Attachment 1 - Technical Order.pdf

1.13.20 ForceTec Retainers (51-03-15). ForceTec

system utilizes a rivetless nutplate retainer designed to cold work the detail hole on installation.

NOTE

• These procedures address rivet hole require-ments, new installation and removal of pre-viously installed ForceTec retainers utilizing tool set FTTS-F16483-FK-USAF. FTTS- 483FK-BHOS has been incorporated into FTTS-F16483-FK-USAF tool set. Reference Table 9-11 Miscellaneous Tools and Equip-ment (51-82-04) for complete breakdown of tool kits.

• TO 32A21-5-1, FTI Rework Procedure Tip Sheet #98617 may be referenced for additional data and aid in installation/repair process.

1.13.20.1 Cold Working Nutplate Rivet Hole. Ream and

cold work existing nut plate retainer rivet holes as follows:

WARNING

Drilling operations create chips which may cause serious eye injury. Protective equipment consisting of industrial goggles and/or eye wear is required. Failure to observe this warn-ing may result in serious injury to personnel.

CAUTION

Exercise care to prevent elongation or damage to hole when drilling or removing rivets. Fail-ure to observe this caution may result in dam-age to aircraft structure.

NOTE

To aid in starting drill process for rivets, center punching head of rivets securing nutplate to structure is recommended.

a. Using drill same size as rivet diameter, drill rivet heads to head-shank junction.

b. Remove rivet head using pin punch.

c. Place backup bar against material adjacent to formed head and drive rivets from holes using pin punch and light hammer. Catch rivets when driven through struc-ture.

d. Remove nutplate.

e. Remove any sealant remnants from structure and holes after nutplate removal.

TO 1F-16CJ-3-1

51-03-15 1-213

NOTE

For holes beyond second oversize tolerance contact F-16 Program Office Engineering for additional guidance.

f. Ream rivet holes to Nominal (Nom.) pre-cold work-ing diameter and perform tolerance verification check with the appropriate gage listed below. Holes beyond the Nom. tolerance will be reamed to the first (1st

Oversize (OS)) or second (2nd OS) oversize accord-ingly.

• Nom.: 1126-133 (Ream), 5337-007 (guide), and 2072-961 (gage).

• 1st OS: 1126-132 (Ream), 5337-010 (guide), and 5426-014 (gage).

• 2nd OS: 1155-047 (Ream), 5337-015 (guide), and 5566-076 (gage).

g. Deburr rivet holes using 1187-144 or equivalent.

h. Perform NDI surface eddy current around rivet hole locations in accordance with TO 33B-1-2. If crack indications exist re-accomplish 1.13.20.1 Step f utiliz-ing the addressed OS tooling accordingly. If cracks exist after utilizing 2nd OS tooling, contact F-16 structural design engineering for additional guidance.

If no cracks are found proceed to 1.13.20.1 Step i.

i. Select the following mandrel/gage which corresponds with hole condition created in 1.13.20.1 Step f.

• Nom.: 2025-340/2843-418

• 1st OS: 2025-370/2843-506

• 2nd OS: 2025-376/5548-081

j. Check mandrel major diameter for wear by inserting mandrel into check gage. If mandrel is excessively worn it will pass through hole in gage and should be discarded and replace with a new mandrel. Install mandrel onto puller HP-20 (2529-001) or equivalent.

k. Select the following nose cap according to application and install onto puller.

• Nom. Application: KBC-041-1A

• 1st and 2nd OS Application: KBC-042-1A

l. Selecting the following split sleeve which corre-sponds with hole condition created in 1.13.20.1 Step f, install onto mandrel.

• Nom.: 2130-080

• 1st OS: 2130-100

• 2nd OS: 2130-129

m. Insert mandrel and sleeve into starting hole. With nose cap pressed firmly against work piece, activate puller to perform cold working process, repeat step for each hole.

CAUTION

Never attempt to re-use split sleeves, discard after performing pulling process. Failure to ob-serve this cation may result in damage to air-craft.

n. Remove and discard used split sleeve.

o. Verify cold expansion of rivet holes utilizing the following gage corresponding with the sleeve used to complete 1.13.20.1 Step m. If gage fails to pass through hole, hole has not been properly cold ex-panded. Reaccomplish 1.13.20.1 Step k through

1.13.20.1 Step n.

• Nom.: 2072-962

• 1st OS: 5426-015

• 2nd OS: 5566-077

p. Countersink holes to accommodate (MS20426AD4) countersink type rivet.

q. Apply AMS-C-27725 corrosion-preventative coating to countersink area of hole.

r. Install rivets wet with corrosion-preventative coating.

Ensure rivet shop heads meet limitations illustrated in Figure 1-96 to avoid contact with retainer.

CO-STPM-3-1-1004X99

0.032 IN MIN 0.250 IN

0.200 IN

Figure 1-96. Rivet Installation Limits / Retainer In-stalled.

s. Micro-shave rivets as required.

