78 00 00 Ri

MSG-3 MAINTENANCE MANUAL
EXHAUST — REMOVAL / INSTALLATION

1. Aft Cowl / Thrust Reverser Assembly — Removal / Installation
A. General
Record the hardware type, quantity and location during removal. Attach a removal tag to the
component and keep the hardware for installation, unless told to discard. The installation hardware
must be the equivalent of Gulfstream Engineering approved hardware. Refer to the appropriate
Illustrated Parts Catalog figure for details. Use Gulfstream Engineering approved procedures to
install the hardware. Refer to the Wiring Diagram Manual for procedures to address any wiring
discrepancies.
B. Preparation
SPECIAL TOOLS AND TEST EQUIPMENT
Caps and plugs ................................................................................................................... Standard
Hoist, 2000 pounds minimum .................................................................. GSE710025 or equivalent
Regulated air supply ........................................................................................................... Standard
Rig pin .............................................................................................. NAS1605-64 bolt or equivalent
Sling ........................................................................................................... 1159P41460-01-02 HOE
Thrust reverser deployed ground safety lock ........................................ GSE7800502 or equivalent
Thrust reverser stowed ground safety lock ........................................... GSE7800501 or equivalent
Torque wrench, 100 - 600 inch-pounds (11.30 - 67.79 Nm) ................. GSE5100726 or equivalent
Torque wrench adapter .......................................................................... GSE7800500 or equivalent
Transportation stand ................................................................................... 1159P41460-01-02 DOL
CONSUMABLES
Safety wire ................................................................................................................... MS20995C32
(1) Reference(s)
• Aircraft Open and Close - Checks, 20-00-00, Maintenance Practices
• External Electrical Power Application - Maintenance Practices, 20-20-10, Maintenance
Practices
• External Hydraulic Power Application, 20-30-10, Maintenance Practices
• Combined / Flight Hydraulic System Reservoir - Filling Procedures, 29-01-00, Servicing
or Code 291057
• Engine Thrust Reverser - Operational Test, 78-00-00, Adjustment / Test or Code
783009
• Thrust Reverser Interlock - Operational Test, 78-00-00, Adjustment / Test or Code
783037
• Thrust Reverser Interlock Feedback Control System - Rigging, 78-00-00, Adjustment /
Test or Code 783015
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C. Removal
WARNING: THRUST REVERSER IS ARMED WHEN AIRCRAFT HYDRAULIC SYSTEM IS
PRESSURIZED, ELECTRICAL POWER IS ON, AND THRUST REVERSER
SELECTOR CONTROL VALVE IS NOT PINNED IN NEUTRAL POSITION. CLEAR
THRUST REVERSER AREA OF ALL PERSONNEL AND EQUIPMENT.
ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THRUST
REVERSER DOORS AND DRIVE LINKAGE BEFORE OPERATION TO PREVENT
SERIOUS INJURY OR DAMAGE TO EQUIPMENT.
BEFORE PERFORMING MAINTENANCE, ENSURE ISOLATION OF THE THRUST
REVERSER SYSTEM BY PINNING THRUST REVERSER SELECTOR CONTROL
VALVE IN NEUTRAL.
WHEN WORKING ON THRUST REVERSER WITH DOORS DEPLOYED, ENSURE
DEPLOY GROUND SAFETY LOCK (P/N 1159GSE40219-1 OR EQUIVALENT) IS
INSTALLED. WITH DOORS STOWED, ENSURE STOW GROUND SAFETY LOCK
(P/N 1159GSE111-1 OR EQUIVALENT) IS INSTALLED.
NOTE: The Thrust Reverser (T/Rev) doors must be stowed and locked for removal.
(1) Remove electrical and hydraulic power. See External Electrical Power Application -
Maintenance Practices, 20-20-10, Maintenance Practices and External Hydraulic Power
Application, 20-30-10, Maintenance Practices.
(2) Pull L/R T/REV CONTROL and NUTCRACKER circuit breaker(s). On aircraft having ASC
242, pull NUTCRACKER BATT PWR circuit breaker.
(3) Pull T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 not having ASC 210 or ASC 418) or
L/R T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183 thru
Aircraft 1435 not having ASC 418) circuit breaker(s) (pilot circuit breaker panel).
(4) Install safety pin in T/Rev selector control valve. Valve must be in neutral (centered) position.
See Figure 401.
NOTE: On Aircraft 1436 and subsequent and Aircraft 1000 thru Aircraft 1435 having ASC
418, valve spool must be pushed into neutral position to install safety pin. The safety
pin is located in storage bracket behind control valve.
(5) Remove upper and lower engine cowl doors.
(6) Remove pylon boards 29/30-UPR/LWR-4 and 31/32-UPR/LWR CWL-1.
(7) Disconnect hydraulic quick-disconnects in lower pylon.
(8) Disconnect electrical connectors at pylon and firewall plugnests. Cap connectors and
receptacles.
(9) Disconnect drain line at combustion drain valve on engine. Cap line and valve.
(10) Disconnect engine breather line. Cap breather line.
(11) Disconnect interlock / feedback cable at quick-disconnect clamp in upper pylon. See Figure
403.
(12) Cut safety wire and remove shear bolts attaching aft portion of fixed cowl to assembly.
Discard safety wire.
(13) Attach sling (P/N 1159P41460-01-02 HOE) to aft cowl / thrust reverser assembly. See Figure
402.
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NOTE: If necessary for sling installation, additional clearance may be obtained at sling
forward attach points by hand pushing inboard on upper aft portion of fixed cowl.
(14) Take up slack to support weight of assembly.
(15) Remove nuts and washers securing assembly to engine flange.
(16) Move assembly straight aft sufficiently to clear engine and structure.
(17) Lower assembly and install on transportation stand.
WARNING: FAILURE TO KEEP LOCK PINS IN PLACE AT ALL TIMES UNLESS HOIST
IS ATTACHED TO LIFTING RING MAY CAUSE SERIOUS INJURY OR
DEATH.
(18) Ensure all lock pins are installed in transportation stand and remove sling.
(19) Inspect T/Rev attach bolt hole inner diameters for corrosion.
D. Installation
WARNING: FAILURE TO KEEP LOCK PINS IN PLACE AT ALL TIMES UNLESS HOIST IS
ATTACHED TO LIFTING RING MAY CAUSE SERIOUS INJURY OR DEATH.
(1) Ensure all lock pins are installed in transportation stand and attach sling to assembly.
(2) Remove assembly from transportation stand and position at rear of engine.
CAUTION: CAREFULLY ALIGN MOUNTING BOLTS LOCATED ON ENGINE WITH
HOLES ON ASSEMBLY TO AVOID DAMAGING THREADS.
DURING INSTALLATION OF ASSEMBLY, PISTON RING SEAL LOCATED ON
AFT END OF ENGINE MUST BE COMPRESSED TO FIT INTO AFT COWL
SEAL RING.
TO PREVENT INJURY TO FINGERS USE SOFT MATERIAL TOOLS (I.E.,
ALUMINUM OR BRASS) TO COMPRESS PISTON RING AS ASSEMBLY IS
BEING INSTALLED.
(3) Fit assembly to engine and install nuts and washers loosely.
(4) Torque securing nuts (thrust reverser to engine) from 280 - 350 inch-pounds (31.64 - 39.54
Nm).
LH TECH _____ LH INSP _____ RH TECH _____ RH INSP _____
NOTE: Torque wrench adapter will be required to torque nuts.
(5) Remove sling.
(6) Install shear bolts securing aft portion of fixed cowl to assembly, snug bolts and safety wire.
(7) Connect hydraulic line quick-disconnect fittings.
(8) Remove cap and connect engine breather line.
NOTE: Before connecting drain line to drain valve, apply air pressure supply to drain line.
This is to ensure no obstructions are in line.
(9) Remove caps from combustion drain valve and line and connect drain line to engine.
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CAUTION: ENSURE ALL CONNECTORS ARE FULLY SEATED AND LOCKING FEATURE
/ INDICATORS ARE VERIFIED. IT IS SUGGESTED THAT EACH
CONNECTOR BE VERIFIED AS IT IS INSTALLED TO ALLOW FOR BETTER
VISUAL ACCESS TO DISCONNECT PANEL. FAILURE TO SECURE
ELECTRICAL CONNECTORS CAN RESULT IN ABNORMAL SYSTEM
OPERATION OR INDICATIONS.
(10) Remove caps from electrical connectors. Connect electrical connectors at forward bulkhead
of T/Rev electrical disconnect panel. Connect electrical connectors at T/Rev firewall and
T/Rev aft disconnect panel in the following order: J15, J18, J17, J16, J19, J14 and J20.
Safety wire connector 900A1P20 / A2P20 as required. See Figure 404.
(11) Connect and rig forward and aft interlock / feedback cables. See Thrust Reverser Interlock
Feedback Control System - Rigging, 78-00-00, Adjustment / Test or Code 783015.
E. Follow On
(1) Inspect the work area for foreign objects and damage.
(2) Inspect for leaks and damage.
(3) Perform Aircraft Open and Close - Checks, 20-00-00, Maintenance Practices.
(4) Close pylon boards 29/30-UPR/LWR-4 and 31/32-UPR/LWR CWL-1.
(5) Install upper and lower engine cowl doors.
(6) Remove safety pin from T/Rev control valve. Place safety pin in storage bracket behind
control valve.
418, control valve will move to stow position.
(7) Depress T/REV CONTROL and NUTCRACKER circuit breakers. On aircraft having ASC 242,
depress NUTCRACKER BATT PWR circuit breaker.
(8) Depress T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 not having ASC 210 or ASC 418)
or L/R T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183
thru Aircraft 1435 not having ASC 418) circuit breakers (pilot circuit breaker panel).
(9) Perform Engine Thrust Reverser - Operational Test, 78-00-00, Adjustment / Test or Code
783009.
(10) Service and bleed combined or flight hydraulic system as necessary. See Combined / Flight
Hydraulic System Reservoir - Filling Procedures, 29-01-00, Servicing or Code 291057.
(11) Perform Thrust Reverser Interlock - Operational Test, 78-00-00, Adjustment / Test or Code
783037.
(12) Record all maintenance actions in accordance with current governing authority.
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Thrust Reverser Selector Control Valve (Aircraft 1000 thru Aircraft 1435 Not Having ASC 418)
Figure 401 (Sheet 1 of 2)
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Thrust Reverser Selector Control Valve (Aircraft 1436 and Subsequent and Aircraft 1000 thru Aircraft 1435
Having ASC 418)
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Aft Cowl Assembly and Thrust Reverser

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CLEARANCE SLAVE DOOR

0.005 IN. MIN. HYDRAULIC ACTUATOR
ROD END SLAVE DOOR LINK (2) PISTON
DEPLOY
LIMIT
SWITCH
SECONDARY
LOCK
FWD
IDLER STOP
INBD
IDLER BELL CRANK VIEW LOOKING UP LH SIDE (STOWED)
DETAIL A
THRUST REVERSER LINKAGE
HYDRAULIC ACTUATOR
PISTON
BLISTER FAIRING
ROD END
CLEARANCE
0.005 IN.
MIN. DEPLOY
LIMIT
SWITCH
SECONDARY
LOCK
IDLER STOP FWD
IDLER BELL CRANK VIEW LOOKING UP LH SIDE (STOWED) INBD

DETAIL B
THRUST REVERSER LINKAGE 04463C00

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Interlock Feedback Cable Assembly

Figure 403
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HOIST ATTACHMENTS UPPER HINGE COWL

