N116FE

Part: SWITCH — INOPERATIVE (DOORS)

DUR TEST FLT AT 12000 CLIMB MC DOOR LIGHT CAME ON. ADJUSTED MC DOOR WARN MICROSWITCHES, AND OPS CK GOOD PER IAW FEDEX MM 52-70-000-5.

Part: FITTING — CRACKED (RT WING) · airframe 65,094 hrs · 49,058 cycles

DURING ROUTINE INSP FOUND SUPPORT FITTING FOR NR 6 LEADING EDGE SLAT UP STOP CRACKED. *S/D* REMOVED AND REPLACED FITTINGS PER IAW SRM 51-20-1.

Part: FITTING — CRACKED (L/E FLAP) · airframe 65,094 hrs · 49,058 cycles

DURING ROUTINE INSP FOUND SUPPORT FITTING NR 2 KRUEGER FLAP ACTUATOR SUPPORT FITTING AT FRONT SPAR CRACKED. *S/D* REMOVED AND REPLACED PER IAW SRM 57-20-1.

Part: FITTING — CORRODED (NLG WW) · corrosion level 2 · airframe 65,094 hrs · 49,058 cycles

DURING ROUTINE INSP FOUND SUPPORT FITTING FOR NLG DOOR ACTUATOR ROD CORRODED. *S/D* REMOVED AND REPLACED FITTING PER IAW SRM 51-30-2.

Part: SKIN — CRACKED (FUSELAGE) · airframe 65,094 hrs · 49,058 cycles

DURING INSP HFEC IND CRACK FUSELAGE SKIN RT AT BS 252 BELOW CO-PILOTS NR 3 WINDOW. *S/D* REMOVED AND REPLACED PER IAW EA 7-5330-57300.

Part: LINK — VIBRATION (NLG)

UPON LANDING WITH SPOILER and REVERSERS ABOUT 90 KTS. NOSE GEAR START VIBRATING. *S/d* Removed and replaced NLG TORSION LINKS PER IAW MM 32-21-051-4, LT & RT NLG WHEELS PER IAW MM 32-45-011-4. OPS CHECK GOOD.

Part: WARNING LIGHT — ILLUMINATED (COCKPIT)

DURING DESCENT, LWR AFT BODY OVERHEAT LIGHT ILLUM. RED TAB PROCEDURE. LIGHT OUT ON GROUND & SYS TEST GOOD. REPEAT.

Part: WARNING SYSTEM — ACTIVATED (E/E BAY)

LOWER AFT BODY OVERHEAT ILLUM DURING FLT, LIGHT FLICKERED CONTINUOUSLY WHILE CRUISING. COMPLIED WITH CK LIST PROC. REPEAT WRITE UP. REMOVED AND REPLACED FIRE DETECTOR, RAN ENGINES AT HI POWER FOR APPROX 10 MIN. OVERHEAT DETECTOR SYS OPER CK NORMAL PER 727 MM 24-14-00.

Part: OVERHEAT LIGHT — ILLUMINATED (TAIL)

LWR AFT BODY OVERHEAT LIGHT ILLUM DURING FLT. REPEAT WRITEUP. REPOSITIONED ENTIRE LOOP LEFT SIDE FROM 1183 AFT. RAN ALL 3 ENG WITH AIRSTAIRS UP AND CK LEAKS. NO LEAKS FOUND. RAN BOTH PACKS ONE AT A TIME DURING GROUND TIME WITH NO LWR AFT BODY OVERHEAT CONDITION. CK LOOP ON RT SIDE FOR RUBBING, NONE FOUND.

Part: FIRE LOOP — OUT OF POSITION (FUSELAGE)

LWR AFT BODY OVERHEAT LIGHT ILLUM. COMPLIED WITH CKLIST AND LEFT THE NR 2 BLD & PACK CLOSED REMAINDER OF FLT. REPOSITIONED FIRE WIRE. SYSTEM FUNCTIONAL CK. OK PER MM 26-14-001.

Part: DNLOCK SWITCH — INOP (NLG)

LANDING NOSE GEAR IND DOWN THEN WHEN GEAR DOOR LIGHT EXT NOSE GEAR LIGHT WENT OUT. ALL LANDING DOWNLOCK PINS INSTALLED. REMOVED AND REPLACED LANDING ANNUNCIATOR PNL. REPLACED NOSE GEAR DOWNLOCK SWITCH PER AMM 32-61-021-4 & CONNECTOR D298 PER SMP. SYS OPS CK GOOD.

