AircraftSubscriber OnlyFlight Control SystemsThey can be simple or complex, but they all have failure modes. Close inspection and regular maintenance are key to reliability.By Mike Berry - November 21, 20230PrintEmailFacebookTwitter Cables and pulleys are the most common method of transmitting the pilot's inputs to the flight-control surfaces. The image at left shows a well-worn system, with obvious metal shavings and even some contact between the cables themselves and nearby aircraft structure (the shiny portion of the crossmember's edge circled in red). It's impossible to know how long the metal shavings (circled in blue) and additional wear have been occurring, but all of this should be remedied sooner rather than later. Repairs might include replacing any worn pulleys and adjusting cable tension, for starters. At a minimum, the metal shavings should be removed and the cables and pulleys inspected for wear or further damage. Finally, loose tools like the pliers at lower left can remain behind after inspection or maintenance, and make for a really bad day. They can be simple or complex, but they all have failure modes. Close inspection and regular maintenance are key to reliability.To continue reading this article or issue you must be a paid subscriber. Sign in SubscribeSubscribe to Aviation SafetyStart a subscription to Aviation Safety for just $74 and access all of our online content - over 2,000 articles - free of charge. Subscribe today and save 19%. It's like getting 2 months FREE!Already Subscribed? Click Here to Sign In | Forgot your password? | Activate Web Access