SERVICE MANUAL

PA-28-140
PA-28-150
PA-28-160
PA-28-180
PA-28-235
PA-28R-180
PA-28R-200

PIPER AIRCRAFT CORPORATION

PART NUMBER 753-586 SEPTEMBER 18, 2021
 Published by

Piper Aircraft, Inc.

Attn: Technical Publications
2926 Piper Drive
Vero Beach, Florida 32960
U.S.A.

© 1972, 1981, 1983-1984, 1986–1987, 1995, 2002, 2004, 2008, 2019, 2022 Piper Aircraft, Inc.

Member
General Aviation
Manufacturers Association

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 PIPER CHEROKEE SERVICE MANUAL

REVISION STATUS

1. Definitions
The following definitions apply to the columns in paragraph “2”.
A. Revision
The data in the revision column is comprised of two elements:
(1) A Type of Revision Code: ORG = Original, CR = Complete Revision, and PR = Partial Revision.
NOTE: Partial Revisions (PR) are listed only until the next Complete Revision (CR) is published.
Then they are removed.
(2) The Revision Date in YYYYMMDD format.
NOTE: The Revision Date is the date placed on each revised page. It exists to separate one
version of a page from another. Revision Date does not indicate the calendar date when
the revision was actually published and available to the public. However, this is the date
that appears in the Current Revision Checklist in the Customer Service Information
File.
B. Publication Date
Publication Date usage has varied over the years. 1972–1996 is unknown. 1997–2013 it generally was
synchronized with the revision date regardless of when the revision was published. In mid 2013 and
later, the Publication Date is the calendar date when the revision was actually published and available
to the public.
NOTE: This date does not appear in the Current Revision Checklist in the Customer Service
Information File.
2. Revisions
Revisions to the Cherokee Service Manual (P/N 753-586) originally published August 16, 1972 are as
follows:
Revision Publication Date
ORG19720816 August 16, 1972
CR19810115 January 15, 1981
PR19810803 August 3, 1981
PR19831003 August 3, 1983
PR19840423 April 23, 1984
PR19860115 January 15, 1986
IR19860730 July 30, 1986
IR19870506 June 12, 1987
IR19950215 February 15, 1995
IR20020228 February 28, 2002
IR20040227 February 27, 2004
PR20080131 January 31, 2008
PR20191130 November 19, 2019
PR20210918 December 23, 2022

09/18/21 REVISION STATUS

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 PIPER CHEROKEE SERVICE MANUAL

3. Availability
This maintenance manual, related inspection reports and manuals, service publications (SB, SL, etc.) and
other Piper publications are available as described in the Owner Publications Catalog (part of the Customer
Service Information File, see below).
Consult the “Customer Service Information File” (a free download from the Piper Aircraft, Inc. website at
http://www.piper.com/technical-publications-documents/ ) to verify that you have the latest revision.

REVISION STATUS 11/30/19

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INTRODUCTION

TABLE OF CONTENTS

Paragraph
Grid No.

REVISION STATUS
iii
Definitions iii
Revision iii
Publication Date iii
Revisions iii
Availability iv

INTRODUCTION INTR1
Instructions for Continued Airworthiness INTR1
General INTR1
Effectivity INTR2
Serial Number Explanation INTR4
Assignment of Subject Material INTR4
Pagination INTR4
Aerofiche Grid Numbering INTR4
Identifying Revised Material INTR5
1981 thru 2004 INTR5
2008 INTR5
2019 and later INTR5
Indexing INTR5
Warnings, Cautions and Notes INTR5
Accident/Incident Reporting INTR6
Supplementary Publications INTR6
Piper Publications INTR6
Vendor Publications INTR6
Section Index Guide INTR11

LIST OF ILLUSTRATIONS LOI1

LIST OF TABLES LOT1

09/18/21 INTRO – CONTENTS

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INTRO – CONTENTS 09/18/21

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INTRODUCTION

1. Instructions for Continued Airworthiness

WARNING: INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) FOR ALL NON-PIPER
APPROVED STC INSTALLATIONS ARE NOT INCLUDED IN THIS MANUAL.
WHEN A NON-PIPER APPROVED STC INSTALLATION IS INCORPORATED
ON THE AIRPLANE, THOSE PORTIONS OF THE AIRPLANE AFFECTED BY
THE INSTALLATION MUST BE INSPECTED IN ACCORDANCE WITH THE ICA
PUBLISHED BY THE OWNER OF THE STC. SINCE NON-PIPER APPROVED
STC INSTALLATIONS MAY CHANGE SYSTEMS INTERFACE, OPERATING
CHARACTERISTICS AND COMPONENT LOADS OR STRESSES ON ADJACENT
STRUCTURES, THE PIPER PROVIDED ICA MAY NOT BE VALID FOR AIRPLANES
SO MODIFIED.
The PIPER PA-28-140/150/160/180/235 / PA-28R-180/200 (Cherokee) Service Manual constitutes the
Instructions for Continued Airworthiness in accordance with Federal Aviation Regulations (FAR) Part 23,
Appendix G. Section I contains the Airworthiness Limitations and the Inspection Program is in Section III.
2. General
This publication is prepared in PIPER proprietary format with respect to arrangement and content.
WARNING: USE ONLY GENUINE PIPER PARTS OR PIPER APPROVED PARTS OBTAINED FROM
PIPER APPROVED SOURCES, IN CONNECTION WITH THE MAINTENANCE AND
REPAIR OF PIPER AIRPLANES.
This manual generally does not contain hardware callouts for installation. Hardware callouts are only
indicated where a special application is required. To confirm the correct hardware used, refer to the
PA-28-140/150/160/180/235 / PA-28R-180/200 (Cherokee) Parts Catalog, P/N 753-582, and FAR 43 for
proper utilization.
Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and
suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even
though identical in appearance, may not have had the required tests and inspections performed, may be
different in fabrication techniques and materials, and may be dangerous when installed in an airplane.
Additionally, reworked or salvaged parts or those parts obtained from non-PIPER approved sources,
may have service histories which are unknown or cannot be authenticated, may have been subjected to
unacceptable stresses or temperatures or may have other hidden damage not discernible through routine
visual or nondestructive testing. This may render the part, component or structural assembly, even though
originally manufactured by PIPER, unsuitable and unsafe for airplane use.
PIPER AIRCRAFT, INC. expressly disclaims any responsibility for malfunctions, failures, damage or
injury caused by use of non-PIPER approved parts.
NOTE: PIPER AIRCRAFT, INC. expressly reserves the right to supersede, cancel and/or declare obsolete
any part, part numbers, kits or publication that may be referenced in this manual without prior
notice.
In any question concerning the care of your airplane, be sure to include the airplane serial number in any
correspondence.

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3. Effectivity
This service manual is effective for PA-28-140/150/160/180/235 and PA-28R-180/200 Cherokee airplanes,
serial numbers 28-1 thru 28-7725290 and serial numbers 28R-30001 thru 28R-7635462.
This encompasses the following model years:
NOTE: The following is provided as a general reference only.
Model Sub-Model Serial Numbers Model Year
PA-28-140 28-20002 thru 28-20391 1964
28-20392 thru 28-21161 1965
28-21162 thru 28-22200 1966
28-22201 thru 28-23792 1967
28-23793 thru 28-24945 1968
“B” 28-25001 thru 28-26331 1969
“C” 28-26401 thru 28-26946 1970
“D” / Fliteliner 28-7125001 thru 28-7125641 1971
“E” / Cruiser / Fliteliner 28-7225002 thru 28-7225602 1972
“F” / Cruiser / Fliteliner 28-7325001 thru 28-7325674 1973
Cruiser / Fliteliner 28-7425001 thru 28-7425444 1974
Cruiser / Fliteliner 28-7525001 thru 28-7525340 1975
Cruiser 28-7625001 thru 28-7625275 1976
Cruiser 28-7725001 thru 28-7725290 1977

PA-28-150 28-1 thru 28-100 1961

28-101 thru 28-820 1962
“B” 28-821 thru 28-1440 1963
28-1441 thru 28-1760A 1964
“C” 28-1761 thru 28-1891
28-1892 thru 28-2792 1965
28-2793 thru 28-3674 1966
28-3675 thru 28-4377 1967

PA-28-160 28-1 thru 28-100 1961

28-101 thru 28-820 1962
“B” 28-821 thru 28-1440 1963
28-1441 thru 28-1760A 1964
“C” 28-1761 thru 28-1891
28-1892 thru 28-2792 1965
28-2793 thru 28-3674 1966
28-3675 thru 28-4377 1967

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Model Sub-Model Serial Numbers Model Year

PA-28-180 28-671 thru 28-820 1962
“B” 28-821 thru 28-1440 1963
28-1441 thru 28-1760A 1964
“C” 28-1761 thru 28-1891
28-1892 thru 28-2792 1965
28-2793 thru 28-3674 1966
28-3675 thru 28-4377 1967
“D” 28-4378 thru 28-5279 1968
28-5280 thru 28-5499 1969
“E” 28-5601 thru 28-5859 1970
“F” 28-7105001 thru 28-7105234 1971
“G” 28-7205001 thru 28-7205318 1972
“Challenger” 28-7305001 thru 28-7305601 1973
“Archer” 28-7405001 thru 28-7405280 1974
28-7505001 thru 28-7505261 1975

PA-28-235 28-10003 thru 28-10505 1964

28-10506 thru 28-10715 1965
“B” 28-10716 thru 28-10755 1966
28-10756 thru 28-11039 1967
“C” 28-11040 thru 28-11226 1968
28-11227 thru 28-11255 1969
“D” 28-11301 thru 28-11378 1970
“E” 28-7110001 thru 28-7110028 1971
“F” 28-7210001 thru 28-7210023 1972
“Charger” 28-7310001 thru 28-7310176 1973
“Pathfinder” 28-7410001 thru 28-7410110 1974
28-7510001 thru 28-7510135 1975
28-7610001 thru 28-7610181 1976
28-7610182 thru 28-7610202 1977
28-7710001 thru 28-7710089 1977

PA-28R-180 Arrow 28R-30005 thru 28R-30097 1967

28R-30098 thru 28R-31087 1968
28R-31088 thru 28R-31135 1969
28R-31251 thru 28R-31270 1970
“B” 28R-7130001 thru 28R-7130013 1971

PA-28R-200 Arrow 28R-30482 (Prototype) 1968

28R-35001 thru 28R-35392 1969
28R-35601 thru 28R-35820 1970
“B” 28R-7135001 thru 28R-7135229 1971
“Arrow II” 28R-7235001 thru 28R-7235320 1972
28R-7335001 thru 28R-7335446 1973
28R-7435001 thru 28R-7435323 1974
28R-7535001 thru 28R-7535383 1975
28R-7635001 thru 28R-7635462 1976

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4. Serial Number Explanation

Example (1961-1970): 28 671
28R 30001

TYPE CERTIFICATE DESIGNATION SEQUENCE NUMBER (1–4; or 5 digits)

(No Model Year Designation) (No Model Code)

Example (1971 and Up): 28 77 25 163

28R 71 30 001

TYPE CERTIFICATE DESIGNATION SEQUENCE NUMBER (3 digits)

MODEL YEAR MODEL CODE

5. Assignment of Subject Material

This publication is divided into logical subject groupings based on aircraft system or task function. Refer
to “Section Index Guide” on page INTR11.
6. Pagination
This manual is in transition.
A. Pages dated 1981–2008
These pages are laid out in the Piper legacy format. The “Aerofiche Grid Numbering” system (explained
below) forms the only page numbering system.
B. Pages dated 2019 and later
These pages may be numbered as described in “Pages dated 1981–2008”, above; or, if the entire Section
has been revised: then the Section provides the basis for the page numbering system. Within each
Section, pages are numbered consecutively beginning with the title pages X-i, and then restarting at
the first page of the Section body as Page X-1 (i.e., X = section number). Aerofiche grid numbers are
removed when an entire section is revised. These pages may also have a modified page header.
7. Aerofiche Grid Numbering
Piper has ceased production of all Aerofiche (i.e., microfiche) products. In the interim, as Sections are
partially revised, the legacy Aerofiche grid numbering system may be modified, as explained below, to
simplify production.
Deviations from the legacy Aerofiche grid numbering system will occur when it becomes necessary to add
pages to the manual and will typically take two forms:
A. Inserting pages between two existing grids in the same row.
When inserting two pages between the existing grids 1A8 and 1A9, the two new pages will be
numbered 1A8A and 1A8B.

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B. Inserting pages at the end of an Aerofiche grid row.

The legacy Aerofiche grid numbering system limited page numbers in a row to a maximum of 24 (i.e.,
row 1A would be numbered 1A1–1A24). That limit no longer applies. Accordingly, if two pages need
to be added between any existing grid row end and grid row start (i.e., 1A24 and 1B1), the new pages
will simply be numbered 1A25 and 1A26.
8. Identifying Revised Material
A. 1981 thru 2004
Revised text and illustrations are indicated by a vertical line along the left-hand margin of the frame,
opposite revised, added or deleted material. Revision lines indicate only current revisions with
changes and additions to or deletions of existing text and illustrations. Changes in capitalization,
spelling, punctuation, indexing, the physical location of the material or complete page additions are
not identified by revision lines.
B. 2008
Revisions, additions and deletions are identified by a vertical line (i. e., change bar) along the lefthand
margin of the page opposite only that portion of the printed matter that was changed. Changes in
capitalization, spelling or punctuation are not identified by revision lines.
A change bar in the left-hand margin opposite the footer (i.e., chapter/section/subject, page number
and date), indicates that the text was unchanged but the material was relocated to a different page.
NOTE: Change bars are not used in the title pages. Likewise, all change bars are removed when a
publication is completely revised (i.e., reissued).
C. 2019 and later
A revision to a page is defined as a change to the text or illustrations that existed previously. Revisions,
additions and deletions are identified by a vertical line (aka change bar) along the left-hand margin of
the page opposite only the text or illustration that was changed. Reformatted, but otherwise unchanged,
text is not identified by a change bar.
Change bars in the individual section Tables of Contents do not indicate a change to that page, but
rather that the information in the referenced paragraph has changed.
A change bar in the left-hand margin opposite the footer (i.e., chapter/section/subject, page number
and date), indicates that the text was unchanged but the material was relocated to a different page.
Example.
NOTE: Change bars are not used in the title pages, list of illustrations, and list of tables.
9. Indexing
See the “Section Index Guide” on page INTR11 for assistance in locating desired information. In addition,
each Section begins with an individual Table of Contents.
10. Warnings, Cautions and Notes
These adjuncts to the text are used to highlight or emphasize important points when necessary. Warnings
call attention to use of materials, processes, methods, procedures or limits which must be followed
precisely to avoid injury or death to persons. Cautions call attention to methods and procedures which
must be followed to avoid damage to equipment. Notes call attention to methods which make the job easier.
Warnings and Cautions shall be located directly above and Notes directly beneath the text and be in line
with the paragraphs to which they apply.

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11. Accident/Incident Reporting

To improve our Service and Reliability system and aid in Piper’s compliance with FAR 21.3, knowledge
of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting
all incidents and accidents, Piper Form 420-01 has been created. See latest revision of Service Letter 1041.
This procedure is to be used by all Dealers, Service Centers and Repair Facilities.
12. Supplementary Publications
The following publications/sources provide servicing, overhaul and parts information for the
PA-28-140/150/160/180/235 / PA-28R-180/200 (Cherokee) airplane and its various components. Use them
to supplement this manual.
A. Piper Publications
Model Piper P/N
(1) Parts Catalog: PA-28-140/150/160/180/235 753-582
PA-28-140 Fliteliner 753-582
PA-28R-180/200 753-582
(2) Periodic Inspection Report: PA-28-140/150/160/180/235 230-207
PA-28-140 Fliteliner 230-207
PA-28R-180/200 230-259
(3) Progressive Inspection Manual: PA-28-140/150/160/180/235 761-497
PA-28-140 Fliteliner 761-497
PA-28R-180/200 761-500
B. Vendor Publications
WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN
SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER
AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY.

(1) ALTERNATOR
Vendor Address: Hartzell Engine Technologies PH: (877) 359-5355
2900 Selma Hwy FAX: (334) 386-5410
Montgomery, Alabama 36108
http://hartzell.aero/
Overhaul Manual: OE-A2 Starter and Alternator Overhaul Manual
(2) AUTOFLIGHT
Vendor Address: Honeywell (or) S-TEC Corporation
One Technology Center One S-TEC Way
23500 W. 105th St., M/D #45 Mineral Wells, TX 76067
Olathe, Kansas 66061-1950 PH: (940) 325-9406
http://www.bendixking.com/ http://www.s-tec.com
Rockwell Collins, Inc.
400 Collins Road N.E.
Cedar Rapids, IA 52498
PH: (888) 265-5467
http://www.rockwellcollins.com

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(3) BATTERY
Vendor Address: GILL Batteries PH: (800) 456-0070
A Division of Continental Aero Technologies
http://www.gillbatteries.com
(4) BRAKES AND WHEELS
Vendor Address: Parker Hannifin Corp PH: (800) 272-5464
Aircraft Wheel and Brake Division
1160 Center Road
Avon, Ohio 44011
http://www.parker.com/
(5) EMERGENCY LOCATOR TRANSMITTER
Vendor Address: Artex Aircraft Supplies PH: (800) 547-8901
14405 Keil Road NE
Aurora, Oregon 97002
http://www.artex.net/
(6) ENGINE
Vendor Address: Lycoming Engines PH: (717) 323-6181
652 Oliver Street FAX: (717) 327-7101
Williamsport, PA 17701
http://www.lycoming.com/
Overhaul Manual: DIRECT DRIVE MODELS - P/N 60294-7
Parts Catalog: O, IO, LIO-320 Series Engines - P/N PC-103
O-320 A & E Series Engines - P/N PC-203-1
O-320 B & D Series Engines - P/N PC-203-2
O-360-A Wide Cyl. Flange Engines - P/N PC-306-1
IO, AIO-360 A & B Series Engines - P/N PC-406-1
IO/LIO-360 C & J Series Engines - P/N PC-406-2
O-540-B, E and G Series Engines - P/N PC-115-2
Operators Handbook: O-320 Series - P/N 60297-30
O, HO, IO, AIO, HIO, TIO-360 Series - P/N 60297-12
O-540, IO-540 Series - P/N 60297-10

(7) FIRE EXTINGUISHER (PORTABLE)

Vendor Address: H3R Inc. PH: (800) 249-4289
43 Magnolia Ave # 4
San Francisco, California 94123-2911
http://www.h3r.com/index.htm
(8) LANDING GEAR ACTUATOR, EXTENSION AND RETRACTION
Vendor Address: See listing under Brakes and Wheels, above.
Component (Effective for P/N’s 96860-002 and 96860-003 only.)
Maintenance Manual: CMSFA232-5 (011-00504)

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(9) LIGHTS - NAVIGATION, STROBE, AND MAP LIGHTS

Vendor Address: Whelen Engineering Co. Inc. PH: (860) 526-9504
Route 145, Winthrop Rd. FAX: (860) 526-2009
Chester, Conneticut 06412
http://www.whelen.com/
(10) MAGNETOS
Vendor Address: Continental Aerospace Technologies PH: (888) 826-5465
2039 South Broad Street (800) 326-0089
Mobile, AL 36615
http://www.continentalmotors.aero/
Service Support Manual: S-1200 Series High Tension Magnetos, P/N x42001
Service Support Manual: S-20 / S-200 Series High Tension Magnetos, P/N x42002
or, if installed:
Vendor Address: Slick Aircraft Products PH: (904) 772-1909
Champion Aerospace
P.O. Box 686
1230 Old Norris Road
Liberty, SC 29657
http://www.championaerospace.com/
Installation, Operation
and Maintenance
Instructions: F1100 Master Service Manual
(11) PROPELLER
Vendor Address: Sensenich Corporation PH: (717) 569-0435
14 Citation Lane FAX: (717) 560-3725
Lititz, PA 17543
http://www.sensenich.com/
Repair Manual: Metal Propeller Repair Manual - SPRM 590
or,
Vendor Address: Hartzell Propeller Inc. PH: (937) 778-4379
One Propeller Place FAX: (937) 778-4321
Piqua, OH 45356-2634
http://www.hartzellprop.com/index2.htm
Overhaul
and Maintenance: Manual No. 113B
Aluminum Blade
Overhaul: Manual No. 133C
Propeller Owner’s
Manual and Logbook: Manual No. 115N
or,

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Vendor Address: McCauley Propeller Systems

P.O. Box 7704
Wichita, KS 67277-7704
Service Manuals: McCauley Fixed Pitch - P/N 730720
McCauley Constant Speed - P/N 720415

(12) PROPELLER GOVERNOR

Vendor Address: See listing under Propeller, Hartzell, above.
Governor Maintenance: Manual No. 130B

(13) STARTER
Vendor Address: Sky-Tec PH: (800) 476-7896
350 Howard Clemmons Rd. FAX: (817) 573-2252
Granbury, Texas 76048
http://www.skytecair.com
or
Electro Systems, Inc. (now Hartzell Engine Technologies)
See listing under Alternator, above.

(14) VACUUM PUMP

Vendor Address: Aero Accessories, Inc. PH: (800) 822-3200
1240 Springwood Avenue
Gibsonville, NC 27249
http://www.aeroaccessories.com/index.html
(15) VACUUM REGULATOR
Vendor Address: Parker Hannifin Corp. PH: (800) 382-8422
Airborne Division
711 Taylor Street
Elyria, Ohio 44035
http://www.parker.com/ag/nad
(16) VOLTAGE REGULATOR
Vendor Address: Electro Systems, Inc. (now Hartzell Engine Technologies)
See listing under Alternator, above.

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13. Section Index Guide

SECTION TITLE GRID NO.

INTRODUCTION INTRi

I AIRWORTHINESS LIMITATIONS I-i

II HANDLING AND SERVICING 1A24

III INSPECTION III-i

IV STRUCTURES 1G13

V SURFACE CONTROLS 2A1

VI HYDRAULIC SYSTEM (PA-28R) 2D3

VII LANDING GEAR AND BRAKEs (PA-28) 2E22

VIIA LANDING GEAR AND BRAKEs (PA-28R) 2H1

VIII POWERPLANT (PA-28) 2K2

VIIIA POWERPLANT (PA-28R) 3A1

IX FUEL SYSTEM 3C8

X INSTRUMENTS 3D19

XI ELECTRICAL SYSTEM 4A1

XII ELECTRONICS 4I1

XIII HEATING AND VENTILATION SYSTEM 4I14

XIV ACCESSORIES AND UTILITIES 4J4

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LIST OF ILLUSTRATIONS

Figure Page No. /

No. Grid No.
2-1. Three View of Cherokee, PA-28-140 and
PA-28-150, -160, -180, S/N’s 28-1 thru 28-1760,
PA-28-140 Flite Liner, S/N’s 28-7125174 and up.......................... 1B4
2-2. Three View of Cherokee,
PA-28-140, S/N’s 28-7225001 and up ........................................... 1B5
2-3. Three View of Cherokee,
PA-28-150, -160, -180, S/N’s 28-1761 thru 28-4377 .................... 1B6
2-4. Three View of Cherokee,
PA-28-180, S/N’s 28-4378 thru 28-7105244.................................. 1B7
2-5. Three View of Cherokee,
PA-28-180, S/N’s 28-7205001 thru 28-7205328............................ 1B8
2-6. Three View of Cherokee,
PA-28-180, S/N’s 28-7305001 and up............................................ 1B9
2-7. Three View of Cherokee,
PA-28-235, S/N’s 28-10000 thru 28-11039.................................... 1B10
2-8. Three View of Cherokee,
PA-28-235, S/N’s 28-11040 thru 28-7110042 ............................... 1B11
2-9. Three View of Cherokee,
PA-28-235, S/N’s 28-7210001 thru 28-7210033............................ 1B12
2-10. Three View of Cherokee,
PA-28-235, S/N’s 28-7310001 and up ........................................... 1B13
2-11. Three View of Cherokee,
PA-28R-180 S/N’s 28-30005 thru 28-7130019,
PA-28R-200 S/N’s 28-30482 thru 28-7135238 ............................. 1B14
2-12. Three View of Cherokee,
PA-28R-200, S/N’s 28-7235001 and up ........................................ 1B15
2-13. Station Reference Lines, PA-28-140 and
PA-28-150, -160, -180, S/N’s 28-1 thru 28-1760;
PA-28-140 Flite Liner, S/N’s 28-7125174 and up ......................... 1C4
2-14. Station Reference Lines,
PA-28-140, S/N’s 28-7225001 and up ........................................... 1C5
2-15. Station Reference Lines,
PA-28-150, -160, -180, S/N’s 28-1761 thru 28-4377 .................... 1C6
2-16. Station Reference Lines,
PA-28-180, S/N’s 28-4378 thru 28-7105244 ................................. 1C7
2-17. Station Reference Lines,
PA-28-180, S/N’s 28-7205001 thru 28-7205328 .......................... 1C8
2-18. Station Reference Lines,
PA-28-180, S/N’s 28-7305001 and up ........................................... 1C9
2-19. Station Reference Lines,
PA-28-235, S/N’s 28-10000 thru 28-11039 ................................... 1C10
2-20. Station Reference Lines,
PA-28-235, S/N’s 28-11040 thru 28-7110042 ............................... 1C11

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LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
2-21. Station Reference Lines,
PA-28-235, S/N’s 28-7210001 thru 28-7210033 ........................... 1C12
2-22. Station Reference Lines,
PA-28-235, S/N’s 28-7310001 and up ........................................... 1C13
2-23. Station Reference Lines,
PA-28R-180 S/N’s 28-30005 thru 28-7130019;
PA-28R-200 S/N’s 28-30482 thru 28-7135238 ............................. 1C14
2-24. Station Reference Lines,
PA-28R-200, S/N’s 28-7235001 and up ....................................... 1C15
2-25. Access Plates and Panels, PA-28-140 and
Flite Liner, S/N’s 28-7225001 and up as noted ............................. 1C16
2-26. Access Plates and Panels, PA-28-150, -160, -180 ................................ 1C17
2-27. Access Plates and Panels, PA-28-235 .................................................. 1C18
2-28. Access Plates and Panels, PA-28R ....................................................... 1C19
2-29. Identification of Aircraft Fluid Lines ................................................... 1D7
2-30. Torque Wrench Formula ....................................................................... 1C20
2-31. Removing Cherrylock Rivets ............................................................... 1D8
2-32. Jacking Arrangement ........................................................................... 1D9
2-33. Weighing Airplane ................................................................................ 1D10
2-34. Leveling Longitudinally ....................................................................... 1D11
2-35. Leveling Laterally ................................................................................. 1D11
2-36. Servicing Points, PA-28-140 ............................................................... 1D19
2-37. Servicing Points, PA-28-150, -160, -180 .............................................. 1D20
2-38. Servicing Points, PA-28-235 ............................................................... 1D21
2-39. Servicing Points, PA-28R ..................................................................... 1D22
2-40. Main Gear Oleo Struts (Cutaway View),
PA-28-140; PA-28-150, -160, -180; PA-28-235 ............................ 1D23
2-41. Tire Balancer ........................................................................................ 1E4
2-42. Fuel Strainer, PA-28-140; PA-28-150, -160, -180; and PA-28R ......... 1E9
2-43. Fuel Selector and Filter, PA-28-235 ..................................................... 1E9
2-44. Lubrication Chart (Landing Gear, Main),
PA-28-140, -150, -160, -180 and -235 ........................................... 1E18
2-45. Lubrication Chart (Landing Gear, Main), PA-28R-180 and -200 ........ 1E19
2-46. Lubrication Chart (Landing Gear, Nose),
PA-28-140, -150, -160, -180 and -235 ........................................... 1E20
2-47. Lubrication Chart (Landing Gear, Nose), PA-28R-180 and -200 ........ 1E21
2-48. Lubrication Chart (Control System, Sheets 1 thru 4) ........................... 1E22
2-49. Not used
2-50. Not used
2-51. Lubrication Chart (Cabin Door, Baggage Door and Seat) ................... 1F2
2-52. Lubrication Chart (Power Plant, Propeller and Control Pivot Points) .. 1F3
2-53. Lubrication Chart (Back-Up Extender and Fuel Selector) .................. 1F4
2-54. Lubrication Chart (Air Conditioning Condenser) ................................. 1F5

LIST OF ILLUSTRATIONS 11/30/19

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 PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
3-1. Electric Trim Switch Inspection .......................................................... III-49
3-2. Air Induction Inlet Hose Inspection .................................................... III-50
3-3. Spinner and Spinner Bulkhead Inspection ........................................... III-51
3-4. Stabilator Balance Weight Tube Inspection ........................................ III-53
3-5. Fuel Selector Valve Inspection ............................................................ III-56
3-6. Wing Rib Assembly Inspection ........................................................... III-59
3-7. Stabilator Attach Fitting Corrosion Inspection .................................... III-64
3-8. Flap Control Cable Attachment Bolt Inspection .................................. III-65
3-9. Wing Attach Fittings ............................................................................. III-67
3-10. Drain Hole Installation ......................................................................... III-68
3-11. Fuel Tank and Wing Spar Corrosion Inspection ................................. III-71
3-12. Main Gear Strut Cylinder ..................................................................... III-72
3-13. Control Cable Inspection ...................................................................... III-74
3-14. External Cable Patterns ......................................................................... III-75
3-15. Internal Cable Patterns .......................................................................... III-76
3-16. Pulley Wear Patterns ............................................................................. III-78
3-17. Typical Muffler Fatigue Areas ............................................................. III-79
3-18. Exhaust System Inspection Points ........................................................ III-80
3-19. Exhaust System Installation, PA-28R-180,-200 ................................... III-83
3-20. Control Wheel Inspection Points ......................................................... III-84
3-21. Aileron Hinge Doubler 100 Hour Inspection ....................................... III-86
3-22. Inspection of Main Landing Gear Torque Links .................................. III-87
3-23. Upper Nose Gear Oleo Bearing Inspection .......................................... III-89
3-24. Rudder Bar Assembly 100 Inspection .................................................. III-91
3-25. Retention Clip Adjustment ................................................................... III-94
3-26. Main Landing Gear Torque Link Greaser Bolt Inspection ................... III-95
4-1. Aileron and Flap Installation ................................................................ 1G19
4-2. Wing Installation .................................................................................. 1G23
4-3. Methods of Securing Control Cables .................................................... 1H7
4-4. Empennage Group Installation ............................................................. 1H11
4-5. Windshield Installation (Typical) ......................................................... 1H16
4-6. Side Window Installation, Single Pane (Typical) ................................. 1H18
4-7. Side Window Installation, Double Pane (Typical) ............................... 1H18
4-8. Door Snubber Installation ..................................................................... 1H20
4-9. Seat Back Lock ..................................................................................... 1H23
4-10. Skin Materials and Thickness ............................................................... 1I1
4-10a. Metal Wire Stitching Repair ................................................................. 1I3
4-11. Surface Scratches, Abrasions or Ground-in-Dirt .................................. 1I8
4-12. Deep Scratches, Shallow Nicks and Small Holes ................................. 1I9
4-13. Mixing of Epoxy Patching Compound ................................................. 1I9
4-14. Welding Repair Method ....................................................................... 1I11

11/30/19 LIST OF ILLUSTRATIONS

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LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
4-15. Repairing of Cracks .............................................................................. 1I11
4-16. Various Repairs .................................................................................... 1I12
4-17. Repair of Stress Lines ........................................................................... 1I13
4-18. Repair of Impacted Damage ................................................................. 1I13
4-19. Control Surface Balance Tool .............................................................. 1I20
4-20. Aileron and Rudder Balance Configuration ......................................... 1I21
4-21. Stabilator Balance ................................................................................. 1I22
4-22. Wing Rib Modification ......................................................................... 1I24
4-23. Balance Weight Assembly Installation ................................................. 1I24
4-24. Fabricated Tool for Baggage Door Lock .............................................. 1J1
4-25. Additional Drain Holes in Stabilator .................................................... 1J2
4-26. Baggage Compartment Inspection Holes Cutout Details ..................... 1J5
4-27. Millivolt Drop Test ............................................................................... 1J7
5-1. Control Column Assembly, PA-28-140, -150, -160, -180 and -235 .... 2A16
5-2. Control Column Assembly, PA-28R .................................................... 2A17
5-2a. Universal, or Flex, Joint Installation ..................................................... 2A19
5-3. Aileron Controls ................................................................................... 2A20
5-4. Bellcrank Rigging Tool Application and Fabrication .......................... 2B2
5-5. Aileron Rigging Tool Application and Fabrication .............................. 2B3
5-6. Stabilator Controls ................................................................................ 2B6
5-7. Stabilator Rigging Tool Application and Fabrication .......................... 2B8
5-8. Stabilator Trim Control (Overhead Control) ........................................ 2B10
5-9. Methods of Securing Trim Cables ........................................................ 2B12
5-10. Stabilator Trim Control (Floor Control) ............................................... 2B20
5-11. Rudder and Steering Pedal Assembly ................................................... 2B24
5-12. Rudder Controls .................................................................................... 2C3
5-13. Rudder Rigging Tool Application and Fabrication .............................. 2C5
5-14. Rudder and Stabilator Travel Adjustments ........................................... 2C6
5-15. Rudder Trim Control Installation - PA-28-140/150/160/180/235......... 2C8
5-16. Rudder Trim Control ............................................................................ 2C9
5-17. Flap Controls ........................................................................................ 2C12
5-18. Flap Rigging Tool Application and Flap Step Adjustment .................. 2C14
5-19 Correct Method of Installing Rod End Bearings .................................. 2C16
5-20. Not used
5-21. Not used
5-22. Not used
5-23. Not used
5-24. Not used
5-25. Not used
6-1. Schematic Diagram of Hydraulic System ............................................. 2D5
6-2. Hydraulic System Installation ............................................................... 2D6
6-3. Hydraulic Pump/Reservoir, Exploded View ........................................ 2D10
6-4. Test and Adjustments of Hydraulic Pump ............................................ 2D13

LIST OF ILLUSTRATIONS 11/30/19

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LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
6-5. Pump Shock Mounts ............................................................................. 2D14
6-5a. Hydraulic Pump/Reservoir ................................................................... 2D17
6-6. Checking Aligning Brackets of Gear Back-Up Extender Actuator
and Fabrication of the Aligning Tool ............................................. 2D20
6-7. Gear Back-Up Extender Actuator ......................................................... 2D23
6-8. Nose Gear Actuating Cylinder .............................................................. 2E4
6-9. End Gland Locking Device .................................................................. 2E7
6-10. Main Gear Actuating Cylinder ............................................................. 2E7
6-11. Not used
7-1. Nose Gear Oleo Strut Assembly ........................................................... 2F2
7-2. Nose Gear Installation .......................................................................... 2F6
7-3. Clamping Rudder Pedals in Neutral Position ....................................... 2F8
7-4. Rudder Pedals at Neutral Angle ........................................................... 2F8
7-5. Main Gear Oleo Strut Assembly, PA-28-140, -150, -160 and -180 ..... 2F13
7-6. Main Gear Oleo Strut Assembly, PA-28-235 ....................................... 2F15
7-7. Main Gear Installation .......................................................................... 2F19
7-8. Nose Wheel Assembly .......................................................................... 2F21
7-9. Main Wheel Assembly ......................................................................... 2F23
7-10. Wheel Brake Assembly ........................................................................ 2G1
7-11. Removal of Anchor Bolt ....................................................................... 2G2
7-12. Installation of Anchor Bolt ................................................................... 2G3
7-13. Brake Disc Minimum Thickness .......................................................... 2G5
7-14. Brake System Installation ..................................................................... 2G5
7-15. Brake Master Cylinder (Hand Brake),
PA-28-150, -160, S/N’s 28-1 thru 28-250 ..................................... 2G8
7-16. Brake Master Cylinder (Hand/Parking Brake),
PA-28-140, S/N’s 28-20002 thru 28-21036;
PA-28-150, -160, -180, S/N’s 28-251 thru 28-2700;
PA-28-235, S/N’s 28-10003 thru 28-10697 ................................... 2G8
7-17. Brake Master Cylinder (Hand/Parking Brake),
PA-28-140, S/N’s 28-21037 and up;
PA-28-150, -160, -180, S/N’s 28-2701 and up;
PA-28-235, S/N’s 28-10698 and up ............................................... 2G9
7-18. Parking Valve, PA-28-150, -160, S/N’s 28-1 thru 28-250 ................... 2G11
7-19. Toe Brake Installation ........................................................................... 2G12
7-20. Brake Cylinder 10-20, 10-27, 17000 (Toe Brake) ................................ 2G14
7-21. Brake Cylinder 10-30 (Toe Brake) ....................................................... 2G15
7-22. Bleeding Brake (Gravity) ..................................................................... 2G18
7-23. Bleeding Brake (Pressure) .................................................................... 2G18
7-24. Orifice Replacement Tool ..................................................................... 2G23
7-25. Retainer Ring Tool ............................................................................... 2G24
7A-1. Nose Gear Oleo Strut Assembly ........................................................... 2H9
7A-2. Nose Gear Installation .......................................................................... 2H11

11/30/19 LIST OF ILLUSTRATIONS

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LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
7A-3. Nose Gear Adjustment (Without Gear Up Stop) .................................. 2H16
7A-4. Nose Gear Adjustment (With Gear Up Stop) ....................................... 2H16
7A-5. Clamping Rudder Pedals in Neutral Position ....................................... 2H19
7A-6. Rudder Pedals at Neutral Angle ........................................................... 2H19
7A-7. Nose Gear Door Retraction Mechanism ............................................... 2H20
7A-8. Main Gear Oleo Strut Assembly ........................................................... 2H24
7A-9. Main Gear Installation .......................................................................... 2I3
7A-9a. Main Landing Gear Trunnion Repair ................................................... 2I6
7A-10. Aligning Main Gear .............................................................................. 2I10
7A-11. Adjustment of Nose Gear Down Limit Switch ..................................... 2I15
7A-12. Adjustment of Main Gear Down Limit Switch .................................... 2I15
7A-13. Wiring Diagram of Landing Gear Electrical Circuit ............................ 2I17
7A-14. Throttle Warning Switches ................................................................... 2I19
7A-15. Nose Wheel Assembly .......................................................................... 2I22
7A-16. Main Wheel Assembly ......................................................................... 2I23
7A-17. Wheel Brake Assembly ........................................................................ 2J1
7A-18. Brake Disc Minimum Thickness .......................................................... 2J3
7A-19. Brake System Installation ..................................................................... 2J3
7A-20. Brake Master Cylinder (Hand/Parking Brake) ..................................... 2J5
7A-21. Toe Brake Installation ........................................................................... 2J6
7A-22. Brake Cylinder (Toe Brake) (10-20, 10-27, 17000) ............................. 2J8
7A-23. Brake Cylinder (Toe Brake) (10-30) .................................................... 2J10
7A-24. Bearing Installation ............................................................................... 2J11
7A-25. Nose Gear Service Tolerances, PA-28R ............................................... 2J20
7A-26. Main Gear Service Tolerances, PA-28R .............................................. 2J23
8-1. Typical Nicks and Removal Method .................................................... 2K8
8-2. Propeller Installation (Constant Speed), PA-28-235 ............................ 2K8
8-3. Propeller Installation ............................................................................. 2K9
8-4. Adjustment of Propeller Control, PA-28-235 ....................................... 2K13
8-5. Propeller Governor, PA-28-235 ............................................................ 2K13
8-6. Engine Installation,
PA-28-140,-150,-160,-180, S/N’s 28-1 thru 28-1760 .................... 2K16
8-7. Engine Installation,
PA-28-140,-150,-160,-180, S/N’s 28-1761 and up ........................ 2K17
8-8. Engine Shock Mount Installation.
PA-28-140, S/N’s 28-25000 and up ............................................... 2K18
8-9. Engine Installation, PA-28-235 ............................................................ 2K22
8-10. Adjustment of Engine Controls ............................................................ 2K24
8-10a. Throttle/Mixture Control Ball Joint Inspection .................................... 2K24
8-11. Carburetor, PA-28-140, -150, -160 ....................................................... 2L3
8-12. Carburetor, PA-28-180, -235 ................................................................ 2L3
8-13. Magneto Inspection .............................................................................. 2L5
8-14. Contact Spring Inspection ..................................................................... 2L6
8-15. Impulse Coupling .................................................................................. 2L6

LIST OF ILLUSTRATIONS 11/30/19

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 PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
8-16. Magneto Timing Marks ........................................................................ 2L7
8-17. Timing Pointer ...................................................................................... 2L7
8-18. Timing Kit Installed .............................................................................. 2L8
8-19. Breaker Compartment With Cast Timing Marks .................................. 2L8
8-20. Removing Spark Plug Frozen to Bushing ............................................ 2L13
8-21. Ignition Switch Wiring Positions .......................................................... 2L16
8A-1. Propeller Installation ............................................................................. 3A12
8A-2. Typical Nicks and Removal Method .................................................... 3A13
8A-3. Propeller Governor ............................................................................... 3A16
8A-4. Engine Installation, PA-28R-180 .......................................................... 3A19
8A-5. Engine Installation, PA-28R-200 .......................................................... 3A21
8A-6. Adjustment of Engine Controls ............................................................ 3B1
8A-6b. Throttle/Mixture Control Ball Joint Inspection .................................... 3B1
8A-7. Fuel Injector .......................................................................................... 3B3
8A-8. Schematic Diagram of RSA Fuel Injection System ............................. 3B4
8A-9. Fuel-Air Bleed Nozzle .......................................................................... 3B6
8A-10. Contact Points ....................................................................................... 3B8
8A-11. Rotor Holding Tool Installed................................................................. 3B10
8A-12. Timing Kit Installed............................................................................... 3B10
8A-13. Aligning Timing Marks......................................................................... 3B11
8A-14. Checking Flyweight Clearance of Impulse Coupling............................ 3B12
8A-15. Engine Timing Marks............................................................................ 3B13
8A-16. Magneto Adjustment Limits.................................................................. 3B14
8A-17. Magneto Timing Marks......................................................................... 3B14
8A-18. Removing Spring From Lead Assembly .............................................. 3B16
8A-19. Assembly Tool ...................................................................................... 3B16
8A-20. Using Assembly Tool ........................................................................... 3B17
8A-21. Measuring Lead Assembly Length ....................................................... 3B17
8A-22. Cutting Metallic Braid From End of Lead ............................................ 3B18
8A-23. Unbraiding Metallic Shielding ............................................................. 3B18
8A-24. Forming Shielding Around Ferrule ...................................................... 3B19
8A-25. Ferrule Seating Tool ............................................................................. 3B19
8A-26. Needle ................................................................................................... 3B19
8A-27. Measuring Wire From Top of Ferrule .................................................. 3B20
8A-28. Installing Grommet Over Lead Assemblies ......................................... 3B20
8A-29. Lead Assembly Installed in Grommet .................................................. 3B20
8A-30. Wire Doubled Over For Installation of Eyelet ..................................... 3B20
8A-31. Removing Spark Plug Frozen to Bushing ............................................ 3B22
8A-32. Ignition Switch Wiring Positions .......................................................... 3B24
9-1. Fuel System Diagram, PA-28-140, -150, -160, -180 ............................ 3C11
9-2. Fuel System Diagram, PA-28-235, S/N’s 28-10003 thru 28-10719 .... 3C12
9-3. Fuel System Diagram, PA-28-235, S/N’s 28-10720 and up ................ 3C13
9-4. Fuel System Diagram, PA-28R ............................................................ 3C14
9-5. Not used

11/30/19 LIST OF ILLUSTRATIONS

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LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
9-6. Fuel Quantity Transmitter (P/N 62037-00) .......................................... 3C21
9-7. Fuel Quantity Transmitter (P/N 68101-00) .......................................... 3C21
9-7a. Fuel Quantity Transmitter (P/N 548-671) ............................................ 3C22
9-8. Fuel Selector and Filter, PA-28-235 ..................................................... 3C24
9-9. Fuel Filter, PA-28-235 .......................................................................... 3D1
9-10. Fuel Filter Bowl and Screen,
PA-28-140, -150, -160, -180 and PA-28R ..................................... 3D3
9-11. Plunger Fuel Pump (Early), PA-28-150, -160, -180 ............................. 3D6
9-12. Plunger Fuel Pump (Late), PA-28-140, -150, -160, -180, -235 ............ 3D6
9-13. Engine Primer ....................................................................................... 3D12
9-14. Fabricated Fuel Quantity Transmitter Checking Jig ............................. 3D17
10-1. Instrument Panel, PA-28-140, S/N’s 28-25000 thru 28-26956 ............ 3E4
10-2. Instrument Panel, PA-28-140, S/N’s 28-7125001 thru 28-7325684 .... 3E5
10-3. Instrument Panel, PA-28-140, S/N’s 28-7425001 and up .................... 3E6
10-4. Instrument Panel ................................................................................... 3E7
10-5. Instrument Panel,
PA-28-150, -160, -180, S/N’s 28-1761 thru 28-4377 ................... 3E8
10-6. Instrument Panel, PA-28-180, S/N’s 28-4378 thru 28-7205328 .......... 3E9
10-7. Instrument Panel, PA-28-180, S/N’s 28-7305001 thru 28-7305611 .... 3E10
10-8. Instrument Panel, PA-28-180, S/N’s 28-7405001 and up .................... 3E11
10-9. Instrument Panel, PA-28-235, S/N’s 28-10720 thru 28-11039 ............ 3E12
10-10. Instrument Panel, PA-28-235, S/N’s 28-11040 thru 28-7210033 ........ 3E13
10-11. Instrument Panel, PA-28-235, S/N’s 28-7310001 thru 28-7310187 .... 3E14
10-12. Instrument Panel, PA-28-235, S/N’s 28-7410001 and up .................... 3E15
10-13. Instrument Panel, PA-28R-180, S/N’s 28-30005 thru 28-30879 ......... 3E16
10-14. Instrument Panel, PA-28R-180, S/N’s 28-30880 thru 28-7130019;
PA-28R-200, S/N’s 28-30482, 28-35001 thru 28-35830
and 28-7135001 thru 28-7135238 .................................................. 3E17
10-15. Instrument Panel, PA-28R-200, S/N’s 28-7235001 thru 28-7335455 . 3E18
10-16. Instrument Panel, PA-28R-200, S/N’s 28-7435001 and up ................. 3E19
10-17. Warning Light Pressure Switch ............................................................ 3E23
10-17a. Vacuum Pump Vane Wear Inspections - Aero Accessories only ......... 3F2
10-18. Typical Pitot Static System,
PA-28-140, -150, -160, -180, -235, PA-28R-180 and -200 ........... 3F4
10-19. EGT Probe Location, PA-28R-180 and -200 ....................................... 3F24
10-20. EGT Probe Location, PA-28-235 ......................................................... 3G1
10-21. EGT Probe Location, PA-28-150, -160, -180, S/N’s 1761 and up ....... 3G2
11-1. Generator and Starter System ............................................................... 4A18
11-2. Generator Wiring Diagram ................................................................... 4A19
11-3. Sectional View of Generator ................................................................ 4A22
11-4. Current/Voltage Regulator .................................................................... 4B7
11-5. Use of Riffler File to Clean Contact Points .......................................... 4B10
11-6. Voltage Regulator Air Gap ................................................................... 4B10

LIST OF ILLUSTRATIONS 11/30/19

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LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
11-7. Checking Voltage Setting Fixed Resistance Method ........................... 4B11
11-8. Checking Voltage Setting Variable Resistance Method ....................... 4B11
11-9. Adjusting Voltage Regulator Setting .................................................... 4B12
11-10. Cutout Relay Air Gap Check and Adjustment ..................................... 4B14
11-11. Cutout Relay Point Opening Check and Adjustment ........................... 4B14
11-12. Checking Cutout Relay Closing Voltage .............................................. 4B15
11-13. Adjustment of Cutout Relay Closing Voltage ...................................... 4B15
11-14. Checking Current Regulator, Load Method ......................................... 4B16
11-15. Checking Current Regulator, Jumper Lead Method ............................. 4B16
11-16. Alternator and Starter System,
PA-28-140, S/N’s 28-20000 thru 28-24999;
PA-28-150, -160, S/N’s 28-508 thru 28-3643;
PA-28-180, S/N’s 28-671 thru 28-3643;
PA-28-235, S/N’s 28-10002 thru 28-10762 ................................... 4B20
11-17. Alternator and Starter System,
PA-28-140, S/N’s 28-25000 and up;
PA-28-150, -160, -180, S/N’s 28-3644 and up;
PA-28-235, S/N’s 10763 and up and
PA-28R ........................................................................................... 4B21
11-18. Lamp-Bank Load .................................................................................. 4B23
11-19. Checking Field Circuit .......................................................................... 4B24
11-20. Testing Field Circuit ............................................................................. 4B24
11-21 . Testing Rectifiers ( Positive) ................................................................ 4C2
11-22. Testing Rectifiers (Negative) ................................................................ 4C3
11-23. C-3928 Fixtures and Adapters .............................................................. 4C4
11-24. Removing Rectifiers ............................................................................. 4C4
11-25. Installing Rectifiers ............................................................................... 4C5
11-26. Soldering Rectifier Lead ....................................................................... 4C6
11-27. Testing Stator Coils .............................................................................. 4C7
11-28. Removing End Bearing ......................................................................... 4C9
11-29. Installing End Bearing .......................................................................... 4C9
11-30. Removing Drive Pulley ........................................................................ 4C10
11-31. Removing Drive End Bearing .............................................................. 4C10
11-32. Removing Slip Ring ............................................................................. 4C11
11-33. Aligning Slip Ring ................................................................................ 4C11
11-34. Installing Slip Ring ............................................................................... 4C12
11-35. Installing Retainer ................................................................................. 4C12
11-36. Solder Points ......................................................................................... 4C13
11-37. Installing Drive End Shield and Bearing (Typical) .............................. 4C14
11-38. Installing Pulley .................................................................................... 4C14
11-39. Meter Connections for Alternator Performance Test ........................... 4C17
11-40. Voltage Regulator ................................................................................. 4C19
11-41. Checking Air Gap ................................................................................. 4C19

11/30/19 LIST OF ILLUSTRATIONS

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LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
11-42. Voltage Regulator Fusible Wires .......................................................... 4C20
11-43. Voltage Regulator Resistance Units ..................................................... 4C20
11-44. No-Load Test Hookup .......................................................................... 4D2
11-45. Lock Torque Test Hookup .................................................................... 4D3
11-46. Resistance Test Hookup ....................................................................... 4D3
11-47. Exploded View of Gear Reduction Starting Motor .............................. 4D8
11-48. Turning Starting Motor Commutator .................................................... 4D11
11-49. Testing Motor Armature for Shorts ...................................................... 4D11
11-50. Testing Motor Field for Grounds .......................................................... 4D11
11-51. No-Load Test Hookup .......................................................................... 4D13
11-52. Stall Torque Hookup ............................................................................. 4D13
11-53. Terminal Block ..................................................................................... 4F5
11-54 thru 11-70 See Table XI-I, Index - Electrical System Schematics ......... 4F11 thru 4G17
11-71. Exploded View of Alternator ................................................................ 4D20
11-72. Removal of Slip Ring End Bearing ...................................................... 4D21
11-73. Removal of Rectifier ............................................................................. 4D21
11-74. Removal of Drive End Head ................................................................. 4D22
11-75. Removal of End Head Bearing ............................................................. 4D22
11-76. Testing Rotor for Ground ..................................................................... 4D23
11-77. Testing Rotor for Shorts ....................................................................... 4D23
11-78. Installation of Bearing .......................................................................... 4D24
11-79. Installation of Rectifier ......................................................................... 4D24
11-80. Terminal Assembly ............................................................................... 4E1
11-81. Slip Ring End Bearing Assembly ......................................................... 4E2
11-82. Testing Alternator ................................................................................. 4E2
11-83. Brush Installation .................................................................................. 4E3
11-84. Internal Wiring Diagram ....................................................................... 4E3
11-85 thru 11-144 See Table XI-I, Index - Electrical System Schematics ......... 4G20 thru 4H24
11-145. Strobe Light Connections ..................................................................... 4E9
12-1. Two Year, Magnesium Battery Connections ........................................ 4I3
12-2. ELT Portable Folding Antenna (Narco) ............................................... 4I4
12-3. ELT Using Fixed Aircraft Antenna (Narco) ......................................... 4I4
12-4. Emergency Locator Transmitter Schematic (Narco) ............................ 4I5
12-5. Communications Components ELT Schematic .................................... 4I6
13-1. Cabin Heater, Defroster and Fresh Air System,
PA-28-140, S/N’s 28-2002 thru 28-24999, and
PA-28-150, -160, -180, S/N’s 28-1 thru 28-1760 .......................... 4I17
13-2. Cabin Heater, Defroster and Fresh Air System,
PA-28-140, S/N’s 28-25000 and up ............................................... 4I18
13-3. Cabin Heater, Defroster and Fresh Air System,
PA-28-150, -160, -180, S/N’s 28-1761 thru 28-2477 .................... 4I19

LIST OF ILLUSTRATIONS 11/30/19

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LIST OF ILLUSTRATIONS (cont.)

Figure Page No. /

No. Grid No.
13-4. Cabin Heater, Defroster and Fresh Air System,
PA-28-150, -160, -180, S/N’s 28-2478 thru 28-4377 .................... 4I20
13-5. Cabin Heater, Defroster and Fresh Air System,
PA-28-180, S/N’s 28-4378 and up ................................................. 4I21
13-6. Cabin Heater, Defroster and Fresh Air System,
PA-28-235, S/N’s 28-10003 thru 28-10675 ................................... 4I22
13-7. Cabin Heater, Defroster and Fresh Air System,
PA-28-235, S/N’s 28-10676 thru 28-11039 ................................... 4I23
13-8. Cabin Heater, Defroster and Fresh Air System,
PA-28-235, S/N’s 28-11040 thru 28-7210033 ............................... 4I24
13-9. Cabin Heater, Defroster and Fresh Air System,
PA-28-235, S/N’s 28-7310001 and up ........................................... 4J1
13-10. Cabin Heater, Defroster and Fresh Air System, PA-28R ..................... 4J2
13-11. Overhead Vent System ......................................................................... 4J3
14-1. Air Conditioning System Installation ................................................... 4J7
14-2. Service Valves ...................................................................................... 4J12
14-3. Test Gauge and Manifold Set ............................................................... 4J13
14-4. Manifold Set Operation ........................................................................ 4J14
14-5. Leak Test Hookup ................................................................................. 4J15
14-6. Evacuation Hookup .............................................................................. 4J17
14-7. Charging Stand ..................................................................................... 4J19
14-8. Charging Hookup .................................................................................. 4J21
14-9. Compressor and Fabricated Oil Dipstick .............................................. 4K1
14-10. Compressor and Alternator Belt Installation ........................................ 4K5
14-11. Magnetic Clutch .................................................................................... 4K7
14-12. Condenser Air Scoop Installation ........................................................ 4K11
14-13. Expansion Valve ................................................................................... 4K13
14-14. Components Installation ....................................................................... 4K15
14-15. Control Head - Diode Mounting Board, Diode Location and Number,
PA-28-140, S/N’s 28-7125472 thru 28-7325057;
PA-28-180, S/N’s 28-7205092 thru 28-7305071;
PA-28R-200, 28R-7235001 thru 28R-7335057 ............................. 4K16
14-16. Air Conditioning Wiring Schematic,
PA-28-140, S/N’s 28-7125472 thru 28-7225131
PA-28-180, S/N’s 28-7205092 thru 28-7205144 ........................... 4K18
14-17. Air Conditioning Wiring Schematic,
PA-28-140, S/N’s 28-7225132 thru 28-7225612;
PA-28-180, S/N’s 28-7205145 thru 28-7205328;
PA-28R-200, S/N’s 28R-7235001 thru 28R-7235330 ................... 4K19
14-18. Air Conditioning Wiring Schematic,
PA-28-140, S/N’s 28-7325001 and up;
PA-28-180, S/N’s 28-7305001 and up;
PA-28R-200, S/N’s 28-7335001 and up ........................................ 4K20

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LIST OF ILLUSTRATIONS 11/30/19

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LIST OF TABLES

Table Aerofiche
No. Grid No.
II-I. Leading Particulars and Principal Dimensions ..................................... 1B16
II-II. Not used ............................................................................................... 1C3
II-III. Flare Fitting Torque Values .................................................................. 1C22
II-IV. Recommended Nut Torques ................................................................. 1C24
II-IV-A. Torque Conversion ............................................................................... 1D2A
II-V. Conversion Tables ................................................................................ 1D2B
II-VI. Decimal/Millimeter Equivalents of Drill Sizes .................................... 1D6
II-VII. Maximum Distance Between Supports for Fluid Tubing ..................... 1D6A
II-VIII. Hose Clamp Tightening ........................................................................ 1D6A
II-VIII-A. Hose Specifications .............................................................................. 1D6B
II-IX. Recommended Engine Lubricating Oils ............................................... 1E14B
II-X. Thread Lubricants ................................................................................. 1E14B
II-XI. List of Consumable Materials................................................................ 1E15
II-XI-A. Vendor Contact Information ................................................................. 1E16B
II-XI-B. Lubricant Specification Cross-Reference ............................................. 1E16E
II-XII. Special Instructions................................................................................ 1E17
III-I. Inspection Report, PA-28-140, -150, -160, -180; PA-28-235 .............. III-11
III-II. Inspection Report, PA-28R ................................................................... III-25
III-III. Special Publications List ....................................................................... III-105
IV-I. List of Materials (Thermoplastic Repair) ............................................. 1I7
IV-II. Balancing Specifications ...................................................................... 1I17
IV-III. Electrical Bonding Resistance Index .................................................... 1J7
V-I. Cable Tension Vs. Ambient Temperature ............................................ 2A12
V-II. Flight Control Surfaces Rigging Limits ............................................... 2A13
V-III. Troubleshooting - Surface Controls ...................................................... 2C19
VI-I. Leading Particulars, Hydraulic System ................................................ 2D8
VI-II. Characteristics, Hydraulic Pump Motor ............................................... 2D15
VI-IIA. Pipe Thread Specifications ................................................................... 2D21
VI-III. Hydraulic System Troubleshooting ...................................................... 2E9
VII-I. Nose Gear Alignment Tolerances ......................................................... 2F9
VII-II. Landing Gear Troubleshooting ............................................................. 2G20
VIIA-I. Landing Gear Troubleshooting ............................................................. 2J12
VIIA-II. PA-28R Nose Gear Service Tolerances ................................................ 2J21
VIIA-III. PA-28R Main Gear Service Tolerances ............................................... 2J24
VIII-I. Propeller Torque Limits ........................................................................ 2K10
VIII-II. Engine Troubleshooting Chart .............................................................. 2L17
VIIIA-I Propeller Torque Limits ........................................................................ 3A11
VIIIA-II. Engine Troubleshooting Chart .............................................................. 3C1
IX-I. Transmitter/Fuel Gauge Tolerances ..................................................... 3C20
IX-II. Fuel Quantity Transmitter Calibration Tolerances ............................... 3C21
IX-III. Fuel System Troubleshooting ............................................................... 3D15
X-I. Troubleshooting - Vacuum System ...................................................... 3E1
X-II. Troubleshooting - Directional Gyro Indicator ...................................... 3F5
X-III. Troubleshooting - Gyro Horizon Indicator ........................................... 3F7

11/30/19 LIST OF TABLES

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LIST OF TABLES (cont.)

Table Page No. /

No. Grid No.
X-IV. Troubleshooting - Rate of Climb Indicator .......................................... 3F8
X-V. Troubleshooting - Altimeter ................................................................. 3F10
X-VI. Troubleshooting - Airspeed Tubes and Indicator ................................. 3F12
X-VII. Magnetic Compass ................................................................................ 3F14
X-VIII. Manifold Pressure Indicator ................................................................. 3F15
X-IX. Tachometer ........................................................................................... 3F16
X-X. Engine Oil Pressure Gauge ................................................................... 3F17
X-XI. Fuel Pressure Gauge ............................................................................. 3F18
X-XII. Turn and Bank Indicator ....................................................................... 3F19
X-XIII. Fuel Quantity Indicators ....................................................................... 3F20
X-XIV. Oil Temperature Indicators ................................................................... 3F21
X-XV. Troubleshooting EGT Gauge ................................................................ 3F23
X-XVI. Cylinder Head Temperature Gauge ...................................................... 3F24
X-XVII. Fuel Flow Gauge ................................................................................... 3G1
XI-I. Electrical System Schematic Index ...................................................... 4A7
XI-II. Electrical System Troubleshooting ....................................................... 4E10
XI-III. Electrical System Component Loads .................................................... 4F8
XI-IV. Electrical Symbols ................................................................................ 4F9
XI-V. Electrical Wire Coding ......................................................................... 4F10
XIV-I. Temperature Pressure Chart ................................................................. 4J8
XIV-II. Aluminum Tubing Torque .................................................................... 4J11
XIV-III. Compressor Oil Change ........................................................................ 4J24
XIV-IV. Air Conditioning System Troubleshooting ........................................... 4K21
XIV-V. Blower System Wire Color Codes ........................................................ 4L6

LIST OF TABLES 11/30/19

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SECTION

I
AIRWORTHINESS
LIMITATIONS

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SECTION I - AIRWORTHINESS LIMITATIONS

TABLE OF CONTENTS

Paragraph Page No.

AIRWORTHINESS LIMITATIONS I-1

Approved Mandatory Replacement Times for Type Certification I-1
Approved Mandatory Structural Inspection Intervals I-1
Inspection Procedures for those Approved Mandatory Structural Inspection Items I-1

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AIRWORTHINESS LIMITATIONS

NOTE: The Airworthiness Limitations section is FAA approved and specifies maintenance required
under §§ 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program
has been FAA approved.
1. Approved Mandatory Replacement Times for Type Certification
(PIR-TCDS 2A13, Rev. 49.)

No limitations related to fatigue life of the airplane and its components have been established for the
PA-28-140, PA-28-150, PA-28-160, PA-28-180, PA-28-235, PA-28R-180, and PA-28R-200 Cherokee
family of airplanes.
2. Approved Mandatory Structural Inspection Intervals
None.
3. Inspection Procedures for those Approved Mandatory Structural Inspection Items
None.

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I - AIRWORTHINESS LIMITATIONS 11/30/19

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SECTION II - HANDLING AND SERVICING

TABLE OF CONTENTS

Paragraph Grid No.

2-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3

2-2. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3
2-3. Station Reference Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3
2-4. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3
2-5. Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3
2-6. Access and Inspection Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3
2-7. Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3
2-8. Threaded Fastener Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C20
2-8a. Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C21
2-8b. Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C21
2-9. Walkway, Handhold and Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1
2-9a. Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1
2-10. Removal of Cherrylock Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D8
2-11. Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D9
2-12. Introduction to Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1D9
2-13. Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D9
2-14. Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D10
2-15. Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D10
2-16. Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D11
2-17. Locking Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D11
2-18. Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D12
2-19. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D13
2-20. Taxiing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D13
2-21. External Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D13
2-22. Operation of External Power Receptacle . . . . . . . . . . . . . . . . . . . 1D13
2-23. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D14
2-24. Cleaning Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D14
2-25. Cleaning Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D14
2-26. Cleaning Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D15
2-27. Cleaning Windshield and Windows . . . . . . . . . . . . . . . . . . . . . . . 1D15
2-28. Cleaning Headliner, Side Panels and Seats . . . . . . . . . . . . . . . . . 1D15
2-29. Cleaning Carpets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D15
2-30. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D16
2-31. Introduction to Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D16
2-32. Hydraulic System (PA-28R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D16
2-33. Servicing Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D16
2-34. Servicing Hydraulic Pump/Reservoir . . . . . . . . . . . . . . . . . . . . . . 1D16

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SECTION II - HANDLING AND SERVICING

TABLE OF CONTENTS (cont.)

Paragraph Grid No.

2-35. Landing Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D16

2-36. Servicing Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D16
2-37. Oleo Struts (PA-28-140, -150. -160, -180 and PA-28-235) . . . . . . . . 1D17
2-38. Servicing Oleo Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D17
2-39. Filling Nose Gear Oleo Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D17
2-40. Filling Main Gear Oleo Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D23
2-41. Inflating Oleo Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D24
2-42. Oleo Struts (PA-28R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1
2-43. Servicing Oleo Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1
2-44. Filling Oleo Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1
2-45. Inflating Oleo Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2
2-46. Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E3
2-47. Servicing Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E3
2-48. Filling Brake Cylinder Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . 1E3
2-49. Draining Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E3
2-50. Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E4
2-51. Servicing Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E4
2-51a. Tire Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E4
2-52. Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E6
2-53. Servicing Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E6
2-54. Induction Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E6
2-55. Removal of Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E6
2-56. Service Instruction (Cleaning and Inspection) . . . . . . . . . . . . . . . 1E7
2-57. Installation of Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E7
2-58. Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E7
2-59. Servicing Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E7
2-60. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E7
2-61. Servicing Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E7
2-62. Filling Fuel Tanks (PA-28-140, -150, -180 and PA-28R) . . . . . . . 1E8
2-63. Filling Fuel Tanks (PA-28-235) . . . . . . . . . . . . . . . . . . . . . . . . . . 1E8
2-64. Draining Moisture From Fuel System
(PA-28-140, -150, -160. -180 and PA-28R) . . . . . . . . . . . . . . . . . . 1E8
2-65. Draining Moisture From Fuel System (PA-28-235) . . . . . . . . . . . 1E8
2-66. Draining Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E10
2-67. Anti-Icing Fuel Additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E10
2-68. Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E10
2-69. Servicing Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E10
2-70. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E11
2-71. Oil System (Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E11
2-72. Servicing Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E11
2-73. Filling Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E11

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SECTION II - HANDLING AND SERVICING

TABLE OF CONTENTS (cont.)

Paragraph Grid No.

2-74. Draining Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E11

2-75. Oil Screens. (Suction.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E11
2-76. Oil Screen. (Pressure.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E11
2-77. Oil Filter. (Full Flow.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E12
2-78. Recommendations for Changing Oil . . . . . . . . . . . . . . . . . . . . . . 1E12
2-79. Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E12
2-80. Application of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E13
2-81. Application of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E13
2-82. Winterization Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E13
2-83. Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E13

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SECTION II

HANDLING AND SERVICING

2-1. INTRODUCTION. This section contains routine handling and servicing procedures that are most
frequently encountered. Frequent reference to this section will aid the individual by providing
information such as the location of various components, ground handling procedures, routine service
procedures and lubrication. When any system or component requires service other than the routine
procedures as outlined in this section, refer to the appropriate section for that component.
2-2. DIMENSIONS. The principal airplane dimensions are shown in Figures 2-1 through 2-12 and are listed
in Table II-I.
2-3. STATION REFERENCE LINES. In order to facilitate the location of various components of the airplane
which require maintenance and servicing, a method utilizing fuselage station (Sta.), wing station or
buttock line (BL), and water line (WL) designations is frequently employed in this manual. (Refer to
Figures 2-13 thru 2-24.) Fuselage stations, buttock lines, and water lines are reference points measured
by inches in the vertical or horizontal direction from a given reference line which indicates station
locations of structural members of the airplane. Station 0 of the fuselage is 78.4 inches ahead of the wing
leading edge or 49.5 inches ahead of the lower edge of the firewall; station 0 (BL) of the wing and
stabilator is the centerline of the airplane; and station 0 (WL) of the fuselage vertical stabilizer and
rudder is 20.5 inches below the cabin floor as measured at the rear wing spar with the airplane level. The
reference datum line is located 78.4 inches ahead of the wing leading edge at the intersection of the
straight and tapered section.
2-4. WEIGHT AND BALANCE DATA. When figuring various weight and balance computations, the empty,
static and gross weight, and center of gravity of the airplane may be found in the Weight and Balance
Form of the Airplane Flight Manual.
2-5. SERIAL NUMBER PLATE. The serial number plate is located on the left side of the fuselage near the
leading edge of the stabilator. The serial number should always be used when referring to the airplane on
service or warranty matters.
2-6. ACCESS AND INSPECTION PROVISIONS. The access and inspection provisions for the airplane are
shown in Figures 2-25 thru 2-28. The component to be serviced or inspected through each opening is
identified in the illustration. All access plates and panels are secured by either metal fasteners or screws.
CAUTION: BEFORE ENTERING THE AFT SECTION OF THE FUSELAGE, BE SURE THE
AIRPLANE IS SUPPORTED AT THE TAIL SKID.
To enter the aft section of the fuselage, open the baggage compartment door and remove the access
panel.
2-7. TOOLS AND TEST EQUIPMENT. Because of the simplicity and easy accessibility of components, few
special tools outside normal shop tools will be required. Tools that are required are listed in the back of
the PA-28 Parts Catalog and may be fabricated to dimensions given in the back of the section that
pertains to a particular component.

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2-8. THREADED FASTENER INSTALLATION (PIR-PPS20015-1, Rev. S.)

a. Fastener Lengths
Fastener lengths must be long enough to prevent bearing loads on threads. The complete chamfer or
end radius of the fastener or screw must extend through the nut.
The specified fastener grip length can be varied by one size (longer or shorter) to meet requirements
stated above. Where needed, use a maximum of two standard filler washers (spacers) under the nut
to adjust for fastener length or alignment of cotter key hole. Where nutplates are used, adjust for
protruding head fastener length by using up to a maximum of two standard filler washers under the
fastener head.
b. Washer Usage
Add a maximum of two NAS1149 washers (of the correct diameter, material and finish that
matches the fastener being installed) under fastener heads or nuts to correct for variations in
material thickness within the tolerances permitted.
c. Self-locking Fasteners
The use of self-locking nuts, fasteners and screws, including fasteners with non-metallic inserts is
subject to the following limitations:
1. Fasteners incorporating self-locking devices must not be re-used if they can be run up using
less than the required minimum torque values specified or as shown in Table II-IV. They may
be reused, if hand tools are required to run them up, providing there is no obvious damage to
the self-locking device prior to installation.
2. Fasteners 5/16 inch diameter and over with cotter pin holes may be used with self-locking
nuts. Nuts with non-metallic locking devices may be used in this application only if the
fasteners are free from burrs around the cotter pin holes.
3. Self-locking nuts must not be used at joints which subject either the nut or the fastener to
rotation.
4. Self-locking fasteners shall never be tapped or rethreaded. Nuts, fasteners and screws with
damaged threads or rough ends shall not be used, or rethreaded.
d. Torque
See Torque Wrenches and Torque Requirements, below.

Figure 2-30. Torque Wrench Formula

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2-8a. TORQUE WRENCHES

Torque wrenches should be checked daily and calibrated by means of weights and a measured lever arm
to ensure that inaccuracies are not present. Checking one torque wrench against another is not sufficient
and is not recommended. Some wrenches are quite sensitive to the way they are supported during a
tightening operation. Any instructions furnished by the manufacturer must be followed explicitly.
When it is necessary to use a special extension or adapter wrench together with a torque wrench, a
simple mathematical equation must be worked out to arrive at the correct torque reading. Following is
the formula to be used: (Refer to Figure 2-30.)
T = Torque desired at the part.
A = Basic lever length from center of wrench shank to center of handle or stamped on wrench or
listed for that model wrench.
B = Length of adapter extension, center of bolt to center of shank.
C = Scale reading needed to obtain desired torque (T).
The formula: C=AxT
A+B

EXAMPLE: A bolt requires 30 foot pounds and a 3 inch adapter (one-quarter of a foot or
0.25’) is needed to get at it. You want to know what scale reading it will take
on a one-foot lever arm wrench to obtain the 30 foot pounds at the bolt.

C = 1 x 30 or C = 30
1 + 0.25 1.25

Remember, the 3 inch adapter must be projecting 3 inches straight along the
wrench axis. In general, avoid all complex assemblages or adapters and
extensions of flex joints.
2-8b. TORQUE REQUIREMENTS (PIR-PPS20015-1, Rev. S.)

CAUTION: DO NOT OVERTORQUE FITTINGS.

Table II-III lists the torque values for flared fittings of various sizes and material.
NOTE: When installing flared fittings, verify that male threads are properly lubricated.
The torque values given in Table II-IV are derived from oil-free cadmium-plated threads and are
recommended for all airframe installation procedures where torquing is required, unless other values are
specified in subject chapter/section. Engine torque values are found in the latest revision of Lycoming
Service Table of Limits SSP-1776; and propeller torque values are found in Section VIII or VIIIA.
NOTE: If normal operation requires movement between any of the components being clamped together,
tighten the nut (or bolt) enough to ensure intended operation of the assembly.
a. Calibrate the torque wrench periodically to assure accuracy, and recheck frequently.

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b. If the fastener, screw, or nut is listed in Table II-IV, but the mating fastener is not listed, tighten only
to the low end of the torque range specified for the listed fastener. In addition, the following
limitations shall apply:
1. Fastener and nut threads shall be clean and dry (free of lubricants). If the subject
chapter/section requires the fastener and/or nut to be lubricated prior to tightening and does not
specify a torque requirement, use the Table II-IV torque range reduced 50 percent.
2. Table II-IV, Sheet 1, shall be used for free running nuts, provided minimal friction drag is
determined as specified below.
3. The friction drag torque can be determined as follows: Run the nut down to near contact (but
not in contact) with the bearing surface and check the "friction drag torque" required to turn
the nut.
NOTE: Check the friction drag torque by attaching a scale type torque wrench to the nut and
determining the torque required to turn the nut on the bolt. (Before the nut makes
contact with the bearing surface.)
4. The friction drag torque (if any) shall be added to the desired torque specified in Table II-IV,
Sheet 1. This final torque should register on the indicator or be the setting for a snap-over
torque limiting device.
5. Torque requirements do not apply to cross recessed or slotted screws or to fasteners installed
into rivnuts, pressnuts or other nuts not designed to rotate for wrenching at the fastener unless
otherwise specified in the subject chapter/section.
6. Fasteners listed in Table II-IV installed into nutplates, and which are accessible to be torqued
at the fastener, must be tightened to the low end of the torque range specified in the appropriate
“shear” column. Torque requirements do not apply if the fastener can not be torqued due to
torque device accessibility.

TABLE II-III. FLARE FITTING TORQUE VALUES

Torque — Inch-Pounds
Tubing Aluminum - Alloy Steel Tubing Hose End Fitting
OD Tubing Flare - and Flare and
Inches 10061 or 10078 and 10061 Hose Assemblies
Minimum Maximum Minimum Maximum Minimum Maximum
1/8 ——— ——— ——— ——— ——— ———
3/16 ——— ——— 90 100 70 100
1/4 40 65 135 150 70 120
5/16 60 80 180 200 85 180
3/8 75 125 270 300 100 250
1/2 150 250 450 500 210 420
5/8 200 350 650 700 300 480
3/4 300 500 900 1000 500 850
1 500 700 1200 1400 500 1150
1-1/4 600 900 ——— ——— ——— ———
1-1/2 600 900 ——— ——— ——— ———
1-3/4 ——— ——— ——— ——— ——— ———
2 ——— ——— ——— ——— ——— ———

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NOTE: When the fastener is stationary and the nut is torqued, use the lower side of the torque
range.
When the nut is stationary and the fastener is torqued, use the higher side of the torque
range. In this case, ensure one (1) washer is installed under the head as follows:
(a) If the subject chapter/section does not specify the use of a washer under the head,
install one (1) NAS1149 .032 thick washer under the head. If additional washers are
required under nut to adjust for grip length variation as described under Threaded
Fastener Installation in 20-00-00: reduce them .032 to allow for the additional .032
washer now installed under head. Check to ensure threads are not bearing loads, due
to the added .032 washer thickness.
(b) All added washers are to be of the correct diameter, material and finish that matches
the fastener being installed.
7. Apply a smooth even pull when applying torque pressure. If chattering or a jerking motion
occurs during final torque, back off and re-torque.
8. When installing a castellated nut, start alignment with the cotter pin hole at minimum
recommended torque, and do not exceed maximum recommended torque. If the hole in the
fastener shank and the nut castellation do not align within this range, change washers and try
again. Do not exceed the maximum recommended torque. If self-locking castellated nuts are
used, include friction drag torque.
9. Unless otherwise specified in the subject chapter/section, when castellated nuts are used with a
cotter pin on moving joints, the nut shall not be torqued to Table II-IV values. Nuts shall be
tightened to remove looseness in the joint and then the cotter pin installed.
c. Gap Conditions Between Parts Attached with Threaded Fasteners
If a gap condition exists between mating parts where a threaded fastener is to be installed, install
fasteners and associated hardware per subject chapter/section or to buildup noted during removal.
Then, torque to a value 10% of the final torque required plus the friction drag torque.
For example, if Table II-IV, Sheet 2, torque is 190 in.-lbs. and the friction drag torque of the nut is
80 in.-lbs. (i.e. - Table II-IV, Sheet 2, torque minus Table II-IV, Sheet 1, torque), torque to a value
of:
Maximum Permissible
Gap Closing Torque = (Table II-IV, Sheet 1, torque x .10) + (Sheet 2 - Sheet 1) torque
Example: 3/8-24 (190 x .10) + (270-190) = 19 + 80 = 99 in.-lbs.
Accomplish this for all fasteners common to the gapped interface. If no gap exists after
accomplishing the above, finish torquing to final torque. If a gap remains consult your Piper
Dealer’s Service Advisor (DSA) for further assistance.
d. After the final torque, apply a slippage mark to the nut or bolt or screw head as applicable.
NOTE: For more details on torquing, refer to FAA AC 43.13-1, latest revision.

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TABLE II-IV. RECOMMENDED NUT TORQUES (SHEET 1 OF 2)

Bolts - Steel Bolts - Aluminum

AN 3 thru AN 20 MS 20004 AN 3DD Series
AN 42 thru AN 49 NAS 333 thru NAS 340
AN 525 NAS 464
MS 20033 thru MS 20046 NAS 624 thru NAS 644
MS 20073 NAS 1580
MS 20074 NAS 6203 thru NAS 6220
MS 24694 NAS 6603 thru NAS 6620
MS 27039 NAS 6703 thru NAS 6720
Nuts - Steel Nuts - Aluminum
Tension Shear Tension Shear Tension Shear
AN 310 AN 320 AN 310 AN 320 AN 310D AN 320D
AN 315 MS 20364 AN 315 MS 20364 AN 315D
MS 20365 MS 21083 MS 20365 MS 21083
MS 21042 MS 21245 MS 21042 MS 21245
MS 21044 MS 21044
MS 21045 MS 21045
NAS 679 NAS 679
FINE THREAD SERIES - ADD FRICTION DRAG
Nut-Bolt Torque Limits Torque Limits Torque Limits Torque Limits Torque Limits Torque Limits
Size In.-Lbs. In.-Lbs. In.-Lbs. In.-Lbs. In.-Lbs. In.-Lbs.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
8-36 12 15 7 9 5 10 3 6
10-32 20 25 12 15 25 30 15 20 10 15 5 10
1/4-28 50 70 30 40 80 100 50 60 30 45 15 30
5/16-24 100 140 60 85 120 145 70 90 40 65 25 40
3/8-24 160 190 95 110 200 250 120 150 75 110 45 70
7/16-20 450 500 270 300 520 630 300 400 180 280 110 170
1/2-20 480 690 290 410 770 950 450 550 280 410 160 260
9/16-18 800 1,000 480 600 1,100 1,300 650 800 380 580 230 360
5/8-18 1,100 1,300 660 780 1,250 1,550 750 950 550 670 270 420
3/4-16 2,300 2,500 1,300 1,500 2,650 3,200 1,600 1,900 950 1,250 560 880
7/8-14 2,500 3,000 1,500 1,800 3,550 4,350 2,100 2,690 1,250 1,900 750 1,200
1-14 3,700 4,500 2,200 3,300 4,500 5,500 2,700 3,300 1,600 2,400 950 1,500
1-1/8-12 5,000 7,000 3,000 4,200 6,000 7,300 3,600 4,400 2,100 3,200 1,250 2,000
1-1/4-12 9,000 11,000 5,400 6,600 11,000 13,400 6,600 8,000 3,900 5,600 2,300 3,650
COARSE THREAD SERIES - ADD FRICTION DRAG
Nut-Bolt Torque Limits Torque Limits
Size In.-Lbs. In.-Lbs.
Min. Max. Min. Max.
8-32 12 15 7 9
10-24 20 25 12 15
1/4-20 40 50 25 30 NOTE: Unless otherwise specified, torque size No. 6
5/16-18 80 90 48 55 screws used with self-locking nutplates to no greater
3/8-16 160 185 95 110 than 4 to 5 in.-lbs.
7/16-14 235 255 140 155 Use an appropriately calibrated driver.
1/2-13 400 480 240 290
9/16-12 500 700 300 420
5/8-11 700 900 420 540
3/4-10 1,150 1,600 700 950
7/8-9 2,200 3,000 1,300 1,800
1-8 3,700 5,000 2,200 3,000
1-1/8-8 5,500 6,500 3,300 4,000
1-1/4-8 6,500 8,000 4,000 5,000

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TABLE II-IV. RECOMMENDED NUT TORQUES (SHEET 2 OF 2)

Bolts - Steel Bolts - Aluminum

AN 3 thru AN 20 MS 20004 AN 3DD Series
AN 42 thru AN 49 NAS 333 thru NAS 340
AN 525 NAS 464
MS 20033 thru MS 20046 NAS 624 thru NAS 644
MS 20073 NAS 1580
MS 20074 NAS 6203 thru NAS 6220
MS 24694 NAS 6603 thru NAS 6620
MS 27039 NAS 6703 thru NAS 6720
Nuts - Steel Nuts - Aluminum
Tension Shear Tension Shear Tension Shear
AN 310 AN 320 AN 310 AN 320 AN 310D AN 320D
AN 315 MS 20364 AN 315 MS 20364 AN 315D
MS 20365 MS 21083 MS 20365 MS 21083
MS 21042 MS 21245 MS 21042 MS 21245
MS 21044 MS 21044
MS 21045 MS 21045
NAS 679 NAS 679
FINE THREAD SERIES - INCLUDES FRICTION DRAG
Nut-Bolt Torque Limits Torque Limits Torque Limits Torque Limits Torque Limits Torque Limits
Size In.-Lbs. In.-Lbs. In.-Lbs. In.-Lbs. In.-Lbs. In.-Lbs.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
10-32 38 43 30 33 43 48 33 38 28 33 23 28
1/4-28 65 100 60 70 110 130 80 90 60 75 45 60
5/16-24 160 200 120 145 180 205 130 150 100 125 85 100
3/8-24 240 270 175 190 280 330 200 230 155 190 125 150
7/16-20 550 600 370 400 620 730 400 500 280 380 210 270
COARSE THREAD SERIES - INCLUDES FRICTION DRAG
Nut-Bolt Torque Limits Torque Limits
Size In.-Lbs. In.-Lbs.
Min. Max. Min. Max. NOTE: Unless otherwise specified, torque size No. 6
8-32 27 30 22 24 screws used with self-locking nutplates to no greater
10-24 38 43 30 33 than 4 to 5 in.-lbs.
1/4-20 70 80 55 60 Use an appropriately calibrated driver.
5/16-18 140 150 108 115
3/8-16 240 265 175 190
7/16-14 335 355 240 255

2-9. WALKWAY, HANDHOLD AND STEP. The walkway is made of a non-skid compound applied to paper
and bonded to the wing surface. A fixed handhold is located on the right side of the fuselage near the
rear window. A step is available as optional equipment and is installed just aft of the trailing edge of the
right flap.
2-9a. METRIC CONVERSION
Use the following tables to convert capacities, lengths, temperatures, and various weights and measures
from the English system values to the metric system values or vice versa.

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TABLE II-V. CONVERSION TABLES

MULTIPLY BY TO OBTAIN MULTIPLY BY TO OBTAIN

CENTIMETERS 0.3937 IN. KILOGRAMS 2.205 LB.
0.03281 FT. 35.27 OZ.
1000 GRAMS
CU. CENTIMETERS 0.001 LITERS
0.06102 CU. IN. LITERS 1000 CU. CM.
0.0002642 U.S. GAL. 61.03 CU. IN.
0.03532 CU. FT.
CU. FT. 28.320 CU. CM.
0.2642 U.S. GAL.
1.728 CU. IN.
0.22 IMPERIAL GAL.
7.481 U.S. GAL.
1.057 QUARTS
28.32 LITERS
METERS 39.37 IN.
CU. IN. 16.39 CU. CM.
3.281 FT.
0.01639 LITERS
1000 MM.
0.004329 U.S. GAL.
0.01732 QUARTS METER-KILOGRAM 7.233 FT.-LB.
9.807 JOULES
CU. METERS 1000000 CU. CM.
35.314 CU. FT. OUNCES, AVDP 0.0625 LB., AVDP
61.023 CU. IN. 28.35 GRAMS
264.17 GAL. 437.5 GRAINS
999.97 LITERS
OUNCES, FLUID 29.57 CU. CM.
FEET 0.3048 METERS 1.805 CU. IN.
12.000 MILS
LB., AVDP 453.6 GRAMS
304.8 MM.
7000 GRAINS
0.3333 YARDS
16.0 OUNCES
FT.-LB. 0.1383 M-KG
SQUARE INCH 6.4516 SQ. CM.
0.001285 BTU
0.000000376 KW-HR POUND PER 0.0703 KG.-CM
SQUARE INCH SQUARED
FLUID OZ. 8 DRAM
(PSI)
29.6 CU. CM.
STATUTE MILE 1.609 KILOMETER
GAL., IMPERIAL 277.4 CU. IN.
0.8684 NAUTICAL MILE
1.201 U.S. GAL.
4.546 LITERS NAUTICAL MILE 1.151 STATUTE
MILE
GAL., U.S. DRY 268.8 CU. IN.
0.1556 CU. FT. QUART .9463 LITER
1.164 U.S. GAL., LIQ.
4.405 LITERS MILLIMETER 1000 MICRON

GAL., U.S. LIQ. 231.0 CU. IN. MICRON 0.001 MILLIMETER

0.1337 CU. FT. 0.000039 INCH
3.785 LITERS INCH 11.521 METER
0.8327 IMPERIAL GAL. POUNDS GRAMS
128 FLUID OZ.
INCH 0.72 METER
IN. 2.540 CM. OUNCES GRAMS
.08333 FT.
POUNDS 0.453 KILOGRAMS
JOULES 0.000948 BTU
0.7376 FT.-LB.

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TABLE II-V. CONVERSION TABLES (cont.)

Example: Convert 1.5 inches to millimeters.
(1) Read down inches column to 1. inches.
(2) Read across top inch column to 0.5.
(3) Read down and across to find millimeters (1.5 inches is 38.10 millimeters).

INCHES TO MILLIMETER
INCHES 0.0000 0.0001 0.0002 0.0003 0.0004 0.0005 0.0006 0.0007 0.0008 0.0009
MILLIMETER
0.000 0.0025 0.0050 0.0076 0.0101 0.0127 0.0152 0.0177 0.0203 0.0228
0.001 0.0254 0.0279 0.0304 0.0330 0.0355 0.0381 0.0406 0.0431 0.0457 0.0482
0.002 0.0508 0.0533 0.0558 0.0584 0.0609 0.0635 0.0660 0.0685 0.0711 0.0736
0.003 0.0762 0.0812 0.0838 0.0863 0.0889 0.0914 0.0939 0.0965 0.0965 0.0990
0.004 0.1016 0.1041 0.1066 0.1092 0.1117 0.1143 0.1168 0.1193 0.1219 0.1244
0.005 0.1270 0.1295 0.1320 0.1346 0.1371 0.1397 0.1422 0.1447 0.1447 0.1498
0.006 0.1524 0.1549 0.1574 0.1600 0.1625 0.1651 0.1676 0.1701 0.1727 0.1752
0.007 0.1778 0.1803 0.1828 0.1854 0.1879 0.1905 0.1930 0.1955 0.1981 0.2006
0.008 0.2032 0.2057 0.2082 0.2108 0.2133 0.2159 0.2184 0.2209 0.2235 0.2260
0.009 0.2286 0.2311 0.2336 0.2362 0.2387 0.2413 0.2438 0.2463 0.2489 0.2514
INCHES 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
MILLIMETER
0.00 0.025 0.050 0.076 0.101 0.127 0.152 0.177 0.203 0.228
0.01 0.254 0.279 0.304 0.330 0.355 0.381 0.406 0.431 0.457 0.482
0.02 0.508 0.533 0.558 0.584 0.609 0.635 0.660 0.685 0.711 0.736
0.03 0.762 0.787 0.812 0.838 0.863 0.889 0.914 0.939 0.965 0.990
0.04 1.016 1.041 1.066 1.092 1.117 1.143 1.168 1.193 1.219 1.244
0.05 1.270 1.295 1.320 1.346 1.371 1.397 1.422 1.447 1.473 1.498
0.06 1.524 1.549 1.574 1.600 1.625 1.651 1.676 1.701 1.727 1.752
0.07 1.778 1.803 1.828 1.854 1.879 1.905 1.930 1.955 1.981 2.006
0.08 2.032 2.057 2.082 2.108 2.133 2.159 2.184 2.209 2.235 2.260
0.09 2.286 2.311 2.336 2.362 2.387 2.413 2.438 2.463 2.489 2.514
INCHES 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
MILLIMETER
0.0 0.254 0.508 0.762 0.016 1.270 1.524 1.778 2.032 2.286
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.558 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
INCHES 0.00 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
MILLIMETER
0.0 2.54 5.08 7.62 10.16 12.70 15.24 17.78 20.32 22.86
1.0 25.40 27.94 30.48 33.02 35.56 38.10 40.64 43.18 45.72 48.26
2.0 50.80 53.34 55.88 58.42 60.96 63.50 66.04 68.58 71.12 73.66
3.0 76.20 78.74 81.28 83.82 86.36 88.90 91.44 93.98 96.52 99.06
4.0 101.60 104.14 106.68 109.22 111.76 114.30 116.84 119.38 121.92 124.46
5.0 127.00 129.54 132.08 134.62 137.16 139.70 142.24 144.78 147.32 149.86
6.0 152.40 154.94 157.48 160.02 162.56 165.10 167.64 170.18 172.72 175.26
7.0 177.80 180.34 182.88 185.42 187.96 190.50 193.04 195.58 198.12 200.66
8.0 203.20 205.74 208.28 210.82 213.36 215.90 218.44 220.98 223.52 226.06
9.0 228.60 231.14 233.68 236.22 238.76 241.30 243.84 246.38 248.92 251.46

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Figure 2-32. Jacking Arrangement

2-11. GROUND HANDLING.

2-12. INTRODUCTION TO GROUND HANDLING. This includes jacking, weighing, leveling, mooring,
parking, towing and taxiing. Handling the airplane in the manner described in the following paragraphs
will minimize damage to the airplane and its equipment.
CAUTION: WHEN MOVING AIRPLANE FORWARD BY HAND, AVOID PUSHING ON THE
TRAILING EDGE OF THE AILERONS FOR THIS WILL RESULT IN AN OUT OF
TRIM CONDITION.
2-13. JACKING. Jacking the airplane is necessary to service the landing gear and to perform other service
operations. Proceed as follows:
a. Place jacks under jack pads on the front wing spar. (Refer to Figure 2-32.)
b. Attach the tail support to the tail skid. Place approximately 250 pounds of ballast on the base of the
tail support to hold down the tail.
CAUTION: BE SURE TO APPLY SUFFICIENT TAIL SUPPORT BALLAST; OTHERWISE THE
AIRPLANE WILL TIP FORWARD.
NOTE: A jacking point on the PA-28R airplanes is also provided on the underside of the fuselage
directly behind the nose gear actuating cylinder, This may be used along with the wing jack
points to raise the airplane, or alone it may be used to raise the front end.
c. Raise the jacks until all three wheels are clear of the surface.

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Figure 2-33. Weighing Airplane

2-14. WEIGHING. (Refer to Figure 2-33.) For weighing purposes, place the airplane on scales as follows:
a. Position a scale and ramp in front of each of the three wheels.
b. Secure the scales from rolling forward and tow the airplane up onto the scales. (Refer to Paragraph
2-19.)
c. Remove the ramp so as not to interfere with the scales.
d. If the airplane is to be weighed for weight and balance computations, level the airplane per
instructions given in paragraph 2-15.

2-15. LEVELING.
NOTE: Always level the airplane laterally first, then level the airplane longitudinally.
All configurations of the airplane are provided with a means for longitudinal and lateral leveling. The
airplane may be leveled while on jacks, during the weighing procedure while the wheels are on scales, or
while the wheels are on the ground. To level the airplane for purposes of weighing or rigging, the
following procedures may be used:
a. To laterally level the airplane, place a level across the spar box assembly located at the forward
baggage area of the PA-28-140 or under the rear seat of the PA-28-150, -160, -180; PA-28-235; PA-
28R. (Refer to Figure 2-35.) Raise or lower one wing tip by deflating the appropriate tire on the
high side of the airplane or adjust either jack until the bubble of the level is centered.
b. To longitudinally level the airplane, partially withdraw the two leveling screws located immediately
below the left front side window (Refer to Figure 2-34.) Place a level on these screws heads and
adjust the jacks until the level is centered. Should the airplane be either on scales or on the floor,
first block the main gear oleos to full extension; then deflate the nose wheel until the proper
position is reached.

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Figure 2-34. Leveling Longitudinally Figure 2-35. Leveling Laterally

2-16. MOORING. The airplane is moored to ensure its immovability, protection and security under various
weather conditions. In order to properly moor the airplane use the following procedures:
a. Head the airplane into the wind, if possible.
b. Block the wheels.
c. Secure the aileron and stabilator controls using the front seat belt or control surface blocks.
d. Secure tie-down ropes to the wing tie-down rings and the tail skid at approximately 45 degree
angles to the ground. When using rope constructed of non-synthetic material, leave sufficient slack
to avoid damage to the airplane when the ropes contract due to moisture.
CAUTION: USE SQUARE OR BOWLINE KNOTS. DO NOT USE SLIP KNOTS.
NOTE: Additional preparations for high winds include using tie-down ropes on the landing gear
forks, and securing the rudder.
e. Install pitot tube cover, if available.
2-17. LOCKING AIRPLANE. The cabin and baggage compartment doors are provided with an outside lock.
The ignition switch and cabin door require the same key while the baggage compartment door has a
different key.

