Installation of the Inboard Flap

TASK 27-54-61-400-001-A
Installation 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 FLIGHT CONTROL SAFETY-LOCKS AND THE WARNING NOTICES ARE IN POSITION.

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.

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	1	ACCESS PLATFORM 3M (10 FT)
No specific	AR	SAFETY BARRIER(S)
No specific	AR	TAPE - ADHESIVE
No specific	AR	WARNING NOTICE(S)
No specific	1	WRENCH - PNEUMATIC
No specific	Torque wrench: range to between 27 and 24 m.N (19.91 and 17.70 lbf.ft )
No specific	Torque wrench: range to between 0.12 and 0.05 m.daN (10.62 and 4.42 lbf.in )
No specific	Torque wrench: range to between 0.17 and 0.15 m.daN (15.04 and 13.27 lbf.in )
No specific	Torque wrench: range to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )
No specific	Torque wrench: range to between 1.5 and 1.0 m.daN (132.74 and 88.50 lbf.in )
No specific	Torque wrench: range to between 1.8 and 1.2 m.daN (159.29 and 106.19 lbf.in )
No specific	Torque wrench: range to between 1.8 and 1.6 m.daN (13.27 and 11.80 lbf.ft )
No specific	Torque wrench: range to between 2.3 and 1.8 m.daN (16.96 and 13.27 lbf.ft )
No specific	Torque wrench: range to between 7.0 and 5.4 m.daN (51.62 and 39.82 lbf.ft )
No specific	Torque wrench: range to between 20 and 15 m.daN (147.49 and 110.62 lbf.ft )
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. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03GBB1)	Synthetic Oil base Grease-General Purpose Clay Thickened -
(Material No.03GBC1)	Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. -
(Material No.04SAB2)	Varnish Polyurethane-- Marking Structure
(Material No.06CMD9)	Silicone Adhesive Sealant-General Purpose One part legacy
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.12ACC1)	Corrosion Preventive Compound-Heavy Duty Soft Film -
(Material No.14QFB1)	Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

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

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
89	COTTER PIN	AIPC 27-54-05-33-025
83	COTTER PIN	AIPC 27-54-05-33-030
82	COTTER PIN	AIPC 27-54-05-33-035
77	COTTER PIN	AIPC 27-54-05-33-150
175	COTTER PIN	AIPC 27-54-46-04-035
176	CRUSHABLE SPACER	AIPC 27-54-46-04-080
77	COTTER PIN	AIPC 27-54-85-32-050
83	COTTER PIN	AIPC 27-54-85-32-110
112	TABWASHER	AIPC 57-52-21-02-280
109	LOCKWASHER	AIPC 57-52-21-02-310

