N204FE

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 29,785 hrs · 20,218 cycles

EMERGENCY EXIT LIGHT ABOVE COCKPIT DOOR DOES NOT ILLUMINATE DURING BATTERY AND STANDBY POWER CHECK. R & R BATTERIES IN EMERGENCY EXIT LIGHT ABOVE COCKPIT DOOR IAW AMM 33-50-101-2, OPS CHECKED GOOD.

Part: HINGE — DAMAGED (PAX DOOR GATE) · airframe 29,752 hrs · 20,192 cycles

LOUD SQUEL COMING FROM AREA UPPER FRONT SIDE OF COCKPIT NEXT TO S/O PANEL. CLOSING CARGO OUTFLOW VALVE HAS NO EFFECT. STARTED DURING CLIMB AROUND 250. WENT AWAY AT LEVEL OFF AT 350 THEN IMMEDIATELY CAME BACK. CONTINUED TO 370. ALL PRESSURIZATION INDICATIONS NORMAL. PRESSURIZED ACFT WITH APU IAW JRH, LOUD HARMONIC VIBRATIONS COMING FROM L1 DOOR. FOUND UPPER HINGE FLAP ASSY WITH A BROKEN LOCATING PIN. R & R HINGE IAW SRM 51-30-2. INSTALLED & ADJUSTED SEAL ON L1 DOOR UPPER FLAP HINGE IAW AMM 52-11-022. PRESSURIZED ACFT IAW JRH, NO LEAKS NOTED.

Part: BATTERY PACK — FAILED (EMERGENCY LIGHTS) · airframe 29,690 hrs · 20,151 cycles

L1 DOOR EMERGENCY EXIT LIGHTS LT SIDE, LIGHT INOPERATIVE. BATTERY PACK ONLY READS 1.3VDC, REMOVED AND REPLACED EMERGENCY EXIT LIGHT POWER SUPPLY LIGHTS. OPS CHECKED NORMAL IAW MM 33-50-051-2.

Part: BOTTLE — DISCHARGED · airframe 29,670 hrs · 20,135 cycles

LEFT "BOTTLE DISCHARGED" LIGHT ILLUMINATED ON OVERHEAD PANEL. R & R LT ENGINE FIRE EXTINGUISHER BOTTLE IAW MM 26-21-001-4 AND PERFORMED INSPECTION CHECK IAW MM26-21-001-6. OPS NORMAL.

Part: DOOR — OUT OF ADJUST (L1) · airframe 29,600 hrs · 20,067 cycles

ON LANDING, FWD ENTRY DOOR LIGHT ILLUMINATED ON S/O PANEL VISUAL INSPECTION, DURING SHUTDOWN VERIFIED FWD ENTRY DOOR WAS SLIGHTLY AJAR. ADJUSTED UPPER LINK ARM AND ALIGNED TORQUE TUBES REF 52-11-001-5. START WITH C. STEP (8). ADJUSTED IAW STEP 3. FORWARD ENTRY DOOR ADJUSTMENT FOR SOFT UNLATCHING. , DOOR LIGHT CHECKED GOOD AND CLOSING FORCE WAS GOOD REF AMM 7270200-52-11-001-5.

Part: WARNING LIGHT — FALSE ACTIVATION (PAX DOOR) · airframe 29,599 hrs · 20,066 cycles

ON LANDING, FWD ENTRY DOOR LIGHT ON S/O PANEL ILLUMINATED. VISUAL INSPECTION DURING SHUTDOWN, CHECKLIST VERIFIED FWD ENTRY DOOR WAS SLIGHTLY AJAR. OPS CHECK OF FWD ENTRY DOOR WARNING SWITCH CHECKED GOOD REF AMM CH 52-70-001-5.

Part: DOOR — OUT OF ADJUST (MAIN PAX) · airframe 29,598 hrs · 20,065 cycles

DURING CLIMB, PASSING 2000 AGL. FWD ENTRY ANNUNCIATOR LIGHT ON, SO PANEL ANNUNCIATED. RAN QRH. INSPECTED DOOR HANDLE AND LIGHT EXTINGUISHED. PRESSURIZATION OK THROUGHOUT. CONTINUED IAW QRH. FOUND LT ENTRY DOOR NOT LATCHING IN DETENT. ADJUSTED DOOR TO CORRRECT FOR SOFT UNLATCHING IN REF TO AMM 52-11-001-5. OPS CHECKED FORWARD ENTRY DOOR SWITCH IN REF TO AMM 52-70-001-5. OPS CHECKED GOOD.

Part: DOOR — OUT OF ADJUST · airframe 29,587 hrs · 20,058 cycles

FWD ENTRY DOOR HANDLE MOVED SLIGHTLY TOWARD OPEN DURING LANDING AND FWD ENTRY DOOR LIGHT ILLUMINATED. ADJUSTED FWD ENTRY DOOR FOR SOFT UNLATCHING AND OPS CHECKED FWD ENTRY DOOR OK IAW MM 52-11-001-5.

