N209FE

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 33,336 hrs · 19,358 cycles

AT FL310 PILOTS WINDSHIELD BEGAN TO CRACK ON INNER AND OUTER PANELS. REMOVED AND REPLACED CAPT'S WINDSHIELD IAW 727 MM 56-11-011-4. ALSO REPLACED WINDOW HEAT CONTROLLER IAW 30-41-033-4 AND 30-41-013-5. CHECKED WINDOW HEAT CONDUCTIVE COATING AND SENSOR PER MM 30-41-042-5 AND WDM 30-41-11 PIN 14 HAS 37.5 OHMS, WHICH IS CORRECT FOR THIS WINDOW A/C OK TO CONTINUE.

Part: WEB — CORRODED (CTR TANK) · airframe 32,274 hrs · 18,572 cycles

R1 CORROSION CENTER WING TANK FWD WEB REPAIR LBL29.12. COMPLIED WITH EA 7-5710-101998 WINGS-SKIN (AD2002-02-19 2ND AD 98-11-03 R1) CORROSION CENTER WING TANK FWD WEB REPAIR LBL 29.121.

Part: SUPPORT ANGLE — CRACKED (BODY FAIRING) · airframe 32,274 hrs · 18,572 cycles

SUPPORT ANGLE FOR LWR BODY FAIRING IS CRACKED FS 720 STR29L REMOVED AND REPLACED BRACKET IAW SRM 51-30-2 REMOVED AND REPLACE DOUBLER IAW SRM 51-30-2. FABRICATED DOUBLER FROM 7075 T6 .050C BATCH 1152573 TREATED AND PRIMED IAW SRM 51-10-2. PREPPED AND PAINTED AREA IAW MM 51-20-151-7.

Part: SKIN — DENTED (BS 184-194) · airframe 32,274 hrs · 18,572 cycles

RIGHT FORWARD EXTERIOR FUSELAGE HAS TWO DENTS STA 188 REPAIRED AREA AT FS 188 IAW SRM 53-30-3 FIG 24. FABRICATED SHIM FROM 2024 T3 .040C BATCH 1108881. FABRICATED DOUBLER FROM 2024 T-3 BATCH 1146579 IAW SRM 53-30-3 FIG 24. TREATED AND PRIMED IAW SRM 51-10-2. INSTALLED DOUBLER AND FILLER IAW SRM 51-30-2. PREPPED AND PAINTED AREA IAW MM 51-20-151-7. DOUBLER IS LOCATED AT FS 184 TO FS 194, STR24R TO 25R MEASURES 10.5" BY 11".

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 32,073 hrs · 18,442 cycles

ON TAKEOFF ROLL, WHEN SETTING TAKEOFF POWER (STANDARD EPR) NR 1 THRUST LEVER WAS 4 INCHES BEHIND OTHER TWO WITH TAKE OFF POWER SET. REJECTED TAKEOFF MAX SPEED ON TAKEOFF ROLL PRIOR TO REJECT 100KTS INDICATED AIRSPEED. R&R NR 1 FUEL PUMP AND ENGINE FUEL CONTROL IAW 727 M/M73-12-002- 2. COMPLETED WET & DRY MOTOR NO DEFECTS NOTED. COMPLETED IDLE RUN PER JRH. NEEDS HIGH POWER RUNS BEFORE SIGN OFF COMPLETE. RAN NR 1 ENG PER JRH & 727 MM 71-00-030-2 FOR POWER TRIM RUN & ADJUST THROTTLE SPLIT WITH NR 3 ENGINE.

