N17085

Part: PUMP — FAILED (FUEL SYSTEM) · airframe 108,464 hrs · 20,292 cycles

REJECTED TAKE OFF AT 80 KNOTS NR 2 ENGINE WILL NOT MAKE POWER ONLY WENT TO 110 PERCENT N1 LOWER THAN 1&3. CORRECTIVE ACTION REMOVED AND REPLACED THE FUEL PUMP AND M.E.C. STILL IN WORK.

Part: POWER SUPPLY — FAILED (EMERGENCY LIGHT) · airframe 108,132 hrs · 20,225 cycles

ON PRE-FLIGHT, FOUND EMERGENCY LIGHT TEST LAMP INOP (GREEN LIGHT ON OVERHEAD PANEL). REMOVED AND REPLACED EMERGENCY LIGHT POWER SUPPLY PER MM 33-51.

Part: FLOOR PANEL — OVERHEATED (CABIN) · airframe 106,452 hrs · 19,913 cycles

EXCESSIVE HEAT COMING FROM FLOOR AND WALL FORWARD AND AFT OF L-2 DOOR. TROUBLESHOOTING AS OF 10/5/04.

Part: DUCT — BLOWN (BLEED AIR) · airframe 106,448 hrs · 19,911 cycles

AIRCRAFT DIVERTED TO BWI ,DUE TO BLEED AIR LEAK IN L2 DOOR AREA. NR 3 PNEUMATIC SYSTEM ALREADY DEFERRED. REPLACED BLOWN DUCT IN FWD CARGO AREA.

Part: BATTERY PACK — FAILED (EMERGENCY LIGHT) · airframe 103,866 hrs · 19,421 cycles

EMERGENCY EGRESS LIGHTS FAIL TO TEST. BATTERY PACK FAILED.

Part: SKIN — CRACKED (FWD CARGO DR) · airframe 101,053 hrs · 18,900 cycles

INSPECTION FOUND A 1" CRACK IN FORWARD CARGO DOOR SKIN(DOUBLER) ON LATCH ACCESSORY DOOR CUTOUT AREA. THE CRACKED AREA WAS CUT OUT AND A REPAIR DOUBLER WAS INSTALLED IAW SRM 52-00-01, FIGURE 9.

Part: SEAT TRACK — CORRODED (STA 1860) · airframe 101,050 hrs · 18,899 cycles

INSPECTION FOUND MAIN DECK SEAT TRACK CORRODED AT Y = 1860, X = -60.00, JUST AFT OF R-4 ATTENDANT SEAT. THE CORRODED SECTION OF SEAT TRACK WAS CUT OUT AND A NEW SECTION OF SEAT TRACK WAS INSTALLED USING SPLICE HAT AND SPLICE PLATE IAW SRM 53-70-00, FIGURE 1.

Part: SEAT TRACK — CORRODED (STA 800-824) · airframe 101,050 hrs · 18,899 cycles

INSPECTION FOUND MAIN DECK SEAT TRACK CORRODED AT X = 107.25 AND Y = 800-824. THE CORRODED SECTION OF SEAT TRACK WAS REMOVED AND A NEW SEAT TRACK SECTION WAS SPLICED IN IAW SRM 53-70-00, FIGURE 1.

Part: PANEL — DELAMINATED (ENGINE COWL) · airframe 97,248 hrs · 18,260 cycles

INSPECTION FOUND NR 2 ENGINE NOSE COWL PANEL 363AL DELAMINATED. THE PANEL WAS REPLACED IAW MM 20-50-02.

Part: SKIN — CORRODED (LT AILERON)

INSPECTION FOUND LT WING O/B AILERON UPPER SKIN CORRODED AT STA 917. THE AILERON WAS REPLACED IAW MM 27-10-02.

Part: SKIN — CRACKED (NR 2 PYLON)

INSPECTION FOUND A 2 INCH CRACK IN NR 2 ENGINE PYLON SKIN WITH LOOSE FASTENERS ON PYLON FIN. THE SKIN WAS REPAIRED IAW SRM 54-20-00, FIGURE 6 AND FASTENERS WERE REPLACED IAW SRM 51-31-00.

Part: SKIN — DELAMINATED (NR 4 SPOILER)

INSPECTION FOUND THE UPPER AND LOWER SURFACE OF RT WING NR 4 SPOILER SKIN DELAMINATED. THE SPOILER WAS REMOVED AND REPLACED IAW MM 27-60-01.

Part: LONGERON — CRACKED (NR 2 ENGINE COWL)

INSPECTION FOUND A 1 CRACK IN LEFT LONGERON AND A 1 CRACK IN RT LONGERON OF NR 2 ENGINE CORE COWL. THE CRACKS WERE LOCATED NEAR HINGES. THE LONGERONS WERE REPAIRED IAW ECRA 7110-01496.

Part: FLOORBEAM — CRACKED (BS 1721-1741)

INSPECTION FOUND A 3 CRACK IN CENTER CARGO STRUCTURAL FLOORBEAM NR 12 BETWEEN STA 1721 AND 1741. A NEW BEAM WAS INSTALLED IAW MM 53-00-00 AND DRAWING AFT7009.

Part: JAMB — CRACKED (BS 1721)

INSPECTION FOUND A 1 CRACK IN CENTER CARGO DOOR JAMB AT STA 1721. THE JAMB WAS REPLACED IAW SRM 53-10-00.

