N183JB

Part: GIRT BAR — DIRTY · airframe 41,949 hrs · 27,293 cycles

FLT#1967, HPN-PBI. ' R2 DOOR LEVER WON'T DISARM; CLEANED DEBRIS FROM LOWER GRIT BAR AND OPS CHECK DOOR IAW 25-40-00. DOOR DISARMS/ARMS OK.'

Part: ACTUATOR — FAILED (SF-ACE-1) · airframe 41,891 hrs · 27,260 cycles

FLT#233, BTV- JFK (AIRCRAFT DECLARED A EMERGENCY). ' SLAT FAIL IN FLIGHT - SLATS WOULD NOT MOVE OUT OF 0 POSITION; PER TSM 27-83-00-810-814A. REMOVED AND REPLACED SLAT/FLAP ACTUATOR CONTROL ELECTRONIC UNIT IAW AMM 27-53-02. OPS CHECK GOOD, NO FAULTS NOTED.'

Part: NONE — NONE · airframe 41,597 hrs · 27,058 cycles

FLT#6266, RSW-BOS. 'R-2 DOOR WILL NOT DISARM; PERFORMED EMERGENCY EVACUATION SLIDE ASSY INSPECTION PER AMM 25-65-01. NO DEFECTS WERE NOTED. R 2 DOOR OPERATES NORMALLY AT THIS TIME.'

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-- 77 BTW STGR-27L / STGR-28L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00123 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-- 03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-83 AND STGR-22L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00151 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, INITIAL INSPECTION CPCP FINDING CORROSION IN SHEAR CLIP AT FR 89 AND STGR 29 L-29R AT AFT CARGO COMPARTMENT; SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-03 PAR 4 A, SRM 51-41-01 PAR 4 AND SRM 51-41-02 PAR-.4 AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29. ALL WORK ACCOMPLISHED ON TOMEX NRC 000165 (CLASSIFIED AS A MAJOR REPAIR)

Part: SHEAR TIE — CORRODED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, : INITIAL INSPECTION: [CPCP FINDING] CORROSION ON SHEAR CLIP OVER FR-81 BTW STGR-27L / STGR-28L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00137: SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-75 BTW STGR-26L / STGR-27L AT AFT CARGO COMPARTMENT; (RESOLVED ON W/O: 1153864 TASK CARD: NR-00044 ) REF TOMX WO 1846 NR -00107 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-- 03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29 REF TOMX WO 1846 NR -00107 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-- 03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-- 76 BTW STGR-26L / STGR-27L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00114 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-- 03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29.

Part: SHEAR TIE — CORRODED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-82 BTW STGR-28L / STGR-27L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00141 SHEAR CLIP WAS REPLACED PER EMB 190 SRM 51-12-01 PAR 6 AND 51-10-03 PAR 4 D AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: FRAME — PUNCTURED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, (EC E22-151-01) FUSELAGE / CENTER FUSELAGE II / FRAME 72 / BTW S26L & S27L / PUNCTURE – PERMANENT REPAIR (CLASSIFIED AS A MAJOR REPAIR)

Part: SHEAR TIE — CORRODED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP AT FR 90 & STGR 24L-25L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00169 SHEAR CLIP WAS REPLACED PER EMB 190 SRM 51-41-01, SRM 51-41-02, AND SRM 51-75-16 PAR 4. TABLE 1 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-83 BTW STGR-27L / STGR-28L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00143 SHEAR CLIP WAS REPLACED PER EMB 190 SRM 51-12-01 PAR 6 AND SRM 51-10-03 PAR 4 D AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, INITIAL INSPECTION : [CPCP FINDING] CORROSION ON SHEAR CLIP OVER FR-- 74 BTW STGR-28L / STGR-27L AT AFT CARGO COMPARTMENT; (RESOLVED ON W/O: 1153864 TASKCARD: NR-00010 ) ALL WORK ACCOMPLISHED ON TOMEX NR000101, SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29. SHEAR CLIP P/N 17066086-001 WAS REPLACED.

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP AT FR 72 & STGR 27L-28L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00161 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-03 PAR 4 D AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.- 4.1 PAR.13 REV.29.

Part: SHEAR TIE — CORRODED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEARCLIP AT FR 90 & STGR 29L-29R AT AFT CARGO COMPARTMENT; SUMMARY OF NRC 00166: CORROSION WAS REMOVED ON SHEARCLIP AT FR 90 STGR29L-29R AT AFT CARGO COMPARTMENT AND MEASURE, OT= 0.40" AND MINIMUM RT 0.011" THEREFORE ITS OUT OF LIMITS, SHEARCLIP WAS REPLACED PER EMB 190 SRM 51-41-02, AND SRM 51-43-01, SRM 51-75-16 PAR 4. TABLE 1 AND JETBLUE GMM 8.18.4.1 PAR 13 REV 29. ALL WORK WAS ACCOMPLISHED ON TECHOPSMX NRC# 00166. SHEAR CLIP-CTL III, AL P/N: 170-66324-001. (CLASSIFIED AS A MAJOR REPAIR)

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP AT FR 72 & STGR 26L-27L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00160 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-03 PAR 4 A AND PER EMB-190 SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION ON SHEAR CLIP OVER FR-- 76 BTW STGR-27L / STGR-28L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00115 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10- 03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-- 80 BTW STGR-28L / STGR-27L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00134 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-- 03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29.

