Installation of the Flap Kink-Seals and Cushion-Seals

TASK 27-54-61-400-006-A
Installation of the Flap Kink-Seals and Cushion-Seals

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.

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.

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	SAFETY BARRIER(S)
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 4.5 and 4 m.N (39.82 and 35.40 lbf.in )
No specific	Torque wrench: range to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )
98D27504009000	1	ADJUSTER-KINK SEAL (UPPER FWD WY5396)
98D27504010000	1	ADJUSTER-KINK SEAL (UPPER AFT WY5658)
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.06AAA1)	Polysulfide Sealant_General Purpose Brushable -
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
580	LEFT WING FLAPS AND SPOILERS
680	RIGHT WING FLAPS AND SPOILERS

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
21	UPPER KINK-SEAL	AIPC 57-52-21-15-110
21	UPPER KINK-SEAL	AIPC 57-52-21-15-120
20	SEAL RETAINER	AIPC 57-52-21-15-220
20	SEAL RETAINER	AIPC 57-52-21-15-230
24	CUSHION-SEAL	AIPC 57-52-21-15-250
24	CUSHION-SEAL	AIPC 57-52-21-15-260
7	RH LOWER KINK-SEAL	AIPC 57-52-21-15-270
70	RH LOWER KINK-SEAL	AIPC 57-52-21-15-270
20	LH SEAL RETAINER	AIPC 57-52-23-03-050
20	RH SEAL RETAINER	AIPC 57-52-23-03-060
7	LOWER KINK-SEAL	AIPC 57-52-23-03-070
23	LH CUSHION-SEAL	AIPC 57-52-23-03-080
23	RH CUSHION-SEAL	AIPC 57-52-23-03-090
21	LH UPPER KINK-SEAL	AIPC 57-52-23-03-100
21	RH UPPER KINK-SEAL	AIPC 57-52-23-03-110
2	LH CLAMPING STRIP	AIPC 57-53-21-05-020
2	RH CLAMPING STRIP	AIPC 57-53-21-05-030
3	LH UPPER KINK-SEAL	AIPC 57-53-21-05-040
3	RH UPPER KINK-SEAL	AIPC 57-53-21-05-050
5	CUSHION-SEAL	AIPC 57-53-21-05-160
5	CUSHION-SEAL	AIPC 57-53-21-05-170
5	LH CUSHION-SEAL	AIPC 57-53-23-02-110
5	RH CUSHION-SEAL	AIPC 57-53-23-02-120
2	LH PRESSURE PLATE	AIPC 57-53-23-02-130
2	RH PRESSURE PLATE	AIPC 57-53-23-02-140
3	LH UPPER KINK-SEAL	AIPC 57-53-23-02-150
3	RH UPPER KINK-SEAL	AIPC 57-53-23-02-160
2	CLAMPING STRIP	AIPC 57-53-85-05-030
2	CLAMPING STRIP	AIPC 57-53-85-05-040
3	UPPER KINK-SEAL	AIPC 57-53-85-05-050
3	UPPER KINK-SEAL	AIPC 57-53-85-05-060
5	CUSHION-SEAL	AIPC 57-53-85-05-170
5	CUSHION-SEAL	AIPC 57-53-85-05-180

E. Referenced Information

REFERENCE	DESIGNATION
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
SRM 575300	(for corrective action)
Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL
Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL
Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL
Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL
Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL
Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL
Kink Upper-Seal Installation Tool. ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 27-54-61-941-061-A

A. Safety Precautions
(1) Make sure that the SAFETY BARRIER(S) are in position.
(2) Make sure that the WARNING NOTICE(S) is in position to tell persons not to operate the flight controls.

Subtask 27-54-61-860-050-A

B. Aircraft Maintenance Configuration
(1) Make sure that the flaps are at position 1 (Ref. AMM TASK 27-50-00-866-008) (Ref. AMM TASK 27-50-00-866-009).
(2) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is installed on the slat/flap control lever.
(3) Make sure that the ACCESS PLATFORM 3M (10 FT) is installed below the applicable flap kink-seal and cushion-seal.

4. Procedure
Subtask 27-54-61-420-087-A

A. Preparation for Installation
(1) Clean the component interface and/or the adjacent area with a Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
(2) Make sure that the parts retained from the removed component are clean and in the correct condition.
(3) Do an inspection of the component interfaces and the adjacent area.

