What was found
DURING SCHEDULED MAINTENANCE, A DETAILED VISUAL INSPECTION OF THE RUDDER CONTROL SYSTEM DISCOVERED A RUDDER CONTROL CABLE RUBBING AGAINST A PULLEY BRACKET WHICH WAS ALSO PART OF THE RUDDER CONTROL SYSTEM. CABLE WEAR WAS MINIMAL AND WITHIN SERVICEABLE LIMITS SPECIFIED IN THE MAINTENANCE MANUAL. THE PULLEY BRACKET EXHIBITS WEAR THROUGH THE PROTECTIVE COATING AND INTO THE BASE METAL. THE BRACKET EXHIBITS WEAR FROM CONTACT AND RELATIVE MOTION WITH THE PRIMARY RUDDER CONTROL CABLE. ADDITIONALLY, THE BRACKET EXHIBITS DEFORMATION AND TOOL MARKS, ASSUMED TO BE THE RESULT OF A PREVIOUS OPERATOR’S UNSUCCESSFUL ATTEMPT TO CREATE CLEARANCE BETWEEN THE CABLE AND THE PULLEY BRACKET. CABLE WEAR WAS FOUND TO BE WITHIN ALLOWABLE LIMITS SPECIFIED IN THE MAINTENANCE MANUAL. A THOROUGH INSPECTION OF THE RUDDER CONTROL SYSTEM WAS COMPLETED TO ASCERTAIN WHETHER THE INTERFERENCE WAS CAUSED BY: COMPONENT OR PART WEAR, DEFORMATION, OR FAILURE; MISSING OR WORN HARDWARE; IMPROPER ASSEMBLY, INSTALLATION OR RIGGING BY PRIOR MAINTENANCE PERSONNEL; AND USE OF INCORRECT PARTS. NO EVIDENCE COULD BE FOUND TO INDICATE ANY OF THESE CONDITIONS. ABSENT THESE CAUSES, INCORRECT POSITIONING OF THE BRACKET AT SOME POINT IS THE MOST PLAUSIBLE REASON FOR THE DEFECT.