STRUT ATTACHMENT
FIXED COWL
ATTACH POINTS
MOUNTING HOLES
THRUST REVERSER
ACTUATOR
HYDRAULIC
LINES
THRUST REVERSER
FEEDBACK CABLE
DISCONNECT POINT
SEE
DETAIL A
THRUST REVERSER
INDICATION
ELECTRICAL
WIRES
FIXED COWL ENGINE

ATTACH POINT CENTRIFUGAL
BREATHER
OUTLET DUCT
ELECTRICAL
DISCONNECT PANEL
ENGINES STAND
LOWER HINGE COWL
MOUNT ATTACHMENTS
STRUT ATTACHMENT
AFT
ENGINE STAND DRAIN
MOUNT
J20 ATTACHMENTS
J14 J19
J16
LEFT REAR NACELLE
LOOKING AFT
J17
J18
J15
ELECTRICAL DISCONNECT
PANEL
DETAIL A 93355C00
Aft Electrical Disconnect Panel

Figure 404
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2. Thrust Reverser Hydraulic Actuator — Removal / Installation

A. General
discrepancies.
B. Preparation
Air operated hydraulic test stand, 0 - 3000 psi ..................................... GSE2900401 or equivalent
Digital multimeter ................................................................................... GSE2400116 or equivalent
External power cart, 115 Vac, 400Hz .................................................... GSE2400108 or equivalent
Hydraulic rig, 3000 psi capacity (9 gpm minimum) ............................... GSE2900149 or equivalent
Thrust reverser stow ground safety lock ............................................... GSE7800501 or equivalent
Thrust reverser deploy ground safety lock ............................................ GSE7800502 or equivalent
Torque wrench, 0 - 300 inch-pounds (0 - 33.9 Nm) .............................. GSE5101082 or equivalent
CONSUMABLES
Antiseize compound .................................................................................................... DOD-L-25681
Cotter pin ............................................................................................................... MS24665-153 (3)
Cotter pin .................................................................................................................... MS24665-300
Hydraulic fluid ..................................................................................................................... See Note
O-ring ......................................................................................................................... NAS1612-6 (2)
Safety wire ................................................................................................................... MS20995C32
NOTE: See Hydraulic Servicing, 12-01-05, System Description for approved hydraulic fluids.
(1) Reference(s)
• Hydraulic Servicing, 12-01-05, System Description
Practices
• Combined / Flight Hydraulic System Reservoir - Filling Procedures, 29-01-00, Servicing
or Code 291057
783009
• Thrust Reverser Deploy Limit Switches - Removal / Installation, 78-00-00, Removal /
Installation or Code 783400
• Thrust Reverser Door - Rigging, 78-00-00, Adjustment / Test or Code 783003
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C. Removal
WARNING: THE THRUST REVERSER IS ARMED WHEN THE AIRCRAFT HYDRAULIC
SYSTEM IS PRESSURIZED, ELECTRICAL POWER IS ON, AND THE THRUST
REVERSER SELECTOR CONTROL VALVE IS NOT PINNED IN THE NEUTRAL
POSITION. CLEAR THE THRUST REVERSER AREA OF ALL PERSONNEL AND
EQUIPMENT.
ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE THRUST
REVERSER SYSTEM BY PINNING THE THRUST REVERSER SELECTOR
CONTROL VALVE IN NEUTRAL.
WHEN WORKING ON THE THRUST REVERSER WITH DOORS DEPLOYED,
ENSURE THE DEPLOY GROUND SAFETY LOCK (P/N 1159GSE40219-1 OR
EQUIVALENT) IS INSTALLED. WITH THE DOORS STOWED, ENSURE THE
STOW GROUND SAFETY LOCK (P/N 1159GSE111-1 OR EQUIVALENT) IS
INSTALLED.
(1) Ensure the following circuit breaker(s) are depressed:
Pilot Circuit Breaker Panel
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
• T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 not having ASC 210 or ASC
418)
• L T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft
1183 thur Aircraft 1435 not having ASC 418)
• R T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft
1183 thru Aircraft 1435 not having ASC 418)
• WARN LTS PWR #4
• WARN LTS PWR #8
Copilot Overhead Circuit Breaker Panel
• NUTCRACKER
• NUTCRACKER BATT PWR
CAUTION: SPOILER BOARDS MAY DEPLOY AND RETRACT UPON APPLICATION OF
HYDRAULIC POWER. REMAIN CLEAR OF SPOILER BOARDS.
(2) Apply electrical and hydraulic power to aircraft (left - combined; right - flight). See External
Electrical Power Application - Maintenance Practices, 20-20-10, Maintenance Practices and
External Hydraulic Power Application, 20-30-10, Maintenance Practices.
NOTE: Utility pump hydraulic pressure will not operate either Thrust Reverser (T/Rev).
(3) Ensure T/REV EMER STOW switch light is OFF. On Aircraft 1000 thru Aircraft 1182 not
having ASC 210 or ASC 418, pull T/R EMER STOW circuit breaker (pilot circuit breaker
panel). On Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183 thru Aircraft 1435
not having ASC 418, pull L/R T/R EMER STOW circuit breaker(s) (pilot circuit breaker panel).
(4) Place reverse thrust lever in deploy position. T/Rev doors will deploy.
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CAUTION: SECONDARY LOCK ACTUATOR HAS A LIMITED DUTY CYCLE OF 1

SECOND PULL, 1 MINUTE HOLD AND 30 MINUTES OFF. WHENEVER
ELECTRICAL POWER IS APPLIED TO AIRCRAFT WITH REVERSE THRUST
LEVER IN DEPLOY POSITION, THE ACTUATOR IS ACTIVATED. ON
AIRCRAFT 1000 THRU AIRCRAFT 1143, EXCLUDING AIRCRAFT 1034
HAVING ASC 166 AND AIRCRAFT 1034, AIRCRAFT 1144 AND
SUBSEQUENT, SECONDARY LOCK ACTUATOR WILL BE DE-ENERGIZED
AFTER 5 SECONDS AND RETURN TO LATCHED POSITION.
(5) With reverse thrust lever in deploy position, remove hydraulic power from aircraft. Operate
flight controls to bleed hydraulic pressure off system.
(6) Remove electrical power from aircraft. See External Electrical Power Application -
Maintenance Practices, 20-20-10, Maintenance Practices.
(7) Place reverse thrust lever in stow position.
(8) Secure secondary lock latch in open position using safety wire or similar device.
(9) Pull L/R T/REV CONT and L/R SEC LOCK. On Aircraft 1000 thru Aircraft 1182 not having
ASC 210 or ASC 418, pull T/R EMER STOW circuit breaker (pilot circuit breaker panel). On
Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183 thru Aircraft 1435 not having
ASC 418, pull L/R T/R EMER STOW circuit breaker(s) (pilot circuit breaker panel) as soon as
doors are deployed.
NOTE: The T/Rev doors may creep forward toward the stow position when hydraulic
pressure is removed, i.e., circuit breaker(s) pulled.
If REV DPLY light remains ON, fault isolate T/Rev system to find cause, i.e., control
valve may not have shifted to neutral. If REV UNLK and REV DPLY lights go OFF,
fault isolate thrust reverser system to find cause, i.e., control valve may have cycled
to stow position.
The T/Rev doors may remain in a fully deployed position with control valve in neutral
due to friction in operating mechanism. This is acceptable if pivot point hardware is
not turning and deploy / stow cycle times are less than 4 seconds.
See Figure 401.
418, valve spool must be pushed into neutral position to install safety pin. Safety pin
is located in storage bracket behind control valve.
(11) On Aircraft 1000 thru Aircraft 1040 having ASC 45 and Aircraft 1041 and subsequent, remove
fixed blister fairing (31/32-TR-5). See Figure 405.
(12) On Aircraft 1000 thru Aircraft 1040 not having ASC 45, remove access panel 31/32-TR-5
(slave door) as follows (see Figure 405):
(a) Manually position T/Rev doors until slave door is fully open.
(b) Remove screws securing slave door hinges.
CAUTION: FAILURE TO REMOVE THE SLAVE DOOR OPERATING LINKS WITH
SLAVE DOOR REMOVED CAN RESULT IN T/REV DAMAGE DURING
OPERATION.
(c) Remove operating links from slave door.
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(d) Remove operating links from T/Rev idler bellcrank and loosely attach to slave door
fittings in same position as from which it was removed.
NOTE: Do not loosen slave door operating links jam nuts. Slave door will require
rigging if links are inadvertently adjusted.
(13) Manually open T/Rev doors to deploy position.
(14) Install ground safety lock assembly on T/Rev doors. See Figure 406.
(15) Disconnect hydraulic hoses at fittings on stang support clip. Cap lines and fittings.
(16) Remove electrical connector from actuator primary lock indicator switch. See Figure 407.
CAUTION: DO NOT EXTEND PISTON. ACTUATOR WILL LOCK WHEN IN FULLY
EXTENDED POSITION AND MUST BE RETRACTED HYDRAULICALLY.
IF PISTON IS INADVERTENTLY EXTENDED, DO NOT ROTATE PISTON.
PISTON ROTATION WILL RESULT IN DAMAGE TO LOCK PLUNGER AND /
OR LATCHES, NECESSITATING ACTUATOR REPLACEMENT.
(17) Disconnect actuator from idler crank assembly and aft stang actuator mount attachment
structure. Retain attaching hardware.
CAUTION: USE CAUTION WHEN MANUALLY POSITIONING T/REV DOORS.
(18) Remove ground safety lock assembly.
(19) Manually close T/Rev doors until adequate clearance is available to remove actuator.
(20) Remove hydraulic actuator from T/Rev by moving actuator forward and rotating actuator body
approximately 90° until actuator clears T/Rev stang structure. Do not rotate piston in relation
to actuator cylinder.
(21) Install ground safety lock assembly on T/Rev doors.
CAUTION: ENSURE RESTRICTOR LOCATION IS NOTED IN ACTUATOR STOW PORT.
INCORRECT INSTALLATION WILL CAUSE IMPROPER T/REV OPERATION
AND POSSIBLY ACTUATOR PRIMARY LOCK DAMAGE.
(22) Remove lines and fittings from actuator. Plug actuator ports.
CAUTION: IF ACTUATOR IS BEING REPLACED DUE TO AN ACTUATOR FAILURE,
INSPECT HYDRAULIC LINES FROM DISCONNECTS TO ACTUATOR AND
RETURN FILTER FOR METAL CONTAMINATION. REPLACE FILTER IF
CONTAMINATED.
(23) Discard O-rings on fittings. Cap fittings and lines.
D. Installation
CAUTION: ACTUATOR ROD LENGTH IS PRESET. DO NOT ADJUST LENGTH OF ACTUATOR
ROD. DO NOT EXTEND PISTON.
ACTUATOR WILL LOCK WHEN IN FULLY EXTENDED POSITION AND MUST BE
RETRACTED HYDRAULICALLY.
IF PISTON IS INADVERTENTLY EXTENDED, DO NOT ROTATE PISTON. PISTON
ROTATION WILL RESULT IN DAMAGE TO LOCK PLUNGER AND / OR LATCHES,
NECESSITATING ACTUATOR REPLACEMENT.
(1) Remove bearing from actuator piston rod end. Apply antiseize compound (DOD-L-25681) to
outside diameter of bearing and to inside diameter of race. Install bearing in rod end.
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(2) Lubricate O-rings with hydraulic fluid and install on fittings.

