B757-200
Maintenance Powerplant; Maintenance Airframe
Communication Breakdown; Training / Qualification; Confusion
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
Aircraft Aircraft Damaged; General Maintenance Action
Procedure; Human Factors
During maintenance procedure to lock out #2 Engine Thrust Reversers (T/R) because [of an] active hydraulic leak; could not install mechanical Deactivation Pin into Outboard (O/B) reverser translating sleeve as per MEL 78-31-01 Maintenance (M) procedure.  Was able to install deactive pin into Inboard (I/B) side correctly. Contacted Air Carrier Y for further instructions. Was instructed to keep the Inboard (I/B) pin installed and hydraulically cycle #2 Engine Reverser to 'Open' and 'Stow' for possible pin alignment; as this has been a problem in the past. Was also informed that only the Outboard T/R would move and not the Inboard because of it being mechanically deactivated [by Lock-Out pin]. Both Inboard and Outboard T/R deployed; causing damage to the Inboard T/R internally at [Lock-Out] pin location. Contacted Air Carrier Y to inform [them] of damage and Air Carrier Y's Maintenance was flown to ZZZ to access and repair. Aircraft Out of Service: Maintenance.
Reporter stated his Air Carrier X has agreements to perform maintenance on other air carrier aircraft. In this case; a B757-200 for Air Carrier Y blew hydraulic seals in the #2 Engine Thrust Reverser Sync-Lok module on landing at their Station. A large amount of Skydrol hydraulic fluid was lost; creating a very heavy spray mist that was thought to be an engine fire; resulting in dispatching of the airport fire trucks.Reporter stated the Lock-Out Pin installation procedure that was directed by the Air Carrier Y's Maintenance Controller was later determined to be an incorrect procedure to use on Rolls Royce Reversers. When they followed the Maintenance Controller's direction and installed the Lock-Out Pin at Inboard C-Duct reverser and applied hydraulic pressure to try and align the Outboard C-Duct Lockout pin hole; the 3;000 PSI hydraulic pressure ripped the Inboard Lock-Out Pin right out of the casting; driving both reverser sleeves aft. Reporter stated he was informed by Air Carrier Y's field trip repair technicians that he (reporter) would most likely not have been able to insert the Outboard Lock-Out Pin because the entire Reverser Assembly on #2 Engine had not been rigged correctly prior to the B757's arrival at his Station.  Air Carrier Y's technicians replaced the Sync-Lok module; pinned the Thrust Reversers and the aircraft was ferried back to their Maintenance Base. A new set of thrust reversers were later installed.
An air carrier Line Aircraft Maintenance Technician (AMT) contracted to perform maintenance on another air carrier's B757-200 aircraft; describes his efforts to install Lock-out pins on a Rolls Royce # 2 Engine Reverser assembly. The aircraft had lost hydraulic fluid on landing when hydraulic seals had failed in the reverser sync-lok module.