Maintenance technicians reported incorrectly re-assembled rudder control cables went unnoticed and f...

Attributes
ACN	1601364
Time
Date	201812
Local Time Of Day	0601-1200
Place
Locale Reference	ZZZ.Airport
State Reference	US
Aircraft 1
Make Model Name	Skyhawk 172/Cutlass 172
Operating Under FAR Part	Part 91
Component
Aircraft Component	Rudder Control System
Person 1
Function	Inspector Technician
Qualification	Maintenance Airframe Maintenance Inspection Authority Maintenance Powerplant Maintenance Repairman
Experience	Maintenance Inspector 16 Maintenance Repairman 6 Maintenance Technician 36
Person 2
Function	Technician
Qualification	Maintenance Airframe Maintenance Powerplant
Experience	Maintenance Technician 1
Events
Anomaly	Aircraft Equipment Problem Less Severe Deviation - Procedural Maintenance Deviation - Procedural Published Material / Policy

Narrative:

Training technician installed rudder cables after aircraft was reassembled from being transported and disassembled for transportation. Technician who among several other technicians failed to recognize that the rudder cables were not safetied. Chief inspector did not see that the rudder cables were not safetied during final inspection. Aircraft was signed off and returned to service. Aircraft was test flown after repairs were completed and minor items fixed. Aircraft returned to service. Rudder cable became disconnected after aircraft was flown 16 times. Aircraft landed without any incident. Inspection revealed rudder cable had become disconnected. While trying to reinstall cable and rig the rudder system we found that it would not rig correctly. After further investigation found that the rudder cables had been misrouted. Cables were damaged. Replaced cables with new and rigged rudder cables in accordance with [cessna] 172 maintenance manual. Removed necessary panels and inspected all turnbuckles for safety and control surfaces for rigging. All found to be okay. Reassembled and completed logbooks and returned to service.

Original NASA ASRS Text

Title: Maintenance Technicians reported incorrectly re-assembled Rudder Control Cables went unnoticed and failed during subsequent flight; when aircraft returned to field without incident.

Narrative: Training Technician installed rudder cables after aircraft was reassembled from being transported and disassembled for Transportation. Technician who among several other Technicians failed to recognize that the rudder cables were not safetied. Chief Inspector did not see that the Rudder Cables were not safetied during Final Inspection. Aircraft was signed off and returned to Service. Aircraft was test flown after repairs were completed and minor items fixed. Aircraft returned to service. Rudder cable became disconnected after aircraft was flown 16 times. Aircraft landed without any incident. Inspection revealed rudder cable had become disconnected. While trying to reinstall cable and rig the rudder system we found that it would not rig correctly. After further investigation found that the rudder cables had been misrouted. Cables were damaged. Replaced cables with new and rigged rudder cables in accordance with [Cessna] 172 Maintenance Manual. Removed necessary panels and inspected all turnbuckles for safety and Control Surfaces for rigging. All found to be okay. Reassembled and completed logbooks and returned to service.

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.

Maintenance technicians reported incorrectly re-assembled rudder control cables went unnoticed and failed during subsequent flight; when aircraft returned to field without incident.