CAUTION: ENSURE RESTRICTOR IS INSTALLED IN ACTUATOR STOW PORT AS
NOTED DURING REMOVAL. INCORRECT INSTALLATION WILL CAUSE
IMPROPER T/REV OPERATION AND POSSIBLY ACTUATOR PRIMARY
LOCK DAMAGE.
(3) Remove plugs from actuator fittings. Install fittings and lines.
(4) Position actuator in T/Rev.
(5) Remove ground safety lock assembly from T/Rev doors.
CAUTION: USE CAUTION WHEN MANUALLY POSITIONING T/REV DOORS.
(6) Manually open T/Rev doors until mounting holes in idler crank assembly and aft stang
actuator mount attachment structure are aligned with actuator mounting holes.
NOTE: Only apply antiseize compound to pins that are coated with dry film lubricant.
Antiseize compound should not be applied to Karon (plastic) coated pins. Exterior
surfaces of Karon coated pins should be free of any lubricants.
(7) Apply antiseize compound to bolt threads, bolt shanks and bushings.
(8) Inspect and install actuator attachment hardware and bushings.
NOTE: Forward bolt should be installed with head facing downward. Aft bolt should be
installed with head facing upward.
(9) Torque forward nut to 30 - 40 inch-pounds (3.39 - 4.52 Nm). Install cotter pins.
(10) Torque aft nut to 234 - 292 inch-pounds (26.44 - 32.99 Nm). Install cotter pins.
(11) Connect hydraulic flex hoses to fittings on support clip.
(12) Connect electrical connector to actuator primary lock indicator switch.
(13) Inspect T/Rev for foreign objects and security of installation.
E. Door Rigging and Lock / Unlock Pressure Checks
CAUTION: THE FOLLOWING PROCEDURE SHOULD NOT BE USED IF DOOR PUSHRODS
WERE ADJUSTED DURING TROUBLESHOOTING PRIOR TO ACTUATOR
REPLACEMENT.
ENSURE SLAVE DOOR OPERATING LINKS HAVE BEEN REMOVED FROM IDLER
CRANK ASSEMBLY TO PREVENT DAMAGE TO THRUST REVERSER.
NOTE: If door pushrods were adjusted, comply with Thrust Reverser Door - Rigging, 78-00-00,
Adjustment / Test or Code 783003.
(1) Open doors and install ground safety lock assembly.
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CAUTION: DISCONNECTING LOWER DOOR PUSHRODS FROM IDLER BELLCRANK

BEFORE DISCONNECTING UPPER PUSHRODS WILL CAUSE UPPER
DOOR TO CLOSE SUDDENLY BECOMING A HAZARD TO PERSONNEL AND
POSSIBLE DAMAGE TO AIRCRAFT. USE CAUTION AND EITHER SECURE
UPPER DOOR OR REMOVE UPPER PUSHRODS FIRST.
(2) Disconnect upper and lower door pushrods from idler bellcrank. Secure door pushrods clear
of idler bellcrank.
(3) Remove deploy limit switch. See Thrust Reverser Deploy Limit Switches - Removal /
Installation, 78-00-00, Removal / Installation or Code 783400.
CAUTION: ON AIRCRAFT 1000 THRU AIRCRAFT 1040 NOT HAVING ASC 45, TAPE
SLAVE DOOR HINGE AWAY FROM MECHANISM TO PREVENT
INTERFERENCE WHEN ACTUATOR IS CYCLED.
(4) Remove lower pylon board (29/30-LWR-4).
(5) Remove safety pin from T/Rev selector control valve. Place safety pin to storage bracket.
CAUTION: ENSURE ALL PERSONNEL ARE CLEAR OF T/REV DURING OPERATION.
SPOILER BOARDS MAY DEPLOY AND RETRACT UPON APPLICATION OF
(6) Connect hydraulic power source to T/Rev quick-disconnects or connect to T/Rev actuator
lines.
(7) Slowly apply hydraulic pressure (500 psi) to stow position. Actuator may lock during bleeding
procedure. Use adequate pressure to unlock, if necessary.
(8) Bleed actuator extensively (3 times), both in stowed and deployed position.
CAUTION: A MINIMUM PRESSURE OF 1250 PSIG TO STOW SIDE OF ACTUATOR
MUST BE MAINTAINED BEFORE SWITCHING TO DEPLOY.
FAILURE TO DO SO CAN RESULT IN DAMAGE TO ACTUATOR.
NOTE: The REV UNLOCK light will flicker if actuator is not bled sufficiently.
(9) Slowly increase hydraulic pressure to 2700 - 3000 psig and extend actuator toward stowed
position.
(10) Check for 0.005 inch minimum clearance between idler bellcrank and stop. See Figure 402,
Detail A and Detail B.
(11) Pressurize actuator to unlock and start to deploy actuator.
(12) Remove hydraulic and electrical power. See External Electrical Power Application -
See Figure 401.
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(14) Connect upper and lower door pushrods to idler bellcrank as follows (see Figure 408):
(a) Carefully align pushrod (3) with idler bellcrank (12).
(b) Connect pushrod to idler bellcrank with hardware (13, 14, 15, 16, 17, 18).
(c) Torque nut (18) to 30 - 40 inch-pounds (3.39 - 4.52 Nm). Install cotter pin (19) in nut
(18).
(15) Remove ground lock tool assembly.
(16) Remove safety pin from T/Rev selector control valve. Place safety pin to storage bracket.
WARNING: ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THRUST
REVERSER DOORS AND DRIVE LINKAGE BEFORE OPERATION TO
PREVENT SERIOUS INJURY OR DAMAGE TO EQUIPMENT.
ON AIRCRAFT 1436 AND SUBSEQUENT AND AIRCRAFT 1000 THRU
AIRCRAFT 1435 HAVING ASC 418, DOORS WILL CLOSE AND LOCK
QUICKLY UPON APPLICATION OF HYDRAULIC POWER.
CAUTION: DO NOT USE STOW ELECTRICAL SIGNAL AS VERIFICATION OF PRIMARY
(ACTUATOR) LOCK ENGAGEMENT. USE LOCKING SOUND (CLICK) OF
ACTUATOR TO VERIFY LOCK ENGAGEMENT.
(17) If installed, remove electrical connector (08L3S1P1 L/H or 08L4S1P1 R/H) from primary lock
switch (see Figure 407, Item 4). Using ohmmeter, check for continuity through switch at pins
A and B. Replace actuator if continuity is not present. Connect electrical connector.
(18) Slowly apply hydraulic pressure (500 psi).
• On Aircraft 1436 and subsequent and Aircraft 1000 thru Aircraft 1435 having ASC 418,
doors will quickly stow
• On Aircraft 1000 thru Aircraft 1435 not having ASC 418, doors will slowly move to stow
position
CAUTION: IF HYDRAULIC PRESSURE EXCEEDS 1500 PSIG IN NEXT STEP, DAMAGE
TO ACTUATOR WILL RESULT. PRESSURES IN EXCESS OF 3000 PSIG WILL
BE REQUIRED TO UNLOCK ACTUATOR. REPLACEMENT OF ACTUATOR
FOR THIS CONDITION IS MANDATORY.
(19) Slowly apply hydraulic pressure, not to exceed 1450 psig, to stow T/Rev doors. Proper
locking pressure should be 1200 - 1400 psig range.
NOTE: If actuator does not lock by 1400 psi, reduce pressure to 0 and perform Thrust
Reverser Door - Rigging, 78-00-00, Adjustment / Test or Code 783003. Monitor the
following:
(a) During closing of upper and lower doors, ensure inboard and outboard adjustable door
stop cones mate smoothly with door stop receptacles on outboard stang beam.
(b) Note pressure at which actuator primary lock engages (1200 - 1400 psi). Actuator
locking will also be confirmed by an audible ″click″ as primary lock engages. Record
pressure at which actuator locks.
RECORD___________
78-00-00
Page 418
April 30/22
NOTE: Audible click is not present with 1159SCP402-11 actuators. Use Step
2.E.(19)(c) thru Step 2.E.(20) to confirm lock engagement.
(c) Remove primary lock actuator connector (08L3S1 (Left) or 08L4S1 (Right).
(d) Using multimeter, check for open between pins A and B. Remove multimeter and
connect electrical connector.
(20) Doors should not relax toward deploy position, indicating actuator primary lock is engaged.
(21) Verify T/Rev doors are within contour. Contour can be checked at forward outboard edge of
door between fairing door leading edge contour limits: ±0.060 inch with stow pressure of 0
psi.
NOTE: If contour is not within limits, perform Thrust Reverser Door - Rigging, 78-00-00,
(22) Increase stow pressure to 2400 psi. Select test stand to deploy T/Rev doors.
(23) Cycle T/Rev doors several times, returning to stow / locked position.
(a) Verify actuator primary lock engages when stow hydraulic pressure is between 1200 -
1400 psig. Record pressure at which actuator locks.
RECORD___________
(b) Verify unlocking pressure is less than 2400 psig. Record pressure at which actuator
unlocks.
RECORD___________
(24) Remove hydraulic power from aircraft. Operate flight controls to bleed hydraulic pressure off
system. See External Hydraulic Power Application, 20-30-10, Maintenance Practices.
(26) Inspect actuator for leaks.
(27) Return secondary lock latch to normal operation (remove safety wire).
(28) Disconnect hydraulic power source from T/Rev quick-disconnects or T/Rev actuator. Connect
T/Rev quick-disconnects or actuator lines.
(29) Install deploy limit switch. See Thrust Reverser Deploy Limit Switches - Removal /
(32) On Aircraft 1000 thru Aircraft 1040 not having ASC 45, install access panel 31/32-TR-5 (slave
door) as follows (see Figure 405):
NOTE: Operating links attaching hardware should be finger tight, then backed off to nearest
castellation and cotter pin installed.
(a) Install slave door.
(b) Install slave door operating links.
NOTE: If operating links were adjusted, perform slave door rigging procedure. See
Thrust Reverser Door - Rigging, 78-00-00, Adjustment / Test or Code 783003.
(33) On Aircraft 1000 thru Aircraft 1040 having ASC 45 and Aircraft 1041 and subsequent, install
78-00-00
Page 419
April 30/22
fixed blister fairing. See Figure 405.

(35) Install lower pylon board (29/30-LWR-4).
(36) Bleed and service hydraulic reservoir. See Combined / Flight Hydraulic System Reservoir -
Filling Procedures, 29-01-00, Servicing or Code 291057.
783009.
78-00-00
Page 420
April 30/22
31/32-TR-4
STANG ACCESS PANEL
31/32-TR-5 SLAVE DOOR

AIRCRAFT 1000 THRU AIRCRAFT 1040
NOT HAVING ASC 45
T/R DOOR LOCKDOWN BOLT

AND GROUND SAFETY
BOLT INSTALLATION HOLE
31/32-TR-5 BLISTER FAIRING

AIRCRAFT 1000 THRU AIRCRAFT 1040
WITH ASC 45 AND AIRCRAFT 1041
AND SUBSEQUENT.
04477C00
Thrust Reverser Access Panels

Figure 405
78-00-00
Page 421
April 30/22
Thrust Reverser Ground Lock Assembly (Deploy Position)

Figure 406
78-00-00
Page 422
April 30/22
2
4
SEE DETAIL A
5
1
1. THRUST REVERSER HYDRAULIC ACTUATOR

2. STOW PRESSURE HOSE
3. DEPLOY PRESSURE HOSE
4. PRIMARY LOCK INDICATOR SWITCH
DETAIL A 5. IDLER BELL CRANK
6. ACTUATOR PISTON
7. ACTUATOR ROD END
NOTE : DO NOT ADJUST ACTUATOR ROD END.

