Installation of the Sync Tubes, Sync Shafts, Flex Tube and Flex Shaft [CFML]

TASK 78-31-44-400-802-A
Installation of the Sync Tubes, Sync Shafts, Flex Tube and Flex Shaft

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE SHUTDOWN. USE APPLICABLE THERMAL GLOVES. THE ENGINE PARTS CAN STAY HOT FOR ONE HOUR AFTER SHUTDOWN AND CAN BURN YOU.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

ZONE: 210
ZONE: 400

1. Reason for the Job
A. This installation task includes three primary subtasks:
- Installation of the right sync tube and sync shaft
- Installation of the over-the-top flex tube and flex shaft
- Installation of the left sync tube and sync shaft.
B. The last step in this installation task is to do a special adjustment procedure to the synchronize the four actuators.
C. As an alternative to this installation task, you can do the special adjustment procedure to synchronize the four actuators (Ref. AMM TASK 78-31-41-820-801). The instructions in the synchronizing task include all the same instructions as in this installation task.
D. A sync shaft connects the right upper actuator with the right lower actuator. An over-the-top flex shaft connects the two upper actuators. A sync shaft connects the left upper actuator with the left lower actuator. Each shaft is installed in a tube.
E. If you replace one of these three components (or an actuator), you must do a special adjustment procedure to synchronize the four actuators (Ref. AMM TASK 78-31-41-820-801).
F. The two upper actuators are also known as the Synchronized Locking Feedback Actuators (SLFAs). The right lower actuator is also known as the Synchronized Manual Locking Actuator (SMLA). The left lower actuator is also known as the Synchronized Non-Locking Actuator (SNLA).
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 0.39 and 0.29 m.daN (34.51 and 25.66 lbf.in )
No specific	Torque wrench: range to between 0.43 and 0.36 m.daN (38.05 and 31.86 lbf.in )
No specific	Torque wrench: range to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.CPNCL00062)	Synthetic base lubricating oil - turbine engine

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
210	CKPT,FWD COMPT BHD TO FLT COMPT BULKHEAD
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR

D. Referenced Information

REFERENCE	DESIGNATION
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 29-14-00-614-002-A	Pressurization of the Hydraulic Reservoirs through the Ground Connector
TASK 29-14-00-614-002-A-01	Pressurization of the Hydraulic Reservoirs with the Auxiliary Power Unit (APU)
TASK 70-70-00-910-804-A	Electrical Standard Practices
TASK 71-13-00-010-803-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-803-A	Closing of the Fan Cowl Doors
TASK 73-29-00-740-804-A	Thrust Reverser Cycling Test (Menu Mode)
TASK 78-30-00-040-807-A	Deactivation of the Thrust Reverser System for Nacelle Maintenance (ICU)
TASK 78-30-00-440-807-A	Reactivation of the Thrust Reverser System after Nacelle Maintenance (ICU)
TASK 78-31-41-820-801-A	Synchronize the Thrust Reverser Actuators
TASK 78-31-43-040-802-A	Locking of the Right Lower Actuator (Synchronized Manual Locking Actuator)
TASK 78-32-50-010-801-A	Manually Deploy the Translating Cowl
TASK 78-32-50-410-801-A	Manually Stow the Translating Cowl
Right Sync Tube and Shaft
Flex Tube and Shaft
Left Sync Tube and Shaft

3. Job Set-up
Subtask 78-31-44-941-055-A

A. Safety Precautions
(1) On the center pedestal, on ENG panel 115VU:
(a) Make sure that the ENG/MODE selector switch is in the NORM position.
(b) Make sure that the ENG/MASTER 1(2) control switch was in the OFF position not less than five minutes before you do this procedure.
(c) Make sure that the WARNING NOTICE(S) are in position to tell persons not to operate:

The ENG/MODE selector switch
The ENG/MASTER 1(2) control switch.

(2) On the ENG section of maintenance panel 50VU:
(a) Make sure that the ON legend of the FADEC GND PWR/1(2) pushbutton switch is off.
(b) Make sure that the WARNING NOTICE(S) is in position to tell persons not to energize FADEC 1(2).

