Narrative:

On feb/xa/01 I was assigned to replace #2 engine fuel pump on ship xyz per engineering order WX wxwx airworthiness directive revision B per maintenance manual xy-xx-xa after installing #2 engine fuel pump, ran engine at idle to leak check and get engine parameters. Idle leak check was good. Proceeded to take ship xyz over to hangar to perform maintenance procedure test B. Maintenance procedure test B checked good -- found no oil, fuel or air leaks. After performing test B, I ran all 3 engines to takeoff power to see how #2 engine faired with #1 and #3 engines and also to leak check #2 engine at takeoff power. All 3 engines checked good at takeoff power and #2 engine leak checked good at takeoff power. Brought aircraft back to gate. All procedures were performed per maintenance manual. Checked all parts used per illustrated parts catalog. I would just like to restate that I went beyond what the maintenance procedures test B says and took #2 engine to takeoff power to perform a leak check to double check and make sure there was nothing wrong! Callback conversation with reporter revealed the following information: the reporter stated the in-flight shutdown of #2 engine for loss of oil pressure and quantity was caused by an incorrect o-ring seal installed on the pump drive spline. The reporter said the seal was installed in the fuel pump replacement kit and appeared to be the correct seal. The reporter said the oil leak did not appear on the idle run and high power run after installation.

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Original NASA ASRS Text

Title: A B727-200 INCURRED AN INFLT SHUTDOWN TO #2 ENG DUE TO LOSS OF OIL CAUSED BY A FUEL PUMP REPLACEMENT USING THE WRONG O-RING SEAL.

Narrative: ON FEB/XA/01 I WAS ASSIGNED TO REPLACE #2 ENG FUEL PUMP ON SHIP XYZ PER ENGINEERING ORDER WX WXWX AIRWORTHINESS DIRECTIVE REVISION B PER MAINT MANUAL XY-XX-XA AFTER INSTALLING #2 ENG FUEL PUMP, RAN ENG AT IDLE TO LEAK CHK AND GET ENG PARAMETERS. IDLE LEAK CHK WAS GOOD. PROCEEDED TO TAKE SHIP XYZ OVER TO HANGAR TO PERFORM MAINT PROC TEST B. MAINT PROC TEST B CHKED GOOD -- FOUND NO OIL, FUEL OR AIR LEAKS. AFTER PERFORMING TEST B, I RAN ALL 3 ENGS TO TKOF PWR TO SEE HOW #2 ENG FAIRED WITH #1 AND #3 ENGS AND ALSO TO LEAK CHK #2 ENG AT TKOF PWR. ALL 3 ENGS CHKED GOOD AT TKOF PWR AND #2 ENG LEAK CHKED GOOD AT TKOF PWR. BROUGHT ACFT BACK TO GATE. ALL PROCS WERE PERFORMED PER MAINT MANUAL. CHKED ALL PARTS USED PER ILLUSTRATED PARTS CATALOG. I WOULD JUST LIKE TO RESTATE THAT I WENT BEYOND WHAT THE MAINT PROCS TEST B SAYS AND TOOK #2 ENG TO TKOF PWR TO PERFORM A LEAK CHK TO DOUBLE CHK AND MAKE SURE THERE WAS NOTHING WRONG! CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATED THE INFLT SHUTDOWN OF #2 ENG FOR LOSS OF OIL PRESSURE AND QUANTITY WAS CAUSED BY AN INCORRECT O-RING SEAL INSTALLED ON THE PUMP DRIVE SPLINE. THE RPTR SAID THE SEAL WAS INSTALLED IN THE FUEL PUMP REPLACEMENT KIT AND APPEARED TO BE THE CORRECT SEAL. THE RPTR SAID THE OIL LEAK DID NOT APPEAR ON THE IDLE RUN AND HIGH PWR RUN AFTER INSTALLATION.

Data retrieved from NASA's ASRS site as of July 2007 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.