ROD END IS FACTORY SET. 04469C01
Thrust Reverser Hydraulic Actuator

Figure 407
78-00-00
Page 423
April 30/22
1 2
2
SEE DETAIL A
10
9
8
7 6 5 4
11
26 13
25
14
24
23 15
16
22 17
12
21
18
20 19
DETAIL A
27933C01
Thrust Reverser Pushrod Installation

Figure 408
78-00-00
Page 424
April 30/22
3. Thrust Reverser Selector Control Valve — Removal / Installation

A. General
discrepancies.
B. Preparation

Circuit breaker safety clips .................................................................... GSE2400984 or equivalent
Torque wrench, 40 - 200 inch-pounds (4.52 - 22.60 Nm) ..................... GSE5100721 or equivalent
Torque wrench, 100 - 600 inch-pounds (11.30 - 67.79 Nm) ................. GSE5100726 or equivalent
CONSUMABLES
O-ring ............................................................................................ 1159H20011-8 or NAS1612-8 (4)
Retainer ......................................................................................................................... MS28773-08
(1) Reference(s)
C. Removal
(1) Ensure hydraulic power is off.
CAUTION: DISSIPATE HYDRAULIC SYSTEM PRESSURE BEFORE PERFORMING
MAINTENANCE.
(2) Pull, tag and safety clip L/R T/REV CONT circuit breaker. On Aircraft 1000 thru Aircraft 1182
not having ASC 210 or ASC 418, pull and tag T/R EMER STOW circuit breaker. On Aircraft
1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183 thru Aircraft 1435 not having ASC
418, pull and tag LR T/R EMER STOW circuit breaker.
(3) Gain access to control valve located in tail compartment at FS 688 just aft of air cycle
machine. See Figure 401.
(4) Disconnect electrical connector.
(5) Disconnect and cap hydraulic lines.
(6) Remove mounting hardware and remove valve from mounting bracket.
(7) Remove and retain the following fittings from valve:
• Two reducers
• One union
• One elbow
(8) Discard O-rings.
NOTE: Return safety pin with valve if replacement valve was received with a safety pin.
D. Installation
(1) Install O-rings.
78-00-00
Page 425
April 30/22
(2) Install the following fittings on new valve:

• Two reducers (cyl 1 and cyl 2 ports)
• One union (pressure and return ports)
• One elbow (pressure port)
(3) Torque fittings to 265 - 295 inch-pounds (29.94 - 33.33 Nm).
(4) Install valve on mounting bracket. Install mount bolts and torque to 65 - 75 inch-pounds (7.34
- 8.47 Nm).
(5) Install hydraulic lines and torque to 340 - 380 inch-pounds (38.41 - 42.93 Nm).
(6) Connect electrical connector.
E. Follow On
(2) Ensure safety pin is stowed in storage bracket located behind control valve.
(3) In cockpit, ensure reverse thrust lever is in stow position (down and forward).
(4) Remove safety clip, tag and depress L/R T/REV CONT circuit breaker. On Aircraft 1000 thru
Aircraft 1182 not having ASC 210 or ASC 418, depress T/R EMER STOW CB. On Aircraft
418, depress L/R T/R EMER STOW circuit breaker.
(5) Energize aircraft electrical system and ensure REV ARM light is ON.
(6) Pressurize aircraft hydraulic system and check for leaks. Valve should be in stow position.
783009.
4. Thrust Reverser Deploy Limit Switches — Removal / Installation
A. General
discrepancies.
B. Preparation
Multimeter ............................................................................................... GSE2400116 or equivalent

T/Rev deploy ground safety lock ........................................................... GSE7800502 or equivalent
T/Rev stowed ground safety lock .......................................................... GSE7800501 or equivalent
78-00-00
Page 426
April 30/22
CONSUMABLES
Safety wire ................................................................................................................... MS20995C32
(1) Reference(s)
Practices
C. Removal
EQUIPMENT.
WHEN WORKING ON THE THRUST REVERSER WITH THE DOORS DEPLOYED,
ENSURE DEPLOY GROUND SAFETY LOCK (P/N 1159GSE40219-1 OR
EQUIVALENT) IS INSTALLED. WITH DOORS STOWED, ENSURE STOW
GROUND SAFETY LOCK (P/N 1159GSE111-1) IS INSTALLED.
NOTE: On Aircraft 1000 thru Aircraft 1040 having ASC 45 and Aircraft 1041 and subsequent,
T/Rev doors do not need to be deployed to remove and / or install deploy switch. T/Rev
doors must be deployed to rig switch.
(1) Ensure circuit breakers are depressed.
WARNING: THE SPOILER BOARDS MAY DEPLOY AND RETRACT UPON
APPLICATION OF HYDRAULIC POWER. REMAIN CLEAR OF SPOILER
BOARDS.
NOTE: Utility hydraulic pressure will not operate either thrust reverser.
(3) Place reverse thrust lever in deploy position. The T/Rev doors will deploy.
MINUTE ENERGIZED (REVERSE THRUST LEVER IN DEPLOYED
POSITION) AND 30 MINUTES DE-ENERGIZED (REVERSE THRUST LEVER
IN THE STOW POSITION).
flight controls to bleed hydraulic pressure off system. See External Hydraulic Power
78-00-00
Page 427
April 30/22
(7) Ensure the following circuit breaker(s) are pulled on pilot circuit breaker panel:
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
• T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 not having ASC 210 or ASC 418)
• L T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183
thru Aircraft 1435 not having ASC 418)
• R T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183
• WARN LTS PWR #4
• WARN LTS PWR #8
NOTE: The T/Rev doors may creep forward toward the stow position when hydraulic
pressure is removed, i.e., circuit breaker(s) pulled. If the thrust reverser deploy light
remains ON, fault isolate thrust reverser system to find cause. On Aircraft 1000 thru
Aircraft 1435 not having ASC 418, control valve may not have shifted to neutral. If
thrust reverser unlock and deploy lights go OFF, fault isolate thrust reverser system
to find cause, i.e., control valve may have cycled to stow position (Aircraft 1000 thru
Aircraft 1435 not having ASC 418).
See Figure 401.
(9) Remove access panel (31/32-TR-4).
CAUTION: FAILURE TO REMOVE SLAVE DOOR OPERATING LINKS WITH SLAVE
DOOR REMOVED CAN RESULT IN THRUST REVERSER DAMAGE
DURING OPERATION.
78-00-00
Page 428
April 30/22
(12) Manually open T/Rev doors to full deploy position.
(13) Install ground safety lock on trailing edges of T/Rev doors. See Figure 406.
(14) Disconnect deploy limit switch electrical leads from terminal block. Label terminal studs and
wires.
(15) Remove safety wire and nut from switch. Discard safety wire.
(16) Remove switch from bracket.
D. Installation
(1) Install deploy limit switch to bracket.
(2) Install nuts loosely.
(3) Connect multimeter to electrical leads of deploy limit switch.
CAUTION: WHEN ADJUSTING DEPLOY LIMIT SWITCH, ROTATE NUTS. DO NOT
ROTATE SWITCH AS DAMAGE TO WIRES MAY RESULT.
(4) Rotate jam nuts as required so switch contacts just open (loss of continuity) as doors are fully
deployed.
(5) Rotate one full turn toward bellcrank.
CAUTION: ENSURE SWITCH IS SEATED IN ANTI-ROTATION KEY WAY. FAILURE TO
DO SO COULD RESULT IN DAMAGE TO SWITCH.
(6) Tighten nut and safety wire.
(7) Disconnect multimeter from switch electrical leads.
(8) Connect electrical leads to terminal block.
E. Follow On
(4) Install T/Rev panel 31/32-TR-4.
castellation and install cotter pin.
(7) Remove ground safety lock assembly from thrust reverser doors.
78-00-00
Page 429
April 30/22
control valve.
(9) Depress circuit breakers pulled in Step 4.C.(7).
WARNING: ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THRUST
AIRCRAFT 1435 HAVING ASC 418, THE DOORS WILL CLOSE AND LOCK
(10) Apply electrical and hydraulic power to aircraft. See External Electrical Power Application -
CAUTION: ON AIRCRAFT 1000 THRU AIRCRAFT 1045 NOT HAVING ASC 45, NEVER
ACTUATE THRUST REVERSER DOORS WITH SLAVE DOOR REMOVED
UNLESS DRIVE LINKS ARE ALSO REMOVED. MAJOR STRUCTURAL
DAMAGE COULD RESULT.
(11) Cycle doors with hydraulic pressure to verify switch operation.
(12) Remove electrical and hydraulic power from aircraft. See External Electrical Power
Application - Maintenance Practices, 20-20-10, Maintenance Practices and External
Hydraulic Power Application, 20-30-10, Maintenance Practices.
(13) Inspect for hydraulic leaks and / or damage.
78-00-00
Page 430
April 30/22
CLEARANCE SLAVE DOOR

0.005 IN. MIN. HYDRAULIC ACTUATOR
ROD END SLAVE DOOR LINK (2) PISTON
DEPLOY
LIMIT
SWITCH
SECONDARY
LOCK
FWD
IDLER STOP
INBD
IDLER BELL CRANK VIEW LOOKING UP LH SIDE (STOWED)
DETAIL A
THRUST REVERSER LINKAGE
HYDRAULIC ACTUATOR
PISTON
BLISTER FAIRING
ROD END
CLEARANCE
0.005 IN.
MIN. DEPLOY
LIMIT
SWITCH
SECONDARY
LOCK
IDLER STOP FWD
IDLER BELL CRANK VIEW LOOKING UP LH SIDE (STOWED) INBD

DETAIL B
THRUST REVERSER LINKAGE 04463C00
Slave Door and Operating Links

Figure 409
78-00-00
Page 431
April 30/22
5. Secondary Lock Actuator — Removal / Installation

A. General
discrepancies.
B. Preparation

Hydraulic test stand, 3000 psi capacity (9 gpm minimum) ................... GSE2900149 or equivalent
Rig pin .............................................................................................. NAS1605-64 bolt or equivalent
CONSUMABLES
Cotter pin ...................................................................................................................... MS24665-86
(1) Reference(s)
Practices
783009
(2) Aircraft Preparation
(a) Pull, tag and safety clip WARN LTS PWR #4 and WARN LTS PWR #8 circuit
breaker(s).
78-00-00
Page 432
April 30/22
C. Removal
EQUIPMENT.
STOW GROUND SAFETY LOCK (P/N 1159GSE111-1) IS INSTALLED.
NOTE: On Aircraft 1000 thru Aircraft 1040 having ASC 45 and Aircraft 1041 and subsequent,
deployment of thrust reverser doors is not required. Proceed to Step 5.C.(8).
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
418)
• NUTCRACKER
WARNING: SPOILER BOARDS MAY DEPLOY AND RETRACT UPON APPLICATION OF
NOTE: The utility hydraulic pressure will not operate either Thrust Reverser (T/Rev).
(3) Ensure T/REV EMER STOW switch is not on.
78-00-00
Page 433
April 30/22

