Installation of the Main Gear Box (MGB) [PW11]

TASK 72-61-01-400-801-A
Installation of the Main Gear Box (MGB)

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

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.

ZONE: 400

1. Reason for the Job
Use this procedure to install the main gearbox.
For more information about the main gearbox, refer to 72-61-00-00
CONF 21 - MAIN GEARBOX ASSEMBLY - DESCRIPTION AND OPERATION.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	COVER - PROTECTION
No specific	Torque wrench: range to between 44 and 38 lbf.in (0.50 and 0.43 m.daN )
No specific	Torque wrench: range to between 70 and 60 lbf.in (0.79 and 0.68 m.daN )
No specific	Torque wrench: range to between 95 and 78 lbf.in (1.07 and 0.88 m.daN )
No specific	Torque wrench: range to between 100 and 90 lbf.in (1.13 and 1.02 m.daN )
No specific	Torque wrench: range to between 125 and 110 lbf.in (1.41 and 1.24 m.daN )
No specific	Torque wrench: range to between 225 and 200 lbf.in (2.54 and 2.26 m.daN )
No specific	Torque wrench: range to between 300 and 265 lbf.in (3.39 and 2.99 m.daN )
No specific	Torque wrench: range to between 375 and 340 lbf.in (4.24 and 3.84 m.daN )
No specific	Torque wrench: range to between 625 and 550 lbf.in (7.06 and 6.22 m.daN )
PWA111736	1	FIXTURE, LIFT - MAIN GEARBOX ASSEMBLY
PWA211305	1	ADAPTER HANDLING
PWA80611	1	JACK-HYDRAULIC

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.P04-010)	grease
(Material No.P06-054)	compound, paste, anti-seize

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 451AL, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 461AL, 462AR

D. Referenced Information

REFERENCE	DESIGNATION
TASK 24-21-51-400-803-A	Installation of the Integrated Drive Generator - IDG 1(2)
TASK 29-11-51-400-805-A	Installation of the Green Engine-Driven Pump
TASK 29-13-51-400-806-A	Installation of the Yellow Engine-Driven Pump
TASK 71-00-00-700-802-A	Test No. 8 - Vibration Analysis (Vibration Survey)
TASK 71-00-00-720-811-A	Test No. 3A - Idle Power Test
TASK 71-00-00-780-802-A	Test No. 13 - Main Oil Pressure Test and Adjustment
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
TASK 71-71-01-400-802-A	Installation of the Engine Drain Mast
TASK 71-71-49-400-801-A	Installation of the Engine Drain Tubes and Pylon Drain Hoses
TASK 72-21-08-400-801-A	Installation of the Fan Exit Liner Segments
TASK 72-62-01-400-801-A	Installation of the Angle Gearbox
TASK 73-11-01-400-801-A	Installation of the Integrated Fuel Pump and Control (IFPC)
TASK 73-11-02-400-801-A	Installation of the Fuel Manifold
TASK 73-11-03-400-801-A	Installation of the Fuel Flow Divider
TASK 73-13-02-400-801-A	Installation of the Fuel Return Pump
TASK 73-21-04-400-801-A	Installation of the Permanent Magnet Alternator (PMA) Stator
TASK 75-25-49-400-802-A	Installation of the Turbine Cooling Air System
TASK 78-30-00-040-805-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-805-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-36-00-010-802-A	Opening of the Thrust Reverser Cowl-Doors
TASK 78-36-00-410-802-A	Closing of the Thrust Reverser Cowl-Doors
TASK 79-21-01-400-801-A	Installation of the Lubrication and Scavenge Oil Pump
TASK 79-21-02-400-801-A	Installation of the Oil Control Module
TASK 79-21-15-400-801-A	Installation of the Variable Oil Reduction Valve (VORV)
TASK 80-11-01-400-801-A	Installation of the Starter
Installation of the Lift Fixture
Installation of the Handling Fixture
Installation of the Main Gearbox Brackets and Tube (FD01)
Connection of the Main Gearbox from the Left Flange H Mount Bracket
Connection of the Main Gearbox from the Flange E Mount Bracket and from the Right Flange H Mount Bracket
Installation of the Right Connecting Link
Installation of the Left Connecting Link
Connection of the Manifold (LB30) and Tube (LB64)
Connection of the Tube (LB60), Manifold (LR40), Tube (LR46) and Ground Strap
Installation of the Tube (FD04)
Installation of the Tube (FD01)

3. Job Set-up
Subtask 72-61-01-941-052-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Make sure that you did the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833).

