N203FE

Part: FAN — FAILED (GASPERS) · airframe 29,060 hrs · 19,593 cycles

BURNING ODOR DETECTED IN COCKPIT FOLLOWED BY TRIPPED GASPER FAN CIRCUIT BREAKER. R & R GASPER FAN ASSY, IAW MM 21-23-011-4. OPS CHECKED GOOD, ACFT OK FOR SERVICE.

Part: CONTROL CABLE — FAILED (NLG STEERING) · airframe 29,011 hrs · 19,553 cycles

BEGINNING A 90 DEGREE TURN INTO PARKING GATE, TILLER BROKE AND WAS UNABLE TO COMPLETE TURN. R & R THE NWSB STEERING CABLE AND OPS TESTED ON GROUND OK FOR SERVICE IAW THE MM 32-51-011-4. ACFT IS OK FOR SERVICE AT THIS TIME. ORIGINAL SUBMISSION: 12/01/2011

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 28,856 hrs · 19,433 cycles

DURING STBY POWER CHECK NEITHER EXIT LIGHT ILLUMINATED (INTERIOR) R & R BATTERIES IAW BMM 33-50-101-2, CHECKS NORMALLY. FINAL CLOSED.

Part: STRINGER — CRACKED (BS 720B S15L) · airframe 28,732 hrs · 19,322 cycles

CRACK COMING FROM LOCK FASTENER STR 15L STA 720B 18" NEAR OVER WING LIGHT ASSY MAIN CABIN. CUT-OUT DAMAGED AREA, FABRICATED REPAIR PARTS AT STR 15L BS 720B + 18", AND INSTALLED REPAIR PARTS IAW SRM 53-10-3 FIG 5, 51-10-1, AND 51-10-2.

Part: SKIN — DENTED (BS 1050 S16-17R) · airframe 28,732 hrs · 19,322 cycles

DENTS 2EA EXTERIOR FUSELAGE STA 1050 BETWEEN STR 16R-17R. CUT OUT DAMAGED AREA IAW SRM 51-10-1. FABRICATED REPAIR DOUBLER AND FILLER IAW SRM 53-30-3 FIG 3 AND INSTALLED REPAIR DOUBLER AND FILLER IAW SRM 53-30-3 FIG 3 AND 51-30-2.

Part: STRUCTURE — GOUGED (RT WING TE FLAP) · airframe 28,732 hrs · 19,322 cycles

RIGHT INBD FOREFLAP OUTBD LOWER L/E GOUGED. CUT OUT DAMAGED SKIN IAW SRM 57-30-4 FIG 1. FABRICATED AND INSTALLED REPAIR DOUBLER IAW SRM 57-50-4 FIG 1 REV 103 AND EA 7-5750-136765

Part: STRINGER — CORRODED (BS 450 S28R) · corrosion level 2 · airframe 28,732 hrs · 19,322 cycles

E AND E COMPARTMENT - STRINGER 28R IS CORRODED AT BS 450 CUT OUT DAMAGED STRINGER SECTION IAW SRM 53-10-3 FIG 1. FABRICATED REPAIR STRINGER SECTION, DOUBLERS AND SHIMS IAW SRM 53-10-3 FIG 1. INSTALLED STRINGER, DOUBLERS, AND SHIMS IAW SRM 53-10-3 FIG 1, REV 103.

Part: SKIN — CORRODED (BS 1166-1183) · corrosion level 2 · airframe 28,732 hrs · 19,322 cycles

FUSELAGE SKIN HAS CORROSION OUTBD OF STR 26R BS 1166 TO 1183. REPAIRED FUSELAGE SKIN S26R BS 1166 TO 1183 IAW EA 7-5330-136759.

Part: SKIN — DELAMINATED (NR 14 SPOILER) · airframe 27,820 hrs · 18,605 cycles

NR 14 SPOILER PANEL HAS DELAMINATION. COMPLIED WITH PART 1 OF EA 7-5770-134135. NO FURTHER DAMAGE FOUND, APPLIED TAPE TO CRACK ON T/E OF SPOILER, OK TO CONTINUE. PART 2 TO BE ACCOMPLISHED WITHIN 2 FLIGHT CYCLES. OIL 11SEP09 22:33 COS R NO RESTRICTION NR 14 SPOILER DELAMINATED. FOUND NR 14 SPOILER ACTUATOR LOCK KEY BROKEN. HAD TO MSN KEY. COMPLETED INSTALLATION (SATIES) AND ADJUSTED AND OPS CK'D GOOD. REF AMM 727-27-61-001-5.

Part: SKIN — DELAMINATED (NR 10 SPOILER) · airframe 27,820 hrs · 18,605 cycles

NR 10 SPOILER HAS DELAMINATION, COMPLIED WITH PART 1 OF EA 7-5770-134135. . REMOVED AND REPLACED SPOILER WITH 2 DIFFERENT SPOILERS, SAME RESULTS. INSTALLED ORIGINAL SPOILER REPLACEMENT FOR EVALUATION. NO BOLTS, PINS SAFTIED. COMPLETED INSTALLATION OF SPOILER PANEL (SAFTIES). ADJUSTED AND OPS CK'D ARE NOW GOOD, REF AMM 727-27-61-001-5. REMOVED AND INSTALLED NR 10 SPOILER IAW MM 27-61-001-4 UP TO STEP 6H.