Subtask 78-31-44-010-051-A

B. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR
(2) Make sure that the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE is in position.

Subtask 78-31-44-040-053-A

C. Deactivation of the Thrust Reverser System for Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Make sure that you did the deactivation of the thrust reverser system for nacelle maintenance (Ref. AMM TASK 78-30-00-040-807).

Subtask 78-31-44-010-053-A

D. Get Access
(1) Make sure that the applicable hydraulic system is depressurized (Ref. AMM TASK 29-14-00-614-001).
(2) Make sure that the translating cowl is in the fully deployed position (Ref. AMM TASK 78-32-50-010-801).

4. Procedure
Subtask 78-31-44-420-052-A

A. Installation of the Sync Tubes, Sync Shafts, Flex Tubes and Flex Shaft
(1) Installation of the right sync tube and sync shaft:
(a) Remove all the protective covers and caps from the openings, tubes, hoses and connectors.
(b) Lubricate the threads of the bolt (10) and the eight bolts (11) with Synthetic base lubricating oil - turbine engine (Material No.CPNCL00062) .
(c) Put the P-clamp (9) in position on the sync tube (3). Use the record made during the removal procedure to get the correct location and position.
(d) If not done before, put the sync shaft (2) in the sync tube (3).
(e) Synchronize the right half of the thrust reverser (Ref. AMM TASK 78-31-41-820-801).
(f) Put the sync tube (3) in position on the thrust reverser. Do not let the sync shaft (2) fall out of the sync tube during this step.
(g) Loosely install the bolt (10) to attach the P-clamp (9) to the support bracket (8).
(h) Loosely install the eight bolts (11) that attach the four saddle clamps (12) to each of the four support brackets (13).
(i) Pull the trombone fitting (4) down and engage the upper end of the sync shaft (2) with the square hole in the right upper actuator (SLFA) (1).
(j) Manually connect the coupling nut on the sync tube (3) to the right upper actuator (SLFA) (1).
(k) Engage the lower end of the sync shaft (2) with the square hole in the right lower actuator (SMLA) (5).
(l) Manually connect the coupling nut on the sync tube (3) to the right lower actuator (SMLA) (5).
(m) TRIPLE TORQUE the coupling nut on the lower end of the sync tube (3) to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

.
(n) TRIPLE TORQUE the coupling nut on the upper end of the sync tube (3) to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

.
(o) TORQUE the eight bolts (11) to between 0.43 and 0.36 m.daN (38.05 and 31.86 lbf.in )

.
(p) TORQUE the bolt (10) to between 0.39 and 0.29 m.daN (34.51 and 25.66 lbf.in )

.

PRE SPOL BD-TR-19007

(2) Installation of the over-the-top flex tube and the flex shaft:
(a) Remove all the protective covers and caps from openings, tubes, hoses and connectors.
(b) Lubricate the threads of the two bolts (29), the two bolts (32), the two bolts (39) and the two bolts (40) with the Synthetic base lubricating oil - turbine engine (Material No.CPNCL00062) .
(c) Lock the right lower actuator (SMLA) (5) (Ref. AMM TASK 78-31-43-040-802).
(d) If not done before, put the flex shaft (22) in the flex tube (21).
(e) Synchronize the left and right halves of the thrust reverser (Ref. AMM TASK 78-31-41-820-801).
(f) Installation of the flex tube:

CAUTION: HOLD THE SYNC SHAFT IN THE SYNC TUBE. IF THE SYNC SHAFT FALLS OUT OF THE SYNC TUBE, DAMAGE TO THE SYNC SHAFT CAN OCCUR.

