2011-06 · NASA ASRS report 952602
B767 flight crew is informed of a gap and air leak under the 1R door passing 10;000 FT during climb; after examination and discussion it is decided to return for an over weight landing. Maintenance discovers debris sticking to the bottom of the door seal preventing the seal from assuming its' normal position when the door is closed.
The flight was climbing out and approaching 10;000 FT. The Chief Purser called to inform us that she could see daylight coming from door 1R coupled with a loud whistling noise. The cabin pressure indications were all normal. The Relief Pilot went to inspect door 1R. The Relief Pilot came back and informed me that there was a lot of daylight which was visible at the bottom of door 1R. We informed Center that we needed to return. I spoke with Dispatch to coordinate our return. After reviewing the landing distance and performance charts for our landing weight; I determined that there was no need to dump fuel. The Relief Pilot was keeping track of the weight of the plane at landing and said we were about 11;000 LBS overweight. At the gate; Maintenance inspected door 1R and determined that there was debris sticking to the bottom of the door seal. The debris prevented the door seal from assuming its normal position when the door was closed. Interestingly; the debris didn't prevent the door from being locked and properly armed.
After takeoff and level at 10;000 FT; the Purser called to say that she could see daylight coming from underneath door 1R accompanied by a very loud squeal. The Captain directed me to go back and take a look. Upon visual inspection; I determined that there was an approximately 3-inch gap in the bottom door seal and I could also see through it and hear the loud squeal. Upon return to the flight deck; I advised the Captain that a return for maintenance would be advisable. We informed ATC and returned for an uneventful approach and landing. The landing weight of the aircraft was 11;100 LBS over maximum landing weight. The Captain consulted with Dispatch before making the decision to land. All appropriate checklists and irregular procedures were followed.
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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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