Gulfstream V / G500 / G550
Maintenance Airframe; Maintenance Powerplant
Communication Breakdown; Distraction; Fatigue; Situational Awareness; Workload
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Published Material / Policy
Flight Crew Returned To Departure Airport
Aircraft; Procedure; Human Factors
May 2012 evening; I was dispatched to go to ZZZ1 to work on a Gulfstream G-V aircraft. I was told it had a # 4 Brake Assembly that was worn to limits and that I would need to make arrangements to go to our Repair Station at ZZZ to acquire the proper tooling. I left my house at XA:00 am the next morning to fly to ZZZ2. My flight was delayed one hour; so I didn't arrive until noon. I then drove to our Repair Station facility in ZZZ to pickup equipment; I left there approximately two and a half hours later. I then drove to ZZZ1 (139 miles). It took me six hours in rush hour/holiday traffic to make the trip. I met up with Mechanic Y. We got to the aircraft and started to work on the aircraft. I disconnected the right outboard Main Landing Gear (MLG) door rod end from the outboard MLG door and I reinstalled the hardware into rod end so we wouldn't lose it. I then used a rubber chock to prop the Main Gear door outward so we could get the # 4 Tire/Wheel Assembly off; to gain access to the # 4 brake. When we went to pull the wheel off; Mechanic Y bumped the door and the chock fell down; so Mechanic Y used the rod assembly and placed it against the gear door to keep it out of our way. We got the wheel assembly off and started removing the brake. [An] air-turn back [occurred later.]
An Aircraft Mechanic describes the events that led to an air turnback of a Gulfstream G-V aircraft. He and another Mechanic had just completed a # 4 brake change on the right-hand Main Landing Gear (MLG); but failed to reconnect the outboard MLG door.