Appendix_C_-_Publications_and_Forms_30_Dec_2015.pdf

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DEPARTMENT OF THE AIR FORCE

TECHNICAL ORDER

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT E - Distribution authorized to the DoD components only, Direct Military Support, 01 November, 2011.

Other requests shall be referred to OO-ALC/GHMEH, HILL AFB, Utah 84056-5820.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq). Violations of these export laws are subject to severe penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of the contents or reconstruction of the document.

TO 1T-38- 856

DATA CODE 0110792

01 November 2011

REPLACEMENT OF NOSE LANDING GEAR (NLG)

STRUT ASSEMBLY P/N 7227219-10, NLG DRAG

BRACE P/N 6-41650-505, MAIN LANDING GEAR

(MLG) LEFT STRUT ASSEMBLY P/N 7227217-10

OR 7227217-70, MLG RIGHT STRUT ASSEMBLY

P/N 7227217-20 OR 7227217-80, MLG LEFT SIDE

BRACE P/N 6-40650-513 OR 9235382-10, AND MLG

RIGHT SIDE BRACE 6-40650-513 OR 9235382-20

ON T-38 AIRCRAFT

NOTE

Commanders are responsible for bringing this technical order to the attention of all Air Force personnel cleared for operation of the affected system.

1. APPLICATION.

1.1 Identification. This Time Compliance Technical Order (TCTO) is applicable to all T-38 aircraft.

1.2 Kit Applicability. Kits are not required by this TCTO. However, the six major landing gear assemblies will be provided as a ship set.

1.3 Proofing. TCTO Verification, In Accordance With (IAW) TO 00-5-15, was accomplished on aircraft 66-4378 at Vance AFB OK on 29 Sept 2011.

2. PURPOSE. The purpose of this technical order is to replace nose and main landing gear, drag brace and sidebrace assemblies . Engineering analysis has determined these assemblies are approaching the end of their service life cycle. Failure to comply with this technical order could result in a catastrophic failure of the landing gear.

TO 1T-38-856

3. WHEN TO BE ACCOMPLISHED.

At the next maintenance opportunity but not later than next phase inspection after receipt of this TCTO and ship sets. Failure to accomplish this TCTO shall be justification for withdrawing affected system/equipment from service until compliance is accomplished. If the compliance period cannot be met before the TCTO rescission date, the performing organization will request an extended compliance period IAW TO 00-5-15.

3.1 TCTO Rescission Date. The rescission date for this technical order is 30 September, 2017, unless extended via TCTO supplement or notices received through the Reliability and Maintainability Information System (REMIS) or other Management Information Systems (MIS). This TCTO will be retained until listed as rescinded in the applicable index.

3.2 Remove From Service. The Remove From Service date is 60 days prior to the rescission date.

4. BY WHOM TO BE ACCOMPLISHED.

Organizational/Intermediate Level Maintenance or Contractor Equivalent.

5. WHAT IS REQUIRED.

5.1 Supply Information and Requirements.

5.1.1 Kits/Parts/Materials Required. The following parts will not be furnished in a kit and shall be obtained from the appropriate supply source. The complete kit concept is waived by John Michalski (Chief, Primary Trainer Aircraft Section), HQ AETC/A4MAT, DSN 487-3171. Instead of kits, the six major landing gear assemblies will be supplied as a ship set.

AF activities shall ensure that requisitioning of TCTO ship sets is effected in an expeditious manner to ensure accomplishment of this TCTO within the designated time period.

Nose strut, left and right MLG struts, drag brace and left and right sidebrace assemblies will be issued as ship sets.

All MICAP requirements for ship set components should be requisitioned to FGZ (Ogden) for fulfillment, no lateral support should be processed.

Qty Stock Number Part Number Nomenclature Source

1 1620-01-564-4690 7227217-80 Strut assembly, MLG R/H AF Supply 1 1620-01-564-4691 7227217-70 Strut assembly, MLG L/H AF Supply 1 1620-00-299-0278 7227219-10 Strut assembly, NLG AF Supply 1 1620-01-358-1247 9235382-20 Side Brace Assembly R/H AF Supply 1 1620-01-358-1246 9235382-10 Side Brace Assembly L/H AF Supply 1 1620-00-105-8933 6-41650-505 Drag Brace Assembly AF Supply 13 5315-00-815-1405 MS24665-151 Cotter Pin AF Supply 3 5315-00-234-1863 MS24665-300 Cotter Pin AF Supply 2 5315-00-236-8359 MS24665-370 Cotter Pin AF Supply 2 5315-00-059-0491 MS24665-372 Cotter Pin AF Supply 4 5315-00-234-1856 MS24665-155 Cotter Pin AF Supply 1 5315-00-241-7332 MS24665-374 Cotter Pin AF Supply 1 5315-00-839-5820 MS24665-134 Cotter Pin AF Supply 1 5315-00-839-2325 MS24665-132 Cotter Pin AF Supply

5 5315-00-234-1854 MS24665-153 Cotter Pin AF Supply 3 5310-00-176-8109 AN320-5 Nut AF Supply 24 5310-00-807-1474 MS21042L3 Nut AF Supply 2 5310-00-176-8110 AN320-6 Nut AF Supply 2 5310-00-969-4340 EWSN926-4 Nut AF Supply 10 5310-00-807-1472 MS21042L06 Nut AF Supply 8 5310-00-167-1343 AN315-3R Nut AF Supply 4 5310-00-226-3911 MS17826-4 Nut AF Supply 1 5310-00-167-1285 AN310-4 Nut AF Supply 2 5310-00-167-1286 AN310-5 Nut AF Supply 1 5310-00-167-1279 AN310C3 Nut AF Supply 4 5365-00-691-4040 9757E20 Shim AF Supply 4 5365-00-196-7126 7881837001 Shim AF Supply 2 5365-00-227-6310 6-40612-1 Shim AF Supply 4 5365-00-802-1434 2-41024-1 Shim AF Supply 1 5315-00-198-8091 AN386-1-6A Pin, Tapered, Threaded AF Supply

5.1.2 Action Required on Items in Chief of Supply or Units Stock. Repairable assets (100% new, zero time) for TCTO completion will be released from depot as condition code B. All other overhauled components will be stored and issued from depot as condition code A for sustainment. As condition code B assets arrive for TCTO completion, the condition code will need to be changed to A before receipt processing.

