Replacement of the Fan Case Assembly Composite Studs [PW11]

TASK 72-21-01-960-802-A
Replacement of the Fan Case Assembly Composite Studs

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AND THE ADJACENT COMPONENTS AFTER ENGINE SHUTDOWN. THE ENGINE, THE ENGINE OIL AND THE ADJACENT COMPONENTS CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

WARNING: OBEY THE APPLICABLE FIRE SAFETY PROCEDURES WHEN YOU COMPLETE THE REPAIR ON OR NEAR:

THE HYDRAULIC LINES,
THE IGNITOR CABLES AND
THE CABLES OF THE PRIMARY HEALTH MONITORING UNIT.

IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY TO PERSONNEL CAN OCCUR.

1. Reason for the Job
Use this procedure to repair missing, loose, or damaged stud(s) on the fan case.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
No specific	1	HEAT SOURCE - RADIANT

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.P05-038)	cheesecloth - bleached, new, woven, unsized
(Material No.P05-131)	non - metallic grit cloth
(Material No.P05-153)	abrasive paper, silicon carbide
(Material No.P05-223)	Tape, protective masking (aluminum foil)
(Material No.P05-479)	gloves latex, powder-free
(Material No.P08-060)	Adhesive paste epoxy
(Material No.P11-065)	Acetone
(Material No.P11-078)	alcohol, isopropyl

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR

D. Referenced Information

REFERENCE	DESIGNATION
TASK 70-27-00-910-804-A	SPOP 208 - Degreasing of Parts by Solvent Wiping
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-802-A	Closing of the Fan Cowl Doors
Fan Case Assembly Composite Studs

3. Job Set-up
Subtask 72-21-01-941-063-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Do the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833).

Subtask 72-21-01-010-060-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR
(2) Put an ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE in position.

4. Procedure

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

Subtask 72-21-01-960-052-A ** ON A/C NOT FOR ALL

A. Replacement of the Fan Case Assembly Composite Studs
(1) Put P05-479gloves latex, powder-free on your hands.
(2) Clean the repair areas on the fan case by SPOP 208 (Ref. AMM TASK 70-27-00-910-804), with clean P05-038cheesecloth - bleached, new, woven, unsized and P11-078alcohol, isopropyl or Acetone (Material No.P11-065) . See the sheet 1 of the figure.

NOTE: This repair must be done in a clean area with no oils, greases, or smoke. Apply a mask to the area as necessary.

(3) Remove the damaged or loose studs from the fan case. Pry the studs off. Discard the removed studs. Do no use impact loading.
(4) Remove all remaining unwanted material with non - metallic grit cloth (Material No.P05-131) or P05-153abrasive paper, silicon carbide. Do not remove material through the fiberglass into the case wall carbon fiber.
(5) Clean the repair areas on the fan case by SPOP 208 (Ref. AMM TASK 70-27-00-910-804) with clean P05-038cheesecloth - bleached, new, woven, unsized and P11-078alcohol, isopropyl or Acetone (Material No.P11-065) .
(6) Do a visual inspection of the fan case bond areas where the studs were removed. Delamination, missing, or damaged outer ply/layer is not permitted.
(7) Clean the stud and fan case bond surfaces by SPOP 208 (Ref. AMM TASK 70-27-00-910-804) with clean P05-038cheesecloth - bleached, new, woven, unsized and P11-078alcohol, isopropyl or Acetone (Material No.P11-065) .
(8) Prepare the stud and fan case bond surfaces to produce a smooth, matte surface with non - metallic grit cloth (Material No.P05-131) or P05-153abrasive paper, silicon carbide. The non - metallic grit cloth (Material No.P05-131) or P05-153abrasive paper, silicon carbide must be kept free from contamination harmful to adhesive bonding, sealing, or filling processes.
(9) Clean all mating parts in the bond area, such as wiring harnesses, by SPOP 208 (Ref. AMM TASK 70-27-00-910-804), with clean P05-038cheesecloth - bleached, new, woven, unsized and P11-078alcohol, isopropyl or Acetone (Material No.P11-065) .
(10) Clean the stud and fan case bond surfaces by SPOP 208 (Ref. AMM TASK 70-27-00-910-804) with clean P05-038cheesecloth - bleached, new, woven, unsized moist with P11-078alcohol, isopropyl or Acetone (Material No.P11-065) .
(a) Let the parts air dry for 15 minutes minimum. This step is necessary to remove contamination from the abrading process.
(11) Remove the studs from the plastic tool, if necessary. Use the mating part locations of the studs on the fan case.
(12) Bond the new studs (P/N ST5211-10) to the fan case with Adhesive paste epoxy (Material No.P08-060) as follows. See the sheet 2 and the sheet 3 of the figure.
(a) Apply a bead of Adhesive paste epoxy (Material No.P08-060) approximately 0.125 in. (3.17 mm) in diameter. Start to between 0.25 in. (6.35 mm) and 0.40 in. (10.16 mm) from the base plate edge and work towards the center in either the counterclockwise or clockwise direction to the center of the base plate.
(b) Lower temperature cure method

