Latest / Aviation Survival Stories / Thirty-Five Thousand Feet of Silence: The Rudder That Took Flight
Transcript
- 0:03Speaker 1: At 540 in the afternoon, 35,000 feet above the Bering Sea,
- 0:08Speaker 1: a 747 rolled 30 to 40 degrees to the left.
- 0:12Speaker 1: No warning, no crew input, no checklist that could fix it.
- 0:15Speaker 1: The aircraft was Northwest Airlines Flight 85, approximately seven hours
- 0:19Speaker 1: out of Detroit and bound for Tokyo. In that moment,
- 0:22Speaker 1: four pilots held the lives of everyone on board in
- 0:24Speaker 1: their hands, and not one of them had ever trained
- 0:27Speaker 1: for what was about to happen next. This is the
- 0:29Speaker 1: story of a metal crack no one could see. a
- 0:32Speaker 1: procedure that did not exist and the four men who
- 0:34Speaker 1: invented a solution from nothing while the ocean weighted 40,000
- 0:38Speaker 1: feet below. To understand what made that moment so extraordinary,
- 0:41Speaker 1: it helps to know something about the machine at the
- 0:44Speaker 1: center of it. The aircraft registered as November 60, 61
- 0:47Speaker 1: Uniform Sierra, was not just any 747, it was the
- 0:50Speaker 1: first one, Construction number 23719, the original prototype of the
- 0:57Speaker 1: 747-400 series, flight testing had begun in April of 1988,
- 1:03Speaker 1: when the aircraft flew under the registration November 401 Papa Whiskey.
- 1:07Speaker 1: Boeing engineers put it through everything the airframe could be
- 1:10Speaker 1: asked to endure before a single paying passenger ever stepped aboard.
- 1:14Speaker 1: Northwest Airlines took delivery of November 661, Uniform Sierra, on
- 1:19Speaker 1: December 8, 1989. By the morning of October 9, 2002,
- 1:24Speaker 1: that aircraft had been carrying passengers for nearly 13 years.
- 1:27Speaker 1: Nearly 13 years of oceanic crossings, pressurization cycles, temperature swings
- 1:32Speaker 1: from equatorial heat to polar cold. Nearly 13 years of
- 1:36Speaker 1: metal under stress. The route that day was one of
- 1:38Speaker 1: the longest Northwest operated. Detroit Metropolitan Airport to Tokyo Narita,
- 1:43Speaker 1: a great circle arc that sweeps Northwest across Canada, hugs
- 1:46Speaker 1: the Alaskan coast, and crosses the North Pacific. The flight
- 1:49Speaker 1: departed at 2.30 in the afternoon Eastern Daylight Time. By
- 1:53Speaker 1: the time the Bering Sea appeared beneath the clouds about
- 1:55Speaker 1: seven hours later, the crew was deep into the rhythm
- 1:58Speaker 1: that long-haul flying demands. Long-haul operations on a flight of
- 2:02Speaker 1: this duration require more than two pilots. Northwest Flight 85
- 2:06Speaker 1: carried four, two captains and two first officers, rotating in
- 2:10Speaker 1: pairs so each crew member progressed. It is a system
- 2:13Speaker 1: designed around human endurance. the understanding that no pilot can
- 2:16Speaker 1: sustain peak concentration across 11 hours of oceanic flying without relief.
- 2:21Speaker 1: Senior Captain John Hansen was the most experienced man on
- 2:24Speaker 1: the aircraft. First Officer Mike Fagan flew alongside him. Junior
- 2:28Speaker 1: Captain Frank Geib and First Officer David Smith formed the
- 2:31Speaker 1: relief crew. At approximately 5.40 in the afternoon, Alaska Daylight Time, G.
- 2:36Speaker 1: Kame and Smith were in the active seats. Hansen and
- 2:39Speaker 1: Fagan were in crew rest, That rotation, that ordinary procedurally
- 2:43Speaker 1: correct transfer of control, placed Guy at the controls at
- 2:46Speaker 1: precisely the moment the aircraft decided to do something none
- 2:49Speaker 1: of them had seen before. What no one on that
- 2:52Speaker 1: flight deck knew what no visual inspection could have revealed,
- 2:55Speaker 1: was that somewhere inside the lower rudder power control module,
- 2:59Speaker 1: a fatigue crack had been quietly growing. Cast metal does
- 3:02Speaker 1: not announce its failures. It accumulates stress across thousands of cycles, invisibly,
- 3:07Speaker 1: until the moment it does not. That moment was now.