Part: LIGHT — LOOSE (CABIN) · airframe 29,546 hrs · 20,016 cycles

EMERGENCY EXIT LIGHT CAME LOOSE ON LANDING. RE-INSTALLED LIGHT IAW AMM 33-50-001-2-0. OPS NORMAL.

Part: WIRE — DAMAGED (LE FLAP SYSTEM) · airframe 29,439 hrs · 19,918 cycles

UPON INTIAL FLAP RETRACTION FROM 5 DEG TO 2 DEG, NR6 L/E FLAP DID NOT RETRACT, QRH PROCEDURE RAN WITH NO SUCCESSFUL RETRACTION. ON TAXI-IN, FLAP HANDLE BROUGHT UP AND NR6 L/E FLAP STILL INDICATED EXTENDED. TROUBLE SHOT TO WIRES AT CONNECTOR D916. BUILT UP AND INSTALLED A NEW CONNECTOR (AIRCRAFT SIDE) WITH NEW WIRE PER SWP MANUAL 20-61-00. SPLICED WIRE W568-005-20 AND W568-006-20. APPROX 12 INCHES FROM CONNECTOR TO AIRCRAFT WIRES PER SWP 20-30-12.WIRES W568-050-20 AND W568-048-20 ARE ALL NEW. PERFORMED OPS CHECK OF FLAP/SLAT SYSTEM PER AMM 27-82-000-0. OPS CHECKED NORMAL.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 29,312 hrs · 19,818 cycles

EMERGENCY EXIT LIGHT INOPERATIVE DURING STBY POWER TEST OVER COCKPIT DOOR & OVER MAIN ENTRANCE DOOR. REPLACED EMERGENCY EXIT LIGHTS BATTERY IAW SMP. OPS CHECKED GOOD. AC OK FOR SERVICE.

Part: DOOR — OUT OF ADJUST (MAIN PAX) · airframe 29,286 hrs · 19,796 cycles

UPON LANDING THE FWD ENTRY LIGHT ON THE SO DOOR WARNING PANEL ILLUMINATED. ON INSPECTION, CREW FOUND CREW ENTRY DOOR TO BE OPEN AND UNSECURED. PERFORMED ADJUSTMENT TEST REF AMM 52-11-001-5 NO DEFECTS NOTED. ACFT OK TO CONTINUE SERVICE.

Part: DOOR — UNSECURE (FWD ENTRY) · airframe 29,286 hrs · 19,796 cycles

UPON LANDING THE FWD ENTRY LIGHT ON THE SO DOOR WARNING PANEL ILLUMINATED. UPON INSP, CREW FOUND CREW ENTRY DOOR TO BE OPEN AND UNSECURED. PERFORMED ADJUSTMNET TEST REF AMM 52-11-001-5. NO DEFECTS NOTED. OK FOR SERVICE.

Part: ENGINE — OVERHEATED (NR 2) · airframe 29,034 hrs · 19,610 cycles

NR 2 ENG FIRE LIGHT AT 340, BOTH BOTTLES FIRED AFTER FOLLOWING QRH. FIRE DEPT INDICATED NR 2 ENG HAD SIGNIFICANT HEAT SIGNATURE. R & R NR 2 ENG FIRE SENSING ELEMENTS BOTH BOTTOM & TOP. INSTALLED SQUIBS & FIRE BOTTLES. C/W HIGH POWER RUN.

Part: FIRE LOOP — DIRTY (NR 1 NACELLE) · airframe 28,802 hrs · 19,428 cycles

RECEIVED NR 1 ENGINE FIRE INDICATION ON FINAL APPROACH WITH POWER AT IDLE. SYS TESTED OK & ENGINE WAS SHUTDOWN AND BOTTLE DISCHARGED IAW CHECKLIST. FIRE WARNING SYS STILL DID NOT SILENCE UNTIL ON THE GROUND & NR 1 ENGINE DET "B" CB PULLED. EMERGENCY VEHICLES CONFIRMED NO SIGN OF FIRE. *(NO OTHER INDICATIONS OF FIRE WERE RECOGNIZED.) R & R NR1 ENG PYLON FIRE DETECTION LOOP ASSY IAW AMM 26-11-012-4-0. OPS CHECKS GOOD. R & R ENGINE FIRE DETECTION CONTROLLER IAW MM 26-11-000-4. OP'S CHECK OK. RAN ENG IAW OP'S CHECK OK. NO LEAKS NOTED.