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-82 BTW STGR-29L / STGR-28L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00142 SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-- 03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.29

Part: SHEAR TIE — CORRODED

DURING HEAVY MAINTENANCE, CORROSION FOUND ON SHEARCLIP AT FRAME 76 STR 22L & 23L AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00270 CORROSION WAS REMOVED ON SHEARCLIP AT FRAME 76 STR 22L & 23L AFT CARGO COMPARTMENT AND EVALUATE, ORIGINAL THICKNESS IS .040" AND MINIMUM REMAINING THICKNESS IS 0.- 020" THEREFORE IT IS OUT OF WITHIN LIMITS, SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-41-01, SRM 51-41-02 AND SRM 51-43-03 AND SRM 51-75-16 PAR 4. TABLE 1

Part: SHEAR TIE — CORRODED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, INITIAL INSPECTION: [CPCP FINDING] CORROSION IN SHEAR CLIP OVER FR-85 BTW STGR-27L / STGR-28L AT AFT CARGO COMPARTMENT; REF TOMX WO 1846 NR -00145: SHEAR CLIP WAS REPLACED PER EMB-190 SRM 51-12-01 PAR 6 AND SRM 51-10-03 PAR 4 A AND SRM 51-75-16 PAR 4 AND JETBLUE GMM 8.18.4.1 PAR.13 REV.2

Part: FITTING — CRACKED · airframe 41,577 hrs · 27,043 cycles

DURING HEAVY MAINTENANCE, AWR SECONDARY NRC IN REF. NRC 00178. AFTER BUSHINGS REMOVAL CRACK ON BUSHING HOUSING AT RH PYLON AFT INBOARD FITTING WAS NOTED; REF TOMX WO 1846 NR -00203, : INBOARD FITTING ON RH PYLON AFT WAS REPLACED PER EMB-190 SRM 51-43-01,EMB-190 SRM 51-43-02,-EMB-190 SRM 51-41-01,EMB-190 SRM 51-41-02 AND EMB-190 DWG 190-03199-003 REV. C

Part: SEAL — LEAKING (LT OVERWING EXIT) · airframe 40,405 hrs · 26,248 cycles

FLT 1484, RDU-BOS. LEFT OVERWING EXIT SEAL IS WHISTLING IN FLIGHT; R & R LEFT OVERWING EXIT HATCH IAW AMM 52-21-00

Part: SKIN — DENTED (FUSELAGE) · airframe 39,551 hrs · 25,742 cycles

DURING HEAVY MAINTENANCE, FUSELAGE SKIN FR 3-4 & STR 23R-24R DENT DAMAGE. PERMANENT REPAIR, CLASSIFIED AS MAJOR.

Part: SKIN — CRACKED (LT WING) · airframe 37,234 hrs · 24,081 cycles

DURING HEAVY MAINTENANCE, ONE CRACK WAS FOUND ON THE LH WING MAIN BOX LOWER SKIN P/N190-33065-005 AFT EDGE BETWEEN RIBS 10-11. SEE REF.(1) FOR DETAILS. AEROMAN CONTACTED EMBRAER FOR REPAIR DISPOSITION, AND EMBRAER PROVIDED THE REF.(2) ETD, INSTRUCTING TO CUT OUT THE DAMAGE, ACCOMPLISHING NDT INSPECTIONS, AND INSTALLING A REPAIR DOUBLER. REPAIR WAS CLASSIFIED AS A MAJOR PERMANENT.

Part: BEAM — CRACKED (FRAME 49) · airframe 37,234 hrs · 24,081 cycles

DURING HEAVY MAINTENANCE, A CRACK WAS FOUND ON THE LH LONGITUDINAL BEAM AT FR49 ON THE CENTER FUSELAGE II FLOOR STRUCTURE THE CRACK WAS EVALUATED AGAINST SRM AND FOUND TO BE OUT OF THE SRM SCOPE. REPAIRED IAW EC E19-322-01. REPAIR IS CLASSIFIED AS MAJOR.

Part: FLOOR SUPPORT — CORRODED (FRAMES 86-89) · airframe 37,234 hrs · 24,081 cycles

DURING HEAVY MAINTENANCE, CORROSION FLOOR STRUCTURE BEAM FROM FR 86-FR 89 CENTER AFT GALLEY AREA. REPLACED NEW FLOOR BEAM AND FASTENERS LO ON FR 86-FR 89 CENTER AT AFT GALLEY AREA IAW \SRM 51-40-08 AND DRAWING 170-66-000-435.

Part: SKIN — CRACKED (RT WING) · airframe 37,234 hrs · 24,081 cycles

DURING HEAVY MAINTENANCE, REPORTED A 2 CRACKS ON THE RH WING REAR LOWER SKIN (P/N 190-33065-006) BETWEEN RIBS 10-11, AS SHOWN IN THE REF /1/ EA. THE DAMAGE WAS EVALUATED AGAINST THE SRM AND FOUND TO BE OUT OF LIMITS OF THE REF /3/ SRM. THEREFORE AEROMAN CONTACTED EMBRAER FOR REPAIR DISPOSITION. MANUFACTURER PROVIDED THE REF /2/ ETD WHICH PROVIDES INSTRUCTIONS TO CUT OUT THE CRACK AND OVERSIZE THE CRACKED HOLE TILL CRACK INDICATION DISAPPEARS, PERFORM NDT INSPECTIONS AND INSTALL A REPAIR DOUBLER. THE REF /2/ ETD IS A TIME LIMITED REPAIR REQUIRING A DETAILED STRUCTURAL ANALYSIS WITH 12 MONTHS. THIS EC PROVIDES THE TIME LIMITED REPAIR INSTRUCTIONS AND COMPLIES WITH REF /2/ ETD WITHOUT DEVIATION. THIS EC E19-359-01 PROVIDES THE PERMANENT REPAIR INSTRUCTIONS PER THE REF /2/ ETD. EC E19-359-02 PROVIDES A PLACEHOLDER TO TRACK THE FOLLOW UP ANALYSIS REQUIRED WITHIN 12 MONTHS; THIS TIME LIMITED REPAIR, REQUIRING FURTHER ANALYSIS WITHIN 12 MONTHS, HAS BEEN APPROVED VIA REF /2/ETD AND IS CLASSIFIED AS MAJOR.