SECOND PULL, 1 MINUTE HOLD, AND 30 MINUTES OFF. WHENEVER
LEVER IN DEPLOY POSITION, ACTUATOR IS ACTIVATED. ON AIRCRAFT
1000 THRU AIRCRAFT 1143 HAVING ASC 166 AND AIRCRAFT 1144 AND
flight controls to bleed hydraulic pressure off the system.
(8) Pull, tag and safety clip L/R T/REV CONTROL and L/R SEC LOCK circuit breaker(s). On
Aircraft 1000 thru Aircraft 1182 not having ASC 210 or ASC 418, ensure T/R EMER STOW
circuit breaker is pulled. On Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183
thru Aircraft 1435 not having ASC 418, ensure L/R T/R EMER STOW circuit breaker(s) are
pulled.
NOTE: The T/Rev doors may creep forward toward stow position when hydraulic pressure
is removed, i.e., circuit breaker(s) pulled. If thrust reverser deploy light remains ON,
fault isolate thrust reverser system to find cause. On Aircraft 1000 thru Aircraft 1435
not having ASC 418, control valve may not have shifted to neutral. If thrust reverser
unlock and deploy lights go OFF, fault isolate thrust reverser system to find cause,
i.e., control valve may have cycled to stow position (Aircraft 1000 thru Aircraft 1435
not having ASC 418).
See Figure 401.
418, valve spool must be pushed into neutral position to install safety pin.
Safety pin is located in storage bracket behind control valve.
DURING OPERATION.
78-00-00
Page 434
April 30/22
(12) Manually open T/Rev doors to full deploy position.
(13) Install ground safety lock on T/Rev doors. See Figure 406.
(14) Remove access panel 31/32-TR-4.
(15) Gain access to electrical terminal board and secondary lock actuator. See Figure 410.
(16) Remove cover from terminal board.
(17) Remove and label actuator wires from the following terminals and apply identification tapes to
wires (see Figure 412):
TERMINAL WIRE
1 11
4 9
5 2
6 1
7 8
8 5
9 6
(18) Remove electrical ties from wire harness and separate actuator wires.
(19) Pull wires back until free of structure.
(20) Remove cotter pin, then attaching hardware securing actuator piston clevis to secondary lock
latch. Note orientation of hardware. Discard cotter pin.
(21) Remove hardware securing actuator to T/Rev structure. Note position of shims if any are
installed.
(22) Remove actuator from T/Rev.
D. Installation
NOTE: Do not apply lubricants to actuator piston. Use avionics type cleaner to clean piston.
(1) Loosen jam nut securing clevis to actuator piston. Do not adjust clevis at this time.
(2) Position actuator in T/Rev.
(3) Install attaching hardware and any shims removed in Step 5.C.(21). Leave hardware slightly
loose at this time.
NOTE: For Aircraft 1000 thru Aircraft 1309 having ASC 361 and Aircraft 1310 and
subsequent, ensure 1159P41553-47 shim is installed with chamfered side facing
against actuator bracket. See Figure 411.
(4) Install rig pin in secondary lock latch. Position clevis to align with attachment hole in latch.
Install attaching hardware.
(5) If necessary, remove rig pin and adjust clevis until clevis is aligned with rig pin installed.
Tighten nut until snug, then back off 1/3 to 1/2 turn to align cotter pin hole. Install cotter pin.
78-00-00
Page 435
April 30/22
(6) Tighten clevis jam nut.

(7) Remove rig pin from latch.
(8) Move secondary lock latch through its range of travel. No binding (or cushion) should be
evident. If binding is evident, shim actuator attachment points to alleviate binding. Tighten
attaching hardware securely.
(9) Route actuator wires to terminal board and secure with ties. Install wires to terminal board as
removed in Step 5.C.(17) and secure spare wires.
E. Follow On
(4) Install terminal board cover and access panel 31/32-TR-4.
fixed blister fairing (31/32-TR-5).
castellation and cotter pin installed.
(8) Remove ground safety lock assembly from T/Rev doors.
control valve.
WARNING: ENSURE PERSONNEL AND EQUIPMENT ARE CLEAR OF THRUST
REVERSER DOOR PATH.
(10) Apply electrical power to aircraft. See External Electrical Power Application - Maintenance
Practices, 20-20-10, Maintenance Practices.
(11) Remove safety clip, tag and depress L/R T/REV CONTROL and L/R SEC LOCK circuit
breakers. On Aircraft 1000 thru Aircraft 1182 not having ASC 210 or ASC 418, depress T/R
EMER STOW circuit breaker. On Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft
1183 thru Aircraft 1435 not having ASC 418, depress L/R T/R EMER STOW circuit breaker.
On Aircraft 1000 thru Aircraft 1435, T/Rev doors should close.
78-00-00
Page 436
April 30/22
(12) Remove safety clip, tag and depress WARN LTS PWR #4 and WARN LTS PWR #8 circuit
breakers.
783009.
(15) Inspect for leaks and / or damage.
78-00-00
Page 437
April 30/22
Secondary Lock Actuator (Aircraft 1000 thru Aircraft 1309 Not Having ASC 361)
Figure 410
78-00-00
Page 438
April 30/22
Secondary Lock Actuator - Installation (Aircraft 1000 thru Aircraft 1309 Having ASC 361 and Aircraft 1310
and Subsequent )
Figure 411
78-00-00
Page 439
April 30/22
Secondary Lock Actuator Solenoid - Electrical Schematic

Figure 412
78-00-00
Page 440
April 30/22
6. Thrust Reverser Forward Interlock Feedback Cable — Removal / Installation

A. General
discrepancies.
B. Preparation

Torque wrench, 10 - 50 inch-pounds (1.13 - 5.65 Nm) ......................... GSE5100720 or equivalent
Torque wrench, 40 - 200 inch-pounds (4.52 - 22.6 Nm) ....................... GSE5100721 or equivalent
CONSUMABLES
Antiseize compound ......................................................................... Molykote G-n or DOD-L-25681
Cotter pin .................................................................................................................... MS24665-151
Safety wire ................................................................................................................... MS20995C32
(1) Reference(s)
Practices
• Thrust Reverser Interlock Feedback Control System - Operational Test, 78-00-00,
Adjustment / Test or Code 783013
Test or Code 783015
• Thrust Reverser Forward and Aft Feedback Cables - Lubrication, 78-00-00, Servicing
or Code 783019
78-00-00
Page 441
April 30/22
C. Removal
EQUIPMENT.
STOW GROUND SAFETY LOCK (P/N 1159GSE111-1) IS INSTALLED.
(1) Ensure Thrust Reverser (T/Rev) doors are stowed and locked. Install stow ground safety lock
in secondary lock. See Figure 413.
(3) Pull, tag and safety clip the following circuit breakers on pilot circuit breaker panel: L/R T/REV
CONTROL, L/R SEC LOCK circuit breakers and T/R EMER STOW (Aircraft 1000 thru Aircraft
1182 not having ASC 210 or ASC 418) or L/R T/R EMER STOW circuit breakers (Aircraft
418).
See Figure 401.
is located in storage bracket behind the control valve.
(5) Remove pylon boards 29/30-LWR-2, 29/30-LWR-3 and 29/30-UPR-4.
NOTE: Retain all removed hardware for installation.
(6) Remove safety wire and bolts from interlock feedback cable quick-disconnect clamp and
remove clamp. Disconnect forward cable from aft cable. Discard safety wire. See Figure 415.
(7) Remove cotter pin and hardware securing forward feedback cable to feedback crank
assembly.
(8) At pylon bracket, remove safety wire on jam nuts and casing hex nut. Discard safety wire.
See Figure 414.
NOTE: Removal of 29/30-UPR-3 and HP bleed air regulating valve may provide additional
access to telescopic assembly.
(9) Loosen jam nut securing assembly to bracket. Slide nut down casing past hex nut.
(10) While holding hex nut, loosen telescopic assembly nut until assembly is free of casing.
78-00-00
Page 442
April 30/22
(11) Remove telescopic assembly and cable from casing.

(12) Remove jam nut from casing.
(13) Remove all clamps securing casing assembly to other components.
(14) Attach safety wire or equivalent to forward end of cable casing. This will provide proper
routing when casing is installed.
(15) Slowly pull casing at aft end. Guide casing until removed from aircraft.
D. Installation
(1) Inspect assembly for cleanliness and light coat of grease. If assembly is not present, perform
Thrust Reverser Forward and Aft Feedback Cables - Lubrication, 78-00-00, Servicing or Code
783019.
(2) Attach safety wire and slowly pull casing through pylon, starting at aft end. Guide casing until
positioned in aircraft. Remove safety wire or equivalent from casing.
(3) Install jam nut on forward end of casing.
(4) Install telescopic assembly and cable into casing.
(5) Lubricate all threaded connections with Molykote G-n (Dow Corning) or DOD-L-25681 before
assembling.
(6) While holding hex nut, install telescopic assembly to casing. Torque telescopic assembly nut
to 35 - 45 inch-pounds (3.95 - 5.08 Nm).
(7) At pylon bracket, install jam nut on telescopic assembly. Torque jam nut to 80 - 100 inch-
pounds (9.04 - 11.3 Nm). Safety wire telescopic assembly nut, jam nut and hex nut. See
Figure 414.
(8) Install hardware to secure forward feedback cable to feedback crank assembly. Install nut
until snug, then back off to first castellation and install cotter pin.
(9) Install all clamps securing casing assembly to other components.
(10) Perform Thrust Reverser Interlock Feedback Control System - Rigging, 78-00-00, Adjustment
/ Test or Code 783015.
(11) Install interlock feedback cable quick-disconnect clamp and bolts. Safety wire bolts.
E. Follow On
(3) Operate reverse thrust lever and verify lever stops at interlock position. Ensure no binding is
evident.
control valve.
78-00-00
Page 443
April 30/22
(6) Install pylon boards.
(7) Remove safety clip, tag and depress the following circuit breakers on the pilot circuit panel:
L/R T/REV CONTROL, L/R SEC LOCK circuit breakers and T/R EMER STOW (Aircraft 1000
thru Aircraft 1182 not having ASC 210 or ASC 418) or L/R T/R EMER STOW circuit breakers
(Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft 1183 thru Aircraft 1435 not
having ASC 418).
(8) Perform Thrust Reverser Interlock Feedback Control System - Operational Test, 78-00-00,
78-00-00
Page 444
April 30/22
Thrust Reverser Ground Lock Assembly (Stow Position)

Figure 413
78-00-00
Page 445
April 30/22
1. JAM NUT
2. HEX NUT
3. WASHER 1
4. SWIVEL ASSEMBLY 2 6
5. SILICONE SEAL 1 INTERLOCK FEEDBACK
4 QUICK-DISCONNECT CLAMP
6. FLEX CASING
7. SAFETY WIRE 5
8. TELESCOPIC ASSY
9. PYLON BRACKET 8
7
3
7 9
MICRO - ADJUSTER
(REF)
FS
550.00
FS
605.00
FS FS
556.00 563.00
(CONTINUED)
FORWARD INTERLOCK AFT INTERLOCK FEEDBACK
FEEDBACK CABLE CABLE ASSEMBLY
PYLON SECTOR ASSEMBLY
ASSEMBLY
04472C00
Forward (Pylon) Thrust Reverser Feedback Cable Installation

Figure 414
78-00-00
Page 446
April 30/22
Interlock Feedback Cable Assembly

Figure 415
78-00-00
Page 447
April 30/22
7. Thrust Reverser Aft Interlock Feedback Cable — Removal / Installation

A. General
discrepancies.
B. Preparation

Torque wrench, 40 - 200 inch-pounds (4.52 - 22.6 Nm) ....................... GSE5100720 or equivalent
CONSUMABLES
Antiseize compound ......................................................................... Molykote G-n or DOD-L-25681
Cotter pin .................................................................................................................... MS24665-153
Safety wire ................................................................................................................... MS20995C32
(1) Reference(s)
Practices
• Thrust Reverser Interlock Feedback Control System - Operational Test, 78-00-00,
Adjustment / Test or Code 783013
Test or Code 783015
• Thrust Reverser Forward and Aft Feedback Cables - Lubrication, 78-00-00, Servicing
or Code 783019
78-00-00
Page 448
April 30/22
C. Removal
EQUIPMENT.
EQUIVALENT) IS INSTALLED. WITH THE DOORS STOWED, ENSURE STOW
(2) Install safety pin in Thrust Reverser (T/Rev) selector control valve. Valve must be in neutral
(centered) position. See Figure 401.
(3) Remove pylon board 29/30-UPR-4.
(4) Remove safety wire and bolts from interlock feedback cable quick disconnect clamp and
loosen up clamp. Disconnect forward cable from aft cable. See Figure 415. Discard safety
wire.
(5) Remove safety pin from thrust reverser control valve. Place safety pin in storage bracket
behind control valve.
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
418)
• WARN LTS PWR #4
78-00-00
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April 30/22
• WARN LTS PWR #8