Part: FLOORBEAM — CORRODED (BS 1050)

WHILE WORKING ON 72C201-01 DISCOVERED CORROSION ON FLOORBEAM BS 1050, RBL 20, WL 200. ** S/D ** REPAIRED FLOORBEAM PER FEDEX EA 7-5310-43772A.

Part: WEB — CORRODED (BS 440-650)

WHILE WORKING NRO418, FOUND CORROSION ON WEB AT BS 440 TO 650 LBL 60 TO 65 WL 208.1. *S/D* REMOVED AND REPLACED WEB PER EA 7-5310-43763.

Part: SKIN — CORRODED (BS 1166)

NR 0620 015 - BULGING SKIN JUST BELOW LOWER FWD CORNER OR AFT LAV SERVICE DOOR BETWEEN BS 1166 AND 1183 AT STR 22L. REPAIRED SKIN AT BS 1166-1183 STR 19-26L PER EA FEDEX 7-5330-44712.

Part: FRAME — CRACKED (BS 1166)

NR 0632 017 - WHILE WORKING NRO 578, FOUND REINFORCEMENT CHORD FOR BS 1166 FRAME CRACKED AT STR 29R WL 140. REMOVED REINFORCEMENT CHORD, FABRICATED NEW CHORD AND INSTALLED CHORD IAW FEDEX SRM 51-10-1 51-30-2.

Part: FRAME — CORRODED (BS 1166)

NR 0578 016 - CORROSION ON SHEAR TIE BS 1166 STR 29L AND STR 30 WL 138. REMOVED SHEAR TIES AT BS 1166 STR 29 L/R. FABRICATED AND INSTALLED NEW SHEAR TIES IAW FEDEX SRM 51-30-2 53-10-4.

Part: STRINGER — CORRODED (BS 1148-1183)

NR 636 - WHILE WORKING NR 620 FOUND STR 20 LEFT BS 1148-1183 CORRODED ON OTBD SURFACE FROM 1170-1178. REMOVED STR 20 BS 1148-1183, FABRICATED AND INSTALLED NEW STR (LT) IAW FEDEX SRM 51-10-1, 51-30-2, FEDEX MM 51-20-151 AND FEDEX EA 7-5100-44396.

Part: SILL — CORRODED (CARGO DOOR)

WHILE WORKING NR 420 FOUND CORROSION ON MAIN CARGO DOOR LWR SILL WEB AT BS 480 TO 620 LBL 65 WL 200 TO 208. *S/D* REMOVED AND REPLACED MAIN CARGO DOOR LWR SILL WEB IAW FEDEX SRM 51-30-2 AND FEDEX DWG 65-40507.

Part: SILL — CORRODED (BS 500 - 580)

WHILE WORKING NR 419, FOUND CORROSION ON MAIN CARGO DOOR LWR SILL CHORD AT BS 500-580, LBL 62.5, WL 208. REMOVED AND REPLACED, FAB MAIN CARGO DOOR LWR SILL CHORD FROM BS 440-660, LBL 65, WL 208 IAW, DWG NR 65-40507 AND FEDEX SRM 51-30-2.

Part: STRINGER — CORRODED (BS 1166-1183)

WHILE WORKING NR-0620 FOUND STR 22 LT, BS 1166 TO BS 1183 CORRODED AND MECHANICALLY DAMAGED. *S/D* REMOVED AND REPLACED STR 22 LT.

Part: CHORD — CORRODED (BS 1048)

WHILE WORKING NR 515 FOUND CORROSION ON BL 0 CHORD AT BS 1048, RBL 2, WL 200. *S/D* REMOVED AND REPLACED BL 0 CHORD BS 950 TO 1060, WL 200 IAW FEDEX SRM 51-30-2, 53-10-1.

Part: STRAP — CORRODED (PAX DOOR)

FWD ENTRY DOOR I/B TENSION STRAP ON NR 7 TRANSVERSE BEAM IS CORRODED (COUNTING FROM TOP). *S/D* REMOVED AND REPLACED NR 7 TRANSVERSE BEAM TENSION STRAP IAW FEDEX SRM 51-30-2.

Part: STRAP — CORRODED (PAX DOOR)

FORWARD ENTRY DOOR, I/B TENSION STRAP ON NR 1 TRANVERSE BEAM WAS CORRODED. *S/D* REMOVED AND REPLACED NR 1 TRANSVERSE BEAM TENSION STRAP PER FEDEX SRM 51-30-2.

