Detailed Inspection of the Flap Carriage Rollers for In-Service Wear

TASK 27-54-46-200-002-A
Detailed Inspection of the Flap Carriage Rollers for In-Service Wear

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

WARNING: MAKE SURE THAT THE GROUND SAFETY-LOCKS ARE IN POSITION ON THE LANDING GEAR. THIS WILL PREVENT UNWANTED MOVEMENT OF THE LANDING GEAR, AND THUS POSSIBLE INJURY TO PERSONS AND DAMAGE TO THE AIRCRAFT AND/OR EQUIPMENT.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

CAUTION: BE CAREFUL WHEN YOU DO MAINTENANCE TASKS ON THE WING TRAILING EDGE:

DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE RACEWAYS.
DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE INSTALLATIONS.
MAKE SURE THAT THE ELECTRICAL CABLES ARE INSTALLED CORRECTLY. INCORRECT INSTALLATION CAN CAUSE DAMAGE.

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 4M (13 FT)
No specific	AR	SAFETY BARRIER(S)
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 48 and 35 m.N (35.40 and 25.81 lbf.ft )
No specific	Torque wrench: range to between 57 and 55 m.N (42.04 and 40.56 lbf.ft )
No specific	Torque wrench: range to between 101 and 93 m.N (74.48 and 68.58 lbf.ft )
No specific	Torque wrench: range to between 4.8 and 3.5 m.daN (35.40 and 25.81 lbf.ft )
No specific	Torque wrench: range to between 4.6 and 4.0 m.daN (33.92 and 29.50 lbf.ft )
No specific	Torque wrench: range to between 5.7 and 5.5 m.daN (42.04 and 40.56 lbf.ft )
No specific	Torque wrench: range to between 10.1 and 9.3 m.daN (74.48 and 68.58 lbf.ft )
No specific	Torque wrench: range to between 15.0 and 13.0 m.daN (110.62 and 95.87 lbf.ft )
No specific	Torque wrench: range to between 15.7 and 14.4 m.daN (115.78 and 106.19 lbf.ft )
98D27803500001	1	LOCKING TOOL ZERO POS
98D27803500002	1	LOCKING TOOL ZERO POS

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03GBD1)	Synthetic Oil base Grease-General Purpose Lithium Thickened -
(Material No.03HBD9)	Synthetic Ester base Grease-General Purpose Low Temp -
(Material No.03QBA1)	Dry lubricant-General Assembly - -
(Material No.06AAA1)	Polysulfide Sealant_General Purpose Brushable -
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
8	LOCKPLATE	AIPC 27-54-46-01-030
9	LOCK PLATES	AIPC 27-54-46-01-030
3	LOCK PLATES	AIPC 27-54-46-01-110
19	COTTER PINS	AIPC 27-54-46-04-110
20	COTTER PINS	AIPC 27-54-46-04-110
22	COTTER PINS	AIPC 27-54-46-04-110
18	COTTER PINS	AIPC 27-54-46-04-160
20	COTTER PINS	AIPC 27-54-46-04-160
9	COTTER PINS	AIPC 27-54-46-20-070
20	COTTER PINS	AIPC 27-54-46-22-180
22	COTTER PINS	AIPC 27-54-46-22-220
8	LOCKPLATE	AIPC 27-54-85-40-030
9	LOCK PLATES	AIPC 27-54-85-40-030
3	LOCK PLATES	AIPC 27-54-85-40-110
9	COTTER PINS	AIPC 27-54-85-40-117

D. Referenced Information

REFERENCE	DESIGNATION
TASK 12-22-27-640-004-A	Lubricate all Carriage Rollers on all Flap Tracks
TASK 20-11-11-911-001-A	Safetying with Lockwire
TASK 27-54-46-000-001-A	Removal of the Nos 2, 3 and 4 Flap Carriages
TASK 27-54-46-000-002-A	Removal of Flap Carriage 1
TASK 27-54-46-400-001-A	Installation of the Nos 2, 3 and 4 Flap Carriages
TASK 27-54-46-400-002-A	Installation of Flap Carriage 1
TASK 27-54-61-000-001-A	Removal of the Inboard Flap
TASK 27-54-61-000-003-A	Removal of the Inboard Double-Slotted Flap
TASK 27-54-61-400-001-A	Installation of the Inboard Flap
TASK 27-54-61-400-003-A	Installation of the Inboard Double-Slotted Flap
TASK 27-54-62-000-001-A	Removal of the Outboard Flap
TASK 27-54-62-000-002-A	Removal of the Outboard Double-Slotted Flap
TASK 27-54-62-400-001-A	Installation of the Outboard Flap
TASK 27-54-62-400-002-A	Installation of the Outboard Double-Slotted Flap
TASK 27-60-00-866-002-A	Extension-Retraction of the Spoilers for Maintenance
TASK 32-00-00-481-002-A	Installation of the Safety Devices on the Landing Gear Doors
TASK 32-12-00-010-001-A	Open the Main Gear Doors for Access
TASK 32-12-00-410-001-A	Close the Main Gear Doors after Access
Nos 1, 2, 3 and 4 Flap Carriages ** ON A/C NOT FOR ALL
Nos 1, 2, 3 and 4 Flap Carriages ** ON A/C NOT FOR ALL
Nos 1, 2, 3 and 4 Flap Carriages ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 27-54-46-941-065-A

