BOEING 767Dynamic International

The failure of the American Airlines aviation maintenance technicians to properly reassemble the two-piece bracket and spray shield on the integrated drive generator fuel-oil heat exchanger that caused a fuel leak that sprayed out and ignited on hot engine cases. Contributing to the cause of the fire was the 767 Aircraft Maintenance Manual’s lack of any graphical or pictorial displays of the correct assembly of the two-piece bracket and spray shield.

The failure of the high-pressure turbine (HPT) stage 2 disk, which severed the main engine fuel feed line and breached the right main wing fuel tank, releasing fuel that resulted in a fire on the right side of the airplane during the takeoff roll. The HPT stage 2 disk failed because of low-cycle fatigue cracks that initiated from an internal subsurface manufacturing anomaly that was most likely not detectable during production inspections and subsequent in service inspections using the procedures in place. Contribu…

the failure of the right engine's fuel control unit to operate correctly when the fuel metering valve became frozen in the full open position because of corrosion on the fuel metering valve slide and sleeve, which caused the engine to be overfueled during engine start and resulted in a tailpipe fire.

Fuel leaking from the fuel flow transmitter that ignited on contact with the engine’s hot cases which resulted in an engine undercowl fire. The fuel leak resulted from the fuel flow transmitter end housing backing off from the main housing, creating a gap that allowed high pressure fuel to escape. Under certain assembly variances and operational load and temperature variations, the end housing joint may not be able to maintain the preload without eventually yielding, which results in the loosening of the joint and…

An engine fire in the No. 3 engine due to the failure of, and subsequent flammable fluid leak from, one of three fuel or hydraulic lines located in the engine's accessory raceway that ignited when the fluid came in contact with the hot engine cases. Contributing to the incident were the lack of adequate inspection and test requirements and appropriate life limit or inspection interval requirements by the manufacturer.