Subtask 27-54-61-420-069-B ** ON A/C NOT FOR ALL

B. Installation of the Flap Kink-Seals and Cushion-Seals

Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL

Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL

(1) If a structural repair has been done, refer to SRM 575300 for the installation of the flap kink-seals.
(2) Attach the AIPC 57-52-23-03-080 LH CUSHION-SEAL (23) ( AIPC 57-52-23-03-090 RH CUSHION-SEAL (23)) to the inboard flap with the screw (22).
(3) TORQUE the screw (22) to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )

.
(4) Attach the AIPC 57-53-23-02-110 LH CUSHION-SEAL (5) ( AIPC 57-53-23-02-120 RH CUSHION-SEAL (5)) to the outboard flap with the screws (4) and the screw (6).
(5) TORQUE the screws (4) and (6) to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )

Subtask 27-54-61-420-070-B ** ON A/C NOT FOR ALL

C. Installation of the Upper Kink-Seals

Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL

Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL

(1) Install the AIPC 57-52-23-03-100 LH UPPER KINK-SEAL (21) ( AIPC 57-52-23-03-110 RH UPPER KINK-SEAL (21)), the AIPC 57-52-23-03-050 LH SEAL RETAINER (20) ( AIPC 57-52-23-03-060 RH SEAL RETAINER (20)) and the screws (19) on the inboard flap. Do not tighten the screws (19).
(2) Install the AIPC 57-53-23-02-150 LH UPPER KINK-SEAL (3) ( AIPC 57-53-23-02-160 RH UPPER KINK-SEAL (3)), the AIPC 57-53-23-02-130 LH PRESSURE PLATE (2) ( AIPC 57-53-23-02-140 RH PRESSURE PLATE (2)) and the screws (1) on the outboard flap. Do not tighten the screws (1).
(3) Set the seals and the clamping strips equally between the inboard flap and the outboard flap.
(4) TORQUE the screws (1) and (19) to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )

Subtask 27-54-61-420-069-D ** ON A/C NOT FOR ALL

D. Installation of the Cushion-Seals

Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL

Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL

(1) If a structural repair was done, refer to SRM 575300 for the installation of the flap kink-seals.
(2) If necessary, drill the holes through the cushion-seal (24) that follow:

For the left hand side, the AIPC 57-52-21-15-250 CUSHION-SEAL (24)
For the right hand side, the AIPC 57-52-21-15-260 CUSHION-SEAL (24).

(a) Put the cushion-seal (24) in position and make marks for related holes of the screws (22) and (23).
(b) Remove the cushion-seal (24).
(c) Drill the holes with a diameter of 5.5 mm (0.2165 in.) and deburr the holes.
(3) Attach the cushion-seal (24) to the applicable inboard flap with the screws (22) and (23).
(4) TORQUE the screws (22) and (23) to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )

.
(5) If necessary, drill the holes through the cushion-seal (5) that follow:

For the left hand side, the AIPC 57-53-85-05-170 CUSHION-SEAL (5) or the AIPC 57-53-21-05-160 CUSHION-SEAL (5)
For the right hand side, the AIPC 57-53-85-05-180 CUSHION-SEAL (5) or the AIPC 57-53-21-05-170 CUSHION-SEAL (5).

(a) Put the cushion-seal (5) in position and make marks for related holes of the screws (4) and (6).
(b) Remove the cushion-seal (5).
(c) Drill the holes with a diameter of 5.5 mm (0.2165 in.) and deburr the holes.
(6) Attach the cushion-seal (5) to the applicable outboard flap with the screws (4) and (6).
(7) TORQUE the screws (4) and (6) to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )

Subtask 27-54-61-420-070-D ** ON A/C NOT FOR ALL

E. Installation of the Upper Kink-Seals

Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL

Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL

(1) On the applicable inboard flap, install the items that follow:
(a) For the left hand side:

Install the AIPC 57-52-21-15-110 UPPER KINK-SEAL (21), the AIPC 57-52-21-15-220 SEAL RETAINER (20) and the screws (19). Do not tighten the screws (19).

(b) For the right hand side:

Install the AIPC 57-52-21-15-120 UPPER KINK-SEAL (21), the AIPC 57-52-21-15-230 SEAL RETAINER (20) and the screws (19). Do not tighten the screws (19).

(2) On the applicable outboard flap, install the items that follow:
(a) For the left hand side:

Install the AIPC 57-53-85-05-050 UPPER KINK-SEAL (3) or the AIPC 57-53-21-05-040 LH UPPER KINK-SEAL (3), the AIPC 57-53-85-05-030 CLAMPING STRIP (2) or the AIPC 57-53-21-05-020 LH CLAMPING STRIP (2) and the screws (1). Do not tighten the screws (1).

(b) On the right hand side:

Install the AIPC 57-53-85-05-060 UPPER KINK-SEAL (3) or the AIPC 57-53-21-05-050 RH UPPER KINK-SEAL (3), the AIPC 57-53-85-05-040 CLAMPING STRIP (2) or the AIPC 57-53-21-05-030 RH CLAMPING STRIP (2) and the screws (1). Do not tighten the screws (1).
Kink Upper-Seal Installation Tool. ** ON A/C NOT FOR ALL

(3) Install the 98D27504009000 ADJUSTER-KINK SEAL (UPPER FWD WY5396) on the flap seals at position WY5396.
(4) Install the 98D27504010000 ADJUSTER-KINK SEAL (UPPER AFT WY5658) on the flap seals at position WY5658.
(5) Tighten the star-knob on the 98D27504009000 ADJUSTER-KINK SEAL (UPPER FWD WY5396) and the 98D27504010000 ADJUSTER-KINK SEAL (UPPER AFT WY5658) at the same time until they cannot move. This will compress the seals together.
(6) Set the seals and the clamping strips equally between the inboard flap and the outboard flap.
(7) TORQUE the screws (1) and (19) to between 0.45 and 0.4 m.daN (39.82 and 35.40 lbf.in )

.
(8) Remove the 98D27504009000 ADJUSTER-KINK SEAL (UPPER FWD WY5396) and the 98D27504010000 ADJUSTER-KINK SEAL (UPPER AFT WY5658) from the flap seals.