A. Safety Precautions
(1) As necessary, use the applicable SAFETY BARRIERS, specified by the operator's instructions and your local regulations.
(2) Put a WARNING NOTICE(S) in position to tell persons not to operate the flap controls.
(3) Put a WARNING NOTICE(S) in position to tell persons not to operate the landing gear doors.

Subtask 27-54-46-860-059-A ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration

WARNING: MAKE SURE THAT THE TRAVEL RANGES OF THE FLIGHT CONTROLS SURFACES ARE CLEAR. MOVEMENT OF FLIGHT CONTROLS CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT.

(1) Put the Nos 1, 2, 3, 4 and 5 spoilers to the maintenance position (Ref. AMM TASK 27-60-00-866-002).
(2) Remove the flaps (Ref. AMM TASK 27-54-61-000-001), (Ref. AMM TASK 27-54-62-000-001).
(3) Put the 98D27803500001 LOCKING TOOL ZERO POS or 98D27803500002 LOCKING TOOL ZERO POS on the flap/slat control lever in the cockpit.
(4) Remove the safety collar from the circuit breakers 10CV and 12CV.

Subtask 27-54-46-860-059-B ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration

WARNING: MAKE SURE THAT THE TRAVEL RANGES OF THE FLIGHT CONTROLS SURFACES ARE CLEAR. MOVEMENT OF FLIGHT CONTROLS CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT.

(1) Put the Nos. 1, 2, 3, 4 and 5 spoilers to the maintenance position (Ref. AMM TASK 27-60-00-866-002).
(2) Remove the flaps (Ref. AMM TASK 27-54-61-000-003) (Ref. AMM TASK 27-54-62-000-002).
(3) Put the 98D27803500001 LOCKING TOOL ZERO POS or 98D27803500002 LOCKING TOOL ZERO POS on the flap/slat control lever in the cockpit.
(4) Remove the safety collar from the circuit breakers 10CV and 12CV.

Subtask 27-54-46-865-061-A

C. Open, safety and tag this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B07
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
** ON A/C ALL
121VU	FLIGHT CONTROLS/WTB/FLP/SYS2	12CV	P20
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21
122VU	FLIGHT CONTROLS/WTB/FLP/SYS1	10CV	S07

Subtask 27-54-46-010-059-A

D. Get Access
(1) Open the applicable MLG doors (Ref. AMM TASK 32-12-00-010-001).
(2) Make sure that the 460005835 SLEEVE - GROUND LOCK is on the applicable MLG door actuator (Ref. AMM TASK 32-00-00-481-002).
(3) Put the NOs. 1, 2, 3, 4 and 5 spoilers to the maintenance position (Ref. AMM TASK 27-60-00-866-002).
(4) Make sure that the 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER is installed on the piston rod of each servo-control.
(5) Put the ACCESS PLATFORM 4M (13 FT) below the flap tracks 1, 2, 3 and 4.
(6) Remove the applicable flap carriage:

for the NO.1 flap carriage (Ref. AMM TASK 27-54-46-000-002)
for the NOs. 2, 3 and 4 flap carriages (Ref. AMM TASK 27-54-46-000-001).

4. Procedure

CAUTION: BE CAREFUL WHEN YOU DO MAINTENANCE TASKS ON THE WING TRAILING EDGE:

DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE RACEWAYS.
DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE INSTALLATIONS.
MAKE SURE THAT THE ELECTRICAL CABLES ARE INSTALLED CORRECTLY. INCORRECT INSTALLATION CAN CAUSE DAMAGE.