• NUTCRACKER
CAUTION: SPOILER BOARDS MAY DEPLOY AND RETRACT UPON APPLICATION OF
NOTE: Utility hydraulic pressure will not operate either T/Rev.
(8) Ensure T/REV EMER STOW switch light is not on. On pilot circuit breaker panel pull T/R
EMER STOW (Aircraft 1000 thru Aircraft 1182 not having ASC 210 or ASC 418) or L/R T/R
EMER STOW circuit breaker(s) (Aircraft 1000 thru Aircraft 1182 having ASC 210 and Aircraft
1183 thru Aircraft 1435 not having ASC 418).
(10) Remove hydraulic and electrical power. See External Electrical Power Application -
(13) Pull the following circuit breaker(s) on pilot circuit breaker panel: L/R T/REV CONTROL, L/R
SEC LOCK circuit breaker(s) and T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 not
having ASC 210 or ASC 418) or L/R T/R EMER STOW circuit breaker(s) (Aircraft 1000 thru
Aircraft 1182 having ASC 210 and Aircraft 1183 thru Aircraft 1435 not having ASC 418).
is removed, i.e., circuit breaker(s) pulled. If thrust reverser deploy light remains on,
unlock and deploy lights go off, fault isolate thrust reverser system to find cause, i.e.,
the control valve may have cycled to the stow position (Aircraft 1000 thru Aircraft
1435 not having ASC 418).
The thrust reverser doors may remain in a fully deployed position with control valve
in neutral due to friction in operating mechanism. This is acceptable if pivot point
hardware is not turning and deploy / stow cycle times are less than 4 seconds.
See Figure 401.
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April 30/22
(15) Manually position T/Rev doors fully open.
(17) Remove cotter pin and hardware securing aft feedback cable to mechanical feedback
pushrod assembly. Retain hardware for installation. Discard cotter pin. See Figure 403.
(18) At forward end of assembly, remove safety wire and loosen jam nut securing connector to
bracket. Slide jam nut down casing past hex nut. See Figure 416.
(19) While holding casing hex nut (next to micro-adjuster), loosen connector until hex nut is free
from connector.
(20) Remove connector from bracket.
(21) Remove all clamps securing casing assembly to other components. If clamp located in
precooler area of pylon cannot be accessed, it may be necessary to remove engine or thrust
reverser.
(22) At aft end of assembly, remove safety wire on jam nuts and casing hex nut. Loosen jam nut
securing aft end of assembly to bracket. Slide nut down casing past hex nut. See Figure 416.
(23) While holding hex nut, loosen telescopic assembly nut until assembly is free of casing.
(24) Remove telescopic assembly and cable from casing.
(25) Remove jam nut from casing.
(26) Attach safety wire or equivalent to forward end of cable casing. This will provide proper
routing when casing is installed.
(27) Slowly pull casing at aft end. Guide casing until removed from aircraft.
D. Installation
(1) Inspect assembly for cleanliness and light coat of grease. If assembly is not, perform Thrust
Reverser Forward and Aft Feedback Cables - Lubrication, 78-00-00, Servicing or Code
783019.
(2) Attach safety wire and slowly pull casing through thrust reverser starting at aft end. Guide
casing until positioned in thrust reverser. Remove safety wire or equivalent from casing.
(3) Install jam nuts on forward and aft ends of casing.
(4) Install telescopic assembly and cable into casing.
Antiseize compound should not be applied to the Karon (plastic) coated pins.
Exterior surfaces of Karon coated pins should be free of any lubricants.
(5) Lubricate all threaded connections with Molykote G-n (Dow Corning) or DOD-L-25681 before
assembling.
(6) While holding hex nut, install telescopic assembly through bracket to casing. Torque
telescopic assembly nut to 35 - 45 inch-pounds (3.95 - 5.08 Nm). Safety wire telescopic
assembly nut, jam nut and hex nut. See Figure 414.
(7) At forward end of assembly, install connector through bracket over cable to casing. Install jam
78-00-00
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April 30/22
nut and torque to 80 - 100 inch-pounds (9.04 - 11.3 Nm). Safety wire connector, jam nut and
hex nut. See Figure 414.
(8) Install all clamps securing casing assembly to other components.
(9) Install hardware securing aft feedback cable to mechanical feedback pushrod assembly.
Install nut until snug, then back off to first castellation. Install cotter pin.
WARNING: ON AIRCRAFT 1436 AND SUBSEQUENT AND AIRCRAFT 1000 THRU
NOTE: The T/Rev doors must be in stowed position to rig aft cable.
(11) Install interlock feedback cable quick disconnect clamp and bolts. Safety wire bolts.
E. Follow On
(3) Operate reverse thrust lever and verify lever stops at interlock position. Ensure no binding is
evident.
control valve.
(6) Install pylon boards.
(7) Depress the following circuit breakers on pilot circuit panel: L/R T/REV CONTROL, L/R SEC
LOCK circuit breakers and T/R EMER STOW (Aircraft 1000 thru Aircraft 1182 not having ASC
210 or ASC 418) or L/R T/R EMER STOW circuit breakers (Aircraft 1000 thru Aircraft 1182
having ASC 210 and Aircraft 1183 thru Aircraft 1435 not having ASC 418).
(8) Perform Thrust Reverser Interlock Feedback Control System - Operational Test, 78-00-00,
78-00-00
Page 452
April 30/22
AFT END
(EXTENDED POSITION) 16 5 17
0.68"
1 0.64"
10 MIN CONICAL
SWIVEL
RETRACTED
POSITION 2 3 4 14 15 14
(RIG POSITION)
13 12 11 10 9 8
0.375"
"B"
CASING END
FORWARD
END
17 6 7
PARTS LISTS
1-CLEVIS 7-JAM NUT 13-CONNECTOR
2-LOCKING DEVICE 8-RIGID CASING ASSY 14-JAM NUT
3-HEX NUT 9-CABLE ASSY 15-WASHER
4-SILICONE SEAL 10-LINE CONNECTOR 16-TELESCOPIC ASSY
5-SWIVEL ASSY 11-FLEX CASING ASSY 17-T/REV BRACKET
6-WASHER 12-MICROADJUSTER ASSY
04471C01
Aft Thrust Reverser Interlock Feedback Control Assembly

Figure 416
78-00-00
Page 453
April 30/22
8. Thrust Reverser Stow Limit Switches — Removal / Installation

A. General
discrepancies.
B. Preparation
Multimeter ............................................................................................... GSE2400116 or equivalent

CONSUMABLES
Safety wire ................................................................................................................... MS20995C32
(1) Reference(s)
Practices
• Thrust Reverser Door Limit (Stow) Switches - Adjustment, 78-00-00, Adjustment / Test
or Code 783414
C. Removal
EQUIPMENT.
EQUIVALENT) IS INSTALLED. WITH DOORS STOWED, ENSURE THE STOW
(1) Ensure circuit breaker(s) are depressed.
78-00-00
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April 30/22
WARNING: SPOILER BOARDS MAY DEPLOY AND RETRACT UPON APPLICATION OF

(2) Apply electrical and hydraulic power to aircraft (left - combined; right - flight). See Aircraft
Open and Close - Checks, 20-00-00, Maintenance Practices and External Electrical Power
Application - Maintenance Practices, 20-20-10, Maintenance Practices.
NOTE: The utility hydraulic pressure will not operate either Thrust Reverser (T/Rev).
MINUTE ENERGIZED (REVERSE THRUST LEVER IN DEPLOYED
POSITION) AND 30 MINUTES DE-ENERGIZED (REVERSE THRUST LEVER
IN STOW POSITION).
(7) Ensure the following circuit breaker(s) are pulled on pilot circuit breaker panel:
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
• WARN LTS PWR #4
• WARN LTS PWR #8
not having ASC 418, control valve may not have shifted to neutral. If T/Rev unlock
and deploy lights go OFF, fault isolate the thrust reverser system to find cause, i.e.,
control valve may have cycled to stow position (Aircraft 1000 thru Aircraft 1435 not
having ASC 418).
The thrust reverser doors may remain in a fully deployed position with control valve
in neutral due to friction in operating mechanism. This is acceptable if pivot point
See Figure 401.
(9) Remove T/Rev panel 31/32-TR-4.
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April 30/22
slave door as follows (see Figure 405):
DURING OPERATION.
NOTE: Do not loosen slave door operating links jam nuts. The slave door will require
(12) Manually open thrust reverser doors to full deploy position.
(13) Install deploy ground safety lock on trailing edges of T/Rev doors. See Figure 406.
(14) Disconnect stow limit switch electrical leads from terminal block. Label terminal studs and
wires.
(15) Remove safety wire and nut from switch. See Figure 410.
(16) Remove switch from bracket.
D. Installation
(1) Install stow limit switch to bracket.
(2) Install nuts loosely.
control valve.
NOTE: The utility hydraulic pressure will not operate either T/Rev.
WARNING: ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF T/REV
DOORS AND DRIVE LINKAGE BEFORE OPERATION TO PREVENT
78-00-00
Page 456
April 30/22
CAUTION: ON AIRCRAFT 1000 THRU AIRCRAFT 1045 NOT HAVING ASC 45, NEVER
ACTUATE T/REV DOORS WITH SLAVE DOOR REMOVED UNLESS DRIVE
LINKS ARE ALSO REMOVED. MAJOR STRUCTURAL DAMAGE COULD
RESULT.
(7) Stow T/Rev doors.
(8) Remove hydraulic and electrical power. Operate flight controls to bleed hydraulic pressure off
system.
(9) Perform T/Rev Door Limit (Stow) Switches Adjustment test. See Thrust Reverser Door Limit
(Stow) Switches - Adjustment, 78-00-00, Adjustment / Test or Code 783414.
E. Follow On
(4) Install T/Rev panel 31/32-TR-4.
(5) On Aircraft 1000 thru Aircraft 1040 not having ASC 45, install access panel 31/32-TR-5 slave
door as follows (see Figure 405):
castellation and install cotter pin.
NOTE: If the operating links were adjusted, perform slave door rigging procedure.
See Thrust Reverser Door - Rigging, 78-00-00, Adjustment / Test or Code
783003.
(7) Remove ground safety lock assembly.
(8) Remove safety pin from thrust reverser control valve. Place safety pin in storage bracket
behind control valve.
(9) Depress circuit breaker(s) pulled in Step 8.C.(7).
WARNING: ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF T/REV
DOORS AND DRIVE LINKAGE BEFORE OPERATION TO PREVENT
(11) Cycle doors with hydraulic pressure to verify switch operation.
78-00-00
Page 457
April 30/22
9. Thrust Reverser Door — Removal / Installation
A. General
discrepancies.
B. Preparation