Part: SMOKE WARNING — FALSE ACTIVATION (CARGO BAY) · airframe 28,634 hrs · 19,306 cycles

DURING FLIGHT, LOWER AFT CARGO SMOKE AND ARMED LIGHT ILLUMINATE WITH ASSOCIATED BELL. THIS OCCURED 10 SECONDS AFTER WING ANTI-ICE SELECTED OPEN. LIGHT WENT OUT AFTER THE BOTTLE WAS DISCHARGED AND THE SYSTEM TESTED GOOD. REMOVED FWD/AFT CARGO COMPARTMENT LINING AS REQUIRED IAW MM 25-52-002-4. PERFORMED DETAIL VISUAL INSPECTION AT FWD/AFT CARGO COMPARTMENT AREAS FOR ANY DAMAGE. NO DAMAGE FOUND. REMOVED AND REPLACED NR 1 AFT CARGO FIRE BOTTLE IAW MM 26-17-001-5. PERFORMED OPS CHECK LEAK CHECK GOOD IAW MM 26-17-001-5. INSTALLED FWD/AFT CARGO COMPARTMENT LINING IAW MM 25-52-002-4.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 28,633 hrs · 19,304 cycles

MAIN CABIN SEAT TRACK AT BS 495 LBL 45 INBD FLANGE LOWER SURFACE IS CORRODED.

Part: SEAT TRACK — GOUGED (BS 1150-1160) · airframe 28,633 hrs · 19,304 cycles

AFT CABIN STA 1150-1160 BL0 AFT SEAT TRACK SECTION HAS GOUGES AND DAMAGE AROUND SEVERAL SCALLOPS.

Part: STIFFENER — CRACKED (NOSE COWL) · airframe 28,633 hrs · 19,304 cycles

NR 1 ENGINE NOSE COWL EXTERIOR AFT BACKSIDE BULKHEAD I/B AT 5 O'CLOCK POSITION VERTICAL ANGLE STIFFENER SUPPORT IS CRACKED AT TOP END REMOVED VERTICAL STIFFENER NR 1 ENG NOSE COWL AFT AT 5 O'CLOCK BULKHEAD IAW SRM REV 103 51-30-2 FABRICATED NEW STIFFENER FROM 2024T3 .040" DIM 6" X 3" IAW SRM 51-20-1 FIG 7 INSTALLED STIFFENER IAW SRM 51-30-2 REV 103

Part: NOSE COWL — DAMAGED (NR 3) · airframe 28,633 hrs · 19,304 cycles

DAMAGE BOTTOM NR 3 NOSE COWL. REMOVED AND REPLACED NR 3 ENGINE NOSE COWL IAW MM 71-10-021-4. REFERENCE NON-ROUTINE N00917 WORK ORDER 00049152.

Part: SEAT TRACK — DAMAGED (BS 835) · airframe 28,633 hrs · 19,304 cycles

MAIN CABIN SEAT TRACK SEAT TRACK BS 835 LBL 45 HAS BROKEN SCALLOP. REMOVED AND REPLACE SEAT TRACK SECTION FROM BAC 1520-1331 7178-T6511 DIM 95 1/8" IAW SRM 51-30-2, 51-10-1, 53-10-2 FIG 7, 51-20-2 FIG 21, 51-30-5, AND 51-10-2 AT BS 760 TO 850 RBL 45.

Part: SEAT TRACK — DAMAGED (BS 500-510) · airframe 28,633 hrs · 19,304 cycles

MAIN CABIN SEAT TRACK AT BS 500-510 BL 0 HAS BROKEN SCALLOPS. REMOVED SEAT TRACK SECTION AT STA 360 TO 550 BL0, FABRICATED SEAT TRACK FROM BAC 1520-1331 7178-T6511 DIM. 189 1/2", TREATED AND PRIMED SEAT TRACK, AND INSTALLED SEAT TRACK AND SPLICE IAW SRM 51-30-2, 51-30-5, 51-10-1, 51-20-2 FIG 21, 53-10-2 FIG 7, AND 51-10-2.

Part: SKIN — GOUGED (NR 2 SLAT) · airframe 28,633 hrs · 19,304 cycles

NR 2 SLAT LOWER T/E SKIN GOUGED AT O/B SLAT HOOK AREA TRIMMED OUT DAMAGED AREA DIM: 1/2" X 1/2" IAW SRM 51-10-1. FABRICATED REPAIR PLATE FROM 2024 T-3 .125" DIM: 4" X 6" IAW SRM 57-50-3 FIG 10. INSTALLED REPAIR PLATE IAW SRM 51-30-2, REV 103.

Part: SEAT TRACK — DAMAGED (BS 680-700) · airframe 28,633 hrs · 19,304 cycles

MAIN CABIN SEAT TRACK AT BS 680-700, LBL 62.5 HAS DAMAGED SCALLOPS. CUT OUT DAMAGED AREA BS 656 TO 728 LBL 62.5, FABRICATED NEW SECTION, SPLICE REPAIR, ANGLES, AND FILLERS IAW SRM 53-10-5 FIG 1. INSTALLED REPAIR IAW SRM 53-10-5 FIG 1.