Part: BULKHEAD WEB — DENTED (BS 178)

DENT IN PRESSURE BULKHEAD AT BS 178, RBL 27, WL 210. *S/D* REPAIRED PART PER EA 7-5330-43765.

Part: KEEL BEAM — CORRODED (BS 1121-1180)

NR 577 - CORROSION ON LEFT KEEL BEAM AT BS 1166. REMOVED AND REPLACED KEEL BEAM FROM BS 1121 TO 1180, LBL 10 PER FED-EX SRM 51-30-2.

Part: FRAME — CORRODED (BS 870)

NR 500 - CORROSION (C53-132-02(1)) INDICATIONS BETWEEN LWR FLANGE AND WEB OF BS 870 UPPER CHORD LBL 40-50. REMOVED AND REPLACED UPPER SPAR CHORD BS 870, RBL 70 - LBL 70 PER FEDEX EA 7-5710-43764.

Part: FLOORBEAM — CORRODED (BS 1050)

NR 575 WHILE WORKING ON NR 395, DISCOVERED CORROSION ON FLOORBEAM LWR CHORD BS 1050, RBL 2, WL 200. REPAIRED FLOORBEAM PER FEDEX EA 7-5310-43772 REV A.

Part: SPAR — CORRODED (BS 870)

UPON REMOVAL OF CTR WING SECTION AFT BULKHEAD WEB FOUND VERTICAL FLANGE OF LWR 870 SPAR CHORD TO BE CORRODED FROM LBL 60-RBL 35.

Part: BULKHEAD WEB — CORRODED (BS 870)

WHILE WORKING NR 500, FOUND AFT BULKHEAD FOR WING CTR SECTION TO BE CORRODED AT RBL 7.5 AND 14.5, WL 150 AND AT BL 0, WL 165, BS 870. *S/D* REMOVED AND REPLACED AFT BULKHEAD FOR WING CTR SECTION BS 870, RBL 70 - LBL 70 PER FEDEX EA 7-5710-43764.

Part: CHORD — CORRODED (BS 1090 & 1110)

NR 574 - WHILE WORKING ON NR 395 DISCOVERED CORROSION ON BL0 CHORD AT BS 1090 AND 1110, LBL 2, WL 200. REPLACED BLO CHORD FROM 1157 TO 1060 PER FED-EX DRAWING 65-44234.

Part: ENGINE — FOD (NR 3)

SUSPECTED BIRDSTRIKE ON CLIMB-OUT, NR 3 ENG CONTINUED TO RUN W/SEVERE VIBRATION. UNDER VOLTAGE SYS NR 3. NR 3 GEN FIELD, AGR AND BUS TIE TRIP. NR 3 ENG OIL PRESS DROPPED TO 16 PSI AFTER SHUTDOWN FOR 10 MIN. ACCOMP ENG FAILURE SEVERE DAMAGE CHECKLIST. AFT CARGO DOOR LIGHT ILLUM'D AFTER BIRDSTRIKE. REMOVED AND REPLACED NR 3 ENG PER MM 71-00 AND WORKCARD KIT 70T0503. C/W ENG TYPE 'A' PER JT8-D MM 72-00 PG 553-554, ALL CK GOOD. AFT CARGO DOOR LIGHT FUNCTIONING NORMALLY. A/C OK FOR SERVICE.

Part: SWITCH — INOPERATIVE (LT MLG DOOR)

AFTER TAKEOFF FOLLOWING GEAR RETRACTION, LEFT MAIN GEAR DOOR LIGHT AND RED DOORS LIGHT REMAINED ILLUMINATED. RECYCLED GEAR SAME RESULTS. *S/D* REMOVED AND REPLACED LEFT MAIN LANDING GEAR DOOR WARNING SWITCH. OPERATIONAL CHECK OF LEFT MAIN LANDING GEAR DOOR WARNING SYSTEM IS GOOD. REFERENCE MAINTENANCE MANUAL 32-62-11.

Part: SOLENOID — FAILED (GEAR HANDLE)

LANDING GEAR HANDLE FAILED TO GO UP BEYOND OFF POSITION. COMPLETED LANDING GEAR LEVER LATCH FAIL TO RELEASE CHECK LIST THROUGH STEP 7. DETERMINE LEVER LATCH SOLENOID IS INOPERATIVE. REMOVED AND REPLACED MAIN LANDING GEAR SAFETY SWITCH PER MAINTENANCE MANUAL 32-09-211, NO HELP. REMOVED AND REPLACED LANDING GEAR HANDLE LOCK SOLENOID PER MAINTENANCE MANUAL 32-31-12 PAGE 401-403, OPERATIONAL CHECKS GOOD.

