Removal of the Inboard Flap

TASK 27-54-61-000-001-A
Removal of the Inboard Flap

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.

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.

CAUTION: THIS PART IS A REMOVABLE STRUCTURAL COMPONENT (RSC), WHICH CAN BE MOVED BETWEEN AIRCRAFT. THUS IT CAN HAVE DIFFERENT OPERATION CONDITIONS AND A DIFFERENT LIFE RECORD (FLIGHT HOURS/FLIGHT CYCLES/CALENDAR) FROM THE AIRCRAFT IT IS INSTALLED ON OR REMOVED FROM. THE OPERATOR IS RESPONSIBLE FOR THE SPECIFIC TRACKING AND CONTINUED AIRWORTHINESS OF REMOVABLE STRUCTURAL COMPONENTS. INCORRECT MAINTENANCE OF THESE COMPONENTS CAN CAUSE A RISK FOR THE FLIGHT SAFETY.

ZONE: 581
ZONE: 681

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

REFERENCE	QTY	DESIGNATION
No specific	AR	ACCESS PLATFORM 3M (10 FT)
No specific	AR	CAP - BLANKING
No specific	AR	COVER - PROTECTION
No specific	AR	SAFETY BARRIER(S)
No specific	AR	SUPPORT STRUCTURE - FLAP
No specific	AR	TAPE - ADHESIVE
No specific	AR	WARNING NOTICE(S)
98D27504035000	1	TORQUE ADAPTER-TRUNNION NUT
98D27504084000	1	EXTRACTOR - PIN, TRACK 4
98D27803500001	1	LOCKING TOOL ZERO POS
98D27803500002	1	LOCKING TOOL ZERO POS
98L12003001000	1	HARNESS,SAFETY

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
581	FLAP N° 1
681	FLAP N° 1
193AB, 193BB, 194AB, 194BB

C. Referenced Information

REFERENCE	DESIGNATION
TASK 27-50-00-000-002-A	Removal of the Inboard and Outboard Flap Hoisting-Sling
TASK 27-50-00-400-002-A	Installation of the Inboard and Outboard Flap Hoisting-Sling
TASK 27-50-00-400-003-A	Installation of the Lock-Torque Shaft - Flaps and Slats (98D27504030001)
TASK 27-50-00-866-009-A	Retraction of the Flaps on the Ground
TASK 27-50-00-866-009-A-01	Retraction of the Flaps/Slats on the Ground
TASK 27-50-00-866-011-A	Manual Extension of the Flaps
TASK 27-54-61-000-002-A	Removal of the Flap Kink-Seals and Cushion-Seals
TASK 27-60-00-866-002-A	Extension-Retraction of the Spoilers for Maintenance
TASK 53-35-11-000-001-A	Removal of the Wing-to-Fuselage Fairings
TASK 54-54-00-000-802-A	Removal of the Rear Pylon Fairing (RPF)
TASK 54-55-00-000-001-A	Removal of the Aft Movable Fairing
TASK 57-55-11-010-001-A	To Lower the Flap Track No. 2 Movable Fairing for Access
Details of the Wing to Fuselage Panels
Interconnecting Strut - Location and Detail
Flap to Rotary Actuator Drive-Lever Connection ** ON A/C NOT FOR ALL
Flap to Rotary Actuator Drive-Lever Connection ** ON A/C NOT FOR ALL
Flap to Flap Carriage Connection (Track 2)
Flap Installation Tool
Flap to Flap Carriage Connection (Track 1) ** ON A/C NOT FOR ALL
Flap Drive Trunnion - Detail ** ON A/C NOT FOR ALL
Flap to Flap Carriage Connection (Track 1) ** ON A/C NOT FOR ALL
Flap Drive Trunnion - Detail ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 27-54-61-941-050-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) As necessary, use the applicable SAFETY BARRIERS, specified by the operator's instructions and your local regulations.
(2) On panel 400VU, put WARNING NOTICE(S) in position to tell persons not to operate the landing gear.
(3) In the cockpit, put WARNING NOTICE(S) in position to tell persons not to operate the flight controls.

Subtask 27-54-61-860-052-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) Make sure that the flaps are in the fully retracted position (Ref. AMM TASK 27-50-00-866-009).
(2) Make sure that the 98D27803500001 LOCKING TOOL ZERO POS or 98D27803500002 LOCKING TOOL ZERO POS is on the flap/slat control lever.