CAUTION: WHEN YOU APPLY TAPE, MAKE SURE THAT THE TAPE DOES NOT TOUCH THE TITANIUM PARTS. IF YOU DO NOT OBEY THIS PRECAUTION, YOU CAN CAUSE DAMAGE TO ENGINE PARTS.

CAUTION: DO NOT APPLY TAPE ON THE THREADS. IF YOU DO NOT OBEY THIS PRECAUTION, YOU CAN CAUSE DAMAGE TO ENGINE PARTS.

1 If the lower temperature cure method will be used, use P05-223Tape, protective masking (aluminum foil) to make sure that enough pressure is applied to the studs.

NOTE: P05-223Tape, protective masking (aluminum foil) can be applied before or after the stud is installed to the fan case.

NOTE: It is permitted to cut the P05-223Tape, protective masking (aluminum foil) to install it around the stud after the stud is installed. Two pieces of P05-223Tape, protective masking (aluminum foil) must be applied in a cross pattern if the P05-223Tape, protective masking (aluminum foil) is cut.

NOTE: P05-223Tape, protective masking (aluminum foil) must not cause blockage of the threads. Cut the P05-223Tape, protective masking (aluminum foil) before or after stud installation to make sure threads are not blocked.

NOTE: P05-223Tape, protective masking (aluminum foil) must extend 2.0 in. (50.80 mm) minimum more than the base plate on each side unless blocked.

(c) Install the stud by turning it into the mating part for location of the studs on the fan case.
(d) Press the stud against the fan case. Adhesive paste epoxy (Material No.P08-060) squeeze-out must not extend more than 0.1 in. (2.54 mm) more than the base plate edge. Squeeze-out is necessary all around. No space is permitted. The Adhesive paste epoxy (Material No.P08-060) thickness must be to between 0.01 in. (0.25 mm) and 0.03 in. (0.76 mm) below the base plate after the stud is pressed into position at final assembly. Remove unwanted Adhesive paste epoxy (Material No.P08-060) around the stud once you get the correct amount of squeeze-out. See the sheet 1 of the figure.

NOTE: If P05-223Tape, protective masking (aluminum foil) is not used, the Adhesive paste epoxy (Material No.P08-060) squeeze-out height must not be more than the base plate height.

(e) Tighten the nuts on the mating parts to attach the studs to the fan case.
(f) Let the Adhesive paste epoxy (Material No.P08-060) cure by one of the methods that follow. Use an appropriate HEAT SOURCE - RADIANT to cure the Adhesive paste epoxy (Material No.P08-060) .
1 Cure to between 165 deg.F (73.89 deg.C) and 195 deg.F (90.56 deg.C) for one hour minimum.
2 Cure to between 65 deg.F (18.33 deg.C) and 160 deg.F (71.11 deg.C) for 24 hours minimum.

NOTE: Pressure must be applied by the mating part for the duration of the cure.

(g) Do a visual inspection of the P05-223Tape, protective masking (aluminum foil) to make sure it appears smooth. Remove and replace the P05-223Tape, protective masking (aluminum foil) if there are wrinkles, damage, or cuts from previous operations. See the sheet 2 of the figure.
(13) Examine the assembly for foreign objects, damage, and correct assembly.

5. Close-up
Subtask 72-21-01-410-058-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR
(3) Remove the access platform(s).
(4) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 13:02:29 UTC