Subtask 27-54-61-420-071-A ** ON A/C NOT FOR ALL

F. Installation of the Lower Kink Seal

Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL

Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL

(1) Fully retract the flaps on the ground (Ref. AMM TASK 27-50-00-866-009).
(2) Attach the AIPC 57-52-21-15-270 RH LOWER KINK-SEAL (7) to the inboard flap with the screws (25).
(3) Fully extend the flaps on the ground (Ref. AMM TASK 27-50-00-866-008).
(4) Attach the AIPC 57-52-21-15-270 RH LOWER KINK-SEAL (7) to the outboard flap at the forward five holes with the screws (8).
(5) Retract the flaps on the ground to position 1 or 2 to get access to the aft outboard-seal attachment-holes (Ref. AMM TASK 27-50-00-866-009).
(6) Install the remaining six screws (9).
(7) TORQUE the screws (8), (9) and (25) to between 4.5 and 4 m.N (39.82 and 35.40 lbf.in )

Subtask 27-54-61-420-071-B ** ON A/C NOT FOR ALL

F. Installation of the Lower Kink Seal

Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL

Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL

(1) Fully retract the flaps on the ground (Ref. AMM TASK 27-50-00-866-009).
(2) Attach the AIPC 57-52-23-03-070 LOWER KINK-SEAL (7) to the inboard flap with the screws (8).
(3) Fully extend the flaps on the ground (Ref. AMM TASK 27-50-00-866-008).
(4) Attach the AIPC 57-52-23-03-070 LOWER KINK-SEAL (7) to the outboard flap at the forward five holes with the screws (8).
(5) Retract the flaps on the ground to position 1 or 2 to get access to the aft outboard-seal attachment-holes (Ref. AMM TASK 27-50-00-866-009).
(6) Install the remaining screws (8).

NOTE: There is one hole of the lower kink seal (at the outboard flap interface) where you cannot install a screw. The cause for this is the modification of the outboard flap to increase the clearance to the interconnecting strut. You can seal or tape this hole or you can bond a plug or an applicable solid rivet.
You can also let the hole open: This open hole has no impact for damages or aerodynamic.

(a) If you will close the hole (30):

Seal the hole (30) with Polysulfide Sealant_General Purpose Brushable - (Material No.06AAA1) and/or an applicable solid rivet/plug.

(7) TORQUE the screws (8) to between 4.5 and 4 m.N (39.82 and 35.40 lbf.in )

Subtask 27-54-61-420-071-D ** ON A/C NOT FOR ALL

F. Installation of the Lower Kink Seal

Details of the Kink-Seals and Cushion-Seals (Inboard Flap) ** ON A/C NOT FOR ALL

Details of the Kink-Seals and Cushion-Seals (Outboard Flap) ** ON A/C NOT FOR ALL

(1) If you use a new lower kink seal: Prepare the AIPC 57-52-21-15-270 LH LOWER KINK-SEAL (7) or the AIPC 57-52-21-15-270 RH LOWER KINK-SEAL (70) as follows:

NOTE: Item 70 is not shown on the figures because the LH side is only shown.

(a) If there is a fourth hole in the new lower kink seal on the outboard side, seal it. Use Polysulfide Sealant_General Purpose Brushable - (Material No.06AAA1) and/or tape or an applicable solid rivet.
(2) If you use the old lower kink seal: Do a check of the old lower kink seal as follows:
(a) If there is a fourth hole in the lower kink seal on the outboard side, make sure that it is sealed and/or tapped (or sealed with an applicable solid rivet).
(3) Fully retract the flaps (Ref. AMM TASK 27-50-00-866-009).
(4) Attach the lower kink seal to the inboard flap with the screws (25).
(5) Fully extend the flaps (Ref. AMM TASK 27-50-00-866-008).
(6) Attach the lower kink seal to the outboard flap at the five forward holes with the screws (8).
(7) Retract the flaps to position 1 or 2 to get access to the aft outboard-seal attachment-holes (Ref. AMM TASK 27-50-00-866-009).
(8) Install the remaining screws (9).
(9) TORQUE the screws (8), (9) and (25) to between 4.5 and 4 m.N (39.82 and 35.40 lbf.in )

5. Close-up
Subtask 27-54-61-860-051-A

A. Aircraft Configuration
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION from the slat/flap control lever.
(3) Fully retract the flaps (Ref. AMM TASK 27-50-00-866-009).

Subtask 27-54-61-942-058-A

B. Removal of Equipment
(1) Remove the safety barriers.
(2) Remove the WARNING NOTICE(S).
(3) Remove the access platform(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 23:54:43 UTC