Removal of the Inboard Double-Slotted Flap

TASK 27-54-61-000-003-A
Removal of the Inboard Double-Slotted 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.

ZONE: 580
ZONE: 680

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	PAD - PROTECTIVE FOAM
No specific	AR	SAFETY BARRIER(S)
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	SUPPORT STRUCTURE - FLAP
No specific	AR	TAPE - ADHESIVE
No specific	AR	WARNING NOTICE(S)
No specific	AR	WRENCH - PNEUMATIC
98D27504083000	1	EXTRACTOR - PIN TRACKS 2 AND 3
98D27504095000	1	SPANNER - TRUNNION NUT, TRACK 1
98D27504114000	1	DISTANCE GAUGE
98D27604000000	1	COLLAR-SAFETY, SPOILER
98D27604004000	1	COLLAR SAFETY SPOILER
98D27804001000	1	ADAPTOR-DRIVE, SLAT (AND FLAP)
98L12003001000	1	HARNESS,SAFETY

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
580	LEFT WING FLAPS AND SPOILERS
680	RIGHT WING FLAPS AND SPOILERS
193AB, 193BB, 194AB, 194BB, 573CB, 575AB, 575BB, 673CB, 675AB, 675BB

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 27-50-00-866-008-A	Extension of the Flaps on the Ground
TASK 27-50-00-866-008-A-01	Extension of the Flaps/Slats on the Ground
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 27-51-44-000-001-A	Removal of the Interconnecting Strut
TASK 27-54-41-000-001-A	Removal of the Right Angle Gearbox
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 54-55-00-000-001-A	Removal of the Aft Movable Fairing
TASK 57-51-37-000-002-A	Removal of the Access Panels 571AB(671AB), 573AB(673AB), 573BB(673BB), 573CB(673CB), 573EB(673EB)
TASK 57-51-37-000-004-A	Removal of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
TASK 57-55-11-000-005-A	Removal of the Inboard and Outboard-Flap Tab Hinge-Fairings
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
Details of the Z-Coupling
Details of the Hinge 1A Operating Mechanism
Details of the Tab Drive Control-Rod at the Track 2 Carriage
Distance Gages - 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 Removal and Installation Tools
Details of the Flap Disconnect Cables
Flap to Flap Carriage Connection (Track 1)

3. Job Set-up
Subtask 27-54-61-941-056-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Put the SAFETY BARRIER(S) in position.
(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 27-54-61-860-053-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) Fully extend and lock spoilers 1 and 2 (Ref. AMM TASK 27-60-00-866-002).
(2) Put the 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER on the applicable rod of the servo control.
(3) Make sure that the flaps are in the fully retracted position (Ref. AMM TASK 27-50-00-866-009).
(4) Install the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION on the slat/flap control lever.

Subtask 27-54-61-865-052-A ** ON A/C NOT FOR ALL

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 NOT FOR ALL
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 27-54-61-010-052-B ** 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 an 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) If installed remove the pylon aft movable fairing (Ref. AMM TASK 54-55-00-000-001).

NOTE: NEO aircraft do not have a pylon aft movable fairing.

(5) Move the flaps (Ref. AMM TASK 27-50-00-866-008) to get access to the fasteners of the rubbing strip (2).
(6) Remove the support (1) and the rubbing strip (2).
(7) Remove the applicable wing to fuselage fairing panels (Ref. AMM TASK 53-35-11-000-001):
(a) For the left wing, remove 193AB 193BB.
(b) For the right wing, remove 194AB 194BB.
(8) Remove the applicable wing access panels:

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

(a) For the left wing:
1 Remove 573CB (Ref. AMM TASK 57-51-37-000-002).
2 Remove 575AB 575BB (Ref. AMM TASK 57-51-37-000-004).
(b) For the right wing:
1 Remove 673CB (Ref. AMM TASK 57-51-37-000-002).
2 Remove 675AB 675BB (Ref. AMM TASK 57-51-37-000-004).
(9) Remove the hinge 1A fairings (Ref. AMM TASK 57-55-11-000-005).
(10) Disconnect the applicable torque shaft from the right angle gearbox (Ref. AMM TASK 27-54-41-000-001).
(11) Make sure that the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT is on the applicable torque shaft.
(12) Install the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) on the right angle gearbox.
(13) Use a WRENCH - PNEUMATIC to turn the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to extend the flaps to position 1.
(14) Remove the flap kink seals (Ref. AMM TASK 27-54-61-000-002).