Part: SUPPORT — DAMAGED (LT WING TE FLAP) · airframe 26,821 hrs · 17,832 cycles

LT IB MID-FLAP LOWER T/E CHORD WBL 104 ON PUSH-ROD CUT OUT IS CRACKED ON BOTH CORNERS CUT OUT DAMAGE AREA DIM CUT-OUT 47 1/4 INCH LONG IAW SRM 51-40-3 FIG 1. FAB NEW ANGLE "CHORD" 1 SPLICER IAW SRM 57-50-2 FIG 8 AND 51.40.3 FIG 1. TREATED AND PRIMED IAW SRM 51-10-2. INSTALLED REPAIR PARTS IAW SRM 51-30-2.

Part: STRINGER — CRACKED (VERTICAL STAB) · airframe 26,821 hrs · 17,832 cycles

STRINGER 8R CRACKED AT RIB NR 8 STRINGER 8R, FIN STA 157.200 CRACK TERMINATES IN FASTENER HOLD AND HFEC INSPECTED AREA AND VERIFIED IAW NDTM 51.00.00 PART 6. FABRICATED REPAIR ANGLE IAW SRM 55.30.5 FIGURE 7. TREATED AND PRIMED AREA IAW SRM 51.10.2. INSTALLED REPAIR PARTS AT STRINGER 8RT, RIB NR 8 FIN STA 157.2 IAW SRM 55.30.5 FIGURE 1 AND 51.30.2.

Part: STRINGER — CORRODED (BS 1010-1030) · airframe 26,821 hrs · 17,832 cycles

STR 26 R HAS EXFOLIATION CORROSION BETWEEN STA 1010 AND 1030 CUT-OUT DAMAGED STRINGER SECTION (DIMENSION 12" LONG) AND FABRICATED HAT SECTION AND 1 SPLICER IAW SRM 53-10-3 FIGURE 1 AND 53-10-2 FIGURE 9. TREATED AND PRIMED PARTS IAW SRM 51-10-2 AND INSTALLED REPAIR PARTS AT STRINGER 26RT BETWEEN STA 1010 AND 1030 IAW SRM 53-10-3 FIGURE 1 AND 51-30-2.

Part: STRINGER — CRACKED (VERTICAL STAB) · airframe 26,821 hrs · 17,832 cycles

STRINGER 8L CRACKED AT RIB NR 8 STRINGER 8L, FIN STA 157.200 CRACK TERMINATES IN FASTENER HOLE AND HFEC INSPECTED AREA AND VERIFIED IAW NDTM 51.00.00 PART 6. FABRICATED REPAIR ANGLE IAW SRM 55.30.5 FIGURE 1. TREATED AND PRIMED PARTS IAW SRM 51.10.2. INSTALLED REPAIR PARTS AT STRINGER 8LT RIB NR 8 FIN STA 157.2 IAW SRM 55.30.5 FIGURE 1 AND 51.30.2.

Part: SUPPORT ANGLE — CRACKED (RT WING TE FLAP) · airframe 26,821 hrs · 17,832 cycles

RT WING INBD MID-FLAP AFT LOWER SUPPORT ANGLE IS CRACKED 2 PLACES AT WBL 100. REMOVED I/B MID FLAP LOWER PANEL FOR ACCESS IAW SRM 51-30-2. CUT OUT DAMAGE SECTION DIM CUT OUT (61 INCHES BY 2 INCHES) IAW SRM 51-10-1, AND 51-40-4 FIG 3. FAB REPAIR ANGLE IAW SRM 57-50-2 FIG 5 AND 51-40-03 FIG 3. TREAT AND PRIMED ALL PARTS IAW SRM 57-10-2. INSTALLED REPAIR PARTS IAW SRM 51-30-2. INSTALLED LWR SKIN PANEL IAW SRM 51-30-2.

Part: ANGLE — CRACKED (ZONE 300) · airframe 26,821 hrs · 17,832 cycles

RIB NR 2 ATTACH ANGLE CRACKED AT STR 6R ATTACHMENT BOLT INSIDE VERTICAL STAB, STR 6R, RIB NR 2 FIN STA 22.5 CUT-OUT DAMAGED AREA IAW SRM 51-10-1 & 55-30-5 FIGURE 1, FABRICATED REPAIR ANGLE & REPAIR FILLER, TREATED & PRIMED PARTS IAW SRM 51-1-2, INSTALLED REPAIR PARTS IAW SRM 55.30.5 FIGURE 1 & 51-30-2

Part: SKIN — CRACKED (BS 1055 S29R) · airframe 26,821 hrs · 17,832 cycles

CRACK IN LWR FUSELAGE AT STA 1055, 5.5 INCHES RIGHT OF CENTERLINE STR 29R. CUT-OUT DAMAGED AREA & FABRICATED REPAIR FILLER & REPAIR DOUBLER IAW SRM 53-30-3 FGIURE 3 & 53-30-2 FIGURE 2, TREATED & PRIMED PARTS IAW SRM 51-10-2 & INSTALLED REPAIR PARTS IAW SRM 53-30-3 FIGURE 3 & 51-30-2.

Part: WEB — CRACKED (FUSELAGE) · airframe 26,821 hrs · 17,832 cycles

LT AIRSTAIR LWR TORQUEBOX OUTER WEB CRACKED AT LIGHTING HOLE BS 1329. TRIMMED OUT DAMAGED AREA IAW SRM 51-10-1, 51-40-2 FIG 1. FABRICATED REPAIR DOUBLER IAW SRM 53-10-2 FIG 6 AND 51-40-2 FIG 1. TREATED AND PRIMED IAW SRM 51-10-2. INSTALLED REPAIR PART IAW SRM 51-30-2.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 26,821 hrs · 17,832 cycles

CORROSION ON OUTBRD SIDE OF STRINGER 26L AT STA 1133 (AFT PIT). CLEANED AND EVALUATED AREA, NO CORROSION FOUND IAW SOPM 20-30-03, SRM 51-10-06 PAR. 3

Part: SPAR — CRACKED (ZONE 600) · airframe 26,821 hrs · 17,832 cycles

RT FALSE SPAR CRACKED JUST AFT OF NR 8 SPOILER FITTING. REPAIRED IAW DRAWING SR 27-57-038 REV C.

