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How to Properly Maintain Aviation Cable for Longevity

Aviation cable is the vital, silent workhorse within aircraft control systems, landing gear, and countless critical applications. Its failure is not an option. Proper maintenance isn’t just about saving money on replacements; it’s fundamental to safety and operational reliability. Follow these essential, practical steps to maximize your aviation cable’s lifespan.

1. Regular Visual & Tactile Inspection: Your First Line of Defense

• ​What to Look For: Schedule frequent inspections (at least every 6 months or per manufacturer/aircraft manual). Look for:
  • ​Broken Wires (“Fishhooks”): Especially near fittings, pulleys, or fairleads. Run a clean rag along the cable – snags indicate broken wires. ​Replace immediately if broken wires are found.
  • ​Corrosion: White powder, discoloration (red/brown rust), or green patina. Pay close attention to areas exposed to moisture or chemicals.
  • ​Wear & Abrasion: Flattened sections, excessive “fuzziness,” or noticeable thinning compared to protected areas. Check where cables pass through pulleys, guides, or rub against structures.
  • ​Kinks, Dents, or Birdcaging: Severe deformation where strands bulge outwards. ​This often requires immediate replacement.
  • ​Fitting Damage: Cracks, deformation, corrosion, or loose swages on cable ends and turnbuckles.
• ​Action: Document findings. Tag and remove any cable showing significant damage, corrosion, or the specified number of broken wires in a given length (refer to the specific aircraft/service manual – ​never guess).

2. Thorough & Gentle Cleaning: Removing Destructive Contaminants

• ​Why: Dirt, grease, salt, and chemicals accelerate wear and corrosion.
• ​How:
  • Use a clean, soft cloth or brush.
  • Apply a mild solvent recommended for aviation use (like isopropyl alcohol or specialized aviation cable cleaners). ​Avoid harsh degreasers, strong acids/bases, or petroleum solvents unless explicitly approved.
  • Wipe gently along the lay of the cable, not across it, to avoid catching broken wires.
  • ​Crucial: ​Always dry the cable thoroughly with clean, dry compressed air or lint-free cloths immediately after cleaning. Moisture left behind is a primary cause of corrosion.

3. Correct Lubrication: Reducing Friction & Preventing Corrosion

• ​Why: Lubrication minimizes internal friction between strands during flexing and forms a protective barrier against moisture.
• ​How:
  • ​Use Aviation-Specific Cable Lubricant: Never use motor oil, WD-40, or general-purpose grease. These can attract dirt or degrade the cable.
  • ​Apply Sparingly & Correctly: Apply lubricant to a clean cloth and wipe it along the cable lay. The goal is a thin, even film – excess lubricant attracts dirt and grime. Focus on areas of flex and potential moisture ingress.
  • ​Frequency: Follow the aircraft manufacturer’s maintenance schedule. Typically, lubrication is needed after cleaning or when the cable appears dry, but avoid over-lubrication.

4. Protection from Chafing & Environmental Damage

• ​Identify Rubbing Points: Inspect the cable’s entire run. Where does it contact pulleys, fairleads, bulkheads, or other structures?
• ​Install/Inspect Guards: Ensure proper chafe guards (e.g., nylon or teflon sleeves, grommets) are installed at all contact points and are in good condition, not worn through or missing.
• ​Reroute if Possible: If excessive chafing is found, investigate if the cable can be safely rerouted to avoid the contact point.
• ​Shield from Elements: Protect cables from direct exposure to rain, de-icing fluids, fuel, and hydraulic fluid where possible. Ensure drain holes in fairings are clear.

5. Professional Tension Checks & Rigging

• ​Why: Incorrect tension accelerates wear, causes poor system response, and can lead to cable failure.
• ​Action: Have cable tension checked regularly by qualified personnel using calibrated tensiometers, strictly following the aircraft manufacturer’s specifications. Do not rely on feel. Ensure the entire control system (pulleys, bellcranks) is correctly aligned and moves freely without binding.

6. Proper Storage (Spares or Removed Cables)

• ​Coil Carefully: Coil large diameters (avoid tight kinks) and hang or store flat.
• ​Protect: Store in a clean, dry, temperature-controlled environment. Protect ends with caps or tape. Apply a light coat of preservative lubricant if storing long-term.

7. Know When to Replace: Don’t Push Limits

• ​Follow the Manual: Strictly adhere to the aircraft manufacturer’s replacement schedules and criteria (e.g., hours flown, calendar time, cycles, or specific damage limits like number of broken wires per strand length).
• ​Err on the Side of Caution: If a cable shows significant corrosion, kinks, birdcaging, or damage near a fitting, ​replace it immediately. The cost of replacement is insignificant compared to the risk of failure.

Key Takeaways for Long-Lasting Aviation Cable:

1. ​Inspect Religiously: Look for broken wires, corrosion, wear, and fitting damage.
2. ​Clean Gently & Dry Thoroughly: Remove contaminants and prevent moisture buildup.
3. ​Lubricate Correctly: Use approved aviation lubricant sparingly.
4. ​Protect from Chafing: Ensure guards are in place and effective.
5. ​Maintain Correct Tension: Have professionals check tension regularly.
6. ​Replace Proactively: Never exceed manufacturer-defined limits; replace damaged cables immediately.

By implementing these straightforward, practical maintenance steps consistently, you significantly enhance the safety, reliability, and longevity of your critical aviation cables. Always prioritize the specific procedures outlined in your aircraft’s maintenance manual and consult with certified aviation maintenance technicians.