Part: SHUTOFF VALVE — MALFUNCTIONED (BLEED SYSTEM) · airframe 37,083 hrs · 23,981 cycles

FT # 2267, BOS-CHS. DIVERTED TO JFK DUE TO ENG #1 BLEED FAIL AFTER TAKEOFF AND ENG2 BLEED IS ALREADY ON MEL 36-00-00A. BLEED 1 FAIL CAUTION MESSAGE ON CLIMB OUT. INITIALLY RESET BUT THEN FAILED AGAIN TWICE AT DIVERT TO JFK. ON DESCENT A-I WING FAIL AND ON LDG. BLEED 2 FAIL EVEN THOUGH IT WAS OFF.

Part: VALVE — FAILED (NR 1 BLEED) · airframe 37,083 hrs · 23,981 cycles

FT # 2267, BOS-CHS. DIVERTED TO JFK DUE TO ENG #1 BLEED FAIL AFTER TAKEOFF AND ENG2 BLEED IS ALREADY ON MEL 36-00-00A. BLEED 1 FAIL CAUTION MESSAGE ON CLIMB OUT. INITIALLY RESET BUT THEN FAILED AGAIN TWICE AT DIVERT TO JFK. ON DESCENT A-I WING FAIL AND ON LDG. BLEED 2 FAIL EVEN THOUGH IT WAS OFF.

Part: RELIEF VALVE — FAILED (FUEL SYSTEM) · airframe 36,369 hrs · 23,481 cycles

FLT 6211, JFK-SAL. RETURNED TO FIELD (JFK). FUEL LEAK CAUTION ON EICAS RAN QRH QRH AND VISIBLE INSPECTION CONFIRMED FUEL LEAK FROM RIGHT WING NACA VENT. NO EVIDENCE OF LEAK FROM ENGINE DRAIN MAST; PERFORMED TEST / INSPECT OF FLOAT VENT VALVE CHECK WAS NORMAL. REF TO AMM 28-12-05/401. REPLACED FUEL PRESSURE RELIEF VALVE AS REQUESTED. REF TO AMM 28-12-01. ALL GROUND OPS WERE NORMAL, LEAK CHECK OF FUEL ACCESS DOOR / PANEL OK.

Part: POWER UNIT — FAILED (CABIN) · airframe 35,496 hrs · 22,850 cycles

FLT 1446, CLT-BOS. EXTERIOR LT CENTER EMERGENCY LIGHT INOP. R&R EMERGENCY LIGHT POWER UNIT IAW AMM 33-50-01. OPS CHECK GOOD.

Part: POWER SUPPLY — FAILED (EMERGENCY LIGHT) · airframe 34,821 hrs · 22,362 cycles

LOWER RT EMERGENCY LIGHT WAS INOPERATIVE. REMOVED & REPLACED THE POWER SUPPLY IAW AMM 33-50-01. OPS CHECKED NORMAL.

Part: POWER SUPPLY — FAILED (EMERGENCY LIGHT) · airframe 34,821 hrs · 22,362 cycles

LOWER RT EMERGENCY LIGHT WAS INOPERATIVE. REMOVED & REPLACED THE POWER SUPPLY IAW AMM 33-50-01. OPS CHECKED NORMAL.

Part: BATTERY PACK — FAILED (EMERGENCY LIGHT) · airframe 34,222 hrs · 21,912 cycles

OVERHEAD CEILING EMERGENCY LIGHT INOPERATIVE. R & R THE BATTERY PACK IAW AMM 33-50-01. OPS CHECKED GOOD.

Part: BATTERY PACK — FAILED (EMERGENCY LIGHT) · airframe 34,223 hrs · 21,913 cycles

COCKPIT EMERGENCY LIGHT INOPERATIVE. R & R THE BATTERY PACK IAW AMM 33-50-01.

Part: CONNECTOR — UNSECURE (EMERGENCY LIGHTS) · airframe 31,487 hrs · 19,945 cycles

FOUND THE LT AND RT OVERWING EMERGENCY EXIT SIGNS INOPERATIVE. INSPECTED EMERGENCY EXIT DOOR LINER AND FOUND LOOSE CONNECTORS AND SECURED IAW SCHEMATIC DIAGRAM 33-50-80. OPS CHECKED GOOD. NO OTHER DEFECTS NOTED AT THIS TIME.

Part: SEAL REST — CORRODED (FRAME 77) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON AFT CARGO DOOR LWR CUT OUT SEAL REST, FRAME 77+14. BLENDED CORROSION BEYOND LIMITS IAW SRM 51-10-03.

Part: FLOOR SUPPORT — CORRODED (FRAME 18) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON FWD GALLEY FLOOR SUPPORT AT FRAME 18, RBL 10. THE CORROSION WAS BLENDED OUT BEYOND LIMITS. REPLACED THE FLOOR SUPPORT IAW SRM 51-41-02.

Part: SEAL REST — CORRODED (FRAME 78) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON AFT CARGO DOOR LOWER CUT OUT SEAL REST AT FRAME 78 + 14. BLENDED BEYOND LIMITS IAW SRM 51-10-03.