Part: FRAME — CORRODED (ZONE 100) · airframe 26,821 hrs · 17,832 cycles

FWD PIT, FRAME AT STA 720D HAS CORROSION ON THE FWD FACE AROUND CABLE CUT OUT AT LBL 1. FOUND WITHIN LIMITS IAW SRM 53-10-2.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 26,821 hrs · 17,832 cycles

VENTRAL STAIRWELL RT SIDE BELOW AIRSTAIR ACTUATOR FITTING, TORQUE BOX BS 1263 UPPER ANGLE AFT SIDE OF BULKHEAD HAS CRACK. REMOVED UPPER ANGLE AFT SIDE IAW SRM 51-30-2. REMOVED WEB DOUBLER AND SEAL AND SEAL RETAINER FOR ACCESS IAW SRM 51-30-2. CUT OUT WEB DIM 29" X 25" FOR ACCESS IAW SRM 51-10-1. LOCATED AND DRILLED NEW ANGLE IAW SRM 51-30-5. INSTALLED NEW ANGLE IAW SRM 51-20-0. FABRICATED NEW WEB IAW 51-20-01 AND 53-10-02. TREATED AND PRIMED NEW WEB IAW SRM 51-10-2. WEB INSTALLED IAW SRM 51-30-2.

Part: INTERCOSTAL — CORRODED (FUSELAGE) · corrosion level 2 · airframe 26,821 hrs · 17,832 cycles

LWR FUSELAGE AFT PIT CORROSION ON INTERCOSTAL AT STA 885 FROM 28L TO 29L. REMOVED CORROSION AND EVALUATED AREA ORIGINAL MAT 0.032, MAT. REMAINING 0.029, MAT LOSS 0.003". TREATED AND PRIMED IAW SRM 51-10-06, 51-10-01 FIG 1, 51-10-02 AND SOPM 20-30-03.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 26,821 hrs · 17,832 cycles

LWR FUSELAGE AFT PIT CORROSION ON 29L OUTBRD SIDE AND STA 1010 CLEANED AND EVALUATED AREA, NO CORROSION FOUND IAW B727 SRM 51-10-01 AND SOPM 20-30-03.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 26,821 hrs · 17,832 cycles

LWR FUSELAGE STA 1125 6.5 INCHES RIGHT OF CENTER LINE SKIN HAS A PULLED THROUGH RIVET STR 29R. CUT-OUT DAMAGED AREA (DIMENSION 4" X 3") IAW SRM 51-10-1 & FABRICATED REPAIR DOUBLER & REPAIR FILLER IAW SRM 53-30-3 & 53-30-2 FIGURE 2, TREATED & PRIMED PARTS IAW SRM 51-10-2, INSTALLED REPAIR WASHERS & REPAIR PARTS IAW SRM 51-30-28, 53-30-3 & 51-30-2 SEALED REPAIR IAW SRM 51-20-4.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 26,821 hrs · 17,832 cycles

LOWER FUSELAGE AFT PIT CORROSION ON 29R STRINGER FROM STA 885-890. REMOVED CORROSION AT AFT PIT ON STIFFENER , ORIG MAT 0.063, MAT LOSS 0.003, MAT REMAINING 0.060", TREATED AND PRIMED IAW SRM 51-10-01, 53-10-02, 53-10-01.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 26,821 hrs · 17,832 cycles

AFT PIT CORROSION ON INBD SIDE OF STRINGER 28R AT BS 990. CLEANED AND EVALUATED AREA, NO CORROSION FOUND IAW SOPM 20-30-03 AND SRM 51-10-01.

Part: WEB — CRACKED (ZONE 100) · airframe 26,821 hrs · 17,832 cycles

LT AIRSTAIR LOWER TORQUE BOX OUTER WEB CRACKED AT LIGHTING HOLE BS 1239. CUT OUT DAMAGE AREA DIM CUT OUT IAW SRM 51-10-1 AND 51-40-2. FAB REPAIR PARTS IAW SRM 51-40-2 & 53-10-2. TREATED AND PRIMED IAW SRM 51-10-2 INSTALLED REPAIR PARTS IAW SRM 51-30-2.

Part: SKIN — DENTED (ZONE 100) · airframe 26,821 hrs · 17,832 cycles

RT LWR FUSELAGE SURFACE STA 1030 STA 1050, BELOW STR 26R HAS DENT. REMOVED PREVIOUS REPAIR IAW SRM 51-30-2, CUT OUT DAMAGED AREA , FABRICATED REPAIR DOUBLER AND STRUCTURAL FILLER IAW SRM 53-30-3, TREATED AND PRIMED PARTS IAW SRM 51-30-2, INSTALLED COUNTERSINK WASHERS AND REPAIR PARTS IAW SRM 51-30-8 AND 51-30-2.

