Narrative:

The modification is an FAA airworthiness directive involving the transformer rectifier units and main battery charger ground brackets. The old bracket is removed and the paint is removed from its mounting location. A new bracket is added directly above it on top of the rib the original is mounted too. This relocates 1 ground wire to the new bracket. Both brackets are installed onto bare metal without alodining. 1) the documents called for a fillet seal to be applied all the way around the bracket. The diagrams provided showed sealant only on 3 sides. The lower side overhangs the mounting structure leaving an air gap of about .060 inches under the lower 3/4 inch (approximately) of the bracket. This has since been changed. It is extremely difficult to apply sealant in this confined and awkward location. 2) one step calls for the removal of a ground stud and nut and to discard it. This instruction was at the end of a seemingly routine step. I overlooked it and assumed that the whole step was completed. 3) the paperwork states to apply primer and enamel paint to all bare metal surfaces in the modification. I believe that I accomplished this; but cannot say 100% that I didn't miss something. 4) with the state the airline is in; we are constantly being reminded of the importance of on-time departures. I rushed through this task trying to finish it before shift end; so as not to encroach onto the following day's workload. Suggest placing more stress on attention to detail and less on aircraft scheduling. Contributing factors: document statements conflicted with diagrams. Second time to perform job task. Rushed to complete task to aid in on-time release of aircraft. Supplemental information from acn 801220: while working on this job; the aircraft power was off. Reduced lighting and confined space in main east&east bay -- the frame of the aircraft is sharply tapered; ctring the bracket on the narrow flange of the frame and concerned about good edge distance. I was informed that the gap between the bracket and the frame splice was incorrect.

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Original NASA ASRS Text

Title: TWO MECHANICS REPORT ON THE DIFFICULTIES IN FOLLOWING AN FAA AD ENGINEERING DOCUMENT TO REMOVE A GND STUD AND REPOSITION A BRACKET UNDER A TRANSFORMER RECTIFIER UNIT GND BRACKET REWORK ON THEIR B767-300'S.

Narrative: THE MODIFICATION IS AN FAA AIRWORTHINESS DIRECTIVE INVOLVING THE TRANSFORMER RECTIFIER UNITS AND MAIN BATTERY CHARGER GND BRACKETS. THE OLD BRACKET IS REMOVED AND THE PAINT IS REMOVED FROM ITS MOUNTING LOCATION. A NEW BRACKET IS ADDED DIRECTLY ABOVE IT ON TOP OF THE RIB THE ORIGINAL IS MOUNTED TOO. THIS RELOCATES 1 GND WIRE TO THE NEW BRACKET. BOTH BRACKETS ARE INSTALLED ONTO BARE METAL WITHOUT ALODINING. 1) THE DOCUMENTS CALLED FOR A FILLET SEAL TO BE APPLIED ALL THE WAY AROUND THE BRACKET. THE DIAGRAMS PROVIDED SHOWED SEALANT ONLY ON 3 SIDES. THE LOWER SIDE OVERHANGS THE MOUNTING STRUCTURE LEAVING AN AIR GAP OF ABOUT .060 INCHES UNDER THE LOWER 3/4 INCH (APPROX) OF THE BRACKET. THIS HAS SINCE BEEN CHANGED. IT IS EXTREMELY DIFFICULT TO APPLY SEALANT IN THIS CONFINED AND AWKWARD LOCATION. 2) ONE STEP CALLS FOR THE REMOVAL OF A GND STUD AND NUT AND TO DISCARD IT. THIS INSTRUCTION WAS AT THE END OF A SEEMINGLY ROUTINE STEP. I OVERLOOKED IT AND ASSUMED THAT THE WHOLE STEP WAS COMPLETED. 3) THE PAPERWORK STATES TO APPLY PRIMER AND ENAMEL PAINT TO ALL BARE METAL SURFACES IN THE MODIFICATION. I BELIEVE THAT I ACCOMPLISHED THIS; BUT CANNOT SAY 100% THAT I DIDN'T MISS SOMETHING. 4) WITH THE STATE THE AIRLINE IS IN; WE ARE CONSTANTLY BEING REMINDED OF THE IMPORTANCE OF ON-TIME DEPS. I RUSHED THROUGH THIS TASK TRYING TO FINISH IT BEFORE SHIFT END; SO AS NOT TO ENCROACH ONTO THE FOLLOWING DAY'S WORKLOAD. SUGGEST PLACING MORE STRESS ON ATTN TO DETAIL AND LESS ON ACFT SCHEDULING. CONTRIBUTING FACTORS: DOCUMENT STATEMENTS CONFLICTED WITH DIAGRAMS. SECOND TIME TO PERFORM JOB TASK. RUSHED TO COMPLETE TASK TO AID IN ON-TIME RELEASE OF ACFT. SUPPLEMENTAL INFO FROM ACN 801220: WHILE WORKING ON THIS JOB; THE ACFT PWR WAS OFF. REDUCED LIGHTING AND CONFINED SPACE IN MAIN E&E BAY -- THE FRAME OF THE ACFT IS SHARPLY TAPERED; CTRING THE BRACKET ON THE NARROW FLANGE OF THE FRAME AND CONCERNED ABOUT GOOD EDGE DISTANCE. I WAS INFORMED THAT THE GAP BTWN THE BRACKET AND THE FRAME SPLICE WAS INCORRECT.

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.