- 3:10Speaker 1: The aircraft banked left, not gradually, not with any warning
- 3:14Speaker 1: from the instruments that something was building. At 5.40 in
- 3:17Speaker 1: the afternoon Alaska daylight time, at 35,000 feet above the
- 3:20Speaker 1: Bering Sea, Northwest Flight 85 rolled 30 to 40 degrees
- 3:24Speaker 1: to the left, and Frank Geib had not touched the controls.
- 3:28Speaker 1: He reached for them immediately. The aircraft did not respond
- 3:30Speaker 1: the way it should. Geib's first instinct was an engine.
- 3:34Speaker 1: On a four-engine widebody, asymmetric thrust from a failing power plant,
- 3:38Speaker 1: can produce exactly this kind of uncommanded roll. It was
- 3:41Speaker 1: a reasonable diagnosis. It was the logical one. Pilots are
- 3:44Speaker 1: trained to work from probabilities, and an engine failure is
- 3:47Speaker 1: among the most probable emergencies a 747 crew will ever face. G.I. Portet.
- 3:53Speaker 1: He ran the mental model. He checked. The engines were fine.
- 3:57Speaker 1: Every one of them was producing normal thrust. The aircraft
- 4:00Speaker 1: was still rolling against his inputs, still held in that
- 4:03Speaker 1: left bank, as if something had locked the rudder there.
- 4:05Speaker 1: Because something had, The end section of the lower rudder
- 4:09Speaker 1: power control module, the piece that houses the yaw damper actuator,
- 4:13Speaker 1: had broken away from its cast metal housing. The actuator,
- 4:16Speaker 1: now unhoused, was driving the lower rudder surface to its
- 4:19Speaker 1: full left limit, and it was not going to stop.
- 4:22Speaker 1: There is a difference between a malfunctioning component and a
- 4:24Speaker 1: fractured one. A malfunction can be overridden, reset, isolated. A
- 4:29Speaker 1: fracture is permanent. The lower rudder was at full hardover
- 4:32Speaker 1: to the left, locked there by physics, and no switch
- 4:35Speaker 1: position on any panel in that cockpit was going to
- 4:38Speaker 1: change it. Guy breached for the checklist. There was no
- 4:41Speaker 1: checklist for this, that is not a figure of speech.
- 4:44Speaker 1: The manuals carried by Northwest Flight 85, the thick meticulously
- 4:47Speaker 1: organized binders that cover thousands of possible failure modes, did
- 4:51Speaker 1: not contain a procedure for a fatigue fracture of the
- 4:54Speaker 1: rudder power control module housing. Boeing had not written one.
- 4:57Speaker 1: The failure mode had not been anticipated. The crack that
- 5:00Speaker 1: caused it was not something any inspector walking around the
- 5:03Speaker 1: aircraft with their eyes could have seen. It required ultrasonic inspection.
- 5:07Speaker 1: No one had known to look. Geib declared the emergency
- 5:10Speaker 1: and reached for the radio. Here is where the geography
- 5:13Speaker 1: became its own problem. The Bering Sea sits at the
- 5:16Speaker 1: edge of reliable radio coverage. Northwest Flight 85 was in
- 5:19Speaker 1: a communications dead zone. The kind of remote airspace where
- 5:23Speaker 1: the normal assumption that someone is listening cannot be taken
- 5:25Speaker 1: for granted. Geib transmitted. He received nothing back. The aircraft
- 5:30Speaker 1: continued to hold its left bank, fighting every correction, burning
- 5:33Speaker 1: through the crew's options, one by one. It was another
- 5:36Speaker 1: Northwest aircraft that saved the radio problem. Flight 19, operating nearby,
- 5:41Speaker 1: picked up the transmission and relayed the emergency to air
- 5:44Speaker 1: traffic control. That relay established the chain that would eventually
- 5:48Speaker 1: bring ground support into the picture. But the radio working
- 5:51Speaker 1: again did not solve the problem at the center of everything.
