Accident Summary
On October 7, 2019, at 2305 eastern daylight time, a Raytheon Corporate Jets Inc. Hawker 800XP airplane, registration N86MN, touched down on runway 6 at Southwest Florida International Airport (RSW) in Fort Myers, Florida, with the nose landing gear (NLG) retracted. The two airline-transport pilots and two passengers were not injured. The aircraft was operated by Delta Private Jets under 14 CFR Part 135 as an on-demand charter flight. The flight originated from Naples Municipal Airport (APF) in Naples, Florida, at 1953 and was en route to Kerrville Municipal Airport (ERV) in Kerrville, Texas.
Narrative
The pilot-in-command reported that after a normal takeoff roll and rotation from APF, during initial climb and landing gear retraction, a red warning light indicated the NLG remained in transit and not fully retracted. A vibration and a "thud" were felt from the NLG section; at that time the main landing gear indicated retracted. The flight crew attempted to extend the landing gear using the checklist but could not get the NLG to indicate extended or retracted. The crew diverted to RSW due to the availability of a 12,000 ft dry runway. During the landing, the NLG failed to extend, the airplane skidded to a stop on the runway, and the flight crew and passengers performed an emergency evacuation via the main cabin door.
Post-Accident Examination
Photographs taken immediately after the landing showed the main landing gear extended, but the NLG remained retracted in its wheel well. The fuselage sustained substantial damage. Review of photographs provided by the Federal Aviation Administration inspector and the operator revealed that the NLG actuator push rod linkage (drag stay) was disconnected from its attach point, and the nut, washer, and split pin assembly were missing. The actuator remained attached at its opposing end. Deformation was observed in the area where the nut, washer, and split pin assembly were expected to be installed. When the NLG was manually extended by hand by operator maintenance personnel, it locked into place.
Maintenance Background
Maintenance records from StandardAero, the heavy check maintenance facility contracted by Delta Private Jets (DPJ), indicated that the NLG and main landing gear were overhauled in January 2019 as part of a larger inspection for DPJ's Approved Aircraft Inspection Program (AAIP). StandardAero maintenance task job cards stated that the NLG unit was removed, overhauled, and reinstalled by a mechanic and checked and signed off by a quality assurance inspector. The endorsement for the NLG task stated the work was performed in accordance with airplane maintenance manual instructions #32-20-12. The quality assurance inspector who signed off the work reported it was standard practice to use approved manuals during inspections and that quality assurance inspectors check the work performed by mechanics. No discrepancies were noted regarding the NLG work. No other repairs or inspections of the NLG leg or its actuator drag stay had been performed since StandardAero completed the work. At the time of the accident, the landing gear had accumulated 124 cycles since the overhaul. The airplane's maintenance manual, nose landing gear and nose leg assembly installation instructions (#32-20-12), contained 19 steps; step 6 stated: "Attach the drag stay to the leg forging with the pin, make sure the flat on the head of the pin engages the flat on the drag stay, install the washer and nut. Tighten the nut and lock with a new split pin."