Part: BEAM — CRACKED (BS 1821)

INSPECTION FOUND A 3 CRACK IN CENTER CARGO NR 12 FLOOR STRUCTURAL BEAM AT STA 1821. A NEW BEAM WAS INSTALLED IAW SRM 51-30-00 AND MM 25-50-00.

Part: SKIN — DELAMINATED (LT I/B TE FLAP)

INSPECTION FOUND LEFT WING INBOARD FLAP UPPER SKIN UNBONDED ON INBOARD SIDE. THE SKIN WAS REPLACED IAW SRM 51-30-00.

Part: FLOORBEAM — CRACKED (BS 1741-1761)

INSPECTION FOUND ONE EACH 1 CRACK IN CENTER CARGO STRUCTURAL FLOORBEAMS NR 9 AND NR 10 BETWEEN STA 1761 AND 1741. THE BEAMS WERE REPLACED IAW SRM 53-00-00 AND MM 25-52-00.

Part: ANGLE — CRACKED (CARGO DOOR)

INSPECTION FOUND A 1 CRACK IN ANGLE AT UPPER AFT SECTION OF CENTER CARGO DOOR. THE ANGLE WAS REPLACED IAW SRM 51-30-00.

Part: SKIN — DENTED (BS 1090)

INSPECTION FOUND LEFT WING LOWER SKIN DENTED AT STA 1090. THE SKIN WAS REPLACED IAW SRM 51-30-00.

Part: SKIN — CRACKED (NR 2 LE SLAT)

INSPECTION FOUND A 2 CRACK IN LEFT WING NR 2 SLAT SKIN. REPAIRED IAW SRM 57-10-00, FIGURE 31.

Part: SKIN — CRACKED (RT WING)

INSPECTION FOUND A 1.25 CRACK ON RT WING UPPER SKIN DROOPED LEADING EDGE. A REPAIR WAS INSTALLED IAW SRM 57-10-00.

Part: BOLT — BROKEN (BS 1370)

INSPECTION FOUND TRAPEZOIDAL PANEL BOLT IN RT MLG WHEEL WELL BROKEN AT STA 1370. THE BOLT WAS REPLACED IAW MM 20-50-02.

Part: STRAP — CRACKED (WS 405 & 506)

INSPECTION FOUND A 2 INCH EFTACK IN LEFT WING LEADING EDGE STRIP AT STA XORS 455 AND XORS 506. REPAIRED IAW DRAWING 2933 AND SRM 51-30-00.

Part: STRAP — CRACKED (WS 433-455)

INSPECTION FOUND A 1.5 CRACK IN RT WING LOWER SKIN LEADING EDGE STRAP BETWEEN STA XORS 433 AND XORS 455. A NEW STRAP WAS INSTALLED IAW DRAWING ARB2935 AND SRM 51-31-01.

Part: SKIN — CRACKED (NR 4 LE SLAT)

INSPECTION FOUND A .25 INCH CRACK IN INTERNAL SKIN OF RT WING LEADING EDGE SLAT NR 4. A REPAIR WAS PERFORMED IAW SRM 57-00-01, PAGE 12, FIGURE 4, SHEET 2.

Part: BOTTLE — BLOWN (L4 DOOR)

DOOR 4L DOOR ASSIST BOTTLE BLOWN. RESET HANDLE AND SERVICED DOOR ASSIST BOTTLE, OPERATES NORMAL.

Part: RECIRC FAN — FAILED (CABIN)

A/C DIVERTED TO MAD FROM FCO DUE TO ELECTRIC SMELL IN CABIN. FOUND NR 4 CABIN AIR RECIRCULATION FAN FAILED. FAN TO BE REPLACED.

Part: INTERCOSTAL — CRACKED (BS 1721)

INSPECTION FOUND A 1 INCH CRACK ON LOWER CAP OF INTERCOSTAL AT CEILING CENTER CARGO, RBL 82, STA 1721 WITH DISTORTION ON CEILING SUPPORT AT RBL 78. A REPAIR WAS ACCOMPLISHED IAW SRM 51-21-01 AND 51-33-01.

Part: TRANSFER VALVE — LEAKING (NR 1 HYD SYS)

THE AIRCRAFT LOST NR 1 HYDRAULIC SYSTEM QUANTITY AFTER TAKEOFF FROM EWR. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND NR 1 AND NR 3 REVERSIBLE PUMP LEAKING AT HYDRAULIC TRANSFER VALVE. THE TRANSFER VALVE, FITTINGS, AND O-RINGS WERE REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: BLADE — MISINSTALLED (NR 3 ENGINE)

T/O WAS REJECTED AT 5 KNOTS WHEN NR 3 ENG COMPRESSOR STALLED. THE NR 3 ENG WAS SHUT DOWN AND THE ACFT RETURNED TO THE GATE. MX INSPECTED THE NR 3 ENG AND FOUND DAMAGE. THE NR 3 ENG WAS REMOVED AND REPLACED. *S/D* THE PRIMARY CAUSE OF THE ENGINE FAILURE TO BE LIBERATION OF A STAGE 13 HPC BLADE. DURING CLOSER EXAMINATION IT WAS DISCOVERED THAT THE TWO EACH 13TH STAGE COMPRESSOR BLADE LOCKING LUGS WERE INCORRECTLY INSTALLED, WHICH ALLOWED ONE BLADE TO MIGRATE INTO THE LOADING SLOT POSITION AND LIBERATE. THE LIBERATED BLADE CAUSED SEVERE SUBSEQUENT DAMAGE TO THE REMAINING HPC BLADES.