Repair Damaged Thinwall Insert(s) in the HP-Compressor Rear-Outer-Case Assembly with Oversized Insert(s) (Keensert Insert(s)) - VRS9170 [IAE]

TASK 72-41-23-300-802-A
Repair Damaged Thinwall Insert(s) in the HP-Compressor Rear-Outer-Case Assembly with Oversized Insert(s) (Keensert Insert(s)) - VRS9170

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE SHUTDOWN. USE APPLICABLE THERMAL GLOVES. THE ENGINE PARTS CAN STAY HOT FOR ONE HOUR AFTER SHUTDOWN AND CAN BURN YOU.

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

ZONE: 400

1. Reason for the Job
To replace worn or damaged insert(s) with oversized keensert(s).
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 2M (6 FT)
No specific	1	HAMMER - SLIDE, PULLER, STANDARD
No specific	1	MACHINE - DRILLING
No specific	1	MAGNIFYING GLASS POWER 10X
No specific	AR	PAINTBRUSH
No specific	1	TANG BREAK-OFF TOOL
No specific	1	VACUUM CLEANER
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 3 and 0.5 lbf.in (0.03 and 0.01 m.daN )
70947ASBK-202H	AR
70951-1	AR
70951-6	AR
AGS3707	1
B397-2	AR
KU37022	AR
MS51831CA202L	AR
MS51831CA203L	AR
MS51832CA202L	AR
TDH428L	AR
THD428L	AR

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.V02-001)	adhesive tape (masking)
(Material No.V02-005)	adhesive tape
(Material No.V02-099)	lint free cloth
(Material No.V04-004)	jointing compound
(Material No.V06-064)	Fluorescent penetrant

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [1000EM1] (ENGINE-1)
437AL, 438AR, 451AL, 452AR
FOR [1000EM2] (ENGINE-2)
447AL, 448AR, 461AL, 462AR

D. Referenced Information

REFERENCE	DESIGNATION
TASK 70-23-05-230-010-A	Local Application of Fluorescent Penetrant Inspection
TASK 70-35-26-300-010-A	Replace Damaged Thinwall Self Lock Inserts
TASK 71-13-00-010-010-A	Opening of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 71-13-00-410-010-A	Closing of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 78-30-00-040-012-A	Deactivation of the Thrust Reverser Hydraulic Control Unit (HCU) for Ground Maintenance
TASK 78-30-00-440-012-A	Re-activation of the Thrust Reverser Hydraulic Control Unit (HCU) after Ground Maintenance
TASK 78-32-00-010-010-A	Opening of the Thrust Reverser Halves
TASK 78-32-00-410-010-A	Closing of the Thrust Reverser Halves
Repair Details
Dimensions for the Tapped Insert Hole Using MS51831CA202L or MS51832CA202L
Dimensions for the Tapped Insert Hole Using MS51831CA203L
Installation Sequence
Repair Details and Dimensions
Installation of Repair Inserts
Installation Procedure
Removal of Insert Tag
Torque Check of Screw Lock Inserts

3. Job Set-up
Subtask 72-41-23-941-051-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) On the center pedestal, on ENG panel 115VU:
(a) Put the WARNING NOTICE(S) to tell persons not to start the engine.
(2) Make sure that the engine 1(2) shutdown occurred not less than 5 minutes before you do this procedure.
(3) On overhead maintenance panel 50VU:
(a) Make sure that the ON legend of the ENG/FADEC GND PWR/1(2) pushbutton switch is off.
(b) Put the WARNING NOTICE(S) to tell persons not to energize FADEC 1(2).

Subtask 72-41-23-010-052-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Open the fan cowls (Ref. AMM TASK 71-13-00-010-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR.
(2) Put the ACCESS PLATFORM 2M (6 FT) in position.

Subtask 72-41-23-040-051-A ** ON A/C NOT FOR ALL

C. Deactivation of the Thrust Reverser Hydraulic-Control-Unit (HCU)

WARNING: MAKE SURE THAT THE THRUST REVERSER HYDRAULIC CONTROL UNIT (HCU) IS DEACTIVATED BEFORE YOU DO WORK ON OR AROUND THE THRUST REVERSER. IF THE HCU IS NOT DEACTIVATED, THERE IS A RISK OF UNWANTED THRUST REVERSER OPERATION WHICH CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT.

(1) Deactivate the thrust reverser HCU (Ref. AMM TASK 78-30-00-040-012).