Part: FLOORBEAM — CORRODED (FRAME 84) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON THE FLOORBEAM AT FRAME 84, LBL 11.5. BLENDED THE CORROSION IAW SRM 51-10-03 AND FOUND TO BE OUT OF LIMITS IAW SRM 53-23-10. FABRICATED SPLICE ANGLES IAW SRM 53-00-10. LOCATED, DRILLED, & INSTALLED SPLICE ANGLES AND EXTRUSION IAW SRM 53-00-10.

Part: FLOORBEAM — CORRODED (FRAME 84) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON FLOORBEAM FRAME 84, LBL 11.5. CORROSION BEYOND LIMITS.

Part: FITTING — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON AFT CARGO SHEAR CLIP CORR FR72 STR 28L. RPL SHEAR CLIP FR72 SRM 51-41-01, 5140-02.

Part: STRUCTURE — CORRODED (FRAMES 88-89) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED AT WASTE SERVICE BOX FWD IN BD CORNER, FRAMES 88 - 89, STRINGER 28R. REPAIRED THE WASTE SERVICE DOOR IAW SRM 51-43-04, AND SRM 51-12-01.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON CABIN SEAT TRACK CORR FR17 +5" RBLK 10.5"; C/W EC E17-204-01. EC E17-204-01, FUSELAGE/FWD FUSELAGE/SEAT TRACK AT FR17 RBL 10-CORROSION DAMAGE/PERMANENT REPAIR.

Part: FLOOR SUPPORT — CORRODED (FRAME 19) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON RH CABIN FLOOR SUPPORT FRAME 19 +14. BLENDED CORROSION IAW SRM 51-10-03 BEYOND LIMITS.

Part: SEAT TRACK — CORRODED (FRAME 17) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON THE CABIN SEAT TRACK FRAME17, RBL 10.5. REPAIRED IAW EC E17-204-01.

Part: FLOOR SUPPORT — CORRODED (FRAME 90) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON FLOOR SUPPORT SPLICE AT FRAME 90, LBL 4.25. REPLACED THE FLOOR SUPPORT SPLICE IAW SRM 51-43-03.

Part: FLOOR SUPPORT — CORRODED (FRAME 88) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON FLOOR SUPPORT FRAME 88 + 9, LBL 38.75. BLENDED CORROSION IAW SRM 51-10-03.

Part: FLOOR SUPPORT — CORRODED · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON THE FLOOR SUPPORT FRAMES 19 +4 AND 19 + 9. BLENDED CORROSION IAW SRM 51-10-03, FOUND BEYOND LIMITS.

Part: SHEAR TIE — CORRODED (FRAME 73) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON AFT CARGO SHEAR TIE AT FRAME 73, STRINGER 27L. REMOVED AND REPLACED IAW SRM 51-41-01.

Part: SEAL REST — CORRODED (CARGO DOOR) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON AFT CARGO DOOR LOWER CUT OUT SEAL REST. REPLACED THE AFT CARGO DOOR SEAL REST IAW SRM 51-41-01, AND 53-23-29.

Part: FLOOR SUPPORT — CORRODED (FRAME 17) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON CABIN FLOOR SUPPORT AT FRAME 17, RBL 49. REMOVED AND REPLACED THE FLOOR SUPPORT IAW SRM 51-41-02.

Part: FLOORBEAM — CORRODED (FRAME 16) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON THE CABIN FLOORBEAM AT FRAME 16, LBL 10 TO 12.3. REMOVED THE CORROSION AND FOUND OUT OF LIMITS. REMOVED, DRILLED, AND INSTALLED A NEW FLOORBEAM IAW SRM 51-43-03, 51-43-04, 51-40-02, 51-23-04, 51-23-05, AND 51-23-06.

Part: SPLICE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON FLOOR STRUCTURE SPLICE FR90 RBL 22.5"; C/W EC E17-202-1. EC E17-202-1, FUSELAGE/FWD FUSELAGE/FLOOR SUPPORT CORROSION/PERMANENT REPAIR.

Part: BEAM — CORRODED (FRAME 85) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON L2 DOOR CUT OUT, FR AME 85 +2.5 INCHES, ADJACENT TO FWD SIDE OF GIRT BAR FITTING, O/B BOLT HOLE, SILL PLATE HAS CORROSION. BLENDED AREA IAW SRM 51-10-03. FOUND TO BE OUT OF LIMITS IAW SRM 53-23-11. INSTALLED NEW SILL BEAM, CENTER AND CORNER SEAL RESTS AND TWO GIRT BAR FITTINGS IAW SRM 51-43-01, 51-43-02, 51-43-03, 51-43-04 AND AMM 20-10-01. RESPECTIVELY. APPLIED TOUCH UP TO FASTENERS IAW SRM 51-23-05, 51-23-06. INSTALLED NUT PLATES IAW SRM 51-45-00.

Part: FLOOR SUPPORT — CORRODED (FRAME 89) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON FLOOR SUPPORT AT FRAME 89 +14.5. THE CORROSION WAS BLENDED OUT BEYOND LIMITS REPLACED THE FLOOR SUPPORT IAW SRM 51-43-01, 51-41-01, AND 51-42-02.

Part: FLOORBEAM — CORRODED (FRAME 19) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON RT CABIN FLOORBEAM FRAME 19, RBL 49. BLENDED CORROSION IAW SRM 51-10-03, FOUND TO BE BEYOND LIMITS.