5.1.3 Kits/Parts/Materials Required to Modify Items in Stock. Not applicable.

5.1.4 Disposition of Removed and Replaced Parts/Materials.

Parts removed, but not listed, shall be processed to the local Defense Reutilization and Marketing Service (DRMS) if unserviceable or not catalogued.

Serviceable stock listed items shall not be returned to stock unless the quantity removed exceeds $25.00 line item value.

Repairable items removed/replaced shall be returned to FGZ (Ogden). Tag removed components as condition code F and turn into supply.

Stock Number

Part Number Nomenclature

1620-00-279-5839 Or 1620-01-564-4690

1620-00-264-0744 Or 1620-01-564-4691

1620-00-140-5242 Or 1620-01-358-1247

1620-00-140-5241 or 1620-01-358-1246

1620-00-299-0278

1620-00-105-8933

7227217-20 Or 7227217-80

7227217-10 Or 7227217-70

6-40650-514 or 9235382-20

6-40650-513 or 9235382-10

7227219-10

6-41650-505

Strut Assembly, MLG R/H

Strut Assembly, MLG L/H

Side Brace Assembly, R/H

Side Brace Assembly, L/H

Strut Assembly, NLG

Drag Brace Assembly, NLG

5.1.5 Drawings and Instructions Required. Not applicable.

5.1.6 Size, Weight and Cost of Kits/Parts/Materials. Not applicable.

5.1.7 Disposition of Kits/Parts/Materials. Not applicable.

5.2 Personnel Information and Requirements.

Work Phases AFSC Skills Man-Hours

Unpacking 2A3X3 or equivalent 1.0 Disassembly 2A3X3 or equivalent 0.5 Installation 2A3X3 or equivalent 36.0 Assembly 2A3X3 or equivalent 0.5 Operational check 2A3X3 or equivalent 4.0

Total Man-Hours 42.0

5.3 Special Tools, Fixtures, Test Equipment and Software Required. Not applicable.

6. HOW WORK IS ACCOMPLISHED.

Personnel are advised to read and thoroughly familiarize themselves with the information contained in this TCTO. Minor deviations are authorized providing the intent of this TCTO is accomplished and safety is not compromised. Observe all WARNINGS, CAUTIONS, and NOTES that apply to the following steps.

a. Make aircraft safe for maintenance IAW TO 1T-38A/C-2-1, TO 1T-38A/C-2-2, and TO 1T-38A/C-2-8.

b. Jack aircraft IAW TO 1T-38A/C-2-2CL-3.

c. Remove left and right MLG wheel assemblies IAW TO 1T-38A/C-2-8.

d. Remove left and right wheel brake assemblies IAW TO 1T-38A/C-2-8.

e. Remove left and right MLG strut assemblies IAW TO 1T-38A/C-2-8.

f. Remove left and right MLG sidebrace assemblies IAW TO 1T-38A/C-2-8.

g. If required, disconnect aft attach point of the left and right MLG rotary actuators to facilitate the removal of the side brace collars. Remove and replace collars IAW TO

h. If previously disconnected, secure left and right MLG rotary actuators IAW TO

i. Remove left and right MLG actuating cylinders from the removed side brace assemblies and reinstall on replacement side brace assemblies IAW TO 1T-38A/C-2-8.

Point “C” eyebolt comes pre-assembled in the replacement MLG strut assemblies. It may be removed and installed on the side brace assemblies to facilitate maintenance.

j. Install replacement left and right MLG sidebrace assemblies IAW TO 1T-38A/C-2-8.

k. Remove all hardware (clamps, standoffs, lines and hoses) not supplied with the new MLG assemblies from the removed assemblies and install in the replacement assemblies IAW TO 1T-38A/C-2-8.

l. Install replacement left and right MLG strut assemblies IAW TO 1T-38A/C-2-8.

m. Install left and right wheel brake assemblies IAW TO 1T-38A/C-2-8.

n. Install left and right MLG wheel assemblies IAW TO 1T-38A/C-2-8.

o. Remove NLG wheel assembly IAW TO 1T-38A/C-2-8.

p. Remove NLG assembly IAW TO 1T-38A/C-2-8.

q. Remove NLG drag brace IAW TO 1T-38A/C-2-8.

r. Remove nose wheel steering actuator and hydraulic lines from removed NLG assembly and install on replacement assembly IAW TO 1T-38A/C-2-8.

s. Remove barrier probe from removed NLG assembly and install on replacement assembly

IAW 1T-38A/C-2-8.

t. Remove nose wheel steering control torque rod from removed NLG assembly and install on replacement assembly IAW TO 1T-38A/C-2-8.

u. Remove all hardware (clamps, standoffs, lines and hoses) not supplied with the new NLG assembly from the removed assembly and install in the replacement assembly IAW TO 1T- 38A/C-2-8.

v. Remove NLG actuating cylinder from removed drag brace assembly and install on replacement drag brace assembly IAW TO 1T-38A/C-2-8.

w. Install replacement NLG drag brace assembly IAW TO 1T-38A/C-2-8.

x. Install replacement NLG assembly IAW TO 1T-38A/C-2-8.

y. Install NLG wheel assembly IAW TO 1T-38A/C-2-8.

z. Service MLG and NLG assemblies IAW TO 1T-38A/C-2-8.

aa. Bleed the left and right brake system IAW TO 1T-38A/C-2-8.

ab. Lubricate left and right MLG struts, left and right sidebrace, NLG strut and drag brace assemblies IAW TO 1T-38A/C-2-2.

ac. Perform Adjust Main Landing Gear IAW TO 1T-38A/C-2-8.

ad. Perform Adjust Nose Landing Gear IAW TO 1T-38A/C-2-8.

ae. Perform Testing Landing Gear Normal Operation IAW TO 1T-38A/C-2-8.

af. Perform Operational Checkout of Landing Gear Alternate Release System IAW TO 1T-38A/C-2-8.

ag. Perform Operational Check of Rudder Travel Limiter IAW TO 1T-38A/C-2-3.

ah. Perform Operational Checkout of Nosewheel Steering System IAW TO 1T-38A/C-2-8.

ai. Perform Testing Landing Gear Indication and Warning System IAW TO 1T-38A/C-2-8.

aj. Install ground safety pins and lower aircraft from jacks IAW TO 1T-38A/C-2-2CL-3.

