Narrative:

Dc-9 windows are improperly installed allowing them to migrate and make contact to window belt structure. Boeing was contacted by management to try and cut the cost of window seal usage. The answer came back the windows are improperly installed and must be replaced and is isolated to air carrier xyz aircraft only. 40 to 60 percent of all air carrier xyz dc-9 windows have migrating seals within weeks of installation. Management is aware of this problem but has yet to train anyone on the proper installation of the windows or has attempted to change the time frame to check the seals for migration.callback conversation with reporter revealed the following information: the reporter stated a large portion of the dc-9 fleet at this carrier has the cabin windows installed incorrectly. This allows the windows to migrate and damage the window seals by contacting structure. The reporter stated the seal deteriorates within several weeks of installation and replacement can take from 1 seal per hour to all day depending on the experience level of the installer. The manufacturer was made aware of the incorrect installation and advises the window removal; installing a new seal; and reinstalling the window correctly. Reporter stated the carrier has not started training technicians or changed any time limits for the cabin window inspection. The worn seals can cause pressure leaks and noise.

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Original NASA ASRS Text

Title: A TECHNICIAN RPTS A LARGE NUMBER OF DC-9 CABIN WINDOW SEALS REQUIRE REPLACEMENT DUE TO IMPROPER WINDOW INSTALLATION.

Narrative: DC-9 WINDOWS ARE IMPROPERLY INSTALLED ALLOWING THEM TO MIGRATE AND MAKE CONTACT TO WINDOW BELT STRUCTURE. BOEING WAS CONTACTED BY MANAGEMENT TO TRY AND CUT THE COST OF WINDOW SEAL USAGE. THE ANSWER CAME BACK THE WINDOWS ARE IMPROPERLY INSTALLED AND MUST BE REPLACED AND IS ISOLATED TO ACR XYZ ACFT ONLY. 40 TO 60 PERCENT OF ALL ACR XYZ DC-9 WINDOWS HAVE MIGRATING SEALS WITHIN WEEKS OF INSTALLATION. MANAGEMENT IS AWARE OF THIS PROBLEM BUT HAS YET TO TRAIN ANYONE ON THE PROPER INSTALLATION OF THE WINDOWS OR HAS ATTEMPTED TO CHANGE THE TIME FRAME TO CHK THE SEALS FOR MIGRATION.CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATED A LARGE PORTION OF THE DC-9 FLEET AT THIS CARRIER HAS THE CABIN WINDOWS INSTALLED INCORRECTLY. THIS ALLOWS THE WINDOWS TO MIGRATE AND DAMAGE THE WINDOW SEALS BY CONTACTING STRUCTURE. THE RPTR STATED THE SEAL DETERIORATES WITHIN SEVERAL WEEKS OF INSTALLATION AND REPLACEMENT CAN TAKE FROM 1 SEAL PER HOUR TO ALL DAY DEPENDING ON THE EXPERIENCE LEVEL OF THE INSTALLER. THE MANUFACTURER WAS MADE AWARE OF THE INCORRECT INSTALLATION AND ADVISES THE WINDOW REMOVAL; INSTALLING A NEW SEAL; AND REINSTALLING THE WINDOW CORRECTLY. RPTR STATED THE CARRIER HAS NOT STARTED TRAINING TECHNICIANS OR CHANGED ANY TIME LIMITS FOR THE CABIN WINDOW INSPECTION. THE WORN SEALS CAN CAUSE PRESSURE LEAKS AND NOISE.

Data retrieved from NASA's ASRS site as of January 2009 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.