A B737-500 after pushback returned to the gate with rudder travel problems. Found brake control rod on first officer's pedal not connected properly and rod end fractured. Previous first officer's rudder pedal shroud assembly installed.

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Attributes
ACN	646121
Time
Date	200502
Local Time Of Day	1201 To 1800
Place
Locale Reference	airport : zzz.airport
State Reference	US
Altitude	agl single value : 0
Environment
Light	Daylight
Aircraft 1
Operator	common carrier : air carrier
Make Model Name	B737-500
Operating Under FAR Part	Part 121
Flight Phase	ground : pushback ground : maintenance
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	maintenance : technician
Qualification	technician : airframe technician : powerplant
Experience	maintenance technician : 18
ASRS Report	646121
Person 2
Affiliation	company : air carrier
Function	maintenance : technician
Qualification	technician : airframe technician : fcc technician : powerplant
Experience	maintenance avionics : 19
ASRS Report	646076
Events
Anomaly	aircraft equipment problem : critical maintenance problem : improper documentation maintenance problem : improper maintenance non adherence : far non adherence : published procedure
Independent Detector	other flight crewa other flight crewb
Resolutory Action	other
Consequence	other other other
Factors
Maintenance	contributing factor : schedule pressure performance deficiency : inspection performance deficiency : logbook entry performance deficiency : non compliance with legal requirements performance deficiency : testing performance deficiency : installation
Supplementary
Problem Areas	Environmental Factor Maintenance Human Performance Aircraft Chart Or Publication
Primary Problem	Maintenance Human Performance

Narrative:

I'm writing this to inform that I worked on the installation of the first officer's rudder pedal shroud assembly. I disconnected both first officer's pedals at the upper brake control rod ends for better access to install the forward and upper sections of the shroud assembly. I finished the installation of the shrouds; clamped the rudder pedal position adjustment conduit to the forward shroud and re-connected both first officer's rudder pedals to the brake control rod ends -- tightened and checked pedal travel with adjustment knob. (Flight crew returned to gate after encountering rudder pedal travel issues -- inspection determined brake control rod not connected properly and rod end fractured.)

Original NASA ASRS Text

Title: A B737-500 AFTER PUSHBACK RETURNED TO THE GATE WITH RUDDER TRAVEL PROBS. FOUND BRAKE CTL ROD ON FO'S PEDAL NOT CONNECTED PROPERLY AND ROD END FRACTURED. PREVIOUS FO'S RUDDER PEDAL SHROUD ASSEMBLY INSTALLED.

Narrative: I'M WRITING THIS TO INFORM THAT I WORKED ON THE INSTALLATION OF THE FO'S RUDDER PEDAL SHROUD ASSEMBLY. I DISCONNECTED BOTH FO'S PEDALS AT THE UPPER BRAKE CTL ROD ENDS FOR BETTER ACCESS TO INSTALL THE FORWARD AND UPPER SECTIONS OF THE SHROUD ASSEMBLY. I FINISHED THE INSTALLATION OF THE SHROUDS; CLAMPED THE RUDDER PEDAL POS ADJUSTMENT CONDUIT TO THE FORWARD SHROUD AND RE-CONNECTED BOTH FO'S RUDDER PEDALS TO THE BRAKE CTL ROD ENDS -- TIGHTENED AND CHKED PEDAL TRAVEL WITH ADJUSTMENT KNOB. (FLT CREW RETURNED TO GATE AFTER ENCOUNTERING RUDDER PEDAL TRAVEL ISSUES -- INSPECTION DETERMINED BRAKE CTL ROD NOT CONNECTED PROPERLY AND ROD END FRACTURED.)

Data retrieved from NASA's ASRS site as of January 2009 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.