0 Sikorsky 

A United Technologies Company 

Sikorsky Aircraft Corporation 

6900 Maln Street 

P.O. Bo~ 9729 

Stratford, Connecticut 06615·9129 

(203) 386·4000 

moHrnTI ~~rnmorn~ ~ I 

I I ~ 

THIS ALERT SERVICE BULLETIN IS THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION AND IS PROTECTED UNDER THE COPYRIGHT LAWS OF THE 

UNITED STATES AND OTHER COUNTRIES. THIS ALERT SERVICE BULLETIN IS DISTRIBUTED ONLY TO OWNERS/OPERATORS OF COMMERCIALLY-CERTIFIED 

SIKORSKY HELICOPTERS AND SIKORSKY-AUTHORIZED LOGISTIC AND SERVICE CENTERS FOR THE PURPOSE OF FOSTERING THE SAFE AND EFFICIENT 

OPERATION OF SUCH HELICOPTERS AND UNDER THE EXPRESS CONDITION THAT THE CONTENTS OF THIS ALERT SERVICE BULLETIN ARE NOT TO BE 

DISCLOSED, REPRODUCED. OR DISTRIBUTED, IN WHOLE OR IN PART, TO ANY THIRD PARTY, OR ADAPTED AS A DERIVATIVE WORK, WITHOUT THE 

EXPRESS DOCUMENTED CONSENT OF SIKORSKY AIRCRAFT CORPORATION. ANY ACT IN VIOLATION OF APPLICABLE LAW MAY RESULT IN CIVIL AND/OR CRIMINAL PENAL TIES. 

LIMITED DISTRIBUTION • SIKORSKY AIRCRAFT CORPORATION 1999 

ALL RIGHTS RESERVED 

No. 92-63-014A 

Subject: ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter 

Components - One-Time Replacement of Mounting Studs 

1. PLANNING INFORMATION 

A. Effectivity 

S-92A Model Main Gearboxes which contain a 92351-15110-042, -043, -044 main housing 

assembly which have not been reworked. Main housing assemblies reworked will be 

identified by part marking TS-062-01 in the same location as part number. 

Component 

MGB Oil Filter Assembly 

B. Purpose 

This Alert Service Bulletin (ASB) provides instruction to remove MGB filter bowl assembly 

mounting titanium studs and replace them with steel mounting studs. 

Background 

Undetected damage to an oil filter stud can lead to failure of the stud. Enhanced 

procedures are being added to the maintenance manual to help identify potentially 

damaged studs. To further enhance reliability of this connection, the titanium studs are 

being replaced with steel. 

C. Description 

Helicopter is prepared for maintenance. Central cover is removed, if required. MGB oil filter 

assembly is removed. Titanium filter bowl assembly mounting studs are removed. Steel 

mounting studs are installed. MGB oil filter assembly is reinstalled. Main transmission is 

January 28/09 Page 1 of 10 63-24-02 

Revision A - March 20/09 
I 

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No. 92-63-014A 

ROTOR DRIVES • Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs 

1. PLANNING INFORMATION (Continued) 

D. 

E. 

serviced. Reinstall central cover, if removed. A ground test procedure is performed. Helicopter is 

returned to service. 

Compliance 

Compliance is essential. One-time replacement outlined herein Is to be accomplished before 

next flight. 

Approval 

The change effected by this document is classified as Major, and is FAA approved in 

accordance with the applicable requirements of Federal Aviation Regulations FAR 29. This 

constitutes EASA approval under the terms of the current interim procedures for working with 

the European Community on airworthiness certification and continued airworthiness. The repair 

data provided in this document is automatically approved by ED Decision 2004/04/CF, as 

amended by ED Decision 2007/001/C. Reference to the ED Decisions mentioned above shall be 

made in the release documents issued by the EASA 145 approved organization, releasing the 

relevant EU registered helicopter or component to service. 

F. Personnel Qualifications 

Personnel required to perform this task must have experience with metal working or machining. 

