757-78-30-01 THRUST REVERSER REMOVAL INSTALLATION ISS1Dec16
757-78-30-01 THRUST REVERSER REMOVAL INSTALLATION ISS1Dec16
757-78-30-01 THRUST REVERSER REMOVAL INSTALLATION ISS1Dec16
ADDITIONAL TASKS
REQUIRED ON REPLACEMENT
THRUST REVERSER
DURING/FOLLOWING
INSTALLATION:
10 Install the Floating Beam GSE pins to attach the floating Beam to the strut bracket when the thrust
reverser is removed IAW AMM TASK 78-31-20-024-001-R04 2.F.10
WARNING: THE HYDRAULIC FLUID CONTAINED IN THIS SYSTEM CAN CAUSE
INJURY TO YOU. IT IS POISONOUS WHEN IT IS ABSORBED INTO THE SKIN AND
WHEN IT PASSES THROUGH THE BODY. IN CASE THE FLUID TOUCHES THE
EYE, FLUSH THE EYES WITH WATER AND GET MEDICAL HELP.
CAUTION: THE HYDRAULIC FLUID WILL CAUSE DAMAGE TO AIRCRAFT
SURFACES WHERE THE HYDRAULIC FLUID DOES NOT USUALLY TOUCH.
REMOVE ANY FLUID WHICH HAS LEAKED IMMEDIATELY WITH A DRY CLOTH.
WASH THE AREA TO REMOVE THE CONTAMINATION.
11 Do the steps to disconnect the thrust reverser from all other systems IAW AMM TASK 78-31-20-
024-001-R04 2.F.11
CAUTION: MAKE SURE THE LOCKING PIN IS REMOVED FROM THE MANUAL
BYPASS VALVE BEFORE YOU DRAIN THE HYDRAULIC SYSTEM OF THE THRUST
REVERSER. IF THE LOCKING PIN IS NOT REMOVED, THE HYDRAULIC SYSTEM
OF THE AIRPLANE WILL DRAIN.
NOTE: Use the four bolts which are kept with the strap attach fittings.
NOTE: The left thrust reverser weighs approximately 670 lb (303.9 kg). The right thrust
reverser weighs approximately 660 lb (299.4 kg).
NOTE: The left thrust reverser weighs approximately 670 lb (303.9 kg). The right thrust
reverser weighs approximately 660 lb (299.4 kg).
28 Make sure the hinges of the hinge access door are attached in the vertical position IAW AMM
TASK 78-31-20-424-028-R04 3.I.3
29 Make sure the opening actuator is retracted IAW AMM TASK 78-31-20-424-028-R04 3.I.4
30 Apply silicone grease to all the open closing seals, the engine mating faces and the V-groove
system IAW AMM TASK 78-31-20-424-028-R04 3.I.5.
31 Release the lower feedback cable rodend from the feedback actuation lever IAW AMM TASK 78-
31-20-424-028-R04 3.I.6
NOTE: Do a check of the bolt which attaches the feedback rod end. If it is attached with the
bolt head rearward, it will be necessary to manually retract the thrust reverser.
Retract the thrust reverser approximately 4.0 inches (101.6 mm) so that the bolt can be
removed (PAGEBLOCK 78-31-00/201 Config 4).
NOTE: The left thrust reverser weighs approximately 670 lbs (303.91 kg). The right thrust
reverser weighs approximately 660 lbs (299.67 kg).
33 Install the Boeing handling equipment, if available IAW AMM TASK 78-31-20-424-028-R04
3.I.8 and IAW AMM TASK 78-31-20-424-028-R04 3.I.9
WARNING: MAKE SURE ALL THE WEIGHT OF THE THRUST REVERSER IS HELD
BY THE 'c' duct hold open equipment. DO NOT STAND BETWEEN THE THRUST
REVERSER AND THE ENGINE. THE THRUST REVERSER COULD CLOSE
SUDDENLY AND INJURE PERSONS.
Install the washer and the nut to the aft hinge bolt.
36 Attach the support assembly to the arch IAW AMM TASK 78-31-20-424-028-R04 3.I.12
37 Attach the fishpole hoist (2 preferred) to the support assembly IAW AMM TASK 78-31-20-424-
028-R04 3.I.13
38 Attach the sling to the brackets which are found on the bottom of the thrust reverser IAW AMM
TASK 78-31-20-424-028-R04 3.I.14.
40 Use the fishpole hoist to open the thrust reverser IAW AMM TASK 78-31-20-424-028-R04 3.I.16
41 Install the hold open rods IAW AMM TASK 78-31-20-424-028-R04 3.I.17
42 Make sure the translating sleeve is in the fully retracted position IAW AMM TASK 78-31-20-
424-028-R04 3.I.18:
44 Turn the feedback cam to the retracted position and install the rig pin in rig pin set IAW AMM
TASK 78-31-20-424-028-R04 3.I.20
45 Align the lower feedback cable rodend with the actuation lever IAW AMM TASK 78-31-20-424-
028-R04 3.I.21.
NOTE: If the cable rod end does not align, loosen the locknut and adjust the rod end as
necessary.