Part: LINE — LEAKING (HYD SYSTEM) · airframe 31,225 hrs · 17,935 cycles

HYD "B" LOW PRESS LT PUMP 1 CAME ON IN FLT PRESSURE STARTED DROPPING AND PUMP 2 LOW PRESSURE LT CAME FOLLOWED QRH TO LANDING SHGN. FOUND FLEX LINE CHAFED AGAINST HARD LINE IN "B" PUMP AREA CREATING SIGNIFICANT HYDRAULIC LEAK. NEEDS BOTH THE FLEX LINE AND HARD LINE. R & R BALANCE LINE TO RESERVOIR & OUTLET HARD LINE OPS AND LEAK CK GOOD ALL MAINT PER B727 M/M 29-00-00 0-6,20-80-001-2

Part: WARNING LIGHT — ILLUMINATED (AIRSTAIR) · airframe 30,635 hrs · 17,571 cycles

JUST AT BRAKE RELEASE AN "AFT AIRSTAIR" LIGHT ILLUMINATED. TAKEOFF WAS REJECTED. RTO CHECKLIST WAS ACCOMPLISHED. REJECTED TAKEOFF PARAMETERS, AIRSPEED <50 KIAS, EPR NR 1 NR 3 1.83, NR 2 1.75. TAKEOFF TIME 02:18. RELEASED FOR SERVICE PER MEL/CDL: 52-06-B. CREW COMMENTED NO PROBLEMS WITH AFT A/S WARNING LIGHT SYS LAST TWO LEGS. INSPECTED ALL UP LOCK & INTERIOR HANDLE SWITCHES & TESTED SYS SEVERAL TIMES IAW B727MM 52-70-001-5.

Part: WARNING LIGHT — ILLUMINATED (AFT AIRSTAIR) · airframe 29,689 hrs · 17,004 cycles

AFT STAIR LIGHT ILLUMINATE. OAK-LINE ENT BY: 390984 ON: 27DEC04 23:46:58:3 S=M MEL 27DEC04. RELEASED FOR SERVICE PER MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 06JAN05 MEL 52-06-B: AMBER AFT AIRSTAIR DOOR WARNING LIGHT INOP.

Part: CONNECTOR — DAMAGED (PRESSURE SWITCH) · airframe 29,331 hrs · 16,796 cycles

NR 3 ENG ICING LIGHT CAME ON 5 MIN AFTER T/O LIGHT FLICKERED FOR 2 MIN THEN ON STEADY. QRH COMPLIED WITH RTN TO MEM, LIGHT STILL ON AT BLOCK IN ENT BY: 038459 RPT BY: 096894. FOUND FUEL FILTER DIFFERENTIAL PRESS SWITCH AND CONNECTOR PINS PUSHED BACK MEM AVIONICS SHOP. REPLACED CONNECTOR. ALSO, R/R'D FUEL FILTER DIFF PRESS SWITCH..

Part: SKIN — DENTED (FUSELAGE) · airframe 28,997 hrs · 16,602 cycles

STA 1037 ABOVE STR 23R SKIN IS DENTED. DENT AT BS 1037 STR 23 FOUND TO BE OUT OF LIMITS. REPAIRED DENT PER SRM 53-30-3 FIGURE 1.

Part: FUEL TANK — CORRODED (CENTER WING) · corrosion level 2 · airframe 28,997 hrs · 16,602 cycles

CORROSION ON UPPER SURFACE OF CENTER WING TANK AT BS 821 RBL 13. *S/D* CORROSION ON UPPER SURFACE OF CENTER WING TANK AT BS 821, RBL 13 REPAIRED PER EA NR 7-5730-55326.

Part: SENSOR — FAILED (ZONE 300) · airframe 28,519 hrs · 16,347 cycles

DURING CRUISE FLT AT FL330 AT .82 MACH THE A/C PERF U/C ROLL DOUBLETS (DUTCH ROLL MOTION). A/P AND STAB WAS OUT OF TRIM WITH A PITCH UP ATT DEV. TRIMMED THE STAB AND LEVELED A/C AND RECONN A/P. A/P WAS IN SYS-B. WHEN RECONN, THE A/P TRIMMED NOSE UP, HAD TO DISC A/P AND APPLY 20 LBS OF DOWN ELEV FORCE TO LEVEL A/C. TRIED SYS-A AND IT WAS WORSE. THE ELEV POS IND SHOWED A SPLIT STAB (LT HIGHER THAN RT). DECLARED AN EMERGENCY, DUMPED 9K OF FUEL AND WITH A/P OFF A/C TOOK MORE PRESS TO TURN RT THAN LT. CHECK PER MM 27-10-000-5, CHECKS NORMALLY. CHECKED ALL CABLES AND PULLEYS ASSOC WITH AILERONS, ALL CHECK NORMALLY. REMOVED LT ELEV POS SENS PER MM 22-11-071-5 REF WRI 22-10/7229 AND 22-30/7234.