7. SUPPLEMENTAL INFORMATION.

7.1 Fuel System Defuel/Purge. Defueling/purging of the fuel system is not required prior to accomplishing this

TCTO.

7.2 Operational Checkout Requirements. Functional Check Flight is not required. Perform Operational Check of Rudder Travel Limiter IAW TO 1T-38A/C-2-3. Perform Operational Checkout of Nosewheel Steering System IAW TO 1T-38A/C-2-8. Perform Testing Landing Gear Normal Operation IAW TO 1T-38A/C-2-8. Perform Testing Landing Gear Indication and Warning System IAW TO 1T-38A/C-2-8. Perform Operational Checkout of Landing Gear Alternate Release System IAW TO 1T-38A/C-2-8.

7.3 Weight and Balance Information. There are no weight and balance changes resulting from the instructions contained herein.

7.4 Technical Manuals Affected.

TO Number Date of Basic Issue

1T-38A-4-8 30 September 2003

1T-38C-4-8 15 September 2008

1T-38A-06 15 December 2008

1T-38C-06 15 June 2008

8. RECORDS.

8.1 Action Required on Maintenance Records.

a. Report TCTO compliance IAW TO 00-20-2, Chapter 9.

b. Update AFTO Form 95 to show TCTO compliance.

8.2 Action Required on Supply Records. Not applicable.

BY ORDER OF THE SECRETARY OF THE AIR FORCE

NORTON A. SCHWARTZ, General, USAF Chief of Staff

DONALD HOFFMAN, General, USAF Commander, AFMC

Prepared by James Simpson, OO-ALC/GHMEH, Hill AFB, Utah 84056/DSN 777-1766.

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT E - Distribution authorized to the Department of Defense components only for Direct Military Support, 15 October 2012. Other requests for this document shall be referred to AFLCMC/WLDEH, HILL AFB, Utah 84056-5811.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq). Violations of these export laws are subject to severe penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or

TO 1T-38-858

Data Code: 0110803 20121015

MODIFICATION OF DORSAL LONGERON AFT

FIXED COVER FASTENER ASSEMBLY AT

FUSELAGE STATION (FS) 393.50 TO FS 400.50

1.1 Identification. This Time Compliance Technical Order (TCTO) is applicable to all T-38 aircraft.

1.2 Kit Applicability. Kits are not required by this TCTO.

1.3 Proofing. Verification was performed at Randolph AFB, Texas on 3 November, 2011 on aircraft 66-08350 In Accordance With (IAW) TO 00-5-15.

2. PURPOSE.

The purpose of this technical order is to install a nutplate strip and removable fasteners along both left and right sides of the aft fixed cover, FS 393.50 to FS 400.50, reference Engineering Order No. 11A1775-H. This will enable reoccurring inspections of these holes without the removal of solid rivets.

3. WHEN TO BE ACCOMPLISHED.

Concurrently with TCTO 1T-38C-569, not to exceed 450 flight hours or concurrently with TCTO 1T-38-868, not to exceed 900 flight hours. Failure to accomplish the work by expiration of the compliance period, or 60 days prior to the TCTO rescission date, whichever comes first, shall be justification for withdrawing affected system /equipment from service until compliance is accomplished. If the compliance period cannot be met before the TCTO rescission date, the performing organization will request an extended compliance period IAW TO 00-5-15.

Shaunna.Johnson

Text Box

See Sup C, dated 18 Oct 2012

Billie.Gipson

Typewritten Text

See Sup D, dated 24 Jun 2013

3.1 TCTO Rescission Date. The TCTO Rescission date is 14 October 2017, unless extended via TCTO supplement or notices received through the Reliability and Maintainability Information System (REMIS) or other management information systems. This TCTO will be retained until listed as rescinded in the applicable index.

4. BY WHOM TO BE ACCOMPLISHED.

Organizational/Intermediate Level Maintenance or Contractor Equivalent.

5. WHAT IS REQUIRED.

5.1 Supply information and requirements.

5.1.1 Kits/Parts/Materials Required. The following parts/materials will not be furnished in a kit, complete kit concept waived by John Michalski GS-12 AETC/A4MAT, DSN 487-3171 John.Michalski@us.af.mil. The following individual items shall be requisitioned IAW AFMAN 23-110.

AF activities shall ensure that requisitioning of TCTO kits/parts is effected in an expeditious manner to ensure accomplishment of this TCTO within the designated time period.

Qty Stock Number Part Number Nomenclature Source

AR 8030-00-152-0013 SAE AMS-S-8802 Sealant AF Supply

* 1 9535-00-508-8614 9535-00-230-7546

AMS-QQ-A-250/12

Aluminum 7075-T73 or 7075-T6 0.040

AF Supply

* 1 9535-01-015-3477 9535-00-243-3512

AMS-QQ-A-250/12

Aluminum 7075-T73 or 7075-T6 0.090

16 5305-00-838-7330 NAS 1153-6 Bolt, Shear AF Supply 2 5310-00-763-7887 MS 21074L3 Nutplate AF Supply

14 5310-00-772-3720 NAS 1068A3 Nutplate AF Supply 4 5320-00-117-6938 MS 20426AD3-4 Rivets AF Supply

28 5320-00-117-6939 MS 20426AD3-5 Rivets AF Supply

* Items marked with an asterisk specify a 48-inch X 144-inch sheet of aluminum which can be used to manufacture nutplate bases and nutplate spacers for all aircraft affected by this TCTO.

5.1.2 Action Required on Items in Chiefs of Supply or Units Stock. Not applicable.

Reutilization and Marketing Office if unserviceable or not cataloged.

