N204US

Part: KEELBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 50,599 hrs · 31,785 cycles

DURING H-CHECK, FOUND CORROSION ON LT KEEL BEAM FROM BS 950-1010 WL 156. REPAIRED PER EA 22-170782.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 50,599 hrs · 31,785 cycles

DURING H-CHECK, FOUND CORROSION ON UPPER CHORD FLANGE OF THE BS 460 FLOORBEAM, FROM RBL 30 TO RBL 65. REPAIRED PER EA 22-170786.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 50,599 hrs · 31,785 cycles

DURING H-CHECK, FOUND CORROSION ON UPPER FLANGE OF FLOORBEAM UPPER AND LOWER SURFACES. REPAIRED PER EA 22-170785.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 50,599 hrs · 31,785 cycles

DURING H-CHECK, FOUND CORROSION ON FLOORBEAM UPPER FLANGE. REPAIRED PER EA22-170787.

Part: KEELBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 50,599 hrs · 31,785 cycles

DURING H-CHECK, FOUND CORROSION ON THE RT KEEL BEAM AFT OF BS 950F. REPAIRED PER EA 22-170781 REV A.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 50,599 hrs · 31,785 cycles

DURING H-CHECK, FOUND CORROSION ON TOP FLANGE OF FLOORBEAM AT BS 1110, LBL 12 TO RBL 23, WATER LINE 208. REPAIRED PER EA22-170790.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 50,599 hrs · 31,785 cycles

DURING H-CHECK, FOUND CORROSION ON FLOORBEAM UPPER FLANGE, TOP SURFACE BS 1130, LBL 13, LBL 25-45 AND LBL 60 WATERLINE 208. REPAIRED PER EA 22-170783.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING PREFLIGHT, FOUND LEFT CENTER EXTERIOR OVERWING EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK. OPERATIONAL CHECK OK.

Part: HEATER — INOPERATIVE (LT STATIC PORT)

AT FL350, THE LEFT STATIC PORT HEATER INDICATION LIGHT ILLUMINATED. RESET CIRCUIT BREAKER, NO HELP. AIRCRAFT DIVERTED TO CLE AND LANDED WITHOUT INCIDENT. REPLACED THE LEFT STATIC PORT HEATER, OPERATIONAL CHECK OK.

Part: PRBC — MALFUNCTIONED (CENTER ENGINE)

AS TAKEOFF POWER WAS APPLIED, THE CENTER ENGINE EXPERIENCED COMPRESSOR STALLS. CREW ABORTED TAKEOFF AND RETURNED TO GATE. MAINTENANCE REPLACED THE CENTER ENGINE PRESSURE RATIO BLEED CONTOL VALVE. ENGINE OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY LIGHTING ON CABIN FLOOR INOPERATIVE. REPLACED BATTERY PACK, OPERATIONAL CHECK OK.

Part: OUT FLOW VALVE — FAILED (LT/RT)

DURING CLIMB, COULD NOT HOLD AND MAINTAIN CABIN PRESSURIZATION. RETURNED TO MSP AND LANDED WITHOUT INCIDENT. REPLACED THE LEFT AND RIGHT OUTFLOW VALVES, RIGHT AIR CYCLE MACHINE, LEFT AND RIGHT 35 DEGREE SWITCHES AND SEALS AT FLOW MULTIPLIER DUCT, AND CHECKED AND TIGHTENED LOOSE CLAMPS. LEAK AND OPERATIONAL CHECK OK. AIRCRAFT OK FOR SERVICE.

Part: SWITCH — OUT OF ADJUST (NR 1 LE FLAP)

DURING CLIMB ON LEADING EDGE FLAP AND SLAT RETRACTION, NR 1 KRUEGER FLAP INDICATED STILL DOWN. FLIGHT RETURNED TO MSP. PERFORMED FUEL DUMP AND LANDED WITHOUT INCIDENT. MAINTENANCE ADJUSTED NR 1 KRUEGER FLAP SWITCH AND PERFORMED OPERATIONAL CHECK, SYSTEM CHECKED OK.

Part: TRIM BRAKE — MALFUNCTIONED (STAB TRIM)

DURING APPLICATION OF THRUST POWER, TAKEOFF WAS ABORTED TO THE HEAVY STICK PRESSURES. TAKEOFF WAS ABORTED AT 140 KNOTS AND PERFORMED WITH NO INCIDENTS. REPLACED STABILIZER TRIM BRAKE MECHANISM, MAIN STABILIZER TRIM ACTUATOR, AND R27 NOSE UP STABILIZER TRIM RELAY. PERFORMED OPERATIONAL CHECK OF STABILIZER SYSTEM. CHECKED OK.

Part: CROSSFEED VALVE — MALFUNCTIONED (NR 1)

DURING CRUISE, THE NR 1 FUEL CROSSFEED VALVE WOULD NOT OPEN. AIRCRAFT DIVERTED TO MEM, FUEL WAS DUMPED AND AIRCRAFT LANDED WITHOUT INCIDENT. LOCKED OPEN NR 1 FUEL CROSSFEED VALVE AND PLACED ON MEL.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING PRE-FLIGHT, FOUND EMERGENCY LIGHTS INOPERATIVE AT BOTTOM OF AFT AIRSTAIRS. REPLACED BATTERY PACK. OPERATIONAL CHECK OK.

