N189FE

Part: A/C PACK — CONTAMINATED · airframe 1,752 hrs · 880 cycles

DURING PUSH BACK, MAIN CARGO FIRE WARNING ON FLT DECK AND MX CAME IN TO THE A/C TO INVESTIGATE & NOTICED LOW LINE FOG THROUGH OUT THE MAIN CARGO DECK W/ NO ODOR. PRIOR PUSH BACK, WE WERE DEICED & WAITED ATLEAST 1 MIN BEFORE PACKS WERE TURNED ON. INSPECTED MAIN DECK CARGO COMPARTMENT, VERIFIED NO EVIDENCE OF FIRE ON BOARD. DETERMINED DE-ICE FLUID WAS INGESTED INTO PAC SYSTEM. ACCOMPLISHED AMM 21-00-21-2 AIR CONDITIONING SYSTEM OIL SMOKE/FUME CONTAMINATION (REMOVAL) - MAINTENANCE PRACTICES AS REQUIRED. AIRCRAFT CHECKS GOOD, OK FOR CONTINUED SERVICE.

Part: DOOR — OBSTRUCTED (CARGO BAY) · airframe 67,286 hrs · 50,290 cycles

ON DEPARTURE, FORWARD CARGO DOOR LIGHT ILLUMINATED, COULD NOT PRESSURIZE AIRCRAFT, RETURNED TO MEM. FOUND DOOR LATCH HANDLE STOWED, DOOR CL0SED BUT NOT LOCKED OVER CENTER. ALSO, FOUND BUNGEE STUCK IN DOOR LATCH MECHANISM ON FWD SIDE OF DOOR. OPENED DOOR, PULLED HANDLE OUT, ROTATED LOCKED. OK FOR SVC DOOR OPERATES NORMALLY.

Part: FAN — MALFUNCTIONED (AIR DISTRIBUTION) · airframe 66,545 hrs · 49,585 cycles

ACRID BURNING ODOR WHEN GASPER FAN IS TURNED ON. MAINTENANCE WAS NOTIFIED AND NOTICED AN UNUSUAL SOUND WHEN GASPER FAN WAS TURNED ON. REMOVED AND REPLACED GASPER FAN, OPS CHECK GOOD PER 727-100 MM 21-23-011-4.

Part: CONTROL UNIT — FAILED (CARGO FIRE DETEC) · airframe 66,238 hrs · 49,268 cycles

DURING TAXI INTO IND, LWR AFT CARGO SMOKE ALARM ACTIVATED WITH AFT SMOKE LIGHT AND ARMED LIGHT. PERFORMED CHECKLIST ITEMS, INCLUDING DISCHARGE OF BOTH BOTTLES. NO OTHER INDICATIONS OF SMOKE OR FIRE; SYS TEST INDICATES FAULT IN AFT SYSTEM. REMOVED AND REPLACED LWR AFT CARGO COMP CEU IAW 26-16-012-2. SYSTEM NOW OPERATES NORMAL.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 66,177 hrs · 49,202 cycles

AFT CARGO COMPARTMENT, STA 1070 TO 1090, STRINGER 29R IS CORRODED. REMOVED AND REPLACED STRINGER SECTION IAW SRM.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 66,177 hrs · 49,202 cycles

LOWER FUSELAGE, STRINGER 21R, IS CRACKED AT STA 400.

Part: LAP JOINT — BULGED (FUSELAGE) · corrosion level 2 · airframe 66,177 hrs · 49,202 cycles

FUSELAGE SKIN BETWEEN STA 595 AND 620 ALONG STR 14R SKIN LAP JOINT IS BULGING AT RIVETS. REPAIRED IAW EA.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 66,177 hrs · 49,202 cycles

LOWER FUSELAGE, STRINGER 21R, IS CRACKED AT STA 400. REMOVED DAMAGED SECTION OF STRINGER FROM STATION 390-410 AND REPLACED IAW SRM.

Part: SWITCH — FAILED (CARGO DOOR) · airframe 66,054 hrs · 49,100 cycles

AIRPLANE DIVERTED TO TPA. MAIN CARGO DOOR WARNING ON S/O'S ANNUNCIATOR CAME ON IN FLIGHT. REPLACED LOCK BAR CLOSED SWITCH PER M/M 52-34-009-5. OPS CHECK OK.

Part: ACTUATOR — FAILED (L/E FLAP)

LEADING EDGE FLAP LIGHT CAME ON AT 10L FT WITH FLAPS UP. REMOVED AND REPLACED NR 2 & 6 SLAT ACTUATORS PER MM 27-81-032-4.

