Date: 201310
Local time of day: 1201-1800
Location: ZZZ.Airport, US
Light: Daylight
Aircraft: Regional Jet 200 ER/LR (CRJ200)
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Parked
Aircraft component: Rudder
Reporter organization: Air Carrier
Reporter function: Inspector
Reporter qualification: Maintenance Powerplant; Maintenance Airframe
Human factors: Training / Qualification; Situational Awareness; Communication Breakdown
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Maintenance
When detected: Routine Inspection
Result: General Maintenance Action
Contributing factors: Incorrect / Not Installed / Unavailable Part; Human Factors; Company Policy
Primary problem: Incorrect / Not Installed / Unavailable Part

Narrative: During RII Inspection of Rudder Power Control Units (PCU)'s after PCU replacements in October 2013; noted rudder was sitting low (sagging) in the aperture [cutout opening in vertical stabilizer fin for the rudder]. Inspection of rudder hinges noted some attachment hardware was missing from previous installation. Parts missing were top hat bushings on main rudder hinges. The party involved [with the] responsibility for the missing parts was a Sub-Contract Repair Station. This is the 4th or 5th documented incident of rudder parts missing from our aircraft in the last couple of years. A Maintenance Management person instituted changes in Aircraft Maintenance Manual (AMM) and IPC to correct this; but its starting to happen all over again. The Repair Station installed this rudder in July 2013. The repair installation of missing rudder attachment points was complied with on our Air Carrier Work Cards. This event took place on a CRJ-200 aircraft. [Contract] Vendor discrepancy forms were filled out before and [now] again; as per our General Maintenance Manual (GMM) in regards to our Continuing Analysis Surveillance System (CASS) Program.

Callback: Reporter stated the CRJ-200 has a single panel rudder that is approximately 15 FT high. Three hydraulic Power Control Units (PCUs) move the rudder. While performing a Structural Integrity Inspection (SSI) of the rudder; he noticed the paint lines of the United States flag did not line up with the paint lines on the rudder. That visual discrepancy was usually the first indication that the top hat bushings were missing at one of the two center hinge fittings where the rudder hinge fitting connects to the vertical stabilizer hinge fitting. There are a total of four hinge fittings; numbered one through four starting from the top; that secure the rudder to the vertical stab. One of the center hinge fittings floats and the other sets the gap for the vertical position of the rudder in the vertical fin cutout.Reporter stated that in the past; information involving a rudder installation involved two different AMM Chapters: Chapter 27 Flight Controls and PCUs and Chapter 55 Rudder Airframe installation and the Illustrated Parts Catalog (IPC). That was organized into a single reference source to address the previous incidences of hat bushings not being installed by the Heavy Maintenance Contract Vendor. The Contract Vendor also sub-contracts out the repair of the hat bushings. His Air Carrier does not have their own Quality Assurance (Q/A) Representative at the Contract Repair Station; but they do have a Production Representative on-site. He believes training at the Repair Station is severely lacking and his Air Carrier's oversight of the Repair Station needs improvement.



Synopsis: An Aircraft Maintenance Inspector reports finding hat bushings missing from the rudder hinges on a CRJ-200 aircraft; three months after the aircraft returned from a Heavy Maintenance Check at a Contract Repair Station. While performing an RII Inspection of the rudder Power Control Units (PCUs); he noticed the United States flag paint lines did not line up with the paint lines on the rudder.