N216FE

Part: ACTUATOR — MALFUNCTIONED (TE FLAPS) · airframe 33,962 hrs · 19,699 cycles

DURING T/O AND FLAP RETRACTION AMBER FLAP LIGHT REMAINED ON AT FLAPS 2. SLATS 2367 WERE OUT AND THE AMBER LIGHT UNDER NR 6 SLAT POS ON SO PANEL WAS ON. ATTEMPTED TO RECTIFY WITH THE QRH. NO LUCK. PUT FLAPS BACK TO 5 AND LANDED AT BIL IAW GOC DIRECTIVES. RAN FLAP CONTROL TO BOTH, 2 DEGREES AND 5 DEGREES NUMEROUS TIMES. NO TROUBLE OUT OF L/E SLAT NR 6, L/E FLAP NR 5 DID NOT EXTEND OR RETRACT PROPERLY. NR 5 L/E FLAP REMAINED STUCK IN EXTENDED POSITION. TRIED EXERCISING IT W/O HYD PWR ON, NO HELP. NR 5 L/E F. REMAINS IN THE EXTENDED POSITION. R&R NR 5 L/E FLAP ACTUATOR. ACTUATOR OPS AND LEAK CKS GOOD REF 27-81-022-4.

Part: APU — BURNED · airframe 33,929 hrs · 19,680 cycles

ON BLOCK-IN APU WAS SMOKING FROM EXHAUST-PIPE. UPON ENTERING COCKPIT FOUND EGT INDCATOR RISING RAPIDLY WENT BACK OUTSIDE AND SAW FLAMES AROUND 6 TO 12 INCHES COMING FROM TAIL PIPE, NOTIFIED FLIGHT CREW OF FIRE AND TO BLOW FIRE BOTTLE. AROUND 1 TO 2 MINUTES AFTER APU FIRE BOTTLE DISCHARGE, FIRE WARNING CAME ON. INSPECTED APU EXTERNALLY AROUND APU SHROUD, NO DAMAGE FOUND. OPENED PANEL ON APU SHROUD IN RT WHEEL WELL AND FOUND HEAT/FIRE DAMAGE AROUND TURBINE/EGT PROBE AREA. INSPECTED TAIL PIPE FROM ON TOP OF WING AND FOUND ORANGE DIS-COLORATION ON INNER TAIL PIPE. RELEASED FOR SERVICE IAW MEL: 49-01 CATEGORY: C EXPIRATION. PLEASE COMPLY WITH ALL STEPS IN TSI 49-10/3912 AND ENSURE APU FIRE BOTTLE IS REPLACED BEFORE ANY ATTEMPT TO START APU.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AT RBL 24 STA 1148 FLOORBEAM UPPER FLANGE CORRODED. DUE TO FLOOR SUPPORT REPAIR 1'4 INCH HOLE IN SEAT TRACK WILL NOT HAVE EDGE DISTANCE IF DRILLED IN SAME LOCATION AS ORIGINAL. SEE SNRM N00516 FOR FLOOR REPAIR DUE TO "T" CAP REPLACEMENT, A 1/4 INCH HOLE REQUIRED IN SEAT TRACK WOULD HAVE BEEN IN RADIUS OF "T" CHORD. CUT OUT AND SPLICED IN NEW SECTION OF SEAT TRACK FROM STA 100-1148 REF SRM 53-10-5 FIG 1 AND RELOCATED AFFECTED FASTENER HOLE. EA 7-5310-1232825 AUTHORIZES MATERIAL SUBSTITUTION ON STRAP. THIS IS CLASSIFIED AS A MAJOR REPAIR

Part: SKIN — MISREPAIRED (ZONE 300) · airframe 33,009 hrs · 19,197 cycles

FOUND RT STAB UPPER EXTERNAL REPAIR LOCATED AT APPROX SS 180, 6 INCHES FWD OF AFT EDGE. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. FOUND REPAIR DOES NOT COMPLY WITH CURRENTS SRM REPAIR. REMOVED PREVIOUS REPAIR, LAID OUT TWO ADDITIONAL ROWS OF FASTENERS ON INBD SIDE OF DAMAGE CUTOUT. FABRICATED NEW REPAIR DOUBLER, TREATED, PRIMED AND INSTALLED, REF SRM 55-10-3/FIGURE 3, AND FED EX EA 7-5510-118314. THIS IS CLASSIFIED AS A MAJOR REPAIR. THIS IS A CATEGORY "C" REPAIR.