Part: WARNING LIGHT — INOPERATIVE (AIRSTAIR DOOR) · airframe 28,485 hrs · 16,325 cycles

AFTER PASSING APPROXIMATELY 11,000 FEET, AFT AIRSTAIR LIGHT ILLUMINATED. AIRCRAFT BEGAN ACCELERATING THRU 250 KIAS. RELEASED FOR SERVICE PER MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 08MAR04 MEL 52-06-B: AMBER AFT AIRSTAIR DOOR WARNING LIGHT INOP.

Part: WARNING LIGHT — ILLUMINATED (AIRSTAIR DOOR) · airframe 27,834 hrs · 15,956 cycles

DURING CLIMBOUT AT FL180, LIGHT CHOP, AFT AIRSTAIR AMBER LIGHT ILLUMINATED, AND REMAINED ON, COMPLIED WITH QRH. INSPECTED AFT AIRSTAIR WARNING INDICATION AND STAIR POSITION MICROSWITCHES IAW M/M 52-62-001-6-1, A (11). NO DEFECTS FOUND. FLIGHT CREW REPORTED NO PROBLEMS LAST 3 LEGS. CLEANED SWITCHES AND OPS CHECKED OK..

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 26,556 hrs · 15,326 cycles

AFT AIRSTAIR LIGHT CAME ON AFTER TAKE OFF AND REMAINED ILLUMINATED THROUGH BLOCK IN. CYCLED AIR STAIRS SEVERAL TIMES. STAIRS WORKED & LIGHT WENT OUT EACH OUT.

Part: FLOORBEAM — CRACKED (FUSELAGE) · corrosion level 2 · airframe 25,766 hrs · 14,899 cycles

CORROSION BS 870, WL 208, LBL 65 TO RBL 65. REMOVED AND REPLACED FLOORBEAM PER EA 7- 5310-54227.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 25,766 hrs · 14,899 cycles

CORROSION ON TOP OF FRETTED FLOORBEAM BS 740, WL 208, LBL 60 - RBL 65. REMOVED AND REPLACED FLOORBEAM PER SRM 51-20-4, 51-30-2.

Part: FRAME — CORRODED (FUSELAGE) · airframe 25,766 hrs · 14,899 cycles

CORROSION ON FRAME BS 720F FWD FACE BETWEEN STR 4 & 5 RT.

Part: FRAME — DENTED (FUSELAGE) · airframe 25,766 hrs · 14,899 cycles

DENT IN FRAME AT BS 700, STR 25 RT. REMOVED AND REPLACED FRAME PER SRM 53-10-1.

Part: FRAME — DENTED (FUSELAGE) · airframe 25,766 hrs · 14,899 cycles

DENT IN FRAME AT BS 1110 BETWEEN STR 25 - 26 L. REMOVED AND REPLACED FRAME PER SRM 51-40-3.

Part: SKIN — CHAFED (FUSELAGE) · airframe 25,766 hrs · 14,899 cycles

N 321 SKIN CHAFED AT SKIN LAP STR 19 RT, BS 720D+13. R&R SKIN PER SRM 53-30-3 FIG 14.

Part: CHANNEL — CRACKED (MLG WW) · airframe 23,708 hrs · 13,525 cycles

NOSE GEAR LOCK ACTUATOR MOUNT CHANNEL CRACKED, NLG WHEEL WELL AFT WALL. INSP NOTE - MEASURED CRACK TO BE APPROX 5 INCHES LONG FROM RT UPPER MOUNT HOLE PROGRESSING DOWN FWD FACE OF FITTING CHANNEL. *S/D* INSTALLED MOUNT BRACKET IAW B727 SRM 53-43-00.