Subtask 27-54-46-020-054-B ** ON A/C NOT FOR ALL

A. Removal of the Components for Inspection
(1) For the No. 1 flap carriage center rollers:
(a) Remove the nuts (4), the washers (5) the bolt assemblies (8), the rollers (7) and the spacers (6).
(2) For the No. 1 flap carriage side rollers:
(a) Remove the cotter pins (9) from the nuts (10). Discard the cotter pins (9).
(b) Remove the nuts (10), the washers (11), the bolts (2) and the rollers (1).
(3) For the Nos. 2 and 3 flap carriage aft top rollers:
(a) Remove the nut (16), the washer (15), the hinge pin (34) and the roller block assembly (13).
(b) Remove the pivot pin (12) and the roller (14) from the roller block assembly (13).
(4) For the No. 4 flap carriage aft top rollers:
(a) Remove the nut (39), the washer (38), the hinge pin (40) and the roller block assembly (35).
(b) Remove the sleeve (37) from the flap carriage (33).
(c) Remove the pivot pin (36), the bush (42) and the roller (41) from the roller block (35).
(5) For the Nos. 2, 3 and 4 flap carriage forward top rollers:
(a) Remove the cotter pin (32) from the nut (31). Discard the cotter pin (32).
(b) Remove the nut (31), the washer (30), the hinge pin (25) and the roller block assembly (29).
(c) Remove the pivot pin (27) and the roller (28) from the roller block assembly (29).
(6) For the Nos. 2, 3 and 4 flap carriage side rollers:
(a) Remove the cotter pins (20) from the nuts (19). Discard the cotter pins (20).
(b) Remove the nuts (19), the bolt assemblies (17) and the rollers (18).
(7) For the Nos. 2, 3 and 4 flap carriage bottom rollers:
(a) Remove the cotter pins (22) from the nuts (21). Discard the cotter pins (22).
(b) Remove the nuts (21), the washers (23), the bolts (26) and the rollers (24).

Subtask 27-54-46-110-054-B ** ON A/C NOT FOR ALL

B. Preparation for Inspection
(1) Clean the parts:
(a) Use a Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) to clean:

the No. 1 flap carriage rollers (1) and (7)
the Nos. 2 and 3 flap carriage rollers (14), (18), (24) and (28)
the No. 4 flap carriage rollers (41), (18), (24) and (28).

Subtask 27-54-46-220-050-B ** ON A/C NOT FOR ALL

C. Detailed Inspection of the Flap Carriage Rollers
(1) Do an inspection of these items for corrosion, damage and the correct condition:

the No. 1 flap carriage rollers (1) and (7)
the Nos. 2 and 3 flap carriage rollers (14), (18), (24) and (28)
the No. 4 flap carriage rollers (41), (18), (24) and (28).

(2) Do an inspection of the flap carriage rollers (1), (7), (14), (18), (24), (28) and (41) for in-service wear:
(a) Inspect the outer diameter (OD) of the roller outer case (43) for wear marks. You must replace the applicable roller(s) if the Dim 'Y' is more than 0.1 mm (0.0039 in.).
(b) Hold the roller outer case (43) and move the inner case (44) from left to right. Measure the total lateral play (Dim 'X'). You must replace the applicable roller(s) if the total lateral play Dim 'X' is more than 0.13 mm (0.0051 in.).
(c) Measure the OD of the roller(s) (Dim 'Z'). You must replace the applicable roller(s) if the Dim 'Z' is less than the applicable dimension shown in Table 1.

TRACK No.	MINIMUM BEARING OD (DIM 'Z')
TRACK 1
SIDE ROLLER (1) CENTER ROLLER (7)	57.065 mm (2.247 in.) 57.065 mm (2.247 in.)
TRACK 2
TOP ROLLER (14),(28) SIDE ROLLER (18) BOTTOM ROLLER (24)	38.070 mm (1.499 in.) 38.070 mm (1.499 in.) 63.186 mm (2.488 in.)
TRACK 3
TOP ROLLER (14),(28) SIDE ROLLER (18) BOTTOM ROLLER (24)	38.070 mm (1.499 in.) 38.070 mm (1.499 in.) 63.186 mm (2.487 in.)
TRACK 4
TOP ROLLER (41),(28) SIDE ROLLER (18) BOTTOM ROLLER (24)	33.312 mm (1.312 in.) 33.312 mm (1.312 in.) 44.412 mm (1.749 in.)

