Installation of the Outboard Flap Tab

TASK 27-54-62-400-006-A
Installation of the Outboard Flap Tab

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.

ZONE: 587
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	1	ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE
No specific	AR	SAFETY BARRIER(S)
No specific	1	STRAIGHT EDGE
No specific	AR	WARNING NOTICE(S)
No specific	1	WRENCH - PNEUMATIC
No specific	Torque wrench: range to between 1.35 and 1.2 m.daN (119.47 and 106.19 lbf.in )
No specific	Torque wrench: range to between 2.2 and 1.95 m.daN (16.22 and 14.38 lbf.ft )
No specific	Torque wrench: range to between 3.0 and 2.6 m.daN (22.12 and 19.17 lbf.ft )
No specific	Torque wrench: range to between 4.4 and 3.9 m.daN (32.45 and 28.76 lbf.ft )
No specific	Torque wrench: range to between 7.8 and 6.8 m.daN (57.52 and 50.15 lbf.ft )
98D27504115000	2	GAUGES-DISTANCE
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION
98D27804001000	1	ADAPTOR-DRIVE, SLAT (AND FLAP)

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(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
587	FLAP N° 2
687	FLAP N° 2

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
14	COTTER PIN	AIPC 57-53-23-08-020
3	COTTER PIN	AIPC 57-53-23-08-230
4	COTTER PIN	AIPC 57-53-23-10-070
12	COTTER PIN	AIPC 57-53-23-10-160
17	COTTER PIN	AIPC 57-53-23-10-390
24	COTTER PIN	AIPC 57-53-23-11-070
18	COTTER PIN	AIPC 57-53-23-11-200
1	COTTER PIN	AIPC 57-53-23-11-270

E. Referenced Information

REFERENCE	DESIGNATION
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
TASK 27-00-00-080-002-A	Removal of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
TASK 27-00-00-480-002-A	Installation of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
TASK 27-50-00-860-801-A	Readout of the Flap Position Pickoff Unit (PPU) Data
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 27-54-00-710-001-A	Operational Test of the Flap System
TASK 27-54-45-000-001-A	Removal of the Torque Shaft
TASK 27-54-45-400-001-A	Installation of the Torque Shaft
TASK 27-54-62-400-002-A	Installation of the Outboard Double-Slotted Flap
TASK 57-55-11-000-005-A	Removal of the Inboard and Outboard-Flap Tab Hinge-Fairings
TASK 57-55-11-010-002-A	To Lower the Flap Track No. 3 & No. 4 Movable Fairings for Access
TASK 57-55-11-400-005-A	Installation of the Inboard and Outboard-Flap Tab Hinge-Fairings
TASK 57-55-11-410-002-A	To Lift the Flap Track No. 3 & No. 4 Movable Fairings after Access
Details of the Tab Hinge at the Track 3 Position
Details of the Tab Hinge at the Track 4 Position
Details of the Intermediate Tab Hinges at the 3A, 3B and 3C Positions

3. Job Set-up
Subtask 27-54-62-941-063-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) Make sure that the SAFETY BARRIER(S) are in position.
(2) Make sure that the WARNING NOTICE(S) is in position on panel 400VU to tell persons not to operate the landing gear.
(3) Make sure that the WARNING NOTICE(S) is in position on panel 114VU to tell persons not to operate the flight controls.

Subtask 27-54-62-865-065-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 27-54-62-860-064-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 ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE is below the applicable outboard flap tab.
(2) Make sure that the flaps are in the fully retracted position (Ref. AMM TASK 27-50-00-866-009).
(3) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is on the flap/slat control lever (Ref. AMM TASK 27-00-00-480-002).
(4) Make sure that the fairings have been removed from the tab hinges at the 3A, 3B and 3C positions (Ref. AMM TASK 57-55-11-000-005).
(5) Make sure that the flap track No. 3 and No. 4 movable fairings have been lowered (Ref. AMM TASK 57-55-11-010-002).

4. Procedure
Subtask 27-54-62-420-090-A ** ON A/C NOT FOR ALL

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) Do an inspection of the component interfaces and the adjacent area.
(3) Make sure that the parts retained from the removed component are clean and in the correct condition.
(4) If you replace the tab, install the tab drive control-rod (13) at the track 3 position:

Details of the Tab Hinge at the Track 3 Position ** ON A/C NOT FOR ALL

(a) Connect the tab drive control-rod (13) with the bolt (1), the washers (2) and (3) and the nut (5).
(b) TORQUE the nut (5) to between 7.8 and 6.8 m.daN (57.52 and 50.15 lbf.ft )

.
(c) Safety the nut (5) with the new AIPC 57-53-23-10-070 COTTER PIN (4).
(5) If you replace the tab, install the tab drive control-rod (23) to the replacement tab at the track 4 position:

Details of the Tab Hinge at the Track 4 Position ** ON A/C NOT FOR ALL

(a) Connect the tab drive control-rod (23) with the bolt (21), the washers (22) and (26) and the nut (25).
(b) TORQUE the nut (25) to between 3.0 and 2.6 m.daN (22.12 and 19.17 lbf.ft )

.
(c) Safety the nut (25) with the new AIPC 57-53-23-11-070 COTTER PIN (24).