E. Referenced Information

REFERENCE	DESIGNATION
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
TASK 27-50-00-000-002-A	Removal of the Inboard and Outboard Flap Hoisting-Sling
TASK 27-50-00-000-003-A	Removal of the Lock-Torque Shaft - Flaps and Slats (98D27504030001)
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 27-50-00-866-011-A	Manual Extension of the Flaps
TASK 27-50-00-866-012-A	Manual Retraction of the Flaps
TASK 27-51-00-820-003-A	To do a Check of the Flap Rigged Position (with the Sharks Fin)
TASK 27-51-00-820-008-A	Adjustment (Rigging) of the Flaps with the Sharks Fin Tool (A318/319/320)
TASK 27-51-44-400-001-A	Installation of the Interconnecting Strut
TASK 27-54-00-710-001-A	Operational Test of the Flap System
TASK 27-54-61-000-002-A	Removal of the Flap Kink-Seals and Cushion-Seals
TASK 27-54-61-400-006-A	Installation of the Flap Kink-Seals and Cushion-Seals
TASK 27-60-00-866-002-A	Extension-Retraction of the Spoilers for Maintenance
TASK 27-64-00-710-001-A	Operational Test of the Spoiler Hydraulic Actuation
TASK 27-64-00-820-001-C	Adjustment of the Spoilers
TASK 27-64-00-820-001-E	Adjustment of the Spoilers
TASK 53-35-11-000-001-A	Removal of the Wing-to-Fuselage Fairings
TASK 53-35-11-400-001-A	Installation of the Wing-to-Fuselage Fairings
TASK 54-54-00-000-802-A	Removal of the Rear Pylon Fairing (RPF)
TASK 54-54-00-400-802-A	Installation of the Rear Pylon Fairing (RPF)
TASK 54-55-00-000-001-A	Removal of the Aft Movable Fairing
TASK 54-55-00-400-001-A	Installation of the Aft Movable Fairing
TASK 57-55-11-010-001-A	To Lower the Flap Track No. 2 Movable Fairing for Access
TASK 57-55-11-410-001-A	To Lift the Flap Track No. 2 Movable Fairing after Access
TASK 12-22-00-00	LUBRICATION - DESCRIPTION AND OPERATION
Alignment of the Outboard Cruise-Roller of the Inboard Flap. ** ON A/C NOT FOR ALL
Flap to Flap Carriage Connection (Track 1) ** ON A/C NOT FOR ALL
Flap to Flap Carriage Connection (Track 1) ** ON A/C NOT FOR ALL
Interconnecting Strut - Location and Detail ** ON A/C NOT FOR ALL
Flap Installation Tool ** ON A/C NOT FOR ALL
Flap to Flap Carriage Connection (Track 2) ** ON A/C NOT FOR ALL
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 Drive Trunnion - Detail ** ON A/C NOT FOR ALL
Flap Drive Trunnion - Detail ** ON A/C NOT FOR ALL
Details of the Wing to Fuselage Panels

3. Job Set-up
Subtask 27-54-61-941-060-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Make sure that the SAFETY BARRIER(S) are in position.
(2) On panel 400VU, make sure that the WARNING NOTICE(S) is(are) in position to tell persons not to operate the landing gear.
(3) In the cockpit, make sure that the WARNING NOTICE(S) is(are) in position to tell persons not to operate the flight controls.

Subtask 27-54-61-865-051-A ** ON A/C NOT FOR ALL

B. 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
** 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 27-54-61-860-058-A ** ON A/C NOT FOR ALL

C. 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 position 3 (Ref. AMM TASK 27-50-00-866-011).
(2) Make sure that the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT is on the applicable torque shaft.
(3) 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.
(4) Make sure that the ACCESS PLATFORM 3M (10 FT) is in position below the applicable inboard flap.
(5) Make sure that spoiler 1 is fully extended (Ref. AMM TASK 27-60-00-866-002).
(6) Make sure that the applicable wing to fuselage panels are removed (Ref. AMM TASK 53-35-11-000-001):
(a) For the left wing, remove 193AB, 193BB.
(b) For the right wing, remove 194AB, 194BB.
(7) Make sure that the pylon aft movable fairing are removed (Ref. AMM TASK 54-55-00-000-001).
(8) Make sure that the flap track No 2 movable fairing are removed (Ref. AMM TASK 57-55-11-010-001).
(9) Make sure that the flap kink seals are removed (Ref. AMM TASK 27-54-61-000-002).
(10) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is on the slat/flap control lever.

Subtask 27-54-61-860-058-C ** ON A/C NOT FOR ALL

C. 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.

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.
(4) Make sure that the ACCESS PLATFORM 3M (10 FT) is in position below the applicable inboard flap.
(5) Make sure that spoiler 1 is fully extended (Ref. AMM TASK 27-60-00-866-002).
(6) Make sure that the applicable wing to fuselage panels are removed (Ref. AMM TASK 53-35-11-000-001):
(a) For the left wing, remove 193AB, 193BB.
(b) For the right wing, remove 194AB, 194BB.
(7) Make sure that the rear pylon fairing is removed (Ref. AMM TASK 54-54-00-000-802).
(8) Make sure that the flap track No. 2 movable fairing are removed (Ref. AMM TASK 57-55-11-010-001).
(9) Make sure that the flap kink seals are removed (Ref. AMM TASK 27-54-61-000-002).
(10) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is on the slat/flap control lever.

