Narrative:

This is in regards to the incident that occurred [date]. I was assigned to work a boost pump task card with 2 other mechanics; we all got together to figure out what we had to do to accomplish this task since none of us have done this procedure before we printed out the amm (aircraft maintenance manual) and we followed the instructions; a took the initiative to remove one pump and B volunteered to remove the other. I was assistant on the ground. We removed both pumps we had no issues; when we started the procedure to install the new pumps we got together again and reviewed the amm for the installation procedure. A took the initiative again to install the new pump while B was assisting him. I was on the ground helping them with any tools that they needed. Since they were working on a ladder while following the amm we called the inspector since some of this task required the inspector to be present. When a started the installation of the pump he was having a hard time with the alignment of the pin that is called out on the amm. He informed us that the pump was not aligning properly after the second time of him saying that; that's when the fuel started pouring out of the wing. After that I was only trying to assist from the ground since we had no idea what happened or why it happened. Recommend changing the amm procedure to require the amt (aircraft maintenance technician) or management to defuel the aircraft before any pump removal or installation or to transfer the fuel from one wing to the other before you start this maintenance procedure.

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Original NASA ASRS Text

Title: Aircraft Maintenance Technician working on B-767 encountered fuel spill during installation of fuel pump.

Narrative: This is in regards to the incident that occurred [date]. I was assigned to work a boost pump task card with 2 other mechanics; we all got together to figure out what we had to do to accomplish this task since none of us have done this procedure before we printed out the AMM (Aircraft Maintenance Manual) and we followed the instructions; A took the initiative to remove one pump and B volunteered to remove the other. I was assistant on the ground. We removed both pumps we had no issues; when we started the procedure to install the new pumps we got together again and reviewed the AMM for the installation procedure. A took the initiative again to install the new pump while B was assisting him. I was on the ground helping them with any tools that they needed. Since they were working on a ladder while following the AMM we called the inspector since some of this task required the inspector to be present. When A started the installation of the pump he was having a hard time with the alignment of the pin that is called out on the AMM. He informed us that the pump was not aligning properly after the second time of him saying that; that's when the fuel started pouring out of the wing. After that I was only trying to assist from the ground since we had no idea what happened or why it happened. Recommend changing the AMM procedure to require the AMT (Aircraft Maintenance Technician) or Management to defuel the aircraft before any pump removal or installation or to transfer the fuel from one wing to the other before you start this maintenance procedure.

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.