Part: WEB — CRACKED (BS 1220) · airframe 28,633 hrs · 19,304 cycles

AFT AIRSTAIRS LT LOWER TORQUE BOX INBD WEB HAS CRACK AT LIGHTING HOLE BS 1220. TRIMMED OUT DAMAGED AREA DIM. 3/4" X 3/8" IAW SRM 51-10-1. FABRICATED REPAIR DOUBLER FROM 7075T6 0.032" DIM. 4" X 2" IAW SRM 53-10-2 FIG 6 AND 51-40-2 FIG 1. INSTALLED REPAIR DOUBLER IAW SRM 51-30-2 AT AFT AIRSTAIRS LT LOWER TORQUE BOX INBD WEB AT LIGHTING HOLE BS 1220.

Part: SHEAR TIE — CORRODED (BS 950E S28-29R) · corrosion level 2 · airframe 28,633 hrs · 19,304 cycles

CORROSION ON SHEAR TIE AT BS 950E BETWEEN STRINGERS 29R AND 28R. FABRICATED NEW STUB FRAME FROM 7075 0 .040" DIM 22" X 5" IAW SRM 51-10-3 AND 51-20-1 FIG 7 REV 103. REMOVED SHEAR TIE AT BS 950E BETWEEN STR 29R AND 28R IAW SRM 51-30-2 AND REINSTALLED SHEAR TIE IAW SRM 51-30-2.

Part: FLOORBEAM — CORRODED (BS 400) · corrosion level 2 · airframe 28,633 hrs · 19,304 cycles

MAIN CABIN FLOORBEAM AT BS 400 BETWEEN LBL 45 AND 25 UPPER I BEAM TOP AND BOTTOM SURFACE IS CORRODED. CUT OUT DAMAGED AREA IAW SRM 53-10-8 FIG 3. FABRICATED REPAIR PARTS. INSTALLED REPAIR IAW SRM 53-10-8 FIG 3 AND 51-10-2.

Part: FRAME SPLICE — DAMAGED (BS 950B S24L) · airframe 28,633 hrs · 19,304 cycles

UPON FRAME REMOVAL, FOUND DOUBLE DRILLED HOLES IN FRAME SPLICE, STA 950B, STR 24L. REMOVED PRODUCTION SPLICE/DOUBLER IAW SRM 51-30-2 FORMED NEW DOUBLER IAW SRM 51-20-1 FIG 7 INSTALLED NEW DOUBLER IAW SRM 51-30-2 REV 103.

Part: FLOORBEAM — CORRODED (BS 344) · corrosion level 2 · airframe 28,633 hrs · 19,304 cycles

CORROSION ON UPPER FLANGE OF FLOORBEAM AT BS 344 FROM LBL 10 TO RBL 10. REMOVED DAMAGED AREA 8' SECTION IAW SRM 53-10-8 AND 51-30-2. FABRICATED REPAIR TEE SECTION, ANGLES, AND SHIMS IAW SRM 53-10-8 FIG 9 DETAIL 1. INSTALLED REPAIR PARTS IAW SRM 51-30-2 AND 53- 10-8 FIG 9 DETAIL 1.

Part: ATTACH ANGLE — CRACKED (LT WING) · airframe 28,633 hrs · 19,304 cycles

LT WING FALSE SPAR ATTACH ANGLE IS CRACKED WBL 118. REMOVED DOUBLER AND CUT OUT LOWER CHORD IAW DRAWING SR27-57-038 REV C. FABRICATED REPAIR ANGLES, NEW WEB, NEW I/B CHORD SECTION, NEW STRAP, RADIUS FILLERS, AND NEW WEB IAW DRAWING SR 27-57-038 REV C. INSTALLED NEW WEB, I/B WEB SECTION, LOWER CHORD, STRAPS AND RADIUS FILLERS IAW DRAWING 27-57-038 REV C.

Part: KEELBEAM — CRACKED (BS 870) · airframe 28,633 hrs · 19,304 cycles

RT WW, RT KEEL BEAM IS CRACKED AT BS 875 RBL10 TRIMMED OUT DAMAGED AREA AT LOWER CHORD OF KEEL BEAM STA 875 RBL 6 IAW SRM 51-10-1. FABRICATED DOUBLER FROM PN 15-5PH 0.071" DIM. 8.6250' X 4" AND INSTALLED DOUBLER IAW EA 7-5310-135591.

