Date: 201501
Local time of day: 1201-1800
Location: ZZZ.Airport, US
Flight conditions: VMC
Light: Daylight
Aircraft: B757-200
Operator: Air Carrier
Operating under: Part 121
Flight plan: IFR
Mission: Passenger
Flight phase: Takeoff / Launch
Airspace: Class B ZZZ
ATC / advisory: Center ZZZ; TRACON ZZZ
Aircraft component: Brake System
Reporter organization: Air Carrier
Reporter function: Captain; Pilot Flying
Reporter qualification: Flight Crew Air Transport Pilot (ATP)
Human factors: Confusion; Distraction; Training / Qualification; Troubleshooting; Workload
Anomaly: Aircraft Equipment Problem Less Severe; Deviation - Track / Heading All Types; Deviation / Discrepancy - Procedural Clearance; Flight Deck / Cabin / Aircraft Event Smoke / Fire / Fumes / Odor
Detector: Person Flight Crew
When detected: In-flight
Result: Flight Crew Landed in Emergency Condition; General Declared Emergency; General Maintenance Action
Contributing factors: Aircraft
Primary problem: Aircraft

Narrative: Arrived at airplane for ferry flight. I understood that the aircraft had just come out of heavy maintenance. Taxied to [runway.] Immediately during takeoff; got unusual vibration; felt in seat and noted on control yoke. Considered rejecting; but felt it would lessen during takeoff roll. Vibration remained until liftoff; ceased once airborne. Called for LNAV at 400 feet AFL; began to notice odor. Odor got stronger; could not identify it; called for CLB THRUST/VNAV at 1000 feet AFL and AUTOPILOT LEFT COMMAND. Asked FO if he noticed odor; he replied he did.  We were focusing on getting the flaps up and were very concerned with the odor when I noticed that the airplane had continued turning left and was not staying on the departure routing. As I began to take corrective action; departure control asked us our heading and told us to turn right to 330 degrees. I disengaged the autopilot; called for HEADING 330; and turned to the right. After passing about 300 degrees; departure told us to turn left to 270. After stabilized in the climb and on heading; I called for autopilot on again. We were then cleared direct to a fix on the departure; engaged LNAV and continued with the departure. We discussed the unknown odor; decided that one of us should go on oxygen. I transferred flying duties to the FO and donned the oxygen mask. The fumes; which began after gear retraction; seemed to be decreasing in intensity; and we agreed they smelled like hot rubber. Since the fumes were seemingly decreasing; we agreed to continue the flight; referring to the QRH for guidance. Not knowing the source of the fumes; we thought there was a possibility we may have had a tire failure due to the vibration during takeoff roll; followed by the rubber-like fumes after airborne. There were no abnormal indications on any aircraft systems. I assumed flying duties after level off at cruise altitude. Not knowing for sure if we had a tire problem or not; we elected to have the arrival tower roll the equipment out for our landing; which was uneventful. After parking at the gate; we were told by maintenance personnel that new brake pads were a known source of the odor as we described it.Neither the FO nor I understand why the airplane did not remain in LNAV and fly the departure routing. As the flying pilot; I may have bumped the HEADING SELECT button when I rotated the heading know after our initial left turn on the departure. Even with our focus on our other issues; it did not take long for us to notice that we were not on the departure routing and begin to intervene when departure called and gave us a heading back to the left. Obviously; we were distracted by the odor and would have noticed going off the departure much sooner than we did.As always; fly the airplane first; ensuring that it stays on the desired course. If unable to do that; declare an emergency.




Synopsis: A B757 developed an unfamiliar odor during the first takeoff and climb on a ferry flight following heavy maintenance. The distracted crew had a track deviation and determined after the flight that new brakes were the odor's source.