Subtask 27-54-61-020-061-A ** ON A/C NOT FOR ALL

E. Preparation for Removal
(1) Use the pneumatic wrench and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to retract the flap to the 0 position.
(2) Disconnect the interconnecting strut (Ref. AMM TASK 27-51-44-000-001).
(3) Disconnect the Z-coupling:

Details of the Z-Coupling ** ON A/C NOT FOR ALL

(a) Use the pneumatic wrench and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to extend the flap to position 1.
(b) Remove and discard the cotter pin (22).
(c) Remove the nut (23) and the washer (24).
(d) Use the pneumatic wrench and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to retract the flap to the 0 position.
(e) Remove and discard the cotter pin (16).
(f) Remove the nut (17), the washer (18) and the spacer(s) (19).
(g) Remove the bolt (20).
(h) Remove the lever (25) and the remaining spacer(s) (19).
(i) Temporarily install the spacer(s) (19), washer (18) and nut (17) on the lever (25).
(j) Temporarily install the lever (25) on the attachment bracket (21) with the bolt (20), washer (24) and nut (23). Turn the lever (25) forward as far as possible and hold it in this position with TAPE - ADHESIVE.
(k) Turn the lever (15) forward as far as possible and hold it in this position with TAPE - ADHESIVE.
(4) Use the pneumatic wrench and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to fully extend the flaps.
(5) Disconnect the upper tab drive control-rod (36) from the shroud box assembly attachment-bracket (39) as follows:

Details of the Hinge 1A Operating Mechanism ** ON A/C NOT FOR ALL

(a) Remove and discard the cotter pin (43).
(b) Remove the nut (42), washer (41) and bolt (40).
(c) Put an applicable PAD - PROTECTIVE FOAM in position on the inboard flap to put the tab drive control-rod (36) on.
(d) Put the tab drive control-rod (36) on the PAD - PROTECTIVE FOAM and hold it to the flap with TAPE - ADHESIVE.
(6) Disconnect the tab drive control-rod (68) from the track 2 carriage (56):

Details of the Tab Drive Control-Rod at the Track 2 Carriage ** ON A/C NOT FOR ALL

(a) Remove and discard the cotter pin (59).
(b) Remove the nut (60), washer (58), bolt (70) and the loose bush (57).

Subtask 27-54-61-480-050-A ** ON A/C NOT FOR ALL

F. Installation of the Support Equipment

Distance Gages - Location and Detail ** ON A/C NOT FOR ALL

(1) Manually push the tab forward and install the 98D27504114000 DISTANCE GAUGE (82) and (88):

CAUTION: MAKE SURE THAT THE DISCONNECTED PARTS DO NOT TOUCH AND/OR CATCH THE ADJACENT STRUCTURE WHEN YOU MOVE THE FLAP. THIS WILL PREVENT DAMAGE TO THE WING.

(a) At hinge 1A position, put the distance gauge (88) in position.
(b) Install the rear pin (89).
(c) Install the forward pin (86) and lock it with the knurled screw (87).
(d) At track 2 position, put the distance gauge (82) in position.
(e) Install the rear pin (85) and lock it with the knurled screw (81).
(f) Install the forward pin (83) and lock it with the knurled screw (84).
(2) Install the hoisting sling (Ref. AMM TASK 27-50-00-400-002):

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

(a) Use the hoist to carefully lift the hoisting sling until it holds the weight of the inboard flap.

Subtask 27-54-61-860-054-A

DELETED

4. Procedure
Subtask 27-54-61-020-055-B ** ON A/C NOT FOR ALL

A. Removal of the Inboard Double-Slotted Flap

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.