5.1.7 Disposition of Kits/Parts/Materials. Not applicable.

5.2 Personnel Information and Requirements.

Work Phases AFSC Skills Man-Hours

Unpacking N/A 0.0

Disassembly

2A3X3 and 2A7X3 or equivalent

30.0

Installation

2A7X3 or equivalent

5.0

Assembly

2A3X3 and 2A7X3 or equivalent

8.0

Operational/leak check 2A3X3 and 2A7X3 or equivalent 2.0

Total Man-Hours 45.0

Personnel are advised to read and thoroughly familiarize themselves with the information contained in this TCTO. Minor deviations are authorized providing the intent of this TCTO is accomplished and safety is not compromised.

a. Make aircraft safe for maintenance IAW TO 1T-38A/C-2-1 and TO 1T-38A/C-2-2.

b. Defuel and purge aircraft IAW TO 1T-38A/C-2-5.

c. Remove forward and center dorsal fuel cells IAW TO 1T-38A/C-2-5.

Removal of remaining dorsal covers not removed in TO 1T-38A/C-2-5 for fuel cell removal will be accomplished for TCTO 1T-38C-569 or 1T-38-868, as applicable, that will be complied with concurrently with this TCTO.

d. Remove dorsal covers numbers two and seven by removing screws and remove cover IAW TO 1T-38A/C-3.

See Figure 1.

Figure 1. Dorsal Covers to be Removed to Access Dorsal Deck.

(Remove Covers 1 thru 7)

e. Loosen and move electrical conduits (right hand side) for access to area under the forward and aft fixed dorsal covers, see Figures 2 thru 8.

f. Remove air conduits (left hand side) IAW TO 1T-38A/C-2-4 for access to area under the forward and aft fixed dorsal covers. See Figures 2 thru 8.

Figure 2. Area of Aft Fixed Cover Fastener Replacement.

Figure 3. Area of Aft Fixed Cover Fastener Replacement.

(Right Side Looking Inboard)

Area along Fixed Cover for Fastener Replacement (right side shown)

Dorsal Longeron

When Aft Hole #9 is Drilled, Leave Empty (no Fastener Installed). When Aft Hole #9 is Undrilled, as Shown, Leave Undrilled.

FS 400.50 FS 393.50

Figure 4. Electrical and Air Conduits to Remove or Loosen for Access.

(View Looking Aft along Dorsal Deck)

Figure 5. Electrical and Air Conduits to Remove or Loosen for Access.

(View Looking Inboard at Left Hand Side, Aft of FS 284.00)

Dorsal Deck Plumbing and Wiring to be Loosened and Moved or Removed for Initial Inspection

Areas along Fixed Cover for Fastener Replacement

Duct Removal Required

Cable Required to be Moved Inboard

Electrical Conduits Required to be Loosened for Access

Fuel Filler Cap Removal Required

FS 284.00

FS 299.00

Figure 6. Electrical Conduits to Remove or Loosen for Access.

(View Looking Down on Right Hand Dorsal Deck)

Figure 7. Electrical Conduits to Remove or Loosen for Access.

(View Looking Inboard at Right Hand Side of FS 299.00)

Electrical Conduits Required to be Loosened for Access

Cable Ties Removed to Allow Cable Movement From Conduit

Fitting Loosened to Allow Conduit Movement

FS299.00

FS 299.00

Figure 8. Electrical Conduits to Remove or Loosen for Access.

(View Looking Inboard at Right Hand Side at FS 400.50)

Only non-metallic scrapers and/or sealant removal tools will be used to remove sealant along the dorsal longeron or damage to the longeron may result.

g. Remove fuel sealant from the inboard side of the dorsal longeron located under the aft fixed cover between FS 393.50 and FS 400.50. This will expose seven solid rivets and either one or two Hi-Lok fasteners on both left and right sides. It will also provide a clean surface for subsequent NDI and mounting the required nutplate bases, see Figures 9 and 10.

Fittings Loosened behind Aft Fixed Dorsal Cover to allow Conduit Movement

FS 400.50

CAUTION

Figure 9. Sealant Removal Under Electrical Conduits.

(View Looking Outboard at Right Hand Side Under Aft Fixed Dorsal Cover)

Figure 10. Air Duct and Sealant Removal Under Aft Fixed Cover.

(View Looking Aft and Outboard at Left Hand Side Under Aft Fixed Dorsal Cover)

Sealant Removal Required under Conduits at Aft Fixed Dorsal Cover, Left and Right Sides

Sealant Removed at Aft Fixed Dorsal Cover to Allow NDI and Nutplate Base

Air Duct Removed for Access

FS 393.50FS 400.50

Accomplish the fastener replacement modification on one side at a time, left or right, to avoid removing all affected fasteners at the same time. This will keep fastener holes from shifting.

Remove solid rivets using approved removal procedures stated IAW TO 1T-38A/C-3, Chapter 12. Improper head drilling could damage the steel dorsal longeron.

Hi-Lok collar cutters shall not be used under any circumstances to remove Hi-Lok collars from Hi-Lok fasteners on the longeron structure or damage to aircraft may result.

Prior TCTOs 1T-38-572 and 1T-38A-974 installed 1 or 2 Hi-Loks at the aft end (FS 400.50) of the aft fixed cover.

h. Remove seven (7) solid rivets, P/N MS20426B6, and one or two Hi-Lok fasteners, P/N HL63PB-6, left and right. Some aircraft will have two Hi-Lok fasteners at the aft end of the fixed cover; other aircraft will have only one Hi-Lok at this location, see Figures 11 and 12.

Figure 11. Fastener Replacement Under Air Conduit.

(View Looking Outboard at Left Hand Side Under Aft Fixed Dorsal Cover)

Location of Nutplate Base to Replace Seven Solid Rivets and One Hi-Lok Fastener

When Aft Hole #9 is Drilled, Leave Empty (no Fastener Installed). When Aft Hole #9 is Undrilled, as Shown, One Hi-Lok Removal Required for NDI and

Figure 12. Fastener Replacement Under Electrical Conduits.

(View Looking Outboard at Right Hand Side Under Aft Fixed Dorsal Cover)

If any of the fastener holes require oversize or rework as a result of the NDI, contact engineering via TO 00-25-107 action for rework limits and replacement fastener.

i. Inspect by bolt hole eddy current eight or nine open fastener holes in left and right dorsal longerons between FS 393.50 and FS 400.50 IAW TO 1T-38A/C-36.

j. Local manufacture nutplate base and spacer as shown in Figure 13.

