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Roger Lee
Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.
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 Posted: Thu Aug 12, 2010 8:30 pm Post subject: Rotax 912ULS gearbox tear down |
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Hi All,
Here are some pictures from a Rotax 912 gearbox. This is being torn down and examined from a prop strike.
You will see a gearbox clutch in one of the pictures and they are installed in the 912ULS 100 hp, but not the 912UL 80 hp. Everything has to come out including the oil seal and bearing. A dye penetrant test now needs to be done down by the bearing opening. The shaft was checked for run out tolerances on the flange and crankcase shaft. These happen to be okay on this plane, this time. that isn't always the case. If you are going to have a prop strike do it at idle or engine off. High speed strikes don't do the prop shaft any favors.
I thought some of you may enjoy looking at the inside of a gearbox.
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_________________
Roger Lee
Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
Cell 520-349-7056 |
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Thom Riddle
Joined: 10 Jan 2006
Posts: 1597
Location: Buffalo, NY, USA (9G0)
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| Posted: Fri Aug 13, 2010 2:33 am Post subject: Re: Rotax 912ULS gearbox tear down |
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Roger,
Where did all that rust come from? I don't live in a desert like you do. We have real humidity in this part of the world but never seen any rust in any of the 912 gearboxes I've inspected.
My guess is that engine is a fairly old one that was sitting unused for quite a long time before it was installed in the RV-12. Use 'em or lose 'em. Do you know the history of that engine?
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Thom Riddle
Buffalo, NY (9G0)
Don't worry about old age... it doesn't last very long.
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Roger Lee
Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.
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| Posted: Fri Aug 13, 2010 4:41 am Post subject: Re: Rotax 912ULS gearbox tear down |
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Hi Thom,
There is no rust here. It is factory applied anti-seize. It is on every new gearbox from the factory and I will use it to put it back together. It's not on every part, but enough for you to see. Over time it goes away.
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Roger Lee
Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
Cell 520-349-7056 |
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Thom Riddle
Joined: 10 Jan 2006
Posts: 1597
Location: Buffalo, NY, USA (9G0)
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| Posted: Fri Aug 13, 2010 4:59 am Post subject: Re: Rotax 912ULS gearbox tear down |
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Aha! That explains why I've never seen it before. I've never inspected a new gearbox, only ones that have reached the specified time in service. Sure looks like rust in the photos, glad its not.
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Thom Riddle
Buffalo, NY (9G0)
Don't worry about old age... it doesn't last very long.
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docyukon(at)ptcnet.net
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| Posted: Fri Aug 13, 2010 7:06 am Post subject: Rotax 912ULS gearbox tear down |
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Re: Fig #9 (Large retaining collar) Is thair a proper tool for the
removal of this collar? Doc
---
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Thom Riddle
Joined: 10 Jan 2006
Posts: 1597
Location: Buffalo, NY, USA (9G0)
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| Posted: Fri Aug 13, 2010 7:14 am Post subject: Re: Rotax 912ULS gearbox tear down |
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Doc,
There may be a special tool but I insert a large common (flat blade) screwdriver in the gap and twist so that it comes apart enough to slide over the parts above it.
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Thom Riddle
Buffalo, NY (9G0)
Don't worry about old age... it doesn't last very long.
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Roger Lee
Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.
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| Posted: Fri Aug 13, 2010 10:51 am Post subject: Re: Rotax 912ULS gearbox tear down |
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Hi Doc,
Thom's right, just a really wide tip flat head screwdriver. It's still a PITA to take off. Keep your hand and fingers from behind the screwdriver tip. It will slip and it will jab you in the hand enough to make you use some new words. 
Been there.
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_________________
Roger Lee
Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
Cell 520-349-7056 |
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Thom Riddle
Joined: 10 Jan 2006
Posts: 1597
Location: Buffalo, NY, USA (9G0)
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| Posted: Fri Aug 13, 2010 11:14 am Post subject: Re: Rotax 912ULS gearbox tear down |
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Roger,
I have already forgotten the blood blister I acquired from the first time I did that. Glad you brought up that caution.
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Thom Riddle
Buffalo, NY (9G0)
Don't worry about old age... it doesn't last very long.
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