Special Service Project - Cessna

Special Service Project

August 30, 2004 SSP04-57-02

TITLE

WING RIB INSPECTION/MODIFICATION

EFFECTIVITY

Model Serial Numbers

182T 18281292 thru 18281297 and 18281299

T182T T18208224 and T18208225

REASON

It has been determined that some airplanes may have been delivered with a cracked rib in the left and rightwing assemblies.

DESCRIPTION

The left and right wings shall be inspected for a possible cracked rib and if necessary, modified as specified inthis Special Service Project. Non-compliance with this Special Service Project could result in less than thedesigned structural integrity of the affected wing rib.

COMPLIANCE

Mandatory: shall be accomplished within the next 25 hours of operation or 3 months, whichever occurs first.

APPROVAL

FAA approval has been obtained on technical data in this publication that affects airplane type design.

MANPOWER

1.7 man-hours per airplane for inspection

If necessary, 3.9 man-hours to modify the rib in one wing and an additional 2.9 man-hours to modify the ribin a second wing

Page 1 of 20

To obtain satisfactory results, procedures specified in this publication must be accomplished in accordance with accepted methods andprevailing government regulations. Cessna Aircraft Company cannot be responsible for the quality of work performed in accomplishing therequirements of this publication.

Cessna Aircraft Company, Product Support, P.O. Box 7706, Wichita, Kansas 67277, U.S.A. (316) 517-5800, Facsimile (316) 942-9006

COPYRIGHT © 2004

REFERENCES

Model 182/T182 Series 1996 and On Maintenance ManualSingle Engine Models 172, 182, T182, 206 And T206 1996 and On Structural Repair Manual

NOTE: Make sure all publications used are complete and current.

NOTE: This information shall be considered an amendment to the Cessna Manufacturer’s Service/MaintenanceManual or Instructions for continued airworthiness and must be accomplished for ongoing airworthinesscompliance as required per 14 CFR Part 43.13.

OTHER PUBLICATIONS AFFECTED

Model 182S/182T/T182T Illustrated Parts Catalog

NOTE: Make sure all publications used are complete and current.

MATERIAL PRICE AND AVAILABILITY

The parts below are available from Cessna Parts Distribution through an appropriate Cessna Service Stationfor the suggested list price shown.

Part Number Description Qty/Airplane Price

CR3243-4-02(AlternateS2456-4-2)

Rivet 6 (if required) $ 0.81 (PS) ea MQ 25

MS20470AD3-4A Rivet 22 (if required) $ 52.37 (PS) lb

MS20470AD4-4A Rivet 6 (if required) $ 31.13 (PS) lb

MS20470AD4-3A5 Rivet 4 (if required) $ 27.63 (PS) lb

S1022Z8-8 Screw 12 (if required) $ 0.13 (PS) ea MQ 100

1222021-1 Doubler Assembly 2 (if required) $ 87.80 (SE) ea

1222021-2 Access Cover Plate 2 (if required) $ 14.30 (SE) ea

U074093 Alodine 1132 Marker (as required) $ 135.00 (VR) ea

K000912 Primer(1.5 Gal Kit)

(as required) $ 301.00 (VS) ea

ALL PRICES SUBJECT TO CHANGE WITHOUT NOTICE

CREDIT INFORMATION

A labor allowance credit of 1.7 man-hours per airplane will be provided to inspect the left and right wingsfor a cracked rib.If necessary, a miscellaneous parts credit of $ 115.00 per wing and a labor allowance credit of 3.9 man-hourswill be provided to modify one wing rib and an additional 2.9 man-hours will be provided to modify a secondwing rib as specified in this Special Service Project.To receive credit, the work must be completed and a Warranty Claim submitted by a Cessna Single EngineService Station within 30 calendar days of Special Service Project compliance before the credit expirationdates shown below.

Domestic . . . . . . . . . . . . . . . . . . November 30, 2004International . . . . . . . . . . . . . . . December 30, 2004

SSP04-57-02Page 2 August 30, 2004

ACCOMPLISHMENT INSTRUCTIONS

Weight And Balance Information

MODEL . . . . . . . . . . . . . . . . . . . . . . . 182T/T182T

WEIGHT CHANGE . . . . . . . . . . . . . . . Negligible

Material Information

The parts listed below may be necessary.

NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSI-TION

CR3243-4-02 6 Rivet None None

MS20470AD3-4A 22 Rivet None None

MS20470AD4-4 6 Rivet None None

MS20470AD4-3.5 4 Rivet MS20470AD4-3.5 Discard

S1022Z8-8 12 Screw None None

1222021-1 2 (as required) Doubler Assembly None None

1222021-2 2 (as required) Access Cover Plate None None

The materials, or equivalent, listed in this table may be necessary.

NAME NUMBER MANUFACTURER USE

Aluminum 2024-T3 (0.040 inch) Commercially available To make flange bracket.

Touch-N-Prep Alodine 1132 Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218 USA

To apply to bare metaledges.

Primer K000912 Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218 USA

To put on doubler andrepair angle.

Corrosion resistantprimer

513 x 419910 Courtaulds Aerospace1608 Fourth StreetBerkeley, CA 94710

To put on the bare metaledges.

SSP04-57-02August 30, 2004 Page 3

Instructions

1. Electrically ground the airplane and turn all switches to the "OFF" position. If external power is connectedto the airplane, disconnect external power from receptacle.

2. Disconnect the airplane battery. (Refer to the Model 182/T182 Series 1996 and On Maintenance Manual,Chapter 24, Electrical Power.)

3. Attach maintenance warning tags to the battery and external power receptacle that have "DO NOTCONNECT ELECTRICAL POWER - MAINTENANCE IN PROGRESS" written on them.

4. (Refer to Figure 1, Detail B, C and View B-B.) Inspect and modify the right wing 0722195-1 Rib-CenterSection as necessary.

A. Remove the 610EB, 620DB, and 620JB Access Panels from the right wing and keep thescrews. (Refer to the Model 182/T182 Series 1996 and On Maintenance Manual, Chapter 6,Access/Inspection Plates.)

B. Do an inspection on the 0722195-1 Rib.

(1) Use a flashlight and mirror and look for cracks on the aft corners of the 0722195-1 Rib.

(a) If no cracks are found on the right wing 0722195-1 Rib, go to Step 4E.

(b) If cracks are found, go to Step 4C for modification instructions.

C. (Refer to Figure 1, Detail B, F.) Install a new right wing access panel outboard of WS 118.0.

NOTE: The new access panel provides room for the 0722195-1 Rib to be modified.

(1) Measure and put a mark on the wing skin 4.0 inches outboard from the center of the rivetsinstalled in the wing rib at WS 118.0, and even with the center of the fourth rivet forward ofthe aft wing spar on WS 118.0.

(2) Measure and put a mark on the wing skin 3.75 inches forward of the center of the rivetsinstalled in the aft wing spar, and even with the center of the third rivet outboard of the wing ribat WS 118.0.

(3) (Refer to Figure 1, Detail C.) Make a 5.70 inch diameter circle (2.85 inch radius) on the wingskin with the mark located in Step 4C(1) and (2) as a center point.

NOTE: (Refer to Figure 1, Detail F.) Before you cut the new wing skin access panel hole, use a1222021-1 Doubler to make sure it will fit where you will locate the new access panelhole on the wing skin, Make sure it does not touch the aft wing spar, and make surethe flat edge of the doubler is towards the aft spar for proper fit. Adjust the new holelocation as necessary until the doubler will fit.

CAUTION: IF THE NEW ACCESS HOLE IS NOT CUT IN THE CORRECT LOCATION,THE HOLE DOUBLER WILL NOT FIT.

(a) Remove the wing skin in the 5.70 inch diameter circle, deburr the new wing skin holeand then alodine the hole edge.

SSP04-57-02Page 4 August 30, 2004

(4) (Refer to Figure 1, Detail F.) Install a new wing access panel 1222021-1 Doubler on theinside of the wing skin.

(a) Use the Number 40 (0.098 inch diameter) holes already drilled in the 1222021-1 Doubleras a guide to drill the eleven Number 40 (0.098 inch diameter) rivet holes through thewing skin. (Refer to the Single Engine Models 172, 182, T182, 206 And T206 1996 andOn Structural Repair Manual.)

