This report details an incident where a Boeing 737-800 operated by American Airlines overran the runway at Dallas Fort Worth International Airport in February 2024. The aircraft failed to stop properly after landing due to brake system issues caused by maintenance errors during a scheduled upgrade. The National Transportation Safety Board (NTSB) investigation found that improper reconnection of hydraulic hoses and electrical connectors resulted in brake malfunction, leading to tire skidding and eventual tire failure.
The aircraft’s autobrakes deactivated upon touchdown, forcing pilots to rely solely on manual braking and thrust reversers to stop the plane. The investigation revealed that swapping of hydraulic hoses and wiring harness connectors caused automatic anti-skid and brake system controls to malfunction, resulting in overbraking on the wrong wheels. Consequently, the outboard tires experienced heavy skidding and were damaged, increasing the aircraft's stopping distance and causing the aircraft to go beyond the runway limits. All 104 passengers and crew evacuated safely, with no injuries reported.
In response, American Airlines implemented changes in their maintenance manuals and added operational tests to detect cross-wiring issues. They also inspected their fleet of 300 Boeing 737 Next Generation aircraft without discovering additional problems. Boeing issued revised service bulletins highlighting the risks of crossing hydraulic hoses during brake system upgrades and introduced preventative measures to improve safety procedures. The incident underscores the critical importance of meticulous maintenance practices and thorough checks to prevent human errors that can lead to accidents.
