Falcon 2000
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural Maintenance
General Maintenance Action
Aircraft; Human Factors; Incorrect / Not Installed / Unavailable Part
Working with Aircraft Maintenance Technician (AMT) in ZZZ on a Dassault Falcon DA-2000 aircraft. The crew discrepancy reported during flight that the ailerons felt 'no where near normal; and were very sloppy when flown by hand'.  We opened the cockpit floor boards 114DZ and 114FZ to inspect the roll Artificial Feel Unit (AFU) and related components. After removing the panels we discovered the sloppy ailerons were caused by the fact that the aft attach hardware for the roll AFU had fallen out due to the pin not being safe-tied. This allowed the AFU to pivot out of position. Upon further inspection we noticed several other item were not properly safe-tied. On the roll trim actuator neither end was satisfactorily safe-tied and neither was the length adjusting jam nut. We also noted the AFU was installed with the drain hole on top; this should be within 10-degrees from the bottom. We also found two nylon anti-rotation washers laying in close proximity to the pin that fell out of the roll AFU. We are no sure where those came from. Mechanic Z is looking into that. The Maintenance Manual (M/M) procedure frequently tells you 'not' to safety the attaching hardware after each and every time it tells you to install it; because there is a good chance you will need to take it back apart to make adjustments. In this type of situation I would suggest one makes a point to triple check that all items worked are safe-tied once the rigging procedures are complete. Aileron feels sloppy in flight.  The Aileron controls; roll AFU and roll trim actuator are under copilot seat floor boards.
While troubleshooting; a flight crew reports that the ailerons felt 'nowhere near normal and were very sloppy when flown by hand.' An Aircraft Maintenance Technician (AMT) finds the aft attach hardware for the roll Artificial Feel Unit (AFU); had fallen out due to the pin not being safe-tied. The roll Aileron Trim actuator was also; not properly safe-tied. The Dassault Falcon DA-2000 Maintenance Manual (M/M) instructs Maintenance 'not' to safety attaching hardware until rigging is completed.