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2-18. PARKING. When parking the airplane, ensure that it is sufficiently protected against adverse weather
conditions and presents no danger to other aircraft. When parking the airplane for any length of time or
overnight, it is recommended that it be moored as in Paragraph 2-16.
a. Park the airplane headed into the wind, if possible.
b. PA-28-150, -160, Serial Nos. 28-1 to 28-250 incl. Set the parking brake by pulling back the brake
lever and pulling the parking brake knob located at the left of the control panel. Release the brake
lever while holding the knob, then release the knob. To release the parking brake, either push in the
parking brake knob or pull back the brake lever.
c. PA-28-140; PA-28-150, -160, -180, Serial Nos. 28-251 and up; PA-28-235 and PA-28R. Set the
parking brake by pulling back the brake lever and depressing the knob attached to the left side of
the handle, then release the handle. To release the parking brake, pull back on the brake lever to
disengage the catch mechanism, and allow the handle to swing forward.
NOTE: Care should be taken when setting brakes that are overheated during cold weather when
accumulated moisture may freeze the brakes.
d. The aileron and stabilator controls may be secured using the front seat belt.
2-19. TOWING. The airplane may be moved by using the nose wheel steering bar that is stowed in the
baggage area of the PA-28-150, -160, -180; PA-28-235 and PA-28R, or by using power equipment that
will not damage or cause excess strain to the nose gear steering assembly. Towing lugs are incorporated
as part of the nose gear fork of models PA-28-140; PA-28-150, -160, -180; PA-28-235 and PA-28R. On
the PA-28R, the stem on the bar is inserted in the hollow of the nose wheel axle at its right side.
CAUTIONS:
1. WHEN TOWING WITH POWER EQUIPMENT, DO NOT TURN THE NOSE GEAR IN
EITHER DIRECTION BEYOND ITS STEERING RADIUS LIMITS AS THIS WILL
RESULT IN DAMAGE TO THE NOSE GEAR AND STEERING MECHANISM.
2. DO NOT TOW THE AIRPLANE WITH CONTROL LOCKS INSTALLED.
3. WHEN MOVING THE AIRPLANE FORWARD BY HAND, AVOID PUSHING ON THE
TRAILING EDGE OF THE CONTROL SURFACES AS THIS WILL CAUSE THE
CONTROL SURFACE CONTOUR TO CHANGE RESULTING IN AN OUT-OF-TRIM
CONDITION.
In the event towing lines are necessary, lines (rope) should be attached to both main gear struts as high
up on the tubes as possible. Lines should be long enough to clear the nose and/or tail by not less than 15
feet, and a qualified person to ride in the pilot’s seat to maintain control by use of the brakes.

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2-20. TAXIING. Before attempting to taxi the airplane, ground personnel should be checked out by a
qualified pilot or other responsible person. Engine starting and shutdown procedures should be covered
as well. When it is ascertained that the propeller back blast and taxi areas are clear, apply power to start
the taxi roll and perform the following checks:
a. Taxi forward a few feet and apply brakes to determine their effectiveness.
b. Taxi with propeller set in low pitch, high RPM setting, where applicable.
c. While taxiing, make slight turns to ascertain the effectiveness of steering.
d. Observe wing clearances when taxiing near buildings or other stationary objects. If possible, station
a guide outside the airplane to observe.
e. When taxiing on uneven ground, avoid holes and ruts.
f. Do not operate the engine at high RPM when running-up, or taxiing, over ground containing loose
stones, gravel or any loose material that may cause damage to the propeller blades.
2-21. EXTERNAL POWER RECEPTACLE.
2-22. OPERATION OF EXTERNAL POWER RECEPTACLE. The receptacle is located on the left side of
the nose section, just aft of the engine cowling. When used for engine starting or operation of the
airplanes’ other equipment, proceed as follows:
a. Set MASTER SWITCH to OFF.
b. Ensure that the RED lead of PEP (Piper External Power) kit jumper cable is connected to the
POSITIVE (+) terminal of an external 12-volt battery or a power cart and that the BLACK lead is
connected to the NEGATIVE (-) terminal of same.
NOTE: If using an external battery, and the airplanes’ battery is low or depleted, disconnect the
airplane battery at the negative terminal to prevent excessive loading of the external battery.
c. Insert the plug of the jumper cable into the receptacle.
d. Set MASTER SWITCH to ON and proceed with NORMAL engine starting.
e. After starting engine, set the MASTER SWITCH to OFF and remove the jumper cable plug from
the receptacle.
f. Set the MASTER SWITCH to ON and check the alternator ammeter for an indication of output.
WARNING: DO NOT ATTEMPT ANY FLIGHT WITHOUT AN INDICATION OF
ALTERNATOR OUTPUT.

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2-23. CLEANING.
2-24. CLEANING ENGINE COMPARTMENT. Before cleaning the engine compartment, place a strip of
tape on the magneto vents to prevent any solvent from entering these units.
a. Place a pan under the engine to catch waste.
b. With the engine cowling removed, spray or brush the engine with solvent or a mixture of solvent
and degreaser, as desired. Brushing may be necessary where heavy grease and dirt deposits have
collected.
CAUTION: DO NOT SPRAY SOLVENT INTO THE ALTERNATOR, STARTER, AIR INTAKE,
AND ALTERNATE AIR INLETS.
c. Allow the solvent to remain on the engine from five to ten minutes; then rinse the engine clean with
additional solvent and allow to dry.
CAUTION: DO NOT OPERATE ENGINE UNTIL EXCESS SOLVENT HAS EVAPORATED OR
OTHERWISE BEEN REMOVED.
d. Remove the protective covers from the magnetos.
e. Lubricate controls, bearing surfaces, etc., per Lubrication Chart.
2-25. CLEANING LANDING GEAR.
a. Struts and Torque Links
Before cleaning the landing gear struts and torque links, place a plastic cover or similar material
over the wheel and brake assembly.
1. Place a pan under the gear to catch waste.
2. Spray (low pressure only) or brush the gear area with solvent or a mixture of solvent and
degreaser, as desired. Brushing may be necessary where heavy grease and dirt deposits have
collected.
3. Allow the solvent to remain on the gear for five to ten minutes. Rinse gear with additional
solvent and allow to dry.
4. Remove cover from wheel and remove the catch pan.
5. Lubricate gear per Lubrication Chart.
b. Wheels and Brakes
CAUTION: DO NOT USE HIGH PRESSURE SPRAY WASH EQUIPMENT. ITS USE CAN
INJECT SOAP SOLUTION AND WATER INTO THE WHEEL BEARINGS AND
OTHER INTERNAL CAVITIES RESULTING IN CORROSION AND REDUCED
SERVICE LIFE.
1. Hand wash wheels and brakes with a mild soap and water solution.
2. Rinse with low-pressure spray.
3. Lubricate gear per Lubrication Chart, if not already done, above.

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2-26. CLEANING EXTERIOR SURFACES. The airplane should be washed with a mild soap and water.
Harsh abrasives or detergents used on painted or plastic surfaces could make scratches or cause
corrosion of metal surfaces. Cover areas where cleaning solution could cause damage. Cover the mast of
the PA-28R-180 gear back-up extender. To wash the airplane, the following procedure may be used:
a. Flush away loose dirt with water.
b. Apply cleaning solution with a rag, sponge or soft bristle brush.
c. To remove stubborn oil and grease, use a cloth dampened with naptha.
d. Where exhaust stains exist, allow solution to remain on the surface longer.
e. Any good automotive wax may be used to preserve the painted surfaces. Soft cleaning cloths or a
chamois should be used to prevent scratches when cleaning or polishing. A heavier coating of wax
on the leading surfaces will reduce the abrasion problems in these areas.
2-27. CLEANING WINDSHIELD AND WINDOWS.
a. Remove dirt, mud, etc. from exterior surfaces with clean water.
b. Wash with mild soap and warm water or an aircraft plastic cleaner using a soft cloth or sponge and
a straight rubbing motion. Do not harshly rub surfaces.
c. Remove oil and grease with a cloth moistened with kerosene.
NOTE: Do not use gasoline, alcohol, benzene, carbon tetrachloride, thinner, acetone or window
cleaning sprays.
d. After cleaning plastic surfaces, apply a thin coat of hard polishing wax. Rub lightly with a soft
cloth. Do not use a circular motion.
e. A severe scratch or mar in plastic can be removed by using jeweler’s rouge to rub out the scratch.
Smooth both sides and apply wax.
f. To improve visibility through windshield and windows during flight through rain, a rain repellent
such as REPCON should be applied to the windshield and windows. The surfaces of the windshield
and windows treated become so smooth that water beads up and readily flows off the surface. Apply
this product in accordance with the manufacturer’s instructions. (Refer to Table II-XI Consumable
Materials, for specifications and Manufacturer’s address.)
2-28. CLEANING HEADLINER, SIDE PANELS AND SEATS.
a. Clean headliner, side panels and seats with a stiff bristle brush and vacuum where necessary.
b. Soiled upholstery, except leather, may be cleaned by using an approved air type cleaner or foam
upholstery cleaner. Carefully follow the manufacturer’s instructions. Avoid soaking or harsh
rubbing.
CAUTION: SOLVENT CLEANERS REQUIRE ADEQUATE VENTILATION.
c. Leather material should be cleaned with saddle soap or mild soap and water.
2-29. CLEANING CARPETS. Use a small whisk broom or vacuum to remove dirt. For soiled spots, use a
non-inflammable dry-cleaning fluid.

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2-30. SERVICING.
2-31. INTRODUCTION TO SERVICING. This includes replenishment of fuel, oil, and hydraulic fluids; the
maintenance of tire pressures; and the lubrication of various items.
2-32. HYDRAULIC SYSTEM (PA-28R)
2-33. SERVICING HYDRAULIC SYSTEM. The general condition of the hydraulic pump and landing gear
actuating cylinders should be checked. Ensure that there are no leaks and that the line fittings are tight.
The cylinder rods are to be free of all dirt and grit. To clean the rods use an oil soaked rag and carefully
wipe them. All the hydraulic lines should also be checked for freedom of leaks, kinks, and corrosion.
Check for tightness of the attachment fittings.
The gear back up extender actuator assembly is located beneath the rear seat and should be checked to
determine that it is operating properly. The diaphragm shaft may be operated by hand to make sure that it
is free to fluctuate and that the actuating arm and its components are operating freely. Check the pressure
housing assembly for absence of cracks, breaks, or fatigue. Check to ensure that the hydraulic valve and
fittings are free of leaks.
Repair and check procedures for the hydraulic pump, cylinders and various components may be found in
Section VI of this manual.
2-34. SERVICING HYDRAULIC PUMP / RESERVOIR. The fluid level of the reservoir of the combination
pump and reservoir should be checked every 50 hours by viewing the fluid through the filler plug hole in
the hydraulic pump. Access to the pump is through the panel at the right rear side of the baggage
compartment.
To check fluid level, remove the plug located on the forward side of the pump and ascertain that fluid is
visible up to the bottom of the filler plug hole. Should fluid be below the hole, add fluid, MIL-PRF-
5606, through the filler hole until full. Reinstall the filler plug and tighten.
NOTE: A small vent hole is located under the vent screw head. Retain 1/64 inch clearance between the
screw head and the small vent hole.
2-35. LANDING GEAR SYSTEM.
2-36. SERVICING LANDING GEAR. The landing gear consists of tires, brakes, oleo strut assemblies and on
some models, wheel fairings. The gear should be inspected for proper extension, unscored piston tubes,
soundness of hydraulic fluid seals, the security and firm mechanical condition of all connection points
and the absence of cracks in the fiberglass fairings. Check the brake linings for excessive wear, the brake
discs for scoring and replace as necessary. The PA-28R should be checked for proper adjustment of
down locks, the mechanical soundness and firm action of drag and side brace links. Minor servicing is
described in the following paragraphs. Detailed service and overhaul instructions are given in Sections
VII or VIIA.

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2-37. OLEO STRUTS. (PA-28-140; PA-28-150,-160,-180 and PA-28-235.)

2-38. SERVICING OLEO STRUTS. Air-oil struts are incorporated in each landing gear oleo to absorb the
shock resulting from the impact of the wheels on the runway during landing. To obtain proper oleo
action, the nose gear oleo strut must have approximately 3.25 ± .25 inches of piston tube exposed, while
the main gear struts require approximately 4.5 ± .50 inches of tube exposure.
CAUTION: DO NOT EXCEED THE FOREGOING TUBE EXPOSURES.
These measurements are taken with the airplane setting on a level surface under normal static load
(empty weight of airplane plus full fuel and oil). If the strut has less tube exposed than that prescribed,
determine whether it needs air or oil by raising the airplane on jacks. With the strut extended, remove the
cap from the air valve at the top of the housing and depress the valve core to allow air to escape from the
strut piston until it is fully compressed. Allow the foam from the air-oil mixture to settle and then
determine if oil is visible up to the bottom of the filler plug hole. If oil is visible at the bottom of the
hole, then all that is required is the valve be checked for unsatisfactory conditions and air added as
described in paragraph 2-41. Should fluid be at any level below the bottom of the filler plug hole, the
oleo should be checked for leaks, etc. and oil added as described in paragraph 2-39 for the nose gear or
paragraph 2-40 for the main gear. For repair procedures of the landing gear and/or oleo struts, refer to
Section VII or VIIA.
WARNING: DO NOT RELEASE AIR BY REMOVING THE STRUT VALVE CORE OR FILLER
PLUG. DEPRESS THE VALVE CORE PIN UNTIL STRUT CHAMBER PRESSURE
HAS DIMINISHED.
CAUTION: DIRT AND FOREIGN PARTICLES FORM AROUND THE FILLER PLUGS OF THE
LANDING GEAR STRUTS, THEREFORE, BEFORE ATTEMPTING TO REMOVE
THESE PLUGS, THE TOPS OF THE STRUTS SHOULD BE CLEANED WITH
COMPRESSED AIR AND/OR WITH A DRY SOLVENT .
2-39. FILLING NOSE GEAR OLEO STRUT. Regardless of the amount of oil required, fill the nose gear
oleo strut with hydraulic fluid (MIL-PRF-5606) as follows:
a. Raise the airplane on jacks until the nose wheel is completely clear of the ground. (Refer to
Paragraph 2-13.)
b. Place a pan under the gear to catch spillage.
c. If not previously accomplished, remove the engine cowl and relieve air from the strut housing
chamber by removing the cap from the air valve and depressing the valve core.

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d. There are two methods by which the strut chamber may be filled and these are as follows:
Method 1:
1. Remove the valve core from the filler plug at the top of the strut housing. Allow the plug to
remain installed.
2. Attach one end of a clear plastic hose to the valve stem of the filler plug and submerge the
other end in a container of hydraulic fluid. Ascertain that the end of the hose on the valve stem
is tight and the fluid container is approximately equal in height to the top of the strut housing.
3. Fully compress and extend the strut thus drawing fluid from the fluid container and expelling
air from the strut chamber. By watching the fluid pass through the plastic hose, it can be
determined when the strut is full and no air is present in the chamber.
4. When air bubbles cease to flow through the hose, compress the strut fully and remove the hose
from the valve stem.
5. With strut compressed, remove the filler plug to determine that the fluid level is visible up to
the bottom of the filler plug hole.
6. Reinstall the core in the filler plug and apply thread lubricated (See Thread Lubricant, Oleo
Strut, Air Valve - Kopr-Kote.) to the threads of the filler plug and install the plug in the top of
the strut housing. Torque the plug to 45 foot pounds.

Method 2:
1. Remove the filler plug from the top of the strut housing.
2. Raise the strut piston until it is fully compressed.
3. Pour fluid from a clean container through the filler opening until it reaches the bottom of the
filler plug hole.
4. Install the filler plug finger tight, and extend and compress the strut two or three times to
remove any air that may be trapped in the housing.
5. Remove the filler plug, raise the strut to full compression and fill with fluid if needed.
6. Apply thread lubricant (See Thread Lubricant, Oleo Strut, Air Valve - Kopr-Kote.) to the
threads of the filler plug. Reinstall the filler plug and torque to 45 foot pounds.
e. With the airplane raised, compress and extend the gear strut several times to ascertain that the strut
actuates freely. The weight of the gear fork and wheel should extend the strut.
f. Clean off overflow of fluid, and inflate the strut as described in Paragraph 2-41.
g. Check that fluid is not leaking from around the strut piston at the bottom of the housing.

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Figure 2-36. Servicing Points

PA-28-140

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Figure 2-37. Servicing Points

PA-28-150, -160, -180

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Figure 2-38. Servicing Points

PA-28-235

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Figure 2-39. Servicing Points

PA-28R

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2-40. FILLING MAIN GEAR OLEO STRUT. A main

gear oleo strut that is partly full or one that has
been completely emptied may be filled with
MIL-PRF-5606 fluid as follows:
a. Raise the airplane on jacks until the landing
gear torque link assembly has almost
reached its full travel. (Refer to Paragraph
2-13.)
b. Place a pan under the gear to catch spillage.
c. If not previously accomplished, remove the
cap on top of the wing to gain access to the
top of the strut housing, and relieve air from
the strut housing chamber by removing the
cap from the air valve and depressing the
valve core.
d. Remove any one of the three torque link
bolts, and again raise the airplane until a
minimum of ten inches (do not exceed
twelve inches of tube exposure) of strut tube
is exposed with the wheel remaining on the
ground. With this amount of tube exposed,
fluid will flow from the middle chamber to
the bottom chamber of the strut housing,
ensuring that the bottom chamber is filled
with fluid.
NOTE: With the torque links disconnected,
the piston tube is free to slide from
the strut housing.
e. Fill the main gear housing by one of two
methods which are as follows:
Method I:
1. Remove the valve core from the filler
plug at the top of the strut housing.
Allow the plug to remain installed.
2. Attach one end of a clear plastic hose
to the valve stem of the filler plug and
submerge the other end in a container
of hydraulic fluid.

Figure 2-40. Main Gear Oleo Struts

(Cut-Away View) PA-28-140;
PA-150, -160, -180; PA-28-235

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3. Fully compress and extend (10 + 2-0 inches of strut tube exposed) the strut thus drawing fluid
from the strut chambers. By watching the fluid pass through the plastic hose, it can be
determined when the strut is full and no air is present in the chambers. The strut must be
extended to full ten inches to allow fluid to enter the bottom chamber of strut housing.
4. When air bubbles cease to flow through the hose, compress the strut fully and remove the hose
from the valve stem.
5. With the strut fully compressed, remove the filler plug to determine that the fluid level is
visible up to the bottom of the filler plug hole.
6. Reinstall the core in the filler plug and apply thread lubricant (See Thread Lubricant, Oleo
Strut, Air Valve - Kopr-Kote.) to the threads of the filler plug and install the plug in the top of
the strut housing. Torque the plug to 45 foot pounds.
Method 2:
1. Remove the filler plug from the top of the strut housing.
2. Raise the strut to full compression.
3. Pour fluid from a clean container through the filler opening until it is visible at the top of the
strut chamber. If the housing has been completely emptied or nearly so, allow sufficient time
for the fluid to drain through the orifice from the upper chamber into the middle chamber.
4. Lower the gear until the wheel touches the ground (10 + 2-0 inches of strut exposure) and then
fully compress and extend the strut three or four times to remove any air that may be trapped
and to allow fluid to enter the bottom chamber of the housing.
5. Raise the strut to full compression and if needed, fill with fluid to the bottom of the filler plug.
6. Apply thread lubricant (See Thread Lubricant, Oleo Strut, Air Valve - Kopr-Kote.) to the
threads of the filler plug. Reinstall the filler plug and torque to 45 foot pounds.
f. Replace the torque link bolt. Tighten bolt only tight enough to allow no side play in the connection.
g. With the airplane raised, retract and extend the gear strut several times to ascertain that the strut
actuates freely. The weight of the gear fork and wheel should extend the strut.
h. Clean off overflow of fluid and inflate the strut as described in Paragraph 2-41.
i. Check that fluid is not leaking around the strut piston at the bottom of the housing.
2-41. INFLATING OLEO STRUTS. After making certain that the oleo strut has sufficient fluid, attach a strut
pump to the air valve and inflate the oleo strut. The strut should be inflated until the correct inches of
piston is exposed with normal static load (empty weight of airplane plus full fuel and oil) on the gears.
(Refer to Paragraph 2-38.) Rock the airplane several times to ascertain that the gear settles back to the
correct strut position. (If a strut pump is not available, the airplane may be raised and line pressure from
a high pressure air system used. Lower the airplane and while rocking it, let air from the valve to bring
the strut down to the proper extension.) Before capping the valve, check for valve core leakage.

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2-42. OLEO STRUTS. (PA-28R)

2-43. SERVICING OLEO STRUTS. The air-oil type oleo strut should be maintained at proper strut tube
exposures for best oleo action. The nose gear strut must have approximately 2.75 inches of piston tube
exposed, while the main gear strut requires approximately 2.0 inches of tube exposure. These
measurements are taken with the airplane sitting on level surface under normal static load. (Empty
weight of airplane plus full fuel and oil.) If the strut has less tube exposure than prescribed, determine
whether it needs air or oil by rocking the airplane. If the oleo strut oscillated with short strokes
(approximately one inch) and the airplane settles to its normal position within one or two cycles after the
rocking force is removed, the oleo strut requires inflating. Check the valve core and filler plug for air
leaks, correct if required, and add air as described in Paragraph 2-45. If the oleo strut oscillates with long
strokes (approximately three inches) and the airplane continues to oscillate after the rocking force is
removed, the oleo struts require fluid. Check the oleo for indications of oil leaks, correct if required and
add fluid as described in Paragraph 2-44. For repair procedures of the landing gear and/or oleo struts,
refer to Section VIIA.
WARNING: DO NOT RELEASE AIR BY REMOVING THE STRUT VALVE CORE OR FILLER
PLUG. DEPRESS THE VALVE CORE PIN UNTIL STRUT CHAMBER PRESSURE
HAS DIMINISHED.
CAUTION: DIRT AND FOREIGN PARTICLES FORM AROUND THE FILLER PLUGS OF THE
LANDING GEAR STRUTS, THEREFORE, BEFORE ATTEMPTING TO REMOVE
THESE PLUGS, THE TOPS OF THE STRUTS SHOULD BE CLEANED WITH
COMPRESSED AIR AND/OR WITH A DRY SOLVENT.
2-44. FILLING OLEO STRUTS. To fill the nose or main gear oleo strut with fluid (MIL-PRF-5606), whether
it be the addition of a small or large amount, proceed as follows:
a. Raise the airplane on jacks. (Refer to Paragraph 2-13.)
b. Place a pan under the gear to catch spillage.
c. At the filler plug, relieve air pressure from the strut housing chamber by removing the cap from the
air valve and depressing the valve core.
d. There are two methods by which the strut chamber may be filled and these are as follows:
Method 1:
1. Remove the valve core from the filler plug at the top of the nose gear strut housing or at the top
inboard side of the main gear housing. Allow the filler plug to remain installed.
2. Attach one end of a clean plastic hose to the valve stem of the filler plug and submerge the
other end in a container of hydraulic fluid.
NOTE: An air-tight connection is necessary between the plastic tube and the valve stem.
Without such a connection, a small amount of air will be sucked into the oleo strut
during each sequence, resulting in an inordinate amount of air bubbles and a
prolonged filling operation.

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3. Fully compress and extend the strut thus drawing fluid from the fluid container and expelling
air from the strut chamber. By watching the fluid pass through the plastic hose, it can be
determined when the strut is full and no air is present in the chamber.
4. When air bubbles cease to flow through the hose, compress the strut fully and remove the hose
from the valve stem.
5. With the strut compressed, remove the filler plug to determine that the fluid level is visible up
to the bottom of the filler plug hole.
6. Reinstall the core in the filler plug and apply thread lubricant (See Thread Lubricant, Oleo
Strut, Air Valve - Kopr-Kote.) to the threads of the filler plug and install the plug in the top of
the strut housing. Torque the plug to 45 foot pounds.
Method 2:
1. Remove the filler plug from the top of the nose gear strut housing or at the top inboard side of
the main gear housing.
2. Raise the strut piston tube until it is fully compressed.
3. Pour fluid from a clean container through the filler opening until it reaches the bottom of the
filler plug hole. (Air pressure type oil container may be helpful.)
4. Install the filler plug finger-tight and extend and compress the strut two or three times to
remove air from the housing.
5. Remove the filler plug, raise the strut to full compression and fill with fluid if needed.
6. Apply thread lubricant (See Thread Lubricant, Oleo Strut, Air Valve - Kopr-Kote.) to the
threads of the filler plug. Reinstall the filler plug and torque-to 45 foot pounds.
e. With the airplane raised, compress and extend the gear strut several times to ascertain that the strut
moves freely. The weight of the gear fork and wheel should extend the strut.
f. Clean off overflow of fluid and inflate the strut as described in Paragraph 2-45.
g. Check that fluid is not leaking around the strut piston at the bottom of the housing.
2-45. INFLATING OLEO STRUTS. After making certain that an oleo strut has sufficient fluid, attach a strut
pump to the air valve and inflate the oleo strut. The strut should be inflated until the correct inches of
piston are exposed with normal static load on the gears (empty weight of the airplane plus full fuel and
oil). (Refer to Paragraph 2-43.) Rock the airplane several times to ascertain that the gear settles back to
the correct strut position. If a strut pump is not available, the airplane may be raised and line pressure
from a high pressure air system used. Lower the airplane and while rocking it, let air from the valve to
bring the strut down to the proper extension. (Before capping the valve, check for tightness of the valve
core, that is, no leakage.)

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2-46. BRAKE SYSTEM.

2-47. SERVICING BRAKE SYSTEM. The brake system incorporates a hydraulic fluid reservoir through
which the brake system is periodically serviced. Fluid is drawn from the reservoir by the brake cylinders
to maintain the volume of fluid required for maximum braking efficiency. Spongy brake pedal action is
often an indication that the brake fluid reservoir is running low on fluid. Instructions for filling the
reservoir are given in Paragraph 2-48. When necessary to repair any of the brake system components, or
to bleed the system, refer to instructions in Section VII or VIIA.
2-48. FILLING BRAKE CYLINDER RESERVOIR. The brake cylinder reservoir should be filled to the level
marked on reservoir, with the fluid specified in Table II-I. The reservoir, located on the left side of the
firewall in the engine compartment, should be checked at every
50 hour inspection and replenish as necessary. No adjustment of the brakes is necessary, though they
should be checked periodically per instructions given in Section VII or VIIA.
2-49. DRAINING BRAKE SYSTEM. To drain the brake system, connect a hose to the bleeder fitting on the
bottom of the cylinder and place the other end of the line in a suitable container. Open the bleeder and
slowly pump the hand brake lever and the desired brake pedal until fluid ceases to flow. To clean the
brake system, flush with denatured alcohol.

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2-50. TIRES.
2-51. SERVICING TIRES. The tires should be maintained at the pressure specified in Table II-I. When
checking tire pressure, examine the tires for wear, cuts, bruises and slippage on the wheel. The tire, tube,
and wheel should be properly balanced when installed with the - index mark on the tire aligned with the
index mark on the tube.
2-51a. TIRE BALANCE
Proper balancing is critical for the life of aircraft tires. If a new tire is balanced upon installation it will
usually remain balanced for the life of the tire without having any shimmy or flat spots.
a. Tire Balancer
An inexpensive balancing fixture that will balance almost any light aircraft tire can be made from
the materials shown in Figure 2-41.
1. Chamfer top edges of -3 sides, leaving 1/16 inch flat on top of the inboard edge. Rivet -2 tee’s
to -3 sides using AN 470-AD5 rivets, with 2 inch spacing, and using AN 426-AD5 rivets ( 2
inch center to center ) to secure -2 tee’s to -1 base. If tee extrusion is unavailable, heavy angle
extrusion could be used. -3 sides must be vertical.
2. The -4 axle must slide through the -8 pipe, the -5 nuts are made by reaming the existing
threads in the AN 365-624 nuts with an R drill, then tapping them with a 1/8-27 pipe tap.

Figure 2-41. Tire Balancer

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3. The -6 spacers were made from 1/2 inch aluminum tubing, the two lengths of spacers are
suitable for balancing most any aircraft wheel.
4. The -7 bushings may be made from one inch phenolic or aluminum using a 1-1/2 inch hole
saw to cut out the smaller bushing and a 1-3/4 hole saw to cut out the larger. By inserting a 1/4
inch long threaded bolt through the pilot hole and securing with a washer and nut, a drill press
and file may be used to make the off-set on the bushing. The turned-down part should just slide
inside the bearing race and then ream the pilot hole to slide over the -8 pipe threads.
5. The -8 pipe was made from a piece of 1/8 inch black pipe and threaded with a 1/8-27 pipe die,
this will be thread 3 inches in from each end of the pipe.
b. Procedure
Balance tires as follows:
1. Mount the tire and tube (if one is used) on the wheels, but do not install the securing bolts.
Install the wheel bearings in the wheels; then, using the -7 bushings, -6 spacers, and -5 nuts,
install the wheel/tire assembly on the -8 pipe. Secure the -5 nuts finger tight so that the wheel
halves touch each other. Be sure the bolt holes are aligned. Insert the -4 axle through the -8
pipe and place the wheel in the center of the balancer. Make sure the axle is only on the
chamfered edges of the balancer and that it is at 90° to the sides of the balancer.
2. Release the tire. If it is out of balance it will rotate, coming to rest with the heaviest point on
the bottom. Tape an ounce patch across the top center of the tire. Rotate the tire 45° and release
it again. If the tire returns to the same position, add a 1 ounce patch and again rotate the tire
and release it. Continue this procedure until the tire is balanced.
3. When balance is attained, put a chalk mark on the sidewall directly below the patch. Use one
mark for each half ounce of weight needed. Mark the valve stem location on the tire and the
opposite wheel half to assure reassembly in the same position. Remove the wheel from the
balance stand, break it down and clean the inside of the tire with toluol. Apply a coat of patch
cement to both the patch and the inside center of the tire in line with the chalk marks. When
the cement has dried, install the patches making certain they are on the centerline of the tire
and aligned with the chalk marks on the sidewall. Burnish the patches to remove trapped air,
etc.
4. When reassembling the wheel, powder the inside of the tire. Mount the tire on the valve side of
the wheel in the same position it was in when it was balanced. Install the other wheel half,
aligning the chalk marks. Install the bolts and tighten to required torque, then inflate the tire to
the pressure specified in Table II-I, and recheck the balance. The wheel should not be more
than one ounce out of balance.

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2-52. POWER PLANT.

2-53. SERVICING POWER PLANT. Regularly check the engine compartment for oil and fuel leaks, chaffing
of lines, loose wires and tightness of all parts. For cleaning of the engine compartment, refer to
paragraph 2-24. Maintenance instructions for the power plant may be found in Section VIII or VIIIA of
this manual and in the appropriate manufacturers’ manuals.
2-54. INDUCTION AIR FILTER.
2-55. REMOVAL OF AIR FILTER.
a. PA-28-140; PA-28-150. -160, -180, Serial Nos. 28-1 to 28-1760 incl. The induction air filter is
located below the spinner assembly within the nose cowling. If the airplane is equipped for night
flying, a landing light will be installed within the center of the filter assembly. The filter may be
removed in accordance with the following instructions:
1. Within the aft side of the nose cowl, loosen and remove the thumb screw on the back of the
assembly.
2. Remove the retainer assembly. If a landing light is installed, it will be necessary to remove the
wires aft the connections on the light before removal.
3. Remove the filter and clean or replace in accordance with Paragraph 2-56.
b. On PA-28-180, Serial Nos. 28-1761 and up, the filter is located on the right side and midway in the
engine compartment and may be removed by the following procedure:
1. Remove the two nuts and washers on the cover assembly and pull off the cover.
2. The filter is now free to be removed and cleaned per Paragraph 2-56.
c. On PA-28-235, Serial Nos. 28-10003 to 28-10560 incl., the air filter is located on the right side and
midway in the engine compartment. For removal, refer to the following steps:
1. Loosen and remove the wing nut on the filter cover and remove cover.
2. Remove the filter and clean or replace in accordance with Paragraph 2-56.
d. On PA-28-235, Serial Nos. 28- 10561 and up, the air filter is located on the right side of the engine
and in front of the fire wall. Remove the filter per the following instructions:
1. Remove the two wing nuts and remove the cover.
2. The filter is now free to be removed and cleaned per Paragraph 2-56.
e. On PA-28R, the filter is located on the left side and just in front of the fire wall. Remove by the
following procedure:
1. Loosen the three studs and carefully move the cover assembly aside. Be sure not to damage or
bend the alternate air cable.
2. The filter is now free for removal. Clean or replace the filter as given in Paragraph 2-56.

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2-56. SERVICE INSTRUCTION. (CLEANING AND INSPECTION.)

a. The filter should be cleaned daily when operating in dusty conditions and if any holes or tears are
noticed, the filter should be replaced immediately. For type of replacement filter, refer to PA-28
Parts Catalog.
CAUTION: NEVER WASH THE FILTER ELEMENT IN ANY LIQUID OR SOAK IN OIL.
NEVER ATTEMPT TO BLOW OFF DIRT WITH COMPRESSED AIR.
b. Remove the filter element and shake off loose dirt by tapping on a hard surface, being careful not to
damage or crease the sealing ends.
c. The filter housing can be cleaned by wiping with a clean cloth soaked in suitable quick drying type
solvent. When the housing is dry, reinstall in accordance with Paragraph 2-56.
2-57. INSTALLATION OF AIR FILTER. After cleaning and inspection, install the filter element and cover in
reverse order of removal instructions.
2-58. PROPELLER.
2-59. SERVICING PROPELLER. The spinner, back plate and propeller surfaces should be cleaned and
inspected frequently for freedom from nicks, scratches, corrosion and cracks. Minor nicks and scratches
may be removed as found in Section VIII or VIIIA. The face of each blade should be painted when
necessary with a flat paint to retard glare. To prevent corrosion, wipe surfaces with a light oil or wax.
In addition, constant speed propellers should be inspected for absence of grease or oil leakage and
freedom of rotation on the hub pilot tube. To check freedom of rotation, rock the blade back and forth
through the slight freedom allowed by the pitch change mechanism. Lubricate the propeller at 100-hour
intervals in accordance with the Lubrication Chart.
Additional service information for the propeller may be found in Section VIII or VIIIA.
2-60. FUEL SYSTEM.
2-61. SERVICING FUEL SYSTEM.
a. At intervals of 50 hours or 90 days, whichever comes first, clean the fuel screens and/ or filters as
follows:
1. PA-28-140; PA-28-150, -160, -180. The fuel strainer screen, located in the fuel bowl, mounted
on the lower left side of the fire wall; the screen in the electric fuel pump, located at the lower
left side of the engine compartment; and the screen in the inlet side of the carburetor.
2. PA-28-235. The screens and bowl of the fuel filter unit of the fuel selector and the screen of the
electric fuel pump(s), located in the area under the rear seat aft of the main spar; and the screen
located in the inlet side of the carburetor.
3. PA-28R. The fuel strainer screen, located in the fuel bowl mounted on the lower left side of the
fire wall; and the screen in the inlet side of the injector.
b. Remove and clean the screens in accordance with the instructions outlined in Section IX. Additional
service information is given in Section IX. Inspection intervals of the various fuel system
components is given in Section III.

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2-62. FILLING FUEL TANKS. (PA-28-140; PA-28-150, -160, -180 and PA-28R.)
Observe all required precautions for handling gasoline. Fill the fuel tanks with the fuel as specified in
Table II-I. Each fuel tank holds a maximum of 25 U.S. gallons. To obtain the standard fuel quantity of 36
U.S. gallons total, or 18 gallons per tank, the tanks are filled only to the bottom of the filler neck tube or
visual indicator, each of which extend into the fuel tank about 3.50 inches. To obtain the standard plus
reserve quantity, the tanks are filled to the top of the filler neck.
2-63. FILLING FUEL TANKS. (PA-28-235.)
The fuel tanks of each wing are filled through filler necks located on the forward slope of the wings and
at the wing tip. Each wing tank holds 25 U.S. gallons while each tip tank holds 17 U.S. gallons. Observe
all required safety precautions for handling gasoline. Fill the tanks with fuel as specified on the placard
adjacent to the filler neck or as indicated in Table II-I.
2-64. DRAINING MOISTURE FROM FUEL SYSTEM. (PA-28-140, -150, -160, -180 and PA-28R.)
CAUTION: WHEN DRAINING ANY AMOUNT OF FUEL, CARE SHOULD BE TAKEN TO
ENSURE THAT NO FIRE HAZARD EXISTS BEFORE STARTING ENGINE.
The fuel tanks and fuel strainer should be drained daily prior to first flight and after refueling to avoid
the accumulation of water or sediment. Each fuel tank is equipped with an individual quick drain located
at the lower inboard rear corner of the tank. The fuel strainer with a quick drain valve (refer to Figure
2-42) is located on the lower left side of the fire wall. Drain fuel tanks and strainer per the following:
a. Drain each tank through its individual quick drain located at the lower inboard rear comer of the
tank, making sure that enough fuel has been drained to ensure that all water and sediment is
removed.
b. Place a container under the fuel strainer drain. Drain the fuel strainer by opening the quick drain on
the strainer.
c. Examine the contents of the container placed under the fuel strainer drain for water and sediment
and dispose of the contents.
2-65. DRAINING MOISTURE FROM FUEL SYSTEM. (PA-28-235.)
CAUTION: WHEN DRAINING ANY AMOUNT OF FUEL, CARE SHOULD BE TAKEN TO
ENSURE THAT NO FIRE HAZARD EXISTS BEFORE STARTING ENGINE.
The fuel system should be drained daily prior to first flight and after refueling to avoid the accumulation
of water or sediment. Each fuel tank is equipped with an individual quick drain located at the lower
inboard rear comer of the tank. The fuel strainer and a system quick drain valve (refer to Figure 2-43) are
located in the fuselage at the lowest point of the fuel system. It is important that the fuel system be
drained in the following manner:

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Figure 2-42. Fuel Strainer Figure 2-43. Fuel Selector and Filter
PA-28-140; PA-150, -160, -180 PA-28-235
PA-28R

a. Drain each tank through its individual quick drain located at the lower inboard rear corner of the
tank, making sure that enough fuel has been drained to ensure that all water and sediment is
removed.
b. Place a container under the fuel sump drain outlet, which is located under the fuselage.
c. Drain the fuel strainer by pressing down on the lever located on the right-hand side of the cabin
below the forward edge of the rear seat. The fuel selector must be positioned in the following
sequence: off position, left tip, left main, right main, and right tip while draining the strainer to
ensure that the fuel lines between each tank outlet and fuel strainer are drained as well as the
strainer. When the fuel tanks are full, it will take approximately 11 seconds to drain all the fuel in
one of the lines between a tip tank and the fuel strainer and approximately six seconds to drain all
the fuel in one of the lines from a main tank to the fuel strainer. When the fuel tanks are less than
full, it will take a few seconds longer.
NOTE: After using the underseat quick drain, it should be checked from outside to make sure it has
closed completely and is not leaking.
d. Examine the contents of the container placed under the fuel sump drain outlet for water and
sediment and dispose of the contents.

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2-66. DRAINING FUEL SYSTEM. Fuel may be drained from the system by opening the valve at the inboard
end of each fuel tank. Push up on the arms of the drain valve and turn counterclockwise to hold the drain
in the open position. The flush type drain valve requires the drain cup pin to hold valve open. The
remaining fuel in the system may be drained through the filter bowl. Any individual tank may be drained
by closing the selector valve and then draining as desired.
2-67. ANTI-ICING FUEL ADDITIVE. (Refer to the latest revision of Lycoming Service Letter No. L172.)
CAUTION: ASSURE THAT THE ADDITIVE IS DIRECTED INTO FLOWING FUEL STREAM.
THE ADDITIVE FLOW SHOULD START AFTER AND STOP BEFORE THE FUEL
FLOW. DO NOT PERMIT THE CONCENTRATED ADDITIVE TO COME IN
CONTACT WITH THE AIRCRAFT PAINTED SURFACES OR THE INTERIOR
SURFACES OF THE FUEL TANKS.
CAUTION: SOME FUELS HAVE ANTI-ICING ADDITIVES PREBLENDED IN THE FUEL AT THE
REFINERY, SO NO FURTHER BLENDING SHOULD BE PERFORMED.
CAUTION: THIS ADDITIVE SHOULD NOT BE USED AS A REPLACEMENT FOR PREFLIGHT
DRAINING OF THE FUEL SYSTEM DRAINS.
The operation of the aircraft is approved with an anti-icing additive in the fuel. When an anti-icing
additive is used it must meet the specification MIL-DTL-27686, must be uniformly blended with the fuel
while refueling, must not exceed 0.15% by volume of the refueled quantity, and, to ensure its
effectiveness, should be blended at not less than 0.10% by volume. One and one half liquid ozs. per ten
gallon of fuel would fall within this range. A blender supplied by the additive manufacturer should be
used. Except for the information contained in this section, the manufacturer’s mixing or blending
instructions should be carefully followed.
2-68. ELECTRICAL SYSTEM.
2-69. SERVICING ELECTRICAL SYSTEM. Servicing the electrical system involves adding distilled water
to the battery to maintain correct electrolyte level, and checking cable connections and for any spilled
electrolyte that would lead to corrosion. The security of all electrical connections should be checked as
well as the operation of all lights, general condition of the generator or Alternator and starter. All
electrical wires should be inspected for chafing and bare wires. For detailed information on this system,
refer to Section XI of this manual.
2-70. LUBRICATION.
2-71. OIL SYSTEM. (ENGINE.)
2-72. SERVICING OIL SYSTEM.
CAUTION: DO NOT INTRODUCE ANY TRADE ADDITIVE TO THE BASIC LUBRICANT
UNLESS RECOMMENDED BY THE ENGINE MANUFACTURER.
The engine oil level should be checked before each flight and changed after each 50 hours of engine
operation. During oil change, the oil screen(s) should be removed and cleaned, and when installed, the
oil filter cartridge replaced. Intervals between oil changes can be increased as much as 100% on engines
equipped with full flow (cartridge type) oil filters provided the element is replaced each 50 hours of
operation.
Should fuel other than the specified octane rating for the power plant be used, refer to the latest revision
of Lycoming Service Letter No. L185 for additional information and recommended service procedures.

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The engine manufacturer does not recommend oils by brand names. Use a quality brand Aviation Grade
Oil of the proper season viscosity. For information on the use of detergent oil, refer to paragraph 2-77
and/or the latest revision of Lycoming Service Instruction No. 1014.
2-73. FILLING OIL SUMP.
The oil sump should normally be filled with oil to the mark on the engine dipstick. The quantity of oil
required for the engines may be found in Table II-I. The specified grade of oil may be found in Table II-
IX, the Lubrication Chart, or on the right cowl panel or each engine oil filler access door. To service the
engine with oil, open the right cowl panel or quick release access door on top of the cowl and remove the
oil filler cap with dipstick.
2-74. DRAINING OIL SUMP.
CAUTION: ON PA-28R-200 AIRCRAFT, IF AN OIL QUICK DRAIN VALVE IS INSTALLED,
ASCERTAIN THAT IT IS PIPER P/N 492-172. (SEE FIGURE 8A-5.) INSTALLATION
OF AN INCORRECT DRAIN COULD DAMAGE THE SUMP OR THE DRAIN ITSELF.
THIS MAY RESULT IN LOSS OF ENGINE OIL AND A POSSIBLE ENGINE SEIZURE.
To drain the oil sump, provide a suitable container with a minimum capacity of that required to fill the
sump. Remove the engine cowl and open the oil drain valve located on the underside of the engine by
pushing the arms of the drain up and turning counterclockwise. This will hold the drain in the open
position. It is recommended the engine be warmed to operating temperature to ensure complete draining
of the old oil.
2-75. OIL SCREENS. (SUCTION.)
The oil suction screen, located either on the bottom aft end of the engine sump, installed horizontally, or
forward of the carburetor installed vertically. To remove both types, cut the safety wire and remove the
hex head plug. The screen should be cleaned at each oil change to remove any accumulation of sludge
and to examine for metal filings or chips. If metal particles are found in the screen, the engine should be
examined for internal damage. After cleaning and inspection, place the screen inside the recess in the
hex head plug, to eliminate possible damage to the screen. Insert the screen into the housing and when
certain that the screen is properly seated, tighten and safety the plug with MS-20995-C41 safety wire.
2-76. OIL SCREEN. (PRESSURE.)
The oil pressure screen, located in a housing on the accessory case of the engine, between the magnetos,
should be cleaned at each oil change to remove any accumulation of sludge and to examine for metal
filings or chips. If metal particles are found in the screen, the engine should be examined for internal
damage. When reinstalling the screen, it is recommended that a new gasket be used. Ascertain that the
screen fits flush with the base surface of the screen housing. Position housing on mounting pad and
install attachment bolts. Torque bolts within 50 to 70 inch-pounds.

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2-77. OIL FILTER. (FULL FLOW.)

a. The oil filter element should be replaced after each 50 hours of engine operation; this is
accomplished by removing the lockwire from the bolt-head at the end of the filter housing,
loosening the bolt, and removing the filter assembly from the adapter.
b. Before discarding the filter element, remove the outer perforated paper cover, and using a sharp
knife, cut through the folds of the element at both ends, close to the metal caps. Then, carefully
unfold the pleated element and examine the material trapped in the filter for evidence of internal
engine damage such as chips or particles from bearings. In new or newly overhauled engines, some
small particle of metallic shavings might be found; these are generally of no consequence and
should not be confused with particles produced by impacting, abrasion or pressure. Evidence of
internal engine damage found in the oil filter justifies further examination to determine the cause.
c. After the element has been replaced, tighten the attaching bolt within 15 to 18 foot-pounds of
torque. Lockwire the bolt through the loops on the side of the housing to the drilled head of the
thermostatic valve. Be sure the lockwire is replaced at both the attaching bolt head and the
thermostatic oil cooler bypass valve.
2-78. RECOMMENDATIONS FOR CHANGING OIL. (Refer to the latest revision of Lycoming Service
Instruction No. 1014 and Lycoming Service Letter No. L185.)
a. In engines that have been operating on straight mineral oil for several hundred hours, a change to
additive oil should be made with a degree of caution, since the cleaning action of some additive oils
will tend to loosen sludge deposits and cause plugged oil passages. When an engine has been
operating on straight mineral oil and is known to be in excessively dirty condition, the switch to
additive or compounded oil should be deferred until after the engine is overhauled.
b. When changing from straight mineral oil to compounded oil, the following precautionary steps
should be taken:
1. Do not add additive oil to straight mineral oil. Drain the straight mineral oil from the engine
and fill with additive oil.
2. Do not operate the engine longer than five hours before the first oil change.
3. Check all oil screens for evidence of sludge or plugging and change oil every ten hours if
sludge conditions are evident. Resume normal oil drain periods after sludge conditions
improve.
2-79. LUBRICATION INSTRUCTIONS.
Proper lubrication procedures are valuable for prolonging the service life of the airplane and as a means
of reducing the frequency of extensive and expensive repairs. The periodic application of recommended
lubricants to relevant bearing surfaces combined with cleanliness, as detailed in the following
paragraphs, ensures maximum efficiency and utmost service of all moving parts. Lubrication instruction
regarding locations, time intervals, and type of lubricants used are found in proper lubrication charts.
To ensure the best possible results from lubricant application, observe the following precautions:
NOTE: If the airplane is inactive for long periods of time, it should be lubricated in accordance with the
Lubrication Charts every 90 days.
a. Use only recommended lubricants. Where general purpose lubricating oil is specified, but
unavailable, clean reciprocating engine oil is a satisfactory substitute.
b. Check components for evidence of excessive wear and replace as necessary.

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c. Remove all excess lubricants from components to prevent collecting dirt and sand in abrasive
quantities capable of causing excessive wear or damage to bearing surfaces.
2-80. APPLICATION OF GREASE.
When lubricating bearings and bearing surfaces with a grease gun, ensure gun is filled with new, clean
grease specified for the particular application before applying lubricant to grease fittings.
a. If a reservoir is not provided around a bearing, apply lubricant sparingly and wipe off excess.
b. Remove wheel bearings from wheel hub and clean thoroughly with suitable solvent. When
repacking with grease, ensure lubricant enters space between rollers in retainer ring. Do not pack
grease into wheel hub.
c. Use extra care when greasing constant speed propeller hub to avoid blowing clamp gaskets.
Remove one grease fitting while applying grease to other fitting until fresh grease appears at hole of
removed fitting. Uneven greasing effects propeller balance.
2-81. APPLICATION OF OIL.
CAUTION: AFTER THOROUGHLY WASHING AIRPLANE, ENSURE LANDING GEAR, FLIGHT
CONTROLS, FLAP TRACKS, ELEVATOR TRIM SCREW, AND ENGINE
COMPARTMENT ARE STILL PROPERLY LUBRICATED.
If specific lubrication instructions for certain components are not available, observe the following
precautions:
a. Apply oil sparingly, never apply more than enough to coat bearing surfaces.
b. Do not oil control cables.
CAUTION: BE CAREFUL NOT TO ADD TOO MUCH OIL, BECAUSE THE EXCESS WILL BE
THROWN OFF DURING OPERATION AND WILL CAUSE PITTING AND BURNING
OF THE MAGNETO POINTS.
c. Squeeze the magneto cam follower felts at regular inspection periods. If oil appears on fingers, do
not add oil. If the felt is dry, moisten with light oil.
2-82. WINTERIZATION PLATE.
For winter operations, winterization plate kit, No. 763 828V is available. When the ambient temperature
is 50°F or less the plate is installed on the inlet opening of the oil cooler plenum chamber.
When the plate is not being used it can be stowed on a bracket, provided for this purpose, located on the
oil cooler plenum chamber.
2-83. LUBRICATION CHARTS.
CAUTION: MIL-PRF-23827 AND MIL-PRF-81322 CONTAIN CHEMICALS WHICH MAY BE
HARMFUL TO PAINTED SURFACES.
The lubrication charts consist of individual illustrations for the various aircraft systems. Each component
to be lubricated is indicated a number, the type of lubricant and the frequency of application. Special
instructions, Cautions and Notes are listed at the beginning of the lubrication charts, with each
applicable component illustration,and are consistent throughout.

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TABLE II-IX. RECOMMENDED ENGINE LUBRICATING OILS

Average Average Ambient Oil Inlet Temperatures

Grade Oil Air Temperature Desired Maximum

SAE 50 Above 60° F 180° F 245° F

(16° C) (82° C) (118° C)
SAE 40 30° F to 90° F 180° F 245° F
(-1° C to 32° C) (82° C) (118° C)
SAE 30 0° F to 70° F 170° F 225° F
(-17° C to 20° C) (77° C) (107° C)
SAE 20 Below 10° F 160° F 210° F
(12° C) (71° C) (99° C)

TABLE II-X. THREAD LUBRICANTS

Line Lubricant
Brakes MIL-PRF-5606
WARNING: DO NOT PERMIT MIL-T-5544 ANTI-SEIZE COMPOUND TO ENTER SYSTEM.
APPLY TO FITTING THREADS ONLY.
Air Conditioning Refrigerant MIL -T-5544, Anti-Seize, Compound, Graphite Petrolatum
Fuel MIL -T-5544, Anti-Seize, Compound, Graphite Petrolatum
Landing Gear Air Valve MIL-PRF-907E, Anti-Seize, Thread Compound,
High Temperature
Oil SAE-AMS-G-6032, Grease
(Gasoline and Oil Resistant)
Pitot and Static TT-A-580 (TT-S-1732). Anti-Seize Compound

CAUTION: LUBRICATE ENGINE FITTINGS ONLY WITH THE FLUID CONTAINED IN THE
PARTICULAR LINE.

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TABLE II-XI. LIST OF CONSUMABLE MATERIALS

MATERIAL SPECIFICATION PRODUCT VENDOR

Adhesive Carboline F-l Carboline Co.
328 Hanley Ind. Ct.
St. Louis, MO 63144
Scotch Grip 210 3M Co. Adhesive Coatings
(Rubber Adhesive) and Sealers Div.
3M Center
St. Paul, MN 55101
Proco Adhesive Protective Coating Inc.
6205-1 807 N. Fremont Ave.
Tampa, FL
Cleaner, Prep-Sol DuPont
Surface Preparation No. 3919S 1007 Market St.
Wilmington, DE 19898
Dry Lubricant MS-122AD Miller-Stephenson
George Washington Hwy.
Danbury, CT 06810
PH: 203-743-4447
www.miller-stephenson.com
Grease, Aircraft MIL-PRF-23827 Royco 27A Royal Lubricants Co.
and Instrument River Road
Gear and Actuator E. Hanover, NJ 07936
Screw
Grease, General MIL-PRF-81322 Marfak All Purpose Texaco Inc.
Purpose, Wide 2000 West Chester Ave.
Temperature Range White Plains, NY 10650
Mobil Grease 28 Mobil Oil Corporation
Mobil Grease 77 150 E. 42nd St.
or Mobilux EP2 New York, NY 10017
Shell Alvania EP2 Shell Oil Company
Aeroshell No. 6 One Shell Plaza
Aeroshell No. 22 Houston, TX 77002
Grease, Aircraft, MIL-PRF-7711 Aeroshell No. 6 Shell Oil Company
General Purpose, Royco II Royal Lubricants Co.
Hydraulic Fluid MIL-PRF-5606
Lubricant Lubriplate #907 LUBRIPLATE Lubricants Co.
129 Lockwood St.
Newark, NJ 07105
PH: 800-733-4755
www.lubriplate.com

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TABLE II-XI. LIST OF CONSUMABLE MATERIALS (cont.)

MATERIAL SPECIFICATION PRODUCT VENDOR

Oil, Lubricating, MIL-PRF-7870
General Purpose,
Low Temperature
Oil, Engine (Piston)
Mineral Grade MIL-PRF-6082
Ashless Dispersant MIL-L-22851
Grades
O-Ring Lubricant Parker O-Lube Parker Hannifin Corp.
O-Ring Division
2360 Palumbo Drive
Lexington, KY 40509
PH: 859-269-2351
www.parker.com
Rain Repellent Repcon UNELKO Corporation
FSCM 50159 727 E. 110th Street
Chicago, Illinois 60628
Sealant, Fuel PR 1422 A-2 Sealant Products Research Co.
Tank Sealing (Brushing Consistency) 2919 Empire Avenue
Burbank, CA 91504
213-849-3992
Silicone Compound MIL-C-21567
Tape, Teflon Teflon— Minnesota Mining &
.003 x .50 wide/-l Manufacturing Co.
3M Center
St. Paul, MN 55144
Shamban W.S. & Co.
1857 Centinela Ave.
Santa Monica, CA 90404
Teflon— Johnson & Johnson Inc.
.003 x .25 wide/-2 Permacel Division
501 George St.
New Brunswick, NJ 08903
Thread Lubricant, MIL-PRF-907E Kopr-Kote Jet Lube, Inc.
Oleo Strut, Air Valve P.O. Box 21258
Houston, TX 77226-1258
PH: 800-538-5823
www.jetlube.com

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TABLE II-XII. SPECIAL INSTRUCTIONS

1. BEARINGS AND BUSHINGS - Clean exterior with a quick drying solvent before lubricating.
2. LUBRICATION POINTS - Wipe all lubrication points clean of old grease, oil, dirt, etc., before
lubricating.
3. WHEEL BEARINGS - Disassemble and clean with a quick drying solvent. Ascertain that grease is
packed between the roller and cone. Do not pack grease in wheel housing. Wheel bearings require
cleaning and repacking after exposure to any abnormal quantity of water.
4. OLEO STRUTS, HYDRAULIC PUMP RESERVOIR AND BRAKE RESERVOIR - Fill per
instructions on unit or container, or refer to applicable chapter in this manual.
5. DOOR SEALS - Apply release agent/dry lubricant to door seals at least once a month to improve
sealing characteristics and to prevent the seal from sticking.
6. CONTROL CABLES - Do not oil control cables. Grease control cables where they pass over a pulley
or through a fairlead.
7. AIR FILTER - To clean filter, tap gently to remove dirt particles. Do not blow out with compressed air
or use oil. Replace filter if excessively contaminated, damaged, or punctured. Air filter is located on left
side on PA-28R models; on right side on PA-28-150, -160, -180 and -235 and on nose of PA-28-140.
8. OIL AND FILTER - Lycoming recommends changing the oil and filter every 50 hours or four months,
whichever comes first. Intervals between oil changes can be increased as much as 100% on engines
equipped with full flow (cartridge type) oil filters, provided the specified octane fuel is used and the
filter replaced each 50 hours of operation. Should fuel other than the specified octane rating for the
power plant be used, refer to the latest revision of Lycoming Service Letter No. L185, for additional
information and recommended service procedures.
9. See the latest revision of Lycoming Service Instructions No. 1014 for use of detergent oil.
10. O-RING, CONTROL WHEEL SHAFT BUSHING - Disassemble the retainer plates and lubricate the
control wheel shaft bushing O-ring as required. Ensure thick retainer plate is reassembled with slot up.
11. BUNGEE - Lubricate springs if bungee is disassembled.
12. AILERON HINGES - Aileron hinges with teflon sleeves should NOT be lubricated. Aileron hinges
without teflon sleeves should first be cleaned with a dry type solvent then lubricated with MIL-PRF-
7870.
13. PROPELLER - For each blade: remove a grease fitting; apply grease through the remaining fitting until
fresh grease appears at hole of removed fitting. If annual usage is significantly less than 100 hours,
increase lubrication frequency to every six months.
14. ALTERNATOR IDLER PULLEY BEARING - Lubricate bearing by removing front grease seal.
15. DIAPHRAGM SHAFT AND BUSHING - Soft film silicon compound (MIL-C-21567) is
recommended for use when operating at temperatures below 20°F.
16. FUEL SELECTOR VALVE - Lubricate area where detent ball moves across cover plate (on external
detent valves only).
17. CONDENSER DOOR ACTUATING TRANSMISSION - Transmission to be 1/2 full of grease. Apply
grease during assembly and lubricate transmission ball nut and screw with MIL-PRF-23827 grease.

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COMPONENT LUBRICANT FREQUENCY

1. OLEO STRUT FILLER POINT (See Spec. Instr. 4) MIL-PRF-5606 AS REQUIRED
2. UPPER TORQUE LINK BEARING (See Spec. Instr. 1) MIL-PRF-23827 100 HRS
3. TORQUE LINK BUSHING (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
4. TORQUE LINK CONNECTING BUSHING (See Spec. Instr. 1) MIL-PRF-23827 100 HRS
5. MAIN GEAR WHEEL BEARINGS (See Spec. Instr. 3) MOBIL-GREASE 28
MIL-PRF-81322E 100 HRS
6. EXPOSED OLEO STRUT (See Spec. Instr. 2) DRY LUBRICANT
MS-122AD 100 HRS
7. BRAKE RESERVOIR (See Spec. Instr. 4) MIL-PRF-5606 100 HRS

Figure 2-44. Lubrication Chart (Landing Gear, Main) PA-28-140, -150, -160, -180, and -235

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COMPONENT LUBRICANT FREQUENCY

1. MAIN GEAR PIVOT POINTS (See Spec. Instr. 1 and 2) MIL-PRF-23827 100 HRS
2. MAIN GEAR DOOR HINGE (See Spec. Instr. 2) MIL-PRF-7870 100 HRS
3. MAIN GEAR TORQUE LINKS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
4. EXPOSED OLEO STRUT MAIN (See Spec. Instr. 2) DRY LUBRICANT
MS-122AD 100 HRS
5. MAIN GEAR WHEEL BEARINGS (See Spec. Instr. 3) MOBIL-GREASE 28
MIL-PRF-81322E 100 HRS
6. MAIN GEAR DOOR CONTROL ROD ENDS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
7. MAIN GEAR SIDE BRACE LINK ASSEMBLY (See Spec. Instr. 1 and 2) MIL-PRF-23827 100 HRS
8. UPPER SIDE BRACE SWIVEL FITTING (See Spec. Instr. 1 and 2) MIL-PRF-23827 100 HRS
9. MAIN GEAR DOWNLOCK ASSEMBLY
RETRACTION FITTING AND CYLINDER
ATTACHMENT POINTS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
10. OLEO STRUT FILLER POINT (See Spec. Instr. 4) MIL-PRF-5606 AS REQUIRED
11. HYDRAULIC PUMP RESERVOIR (See Spec. Instr. 4) MIL-PRF-5606 100 HRS
12. BRAKE RESERVOIR (See Spec. Instr. 4) MIL-PRF-5606 100 HRS

Figure 2-45. Lubrication Chart (Landing Gear, Main) PA-28R-180 and -200

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COMPONENT LUBRICANT FREQUENCY

1. OLEO STRUT FILLER POINT (See Spec. Instr. 4) MIL-PRF-5606 AS REQUIRED
2. STEERING BELLCRANK PIVOT POINT (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
3. SHIMMY DAMPENER PIVOT POINT (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
4. TORQUE LINK ASSEMBLY (See Spec. Instr. 2) MIL-PRF-7870 100 HRS
5. NOSE WHEEL BEARINGS (See Spec. Instr. 3) MOBIL-GREASE 28
MIL-PRF-81322E 100 HRS
6. NOSE GEAR STEERING ROD END BEARINGS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
7. BUNGEE SEAL (1974 MODELS AND UP) PARKER O-LUBE
(See Spec. Instr. 11) 100 HRS
8. EXPOSED OLEO STRUT (See Spec. Instr. 2) DRY LUBRICANT
MS-122AD 100 HRS

Figure 2-46. Lubrication Chart (Landing Gear, Nose) PA-28-140, -150, -160, -180, and -235

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COMPONENT LUBRICANT FREQUENCY

1. NOSE GEAR STRUT HOUSING GREASE FITTING (See Spec. Instr. 2) MIL-PRF-23827 100 HRS.
2. NOSE GEAR PIVOT POINT AND HYDRAULIC CYLINDER ROD END
(See Spec. Instr. 2) MIL-PRF-7870 100 HRS
3. NOSE GEAR DOOR RETRACTION MECHANISM (See Spec. Instr. 2) MIL-PRF-7870 100 HRS
4. NOSE GEAR DOOR HINGES (See Spec. Instr. 2) MIL-PRF-7870 100 HRS
5. EXPOSED OLEO STRUT (See Spec. Instr. 2) DRY LUBRICANT
MS-122AD 100 HRS
6. NOSE WHEEL BEARINGS (See Spec. Instr. 3) MOBIL-GREASE 28
MIL-PRF-81322E 100 HRS
7. NOSE GEAR DRAG LINK ASSEMBLIES (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
8. NOSE GEAR TORQUE LINK ASSEMBLY AND STRUT HOUSING
(See Spec. Instr. 2) MIL-PRF-23827 100 HRS
9. DOWNLOCK, ROLLER TENSION SPRING, SHIMMY DAMPENER
AND ALIGNING ROLLER PIVOT POINTS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
10. STEERING BELLCRANK PIVOT POINTS AND ROD ENDS
(See Spec. Instr. 1) MIL-PRF-7870 100 HRS
11. NOSE GEAR OLEO STRUT FILLER POINT (See Spec. Instr. 4) MIL-PRF-5606 AS REQUIRED
12. BUNGEE SPRING (1974 MODELS AND UP) (See Spec. Instr. 11) MIL-PRF-7711 100 HRS
13. FIREWALL BUNGEE SEAL (1974 MODELS AND UP) LUBRIPLATE #907 100 HRS

Figure 2-47. Lubrication Chart (Landing Gear, Nose) PA-28R-180 and -200

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COMPONENT LUBRICANT FREQUENCY

1. AILERON HINGE PINS (See Spec. Instr. 1 and 12) MIL-PRF-7870 100 HRS
2. FLAP HINGE BEARINGS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
3. STABILATOR HINGE PINS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
4. RUDDER HINGE BEARINGS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
5. CONTROL CABLE PULLEYS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
6. TRIM CONTROL WHEEL OR OVERHEAD CRANK
(See Spec. Instr. 1 and Caution) MIL-PRF-7870 100 HRS
7. O-RING, CONTROL SHAFT BUSHING PARKER O-LUBE
(See Spec. Instr. 10 and Caution) AS REQUIRED
8. TEE BAR PIVOT POINT (See Spec. Instr. 1 and Caution) MIL-PRF-7870 100 HRS
9. CONTROL COLUMN CHAIN (See Spec. Instr. 2 and Caution) MIL-PRF-7870 500 HRS
10. CONTROL COLUMN FLEX JOINTS AND SPROCKET
(See Spec. Instr. 2 and Caution) MIL-PRF-7870 100 HRS
11. STABILATOR CONTROL (See Spec. Instr. 1 and Caution) MIL-PRF-7870 100 HRS
12. CONTROL T-BAR DOUBLE SPROCKET SHAFT
(S/N’s 28-1 thru 28-971 only) (See Spec. Instr. 1 and Caution) MIL-PRF-7870 50 HRS
13. AILERON, STABILATOR, AND RUDDER CONTROL CABLES,
AND STABILATOR TRIM CABLES (See Spec. Instr. 2 & 6) AEROSHELL 33 /
( Not Shown ) MIL-PRF-23827 100 HRS
CAUTION: DO NOT LUBRICATE CONTROL WHEEL SHAFT OR BUSHING. CLEAN ONLY USING ALCOHOL OR OTHER
SUITABLE SOLVENT.
CAUTION: DO NOT OVER-LUBRICATE COCKPIT CONTROLS.

Figure 2-48. Lubrication Chart (Control System, Sheet 1 of 4)

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COMPONENT LUBRICANT FREQUENCY

1. FLAP TORQUE TUBE BEARING BLOCKS (See Spec. Instr. 2) MIL-PRF-7870 100 HRS
2. FLAP CONTROL ROD END BEARINGS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
3. FLAP HANDLE PIVOT POINT, LOCK MECHANISM
AND TURNBUCKLE END MIL-PRF-7870 100 HRS
4. FLAP RETURN AND TENSION CHAINS MIL-PRF-7870 500 HRS
5. AILERON BELLCRANK pivot points (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
6. AILERON CONTROL ROD END BEARINGS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
7. AILERON BELLCRANK cable ends (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
8. FLAP CABLE (See Spec. Instr. 2 & 6) AEROSHELL 33
MIL-PRF-23827 100 HRS
CAUTION: DO NOT OVER-LUBRICATE COCKPIT CONTROLS.

Figure 2-48. Lubrication Chart (Control System, Sheet 2 of 4)

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COMPONENT LUBRICANT FREQUENCY

1. RUDDER TUBE BEARING BLOCKS (See Spec. Instr. 2) DRY LUBRICANT
MS-122AD 100 HRS
2. TOE BRAKE CYLINDER ATTACHMENTS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
3. RUDDER TUBE CONNECTIONS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
4. BRAKE ROD ENDS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS

Figure 2-48. Lubrication Chart (Control System, Sheet 3 of 4)

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COMPONENT LUBRICANT FREQUENCY

1. RUDDER ARM CABLE ENDS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
2. STABILATOR TRIM SCREW (See Spec. Instr. 2) LUBRIPLATE #907 100 HRS
3. STABILATOR SCREW/TAB LINKS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
4. STABILATOR HINGE POINTS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
5. RUDDER TRIM ASSEMBLY (See Spec. Instr. 1) MIL-PRF-7870 100 HRS

Figure 2-48. Lubrication Chart (Control System, Sheet 4 of 4)

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COMPONENT LUBRICANT FREQUENCY

1. DOOR HINGES (See Spec. Instr. 2) MIL-PRF-7870 100 HRS
2. DOOR SEALS (See Spec. Instr. 5) DRY LUBRICANT
MS-122AD 50 HRS
3. DOOR LATCH MECHANISMS (See Spec. Instr. 2) MIL-PRF-7870 500 HRS
4. SEAT TRACK ROLLERS, STOP PINS AND REAR SEAT
LEG RETAINER (CLIP AND CAM) (See Spec. Instr. 2) LUBRIPLATE #907 100 HRS

Figure 2-51. Lubrication Chart (Cabin Door, Baggage Door and Seats)

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COMPONENT LUBRICANT FREQUENCY

1. ENGINE SUMP (See Spec. Instr. 8 and 9) MIL-PRF-6082 50 HRS
SEE TABLE II IX
2. CARTRIDGE TYPE OIL FILTER (See Spec. Instr. 8) 50 HRS
3. AIR FILTERS (See Spec. Instr. 7) 50 HRS
4. PROPELLER ASSEMBLY (See Spec. Instr. 2 and 13) AEROSHELL 6 OR MIL-PRF-23827 100 HRS
5. ENGINE CONTROL AND ENVIRONMENTAL
CONTROL PIVOT POINTS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
6. FRESH AIR VENT SHAFTS (See Spec. Instr. 2) MIL-PRF-7711 500 HRS
7. ALTERNATOR AND COMPRESSOR IDLER PULLEY BEARINGS MIL-PRF-81322 100 HRS
(IF INSTALLED) (See Spec. Instr. 2 and 14)

Figure 2-52. Lubrication Chart (Power Plant, Propeller & Control Pivot Points)

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COMPONENT LUBRICANT FREQUENCY

1. DIAPHRAGM SHAFT AND BUSHING MIL-PRF-7870 ABOVE
(See Spec. Instr. 15) 20°F
MIL-C-21567 BELOW
20°F 100 HRS
2. BACK-UP EXTENDER LINKS AND CONTROL ARM
PIVOT POINTS (See Spec. Instr. 2) MIL-PRF-7870 100 HRS
3. BACK-UP EXTENDER SPRING ATTACHMENT POINTS (See Spec. Instr. 2) MIL-PRF-7870 100 HRS
4. FUEL SELECTOR LINKAGE (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
5. FUEL SELECTOR VALVE COVER PLATE DRY LUBRICANT
(See Spec. Instr. 2 and 16) MS-122AD 100 HRS
6. ACTUATING ROD CONTACT POINTS (See Spec. Instr. 2) LUBRIPLATE #907 100 HRS

Figure 2-53. Lubrication Chart (Back-Up Extender and Fuel Selector)

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COMPONENT LUBRICANT FREQUENCY

1. CONDENSER HINGE AND ACTUATORS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS
2. CONDENSER DOOR ACTUATING TRANSMISSION MIL-PRF-23827 500 HRS
(See Spec. Instr. 2 and 17)

Figure 2-54. Lubrication Chart (Air Conditioning Condenser)

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— END OF SECTION —

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SECTION

III
INSPECTION

III-i
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THIS PAGE INTENTIONALLY BLANK

III-ii
 PIPER CHEROKEE SERVICE MANUAL

SECTION III – INSPECTION

TABLE OF CONTENTS

PARAGRAPH SECTION PAGE

INSPECTION III III-1

General III-1
Time Limits III-3
General III-3
Life Limited Parts Marking and Disposition III-3
Scheduled Maintenance III-5
Description III-5
Definitions III-5
Inspection Requirements III-8
Annual / 100 Hour Inspection Procedure III-9
Inspection Report - PA-28-140/150/160/180/235 III-11
Propeller Group III-11
Engine Group III-11
Cabin And Cockpit Group III-13
Fuselage And Empennage Group III-14
Wing Group III-16
Landing Gear Group III-17
Float Group (If Installed) III-18
Special Inspections III-18
Operational Inspection III-19
General III-19
Notes III-20
Inspection Report - PA-28R-180/200 III-25
Propeller Group III-25
Engine Group III-25
Cabin And Cockpit Group III-27
Fuselage And Empennage Group III-28
Wing Group III-30
Landing Gear Group III-32
Special Inspections III-32
Operational Inspection III-33
General III-33
Notes III-34
Special Inspections III-37
Requirements III-37
Per Flight Hour III-37
Per Calendar Year III-42
Per Specific Operation / Operating Environment III-46

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SECTION III - INSPECTION

TABLE OF CONTENTS (continued)

PARAGRAPH SECTION PAGE

INSPECTION (cont.) III (cont.)

Special Inspections (cont.)
Procedures III-48
Electric Trim Switch Inspection III-48
Air Induction Inlet Hose 10 Hour Inspection III-50
Spinner/Bulkhead 25 Hour Inspection III-51
Fuel Selector Valve 50 Hour Leak Check III-52
Stabilator Balance Weight Tube Assembly 200 Hour Inspection. III-52
Fuel Selector Valve 400 Hour Inspection III-55
Induction Air Inlet Duct And Alternate Heat Duct Inspection III-57
Wing Rib Assembly W.S. 49.25 Inspections III-58
Wing Spar Inspection III-60
Landing Light Seal Inspection III-63
Stabilator Attach Fittings Corrosion Inspection III-64
Flap Control Cable Attachment Bolt Inspection. III-65
Aft Wing Attach Fittings 100 Hour Inspection. III-66
Fuel Tank/Wing Spar Corrosion Inspection. III-70
Cast Main Landing Gear Strut Cylinder 100 Hour Inspection. III-72
Nose Gear Drag Link 500 Hour Inspection and Bolt Replacement. III-73
Control Cable Inspection. III-74
Exhaust System Inspection III-79
Field Check Of PA-28R-180 And PA-28R-200 Muffler Assemblies. III-82
Control Wheel 100 Hour Inspection. III-84
Aileron Hinge Doubler 100 Hour Inspection III-85
Main Landing Gear Torque Link Inspection III-87
Upper Nose Gear Oleo Bearing Inspection. III-88
Flap Torque Tube/Push Rod Distortion Inspection III-88
Rudder Bar Assembly 100 Hour Inspections III-90
Rear Seat Quick Disconnect Mechanism Inspection III-94
Main Landing Gear Torque Link Greaser Bolt Inspection III-95
Wing Aft Spar-to-Fuselage Attachment Hardware 100 Hour Inspection III-96
Unscheduled Maintenance Checks III-97
Lightning Strike III-97
Engine Overtemp, Loss of Oil, or Sudden Stoppage III-98
Severe Turbulence, Hard or Overweight Landing III-98
Flaps Extended Above Maximum Flap Extension Speed (Vfe) III-100
Flood Damage, Immersion in Water III-100
Service Publications List III-105

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INSPECTION

1. General
Piper Aircraft, Inc. (Piper) takes a continuing interest in having the owner get the most efficient use from
his airplane, and keeping the airplane in the best mechanical condition. To that end, Piper publishes a
recurring maintenance schedule which is supplemented with Service Bulletins, Service Letters and Service
Spares Letters as required.
A. The recurring maintenance schedules for the PA-28-140/150/160/180/235 and PA-28R-180/200 are
provided in “Table III-I” on page III-11 and “Table III-II” on page III-25, respectively.
B. Piper Service Bulletins are of special importance and Piper considers compliance mandatory. These
are sent to the latest U.S. registered owners and Piper Service Centers.
C. Service Letters deal with product improvements and service hints pertaining to the aircraft. They
are sent to Piper Service Centers and sometimes directly to owners, so they can properly service the
aircraft and keep it up to date with the latest changes. Owners should give careful attention to the
service letter information.
D. Service Spares Letters, which are sent only to Piper Service Centers, offer improved parts, kits and
optional equipment which were not available originally and which may be of interest to the owner.
E. Service Bulletins, Service Letters and Service Spares Letters are emailed to Piper Dealers/Service
Centers. U.S. registered owners are encouraged to download these service publications from
https://www.piper.com/technical-publications-documents/.
NOTE: Piper mails Service Bulletins, Service Letters, and P.O.H. Revisions to the registered owner’s
name and address as shown on the Aircraft Registration Certificate. If the aircraft is based
and/or operated at a different location (or locations) and/or by a person (or persons) other
than those recorded on the aircraft registration, then the registered owner(s) is responsible for
forwarding these Bulletins and Letters to the operating location(s) or person(s).
Changes in aircraft registration may take a substantial amount of time to be recorded by
the Federal Aviation Administration and received by Piper to change the mailing address.
Owners and operators should make arrangements to keep abreast of service releases during
this interim period through their Piper Service Center.
The Federal Aviation Administration (FAA) publishes Airworthiness Directives (AD’s) that apply to
specific aircraft. They are mandatory changes and are to be complied within a time limit set by the
FAA. When an AD is issued, it is sent to the latest registered owner of the affected aircraft and also
to subscribers of the service. The owner is solely responsible for being aware of and complying with
airworthiness directives.
NOTE: A searchable database of AD’s is available on the FAA website. See the “Airworthiness
Directives” link at “http://www1.faa.gov”.
Owners should periodically check with a Piper Dealer/Service Center to find out the latest information
to keep his aircraft up to date.
Service Bulletins, Service Letters, and Service Spares Letters are also available by subscription. See
the availability statement in Revision Status.

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2. Time Limits
A. General
(1) Refer to the remainder of this section for Piper’s recommended Inspection Programs. They
include the frequency and extent of the inspections required for the continued airworthiness of
these airplanes.
(2) Inspections required by Flight Hour or Calendar Year, if due, are included as part of the Annual
/ 100 Hour Inspection and/or the Progressive Inspection Event cycles, and are listed individually
in “Special Inspections” on page III-37.
B. Life Limited Parts Marking and Disposition
14 CFR Part 43.10, Disposition of Life-Limited Aircraft Parts requires that proper procedures are
followed when removing life limited parts with time and/or cycles remaining on them as well as the
disposition of life limited parts with no time and/or cycles left. As stated in Section I, there are no
life limited parts defined by Type Certificate (TC) for these airplanes. Other parts which are replaced
or rebuilt after having accumulated cycles, hours, or other replacement interval are specified in the
Inspection Report or Special Inspections.
(1) Parts that are removed prior to accumulating their life limit, are to be marked with indelible ink
or marker with the part number, serial number and accumulated life status as defined in 14 CFR
Part 43.10 in a manner that does not affect part structural integrity, i.e. - no surface deformation
such as vibration/etching allowed.
(2) Parts that have accumulated the life limit shall be disposed of in accordance with the applicable
FARs. Piper recommends life limited parts with no time and/or cycles remaining be completely
destroyed.

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SECTION III - INSPECTION

TABLE OF CONTENTS (continued)

PARAGRAPH SECTION PAGE

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3. Scheduled Maintenance
WARNING: GROUND THE MAGNETO PRIMARY CIRCUIT (P LEAD), BEFORE PERFORMING
ANY MAINTENANCE OPERATION ON THE ENGINE.
This section provides instructions for conducting inspections - see Tables III-I (PA-28-140/150/
160/180/235) and III-II (PA-28R-180/200). Repair or replacement instructions for those components
found to be unserviceable during inspections will be found in the applicable airplane system section. (See
Section Index Guide, Introduction.)
4. Description
WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN
SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER
AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION
- SUPPLEMENTARY PUBLICATIONS.)
The recurring maintenance schedules for the PA-28-140/150/160/180/235 and PA-28R-180/200 are
provided herein as Annual / 100 Hour Inspections. Progressive Inspection Programs (50 Hour) are
available exclusively from Avantext, Inc., in a separate manual form. See Piper Publications in the
Introduction under Supplementary Publications.
Piper inspection programs comply with the F.A.A. Federal Aviation Regulations Parts 43, 91 and 135.
The owner/operator is primarily responsible for maintaining the airplane in an airworthy condition,
including compliance with all applicable Airworthiness Directives and conformity with the requirements
in FAR 91.409, 91.411 and 91.413.
The first overhaul or replacement of components should be performed at the given periods. The
condition of various components can then be used as criteria for determining subsequent periods
applicable to the individual airplane, depending on usage, providing the owner/operator has an
established Part 91 Progressive Inspection Program (see 91.409(d)) or Part 135 Approved Aircraft
Inspection Program (see 135.419).
The time periods given for inspections of various components are based on average usage and
environmental conditions.
NOTE: The listed inspection, overhaul and replacement schedules do not guarantee that a particular
item or component will reach the listed time without malfunction. Unique operating conditions
encountered by individual airplanes cannot be controlled by the manufacturer.
5. Definitions
A. Inspections - Must be performed only by persons authorized by the FAA who are qualified on these
aircraft, using acceptable methods, techniques and practices to determine physical condition and
detect defects.
(3) Routine Inspection - Consists of a visual examination or check of the aircraft and its components
and systems without disassembly.
NOTE: This includes examination of all fasteners for broken torque stripe. If broken torque
stripe is found, loosen fastener, retorque, apply torque stripe, and safety, as required.
Please report broken torque stripe via the FAA Service Difficulty Reporting (SDR)
system.
(4) Detailed Inspection - Consists of a thorough examination of the aircraft, appliance, component,
or system; with disassembly as necessary to determine condition.

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(5) Special Inspection - Involves those components, systems or structure which by their application
or intended use require an inspection peculiar to, more extensive in scope or at a time period
other than that which is normally accomplished during an event or annual inspection.
B. Checks - Can be performed by pilots and/or mechanics who are qualified on this aircraft and consists of
examinations in the form of comparisons with stated standards for the purpose of verifying condition,
accuracy and tolerances.
C. Approved Inspection - Means a continuing airworthiness inspection of an airplane and its various
component and systems at scheduled interval in accordance with procedures approved by the FAA
under FAR Part 91.409(d) or Part 135.419.
D. Tests - Operation of aircraft components, appliances or systems to evaluate functional performance.
(1) Operational Test - A task to determine that an item is fulfilling its intended purpose. The task
does not require quantitative tolerances. This is a fault finding task.
(2) Functional Test - A quantitative check to determine if one or more functions of an item performs
within specified limits. This test may require the use of supplemental bench test equipment.
(3) In addition, each of the above tests must be performed by an FAA Certified Repair Station with
appropriate ratings or by a Certified Mechanic who is qualified on this aircraft. The recording of
the above function must be made in the permanent aircraft records by the authorized individual
performing the test.
E. Bench Test - Means removal of component from the aircraft to inspect for cleanliness, impending
failure, need for lubrication, repair or replacement of parts and calibration to at least the manufacturers
specifications using the manufacturers recommended test equipment or standards or the equivalent.
F. Each bench test will be performed by a Piper Service Center, FAA Certified Repair Station with
appropriate rating or by a certified mechanic. This test will be performed at the scheduled interval
regardless of any bench test performed on a particular component while being repaired/overhauled
before scheduled interval bench test. After the component is installed into the aircraft, an operational
test of the component and its related system should be performed to ensure proper function. Serviceable
parts that were issued to the component will be filed in the aircraft permanent records. The person
performing the test must make appropriate entries in the aircraft’s permanent maintenance record.
G. Maintenance - The word maintenance as defined by FAR Part 1, means “inspection, overhaul, repair,
preservation and the replacement of parts, but excludes preventive maintenance.”
H. On Condition Maintenance - A primary maintenance process having repetitive inspections or tests
to determine the condition of units, systems, or portions of structure with regard to continued
serviceability (corrective action is taken when required by item condition.)

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I. Time - as used in this manual.

(1) Time-in-service for aircraft components, unless otherwise specified, is a cumulative total of
flight hours or calendar time calculated from the time a new or overhauled component was first
installed in any aircraft, and including:
(a) the aircraft time that elapses from the initial installation to the first removal, if any; and,
(b) the aircraft time that elapses from each subsequent installation to each subsequent removal,
if any; or,
(c) the calendar time elapsed since the installation.
NOTE: Dates stamped on individual components at the time of manufacture are typically
applied to determine shelf life - i.e. the maximum time allowed from manufacture/
assembly/cure until actually installed in an aircraft and are not relevant.
Do not, however; ignore markings applied to life-limited parts when removed with time
and/or cycles remaining on them.
(2) Aircraft time, flight hours, or aircraft hours are the “Hobbs Time” shown on, or calculated from,
the installed “Hour Meter.”

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6. Inspection Requirements
WARNING: INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) FOR ALL NON-PIPER
APPROVED STC INSTALLATIONS ARE NOT INCLUDED IN THIS MANUAL.
WHEN A NON-PIPER APPROVED STC INSTALLATION IS INCORPORATED
ON THE AIRPLANE, THOSE PORTIONS OF THE AIRPLANE AFFECTED BY
THE INSTALLATION MUST BE INSPECTED IN ACCORDANCE WITH THE ICA
PUBLISHED BY THE OWNER OF THE STC. SINCE NON-PIPER APPROVED
STC INSTALLATIONS MAY CHANGE SYSTEMS INTERFACE, OPERATING
CHARACTERISTICS AND COMPONENT LOADS OR STRESSES ON ADJACENT
STRUCTURES, THE PIPER PROVIDED ICA MAY NOT BE VALID FOR AIRPLANES
SO MODIFIED.
Inspections must be accomplished by persons authorized by the FAA or appropriate National Aviation
Authority. Checks may be performed by a pilot or owner who is checked out on the airplane.
A. Annual / 100 Hour Inspection. (See paragraph 7.)
Owners/operators may maintain the airplane solely under FAR 91.409 (a) and (b) inspection
requirements. The 100 hour inspection cycle is a complete inspection of the airplane and is identical
in scope to an annual inspection.
B. Progressive Inspection.
The Progressive Inspection programs are designed to permit the best utilization of the aircraft through
the use of a planned inspection schedule. These schedules :
P/N 761-497 for the PA-28-140/150/160/180/235 Cherokee Series, and
the PA-28-140 Fliteliner, and
P/N 761-500 for the PA-28R-180/200
are prepared in a manual form, available exclusively by subscription to the Avantext TechPubs
Maintenance Libraries for Piper Aircraft (see www.Avantext.com).
Refer to Piper’s Customer Service Information File P/N 1753-755 for a checklist to ensure
obtaining latest issue.
NOTE: The 50 Hour Progressive Inspection Manuals (P/N’s 761-497 and 761-500) referenced above
are not stand-alone documents. They constitute snapshots of the Airworthiness Limitations
and Inspection sections of the Instructions for Continued Airworthiness (ICA) and are current
only at the time of printing. Use them as follows:
(a) (1) Owners/operators desiring to establish a Part 91 Progressive Inspection
Program (PIP) (see 91.409(d)) or a Part 135 Approved Aircraft Inspection Program
(AAIP) (see 135.419) should use the appropriate Progressive Inspection Manual as a
template for submission to their regional FAA office.
(b) (2) Service centers conducting Event Cycle inspections under a FAA-approved
PIP or AAIP can use the appropriate Progressive Inspection Manual as a working check-
off list/form, provided they verify its currency against the FAA-approved PIP or AAIP.
C. Overlimits Inspection.
If the airplane has been operated so that any of its components have exceeded their maximum
operational limits, special inspections may be required by Piper and/or the component manufacturer.
See Section III and applicable vendor publications.

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7. Annual / 100 Hour Inspection Procedure

A. Scheduled Maintenance (i.e. - Tables III-I (PA-28-140/150/160/180) and III-II (PA-28R-180/200)
(1) The required periodic inspection procedures are listed in Tables III-I (PA-28-140/150/160/180)
and III-II (PA-28R-180/200). These inspection procedures are broken down into major groups
which include Propeller, Engine, Cabin and Cockpit, Fuselage and Empennage, Wing, Landing
Gear, Special Inspections, Operational Inspection, and General. The first column in each group
lists the inspection or procedure to be performed. The second column is divided into two sub-
columns indicating the required inspection interval of 50 hours or 100 hours. Each inspection or
operation is required at each of the inspection intervals indicated by a circle (O). When a vendor
publication specifies a time outside the 50 / 100 hour cycle, it will be listed as a special inspection
in paragraph 8.
(2) Refer to the applicable section of this manual for instructions on how to gain access to remove
any item that must be removed and is not completely accessible.
(3) Inspection Report Forms.
To help in the performance of periodic inspections, an Inspection Report form:
(a) P/N 230-207 for the PA-28-140/150/160/180/235; or,
(b) P/N 230-259 for the PA-28R-180/200.
is available exclusively by subscription to the Avantext TechPubs Maintenance Libraries for
Piper Aircraft (see www.Avantext.com).
NOTE: Service centers conducting Part 91 Annual / 100 Hour Inspections can use the appropriate
Inspection Report Form (above), as a working check-off list, provided they verify its
currency against an up-to-date copy of the ICA (i.e. – this Service Manual, see Section
I and Tables III-I and III-II).
(4) In addition to inspection intervals required in scheduled maintenance (i.e. - Tables III-I
and III-II), preflight inspection must also be performed.
(5) References to service manual applicable areas are per the Piper proprietary system defined by
the Section Index Guide.
B. Special Inspections (See paragraph 8.)
C. Unscheduled Maintenance (See paragraph 9.)

