Removal of the Outboard Flap

TASK 27-54-62-000-001-A
Removal of the Outboard 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: 575
ZONE: 587
ZONE: 675
ZONE: 687

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	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	TAPE - ADHESIVE
No specific	AR	WARNING NOTICE(S)
No specific	1	WRENCH - PNEUMATIC
98D27504030001	1	LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT
98D27504084000	2	EXTRACTOR - PIN, TRACK 4
98D27604000000	4	COLLAR-SAFETY, SPOILER
98D27604004000	4	COLLAR SAFETY SPOILER
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION
98D27804001000	1	ADAPTOR-DRIVE, SLAT (AND FLAP)

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
575	AFT OUTBD SE OF WING AND TE FIXED STRUCT
587	FLAP N° 2
675	AFT OUTBD SE OF WING AND TE FIXED STRUCT
687	FLAP N° 2
573CB, 575AB, 575BB, 673CB, 675AB, 675BB

C. Referenced Information

REFERENCE	DESIGNATION
TASK 27-00-00-480-002-A	Installation of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
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 27-50-00-866-012-A	Manual Retraction of the Flaps
TASK 27-51-00-820-004-A	Adjustment of the Forward Eccentrics (Tracks 3 and 4)
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 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 57-55-11-000-001-A	Removal of the Flap Track Fairings Nos. 2, 3 and 4
TASK 57-55-11-010-002-A	To Lower the Flap Track No. 3 & No. 4 Movable Fairings for Access
Interconnecting Strut - Location and Detail
Flap to Rotary Actuator Drive-Lever ** ON A/C NOT FOR ALL
Flap to Flap Carriage Connection
Flap Installation Tools
Flap to Rotary Actuator Drive-Lever ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 27-54-62-941-050-A ** ON A/C NOT FOR ALL

A. Safety Precautions

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.

(1) As necessary, use the applicable SAFETY BARRIERS, specified by the operator's instructions and your local regulations.
(2) Put the WARNING NOTICE(S) in position to tell persons not to pressurize the hydraulic system.
(3) Put a WARNING NOTICE(S) in position to tell persons not to operate the flight controls.

Subtask 27-54-62-860-053-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) Make sure that the flaps are fully retracted (Ref. AMM TASK 27-50-00-866-009).
(2) Install the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION on the slat/flap control lever (Ref. AMM TASK 27-00-00-480-002).

Subtask 27-54-62-865-053-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
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 27-54-62-010-050-A ** ON A/C NOT FOR ALL

D. Get Access
(1) Put the ACCESS PLATFORM 3M (10 FT) in position for the applicable zones:

for the left wing, below zones 575 and 587
for the right wing, below zones 675 and 687.

(2) Remove the access panels for the applicable wing:
(a) For the LH 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 RH wing:
1 Remove 673CB (Ref. AMM TASK 57-51-37-000-002).
2 Remove 675AB 675BB (Ref. AMM TASK 57-51-37-000-004).
(3) Do one of the two worksteps that follow:
(a) Lower the flap track No. 3 and No. 4 movable fairings for access (Ref. AMM TASK 57-55-11-010-002).
(b) Remove the flap track No. 3 and No. 4 movable fairings for access (Ref. AMM TASK 57-55-11-000-001).

Subtask 27-54-62-865-067-A ** ON A/C NOT FOR ALL

E. 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
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 27-54-62-860-065-A ** ON A/C NOT FOR ALL

F. 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) Use the WRENCH - PNEUMATIC and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to manually extend the flaps to position 1 (Ref. AMM TASK 27-50-00-866-011).
(2) Remove the flap kink seals (Ref. AMM TASK 27-54-61-000-002).

Subtask 27-54-62-865-068-A ** ON A/C NOT FOR ALL

G. Get access to the avionics compartment and to the bulk cargo compartment. Then 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
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

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 27-54-62-020-059-B ** ON A/C NOT FOR ALL

A. Preparation for Removal of the Outboard Flap

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

(1) Disconnect the interconnecting strut (1):
(a) Remove the electrical connectors (8) and (10) from connectors (7) and (9).
(b) Put the CAP-BLANKING on each disconnected electrical connector and receptacle.
(c) Remove and discard the cotter pin (11).
(d) Remove the nut (6) and washer (5).
(e) Remove the bolt (2), washer (3) and bush (4).
(f) Hold the interconnecting strut (1) to the outboard flap with TAPE - ADHESIVE.

Subtask 27-54-62-860-054-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) Manually fully retract the flaps to the zero position (Ref. AMM TASK 27-50-00-866-012).
(2) Check the value shown on the label at the track 3 position. If the label shows a value different from "0", set the flap forward eccentrics to zero datum position (Ref. AMM TASK 27-51-00-820-004).

NOTE: The label is on the outboard side of the flap track beam.

(3) Manually extend the flaps to position 3 (Ref. AMM TASK 27-50-00-866-011).
(4) Install the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT on the applicable torque shaft (Ref. AMM TASK 27-50-00-400-003).

