N205FE

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 32,323 hrs · 18,751 cycles

AFT AIRSTAIR LIGHT ILLUMINATED IN FLIGHT. ACN RELEASED FOR SERVICE PER MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 02SEP06"MEL 52-06-B: AMBER AFT AIRSTAIR DOOR WARNING LIGHT INOP "C/0287060. PERFORMED OPS CHECK OF AFT AIRSTAIR WARNING SYSTEM PER M/M 52-70-001-5 PART G, USED BOTH HANDLES AND VERIFIED INDICATION IN THE COCKPIT AS WELL. NO DEFECTS NOTED, ALSO INBOUND FLIGHT CREW REPORTED. NO DEFECTS AS WELL. DEF CLEARED AND A/C IS GOOD FOR CONT SERVICE.

Part: WARNING LIGHT — FALSE ACTIVATION (COCKPIT) · airframe 32,323 hrs · 18,751 cycles

AMBER AFT AIRSTAIR LIGHT ILLUMINATED IN FLIGHT. RELEASED FOR SERVICE IAW MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 02SEP06 (MEL 52-06-B: AMBER AFT AIRSTAIR DOOR WARNING LIGHT INOP).

Part: INDICATOR — MALFUNCTIONED (AIRSPEED) · airframe 31,976 hrs · 18,521 cycles

REJECTED T/O AT 100 KTS 160,000 PDS. REQUIRES 33 MIN BRAKE COOLING FROM 0317Z. REJECT FOR CAPTAINS A/S INDICATOR. PERFORMED 33 MIN BRAKE COOLING INSP. CAPTAINS A/S INDICATOR CB PULLED BY MISTAKE FOR MEL 34-04-02. CB WAS RESET AND A/C RELEASED FOR SERVICE.

Part: ACTUATOR — FAILED (MLG) · airframe 31,266 hrs · 18,106 cycles

UPON GEAR EXTENSION, WHEN LANDING GEAR HANDLE WAS LOWERED, THE NOSE GEAR REMAINED UP. THE NOSE GEAR DOOR LT ON THE ENGINEERS PANEL NEVER ILLUMINATED, THE RED NOSE GEAR LT REMAINED ON ON THE FORWARD PANEL, THE GREEN NOSE GEAR LT REMAINED OUT, AND NO AURAL CLUES WERE HEARD THAT WOULD INDICATE GEAR EXTENSION. NORMAL HYDRAULIC QTY AND PRESSURE. AFTER APPROXIMATELY 3 MINUTES, WITH NO CREW ACTION, THE NOSE GEAR CAME DOWN NORMALLY, WITH GOOD INDICATIONS.

Part: INDICATOR — MALFUNCTIONED (EPR) · airframe 31,090 hrs · 17,992 cycles

REJECTED TAKEOFF UNDER 70 KNOTS DUE TO NO INDICATION ON NR 3 EPR GAUGE. COMPLIED WITH QRH AND MEL 77-01-01 NR 3 EPR INOP PROCEDURES. SUBSEQUENT TAKEOFF WAS UNEVENTFUL. PURGED MOISTURE FROM PT2 AND PT7 LINES TO NR 3 EPR TRANSMITTER WITH DRY NITROGEN AND RAN ENG'S NR 3 AND NR 2 ( NR 2 FOR COMPARISON). GROUND CHECKS NORMAL. NO 90 DAY HISTORY FOR THIS DISCREPANCY. OK TO CONTINUE.

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 30,526 hrs · 17,634 cycles

DURING DESCENT FOR APPROACH FROM 8000-4000 FT., REDUCED THROTTLES TO IDLE NR 1 ENG DID NOT RESPOND APPROPRIATELY. NR 1 ENG PARAMETERS WERE 1.09 EPR, N1 46.8, EGT 450, N2 72.5, FF 2000 PPH. RAN RED TABS FOR LOSS OF THROTTLE CONTROL. ENGINE WOULD ACCELERATE BUT WOULD NOT COME DOWN TO NORMAL IDLE. TAT 19.2. SHUTDOWN ENGINE IAW QRH AND LANDED. REMOVED AND REPLACED APPROACH IDLE SOLENOID VALVE PER B727-200 (JT8D-217C) NR 1 ENG. OPS CHECK GOOD, OK FOR SERVICE.