Part: CROSSBEAM — CORRODED (FRAME 90) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON CROSSBEAM AT FRAME 90, LBL 14. REMOVED CORROSION AND FOUND TO BE OUT OF LIMITS IAW SRM 51-12-01, AND SRM 53-23-10. FABRICATED DOUBLER IAW SRM 53-23-10. HEAT TREATED IAW SM NE 40-002. LOCATED, DRILLED DOUBLER IAW SRM 51-41-02. TREATED, PRIMED, AND TOP COATED IAW SRM 51-23-04, 51-23-05, 51-23-06. INSTALLED IAW SRM 53-23-10.

Part: FLOORBEAM — CORRODED (FRAME 88) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON FLOORBEAM ANGLE FRAME 88 + 11.75, LBL 37.5, BLENDED AND FOUND BEYOND LIMITS IAW SRM 51-10-03.

Part: SEAT TRACK — CORRODED (FRAME 17) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON THE MAIN CABIN SEAT TRACK AT FRAME 17, RBL 10.5. REPAIRED IAW EC E17-204-01. EC E17-204-01.

Part: SEAL REST — CORRODED (FRAME 78) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON THE AFT CARGO DOOR LOWER CUT OUT SEAL REST AT FRAME78. BLENDED CORROSION BEYOND LIMITS IAW SRM 51-10-03.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON UNDERSIDE FASTENER HOLE FLOORBEAM CORR FR 87+14" STGR 16+7, LBL 11.25. RPR PER SRM 53-23-10.

Part: SEAL REST — CORRODED (FRAME 78) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

CORROSION WAS DISCOVERED ON AFT CARGO DOOR LOWER CUT OUT SEAL REST AT FRAME 78. BLENDED BEYOND LIMITS IAW SRM 51-10-03.

Part: DOOR SILL — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON MAIN DOOR FWD FLOOR SILL FR16. COMPLIED WITH EC E17-201-01. EC E17-201-01, FUSELAGE/FWD FUSELAGE/FWD FUSELAGE STRUCTURE SILL/CORROSION DAMAGE - PERMANENT REPAIR.

Part: FLOORBEAM — CORRODED (FRAME 17) · corrosion level 2 · airframe 31,393 hrs · 19,873 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON RH CABIN FLOORBEAM FRAME 17 RBL 38.3. BLENDED CORROSION IAW SRM 51-10-03 BEYOND LIMITS PART REPLACED.

Part: BATTERY PACK — FAILED (EMERGENCY LIGHTS) · airframe 30,756 hrs · 19,464 cycles

DURING MAINTENANCE, THE LEFT EXTERNAL EMERGENCY LIGHT AT MIDDLE POSITION WAS FOUND TO BE INOPERATIVE. R & R EPSU BATTERY IAW AMM 33-50-01. OPS CHECK PASSED.

Part: SHEAR TIE — CORRODED (FRAME 17) · corrosion level 2 · airframe 30,661 hrs · 19,398 cycles

DURING ROUTINE MAINTENANCE, CORROSION WAS DISCOVERED ON FWD CARGO SHEAR TIE AT FRAME 17 BETWEEN STRINGERS 27 TO 28R. REMOVED AND REPLACED THE SHEAR TIE IAW SRM 51-41-01 AND 51-41-02.

Part: SHEAR TIE — CORRODED (FRAME 17) · corrosion level 2 · airframe 30,661 hrs · 19,398 cycles

DURING ROUTINE MAINTENANCE, CORROSION WAS DISCOVERED ON THE FWD CARGO SHEAR TIE AT FRAME 17 BETWEEN STRINGERS 27 TO 28L. REMOVED AND REPLACED THE SHEAR TIE IAW SRM 51-41-01 AND 51-41-02.

Part: SHEAR TIE — CORRODED (FRAME 17) · corrosion level 2 · airframe 30,661 hrs · 19,398 cycles

DURING ROUTINE MAINTENANCE, CORROSION WAS DISCOVERED ON SHEAR TIE ON FRAME 17 BETWEEN STRINGERS 26 AND 27R. REMOVED AND REPLACED THE SHEAR TIE IAW SRM 51-41-01 AND 51-41-02.

Part: SHEAR TIE — CORRODED (FRAME 17) · corrosion level 2 · airframe 30,661 hrs · 19,398 cycles

DURING ROUTINE MAINTENANCE, CORROSION WAS DISCOVERED ON SHEAR TIE AT FRAME 17 BETWEEN STRINGERS 25 AND 26R. REMOVED AND REPLACED THE SHEAR TIE IAW SRM 51-41-01, AND 51-41-02.

Part: SHEAR TIE — CORRODED (FRAME 16) · corrosion level 2 · airframe 30,661 hrs · 19,398 cycles

DURING ROUTINE MAINTENANCE, CORROSION WAS DISCOVERED ON FWD CARGO SHEAR TIE AT FRAME 16 BETWEEN STRINGERS 27 TO 28L. REMOVED AND REPLACED THE SHEAR TIE IAW SRM 51-41-01 AND 51-41-02.

Part: SHEAR TIE — CORRODED (FRAME 16) · corrosion level 2 · airframe 30,661 hrs · 19,398 cycles

DURING ROUTINE MAINTENANCE, CORROSION WAS DISCOVERED ON FWD CARGO SHEAR TIE AT FRAME 16 BETWEEN STRINGERS 27 TO 28R. REMOVED AND REPLACED THE SHEAR TIE IAW SRM 51-41-01 AND 51-41-02.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 29,862 hrs · 18,805 cycles

EMERGENCY DECLARED, WHILE DESCENDING INTO DESTINATION AT ABOUT 16000 FT, CREW RECEIVED 2 EICAS MESSAGES. PITCH CONTROL DISC AND AUTO PILOT FAIL. AN EMERGENCY WAS DECLARED INTO DESTINATION. ACFT LANDED UNEVENTFULLY, NO FAULTS FOUND. TRANSITORY CONDITION.