TABLE 1

Subtask 27-54-46-410-054-B ** ON A/C NOT FOR ALL

D. Installation of the Components After Inspection
(1) For the No. 1 flap carriage side rollers:
(a) Install the bolts (2) and the rollers (1) on the flap carriage (3).
(b) Install the washers (11) and the nuts (10).
(c) TORQUE the nuts (10) to between 15.7 and 14.4 m.daN (115.78 and 106.19 lbf.ft )

.
(d) Safety the nuts (10) with the new AIPC 27-54-46-20-070 COTTER PINS (9) or AIPC 27-54-85-40-117 COTTER PINS (9).
(2) For the No. 1 flap carriage center rollers:
(a) Install the bolt assemblies (8), the rollers (7) and the spacers (6) on the flap carriage (3).
(b) Install the washers (5) and the nuts (4).
(c) TORQUE the nuts (4) to between 15.7 and 14.4 m.daN (115.78 and 106.19 lbf.ft )

.
(3) For the Nos. 2, 3 and 4 flap carriage side rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolt assemblies (17) but not the threads.
(b) Install the rollers (18), the bolt assemblies (17) and the nuts (19).
(c) Make sure that the greasers on the bolt assemblies (17) point in the correct direction.
(d) TORQUE the nuts (19) to between 4.8 and 3.5 m.daN (35.40 and 25.81 lbf.ft )

.
(e) Safety the nuts (19) with the new AIPC 27-54-46-22-180 COTTER PINS (20) or AIPC 27-54-46-04-160 COTTER PINS (20).
(4) For the Nos. 2, 3 and 4 flap carriage bottom rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolts (26) but not the threads.
(b) Install the bolts (26) and the rollers (24) on the flap carriage (33).
(c) Install the washers (23) and the nuts (21).
(d) TORQUE the nuts (21) to between 10.1 and 9.3 m.daN (74.48 and 68.58 lbf.ft )

.
(e) Safety the nuts (21) with the new AIPC 27-54-46-22-220 COTTER PINS (22) or AIPC 27-54-46-04-110 COTTER PINS (22).
(5) For the Nos. 2 and 3 flap carriage aft top rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the pivot pin (12).
(b) Install the roller (14) on the roller block assembly (13) with the pivot pin (12).
(c) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the hinge pin (34) but not the thread.
(d) Install the roller block assembly (13) on the flap carriage (33).
(e) Install the hinge pin (34), the washer (15) and the nut (16).
(f) Tighten the nut (16) with your hand.
(6) For the No. 4 flap carriage aft top roller:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the pivot pin (36).
(b) Install the roller (41) on the roller block (35) with the pivot pin (36).
(c) Install the bush (42) on the roller block (35).
(d) Install the sleeve (37) and the roller block assembly (35) on the flap carriage (33).
(e) Install the hinge pin (40), the washer (38) and the nut (39). Do not tighten the nut (39).
(7) For the Nos. 2, 3 and 4 flap carriage forward top rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the pivot pin (27).
(b) Install the roller (28) on the roller block assembly (29) with the pivot pin (27).
(c) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the hinge pin (25) but not the thread.
(d) Install the roller block assembly (29) on the flap carriage (33).
(e) Install the hinge pin (25), the washer (30) and the nut (31). Hand tighten the nut (31).

Subtask 27-54-46-020-054-C ** ON A/C NOT FOR ALL

E. Removal of the Components for Inspection
(1) For the No 1 flap carriage center rollers:
(a) Release the lock plates (8) from the nuts (6).
(b) Remove the nuts (6), the washers (7) and the lock plates (8). Discard the lock plates (8).
(c) Remove the bolt assemblies (11), the rollers (10) and the washers (9).
(2) For the No 1 flap carriage side rollers:
(a) Remove the lockwire:

WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

1 Remove and discard the lockwire from the lock plates (3) and the nuts (5).
(b) Release the lock plates (3) from the nuts (5).
(c) Remove the nuts (5) and the washers (4).
(d) Remove and discard the lock plates (3).
(e) Remove the bolts (1), the bolt assemblies (13) and the rollers (2).
(3) For the Nos 2, 3 and 4 flap carriage top rollers:
(a) Remove the nuts (27), the washers (28) and the hinge pins (22).
(b) Remove the roller block assemblies (26) from the flap carriage (29).
(4) Remove the hinge pins (24) and the rollers (25) from the roller block assemblies (26).
(5) For the Nos 2, 3 and 4 flap carriage side rollers:
(a) Remove the nuts (17), the washers (16), the bolt assemblies (14) and the rollers (15).
(6) For the Nos 2, 3 and 4 flap carriage bottom rollers:
(a) Remove and discard the cotter pins (19) from the nuts (18).
(b) Remove the nuts (18), the washers (20), the bolts (23) and the rollers (21).

