechanical and corrosion damage.
Superficial damage is acceptable providing all
corrosion is removed. 2. Lubricate rotor tachometer generator (5) shaft
splines with bearing grease (C-007).
2. Inspect electrical connector for damaged threads
and distorted or missing pins. 3. Position gasket (4) on hydraulic pump and
tachometer generator drive quill (2).
63-204. Rotor Tachometer Generator — Repair
4. Position rotor tachometer generator (5) on
hydraulic pump and tachometer generator drive quill
MATERIALS REQUIRED (2) with electrical connector positioned for attachment
of wiring. Install steel washers (6) and nuts (7).
5. Apply a bead of sealant (C-308) around mating
NUMBER NOMENCLATURE flange of rotor tachometer generator (5) and hydraulic
pump and tachometer generator drive quill (2). Allow
sealant to cure.
63-00-00
BHT-412-MM-6
6. Perform helicopter ground run (BHT-412-FM). 7. Install jackscrews (T101338) in holes on quill.
Check for oil leaks and perform operational check of Tighten jackscrews carefully and evenly to remove tail
triple tachometer indicating system (Chapter 95). rotor drive quill (7) from sump assembly (11).
63-206. TAIL ROTOR DRIVE QUILL 8. Remove and discard packing (8).
Helicopters prior to S/N 36020 and not modified by 9. Cover open mounting port to prevent foreign
412-570-001-103 or Pre BHT-412-SI-74 (412SP to objects from entering transmission case.
412HP Upgrade have a tail rotor drive quill equipped
with a flexible coupling and located on aft side of
transmission sump case. The tail rotor driveshaft is 63-208. Tail Rotor Drive Quill — Inspection
connected to the drive quill by a V-band clamp set.
Helicopters S/N 36020 and subsequent and MATERIALS REQUIRED

BHT-412-SI-74 (412SP to 412HP Upgrade) have a tail Refer to BHT-ALL-SPM for specifications.
rotor drive quill equipped with a rigid adapter rather
NUMBER NOMENCLATURE
than the flexible coupling noted previously and is also
located on aft side of transmission sump case. The tail C-304 Drycleaning Solvent
rotor driveshaft is bolted to an independent flex
coupling, which is attached to the rigid adapter.
NOTE
63-207. Tail Rotor Drive Quill — Removal
The following inspection procedures shall
be accomplished when tail rotor drive quill
(7, Figure 63-54) is removed for normal
SPECIAL TOOLS REQUIRED maintenance. Step 1 and step 2 are not
applicable to helicopters S/N 36020 and
subsequent and helicopters modified by
NUMBER NOMENCLATURE
412-570-001-103 or Post BHT-412-SI-74
T101338 Jackscrew Set (412SP to 412HP Upgrade).
1. Inspect coupling (10) for grease leakage. Wetting

1. Remove access doors from left and right side of of adjacent areas by grease is cause for replacement
pylon support in cabin area. of defective parts with the following exception: A small
amount of grease expelled from around lip of seal (9)
2. Disconnect and remove forward section of tail and/or other quill parts, provided the following
rotor driveshaft (Chapter 65). evaluation of grease leakage is accomplished.
3. Drain transmission oil (Chapter 12) as necessary

to a level below quill mounting port. CAUTION
4. Remove nuts (1, Figure 63-54), steel washers

(2), spacers (3), steel washers (4), and washers (5). DO NOT CLEAN OR SPRAY COUPLING
WITH ANY TYPE OF SOLVENT DURING
INSPECTION. USE ONLY CLEAN CLOTH
5. Using a sharp plastic scraper, cut sealant DAMPENED WITH DRYCLEANING
between quill mounting flange and transmission case. SOLVENT (C-304) TO CLEAN EXTERIOR
Remove sealant from jackscrew holes (6). OF QUILL.
6. Using a heat lamp, heat sump mounting port until a. Wipe grease from coupling (10) and adjacent
it is hot to the touch. parts with clean cloths.
63-00-00
BHT-412-MM-6
Figure 63-54. Tail Rotor Drive Quill
63-00-00
30 MAR 2007 Rev. 11 Page 135
BHT-412-MM-6
b. Inspect coupling (10) over-temperature 2. Clean external surfaces of parts using

indicator (TEMP-PLATE) for discoloration and drycleaning solvent (C-304).
overheat condition. A change in color of
over-temperature indicator (TEMP-PLATE) (from white 3. Dry with filtered, compressed air or clean, dry,
to black) indicates a possible overheat condition and/ lint-free cloths.
or component degradation. Cause of discoloration
shall be determined and corrected prior to continued 63-210. Tail Rotor Drive Quill — Repair
operation. Refer to the BHT-412-CR&O Manual for
inspection procedures.
1. Repair mechanical and corrosion damage in
accordance with the BHT-412-CR&O Manual.
c. Inspect coupling (10) for grease leakage and
for discoloration due to overheating at frequent 2. Replace seal (9, Figure 63-54) in accordance
intervals during the next 10 flight hours. If grease with the BHT-412-CR&O Manual.
leakage and/or overheating occurs, replace tail rotor
drive quill (7).
3. Lubricate the tail rotor coupling (10) (Chapter 65).
2. Inspect seal (9) for protrusion and other evidence 4. Replace over-temperature indicator (TEMP-PLATE)
of damage. Protruding and/or damaged seals are not if required (BHT-412-CR&O).
acceptable.
63-211. Tail Rotor Drive Quill — Installation
3. Inspect tail rotor drive quill (7) in accordance with
the BHT-412-CR&O Manual.
MATERIALS REQUIRED
63-209. Tail Rotor Drive Quill — Cleaning
NUMBER NOMENCLATURE
MATERIALS REQUIRED
C-308 Sealant
NUMBER NOMENCLATURE
transmission oil (Chapter 12). Install packing in groove
C-304 Drycleaning Solvent around tail rotor drive quill (7) sleeve.
2. Verify mating surfaces of tail rotor drive quill (7)

sleeve and transmission case are free of all foreign
CAUTION material.
3. Lubricate mating surfaces of tail rotor drive quill

DO NOT IMMERSE TAIL ROTOR DRIVE (7) and transmission mounting port with transmission
QUILL IN SOLVENT OR SPRAY SOLVENT oil (Chapter 12).
ON QUILL. USE ONLY CLEAN CLOTHS
DAMPENED WITH DRYCLEANING 4. Use a heat lamp or 250 watt light bulb to heat
SOLVENT (C-304) TO EXTERIOR OF sump mounting port until unit is hot to the touch.
QUILL.
5. Insert tail rotor drive quill (7) into transmission
1. Clean sealant residue from both quill and while rotating pinion simultaneously to permit gear
transmission mounting port using a sharp plastic meshing. Position mounting holes in sleeve over
scraper. transmission studs.
63-00-00
BHT-412-MM-6
3. If required, remove brake disc (paragraph