If personnel with suitable qualifications are not available, contact Customer Service Engineering 

at 1-800-Winged-S or 1-203·416-4299 regarding training or information regarding contractors 

capable of performing this work. As well, check EASA requirements for personnel certification/ 

qualifications. Demonstration video will be provided. 

G. Manpower (Estimated) 

Removal of Oil Filter 

Assembly 

Removal of Filter Bowl 

Mounting Assembly Studs 

Install Filter Bowl 

Mounting Assembly Studs 

Reinstallation of Oil 

Filter Assembly 

No. of Men 

1 

1 

No. of Hours 

0.40 

1.50 

1.50 

0.40 

"Man-Hours 

0.40 

1.50 

1.50 

0.40 

NOTE: •Estimate does not include time required to prepare helicopter or return it to flight status. 

January 28/09 Page 2 63-24-02 

Revision A - March 20/09 
ffi[~rnu ~~rnvm;~ mmiTIT~uJm No. 92-63-014A 

ROTOR DRIVES • Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs 

1. PLANNING INFORMATION (Continued) 

H. Material 

One-quart container, or equivalent. 

I. Tooling 

NOTE: For tooling availability, contact Helicopter Support Inc. Refer to Material Information 

sectfon of this ASB. 

(1) Lockring Cutter, BT309, or equivalent. 

(2) Lockring Drive Tool, S101D12, M101D12N, or equfvalent. 

(3) Stud Install Wrench, R1105W, or equivalent. 

(4) Housing, Tapered Collet 1/4- 28, CGS00-4, or equivalent. 

J. Weight and Balance 

None. 

K. Electrical Load Data 

Not affected. 

L. Software Load Data 

Not applicable. 

M. References 

(1) Maintenance Manual, SA S92A-AMM-OOO, Chapter/Section 54-40-01. 

(2) Maintenance Manual, SA S92A-AMM-OOO, Chapter/Section 63-20-00-610-001. 

(3) Maintenance Manual, SA S92A-AMM-OOO, Chapter/Section 63-24-02-900-002. 

(4) Functional Check Flight Procedures Manual, SA S92A-FCP-OOO. 

N. Publications Affected 

(1) Temporary Revision No. 63-12 against Maintenance Manual, SA S92A-AMM-OOO, 

Chapters/Sections 63-24-02-900-002, will be issued to introduce a new nut (SS5086-04). 

January 28/09 Page 3 63-24-02 

Revision A - March 20/09 
ffi[~mu ~~rn~m;~ mm[ITauJm 

No. 92-63-014A 

ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs 

1. PLANNING INFORMATION (Continued) 

0. Attachment 

(1) None. 

2 MATERIAL INFORMATION 

A. Basis for Material Data 

Per helicopter. 

B. Bill of Material 

New Part No. 

MS51990-1 05P 

SS5086-04 

M83248/1-033 

M83248/1-238 

SLS11FJ101-

11SN12A 

I (DMYN0-97393-

503) 

MS20002-4 

3 

3 

1 

3 

3 

Key Word 

Lockring 

Nut 

Packing 

Packing 

Stud 

Washer 

Old Part No. 

MS51990-105P 

MS21043-4 

M83248/1-033 

M83248/1-238 

SFJ101-

11TA 12AE0301 

(DMYN0-83324-

214) 

MS20002-4 

Instructions/ 

Disposition 

(1) 

(1) 

(1) 

(1) 

(1) 

( 1) 

(1) Parts and tooling are available at no cost. For parts and tooling availability and lead time 

requirements, contact your Customer Service Representative at Helicopter Support, Inc 

(HSI). Submit a purchase order referencing the ASB number and helicopter serial numbers 

upon which these will be used. This will allow HSI and the operator to track shipment 

January 28/09 

and receipt of parts. Orders will be accepted by letter, telephone, facsimile (FAX), or HSI 

website: www.HSIUS.com. For prompt shipment, reference address of each shipping 

destination. Direct your order to: 

HELICOPTER SUPPORT INC. 