Part: SKIN — MISREPAIRED (ZONE 300) · airframe 33,009 hrs · 19,197 cycles

FOUND RT STAB UPPER SURFACE EXTERNAL REPAIR LOCATED AT APPROX SS 145 8 INCHES FWD OF AFT EDGE. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA FOUND REPAIR DOES NOT COMPLY WITH CURRENT SRM REPAIR. REMOVED PREVIOUS REPAIR, LAID OUT TWO ADDITIONAL ROWS OF FASTENERS ON INBD SIDE OF DAMAGE CUTOUT. FABRICATED NEW REPAIR DOUBLER, TREATED, PRIMED, AND INSTALLED REF SRM 55-10-3/FIGURE 3. THIS IS CLASSIFIED AS A MAJOR REPAIR. THIS IS CATEGORY "C" REPAIR, EA 7-5510-118322.

Part: SKIN — MISREPAIRED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

FOUND FLUSH SKIN REPAIR LOCATED AT APPROX BS 308 BETWEEN STR S-10L AND S-11L. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. REMOVED FLUSH REPAIR, NDT'D ALL COMMON FASTENER HOLES AND EDGE OF CUTOUT, AND ACCOMPLISHED INSURANCE CUT. FABRICATED DOUBLER, STRUCTURAL FILLER,AND FILLER. ALODINED, PRIMED AND INSTALLED REF EA 7-5330-123826. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: CHANNEL — CORRODED (FUSELAGE) · airframe 33,009 hrs · 19,197 cycles

OTBD HAT CHANNEL HAS CORROSION AROUND NUT PLATE HOLES. REMOVED CORROSION. FOUND TO BE OUT OF LIMITS. FABRICATED, LOCATED AND DRILLED HOLES, TREATED, PRIMED AND INSTALLED NEW HAT CHANNEL, REFERENCE DWG NR 65-19606/ITEM NR 19, CLASSIFIED AS A MAJOR REPAIR.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT BULKHEAD UPPER ANGLE CORRODED CENTERLINE TO RBL 1166. REMOVED AND REPLACED UPPER CHORD ANGLE AT STA 1166 IN LWR AFT CARGO PIT REF SRM 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FLOORBEAM — CORRODED (BS 1176) · airframe 33,009 hrs · 19,197 cycles

MAIN DECK FLOOR BS 1176.5 CHORD HAS CORROSION ON UPPER FWD FLANGE AND INSIDE FASTENER HOLES FROM RBL 1 TO 24. REPLACED CHORD REF SRM 51-30-02, THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (BS 1148) · airframe 33,009 hrs · 19,197 cycles

AT RBL 45 STA 1148 FLOORBEAM UPPER FLANGE CORRODED DUE TO REPAIR ON SNRM NR N00516 1/4 INCH HOLE IN SEAT TRACK WILL NOT HAVE EDGE DISTANCE IF DRILLED IN SAME LOCATION AS ORIGINAL. DUE TO TEE CAP REPLACMENT A 1/4 INCH HOLE REQUIRED IN SEAT TRACK WOULD HAVE BEEN IN RADIUS OF TEE CAP. CUT OUT AND SPLICED IN NEW SECTION OF SEAT TRACK. REF SRM 53-10-5 FIG 1 AND RELOCATED AFFECTED FASTENER HOLE. EA 7-5310-123825 AUTHORIZES MATERIAL SUBSTITUTION ON STRAP. THIS IS CLASSIFED AS A MAJOR REPAIR. SECTION REPLACED IS FROM STA 1100-1148

Part: SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN DECK BULKHEAD SUPPORT CORRODED AT AFT BULKHEAD FITTING STA 1183 LBL 18, WL 208. REMOVED CORROSION, OUT OF LIMITS .018 MATERIAL REMOVED, ORIGINAL MATERIAL .063, .045 REMAINING. INSTALLED DOUBLER AND SPLICED FLOOR SUPPORT REF SRM 51-40-3 PG 1, DWR 65-31774. THIS IS CLASSIFIED AS A MAJOR REPAIR. TREATED AND PRIMED REPAIR SPLICE AND DOUBLER REF SRM 51-10-2.