(b) Install the 1222021-1 Doubler in the wing with temporary fasteners to make sure it fitscorrectly, and then remove the doubler until the wing rib modification is completed.

D. Modify the aft edge of the 0722195-1 Rib in the wing at WS 118.0.

(1) Remove the 4 rivets that attach the autopilot trim cable pulley bracket to the aft spar asnecessary. (Refer to the Model 182S/182T/T182T Illustrated Parts Catalog, Chapter 22,Autopilot Installation.)

NOTE: It is not necessary to loosen the autopilot trim cable tension when removing thecable bracket.

NOTE: You may allow the cable pulley bracket to hang down or you can put it into thecorner out of the way.

(2) Remove the 3 rivets that attach the aft flange of the 0722195-1 Rib to the aft wing spar.

(3) (Refer to Figure 1, Detail G.) Put a vertical line on the aft flange of 0722195-1 Rib about 0.05inch forward of the radius of the flange. Use this line to cut the flange off.

CAUTION: TO PREVENT DAMAGE TO THE AFT SPAR WHEN THE AFT FLANGE OFTHE RIB IS CUT OFF, INSERT A PIECE OF APPROPRIATE THICKNESSSTAINLESS STEEL SHEET METAL BETWEEN THE AFT SPAR AND THE AFTRIB FLANGE UNTIL THE FLANGE IS CUT OFF.

(4) Cut and remove the aft flange of the 0722195-1 Rib with a rotary cutter and deburr the ribedges.

(5) (Refer to Figure 1, Detail H, View B-B and C-C.) Make a new flange bracket for the aft edge ofthe 0722195-1 Rib.

(a) Make a new flange bracket with ALCLAD 2024-T3 0.032 inch aluminum as shown,deburr and round the edges.

(b) Put a bend line 0.063 inches along the length of the bracket as shown.

(c) Bend the new bracket with a 0.12 inch radius 90 degrees along the bend line as shown.

(d) Drill three Number 40 (0.098 inch diameter) pilot holes into the bracket in the locationsshown.

(e) Put epoxy primer on the new bracket.

(6) (Refer to Figure 1, Detail H.) Install the new bracket.

(a) Put the new bracket on the aft edge of the 0722195-1 Rib flush against the aft spar.

(b) Hold the bracket flange in place flush against the rib with the 0.63 inch wide flange flushagainst the aft spar. Use the three Number 40 (0.098 inch diameter) pilot holes in the newbracket to drill three Number 27 (0.144 inch diameter) holes through the 0722195-1 Rib.

(c) Use temporary fasteners to hold the new bracket to the rib and flush against the aft spar.

(d) Match drill 3 Number 30 (0.1285 inch diameter) holes in the aft spar and through thenew bracket flange.

SSP04-57-02August 30, 2004 Page 5

(e) Remove the new bracket, deburr, alodine, and prime the new bracket.

(f) Install the new bracket with three CR3243-4-02 Rivets through the bracket and the0722195-1 Rib.

NOTE: Use temporary fasteners as necessary to hold bracket to the rib and to the rearspar while the bracket is riveted to the rib.

(g) Install three MS20470AD4-4 Rivets through the bracket flange and the aft spar.

(h) Install the autopilot trim pulley bracket with four MS20470AD4-3.5 Rivets.

(i) Apply alodine and primer on the installed bracket as necessary.

E. (Refer to Figure 1, Detail I.) Use a borescope and do an inspection of the lower forward radius of the0722195-1 Rib for cracks.

(1) If no cracks are found, go to Step 4G.

(2) If cracks are found on the lower forward radius, use a round hand file and remove materialalong the crack until the crack is completely removed. Alodine and prime the repaired rib areas.

F. (Refer to Detail F.) Install the 1222021-1 Doubler with MS20470AD3 Rivets and install the new1222021-2 Access Cover Plate with S10222Z8-8 Screws.

G. Apply alodine and primer as necessary.

H. Install the access panels removed in Step 4A with the kept screws.

5. (Refer to Figure 1, Sheet 5.) Inspect and modify the left wing 0722195-1 Rib as necessary.