NOTE 63-262).
Install aluminum washers AN960JD616 (5)
next to quill sleeve. Do not substitute any 4. Using a sharp plastic scraper, cut sealant from
other type washer (including NAS1197). between quill mounting flange and transmission case.
Clean sealant from jackscrew holes.
6. Install washers (5), steel washers (4), spacers
(3), steel washers (2), and nuts (1). Torque nuts to 50 5. Remove bolts (5, Figure 63-55), steel washers
to 70 inch-pounds (5.45 to 7.91 Nm). (4), and aluminum washers (3).
7. Check quill pinion for freedom of rotation and 6. Use a heat lamp or 250 watt light bulb to heat
existence of backlash. sump mounting port until it is hot to the touch.
8. Fill gap between flange on tail rotor drive quill (7) 7. Install jackscrews (T101308) and tighten carefully
and flange on transmission sump assembly (11) with and evenly to remove rotor brake quill (2) with packing
sealant (C-308). Also fill jackscrew holes (6) with same (1) from transmission. Discard packing.
sealant. Allow to cure.
8. Cover mounting port in transmission to prevent
9. Install forward section of tail rotor driveshaft entry of foreign material.
(Chapter 65).
63-214. Rotor Brake Quill — Cleaning
10. Ground run helicopter (BHT-412-FM) and check
for leaks at quill flange and loss of lubricant at
coupling. If lubricant loss is evident, refer to MATERIALS REQUIRED
Chapter 65.
11. Install access doors on both sides of pylon
support in cabin area. NUMBER NOMENCLATURE

63-212. ROTOR BRAKE QUILL
1. Clean sealant residue from both quill and mating

For helicopters so equipped, the rotor brake quill is
surface of transmission using a sharp plastic scraper
installed on left side of transmission main case
and drycleaning solvent (C-304).
(Figure 63-55).
63-213. Rotor Brake Quill — Removal 2. Clean external surfaces of parts using

63-215. Rotor Brake Quill — Inspection

NUMBER NOMENCLATURE
1. Inspect quill for signs of leakage.
2. Inspect quill and pinion gear for obvious

1. Open transmission cowling to gain access to mechanical and corrosion damage (BHT-412-CR&O).
transmission.
3. Rotate pinion and check for rough bearings.
2. Remove outboard brake assembly half Bearing roughness which can be detected by feel is
(paragraph 63-254). not acceptable.
63-00-00
BHT-412-MM-6
quill
9. Flange
SEE VIEW A
1 2
VIEW A
NOTES
1 The 412-040-123-101 quill assembly contains a look alike gear. Ensure pinion has six holes before installation
in 412-040-002-ALL transmission and mast assembly (S/N 33001 to 33213 and 36001 to 36019).
2 The 412-040-123-103 quill assembly contains a look alike gear. Ensure pinion has four holes before installation
in 412-040-004-ALL transmission and mast assembly (S/N 36020 and sub).
_c01
Figure 63-55. Rotor Brake Quill
63-00-00
Page 138 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-216. Rotor Brake Quill — Repair MA ST AS S EM BLY 4 12- 0 40- 00 4- AL L

(HELICOPTERS S/N 36020 AND
For complete repair procedures, refer to the S U B S E Q U E NT A N D H E L I CO P T E RS
BHT-412-CR&O Manual. MODIFIED BY 412-570-001-103 OR POST
B H T- 4 1 2 - S I - 7 4 ( 4 1 2 S P T O 4 1 2 H P
UPGRADE)). INSTALLATION OF
63-217. Rotor Brake Quill — Installation
INCORRECT QUILL ASSEMBLY WILL
RESULT IN INTERNAL TRANSMISSION
DAMAGE.
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications. NOTE
NUMBER NOMENCLATURE During installation of quill assembly, lightly

tap quill inward uniformly around face of
C-308 Sealant quill flange near outer edge with a plastic
mallet. Do not strike end of quill shaft.
C-405 Lockwire
6. Insert rotor brake quill (2) into transmission while

simultaneously rotating pinion to permit gear meshing.
1. Remove cover from mounting port in
transmission.
7. Install aluminum washers (3) against flange of
quill, steel washers (4) under head of bolts (5), and
2. Make sure mating surfaces of quill and
install bolts. Torque bolts to 160 to 190 inch-pounds
transmission are free of all sealant and other foreign
(18.1 to 21.47 Nm).
matter. Clean as required.
3. Lubricate new packing (1, Figure 63-55) with 8. Check quill pinion for freedom of rotation and
transmission oil (Chapter 12). Install packing in groove existence of backlash.
on rotor brake quill (2).
9. Secure bolts (5) in pairs with lockwire (C-405)
4. Apply a light coat of transmission oil to bore of (helicopters S/N 36020 and subsequent and
transmission quill port and to mating diameter of quill helicopters modified by 412-570-001-103 or Post
assembly. BHT-412-SI-74 (412SP to 412HP Upgrade)).
5. Use a heat lamp or 250 watt light bulb to heat 10. Fill gap between flange on rotor brake quill (2)
sump mounting port until it is hot to the touch. and flange on transmission sump with sealant (C-308).
Also fill jackscrew holes with same sealant. Allow to
cure.
CAUTION
11. Install inboard brake assembly half (paragraph
63-259).
ROTOR BRAKE QUILL ASSEMBLIES
HAVE LOOKALIKE GEARS. ENSURE 12. If not previously accomplished, install brake disc
SIX-HOLE PINION IS ONLY INSTALLED
(paragraph 63-260).
IN TRANSMISSION AND MAST
ASSEMBLY 412-040-002-ALL. ENSURE
FOUR-HOLE PINION IS ONLY 13. Install outboard brake assembly half (paragraph
INSTALLED IN TRANSMISSION AND 63-259).
63-00-00
ECCN EAR99 1 MAY 2012 Rev. 15 Page 139/140
BHT-412-MM-6
TRANSMISSION QUILL PORT COVERS
63-218.TRANSMISSION QUILL PORT COVERS 4. Install jackscrew set (T100929) in three tapped
holes (6).
NOTE 5. Carefully and evenly, tighten all three jackscrews

Removal and installation procedures for and remove cover (5).
both left and right quill port covers are
identical. The following procedures detail 6. Remove and discard packing (1).
removal and installation of rotor brake quill
port cover which is used when there is no 63-220. TRANSMISSION QUILL PORT COVERS —
rotor brake quill installed. INSTALLATION
63-219. TRANSMISSION QUILL PORT COVERS —