4. Procedure
Subtask 27-54-61-420-056-C ** ON A/C NOT FOR ALL

A. Install the Inboard Flap
(1) If necessary, install the hoisting sling (Ref. AMM TASK 27-50-00-400-002).

Alignment of the Outboard Cruise-Roller of the Inboard Flap. ** ON A/C NOT FOR ALL

(2) Make sure that the flap cruise roller (126), at the outboard end of the flap, is set to the minimum position.
(3) If necessary, remove the nut (123), collar (122) and serrated plate (124).
(4) Turn the eccentric (125) until the minimum alignment marks are aligned.
(5) Install the serrated plate (124), collar (122) and nut (123). Tighten the nut (123) by hand.
(6) Make sure that the flap is set to its lowest position. At this position:

The painted (red) marks of the spherical bearing are aligned, and/or
The hole of the spherical bearing is at its maximum aft position.

(7) If necessary, repair the painted (red) marks as follows:.

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

(a) Use a Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) to clean the surfaces on which you will make marks.
(b) Identify the related surface(s) with a torque seal Varnish Polyurethane-- Marking Structure (Material No.04SAB2) .
(c) Let it dry.
(d) Apply a thin layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to protect the marked area.
(8) Use TAPE - ADHESIVE to keep the eccentric disc (114) in position on the inboard flap drive trunnion.

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

(9) Make sure that the interconnecting strut (10) is safetied to the outboard flap with adhesive tape.
(10) With the hoist and the hoisting sling, carefully lift the flap and put it in position over the wing:

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

(a) Lower the flap with the hoist and engage the flap drive trunnion in the flap track carriage at the track 1 position.
(b) Lower the outboard end of the flap and engage the flap in the flap track carriage at the track 2 position.
(11) If necessary, use a clean Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) to clean the eccentric disc (114) and to remove the remaining adhesive tape.

Subtask 27-54-61-480-051-D ** ON A/C NOT FOR ALL

B. Installation of the Support Equipment

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

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

(1) Install the 98D27504084000 EXTRACTOR - PIN, TRACK 4 on the bolt (181).
(2) 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 installation of the bolt (181) through the flap carriage.

Subtask 27-54-61-420-051-F ** ON A/C NOT FOR ALL

C. Continue with the Installation Procedure
(1) At the track 1 position:

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

(a) Install the eccentric bush (107) on the flap drive-trunnion. If necessary, carefully move the flap with the hoist and the sling to let you install the eccentric bush (107).
(b) Axis align the anti-rotation spigot of the eccentric bush (107) with the hole in the outer diameter of the eccentric disc (114).
(c) Temporarily install the toothplate (108) and the locknut (110).
(d) Make sure that the eccentric bush (107) shows the zero datum position.
(2) At the track 2 position:

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

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

CAUTION: MAKE SURE THAT THE SPLINED BUSH IS FULLY ENGAGED WITH THE SPHERICAL BEARING. THIS PREVENTS DAMAGE TO THE PARTS.

(a) Apply a thin layer of Synthetic Oil base Grease-General Purpose Clay Thickened - (Material No.03GBB1) or Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. - (Material No.03GBC1) to the bolt (181) and the splined bush (180).

NOTE: For the lubricant grease specification and lubrication requirements, refer to (Ref. AMM D/O 12-22-00-00).

(b) Installation of 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 Use the 98D27504084000 EXTRACTOR - PIN, TRACK 4 to install the carriage bolt (181) in the flap track carriage.
(c) Install the splined bush (180) correctly over the bolt (181).
(d) Remove the 98D27504084000 EXTRACTOR - PIN, TRACK 4 from the bolt (181).
(e) Temporarily install the locking plate (179) and the nut (174) hand tight only.
(f) Make sure that the failsafe hook nuts (184) are hand tight only.
(3) Hold the trailing edge of the flap and lower the hoisting sling sufficiently to let the flap move forward.
(4) Manually push the flap forward until the flap drive arms engage with the rotary actuator drive-levers.