1.13.20.2 Installation of Retainer. Install nominal or

oversize retainer as follows:

TO 1F-16CJ-3-1

51-03-15 1-214

WARNING

Drilling, reaming, and spot facing operations create chips which may cause serious eye in-jury. Protective equipment consisting of in-dustrial goggles is required. Failure to observe this warning may result in serious injury to personnel.

a. Using the following core bit/guide combination, en-large fastener hole.

• FTCD-483-A-0 (Bit)

• 5337-013 (Guide)

NOTE

For fastener holes beyond 1st OS tolerance, an F-16 structural engineer must be contacted for 2nd OS authorization and/or additional gui-dance.

b. Ream fastener holes to Nominal (Nom.) pre-cold working diameter and perform tolerance verification check with the appropriate gage listed below. Holes beyond the Nom. tolerance will be reamed to the first (1st OS).

• Nom: FTSR-483-A-0 (Ream), 5337-014 (guide), and FTG-483-A-0-1 (gage).

• 1st OS: FTSR-483-A-1 (Ream), 5337-004 (guide), and FTG-483-A-1-1 (gage).

• 2nd OS: FTSR-483-A-2 (Ream), 5337-017 (guide), and FTG-483-A-2-1 (gage).

c. Deburr fastener holes using the following tools cor-responding with ream used to complete 1.13.20.2 Step b.

• Nom: 1187-143 (Deburr), and 5337-022 (guide).

• 1st and 2nd OS: 1187-142 (Deburr), and 5337- 023 (guide).

d. Perform NDI bolt hole inspection at fastener loca-tions. Reference TO 33B-1-2 for inspection process.

If cracks exist at fastener hole locations, re-accomplish 1.13.20.2 Step b through 1.13.20.2 Step d utilizing 1st OS tooling. If cracks exist after 1st OS, F- 16 structural engineer must be contacted for 2nd OS authorization or additional guidance. If no cracks are found proceed with next step

e. Chamfer the edge of holes on the retainer side to accommodate the retainer head filet radius (0.015 ±0.005 typical).

NOTE

Mandrel (FTM-483-A-0-8), Nosecap (FTN- 483-A-0) and Split Sleeve (FTS-483-A-0-8) will be used for Nom., 1st and 2nd OS retainer installation.

f. Check mandrel (FTM-483-A-0-8) major diameter for wear by inserting mandrel into check gage (FTMG- 483-A-0). If mandrel is excessively worn it will pass through hole in gage and should be discarded and replaced with a new mandrel.

g. Install mandrel and nosecap (FTN-483-A-0) onto puller HP-20 (2529-001) or equivalent.

NOTE

Sleeves are pre-lubricated from the manufac-ture. Do not attempt to remove manufacturer applied lubricant or add additional lubricant of any kind.

h. Slide sleeve (flare facing nose cap) onto the mandrel.

NOTE

It is recommended that retainers be visually inspected for flushness prior to installation.

Retainers should not be more than 0.010 inch below flush or more than 0.050 above flush before cold working. Retainers having a grip length greater than the depth of the hole shall be shaved/trimmed to meet flushness require-ments before cold expansion. Remove any knife edge created during shave/trimming pro-cess.

i. Select the following retainer which meets hole con-dition created in 1.13.20.2 Step b. (-XXX) denotes grip length, reference Table 9-1 Special Fasteners and Sealing Devices (51-81-01) for various retainer part numbers.

• Nom: FTSRC-483-A-0-XXX-S

• 1st OS: FTSRC-483-A-1-XXX-S

• 2nd OS: FTSRC-483-A-2-XXX-S

NOTE

Ensure flat portion of the retainer head is par-allel to access opening or structural edge.

TO 1F-16CJ-3-1

51-03-15 1-215

j. Install retainer wet by applying AMS-C-27725 cor-rosion-preventative coating to fastener hole.

k. Insert assembled pulling unit with sleeve through part into retainer from side opposite the retainer head.

With nose cap placed firmly against the part, sleeve shall protrude past retainer head 0.125 inch minimum.

l. Activate puller to perform cold working process.

CAUTION

Used sleeves shall never be reused, discard after performing pulling process. Failure to ob-serve this caution may result in damage to the aircraft.

m. Remove and discard used sleeve.

NOTE

An axial ridge mark is typically left by the split sleeve during cold expansion. This is not considered reason for replacement of retainer.

n. Using the following gages which correspond with retainer installed in 1.13.20.2 Step i, inspect retainer diameter to ensure cold working process was ac-complished correctly. For Nom. retainers which fail inspection, proceed with 1st OS installation, for all other failures contact F-16 structural engineer for ad-ditional guidance.