124 Quarry Road 

P.O. Box 11068 

Trumbull, CT 06611 

Attn: Customer Service 

Page 4 63-24-02 

Revision A - March 20/09 
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No. 92-63-014A 

ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs 

2. MATERIAL INFORMATION (Continued) 

FAX: (203) 416-4291 Telephone: (203) 416·4000 

HSI website: www.HSIUS.com 

C. Consumable Material 

QTY 

AS REQ'D 

AS REQ'D 

AS REQ'D 

AS REQ'D 

AS REQ'D 

AS REQ'D 

AS REQ'D 

AS REQ'D 

WARNING I OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN 

.._ ____ .. USING CONSUMABLES. WHEN APPLICABLE, WEAR NECESSARY 

..., PROTECTIVE GEAR DURING HANDLING AND USE. IF A 

CONSUMABLE IS FLAMMABLE OR EXPLOSIVE, MAKE CERTAIN 

CONSUMABLE AND ITS VAPORS ARE KEPT AWAY FROM HEAT, 

SPARK, AND FLAME. MAKE CERTAIN FIREFIGHTING EQUIPMENT IS 

READILY AVAILABLE PRIOR TO USE. FOR ADDITIONAL 

INFORMATION ON TOXICITY, FLASHPOINT, AND FLAMMABILITY OF 

CHEMICALS, CONSULT YOUR MEDICAL PEOPLE, OR THE 

MANUFACTURER OF THE CONSUMABLE. 

INSTRUCTIONS/ 

KEY WORD NOMENCLATURE DISPOSITION 

ISOPROPYL ALCOHOL COMMERCIAL GRADE OR ( 1) 

EQUIVALENT 

Q-TIP COMMERCIAL GRADE OR (1) 

EQUIVALENT 

LINT FREE CLOTH CCC-C-440 OR EQUIVALENT (1) 

LUBRICATING OIL DOD-PRF-857 43 (1) 

OR EQUIVALENT 

CLEAR EPOXY MIL-PRF-22750 (2) 

OR EQUIVALENT 

EPOXY PRIMER MIL-P-23377, OR MIL-P-85582, (3) 

OR EQUIVALENT 

SEALING COMPOUND AMS 3265 TYPE 2 (4) 

CHEM SEAL (CS) 

5500CI CLASS B 

OR EQUIVALENT 

INK A-A-208 (5) 

(1) Locally procure. 

(2) Manufactured by Chesapeake Bay Coatings, Website: http://chesapeakebaycoatings.com/ 

January 28/09 Page 5 63-24·02 

Revision A - March 20/09 

I 
ffi[~rnu ~~rnv~~~ mm[rrauJm No. 92-63-014A 

ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - Onenme Replacement of Mounting Studs 

2. MATERIAL INFORMATION (Continued) 

(3) Manufactured by Trans Chern Coatings-Industrial Finishes, Website: http://www.transchem.com/ 

(4) Manufactured by Flamemaster, Website: http://www.flamemaster.com/ 

(5) Manufactured by Specialty Adhesives lnc.,Website: http://www.specialtyadhesives.com/ 

milspecs.htm 

3. ACCOMPLISHMENT INSTRUCTIONS 

A. Perform one-time removal of MGB filter bowl assembly mounting studs as follows: 

WARNING I TAKE ANY STEPS NECESSARY TO ENSURE THAT NO FOREIGN 

OBJECTS FALL INTO THE GEARBOX DURING THE REMOVAL AND 

REPLACEMENT OF STUDS AND LOCKRINGS. 

(1) Prepare helicopter for maintenance. 

(2) Turn off electrical and hydraulic power. 

(3) Remove central cover, if required. Refer to Maintenance Manual, SA S92A-AMM-000, 

Chapter/Section 54-40-01. 

(4) Remove MGB oil filter assembly, 92351-15802-101. 

(a) Remove nuts (MS21 043-4) and washers (MS20002-4) securing filter to main gearbox 

sump. Discard nuts. 