- 5:54Speaker 1: The aircraft still could not be flown normally and no one,
- 5:57Speaker 1: not on the flight deck, not on the ground, had
- 6:00Speaker 1: a procedure for what was happening. Northwest personnel in Minneapolis-Saint
- 6:03Speaker 1: Paul joined a conference call. The people on the other
- 6:06Speaker 1: end were experienced. They had access to documentation. They listened
- 6:10Speaker 1: to what the crew described. They could not identify a solution.
- 6:13Speaker 1: In crew rest, John Hansen felt something change. The exact
- 6:16Speaker 1: nature of what a sleeping pilot feels when the aircraft
- 6:19Speaker 1: beneath him shifts is difficult to quantify. But Hansen knew
- 6:23Speaker 1: he was the senior captain on the flight. and nearly
- 6:25Speaker 1: 13 years in aviation teaches the body things that wakefulness cannot.
- 6:30Speaker 1: He came forward, what he found on the flight deck
- 6:32Speaker 1: was an aircraft being held in an uncomfortable configuration by
- 6:36Speaker 1: two pilots working hard to keep it there a declared
- 6:38Speaker 1: emergency with no checklist attached to it, and a conference
- 6:42Speaker 1: call with the airline that had produced nothing actionable. Fagan
- 6:45Speaker 1: came forward with him. Hansen looked at the situation and
- 6:48Speaker 1: understood something that would take investigators months to fully document.
- 6:52Speaker 1: The lower rudder was gone, not malfunctioning, gone structurally separated,
- 6:56Speaker 1: irrecoverably locked. The upper rudder still responded. The ailerons still responded.
- 7:02Speaker 1: The engines still responded. And if you held the upper
- 7:04Speaker 1: rudder full right, combined full right aileron, and adjusted the
- 7:08Speaker 1: thrust asymmetrically across four engines, you could theoretically counteract the
- 7:12Speaker 1: force being exerted by the locked lower surface and steer
- 7:14Speaker 1: the aircraft. Theoretically, this was not a technique from any checklist.
- 7:19Speaker 1: It was not a maneuver any of the four pilots
- 7:21Speaker 1: had trained for in a simulator. It was engineering intuition
- 7:24Speaker 1: applied at 35,000 feet over open ocean, with a conference
- 7:27Speaker 1: call full of experts who had already run out of answers.
- 7:30Speaker 1: Hansen took the controls with Fagan alongside him. They flew
- 7:34Speaker 1: the aircraft by hand. The nearest suitable airport was Ted
- 7:37Speaker 1: Stevens Anchorage International. To reach it, they had to maintain
- 7:40Speaker 1: directional control across hundreds of miles of overwater flight. Descend
- 7:44Speaker 1: from cruise altitude without the standard control authority a 747
- 7:47Speaker 1: commander expects. configure for landing with a rudder that would
- 7:52Speaker 1: fight every approach input, and then, this is the part
- 7:55Speaker 1: that Hansen himself described plainly, not be certain they could
- 7:58Speaker 1: keep the aircraft on the runway. He said that out loud,
- 8:01Speaker 1: not to the passengers, to the flight attendants. Hansen walked
- 8:05Speaker 1: back through the cabin and briefed the senior flight attendant.
- 8:07Speaker 1: He used the words red emergency. He told them there
- 8:10Speaker 1: was a solid chance the aircraft would need to be
- 8:12Speaker 1: evacuated on the runway, he asked them to prepare, then
- 8:15Speaker 1: he returned to the flight deck and continued flying, The
- 8:18Speaker 1: passengers did not know what the crew knew. The cabin
- 8:21Speaker 1: stayed quiet in the way cabins do when the seatbelt
- 8:23Speaker 1: sign is on, and the flight has stopped feeling routine.
- 8:26Speaker 1: Outside the windows, the Bering Sea gave way to the
- 8:29Speaker 1: Alaskan coast. The aircraft descended. Hansen and Fagan held their
- 8:33Speaker 1: improvised configuration. Upper rudder full right, aileron full right. Asymmetric thrust,
- 8:38Speaker 1: mile after mile, as if the four of them had
- 8:40Speaker 1: always known how to fly this way. They had not.