Part: CONTROL CABLE — OUT OF RIG (MLG) · airframe 28,874 hrs · 16,679 cycles

WHEN GEAR HANDLE WAS SELECTED TO OFF POS AFTER GEAR RETRATION, ALL UNSAFE LIGHTS ILLUMINATED AND GEAR EXTENDED UNCOMMANDED. GEAR HANDLE WAS SELECTED TO DOWN POS AND ALL SAFE LIGHTS ILLUMINATED. PUT A/C ON JACKS PER 727 AMM 07-11-000-2. DURING GEAR RETRACT, DUPLICATED THE PILOT WRI. FOUND LANDING GEAR CONTROL CABLES LGVB AND LGVA OUT OF RIG, SO RIG PIN WILL NOT LINE UP WITH RIG HOLE IN BEARING RETAINER (ABOUT A .5 INCH OFF) SEE REF: AMM 32-31-000-5, FIG 502 SHEET 1. ADJ/ RIG PER 727 AMM 32-31-000-5, PERFORM GEAR RETRACTION.

Part: INDICATOR — FAILED (COCKPIT) · airframe 28,483 hrs · 16,452 cycles

F/O'S MACH AIRSPEED INDICATOR INOP, FLAG IN VIEW. REPLACED F/O MACH/AIRSPEED INDICATOR. OPS CHECKS NORMAL ON GROUND AT THIS STATION IAW MM 34-12-000-5.

Part: ENGINE — MALFUNCTIONED (NR 2) · airframe 26,308 hrs · 15,329 cycles

NR 2 ENGINE LOST OIL QUANTITY AND PRESSURE SHORTLY AFTER TAKEOFF, WITH CORRESPONDING LOW OIL PRESSURE/FILTER BYPASS LIGHT ON IN FRONT PANEL. SHUTDOWN ENGINE IAW CHECKLIST AND RETURNED FOR UNEVENTFUL LANDING. REPLACED NR 2 ENGINE. OPS AND LEAK CHECK OK.

Part: STRUCTURE — DENTED (CARGO DOOR)

FWD CARGO DOOR LWR AFT CORNER DENTED. REMOVED AND REPLACED DOOR PER SRM 52-00-3.

Part: WEB — DAMAGED (FUSELAGE)

TWO HOLES IN FLOOR WEB BS 1134, LBL 24-26, WL 208. REMOVED AND REPLACED WEB PER SRM 51-40-2.

Part: WEB — DAMAGED (FUSELAGE)

TWO HOLES IN FLOOR WEB BS 1134, LBL 43-47, WL 208.

Part: WEB — PUNCTURED (FUSELAGE)

THREE PUNCTURES IN FLOOR WEB BS 1134-1138, RBL 24-26, WL 208. REMOVED AND REPLACED WEB PER SRM 51-40-2.

Part: WEB — PUNCTURED (FUSELAGE)

THREE PUNCTURES IN FLOOR WEB BS 1134 - 1138, RBL 43 - 47, WL 208. REMOVED AND REPLACED DOUBLER FOR WEB PER SRM 51-40-02.

Part: SKIN — CHAFED (FUSELAGE)

EXT FUSELAGE SKIN CHAFED AT BS 720D+13 INCHES AT STR 19L. REMOVED AND REPLACED SKIN PER SRM 53-30-3.

Part: FRAME — DENTED (FUSELAGE)

DENT ON I/B FLANGE OF FRAME BS 950C BETWEEN STR 26-27L. *S/D* REMOVED AND REPLACED FRAME PER SRM 51-40-3.

Part: FRAME — DENTED (FUSELAGE)

DENT IN FRAME I/B FLANGE BS 990 BETWEEN STR 23-24L. REMOVED AND REPLACED FRAME PER SRM 51-40-3.

Part: FRAME — DENTED (FUSELAGE)

DENT IN FRAME I/B FLANGE BS 1050 BETWEEN STR 26-27R. REMOVED AND REPLACED FRAME PER SRM 51-40-3.

Part: FRAME — DENTED (FUSELAGE)

DENT IN FRAME FLANGE BS 580, STR 23-24L. REPAIRED FRAME BS 580 BETWEEN STR 23 & 24L PER FEDEX EA 7-5310-62674.

Part: FRAME — DENTED (FUSELAGE)

DENT IN FRAME FLANGE BS 660, STR 23-24R. REPAIRED FRAME BS 660 BETWEEN STR 23R & 24R PER FEDEX EA 7-5310-62673.

Part: FRAME — DENTED (FUSELAGE)

DENT IN FRAME FLANGE BS 560, STR 24L. REPAIRED FRAME BS 560 AT STR 24L PER SRM 51-40-3 & FEDEX EA 7-5310-62674.