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Table III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Refer to Notes 1, 2, 3, and “4” on page III-20 before performing the following inspections.
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100
A. PROPELLER GROUP
WARNING: USE EXTREME CAUTION WHEN ROTATING PROPELLER BY
HAND; PROPELLER MAY KICK BACK. PRIOR TO ROTATING
PROPELLER ENSURE BOTH MAGNETO SWITCHES ARE OFF
(GROUNDED). IF MAGNETOS ARE NOT GROUNDED, TURNING
PROPELLER MAY START ENGINE.
1. Inspect spinner and back plate for cracks, dents, missing screws,
and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
2. Inspect blades for nicks and cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
3. In PA-28-235 models only, if constant speed propeller installed:
inspect for grease and oil leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
4. In PA-28-235 models only, if constant speed propeller installed:
lubricate propeller per Lubrication Chart, Section II . . . . . . . . . . . . . . . . . . . . . . O
5. Inspect spinner mounting brackets for cracks and security . . . . . . . . . . . . . . . . . O
6. Inspect propeller mounting bolts for condition and security.
If safety is broken, re-torque and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
7. In PA-28-235 models only, if constant speed propeller installed:
inspect hub parts for cracks and corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

8. Inspect complete propeller and spinner assembly for security, chafing,

cracks, deterioration, wear, and correct installation . . . . . . . . . . . . . . . . . . . . . . . O
B. ENGINE GROUP
WARNING: IF MAGNETOS ARE NOT GROUNDED, TURNING PROPELLER
MAY START ENGINE. USE EXTREME CAUTION WHEN
ROTATING PROPELLER BY HAND; PROPELLER MAY KICK
BACK. PRIOR TO ROTATING PROPELLER ENSURE BOTH
MAGNETO SWITCHES ARE OFF (GROUNDED).
NOTE: Read Note “5” on page III-20 prior to completing this group.
1. Remove engine cowling and inspect for internal and external damage . . . . . . . . O O
2. Clean and inspect cowling for cracks, distortion, and loose or missing
fasteners. (See Note “6” on page III-20.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
3. Drain oil sump. (See Note “8” on page III-21.) . . . . . . . . . . . . . . . . . . . . . . . . . . O O
4. Clean suction oil strainer at oil change; inspect strainer for foreign particles . . . O O
5. Clean pressure oil strainer or change full-flow (cartridge-type) oil filter element.
Inspect strainer or element for foreign particles . . . . . . . . . . . . . . . . . . . . . . . . . . O O
6. Inspect oil temperature sender unit for leaks and security . . . . . . . . . . . . . . . . . . O
7. Inspect oil lines and fittings for leaks, security, chafing, dents, & cracks . . . . . . O O
8. Clean and inspect oil radiator cooling fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

B. ENGINE GROUP (CONT.)

9. Fill engine with oil per information on cowling or in Lubrication Chart,
Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
CAUTION: USE CAUTION NOT TO CONTAMINATE VACUUM PUMP WITH
CLEANING FLUID.
10. Clean engine with approved solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
11. Inspect condition of spark plugs. Clean and adjust gap as required; adjust per
latest revision of Lycoming Service Instruction No. 1042 . . . . . . . . . . . . . . . . . . O
NOTE: If fouling of spark plugs is apparent, rotate bottom plugs to upper plugs.
12. Inspect spark plug cable leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
13. Test cylinder compression. (Refer to AC 43.13-1, latest revision.) . . . . . . . . . . . O
14. Inspect cylinders for cracked or broken fins. (See Note “10” on page III-21.) . . O
15. Inspect rocker box covers for evidence of oil leaks. If found, replace gasket;
torque cover screws 50 inch-pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
16. Inspect ignition harness and insulators for high tension leakage
and continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

17. Inspect magnetos for oil seal leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

18. Inspect magnetos to engine timing. (See Note “34” on page III-22.) . . . . . . . . . O
19. Remove air filter and clean per Section II. Replace as required . . . . . . . . . . . . . O O
20. Drain carburetor and clean inlet line fuel strainer . . . . . . . . . . . . . . . . . . . . . . . . O O
21. Inspect condition of alternate air valve and housing . . . . . . . . . . . . . . . . . . . . . . O O
22. Inspect condition of carburetor heat air door and box . . . . . . . . . . . . . . . . . . . . . O O
23. Inspect throttle body attaching screws for tightness. (Torque 40–50 in·lbs) . . . . O O
24. Inspect vent lines for evidence of fuel or oil seepage . . . . . . . . . . . . . . . . . . . . . O O
25. Inspect intake seals for leaks and clamps for tightness.
(Torque clamps 40–50 in·lbs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
26. Inspect condition of flexible fuel lines. Replace as required . . . . . . . . . . . . . . . . O
27. Inspect fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
28. Clean screens in electric fuel pump(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
29. Inspect engine-driven and electric fuel pumps for condition and operation.
Replace as required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
30. In PA-28-140/150/160/180 models only, remove and clean fuel filter bowl
and screen on lower left side of firewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
31. Inspect and operationally test engine driven vacuum pumps and lines.
(See Note “35” on page III-23.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
32. Inspect throttle, carburetor heat, mixture, and, if installed, propeller controls
for security, travel and operating condition. (See Notes 27 and 29.) . . . . . . . . . . O

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TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

B. ENGINE GROUP (CONT.)

33. Inspect exhaust stacks, connections and gaskets per
“Exhaust System Inspection” on page III-79. Replace gaskets as required . . . . . O O
34. Inspect muffler, heat exchange and baffles per
“Exhaust System Inspection” on page III-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
35. Inspect breather tube for obstructions and security . . . . . . . . . . . . . . . . . . . . . . . O
36. Inspect crankcase for cracks, leaks, and security of seam bolts . . . . . . . . . . . . . . O
37. Inspect engine mounts for cracks and loose mounting . . . . . . . . . . . . . . . . . . . . . O
38. Inspect all engine baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
39. Inspect engine compartment wiring for condition (chafing, cracked insulation,
general deterioration), security, proper routing, and correct installation . . . . . . . O
40. Inspect rubber engine mount bushings for deterioration. Replace as required . . O
41. Inspect firewall seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
42. Lubricate alternator idler pulley; remove front grease seal and add grease
per Lubrication Chart in Section II. Disregard if sealed bearing is installed . . . . O
43. Inspect condition of alternator and starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
44. Inspect security of alternator and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
45. Inspect condition and tension of alternator drive belt.
(See Checking Generator or Alternator Belt Tension in Section XI.) . . . . . . . . . O
46. If installed, inspect condition of A/C compressor belt and tension.
(See Adjustment of Drive Belt Tension in Section XIV.) . . . . . . . . . . . . . . . . . . . O
47. If installed, inspect A/C compressor oil level. (See Note 12.) . . . . . . . . . . . . . . . O
48. If installed, inspect A/C compressor clutch security and wiring.
(See Note 13.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
49. If installed, inspect A/C compressor mounting for cracks, corrosion,
and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
50. Check fluid in brake reservoir. Fill as required . . . . . . . . . . . . . . . . . . . . . . . . . . O O
51. Inspect and lubricate all controls per Lubrication Chart, Section II . . . . . . . . . . O
52. Install engine cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
C. CABIN AND COCKPIT GROUP
1. Inspect cabin door latch and hinges, and windows, for damage,
operation and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
2. Inspect windows for scratches, crazing, and condition . . . . . . . . . . . . . . . . . . . . O
3. Inspect window and door seals for deterioration, cracks, and voids . . . . . . . . . . O
4. Inspect upholstery for tears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
5. Inspect seats and attaching brackets and hardware for condition,
security and operation. (See Note 32.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
6. Inspect seat belts and shoulder harnesses per Section XIV, Restraint System . . . O
7. Inspect trim control operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
8. Inspect condition and operation of rudder pedals and
rudder bar assembly. (See Note 28.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

C. CABIN AND COCKPIT GROUP (CONT.)

9. Inspect parking brake and brake handle for operation and cylinder leaks . . . . . . O
10. Inspect control wheels, column, pulleys, cables, and fittings.
(See Notes 14 and 22.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
11. Perform “Flap Control Cable Attachment Bolt Inspection.” on page III-65.
(See Note 14.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
12. Inspect landing, navigation, strobe, cabin, and instrument lights. (See Note 23.) . O O
13. Inspect instruments, avionics, lines, and attachments . . . . . . . . . . . . . . . . . . . . . O
14. Inspect gyro operated instruments and electric turn and bank. (Overhaul or
replace as required.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
15. Cycle each circuit breaker with airplane power off . . . . . . . . . . . . . . . . . . . . . . . . O O
16. If installed, replace filters on the gyro horizon and directional gyro
17. If installed, replace vacuum regulator filter element . . . . . . . . . . . . . . . . . . . . . . O
18. Inspect static system, altimeter and transponder for installation/certification
per latest revision of AC 43.13-1 and current test/inspection per
FAR’s 91.411 and 91.413, respectively . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

19. Inspect operation of fuel selector valve. (See Notes 15 and 25.) . . . . . . . . . . . . . O
20. In PA-28-235 models only, inspect operation of fuel drain . . . . . . . . . . . . . . . . . O
21. In PA-28-235 models only, inspect fuel valve drain lever cover for security.
Verify door opens and closes freely and prevents operation of lever when closed . . O O
22. Inspect condition of heater controls and ducts. (See Note “7” on page III-20.) . O
23. Inspect condition and operation of air vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
24. If installed, inspect condition of air conditioning ducts . . . . . . . . . . . . . . . . . . . . O
25. If installed, remove and clean air conditioning evaporator filter . . . . . . . . . . . . . O
26. If installed, inspect disposable-type (non-gauged) fire extinguisher minimum
weight as specified on nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
D. FUSELAGE AND EMPENNAGE GROUP
1. Remove inspection plates and panels. (See Figures 2-25 thru 2-27.) . . . . . . . . . O
2. Inspect forward wing attach fittings for condition and security . . . . . . . . . . . . . . O
3. Inspect aft wing attach fittings per
“Aft Wing Attach Fittings 100 Hour Inspection.” on page III-66 . . . . . . . . . . . . . O
4. Inspect baggage door, latch and hinges for damage, operation and security . . . . O O
5. Inspect battery, box and cables. Clean and flush area as required and fill battery
per instructions on box and in Electrical System, Section XI . . . . . . . . . . . . . . . O O
6. Conduct a general visual inspection of electrical and electronic installations
(mounting, wiring, harnesses, shields, connectors, etc.) for
condition and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
7. Inspect skins, bulkheads, frames, and stringers for damage, irregularities,
or structural defects (i.e., skin cracks, distortion, dents, corrosion,
and loose or missing rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

D. FUSELAGE AND EMPENNAGE GROUP (CONT.)

8. Inspect condition and security of antenna mounts and electric wiring . . . . . . . . O
9. If installed, inspect air conditioning system for refrigerant leaks. (See Note 12.) . O
10. If installed, inspect refrigerant level in sight gauge of receiver-dehydrator. Refer
to Section XIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
11. If installed, inspect air conditioner condenser air scoop for condition and rigging.
(See Note 16.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
12. Inspect fuel lines, valves, and gauges for damage and operation . . . . . . . . . . . . . O
13. In PA-28-235 models only, clean screens in fuel pumps . . . . . . . . . . . . . . . . . . . O
14. In PA-28-235 models only, remove, drain and clean fuel strainer bowl, located
at the bottom of selector valve. Refer to Fuel System, Section IX . . . . . . . . . . . O O
15. Inspect security of all lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
16. Inspect vertical fin for surface damage or irregularities (i.e., skin cracks,
distortion, dents, and corrosion); structural defects (i.e., loose or missing
rivets); excessive wear, and attachment points for missing, damaged
or worn hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
17. Inspect vertical fin attachments for security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
18. Inspect rudder for surface damage or irregularities (i.e., skin cracks, distortion,
dents, and corrosion); structural defects (i.e., loose or missing rivets);
misrigging; hinge damage, excessive wear, freedom of movement and proper
lubrication; and attachment points for missing, damaged or worn hardware . . . . O
19. Inspect rudder hinges, horn and attachments for damage, security,
and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
20. Inspect rudder control stops to ensure stops have not loosened and
locknuts are tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
21. Inspect rudder hinge bolts for excess wear. Replace as required . . . . . . . . . . . . . O
22. Inspect stabilator and trim tab for surface damage or irregularities (i.e., skin
cracks, distortion, dents, and corrosion); structural defects (i.e., loose or
missing rivets); misrigging; hinge damage, excessive wear, freedom of
movement and proper lubrication; and attachment points for missing, damaged
or worn hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
23. Inspect the stabilator and stabilator trim tab hinges, horns and attachments for
damage, security and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
24. Inspect stabilator attachments per
“Stabilator Attach Fittings Corrosion Inspection” on page III-64 . . . . . . . . . . . . . O
25. Inspect stabilator and tab hinge bolts and bearings for excess wear.
Replace as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
26. Inspect stabilator control stops to ensure stops are not loose. Ensure bolts and
locknuts are tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
27. Inspect aileron, rudder, stabilator, and stabilator trim cables and pulleys for
safety, condition, and operation. Inspect cable terminals, turnbuckles, guides,
and fittings for safety and condition. (See Notes 14 and 21.) . . . . . . . . . . . . . . . O

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TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

D. FUSELAGE AND EMPENNAGE GROUP (CONT.)

28. Inspect rudder, stabilator, and stabilator trim cable tension per Table V-II.
Use a tensiometer. (See Note 14.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
29. Lubricate per Lubrication Chart, Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
30. Inspect rotating beacon for security and operation . . . . . . . . . . . . . . . . . . . . . . . O
31. Inspect security of Autopilot servo bridle cable clamps. (See Note 14.) . . . . . . . O
32. Inspect all non-flight control cables, air ducts, electrical leads, harnesses, lines,
radio antenna leads, and attaching parts for security, routing, chafing,
deterioration, wear, and correct installation. (See Note 14.) . . . . . . . . . . . . . . . . O
33. Inspect ELT battery for condition / date per FAR 91.207 . . . . . . . . . . . . . . . . . . O
34. Inspect ELT and antenna installation for condition and security.
Replace antenna if bent or damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
35. Install inspection plates and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
E. WING GROUP
1. Remove inspection plates and fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
2. Inspect exterior surfaces, skins, and tips for damage and loose or
missing fasteners, and condition of walk-way . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
3. Inspect visible interior structural components (skins, spars, ribs, stringers, etc.)
for condition, security, distortion, or failure. (See Note 24.) . . . . . . . . . . . . . . . . O
4. Inspect wing carry-through structure for condition, security, distortion, or
failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
5. Inspect ailerons for surface damage or irregularities (i.e., skin cracks,
distortion, dents, and corrosion); structural defects (i.e., loose or missing
rivets); misrigging; hinge damage, excessive wear, freedom of movement and
proper lubrication; and attachment points for missing, damaged or
worn hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
6. Inspect aileron hinges and attachments. (See Note 24.) . . . . . . . . . . . . . . . . . . . . O
7. Inspect aileron control stops to ensure stops have not loosened
and locknuts are tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
8. Inspect aileron cables, pulleys, and bellcranks for safety, condition, and
operation. Inspect aileron cable terminals, turnbuckles, fittings, and guides for
safety and condition. (See Note 14.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
9. Inspect aileron cable tension per Table V-II. Use a tensiometer . . . . . . . . . . . . . . O
10. Inspect flaps for surface damage or irregularities (i.e., skin cracks, distortion,
dents, and corrosion); structural defects (i.e., loose or missing rivets);
misrigging; hinge damage, excessive wear, freedom of movement and proper
lubrication; and attachment points for missing, damaged or worn hardware . . . O
11. Inspect condition of flap hinge bolts. Replace as required . . . . . . . . . . . . . . . . . . O
12. Lubricate per Lubrication Chart, Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
13. Inspect wing fore and aft attach fittings, and bolts, for security, corrosion
and condition. (See Note 31.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

E. WING GROUP (CONT.)

14. Retorque wing aft spar attach bolts per Wing Aft Spar-to-Fuselage Attachment
Hardware 100 Hour Inspection on page “III-96” . . . . . . . . . . . . . . . . . . . . . . . . . O
15. Inspect pitot tube for damage and condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
CAUTION: SEVERE BURNS CAN RESULT FROM COMING IN CONTACT
WITH A HEATED PITOT TUBE.
16. Inspect pitot heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
17. Inspect fuel tanks and lines for leaks and water. (See Note 18.) . . . . . . . . . . . . . O
18. Inspect fuel caps, cap gaskets, fuel filler neck, fuel gage transmitter gaskets,
and gage transmitter access covers for condition, proper sealing, security,
alignment, etc. Ensure to service and clean these areas, replacing parts
as necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
19. Inspect the interior of metal fuel tanks for signs of corrosion, which may
indicate water contamination. If signs of contamination are found, alert the
owner and fuel supplier of your findings for corrective action . . . . . . . . . . . . . . . O
20. Inspect fuel tanks for minimum octane markings . . . . . . . . . . . . . . . . . . . . . . . . O
21. Confirm fuel tanks are marked for capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
22. Inspect fuel tank vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
23. Inspect all non-flight control cables, air ducts, electrical leads, lines, and
attaching parts for security, routing, chafing, deterioration, wear, and
correct installation. (See Note 14.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
24. Install inspection plates and fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F. LANDING GEAR GROUP
1. Check oleo struts for proper extension and evidence of fluid leakage.
See Landing Gear, Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
2. Inspect nose gear steering control and travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
3. Remove wheel fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
4. Inspect wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
5. Put airplane on jacks. (Refer to Section II.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
6. Inspect tires for cuts, uneven or excessive wear, and slippage . . . . . . . . . . . . . . . O
7. Remove wheels; clean, inspect, and repack bearings . . . . . . . . . . . . . . . . . . . . . . O
8. Inspect wheels for cracks, corrosion, and broken bolts . . . . . . . . . . . . . . . . . . . . O
9. Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
10. Inspect brake linings and discs for condition and wear . . . . . . . . . . . . . . . . . . . . O
11. Inspect brake backing plates for condition and wear . . . . . . . . . . . . . . . . . . . . . . O
12. Inspect brake lines for condition and security . . . . . . . . . . . . . . . . . . . . . . . . . . . O
13. Inspect shimmy dampener operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
14. Inspect gear forks for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
15. Inspect oleo struts for fluid leaks and scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

F. LANDING GEAR GROUP (CONT.)

16. Inspect gear struts and mounting bolts for condition and
security. (See Note 26.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
17. Inspect torque links for cracks, bolts for condition and security. Inspect
assembly for excessive side play. (See Note 33.) . . . . . . . . . . . . . . . . . . . . . . . . . O
18. Inspect wheel fairings and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
19. Inspect hydraulic lines, electrical leads, and attaching parts for condition
and security (i.e., routing, chafing, damage, wear, etc.). . . . . . . . . . . . . . . . . . . . O
20. Lubricate per Lubrication Chart, Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
21. Install wheel fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
22. Remove airplane from jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
G. FLOAT GROUP (IF INSTALLED)
1. Inspect float attachment fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
2. Inspect floats for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
3. Inspect pulleys and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H. SPECIAL INSPECTIONS
Review inspections in Special Inspections, “Requirements” on page III-37. Perform
all special inspections applicable to your aircraft and currently due per the given
inspection interval.

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

I. OPERATIONAL INSPECTION
NOTE: Refer to Note 19 prior to starting engine or taxiing airplane.
1. Inspect fuel pump and fuel tank selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
2. Inspect fuel quantity, pressure, and flow readings . . . . . . . . . . . . . . . . . . . . . . . . O O
3. Inspect oil pressure and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
4. Inspect alternator output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
5. Inspect manifold pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
6. Inspect carburetor heat or alternate air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
7. Inspect parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
8. If installed, inspect vacuum gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
9. Inspect gyros for noise and roughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
10. Inspect cabin heater operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
11. Inspect magneto switch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
12. Inspect magneto RPM variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
13. Inspect throttle and mixture operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
14. Inspect propeller smoothness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
15. Inspect propeller governor action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
16. Inspect engine idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
17. Inspect electronic equipment operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
18. If installed, inspect operation of autopilot, including automatic pitch trim, and
manual electric trim. (See Note 20.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
19. If installed, inspect air conditioner compressor clutch operation . . . . . . . . . . . . . O O
20. If installed, inspect air conditioner condenser scoop operation . . . . . . . . . . . . . . O O
21. Inspect free and correct operation of flight controls . . . . . . . . . . . . . . . . . . . . . . . . O O
J. GENERAL
1. Aircraft conforms to FAA Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
2. Latest revision of applicable FAA Airworthiness Directives complied with . . . . O O

3. Current and correct Pilot’s Operating Manual (POM) and/or Airplane Flight
Manual (AFM) is in the airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
4. Inspect airplane for required placards as identified in
the Limitations section of the AFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
5. Appropriate entries made in the Aircraft and Engine Log books . . . . . . . . . . . . . O O
6. Airworthiness & Registration Certificates in the aircraft and properly displayed . . O O
7. Aircraft Equipment List, Weight and Balance and FAA Form(s) 337
(if applicable) are in the aircraft and in proper order . . . . . . . . . . . . . . . . . . . . . . O O
8. Operational inspection and run-up completed . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
9. Aircraft cleaned and lubricated after wash (as required) . . . . . . . . . . . . . . . . . . . O O

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TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235

K. NOTES
1. Refer to Piper’s Customer Service Information File (see Availability under Revision Status on
page iii) for latest revision dates to Piper Inspection Reports/Manuals and this service manual.
References to Section are to the appropriate Section in this manual.
WARNING: INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) FOR ALL
NON-PIPER APPROVED STC INSTALLATIONS ARE NOT INCLUDED IN
THIS MANUAL. WHEN A NON-PIPER APPROVED STC INSTALLATION
IS INCORPORATED ON THE AIRPLANE, THOSE PORTIONS OF THE
AIRPLANE AFFECTED BY THE INSTALLATION MUST BE INSPECTED
IN ACCORDANCE WITH THE ICA PUBLISHED BY THE OWNER OF
THE STC. SINCE NON-PIPER APPROVED STC INSTALLATIONS MAY
CHANGE SYSTEMS INTERFACE, OPERATING CHARACTERISTICS AND
COMPONENT LOADS OR STRESSES ON ADJACENT STRUCTURES,
THE PIPER PROVIDED ICA MAY NOT BE VALID FOR AIRPLANES SO
MODIFIED.
2. Inspections or operations are to be performed as indicated by a “O” at the 50 or 100 hour inspection
interval. Inspections or operations (i.e., component overhauls/replacements, etc.) required outside
the 50 / 100 hour cycle are listed as “Special Inspections” on page III-37. Inspections must be
accomplished by persons authorized by the FAA or appropriate National Aviation Authority.
Checks may be performed by a pilot or owner who is checked out on the airplane.
(a) The 50 hour inspection accomplishes preventive maintenance, lubrication and servicing as
well as inspecting critical components.
(b) The 100 hour inspection is a complete inspection of the airplane, identical to an annual
inspection.
NOTE: A log book entry should be made upon completion of any inspections.
3. Piper Service Bulletins are of special importance and Piper considers compliance mandatory. In
all cases, see Service Bulletin/Service Letter Index P/N 762-332 to verify latest revision. See also
“Table III-III” on page III-105.
4. Piper Service Letters are product improvements and service hints pertaining to servicing the
airplane and should be given careful attention.
5. Inspections given for the power plant are based on the engine manufacturer’ operator’s manuals
for these airplanes (see Introduction, Supplementary Publications, Vendor Publications, Engine).
Any changes issued to the engine manufacturer’s operator’s manuals shall supersede or supplement
the inspections outlined in this report. In the PA-28-140/150/235 only, should fuel other than
the specified octane rating for the power plant be used, refer to the latest revision of Lycoming
Service Letter No. L185 for additional information and recommended service procedures.
6. In PA-150/160/180 S/N’s 28-1761 and up; and PA-28-235’s: inspect teflon bushings and pins
attaching top and bottom engine cowlings at nose for condition and security. Replace as required.
7. In PA-28-140 S/N’s 28-20001 thru 28-7225172; PA-28-150/160/180 S/N’s 28-03, 28-l thru 28-
7305012; PA-28-235 S/N’s 28-10001 thru 28-7310005; for airplanes which have not installed
either Piper Kit No. 760-634V, 760-635V, 760-639V, or 760-640V per Piper Service Bulletin No.
360: conduct the Induction Air Inlet Duct and Alternate Heat Duct Inspection on page “III-57”.

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TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235

K. NOTES (CONT.)

8. Refer to latest revision of Lycoming Service Bulletin No. 480 and Service Instruction 1014.
9. Not used.
10. Check cylinders for evidence of excessive heat indicated by burned paint on the cylinders.
This condition is indicative of internal damage to the cylinder and, if found, its cause must be
determined and corrected before the airplane is returned to service. Heavy discoloration and
appearance of seepage at the cylinder head and barrel attachment area is usually due to emission
of thread lubricant used during assembly of the barrel at the factory, or by slight gas leakage
which stops after the cylinder has been in service for a while. This condition is neither harmful
nor detrimental to engine performance and operation. If it can be proven that leakage exceeds
these conditions, the cylinder must be replaced.
11. Not used.
CAUTION: ENVIRONMENTAL REGULATIONS MAY REQUIRE SPECIAL EQUIPMENT
AND PROCEDURES BE USED WHEN CHARGING AIR CONDITIONING
SYSTEMS.
12. The compressor oil level should not be checked unless a refrigerant leak has occurred or system
pressure has been released, requiring an addition of refrigerant to the system.
13. Clean any traces of oil from the clutch surface.
14. Examine cables for broken strands by wiping them with a cloth for their entire length. Visually
inspect the cable thoroughly for damage not detected by the cloth. Replace any damaged or
frayed cables.
(a) See “Control Cable Inspection.” on page III-74, or the latest edition of FAA AC 43.13-1.
(b) At fifteen (15) years time-in-service, begin Cable Fittings “100 Hour Special Inspection”
on page III-77.
15. In PA-28-140 S/N’s 28-20002 thru 28-26783 and 28-26945 thru 28-7125595; PA-28-150/160/180
S/N’s 28-l thru 28-7105179: if fuel selector valve is difficult to rotate, inspect and lubricate valve
per “Fuel Selector Valve 400 Hour Inspection” on page III-55.
16. Refer to Section XIV (Paragraphs 14-31 through 14-35) for condenser assembly rigging and
adjustment.
17. Not used.
18. Sloshing of fuel tanks not approved. For airplanes with fuel tanks which have previously been
sloshed, perform Sloshed Fuel Tank 100 Hour Inspection in Section IX.
19. Refer to Section 4 of the Flight Manual/Pilot’s Operating Handbook for preflight and flight
check list.
20. Refer to Flight Manual/Pilot’s Operating Handbook Supplement for preflight and flight check
and for intended function in all modes.
21. If not accomplished already, create access panels for inspection (refer to Section IV, Paragraph
4-79). Inspect stabilator control cables.

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TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235

K. NOTES (CONT.)

22. In PA-28-140 S/N’s 28-20001 thru 28-7725290, PA-28-150, -160, -180 S/N’s 28-1 thru 28-4377,
PA-28-235 S/N’s 28-10001 thru 28-11039, for airplanes with the original equipment “butterfly”
control wheels still installed, perform the “Control Wheel 100 Hour Inspection.” on page III-84.
23. If the landing light is located in the air filter and the improved Landing Light Support P/N
85174-002 has not been installed, perform “Landing Light Seal Inspection” on page III-63.
24. In PA-28-140 S/N’s 28-20000 thru 28-26233, PA-28-150, -160, -180 S/N’s 28-1 thru 28-
5611, PA-28-235 S/N’s 28-10001 thru 28-11300, perform “Aileron Hinge Doubler 100 Hour
Inspection” on page III-85.
25. In PA-28-235 S/N’s 28-10001 thru 28-74100093, for airplanes which have not installed Piper
Kit No. 757-148 (with the 1-H65-2 valve) or 760-895: each 50 hours, perform the “Fuel Selector
Valve 50 Hour Leak Check” on page III-52.
26. For airplanes which are not equipped with forged main landing gear strut cylinders P/N
65489-002 on both left and right sides, perform “Cast Main Landing Gear Strut Cylinder 100
Hour Inspection.” on page III-72.
27. During inspection of throttle, determine if there is internal cable ballooning. If so, replace the
affected cables.
28. In airplanes with a rudder pedal and bar assembly or with a rudder bar support assembly, that has
1,200 hours or more time-in-service each 100 hours perform “Rudder Pedal And Bar Assembly
Inspection” and/or “Rudder Bar Support Assembly Inspection” on page III-90, as appropriate.
29. In PA-28-180 S/N’s 28-5153 thru 28-7405188 and PA-28-235 S/N’s 28-7310001 thru 28-
7410081; for those airplanes which have not installed Piper Kit No. 760-890 (PA-28-180) or
760-891 (PA-28-235): inspect throttle and mixture cable forward end balljoints for excessive
wear (see Figure 8-10a).
30. Not used.
31. Verify initial compliance with Piper Service Bulletin No. 886.
32. In PA-28-180 S/N’s 28-7105001 thru 28-7505046 and PA-28-235 S/N’s 28-7110001 thru 28-
7510016: inspect the quick-disconnect mechanism for each rear seat per “Rear Seat Quick
Disconnect Mechanism Inspection” on page III-94.
33. In PA-28-140 S/N’s 28-20001 thru 28-7725290, PA-28-150, -160 S/N’s 28-1 thru 28-4377, PA-
28-180 S/N’s 28-671 thru 28-7505259 and PA-28-235 S/N’s 28-10001 thru 28-7710089; for
those airplanes which have not installed Piper Kit No. 760-910 or a new greaser bolt P/N 79543-
002 and have accumulated 500 hours time-in-service: perform “Main Landing Gear Torque Link
Greaser Bolt Inspection” on page III-95.
34. Inspect magnetos:
(a) For airplanes equipped with Slick Magnetos: inspect magneto(s) per the appropriate 100
Hour Inspection in the Slick F1100 Master Service Manual.
(b) For airplanes equipped with Continental/Bendix Magnetos: inspect magneto(s) per the
procedures in the Periodic Maintenance section of the applicable Service Support Manual.

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TABLE III-I
INSPECTION REPORT - PA-28-140/150/160/180/235

K. NOTES (CONT.)

35. For airplanes equipped with Parker Hannifin / Airborne vacuum pump(s), verify compliance with
Parker Hannifin / Airborne Service Letter No. 72.

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Table III-II
INSPECTION REPORT - PA-28R-180/200
Refer to Notes 1, 2, 3, and 4 before performing the following inspections.
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100
A. PROPELLER GROUP
WARNING: USE EXTREME CAUTION WHEN ROTATING PROPELLER BY
HAND; PROPELLER MAY KICK BACK. PRIOR TO ROTATING
PROPELLER ENSURE BOTH MAGNETO SWITCH(S) ARE
OFF (GROUNDED). IF MAGNETO(S) ARE NOT GROUNDED,
TURNING PROPELLER MAY START ENGINE.
1. Inspect spinner and back plate for cracks, dents, missing screws,
and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
2. Inspect blades for nicks and cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
3. Inspect for grease and oil leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
4. Lubricate propeller per Lubrication Chart, Section II . . . . . . . . . . . . . . . . . . . . . O
5. Inspect spinner mounting brackets for cracks and security . . . . . . . . . . . . . . . . . O
6. Inspect propeller mounting bolts for condition and security.
If safety is broken, re-torque and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
7. Inspect hub parts for cracks and corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

8. Inspect complete propeller and spinner assembly for security, chafing, cracks,
deterioration, wear, and correct installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
B. ENGINE GROUP
WARNING: IF MAGNETO(S) ARE NOT GROUNDED, TURNING PROPELLER
MAY START ENGINE. USE EXTREME CAUTION WHEN
ROTATING PROPELLER BY HAND; PROPELLER MAY KICK
BACK. PRIOR TO ROTATING PROPELLER ENSURE BOTH
MAGNETO SWITCHES ARE OFF (GROUNDED).
NOTE: Read Note 5 prior to completing this group.
1. Remove engine cowling and inspect for internal and external damage . . . . . . . . O O
2. Clean and inspect cowling for cracks, distortion, and loose
or missing fasteners. (See Note 6.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
3. Drain oil sump. (See Note 8.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
4. Clean suction oil strainer at oil change; inspect strainer for foreign particles . . . O O
5. Clean pressure oil strainer or change full-flow (cartridge-type) oil filter element.
Inspect strainer or element for foreign particles . . . . . . . . . . . . . . . . . . . . . . . . . . O O
6. Inspect oil temperature sender unit for leaks and security . . . . . . . . . . . . . . . . . . O
7. Inspect oil lines and fittings for leaks, security, chafing, dents, and cracks . . . . . O O
8. Clean and inspect oil radiator cooling fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
9. Fill engine with oil per information on cowling or in Lubrication Chart,
Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

B. ENGINE GROUP (CONT.)

CAUTION: DO NOT CONTAMINATE VACUUM PUMP WITH CLEANING
FLUID.
10. Clean engine with approved solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
11. Inspect condition of spark plugs. Clean and adjust gap as required; adjust
per latest revision of Lycoming Service Instruction No. 1042 . . . . . . . . . . . . . . . O
NOTE: If fouling of spark plugs is apparent, rotate bottom plugs to upper plugs.
12. Inspect spark plug cable leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
13. Test cylinder compression. (Refer to AC 43.13-1, latest revision.) . . . . . . . . . . . O
14. Inspect cylinders for cracked or broken fins. (See Note 10.) . . . . . . . . . . . . . . . . O
15. Inspect rocker box covers for evidence of oil leaks. If found, replace gasket;
torque cover screws 50 inch-pounds. (See Note 10.) . . . . . . . . . . . . . . . . . . . . . . O O
16. Inspect ignition harness and insulators for high tension leakage
and continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

17. Inspect magneto for oil seal leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

18. Inspect magnetos to engine timing. (See Note “33” on page III-36.) . . . . . . . . . . O
19. Remove air filter and clean per Section II. Replace as required . . . . . . . . . . . . . O O
20. Clean fuel injector inlet line screen. (Clean injector nozzles
as required.) (Clean with acetone only.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
21. Inspect induction alternate air door and box for condition and operation
per 50 and 100 hour Inspections, Alternate Air Door, Section VIIIA . . . . . . . . . O O
22. Check throttle body attaching screws for tightness.
(Correct torque is 40–50 in·lbs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
23. Inspect vent lines for evidence of fuel or oil seepage . . . . . . . . . . . . . . . . . . . . . O O
24. Inspect intake seals for leaks and clamps for tightness.
(Torque clamps 40–50 in·lbs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
25. Inspect all induction air and alternate heat ducts per
“Induction Air Inlet Duct And Alternate Heat Duct Inspection” on page III-57.
(See Note 7.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
26. Inspect condition of flexible fuel lines. Replace as required . . . . . . . . . . . . . . . . O
27. Inspect fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
28. Inspect engine-driven and electric fuel pumps for condition and operation.
Replace as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
29. Clean screens in electric fuel pump(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
30. Clean gascolator bowl and screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
31. Inspect and operationally test engine-driven vacuum pumps and lines.
(See Note “34” on page III-36.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

B. ENGINE GROUP (CONT.)

32. Inspect throttle, alternate air, mixture, and propeller governor controls
for security, travel, and operating condition. (See Note 29.) . . . . . . . . . . . . . . . . O
33. Inspect exhaust stacks, connections and gaskets per
“Exhaust System Inspection” on page III-79. Replace gaskets as required . . . . . O O
34. Inspect muffler, heat exchange and baffles per
“Exhaust System Inspection” on page III-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
35. Inspect breather tube for obstructions and security . . . . . . . . . . . . . . . . . . . . . . . O
36. Inspect crankcase for cracks, leaks, and security of seam bolts . . . . . . . . . . . . . . O
37. Inspect engine mounts for cracks and loose mountings . . . . . . . . . . . . . . . . . . . . O
38. Inspect all engine baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
39. Inspect engine compartment wiring for condition (chafing, cracked insulation,
general deterioration), security, proper routing, and correct installation . . . . . . . O
40. Inspect rubber engine mount bushings for deterioration. Replace as required . . O
41. Inspect firewall seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
42. If installed, lubricate idler pulley; remove front grease seal and
add grease per Lubrication Chart, Section II. Disregard if sealed bearing
is installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
43. Inspect condition of alternator and starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
44. Inspect security of alternator and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
45. Inspect condition and tension of alternator drive belt. (See Checking Generator
or Alternator Belt Tension in Section XI.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
46. If installed, inspect condition of air conditioning (A/C) compressor belt and
tension. (See Adjustment of Drive Belt Tension in Section XIV.) . . . . . . . . . . . . O O
47. If installed, check A/C compressor oil level. (See Note 12.) . . . . . . . . . . . . . . . . O
48. If installed, inspect A/C compressor clutch security and wiring. (See Note 13.) . O
49. If installed, inspect A/C compressor mounting for cracks, corrosion and security . . O
50. Check fluid in brake reservoir. Fill as required . . . . . . . . . . . . . . . . . . . . . . . . . . O O
51. Inspect and lubricate all controls per Lubrication Chart, Section II. . . . . . . . . . . O
52. Install engine cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
C. CABIN AND COCKPIT GROUP
1. Inspect cabin door latch and hinges, and windows, for damage, operation,
and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
2. Inspect windows for scratches, crazing, and condition . . . . . . . . . . . . . . . . . . . . O
3. Inspect window and door seals for deterioration, cracks, and voids . . . . . . . . . . O
4. Inspect upholstery for tears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
5. Inspect seats and attaching brackets and hardware for condition,
security and operation. (See Note 32.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
6. Inspect seat belts and shoulder harnesses per Restraint System in Section XIV . O
7. Inspect trim control operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

C. CABIN AND COCKPIT GROUP (CONT.)

8. Inspect condition and operation of rudder pedals and rudder bar assembly.
(See Note 28.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
9. Inspect parking brake and brake handle for operation and cylinder leaks . . . . . . O
10. Inspect control wheels, column, pulleys, cables, and fittings. (See Note 14.) . . . O
11. Perform “Flap Control Cable Attachment Bolt Inspection.” on page III-65.
(See Note 14.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
12. Inspect landing, navigation, strobe, cabin, and instrument lights . . . . . . . . . . . . O O
13. Inspect instruments, avionics, lines, and attachments . . . . . . . . . . . . . . . . . . . . . O
14. Inspect gyro operated instruments and electric turn and bank.
(Overhaul or replace as required.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
15. Cycle each circuit breaker with airplane power off . . . . . . . . . . . . . . . . . . . . . . . . O O
16. If equipped, replace filters on the gyro horizon and directional gyro . . . . . . . . . . O
17. If installed, replace vacuum regulator filter element . . . . . . . . . . . . . . . . . . . . . . O
18. Inspect static system, altimeter and transponder for installation/certification
per latest revision of AC 43.13-1 and current test/inspection per
FAR’s 91.411 and 91.413, respectively . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

19. Inspect operation of fuel selector valve. (See Note 15.) . . . . . . . . . . . . . . . . . . . . O

20. Inspect fuel valve drain lever cover for security. Verify door opens
and closes freely and prevents operation of lever when closed . . . . . . . . . . . . . . O O
21. Inspect condition of heater controls and ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . O
22. Inspect condition and operation of air vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
23. If installed, inspect condition of air conditioning ducts . . . . . . . . . . . . . . . . . . . . O
24. If installed, remove and clean air conditioning evaporator filter . . . . . . . . . . . . . O
25. If installed, inspect disposable-type (non-gauged) fire extinguisher minimum
weight as specified on nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
D. FUSELAGE AND EMPENNAGE GROUP
1. Remove inspection plates and access panels. (See Figure 2-28.) . . . . . . . . . . . . O
2. Inspect forward wing attach fittings for condition and security . . . . . . . . . . . . . . O
3. Inspect aft wing attach fittings per
“Aft Wing Attach Fittings 100 Hour Inspection.” on page III-66 . . . . . . . . . . . . . O
4. Inspect baggage door, latch and hinges for damage, operation and security . . . . O O
5. Inspect battery, box and cables. Clean and flush area as required and fill battery
per instructions on box and in Electrical System, Section XI . . . . . . . . . . . . . . . O O
6. Conduct a general visual inspection of electrical and electronic installations
(mounting, wiring, harnesses, shields, connectors, etc.) for
condition and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
7. Inspect skins, bulkheads, frames, and stringers for damage, irregularities,
or structural defects (i.e., skin cracks, distortion, dents, corrosion,
and loose or missing rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

D. FUSELAGE AND EMPENNAGE GROUP (CONT.)

8. Inspect condition and security of antenna mounts and electric wiring . . . . . . . . O
9. If installed, inspect air conditioning system for refrigerant leaks.
(See Note 12.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
10. If installed, inspect refrigerant level in sight gauge of receiver-dehydrator.
Refer to Section XIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
11. If installed, inspect air conditioner condenser air scoop for condition and rigging.
(See Note 16.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
12. Inspect fuel lines, valves and gauges for damage and operation . . . . . . . . . . . . . O
13. Inspect security of all lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
14. Inspect vertical fin for surface damage or irregularities (i.e., skin cracks,
distortion, dents, and corrosion); structural defects (i.e., loose or missing
rivets); misrigging; hinge damage, excessive wear, and proper lubrication;
and attachment points for missing, damaged or worn hardware . . . . . . . . . . . . . O
15. Inspect vertical fin attachments for security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
16. Inspect rudder for surface damage or irregularities (i.e., skin cracks, distortion,
dents, and corrosion); structural defects (i.e., loose or missing rivets);
misrigging; hinge damage, excessive wear, freedom of movement and proper
lubrication; and attachment points for missing, damaged or worn hardware . . . . O
17. Inspect rudder hinges, horn and attachments for damage, security,
and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
18. Inspect rudder control stops to ensure stops have not loosened
and locknuts are tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
19. Inspect rudder hinge bolts for excess wear. Replace as required . . . . . . . . . . . . . O
20. Inspect stabilator and trim tab for surface damage or irregularities (i.e., skin
cracks, distortion, dents, and corrosion); structural defects (i.e., loose or
missing rivets); misrigging; hinge damage, excessive wear, freedom of
movement and proper lubrication; and attachment points for missing, damaged
or worn hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
21. Inspect stabilator trim tab hinges, horn, and attachments for damage,
security and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
22. Inspect stabilator attachments per
“Stabilator Attach Fittings Corrosion Inspection” on page III-64 . . . . . . . . . . . . O
23. Inspect stabilator and trim tab hinge bolts, pins, and bearings for excess wear.
Replace as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
24. Inspect stabilator control stops to ensure stops are not loose. Ensure bolts and
locknuts are tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
25. Inspect aileron, rudder, stabilator, and stabilator trim cables and pulleys for
safety, condition, and operation. Inspect cable terminals, turnbuckles, guides,
and fittings for safety and condition. (See Notes 14 and 21.) . . . . . . . . . . . . . . . O

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

D. FUSELAGE AND EMPENNAGE GROUP (CONT.)

26. Inspect rudder, stabilator, and stabilator trim cable tension per
Table V-II. Use a tensiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
27. Lubricate per Lubrication Chart in Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
28. Inspect anti-collision light for security and operation . . . . . . . . . . . . . . . . . . . . . O O
29. If installed, inspect security of autopilot servo bridle cable clamps.
(See Note 14.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
30. Inspect all non-flight control cables, air ducts, electrical leads, harnesses, lines,
radio antenna leads, and attaching parts for: security, routing, chafing,
deterioration, wear, and correct installation. (See Note 14.) . . . . . . . . . . . . . . . . O
31. Inspect ELT battery and mount for condition and security . . . . . . . . . . . . . . . . . O
32. Inspect ELT and antenna installation for condition and security.
Replace antenna if bent or damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
33. If equipped and airplane is used for training, inspect Prestolite hydraulic pump
motor brushes. (See Notes 22 and 23.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
34. Inspect hydraulic pump fluid level. Fill as required . . . . . . . . . . . . . . . . . . . . . . . O O
35. Inspect hydraulic pump lines for damage and leaks . . . . . . . . . . . . . . . . . . . . . . . O
36. If installed, inspect for obstructions and contamination in inlet of backup
landing gear extender actuator inlet head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
37. Install inspection plates and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
E. WING GROUP
1. Remove inspection plates and fairings. (See Figure 2-28.) . . . . . . . . . . . . . . . . . . O
2. Inspect exterior surfaces, skins, and tips for damage and loose or
missing fasteners, and condition of walk-way . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
3. Inspect visible interior structural components (skins, spars, ribs, stringers, etc.)
for condition, security, distortion, or failure. (See Note 24.) . . . . . . . . . . . . . . . . O
4. Inspect wing carry-through structure for condition, security, distortion, or
failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
5. Inspect ailerons for surface damage or irregularities (i.e., skin cracks,
distortion, dents, and corrosion); structural defects (i.e., loose or missing
rivets); misrigging; hinge damage, excessive wear, freedom of movement
and proper lubrication; and attachment points for missing, damaged or
worn hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
6. Inspect aileron hinges, attachments, balance weight and arm for security
and condition. (See Note 25.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
7. Inspect aileron control stops to ensure stops have not loosened and
locknuts are tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
8. Inspect aileron cables, pulleys, and bellcranks for safety, condition, and
operation. Inspect cable terminals, turnbuckles, guides, and fittings for safety
and condition. (See Note 14.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

E. WING GROUP (CONT.)

9. Inspect aileron cable tension per Table V-II. Use a tensiometer. . . . . . . . . . . . . . . O
10. Inspect pitot tube for damage and condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
CAUTION: SEVERE BURNS CAN RESULT FROM COMING IN CONTACT
WITH A HEATED PITOT TUBE.
11. Check pitot heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
12. Inspect flaps for surface damage or irregularities (i.e., skin cracks, distortion,
dents, and corrosion); structural defects (i.e., loose or missing rivets);
misrigging; hinge damage, excessive wear, freedom of movement and proper
lubrication; and attachment points for missing, damaged or worn hardware . . . O
13. Inspect condition of flap hinge bolts. Replace as required . . . . . . . . . . . . . . . . . . O
14. Lubricate per Lubrication Chart in Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
15. Inspect wing fore and aft attach fittings, and bolts for security, corrosion
and condition. (See Note 31.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
16. Retorque wing aft spar attach bolts per Wing Aft Spar-to-Fuselage Attachment
Hardware 100 Hour Inspection on page “III-96”. . . . . . . . . . . . . . . . . . . . . . . . . . O
17. Inspect fuel tanks and lines for leaks and water. (See Note 18.) . . . . . . . . . . . . . O
18. Inspect fuel caps, cap gaskets, fuel filler neck, fuel gage transmitter gaskets,
gage transmitter access covers, and upper surface inspection covers for
condition, proper sealing, security, alignment, etc. Ensure to service and clean
these areas, replacing parts as necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
19. Inspect the interior of metal fuel tanks for signs of corrosion, which may
indicate water contamination. If signs of contamination are found, alert the
owner and fuel supplier of your findings for corrective action . . . . . . . . . . . . . . . O
20. Fuel tanks marked for capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
21. Inspect fuel tanks for minimum octane markings . . . . . . . . . . . . . . . . . . . . . . . . O
22. Inspect fuel tank vents clear of obstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
23. Inspect all non-flight control cables, air ducts, electrical leads, lines, and
attaching parts for security, routing, chafing, deterioration, wear, and correct
installation. (See Note 14.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
24. Install inspection plates and fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

F. LANDING GEAR GROUP

1. Check oleo struts for proper extension and evidence of fluid leakage.
See Landing Gear, Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
2. Inspect nose gear steering control and travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
3. Inspect wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
4. Put airplane on jacks. (Refer to Section II.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
5. Inspect tires for cuts, uneven or excessive wear, and slippage . . . . . . . . . . . . . . . O
6. Remove wheels; clean, inspect, and repack bearings . . . . . . . . . . . . . . . . . . . . . . O
7. Inspect wheels for cracks, corrosion, and broken bolts . . . . . . . . . . . . . . . . . . . . O
8. Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
9. Inspect brake linings and discs for condition and wear . . . . . . . . . . . . . . . . . . . . O
10. Inspect brake backing plates for condition and wear . . . . . . . . . . . . . . . . . . . . . . O
11. Inspect brake and hydraulic lines for condition and security . . . . . . . . . . . . . . . . O
12. Inspect shimmy dampener operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
13. Inspect gear forks for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
14. Inspect oleo struts for fluid leaks and scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
15. Inspect gear struts, attachments, torque links, retraction links, and bolts
for condition and security. (See Note 26.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
16. Inspect downlock for operation and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . O
17. Inspect torque link bolts and bushings. Rebush as required . . . . . . . . . . . . . . . . . O
18. Inspect drag and side brace link bolts. Replace as required . . . . . . . . . . . . . . . . . O
19. Inspect gear doors and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
20. Inspect warning horn and light for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
21. Retract gear, check operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
22. Retract gear, check doors for clearance and operation . . . . . . . . . . . . . . . . . . . . . O
23. Inspect anti-retraction system squat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
24. Inspect actuating cylinders for leaks and security . . . . . . . . . . . . . . . . . . . . . . . . O
25. Inspect hydraulic lines, electrical leads, and attaching parts for condition
and security (i.e., routing, chafing, damage, wear, etc.) . . . . . . . . . . . . . . . . . . . . O
26. Inspect position indicator switch and electrical leads for security . . . . . . . . . . . . O
27. Lubricate per Lubrication Chart in Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
28. Remove airplane from jacks. (Refer to Section II.) . . . . . . . . . . . . . . . . . . . . . . . . O
G. SPECIAL INSPECTIONS
Review inspections in Special Inspections, “Requirements” on page III-37. Perform
all special inspections applicable to your aircraft and currently due per the given
inspection interval.

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

H. OPERATIONAL INSPECTION
NOTE: Refer to Note 19 prior to starting engine or taxiing airplane.
1. Inspect fuel pump and fuel tank selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
2. Inspect fuel quantity, pressure, and flow readings . . . . . . . . . . . . . . . . . . . . . . . . O O
3. Inspect oil pressure and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
4. Inspect alternator output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
5. Inspect manifold pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
6. Inspect alternate air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
7. Inspect parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
8. Inspect vacuum gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
9. Inspect gyros for noise and roughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
10. Inspect cabin heater operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
11. Inspect magneto switch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
12. Inspect magneto RPM variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
13. Inspect throttle and mixture operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
14. Inspect propeller smoothness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
15. Inspect propeller governor action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
16. Inspect engine idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
17. Inspect electronic equipment operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
18. If installed, inspect operation of autopilot, including automatic pitch trim,
and manual electric trim. (See Note 20.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
19. If installed, inspect air conditioner compressor clutch operation . . . . . . . . . . . . . O O
20. If installed, inspect air conditioner condenser scoop operation . . . . . . . . . . . . . . O O
21. Inspect free and correct operation of flight controls . . . . . . . . . . . . . . . . . . . . . . . . O O
22. Inspect (by flying the airplane) the Landing Gear System. (See Note 27.) . . . . . O O
I. GENERAL
1. Aircraft conforms to FAA Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
2. Latest revision of applicable FAA Airworthiness Directives complied with . . . . O O

3. Current and correct Pilot’s Operating Manual (POM) and/or Airplane Flight
Manual (AFM) is in the airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
4. Inspect airplane for required placards as identified in
the Limitations section of the AFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
5. Appropriate entries made in the Aircraft and Engine Log books . . . . . . . . . . . . . O O
6. Airworthiness & Registration Certificates in the aircraft and properly displayed . . O O
7. Aircraft Equipment List, Weight and Balance and FAA Form(s) 337
(if applicable) are in the aircraft and in proper order . . . . . . . . . . . . . . . . . . . . . . O O
8. Operational inspection and run-up completed . . . . . . . . . . . . . . . . . . . . . . . . . . . O O
9. Aircraft cleaned and lubricated after wash (as required) . . . . . . . . . . . . . . . . . . . O O

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200
Inspection
NATURE OF INSPECTION Interval (Hrs)
50 100

J. NOTES
1. Refer to Piper’s Customer Service Information File (see Availability under Revision Status on
page iii) for latest revision dates to Piper Inspection Reports/Manuals and this service manual.
References to Section are to the appropriate Section in this manual.
WARNING: INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) FOR ALL
NON-PIPER APPROVED STC INSTALLATIONS ARE NOT INCLUDED IN
THIS MANUAL. WHEN A NON-PIPER APPROVED STC INSTALLATION
IS INCORPORATED ON THE AIRPLANE, THOSE PORTIONS OF THE
AIRPLANE AFFECTED BY THE INSTALLATION MUST BE INSPECTED
IN ACCORDANCE WITH THE ICA PUBLISHED BY THE OWNER OF
THE STC. SINCE NON-PIPER APPROVED STC INSTALLATIONS MAY
CHANGE SYSTEMS INTERFACE, OPERATING CHARACTERISTICS AND
COMPONENT LOADS OR STRESSES ON ADJACENT STRUCTURES,
THE PIPER PROVIDED ICA MAY NOT BE VALID FOR AIRPLANES SO
MODIFIED.
2. Inspections or operations are to be performed as indicated by a “O” at the 50 or 100 hour inspection
interval. Inspections or operations (i.e., component overhauls/replacements, etc.) required outside
the 50 / 100 hour cycle are listed as “Special Inspections” on page III-37. Inspections must be
accomplished by persons authorized by the FAA or appropriate National Aviation Authority.
Checks may be performed by a pilot or owner who is checked out on the airplane.
(a) The 50 hour inspection accomplishes preventive maintenance, lubrication and servicing as
well as inspecting critical components.
(b) The 100 hour inspection is a complete inspection of the airplane, identical to an annual
inspection.
NOTE: A log book entry should be made upon completion of any inspections.
3. Piper Service Bulletins are of special importance and Piper considers compliance mandatory. In
all cases, see Service Bulletin/Service Letter Index P/N 762-332 to verify latest revision. See also
“Table III-III” on page III-105.
4. Piper Service Letters are product improvements and service hints pertaining to servicing the
airplane and should be given careful attention.
5. Inspections given for the power plant are based on the engine manufacturer’s operator’s
manual (Lycoming Part No. 60297-12) for these airplanes. Any changes issued to the engine
manufacturer’s operator’s manual shall supersede or supplement the inspections outlined in this
report.
6. Inspect teflon bushings and pins attaching top and bottom engine cowlings at nose for condition
and security. Replace as required.

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200

K. NOTES (CONT.)

7. In PA-28R-180 S/N’s 28R-30004 thru 28R-7130013; PA-28R-200 S/N’s 28R-35001 thru 28R-
7235077; for airplanes which have not installed Piper Kit No. 760-638V per Piper Service
Bulletin No. 360: conduct the “Induction Air Inlet Duct And Alternate Heat Duct Inspection” on
page III-57.
8. Refer to latest revision of Lycoming Service Bulletin No. 480 and Service Instruction 1014.
9. Not used.
10. Check cylinders for evidence of excessive heat indicated by burned paint on the cylinders.
This condition is indicative of internal damage to the cylinder and, if found, its cause must be
determined and corrected before the airplane is returned to service. Heavy discoloration and
appearance of seepage at the cylinder head and barrel attachment area is usually due to emission
of thread lubricant used during assembly of the barrel at the factory, or by slight gas leakage
which stops after the cylinder has been in service for a while. This condition is neither harmful
nor detrimental to engine performance and operation. If it can be proven that leakage exceeds
these conditions, the cylinder must be replaced.
11. Not used.
CAUTION: ENVIRONMENTAL REGULATIONS MAY REQUIRE SPECIAL EQUIPMENT
AND PROCEDURES BE USED WHEN CHARGING AIR CONDITIONING
SYSTEMS.
12. The compressor oil level should not be checked unless a refrigerant leak has occurred or system
pressure has been released, requiring an addition of refrigerant to the system.
13. Clean any traces of oil from the clutch surface.
14. Examine cables for broken strands by wiping them with a cloth for their entire length. Visually
inspect the cable thoroughly for damage not detected by the cloth. Replace any damaged or
frayed cables.
(a) See “Control Cable Inspection.” on page III-74, or the latest edition of FAA AC 43.13-1.
(b) At fifteen (15) years time-in-service, begin Cable Fittings “100 Hour Special Inspection”
on page III-77.
15. In PA-28R-180 S/N’s 28R-30001 thru 28R-7130007 and PA-28R-200 S/N’s 28R-35001 thru
28R-7135163: if fuel selector valve is difficult to rotate, inspect and lubricate valve per “Fuel
Selector Valve 400 Hour Inspection” on page III-55.
16. Refer to Section XIV (Paragraphs 14-31 through 14-35) for condenser assembly rigging and
adjustment.
17. Not used.
18. Sloshing of fuel tanks not approved. For airplanes with fuel tanks which have previously been
sloshed, perform Sloshed Fuel Tank 100 Hour Inspection in Section IX.
19. Refer to Section 4 of the Flight Manual/Pilot’s Operating Handbook for preflight and flight
check list.
20. Refer to Pilot’s Operating Handbook Supplement for preflight and flight check and for intended
function in all modes.

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TABLE III-II
INSPECTION REPORT - PA-28R-180/200

X. NOTES (CONT.)

21. If not already accomplished, create access panels for inspection (refer to Sec. IV, Para. 4-79).
Inspect stabilator control cables.
22. Refer to Section VI.
23. Inspection of hydraulic pump brushes applies only to Prestolite pumps. Replacement brushes are
no longer available. When the brushes wear out, replace pump with a new Oildyne pump.
24. Conduct the 100 Hour Standard Inspection under “Wing Rib Assembly W.S. 49.25 Inspections”
on page III-58.
25. In PA-28R-180 S/N’s 28R-30001 thru 28R-31250 and PA-28R-200 S/N’s 28R-30482, 28R-
35001 thru 28R-35390, perform “Aileron Hinge Doubler 100 Hour Inspection” on page III-85.
26. In PA-28R-180 S/N’s 28R-30005 thru 28R-7130007 and PA-28R-200 S/N’s 28R-35001 thru
28R-7135131; for airplanes equipped with original equipment trunnion assemblies P/N 67735-
00V (left) or P/N 67735-01V (right), which have been repaired per Piper Service Letter No. 616
or Main Landing Gear Trunnion Repair in Section VIIA, each 100 hours or annually, whichever
comes first, inspect repaired web area for cracks using a dye penetrant method.
27. Fly the airplane to check landing gear system in accordance with instructions given in Section
VI, Paragraph 6-16.
28. In airplanes with a rudder pedal and bar assembly, that has 1,200 hours or more time-in-service,
each 100 hours perform “Rudder Pedal And Bar Assembly Inspection” on page III-90.
29. In PA-28R-180 S/N’s 28R-30737 thru 28R-7130013 and PA-28R-200 S/N’s 28R-35001 thru
28R-7435260; for those airplanes which have not installed Piper Kit No. 760-889 (PA-28R-180)
or 760-890 (PA-28R-200): inspect throttle and mixture cable forward end balljoints for excessive
wear (see Figure 8A-6a).
30. Not used.
31. Verify initial compliance with Piper Service Bulletin No. 886.
32. In PA-28R-180 S/N’s 28R-7130001 thru 28R-7130013 and PA-28R-200 S/N’s 28R-7135001
thru 28R-7535041: inspect the quick-disconnect mechanism for each rear seat per “Rear Seat
Quick Disconnect Mechanism Inspection” on page III-94.
33. Inspect magnetos:
(a) For airplanes equipped with Slick Magnetos: inspect magneto(s) per the appropriate 100
Hour Inspection in the Slick F1100 Master Service Manual.
(b) For airplanes equipped with Continental/Bendix Magnetos: inspect magneto(s) per the
procedures in the Periodic Maintenance section of the applicable Service Support Manual.
34. For airplanes equipped with Parker Hannifin / Airborne vacuum pump(s), verify compliance with
Parker Hannifin / Airborne Service Letter No. 72.

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8. Special Inspections
WARNING: F AILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN
SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER
AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE
INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.)
A. Requirements
The following inspections are in addition to those listed in Tables III-I and III-II. These inspections
are performed at intervals of:
Q Flight hours;
Q Calendar Year; or
Q the specific operation being conducted or the environment being operated in.
Unless otherwise indicated, these inspections are to be repeated at each occurrence of the specified
interval. Note that the items listed herein are guidelines based on past operating experience. Each
operator should closely monitor his own unique operating conditions/environment and react
accordingly to keep his aircraft airworthy.
NOTE: A log book entry should be made upon completion of any inspections.

(1) Per Flight Hour

(a) Before Each Flight
[ ] In PA-28-180 S/N’s 28-4378 thru 28-7105122; PA-28-235 S/N’s 28-11040 thru
28-7110011; PA-28R-180 S/N’s 28R-30005 thru 28R-7130005; PA-28R-200
S/N’s 28R-35001 thru 28R-7135102 for airplanes equipped with Manual Electric
Pitch Trim which have not installed Piper Kit No. 760-517V or 761-039, before
each flight conduct “Electric Trim Switch Inspection” on page III-48.
(b) Each 10 Hours
[ ] 1) In PA-28R-180 S/N’s 28R-30004 thru 28R-30478, for airplanes which have not
installed Piper Kit No. 760-328V per Piper Service Bulletin No. 297, each 10
hours time-in-service conduct “Air Induction Inlet Hose 10 Hour Inspection” on
page III-50.
[ ] 2) In PA-28R-180 S/N’s 28R-30479 thru 28R-31092; and, PA-28R-200 S/N’s 28R-
35000 thru 35256, less 28R-35238 and 28R-35252; for airplanes which have not
installed Piper Kit No. 760-334V per Piper SB No. 297, each 10 hours time-in-
service conduct “Air Induction Inlet Hose 10 Hour Inspection” on page III-50.

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(c) Each 25 Hours

[ ] 1) In PA-28R-180 S/N’s 28R-30001 thru 28R-31266, less 28R-31072, for airplanes
which have not installed Piper Kit No. 760-410V per Piper Service Bulletin
No. 309, each 25 hours time-in-service conduct “Spinner/Bulkhead 25 Hour
Inspection” on page III-51.
[ ] 2) In PA-28R-200 S/N’s 28R-35001 thru 28R-35713, less 28R-35699, 28R-35701,
28R-35703, 28R-35706, 28R-35707, 28R-35708, and 28R-35710; for airplanes
which have not installed Piper Kit No. 760-410V per Piper SB No. 309, each 25
hours time-in-service conduct “Spinner/Bulkhead 25 Hour Inspection” on page
III-51.
(d) Each 200 Hours
[ ] 1) For airplanes with wing flap(s) which have accumulated ten (10) years time-
in-service, conduct the following special inspection each 200 hours: Inspect
the interior of the wing flap for evidence of dissimilar metal corrosion where
aluminum sheet metal is in contact with steel flap brackets. Use a bore scope
or other suitable tool. Installation of a new wing flap will relieve this inspection
requirement until such time as the replacement wing flap reaches ten (10) years
time-in-service.
[ ] 2) In PA-28-140 S/N’s 28-20000 thru 28-7125334; PA-28-150/160/180 S/N’s 28-l
thru 28-7105126; PA-28-235 S/N’s 28-10001 thru 28-7110011; PA-28R-180
S/N’s 28R-30001 thru 28R-7130005; PA-28R-200 S/N’s 28R-30482 and
28R-35001 thru 28R-7135104; for airplanes with at least 500 hours time-in-
service and which have not installed Stabilator Balance Weight Tube P/N 69623-
002 or 69623-004 per Piper Service Letter No. 576, upon reaching 500 hours, and
each 200 hours time-in-service thereafter, conduct “Stabilator Balance Weight
Tube Assembly 200 Hour Inspection.” on page III-52.
(e) Each 400 Hours
[ ] 1) At every 400 hours of engine operation, remove the rocker box covers and
check for freedom of valve rockers when valves are closed. Look for evidence
of abnormal wear or broken parts in the area of the valve tips, valve keepers,
springs, and spring seats. If any indications are found, the cylinder and all of its
components must be removed (including the piston and connecting rod assembly)
and inspected for further damage. Replace any parts that do not conform with
limits shown in the latest revision for Lycoming Service Table of Limits SSP1776.
[ ] 2) In PA-28-140 S/N’s 28-20002 thru 28-26783 and 28-26945 thru 28-7125595; PA-
28-150/160/180 S/N’s 28-l thru 28-7105179; PA -28R-180 S/N’s 28R-30001 thru
28R-7130007; PA-28R-200 S/N’s 28R-35001 thru 28R-7135163; for airplanes
with the original equipment fuel selector valve (P/N 11383-004) still installed:
each 400 hours time-in-service, or annually, whichever comes first, conduct “Fuel
Selector Valve 400 Hour Inspection” on page III-55.

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(f) Each 500 Hours

[ ] 1) If installed, and airplanes is used for normal service (i.e., not training), inspect
brushes in Prestolite hydraulic pump every 500 hours time-in-service.

[ ] 2) For airplanes equipped with Slick Magnetos: inspect and clean magneto(s) per
500 Hour Inspection in the Slick F1100 Master Service Manual.
[ ] 3) For airplanes equipped with Continental/TCM/Bendix Magnetos: inspect and
clean magneto(s) per the procedures in the Periodic Maintenance section of the
applicable Service Support Manual.
[ ] 4) In PA-150/160/180 S/N’s 28-1761 and up, PA-28-235 and PA-28R-180/200
models: replace teflon bushings in nose of lower engine cowling.
[ ] 5) Clean and lubricate stabilator trim drum screw.
[ ] 6) For PA-28R-180 and -200, and for PA-28-235’s with optional constant speed
propeller: remove propeller; remove sludge from crankshaft. Clean any residual
sludge clinging to the exterior of propeller / crankshaft mating surfaces.
[ ] 7) In PA-28R-180/200 models only, for airplanes which have not installed Piper
Kits No. 767-397 (LH) and 767-398 (RH), conduct the 500 hour inspection under
“Wing Rib Assembly W.S. 49.25 Inspections” on page III-58.
[ ] 8) In PA-28R-180/200 models only, each 500 hours time-in-service inspect the nose
gear drag links and replace the nose gear drag link bolt and cotter pin per “Nose
Gear Drag Link 500 Hour Inspection and Bolt Replacement.” on page III-73.
[ ] 9) In PA-28-140 S/N’s 28-20001 thru 28-7225496, PA-28-150/160/180 S/N’s
28-03, 28-1 thru 28-7205293; and PA-28-235 S/N’s 28-10001 thru 28-7310001;
for airplanes with main landing gear torque links (P/N 65691-000) installed which
have accumulated 800 hours or more time-in-service: perform Main Landing Gear
Torque Link Inspection (see Procedures, below).
[ ] 10) In PA-28-140 S/N’s 28-20001 thru 28-7725290, PA-28-150/160 S/N’s 28-1
thru 28-4377, PA-28-180 S/N’s 28-671 thru 28-7505259, and PA-28-235 S/N’s
28-10001 thru 28-7710089; for those airplanes which have installed either Piper
Kit No. 760-910V or main landing gear torque link greaser bolt P/N 79543-
002: each 500 hours time-in-service, perform “Main Landing Gear Torque Link
Greaser Bolt Inspection” on page III-95.
[ ] 11) In PA-28-150/160/180 S/N’s 28-1 thru 28-90, 28-92 thru 28-365, 28-367 thru
28-764, 28-766 thru 28-886, 28-888 thru 28-1109, 28-1111 thru 28-1146,
28-1148 thru 28-1154, 28-1156 thru 28-1206, 28-1209 thru 28-1218, 28-1220
thru 28-1223, 28-1225 thru 28-1227, 28-1229, 28-1232, 28-1233, 28-1235
thru 28-1237, 28-1239 thru 28-1245, 28-1248 thru 28-1251, 28-1253, 28-1255
thru 28-1261, 28-1263 thru 28-1268, 28-1270, 28-1273, 28-1274, 28-1276 thru
28-1280, 28-1286, 28-1287, 28-1293, 28-1285, 28-1301 and 28-1303; for
airplanes which have not installed upper nose gear oleo bearing (P/N 452-419):
perform “Upper Nose Gear Oleo Bearing Inspection.” on page III-88.
[ ] 12) Lubricate per Lubrication Charts, Section II.

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(h) Each 500 Hours (cont.)

[ ] 13) If installed, replace the vacuum system inlet air filter (i.e., central air filter, gyro
filter, etc.) element each 500 hours time-in-service, annually, and at vacuum pump
replacement, whichever comes first.
(g) First 600 Hours
[ ] If equipped with Aero Accessories service replacement dry air pumps, beginning
at 600 hours time-in-service, and thereafter as specified, inspect vacuum pump
vane wear per latest revision of Aero Accesories SB-008.
(h) Each 800 Hours
[ ] 1) In PA-28-235 models only, for airplanes in “Usage Class B” (i.e., severe usage),
beginning at 1,800 hours total time-in-service, and each 800 hours thereafter,
conduct “Wing Spar Inspection” on page III-60.
[ ] 2) In PA-28-235 models only, for airplanes in “Usage Class C” (i.e., extreme usage),
conduct “Wing Spar Inspection” on page III-60.

NOTE: Instructions for determining “Usage Class” are included in the “Wing
Spar Inspection” on page III-60.
(i) Each 1000 Hours
[ ] 1) Replace engine compartment flexible fuel and oil hoses as required; but not to
exceed 1000 hours time-in-service, eight (8) years, or engine overhaul, whichever
comes first; except for TSO-C53a - Type D hoses which are replaced on-condition.
[ ] 2) Muffler replacement is recommended at or near 1000 hours time-in-service.

[ ] 3) In PA-28-150/160/180 S/N’s 28-1 thru 28-90, 28-92 thru 28-365, 28-367 thru
28-764, 28-766 thru 28-886, 28-888 thru 28-1109, 28-1111 thru 28-1146,
28-1148 thru 28-1154, 28-1156 thru 28-1206, 28-1209 thru 28-1218, 28-1220
thru 28-1223, 28-1225 thru 28-1227, 28-1229, 28-1232, 28-1233, 28-1235
thru 28-1237, 28-1239 thru 28-1245, 28-1248 thru 28-1251, 28-1253, 28-1255
thru 28-1261, 28-1263 thru 28-1268, 28-1270, 28-1273, 28-1274, 28-1276 thru
28-1280, 28-1286, 28-1287, 28-1293, 28-1285, 28-1301, and 28-1303; for
airplanes with sealed upper nose gear oleo bearing (P/N 452-419) installed; and
later PA-28-150/160/180/235 airplanes: inspect upper nose gear oleo bearing per
“Upper Nose Gear Oleo Bearing Inspection.” on page III-88.
(j) Each 1200 Hours
[ ] Overhaul engine at 1200 or 2000 hours time-in-service or per Lycoming Service
Instruction No. 1009, latest revision.

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(k) Each 1600 Hours

[ ] 1) In PA-28-140/150/160/180 and PA-28R-180/200 models in Usage Class “B” (i.e.,
severe usage), which have accumulated 3700 hours total time-in-service or 3700
hours factored time-in-service: conduct “Wing Spar Inspection” on page III-60.
[ ] 2) In PA-28-140/150/160/180 and PA-28R-180/200 models in Usage Class “C” (i.e.,
extreme usage), conduct “Wing Spar Inspection” on page III-60.

NOTE: Instructions for determining “Usage Class” are included in the “Wing
Spar Inspection” on page III-60.
(l) Each 2000 Hours
[ ] 1) Each 2000 hours or seven (7) years, whichever occurs first, remove interior panels
and headliner and conduct detailed inspection of aircraft structure (skin, bulkheads,
stringers, etc.) for condition and security. Inspection of structure concealed by
headliner may be accomplished by alternate means (i.e., through the use of a
borescope) without removing the headliner, providing access is obtained to all
concealed areas and borescope provides sufficient detail to adequately accomplish
the inspection. At F.S. 73, examine the two steel Upper Forward Cockpit Fittings
(one each side), P/N’s 79553-000/-001 or 62522-000/68257-000, as applicable,
for signs of corrosion.
[ ] 2) Overhaul engine at 1200 or 2000 hours time-in-service or per Lycoming Service
Instruction No. 1009, latest revision.
[ ] 3) At engine overhaul or each 2000 hours, whichever comes first, overhaul or replace
alternator.
[ ] 4) Recommended Time-Between-Overhaul (TBO) / Reconditioning of Sensenich
fixed-pitch metal propellers is 2000 hours, if propeller does not receive damage
requiring immediate attention. Airplanes in flight school operations or operating
from unpaved or poorly maintained runways may expose the propeller to increased
foreign object damage which will require a shorter interval between overhauls.
Reconditioning is removal of fatigued surface metal and accumulated small nicks
too numerous to repair individually. Contact a Sensenich factory approved repair
station. (Refer to latest revision of Sensenich Service Bulletin No. R17.)
[ ] 5) Overhaul McCauley fixed pitch propellers each 2000 hours or 72 calendar months
which ever occurs first; or per the latest revision of McCauley Service Bulletin
No. 137.
[ ] 6) Overhaul or replace Hartzell propellers each five or six years or each 2000 or 2400
hours. (Refer to latest revision of Hartzell Service Letter No. 61 to determine
specific requirements for individual engines.)
[ ] 7) Each 2,000 operating hours or seven (7) calendar years time-in-service, whichever
occurs first, conduct the Aft Wing Spar/Attach Fitting Inspection per the latest
revision of Piper Service Bulletin No. 1244.
[ ] 8) Each 2,000 operating hours or seven (7) calendar years time-in-service, whichever
occurs first, conduct the Stabilator Control System Inspection per the latest
revision of Piper Service Bulletin No. 1245.

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(m) Each 2400 Hours

[ ] 1) Overhaul or replace Hartzell propeller governors each 2400 hours or at engine
overhaul. (Verify TBO in latest revision of Hartzell Service Letter No. 61.)
[ ] 2) Overhaul or replace Hartzell propellers each five (5) or six (6) years or each
2000 or 2400 hours. (Refer to latest revision of Hartzell Service Letter No. 61 to
determine specific requirements for individual airplanes.)
(n) Each 3000 Hours
[ ] In PA-28-235 models only, for airplanes in “Usage Class A” (i.e., normal usage),
beginning at 30,600 hours total time-in-service, and each 3000 hours thereafter,
conduct “Wing Spar Inspection” on page III-60.

NOTE: Instructions for determining “Usage Class” are included in the Wing Spar
Inspection.
(o) Each 6000 Hours
[ ] In PA-28-140/150/160/180 and PA-28R-180/200 models, for airplanes in Usage
Class “A” (i.e., normal usage), which have accumulated 62,900 hours total time-
in-service: conduct “Wing Spar Inspection” on page III-60.

NOTE: Instructions for determining “Usage Class” are included in the Wing Spar
Inspection.

(2) Per Calendar Year

(a) Each Ninety (90) Days

[ ] 1) Inspect battery, box or shelf, and cables. Flush box as required and fill battery
per instructions on box and in Electrical System, Section XI. (Not required if
maintenance-free battery installed.)
[ ] 2) Remove, drain and clean fuel strainer bowl, located at the bottom of selector valve
on PA-28-235 models only. On PA-28-140/150/160/180 models only, remove
and clean fuel filter bowl and screen, at lower left side of firewall. Refer to Fuel
System, Section IX.
[ ] 3) For PA-28R-180/200 models only, clean gascolator bowl and screens.
(b) Each Four (4) Months
[ ] Change the engine oil and full-flow cartridge oil filter each four (4) months or
every 50 hours time-in-service, whichever comes first.
(c) Each Six (6) Months
[ ] If annual usage is significantly less than 100 Hours, lubricate Hartzell constant
speed propeller each six (6) months. See Hartzell Standard Practices Manual No.
202A.

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 PIPER CHEROKEE SERVICE MANUAL

(d) Each Twelve (12) Months

[ ] 1) Lubricate Hartzell constant speed propeller every 100 Hours or annually, whichever
comes first. If annual usage is significantly less than 100 Hours, lubricate propeller
each six (6) months. See Hartzell Standard Practices Manual No. 202A.
[ ] 2) In PA-28-140/150/160/180 models where the landing light is located in the air
filter; for those airplanes which have not installed the improved Landing Light
Support P/N 85174-002: each 100 hours or annually, whichever comes first,
conduct”Landing Light Seal Inspection” on page III-63.
[ ] 3) In PA-28-140 S/N’s 28-20002 thru 28-26783 and 28-26945 thru 28-7125595; PA-
28-150/160/180 S/N’s 28-l thru 28-7105179; PA -28R-180 S/N’s 28R-30001 thru
28R-7130007; PA-28R-200 S/N’s 28R-35001 thru 28R-7135163; for airplanes
using original equipment fuel selector valves P/N 11383-004: each 400 hours
time-in-service, or annually, whichever comes first, conduct “Fuel Selector Valve
400 Hour Inspection” on page III-55.
[ ] 4) If installed, replace the vacuum system inlet air filter (i.e., central air filter, gyro
filter, etc.) element each 500 hours time-in-service, annually, and at vacuum pump
replacement, whichever comes first.
[ ] 5) If equipped, each twelve (12) months, have the rechargeable (gauged) fire
extinguisher professionally inspected.
(e) Each Two (2) Years
[ ] 1) Test and inspect the static pressure system and altimeters. Ensure compliance with
the requirements of FAR 43, Appendix E. (See FAR 91.411.)
[ ] 2) Test and inspect the transponder. Ensure compliance with the requirements of
FAR 43, Appendix F. (See FAR 91.413.)
(f) Each Four (4) Years
[ ] For airplanes equipped with TCM/Bendix Magnetos: overhaul or replace TCM/
Bendix magnetos at engine overhaul, or each four (4) years time-in-service,
whichever comes first.
(g) Each Five (5) Years
[ ] Overhaul or replace Hartzell propellers each five or six years or each 2000 or 2400
hours. (Refer to latest revision of Hartzell Service Letter No. 61 to determine
specific requirements for individual airplanes.)
(h) Each Six (6) Years
[ ] 1) Overhaul McCauley fixed pitch propellers each 2000 hours or 72 calendar months
which ever occurs first. (Verify TBO in latest revision of McCauley Service
Bulletin No. 137.)
[ ] 2) Overhaul or replace Hartzell propellers each five or six years or each 2000 or 2400
hours. (Refer to latest revision of Hartzell Service Letter No. 61 to determine
specific requirements for individual airplanes.)
[ ] 3) For airplanes equipped with Aero Accessories, Inc. vacuum pump(s), replace the
shear coupling each six (6) years time-in-service.

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(h) Each Six (6) Years (cont.)

[ ] 4) For airplanes equipped with rechargeable (gauged) fire extinguishers, each
six years time-in-service, completely discharge the extinguisher and have it
professionally inspected and recharged.
(i) Each Seven (7) Years
[ ] 1) Each 2000 hours or seven (7) years, whichever occurs first, remove interior
cabinets, panels, and headliner and conduct detailed inspection of aircraft
structure (skin, bulkheads, stringers, etc.) for condition and security. Inspection
of structure concealed by headliner may be accomplished by alternate means
(i.e. – through the used of a bore scope) without removing the headliner, providing
access is obtained to all concealed areas and bore scope provides sufficient detail
to adequately accomplish the inspection. At F.S. 73, examine the two steel Upper
Forward Cockpit Fittings (one each side), P/N’s 79553-000/-001 or 62522-
000/68257-000, as applicable, for signs of corrosion.
[ ] 2) Each seven (7) years time-in-service, drain and remove the inboard metal fuel
tank from each wing and inspect for corrosion as specified in “Fuel Tank/Wing
Spar Corrosion Inspection.” on page III-70.
[ ] 3) Replace fuel tank flexible hose interconnect couplings and fuel tank vent line
flexible hose and hose couplings as required; but not to exceed seven (7) years or
fuel tank removal, whichever comes first.
[ ] 4) Each 2,000 operating hours or seven (7) calendar years time-in-service, whichever
occurs first, conduct the Aft Wing Spar/Attach Fitting Inspection per the latest
revision of Piper Service Bulletin No. 1244.
[ ] 5) Each 2,000 operating hours or seven (7) calendar years time-in-service, whichever
occurs first, conduct the Stabilator Control System Inspection per the latest
revision of Piper Service Bulletin No. 1245.
(j) Each Eight (8) Years
[ ] Replace engine compartment flexible fuel and oil hoses as required; but not to
exceed 1000 hours time-in-service, eight (8) years, or engine overhaul, whichever
comes first; except for TSO-C53a - Type D hoses which are replaced on-condition.
(k) Each Ten (10) Years
[ ] Each ten (10) years time-in-service, test fuselage and wing fluid hoses to system
pressure. Visually inspect for leaks. Hoses that pass inspection may remain in
service, but must be rechecked each five (5) years additional time-in-service. No
fluid hose may exceed twenty (20) years total time-in-service.

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 PIPER CHEROKEE SERVICE MANUAL

(l) Each Twelve (12) Years

[ ] 1) If equipped, replace disposable-type (non-gauged) fire extinguishers at twelve
(12) years from date of manufacture.
[ ] 2) If equipped, hydrostatically test rechargeable (gauged) fire extinguishers at each
twelve (12) years time-in-service.
[ ] 3) If equipped with a Hartzell Engine Technologies (formerly Kelly, Electrosystems,
Prestolite) alternator, each 2,000 Hours, Twelve (12) Years, or at engine overhaul,
whichever comes first: replace or overhaul the alternator.
(m) Each Twenty (20) Years
[ ] No fluid hose may exceed 20 years total time-in-service.

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(3) Per Specific Operation / Operating Environment

(a) Operation in High Dust or Industrial Pollution Environment
CAUTION: DISCONNECT LINES FROM PITOT/STATIC SYSTEM BEFORE CONDUCTING THIS
INSPECTION.
Item Inspection Inspection Interval
†† Engine Air Filter. Clean and inspect. Daily.
†† Cabin Environmental and Inspect and replace if necessary. 100 Hours.
Instrument Air Filters.
†† Pitot/Static system. Check for obstruction. Reverse 100 Hours or
flow to lines. as required.
†† Landing Gear Oleos Clean. Before each flight.

Inspect. 100 Hours.
†† Landing Gear Wheel Clean, inspect and repack. 50 Hours.
Bearings.
†† Windows. Inspect for cracks, erosion, crazing, Daily.
visibility, and cleanliness.
†† Structure drain holes. Clean with pipe cleaner. Before each flight.

(b) Operation in High Salt or High Humidity Environment

Item Inspection Inspection Interval
†† Fuselage, Empennage, Remove floor panels and exterior 200 Hours.
Wings, and Control Surfaces. access plates; inspect for corrosion
using a borescope or other suitable tool.
†† Landing Gear. Inspect for corrosion and lubrication. 200 Hours.
WARNING: ENSURE BOTH MAGNETO SWITCHES ARE OFF (GROUNDED), BEFORE TURNING
PROPELLER. ENGINE MAY START IF BOTH SWITCHES ARE NOT OFF. USE
EXTREME CAUTION WHEN ROTATING PROPELLER BY HAND; PROPELLER MAY
KICK BACK.
†† Engines with more than Each five days, pull prop through five Each 5 days
50 hours total time. complete revolutions. and
Each 30 days, fly aircraft for 30 minutes each 30 days.
or, ground run until oil temperature is in
the green arc. Avoid excessive ground run.
†† Engines with less than Each day, pull prop through five Daily
50 hours total time. complete revolutions. and
Each 30 days, fly aircraft for 30 minutes each 30 days.
or, ground run until oil temperature is in
the green arc. Avoid excessive ground run.

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(b) Operation in High Salt or High Humidity Environment (continued)

Item Inspection Inspection Interval
†† Instruments and Wiring. Inspect for proper seal of cases and 100 Hours.
corrosion.
†† Interior. Inspect upholstery, seat belts, seats and 100 Hours.
rugs for corrosion and integrity.
NOTE: Do not use metallic tie downs (i.e., chains, cables, etc.) in high salt or high humidity environments.

(c) Operation in Extreme Cold

Item Inspection Inspection Interval
†† Hydraulic, Pneumatic Check all fittings and attachments for First 100 Hour, then
and Environmental. security and leaks. as required.

(d) Operation from Soft or Unusual Terrain

Item Inspection Inspection Interval
†† Landing Gear. Inspect for cracks, attachment, 100 Hours.
damage, cleanliness and lubrication.
†† Wheels. Inspect for cracks, damage, chipped 100 Hours.
rims; bearings for damage, corrosion
and lubrication.
†† Tires. Inspect for cuts, wear, inflation and Daily.
deterioration.
†† Wheel Wells. Inspect for foreign material, damage 100 Hours.
and corrosion.
†† Brakes. Inspect for damage, foreign material, Daily.
cracks and overheating.
†† Flaps, Lower Fuselage Inspect for damage, cracks and 100 Hours.
and Wing. corrosion.

(e) At Engine Overhaul

Item Inspection Inspection Interval
†† Oil Cooler. Replace or overhaul at engine Each Occurrence.
overhaul.

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B. Procedures
(1) Electric Trim Switch Inspection
The following incorporates the recurring inspection requirements of Piper SB 332.
In PA-28-180s S/N’s 28-4378 thru 28-7105122; PA-28-235s S/N’s 28-11040 thru 28-7110011;
PA-28R-180s S/N’s 28R-30005 thru 28R-7130005; PA-28R-200s S/N’s 28R-35001 thru 28R-
7135102; for airplanes equipped with Manual Electric Pitch Trim which have not installed Piper
Kit No. 760-517V or 761-039, before each flight inspect the pilot’s control wheel mounted rocker
type trim switch for proper operation as follows:
NOTE: Installation of Piper Kit No. 760-517V or 761-039 relieves this repetitive inspection
requirement.
(a) Pre-flight Inspection.
1) Turn master switch “ON,” move rocker switch knob fore and aft, the trim tab indicator
should move in the appropriate direction.
2) When the switch is released at the fore or aft position, the switch should consistently
return to the “OFF” (neutral) position.
3) Should the switch not operate as described above, it must be replaced or disabled (see
below) before further flight.
4) To replace the switch, install Piper Kit No. 761-039.
(b) Disabling the Switch.
(c) Should a switch malfunction occur in a location where parts/service facilities are not available,
the aircraft may be flown to a service facility in the following temporary configuration:
1) Disengage the electric trim system, ensure the electric trim disengage switch is in the
“OFF” (out) position.
2) Prepare a temporary placard (as follows) and install in a conspicuous location in full
view of pilot on instrument panel.
“DO NOT ENGAGE ELECTRIC TRIM INOPERATIVE”
(d) Some airplanes with Piper Kit No. 760-517V installed may still experience the electric trim
switch sticking “ON” in either the fore or aft position. If so, the following modification will
remedy the problem.
NOTE: Installation of Piper Kit No. 761-039 will also remedy the problem by replacing the
switch entirely.
1) Obtain a new knob retaining rivet P/N 756-047 before beginning this modification.
2) Carefully remove placards from electric trim switch.
3) Remove two screws which secure the switch to the control wheel and remove switch.
4) Remove knob retaining rivet by filing peened or crimped head and carefully knocking
the rivet out.
5) Remove knob and spring from switch.

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6) Inspect spring to determine if coils consist of 2 l/4 turns or 2 l/2 turns.

a) If coils consist of 2 l/4 turns as shown in Figure 3-1, proceed to Step 7.
b) If coils consist of 2 l/2 turns, modify spring by cutting l/4 turn from top of coils
before proceeding. See Figure 3-1.
7) Place spring over micro-switch buttons with open ends of spring facing up. Spring
coils must be concentric with micro-switch buttons and shoulders, and must not rest
upon them.
8) Place knob in position and depress slightly so that the new retaining rivet (P/N
756-047) can be installed. Take care not to dislodge spring from position.
9) Test switch action.
10) Crimp or peen end of retaining rivet to retain.
11) Reinstall switch on control wheel with existing screws and cement placards to switch.
12) Make appropriate log book entry documenting this modification.

Figure 3-1
Electric Trim Switch Inspection

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(2) Air Induction Inlet Hose 10 Hour Inspection

NOTE: Installation of Piper Kit No. 760-328V or 760-334V, as appropriate, relieves this
inspection requirement.
(a) In PA-28R-180s S/N’s 28R-30004 thru 28R-30478, for airplanes which have not installed
Piper Kit No. 760-328V per Piper Service Bulletin No. 297, each 10 hours time-in-service
visually inspect the air induction inlet hose, P/N 63633-43 (Figure 3-2), for deterioration,
broken or frayed cord wrapping, evidence of hose partially collapsed, indication of
reinforcement wire slippage, or evidence of the wire not being bonded properly to the hose
interior wall, especially in the vicinity of Koroseal ties or clamps.
(b) In PA-28R-180s S/N’s 28R-30479 thru 28R-31092 and PA-28R-200s S/N’s 28R-35000 thru
35256, less 28R-35238 and 28R-35252; for airplanes which have not installed Piper Kit
No. 760-334V per Piper Service Bulletin No. 297, each 10 hours time-in-service visually
inspect the air induction inlet hose, P/N 63633-43 (Figure 3-2), for deterioration, broken
or frayed cord wrapping, evidence of hose partially collapsed, indication of reinforcement
wire slippage, or evidence of the wire not being bonded properly to the hose interior wall,
especially in the vicinity of Koroseal ties or clamps.
(c) If any of the above conditions are evident, install the appropriate kit before further flight.

Figure 3-2
Air Induction Inlet Hose Inspection

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(3) Spinner/Bulkhead 25 Hour Inspection

In PA-28R-180s S/N’s 28R-30001 thru 28R-31266, less 28R-31072; and
in PA-28R-200s S/N’s 28R-35001 thru 28R-35713, less 28R-35699, 28R-35701, 28R-35703,
28R-35706, 28R-35707, 28R-35708, and 28R-35710; for airplanes which have not installed Piper
Kit No. 760-410V per Piper Service Bulletin No. 309, each 25 hours time-in-service inspect the
spinner and spinner bulkhead as follows:
NOTE: Installation of Piper Kit No. 760-410V or removal of the spinner and spinner bulkhead
entirely relieve this inspection requirement.
(a) Remove spinner and inspect for cracks in the areas shown in Figure 3-3, Sketches A or B,
as appropriate.
(b) Inspect the spinner bulkhead for cracks in the area of the nut plates and attachment points as
shown in Figure 3-3, Sketches A or B, as appropriate.
(c) If no cracks are noted, spinner and bulkhead can be reinstalled and a log book entry made
indicating completion of this inspection.
(d) If cracks are noted, spinner and/or bulkhead must be removed from service.

Figure 3-3
Spinner and Spinner Bulkhead Inspection

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(4) Fuel Selector Valve 50 Hour Leak Check

The following incorporates the recurring inspection requirements of Piper SB 571A.
In PA-28-235s S/N’s 28-10001 thru 28-74100093; for airplanes which have not installed Piper
Kit No. 757-148 (with the 1-H65-2 valve) or 760-895: each 50 hours check the fuel selector
valve for internal leaks using the following procedure.
NOTE: This check can be performed by the pilot.
NOTE: Installation of Piper Kit No. 757-148 or 760-895 eliminates this repetitive inspection
requirement.
WARNING: OBSERVE ALL SAFETY PRECAUTIONS REQUIRED WHEN HANDLING
GASOLINE.
(a) Position aircraft on relatively level ground with a minimum of one (1) gallon in each tank.
Drain fuel tank sumps and fuel selector sump using normal preflight procedures.
(b) With fuel selector in the “OFF” position, drain fuel selector by operating drain lever through
the access panel located on the right side of the cabin on the forward edge of the wing spar
housing. Valve should be held “open” for one minute. Collect contents and discard.
NOTE: Because of residual fuel in the fuel selector sump bowl, several attempts may be
required to drain all fuel from the sump bowl, A leaking fuel valve is indicated by
continued draining when the fuel selector is in the “OFF” position. The volume of
this drainage depends on the size of the leak.
(c) Close drain valve and wait three minutes. Drain fuel selector for one minute, collecting
contents in a graduated container. Close drain valve. Contents collected must be less than
1/2 fluid ounce.
(d) If fuel collected exceeds one half fluid ounce, repeat step (c), above.
(e) If repeated collected fuel exceeds one half fluid ounce, an excessive internal leaking fuel
selector is indicated. Remove and clean the fuel selector valve or replace fuel valve with
Piper Kit No. 757-148 or 760-895 (see Parts Catalog, P/N 753-582).
(f) Make an appropriate log book entry documenting performance of this check.
(5) Stabilator Balance Weight Tube Assembly 200 Hour Inspection.
The following incorporates the recurring inspection requirements of Piper SB 327.
In PA-28-140s S/N’s 28-20000 thru 28-7125334; PA-28-150/160/180s S/N’s 28-l thru
28-7105126; PA-28-235s S/N’s 28-10001 thru 28-7110011; PA-28R-180s S/N’s 28R-30001 thru
28R-7130005; PA-28R-200s S/N’s 28R-30482 and 28R-35001 thru 28R-7135104; for airplanes
with at least 500 hours time-in-service and which have not installed Stabilator Balance Weight
Tube P/N 69623-002 or 69623-004 per Piper Service Letter No. 576, upon reaching 500 hours,
and each 200 hours time-in-service thereafter, inspect the Stabilator Balance Weight Tube
Assembly as follows:
NOTE: Installation of Stabilator Balance Weight Tube P/N 69623-002 or 69623-004 per Piper
Service Letter No. 576 relieves this repetitive inspection requirement as well as those of
AD 70-26-04.
(a) Remove tail cone assembly and bulkhead close out plate, if so equipped.

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Figure 3-4
Stabilator Balance Weight Tube Inspection

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(b) In the tail cone section, remove safeties from stabilator cable turnbuckles and release cable
tension.
(c) Disconnect stabilator cables at the balance weight tube assembly.
NOTE: Do not misplace the bushing fitted in the tube/cable attachment lugs.
(d) Remove the stabilator balance weight tube assembly attachment bolts as shown in Figure
3-4 and inspect bolts for wear.
(e) Pull stabilator balance weight tube assembly forward and remove from stabilator. (Removing
balance weight from tube is not required.)
CAUTION: USE ANY COMMERCIAL PAINT REMOVER OR CAUSTIC SODA TO
REMOVE PAINT; WASH PART IN GASOLINE TO REMOVE ANY WAX.
(f) Remove paint from balance weight tube in areas of the stabilator attachment bolt holes.
(g) Using a dye penetrant method, inspect tube for cracks in the areas of the stabilator attachment
bolt holes.
1) Should cracks be detected, replace balance weight tube assembly per Piper Service
Letter No. 576.
2) If cracks are not detected, prime tube with zinc chromate primer equivalent and paint
with flat black enamel prior to reinstallation.
NOTE: Installation of a new Stabilator Balance Weight Tube P/N 69623-002 or
69623-004 per Piper Service Letter No. 576 relieves this repetitive inspection
requirement as well as those of AD 70-26-04.
(h) Inspect stabilator mounting points for possible stabilator side movement. Should side
movement be evident, install combination of AN960-0416L (P/N 407-585) and AN960-
416 (P/N 407-565) washers, as many as necessary to center the stabilator assembly and
eliminate any side movement.
(i) Visually inspect stabilator fittings (P/N 63567-03) for evidence of cracks and/or loose rivets
as shown in Figure 3-4.
1) Should the fitting(s) be cracked, replace with new stabilator fitting(s), P/N 63567-03.
2) Remove loose rivets and replace with new rivets.
(j) Install stabilator balance weight tube assembly and stabilator fittings. Install and tighten
bolts (forward bolt should be installed first for ease).
CAUTION: ENSURE BUSHINGS ARE INSTALLED IN TUBE LUGS BEFORE
ATTACHING CABLE ENDS AND BOLTS. INSTALL WASHER, NUT AND
COTTER PIN.
(k) Attach stabilator control cables to tube assembly.
(l) Tighten cable turnbuckles to acquire cable tension 40 plus or minus 5 pounds. Install
turnbuckle safety clips.
(m) Actuate stabilator controls to ensure freedom of movement and that stabilator contacts both
upper and lower stops.
(n) Install bulkhead close out plate and tail cone assembly.
(o) Make appropriate log book entry documenting completion of this inspection and installation
of any parts installed.

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(6) Fuel Selector Valve 400 Hour Inspection

The following incorporates the recurring inspection requirements of Piper SB 355.
In PA-28-140 S/N’s 28-20002 thru 28-26783 and 28-26945 thru 28-7125595; PA-28-150/160/180
S/N’s 28-l thru 28-7105179; PA-28R-180 S/N’s 28R-30001 thru 28R-7130007; and PA-28R-200
S/N’s 28R-35001 thru 28R-7135163; for airplanes with the original equipment fuel selector
valve still installed: each 400 hours time-in-service, annually, or whenever the selector is difficult
to rotate, inspect and lubricate the fuel selector valve (P/N 11383-004) as follows:
NOTE: The tapered plug cock is subject to binding or “freezing” unless properly lubricated.
Binding is typically caused by (1) fuel coming in contact with the plug cock and gradually
dissolving the film of lubricant, (2) presence of foreign material, and (3) hardened or
congealed lubricants (usually, wrong type).
(a) With the valve removed from the aircraft, remove the valve cap and interior parts (see Figure
3-5).
(b) Inspect position washer to ascertain that it will not allow the valve to rotate beyond its stop
positions. Also, inspect position washer inner perimeter surface for indications of extreme
wear; should this be evident, replace position washer (P/N 756-645).
(c) Check condition of plug cock and valve body for scored surfaces. The surfaces, if not badly
scored, may be reconditioned by lapping with a fine grinding compound. Clean away all
compound after lapping. If plug cock will not seat properly or if scoring remains evident,
replace valve.
(d) Check condition of valve stem in the area where the “0” ring seats. Should the stem be worn
or damaged so that the “0” ring will not seal, replace valve.
(e) With a 10X magnifying glass, inspect valve ports for cracks; if cracks are visible, replace
valve.
(f) Clean valve of all foreign matter, lubricate plug cock with a light film of MIL-G-6032
(Type I) grease, turn the plug several times in its seat and wipe off any excess, especially
in the valve ports. Also, lubricate position washer with a light film of MIL-G-6032
(Type I) grease. Reassemble valve with a new “0” ring, P/N 752-822.
(g) Before reinstalling valve, it may be checked by attaching an air hose and demonstrating that
it will hold 50 pounds of air pressure.

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Figure 3-5
Fuel Selector Valve Inspection

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(7) Induction Air Inlet Duct And Alternate Heat Duct Inspection
The following incorporates the recurring inspection requirements of Piper SB 356.
NOTE: Installation of Piper Kit No. 760-634V, 760-635V, 760-638V, 760-639V, or 760-640V,
as appropriate, relieves this inspection requirement.
In PA-28-140s S/N’s 28-20001 thru 28-7225172; PA-28-150/160/180s S/N’s 28-03, 28-l thru
28-7305012; PA-28-235s S/N’s 28-10001 thru 28-7310005; PA-28R-180s S/N’s 28R-30002
thru 28R-7130013; PA-28R-200s S/N’s 28R-35001 thru 28R-7235077; for airplanes which have
not installed either Piper Kit No. 760-634V, 760-635V, 760-638V, 760-639V, or 760-640V per
Piper Service Bulletin No. 360, each 50 hours time-in-service, conduct a visual inspection of the
external surface of the subject ducts. Duct removal is not required. Inspect the ducts for evidence
of deterioration as follows:
(a) Inspect the external surface of the ducts for loose or broken strings.
(b) Inspect the ducts for loose or displaced supporting wire.
(c) Inspect the ducts for signs of wear or perforation.
Should any of the above conditions exist, remove and replace the affected duct or ducts prior to
the next flight.