Part: SKIN — DENTED (FUSELAGE) · airframe 26,821 hrs · 17,832 cycles

LWR FUSELAGE SKIN SURFACE DENT AT STR 21 L APPROX STA 1130. CUT OUT DAMAGED AREA DIM CUT OUT (4" X 1') IAW SRM 53-30-3 FAB REPAIR. TREATED AND PRIMED DOUBLER REPAIR AND AREA IAW SRM 51-10-2. INSTALLED REPAIR DOUBLER IAW SRM 51-30-2. TREATED AND PRIMED DOUBLER REPAIR AND AREA IAW SRM 51-10-2 INSTALLED REPAIR DOUBLER IAW SRM 51-30-2.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 26,821 hrs · 17,832 cycles

VENTRAL STAIRWELL RT SIDE BELOW AIRSTAIR ACTUATOR FITTING, TORQUE BOX BS 1263 UPPER ANGLE FWD SIDE OF BULKHEAD HAS CRACK. REMOVED ANGLE FWD SIDE IAW SRM 51-30-2. LOCATED AND DRILLED NEW ANGLE IAW SRM 51-30-5. INSTALLED NEW ANGLE IAW SRM 51-30-2.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 26,821 hrs · 17,832 cycles

LWR FUSELAGE STR 29 R AT STA 990 CORROSION ON SPARE TIES, CLIPS, AND TOP OF STRINGER. REMOVED CORROSION FROM SHEAR TIE IAW SRM 51-10-6, ORIG. MAT. 0.063, MAT. LOSS 0.004, REMAINING MAT. 0.059 AND FOUND WITHIN LIMITS IAW SRM 53-10-2, 53-10-1, CLEANED AREA CLIPS AND STRINGER IAW SOPM 20-30-03 AND NO CORROSION FOUND IAW SRM 51-1-6.TREATED AND PRIMED AREA IAW SRM 51-10-2.

Part: WARNING LIGHT — FALSE ACTIVATION (AIRSTAIR DOOR) · airframe 24,592 hrs · 16,204 cycles

CLIMBING THROUGH 11,000 ON DEPARTURE, AFT AIRSTAIR ANNUNCIATOR ILLUMINATED ON ENGINEER'S PANEL. ACFT FLYING STABLE WITHOUT ANY INCREASED DRAG. AN EMERGENCY DECLARED DUE TO POSSIBILITY OF AIRSTAIRS STRIKING RUNWAY DURING TOUCHDOWN. AFT AIRSTAIR ILLUMINATED INFLT CHKLIST RUN & DIRECTED A LANDING AT NEAREST SUITABLE AIRPORT. DURING ROLLOUT LIGHT EXTINGUISHED & THEN FLICKERED JUST BEFORE COMING TO A STOP AT THE GATE. RELEASED FOR SERVICE PER MEL/CDL. 01NOV05 AMBER AFT AIRSTAIR DOOR WARNING LIGHT INOP.

Part: SWITCH — FAILED (LE FLAPS) · airframe 24,512 hrs · 16,156 cycles

GOT AMBER LE FLAP LT ON FLAP RETRACTION AT FLAP 2 DEGREE SETTING. LE FLAP ANNUNCIATOR ON S/O PANEL SHOWED NR 6 IN TRANSIT. FOLLOWED QRH PROCEDURES, NO HELP RETURNED TO DEPARTURE AIRPORT. REMOVED AND REPLACED NR 6 L/E FLAP SWITCH PER MM 27-82-001-4. DURING SWITCH REPLACEMENT FOUND LINKAGE INSTALLED INCORRECTLY PER FIG 401. OPS CHECKED L/E FLAPS AND SLATS PER MM 27-82-001-4. ACFT OK FOR SERVICE.

Part: SMOKE DETECTOR — MALFUNCTIONED (ZONE 200) · airframe 24,324 hrs · 16,041 cycles

MAIN CARGO SMOKE ALARM NR 4 ILLUMINATED WITH ASSOCIATED BELL .WENT OUT 2 MIN AFTER ILLUMINATION , NO OTHER INDICATIONS OF FIRE WERE PRESENT. REMOVED AND REPLACED THE NR 4 SMOKE DETECTOR PER B727-200 MM 26-16-001-4, OPS CHECK GOOD, OK FOR SERVICE. *S/D* REMOVED AND REPLACED THE NR 4 SMOKE DETECTOR PER B727-200 M/M 26-16-001-4. OP'S CHECK GOOD OK FOR SERVICE.

Part: HINGE FITTING — CRACKED (RT WING TE FLAP) · airframe 24,234 hrs · 15,981 cycles

AFT FLAP RT INBD AT HINGE FITTING 111.0 FROM INBD, LE LWR SKIN CRACKED (.450 LONG) REPLACED FLAP ON W/C 76C071-00

Part: ANTENNA — DELAMINATED (NR 1 ADF) · airframe 24,234 hrs · 15,981 cycles

NR 1 ADF LOOP ANTENNA IS DELAMINATED. REMOVED AND REPLACED NR 1 ADF ANTENNA IAW MM 34-37-012-4. OPS CHECKED GOOD IAW M/M 34-37-001-5

Part: FLOOR SUPPORT — CORRODED (CARGO BAY) · corrosion level 2 · airframe 24,234 hrs · 15,981 cycles

AFT PIT BS 950A BL 0 FLOOR SUPPORT ANGLE HAS CORROSION UNDER NUT PLATES. REPLACED FLOOR SUPPORT ANGLE IAW SRM 51-30-2

Part: COVER — CRACKED (THRUST REVERSER) · airframe 24,234 hrs · 15,981 cycles

PANEL RACK NR 1 ENGINE UPPER AFT THRUST REVERSER PANEL CRACKED AND GOUGED AT BOTH ENDS. REPLACED PART TO BE INSTALLED DURING C-CHECK.

