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more visible in exposed
cable in Figure 6), then
employing an 11/16" crow
foot wrench (Figure 5) by
hand to begin loosening
the inner locking nut of
the cable. Figure 6 shows the
Figure 5
inside locking nut as well as the one
on the outside after cable removal. If you are lucky, you’ll
be able to loosen the inner cable nut by hand after the
initial release of the first rotation or two. I wasn’t so lucky
and had to rely on additional doses of Corrosion X and
crow foot wrenching by hand. You may be more “tool
creative” than me and come up with another tool that can
get into that small space to get the job done.
After I removed the inner cable nut I noticed that the
cable was still being held in the motor drive shaft by a
locking collar that has two set screws. Figure 7 shows this
locking collar arrangement and why it was important to
line up the collar’s slot with the drive shaft slot to allow
the keyed cable end (Figure 8) to be removed from the
whole affair.
With the collar loosened, I began rotating the collar
while pulling on the flap cable to locate the place
Figure 6
Figure 7
where the collar slot and drive shaft slot line up and
allow the keyed cable to emerge from its home. After
you’ve done one side, the opposite side will seem like
child’s play.
Now that the most tedious part of the extraction
has been completed, I turned my attention to the four
mounting screws on the base of the U-channel portion
of the airframe. After I removed the safety wire there
was enough room for a 1/4" drive socket and small box
wrenches to loosen the four bolts and then the flap
motor could be liberated from its location. But wait!
We haven’t dealt with the electrical connections! As a
final step before extraction, mark the motor’s wires
with tags (A - B - C or 1 - 2 - 3) so you can match each wire
position in the case with the refurbished motor and
its mating wires back on the airframe. A cell phone
camera can be pressed into service for additional
visual backup.
Installing the new flap motor is pretty much the reverse
of the removal. Be sure to have your A&P/IA observe and
check your work and (if you’re like me) make him feel
16 AMERICAN BONANZA SOCIETY JANUARY 2013