REMOVAL MATERIALS REQUIRED
SPECIAL TOOLS REQUIRED NUMBER NOMENCLATURE
C-308 Sealant
NUMBER NOMENCLATURE
T100929 Jackscrew Set 1. Lubricate new packing (1, Figure 63-56) with
transmission oil (Chapter 12).
1. Remove bolts (4, Figure 63-56), steel washers 2. Install packing (1) on cover (5).
(3), and aluminum washers (2).
3. Place cover (5) over transmission quill port and
install bolts (4) with steel washers (3) under bolt heads
2. Cut sealant from around edge of cover (5) using a
and aluminum washers (2) next to cover. Torque bolts
sharp plastic scraper. Clean sealant from jackscrew
to 160 to 190 inch-pounds (18.1 to 21.4 Nm).
holes.
4. Apply a bead of sealant (C-308) around perimeter
3. Clean sealant from tapped holes (6). of cover (5) where it meets transmission case (7).
63-00-00
BHT-412-MM-6
Figure 63-56. Quill Port Covers
63-00-00
Page 142 Rev. 11 30 MAR 2007
BHT-412-MM-6
TRANSMISSION MOUNTS
63-221. TRANSMISSION MOUNTS increments and should have a range of 0 to 5000

pounds (or equivalent).
The transmission mounts consists of forward and aft
isolation mounts, aft friction dampers, and a lift link. d. Center steel pressing button over inner sleeve
of mount.
63-222. AFT ISOLATION MOUNT AND FRICTION
DAMPERS
e. Apply pressure to button and mount with
press ram so as to deflect mount in a vertical plane to
NOTE 0.4 inch (10.16 mm) at approximately one cycle per
minute. Repeat cycle three times.
Maintenance procedures for left and right
mounts are identical.
f. Mount a dial indicator to press with the finger
63-223. Aft Isolation Mount and Friction Dampers of indicator touching pressing button.
— Removal
g. Apply slight pressure to button with ram to
1. Remove transmission and mast assembly ensure button is seated.
(paragraph 63-30).
h. Apply enough pressure to button to deflect
2. Remove bolts (15, Figure 63-57) and thin steel mount 0.1 inch (2.54 mm) and record load. Apply
washers (14). enough pressure to pressing button to deflect mount
0.3 inch (7.62 mm) and record load. Subtract load
3. Disengage boot (5) from isolation mount support noted at 0.1 inch (2.54 mm) from the load at 0.3 inch
(1). Remove mount and filler plate (2). (7.62 mm). If the value is less than 1320 pounds
(5872 N) for -105 mount or 1610 pounds (7162 N) for
-107 mount, replace mount.
4. Remove nut (10) and bolt (8). Remove friction
damper (9), bolt (13), bushing (6), and boot (5) as a
unit. 2. Inspect elastomer for cracks, tears, or debonded
areas. Replace if a 0.005 inch (0.127 mm) feeler
gauge can be inserted more than 0.25 inch (6.35 mm).
63-224. Transmission Mounts — Inspection
Normal elastomer fretting (eraser type dust) is not
cause for replacement.
NOTE
Inspection procedures for all four mounts 3. Inspect bolts and bushings for cracks, corrosion,
are the same. scoring, wear, and scratches. Replace damaged parts.
Replace damaged boots.
1. Perform spring rate check as follows:
4. Replace isolation mounts when excessive
a. Fabricate a steel support sleeve and pressing vibration is believed to be caused by defective mounts
button (Figure 63-58). Top and bottom of sleeve must or when there is other evidence of malfunction.
be square in relation to sides so mount will be
deflected in vertical plane only.
63-225. Aft Mount Friction Dampers — Inspection
b. Place mount, long end down, in support
sleeve. 1. Inspect friction damper (9, Figure 63-57) for oil
and grease contamination. If oil and grease
c. Place support and mount in a suitable press. contamination is present, disassemble and inspect
Press indicator should be marked in 5 pound damper (BHT-412-CR&O).
63-00-00
27 FEB 2009 Rev. 12 Page 143
BHT-412-MM-6
15 T 1
1
14
SEE DETAIL A 2
4
13
12
5
11
6
7
10
8
9
1. Isolation mount support DETAIL A

2. Filler plate
3. Pylon support
4. Damper fitting
5. Boot 100 TO 140 IN-LBS
T (11.30 TO 15.82 Nm)
6. Bushing
7. Bolt
8. Bolt
9. Friction damper
10. Nut NOTE
11. Thin steel washer 1 Install longer bolts in forward outboard and aft
12. Nut inboard mounting holes. Install shorter bolts in
13. Bolt remaining holes.
14. Thin steel washer
15. Bolt
412_MM_63_0057
Figure 63-57. Transmission Aft Isolation Mounts and Friction Dampers
63-00-00
BHT-412-MM-6
Figure 63-58. Isolation Mount Inspection Work Aid — Tool Application
63-00-00
30 MAR 2007 Rev. 11 Page 145
BHT-412-MM-6
2. Inspect bearing and damper fittings on dampers 63-227. FORWARD ISOLATION MOUNTS
for maximum radial play of 0.004 inch (0.101 mm) and
no axial movement. 63-227A.Forward Isolation Mounts — Removal
3. Inspect dampers for binding, rough movement, or 1. Remove transmission and mast assembly
actual lack of movement by stationing personnel (paragraph 63-30).
around pylon mounting point. Move pylon fore and aft
using the mast as a lever to rock pylon. If any of the 2. Remove bolt (8, Figure 63-59).
above conditions are noted, replace damper(s).
3. Disengage boot (6) from isolation mount

63-226. Aft Isolation Mount and Friction Dampers assembly (3). Remove boot and bushing (7).
— Installation
4. Remove bolts (1) and thin steel washer (2).
1. Place bolt (13, Figure 63-57) on friction damper Remove isolation mount assembly (3) and filler
(9), and install bolt (7), thin steel washer (11), and plate (4).
nut (12).
63-228. Forward Isolation Mounts — Inspection
2. Place bushing (6) and boot (5) on bolt (13).
Refer to paragraph 63-224 for inspection procedures.
3. Place friction damper (9) and bolt (13) in pylon
support (3) from inside pylon. Fit bottom of friction 63-229. Forward Isolation Mounts — Installation
damper (9) on damper fitting (4). Install bolt (8) and
nut (10). 1. Place isolation mount assembly (3, Figure 63-59)
and filler plate (4) on pylon support (5).
4. Place filler plate (2) on isolation mount support
(1). Place isolation mount support on bolt (13) and 2. Place bushing (7) and boot (6) on bolt (8). Install
ensure bushing (6) and boot (5) are installed on bolt assembly in isolation mount assembly (3) from the
bolt (13). bottom. Fit boot to bushing and isolation mount
assembly.
3. Tie bolt (8) in position until transmission

CAUTION installation is completed.
BOLTS (15) ARE DIFFERENT LENGTHS.

THE TWO LONGER BOLTS SHALL BE CAUTION
INSTALLED IN FORWARD OUTBOARD
AND AFT INBOARD HOLES. THE TWO
SHORTER BOLTS SHALL BE INSTALLED BOLTS (1) ARE DIFFERENT LENGTHS.
IN REMAINING HOLES. LONGER BOLTS SHALL BE INSTALLED
IN FORWARD MOUNTING HOLES AND
5. Install bolts (15) and thin steel washers (14). SHORTER BOLTS SHALL BE INSTALLED
Make sure bolts are the correct grip length. Torque the IN AFT MOUNTING HOLES.
bolts 100 to 140 inch-pounds (11.30 to 15.82 Nm).
4. Install bolts (1) and thin steel washers (2). Make
sure bolts are the correct grip length. Torque the bolts
6. Install boot (5) on isolation mount support (1). 100 to 140 inch-pounds (11.30 to 15.82 Nm).
7. Install transmission and mast assembly 5. Install transmission and mast assembly
(paragraph 63-33). (paragraph 63-33).
63-00-00
BHT-412-MM-6
SEE DETAIL A
T 1 1
3
2
D
FW 4
7
1. Bolt
2. Thin steel washer
3. Isolation mount assembly
4. Filler plate
5. Pylon support
6. Boot
7. Bushing 8
8. Bolt
100 TO 140 IN-LBS

