Narrative:

On the eve of fri/jun/2005; myself and another tech were assigned aircraft X. During line check; I found #3 tire worn to overnight limits. After tire removal; I was checking the brake; and I was unable to turn the discs by hand; and I noticed brake pad chunks. At the time we had no brakes in ZZZ. I copied the logbook; and on sun/jun/2005; I returned to work. My co-worker informed me of a manager; mr X; that signed off the brake as ok. Needless to say; I was pretty upset. This 'new hire' manager comes in here and questions my technical capabilities. I hope this aircraft has no incidents. We also need some FAA oversight of the manufacturer and the product of brakes and tires. Callback conversation with reporter revealed the following information: after removing the #3 tire and wheel assembly; the brake was inspected and was found to have seized rotors. The rotors were freed; and upon turning the rotors; brake chunks fell out. A non-routine card was written to replace the brake due to wear and brake pad failure. A records check revealed this brake had been on the airplane 14 days and had been overhauled and assembled by a contract maintenance facility. The reporter stated the contract facility; when assembling a new brake; will intermix stator brake pad discs showing limited wear with new stator pads. The non routine card was signed off by a manager with a statement; '#3 brake found ok for service.'

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Original NASA ASRS Text

Title: A DC9-30; DURING A #3 TIRE AND WHEEL ASSEMBLY REPLACEMENT; BRAKE WAS CHKED AND FOUND UNABLE TO MOVE BRAKE ROTORS. WHEN ROTORS WERE FREED; BRAKE PAD CHUNKS BEGAN TO FALL OUT. NON ROUTINE CARD WAS WRITTEN UP TO REPLACE #3 BRAKE.

Narrative: ON THE EVE OF FRI/JUN/2005; MYSELF AND ANOTHER TECH WERE ASSIGNED ACFT X. DURING LINE CHK; I FOUND #3 TIRE WORN TO OVERNIGHT LIMITS. AFTER TIRE REMOVAL; I WAS CHKING THE BRAKE; AND I WAS UNABLE TO TURN THE DISCS BY HAND; AND I NOTICED BRAKE PAD CHUNKS. AT THE TIME WE HAD NO BRAKES IN ZZZ. I COPIED THE LOGBOOK; AND ON SUN/JUN/2005; I RETURNED TO WORK. MY CO-WORKER INFORMED ME OF A MANAGER; MR X; THAT SIGNED OFF THE BRAKE AS OK. NEEDLESS TO SAY; I WAS PRETTY UPSET. THIS 'NEW HIRE' MANAGER COMES IN HERE AND QUESTIONS MY TECHNICAL CAPABILITIES. I HOPE THIS ACFT HAS NO INCIDENTS. WE ALSO NEED SOME FAA OVERSIGHT OF THE MANUFACTURER AND THE PRODUCT OF BRAKES AND TIRES. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: AFTER REMOVING THE #3 TIRE AND WHEEL ASSEMBLY; THE BRAKE WAS INSPECTED AND WAS FOUND TO HAVE SEIZED ROTORS. THE ROTORS WERE FREED; AND UPON TURNING THE ROTORS; BRAKE CHUNKS FELL OUT. A NON-ROUTINE CARD WAS WRITTEN TO REPLACE THE BRAKE DUE TO WEAR AND BRAKE PAD FAILURE. A RECORDS CHK REVEALED THIS BRAKE HAD BEEN ON THE AIRPLANE 14 DAYS AND HAD BEEN OVERHAULED AND ASSEMBLED BY A CONTRACT MAINT FACILITY. THE RPTR STATED THE CONTRACT FACILITY; WHEN ASSEMBLING A NEW BRAKE; WILL INTERMIX STATOR BRAKE PAD DISCS SHOWING LIMITED WEAR WITH NEW STATOR PADS. THE NON ROUTINE CARD WAS SIGNED OFF BY A MANAGER WITH A STATEMENT; '#3 BRAKE FOUND OK FOR SERVICE.'

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.