No Aircraft
Maintenance Airframe; Maintenance Powerplant
Maintenance Inspector 15; Maintenance Lead Technician 28
Communication Breakdown
Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural Published Material / Policy
Aircraft; Procedure
As reported by a former trainee and my own experiences. During the process of assembling an Pratt & Whitney PW100 gearbox. During the assembly process of the gearbox;(RGB) the process to assemble the 'bullgear' onto the propeller shaft assembly is very detailed as to the specific tools called out in the repair manuals for this model engine series. There are special tools called out by part number during the process.During this process there was a failure of the assembly tool installation due to incorrect pressures being applied to the wrong tooling. The results were the hydraulic ram departed from the containment ram of 25 lbs to crash down upon the bullgear and the propshaft. After reporting the incident the supervisor was briefed and instructed to repair the gearbox as. I have been instructed with the same instructions and I was fired for complaining about the very practices. There is a culture of corruption in place there reporting illegal practices is punished to the point where you either get treated as a 'bad employee who HR was already think of getting rid of'; where paperwork will come out of the blue that suddenly produced to say you're not a proper mechanic. There [are] many cases of used uninspected parts being used to save money through several engine lines. There are many people there too afraid to say anything to keep [their] jobs.
During the process of assembling a Pratt & Whitney PW100 gearbox the incorrect tooling was used and the incorrect pressure was applied causing the hydraulic ram to depart and crashed onto the bullgear and propeller shaft.