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

FLOOR SUPPORT AT FS 1130 TO FS 1148, RBL 62, WL 206, HAS CORROSION AROUND SEVERAL NUT PLATES. REMOVED CORROSION AND FOUND TO BE OUT OF LIMITS. FABRICATED, LOCATED AND DRILLED HOLES, TRIMMED, TREATED, PRIMED AND INSTALLED NEW FLOOR SUPPORT. REF BOEING DWR 69-72846/ ITEM 3 AND SRM 51-10-2. THIS IS CLASSIFIED AS A MINOR REPAIR

Part: FLOOR SUPPORT — CORRODED (BS 1169-1172) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN DECK FLOOR STRUCTURE, BL 0 BEAM, RT ATTACH ANGLE IS CORRODED AT LWR EDGE AT 1169 TO 1172, RBL 1 WL 205. REMOVED, FABRICATED NEW ANGLE REF DRAWING 69-34832 AND INSTALLED REF SRM 51-30-2. THIS IS CLASSIFED AS A MINOR REPAIR

Part: FLOOR SUPPORT — DAMAGED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

REWORK OF SNRM N00933, FLOOR SUPORT AT FS 1148 RBL 45 WAS MISSDRILLED FABRICATED NEW FLOOR SUPPORT REF DRAWING B27-53-015B. INSTALLED REF SRM 51-30-2 THIS IS CLASSIFED AS A MAJOR REPAIR

Part: PAN — CRACKED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

BS 1166 RBL 45-60 DITCHING PAN HAS 3 CRACKS REPLACED DITCH PAN REF DWR 65-29548 AND SRM 51-30-2 PG 4. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN DECK FLOORBEAM LWR FLANGE IS CORRODED BS 1166, RBL 10-42, WL 200. REMOVED CORROSION FROM LOWER CHORD, ORIGINAL TEE .125 REMAINING .110. REMOVED .015 OUT OF LIMITS, REMOVED DAMAGED AREA, FABRICATED REPAIR PIECES, ALODINED, PRIMED AND INSTALLED REPAIR PIECES REF EA 7-5310-123823. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT BILGE KEELBEAM IS CORRODED BS 950E-950F, S29R, WL 139. REPAIR STRAP INSTALLED REF EA 7-5310-118316 PG 1-2. ORIGINAL MATERIAL THICKNESS .150, MATERIAL REMOVED .029, .121 REMAINING. OUT OF LIMITS, REF EA 7-5310-118316. THIS IS CLASSIFIED AS A MAJOR.

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LOWER AFT CARGO BAY LT KEELBEAM BS 950E 6 OTBD FLANGE IS CORRODED. INSTALLED REPAIR STRAP REF EA 7-5310-118316. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT KEELBEAM IS CORRODED BS 950F - 970, STR 29R, WL 139. INSTALLED REPAIR STRAP REF EA 7-5310-118316 P 1-2. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: BEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

CABIN FLOORBEAM, UPPER CAP LOWER SURFACE, CORRODED AROUND NUTPLATE, STA 950 RBL 5 BLENDED AREA TO REMOVE CORROSION, ORIGINAL MAT .150, LOSS .035 REMAINING .115 AND FOUND TO BE OUT OF LIMITS REF SRM 53-10-1. OBTAINED EA 7-5310-123812. FOUND MORE CORROSION DURING FLAP PEEN. REMOVED CORROSION ORIG .150 LOSS .046 REMAINING .104, OBTAINED REVISION TO EA 7-5310-123812 FLAP PEENED AREA TREATED AND PRIMED AREA REF EA 7-5310-123812. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LOWER AFT CARGO AREA CORROSION AT STA 950E - 950C ON LEFT KEELBEAM. INSTALLED REPAIR STRAP REF EA 7-5310-118316. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: FRAME — MISREPAIRED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

FOUND AFT PIT FRAME REPAIR LOCATED AT APPROX BS 1050 STR S-27L TO 26L. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA EVALUATION DETERMINED INSUFFICIENT FASTENERS. REMOVED REPAIR SRM 51-30-2, VERIFIED MATERIAL FOR REPLACEMENT AND FABRICATED REPLACEMENT REF DWR 65-16343 A35227 PO 1041113. HEAT TREATED NR 8130 2008-11-08. DRILLED AND FINAL TRIM DOUBLER REF SRM 51-30-3 FIG 1. TREATED AND PRIMED PARTS REF SRM 51-10-2. INSTALLED DOUBLER REF SRM 51-70-3. FAB REPAIR ANGLE REF DWR 65-67276-50 MATERIAL A 66622 PO 1008655 INSTALLED REPAIR ANGLE SRM 51-30-6. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: FRAME — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