Use caution when countersinking the aft fixed cover at holes 1 thru 8. Over countersinking could damage the mating steel dorsal longeron.

k. Check for proper fastener head countersinking in the aft fixed cover at holes 1 thru 8. Accomplish additional (minor) countersinking if needed for replacement fastener IAW TO 1T-38A/C-3.

One Hi-Lok Removal Required for NDI and

When Aft Hole #9 is Drilled, Leave Empty (no Fastener Installed). When Aft Hole #9 is Undrilled, as Shown, Location of Nutplate Base to Replace Seven Solid Rivets and One Hi-Lok Fastener

Original design had this hole configuration, do not drill on any new installation.

When hole is present on existing installation, leave unfilled, i.e., no fastener or nutplate.

0.190” ± .001” inch diameter to mate with existing holes in 3-11413 (15 PL).

Install nutplate bases and spacers on the dorsal longeron with MIL-S-8802 sealant.

Use caution to avoid excess sealant that could plug the self aligning nutplates.

-505 configuration only applicable to A/C after TCTO 1T-38-858 aft fixed dorsal cover fastener modification.

0.190” ± .001” inch diameter to mate with existing holes in 2-11860 (8 PL) for new dorsal longeron (3-11413) installation.

Fabricate -9, -10 nutplate spacer from 7075-T73 or 7075-T6 aluminum with dimensions of

0.090 x 0.080 x 5.44 inches.

Fabricate -11, -12 nutplate base from 7075-T73 or 7075-T6 aluminum with dimensions of

0.040 x 0.080 x 7.00 inches.

Figure 13. Installation of Aft Fixed Cover Replacement Fasteners and Nutplate Base.

INBD

FWD

3-11413 (REF)

FUS.

400.50

STA.

FUS.

393.50

STA.

NAS1068A3

MS20426AD3-5(2)

(THRU -9 & -11

or -10 & -12)

-505 ASSY

NAS1153-6 (8 PL)

2-11859 (REF)

-11 -12

-9 -10

-3

(7 PL)

MS21074L3

MS20426AD3-4 (2)

(THRU -11 or -12)

2-11860 (REF)

Avoid the use of excess sealant when installing the nutplate bases as it could plug the self aligning nutplate feature.

l. Using light grit sandpaper or equivalent, remove burrs and cut edges of metal and treat bare metal IAW TO 1T-38A/C-23.

CORROSION INHIBITIVE SEALANT SAE AMS-S-8802 is toxic to skin, eyes and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Use in well ventilated areas. Keep away from open flames and other sources of ignition.

m. Install nutplate bases and fasteners, see Figure 13. Nutplate bases can be secured to the inboard side of the dorsal longeron with SAE AMS-S-8802 sealant as needed to retain in place while installing fasteners.

n. Repeat procedures g. thru m. on the opposite side of the aft fixed cover.

o. Following the fastener replacement on both sides of the aft fixed cover, reseal the rework area IAW TO 1T-38A/C-2-5.

p. Accomplish comprehensive inspection of the dorsal longeron from FS 284.00 to FS 445.00, with the exception of the bolt hole eddy current inspection previously complied with in step i., IAW TCTO 1T-38C-569 or TCTO 1T-38-868 as applicable.

q. Reinstall air conduits (left hand side) and perform air leak check IAW TO 1T-38A/C-2-4.

r. Reinstall electrical conduits (right hand side) which were moved for access to area under the forward and aft fixed dorsal covers in Figures 2 thru 8.

s. Reinstall forward and center dorsal fuel cells and perform fuel leak check IAW TO 1T-38A/C-2-5.

t. Reinstall dorsal covers two and seven by positioning covers and installing screws IAW TO 1T-38A/C-3, see Figure 1.

7.1 Fuel System Defuel/Purge. Defueling/purging of the fuel system shall be accomplished prior to accomplishing the TCTO.

7.2 Operational Checkout Requirements. Fuel leak check and bleed air leak check required IAW TO 1T-38A/C-2-4 and TO 1T-38A/C-2-5.

7.3 Weight and Balance Information. There are no weight or balance changes resulting from the instructions

WARNING

1T-38A-6 31 Jan 2007 1T-38C-6 15 Sept 2011 1T-38A-4-1 15 Sept 2011 1T-38C-4-1 01 Mar 2010 1T-38A-4-11 31 May 2007 1T-38C-4-11 15 Aug 2011 1T-38A-36 01 June 2004 1T-38C-36 30 June 2006

a. Report TCTO compliance IAW TO 00-20-2.

b. NASA and NAVY shall report TCTO compliance via email to Robert.Mcentee@hill.af.mil and Mark.Miller@hill.af.mil.

c. Update AFTO Form 95 to show TCTO compliance.

8.3 Retrofit Change or Inspection Identification Marking. Not applicable.

9. POINT OF CONTACT. Point of Contact (POC) for questions and comments regarding this TCTO is Mark Miller, AFLCMC/WLDEH, Mark.Miller@hill.af.mil, DSN: 777-3182.

MARK A. WELSH III, General, USAF

JANET C. WOLFENBARGER, General, USAF

Prepared by Mark Miller for AFLCMC/WLDEH, DSN 777-3182

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT E - Distribution authorized to the Department of Defense components only for Direct Military Support, 18 October 2012. Other requests for this document shall be referred to AFLCMC/WLDEH, HILL AFB, Utah 84056-5811.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq). Violations of these export laws are subject to severe penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or

TO 1T-38-858C

20121018

SUPPLEMENT TO BASIC TECHNICAL ORDER

MODIFICATION OF DORSAL LONGERON AFT FIXED

COVER FASTENER ASSEMBLY AT FUSELAGE

STATION (FS) 393.50 TO FS 400.50 ON T-38

AIRCRAFT

This technical order supplements TO 1T-38-858, data code 0110803, dated 15 October 2012, to make corrections as indicated herein. A SUITABLE

REFERENCE TO THIS SUPPLEMENT SHALL BE MADE ON PAGE 1 AND

OPPOSITE EACH PARAGRAPH OR FIGURE IN THE TCTO.