Subtask 27-54-46-110-054-C ** ON A/C NOT FOR ALL

F. Preparation for Inspection
(1) Clean the parts:
(a) Use a Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) to clean:

the No. 1 flap carriage rollers (2) and (10)
the Nos. 2, 3 and 4 flap carriage rollers (15), (21) and (25).

Subtask 27-54-46-220-050-C ** ON A/C NOT FOR ALL

G. Detailed Inspection of the Flap Carriage Rollers
(1) Do an inspection of these items for corrosion, damage and the correct condition:

the No. 1 flap carriage rollers (2) and (10)
the Nos. 2, 3 and 4 flap carriage rollers (15), (21) and (25).

(2) Do an inspection of the flap carriage rollers (2), (10), (15), (21) and (25) for in-service wear:
(a) Inspect the outer diameter (OD) of the roller outer case (30) for wear marks. You must replace the applicable roller(s) if the Dim 'Y' is more than 0.1 mm (0.0039 in.).
(b) Hold the roller outer case (30) and move the inner case (31) from left to right. Measure the total lateral play (Dim 'X'). You must replace the applicable roller(s) if the total lateral play Dim 'X' is more than 0.13 mm (0.0051 in.).
(c) Measure the OD of the roller(s) (Dim 'Z'). You must replace the applicable roller(s) if the Dim 'Z' is less than the applicable dimension shown in Table 1.

TRACK No.	MINIMUM BEARING OD (DIM 'Z')
TRACK 1
SIDE ROLLER (2) CENTER ROLLER (10)	44.352 mm (1.746 in.) 44.352 mm (1.746 in.)
TRACK 2
TOP ROLLER (25) SIDE ROLLER (15) BOTTOM ROLLER (21)	33.312 mm (1.312 in.) 33.312 mm (1.312 in.) 44.425 mm (1.749 in.)
TRACK 3
TOP ROLLER (25) SIDE ROLLER (15) BOTTOM ROLLER (21)	33.312 mm (1.312 in.) 33.312 mm (1.312 in.) 44.425 mm (1.749 in.)
TRACK 4
TOP ROLLER (25) SIDE ROLLER (15) BOTTOM ROLLER (21)	33.312 mm (1.312 in.) 33.312 mm (1.312 in.) 38.070 mm (1.499 in.)

TABLE 1

Subtask 27-54-46-410-054-C ** ON A/C NOT FOR ALL

H. Installation of the Components After Inspection

(1) For the No. 1 flap carriage side-rollers:
(a) Install the bolts (1), the bolt assemblies (13) and the rollers (2) on the flap carriage (12).
(b) Apply Polysulfide Sealant_General Purpose Brushable - (Material No.06AAA1) to the installation surface of the new AIPC 27-54-46-01-110 LOCK PLATES (3) or the new AIPC 27-54-85-40-110 LOCK PLATES (3).
(c) Install the new lock plates (3), the washers (4) and the nuts (5).
(d) TORQUE the nuts (5) to between 4.6 and 4.0 m.daN (33.92 and 29.50 lbf.ft )

.
(e) Safety the lock plates (3) with lockwire (Ref. AMM TASK 20-11-11-911-001).
(2) For the No. 1 flap carriage center-rollers:
(a) Install the washers (9), the rollers (10) and the bolt assemblies (11) on the flap carriage (12).
(b) Apply a thin layer of Dry lubricant-General Assembly - - (Material No.03QBA1) to the threads of the nuts (6).
(c) Apply Polysulfide Sealant_General Purpose Brushable - (Material No.06AAA1) to the installation surface of the new AIPC 27-54-46-01-030 LOCKPLATE (8) or the new AIPC 27-54-85-40-030 LOCKPLATE (8).
(d) Install the new lock plates (8), the washers (7) and the nuts (6).
(e) TORQUE the nuts (6) to between 4.6 and 4.0 m.daN (33.92 and 29.50 lbf.ft )