CAUTION: SUPPORT THE FLAP ALONG THE FULL LENGTH OF THE TRAILING EDGE. THIS WILL PREVENT DAMAGE TO THE FLAP.

(1) Disconnect the flap drive arms (106) from the rotary actuator drive-levers (110) at the track 1 and the track 2 positions:

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

NOTE: The weight of the inboard flap is 201 kg (443.13 lb).

(a) Remove the nut (103), bolt (100), washer (101) and disconnect the bonding strap (102).
(b) Remove and discard the cotter pins (109).
(c) Remove the nuts (108), washers (107) and bolts (104).
(2) Carefully let the inboard flap move aft until the flap track 2 carriage touches the end stop (130).

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

(3) Disconnect the inboard flap from the flap track 2 carriage:

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

(a) Cut, remove and discard the lockwire from the bolt (128).
(b) Remove the bolt (128) and disconnect the bonding strap (129).
(c) Remove and discard the cotter pin (125).
(d) Remove the nut (124).
(e) Remove and discard the crushable washer (123).
(f) Remove the nut (126), washer (127) and locking plate (122).
(g) Cut, remove and discard the lockwire from the nuts (133).
(h) Loosen the nuts (133) sufficiently to let the failsafe hook assembly (134) move.
(i) Install the 98D27504083000 EXTRACTOR - PIN TRACKS 2 AND 3 to the carriage bolt (132).

Flap Removal and Installation Tools ** ON A/C NOT FOR ALL

(j) Make sure that you screw the extractor tool fully on to the threads.
(k) Remove the carriage bolt (132). If necessary, carefully lift the flap with the hoist and sling sufficiently to release the weight off the bolt (132).
(l) Remove the splined bush (121).
(4) Disconnect the electrical cable connectors (144) and (145) from the connectors (143) and (146) on the track 2 beam assembly:

Details of the Flap Disconnect Cables ** ON A/C NOT FOR ALL

(a) Put CAP - BLANKING on the disconnected electrical connectors.
(b) Hold the disconnected electrical cables to the flap with adhesive tape.
(5) Disconnect the inboard flap from the flap track 1 carriage:

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

(a) Remove the nut (166), bolt (168) and disconnect the bonding strap (167) from the carriage (169).
(b) Remove the bolt (159).
(c) Remove and discard the tabwasher (160).
(d) Remove the retainer (161).
(e) Use the 98D27504095000 SPANNER - TRUNNION NUT, TRACK 1 to remove the locknut (162).
(f) Remove and discard the tabwasher (158).
(g) Remove the toothplate (157).
(h) Remove the eccentric bush (163). If necessary, carefully lift the flap with the hoist and the sling to release the weight from the eccentric bush (163).
(i) Lift the flap with the hoist until it is clear of the flap track carriage at the track 2 position.
(j) Move the outboard end of the flap aft, until it is clear of the wing.
(k) Pull the flap outboard until the flap drive trunnion (165) is clear of the flap track carriage (169).
(l) Remove the spacer (164).
(6) Remove the flap from the wing:

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

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

(a) Move the inboard flap with the hoist and lower it onto the SUPPORT STRUCTURE - FLAP.
(7) Put COVER - PROTECTION, where necessary, over the disconnected items of the flap.

Subtask 27-54-61-080-051-A ** ON A/C NOT FOR ALL

B. Removal of the Equipment
(1) If necessary, remove:

The hoisting sling from the inboard flap (Ref. AMM TASK 27-50-00-000-002)
The 98D27504083000 EXTRACTOR - PIN TRACKS 2 AND 3 from the carriage bolt (132).
Flap Removal and Installation Tools ** ON A/C NOT FOR ALL
Flap to Flap Carriage Connection (Track 2) ** ON A/C NOT FOR ALL

(2) Remove the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) from the right angle gearbox.

[Rev.10 from 2021] 2026.03.31 23:54:49 UTC