Air carrier technician reported while observing a maintenance crew replacing a nose landing tire on a B767; they encountered a problem removing an axle nut.

Narrative

Defining Routine Maintenance: Have we changed wheel assemblies; brake assemblies; door slides; or serviced oxygen? Are these tasks considered routine? What began as a routine nose tire replacement escalated into a near-miss incident; highlighting the importance of strictly adhering to Aircraft Maintenance Manual (AMM) procedures and safety protocols. This situation is a stark reminder that even the most familiar tasks require precision; caution; and an unwavering commitment to safety. Two nights ago; a maintenance crew was assigned to change two nose landing gear tires on an aircraft that had arrived for overnight servicing. The procedure was familiar--one they had performed countless times before. Confident in their experience; they proceeded with the tire change; working efficiently through the steps. The first tire was replaced without incident. However; as they began to work on the second tire; they encountered a significant challenge: the axle nut was tough to remove. This unexpected challenge is a stark reminder of the potential risks even in routine tasks. Questions arose: Was the axle nut cross-threaded? Was it over-torqued? Were the tools being used defective? Were they following the AMM correctly? Most importantly; a crucial oversight occurred in their routine approach: no one verified the steps according to the AMM. A potential catastrophic failure was identified due to lose split rim tie bolts on the tire; which could have resulted in severe injuries or even death. This incident serves as a reminder that diligently following established procedures is crucial; no matter how familiar the task may seem. Challenges Faced During Maintenance: Axle nut removal was challenging causes: Cross-threaded axle nut; Over-torqued axle nut; Defective tools; Deviation from AMM procedures; Safety protocols not thoroughly followed. Potential Catastrophic Failure Identified: There are Loose split rim tie-bolts on the tire. It was not easily visible when the wheel assembly was installed; and the tire was properly inflated. Raised questions: Was the tire unserviceable before removal?; Are there existing procedures to prevent such risks and injuries? This incident strongly reminds us that routine tasks in aviation maintenance are only safe when carried out with complete diligence. Following established procedures is essential; but taking a moment to reassess and confirm that the job is done correctly is invaluable. Safety is not just a policy; it is a mindset that must always be maintained. The tire was finally removed without incident; and the parties involved headed home as they had come to work. Key Takeaways: No maintenance task should be considered routine. Each component is unique and requires full attention and adherence to procedures. Follow the AMM thoroughly: Read notes and cautions; and re-read if necessary. If a task deviates from routine expectations: STOP! Ask questions. Seek help. Get a second opinion. REPORT IT! Reporting near-misses is as crucial as reporting damages. Reporting near-misses is equally essential as reporting damages