Torque wrench, 50 - 250 foot-pounds (67.79 - 338.95 Nm) ................. GSE5100455 or equivalent
CONSUMABLES
Cotter pin ............................................................................................................... MS24664-153 (2)
Cotter pin ............................................................................................................... MS24664-372 (2)
NOTE: See Hydraulic Servicing, 12-01-05, System Description.
(1) Reference(s)
Practices
78-00-00
Page 458
April 30/22
C. Removal
SYSTEM IS PRESSURIZED, ELECTRICAL POWER IS ON AND THE THRUST
EQUIPMENT.
ENSURE THE DEPLOY GROUND SAFETY LOCK (1159GSE40219-1 OR
STOW GROUND SAFETY LOCK (1159GSE111-1 OR EQUIVALENT) IS
INSTALLED.
NOTE: The following numbers in parentheses ( ) are used in conjunction with Figure 418.
(1) Remove access panels 31/32-TR-6 and 31/32-TR-7. See Figure 417.
WARNING: ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE
FLIGHT CONTROL SURFACES BEFORE OPERATING.
(2) Apply electrical power and connect hydraulic power source (3000 psi at 9 gpm) to combined
/ flight system, as applicable. See External Electrical Power Application - Maintenance
NOTE: Utility hydraulic pressure will not operate either Thrust Reverser (T/Rev).
AFTER 5 SECONDS AND RETURN TO THE LATCHED POSITION.
(7) On pilot circuit breaker panel, pull, tag and safety clip the following circuit breaker(s):
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
78-00-00
Page 459
April 30/22
• R T/R EMER STOW (Aircraft 1000 thru 1182 having ASC 210 and Aircraft 1183 thru
Aircraft 1435 not having ASC 418)
unlock and deploy lights go off, fault isolate thrust reverser system to find cause, i.e.,
control valve may have cycled to stow position (Aircraft 1000 thru Aircraft 1435 not
having ASC 418).
See Figure 401.
(9) If lower door (2) is to be removed, remove hardware (3, 4, 5, 6, 7, 8) securing feedback rod
to inboard hinge point. Discard cotter pin (8).
WARNING: WEIGHT OF EACH DOOR IS APPROXIMATELY 135 POUNDS. BE
CAREFUL WHEN PUSHROD IS DISCONNECTED AND DOOR IS
REMOVED. INJURY TO PERSONNEL AND DAMAGE TO EQUIPMENT CAN
OCCUR.
(10) Provide support for door to prevent movement when pushrod is disconnected. Use of a strap
and crane is recommended to support and transport door.
(11) Remove hardware (17, 18, 19, 20, 21, 22, 23) securing pushrod (16) to door (2). Discard
cotter pin (23).
(12) Remove hardware (9, 10, 11, 12, 13, 14, 15) securing inboard door hinge to T/Rev. Discard
cotter pin (15).
(13) Remove hardware (9, 10, 11, 12, 13, 14, 15) securing outboard door hinge to T/Rev. Discard
cotter pin (15).
(14) Remove door (2) from T/Rev (1).
D. Installation
(1) Inspect fittings on inboard and outboard stang assemblies for damage.
(2) Lubricate bolts (9, 17) and bushings (11, 19) with antiseize compound.
78-00-00
Page 460
April 30/22

CAREFUL WHEN DOOR IS BEING POSITIONED. INJURY TO PERSONNEL
AND DAMAGE TO EQUIPMENT CAN OCCUR.
(3) Supporting door, carefully align door hinge fittings with fittings on inboard and outboard stang
assemblies.
(4) Install bushings (11) in inboard side of inboard stang fitting and outboard side of outboard
stang fitting.
(5) Install bolt (9) with countersunk washer (10) under head through inboard stang fitting and
inboard door fitting. Install washers (12, 13) and nut (14).
NOTE: On inboard hinge fitting, up to three washers may be used under nut.
(6) Install bolt (9) with countersunk washer (10) under head through outboard stang fitting and
outboard door fitting. Install washers (12, 13) and nut (14).
(7) Torque nuts (14) to 100 - 133 foot-pound (135.58 - 180.32 Nm). Secure nuts (14) with cotter
pins (15).
(8) Manually position door (2) until pushrod (16) slides into door fitting. Connect pushrod to door
fitting with hardware (17, 18, 19, 20, 21, 22). Torque nut (22) to 30 - 40 inch-pounds (3.39 -
4.52 Nm). Install cotter pin (23) in nut (22).
NOTE: If the gap between pushrod and shoulder bushing in door fitting is greater than
0.016 inch, add 1 - 3 washers as required.
(9) If lower door (2) was removed, lubricate bolt (3) and bushing (5) with antiseize compound.
Install hardware (3, 4, 5, 6, 7) securing feedback rod to inboard door hinge. Torque nut (7) to
30 - 40 inch-pounds (3.39 - 4.52 Nm). Install cotter pin (8) in nut (7).
E. Follow On
(3) Inspect for damage and leaks.
(4) Install access panels removed in Step 9.C.(1).
(6) Perform Thrust Reverser Door - Rigging, 78-00-00, Adjustment / Test or Code 783003.
NOTE: Ensure safety pin is removed from T/Rev selector in control valve and returned to
storage bracket behind control valve following T/Rev rigging.
78-00-00
Page 461
April 30/22
Thrust Reverser Access Doors

Figure 417
78-00-00
Page 462
April 30/22
Thrust Reverser Door Installation

Figure 418
78-00-00
Page 463
April 30/22
10. Thrust Reverser Door Pushrod — Removal / Installation

A. General
discrepancies.
B. Preparation

CONSUMABLES
Cotter pin ............................................................................................................... MS24664-153 (2)
(1) Reference(s)
Practices
78-00-00
Page 464
April 30/22
C. Removal
EQUIPMENT.
ENSURE THE DEPLOY GROUND SAFETY LOCK (1159GSE40219-1 OR
STOW GROUND SAFETY LOCK (1159GSE111-1 OR EQUIVALENT) IS
INSTALLED.
ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE FLIGHT
CONTROL SURFACES BEFORE OPERATING.
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
78-00-00
Page 465
April 30/22
not having ASC 418, the control valve may not have shifted to neutral. If thrust
reverser unlock and deploy lights go off, fault isolate thrust reverser system to find
cause, i.e., control valve may have cycled to stow position (Aircraft 1000 thru Aircraft
1435 not having ASC 418).
See Figure 401.
NOTE: On Aircraft 1436 and subsequent and Aircraft 1000 thru Aircraft 1435 not having
ASC 418, valve spool must be pushed into neutral position to install safety pin.
Safety pin is located in storage bracket behind control valve.
OCCUR.
(10) Remove hardware (4, 5, 6, 7, 8, 9, 10, 11) securing pushrod (3) to door (2). Discard cotter pin
(10).
(11) Remove hardware (13, 14, 15, 16, 17, 18, 19, 20, 21) securing pushrod (3) to idler bellcrank
(12). Discard cotter pin (21).
(12) Remove door (2) from T/Rev (1).
D. Installation
(1) Inspect push rod fitting on door (2) and idler bellcrank (12) for damage.
(2) Lubricate bolts (4, 13) and bushings (6, 15, 16) with antiseize compound.
WARNING: THE WEIGHT OF EACH DOOR IS APPROXIMATELY 135 POUNDS. BE
CAREFUL WHEN THE DOOR IS BEING POSITIONED. INJURY TO
PERSONNEL AND DAMAGE TO EQUIPMENT CAN OCCUR.
(3) Ensure actuator piston is fully retracted.
(4) Carefully align pushrod (3) with idler bellcrank (12). Connect pushrod to idler bellcrank with
78-00-00
Page 466
April 30/22
hardware (13, 14, 15, 16, 17, 18, 19, 20). Torque nut (20) to 30 - 40 inch-pounds (3.39 - 4.52
Nm). Install cotter pin (21) in nut (20).
NOTE: One additional washer (18) may be added under nut to obtain proper positioning of
cotter pin hole in bolt (13).
(5) On T/Rev Serial Number 276 and subsequent, if gap between pushrod and shoulder
bushings in idler bellcrank is greater than 0.016 inch, shim with 1159PM41564-19 washers as
required.
(6) Carefully align pushrod (3) with door fitting. Connect pushrod to door fitting with hardware (4,
5, 6, 7, 8, 9, 11). Torque nut (9) to 30 - 40 inch-pounds (3.39 - 4.52 Nm). Install cotter pin (10)
in nut (9).
NOTE: If gap between pushrod and shoulder bushing in door fitting is greater than 0.016
inch, add up to three washers, as required.
E. Follow On
(3) Remove ground safety lock assembly from T/REV doors.
(4) On pilot circuit breaker panel, remove safety clips, tags and depress circuit breakers pulled in
Step 10.C.(6).
NOTE: Ensure safety pin is removed from T/Rev selector control valve and returned to
78-00-00
Page 467
April 30/22
SEE DETAIL A
1
SEE DETAIL B
10
7 2
9
8
11 6
5
4
11
3
DETAIL A
TYPICAL 2 PLACES
TIL-69225CC

78-00-00
Page 468
April 30/22
13
12
14
15
17
13
12 14
18
3
15
20
17 16
21
THRUST REVERSER
EFFECTIVITY 1 THRU 5
13
18 3
12 14
19 21 17
15 20
17
THRUST REVERSER
18 EFFECTIVITY 6 THRU 275
21
3
20
17
THRUST REVERSER
EFFECTIVITY 276 THRU SUBQ
DETAIL B
TYPICAL 2 PLACES
92448C00

78-00-00
Page 469
April 30/22
11. Thrust Reverser Idler Bellcrank — Removal / Installation

A. General
discrepancies.
B. Preparation

Torque wrench, 100 - 600 inch-pounds (11.3 - 67.79 Nm) ................... GSE5100726 or equivalent
CONSUMABLES
Cotter pin ............................................................................................................... MS24664-153 (2)
Cotter pin ............................................................................................................... MS24664-300 (2)
(1) Reference(s)
Practices
• Thrust Reverser Hydraulic Actuator - Removal / Installation, 78-00-00, Removal /
Installation or Code 783021
78-00-00
Page 470
April 30/22
C. Removal
EQUIPMENT.
EQUIVALENT) IS INSTALLED. WITH DOORS STOWED, ENSURE THE STOW
GROUND SAFETY LOCK (P/N 1159GSE111-1 OR EQUIVALENT) IS INSTALLED.
ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE FLIGHT
CONTROL SURFACES BEFORE OPERATING.
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
78-00-00
Page 471
April 30/22
unlock and deploy lights go OFF, fault isolate thrust reverser system to find cause,
i.e., control valve may have cycled to stow position (Aircraft 1183 thru Aircraft 1435
not having ASC 418).
See Figure 401.
slave door as follows (see Figure 405):
DURING OPERATION.
OCCUR.
(12) Remove hydraulic actuator from T/Rev (1). See Thrust Reverser Hydraulic Actuator -
Removal / Installation, 78-00-00, Removal / Installation or Code 783021.
(13) Remove hardware (13, 14, 15, 16, 17, 18, 19, 20, 21) securing upper pushrod (3) to idler
bellcrank (12). Discard cotter pin (21). Secure pushrod away from idler bellcrank.
(14) Remove hardware (13, 14, 15, 16, 17, 18, 19, 20, 21) securing lower pushrod (3) to idler
78-00-00
Page 472
April 30/22
bellcrank (12). Discard cotter pin (21). Secure pushrod away from idler bellcrank.
(15) Remove hardware (20, 21, 22, 23, 24, 25, 26) from upper and lower attach points securing
idler bellcrank (12). Discard cotter pins (26).
(16) Remove idler bellcrank (12) from T/Rev (1).
D. Installation
(1) Inspect fittings on stang assembly and idler bellcrank (12) for damage.
(2) Lubricate bolts (13, 20) and bushings (15, 16, 22, 23) with antiseize compound.
(3) Carefully align idler bellcrank (12) with fittings on stang assembly. Connect idler bellcrank to
fittings with hardware (20, 21, 22, 23, 24, 25). Torque nuts (25) to 220 - 340 inch-pounds
(24.86 - 38.41 Nm). Install cotter pins (21) in nuts (25).
NOTE: One additional washer may be added under nut to obtain proper positioning of cotter
pin hole in bolt.
(4) Carefully align upper pushrod (3) with idler bellcrank (12). Connect pushrod to idler bellcrank
with hardware (13, 14, 15, 16, 17, 18, 19, 20). Torque nut (20) to 30 - 40 inch-pounds (3.39 -
(5) Carefully align lower pushrod (3) with idler bellcrank (12). Connect pushrod to idler bellcrank
with hardware (13, 14, 15, 16, 17, 18, 19, 20). Torque nut (20) to 30 - 40 inch-pounds (3.39 -
E. Follow On
(3) Install hydraulic actuator in T/Rev. See Thrust Reverser Hydraulic Actuator - Removal /
(5) Remove safety clips, tags and depress circuit breakers pulled in Step 11.C.(6).
storage bracket behind control valve following T/Rev rigging. Ensure fixed fairing /
slave door is installed.
78-00-00
Page 473
April 30/22
12. Thrust Reverser Feedback Bellcrank / Pushrod — Removal / Installation