Part: FRAME — DENTED (FUSELAGE)

DENT IN FRAME FLANGE BS 680, STR 24-25R. REPAIRED FRAME BS 680 BETWEEN STR 24R & 25R PER FEDEX EA 7-5310-62673.

Part: FRAME — DENTED (FUSELAGE)

DENT IN FRAME FLANGE. REPAIRED DENTED FRAME BS 500 2 INCHES BELOW STR 24R PER SRM 51-40-3 & FEDEX EA 7-5310-62673.

Part: FRAME — DENTED (FUSELAGE)

DENT IN FRAME FLANGE BS 600, STR 22-25 LT. REPAIRED FRAME AT BS 600 BETWEEN STR 24L & 25L PER SRM 51-40-3 & PER FEDEX EA 7-5310-62674.

Part: SKIN — DAMAGED (FUSELAGE)

TEMPORARY REPAIR ON EXTERNAL SKIN AT BS 1198 WL 182 BELOW STR 20R.

Part: SKIN — DAMAGED (FUSELAGE)

MECHANICAL DAMAGE ON EXTERNAL FUSELAGE SKIN AT BS 720A AT STR 23L. REMOVED AND REPLACED SKIN PER SRM 53-30-3.

Part: FRAME — DENTED (FUSELAGE)

FRAME DENTED I/B FLANGE. REMOVED AND REPLACED FRAME PER SRM 53-10-1 & EA 7-5310-62672.

Part: FRAME — DENTED (FUSELAGE)

FRAME DENTED I/B FLANGE. REMOVED AND REPLACED FRAME PER SRM 53-10-1, 51-40-3 & EA 7-5310-62672.

Part: SKIN — DENTED (FUSELAGE)

SKIN DENTED AT SKIN LAP BS 1133, STR 20L. REMOVED AND REPLACED SKIN PER SRM 53-30-1.

Part: THRUST REVERSER — LEAKING (NR 1 ENGINE)

HYD PRESS LOST, BOTH PRESS LIGHT ILLUM. REMOVED AND REPLACED NR 1 T/R AND 2 PUMP CASE DRAIN FILTERS PER IAW MM 29-11-041-2.

Part: SWITCH — FAILED

01-344 #6 L/E FLAP INDICATING IN TRANSIT AFTER RETRACTION. AIR RETURN. ** S/D ** COMING

Part: FIRE LOOP — INOPERATIVE (NR 1 ENGINE)

99-119 - NR 1 FIRE WARN ILLUM. BELL SOUND INTERMITTENT. THIS IS A REPEAT OCCURRENCE, FIRE WARNING SYS CK PER CKLIST OPER NORM. INSTALL NR 1 ENG FIREWALL DETECTOR LOOP PER MM 26-11-012-4. RAN HIGH PWR ENG RUN ON NR 1 ENG, NO DEFECTS NOTED. OK FOR SERVICE.

Part: FIRE WARNING — ACTIVATED (NR 1 ENGINE)

NR 1 ENGINE FIRE WARN LIGHT AND BELL SOUND INTERMITTENT DURING CRUISE FLT.

Part: CONTROL UNIT — FAILED (FIRE DET SYST)

NR 1 ENG FIRE WARNING LIGHT AND BELL SOUND INTERMITTENTLY. WARNING SILENCED BY OPEN NR 1 ENG SYS A DETECTION CIRCUIT BREAKER, BOTH FIRE SYS TEST SAT. *S/D* INSTALLED STUB WING PNLS. REMOVED AND REPLACED FIRE DETECTION CONTROL UNIT, ALL CK OK MM 26-11.

Part: FIRE DET BOX — INOPERATIVE (ENGINE)

FIRE BELL CHIMED INTERMITTENTLY WITH ILLUM OF BOTH MASTER FIRE WARNING LIGHT ON GLARESHIELD. INSTALLED SERVICEABLE ENGINE FIRE DETECTION BOX AND ENG ELEMENT SUPPORT ASSY, SYS OPER CK NORM IN MM 26-11-01.

