11-18 FUSELAGE AND VERTICAL TAIL / WATER RUDDER
ICON A5 / MAINTENANCE MANUAL CHANGE C1
5. Coat two MS24694C53 screws with Tef-Gel
®
and install them through the water rudder,
attaching it to the puck inside. Note that one screw installs from the left and one from the right.
Torque these screws to 20 in-lb
f
.
6. Reinstall the two M81934/2-05C012 bearings M81934/2-05C012 in water rudder using
LOCTITE
®
609™.
7. Slide a ICA008934 Pivot Bushing into the pivot bore in the water rudder.
8. Verify that nylon tubes are still bonded to pivot flange and secure. Run cable through each one
to make sure the cables slides through freely. If either of these are not OK, the nylon tubing will
need to be replaced and rebonded.
9. Insert the cable ends into the Nylon tubes in the aft face of the pivot flange. The cable coming off
the top of the puck inserts into the top tube, bottom into the bottom.
10. Pull the cable ends out through the top of the pivot flange while guiding the rudder into position
with pivot bores aligned. Pay special attention as to not kink the cable.
11. Connect the water rudder to the pivot flange with a 97851A104 Binding Post, with a 91950A029
Washer under each head. Use LOCTITE
®
243™ on the threads and torque to 20 in-lb
f
.
12. Measure each cable from the top face of the pivot flange torque tube and mark with a paint
marker. The cable on aircraft right-hand side gets a mark at 71-9/16” form the top face. The cable
on aircraft left-hand side gets a mark at 70-1/4” from the top face.
13. Insert the two cable ends up through the water rudder bellcrank assembly in the hull. There is a
fore/aft bushing in the bore of the water rudder bellcrank, visible from the bottom. The rudder
right-side cable must pass to the right of the bushing and the left cable to the left of it.
14. Pull cable ends out through the water rudder access panel and keep pulling while guiding the
water rudder assembly into position, pushing its steering shaft up into the water rudder bellcrank
assembly. Use caution to not damage the shaft seal.
15. Install the ICA009078 Bottom Pivot Tang with two MS24694C56 screws coated with Tef-Gel
®
.
Torque these to 26 in-lb
f
.
16. Tape the cable that comes off the top of the water rudder puck to the previously installed “A”
string and the cable end that comes off the bottom of the puck to the “S” string. Use the strings
to pull the cable ends under the pulley cable guard bolt, over the water rudder retraction pulleys,
and once around the pulleys, pull the cable ends out through the water rudder access panel.
Remove the string from the cable ends temporarily (keep them marked).
NOTE: It helps to pull one cable at a time through the pulley, swage it, then
go to the actuator bay and connect it before doing the other. This
prevents any accidental crossing of cables.
17. Terminate the two cable ends as follows:
a. Spread open an AN100C-3 cable thimble just enough to slide it through the aft cable eye
of the retraction turnbuckle assembly. Repeat this with the aft cable eye of the extension
turnbuckle assembly.
b. Feed the end of the retraction cable first through one side of an MS51844-22 sleeve then
through the retraction turnbuckle eye from the previous step, then back around through
the other end of the sleeve. Repeat this for the extension end of the cable and its turn-
buckle.
c. Find the swage location mark on the retraction cable end. Position the cable so that the
center mark is located at the center point of the thimble of the retraction turnbuckle
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