Narrative:

On oct/thu/03, aircraft was in maintenance for a c-chk. I was assigned a job card to change 2 worn pulleys for the aileron bus cable system at body station 663 in the r-hand wheelwell. The card was stamped critical inspection not required. Conferred with inspection to see if the buy back block should be a narii. Inspection said as long as cable tension was not disturbed, the card could remain as written. I changed the 2 pulleys without loosening cable tension and signed the card off. Reference maintenance policy and procedures paragraph 1 states for mechanics duty: in the event a flight control cable or a qai cable system (referenced from a job procedure card) is disconnected or loosened to a zero tension condition, on a cable system that can not be entirely visually inspected after the work is completed, notify inspection of the situation before the system is disturbed. This system can be visually inspected. Aircraft went back into service. Aircraft was taken OTS for suspicion of loose aileron bus cables. Cable tensions were checked by maintenance in ZZZ hangar on the left and right aileron bus cables. To the best of my knowledge, there were no write-ups in the logbooks on the ailerons. As I stated earlier, since I did not loosen cable tension to change the pulleys, nor did the card instruct me to check tension after installation of the pulleys, I did not check the cable tension on the right hand side aileron bus cable.

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Original NASA ASRS Text

Title: A B737-400 WAS REMOVED FROM SVC FOR LOOSE AILERON BUS CABLES. 2 WORK AILERON BUS CABLE PULLEYS WERE REPLACED ON PREVIOUS MAINT CHK.

Narrative: ON OCT/THU/03, ACFT WAS IN MAINT FOR A C-CHK. I WAS ASSIGNED A JOB CARD TO CHANGE 2 WORN PULLEYS FOR THE AILERON BUS CABLE SYS AT BODY STATION 663 IN THE R-HAND WHEELWELL. THE CARD WAS STAMPED CRITICAL INSPECTION NOT REQUIRED. CONFERRED WITH INSPECTION TO SEE IF THE BUY BACK BLOCK SHOULD BE A NARII. INSPECTION SAID AS LONG AS CABLE TENSION WAS NOT DISTURBED, THE CARD COULD REMAIN AS WRITTEN. I CHANGED THE 2 PULLEYS WITHOUT LOOSENING CABLE TENSION AND SIGNED THE CARD OFF. REF MAINT POLICY AND PROCS PARAGRAPH 1 STATES FOR MECHS DUTY: IN THE EVENT A FLT CTL CABLE OR A QAI CABLE SYS (REFED FROM A JOB PROC CARD) IS DISCONNECTED OR LOOSENED TO A ZERO TENSION CONDITION, ON A CABLE SYS THAT CAN NOT BE ENTIRELY VISUALLY INSPECTED AFTER THE WORK IS COMPLETED, NOTIFY INSPECTION OF THE SIT BEFORE THE SYS IS DISTURBED. THIS SYS CAN BE VISUALLY INSPECTED. ACFT WENT BACK INTO SVC. ACFT WAS TAKEN OTS FOR SUSPICION OF LOOSE AILERON BUS CABLES. CABLE TENSIONS WERE CHKED BY MAINT IN ZZZ HANGAR ON THE L AND R AILERON BUS CABLES. TO THE BEST OF MY KNOWLEDGE, THERE WERE NO WRITE-UPS IN THE LOGBOOKS ON THE AILERONS. AS I STATED EARLIER, SINCE I DID NOT LOOSEN CABLE TENSION TO CHANGE THE PULLEYS, NOR DID THE CARD INSTRUCT ME TO CHK TENSION AFTER INSTALLATION OF THE PULLEYS, I DID NOT CHK THE CABLE TENSION ON THE R HAND SIDE AILERON BUS CABLE.

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.