Subtask 72-61-01-010-055-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-802).
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
1 437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
1 447AL, 448AR.

Subtask 72-61-01-040-052-A ** ON A/C NOT FOR ALL

C. Deactivation of the Thrust Reverser System for Ground Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Make sure that you did the deactivation of the thrust reverser system for ground maintenance (Ref. AMM TASK 78-30-00-040-805).

Subtask 72-61-01-010-056-A ** ON A/C NOT FOR ALL

D. Get Access
(1) Make sure that the thrust reverser cowl-doors are open (Ref. AMM TASK 78-36-00-010-802).
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
1 451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
1 461AL, 462AR.

4. Procedure

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

Subtask 72-61-01-420-050-A ** ON A/C NOT FOR ALL

A. Installation of the Main Gear Box (MGB)
(1) Removal of the protection covers:

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

(a) Make sure that you remove all the necessary COVER - PROTECTION to prevent damage to the engine.
(2) Install the PWA111736 FIXTURE, LIFT - MAIN GEARBOX ASSEMBLY on the MGB (1) as follows:

Installation of the Lift Fixture ** ON A/C NOT FOR ALL

(a) Attach the hoist to the PWA111736 FIXTURE, LIFT - MAIN GEARBOX ASSEMBLY.
(b) Put the three lift arms in position between the MGB (1) mount lugs.
(c) Install the three detail bolts and tighten them with your hand to safety the lift arms on the MGB (1) mount lugs.
(d) Lift the MGB (1).
(3) Attach the PWA211305 ADAPTER HANDLING to the PWA80611 JACK-HYDRAULIC and the MGB (1) as follows:

Installation of the Handling Fixture ** ON A/C NOT FOR ALL

(a) Attach the PWA211305 ADAPTER HANDLING to the PWA80611 JACK-HYDRAULIC with the four detail bolts.
(b) Tighten each detail bolt gradually until the PWA211305 ADAPTER HANDLING is installed.
(c) Attach the PWA211305 ADAPTER HANDLING to the MGB (1) with the three captive bolts.
(d) Tighten each captive bolt gradually until the PWA211305 ADAPTER HANDLING is installed on the MGB (1).
(e) Remove the PWA111736 FIXTURE, LIFT - MAIN GEARBOX ASSEMBLY from the MGB (1).

Installation of the Lift Fixture ** ON A/C NOT FOR ALL

(4) If necessary, install the MGB brackets (12), (13), (14), (15), (16) and (17) as follows:

Installation of the Main Gearbox Brackets and Tube (FD01) ** ON A/C NOT FOR ALL

(a) Apply the grease (Material No.P04-010) on the threads of the 12 bolts (11).

NOTE: For the new or the refurbished bolts or nuts with the baked-on lubricant, do not do the wet application.

(b) Install the brackets (12), (13), (14), (15), (16) and (17) on the MGB (1) with the 12 bolts (11).
(c) TORQUE the 12 bolts (11) to between 95 and 78 lbf.in (1.07 and 0.88 m.daN )

.
(5) Attach the tube (FD01) (28) to the MGB (1) as follows:

Installation of the Main Gearbox Brackets and Tube (FD01) ** ON A/C NOT FOR ALL

(a) Apply the grease (Material No.P04-010) on the threads of the two bolts (11) and the bolt (29).

NOTE: For the new or the refurbished bolts or nuts with the baked-on lubricant, do not do the wet application.

(b) Install the bracket (27) on the MGB (1) with the two bolts (11).
(c) TORQUE the two bolts (11) to between 95 and 78 lbf.in (1.07 and 0.88 m.daN )

.
(d) Install the clamp (30) and the tube (FD01) (28) on the bracket (27) with the bolt (29).
(e) TORQUE the bolt (29) to between 44 and 38 lbf.in (0.50 and 0.43 m.daN )

.
(6) Install the MGB (1) as follows:
(a) Apply the P06-054compound, paste, anti-seize on the threads of the bolts (37), (41), (42), (49), (59), (63), (72), (73), (74), (87), (88) and (90).