Part: ACTUATOR — MALFUNCTIONED (NR 2 LE SLAT)

DURING DEPARTURE CLIMB UPON FLAP RETRACTION, THE NR 2 LEADING EDGE SLAT REMAINED EXTENDED WITH FLAPS UP SELECTED. NOTABLE VIBRATION WAS FELT. CREW JETTISONED 20,000 LBS OF FUEL AND RETURNED TO MSP WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE NR 2 SLAT ACTUATOR AND SLAT ASSEMBLY. OPERATIONAL CHECKS WERE NORMAL.

Part: ACTUATOR — MALFUNCTIONED (NR 2 LE SLAT)

DURING CLIMB UPON FLAP RETRACTION, THE NR 2 LEADING EDGE FLAP WOULD NOT RETRACT. CYCLED FLAPS TO NO AVAIL. CREW DECLARED A YELLOW EMERGENCY AND JETTISONED 20,000 POUNDS OF FUEL. AIRCRAFT RETURNED TO TPA WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE NR 2 LEADING EDGE SLAT VALVE AND ACTUATOR. LEAK AND OPERATIONAL CHECK WERE SATISFACTORY. PART TOTAL CYCLES, 32,960.

Part: RETRACT MECH — MALFUNCTIONED (NR 2 LE SLAT)

AFTER TAKEOFF DURING FLAP RETRACTION, THE NR 2 LEADING EDGE SLAT WOULD NOT RETRACT. RECYCLED FLAPS TO NO AVAIL. VISUAL INSPECTION AND INDICATION SYSTEM SHOWED NR 2 LEADING EDGE SLAT FULLY EXTENDED. FLIGHT CREW DECLARED A YELLOW EMERGENCY AND JETTISONED 22,000 POUNDS OF FUEL. FLIGHT RETURNED TO TPA WITHOUT FURTHER INCIDENT. MAINTENANCE PERFORMED A TEST HOP AND COULD NOT DUPLICATE MALFUNCTION. INVESTIGATION CONTINUES.

Part: STAB TRIM — OUT OF POSITION (COCKPIT)

WHEN POWER WAS ADVANCED FOR TAKEOFF, CONFIGURATION AURAL WARNING HORN SOUNDED, ABORTED DEPARTURE. RESET STABILIZER TO 3.1 UNITS AND SYSTEM CHECKED NORMAL.

Part: FLANGES — CORRODED (NR 1140)

DURING PERIODIC CHECK, FOUND CORROSION ON PANEL NR 1104 CUTOUT FLANGES, LBL 5 RBL 9. REPAIRED PER EA 22-99245.

Part: LONGERON — CORRODED (FS 620)

DURING PERIODIC CHECK, FOUND CORROSION ON LONGERON 27R AT FS 620. REPAIRED PER EA 22-99243.

Part: CASTING — CRACKED (EMERGENCY EXIT)

DURING PERIODIC CHECK, FOUND A CRACK IN THE LEFT AFT EMERGENCY EXIT LATCH OPENING FRAME. REPLACED CASTING.

Part: FLOORBEAM — CORRODED (FS 1130)

DURING PERIODIC CHECK, FOUND CORROSION ON THE BS 1130 FLOOR BEAM UPPER CHORD. REPAIRED BEAM (P/N 65-20838-16), PER EA 22-99070.

Part: SKIN — DELAMINATED (TE FLAP)

DURING PERIODIC CHECK, FOUND INBOARD AFT FLAP DELAMINATED AND SPLIT. REPLACED FLAP.

Part: SKIN — DELAMINATED (NR 2 SPOILER)

DURING PERIODIC CHECK, FOUND DELAMINATION IN THE LEFT WING NR 2 SPOILER UPPER SKIN. REPLACED SPOILER.

Part: SKIN — DELAMINATED (NR 5 SPOILER)

DURING PERIODIC CHECK, FOUND DELAMINATION IN THE LEFT WING NR 5 SPOILER UPPER SKIN. REPLACED SPOILER.

Part: AURAL WARNING — SOUNDED (FLIGHT DECK)

WEAK AURAL WARNING HORN SOUNDED ON TAKEOFF WITH 15 DEGREE FLAP SETTING, ABORTED TAKEOFF. SECOND DEPARTURE WAS NORMAL. MAINTENANCE REPLACED AURAL WARNING HORN UNIT. OPERATIONAL CHECK NORMAL.

Part: INDICATION — MALFUNCTIONED (TAIL SKID)

DURING DEPARTURE CLIMB UPON PLACING GEAR HANDLE IN 'OFF' POSITION, TAIL SKID INDICATION REMAINED ILLUMINATED. JETTISONED 6000 LBS OF FUEL AND RETURNED TO DTW WITHOUT FURTHER INCIDENT. MAINTENANCE VERIFIED INDICATION NOT DUE TO TAIL STRIKE. DEFERRED TAIL SKID INDICATION PER MEL 32-13.

Part: APEX PIN — MISSING (NOSE GEAR)

ON LANDING ROLLOUT AT 100 KTS, AIRCRAFT VEERED TO THE LEFT AND BEGAN TO SHUDDER. MAINTENANCE INSPECTED AIRCRAFT ON RUNWAY AND FOUND NOSE GEAR TORSION LINK APEX PIN MISSING. TOWED OFF RUNWAY AND REPLACED APEX PIN. OPERATIONAL CHECK WAS NORMAL.