B757-200
Flight Crew Multiengine; Flight Crew Air Transport Pilot (ATP); Flight Crew Instrument
Flight Crew Total 35000
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
Air Traffic Control Provided Assistance; Flight Crew Returned To Departure Airport; Flight Crew Overcame Equipment Problem; Flight Crew Requested ATC Assistance / Clarification; Flight Crew Landed in Emergency Condition; General Maintenance Action; General Flight Cancelled / Delayed
Aircraft
On initial climb it took a lot of left control wheel input to maintain level flight at slow speeds 250 kts. Once above 10;000 ft. we increased speed to Econ climb speed; control wheel inputs increased. The aileron trim had no effect on control column displacement. We had to use 7-8 Units of rudder trim displacement to maintain controlled flight at higher speeds with 7-8 units of rudder trim to the left; the control column was not centered. We still had 2.5 units of ailerons deflection to the left. I tried the autopilot but it also could not maintain controlled flight. We stopped our climb at FL230 and advised ATC we had mechanical issues and may need to return to ZZZ. ATC assigned us a heading to keep us out of [foreign] airspace. The First Officer and I assessed the situation. We slowed to 250 kts.; flaps were up no lights; gear was up no lights; spoilers were stowed no lights; yaw dampers no lights; engine thrust symmetrical; no vibrations; just 8 units of left rudder trim and control wheel 2.5 - 3.0 units to the left. We both were concerned about engine failure if we could control the aircraft with the rudder displacement we had. Our rudder pedals were also displaced to the left. We contacted maintenance for their input and was told to return to ZZZ. We contacted Dispatch via patch through Operations in ZZZ. Dispatch advised us to return to ZZZ. Dispatch also sent us an Acars message while in flight dealing with this [situation]; that they had another aircraft for us when we landed to take to ZZZ1. I don't think Dispatch realized the severity of our situation. I have all the Acars print outs if necessary. We then [requested priority handling] with ATC and confirmed we needed ATC to have the emergency equipment standing by. We advised the Flight Attendants we were returning to ZZZ because of a maintenance issue with our flight controls to prepare the cabin for a precautionary landing. I also advised the Flight Attendants they would see the emergency equipment with lights for a precaution due to our overweight landing. I made a PA to the passengers advising them we we're returning to ZZZ for a Maintenance Issue. The First Officer Completed all Required Checklists and Items as we returned to ZZZ. We made an overweight landing on Runway XX in ZZZ; 220;000 pounds; Flaps 30; 140 kt.s at touchdown; less than 200 ft. per minute at touchdown we landed with 5.0 units of left rudder trim with control wheel displaced 2.5 units to the left. Once we added flaps the roll to the left was even more severe. Aircraft X landed without incident. I am very thankful I had a very experienced First Officer on this flight with me. He was very calm and methodical and had 'Excellent' input working this [situation]. Once we arrived at the gate we removed the passengers. I then recorded in the AML the items we had on this flight. Also recorded the overweight landing . Maintenance came up to the flight deck with a sheet and advised us that they just re-rigged the rudder PCU's all of them and did not do a test flight. Maintenance stated that our rudder was way out of limits based on their data. Also that there was a previous AML entry such as ours. Maintenance stated they would take this to the hanger to fix and stated again our rudder rigging was way out of limits again. They also said they would do a test flight. We should have never flown this aircraft with passengers on board without a test flight.
B757 Captain reported that the flight controls were mis-rigged; and resulted in control difficulties and a return to the departure airport.