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(8) Wing Rib Assembly W.S. 49.25 Inspections

The following incorporates the recurring inspection requirements of Piper SB 1161A.
The left and right rib assemblies in PA-28R-180/200’s, aft of the main spar at W.S. 49.25 can,
under certain conditions, crack. The cracking is typically observed vertically along the bend
radius of the flange common to the main spar and the main landing gear side brace attach fitting
(see Figure 3-6). Accordingly, in PA-28R-180/200’s only, perform the following inspections at
the intervals indicated:
NOTE: Installation of Kit P/N 767-397 (LH) or 767-398 (RH), as applicable, with kit instructions
marked Dwg. No. 88373, revision “J” or later relieves the recurring 500 hour special
inspection requirements. Installation of these kits with kit instructions marked Dwg. No.
88373, revisions “New” through “H” does not relieve the recurring inspections.
(a) 100 Hour Standard Inspection
1) Inspect the rib assembly (LH and RH) for evidence of cracks for evidence of cracks in
the bend radius of the flange common to the main spar web (as shown in Figure 3-6),
except the inspection shall be limited to a visual examination of the exposed (upper
half) portion of the flange bend radius. Removal of the main landing gear side brace is
not required at the 100 hour inspection interval.
NOTE: If evidence of a crack or cracks is detected, proceed to the 500 hour inspection.
2) Make an appropriate logbook entry.
(b) 500 Hour Special Inspection
Except as described above, each 500 hours time-in-service:
1) Place the airplane on jacks per Sec. II, Para. 2-13.
2) In both the right and left wings:
a) Remove the Main Landing Gear Side Brace, by removing the five (5) bolts that
fasten it to the wing structure. Retain hardware for reassembly.
b) Inspect the Rib Assembly for evidence of cracks in the bend radius of the flange
common to the Main Spar Web (as shown in Figure 3-6), using dye penetrant
inspection techniques.
3) If a crack is detected, identify the path of the propagation, and determine if trimming,
as shown in Figure 3-6, will remove all the material affected by the crack.
a) If so, install the appropriate kit (see above).
b) If this cannot be accomplished, replace the cracked Rib Assembly.
NOTE: If the rib assembly is replaced, the applicable kit, P/N 767-397 (LH)
or 767-398 (RH), must also be installed to eliminate these repetitive
inspection requirements. Kit instructions must be marked Dwg. No.
88373, revision J (or later).
4) If no cracks are detected, reassemble/reinstall any parts or components previously
removed.
5) Verify proper functioning of landing gear.
6) Verify gear are down and locked and remove airplane from jacks.
7) Make an appropriate logbook entry.

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MAIN SPAR

DETERMINE THAT TRIMMING

THE RIB BACK TO THIS LINE
WILL REMOVE ALL THE MATERIAL
AFFECTED BY THE CRACK.

MAIN AREA TO INSPECT FOR

CRACKS OF THE FLANGE BEND
RADIUS (See Note)

UP

FWD

NOTE: Applicable to the 500 hour inspection only.

LOOKING OUTBOARD AT LEFT WING

(RIGHT WING OPPOSITE)

Figure 3-6
Wing Rib Assembly Inspection

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(9) Wing Spar Inspection

WARNING: FAILURE TO FULLY COMPLY WITH THIS INSPECTION COULD
SERIOUSLY AFFECT THE STRUCTURAL INTEGRITY; SAFETY AND
AIRWORTHINESS OF THE AIRCRAFT.
The following incorporates the recurring inspection requirements of Piper SB 886.
(a) Background
On March 30, 1987, a PA-28 engaged in pipeline patrol operations suffered an inflight wing
separation resulting in a fatal accident. Investigation revealed the wing failure was due to
propagation of a fatigue crack, which originated in the wing lower main spar cap.
Based on more than five hundred (500) inspections of PA-28 and PA-32 airplanes with more
than 5000 hours total time-in-service, and extensive wing fatigue and fracture analysis by
Piper, the following inspection requirements have been developed.
NOTE: In the course of the inspections cited above, only two (2) negative findings were
reported on a pair of PA-32’s operating in a severe environment and with considerable
damage histories. Piper understands that the majority of aircraft are, have been, and
will continue to be operated well within the aircraft’s design parameters during all
of their operational life. HOWEVER, Piper also realizes that some small number
of aircraft engage in operations which are defined herein as “severe” or “extreme”
and those airplanes will require more frequent wing removal and inspection.
(b) Procedure
First, determine the airplane’s “usage class”; second, determine the recurring inspection
intervals; and, third, when required, accomplishing the wing spar inspection.
1) Determining Usage Class
NOTE: Airplane operating history and usage class are established during initial
compliance with Piper Service Bulletin No. 886, check the logbook entry.
Complete documentation and/or knowledge of the airplane’s entire operating history
is required in order to make a valid determination of “Usage Class” and inspection
intervals.
a) Usage Class “A” - Normal
All aircraft which do not and have nor engaged in operations considered as
“Severe,” “Extreme,” or “Unknown” in the Usage Classes described below. Most
aircraft will fall into this “Usage Class.” Normal flight training operations fall into
this class as well.
NOTE: If there is any doubt as to the airplane’s operating history, it is
recommended that the initial inspection be conducted in accordance with
the “Next 50 Hours” inspection requirement, below.

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b) Usage Class “B” - Severe

Aircraft which have engaged in severe usage, involving contour or terrain following
operations, (such as power/pipeline patrol, fish/game spotting, aerial application,
aerial-advertising, police patrol, livestock management or other activities) where
a significant part of the total flight time has been spent below one-thousand (1000)
feet AGL altitude.
NOTE: Aircraft with part of total time-in-service in Usage Class “B” operations
and part in Usage Class “A”, may adjust inspection intervals by a
“Factored Service Hours” calculation. See “Factored Service Hours,”
below.
c) Usage Class “C” - Extreme
Aircraft which have been damaged due to operations from extremely rough
runways, flight in extreme damaging turbulence or other accident/incident which
required major repair or replacement of wing(s), landing gear or engine mount.
d) Usage Class “D” - Unknown
Aircraft and/or wings of unknown or undetermined operational or maintenance
history.
e) Factored Service Time
NOTE: This formula applies only to airplanes in Usage Class “B” - Severe. It
may be used to calculate the initial and repetitive inspection times in
factored hours, provided a portion of the airplane’s operating time-in-
service has been in Usage Class “A” - Normal.
Determine Factored Service Time as follows:

Hours in
Hours in
Example Normal Service = Factored Service Hours
Severe Service +
(PA-28-235) 17

(1) 800 + 4000 = 1035

17

(2) 1000 + 14000 = 1823

17

Results
(1) Initial inspection not required at this time. Will require initial inspection when
Total Factored Service Hours reach 1800.
(2) Initial inspection required within the next 50 hours time-in-service.

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2) Inspection Requirements
a) Next 50 Hours:
o For airplanes in “Usage Class D” (i.e. - unknown usage), conduct Wing
Spar Inspection and establish usage class for next inspection based on
current aircraft operations.
b) Each 800 Hours:
o In PA-28-235’s only, for airplanes in “Usage Class B” (i.e. - severe
usage), beginning at 1,800 hours total time-in-service, and each 800 hours
thereafter, conduct Wing Spar Inspection.
o In PA-28-235’s only, for airplanes in “Usage Class C” (i.e. - extreme
usage), conduct Wing Spar Inspection, each 800 hours time-in-service.
c) Each 1600 Hours:
o In PA-28-140/150/160/180’s and PA-28R-180/200’s, for airplanes in
“Usage Class B” (i.e. - severe usage), beginning at 3700 hours total time-
in-service, and each 1600 hours thereafter, conduct Wing Spar Inspection.
o In PA-28-140/150/160/180’s and PA-28R-180/200’s, for airplanes in
“Usage Class C” (i.e. - extreme usage), conduct Wing Spar Inspection,
each 1600 hours time-in-service.
d) Each 3000 Hours:
o In PA-28-235’s only, for airplanes in “Usage Class A” (i.e. - normal
usage), beginning at 30,600 hours total time-in-service, and each 3000
hours thereafter, conduct Wing Spar Inspection.
e) Each 6000 Hours:
o In PA-28-140/150/160/180’s and PA-28R-180/200’s, for airplanes in
“Usage Class A” (i.e. - normal usage), beginning at 62,900 hours total
time-in-service, and each 6000 hours thereafter, conduct Wing Spar
Inspection.
3) Inspection.
CAUTION: USE EXTREME CARE IN REMOVING AND REPLACING THE
WING MAIN SPAR TO FUSELAGE (I.E. - SPAR CARRYTHROUGH)
ATTACHMENT BOLTS (18 PER SIDE) TO PRECLUDE DAMAGING
THE BOLT HOLES OR BOLT HOLES. DO NOT DRIVE THE BOLTS
IN OR OUT OF THE HOLES. AS THE BOLTS ARE REMOVED,
NUMBER EACH BOLT AND HOLE TO ENSURE REPLACEMENT
IN THE SAME HOLE. USE PROPER TORQUE VALUES WHEN
INSTALLING BOLTS. IF REPLACEMENT OF SOME BOLTS
IS REQUIRED, ENSURE PROPER PART NUMBER AND GRIP
LENGTH. INSTALLATION OF EIGHTEEN (18) NEW NUTS (SEE
BOLT LEGEND, FIGURE 4-2) DURING WING REINSTALLATION
IS RECOMMENDED.
a) Remove both wings in accordance with Wings - Removal, Section IV.

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b) Visually inspect, using a 10-power (minimum) magnifying glass and a dye-

penetrant method or equivalent, for cracks in the wing lower spar cap from the
wing skin line outboard of the outboard row of wing attach bolt holes to an area
midway between the second and third row of bolt holes from the outboard row.
1) If no cracks are found, prior to further flight, accomplish the actions
specified in paragraph (c) below.
2) If any cracks are found, prior to further flight, replace the spar or wing with
a new or serviceable unit shown to be free of cracks when subjected to the
inspections specified in this paragraph.
c) Visually inspect for cracks in each upper wing skin adjacent to the fuselage and
forward of each main spar.
1) If no cracks are found, reinstall the wings in accordance with Wings
-Installation, Section IV.
2) If cracks are found, prior to further flight, replace with new parts or repair
in accordance with latest revision of AC 43.13-1, and reinstall the wings in
accordance with Wings - Installation, Section IV.
d) Make an appropriate entry in the aircraft logbook documenting this inspection
and any maintenance actions taken as a result.
(10) Landing Light Seal Inspection
WARNING: TURN MAGNETOS SWITCHES AND MASTER SWITCH OFF BEFORE
WORKING NEAR PROPELLER.
The following incorporates the recurring inspection requirements of Piper SB 975.
In PA-28-140/150/160/180’s, where the landing light is located in the air filter, the original
landing light support assembly can allow pieces of the landing light or retainer ring seals into
the induction air system if those seals become brittle with age and begin to fail. Accordingly, for
those airplanes which have not installed the improved Landing Light Support P/N 85174-002,
each 100 hours or annually, whichever comes first, inspect as follows:
NOTE: Installation of the improved Landing Light Support P/N 85174-002 eliminates the
requirement for this repetitive inspection.
(a) Remove the retainer ring screws (4 ea.) and remove the retainer ring. Catch and support the
landing light.
(b) Inspect the seals installed on the inside and outside edges of the retainer ring for condition
and security. Check pliability. Replace as required.
(c) If either seal is found to be missing pieces, remove the air filter retainer and inspect the
induction air system for contamination. Disassemble as required to ensure the missing seal
pieces will not be ingested by the carburetor.
(d) Upon completion of the inspection, reassemble any other components removed and reinstall
the landing light by holding it in position and capturing it with the retainer ring. Secure
retainer ring with screws (4 ea.).

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(11) Stabilator Attach Fittings Corrosion Inspection

The following incorporates the recurring inspection requirements of Piper SB 856.
At each annual or 100 hour inspection or anytime the stabilator is removed:
(a) Remove upper and lower tailcone fairing assembly.
(b) Remove the aft fuselage closeout plate assembly, if so equipped.
(c) Inspect the steel attach fittings (4 places) for the stabilator and adjacent fuselage structure
for rust and/or corrosion. (See Figure 3-7.)
(d) If rust and/or corrosion is found, repair or replace as required, and add corrosion protection
per latest revision of AC43.13-1.
(e) If so equipped, reinstall aft fuselage closeout plate assembly. (Verify integrity of rubber
seals, replace if required).
(f) Reinstall upper and lower tailcone fairing assembly.

Figure 3-7
Stabilator Attach Fitting Corrosion Inspection

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(12) Flap Control Cable Attachment Bolt Inspection.

The following incorporates the recurring inspection requirements of Piper SB 965.
Each 100 hours time-in-service, or annually, whichever comes first, inspect the flap control cable
attachment bolt as specified below. See Figure 3-8. Should any evidence of wear be detected
replace the bolt.
(a) Remove the royalite flap or flap/trim cover.
(b) On aircraft having the flap handle only, proceed as follows:
1) Remove flap handle mounting bracket attachment bolts.
2) Raise flap handle and bracket assembly to gain access to the control cable attachment
bolt.
(c) On aircraft having the flap handle and trim wheel mounted together, proceed as follows:
1) Loosen the trim wheel attachment bolt.
2) Remove the trim wheel bracket attachment bolts and remove bracket from top of tunnel.
3) Remove flap handle mounting bracket attachment bolts and raise handle and bracket
assembly to gain access to control cable attachment bolt.
(d) Remove and inspect cable attachment bolt for possible wear. Should wear be detected,
replace bolt with new AN23-11 clevis bolt.
(e) Reinstall all parts that were removed and make appropriate log book entry.

Figure 3-8
Flap Control Cable Attachment Bolt Inspection (Typical)

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(13) Aft Wing Attach Fittings 100 Hour Inspection.

The following incorporates the recurring inspection requirements of Piper SB 977.
(a) Background
Should the seals for the windows and doors not be maintained, leaks may develop which,
if not corrected, will allow water ingress. This water contamination will wet the insulation
around the aft wing attach fittings creating a highly corrosive environment.
(b) Inspection Procedure
NOTE: The following inspection assumes the airplane has been previously modified
with the installation of baggage floor inspection access panels and drain holes in
the fuselage bottom. If not, perform Fabrication Procedure, para. 4-79. Baggage
Compartment Inspection Hole and Cover Plate, before continuing with the
inspection.
(c) Each 100 hours, inspect to determine condition of the aircraft window and door seals, the
condition of the aft wing attach fittings, the insulation material around the affected area, and
the drain holes in the bottom fuselage skin at the aft attach fittings area.
1) Gain access to the left and right aft wing attach fittings. (See Figure 3-9.)
a) Remove rear seats and the rear floorboard.
b) Remove interior mouldings and carpet as necessary.
c) Remove the carpet from the baggage area floor and remove the two access panels
in the baggage area floor.
2) Inspect thoroughly the left and right aft wing attach fittings for evidence of flaking
paint and/or corrosion. (Flaking paint may be a symptom of hidden corrosion.)
a) If corrosion exists:
1) If corrosion is superficial and there is no metal flaking and/or pitting, clean
and paint fittings, using a good quality aircraft primer.
2) If serious corrosion is found, consult the Piper Illustrated Parts Catalog
(P/N 753-582) for replacement part numbers and obtain and install new
parts before next flight. See removal and installation procedure below.
3) Upon completion of the inspection and after replacement or refurbishment
of fittings, treat the aft attach fittings area using DINOL AV 8 corrosion
compound (P/N 89500-800). The treatment may be brushed or sprayed.
b) If no corrosion exists, continue with these instructions.
3) Inspect insulation in and around the rear fittings.
a) If insulation is wet or matted down where it has been wet, it will be necessary to
replace this insulation and it will be necessary to inspect all windows, doors, and
exterior panels leading to the cabin.
1) Check door seals for deterioration, cracks, and voids in adhesive.
2) Check window seals for voids, cracks, and deterioration.
3) Perform a leak check with water to determine where the water is entering.
Cure all leak paths before continuing these instructions.
4) Consult the Piper Illustrated Parts Catalog (P/N 753-582) for replacement
part numbers and obtain and install new parts before continued operation.

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5) If sealing windows, use P/N 279-058 Sealant (Bostik 1100 FS) or

equivalent.
6) If using insulation other than Piper original material, be sure that the
insulation is flame resistant and conforms to FAR part 23.853.
b) If the insulation material has not been wet, or if new material is being installed,
ensure a six (6) inch clearance in the insulation has been cut out in all directions
around each attach fitting.
4) Locate the two 0.191 inch drain holes, one beneath each rear attach fitting, in the
bottom fuselage skin and ensure each is clean and free of obstruction.
NOTE: If there are no drain holes, install them as described in Figure 3-10.
5) Re-install floorboards, seats, interior panels, and other articles previously removed.
Perform a functional test of any system or component that may have been interrupted
or removed.

Figure 3-9
Wing Attach Fittings

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Figure 3-10
Drain Hole Installation

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(d) Removal and Installation Procedure (if required). (See Figure 3-9.)
NOTE: If both fittings are to be changed, remove and replace one fitting at a time.
1) Remove electrical power from aircraft by disconnecting the battery.
2) Place jacks under wings and tail - tie down to stabilize aircraft.
3) Remove seats, removable floorboards and interior panels necessary to gain access to
the rear wing attach fittings.
4) On L/H side, remove bus bar assembly from spar.
5) If necessary, drill off baggage compartment floor and remove from aircraft.
6) Remove bolt from wing rear spar and fuselage attach fitting.
7) Carefully drill out the rivets that attach the fitting to the spar.
8) With all the rivets removed, remove wing attach fitting from the fuselage. Discard
fitting.
9) Clean and inspect the areas that were under bracket for any signs of corrosion.
10) If corrosion is found, repair or replace parts as necessary. Coat the area with primer
and allow to dry.
11) If no corrosion is found, coat the area with primer. Allow time to dry.
12) Install new wing attach fitting and align rivet holes. It may be necessary to ream open
the bolt hole to proper size. The hole is close tolerance and should be .3115 / .3135
(5/16) or .3745 / .3765 (3/8) depending on model and year. Replace attach fitting bolt
should there be any sign of wear or corrosion.
13) Re-rivet wing attach fitting into place with appropriate fasteners.
NOTE: For hard to reach areas the existing MS20470AD-5 rivets may be replaced with
Hi Lok fasteners. Use HL30-5 with HL-94 Hi Lok collars. Torque to 15 to 25
in.-lbs. Observe standard practices for use of Hi Lok fasteners.
14) Install wing spar and fuselage attach fitting bolt per Section IV and Figure 4-2.
15) Seal edges of attach fittings with PRC PR1422 (or equivalent) before installing interior.
16) Complete same process to the opposite side, if replacing both attach fittings.
17) Reinstall baggage door, floorboards, interior panels, and seats. Connect battery and
check for operation.

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(14) Fuel Tank/Wing Spar Corrosion Inspection.

The following incorporates the recurring inspection requirements of Piper SB 1006.
Paragraphs (a) and (b) are keyed to Figure 3-11 (i.e. – (a)1 corresponds to A1 in figure).
(a) Each seven calendar years time-in-service, remove the fuel tanks and conduct inspections
as specified below. Each inspection is for corrosion (intergranular, exfoliation, etc.), but
while exposed all areas and parts should be checked for other anomalies such as damage,
cracking, or wear. Any part or area determined to be defective must be repaired or replaced
using standard FAA approved parts and methods.
1) Inspect the fuel tank attach hardware and gang channels (nut plate strips).
2) Inspect the exterior of the fuel tanks for leaks. Inspect the interior for corrosion or
sloshing compound. If either condition exists, clean, repair, or replace the fuel tank as
required.
3) Remove fuel quantity senders. Inspect for condition, operation, and security and
freedom of movement of the float arm. Inspect condition of wires and terminals.
Replace components as required. Replace gaskets.
4) Inspect hard fuel vent lines for interior and exterior corrosion, wear, or deposits.
Flush and clean with mineral spirits under pressure. If excessive debris, deposits,
or corrosion observed, replace the line.
5) Inspect flexible fuel hoses and couplings. Replace as required. Replacement is
recommended regardless of serviceability.
6) Inspect the spar, spar angles (cap), and ribs behind and adjacent to the fuel tank. If
corrosion is detected, conduct a thorough inspection of the entire wing.
7) Remove the lacing at the wing root and inspect the spar and forward wing attach fittings.
(b) Treat the following areas with Dinotrol AV 8 before reassembly.
1) Wing spar at root and forward wing attach fittings.
2) Entire wing spar, spar angles (cap), and ribs behind and adjacent to the fuel tank.

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Figure 3-11
Fuel Tank and Wing Spar Corrosion Inspection

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(15) Cast Main Landing Gear Strut Cylinder 100 Hour

Inspection.
The following incorporates the recurring inspection
requirements of Piper SB 1131A.
In PA-28-140/150/160/180/235’s, for those airplanes
which are not equipped with forged main landing gear
strut cylinders P/N 65489-002 on both left and right sides;
each 100 hours time-in-service, inspect the cast main
landing gear strut cylinders (P/N’s 65319-002/-003/-004)
as follows:
NOTE: Installation of the improved forged main landing
gear strut cylinder P/N 65489-002 on both the
left and right sides eliminates this repetitive
inspection requirement.
(a) Thoroughly clean the area to be inspected as
indicated in Figure 3-12 using a suitable cleaner.
(b) Using a 10X power magnifying glass, visually inspect
the gear cylinder top and bottom radii at the torque
link attach lugs for cracks (Figure 3-12). If no cracks
are found by visual inspection, proceed to Liquid
Penetrant Inspection per latest revision of AC43.13-
1 to check for cracks. Strip the paint and primer
from the area to be inspected using a commercially
available chemical paint stripper taking care only to
remove paint and primer from the inspection area.
(c) If a crack is detected, prior to further flight, replace Figure 3-12
the “cast” main gear strut cylinder with the “forged” Main Gear Strut Cylinder
main gear strut cylinder per Section VII.
(d) If no cracks are detected, thoroughly clean the
surfaces and touch-up paint and primer removed during the inspection process.
(e) Make an appropriate logbook entry indicating completion of this inspection.

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(16) Nose Gear Drag Link 500 Hour Inspection and Bolt Replacement.
The following incorporates the recurring inspection requirements of Piper SB 1156.
(a) Jack the aircraft per Jacking, Section II.
(b) Disassemble Upper Drag Link from Lower Drag Link, by removing the NAS464P4-27 bolt
(Item 34, Figure 7A-2) that functions as a hinge pin for the two parts. Discard bolt and cotter
pin, regardless of condition. Nut and washers may be reused, depending on condition.
(c) Inspect bearings in the drag links for excessive wear, and verify that bushing IDs are within
Service Dimension range of .2515 to .2495 inches, replacing as necessary.
(d) Reassemble Upper and Lower Drag Links by installing a new NAS464P4-27 bolt, taking
care to reposition washers retained in Step B. Reinstall castellated nut retained in Step B.
and secure with a new MS24665-134 cotter pin.
(e) Lubricate as required per Lubrication Charts in Section II.
(f) Verify proper operation of the Nose Gear.
(g) Remove airplane from jacks, and return to service.
(h) Make an appropriate logbook entry documenting completion of this inspection.

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(17) Control Cable Inspection.

Aircraft control cable systems are subject to a variety of environ­mental conditions and forms
of deterioration that, with time, may be easy to recognize as wire/strand breakage or the not-
so-readily visible types of wear, corrosion, and/or distortion. The following data may help in
detecting the presence of these con­ditions:
(a) Cable Damage­.
Critical areas for wire breakage are sections of the cable which pass through fairleads and
around pulleys. To inspect each section which passes over a pulley or through a fairlead,
remove cable from air­craft to the extent necessary to expose that particu­lar section. Examine
cables for broken wires by passing a cloth along length of cable. This will clean the cable
for a visual inspection, and detect broken wires, if the cloth snags on cable. When snags are
found, closely examine cable to determine full extent of damage.
The absence of snags is not positive evidence that broken wires do not exist. Figure 3-13A
shows a cable with broken wires that were not de­tected by wiping, but were found during a
visual inspection. The damage became readily apparent (Figure 3-13B) when the cable was
removed and bent using the techniques depicted in Figure 3-13C.

Figure 3-13
Control Cable Inspection

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(b) External Wear Patterns.

Wear will nor­mally extend along cable equal to the distance cable moves at that location.
Wear may occur on one side of the cable only or on its entire circumference. Replace flexible
and non-­flexible cables when individual wires in each strand appear to blend together (outer
wires worn 40-50 percent) as depicted in Figure 3-14.
(c) Internal Cable Wear.
As wear is tak­ing place on the exterior surface of a cable, the same condition is taking place
internally, par­ticularly in the sections of the cable which pass over pulleys and quadrants.
This condition, shown in Figure 3-16, is not easily detected unless the strands of the cable
are separated. Wear of this type is a result of the relative mo­tion between inner wire surfaces.
Under cer­tain conditions the rate of this type wear can be greater than that occurring on the
surface.

Figure 3-14
External Cable Patterns

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(d) Corrosion.
Carefully examine any cable for corrosion that has a broken wire in a sec­tion not in contact
with wear producing air­frame components such as pulleys, fairleads, etc. It may be necessary
to remove and bend the cable to properly inspect it for internal strand corrosion as this
condition is usually not evident on the outer surface of the cable. Replace cable segments if
internal strand rust or corrosion is found.
Areas especially conducive to cable corrosion are battery compartments, lavatories, wheel
wells, etc., where concentrations of corrosive fumes, vapors, and liquids can accumulate.
NOTE: Check all exposed sections of cable for corrosion after a cleaning and/or metal-
brightening operation has been accomplished in that area.
(e) Cable Maintenance.
CAUTION: TO AVOID REMOVAL OF CORROSION-PREVENTATIVE COMPOUNDS
AND CABLE INTERNAL LUBRICANT, DO NOT USE VAPOR
DEGREASING, STEAM CLEANING, METHYLETHYLKETONE (MEK)
OR OTHER SOLVENTS.

CAUTION: DO NOT OIL CONTROL CABLES.

Frequent inspections and preservation measures such as rust pre­vention treatments for
bare cable areas will help to extend cable service life. Where cables pass through fairleads,
pressure seals, or over pulleys, remove accumulated heavy coatings of corrosion prevention
compound. Provide corrosion protection for these cable sections by lu­bricating as specified
in the Lubrication Chart, Section II.

Figure 3-15
Internal Cable Patterns

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(f) Cable Fittings.

1) 100 Hour Standard Inspection
Check swaged terminal ref­erence marks for any indication of cable slip­page within
fitting. Inspect fitting as­sembly for distortion and/or broken strands at the terminal.
Check that all bearings and swivel fittings (bolted or pinned) pivot freely to prevent
binding and subsequent failure. Check turnbuckles for proper thread exposure and
broken or missing safety wires/clips.
Pay particular attention to corrosion and “pitting” on cable terminals, turnbuckles and
cable fittings. Any corrosion or pitting found requires replacement of the corroded
fitting and/or cable.
2) 100 Hour Special Inspection
For airplanes 15 years old or older, using a 10X magnifier, visually inspect the
entire surface of each cable terminal, turnbuckle, or other cable fitting for corrosion
or cracking. Inspect under safety wire or clips wrapped around the cable or fitting.
Any evidence of corrosion or cracking, however minute, is cause for replacement. A
logbook entry documenting the replacement of a cable terminal, turnbuckle, or other
cable fitting relieves the inspection requirement for that fitting only, until such time as
that fitting has been in service for 15 years.
(g) Pulleys.
Inspect pulleys for roughness, sharp edges, and presence of foreign material embedded in
the grooves. Examine pulley bear­ings to assure proper lubrication, smooth rota­tion, freedom
from flat spots, dirt, and paint spray. Periodically rotate pulleys, which turn through a small
arc, to provide a new bearing surface for the cable. Maintain pulley align­ment to prevent
the cable from riding on flanges and chafing against guards, covers, or adjacent structure.
Check all pulley brackets and guards for damage, alignment, and secur­ity.
(h) Pulley Wear Patterns.
Various cable sys­tem malfunctions may be detected by analyzing pulley conditions. These
include such discrepancies as too much tension, misalignment, pulley bearing problems,
and size mismatches be­tween cables and pulleys. Examples of these conditions are shown
in Figure 3-16.

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Figure 3-16
Pulley Wear Patterns

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(18) Exhaust System Inspection

The following incorporates the recurring inspection requirements of Piper SL 324C and SL 389.
Refer to Figure 3-17 thru 3-18.
WARNING: A VERY THOROUGH INSPECTION OF THE ENTIRE EXHAUST SYSTEM,
INCLUDING EXHAUST HEATER SHROUD ASSEMBLY, MUFFLER AND
MUFFLER BAFFLES, STACKS AND ALL EXHAUST CONNECTIONS AND
WELDS MUST BE ACCOMPLISHED AT EACH 100 HOUR INSPECTION.
The possibility of exhaust system failure increases with use. It is recommended that the system
be checked more carefully as the number of hours increase, therefore inspection at the 700 hour
period, that the exhaust system has been in use would be more critical than ones in the 100 hour
period. The system should also be checked carefully before winter operation when the cabin heat
will be in use.
NOTE: Piper recommends that all PA-28 airplanes be fitted with a new muffler at or near the
1000 hour period of which the muffler has been used.

Figure 3-17
Typical Muffler Fatigue Areas

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Figure 3-18
Exhaust System Inspection Points (Sheet 1)

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Figure 3-18
Exhaust System Inspection Points (Sheet 2)

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CAUTION: WHEN REMOVING OR INSTALLING COUPLING CLAMP, SLIDE CLAMP

OVER END OF PIPE BEFORE ASSEMBLY / DISASSEMBLY. EXCESSIVE
SPREADING CAN LEAD TO PREMATURE FAILURE OF CLAMP.

NOTE: When installing an exhaust clamp having an alignment pin be certain that the pin engages
the mating holes in exhaust pipe and muffler to prevent separation of components.
Removal of the tail pipe and stacks is required for inspection of the muffler baffle. Remove
or loosen all exhaust shields, carburetor and cabin heat muffs, shrouds, heat blankets, etc., as
required to permit inspection of the complete system. Perform the necessary cleaning operations
and inspect all external surfaces for dents, cracks and missing parts. Pay particular attention
to welds, clamps, supports and support attachment lugs, slip joints, stack flanges and gaskets.
Inspect internal baffle or diffusers. Any cracks, warpage or severe oxidation are cause for
replacement of the muffler.
If any component is inaccessible for a thorough visual inspection, accomplish one of the
following:
(a) Accomplish a submerged pressure check of the muffler and exhaust stack at 2 psi air
pressure.
(b) Conduct a ground test using a carbon monoxide indicator by heading the airplane into the
wind, warming the engine on the ground, advancing the throttle to full static RPM with
cabin heat valves open, and taking readings of the heated airstream inside the cabin at
each outlet (including rear seat heat outlet, if installed). Appropriate sampling procedures
applicable to the particular indicator must be followed. If carbon monoxide concentration
exceeds .005 percent or if a dangerous reading is obtained on an indicator not calibrated in
percentages, the muffler must be replaced.
(19) Field Check Of PA-28R-180 And PA-28R-200 Muffler Assemblies.
Refer to Figure 3-19.
(a) Remove end clips.
(b) Check for any movement between the heater muff end plates and the muffler pipes in
the directions shown on Figure 3-20. If there is no movement, the muffler assembly is
acceptable.
(c) If there is any movement, remove the muffler assembly and inspect all parts, especially
for abnormal wear on muffler shroud. Rework the end plates to give a .03” min. gap after
assembly.
(d) Prior to reassembly, the two top screw holes in the upper shroud assembly should be slotted
as necessary to allow the screws to be installed without causing any deformations of the
skin.
(e) Install, but do not tighten, the two screws which hold the lower shroud assembly in place.
(f) Install the end strap clamps and torque them from 25 to 30 inch-pounds before installing the
two top screws which hold the top shroud assembly in place.
(g) Tighten the two lower screws and then the two upper screws.
(h) Check the muffler for tightness after assembly.

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Figure 3-19
Exhaust System Installation, PA-28R-180, -200

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(20) Control Wheel 100 Hour Inspection.

The following incorporates the recurring inspection requirements of Piper SL 527D.
Refer to Figure 3-20.
NOTE: Installation of “ram’s horn” control wheels (P/N 78729-002 (.75 inch dia. shaft) or
79276-000 (1.25 inch dia. shaft)) eliminates this repetitive inspection requirement.
In PA-28-140 S/N’s 28-20001 thru 28-7725290, PA-28-150, -160, -180 S/N’s 28-1 thru 28-4377,
PA-28-235 S/N’s 28-10001 thru 28-11039, for airplanes with the original equipment “butterfly”
control wheels still installed, each 100 hours, inspect as follows:
CAUTION: NO SOLVENTS OR DYE PENETRANT SHOULD BE USED TO PERFORM
THIS INSPECTION.
(a) This inspection should be accomplished at the next 100 hour or annual inspection and
repeated at each 100 hour or annual inspection thereafter.
(b) It is required to detect and replace any cracked control wheels.
(c) Inspect the front, bottom and back of the control wheels using an ordinary (3x) magnifying
glass and light.
NOTE: Do not confuse any surface irregularities or mold marks with actual cracks. (Refer
to Figure 3-20.)
(d) Any control wheel assemblies which are found defective should be replaced immediately.
Refer to PA-28 Parts Catalog for applicable part numbers.

Figure 3-20
Control Wheel Inspection Points

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(21) Aileron Hinge Doubler 100 Hour Inspection

The following incorporates the recurring inspection requirements of Piper SL 581.
In PA-28-140 S/N’s 28-20000 thru 28-26233, PA-28-150, -160, -180 S/N’s 28-1 thru 28-5611,
PA-28-235 S/N’s 28-10001 thru 28-11300, PA-28R-180 S/N’s 28R-30001 thru 28R-31250 and
PA-28R-200 S/N’s 28R-30482, 28R-35001 thru 28R-35390; each 100 hours inspect as follows:
(a) Inspect the aileron hinge doublers inboard (next to control rod) and outboard (next to balance
weight) to determine if cracks exist in the bend radii. (See Figure 3-21).
(b) If cracks are found, install Piper Kit No. 760-540V.

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Figure 3-21
Aileron Hinge Doubler 100 Hour Inspection

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(22) Main Landing Gear Torque Link Inspection

The following incorporates the recurring inspection requirements of Piper SL 600.
NOTE: Installation of the service replacement improved torque link P/N 78032-000 per Piper
SL 621 relieves this repetitive inspection requirement. The new links must be installed
in pairs and each pair will require two washers P/N 63312-002.
In PA-28-140 S/N’s 28-20001 thru 28-7225496, PA-28-150, -160, -180 S/N’s 28-03, 28-1 thru
28-7205293; and PA-28-235 S/N’s 28-10001 thru 28-7310001; for airplanes with main landing
gear torque links (P/N 65691-000) installed which have accumulated 800 hours or more time-in-
service, beginning at 800 hours and each 500 hours thereafter, inspect as follows:
(a) Inspect each main landing gear torque link for cracks in areas shown in Figure 3-22. These
cracks may form just behind the large boss which attaches to the strut or to the wheel, and
in the center of the link progressing toward the edge. The following steps should be used to
make this inspection:
1) Remove paint from the area to be inspected, using acetone, MEK, or any suitable
commercial paint remover which does not contain wax.
2) Allow the cleaned part to dry thoroughly.
3) If cracks do not readily appear, inspect by one of the following methods
a) 10X magnifying glass.
b) Dye check or other penetrant inspection.
(b) Should cracks be detected, replace defective torque links prior to further flight
(c) If no cracks appear, make proper log book entry and return aircraft to service.

Figure 3-22
Inspection of Main Landing Gear Torque Links

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(23) Upper Nose Gear Oleo Bearing Inspection.

The following incorporates the recurring inspection requirements of Piper SL 413.
Refer to Figure 3-23.
NOTE: Installation of the service replacement upper nose gear oleo bearing P/N 452-419
relieves this 500 hour inspection requirement.
In PA-28-150, -160, -180 S/N’s 28-1 thru 28-90, 28-92 thru 28-365, 28-367 thru 28-764,
28-766 thru 28-886, 28-888 thru 28-1109, 28-1111 thru 28-1146, 28-1148 thru 28-1154, 28-1156
thru 28-1206, 28-1209 thru 28-1218, 28-1220 thru 28-1223, 28-1225 thru 28-1227, 28-1229,
28-1232, 28-1233, 28-1235 thru 28-1237, 28-1239 thru 28-1245, 28-1248 thru 28-1251,
28-1253, 28-1255 thru 28-1261, 28-1263 thru 28-1268, 28-1270, 28-1273, 28-1274, 28-1276
thru 28-1280, 28-1286, 28-1287, 28-1293, 28-1285, 28-1301 and 28-1303; for airplanes which
have not installed upper nose gear oleo bearing (P/N 452-419), each 500 hours, inspect as follows:
(a) Remove the nose gear steering arm, P/N 63300-08, then remove the threaded collar, P/N
13071-00 and seal washer, P/N 85012-72.
(b) Check that the bearing is in satisfactory condition and installed with loading grooves facing
upward.
(c) Lubricate bearing with MIL-PRF-23827 and reassemble steering mechanism.
(d) If loading grooves are not visible, is will be necessary to lower oleo assembly to remove
bearing. The bearing should be removed, checked, lubricated and installed with the bearing
loading grooves facing upward.
(e) If the bearing is not in satisfactory condition, replace with sealed bearing P/N 452-419.
(24) Flap Torque Tube/Push Rod Distortion Inspection
If flaps have been extended at or above Vfe, inspect the flap torque tube arms and pushrods for
evidence of distortion.
(a) If the paint is cracked or peeling anywhere along the torque tube arm or pushrod, torsional
movement has occurred.
(b) Remove the paint and inspect for cracks:
1) In the welds at the arm on the torque tube end.
2) In the rod ends and pushrod tube.
3) Use a dye penetrant method of inspection.
(c) If cracks are not found, repaint the part(s) and reinstall.
(d) If cracked, replace the affected part(s).

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Figure 3-23
Upper Nose Gear Oleo Bearing Inspection

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(25) Rudder Bar Assembly 100 Hour Inspections

The following incorporates the recurring inspection requirements of Piper SL 1242.
Refer to Figure 3-24.
In airplanes with a rudder pedal and bar assembly or, for fixed gear airplanes only, with a rudder
bar support assembly, that has 1,200 hours or more time-in-service each 100 hours inspect the
rudder pedal and bar assembly and/or the the rudder bar support assembly for cracks, as follows:
NOTE: Installation of a new rudder pedal and bar assembly and/or, if applicable, a new rudder
bar support assembly will relieve this recurring inspection requirement, until the new
component(s) reach 1,200 hours time in service.
(a) Rudder Pedal And Bar Assembly Inspection
NOTE: Temporary removal of interior components may be required in order to accomplish
the instructions that follow.
1) Gain access to the areas identified in “Figure 3-24 (Sheet 1 of 2)” on page III-91.
2) Using a 10X magnifier, a mirror, and a suitable light source (or other equipment
capable of providing equal or better resolution), visually inspect all welds, with specific
emphasis on the locations identified in “Figure 3-24” Sheet 1.
3) Any cracked components must be replaced prior to next flight.
4) If the rudder bar assembly conforms to Detail A in “Figure 3-24 (Sheet 2 of 2)”,
modification is required. Proceed to Step “(d)” on page III-93.
(b) Rudder Bar Support Assembly Inspection
In fixed gear models only:
1) Remove and retain the four (4) bolts that secure the rudder bar support assembly to the
cockpit floor.
NOTE: It is not necessary to remove the rudder bar support assembly to accomplish
this inspection.
2) Visually inspect the four (4) bolt holes for cracks and elongation. See “Figure 3-24
(Sheet 1 of 2)” on page III-91. The diameter of the four bolt holes should measure 0.250
+0.005/-0.001 inches.
3) Visually inspect the two (2) sheet metal bends common to the base for cracking, the
entire length of each bend, both inner and outer surfaces. See “Figure 3-24” Sheet 1.
4) If cracking or elongated bolt holes are found, the Rudder Bar Support Assembly must
be replaced before further flight. See the Cherokee Airplane Parts Catalog, P/N 753-
582 to order the appropriate replacemant part.
5) Reinstall the four (4) bolts that secure the rudder bar support assembly to the cockpit
floor.
(c) If no cracks are detected (or upon appropriate replacement of cracked or damaged parts),
make proper log book entry documenting completion of this inspection.

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STEP 2: Inspect welded areas

FW UP
D

SEE SHEET2
DETAILA
DETAIL B

STEPS 3a/3d:
Remove/reinstall 4 bolts

STEP 3b:
Inspect 4 bolt holes
Pedal and Bar
Assembly (ref.)

Rudder Bar STEP 3c:

Support Assembly Inspect 2 bends

Figure 3-24 (Sheet 1 of 2)

Rudder Bar Assembly 100 Inspection

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RUDDER BAR ASSEMBLY

UP

INBD

DETAIL A

RUDDER BAR ASSEMBLY

RUDDER BAR STRAPS:

99938-000 NEAR SIDE
99938-001 FAR SIDE

0.10 IN.

DETAIL B

Figure 3-24 (Sheet 2 of 2)

Rudder Bar Assembly 100 Inspection

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(d) Rudder Bar Assembly Modification

New replacement rudder bar assemblies conform to the configuration shown in Detail B. At
the operator’s discretion, a new replacement rudder bar assembly may be installed in lieu of
the modification described below.
1) Order one each of Piper part numbers (P/N) 99938-000 and 99938-001 rudder bar
straps.
2) Remove the rudder bar assembly from the airplane and disassemble.
NOTE: Removing and reinstalling the rudder bar assembly from the aircraft will
require disconnecting, reinstalling, and rigging of flight control, braking, and
steering systems. Refer to the appropriate sections in this manual for specific
instructions for each system, as well as the required installation torque for
threaded fasteners.
3) Strip the area to be modified using a commercially available chemical paint stripper,
such as Cee-Bee E-2012 or E-2060 paint stripper.
4) Examine the area to be modified for cracks, using the inspection criteria described
in the “Rudder Pedal And Bar Assembly Inspection” on page III-90. Any cracked
components must be replaced prior to proceeding.
5) TIG weld in place one each of (P/N) 99938-000 and 99938-001 rudder bar straps. as
shown in Detail B in “Figure 3-24 (Sheet 2 of 2)” on page III-92, per Chapter 4 of AC
43.13-1B (or latest revision). After welding, relieve residual stress in the affected area:
Heat with a non-carburizing torch flame to 1,000°–1,100° F (538°–593° C) (a brown
red color) then air cool to room temperature. All welding must be performed by a
certified welder.
NOTE: Installation of the rudder bar straps does not relieve the requirement for the
recurring inspection in the “Rudder Pedal And Bar Assembly Inspection” on
page III-90.
6) The following information will assist in the modification:
a) All materials are 4130 normalized steel.
b) The rudder bar tubes have a nominal outside diameter of 0.875 inches and nominal
wall thickness of 0.058 inches.
c) P/N 99938-000 and 99938-001 rudder bar straps are made from sheet steel with a
nominal thickness of 0.040 inches.
7) Descale, degrease and repaint the bare steel on the rudder bar assembly using epoxy
primer (two coats) and a topcoat of matching black color.
8) Reassemble the rudder bar and reinstall into the airplane.
9) Make a logbook entry documenting the modification.

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(26) Rear Seat Quick Disconnect Mechanism Inspection

See Figure 3-25.
This inspection incorporates the recurring inspection requirements of Piper SL 763A as referenced
in AD75-24-02.
(a) Inspection. In PA-28-180 S/N’s 28-7105001 thru 28-7505046, PA-28-235 S/N’s 28-7110001
thru 28-7510016, PA-28R-180 S/N’s 28R-7130001 thru 28R-7130013 and PA-28R-200
S/N’s 28R-7135001 thru 28R-7535041: each 100 hours or at each annual inspection,
whichever comes first, inspect the quick-disconnect mechanism for each rear seat as follows:
1) With one hand, grasp the lower rear portion of the seat and lift up.
2) The rear seat legs should disengage from the retention mechanism with a noticeable
“snap,” when a minimum of 10-15 lbs of pull is applied. If so, inspection is complete.
3) If less effort is required and there is not a noticeable “detent” feel when disengaging
the seat legs, the retention mechanism must be adjusted, below, or replaced (see Parts
Catalog, P/N 753-689).
(b) Adjustment. If the quick-disconnect mechanism fails the above inspection, remove and
adjust the retention clips as shown in Figure 3-26. Reinstall the adjusted clips and reinspect.
1) If the quick-disconnect mechanism passes inspection after adjustment, no further
action is required.
2) If the quick-disconnect mechanism fails the above inspection after adjustment, replace
the retention clips per parts catalog.
(c) Parts Availability. If replacement parts are not immediately available, the aircraft may be
operated with the seat belts securely fastened across each rear seat when unoccupied. A
temporary placard must be installed in full view of the pilot stating: “PRIOR TO TAKE-OFF
ALL SEAT BELTS MUST BE SECURELY FASTENED ACROSS EACH UNOCCUPIED
AFT SEAT.” The airplane may be operated in this fashion only until replacement parts are
delivered, but no longer than the next 100 hour or annual inspection, whichever comes first.

Figure 3-25
Retention Clip Adjustment

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(27) Main Landing Gear Torque Link Greaser Bolt Inspection

This inspection incorporates the recurring inspection requirements of Piper SL 842.
In PA-28-140 S/N’s 28-20001 thru 28-7725290, PA-28-150, -160 S/N’s 28-1 thru 28-4377, PA-
28-180 S/N’s 28-671 thru 28-7505259 and PA-28-235 S/N’s 28-10001 thru 28-7710089; inspect
the main landing gear torque link greaser bolts as follows:
NOTE: The 100 hour inspection requirement can be extended to 500 hours by the installation of
Piper Kit No. 760-910V (to replace Sketch “A” bolt) or a new greaser bolt P/N 79543-
002 (to replace Sketch “B” bolt) depending on which bolt is being replaced (see Figure
3-26).
(a) If the aircraft is on jacks, the main gear struts must be deflated (see Section II) and the piston
axle assembly supported before proceeding.
(b) Remove the greaser bolt holding the main landing gear torque links together.
(c) Thoroughly inspect each bolt using a 10X magnifying glass, or dye check, or magnetic
partical inspection for cracks as shown in Sketches “A” and “B”, Figure 3-26.
(d) If any cracks are found, replace the bolt:
1) When replacing bolts shown in Sketch “A,” install Piper Kit No. 760-910V.
NOTE: For bolts shown in Sketch “A,” Piper recommends they be replaced even if no
cracks are found.
2) When replacing bolts shown in Sketch “B,” replace with P/N 79543-002.
(e) If the struts were deflated, above, re-inflate the struts per Section II and remove airplane
from jacks.
(f) Make appropriate log book entry documenting performance of this inspection.

Figure 3-26
Main Landing Gear Torque Link Greaser Bolt Inspection

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(28) Wing Aft Spar-to-Fuselage Attachment Hardware 100 Hour Inspection

Each 100 hours time-in-service, inspect the aft wing spar-to-fuselage attachment hardware for
both the right and left wings, as follows:
NOTE: Perform the following with weight on wheels (i.e. - not on jacks).
(a) Remove the lower wing-to-fuselage fairing in the area of the wing aft spar.
(b) Lower the flaps to gain access to the head of the wing-to-fuselage attachment bolt.
(c) Inspect the bolt for tightness in the fittings.
1) If bolt is tight:
a) Ensure that the washer(s) are in place on the bolt and ensure the bolts are torqued
as specified in Section IV, Figure 4-2, Sketch B.
b) Re-install the fairings and make a log book entry indicating completion of this
inspection.
2) If the bolt is loose:
a) Remove the bolt and inspect the holes in the fittings for size and make sure no
out-of-round condition exists outside of allowable limits. The specified hole size
for each fitting is 0.3745–0.3765 inch diameter.
b) If the holes meet the requirements specified above, inspect the gap between the
fittings.
1) If gap is below 0.032 inches, it is acceptable to install a replacement
nut P/N 404-532 (MS21042-6), bolt P/N 402-915 (NAS464P6LA6),
and washers P/N’s 690-629 (NAS1149F0663P) and P/N 690-620
(NAS1149F0632P) and torque as specified in Section IV, Figure 4-2,
Sketch B. Ensure that 1½ threads of the bolt protrude from the nut.
2) If the gap is above 0.032 inches, install a thick or thin washer (or any
combination) as necessary to fill the gap, as described in Section IV, Figure
4-2, Sketch B, prior to installation of the nut/bolt combination above.
NOTE: If the gap (before shimming with washers) exceeds 0.15 inches,
contact Piper factory Technical Support through your Piper Dealer
for further instructions.
c) If the holes do not meet the requirements specified above, install Piper Kit No.
767-383.
d) Re-install the fairings and make a log book entry documenting completion of this
inspection.

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9. Unscheduled Maintenance Checks

WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN
SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER
AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION
- SUPPLEMENTARY PUBLICATIONS.)
The following inspections are required in response to specific anomalies encountered during aircraft
operation. Note that the items listed herein are guidelines based on past operating experience. Each
operator should closely monitor his own unique operating conditions/environment and react accordingly
to keep his aircraft airworthy.
NOTE: A log book entry should be made upon completion of any inspections.

A. Lightning Strike
Item Inspection Inspection Interval
†† Propeller. Hartzell Propellers - refer to the Each occurrence,
inspection requirements in the latest before further flight.
revision of Hartzell Manual No. 115N.
McCauley Propellers - see latest
revision of McCauley SB 177.
†† Engine. See latest revisions of appropriate Each occurrence,
Lycoming Service Bulletins before further flight.
and Overhaul Manual.
†† Electrical and Avionics Inspect and check harness, connections, Each occurrence,
Systems. and equipment for high voltage damage, before further flight.
burns and insulation degradation. Replace
or overhaul as required. Consult with
appropriate avionics vendor(s) for
inspections and operational checks. Bench
test alternator and voltage regulator(s).
(See Section XI.)
†† Antennas. Inspect all antenna connections Each occurrance,
for condition and security. before further flight.
†† All exterior surfaces, skins, Inspect for burns, evidence of arcing, Each occurrence,
and structure. and damage on surfaces and bearings. before further flight.
Check for correct material properties in
the area of the strike path. Degauss
engine mount. Replace or repair
affected areas/parts.
†† System Components. Inspect instrumentation, vacuum, Each occurrence,
pitot/static, and fuel systems, before further flight.
for damage and correct operation.
†† Static Wicks. Replace. Each occurrence,
before further flight.

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A. Lightning Strike (continued)

Item Inspection Inspection Interval
†† Bearings. Inspect all control surface hinges and Each occurrence,
bearings, and landing gear and wheel before further flight.
bearings for pitting and damage.
Replace as required.

B. Engine Overtemp, Loss of Oil, or Sudden Stoppage

Item Inspection Inspection Interval
†† Engine. See latest revisions of appropriate Each occurrence,
Lycoming Service Bulletins before further flight.
and Overhaul Manual.
†† Propeller. Refer to latest Sensenich Repair Manual. Each occurrence,
(Sudden Stoppage only.) Remove and recondition before before further flight.
return to service, if required.
†† Propeller. Hartzell Propellers - refer to the Each occurrence,
inspection requirements in the latest before further flight.
revision of Hartzell Manual No. 115N.
McCauley Propellers - see latest revision
of McCauley SB 176 for stoppages/strikes;
McCauley SL 1998-23 for overspeed.
†† Engine Mount and Inspect for distortion and Each occurrence,
Attachments. damage. Replace or repair before further flight.
as required.

C. Severe Turbulence, Hard or Overweight Landing

CAUTION: MINOR OR APPARENTLY SUPERFICIAL DAMAGE MAY INDICATE A MORE
SEVERE CONDITION SOMEWHERE ELSE IN THE STRUCTURE.
(1) Place aircraft in a normal level attitude.
(2) Make a preliminary inspection of checking alignment and out-of-track condition of engine,
wings, tail, landing gear and doors.
(3) Follow Piper and Lycoming Maintenance Manual procedures. If there are any questions regarding
repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA).
(4) Inspect the following items closely to determine the extent of damage:
Item Inspection Inspection Interval
†† Landing Gear Struts. Cracks, signs of overstress Each occurrence,
(Not required for deformation, loose or damaged before further flight.
severe turbulence.) strut housings. Axles for cracks,
bending or flat spots. Damaged oleos
and seals, hydraulic leaks and landing
gear alignment.

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C. Severe Turbulence, Hard or Overweight Landing (continued)

Item Inspection Inspection Interval
†† Wheels, Tires, Brakes. Cracks, chips, loose or cracked Each occurrence,
(Not required for mounting bolts, alignment of slippage before further flight.
severe turbulence.) marks, sidewall distress, hydraulic or
air leaks. Inspect the wheels (dye
penetrant method) and wheel bolts
(magnetic particle method).
†† Wheel Wells and Landing Buckling, cracks, overstress, wing skin Each occurrence,
Gear attach points. buckling, and side brace for before further flight.
(Not required for damage and condition. Inspect
severe turbulence.) landing gear attachment bolts
(magnetic particle method).
†† Wings. Wing attach bolts for slippage, damage Each occurrence,
and overstress. Fasteners securing before further flight.
wing attachment fittings to fuselage
frames and wing spars for condition and
security. Upper and lower wing
skins for wrinkles, cracks, popped or
loose rivets.
†† Remove access plates and inspect for Each occurrence,
internal damage to ribs, stringers and before further flight.
sparwebs; and fuel tanks for damage,
attachment, and leaks.
†† Engine. Engine mounts for distortion and Each occurrence,
damage to elastomeric parts. before further flight.
†† Propeller. Propeller for evidence of ground strike Each occurrence,
(i.e. - hard or overweight landing). before further flight.
†† Fuselage. Loose or missing rivets, door alignment, Each occurrence,
windows and attachments for overstress, before further flight.
cracks or damage. Wing carry through
member for overstress damage.
Stringers, bulkheads, keel beams for
buckling, cracks, or damage. Avionics,
instruments and accessories installation
for security and operation.
†† Empennage. Skins for buckling wrinkles, loose or Each occurrence,
missing rivets. Stabilator, rudder, and before further flight.
vertical fin for security of attachment
and overstress of bolts. Ribs, stringers
for buckling, cracks and damage.

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D. Flaps Extended Above Maximum Flap Extension Speed (Vfe)

Item Inspection Inspection Interval
†† Flap torque tube/pushrod. Inspect for distortion. Replace as Each occurrence,
required. (See Flap Torque Tube/Pushrod before further flight.
Distortion Inspection on page “III-88”.)
†† Flaps. Inspect for damage to the skin and Each occurrence,
attach points. Replace as required. before further flight.

E. Flood Damage, Immersion in Water

(1) These guidelines are general in nature and should be applied or varied to fit the individual aircraft
according to water level, length of time of exposure and other variables. Only those areas that
might not be obvious to the mechanic are addressed.
CAUTION: MAKE ALL REPAIRS AND/OR ADJUSTMENTS IN ACCORDANCE WITH
THE APPROPRIATE PIPER MAINTENANCE MANUAL, THE COMPONENT
MANUFACTURER’S MAINTENANCE MANUAL, AND FAR PART 43. PAY
PARTICULAR ATTENTION TO SILT, CORROSION AND CONTAMINANTS.
(2) Follow Piper and Lycoming Maintenance Manual procedures. If there are any questions regarding
repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA).
(3) Determine the water level on the aircraft. Determine which operating and/or electrical components
have been exposed to the water.
(4) If the following items were immersed, inspect them closely to determine the extent of damage:
Item Inspection Inspection Interval
†† Airframe. Clean silt and contaminants from airframe. If immersed, each
event, before further
flight.
†† Tubular Structures. Check for internal corrosion. If immersed, each
(i.e., Engine Mounts, etc.) event, before further
Clean and represerve as required. flight.
NOTE: See Engine Mount Corrosion Inspection, Immersion in Water, Section VIII.
†† Wings. Inspect to ensure that contaminants If immersed, each
are cleaned from fuel cell areas event, before further
flight.
†† Landing Gear and associated Jack airplane and cycle landing If immersed, each
Bearings, Torque Links, Inspect gear oleos and torque links event, before further
Shimmey Dampeners, etc. to ensure proper operation. flight.
†† Control Surfaces. Remove surface, clean and check If immersed, each
all bearings - relube or replace event, before further
as necessary. flight.
Rebalance before installation.

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E. Flood Damage, Immersion in Water (continued)

Item Inspection Inspection Interval
†† Flight Control System. Clean and inspect all cables, pulleys, If immersed, each
and bearings for evidence of corrosion. event, before further
Replace corroded cables. flight.
Re-preserve galvanized cable
with MIL-C-11796 Class 2 (hot).
†† Trim Control System. Clean and inspect all trim system If immersed, each
cables, pulleys, drums, bearings, event, before further
jack screws, etc. Do not apply flight.
preservation to trim cables.
†† Actuating Cables. Inspect “push-pull” actuating cables If immersed, each
for powerplant, heating and event, before further
ventilating system, fuel system, etc. flight.
for proper operation.
†† Engine. Remove, disassemble, and inspect. If immersed, each
Examine all parts paying particular event, before further
attention for evidence of corrosion, flight.
rust or contaminants imbedded on
bearing surfaces, piston, mounting
flanges or any aluminum, magnesium
or bronze surface that may be porous.
†† Remove evidence of rust, or corrosion. If immersed, each event,
If pitting in stressed areas is found the before further flight.
part should not be reused. Silt imbedded
in porous surfaces may be removed.
Be certain oil passages, dowel holes and
similar hidden openings and recesses
are thoroughly free from contaminants.
†† Test electrical components and fuel If immersed, each event,
metering devices in accordance with before further flight.
manufacturer’s instructions to determine
fitness for future use.
†† Reassemble engine using new seals, If immersed, each event,
gaskets, stressed bolts nuts and before further flight.
crankshaft sludge tubes. All reused parts
must conform with Lycoming Table of
Limits No. SSP-1776 for fits and
clearances.
†† See latest revision of Lycoming Service If immersed, each event,
Bulletin No. 357. before further flight.

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E. Flood Damage, Immersion in Water (continued)

Item Inspection Inspection Interval
†† Engine Accessories. Inspect. Aircraft systems that supply If immersed, each
either fuel or oil to the engine must be event, before further
thoroughly cleaned, including oil cooler, flight.
lines, valves, etc. to prevent
contamination of the engine after
reinstallation.
†† Propeller. Inspect and repair as necessary If immersed, each
in an authorized propeller shop. event, before further
flight.
†† Electrical Systems. Replace all circuit breakers and If immersed, each event,
switches. before further flight.
†† Replace all solenoids, relays and If immersed, each event,
master contactors. before further flight.
†† Replace battery. If immersed, each event,
before further flight.
†† Disassemble all connectors; clean If immersed, each event,
and inspect for corrosion. Replace all before further flight.
corroded or pitted connectors. Inspect
for wire corrosion at connector.
†† Check all harness assemblies for If immersed, each event,
entrapped contaminants. Clean and before further flight.
check for short circuits.
†† Remove electric motors and electric If immersed, each event,
pumps. before further flight.
†† Remove all potted solid state electrical If immersed, each event,
equipment such as alternator inop. before further flight.
switches, low fuel warning switches, etc.
Clean, dry and bench test per
appropriate maintenance manual.
†† Clean and check voltage regulators and If immersed, each event,
overvoltage relays. Replace as necessary before further flight.
†† Clean and check aIl strobe light power If immersed, each event,
supplies. Refer to appropriate before further flight.
maintenance manual.
†† Replace all fuel senders, etc. If immersed, each event,
before further flight.
†† Clean, inspect and check heated If immersed, each event,
pitot systems. before further flight.

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E. Flood Damage, Immersion in Water (continued)

Item Inspection Inspection Interval
†† Autopilot System. Bench test in accordance with If immersed, each
(If Installed.) appropriate maintenance manual. event, before further
Pay particular attention to clutch settings. flight.
†† Vacuum and Pitot-Static Replace gyros. If immersed, each event,
Systems. before further flight.
†† Replace filters. If immersed, each event,
before further flight.
†† Clean and inspect all lines, and pitot If immersed, each event,
and static vents. before further flight.
†† Clean and check all regulating valves. If immersed, each event,
before further flight.
†† Remove and inspect engine driven and If immersed, each event,
auxiliary vacuum pumps. before further flight.
†† Induction System. Clean and inspect for silt and If immersed, each
corrosion. Check all ducts and gaskets. event, before further
Replace as necessary. flight.
†† Clean and inspect all heat shrouds If immersed, each event,
and ducting. before further flight.
†† Fuel System. Perform Fuel Tank/Wing Spar Corrosion If immersed, each
Inspection. Remove and clean event, before further
fuel cells and fuel cells wing area. Clean flight.
all associated lines and pumps.
†† Clean and inspect all fuel tank vents, If immersed, each event,
cap vents and vent lines. before further flight.
†† Instruments. Clean and inspect instruments. Bench If immersed, each
check per appropriate maintenance event, before further
manual. flight.
†† Heating and Ventilating Replace blower. If immersed, each event,
Systems. before further flight.
†† Clean and inspect all distribution boxes, If immersed, each event,
ducting and valves. before further flight.
†† Inspect and check system control cables. If immersed, each event,
Replace corroded or binding cables. before further flight.
†† If installed, clean and inspect air If immersed, each event,
conditioning evaporator, condenser, before further flight.
and compressor.

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E. Flood Damage, Immersion in Water (continued)

Item Inspection Inspection Interval
†† Avionics Systems. Replace avionics. If immersed, each event,
before further flight.
†† Antennas. Clean and inspect antennas If immersed, each event,
and connectors. before further flight.
†† Insulation and Upholstery. Remove all wet insulation and upholstery. If immersed, each
Thoroughly clean and dry (or replace) event, before further
to ensure corrosion is not promoted in flight.
adjacent structures.

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10. Service Publications List

“Table III-III” is a cumulative list of Piper service publications (i.e., Service Bulletins (SB), Service
Letters (SL), and Vendor Service Publications (VSP)) applicable to the airplane models covered by this
manual, with the following exceptions:
A. Service publications which have been fully incorporated into this manual are not listed, These include
SBs 251C, 297, 309, 327, 332, 355, 356, 448, 556, 571A, 691A, 856, 886, 965, 975, 977, 1006,
1131A, 1156, 1161A, 1242, 1244C, and 1245A; SLs 324C, 381, 396, 413, 436, 527D, 576, 581, 600,
609. 615, 616, 621, 662, 740, 747, 763A, 842, 903A, 910, 997, 1041, 1052, 1069, 1087, and 1135;
and VSPs .
B. Nor are service publications which have become obsolete. These include SL 493.
Kits are listed when installation of that single kit indicates compliance with the associated service
publication. Kits listed may be no longer available or may have been replaced.
Effectivity is listed by airplane model and year. See the individual service publication for specific serial
number applicability.
NOTE: Owners of PA-28S’s should consider service publications applicable to PA-28 airplanes of the
same model year and serial number range to be effective for their airplanes.

Table III-III
SERVICE PUBLICATIONS LIST
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28 All SL 682B Lycoming SB 367D, Piston Pin Inspection
SL 653 Lycoming SI 1265, Serrated Throttle Lever and Shaft
SL 718 Lycoming SB 373, Bendix SB 566, S-1200 Distributor Block
and Gear Change
SL 1141 Gascolater Maintenance Procedures
SL 1229 Control Quadrant Inspection
SL 1265 Flight Control System Checks
AltiMaticAP SL 638A Edo-Aire Mitchell SL No. ML-35, Servo Lubrication
Piper II AP SL 695 Edo-Aire Mitchell SL No. ML-38, Roll Servo Inspection,
Maintenance, and Shear Pin Installation
PA-28-140 1964 SL 425 Lycoming SB 298 - AC Fuel Pump Vent Restrict
SL 442 AC Fuel Pump Replacement
1964-1965 SL 458 Throttle Clamp Replacement
1964-1966 SB 240 Corrosion Inspection - Aileron, Stabilator, Rudder
1964-1967 SB 245 Family Seats Center Safety Belt Inspection
SB 248 757-123 Main Gear Torque Links
SB 261 760-162 Aft Spar Wing Attachment Bolts Inspection
SB 313 Magneto Filter Terminals
1964-1968 SL 503 Oil Cooler Hose Inspection
SL 577 Servo Bridle Cable Clamp Replacement
SL 864 III 763-874 Turn & Slip Indicator Conversion
1964-1969 SB 287 Tailpipe Replacement

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TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-140 1964-1970 SB 317 760-451 Vertical Fin Rib Inspection
(cont.) SB 322 760-477 Vacuum Pump Adapter Drive Assembly
SB 326 Fuel Valve Selector Handle (2-Tank) Inspection
1964-1971 SL 566 760-508 Autopilot Servo Spacer Bushing Install
SL 644 Throttle Operation - Precautionary Placard
SB 360 760-640 Air Induction Hose System Mod
SB 531 Engine Oil Hose Replacement
SB 840A Fuel Selector Valve Cover Replacement
SL 571 760-531 Flap Handle Assembly Modification
1964-1973 SB 387 760-741 Alternator Installation Mod
SB 395 Warning - Improper Use of Rudder Pedals
SB 789B 764-998 Aft Wing Spar Modification
SB 789B 765-106 Aft Inboard Wing Access Panel Retrofit
SL 620 760-729 Forward Cabin Door Reinforcement
1964-1975 SL 761 760-795 Magnetic Compass Relocation Kit
1964-1977 SB 717 Fuel Selector Line Inspection
SB 753 Expanded Spin Recovery Procedures
SB 836A Aluminum Wire Inspection / Replacement
SB 896 Shoulder Harness Installation and Usage
SB 1022 Inspection of Induction Air Filter / Purolator SB
SB 1026 Airborne SL 48 / Dry Air Pump Flexible Couplings
SB 1041 Airborne SL 56 / Air Filter Inspection & Cleaning
SB 1197E Control Wheel Shaft Inspection
SB 1304A Main Wing Spar Inspection
SB 1309A Fuel Tank Selector Placards Examination
SB 1131A Inspection Of ‘Cast’ Main Landing Gear Strut Cylinders
SB 1199 Main Landing Gear Torque Link Inspection (AD 72-08-06)
SL 793 Flap Warning Placard
SL 845 763-828 Engine Breather Tube Winterization Kit
SL 1093B Electrical Contactor Replacement Kit
SL 1116A Contactor Maintenance
1965 SB 223 756-906 Fuel Quantity Gauge Sender Unit Mod
1965-1966 SB 237 757-085 Rudder Trim Installation Mod
1965-1977 SL 612A Fuselage Leak - Fuel Sender Unit
1966-1967 SL 494 757-165 Cherokee Landing Gear Inspection
1967-1969 SL 535A Rudder Trim Locking Pin - Securing
1967-1977 SB 642 Air Filter Seal Inspection
1968 SB 281 R.C. Allen Service Bulletin No. 1, Artificial Horizon
1969 SB 293 760-314 Baggage Floor Brace
SB 312 760-387 Carburetor Heat Cable Replacement
1969-1970 SB 305 Carburetor Drain Plugs Inspection
1969-1972 SB 357A Alternator Output Wire Terminal Replacement
1969-1974 SB 427 760-822 Air Conditioning System Mod
SL 670A Throttle Control Modification
1969-1976 SL 758 761-065 Bendix Ignition Switches Inspection

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TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-140 1969-1977 SB 548 Engine Control Rod End Bearing Inspection
(cont.) SL 864 II 763-870 Cabin Heat Control Refinement
1970-1971 SB 337 760-532 Vertically Adjustable Seat Frame Tube Replace
1971-1972 SB 348 760-581 Air Conditioning System Improvement
SB 360 760-635 Air Induction Hose System Mod
SL 611 760-599 Oil Cooler Hose Repositioning
1971-1976 SL 788 Air Conditioning Installation
1971-1977 SB 1313A Stabilator Trim Pulley Bracket Inspection
1972 SB 350 Stabilator Hinge Attaching Bolts Inspection
SB 368 760-697 Transponder Antenna Protector Installation
1972-1973 SB 393 760-794 Rear Seat Belt Attachment Mod
1972-1977 SB 533 Fuel Gauge Calibration Inspection
1973 SL 647 760-740 Seat Back Stop Modification
1973-1974 SL 734 760-857 Bendix ADF-T-12
1974 SL 700 760-842 Toe Brake System Modification
SL 715 760-876 ELT Switch Cover Modification
1974-1975 SB 450 Fuel Gascolator Quick Drain Valve Inspection
SB 475 Instrument Panel Dimmer Control Assy Mod
SL 745 Wing Main Spar Attachment Bolts Inspection
1974-1976 SL 762 761-009 ELT Remote Switch Modification
1975 SB 449A Chrysler Alternator Mod & Wire End Terminal Repl
1975-1976 SL 800 Narco ADF-140 Installation
1975-1977 SB 623 Diode Assembly Inspection
SL 836 Narco ADF-140/141 Antenna Inspection & Mod.
PA-28-150 1961 SL 375 Micarta Sleeve
1961-1962 SB 209 754-462 Propeller Bolts Replacement
SL 373 Oil Shields on Dry Vacuum Pumps (Airborne)
SL 374 Bulkhead Modification
SL 389 756-704V Exhaust Stacks Inspection and Modification
1961-1963 SL 390 Cherokee Gas Cap Placard
1961-1964 SB 287 Tailpipe Replacement
SB 360 760-640 Air Induction Hose System Mod
SB 774 760-455 Baggage Door Latch Replacement
SB 1304A Main Wing Spar Inspection
SB 1309A Fuel Tank Selector Placards Examination
SB 1131A Inspection Of ‘Cast’ Main Landing Gear Strut Cylinders
SL 425 Lycoming SB 298 - AC Fuel Pump Vent Restrict
SL 442 AC Fuel Pump Replacement
1961-1965 SL 458 Throttle Clamp Replacement
1961-1966 SB 240 Corrosion Inspection - Aileron, Stabilator, Rudder
1961-1967 SB 248 757-123 Main Gear Torque Links
SB 261 760-162 Aft Spar Wing Attachment Bolts Inspection
SB 313 Magneto Filter Terminals
SB 717 Fuel Selector Line Inspection
SB 789B 764-998 Aft Wing Spar Modification
SB 789B 765-106 Aft Inboard Wing Access Panel Retrofit

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TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-150 1961-1967 SB 836A Aluminum Wire Inspection / Replacement
(cont.) (cont.) SB 840A Fuel Selector Valve Cover Replacement
SB 896 Shoulder Harness Installation and Usage
SB 1022 Inspection of Induction Air Filter / Purolator SB
SB 1026 Airborne SL 48 / Dry Air Pump Flexible Couplings
SB 1041 Airborne SL 56 / Air Filter Inspection & Cleaning
SB 1199 Main Landing Gear Torque Link Inspection (AD 72-08-06)
SL 571 760-531 Flap Handle Assembly Modification
SL 620 760-729 Forward Cabin Door Reinforcement
SL 644 Throttle Operation - Precautionary Placard
SL 761 760-795 Magnetic Compass Relocation Kit
SL 793 Flap Warning Placard
SL 845 763-828 Engine Breather Tube Winterization Kit
SL 864 III 763-874 Turn & Slip Indicator Conversion
SL 11093B Electrical Contactor Replacement Kit
SL 1116A Contactor Maintenance
1961-1970 SB 317 760-451 Vertical Fin Rib Inspection
SB 326 Fuel Valve Selector Handle (2-Tank) Inspection
1961-1973 SB 395 Warning - Improper Use of Rudder Pedals
1963-1967 SL 566 760-508 Autopilot Servo Spacer Bushing Install
SL 577 Servo Bridle Cable Clamp Replacement
1964-1965 SB 223 756-906 Fuel Quantity Gauge Sender Unit Mod
SL 457 756-963 Plastic Spinners on Cherokee C
1964-1966 SB 234 757-047 Spinner Mod
SB 237 757-085 Rudder Trim Installation Mod
SL 471A 757-006 Prop Spinner Inspection
1964-1967 SB 360 760-639 Air Induction Hose System Mod
SB 774 760-456 Baggage Door Latch Replacement
SB 1197E Control Wheel Shaft Inspection
SL 612A Fuselage Leak - Fuel Sender Unit
SL 796 Lower Cowl Drain Insp & Mod
1964-1973 SB 387 760-742 Alternator Installation Mod
1966-1967 SB 811A 765-186 Ammeter Replacement
SL 494 757-165 Throttle Clamp Replacement
1966-1972 SB 357A Alternator Output Wire Terminal Replacement
PA-28-160 1961 SL 375 Micarta Sleeve
1961-1962 SB 209 754-462 Propeller Bolts Replacement
SL 373 Oil Shields on Dry Vacuum Pumps (Airborne)
SL 374 Bulkhead Modification
SL 389 756-704V Exhaust Stacks Inspection and Modification
1961-1963 SL 390 Cherokee Gas Cap Placard
1961-1964 SB 287 Tailpipe Replacement
SB 360 760-640 Air Induction Hose System Mod
SB 774 760-455 Baggage Door Latch Replacement
SB 1304A Main Wing Spar Inspection

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-160 1961-1964 SB 1309A Fuel Tank Selector Placards Examination
(cont.) (cont.) SB 1131A Inspection Of ‘Cast’ Main Landing Gear Strut Cylinders
SL 425 Lycoming SB 298 - AC Fuel Pump Vent Restrict
SL 442 AC Fuel Pump Replacement
1961-1965 SL 458 Throttle Clamp Replacement
1961-1966 SB 240 Corrosion Inspection - Aileron, Stabilator, Rudder
1961-1967 SB 248 757-123 Main Gear Torque Links
SB 261 760-162 Aft Spar Wing Attachment Bolts Inspection
SB 313 Magneto Filter Terminals
SB 317 760-451 Vertical Fin Rib Inspection
SB 326 Fuel Valve Selector Handle (2-Tank) Inspection
SB 395 Warning - Improper Use of Rudder Pedals
SB 717 Fuel Selector Line Inspection
SB 789B 764-998 Aft Wing Spar Modification
SB 789B 765-106 Aft Inboard Wing Access Panel Retrofit
SB 836A Aluminum Wire Inspection / Replacement
SB 840A Fuel Selector Valve Cover Replacement
SB 896 Shoulder Harness Installation and Usage
SB 1022 Inspection of Induction Air Filter / Purolator SB
SB 1026 Airborne SL 48 / Dry Air Pump Flexible Couplings
SB 1041 Airborne SL 56 / Air Filter Inspection & Cleaning
SB 1199 Main Landing Gear Torque Link Inspection (AD 72-08-06)
SL 571 760-531 Flap Handle Assembly Modification
SL 620 760-729 Forward Cabin Door Reinforcement
SL 644 Throttle Operation - Precautionary Placard
SL 761 760-795 Magnetic Compass Relocation Kit
SL 793 Flap Warning Placard
SL 845 763-828 Engine Breather Tube Winterization Kit
SL 864 III 763-874 Turn & Slip Indicator Conversion
SL 1093B Electrical Contactor Replacement Kit
SL 1116A Contactor Maintenance
SL 1125 Stall Horn Bracket Replacement
VSP-153 Lycoming SB 555 - Oil Pump Body Plug Inspect
1963-1967 SL 566 760-508 Autopilot Servo Spacer Bushing Install
SL 577 Servo Bridle Cable Clamp Replacement
1964-1965 SB 223 756-906 Fuel Quantity Gauge Sender Unit Mod
SL 457 756-963 Plastic Spinners on Cherokee C
1964-1966 SB 234 757-047 Spinner Mod
SB 237 757-085 Rudder Trim Installation Mod
SL 471A 757-006 Prop Spinner Inspection
1964-1967 SB 360 760-639 Air Induction Hose System Mod
SB 387 760-742 Alternator Installation Mod
SB 774 760-456 Baggage Door Latch Replacement
SB 1197E Control Wheel Shaft Inspection
SL 612A Fuselage Leak - Fuel Sender Unit
SL 796 Lower Cowl Drain Insp & Mod

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TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-160 1966-1967 SB 357A Alternator Output Wire Terminal Replacement
(cont.) SB 811A 765-186 Ammeter Replacement
SL 494 757-165 Throttle Clamp Replacement
PA-28-180 1962-1963 SL 390 Cherokee Gas Cap Placard
1962-1964 SB 287 Tailpipe Replacement
SB 360 760-636 Air Induction Hose System Mod
SL 425 Lycoming SB 298 - AC Fuel Pump Vent Restrict
SL 442 AC Fuel Pump Replacement
1962-1965 SL 458 Throttle Clamp Replacement
SL 473 Sensenich SB R-11 (Inspection)
1962-1966 SB 240 Corrosion Inspection - Aileron, Stabilator, Rudder
1962-1967 SB 248 757-123 Main Gear Torque Links
SB 261 760-162 Aft Spar Wing Attachment Bolts Inspection
SB 1199 Main Landing Gear Torque Link Inspection (AD 72-08-06)
SB 313 Magneto Filter Terminals
SL 864 III 763-874 Turn & Slip Indicator Conversion
1962-1970 SB 317 760-451 Vertical Fin Rib Inspection
SB 322 760-477 Vacuum Pump Adapter Drive Assembly
SB 326 Fuel Valve Selector Handle (2-Tank) Inspection
1962-1971 SB 840A Fuel Selector Valve Cover Replacement
SL 571 760-531 Flap Handle Assembly Modification
1962-1972 SL 620 760-729 Forward Cabin Door Reinforcement
SL 1116A Contactor Maintenance
SL 1125 Stall Horn Bracket Replacement
1962-1973 SB 395 Warning - Improper Use of Rudder Pedals
SB 789B 764-998 Aft Wing Spar Modification
SB 789B 765-106 Aft Inboard Wing Access Panel Retrofit
1962-1975 SB 717 Fuel Selector Line Inspection
SB 836A Aluminum Wire Inspection / Replacement
SB 896 Shoulder Harness Installation and Usage
SB 1022 Inspection of Induction Air Filter / Purolator SB
SB 1026 Airborne SL 48 / Dry Air Pump Flexible Couplings
SB 1041 Airborne SL 56 / Air Filter Inspection & Cleaning
SB 1309A Fuel Tank Selector Placards Examination
SB 1131A Inspection Of ‘Cast’ Main Landing Gear Strut Cylinders
SB 1304A Main Wing Spar Inspection
SL 761 760-795 Magnetic Compass Relocation Kit
SL 793 Flap Warning Placard
SL 845 763-828 Engine Breather Tube Winterization Kit
VSP-174 Lycoming SB 569 - Crankshaft Retirement
1963-1968 SL 577 Servo Bridle Cable Clamp Replacement
1963-1970 SL 566 760-508 Autopilot Servo Spacer Bushing Install
1964-1965 SB 223 756-906 Fuel Quantity Gauge Sender Unit Mod
SL 457 756-963 Plastic Spinners on Cherokee C

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-180 1964-1966 SB 234 757-046 Spinner Mod
(cont.) SB 237 757-085 Rudder Trim Installation Mod
SL 471A 757-006 Prop Spinner Inspection
1964-1969 SB 774 760-456 Baggage Door Latch Replacement
1964-1973 SB 360 760-639 Air Induction Hose System Mod
SB 387 760-742 Alternator Installation Mod
1964-1975 SB 1197E Control Wheel Shaft Inspection
SL 612A Fuselage Leak - Fuel Sender Unit
SL 796 Lower Cowl Drain Insp & Mod
1964-1977 SL 1116A Contactor Maintenance
1966-1967 SL 494 757-165 Throttle Clamp Replacement
1966-1972 SB 357A Alternator Output Wire Terminal Replacement
1966-1975 SB 811A 765-186 Ammeter Replacement
1967-1971 SB 510B 761-074 Nose Landing Gear Trunnion Mod
SB 1286A Lycoming Service Bulletin No. 621B
1968 SB 281 R.C. Allen Service Bulletin No. 1, Artificial Horizon
1968-1969 SB 295 Control Wheel Retaining Pin
SB 298 760-320 Carburetor Heat Control Assembly
1968-1969 SL 535A Rudder Trim Locking Pin - Securing
1968-1970 SB 305 Carburetor Drain Plugs Inspection
1968-1975 SB 548 Engine Control Rod End Bearing Inspection
SB 1313A Stabilator Trim Pulley Bracket Inspection
SL 758 761-065 Bendix Ignition Switches Inspection
SL 864 II 763-870 Cabin Heat Control Refinement
SL 1093B Electrical Contactor Replacement Kit
1970-1971 SB 337 760-532 Vertically Adjustable Seat Frame Tube Replace
1970-1974 SB 427 760-822 Air Conditioning System Mod
1972 SB 350 Stabilator Hinge Attaching Bolts Inspection
SB 368 760-697 Transponder Antenna Protector Installation
1972-1973 SB 393 760-794 Rear Seat Belt Attachment Mod
1972-1975 SB 533 Fuel Gauge Calibration Inspection
SL 1040 767-310 Alternator Drive Belt Conversion Kit
SL 735 Muffler Shroud Modification
SL 788 Air Conditioning Installation
1973 SL 647 760-740 Seat Back Stop Modification
1973-1974 SL 734 760-857 Bendix ADF-T-12
1973-1975 SB 436 Operating Limitations Placard Inspection
1974 SL 700 760-842 Toe Brake System Modification
SL 715 760-876 ELT Switch Cover Modification
1974-1975 SB 450 Fuel Gascolator Quick Drain Valve Inspection
SB 475 Instrument Panel Dimmer Control Assy Mod
SL 745 Wing Main Spar Attachment Bolts Inspection
SL 756 Dual Glideslope Indicator Placard
SL 762 761-009 ELT Remote Switch Modification

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-180 1975 SB 449A Chrysler Alternator Mod & Wire End Terminal Repl
(cont.) SB 623 Diode Assembly Inspection
SB 804 765-157 Battery Strap Installation
SL 800 Narco ADF-140 Installation
SL 836 Narco ADF-140/141 Antenna Inspection & Mod.
PA-28-235 1964 SB 774 760-455 Baggage Door Latch Replacement
SL 421 Oil Cooler Inspection, Stewart-Warner
SL 425 Lycoming SB 298 - AC Fuel Pump Vent Restrict
SL 429 Oil Cooler Replacement
SL 442 AC Fuel Pump Replacement
1964-1965 SB 223 756-906 Fuel Quantity Gauge Sender Unit Mod
SB 253 757-151 Tip Tank Fuel Line Mod
SL 456 756-959 Constant Speed Propeller Control
SL 458 Throttle Clamp Replacement
SL 856 763-883 Fuel Drain Cover Replacement
SL 864 III 763-874 Turn & Slip Indicator Conversion
1964-1966 SB 237 757-085 Rudder Trim Installation Mod
SB 240 Corrosion Inspection - Aileron, Stabilator, Rudder
SB 285 760-251 Fuel Selector Control Stop Assembly
SB 313 Magneto Filter Terminals
1964-1967 SB 248 757-123 Main Gear Torque Links
SB 249A 757-139 Fuel System Improvement
SB 261 760-162 Aft Spar Wing Attachment Bolts Inspection
SB 376 760-681 Fuel Selector Control System Mod
SL 495 Constant Speed Propeller Control Cable Inspection
SL 577 Servo Bridle Cable Clamp Replacement
SL 1268 Hartzell “K” Flange Propeller Hub Replacement
1964-1969 SB 774 760-456 Baggage Door Latch Replacement
1964-1970 SB 311A 760-438 Fuel Selector Valve Mod
SB 317 760-451 Vertical Fin Rib Inspection
SB 322 760-477 Vacuum Pump Adapter Drive Assembly
SL 566 760-508 Autopilot Servo Spacer Bushing Install
SL 571 760-531 Flap Handle Assembly Modification
1964-1971 SB 342 760-560 Fuel System Instructions and Mod
1964-1972 SL 620 760-729 Forward Cabin Door Reinforcement
1964-1973 SB 360 760-634 Air Induction Hose System Mod
SB 387 760-742 Alternator Installation Mod
SB 395 Warning - Improper Use of Rudder Pedals
SB 789B 764-998 Aft Wing Spar Modification
SB 789B 765-106 Aft Inboard Wing Access Panel Retrofit
SL 796 Lower Cowl Drain Insp & Mod
1964-1975 SL 761 760-795 Magnetic Compass Relocation Kit
SL 793 Flap Warning Placard
1964-1976 SB 519A Fuel Selector Valve Inspection & Replacement
1964-1977 SB 580 Engine Cowling Air Scoop Drain Hole
SB 805A Hartzell SB No. 142B - O-Ring Deterioration

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-235 1964-1977 SB 836A Aluminum Wire Inspection / Replacement
(cont.) (cont.) SB 896 Shoulder Harness Installation and Usage
SB 1022 Inspection of Induction Air Filter / Purolator SB
SB 1026 Airborne SL 48 / Dry Air Pump Flexible Couplings
SB 1041 Airborne SL 56 / Air Filter Inspection & Cleaning
SB 1197E Control Wheel Shaft Inspection
SB 1131A Inspection Of ‘Cast’ Main Landing Gear Strut Cylinders
SB 1304A Main Wing Spar Inspection
SL 612A Fuselage Leak - Fuel Sender Unit
SL 1093B Electrical Contactor Replacement Kit
SL 1116A Contactor Maintenance
SL 1268 Hartzell ‘K’ Flange Propeller Hub Replacement
VSP-148 Lycoming SB 554 - Crankshaft Gear Bolt Replace
VSP-152 Lycoming SB 554, Supl 3 - Crankshaft Gear Bolt
VSP-174 Lycoming SB 569 - Crankshaft Retirement
1965-1967 SB 253 757-152 Tip Tank Fuel Line Mod
1966-1967 SL 494 757-165 Throttle Clamp Replacement
1966-1972 SB 357A Alternator Output Wire Terminal Replacement
1966-1977 SB 811A 765-186 Ammeter Replacement
1967 SB 376 760-682 Fuel Selector Control System Mod
1967-1968 SB 281 R.C. Allen Service Bulletin No. 1, Artificial Horizon
1968-1969 SB 295 Control Wheel Retaining Pin
SB 298 760-320 Carburetor Heat Control Assembly
SB 376 760-683 Fuel Selector Control System Mod
1968-1970 SB 305 Carburetor Drain Plugs Inspection
SL 535A Rudder Trim Locking Pin - Securing
1968-1976 SL 758 761-065 Bendix Ignition Switches Inspection
1968-1977 SL 864 II 763-870 Cabin Heat Control Refinement
1970-1971 SB 337 760-532 Vertically Adjustable Seat Frame Tube Replace
1970-1973 SB 376 760-684 Fuel Selector Control System Mod
1971-1977 SL 836 Narco ADF-140/141 Antenna Inspection & Mod
SB 1199 Main Landing Gear Torque Link Inspection (AD 72-08-06)
1972 SB 350 Stabilator Hinge Attaching Bolts Inspection
1972-1973 SB 368 760-697 Transponder Antenna Protector Installation
SB 393 760-794 Rear Seat Belt Attachment Mod
1972-1976 SB 533 Fuel Gauge Calibration Inspection
1973 SL 647 760-740 Seat Back Stop Modification
SL 1125 Stall Horn Bracket Replacement
1973-1974 SL 720 Fuel - Placard - Light Wire Rerouting
SL 734 760-857 Bendix ADF-T-12
1973-1977 SB 548 Engine Control Rod End Bearing Inspection
SB 1198A Fuel Selector O-Ring
1974 SL 700 760-842 Toe Brake System Modification
SL 715 760-876 ELT Switch Cover Modification

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28-235 1974-1975 SB 444 760-895 Fuel Valve Replacement
(cont.) SB 475 Instrument Panel Dimmer Control Assy Mod
SL 745 Wing Main Spar Attachment Bolts Inspection
SL 756 Dual Glideslope Indicator Placard
1974-1976 SL 762 761-009 ELT Remote Switch Modification
1975 SB 449A Chrysler Alternator Mod & Wire End Terminal Repl
1975-1976 SL 800 Narco ADF-140 Installation
1975-1977 SB 623 Diode Assembly Inspection
SB 804 765-157 Battery Strap Installation
1976 SB 543 Starter/Magneto Switch Inspection & Replacement
1977 SB 646A 763-934 Fuel Tank Vent Mod & Vent Hose Replacement
PA-28R All SB 1251 Stabilator Trim Barrel Inspection
SB 1284B Lycoming Service Bulletin No. 622A
SL 1141 Gascolater Maintenance Procedures
SL 1165 Hydraulic Pump Indentification and Service Requirements
SL 1229 Control Quadrant Inspection
SL 1265 Flight Control System Checks
PA-28R-180 1967-1968 SB 261 760-162 Aft Spar Wing Attachment Bolts Inspection
SB 274 760-208 Main Gear Retraction Fitting Replacement
SB 288 Engine Breather Line Mod
SL 577 Servo Bridle Cable Clamp Replacement
1967-1969 SB 292 760-292 Landing Gear Mods
SB 295 Control Wheel Retaining Pin
SB 774 760-456 Baggage Door Latch Replacement
1967-1970 SB 316 Flight Manual Weight and Balance Data Revision
SB 317 760-451 Vertical Fin Rib Inspection
SB 322 760-477 Vacuum Pump Adapter Drive Assembly
SB 326 Fuel Valve Selector Handle (2-Tank) Inspection
SL 566 760-508 Autopilot Servo Spacer Bushing Install
SL 568 Engine Mount Tubes Inspection
SL 571 760-531 Flap Handle Assembly Modification
1967-1971 SB 357A Alternator Output Wire Terminal Replacement
SB 360 760-638 Air Induction Hose System Mod
SB 387 760-742 Alternator Installation Mod
SB 395 Warning - Improper Use of Rudder Pedals
SB 611 Hose Assembly Inspection and Replacement
SB 717 Fuel Selector Line Inspection
SB 738 Nose Landing Gear Actuator Rod End Inspection
SB 769 760-542 Landing Gear Back-up Actuator Override Mech
SB 789B 764-998 Aft Wing Spar Modification
SB 789B 765-106 Aft Inboard Wing Access Panel Retrofit
SB 805A Hartzell SB No. 142B - O-Ring Deterioration
SB 811A 765-186 Ammeter Replacement
SB 836A Aluminum Wire Inspection / Replacement

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 PIPER CHEROKEE SERVICE MANUAL

TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28R-180 1967-1971 SB 840A Fuel Selector Valve Cover Replacement
(cont.) (cont.) SB 866A 765-303 Backup Landing Gear Extender Removal / AM of C
SB 896 Shoulder Harness Installation and Usage
SB 940A Throttle Microswitch
SB 1023 Inspection of Landing Gear Retract Cylinder
SB 1026 Airborne SL 48 / Dry Air Pump Flexible Couplings
SB 1041 Airborne SL 56 / Air Filter Inspection & Cleaning
SB 1118 Alternate Air Inlet Adapter Inspection
SB 1134 Servo Metered Fuel Pressure Port Leakage
SB 1197E Control Wheel Shaft Inspection
SB 1309A Fuel Tank Selector Placards Examination
SB 1313A Stabilator Trim Pulley Bracket Inspection
SB 1331A Stabilator Idler Arm Assembly Inspection
SB 1161A Rib Assembly Inspection & Modification - Aft Wing, WS 49.25
SB 578B Fuel Line and Support Clamp Inspection and Installation
SL 612A Fuselage Leak - Fuel Sender Unit
SL 620 760-729 Forward Cabin Door Reinforcement
SL 758 761-065 Bendix Ignition Switches Inspection
SL 761 760-795 Magnetic Compass Relocation Kit
SL 793 Flap Warning Placard
SL 808 Hydraulic Pump Terminal Inspection
SL 810 761-138 Diaphragm - Backup LG Extender
SL 845 763-828 Engine Breather Tube Winterization Kit
SL 864 II 763-871 Cabin Heat Control Refinement
SL 988 764-377 Nose Landing Gear Modification
SL 1093B Electrical Contactor Replacement Kit
SL 1116A Contactor Maintenance
SL 1268 Hartzell “K” Flange Propeller Hub Replacement
VSP-155 Cleveland SB 7076 - Inspect/Repl Gear Actuator
VSP-174 Lycoming SB 569 - Crankshaft Retirement
1968 SB 281 R.C. Allen Service Bulletin No. 1, Artificial Horizon
1968-1971 SB 548 Engine Control Rod End Bearing Inspection
1969 SL 535A Rudder Trim Locking Pin - Securing
1970-1971 SB 337 760-532 Vertically Adjustable Seat Frame Tube Replace
SL 607 Emergency Gear Lever Knob
1971 SB 339 Owner’s Handbook Revision
SL 626 Landing Gear Bolt Lubrication
PA-28R-200 1968-1971 SL 587 760-558 Engine Baffle Modification
1968-1976 SB 811A 765-186 Ammeter Replacement
SL 1268 Hartzell “K” Flange Propeller Hub Replacement
1969 SB 295 Control Wheel Retaining Pin
SL 535A Rudder Trim Locking Pin - Securing
1969-1970 SB 316 Flight Manual Weight and Balance Data Revision
SB 317 760-451 Vertical Fin Rib Inspection
SB 322 760-477 Vacuum Pump Adapter Drive Assembly
SB 326 Fuel Valve Selector Handle (2-Tank) Inspection

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TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28R-200 1969-1970 SL 566 760-508 Autopilot Servo Spacer Bushing Install
(cont.) (cont.) SL 568 Engine Mount Tubes Inspection
SL 571 760-531 Flap Handle Assembly Modification
1969-1971 SB 769 760-542 Landing Gear Back-up Actuator Override Mech
SB 840A Fuel Selector Valve Cover Replacement
SL 620 760-729 Forward Cabin Door Reinforcement
1969-1972 SB 357A Alternator Output Wire Terminal Replacement
SL 1116A Contactor Maintenance
1969-1973 SB 360 760-638 Air Induction Hose System Mod
SB 387 760-742 Alternator Installation Mod
SB 395 Warning - Improper Use of Rudder Pedals
SB 789B 764-998 Aft Wing Spar Modification
SB 789B 765-106 Aft Inboard Wing Access Panel Retrofit
1969-1975 SL 761 760-795 Magnetic Compass Relocation Kit
1969-1976 SB 510B 761-074 Nose Landing Gear Trunnion Mod
SB 548 Engine Control Rod End Bearing Inspection
SB 578B Fuel Line and Support Clamp Inspection and Installation
SB 611 Hose Assembly Inspection and Replacement
SB 717 Fuel Selector Line Inspection
SB 738 Nose Landing Gear Actuator Rod End Inspection
SB 805A Hartzell SB No. 142B - O-Ring Deterioration
SB 836A Aluminum Wire Inspection / Replacement
SB 866A 765-303 Backup Landing Gear Extender Removal / AM of C
SB 896 Shoulder Harness Installation and Usage
SB 940A Throttle Microswitch
SB 1023 Inspection of Landing Gear Retract Cylinder
SB 1026 Airborne SL 48 / Dry Air Pump Flexible Couplings
SB 1041 Airborne SL 56 / Air Filter Inspection & Cleaning
SB 1118 Alternate Air Inlet Adapter Inspection
SB 1134 Servo Metered Fuel Pressure Port Leakage
SB 1164 767-510 Propeller RPM Limitation & Tach Re-marking
SB 1286A Lycoming Service Bulletin No. 621B
SB 1309A Fuel Tank Selector Placards Examination
SB 1331A Stabilator Idler Arm Assembly Inspection
SB 1161A Rib Assembly Inspection & Modification - Aft Wing, WS 49.25
SL 612A Fuselage Leak - Fuel Sender Unit
SL 758 761-065 Bendix Ignition Switches Inspection
SL 793 Flap Warning Placard
SL 808 Hydraulic Pump Terminal Inspection
SL 810 761-138 Diaphragm - Backup LG Extender
SL 845 763-828 Engine Breather Tube Winterization Kit
SL 864 II 763-871 Cabin Heat Control Refinement
SL 988 764-377 Nose Landing Gear Modification
SL 1093B Electrical Contactor Replacement Kit

III - INSPECTION 11/30/19

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TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject
PA-28R-200 1969-1976 SL 1116A Contactor Maintenance
(cont.) (cont.) VSP-155 Cleveland SB 7076 - Inspect/Repl Gear Actuator
VSP-174 Lycoming SB 569 - Crankshaft Retirement
1970-1971 SB 337 760-532 Vertically Adjustable Seat Frame Tube Replace
SL 607 Emergency Gear Lever Knob
1971 SB 339 Owner’s Handbook Revision
1971-1973 SL 626 Landing Gear Bolt Lubrication
1971-1976 SB 1197E Control Wheel Shaft Inspection
SB 1313A Stabilator Trim Pulley Bracket Inspection
1972 SB 350 Stabilator Hinge Attaching Bolts Inspection
SB 368 760-697 Transponder Antenna Protector Installation
SL 634 POH Revision
1972-1973 SB 393 760-794 Rear Seat Belt Attachment Mod
1972-1974 SB 427 760-822 Air Conditioning System Mod
1972-1976 SB 533 Fuel Gauge Calibration Inspection
SL 788 Air Conditioning Installation
SL 1040 767-310 Alternator Drive Belt Conversion Kit
1973 SL 647 760-740 Seat Back Stop Modification
1973-1974 SL 734 760-857 Bendix ADF-T-12
1974 SL 700 760-842 Toe Brake System Modification
SL 715 760-876 ELT Switch Cover Modification
1974-1975 SB 450 Fuel Gascolator Quick Drain Valve Inspection
SB 475 Instrument Panel Dimmer Control Assy Mod
SL 745 Wing Main Spar Attachment Bolts Inspection
SL 756 Dual Glideslope Indicator Placard
1974-1976 SB 694 Throttle Rod End Attachment
SL 762 761-009 ELT Remote Switch Modification
1975 SB 449A Chrysler Alternator Mod & Wire End Terminal Repl
1975-1976 SL 836 Narco ADF-140/141 Antenna Inspection & Mod.
1975-1976 SB 623 Diode Assembly Inspection
SB 804 765-157 Battery Strap Installation
1976 SB 543 Starter/Magneto Switch Inspection & Replacement
SB 565 Edo-Aire Mitchell SB No. MB-13
SB 724A Nose Landing Gear Inspection and Mod
VSP-170A Lycoming SB 566, Supl 1 - Cranshaft Inspection

11/30/19 III - INSPECTION

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TABLE III-III
SERVICE PUBLICATIONS LIST (cont.)
Airplane Model
Model Year Pub No. Kit No. Subject

— END OF SECTION —

III - INSPECTION 11/30/19

III-118
 PIPER CHEROKEE SERVICE MANUAL

SECTION IV - Structures

TABLE OF CONTENTS

Paragraph
Grid No.