T (11.30 TO 15.82 Nm)
DETAIL A
NOTE
1 Install longer bolts in forward mounting holes and
shorter bolts in aft mounting holes.
412_MM_63_0059
Figure 63-59. Forward Isolation Mounts
63-00-00
BHT-412-MM-6
63-230. LIFT LINK 63-232. Lift Link — Cleaning
63-231. Lift Link — Removal

MATERIALS REQUIRED
NUMBER NOMENCLATURE NUMBER NOMENCLATURE
T101581 Hoist C-304 Drycleaning Solvent
204-011-128-001 Clevis
CAUTION
1. Open transmission cowling. Remove right or left
access doors on pylon support in cabin.
DO NOT IMMERSE BEARING END OF
2. Erect hoist (T101581 or equivalent) to steady LINK IN DRYCLEANING SOLVENT
transmission while link is removed. (C-304).
1. Wipe link clean with a clean cloth dampened with

WARNING drycleaning solvent (C-304).
2. Dry with a clean, dry cloth or filtered, compressed

MAST NUT (CAP A S S E M B LY air.
RETENTION NUT) (412-010-160-103)
SHALL NOT BE USED TO LIFT 63-233. Lift Link — Inspection and Repair
HELICOPTER OR HELICOPTER
COMPONENTS EXCEPT WHEN MAIN Refer to the BHT-412-CR&O for inspection criteria and
ROTOR HUB IS INSTALLED. IF MAIN repair limits and procedures.
ROTOR HUB IS NOT INSTALLED, USE
MAST NUT (204-010-481-001) ON MAST. 63-234. Lift Link — Installation
3. Install clevis (204-011-178-001) on mast nut. 1. Install hoist and clevis (paragraph 63-231).
Attach hoist to clevis. Raise transmission sufficiently to
remove bolt (12, Figure 63-60) by hand.
2. Position washer (special) (5, Figure 63-60) and
link assembly (7) on transmission lift link fitting (1).
4. Remove cotter pin (8), nut (9), thin steel washer
(10), and remove bolt (12) from lift beam (11).
3. Install bolt (special) (6), steel washers (4), and
nut (3).
5. Remove cotter pin (2), nut (3), steel washer (4),
bolt (special) (6), washer (special) (5), and remove link
4. Torque nut (3) to 60 to 80 foot-pounds (81 to
assembly (7).
108 Nm). Install cotter pin (2).
5. Raise transmission sufficiently to allow insertion

of bolt (special) (12) by hand pressure only.
NOTE
Large diameter of lift beam (11) fitting for
bolt (special) (12) shall be forward.
6. Position link assembly (7) on lift beam (11) fitting.
63-00-00
BHT-412-MM-6
2
3 T 1
4 1
D
FW
6
7
8 1. Transmission lift link fitting 7. Link assembly

2. Cotter pin 8. Cotter pin
3. Nut 9. Nut
4. Steel washer 10. Thin steel washer
5. Washer (special) 11. Lift beam
9 T 2
6. Bolt (special) 12. Bolt (special)
10 1 60 TO 80 FT-LBS 108 TO 125 FT-LBS

T 1 (81 TO 108 Nm) T 2 (147 TO 170 Nm)
11 NOTE
1 A total combination of three (thick and/or thin) steel washers
maybe used to ensure proper cotter pin (8) installation.
12
412_MM_63_0060
Figure 63-60. Transmission Lift Link
63-00-00
27 FEB 2009 Rev. 12 Page 149
BHT-412-MM-6
Figure 63-61. Lift Link Fitting
63-00-00
Page 150 Rev. 11 30 MAR 2007
BHT-412-MM-6
7. Install bolt (special) (12), thin steel washer (10), 63-237. Lift Link Fitting — Cleaning
and nut (9). Torque nut (9) to 108 to 125 foot-pounds
(146.8 to 170 Nm).
MATERIALS REQUIRED
8. Install cotter pin (8).
9. Remove hoist and clevis. NUMBER NOMENCLATURE

10. Close cowling and install access doors as
required. 1. Wipe fitting clean with a clean cloth dampened
with drycleaning solvent (C-304).
63-235. LIFT LINK FITTING
2. Dry with a clean, dry cloth or filtered, compressed
air.
NOTE
TB 412-89-82 adds a washer (2, 63-238. Lift Link Fitting — Inspection and Repair
Figure 63-61) between lift link fitting (6) and
existing steel washer (3). It is Refer to the BHT-412-CR&O for inspection criteria and
recommended this washer (2) be added repair limits and procedures.
any time fitting is removed for any reason.
63-239. Lift Link Fitting — Installation
63-236. Lift Link Fitting — Removal 1. Position lift link fitting (6, Figure 63-61) on
mounting studs of main support case (1).
1. Remove lift link (paragraph 63-231).
2. Install washers (2 and 3). Install nuts (4). For
helicopters not modified by TB 412-89-82, torque nuts
2. Remove cotter pins (5, Figure 63-61), nuts (4),
to 37 to 42 foot-pounds (50 to 56 Nm). For helicopters
steel washers (3), and washers (2) if installed.
modified by TB 412-89-82, torque nuts to 40 to
58 foot-pounds. (54 to 79 Nm). Install cotter pins (5).
3. Remove lift link fitting (6) from mounting studs of
main support case (1). 3. If desired, install lift link (paragraph 63-234).
63-00-00
27 FEB 2009 Rev. 12 Page 151/152
BHT-412-MM-6
SERVICEABILITY CHECKS
63-240. SERVICEABILITY CHECKS — 9. If number of particles has increased, or if there

TRANSMISSION, TAIL ROTOR are particles which can be visually identified as chip or
GEARBOX, AND INTERMEDIATE flakes from a gear or bearing, replace transmission,
GEARBOX mast assembly, and transmission oil cooler. Flush oil
lines. If number of particles has decreased and only
minute particles are found, continue transmission in
Perform the following procedures when any doubt service.
exists as to the serviceability of a transmission, tail
rotor gearbox, or intermediate gearbox after finding
metal particles in operating oil. 10. After 5 hours of service, inspect sump internal
filter and three chip detectors for particles.
63-241. SERVICEABILITY CHECK —

TRANSMISSION 11. If the number of particles has increased, or if
there are particles which can visually be identified as
chips or flakes from a gear or bearing, replace
1. Drain transmission, oil cooler, and connecting transmission, mast assembly, and transmission oil
lines. cooler. Flush oil lines. If the number of particles has
decreased and only minute particles are found,
2. Insert a magnet into pump screen boss of plug to continue transmission in service.
check for additional contamination.
63-242. SERVICEABILITY CHECK —
INTERMEDIATE OR TAIL ROTOR
3. Flush oil cooler and connecting lines with clean
GEARBOX
approved oil (Chapter 12).
1. Remove, inspect, and clean appropriate chip

4. Clean and install chip detector plug, pump inlet detector.
screen, and sump oil filter. Replace external oil filter
element.
2. Drain gearbox oil into a clean container. Inspect
oil for chips.
CAUTION 3. Flush gearbox with clean, approved oil (Chapter

12). Inspect for chips.
N O T E C O N D I T I O N O F PA C K I N G S , 4. Service gearbox with clean, approved oil.