A. Remove the 520FB, 520JB, and 520DB Access Panels on the left wing and keep the screws. (Referto the Model 182/T182 Series 1996 and On Maintenance Manual, Chapter 6, Access/InspectionPlates.)

B. Do an inspection on the left wing 0722195-1 Rib.

(1) Use a flashlight and mirror and look for cracks on the aft corners of the 0722195-1 Rib.

(a) If no cracks are found on the left wing 0722195-1 Rib, go to Step 5E.

(b) If cracks are found, go to Step 5C for repair instructions.

C. (Refer to Figure 1, Detail D and E.) Install a new left wing access panel inboard of WS 118.0.

NOTE: The new access panel provides room for the 0722195-1 Rib to be repaired.

(1) Measure and put a mark on the wing skin 4.0 inches inboard from the center of the rivetsinstalled in the wing rib at WS 118.0, and even with the center of the fourth rivet forward ofthe aft wing spar on WS 118.0.

(2) Measure and put a mark on the wing skin 3.75 inches forward of the center of the rivetsinstalled in the aft wing spar, and even with the center of the third rivet inboard of the wing ribat WS 118.0.

(3) Make a 5.70 inch diameter circle (2.85 inch radius) on the wing skin with the mark locatedin Step 5C(1) and 5C(2) as a center point.

NOTE: (Refer to Figure 1, Detail F.) Before you cut the new wing skin access panel hole, usea 1222021-1 Doubler to make sure it will fit where you will located the new accesshole on the wing skin so it does not touch the aft wing spar. Make sure the flat edgeof the doubler is towards the aft spar for proper fit. Adjust the new hole locationas necessary until the doubler will fit.

CAUTION: IF THE NEW ACCESS HOLE IS NOT CUT IN THE CORRECT LOCATION,THE HOLE DOUBLER WILL NOT FIT.

(a) Remove the wing skin in the 5.70 inch diameter circle with a rotary cutter, deburr the newwing skin hole and then alodine the hole edge.

SSP04-57-02Page 6 August 30, 2004

(4) (Refer to Figure 1, Detail F.) Install a new wing access panel 1222021-1 Doubler on the insideof the wing skin with MS20470AD3-3 Rivets.

(a) Use the Number 40 (0.098 inch diameter) holes already drilled in the 1222021-1 Doubleras a guide to drill the eleven Number 40 (0.098 inch diameter) rivet holes through thewing skin. (Refer to the Single Engine Models 172, 182, T182, 206 And T206 1996 andOn Structural Repair Manual.)

(b) Install the 1222021-1 Doubler in the wing with temporary fasteners to make sure it fitscorrectly, and then remove the doubler until the wing rib modification is completed.

D. Modify the aft edge of the 0722195-1 Rib in the wing at WS 118.0.

(1) Remove the 3 rivets that attach the aft flange of the 0722195-1 Rib to the aft wing spar.

(2) (Refer to Figure 1, Detail G.) Put a vertical line on the aft flange of 0722195-1 Rib about 0.05inch forward of the radius of the flange to use to cut the flange off.

CAUTION: TO PREVENT DAMAGE TO THE AFT SPAR WHEN THE AFT FLANGE OFTHE RIB IS CUT OFF, INSERT A PIECE OF APPROPRIATE THICKNESSSTAINLESS STEEL SHEET METAL BETWEEN THE AFT SPAR AND THE AFTRIB FLANGE UNTIL THE FLANGE IS CUT OFF.

(3) Cut and remove the aft flange of the 0722195-1 Rib with a rotary cutter, deburr the rib edges.

(4) (Refer to Figure 1, Detail H.) Make a new flange bracket for the aft edge of the 0722195-1 Rib.

(a) Make a new flange bracket with ALCLAD 2024-T3 0.032 inch aluminum as shown,deburr and round the edges.

(b) Put a bend line 0.63 inches along the length of the bracket as shown.

(c) Bend the new bracket with a 0.12 inch radius 90 degrees along the bend line as shown.

(d) Drill three Number 40 (0.098 inch diameter) pilot holes into the bracket in the locationsshown.