Part: ENGINE — FAULTY (NR 3)

ENGINE FIRE NR 3 AFT T/O AT 100 FT. FIRED BOTH BOTTLES. *S/D* REMOVED AND REPLACED NR 3 ENG PER WORK CARD 70T0501-03. OK FOR SERVICE.

Part: PUMP — FAILED (NR 1 ENGINE)

ON T/O NR 1 ENG SHUTDOWN. ENG MET ALL RESTART PREM. REMOVED AND REPLACED NR 1 ENG FUEL CONTROL UNIT AND FUEL PUMP PER JRH, LEAK CK GOOD. OK FOR SERVICE.

Part: WARNING SYSTEM — ACTIVATED (CABIN PRESSURE)

DURING CLIMBOUT ALTITUDE WARN WENT OFF. PERFORMED AIR CONDITIONING AND PRESSURIZATION OPERATION TEST. CHECKED GOOD TWO TIMES. AC OK FOR SERVICE PER B727 JET RUN HANDBOOK 7-13.

Part: ANNUNCIATOR — INOPERATIVE (COCKPIT)

GREEN NOSE GEAR DOWN AND LOCKED IND INOP ON EXTENSION. RED TABS COMPLETED WITH NO JOY. NORMAL LANDING. *S/D* REMOVED AND REPLACED PER WIRING DIAGRAM 32-64-01 & 32-64 PG 4. REMOVED AND REPLACED GEAR WARNING ANNUNCIATOR PNL, OPS CK NORM PER 727-100 MM 32-61-21. OK FOR SERVICE.

Part: STRUCTURE — CORRODED (NR 6 LE FLAP) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, NR 6 LEAD EDGE FLAP CORRODED BEYOND ALLOWED LIMITS ON THE OUTER SURFACE. REMOVED AND REPLACED PER IAW MM 27-81-1. OPS CK GOOD IAW MM 27-81-1.

Part: BATTERY PACK — CRACKED (ESCAPE SLIDE) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, FWD ENTRY DOOR ESCAPE SLIDE LIGHT BATTERY PACK FOUND CRACKED. REMOVED AND REPLACED PER IAW MM 33-50-112.

Part: WEB — CRACKED (LT WING) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, WEB AT LEFT WING LEAD EDGE BS 920 FOUND CRACKED ADJACENT TO BOTTLE BOLT. REMOVED AND REPLACED PER IAW SRM 51-40-2.

Part: RIB — CRACKED (NR 4 LE SLAT) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, NR 4 LEAD EDGE SLAT FOUND CRACKED AT I/B ACTUATOR ATTACH RIB. STOP DRILL, FAB AND INSTALLED PER IAW SRM 51-40-3 & SRM 51-30-2.

Part: COVER — CRACKED (ESCAPE SLIDE) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, FWD ENTRY DOOR EMERGENCY ESCAPE SLIDE LWR CASE FOUND CRACKED AT BOTH SIDES OF STOW HOOKS. REMOVED AND REPLACED WELD PER IAW BAC 5975, MM 25-60-13.

Part: WINDOW POST — CRACKED (COCKPIT) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, RT E-N WINDOW POST FOUND CRACKED. REPAIRED E-N WINDOW POST IAW FEDEX EO 7-5330-7-3354, PT 5.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, FWD ENTRY DOOR EMERGENCY EXIT LIGHT FOUND INOP WHEN SWITCH IS IN THE ARM POSITION. REMOVED AND REPLACED PER IAW MM 33-50-1.

Part: RIB — CRACKED (NR 5 SLAT) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, THE NR 5 LEAD EDGE SLAT FOUND CRACKED AT O/B ACTUATOR ATTACH RIB. STOP DRILLED CRACK, FAB REPAIR, AND INSTALLED IAW SRM 51-40-3 & SRM 51-30-2.

Part: HEAT SHIELD — CRACKED (NR 3 ENGINE) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTION, NR 3 ENGINE PRE-COOLER HEAT SHIELD FOUND CRACKED ON UPPER I/B SIDE. STOP DRILLED CRACK, FAB, AND INSTALLED PER IAW SRM 51-40-2.

Part: PRESSURE PANEL — CRACKED (RT MLG WW) · airframe 64,789 hrs · 48,105 cycles

DURING ROUTINE INSPECTON, RIGHT WHEEL WELL FOUND CRACKED AT I/B WEB AT BS 920. REMOVED AND REPLACED PER IAW SRM 51-40-2.

