Date: 201508
Local time of day: 1801-2400
Location: ZZZ.Airport, US
Light: Night
Aircraft: A320
Operator: Air Carrier
Operating under: Part 121
Flight plan: IFR
Mission: Passenger
Flight phase: Takeoff / Launch
ATC / advisory: Tower ZZZ
Aircraft component: Main Gear
Component problem: Malfunctioning
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Workload; Time Pressure; Situational Awareness; Distraction; Communication Breakdown
Second reporter function: Lead Technician
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural MEL / CDL
Detector: Person Flight Crew
When detected: In-flight
Result: Flight Crew Returned To Departure Airport; General Flight Cancelled / Delayed; General Maintenance Action
Contributing factors: Human Factors; Company Policy; Aircraft; Procedure
Primary problem: Human Factors

Narrative: A320 Aircraft has a recurring landing gear fault. This time the fault occurred in ZZZ1 and was made a Deferred Maintenance Item (DMI) in ZZZ1. Aircraft ferried to ZZZ with the landing gear lock down. Confirmed the aircraft was in the non-MEL configuration before starting work for the L/G not unlocked ECAM Message. The right landing gear retract actuator was ultimately removed and replaced. After all the operation checks were completed and all cockpit indications were normal; cleared DMI for the Landing Gear Indication System. The aircraft took off from ZZZ and returned to the field for FLT L/G Down indication after gear retraction. Aircraft restricted & advised to 235 knots ECAM message per flight crew and log book entry.After removing and replacing flight controls; landing gear components etc.. after inconvenient chronic or recurring faults; no Test flights are required by our Air Carrier. Inadvertently causing major anxiety and inconveniencing our paying passengers. Prior experience with other operators; a Test Flight would be required before the aircraft was returned to revenue flight.


Second narrative: Aircraft had multiple crew reports for the Right Main Landing Gear (MLG) not uplocked ECAM message upon gear retraction. The fault was worked in ZZZ2 and made a few flights; then the fault returned while the aircraft was in ZZZ1. The Landing Gear Indication System was deferred per the MEL by Maintenance team in ZZZ1. Request was made to the company to send the aircraft to our Maintenance facility in ZZZ3 for this repeat problem. They have the proper facility and tooling. Aircraft was Maintenance Ferried to ZZZ with the gear lock down only because we had jacks. No facility and no tools for the job. We work in a Line environment on an un-level ramp and had to jack the aircraft high enough to preform gear swings and trouble shoot the Landing Gear Retract System in an AOG situation on the flight line. Company sent a retract actuator; but the paperwork was incomplete. By the Second night we received loaner tooling from another Operator and a replacement actuator from Airbus which had paperwork issues as well. Late into the shift and after working multiple other aircraft; the paperwork issues were resolved and the actuator was released to maintenance to install. The right main landing gear retract actuator was removed and replace per the Trouble Shooting Manual (TSM) and Aircraft Maintenance Manual (AMM). All operational and leak checks and cockpit indications were normal with the aircraft on jacks. The DMI was cleared by the replacement of the retract actuator. The aircraft took off from ZZZ on a revenue flight and the cockpit crew reported an ECAM Advisory Message FLT L/G DOWN indication after retraction and restricted advised to 235 knots. Crew returned to the field. Upon further trouble shooting found the L/G DOWN VMO/MMO selection switch (22FP) on the 188VU panel in the aft E&E bay was inadvertently left in the L/G down position. Reset L/G DOWN VMO/MMO selection switch (22FP) to the L/G normal position. Messages cleared. Due to time constrains and pressure to return the AOG aircraft to service the (22FP) Switch was overlooked when clearing the DMI.


Synopsis: Two Aircraft Maintenance Technicians reported recurring Right Main Landing Gear (MLG) L/G Not UNLOCKED ECAM faults on an A320 aircraft. Aircraft ferried to a Line Maintenance Station with limited resources. Right MLG Retract actuator replaced. No Flight Test required. Aircraft departed but returned to field with ECAM Advisory message FLT L/G DOWN. Found the L/G DOWN VMO (Maximum Operating Speed Limit)/MMO (Maximum Mach Operating Speed) selection switch (22FP) on the 188VU panel inadvertently left in the L/G down position. Reset switch to L/G 'Normal' position.