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. 

Doc # 6.02.01 Page 205
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AMM

C. Install the Rudder Control Cables (from the Firewall to the Yoke)
DA 40 Series

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 enS Inspect the cable eye-end for correct assembly. S If necessary for your airworthiness authority, send a sample for proof test.  d. 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. 

Page 206 Doc # 6.02.01 09 Jan 2003 Rev. 4
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Flight Controls
AMM

DA 40 Series

(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. 
　
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