Flight Crew Last 90 Days 225; Flight Crew Total 5000; Flight Crew Type 3000
Confusion; Human-Machine Interface
Aircraft Equipment Problem Less Severe
Flight Crew Returned To Departure Airport; Flight Crew Landed As Precaution; General Maintenance Action; General Declared Emergency
Aircraft
Shortly after rotation we heard a couple of loud popping noises from the aircraft that seemed to come from the right side and aft of the First Officer. After flap retraction there was an audible noise in the cabin accompanied by a vibration that could be felt in the floor by the flight attendants from the overwing area forward up into Business Class. At the same time the stall buffet feathers on the First Officer's ADI remained displayed despite both the flap handle and flap indicator showing the flaps were fully retracted. We extended the flaps again and the noise and vibration dissipated; but once we retracted the flaps the noise and vibration returned. We coordinated with ATC to stop our climbout; and called Dispatch and Maintenance Control to seek assistance. With no solution found; we determined that a return to the field would be required. We declared an emergency with Center; coordinated dumping fuel with them and then returned. The landing was at 324;000 LBS (overweight) but was very smooth with minimal sink rate at touchdown. We debriefed with Maintenance upon arrival and relayed to them all of our indications.
B767 First Officer reported hearing a couple of loud popping noises shortly after rotation. After flap retraction there was an audible noise in the cabin accompanied by vibration and the stall buffet feathers on the First Officer's ADI remained displayed despite the flaps showing fully retracted. When the flaps are extended the vibration dissipates and the crew elects to dump fuel and return to the departure airport.