Subtask 27-54-61-420-054-C ** ON A/C NOT FOR ALL

D. Connect the Flap Drive Arms to the Rotary Actuator Drive-Levers

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

(1) At the track 1 position:
(a) Connect the flap drive arm to the rotary actuator drive-lever as follows:
1 Install the bushes (85) on the rotary actuator drive-lever.
2 Put and hold the packers (84) in position on the rotary actuator drive-lever.
3 Put the rotary actuator drive-lever in position on the flap drive arm.
4 Install the shear bolt (80), with the bolt head inboard.
5 Install the washer (81) and the nut (83).
(2) At the track 2 position:
(a) Connect the flap drive arm to the rotary actuator drive-lever as follows:
1 Put the rotary actuator drive-lever in position on the flap drive arm.
2 Install the bolt (86), washer (87) and nut (88).

Subtask 27-54-61-420-054-E ** ON A/C NOT FOR ALL

D. Connect the Flap Drive Arms to the Rotary Actuator Drive-Levers

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

(1) At the track 1 position:
(a) Connect the flap drive arm to the rotary actuator drive-lever as follows:
1 Put the rotary actuator drive-lever in position on the flap drive arm.
2 Install the bolt (79), washer (78) and nut (76).
(2) At the track 2 position:
(a) Connect the flap drive arm to the rotary actuator drive-lever as follows:
1 Put the rotary actuator drive-lever in position on the flap drive arm.
2 Install the bolt (80), washer (81) and nut (82).

Subtask 27-54-61-860-056-A ** ON A/C NOT FOR ALL

E. Aircraft Configuration
(1) Remove the hoisting sling (Ref. AMM TASK 27-50-00-000-002).
(2) Lower the spoilers as follows:
(a) Connect a WRENCH - PNEUMATIC to the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) and slowly move the flaps to the fully retracted position.
(b) Lower the spoilers (Ref. AMM TASK 27-60-00-866-002).

NOTE: You can put the spoiler on the upper surface of the flap.

(c) On the servo control, make sure that the pointer on the hexagon head is opposite the letter 'O' (Operation) on the housing.

Subtask 27-54-61-820-051-B ** ON A/C NOT FOR ALL

F. Check and Adjustment of the Inboard Flap Rigged Position
(1) Before you do the rigging procedure, make sure that:

The aircraft weight is on the landing gear or on jacks.
The two engines 1 and 2 are installed or not installed.
The fuel load is symmetrical or the wing tanks are empty.
The flaps are fully retracted (Ref. AMM TASK 27-50-00-866-012).

(2) Install the sharks fin flap rigging kit and do a check of the inboard flap rigged position (Ref. AMM TASK 27-51-00-820-003).
(3) If necessary, adjust the inboard flap rigged position (Ref. AMM TASK 27-51-00-820-008).

NOTE: It is only necessary to do the adjustment of the inboard flap.

Subtask 27-54-61-420-052-C ** ON A/C NOT FOR ALL

G. Continue to Connect the Flap Drive Arms
(1) At the track 1 position:

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

(a) Safety the flap drive arm to the rotary actuator drive-lever as follows:
1 Make sure that the bushes (85), packers (84), shear bolt (80), washer (81) and nut (83) are correctly installed.
2 TORQUE the nut (83) to between 1.8 and 1.6 m.daN (13.27 and 11.80 lbf.ft )

.
3 Safety the nut (83) with a new AIPC 27-54-05-33-035 COTTER PIN (82).
4 Install the indicator pin (79), indicator plate (78), washers (77) and bolts (76).
5 TORQUE the bolts (76) to between 0.17 and 0.15 m.daN (15.04 and 13.27 lbf.in )

.
6 Safety the bolts (76):

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.

a Safety the bolts (76) together with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
(2) At the track 2 position:
(a) Safety the flap drive arm to the rotary actuator drive-lever as follows:
1 Make sure that the bolt (86), washer (87) and nut (88) are correctly installed.
2 TORQUE the nut (88) to between 1.8 and 1.2 m.daN (159.29 and 106.19 lbf.in )

.
3 Safety the nut (88) with a new AIPC 27-54-05-33-025 COTTER PIN (89).

