- Location: Oakland, California
- Accident Number: DCA24LA206
- Date & Time: May 25, 2024, 07:44 Local
- Registration: N8825Q
- Aircraft: Boeing 737-8
- Aircraft Damage: Substantial
- Defining Event: Flight control sys malf/fail
- Injuries: 181 None
- Flight Conducted Under: Part 121: Air carrier - Scheduled
https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/GenerateNewestReport/194423/pdf
https://data.ntsb.gov/Docket?ProjectID=194423
On May 25, 2024, about 0744 Pacific daylight time, SWA flight 746, a Boeing 737-8, N8825Q, experienced a rudder control system anomaly in flight. SWA flight 746 was operating under the provisions of Title 14 Code of Federal Regulations Part 121 as a scheduled domestic passenger flight from PHX to OAK. The 6 crew members and 175 passengers were uninjured. SWA flight 746 continued to its destination and landed without incident.
Southwest Airlines (SWA) flight 746 experienced a rudder control system anomaly during flight between Phoenix Sky Harbor International Airport (PHX), Phoenix, Arizona and Metro Oakland International Airport (OAK), Oakland, California. The captain stated, shortly after reaching their cruise altitude and while flying through light turbulence, the airplane began to experience “a small amount of Dutch roll.” The oscillations lasted a few seconds and the autopilot remained engaged throughout the event.
The first officer (FO) characterized the event as a “strange movement of the tail of the airplane back and forth, coupled with very slight rudder movement left and right.” The flight crew discussed the event and noted that they felt the rudder pedals move during the oscillations. The flight crew deduced that the oscillations were not caused by turbulence but rather by the airplane. SWA flight 746 continued to OAK and landed without incident. Postlanding inspection found damage to include the vertical stabilizer trailing edge ribs, both above and below the standby rudder power control unit (PCU).
On the evening of May 16, 2024, the accident airplane was parked overnight at Louis Armstrong New Orleans International Airport (MSY), New Orleans, Louisiana. Overnight, thunderstorms at MSY generated high winds with gusts up to 73 kts. The Boeing 737 rudder system does not incorporate a gust-lock function. It is likely that these high winds resulted in movement of the rudder that damaged the vertical stabilizer ribs to which the standby rudder PCU was connected.
At the time of the accident, the Boeing 737 aircraft maintenance manual conditional inspection for parked or moored airplanes that experienced an extreme high wind event lacked a defined wind threshold for requiring the conditional inspection to be performed. Additionally, SWA did not have a process in place to notify maintenance control for when their parked aircraft may have experienced an extreme high wind event. Therefore, the conditional inspection for extreme high wind events, which could have detected structural damage to the vertical stabilizer, was not accomplished after the thunderstorms. The accident airplane resumed flying the next morning.
Between May 17 to 23, 2024, the accident airplane flew a total of 38 flights with no reported anomalies of the rudder control system. Therefore, the damaged vertical stabilizer ribs remained undetected for these flights. The airplane underwent scheduled maintenance inspections on the evening of May 23, 2024. These inspections included an operational test of the standby hydraulic system.
The damage to the vertical stabilizer trailing edge ribs, to which the standby rudder PCU was attached, that existed at the time of this operational test would have revealed itself as a rudder that would not return to its neutral position. However, contrary to the required procedure, SWA maintenance personnel did not visually confirm the rudder position during this operational test.
Nonetheless, SWA maintenance signed off that the accident airplane passed the operational test of the standby hydraulic system, and the airplane was released for flight. As a result, the damage to the vertical stabilizer remained undetected. Investigators could not determine if the existing vertical stabilizer rib damage was further damaged during this maintenance activity.
On May 24, 2024, during the accident airplane's fourth flight of the day, the damaged vertical stabilizer ribs exhibited the first operational symptoms in which that flight crew believed the yaw damper had malfunctioned. The accident airplane subsequently flew another flight on May 24, 2024, with the yaw damper disabled. Flight 746 was the first flight the next day.
- Probable Cause: Damage to the standby rudder power control unit connection to the vertical fin due to an extreme high wind event while the airplane was parked, which remained undetected and resulted in anomalous operation of the standby rudder power control unit. Contributing to the nondetection of the damage was 1) the improper accomplishment of the standby hydraulic system operational test by Southwest Airlines maintenance personnel; 2) the lack of a defined wind speed threshold, in the Boeing 737 aircraft maintenance manual, to perform the extreme high wind conditional inspection for parked and moored aircraft; and 3) the absence of an adequate process at Southwest Airlines to notify maintenance control when parked aircraft experience an extreme high wind event that may require the relevant conditional inspection.