(e) Put epoxy primer on the new bracket.

(5) (Refer to Figure 1, Detail H, View B-B and C-C.) Install the new bracket.

(a) Put the new bracket on the aft edge of the 0722195-1 Rib against the aft spar.

(b) Hold the bracket in place flush against the rib with the 0.63 inch flange flush against theaft spar. Use the 3 Number 40 (0.098 inch diameter) pilot holes in the new bracket to drill3 Number 27 (0.144 inch diameter) holes through the 0722195-1 Rib.

(c) Use temporary fasteners to hold the bracket to the rib and flush against the aft spar.

(d) Match drill 3 Number 30 (0.1285 inch diameter) holes in the aft spar and through thenew bracket.

(e) Remove the new bracket, deburr, alodine, and prime the new bracket flange.

(f) Install the new bracket with 3 each CR3243-4-02 Rivets through the bracket and the0722195-1 Rib.

NOTE: Use temporary fasteners as necessary to hold bracket to the rib and to the rearspar while the bracket is riveted to the rib.

(g) Install 3 MS20470AD4-4 Rivets into the bracket flange and the aft spar.

(h) Apply alodine and primer on the installed bracket as necessary.

SSP04-57-02August 30, 2004 Page 7

E. (Refer to Detail I.) Use a borescope and do an inspection of the lower forward radius of the0722195-1 Rib for cracks.

(1) If no cracks are found, go to Step 5G.

(2) If cracks are found on the lower forward radius, use a round hand file and remove materialalong the crack until the crack is completely removed, and then alodine and prime the rib areas.

F. (Refer to Detail F.) Install the 1222021-1 Doubler in the left wing with MS20470AD3 Rivets and installa new 1222021-2 Access Cover Plate with S10222Z8-8 Screws.

G. Install the access panels removed in Step 5A with the kept screws.

H. Do a paint touch-up with paint that matches as necessary.

6. Remove maintenance warning tags from battery and external power receptacle.

7. Reconnect the airplane battery. (Refer to the Model 182/T182 Series 1996 and On Maintenance Manual,Chapter 24, Electrical Power.)

8. Make an entry in the airplane logbook that states compliance and method of compliance with this SpecialService Project.

SSP04-57-02Page 8 August 30, 2004

Figure 1. Wing Rib Inspection/Modification (Sheet 1)

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OWNER NOTIFICATION

On August 30, 2004 the following message will be sent to applicable owners of record in SSP04-57-02A.

Dear Cessna Owner:

This Owner Advisory is to inform you that it has been determined that some airplanes may have been deliveredwith a cracked rib in the left and right wing assemblies.

The left and right wings shall be inspected for a possible cracked rib and if necessary, modified as specifiedin Special Service Project SSP04-57-02. Non-compliance with SSP04-57-02 could result in less than thedesigned structural integrity of the affected wing rib.

Compliance is mandatory: shall be accomplished within the next 25 hours of operation or 3 months, whicheveroccurs first.

The information contained in the referenced Cessna Special Service Project shall be considered an amendmentto the Cessna Manufacturer’s Service/Maintenance Manual or Instructions for continued airworthiness, andmust be accomplished for ongoing airworthiness compliance as required per 14 CFR Part 43.13.

A labor allowance credit of 1.7 man-hours per airplane will be provided to inspect the left and right wingsfor a cracked rib.

If necessary, a miscellaneous parts credit of $ 115.00 per wing and a labor allowance credit of 3.9 man-hourswill be provided to modify one wing rib and an additional 2.9 man-hours will be provided to modify a secondwing rib as specified in SSP04-57-02.

To receive credit, the work must be completed and a Warranty Claim submitted by a Cessna Single EngineService Station within 30 calendar days of Special Service Project compliance before the credit expirationdates shown below.

Domestic . . . . . . . . . . . . . . . . . . November 30, 2004International . . . . . . . . . . . . . . . December 30, 2004

Please contact a Cessna Single Engine Service Station for detailed information and arrange to have CessnaSpecial Service Project SSP04-57-02 accomplished on your airplane.

* * * * * * *

SSP04-57-02Page 20 August 30, 2004

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Special Service Project - Cessna