1 Put the flex tube (21) in position on the thrust reverser. Do not let the flex shaft (22) fall out of the flex tube during this step.
(g) On the right side of the engine, put the saddle clamp (41) around the flex tube (21) and align it with the holes in the right bracket (42).
(h) Loosely install the two bolts (40) to attach the saddle clamp (41) to the right bracket (42).
(i) Put the saddle clamp (31) around the flex tube (21) and align it with the holes in the support bracket (30).
(j) Loosely install the two bolts (29) to attach the saddle clamp (31) to the support bracket (30).
(k) On the right-hand side of the engine, pull the flex tube (21) up so that it straightens between saddle clamps (31), (41) and (38).
(l) Engage the right end of the flex shaft (22) with the square hole in the right upper actuator (SLFA) (1).
(m) Connect the coupling nut on the flex tube (21) to the right upper actuator (SLFA) (1).
(n) TRIPLE TORQUE the coupling nut on the right end of the flex tube (21) to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

.
(o) TORQUE the two bolts (29) and the two bolts (40) to between 0.43 and 0.36 m.daN (38.05 and 31.86 lbf.in )

.
(p) Make sure that the bend shape of the flex tube (21) is localized between the saddle clamp (31) and the right upper actuator (SLFA) (1).
(q) Move the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE to the left side of the thrust reverser.
(r) On the left side of the engine, put the saddle clamp (38) around the flex tube (21) and align it with the holes in the left bracket (37).
(s) Loosely install the two bolts (39) to attach the saddle clamp (38) to the left bracket (37).
(t) Put the saddle clamp (33) around the flex tube (21) and align it with the holes in the support bracket (34).
(u) Loosely install the two bolts (32) to attach the saddle clamp (33) to the support bracket (34).
(v) Engage the left end of the flex shaft (22) with the square hole in the T-fitting (26) on the left upper actuator (SLFA) (25).
(w) Connect the coupling nut on the flex tube (21) to the T-fitting (26).
(x) TRIPLE TORQUE the coupling nut on the left end of the flex tube (21) to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

.
(y) TORQUE the two bolts (32) and the two bolts (39) to between 0.43 and 0.36 m.daN (38.05 and 31.86 lbf.in )

.
(z) Connect the two electrical harnesses (23) to the proximity sensors (24) on the left upper actuator (SLFA) (25) (Ref. AMM TASK 70-70-00-910-804).

END OF PRE SPOL BD-TR-19007

POST SPOL BD-TR-19007

(3) Installation of the over-the-top flex tube and the flex shaft:
(a) Remove all the protective covers and caps from openings, tubes, hoses and connectors.
(b) Lubricate the threads of the two bolts (29), the two bolts (32), the two bolts (39) and the two bolts (40) with the Synthetic base lubricating oil - turbine engine (Material No.CPNCL00062) .
(c) Lock the right lower actuator (SMLA) (5) (Ref. AMM TASK 78-31-43-040-802).
(d) If not done before, put the flex shaft (22) in the flex tube (21).
(e) Synchronize the left and right halves of the thrust reverser (Ref. AMM TASK 78-31-41-820-801).
(f) Installation of the flex tube:

CAUTION: HOLD THE SYNC SHAFT IN THE SYNC TUBE. IF THE SYNC SHAFT FALLS OUT OF THE SYNC TUBE, DAMAGE TO THE SYNC SHAFT CAN OCCUR.

1 Put the flex tube (21) in position on the thrust reverser. Do not let the flex shaft (22) fall out of the flex tube during this step.
(g) On the right side of the engine, put the saddle clamp (41) around the flex tube (21) and align it with the holes in the right bracket (42).
(h) Loosely install the two bolts (40) to attach the saddle clamp (41) to the right bracket (42).
(i) Put the saddle clamp (31) around the flex tube (21) and align it with the holes in the support bracket (30).
(j) Loosely install the two bolts (29) to attach the saddle clamp (31) to the support bracket (30).
(k) Engage the right end of the flex shaft (22) with the square hole in the right upper actuator (SLFA) (1).
(l) Connect the coupling nut on the flex tube (21) to the right upper actuator (SLFA) (1).
(m) TRIPLE TORQUE the coupling nut on the right end of the flex tube (21) to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

.
(n) TORQUE the two bolts (29) and the two bolts (40) to between 0.43 and 0.36 m.daN (38.05 and 31.86 lbf.in )

