Rear gas strut replacement

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Rear gas strut replacement

Postby Rich » Wed May 16, 2018 1:33 pm

The rear strut is getting where it barely works, so I ordered a replacement. But there's a problem with fit. The problem is that the threaded attachment on the replacement part is too long for the upper bracket. The shorter threads in the photo are on the original one. There is not nearly enough depth in the upper bracket to screw it all the way in. Screwing partially in would add torque being transmitted to that bracket.

rear strut.jpg
Original vs new strut


I could swap the ball ends out (my fallback position), but also trying to find out from Diamond what the deal is. Anyone else seen this? I suppose it's possible that Diamond has a different upper bracket from what was installed in the early (2002) models, but I'd rather not change it out.
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Re: Rear gas strut replacement

Postby Steve » Wed May 16, 2018 2:52 pm

Rich:

I had this problem as well. This is the part you need, although you can swap out the one from the old gas strut if you wish. I believe that I simply ground the new one down a couple of millimeters using my grinder. I don't recall where I purchased it, but an online search should fix you up.

Steve

DSCN2826.jpg
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OriensFlight
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Re: Rear gas strut replacement

Postby OriensFlight » Wed May 16, 2018 8:49 pm

Update:
I spoke with Diamond, the reference in the Illustrated Parts Catalog to part # DA4-9052-00-11 is a typo. The correct part for the Passenger Door Gas Spring is DAI-9052-00-11. (The Front Canopy Gas Spring without the sun visors is DAI-9052-00-10.)


Also, about the installation instructions, in:
DA40-Serie/Airplane_Maintenance_Manual/Basic_Manual/60201-r7-DA40-AMM-complete.pdf
on page 207 (52-10-00 5A (2)) it says to:

Remove the gas strut:
- Remove the locking clips from the gas strut top and bottom ball-end fittings.
- Pull the gas strut off the ball end fittings on the fuselage and clear of the airplane.

Is that what you're supposed to do?

-
Hans
N556LU - 2007 DA40 XL 40.763 @ RAM Aviation in Santa Rosa, California
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Re: Rear gas strut replacement

Postby Rich » Wed May 16, 2018 10:16 pm

OriensFlight wrote:Rich:
Since I'm about to order the same gas spring, I'm curious, which part number did you order?
DA4-9052-00-11 or DAI-9052-00-11?

I'm still a newbie when it comes to this stuff, but I perused the parts manual and there are definitely differences between the -180 and -NG, but I also don't really trust that the parts manual is properly synced with the serial numbers. (I've found discrepancies, but they may be related to MÄMs.)

DA40-180/F (Doc.No. 6.03.01/02, updated 2018-02-21)
52-10 Passenger Door Installation
Gas Spring
DA4-9052-00-11

DA40-NG (Doc.No. 6.03.15, updated 2018-02-21)
52-10 Passenger Door Installation
Gas Spring
DAI-9052-00-11 from DA40-NG
Remarks: G08-19-0200-1-0425-WG18-WG18-00400N

Also, about the installation instructions, in:
DA40-Serie/Airplane_Maintenance_Manual/Basic_Manual/60201-r7-DA40-AMM-complete.pdf
on page 207 (52-10-00 5A (2)) it says to:

Remove the gas strut:
- Remove the locking clips from the gas strut top and bottom ball-end fittings.
- Pull the gas strut off the ball end fittings on the fuselage and clear of the airplane.

Is that what you're supposed to do?

-
Hans
N556LU - 2007 DA40 XL 40.763 @ RAM Aviation in Santa Rosa, California


What was listed on the IPC was DA4-9052-00-11, but DAI-9052-00-11 was what got ordered.

Popping the strut off the ball ends is probably what I'll wind up doing. Because the strut came with these fittings already installed I unscrewed them from the frame and made this discovery.
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Re: Rear gas strut replacement

Postby OriensFlight » Wed May 16, 2018 11:07 pm

I spoke with Diamond, the reference in the Illustrated Parts Catalog to part # DA4-9052-00-11 is a typo. The correct part for the Passenger Door Gas Spring is DAI-9052-00-11. (The Front Canopy Gas Spring without the sun visors is DAI-9052-00-10.)

-
Hans
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Re: Rear gas strut replacement

Postby Rich » Thu May 17, 2018 9:18 pm

Wound up popping the ball-sockets apart on the replacement and the plane, of course and popping the new strut in. It's actually quicker and easier than removing/installing with a wrench. Of course, this wouldn't work if the upper ball were worn out. In that case you need the part Steve dug up.

To support the door while doing this:
door support.jpg
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Re: Rear gas strut replacement

Postby Rich » Sat May 19, 2018 3:04 am

And then there was the front strut replacement. The lower pivot is especially fun. It's in front of the rudder pedals. Need to manage to remove and then reinstall into the mounting bracket:

1 bolt - teeny
1 nut - teeny
3 washers - teeny
2 bushings - teeny
the strut itself

reaching past the rudder cables, brake lines, etc., mostly without being able to see the stuff - you know, by feel. Success rating: high, with no blood loss :D
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Re: Rear gas strut replacement

Postby smoss » Sat May 19, 2018 3:09 am

Rich- I learned the hard way that there is a really easy way! (lots of swearing, dropped tiny pieces, and then finally the epiphany). Simply leave the eye bolt end of the old strut attached down there, unscrew the rest of the strut from the end fitting (easily unscrews), and then screw the new one on (minus the end fitting) to the old one. 1 minute job!
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Re: Rear gas strut replacement

Postby Steve » Sat May 19, 2018 3:31 am

smoss wrote:Rich- I learned the hard way that there is a really easy way! (lots of swearing, dropped tiny pieces, and then finally the epiphany). Simply leave the eye bolt end of the old strut attached down there, unscrew the rest of the strut from the end fitting (easily unscrews), and then screw the new one on (minus the end fitting) to the old one. 1 minute job!


I like that method (especially since my front strut is getting weaker). I could just imagine all of the lost parts and blood loss...

Steve

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