SEALS, AND GASKETS BEFORE
INSTALLATION. REPLACE IF DAMAGED.
5. Accomplish ground run in accordance with
paragraph 63-241, step 6.
5. Service transmission with oil (Chapter 12).
6. Repeat step 1, step 2, and step 4.

6. Ground run helicopter (BHT-412-FM) for 1 hour at
100% NR with maximum pitch which can be applied
without becoming airborne and tail rotor pedal 7. If number of particles has increased, or if particles
equivalent to flight position. can be visually identified as chips or flakes from a gear
or bearing, replace gearbox. If number of particles has
decreased and only minute particles are found,
7. Drain transmission oil into a clean container and continue gearbox in service.
inspect for chips.
8. After 5 hours of service, repeat step 1, step 2,
8. Inspect sump internal filter and all chip detectors. and step 4.
63-00-00
30 MAR 2007 Rev. 11 Page 153
BHT-412-MM-6
9. If the number of particles has increased, or

particles can be visually identified as chips or flakes
from a gear or bearing, replace gearbox. If the number
of particles has decreased and only minute particles
are found, continue gearbox in service.
63-00-00
Page 154 Rev. 11 30 MAR 2007
BHT-412-MM-6
ROTOR BRAKE SYSTEM
63-243. ROTOR BRAKE SYSTEM 63-244. ROTOR BRAKE SYSTEM

TROUBLESHOOTING
The rotor brake system is an optional equipment kit.
For additional information on initial kit installation, refer Table 63-3 lists probable causes, isolation procedures,
to the BHT-412-SI-12. and remedies, and is intended to aid in rotor system
troubleshooting.
Hydraulic pressure to operate the rotor brake system
is provided by actuation of handle (5, Figure 63-62) on
master cylinder (6) located in the cabin roof.
Table 63-3. Rotor Brake System — Troubleshooting
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
No braking action. Insufficient fluid in system. Fill and bleed system.
Foreign substance in fluid. Purge system.
Primary valve open. Replace master cylinder.
Relief valve open. Replace master cylinder.
Excessive brake lining wear. Replace lining.
Spongy action of control. Air in system. Fill and bleed system.
Loss of braking action. Worn seal in master cylinder. Replace master cylinder.
Worn seal in brake assembly. Replace brake assembly.
Excessive brake lining wear. Replace lining.
Leaks at master cylinder. Worn or damaged seal in cylinder. Replace master cylinder seals.
Leaks at brake assembly. Worn or damaged seals in brake Replace brake assembly seals.
assembly.
Indicator light inoperative. Burned out bulbs. Replace bulbs.
Loose electrical connection. Tighten connections.
Broken or disconnected wire. Replace or connect wire.
Improper microswitch adjustment. Adjust microswitches.
Indicator light illuminates when Faulty microswitch. Replace switch.

master cylinder not applied.
Improper microswitch adjustment. Adjust microswitches.
Lining binding. Clean brake cylinder.
63-00-00
30 MAR 2007 Rev. 11 Page 155
BHT-412-MM-6
SEE DETAIL A AND B
412_MM_63_0006
Figure 63-62. Rotor Brake System (Sheet 1 of 2)
63-00-00
Page 156 Rev. 11 30 MAR 2007
BHT-412-MM-6
9 10 11
DETAIL B
BRAKE ASSEMBLY (9450103-1)
NOTES
1. Rotor brake assembly 1 Loosen screw while making adjustment.
2. Hydraulic line
3. Bleed valve 2 Loosen jam nut, turn screw to adjust switch,
4. Microswitch tighten jam nut.
5. Handle
6. Master cylinder 3 Do not mix brake assembly 9450103-1 and
7. Microswitch electrical harness 9450103 in any installation.
8. Microswitch
9. Screws
10. Washers
11. Lockwire
412_MM_63_0007
Figure 63-62. Rotor Brake System (Sheet 2 of 2)
63-00-00
30 MAR 2007 Rev. 11 Page 157
BHT-412-MM-6
63-245. BLEEDING 8. Repeat step 2 through step 6 until discharged

fluid is free of air.
NOTE
63-247. Bleeding — Brake Assembly P/N
Bleeding is invalid if hydraulic quick 9450103-1
disconnect is removed.
63-246. Bleeding — Brake Assembly P/N 9450103 MATERIALS REQUIRED

NUMBER NOMENCLATURE

NUMBER NOMENCLATURE
Commercial Rubber Hose

NOTE
Drain a minimum of one-half pint (236.6
NOTE mL) of fluid from each valve before starting
bleeding operation.
Drain a minimum of one-half pint (236.6
mL) of fluid from each valve before starting
1. Check master cylinder (6, Figure 63-62) for
bleeding operation.
proper fluid level (Chapter 12).
1. Check master cylinder (6, Figure 63-62) for
proper fluid level (Chapter 12). 2. Place rags under bleed valves (3) to catch fluid
during bleeding.
NOTE 3. Slowly open one bleed valve.

Ensure rubber hose used in step 2 is clean.
NOTE
2. Place one end of a length of clean rubber hose on
bleed valve (3) extension. Do not allow handle to pass center into fully
deployed position.
3. Route other end of hose to a suitable container in 4. Slowly pull handle (5) down and hold before the
order to capture brake fluid discharged during fully deployed position.
bleeding operation.
5. Close bleed valve (3).
4. Open one bleed valve (3).
6. Service fluid in master cylinder (6) (Chapter 12).
NOTE
7. Return handle (5) to stowed position.
Do not allow handle to pass center into fully
deployed position.
8. Repeat step 2 through step 7 until discharged
fluid is free of air.
5. Slowly pull handle (5) down and hold before the
fully deployed position.
9. Repeat step 2 through step 8 for other bleed
valve (3).
6. Close bleed valve (3).
10. Clean area of any spilled fluid with drycleaning
7. Service fluid in master cylinder (6) (Chapter 12). solvent (C-304).
63-00-00
Page 158 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-248. ROTOR BRAKE SYSTEM 5. Disconnect hydraulic line (2) from master
COMPONENT cylinder.
63-249. MASTER CYLINDER 6. Plug openings to prevent entry of foreign

materials.
63-250. Master Cylinder — Removal
7. Remove bolts, nuts, and washers attaching
master cylinder (6) to roof structure.
MATERIALS REQUIRED
8. Remove master cylinder (6).
NUMBER NOMENCLATURE 63-251. Master Cylinder — Inspection
C-304 Drycleaning Solvent Refer to the BHT-412-CR&O.
63-252. Master Cylinder — Repair
CAUTION Refer to the BHT-412-CR&O.
63-253. Master Cylinder — Installation

CLEANING HYDRAULIC COMPONENTS
SHALL BE ACCOMPLISHED WITH
DRYCLEANING SOLVENT (C-304) ONLY.
DO NOT USE ALCOHOL. MATERIALS REQUIRED
1. Open transmission fairing (Chapter 52). Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
2. On cabin roof, remove sealing compound from
around top of master cylinder reservoir (6, C-308 Adhesive
Figure 63-62).
1. Locate master cylinder (6, Figure 63-62) to the

3. Gain access to master cylinder (6) located inside right of overhead console inside cabin and attach to
cabin above pilot seat. roof structure with four bolts, four nuts, and eight
washers.
CAUTION 2. Apply bead of sealant (C-308) to top of cabin roof

surface around master cylinder (6) fill port.
U S E S U I TA B L E P R E C A U T I O N S T O 3. Attach hydraulic line (2) to master cylinder.