Subtask 27-54-61-865-050-A ** ON A/C NOT FOR ALL

C. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

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

Subtask 27-54-61-010-051-D ** ON A/C NOT FOR ALL

D. Get Access

Details of the Wing to Fuselage Panels ** ON A/C NOT FOR ALL

(1) Put on a safety harness:

WARNING: BEFORE YOU START WORK, YOU MUST PUT ON A SAFETY HARNESS AND ATTACH IT TO THE ACCESS PLATFORM. WITHOUT A SAFETY HARNESS, YOU CAN FALL. THIS CAN KILL YOU OR CAUSE YOU INJURY.

(a) Put on and attach a 98L12003001000 HARNESS,SAFETY before you start work in the work area.
(2) Put the ACCESS PLATFORM 3M (10 FT) in position below the applicable inboard flap.
(3) Lower the flap track No 2 movable fairing for access (Ref. AMM TASK 57-55-11-010-001).
(4) Remove the pylon aft movable fairing (Ref. AMM TASK 54-55-00-000-001).
(5) Manually extend the flaps to get access to the fasteners of the rubbing strip (2) (Ref. AMM TASK 27-50-00-866-011).
(6) Install the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT on shaft 6220CM (6270CM) (Ref. AMM TASK 27-50-00-400-003).
(7) Remove the support (1) and the rubbing strip (2).
(8) Remove the fairing panels (Ref. AMM TASK 53-35-11-000-001):
(a) For left wing, remove 193AB, 193BB.
(b) For right wing, remove 194AB, 194BB.
(9) Remove the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT from the applicable torque shaft.
(10) Manually extend the flaps to position 1 (Ref. AMM TASK 27-50-00-866-011).
(11) Install the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT is on the applicable torque shaft.
(12) Remove the flap kink seals (Ref. AMM TASK 27-54-61-000-002).

Subtask 27-54-61-010-051-G ** ON A/C NOT FOR ALL

D. Get Access

Details of the Wing to Fuselage Panels ** ON A/C NOT FOR ALL

(1) Put on a safety harness:

WARNING: BEFORE YOU START WORK, YOU MUST PUT ON A SAFETY HARNESS AND ATTACH IT TO THE ACCESS PLATFORM. WITHOUT A SAFETY HARNESS, YOU CAN FALL. THIS CAN KILL YOU OR CAUSE YOU INJURY.

(a) Put on and attach the 98L12003001000 HARNESS,SAFETY before you start work in the work area.
(2) Put the ACCESS PLATFORM 3M (10 FT) in position below the applicable inboard flap.
(3) Lower the flap track No. 2 movable fairing for access (Ref. AMM TASK 57-55-11-010-001).
(4) Remove the rear pylon fairing (Ref. AMM TASK 54-54-00-000-802).
(5) Manually extend the flaps to get access to the fasteners of the rubbing strip (2) (Ref. AMM TASK 27-50-00-866-011).
(6) Install the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT on shaft 6220CM (6270CM) (Ref. AMM TASK 27-50-00-400-003).
(7) Remove the support (1) and the rubbing strip (2).
(8) Remove the fairing panels (Ref. AMM TASK 53-35-11-000-001):
(a) For left wing, remove 193AB, 193BB.
(b) For right wing, remove 194AB, 194BB.
(9) Remove the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT from the applicable torque shaft.
(10) Manually extend the flaps to position 1 (Ref. AMM TASK 27-50-00-866-011).
(11) Install the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT on the applicable torque shaft.
(12) Remove the flap kink seals (Ref. AMM TASK 27-54-61-000-002).

4. Procedure
Subtask 27-54-61-020-058-A ** ON A/C NOT FOR ALL

A. Disconnect the Interconnecting Strut

Interconnecting Strut - Location and Detail ** ON A/C NOT FOR ALL

(1) Remove the electrical connectors (18) and (20) from the connectors (17) and (19).
(2) Remove the electrical connectors (21) and (22).
(3) Put the CAP-BLANKING on each disconnected electrical connector and receptacle.
(4) Remove and discard the cotter pin (16) from the nut (15).
(5) Remove the nut (15) and the washer (14).
(6) Remove the bolt (11), washer (12) and bush (13).
(7) Hold the interconnecting strut (10) with TAPE - ADHESIVE to the outboard flap.

Subtask 27-54-61-020-059-D ** ON A/C NOT FOR ALL

CAUTION: OPERATE THE HOIST SLOWLY, WHEN YOU PUT THE SLING IN TENSION. DO NOT TRY TO REMOVE THE FLAP BECAUSE THIS WILL CAUSE DAMAGE.

