Used the digital level to measure the elevator down travel and realized that the elevator horns didn’t even touch the stop in the maximum down position. Upon further investigation we found that the F-840 aft pushrod bearing would contact the lower clevis in the F-635 bellcrank assembly before the elevator horns could reach the down stop.
Once we removed the bolt from the forward end of the F-841 pushrod the elevator horns moved forward to touch the down stop. Re-measured the elevator down travel and found it was now more than the maximum specification of 25 degrees.
Made a new elevator down stop by using the old one as a template and extending the aft side by about 1/8". Trimmed the aft side of the stop so that both elevator horns contact it at 23 degrees down travel.
Re-connected the F-841 pushrod and found that once again the elevator horns didn’t touch the stop in the down position due to interference between the F-840 aft pushrod bearing and the lower F-635 bellcrank clevis.
After some thought we decided to shorten the F-840 and F841 pushrods to change the angle of the F-635 bellcrank assembly and this solved the problem.