4-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G15

4-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G15
4-3. Wing Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G16
4-4. Wing Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G16
4-5. Removal of Wing Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G16
4-6. Installation of Wing Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G17
4-7. Aileron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G17
4-8. Removal of Aileron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G17
4-9. Installation of Aileron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G17
4-10. Wing Flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G18
4-11. Removal of Wing Flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G18
4-12. Installation of Wing Flap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G18
4-13. Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G18
4-14. Removal of Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G18
4-15. Installation of Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H2
4-16. Empennage Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H6
4-17. Stabilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H6
4-18. Removal of Stabilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H6
4-19. Installation of Stabilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H8
4-20. Stabilator Trim Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H13
4-21. Removal of Stabilator Trim Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H13
4-22. Installation of Stabilator Trim Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H13
4-23. Rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H13
4-24. Removal of Rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H13
4-25. Installation of Rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H13
4-26. Vertical Fin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H14
4-27. Removal of Vertical Fin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H14
4-28. Installation of Vertical Fin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H14
4-29. Fuselage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H15
4-30. Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H15
4-31. Removal of Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H15
4-32. Installation of Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H15
4-33. Side Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H17
4-34. Removal of Side Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H17
4-35. Installation of Side Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H18
4-36. Door (Entrance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H19
4-37. Removal of Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H19
4-38. Installation of Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H19
4-39. Adjustment of Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H19
4-40. Removal of Door Latch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H19

09/18/21 IV – CONTENTS
1G13
 PIPER CHEROKEE SERVICE MANUAL

SECTION IV - Structures

TABLE OF CONTENTS (continued)

Paragraph
Grid No.

4-41. Removal and Installation of Door Seal Snubbers . . . . . . . . . . . . . . . . . . . 1H20

4-42. Installation of Door Latch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H21
4-43. Adjustment of Door Latch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H21
4-44. Removal of Door Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H21
4-45. Installation of Door Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H21
4-46. Removal of Door Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H21
4-47. Installation of Door Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H21
4-48. Adjustment of Door Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H22
4-49. Baggage Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H22
4-50. Removal of Baggage Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H22
4-51. Installation of Baggage Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H22
4-52. Removal of Baggage Door Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1H22
4-53. Installation of Baggage Door Lock Assembly . . . . . . . . . . . . . . . . . . . . . . 1H22
4-54. Removal of Baggage Door Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H22
4-55. Installation of Baggage Door Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H22
4-56. Rigging Instructions - Seat Back Lock and Release . . . . . . . . . . . . . . . . . . . . . 1H23
4-57. Structural Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H24
4-57a. Metal Wire Stitching Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H24
4-58. Fiberglass Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I4
4-59. Fiberglass Touch-Up and Surface Repairs . . . . . . . . . . . . . . . . . . . . . . . . . 1I4
4-60. Fiberglass Fracture and Patch Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I5
4-61. Thermoplastic Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I6
4-62. A.B.S. Thermoplastic Wheels and Strut Fairing Repair Instructions . . . . 1I10
4-63. Safety Walk Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I14
4-64. Surface Preparation for Liquid Safety Walk . . . . . . . . . . . . . . . . . . . . . . . 1I14
4-65. Product Listing for Liquid Safety Walk Compound . . . . . . . . . . . . . . . . . 1I14
4-66. Application of Liquid Safety Walk Compound . . . . . . . . . . . . . . . . . . . . . 1I14
4-67. Surface Preparation for Pressure Sensitive Safety Walk . . . . . . . . . . . . . . 1I14
4-68. Application of Pressure Sensitive Safety Walk . . . . . . . . . . . . . . . . . . . . . 1I15
4-69. Control Surface Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I16
4-70. Checking Control Surface Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I16
4-71. Checking Control Surface Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I16
4-72. Balancing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I18
4-73. Balancing Ailerons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I18
4-74. Balancing Rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I19
4-75. Balancing Stabilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I22
4-76. Aileron Balance Weight Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I23
4-77. Flap Inspection and Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J1
4-78. Stabilator Drain Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J1
4-79. Baggage Compartment Inspection Hole and Cover Plate . . . . . . . . . . . . . . . . 1J3
4-80. Electrical Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J6

IV – CONTENTS 09/18/21
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 PIPER CHEROKEE SERVICE MANUAL

4-6. INSTALLATION OF WING TIP.

a. PA-28-140; PA-28-150, -160, -180 and PA-28R:
1. Place the wing tip in a position that the navigation light leads may be connected. Connect the
ground lead to the wing rib by use of a screw and nut, and the positive lead to the position light
by connecting the wire terminals or screwing the connectors together. Insulate the wire
terminals and be certain that the ground lead is free of dirt and film to ensure a good
connection.
2. Insert the wing tip into position and install the screws around the tip. Use caution to refrain
from damaging the wing tip or wing. Check operation of the position light.
b. PA-28-235:
1.
Position the wing tip in place on the wing and insert the two bolts, washers and nuts into their
proper places and tighten. Replace the several screws around the tip tank and tighten. Connect
the position light leads, the fuel quantity transmitting wire and the fuel line.
2. After the wing tip is installed and all connections are secured, fill the tip tank and check for
fuel leaks, operation of the fuel gauge and position light. Install the access cover to the bottom
of the wing tip.
4-7. AILERON.
CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE
OR EXHIBIT CRACKS.
4-8. REMOVAL OF AILERON. (Refer to Figure 4-1.)
a. Disconnect the aileron control rod at the aileron attachment point by removing the nut, washers and
bolt from the rod end bearing. To simplify installation note location of washers removed.
b. Remove the attaching screws, with nuts, from the hinges at the leading edge of the aileron, and
remove the aileron by lowering the inboard end and swinging it forward to allow the balance arm to
clear the opening in the outboard rib.
4-9. INSTALLATION OF AILERON. (Refer to Figure 4-1.)
WARNING: ALL CONTROL SURFACES THAT HAVE BEEN REPLACED OR REPAINTED MUST
BE BALANCED BEFORE INSTALLATION PER INSTRUCTIONS IN CONTROL
SURFACE BALANCING, BELOW.
a. Install the balance arm into the opening in the outboard rib by moving the inboard end of the
aileron forward to allow the arm to be inserted through the opening. (When installing an aileron,
should the balance weight assembly, P/N 66766-00, replace an earlier balance weight assembly,
P/N 65388-34 (L) or 65388-35 (R), the wing butt rib will require modifying per instructions in
Paragraph 4-75.) Move the aileron into place and install attaching screws and nuts. Ascertain that
the aileron is free to move with no interference.
b. Attach the aileron control rod with bolt, washers and nut, dividing the washers so that the aileron is
free to rotate from stop to stop without the control rod binding or rubbing on the opening in the aft
spar. Be certain that the rod end bearing has no side play when tightening the bolt and that the rod
does not contact the side of the bracket.
c. Actuate the aileron controls to ensure freedom of movement.

01/31/08 IV - STRUCTURES
1G17
 PIPER CHEROKEE SERVICE MANUAL

4-10. WING FLAP

CAUTION: FLAP SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS.
4-11. REMOVAL OF WING FLAP
Refer to “Figure 4-1” on page 1G19.
A. Extend the flaps to their fullest degree and remove the bolt and bushing from the rod end bearing by
use of an angle or offset screwdriver.
B. Remove the nuts, washers, bushing and hinge bolts that hold the flap to the wing assembly.
C. Pull the flap straight back off the wing. (Refer to Paragraph “Balancing Stabilator” on page 1H46 for
flap inspection and modification.)
4-12. INSTALLATION OF WING FLAP
Refer to “Figure 4-1” on page 1G19.
A. Replace the wing flap by placing the flap onto its proper position and inserting the hinge bolts,
bushings, washers, and nuts.
B. With the flap control in the full flap position, place the bushing on the outboard side of the rod end
bearing and insert and tighten the bolt.
C. Operate the flap several times to be certain it is operating freely.
4-13. WING
NOTE: The major subassemblies of each wing may be removed individually or the wing may be removed
as a unit. To remove a wing, a fuselage supporting cradle is required.
4-14. REMOVAL OF WING
Refer to “Figure 4-2” on page 1G22.
A. PA-28-140; PA-28-150, -160, -180 and PA-28-235.
1. Disconnect battery.
2. Close the fuel valve and drain the fuel from the wing to be removed. (Refer to Draining Fuel
System, Section II.)
3. Drain the brake lines and reservoir. (Refer to Draining Brake System, Section II.)
4. Remove the access plate at the wing butt rib and wing inspection panels. (Refer to Access Plates
and Panels, Section II.)
5. Remove the front and back seats from the airplane.
6. Expose the spar box and remove the cockpit side trim panel assembly that corresponds with the
wing being removed.
7. Place the airplane on jacks. (Refer to Jacking, Section II.)
NOTE: To facilitate reinstallation of control cables, fuel and hydraulic lines, mark cable and
line ends and/or attach a line where applicable to cables before drawing them through
fuselage or wing.
8. Disconnect the aileron balance and control cables at the turnbuckles that are located within the
fuselage aft of the spar.
9. If the left wing is being removed, remove the cotter pin from the pulley bracket assembly to allow
the left aileron balance cable end to pass between the pulley and bracket.

IV – Structures mm/dd/yy
09/18/21
1G18
 PIPER CHEROKEE SERVICE MANUAL

10. Disconnect flaps from the torque tube by fully lowering flaps and removing the bolt and bushing
from the bearing at the aft end of the control rod.
CAUTION: TO PREVENT DAMAGE AND CONTAMINATION OF FUEL, HYDRAULIC
AND OTHER LINES, CAP OR PLUG ALL LINE ENDS WHICH ARE
SEPARATED DURING WING REMOVAL.
11. Disconnect the fuel line at the fitting located aft of the spar at the wing butt line.
12. Remove clamps and/or ties as required to release the electrical harness assembly. Disconnect
applicable electrical leads from the terminal strip assembly, (located on the aft spar frame, left
side within the fuselage), by removing the cover, and appropriate nuts and washers.
13. With the appropriate trim panel removed, disconnect the hydraulic brake line at the fitting located
within the cockpit at the leading edge of the wing.
14. If the left wing is being removed, it will be necessary to disconnect the pitot and static tubes at
the elbows located within the cockpit at the wing butt line.
15. Arrange and put in place a suitable fuselage cradle and supports for both wings. Proper placement
of these supports can neutralize the shear loading of the bolt at the interface of the wing spar and
spar box, easing bolt removal.
16. Remove wing jacks.
17. Remove the front and rear spar to fuselage attach nuts, washers and bolts, discard nuts. (Note
number and position of washers at each attach point for reinstallation.)
WARNING: DO NOT DRIVE OR WRENCH OUT SPAR TO FUSELAGE ATTACH BOLTS
(SKETCHES C AND D IN “FIGURE 4-2” ON PAGE 1G24). TAKE EXTREME
CARE IN REMOVING THESE BOLTS TO PRECLUDE DAMAGING THE
BOLT HOLES. NUMBER BOLTS AND BOLT HOLES TO ENSURE THAT, IF
REUSED, THE SAME BOLTS ARE REINSTALLED IN THE SAME HOLES.
18. Remove the eighteen (18) main spar bolts. Do not drive out bolts. Take care not to damage bolt
holes. Number bolts and bolt holes to ensure that, if reused, each bolt is reinstalled in the same
hole it came out of. To ease bolt removal and avoid damage to the bolt holes, follow this guidance.
(a) Apply penetrating oil around all washers. Capillary action will draw the oil to the bolt shank
to facilitate removal. One such oil is Kroil Penetrating Oil Aerosol, from Kano Laboratories
(visit www.kroil.com and see “Where To Buy”).
(b) Remove the nut and washers. After removing the nut, apply torque to the bolt head to rotate
the bolt approximately one turn, to help draw in the penetrating oil and break the bolt shank
free from the hole. Do not wrench the bolt out of its hole, because this can result in thread
marking of the hole.
(c) Before removing a bolt from its hole, thoroughly clean all debris from the exposed threaded
end. Use a nylon bristle brush, as necessary, to remove all debris from the threads and
solvent clean using acetone.
(d) Ideally, three people should work simultaneously to remove the bolts. This approach should
not demand a lot of effort from the group, as follows:
1) One person adjusts the wing supports or deflects the wing tip up and/or down to
neutralize the shear loading.
2) A second person underneath the aircraft pushes the threaded end of the bolt to move it
up and out of the hole.

09/18/21 IV – Structures
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906

Wing Installation
Figure 4-2 (Sheet 1 of 4)

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 PIPER CHEROKEE SERVICE MANUAL

Wing Installation
Figure 4-2 (Sheet 2 of 4)

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Bolt Legend Washers

Position Bolt (1) Nut (1) Under Head Under Nut
A1 NAS6606-13 MS21042-L6 NAS1149F0663P NAS1149F0663P (1 ea.) & 96352-3 (2) (1 ea.)
A2 NAS6606-11 MS21042-L6 NAS1149F0663P NAS1149F0663P (1 ea.) & 96352-3 (2) (1 ea.)
A3 NAS6606-11 MS21042-L6 NAS1149F0663P NAS1149F0663P (1 ea.) & 96352-3 (2) (1 ea.)
A4 NAS6606-11 MS21042-L6 NAS1149F0663P NAS1149F0663P (1 ea.) & 96352-3 (2) (1 ea.)
B1 NAS6606-15 MS21042-L6 NAS1149F0663P NAS1149F0663P (2 ea.)
B2 NAS6606-13 MS21042-L6 NAS1149F0663P NAS1149F0663P (2 ea.)
B3 NAS6606-13 MS21042-L6 NAS1149F0663P NAS1149F0663P (2 ea.)
B4 NAS6606-13 MS21042-L6 NAS1149F0663P NAS1149F0663P (2 ea.)
C1 NAS6606-13 MS21042-L6 96352-3 (2) NAS1149F0663P
C2 NAS6606-13 MS21042-L6 96352-3 (2) NAS1149F0663P (2 ea.)
C3 NAS6606-13 MS21042-L6 96352-3 (2) NAS1149F0663P (2 ea.)
C4 NAS6606-13 MS21042-L6 96352-3 (2) NAS1149F0663P (2 ea.)
C5 NAS6606-13 MS21042-L6 96352-3 (2) 96352-3 (2)
D1 NAS6606-13 MS21042-L6 96352-3 (2) NAS1149F0663P
D2 NAS6606-13 MS21042-L6 96352-3 (2) NAS1149F0663P (2 ea.)
(2)
D3 NAS6606-13 MS21042-L6 96352-3 NAS1149F0663P (2 ea.)
D4 NAS6606-13 MS21042-L6 96352-3 (2) NAS1149F0663P (2 ea.)
D5 NAS6606-13 MS21042-L6 96352-3 (2) 96352-3 (2)

(1) Torque Bolt Heads on Upper Spar Cap and Nuts on Lower Spar Cap 360–390 in·lbs.
(2) The 96352-3 washers feature a rounded edge (i.e., radius) on one side. Ensure that the flat side of each 96352-3 washer is
installed against the bolt head or nut or adjacent washer. The rounded edge is designed to face and abut the aircraft structure.

Wing Installation
Figure 4-2 (Sheet 3 of 4)

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WING SPAR BOX

ROUND EDGE (RADIUS) WASHER

SHIM
(ENSURE SHIM IS ORIENTED
AS SHOWN) DETAIL D
B-4 A-4

UP

FWD

DETAIL D
ROUND EDGE (RADIUS) WASHER
CORRECT ORIENTATION
(ALL LOCATIONS SIMILAR)
D-5 C-5
SPAR CAP

SECTION D−D

Wing Installation
Figure 4-2 (Sheet 4 of 4)

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3) A third person, in the aircraft, would receive and remove the pushed bolt.
4) For the person underneath the aircraft: a suitable non-marring tool (such as a 1/4-inch
wooden dowel) may be used to push the bolt completely upwards through the hole. If
necessary, use a rubber mallet or equivalent to very gently tap the lower end of the tool
upwards – do not to make contact with the hole bore.
19. Slowly and very carefully extract wing from fuselage being certain all electrical leads, cables
and lines are disconnected and that no undue upward or downward pressure is exerted upon the
inboard spar within the spar carrythrough.
NOTE: Inspect wing spar in accordance with Section III, Special Inspections, Procedures, Wing
Spar Inspection.
B. PA-28R:
1. Disconnect battery.
2. Close the fuel valve and drain the fuel from the wing to be removed. (Refer to Draining Fuel
System, Section II.)
3. Drain the brake lines and reservoir. (Refer to Draining Brake System, Section II.)
4. Drain the hydraulic lines of the landing gear of the wing to be removed by separating the lines
and elbows at the actuating cylinder.
5. Remove the access plate at the wing butt rib and wing inspection panels. (Refer to Access Plates
and Panels, Section II.)
6. Remove the front and back seats from the airplane.
7. Expose the spar box and remove the side trim cockpit panel assembly that corresponds with the
wing being removed.
8. Place the airplane on jacks. (Refer to Jacking, Section II.)
NOTE: To facilitate reinstallation of control cables, fuel and hydraulic lines, mark cable and
line ends and/or attach a line where applicable to cables before drawing them through
fuselage or wing.
9. Disconnect the aileron balance and control cables at the turnbuckles that are located within the
fuselage aft of the spar.
10. If the left wing is being removed, remove the cotter pin from the pulley bracket assembly to allow
the left aileron balance cable end to pass between the pulley and bracket.
11. Disconnect flaps from the torque tube by fully lowering flaps and removing the bolt and bushing
from the bearing at the aft end of the control rod.
CAUTION: TO PREVENT DAMAGE AND CONTAMINATION OF FUEL, HYDRAULIC
AND OTHER LINES, CAP OR PLUG ALL LINE ENDS WHICH ARE
SEPARATED DURING WING REMOVAL.
12. Disconnect the fuel line at the fitting located inside of the wing, by removing the access panel
on the forward inboard portion of the wheel well and reaching through to the fuel line coupling.
13. Remove clamps and/or ties as required to release the electrical harness assembly. Disconnect
applicable electrical leads from the terminal strip assembly by removing the cover, and appropriate
nuts and washers.
14. With the appropriate trim panel removed, disconnect the hydraulic brake line at the fitting located
within the cockpit at the leading edge of the wing.

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 PIPER CHEROKEE SERVICE MANUAL

15. Disconnect the landing gear hydraulic lines at the fittings aft of the spar and within the fuselage.
16. If the left wing is being removed, it will be necessary to disconnect pitot and static tubes at the
elbows located within the cockpit at the wing butt line.
17. Arrange and put in place a suitable fuselage cradle and supports for both wings. Proper placement
of these supports can neutralize the shear loading of the bolt at the interface of the wing spar and
spar box, easing bolt removal.
18. Remove wing jacks.
19. Remove the front and rear spar to fuselage attach nuts, washers and bolts, discard nuts. (Note
number and position of washers at each attach point for reinstallation.)
WARNING: DO NOT DRIVE OR WRENCH OUT SPAR TO FUSELAGE ATTACH BOLTS
(SKETCHES C AND D IN “FIGURE 4-2” ON PAGE 1G24). TAKE EXTREME
CARE IN REMOVING THESE BOLTS TO PRECLUDE DAMAGING THE
BOLT HOLES. NUMBER BOLTS AND BOLT HOLES TO ENSURE THAT, IF
REUSED, THE SAME BOLTS ARE REINSTALLED IN THE SAME HOLES.
20. Remove the eighteen (18) main spar bolts. Do not drive out bolts. Take care not to damage bolt
holes. Number bolts and bolt holes to ensure that, if reused, each bolt is reinstalled in the same
hole it came out of. To ease bolt removal and avoid damage to the bolt holes, follow this guidance.
(a) Apply penetrating oil around all washers. Capillary action will draw the oil to the bolt shank
to facilitate removal. One such oil is Kroil Penetrating Oil Aerosol, from Kano Laboratories
(visit www.kroil.com and see “Where To Buy”).
(b) Remove the nut and washers. After removing the nut, apply torque to the bolt head to rotate
the bolt approximately one turn, to help draw in the penetrating oil and break the bolt shank
free from the hole. Do not wrench the bolt out of its hole, because this can result in thread
marking of the hole.
(c) Before removing a bolt from its hole, thoroughly clean all debris from the exposed threaded
end. Use a nylon bristle brush, as necessary, to remove all debris from the threads and
solvent clean using acetone.
(d) Ideally, three people should work simultaneously to remove the bolts. This approach should
not demand a lot of effort from the group, as follows:
1) One person adjusts the wing supports or deflects the wing tip up and/or down to
neutralize the shear loading.
2) A second person underneath the aircraft pushes the threaded end of the bolt to move it
up and out of the hole.
3) A third person, in the aircraft, would receive and remove the pushed bolt.
4) For the person underneath the aircraft: a suitable non-marring tool (such as a 1/4-inch
wooden dowel) may be used to push the bolt completely upwards through the hole. If
necessary, use a rubber mallet or equivalent to very gently tap the lower end of the tool
upwards – do not to make contact with the hole bore.
21. Slowly and very carefully extract wing from fuselage being certain all electrical leads, cables
and lines are disconnected and that no undue upward or downward pressure is exerted upon the
inboard spar within the spar carrythrough.
NOTE: Inspect wing spar in accordance with Section III, Special Inspections, Procedures, Wing
Spar Inspection.

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15. Installation of Wing

Refer to “Figure 4-2” on page 1G22.
NOTE: When installing a “replacement” wing, ensure Stall Warning occurs as specified in the POH during
the first test flight upon completion of wing installation.
A. PA-28-140; PA-28-150, -160, -180 and PA-28-235:
WARNING: DO NOT INSTALL A NON-TWISTED WING PANEL ON AN AIRPLANE WITH A
TWISTED WING PANEL ON THE OTHER SIDE. OR VICE VERSA.
NOTE: PA-28-150,-160 S/N’s 28-1 to 28-45 incl., 28-47 to 28-54 incl., 28-56, 28-57, 28-61 to 28-77
incl., 28-79 to 28-84 incl., 28-86 to 28-89 incl., 28-92, 28-93 and 28-94.
Airplanes indicated by the above serial numbers were equipped at the factory with wing
panel assemblies having a washout of 0° (i.e., non-twisted), (P/N 62010-041 LH and P/N
62010-042 RH).
All airplanes not included in the above serial number listing are equipped with wing panels
modified to a washout of 2° (i.e., twisted), (P/N 62015-004 LH and P/N 62015-003 RH).
During the service life of these airplanes there may be occasion to replace one or both of
the wing panels having 0° washout. Under no circumstances should one twisted and one
non-twisted wing be used on the same airplane. If an interchange of salvaged non-twisted
wing panels is made in the field, the stall characteristics shall be tested to the requirement of
Civil Air Regulation 3.120 by an authorized representative of Piper or the Federal Aviation
Administration. Since the number of airplanes equipped with 0° washout wing panels is
relatively small, this type wing assembly will not be available for replacement. All replacement
wing panels, when required, will be furnished twisted having the 2° washout.
WARNING: IF REPLACEMENT OF BOLTS IS REQUIRED, ENSURE PROPER GRIP LENGTH
IS MAINTAINED. INSTALL NEW NUTS ON MAIN SPAR AND FORWARD AND
AFT SPAR ATTACH BOLTS, SEE BOLT LEGEND, “FIGURE 4-2” ON PAGE 1G24
FOR PROPER HARDWARE .
1. Ascertain that the fuselage is solidly positioned on the support cradle.
2. Place the wing in position for installation, with the spar end a few inches from the side of the
fuselage and set on trestles.
3. Prepare the various lines, cables and electrical leads for inserting into the wing or fuselage when
the wing is slid into place. Ensure that the front wing fitting bushing is installed.
4. Slide the wing into position in the fuselage, assuring that the lines, cables and electrical leads are
fed into place.

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WARNING: DO NOT DRIVE OR WRENCH SPAR TO FUSELAGE ATTACH BOLTS IN (SEE

SKETCHES C AND D IN “FIGURE 4-2” ON PAGE 1G24). TAKE EXTREME
CARE IN REPLACING THESE BOLTS TO PRECLUDE DAMAGING THE
BOLT HOLES. IF REUSED, ENSURE THE SAME BOLTS ARE REINSTALLED
IN THE SAME HOLES.
NOTE: Top spar cap shims must be in place prior to installing bolts, below.
5. Install the 18 main spar to fuselage (i.e., spar carrythrough) attachment bolts in accordance with
the bolt legend in “Figure 4-2” on page 1G24. Use 18 new nuts (see bolt legend). Ensure the
asymmetric shim under the washers and nuts on the B-1 through B-4 bolts is oriented as shown
in “Figure 4-2” on page 1G25. If reusing bolts, ensure that each bolt goes back into the same hole
that it came out of.
NOTE: If new bolts are used, install in accordance with the bolt legend in “Figure 4-2” on page
1G24.
NOTE: When replacing a wing assembly, ascertain the wing butt clearance is maintained. (Refer
to Sketch A, “Figure 4-2” on page 1G23.)
6. Ideally, at least two people should work simultaneously to install the bolts. This approach should
not demand a lot of effort from the pair, as follows:
(a) One person adjusts the wing supports or deflects the wing tip up and/or down to neutralize
the shear loading.
(b) A second person in the aircraft, pushes the bolt head to move it down and into the hole. Do
not rotate the bolt in the hole during this process.
7. Install the bolt, washers and nut that attaches the front spar with the fuselage per “Figure 4-2”
on page 1G23.
8. Insert washers at the rear spar between the forward face of the wing fitting and aft face of the
fuselage fitting, then install the bolt, washers, and nut that attaches the aft spar with the fuselage
per “Figure 4-2” on page 1G23.
CAUTION: BE CERTAIN THAT ALL BOLTS, NUTS AND WASHERS ARE INSTALLED
IN ACCORDANCE WITH “FIGURE 4-2” (I.E., THE BOLT LEGEND AND
SKETCHES A, B, C, AND D).
9. Torque the eighteen main spar bolt nuts or bolt heads per Figure 4-2. Be certain that the bolts, nuts
and washers are installed in accordance with the bolt legend. Torque the forward spar attachment
bolt and the rear spar attachment bolt per Figure 4-2.
10. Install the wing jacks and the tail support to the tail skid with approximately 250 pounds of
ballast on the base of the tail support. Remove the fuselage cradle and wing supports.
11. If the left wing was removed, it is necessary that the pitot and static tubes to be connected at the
elbows located within the cockpit at the wing butt line. On occasion, one tube may be painted
red, denoting the pitot tube. Replace or install clamps where found necessary. In the event that a
heated pitot is installed, the plus lead must be connected at the fuselage.
12. Connect the hydraulic brake line onto the fitting located within the cockpit at the leading edge of
the wing and torque “B” nuts.
13. Connect the leads to the appropriate posts on the terminal strip and install the washers and
nuts. (For assistance in connecting the electrical lead, refer to the Electrical Schematics in
Section XI.) Place the clamps and ties along the electrical harness to secure it in position and
install the terminal strip dust cover.

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14. Remove the cap from the fuel line and connect it at the fitting located aft of the spar at the wing
butt line. Torque “B” nuts.
15. Connect the aileron balance and control cables at the turnbuckles that are located within the
fuselage aft of the spar. After the left balance cable has been inserted through the bracket
assembly and connected, install a cotter pin cable guard into the hold that is provided in the
bracket assembly.
16. Connect the flap by placing the flap handle in the full flap position, place the bushing on the
outside of the rod end bearing, insert and tighten bolt.
17. Check the rigging and control cable tension of the ailerons and flaps. (Refer to Rigging and
Adjustment of Ailerons, and Rigging and Adjustment of Flaps, Section V.)
18. Service and refill the brake system with hydraulic fluid in accordance with Servicing Brake
System, Section II. Bleed the system as given in Section VII and check for fluid leaks.
19. Service and fill the fuel system in accordance with Servicing Fuel System, Section II. Open the
fuel valve and check for leaks and flow.
20. Check the operation of all electrical equipment, and pitot and static system.
21. Remove the airplane from the jacks.
22. Install the cockpit trim panel assembly, spar box carpet, the front and back seats, and wing butt
rubber molding. Check pilot’s and co-pilot’s seat operation.
23. Replace all the access plates and panels on the wing involved.
24. Ground run aircraft to verify proper operation of fuel and brake systems.
b. PA-28R:
1. Ascertain that the fuselage is solidly positioned on the support cradle.
2. Place the wing in position for installation, with the spar end a few inches from the side of the
fuselage and set on trestles.
3. Prepare the various lines, cables and electrical leads for inserting into the wing or fuselage when
the wing is slid into place. Ensure that the front wing fitting bushing is installed.
4. Slide the wing into position in the fuselage, assuring that the lines, cables and electrical leads are
fed into place.
WARNING: DO NOT DRIVE OR WRENCH SPAR TO FUSELAGE ATTACH BOLTS IN (SEE
SKETCHES C AND D IN “FIGURE 4-2” ON PAGE 1G24). TAKE EXTREME
CARE IN REPLACING THESE BOLTS TO PRECLUDE DAMAGING THE
BOLT HOLES. IF REUSED, ENSURE THE SAME BOLTS ARE REINSTALLED
IN THE SAME HOLES.
NOTE: Top spar cap shims must be in place prior to installing bolts, below.
5. Install the 18 main spar to fuselage (i.e., spar carrythrough) attachment bolts in accordance
with the bolt legend in “Figure 4-2” on page 1G24. Use 18 new nuts (see bolt legend, Figure 1).
Ensure the asymmetric shim under the washers and nuts on the B-1 through B-4 bolts is oriented
as shown in “Figure 4-2” on page 1G25. If reusing bolts, ensure that each bolt goes back into the
same hole that it came out of.
NOTE: If new bolts are used, install in accordance with the bolt legend in “Figure 4-2” on page
1G24.
NOTE: When replacing a wing assembly, ascertain the wing butt clearance is maintained. (Refer
to Sketch A, “Figure 4-2” on page 1G23.)

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6. Ideally, at least two people should work simultaneously to install the bolts. This approach should
not demand a lot of effort from the pair, as follows:
(a) One person adjusts the wing supports or deflects the wing tip up and/or down to neutralize
the shear loading.
(b) A second person in the aircraft, pushes the bolt head to move it down and into the hole. Do
not rotate the bolt in the hole during this process.
7. Install the bolt, washers, and nut that attaches the front spar and fuselage fitting per “Figure 4-2”
on page 1G23.
8. Install the bolt, washers and nut that attaches the aft spar with the fuselage fitting per “Figure
4-2” on page 1G23.
CAUTION: BE CERTAIN THAT ALL BOLTS, NUTS AND WASHERS ARE INSTALLED
IN ACCORDANCE WITH “FIGURE 4-2” (I.E., THE BOLT LEGEND AND
SKETCHES A, B, C, AND D).
9. Torque the eighteen main spar bolt nuts or bolt heads per “Figure 4-2” on page 1G24. Be certain
that the bolts, nuts and washers are installed in accordance with the bolt legend. Torque the
forward spar attachment bolt and the rear spar attachment bolt per Figure 4-2.
10. Install the wing jacks and the tail support to the tail skid with approximately 250 pounds of
ballast on the base of the tail support. Remove the fuselage cradle and wing supports.
11. If the left wing was removed, it is necessary that the pitot and static tubes be connected at the
elbows located within the cockpit at the wing butt line. On occasion, one tube may be painted
red, denoting the pitot tube. Replace or install clamps where found necessary. In the event that a
heated pitot is installed, the plus lead must be connected at the fuselage.
12. Connect the hydraulic brake line onto the fitting located within the cockpit at the leading edge of
the wing and torque “B” nuts.
13. Connect the landing gear hydraulic lines at the fittings within the fuselage aft of the spar carry
through and torque “B” nuts.
14. Connect the leads to the appropriate posts on the terminal strip and install the washers and nuts.
(For assistance in connecting the electrical leads, refer to the electrical schematics in Section
XI.) Place the clamps and ties along the electrical harness to secure it in position and install the
terminal strip dust cover.
15. Connect the fuel line at the fitting located inside of the wing, by reaching through the access
panel on the forward inboard portion of the wheel well. Torque “B” nuts.
16. Connect the aileron balance and control cables at the turnbuckles that are located within the
fuselage aft of the spar. After the left balance cable has been inserted through the bracket
assembly and connected, install a cotter pin cable guard into the hole that is provided in the
bracket assembly.
17. Connect the flap by placing the flap handle in the full flap position, place the bushing on the
outside of the rod end bearing, insert and tighten bolt.
18. Check the rigging and control cable tension of the ailerons and flaps. (Refer to Rigging and
Adjustment of Ailerons, and Rigging and Adjustment of Flaps, Section V.)
19. Service and refill the brake system with hydraulic fluid in accordance with Servicing Brake
System, Section II. Bleed the system as given in Section VII and check for fluid leaks.

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20. Check the fluid level of the landing gear hydraulic system and fill in accordance with Servicing
Hydraulic Pump/Reservoir, Section II. With the airplane setting on jacks, operate the gear
through several retraction and extension cycles to be certain that there are no hydraulic leaks.
Bleed the hydraulic system in accordance with Section VI.
21. Service and fill the fuel system in accordance with Servicing Fuel System, Section II. Open the
fuel valve and check for leaks and flow.
22. Check the operation of all electrical equipment, pitot and static systems.
23. Remove the airplane from jacks.
24. Install the cockpit trim panel assembly, spar box carpet, the front and back seats, and wing root
rubber. Check pilot’s and co-pilot’s seat operation.
25. Replace all the access plates and panels on the wing involved.
26. Ground run aircraft to verify proper operation of fuel and brake systems.
4-16. EMPENNAGE GROUP
4-17. STABILATOR
CAUTION: STABILATOR SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT
CRACKS.
4-18. REMOVAL OF STABILATOR
Refer to “Figure 4-4” on page 1H11.
CAUTION: AT EACH REMOVAL OF THE STABILATOR, CONDUCT STABILATOR ATTACH FITTINGS
CORROSION INSPECTION, SECTION III, SPECIAL INSTRUCTIONS, PROCEDURES.
NOTE: Before entering the aft portion of the fuselage, attach a stand to the tail skid for support; and with
the use of a heavy pad, protect the inside of the fuselage. Be certain to distribute weight on top of
the bulkheads so as not to damage the fuselage skin.
NOTE: Should it be necessary to move the rudder to its extreme left or right for clearance, do so with the
use of the rudder pedals or toe bar.
a. PA-28-150,-160,-180, S/N’s 28-1 to 28-2171 incl. and PA-28-235, S/N’s 28-10003 to 28-10605
incl. (The exception being those airplanes with Piper Kit No. 756-930 or 756-896, Stabilator Trim
Modification, installed. Airplanes with either kit installed, refer to step b.)
1. Remove the access panel to the aft section of the fuselage located at the back wall of the baggage
compartment.
2. Install cable blocks, as illustrated in “Figure 4-3” on page 1H7, on the stabilator trim control
cable at the first set of pulleys forward of the cable turnbuckle to prevent the forward portion of
the cable from unwrapping.
3. Disconnect the trim cable at the turnbuckle within the aft section of the fuselage.
4. Relieve tension from the stabilator control cables by loosening one of the cable turnbuckles in
the aft section of the fuselage.
5. Disconnect the stabilator control cables from the stabilator balance arm by removing cotter pins,
nuts, washers, bushings and clevis bolts.
6. Remove the screws from around the upper and lower tail cone fairing assembly and remove the
fairings separately.

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Figure 4-3. Methods of Securing Control Cables

7. Disconnect trim indicator cable at trim screw and trim tab control arm from the trunnion or
screw link by removing nut, washers, bushings and bolt.
8. Disconnect the trim assembly from the aft bulkhead of the fuselage by removing the attaching
nuts, washers and bolts of the horizontal and diagonal support brackets.
9. Move the trim assembly up through the tail cone fairing cutout in the stabilator, allowing cable
to draw out, and tape it to the tail cone out of the way.
10. Remove the stabilator by disconnecting the stabilator at its hinge points by removing attaching
nuts, washers and bolts.
b. PA-28-140; PA-28-150, -160, -180, Serial Nos. 28-2171 and up; PA-28-235, Serial Nos. 28-10606
and up; and PA-28R:
1. Remove the screws from around the upper and lower tail cone fairing assembly and remove the
fairing separately.
2. Block the trim cable at the barrel of the trim screw assembly to prevent the cable from
unwrapping.
3. Remove the access panel to the aft section of the fuselage located at the back wall of the
baggage compartment.
4. Install cable blocks, as illustrated in Figure 4-3, on the stabilator trim control cable at the first
set of pulleys forward of the cable turnbuckles to prevent the forward cable from unwrapping.
5. Disconnect the trim cables at the turnbuckles within the aft section of the fuselage.
6. Relieve tension from the stabilator control cables by loosening one of the cable turnbuckles in
the aft section of the fuselage.
7. Disconnect the stabilator control cables from the stabilator balance arm by removing cotter
pins, nuts, washers, bushings and clevis bolts.
8. Disconnect the trim indicator cable (overhead trim only) and the tab control arm connecting
links from the trim screw by removing nut, washers, bushings and bolts.

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9. Disconnect the trim assembly from the aft bulkhead of the fuselage by removing the attaching
nuts, washers and bolts of the horizontal and diagonal support brackets.
10. Move the trim assembly up through the tail cone fairing cutout in the stabilator and remove,
with cable, from the airplane.
11. Remove the stabilator by disconnecting the stabilator at its hinge points by removing attaching
nuts, washers and bolts.

4-19. INSTALLATION OF STABILATOR. (Refer to Figure 4-4.)

WARNING: ALL CONTROL SURFACES THAT HAVE BEEN REPLACED OR REPAINTED MUST
BE BALANCED BEFORE INSTALLATION PER INSTRUCTIONS IN CONTROL
SURFACE BALANCING, BELOW.
NOTE: A clearance of .25 + .06 of an inch between the stabilator and the side of the fuselage and .18 of
an inch minimum between all parts of the stabilator and the tail cone assembly must be
maintained throughout the stabilator travel. Use a proper washer combination on the stabilator
hinges to attain the necessary tolerances.
a. PA-28-150,-160,-180, Serial Nos. 28-1 to 28-2171 incl. and PA-28-235, Serial Nos. 28-10003 to
28-10605 incl. (The exception being those airplanes with Piper Kit No. 756-930 or 756-896,
Stabilator Trim Modification, installed. Airplanes with either kit installed, refer to step b.)
1. Insert the stabilator in position and install attaching hinge bolts, washers and nuts.
2. Move the trim assembly through the cutout in the stabilator and attach the brackets of the
assembly to the aft bulkhead with bolts, washers and nuts. Draw the trim cable around the idler
pulley and trim drum, and insert the cable end into the fuselage.
3. Attach the stabilator control cables to the stabilator balance arm with clevis bolts, bushings,
washers, nuts and cotter pins.
4. Connect the fore and aft end of the trim cable at the turnbuckle within the aft section of the
fuselage.
5. Remove the cable blocks from the trim control cable.
6. Set stabilator control cable tension and check rigging and adjustment according to Rigging and
Adjustment of Stabilator, Section V.
7. Set stabilator trim control cable tension and check rigging and adjustment according to
instructions in Section V. During this procedure, connect the trim indicator cable and tab
control arm to the trim screw trunnion or links with bolt, washers, bushings and nut. Ensure
that the tab attachment bolt head is on the side next to the trim indicator cable to ensure no
interference with indicator cable.
8. Remove the pad from the aft section of the fuselage and replace the access panel.
9. Install the tail cone fairing and remove tail stand.

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b. PA-28-140; PA-28-150, -160, -180, Serial Nos. 28-2171 and up; PA-28-235, Serial Nos. 28-10606
and up; and PA-28R:
1. Insert the stabilator in position and install attaching hinge bolts, washers and nuts.
2. Move the trim assembly through the cutout in the stabilator and attach the brackets of the
assembly to the aft bulkhead with bolts, washers and nuts. Insert the trim cable ends into the
fuselage.
3. Attach the stabilator control cables to the stabilator balance arm with clevis bolts, bushings,
washers, nuts and cotter pins.
4. Connect the ends of the fore and aft trim cables at the turnbuckles within the aft section of the
fuselage.
5. Remove the cable block from the trim control cable within the fuselage.
6. Set stabilator control cable tension and check rigging and adjustment according to Rigging and
Adjustment of Stabilator, Section V.
7. Remove the cable blocks from the trim cable at the barrel of the trim screw assembly.
8. Set stabilator trim control cable tension and check rigging and adjustment according to
instructions in Section V. During this procedure, connect the trim indicator cable (overhead
trim only) and the tab control arm to the trim screw, with the connecting links of the control
arm, with bolt, bushings, washers and nut. Ensure that the tab attachment bolt head is on the
side next to the trim indicator cable to ensure no interference with indicator cable.
9. Remove the pad from the aft section of the fuselage and replace the access panel.
10. Install the tail cone fairing and remove tail stand.

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4-20. STABILATOR TRIM TAB.

4-21. REMOVAL OF STABILATOR TRIM TAB. (Refer to Figure 4-4.)

a. Disconnect the stabilator trim control rod by removing the bolts that attach the control rod to the
stabilator trim tab.
b. Remove the stabilator trim hinge pins by cutting one end of the wire pins and removing.
c. The stabilator trim tab can now be removed.

4-22. INSTALLATION OF STABILATOR TRIM TAB. (Refer to Figure 4-4.)

a. Place the trim tab in position on the aft end of the stabilator.
b. Insert new pins and secure by bending the end to a 45 degree angle.
c. Install the control rod and attach with the four bolts and washers.

4-23. RUDDER.
CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE
OR EXHIBIT CRACKS.

4-24. REMOVAL OF RUDDER.

a. Remove the screws from around the upper tail cone fairing assembly and remove the fairing.
b. Remove the rudder tip by removing the attaching screws and disconnect the tail position light wire
at the quick disconnect located at the tip of the rudder. Open the access panel in the rear of the
baggage compartment to gain access to the aft section of the fuselage.
c. Relieve the cable tension from the rudder control system by loosening one of the cable turnbuckles
in the aft section of the fuselage.
d. Disconnect the two control cables from the rudder horn by removing the cotter pins, nuts, washers,
bushings and bolts.
e. Remove the cotter pins, nuts, washers and bolts from the upper and lower rudder hinge pivot points.
f. Pull the rudder up and aft from the vertical fin.

4-25. INSTALLATION OF RUDDER. (Refer to Figure 4-4.)

WARNING: ALL CONTROL SURFACES THAT HAVE BEEN REPLACED OR REPAINTED MUST
BE BALANCED BEFORE INSTALLATION PER INSTRUCTIONS IN CONTROL
SURFACE BALANCING, BELOW.
a. Place the rudder in position and install the hinge bolts, washers, nuts and cotter pins.

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lent, between the edges of the outer (heavy gauge) and inner (light gauge) windows, prior to
installation.
3. Apply Behr-Manning sealant number PRC 5000 or equivalent, completely around the outer
surface of the attachment flanges.
4. Insert the window assembly in the frame and install the retainer moldings.
5. Secure the window and retainer moldings in position by installing the attachment screws.
6. Install the trim moldings and attachment screws.
7. Remove the excess exposed sealer from around the window.

4-36. DOOR (ENTRANCE).

4-37. REMOVAL OF DOOR.

a. Remove the clevis bolt, washer and bushing from the door holder assembly.
b. Remove cotter pins, clevis pins and washers from serrated door hinges.
c. Remove the door from the airplane.

4-38. INSTALLATION OF DOOR.

a. Insert the door into position and install the washers, clevis bolts and cotter pins on the door hinges.
b. For adjustment of door, refer to Paragraph 4-39.
c. Hook up and install the clevis bolt, bushing and washer into the door holder assembly.

4-39. ADJUSTMENT OF DOOR.

a. To acquire the proper vertical adjustment of the door, insert the necessary washer combination
between the cabin door hinge and fuselage bracket assembly.
b. Additional adjustments may be made by tapping out the serrated door hinge, bushings and rotating
them to obtain the hinge centerline location that will provide proper door fit.
c. To ensure long life of door seals and improve sealing characteristics, it is recommended they be
lubricated with a dry lubricant in a spray can.

4-40. REMOVAL OF DOOR LATCH MECHANISM

a. Remove the door latch mechanism by removing the door trim upholstery and the screws that attach
the latch plate and latch mechanism to the door.
b. Disconnect the latch pull rod from the inside door handle.
c. Remove the complete latch mechanism.

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4-42. INSTALLATION OF DOOR LATCH MECHANISM.

a. Place the latch assembly into position on the door.
b. Connect the latch pull rod to the inside door handle.
c. Replace the screws that attach the latch plate and mechanism to the door. Install the door trim
upholstery and secure with screws.
4-43. ADJUSTMENT OF DOOR LATCH MECHANISM.
To adjust the door latch, loosen the screws on the striker plate, make necessary adjustment, and retighten
the screws.
4-44. REMOVAL OF DOOR LOCK ASSEMBLY.
a. Remove the door trim upholstery by removing the attachment screws.
b. Loosen the nut on the lock assembly and remove the lock by turning it sideways.
4-45. INSTALLATION OF DOOR LOCK ASSEMBLY.
a. Install the lock in the door by turning it sideways and placing it through the opening provided.
b. Replace the nut on the back of the lock assembly and tighten.
c. Replace the door trim upholstery and secure with the attachment screws.
4-46. REMOVAL OF DOOR SAFETY LATCH.
a. PA-28-150,-160,-180 Serial Nos. 28-1 to 28-990 incl:
1. Remove the latch assembly by removing the two knobs and the small trim plate at the aft end
of the latch.
2. Remove the two screws from the inside trim plate and remove the plate.
3. Remove the latch assembly from the door.
b. PA-28-140; PA-28-150, -160, -180, Serial Nos. 28-991 and up; PA-28-235 and PA-28R:
1. Remove the two handles and the five screws holding the pan on the inside of the door.
2. Remove the pane and pull the latch assembly through the opening on the door.
4-47. INSTALLATION OF DOOR SAFETY LATCH.
a. PA-28-150, -160, -180 Serial Nos. 28-1 to 28-990 incl:
1. Place the latch assembly into position for installation.
2. Install the small trim plate on the aft end of the door and on the inside of the door. Secure in
place with the attachment screws.
3. Replace the knobs and tighten. Check latch for proper operation and that the knobs are free of
rubbing on the trim panels.
b. PA-28-140; PA-28-150,-160,-180 Serial Nos. 28-991 and up; PA-28-235 and PA-28R:
1. Place the latch assembly into position for installation.
2. Replace the pan and install the five screws and handles.
3. Check the latch assembly for operation and be certain that it is free of rubbing on the trim
panels.

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4-48. ADJUSTMENT OF DOOR SAFETY LATCH. (PA-28-140; PA-28-150,-160,-180, Serial Nos. 28-991
and up; PA-28-235 and PA-28R.)
a. To adjust the door safety latch remove the two screws from latch plate found at the top of the door
opening.
b. Remove the plate and turn the loop assembly in or out to make necessary adjustments.
c. Replace the latch plate and secure with the two attachment screws.
4-49. BAGGAGE DOOR.
4-50. REMOVAL OF BAGGAGE DOOR.
With the door open remove the hinge pin from the hinge and remove the door.
4-51. INSTALLATION OF BAGGAGE DOOR.
Place the door in position so that the hinge halves are properly matched and install the hinge pin. It will
not be necessary to replace the hinge pin with a new pin if it is free of bends and wear.
4-52. REMOVAL OF BAGGAGE DOOR LOCK ASSEMBLY.
a. With the door open remove the nut from the back of the lock assembly by use of a special made
wrench. (This tool may be fabricated from the dimensions given in Figure 4-24.)
b. Remove the lock assembly through the front of the door.
4-53. INSTALLATION OF BAGGAGE DOOR LOCK ASSEMBLY.
a. Place the lock into position for installation.
b. Install the nut on the lock assembly and tighten with the use of a special wrench.
4-54. REMOVAL OF BAGGAGE DOOR HINGE.
a. Remove the door from the airplane as described in Removal of Baggage Door, Paragraph 4-49.
b. Remove the hinge half from the airplane or door by drilling out the rivets and removing the hinge.
4-55. INSTALLATION OF BAGGAGE DOOR HINGE.
a. Place the hinge halves together and install the hinge pin.
b. Install the door into the closed position and drill the two end rivet holes and install the rivets.
c. Operate the door and check for proper fit and installation. Drill the remaining holes and install the
rivets.

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4-56. RIGGING INSTRUCTIONS - SEAT BACK LOCK AND RELEASE. (Refer to Figure 4-9.)
a. Loosen screws (1 and 2) and ascertain that clamps (3 and 4) are in a relaxed condition. (Push-pull
cable (6) is able to move within the clamps.)
b. Place a straightedge along the lower surface of bushing (5) of the seat back release.
c. Adjust the push-pull cable (6) by raising or lowering it until the lower surface of the stop assembly
(7) is parallel to the straightedge.
d. Secure the push-pull cable in this position by tightening screws (1 and 2) on clamps (3 and 4). The
stop 17) should be lubricated and free to swivel without excessive play.
e. Push on seat back with stop assembly (7) in an engaged position to check engagement. Rotate the
seat back release handle and check for disengagement of seat back.

Figure 4-9. Seat Back Lock

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4-57. STRUCTURAL REPAIRS. Structural repair methods used may be made in accordance with the
regulations set forth in Federal Aeronautics Manual 18 or FAA Advisory circular 43.13-1A. To assist in
making repairs, Figure 4-10 identifies the type and thickness of skin structure used. Never make a skin
replacement or patch from a material thinner than the original skin. Original material and thickness is
recommended and must result in a surface which is as strong as, or stronger than, the original skin.
However, flexibility must be retained so that the surrounding areas will not receive extra stress.
When making major structural repairs, other than using factory manufactured parts, it is recommended
the manufacturer be contacted. No major alterations are recommended without contacting the
manufacturer.
4-57a. METAL WIRE STITCHING REPAIR. (See Figure 4-10a.) (PIR-PPS20024, Rev. A.)

CAUTION: METAL/WIRE STITCHING (AND THE ALTERNATE METHOD OF JOINING

DESCRIBED BELOW) SHALL ONLY BE USED FOR NON-STRUCTURAL, NON-
LOAD CARRYING APPLICATIONS.
A metal/wire stitching process is used to staple fabric and rubber seal materials to engine baffles and
some composite materials. The following alternate method of joining is approved for field use when
replacing these fabric and rubber seal materials.
Alternate (Rivet) Method of Joining.
(1) Substitute two rivets in lieu of each staple where stitching was previously used or is specified.
Maintain a minimum of .75 inch spacing between rivets.
(2) When materials being joined include Stainless Steel, Galvanized Steel or Steel, use:
(a) MS20615M4 Rivet (Monel) and NAS1149CN432R Washer (See Figure 4-10a.)
(b) Install with manufactured (factory) head against hardest material. Install washer against
opposite side of joint and upset rivet (bucktail) against washer.
(3) When materials being joined include only aluminum and nonmetallic materials use:
(a) MS20470A4 Rivet and NAS1149DN432H Washer (See Figure 4-10a.)
(b) Install with manufactured (factory) head against hardest material. Install washer against
opposite side of joint and upset rivet (bucktail) against washer.

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Figure 4-10. Skin Materials and Thickness

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Figure 4-10. Skin Materials and Thickness (cont.)

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Figure 4-10a. Metal Wire Stitching Repair

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4-58. FIBERGLASS REPAIRS.

The repair procedure in this manual will describe the methods for repair of fiberglass reinforced
structures. Paragraph 4-59 describes Fiberglass Touch-Up and Surface Repairs such as blisters, open
seams, delamination, cavities, small holes and minor damages that have not harmed the fiberglass cloth
material. Paragraph 4-60 describes Fiberglass Fracture and Patch Repairs as puncture, breaks and holes
that have penetrated through the structure and damaged the fiberglass cloth. A repair kit, part number
756 729 will furnish necessary material for such repairs, is available through Piper Aircraft Dealers.
NOTE: Very carefully follow resin and catalyst mixing instructions furnished with repair kit.
4-59. FIBERGLASS TOUCH-UP AND SURFACE REPAIRS.
a. Remove wax, oil and dirt from around the damaged area with acetone, Methylethylketone or
equivalent and remove paint to gel coat.
b. The damaged area may be scraped with a fine blade knife or a power drill with a burr attachment to
roughen the bottom and sides of the damaged area. Feather the edge surrounding the scratch or
cavity. Do not undercut the edge. (If the scratch or cavity is shallow and penetrates only the surface
coat, continue to step h.)
c. Pour a small amount of resin into a jar lid or on a piece of cardboard, just enough to fill the area
being worked on. Mix an equal amount of milled fiberglass with the resin, using a putty knife or
stick. Add catalyst, according to kit instruction, to the resin and mix thoroughly. A hypodermic
needle may be used to inject gel into small cavities not requiring fiberglass millings mixed with the
gel.
d. Work the mixture of resin, fibers and catalyst into the damaged area, using the sharp point of a putty
knife or stick to press it into the bottom of the hole and to puncture any air bubbles which may be
present. Fill the scratch or hole above the surrounding undamaged area about 1/16 inch.
e. Lay a piece of cellophane or waxed paper over the repair to cut off air and start the cure of gel
mixture.
f. Allow the gel to cure 10 to 15 minutes until it feels rubbery to the touch. Remove the cellophane
and trim flush with the surface, using a sharp razor blade or knife. Replace the cellophane and allow
to cure completely for 30 minutes to an hour. The patch will shrink slightly below the structure
surface as it cures. (If wax paper is used, ascertain wax is removed from surface.)
g. Rough up the bottom and edges of the hole with the electric burr attachment or rough sand paper.
Feather hole into surrounding gel coat, do not undercut.
h. Pour out a small amount of resin, add catalyst and mix thoroughly, using a cutting motion rather
than stirring. Use no fibers.
i. Using the tip of a putty knife or finger tips, fill the hole at about 1/16 inch above the surrounding
surface with the gel coat mixture.
j. Lay a piece of cellophane over the patch to start the curing process. Repeat step f, trimming patch
when partially cured.
k. After trimming the patch, immediately place another small amount of gel coat on one edge of the
patch and cover with cellophane. Then, using a squeegee or the back of a razor blade, squeegee
level with area surrounding the patch, leave the cellophane on patch for one or two hours or
overnight, for complete cure.

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l. After repair has cured for 24 hours, sand patched area using a sanding block with fine wet
sandpaper. Finish by priming, again sanding and applying color coat.
4-60. FIBERGLASS FRACTURE AND PATCH REPAIRS.
a. Remove wax, oil and dirt from around damaged area with acetone, methylethylketone or equivalent.
b. Using a key hole saw, electric saber saw, or sharp knife cut away ragged edges. Cut back to sound
material.
c. Remove paint three inches back from around damaged area.
d. Working inside the structure, bevel the edges to approximately a 30 degree angle and rough-sand
the hole and the area around it, using 80-grit dry paper. Feather back for about two inches all
around the hole. This roughens the surface for strong bond with patch.
e. Cover a piece of cardboard or metal with cellophane. Tape it to the outside of the structure covering
the hole completely. The cellophane should face toward the inside of the structure. If the repair is on
a sharp contour or shaped area, a sheet of aluminum formed to a similar contour may be placed over
the area. The aluminum should also be covered with cellophane.
f. Prepare a patch of fiberglass mat and cloth to cover an area two inches larger than the hole.
g. Mix a small amount of resin and catalyst, enough to be used for one step at a time, according to kit
instructions.
h. Thoroughly wet mat and cloth with catalyzed resin. Daub resin on mat first, and then on cloth. Mat
should be applied against structures surface with cloth on top. Both pieces may be wet out on
cellophane and applied as a sandwich. Enough fiberglass cloth and mat reinforcements should be
used to at least replace the amount of reinforcements removed in order to maintain the original
strength. If damage occurred as a stress crack, an extra layer or two of cloth may be used to
strengthen area.
i. Lay patch over hole on inside of structure, cover with cellophane, and squeegee from center to
edges to remove all air bubbles and assure adhesion around edge of hole. Air bubbles will show
white in the patch and they should all be worked out to the edge. Remove excess resin before it gels
on the part. Allow patch to cure completely.
j. Remove cardboard or aluminum sheet from outside of hole and rough-sand the patch and edge of
hole. Feather edge of hole about two inches into undamaged area.
k. Mask area around hole with tape and paper to protect surface. Cut a piece of fiberglass mat about
one inch larger than the hole and one or more pieces of fiberglass cloth two inches larger than the
hole. Brush catalyzed resin over hole, lay mat over hole and wet out with catalyzed resin. Use a
daubing action with brush. Then apply additional layer or layers of fiberglass cloth to build up patch
to the surface of structure. Wet out each layer thoroughly with resin.
l. With a squeegee or broad knife, work out all air bubbles in the patch. Work from center to edge,
pressing patch firmly against the structure. Allow patch to cure for 15 to 20 minutes.
m. As soon as the patch begins to set up, but while still rubbery, take a sharp knife and cut away extra
cloth and mat. Cut on outside edge of feathering. Strip cut edges of structure. Do this before cure is
complete, to save extra sanding. Allow patch to cure overnight.
n. Using dry 80 grit sandpaper on a power sander or sanding block, smooth patch and blend with
surrounding surface. Should air pockets appear while sanding, puncture and fill with catalyzed
resin. A hypodermic needle may be used to fill cavities. Let cure and resand.

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o. Mix catalyzed resin and work into patch with fingers. Smooth carefully and work into any crevices.
p. Cover with cellophane and squeegee smooth. Allow to cure completely before removing
cellophane. Let cure and resand.
q. Brush or spray a coat of catalyzed resin to seal patch. Sand patch, finish by priming, again sanding
and applying color coat.
NOTE: Brush and hands may be cleaned in solvents such as acetone or methylethylketone. If
solvents are not available, a strong solution of detergent and water may be used.
4-61. THERMOPLASTIC REPAIRS. The following procedure will assist in making field repairs to items
made of thermoplastic which are used throughout the airplane. A list of material needed to perform these
repairs is given along with suggested suppliers of the material. Common safety precautions should be
observed when handling some of the materials and tools used while making these repairs.
a. Surface Preparation:
1. Surface dirt and paint if applied must be removed from the item being repaired. Household
cleaners have proven most effective in removing surface dirt.
2. Preliminary cleaning of the damaged area with perchlorethylene or VM&P Naptha will
generally insure a good bond between epoxy compounds and thermoplastic.
b. Surface Scratches, Abrasion or Ground-in-Dirt: (Refer to Figure 4-11.)
1. Shallow scratches and abraded surfaces are usually repaired by following directions on
containers of conventional automotive buffing and rubbing compounds.
2. If large dirt particles are embedded in thermoplastic parts, they can be removed with a hot air
gun capable of supplying heat in the temperature range of 300° to 400° F. Use care not to
overheat the material. Hold the nozzle of the gun about 1/4 of an inch away from the surface
and apply heat with a circular motion until the area is sufficiently soft to remove the dirt
particles.
3. The thermoplastic will return to its original shape upon cooling.
c. Deep Scratches, Shallow Nicks and Small Holes: (Less than 1 inch in diameter.) (Refer to Figure 4-
12.)
1. Solvent cements will fit virtually any of these applications. If the area to be repaired is very
small, it may be quicker to make a satisfactory cement by dissolving thermoplastic material of
the same type being repaired in solvent until the desired paste-like consistency is achieved.
2. This mixture is then applied to the damaged area. Upon solvent evaporation, the hard durable
solids remaining can easily be shaped to the desired contour by filing or sanding.
3. Solvent adhesives are not recommended for highly stressed areas, on thin walled parts or for
patching holes greater than 1/4 inch in diameter.
4. For larger damages an epoxy patching compound is recommended. This type material is a two
part, fast curing, easy sanding commercially available compound.
5. Adhesion can be increased by roughing the bonding surface with sandpaper and by utilizing as
much surface area for the bond as possible.
6. The patching compound is mixed in equal portions on a hard flat surface using a figure eight
motion. The damaged area is cleaned with perchlorethylene or VM&P Naptha prior to
applying the compound. (Refer to Figure 4-13.)
7. A mechanical sander can be used after the compound is cured, providing the sander is kept in
constant motion to prevent heat buildup.

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TABLE IV-II. BALANCING SPECIFICATIONS

Maximum Limits - Flight Conditions (PIR - PPS50015, Rev. AF)

STATIC BALANCE LIMITS (INCH-POUNDS)

SERIAL NOS. HEAVY SIDE HEAVY SIDE

SURFACE MODEL AFFECTED LEADING EDGE TRAILING EDGE

STABILATORS
PA-28-140 THRU 28-7325614 0 TO -30
PA-28-140 28-7425001 AND UP 0 TO -30
PA-28-150 ALL 0 TO -30
PA-28-160 ALL 0 TO -30
PA-28-180 NON-STRETCHED STABILATOR 0 TO -30
PA-28-180 STRETCHED STABILATOR
28-7305001 TO 28-7305601 +5 TO -40
PA-28-180 28-7405001 AND UP +5 TO -40
PA-28R-180/200 TO 28R-7235000 +5 TO -14
PA-28R-200 STRETCHED STABILATOR
28R-7235001 TO 28R-7335446 +5 TO -40
PA-28R-200 28R-7435001 AND UP +5 TO -40
PA-28-235 NON-STRETCHED STABILATOR +5 TO -14
PA-28-235 28-7310001 TO 28-7310176 +5 TO -40
PA-28-235 28-7410001 AND UP +5 TO -40

RUDDERS
PA-28-140 UP TO 28-7325614 0 TO -20.9
PA-28-140 28-7425001 AND UP 0 TO -13.0
PA-28-150 ALL 0 TO -20.9
PA-28-160 ALL 0 TO -20.9
PA-28-180 THRU 28-7305000 0 TO -20.9
PA-28-180 28-7305001 AND UP 0 TO -25.0
PA-28-180 28-7435001 AND UP 0 TO -13.0
PA-28R-180 THRU 28R-7235000 0 TO -15.0
PA-28R-200 THRU 28R-7235000 0 TO -15.0
PA-28R-200 28R-7235001 AND UP 0 TO -14.0
PA-28R-200 28R-7435001 AND UP 0 TO -13.0
PA-28-235 THRU 28-7310000 0 TO -15.0
PA-28-235 28-731001 AND UP 0 TO -14.0
PA-28-235 28-741001 AND UP 0 TO -13.0

AILERONS
PA-28-140 ALL 0 TO -17
PA-28-150 ALL 0 TO -17
PA-28-160 ALL 0 TO -17
PA-28-180 ALL 0 TO -17
PA-28R-180 ALL +2 TO -15
PA-28R-200 ALL +2 TO -15
PA-28-235 ALL +2 TO -20

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4-72. BALANCING EQUIPMENT (Refer to Figure 4-19).

The balancing must be done using a suitable tool capable of measuring unbalance in inch-pounds from
the centerline of the control surface hinge pin. See the tool configuration in Figure 4-19. Other tool
configurations may be used if accuracy is maintained and recalibration capability is provided.
To use this tool:
a. Ensure that the control surface is in its final Flight configuration, static wicks, trim tabs, trim tab
push pull rod and control surface tip (as applicable) should be installed. The surface should be
painted and trim/servo tabs should be in the neutral position.
NOTE: Because paint is a considerable balance factor, it is recommended that existing paint be
removed prior to repainting a control surface.
b. Place hinge bolts through control surfaces and place control surface on a holding fixture.
c. Calibrate the tool.
1. Avoiding rivets, place the balancing tool on the control surface with the tool’s hinge centerline
directly over the hinge line of the control surface.
2. Adjust the movable trailing edge support to fit the width of the control surface. Tighten the set
screw on the trailing edge support.
3. Adjust the trailing edge support vertically until the beam is parallel with the control surface
chord line.
4. Remove the tool from the control surface and balance the tool itself by adding or removing
nuts or washers from the beam balancing bolt. When balancing the tool, the movable weight
must be at the bar’s hinge centerline.
d. After balancing the tool, reattach it to the control surface per Figures 4-20 and 4-21. Keep the beam
positioned 90° from the control surface hinge line.
e. Determine balance of control surface by sliding movable weight along the balance beam.
f. Read the scale when the bubble level has been centered. Multiply by three to determine inch-lbs.
(I.E. - Since the movable weight weighs three pounds, every inch it is moved from the center of the
beam equals three inch-lbs of force.)
4-73. BALANCING AILERONS. (Refer to Figure 4-20.)
Position the aileron on the balancing fixture in a draft free area and in a manner which allows
unrestricted movement of the aileron. Place the tool on the aileron, avoid rivets and keep the beam
perpendicular to the hinge centerline. Calibrate the tool as described in Paragraph 4-72. Read the scale
when the bubble level has been centered by adjustment of the movable weight and determine the static
balance. If the static balance is not within the limits specified in Table IV-II, proceed as follows:
a. Leading Edge Heavy: This condition is highly improbable; recheck measurements and calculations.
b. Training Edge Heavy: There are no provisions for adding weight to balance weight to counteract a
trailing edge heavy condition; therefore, it will be necessary to determine the exact cause of the
unbalance. If the aileron is too heavy because of painting over old paint, it will be necessary to strip
all paint from the aileron and repaint. If the aileron is too heavy resulting from repair to the skin or
ribs, it will be necessary to replace all damaged parts and recheck the balance.

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4-74. BALANCING RUDDER. (Refer to Figure 4-20.)

To balance the rudder, the assembly must be complete including the tip assembly with all attaching
screws and the position light wiring. Place the complete assembly horizontally on knife edge supports in
a draft-free area in a manner that allows unrestricted movement. Place the tool on the rudder with the
beam perpendicular to the hinge centerline. Calibrate the tool as described in Paragraph 4-72. Read the
scale when the bubble level has been centered by adjustment of the movable weight and determine the
static balance limit. If the static balance is not within the limits given in Table IV-II, proceed as follows:
a. Nose Heavy: This condition is highly improbable; recheck calculations and measurements.
b. Nose Light: In this case, the mass balance weight is too light or the rudder is too heavy because of
painting; it will be necessary to strip the paint and repaint. If the rudder is too heavy as a result of
repairs, the repair must be removed and the damaged parts replaced.

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Figure 4-19. Control Surface Balance Tool

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Figure 4-25. Additional Drain Holes in Stabilator (Typical)

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4-79. BAGGAGE COMPARTMENT INSPECTION HOLE AND COVER PLATE.

a. General.
Airplanes manufactured before 1979 may not have had control cable inspection access holes in the
baggage compartment floor. The following is a method of fabricating inspection access holes in the
floor of the baggage compartment, if desired.
b. Baggage Compartment Inspection Holes Fabrication Procedure. (Refer to Figure 4-26.)
While Figure 4-26 shows the hole in the left side of the baggage compartment, a similar hole is also
cut out in the right side baggage compartment floor. Installation will require two each inspection
access covers, P/N 62109-000.
1. Layout cut lines.
(a) Gain access to baggage compartment.
(b) Carefully remove:
(1) Right side baggage compartment Royalite plastic close out panel.
(2) Rear close out panel.
(3) Carpeting from baggage compartment floor.
(c) Determine and mark a reference center line running through baggage compartment. Refer
to Figure 4-26 for measurements.
(d) Measure two points 14.99 inches each side of the reference centerline. Joining these two
points will form the centerlines of each inspection hole.
(e) Measure two points on each side of each centerline of both holes at distances of 8.48
inches and 10.98 inches from the aft edge of the baggage compartment floor.
(f) Connect the two 8.48 inch points and the two 10.98 inch points so that the resulting lines
cross the centerline of each hole.
(g) Using the intersection of the lines constructed in step (f) with each hole’s centerline as the
center, scribe an arc having a radius of 2.00 inches.
(h) Draw a line (four lines total) tangent to the each side of the arcs constructed on step (g).
(i) There should now be two ovals, like the one in Figure 4-26, laid out on each side of the
baggage compartment floor.
2. Cutting the holes.
CAUTION: BAGGAGE COMPARTMENT FLOORING IS MADE OF 0.025 INCH THICK
ALUMINUM. USE CARE WHEN CUTTING THROUGH FLOORING SO AS
NOT TO DAMAGE CABLES AND WIRING ROUTED BELOW THE FLOOR.
(a) Drill a 1/4 inch hole inside of, and adjacent to, one of the scribed lines layed out for each
hole.
(b) Using a 1/8 inch router bit, cut out the two inspection holes by following the lines layed
out on each side of the baggage compartment floor.
(c) Deburr each cut edge using a file or emery wheel.

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4-80. ELECTRICAL BONDING

a. General. (PIR-PPS55006, Rev. U.)

All electrical and electronic equipment and specified components shall be installed in such a
manner as to provide a continuous low resistance path (bonds) from the equipment
enclosure/component to the airplane structure. Bonds must be installed to ensure that the structure
and equipment are electrically stable and free from the hazards of lightning, static discharge,
electrical shock, etc.
1. All parts shall be bonded with as short a lead as possible.
2. All bonding surfaces shall be cleaned prior to the installation of the bonded joint.
3. All nuts used in bonding shall be of the self-locking type. (Do Not use fiber-locking type).
4. All electrical bonding shall be accomplished without affecting the structural integrity of the
airframe.
b. 100 Hour Inspection (PIR-AC 43.13-1, Rev. B.)

Each 100 hours, visually inspect shield and shield terminations of each electrical harness for
integrity, condition, and security. If electrical arcing is evident, check for intermittent contact
between conducting surfaces. Arcing can be prevented by bonding or insulation, as appropriate.
Inspect the components listed in Table IV-III as follows:
1. Bond connections shall be secure and free from corrosion.
2. Bonding jumpers installed so as not to interfere in any way with the operation of moveable
components of the aircraft.
3. No self-tapping screws used for bonding purposes.
4. Exposed conducting frames or parts of electrical or electronic equipment should have a low
resistance bond of less than 2.5 millohms to structure. If the equipment design includes a
ground terminal or pin, which is internally connected to such exposed parts, a ground wire
connection to such terminal will satisfy this requirement.
5. Parts shall be bonded directly to the primary structure rather than to other bonded parts.
6. Where aluminum or copper is bonded to dissimilar metallic structures, ensure installed
hardware (typically washers) is as called out in the parts catalog to minimize electrolytic
corrosion and ensure the hardware should corrode first.
c. On Condition Inspection
Whenever any electrically bonded component (see Table IV-III) is removed and reinstalled, or
visual inspection reveals the electrical bonding to be suspect, measure resistance between
component and aircraft structure.
To ensure proper operation and suppression of radio interference from hazards, electrical bonding
of equipment must not exceed the maximum allowable resistance values specified in Table IV-III.
1. Measurements should be performed after the grounding and bonding mechanical connections
are complete to determine if the measured resistance values meet the basic requirements.
2. A high quality test instrument (an AN/USM-21A or equivalent) will accurately measure the
very low resistance values specified.
3. Another method of measurement is the millivolt drop test as shown in Figure 4-27.

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TABLE IV-III. ELECTRICAL BONDING RESISTANCE INDEX

Maximum Allowable
Component Resistance Value in Ohms
Engine Mount(s) .003
Generator(s) .010
Ailerons .003
Elevator / Stabilator .003
Rudder .003
Alternator(s) .010
Trim Tab(s)
Conventional Hinge .003
Piano Hinge .010
Instrument Panel Inserts .010
Exterior Lights Mounted on Non-Conductive Material .003
Avionics ‘Black Boxes’ .003
NOTE: Harnesses should be installed and connected for this check, internal chassis
wiring through the connector to ground is permissible for this grounding.
Battery Ground Point .010
Static wick mounting plates (TCO Model B-4) P/N 452-094 1.00
NOTE: Where jumper wires or cables are used to accomplish a proper bond, resistance between the
jumper terminal and the component or structure shall not exceed .001 ohms. The controlling
points for measuring resistance will be within the limits of the cleaned area to be bonded and
within 1/4 inch of the exterior limits of the bonding jumper terminal or material called for in
the bill of materials of the drawing.
Resistance to ground will be measured from wire terminal to structure for electrical /
electronic equipment not internally grounded and from mounting flange to structure for
equipment that is internally grounded.

COMPONENT SURFACE VOLT METER AIRCRAFT STRUCTURE SURFACE

MV

BONDING STRAP

Adjust rheostat (R1) so that ammeter (A)

reads 10 Amps.
28 VDC SOURCE
- Resistance in milliohms is then the reading
on the volt meter (i.e. - millivolts (MV))
divided by the amps (10) set on the
+ ammeter. For example, where MV equals
30:
A
R1 30 MV
= .003 OHMS RESISTANCE
AMMETER 10 AMPS

Figure 4-27. Millivolt Drop Test

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SECTION

V
SURFACE CONTROLS

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SECTION V - SURFACE CONTROLS

TABLE OF CONTENTS

Grid No.
Paragraph

5-1. Introduction ........................................................................................... 2A9

5-2. Description ............................................................................................ 2A9
5-2a. Troubleshooting..................................................................................... 2A9
5-3. Standard Procedures ............................................................................. 2A11
5-3a. Flight Control Surface Travel ............................................................... 2A12
5-3b. Flight Control Cable Tension ............................................................... 2A12
5-4. Control Column Assembly ................................................................... 2A15
5-5. Removal of Control Column Assembly ......................................... 2A15
5-6. Installation of Control Column Assembly ..................................... 2A18
5-6a. Installation of Universal Joint ............................................................... 2A19
5-7. Aileron Controls ................................................................................... 2A19
5-8. Removal of Aileron Control Cables ............................................... 2A19
5-9. Installation of Aileron Control Cables ........................................... 2A22
5-10. Removal of Aileron Bellcrank Assembly ...................................... 2A23
5-11. Installation of Aileron Bellcrank Assembly ................................... 2A23
5-12. Rigging and Adjustment of Aileron Controls ................................ 2A24
5-13. Adjustment of Aileron Trim ........................................................... 2B1
5-14. Stabilator Controls ................................................................................ 2B4
5-15. Removal of Stabilator Control Cables ........................................... 2B4
5-16. Installation of Stabilator Control Cables ........................................ 2B5
5-17. Rigging and Adjustment of Stabilator Controls ............................. 2B7
5-18. Stabilator Trim Controls (Overhead Trim) ........................................... 2B9
5-19. Removal of Stabilator Trim Assembly (Forward) ......................... 2B9
5-20. Installation of Stabilator Trim Assembly (Forward) ...................... 2B11
5-21. Removal of Stabilator Trim Controls (Aft) .................................... 2B11
5-22. Installation of Stabilator Trim Controls (Aft) ................................ 2B14
5-23. Rigging and Adjustment of Stabilator Trim (Overhead Control) .. 2B16
5-24. Stabilator Trim Controls (Floor Trim) .................................................. 2B18
5-25. Removal of Stabilator Trim Assembly (Forward) ......................... 2B18
5-26. Installation of Stabilator Trim Assembly (Forward) ...................... 2B19
5-27. Removal of Stabilator Trim Assembly (Aft) ................................. 2B21
5-28. Installation of Stabilator Trim Assembly (Aft) .............................. 2B21
5-29. Rigging and Adjustment of Stabilator Trim (Floor Control) ......... 2B22
5-30. Rudder and Steering Pedal Assembly ................................................... 2B22
5-31. Removal of Rudder and Steering Pedal Assembly ........................ 2B22
5-32. Installation of Rudder and Steering Pedal Assembly ..................... 2C1
5-33. Rudder Controls .................................................................................... 2C2
5-34. Removal of Rudder Control Cables ............................................... 2C2
5-35. Installation of Rudder Control Cables ............................................ 2C2
5-36. Rigging and Adjustment of Rudder Controls ................................. 2C4

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SECTION V - SURFACE CONTROLS

TABLE OF CONTENTS (cont.)

Paragraph
Grid No.

5-37. Rudder Trim Controls ........................................................................... 2C7

5-38. Removal of Rudder Trim Controls ................................................ 2C7
5-39. Installation of Rudder Trim Controls ............................................. 2C7
5-40. Rigging and Adjustment of Rudder Trim Controls ........................ 2C7
5-41. Wing Flap Controls ............................................................................... 2C10
5-42. Removal of Wing Flap Controls .................................................... 2C10
5-43. Installation of Wing Flap Controls ................................................. 2C11
5-43a. Torque Tube/Push Rod Distortion Inspection ................................ 2C13
5-44. Rigging and Adjustment of Wing Flaps ......................................... 2C13

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SECTION V

SURFACE CONTROLS

5-1. INTRODUCTION.
This section contains removal, installation, rigging, adjustment and trim procedures for ailerons,
flaps (less trim), stabilator and rudder flight control surfaces. Also included are similar procedures for
the control column and rudder and steering pedal assembly. For removal, installation, and repair of
structural surfaces of the airplane, refer to Section IV.
5-2. DESCRIPTION.
The PA-28 is controlled in flight by the use of three standard primary control surfaces, consisting of the
ailerons, stabilator and rudder. Operation of these controls is through the movement of the dual control
columns and dual rudder pedals. The individual surfaces are connected to their control components
through the use of cables and push-pull tubes. Provision for directional and longitudinal trim control
is provided by an adjustable trim mechanism for the rudder and stabilator. The flaps on the PA-28 are
mechanically operated and can be positioned in four locations of 0, 10, 25 and 40 degrees.
The aileron controls consist of two-control wheels connected by torque tubes to sprockets on each
end of the horizontal control column. A chain is wrapped around the sprockets and around a double
sprocket on the vertical post of the control column. The chain is connected to the primary aileron control
cable which is routed through the center of the fuselage to the main spar and out through the wings to
a bellcrank in each wing. A balance cable is also connected to the bellcrank. As the control wheels are
moved, the control cables move the bellcranks and actuate push-pull rods to move the ailerons.
The stabilator controls are also connected to the control column. From the connecting point, cables are
routed around a series of pulleys down under the floor and aft to the tail section of the airplane. The aft
end of the cables connect to the stabilator balance arm which in turn is connected to the stabilator. When
the control wheels are moved forward or aft, the cables move the balance arm up and down rotating the
stabilator on its hinge points.
The rudder is controlled by the pilot’s and co-pilot’s rudder pedals. Cables are connected to both sides
of the rudder pedal assembly and are routed aft through the bottom of the fuselage to the rudder horn.
When one rudder pedal is pushed, the cables move in opposite directions turning the rudder horn and
rudder. The wing flap system is operated by a lever located between the front seats.
For a visual description of the various control systems, refer to the illustrated figures throughout this
section.
5-2a. TROUBLESHOOTING.
See Table V-III.

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5-3. STANDARD PROCEDURES.

The following tips may be helpful in the removal, installation and rigging of the various assemblies:
a. It is recommended, though not always necessary, to level and place the airplane on jacks during
rigging and adjustment.
b. Remove turnbuckle barrels from cable ends before withdrawing the cables through the structures.
c. Tie a cord to the cable end before withdrawing the cable through the structures to facilitate
reinstallation of cable.
d. Turnbuckle stations are given at their neutral positions.
e. Mark cable ends, etc., before disconnecting, use a felt tip marking pen.
f. Assemble and adjust the turnbuckles so that each terminal is screwed an approximately equal
distance into the barrel. Do not turn the terminals in such a manner that will put a permanent “twist”
into the cables.
g. Cable tensions should be taken with the appropriate control surface in its neutral position.
NOTE: Cable rigging tensions specified must be corrected to ambient temperature in the area
where the tension is being checked, using Table V-I.
h. After completion of each adjustment, check the turnbuckles to be sure not more than three terminal
threads are visible outside the barrel. Install the locking clips, and check for proper installation by
trying to remove the clips using fingers only. Both locking clips may be installed in opposite holes.
Locking clips which have been installed and removed must be scrapped and not reused.
Turnbuckles may be safetied in accordance with Advisory Circular 43.13-1 A Chapter 4, Section 2.
i. When push rods or rod ends are provided with an inspection hole, the screw must be screwed in far
enough to pass the inspection hole. This can be determined visually or by feel, inserting a piece of
wire into the inspection hole. If no hole is provided, there must be a minimum of .375 of an inch
thread engagement.
j. After completion of adjustments, each jam nut must be tightened securely (Refer to Figure 5-19 for
proper installation method).
NOTE: Torque all nuts in the flight control system (including nose wheel steering). Refer to
Table II-IV.
k. When normal operation requires movement between any of the components being clamped
together, the bolt (screw) -nut shall be tightened as required to ensure intended normal operation of
the assembly, without reference to Table II-IV.
l. Unless otherwise specified, when castellated nuts are used with a cotter pin on moving joints, the
nut shall not be torqued to the Table II-IV values. Nuts shall be tightened to remove looseness in the
joint and then the cotter pin installed.

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TABLE V-I. CABLE TENSION VS. AMBIENT TEMPERATURE

120

110
Temperature, Degrees Fahrenheit (°F) 100

90

80

70

60

50

40

30

20

-10 -8 -6 -4 -2 0 2 4 6 8 10
Subtract Add
Rigging Load Correction, Pounds

5-3a. FLIGHT CONTROL SURFACE TRAVEL.

See Table V-II for specifications, see appropriate section for rigging instructions.
5-3b. FLIGHT CONTROL CABLE TENSION
CAUTION: CABLE TENSIONS GIVEN IN TABLE V-II APPLY ONLY TO AIRPLANES WITHOUT
AUTOPILOT BRIDLE CABLE INSTALLATIONS. IF AN AUTOPILOT USING BRIDLE
CABLES HAS BEEN INSTALLED, CONSULT THE APPROPRIATE AUTOPILOT
VENDOR PUBLICATION (SEE NOTE BELOW) FOR CORRECT CABLE TENSIONS
WITH AUTOPILOT BRIDLE CABLES ATTACHED.
NOTE: For original autopilots carrying the Piper brand, consult the appropriate Piper Autopilot Service
Manual. Adjusting primary control cable tension and bridle cable tension is usually addressed in
the “Installation” paragraph for the corresponding servo.
a. See Table V-II for specifications, see appropriate section for rigging instructions.
b. When a new cable is installed, cable tension must be rechecked after flight test.

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TABLE V-II. FLIGHT CONTROL SURFACES RIGGING LIMITS (PIR-PPS-50005-1, Rev. K.)

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TABLE V-II. FLIGHT CONTROL SURFACES RIGGING LIMITS (cont.)

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5-4. CONTROL COLUMN ASSEMBLY.

5-5. REMOVAL OF CONTROL COLUMN ASSEMBLY. (Refer to Figure 5-1 or 5-2.)
a. To remove either control wheel (l) with tube (2), the following procedure may be used:
1. Separate the control wheel tube (2) from the flexible joint (4) that is located on either side of
the tee bar assembly (5) by removing the nut, washer and bolt (3). Pull the tube from the
flexible joint.
2. If removing the left control tube, slide the stop (6) from the tube.
3. Should wires for the various Autopilot systems be installed in the control tube, disconnect
them at the quick disconnect terminals behind the instrument panel. Draw the wires back into
the tube and out through the forward end of the tube.
4. Remove the control wheel assembly from the instrument panel.
b. The tee bar (5) with assembled parts may be removed from the airplane by the following procedure:
1. Remove the access panel or door to the aft section of the fuselage.
2. Relieve cable tension from the stabilator control cables (11) at one of the stabilator cable
turnbuckles in the aft section of the fuselage.
3. Relieve tension from the aileron control cables (12) and chains (7 and 8) and at the turnbuckle
(9) that connects the chains at the top of the tee bar (5).
4. Disconnect the control chains from the control cables where the chains and cables join by
removing the cotter pins, nuts, bolts and bushings (10).
5. Remove the tunnel cover by the following procedure:
(a) PA-28-140; PA-28-150, -160, -180; and PA-28R: Remove the rudder trim control knob
and trim cover attaching screws. Roll back the carpet from the tunnel and remove the
tunnel plate that is located just aft of the tee bar assembly, by removing the plate attaching
screws.
(b) PA-28-235: Remove the fuel selector and rudder trim covers by removing the knobs and
the attaching screws. Disconnect the fuel indicator control lever from the fuel selector
torque tube by removing the attaching pin located at the bottom of the lever. Remove the
tunnel plate, located just aft of the tee bar, by laying back enough tunnel carpet to remove
the plate attaching screws.
6. Remove the two aileron control cable pulleys (13) attached to the lower section of the tee bar
by removing the pulley attaching bolt (14).
7. Disconnect the stabilator controls (11) from the lower end of the tee bar assembly.
8. Disconnect the necessary controls, such as the mixture control, throttle control, etc., that will
allow the tee bar assembly to be removed.
9. Remove the tee bar assembly by removing the attaching bolts (15) with washers and nuts,
which are through each side of the floor tunnel, and lifting it up and out through the right side
of the cabin.

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Figure 5-1. Control Column Assembly (Typical)

PA-28-140, -150, -160, -180, -235

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Figure 5-2. Control Column Assembly

PA-28R

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5-6. INSTALLATION OF CONTROL COLUMN ASSEMBLY. (Refer to Figure 5-1 or 5-2.)

a. The tee bar assembly may be installed in the airplane by the following procedure:
1. Swing the tee bar assembly into place from the right side of the cabin and secure with
attaching bolts (15), washers and nuts inserted in through each side of the floor tunnel.
2. Connect the stabilator controls (11) to the lower end of the tee bar with bolt, washer, nut and
cotter pin (16). Allow the cable ends free to rotate.
3. Place the aileron control cables (12) around the pulleys (13) that attach to the lower section of
the tee bar (5), position pulleys and secure with bolt, washers and nut (14).
4. Install the control wheel per step b.
5. Place the control wheels in neutral (centered) position and install the aileron control chains (7
and 8) on the control wheel sprockets (17 and 18) and idler crossover sprockets (19 and 21).
This turnbuckle (9) must be centered between the two control wheel sprockets.
6. Loosen the connecting bolts (22) of the idler sprockets (19 nd 21) to allow the chain to fit snug
around the control wheel sprockets and over the idler sprockets.
7. Connect the aileron control cables (12) to the ends of the chains (7 and 8) with bolts, bushings,
nuts and cotter pins (10).
8. Adjust the chain turnbuckle (9) between the two control wheel sprockets to allow the control
wheels to be neutral and obtain proper cable tension as given in Table V-II. It may be
necessary, in order to have both control wheels neutral, to set the chain turnbuckle to neutralize
the wheels and then set cable tension with the turnbuckles located under the floor panel aft of
the main spar as instructed in paragraph 5-12. Before safetying the turnbuckle, check that
when the ailerons are neutral, the control wheels will be neutral and the chain turnbuckle
centered. Also, the aileron bellcranks should contact their stops before the control wheel hits
its stop. Maintain .030 to .040 clearance between sprocket pin and adjustable stop bolts on
models having adjustable aileron tee bar stops.
9. Set stabilator cable tension with the turnbuckle in the aft section of the fuselage and
instructions given in paragraph 5-17. Check safety of all turnbuckles upon completion of
adjustments.
10. Tighten the connecting bolts (22) of the idler sprockets (19 and 21). (Torque 45 ± 5 in.-lbs.)
11. Install the floor tunnel plate trim covers by the following procedure:
(a) PA-28-140; PA-28-150, -160, -180; and PA-28R: Place the tunnel plate into position for
installation and secure with the appropriate screws. Roll the carpet into place and install
the rudder trim cover and knob.
(b) PA-28-235: Install the floor tunnel plate and secure with the appropriate screws. Fasten the
tunnel carpet into place and install the fuel selector lever on the selector torque tube and
secure with a clevis pin and cotter pin. Replace the fuel selector and rudder trim knob.
b. Either control wheel assembly may be installed by the following procedure:
1. Insert the control wheel tube through the instrument panel.
2. Should wires for the various Autopilot systems need to be installed in the control tube, route
them through the hole in the forward side of the tube and out of the small hole in the forward
side. Position the rudder grommet in the hole in the side of the tube.
3. On the left control tube install the stop (6).

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4. Connect the control wheel tube (2) to the flexible joint (4) of the tee bar assembly. If the
control cables and/or chains have not been removed or loosened, place the ailerons in neutral
and install the control tube on the flexible joint to allow the control wheel to be neutral. Install
bolt, washer and nut (3) and tighten.
5-6a. INSTALLATION OF UNIVERSAL JOINT (Refer to Figures 5-1, 5-2 and 5-2a.)
a. Carefully lay out location for hole to be drilled in flex joint tube to match hole in control column
shaft.
b. Using a #5 (0.2055) drill bit, drill hole through flex joint tube at location determined above.
c. Ream drilled hole, in steps, with a #1 reamer, checking to ensure proper depth for taper pin and
sufficient pin thread protrusion for proper installation.
NOTE: Reamer may be purchased from your Piper Dealer as P/N 906-713.
d. Install pin through tube and shaft.
1. If pin shoulder does not protrude past sprocket hub, install an AN960-10 washer
2. If pin shoulder does protrude past sprocket hub, install an AN975-3 washer
3. Install nut. Torque 35 - 40 inch-pounds.
5-7. AILERON CONTROLS.
5-8. REMOVAL OF AILERON CONTROL CABLES. (Refer to Figure 5-3.)
a. For the removal of either the control cables in the fuselage or the wings, first remove the baggage
area floor panel of the PA-28-140 airplane, or the rear seat bottom on the PA-28-150, -160, -180;
PA-28-235 and PA-28R airplanes.

68028
SMALL END OF TAPERED SHANK SHALL NOT EXTEND
MORE THAN 0.030 INSIDE THE O.D. OR 0.062 OUTSIDE
THE O.D. OF THE SPOCKET HUB. TAPER PIN (480-730)
WASHER (407-564 [AN960-10])
OR (494-093 [AN975-3])
NUT (484-835 [MS20364-1032C])

SHAFT (P/N 62716-07)

FWD

0.098 DIA.
USE WITNESS HOLE TO ENSURE PROPER SHAFT INSERTION

Figure 5-2a. Universal, or Flex, Joint Installation

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Figure 5-3. Aileron Controls (Typical)

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b. To remove either the right or left primary control cables (14 or 15) that are located in the fuselage,
the following procedure may be used:
1. Remove the two front seats from the airplane.
2. Remove the tunnel cover located aft of the tee bar assembly by the following procedure:
(a) PA-28-140; PA-28-150, -160, -180; and PA-28R: Remove the rudder trim control knob and
trim cover attaching screws. Roll back the carpet from the tunnel and remove the tunnel
plate that is located just aft of the tee bar assembly by removing the plate attaching screws.
(b) PA-28-235: Remove the fuel selector and rudder trim covers by removing the knobs and
the attaching screws. Disconnect the fuel indicator control lever from the fuel selector
control lever from the fuel selector torque tube by removing the attaching pin located at
the bottom of the lever. Remove the tunnel plate located just aft of the tee bar by laying
back enough tunnel carpet to remove the plate attaching screws.
NOTE: To help facilitate reinstallation of control cables, mark the cable ends and attach a
line where applicable before drawing them through the fuselage or wing.
3. Separate the primary control cable (14 or 15) at the turnbuckle (12 or 16) located under the
rear seat or floor panel aft of the main spar.
4. Remove the cable pulleys (8) attached to the lower section of the control column tee bar
assembly by removing the pulley attaching bolt (21).
5. Move the cable guard (20) under the pulley cluster (9) located just aft of the lower portion of
the tee bar by removing the cotter pin from the exposed end of the guard and sliding it to the
left or right as required.
6. Remove the cotter pins used as cable guards at the pulley (10) in the forward area of the floor
opening aft of the main spar.
7. Disconnect the cable (14 or 15) from the control chain (4) at the control column tee bar assembly
by removing the cotter pin, nut, bolt and bushing (23) that connect the two together. Secure the
chains in some manner to prevent them from unwrapping from around the sprockets.
8. Draw the cable back through the floor tunnel.
c. The primary control cable (13 or 17) in either wing may be removed by the following procedure:
1. Remove the access plate to the aileron bellcrank (6) located on the underside of the wing
forward of the inboard end of the aileron.
2. If not previously disconnected, separate the cable at the turnbuckle (12 or 16) located in the
area aft of the main spar.
3. Disconnect the cable from the forward end of the aileron bellcrank by removing the cotter pin,
nut, washer and bolt.
4. Draw the cable from the wing
d. Either balance cable (18 or 19) may be removed by the following procedure:
1. Separate the balance cable at the turnbuckle (24) in the right side of the opening aft of the main
spar.
2. If the left balance cable is to be removed, remove the cotter pin used as a cable guard at the
pulley (11) in the center of the opening.
3. Remove the access plate to the aileron bellcrank (6) located on the underside of the wing
forward of the inboard end of the aileron.