Subtask 27-54-61-420-052-F ** ON A/C NOT FOR ALL

G. Continue to Connect the Flap Drive Arms
(1) At the track 1 position:

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

(a) Safety the flap drive arm to the rotary actuator drive-lever as follows:
1 Make sure that bolt (79), washer (78) and nut (76) are correctly installed.
2 TORQUE the nut (76) to between 1.8 and 1.2 m.daN (159.29 and 106.19 lbf.in )

.
3 Safety the nut (76) with a new AIPC 27-54-05-33-150 COTTER PIN (77).
(2) At the track 2 position:
(a) Safety the flap drive arm to the rotary actuator drive-lever as follows:
1 Make sure that the bolt (80), washer (81) and nut (82) are correctly installed.
2 TORQUE the nut (82) to between 1.8 and 1.2 m.daN (159.29 and 106.19 lbf.in )

.
3 Safety the nut (82) with a new AIPC 27-54-05-33-030 COTTER PIN (83).

Subtask 27-54-61-420-052-G ** ON A/C NOT FOR ALL

G. Continue to Connect the Flap Drive Arms
(1) At the track 1 position:

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

(a) Safety the flap drive arm to the rotary actuator drive-lever as follows:
1 Make sure that the bolt (79), washer (78) and nut (76) are correctly installed.
2 TORQUE the nut (76) to between 1.8 and 1.2 m.daN (159.29 and 106.19 lbf.in )

.
3 Safety the nut (76) with a new AIPC 27-54-05-33-150 COTTER PIN (77) or AIPC 27-54-85-32-050 COTTER PIN (77).
(2) At the track 2 position:
(a) Safety the flap drive arm to the rotary actuator drive-lever as follows:
1 Make sure that the bolt (80), washer (81) and nut (82) are correctly installed.
2 TORQUE the nut (82) to between 2.3 and 1.8 m.daN (16.96 and 13.27 lbf.ft )

.
3 Safety the nut (82) with a new AIPC 27-54-05-33-030 COTTER PIN (83) or AIPC 27-54-85-32-110 COTTER PIN (83).

Subtask 27-54-61-420-073-D ** ON A/C NOT FOR ALL

H. Safety the Inboard Flap Connections

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

(1) At the track 2 position:
(a) Make sure that the failsafe hook nuts (184) are hand tight only.
(b) Remove the nut (174).
(c) Make sure that the spherical bearing, splined bush (180) and locking plate (179) are engaged correctly.
(d) Install a new AIPC 27-54-46-04-080 CRUSHABLE SPACER (176) and the nut (174).
(e) TORQUE the nut (174) to between 20 and 15 m.daN (147.49 and 110.62 lbf.ft )

.
(f) Safety the nut (174) with a new AIPC 27-54-46-04-035 COTTER PIN (175).
(g) Install the washer (178) and the nut (177).

Subtask 27-54-61-220-055-C ** ON A/C NOT FOR ALL

I. Do a Check of the Flap Rigged Position
(1) Make sure that the inboard flap remains in the correct rigged position (Ref. AMM TASK 27-51-00-820-003).