Part: STRINGER — CORRODED (BS 950D-950E) · corrosion level 2 · airframe 28,633 hrs · 19,304 cycles

CORROSION ON STRINGER 29L BETWEEN BS 950D AND 950E. REMOVED AND REPLACED STRINGER 29L FROM BS 950 - 1010 IAW B727 SRM 53-10-2 FIG 9, 51-30-5 AND 51-30-2 REV 103

Part: SKIN — CORRODED (BS 1030) · corrosion level 2 · airframe 28,633 hrs · 19,304 cycles

UPON REMOVAL OF STRINGER SECTION, FOUND SKIN CORRODED, BS 1030 AFT OF FRAME AT STRINGER 26R. CUT OUT DAMAGED AREA AT BS 1045 DIM 9" X 3" IAW B727 SRM 53-30-3 FIG 5 FABRICATED DOUBLER, FILLER, AND SKIN FILLER IAW 53-30-3 FIG 5 REV 103, INSTALLED REPAIR PARTS IAW SRM 53-30-3 FIG 5

Part: SKIN — CORRODED (100) · corrosion level 2 · airframe 28,633 hrs · 19,304 cycles

SKIN BULGE STA 1173 AT LAP SEAM STR 20R. COMPLIED WITH EA 7-5330-135593.

Part: SKIN — BULGED (BS 1052 S26L) · airframe 28,633 hrs · 19,304 cycles

SKIN BULGE STA 1052, STR 26L, LAP SEAM. CUT OUT LOWER SKIN DIM. 2" X 2" AT STA 1052 STR 26L LAP SEAM. FABRICATED REPAIR FROM 2024T3 0.071" DIM. 9.750" X 9", DOUBLER FROM 2024T3 0.063" DIM. 11" X 5", AND FILLER FROM 2024T3 0.050" DIM. 2" X 2". IAW SRM 53-30-3 FIG 5. INSTALLED REPAIR IAW SRM 53-30- 3 FIG 5.

Part: WEB — CRACKED (BS 1223) · airframe 28,633 hrs · 19,304 cycles

AFT STAIRWELL LT LOWER TORQUE BOX INBD WEB IS CRACKED AT LIGHTING HOLE BS 1223. TRIMMED OUT DAMAGED AREA DIM. 1/2" X 1/4" AND 1/2" X 1/8" IAW SRM 51-10-1. FABRICATED REPAIR DOUBLERS. IAW SRM 53-10-2 FIG 6 AND 51-40-2 FIG 1. INSTALLED REPAIR DOUBLERS IAW SRM 51-30-2.

Part: STRINGER — CORRODED (BS 1040-1055) · airframe 28,633 hrs · 19,304 cycles

STRINGER 26L AT BS 1040-1055 IS CORRODED AT LOWER SURFACED. CUT OUT DAMAGED STRINGER FROM STA 1040 TO 1055 IAW SRM 53-10-1 FIG 1. FABRICATED STRINGER FROM BAC1498-147 7075T6 DIM 15 7/8" AND 2EA SPLICES FROM BAC1498-131 7075T6 DIM 12 1/4". INSTALLED REPAIR IAW SRM 53-10-1 FIG 1 AND 51-30-2.

Part: WEB — CRACKED (BS 1303) · airframe 28,633 hrs · 19,304 cycles

AFT AIRSTAIRS RT LOWER TORQUE BOX INBD WEB HAS CRACK AT LIGHTING HOLE BS 1303. TRIMMED OUT DAMAGED AREA DIM. 1" X 1/2" IAW SRM 51-10-1. FABRICATED REPAIR DOUBLER IAW SRM 53-10-2 FIG 6 AND 51-40-2 FIG 1. INSTALLED REPAIR DOUBLER IAW SRM 51-30-2.

Part: SKIN — BULGED (BS 1045 S26R) · airframe 28,633 hrs · 19,304 cycles

SKIN BULGE STA 1045 STR 26R LAP SEAM. REMOVED CORRODED STRINGER SECTION FROM BS 1026 TO 1070, STR 26R IAW SRM 51-30-2. FABRICATED 3 (EA) STRINGER SECTIONS FROM BAC1498-147 7075 T62 DIM 19" AND 4 (EA) SPLICE SECTIONS FROM BAC1498-131 7075 T6 DIM 9" IAW SRM 53-10-3, FIG 1 AND 51-30-5 INSTALLED 3 (EA) STRINGER SECTIONS AND 4 (EA) SPLICE SECTIONS IAW SRM 51-30-2 AND 53-10-3, FIG 1, REV 103.

Part: SKIN — CRACKED (BS 1010 S28R) · airframe 28,633 hrs · 19,304 cycles

RT LOWER AFT FUSELAGE AT BS 1010 STR 28R EXTERIOR SKIN IS CRACKED AND BULGING. CUT OUT DAMAGED AREA IAW SRM 53-30-3 FIG 3A REV 103. FABRICATED REPAIR DOUBLER AND FILLER IAW EA 7-5330-135592. INSTALLED REPAIR DOUBLER AND FILLER IAW EA 7-5330-135592.

