Date: 201506
Local time of day: 1801-2400
Location: ZZZ.Airport, US
Light: Night
Aircraft: B767-300 and 300 ER
Operator: Air Carrier
Operating under: Part 121
Flight phase: Parked
Aircraft component: Gear Extend/Retract Mechanism
Component problem: Malfunctioning
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Communication Breakdown; Confusion; Workload; Time Pressure; Situational Awareness
Second reporter function: Technician; Trainee
Anomaly: Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Maintenance; Inflight Event / Encounter Other / Unknown
Detector: Person Flight Crew
When detected: In-flight
Result: Flight Crew Returned To Departure Airport; General Maintenance Action; General Flight Cancelled / Delayed
Contributing factors: Equipment / Tooling; Human Factors
Primary problem: Human Factors

Narrative: I; [Mechanic X] was assigned to exterior portion of ETOPS; Mechanic Y had interior. Lead Mechanic had Mechanic Z shadow me to familiarize him with ETOPS operation because he was not ETOPS qualified. Found #4 MLG tire below pressure limits per General procedures Manual (GPM). I proceeded to pull paperwork while Mechanic Y and Z gathered the tire jacks and equipment for tire change. Mechanic Y showed Mechanic Z where the gear pins were in the aircraft; I witnessed them install gear pins from the right hand MLG [area]. At this time all of us helped change the #4 MLG tire. During this time Mechanic Z was shown by myself and Mechanic Y how to fill out tags / paperwork and some details of removing and installing a B767 MLG tire. After tire installation I witnessed Mechanic Z remove MLG pins and looking forward from right hand MLG [area]; I saw Mechanic Y and Z with the pins/flags [streamers] and gear pin pouch under the E/E Compartment. I then saw them put the pouch into the E/E Compartment. Finishing up paperwork; I then asked Mechanic Y if the pins were removed. He answered 'yes' the pins were out; as a further confirmation for what I thought I witnessed. Finished up ETOPS paperwork and logbook; aircraft departed. Approximately early evening; the Manager approached me and stated that the B767-300 aircraft was returning from flight due to no gear retraction. Upon arrival of the B767 to gate; myself and Mechanic Y then inspected NLG area and found NLG pin still installed. Mechanic Z was present at the gate and we discussed if he remembers removing the NLG pin and he replied yes. During further discussion; he (Mechanic Z) was not clear on the NLG [towing] bypass pin and the NLG downlock pin location. I removed the NLG downlock pin from the B767 aircraft.[Contributing causes]:Ferry flight came in late for the outbound ETOPS flight.Scheduled quick turn. Finding #4 MLG tire low and requesting additional one hour before departure.Working with employee new to terminal and ETOPS operations and new to this fleet type of aircraft.Not checking NLG for compliance of pin removal before Aircraft departure.[Recommend]Verify all tasks in detail personally before signing.Additional familiarization with fleet type of aircraft for employees before working live flight/terminal operations.Nose gear strut and fixed gear doors hide current [gear pin] flag length from view unless directly in front of NLG nose strut.Suggesting NLG [downlock] pin flag be longer; to clear NLG doors; bright orange for visibility; wider and [make] possible tether to [towing] bypass pin.Improved NLG flag could have been seen by Pushback crew on their walk around and pushback operation.


Second narrative: I was instructed to pull the gear pins on the aircraft after a main tire change. I did not see the streamer on the nose gear lockout pin and because I am a recent transfer to ZZZ and learning; [I] accidentally pulled the nose gear [towing bypass lever] lockout pin instead. I stowed the correct five pins in the bag and thought I had pulled the correct pin. Due to lack of experience I pulled the wrong Lockout pin. [Recommend to] have a 2nd set of eyes confirm the correct pin was pulled.


Synopsis: Three Aircraft Maintenance Technicians (AMTs); one who was in training; describe their involvement with a B767-300 ETOPs aircraft returning to departure airport with a nose landing gear (NLG) pin not removed. One Technician noted that the AMT in training was not clear on the NLG towing bypass pin and NLG downlock pin locations. Also; the streamer flag for the NLG downlock pin is hidden by the gear strut and fixed gear doors; flag needs to be longer.