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4. Disconnect the cable from the aft end of the aileron bellcrank by removing the cotter pin, nut,
washer and bolt.
5. Draw the cable from the wing.
5-9. INSTALLATION OF AILERON CONTROL CABLES. (Refer to Figure 5-3.)
a. The installation of either the right or left primary control cable (14 or 15) that is located in the
fuselage may be accomplished as follows:
1. Draw the cable through the fuselage floor funnel.
2. Connect the cable to the end of the control chain (4) and secure using bushing, bolt, nut and
cotter pin (23).
3. Place the cable around the pulley (9) that is located in the tunnel aft of the tee bar. Install the
cable guard (20) and secure with a cotter pin.
4. Position cables and install the cable pulleys (8) that attach to the lower section of the tee bar
assembly. Secure with bolt, washer and nut (21).
5. Place the cable around the pulley (10) that is located within access opening just aft of the main
spar and install cotter pin cable guards.
6. If the primary control cable in the wing is installed, connect the control cable ends at the
turnbuckle (12 or 16) located within access opening just aft of the main spar.
7. Check rigging and adjustment per paragraph 5-12.
8. Install the floor tunnel plate trim cowers by the following procedure:
(a) PA-28-140; PA-28-150, -160, -180; and PA-28R: Place the tunnel plate into position for
installation and secure with the attachment screws. Roll the carpet into place and install
the rudder trim cover and knob.
(b) PA-28-235: Install the floor tunnel plate and secure with the attachment screws. Fasten the
tunnel carpet into place and install the fuel selector lever on the selector torque tube and
secure with a clevis pin and cotter pin. Replace the fuel selector and rudder trim covers
and the rudder trim knob.
b. The primary control cable (13 or 17) in either wing may be installed by the following procedure:
1. Draw the control cable into the wing.
2. Connect the cable to the forward end of the aileron bellcrank (6) using a bolt, washer, nut and
cotter pin. Allow the cable end to rotate freely on the bellcrank.
3. If the primary control cable in the fuselage is installed, connect the ends at the turnbuckle (12
or 16) located under the rear seat aft of the main spar.
4. Check rigging and adjustment per paragraph 5-12.
5. Install the access plate on the underside of the wing.
c. Either balance cable (18 or 19) may be installed by the following procedure:
1. Draw the cable into the wing.
2. Connect the cable to the aft end of the aileron bellcrank (6) using a bolt, washer, nut and cotter
pin. Allow the cable end to rotate freely on the bellcrank.
3. Connect the balance cable ends at the turnbuckle (24) that is located under the rear seat aft of
the main spar.

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4. If the left cable was removed, install the cotter pin cable guard at the pulley (10) located within
the fuselage, aft of the main spar.
5. Check rigging and adjustment per paragraph 5-12.
6. Install the access plate on the underside of the wing.
d. Replace the rear seat bottom or floor panel and the two front seats.
5-10. REMOVAL OF AILERON BELLCRANK ASSEMBLY (Refer to Figure 5-3.)
a. Remove the baggage area floor panel of PA-28-140 airplanes or the bottom half of the rear seat of
the PA-28-150, -160, -180; PA-28-235 and PA-28R airplanes.
b. Remove the access plate to the aileron bellcrank (6) located on the underside of the wing, forward
of the inboard end of the aileron.
c. Relieve tension from the aileron control cables by loosening the balance cable turnbuckle (24)
located in the opening aft of the main spar.
d. Disconnect the primary (13 or 17) and balance (18 or 19) control cables from the bellcrank
assembly by removing cotter pins, nuts, washers and bolts.
e. Disconnect the aileron control rod (7) at the aft or forward end, as desired, by removing the cotter
pin, nut, washer and bolt.
f. Remove the nut, pivot bolt (25) and washers that secure the bellcrank. The nut is visible from the
underside of the wing.
g. Remove the bellcrank from within the wing.
5-11. INSTALLATION OF AILERON BELLCRANK ASSEMBLY. (Refer to Figure 5-3.)
a. Ascertain that the bellcrank pivot bushing (26) is lubricated and install in the torque tube portion of
the bellcrank (6).
b. Place the bellcrank in position in the wing with a washer located between each end of the torque
tube and the mounting brackets.
c. Install the bellcrank pivot bolt (25) with the head up. Install a washer and nut on the bolt, and torque
nut within 20 to 25 inch-pounds. Check that the bellcrank rotates freely with little up-down play.
d. Install and adjust control rod (7) and check aileron travel per paragraph 5-12.
e. Connect the ends of the primary (13 or 17) and balance (18 or 19) control cables to the bellcrank
using bolts, washers, nuts and cotter pins. Allow the cable ends to rotate freely on the bellcrank.
f. Tighten the control cables at the balance cable turnbuckle (24) in the floor opening aft of the main
spar. Check cable tension per paragraph 5-12.
g. Install the access plate on the underside of the wing and replace the floor panel or rear seat bottom.

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5-12. RIGGING AND ADJUSTMENT OF AILERON CONTROLS

(Refer to Figures 5-4 and 5-5.)
WARNING: VERIFY FREE AND CORRECT MOVEMENT OF AILERONS. WHILE IT WOULD
SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS
FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY,
UPON COMPLETION OF AILERON RIGGING AND ADJUSTMENT, VISUALLY
CONFIRM THAT THE RIGHT AILERON TRAILING EDGE MOVES UP AND THE
LEFT AILERON TRAILING EDGE MOVES DOWN WHEN THE CONTROL WHEEL
IS TURNED RIGHT; AND THAT THE LEFT AILERON TRAILING EDGE MOVES UP
AND THE RIGHT AILERON TRAILING EDGE MOVES DOWN WHEN THE CONTROL
WHEEL IS TURNED LEFT.
NOTE: Flap rigging and adjustment must be completed before starting aileron rigging and adjustment.
a. To check and adjust the rigging of the aileron controls, first set the right and left aileron bellcranks
at neutral position. (Ascertain that the control chains have been rigged per paragraph 5-6.) This may
be accomplished by the following procedure:
1. Place tee bar in full forward position. Maintain in this position by use of a suitable tool or by
placing weights on aft side of stabilator if stabilator cables have been previously tensioned.
2. Remove the access plate to each aileron bellcrank located on the underside of the wing.
forward of the inboard end of the aileron by removing the plate attaching screws.
3. Affix a bellcrank rigging tool, as shown in Figure 5-4, between the forward arm of each
bellcrank and the adjacent rib. (This tool may be fabricated to dimensions given in Figure 5-4.)
The slotted end of the tool fits on the arm forward of. and adjacent to, the primary control cable
end. The other end of the tool is positioned so that the side of the tool contacts the aft side of
the bellcrank stop. The bellcrank must be moved to allow a snug fit of the tool between the
bellcrank arm and rib. To do so. it may be necessary to loosen a primary control cable or the
balance cable. Neutral position of the bellcranks may also be found by locating the centers of
the forward and aft cable connection holes an equal distance from the adjacent inboard wing rib.
b. With each bellcrank set at neutral, the ailerons on the PA-28-140, -150, -160, -180, -235 and 28R
may be checked and adjusted for neutral as follows:
1. Ascertain that the bellcrank rigging tool fits snug between the bellcrank and the rib.
2. Place an aileron rigging tool as shown in Figure 5-5 against the underside of the wing and
aileron as close as possible to the inboard end of the aileron without contacting any rivets. The
tool must be positioned paralleled with the wing ribs, with the aft end of the tool, even with the
trailing edge of the aileron. (This tool may be fabricated to dimensions given in Figure 5-5.)
3. With the aileron control rod connected between the bellcrank and aileron, check that the
surface of the wing contacts the tool at its forward surface and at the spacer, and the trailing
edge of the flap contacts the aft end of the tool. The aileron is neutral at this position.
4. Should the three points not contact, loosen the jam nut at the aft end of the control rod and
rotate the rod until the three points contact. Apply a slight up pressure against the trailing edge
of the aileron while making this adjustment. After adjustment, retighten the jam nut.
c. Adjust primary and balance cable tension as given in Table V-II by the following procedure:
1. Remove the two front seats, if desired, and the baggage area floor panel of the PA-28-140
airplanes or the bottom of the rear seat of the PA-28-150, -160, -180; PA-28-235 and PA-28R
airplanes to facilitate in the necessary operation.

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2. Loosen the connecting bolts of the idler cross-over sprockets at the control tee bar to allow the
chain to fit snug around the control wheel sprockets, and- over the idler sprockets.
3. Ascertain that both bellcranks are at neutral position.
4. Adjust the turnbuckles, located in the access opening just aft of the main spar, of the primary
and balance cables to their proper cable tension and maintain neutral-center position of the
control wheels. To obtain neutral position of both control wheels, it may also be necessary to
adjust the roller chain turnbuckle located between the control wheel sprockets. During
adjustment, obtain a little more tension on the primary control cables to hold the bellcranks in
neutral against the rigging tools, finishing with even tension on all cables.
5. Tighten the bolts to secure the idler cross-over sprockets.
6. Remove the aileron bellcrank rigging tool from each wing.
d. Check the ailerons for correct travel from neutral per dimensions given in Table V-II, by the
following procedure:
1. Center the bubble of a protractor over the surface of an aileron at neutral position and note the
reading.
2. Move the aileron full up and down, checking the degree of travel for each direction. The
degree of travel on the protractor is determined by taking the difference between the protractor
reading at neutral and up, and neutral and down. The bubble must be centered at each reading.
When measuring down travel from the neutral position, maintain a light up pressure at the
center of the aft edge of the aileron. When measuring up travel from the neutral position,
maintain a light down pressure at the center of the aft edge of the aileron; just sufficient to
remove the slack between the bellcrank and the aileron.
3. Should the travel not be correct, the travel may be set by rotating the bellcrank stops in or out.
Stops are located in the wing attached to the rib that is adjacent to the aileron bellcrank.
4. Repeat this procedure for the other aileron.
e. Check to ensure that the left aileron up and right aileron down stops are contacted simultaneously
and vice versa. Adjust stops as required.
f. Check the bellcrank stops to assure that the bellcrank contact is made simultaneously, but still have
cushion before contacting the control wheel stops. Maintain .030 to .040 clearance between
sprocket pin and adjustable stop bolts on models having adjustable tee bar stops.
g. Check complete system for operation and safety of turnbuckles, bolts, etc.
h. Install access plates and panels.
5-13. ADJUSTMENT OF AILERON TRIM. (PA-28-150, -160, -180, S/N’s 28-1 to 28-1321 incl.) Lateral
trim can be effected on the ground by adjusting the metal tab attached to the trailing edge of the left
aileron.
NOTE: When an out of trim condition persists despite all the rigging corrections that can be made, there
is a possibility that the trailing edge of the aileron has been used to move the aircraft forward.
This can result in a slight bulging of the aileron contour at the trailing edge which will cause an
out of rig condition that is very difficult to correct.

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Figure 5-4. Bellcrank Rigging Tool Application and Fabrication

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Figure 5-5. Aileron Rigging Tool Application and Fabrication

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5-14. STABILATOR CONTROLS.

5-15. REMOVAL OF STABILATOR CONTROL CABLES. (Refer to Figure 5-6.)
a. To remove either the forward or aft stabilator cables, first remove the access panel to the aft section
of the fuselage located in the baggage compartment, the two front seats, and the baggage area floor
panel on the PA-28-140 airplanes or the bottom of the rear seat on the PA-28-150, -160, -180; PA-
28-235 and PA-28R airplanes.
b. Disconnect the desired control cable at the turnbuckle in the aft section of the fuselage.
c. Either forward stabilator cable (2 or 3) may be removed by the following procedure:
1. Remove the tunnel carpet and cover plate by the following procedure:
(a) PA-28-140; PA-28-150, -160, -180 and PA-28R:
Remove the rudder trim control knob and trim cover attaching screws. Roll back the
carpet from the tunnel and remove the tunnel plate that is located just aft of the tee bar
assembly by removing the plate attaching screws.
(b) PA-28-235:
Remove the fuel selector and rudder trim covers by removing the knobs and the attaching
screws. Disconnect the fuel indicator control lever from the fuel selector torque tube by
removing the attaching pin located at the bottom of the lever. Remove the tunnel plate
located just aft of the tee bar by laying back enough tunnel carpet to remove the plate
attaching screws.
2. If the right (upper) stabilator control cable (2) is to be removed, remove the cotter pin guards at
the pulley(2) located in the forward area of the tunnel.
3. Disconnect the cables (2 and 3) from the lower end of the tee bar on PA-28-140; PA-28-150, -
160, -180 and PA-28-235 or from the idler arm on the PA-28R by removing cotter pin, nut,
washer and bolt (15).
4. Within the access opening aft of the main spar, remove the cable rub blocks that are attached to
the spar housing by removing the block attaching screws.
5. Remove the cotter pin cable guard at the pulley cluster located in the aft area the access
opening aft of the main spar.
NOTE: To facilitate in the installation of control cables, a line may be attached to the cable end
prior to removal.
6. Draw the cable aft through the floor tunnel.
d. Either aft stabilator control cable (4 or 5) may be removed by the following procedure:
1. Disconnect the cable end at the balance arm (18) of the stabilator by removing the cotter pin,
nut, washer and bolt (8).
2. Remove the cotter pin cable guard at the pulley (7) located either above or below the balance
arm.
3. Remove the cable from the airplane.

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5-16. INSTALLATION OF STABILATOR CONTROL CABLES. (Refer to Figure 5-6.)

a. The forward stabilator cables (2 and 3) may be installed by the following procedure:
1. Draw the control cable through the floor tunnel. Ascertain that the right (upper) cable (2) is
routed around the pulley(s) (14) in the forward area of the floor tunnel.
2. Connect the cables (2 and 3) to the lower end of the control column tee bar (1) or the idler arm
with bolt, washer, nut and cotter pin (15). Allow the cable ends freedom to rotate.
3. If the aft control cable (4 or 5) is not installed, install per step b.
4. Connect the control cable to the aft cable at the turnbuckle (16) in the aft section of the
fuselage.
5. For the right control cable (2), install the cotter pin cable guards at the pulley(s) (14) in the
forward area of the tunnel.
6. Within the access opening aft of the main spar, install the cable rub blocks (10) to the spar
housing and secure with screws.
7. In the access opening, install the cotter pin cable guard at the pulley cluster (6).
8. Set cable tension and check rigging and adjustment per paragraph 5-17.
9. Install the floor tunnel plate and trim covers by the following procedure:
(a) PA-28-140; PA-28-150, -160, -180 and PA-28R: Place the tunnel plate into position for
installation and secure with the attaching screws. Roll the carpet into place and install the
rudder trim cover and knob.
(b) PA-28-235: Install the floor tunnel plate and secure with the attachment screws. Fasten the
tunnel carpet into place and install the fuel selector lever on the selector torque tube and
secure with a clevis pin and cotter pin. Replace the fuel selector and rudder trim covers
and the rudder trim knob.
10. Install the front seats and rear seat bottom on floor panel.
b. Either aft stabilator control cable (4 or 5) may be installed by the following procedure:
1. Route the cable (4 or 5) around its pulley (7) located either over or under the balance arm (18)
of the stabilator.
2. Connect the cable to the stabilator balance arm and secure with bolt, washer, nut and cotter pin
(8). (Ensure bushing is installed with bolt.)
3. Connect the cable to the forward cable at the turnbuckle (16) in the aft section of the fuselage.
The upper aft cable (5) connects to the right forward cable (2) and the lower cable (4) to the
left cable (3).
4. Install the cotter pin cable guard at the pulley (7), where required.
5. Set cable tension and check rigging and adjustment per paragraph 5-17.
6. Install the seats and access panels.

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Figure 5-6. Stabilator Controls

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5-17. RIGGING AND ADJUSTMENT OF STABILATOR CONTROLS

WARNING: VERIFY FREE AND CORRECT MOVEMENT OF STABILATOR. WHILE IT WOULD
SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS
FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY,
UPON COMPLETION OF STABILATOR RIGGING AND ADJUSTMENT, VISUALLY
CONFIRM THAT THE STABILATOR TRAILING EDGE MOVES UP WHEN THE
WHEEL IS PULLED BACK; AND, THAT THE STABILATOR TRAILING EDGE MOVES
DOWN WHEN THE WHEEL IS PUSHED FORWARD.
a. Level the airplane. (Refer to Leveling, Section II.)
b. To check and set the correct degree of stabilator travel, the following procedure may be used:
1. Check the stabilator travel by placing a rigging tool on the upper surface of the stabilator as
shown in Figure 5-7. (This tool may be fabricated from dimensions given in Figure 5-7.)
2. Set on a bubble protractor the number of degree up travel as given in Table V-II and place it on
the rigging tool. Raise the trailing edge of the stabilator and determine that when the stabilator
contacts its stops, the bubble of the protractor is centered.
NOTE: The stabilator should contact both of its stops before the control wheel contacts its
stops. The neutral position of the stabilator is with the stabilator chord line parallel
with the top of the front seat tracks.
3. Set on the protractor the number of degrees down travel as given in Table V-II and again
place it on the rigging tool. Lower the trailing edge of the stabilator and determine that when it
contacts its stops, the bubble of the pro-tractor is centered.
4. Should the stabilator travel be incorrect in either the up or down position, remove the tail
cone fairing by removing the attaching screws and with the use of the rigging tool and bubble
protractor turn the stops located at each stabilator hinge in or out (Refer to Figure 5-14) to
obtain the correct degree of travel
5. Ascertain that the lock nuts of the stop screws are secure and reinstall the tail cone fairing.
c. To check and set stabilator control cable tension, the following procedure may be used:
1. Ascertain that the stabilator travel is correct.
2. Remove the access panel to the aft section of the fuselage.
3. Secure the control column in the near forward position. Allow one-quarter inch between the
column and the stop bumper
4. Check each control cable for the correct tension as given in Table V-II.
5. Should tension be incorrect, loosen the turnbuckle of the lower cable in the aft section of the
fuselage and adjust the turnbuckle of the upper cable to obtain correct tension. Cable tension
should be obtained with the control wheel at the one-quarter inch dimension from the stop and
the stabilator contacting its stop.
6. Check safety of all turnbuckles and bolts.
7. With the tension of the upper, cable correct and the control wheel still forward, adjust the
turnbuckle of the lower cable to obtain correct tension.

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Figure 5-7. Stabilator Rigging Tool Application and Fabrication

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8. Check the full travel of the control wheel with relation to the full travel of the stabilator to
determine that the stabilator contacts its stops before the control wheel contacts its stops. With
the control wheel in the fore and aft positions, the travel distance from the point where the
stabilator contacts its stops and the control wheel contacts its stops should be approximately
equal. Readjust turnbuckles if incorrect.
9. Reinstall access panels.
d. Remove the airplane from jacks.
5-18. STABILATOR TRIM CONTROLS. (OVERHEAD TRIM.)
NOTE: If the airplane involved is equipped with a single stabilator trim cable (one turnbuckle), it will
be necessary to follow the combined instructions for removal of both forward and aft cables.
5-19. REMOVAL OF STABILATOR TRIM ASSEMBLY. (FORWARD. ) (Refer to Figure 5-8.)
a. Rotate the stabilator trim crank to bring the indicator to full aft (extreme nose high) position to
facilitate removal of the trim indicator from the panel.
b. Remove the spring clip from the stabilator trim crank handle and remove the handle.
c. Remove the headliner trim panel (light panel) from around the trim crank assembly by the
following procedure:
1. Remove the attaching screws that secure the panel.
2. Disconnect the light wires at the quick disconnects.
NOTE: It is recommended that the wires be marked for identification before removal.
3. Remove the panel.
d. Remove the access panel at the aft wall of the baggage compartment to gain entry to the aft section
of the fuselage.
e. Install a cable block on the aft trim control cables, as shown in Figure 5-9.
f. Disconnect the stabilator trim cable(s) at the turnbuckle(s) located in the aft section of the fuselage.
g. Remove the cable guard pins from the pulleys located at stations 108.16 and 138.33. Station 138.33
is accessible through the zipper on the aft area of the headliner.
h. Remove the clevis pin cable guard from the trim crank assembly.
NOTE: To facilitate installation, it is recommended that a line be attached to the cable end prior to
removal.
i. Remove the cable from the airplane.
j. The trim crank and pulley assembly may be removed by removing the mounting bracket attaching
screws.

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Figure 5-8. Stabilator Trim Control (Overhead Control)

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5-20. INSTALLATION OF STABILATOR TRIM ASSEMBLY. (FORWARD.) (Refer to Figure 5-8.)

a. If the trim crank and pulley assembly has been removed, install assembly and secure with
attachment screws.
b. Install the forward stabilator trim cable using the following procedure:
1. Attach a line to the right end of the control cable and pull the cable forward to the crank
assembly.
2. Route the cable clockwise (as view from the underside) around and into the top groove of the
crank pulley, and on to the left side of the idler pulley.
3. From around the idler pulley, route the cable around and in the bottom groove of the crank
pulley.
4. With the use of a line attached to the cable end, pull the cable through to the turnbuckle located
in the aft section of the fuselage.
c. Attach the cable ends together and install guard pins in the pulley assemblies.
d. Insert the guard pin in the trim bracket assembly and safety with a cotter pin.
e. Actuate the trim crank fore and aft several times to seat the cables into the pulleys.
f. Rig and adjust in accordance with paragraph 5-23.
g. Replace all the access plates and panels.
h. Install the headliner trim panel by connecting the electrical leads and in-stalling attaching screws.
i. Replace the trim handle and secure with the snap ring.
5-21. REMOVAL OF STABILATOR TRIM CONTROLS. (AFT.) (Refer to Figure 5-8.)
a. PA-28-150,-160,-180, S/N’s 28-1 to 28-1410 incl. (The exception being airplanes with Piper Kit No.
756 930 Stabilator Trim Modifications installed. Airplanes with this kit installed, refer to step c.)
1. Remove the tail cone fairing by removing attaching screws.
2. Remove the access panel located at the aft wall of the baggage compartment to allow access to
the aft section of the fuselage.
3. To remove the trim control cable, proceed as follows:
(a) Disconnect the cable at the turnbuckle (8) in the aft section of the fuselage.
(b) Remove the cable guard pin from the pulleys located within the fuselage at station 228.30.
(c) Remove the cable guard from the top support brace of the trim mechanism located just aft
of the trim screw pulley.
(d) Remove the cotter pin cable guard at the idler pulley (18) which is attached to the aft side
of the rearward most bulkhead of the fuselage.
(e) Draw the cable aft around the trim screw pulley (10) and then forward.
(f) Remove the forward portion of the cable as given in paragraph 5-19.
4. The trim mechanism may be disassembled and removed from the aft bulkhead of the fuselage
as follows:
(a) Disconnect the trim tab control arm (15) from its support bracket by removing nuts,
washers, bushings and bolts.

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Figure 5-9. Methods of Securing Trim Cables

(b) Disconnect the trim indicator cable (17) from the trim screw trunnion (12) by removing
attaching nut, washer and screw. Remove the cotter pin cable guard at the cable pulley
(10) located directly below the trunnion.
(c) Remove the trim mechanism assembly (11) by removing the nut, washer and bolt at each
support brace (20) attachment point, and at the aft most fuselage bulkhead.
(d) Disassemble the trim mechanism by removing the cotter pin, washer and nut located at
each end of shaft assembly, and pulling the supports with washers from the shaft.
(e) Disassemble the shaft by removing the roll pins from the desired component.
b. PA-28-140, Serial Nos. 28-20002 to 28-20656 incl; PA-28-150, -160, -180, Serial Nos. 28-1411 to
28-2171 incl. and PA-28-235, Serial Nos. 28-10603 to 28-10605 incl. (The exception being those
airplanes with Piper Kit No. 756 896 Stabilator Trim Modification installed. Airplanes with this kit
installed, refer to step c.)
1. Remove the tail cone fairing by removing attaching screws.
2. Remove the access panel located at the aft wall of the baggage compartment to allow access to
the aft section of the fuselage.
3. To remove the trim control cable, proceed as follows:
(a) Disconnect the cable at the turnbuckle (8) in the aft section of the fuselage.
(b) Remove the cable guard pin from the pulleys located within the fuselage at station 228.30.
(c) Disconnect the links (19), located between the trim screw (11) and control arm (15) at the
trim screw, by removing nut, washers, bushing and bolt.
(d) Remove the cotter pin that extends through the top of the trim screw and the cable guard
pin located just aft of the trim barrel (10).
(e) Remove the cotter pin cable guard at the idler pulleys which are attached to the aft side of
the rearward most bulkhead.
(f) Turn the screw down and out from the underside of the barrel.

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(g) Remove the snap ring, washer and thrust washer from the bottom of the barrel.
(h) Disconnect the diagonal and horizontal trim assembly support ribs from one another by
removing their four attaching nuts, washers and bolts.
(i) Loosen the bolts where the horizontal ribs attach to the fuselage bulkhead, raise the aft
end of the ribs, and move the barrel (21) aft far enough to unwrap the trim cable from
around the barrel and idler pulleys (18).
(j) Remove the forward portion of the cable (6) as given in paragraph 5-19.
4. The horizontal and diagonal support ribs may be removed by removing the cotter pin cable
guard at the trim indicator cable pulley located on the diagonal rib, and removing the attaching
nuts, washers and bolts that secure the ribs to the aft bulkhead.
c. PA-28-140, Serial Nos. 28-20657 and up; PA-28-150,-160,-180, Serial Nos. 28-2172 to 28-9377
incl. and PA-28-235, Serial Nos. 28-10606 to 28-10719 incl.
1. Remove the tail cone fairing by removing attaching screws.
2. Remove the access panel located at the aft wall of the baggage compartment to allow access to
the aft section of the fuselage.
3. To remove the trim control cable, proceed as follows:
(a) Block the first set of pulleys forward of the cable turnbuckles (8) in the aft section of the
fuselage by the method shown in Figure 5-9.
(b) Remove the cable guard pin from the pulleys located within the fuselage at station 228.30.
(c) Disconnect the links (19), located between the trim screw (11) and control arm (15) at the
trim screw by removing nut, washers and bolt.
(d) Remove the cotter pin that extends through the top of the trim screw and the cable guard
pin located just aft of the trim barrel (21).
(e) Turn the screw down and out from the underside of the barrel.
(f) Remove the snap ring, washer and thrust washer from the bottom of the barrel.
(g) Disconnect the diagonal and horizontal (20) trim assembly support ribs from one another
by removing their four attaching nuts, washers and bolts.
(h) Loosen the attaching bolts where the horizontal ribs attach to the fuselage bulkhead, raise
the aft end of the ribs and remove the barrel with cable. Draw the cable from the fuselage.
4. The horizontal and diagonal support ribs may be removed by removing the cotter pin cable
guard at the trim indicator cable pulley located on the diagonal rib, and removing the
attachment nuts, washers and bolts that secure the ribs to the aft bulkhead.
d. The trim indicator cable (17) may be removed from the aft area of the fuselage by disconnecting the
cable from the trim screw trunnion or at the lower end of the trim screw (11), removing the cotter
pin cable guard at the pulley located below the trim screw and disconnecting the cable from the
indicator wire.

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5-22. INSTALLATION OF STABILATOR TRIM CONTROLS. (AFT.) (Refer to Figure 5-8.)

a. PA-28-150,-160, -180, Serial Nos. 28-1 to 28-1410 incl. (The exception being airplanes with Piper
Kit No. 756 930, Stabilator Trim Modification, installed. Airplanes with this kit installed, refer to
step c.)
1. The trim mechanism may be assembled and attached to the aft bulkhead of the fuselage as
follows:
(a) Assemble the trunnion (12), stops and pulley (10) in the trim shaft and secure with roll
pins.
(b) Assemble the trim mechanism by placing an AN960-516L washer followed by a support
on each end of the shaft assembly (11). Install washers and nuts, check freedom of
rotation of the shaft with no end play and then secure nuts with cotter pins.
(c) Align the attachment hole of each support brace with those of the aft bulkhead, install
bolts and secure with washers and nuts.
(d) Draw the trim cable and attach the end to the trim screw trunnion, and secure with bolts,
nut and washer. With the cable placed around the pulley located directly below, the
trunnion, install the cotter pin cable guard at the pulley.
2. The trim control cable may be installed by the following procedure:
(a) Install the forward portion of the cable as given in paragraph 5-20.
(b) With the forward portion installed, route the long length (the long length should be the
left end of the cable) aft, counterclockwise around to the top groove of the trim pulley
(10), around the idler pulley (18), back around the bottom groove of the trim pulley and
forward to the inside of the fuselage.
(c) Draw the cable end forward and connect it with its mating end within the fuselage.
(d) Ascertain that the cable is seated in the groove of each pulley, and install the cotter pin
cable guards at the pulleys located within the fuselage at station 228.30 and at idler pulley
at the aft fuselage bulkhead.
(e) Install the cable guard at the top support brace located just aft the trim screw pulley.
3. The trim indicator cable may be installed by attaching one end to the trim screw trunnion.
(Refer to Figure 5-8 for correct location.) Loop the cable around the pulley below the trim
screw; Install the cotter pin cable guard at the pulley. Attach other end of the cable to the
indicator wire, and at the same time make adjustments given in paragraph 5-23.
4. Set cable tension and check rigging and adjustment per paragraph 5-23. Check safety of
turnbuckle.
5. Install tail cone fairing and secure with screws.
6. Install the access panel to the aft section of the fuselage.
b. PA-28-140, Serial Nos. 28-20002 to 28-20656 incl; PA-28-150, -160, -180, Serial Nos. 28-1411 to
28-2171 incl. and PA-28-235, Serial Nos. 28-10003 to 28-10605 incl. (The exception being those
airplanes with Piper Kit No. 756 896, Stabilator Trim Modification, installed. Airplanes with this kit
installed, refer to step c.)
1. Ascertain that the trim barrel bushings are lubricated and installed in the rib plate and clip.
2. Attach the horizontal (20) and diagonal support ribs to the aft bulkhead of the fuselage with
bolts, washers and nuts. Start nuts only a few threads so as to allow ribs to hang loose. Do not
connect the ribs at this time.

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3. Install the forward portion of the cable as given in paragraph 5-20.

4. Wrap the trim cable around the barrel (21) and idler pulley (18). To do this, hold the barrel
next to the aft end of the support braces and wrap, bringing the end of the long length (The
long length should be the left end of the cable.) aft to the left side of the trim barrel, around the
bottom groove of the idler pulley, then continuing to wrap in this direction until all grooves are
filled.
5. Install the trim barrel (21) in the bushing between the horizontal and diagonal ribs, and then
attach the ribs, securing with bolts, washers and nuts. Tighten bolts where the ribs attach to the
aft bulkhead.
6. Install the thrust washer, washer and snap ring on lower end of the barrel.
7. Install the trim screw in the barrel and secure each end with a cotter pin through the screw.
8. Draw the cable end forward and connect it with its mating end within the fuselage.
9. Ascertain that the cable is seated in the groove of each pulley and install the cotter pin cable
guards at the pulleys located within the fuselage at station 228.30 and at the idler pulley at the
aft fuselage bulkhead.
10. Set cable tension and check rigging and adjustment per paragraph 5-17. Check safety of
turnbuckle.
11. The trim indicator cable may be installed by attaching one end to the lower end of the trim
screw (Refer to Figure 5-8 for correct location.) and looping the cable around the pulley below
the trim screw. Install the cotter pin cable guard at the pulley. Attach other end of the cable to
the indicator wire, and at the same time make adjustments given in paragraph 23.
12. Install tail cone fairing and secure with screws.
13. Install access panel to the aft section of the fuselage.
c. PA-28-140, Serial Nos. 28-20657 and up; PA-28-150,-160,-180, Serial Nos. 28-2172 to 28-9377
incl. and PA-28-235, Serial Nos. 28-10606 to 28-10719 incl.
1. Ascertain that the trim barrel bushings are lubricated and installed in the rib plate and clip.
2. Attach the horizontal (20) and diagonal support ribs to the aft bulkhead of the fuselage with
bolts, washers and nuts. Start nuts only a few threads so as to allow ribs to hang loose. Do not
connect the ribs at this time.
3. Wrap the trim barrel (21). To do this, first lay the center (as measured equally from each end to
the center of the cable) of the trim cable in the slot of the barrel. Bring the upper cable through
the diagonal slot in the flange at the upper end of the barrel and wrap down in a
counterclockwise direction. Bring the lower cable through the diagonal slot in the lower end of
the barrel and wrap up in a clockwise direction. Wrap the cable as evenly as possible to obtain
23 wraps on the barrel as viewed from the side opposite the slot and with the cables extending
out from the slotted side.
4. Block both cables by clamping them between two pieces of wood laid next to the wraps to
prevent them from unwrapping. (Refer to Figure 5-9.)
5. Install the barrel in the bushings between the horizontal and diagonal ribs, and then attach rib
securing with bolts, washers and nuts. Tighten bolts where the ribs attach to the aft bulkhead.
6. Install the thrust washer, washer and snap ring on the lower end of the barrel.
7. Install the trim screw (11) in the barrel and secure each end with a cotter pin through the screw.

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8. Route the cable ends into the fuselage and attach the ends to the mating end of the forward cable.
9. Remove the blocks holding the forward cable tight and the aft cables at the barrel.
10. Set cable tension and check rigging and adjustment per paragraph 5-23. Check safety of
turnbuckles.
11. The trim indicator cable may be installed by attaching one end to the lower end of the trim
screw (Refer to Figure 5-8 for correct location.) and looping the cable around the pulley below
the trim screw. Install the cotter pin cable guard at the pulley. Attach other end of the cable to
the indicator wire, and at the same time make adjustments given in paragraph 5-23.
12. Install tail cone fairing and secure with screws.
13. Install the access panel to the aft section of the fuselage.
5-23. RIGGING AND ADJUSTMENT OF STABILATOR TRIM (OVERHEAD CONTROL)
WARNING: VERIFY FREE AND CORRECT MOVEMENT OF STABILATOR TRIM TAB. WHILE
IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT
THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT
ALL. ACCORDINGLY, UPON COMPLETION OF STABILATOR TRIM RIGGING
AND ADJUSTMENT, VISUALLY CONFIRM THAT THE STABILATOR TRIM TAB
TRAILING EDGE MOVES UP WHEN THE TRIM CRANK IS TRIMMED NOSE DOWN;
AND, THAT THE STABILATOR TRIM TAB TRAILING EDGE MOVES DOWN WHEN
THE TRIM CRANK IS TRIMMED NOSE UP.
a. PA-28-150, -160, -180, Serial Nos. 28-1 to 28-1410 incl. (The exception being those airplanes with
Piper Kit No. 756 930, Stabilator Trim Modification, installed. Airplanes with this kit installed,
refer to step b.) (Refer to Figure 5-8.)
1. Level the airplane. (Refer to Leveling, Section II.)
2. Check for proper stabilator trim cable tension as given in Table V-II. If the cables were
disconnected, rotate control crank (1) several times to allow the cables to seat and recheck
tension.
3. Position the stabilator against its down stop. Ascertain that the stabilator travel is correctly set
according to Table V-II.
4. Turn the trim crank until the aft end of the turnbuckle of the right trim cable is positioned
approximately one-half inch forward of the double pulley cluster at the top of the rear bulkhead
at station 228.3.
5. Check that the trim screw trunnion (12) is turned down until it contacts the top of the lower screw
stop of the trim assembly If the trunnion is not contacting the stop, and the fork (14) between the
trim support bracket (13) and the trim control arm (15) is not disconnected, -disconnect the arm
from the tab by removing the connecting bolts. With the turnbuckle still at the one-half dimension
from the pulley, turn the screw down until the trunnion contacts the stop.
6. With the stabilator positioned against its down stop, adjust the trim actuating arm until the
trailing edge of the tab aligns with the trailing edge of the stabilator. Adjust by loosening the
jam nut on the fork of the control arm and turning the fork in or out as required.
7. Connect the control arm to the tab and secure with bolts.
8. Move the stabilator to the neutral position and secure. To find neutral, place a rigging tool on
the upper surface of the stabilator as shown in Figure 5-7. Zero a bubble protractor, set it on the
rigging tool and tilt the stabilator until the bubble is centered.

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9. Turn the trim crank until the trailing edge of the tab aligns with the trailing edge of the stabilator.
10. Check the bubble of the protractor over the neutral tab and then check tab travels as given
in Table V-II. The degree of travel on the protractor is determined by taking the difference
between the protractor reading at neutral and up, and neutral and down. The bubble must be
centered at each reading with the airplane level.
11. To obtain correct travels, if incorrect, adjust by disconnecting the actuating arm and turning it
in or out as required. Reconnect the arm to the tab.
12. Secure the jam nut against the fork.
13. Turn the trim wheel to full travel and check for turnbuckle clearance and location of tab
indicator.
b. PA-28-140;PA-28-150, -160, -180, Serial Nos. 28-1411 to 28-4377 incl. and PA-28-235, Serial
Nos. 28-10003 to 28-10719 incl. (Refer to Figure 5-8.)
1. Level the airplane. (Refer to Leveling, Section II.)
2. Check for proper stabilator trim cable tension as given in Table V-II. If the cables were
disconnected, rotate control crank (1) several times to allow the cables to seat and recheck
tension.
3. Position the stabilator against its down stop. Ascertain that the stabilator travel is correctly set
according to Table V-II.
4. Turn the trim crank until the aft end of the turnbuckle of the right trim cable is positioned
approximately one-half inch forward of the double pulley cluster at the top of the rear bulkhead
at station 228.3.
5. Check that the trim screw is turned down until the cotter pin stop in the top of the screw is
contacting the plate (9) on the horizontal support rib (20) of the trim assembly. If the stop is
not contacting the plate, and the links between the screw (11) and the trim control arm (15) are
not disconnected, disconnect the two by removing the connecting nut, washer and bolt. With
the turnbuckle still at the one-half dimension from the pulley, turn the screw down until the pin
contacts the plate.
6. With the stabilator positioned against its down stop, adjust the trim actuating arm until the
trailing edge of the tab aligns with the trailing edge of the stabilator. Adjust by loosening the
jam nut on the end bearing of the control arm and turning the bearing in or out as required.
7. Connect the links to the control arm and secure with bolt, washers and nut.
8. Move the stabilator to the neutral position and secure. To find neutral, place a rigging tool on
the upper surface of the stabilator as shown in Figure 5-7. Zero a bubble protractor, set it on the
rigging tool and tilt the stabilator until the bubble is centered.
9. Turn the trim crank until trailing edge of the tab aligns with the trailing edge of the stabilator.
10. Check the bubble of the protractor over the neutral tab and then check tab travels as given
in Table V-II. The degree of travel on the protractor is determined by taking the difference
between the protractor reading at neutral and up, and neutral and down. The bubble must be
centered at each reading with the airplane level.
11. To obtain correct travels, if incorrect, adjust by disconnecting the links at the actuating arm rod
end and turning the end in or out as required. Reconnect links to rod end.
12. Secure the jam nut on the actuating arm rod end.
13. Turn the trim wheel to full travel and check for turnbuckle clearance and location of tab
indicator.

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5-24. STABILATOR TRIM CONTROLS. (FLOOR TRIM.)

5-25. REMOVAL OF STABILATOR TRIM ASSEMBLY. (FORWARD.) (Refer to Figure 5-10.)
a. To remove the trim control wheel assembly and/or the trim control cables, first remove the panel to
the aft section of the airplane.
b. If the aft trim cable (12) is not to be removed, block the cables at the pulleys (13) in the upper aft
section of the fuselage to prevent them from unwrapping from the trim drum. (Refer to Figure 5-9.)
c. Loosen the cables if the trim control wheel (1) is to be removed or disconnect if the cables are also
to be removed. Do this at the trim cable turnbuckles (10 and 11) in the aft section of the fuselage.
d. The control wheel (1) with drum (3) may be removed by the following procedure:
1. Remove the control wheel cover by removing the cover attaching screws.
2. The wheel assembly may be removed from its mounting brackets by removing nut, washer and
bolt (7) that secures the wheel between the brackets. Draw the wheel from the brackets. Use
caution not to damage trim indicator wire (2).
3. Unwrap the left cable (9) from the drum.
4. The wheel and drum are joined by a push fit, separate these two items with their center bushing
and unwrap the right cable (8).
5. Tie the cables forward to prevent them from slipping back into the floor tunnel.
e. The trim control cables (8 and 9) may be removed by the following procedure:
1. Remove the rear seat bottom or floor panel, whichever applies, and the front seats, if desired.
2. Unfasten the carpet from the aft portion of the floor tunnel and lay it forward.
3. Remove the tunnel cover located between the trim control wheel and the spar cover by
removing attaching screws.
4. Remove the cable pulleys (6) located in the tunnel by removing the cotter pin, washer and
clevis pin (5).
5. Remove the cable rub blocks (37) located on the aft side of the main spar by removing the
block attaching screws.
6. Remove the cable guard pin (36) at the pulley cluster (34) located just aft of the wing flap
torque tube at station 127.25.
7. If installed, remove the cable pulleys (33) within the aft section of the fuselage at station 156.5
by removing nut, washer, bushing and bolt.
8. With the cables disconnected from the trim control wheel, draw the cable(s) through the floor
tunnel.

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5-26. INSTALLATION OF STABILATOR TRIM ASSEMBLY. (FORWARD.) (Refer to Figure 5-10.)

a. The trim control wheel with drum may be installed by the following procedure:
1. Wrap the right trim cable on the trim drum by inserting the swaged ball of the cable in the slot
provided in the side (right side) of the drum that mates with the control wheel, and looking at
this side, wrap the drum with three wraps of the cable in a clockwise direction.
2. Attach the control wheel to the cable drum by aligning the long lug of the drum with the long
slot of the wheel and pushing the two pieces together.
3. Wrap the left trim cable on the drum by inserting the swaged ball of the cable in the slot
provided in the flanged side (left side) of the drum and looking at this side, wrap the drum with
three wraps of the cable in a clockwise direction.
4. Lubricate and install the bushing in the control wheel and drum.
5. Align the control cables and position the control wheel assembly between its mounting
brackets. Ascertain that the end of the trim indicator wire is positioned in the spiraled slot of
the drum with no bind on the end. Install the retainer bolt from the left side and install washer
and nut.
6. Install the cover over the control wheel and secure with screws, unless the control cables have
yet to be installed.
b. The trim control cables may be installed by the following procedure:
1. Draw the cable(s) through the floor tunnel.
2. Wrap the cable drum and install the trim control wheel as given in step a.
3. Position the cable pulleys on their mounting bracket within the floor tunnel and install the
clevis pin, washer and cotter pin.
4. Connect the cable to the aft cable at the turnbuckle in the aft section of the fuselage. Install aft
cable if not installed.
5. If previously installed, install the pulleys in the aft lower section of the fuselage at station
156.5 forward of the cable turnbuckles.
6. Install the cable guard at the underside of the pulleys located just aft of the flap torque tube at
station 127.25 and secure.
7. Install the cable rub blocks located on the aft side of the main spar housing and secure with
screws.
8. Remove the blocks that secure the aft trim cable and check that the cables are seated on their
pulleys.
c. Set cable tension and check rigging and adjustment per paragraph 5-29. Check safety of all
turnbuckles.
d. Install the tunnel cover on the tunnel and secure with screws.
e. Install the carpet over the floor tunnel.
f. Install the cover over the trim control wheel and secure with screws and special washers.
g. Install the floor panel and seat belt attachments aft of the main spar and secure panel with screws.
h. Install the panel to the aft section of the airplane and the seats.

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Figure 5-10. Stabilator Trim Control (Floor Control)

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5-27. REMOVAL OF STABILATOR TRIM ASSEMBLY. (AFT.) (Refer to Figure 5-10.)

a. Remove the access panel to the aft section of the fuselage.
b. Block the trim cables at the first set of pulleys (33) forward of the cable turnbuckles (10 and 11) in
the aft section of the fuselage by a method shown in Figure 5-9.
c. Disconnect the cable (12) at the turnbuckles (10 and 11) in the aft section of the fuselage.
d. Remove the tail cone by removing its attaching screws.
e. Disconnect the link (25) between the trim screw (23) and the trim control arm (28) by removing the
nut, washer and bolt (24) that connects the link to the screw.
f. Remove the cotter pin from the top of the screw (23), and turn the screw down and out of the barrel
(20).
g. Remove the snap ring (32), washer (31) and thrust washer (30) from the bottom of the barrel.
h. Disconnect the diagonal rib (22) from the horizontal rib (16) that supports the trim assembly by
removing the four attaching nuts, washers and bolts.
i. Draw the trim cable (12) from the fuselage.
5-28. INSTALLATION OF STABILATOR TRIM ASSEMBLY. (AFT.) (Refer to Figure 5-10.)
a. Wrap the trim barrel (20) by first laying the center (as measured equally from each end to the center
of the cable) of the trim cable (12) in the slot of the barrel. Bring the upper cable through the
diagonal slot in the flange at the upper end of the barrel and wrap down in a counterclockwise
direction. Bring the lower cable through the diagonal slot in the lower end of the barrel and wrap up
in a clockwise direction. Wrap the cable as evenly as possible to obtain 23 wraps on the barrel as
viewed from the side opposite the slot and with the cables extending out from the slotted side.
b. Block both cables by clamping them between two pieces of wood laid next to the wraps to prevent
them from unwrapping.
c. Ascertain that the barrel bushings (19 and 29) are installed in the rib plate (17) and clip (21).
d. Lubricate the bushings and install the trim barrel (20) in the bushings between the two support ribs.
Attach the bottom diagonal rib (22) to horizontal rib (16) and secure with bolt, washers and nuts.
e. Install the thrust washer (30), washer (31) and snap ring (32) on the lower end of the barrel.
f. Install the trim screw (23) in the barrel (20) and secure each end with a cotter pin through the screw.
g. Route the cables into the fuselage and attach the ends to the forward trim cables (8 and 9).
h. Remove the blocks that are holding the forward cables tight and aft cables at the barrel.
i. Set cable tension and check rigging and adjustment per paragraph 5-29. Check safety of all
turnbuckles.
j. Install the tail cone and secure with screws.
k. Install the access panel to the aft section of the fuselage.

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5-29. RIGGING AND ADJUSTMENT OF STABILATOR TRIM. (FLOOR CONTROL.) PA-28-180, S/N’s
28-4378 and up; PA-28-235, S/N’s 28-10720 and up; and PA-28R. (Refer to Figure 5-10.).
WARNING: VERIFY FREE AND CORRECT MOVEMENT OF STABILATOR TRIM TAB. WHILE
IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT
THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT
ALL. ACCORDINGLY, UPON COMPLETION OF STABILATOR TRIM RIGGING
AND ADJUSTMENT, VISUALLY CONFIRM THAT THE STABILATOR TRIM TAB
TRAILING EDGE MOVES UP WHEN THE TRIM WHEEL IS TRIMMED NOSE DOWN;
AND, THAT THE STABILATOR TRIM TAB TRAILING EDGE MOVES DOWN WHEN
THE TRIM WHEEL IS TRIMMED NOSE UP.
a. Level the airplane. (Refer to Leveling, Section II.)
b. Check for proper stabilator trim cable tension as given in Table V-II. If cables were disconnected,
rotate control wheel several times to allow the cables to seat and recheck tension.
c. Secure the stabilator in neutral position. To find neutral, place a rigging tool on the upper surface of
the stabilator as shown in Figure 5-7. Zero a bubble protractor, set it on the rigging tool and tilt the
stabilator until the bubble is centered.
d. With the stabilator centered, turn the trim wheel (1) until the aft end of the turnbuckle (10) of the
right trim cable (8) is approximately two inches forward of the double pulleys (13) at the top of the
rear bulkhead at station 228.3.
e. Check that the trim screw (23) is turned down until the cotter pin stop in the top of the screw is
contacting the plate (17) on the horizontal support rib (16) of the trim assembly. If the stop is not
contacting the plate, the links (25) between the screw (23) and the trim control arm (28) are not
disconnected, disconnect the two by removing the connecting nut, washers and bolt (24). With
the turnbuckle still at the two inch dimension from the pulley, turn the screw down until the pin
contacts the plate.
f. Check the rod end (26) on the tab actuating arm (28) for approximately six threads forward of the
jam nut (27).
g. Connect the links to the trim screw and secure with bolt, washers and nut.
h. Turn the trim control wheel until the trim tab streamlines with the neutral stabilator.
i. Check the bubble of the protractor over the neutral tab and then check tab travels as given in Table
V-II. The degree of travel on the protractor is determined by taking the difference between the
protractor reading at neutral and up, and neutral and down. The bubble must be centered at each
reading with the airplane level.
j. To obtain correct travels, if incorrect, adjust by disconnecting the links (25) at the actuating arm rod
end (26) and turning the end in or out as required. Reconnect links to rod end.
k. Secure the jam nut (27) on the actuating arm rod end.
l. Turn the trim wheel to full travel and check for turnbuckle clearance and location of tab indicator.
5-30. RUDDER AND STEERING PEDAL ASSEMBLY.
5-31. REMOVAL OF RUDDER AND STEERING PEDAL ASSEMBLY. (Refer to Figure 5-11.)
a. Remove the access panel to the aft section of the fuselage.

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b. Relieve rudder and stabilator cable tension by loosening one of the rudder and stabilator cable
turnbuckles in the aft section of the fuselage.
c. Remove the tunnel plate located just aft of the tee bar assembly by the following procedure:
1. PA-28-140; PA-28-150, -160, -180 and PA-28R. Remove the rudder trim control knob, trim
cover attaching screws and trim cover. Roll back the carpet from the tunnel and remove the
tunnel plate that is located just aft of the tee bar assembly by removing the plate attaching
screws.
2. PA-28-235: Remove the fuel selector and rudder trim covers by removing the knobs and the
attaching screws. Disconnect the fuel indicator control lever from the fuel selector torque
tube by removing the attaching pin located at the bottom of the lever. Remove the tunnel plate
located just aft of the tee bar by laying back enough tunnel carpet to remove the plate attaching
screws.
d. Disconnect the stabilator control cable from the lower end of the tee bar assembly.
e. Remove the tee bar attaching bolts with their washers and nuts which are through each side of the
floor tunnel. Pull the lower end of the tee bar aft.
f. Disconnect the control cable (19) ends from the arms on the torque tube (3) by removing the cotter
pins, washers, nuts and bolts (20).
g. Disconnect the rudder trim from the torque tube assembly by removing the cotter pin, washers and
bolt that connects the arm to the trim. Remove the cotter pin and clevis pin from the rudder trim
mechanism and remove the mechanism from the mounting channel. Remove the screw from the
engine control bracket assembly and swing it out of the way. Disconnect the alternate air cable and
move aside.
h. Disconnect the steering rods (21) at the rudder (32 and 33) by removing nuts and bolts (24).
i. If airplane is equipped with toe brakes, disconnect the brake cylinders (12) at the lower end of each
cylinder rod (11) by removing the cotter pins, washers, nut and bolts (20).
j. Disconnect the vee brace(s) (29) (two braces are used with right hand brakes) from the torque tube
by removing nuts, washers and bolts (27) that secure the strap bracket (28) to the vee brace.
k. Disconnect the torque tube support bracket (35) where it attaches by removing its attaching bolts.
l. Remove the two bolts (25 and 26) that extend through the torque tube and are located at the center
of the tube assembly over the floor tunnel. Compress the tubes. Remove the left and right toe brake
pedal assembly.
m. Disconnect the torque tube support blocks (7 and 8) from their support brackets on each side of the
fuselage by removing the attaching nuts, washers and bolts (6).
n. Remove the trim side panels, if desired.
o. Rotate the rudder pedal bar assembly toward the cabin door far enough to pull the right pedal bar
out. Rotate the remaining assembly to the left and remove the assembly from the aircraft. Note the
spacers and washers (9) on each end and between the support blocks.

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Figure 5-11. Rudder and Steering Pedal Assembly

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5-32. INSTALLATION OF RUDDER AND STEERING PEDAL ASSEMBLY. (Refer to Figure 5-11.)
a. Assemble the torque tube assembly (1, 2, 3 and 4) as shown in Figure 5-11. Do not at this time
install the two bolts (25 and 26) through the center of the tube assembly.
b. Place the upper support blocks (7) on the ends of the torque tube assembly. Note that a washer (9) is
required on each end of the tube.
c. Position the support blocks (7 and 8) on their mounting brackets at each side of the fuselage and
secure with bolts, washers and nuts. Note that a bushing is required in the bolt holes of the upper
support block, a plate on top of the upper block, between the upper and lower blocks and under the
block mounting bracket.
d. Align the bolt holes in the center area of the torque tube assembly, install bolts, washers and nuts
(25 and 26) and tighten.
e. Position the torque tube support bracket (35) on the floor tunnel and secure with bolts.
f. Position the vee brace(s) (29) on the torque tube, install the strap bracket (28) around the torque
tube and brace and secure with bolts, washers and nuts (27).
g. Check that the rod end (17) on the clevis rod (15) is adjusted to give a dimension of 7.94 inches
between hole centers.
h. Connect the ends of the brake cylinder rods (11) and clevis rods (15) to the idler arms (10) and
secure with clevis and cotter pins (13).
i. Connect the steering rods (21) to the rudder pedals (32 and 33) and secure with bolts and nuts (24).
Check steering rod adjustment per Alignment of Nose Gear, Section VII or VIIA.
j. Connect the rudder trim to the arm of the torque tube and secure with bolt, washer, nut and cotter
pin. A thin washer is installed under the nut which is tightened only finger tight.
k. Connect the ends of the rudder control cables (19) to the arms provided on the torque tube and
secure with bolts, washers, nuts and cotter pins (20). Allow the ends free to rotate.
1. Swing the tee bar into place and secure with attachment bolts, washers and nuts (15). Insert bolts
through each side of the floor tunnel. (See Figure 5-1 or 5-2.)
m. Connect the stabilator control cables (11) to the lower end of the tee bar with bolt, washer and nut
(16), and secure with cotter pin. (See Figure 5-1 or 5-2.) Allow the cable ends to rotate freely.
n. Set rudder cable tension and check rigging and adjustment per paragraph 5-40.
o. Set stabilator cable tension and check rigging and adjustment per paragraph 5-17.
p. Check aileron cable tension.
q. Check safety of bolt and turnbuckles.
r. Install the floor tunnel plate and secure with screws. Fasten the tunnel carpet in place.
s. Install the rudder trim cover and control knob.
t. Install the access to the aft section of the fuselage.

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5-33. RUDDER CONTROLS.

5-34. REMOVAL OF RUDDER CONTROL CABLES. (Refer to Figure 5-12.)
a. To remove either the forward (10 or 11) or aft (14 or 15) rudder cables, first remove the access
panel to the aft section of the fuselage.
b. Disconnect the desired cable at the turnbuckle (12 or 13) in the aft section of the fuselage.
c. Either forward rudder cable may be removed by the following procedure:
1. Remove the rear seat or floor panel, whichever applies, and the front seats.
2. Remove the cable guard pin (7) from the underside of the pulley cluster (9) that is located in
the aft area of the flap torque tube.
3. From within the area aft of the main spar, remove the cable rub blocks (6) that are attached to
the spar housing by removing the block attaching screws.
4. Remove the rudder trim knob and the cover attaching screws.
5. Remove the tunnel plate just aft of the tee bar by removing enough carpet from the tunnel to
allow the plate attaching screws and the plate to be removed.
6. Move the cable guard pin (4) located under the pulley cluster (5) just aft of the tee bar by
removing the cotter pin from the exposed end and sliding it to the left or right, as required.
7. Disconnect the end of the cable from the arm on the rudder pedal torque tube by removing the
cotter pin, nut, washer and bolt (2).
8. Draw the cable from the floor tunnel.
d. The aft rudder control cables may be removed by the following procedure:
1. Remove the tail cone fairing by removing its attaching screws.
2. Disconnect the cable (14 or 15) from the rudder horn (17) by removing cotter pin, nut, washer
and bolt (16).
3. Draw the cable through the fuselage.
5-35. INSTALLATION OF RUDDER CONTROL CABLES. (Refer to Figure 5-12.)
a. The forward rudder control cables may be installed by the following procedure:
1. Draw the control cable through the floor tunnel.
2. Connect the end of the cable to the arm on the rudder pedal torque tube by installing bolt,
washer, nut and cotter pin (2). Allow the cable end free to rotate on the arm.
3. Connect the cable to the aft control cable at the turnbuckle (12 or 13) in the aft section of the
fuselage. If the aft control cables are not installed, install at this time per step b. Ascertain that
each cable is in the groove of its pulley.
4. Move the cable guard (4) into position, that is located in the forward area of the tunnel, under
the pulley cluster (5) and secure with cotter pin.
5. Within the area aft of the main spar, install the cable guard blocks (6) onto the spar housing
and secure with screws.
6. Install the cable guard (7) under the pulley cluster (9) located just aft of the flap torque tube.
7. Set cable tension and check rigging and adjustment per paragraph 5-36.
8. Install the forward tunnel plate aft of the tee bar and secure with screws.
9. Put the floor carpet in place and secure.

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Figure 5-12. Rudder Controls

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10. For PA-28-235 only: Place the fuel selector lever on the selector torque tube and secure with
pin and cotter pin.
11. Install the lower and upper selector covers and secure with screws.
12. Install the rear seat or floor panel and install the seats.
b. The aft rudder control cables may be installed by the following procedure:
1. Position the control cable in the fuselage.
2. Connect the end of the cable (14 or 15) to the rudder horn (17) with bolt, washer, nut and cotter
pin (16). Allow the cable end free to rotate.
3. Connect the other cable end to forward control cable (10 or 11) at the turnbuckle (12 or 13) in
the aft section of the fuselage.
4. Set cable tension and check rigging and adjustment per paragraph 5-36.
5. Install tail cone fairing and secure with screws.
c. Install the access panel to the aft section of the fuselage.
5-36. RIGGING AND ADJUSTMENT OF RUDDER CONTROLS.
WARNING: VERIFY FREE AND CORRECT MOVEMENT OF RUDDER. WHILE IT WOULD
SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS
FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY,
UPON COMPLETION OF RUDDER RIGGING AND ADJUSTMENT, VISUALLY
CONFIRM THAT THE RUDDER TRAILING EDGE MOVES RIGHT WHEN THE RIGHT
PEDAL IS DEPRESSED; AND, THAT THE RUDDER TRAILING EDGE MOVES LEFT
WHEN THE LEFT PEDAL IS DEPRESSED.
a. To check and set the correct degree of rudder travel, the following procedure may be used:
1. Check the rudder travel by swinging the rudder until it contacts its stop. If the control cables
are connected, use the rudder pedals to swing the rudder.
2. With the rudder against its stop, place a rigging tool against the side of the rudder and vertical
stabilizer as shown in Figure 5-13. (Ascertain that the tool is not contacting any rivets.) If no
gap exists between the rigging tool and the surface of the rudder and vertical stabilizer, the
rudder stop for one direction of travel is correct as required in Table V-II. (This tool may be
fabricated from dimensions given in Figure 5-5.)
3. Swing the rudder in the other direction and check travel as directed in step 2.
4. Should the rudder travel be incorrect showing a gap between the tool and any part of the
control surfaces, the tail cone fairing should be removed and the stops reset to obtain correct
rudder travel. (Refer to Figure 5-14.)
b. To set cable tension and alignment of the rudder, the following procedure may be used:
1. Remove the access panel to the aft section of the fuselage.
2. Ascertain that the nose gear steering has been aligned and rudder pedals set fore and aft
according to Alignment of Nose Landing Gear, Section VII or VIIA.
3. Clamp the rudder pedals to align in a lateral position as shown in Figure 5-13.

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4. Adjust the turnbuckles in the aft section of the fuselage to obtain proper cable tension as given
in Table V-II and to allow the rudder to align at neutral position. Adjust cables evenly to
prevent undue strain on aircraft components. Neutral position can be determined by standing
behind the airplane and sighting the rudder with the vertical stabilizer or the center of the trim
screw.
5. Check safety of turnbuckles.
c. On fixed landing gears check that when the rudder contacts its stop, the clearance between the nose
wheel stops and the nose wheel horn is between 0.06 and 0.12 inch. A more accurate check can be
made with the weight off the nose wheel. Adjust the stops according to Alignment of Nose Landing
Gear. Section VII.

Figure 5-13. Rudder Rigging Tool Application and Fabrication

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Figure 5-14. Rudder and Stabilator Travel Adjustments

d. On 1974 models (PA-28-140 S/N’s 28-7425001 to 28-7425444, PA-28-180 S/N’s 28-7405001 to

28-7405280, PA-28-235 S/N’s 28-7410001 to 28-7410110, and PA-28R-200 S/N’s 28R-7435001
to 28R-7435323), adjust the rudder pedal stops by pushing on the pilot’s left rudder pedal until
the rudder stop is contacted. Adjust the pedal stop (on the fire wall) to provide 0.060 to 0.120 of
an inch clearance. Repeat the procedure with the copilot’s right rudder pedal. Do not push rudder
harder than necessary to avoid cable stretch.
e. Install the tail cone fairing and the access panel to the aft section of the fuselage.

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5-37. RUDDER TRIM CONTROLS.

5-38. REMOVAL OF RUDDER TRIM CONTROLS. (Refer to Figures 5-15 and 5-16.)
a. Remove the cover (1) from over the trim control assembly by removing attaching screws.
b. Remove the rudder trim knob (2) and the cover attaching screws.
c. Rotate the trim knob to the extreme left (counterclockwise) trim position.
d. Disconnect the housing lug from the arm on the rudder pedal torque tube by removing cotter pin,
nut, washer and bolt (7).
e. Remove the threaded bushing (4) from the aft end of the mounting channel (8) by removing cotter
pin and clevis pin (5). Some mounting channels have two holes in the aft end, note from which hole
in the clevis pin was removed.
f. The mounting channel may be removed by removing the channel attaching screws at the inside of
the channel.
5-39. INSTALLATION OF RUDDER TRIM CONTROLS. (Refer to Figures 5-15.)
Install the rudder trim mechanism and set it at the neutral (no load on spring) position. Perform the
procedure only after all other rudder and nose wheel rigging is complete.
a. Install the trim control mounting channel (8) on the upper side of the floor tunnel. A spacer plate
(14) on some models is installed between the channel and the tunnel. Install the attaching screws
(9) which are secured with anchor nuts.
b. Before attaching the assembly to the mounting channel, ascertain that the clips (11) are installed so
the safety wire (12) will be on top. Also, that the threaded bushing (4) is installed on the assembly
shaft (15) with the welded attachment bushing forward or toward the housing.
c. Attach the housing lug to the arm provided on the rudder pedal torque tube and secure with bolt,
washer and nut (7). Tighten the nut only finger tight and safety with cotter pin.
d. Clamp the rudder pedals in neutral and position the threaded bushing in the mounting channel (8).
Turn the control shaft until the holes in the bushing and channel align and then install the clevis pin
and cotter pin (5). Should two thru holes be located in the aft end of the mounting channel, the pin
must be installed through the hole that will give equal travel and hit rudder stops before bottoming
out of the trim assembly.
e. With the rudder pedals neutral and no pressure fore or aft on the clevis pin, install the assembly
cover (1) so that the indicator washer (13) and the neutral mark on the cover align.
f. Install the trim cover, secure with screws, and install the trim control knob.
5-40. RIGGING AND ADJUSTMENT OF RUDDER TRIM CONTROLS. Perform these procedures only
after all other rudder and nose wheel rigging is complete. No adjustments are necessary other than those
required during installation of the assembly in the airplane as given in paragraph 5-39.
WARNING: VERIFY FREE AND CORRECT MOVEMENT OF RUDDER. WHILE IT WOULD
SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS
FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY,
UPON COMPLETION OF RUDDER TRIM RIGGING AND ADJUSTMENT, VISUALLY
CONFIRM THAT THE RUDDER TRAILING EDGE MOVES LEFT WHEN THE
RUDDER TRIM KNOB IS TRIMMED NOSE LEFT; AND, THAT THE RUDDER
TRAILING EDGE MOVES RIGHT WHEN THE RUDDER TRIM KNOB IS TRIMMED
NOSE RIGHT.

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Figure 5-15. Rudder Trim Control Installation - PA-28-140/150/160/180/235

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Figure 5-16. Rudder Trim Control

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5-41. WING FLAP CONTROLS.

5-42. REMOVAL OF WING FLAP CONTROLS. (Refer to Figure 5-17.)
a. The flap torque tube assembly may be removed by the following procedure:
1. Remove the access plate located between the underside of the aft section of each wing and the
fuselage by removing attaching screws.
2. Remove the two front seats and the bottom half of the rear seat or floor panel, whichever applies.
3. Disconnect the left and right flap control tubes (rods) (4) at the flaps by removing the nuts,
washers and bolts (2) or at the torque tube cranks (arms) (11) by removing the bolts (12) and
washers from the inner side of each crank. It will be necessary to remove bolt through a hole in
the side skin of the fuselage located over the torque tube with the flap handle moved to its 40
degree position.
4. With the flap handle (29), fully extend the flaps and disconnect the flap tension spring (22) at
the spar or the aft end of the control cable (23), as desired.
5. Grasp the flap handle, release the plunger (33) and allow the flap to return to the retracted
position. Use caution as forward pressure will be on the handle with the tension spring
disconnected.
6. Disconnect the flap return spring (32) at the spar or return chain (30), as desired.
7. Disconnect the control cable from the chain (20) by removing cotter pin, nut and clevis bolt (21).
8. Remove the tube support blocks (16 and 31) by removing the block attaching bolts (15).
9. Remove the nuts, washers and bolts (10) securing the right and left cranks ( 1) and stop fittings
(13) on the torque tube.
10. From between each wing and the fuselage, remove the cranks from the torque tube.
11. Disconnect one bearing block (7) from its mounting brackets (6) by removing nuts, washers
and bolts (5).
12. Slide the tube from the bearing block still attached to its brackets; raise the end and lift it from
the floor opening.
b. The flap control cable (23) may be removed by the following procedure:
1. If the front seats and bottom of the rear seat have not been removed, remove the seats.
2. Disconnect the flap tension spring (22) from the cable, if not previously disconnected, by
extending the flaps to relieve spring tension.
3. Retract the flap. Use caution as forward pressure will be on the handle with the spring
disconnected.
4. Disconnect the cable from the chain (20) by removing cotter pin, nut, clevis pin and bushing (21).
5. Remove the flap handle bracket and cover.
6. Lift the aft section of the tunnel carpet far enough to remove the screws securing the tunnel
cover that is between the flap handle and the spar cover. Remove the cover.

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7. Remove the cotter pin cable guard from the flap cable pulley (24) located inside the floor
tunnel just ahead of the spar housing.
8. Remove the cable rub blocks located in the floor opening on the aft side of the spar housing by
removing the attaching screws.
9. Disconnect the cable turnbuckle (25) at the flap handle by removing cotter pin, nut and bolt
(26). Check clevis bolt (26) for wear. Replace bolt if any wear is evident.
c. Remove the flap handle (29)and bracket (28) by disconnecting the cable turnbuckle from the handle
and removing the bolts securing the bracket to the floor tunnel.
5-43. INSTALLATION OF WING FLAP CONTROLS. (Refer to Figure 5-17.)
a. The flap torque tube assembly may be installed by the following procedure:
1. Install the chain sprocket (17) with chain (20 and 30) on the torque tube (14) and secure with
bolts, washers and nuts (18).
2. Slide the tube stop fittings (13) on their respective ends of the torque tube.
3. Ascertain that one bearing block fitting (7) is installed between its attachment brackets (6).
4. Slide the other bearing block over its respective end of the torque tube.
5. Position the torque tube by placing the end with the bearing block on it between the mounting
bracket and sliding the other end into the previously attached bearing block.
6. Position the remaining bearing block and secure with bolts, washers and nuts (5).
7. Push the torque tube cranks (arms) (11) on each end of the torque tube and slide the stop fitting
(13) in place. Align the bolt hole of the crank and stop fitting with the holes in the torque tube
and install bolts. The holes in the stop fitting are elongated to allow the stop fitting to be
pushed against the bearing blocks (7) thus allowing no side play of the assembly. Tighten the
bolt assemblies (10) on the stop fittings.
8. Install the tube support blocks (16 and 31) on their support brackets (19) and secure with bolts
(15).
9. Connect the flap return spring (32) to the return chain (30) and/or at the spar housing.
10. Connect the control cable end to the tension chain (20) and secure with bushing, clevis bolt,
nut and cotter pin.
11. Pull the flap handle full back and connect the tension spring (22). Release the flap handle to
the forward position.
12. Connect the flap control tube (4) to the flap and/or torque tube crank (11) and secure. The bolt
(12) and bushing that connects the control tube to the crank is installed through a hole in the
side of the fuselage located over the torque tube.
b. To install the flap handle (29) with bracket (28), place the assembly on the floor tunnel and secure
with bolts.

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Figure 5-17. Flap Controls

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c. The flap control cable (23) may be installed by the following procedure:
1. Attach the cable and turnbuckle (25) to the flap handle arm and secure with clevis bolt, nut and
cotter pin (26). Ascertain that the turnbuckle end is free to rotate on the arm.
2. Route the cable through the tunnel and spar housing.
3. Install the cable rub blocks on the aft side of the spar housing and secure with screws.
4. Install cotter pin cable guard over pulley (24) located just ahead of the spar housing in the
floor tunnel.
5. Attach the cable end to the tension chain(20) and secure with bushings, clevis bolt, nut and
cotter pin. If the chain is not installed because of the torque tube assembly being removed,
install the assembly as given in step c.
6. Pull the flap handle (29) full back and connect the tension spring (22) to the cable end.
d. Install the tunnel cover and secure with screws. Also, the tunnel carpet and bracket cover.
e. Install and secure the seats.
5-43a. TORQUE TUBE/PUSH ROD DISTORTION INSPECTION.
If flaps have been extended at or above Vfe, inspect the flap torque tube arms and pushrods for evidence
of distortion.
a. If the paint is cracked or peeling anywhere along the torque tube arm or pushrod, torsional
movement has occurred.
b. Remove the paint and inspect for cracks:
1. In the welds at the arm on the torque tube end.
2. In the rod ends and pushrod tube.
3. Use a dye penetrant method of inspection.
c. If cracks are not found, repaint the part(s) and reinstall.
d. If cracked, replace the affected part(s).
5-44. RIGGING AND ADJUSTMENT OF WING FLAP CONTROLS.
WARNING: VERIFY FREE AND CORRECT MOVEMENT OF FLAPS. WHILE IT WOULD
SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS
FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY,
UPON COMPLETION OF FLAP RIGGING AND ADJUSTMENT, VISUALLY CONFIRM
THAT THE FLAP TRAILING EDGES MOVE UP WHEN THE FLAP HANDLE IS
PUSHED DOWN; AND, THAT THE FLAP TRAILING EDGES MOVE DOWN WHEN
THE FLAP HANDLE IS PULLED UP.
NOTE: Flap rigging and adjustment must be completed before starting aileron rigging and adjustment.
a. Place the flap handle in the full forward position.
b. If not previously removed, remove the bottom half of the rear seat.

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Figure 5-18. Flap Rigging Tool Application and Flap Stop Adjustment

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c. To adjust the flap up stop and step lock, loosen the jam nut of the right torque tube stop screw,
located in the floor opening along the outer end of the flap torque tube, and turn the stop screw to
obtain approximately .60 of an inch between the stop fitting and the bearing block as measured
along the top side of the screw. (Refer to Figure 5-18.) It may be necessary to loosen the adjustment
screw of the left stop.
d. Place a 0.125 spacer between the stop fitting and the end of the screw. Determine that when
pressure is applied down on the flap, it will remain in the up-lock position. If it extends, turn the
adjustment screw out a few threads at a time until the flap remains in the up-lock position with the
spacer inserted. Tighten the jam nut.
e. Rotate the left stop adjustment screw until it contacts the stop fitting. Tighten the jam nut.
f. Set the flap control cable tension (handle next to floor, 0 degrees) as given in Table V-II at the
turnbuckle that is attached to the lower end of the flap handle in the floor tunnel. To do this and if
not previously removed, remove the flap handle cover and enough tunnel carpet to remove the
tunnel cover just aft of the handle. Adjust and resafety the turnbuckle.
NOTE: Do not rotate the torque tube while retensioning the cable or tighten tight enough to allow
tube to be pulled away from its stops.
g. To check up-neutral position of the flaps, place a flap rigging tool as shown in Figure 5-18 against
the underside of the wing and flap as close as possible to the outboard end of the flap without
contacting any rivets. The tool must be positioned parallel with the wing ribs with the aft end of the
tool even with the trailing edge of the flap. (This tool may be fabricated from dimensions given in
Figure 5-5.)
h. With the flap control rod connected between the torque tube crank arm and the flap, check that the
surface of the wing contacts the tool at its forward surface and at the spacer, and the aft end of the
flap contacts the aft end of the tool. The flap is neutral at this position.
i. Should the three points not contact, loosen the jam nuts on each end of the control rod and rotate
the rod until the three points contact. Apply a slight up pressure against the trailing edge of the flap
while making this adjustment. After adjustment, retighten the jam nuts.
j. Check and adjust the other flap in a like manner.
NOTE: In the event of wing heaviness during flight, the flap on the side of the heavy wing can be
adjusted down from neutral to remedy this condition by lengthening the control rod. Check
the inspection hole in each rod end to ascertain that there are sufficient threads remaining
and a wire cannot be inserted through these holes. Rod ends without check holes, maintain
a minimum of .375 of an inch thread engagement. Do not raise the flap of the other wing
above neutral.
k. Check the flap for full down travel to the degrees required in Table V-II. Should the travel not be as
that required, readjust the torque tube stop screw in or out as required. After readjusting the screw, it
will be necessary to review-steps d thru j.
1. Check operation of the flap and flap handle ratchet mechanism.
m. Install access plates and panels.

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Figure 5-19. Correct Method of Installing Rod End Bearings

V - SURFACE CONTROLS 01/31/08

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SECTION VI - HYDRAULIC SYSTEM

TABLE OF CONTENTS

Paragraph Grid No.

6-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D4

6-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D4
6-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D8
6-4. Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D8
6-4a. Original Equipment Prestolite Pump, P/N 96671-002 . . . . . . . . . . . . 2D8
6-5. Removal of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D8
6-6. Disassembly of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . 2D9
6-7. Cleaning, Inspection and Repairs of Hydraulic Pump . . . . . . . . . 2D9
6-8. Assembly of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D11
6-9. Test and Adjustment of Hydraulic Pump . . . . . . . . . . . . . . . . . . . 2D12
6-10. Installation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D14
6-10a. Servicing Replacement Oildyne Pump . . . . . . . . . . . . . . . . . . . . . 2D14
6-11. Filling Hydraulic Pump Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 2D19
6-11a. Hydraulic Installation, Landing Gear . . . . . . . . . . . . . . . . . . . . . . 2D19
6-12. Gear Back-Up Extender Actuator Assembly . . . . . . . . . . . . . . . . . . . . 2D21
6-13. Removal of Gear Back-Up Extender Actuator Assembly . . . . . . 2D21
6-14. Installation of Gear Back-Up Extender Actuator Assembly . . . . . 2D22
6-15. Check and Adjustment of Gear Back-Up Extender Actuator . . . . 2D22
6-16. Operational Check of Retractable Landing Gear System . . . . . . . 2E2
6-17. Nose Gear Actuating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E3
6-18. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E3
6-22. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E4
6-19. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E5
6-20. Cleaning, Inspection, and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 2E5
6-21. Assembly of Nose Gear Actuating Cylinder . . . . . . . . . . . . . . . . 2E5
6-23. Main Gear Actuating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E6
6-24. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E6
6-25. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E6
6-26. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E6
6-27. Cleaning, Inspection, and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 2E7
6-28. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E8
6-29. Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E8
6-30. Removal and Installation of Hydraulic Lines . . . . . . . . . . . . . . . . 2E8

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Figure 6-1. Schematic Diagram of Hydraulic System

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TABLE VI-I. LEADING PARTICULARS, HYDRAULIC SYSTEM

Hydraulic Pump 96671-002 (Prestolite) 38998-004 (Oildyne)

High Pressure 1600 to 2000 psi 2400 ± 200 psi

Low Pressure 650 ± 150 psi 600 ± 200 psi
Flow Rate @ 1000 psi 45 cu. in. per min. 60 cu. in. per min.
High Pressure Control 1600 to 2000 psi 2400 ± 200 psi
Thermal Relief 4000 psi 3000 +300, -200 psi
Hydraulic Fluid MIL-H-5606 MIL-H-5606

Pressure Switch
Open (OFF) Pressure 1100 ± 100 psi 1800 ± 100 psi
Close (ON) Pressure 400 ± 200 psi below 300 ± psi below
opening pressure opening pressure

6-3. TROUBLESHOOTING. Malfunctions of the hydraulic system will result in failure of the landing gear to
operate properly. When trouble arises, jack up the airplane (Refer to Jacking, Section II.) and then
proceed to determine the extent of the trouble. Generally, hydraulic system troubles fall into two types,
troubles involving the hydraulic supplying system and troubles in the landing gear hydraulic system.
Table VI-III at the back of this section, lists the troubles which may be encountered and their probable
cause, and suggests a remedy for the trouble involved. A hydraulic system. operational check may be
conducted using Figures 6-1 or 6-2. When the trouble has been recognized, the first step in trouble-
shooting is isolating the cause. Hydraulic system troubles are not always traceable to one cause. It is
possible that a malfunction may be the result of more than one difficulty within the system. Starting first
with the most obvious and most probable reasons for the trouble, check each possibility in turn and, by
process of elimination, isolate the troubles.
NOTE: If it is found that the hydraulic pump is at fault and requires disassembly, it is recommended that
it be overhauled by a recommended overhaul shop. However, if this cannot be achieved, minor
repairs of the pump such as replacement of gaskets and motor components, and pressure checks
with adjustments maybe accomplished in accordance with instructions given in paragraphs 6-6
thru 6-9.
6-4. HYDRAULIC PUMP
6-4a. ORIGINAL EQUIPMENT PRESTOLITE PUMP, P/N 96671-002 ONLY.
6-5. REMOVAL OF HYDRAULIC PUMP. The hydraulic pump with reservoir incorporated is located in the
aft section of the fuselage. Access to the pump is through the access panel in the aft wall of the baggage
compartment.
a. Disconnect the pump electrical leads from the pump solenoid relays and the ground wire from the
battery shelf.
b. Disconnect the hydraulic lines from the pump. Cap the line ends to prevent contamination.
c. Remove the pump by removing the pump attaching bolts.

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6-6. DISASSEMBLY OF HYDRAULIC PUMP. (Refer to Figure 6-3.) After the hydraulic pump has been
removed from the airplane, cap or plug all ports and clean the exterior of the pump with a dry type
solvent to remove accumulated dust or dirt. To disassemble any one of the three main components of the
pump, proceed as follows:
a. The base (16) of the pump may be removed from the case (15) as follows:
1. Cut the safety wire and remove the bolts (17) with washers that secure the base to the pump
case.
2. The shuttle valve within the base should be removed for cleaning purposes only. To remove the
valve, cut safety wire. Remove plug with spring and valve.
NOTE: The shuttle valve and pump base are matched, lapped parts. Should it be necessary to
replace, replace as an assembly only.
b. Pump Motor: The pump motor may be removed from the pump and disassembled as follows:
1. Remove thru bolts (4) from head (1) of motor. Using a knife cut the seal coating between the
motor head and case.
2. Lift the head up from the case approximately .50 of an inch, this will allow inspection of
brushes (3) without the brushes unseating from the commutator. (Refer to Paragraph 6-7 for
brush inspection.) The brush leads are secured to the head assembly.
3. Raise the head assembly (1) off the armature (8) and note the small thrust ball (7) located
between the end of the armature (8) and motor head. Do not misplace this bearing.
4. Draw the armature from the motor frame (9). Note the number of thrust washers (11) mounted
on the drive end of the armature shaft.
5. Remove the motor frame from the pump reservoir (13.)
c. The valve body and gear case assembly (15) may be separated from the reservoir (13) as follows:
1. Remove the screws from the flange of the body and separate the two assemblies.
2. The pump gears and valves should be removed for cleaning purposes only. To remove cap
securing gears, remove cap attaching bolts. There are two valve springs that should be
positively identified with their valve cavities. Otherwise, it will be necessary to readjust each
valve for proper operating pressure.
6-7. CLEANING, INSPECTION AND REPAIRS OF HYDRAULIC PUMP.
a. Discard all old O-rings.
b. Remove cap or plugs and clean all parts with a dry type cleaning solvent and dry thoroughly.
NOTE: The conditions at repair require cleanliness, carefulness and proper handling of parts.
Ensure that foreign materials are prevented from entering the system and that no parts are
damaged.
c. Inspect pump components for scratches, scores, chips, cracks and wear.
d. Inspect motor for worn brushes (minimum of 0.218 brush remains between the braided wire and
commutator end), excess commutator wear and excess bearing wear.
NOTE: Replacement brushes for the original equipment Prestolite pump are no longer available.
When the existing brushes wear out, install a new service replacement Oildyne pump, P/N
38998-004 (order as pump assembly, P/N 38992-805).

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6-8. ASSEMBLY OF HYDRAULIC PUMP. (Refer to Figure 6-3.)

a. The pump motor may be assembled and installed on the pump reservoir assembly as follows:
1. Position the motor frame (referring to Figure 6-3, identified as No. 9) on the reservoir (No.
13). Note the aligning marks on the frame and reservoir.
2. Place thrush washers (1), of the same amount removed, on the drive end of the armature (8).
3. Lubricate the entire length of the armature shaft, on the drive end, with a light grease to protect
the O-ring seal from damage and insert the end of the shaft in the reservoir.
4. Saturate the felt oiling pad around the commutator end bearing with SAE20 oil. Allow excess
oil to drain off before assembling motor.
5. Insert the thrust ball (7) in the bearing of the head assembly (1). To hold the ball in position,
place a small amount of light grease inside the bearing.
6. Place head assembly on frame and allow brushes to extend over commutator. Remove the
string securing the brushes in the holders. Push head assembly on frame and ensure proper
indexing of head and frame assemblies. Secure in place with thru bolts (4).
7. Check freedom of rotation and end play (thrust) of the armature within the assembly. A
minimum of .005 of an inch end play is allowable. Should this be incorrect, adjust by adding
or removing thrust washers (11) on drive end of armature shaft, as required.
b. The valve body and gear case assembly (15) may be assembled to the reservoir (13) as follows:
1. If removed, place the pump gears in the gear case and install cover. Install cover attaching
bolts and secure.
2. Lubricate the reservoir seal ring (14) with hydraulic fluid (MIL-H-5606) and place it in the
recess provided in the case (15).
3. Position the valve body and gear case assembly (No. 15) with the reservoir (13). Care should
be taken when lining up the armature drive with the pump gear. Do not run the motor to do
this.
4. Ascertain that the seal ring is properly positioned and install attaching screws. Tighten the
screws so that with the motor connected to a 14-volt source and with an ammeter in the circuit,
the current drawn does not exceed 12-amperes.
c. The base of the pump may be attached to the pump as follows:
1. With the pump in the upside down position, lubricate O-ring seals, and install in the recesses
provided in the valve body and gear case assembly (15).
2. Install attaching bolts with washers and torque to 70 inch pounds.
3. Safety attaching bolts with MS20995-C32 wire.
d. Conduct motor operational check not to exceed 10 seconds running time.

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6-9. TEST AND ADJUSTMENT OF HYDRAULIC PUMP. (Refer to Figure 6-4.)

a. Test Equipment:
1. Hydraulic pump and mounting base.
2. Pressure gauge (0 to 1000 psi).
3. Pressure gauge (0 to 3000 psi).
4. Hoses with fittings to connect between base and gauges.
5. Power supply (14V DC).
6. Ammeter (0 to 100 amps).
7. Fuse or circuit protector (100 amp).
b. Test and Adjustment:
1. Connect a 0 to 1000 psi gauge to the low pressure port (port No. 3) of the pump base. (The low
pressure port, No. 3, is located nearest to the pipe plug installed in the base.)
2. Connect a 0 to 3000 psi gauge to the high pressure port (port No. 1) of the pump base. (The
high pressure port, No. 1, is located farthest from the pipe plug installed in the base.)
3. Connect the black lead of the pump motor to the negative terminal of the DC power supply.
4. Fill the pump reservoir and bleed all air from the attached lines. (Lines may be bled by
alternately connecting the blue electrical lead and green lead to the positive terminal of the
power supply until all air is exhausted.)
5. Connect the blue lead to the positive terminal of the power supply. Pump should operate and
the high pressure gauge should indicate between 1600 to 2000 psi. (Should the pressure be
incorrect, adjust valve “A”, Figure 6-3, in pump reservoir.)
6. Disconnect the blue lead, and the high pressure reading should not drop more than 300 psi in
five minutes. High pressure may not be selected until after five minutes.
7. Connect the green lead to the positive terminal of the power supply. Pump should operate in
reverse, dropping the high pressure gauge to zero and the low pressure gauge should indicate
between 500 to 800 psi. When the green lead is disconnected, both pressure gauges should
indicate zero psi. (Should the pressure of 500 to 800 psi be incorrect, adjust valve “B”, Figure
6-3, in pump reservoir.)
NOTE: During test steps (5) thru (7), there should not be any external leakage.
8. Should it be necessary to check the pump motor, first connect the ammeter in the electrical
circuit with the positive terminal of the meter to the black lead and the negative terminal of the
meter to negative terminal of the DC power supply.
9. Connect the blue lead to the positive terminal of the power supply. With the high pressure
indication within the 1600 to 2000 psi range on the pressure gauge, the ammeter should read
between 35 to 60 amperes. Disconnect the electrical lead.
10. Connect the green lead to the positive terminal of the power supply. With the high pressure
indication within the 500 to 800 psi range, the ammeter should read between 15 to 35 amperes.
NOTE: In the event that any of the various tests do not perform satisfactorily, the pump
assembly should be overhauled or replaced.
11. Connect the green lead to the power supply to drop pressures before disconnecting the
hydraulic lines.

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Figure 6-4. Test and Adjustments of Hydraulic Pump

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6-10. INSTALLATION OF HYDRAULIC PUMP.

a. Install the rubber shock mounts through
the mounting holes of the pump. Insert a
bushing through the holes of each shock
mount.
b. Position the pump on its mounting flange.
Install mounting bolt with washer and
tighten. (Refer to Figure 6-5.)
c. Connect the hydraulic lines to the pump.
d. Connect the pump electrical leads. Green
wire to outboard relay, blue wire to
inboard relay and black wire to ground on
battery shelf.
e. Check fluid level in pump. Fill per
instructions given in Section II.
f. With the airplane on jacks, operate the
Figure 6-5. Pump Shock Mounts
pump to purge the hydraulic system of air,
and check for leaks. After operation,
recheck fluid level.
6-10a. SERVICING REPLACEMENT OILDYNE PUMP (P/N 39998-004) ONLY.
a. Servicing Hydraulic Pump/Reservoir
CAUTION: THE PUMP MUST HAVE THE DIPSTICK LOOSENED 1 1/2 TURNS TO PROPERLY
VENT IT.
The fluid level of the reservoir of the combination pump and reservoir should be checked every 50
hours by checking the dipstick indication. Access to the pump is through the access panel in the aft
wall of the baggage compartment.
Should the fluid level be low, add fluid, MIL-H-5605A, and return the dipstick. After tightening the
dipstick, loosen it 1 1/2 turns to allow the reservoir to vent.
NOTE: No field repair of Oildyne hydraulic pumps is authorized. any faulty hydraulic pump must be
replaced; or, returned to Piper, via the local piper distributor, for repairs.
b. Removal
The hydraulic pump, with reservoir incorporated, is located in the aft section of the
fuselage. Access to the pump is through the access panel in the rear of the baggage compartment.
To remove pump:
1. Disconnect the pump electrical leads from the pump solenoid relays and the ground wire from
the battery shelf.
2. Disconnect the hydraulic lines from the pump. Cap the line ends to prevent contamination.
3. Remove pump by removing pump attaching bolts.
4. Cap or plug all ports.
5. Clean exterior of pump using a dry cleaning solvent to remove accumulated dirt and dust.

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c. Installation (Refer to Figure 6-5a.)

1. Position assembled pump, bracket, and pump mount on pump deck in airplane.
2. Secure pump assembly to deck by installing the three AN3-10 bolts with one MS35489-64
washer under each bolt head and three No. 5712-45 (Piper P/N 494 192) washers between
Piper mount assembly and pump deck.
NOTE: Before positioning the complete hydraulic pump assembly on the mounting bracket,
ensure that the cushion pad is secured in place on the reservoir base.
3. Install the UP and DOWN pressure hydraulic lines to pump mount.
4. Connect the three knife connectors that attach the black, blue, and green forward and reverse
harness wires.
5. Check fluid level in pump. Fill per instructions given in Section II.
6. Install baggage compartment access panel.

TABLE VI-II. CHARACTERISTICS, HYDRAULIC PUMP MOTOR

Electrical Characteristics:
Voltage 14 DC
Rotation Reversible
Polarity Negative Ground
Operating Current 18 amps, max. at 14 volts (both rotations)
Operating Time 5 to 10 seconds with a current load
of 100 amperes at 77° F
Overload Protection Thermal circuit breaker
Automatic Reset Time 12 seconds, max.
Location, Automatic Reset Commutator end head of motor

Mechanical Characteristics:
Bearings Absorbent bronze
(Drive end bearing in upper pump and
valve assembly casting.)
Steel ball
(Thrust, between commutator end head
and end of armature shaft.)

End Play, Armature 0.005 inch, min.

(Adjust by selection of thrust washers
on drive end of armature shaft.)

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d. Field Service
NOTE: No field repair of Oildyne hydraulic pumps is authorized. Any faulty hydraulic pump must
be replaced; or, returned to Piper, via the local piper distributor, for repairs.
Field service of the hydraulic pump is limited to removal, cleaning, and inspecting the hydraulic
fluid reservoir. Should pump malfunction, either replace pump, or return pump to Piper, via the
local Piper distributor, for servicing or repairs.
The Oildyne pump incorporates a dipstick to check the quantity of hydraulic fluid in the reservoir.
Replenish only with MIL-H-5606 petroleum base hydraulic fluid.
1. Hydraulic Pump (1, 2, 3) and Bracket (4)/Pump Mount (5) (Keyed to Figure 6-5a.)
(a) Disassembly
1 Remove safety wire securing two bolts that attach bracket to pump.
2 Remove the two bolts and washers.
3 Separate pump assembly from bracket.
(b) Assembly
1 If bracket was removed from was removed from pump mount, install bracket to
pump mount with four MS24693-S298 screws.
2 Position pump assembly on bracket so that tapped holes in oildyne adapter align with
bolt holes on bracket.
3 Install two AN960-616 washers and two MS20074-06-05 bolts to secure pump
assembly to bracket.
4 Safety bolts with MS20995-C41 wire.
2. Motor Assembly (1) and Pump-Adapter (2) (Keyed to Figure 6-5a.)
(a) Disassembly
1 Remove two each mounting bolts on flange of motor assembly and separate the
motor assembly from the pump.
2 Remove coupling and O-ring and discard.
NOTE: New O-ring and coupling are included in replacement motor assembly.
(b) Assembly
1 Locate the replacement O-ring and coupling.
2 Place the coupling and O-ring into position between the motor assembly and pump-
adapter assembly.
3 Apply light coating of Titeseal No. 3 in back of the first two threads of mounting
bolts.
4 Positioning the two units in place, install two each mounting bolts through the flange
of the motor assembly and into the pump-assembly housing.
5 Torque bolts to 15 -20 inch pounds.

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Figure 6-5a. Hydraulic Pump/Reservoir (Sheet 1 of 2)

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Figure 6-5a. Hydraulic Pump/Reservoir (Sheet 2 of 2)

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3. Reservoir (3) and Pump-Adapter (2) (Keyed to Figure 6-5a.)

CAUTION: DO NOT DISASSEMBLE PUMP ASSEMBLY FROM PUMP ADAPTER.
DAMAGE TO VALVES AND CHANGES TO PRESSURE SETTINGS, WHICH
ARE NON-ADJUSTABLE, WILL OCCUR.
(a) Disassembly
1 Remove screw and O-ring securing the reservoir to the adapter assembly.
2 Remove reservoir and reservoir seal.
3 When replacing reservoir, remove the cushion pad. It will have to be bonded to the
new reservoir base using Scotch Grip 2210 or Contact Adhesive B-10161 rubber
cement.
(b) Assembly
1 Locate the cushion pad and bond it to the bottom surface of the reservoir using
Scotch Grip 2210, or Contact Adhesive B-10161 rubber cement.
2 Position the reservoir seal between the reservoir and the adapter assembly.
3 Locate the O-ring and bolt that secures the reservoir to the pump-adapter assembly
and apply a light coating of Titeseal No. 3 in back of first two bolt threads.
4 Position the O-ring on the bolt, and install it through the reservoir and into the pump-
adapter securing the reservoir.
5 Tighten this bolt to a torque value of 40 - 50 inch pounds.
6-11. FILLING HYDRAULIC PUMP RESERVOIR. To check fluid level, remove the plug located on the
forward side of the pump and ascertain that fluid is visible up to the bottom of the filler plug hole.
Should fluid be below the hole, add fluid, MIL-H-5606A, through the filler hole until full. Reinstall the
filler plug and tighten.
NOTE: A small vent hole is located under the vent screw head. Retain 1/64 inch clearance between the
screw head and the small vent hole.
6-11a. HYDRAULIC INSTALLATION, LANDING GEAR. (PIR-PPS20007, Rev. AA.)