Part: INDICATOR — BURNED · airframe 27,589 hrs · 18,512 cycles

AT FLIGHT LEVEL 390 SMELLED FUMES IN COCKPIT. DECLARED AN EMERGENCY AND LANDED AT DEN AIRPORT. MED BRAKE WAS USED AND EMERGENCY EGRESS CONDUCTED. FSFO CHECKLIST EXECUTED. ISOLATED BURNED ODOR TO FLT ENGINEERS PANEL AND FOUND NR 3 ENGINE OIL QUANTITY IND INOP WHEN RUNNING NR 3 ENGINE. INDICATOR WOULD TEST NORMALLY, BUT INDICATION WOULD STAY FULL AFTER ENGINE START. REMOVED CONNECTOR AND FOUND BURNED ODOR AT INDICATOR. ORDERED NEW INDICATOR. REMOVED AND REPLACED NR 3 ENG OIL QTY INDICATOR PER MM 31-00-011-4 AND REF 79-31-000-5 FOR OPS CHECK. GAGE OPS CHECKS NORMAL. DURING TROUBLE SHOOTING, RAN ALL 3 ENGINES WITH PACKS OPERATING. NO ELECT BURNED ODOR NOTED.

Part: INDICATOR — FAILED (AIRSPEED) · airframe 27,547 hrs · 18,483 cycles

F/O AIRSPEED INDICATOR FAILED: NEEDLE STOPPED AT 200 KTS AND OFF FLAG, RESTORED THEN SECOND FAILURE AT 250 KTS AND OFF FLAG. REMOVED AND REPLACED NR 2 AIRSPEED INDICATOR. SYS CKS NORMAL. NO LEAKS NOTED IAW 727 M/M 34-12-000-5. PREMATURE REMOVAL/INSTALLATION OFF MFG 2083-08-1 POS P2 SRL 1237 ON MFG 2083-12-1 SRL RM063 TAG 702207.

Part: ACTUATOR — BROKEN (DOOR WARNING) · airframe 27,418 hrs · 18,391 cycles

AFT AIRSTAIR LIGHT ILLUMINATED IN-FLIGHT CLIMBING THROUGH 4,500 FEET. ACN RELEASED FOR SERVICE PER MEL/CDL: 52-06-B. AMBER AFT AIRSTAIR DOOR WARNING LIGHT INOP." REPLACED WARN RT HAND UPLOCK ROLLER FITTING PER SMP, FOUND SWITCH S395 ROLLER ACTUATOR BROKEN AND SWITCH INOP. REPLACED S395 AND ROLLER ACTUATOR PER WDM 52-71-01 AFT AIRSTAIR OPERATION AND ALL INDICATIONS CK OK PER MM 52-62-001-5

Part: TRANSMITTER — LOOSE (NR 2 OIL PRESS) · airframe 26,539 hrs · 17,742 cycles

NR 2 LOW OIL PRESSURE FILTER BYPASS LIGHT ILLUMINATED IN DESCENT FOLLOWED BY OIL PRESSURE DROP TO ZERO. QRH PERFORMED, ENGINE SHUT DOWN WITH OIL PRESSURE AT 5 TO 10 PSI OIL QUANTITY NORMAL. TEMP RISING GRADUALLY ENGINE SHUTDOWN 13 MINUTES AFTER FIRST INDICATION. ENGINE WIND MILLED APPROXMATELY 15 MINUTES BEFORE LANDING. DURING NR 2 ENG PURGE PROCESS, FOUND THAT THE OIL LINE TO THE OIL PRESSURE TRANSMITTER WAS LOOSE AT THE TRANSMITTER CONNECTION FITTING. PRATT-WHITNEY HAS BEEN SATISFIED THAT THE NR 2 ENG IS OK FOR SERVICE.

Part: WINDOW — DELAMINATED (R1) · airframe 24,394 hrs · 16,136 cycles

UPPER PORTION OF WINDOW R1 IS DELAMINATING, AND A BUBBLING FLUID IS PRESENT INSIDE THE DELAM, R1 OUTER PANE CRACKED. REMOVED AND REPLACED RT NR 1 WINDSHIELD PER MM 56-11-011-4. REMOVED AND REPLACED WINDOW HEAT CONTROLLER PER MM 30-41-02, PRECAUTIONARY R/I. PREMATURE REMOVAL/INSTALLATION OFF MFG 5-89354-3130, POS RT SRL 01346R5016, TAG 61A952 ON MFG 5-89354-3136 SRL 03077R9056, TAG 794227 R/I. PREMATURE REMOVAL/INSTALLATION OFF MFG 231-3, POS 3 SRL 5511 TAG A62037 ON MFG 231-3 SRL 3923, TAG 5A6658. INSTALLED TRIM PIECES INSTALLATION COMPLETE. WINDSCREEN HEAT OPS NORMAL PER MM 30-41-02.

