FlyingMonkey Posted February 23, 2021 Report Share Posted February 23, 2021 I'm about 150 hours out from my 1000hr Rotax gearbox overhaul. I'll probably do it next February during my annual, and I will likely replace my prop at the same time, with either a Sensenich or an E-Props Durendal. I think the gearbox removal requires a special puller tool you can rent from Lockwood. Does anybody that has done this have any recommendations or cautions on this? I'm just curious what to expect. I assume an oil purge is required afterwards since you are opening the engine up to air. Thanks! Quote Link to comment Share on other sites More sharing options...
BravoFoxtrot Posted February 23, 2021 Report Share Posted February 23, 2021 Here is a nice writeup on the procedure: ROTAX 912ULS Removal of Propeller Reduction Gearbox (aerofixaviation.co.uk) Are you going to have Lockwood do the overhaul? I know Roger also does these. Perhaps he has a puller you could use? Quote Link to comment Share on other sites More sharing options...
Tom Baker Posted February 23, 2021 Report Share Posted February 23, 2021 I made my puller. Quote Link to comment Share on other sites More sharing options...
BravoFoxtrot Posted February 23, 2021 Report Share Posted February 23, 2021 Does your puller look like the Rotax one? Did you just use a slide hammer and make the adapter for the gearbox? Any photos or patterns available? Quote Link to comment Share on other sites More sharing options...
Roger Lee Posted February 23, 2021 Report Share Posted February 23, 2021 The one from CPS is $90 and you may only use it once ever unless you do it for a living. I'll take a picture tomorrow when I go to the field of my homemade one. It cost around $30 for everything and was easy to do. Just a bolt together setup with some 1" angle iron and a slide hammer from Harbor Freight. Quote Link to comment Share on other sites More sharing options...
BravoFoxtrot Posted February 23, 2021 Report Share Posted February 23, 2021 Great! Thanks. Quote Link to comment Share on other sites More sharing options...
Tom Baker Posted February 23, 2021 Report Share Posted February 23, 2021 1 hour ago, Roger Lee said: The one from CPS is $90 and you may only use it once ever unless you do it for a living. I'll take a picture tomorrow when I go to the field of my homemade one. It cost around $30 for everything and was easy to do. Just a bolt together setup with some 1" angle iron and a slide hammer from Harbor Freight. My homemade one is the same as Roger's. I used what I had on hand. Quote Link to comment Share on other sites More sharing options...
Jacques Posted February 23, 2021 Report Share Posted February 23, 2021 like this ........I think this one is Roger's Quote Link to comment Share on other sites More sharing options...
FlyingMonkey Posted February 23, 2021 Author Report Share Posted February 23, 2021 6 hours ago, BravoFoxtrot said: Here is a nice writeup on the procedure: ROTAX 912ULS Removal of Propeller Reduction Gearbox (aerofixaviation.co.uk) Are you going to have Lockwood do the overhaul? I know Roger also does these. Perhaps he has a puller you could use? I think you have to send the gearbox to Lockwood. If Roger does them I'd certainly prefer to use him. Quote Link to comment Share on other sites More sharing options...
Roger Lee Posted February 24, 2021 Report Share Posted February 24, 2021 My gearbox puller looks very close to Jacques. My only difference is my slide hammer part. Mine is a slide hammer I got from Harbor Freight. Quote Link to comment Share on other sites More sharing options...
FlyingMonkey Posted February 24, 2021 Author Report Share Posted February 24, 2021 Roger, do you do gearbox overhauls? Quote Link to comment Share on other sites More sharing options...
Jacques Posted February 24, 2021 Report Share Posted February 24, 2021 12 hours ago, Roger Lee said: My gearbox puller looks very close to Jacques. actually, Roger, the picture come from you.... in that 2013 post but, I don't see it anymore Quote Link to comment Share on other sites More sharing options...
Roger Lee Posted February 25, 2021 Report Share Posted February 25, 2021 Homemade gearbox puller. Then you can use either an all thread 18" bolt with a 5 lb weight or just go to harbor Freight and buy a cheap slide hammer. Homemade Gearbox puller1.pdf Quote Link to comment Share on other sites More sharing options...
FlyingMonkey Posted February 25, 2021 Author Report Share Posted February 25, 2021 12 hours ago, Roger Lee said: Homemade gearbox puller. Then you can use either an all thread 18" bolt with a 5 lb weight or just go to harbor Freight and buy a cheap slide hammer. Homemade Gearbox puller1.pdf 147.91 kB · 4 downloads Thanks Roger. Is 1/8" thick aluminum angle strong enough, or does it need to be steel? Aluminum is much easier to cut and drill! Quote Link to comment Share on other sites More sharing options...
Roger Lee Posted February 25, 2021 Report Share Posted February 25, 2021 1/8" aluminum will bend. It takes a pretty good pounding to pop the gearbox off. p.s. Don't tighten down the bolts that join the tree pieces together. They need to be able to move so you can line up the screw holes on the puller and gearbox. Quote Link to comment Share on other sites More sharing options...
FlyingMonkey Posted February 26, 2021 Author Report Share Posted February 26, 2021 15 hours ago, Roger Lee said: 1/8" aluminum will bend. It takes a pretty good pounding to pop the gearbox off. p.s. Don't tighten down the bolts that join the tree pieces together. They need to be able to move so you can line up the screw holes on the puller and gearbox. Got it, thanks! Quote Link to comment Share on other sites More sharing options...
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