A. General
discrepancies.
B. Preparation

CONSUMABLES
Cotter pin ............................................................................................................... MS24664-153 (3)
(1) Reference(s)
Practices
• Thrust Reverser Door - Removal / Installation, 78-00-00, Removal / Installation or Code
783040
Test or Code 783015
(2) Aircraft Preparation
78-00-00
Page 474
April 30/22
WARNING: THE TRUST REVERSER IS ARMED WHEN THE AIRCRAFT HYDRAULIC

SYSTEM IS PRESSURIZED, ELECTRICAL POWER IS ON AND THE TRUST
REVERSER SELECTOR CONTROL VALVE IS NOT PINNED IN THE
NEUTRAL POSITION. CLEAR THE TRUST REVERSER AREA OF ALL
PERSONNEL AND EQUIPMENT.
ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE TRUST
BEFORE PERFORMING MAINTENANCE, ENSURE THE ISOLATION OF
THE TRUST REVERSER SYSTEM BY PINNING THE TRUST REVERSER
SELECTOR CONTROL VALVE IN NEUTRAL.
WHEN WORKING ON THE TRUST REVERSER WITH THE DOORS
DEPLOYED, ENSURE THE DEPLOY GROUND SAFETY LOCK
(1159GSE40219-1 OR EQUIVALENT) IS INSTALLED. WITH THE DOORS
STOWED, ENSURE THE STOW GROUND SAFETY LOCK (1159GSE111-1
OR EQUIVALENT) IS INSTALLED.
ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE
FLIGHT CONTROL SURFACES BEFORE OPERATING.
(a) Apply electrical power and connect hydraulic power source (3000 psi at 9 gpm) to
combined / flight system, as applicable. See External Electrical Power Application -
ELECTRICAL POWER IS APPLIED TO AIRCRAFT WITH REVERSE
THRUST LEVER IN DEPLOY POSITION, ACTUATOR IS ACTIVATED.
ON AIRCRAFT 1000 THRU AIRCRAFT 1143 HAVING ASC 166 AND
AIRCRAFT 1144 AND SUBSEQUENT, SECONDARY LOCK ACTUATOR
WILL BE DE-ENERGIZED AFTER 5 SECONDS AND RETURN TO
LATCHED POSITION.
(b) Place reverse thrust lever in deploy position. T/Rev doors will deploy.
(c) With reverse thrust lever in deploy position, remove hydraulic power from aircraft.
Operate flight controls to bleed hydraulic pressure off system.
(d) Remove electrical power from aircraft. See External Electrical Power Application -
(e) Place reverse thrust lever in stow position.
(f) On pilot circuit breaker panel, pull, tag and safety clip the following circuit breaker(s):
• L T/REV CONTROL
• R T/REV CONTROL
• L SEC LOCK
• R SEC LOCK
418)
78-00-00
Page 475
April 30/22
NOTE: The T/Rev doors may creep forward toward stow position when hydraulic
pressure is removed, i.e., circuit breaker(s) pulled. If thrust reverser deploy
light remains ON, fault isolate thrust reverser system to find cause. On Aircraft
1000 thru Aircraft 1435 not having ASC 418, control valve may not have
shifted to neutral. If thrust reverser unlock and deploy lights go OFF, fault
isolate thrust reverser system to find cause, i.e., control valve may have
cycled to stow position (Aircraft 1000 thru Aircraft 1435 not having ASC 418).
The T/Rev doors may remain in a fully deployed position with control valve in
neutral due to friction in operating mechanism. This is acceptable if pivot point
C. Removal
See Figure 401.
NOTE: On Aircraft 1000 thru Aircraft 1182 not having ASC 210 or ASC 418, valve spool
must be pushed into neutral position to install safety pin.
The safety pin is located in storage bracket behind control valve.
(2) Remove hardware (5, 6, 7, 8) securing feedback cable (4) to bellcrank (3). Discard cotter pin
(8).
(3) Remove hardware (10, 11, 12, 13, 16) securing feedback pushrod (9) to lower door (2)
inboard hinge point. Discard cotter pin (16).
(4) Remove hardware (20, 21, 22, 23, 24) securing bellcrank (3) to T/Rev (1). Remove bellcrank
from T/Rev. Discard cotter pin (24).
NOTE: Retain any washers used to shim bellcrank into bracket.
(a) If mounting stud (14) is to be replaced, remove hardware (15, 17, 18, 19) securing stud
to door hinge. Discard cotter pin (19).
(b) If pushrod (9) is to be replaced, drill out special rivet (24) to separate pushrod (9) from
bellcrank (3).
(c) If bellcrank bracket is to be removed, see Thrust Reverser Door - Removal /
Installation, 78-00-00, Removal / Installation or Code 783040 for removal of door hinge
point hardware.
D. Installation
(1) If bellcrank bracket was removed, see Thrust Reverser Door - Removal / Installation,
78-00-00, Removal / Installation or Code 783040 for installation of bracket and door hinge
point hardware.
(2) If pushrod (9) was removed, install pushrod (9) to bellcrank (3) with special rivet (24).
(3) If mounting stud (14) was removed, install stud (14) with hardware (15, 17, 18) to door hinge.
Torque nut (18) to 30 - 40 inch-pounds (3.39 - 4.52 Nm). Install cotter pin (19) in nut (18).
78-00-00
Page 476
April 30/22
(4) Inspect bellcrank (3), pushrod (9), feedback cable (4) end fitting and bellcrank bracket for
damage.
(5) Lubricate bolts (5, 20), mounting stud (14) and bushings (12, 21) with antiseize compound.
(6) Align bellcrank (3) with bushing (21) in bellcrank bracket. Install hardware (20, 22, 23). Torque
nut (23) to 30 - 40 inch-pounds (3.39 - 4.52 Nm). Install cotter pin (24) in nut (23).
NOTE: Reinstall any washers that were used to shim bellcrank into bracket.
(7) Install feedback pushrod (9) to lower door (2) inboard hinge point mounting stud (14) with
hardware (10, 11, 12, 13). Torque nut (11) to 30 - 40 inch-pounds (3.39 - 4.52 Nm). Install
cotter pin (16) in nut (11).
(8) Install feedback cable (4) to bellcrank (3) hardware (5, 6, 7). Torque nut (7) to 30 - 40 inch-
pounds (3.39 - 4.52 Nm). Install cotter pin (8) in nut (7).
E. Follow On
(3) Remove safety clips, tags and depress circuit breakers pulled in Step 12.B.(2)(f).
78-00-00
Page 477
April 30/22
Thrust Reverser Feedback Bellcrank / Pushrod Installation

Figure 420
78-00-00
Page 478
April 30/22

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MSG-3 MAINTENANCE MANUAL

EXHAUST — REMOVAL / INSTALLATION

Aft Cowl Assembly and Thrust Reverser

CLEARANCE SLAVE DOOR

IDLER BELL CRANK VIEW LOOKING UP LH SIDE (STOWED) INBD

Aft Cowl Assembly and Thrust Reverser

Aft Cowl Assembly and Thrust Reverser

Interlock Feedback Cable Assembly

HOIST ATTACHMENTS UPPER HINGE COWL

FIXED COWL ENGINE

Aft Electrical Disconnect Panel

2. Thrust Reverser Hydraulic Actuator — Removal / Installation

CAUTION: SECONDARY LOCK ACTUATOR HAS A LIMITED DUTY CYCLE OF 1

(2) Lubricate O-rings with hydraulic fluid and install on fittings.

CAUTION: DISCONNECTING LOWER DOOR PUSHRODS FROM IDLER BELLCRANK

fixed blister fairing. See Figure 405.

31/32-TR-5 SLAVE DOOR

T/R DOOR LOCKDOWN BOLT

31/32-TR-5 BLISTER FAIRING

Thrust Reverser Access Panels

Thrust Reverser Ground Lock Assembly (Deploy Position)

1. THRUST REVERSER HYDRAULIC ACTUATOR

NOTE : DO NOT ADJUST ACTUATOR ROD END.

Thrust Reverser Hydraulic Actuator

Thrust Reverser Pushrod Installation

3. Thrust Reverser Selector Control Valve — Removal / Installation

Caps and plugs ................................................................................................................... Standard

(2) Install the following fittings on new valve:

Multimeter ............................................................................................... GSE2400116 or equivalent

CLEARANCE SLAVE DOOR

IDLER BELL CRANK VIEW LOOKING UP LH SIDE (STOWED) INBD

Slave Door and Operating Links

5. Secondary Lock Actuator — Removal / Installation

Circuit breaker safety clips .................................................................... GSE2400984 or equivalent

CAUTION: SECONDARY LOCK ACTUATOR HAS A LIMITED DUTY CYCLE OF 1

(6) Tighten clevis jam nut.

Secondary Lock Actuator Solenoid - Electrical Schematic

6. Thrust Reverser Forward Interlock Feedback Cable — Removal / Installation

Circuit breaker safety clips .................................................................... GSE2400984 or equivalent

(11) Remove telescopic assembly and cable from casing.

Thrust Reverser Ground Lock Assembly (Stow Position)

Forward (Pylon) Thrust Reverser Feedback Cable Installation

Interlock Feedback Cable Assembly

7. Thrust Reverser Aft Interlock Feedback Cable — Removal / Installation

Thrust reverser deployed ground safety lock ........................................ GSE7800502 or equivalent

• WARN LTS PWR #8

Aft Thrust Reverser Interlock Feedback Control Assembly

8. Thrust Reverser Stow Limit Switches — Removal / Installation

Multimeter ............................................................................................... GSE2400116 or equivalent

WARNING: SPOILER BOARDS MAY DEPLOY AND RETRACT UPON APPLICATION OF

Circuit breaker safety clips .................................................................... GSE2400984 or equivalent

WARNING: WEIGHT OF EACH DOOR IS APPROXIMATELY 135 POUNDS. BE

Thrust Reverser Access Doors

Thrust Reverser Door Installation

10. Thrust Reverser Door Pushrod — Removal / Installation

Circuit breaker safety clips .................................................................... GSE2400984 or equivalent

Thrust Reverser Pushrod Installation

Thrust Reverser Pushrod Installation

11. Thrust Reverser Idler Bellcrank — Removal / Installation