Subtask 27-54-62-420-091-A ** ON A/C NOT FOR ALL

B. Installation of the Tab to the 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: MAKE SURE THAT THE DISCONNECTED PARTS DO NOT TOUCH AND/OR CATCH THE ADJACENT STRUCTURE WHEN YOU MOVE THE TAB. THIS WILL PREVENT DAMAGE TO THE FLAP.

(1) Put the tab in position at track No. 3 and No. 4 and at hinges 3A, 3B and 3C.
(2) At track 3, do the steps that follow:

Details of the Tab Hinge at the Track 3 Position ** ON A/C NOT FOR ALL

(a) Engage the tab drive control-rod (13) with the track 3 carriage. Do not connect the tab drive control-rod (13) at this time.
(b) Move the tab forward and install the 98D27504115000 GAUGES-DISTANCE at the track 3 position.
(c) Temporarily connect the rear strut (15) with the bolt (24), the washers (23) and (16) and the nut (18).
(d) Hold the tab and remove the 98D27504115000 GAUGES-DISTANCE from the track 3 position.
(3) At track 4, do the steps that follow:

Details of the Tab Hinge at the Track 4 Position ** ON A/C NOT FOR ALL

(a) Engage the tab drive control-rod (23) with the track 4 carriage. Do not connect the tab drive control-rod (23) at this time.
(b) Move the tab forward and install the 98D27504115000 GAUGES-DISTANCE at the track 4 position.
(c) Temporarily connect the rear strut (6) with the bolt (8), the washers (7) and (3) and the nut (2).
(d) Hold the tab and remove the 98D27504115000 GAUGES-DISTANCE from the track 4 position.
(4) Fully extend the flaps (Ref. AMM TASK 27-50-00-866-008).
(5) At the track 4 position:

Details of the Tab Hinge at the Track 4 Position ** ON A/C NOT FOR ALL

(a) Temporarily connect the forward strut (17) with the bolt (13), the washers (14) and (20) and the nut (19).
(6) At the track 3 position:

Details of the Tab Hinge at the Track 3 Position ** ON A/C NOT FOR ALL

(a) Temporarily install the eccentric bolt (9), the washer (10) and the nut (11).
1 Make sure that you install the cutout of the washer (10) in the direction to the head of eccentric bolt (9).
2 Make sure that the punch marks are in the same position that you wrote down when the tab was removed.
(7) Put the flaps back in the fully retracted position (Ref. AMM TASK 27-50-00-866-009).
(8) Make sure the tab is forward and install the 98D27504115000 GAUGES-DISTANCE at track 3 and track 4 positions.
(9) Adjust the tab at the track 4 position to get the correct upper-surface contour:

Details of the Tab Hinge at the Track 4 Position ** ON A/C NOT FOR ALL

(a) Use a STRAIGHT EDGE to do a check and make sure that:

The flap and the tab trailing edges outboard of the track 4 position are aligned
The tab upper-surface contour and the flap trailing edge are aligned.

(b) If necessary, adjust the length of the rear strut (6) and the forward strut (17) until the flap and tab are correctly aligned:
1 Unlock the locking device of the rear strut (6).
2 Loosen the nut (5).
3 Remove the nut (2), the washers (3) and (7) and the bolt (8).
4 Hold the tab and remove the 98D27504115000 GAUGES-DISTANCE from the track 4 position.
5 Fully extend the flaps (Ref. AMM TASK 27-50-00-866-008).
6 Unlock the locking device of the forward strut (17).
7 Loosen the nut (16).
8 Remove the nut (19), the washers (20) and (14) and the bolt (13).
9 Put the flaps back in the fully retracted position (Ref. AMM TASK 27-50-00-866-009).
10 Make sure the tab is forward and install the 98D27504115000 GAUGES-DISTANCE at the track 4 position.
11 Adjust the length of the rear strut (6) and the forward strut (17) as necessary, until the tab and flap are aligned. This is when:

The flap and the tab trailing edges outboard of the track 4 position are aligned
The tab upper-surface contour and the flap trailing edge are aligned.

