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Spent 11 hours chasing a flap disagree on a King Air and it was two wires touching behind the panel
About four months back I got handed a flap disagree write up on a King Air 200 and figured it was a rigging job, maybe an hour of work. Pulled the maintenance manual, checked the flap position pots, ran the rigging procedure twice, and everything read clean on the meter. Swapped the flap control unit because that is the usual suspect, no change. Spent most of a Tuesday on my back under the panel with a flashlight in my teeth tracing wire runs, and the schematics in that old manual do not match the airplane at all, half the wire numbers are different. Turned out two wires in the bundle behind the pedestal had rubbed through their insulation on a clamp and were kissing each other when the flaps moved, so the signal only went bad in transit and never on the ground. Total time from write up to fix was 11 hours across three shifts and the actual repair was ten minutes of shrink tube and a new clamp. Fifty years ago you could have found that with a wiggle test and a test light, but now everything is digital and the box just says fault and you get to go find it yourself. Anybody got a better trick for chasing intermittent chafing in old harnesses, because the wiggle and pray method is wearing me out.
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