- 8:44Speaker 1: They were inventing it. Picture the lower rudder of a 747.
- 8:48Speaker 1: in normal operation. It moves in small precise increments, fractions
- 8:52Speaker 1: of a degree at a time responding to your damper
- 8:54Speaker 1: inputs that the pilots never consciously command. The system is
- 8:58Speaker 1: designed to make long-haul flight smooth and stable. It operates quietly, automatically, invisibly.
- 9:04Speaker 1: Most passengers who have crossed an ocean on a 747
- 9:07Speaker 1: have never thought about it once. Now picture the housing
- 9:09Speaker 1: that holds the actuator in place. It is cast metal
- 9:12Speaker 1: not a moving part. not a component subject to wear
- 9:15Speaker 1: in the way a bearing or a valve wears. It
- 9:18Speaker 1: is the structure, it is the thing that is supposed
- 9:20Speaker 1: to be permanent, but cast metal fatigues. Every pressurization cycle
- 9:25Speaker 1: flexes the airframe. Every thermal cycle, the heat of a
- 9:27Speaker 1: tropical ramp, the cold of polar cruise altitude, expands and
- 9:31Speaker 1: contracts the metal microscopically. Across nearly 13 years and thousands
- 9:35Speaker 1: of flights, a crack had been growing inside that housing,
- 9:38Speaker 1: not on its surface, where a maintenance technician's flashlight might
- 9:41Speaker 1: catch it. Deep inside the material, propagating through the cast
- 9:45Speaker 1: structure with each cycle, invisible to any inspection method then required.
- 9:49Speaker 1: When the housing fractured on October 9, 2002, the end
- 9:52Speaker 1: section broke away completely. The yaw damper actuator, no longer constrained,
- 9:57Speaker 1: drove the lower rudder to its full travel limit and
- 10:00Speaker 1: held it there. The system designed to make the aircraft
- 10:02Speaker 1: stable had become the mechanism of its instability, and because
- 10:06Speaker 1: the failure was structural rather than electronic or hydraulic, no reset,
- 10:09Speaker 1: no circuit breaker, no isolation procedure could undo it. Here
- 10:13Speaker 1: is what the investigation would eventually confirm, and what makes
- 10:16Speaker 1: this event worth sitting with. The failure mode was not
- 10:18Speaker 1: unknown in a general sense. Fatigue in cast metal components
- 10:22Speaker 1: is a recognized phenomenon. But the specific failure, the housing
- 10:26Speaker 1: fracturing as a structural element, rather than an internal component failing,
- 10:30Speaker 1: had not been anticipated for this part. No one had
- 10:33Speaker 1: written an ultrasonic inspection requirement for it. No one had
- 10:36Speaker 1: written a procedure for the result of it. The aircraft
- 10:38Speaker 1: that had carried passengers across oceans for nearly 13 years
- 10:42Speaker 1: was flying with a crack that no one was looking
- 10:44Speaker 1: for inside a component no one was watching, And the
- 10:47Speaker 1: first sign of it was a 30 to 40 degree, uncommanded,
- 10:50Speaker 1: rollover the most remote airspace on the route. The question
- 10:53Speaker 1: the National Transportation Safety Board would need to answer was
- 10:56Speaker 1: not whether the crew had done something wrong. The evidence
- 10:59Speaker 1: made that answer clear before the investigation formally began. The
- 11:03Speaker 1: question was structural and systemic. How does a cast metal
- 11:06Speaker 1: housing accumulator fatigue crack to fracture point without any required
- 11:09Speaker 1: inspection catching it? And what does the rest of the
- 11:12Speaker 1: fleet look like right now? Walk back through what the
- 11:14Speaker 1: crew faced with that answer in mind. There was no
- 11:17Speaker 1: checklist because no one had modeled this failure. There was
- 11:20Speaker 1: no conference call solution because no one had solved this
- 11:23Speaker 1: failure before. The improvised technique Hansen and Fagan developed upper rudder, aileron,
- 11:28Speaker 1: asymmetric thrust, worked not because it was trained but because
- 11:32Speaker 1: they understood the aerodynamics well enough to construct a solution
- 11:35Speaker 1: from first principles. in real time, at altitude, with passengers aboard.
