A Mechanic reports he had unknowingly used incorrect length bolts when he installed a Fuel Flow Transmitter on the # 1 engine of a B777 aircraft. At least one bolt backed-off with the O-ring causing an inflight fuel leak and a Return to Field. The Maintenance Manual installation procedure did not reference specific bolt locations.
Synopsis
A Mechanic reports he had unknowingly used incorrect length bolts when he installed a Fuel Flow Transmitter on the # 1 engine of a B777 aircraft. At least one bolt backed-off with the O-ring causing an inflight fuel leak and a Return to Field. The Maintenance Manual installation procedure did not reference specific bolt locations.
Narrative
I was told when I came to work on December 2009; that there had been an air interrupt on a B-777; aircraft 'X'; because of a fuel leak from the left hand engine Fuel Flow Transmitter. In November 2009; I was assigned to install a Fuel Flow Transmitter (FFT) on the left hand engine on another B777; aircraft 'Y'. The original FFT was borrowed and installed on aircraft 'Y'. It was removed from aircraft 'X' and installed on aircraft 'Y' by another Mechanic. This was the first time I have installed an FFT and so I talked to other Mechanics about what the job entailed and I read through the Maintenance Manual. During installation I don't recall any major problems with the installation. I installed all new o-rings that came with the FFT and used the old bolts that were on the old FFT. I laid out the bolts in the same pattern as they came off the engine. I installed them in the same order. I used Maintenance Manual (AMM 73-31-11-4).I have been a Mechanic for 23 years and this is the first time something like this has happened with me involved. I take the time to recheck important stuff like Engine components or Flight controls and I am very troubled by this incident.
NASA callback
Reporter stated the air interrupt of the B777 and Return to Field was due to fuel coming out of # 1 engine. At least one; and possibly two bolts had backed-off along with their O-rings from the Fuel Flow Transmitter mounts. There are eight bolts total; four longer bolts are installed on the inboard side of the Fuel Flow transmitter and four shorter bolts on the outboard side.Reporter stated the Maintenance Manual did not have any references to the different bolt lengths or their positions. That has changed recently; because his carrier has revised their Maintenance Manual with better information. The bolts do have different Part Numbers. His carrier also issued a special alert for Mechanics to check all Fuel Flow Transmitter (FFT) bolt head Part Numbers and their mounting positions. They have already found Fuel Flow Transmitter bolt heads in the wrong position on other B777 engines.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.