An MD80 was dispatched with an interim repair to the right main gear down hydraulic pressure line. Flexible line installed. Aircraft returned due to gear indication.

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Attributes
ACN	613887
Time
Date	200404
Day	Thu
Local Time Of Day	1801 To 2400
Place
Locale Reference	airport : zzz.airport
State Reference	US
Altitude	agl single value : 0
Environment
Light	Night
Aircraft 1
Operator	common carrier : air carrier
Make Model Name	MD-80 Series (DC-9-80) Undifferentiated or Other Model
Operating Under FAR Part	Part 121
Flight Phase	ground : maintenance ground : parked
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	maintenance : technician
Qualification	technician : powerplant technician : airframe
ASRS Report	613887
Person 2
Affiliation	company : air carrier
Function	maintenance : lead technician oversight : supervisor
Events
Anomaly	aircraft equipment problem : critical maintenance problem : improper maintenance non adherence : published procedure non adherence : far
Independent Detector	aircraft equipment other aircraft equipment : landing gear warning
Resolutory Action	flight crew : diverted to another airport flight crew : overcame equipment problem
Consequence	other other
Factors
Maintenance	contributing factor : schedule pressure contributing factor : non availability of parts
Supplementary
Problem Areas	Chart Or Publication Maintenance Human Performance Aircraft
Primary Problem	Maintenance Human Performance

Narrative:

Aircraft X right main landing gear down pressure hydraulic line was leaking was unable to stop the leak and didn't have the line in our stock system. Maintenance manual 20-12-04 page 208A gives criteria for use of temporary flex hoses in place of pipe lines and supplement 20-10-52 page 201 gives the flex hose interim repair procedures for hydraulic lines. He didn't have the exact length line, so we used a longer line and clamped the line secure. The extra length of line was hanging in a cavity below the hydraulic lines. I questioned the cavity area for fit with the gear linkage and didn't think the linkage would contact the line. We pressurized hydraulics to leak check and check flex with pressure on the line. Leak check'ed ok and interference with other lines ok also. At our crew briefing at XA00 that night, I found out about an air turn back due to gear handle up and red unsafe light on.

Original NASA ASRS Text

Title: AN MD80 WAS DISPATCHED WITH AN INTERIM REPAIR TO THE R MAIN GEAR DOWN HYD PRESSURE LINE. FLEXIBLE LINE INSTALLED. ACFT RETURNED DUE TO GEAR INDICATION.

Narrative: ACFT X R MAIN LNDG GEAR DOWN PRESSURE HYD LINE WAS LEAKING WAS UNABLE TO STOP THE LEAK AND DIDN'T HAVE THE LINE IN OUR STOCK SYS. MAINT MANUAL 20-12-04 PAGE 208A GIVES CRITERIA FOR USE OF TEMPORARY FLEX HOSES IN PLACE OF PIPE LINES AND SUPPLEMENT 20-10-52 PAGE 201 GIVES THE FLEX HOSE INTERIM REPAIR PROCS FOR HYD LINES. HE DIDN'T HAVE THE EXACT LENGTH LINE, SO WE USED A LONGER LINE AND CLAMPED THE LINE SECURE. THE EXTRA LENGTH OF LINE WAS HANGING IN A CAVITY BELOW THE HYD LINES. I QUESTIONED THE CAVITY AREA FOR FIT WITH THE GEAR LINKAGE AND DIDN'T THINK THE LINKAGE WOULD CONTACT THE LINE. WE PRESSURIZED HYDS TO LEAK CHK AND CHK FLEX WITH PRESSURE ON THE LINE. LEAK CHK'ED OK AND INTERFERENCE WITH OTHER LINES OK ALSO. AT OUR CREW BRIEFING AT XA00 THAT NIGHT, I FOUND OUT ABOUT AN AIR TURN BACK DUE TO GEAR HANDLE UP AND RED UNSAFE LIGHT ON.

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.