Part: FRAME — CRACKED (COCKPIT) · airframe 24,234 hrs · 15,981 cycles

COCKPIT LT FRAME STA 277 BTWN STR S-14 TO S-16 FRAME WEB ANGLES CRACKED AT FWD & AFT SIDE OF FRAME AT 6 EA PLACES AS MARKED. REPAIRED FRAME WEB ANGLE IAW SRM 53-10-4 MAJOR REPAIR

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 24,234 hrs · 15,981 cycles

MAIN DECK BELOW FLOOR FS 1183 L-ANGLE CRACKED RBL 55, REMOVED L-ANGLE DITCHING SEAL, SEAL SUPPORT AND LT AND RT ANGLES IAW SRM 51-30-2. FABRICATED SEALS SUPPORT IAW DWG 65-29548. LOCATED, DRILLED AND INSTALLED PARTS IAW SRM 51-30-5 AND 51-30-2 MINOR REPAIR.

Part: STRAP — CRACKED (RT WING) · airframe 24,234 hrs · 15,981 cycles

RT WING LANDING LIGHT RETENSION STRAP CRACKED ON BACK OF NR 6 K-FLAP. REMOVED AND REPLACED RETENSION STRAP IAW SRM 51-30-2.

Part: HANDLE — CRACKED (EMERGENCY EXIT) · airframe 24,234 hrs · 15,981 cycles

LT AFT EMERGENCY EXIT LOWER HANDLE ESCATION IS CRACKED. REMOVED AND REPLACED HANDLE ASSY IAW SRM 51-30-2.

Part: ANGLE — CRACKED (NR 2 SPOILER) · airframe 24,234 hrs · 15,981 cycles

NR 2 SPOILER UPPER SURFACE CRACKED AT 2 CENTER ATTACHMENTS. REMOVED AND REPLACED LT NR 2 SPOILER HINGE CUTOUT ANGLE IAW SRM 51-30-2.

Part: ANTENNA — CORRODED (NR 2 ATC) · corrosion level 2 · airframe 24,234 hrs · 15,981 cycles

LOWER NR 2 ATC ANTENNA CORRODED. REMOVED AND REPLACED NR 2 ATC ANTENNA IAW MM 34-54-001-2.

Part: HANDLE — CRACKED (EMERGENCY EXIT) · airframe 24,234 hrs · 15,981 cycles

LT FWD EMERGENCY EXIT LOWER HANDLE ESCATION IS CRACKED. REMOVED AND REPLACED HANDLE ASSY IAW SRM 51-30-2. (M)

Part: ANTENNA — CORRODED (NR 2 ADF) · airframe 24,234 hrs · 15,981 cycles

NR 2 ADF ANTENNA DISBONDED AND CORRODED. REMOVED AND REPLACED NR 2 ADF LOOP ANTENNA IAW 34-37-012-4. PERFORMED OP CHECK IAW MM 34-37-001-5. OPS CHECKS GOOD.

Part: SHEAR WEB — CORRODED (MAIN DECK) · corrosion level 2 · airframe 24,234 hrs · 15,981 cycles

MAIN DECK SHEAR WEB BTWN 1164 TO 1183, RBL 18 TO 65 IS CORRODED. REMOVED AND REPLACED L-CHANNEL IAW SRM 51-30-2.

Part: ANTENNA — CORRODED (NR 1 DME) · corrosion level 2 · airframe 24,234 hrs · 15,981 cycles

NR 1 DME ANTENNA CORRODED. REMOVED AND REPLACED NR 1 DME ANTENNA IAW 34-45-011-4.

Part: ANTENNA — CORRODED (NR 2 DME) · corrosion level 2 · airframe 24,234 hrs · 15,981 cycles

NR 2 DME ANTENNA CORRODED. REMOVED AND REPLACED NR 2 DME ANTENNA IAW MM34-45-011-4. PERFORMED OPS CHK IAW MM 34-45-000-0. OPS CHECKS GOOD.

Part: FRAME — CRACKED (NR 1 ENG COWL) · airframe 24,234 hrs · 15,981 cycles

NR 1 ENG FIXED COWL UPPER FRAME CRACKED BETWEEN NR 2 AND NR 3 LATCHES. REMOVED AND REPLACED COWL PANEL IAW SRM 51-30-2.

Part: SUPPORT — CRACKED (RT MLG) · airframe 24,234 hrs · 15,981 cycles

RT SHAFT ASSY HOUSING SUPPORT AT WING STA 315 NEXT TO RT MLG SUPPORT BEAM BUSHING CRACKED. REMOVED AND REPLACED TORQUE TUBE BEARING SUPPORT FITTING IAW MM 27-51-131-2.

Part: FLOOR PANEL — CRACKED (COCKPIT) · airframe 24,234 hrs · 15,981 cycles

COCKPIT F/O OUTBOARD RUDDER PEDAL FLOOR PANEL CRACKED. REMOVED AND REPLACED PANEL IAW SRM 51-30-2.

Part: SKIN — CORRODED (ZONE 100) · airframe 23,842 hrs · 15,726 cycles

STA 1130 STR 28L IS BULGING 1 RIVET PULLED AND RIVET SHEARED. REMOVED FLOOR PANEL STA 1070-STA 1183 AFT PIT FOR ACCESS IAW SRM 51-30-2. REMOVED EXISTING REPAIR DOUBLER AT STA 1130 IAW SRM 51-30-02. FOUND CORROSION UNDER REPAIR DOUBLER, REMOVED DAMAGED AREA IAW SRM 53-30-3. FABBED REPAIR DOUBLER AND FILLER IAW SRM 53-30-3 FIG 3. INSTALLED NEW REPAIR DOUBLER AND FILLER IAW SRM 53-30-3 FIG 3. INSTALLED FLOOR PANELS IAW SRM 51-30-2.