NOTE: For the new or the refurbished bolts or nuts with the baked-on lubricant, do not do the wet application.

(b) Install the connecting link (64) on the MGB (1) with the bolt (63), bushing (62), washer (61) and nut (60).

Connection of the Main Gearbox from the Flange E Mount Bracket and from the Right Flange H Mount Bracket ** ON A/C NOT FOR ALL

.
(d) Use the PWA80611 JACK-HYDRAULIC to put the MGB (1) in position for the installation.
(e) Align the flange E mount bracket and the flange H mount bracket (left) connecting link holes.

Connection of the Main Gearbox from the Left Flange H Mount Bracket ** ON A/C NOT FOR ALL

Connection of the Main Gearbox from the Flange E Mount Bracket and from the Right Flange H Mount Bracket ** ON A/C NOT FOR ALL

(f) Install the link (40) on the flange H mount bracket (left) and the MGB (1) with the bolts (37), (41) and (42), the three washers (38) and the three nuts (39) and tighten them with your hand.

Connection of the Main Gearbox from the Left Flange H Mount Bracket ** ON A/C NOT FOR ALL

(g) Install the link (40) on the flange E mount bracket and the MGB (1) with the bolts (49), (41) and (42), the three washers (38) and the three nuts (39) and tighten them with your hand.

Connection of the Main Gearbox from the Flange E Mount Bracket and from the Right Flange H Mount Bracket ** ON A/C NOT FOR ALL

(h) Install the connecting link (64) on the flange H mount bracket (right) with the two bolts (59), the washers (66) and the nuts (65).

Connection of the Main Gearbox from the Flange E Mount Bracket and from the Right Flange H Mount Bracket ** ON A/C NOT FOR ALL

(i) Install the connecting link (76) on the MGB (1) and the Compressor Intermediate Case (CIC) mount bracket (right) with the bolts (72), (73) and (74), the bushing (75), the three washers (38) and the three nuts (39).

Installation of the Right Connecting Link ** ON A/C NOT FOR ALL

(j) Install the connecting link (86) on the MGB (1) and the CIC mount bracket (left) with the bolts (87), (88) and (90), the bushing (89), the three washers (38) and the three nuts (39).

Installation of the Left Connecting Link ** ON A/C NOT FOR ALL

(k) TORQUE the 12 nuts (39) to between 125 and 110 lbf.in (1.41 and 1.24 m.daN )

Connection of the Main Gearbox from the Left Flange H Mount Bracket ** ON A/C NOT FOR ALL

Connection of the Main Gearbox from the Flange E Mount Bracket and from the Right Flange H Mount Bracket ** ON A/C NOT FOR ALL

Installation of the Right Connecting Link ** ON A/C NOT FOR ALL

Installation of the Left Connecting Link ** ON A/C NOT FOR ALL

(l) TORQUE the two nuts (65) to between 300 and 265 lbf.in (3.39 and 2.99 m.daN )

.
(m) Remove the PWA80611 JACK-HYDRAULIC and the PWA211305 ADAPTER HANDLING.

Installation of the Handling Fixture ** ON A/C NOT FOR ALL

(7) Connect the manifold (LB30) to the MGB (1) as follows:

Connection of the Manifold (LB30) and Tube (LB64) ** ON A/C NOT FOR ALL

CAUTION: USE A SECOND WRENCH TO HOLD THE MATING PARTS WHEN YOU LOOSEN OR TIGHTEN THE TUBE OR HOSE NUTS. IF YOU DO NOT OBEY THIS CAUTION, YOU CAN TWIST OR CAUSE DAMAGE TO THE TUBES OR HOSES.

(a) Connect the tube (LB64) to the manifold (LB30).
(b) Apply the P06-054compound, paste, anti-seize on the threads of the three bolts (101).

NOTE: For the new or the refurbished bolts or nuts with the baked-on lubricant, do not do the wet application.

