IAI1124/1124A Westwind
Flight Crew Multiengine; Flight Crew Instrument; Flight Crew Flight Instructor; Flight Crew Air Transport Pilot (ATP)
Flight Crew Last 90 Days 58; Flight Crew Total 10000; Flight Crew Type 3000
Situational Awareness; Distraction
Aircraft Equipment Problem Critical
General Maintenance Action
Human Factors
The flaps on this aircraft had been removed for inspection and the aircraft was returned to service. Upon departure; the flight controls were tested for correctness and freedom of motion. The First Officer flew the first leg with no issues. The Captain flew the second leg and again the flight controls were checked; but the flaps were left in the takeoff setting after landing for a quick turnaround. Again; the controls were checked and found fully functional. After takeoff; at 400 FT and flaps retracted; the Captain noticed the ailerons were stiff but functional. A serious of tests were performed on the autopilot system as it was the only thing that the crew could think of that would involve the ailerons. Due to the short duration of flight it was decided to continue. The route of flight was almost direct. The Captain elected to land straight in; even though it was against the traffic flow and slightly downwind. Upon calling for the first flap setting the Captain noticed the controls were normal and no longer stiff. A straight in landing was elected with an almost direct crosswind or even slightly downwind. During the after landing checklist it was noticed the ailerons became jammed and impossible to move. The Maintenance Department was notified and the aircraft grounded. Inspection by Maintenance personnel determined that a flashlight had been left in the flap well and apparently moved enough to interfere with the aileron pushrods. A potentially fatal disaster was avoided by the flight crew's election to continue the flight with no turns and no turbulence encountered rather than returning for landing where winds were gusting to 28.
On the third leg following maintenance activity; the ailerons began to bind after flap retraction on a Westwind 24. During flap extension for landing; the ailerons began to operate normally. A flashlight had inadvertently been left in the flap well during maintenance and worked itself loose during flight.