PRO TECT PILO T S EAT A ND CAB IN
INTERIOR FROM HYDRAULIC FLUID
4. Bleed rotor brake system (paragraph 63-245).
WHEN LOOSENING HYDRAULIC LINE.
63-254. BRAKE ASSEMBLY

NOTE
Drain hydraulic fluid into suitable container.
NOTE
4. Loosen hydraulic line (2) from end of master Maintenance practices are the same for
cylinder (6) and allow fluid to drain into suitable brake assembly P/N 9450103 and
container. 9450103-1, unless otherwise noted.
63-00-00
30 MAR 2007 Rev. 11 Page 159
BHT-412-MM-6
80 TO 100 IN-LBS
1 (9.04 TO 11.30 Nm)
120 TO 130 IN-LBS
2 (13.56 TO 14.69 Nm)
412_MM_63_0008
Figure 63-63. Rotor Brake Assembly (Sheet 1 of 3)
63-00-00
Page 160 Rev. 11 30 MAR 2007
BHT-412-MM-6
tube
412_MM_63_0009
63-00-00
30 MAR 2007 Rev. 11 Page 161
BHT-412-MM-6
63-00-00
Page 162 Rev. 11 30 MAR 2007
BHT-412-MM-6
63-255. Brake Assembly — Removal (P/N 3. Remove rotor brake assembly (1, Figure 63-62)
9450103) as a unit.
1. Remove microswitches (4, Figure 63-62) from

4. Remove lockwire (11), screws (9), and
rotor brake assembly (1).
washers (10).
2. Disconnect hydraulic line (2) from rotor brake

assembly (1). 5. Remove microswitches (8).
3. Remove bolts (12, Figure 63-63), washers, and 6. Remove bolts (12, Figure 63-63), washers (13),
outboard brake assembly half (11). and outboard brake assembly half (11).
4. Remove brake assembly spacer (23) from oil

7. Remove brake assembly spacer (23) from oil
transfer tube (14) in inboard brake assembly half (5).
transfer tube (14) in inboard brake assembly half (5).
5. Remove brake oil transfer tube (14) from inboard

brake assembly half (5). 8. Remove brake oil transfer tube (14) from inboard
brake assembly half (5).
6. Remove and discard packings (22) from
counterbored cavities in mating surfaces of inboard 9. Remove and discard packings (22) from
brake assembly (5) and outboard brake assembly counterbored cavities in mating surfaces of inboard
(11). brake assembly half (5) and outboard brake assembly
half (11).
7. Remove rotor brake disc (paragraph 63-262)
10. Remove rotor brake disc (paragraph 63-262).
8. Cut lockwire (4), remove bolts (2), washers (3),
and inboard brake assembly half (5) from quill
assembly (1). 63-257. Brake Assembly — Inspection
63-256. Brake Assembly — Removal (P/N 1. Replace brake lining (16, Figure 63-63, Detail E)
9450103-1) when worn within 0.150 inch (3.81 mm) or less of
piston (21) or when overall thickness of brake lining
1. Disconnect hydraulic line (2, Figure 63-62) from (16) measures 0.289 inch (7.34 mm) or less.
rotor brake assembly (1).
2. Inspect brake assembly in accordance with
NOTE Figure 63-64.
Access to bolts (2, Figure 63-63) can be

achieved by turning rotor brake disc until 3. Inspect bolts (12) for cleanliness, damage, and
holes in disc align with bolts. cracks.
2. Remove lockwire (4), bolts (2), and washers (3).

4. Inspect piston return pin (19) for condition and
nicks and burrs at cotter pin hole, which might damage
return pin packing (20) on installation.
CAUTION
5. Inspect return spring (18) for rust and condition.
USE CARE SO AS NOT TO DAMAGE
MICROSWITCH WIRING WHEN 6. Inspect microswitches (8, Figure 63-62) for loose
REMOVING BRAKE ASSEMBLY. or cracked potting compound at electrical leads.
63-00-00
30 MAR 2007 Rev. 11 Page 163
BHT-412-MM-6
K K
SEE DETAIL A L
F
L
K G
DETAIL A
B F
J C
D
H H
E B SECTION B-B
E
412_MM_63_0017
Figure 63-64. Rotor Brake Assembly — Damage Limits (Sheet 1 of 2)
63-00-00
Page 164 Rev. 11 30 MAR 2007
BHT-412-MM-6
NO. REF LTR CHARACTERISTIC INSPECTION LIMIT

METHOD
1. C Wear Measure 0.015 inch (0.38 mm) deep 2

1.0 inch (25.4 mm) long
maximum two places.
2. D Mechanical/ Visual/ 0.002 inch (0.051 mm) deep in piston 2

corrosion damage measure cavity area, provided sealing qualities
are maintained. Surface finish should
be 15/30 microinches RHR.
3. E Wear Visual/ 0.015 inch (0.38 mm) maximum oversize

measure on hole diameter. Round off sharp edges
(for P/N 9421067 and 9431108).
4. F Thread Visual Remove housing from service if threads

are stripped or badly damaged.
5. G Wear Measure 0.030 inch (0.76 mm) deep, maximum on

piston boss face.
6. H Wear Measure 0.030 inch (0.76 mm) deep, maximum 2

on mounting flange face.
0.010 inch (0.25 mm) deep, maximum on
flange face area covered by mounting bolt
washers (for P/N 9421067 and 9431108).
7. J Wear Measure 0.010 inch (0.25 mm) deep, maximum 2

on return spring boss face and
housing interface surface.
8. K Wear Measure 0.030 inch (0.76 mm) deep, maximum on

housing exterior.
9. L Wear Visual/ 0.030 inch (0.76 mm) deep, maximum on

measure housing mounting flange; blend on both
surfaces is permitted as long as they are
not directly opposite each other (for P/N
9421067 and 9431108).
NOTES
1. Inboard brake assembly half shown, outboard identical.
2 Since removal of material in areas C, D, H, and J can shorten the life of the part, it is recommended that if
removal of metal in these areas is necessary, it be kept to a minimum.
3. Scratches and/or pits in the areas designated, may be blended or polished out within the dimensional limits
shown.
412_MM_63_0018
Figure 63-64. Rotor Brake Assembly — Damage Limits (Sheet 2 of 2)
63-00-00
30 MAR 2007 Rev. 11 Page 165
BHT-412-MM-6
63-258. Brake Assembly — Repair 63-259. Brake Assembly — Installation (P/N

9450103)
MATERIALS REQUIRED
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
Commercial 400 Grit Aluminum
Oxide Cloth C-405 Lockwire
Commercial Chromic Acid Solution