Part: POSITION SW — FAILED (NLG)

ON FINAL, APPROXIMATELY 1,000 FEET ABOVE GROUND LEVEL THE NOSE GEAR GREEN INDICATION WENT OUT CAUSING HORN TO SOUND. EXECUTED GO-AROUND AND ON CLIMBOUT GREEN INDICATION RE-ILLUMINATED. THREE GEAR PINS INSTALLED, RAN GEAR HANDLE SEVERAL TIMES, OPERATIONAL CHECKS NORMAL ON GROUND. REMOVED GEAR PINS, REMOVED AND REPLACED NOSE LANDING GEAR LOCK AND POSITION SWITCHES PER MAINTENANCE MANUAL 32-61-21. OPERATIONAL TEST PER MAINTENANCE MANUAL 32-61-21 PAGE 502 IS NORMAL.

Part: DOOR LIGHT — ILLUMINATED (RT MLG)

RIGHT MAIN LANDING GEAR DOOR LIGHT ILLUMINATED, RED DOOR AND ON DOORS PANEL, GEAR UP OR DOWN. RECYCLED GEAR BUT DID NOT CORRECT. RIGHT MAIN LANDING GEAR LIGHT NOT ILLUMINATED ON GROUND IN ROC. LEFT MAIN LANDING GEAR DOOR LIGHT ON AND RIGHT MAIN LANDING GEAR DOOR LIGHT OPERATIONS NORMAL. DEFERRED PER THE MEL. AIRCRAFT MADE SEVERAL FLIGHTS AND GROUND CHECKED DOORS SEVERAL TIMES. LIGHT CHECKS NORMAL. REMOVED PLACARD.

Part: FLOOR BEAM — CORRODED (BS 400)

DISCREPANCY: (NR 1123) FLOORBEAM CORRODED UPPER CHORD STA 400, LBL 32-41 (MAIN CARGO). CORRECTIVE ACTION: REMOVED DAMAGED SECTION OF UPPER CHORD. INSTALLED FLOORBEAM REPAIR PER SRM 53-10-8, FIG 3.

Part: FITTING — CRACKED (BS 740)

DISCREPANCY: STRINGER END FITTING CRACKED STA 740, AFT SIDE, AT STRINGER 5 RT. CORRECTIVE ACTION: REMOVED AND REPLACED STRINGER END FITTING PER SRM 51-10-01.

Part: RIB — CRACKED (WS 436.5)

DISCREPANCY: NR 1 FUEL TANK RIB AT WING STA 436.5 CRACKED AT LOWER ATTACHMENT POINT FOR STRINGER, JUST AFT OF ACCESS OPENING. CORRECTIVE ACTION: STOP DRILLED CRACK, FABRICATED AND INSTALLED DOUBLER PER SRM 57-10-5.

Part: SKIN — CRACKED (FUSELAGE)

FUSE AFT/LWR CORNER OF PILOTS NR 3 WINDOW SKIN CRACKED. DOUBLER INSTALLED PER SRM 53-30-3.

Part: CASTING — CRACKED (BS 870)

UPPER LOBE MAIN CARGO STA 870 CASTING WL 190 LT HFEC INDICATES CRACK, AREA MARKED. CUT OUT CORROSION AND CRACK PER EA, INSTALLED REPAIR FITTING IAW EA 7-5310-28783.

Part: CTR POST — DAMAGED (COCKPIT)

FUSE CENTER POST BETWEEN PILOT AND COPILOT NR 1 WINDOWS CRACKED RIGHT 3RD SCREW DOWN, PILOTS NR 4 WINDOW. NDT VERIFIED NO CRACK FOUND WITH HFEC.

Part: CENTER POST — CRACKED (COCKPIT)

FUSE CENTER POST BETWEEN PILOT AND COPILOTS NR 1 WINDOWS CRACKED RT 2RD SCREW DOWN PILOTS NR 4 WINDOW.

Part: SKIN — CRACKED (FUSELAGE)

FUSE SKIN CRACKED I/B LWR CORNER OF PILOTS NR 4 WINDOW. DOUBLER INSTALLED AT LWR I/B CORNER OF PILOTS NR 4 WINDOW PER SRM 53-30-3.

Part: VALVE — DAMAGED (LT/RT)

BOTH LT AND RT PURGE SHUTOFF VALVES PHYSICALLY DAMAGED, ENDS BLOWN OFF. REMOVED AND REPLACED VALVES, LT-12231, RT-C64198.