Subtask 72-41-23-010-053-A ** ON A/C NOT FOR ALL

D. Get Access
(1) Open the thrust reverser halves (Ref. AMM TASK 78-32-00-010-010):
(a) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(b) FOR [1000EM2] (ENGINE-2)
461AL 462AR.

4. Procedure
Subtask 72-41-23-210-053-A ** ON A/C NOT FOR ALL

A. Examine the Damaged Area

Repair Details ** ON A/C NOT FOR ALL

(1) Make sure that the condition is as reported.
(a) If the thin wall self-lock insert is NOT removed, remove it (Ref. AMM TASK 70-35-26-300-010). Use approved workshop equipment.

Subtask 72-41-23-950-050-A ** ON A/C NOT FOR ALL

B. Mask the Repair Area

NOTE: This step is to prevent foreign objects falling into engine.

(1) Mask and cover all holes and openings to the inner side of the case which need to be repaired. Prepare the inner-free area of the hole(s) by placing the clean lint free cloth (Material No.V02-099) over hole(s) so that no cutting debris can fall into the engine. Mask the holes by taping the lint free cloth (Material No.V02-099) with the V02-001adhesive tape (masking).
(2) Mask all open holes adjacent to the repair area, use V02-001adhesive tape (masking) or adhesive tape (Material No.V02-005) .

Subtask 72-41-23-350-064-A ** ON A/C NOT FOR ALL

C. Removal of the Damaged Thinwall Insert(s)
(1) Remove the damaged thinwall insert(s) (Ref. AMM TASK 70-35-26-300-010).
(a) Discard the insert(s) and continue with Para. 4.D.

Subtask 72-41-23-140-050-A ** ON A/C NOT FOR ALL

D. Clean the Hole

Repair Details ** ON A/C NOT FOR ALL

(1) Remove all the debris from the hole with the VACUUM CLEANER.

Subtask 72-41-23-320-050-A ** ON A/C NOT FOR ALL

E. Drill, counterbore and tap the insert hole for fitment of self-broaching keensert insert(s)
(1) Determine the proper oversize insert required for the replacement. The size required can be determined by using the standard equipment for measuring the diameters.

Repair Details ** ON A/C NOT FOR ALL

Use the KU37022 for the holes identified as 1A.
Use the MS51831CA202L for the holes identified as 2B. If a bleed port hole requires a 1/4-28 internal thread for the screw use the MS51832CA202L .
Use the MS51831CA203L for the holes identified as 3C.

(a) For the MS51831CA202L , MS51832CA202L or the MS51831CA203L use the MACHINE - DRILLING, the standard drill, standard countersink (82 deg. to 100 deg.) and standard unified thread series tap.

Dimensions for the Tapped Insert Hole Using MS51831CA202L or MS51832CA202L ** ON A/C NOT FOR ALL

Dimensions for the Tapped Insert Hole Using MS51831CA203L ** ON A/C NOT FOR ALL

Installation Sequence ** ON A/C NOT FOR ALL

(b) For the KU37022 drill the hole for the repair insert. Then tap the hole for the repair insert. Refer to:

Repair Details and Dimensions ** ON A/C NOT FOR ALL

Subtask 72-41-23-160-050-A ** ON A/C NOT FOR ALL

F. Clean the Self-Broaching Keensert Insert(s) Hole
(1) Clean the keensert insert(s) hole to remove debris.
(a) Remove unwanted material from the machined self-broaching keensert insert hole with the VACUUM CLEANER. All the debris must be removed from the tapped hole to permit the correct installation of the insert.
(b) Chemically clean the self-broaching keensert insert hole (Ref. AMM TASK 70-23-05-230-010).

Subtask 72-41-23-230-050-A ** ON A/C NOT FOR ALL

G. Crack Test
(1) Do a local fluorescent penetrant inspection of the repair area (Ref. AMM TASK 70-23-05-230-010).
(a) Locally clean and inspect the repair area using fluorescent penetrant.
(b) Use the Fluorescent penetrant (Material No.V06-064) with the clean PAINTBRUSH.
(c) If you find cracks, reject the part.

Subtask 72-41-23-210-054-A ** ON A/C NOT FOR ALL

H. Visual Inspection of the Self-Broaching Keensert Insert Hole
(1) Do a visual inspection of the tapped hole with the MAGNIFYING GLASS POWER 10X.
(a) Make sure that there are no burrs, unwanted particles, grease or oil.