NOTE: Let oil drain into one-quart container when filter bowl is removed. 

(b) Pull filter bowl off MGB. 

(c) Remove packings (M83248/1-033 and M83248/1-238). 

(d) Inspect for any damage to packing. Any damage found, replace packings. 

(5) Carefully inspect the three studs where they attach to the MGB housing. Housing must be 

free from damage or corrosion in order to proceed with stud replacement. 

(6) Mask MGB filter bowl inside diameter to prevent foreign objects from entering housing. 

(7) Begin cutting lockrings, securing titanium studs (SFJ101 -11TA12AE0301) (DMYN0-83324-

214). Typical three places. 

January 28/09 Page 6 63-24-02 

Revision A - March 20/09 
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ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs 

3. ACCOMPLISHMENT INSTRUCTIONS (Continued) 

(8) Using an indelible marker, mark housing to show location where lockring teeth were in 

contact with MGB housing. 

(9) Using hand drill and lockring cutter (BT309, or equivalent), cut lockring by rotating drill at 

slow speed. 

CAUTION MUST BE USED WHEN DRILLING, AS TO PREVENT 

DAMAGE FROM DRILLING TOO DEEP. 

(a) Drill a little and stop, checking cutter depth; just enough to cut lockring. 

1 If unsuccessful, repeat drilling, maintaining a slow drill speed, until lockring is either 

cut through, or cut enough so that it can be collapsed. Remove lockring. 1 

~~ ~6g~ CONTACT WITH HOUSING WHEN USING REMOVAL 

(10) Using stud tool, wind out stud (SFJ101-11TA12AE0301) (DMYN0-83324-214) by rotating 

counterclockwise. Typical three places. 

(11) Thoroughly clean out tapped hole using Isopropyl Alcohol (commercial grade, or 

equivalent) and Q-tip (commercial grade, or equivalent), and shop air. 

B. Perform visual inspection of MGB housing and tapped holes as follows: 

(1) Carefully, visually inspect tapped holes for signs of damage. If any damage to threads is 

detected, stop work and contact a Sikorsky Field Service Representative, Customer 

Service Manager or Customer Service engineering at 1·800-WINGED·S or 1-203-416-4299 

for assistance. 

(2) Visually inspect housing lockring counterbore to determine suitability for installation of new 

lock ring. 

(a) Make sure new location, at 90 degrees from original position, is available for lockring 

teeth. Lockring can only be installed twice (including original installation) without 

reworking MGB housing. If rework of MGB housing is required, contact Sikorsky (see 

step above). 

(b) If lockring counterbore is acceptable for installation of new lockring, proceed to section 

C. 

C. Perform one-time installation of MGB filter bowl assembly mounting studs as follows: 

January 28/09 Page 7 63-24-02 

Revision A - March 20/09 
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No. 92-63-014A 

ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs 

3. ACCOMPLISHMENT INSTRUCTIONS (Continued) 

NOTE: Repeat this procedure to install all three studs. 

(1) Locate previous mark made on MGB housing. Teeth of new lockring (MS51990-105P) will 

be installed 90 degrees from that point. 

1 (2) Apply epoxy primer (MIL-P-85582, or MIL-P-23377, or equivalent) onto threads of new 

stud. Install stud while epoxy primer is wet. 

(3) Thread new stud (SLS11FJ101-11SN12A) (DMYN0-97393-503) into MGB housing tapped 

hole, using stud tool kit, or equivalent (listed in Tooling section of this ASB). Stud external 

spline should be .010-.020-inch below mounting surface. Refer to Figure 1. 

NOTE: Make sure new lockring teeth are located 90 degrees from previous lockring 

position. 

(4) Install lockring by placing lockring over stud and onto MGB housing lockring counterbore 

so that lockring internal spline aligns with stud external spline. Set lockring into MGB 

housing lockring counterbore using lockring drive tool (S1 01 012, M1 01D12N, or 

equivalent). 

