Incident Overview
Following a night takeoff from São Paulo-Guarulhos Airport, en route to Buenos Aires, the captain informed air traffic control about technical problems and was cleared to return for an emergency landing. The aircraft landed at a speed of 185 knots with flaps extended to 15° on wet runway 09L. Unable to stop within the remaining distance, the aircraft overran, lost its undercarriage, and came to rest 200 metres further.
Emergency Landing and Evacuation
All 128 occupants were evacuated safely. Among them, two passengers were slightly injured. The aircraft sustained substantial damage and was written off.
Investigation Findings
The investigation determined that the number 3 leading edge flap actuator attachment fitting on the wing front spar had fractured due to corrosion. The actuator came away, causing failure of some hydraulic lines and damage to the thrust control cables. Several 1981 Boeing Service Bulletins had not been complied with, including one that mandated replacement of the aluminum leading edge flap actuator attachment fitting with a steel unit. Contributing factors included: excessive workload on approach and landing due to the emergency, poor approach planning, lack of visibility at night, poor crew coordination and resource management, the crew forgetting to lower the flaps electrically on approach (resulting in an excess speed of 32 knots), poor aircraft maintenance and supervision, and failures in the oversight of the company's operating sector.