(c) Install the manifold (LB30) and the metering seal (100) on the MGB (1) with the three bolts (101).
(d) TORQUE the three bolts (101) to between 100 and 90 lbf.in (1.13 and 1.02 m.daN )

.
(e) Torque the tube (LB64) B-nut as follows:
1 TORQUE the tube (LB64) B-nut to between 225 and 200 lbf.in (2.54 and 2.26 m.daN )

.
2 Loosen the tube (LB64) B-nut to zero.
3 TORQUE the tube (LB64) B-nut again to between 225 and 200 lbf.in (2.54 and 2.26 m.daN )

NOTE: Do not loosen the tube (LB64) B-nut.

(8) Connect the tube (LB60) and the manifold (LR40) to the MGB (1) as follows:

Connection of the Tube (LB60), Manifold (LR40), Tube (LR46) and Ground Strap ** ON A/C NOT FOR ALL

(a) Apply the P06-054compound, paste, anti-seize on the threads of the three bolts (111) and the three bolts (112).

NOTE: For the new or the refurbished bolts or the nuts with the baked-on lubricant, do not do the wet application.

(b) Install the face seal (114), tube (LB60) and bracket (115) on the MGB (1) with the three bolts (111).
(c) TORQUE the three bolts (111) to between 100 and 90 lbf.in (1.13 and 1.02 m.daN )

.
(d) Install the face seal (113) and the manifold (LR40) on the MGB (1) with the three bolts (112).
(e) TORQUE the three bolts (112) to between 100 and 90 lbf.in (1.13 and 1.02 m.daN )

.
(9) Connect the tube (LR46) and the ground strap to the MGB (1) as follows:

Connection of the Tube (LB60), Manifold (LR40), Tube (LR46) and Ground Strap ** ON A/C NOT FOR ALL

(a) Apply the P06-054compound, paste, anti-seize on the threads of the three bolts (126) and the bolt (124).

NOTE: For the new or the refurbished bolts or nuts with the baked-on lubricant, do not do the wet application.

(b) Install the face seal (125) and the tube (LR46) on the MGB (1) with the three bolts (126).
(c) TORQUE the three bolts (126) to between 100 and 90 lbf.in (1.13 and 1.02 m.daN )

.
(d) Attach the ground strap to the MGB (1) with the bolt (124).
(e) TORQUE the bolt (124) to between 70 and 60 lbf.in (0.79 and 0.68 m.daN )

.
(10) Connect the tube (FD04) (135) and the manifold (LR02) to the MGB (1) as follows:

Installation of the Tube (FD04) ** ON A/C NOT FOR ALL

(a) Apply the P06-054compound, paste, anti-seize on the threads of the two bolts (126) and the two bolts (140).

NOTE: For the new or the refurbished bolts or nuts with the baked-on lubricant, do not do the wet application.

(b) Connect the tube (FD04) (135) as follows:

CAUTION: USE A SECOND WRENCH TO HOLD THE MATING PARTS WHEN YOU LOOSEN OR TIGHTEN THE TUBE OR HOSE NUTS. IF YOU DO NOT OBEY THIS CAUTION, YOU CAN TWIST OR CAUSE DAMAGE TO THE TUBES OR HOSES.

1 Connect the tube (FD04) (135) to the tube (FD03).
(c) Torque the tube (FD04) (135) B-nut as follows:
1 TORQUE the tube (FD04) (135) B-nut to between 225 and 200 lbf.in (2.54 and 2.26 m.daN )

.
2 Loosen the tube (FD04) (135) B-nut to zero.
3 TORQUE the tube (FD04) (135) B-nut again to between 225 and 200 lbf.in (2.54 and 2.26 m.daN )

NOTE: Do not loosen the tube (FD04) (135) B-nut.

(d) Install the bracket (136) on the MGB (1) with the two bolts (126).
(e) TORQUE the two bolts (126) to between 100 and 90 lbf.in (1.13 and 1.02 m.daN )

.
(f) Connect the manifold (LR02) to the MGB (1) with the bracket (138), the clamp (139) and the two bolts (140).
(g) TORQUE the two bolts (140) to between 44 and 38 lbf.in (0.50 and 0.43 m.daN )

.
(11) Install the tube (AP13) and the tube (AP14) (Ref. AMM TASK 75-25-49-400-802).
(12) Install the tube (FD01) (28) on the tube (FD02) and the three brackets as follows:

Installation of the Tube (FD01) ** ON A/C NOT FOR ALL

(a) Install the tube (FD01) (28) on the fuel flow divider (Ref. AMM TASK 73-11-03-400-801).
(b) Apply the P06-054compound, paste, anti-seize on the threads of the two bolts (162) and the four bolts (29).

