ENGINEERING INSTRUCTION Nº 2016-78-062

DATE: MAY-08-2016
Engineering Management REV: 0
Pudahuel, Santiago, Chile
PAGE: 1 OF 6

1) SUBJECT:
HINGE BUSHING REPLACEMENT

2) REASON:
Hinge Bushing Migration

3) REFERENCE: 4) DAMAGE CLASIFICATION:

CMM 78-3-00 check 035 In evaluation

5) INSTRUCTIONS:
6)
I. Preparation Zone.

a. Verify extent of damage, perform FPI inspection of the lug per IAE V2500 SPPM TASK 70-23-
02-230-501 “Medium Sensitivity Water Washable Fluorescent Penetrant Crack Inspection”. No
cracks allowed.

7) b. Ream the hole on the lug as follows:

8)
Notes:
 If the hole diameter size is out of round by more than 0.001 in. Total Indicator Reading (TIR) or
larger, resubmit results to Engineering department for review.
 Make sure the bushing wall stays within the specified thickness. See Figure 2.
 If damage couldn’t be removed with the indicated rework dimensions, contact Engineering
Department for further disposition.

i. Inline to a maximum diameter of DLH=1.0700”. The surface finish of the hole must be 63
RMS or better. Break the sharp edges of the hole to 0.015” maximum. See below Figure 2.

ii. Perform FPI inspection per step a. after reaming the lug. No cracks are allowed.

c. Alodine and Prime the bare surfaces of the lugs per IAE V2500 SRM chapter 54-02-00, Group 1
Protective Treatment of Metals.

d. Fabricate flanged bushing in accordance with the following instructions and Figure 2.

i. Bushing material: See Table 1.

ii. Maintain surface finish of 32RMS max on bushing bore and 63 RMS on all surfaces

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 ENGINEERING INSTRUCTION Nº 2016-78-062
DATE: MAY-08-2016
Engineering Management REV: 0
Pudahuel, Santiago, Chile
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e. Inspect manufactured bushing visually and also magnetically. Do the magnetic particle inspection
per SPPM 70-24-01-240-501 and ensure the bushings have no defects.

f. Passivate bushing per AMS-QQ-P-35.

g. Install the new bushing in accordance with bushing installation instructions of this document Step
II.

h. Final Ream new bushing to a final hole of 0.8750” (0.000 to +0.0015”) in. diameter.

i. Locally identify repair with repair document number using a non-corrosive permanent ink stamp or
marker.

II. Bushing Installation and Refinish the Reworked Area

1. Bushing Installation.

A. General installation requirements.

NOTE: Unless specified differently in applicable repair, all bushing must be wet installed
with CoMat 08-141, P/S 870 sealant or equivalent.

a. Wet the internal diameter of the hole where the bushing will be installed with CoMat 08-
141, P/S 870 sealant or equivalent. Bushing must be installed during pot life of the
sealant.

B. Freeze bushings. Method 1.

a. Use a clean one-half pint container with a shop cloth around it. Fill the can halfway with
crushed dry ice.

b. Slowly pour Methylene Chloride (ASTM D 4701) over the dry ice until the can is about
2/3 full.

WARNING: DO NOT TOUCH A FROZEN BUSHING WITH YOUR BARE HANDS. IF IT

IS NECESSARY TO TOUCH A FROZEN BUSHING, USE METAL
TONGS. THIS WILL HELP PREVENT INJURY TO PERSONS.

c. After the bubbling of the solution has stopped, place the bushing into the solution.

NOTE: Do not remove the bushing until the bubbling has stopped.

d. Insert the tip of the metal tongs into the solution and remove the bushing after the
bubbling has stopped.

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 ENGINEERING INSTRUCTION Nº 2016-78-062
DATE: MAY-08-2016
Engineering Management REV: 0
Pudahuel, Santiago, Chile
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C. Freeze bushings. Method 2.

WARNING: LIQUID NITROGEN IS APPROXIMATELY MINUS 320°F (MINUS 196°C).

WEAR PROTECTIVE CLOTHING, AND USE IN A WELLVENTILATED
AREA TO PREVENT INJURY.

a. Put the bushing in liquid nitrogen for a minimum of 10 minutes immediately before
installation.

b. Insert the tip of the metal tongs into the solution, and remove the bushing after the
required 10 minutes.

NOTE: Bushings must be installed within 30 seconds after removal from the solution.

c. Push the bushing into place while the sealant is wet. Apply force to the
circumference of the bushing. If necessary, use a flush set and rivet gun, an
arbor press or pull in with a bolt and nut.

NOTE: Make sure the bushing is perpendicular to the hole when you start to push the
bushing.

d. Make sure the bushing is flush (0.000 in. to -0.007 in (0.000 mm to -0.178 mm))
with the mold line surface (this does not apply to the flange bushing). If
necessary, shave bushing using best shop practice.

2. Refinish Reworked Area.

A. After bushings have been installed and accepted by inspection, both ends of bushings
plus 1/8 to 1/4 inch of the surrounding housing surface must be over coated with
CoMat 08-141, P/S 870 sealant. If flanges are present, a fillet of sealant must be
applied around the edges of the flange.

B. Apply Primer as necessary in accordance with SRM 54-02-00 group 3.

Form D145-46
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 ENGINEERING INSTRUCTION Nº 2016-78-062
DATE: MAY-08-2016
Engineering Management REV: 0
Pudahuel, Santiago, Chile
PAGE: 4 OF 6

Form D145-46
Rev 0
 ENGINEERING INSTRUCTION Nº 2016-78-062
DATE: MAY-08-2016
Engineering Management REV: 0
Pudahuel, Santiago, Chile
PAGE: 5 OF 6

Form D145-46
Rev 0
 ENGINEERING INSTRUCTION Nº 2016-78-062
DATE: MAY-08-2016
Engineering Management REV: 0
Pudahuel, Santiago, Chile
PAGE: 6 OF 6

_________________ ____________________
MECHANIC INSPECTOR

_____________________________
PREPARED BY:
JUAN FARIAS ROMERO
MAINTENANCE ENGINEER

Form D145-46
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