12 Install the rear strut (6) with the bolt (8), the washers (7) and (3) and the nut (2).
13 Do a check through the safety hole and make sure that the threads of the eye-end (4) is in safety.
14 Tighten the nut (5).
15 Safety the nut (5) with the locking device of the rear strut (6).
16 TORQUE the nut (2) to between 3.0 and 2.6 m.daN (22.12 and 19.17 lbf.ft )

.
17 Safety the nut (2) with the new AIPC 57-53-23-11-270 COTTER PIN (1).
18 Hold the tab and remove the 98D27504115000 GAUGES-DISTANCE from the track 4 position.
19 Fully extend the flaps (Ref. AMM TASK 27-50-00-866-008).
20 Install the forward strut (17) with the bolt (13), the washers (14) and (20) and the nut (19).
21 Do a check through the safety hole and make sure that the threads of the eye-end (15) is in safety.
22 Tighten the nut (16).
23 Safety the nut (16) with the locking device of the forward strut (17).
24 TORQUE the nut (19) to between 1.35 and 1.2 m.daN (119.47 and 106.19 lbf.in )

.
25 Safety the nut (19) with the new AIPC 57-53-23-11-200 COTTER PIN (18).
26 Put the flaps back in the fully retracted position (Ref. AMM TASK 27-50-00-866-009).
(10) At track 4, connect the bonding strap (11) as follows:

Details of the Tab Hinge at the Track 4 Position ** ON A/C NOT FOR ALL

(a) Make sure the tab is forward and install the 98D27504115000 GAUGES-DISTANCE at the track 4 position.
(b) Connect the bonding strap (11) with the bolt (12), the washer (10) and the nut (9) (Ref. AMM TASK 20-28-00-912-802).
(11) Adjust the tab at the track 3 position to get the correct upper-surface contour:

Details of the Tab Hinge at the Track 3 Position ** ON A/C NOT FOR ALL

(a) Use a STRAIGHT EDGE to do a check and make sure that:

The flap and the tab trailing edges inboard of the track 3 position are aligned
The tab upper-surface contour and the flap trailing edge are aligned.

(b) If necessary, adjust the length of the rear strut (15) and turn the eccentric bolt (9) until the flap and tab are correctly aligned:
1 Unlock the locking device of the rear strut (15).
2 Loosen the nut (14).
3 Remove the nut (18), the washers (16) and (23) and the bolt (24).
4 Loosen the nut (11).
5 Adjust the length of the rear strut (15) and turn the eccentric bolt (9) as necessary, until the tab and flap are aligned. This is when:

The flap and the tab trailing edges inboard of the track 3 position are aligned
The tab upper-surface contour and the flap trailing edge are aligned.

6 Install the bolt (24), the washers (23) and (16) and the nut (18).
7 Do a check through the safety hole and make sure that the rear strut (15) is in safety.
8 Tighten the nut (14).
9 Safety the nut (14) with the locking device of the rear strut (15).
10 TORQUE the nut (18) to between 4.4 and 3.9 m.daN (32.45 and 28.76 lbf.ft )

.
11 Safety the nut (18) with the new AIPC 57-53-23-10-390 COTTER PIN (17).
12 Hold the tab and remove the 98D27504115000 GAUGES-DISTANCE from the track 3 position.
13 Fully extend the flaps (Ref. AMM TASK 27-50-00-866-008).
14 TORQUE the nut (11) to between 2.2 and 1.95 m.daN (16.22 and 14.38 lbf.ft )

.
15 Safety the nut (11) with the new AIPC 57-53-23-10-160 COTTER PIN (12).
(12) At track 3, install the eccentric bolt (9) as follows:

Details of the Tab Hinge at the Track 3 Position ** ON A/C NOT FOR ALL

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) Install the toothplate (8) on the eccentric bolt (9).
(b) Install the bolt (7) and the washer (6).
(c) Safety the bolt (7) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
(13) Put the flaps back in the fully retracted position (Ref. AMM TASK 27-50-00-866-009).
(14) At track 3, connect the bonding strap (19) as follows:

Details of the Tab Hinge at the Track 3 Position ** ON A/C NOT FOR ALL

(a) Make sure the tab is forward and install the 98D27504115000 GAUGES-DISTANCE at the track 3 position.
(b) Connect the bonding strap (19) with the bolt (20), the washer (21) and the nut (22) (Ref. AMM TASK 20-28-00-912-802).
(15) Connect the tab at the hinge 3A, 3B and 3C positions as follows:

Details of the Intermediate Tab Hinges at the 3A, 3B and 3C Positions ** ON A/C NOT FOR ALL

NOTE: The procedure to connect the tab at the hinge 3A, 3B and 3C positions is the same.