C-2 PIT FLOOR FRAME SHEAR TIE AT FS 970, RBL9 TO RBL15, WL 139 HAS CORROSION ON AFT TO BOTTOM SIDE. INSTALLED NEW SHEARTIE REF SRM 53-10-4. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SHEAR TIE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

FOUND AFT PIT FRAME SHEAR TIE REPAIR LOCATED AT APPROX BS 950D STR S-29L TO S-28L. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING APPROVED DATA. ACCOMPLISHED REPAIR AT BS 950D STR 29L TO S28L FRAME SHEAR TIE. ACCOMPLISHED USING FAA APPROVED DATA AS A MAJOR REPAIR. REF SRM 53-10-4 PG 58-60 FIG 15 AND REPAIR 3. HFEC C/S HOLES AT SKIN SHEAR TIE IAW 727 NDT MAN, PART 6,53-39-00 FIG 3 (NO EFECTS NOTED). THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: INTERCOSTAL — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LOWER AFT CARGO AREA- CORROSION ON WEB RBL 18 STA 950F 4 WL 148 BLENDED OUT CORROSION REMOVED .025 FROM ORIGINAL .040, REMAINING THICKNESS .015. FOUND OUT OF LIMITS IAW SRM 53-10-1. REMOVED INTERCOSTAL WEB STA 950F- 970 RBL 18 WL 148 AND FABRICATED REPLACEMENT AND INSTALLED IAW SRM 51-30-2 AND BOEING DRAWING 69-44880. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SHEAR TIE — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT BILGE BODY FRAME SHEAR TIE IS CORRODED BS 970, STR 29L OB, WL 139. REMOVED FLOOR SUPPORT ANGLE AT FRAME 970 LBL 9 REF SRM 51-30-2 PG 1-9. REMOVED CORROSION ON SHEAR TIE REF SRM 53-10-1, ORIG THICK .073, REMAINING .011, OUT OF LIMITS. REMOVED DAMAGED SHEAR TIE, HEAT TREATED ON 8130-3 2008011-052. FABRICATED NEW FLOOR SUPPORT CHANNEL STA 970 LBL4, REMOVED FLOOR SUPPORT STA 970 LBL8. INSTALLED NEW SHEARTIE, FAB NEW FLOOR SUPPORT STA 970 LBL 8. INSTALLED FLOOR SUPPORT STA 970 LBL 8. INSTALLED FLOOR SUPPORT STA 970 LBL 4. INSTALLED FLOOR SUPPORT STA 970 LBL 9. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SKIN — CHAFED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

LOWER RIGHT EXTERIOR FUSELAGE SKIN IS CHAFED AT AFT CARGO PIT DOOR CUTOUT FWD LWR CORNER STA 950E, STR 26-R REPAIRED FWD LOWER CORNER OF FUSELAGE SKIN AT AFT CAGO DOOR CUT OUT REF EA 7- 5330-123818. BLENDED FOUND OUT OF LIMITS. ORIGINAL .080" , REMAINING .038 . TREATED AND PRIMED. THIS IS CLASSIFIED AS A MAJOR REPAIR

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN CABIN FLOOR, CORROSION ON SEAT TRACK FROM STA 567-639 LBL 46 REMOVED CORROSION FROM SEAT TRACK ORIGINAL MATERIAL THICKNESS TEE .094 AFTER BLENDING .010 MATERIAL. REMOVED REMAINING .084 AND IS OUT OF LIMITS REF SRM 53-10-1. REMOVED SEAT TRACK REF SRM 51-30-2. FABRICATED NEW TRACK REF SRM 51-10-2. INSTALLED NEW TRACK REF SRM 53-10-2. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: FITTING — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT STRINGER BULKHEAD FITTING STA 1183 STR 19R CORRODED. REMOVED AND REPLACED CORRODED FITTING, REF SRM 51-30-2 PG 1-4,8 THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

SEAT TRACK CORRODED, MAIN DECK AT RBL 24 BS 1148 TO 1176 FABRICATED SEAT TRACK, LOCATED AND DRILLED HOLES, TREATED AND PRIMED NEW SEAT TRACK EXTENSION REF SNRM N00801 SRM 51-30-5, SRM 51-10-2 AND MM 51-20-151-07. CLASSIFIED AS A MAJOR REPAIR.