Subtask 27-54-61-420-074-D ** ON A/C NOT FOR ALL

J. Continue to Safety the Inboard Flap Connections

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

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

(1) At the track 1 position:
(a) TORQUE the locknut (110) using the 98D27504035000 TORQUE ADAPTER-TRUNNION NUT to between 7.0 and 5.4 m.daN (51.62 and 39.82 lbf.ft )

.
(b) Lock the locknut (110) with the AIPC 57-52-21-02-310 LOCKWASHER (109).
(c) Apply a layer of Silicone Adhesive Sealant-General Purpose One part legacy (Material No.06CMD9) to the retainer (113).
(d) Install the retainer (113), AIPC 57-52-21-02-280 TABWASHER (112) and bolt (111).
(e) TORQUE the bolt (111) to between 1.5 and 1.0 m.daN (132.74 and 88.50 lbf.in )

and safety with the tabwasher (112).
(2) At the track 2 position:
(a) TORQUE the nuts (184) to between 0.12 and 0.05 m.daN (10.62 and 4.42 lbf.in )

.
(b) Safety the nuts (184):

1 Safety the nuts (184) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.

Subtask 27-54-61-420-074-G ** ON A/C NOT FOR ALL

J. Continue to Safety the Inboard Flap Connections
(1) At the track 1 position:

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

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

(a) Use the 98D27504035000 TORQUE ADAPTER-TRUNNION NUT to TORQUE the locknut (110) to between 7.0 and 5.4 m.daN (51.62 and 39.82 lbf.ft )

.
(b) Lock the locknut (110) with the new AIPC 57-52-21-02-310 LOCKWASHER (109).
(c) Install the washer (120) and the screw (121).
(d) Tighten the screw (121).
(e) Apply a layer of Silicone Adhesive Sealant-General Purpose One part legacy (Material No.06CMD9) to the retainer (113).
(f) Install the retainer (113), new AIPC 57-52-21-02-280 TABWASHER (112) and bolt (111).
(g) TORQUE the bolt (111) to between 1.5 and 1.0 m.daN (132.74 and 88.50 lbf.in )

and safety with the new tabwasher (112).
(2) At the track 2 position:

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

(a) TORQUE the nuts (184) to between 0.12 and 0.05 m.daN (10.62 and 4.42 lbf.in )

.
(b) Safety the nuts (184):

1 Safety the nuts (184) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.

Subtask 27-54-61-820-068-A

DELETED

Subtask 27-54-61-220-051-D ** ON A/C NOT FOR ALL

L. Alignment of the Outboard Cruise Roller of the Inboard Flap

Alignment of the Outboard Cruise-Roller of the Inboard Flap. ** ON A/C NOT FOR ALL

(1) Measure dimension Y. This must be 6.0 mm (0.24 in.) minus dimension X, plus or minus 0.5 mm (0.02 in.). If dimension Y is not correct you must adjust the cruise roller (126).
(2) To adjust the cruise roller (126):
(a) Remove the nut (123), collar (122) and serrated plate (124).
(b) Turn the eccentric (125) until dimension Y is correct.
(c) Lock the eccentric (125) with the serrated plate (124).
(d) Install the collar (122) and the nut (123).
(e) TORQUE the nut (123) to between 27 and 24 m.N (19.91 and 17.70 lbf.ft )

.
(3) Measure dimension Y again.
(4) Measure and record the clearance between the bottom surface of the shroud box and the flap upper surface (measured at the outboard end of the shroud box). This must be between 5 mm (0.20 in.) and 12 mm (0.47 in.).

Subtask 27-54-61-220-051-E ** ON A/C NOT FOR ALL

L. Alignment of the Outboard Cruise Roller of the Inboard Flap

Alignment of the Outboard Cruise-Roller of the Inboard Flap. ** ON A/C NOT FOR ALL

(1) Measure dimension Y. This must be 6.0 mm (0.24 in.) minus dimension X, plus 0.5 mm (0.02 in.) or minus 1.0 mm (0.04 in.):
(a) If dimension Y is not correct, you must adjust the cruise roller (126).
(2) To adjust the cruise roller (126):
(a) Remove the nut (123), the collar (122) and the serrated plate (124).
(b) Turn the eccentric (125) until dimension Y is correct.
(c) Lock the eccentric (125) with the serrated plate (124).
(d) Install the collar (122) and the nut (123).
(e) TORQUE the nut (123) to between 27 and 24 m.N (19.91 and 17.70 lbf.ft )

