B737 crew reported receiving a plane; that had main wheel brake wear pins well below limits. Maintenance commented that the plane had flown with no brake pads on the assembly despite the aircraft having had a maintenance inspection the previous evening.
Synopsis
B737 crew reported receiving a plane; that had main wheel brake wear pins well below limits. Maintenance commented that the plane had flown with no brake pads on the assembly despite the aircraft having had a maintenance inspection the previous evening.
Narrative
Upon rejecting an aircraft for an APU issue; the First Officer and I accepted an aircraft arriving from ZZZ1 overnight. The inbound Captain and First Officer; whose First Officer was completing her OE (Operating Experience); stated it was a good plane. After a brief discussion as passengers deplaned; we proceeded to the gate agent and then to the aircraft for preflight.During the walk-around; the First Officer inspected the left main landing gear and found the left outboard brake pin appeared flush or recessed. Due to the heat; it was difficult to examine closely; but photos confirmed both front and rear brake pins were beyond limits. After completing the walk-around; the First Officer showed me the brake system. We discussed his findings; and I visually confirmed the brakes were indeed beyond limits. Maintenance personnel also agreed there was a problem; and we initiated a write-up for the brake wear.Maintenance determined the left main outboard brake required replacement. Boarding was paused; and passengers were advised they could deplane or remain seated. Once the gear was jacked; I informed passengers they must remain seated for approximately 30 minutes. The brake change was delayed by an additional 15 minutes due to the high temperature of the rotor and brake assembly.After maintenance completion; the lead maintainer briefed us; expressing shock that the outboard tire's fuse plug hadn't popped due to extreme heat. He stated the brake wear was so severe that the aircraft had flown multiple flights with no brake pads remaining on the front and back assembly. Also of note; the aircraft had a maintenance inspection completed in ZZZ1 the previous night; as noted with the ZZZ2 from ZZZ1.Following this; passengers re-boarded; and we departed for ZZZ3. Upon arrival; maintenance in ZZZ3 informed the Captain that the outboard tire was flat; likely due to heat damage from the previous flight; and needed replacement.
Second reporter narrative
Shortly after showing up to the gate the captain and first officer who operated the inbound flight; came up the jet bridge; and said that it was a good plane; and the first officer was completing her OE (Operation Evaluation). After talking for a little bit longer; we proceeded to the gate agent to head down to the aircraft in order to preflight and make sure the flight departed as quick as we safely could do so. Once on the aircraft we completed our preflight flows and I proceeded outside to do the walk around. The plane appeared to be in good condition until I got to the left main landing gear. The left outboard gear pin appear to be completely flush or recessed. I took photos of the rear in front of the brakes where both brake pins appeared beyond limits in order to show the captain upon completion of the walk around. I continued the rest of the preflight inspection and then proceeded to show the photos to the captain; who decided to take a look himself to confirm that the brakes needed to be written up. He concurred that the brakes were beyond wear and talk to maintenance personnel who also agreed that it may be a problem. We then wrote up the brake wear pins in order to get maintenance to inspect/work on the plane. Upon maintenance's arrival; they determined that the left main outboard brake needed to be replaced. Boarding was held once maintenance was called and we determined that egress needed to be offered to the passengers currently on board. We advised them that they could either exit the aircraft or remain seated on the plane however; once the gear was jacked up by maintenance nobody could leave their seat; stand in the aisles or use the restroom for a period of about 30 minutes. We then proceeded to change the tire but it took longer than expected because the temperature was so great near the gear that they needed to release the brakes about 15 minutes into the brake change in order to cool the area quicker. Once maintenance action was complete we resumed the boarding process. Shortly; there after the rest of the passengers were boarded; and we departed the gate and proceeded to ZZZ2. Before leaving though ZZZ maintenance mentioned that the brake wear was so bad that it had flown multiple flights beyond limits.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.