Part: PUMP — FAILED (FUEL SYSTEM)

RIGHT FWD BOOST PUMP LOW PRESSURE LIGHT ILLUM (APPROX 5500 FUEL IN NR 2 TANK). SAME TIME DETECT ELECTRICAL ODOR. *S/D* REMOVED AND REPLACED WATER SEPARATOR CONDENSER BAGS PER MM 21-5-051-4. REMOVED AND REPLACED PUMP PER 28-22-021-4. AC OK FOR SERVICE.

Part: GIRT — FRAYING (ESCAPE SLIDE)

NR 89 - FWD ENTRY DOOR ESCAPE SLIDE GIRT IS FRAYING. REMOVED AND REPLACED FWD ENTRY DOOR ESCAPE SLIDE IAW FEDEX MM 25-60-015-2.

Part: SKIN — GOUGE (BS 1286)

NR 269 - BF GOODRICH REPSPONSIBILITY, AC ENGINE WORK PLATFORM MOVED INTO AC SKIN AT BS 1286, STR 21 LT AND BS 1303 5 BELOW STR 21 LT. REPAIRED DAMAGED SKIN PER FEDEX SRM 53-30-3 FIG 3.

Part: SKIN — CORRODED (BS 1136)

00-253 - CORROSION (C53-113-01(2)) ON SKIN OB AT STR 29L, BS 1136 IN AFT CARGO BAY. FOUND CORROSION OUT OF LIMITS IAW FEDEX SRM 53-30-1 AND REPAIRED AREA IAW FEDEX SRM 53-30-3 FIG 3 AT BS 1136, STR 2L ON SKIN.

Part: WIRE — DAMAGED (FIRE DETECTOR)

THREE INSTANCES OF MASTER WARN LIGHT ILLUM AND WARN BELL. FOUND WIRE WITH INSULATION CUT ON LOWER AFT END OF FIRE LOOP. SPLICED WIRE AT SEP PER MM CHAPTER 20. FIRE TEST NORMAL.

Part: CONTROL UNIT — MALFUNCTIONED (FIRE DETECTION)

WARNING LIGHT & WARN BELL WENT OFF. RED TABS PERF SYS TEST GOOD. 5TH REPEAT GRIPE. R&R ENG FIRE CONTROL UNIT,LOOP,ENG SENSING ELEMENT AT FIREWALL PER 26-11-000-5,26-11-002-5,26-11-012-4. OPS CK NORM.

Part: FIRE WARNING — ACTIVATED (NR 1 ENGINE)

NR 1 ENGINE FIRE WARN INTERMITTENTLY ACTIVATED. OPEN COWLS AND ENG LOWER STUB WING PANEL TO FOM, PERF RESISTANCE CK PER BOEING AC MM 26-11-001-1. INSP ALL DUCTS FOR LEAKS, NONE NOTED. CLEANED ALL CONNECTORS FOR LOOPS, TIGHTENED ALL BLD DUCTS AND ALUMINUM FOIL.

Part: FIRE WARNING — MALFUNCTIONED (NR 1 ENGINE)

INTERMITTENT FIRE WARNING NR 1 ENGINE. REMOVED AND CLEANED GASKET, REPLACED AND RETORQUED ATTACH BOLTS PER 36-10. CLOSED PANELS PER JPF, RAN ENGINE AT T/O AND MAX CONT POWER FOR 4 MIN PER JET RUN HKBK 4-21. NO FIRE WARNING NOTED.

Part: CLAMP — DAMAGED (NR 1 ENGINE)

NR 1 ENGINE FIRE WARNING CAME ON INTERMITTENTLY. CHECKED SENSING ELEM AND SYS TESTED IAW MM 26-11-01. FOUND SOME OUT OF RUBBER CLAMPS, NO OTHER DEFECTS NOTED.

Part: CLAMP — LOOSE (NR 1 ENGINE)

FIRE WARNING ON ENGINE NR 1. REMOVED PYLON ACCESS PANELS AND OPENED ENGINE COWL, CHECKED FIRE LOOP AND CONNECTIONS, TIGHTENED DUCT CLAMPS. OK FOR SERVICE.

