Unauthorized Axle Jacks/Unapproved Jacking Method Used for PIA Boeing 777 (AP-BGZ)

[planefan2003]

Is there any truth to this?

[ThrustVector998]

Yup. I read the preliminary report

[planefan2003]

Yup. I read the preliminary report

Where can i find the report? How devastating

[Usman123]

Yup. I read the preliminary report

Can you please share the link of the report

[Abbas Ali]

PIA Boeing 777-200LR aircraft registration AP-BGZ is on the ground at Karachi Airport since May 12, 2025.

On September 3, 2025, Society of Aircraft Engineers of Pakistan (SAEP) submitted a formal discrepancy report concerning serious and systemic failures observed during the structural modification of Boeing 777-200LR aircraft AP-BGZ, as per Engineering Order 777-SB-57A0122E1. These findings raises serious concerns over safety protocols, regulatory non-compliance, and the use of unapproved tools, placing the aircraft's structural integrity at imminent risk.

The modification on AP-BGZ, mandated by FAA AD 2023-17-14 is to address critical cracking risks on the front spar lower chord, was suspended following a PCAA spot audit. Subsequent investigation reveals a cascade of failures in planning, tooling approval, and execution of tasks, leading to structural damage (misaligned fasteners, cracked sealant) and creating an overall unsafe condition.

Findings & Details of Non-Compliance:

1. Unapproved and Inadequate Tooling:

• Unauthorized Axle Jacks: 50-ton capacity axle jacks were deployed without approval.

These jacks:

o Are not listed in the AMM or ITEM.
o Were not approved by TSE Base Maintenance as alternate tools.
o Were explicitly rejected by manufacturer, which mandates 85-ton axle jacks with locking features.

• Capacity Shortfall: Boeing requires two 85-ton jacks per Main Landing Gear (MLG) and one on the Nose Landing Gear (NLG) (total required capacity: 425 tons). The jacks used had a total shortfall of 175 tons, rendering the jacking setup critically under-capacity.

2. Procedural Deviations and Jacking Process Failures:

• Unapproved Jacking Method: The aircraft was lifted using main jacks and then placed on the unapproved axle jacks, a direct violation of the Engineering Order procedures.
• Lack of Continuous Monitoring: Load was not continuously monitored on main jacks, wing jacks, cradles, or axle jacks as required by OEM procedures.
• Breach of Environmental & Safety Controls: Hangar doors were opened during the critical jacking operation. Engine No. 1 cowling was opened, further violating the EO restrictions.

3. Management and Planning Failures:

• Unresolved Strategy: No formal decision was made to follow the modification strategy. An unapproved amalgamated approach was used instead.
• Ignored Procurement Issues: The non-availability of correct axle jacks and load cells was identified and raised by DCE (B1) Production in March but was not resolved, leading to the use of improper equipment.



Consequences:
• Misalignment of fastener holes at the modification site.
• Cracking of sealant at Body Station 1035 on multiple locations.
• Introduction of uneven structural stresses.
• The aircraft was placed in an unsafe condition while supported by under-capacity jacks.
• Significant financial and operational losses due to rework and delays or unrecoverable damage deformation (God Forbid).

Recommendations for Immediate Actions:
1. Formal Investigation: Initiate a comprehensive Root Cause Analysis (RCA) & Corrective actions into this modification failure, to avoid recurrence.
2. Boeing Consultation: Engage formally with Boeing for expert guidance on damage assessment (hole misalignment, sealant cracks) and to obtain an approved rework plan.
3. Policy Reinforcement: Issue a mandatory directive prohibiting the coercion of staff to use unapproved tools or methods and reinforcing strict adherence to OEM data.

This incident on AP-BGZ represents a profound failure in the Quality Assurance and Safety Management System and must be addressed with the utmost urgency to prevent a serious compromise of airworthiness. Beyond the technical risks, it has already caused the grounding of one of PIACL’s critical aircraft, directly impacting the upcoming UK operations and compromising the LHE–CDG route, which had only recently been restored after years of effort.

SAEP strongly urges immediate corrective action at the highest level to safeguard passenger safety, protect national assets, and preserve the credibility of Pakistan’s international operations.



Pakistan Civil Aviation Authority (PCAA) Additional Director Airworthiness (South) in a letter dated September 9, 2025, to PIA Chief Engineer Base Maintenance expressed concerns on maintenance practices at PIA base maintenance.

* PCAA spot check on Boeing 777-200LR aircraft registration AP-BGZ revealed the use of unapproved jacks during structural modification. The investigation into this matter is still underway and pending final determination of facts and conclusions.



Abbas

[planefan2003]

This will be another BGL situation.

[Usman123]

Where there are no consequences for the management they work as they like, at least 2 line managers should fired and legal notices should be sent to those who approved the use of these unsuitable jacks.

PIA is operating 777s from 2 decades and still these silly decisions. The responsible person should be stripped of every rupee he has to pay for the damages to the plane

[Amaad Lone]

This is what happens when people are hired on QUOTA SYSTEM.

You do not hire the best but rather what you can hire.

The government needs to scrape this bloody quota system and stop hiring people who are stupid.

[Karachi Aviator]

Is the damage repairable or is it damaged beyond economic viability? I thought the aircraft was initially grounded for maintenance only as it had already spent a good time on ground before and it was grounded again after some time. Another asset lost if it's damaged beyond repair.

[AviationLover2020]

Is the damage repairable or is it damaged beyond economic viability? I thought the aircraft was initially grounded for maintenance only as it had already spent a good time on ground before and it was grounded again after some time. Another asset lost if it's damaged beyond repair.

I have no clue who the person in the quoted tweet is, but they seemed to be aware of this incident far before any of us on the forum so presumably someone in PIA Engineering or inside PIA. Seeing his other tweets on BGZ, he seems to be suggesting the aircraft is damaged beyond repair (or at least enough to make it uneconomical to revive), and that the aircraft will be retired early.

[Blackbird]

PIA will be lucky if it doesn't get banned from EU again.

[planefan2003]

PIA will be lucky if it doesn't get banned from EU again.

They will just fly BGK around different european cities hoping for the best

[planefan2003]

RIP to the world distance record holder. Shabash PIA

[MRT]

PIA can forget reviving US operations. I don't understand how it is so hard to spend a bit of money to repair the aircraft. They seem to want to save every rupees, or maybe corruption has just destroyed the airline

[MadViking]

RIP to the world distance record holder. Shabash PIA

It is possible, depending on how severe the structural damage is, that Boeing could provide a repair kit. Though if the costs are prohibitive then it will be a write-off and another multimillion dollar airframe left to be cannibalized.

What a shame that these magnificent machines are being left to the vultures.

And furthermore, this leave BGY as the sole frame with bunks for crew rest, to perform Toronto.