• Nom: FTG-483-A-0-1

• 1st OS: FTG-483-A-1-1

• 2nd OS: FTG-483-A-2-1

o. Spot face retainer if required to ensure flushness.

Retainer shall be flush to 0.010 below flush. The operation shall not damage detail/part surface or re-duce its thickness beyond the original tolerances.

p. Install new dome nut as follows:

(1) Using nut installation wrench (1187-003 or 19/32 equivalent), engage one ear of dome nut to re-tainer.

(2) Press dome nut into retainer so the remaining ear snaps in place.

q. Treat exposed surfaces in accordance with TO 1F-16( )-23.

1.13.20.3 Retainer Removal. Remove retainer as follows:

a. Remove dome nut from retainer as follows:

CAUTION

Care should be taken not to damage retainer during dome nut removal. Failure to observe this caution may result in damage to the air-craft.

(1) Insert nut removal tool (1045-467) or equivalent between dome nut ear and retainer.

(2) Pry ear away from retainer until ear clears the underside of the retainer.

(3) Tip dome nut away from bent ear. Remove and discard dome nut.

WARNING

Drilling operations create chips which may cause serious eye injury. Protective equipment consisting of industrial goggles is required.

Failure to observe this warning may result in serious injury to personnel.

TO 1F-16CJ-3-1

51-03-15 1-216

CAUTION

Exercise care to prevent elongating holes. Fail-ure to observe this caution may result in dam-age to the aircraft.

b. Using core drill (1171-009), and drill block (5337- 016), drill out inner diameter of retainer to be re-moved.

c. Using step removal tool (FTRP-483-A-0), push out retainer.

d. Due to enlarged hole after retainer removal, ream fastener hole utilizing an enlarged pilot ream and verify diameter tolerance using the following tools:

• 1st OS: FTSR-483-A-1-P 0.3370 (Pilot Ream), and FTG-483-A-1-1 (gage).

• 2nd OS: FTSR-483-A-2-P 0.3490 (Pilot Ream), and FTG-483-A-2-1 (gage).

e. Install oversize retainer in accordance with 1.13.20.2 Step c through 1.13.20.2 Step q.

Ream, 2nd OS Rivet Hole

Ream, 1st OS Rivet Hole

Ream, Nom. Rivet Hole

Nut Installation Wrench

Nut Removal Tool

Hand Puller/Wrench

Tooling Set, ForceTec, Con-sisting of the following:

Tooling Set, ForceTec First Oversize

Tool Kit, Pylon Attach In-sert Removal

Tool Kit, Landing Gear Tension Strut Mount Bush-ing Removal/Installation

Tool, Swage

Tool, Installation, Lockring

Tank, Nitrogen

Sling Assembly, Vertical Fin

Sleeve, Straight, Coldwork-ing

Sleeve, Flared, Coldworking

Rocker Assembly, Counter-sink Stop

Rocker Assembly, Counter-sink Stop

Repair Kit, Panel Fastener

Repair Kit, Enhanced Stop- Drill

NOMENCLATURE

Table 9-11. Miscellaneous Tools and Equipment - Continued.

TO 1F-16CJ-3-1

51-82-04 9-53

1155-047

1126-132

1126-133

*1187-003

*1045-467

*HP-20 (2529–001)

FTTS-F16483-FK-USAF

FTTS-483FK-BHOS

16A11696-1

16A13218L1-1

SR37S-A

SR31S-A

SR25S-A

SR19S-A

SR11S-A

R3606D

Dura Cyl III

16A11012-1

2130-129

2130-100

2130-080

FTS-4-0-2-8

FTS-483-A-0-8

70991-7

70991-3

CA21038K-100

FTI-SCK-A1

GOVT SPEC NO.

OR

MFR’S PART NO

51439

81755

Local Manufacture

83324

83324

6K193

81755

51439

56878

29372

51439

MANUFACTUR-

ER

F16483-FK-USAF set.

incorporated into FTTS-

FTTS-483FK-BHOS

*Following tools from

Used to coldwork rivet holes and install/remove ForceTec retainers

Used to install first oversize ForceTec retainer

Used to remove 16W190 pylon attach inserts

Used to remove and install main land-ing gear strut mount bushings

NSN 5120-00-176-8639

NSN 5120-00-953-2196

NSN 5120-00-864-4954

NSN 5120-00-864-4953

NSN 5120-00-062-8342

Used to install lockring on ventral fin insert

Used in removal of parts bonded with FMS-3014 nitrile-phenolic adhesive

Used in conjunction with lifting crane for removal and installation of ver-tical stabilizer

Sleeve to support rivet hole coldwork-ing.

5365-01-498-6521

5365-01-511-1979

Used to hold and position elliptical countersink cutters for NAS1734 and NAS1735 nuts

Used to remove and replace damaged internal hex wrenching retained bolts

Used to stop-drill cracks and cold work stop-drill holes

GENERAL REMARKS