8750A PYLON REPLACEMENT

• Showing imagery for model 208B Caravan model. Images are for part identification reference only as the pylons
were not being removed when images were taken
• Retain all hardware for use during re-installation
• During reassembly, torque all critical hardware to specifications provided in the 8750A service manual unless noted
otherwise
• Apply Tef-gel or equivalent product to all interference surfaces during reassembly

PREPARATION AND AIRCRAFT HOISTING

1. Remove wing gap strips from both wings (if 208, remove lower wing access panel to access wing gap strip bolt)

2. Connect lifting rig and raise airplane enough to bring weight off wheels without lifting the wheels off of the ground.
Make sure the hoist is supporting the weight of the airplane
3. Remove upper pylon fairings, pylon leading edges, and pylon trailing edges
 4. Remove main landing gear bay stiffeners and main landing gear cover assembly

5. Pull parking brake valve

6. Remove and cap both brake lines in gear tunnel

7. Remove cables from the pulleys on aft side of pylons. Pulleys will need to be completely removed to free
cables
NOTE: Tension may be relieved on the cables to help remove the pulleys. Relieve the tension by loosening the
steering balance cable in the turn barrel in the left pylon
8. Make sure the water rudders are down and disconnect retract cables in gear tunnel

9. Unbolt all cable pulley brackets from compression tubes and leave them hanging by cables

10. Pull pump 1 and pump 2 circuit breakers

11. Remove and cap main gear hydraulic lines in gear tunnel
12. Disconnect electrical canon plug in gear tunnel

13. Cut all cable ties securing electrical and hydraulic lines to the gear tunnel and along forward sides of
pylons
14. Remove rudder and elevator cable round access panels in aft cabin floor and disconnect steering cables

Gear tunnel
reference

208B 208
15. Remove cargo steps completely

16. Remove pilot and co-pilot aft step strut attach bolts
17. Loosen, but do not remove, forward strut attach bolts (airplane will pivot on these bolts when hoisted)
18. Loosen forward fly wires enough to tilt the aircraft as instructed in the Lifting and Pylon Replacement
section of this document

Remove

Loosen
19. Break torque on upper aft fly wire attach bolts, upper pylon attach bolts, and lower pylon attach bolts
20. Disconnect fly wire from float fly wire attach point and allow fly wire to hang

Upper fly wire attach bolt

Upper pylon attach bolt

Lower pylon attach bolts

Float fly wire attach point

21. Ensure everything is clear and disconnected in the gear tunnel, fuel selectors are off, and ropes are tied to
all tie down rings
 LIFTING AND PYLON REPLACEMENT
1. Remove saddles that attach floats to airplane

Saddle

2. Slowly raise hoist. The back of the airplane will lift and pivot on the forward strut attach bolts. Continue
lifting until the gear tunnel is clear of the floats (approximately 6 inches raised)
NOTE: When lifting, make sure the forward and aft step struts are not coming in contact with the skin
3. Remove the aft wire pull and attached aft fly wires by removing upper fly wire attach bolts and lower clevis
pin. Set aft wire pull with attached fly wire aside

Upper fly wire

attach bolts

Lower clevis pin

Aft wire pull
 4. Remove compression tubes and spacers from gear journal fitting

Compression
tubes

Spacers

5. Remove the upper pylon attach bolt and slide the gear journal fitting off of the pylon

Upper pylon attach bolt

Gear journal fitting

6. Transfer bolts and gear journal fitting to new pylon. Tighten bolts but do not bring to torque
7. Remove the 2 lower attach bolts and remove pylons from floats
8. Set new pylons in place and install lower pylon attach bolts but do not bring to torque
9. Install compression tubes, spacers, and aft wire pull with attached fly wires to main gear journal and install
upper fly wire attach bolts. Tighten but do not bring to torque
NOTE: Floats may need to be tilted with a floor jack in order to align the compression tubes
10. Insert lower clevis pins
 11. Torque lower pylon attach bolts
NOTE: Torque fore lower pylon bolt to 200 foot pounds
12. Lay pulley brackets in place and ensure all cables, electrical lines, and hydraulic lines are routed correctly
per Wipaire Installation Drawings. Once correct routing is verified, pull everything back out of the way
13. Lower airplane back onto floats
14. Install saddles and torque saddle bolts per applicable Cessna Maintenance Manual
 REASSEMBLY
1. Torque upper pylon attach bolt
2. Torque forward strut attach bolts
3. Reinstall pilot and co-pilot aft step strut attach bolts and bring to torque
4. Torque upper fly wire attach bolts
5. Tighten fore and aft fly wires to eliminate excessive slack in the fly wires. Tension adjustments will be
performed later in this document
6. Reinstall both brake lines in gear tunnel
7. Bleed brakes
8. Reinstall hydraulic lines in gear tunnel
9. Install pulleys to trail end of pylon with cables routed
10. Reinstall pulley brackets in gear tunnel
11. Connect retract cable in gear tunnel
12. Connect and rig steering cables in cabin floor. Make sure cables are not crossed
13. Reinstall canon plug in gear tunnel
14. Tie up all electrical and hydraulics in gear tunnel and along forward side of pylons
15. Reinstall cargo steps and bring bolts to torque
16. Verify steering and retract cable rigging is correct
17. Reinstall pylon leading edges and trailing edges
18. Push in pump 1 and 2 circuit breakers
19. Set aircraft on jacks and perform gear swings and operation checks
20. Perform forward and aft fly wire adjustments as shown later in this document then tighten fly wire jam nuts
21. Leak check brake lines and hydraulic lines in gear tunnel
22. Reinstall main landing gear bay stiffeners and main landing gear cover assembly
23. Reinstall upper pylon fairings
24. Set airplane on ground
25. Install wing gap strips (if 208, reinstall lower wing access panel after access wing gap strip bolt)
 FLY WIRE ADJUSTMENTS
Fly wire adjustments can be performed while aircraft is on jacks or while on wheels
1. Measure aft fly wires as shown below and adjust until length of each fly wire is within 1/16” of the other fly
wire
WARNING!
Do not measure the length of the fly wire from the
lower attach point to the upper attach point. The wire
pull part numbers are not the same on each side of
the aircraft; dimensions would not be correct.
Example of
Choose a fixed point on the airframe to use as fixed point
a reference point. Measure distance from the
base of the threads on lower fly wire attach
point to the chosen fixed point on the aircraft.
Compare to measurement taken from the
same locations for the opposite fly wire
NOTE: Dimension shown in the figure to the
right is for reference only and will vary from
aircraft to aircraft
2. Measure forward fly wires from the base of the threads on fly wire attach points on each end and adjust
until length of each fly wire is within 1/16” of the other fly wire
3. Create a mark on the fly wire 33” up from the jam nut
4. Pick a fixed point on the fuselage above the mark made and measure down to your mark
5. Push up at the mark with 50 lbs. of force, the fly wire should deflect approximately 3/16” to 1/4”