1. Page 12, Figure 13, Flag Notes 24 and 25.

Change to read:

Fabricate -9, -10 nutplate spacer from 7075-T73 or 7075-T6 aluminum with dimensions of 0.090 x .80 x 5.44 inches.

Fabricate -11, -12 nutplate base from 7075-T73 or 7075-T6 aluminum with dimensions of

0.040 x .80 x 7.00 inches.

TO 1T-38-858C

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT E - Distribution authorized to the Department of Defense components only for Direct Military Support, 24 June, 2013. Other requests for this document shall be referred to AFLCMC/WLDEH, HILL AFB, Utah 84056-5811.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec

2751 et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq). Violations of these export laws are subject to severe penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or

TO 1T-38-858D

20130624

MODIFICATION OF DORSAL LONGERON AFT FIXED

COVER FASTENER ASSEMBLY AT FUSELAGE

STATION (FS) 393.50 TO FS 400.50 ON T-38

This technical order supplements TO 1T-38-858, data code 0110803, dated

15 October 2012, to make corrections as indicated herein. A SUITABLE

REFERENCE TO THIS SUPPLEMENT SHALL BE MADE ON PAGE 1 AND

OPPOSITE EACH PARAGRAPH OR FIGURE IN THE TCTO.

1. Page 13, Paragraph 6. m. Preceeding step m, add note to read as follows.

If new screws and/or nutplates interfere with existing fasteners on inboard side of longeron, remove and reinstall existing fasteners with nut and washer down.

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT E - Distribution authorized to the DoD components only, Direct Military Support, (XX XXXX XXXX). Other requests shall be referred to AFLCMC/WLDEH, HILL AFB, Utah 84056-5820.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec

2751 et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq). Violations of these export laws are subject to severe penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of the contents or

TO 1T-38-864

DATA CODE 0110832

XXXXXXXX

INSPECTION OF FLAP OPERATING MECHANISM

CONTROL ROD (Y ROD), PART NUMBER (P/N)

2-74259-1

1.1 Identification. This Time Compliance Technical Order (TCTO) is applicable to all seriesT-38 aircraft.

1.2 Kit Applicability. Kits are not required by this TCTO.

1.3 Verification. Verification has been waived by AFLCMC/WLDEH, In Accordance With (IAW) TO 00-5-15.

2. PURPOSE.

The purpose of this TCTO is to determine serviceability of Flap Operating Mechanism Control Rod (Y Rod), P/N

(2-74259-1). This technical order was initiated as a result of Engineering Investigation (EI) Report Control Number

(RCN) FA0777-12-0053 and FA0777-12-0102 on rods that failed in flight. Investigation determined the failure was due to fatigue caused by a non-conforming threaded feature in the Flap Operating Mechanism Control Rod (Tube)

P/N 2-74260-1 (FA0777-12-0053) and fatigue which caused rod end P/N 01-820-06E-009, (FA0777-12-0102) to fail where the rod end enters the Flap Operating Mechanism Control Rod (Tube) P/N 2-74260-1.

Next maintenance opportunity, but not later than the next 225 HPO inspection after receipt of this TCTO. If not complied with 60 days prior to the TCTO rescission date, the system/equipment shall be removed from active service until compliance is accomplished.

3.1 TCTO Rescission Date. The rescission date is XX XXXX 2015, unless extended via TCTO supplement or notices received through the Reliability and Maintainability Information System (REMIS) or other management information systems. This TCTO will be retained until listed as rescinded in the applicable index.

4. BY WHOM TO BE ACCOMPLISHED.

Organizational/Intermediate Level Maintenance or Contractor Equivalent. If the compliance period cannot be met before the TCTO rescission date, the performing organization will request an extended compliance period according to TO 00-5-15.

5.1 Supply Information and Requirements.

5.1.1 Kits/Parts/Materials Required. The following parts, materials will not be furnished in a kit, complete kit concept is waived by John Michalski/GS-13/HQ AETC/A4MAT/DSN 487-3171 john.michalski@randolph.af.mil.

The following individual items shall be requisitioned IAW AFMAN 23-110.

QTY Stock Number Part Number Nomenclature Source

1 1560-00-947-0207 2-74260-1 ROD, Flap

Operating Mech

Cont (Tube)¹

1 3120-01-174-0607 01-820-06E-012 ROD-END, Flap

Cont²

1 3120-01-172-6636 01-820-06E-011 ROD-END, Flap

Cont²

1 5310-00-961-8394 MS17826-6 NUT, Self locking AF Supply

1 5315-00-241-7330 MS24665-304 PIN, Cotter AF Supply

1 9150-00-834-5608 MIL-L-46010 or equivalent

LUBRICANT, Solid AF Supply

¹ Required only if Flap Rod (Tube) is found discrepant

² Required only if Flap Rod-End is found discrepant

5.1.2 Action Required on Items in Chief of Supply or Units Stock. Stock Screen of Flap Operating Mechanism

Control Rod (Tube) P/N 2-74260-1 was initiated as the result of EI DR (RCN) FA 0777-12-0053 on May 8, 2012.

Stock Screen was completed on January 16, 2013.

mailto:john.michalski@randolph.af.mil

Qty Stock Number Part Number Nomenclature Source

2 5310-00-961-8394 MS17826-6 NUT, Self locking¹ AF Supply

2 5315-00-282-1451 AN381-3-18 PIN, Cotter¹ AF Supply

¹Dispose of IAW local procedures.

5.1.6 Size, Weight and Cost of Kits/Parts/Materials. There are no weight or balance changes resulting from the instructions contained herein.

Equipment Preparation 2A3X3 or contractor equivalent 0.5

Access work area 2A3X3 or contractor equivalent 2.5

Perform inspection 2A3X3, 2A752, NAS-410 Level II or contractor equivalent

4.0

Close work area 2A3X3 or contractor equivalent 4.0

Operational check and documentation

2A3X3 or contractor equivalent 2.0

Total Man-Hours 13.0

5.3 Special Tools, Fixtures, Test Equipment and Software Required. Not Applicable.

information contained in this TCTO. Minor variations are authorized providing the intent of this TCTO is accomplished and safety is not compromised. Observe all WARNINGS, CAUTIONS, and NOTES that apply to the following steps.

