Date: 201208
Local time of day: 1801-2400
Location: ZZZ.Airport, US
Light: Dusk
Aircraft: A320
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Parked
Aircraft component: Wheels/Tires/Brakes
Component problem: Malfunctioning
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Powerplant; Maintenance Airframe
Human factors: Time Pressure; Situational Awareness; Communication Breakdown
Second reporter function: Technician
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Maintenance
When detected: Other Post Departure
Result: General Maintenance Action
Contributing factors: Aircraft; Human Factors
Primary problem: Aircraft

Narrative: Removal and Replacement (R/R) of # 2 Brake was difficult to remove from the [left Main] Landing Gear (MLG) axle. I; Mechanic X; inspected the axle sleeve; but found no obvious damage.  We installed a Serviceable Brake Assembly and Wheel Assembly. One of the Mechanic's working on it went upstairs; signed the Logbook. After a few hours in; I received a phone call from one of the Mechanic's working on the brake to let me know that he and a Supervisior looked over the Unserviceable brake and noticed four axle bushings for the Brake Alignment studs were stuck to the [removed] brake. I talked with the ZZZ1 Supervisor and let him know what had happend. He told me that he was already aware of it; and it would be addressed. Alignment pin bushings seperated from axle flange. Recommend Inspection of Axle Protective Sleeve and Axle Hub and Bushings for proper installation. Thru flight operation.

Callback: Reporter stated he doesn't recall if the bushings on the Brake Axle Flange have a collar; or; are the flush face type. They are part of the Main Landing Gear (MLG) Assembly.  His Air Carrier issued a Maintenance Alert for mechanics to look for flange bushings when they remove brakes. But their Engineering group has not indicated whether Airbus would make a revision to the Aircraft Maintenance Manual (AMM) to check for bushings on the Brake Alignment pins. There are three bolts with nuts securing the brake to the brake flange (not counting the alignment pins).

Second narrative: I; Mechanic Y; was assisting in replacing the Brake Assembly on an A320 aircraft due to both of the Wear Indicator pins missing.  We determined it [brake] need full replacement.  During the removal process; please note that it was very difficult and hard to remove; taking longer than usual to remove the brake assembly.  When the brake assembly was removed; I was installing the new brake with Mechanic A.  After the brake assembly and wheel were installed; I cleaned up the area and got the tooling put away.  We then returned to the Shop; where we spoke with Supervisor X; who opened up the [Brake] container and noted that four of the Axle Flange bushings were still stuck to the brake.  However; the A320 aircraft had already departed to ZZZ1. Supervisor X contacted Maintenance Control and ZZZ1 Supervisor. Was unaware bushings had separated from Axle Flange and the Aircraft Maintenance Manual (AMM) does not specify to inspect axle flange bushings for proper installation. Recommend updating Maintenance Manual (M/M) to reflect an inspection [procedure] of protective sleeve and Axle Flange and bushings for proper installation.


Synopsis: Three Aircraft Maintenance Technicians (AMTs) report that four bushings had separated from the left Main Landing Gear (MLG) Axle Flange when the # 2 Inboard Brake was removed.  The bushings had remained stuck to the removed Brake Assembly alignment pins and were not noticed until the A320 aircraft had departed.