Subtask 72-41-23-350-065-A ** ON A/C NOT FOR ALL

I. Installation of the Self-Broaching Keensert Insert(s) - MS51831CA202L, MS51832CA202L or MS51831CA203L Power Tool Installation (Method A)

Dimensions for the Tapped Insert Hole Using MS51831CA202L or MS51832CA202L ** ON A/C NOT FOR ALL

Dimensions for the Tapped Insert Hole Using MS51831CA203L ** ON A/C NOT FOR ALL

Installation Sequence ** ON A/C NOT FOR ALL

NOTE: The power installation tool is composed of the 70951-6 and the 70947ASBK-202H .

(1) If only the KU37022 is required, go to Para 4.L.
(2) Take care to align the power installation tool with the axis of the insert hole.
(3) Before the installation of self-broaching keensert insert apply a thin layer of jointing compound (Material No.V04-004) to the internal threads and to the external surface of the self-broaching keensert insert.
(a) Air-dry the jointing compound (Material No.V04-004) to the manufacturer's instructions before installing the insert.
(b) Use the clean PAINTBRUSH.
(4) Screw in the self-broaching keensert insert using the power installation tool.
(a) Refer to the manufacturer's instructions.
(b) Use the 70951-1 and the 70947ASBK-202H .
(c) Use the self-broaching keensert insert.
(5) Drive the keensert insert into position.
(a) Refer to manufacturer's instructions. The self-broaching keensert insert should be positioned with keensert maximum offset from the flange edge.
(6) Remove the power installation tool.

Subtask 72-41-23-350-066-A ** ON A/C NOT FOR ALL

J. Installation of the Self-Broaching Keensert Insert(s) MS51831CA202L, MS51832CA202L or MS51831CA203L - Hand Tools Installation (Method B)

Repair Details ** ON A/C NOT FOR ALL

Dimensions for the Tapped Insert Hole Using MS51831CA202L or MS51832CA202L ** ON A/C NOT FOR ALL

Dimensions for the Tapped Insert Hole Using MS51831CA203L ** ON A/C NOT FOR ALL

NOTE: This hand tools installation is an alternative method to the method in Para 4.J. Method A (install the self-broaching keensert insert(s) - power tool) is preferred insert installation procedure. If necessary, method B (install the self-broaching keensert insert(s) - hand tool installation) can be used.

(1) If only the KU37022 is required, go to Para 4.L.
(2) Install the self-broaching keensert insert using fingers or the THD428L .

NOTE: Insert is designed to stop at correct depth bellow the surface.

(a) Use the self-broaching keensert insert.
(b) Use the THD428L .
(3) Mark the location, where the keensert insert stopped on material.
(a) The self-broaching keensert insert should be positioned with keensert maximum offset from the flange edge.
(4) Remove the self-broaching keensert insert - hand tools installation (method B).
(5) Cut the keeways - hand tools installation (method B):
(a) Insert the pilot of the B397-2 into the insert hole aligning the blades with the location markings of the keensert.
1 Make sure the blades in the broaching tool are sharp.
2 Replace as required.
(b) Cut the keeways into the material by striking a blow to the top of the B397-2 .
1 Use the HAMMER - SLIDE, PULLER, STANDARD and the B397-2 .
2 Use the VACUUM CLEANER.

NOTE: Several cuts can be necessary to complete broaching process.

(c) Remove the B397-2 .
(6) Remove unwanted material - hand tools installation (method B).
(a) Remove the burrs in the self-broaching keensert insert hole by using the standard unified thread series tap.
(7) Clean the self-broaching keensert insert hole - hand tools installation (method B).
(a) Clean the self-broaching keensert insert hole with the VACUUM CLEANER to remove debris.
1 Remove unwanted material. All the debris must be removed from the tapped hole to permit the correct installation of the insert.
(b) Chemically clean the self-broaching keensert insert hole (Ref. AMM TASK 70-23-05-230-010).
(8) Install the self-broaching keensert insert - hand tools installation (method B).
(a) Replace the blades in the broaching tool as required (one or three cut per blade are allowed in the rear case).
(b) Before the installation of self-broaching keensert insert apply a thin layer of the jointing compound (Material No.V04-004) to the internal threads and to the external surface of the self-broaching keensert insert.
1 Air-dry the jointing compound (Material No.V04-004) to the manufacturer's instructions before installing the insert.
2 Use the clean PAINTBRUSH.
(c) Install the self-broaching keensert insert using fingers or the TDH428L .
1 Use the self-broaching keensert insert.
2 Use the TDH428L . Refer to manufacturer's instructions.
(d) Immediately align the keensert to keeways.
(e) Tap down the keensert using the TDH428L and the HAMMER - SLIDE, PULLER, STANDARD.
(f) Remove the TDH428L .
(9) Do a visual inspection of the repair area with the MAGNIFYING GLASS POWER 10X.
(a) Make sure the insert is correctly installed.
(b) Make sure that there are no burrs, unwanted particles, grease or oil.