Inspection of the Flap Operating Mechanism Control Rod (Tube) P/N

2-74260-1, may be accomplished by using Non-Destructive Inspection (NDI)

X-Ray procedure, reference para 6.1, or a visual inspection of the Flap

Operating Mechanism Control Rod (Tube), reference para 6.2.

Unless otherwise specified in this TCTO refer to TO 1-1A-8 for applicable torque values, safetying means and general procedures.

a. Make aircraft safe for maintenance IAW TO 1T-38A/C-2-1, TO 1T-38A/C-2-2 and TO 1T-38A/C-2-3.

b. Open flap actuator access doors and flap hinge access panels 148 and 149.

c. Remove Flap Operating Mechanism Control Rod (Y Rod), P/N 2-74259-1 from each side of the aircraft

IAW TO 1T-38A/C-2-3. Record aircraft tail number and left or right side the (Y Rod) came off of. Record the length of (Y Rod) prior to disassembly as required.

d. Visually inspect the Flap Operating Mechanism Control Rod end threads , P/N 2-74259-1(without disassembly) for bends, damage, or cracks to the best extent possible. Report any discrepant rod ends back to the SPO for disposition.

e. After inspection of the rod end threads proceed to paragraph 6.1 Non-Destructive Inspection (NDI) X-Ray of Flap Operating Mechanism Control Rod (Tube) P/N 2-74260-1, or paragraph 6.2 Visual inspection of the

Flap Operating Mechanism Control Rod (Tube) P/N 2-74260-1

f. If Non-Destructive Inspection (NDI) X-Ray is opted, route Flap Operating Mechanism Control Rod (Y rod), P/N 2-74259-1 to back shop for inspection.

6.1 Perform Non-Destructive Inspection (NDI) X-Ray of Flap Operating Mechanism Control Rod (Tube) P/N

2-74260-1, The use of X-rays in nondestructive inspection presents a potential hazard to operating and adjacent personnel, unless all safety precautions and protective requirements are observed. Refer to TO 33B-1-1 for safety requirements.

The NDI inspector shall be, as a minimum, Air Force Skill Code 2A752 or NAS-410

Level II certified inspector in the NDI methods for these inspection procedures.

Requirements Film CR

X-Ray System 160 kVp X-Ray System 160 kVp X-Ray System

Processing System Automatic Processor 50 Micron GE Tower, CR-50, GE

Flex, VMI 5100, or approved

Film/Plate Class 2, Kodak M Lead Pak, Fuji

IX50PB, AGFA D4 Lead Pack or

IPS

Film/Plate Size 8-inch X 10-inch or larger 8-inch X 10-inch or larger

Source To Aiming Point 48-inches 48-inches

Voltage 140 kVp 90 kVp

Current 5 mA 5mA

Time 1:45 1:20

Density/Point Of Profile Value 1.8-3.2 Raw image must have a P.O.P between 7,500 and 40,000

Table 1

a. Inspection Procedure – X-Ray.

Procedure is designed to X-ray one or two Flap Operating Mechanism Control Rod

(Tubes), P/N 2-74260-1 at the same time. More rods may be X-rayed during a single exposure by increasing distance, time, and adding film/plates.

Density/Point of Profile requirements SHALL be met. Reference TO 33B-1-1, Paragraph 6.7.3, Source-to-Film Distance (SFD) for necessary correction factors.

(1) Equipment shall be operated and all process control requirements met IAW TO’s 33B-1-2 WP 106.00, SWP 106.01.

(2) Tube head should be aimed down towards the ground. Place Film/IPS on a lead covered surface; i.e.

floor, table, etc.

(3) Center the aiming point on the barrel of the rod, reference Figure 2.

(4) Reference Table 1 for exposure settings..

b. Inspection/Evaluation.

Procedure is not designed to identify cracks, corrosion, or other types of discrepancies. If such type discrepancies are noted during X-ray they should be reported in the same manner as discrepant threading as identified by this TCTO.

(1) Verify threads conform to Figure 1 and Figure 2. If the barrel threading exceeds requirements it will be cause for rejection.

Figure 1 Flap Y-Rod

Threads exceeding threaded area are not acceptable. Y-Rod is Discrepant

Threaded area

(2) If Flap Operating Mechanism Flap Operating Mechanism Control Rod (Tube) P/N 2-74260-1 is viewed as acceptable, return to aircraft for reinstallation. If defective, replace (Tube).

6.2 Visual inspection of the Flap Operating Mechanism Control Rod (Tube) P/N 2-74260-1.

a. Measure and record the length of the left and right Flap Operating Mechanism Control Rod (Y Rod), P/N

2-74259-1. Use of a locally developed holding fixture (See Figure 4), dial caliper or equivalent may be used to measure (Y-rod) length. Retain this measurement for use when reassembling the control rod. (See Figure 3.)

Figure 2 Flap Operating Mechanism Control Rod (Tube) P/N 2-74260-1 Acceptable

Versus Discrepant Examples

Align Tubehead

Aiming Point At

Center of Tube

Threads Exceed

Threshold

Typical Good

Threading

b. Loosen AN316-10 jam nut from Flap Operating Mechanism Adjusting Control Rod, P/N 2-74261-1. (See

Figure 3.)

c. Remove Flap Operating Mechanism Adjusting Control Rod, P/N 2-74261-1 from Flap Operating Mechanism

Control Rod (Tube), P/N 2-74260-1. Optional, count and record the number of full turns required if desired.

Retain the number of turns for use when reassembling the control rod. (See Figure 3.)

d. Use a flashlight and a depth caliper to measure the depth of the thread area in Flap Operating Mechanism

Control (Tube). (See Figure 1.). If measured depth is greater than 1.040 inches, discard and replace with new

Flap Operating Mechanism Control Rod (Tube), P/N 2-74260-1.

e. If measured depth is 1.040 or less, reassemble all parts ensuring that Thread Flap Operating Mechanism

Adjusting Control Rod, P/N 2-74261-1, and Flap Operating Mechanism Control Rod (Tube), P/N 2-74260-1, are assembled with the same number of turns recorded in step c, or the same length as was recorded prior to disassembly IAW TO 1T-38A/C-2-3.