Part: WIRE HARNESS — DAMAGED (NR 1 ENGINE) · airframe 29,441 hrs · 18,472 cycles

AIR RETURN. PILOT REPORTED ENGINE NR 1 HAS A N-1 VIBRATION OF 4.0 AMBER THROUGH FL 270. FLUCTUATED BETWEEN 3.4-4.0 IN CLIMB TO FL360. AT FL360 ENGINE VIBE 4.0 AMBER AN NOT ABLE TO REDUCE VIBE WITH THRUST LEVER CHANGE. LP VIBE SPIKE. HP VIBE NORMAL.; FOUND W9B HARNESS ON NR 1 ENGINE TO BE DAMAGED. R & R W9B HARNESS. PERFORMED ENGINE VIB CHECK IAW EMM 72-00-00 TESTING 003 LP VIBES FOUND TO BE AT 1.0 UNITS, HP AT 1.6 UNITS. BOTH WITHIN LIMITS. ACFT OK FOR CONTINUED SERVICE AT THIS TIME.

Part: SENSOR — FAILED (SLAT FLAP SYS) · airframe 28,370 hrs · 17,763 cycles

DIVERTED, FLAP LOW RATE MESSAGE DURING DESCENT, SLAT/FLAP ELECTRICAL SYSTEM. R & R SKEW SENSORS LT WING T3 + T4 CLEARING THIS MDDR. MX-4 UPDATED.

Part: SENSOR — FAILED (SLAT FLAP SYS) · airframe 28,370 hrs · 17,763 cycles

DIVERTED, FLAP LOW RATE MESSAGE DURING DESCENT, SLAT/FLAP ELECTRICAL SYSTEM. R & R SKEW SENSORS LT WING T3 + T4 CLEARING THIS MDDR. MX-4 UPDATED.

Part: FADEC — INOPERATIVE (NR 1) · airframe 28,034 hrs · 17,550 cycles

FLIGHT RETURNED TO GATE. ENGINE NR 1 FAIL ON TAXI OUT. R & R 1 ENGINE FADEC. OPS CHECK GOOD. RAN NR 1 ENGINE 2 TIMES. NO DEFECTS NOTED. OK FOR SERVICE

Part: BLEED VALVE — FAILED (NR 1 ENGINE) · airframe 25,725 hrs · 15,996 cycles

NR 1 BLEED FAILED IN ICING CONDITION THEN ANTI-ICE FAILED. R & R HIGH STAGE BLEED VALVE ON NR 1 ENGINE IAW AMM 36-11-01. R & R NR 1 ENGINE NAPRSOV IAW AMM 36-11-03, ALL OPS CHECK GOOD. MFG, NAPRSOV, PN 1013952-1, SN 2011100012, TAT 2186, TAC 1412, TIME SINCE 2186. BLEED NR 2 IS CURRENTLY ON MEL.

Part: LATCH — FAILED (COCKPIT DOOR) · airframe 20,019 hrs · 12,313 cycles

FLT 976 FLL-BOS, COCKPIT DOOR LOCK INOP, LOCK WILL NOT RELEASE AFTER CLOSED. ADJUSTED COCKPIT DOOR PER AMM 52-51-01 AND REMOVED AND REPLACED ELECTRO MECHANICAL LATCH PER AMM 52-51-03. OPS CHECK OK.

Part: DISPLAY — FAILED (COCKPIT) · airframe 19,096 hrs · 11,780 cycles

FLT 1218 BUF-BOS, AIR RETURN TO BUF DUE TO MFD NR 1 / DU NR 2 WENT BLANK AFTER TAKEOFF. PERFORMED QRH 8-16 MFD OVERHEAT PROCEDURE. FOUND DU NR 2 INOP. REPLACED DISPLAY UNIT PER AMM 31-61-04. OPS CHECK NORMAL.

Part: A/C PACK — CONTAMINATED (AC BAY) · airframe 17,944 hrs · 11,070 cycles

FLT 52 MCO-JFK, CREW DECLARED EMERGENCY AND AIR RETURN TO MCO DUE TO STRONG SMELL NOTICED THROUGHOUT CABIN AND COCKPIT. F/A CALLED AND NOTED IT AS WELL. NO SMOKE BUT STRONG ODOR. ACCOMPLISHED FIM TASK 21-20-00-810-801A FOR ABNORMAL SMELL IN CABIN / COCKPIT FOUND EVIDENCE OF COFFEE GRIND INGESTION ON PACK INLET. PERFORMED DUAL HEAT EXCHANGER CLEANING PER AMM 21-51-04. PERFORMED OPS CHECK OF AIRCRAFT PACKS 1 AND 2 PER AMM 21-51-00-710 NO ODORS DETECTED. RAN ENGINES 1 AND 2 PER AMM 71-00-01 NO ABNORMAL SMELLS / ODORS DETECTED.

Part: LOOP — CONTAMINATED (NR I ENGINE) · airframe 15,971 hrs · 9,838 cycles

FLT 1126 FLL- RDU HAD AN AIR RETURN TO FLL, DURING CLIMB, BLEED 1 LEAK EICAS COMPLIED WITH QRH. REMOVED AND REPLACED CERAMIC PIN INSERT AT P2145 ENG NR 1 LOOP 3 IAW AMM 36-20-01. REMOVED CONTAMINATION AT P2145. OPS CHECK GOOD. NO DEFECTS NOTED.