.
(f) Make sure that the lock plates (8) are installed in the correct direction.
(3) For the No. 2 and 3 flap carriage side-rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolt assemblies (14). Do not apply the lubricants to the threads of the bolt assemblies (14).
(b) Install the rollers (15) and the bolt assemblies (14) on the flap carriage (29).
(c) Make sure that the greasers on the bolt assemblies (14) point in the correct direction.
(d) Install the washers (16) and the nuts (17).
(e) TORQUE the nuts (17) to between 5.7 and 5.5 m.daN (42.04 and 40.56 lbf.ft )

.
(4) For the No. 2 and 3 flap carriage bottom-rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolts (23). Do not apply the lubricants to the threads of the bolts (23).
(b) Install the bolts (23) and the rollers (21) on the flap carriage (29).
(c) Install the washers (20) and the nuts (18).
(d) TORQUE the nuts (18) to between 15.0 and 13.0 m.daN (110.62 and 95.87 lbf.ft )

.
(e) Safety the nuts (18) with the new AIPC 27-54-46-04-110 COTTER PINS (19).
(5) For the No. 4 flap carriage side-rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolt assemblies (14). Do not apply lubricants to the threads of the bolts (14).
(b) Install the rollers (15) and the bolt assemblies (14) on the flap carriage (29).
(c) Make sure that the greasers on the bolt assemblies (14) point in the correct direction.
(d) Install the washers (16) and the nuts (17).
(e) TORQUE the nuts (17) to between 4.8 and 3.5 m.daN (35.40 and 25.81 lbf.ft )

.
(6) For the No. 4 flap carriage bottom-rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolts (23). Do not apply the lubricants to the threads of the bolts (23).
(b) Install the bolts (23) and the rollers (21) on the flap carriage (29).
(c) Install the washers (20) and the nuts (18).
(d) TORQUE the nuts (18) to between 10.1 and 9.3 m.daN (74.48 and 68.58 lbf.ft )

.
(e) Safety the nuts (18) with the new AIPC 27-54-46-04-110 COTTER PINS (19).
(7) For the No. 2, 3 and 4 flap carriage top-rollers:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the pivot pins (24).
(b) Install the rollers (25) on the roller block assemblies (26) with the pivot pins (24).
(c) Install the roller block assemblies (26) on the flap carriage (29).
(d) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the hinge pins (22). Do not apply the lubricants to the threads of the hinge pins (22).
(e) Install the hinge pins (22), the washers (28) and the nuts (27).
(f) Tighten the nuts (27).

Subtask 27-54-46-020-054-D ** ON A/C NOT FOR ALL

I. Removal of the Components for Inspection
(1) For the center rollers of the No. 1 flap carriage:
(a) Release the lock plates (9) from the nuts (7).
(b) Remove the nuts (7) and the washers (8).
(c) Remove and discard the lock plates (9).
(d) Remove the bolt assemblies (12), the rollers (11) and the washers (10).
(2) For the side rollers of the No. 1 flap carriage:
(a) Remove the greasers (6) from the bolts (1).

(b) Remove and discard the lockwire from the lock plates (3) and the nuts (5).
(c) Release the lock plates (3) from the nuts (5).
(d) Remove the nuts (5) and the washers (4).
(e) Remove and discard the lock plates (3).
(f) Remove the bolts (1), the bolt assemblies (14) and the rollers (2).
(3) For the top rollers of the Nos. 2, 3 and 4 flap carriage:
(a) Remove the nuts (28), the washers (29) and the hinge pins (23).
(b) Remove the roller block assemblies (27) from the flap carriage (30).
(4) Remove the hinge pins (25) and the rollers (26) from the roller block assemblies (27).
(5) For the side rollers of the Nos. 2, 3 and 4 flap carriage:
(a) Remove and discard the cotter pins (18) from the nuts (17).
(b) Remove the nuts (17), the bolt assemblies (15) and the rollers (16).
(6) For the bottom rollers of the Nos. 2, 3 and 4 flap carriage:
(a) Remove and discard the cotter pins (20) from the nuts (19).
(b) Remove the nuts (19), the washers (21), the bolts (24) and the rollers (22).

Subtask 27-54-46-110-054-D ** ON A/C NOT FOR ALL

J. Preparation for Inspection
(1) Clean the parts:
(a) Use a Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) to clean:

the No. 1 flap carriage rollers (2) and (11)
the Nos. 2, 3 and 4 flap carriage rollers (16), (22) and (26).

Subtask 27-54-46-220-050-D ** ON A/C NOT FOR ALL

K. Detailed Inspection of the Flap Carriage Rollers for In-Service Wear
(1) Do an inspection of these items for corrosion, damage and the correct condition:

the No. 1 flap carriage rollers (2) and (11)
the Nos. 2, 3 and 4 flap carriage rollers (16), (22) and (26).

