Date: 201207
Local time of day: 0601-1200
Location: ZZZ.Airport, US
Light: Daylight
Aircraft: Dash 8-300
Operator: Air Carrier
Operating under: Part 91
Mission: Ferry / Re-Positioning
Flight phase: Takeoff / Launch
Aircraft component: Nose Gear
Component problem: Malfunctioning
Reporter organization: Air Carrier
Reporter function: Other / Unknown
Reporter qualification: Maintenance Powerplant; Maintenance Airframe
Human factors: Situational Awareness; Communication Breakdown; Troubleshooting
Second reporter function: Technician
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural MEL / CDL; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Flight Crew
When detected: In-flight
Result: Flight Crew Returned To Departure Airport; General Flight Cancelled / Delayed; General Maintenance Action
Contributing factors: Aircraft; Company Policy; Procedure; Manuals; MEL; Incorrect / Not Installed / Unavailable Part; Human Factors
Primary problem: Human Factors

Narrative: DHC-8-300 aircraft had hydraulic fluid dripping from nose gear area. [I] had Contract Maintenance try to determine location of leak; possible leak around steering manifold. Had crew run and taxi aircraft with steering 'On' or 'Off'; still leaking around manifold and tubing. Contract Maintenance had to leave aircraft at this time. I [as the Maintenance Controller] decided to send Mechanic X. Mechanic X arrived at the aircraft. After cleaning [the nose gear] area and [performing Engine] run and taxi of aircraft; Mechanic X found line from steering mainfold to solenoid leaking. Mechanic X could not install temporary flex line due to the area. I had Mechanic X cap-off [hydraulic] line for Ferry flight to another station for repairs. Aircraft departed and after take-off; nose gear failed to retract; aircraft returned to departure airport. After inspecting nose gear for any defects; aircraft ferried to the other station for repairs. Under the information I received; I thought I did the right thing. But now I realize I should have ferried aircraft with 'Gear Down' for safety reasons. Capping-off the hydraulic line probably caused Nose Gear not to retract. After inspecting aircraft nose gear; aircraft ferried to the other station with 'Gear Down'. First; I should have sent Mechanic X diagrams; so he could show line that was leaking and what systems are affected. And I should have ferried aircraft 'Gear Down' for safety reasons.


Second narrative: July 2012; I was on a Ferry Flight to get a permanent [hydraulic] line installed into the aircraft; since a temporary line would be quite difficult for just one Mechanic. So; during flight just after takeoff; the Captain informed me to come to the cockpit and observed that the Indication lights for the Nose Landing Gear (NLG) was in the Red; and the Main Gear lights were in the Green. This indication meant that the Main Gear came up and locked; but the nose didn't. The Nose Landing Gear (NLG) doors failed to open. So the Captain checked his Procedural Manual and performed an Alternate Gear Extension; to land us safely back at the departure airport. Well; during my inspection of the reason this aircraft was leaking fluid; located somewhere in the nose gear area. I had found a small crack in a bend of a fluid line connected to a Solenoid Valve that was attached to the Steering Actuator. So; after tracing this line to a fitting that vanished into the aircraft inner wall (not a BULKHEAD); I had determined that a temporary hydraulic line would be out of my 'comfort zone' to install onto this fitting. So I called my Maintenance Controller and asked him [if] instead of placing a temporary line; could I 'Cap' the line at the Solenoid Valve. After a brief waiting period; I was told 'Yes' I could 'Cap' it and we would 'Ferry' to the next station and I would go with the aircraft to help install a more permanent line.The Captain performed an Alternate Gear Extension; and landed back at the departure airport and a new Ferry permit was drawn up; this time we would fly with 'Gear Down'. If I wasn't given the 'go ahead' to cap the line; and if we would have just Ferried with 'Gear Down'; the issue would have never had happened. For the record; 'I asked several times for a diagram of the system I was working on; to maybe something from the Illustrated Parts Catalog (IPC); so I could circle the [hydraulic] line I capped; to make sure it was okay' and was ignored.


Synopsis: A Maintenance Controller and Line Mechanic describe their involvement with a DHC-8-300 aircraft that returned to field after the Nose Landing Gear (NLG) would not retract. The aircraft was on a scheduled Maintenance Ferry Flight to replace a leaking hydraulic line to the Solonoid Valve at the Steering Actuator.