Two Mechanics report on their efforts; difficulties and reduced Maintenance schedule while accomplishing the removal and replacement of a #1 engine VSV (Variable Stator Vane) actuator on a B767-300 aircraft.
Synopsis
Two Mechanics report on their efforts; difficulties and reduced Maintenance schedule while accomplishing the removal and replacement of a #1 engine VSV (Variable Stator Vane) actuator on a B767-300 aircraft.
Narrative
Mechanic Y and I were assigned to a B767-300 to replace the #1 engine VSV (Variable Stator Vane) actuator. We were in the process of removing the actuator; had everything disconnected; but couldn't get it out of the support bracket; we worked on it for quite a while. We checked with other AMTs (Technicians) that were on duty that night; but no one we asked had ever accomplished the task before. After a couple of hours of struggling and trying to get it out; we removed three fittings; reference (Maintenance Manual) MM 75-31-02; Items 9; 12 and 14 on Figure 401; Sheet 2 of 2; which were not called out to be removed in the MM. It would have saved a least an hour plus of time and frustration.After the removal we started to install the new one; got as far as the nut on the eye bolt; I dropped it a couple times and eventually lost it to the point of not being able to find it. We looked and looked for quite a while. While my partner looked; I decided to order a new one; ZZZ did not stock it; so I had to rush it from ZZZ1. After looking for quite awhile we were getting frustrated but we finally found it.At around XA:00am; our Supervisor informed us; they needed our plane to replace another because it was trapped inside the hangar by a broken down cleaners truck. Talk about pressure; we still had to complete the installation; run the engine; accomplish the tests and leak check the actuator. With all the rushing to finish the job and push aircraft out for the [engine] run; I forgot to call for an inspection. After the run; we reopened the engine to find the [actuator] lower line was leaking. At this time the Supervisor was standing there watching our every move; waiting for the plane. We rushed to find the cause of the leak but it was already time for Dayshift to take over; so I notified the Dayshift Lead [Mechanic] we would need somebody to take over.I made a write-up for the leak check; signed off the original write-up and updated the leak check write-up as to where it was leaking. With all the pressure to get the plane out; I forgot to make a write-up to have the actuator inspected and since the installation was complete; I didn't think to give the MM and task paperwork to the Dayshift mechanics. They were working a fuel leak. I gave the Dayshift mechanics a Maintenance Turnover; but forgot to inform them of the Inspection [requirement]. A couple days later; I found the task's paperwork procedures in one of the drawers in my toolbox. I looked it over before throwing it out; right then I realized I had forgot to get it inspected. I looked up in the aircraft maintenance computer to see if the Dayshift mechanics caught it. I notified my Lead and we called Maintenance Control to notify them of the missed inspection. The actuator is not an RII item; but was called out on the task's paperwork. The Maintenance Controller On-Duty issued a special procedure to have the actuator inspected before departure. The inspection was completed and no faults found. I do believe if we weren't rushed to get the plane out; the inspection would have been done. We were all stressed out by the end of shift; all I wanted to do was just sit down and relax.
Second reporter narrative
Mechanic X and I were assigned to a B767-300 aircraft to replace the # 1 engine VSV (Variable Stator Vane) actuator. We worked on the VSV actuator throughout the night taking no breaks or lunch. We were having a hard time getting the actuator out and asked several other AMTs (Technicians) if there was some trick to the actuator removal. Nobody on shift that night had ever done this job before. Eventually we figured out we needed to remove three adapters on the actuator in order to remove it. This step was not called out in the removal text section of the MM; and resulted in the removal procedure taking a lot longer.When we went to run the engine to check for leaks; one of the [actuator] lines was leaking; so Mechanic X ended up writing that leaking line up and signing-off the VSV actuator replacement task card without noticing it needed an inspector's verification (it was now close to our shift finish time). The job to fix the leaking line was turned over to Dayshift. I was not aware of this inspection requirement misstep until days later when the Mechanic X informed me that we missed the inspection verification.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.