Apply a light load to remove the slack in the feedback cable.
46 Install the lower cable rodend in the actuation lever with the bolt, the washer, and the nut. Install a
new cotter pin IAW AMM TASK 78-31-20-424-028-R04 3.I.22.
47 Tighten the locknut of the lower feedback cable using AMM torque values IAW AMM TASK 78-
31-20-424-028-R04 3.I.23
48 Remove the rig pin from the feedback cam and close the strut pressure relief door IAW AMM
TASK 78-31-20-424-028-R04 3.I.24
52 Install the bolt, the bushing, and the nut which attaches the actuator rod end to the strut clevis
IAW AMM TASK 78-31-20-424-028-R04 3.I.28
53 Remove the GSE Pins from the Floating Beam IAW AMM TASK 78-31-20-424-028-R04 3.I.29.
56 If the thrust reverser synchronization procedure was not done, connect the flex synchronizing shaft
which connects the extend hydraulic tube IAW AMM TASK 78-31-20-424-028-R04 3.I.32.
NOTE: Do not bend the flex shaft more than 22.5 degrees.
59 Do a check of the bellows of the pre-cooler fan air intake for damage IAW AMM TASK 78-31-
20-424-028-R04 3.I.36.
60 Do a check of the bellow seals for damage IAW AMM TASK 78-31-20-424-028-R04 3.I.37.
61 Open the valve on the hand pump IAW AMM TASK 78-31-20-424-028-R04 3.I.38.
63 Disconnect the hold open rods IAW AMM TASK 78-31-20-424-028-R04 3.I.40
64 Use a fishpole hoist to lower the thrust reverser to the closed position IAW AMM TASK 78-31-
20-424-028-R04 3.I.41.
65 Remove the sling from the bottom of the thrust reverser and from the fishpole hoist IAW AMM
TASK 78-31-20-424-028-R04 3.I.42
66 CAUTION: THE STEP THAT FOLLOWS MUST BE DONE TO MAKE SURE THAT
ALL THE AIR WHICH REMAINS IN THE HYDRAULIC SYSTEM IS BLED. IF YOU
DO NOT, AIR WHICH REMAINS IN THE SYSTEM CAN CAUSE THE THRUST
REVERSER TO CLOSE IRREGULARLY.
Bleed the hydraulic opening system of the thrust reverser IAW AMM TASK 78-31-20-424-028-
R04 3.I.43.
67 IAW AMM TASK 78-31-20-424-028-R04 3.I.44, Do this procedure: Thrust Reverser Lock
Proximity Sensor - Adjustment/Test (PAGEBLOCK 78-30-00/501 Config 4)
WARNING: OBEY THE INSTRUCTIONS IN THE PROCEDURE TO CLOSE THE
THRUST REVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TO
PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR
68 IAW AMM TASK 78-31-20-424-028-R04 3.I.45, Close the access panels: (PAGEBLOCK 78-31-
00/201 Config 4)
69 Remove the support assembly, the braces, the arch assembly, the two pads, and the two front
brackets IAW AMM TASK 78-31-20-424-028-R04 3.I.46
70 IAW AMM TASK 78-31-20-424-028-R04 3.I.47, Do this procedure: Thrust Reverser Upper and
Lower Bifurcation Bumper and Latch Adjustment (PAGEBLOCK 78-30-00/501 Config 4).
71 Attach the hinge access door hinges to the thrust reverser IAW AMM TASK 78-31-20-424-028-
R04 3.I.48
72 IAW AMM TASK 78-31-20-424-028-R04 3.I.49, Install the hinge access door (PAGEBLOCK
78-31-10/401).
73 IAW AMM TASK 78-31-20-424-028-R04 3.I.50, Pressurize the hydraulic system (PAGEBLOCK
29-11-00/201).
74 Bleed the hydraulic system of the thrust reverser IAW AMM TASK 78-31-20-424-028-R04
3.I.51.
NOTE: This procedure will make sure all the unwanted air is bled from the system. If the
air is not bled from the system, the thrust reverser may not operate satisfactorily.
75 Remove the DO NOT OPERATE tags from the thrust reverser levers IAW AMM TASK 78-31-
20-424-028-R04 3.I.52.
76 IAW AMM TASK 78-31-20-424-028-R04 3.I.53, Do the thrust reverser tests that are listed in the
test reference table (PAGEBLOCK 78-31-00/501 Config 1).
77 Do a check of all the hydraulic connections which have been opened to look for leakage IAW
AMM TASK 78-31-20-424-028-R04 3.I.54.
78 IAW AMM TASK 78-31-20-424-028-R04 3.I.55, Do a check of the adjustment of the upper and
lower bifurcation bumpers and latches (PAGEBLOCK 78-30-00/501 Config 4).
79 After the first engine ground run(s) and no later than 25 flight hours, do the IAW AMM TASK 78-
31-20-424-028-R04 3.I.56 to make sure the force necessary to close the five thrust reverser latches
is satisfactory and that the distance between the upper and lower bifurcation bumpers is
satisfactory.