B767-300 and 300 ER
Maintenance Powerplant; Maintenance Airframe
Maintenance Technician 20
Situational Awareness; Confusion; Communication Breakdown
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
General Maintenance Action; General Flight Cancelled / Delayed; General Release Refused / Aircraft Not Accepted
Human Factors; Incorrect / Not Installed / Unavailable Part; Chart Or Publication; Aircraft; Manuals
We inadvertently installed # 2 slat that turned out to be 'Not-Effective' for our aircraft because it had not been modified for the Winglet Modification (MOD) by adding a vortilon to the leading edge. Our Illustrated Parts Catalog (IPC) showed that Part Number (P/N) XXX-51G was 'Effective'; but we missed the part about being modified for winglet aircraft. The aircraft was Ferry flight back to the U.S. for final repairs in which the slats were removed again and reinstalled. The correct P/N for the modified slat is 767-XXX-51G1. The aircraft has had the winglets installed for awhile. The winglet modified aircraft have several differences that not everyone is aware of; or even know to look for them. The aircraft never made a revenue flight before the problem was found March 2012; when the Captain noticed the vortilon missing and denied the B767-300 aircraft. It was brought back to the Hangar where I installed the vortilon early next morning per an Engineering Authorization (E/A) and a Job Card for modifying the slat to the [correct] configuration. I re-marked the slat with the new P/N 767-XXX-51G1; which is 'Effective' for the aircraft. I then returned the aircraft back to full service. The IPC should be revised to show that only P/N (767-XXX-51G1) is effective for that aircraft; at the #2 slat position.
A Line Mechanic reports he was involved with inadvertently installing a Leading Edge Slat on a B767-300 aircraft that was not 'Effective' for the #2 slat position. The slat had not been modified for winglet modified (mod) aircraft; which required adding a vortilon to the leading edge.