NOTE: For the new or the refurbished bolts or nuts with the baked-on lubricant, do not do the wet application.

(c) Install the tube (FD01) (28) on the tube (FD02) and the CIC firewall with the bracket (163) and the two bolts (162).
(d) TORQUE the two bolts (162) to between 100 and 90 lbf.in (1.13 and 1.02 m.daN )

.
(e) Install the tube (FD01) on the four brackets with the four clamps (30) and the four bolts (29).
(f) TORQUE the four bolts (29) to between 44 and 38 lbf.in (0.50 and 0.43 m.daN )

.
(g) Torque the tube (FD02) B-nut as follows:
1 TORQUE the tube (FD02) B-nut to between 375 and 340 lbf.in (4.24 and 3.84 m.daN )

.
2 Loosen the tube (FD02) B-nut to zero.
3 TORQUE the tube (FD02) B-nut again to between 375 and 340 lbf.in (4.24 and 3.84 m.daN )

NOTE: Do not loosen the tube (FD02) B-nut.

(h) If necessary, install the fan exit liner segments (Ref. AMM TASK 72-21-08-400-801).

Subtask 72-61-01-410-052-A ** ON A/C NOT FOR ALL

B. If necessary, install the following components on the MGB (1):
(1) Install the Angle Gearbox (AGB) (Ref. AMM TASK 72-62-01-400-801).
(2) Install the MGB oil supply tube (LP35) (Ref. AMM D/O 79-21-49-40).
(3) Install the starter (Ref. AMM TASK 80-11-01-400-801).
(4) Install the Permanent Magnet Alternator (PMA) (Ref. AMM TASK 73-21-04-400-801).
(5) Install the oil control module (Ref. AMM TASK 79-21-02-400-801).
(6) Install the Variable Oil Reduction Valve (VORV) (Ref. AMM TASK 79-21-15-400-801).
(7) Install the lubrication and scavenge oil pump (Ref. AMM TASK 79-21-01-400-801).
(8) Install the fuel/oil manifold (Ref. AMM TASK 73-11-02-400-801).
(9) Install the Integrated Fuel Pump and Control (IFPC) (Ref. AMM TASK 73-11-01-400-801).
(10) Install the fuel return pump (Ref. AMM TASK 73-13-02-400-801).
(11) Install the engine driven pump (Ref. AMM TASK 29-11-51-400-805) and (Ref. AMM TASK 29-13-51-400-806).
(12) Install the Integrated Drive Generator (IDG) (Ref. AMM TASK 24-21-51-400-803).
(13) Install the drain tubes (FB02), (DR01), (DR11), (DR21), (DR22), (DR41), (DR51), (DR121) and (DR131) (Ref. AMM TASK 71-71-49-400-801).
(14) Install the engine drain mast (Ref. AMM TASK 71-71-01-400-802).
(15) Examine the assembly for foreign objects, damage and correct assembly.
(16) Installation of the protection covers:

CAUTION: INSTALL PROTECTION COVERS ON ALL THE OPENINGS IMMEDIATELY TO PREVENT DAMAGE TO THE ENGINE.

(a) Make sure that you install all the necessary COVER - PROTECTION to prevent damage to the engine.

5. Close-up
Subtask 72-61-01-410-053-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 cowl-doors (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR.

Subtask 72-61-01-440-051-A ** ON A/C NOT FOR ALL

B. Do the reactivation of the thrust reverser system after ground maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 72-61-01-410-054-A ** ON A/C NOT FOR ALL

C. Close Access
(1) 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.
(2) Remove the WARNING NOTICE(S).

Subtask 72-61-01-710-054-A ** ON A/C NOT FOR ALL

D. Tests
(1) Do engine tests:

Idle Test Power No.3 (Ref. AMM TASK 71-00-00-720-811).
Vibration Analysis Test No.8 (Ref. AMM TASK 71-00-00-700-802).
Main Oil Pressure Test and Adjustment No.13 (Ref. AMM TASK 71-00-00-780-802).

[Rev.10 from 2021] 2026.04.01 02:50:04 UTC