This quote is also from my addendum (supplement) to my first report:
This item is about unauthorized and undocumented rework of engines, that are built by a separate TC and PC than ours, by BCAG mechanics who, in addition to being unauthorized to perform the work, know next to nothing about their vendor assembly and test requirements (as if that would make it O.K.):
A good example of this is the (part number) fuel transmitter installation on the (engine vendor) engine. The mechanics routinely removed part of the (engine vendor) wire bundle assembly so they can install and torque the "U" channel component of the installation. I asked (name), EBU (Engine Build-Up) mechanic on 2/12/02, I believe, why they removed the three (engine vendor) W/B (Wire Bundle) clamps from the vendor (part number) and the (part number)brackets to do that job. He said that, If they didn’t, it was a real bitch to get that channel installed and torqued, and they usually damaged the wire bundle in the process. I asked him if the job stated to remove and reinstall that part of the bundle. He said no. He was right. Not even the drawing mentioned anything about removing and re-installing that vendor installation. A tag or ELR (Engineering Liaison Request) should have been written to get drawing authorization to remove and reinstall that portion of the vendor drawing installation, but at PSD, we hardly ever do what is right, we just do what is cheaper, even if it is patently wrong. Please have us fix this problem. Have us authorize this illegal rework on the drawing, so it is finally legal (after over a thousand engines, I believe). Please also check the AMM/PPBU (Airplane Maintenance Manual/Power Plant Build-Up Manual) Manual, and see if the AMM/PPBU Manual requires removal of the noted part of the vendor W/B during the fuel transmitter replacement. If not, please have Boeing issue an AD or SB to inspect those engines that have had fuel transmitters replaced in service to look for the inevitable W/B damage. Tell BCAG they could have avoided all of this if they had just followed procedures prohibiting unauthorized rework, if we’ll listen. Also have the airlines check for those three clamps hanging loosely off of the wire bundle. PSD inspectors may not be looking for illegally removed and not reinstalled vendor clamps during their shakedowns, especially the roller stamping ones.
The Last Inspector