Part: PUMP — FAILED (HYD SYSTEM) · airframe 24,337 hrs · 16,102 cycles

HYD SYS B OVERHEAT LIGHT IN FLT TURNED ELEC PUMP NR 1 OFF AND LIGHT WENT OUT. REMOVED AND REPLACED NR 1 B PUMP PER MM-29-12-011-2. OPS CKS AND LEAK CKS GOOD. CYCLED ALL FLIGHT CONTROLS ON B SYS TO ENSURE NO AIR IN SYSTEM. NOTE, CASE DRAIN ALSO REMOVED AND REPLACED PER MM, CKS GOOD.

Part: FLAP — JAMMED (TE FLAPS) · airframe 24,283 hrs · 16,067 cycles

ASYMETRICAL INBOARD TRAILING EDGE FLAPS AT 2 DEGREES UPON FLAP RETRACTION. RAN APPROPRIATE QRH PROCEDURES, FOUND LT INBD FLAP COCKED AND JAMMED INTO INBD AILERON. UPON FURTHER TROUBLESHOOTING FOUND BEARING WALKED OUT OF SCREWSHAFT END OF LT INBD TRANSMISSION. REMOVED AND REPLACED REPLACEMENT I/B J/S PER 727-200 M/M 27-51-041-4 . STILL REQUIRES UP-STOPS SET TORQUE TUBES SAFETY, OPS AND RII BUY BACK.

Part: SENSOR — MALFUNCTIONED (ZONE 700) · airframe 24,233 hrs · 16,033 cycles

AFTER DEPARTURE L/G LEVER WOULD NOT MOVE PAST OFF DURING GEAR RETRACTION. L/G LEVER LATCH FAILED TO RELEASE. LEVER LATCH LIGHTES C/B LEFT OUT PER QRH. QRH PROCEDURES COMPLIED WITH, LANDED AT KABE. REMOVED AND REPLACED LANDING GEAR AIR SAFTEY SENSOR PER M/M REF 32-09-221-4. TESTED OK PER EA 7-3210-90155. AIRCRAFT OK FOR FURTHER SERVICE. PREMATURE REMOVAL/INSTALLATION OFF MFG 1-899-15.

Part: FLOORBEAM — DAMAGED (FUSELAGE) · airframe 23,999 hrs · 15,891 cycles

COMPLY WITH EA 7-5321-55461 FUSELAGE - FLOORBEAM LOWER CHORD REPAIR, STA 720 AT RBL 13.0. COMPLIED WITH EA 7-5321-55461.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 23,999 hrs · 15,891 cycles

STA 740 AFT PRESSURE BULKHEAD AFT FACE LOWER SPAR CAP AREA CORROSION RUNNING INTO SUPPORT ANGLE ON LT SIDE OF DELTA KEEL BEAM. ACCESSED AREA TO GAIN ACCESS TO REPAIR AREA, FOUND ANGLE P/N 69-43695-1 CORRODED WITH 100 PERCENT MATERIAL LOSS. REMOVED ANGLE IAW SRM 51-30-2. FABRICATED NEW ANGLE ON MAE TRAVELER T5/498923. LOCATED & DRILLED IAW SRM 51-30-5. INSTALLED ANGLE IAW SRM 51-30-2. REINSTALLED ITEMS, REMOVED FOR ACCESS IAW SRM 51-30-2, MM 20-10-005-4. CORROSION WAS ON ANGLE P/N 69-43695-1 ONLY. NO OTHER CORROSION NOTED.

Part: WARNING LIGHT — FALSE ACTIVATION (AIRSTAIR) · airframe 23,671 hrs · 15,658 cycles

AFT AIRSTAIR LIGHT ILLUMINATED AFTER TAKEOFF. RELEASED FOR SERVICE PER MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 15NOV04 MEL 52-06-B: AMBER AFT AIRSTAIR DOOR WARNING LIGHT INOP. MEM R CHECK AFT AIRSTAIR UP POSITION FOR ADJUSTMENT, PER MM 52-70-001-5 NO FAULTS NOTED. CHECKED AFT AIRSTAIR UP LOCK SWITCH FOR ADJUSTMENT, PER MM 52-70-001-5, NO FAULTS NOTED. R&R AFT AIRSTAIRS_UP LOCK SWITCH AS PRECAUTIONARY PER MM 52-70-001-5.

Part: LIGHT — FALSE ACTIVATION (AIRSTAIR DOOR) · airframe 22,980 hrs · 15,150 cycles

AFT AIRSTAIR LIGHT ILLUMINATED SHORTLY AFTER TAKEOFF AT 4500 FT & 240 KNOTS. RETURNED BACK TO MEM & LIGHT WENT OUT AFTER LANDING. MEL 05MAR04 12:10. ACN RELEASED FOR SERVICE PER MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 15MAR04.

Part: WARNING LIGHT — ILLUMINATED (AIRSTAIR) · airframe 22,866 hrs · 15,073 cycles

ON DEPARTURE, AMBER AFT AIRSTAIR LIGHT ON F/E'S DOOR ANNUNCIATOR PANEL ILLUMINATED. COMPLIED WITH QRH. RETURN TO GTF.