For all PA-28R-180 and 28R-200 airplanes, S/N’s 28R-35001 through 28R-7635462, install threaded
pipe fittings as follows:
Use Loctite No. 567 PST Sealant for lubricating and/or sealing all hydraulic system pipe threads. Care
shall be taken to ensure that material does not enter the lines of fittings involved. Apply Loctite No. 567
PST Sealant to the male pipe threads only. Do not apply material to the first two threads of the fitting or
allow sealant to enter lines. Tighten fittings as follows:
a. Fittings should be turned in by hand the number of turns indicated by Table VI-IIA. If the fitting
does not seat at the number of turns specified for hand tight engagement ± one turn, both fitting and
boss should be gauged per MIL-P-7105. The fitting is to be wrench tightened not to exceed the
number of turns shown in “Minimum Perfect Threads Remaining before Wrenching” column, in
Table VI-IIA. The total number of turns (by hand and wrench) is never to exceed the number
specified in the table’s “Perfect External Threads” column.

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Figure 6-6. Checking Aligning Brackets of Gear Back-up Extender Actuator

and Fabrication of the Aligning Tool

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6-12. GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLY.

NOTE: The following instructions apply to actuators P/N 96860-000 (i.e. - SFA232-3 and SFA232-4)
only. Disassembly, Assembly, and Cleaning, Inspection and Repair instructions for later model
actuators P/N 96860-002 and 96860-003 (i.e. - SFA232-5) are found in Cleveland Wheel and
Brakes publication: Component Maintenance Manual - CMSFA232-5 (011-00504) available
from the vendor. See Vendor Publications in the Introduction.
6-13. REMOVAL OF GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLY. (Refer to Figure 6-6.) The
back-up extender actuator is located under the rear seat. To reach the actuator, remove the rear seats.
a. Disconnect the actuator electrical leads at-the quick disconnect terminals.
b. On early installations disconnect the manual override control rod (30) at the actuator control arm
(19) by removing cotter pin, washer, and clevis pin (1). On later installations the control rod (30) is
not connected to the actuator arm (19).
c. Disconnect the pressure (13) and static (11) hoses from the elbows (12) of the diaphragm housing
(10) by releasing clamps and sliding the hoses from their elbows. The hoses should be tagged for
ease of reassembly.
d. Place a shop cloth under the actuator hydraulic valve (25) to absorb fluid, and then disconnect the
hydraulic lines (5) and (25) from the elbows (4) and (27) of the hydraulic valve (25). Cover the
lines to prevent contamination.
e. Remove the machine screws that secure the actuator base to the mounting brackets. There are two
mounting screws at the inboard side of the base and one at the outboard side of the diaphragm
housing. Remove the actuator from the mounting brackets.

TABLE VI-IIA. PIPE THREAD SPECIFICATIONS

AERONAUTICAL NATIONAL TAPER PIPER THREADS (ANPT) REF. MIL-P-7105
Nominal Threads Minimum Perfect
Pipe Per Hand Tight Perfect External Threads Remaining
Size Inch Engagement Threads Before Wrenching
Length Number Length Number Length Number

1/16 27 0.160 In. 4.32 Thd 0.26111 7.05 0.10111 2.73

1/8 27 0.180 4.86 0.26385 7.12 0.08385 2.26
1/4 18 0.200 3.60 0.40178 7.24 0.20178 3.64

3/8 18 0.240 4.32 0.40778 7.35 0.16778 3.03

1/2 14 0.320 4.48 0.53371 7.46 0.21371 2.98
3/4 14 0.339 4.75 0.54571 7.64 0.20671 2.89

1 11 1/2 0.400 4.60 0.68278 7.85 0.28278 3.25

1/4 11 1/2 0.420 4.83 0.70678 8.13 0.28678 3.30
1/2 11 1/2 0.420 4.83 0.72348 8.13 0.30348 3.48

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6-14. INSTALLATION OF GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLY. (Refer to Figure 6-7.)
a. Position the gear back-up extender actuator against its mounting brackets and install attaching
machine screws. Do not tighten screws.
NOTE: With the base attached and before installing the attaching screw through the ring of the
diaphragm housing, ensure that the attaching holes in the housing and mounting bracket
align without using force. Should they misalign, it may be necessary to reform the main
fuselage mounting bracket.
To reform the main fuselage mounting bracket, an Aligning Tool may be used. (Refer to
Figure 6-6.) This tool may be fabricated from dimensions given in Figure 6-6. When proper
alignment has been accomplished, tighten the machine screws.
b. On early installations connect the manual control push rod (30) to the actuator control arm (19)
using clevis pin (1). Place a washer over end of clevis pin and secure with cotter pin.
c. Move the actuator on its mounting brackets to allow the manual control push rod to have maximum
clearance from the left stabilator cable and center in the fairlead on the aft face of the main spar
box. Check system for sufficient travel and freedom of movement of controls. Tighten actuator
attaching screws.
NOTE: Care should be used when attaching the forward hose (13) to the diaphragm assembly (10)
so that no strain is placed on the teflon bushing (15) and diaphragm shaft (16), thus causing
friction in movement.
d. Connect the hydraulic lines (5) and (26) to the elbows (4) and (27) of the actuator hydraulic valve
(25).
NOTE: A special fitting (27) with a restriction orifice of 0.063 of an inch is installed in the side of
the hydraulic valve (25). Do not mistake this for a standard AN fitting.
e. Connect the pressure (13) and static (11) hoses to the elbows (12) of the diaphragm housing (10).
Secure hoses with clamps.
f. Connect the actuator electrical leads terminal to their mating terminals and insulate. Refer to the
electrical schematic for hookup.
g. Check the actuator adjustments as given in paragraph 6-15.
h. Install the rear seat.
6-15. CHECK AND ADJUSTMENT OF GEAR BACK-UP EXTENDER ACTUATOR. (Refer to Figure 6-7.)
a. If diaphragm failure is suspected note the following:
1. If the landing gear retracts or extends at too high an airspeed or will not retract at all unless the
back-up extender is placed in the override position, then the diaphragm is possibly defective.
2. If it is determined that the diaphragm is defective, then remove the back-up extender per
instructions given in Paragraph 6-13 and install, Piper Kit No. 761 138V, Back-Up Gear
Extender Diaphragm Replacement. Instructions for installing the diaphragm are included in the
kit.
3. Following completion of Replacement Kit, reinstall the extender unit in the aircraft and
functionally test and adjust as outlined below and in Paragraph 6-16.

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Figure 6-7. Gear Back-up Extender Actuator (Sheet 1 of 2)

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Figure 6-7. Gear Back-up Extender Actuator (Sheet 2 of 2)

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b. Adjustment of the gear back-up extender actuator is preset to allow the hydraulic valve (25) of the
actuator to open when the airspeed is reduced below 105 MPH with the engine power OFF. This
adjustment is accomplished by setting the tension of springs (24) on the actuator with adjustment
screw (2).
NOTE: The airspeed at which the hydraulic valve of the actuator opens was preset at the factory
under ideal conditions. There could be some variations at different altitudes and
atmosphere conditions.
CAUTION: THE MICRO SWITCH (21) ON ALL UNITS, AND ECCENTRIC BOLT (35) ON
LATER UNITS MUST NOT BE ADJUSTED. THESE COMPONENTS ARE SET AT
THE FACTORY UNDER SPECIFIC CONDITIONS, WITH THE USE OF SPECIAL
SET-UP EQUIPMENT.
NOTE: This adjustment will require two persons, a qualified pilot and a mechanic to set the
actuator adjustment screw (2).
1. Remove the bottom of the rear seat.
2. The pivot screw (20) should be torqued 8 to 10 inch-pounds.
3. Loosen the jam nut (28) of the adjustment screw (2).
4. Ascertain that the electrical switch (21) will actuate with the use of the emergency gear
extension lever.
5. Fly the airplane (refer to Owner's Handbook). Should the spring tension be out of adjustment
very much, it may be necessary to assist gear retraction with the use of the emergency gear
extension lever moved to the up override position.
6. Loosen the adjustment screw (2) by turning counterclockwise until spring (24) tension is free.
WARNING: WHILE MAKING ADJUSTMENTS, DO NOT LAY TOOLS IN AREA UNDER
SEAT WHICH MAY INTERFERE WITH CONTROL OF THE AIRPLANE.
7. With the airplane at a safe altitude, slow the airplane to a glide of 110 MPH with the gear
selector handle up and the throttle reduced to power OFF. (Gear warning light and horn will
indicate when power is reduced.) At 110 MPH, slow the airplane at a rate of one (1) MPH per
second until 105 MPH is obtained, hold the airplane at this speed.
NOTE: On later installations, adjustment of the nut (32) may be necessary to increase or
decrease the spread between the gear up and gear down actuation speeds. To expand
the spread between these speeds, loosen the nut. Tighten the nut to bring the airspeeds
closer together. Whenever the nut is adjusted, it may be necessary to readjust the
tension on the springs (24) and to repeat the nut adjustment procedure. If the eccentric
bolt (35) is installed on the unit being adjusted, CAUTION should be observed so as
not to disturb its position in relation to the rest of the unit.
8. With the glide established, turn the adjustment screw (2) clockwise until the gear drops. (First
indication of gear dropping will be that the yellow in-transit light comes ON.)
9. Climb again to a safe altitude and check that the gear drops at the correct airspeed.
10. Land the airplane and tighten the adjustment screw jam nut (28).

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c. To check adjustment of electrical switch, the following procedure may be used:

1. Place the airplane on jacks. (Refer to Jacking, Section II.)
2. Move the mixture control back to idle cut-off and the throttle to full forward to prevent gear
warning horn from sounding during adjustment.
3. Ascertain that the actuator tension springs are properly adjusted according to Step a.
4. Retract the landing gear hydro electrically by turning the master switch ON, raising the
emergency gear extension lever and moving the gear selector handle to the up position. The
emergency gear extension lever must be retained in the up position to keep the gear up.
5. Check for proper switch operation by the following procedure:
(a) Turn master switch ON and move gear selector handle to the up position. Pump should not
operate.
(b) Move the emergency gear extension lever to the up override position. Pump should operate
and gear should retract.
(c) With selector lever up, slowly lower emergency gear extension lever to allow gear to drop
to down position. The pump should not operate at any time during extension.
(d) Turn master switch OFF.
6. Check gear operation in the normal manner with the use of the gear selector handle. The
emergency extension lever must be held in the up override position.
7. Ascertain that gear is down and locked and remove airplane from jacks. Then flight check the
retractable landing gear system. (Refer to Paragraph 6-16.)
6-16. OPERATIONAL CHECK OF RETRACTABLE LANDING GEAR SYSTEM.
a. Maximum Gear Extend: Place the gear selector in the down position at 150 MPH (130 Kts). In
approximately 5 to 10 seconds the three green gear lights should be on indicating that the gear is
down and locked.
b. Minimum Gear Retract: Allow approximately 8 seconds for the pressure in the hydraulic system to
normalize between gear extension and retraction. Place the selector switch in the UP position at 125
MPH (109 Kts). In approximately 5 to 10 seconds all the gear indicating lights should be out,
indicating that the gear is fully retracted.
c. Override Gear Down and Up:
1. Down: Establish a normal glide at approximately 120 MPH (104 Kts), with power at idle.
Slowly move the override lever down, while observing the ammeter to confirm that the
hydraulic pump does not start. The gear should go down and lock. Move the gear selector
switch down. Release the override lever. The gear should remain down.
2. Up: Set maximum climb power. Maintain approximately 70 MPH (61 Kts) for approximately
15 seconds. Move the gear selector switch to the up position. The gear should not retract. Pull
the override lever up. The gear should retract. Allow the airspeed to increase to at least 120
MPH (109 Kts). Release the override lever and the gear should remain up.
d. Gear "Back-Up" Down and Up:
1. Gear Down: Set power at idle. Glide the aircraft at 120 MPH (109 Kts). Decrease the airspeed
at the rate of 1 MPH (1 Kt) per second. The gear should start down between. 100 and 110
MPH (87 to 96 Kts). Place the gear selector switch down, after the gear is down and locked.

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2. Gear Up: Set maximum climb power. Maintain approximately 70 MPH (61 Kts) for
approximately 15 seconds. Move the gear selector up. The gear should stay down and locked.
Increase the airspeed at the rate of 1 MPH (1 Kt) per second. The gear should begin to retract
between 80 and 90 MPH (70 and 78 Kts) at zero density altitude. The speed at which the gear
starts up will increase 1.5 MPH (1.3 Kts) for each 1000' increase of density altitude.
3. Manual Override Up Latch: With the gear up, the aircraft in normal flight configuration, select
up on the gear override lever. Engage the up latch. The amber up latch warning light, below the
gear selector switch, should be flashing. Gradually slow the aircraft below the auto gear extend
speed and observe that the gear stays fully retracted. Disengage the up latch. The flashing
amber warning light should stay out.
e. Gear Indicator Lights:
1. The green lights indicate when the corresponding gear is in the down and locked position. Turn
landing light switch on and off - observe ammeter for indication.
2. The amber light indicates when the gear is in an intermediate position, neither fully up nor
down.
3. The Red gear warning light will indicate an unsafe condition. It will indicate when the throttle
setting is less than 14 ± 2 inches of manifold pressure while the gear is not down and locked. It
will also indicate when the gear is down and locked while the selector is in the UP position,
except at full throttle.
f. The Gear Warning Horn: It will sound whenever the red gear warning light is on.
g. Micro Switch Check:
1. The forward throttle micro switch is checked by moving the throttle full forward while the gear
is down and the gear selector switch is in the up position. The horn should stop sounding and
the red light should go out. Retard the throttle slightly and the horn and light should come on.
2. The aft throttle micro switch setting is checked as follows: with the gear up, reduce the throttle
at a normal rate. The gear warning horn and the red light should come on at 14 inches of
manifold pressure ± 2 inches.
6-17. NOSE GEAR ACTUATING CYLINDER.
6-18. REMOVAL.
a. Place the airplane on jacks. (Refer to Jacking, Section II.)
b. Disconnect the hydraulic lines from the actuating cylinder and cover the open line ends to prevent
contamination.
c. Disconnect the cylinder operating rod end from the downlock hook by removing attachment nut and
bolt.
d. Disconnect the cylinder from its attachment fitting by removing nut and bolt.
e. Remove the cylinder from the wheel well.

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6-19. INSTALLATION.
a. Attach the cylinder to its attachment fitting using bolt and nut.
b. Attach the operating rod end to the downlock link using bolt. Install nut after adjustment is
completed.
c. Connect the hydraulic lines to the cylinder fittings.
d. Check the adjustment of the cylinder rod end. (Refer to Adjustment of Nose Landing Gear, Section
VIIA.)
e. Operate pump to purge system of air and check fluid level in reservoir.
f. Remove the airplane from jacks.

Figure 6-8. Nose Gear Actuating Cylinder

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6-20. DISASSEMBLY. (Refer to Figure 6-8.)

a. With the cylinder removed from the airplane, remove the fitting from the piston rod (6) end of the
cylinder (7). Mark the position of the fitting to facilitate reinstallation.
b. On Syncro Devices nose gear actuating cylinders remove the snap ring (1) from the annular slot in
the end of the housing. On Gar-Kenyon nose gear actuating cylinder remove safety wire (9) and
unscrew end gland (2).
c. On Syncro Devices Assemblies pull the piston (6) with end gland (2) from the cylinder housing. On
Gar-Kenyon Assemblies remove piston (6) after unscrewing end gland (2).
6-21. CLEANING, INSPECTION, AND REPAIR.
a. Clean the cylinder parts with a suitable dry type solvent and dry thoroughly.
b. Inspect the cylinder assembly for the following:
1. Interior walls of the cylinder and exterior surfaces of the piston for scratches burrs, corrosion,
etc.
2. Threaded areas for damage.
3. Rod end fitting and swivel fitting of cylinder for wear and corrosion.
c. Repairs to the cylinder and limited to polishing out small scratches, burrs, etc. and replacing parts.
6-22. ASSEMBLY. (Refer to Figure 6-8.)
a. Install O-ring (5) on the exterior of the end gland (2).
b. Install O-ring (4) in the interior of the end gland. The Syncro Devices Assemblies also include a
ring back-up (3) with the O-ring (4).
c. Install O-ring (8) on the body of the piston assembly.
d. Lubricate the areas around the O-rings with hydraulic fluid, slide the end gland on the piston rod
and the piston into the cylinder housing (7).
e. Secure the end gland in the cylinder by installing the snap ring (1) in the annular slot in the Syncro
Devices cylinder. The end gland in the Gar-Kenyon cylinder is secured by threading gland into
cylinder body (7) and securing with safety wire (9).
f. Install restrictor fitting in the piston rod end of the cylinder.
g. Check smoothness of operation of the piston.

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6-23. MAIN GEAR ACTUATING CYLINDER.

6-24. REMOVAL.
a. Place the airplane on jacks. (Refer to Jacking, Section II.)
b. Disconnect the hydraulic lines from the actuating cylinder and cover the open line ends to prevent
contamination.
c. Disconnect the gear downlock spring from the swivel fitting at the upper end of the spring.
d. Remove the downlock spring swivel fitting and disconnect the cylinder operating rod end from the
upper side brace retraction fitting by removing the attaching nut. washer and bolt.
e. Disconnect the cylinder from its attachment by removing nut and bolt.
f. Remove the cylinder from the wheel well.
6-25. INSTALLATION.
NOTE: The following instructions apply to actuators P/N 96860-000 (i.e. - SFA232-3 and SFA232-4)
only. Disassembly, Assembly, and Cleaning, Inspection and Repair instructions for later model
actuators P/N 96860-002 and 96860-003 (i.e. - SFA232-5) are found in Cleveland Wheel and
Brakes publication: Component Maintenance Manual - CMSFA232-5 (011-00504) available
from the vendor. See Vendor Publications in the Introduction.
a. Attach the cylinder to its attachment fitting in the wheel well using bolt and nut.
b. Attach the operating rod end and downlock spring swivel fitting to the upper side brace retraction
fitting by using bolt, washer and nut. Ascertain swivel fitting is free to rotate.
c. Connect the downlock spring to the swivel fitting.
d. Check the adjustment of the cylinder rod end. (Refer to Adjustment of Main Landing Gear, Section
VIIA.)
e. Operate pump to purge system of air and check fluid level in reservoir.
f. Remove the airplane from jacks.
6-26. DISASSEMBLY. (Refer to Figure 6-10.)
a. With the cylinder removed from the airplane, push the piston rod (6) (by hand) toward the clevis (9)
to remove oil from the unit.
b. Put clevis (9) only in a soft jaw vise and clamp against the clevis bearing (10).
c. If no pipe fitting is installed in the port of the end gland (1), install a fitting (1/8 - 27) into the port.
This fitting need not be tight as it will be used for leverage only.
d. Rotate the gland (with use of fitting) until the end of the gland lock ring (4) shows in the slot in the
cylinder body (7). Reverse rotation of the gland to allow the lock ring to move out of the slot. (Refer
to Figure 6-9.) (It may be necessary to give the ring an assist to start out of the slot. If so, insert a
strong wire pick or other available tool in the slot to lift up the end of the ring and then rotate
gland.)
e. Pull the piston (6) and end gland from the cylinder.
f. Remove O-rings as desired.

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6-27. CLEANING, INSPECTION AND REPAIR.

a. Clean the cylinder parts with, a suitable dry type solvent and dry thoroughly.
b. Inspect the cylinder assembly for the following:
1. Interior walls of cylinder and exterior surfaces of piston for scratches, burrs, corrosion, etc.
2. Threaded areas for damage.
3. End fitting retainer slot for excess wear.
4. Rod end fitting and swivel fitting of cylinder for wear and corrosion.
c. Repairs to the cylinder are limited to polishing out small scratches, burrs, etc. and replacing parts.

Figure 6-9. End Gland Locking Device

Figure 6-10. Main Gear Actuating Cylinder

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6-28. ASSEMBLY. (Refer to Figure 6-10.)

a. Install O-ring (5) on the exterior of the end gland (1).
b. Install O-ring (3) and back-up ring (2) in the interior of the end gland.
c. Install O-ring (8) on the body of the piston assembly.
d. Lubricate the areas around the O-rings with hydraulic fluid, park-o-lube or vaseline, slide the end
gland on the piston rod and the piston into the cylinder housing (7).
e. Insert the hook end of a new lock ring (4) (P/N 755 997) in the slot in the cylinder body (7) and slot
in the end gland (1). Rotate gland to completely wrap lock ring into assembly.
f. Align port in end gland and cylinder body.
g. Check smoothness of operation of piston and static pressure test unit to check for possible cut O-
rings.
6-29. HYDRAULIC LINES.
6-30. REMOVAL AND INSTALLATION OF HYDRAULIC LINES.
Remove a damaged hydraulic line by disconnecting the fitting at each end and by disconnecting where
secured by brackets. Refer to Figure 6-2 as an aid in the location of attaching brackets and bends in the
lines. Provide a small container for draining the line. Install a new or repaired line in reverse. Operate the
pump to purge the system of air and check fluid level in reservoir.

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THIS PAGE INTENTIONALLY BLANK

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Figure 7-2. Nose Gear Installation

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TABLE VII-I. NOSE GEAR ALIGNMENT TOLERANCES (PIR-PPS-50005-1, Rev. K.)

Rudder Pedal Neutral Angle (Aft of Vertical) (See Figure 7-4.)

8 degrees, 15 minutes 1. PA-28-140,
S/N’s 28-20002 thru 28-20520
2. PA-28-150, -160, -180,
S/N’s 28-1 thru 28-1760
3. PA-28-235
S/N’s 28-10000 thru 28-10486
11 degrees 1. PA-28-140,
S/N’s 28-20521 thru 28-7325684
2. PA-28-150, -160, -180,
S/N’s 28-1761 thru 28-7305601
3. PA-28-235
S/N’s 28-10487 thru 28-7310187
4. PA-28R-180
S/N’s 28R-7130001 and up
5. PA-28R-200
Models previous to 1974
14 degrees + 3° All 1974 Models and up
- 1°

Nose Wheel Travel

30 degrees left 1. PA-28-140,
30 degrees right + 1° S/N’s 28-20002 thru 28-21845
- 1° S/N’s 28-21847 thru 28-21929
S/N’s 28-21931 thru 28-21934
2. PA-28-150, -160, -180,
S/N’s 28-1 thru 28-3377
3. All PA-28R-200 Models
4. All 1974 Models and up
22 degrees left 1. PA-28-140,
22 degrees right S/N’s 28-21846
S/N’s 28-21830
S/N’s 28-21935 thru 28-7325684
2. PA-28-150, -160, -180,
S/N’s 28-3378 thru 28-7305611
3. PA-28-235
S/N’s 28-10003 thru 28-7310187

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f. Install the hydraulic brake line.

g. If removed, install the landing gear as described in paragraph 7-19.
h. Service the oleo strut as given in Oleo Struts, Section II.
i. Actuate the gear several times by hand to be certain it operates freely.
NOTE: Links should be loose enough to allow free action of the gear. but also resist side play. To
eliminate side play shim washers 63311-03 (.005) may be used as required. Maximum side
play .005 /.007. (See Figure 3-7.)
j. Remove the drip pan and slowly lower the airplane from the jacks.
k. If necessary, bleed brakes by instructions given in paragraph 7-51.

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Figure 7-5. Main Gear Oleo Strut Assembly; PA-140, -150, -160, and -180

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7-18. REMOVAL OF MAIN LANDING GEAR. (Refer to Figure 7-7.)

a. Place the airplane on jacks. (Refer to Jacking, Section II.)
b. Place a drip pan under the main gear to catch spillage.
c. If desired, remove the air from the oleo chamber by depressing the air valve core pin found in the
inspection hole on top of the wing. After the pressure in the oleo chamber has diminished, remove
the valve core pin and attach a small hose to the air valve and drain the fluid by slowly compressing
the piston tube. If it is desirable to extract more fluid from the chamber, remove the filler plug,
insert the siphon hose and drain fluid from the upper area of the housing.
d. Remove the fairing from around the cylinder housing and the access plate located on the bottom of
the wing and to the rear of the housing by removing attaching screws.
e. Unhook the hydraulic brake line inside the wing assembly. This is accessible through the access
plate. Cap the line by use of a threaded cap or wrapping with plastic.
f. Remove the top four bolts by holding them with a slotted screwdriver and turning the nut with the
appropriate wrench. Remove the remaining six by use of a wrench. Carefully remove the gear
assembly from the wing.
7-19. CLEANING, INSPECTION AND REPAIR OF MAIN LANDING GEAR.
a. Clean all parts with a suitable dry type cleaning solvent.
b. Inspect the gear components for excessive wear, corrosion and damage. Check the cylinder housing
and torque links for cracks, nicks and misalignment.
Use a 10-power glass to visually check cast gear cylinder top and bottom radii at drag link attach
lugs for cracks. If no cracks found by visual inspection, use dye penetrant procedure to check for
cracks. Refer to Chapter 20.
c. Repair of the landing gear is limited to reconditioning of parts, replacement of parts, smoothing out
minor nicks and scratches and repainting areas where paint has chipped or peeled.

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TABLE VII-II. TROUBLESHOOTING - LANDING GEAR

Trouble Cause Remedy

Nose landing gear Internal wear in Replace shimmy
shimmies during fast taxi, shimmy dampener. dampener.
takeoff or landing.
Shimmy dampener or Replace necessary
bracket loose at parts and bolts.
mounting.
Tire out of balance. Check balance and
replace tire if necessary.
Worn or loose wheel Replace and/or adjust
bearings. wheel bearings.
Loose torque links. Adjust side play.
Worn torque link bolts Replace bolts and/or
and/or bushings. bushings.
Excessive or uneven wear Incorrect operating Inflate tire to correct
on nose tires. pressure. pressure.
Wear resulting from Refer to proceedings
shimmy. for correction.
Nose gear fails to Oleo cylinder binding Lubricate strut housing
steer properly. in strut housing. (Refer to Lubrication
Chart).
Cylinder and/or strut
housing bushings
damaged.
One brake dragging. Determine cause and
correct.
Steering bellcrank loose Readjust bearing and/or
on attachment plate. bolt.
Steering bellcrank bearing Replace bearing and/or
and/or bolt worn. bolt.
Shimmy dampener galling Replace.
or binding.

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TABLE VII-II. TROUBLESHOOTING - LANDING GEAR (cont.)

Trouble Cause Remedy

Main landing gear Tire out of balance. Check balance and replace
shimmies during fast taxi, tire if necessary.
takeoff or landing.
Worn or loose wheel Replace and/or adjust
bearings. wheel bearings.
Loose torque links. Adjust side play.
Worn torque link bolts Replace bolts and/or
and/or bushings. bushings.
Excessive or uneven wear Incorrect operating Inflate tire to correct
on main tires. pressure. pressure.
Wheel out of alignment Check wheel alignment.
(toe in or out).

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SECTION VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R)

TABLE OF CONTENTS

Paragraph Grid No.

7A-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H4

7A-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H4
7A-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H6
7A-4. Landing Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H6
7A-5. Nose Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H6
7A-6. Disassembly of Nose Gear Oleo . . . . . . . . . . . . . . . . . . . . . . . . . . 2H6
7A-7. Cleaning, Inspection and Repair of Nose Gear Oleo . . . . . . . . . . . 2H7
7A-8. Assembly of Nose Gear Oleo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H7
7A-9. Removal of Nose Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 2H10
7A-10. Cleaning, Inspection, and Repair of Nose Landing Gear . . . . . . . 2H13
7A-11. Installation of Nose Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . 2H14
7A-12. Adjustment of Nose Landing Gear (Without Gear Up Stop) . . . . 2H15
7A-13. Adjustment of Nose Landing Gear (With Gear Up Stop) . . . . . . . 2H17
7A-13a. Adjustment of Nose Landing Gear (With Gear Up Stop) . . . . . . . 2H17
7A-14. Alignment of Nose Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . 2H18
7A-15. Removal of Nose Gear Door Assembly . . . . . . . . . . . . . . . . . . . . . 2H20
7A-16. Cleaning, Inspection and Repair of Nose Gear Door Assembly . . 2H21
7A-17. Installation of Nose Gear Door Assembly . . . . . . . . . . . . . . . . . . . 2H21
7A-18. Adjustment of Nose Gear Doors . . . . . . . . . . . . . . . . . . . . . . . . . . 2H21
7A-19. Main Landing Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H22
7A-20. Disassembly of Main Gear Oleo . . . . . . . . . . . . . . . . . . . . . . . . . . 2H22
7A-21. Cleaning, Inspection and Repair of Main Gear Oleo . . . . . . . . . . 2H22
7A-22. Assembly of Main Gear Oleo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H23
7A-23. Removal of Main Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 2I2
7A-24. Cleaning, Inspection and Repair of Main Landing Gear . . . . . . . . 2I5
7A-24a. Main Landing Gear Trunnion Repair . . . . . . . . . . . . . . . . . . . . . . 2I7
7A-25. Installation of Main Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . 2I8
7A-26. Adjustment of Main Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . 2I9
7A-27. Alignment of Main Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . 2I11
7A-28. Removal of Main Gear Door Assembly . . . . . . . . . . . . . . . . . . . . 2I13
7A-29. Cleaning, Inspection and Repair of Main Gear Door Assembly . . 2I13
7A-30. Installation of Main Gear Door Assembly . . . . . . . . . . . . . . . . . . . 2I13
7A-31. Adjustment of Main Gear Door Assembly . . . . . . . . . . . . . . . . . . 2I14

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SECTION VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R)

TABLE OF CONTENTS (cont.)

Paragraph Grid No.

7A-32. Landing Gear Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I14

7A-33. Adjustment of Nose Gear Up Limit Switch . . . . . . . . . . . . . . . . . 2I14
7A-34. Adjustment of Nose Gear Down Limit Switch . . . . . . . . . . . . . . . 2I15
7A-35. Adjustment of Main Gear Up Limit Switch . . . . . . . . . . . . . . . . . 2I16
7A-36. Adjustment of Main Gear Down Limit Switch . . . . . . . . . . . . . . . 2I16
7A-37. Adjustment of Landing Gear Safety Switch (Squat Switch) . . . . . 2I18
7A-38. Adjustment of Gear Back-Up Extender Actuator Switch . . . . . . . 2I18
7A-39. Landing Gear Warning Switches (Throttle Switches) . . . . . . . . . . . . . 2I18
7A-40. Landing Gear Up/Power Reduced Warning Switch . . . . . . . . . . . 2I18
7A-41. Removal of Landing Gear Up/Power Reduced Warning Switch . . 2I18
7A-42. Installation of Landing Gear Up/Power Reduced Warning Switch 2I18
7A-43. Adjustment of Landing Gear Up/Power Reduced Warning Switch 2I19
7A-44. Gear Down/ Selector Handle Up Warning Switch . . . . . . . . . . . . 2I20
7A-45. Removal of Gear Down/Selector Handle Up Warning Switch . . . 2I20
7A-46. Installation of Gear Down/Selector Handle Up Warning Switch . 2I20
7A-47. Adjustment of Gear Down/Selector Handle Up Warning Switch . 2I20
7A-48. Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I21
7A-49. Removal and Disassembly of Nose Wheel . . . . . . . . . . . . . . . . . . 2I21
7A-50. Inspection of Nose Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . 2I21
7A-51. Assembly and Installation of Nose Wheel . . . . . . . . . . . . . . . . . . . 2I21
7A-52. Removal and Disassembly of Main Wheel . . . . . . . . . . . . . . . . . . 2I23
7A-53. Inspection of Main Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . 2I24
7A-54. Assembly and Installation of Main Wheel . . . . . . . . . . . . . . . . . . 2I24
7A-55. Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I24
7A-56. Wheel Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I24
7A-57. Brake Adjustment and Lining Tolerance . . . . . . . . . . . . . . . . . . . . 2I24
7A-58. Removal and Disassembly of Wheel Brake Assembly . . . . . . . . . 2I24
7A-59. Cleaning, Inspection and Repair of Wheel Brake Assemblies . . . 2J2
7A-60. Assembly and Installation of Wheel Brake Assembly . . . . . . . . . . 2J2

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SECTION VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R)

TABLE OF CONTENTS (cont.)

Paragraph Grid No.

7A-61. Brake Master Cylinder (Hand Parking Brake) . . . . . . . . . . . . . . . . . . 2J2

7A-62. Removal of Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 2J3
7A-63. Disassembly of Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . 2J4
7A-64. Cleaning, Inspection and Repair of Brake
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J4
7A-65. Assembly of Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 2J4
7A-66. Installation of Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . 2J5
7A-67. Brake Cylinder (Toe Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J7
7A-68. Removal of Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J7
7A-69. Disassembly of Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 2J7
7A-70. Cleaning, Inspection and Repair of Brake
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J8
7A-71. Assembly of Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J9
7A-72. Installation of Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J10
7A-73. Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J10
7A-74. Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J10
7A-75. Nose Gear Service Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J20
7A-76. Main Gear Service Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J23

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Figure 7A-2. Nose Gear Installation (Sheet 1 of 2)

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67147 AE 13 76426 BH 13
(BOLT, AN26-25 (BOLT, AN6-14A
WASHER, NAS1149F0663P WASHER, MS35335-35
(UNDER HEAD) (UNDER HEAD)
BEARING, 65003-15 BEARING, 65003-15
NUT, AN320-6 NUT, MS21042-6
COTTER PIN, MS24665-285

WASHERS, 62833-10 WASHERS, 62833-10

(3 REQ., SEE NOTE) (3 REQ., SEE NOTE)
4 55 55
(STEERING BELLCRANK) (ENGINE MOUNT) 4 (ENGINE MOUNT)
(STEERING BELLCRANK)

VIEW B VIEW C
LOOKING AFT LOOKING AFT
PA-28R-180 PA-28R-200
PA-28R-200 (1968 THRU 1971) (1972 AND UP)

NOTE: If the top of the steering bellcrank (4) cam is above the top of the steering arm bushing (5),
move one washer from below steering bellcrank to above (i.e., under nut).

Figure 7A-2. Nose Gear Installation (Sheet 2 of 2)

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c. The drag links (32 and 35) and gear tension spring arm (53) may be installed by the following
procedure:
1. Ascertain that the upper and lower links (32 and 35) are assembled with the downlock hook
attached, and the through travel of the links checked according to paragraph 7A-10.
2. Position the link assembly to allow the bolt holes in the links to align with the bolt holes in the
gear housing and the engine mount. Install the link attachment bolts.
3. Install nuts and washers on the upper link (35) attachment bolts. Tighten the nuts to allow the
links to rotate freely and safety.
4. Check alignment of the downlock hook to determine if it grips the roller bearing so as not to
contact the bolt head, the bearing attachment block or washer. If the downlock hook is inboard,
or it contacts the bolt head, shim between the bearing and the bearing attachment block with
washer AN960-10L, not to exceed three. The bearing must be free to rotate, therefore, it may
be necessary to replace the bearing retaining bolt with longer bolt, AN23-36A, depending on
the number of washers used. Should the downlock hook be onboard, or in contact with the
bearing attachment block, add one washer, P/N 62833-40 of P/N 62833-41 between the engine
mount (55) and upper drag link (35). Washer, P/N 6283341, is to be tried first.
5. Install the gear tension spring arm (53) on the drag link bolt (29) on the right side of the gear
oleo housing (54), secure and safety. A washer is installed on the bolt between the lower drag
link and the arm.
d. Retract and extend the landing gear several times to ascertain smoothness of operation. Also check
that the drag link assembly falls into the through center-locked position.
e. Retract the gear and connect the gear downlock spring (42) between the downlock hook (43) and
the upper drag link (35).
f. Extend the gear and connect the two gear tension springs (15 and 17) between the attachment point
on the oleo housing (54) and the spring arm (53).
g. Ascertain that the landing gear is lubricated per Lubrication Chart, Section II.
h. Check adjustment of the gear per paragraph 7A-12, 7A-13, or 7A-13a.
i. Install engine cowling. (The cowl support jacks located at each forward side of the nose gear door
hinges are adjusted down to contact the cowl surface after attaching screws are secure.)
j. Retract landing gear and check door operation as per paragraph 7A-18.
k. Check the alignment of the nose gear per paragraph 7A-14.
1. Remove the airplane from jacks.
7A-12. ADJUSTMENT OF NOSE LANDING GEAR (Without Gear Up Stop). (Refer. to Figure 7A-3.)
a. Place the airplane on jacks. (Refer to Jacking, Section II. )
b. With the gear extended, disconnect the nose gear door retraction rods from each door by removing
the rod attaching bolts. If desired, the lower engine cowl may be removed to facilitate easier access
for adjustments.
c. Retract the landing gear hydro-electrically by turning the master switch on, raising the emergency
gear extension lever and moving the gear selector handle to the up position. Retain the emergency
extension lever in the up override position.
d. Clearance between the strut housing (10) and the cross-over tube (2) where the steering bellcrank
(1) attaches should be 0.015 ± 0.003 of an inch with the piston of the actuator cylinder bottomed.
Should this dimension be incorrect and it will require more than 0.010 of an inch to bring the
housing to the correct clearance, then block the gear in the up position, disconnect the piston rod
end bearing from the downlock by removing the attaching bolt, loosen the jam nut on the end
bearing to obtain correct adjustment. Reinstall attaching bolt and safety.

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Figure 7A-3. Nose Gear Adjustment (Without Gear Up Stop)

Figure 7A-4. Nose Gear Adjustment (With Gear Up Stop)

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When adjustment requires less than 0.010 of an inch, the rod end bearing need not be disconnected
and therefore all that will be required is to loosen the jam nut, place a wrench on the flat at the end
of the piston rod and turn to obtain the correct adjustment.
e. Check rod end bearing for adequate thread engagement and tighten jam nut.
f. With gear extended, adjust shimmy dampener by turning nose wheel against stops and adjusting rod
end for adequate travel for both extremes.
g. Install engine cowling, retract and cycle landing gear, including free-fall, and rig nose gear door per
paragraph 7A-18.
h. Verify gear are down and locked and remove the airplane from jacks.
7A-13. ADJUSTMENT OF NOSE LANDING GEAR (With Gear Up Stop, except as noted below.)
NOTE: For PA-28R-200s S/N’s 28R-7635522 thru 28R-7635545 with a modified Gar Kenyon actuator
installed, per Piper Service Bulletin No. 724A, see paragraph 7A-13a, below.
The gear up stop (4) is located just above the gear door retraction roller near the lower aft end of the
engine. (Refer to Figure 7A-4.)
a. Remove the engine cowl. For removal instructions, refer to paragraph 7A-9, step a.
b. Place the airplane on jacks. (Refer to Jacking, Section II.)
c. Retract the landing gear hydro-electrically by turning the master switch on, raising the emergency
gear extension lever and moving the gear selector handle to the UP position. Retain the emergency
extension lever in the UP Override position.
d. Check the adjustment of the gear up stop by placing a carpenters square with the longest end along the
bottom of the fuselage, and the shortest end running up through the centerline of the wheel axle. Measure
up along the square from the bottom of the fuselage 6.25 ± 0.25 inches, to determine if the center of the
wheel axle meets this measurement. If this measurement is incorrect, extend the gear, loosen the jam nut
(5) on the gear up stop, and make the required adjustment by turning the stop.
e. Check the adjustment of the hydraulic cylinder by extending the gear and removing the nut and bolt
(9) from the rod end bearing (8). Loosen the jam nut that secures the rod end bearing and turn the
rod end approximately one thread in past the safety hole on the cylinder rod (6).
f. Hook up cylinder rod end bearing and retract gear. Recheck all adjustments and retighten the jam
nut on the gear up stop. When the gear is fully retracted, the upper drag link (3) should be firmly
against the gear up stop. Extend the gear.
g. Adjust shimmy dampener by turning nose wheel against stops and adjusting the rod end of the
dampener for adequate travel to both extremes.
h. Install engine cowling, retract and cycle landing gear, including free-fall, and rig nose gear door per
paragraph 7A-18.
i. Verify gear are down and locked and remove the airplane from jacks.
7A-13a. ADJUSTMENT OF NOSE LANDING GEAR (With Gear Up Stop, as noted below only.)
NOTE: Paragraph 7A-13a applies only to PA-28R-200s S/N’s 28R-7635522 thru 28R-7635545 with a
modified Gar Kenyon actuator installed, per Piper Service Bulletin No. 724A.
The gear up stop (4) is located just above the gear door retraction roller near the lower aft end of the
engine. (Refer to Figure 7A-4.)
a. Remove the engine cowl. For removal instructions, refer to paragraph 7A-9, step a.
b. Place the airplane on jacks. (Refer to Jacking, Section II.)

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c. Loosen the jam nut on the rubber bumper stop and turn in approximately three (3) turns.
NOTE: Some aircraft are equipped with a large 1 l/8” diameter flat rubber stop. If these stops have
washers of any type between the jam nut and the threaded receptacle, remove these
washers and discard.
d. Operate pump to purge system of air and check fluid level in reservoir . Replenish as necessary.
e. Retract landing gear with care, by turning master switch ON, raising the emergency gear extension
lever and moving the gear selector handle to the UP position. Be sure that the actuator piston is
fully retracted (bottomed) before any part of the gear mechanism contacts adjacent parts.
NOTE: If the actuator piston needs adjustment, initially set rod end bearing midway between
witness hole and full engagement and reinstall on downlock hook.
f. Check 5.80” ± 0.12” dimension. (See Figure 7A-4.) Adjust piston rod end to obtain this dimension.
NOTE: Be sure gear retraction is not being limited by rubber bumper. Turn bumper in further if
necessary.
g. With gear retracted and rigged to 5.80” ± 0.12” dimension, turn rubber bumper finger tight against
the upper drag link. Lower gear, extend bumper screw an additional one half turn and tighten jam
nut.
h. With gear down and locked, check to ensure that positive additional actuator rod travel is available
by removing rod end bolt and pulling piston out until it “bottoms.”
i. Check to ensure that rod end threads cover witness hole in the actuator rod.
j. Tighten jam nut on rod end bearing and complete hook-up of piston rod end bearing to downlock
hook.
k. Adjust shimmy dampener by turning nose wheel against stops and adjusting the rod end of the
dampener for adequate travel to both extremes.
l. Install engine cowling, retract and cycle landing gear, including free-fall, and rig nose gear door per
paragraph 7A-18.
m. Verify gear are down and locked and remove the airplane from jacks.
7A-14. ALIGNMENT OF NOSE LANDING GEAR. On 1974 models, the nose wheel steering has been
modified by the addition of the bungee system. This will require some different adjustment procedures
which are included with the regular instructions below.
a. Place the airplane on a smooth level floor that will accommodate the striking of a chalk line.
b. Ascertain that the nose gear is properly adjusted as given in paragraphs 7A-12, 7A-13, or 7A-13a,
above.
c. With the landing gear in the down-locked position, weight proportionally on the nose gear and the
nose wheel facing forward, adjust the steering bellcrank. The bellcrank is attached at the lower front
of the engine mount directly aft of the gear housing and may be adjusted by loosening its
attachment bolt and sliding the bellcrank fore and aft until it clears each steering arm rollers by 0.03
inch. Retighten the attachment bolt.
d. Place the airplane on jacks. (Refer to Jacking, Section II.)
e. Level the airplane laterally and longitudinally. (Refer to Leveling, Section II.)
f. From the center point of the tail skid, extend a plumb bob and mark the contact point on the floor.
g. Extend a chalk line from the mark on the floor below the tail skid to a point approximately three
feet forward of the nose wheel. Allow the line to pass under the wheel at the center line of the tire.
Snap the chalk line.
h. Clamp the rudder pedals to align then in a lateral position. Ascertain that the rudder pedals are in
there neutral position. (Refer to Figure 7A-6 and Table VII-I.)

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Figure 7A-5. Clamping Rudder Pedals Figure 7A-6. Rudder Pedals

in Neutral Position at Neutral Angle

i. Adjust the rod end bearings of each steering control rod to align the nose wheel with the chalk line
and to bring the rudder pedals into neutral angle fore and aft.
j. On 1974 models install the steering push rods on the pilot's rudder pedals. Adjust the rods so the
lengths are both the same and the rudder pedals are at their neutral position. (Refer to Table VII-I.)
k. To align the nose wheel straight forward, stand in front of the nose gear and align the center rib of
the tire with the chalk line, or lay a straight edge along the side of the tire and parallel the straight
edge with the chalk line.
l. On 1974 models install the nose wheel bungees in there neutral position (no load on the bungee
springs). Adjust bungee rod ends as necessary.
m. Place a bubble protractor against a rudder pedal steering tube to check the neutral angle for the
model being serviced as given in Table VII-I.
n. On earlier models, one end of each rod must be disconnected and the jam nuts loosened to make
any adjustments. Do not attempt to make the adjustment by means of one rod end bearing, but
divide the adjustment between the bearings at each end of each rod. Check that the rod ends have
sufficient thread engagement by ascertaining that a wire will not go through the check hole in the
rod. Reinstall the rods and tighten the jam nuts.
o. To check the nose gear steering for its maximum right and left travel, mark on each side of the nose
wheel an angle line from the center line and wheel pivot point. (Refer to Table VII-I for the nose
wheel turning angle of the model being serviced.) Turn the wheel to its maximum travel in both
directions to check for allowable travel. Should travel be exceeded in one direction and not enough
in the other direction, check for possible damage to the gear fork or torque links.

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7A-15. REMOVAL OF NOSE GEAR DOOR ASSEMBLY. (Refer to Figure 7A-7.)

a. With the nose gear extended, disconnect the door retraction rod (1) from the gear door (2) by
removing nut, bolt and washers. The bottom cowl may be removed to facilitate easier removal.
b. To remove the door(s) from the cowl, bend the end of the hinge pin straight and from the other end
pull out the pin.
c. The bellcrank assembly (4) of the door retraction mechanism may be removed by removing the
attached hardware, disconnecting the door down tension spring (3) and removing the cotter pins (8)
at each end of the pivot tube. Slide the insulating sleeve and bushing tube from the bellcrank.
d. The roller assembly (5) of the mechanism may be removed by removing the attached hardware and
pivot bolt with insulator.

Figure 7A-7. Nose Gear Door Retraction Mechanism

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7A-16. CLEANING, INSPECTION AND REPAIR OF NOSE GEAR DOOR ASSEMBLY.

a. Clean all parts with a suitable cleaning solvent.
b. Inspect doors for cracks or damage, loose or damaged hinges and brackets.
c. Inspect door retraction rods for damage and rod end bearing for corrosion.
d. Check the door tension spring for wear and tension below minimum allowable tolerance. Reject
spring if load tension is below 8.0 pounds pull at 4.75 inches.
e. Check general condition of bellcrank and roller assembly.
f. Repairs to the doors may be replacement of hinges, repair of fiberglass and painting.
g. Repairs to the retraction mechanism is limited to replacement of parts, and sanding and painting.
7A-17. INSTALLATION OF NOSE GEAR DOOR ASSEMBLY. (Refer to Figure 7A-7.)
a. The roller assembly (5) of the retraction mechanism may be installed by first assembling the roller
(6), threaded link (7) and roller links (5), and then installing this assembly on its mounting bracket.
Ascertain that an insulator sleeve is installed with the attachment bolt and link bolt.
b. The bellcrank assembly (4) of the retraction mechanism may be installed by positioning the
bellcrank between its mounting bushing and inserting the insulator sleeve and bushing tube. Install
a cotter pin through each attachment bushing and the pivot tube. New tubes will require a 0.070
hole drilled through each end to facilitate a cotter pin. Use the existing hole in the mounting
bushings as a guide. Do not connect link between roller assembly and bellcrank until time of door
adjustment.
c. Install the gear door(s) by positioning the hinge halves of the door and cowl, and inserting the hinge
pin. It is recommended a new pin be used. Bend the end of the pin to secure in place.
d. Install the cowl and adjust doors as given in paragraph 7A-18.
7A-18. ADJUSTMENT OF NOSE GEAR DOORS.
a. Place the airplane on jacks. (Refer to Jacking, Section II.)
b. Adjust the door retraction rods so that the gear will swing through the door opening with a .12 ± .06
of an inch clearance between the gear and door at their closest point. This can best be done with the
nose gear down, tension springs disconnected and operating the nose gear manually.
c. With door clearance adjusted, adjust the link between the roller assembly and bellcrank assembly so
that the doors will pull up tightly when gear is full up. Over-tightening may result in door buckling,
however if the link is too loose, doors will gap in flight.
d. Check all rod ends for adequate thread engagement, for safety and tightness of jam nuts.
e. Remove the airplane from jacks.

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7A-19. MAIN LANDING GEAR SYSTEM.

7A-20. DISASSEMBLY OF MAIN GEAR OLEO. (Refer to Figure 7A-8.) The main gear oleo assembly may
be removed and disassembled from the gear oleo housing with the gear removed from or installed on the
airplane.
a. Place the airplane on jacks. (Refer to Jacking, Section II.)
b. Place a drip pan under the main gear to catch spillage.
c. Remove the air and fluid from the oleo. To do this, depress the air valve core pin until strut pressure
has diminished, remove the filler plug and with a small hose siphon as much hydraulic fluid from
the strut as possible.
d. Disconnect the brake line at the joint located in the wheel well.
e. To remove piston tube (25) assembly from oleo housing (11), remove the upper and lower torque
link connecting bolt assembly (3) and separate the links. Note number and thickness of spacer
washer(s) between the two links (15 and 16).
f. Compress the piston tube (25), reach up along the tube and release the snap ring (24) from the
annular slot at the bottom of the oleo housing.
g. Pull the piston tube (25) with component parts from the cylinder housing.
h. The piston tube (25) components may be removed by reaching in the tube and pushing out the
upper bearing (18) retainer pins (17). Slide off the upper bearing (18), lower bearing (20) with “O”
rings (19 and 21), wiper (22), washer (23) and snap ring (24).
i. To remove the orifice tube (12) from the oleo housing, remove the lock nut (6) and washer (7) from
the top of the housing. Draw the tube with “O” ring (9) and retainer (8) from the housing.
j. The orifice plate (13) is removed from the bottom of the orifice tube (12) by releasing the snap ring
(14) that holds the plate in position.
k. To remove the piston tube plug (26) with “O” ring (27) located in the lower end of the tube, remove
the bolt assembly and insert a rod up through the hole in the body of the fork (28), pushing the plug
out through the top of the tube.
7A-21. CLEANING, INSPECTION AND REPAIR OF MAIN GEAR OLEO.
a. Clean all parts with a suitable dry type cleaning solvent.
b. Inspect the landing gear oleo assembly component for the following:
1. Bearings and bushings for excess wear, corrosion, scratches and overall damage.
2. Retaining pins for wear and damage.
3. Lock rings for cracks, burrs, etc.
4. Cylinder and orifice tube for corrosion, scratches, nicks and excess wear.
5. Orifice plate for hole restriction.
6. Fork tube for corrosion, scratches, nicks, dents and misalignment.
7. Air valve general condition.
c. Repair of the oleo is limited to smoothing out minor scratches, nicks and dents and replacement of
parts. (See Figure 7A-26 and Table VIIA-III for bearing replacement.)

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7A-22. ASSEMBLY OF MAIN GEAR OLEO. (Refer to Figure 7A-8.)

a. Ascertain that all parts are cleaned and inspected.
b. To install the piston tube plug (26), first lubricate the plug “O” ring (27) with hydraulic fluid (MIL-
PRF-5606) and install it on the plug. Lubricate the inside wall of the tube. Insert the plug into the
top of the tube (25) and push it to the fork end. Align the bolt holes of the fork, tube and plug, and
install bolt assembly.
c. If desired, cement a cork in the hole in the bottom of the fork body to prevent dirt from entering
between the fork and tube.
d. To assemble the components of the orifice tube (12) insert the orifice plate (13) into the bottom of
the tube and secure with snap ring (14).
e. To install the tube (12) in the oleo housing (11), insert the tube up through the housing. With the
end of the tube exposed through the top of the housing, install the “O” ring (9), retainer (8), washer
(7), and lock nut (6). Tighten lock nut only finger tight at this time.
f. Assemble the components of the piston tube (25) on the tube by placing, in order, the snap ring
(24), washer (23), lower bearing (20) with outer and inner “O” rings (19 and 21) and upper bearing
(18). Align the two .125 diameter holes and the lock pin holes with the corresponding holes in the
piston tube (25) and install pins (17) without force. The outer surface of the pins must not protrude
beyond the outer diameter of the bearing (18).
g. Lubricate the wall of the cylinder oleo housing (11) and tube (25), and carefully insert the tube
assembly into the housing, guiding the orifice tube (12) into the piston tube until the snap ring (24)
can be installed in the annular slot at the lower end of the housing. Install the wiper strip (22); slide
the washer (23) into position and secure the assembly with snap ring (24).
h. At the top of the housing, tighten the lock nut (6).
i. Ascertain that the bushings are installed in the upper and lower torque links (15 and 16) and then
install links. The torque link bolt assemblies (2, 3 and 4) should be lubricated and installed with the
flat of the bolt head hex adjacent to the milled stop of the wide end of the link. (Use the same
thickness of spacer washers between the two links as those removed to maintain correct wheel
alignment.) Tighten the bolts only tight enough to allow no side play in the links, yet be free enough
to rotate.
j. Connect the brake line and bleed the brakes per paragraph 7A-73.
k. Lubricate the gear assembly. (Refer to Lubrication Chart, Section II.)
l. Compress and extend the strut several times to ascertain that the strut will operate freely. The
weight of the gear wheel and fork should allow the strut to extend.
m. Service the oleo strut with fluid and air. (Refer to Oleo Struts, Section II.)
n. Check main gear alignment (refer to paragraph 7A-27) and gear operation.
o. Remove the airplane from jacks.

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Figure 7A-8. Main Gear Oleo Strut Assembly (Sheet 1 of 2)

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Figure 7A-8. Main Gear Oleo Strut Assembly (Sheet 2 of 2)

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7A-23. REMOVAL OF MAIN LANDING GEAR. (Refer to Figure 7A-9.)

a. Place the airplane on jacks. (Refer to Jacking, Section II.)
b. The side brace link assembly may be removed by the following procedure:
1. With the gear in the extended position, disconnect the gear downlock spring (18).
2. Disconnect the rod end (46) of the actuating cylinder (24) from the retraction fitting (21) of the
upper side brace link (28) by removing the nut, washer and bolt (47) with bushing and spring
swivel (20).
3. Disconnect the lower side brace link (33) from the gear housing (13) by removing the
attachment nut, washer and bolt (7). Note bushings on each side of the end bearing.
4. Disconnect the upper side brace link (28) from the side brace support fitting stud (26) by
removing the cotter pin, nut, washer and attachment bolt (25).
5. The side brace support fitting may be removed by removing the cap bolts that secure the fitting
to the web of the spar.
6. Remove the assembly, and further disassemble and inspect as needed.
c. The landing gear housing (13) with components may be removed by the following procedure:
1. Disconnect the brake line (42) at its upper end in the wheel well.
2. Disconnect the gear door actuating rod (38) at the gear housing.
3. Remove the access plate located on the underside of the wing, aft of landing gear.
4. If not previously disconnected, disconnect the lower side brace link (33) from the gear
housing.
5. Disconnect the forward support fitting (16) of the housing (13) from the web of the main spar
by removing the fitting attachment bolts.
6. Remove the retainer tube (4) in the aft support fitting (1) that supports the aft arm of the
housing by reaching through the access opening on the underside of the wing, through the hole
in the web and removing the bolt (48) that secures the tube in the housing. Insert a hook
through the bolt hole in the tube, and slide it aft from the support fitting. Remove the tube from
the wing. Note the number of spacer washers (52) between the arm and support fitting (1).
7. Allow the gear to drop down removing it from the wing.
8. The aft support fitting (1) may be removed by holding the nuts, reaching through the access
opening, and removing the fitting attachment bolts.
9. The forward support fitting (16) may be removed from the arm of the housing by removing the
bolt and washer from the base side of the fitting. Slide the fitting from the arm. Remove the
washer (52) from the arm.
d. Either bearing (53 or 54) installed in the support fittings may be removed by removing the snap
rings (2) that hold the bearing in the housing. Push the bearing from the housing.

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Figure 7A-9. Main Gear Installation (Sheet 1 of 2)

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Figure 7A-9. Main Gear Installation (Sheet 2 of 2)

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7A-24. CLEANING, INSPECTION AND REPAIR OF MAIN LANDING GEAR.

a. Clean all parts with a suitable dry type cleaning solvent.
b. Inspect the gear components for the following unfavorable conditions:
1. Bolts, bearing and bushings for excess wear, corrosion and damage.
2. Gear housing, side brace links, torque links and attachment plates for cracks, bends or
misalignment.
3. Downlock hook for excessive wear of the bearing surfaces.
c. Inspect the gear downlock spring for the following:
1. Excessive wear or corrosion, especially around the hook portion of the spring. A spring should
be rejected if wear or corrosion exceeds one-quarter the diameter of the spring. Clean away all
corrosion and repaint.
2. Check the spring for load tensions below minimum allowable tolerance. The minimum tension
of the spring is 48 pounds pull at 7.9 inches. Measurement is taken from the inner side of each
hook.
d. Check the general condition of each limit switch and its actuator, and wiring for fraying, poor
connections or conditions that may lead to failures.
e. Check side brace link through center travel by attaching the upper and lower links, setting them on
a surface table, and ascertaining that when the stop surfaces of the two links touch, linkage is not
less than .062 nor more than .125 of an inch though center. Should the distance exceed the required
through center travel and bolt and bushings are tight, replace one or both links.
f. With the side brace links assembled and checked, ascertain that when the stop surfaces of the two
links contact, the clearance between each downlock hook and the flat of the downlock pin is not
less than 0.010 of an inch. Should clearance be less than that required, the hook only may be filed
not to exceed a gap of more than 0.025 of an inch. The maximum allowable clearance between each
hook and the downlock pin that are service worn is 0.055 of an inch. Should clearance be more than
0.055 of an inch, replace the pin, check clearance and then if still beyond tolerance, replace hooks.
The gap between each hook should be equal.
g. Repair of the landing gear is limited to reconditioning of parts such as replacing components,
bearings and bushings, smoothing out minor nicks and scratches and repainting areas where paint
has chipped or peeled.

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Figure 7A-9a. Main Landing Gear Trunnion Repair

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7A-24a.MAIN LANDING GEAR TRUNNION REPAIR. (Refer to Figure 7A-9a.)

NOTE: This procedure applies only to PA-28R-180 S/N’s 28R-30005 thru 28R-7130007 and PA-28R-
200 S/N’s 28R-35001 thru 28R-7135131 which had Trunnion Assemblies part numbers 67735-
00V (left) and -0lV (right) factory installed.
These repair instructions will apply if cracks are discovered in the trunnion web during a routine landing
gear system 100-hour or annual inspection.
a. Remove AN526 screw which holds part number 63900-11 bushing and clamps to the part number
67735-00 or 67735-01 trunnion web; this exposes the existing .191 inch hole.
b. Add a .191 inch hole in the location shown on Figure 7A-9a and deburr the hole.
c. Enlarge the former .191 inch hole to .500 inch diameter and remove material from web as shown on
Figure 7A-9a. Deburr edges where material is removed and polish cutout to remove all scratches;
nicks and irregularities.
d. Reinspect edges of cutout with dye penetrant method to ensure that the crack has been fully
removed. If the crack has not been fully removed, the trunnion must be replaced (part numbers
67716-04V (left) and 67716-05V (right)).
e. Reattach the part numbers 63900-11 bushing and clamps to the new .191 inch hole with an AN23-
10A clevis bolt and an AN365-Cl032 self locking nut.
f. The repaired trunnion web should be reinspected for cracks by the dye penetrant method at every
l00-hour inspection or annual inspection. Should cracks reappear, the trunnion must be replaced.
g. Make appropriate log book entry.

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7A-25. INSTALLATION OF MAIN LANDING GEAR. (Refer to Figure 7A-9.)

NOTE: When assembling components of the landing gear, lubricate bearings, bushings and friction
surfaces with proper lubricant as described in Section II.
a. Insert a gear support bearing (53 or 54) in each support fitting (1 or 16) and secure with snap rings
(2). Check bearing (53) for excess end play, shim as necessary with shim washers (49) (P/N 62833-
44).
b. The gear housing may be installed in the wheel well of the wing by the following procedure:
1. Place a spacer washer (52) and then the forward support fitting (16) on the forward arm of the
housing. Ascertain that the barrel nut (55) is positioned in the arm and insert the attachment
bolt through washer (51) and the fitting into the arm. Tighten bolt and ascertain that the
bearing is free to rotate.
2. Position the aft support fitting (1) at its attachment point in the wheel well and secure with
bolts, washers and nuts. Install the nuts and washers by reaching through the access hole on the
underside of the wing.
3. With the retainer tube (4) for the aft arm of the housing in hand, reach up through the access
opening and insert the tube into the support fitting (1) through the hole in the web.
4. Position the gear housing up in the wheel well and install the forward support fitting (16) bolts
and washers. (One each AN960-416 and AN960-416L washer per bolt.)
5. Push the retainer tube into the arm of the housing and secure with bolt.
6. Check that the gear rotates freely in its support fittings and recheck thrust.
7. Connect the brake line to its mating line in the wheel well and bleed brakes as given in
paragraph 7A-73.
c. The gear side brace link assembly may be installed by the following procedure:
1. Position the link support bracket (27) with swivel stud (26) installed at its attachment point on
the web of the spar and secure with bolts and washers.
NOTE: When installing a new wing, it will be necessary to back drill two (2) holes 0.250 inch
and countersink 100° x .499 through the spar cap. (Screw head should be flush with
spar). Use hole in the support bracket as a guide in the drilling.
2. Ascertain that the upper and lower links (28 and 33) are assembled with downlock hook (30),
retraction fitting (21), etc. attached, and the through travel of the links and downlock hook
clearance checked according to paragraph 7A-24.
3. Attach the upper link to the swivel stud of the support fitting and secure with bolt, bushing,
washer, nut and cotter pin.
4. The actuating cylinder rod end bearing (46) and lower side brace link (33) may be attached
respectively to the retraction fitting (21) and gear housing during the adjustment of the landing
gear.
d. Ascertain that the landing gear is lubricated per Lubrication Chart.
e. Check adjustment of the landing gear per paragraph 7A-26.
f. Check alignment of the wheel per paragraph 7A-27.
g. Install the access plate on the underside of the wing and remove the airplane from jacks.

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7A-26. ADJUSTMENT OF MAIN LANDING GEAR.

a. Place the airplane on jacks. (Refer to Jacking, Section II.)
b. Level the airplane laterally and longitudinally. (Refer to Leveling, Section II.)
c. Disconnect the gear door actuating rods at either the door or the housing, as desired, by removing
the rod attachment bolt. Secure the door out of the way.
d. Adjust the gear oleo housing to obtain a vertical position with the airplane level (90 degrees to
horizontal). To do this, set 90 degrees on a bubble protractor, place the protractor along the side of
the gear piston tube and adjust the end bearing of the lower side brace link allowing the bubble of
the protractor to center when the end bearing is connected to the gear housing. This should allow an
angle of 83 degrees between the gear housing and the spar cap of the wing. Place a bushing on each
side of the end bearing and secure with bolt, washer and nut.
e. Check that the rod end has sufficient thread engagement in the end bearing, align the flat sides of
the bearing casting with the flat side of the bearing and tighten the jam nut.
f. Adjust the turnbuckle of the downlock mechanism by first ascertaining that the gear is down and
locked, and then move the retraction fitting outboard until it contacts the stop slot of the side brace
link. Hold the fitting in this position and turn the turnbuckle barrel until the downlock hooks make
contact with the lock pin. Safety the turnbuckle.
g. For easier adjustment of the downlock limit switch, it may be set at this time as given in paragraph
7A-36.
h. Retract and extend the gear manually several times to ascertain that the side brace link falls through
center, the downlock hook falls into position and there is no binding of the gear assembly.
i. The gear should be adjusted in the up position to allow the gear fork to press lightly into the rubber
bumper pad on the wing. The adjustment may be accomplished as follows:
NOTE: If it requires less than .025 of an inch to move the gear into the correct adjustment, steps 2
and 6 thru 8 need only be followed.
1. Ascertain that the rod end bearing of the actuating cylinder is disconnected from the retraction
fitting.
2. Actuate the hydraulic system to bring the hydraulic cylinder to the up position by turning the
master switch on, raising the emergency gear extension lever and moving the gear selector
handle to the up position. Retain the emergency extension lever in the up override position.
The piston of the cylinder should be bottomed.
3. Raise the gear by pushing up on the retraction fitting, thus disengaging the hooks, and pushing
up on the pivot point at the bottom of the side brace links to bring the links out of the locked
position. Raise the gear until the fork presses, lightly into the rubber pad. Retain the gear in
this position.

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then the outer half.

e. The wheel bearing assemblies may be removed from each wheel half by first removing the snap
rings (1 or 14) that secure the grease seal retainers (2 or 13), and then the retainers, grease seals (4
or 11) and bearing cones (6 or 10). The bearing cups (5 or 9) should not be removed only for
replacement and may be removed by tapping out evenly from the inside.

7A-53. INSPECTION OF MAIN WHEEL ASSEMBLY. The inspection of the main wheel is the same as that
given for the nose wheel, paragraph 7A-50.

7A-54. ASSEMBLY AND INSTALLATION OF MAIN WHEEL. (Refer to Figure 7A- 16)
a. Ascertain that the bearing cup (5 or 9) for each wheel is properly installed. Install the tire with tube
on the outer wheel half (7) and then join the two wheel halves. Position the brake disc (15) in the
inner wheel half and install the through bolts with the nuts on the valve stem side. Torque wheel
nuts to 150 inch-pounds and inflate tire.
b. Lubricate the bearing cones (6 or 10) and install the cones, grease seals (4 or 11), seal retainer rings
(2 or 13) and felt rings (3 or 12). Secure with snap rings (1 or 14).
c. Slide the wheel on the axle and secure with retainer nut. Tighten the nut to allow no side play, yet
allow the wheel to rotate freely. Safety the nut with a cotter pin and install dust cover.
d. Position the brake lining back plates between the wheel and brake disc and the brake cylinder on
the torque plate. Insert the spacer blocks between the back plates and cylinder, and install the four
bolts to secure the assembly. If the brake line was disconnected, reconnect the line and bleed the
brakes.

7A-55. BRAKE SYSTEM.

7A-56. WHEEL BRAKE ASSEMBLY.

7A -57. BRAKE ADJUSTMENT AND LINING TOLERANCE. No adjustment of the brake lining clearance
is necessary as they are self adjusting. Inspection of the lining is necessary, and it may be inspected
visually while installed on the airplane. The linings are of the riveted type and should be replaced if the
thickness of any one segment becomes worn below 0.097 inch or unevenly worn.

7A-58. REMOVAL AND DISASSEMBLY OF WHEEL BRAKE ASSEMBLY. (Refer to Figure 7A-17.)
a. To remove the brake assembly, first disconnect the brake line from the brake cylinder at the tube
fitting (4).
b. Remove the four cap bolts (1) that join the brake cylinder housing (3) and the lining back plate
assemblies (1 and 13). Remove the back plate from between the brake disc and wheel.

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Figure 7A-17. Wheel Brake Assembly

c. Slide the brake cylinder housing (3) from the torque plate.
d. Remove pressure plate (8) by sliding it off anchor bolts (15) of the housing.
e. The pistons may be removed by injecting low air pressure in the cylinder fluid inlet and forcing the
pistons from the housing.

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7A-59. CLEANING, INSPECTION AND REPAIR OF WHEEL BRAKE ASSEMBLIES.

a. Clean the assembly with a suitable solvent and dry thoroughly.
b. Check the walls of the cylinder housing and pistons for scratches, burrs, corrosion, etc., that may
damage O-rings.
c. Check the general condition of the brake bleeder screw and lines.
d. Check the brake disc for grooves. scratches, pits or coning. Coning beyond .015 in either direction
would be cause for replacement. The minimum dimension of Disc 164-19 used on Wheel Assembly
40-84 is .227, and Disc 164-20 used on Wheel Assembly 40-86B is .205. (Refer to Figure 7A-18.)
A single groove or isolated grooves up to .031 of an inch deep would not necessitate replacement,
but a grooving of the entire surface would reduce lining life.
For a light powdery rust coating on the brake disc, perform one or two light taxi-braking
applications to remove it. A heavier coating of rust may require removal of the disc so that it may be
wire-brushed and then sanded with 220 grit sandpaper.
e. Lining may be removed from the backing plates by drilling or punching out the old rivets, and
installing a new set using the proper rivets and a rivet set that will properly stake the lining and form
a correct flair of the rivet.
f. After replacing brake linings, condition them by performing a minimum of six light pedal effort
braking applications from 25 to 40 MPH, allowing the brake discs to partially cool between stops.

7A-60. ASSEMBLY AND INSTALLATION OF WHEEL BRAKE ASSEMBLY. (Refer to Figure 7A-17.)
NOTE: In PA-28R-200, S/N’s 28R-7635001 and up, current (circa 2003) service replacement brake
assemblies, P/N 551-711 (PS50121-1), are delivered configured for installation on the left gear
assembly. To install on the right gear assembly, remove the bleeder seat, cap and screw from the
upper port on the cylinder assembly and install them on the lower port. Torque bleeder seat to
70-90 in.-lbs. (Reference: 67927 AU.)
a. Lubricate the piston O-rings (7 and 17) with fluid MIL-PRF-5606 and install on pistons (6 and 18).
Slide the pistons in cylinder housing until flush with surface of housing.
b. Slide the lining pressure plate (8) onto the anchor bolts(15) of the housing.
c. Slide the cylinder housing assembly on the torque plate of the gear.
d. Position the lining back plates (11 and 13) between the wheel and brake disc. Insert the shim blocks
(5) between the back plates and cylinder, and install the four bolts to secure the assembly.
e. Connect the brake line to the brake cylinder housing.
f. Bleed the brake system as described in paragraph 7A-73.

7A-61. BRAKE MASTER CYLINDER (Hand Parking Brake).

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Figure 7A-18. Brake Disc Minimum Thickness

Figure 7A-19. Brake System Installation

7A-62. REMOVAL OF BRAKE MASTER CYLINDER. (Refer to Figure 7A-19.)

a. To remove the brake master cylinder (8) first disconnect the inlet supply line (13) from the fitting at
the top of the cylinder and allow fluid to drain from the reservoir and line into a suitable container.
b. Disconnect the pressure line from the fitting at the bottom of the cylinder and allow fluid to drain
from the cylinder line.
c. Disconnect the end of the cylinder rod from the brake handle (6) by removing the cotter pin that
safeties the connecting clevis pin (12). Remove the clevis pin and spacer washers.
d. Disconnect the base of the cylinder from its mounting bracket by removing the attachment bolt
assembly (11).

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7A-72. INSTALLATION OF BRAKE CYLINDER. (Refer to Figure 7A-21.)

a. Position the cylinder (14) at its mounting points and attach with clevis pin. Safety the pins with
cotter pins. (See 16, Figure 7A-21.)
b. Connect the brake lines to the cylinder fittings.
c. Bleed the brakes per Paragraph 7A-73.

7A-73. BLEEDING PROCEDURE. When it becomes necessary to bleed the brake system, refer to Section
VII, paragraphs 7-52 through 7-55.

7A-74. BEARING REPLACEMENT. (Refer to Figure 7A-24.) When it becomes necessary to replace a
bearing in any link attachment housing, follow instructions listed below:
a. Remove bearings being replaced.
NOTE: An individual bearing can be removed and replaced only if existing boss includes the .089
grease hole (noted in illustration). If existing boss does not include the .089 grease hole,
both bearings on a boss must be removed and the .089 grease hole added before installing
the new bearings.

Figure 7A-23. Brake Cylinder

(10-30) (Toe Brake)

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TABLE VIIA-III. PA-28R MAIN GEAR SERVICE TOLERANCES (cont.)

Manufacturer Service Service

Fig. No. Part No. Nomenclature Dimension Dimension Tolerance Remarks

16 67716-04 Trunnion housing, ID .7508 ID .749 +0.0 .003

67716-05 side brace attachment .7513 .752

17 67026-05 Bushing, trunnion ID .499 ID .498 .004 Install bearing

.500 .502 with wet zinc
chromate on
adjacent sur-
faces of bear-
ings and
casting.
or, if service trunnion P/N 67926-040 or 67926-041 installed, then:
67026-17 Bushing, trunnion ID .4975
.4990

18 400-810 Bolt, trunnion/side OD .497 +0.0 OD .497 +0.0 .004

(AN28-50A) brace attaching -0.002 -0.004

19 67716-04 Trunnion housing, ID .4385 ID .4395 .0025

67716-05 torquelink attachment .4370 .4370

20 67026-07 (2) Bearing, trunnion ** ID .312 ID .312 .002 Press fit

.313 .314

21 67037-00 Strut Assembly ID .4385 ID .4395 .0025

67037-01 .4370 .4370

22 67026-07 (2) Bearing, strut ** ID .312 ID .312 .002 Press fit

.313 .314

23 67012-00 Torquelink (2) ID .312 +0.001 ID .312 +0.002 .002

-0.000 -0.000

24 67012-00 Torquelink (2) ID .3760 ID .3770 .0025

.3745 .3745

25 31796-00 (2) Bushing, torquelink ** ID .252 ID .253 .002 Press fit

.251 .251

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 PIPER CHEROKEE SERVICE MANUAL

SECTION VIII - POWER PLANT (PA-28)

TABLE OF CONTENTS

Paragraph Grid No.

8-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K4

8-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K4
8-3. Standard Practices – Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K6
8-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K6
8-5. Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K7
8-6. Removal of Propeller (Fixed Pitch) . . . . . . . . . . . . . . . . . . . . . . . 2K7
8-7. Cleaning. Inspection and Repair of Propeller . . . . . . . . . . . . . . . . 2K7
8-8. Installation of Propeller (Fixed Pitch) . . . . . . . . . . . . . . . . . . . . . 2K7
8-9. Removal of Propeller (Constant Speed) . . . . . . . . . . . . . . . . . . . . 2K10
8-10. Cleaning, Inspection and Repair of Propeller (Constant Speed) . 2K10
8-11. Installing Propeller (Constant Speed) . . . . . . . . . . . . . . . . . . . . . . 2K11
8-12. Blade Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K11
8-13. Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K12
8-14. Removal of Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . . 2K12
8-15. Installation of Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . 2K12
8-16. Rigging and Adjustment of Propeller Governor (PA-28-235) . . . 2K12
8-17. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K14
8-17a. Removal of Engine Cowlings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K14
8-17b. Installation of Engine Cowlings . . . . . . . . . . . . . . . . . . . . . . . . . . 2K14
8-17c. Installation of Bushings and Pins for Fiberglass Type Cowlings . 2K14
8-18. Removal of Engine (PA-28-140, -150, -160, -180) . . . . . . . . . . . 2K14
8-19. Installation of Engine (PA-28-140, -150, -160, -180) . . . . . . . . . . 2K15
8-20. Installation of Engine Shock Mounts
(PA-28-140, S/N’s 28-25000 and up) . . . . . . . . . . . . . . . . . . . . . . 2K19
8-21. Removal of Engine (PA-28-235) . . . . . . . . . . . . . . . . . . . . . . . . . 2K20
8-22. Installation of Engine (PA-28-235) . . . . . . . . . . . . . . . . . . . . . . . . 2K21
8-23. Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K23
8-24. Adjustment of Throttle and Mixture Controls . . . . . . . . . . . . . . . . . . . 2K23
8-25. Adjustment of Throttle and Mixture Controls
(PA-28-140, S/N’s 28-25000 and up),
(PA-28-180, S/N’s 28-4378 and up),
(PA-28-235, S/N’s 28-11040 and up) . . . . . . . . . . . . . . . . . . . . . . 2L1
8-26. Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L2
8-27. Carburetor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L2
8-28. Throttle Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L2
8-29. Adjustment of Idle Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L2
8-30. Adjustment of Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L4

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 PIPER CHEROKEE SERVICE MANUAL

SECTION VIII - POWER PLANT (PA-28)

TABLE OF CONTENTS (cont.)

Paragraph Grid No.

8-31. Magneto (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L4

8-32. Inspection of Magnetos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L4
8-33. Removal of Magnetos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L6
8-34. Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L7
8-35. Installation and Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . 2L9
8-36. Magneto (Slick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L11
8-37. Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L11
8-38. Inspection of Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L11
8-39. Removal of Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L11
8-40. Installation of Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L12
8-41. Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L12
8-42. Removal of Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L12
8-43. Inspection and Cleaning of Spark Plug . . . . . . . . . . . . . . . . . . . . 2L14
8-44. Installation of Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L14
8-45. Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L14
8-46. Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L14
8-47. Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L15
8-48. Removal of Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L15
8-49. Installation of Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L15

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f. Disconnect the cabin heat and defroster tubes from the muffler.
g. Disconnect the primer line at the tee connection.
h. Disconnect the throttle and mixture cables at the carburetor and carburetor heat control. The
carburetor may be removed if it is found desirable.
i. Disconnect the mechanical fuel pump supply line at the pump.

NOTE: When a question may arise as where to reconnect hose, line or wire, the item at the separation
should be identified (tagged) to facilitate reinstallation. Open fuel, oil, vacuum lines and fittings
should be capped to prevent contamination.

j. Disconnect the engine oil cooler lines from the cooler.

k. Disconnect the magneto “P” leads at the magnetos. Insert a protective cover over the connec-
tion.
l. Disconnect the engine oil temperature lead at the aft end of the engine.
m. Disconnect the tachometer drive cable from the rear of the engine.
n. Untie the ignition harness, hoses and lines from the aft end of the engine.
o. Disconnect the vacuum pump lines at the pump.
p. Disconnect the oil pressure line from the rear of the engine.
q. Disconnect the generator or alternator leads and the cable attachment clamps.
r. Attach a one-half ton (minimum) hoist to the hoisting straps and relieve the tension from the
mount.

NOTE: Place a tail stand under the tail of the airplane before removing the engine.

s. Check the engine for any attachments remaining to obstruct its removal.
t. Drain the engine oil, if desired, and close the drain.
u. Remove the four engine mount assemblies and swing the engine free, being careful not to dam-
age any attaching parts.

8-19 INSTALLATION OF ENGINE. (PA-28-140, -150, -160, -180) (refer to Figure 8-6 or 8-7)

a. Prior to installing the engine, be certain that all components of the engine such as exhaust
stacks, carburetor, etc. are installed.

NOTE: On PA-28-140 aircraft with serial numbers 28-25000 and up, refer to paragraph 8-20 and Figure
8-8 for shock mount installation instructions. When using these instructions, step c through e, of
paragraph 8-19 may be skipped.

NOTE: When installing an exhaust clamp having an alignment pin, be certain that the pin engages the
mating holes in exhaust pipe and muffler to prevent separation of components.

b. Attach a one-half ton (minimum) hoist to the engine hoisting straps and swing the engine into
alignment with its attaching points.
c. Insert an engine mount bolt, with washer against head, in the engine mount and slide half of the
mount assembly on the bolt. Repeat this procedure for the other three attachment points.
d. Position the mounting lugs of the engine so that they align with the engine mount attaching
points, than move the engine rearward onto the mounts.
e. Slide onto each mounting bolt a spacer washer, spacer and the forward half of the mount.
Install washer and nuts, and torque the nuts of the to 450 to 500 inch pounds.

Revised: 02/27/04 2K15 POWER PLANT

 PIPER CHEROKEE SERVICE MANUAL

f. Connect the generator or alternator leads and secure cables with clamps.
g. Connect the oil pressure line, tachometer drive cable, oil temperature lead and the engine vent tube
to the aft end of the engine.
h. Connect the vacuum pump line at the pump.
i. Secure the ignition harness, hoses and lines at the aft end of the engine using koroseal lacing.
j. Connect both lines to the oil cooler.
k. Connect the mechanical fuel pump supply line at the pump.
l. Connect the magneto “P” leads to the magnetos.
m. Connect the throttle, mixture and carburetor heat cables at the engine components.
n. Connect the cabin heat and defroster tubes to the muffler.
o. Connect the starter positive and ground leads at the starter and secure with attachment clamps.
p. Be certain that the magneto switches are OFF and install the propeller per paragraph 8-8.
q. Install the proper grade and amount of engine oil. Refer to Lubrication Chart, Section II.
r. Connect the battery ground wire at the battery.
s. Open the throttle and fuel valve completely. Turn on the electric fuel pump and check the fuel line
for leaks.
t. Install the engine cowlings and remove the tail stand.
NOTE: To avoid a possible high speed bearing failure resulting from a lack of lubrication during
initial starts, refer to the latest revision of Avco-Lycoming Service Instruction No. 1241 for
information on pre-oiling the engine.
u. Perform an engine operational check. Refer to the engine manufacturer’s appropriate operator’s
manual.
8-20. INSTALLATION OF ENGINE SHOCK MOUNTS. (PA-28-140, Serial Nos. 28-25000 and up.)
(Refer to Figure 8-8.)
a. Assemble the engine shock mounts on the engine mount as shown in Figure 8-8. Note the position
of each mount carefully. The upper right and lower left mounts are the same, as are the upper left
and lower right.
b. Swing the engine into place, positioning the engine mounting lugs so they align with the engine
mount attachment points.
c. Position the shock mount bolts through the mounting lugs and secure with nuts. Torque the nuts
progressively, following a circular sequence until a torque value of 450-500 inch pounds is reached.

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r. Connect the battery ground wire at the battery.

s. Open the throttle and fuel valve completely; turn on the electric fuel pump and check the fuel lines
for leaks.
t. Install the engine cowlings and remove the tail stand.
NOTE: To avoid a possible high speed bearing failure resulting from a lack of lubrication during
initial starts, refer to the latest revision of Avco-Lycoming Service Instruction No. 1241 for
information on pre-oiling the engine.
u. Perform an engine operational check. Refer to engine manufacturer’s appropriate operator’s
manual.
8-23. INSTALLATION OF OIL COOLER.
a. When installing fittings in the oil coolers, care should be used to prevent excessive torque being
applied to the cooler. When a rectangular fitting boss is provided, a backup wrench should be used,
employing a scissor motion, so that no load is transmitted to the cooler. When the oil cooler has a
round fitting boss, care should be taken not to permit excessive torque on the fittings.
b. If a pipe thread fitting is used, it should be installed only far enough to seal with sealing compound.
c. Apply Lubon No. 404 to all male pipe thread fittings; do not allow sealant to enter the system.
d. If fitting cannot be positioned correctly using a torque of 10 to 15 foot-pounds, another fitting
should be used.
e. When attaching lines to the cooler, a backup wrench should be used.
f. After installation, inspect the cooler for distorted end cups.
g. Run-up engine. After run-up, check for oil leaks.
8-24. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLS. (Refer to Figure 8-10.)
Throttle and mixture controls are adjusted so that when the throttle arm on the carburetor is rotated
forward against its full throttle stop and the mixture control is rotated forward against its full rich stop,
the cockpit control knobs of the throttle and mixture should have 0.062 to 0.125 of an inch spring back
when in the forward position.
a. The throttle may be adjusted as follows:
1. At the carburetor, disconnect the clevis end of the throttle control cable from the control arm.
Loosen the jam nut that secures the clevis end.
2. Adjust the linkage by rotating the clevis end on the cable to obtain 0.062 to 0.125 of an inch
spring back when the control is in the forward position.
3. Reconnect the clevis end to the control arm and safety.
b. The mixture may be adjusted as follows:
1. At the carburetor, loosen the swivel fitting that connects the wire of the control cable to the
mixture arm.
2. Reposition the fitting on the wire to obtain 0.062 to 0.125 of an inch spring back between the
knob and plate when the mixture control arm is against its stop.
3. Tighten the swivel fitting and safety. The control wire should be straightened to align with the
control cable casing after tightening the swivel fitting.

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Figure 8-10. Adjustment of Engine Controls

Figure 8-10a. Throttle/Mixture Control Ball Joint Inspection

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 PIPER CHEROKEE SERVICE MANUAL

c. Check security of cable casing attachments.

d. Pull throttle and mixture knobs in cockpit full aft to ascertain that the idle screw contacts its stop
and the mixture control arm contacts its lean position.
8-25. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLS. (PA-28-140, Serial Nos. 28-25000
and up; PA-28-180, Serial Nos. 28-4378 and up; PA-28-235, Serial Nos. 28-11040 and up.) (Refer to
Figure 8-10.)
Throttle and mixture controls are adjusted so that when the throttle arm on the carburetor is rotated
forward against its full throttle stop and the mixture control is rotated forward against its full rich stop,
the cockpit control levers of the throttle and mixture should have 0.010 to 0.030 of an inch spring back
when in the forward position.
a. The throttle may be adjusted as follows:
1. For PA-28-140 aircraft, S/N 28-25001 thru 28-7225373 with Kit 760 780 installed, ascertain
that there is some cushion at the throttle control handle in the cockpit with the throttle
completely closed. Check that the bearing on the carburetor end of the control cable has the
proper thread engagement by use of the inspection hole. Tighten the jam nut against the rod
end of the bearing.
2. For aircraft other than those listed in Step 1, proceed as follows:
(a) At the carburetor, disconnect the clevis end of the throttle control cable from the control
arm. Loosen the jam nut that secures the clevis end.
(b) Adjust the linkage by rotating the clevis end on the cable to obtain 0.010 to 0.030 of an
inch spring back on instrument stop when in full throttle position.
(c) Reconnect the clevis end to the control arm and safety.
b. The mixture may be adjusted as follows:
1. At the carburetor, disconnect the clevis end of the mixture control cable from the control arm.
Loosen the jam nut that secures the clevis end.
2. Adjust the linkage by rotating the clevis end on the cable to obtain 0.010 to 0.030 of an inch
spring back on the instrument panel stop when in full rich position.
3. On aircraft equipped with air conditioning systems, a micro switch is located below the throttle
control which is set to actuate in the full open position. With the throttle control adjusted to
obtain a clearance of 0.010 to 0.030, adjust the micro switch to actuate at this point also.
4. Reconnect the clevis end to the control arm and safety.
c. Check security of cable casing attachment.
d. Pull throttle and mixture levers in cockpit full aft to ascertain that the idle screw contacts its stop
and the mixture control arm contacts its lean position. On 1975 models and up, a mixture control
lock is incorporated in the quadrant cover which prevents the mixture control from being moved to
the idle cutoff position inadvertently. The lock must be depressed before the control can be moved
completely aft. Ascertain that the lock operates freely without any tendency to bind or hang up.

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Figure 8-16. Magneto Timing Marks Figure 8-17. Timing Pointer

8-34. TIMING PROCEDURE. (Internal Timing) (-20 and -200 Series Magnetos)
When installing new or adjusting breaker points and before timing the magneto to the engine, it is
important that the internal timing of the magneto be correct.
NOTE: Verify correct engine timing for the airplane being worked on by checking the engine dataplate.
a. To internally time the -20 series and the early -200 series magnetos without the case in timing
marks, the magneto should be removed from the engine to determine “E” gap.
b. To determine “E” gap, find neutral position of the magneto drive by rotating drive coupling in a left
hand direction until the red or white chamfered tooth on the distributor drive gear appears through
the timing inspection hole. At the same location, the drive should feel to have fallen into a notch or
neutral position.
c. With timing plate and pointer attached. (Refer to Figure 8-17.) and pointer set at zero, rotate
coupling from neutral in a left hand direction 10 degrees. Appearing through timing hole, ascertain
if the white or red tooth aligns with the white line of the distributor block. (Refer to Figure 8-16.)
Alignment may not vary over ± 4 degrees.
NOTE: A timing kit, including timing plate, etc. may be purchased through the engine or magneto
manufacturer. A pointer may be formed as shown in Figure 8-17.

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CAUTION: IF CAM SCREW WAS REMOVED, BE SURE TO REPLACE FLAT WASHER,

LOCK WASHER AND SCREW. TORQUE TO 25 INCH-POUNDS.
f. With internal timing checked, the magneto may be timed to the engine. (Refer to paragraph 8-35.)

8-35. INSTALLATION AND TIMING PROCEDURE. (Timing Magneto to Engine).

The magnetos can be installed and timed to the engine by the following procedure:
NOTE: Ascertain that the breakers are correct for proper internal timing of magnetos.
NOTE: Verify correct engine timing for the airplane being worked on by checking the engine dataplate.
a. Remove the top spark plug from the No. 1 cylinder. Place the thumb of one hand over the spark
plug hole and rotate the crankshaft in direction of normal rotation until the compression stroke is
reached. The compression stroke is indicated by a positive pressure inside the cylinder tending to
lift the thumb off the spark plug hole. In this position both valves of No. 1 cylinder are closed. Turn
the crankshaft opposite to its normal direction of rotation until it is approximately 35 degrees BTC
on the compression stroke of the No. 1 cylinder. Rotate the crankshaft in its normal direction of
rotation until the 25 degrees mark on the starter gear and the crankcase parting flange or the index
on the front of the starter housing are aligned.
b. Rotate the magneto gear on the right magneto until the chamfered tooth on the distributor gear
inside the magneto aligns with the white pointer as seen through the window in the magneto cover.
Without allowing the gear to turn from this position, assemble the magneto and gasket. Secure
magneto in place with washers and nuts; tighten the nuts only finger tight.
c. Fasten ground wire on electric timing light to any unpainted metallic portion of the engine, and one
of the positive wires of the timing light to a suitable terminal connected to the ground terminal
connection of the right magneto. Turn engine crankshaft several degrees from BTC in direction
opposite to that of normal rotation.

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NOTE: The crankshaft should not be rotated more than 10 degrees in direction opposite normal
rotation as the pawl on the impulse coupling will engage with the stop pin and late timing
will be indicated through the impulse coupling mechanism. If this should happen, rotate
crankshaft in normal direction until sharp click is heard; this will indicate that the impulse
coupling has passed through firing position. Turn crankshaft in direction opposite normal
rotation to approximately 35 degrees BTC and proceed with timing check.
NOTE: Verify correct engine timing for the airplane being worked on by checking the engine
dataplate.

8-36. MAGNETO. (Slick.)

a. For service information concerning these magnetos refer to the latest revisions of Lycoming Service
Letter No. L177 and Lycoming Service Instruction No. 1189.

8-37. HARNESS ASSEMBLY

8-38. INSPECTION OF HARNESS.

a. Check lead assemblies for nicks, cuts, mutilated braiding, badly worn section or any other evidence
of physical damage. Inspect spark plug sleeves for chafing or tears and damaged or stripped threads
on coupling nuts. Check compression spring to see if it is broken or distorted. Inspect grommet for
tears. Check all mounting brackets and clamps to see that they are secure and not cracked.
b. Using an ohmmeter, buzzer, or other suitable low voltage device, check each lead for continuity. If
continuity does not exist, wire is broken and must be replaced.
c. Minor repair of the harness assembly, such as replacement of contact springs, spring retainer
assemblies, insulating sleeves or of one lead assembly, can be accomplished with the harness
assembly mounted on the engine. However, should repair require replacement of more than one
lead assembly or of a cable outlet plate, the harness should be removed from the engine and sent to
an overhaul shop.

8-39. REMOVAL OF HARNESS.

a. Disconnect the clamps that secure the wires to the engine and accessories.
b. Loosen the coupling nuts at the spark plugs and remove the insulators from the spark plug barrel
well. Use caution when withdrawing the insulator not to damage the insulator spring.
c. Place a guard over the harness insulators.

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SECTION

VIIIA
POWERPLANT
(PA-28R)

3A1
PIPER CHEROKEE SERVICE MANUAL

GRIDS 3A2 THRU 3A7

INTENTIONALLY BLANK

3A2
 PIPER CHEROKEE SERVICE MANUAL

SECTION VIIIA - POWER PLANT (PA-28R)

TABLE OF CONTENTS

Paragraph Grid No.

8A-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A10

8A-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A10
8A-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A10
8A-4. Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A11
8A-5. Removal of Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A11
8A-6. Cleaning, Inspection and Repair of Propeller . . . . . . . . . . . . . . . . 3A11
8A-7. Installing Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A13
8A-8. Blade Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A14
8A-9. Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A14
8A-10. Removal of Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A14
8A-11. Installation of Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . 3A14
8A-12. Rigging and Adjustment of Propeller Governor . . . . . . . . . . . . . . 3A15
8A-13. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A16
8A-14. Removal of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A16
8A-15. Installation of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A17
8A-16. Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A24
8A-17. Adjustment of Throttle and Mixture Controls . . . . . . . . . . . . . . . . . . . 3A24
8A-18. Induction Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B2
8A-19. Alternate Air Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B2
8A-19a. 50 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B2
8A-19b. 100 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B2
8A-20. Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B3
8A-21. Fuel Injector Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B3
8A-22. Adjustment of Idle Speed and Mixture . . . . . . . . . . . . . . . . . . . . . 3B5
8A-23. Fuel Air Bleed Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B6
8A-24. Removal of Fuel-Air Bleed Nozzle . . . . . . . . . . . . . . . . . . . . . . . . 3B6
8A-25. Cleaning and Inspection of Fuel-Air Bleed Nozzle . . . . . . . . . . . . 3B6
8A-26. Installation of Fuel-Air Bleed Nozzle . . . . . . . . . . . . . . . . . . . . . . 3B6
8A-27. Ignition System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B7
8A-28. Magneto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B7
8A-29. Inspection of Magneto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B7
8A-30. Removal of Magneto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B9
8A-31. Timing Procedure (Internal Timing) . . . . . . . . . . . . . . . . . . . . . . . 3B9
8A-32. Installation and Timing Procedure (Timing Magneto to Engine) . 3B12

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Figure 8A-4. - Engine Installation (PA-28R-180) (cont.)

POWER PLANT Interim Revision: 2/28/02

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Figure 8A-5. - Engine Installation (PA-28R-200)

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Figure 8A-5. - Engine Installation (PA-28R-200) (cont.)

