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Spent 11 hours on a flap position sensor fault that turned out to be one chafed wire behind the panel
I chased that fault for 11 hours over two days at a hangar in Fort Worth, swapping the sensor and reflowing solder joints before I finally found a chafed wire hiding behind the panel. The whole fix took 6 minutes once I saw it, but I went through three different wiring diagrams that all showed the run going a different way. How do you all handle intermittent faults when the manual is wrong about the routing?
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henry_ross4d ago
Had a similar mess on a King Air years back, a gear warning that would only pop up when the plane sat in the sun for a few hours. Went through two days of ground checks in the shade where it never failed, then finally left it out on the ramp and caught it. Turned out a wire bundle was rubbing on a rib and heat made the insulation soft enough to short. Manual showed the run going straight through a frame that the bundle never actually touched. These days when I get an intermittent one, I stop trusting the book and just start wiggling every harness in the zone until something talks to me. Chafed wires behind panels are the worst kind of thief, they steal your whole day and laugh at you.
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