Part: SWITCH — FAILED (KRUEGER FLAP) · airframe 21,735 hrs · 14,187 cycles

DURING FLAP RETRACTION, NR 3 KRUEGER FLAP REMAINED IN TRANSIT. NO GREEN LIGHT ON FRONT PNL. AMBER LIGHT ILLUMINATED ON S/O PNL. PERFORMED QRH FOR LED FAILURE DURING FLAP RETRACTION LED'S WERE POSITIONED NORMALLY AT FLAPS 5. RETURNED TO DLH FOR A NORMAL LANDING. REMOVED AND REPLACED LEADING EDGE FLAP POSITION SWITCH IAW MM 27-82-001. SYSTEM OPS CHECKED NORM.

Part: MOUNT — CRACKED (NLG)

NOSE GEAR DOWN LOCK ACTUATOR MOUNT IS CRACKED. REMOVED AND REPLACED ACTUATOR PER SRM 51-30-2.

Part: SKIN — GOUGED (FUSELAGE)

GOUGE IN SKIN AT BS 588, STR 22L. REMOVED AND REPLACED SKIN PER SRM 53-30-1.

Part: STRAP — CORRODED (FUSELAGE) · corrosion level 2

CORROSION ON STRAP AT BS 870 BULKHEAD, LBL 60 18 INCHES I/B OF TERMINAL FITTING. REMOVED AND REPLACED STRAP PER EA 7-5310-64069.

Part: SKIN — WORN (FUSELAGE)

FUSELAGE SKIN IS WORN AT RT RAIN GUTTER AT BS 1342. REMOVED AND REPLACED SKIN PER SRM 53-10-1, 51-20-1, 54-30-3, 51-10-2.

Part: SKIN — DAMAGED (FUSELAGE)

CREASE IN SKIN AT BS 1105, STR 19R. REMOVED AND REPLACED SKIN PER SRM 53-30-3.

Part: SKIN — DENTED (FUSELAGE)

DENT ON SKIN LAP BS 595, STR 19L. REMOVED AND REPLACED SKIN PER SRM 53-30-1, 53-30-3, 51-10-2, 51-20-4.

Part: KEELBEAM — CORRODED (FUSELAGE)

CORROSION (C53-113-01, 02) ON O/B FLANGE OF KEEL BEAM BS 950B - 950D, RBL 8. REMOVED FLANGE PER EA 7-5310-64072.

Part: SKIN — DAMAGED (FUSELAGE)

CREASE IN SKIN BS 1065, STR 19R - 20R. REMOVED AND REPLACED SKIN PER SRM 53-30-3 FIG 1.

Part: SKIN — BULGED (FUSELAGE)

SKIN BULGED AT BS 975, STR 28R. REMOVED AND REPLACED SKIN PER SRM 53-30-3.

Part: ACCESSORY UNIT — FAILED (E/E BAY)

AFT T/O LG LEVER W/N RAISE PAST OFF POS. LOUD NOISE AND VIB OCCURRED WITH NOSE WHEEL. REMOVED AND REPLACED LAND POSITION WARN ASSY UNIT PER MM 32-09-121-4.

Part: FIRE DETECTOR — FALSE ACTIVATION (NR 1 ENGINE)

01-003 NR 1 ENGINE FIRE INDICATION ON T/O ROLL ABOUT 70 KNOTS. DISCHARGE BOTH BOTTLES, LIGHT STAYED ON. ** S/D ** R&R SENSING ELEMENT & BOTH BOTTLES PER IAW MM 26-11-012-4, 2627-071-4. ALL SYS CK GOOD.

Part: CONNECTOR — DIRTY (CARGO COMPT)

99-157 - AFT T/O CARGO FIRE IND AT POS 4/5. POS 5 LIGHT STEADY 4 WAS INTERMITTENT. BLEW SENSING LINES FROM ALL 6 SMOKE DETECTORS BACK INTO CABIN. CLEANED CANNON PLUGS ON DETECTORS. SMOKE DETECTION TEST NORM IAW MM 26-16-001-5.

Part: ELEMENT — FALSE WARNING (NR 1 ENGINE)

NR 1 MASTER FIRE WARNING ILLUMINATED FOLLOWED BY NR 1 ENGINE FIRE INDICATIONS. EMERGENCY ACTIONS ACCOMPLISHED, LIGHTS WENT OUT, FIRE TEST NORMAL. AFTER LANDING FIRE LIGHT NR 1 REILLUMINATED. CREW AGGRESSED AIRCRAFT, EXITED AIRCRAFT VIA ESCAPE SLIDE. TROUBLESHOT AND FOUND FIRE DETECTION ELEMENT BAD. REMOVED AND REPLACED FIRE DETECTION ELEMENT PER MM 26-11-12. TESTED FIRE DETECTION SYSTEM, SYSTEM GROUND TESTED GOOD PER M/M 26-11-01.