Part: WIRE — BROKEN (TE FLAPS)

ASYMMETRY I/B FLAP IND ON DEPARTURE WITH I/B FLAP AT 5 DEG. INSTALLED NEW IND, NO HELP. REINSTALLED ORIG FLAP IND. REMOVED AND REPLACED RT I/B TRANSMITTER REF MM 27-52-2, NO HELP KH 193173 ORIG. REINSTALLED JHS 12168, CHECK WIRING FROM LT AND RT I/B FLAP POS TRANSMITTER TO I/B FLAP POS IND, ALL WIRING CHECK GOOD PER 727 WDM 27-52-01 GH 81251. FOUND GROUND WIRE 014-20 BROKEN AT STUD GD90 REPAIR.

Part: SWITCH — INOPERATIVE (RT MLG DOOR)

RIGHT MAIN GEAR DOOR LIGHT ON SECOND OFFICER'S PANEL DID NOT EXTINGUISH AFTER GEAR RETRACTION. THE LIGHT REMAINED ON THROUGH FLIGHT. RED DOOR LIGHT ON INSTRUMENT PANEL SAME INDICATION. CYCLED GEAR, NO CHANGE. FUEL BURN WAS NORMAL, NO ASYMMETRIC CONTROL INPUTS NOTED, AND TOWER FLY-BY REPORTED DOOR UP AS PRECAUTION FLIGHT WAS CONTINUED AT OR BELOW MAXIMUM AIR SPEED FOR GEAR DOORS OPEN. REMOVED AND REPLACED RIGHT MAIN GEAR DOOR LIGHT SWITCH PER MAINTENANCE MANUAL 32-62-11 PAGE 401, SYSTEM OPERATIONAL CHECKS OK.

Part: WINDSHIELD — CRACKED (LT COCKPIT)

ON TAKEOFF, CAPTAIN'S WIND SCREEN BEGAN ARCING, HEAT TURNED OFF AND WINDOW CRACKED 20 SECONDS LATER. REMOVED AND REPLACED L-1 WINDOW PER MAINTENANCE MANUAL 56-11-11. REPLACED L-1 WINDOW HEAT CONTROLLER AND SYSTEM OPERATES NORMAL PER MAINTENANCE MANUAL 30-41-13.

Part: RIB — CRACKED (BS 760)

HFECI OF FASTENER HOLES AT BS 760, RBL 70.5 SHOW CORROSION THROUGHOUT ALL SIX HOLES. TOP FWD HOLE IS CRACKED THREE PLACES IN RIB CHORD, AND BOTTOM FWD HOLE HAS A CRACK IN THE RIB CHORD. REPAIRED FASTENER HOLES AT BS 760, RBL 70.5 PER FEDEX EA 7-5710-2368A.

Part: RIB — CRACKED (BS 760)

HFECI OF FASTENER HOLES AT BS 760 LBL 70.5 SHOW CORROSION THROUGHOUT ALL SIX HOLES. TOP FWD HOLE IS CRACKED IN RIB CHORD, AND BOTTOM HOLE HAS A CRACK IN THE RIB CHORD. REPAIRED FASTENER HOLES AT BS 760 LBL 70.5 PER FEDEX EA 7-5710-23684.

Part: SEAT TRACK — DAMAGED (BS 523)

SEAT TRACK HAS MECHANICAL DAMAGE ON TOP SURFACE OF BS 523 RBL 45 WL 209. REMOVED FABRICATED AND INSTALLED SEAT TRACK IAW SRM 53-10-5.

Part: SEAT TRACK — CORRODED (BS 517-523)

SEAT TRACK HAS MECHANCIAL DAMAGE ON TOP SURFACE BS 517-523, BL O, WL 209. BLENDED DAMAGE, IT WAS FOUND TO BE OUT OF LIMITS. REMOVED AND REPLACED SEAT TRACK BS 360-550, BL O, WL 208 IAW SRM 53-10-2.

Part: SKIN — DAMAGED (BS 1284)

DENT WITH GOUGE 1 INCH W BY 1.5 INCH L BY .075 INCH D, BS 1284, JUST ABOVE STR 22R FOUND TO BE OUT OF LIMITS. REPAIRED DAMAGE AREA IN ACCORDANCE WITH FEDEX SRM 53-30-3 FIG 1 AT BS 1284 STR 22R.

Part: WINDOW — CRACKED (COCKPIT)

R-2 WINDOW FAILED WHILE IN CRUISE AT FL 350 AND CABIN DIFF PRESS OF 8.4 PSI DESCENDED TO FL 240 AND REDUCED CABIN PRESS TO 5.0 PSI. APPEARS TO BE INNER PANE. REMOVED AND REPLACED NR 2 SLIDING WINDOW PER MM 56-12-11.