Date: 201204
Local time of day: 0001-0600
Location: ZZZ.Airport, US
Light: Dawn
Aircraft: B767-300 and 300 ER
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Takeoff / Launch
ATC / advisory: Tower ZZZ
Aircraft component: Main Gear
Reporter organization: Air Carrier
Reporter function: Inspector
Reporter qualification: Maintenance Powerplant; Maintenance Airframe
Human factors: Communication Breakdown; Situational Awareness
Anomaly: Aircraft Equipment Problem Critical
Detector: Person Flight Crew
When detected: In-flight
Result: General Maintenance Action
Contributing factors: Aircraft; Chart Or Publication; Human Factors
Primary problem: Human Factors

Narrative: April 2012. [Pilot reported]: Gear Door Light after takeoff. Followed procedure in accordance with QRH. Also had Gear Doors EICAS message. Could not clear. Gear extension. No left Main Gear. Gear extended by using Alternate System per QRH. Landing was not overweight. Landing Gear monitored EICAS status. Corrective Action was to adjust and replac hardware for Main Gear Door Sequence valve per Aircraft Maintenance Manual (AMM) 32-32-08; Operational Checks normal. I was the Inspector on the B767-300 aircraft six-days earlier; when Maintenance had performed Landing Gear changes. On [Job Card] Step-8; (A-7r). It has you install the bolt; bushing; washers and nut between the turnbuckle and the spindle washer. All of these items were installed at time of inspection. The Aircraft Job Card should have a note telling the importance of this hardware.

Callback: Reporter stated a Final Gear Swing Check had been accomplished on all three landing gear after he signed the Job Card for the left Main Gear replacement. During the second  flight leg; after the B767-300 had been released from maintenance; the Main Landing Gear (MLG) Door light stayed on in the cockpit; requiring an air turn-back. All the Gear and Door lights functioned properly when the Gear Alternate Extend procedure was used.Reporter stated all three Landing Gear had been replaced; but each Landing Gear replacement is accomplished on one Job Card. There are just too many maintenance steps involved on one Job Card; especially with so many mechanics working and shift changes. He was informed that a turnbuckle type; connector rod attaching bolt at the inboard end of the left MLG Drag Brace Spindle Washer clevis assembly had apparently migrated out. The other end of the same rod is also connected to a cam box that positions the sequence valve. When the MLG was extended or retracted; the Drag Brace Spindle Washer Assembly rotated and also moved the rod. The turnbuckle rod is adjustable and suspicion is someone may have done some adjustment to the rod ends without proper reconnection and without documentation; which is not uncommon; during the Final Gear Swing Check. There is not; an Inspection sign-off on the Job Card for that specific rod and attachments. Reporter stated his suggestion to separate the Drag Brace Spindle assembly and rod connections into a separate Job Card will be accomplished when his Air Carrier transitions to a new Job Card program format in the near future.



Synopsis: A B767-300 aircraft required an air turnback after the left Main Landing Gear (MLG) door light remained on after takeoff. All three landing gear had been replaced