(2) Do an inspection of the flap carriage rollers (2), (11), (16), (22) and (26) for in-service wear:
(a) Inspect the outer diameter (OD) of the roller outer case (31) for wear marks. You must replace the applicable roller(s) if the Dim 'Y' is more than 0.1 mm (0.0039 in.).
(b) Hold the roller outer case (31) and move the inner case (32) from left to right. Measure the total lateral play (Dim 'X'). You must replace the applicable roller(s) if the total lateral play Dim 'X' is more than 0.13 mm (0.0051 in.).
(c) Measure the OD of the roller(s) (Dim 'Z'). You must replace the applicable roller(s) if the Dim 'Z' is less than the applicable dimension shown in Table 1.

TRACK No.	MINIMUM BEARING OD (DIM 'Z')
TRACK 1
SIDE ROLLER (2) CENTER ROLLER (11)	44.352 mm (1.746 in.) 44.352 mm (1.746 in.)
TRACK 2
TOP ROLLER (26) SIDE ROLLER (16) BOTTOM ROLLER (22)	33.312 mm (1.312 in.) 33.312 mm (1.312 in.) 44.425 mm (1.749 in.)
TRACK 3
TOP ROLLER (26) SIDE ROLLER (16) BOTTOM ROLLER (22)	33.312 mm (1.312 in.) 33.312 mm (1.312 in.) 44.425 mm (1.749 in.)
TRACK 4
TOP ROLLER (26) SIDE ROLLER (16) BOTTOM ROLLER (22)	33.312 mm (1.312 in.) 33.312 mm (1.312 in.) 38.070 mm (1.499 in.)

TABLE 1

Subtask 27-54-46-410-054-D ** ON A/C NOT FOR ALL

L. Installation of the Components after Inspection

(1) For the side rollers of the No. 1 flap carriage:
(a) Install the bolts (1), the bolt assemblies (14) and the rollers (2) on the flap carriage (13).
(b) Apply Polysulfide Sealant_General Purpose Brushable - (Material No.06AAA1) to the installation surface of the new AIPC 27-54-46-01-110 LOCK PLATES (3) or the new AIPC 27-54-85-40-110 LOCK PLATES (3).
(c) Install the new lock plates (3), the washers (4) and the nuts (5).
(d) TORQUE the nuts (5) to between 4.6 and 4.0 m.daN (33.92 and 29.50 lbf.ft )

.
(e) Safety the lock plates (3) with lockwire (Ref. AMM TASK 20-11-11-911-001).
(f) Install the greasers (6) on the bolts (1). Make sure that the greasers (6) point in the correct direction.
(2) For the center rollers of the No. 1 flap carriage:
(a) Install the washers (10), the rollers (11) and the bolt assemblies (12) on the flap carriage (13).
(b) Apply a thin layer of Dry lubricant-General Assembly - - (Material No.03QBA1) to the threads of the nuts (7).
(c) Apply Polysulfide Sealant_General Purpose Brushable - (Material No.06AAA1) to the installation surface of the new AIPC 27-54-46-01-030 LOCK PLATES (9) or the new AIPC 27-54-85-40-030 LOCK PLATES (9).
(d) Install the new lock plates (9), the washers (8) and the nuts (7).
(e) TORQUE the nuts (7) to between 4.6 and 4.0 m.daN (33.92 and 29.50 lbf.ft )

.
(3) For the side-rollers of the Nos. 2 and 3 flap carriage:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolts (15). Do not apply the lubricants to the threads of the bolts (15).
(b) Install the rollers (16) and the bolts (15) on the flap carriage (30).
(c) Install the nuts (17).
(d) TORQUE the nuts (17) to between 48 and 35 m.N (35.40 and 25.81 lbf.ft )

.
(e) Safety the nuts (17) with the new AIPC 27-54-46-04-160 COTTER PINS (18).
(4) For the bottom rollers of the Nos. 2 and 3 flap carriage:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolts (24). Do not apply the lubricants to bolts (24).
(b) Install the bolts (24) and the rollers (22) on the flap carriage (30).
(c) Install the washers (21) and the nuts (19).
(d) TORQUE the nuts (19) to between 101 and 93 m.N (74.48 and 68.58 lbf.ft )