Part: TRANSMITTER — FAILED (RT TE FLAP)

99-121 - ON ROTATION, STICK SHAKER ACTUATED, 2ND REPEAT WRITE UP. REMOVED AND REPLACED RIGHT INBD FLAP TRANSMITTER PER MM 27-52-001 OPER CK GOOD.

Part: FORGING — CORRODED (BS 870)

WHILE WORKING NR 0441, FOUND CORROSION ON BS 870 FORGING, RBL 57, WL 168. *S/D* REMOVED AND REPLACED RIGHT HAND BS 870 FITTING STR 9 TO WL 156 IAW FED-EX NR 7-5310-38683.

Part: SPLICE — CRACKED (BS 870)

NR 0439 014, BS 870 LT UPPER SPLICE PLATE FOR UPPER CHORD HAS 2 CRACKED HOLES AND 1 DAMAGED HOLE AOG ACCESS REQUIRED. REMOVED AND REPLACED BS 870 LT UPPER SPLICE PLATE PER BOEING DRAWING 64-8336.

Part: STRAP — CORRODED (BS 870)

CORROSION (C53-132-02-1, 2) ON LOAD TENSION STRAP BS 870, RBL 35 TO 50. *S/D* REPAIRED BS 870 LOAD TENSION STRAP AT RBL 30 TO 60 IAW FED-EX EA 7-5310-37605.

Part: FRAME — CORRODED (BS 680)

NR 0433 012, WHILE WORKING NR0301, FOUND FRAME TO BE CORRODED AT BS 680, RBL 24, WL 155 (STR 26). REMOVED DAMAGE AT BS 680, RBL 24 FROM STR 22-26 RT. FOUND TO BE OUT OF LIMITS IAW FED-EX SRM 53-10-1. REPAIRED DAMAGED FRAME AT BS 680, RBL 24, STR 22-26 RT IAW FED-EX SRM 51-40-3 FIG 1.

Part: STIFFENER — CORRODED (BS 303)

CORROSION (C53-224-03-1/2) ON NOSE WHEEL WELL HORIZONTAL STIFFENER BS 303, RBL 8, WL 180. *S/D* REMOVED AND REPLACED HORIZONTAL STIFFENER BS 303, RBL 8, WL 180 IAW FEDEX DRAWING NR 65-18417.00.

Part: TEE FITTING — CORRODED (BS 336)

WHILE WORKING NR0328, FOUND CORROSION ON TEE FITTING AT BS 336, LBL 17, WL 150. *S/D* REMOVED AND REPLACED TEE FITTING AT BS 336, LBL 17, WL 155 IAW FED-EX DRAWING 65-18415.

Part: FLOORBEAM — GOUGED (BS 880)

UPON REMOVAL OF RADIUS FILLER, FOUND DEEP GOUGE AT BS 880, LBL 15, WL 201.5. *S/D* BLENDED OUT GOUGE, CRACK AND CORROSION AT BS 880, LBL 15, WL 201.5 ORIGINAL THICKNESS WAS .1, MATERIAL REMOVED WAS .045. BLENDOUT AREA IS .3 X .2, FOUND TO BE OUT OF LIMITS PER FED-EX SRM 53-10-1. REPAIRED FLOORBEAM PER FED-EX EA 7-5310-37396.

Part: CHORD — CORRODED (BS 312)

WHILE WORKING NR 0329, FOUND FRAME FAIL-SAFE CHORD CORRODED AT BS 312, LBL 19, WL 153. *S/D* FOUND CORROSION DAMAGE ON FAIL-SAFE CHORD AT BS 312, LBL 19, WL 153 TO BE OUT OF LIMITS IAW FEDEX SRM 53-10-1. REMOVED CHORD LBL 19 TO LBL 42. FABRICATED NEW PART AND INSTALLED IAW FEDEX DRAWING 65-18915 SHT 3.

Part: SPAR CHORD — CORRODED (BS 870)

CORROSION (C53-132-02-1, 2) ALONG VERTICAL FLANGE OF BS 870 UPPER SPAR CHORD WL 180, RBL 65- LBL 65. *S/D* REMOVED AND REPLACED 870 UPPER SPAR CHORD WL 180, RBL 65 - LBL 65 IAW FED-EX EA 7-5100-37367 AND 7-5710-38653.

Part: BULKHEAD WEB — CORRODED (BS 870)

CORROSION (C53-132-02-1, 2) IN NUMEROUS AREAS ON BS 870 BULKHEAD WEB OF CENTER WING SECTION. *S/D* REMOVED AND REPLACED 870 BULKHEAD WEB OF CENTER WING SECTION PER EA 7-5710-38653.