B. Preparation for Removal of the Inboard Flap

NOTE: The weight of the inboard flap is 114 kg (251.33 lb).

(1) Remove the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT from the applicable torque shaft.
(2) Manually extend the flaps to position 3 (Ref. AMM TASK 27-50-00-866-011).
(3) Install the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT on shaft 6220CM (6270CM) (Ref. AMM TASK 27-50-00-400-003).
(4) Remove the forward rubbing pad from the fixed shroud adjacent to the outboard cruise roller of the inboard flap.
(5) Manually extend and lock spoilers 1 and 2 (Ref. AMM TASK 27-60-00-866-002).
(6) Install the hoisting sling (Ref. AMM TASK 27-50-00-400-002).
(a) Carefully lift the sling with the hoist until the hoist holds the weight of the flap.
(7) Disconnect the inner flap from the rotary actuator drive-levers as follows:

Flap to Rotary Actuator Drive-Lever Connection ** ON A/C NOT FOR ALL

(a) Remove the nut (70), the bolt (72) and disconnect the bonding strap (71).
(8) Remove the nut (73), the bolt (75) and disconnect the bonding strap (74).
(9) Hold the trailing edge of the flap by hand and disconnect the rotary actuator drive-lever at track 1 as follows:
(a) Remove and discard the cotter pin (82).
(b) Remove the nut (83) and washer (81).
(c) Remove the bolts (76), washers (77) and indicator plate (78).
(d) Remove the indicator pin (79) and the shear bolt (80).
(e) Move the rotary actuator drive-lever from the flap drive arm and remove the packers (84).
(f) Remove the bushes (85) from the rotary actuator drive-lever.
(10) Hold the trailing edge of the flap by hand and disconnect the rotary actuator drive-lever at track 2 as follows:
(a) Remove and discard the cotter pin (89).
(b) Remove the nut (88) and the washer (87).
(c) Remove the bolt (86).
(11) Hold the trailing edge and manually extend the inboard flap until the flap carriages rest on the end stops.
(12) Hold the flap on supports at an angle of 20 degrees.

Subtask 27-54-61-020-059-E ** ON A/C NOT FOR ALL

CAUTION: OPERATE THE HOIST SLOWLY, WHEN YOU PUT THE SLING IN TENSION. DO NOT TRY TO REMOVE THE FLAP BECAUSE THIS WILL CAUSE DAMAGE.

B. Preparation for Removal of the Inboard Flap

NOTE: The weight of the inboard flap is 114 kg (251.33 lb).

Flap to Rotary Actuator Drive-Lever Connection ** ON A/C NOT FOR ALL

(a) Remove the nut (70), the bolt (72) and disconnect the bonding strap (71).
(8) Remove the nut (73), the bolt (75) and disconnect the bonding strap (74).
(9) Hold the trailing edge of the flap by hand and disconnect the rotary actuator drive-lever at track 1 as follows:
(a) Remove and discard the cotter pin (77).
(b) Remove the nut (76) and the washer (78).
(c) Remove the bolt (79).
(10) Hold the trailing edge of the flap by hand and disconnect the rotary actuator drive-lever at track 2 as follows:
(a) Remove and discard the cotter pin (83).
(b) Remove the nut (82) and the washer (81).
(c) Remove the bolt (80).
(11) Hold the trailing edge and manually extend the inboard flap until the flap carriages rest on the end stops.
(12) Hold the flap on supports at an angle of 20 degrees.

Subtask 27-54-61-020-050-D ** ON A/C NOT FOR ALL

C. Removal of the Inboard Flap

Flap to Flap Carriage Connection (Track 2) ** ON A/C NOT FOR ALL

(1) Disconnect the inboard flap from the track 2 flap track carriage:
(a) Loosen the nuts (184) sufficiently to let the failsafe hook assembly (185) move.
(b) Remove the nut (183), the bolt (182) and disconnect the bonding strap from the bracket on the inboard flap.
(c) Remove and discard the cotter pin (175).
(d) Remove the nut (174).
(e) Remove and discard the crushable spacer (176).
(f) Install the 98D27504084000 EXTRACTOR - PIN, TRACK 4 onto the carriage bolt (181).

