A B737-400 WAS RETURNED TO SVC WITH RUDDER DAMAGE INCURRED DURING THE RUDDER REPLACEMENT.

Narrative

PART WAS LEFT BTWN RUDDER AND VERT STABILIZER. PANEL WAS DAMAGED AND DISCOVERED ON WALKAROUND BY FLC. VISUAL INSPECTION BEFORE INSTALLATION OF RUDDER POSSIBLE CORRECTIVE ACTION. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATES THE MAINT MANUAL AND JOB CARD DIRECTS THAT REMOVED RUDDER HINGE PARTS BE BAGGED AND TIED IN THE VERT STABILIZER TRAILING EDGE CAVITY. THE RPTR SAID SOMEONE MISSED THE ONE BAG OF REMOVED HINGE FITTINGS AND OBTAINED NEW FITTINGS FROM STORES AND INSTALLED THE NEW HINGE FITTINGS LEAVING THE REMOVED FITTINGS IN THE CAVITY. THE RPTR STATED WHEN THE OPERATIONAL CHK WAS PERFORMED THE BAGGED PARTS DAMAGED THE RUDDER LEADING EDGE. THE RPTR STATED THE JOB CARD AND THE MAINT MANUAL HAVE BOTH BEEN CHANGED TO REMOVE THE BAGGED PARTS BEING TIED IN THE VERT STABILIZER TRAILING EDGE CAVITY. THE RPTR SAID THE FAA HAS MADE CONTACT. CALLBACK CONVERSATION WITH RPTR OF ACN 379072 REVEALED THE FOLLOWING INFO: THE RPTR STATED THIS JOB HAS BEEN DONE MANY TIMES WITH THIS SAME GROUP OF MECHS AND NO DAMAGE RESULTED. THE RPTR SAID THIS PARTICULAR BAG OF PARTS WAS TIED IN A DEEP PORTION OF THE TRAILING EDGE CAVITY AND WAS NOT ACCOUNTED FOR OR RECORDED ON ANY WORK CARD.