Narrative:

Upon completion of the installation of the #5 transmission; the crew began the rigging process. After attaching the torque tubes on the left wing; I went to the front of the aircraft and proceeded to the flight deck. Another co-worker came and gave the clear and flaps up command. Once the flaps came to full 0 degrees; I waited a few moments and moved flaps to full 40 degrees. A few moments into the sequence; a co-worker came to the door and told me to stop the flaps. A quickly shut off the hydraulics. Supplemental information from acn 786323: person 3 and myself (person 2) were put on aircraft to remove and replace #2 and #8 flap transmissions. #2 and #8 were replaced and a parts tag was filled out with write-ups that torque tubes on the inboard and outboard side of #2 transmissions were disconnected and a write-up that #8 transmission torque tube was disconnected. I was on the left wing when person 3 came over and looked to make sure that all was good on the left side. I asked him if all was good on the right side and he said 'yes.' person 1 went to the cockpit to run the flaps. Supplemental information from acn 786324: we completed the right&right of the #5 transmission. At that time; 4 or 5 of our crew came over to assist in the rig of the flaps (trailing). To do this; we move the flaps up and down a few cycles to heat up the hydraulic fluid and soak the flaps for a couple mins. I was on the left wing to clear it. The position was full down when we started it. As the flaps moved up; there was no event. However; when the flaps started to come down; I heard someone say something and I went over to the right wing; noticed the foils mid flaps were digging into the outboard fixed portion of the wing. As noticed the torque tube had not been attached to #8 transmission. I wondered; however; how #2 transmission was attached and not #8 transmission. I think there was too many people all doing something different at the same time. Supplemental information from acn 786325: I went to assist. I asked if all the torque tubes were connected; tools removed from the flap well and if the cannon plug was connected in the wheel well. They answered yes. We discussed what was going to happen next: cycle flaps 2 times and leave in the up position; then check up-stops. The flaps went full up and began to come back down. I heard a slight pop and crunching noise. Noticed the right outboard flap wedged at an angle and noticed damage to the outboard edge and aileron tab.

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Original NASA ASRS Text

Title: FOUR MECHANICS REPORT ON THE EVENTS SURROUNDING DAMAGE TO A B737-300 ACFT RIGHT WING OUTBOARD FLAP; OUTBOARD EDGE WITH THE AILERON TAB DURING RIGGING PROCEDURES; FOLLOWING REPLACEMENT OF FLAP TRANSMISSIONS 2; 5 AND 8.

Narrative: UPON COMPLETION OF THE INSTALLATION OF THE #5 TRANSMISSION; THE CREW BEGAN THE RIGGING PROCESS. AFTER ATTACHING THE TORQUE TUBES ON THE L WING; I WENT TO THE FRONT OF THE ACFT AND PROCEEDED TO THE FLT DECK. ANOTHER CO-WORKER CAME AND GAVE THE CLR AND FLAPS UP COMMAND. ONCE THE FLAPS CAME TO FULL 0 DEGS; I WAITED A FEW MOMENTS AND MOVED FLAPS TO FULL 40 DEGS. A FEW MOMENTS INTO THE SEQUENCE; A CO-WORKER CAME TO THE DOOR AND TOLD ME TO STOP THE FLAPS. A QUICKLY SHUT OFF THE HYDS. SUPPLEMENTAL INFO FROM ACN 786323: PERSON 3 AND MYSELF (PERSON 2) WERE PUT ON ACFT TO REMOVE AND REPLACE #2 AND #8 FLAP TRANSMISSIONS. #2 AND #8 WERE REPLACED AND A PARTS TAG WAS FILLED OUT WITH WRITE-UPS THAT TORQUE TUBES ON THE INBOARD AND OUTBOARD SIDE OF #2 TRANSMISSIONS WERE DISCONNECTED AND A WRITE-UP THAT #8 TRANSMISSION TORQUE TUBE WAS DISCONNECTED. I WAS ON THE L WING WHEN PERSON 3 CAME OVER AND LOOKED TO MAKE SURE THAT ALL WAS GOOD ON THE L SIDE. I ASKED HIM IF ALL WAS GOOD ON THE R SIDE AND HE SAID 'YES.' PERSON 1 WENT TO THE COCKPIT TO RUN THE FLAPS. SUPPLEMENTAL INFO FROM ACN 786324: WE COMPLETED THE R&R OF THE #5 TRANSMISSION. AT THAT TIME; 4 OR 5 OF OUR CREW CAME OVER TO ASSIST IN THE RIG OF THE FLAPS (TRAILING). TO DO THIS; WE MOVE THE FLAPS UP AND DOWN A FEW CYCLES TO HEAT UP THE HYD FLUID AND SOAK THE FLAPS FOR A COUPLE MINS. I WAS ON THE L WING TO CLR IT. THE POS WAS FULL DOWN WHEN WE STARTED IT. AS THE FLAPS MOVED UP; THERE WAS NO EVENT. HOWEVER; WHEN THE FLAPS STARTED TO COME DOWN; I HEARD SOMEONE SAY SOMETHING AND I WENT OVER TO THE R WING; NOTICED THE FOILS MID FLAPS WERE DIGGING INTO THE OUTBOARD FIXED PORTION OF THE WING. AS NOTICED THE TORQUE TUBE HAD NOT BEEN ATTACHED TO #8 TRANSMISSION. I WONDERED; HOWEVER; HOW #2 TRANSMISSION WAS ATTACHED AND NOT #8 TRANSMISSION. I THINK THERE WAS TOO MANY PEOPLE ALL DOING SOMETHING DIFFERENT AT THE SAME TIME. SUPPLEMENTAL INFO FROM ACN 786325: I WENT TO ASSIST. I ASKED IF ALL THE TORQUE TUBES WERE CONNECTED; TOOLS REMOVED FROM THE FLAP WELL AND IF THE CANNON PLUG WAS CONNECTED IN THE WHEEL WELL. THEY ANSWERED YES. WE DISCUSSED WHAT WAS GOING TO HAPPEN NEXT: CYCLE FLAPS 2 TIMES AND LEAVE IN THE UP POS; THEN CHK UP-STOPS. THE FLAPS WENT FULL UP AND BEGAN TO COME BACK DOWN. I HEARD A SLIGHT POP AND CRUNCHING NOISE. NOTICED THE R OUTBOARD FLAP WEDGED AT AN ANGLE AND NOTICED DAMAGE TO THE OUTBOARD EDGE AND AILERON TAB.

Data retrieved from NASA's ASRS site as of May 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.