Narrative:

Installing rudder aircraft X. First off I'd like to mention we have difficulties right&right 737-700 rudders at this location let alone an 800; inadequate facilities/tooling for routine overnight maintenance (ron) mechanics to perform this maintenance on an overnight task; unless/maybe we were able to use [some of our other maintenance bays]. Tasked to remove and replace aircraft X's rudder last night in bay X; overhead crane in this hangar not at sufficient height to perform this task without trying to jump through some hoops (modifying the sling by routing/shortening the web straps through the sling upper casting body and trying to jack the nose of the aircraft to lower tail section for sling usage) this is whats done to perform 700 rudder change; now input an 800 aircraft which is approximately 24' longer; try jacking the nose of aircraft which is outside on ramp on a decline position. Which was attempted numerous times and different configurations (unable to properly seat jacks safely-almost rolled aircraft off jack at one attempt). So supervision instructed us to install rudder using company crane with an added extension arm installed on this crane outside on washrack; this was already attempted by earlier shift with huge headaches and misgivings. We attempted rudder installation outside with crane usage and sling checked out from toolcrib. After lengthy amount of time and manpower (6 mechanics 1 crane operator) we were able to get #1 hinge bolt installed with some degree of difficulty along with numerous scratches; dings; and paint chips. Upon mechanic repositioning to start other bolt installations; the left hand side of sling swivel shackle gave way (popped out) of fitting that's bolted to rudder. Rudder slightly settled down or lodged itself in place due to #1 bolt being installed; it also wedged itself on top or against main power control unit (PCU) actuator. Heavy rain and weather with lightning approached rapidly. Supervisor had us secure rudder in place with rope. No other sling in stock or replacement parts/hardware available at that time. Left in that configuration; due to shift turnover; and heavy weather. Don't know the exact or extent of any damage caused from this operation. Would like to be informed what was damaged or replaced.

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Original NASA ASRS Text

Title: Two Maintenance Technicians reported that replacing a rudder on a 737 became a very difficult task due to inadequate equipment.

Narrative: Installing rudder Aircraft X. First off I'd like to mention we have difficulties R&R 737-700 rudders at this location let alone an 800; Inadequate facilities/tooling for Routine Overnight Maintenance (RON) mechanics to perform this maintenance on an overnight task; unless/maybe we were able to use [some of our other maintenance bays]. Tasked to remove and replace Aircraft X's rudder last night in bay X; overhead crane in this hangar not at sufficient height to perform this task without trying to jump through some hoops (modifying the sling by routing/shortening the web straps through the sling upper casting body and trying to jack the nose of the aircraft to lower tail section for sling usage) this is whats done to perform 700 rudder change; now input an 800 aircraft which is approximately 24' longer; try jacking the nose of aircraft which is outside on ramp on a decline position. Which was attempted numerous times and different configurations (unable to properly seat jacks safely-almost rolled aircraft off jack at one attempt). So supervision instructed us to install rudder using company crane with an added extension arm installed on this crane outside on washrack; this was already attempted by earlier shift with huge headaches and misgivings. We attempted rudder installation outside with crane usage and sling checked out from toolcrib. After lengthy amount of time and manpower (6 mechanics 1 crane operator) we were able to get #1 hinge bolt installed with some degree of difficulty along with numerous scratches; dings; and paint chips. Upon mechanic repositioning to start other bolt installations; the left hand side of sling swivel shackle gave way (popped out) of fitting that's bolted to rudder. Rudder slightly settled down or lodged itself in place due to #1 bolt being installed; it also wedged itself on top or against main Power Control Unit (PCU) actuator. Heavy rain and weather with lightning approached rapidly. Supervisor had us secure rudder in place with rope. No other sling in stock or replacement parts/hardware available at that time. Left in that configuration; due to shift turnover; and heavy weather. Don't know the exact or extent of any damage caused from this operation. Would like to be informed what was damaged or replaced.

Data retrieved from NASA's ASRS site and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.