Subtask 27-54-61-916-052-F ** ON A/C NOT FOR ALL

M. Application of Special Materials

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

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

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

Alignment of the Outboard Cruise-Roller of the Inboard Flap. ** ON A/C NOT FOR ALL

(1) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to:

The bolt (111)
The nut (174), cotter pin (175), nut (177), washer (178) and bolt (181)
The bolts (76), washers (77), shear bolt (80), washer (81), nut (83) and cotter pin (82)
The bolt (86), washer (87), nut (88) and cotter pin (89)
The nut (123).

Subtask 27-54-61-916-052-G ** ON A/C NOT FOR ALL

M. Application of Special Materials

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

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

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

Alignment of the Outboard Cruise-Roller of the Inboard Flap. ** ON A/C NOT FOR ALL

(1) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to:

The bolt (111)
The nut (174), cotter pin (175), nut (177), washer (178) and bolt (181)
The bolt (79), washer (78), nut (76) and cotter pin (77)
The bolt (80), washer (81), nut (82) and cotter pin (83)
The nut (123).

Subtask 27-54-61-420-053-B ** ON A/C NOT FOR ALL

CAUTION: MAKE SURE THAT THE BONDING LEAD DOES NOT TOUCH THE STRUT BRACKET AND IS NOT TWISTED DURING INSTALLATION. THIS WILL HELP PREVENT DAMAGE TO THE BONDING LEAD AND AIRCRAFT STRUCTURE.

N. Installation of the Bonding Straps

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

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

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

(1) Attach the bonding strap (115) from the flap carriage at track 1 to the flap drive trunnion with the bolt (116), the washer (117) and the nut (118) (Ref. AMM TASK 20-28-00-912-802).
(2) Attach the bonding strap from the flap carriage at track 2 to the flap bracket with the bolt (182) and the nut (183) (Ref. AMM TASK 20-28-00-912-802).
(3) Attach the bonding strap (74) between the inboard flap and the outboard flap with the bolt (75) and the nut (73) (Ref. AMM TASK 20-28-00-912-802).
(4) Attach the bonding strap (71) with the bolt (72) and the nut (70) (Ref. AMM TASK 20-28-00-912-802).

Subtask 27-54-61-420-053-D ** ON A/C NOT FOR ALL

CAUTION: MAKE SURE THAT THE BONDING LEAD DOES NOT TOUCH THE STRUT BRACKET AND IS NOT TWISTED DURING INSTALLATION. THIS WILL HELP PREVENT DAMAGE TO THE BONDING LEAD AND AIRCRAFT STRUCTURE.

N. Installation of the Bonding Straps

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

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

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

(1) Attach the bonding strap from the flap carriage at track 2 to the flap bracket with the bolt (182) and the nut (183) (Ref. AMM TASK 20-28-00-912-802).
(2) Attach the bonding strap (74) between the inboard flap and the outboard flap with the bolt (75) and the nut (73) (Ref. AMM TASK 20-28-00-912-802).
(3) Attach the bonding strap (71) with the bolt (72) and the nut (70) (Ref. AMM TASK 20-28-00-912-802).

Subtask 27-54-61-220-075-A ** ON A/C NOT FOR ALL

O. Measure the Spoiler to Inboard Flap Clearance
(1) Do a check of the clearance between the spoiler 1 trailing edge and the top surface of the inboard flap (Ref. AMM TASK 27-64-00-820-001).