6.3 Reinstall Flap Operating Mechanism Control Rod (Y Rod), P/N 2-74259-1 on the side of aircraft from which it was removed IAW TO 1T-38A/C-2-3.

6.4 Perform Operational Checkout of Flap System IAW TO 1T-38A/C-2-3.

Figure 3 Flap Operating Mechanism Control Rod Assy

Record length between points A and point B

01-820-06E-011 01-820-06E-012 AN316-10 2-74260-1 2-74261-1

A B

7.1 Fuel System Defuel/Purge. Defueling/purge of the fuel system is not required to accomplish this TCTO.

7.2 Operational Checkout Requirements. Perform Operational Checkout of Flap System IAW TO 1T-38A/C-2-3.

Functional Check Flight is not required.

7.3 Weight and Balance Information. There are no weight or balance changes resulting from the instructions

7.4 Technical Manuals Affected. Not applicable.

a. Update AFTO Form 95 to show TCTO compliance.

b. Report TCTO compliance in accordance with TO 00-20-2.

c. Annotate PASS/FAIL and document IAW TO 00-5-15.

8.3 Retrofit Change or Inspection Identification Markings. Not applicable.

Figure 4 Example of Adjustable Shop Aid To Hold and Record (Y Rod) Length.

9. POINT OF CONTACT. Point of Contact (POC) for questions and comments regarding this TCTO is Vincent

Sandoval, OO-ALC/GHMEH, email vincent.sandoval2@hill.af.mil, DSN 777-9223.

BY ORDER OF THE SECRETARY OF THE AIR

FORCE

Prepared by Vincent Sandoval, AFLCMC/WLDEH, DSN 777-9223.

mailto:vincent.sandoval2@hill.af.mil

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT E - Distribution authorized to the DoD components only, Direct Military Support, 19 November, 2012.

Other requests shall be referred to AFLCMC/WLDEH HILL AFB, Utah 84056-5820.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq). Violations of these export laws are subject to severe penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of the contents or

TO 1T-38-867

DATA CODE 0110841

20121119

INSPECTION OF FORWARD COCKPIT BRAKE

QUADRANTS, PART NUMBERS (P/NS) 2-73221-1 AND

2-73221-2 FOR CRACKS ON T-38 AIRCRAFT

1.1 Identification. This Time Compliance Technical Order (TCTO) is applicable to all T-38 aircraft.

1.2 Kit Applicability. Kits are not required by this TCTO.

1.3 Verification. TCTO verification, In Accordance With (IAW) TO 00-5-15, was accomplished on aircraft 64-3286 at Randolph AFB, TX on 15 Oct 2012.

2. PURPOSE.

The purpose of this TCTO is to inspect the forward cockpit brake quadrants, P/Ns 2-73221-1 and 2-73221-2 for cracks and replace discrepant brake quadrants. Engineering analytical condition inspections have discovered several cracked brake quadrants and analysis has determined that material failure of the brake quadrant in the forward cockpit will result in the loss of the braking system to one side. Failure to comply with this technical order could result in catastrophic failure of the aircraft braking system to one side during solo flight resulting in asymmetrical braking that could lead to a high speed runway excursion.

At the next maintenance opportunity not to exceed the next phase inspection. If not complied with 60 days prior to the rescission date, the system/equipment shall be removed from active service until compliance with the TCTO is accomplished.

3.1 TCTO Rescission Date. The TCTO rescission date is 18 November 2016, unless extended via TCTO supplement or notices received through the Reliability and Maintainability Information System (REMIS) or other management information systems. This TCTO will be retained until listed as rescinded in the applicable index.

4. BY WHOM TO BE ACCOMPLISHED.

Organizational/Intermediate Level Maintenance or Contractor Equivalent.

5. WHAT IS REQUIRED.

5.1 Supply Information and Requirements.

5.1.1 Kits/Parts/Materials Required. The following parts/materials will not be furnished in a kit, complete kit concept is waived by John Michalski/GS-13/HQ AETC/A4MAT/DSN 487-3171 john.michalski@randolph.af.mil.

The following individual items shall be requisitioned IAW AFMAN 23-110.

Qty

Stock Number Part Number Nomenclature Source

1 1680-01-602-7433 2-73221-1 Quadrant L/H AF Supply 1

1680-01-602-7437 3110-00-034-5257

2-73221-2

MS27641-6

Quadrant R/H Bearing

AF Supply 1 AF Supply 2

12 5315-00-839-5820 MS24665-134 Cotter Pin AF Supply 3

5315-00-839-2325 5310-00-680-4892

MS24665-132

NAS679A3W

Cotter Pin Nut, Self-locking

AF Supply 3

AF Supply 3

1 Required only if quadrant is found discrepant.

2 Required only if quadrant is found serviceable.

3 Required on all aircraft.

5.1.2 Action Required on Items in Chief of Supply or Units Stock. Not applicable.

Stock Number Part Number Nomenclature

1680-01-602-7433 1680-01-602-7437

2-73221-1 2-73221-2

Quadrant L/H 1 Quadrant R/H 1

¹ If a crack is found other than on the inner thin web identified in Figure 1 of the quadrant, attach unserviceable material tag DD 1577 to brake quadrant and notify Engineering at AFLCMC/WLDEB, Branden Krause, DSN 775-6225, or Michael Larsen, DSN 777-3016, for deposition of brake quadrant. All other discrepant quadrants render unserviceable and dispose of IAW local procedures.

5.1.7 Disposition of Kits/Parts/Materials. Not applicable.

5.2 Personnel Information and Requirements.

Work Phases AFSC Skills Man-Hours

Access work area 2A3X3 or contractor equivalent

2A6X3 or contractor equivalent 2A7X3 or contractor equivalent

1.0

Perform inspection 2A752 or NAS410 Level II 1.5 Close work area 2A3X3 or contractor equivalent

2A6X3 or contractor equivalent 2A7X3 or contractor equivalent

10.0

1.5

2A3X3 or contractor equivalent 8.0

Total Man-Hours 34.5 information contained in this TCTO. Minor variations are authorized providing the intent of this TCTO is accomplished and safety is not compromised.