Part: CONNECTOR — LOOSE (NLG) · airframe 22,703 hrs · 14,858 cycles

ON FINAL FOR LANDING WITH FLAPS 30 AND GEAR DOWN THE NOSEWHEEL GREEN DOWN AND LOCKED ILLUMINATED INTERMITTENTLY CAUSING THE GEAR WARNING HORN TO GIVE A STEADY AURAL WARNING. A GO-AROUND WAS ACCOMPLISHED AND QRH CHECK LIST WAS RUN. AFTER RECYCLING, HAD 3 GREEN DOWN AND LOCKED INDICATIONS WITH THE NOSE WHEEL ALIGNMENT STRIP SHOWING DOWN AND LOCKED. NO FURTHER WARNINGS AFTER RECYCLING GEAR. INSP NOSE GEAR LOCK INDICATING SWITCHES, FOUND SWITCH D-298 CONNECTOR LOOSE. TIGHTENED CONNECTOR PLUG AND PERFORMED TEST PER 727-200 AMM 32-61-071-5, OPS CHECK GOOD.

Part: PIVOT — CONTAMINATED (NLG) · airframe 21,848 hrs · 14,149 cycles

DURING NORMAL GEAR EXTENSION, NOSE GEAR DID NOT COME DOWN, HAD NO GREEN LIGHT, HAD RED DOORS AND UNSAFE LIGHT. MAINS CAME DOWN NORMALLY. FOLLOWED RED TABS TO MANUALLY EXTEND NOSE, CAME DOWN OK. FOUND WATER COMING FROM NOSE LANDING GEAR PIVOT KNUCKLE. REMOVED BOTH PLUGS AND LUBED KNUCKLE IAW M/M. PURGED KNUCKLE OF EXCESSIVE WATER. JACKED AIRCRAFT NOSE AND TESTED NOSE LANDING GEAR EXTENSION AND RETRACTION IAW M/M, CYCLED GEAR NUMEROUS TIMES OPS CHECK GOOD. OK FOR SERVICE.

Part: STRINGER — CORRODED (FUSELAGE)

CORROSION SKIN BULGE AT BS 1075, STRINGER R28. REMOVED AND REPLACED STRINGER PER SRM 53-10-1, 53-10-3.

Part: PUMP — FAILED (NR 3 ENGINE)

NR 3 ENGINE QUIT ON TAKEOFF. REMOVED AND REPLACED ENGINE FUEL PUMP AND CONTROL UNIT PER 73-12-001-2, 73-21-000-4. CHECK OK.

Part: PUMP — LEAKING (HYDRUALIC BAY)

AFTER T/O HYD SYS B LOSS. R&R NR 1 B SYS PUMP & FILTERS PER MM 29-12-011-2.

Part: TRANSMITTER — DEFECTIVE (NR 3 ENGINE)

AFT T/O NR 3 OIL PRESS DROPPED TO 20 PSI ALL OTHER ENG IND NORM. REMOVED AND REPLACED NR 3 ENG OIL PRESS TRANSMITTER PER 727-200 MM 79-33-001-2, RUN ENG PER JET RUN HDBK 5A. NO LEAKS FOUND.

Part: WARNING BOX — FAILED (COCKPIT)

00-3 - FIRE DET SYS AFT 30 MIN BELL SOUNDS W/2 QUICK CHIMES AND ILLUMINATED OFF FIRE WARN LIGHT. REMOVED AND REPLACED AURAL WARN BOX PER OPS CK PER MM 31-26-000. OPS CK NORM. CK NR 2 ENG FIRE LOOP. NO DETECTS NOTED.

Part: FIRE LOOP — MALFUNCTIONED (NR 2 ENGINE)

00-4 - INTERMITTENT NR 2 ENG FIRE LIGHT AND BELL CAME ON AND WENT OUT. REPEAT WRITE-UP. SYS CK GOOD. REMOVED AND REPLACED LWR DUAL FIRE LOOP PER MM 26-12 (1739) NO HELP DUP PRO. DRIED BACKSHELL AND RESEALED SYS OPS CK GOOD IAW 26-11-000. RAN ENG FROM IDLE.

Part: FIRE DETECTOR — MALFUNCTIONED (NR 2 ENGINE)

99-289 - FIRE WARNING BELL RANG 1 TIME AND BOTH FIRE LIGHTS ON GLARE SHIELD ILLUMINATED MOMENTARY AS PWR WAS APPLIED. DID NOT SEE OR HEAR ANY OTHER ABNORMAL IND (ONE DING ONLY). REMOVED AND REPLACED FIRE DETECTION ASSY UNIT RAN NR 2 ENG AS WAS STILL ABLE TO DUPLICATE PROBLEM AT OR AROUND 70 PERCENT N2 TRIED TO ISOLATE TO EITHER SYS A AND B FOUND SYSTEM.

Part: SMOKE WARNING — ILLUMINATED (CARGO COMPT)

99-253 - AFT T/O ON CLIMB-OUT LANDING GEAR MAIN CARGO COMP SMOKE WARNING LIGHT NR 4 ILLUM WITH AURAL WARN FOLLOW SHORTLY BY FUMES AND NR 5 WARN LIGHT ILLUM. REMOVED AND REPLACED GRD/AIR SHUTOFF ACTUATOR PER MM 21-00.

Part: TIE — CORRODED (BS 870)

CORROSION UNDER STRINGER TIE, BS 870, STR 9 LT (C53-224-01-2). *S/D * REPAIRED CORROSION AT BS 870, STR 9L IAW FEDEX EA 7-5310-46946.

Part: STRINGER — DAMAGED (BS 1013)

GOUGE IN STRINGER CHANNEL AT 23 RT, BS 1013. *S/D* REPAIRED STR IAW FEDEX EA 7-5310-46927.

