A B737-300 at clt was improperly repaired resulting in a return to the field because of reported stiff rudder control system. Malfunction was caused by rudder control cable not correctly routed. Approved maintenance manual documents were used to accomplish the work. Airplane had 2 successful test flts prior to the incident report.

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Attributes
ACN	358952
Time
Date	199701
Day	Mon
Local Time Of Day	1801 To 2400
Place
Locale Reference	airport : zzz
State Reference	US
Altitude	agl bound lower : 0 agl bound upper : 0
Environment
Light	Night
Aircraft 1
Operator	common carrier : air carrier
Make Model Name	B737-300
Operating Under FAR Part	Part 121
Navigation In Use	Other
Flight Phase	cruise other other
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	other personnel other
Qualification	other other : other
ASRS Report	358952
Person 2
Affiliation	company : air carrier
Function	flight crew : first officer
Qualification	pilot : atp
Experience	flight time last 90 days : 180 flight time total : 13000 flight time type : 7000
ASRS Report	359631
Events
Anomaly	aircraft equipment problem : critical non adherence : far non adherence : published procedure
Independent Detector	other flight crewa other other : unspecified cockpit
Resolutory Action	flight crew : overcame equipment problem other
Consequence	faa : investigated Other
Supplementary
Primary Problem	Aircraft
Air Traffic Incident	other

Narrative:

During cable installation, cable rb-1 was misrted around pulley guide aft of pressure bulkhead. Poor lighting and accessibility contributed to this discrepancy being missed by mechanic and inspector. Supplemental information from acn 359631: noticed rudder pedals heavy when checking flight controls. System associated with rudder were normal but requested maintenance to check system. Maintenance viewed rudder visually during several checks. Rudder system appeared normal. Flew aircraft to clt and made precautionary write-up in logbook. Aircraft was taken to hangar for further evaluate. Callback conversation with reporter acn #358952 revealed the following information: mechanic xxxxx was contacted feb/zz/97 to determine if and when the FAA interviewed persons 1, 4, and 6. Mechanic xxxxx stated persons 1, 4, and 6 were recently interviewed by the FAA. Mechanic xxxxx also advised the guide pin was replaced during the corrective maintenance action for reported stiff rudder.

Original NASA ASRS Text

Title: A B737-300 AT CLT WAS IMPROPERLY REPAIRED RESULTING IN A RETURN TO THE FIELD BECAUSE OF RPTED STIFF RUDDER CTL SYS. MALFUNCTION WAS CAUSED BY RUDDER CTL CABLE NOT CORRECTLY ROUTED. APPROVED MAINT MANUAL DOCUMENTS WERE USED TO ACCOMPLISH THE WORK. AIRPLANE HAD 2 SUCCESSFUL TEST FLTS PRIOR TO THE INCIDENT RPT.

Narrative: DURING CABLE INSTALLATION, CABLE RB-1 WAS MISRTED AROUND PULLEY GUIDE AFT OF PRESSURE BULKHEAD. POOR LIGHTING AND ACCESSIBILITY CONTRIBUTED TO THIS DISCREPANCY BEING MISSED BY MECH AND INSPECTOR. SUPPLEMENTAL INFO FROM ACN 359631: NOTICED RUDDER PEDALS HVY WHEN CHKING FLT CTLS. SYS ASSOCIATED WITH RUDDER WERE NORMAL BUT REQUESTED MAINT TO CHK SYS. MAINT VIEWED RUDDER VISUALLY DURING SEVERAL CHKS. RUDDER SYS APPEARED NORMAL. FLEW ACFT TO CLT AND MADE PRECAUTIONARY WRITE-UP IN LOGBOOK. ACFT WAS TAKEN TO HANGAR FOR FURTHER EVAL. CALLBACK CONVERSATION WITH RPTR ACN #358952 REVEALED THE FOLLOWING INFO: MECH XXXXX WAS CONTACTED FEB/ZZ/97 TO DETERMINE IF AND WHEN THE FAA INTERVIEWED PERSONS 1, 4, AND 6. MECH XXXXX STATED PERSONS 1, 4, AND 6 WERE RECENTLY INTERVIEWED BY THE FAA. MECH XXXXX ALSO ADVISED THE GUIDE PIN WAS REPLACED DURING THE CORRECTIVE MAINT ACTION FOR RPTED STIFF RUDDER.

Data retrieved from NASA's ASRS site as of July 2007 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.