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A B737-800 after takeoff at 1000 ft diverted due to door 1L was not closed properly due to massive air leak. No door warning indication.
| Attributes | |
| ACN | 622931 |
| Time | |
| Date | 200406 |
| Day | Mon |
| Local Time Of Day | 1801 To 2400 |
| Place | |
| Locale Reference | airport : zzz.airport |
| State Reference | US |
| Altitude | agl single value : 1000 |
| Environment | |
| Flight Conditions | VMC |
| Light | Daylight |
| Aircraft 1 | |
| Controlling Facilities | tracon : zzz.tracon |
| Operator | common carrier : air carrier |
| Make Model Name | B737-800 |
| Operating Under FAR Part | Part 121 |
| Navigation In Use | other |
| Flight Phase | climbout : takeoff climbout : initial climbout : intermediate altitude |
| Route In Use | approach : traffic pattern |
| Flight Plan | IFR |
| Person 1 | |
| Affiliation | company : air carrier |
| Function | flight crew : captain oversight : pic |
| Qualification | pilot : atp |
| Experience | flight time total : 5000 |
| ASRS Report | 622931 |
| Person 2 | |
| Affiliation | company : air carrier |
| Function | flight crew : first officer |
| Events | |
| Anomaly | aircraft equipment problem : critical |
| Independent Detector | other other : person 3 |
| Resolutory Action | flight crew : overcame equipment problem flight crew : diverted to another airport |
| Consequence | other other |
| Supplementary | |
| Problem Areas | Aircraft Cabin Crew Human Performance Maintenance Human Performance Flight Crew Human Performance |
| Primary Problem | Aircraft |
Narrative:
Shortly after takeoff, the flight attendant by the 1L door notified the cockpit that the 1L door wasn't sealed properly and that there was a deafening rush of air noise (which could be clearly heard in the backgnd of the interphone transmission). She verified that the handle was in the 'down' position. No door lights appeared on the cockpit overhead panel and they tested ok. We got clearance to turn downwind and land. We estimated that it would be an overweight landing by about 10000 pounds and asked for a full length rollout to allow the thrust reversers to provide a larger percentage of the slowing/energy dissipation before exiting the runway. The mechanics meeting the flight found that the door had sagged on its hinges enough to allow the roller mechanism to engage down into position on the wrong (inside) side of the mating latch fixed to the door jam. This seems to reveal a flaw in the system of ensuring that indications of 'closed and locked' mean that everything really is closed and locked.
Original NASA ASRS Text
Title: A B737-800 AFTER TKOF AT 1000 FT DIVERTED DUE TO DOOR 1L WAS NOT CLOSED PROPERLY DUE TO MASSIVE AIR LEAK. NO DOOR WARNING INDICATION.
Narrative: SHORTLY AFTER TKOF, THE FLT ATTENDANT BY THE 1L DOOR NOTIFIED THE COCKPIT THAT THE 1L DOOR WASN'T SEALED PROPERLY AND THAT THERE WAS A DEAFENING RUSH OF AIR NOISE (WHICH COULD BE CLRLY HEARD IN THE BACKGND OF THE INTERPHONE XMISSION). SHE VERIFIED THAT THE HANDLE WAS IN THE 'DOWN' POS. NO DOOR LIGHTS APPEARED ON THE COCKPIT OVERHEAD PANEL AND THEY TESTED OK. WE GOT CLRNC TO TURN DOWNWIND AND LAND. WE ESTIMATED THAT IT WOULD BE AN OVERWT LNDG BY ABOUT 10000 LBS AND ASKED FOR A FULL LENGTH ROLLOUT TO ALLOW THE THRUST REVERSERS TO PROVIDE A LARGER PERCENTAGE OF THE SLOWING/ENERGY DISSIPATION BEFORE EXITING THE RWY. THE MECHS MEETING THE FLT FOUND THAT THE DOOR HAD SAGGED ON ITS HINGES ENOUGH TO ALLOW THE ROLLER MECHANISM TO ENGAGE DOWN INTO POS ON THE WRONG (INSIDE) SIDE OF THE MATING LATCH FIXED TO THE DOOR JAM. THIS SEEMS TO REVEAL A FLAW IN THE SYS OF ENSURING THAT INDICATIONS OF 'CLOSED AND LOCKED' MEAN THAT EVERYTHING REALLY IS CLOSED AND LOCKED.
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.