Subtask 72-41-23-350-067-A ** ON A/C NOT FOR ALL

K. Installation of the Self-Broaching Keensert Insert KU37022, if Required. If not, go to Para 5. Close-up.

Repair Details and Dimensions ** ON A/C NOT FOR ALL

Installation of Repair Inserts ** ON A/C NOT FOR ALL

Installation Procedure ** ON A/C NOT FOR ALL

Removal of Insert Tag ** ON A/C NOT FOR ALL

Torque Check of Screw Lock Inserts ** ON A/C NOT FOR ALL

(1) Apply the jointing compound (Material No.V04-004) on the thread.
(a) Apply a layer of the jointing compound (Material No.V04-004) on the newly tapped threads and the repair insert outer threads.
(b) Use the repair KU37022 .
(2) Install the repair insert.
(a) Refer to:
Table 1 for 0.4375-20 thread insertion tool P/N 2R19644 and:

Installation of Repair Inserts ** ON A/C NOT FOR ALL

for the installation.
(3) Do a visual inspection of the repair inserts.

Installation of Repair Inserts ** ON A/C NOT FOR ALL

(a) Make sure that the repair insert is fitted under the flush to the internal counterbore (in example below the damaged broached serrations).
(4) Apply the jointing compound (Material No.V04-004) on the threads.
(a) Apply a layer of the jointing compound (Material No.V04-004) on the repair insert inner threads and the wire thread insert outer threads with the wire thread insert AGS3707 .
(5) Install the wire thread insert.

Installation Procedure ** ON A/C NOT FOR ALL

(6) Remove the tang on the wire thread insert using the TANG BREAK-OFF TOOL. Refer to:

Removal of Insert Tag ** ON A/C NOT FOR ALL

(7) Inspect the wire thread insert.
(a) Make sure that the wire thread insert is fitted small distance under the flush to the repair insert.
(8) Do a torque check of the wire thread insert at the applicable torque value range.
(a) TORQUE to between 3 and 0.5 lbf.in (0.03 and 0.01 m.daN )

thread insert No. 4.
(b) For the other torque values, refer to:

Torque Check of Screw Lock Inserts ** ON A/C NOT FOR ALL

Subtask 72-41-23-350-069-A ** ON A/C NOT FOR ALL

L. Approved Hand Tools

	Specified unified thread
	0.250 IN. (6.35 MM)	0.4375 IN. (11.11 MM)
Threads/IN.	28	20
Extraction Tool	IAE 2R19616	IAE 2R19643
Insertion tool (Pre-wind type)	IAE 2R19617	IAE 2R19644
Tang removal tool	IAE 2R19618	IAE 2R19645
Roughing tap	IAE 2R19619	IAE 2R19646
Plug tap	IAE 2R19620	IAE 2R19647
Bottoming tap	IAE 2R19621	IAE 2R19648
Special gage for tapped hole	IAE 2R19622	IAE 2R19649
Cross thread gage	IAE 2R19623	IAE 2R19650
Torque check plug	IAE 2R19624	IAE 2R19651
Torque adapter	IAE 2R19625	IAE 2R19587
Torquemaster	IAE 2R19588 (all threads)
Torque setting rig	IAE 2R19589	IAE 2R19589

Table - Approved Hand Tools by dimension (0.250 IN. to 0.4375 IN.) (6.35 MM to 11.11 MM)

5. Close-up
Subtask 72-41-23-410-052-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 thrust reverser halves (Ref. AMM TASK 78-32-00-410-010):
(a) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(b) FOR [1000EM2] (ENGINE-2)
461AL 462AR.

Subtask 72-41-23-440-051-A ** ON A/C NOT FOR ALL

B. Activation of the Thrust Reverser HCU
(1) Activate the thrust reverser HCU (Ref. AMM TASK 78-30-00-440-012).

Subtask 72-41-23-410-053-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the fan cowls (Ref. AMM TASK 71-13-00-410-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR.
(2) Remove the WARNING NOTICE(S).
(3) Remove the access platform(s).

Subtask 72-41-23-970-050-A ** ON A/C NOT FOR ALL

D. Record of the Repair
(1) Make a record of VRS9170 in the relevant engine documentation.

[Rev.10 from 2021] 2026.04.01 02:46:19 UTC