Part: FIRE LOOP — OUT OF POSITION (ENGINE) · airframe 15,972 hrs · 9,839 cycles

FLT 1799 FLL-SDQ, 2ND AIR RETURN TO FLL- BLEED LEAK AT 31,000 QRH PERFORMED. FOUND LOOPS 3 CHANNEL 1 AND 2 ZONE 16 ROUTED AND TOUCHING FIRE RETARDANT TUBING, RE-ROUTED FIRE LOOP 3 ENG NR 1 CHANNEL 1 AND 2 TO CORRECT CONFIGURATION IAW AMM 36-22-01. LOOP 3 NOT DAMAGED, FOUND OVERHEAT DETECTION SYSTEM LOOP 3 BITE CHECK GOOD. ACCOMPLISHED THRUST ASSURANCE TEST GOOD, BLEED NR 1 CHECK GOOD IAW EMM 72-00-00, NO DEFECTS NOTED.

Part: PRECOOLER — LEAKING (BLEED AIR SYS) · airframe 15,259 hrs · 9,336 cycles

FLT 917 JFK-ORD, CREW DECLARED EMERGENCY AND AIRCRAFT RETURN BACK TO JFK DUE TO BLEED 2 FAIL FOLLOWED BY BLEED 1 LEAK DURING CLIMBOUT. ACCOMPLISHED TSM FOR BLEED 2 FAIL, REMOVED AND REPLACED NR 1 ENGINE PRECOOLER AS PER AMM 36-11-08 DUE FOUND LEAKING. OPS AND LEAK CHECK OK.

Part: ACM — FAILED (NR 2) · airframe 14,768 hrs · 9,050 cycles

FLT 688 DCA-BOS, A/C DIVERTED TO IAD DUE TO STRONG SMELL OF FUMES IN CABIN ON TAKEOFF. PERFORMED FIM TASK 21-20-00-810-801-A FOR SMOKE SMELL IN THE CABIN / COCKPIT. PACK 2 FAILED DURING OPS CHECK GENERATING REPORTED SMOKE / SMELL. PACK 2 FAIL CAUTION MESSAGE W/ PACK 2 OFF ADVISORY MESSAGE DISPLAYED ON EICAS. CMC FAULT CODE 21516700AM2 CONFIRMS ACM NR 2 FAILURE. REMOVED AND REPLACED NR 2 PACK ACM. OPS CHECK GOOD.

Part: PIN — CORRODED (BLEED AIR SYS) · airframe 12,032 hrs · 7,402 cycles

FLT JB1328 BWI-BOS DIVERTED TO JFK, AT FL 270 BLEED 2 LEAK CAUTION MESSAGE ON EICAS. FOLLOWED QRH PROCEDURE MESSAGE CLEARED AFTER 1 MINUTE (END OF PROCEDURE), AT APPROX 5 MINUTES BLEED 2 LEAK CAUTION APPEARED. FOLLOWED QRH PROCEDURE ISOLATING OPPOSITE SIDE BLEED AND APU BLEED. DESCENDED TO 10000 FT PRESSURIZATION DUMP BUTTON (PUSHED IN) BLEED 2 LEAKED PERSISTED, DECLARED EMERGENCY DIVERTED TO JFK. MESSAGE CLEARED ON APPROACH AT LOWER THRUST SETTING. RE-APPEARED AFTER LANDING, LANDED 22R SHUTDOWN ENGINE NR 2, BLEED LEAK 2 MESSAGE CLEARED. MX T/S CMC ACTIVE MESSAGES SHOW ODS PACK LOOPS RT BLD C1&C2 MESSAGE'S. PERFORMED FIM 36-21-00-810-802-A, PERFORMED VISUAL INSPECTION OF BLEED DUCTS RUNNING ALONG LOOP 5, NO DEFECTS FOUND. BLEED OVERHEAT LOCATION WAS AT 6.25 ON CH2 & AS A BLEED 2 SHORT CONDITION AND 41.55 ON CH 1 AS A BLEED 2 OPEN CONDITION. REMOVED AND REPLACED CERAMIC PINS AT CONNECTORS P2146 & J 2348 DUE TO CORROSION PER AMM 36-20-01, PERFORMED AMS RESET AND ODS BIT PER AMM 45-45-00, FAULT CLEARED RAN NR 2 ENGINE NO MESSAGES. A/C RETURNED TO SERVICE.

Part: BATTERY — SHORTED (CABIN) · airframe 11,714 hrs · 7,200 cycles

FLT 1084 CLT-JFK, DURING JFK MX WEEKLY CHECK RIGHT NR 2 SERVICE ENTRY DOOR EMERGENCY EXIT MARKER PASSAGEWAY LIGHT INOP. FOUND THAT THE EXIT MARKER LIGHT SHORTED OUT THE POWER SUPPLY BATTERY UNIT. REMOVED AND REPLACED EMERGENCY POWER UNIT NR 6 AND EXIT MARKER LIGHT IAW AMM 33-50-01 AND 33-50-17, OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE.

