Narrative:

I've noticed at c-chk; and have had write-ups made to fix the problem; that the aft fairing for flap tracks #1; #2 and #7; #8 have arrived with their lube bushing tubes installed backwards. Hence the fittings are not getting properly lubed. Reference ipc 27-51-31-001 item #185 and ipc 27-51-002 item #190. Not sure when or where the fairings are being installed but it is not being done correctly. Please note that not all planes have this problem. Callback conversation with reporter revealed the following information: reporter stated he first noticed the tube (sleeve) bushings were installed backwards when he found a cracked fitting that supports a bracket; for the aft fairing forward attach bolt on a B757-200. The lube bushing tube is installed first; through the bracket pivot point and aft fairing; with the lube tube grease fitting inboard. The bolt is then installed into the tube and bracket. When the flap extends or retracts; the aft fairings; also known as canoes; pivot at the tube bushings. Without proper grease lubing of this pivot point; damage to anyone of the attach points could occur from seizing. Reporter stated the maintenance manual describes how to install the sleeve tubes; but their B757 aircraft are coming into their c-checks with incorrect installations. His carrier does not perform their own heavy overhauls. Reporter stated; since his carrier switched over to an outside maintenance planning and tracking program that also issues job cards; he suspects the lube bushing tube installation procedure may not reflect the maintenance manual procedures.

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Original NASA ASRS Text

Title: DURING NUMEROUS C-CHECKS; MECHANIC NOTICES THE AFT FAIRING FOR FLAP TRACKS #1; #2; AND #7; #8 ON B757-200 AIRCRAFT; HAVE ARRIVED WITH THEIR LUBE BUSHING TUBES (SLEEVES) INSTALLED BACKWARDS. AS A RESULT; THE TUBES ARE NOT GETTING PROPERLY LUBED.

Narrative: I'VE NOTICED AT C-CHK; AND HAVE HAD WRITE-UPS MADE TO FIX THE PROB; THAT THE AFT FAIRING FOR FLAP TRACKS #1; #2 AND #7; #8 HAVE ARRIVED WITH THEIR LUBE BUSHING TUBES INSTALLED BACKWARDS. HENCE THE FITTINGS ARE NOT GETTING PROPERLY LUBED. REF IPC 27-51-31-001 ITEM #185 AND IPC 27-51-002 ITEM #190. NOT SURE WHEN OR WHERE THE FAIRINGS ARE BEING INSTALLED BUT IT IS NOT BEING DONE CORRECTLY. PLEASE NOTE THAT NOT ALL PLANES HAVE THIS PROB. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: REPORTER STATED HE FIRST NOTICED THE TUBE (SLEEVE) BUSHINGS WERE INSTALLED BACKWARDS WHEN HE FOUND A CRACKED FITTING THAT SUPPORTS A BRACKET; FOR THE AFT FAIRING FORWARD ATTACH BOLT ON A B757-200. THE LUBE BUSHING TUBE IS INSTALLED FIRST; THROUGH THE BRACKET PIVOT POINT AND AFT FAIRING; WITH THE LUBE TUBE GREASE FITTING INBOARD. THE BOLT IS THEN INSTALLED INTO THE TUBE AND BRACKET. WHEN THE FLAP EXTENDS OR RETRACTS; THE AFT FAIRINGS; ALSO KNOWN AS CANOES; PIVOT AT THE TUBE BUSHINGS. WITHOUT PROPER GREASE LUBING OF THIS PIVOT POINT; DAMAGE TO ANYONE OF THE ATTACH POINTS COULD OCCUR FROM SEIZING. REPORTER STATED THE MAINTENANCE MANUAL DESCRIBES HOW TO INSTALL THE SLEEVE TUBES; BUT THEIR B757 AIRCRAFT ARE COMING INTO THEIR C-CHECKS WITH INCORRECT INSTALLATIONS. HIS CARRIER DOES NOT PERFORM THEIR OWN HEAVY OVERHAULS. REPORTER STATED; SINCE HIS CARRIER SWITCHED OVER TO AN OUTSIDE MAINTENANCE PLANNING AND TRACKING PROGRAM THAT ALSO ISSUES JOB CARDS; HE SUSPECTS THE LUBE BUSHING TUBE INSTALLATION PROCEDURE MAY NOT REFLECT THE MAINTENANCE MANUAL PROCEDURES.

Data retrieved from NASA's ASRS site as of May 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.