Subtask 27-54-61-860-057-A ** ON A/C NOT FOR ALL

P. Aircraft Configuration
(1) Install the interconnecting strut (Ref. AMM TASK 27-51-44-400-001).
(2) Connect the electrical connectors:

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

(a) Remove the CAP-BLANKING from each electrical connector and receptacle.
(b) Make sure that all the electrical connections are clean and in the correct condition.
(c) Connect the electrical connectors (21) and (22).
(3) Remove the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT which is installed on the applicable torque shaft (Ref. AMM TASK 27-50-00-000-003).
(4) Manually retract the flaps (Ref. AMM TASK 27-50-00-866-012).
(5) Remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION.
(6) Extend the flaps to position 1 (Ref. AMM TASK 27-50-00-866-008).
(7) Install the flap kink seals (Ref. AMM TASK 27-54-61-400-006).

Subtask 27-54-61-410-051-D ** ON A/C NOT FOR ALL

Q. Close Access

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

(1) Make sure that the work area is clean and clear of tools and other items.
(2) Lift the flap track No 2 movable fairing (Ref. AMM TASK 57-55-11-410-001).
(3) Install the pylon aft moveable fairing (Ref. AMM TASK 54-55-00-400-001).
(4) Install the fairing panels (Ref. AMM TASK 53-35-11-400-001):
(a) For the left wing, install 193AB, 193BB.
(b) For the right wing, install 194AB, 194BB.
(5) Extend the flaps sufficiently to install the rubbing strip (2) (Ref. AMM TASK 27-50-00-866-008).
(6) Install the rubbing strip (2) and the support (1).

Subtask 27-54-61-410-051-G ** ON A/C NOT FOR ALL

Q. Close Access

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

(1) Make sure that the work area is clean and clear of tools and other items.
(2) Lift the flap track No. 2 movable fairing (Ref. AMM TASK 57-55-11-410-001).
(3) Install the rear pylon fairing (Ref. AMM TASK 54-54-00-400-802).
(4) Install the fairing panels (Ref. AMM TASK 53-35-11-400-001):
(a) For the left wing, install 193AB, 193BB.
(b) For the right wing, install 194AB, 194BB.
(5) Extend the flaps sufficiently to install the rubbing strip (2) (Ref. AMM TASK 27-50-00-866-008).
(6) Install the rubbing strip (2) and the support (1).

Subtask 27-54-61-866-058-A ** ON A/C NOT FOR ALL

R. Retract the Flaps
(1) Retract the flaps fully (Ref. AMM TASK 27-50-00-866-009).
(2) Put the 98D27803500001 LOCKING TOOL ZERO POS or 98D27803500002 LOCKING TOOL ZERO POS on the flap/slat control lever on panel 114VU.

Subtask 27-54-61-820-055-D ** ON A/C NOT FOR ALL

S. Adjust the Wing to Fuselage Panels

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

(1) At area X, make sure that the upper seal touches the belly fairing.
(2) At areas U and U1:
(a) If possible, adjust the lower seals until they touch the belly fairing.
1 If you cannot adjust the lower seals until they touch the belly fairing, make sure that:

The clearance between the lower seals and the belly fairing is a maximum of 4 mm (0.1575 in.).

(3) If, at area X, the upper seal does not touch the belly fairing:

Loosen the screws (5) and move the upper seal until it touches the belly fairing.

(4) If, at areas U and U1, the lower seals are in incorrect position, do the steps that follow:
(a) At area U:

Loosen the screws (5) and move the lower seal until it is in correct position.

(b) At area U1:

Loosen the screws (4) and move the lower seal until it is in correct position.

(5) TORQUE the applicable screws (4) and/or (5) to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )

.
(6) Remove the access platform(s).

Subtask 27-54-61-865-060-A ** ON A/C NOT FOR ALL

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

Subtask 27-54-61-710-050-A ** ON A/C NOT FOR ALL

U. Test
(1) Do an operational test of the flap system (Ref. AMM TASK 27-54-00-710-001).
(2) Do an operational test of the spoiler system (Ref. AMM TASK 27-64-00-710-001).

5. Close-up
Subtask 27-54-61-942-051-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Make sure that the work area is clean and clear of tools and other items.
(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] 2026.04.01 06:57:44 UTC