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Flight Controls
Doc # 6.02.01
Rev. 5 27-20-00 Page 205
20 Sep 2007
4. Remove/Install Rudder Control Cables
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
Swaging tool. 1 Commercial.
Nicopress Oval & Stop Sleeve Gauge ('go-no-go gauge') for
1/8 inch sleeves.
1
B. Remove the Cockpit Rudder Control Cables (from the Firewall to the Yoke)
Detail Steps/Work Items Key Items/References
(1) Remove these items for access:
S The pilots’ seats.
Section 25-10.
(2) Remove the cable between the firewall and the
yoke:
S Remove the nut, washer, bolt and spacer that
attach the cable to the multi-hole bracket at
the firewall.
S Remove the nut, washer, bolt, bush and
spacer that attach the cable to the yoke.
S Cut the eye-end from the old cable at the
firewall end.
S Remove the old cable.
Refer to Figures 2 and 3.
AIRCRAFT
Flight Controls DA 40 Series
AMM
Page 206
20 Sep 2007 27-20-00 Doc # 6.02.01
Rev. 5
C. Install the Rudder Control Cables (from the Firewall to the Yoke)
Detail Steps/Work Items Key Items/References
WARNING: ONLY TRAINED AND AUTHORIZED PERSONS SHOULD INSTALL
CABLE EYE-ENDS. IF THE EYE-ENDS ARE NOT INSTALLED
CORRECTLY, THE RUDDER CONTROLS CAN FAIL. THIS CAN
CAUSE DEATH OR INJURY TO PERSONNEL.
Note: Install eye-ends in accordance with FAA AC 43.13-1B, Chapter 7, Section 8.
Note: To make the work easier, install an eye-end on one end of the cable before you
install it in the airplane.
(1) Install one new eye-end to the cable before you
install it in the airplane.
S Inspect the cable eye-end for correct
assembly.
S If necessary for your airworthiness authority,
send a sample for proof test.
Use Locoloc thimbles and Nico-Press
clamps for 3.2 mm (1/8 inch) diameter
steel cables to specification LN9374.
Inspect cable swage with go-no-go
gauge for 1/8 inch Nicopress oval
sleeve in accordance with FAA AC
43.13-1B, Chapter 7, Section 8.
(2) Push the control cable through the Teflon tubes
from the rear.
Refer to Figure 3.
(3) Make sure the cable is in the correct position on
the pulley (for the outer cables only).
(4) Push the cable position through the "S" tube on
the rudder pedal assembly.
(5) Install a new eye-end to the cable at the firewall end.
S Inspect the cable eye-end for correct
assembly.
S If necessary for your airworthiness authority,
send a sample for proof test.
Use Locoloc thimbles and Nico-Press
clamps for 3.2 mm (1/8 inch) diameter
steel cables to specification LN9374.
Inspect cable swage with go-no-go
gauge for 1/8 inch Nicopress oval
sleeve in accordance with FAA AC
43.13-1B, Chapter 7, Section 8.
(6) Install the cable to the yoke:
S Install the bolt, bush and spacer that attach
the cable to the yoke.
S Install a washer and self-locking nut.
Torque to 6.4 Nm (4.7 ft.lb.). Use a new
self-locking nut.
AIRCRAFT
DA 40 Series
AMM
Flight Controls
Doc # 6.02.01
Rev. 5 27-20-00 Page 207
20 Sep 2007
Detail Steps/Work Items Key Items/References
(7) Install the cable to the bracket at the firewall:
S Install the bolt and spacer that attach the
cable to the bracket.
S Install a washer and self-locking nut.
Adjust the position of the bolt in the
multi-hole bracket to give the correct
rudder pedal position. The rudder pedal
lever must be vertical when the rudder
is neutral.
Torque to 6.4 Nm (4.7 ft.lb.). Use a new
self-locking nut.
(8) Do a test for the correct range of rudder
movement. If necessary, adjust the rudder
controls.
Refer to Paragraph 2.
Refer to Paragraph 3.
(9) Do an inspection of all the controls that you have
adjusted.
S If necessary for your airworthiness authority,
do a second inspection of the controls.
(10) Install these items:
S The pilots’ seats.
S The passenger seat.
Refer to Section 25-10.
AIRCRAFT
Flight Controls DA 40 Series
AMM
Page 208
20 Sep 2007 27-20-00 Doc # 6.02.01
Rev. 5
D. Remove the Fuselage Rudder Control Cables (from the Yoke to the Rudder)
Detail Steps/Work Items Key Items/References
(1) Remove these items for access:
S The pilots’ seats.
S The passenger seat.
Refer to Section 25-10.
(2) Remove the cable between the yoke and the
turnbuckle:
S Remove the nut, washer, bolt, bush and
spacer that attach the cable to the yoke.
S Cut the eye-end from the old cable at the
　
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