- 11:40Speaker 1: That is not what the manual calls for. The manual
- 11:42Speaker 1: did not exist. What the NTSB ultimately documented was not
- 11:46Speaker 1: a story about a crew making errors. It was a
- 11:49Speaker 1: story about a system encountering a gap it had not
- 11:51Speaker 1: prepared for, and four pilots filling that gap with something
- 11:54Speaker 1: that cannot be written in a checklist. The accumulated judgment
- 11:57Speaker 1: of people who knew their aircraft well enough to improvise
- 12:00Speaker 1: when every prepared answer had run out, the NTSB published
- 12:04Speaker 1: its findings and the regulatory machinery moved, On July 24, 2003,
- 12:09Speaker 1: about nine months after the Bering Sea, Boeing issued Alert
- 12:12Speaker 1: Service Bulletin 74727-27-A23-97. The directive was specific. Inspect the lower
- 12:20Speaker 1: rudder power control module manifold using ultrasonic methods, the only
- 12:24Speaker 1: technique capable of finding a fatigue crack hidden inside cast metal.
- 12:27Speaker 1: Visual inspection, the kind that had been performed on November
- 12:30Speaker 1: 16 C1 uniform Sierra across nearly 13 years of commercial service,
- 12:35Speaker 1: could not have found it. no one had required anything more.
- 12:38Speaker 1: The Federal Aviation Administration followed. Airworthiness Directive 2003-23-01 took effect
- 12:45Speaker 1: on December 18, 2003, mandating the inspection across the affected fleet.
- 12:51Speaker 1: Three years later, a superseding directive, 2006-18-17, tightened the requirement further.
- 12:55Speaker 1: Effective October 13, 2006. By 2008, a proposed replacement had
- 12:57Speaker 1: been published. signaling that the industry considered the original fix
- 13:06Speaker 1: a bridge, not a destination. The GATT the crew had
- 13:09Speaker 1: fallen into on October 9, 2002, was being closed, slowly, methodically,
- 13:14Speaker 1: through the language of service bulletins and federal directives, but
- 13:18Speaker 1: it was being closed because they had survived to report it.
- 13:21Speaker 1: In January 2004, the Airline Pilots Association presented the crew
- 13:25Speaker 1: with its Superior Airmanship Award. The citation covered what the
- 13:29Speaker 1: NTSB report had already documented in careful technical language, an
- 13:33Speaker 1: uncommanded hardover with no applicable checklist, a communications dead zone.
- 13:37Speaker 1: a conference call that produced no answer, and a crew
- 13:40Speaker 1: that constructed a solution from aerodynamic first principles and held
- 13:44Speaker 1: it for hours. There is something worth sitting with in
- 13:46Speaker 1: that award. The ELIPA Superior Airmanship Award does not go
- 13:49Speaker 1: to crews for following procedures. It goes to crews for
- 13:52Speaker 1: performing correctly when procedures do not exist. That distinction matters
- 13:56Speaker 1: more than it might seem. An aviation system built on
- 13:59Speaker 1: checklists and standardization had produced four pilots skilled enough to
- 14:03Speaker 1: function when the checklist ended. The training had prepared them
- 14:05Speaker 1: for the space beyond the training. Captain John Hansen and
- 14:08Speaker 1: First Officer Mike Fagan flew November 16-01 61-uniform Sierra by
- 14:13Speaker 1: hand across the North Pacific. Junior Captain Frank Guy managed
- 14:16Speaker 1: the radios, declared the emergency, and coordinated with Anchorage Approach Control,
- 14:21Speaker 1: under conditions no simulator had ever modeled for this specific failure.