Part: WEB — MISALIGNED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

MAIN CABIN SHEAR DECK AT BS 1148 TO 1166 RBL 8-19 NEEDS FABRICATED, SHEAR DECK WILL NOT BE ABLE TO BE INSTALLED AFTER FLOORBEAM REPAIR ON SNRM N00512. NEW DECK WILL BE FABRICATED FROM REF 65-19602. FABRICATED MAIN CABIN SHEAR DECK AT 1148 TO 1166 RBL 8-19 REF DWR 65-19606, SRM 51-10-2. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SKIN — CHAFED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

LOWER RIGHT EXTERIOR FUSELAGE SKIN IS CHAFED AT AFT CARGO PIT DOOR CUTOUT FWD LWR CORNER STA 950E, STR 26-R. REPAIRED FWD LOWER CORNER OF FUSELAGE SKIN AT AFT CAGO DOOR CUT OUT REF EA 7-5330-123818. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (BS 1148-1176) · airframe 33,009 hrs · 19,197 cycles

SEAT TRACK CORRODED, MAIN DECK AT RBL 24 BS 1148 TO 1176.

Part: FLOORBEAM — CORRODED (BS 1130) · airframe 33,009 hrs · 19,197 cycles

MAIN DECK 1130 FLOORBEAM UPPER TEE CAP HAS A DOUBLE DRILLED 1/4 INCH RBL 57.5 INCH.

Part: SEAT TRACK — CORRODED (BS 1176-1183) · airframe 33,009 hrs · 19,197 cycles

MAIN DECK SEAT TRACK AT LBL 24 BS 1176 TO 1183 IS CORRODED.

Part: SUPPORT ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LWR FUSELAGE ANTENNA SUPPORT ANGLES AT FASTENER HOLES HAVE CORROSION, BS 740-760, RBL 6 TO LBL 6. REMOVED CORROSION AT LWR FUSELAGE ANTENNA SUPPORT ANGLES STA 740 - 760, RBL 6 TO LBL 6, REF SRM 51-10-6, MATERIAL LOSS 50 PERCENT OFF, FOUND TO BE OUT OF LIMITS REF SRM 53-10-1 FIG 1. FABRICATED NEW ANGLES REF BOEING DWG 65-32330, 69-25418. TREATED AND PRIMED AND INSTALLED REF SRM 51-10-2 PG 1-7, MM 51-20-151-7, 51-30-02 PG 2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRAP — CORRODED (ZONE 200) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AREAS OF CORROSION ON FWD CARGO PIT UPPER FLOORBEAM STABILITY STRAP AS MARKED. REMOVED CORROSION FOUND OUT OF LIMITS REF SRM 53-10-01. FABRICATED STRAP AND SPLICE PLATE REF DWG 65-23638 AND 66-14865. TREATED, PRIMED AND INSTALLED STABILITY STRAP AND SPLICE BS 620-720C RBL 48 REF SRM 51-10-2 AND MM 51-20-151-7 AND 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRAP — CORRODED (FLOORBEAM) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AREAS OF CORROSION ON FWD CARGO PIT UPPER FLOORBEAM STABILITY STRAP AS MARKED. REMOVED CORROSION FOUND OUT OF LIMITS REF SRM 53-10-01. FABRICATED STRAP AND SPLICE PLATE REF DWG 65-23638 AND 66-14865. TREATED, PRIMED AND INSTALLED STABILITY STRAP AND SPLICE BS 620-720C RBL 48 REF SRM 51-10-2 AND MM 51-20-151-7 AND 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SKIN — WORN (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

LT EXTERIOR FUSELAGE BS 720D, 12 STR 19L SKIN LAP JUST FWD OF WING LE, SKIN HAS WEAR REPAIRED FUSE SKIN AT STA 720D 12 STR 19L REF SRM 53-30-3 FIG 5. DISPLACED LEFT INBD LEADING EDGE FOR REPAIR AND REINSTALLED REF SRM 51-30-2 PG 1-5. DISCONNECTED LEADING EDGE PNEUMATIC DUCT AND REINSTALLED AND LEAK CHECKED REF MM 36-13-00-4 PG4. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: FLOOR PANEL — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN CARGO FLOOR CORROSION ON SEAT TRACK AT STA 740 LBL46, REMOVED BEYOND LIMITS CORRODED SEAT TRACK REF SRM 51-30-2. FABRICATED REPLACEMENT SEAT TRACK REF SRM 53-10-5. FABRICATED TRACK SPLICE REF SRM 53-10-5. INSTALLED SEAT TRACK AND SPLICE REF SRM 53-10-5, TREATED AND PRIMED REF SRM 51-10-2 PG 3. FABRICATED -3 SPLICE STRAP REF SRM 53-10-5 PG3, HEAT TREAT SPLICE REF 8130 NR 418721, CADMIUM PLATE STRAP REF NR N00957, PRIMED STRAP REF 51-10-2. INSTALLED STRAP SPLICE REF SRM 53-10-5 P3 AND EA 7-5310-118312. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SKIN — WORN (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