MIL-C-5541 NOTE
Ensure that microswitch is adjusted so that
NOTE ROTOR BRAKE light illuminates when
brake piston has moved 0.030 inch (0.76
Repair of the brake is limited to the mm) from the original position.
replacement of damaged parts and to the
specific repairs listed in this section and 1. Install microswitch (8, Figure 63-62) on inboard
Figure 63-64, Detail A. brake assembly half (5, Figure 63-63) using screws (9,
Figure 63-62) and washers (10).
1. Clean nicks on pistons (21, Figure 63-63), piston
cavity (24), and throat with 400 grit aluminum oxide
cloth. 2. Secure with lockwire (C-405).
2. Replace any damaged fasteners. 3. Install inboard brake assembly half (5,
Figure 63-63) on rotor brake quill assembly (1) using
3. Bend out nicks and burrs on shaft of piston return bolts (2) and washers (3).
pin (19). Pay particular attention to the area around
the cotter pin hole. 4. Torque bolts (2) to 80 to 100 inch-pounds (9.04 to
11.30 Nm) and secure with lockwire (C-405).
WARNING 5. Install rotor brake disc (7) (paragraph 63-264).
6. Install packings (22) in counterbored cavities in

CHROMIC ACID SOLUTIONS ARE mating surfaces of inboard brake assembly half (5)
CORROSIVE AND POISONOUS. and outboard brake assembly half (11).
PROTECT THE EYES AND HANDS. DO
NOT BREATHE IN THE FUMES. OBEY 7. Insert brake oil transfer tube (14) through packing
MANUFACTURER’S INSTRUCTIONS. (22) in inboard brake assembly half (5) until it bottoms
out in hole in inboard brake assembly half (5).
4. Treat reworked surfaces of piston (21) and
exterior surfaces of brake assembly halves (5 and 11)
with chromic acid solution MIL-C-5541. NOTE
ROTOR BRAKE light illuminates when
mm) from original position.
8. Install microswitch (8, Figure 63-62) on outboard

brake assembly half (11, Figure 63-63) using screws
(9, Figure 63-62) and washers (10).
63-00-00
Page 166 Rev. 11 30 MAR 2007
BHT-412-MM-6
9. Secure with lockwire (C-405). 3. Install inboard brake assembly half (5,
Figure 63-63) on rotor brake quill assembly (1) using
bolts (2) and washers (3).
10. Place brake assembly spacer (23, Figure 63-63)
over protruding oil transfer tube (14) in inboard brake
assembly half (5). 4. Torque bolts (2) to 80 to 100 inch-pounds (9.04 to
11. Ensure holes for bolts (12) in brake assembly

5. Install rotor brake disc (7) (paragraph 63-264).
spacer (23) align with corresponding holes in inboard
brake assembly half (5).
6. Install packings (22) in counterbored cavities in
mating surfaces of inboard brake assembly half (5)
12. Install outboard brake assembly half (11) on and outboard brake assembly half (11).
inboard brake assembly half (5) using bolts (12) and
washers (13). 7. Insert brake oil transfer tube (14) through packing
(22) in inboard brake assembly half (5) until it bottoms
13. Torque bolts (12) to 120 to 130 inch-pounds out in hole in inboard brake assembly half (5).
(13.56 to 14.69 Nm) and secure with lockwire (C-405).
NOTE
14. Install hydraulic hose (2, Figure 63-62) on rotor
brake assembly (1).
ROTOR BRAKE light illuminates when
15. Bleed system (paragraph 63-246). mm) from original position.
8. Install microswitch (8, Figure 63-62) on outboard

16. Check for proper system operation including
brake assembly half (11, Figure 63-63) using screws
illumination of ROTOR BRAKE light.
(9, Figure 63-62) and washers (10).
63-260. Brake Assembly — Installation (P/N 9. Secure with lockwire (C-405).

9450103-1)
10. Place brake assembly spacer (23, Figure 63-63)
over protruding oil transfer tube (14) in inboard brake
MATERIALS REQUIRED assembly half (5).
Refer to BHT-ALL-SPM for specifications. 11. Ensure holes for bolts (12) in brake assembly
spacer (23) align with corresponding holes in inboard
NUMBER NOMENCLATURE brake assembly half (5).
C-405 Lockwire
12. Install outboard brake assembly half (11) on
inboard brake assembly half (5) using bolts (12) and
washers (13).
NOTE
Ensure that microswitch is adjusted so that 13. Torque bolts (12) to 120 to 130 inch-pounds
ROTOR BRAKE light illuminates when (13.56 to 14.69 Nm) and secure with lockwire (C-405).
mm) from the original position. 14. Install hydraulic hose (2, Figure 63-62) on rotor
brake assembly (1).
1. Install microswitch (8, Figure 63-62) on inboard
brake assembly half (5, Figure 63-63) using screws (9, 15. Bleed system (paragraph 63-247).
Figure 63-62) and washers (10).
16. Check for proper system operation including
2. Secure with lockwire (C-405). illumination of ROTOR BRAKE light.
63-00-00
30 MAR 2007 Rev. 11 Page 167
BHT-412-MM-6
63-261. ROTOR BRAKE DISC 63-263. Rotor Brake Disc — Inspection
63-262. Rotor Brake Disc — Removal

SPECIAL TOOLS REQUIRED NUMBER NOMENCLATURE
AN4-5A Bolt
NUMBER NOMENCLATURE
AN960-416 Washer
Commercial Dial Indicator
T101649-101 Brake Disc Holding
Tool Commercial Lathe
1. Open left side engine and transmission cowling to NOTE

gain access to transmission. If rotor brake disc has been removed using
an arbor press (or equivalent), or warpage
is suspected, the following disc inspection
2. Remove outboard brake assembly half (11, is required.
Figure 63-63) (paragraph 63-250).
1. Install inspection arbor (Figure 63-66) in pilot hole
of disc. Install four bolts (AN4-5A) and washers
3. Cut lockwire and remove nut (5, Figure 63-65)
(AN960-416).
using T101649-101 (3) tool to restrain brake disc (2).
a. Install arbor and disc assembly between lathe
4. Remove and discard packing (4). centers.
b. While rotating disc, measure runout as

indicator probe is swept across full radial width of each
CAUTION friction surface (front and back).
c. Total indicator deflection shall not exceed

ROTO R BRA KE DI SC AND FLAN GE 0.010 inch (0.254 mm).
ASSEMBLY SHALL BE REMOVED AS AN
63-264. Rotor Brake Disc — Installation
A S S E M B L Y. DO N O T A TT E M P T T O
REMOVE DISC FROM FLANGE
ADAPTER WHILE ASSEMBLY IS
INSTALLED ON QUILL. DO NOT
SEPARATE DISC FROM FLANGE IF DISC
IS NOT BEING REPLACED. NUMBER NOMENCLATURE

5. Remove disc and flange adapter from quill
Tool
assembly (1, Figure 63-63).
1. If not previously accomplished, install brake disc

6. To remove rotor brake disc (2, Figure 63-65) from (2, Figure 63-65) on flange adapter (1) (paragraph
flange adapter (1) (paragraph 63-265). 63-267).
63-00-00
Page 168 Rev. 11 30 MAR 2007
BHT-412-MM-6
2 3
7
6
1
5
2
1. Flange adapter
2. Brake disc
3. Brake disc holding tool (T101649-101)
4. Packing
5. Nut
6. Bolt
7. Washer
50 TO 70 IN-LBS
1 (5.65 TO 7.91 Nm)
125 TO 150 FT-LBS