Part: VALVE — FAILED (FLOW CONTROL) · airframe 11,178 hrs · 6,857 cycles

FLT JB1424 - DURING CRUISE AT 36,000 FT CABIN ROSE TO 8800 FT IN AUTO MODE, SWITCHED TO MANUAL AND DESCENDED TO 34000. CABIN ALTITUDE DESCENDED BELOW 8000 FT & SELECTOR WAS RETURNED TO AUTO, ENTIRE SEQUENCE REPEATED AT 34000 & 32000 FT. NORMALLY BOTH CHANNELS OF CPC & MANUAL MODE DID NOT RESPOND TO OUTFLOW VALVE INDICATION ON MFD WAS FULL CLOSED AT ALL TIMES. PER ENGINEERING, MX R & R NR 2 PACK FLOW CONTROL VALVE IAW AMM 21-51-01, OPS CHECK GOOD. R & R PACK NR 2 OUTLET TEMP SENSOR IAW AMM 21-51-18/401. ACCOMPLISHED BLEED SUPPLY ADJUST TEST IAW 36-11-00-05, NO FAULTS NOTED. AS PER ENGINEERING, INSPECTED RT BLEED PRESSURE SENSOR TUBE & FOUND MOISTURE INSIDE. CLEANED TUBE, CLEARED PACK NR 2 MDDR 68919. ACFT RETURNED TO SERVICE.

Part: POWER UNIT — FAILED (CABIN) · airframe 11,132 hrs · 6,830 cycles

FLT 1218 - BUF-BOS "EMERGENCY LIGHT BATTERY FAULT" EICAS MESSAGE AT AIRCRAFT POWERUP. REMOVED AND REPLACED NR 5 AND NR 6 EMERGENCY LIGHT POWER UNITS IAW AMM 33-50-00. OPS CHECK OK.

Part: PLUG — CONTAMINATED (NR 1 & 2 ENGINES) · airframe 9,931 hrs · 6,158 cycles

AFTER T/O AND THRUST APPLICATION STRONG ODOR SMELLED IN COCKPIT AND CABIN (SIMILAR TO WAXY BURNT OIL OR SOAPY MISTY SMELL). DECLARED EMERGENCY, APPLIED QRH PROCEDURE. FUMES E3 RETURNED TO KFLL, IFE CK SELECTED. AS PER FIM 212000810801A PERFORMED DETAILED VISUAL INSPECTION OF NR 1 AND NR 2 ENGINES FOUND EXCESSIVE AMOUNT OF ANTI SEIZE COMPOUND AROUND BORO PLUGS ON NR 1 ENG COMPOUND WAS BURNT CAKED ON AND CREW MEMBER VERIFIED SMELL TO BE THAT FOUND IN COCKPIT AND CABIN. CLEANED AREA AND VERIFIED ODOR ONLY PRESENT DURING NR 1 ENG HIGH POWER OPERATION. NO ODOR PRESENT AT NR 2 ENGINE HIGH POWER OPERATION. HIGH POWER ENG RUN PERFORMED AS PER ESM 720000 ALL OTHER ENG OPS NORMAL. A DEFERRED ITEM "ENG 1 BLEED INOP DUE TO ODOR FROM ANTI-SEIZE USED IN ENGINE" WAS ENTERED. THE DEFERRED ITEM WAS CORRECTED, TROUBLESHOOT PER FIM 21-20-00-810-806, RAN NR 1 ENG, NO FAULTS. AIRCRAFT OK FOR SERVICE.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 4,564 hrs · 3,140 cycles

FLT 1094, CMH TO JFK. FLAP FAIL EICAS AT FL310. LDG WITH FLAPS 0. PERFORMED FIM TASK 27-51-00-810-802A. CLEARED FAULTS. PERFORMED OPERATIONAL CHECKS SEVERAL TIMES AND NO FAULTS FOUND AT THIS TIME. ALL OKAY FOR SERVICE.

Part: WIRE HARNESS — DAMAGED (NR 2 SLAT) · airframe 3,256 hrs · 2,288 cycles

AT 1500 FT FLAPS SELECTED 5. SLATS TRAVELLED TO FULL ON EICAS WHILE FLAPS INDICATED SOMEWHERE BETWEEN 1/2 AND FULL. EXECUTED QRH CHECKLIST. AFTER CHECKLIST COMPLETED, SLATS INDICATED FULL WHILE FLAPS WERE AT 5. NORMAL LANDING. FOUND SLAT NR 2 HARNESS W611 ON RIGHT WING DAMAGED. REMOVED AND REPLACED HARNESS IAW W611 27-83-07-400-801A. OPS CHECK NORMAL & WING THERMAL ANTI-ICE, OPS NORMAL.

Part: BLEED VALVE — FAILED (NR 2 ENGINE) · airframe 2,552 hrs · 1,805 cycles

NR 2 OVERPRESSURE BLEED WOULD NOT EXTINGUISH. REMOVED AND REPLACED HIGH STAGE BLEED VALVE IAW AMM 36-11-01. HI POWER RUN-UP OPS CHECK OK.

Part: SHUTOFF VALVE — UNKNOWN (NR 2 ENGINE) · airframe 1,073 hrs · 789 cycles

AUS TO JFK DIVERTED TO MSY. BLEED 1 FAIL, BLEED 1 OVERPRESSURE, BLEED 1 LEAK, AFTER TAKEOFF ALL 3 CLEARED AFTER APPLYING QRH PROCEDURES. BLEED 2 LEAK, AFTER TAKEOFF. REMOVED AND REPLACED NR 2 ENG NAPRSOV VALVE IAW AMM 36-11-01, LEAK CHECK OK, OPS CHECK NORM IAW AMM 36-11-00-710-801-A. NO FAULTS NOTED.

Part: PUMP — LEAKING (NR 2 ENG AGB) · airframe 954 hrs · 711 cycles

HYD 2 LOW QTY EICAS DURING CRUISE AT 390. FOUND NR 2 EDP LEAKING. REMOVED AND REPLACED NR 2 EDP IAW AMM 29-11-01. OPS CHECK AND LEAK CHECK GOOD.