LT EXTERIOR FUSELAGE BS 720D 12 STR 19L SKIN LAP JUST FWD OF WING LE, SKIN HAS WEAR REPAIRED FUSE SKIN AT STA 720D 12 STR 19L REF SRM 53-30-3 FIG 5. DISPLACED LEFT INBD LEADING EDGE FOR REPAIR AND REINSTALLED REF SRM 51-30-2 PG 1-5. DISCONNECTED LEADING EDGE PNEUMATIC DUCT AND REINSTALLED AND LEAK CHECKED REF MM 36-13-00-4 PG4. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: FLOOR PANEL — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN CARGO FLOOR CORROSION ON SEAT TRACK AT STA 740 LBL46 REMOVED BEYOND LIMITS CORRODED SEAT TRACK REF SRM 51-30-2. FABRICATED REPLACEMENT SEAT TRACK REF SRM 53-10-5. FABRICATED TRACK SPLICE REF SRM 53-10-5. INSTALLED SEAT TRACK AND SPLICE REF SRM 53-10-5, TREATED AND PRIMED REF SRM 51-10-2 PG 3. FABRICATED -3 SPLICE STRAP REF SRM 53-10-5 PG3 HEAT TREAT SPLICE REF 8130 NR 418721, CADIUM PLATE STRAP REF NR N00957, PRIMED STRAP REF 51-10-2. INSTALLED STRAP SPLICE REF SRM 53-10-5 P3. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LWR EXTERIOR FUSELAGE INSIDE DELTA BEAM BS 740 LBL 5 TO RBL 5 WL 149, FWD LOWER CHORD HAS CORROSION AROUND FASTENERS. REMOVED CORROSION FROM TEE ANGLE STA 740 LBL 5 TO RBL 5, FOUND OUT OF LIMITS. REMOVED TEE ANGLE STA 740, FABRICATED NEW TEE ANGLE TREATED AND PRIMED. INSTALLED NEW TEE ANGLE STA 740 TORQUED BOLTS AT STS 740. INSTALLED WEB AT STA 743 TO 788 BL 0 AND INSTALLED COAXIAL DME CABLE STA 740-800 REF SRM 51-30-2 PG 4/5 FASTENERS, 51-10-6 PG 1-4 CORROSION, 53-10-1 PG 2 LIMITS, 51-10-2 PG 1-7. MAJOR REPAIR.

Part: INTERCOSTAL — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LOWER AFT CARGO AREA CORROSION ON INTERCOSTAL AT STA 950E 3 RBL 12. REMOVED INTERCOSTAL, REMOVED CORROSION, ORIGINAL "T" .040, REMOVED .010, REMAINING .030, FOUND TO BE OUT OF LIMITS. FABRICATED NEW DOUBLER FOR INTERCOSTAL, INSTALLED NEW INTERCOSTAL AND DOUBLER REF SRM 51-10-2 PG 2, SRM 51-30-2 PG 1-4, SRM 53-10-1 FIG 1, BOEING DWR 69-47773 ID 001 FRAME 1. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN CABIN FLOOR CORROSION ON SEAT TRACK FLANGE AROUND FASTENER HOLES STA 560-640 LBL 23 REMOVED CORROSION AT BS 560, REMOVED .030 AREA 1 INCH BY 1 INCH, BS 610 REMOVED .047 AREA 1 INCH BY 1 INCH AND BS 620 REMOVED .045 AREA 1 INCH BY 1 INCH ORIGINAL MATERIAL THICKNESS .100" FOUND OUT OF LIMITS IN ALL 3 AREAS OF MAIN SEAT TRACK FLANGE LBL 23 IAW SRM 53-10-1 DETAIL V. REPLACED SEAT TRACK BS 530-690 LBL 25 IAW SRM 51-30-02 AND DRAWING 65C26010. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: RIB — CRACKED (ZONE 600) · airframe 33,009 hrs · 19,197 cycles