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8A-16. INSTALLATION OF OIL COOLER.

a. When installing fittings in the oil coolers, care should be used to prevent excessive torque being
applied to the cooler. When a rectangular fitting boss is provided, a backup wrench should be used,
employing a scissor motion, so that no load is transmitted to the cooler. When the oil cooler has a
round fitting boss, care should be taken not to permit excessive torque on the fittings.
b. If a pipe thread fitting is used, it should be installed only far enough to seal with sealing compound.
c. Apply Lubon No. 404 to all male pipe thread fittings; do not allow sealant to enter the system.
d. If fitting cannot be positioned correctly using a torque of 10 to 15 foot-pounds, another fitting
should be used.
e. When attaching lines to the cooler, a backup wrench should be used.
f. After installation, inspect the cooler for distorted end cups.
g. Run-up engine. After run-up, check for oil leaks.
8A-17. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLS. (Refer to Figure 8A-6.)
Throttle and mixture controls are adjusted so that when the throttle arm on the carburetor is rotated
forward against its full throttle stop and the mixture control is rotated forward against its full rich stop,
the cockpit control levers of the throttle and mixture should have 0.010 to 0.030 of an inch spring back
on instrument panel stop when in full throttle or full rich position.
a. The throttle may be adjusted as follows:
1. At the carburetor, disconnect the clevis end of the throttle control cable from the control arm.
Loosen the jam nut that secures the clevis end.
2. Adjust the linkage by rotating the clevis end on the cable to obtain 0.010 to 0.030 of an inch
spring back on instrument panel stop when in full throttle position.
3. On PA-28R aircraft equipped with air conditioning systems, a micro switch is located below
the throttle control which is set to actuate in the full open position. With the throttle control
adjusted to obtain a clearance of .010 to .030, adjust the micro switch to actuate at this point
also.
4. Reconnect the clevis end to the control arm and safety.
b. The mixture may be adjusted as follows:
1. At the carburetor, disconnect the clevis end of the mixture control cable from the control arm.
Loosen the jam nut that secures the clevis end.
2. Adjust the linkage by rotating the clevis end on the cable to obtain 0.010 to 0.030 of an inch
spring back on the instrument panel stop when in full rich position.
3. Reconnect the clevis end to the control arm and safety.
c. Check security of cable casing attachments
d. Pull the throttle and mixture levers in the cockpit full aft to ascertain that the idle screw contacts its
stop and the mixture control arm contacts its lean position. On 1975 models and up, a mixture
control lock is incorporated in the quadrant cover which prevents the mixture control from being
moved to the idle cutoff position inadvertently. The lock must be depressed before the control can
be moved completely aft. Ascertain that the lock operates freely without any tendency to bind or
hang up.

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Figure 8A-6. Adjustment of Engine Controls

Figure 8A-6a. Throttle/Mixture Control Ball Joint Inspection

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8A-18. INDUCTION AIR FILTER.

a. The filter should be cleaned daily when operating in dusty conditions. If any holes or tears are
noticed, the filter must be replaced immediately.
b. Remove the filter element and shake off loose dirt by rapping on a hard flat surface, being careful
not to damage or crease the sealing ends.
CAUTION: Never wash the filter element in any liquid or soak it in oil. Never attempt to blow off
dirt with compressed air.
c. The filter housing can be cleaned by wiping with a clean cloth soaked in a suitable dry type solvent.
When the housing is dry, reinstall and seal the filter element.

8A-19. ALTERNATE AIR DOOR.

The alternate air door is located in the cover of the filter box to provide a source of air to the engine
should there be an air stoppage through the filter system.

8A-19a. 50 HOUR INSPECTION

a. Check that air door seals are tight and hinge is secure.
b. Ascertain that the spring tension of the door is tight enough to allow the door to remain closed at
full engine RPM, yet should there be an air stoppage, it will be drawn open.
c. Actuate the door by pushing in on it with the fingers to determine that it is not sticking or binding.
d. Check the cockpit control cable for free travel.
e. Check that when the control lever in the cockpit is in the closed position, the cable is adjusted to
allow approximately 0.0625 to 0.125 inch between the actuating arm roller and the door when fully
closed. With rigging complete, operate alternate air lever in cockpit to verify correct operation of
alternate air door.

8A-19b. 100 HOUR INSPECTION

a. Remove complete alternate airbox assembly from injector and remove induction air duct.
b. Clean airbox thoroughly.
c. Inspect for cracks, worn rivets and worn parts.
d. Replace defective parts.

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Figure 8A-7. Fuel Injector

8A-20. FUEL INJECTOR.

8A-21. FUEL INJECTOR MAINTENANCE.
a. In general, little attention is required between injector overhauls. However, it is recommended that
the following items be checked during periodic inspection of the engine.
1. Check tightness and lock of all nuts and screws which fasten the injector to the engine,
torquing all nuts to 135-150 inch-pounds.
2. Seat the pal type locknuts and finger tighten them against the plain nuts. After this has been
done tighten the locknuts an additional 1/3 to 1/2 turn.
3. Check all fuel lines for tightness and evidence of leakage. A slight fuel stain adjacent to the air
bleed nozzles is not cause for concern.
4. Check throttle and mixture control rod ends and levers for tightness and lock.
5. Remove and clean the injector inlet strainer at the first 25 hours of operation and each 50 hour
inspection thereafter. Check the screen for distortion or openings in the strainer. Replace for
either of these conditions. Clean screen assembly in solvent and dry with compressed air.
Damaged strainer "O"rings should be replaced. To install the screen assembly, place the gasket
on the screen assembly and install the assembly in the throttle body and tighten to 35-40 inch-
pounds torque.

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8A-22. ADJUSTMENT OF IDLE SPEED AND MIXTURE.

a. Start the engine and warm up in the usual manner until oil and cylinder head temperatures are
normal.
b. Check magnetos. If the “mag-drop” is normal, proceed with idle adjustment.
c. Set throttle stop screw so that the engine idles at 550-600 RPM. If the RPM changes appreciable
after making the mixture adjustment during the succeeding steps, readjust the idle speed to the
desired RPM.
d. When the idling speed has been stabilized, move the cockpit mixture control lever with a smooth,
steady pull toward the “Idle-Cut-Off” position and observe the tachometer for any change during
the leaning process. Caution must be exercised to return the mixture control to the “Full Rich”
position before the RPM can drop to a point where the engine cuts out. An increase of more than 10
RPM while “leaning out” indicates an excessively rich idle mixture. An immediate decrease in
RPM (if not preceded by a momentary increase) indicates the idle mixture is too lean.
e. If the above indicates that the idle adjustment is too rich or too lean, turn the idle mixture
adjustment in the direction required for correction, and check this new position by repeating the
above procedure. Make additional adjustments as necessary until a check results in a momentary
pick-up of approximately 5 (never more than 10) RPM. Each time the adjustment is changed, the
engine should be run up to 2000 RPM to clear the engine before proceeding with the RPM check.
Make final adjustment of the idle speed adjustment to obtain the desired idling RPM with closed
throttle. The above method aims at a setting that will obtain maximum RPM with minimum
manifold pressure. In case the setting does not remain stable, check the idle linkage; any looseness
in this linkage would cause erratic idling. In all cases, allowance should be made for the effect of
weather conditions and field altitude upon idling adjustment.

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Figure 8A-10. Contact Points

to Figure 8A-10 center). Neither are small pits or mounds, if not too pronounced. If there is a
possibility of pit becoming deep enough to penetrate pad, Figure 8A-10, right, reject contact
assembly.
NOTE: No attempt should be made to stone or dress contact points. Should contact assembly have
bad points or show excessive wear, the complete contact assembly should be replaced.
g. Check the condition of the cam follower felt. Squeeze felt tightly between thumb and forefinger. If
fingers are not moistened with oil, re-oil using 2 or 3 drops of Scintilla 10-391200 lubricant. Allow
approximately 30 minutes for felt to absorb the oil. Blot off the excess with a clean cloth. Too much
oil may, foul contact points and cause excessive burning.
h. Check the capacitor mounting bracket for cracks or looseness. Using the Scintilla 11-1767-1, -2 or
-3 Condenser Tester or equivalent, check capacitor for capacitance, series resistance and leakage.
Capacitance shall be at least 0.30 microfarads.
i. Check magneto to engine timing as follows:
NOTE: Verify correct engine timing for the airplane being worked on by checking the engine
dataplate.
1. Connect Scintilla 11-851 Timing Light or equivalent across the contact assembly.
2. Slowly bring the engine up to number one cylinder advance firing position as
instructed in paragraph 8A-32. At this instant, the timing light should go

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line on the distributor block should line

up between the L and LB marks on the
gear. On single contact magnetos the line
should favor the L mark, if possible.
d. If the distributor block was removed
from the housing, the distributor gear
alignment and internal check may be
accomplished as followed:
1. Turn rotating magnet in direction of
rotation until it is located in firing
position (keyway up and points just
opening). Tighten adjusting knob of
11-8465 Rotor Holding Tool. Apply
a light coating of Bendix Grease
P/N 10-27165 to teeth of distributor
gear, if needed. The large distributor
gear incorporates four timing marks,
L and LB for left hand rotation and Figure 8A-13. Aligning Timing Marks
R and RB for right hand rotation.
2. With distributor gear assembled to
block, turn gear until raised rib on block lines up between the L and LB marks. Assemble
block and gear into housing, meshing the distributor gears together. The rib should favor the L
mark, if possible. (Refer to Figure 8A-13.)
3. Secure distributor block to housing with studs and washers. Tighten studs finger tight. Loosen
the 11-8465 Rotor Holding Tool and turn rotating magnet in reverse direction of rotation until
timing light indicates contact assembly had just opened and check to make certain timing
marks align within tolerance indicated above. Tighten block securing studs, first to 4-8 inch
pounds torque and then final torque to 20 inch pounds.
4. Insert the tip of your small finger through timing hole in housing and against large distributor
gear teeth. Rock distributor gear back and forth slightly. There must be perceptible backlash
between teeth of large and small gears. This check should be made at three different points,
120° apart on gear. If backlash is not evident, replace large distributor gear.
5. Install the breaker cover and complete reassembly of the magneto. Refer to the manufacturer’s
publications for complete disassembly and reassembly procedures.
e. On the magneto employing the impulse coupling, check clearance between each flyweight and each
stop pin as follows:
1. Bend the end of a stiff piece of wire into a right angle 1/8 inch long (maximum).
2. Hold magneto as shown in Figure 8A-14. Pull heel of flyweight outward

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NOTE: The advance timing mark on the top face of the starter ring gear is marked at both 20° and
25° BTC. Use only the 20° BTC mark when timing the magnetos to the engine.
NOTE: Verify correct engine timing for the airplane being worked on by checking the engine
dataplate.
NOTE: If the crankshaft is accidently turned in the direction opposite normal rotation, repeat the
above procedure as accumulated backlash will make the final timing incorrect.
b. At this point, the engine is ready for assembly of the magnetos. Remove the inspection plugs from
both magnetos and turn the drive shafts in direction of normal rotation (counterclockwise facing the
coupling), until the first painted chamfered tooth on the distributor gear is aligned in the center of
the inspection window. (Refer to Figure 8A-16.) Being sure that the gear does not move from this
position, install gaskets and magnetos on the engine. Secure with washers and nuts; tighten only
finger tight.
NOTE: The magnetos are held in place by clamps which allows them to be timed in several
positions. Since all positions will not give the required clearance between magneto and
engine mount, the magnetos must be installed from the horizontal position to 20° above the
horizontal as shown in Figure 8A-16. Improper installation of magnetos could cause
damage or failure.
NOTE: In order to turn the shaft on an impulse coupling magneto, depress pawl on the impulse
coupling with the finger.

Figure 8A-15. Engine Timing Marks

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NOTE: If the crimping tool is not available, a satisfactory connection can be made by
soldering with Kester Flux 709 or equivalent and a non-corrosive solder. After
soldering, clean solder joints using denatured alcohol.
16. Install clamps and cable ties as necessary to secure lead to the engine.

8A-37. INSTALLATION OF HARNESS.

Before installing harness on magneto, check mating surfaces for cleanliness. Spray entire face of
grommet with a light coat of Plastic Mold Spray, SM-O-O-TH Silicone Spray or equivalent. This will
prevent harness grommet from sticking to magneto distributor block.
a. Place the harness terminal plate on the magneto and tighten nuts around the plate alternately to seat
cover squarely on magneto. Torque nuts to 18 to 22 inch pounds.
b. Route ignition wires to their respective cylinders.
c. Clamp the harness assembly in position.
d. Connect the leads to the spark plugs.

8A-38. SPARK PLUGS.

8A-39. REMOVAL OF SPARK PLUGS.

a. Loosen the coupling nut on the harness lead and remove the terminal insulator from the spark plug
barrel well.
NOTE: When withdrawing the ignition cable lead connection from the plug, care must be taken to
pull the lead straight out and in line with the center line of the plug barrel; otherwise a side
load will be applied, which frequently results in damage to the barrel insulator and
connector. If the lead cannot be removed easily in this manner, the resisting contact
between the neoprene collar and the barrel insulator will be broken by a rotary twisting of
the collar. Avoid undue distortion of the collar and possible side loading of the barrel
insulator.

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8A-40. INSPECTION AND CLEANING OF SPARK PLUG.

a. Visually inspect each spark plug for the following non-repairable defects:
1. Severely damaged shell or shield threads nicked up, stripped or cross-threaded.
2. Badly battered or rounded shell hexagons.
3. Out-of-round or damaged shielding barrel.
4. Chipped, cracked or broken ceramic insulator portions.
5. Badly eroded electrodes worn to approximately 50% of original size.
b. Clean the spark plug as required, removing carbon and foreign deposits.
c. Set the electrode gap at .015 to .018 inches.
d. Test the spark plug both electrically and for resistance.

8A-41. INSTALLATION OF SPARK PLUGS.

Before installing spark plugs, ascertain that the threads within the cylinder are clean and not damaged.
a. Apply anti-seize compound sparingly on the threads and install gasket and spark plugs. Torque 360
to 420 inch pounds.
CAUTION: MAKE CERTAIN THE DEEP SOCKET IS PROPERLY SEATED ON THE SPARK
PLUG HEXAGON AS DAMAGE TO THE PLUG COULD RESULT IF THE
WRENCH IS COCKED TO ONE SIDE WHEN PRESSURE IS APPLIED.
b. Carefully insert the terminal insulator in the spark plug and tighten the coupling unit.

8A-42. LUBRICATION SYSTEM.

8A-43. OIL PRESSURE RELIEF VALVE.

The function of the oil pressure relief valve, which is located between the upper right engine mounting
lug and No. 3 cylinder, is to maintain engine oil pressure within specified limits by withdrawing a
portion of the oil from the circulating system and returning the oil to the sump should the pressure
become excessive. This valve is not adjustable; however, particles of metal or other foreign matter
lodged between ball and seat will result in a drop in oil pressure. It it advisable, therefore, to
disassemble, inspect and clean the relief valve if excessive pressure fluctuations are noted.
The oil pressure relief valve is by no means to be confused with the oil

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SECTION IX - FUEL SYSTEM

TABLE OF CONTENTS

Paragraph Grid No.

9-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C10

9-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C10
9-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C17
9-4. Main Fuel Tanks (PA-28-140, -150, -160, -180, -235 and PA-28R) . . 3C17
9-5. Removal of Main Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C17
9-6. Inspection and Repair of Main Fuel Tank . . . . . . . . . . . . . . . . . . 3C17
9-6a. Sloshed Fuel Tank 100 Hour Inspection . . . . . . . . . . . . . . . . . . . . 3C17
9-7. Installation of Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C18
9-8. Tip Fuel Tanks (PA-28-235) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C18
9-9. Removal of Tip Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C18
9-10. Fuel Tank Repair (Fiberglass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C18
9-11. Installation of Tip Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C18
9-12. Fuel Quantity Transmitter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C18
9-13. Removal of Fuel Quantity Transmitter Unit . . . . . . . . . . . . . . . . . 3C18
9-14. Installation of Fuel Quantity Transmitter Unit . . . . . . . . . . . . . . . 3C19
9-15. Fuel Quantity Transmitter/Gauge Check . . . . . . . . . . . . . . . . . . . 3C19
9-16. Check and Adjustment of Fuel Quantity Transmitter Unit . . . . . . 3C19
9-16a. Fuel Quantity Sending Unit (P/N 548-671) Calibration . . . . . . . . 3C20
9-17. Fuel Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C22
9-18. Fuel Shutoff Valve (PA-28-140, -150, -160, -180, and PA-28R) . 3C22
9-19. Removal of Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C22
9-20. Disassembly of Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . 3C22
9-21. Cleaning, Inspection and Repair of Fuel Shutoff Valve . . . . . . . . 3C22
9-22. Assembly of Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 3C23
9-23. Installation of Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C23
9-24. Fuel Selector Valve and Filter (PA-28-235) . . . . . . . . . . . . . . . . . . . . 3C23
9-25. Fuel Selector Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C23
9-26. Removal of Fuel Selector Valve and Filter . . . . . . . . . . . . . . . . . . 3C23
9-27. (Reserved)
9-28. Cleaning Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D1
9-29. Installation of Fuel Selector and Filter Valve . . . . . . . . . . . . . . . . 3D2
9-30. Fuel Filter Bowl and Screen (PA-28-140, -150, -160, -180, and PA-28R) 3D3
9-31. Removal of Fuel Filter Bowl and Housing . . . . . . . . . . . . . . . . . . 3D3
9-32. Installation of Fuel Filter Bowl and Screen . . . . . . . . . . . . . . . . . 3D3
9-33. Cleaning and Inspection of Filter Bowl Screens . . . . . . . . . . . . . 3D4

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9-3. TROUBLESHOOTING.
Troubles peculiar to the PA-28 fuel system are listed in Table IX-III along with their probable causes and
suggested remedies. When troubleshooting, check from the power supply to the items affected. If no
trouble is found by this method, the trouble probably exists inside individual pieces of equipment; they
may then be removed from the airplane and an identical unit or units, tested and known to be good,
installed in their place.
9-4. MAIN FUEL TANKS. (PA-28-140, -150, -160, -180, -235 and PA-28R.)
9-5. REMOVAL OF MAIN FUEL TANKS.
a. Drain the fuel from the fuel tank. (Refer to Draining Fuel System, Section II.)
b. Remove the screws from around the perimeter of the tank assembly.
c. Disconnect fuel line attached to tank.
d. Pull the tank away from the wing assembly far enough to gain access for removal of the sender
wire.
e. The tank is now free to be removed.
9-6. INSPECTION AND REPAIR.
Visually inspect fuel tanks and adjacent areas for signs of leaks. Tell tale stains are frequently the first
indication. Fuel tanks found to be seeping or leaking fuel must be removed and repaired, as authorized
herein, or replaced.
WARNING: SLOSHING OF FUEL TANKS PROHIBITED.
a. Remove tank(s) as described above.
b. Fuel tanks which have previously been sloshed must be replaced if new leaks are detected.
c. Leaks in fuel tanks which have not been sloshed can be sealed with Products Research Corp.
PR-1422A2 sealant.
1. Allow sealant to cure 72 hours.
2. Leak check repair by filling the fuel tanks with 1.5 psi clean dry air and:
(a) applying a water and soap solution; or,
(b) submerging seams in clean water a minimum of one (1) to no more than six (6) inches.
NOTE: Replace the tank if it cannot be successfully repaired by the method above.
9-6a. SLOSHED FUEL TANK 100 HOUR INSPECTION.
WARNING: SLOSHING OF FUEL TANKS PROHIBITED.
Replacement of fuel tanks which have previously been sloshed is recommended. If the fuel tank must
remain in service, each 100 hours inspect as follows:
a. The entire interior of the tank should be inspected with the tanks drained. Use a mirror and
inspection light through the filler neck and inspect for peeling of the sloshing compound. Small
scrapes in the film adjacent to the filler neck may be disregarded provided there is no indication of
peeling.
b. If peeling has occurred and separated material is found, the tank must be removed and replaced.

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9-7. INSTALLATION OF MAIN FUEL TANK.

a. Slide the main tank partly into position and connect the sender wire.
b. Slide the tank completely into place and secure with screws around its perimeter.
c. Connect fuel line on inboard side of tank. The flexible hose from the fuel tank must not be twisted
during installation on applicable models.
d. Fill the fuel tank and check for leaks, unrestricted fuel flow and proper sender indications on the
quantity gauge.
9-8. TIP FUEL TANKS. (PA-28-235.)
9-9. REMOVAL OF TIP TANK.
a. Drain the fuel from the tank to be removed. (Refer to Draining Fuel System, Section II.)
b. Remove the access cover from the bottom of the wing tip.
c. By working through the access, disconnect the fuel line, fuel quantity transmitting wire and position
light wire. Remove the two nuts, washers and bolts which hold the tank to the wing.
d. Carefully remove the screws from around the wing tip and remove the tip assembly.
9-10. FUEL TANK REPAIR. (Fiberglass.)
The wing tip tanks are constructed of Fiberglass. Minor repair of the tank can be accomplished with the
use of Fiberglass Repair Kit No. 756 729. This kit along with instructions is obtained from Piper Dealers
or Distributors. Additional Fiberglass repairs may be found in Section IV of the Manual.
9-11. INSTALLATION OF TIP TANK.
a. Position the wing tip in place on the wing and insert the two bolts, washers and nuts on their proper
places and tighten. Replace the several screws around the tip tank and tighten. Connect the position
light leads, the fuel quantity transmitting wire and the fuel line.
b. After the wing tip is installed and all connections are secured, fill the tip tank and check for fuel
leaks, operation of the fuel gauge and position light.
c. Install the access cover to the bottom of the wing tip.
9-12. FUEL QUANTITY TRANSMITTER UNIT.
9-13. REMOVAL OF FUEL QUANTITY TRANSMITTER UNIT.
a. Remove the fuel tank. (Refer to Paragraph 9-5 or 9-9.)
b. Disconnect the transmitter wire from the connection post.
c. Cut the safety wire which secures the five attaching screws.
d. Remove the five screws or bolts and remove the unit.

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9-14. INSTALLATION OF FUEL QUANTITY TRANSMITTER UNIT.

a. Position the transmitter and gasket to the fuel tank and secure with machine screws or bolts and
washers. Torque bolts to 25 inch-pounds. (Tip tank installation, install ground wire under head of
mounting screw.)
b. Safety the machine screws with MS20995-C32 wire.
c. Install the fuel tank. (Refer to Paragraph 9-7 or 9-10.)
9-15. FUEL QUANTITY TRANSMITTER/GAUGE CHECK.
Fuel quantity transmitter unit and gauge may be checked while installed in the airplane by the following
procedure:
a. Turn the fuel selector valve off.
b. Completely drain the fuel tank that relates to the gauge to be checked. (Refer to Draining Fuel
System, Section II.)
c. Level the airplane longitudinally and laterally.
NOTE: The electrical system should supply 14 volts to the gauge.
d. Turn the master switch on and observe the fuel quantity gauge. It should read empty. Refer to Table
IX-I for tolerances that are permitted between the fuel gauge reading and the actual fuel in the tank.
e. Add fuel to the tank in the amount of five U. S. gallon increments until the tank is full and observe
the gauge readings.
NOTE: It will be permissible to adjust the float assembly to obtain specified tolerances. This
adjustment may be accomplished per instructions given in Paragraph 9-16.
9-16. CHECK AND ADJUSTMENT OF FUEL QUANTITY TRANSMITTER UNIT.
(P/N’s 62037-00 or 68101-00 only. Refer to Figure 9-6 or 9-7.)
a. If not previously removed, remove the transmitter unit to be checked from the fuel tank. (Refer to
Paragraph 9-13.)
b. Check and adjust the transmitter unit float position by using the following procedure:
1. Fasten the unit to a fabricated checking jig with washers and nuts. (This jig may be fabricated
from dimensions given in Figure 9-14.)
2. Ascertain that with the float arm down against the mechanical stop on the transmitter, the float
is just touching (The float may be to .18 of an inch above base.) the base of the jig. Should the
float not be touching the base or the float arm is not against the bottom stop, adjust the arm of
float assembly, P/N 62037-00, by bending it at the location as indicated in Figure 9-6 or the
arm stop of float assembly, P/N 68101-00, by bending it where shown in Figure 9-7. (On
rubber type floats, the entire surface of the float must be horizontal with the base of jig.)

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TABLE IX-I. TRANSMITTER/FUEL GAUGE TOLERANCES

MAIN TANK TIP TANK

Actual Fuel in Gauge Reading Actual Fuel in Gauge Reading

Tank (U.S. Gal) (U.S. Gal) Tank (U.S. Gal) (U.S. Gal)

Full 22 to Full* Full 15 to Full*

20 17 to 24 10 7 to 12
15 12 to 17 5 3 to 7
10 7 to 12 0 0 to -2
5 2 to 6
0 0 to -2

* Plus one needle width

c. Check the transmitter unit for correct resistance and dead spots by the following procedure:
1. Connect an ohmmeter to the transmitter unit and move the float arm to its bottom mechanical
stop. The ohmmeter should indicate the ohm resistance as indicated in Table IX-II.
2. Move the float arm to its upper mechanical stop and check the ohm resistance.
3. Check for dead spots by slowly moving the float arm from the bottom stop to the upper stop
and back. Watch the ohmmeter indicator; it should steadily move up and down the scale
without fluctuation as the float arm is moved.
4. If an incorrect resistance and/or dead spots are found, the transmitter unit should be replaced.
9-16a. FUEL QUANTITY SENDING UNIT (P/N 548-671) CALIBRATION.
NOTE: The fuel quantity sending unit, Piper P/N 548-671 (Rochester Gauges P/N 7740-309) is not
compatible with any A.C. Sparkplug or Stewart Warner fuel quantity gauge. The Rochester fuel
quantity sending unit must be used only with Rochester fuel quantity gauges. Refer to Service
Spares Letter No. 406 for appropriate fuel quantity gauge/sensor systems.
a. See above for fuel quantity sending unit (transmitter) removal and installation.
b. Perform sending unit/gauge system check per above.
NOTE: If an adjustment of the fuel quantity sending unit, Piper P/N 548-671, is required, refer to
instructions below.
1. Fasten unit to a fabricated checking fixture with washers and nuts. (Refer to Figure 9-14 for
dimensions of fuel quantity sending unit checking fixture.)
2. Ascertain that with the float just touching the top of a 0.27 in. spacer block, the resistance of
the sending unit is 3 ± 0.5 ohm. Should the resistance of the sending unit not fall into this
range, adjust the arm of the float assembly by gently bending it as indicated in Figure 9-7a.
The entire float must be horizontal to the base of the fixture.

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Figure 9-6. Fuel Quantity Transmitter Figure 9-7. Fuel Quantity Transmitter
(P/N 62037-00; AC Sparkplug) (P/N 68101-00; Stewart Warner)

TABLE IX-II. FUEL QUANTITY TRANSMITTER

CALIBRATION TOLERANCES (P/N’s 62037-00 or 68101-00 only.)

UNIT POSITION RESISTANCE

P/N 62037-00 Empty .00 to 0.5 ohms

(Metal Float) Full 29.6 to 31.3 ohms
P/N 68101-00 Empty 240 + 20, -0 ohms
(Rubber Float) Full 33.5 + 0, - 4.5 ohms

3. Remove the sending unit from the checking fixture and connect it to an ohmmeter. Allow the
float arm to rest on the bottom mechanical stop. A resistance of 0 ± 0.5 ohm should be
indicated at this position. Move the float assembly to the upper mechanical stop. A resistance
of 45 ± 2 ohms should be indicated at this position.
4. Check for dead spots by slowly moving the float arm from the bottom stop to the upper stop
and back. Watch the ohmmeter indicator: it should steadily move up and down the scale
without fluctuation as the float arm is moved.
5. If an incorrect resistance and/or dead spots are found, the sending unit should be replaced.

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9-17. FUEL VALVES.

9-18. FUEL SHUTOFF VALVE. (PA-28-140, -150, -160, -180 and PA-28R.)
9-19. REMOVAL OF FUEL SHUTOFF VALVE.
a. Remove two screws holding the fuel valve placard plate and the screw holding the fuel shutoff valve
handle.
b. Remove fuel shutoff valve handle and placard plate.
c. Disconnect right and left fuel inlet lines from fuel valve assembly.
d. Disconnect fuel outlet line from fuel valve assembly.
e. Remove fuel valve assembly by removing attaching screws.
9-20. DISASSEMBLY OF FUEL SHUTOFF VALVE.
Aircraft equipped with fuel selector valve P/N 11383-04, must be disassembled per Fuel Selector Valve
400 Hour Inspection (see Special Inspections, Procedures). Disassembly of other fuel selector valves is
not recommended.

Figure 9-7a. Fuel Quantity Transmitter (P/N 548-671; Rochester Gauges)

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9-21. CLEANING, INSPECTION AND REPAIR OF FUEL SHUTOFF VALVE.

Aircraft equipped with fuel selector valve P/N 11383-04, must be cleaned, inspected, and repaired per
Fuel Selector Valve 400 Hour Inspection (see Special Inspections, Procedures). No cleaning, inspection,
or repair is recommended for other fuel selector valves.
9-22. ASSEMBLY OF FUEL SHUTOFF VALVE.
Aircraft equipped with fuel selector valve P/N 11383-04 must be assembled per Fuel Selector Valve 400
Hour Inspection (see Special Inspections, Procedures).
9-23. INSTALLATION OF SHUTOFF VALVE.
a. Secure the valve to the bulkhead attachment plate with attaching screws.
b. Connect the fuel lines to the valve.
c. Install the fuel valve placard with attaching screws.
d. Install the valve control handle with attaching screw.
9-24. FUEL SELECTOR VALVE AND FILTER. (PA-28-235 only.)
9-25. FUEL SELECTOR VALVE OPERATION.
When the fuel selector handle is not in a positive selector detent position, more than one fuel port will be
open at the same time. It should be ascertained that the fuel selector is positioned in a detent, which can
be easily felt when moving the handle through its various positions.
9-26. REMOVAL OF FUEL SELECTOR VALVE AND FILTER.
CAUTION: NO FIELD DISASSEMBLY OR REPAIR OF FUEL SELECTOR VALVES IS
AUTHORIZED. MAINTENANCE IS LIMITED TO REMOVAL AND REPLACEMENT
OF THE WHOLE UNIT.
a. Drain fuel from tanks. (Refer to Draining Fuel System, Section II.)
b. Remove rear seats, seat belt attachments and floor panel just aft of the main spar by removing the
floor attachment screws. Lift the panel and remove.
c. Remove plate from bottom of the fuselage which covers fuel selector.
d. Disconnect the fuel lines and selector linkage from valve assembly.
e. Remove the four mounting screws which hold the fuel selector in place and remove the selector
assembly.

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Figure 9-8. Fuel Selector and Filter (PA-28-235)

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Figure 9-10. Fuel Filter Bowl and Screen

(PA-28-140, -150, -160, -180 and PA-28R)

9-30. FUEL FILTER BOWL AND SCREEN. (PA-28-140, -150, -160, -180 and PA-28R.)
(Refer to Figure 9-10.)
9-31. REMOVAL OF FUEL FILTER BOWL AND HOUSING.
a. Ascertain that the fuel shutoff is in the off position.
b. Remove the engine cowlings by releasing the cowl fasteners or the attaching screws, depending on
the type installed. Be certain that all electrical leads are disconnected prior to removal of the cowl.
c. Disconnect the fuel lines from the filter bowl housing.
d. Cut the safety wire, loosen the bail nut, move the bail wire to the side and remove the bowl.
e. Remove the housing of the filter bowl by spreading the ends of the bail wire allowing the housing to
be lifted from the bracket.
9-32. INSTALLATION OF FUEL FILTER BOWL AND SCREEN.
a. Position the top of the filter bowl to the bracket and connect the fuel lines.
b. Spread the bail wire ends and insert them through the holes in the side of the mounting bracket and
the top of the filter bowl.
c. Position the bowl and bail wire. Tighten the bail nut hand tight and then tighten one nut flat with a
wrench.
d. Safety the bail nut and the bail wire assembly.
e. Install the engine cowling.

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9-33. CLEANING AND INSPECTION OF FILTER BOWL SCREEN.

a. Follow steps a, b and d of paragraph 9-31 for removal of the filter bowl.
b. Remove the gasket and screen from the filter housing.
c. Clean the screen and bowl with acetone or a suitable dry type solvent. If damaged, replace screen.
d. Replace the screen followed by a new gasket.
e. Position the bowl and bail wire. Tighten the bail nut hand tight and then tighten one nut flat with a
wrench.
f. Safety the bail nut and the bail wire assembly.
9-34. ELECTRIC FUEL PUMPS.
9-35. PLUNGER FUEL PUMPS. (PA-28-140, -150, -160, -180 and -235.)
9-36. REMOVAL OF FUEL PUMPS.
a. On the PA-28-140, -150, -160, and -180, the fuel pump may be removed by the following
procedure:
1. Remove the cowlings by releasing the cowl fasteners or the attaching screws, depending on the
type installed. Be certain all electrical leads are disconnected prior to removal.
2. Ascertain that the fuel shutoff valve is in the off position.
3. Disconnect the fuel pump electrical leads.
4. Disconnect the fuel lines from the inlet and outlet sides of the pump.
5. Remove the nuts and bolts securing the pump to its mounting bracket and remove the fuel
pump.
b. On the PA-28-235, the electric fuel pump(s) may be removed by the following procedure:
1. Ascertain the fuel selector is in the off position.
2. Remove the fuel drain placard cover from the front of the rear seat by removing the attaching
screws.
3. Remove the bottom portion of the rear seat by unsnapping it across the front and lifting the
seat pulling it forward at the same time.
4. Remove the pump cover located in the left side of the floor opening.
5. Disconnect the electrical lead from the pump.
6. Disconnect the inlet and outlet lines from the pump.
7. Remove the pump by removing the pump attaching bolts.

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3. Install new O-rings.

CAUTION: SEAL ALL PIPE THREADS WITH LUBON #404. DO NOT APPLY TO THE
FIRST TWO THREADS OR SEALANT MAY ENTER FUEL SYSTEM.
4. Replace fittings. Torque to 230-360 in.-lb.
9-47. ADJUSTMENT OF ELECTRIC FUEL PUMP (BENCH TEST).
a. Ensure that the pump is sufficiently lubricated to prevent damage.
b. Connect the electric leads to a 14-volt DC power source.
c. Using an approved container with the proper octane fuel, connect a fuel line from the container to
the inlet fitting.
d. Connect another line from the pump outlet to a pressure gauge and by-pass valve and back to the
container.
e. Run the pump with the by-pass valve open until a steady flow of fuel is obtained.
f. Close the by-pass valve and check the pressure gauge for a proper reading of 26 to 29 psi, no flow.
Do not keep the by-pass valve closed for more than one minute during pump operation and
adjustment.
g. Loosen the locknut and turn the adjusting screw until there is a reading of 29 psi maximum, no
flow, on the gauge. Repeat steps e, f, and g until the proper pressure is obtained.
h. Disconnect the power source from the pump and lock the adjustment screw with the locknut.
Remove the fuel lines from the pump.
9-48. ADJUSTMENT OF ELECTRIC FUEL PUMP (IN AIRPLANE).
a. With the access panel removed and the fuel selector valve in the OFF position, remove the fuel line
from the outlet end of the pump.
b. Connect a test line with a by-pass valve and pressure gauge to pump outlet.
c. Place a container below the pump to catch any fuel from the test line.
d. Turn the fuel selector valve on, open the by-pass valve on the test line, and start the pump.
e. When fuel flow becomes steady, close the by-pass valve and check the reading on the pressure
gauge. The gauge should read 26 to 29 psi, no flow. Do not keep the by-pass valve closed for more
than one minute during pump operation and adjustment.
f. Loosen locknut on adjusting screw and turn the screw to obtain the proper pressure of 29 psi
maximum, no flow. Repeat this step until adjustment is complete. Lock adjusting screw with
locknut.
g. Turn off fuel pump and close fuel selector valve. Remove the test line from the pump.
h. Connect the original fuel lines to the pump. Open fuel selector valve and run the pump to check for
any fuel leaks.
i. Shut off the pump, close the fuel selector valve and replace access panel.

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9-49. INSTALLATION OF FUEL PUMP.

a. Place fuel pump inside cover assembly and
secure with cap screws, washers and plate.
WARNING: IF O-RINGS ARE DE-
FECTIVE OR IF INLET
FITTING IS NOT PROPERLY
INSTALLED, AIR WILL BE
DRAWN INTO FUEL LINE,
CAUSING ENGINE TO RUN
VERY LEAN OR STOP
RUNNING. INSTALL NEW
O-RINGS WHENEVER FUEL
PUMP IS REMOVED FOR
SERVICE.
b. Inspect chamfered O-ring seat for nicks.
c. Install new O-rings between the fittings and
the pump. Figure 9-13. Engine Primer
d. Connect fittings to fuel pump. Torque to
230-360 in.-lb.
e. Connect fuel lines to fuel pump fittings.
f. Connect the electrical leads to the pump.
g. Turn the fuel selector valve on and operate the fuel pump. Check the line fittings for leakage.
h. Install the cowling.
9-50. ENGINE PRIMER PUMP.
9-51. REMOVAL OF ENGINE PRIMER. (Refer to Figure 9-13.)
a. Disconnect the fuel lines from the primer behind the instrument panel.
b. Loosen the locknut (12) from behind the panel.
c. Unscrew the knurled face nut (10), withdraw the pump handle (9) and piston (7) from the cylinder (5).
d. Remove the remaining portion of the primer.
9-52. DISASSEMBLY, CLEANING, AND ASSEMBLY OF ENGINE PRIMER. (Refer to Figure 9-13.)
a. The primer may be disassembled after removal by removing the screws (3), springs (2), and check
balls (1) from the end of the cylinder housing.
b. Clean the primer parts with acetone or a dry type solvent.
c. Install new O-rings to the piston (7) and lubricate with light motor oil.
d. Install the balls (1), springs (2), and screws (3) to the cylinder housing.
e. Insert the pump handle (9) and piston (7) into the cylinder (5), finger tighten the knurled face nut (10).
f. Immerse the pump in gasoline and operate several times to ensure proper operation.

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Figure 9-14. Fabricated Fuel Quantity Transmitter Checking Jig

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SECTION X - INSTRUMENTS

TABLE OF CONTENTS

Paragraph Grid No.

10-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D22

10-1a. Service Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D22
10-2. Non-Electrical Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D22
10-3. Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D22
10-4. Vacuum System Service Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D22
10-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D24
10-6. Suction Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
10-7. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
10-8. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
10-9. Vacuum Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
10-10. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
10-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
10-12. Adjustment of Vacuum Regulator Valve (Without Vacuum
Warning Lights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
10-13. Adjustment of Vacuum Regulator Valve (With Vacuum
Warning Lights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E22
10-14. Adjustment of Vacuum Warning Light Pressure Switch . . . . . . . 3E22
10-15. Adjustment of Vacuum Turn and Bank Indicator Regulator Valve 3E24
10-16. Removal and Replacement of Regulator Valve . . . . . . . . . . . . . . 3E24
10-17. Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E24
10-18. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E24
10-19. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F1
10-20. Removal of Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F1
10-21. Replacing Pump Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F1
10-22. Installation of Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F2
10-23. Instrument Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F2
10-24. Directional Gyro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F3
10-25. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F3
10-26. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F5
10-27. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F6
10-28. Gyro Horizon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F6
10-29. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F6
10-30. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F7
10-31. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F8
10-32. Rate of Climb Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F8
10-33. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F8
10-34. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F8
10-35. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F9

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SECTION X - INSTRUMENTS

TABLE OF CONTENTS (cont.)

Paragraph Grid No.

10-36. Sensitive Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F9

10-37. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F9
10-38. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F10
10-39. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F11
10-40. Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F11
10-41. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F11
10-42. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F12
10-43. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F12
10-44. Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F13
10-45. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F13
10-46. Adjustment of Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F13
10-47. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F14
10-48. Manifold Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F15
10-49. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F15
10-50. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F15
10-51. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F15
10-52. Tachometer Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F15
10-53. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F15
10-54. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F16
10-55. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F16
10-56. Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F16
10-57. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F16
10-58. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F17
10-59. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F17
10-60. Fuel Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F17
10-61. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F17
10-62. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F18
10-63. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F19
10-64. Turn and Bank Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F19
10-65. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F19
10-66. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F19
10-67. Electrical Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F20
10-68. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F20
10-69. Fuel Quantity Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F20
10-70. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F20
10-71. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F20
10-72. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21

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SECTION X - INSTRUMENTS

TABLE OF CONTENTS (cont.)

Paragraph Grid No.

10-73. Oil Temperature Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21

10-74. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21
10-75. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21
10-76. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21
10-77. Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21
10-78. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21
10-79. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21
10-80. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21
10-81. Removal and Replacement of Face Mounted Instruments . . . . . . . . . 3F21
10-82. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F22
10-83. Removal and Replacement of Cluster Mounted Instruments . . . . . . . 3F22
10-84. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F22
10-85. Exhaust Gas Temperature Gauge (Alcor) . . . . . . . . . . . . . . . . . . . . . . 3F22
10-86. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F22
10-87. Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F23
10-88. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F23
10-89. Cylinder Head Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G3
10-90. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G3
10-91. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G3
10-92. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G3
10-93. Fuel Flow Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G3
10-94. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G3
10-95. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G4
10-96. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G4
10-97. Piper AutoControl System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G4
10-98. Annunciator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G4
10-99. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G4
10-100. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G4
10-101. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G4

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SECTION X

INSTRUMENTS

10-1. GENERAL.
The instrumentation in the Cherokee is designed to give a quick and actual indication of the attitude,
performance and condition of the airplane. Maintenance, other than described in these sections, shall be
done by the instrument manufacturer or an authorized repair station.
The two types of instruments have been classified in this section as non-electrical and electrical. The first
part of this section will pertain to maintenance and troubleshooting of all the instruments and their
systems which depend on non-electrical sources for their operation. The remaining portion of this
section is directed to maintenance and troubleshooting of all the electrically operated instruments.
10-1a. SERVICE REPLACEMENT.
Original equipment A.C. Sparkplug and Stewart Warner engine gauges are no longer available. For
service replacement, see Service Spares Letter No. 406 and the Parts Catalog, P/N 753-582.
10-2. NON-ELECTRICAL INSTRUMENTS.
10-3. VACUUM SYSTEM.
10-4. VACUUM SYSTEM SERVICE TIPS.
The following information is intended to acquaint field service personnel with a means to diagnose
vacuum system service symptoms on those components which are serviced by removal and replacement.
These items include hoses, clamps, gyro filters, vacuum regulating valves and vacuum gauges.
a. Hoses and Clamps:
1. These items should be examined periodically and inspected carefully whenever maintenance
activities cause hose disconnections.
2. Ends of hoses should be examined for rubber separation and slivers of rubber on inside
diameter of hoses. These slivers can and do become detached. If this happens, the loose
particles will migrate throughout the system and may eventually contribute to a failure.
3. Replace old, hard, cracked or brittle hose. Sections of the inner layers may separate.
4. Ensure hoses are clear and clean by blowing them out with shop air. Remove from aircraft as
required.
CAUTION: DO NOT WIGGLE HOSE FROM SIDE TO SIDE DURING INSTALLATION.
WIGGLING COULD CAUSE PARTICLES TO BE CUT FROM INNER WALL
OF HOSE WHICH CAN LEAD TO DAMAGE OF OTHER COMPONENTS.
5. Where hose clearance is tight, making it difficult to reinstall it onto a fitting or barb, spray the
fitting or barb with silicone. Let dry, then install hose by pushing it straight on.
CAUTION: WHEN REPLACING ANY THREADED FITTING, DO NOT USE PIPE DOPE,
THREADLUBE, OR TAPE. USE ONLY SILICONE SPRAY, LETTING IT DRY
BEFORE ASSEMBLY.
6. Hose clamps and fittings should be replaced when broken, damaged or corroded.

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NOTE: The latest systems which employ a central filter in combination with a differential vacuum
gauge will indicate a decline in panel gauge reading when the filter becomes clogged and
vacuum declines below the recommended value. The filters should be replaced when gauge
reading declines below the recommended value; do not adjust regulator.
d. Vacuum Regulator:
1. The vacuum regulating valve seldom needs replacement. Symptoms that suggest replacement
are:
(a) Chatter as indicated by rapid fluctuation of the vacuum gauge needle or an audible sound.
(b) Non-repeatability of the vacuum gauge reading when the panel gauge is not suspect or has
been checked against a known test gauge (cruise RPM only).
2. All modes of regulator malfunction tend to increase the vacuum power applied to the gyros.
Thus, although excess vacuum is applied, a loss of vacuum does not occur.
3. The gyros themselves act as a limiting device to keep the vacuum power applied from
exceeding safe levels.
NOTE: If the panel gauge has been checked and found OK and the vacuum gauge reading
does not repeat within the range of 4.8 to 5.2 inches of mercury, then the regulating
valve should be changed. Observe the usual precautions for maintaining system
cleanliness to avoid premature pump service.
10-5. TROUBLESHOOTING.
See Table X-I below.

TABLE X-I. TROUBLESHOOTING - VACUUM SYSTEM

Trouble Cause Remedy

NOTE: Aircraft S/N’s prior to: 28-7125001, 28-7105001, 28-7110001, 28S-7105001, 28R-7130001 and
28R-7135001.

No vacuum pressure Pump inoperative. Dis- Replace pump. Locate

gauge indication. connected, broken or trouble and correct.
restricted lines.

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TABLE X-I. TROUBLESHOOTING - VACUUM SYSTEM (cont.)

Trouble Cause Remedy

No vacuum gauge indica- Hose from instrument to Check all lines and
tion at instrument. gauge leaking or re- connections.
stricted.
No vacuum gauge indica- Faulty gauge Mal- Check operation of
tion at either instru- functioning, regulator instrument. If oper-
ment or source. valve, or vacuum pump. ation is normal, re-
place gauge. If instru-
ments are inoperative,
check operation of
vacuum pump or regulator
valve.
Vacuum lines restricted Check system.
or broken.
Low vacuum system Vacuum regulator valve Adjust regulator valves
pressure. incorrectly adjusted. in accordance with
Adjustments of this
section.
Leaking of the system Check all lines and
lines or fittings. fittings.
Malfunctioning pump. Replace pump.
Overboard line from Replace line.
vacuum pump restricted.
Sealing plugs loose in
gyros.
Normal pressure indica- Instruments air filter Remove and clean or
tion, but sluggish elements dirty. replace.
operation of instru-
ments.
Line restricted be- Check all lines and
tween gyro and filter. fittings.
High system pressure. Vacuum regulator valve Adjust in accordance
incorrectly adjusted. with adjustments of
this section.
Vacuum regulator valve Clean and check opera-
sticking or dirty tion of regulator
screen. valve.
Faulty gauge. Replace gauge.

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TABLE X-I. TROUBLESHOOTING - VACUUM SYSTEM (cont.)

Trouble Cause Remedy

NOTE: Aircraft S/N’s: 28-7125001, 28-7105001, 28-7110001, 28S-7105001, 28R-7130001 and 28R-
7135001 and above.

No vacuum gauge indication Filter clogged or dirty. Clean or replace filter.

at instrument.
Line from gyro to filter restricted. Check line.
No vacuum gauge indication Faulty gauge or malfunctioning Replace gauge or pump.
at gauge or pump. pump.
Low vacuum system pressure. Filter dirty. Clean or replace filter.
Vacuum regulator valve Adjust regulator valve in
incorrectly adjusted. accordance with
adjustments in this section.
Line from gyros to filter restricted. Repair line.
Line from pump to gyros leaking. Check all lines and fittings.
Replace or tighten
as necessary.
Normal pressure indication Faulty instrument. Replace instrument.
but sluggish operation
of instruments.
High system pressure. Vacuum regulator in- Adjust regulator.
correctly adjusted.
Vacuum regulator Clean and check opera-
sticking or dirty tion of regulator.
screen.
Regulator cannot be Lines leaking. Check lines and fittings.
adjusted to produce
correct pressure.
Vacuum pump mal- Replace pump.
functioning.
Vacuum correct on Vacuum pump mal- Replace pump.
ground but will not functioning.
maintain pressure at
altitude.
Regulator sticky. Clean regulator.

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TABLE X-I. TROUBLESHOOTING - VACUUM SYSTEM (cont.)

Trouble Cause Remedy

Vacuum correct but Regulator sticky. Clean regulator.
pilot reports pressure
erratic or shows
complete loss in
flight.
Oil in pump due to Replace pump.
Ieaky engine seal
or cleaning fluid
blown into pump
while cleaning engine.
Pressure can only be Leak in system. Repair or replace
maintained at full lines.
throttle on ground.
Worn pump. Replace pump.
Stuck regulator. Clean or replace
regulator.

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3. Recheck the high vacuum light by restarting the engine and increasing the RPM. Determine if
the high light indicates high vacuum at 5.2 +0.2 -0. If further adjustment is necessary, return to
step f. After proper adjustment to the high vacuum light has been made, shut down the engine.
g. Readjust the vacuum regulator by setting throttle at a medium RPM. At this setting the suction
gauge should read from 4.6 to 5.2. To prevent intermittent actuation of the warning light due to
closeness of the pressure settings of the light pressure switch and the vacuum regulator, it should be
determined that the regulator is set 0.2 inches of mercury less than that of the pressure switch as
long as vacuum is within the required range. Make necessary adjustments by turning clockwise to
increase the suction and counterclockwise to decrease the suction. Then tighten the jam nut on the
regulator valve adjustment screw and remove the vacuum gauge and fitting from the back of the
artificial horizon. Reinstall the plug into the artificial horizon.
10-15. ADJUSTMENT OF VACUUM TURN AND BANK INDICATOR REGULATOR VALVE.
a. To adjust the turn and bank indicator, remove the plug found in the back of the instrument and
install the proper AN fitting that will accommodate a small hose from a suction gauge.
NOTE: Do not attempt adjustment of any system in this airplane, with the engine in operation,
without a qualified pilot or other responsible person at the controls.
b. Start the engine and operate at a medium RPM with the suction gauge indicating 5.0 with central air
filter. If adjustment is necessary, refer to Paragraph 10-12 or 10-13.
c. With the suction gauge reading within the stated range, the gauge attached to the turn and bank
should indicate 2.0 inches of mercury. If adjustment is necessary, turning the adjustment screw,
found in the valve assembly at the back of the instrument, clockwise will decrease the suction and
counterclockwise will increase the suction. After the proper reading is acquired, shut down the
engine, remove the gauge, hose and fitting from the turn and bank and install the plug.
10-16. REMOVAL AND REPLACEMENT OF REGULATOR VALVE.
a. To remove the regulator valve, disconnect the three lines and remove the mounting nut. Remove the
valve from the airplane.
b. Replace regulator in reverse order given for removal. Check complete vacuum system for proper
operation.
10-17. VACUUM PUMP.
10-18. GENERAL.
A single engine-driven, dry-air vacuum pump is mounted on the accessory section at the rear of the
engine. The vacuum pump is a rotary vane, positive displacement type. These units consist of an
aluminum housing, a carbon rotor and carbon vanes. They are driven by means of a coupling mated to an
engine-driven gear assembly.
10-19. TROUBLESHOOTING.
For troubleshooting of the pumps, refer to Table X-I of this section.

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10-20. REMOVAL OF VACUUM PUMP.

a. Remove the top portion of the engine cowling. (Refer to Section VIII.)
b. Loosen the hose clamp and remove the hose from the pump fitting.
c. Remove the four retaining nuts, lock washers and plain washers used to secure the pump to the
engine; then remove the pump.
10-21. INSTALLATION OF VACUUM PUMP.
CAUTION: A PUMP THAT HAS BEEN DAMAGED OR DROPPED SHOULD NOT BE
INSTALLED.
NOTE: Change the vacuum system filter when installing a new pump.
a. AIRBORNE Vacuum Pump (Original Equipment):
1. If required, install fittings on pump per Replacing Pump Fittings, below.
2. Place the pump gasket in its proper place and align the spline on the pump drive, with spline
on engine drive assembly.
CAUTION: THE ONLY PUMP MOUNTING GASKET AUTHORIZED AND APPROVED
FOR USE ON THE AIRBORNE VACUUM PUMP IS THE AIRBORNE
GASKET B3-1-2, PIPER PART NUMBER 751 859. USE OF ANY OTHER
GASKET MAY RESULT IN OIL SEEPAGE OR LEAKAGE AT THE
MOUNTING SURFACE.
3. Secure the pump to the engine with four plain washers, lock washers and retaining nuts.
Torque the nuts 40 to 50 inch-pounds.
4. Connect the hoses to the pump and secure with hose clamps.
5. Reinstall the engine cowling.
b. AERO ACCESSORIES Vacuum Pump (Service Replacement):
1. If required, install fittings on pump per Replacing Pump Fittings, below.
2. Place pump gasket in its proper place and align the spline on the pump drive, with spline on
engine drive assembly.
3. Secure pump to engine with four plain washers, lock washers and retaining nuts. Torque nuts
50 to 70 inch-pounds.
4. Connect hoses to pump and secure with hose clamps.
5. Reinstall the engine cowling.
10-22. REPLACING PUMP FITTINGS.
CAUTION: WHEN REPLACING ANY OF THE THREADED FITTINGS, DO NOT USE PIPE
DOPE, THREADLUBE, OR TAPE. PIPE DOPE / TAPE PARTICLES INGESTED BY
THE VACUUM PUMP COULD CAUSE THE PUMP TO FAIL. USE ONLY SILICONE
SPRAY, LETTING IT DRY BEFORE ASSEMBLY.
CAUTION: A PUMP THAT HAS BEEN DAMAGED OR DROPPED SHOULD NOT BE
INSTALLED.

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a. Before installing any fittings on the pump, check for any external damage.
CAUTION: DO NOT APPLY VISE PRESSURE TO THE OUTSIDE DIAMETER OR OVERALL
LENGTH OF THE PUMP.
b. When a vise is used to hold the pump while installing fittings, suitable caution must be exercised to
avoid pump damage. The square mounting flange must be held between soft wood blocks and only
at right angles to the vise jaws. Use only enough vise pressure to hold the pump firmly.
c. The ports of the AIRBORNE pump have been treated with a dry film lubricant and the AIRBORNE
fittings are cadmium plated thus eliminating any need for thread lubricants. If thread lubricant is
required, use a powdered moly-sulfide or graphite in dry form or in an evaporating vehicle; or
employ a silicone spray. Apply sparingly to external threads of fittings only.
d. With the pump properly secured in the vise, insert fittings in ports and hand tighten firmly.
e. Using a wrench, tighten each fitting one-half (1/2) to two (2) turns only. Do not overtighten.

Figure 10-17a. Vacuum Pump Vane Wear Inspection - Aero Accessories only

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10-22a. INSPECTION - AERO ACCESSORIES TEMPEST PUMPS ONLY. (Refer to Figure 10-17a.)
These vacuum pumps are available as service replacements. They feature a wear indicator inspection
port on the back cover which allows direct observation of pump vane wear. Beginning at 500 hours time-
in-service, and each 100 hours thereafter, remove the inspection port plug and observe vane wear as
shown in Figure 10-17a.
a. As the vanes wear, they slide outboard in the vane slots in the rotor.
b. When the portion of the vane that can be observed in the inspection hole covers approximately 1/8
of the inspection hole, replace the pump.
10-23. INSTRUMENT AIR SYSTEM. (Refer to Figure 10-18.)
The instrument air system consists of a pitot air system and a static air system. The system supplies both
pitot and static pressure for the airspeed indicator, altimeter and vertical speed indicator. Refer to Figure
10-18 for PA-28-140, -150, -160, -180, -235, and PA-28R-180 and -200 system layout.
Pitot air system consists of a pitot mast located on the underside of the left wing, with its related
plumbing. Impact air pressure entering the pitot is transmitted from the pitot inlet through hose and
tubing routed in the wing to the airspeed indicator on the instrument panel. A partially or completely
blocked pitot head will give erratic or zero readings on the instruments.
Static air system consists of a static port located on the bottom of the pitot mast. The static port is
directly connected to the airspeed indicator, altimeter and rate of climb indicator on the instrument panel
by means of hose and tubing routed through the wing along with the pitot line. An alternate static air
source is located below the instrument panel in front of the pilot. The alternate static source is part of the
standard system and has a shutoff valve which closes the port when it is not needed. A placard giving
instructions for use is located on the instrument panel.
10-24. DIRECTIONAL GYRO.
10-25. GENERAL.
The directional gyro is a flight instrument incorporating an air driven gyro stabilized in the vertical
plane. The gyro is rotated at high speed by lowering the pressure in the air tight case and simultaneously
allowing atmospheric air pressure to enter the instrument against the gyro buckets. Due to gyroscopic
inertia, the spin axis continues to point in the same direction even though the aircraft yaws to the right or
left. This relative motion between the gyro and the instrument case is shown on the instrument dial
which is similar to a compass card. The dial, when set to agree with the airplane magnetic compass,
provides a positive indication free from swing and turning error. However, the directional gyro has no
sense of direction and must be set to the magnetic compass, since the magnetic compass is subject to
errors due to magnetic fields, electric instruments, etc. The directional gyro is only accurate for the
heading it has been set for. If the gyro is set on 270°, for instance, and the aircraft is turned to some other
heading, there can be a large error between the gyro and the magnetic compass due to the error in
compass compensation. This will appear as gyro precession. The gyro should only be checked to the
heading on which it was first set. Due to internal friction, spin axis error, air turbulence and airflow, the
gyro should be set at least every 15 minutes for accurate operation, whether it has drifted or not.

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10-27. REMOVAL AND REPLACEMENT.

Refer to Paragraphs 10-4 and 10-82 of this section.

10-28. GYRO HORIZON.

10-29. GENERAL.
The gyro horizon is essentially an air driven gyroscope rotating in a horizontal plane and is operated by
the same principal as the directional gyro. Due to the gyroscopic inertia, the spin axis continues to point
in the vertical direction, providing a constant visual reference to the attitude of the airplane relative to
pitch and roll axis. A bar across the face of the indicator represents the horizon and aligning the
miniature airplane to the horizon bar simulates the alignment of the airplane to the actual horizon. Any
deviation simulates the deviation of the airplane from the true horizon. The gyro horizon is marked for
different degrees of bank.

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10-31. REMOVAL AND REPLACEMENT.

Refer to Paragraphs 10-4 and 10-82 of this section.

10-32. RATE OF CLIMB INDICATOR.

10-33. GENERAL.
The rate of climb indicator measures the rate of change in static pressure when the airplane is climbing
or descending. By means of a pointer and dial this instrument will indicate the rate of ascent or descent
of the airplane in feet per minute. But due to the lag of the instrument, the aircraft will be climbing or
descending before the instrument starts to read and the instrument will continue to read after the aircraft
has assumed level flight. In rough air this should not be considered a malfunction.
10-34. TROUBLESHOOTING.

TABLE X-IV. TROUBLESHOOTING - RATE OF CLIMB INDICATOR

Trouble Cause Remedy

Pointer does not set Aging of diaphragm. Reset pointer to zero
on zero. by means of setting
screw. Tap instrument
while resetting.
Pointer fails to Obstruction in static Disconnect all instru-
respond. line. ments connected to the
static line. Clear line.
Pitot head frozen over.
Water in static line. Check individual instru-
ments for obstruction
in lines.
Obstruction in pitot Clean lines and head.
head.
Pointer oscillates. Leaks in static lines Disconnect all instru-
ments connected to the
static line. Check
individual instruments
for leaks. Reconnect
instruments to static
line and test installa-
tion for leaks.
Defective mechanism. Replace instrument.

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GRIDS 3G5 THRU 3L24

INTENTIONALLY BLANK

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SECTION

XI
ELECTRICAL
SYSTEM

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GRIDS 4A2 THRU 4A7

INTENTIONALLY BLANK

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TABLE XI-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS

Subject Figure GRID NO.

Electrical System Schematic,

PA-28-140, S/N’s 28-20000 thru 28-24999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-54 4F11
Electrical System Schematic,
PA-28-140, S/N’s 28-25000 thru 28-7325052 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55 4F13
Electrical System Schematic,
PA-28-150, -160, S/N’s 28-1 thru 28-507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56 4F15
Electrical System Schematic,
PA-28-150, -160, S/N’s 28-508 thru 28-670 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-57 4F17
Electrical System Schematic,
PA-28-150, -160, -180, S/N’s 28-671 thru 28-1760 . . . . . . . . . . . . . . . . . . . . . . . . . 11-58 4F19
Electrical System Schematic,
PA-28-150, -160, -180, S/N’s 28-1761 thru 28-3643 . . . . . . . . . . . . . . . . . . . . . . . . 11-59 4F21
Electrical System Schematic,
PA-28- 150, - 160, - 180, S/N’s 28-3644 thru 28-4377 . . . . . . . . . . . . . . . . . . . . . . . 11-60 4F23
Electrical System Schematic,
PA-28-180, S/N’s 28-4378 thru 28-5227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-61 4GI
Electrical System Schematic,
PA-28-180, S/N’s 28-5228 thru 28-7305063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62 4G3
Electrical System Schematic,
PA-28-235, S/N’s 28-10003 thru 28-10719 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-63 4G5
Electrical System Schematic,
PA-28-235, S/N’s 28-10720 thru 28-10762 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-64 4G7
Electrical System Schematic,
PA-28-235, S/N’s 28-10763 thru 28-11039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-65 4G9
Electrical System Schematic,
PA-28-235, S/N’s 28-11040 thru 28-7310038 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-66 4G11
Electrical System Schematic,
PA-28R-180, S/N’s 28-30005 thru 28-30879 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-67 4G13
Electrical System Schematic,
PA-28R-180, -200, S/N’s 28-30880 thru 28-7335054 . . . . . . . . . . . . . . . . . . . . . . . . 11-68 4G15
Landing Gear Back-up Actuator Override Mechanism . . . . . . . . . . . . . . . . . . . . . . . . 11-69 4G11
Landing Gear Back-up Actuator Override Mechanism . . . . . . . . . . . . . . . . . . . . . . . . 11-70 4G17

SEE NOTE CONCERNING FIGURES 11-71 THRU 11-84 ON GRID NO. . . . . 4G19

THE FOLLOWING SYSTEM SCHEMATICS ARE FOR 1973 MODELS AND UP

A/C Air Blower,
PA-28-140, S/N’s 28-7425001 & up;
PA-28-180, S/N’s 28-7405001 & up;
PA-28R-200, S/N’s 28-7435001 & up;
PA-28-235, S/N’s 28-7410001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-107 4H10
Alternator, Starter, Cabin Light, Cigar Lighter and External Power Receptacle,
PA-28-140, S/N’s 28-25000 thru 28-7325052 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-85 4G20

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TABLE XI-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS (cont)

Subject Figure GRID NO.

Alternator, Starter, Cabin Light, Cigar Lighter and External Power Receptacle,
PA-28-140, S/N’s 28-7325053 thru 28-7425454 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-86 4G21
Alternator, Starter, Cabin Light, Cigar Lighter and External Power Receptacle,
PA-28-140, S/N’s 28-7525001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-125 4H15
Alternator, Starter, Cabin Light, Cigar Lighter and External Power Receptacle,
PA-28-180, S/N’s 28-5228 thru 28-7305063;
PA-28-235, S/N’s 28-11040 thru 28-7310038 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-87 4G22
Alternator, Starter, Cabin Light, Cigar Lighter and External Power Receptacle,
PA-28-235, S/N’s 28-7310039 thru 28-7310187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-88 4G23
Alternator, Starter, Cabin Lighter, Cigar Lighter and External Power Receptacle,
PA-28-180, S/N’s 28-7305064 thru 28-7405290;
PA-28R-200, S/N’s 28-7335055 thru 28-7435331;
PA-28-235, S/N’s 28-7410001 thru 28-7410120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-89 4G24
Alternator, Starter, Cabin Lighter, Cigar Lighter and External Power Receptacle,
PA-28-180, S/N’s 28-7505001 & up;
PA-28R-200, S/N’s 28-7535001 & up;
PA-28-235, S/N’s 28-7510001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-126 4H16
Anti-Collision Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-144 4H24
Avionics,
PA-28-140, S/N’s 28-7325053 thru 28-7425454 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-92 4H3
Avionics,
PA-28-180, S/N’s 28-7305064 thru 28-7305611;
PA-28R-200, S/N’s 28-7335055 thru 28-7335455;
PA-28-235, S/N’s 28-7310039 thru 28-7310187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-93 4H3
Avionics,
PA-28-180, S/N’s 28-7405001 thru 28-7405290;
PA-28-235, S/N’s 28-7410001 thru 28-7410120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-94 4H4
Avionics,
PA-28R-200, S/N’s 28-7435001 thru 28-7435331 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-95 4H4
Avionics,
PA-28-140, S/N’s 28-7525001 & up;
PA-28-180, S/N’s 28-7505001 & up;
PA-28-235, S/N’s 28-7510001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-128 4H18
Avionics,
PA-28R-200, S/N’s 28-7535001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-129 4H18
Engine Gauges,
PA-28-180, S/N’s 28-7305064 thru 28-7305611;
PA-28R-200, S/N’s 28-7335055 thru 28-7335455 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-97 4H5
Engine Gauges,
PA-28-235, S/N’s 28-7310039 thru 28-7410120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-98 4H6
Engine Gauges,
PA-28-140, S/N’s 28-7325053 thru 28-7425454;
PA-28-180, S/N’s 28-7405001 thru 28-7405290;
PA-28R-200, S/N’s 28-7435001 thru 28-7435331 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-96 4H5

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TABLE XI-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS (cont)

Subject Figure GRID NO.

Engine Gauges,
PA-28-235, S/N’s 28-7510001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-133 4H20
Engine Gauges,
PA-28-140, S/N’s 28-7525001 & up;
PA-28-180, S/N’s 28-7505001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-134 4H21
Engine Gauges,
PA-28R-200, S/N’s 28-7535001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-135 4H21
Fin Strobe Anti-Collision Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-139 4H23
Fuel Pump,
PA-28-140, S/N’s 28-7325053 thru 28-7520004;
PA-28-180, S/N’s 28-7305064 thru 28-7505004;
PA-28R-200, S/N’s 28-7335055 thru 28-7535004;
PA-28-235, S/N’s 28-7310039 thru 28-7510004 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-110 4H11
Fuel Pump,
PA-28-140, S/N’s 28-7525005 & up;
PA-28-180, S/N’s 28-7505005 & up;
PA-28R-200, S/N’s 28-7535005 & up;
PA-28-235, S/N’s 28-7510005 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-124 4H14
Instrument Lights,
PA-28- 140, S/N’s 28-7325053 thru 28-7325684 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-99 4H6
Instrument Lights,
PA-28-140, S/N’s 28-7325053 thru 28-7425454 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-100 4H7
Instrument Lights,
PA-28-140, S/N’s 28-7525001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-130 4H19
Instrument Lights,
PA-28-180, S/N’s 28-7305064 thru 28-7305611 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-101 4H7
Instrument Lights,
PA-28-180, S/N’s 28-7405001 thru 28-7405290 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-102 4H8
Instrument Lights,
PA-28R-200, S/N’s 28-7335055 thru 28-7335455 . . . . . . . . . . . . . . . . . . . . . . . . . 11-103 4H8
Instrument Lights,
PA-28R-200, S/N’s 28-7435001 thru 28-7435331 . . . . . . . . . . . . . . . . . . . . . . . . . 11-104 4H9
Instrument Lights,
PA-28-235, S/N’s 28-7310039 thru 28-7310187 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-105 4H9
Instrument Lights,
PA-28-235, S/N’s 28-7410001 thru 28-7410120 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-106 4H10
Instrument Lights,
PA-28-180, S/N’s 28-7505001 & up;
PA-28-235, S/N’s 28-7510001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-131 4H19
Instrument Lights,
PA-28R-200, S/N’s 28-7535001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-132 4H20
Landing Gear,
PA-28R-200, S/N’s 28-7335055 thru 28-7335455 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-90 4H1

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TABLE XI-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS (cont)

Subject Figure GRID NO.

Landing Gear,
PA-28R-200, S/N’s 28-7435001 thru 28-7435331 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-91 4H2
Landing Gear,
PA-28R-200, S/N’s 28-7535001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-127 4H17
Landing Light,
PA-28-140, S/N’s 28-7325053 thru 28-7425454;
PA-28-180, S/N’s 28-7305064 thru 28-7405290;
PA-28R-200, S/N’s 28-7335055 thru 28-7435331;
PA-28-235, S/N’s 28-7310039 thru 28-7410120 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-111 4H11
Landing Light,
PA-28-140, S/N’s 28-7525001 & up;
PA-28-180, S/N’s 28-7505001 & up;
PA-28R-200, S/N’s 28-7535001 & up;
PA-28-235, S/N’s 28-7510001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-142 4H24
Navigation Lights,
PA-28-140, S/N’s 28-7325053 thru 28-7425454;
PA-28-180, S/N’s 28-7305064 thru 28-7405290;
PA-28R-200, S/N’s 28-7335055 thru 28-7435331;
PA-28-235, S/N’s 28-7310039 thru 28-7410120 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-112 4H11
Navigation Lights,
PA-28-140, S/N’s 28-7525001 & up;
PA-28- 180, S/N’s 28-7505001 & up;
PA-28R-200, S/N’s 28-7535001 & up;
PA-28-235, S/N’s 28-7510001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-140 4H23
Overhead Flood Light,
PA-28-140, S/N’s 28-7425001 thru 28-7425454;
PA-28-180, S/N’s 28-7405001 thru 28-7405290;
PA-28R-200, S/N’s 28-7435001 thru 28-7435331;
PA-28-235, S/N’s 28-7410001 thru 28-7410120; . . . . . . . . . . . . . . . . . . . . . . . . . . 11-109 4H11
Overhead Flood Light,
PA-28-140, S/N’s 28-7525001 & up;
PA-28-180, S/N’s 28-7505001 & up;
PA-28R-200, S/N’s 28-7535001 & up;
PA-28-235, S/N’s 28-7510001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-141 4H24
Pitch Trim,
PA-28-140, S/N’s 28-7325053 thru 28-7325684;
PA-28-180, S/N’s 28-7305064 thru 28-7305611;
PA-28R-200, S/N’s 28-7335055 thru 28-7335455;
PA-28-235, S/N’s 28-7310039 thru 28-7310187 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-113 4H12
Pitch Trim,
PA-28-140, S/N’s 28-7425001 & up;
PA-28-180, S/N’s 28-7405001 & up;
PA-28R-200, S/N’s 28-7435001 & up;
PA-28-235, S/N’s 28-7410001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-114 4H12

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TABLE X-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS (cont)

Subject Figure GRID NO.

Pitot Heat,
PA-28-140, S/N’s 28-7325053 thru 28-7425454 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-115 4H12
Pitot Heat,
PA-28-180, S/N’s 28-7305064 thru 28-7305611;
PA-28-235, S/N’s 28-7310039 thru 28-7310187 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-116 4H12
Pitot Heat,
PA-28-180, S/N’s 28-7405001 thru 28-7405290;
PA-28-235, S/N’s 28-7410001 thru 28-7410120 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-117 4H13
Pitot Heat,
PA-28-140, S/N’s 28-7525001 & up;
PA-28-180, S/N’s 28-7505001 & up;
PA-28-235, S/N’s 28-7510001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-137 4H23
Pitot and Pressure Head Heater,
PA-28R-200, S/N’s 28-7335055 thru 28-7435331 . . . . . . . . . . . . . . . . . . . . . . . . . 11-118 4H13
Pitot and Pressure Head Heater,
PA-28R-200, S/N’s 28-7535001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-143 4H24
Radio Lights,
PA-28-140, S/N’s 28-7425001 & up;
PA-28-180, S/N’s 28-7405001 & up;
PA-28R-200, S/N’s 28-7435001 & up;
PA-28-235, S/N’s 28-7410001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-119 4H13
Rotating Beacon,
PA-28-140, S/N’s 28-7325053 & up;
PA-28-180, S/N’s 28-7305064 & up;
PA-28R-200, S/N’s 28-7335055 & up;
PA-28-235, S/N’s 28-7310039 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-108 4H10
Stall Warning,
PA-28-140, S/N’s 28-7325053 thru 28-7525350;
PA-28-180, S/N’s 28-7305064 thru 28-7505269;
PA-28R-200, S/N’s 28-7335055 thru 28-7535393;
PA-28-235, S/N’s 28-7310039 thru 28-7510145 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-120 4H13
Stall Warning,
PA-28-140, S/N’s 28-7625001 & up;
PA-28R-200, S/N’s 28-7635001 & up;
PA-28-235, S/N’s 28-7610001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-138 4H23
Turn & Bank,
PA-28-140, S/N’s 28-7325053 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-121 4H14
Turn & Bank,
PA-28-180, S/N’s 28-7405001 & up;
PA-28-235, S/N’s 28-7410001 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-122 4H14
Turn & Bank,
PA-28R-200, S/N’s 28-7335055 & up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-123 4H14

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Figure 11-21. Testing Rectifiers (Positive)

The meter reading for each of the rectifiers should be the same. Always contact the connection nearest
the rectifiers.
Do not break the sealing on the rectifier lead wire or on the top of the rectifiers. The sealing material is
used for corrosion protection.
The reading on the meter will indicate 1.7 or over for good rectifiers. Where two of the rectifiers are
good and one is shorted, the reading taken at the good rectifiers will show low. The reading at the
shorted rectifier will be zero. Cut the lead at the bad rectifier and the reading at the two good rectifiers
will come up to normal. Where one of the rectifiers is open, it will read low (1 amp or less) the two good
rectifiers will show normal.

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Figure 11-145. Strobe Light Connections

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TABLE XI-V. ELECTRICAL WIRE CODING (PIR-PPS55006, Rev. V.)

Circuit Function
Letter Circuit
A AUTOPILOT
AC AIR CONDITIONING
C CONTROL SURFACE
E ENGINE INSTRUMENT
F FLIGHT INSTRUMENT
G LANDING GEAR
H HEATER, VENTILATING & DEICING
J IGNITION
K STARTER
L LIGHTING
M MISC. EQUIP. - (Cigar Lighter, Hour Meter, etc.)
P DC POWER
Q FUEL & OIL QUANTITY
RP RADIO POWER
RG RADIO GROUND
RZ RADIO AUDIO & INTERPHONE
W WARNING

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SECTION XII - ELECTRONICS

TABLE OF CONTENTS

Paragraph Grid No.

12-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I2

12-2. Emergency Locator Transmitter (Garrett Mfg. Ltd.) . . . . . . . . . . . . . 4I2
12-3. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I2
12-4. Battery Removal and Installation (2 Year Magnesium) . . . . . . . . . . . 4I2
12-5. Battery Removal and Installation (NARCO) . . . . . . . . . . . . . . . . . . . 4I5
12-6. Testing Emergency Locator Transmitter . . . . . . . . . . . . . . . . . . . . . . . 4I7
12-7. Pilot's Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I8
12-8. Testing Pilot's Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I8
12-9. Inadvertent Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I9
12-10. Emergency Locator Transmitter (Communications Components Corp.) 4I10
12-11. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I10
12-12. Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I10
12-13. Pilot's Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I11
12-14. Testing Emergency Locator Transmitter . . . . . . . . . . . . . . . . . . . . . . . 4I11
12-15. Testing Pilot's Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I11
12-16. Inadvertent Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I11
12-17. Autoflight - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I12
12-18. Non-Piper A.F.C.S. Equipment Contacts . . . . . . . . . . . . . . . . . . . . . . 4I12
12-19. Piper A.F.C.S. Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I12
12-20. Rack-Mounted Avionics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I13

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Figure 12-2. ELT Portable Folding Antenna (Narco)

Figure 12-3. ELT Using Fixed Aircraft Antenna (Narco)

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12-17. AUTOFLIGHT. - GENERAL. Due to the wide variety of A.F.C.S. (Automated Flight Control
System) options, it is mandatory to follow the service literature published by the individual manufacturer
of the A.F.C.S. equipment installed in any particular airplane. This includes mechanical service such as;
adjusting, bridle cable tension, servo removal & installation, servo clutch adjustments, etc.
12-18. NON-PIPER A.F.C.S. EQUIPMENT CONTACTS. Refer to Introduction - Supplementary
Publications - Vendor Publications for a listing of AutoPilot/Flight Director manufacturers from which to
obtain service direction, parts support, and service literature.
12-19. PIPER A.F.C.S. EQUIPMENT. In the case of early models, Piper AutoPilot equipment bears the
Piper name, and the appropriate Piper AutoPilot/Flight Director Service Manual shall be used.
NOTE: If a Roll Axis-only AutoPilot is installed, or if no AutoPilot is installed, consult the Piper Pitch
Trim Service Manual - 753 771 for manual electric pitch trim service information.
The following is a complete listing of Piper A.F.C.S. equipment service literature. It is imperative to
correctly identify the AutoPilot system by “faceplate” model name, in order to consult the appropriate
service manual. Each manual identifies the revision level and revision status as called out on the Master
Parts Price List - Aerofiche published monthly by Piper. Consult the aircraft's parts catalog for
replacement parts.
NAME PIPER PART NO.
AutoControl I/II & AltiMatic I/II 753 798
AutoControl III and AltiMatic III and IIIB 753 723
AutoControl III B and AltiMatic III B-1 761 502
AltiMatic IIIC 761 602
AltiMatic V and V-1 761 525
AltiMatic V F/D and V F/D-1 761 526
AltiMatic X F.D./A.P./ & X A.P. 761 668
AutoFlite 753 720
AutoFlite II 761 481
Piper Pitch Trim (Manual-Electric) 757 771

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12-20. RACK-MOUNTED AVIONICS (PIR-PPS60237, Rev. New.)

Late-model avionics are rack-mounted, front-removable units generally secured to the instrument panel
tray/rack by a single jackscrew located in the center of their faceplate. If installed, they should be
removed and installed as follows:
a. Removal
1. Insert an appropriate size (generally 3/32 inch) allen wrench into the jackscrew access hole in
the faceplate.
2. Unscrew the jackscrew in a counterclockwise direction.
3. Slide the avionics unit aft and out of the instrument panel tray/rack.
b. Installation
NOTE: Inspect the front of the panel-mounted avionics tray/rack to verify it is not significantly
inset from the panel. If so, correct the tray/rack installation before proceeding.
NOTE: The high insertion forces required to seat a unit with “high density” connectors tend to
limit the effectiveness of the first seating attempt. Accordingly, the following procedure
requires sequential applications of force, and subsequent tightening of the jackscrew, to
ensure all connectors seat properly.
1. Slide the avionics unit into the instrument panel rack and forward applying a moderate
insertion force.
2. Insert an appropriate size (generally 3/32 inch) allen wrench into the jackscrew access hole in
the faceplate and tighten to remove any slack, but do not try to “pull” unit into place with the
jackscrew.
3. Apply additional insertion force to front of unit.
4. Tighten jackscrew again.
5. Apply additional insertion force to front of unit.
6. Finish tightening jackscrew.
7. Ensure that unit bezel is “tight” against panel.

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SECTION XIV- ACCESSORIES AND UTILITIES

TABLE OF CONTENTS

Paragraph Grid No.

14-1. Air Conditioning Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J6

14-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J6
14-3. Air Conditioning System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4J6
14-4. Malfunction Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J9
14-5. Special Servicing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J10
14-6. Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J12
14-7. Service Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J12
14-8. Test Gauge and Manifold Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J13
14-9. Checking the System for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J13
14-10. Leak Check - Method I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J15
14-11. Leak Check - Method II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J16
14-12. Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J16
14-13. Evacuating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J17
14-14. Charging the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J18
14-15. With a Charging Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J19
14-16. Using the Airplane Compressor to Charge the System . . . . . . . . . . . . 4J20
14-17. Addition of Partial Charge to System . . . . . . . . . . . . . . . . . . . . . . . . . 4J21
14-18. Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J22
14-19. Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J23
14-20. Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J23
14-21. Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J24
14-22. Replacement of Compressor and/or Alternator Drive Belts . . . . . . . . 4K1
14-23. Adjustment of Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K3
14-24. Magnetic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K7
14-25. Magnetic Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K7
14-26. Magnetic Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K8
14-27. Refrigerant Lines and Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K8
14-28. Receiver-Dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K9
14-29. Receiver-Dehydrator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K9
14-30. Receiver-Dehydrator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K9
14-31. Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K9
14-32. Condenser Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K9
14-33. Condenser Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K10
14-34. Condenser Door Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K10
14-35. Condenser Assembly Rigging Instructions . . . . . . . . . . . . . . . . . . . . . 4K12
14-36. Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K13
14-37. Expansion Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K13
14-38. Expansion Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K13

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SECTION XIV- ACCESSORIES AND UTILITIES

TABLE OF CONTENTS (cont.)

Paragraph Grid No.

14-39. Evaporator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K14

14-40. Evaporator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K14
14-41. Evaporator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K14
14-42. Pressure Relief Switch (Ranco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K15
14-43. Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K16
14-44. Adjustment of Throttle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K16
14-45. Fuse Replacement (PA-28-140, S/N’s 28-7125472 to 28-7325057,
PA-28-180, S/N’s 28-7205092 to 28-7305071, PA-28R-180,
S/N’s 28R-7235001 to 28R-7335057.) . . . . . . . . . . . . . . . . . . . . . 4K17
14-46. Fuse Replacement (PA-28-140, S/N’s 28-7325058 and up, PA-28-180,
S/N’s 28-7305072 and up, PA-28R-200, S/N’s 28R-7335058 and up.) 4K17
14-47. Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L4
14-48. Overhead Vent Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L4
14-49. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L4
14-50. Removal of Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L4
14-51. Disassembly of Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L5
14-52. Reassembly of Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L5
14-53. Installation of Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L5
14-54. Portable Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L6

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SECTION XIV

ACCESSORIES AND UTILITIES

14-1. AIR CONDITIONING INSTALLATION.

14-2. DESCRIPTION.
This installation consists of a compressor with its special bracketry, an evaporator, a condenser, a
receiver-dehydrator, circulating fan, thermal expansion valve, and related plumbing.
The evaporator filters, dehumidifies and cools the air. The evaporator is mounted in a fabricated housing
along with the receiver-dehydrator, circulating fan, thermal expansion valve and related plumbing. This
housing is located at the rear of the cabin, aft of the baggage area. The compressor is a two cylinder,
piston type compressor which is supported by special bracketry at the front of the engine. A V-belt
connected to the engine ring gear drives the compressor through a magnetic clutch. The condenser is
installed on a hinge mounted door that is located on the bottom portion of the fuselage tail section. The
condenser door is hinge mounted to allow extension into the airstream during system operation. The
condenser door is electrically activated to provide the following positions, (system on - fully extended or
system off - fully retracted).
The system is protected by a Ranco type pressure switch which automatically controls the condenser
maximum head pressure by temporarily de-clutching the compressor in the event the pressure becomes
excessively high. The controls are located on the aircraft instrument panel adjacent to the heater and
defroster levers, and consist of an Air Conditioning control, a fan control to govern the cold air velocity,
and a temperature control.
The system design is such that there is no increase in drag to the aircraft during its take-off flight
conditions. During maximum power demands the compressor is de-clutched and the condenser door is
automatically retracted.
14-3. AIR CONDITIONING SYSTEM OPERATION.
The air conditioning system in this aircraft is a recirculating, independent unit. It filters dehumidifies and
cools the air as it cycles through the evaporator. The unit is operated from controls mounted on the right
side of the instrument panel. The air conditioning master switch has three positions on early models:
“FAN only, OFF and AIR COND” and a two-position ON-OFF switch on later models. When the “AIR
COND” position is selected the compressor clutch engages, the condenser scoop opens and the
circulating fan is turned on. The temperature is controlled by a thermostat operated by the temperature
control selector. A three-position fan switch (LOW-MED-HIGH) operates the blower. The fan may be
operated to circulate air without using the air conditioning unit.
The air conditioning system uses Refrigerant 12 as the refrigerant. The refrigerant enters the compressor
as a vapor. The Compressor pressurized the heat-laden vapor until its pressure and heat reach a point
much hotter than the outside air. The compressor then pumps the vapor to the condenser where it cools
and changes to a liquid. The liquid then passes to the receiver-dehydrator. Its function is to filter, remove
any moisture and ensure a steady flow of liquid refrigerant into the evaporator through the expansion
valve. The expansion valve is a temperature controlled metering valve which regulates the flow of the
liquid refrigerant to the evaporator. The evaporator absorbs the heat from the air passing over the coils.
From the evaporator the refrigerant vapor returns to the compressor where the cycle is repeated.

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14-19. COMPRESSOR REMOVAL. (The removal of the compressor requires a complete system discharge.)
See Paragraph 14-12.
a. Be certain the circuit protector is off for the air conditioning system.
b. Remove the engine cowling and right front baffles.
c. Disconnect the electrical leads to the magnetic clutch on the compressor.
d. Depressurize the air conditioning system.
e. Remove the suction and discharge lines from the service valves on the compressor.
NOTE: All open lines should be capped immediately to prevent dirt and moisture from entering the
system.
f. Loosen the bolt securing the compressor idler pulley to release the belt tension and remove belt
from compressor pulley. (Do not force belt over the pulleys.)
g. Support the compressor and remove, the 6 bolts securing the compressor to the engine mounting
brackets.
14-20. COMPRESSOR INSTALLATION.
NOTE: In PA-28-140 S/N’s 28-7125472 and up, as required, use one (1) NAS1149F0663P washer
and/or one (1) NAS1149F0632P washer, singular or in combination, between air conditioning
brackets 99630-000 and 79584-002 and compressor or those A/C brackets and engine to reduce
any gap condition to 0.000 to 0.030 inch maximum.
a. Place the compressor to the mounting brackets. Install the six bolts and progressively torque to 14-
17 ft. pounds. (Safety all bolts with .032 safety wire.)
b. Check the oil level in the compressor in accordance with instructions given in paragraph 14-21.
c. Place drive belt over clutch pulley and adjust the alignment of the pulleys and belt in accordance
with instructions given in paragraph 14-22.
CAUTION: DO NOT FORCE THE BELT INTO THE PULLEY SHEAVE. IF NECESSARY,
REMOVE THE IDLER ASSEMBLY.
d. Connect the discharge and suction lines to their respective service valve fittings.
e. Evacuate and charge the system per paragraphs 14-13 and 14-14.

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14-39. EVAPORATOR ASSEMBLY.

The evaporator assembly consists of the evaporator core, receiver-dehydrator, expansion valve,
circulating fan and pressure switch together with necessary housing and plumbing. The housing is
fabricated of Cycolac type material. The condensed moisture is dumped overboard through a hose
clamped to a fitting on the bottom of the evaporator housing.
14-40. EVAPORATOR ASSEMBLY REMOVAL.
The evaporator assembly is located behind the cabin rear panel, attached to the mounting panel with 12
screws and washers and a bracket securing the back to the mounting panel.
a. Remove air conditioning filter cover, filter and rear access panels.
NOTE: Discharge the system before disassembling.
b. Uncouple the liquid line from the inlet side of the receiver-dehydrator and the suction line from the
evaporator core outlet. (See Paragraph 14-5, B-7.)
c. Disconnect the related electrical wires.
d. Remove flexible air duct from housing outlet. Remove drain hose from housing.
e. Remove temperature probe from evaporator housing.
f. Remove the screws attaching the support bracket and evaporator housing to the mounting panel.
Remove the assembly through the access hole in the bulkhead.
14-41. EVAPORATOR ASSEMBLY INSTALLATION.
a. Cement gasket in place on the flanges of the evaporator housing and attach the large end of the
mounting gasket to the back of the housing.
b. Install the housing through the access hole with the air duct outlet on top. Mate the mounting
flanges to the mating surface of the mounting panel and insert the screws. (Do not tighten at this
time.)
c. Line up the mounting bracket with mating holes in mounting panel, insert screws and tighten.
Tighten screws in the flange at this time. Be certain gasket is in place. The flange must have an air
tight seal.
d. Couple the suction and discharge lines to their respective fittings (apply Loctite refrigerant sealant
to tube flanges only).
e. Evacuate and charge system. (See Paragraphs 14-13 and 14-14.)
f. Check for leaks (see Paragraph 14-9).
g. If no leaks are detected, seal and install access panel on evaporator housing.
h. Couple flexible air duct and drain tube.
i. Make and check electrical connections. (Refer to Figure 14-14.)
j. Check operation of blower and refrigerant systems.
k. Install rear bulkhead panels. Be certain to seal. (See NOTE.)

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14-47. RESTRAINT SYSTEM.

a. Inspections.
1. Shoulder Harness:
(a) Inspect ends and attachment points for condition and security.
(b) Inspect harness web material for condition and wear over its entire length. Particularly
look for wear and fraying where harness web passes in and out of inertial reel. If
excessively worn, replace.
(c) Check inertia reel mechanism by pulling sharply on strap. Verify reel will lock in place
under sudden stress.
2. Lap Belt:
(a) Inspect ends and attachment points for condition and security.
(b) Inspect harness web material for condition and wear over its entire length. Particularly
look for wear and fraying where harness web passes in and out of adjustable buckle end.
If excessively worn, replace.
(c) Inspect shoulder harness keeper nylon bushing. If excessively worn or missing,
replacement of that half of the lap belt is required.
b. Inertial Reel Adjustment.
The inertial reel locking feature prevents the shoulder strap from extending and holds occupant in
place. For normal movement strap will extend and retract as required. If required, adust inertial reel
as follows:
1. Allow harness to wind up on reel as much as possible.
2. On end of reel, pry off plastic cover over spring. Make sure spring does not come out of plastic
cover. Set aside plastic cover.
3. Unwind the harness completely. Measure and mark the harness 24 inches from the reel center.
4. Wind harness onto reel until the 24-inch mark is reached. Hold reel and place cap with spring
over reel shaft end.
5. Align slot in shaft with spring tang. Wind spring 6 1/2 turns and snap plastic cover into holes
in reel end shaft.
6. Release harness and allow harness to wind up. Extend harness several times to check reel for
smooth operation.
7. Hold inertia reel with reel completely wound and inertia mechanism end up. Pry off plastic
cover over mechanism and set reel aside.
8. Install nut in plastic cover so that stud in cover is flush with nut surface. Position cover over
reel and snap cover into place. Extend harness several times to ensure reel operates smoothly.
14-48. OVERHEAD VENT BLOWER.
14-49. DESCRIPTION. The blower is mounted in the aft section of the fuselage and is connected to the
overhead vent system. The blower draws air in from the dorsal fin and forces it through the ducting,
whenever desired. The four position blower switch on the instrument panel controls the three speed blower.
14-50. REMOVAL OF BLOWER ASSEMBLY.
a. Remove the access door from the aft wall of the baggage area.
b. With the master switch off, disconnect the plug assemblies at the blower assembly.

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c. Remove the inlet and outlet hoses from the blower assembly by removing the clamps.
d. Remove the screws, washers and nuts that secure the blower assembly to the hangar braces.
e. Remove the screws and washers which secure the blower assembly to the retainer and hangars.
f. Remove the blower assembly from the aircraft.
14-51. DISASSEMBLY OF BLOWER ASSEMBLY.
a. Remove the hose duct from the forward edge of the blower assembly by removing the nuts, washers
and screws.
b. Remove the cover from the blower assembly by removing the nuts, washers and screws.
c. Remove the blower fan from the motor shaft by removing the set screw.
d. For removal of the motor, proceed as follows:
1. Separate the plate from the motor cover by carefully drilling out the connecting rivets.
2. Cut the motor wires at the edge of the receptacle and plug and remove the wire ends from the
blocks.
3. Remove the motor from the mounting plate by removing the nuts, washers and bolts.
14-52. REASSEMBLY OF BLOWER ASSEMBLY.
a. Mount the motor on the plate and secure it with the bolts, washers and nuts. Be sure that the motor
nuts are snug and the shaft spins freely.
b. Position the cover over the motor plate with the motor wires protruding through the cover grommet.
c. With the holes in the cover matching the holes in the motor plate, secure the two parts together with rivets.
d. Apply PRC-5000 sealant to fill any opening left after the wires are brought through the grommet.
e. Install the wires in the plug and receptacle according to Table XIV-V.
f. Position the blower fin on the motor shaft and secure with set screw.
g. Secure the cover to the blower assembly with screws, washers and nuts.
h. Position the hose duct on the blower assembly and secure it with screws, washers and nuts. The
screws must be installed with their heads inside the duct.
i. After cleaning the surfaces of all old sealant, use white rubber chalk PRC-5000 sealant to seal
where the duct attaches to the blower assembly.
14-53. INSTALLATION OF BLOWER ASSEMBLY.
a. Position the blower assembly in the hangars and retainer and install the washers and screws.
b. Install the nuts, washers and screws securing the blower assembly to the hangar braces.
c. Seal all hose joints with Arno No. C-520 grap tape; then install the inlet and outlet hoses securing
them with the clamps.
d. With the master switch off, connect the plug and receptacles at the blower.
e. Check the blower for the proper operation.
f. Install the access door to the aft wall of the baggage area and secure with the attaching hardware.

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TABLE XIV-V. BLOWER SYSTEM WIRE COLOR CODES

MOTOR WIRES AIRCRAFT WIRES

Pin. 15920-01 E362Q F0018075FA

Nos. General Singer Leece- Aircraft Pin
Industries Controls Neville Harness Nos.

Receptacle
Ground 2 Brown Brown Black AC26A 2
Plug

Low Speed 1 Red Yellow Yellow Black 1

Receptacle

Medium Speed 2 Black Red Red White 2

Plug
High Speed 1 Yellow Orange Orange Red 1
NOTE: Pin number 1 is at the pointed side of the plug and receptacle. Wire color codes for YY75062
ESB-Universal Electric Company are same as E 362Q Singer Control color code listed above.

14-54. PORTABLE FIRE EXTINGUISHER

a. Inspection
Disposable type fire extinguishers should be maintained and inspected in accordance with the
nameplate instructions.
1. Monthly
Inspect monthly or more frequently. Ensure nozzle is not obstructed and safety seal is intact.
Inspection is a "quick check" that an extinguisher is available and will operate. It is intended to
give reasonable assurance that the extinguisher is fully charged and operable. This is done by
seeing that it is in its designated place, that it has not been actuated (discharged) or tampered
with, and that there is no obvious physical damage or condition to prevent operation.
Determine fullness by weighing or "hefting."
2. 100 Hour / Annual
Each 100 hours or annually, whichever comes first, weigh the extinguisher. Replace and return
to manufacturer if gross weight is below the minimum specified on the nameplate.

XIV - ACCESSORIES AND UTILITIES 01/31/08

4L6
 PIPER CHEROKEE SERVICE MANUAL

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01/31/08 XIV - ACCESSORIES AND UTILITIES

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 PIPER CHEROKEE SERVICE MANUAL

GRIDS 4L8 THRU 4L24

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XIV - ACCESSORIES AND UTILITIES 01/31/08

4L8