Skyhawk 172/Cutlass 172
Maintenance Airframe; Maintenance Inspection Authority; Maintenance Powerplant; Maintenance Repairman
Maintenance Inspector 16; Maintenance Repairman 6; Maintenance Technician 36
Training / Qualification
Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural Published Material / Policy
Flight Crew Returned To Departure Airport; General Maintenance Action
Human Factors
Training Technician installed rudder cables after aircraft was reassembled from being transported and disassembled for Transportation. Technician who among several other Technicians failed to recognize that the rudder cables were not safetied. Chief Inspector did not see that the Rudder Cables were not safetied during Final Inspection. Aircraft was signed off and returned to Service. Aircraft was test flown after repairs were completed and minor items fixed. Aircraft returned to service. Rudder cable became disconnected after aircraft was flown 16 times. Aircraft landed without any incident. Inspection revealed rudder cable had become disconnected. While trying to reinstall cable and rig the rudder system we found that it would not rig correctly. After further investigation found that the rudder cables had been misrouted. Cables were damaged. Replaced cables with new and rigged rudder cables in accordance with [Cessna] 172 Maintenance Manual. Removed necessary panels and inspected all turnbuckles for safety and Control Surfaces for rigging. All found to be okay. Reassembled and completed logbooks and returned to service.
Trainee installed rudder cable for aircraft reassembly after aircraft was transported back to FBO after landing incident. Myself along with a number of other Technicians failed to find that the rudder cable clevis was not safetied. During final inspection; Chief Inspector; failed to find the non-safetied cable and aircraft was returned to service. After a number of flights the aircraft lost rudder during flight; and landed without incident. Upon inspection; it was found that the rudder cable clevis had disconnected. During re-installation and rigging of cable; it was found that the rudder cables were routed incorrectly near front pedals. Due to cable damage; cables were replaced with new. Cables installed and rigged in accordance with Cessna Maintenance manual. All other control cables were reinspected for proper installation and safety. Airplane returned to service.
Maintenance Technicians reported incorrectly re-assembled Rudder Control Cables went unnoticed and failed during subsequent flight; when aircraft returned to field without incident.