Flap Installation Tool ** ON A/C NOT FOR ALL

(g) Make sure that the extractor pin is fully screwed on the threads of the bolt (181). This will hold the locking ring in its compressed position and will let possible the removal of the bolt (181) through the flap carriage.
(h) Remove the carriage bolt:

CAUTION: THE FLAP TO CARRIAGE BOLT ASSEMBLY HAS AN INNER AND AN OUTER BOLT WHICH MAKE ONE PART. DO NOT APPLY AN END OR A TORSION FORCE TO THE INNER BOLT BECAUSE THIS WILL CAUSE DAMAGE TO THE ASSEMBLY. APPLY FORCE TO THE OUTER BOLT ONLY WHEN YOU REMOVE/INSTALL THE BOLT ASSEMBLY.

1 Remove the carriage bolt (181) using the 98D27504084000 EXTRACTOR - PIN, TRACK 4 to push the carriage bolt (181) through the bushes and bearing. If necessary, carefully lift the flap with the hoist and sling sufficiently to release the weight off the bolts (181).
(i) Remove the nut (177) and the washer (178).
(j) Remove the locking plate (179) and the splined bush (180).

Subtask 27-54-61-020-051-C ** ON A/C NOT FOR ALL

D. Continue with the Removal Procedure

Flap to Flap Carriage Connection (Track 1) ** ON A/C NOT FOR ALL

Flap Drive Trunnion - Detail ** ON A/C NOT FOR ALL

(1) Disconnect the inboard flap from the flap track carriage at the track 1 position:
(a) Remove the nut (118), washer (117), bolt (116) and release the bonding strap (115).
(b) Remove these items:

The bolt (111)
The tabwasher (112)
The retainer (113)
The locknut (110) using the 98D27504035000 TORQUE ADAPTER-TRUNNION NUT
The lockwasher (109)
The toothplate (108).

(c) Remove the eccentric bush (107). If necessary, carefully lift the flap with the hoist and the sling to release the weight from the eccentric bush (107).
(d) Discard the tabwasher (112) and the lockwasher (109).
(2) Remove the flap from the wing:

CAUTION: MAKE SURE THAT THE SUPPORT STRUCTURE IS CLEAN AND DOES NOT HAVE ANY SHARP POINTS.

CAUTION: MAKE SURE THAT THE FLAP DOES NOT HIT THE AIRCRAFT STRUCTURE.

(a) Lift the flap with the hoist until it is clear of the flap track carriage at the track 2 position.
(b) Move the outboard end of the flap, aft, until it is clear of the wing.
(c) Pull the flap outboard until the flap drive trunnion is clear of the flap track carriage of the track 1 position.
(d) Move the flap with the hoist to a SUPPORT STRUCTURE - FLAP and lower it onto the support.
(3) Put COVER - PROTECTION, where necessary, over the disconnected items of the flap.
(4) If you install the same flap again, examine the flap drive trunnion for wear.

Subtask 27-54-61-020-051-D ** ON A/C NOT FOR ALL

D. Continue with the Removal Procedure

Flap to Flap Carriage Connection (Track 1) ** ON A/C NOT FOR ALL

Flap Drive Trunnion - Detail ** ON A/C NOT FOR ALL

(1) Disconnect the inboard flap from the flap track carriage at the track 1 position:
(a) Remove these items:

The bolt (111)
The tabwasher (112)
The retainer (113)
The screw (121)
The locknut (110) using the 98D27504035000 TORQUE ADAPTER-TRUNNION NUT
The lockwasher (109)
The toothplate (108)
The washer (120).

(b) Remove the eccentric bush (107). If necessary, carefully lift the flap with the hoist and the sling to release the weight from the eccentric bush (107).
(c) Discard the tabwasher (112) and the lockwasher (109).
(2) Remove the flap from the wing:

CAUTION: MAKE SURE THAT THE SUPPORT STRUCTURE IS CLEAN AND DOES NOT HAVE ANY SHARP POINTS.

CAUTION: MAKE SURE THAT THE FLAP DOES NOT HIT THE AIRCRAFT STRUCTURE.

(a) Lift the flap with the hoist until it is clear of the flap track carriage at the track 2 position.
(b) Move the outboard end of the flap, aft, until it is clear of the wing.
(c) Pull the flap outboard until the flap drive trunnion is clear of the flap track carriage of the track 1 position.
(d) Move the flap with the hoist to a SUPPORT STRUCTURE - FLAP and lower it onto the support.
(3) Put COVER - PROTECTION , where necessary, over the disconnected items of the flap.
(4) If you install the same flap again, examine the flap drive trunnion for wear.

Subtask 27-54-61-080-050-A ** ON A/C NOT FOR ALL

E. Removal of the Equipment
(1) Remove the hoisting sling (Ref. AMM TASK 27-50-00-000-002).

[Rev.10 from 2021] 2026.03.31 23:54:40 UTC