.
(e) Safety the nuts (19) with the new AIPC 27-54-46-04-110 COTTER PINS (20).
(5) For the side rollers of the No. 4 flap carriage:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolts (15). Do not apply the lubricants to the threads of the bolts (15).
(b) Install the rollers (16) and the bolts (15) on the flap carriage (30).
(c) Install the nuts (17).
(d) TORQUE the nuts (17) to between 4.8 and 3.5 m.daN (35.40 and 25.81 lbf.ft )

.
(e) Safety the nuts (17) with the new AIPC 27-54-46-04-160 COTTER PINS (18).
(6) For the bottom rollers of the No. 4 flap carriage:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolts (24). Do not apply the lubricants to the threads of the bolts (24).
(b) Install the bolts (24) and the rollers (22) on the flap carriage (30).
(c) Install the washers (21) and the nuts (19).
(d) TORQUE the nuts (19) to between 57 and 55 m.N (42.04 and 40.56 lbf.ft )

.
(e) Safety the nuts (19) with the new AIPC 27-54-46-04-110 COTTER PINS (20).
(7) For the top rollers of the Nos. 2, 3 and 4 flap carriage:
(a) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the pivot pins (25).
(b) Install the rollers (26) on the roller block assemblies (27) with the pivot pins (25).
(c) Install the roller block assemblies (27) on the flap carriage (30).
(d) Apply a layer of Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the hinge pins (23). Do not apply the lubricants to the threads of the hinge pins (23).
(e) Install the hinge pins (23), the washers (29) and the nuts (28).
(f) Tighten the nuts (28).

Subtask 27-54-46-640-052-A

M. Lubrication
(1) Lubricate the flap track carriage rollers (Ref. AMM TASK 12-22-27-640-004).

5. Close-up
Subtask 27-54-46-860-062-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Install the applicable flap carriage:

For the No 1 flap carriage (Ref. AMM TASK 27-54-46-400-002)
For the Nos 2, 3 and 4 flap carriages (Ref. AMM TASK 27-54-46-400-001).

(2) Install the flaps (Ref. AMM TASK 27-54-61-400-001), (Ref. AMM TASK 27-54-62-400-001).
(3) Remove the 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER from the piston rod of each servo-control.
(4) Put the Nos 1, 2, 3, 4 and 5 spoilers to the operation position (Ref. AMM TASK 27-60-00-866-002).
(5) Remove the 460005835 SLEEVE - GROUND LOCK from the applicable MLG door actuator (Ref. AMM TASK 32-00-00-481-002).
(6) Make sure that the work area is clean and clear of tools and other items.
(7) Close the applicable MLG doors (Ref. AMM TASK 32-12-00-410-001).
(8) Remove the 98D27803500001 LOCKING TOOL ZERO POS or 98D27803500002 LOCKING TOOL ZERO POS from the flap/slat control lever in the cockpit.
(9) Remove the access platform(s).

Subtask 27-54-46-860-062-B ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Install the applicable flap carriage:

for the No.1 flap carriage (Ref. AMM TASK 27-54-46-400-002)
for the Nos. 2, 3 and 4 flap carriages (Ref. AMM TASK 27-54-46-400-001).

(2) Install the flaps (Ref. AMM TASK 27-54-61-400-003), (Ref. AMM TASK 27-54-62-400-002).
(3) Remove the 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER from the piston rod of each servo-control.
(4) Put the Nos. 1, 2, 3, 4 and 5 spoilers to the operation position (Ref. AMM TASK 27-60-00-866-002).
(5) Remove the 460005835 SLEEVE - GROUND LOCK from the applicable MLG door actuator (Ref. AMM TASK 32-00-00-481-002).
(6) Make sure that the work area is clean and clear of tools and other items.
(7) Close the applicable MLG doors (Ref. AMM TASK 32-12-00-410-001).
(8) Remove the 98D27803500001 LOCKING TOOL ZERO POS or 98D27803500002 LOCKING TOOL ZERO POS from the flap/slat control lever in the cockpit.

Subtask 27-54-46-865-062-A

B. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B07
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
** ON A/C ALL
121VU	FLIGHT CONTROLS/WTB/FLP/SYS2	12CV	P20
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21
122VU	FLIGHT CONTROLS/WTB/FLP/SYS1	10CV	S07

Subtask 27-54-46-942-058-A

C. Removal of Equipment
(1) Install the safety collar on circuit breakers 10CV and 12CV.
(2) Remove the safety barriers.
(3) Remove the WARNING NOTICE(S).
(4) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

[Rev.10 from 2021] 2026.03.31 23:53:56 UTC