2010-05 · NASA ASRS report 919856
A Mechanic reports lack of information in their Maintenance Tracking and Inventory computer system about previous aileron cable replacements contributed to numerous trouble shooting efforts to locate the cause of a clicking noise in a CRJ-200 control wheel.
I am submitting this report due to just being made aware of an investigation in a CRJ-200 left aileron cable being misrouted at a Contract [Maintenance] Agency. I came on duty to find the CRJ-200 in work for a pilot squawk pertaining to clicking noise in the control wheel. The aircraft was in work and [Maintenance] had the directive to follow a certain [Bombardier] GREO (Generic Repair Engineering Order) for noise in control yoke. This GREO details the steps to follow to correct the discrepancy. The Maintenance Workcards drive you to follow the GREO. There was no binding reported in the discrepancy--only a clicking sound. When I arrived on the job-the GREO was already being complied with and retorque was accomplished. The GREO allows a retorque below the floor of the control column to correct the clicking sound.I did not personally feel the clicking or hear any unusual noises at all-so I directed our mechanics to assist me in the removal of the floor boards on the left side of the cabin to Detail Inspect the run of the cable from the control column to the cabin rear pressure floor area. The controls were being cycled back and forth for visual confirmation of any problems. There were no problems felt or seen under the floors. I had Inspection work with us and Visual (Visual Inspect) of the cables in the rear spar area of the wing and no defects were noted there.The wheel well area was inspected also and cable movement witnessed as satisfactory with no binding or clicking felt. This entire aircraft had been inspected deeply by several mechanics and inspectors to no avail. We then followed the GREO till completion; which stipulates that this is a one-time retorque and sets a fly-on for 500 hours; at which time the bearings must be replaced. That is what transpired and the bearings were replaced. Again the direction is to follow the GREO for compliance. After the bearing replacement the ailerons were again squawked and this is when Maintenance found the mis-route of the aileron cable in the wheel well area. We at Air Carrier X did not at any time disturb the connection of this cable in question. It has been revealed to me that our Contract Agency in ZZZ changed these cables during Heavy Maintenance. This is where the mis-route occurred I believe. Not knowing what Contact Maintenance does-and how deep put all of Air Carrier X at a definite disadvantage in finding the problem. I requested a Maintenance Check Flight to verify normal flight handling and the Check Flight was performed normally and released for service. GREO [Chapter] in reference is (Maintenance Manual) MM 27-11-031. All Maintenance Manual procedures that we were directed to were followed and accomplished.The Contract Agency must provide; without a shadow of doubt; a complete inspection of any critical system that is disturbed. Complete and absolute RII (Required Inspection Item) buy back. I truly feel that more surveillance is needed to assure safety. I also feel that Contract Maintenance work performed should be entered into our Maintenance and Inventory tracking system faster than it currently is being done. The reason for my thought is the aircraft is out of Heavy and has some problems and we mechanics do not know what system has been disturbed.
Reporter stated the normal troubleshooting procedure to determine cause of a clicking noise; felt or heard in the control wheel; was to follow Bombardier's GREO (Generic Repair Engineering Order) to inspect and retorque the ball bearings at the control wheel. The CRJ-200's have issues with control wheel bearing wear; requiring retorque and later replacement per the GREO. The clicking noise was intermittent; written-up a few times; bearings replaced over five months; but squawked again at a Line Station; the flight was canceled. A Line Mechanic followed the routing of the left aileron control cable in the wheel well and found the cable had been mis-routed over a cable guide; instead of through the cable guide.Reporter stated that at the time of the original clicking squawk; the lack of previous maintenance information in their Maintenance Tracking and Inventory Control System computer about the wheel well aileron cable replacements by the Contract Maintenance Agency did not help their trouble shooting process. He and other mechanics continue to fill out reports to their carrier about maintenance deficiencies found after their CRJ's are released from a Contract Maintenance provider. They (his Carrier) do not have any of their own inspectors on-site at the Repair Stations; only a company representative from their carrier.Reporter stated his carrier agreed with his suggestion to speed up the maintenance data that needs to be entered into their aircraft maintenance history; in order to address flight squawks that occur after an aircraft is released from a Heavy Maintenance visit to an outside Contract Station.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.
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