Part: FIRE LOOP — FAILED (NR 1 ENGINE)

NR 1 ENGINE FIRE WARNING BELL AND LIGHT ILLUMINATED. SHUT DOWN ENGINE PER RED TABS. NR 1 ENGINE COWL OPENED. TAPPED ON ENGINE LOOP ASSY, JUST AFT OF GENERATOR AND FIRE HANDLE AND DETECTOR LIGHTS FLICKERED. REMOVED AND REPLACED ENGINE FIRE LOOP. OPS CHECK GOOD. OK FOR SERVICE.

Part: COALESCER BAG — DIRTY (LT PACK)

AFTER TAKEOFF, AGAIN STRONG SMELL FROM NR 1 ENGINE BLEED ON LEFT PACK. CHANGED TO NR 3 BLEED AND RIGHT PACK, SMELL WENT AWAY. AT 18,000 FT USING NR 2 BLEED AND LEFT PACK, SMELL CAME BACK BUT NOT AS STRONG. SELECTED WARMER TEMPERATURE LEFT PACK, SLOWLY SMELL DISSIPATED. REMOVED AND REPLACED LEFT PACK WATER SEPARATOR BAG, CHECKED AIR CYCLE MACHINE FOR FREEDOM OF MOVEMENT AND CHIP DETECTOR PLUG FOR METAL, NONE. NO EVIDENCE OF OIL FROM NR 1 BLEED, PACK OPERATED NORMAL DURING GROUND OPERATION USING APU.

Part: COALESCER BAGS — DIRTY (CABIN)

AFTER LIFT OFF STRONG ACRID SMELL IN COCKPIT ALONG WITH BURNING EYES (LEFT PACK #1 BLD) SWITCHED PACK/BLD SOURCE (RIGHT PACK #3 BLD) NO CHANGE IN SMELL. INTENSITY SEEMED TO CHANGE WITH PWR SETTINGS. INSPECTED INLETS & EXHAUST OF ALL ENGINES FOR FLUID NONE FOUND RAN ALL 3 ENGINES AT POWER FOR 20 MIN. WITH PACKS ON NO ARID SMELL OR BURNING EYES WHEEL WELL WERE CLEANED DURING WEEKEND LAYOVER SERVICE CK. SUSPECT VAPORS FROM SOLVENT ENTERED APU R&R LEFT AND RIGHT WATER SEPARATOR SOCKS OK FOR SERVICE.

Part: VALVE — MALFUNCTIONED (NR 3 ENGINE)

AGAIN ON DEPARTURE STRONG ACRID SMELL, RETURNED LEFT PACK AND NR 1 BLEED SELECTED. RETURNED TO AIRPORT. REMOVED AND REPLACED 3 HYD BLEED RESERVOIR CHECK VALVES. GROUND RAN NR 1 ENG WITH LT AND RT PACKS ON NR 1 BLEED AT H. POWER AND MAX HEAT, NO SMELL NOTED. SAME ON NR 3 ENG BLEED, NO SMELL NOTED. OPERATED LT PACK NR 1 ENG AND RT PACK ON NR 3 ENG BLEED, NO SMELL NOTED. ALL BLEEDS ON AND LT AND RT PACKS OPERATING, NO SMELL NOTED ON GROUND.

Part: TURBINE — FAILED (NR 2 ENGINE)

DURING LOW SPEED TAKEOFF ROLL, ALOUD POP/SHUDDER OF THE AIRCRAFT WAS FELT WITH A SIMULTANEOUS ENGINE FAIL LIGHT ILLUMINATION. A REJECTED TAKEOFF WAS ACCOMPLISHED. AIRCRAFT WAS TAXIED BACK TO RAMP, WITH MAINTENANCE PERSONNEL IN COCKPIT. THE NR 2 ENGINE WAS ADVANCED TO FULL THROTTLE, BUT EPR DID NOT GO PAST 1.9, A COMPRESSOR STALL WAS FELT AGAIN AND NR 2 ENGINE WAS SHUTDOWN. INSPECTION NR 2 ENGINE TAIL PIPE FOUND LOW PRESSURE TURBINE FAILURE. REMOVED AND REPLACED NR 2 ENGINE PER WORK CARD NR 70T0002.