A while back I noticed that the Short Push/Pull Tubes for the ailerons were binding up on the Bell Cranks inside the wings when the ailerons were fully deflected. This binding was reducing the aileron range of motion from 45 degrees to 35 degrees, 5 degrees on each side.
To alleviate this I needed to add a 1/4" Plastic Washer (PW-4) and a 1/4" Thick Washer (AN960-416) between the Bell Crank and the Male Rod End in each wing. Rans recommended that I use 1/4" Zinc Plated Washers (KSHW0075) instead of the 1/4" Plastic Washers. They also suggested I replace the existing 1/4" Plastic Washers that are between the Male Rod End and the lock nut. I also needed to replace the 1/4" Bolt (AN4-7A) with a longer 1/4" Bolt (AN4-10A) to handle two new washers.
With the above fixes, the binding was completely eliminated. Now when the ailerons are fully deflected, there is a distinctive stop instead of a binding/grinding feeling. This stop is caused by the Long Push/Pull Tubes hitting the same Bell Cranks within the wing.
Below are some pictures of the damage that was being done to the Short Push/Pull tubes from the binding. The last picture was taken from inside the wing to try and get a clear view of the binding prior to the fix. Implementing the fix through the zippered portal wasn't as hard as I had thought it would have been. Removing the Short Push/Pull tube was necessary along with taping the 7/16" wrench to a yard stick to hold the bolt head.
