Regional Jet 200 ER/LR (CRJ200)
Maintenance Airframe; Maintenance Powerplant
Training / Qualification
Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Published Material / Policy
General Maintenance Action
Aircraft; Human Factors; Procedure
During ZZZ visit; Aircraft X had 7 of the 8 flap actuators scheduled to be changed. While changing the Number 1; Number 2 and Number 3 flap actuators on the left hand side; we found several issues.My findings on the previous installation of the LHOBI (Left Hand Outboard Inboard) Number 4 Flap Actuator show a grievous disregard for following the written procedures and it is also evident that there was no RII (Required Inspection Item) performed on this maintenance action. This Actuator was installed [at the beginning of the year]. The following is a list of all the discrepancies associated with Actuator Number 4: 1) The actuator Retract up stops were physically approximately .625' apart; the Limit is .010' max. 2) The Number 3 flex shaft at the IB side of the LHOBI Number 3 Flap Actuator did not have the B Nut installed; the shaft end only was installed into the Actuator. Please Note that the inner diameter of the crush washer located at the Inboard side of the Number 3 Actuator shows clear evidence of long term wear from continual contact with the rotating flex shaft hexagonal end. Simply put; the washer was 'Loose' for a long time. This location is a common disconnection point for the purpose of separating the Inboard and Outboard Flaps which simplifies many aspects of Flap maintenance including Repair and Return of Flap Actuators. Number 3) The Inboard and Outboard Pillow Blocks on the Ball Nut of the LHOBO Number 4 Actuator were not safety wired. 4) The Base Mount Nut Cotter Pin was not replaced with new and was not bent over.Failure to follow procedures and lack of inspection over site while changing the Number 4 LH Flap Actuator. Rigged whole flap system and verified all safeties after installation of 7 flap actuators. The one actuator that was not scheduled for change was the LH Number 4 which was replaced in ZZZ1.
CRJ-200 Maintenance Technician reported previous maintenance discrepancies on flap components.