Date: 201306
Local time of day: 0001-0600
Location: ZZZ.Airport, US
Light: Night
Aircraft: B717 (Formerly MD-95)
Operator: Air Carrier
Operating under: Part 121
Flight phase: Parked
Aircraft component: Aileron Trim System
Component problem: Malfunctioning
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Communication Breakdown; Situational Awareness
Second reporter function: Inspector
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Flight Crew
When detected: Pre-flight
Result: General Maintenance Action
Contributing factors: Chart Or Publication; Human Factors; Incorrect / Not Installed / Unavailable Part; Aircraft
Primary problem: Human Factors

Narrative: Start of my shift (evening); I was asked to travel to ZZZ1 for a Company B717 right aileron change. The previous team working on this aircraft had timed out. Mechanic Y and I (Mechanic X) arrived at ZZZ1 and met up with Inspector Z from ZZZ1 Station at job site. Mechanic Y mentioned he had completed this job before and communicated the previous crew had disassembled as much as they could; but a forklift was required to continue. Mechanic Y and I spent the next couple of hours arranging for a forklift; hangar space and movement of the aircraft. A forklift was procured and Mechanic Y and I started removing the rest of the hardware on the right aileron. [Eventually] the new aileron was on the sling and Mechanic Y and I proceeded to put it on the wing. After the four mounting bolts were installed; I proceeded to work on the outboard end of the aileron and Mechanic Y proceeded to work on the inboard end. [Sometime later] I was finished with the outboard end of the aileron and Mechanic Y was still finishing up the inboard end of the aileron. I then went to work on the other write-up; which was Auxiliary Avionics fan popping circuit breaker. I was in the Forward Cargo Bin changing this fan. [Later] Mechanic Y; Inspector Z and I were ready to hook up [electrical] Ground Power and check out the aileron. We measured the movements as required to confirm the job was completed correctly and all was fine. Some time [later]; Mechanic Y and I cleaned up and prepared to relocate the aircraft back to the gate. The aircraft was at the gate and the paperwork was completed for the acceptance flight. Inspector Z met the crew and performed the steps for the acceptance flight. Mechanic Y and I then waited for the next flight back to ZZZ. Installation incomplete. On-Duty for 13 hours. It is the Inspector's function to ensure jobs are completed properly. A suggestion is that for each job type; the Inspector should have a checklist of the items that he/she is required to ensure have been completed properly; [such as] a Job Card.


Second narrative: I was the (RII) Inspector for a B717 aircraft at ZZZ1 for a Remove and Replacement (R/R) of the right aileron.  All Operational Tests good.  Today; the flight crew at ZZZ2 Station; found aileron tab did not move with aileron. Graveyard shift. Recommend [sending] a Lead Mechanic with the job. On-Duty for 15 hours.

Second callback: Reporter stated that during a preflight walk-around at a downline station; a pilot noticed the aileron control tab did not move in the opposite direction when the aileron was moved up or down. The aileron tab design on the B717 is very similar to the MD-80 aircraft. The inboard tab is the control tab on the left and right aileron. The outboard aileron tab is the electric trim tab. A bolt that connects the aileron control tab sector quadrant pushrod to the aileron had not been installed and could not be seen unless an access panel was removed. They all missed the lack of movement of the control tab when they performed the Operational Check after replacing the aileron.

Synopsis: An Aircraft Inspector and Aircraft Maintenance Technician (AMT) are informed the right aileron control tab would not move in the opposite direction of aileron movement on a B717 aircraft after they had signed-off for replacement of the aileron.