- 14:25Speaker 1: First Officer David Smith called back from rest, joined them
- 14:28Speaker 1: in the cockpit. Together they landed the aircraft, every person
- 14:31Speaker 1: aboard walked off the plane. The investigation had not found
- 14:34Speaker 1: a villain. It had found a fracture, a fatigue crack
- 14:36Speaker 1: in a cast metal housing, propagating invisibly through years of
- 14:40Speaker 1: pressurization cycles and flight loads, until the day it gave
- 14:43Speaker 1: way over the most remote stretch of the route. The
- 14:45Speaker 1: system had a gap. The gap had a cost that,
- 14:48Speaker 1: on this occasion, was paid entirely in fear and professionalism
- 14:51Speaker 1: rather than in lives. November 661 Uniform Sierra returned to
- 14:55Speaker 1: commercial service after the incident. It kept flying for Northwest
- 14:59Speaker 1: then for Delta after the 2008 merger, accumulating more cycles,
- 15:03Speaker 1: more crossings, more passengers who boarded without knowing what the
- 15:06Speaker 1: aircraft had already survived. On September 8, 2015, it made
- 15:10Speaker 1: its final revenue flight. The route was Honolulu to Atlanta,
- 15:14Speaker 1: a last Pacific crossing of a different kind, a long
- 15:17Speaker 1: descent toward the mainland and the end of a working life.
- 15:20Speaker 1: The aircraft that had begun as a prototype in April
- 15:22Speaker 1: 1988 that had entered Northwest service on December 8, 1989,
- 15:27Speaker 1: that had rolled 30 to 40 degrees over the Bering Sea,
- 15:30Speaker 1: with no checklist and no warning. Touched down in Atlanta
- 15:33Speaker 1: for the last time, on April 30, 2016, November 16
- 15:38Speaker 1: 61-uniform Sierra was transferred to the Delta Flight Museum. On
- 15:42Speaker 1: March 28, 2017, the museum opened its 747 experience exhibit.
- 15:47Speaker 1: The aircraft stands in Atlanta now preserved, the first 747.
- 15:51Speaker 1: 400 prototype, the plane that survived a failure, No one
- 15:55Speaker 1: had written a procedure for, available for visitors to walk through.
- 15:59Speaker 1: Most of them will not know the story of October 9th, 2002.
- 16:03Speaker 1: The exhibit does not require them to. The aircraft simply
- 16:05Speaker 1: stands there, a piece of engineering that outlasted the crisis
- 16:09Speaker 1: it was never designed to survive. There is a final
- 16:11Speaker 1: detail that belongs here. The incident over the Bering Sea
- 16:14Speaker 1: did not initially receive media attention. The passengers landed, the
- 16:18Speaker 1: aircraft was inspected, and the investigation began. all without the
- 16:22Speaker 1: kind of public reckoning that follows a visible catastrophe. The
- 16:26Speaker 1: regulatory response happened in the structured, unglamorous language of airworthiness directives.
- 16:31Speaker 1: The crew received their award in January 2004 at an
- 16:34Speaker 1: industry ceremony most people outside aviation never heard about. What
- 16:38Speaker 1: happened at 35,000 feet above the Bering Sea on that
- 16:42Speaker 1: Wednesday afternoon was witnessed in real time by perhaps 200 people,
- 16:46Speaker 1: the crew and the passengers who felt the aircraft roll
- 16:49Speaker 1: without knowing why. The rest of the world learned nothing
- 16:52Speaker 1: about it, and yet the service bulletins that followed the directives,
- 16:55Speaker 1: the ultrasonic inspection requirements, those traveled forward into the maintenance
- 16:59Speaker 1: records of every aircraft they touched, preventing failures that will
- 17:02Speaker 1: never appear in any accident report because they never happened.
- 17:05Speaker 1: That is what safety looks like when it works, not
- 17:07Speaker 1: a headline, a crack that was found before it fractured,
- 17:10Speaker 1: a procedure written for a failure that a crew in
- 17:12Speaker 1: 2002 survived long enough to report. John Hansen, Mike Fagan,
- 17:17Speaker 1: Frank Geib, and David Smith gave the system what it
- 17:20Speaker 1: needed to fix itself. They did not have to. The
- 17:22Speaker 1: margin was close enough that they might not have. The
- 17:25Speaker 1: aircraft stands in Atlanta. The directives are in the maintenance records.
- 17:28Speaker 1: The crack that started it is in the NTSB file.
- 17:31Speaker 1: Documented in the language of fatigue fracture and cast metal housing,
- 17:35Speaker 1: a small invisible failure that four pilots and an entire
- 17:38Speaker 1: regulatory apparatus converted, in the end, into something that will
- 17:42Speaker 1: never happen the same way again. This show is made
- 17:44Speaker 1: by Oba Media.