Glad you've got it all sorted and many thanks for finishing the saga off. So many people don't.
There does seem to be some fettling required with all manner of replacement items these days, I suspect it's because some 'copies of copies' have at some point become the benchmark.
It's a common tale when there are not the original drawings available.
I'm reminded of back in the early 1980s, when I was working on RAF Tornado aircraft; the Landing Gear electrical harnesses were initially classed as scrap when a microswitch was faulty.
Then the maintenance bays were given authority to replace faulty switches. But it was regarded as 'Basic Trade Skills' by those much higher up the management chain and there were no explicit instructions, like lengths of the individual branches of the harnesses.
After a several years, there became a noticeable increase in the number of aircraft suffering damage to the harness, rather than just switch failure.
Basically the harness, going to several places on the individual undercarriage leg has to bend at the right places as the leg retracts and lowers, and not get snagged on anything in the process...
An investigation soon established that the lack of precise overhaul instructions had resulted in engineers allowing a 'smidgin' extra length on the replacement switch cable length. Some overhauled cable harnesses, having been repaired several times, were found to be several inches too long on some of their individual branches.
After that the manufactures build drawings were obtained.
- NLG.JPG (33.81 KiB) Viewed 18205 times
It's amazing what random photos you can find on the internet, that's an actual Tornado Nose Leg harness...