.
(o) Move the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE to the left side of the thrust reverser.
(p) On the left side of the engine, put the saddle clamp (38) around the flex tube (21) and align it with the holes in the left bracket (37).
(q) Loosely install the two bolts (39) to attach the saddle clamp (38) to the left bracket (37).
(r) Put the saddle clamp (33) around the flex tube (21) and align it with the holes in the support bracket (34).
(s) Loosely install the two bolts (32) to attach the saddle clamp (33) to the support bracket (34).
(t) Engage the left end of the flex shaft (22) with the square hole in the T-fitting (26) on the left upper actuator (SLFA) (25).
(u) Connect the coupling nut on the flex tube (21) to the T-fitting (26).
(v) TRIPLE TORQUE the coupling nut on the left end of the flex tube (21) to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

.
(w) TORQUE the two bolts (32) and the two bolts (39) to between 0.43 and 0.36 m.daN (38.05 and 31.86 lbf.in )

.
(x) Connect the two electrical harnesses (23) to the proximity sensors (24) on the left upper actuator (SLFA) (25) (Ref. AMM TASK 70-70-00-910-804).

END OF POST SPOL BD-TR-19007

(4) Installation of the left sync tube and the sync shaft:
(a) Remove all the protective covers and caps from the openings, tubes, hoses and connectors.
(b) Lubricate the threads of the bolt (57), the two bolts (61), the two bolts (67) and the two bolts (68) with the Synthetic base lubricating oil - turbine engine (Material No.CPNCL00062) .
(c) Lock the right lower actuator (Ref. AMM TASK 78-31-43-040-802).
(d) Put the P-clamp (58) in position on the sync tube (51). Use the record made during the removal procedure to get the correct location and position.
(e) If not done before, put the sync shaft (53) in the sync tube (51).
(f) Synchronize the left half of the thrust reverser (Ref. AMM TASK 78-31-41-820-801).
(g) Installation of the sync tube:

CAUTION: HOLD THE SYNC SHAFT IN THE SYNC TUBE. IF THE SYNC SHAFT FALLS OUT OF THE SYNC TUBE, DAMAGE TO THE SYNC SHAFT CAN OCCUR.

1 Put the sync tube (51) in position on the thrust reverser. Do not let the sync shaft (53) fall out of the sync tube during this step.
(h) Loosely install the bolt (57) to attach the P-clamp (58) to the support bracket (59).
(i) Loosely install the two bolts (61) that attach the saddle clamp (62) to the support bracket (63).
(j) Loosely install the four bolts (67) that attach the two saddle clamps (66) to the support brackets (65) at two locations.
(k) Loosely install the two bolts (68) that attach the saddle clamp (69) to the support bracket (70).
(l) Pull the trombone fitting (52) down and engage the upper end of the sync shaft (53) with the square hole in the left upper actuator (SLFA) (25).
(m) Manually connect the coupling nut on the sync tube (51) to the left upper actuator (SLFA) (25).
(n) Engage the lower end of the sync shaft (53) with the square hole in the left lower actuator (SNLA) (54).
(o) Manually connect the coupling nut on the sync tube (51) to the left lower actuator (SNLA) (54).
(p) TRIPLE TORQUE the coupling nut on the lower end of the sync tube (51) to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

.
(q) TRIPLE TORQUE the coupling nut on the upper end of the sync tube (51) to between 11.92 and 9.66 m.daN (87.91 and 71.24 lbf.ft )

.
(r) TORQUE the two bolts (61), the four bolts (67) and the two bolts (68) to between 0.43 and 0.36 m.daN (38.05 and 31.86 lbf.in )

.
(s) TORQUE the bolt (57) to between 0.39 and 0.29 m.daN (34.51 and 25.66 lbf.in )

5. Close-up
Subtask 78-31-44-410-051-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Manually stow the translating cowl (Ref. AMM TASK 78-32-50-410-801).
(3) Do the reactivation of the thrust reverser system after maintenance (Ref. AMM TASK 78-30-00-440-807).
(4) Pressurize the hydraulic reservoirs (Ref. AMM TASK 29-14-00-614-002).
(5) Bleed the thrust reverser hydraulic system:
(a) Perform ten thrust reverser cycles (Ref. AMM TASK 73-29-00-740-804).

Subtask 78-31-44-410-052-A

B. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 03:35:18 UTC