(a) Put the eye-ends (4) and (11) of the struts (6) and (13) in position.
(b) Temporarily install the bolts (7) and (9).
(c) Use a STRAIGHT EDGE to do a check and make sure that:

The tab upper-surface contour and the flap trailing edge are aligned.

(d) If necessary, adjust the length of the struts (6) and (13) until the flap and the tab are correctly aligned:
1 Remove the bolts (7) and (9).
2 Unlock the locking devices of the struts (6) and (13).
3 Loosen the nuts (5) and (12).
4 Adjust the length of the struts (6) and (13), as necessary.
(e) Install the bolt (7), the washers (8) and (1) and the nut (2).
(f) Install the bolt (9), the washers (10) and (16) and the nut (15).
(g) Do a check through the safety hole and make sure that the threads of the eye-ends (4) and (11) are in safety.
(h) Tighten the nuts (5) and (12).
(i) Safety the nuts (5) and (12) with the locking devices of the struts (6) and (13).
(j) TORQUE the nut (2) to between 2.2 and 1.95 m.daN (16.22 and 14.38 lbf.ft )

.
(k) Safety the nut (2) with the new AIPC 57-53-23-08-230 COTTER PIN (3).
(l) TORQUE the nut (15) to between 1.35 and 1.2 m.daN (119.47 and 106.19 lbf.in )

.
(m) Safety the nut (15) with the new AIPC 57-53-23-08-020 COTTER PIN (14).
(16) Hold the tab and remove the 98D27504115000 GAUGES-DISTANCE from the track 3 and track 4 positions.
(17) Move the tab (with your hand) through its full range of movement and do a check that it is free to move.
(18) Push the tab to its fully retracted position and install the 98D27504115000 GAUGES-DISTANCE.

Subtask 27-54-62-420-089-A ** ON A/C NOT FOR ALL

C. Connection of the Tab Drive Control-Rods
(1) At the track 3 flap carriage, connect and if necessary, adjust the tab drive control-rod (13) (Ref. AMM TASK 27-54-62-400-002).
(2) At the track 4 flap carriage, connect and if necessary, adjust the tab drive control-rod (23) (Ref. AMM TASK 27-54-62-400-002).
(3) Remove the 98D27504115000 GAUGES-DISTANCE from the track 3 and track 4 positions.
(4) Make sure that the flaps are in the fully retracted position.
(5) Do the readout of the PPU data (Ref. AMM TASK 27-50-00-860-801)

NOTE: Airbus recommends to do the readout and recording of the PPU angles before you disconnect the torque shaft.
In case of a loss of the torque shaft fixture you can put the flap transmission system back to the initial condition (without a complete adjustment of the system).

CAUTION: MOVE THE FLAPS MANUALLY AFTER THE ADJUSTMENT OF THE FLAP TAP. IF YOU MOVE THE FLAPS WITH HYDRAULIC POWER, DAMAGE TO THE EQUIPMENT CAN OCCUR.

(6) Move the flaps manually as follows:
(a) Remove the related torque shaft [6202CM] or [6252CM] (Ref. AMM TASK 27-54-45-000-001).
(b) Install the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) on the right angle gearbox.
(c) Use a WRENCH - PNEUMATIC to turn the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to fully extend and retract the flaps. Make sure that the tab operates correctly.
(d) Remove the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) from the right angle gearbox.
(e) Install the related torque shaft [6202CM] or [6252CM] (Ref. AMM TASK 27-54-45-400-001).
(7) Do the readout and check of the PPU data (Ref. AMM TASK 27-50-00-860-801).
(8) Make sure that the PPU data are in the specified limits.
(9) Remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION from the flap/ slat control lever (Ref. AMM TASK 27-00-00-080-002).

Subtask 27-54-62-410-058-A ** ON A/C NOT FOR ALL

D. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the hinge fairings at the hinge 3A, 3B and 3C positions (Ref. AMM TASK 57-55-11-400-005).
(3) Lift the flap track No. 3 and No. 4 movable fairings (Ref. AMM TASK 57-55-11-410-002).
(4) Remove the access platform(s).

Subtask 27-54-62-865-066-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
** 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 27-54-62-710-055-A ** ON A/C NOT FOR ALL

F. Test

CAUTION: DO NOT MOVE THE FLAP OR TAB WITH THE DISTANCE GAUGE INSTALLED OR YOU WILL CAUSE DAMAGE TO THE FLAP.

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

5. Close-up
Subtask 27-54-62-942-057-A ** ON A/C NOT FOR ALL

A. Removal of Equipment
(1) Remove the safety barriers.
(2) Remove the WARNING NOTICE(S).
(3) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

[Rev.10 from 2021] 2026.03.31 23:55:00 UTC