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A B757-200 had #2 brake assembly replaced per the maintenance manual. #2 brake failed first flight after brake was replaced. Failure caused by brake equalizing rod disconnected.
| Attributes | |
| ACN | 727203 |
| Time | |
| Date | 200702 |
| Local Time Of Day | 1201 To 1800 |
| Place | |
| Locale Reference | airport : zzz.airport |
| State Reference | US |
| Altitude | agl single value : 0 |
| Environment | |
| Light | Night |
| Aircraft 1 | |
| Operator | common carrier : air carrier |
| Make Model Name | B757-200 |
| Operating Under FAR Part | Part 121 |
| Flight Phase | ground : maintenance |
| Person 1 | |
| Affiliation | company : air carrier |
| Function | maintenance : technician |
| Qualification | technician : airframe technician : powerplant |
| Experience | maintenance technician : 26 |
| ASRS Report | 727203 |
| Person 2 | |
| Affiliation | company : air carrier |
| Function | maintenance : technician |
| Qualification | technician : powerplant technician : airframe |
| Experience | maintenance technician : 12 |
| ASRS Report | 727204 |
| Events | |
| Anomaly | aircraft equipment problem : critical maintenance problem : improper documentation maintenance problem : improper maintenance non adherence : far non adherence : published procedure |
| Independent Detector | other flight crewa other flight crewb |
| Resolutory Action | none taken : detected after the fact |
| Consequence | other other other |
| Factors | |
| Maintenance | contributing factor : schedule pressure performance deficiency : installation performance deficiency : non compliance with legal requirements performance deficiency : logbook entry performance deficiency : inspection |
| Supplementary | |
| Problem Areas | Environmental Factor Maintenance Human Performance Chart Or Publication Aircraft |
| Primary Problem | Maintenance Human Performance |
Narrative:
Was assigned by lead technician to replace #2 brake assembly along with 2 other technicians. Installation; operational and leak checks were performed as per B757-200 amm. No abnormalities were noted at this time. Aircraft experienced a brake failure on first flight after brake was changed -- event is under investigation. No determination has been made to workmanship or other fault. Callback conversation with reporter revealed the following information: there has been no hearing on the cause of the brake failure. The finding was the brake had rotated due to the brake equalizing rod was found disconnected. The possibility of the cotter pin holding the equalizing rod to brake assembly pin being sheared or the pin itself failed are 2 of the ideas being discussed. It was noted the brake operation was ok after replacement when the airplane was taxied to the run-up pad and then taxied back to the gate. Also ok when taxied out for takeoff; no brake problems noted.
Original NASA ASRS Text
Title: A B757-200 HAD #2 BRAKE ASSEMBLY REPLACED PER THE MAINT MANUAL. #2 BRAKE FAILED FIRST FLT AFTER BRAKE WAS REPLACED. FAILURE CAUSED BY BRAKE EQUALIZING ROD DISCONNECTED.
Narrative: WAS ASSIGNED BY LEAD TECHNICIAN TO REPLACE #2 BRAKE ASSEMBLY ALONG WITH 2 OTHER TECHNICIANS. INSTALLATION; OPERATIONAL AND LEAK CHKS WERE PERFORMED AS PER B757-200 AMM. NO ABNORMALITIES WERE NOTED AT THIS TIME. ACFT EXPERIENCED A BRAKE FAILURE ON FIRST FLT AFTER BRAKE WAS CHANGED -- EVENT IS UNDER INVESTIGATION. NO DETERMINATION HAS BEEN MADE TO WORKMANSHIP OR OTHER FAULT. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THERE HAS BEEN NO HEARING ON THE CAUSE OF THE BRAKE FAILURE. THE FINDING WAS THE BRAKE HAD ROTATED DUE TO THE BRAKE EQUALIZING ROD WAS FOUND DISCONNECTED. THE POSSIBILITY OF THE COTTER PIN HOLDING THE EQUALIZING ROD TO BRAKE ASSEMBLY PIN BEING SHEARED OR THE PIN ITSELF FAILED ARE 2 OF THE IDEAS BEING DISCUSSED. IT WAS NOTED THE BRAKE OP WAS OK AFTER REPLACEMENT WHEN THE AIRPLANE WAS TAXIED TO THE RUN-UP PAD AND THEN TAXIED BACK TO THE GATE. ALSO OK WHEN TAXIED OUT FOR TKOF; NO BRAKE PROBS NOTED.
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.