(a) Clean and coat rock hard coating with clear epoxy (MIL-PRF-22750, or equivalent). 

(b) Apply sealing compound (AMS 3265, Type 2, or equivalent) to lockring (MS51990-

1 05P). Remove all squeeze-out in lockring counterbore using lint free cloth (CCC-C-440, 

or equivalent). 

(5) Clean any residue using Isopropyl Alcohol (commercial grade, or equivalent) and lint free 

cloth (CCC-C-440, or equivalent). 

(6) Remove masking from MGB filter bowl diameter. 

(7) Reinstall MGB oil filter assembly. 

(a) Using packing installation tool set (WE301 K, or equivalent), install packings (M83248/1-

033 and M83248/1-238) on filter bowl. 

(b) Install filter bowl onto replacement mounting studs. 

NOTE: Make sure new nuts (SS5086-04) are installed. 

(c) Install washers (MS20002-4) and replacement nuts (SS5086-04). 

January 28/09 Page 8 63-24-02 

Revision A - March 20/09 
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No. 92-63-014A 

ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs 

3. ACCOMPLISHMENT INSTRUCTIONS (Continued) 

~~ 

~ 

USE CAUTION DURING FILTER INSTALLATION TO AVOID 

DAMAGING MOUNTING STUDS. 

SEAT FILTER INTO BORE EITHER BY HAND (PREFERRED) 

OR BY GRADUAL TIGHTENING OF INSTALLATION NUTS. DO 

NOT DRAW FILTER INTO PLACE USING ONLY ONE OR TWO 

NUTS AS THIS MAY CAUSE COCKING OF THE FILTER, 

PINCHING OF THE PACKINGS, OR DAMAGE TO STUDS. 

(d) Draw filter into place by even, gradual tightening of all three nuts. Torque nuts to 100 

inch-pounds. 

(e) Mark MGB housing, TS-062-01, in area of part number and serial number identification 

with ink or impression stamp (A-A-208, or equivalent). but not to be construed as part 

of the component part number. 

(f) Service main transmission. Refer to Maintenance Manual, SA S92A-AMM-OOO, Chapter/ 

Section 63-20-00-610-001. 

(g) Examine components for security. Make sure area is clean and free of foreign objects. 

(h) Reinstall central cover, if removed. Refer to Maintenance Manual, SA S92A-AMM-OOO, 

Chapter/Section 54-40-01. 

(i) Do ground test procedures. Refer to Functional Check Flight Procedures Manual, SA 

S92A-FCP-OOO. 

(8) Return helicopter to service. 

D. Record of Compliance 

(1) Make an appropriate logbook entry to show compliance with this ASB 92-63-014A. 1 

(2) Upon compliance with this Alert Service Bulletin, complete attached ALERT SERVICE 

BULLETIN COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation. 

January 28/09 Page 9 63-24-02 

Revision A - March 20/09 
STUD 

ffi[~rnu ~~mvm;~ mrnrriTauJrn 

No. 92-63-014A 

LOCKRING INSTALLATION NOTES 

1. WITH APPLICABLE WRENCH, INSTALL STUD TO 

DEPTH SHOWN. 

NOTE: LOCATION OF FLANGE IS IMPORTANT SO THAT 

LOCKRING DRIVE TOOL WILL NOT CONTACT STUD EXTERNAL 

SPLINE. ANY IMPACT OR PRESSURE ON THIS SURFACE MAY 

REMOVAL CAUSE DAMAGE TO THREADS IN PARENT MATERIAL, 

TOOL RESULTING IN A LOOSE FIT. 

2. APPLY SEALING COMPOUND {AMS3265, TYPE 2 , OR EQUIVALENT) 

AND WITH APPLICABLE DRIVE TOOL, INSTALL LOCKRING TO 

DEPTH SHOWN. 

REMOVAL NOTES 

1. SECURE REMOVAL TOOL OR MILL IN CHUCK AND 

LOWER OVER STUD BEFORE STARTING MOTOR. 

SET SPINDLE SPEED AT 300-700 RPM. 