A86-2470, RT WING LE RIB UPPER CHORD IS CRACKED AT EXISTING REPAIR FSS 119, 8 INCHES-18 INCHES FROM SPAR (MKD). INSTALLED AND FABRICATED RT WING LE UPPER CHORD AND SPLICE AT FSS 119. REFS BOEING DWG 64-08342-20, SRM 51-40-03, SRM 51-30-02. TREATED AND PRIMED PARTS REF SRM 51-10-2 PGS 1, 2. CLASSIFIED MAJOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

STA 1148 FLOORBEAM UPPER FLANGE CORRODED RBL 45-45 AFT SIDE AND 44-47 FWD SIDE WL 208. REPAIRED DAMAGED FLOORBEAM REF SRM 53-10-8 FIG 3, SUBSTITUTED "T" CHORD REF EA 7-5310-118313. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: MOUNT — CORRODED (E/E BAY) · airframe 33,009 hrs · 19,197 cycles

FWD ELECTRONIC BAY WEATHER RADAR MOUNT SHELF, LT AFT ATTACH BRACKET CRACKED VERIFIED MATERIAL ID. FABRICATED DOUBLER AND NEW LIGHT SWITCH BRACKET. REMOVED ELECTRONIC BAY LIGHT SWITCH BRACKET, STOP DRILLED CRACKS, TREATED, PRIMED AND PAINTED DOUBLER AND NEW LIGHT SWITCH BRACKET. INSTALLED DOUBLER AND NEW LIGHT SWITCH BRACKET, REF SRM 51-20-1 PG 13, SRM 51-40-3 PG 1/4, SRM 51-30-2 PG 8/14, REF DOC 66-14849-2, DOC 65C16129-10, REF MM 51-20-151 PG 1, REF SRM 51-10-1 PG 13 REF NDT MAN PART 6, 51-00-00 FIG 23 THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: WEB — CRACKED (ZONE 300) · airframe 33,009 hrs · 19,197 cycles

VERTICAL STRAP UPPER END, ELEVATOR FEEL CONTROL UNIT MOUNT PLATFORM LEFT AND RIGHT VERTICAL WEBS CRACKED AT L/E FASTENERS. VERIFIED VERT WEBS CRACKED. REMOVED LT AND RT VERTICAL WEBS, FABRICATED, TREATED, PRIMED AND INSTALLED LT AND RT NEW VERTICAL WEBS, REF SRM 51-10-2 PG 2, SRM 51-30-2 PG 1-4, BOEING DWG 69-16765 ID:0001, THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: BULKHEAD — CORRODED (FUSELAGE) · airframe 33,009 hrs · 19,197 cycles

FWD CARGO PIT, AFT BULKHEAD LWR BEAM PRESSURE PANEL IS CORRODED APPROXIMATELY 6 INCHES LBL ON UNDER SIDE, AND IN SEVERAL OTHER AREAS OF LWR BEAM AROUND NUTPLATE HOLES. REMOVED CORROSION ON LOWER BEAM FOR BULKHEAD PRESSURE PANELS ON AFT BULKHEAD IN FWD CARGO PIT LBL 6 AND SEVERAL OTHER AREAS, LEFT SEGMENT AREA 1" X 1.75" X .029 REMAINING MATERIAL .035, RIGHT SEGMENT AREA 1" X 1" X .019 REMAING MATERIAL .045 ORIGINAL THICKNESS .064, BOTH AREAS FOUND OUT OF LIMITS IAW SRM 53-10- 1. REPLACED LOWER BEAM IAW DRAWING 65-57172 AND SRM 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT FLOOR SUPPORT CORRODED ON UNDERSIDE AROUND NUTPLATE STA 1166 LBL 11-12. SPLICED IN NEW SUPPORT SECTION REF SRM 53-10-5 AND 51-30-2. CLASSIFIED AS A MINOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT FLOOR SUPPORT CORRODED ON UNDERSIDE AROUND NUTPLATE STA 1166 RBL 7-8. SPLICE IN NEW SUPPORT SECTION REF SRM 53-10-5 AND 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT FLOOR SUPPORT ON UNDERSIDE AROUND NUTPLATE STA 1166, NO CENTER LINE. SPLICED IN NEW SUPPORT SECTION REF SRM 53-10-5 AND 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: RIB — CRACKED (ZONE 600) · airframe 33,009 hrs · 19,197 cycles