Part: FLOORBEAM — CORRODED (BS 344)

NR 0429 007, WHILE WORKING NR0408, FOUND CORROSION ON FLOORBEAM BS 344, RBL 17 OUT OF LIMITS AND DOUBLE HOLE DRILLED AT RBL 38, WL 208. REMOVED AND REPLACED BS 344 BEAM UPPER CHORD LBL 17 TO RBL 65 PER FED-EX DRAWING SR 27-53-007.

Part: ANGLE — CORRODED (BS 336)

NR 0329 004, CORROSION C53-111-03-1/2 ON LT LOWER NOSE CHORD BS 336 TO 350, LBL 17, WL 149. FOUND CORROSION ON LT LOWER NOSE ANGLE BS 336 TO 350, LBL 17, WL 149 TO BE OUT OF LIMITS IAW FED-EX SRM 53-10-01. REMOVED AND REPLACED ANGLE BS 284 TO BS 350, LBL 17, WL 149 IAW FED-EX DRAWING 65-18415 SHT 2. STORED AIRCRAFT PER FED-EX EA 7-5100-37391.

Part: CHORD — CORRODED (BS 336)

NR 0328 003, CORROSION C53-111-03 1/2 ON RT LOWER NOSE CHORD BS 336 TO 350, RBL 17, WL 149. FOUND CORROSION ON RT LOWER NOSE CHORD BS 336 TO BS 350, RBL 17, WL 149 TO BE OUT OF LIMITS IAW FED-EX SRM 53-10-1. REMOVED AND REPLACED CHORD BS 284 TO BS 350 RT, RBL 17, WL 149 IAW FED-EX DRAWING 65-18415 SHT 2.

Part: STRINGER — CORRODED (BS 1080)

CORROSION ON STR 29 LT KEEL BEAM LT BS 1080, WL 140. *S/D* REMOVED CORROSION ON STR 29L AT BS 1080 TO 1095, WL 140. FOUND TO BE OUT OF LIMITS PER FEDEX SRM 53-10-1. REMOVED CORRODED PIECE IAW FEDEX SRM 53-10-3. FABRICATED REPAIR PARTS PER FEDEX SRM 53-10-3 AND INSTALLED.

Part: CHORD — CORRODED (BS 294-350)

CORROSION (C53-224-03 1, 2) ON RT MID CHORD BS 315 TO 335, RBL 15, WL 169 WILL REQUIRE REMOVAL OF NOSE LANDING GEAR TO GAIN ACCESS. *S/D* REMOVED DAMAGED CHORD AND INSTALLED NEW CHORD BS 259 TO 351, WL 169, RBL 15 IAW FEDEX DRG 65-18415.

Part: GCU — WATER CONTAM (NR 1 GENERATOR)

NR 1 GENERATOR TRIPPED OFF LINE 2-3 MINUTES AFTER TAKEOFF. BUS TIE WOULD NOT CLOSE PER CHECKLIST. FINALLY DID CLOSE BUT FIELD WOULD THEN NOT CLOSE WITH GOOD RESIDUAL VOLTS. REMOVED AND CLEANED WATER FROM GCU. REINSTALLED, OPS CHECKED NORMAL PER JRH 8-3.

Part: DOOR SWITCH — FAILED (CARGO DOOR)

AT FLT LEVEL 310, MCD ANNUNCIATOR LIGHT ILLUMINATED. ACCOMPLISHED CHECKLIST AND DEPRESSURIZED A/C IN DESCENT. LIGHT REMAINED ILLUMINATED UNTIL 2,000 FEET ABOVE GROUND LEVEL ON APPROACH, THEN WENT OUT. NO OTHER SYMPTOMS WERE NOTED, NO NOISE OR LOSS OF PRESSURIZATION. A/C RELEASED FOR SERVICE PER MEL 52-4 CATEGORY A EXP 6-1-96. *S/D* FOUND SCREW GROUNDING OUT LOCK ROD WARNING SWITCH, FOUND SAME SWITCH BROKEN. REPLACED SCREW AND SWITCH, OPS CK GOOD PER MM 52-70-09.

Part: RETRACT MECH — FAILED (LE FLAPS)

DURING FLAP RETRACTION, L/E DEVICES FAILED TO RETRACT PROPERLY. ARRIVED WITH THE L/E DEVICES AND FLAP HANDLE IN THE 2 DEGREE POSITION AMBER LIGHT WAS STILL ON, NO GREEN LIGHT. CYCLED FLAPS AND OPS CHECK NORMAL.