2. STUD: WITHOUT RAISING SPINDLE, START MOTOR. MILL 

THROUGH LOCKRING, RAISING TOOL EVERY FEW 

SECONDS TO ALLOW CHIPS TO CLEAR CUTTING TEETH. 

BEST RESULTS WILL BE OBTAINED BY NOT MILLING 

COMPLETELY THROUGH LOCKRING. 

3. STUD: APPLY REMOVAL TORQUE TO STUD. WHEN 

STUD THREAD FLANKS BEAR AGAINST LOWER 

SURFACE OF LOCKRING TO BE JACKED OUT, STUD 

REMOVAL MAY THUS BE COMPLETED. 

4. IF LOCKRING HAS BEEN MILLED COMPLETELY 

THROUGH AND DOES NOT LIFT OUT WITH STUD OR 

INSERT, PORTION REMAINING MAY BE COLLAPSED 

WITH A PUNCH AND REMOVED. 

TD1819 .. GUIDE FOR REMOVAL AND INSTALLATION OF MGB FILTER BOWL ASSEMBLY MOUNTING STUD 

AND LOCKRING 

FIGURE 1 

January 28/09 Page 10 63-24-02 

Revision A - March 20/09 
(Fold over and tape closed) 

SIKORSKY AIRCRAFT CORPORATION 

FACSIMILE NUMBER (860) 998-7565 

ATTENTION: WCS PRODUCT SAFETY MANAGER 

WORLDWIDE CUSTOMER SERVICE 

I I I I I I I I I I I I I 

IMPORTANT NOTICE 

Upon COMPLIANCE with the attached ASB, Sikorsky requests your cooperation in 

completing and returning by mail or FAX this ENTIRE PAGE. 

Please fill in the requested information at the bottom of the page, so we may maintain proper 

records documenting the configuration of your aircraft. This information is useful when 

determining configuration and effectivity of issues affecting fielded aircraft. 

This request is in keeping with our policy to assure that our customers receive the latest 

information applicable for the maintenance of your aircraft. Thank you. , 

ALERT SERVICE BULLETIN: No. 92-63-014A Compliance Record Card 

TITLE: _...JB:l.lO""-T.L.lO..uBI:l....LD.u:B::u.IVJL..E!;.JS~-...~:Mwa:11linL.l.....lloMw..oLUdJJJ! J!.s:o. e .....t.A:l..>:s,.;:,: seCOJ.mJ.IJhw.lyl'-=--....LJMt.~.~:awin.L...J...:;Gu::;e.a.Ja rwh:u.ox~(M.ILI:G~B),J-L.ll lwlb.~.s::e'-'S~yl'-'=so.~.tteaJmu.__ 

Filter Components - One-Time Replacement of Mounting Studs 

OWNEWOPERATOR:. ____________________________________ _ 

SUBMITTED BY:. ____________ DATE ______ _ 

FOLLOWING SERIAL NUMBERS ARE NOT AFFECTED BY THIS ASB 

ASB HAS BEEN COMPLIED WITH ON THE FOLLOWING SERIAL NUMBERS 

, 

I I I I I I I I ______________ (Fold Up to Arrows)i _______________ ...J 

SA 7673-2 Rev B 
O S _i_k_or_s___; ky::....___ 

A United Technologies Company 

BUSINESS REPLY MAIL 

FIRST- CLASS MAll.. PERMIT NO. 432 BRIDGEPORT CT 

POSTAGE WILL BE PAID BY ADDRESSEE 

SiKORSKY AIRCRAFT CORPORATION 

P.O. BOX 9729 

6900 MAIN STREET 

STRATFORD, CONNECTICUT 06615-9129 U.S.A. 

MAlLSTOP: KlOOA 

ATTENTION: WCS PRODUCT SAFETY MANAGER 

WORLDWIDE CUSTOMER SERVICE 

Please complete the form on the reverse side and FAX to 

FACSIMILE NUMBER (860) 998-7565 

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