Part: FLOORBEAM — CORRODED (BS 950)

CORROSION UNDER NUT PLATES ON FLOORBEAM BS 950, BL 0-RBL 25, WL 208 (C53-224-01, 3). *S/D* REPAIRED FLOORBEAM IAW FEDEX EA NR 7-5310-46929.

Part: SKIN — DENTED (BS 1434)

AFT FUSELAGE, UPPER RIGHT TORQUE BOX, DENT ON SKIN BS 1434, RBL 18, WL 210. *S/D* FAIRING REMOVED FOR ACCESS (5211R) DENT IAW SRM 51-30-2. RECONTOUR TO FEDEX SRM 53-30-1, 51-40-1 NFEC SHOW NO CRACK, SUB FASTENER INSTALLED IAW FEDEX EA 7-5410-46934.

Part: FLOORBEAM — CORRODED (BS 1148)

CORROSION (C53-111-01) UNDER NUTPLATE, LOWER SURFACE OF BS 1148 UPPER CHORD, RBL 57, WL 207.5. *S/D* REPAIRED FLOORBEAM IAW FEDEX EA 7-5310-46923.

Part: HYDRAULIC LINE — RUPTURED (B HYD SYST)

98-202 - LOST 'B' SYS HYD QUANTITY AND PRESSURE ON TAKEOFF. INSPECTED AND FOUND NR 1 'B' PUMP PRESS LINE RUPTURED. REMOVED AND REPLACED LINE WITH NEW ALT LINE PER ENG AUTH 7-2914-38376. OPERATION AND LEAK CHK GOOD PER B-727 M/M 29-12-0.

Part: FIRE LOOP — MALFUNCTIONED (NR 1 ENGINE)

FIFTEEN TO TWENTY MILES FROM MEM, NR 1 ENG FIRE WARN AND BELL CAME ON. RAN ENG FIRE/SEVERE DMG CHECKLIST AND LIGHT REMAIN ON. BOTH FIRE BOTTLES FIRED, LIGHT ON. NR 1 HYDRAULIC A-SYSTEM CLOSED. FWD TO MEL/CDL: 26 - 6A CAT: C EXP: 17AUG98 FOUND A LOOP DEFECT. REMOVED AND REPLACED ENG LOOP, NO HELP. SUSPECT FIREWALL LOOP. ALSO, REMOVED AND REPLACED DETECTOR UNIT, NO HELP. REINSTALLED ORIG ENG LOOP AND DETECT UNIT. REMOVED AND REPLACED RT AND LT ENG FIRE BOTTLES PER 727 M/M 26-21-1. REMOVED AND REPLACED NR 1 ENG FIREWALL LOOP AS M/M 26-11-12, OK FOR SERVICE.

Part: FIRE LOOP — DAMAGED (NR 1 ENGINE)

NR 1 ENGINE FIRE LIGHT AND BELL ON INTERMITTENTLY, ALL ENGINE INDICATIONS NORMAL. DETECTOR NR 1 INOP LIGHT ON CIRCUIT BREAKER PANEL ON AS WELL. PULLED ENGINE DETECTION A NR 1 CIRCUIT BREAKER SYSTEM NORMAL. *S/D* FOUND NR 1 ENG FIRE LOOP DAMAGED IN 2 PLACES CAUSING LOOP TO SHORT. REMOVED AND REPLACED NR 1 ENG FIRE LOOP. TEST AS PER M/M 26-11-01. RAN NR 1 ENG AT HIGH POWER AS PRECAUTION, NO FALSE WARNINGS. OK FOR SERVICE.

Part: OVERHEAT LIGHT — ILLUMINATED (LWR AFT FUSELAGE)

LOWER AFT BODY OVERHEAT LIGHT CAME ON JUST AFTER FIRST LEVEL OFF. NR 2 AND NR 3 BLEEDS OPEN BOTH PACKS ON, LIGHT WENT OUT AFTER ONE MINUTE BUT CAME BACK ON DURING CLIMB. STARTED RED TAB PROCEDURE, LIGHT WENT OUT WHEN NR 1 BLEED AND LEFT PACK TURNED OFF REMAINDER OF FLIGHT WITH NR 3 BLEED AND RIGHT PACK, LIGHT DID NOT COME BACK ON. THE M366 OVERHEAT DETECTOR WAS REPLACED, SHORT ONE IN KEEL BEAM. ALSO, REPLACED M365 OVERHEAT DETECTOR, RIGHT AFT AIRSTAIR DETECTOR. OPERATIONAL CHECKS NORMAL ON ENGINE AND APU RUNS.

Part: OVERHEAT LIGHT — ILLUMINATED (AFT BODY)

LWR AFT BODY OVHT LIGHT CAME ON DURING CLIMB OUT, LIGHT WAS ON STEADY FOR 30 TO 40 SECONDS, THEN FLICKERED FOR 1 MINUTE, THEN WENT OUT, NR 1 AND 3 ENG BLEEDS WERE OPEN, BOTH PACKS WERE ON. CHECKED ALL CONN ON AFT OVHT LOOP AND RAN ENG AND CK'D FOR HOT AIR LEAKS AS IN FLT MODE, ALL CK GOOD. REMOVE AND REPLACED FIRE DETECTION CONTROL BOX FOR TROUBLESHOOTING PURPOSE, OPS CK GOOD ON GROUND, ALL WORK DONE PER MM 26-14-1.

