Narrative:

Replacing left wing fwd & aft fuel boost pump. That work was assigned to me. As we got our assignment we did print amm (aircraft maintenance manual) ref ipc (reference illustrated parts catalog) and followed amm step by step to remove the fuel boost pump. I removed the left fwd boost pump and notice index pin for cam lock was bent; though I have to use an aluminum pipe to turn the pump to unlock it was just for leverage did not take much force to turn. Then [we] removed left aft pump using same pipe. We found index pin bent on that pump too. I checked the cam and was looking good holding the sleeve down. We called our inspector and he verified new pump part number according to ipc and inspected the housing sleeves. Gave me ok to install. Then I picked up the pump slide the pump in aft housing sleeve and was trying to align index pin without any force less than minute fuel started to coming out of housing. The force of fuel was high; that it threw the boost pump out of my hand and dropped down on floor but I managed to stay stable on the ladder. I went down quickly picked up the pump and tried to force it in to stop the fuel flow. I notice the aft sleeve was unlocked and went inside the tank. Our supervisor climbed up the ladder to help me push the pump in and pull the sleeve down to stop the fuel flow but could not succeed the force of fuel flow was high. We tried more than 20 minute; I was soaked with fuel my eyes were burning; hands were tired and it was physically impossible for me to try further. Then I was escorted out of hangar and taken to hospital.

Related reports:

Google
 

Original NASA ASRS Text

Title: B767-300 Maintenance Technician removed fuel boost pump with fuel still in tank causing fuel spill.

Narrative: Replacing left wing FWD & AFT fuel boost pump. That work was assigned to me. As we got our assignment we did print AMM (Aircraft maintenance Manual) ref IPC (Reference Illustrated Parts Catalog) and followed AMM step by step to remove the fuel boost pump. I removed the Left FWD boost pump and notice index pin for cam lock was bent; though I have to use an aluminum pipe to turn the pump to unlock it was just for leverage did not take much force to turn. Then [we] removed left aft pump using same pipe. We found index pin bent on that pump too. I checked the cam and was looking good holding the sleeve down. We called our inspector and he verified new pump part number according to IPC and inspected the housing sleeves. Gave me OK to install. Then I picked up the pump slide the pump in AFT housing sleeve and was trying to align index pin without any force less than minute Fuel started to coming out of housing. The force of fuel was high; that it threw the boost pump out of my hand and dropped down on floor but I managed to stay stable on the ladder. I went down quickly picked up the pump and tried to force it in to stop the fuel flow. I notice the AFT sleeve was unlocked and went inside the tank. Our supervisor climbed up the ladder to help me push the pump in and pull the sleeve down to stop the fuel flow but could not succeed the force of fuel flow was high. We tried more than 20 minute; I was soaked with fuel my eyes were burning; hands were tired and it was physically impossible for me to try further. Then I was escorted out of hangar and taken to hospital.

Data retrieved from NASA's ASRS site 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.