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A B737-800 technician reports due to not shimming the forward lavatory module the cockpit door-to-door header clearance is out of limits.
| Attributes | |
| ACN | 697596 |
| Time | |
| Date | 200605 |
| Local Time Of Day | 0001 To 0600 |
| Place | |
| Locale Reference | airport : zzz.airport |
| State Reference | US |
| Altitude | agl single value : 0 |
| Aircraft 1 | |
| Operator | common carrier : air carrier |
| Make Model Name | B737-800 |
| Operating Under FAR Part | Part 121 |
| Flight Phase | ground : maintenance |
| Person 1 | |
| Affiliation | company : air carrier |
| Function | maintenance : technician |
| ASRS Report | 697596 |
| Person 2 | |
| Affiliation | company : air carrier |
| Function | maintenance : technician |
| ASRS Report | 697595 |
| Events | |
| Anomaly | aircraft equipment problem : critical maintenance problem : improper maintenance maintenance problem : improper documentation non adherence : far non adherence : published procedure |
| Independent Detector | other other : 1 |
| Resolutory Action | none taken : detected after the fact |
| Consequence | other other |
| Factors | |
| Maintenance | contributing factor : engineering procedure contributing factor : work cards performance deficiency : logbook entry performance deficiency : scheduled maintenance performance deficiency : installation performance deficiency : inspection |
| Supplementary | |
| Problem Areas | Chart Or Publication Maintenance Human Performance Aircraft |
| Primary Problem | Maintenance Human Performance |
| Situations | |
| Publication | Maint. Manual Proc |
Narrative:
The gap between the bottom of the header and the top of the cockpit door was out of limits. Engineering stated that the forward lavatory where the cockpit door is mounted on was not properly shimmed. The lavatory had no shimming prior to disassembly and had none after reassembly. This is fairly common. There is no adjustment that would bring header within limits in the manual. I am concerned that other headers in the fleet are out of limits since the lavatories are not usually shimmed. Engineering said to ream holes on bushing end of header to allow it to drop down within limits. Was unaware that lavatory shimming was impacting door to header gap.
Original NASA ASRS Text
Title: A B737-800 TECHNICIAN RPTS DUE TO NOT SHIMMING THE FORWARD LAVATORY MODULE THE COCKPIT DOOR-TO-DOOR HEADER CLRNC IS OUT OF LIMITS.
Narrative: THE GAP BTWN THE BOTTOM OF THE HEADER AND THE TOP OF THE COCKPIT DOOR WAS OUT OF LIMITS. ENGINEERING STATED THAT THE FORWARD LAVATORY WHERE THE COCKPIT DOOR IS MOUNTED ON WAS NOT PROPERLY SHIMMED. THE LAVATORY HAD NO SHIMMING PRIOR TO DISASSEMBLY AND HAD NONE AFTER REASSEMBLY. THIS IS FAIRLY COMMON. THERE IS NO ADJUSTMENT THAT WOULD BRING HEADER WITHIN LIMITS IN THE MANUAL. I AM CONCERNED THAT OTHER HEADERS IN THE FLEET ARE OUT OF LIMITS SINCE THE LAVATORIES ARE NOT USUALLY SHIMMED. ENGINEERING SAID TO REAM HOLES ON BUSHING END OF HEADER TO ALLOW IT TO DROP DOWN WITHIN LIMITS. WAS UNAWARE THAT LAVATORY SHIMMING WAS IMPACTING DOOR TO HEADER GAP.
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.