Subtask 27-54-62-020-051-D ** ON A/C NOT FOR ALL

C. Removal of the Outboard Flap

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

(1) Install the hoisting sling (Ref. AMM TASK 27-50-00-400-002).
(2) Use the hoist to carefully lift the hoisting sling until it holds the weight of the outboard flap.
(3) Fully extend and lock the applicable spoilers 2, 3, 4 and 5 (Ref. AMM TASK 27-60-00-866-002).
(4) Install the 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER on the applicable rod of the servo control of spoilers 2, 3, 4 and 5.
(5) Disconnect the flap drive arms from the rotary actuator drive-levers:

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

(a) Remove the bolts (51) and washers (50), and disconnect the bonding straps (49).
(b) Remove the nut (54), bolt (52) and disconnect the bonding strap (53).
(c) Hold the trailing edge of the outboard flap and remove:

The cotter pins (58)
The nuts (57)
The washers (56)
The bolts (55).

(d) Discard the cotter pins (58).
(e) Carefully move the outboard flap until the flap track carriages touch the end stops.
(6) Disconnect the outboard flap from the flap track carriages:

Flap to Flap Carriage Connection ** ON A/C NOT FOR ALL

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.

(a) Loosen the nuts (144) sufficiently to let the failsafe hook assemblies (145) move.
(b) Remove these items:

The cotter pins (137)
The nuts (136)
The crushable spacers (138)
The nuts (139) and the washers (140)
The locking plates (141)
The splined bushes (142).

(7) Install the 98D27504084000 EXTRACTOR - PIN, TRACK 4 at flap track 3 on the carriage bolt (143).

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

(8) Install the 98D27504084000 EXTRACTOR - PIN, TRACK 4 at flap track 4 on the carriage bolt (143).

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

NOTE: Make sure that you screw the extractor pin fully on the threads of each bolt (143). This will hold the locking ring in position and allow it to be compressed by the bush and the bearing.

(9) Remove the carriage bolts (143).

NOTE: If necessary, carefully lift the flap with the hoist and sling sufficiently to release the weight off the bolts (143).

(10) Discard the cotter pins (137) and crushable spacers (138).
(11) 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) Carefully and slowly lift the outboard flap off the flap track carriages.
(b) Move the outboard flap with the hoist and lower it on the support structure.
(12) Where necessary, put the COVER - PROTECTION on the disconnected items of the flap.

Subtask 27-54-62-020-051-F ** ON A/C NOT FOR ALL

C. Removal of the Outboard Flap

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

(1) Install the hoisting sling (Ref. AMM TASK 27-50-00-400-002).
(2) Use the hoist to carefully lift the hoisting sling until it holds the weight of the outboard flap.
(3) Fully extend and lock applicable spoilers 2, 3, 4 and 5 (Ref. AMM TASK 27-60-00-866-002).
(4) Install the 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER on the applicable rod of the servo control of the spoilers 2, 3, 4 and 5.
(5) Disconnect the flap drive arms from the rotary actuator drive-levers:

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

(a) Remove the bolts (51), the washers (50) and disconnect the bonding straps (49).
(b) Remove the nut (54), the bolt (52) and disconnect the bonding strap (53).
(c) Hold the trailing edge of the outboard flap and remove the nuts (57), the washers (56) and the bolts (55).
(d) Carefully move the outboard flap until the flap track carriages touch the end stops.
(6) Disconnect the outboard flap from the flap track carriages:

Flap to Flap Carriage Connection ** ON A/C NOT FOR ALL

(a) Loosen the nuts (144) sufficiently to let the failsafe hook assemblies (145) to move.
(b) Remove these items:

The cotter pins (137)
The nuts (136)
The crushable spacers (138)
The nuts (139) and the washers (140)
The locking plates (141)
The splined bushes (142).

(7) Install the 98D27504084000 EXTRACTOR - PIN, TRACK 4 at flap track 3 on the carriage bolt (143).

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

(8) Install the 98D27504084000 EXTRACTOR - PIN, TRACK 4 at flap track 4 on the carriage bolt (143).
(9) Make sure that you fully turn the extractor pin on the threads of each bolt (143):

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

(a) This will hold the locking ring in position and will let the bush and the bearing to compress it.
(10) Remove the carriage bolts (143):
(a) If necessary, carefully lift the flap with the hoist and hold it sufficiently to release the weight from the bolts (143).
(11) Discard the cotter pins (137) and the crushable spacers (138).
(12) 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) Carefully and slowly lift the outboard flap from the flap track carriages.
(b) Move the outboard flap with the hoist and lower it on the support structure.
(13) Where necessary, put the COVER - PROTECTION on the disconnected items of the flap.

Subtask 27-54-62-080-050-A ** ON A/C NOT FOR ALL

D. Removal of Equipment
(1) If necessary, remove the hoisting sling from the outboard flap (Ref. AMM TASK 27-50-00-000-002).

[Rev.10 from 2021] 2026.03.31 23:54:52 UTC