2 (169.5 TO 203.4 Nm)
412_MM_63_0003_c2+
Figure 63-65. Rotor Brake Disc
63-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 169
BHT-412-MM-6
0.25 IN. (6.35 mm) -28 UNF-3B THROUGH

CHAMFER COUNTERSINK 90° x 0.260 IN. (6.604 mm)
0.060 IN. (1.524 mm) DIA, 4 PLACES EQ SPACED
x 45° 2 PLACES
0.125 IN. (3.175 mm)

CHAMFER 2 PLACES
1.0 IN.
(25.4 mm) 0.012 IN. (3.048 mm)
x 45° 2 PLACES 0.125 IN. (3.175 mm)
DIA 2 PLACES 2 PLACES
2.2460 TO 30° 2 PLACES

1.5 IN. 2.2465 IN.
(38.1 mm) (57.0484 TO
DIA 2 PLACES 57.0611 mm)
0.19 IN.
(4.826 mm) R 0.75 IN. 3.60 IN.
2 PLACES (19.05 mm) 2.875 IN.
(91.44 mm)
2 PLACES (73.025 mm)
2.5 IN.
(63.5 mm) 2.5 IN. 0.5 IN. (12.7 mm)
(63.5 mm) DIA TO DEPTH SHOWN
0.310 IN.
(7.874 mm)
0.310 IN.
(7.874 mm)
NOTES
1. Material: AISI 4340 steel per MIL-S-5000. Heat treat to RC 36-40 in accordance with MIL-H-6875.
2. Surface finish 125 micro-inches unless otherwise noted.
3. Break edges 0.015 in. (0.381 mm) radius or 0.015 in. (0.381 mm) x 40 to 50° chamfer unless otherwise noted.
412MM_63_0006
Figure 63-66. Rotor Brake Disc Inspection Arbor
63-00-00
Page 170 Rev. 11 30 MAR 2007
BHT-412-MM-6
2. Apply a light coat of transmission oil (Chapter 12) 1. Cut lockwire. Using brake disc holding tool
to splines in rotor brake quill assembly (1, T101469-101, restrain disc (2, Figure 63-65) and
Figure 63-63) and mating splines on flange remove bolts (6) and washers (7).
adapter (6).
2. Using hand pressure only, separate flange
3. Install brake disc (7) and flange adapter (6) and adapter (1) from brake disc (2).
install assembly on rotor brake quill assembly (1).
3. If brake disc (2) and flange adapter (1) cannot be
4. Lubricate new packing (4, Figure 63-65) and separated by hand pressure, proceed as follows:
install on nut (5).
NOTE
5. Install nut (5) in center of brake disc (2) and
The use of an arbor press, or equivalent, to
flange adapter (1). Using T101649-101 to hold disc,
separate flange adapter (1) from brake disc
tighten nut to 125 to 150 foot-pounds (169.5 to
(2) requires brake disc to be inspected for
203.4 Nm) and secure nut with lockwire (C-405).
warpage (paragraph 63-263).
6. Install outboard brake assembly half (paragraph a. To prevent inadvertent separation of the
63-254). assembly, reinstall bolts (6) and washers (7).
b. Place assembly in an arbor press. Remove

63-265. FLANGE ADAPTER
bolts (6) and washers (7).
63-266. Flange Adapter — Removal c. Apply sufficient pressure to separate flange
adapter (1) from brake disc (2).
SPECIAL TOOLS REQUIRED 63-267. Flange Adapter — Installation
1. Install brake disc (2, Figure 63-65) on flange (1)

NUMBER NOMENCLATURE using bolts (6) and washers (7).

2. Torque bolts (6) to 50 to 70 inch-pounds (5.65 to
Tool
63-00-00
30 MAR 2007 Rev. 11 Page 171/172

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BHT-412-MM-6

CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM

Paragraph Chapter/Section Page

MAIN ROTOR DRIVE SYSTEM

63-1 Main Rotor Drive ............................................................................ 63-00-00 11

ENGINE-TO-TRANSMISSION (MAIN) DRIVESHAFT

63-5 Engine-to-Transmission (Main) Driveshaft..................................... 63-00-00 15

MAIN ROTOR MAST

63-20 Main Rotor Mast............................................................................. 63-00-00 29

63-27 Transmission.................................................................................. 63-00-00 37

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-29 Transmission — Maintenance .................................................. 63-00-00 37

TRANSMISSION OIL SYSTEM COMPONENTS

63-35 Electric Chip Detectors .................................................................. 63-00-00 53

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-70 Oil Jet No. 3 .............................................................................. 63-00-00 66

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-117 Oil Pressure Manifold ............................................................... 63-00-00 79

TRANSMISSION OIL COOLING SYSTEM

63-151 Transmission Oil Cooling System .................................................. 63-00-00 97

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-157 Thermal Bypass Valve.............................................................. 63-00-00 99

63-167 Transmission Quills........................................................................ 63-00-00 105

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-190 No. 1 Hydraulic Pump Drive Quill — Cleaning.................. 63-00-00 127

TRANSMISSION QUILL PORT COVERS

63-218 Transmission Quill Port Covers ..................................................... 63-00-00 141

63-221 Transmission Mounts..................................................................... 63-00-00 143

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

63-230 Lift Link ..................................................................................... 63-00-00 148

63-240 Serviceability Checks — Transmission, Tail Rotor Gearbox,

ROTOR BRAKE SYSTEM

63-243 Rotor Brake System....................................................................... 63-00-00 155

63-1 Drive System Chip Detector Debris — Analysis ................................................. 12

63-47 Tool Application .................................................................................................. 114

63-1 Engine-to-Transmission (Main) Driveshaft — Troubleshooting .......................... 15

MAIN ROTOR DRIVE SYSTEM

63-1. MAIN ROTOR DRIVE FRAGMENTS OF TRANSMISSION

Figure 63-1. Drive System Chip Detector Debris — Analysis (Sheet 1 of 3)

Figure 63-1. Drive System Chip Detector Debris — Analysis (Sheet 2 of 3)

Figure 63-1. Drive System Chip Detector Debris — Analysis (Sheet 3 of 3)

ENGINE-TO-TRANSMISSION (MAIN) DRIVESHAFT

63-5. ENGINE-TO-TRANSMISSION (MAIN) 63-7. ENGINE-TO-TRANSMISSION (MAIN)

3. Remove left engine top cowling.

Table 63-1. Engine-to-Transmission (Main) Driveshaft — Troubleshooting

INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

High frequency vibration Improperly assembled driveshaft. Remove, disassemble, inspect,

Loss of grease from coupling. Remove, disassemble, inspect,

Loose engine adapter or adapter Remove, inspect, and install

Dirt or burr on mounting diameters Remove, inspect, clean, and

Loose coupling bolt(s). Loosen, then retighten coupling

Driveshaft out of balance. Balance driveshaft (Chapter 18).

Improperly assembled driveshaft Remove, disassemble, inspect,

Over-temperature indicator Possible overheat condition and/or Refer to paragraph 63-10.

a. If applicable, put a mark to identify the

e. Remove the driveshaft (17). b. If only one over-temperature indicator

Figure 63-2. Engine-to-Transmission (Main) Driveshaft (Sheet 1 of 2)