Part: CONNECTOR — DIRTY (AFT BODY)

LWR AFT BODY OVERHEAT ILLUM'D DURING CLIMB W/LEFT PACK SUPPLIED BY NR 2 ENG, SWP PACK TO NR 1 ENG AND LIGHT STAYED ON, CLOSED NR 1 BAV AND LWR AFT BODY LIGHT WENT OUT. INSPECTED LEFT AND RIGHT OVHT DETECTOR LOOPS, NO DEFECT, CLEANED PLUG SENSORS AND L/LOOP RAN NR 1 AND NR 2 ENG PER JRH W/BLEEDS ON, INSP'D AFT STAIRWELL NO LEAKS FOUND. PERF'D HI PWR ENG RUN PER JRH TO VERIFY OPS OF L/AFT BODY OVHT SENSORS AFTER CLEANING OF CONNECTORS. RAN ENG W/BLEEDS NR 1 AND 2 OPEN AND NR 1 AND 2 PACKS OPD, NO DEFECT, OK FOR SERVICE.

Part: BLEED VALVE — FAILED (NR 1 ENGINE)

CLIMBING THROUGH FLIGHT LEVEL 200 LOWER AFT BODY OVERHEAT LIGHT ILLUMINATED. AS PER RED TABS WE ISOLATED PROBLEM TO THE NR 1 BLEED VALVE AND OPERATED THE RIGHT PACK ONLY. OVERHEAT LIGHT EXTINGUISHED WITH THE REDUCTION OF THE NR 1 THROTTLE TO IDLE. ALSO SYSTEM TESTED NORMAL. ENGINE RUN CARRIED OUT. BOTH PACKS OPERATED AND COULD NOT DUPLICATE OVERHEAT AREA INSPECTED. NO LEAKS FOUND. LOOPS INSPECTED, NO DAMAGE FOUND.

Part: CLAMP — LOOSE (AFT FUSELAGE)

LOWER AFT BODY OVERHEAT LIGHT CAME ON DURING FLIGHT. LIGHT CAME ON WHILE CLIMBING PAST FL240. THE CONFIGURATION WAS NR 1 BLEED CLOSED, NR 2 BLEED OPEN, NR 3 BLEED OPEN WITH BOTH PACKS ON. AS PER RED TABS, OPENED NR 1 BLEED AND CLOSED NR 2 BLEED. AFTER THIS STEP LIGHT WENT OUT. FLIGHT CONTINUED THIS CONFIGURATION. TIGHTENED SEVERAL CLAMPS IN AFT AIRSTAIR. RAN PACKS WITH AIRSTART UNIT, OPS CK GOOD.

Part: CLAMP — FAILED (NR 1 BLEED SYST)

DURING CLIMBOUT AFTER 10 MINUTES OF FLIGHT, THE LOWER AFT BODY HEAT LIGHT CAME ON. CONFIGURATION WAS 1 AND 3 BLEEDS OPEN. PER RED TABS SECTION 2-7-14, NR 1 PACK AND BLEED WERE TURNED OFF. BEFORE NR 1 ENGINE COULD BE RETARDED THE LIGHT WENT OUT. THE OVERHEAT SYSTEM TESTED NORMAL. FLIGHT CONTINUED WITH NR 1 PACK AND NR 1 AND 2 BLEEDS OFF. FOUND LEAK AT A CLAMP ON PNEUMATIC DUCT IN LOWER AFT CARGO BEHIND FORWARD BULKHEAD. RESECURED CLAMP, DUCT LEAK CHECKED GOOD.

Part: CLAMP — LOOSE (NR 2 BLEED SYST)

IN CRUISE FLIGHT AT FL 270, LOWER AFT BODY OVERHEAT LIGHT CAME ON. OPERATING ENGINES 2 AND 3 BLEEDS AT THE TIME WITH BOTH PACKS. OVERHEAT LIGHT WENT OUT AFTER FOLLOWING ABNORMAL EMERGENCY RED TABS CHECKLIST. OVERHEAT LIGHT WENT OUT AFTER SHUTTING OFF NR 2 ENGINE BLEED, (1 MINUTE). CHECKED AFT BODY HEAT AREA FOUND AIR LEAK IN KEEL BEAM AREA. TIGHTENED CLAMP RE-RAN ENGINES, OPERATIONAL CHECK GOOD.

Part: TRANSMITTER — LEAKING (A-HYD SYST)

DURING CRUISE, A-SYS HYD QTY NOTED LOW, READING LESS THAN HALF GALLON. FOLLOWED EMERGENCY PROCEDURES AND FOLLOWED LOSS OF A-SYSTEM MANUAL GEAR EXTENSION AT IAD. GEAR PINS INSTALLED AND TOWED TO GATE. FOUND SYS-A HYD TRANSMITTER LEAKING INTERNALLY. REPLACED SAME IAW MM 29-31-00, LEAK AND OPS CHECKS GOOD. SERVICED HYD A-SYS TO FULL AND REMOVED GEAR PINS.

Part: FLOORBEAM — DOUBLE DRILLED (BS 344)

WHILE WORKING NR O0070, FOUND MECHANICAL DAMAGE AND DOUBLE HOLES IN FLOORBEAM BS 344 RBL 35 TO 55 WL 208. REMOVED EXISTING FLOORBEAM, REPAIRED AND INSTALLED FABRICATED FLOORBEAM AT BS 344 WL 208 RBL 35 TO 55 PER FEDEX SRM 51-10-1, 53-10-2.

Part: FLOOR BEAM — DOUBLE DRILLED (BS 344)

WHILE WORKING NRO0070 FOUND MECHANICAL DAMAGE AND DOUBLE HOLES IN FLOOR BEAM BS 344 RBL 35 - 55 WL 208. REMOVED EXISTING FLOOR BEAM, REPAIRED AND INSTALLED FABRICATED FLOOR BEAM AT BS 344 WL 208 RBL 35 - 55 PER FEDEX SRM 51-10-1, 53-10-2. MFG P/N M446204.