RT WING LE RIB LWR CHORD IS CRACKED IS CRACKED FSS 119, 4 INCHES-18 INCHES FROM SPAR VERIFIED MATERIAL ID FOR REPAIR ANGLE AND FILLER. CUT OUT DAMAGE. FABRICATED REPAIR ANGLE AND FILLER. LOCATED, DRILLED AND TRIMMED REPAIR ANGLE. HEAT TREATED REPAIR ANGLE. TREATED AND PRIMED REPAIR ANGLE AND FILLER. INSTALLED FILLER, REPAIR ANGLE AND RELATED PARTS, REF SRM 51-30-2, DWG 64-08342-19, REF SRM 51- 10-1 PG 1, REF SRM 51-40-3 PG 3-13 REF MM 51-20-151-7 PG1. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT FLOOR SUPPORT CORRODED ON UNDERSIDE AROUND NUTPLATE STA 1166 RBL 3-4. SPLICED IN NEW SUPPORT SECTION REF SRM 53-10-5 AND 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SHEAR TIE — MISINSTALLED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

SHEAR TIE AT STA 720A, STR 18 R HAS NO EDGE MARGIN AT FASTENER HOLE REPLACED SHEAR TIE AT STA 720 STR 18R IN ACCORDANCE WITH SRM 51-30-02 AND DRAWING 69-43668. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

UNDERSIDE OF AFT PIT FLOOR SUPPORT CORRODED AT STA 1166 RBL 11-12. SPLICED IN NEW SUPPORT SECTION REF SRM 53-10-5 AND 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LOWER AFT CARGO AREA, CORROSION ON SKIN AT STA 950E TO 950F AT LEFT KEEL BEAM. REMOVED CORROSION AND FOUND OUT OF LIMITS. REMOVED FLOOR SUPPORTS, REMOVED, DRILLED, COUNTERSUNK, AND TRIMMED DOUBLER, TREATED AND PRIMED DOUBLER AND SKIN, INSTALLED DOUDLER, INSTALLED FLOOR SUPPORTS REF SRM 53-10-1 AND 51-30-2, 53-30-2, 53-30-1. THIS IS CLASSIFIED AS A MAJOR REPAIR

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT PIT FLOOR SUPPORT CORRODED ON UNDERSIDE AROUND NUTPLATE STA 1166 LBL 3-4. SPLICED IN NEW SUPPORT SECTION REF SRM 53-10-5 AND 51-30-2. THIS IS CLASSIFIOED AS A MINOR REPAIR.

Part: SKIN — DAMAGED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

LOWER FUSELAGE SKIN, STA 720A, STR 18R, LIGHTNING STRIKE IN SKIN REPAIRED LIGHTING STRIKE IN SKIN STA 720A STR 18R IN ACCORDANCE WITH SRM 53-30-3 FIG 3 REPAIR CLASSIFIED A MAJOR REPAIR.

Part: SKIN — CRACKED (TRACK FAIRING) · airframe 33,009 hrs · 19,197 cycles

NR 6 FLAP TRACK HINGE FAIRING CRACKED ON LOWER SKIN AT L/E. FABRICATED DOUBLER AND FILLER FOR NR 6 FLAP TRACK PER DWG 65-21795 PG 1 2024-T3 .040 FILLER 2024-T3 .050. DOUBLER INSTALLED, TREATED AND PRIMED AND PAINTED REF SRM 51-10-2 PG 2-7. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

STA 1148 FLOORBEAM UPPER FLANGE CORRODED RBL 45-45 AFT SIDE AND 44-47 FWD SIDE WL 208.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT FLOORBEAM CORRODED RBL 27 AND RBL 43 NUTPLATES STA 1166 WL 208.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

AFT FLOORBEAM CORRODED RBL 27 AND RBL 43 NUTPLATES STA 1166 WL 208. REPAIRED CORRODED FLOORBEAM REF SRM 53-10-8 FIG 3. SUBSTITUTED "T" CAP MATERIAL REF EA 7-5310-118313. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: INTERCOSTAL — CRACKED (ZONE 200) · airframe 33,009 hrs · 19,197 cycles

FORWARD LAVATORY BELOW FLOOR WATERLINE 208 APPROX STA 294-312 AND APPROX 41 INCHES INTERCOSTAL WEB BETWEEN FLOORBEAMS IS CRACKED, JUST INBD OF LAV DUMP TUBE. REMOVED INTERCOSTAL FOR REPAIR REF SRM 51-10-2, REPAIRED INTERCOSTAL REF SRM 51-40-03 FIG 1. TREATED PRIMED AND PAINTED, REF SOPM 20-43-03 PG3, SOPM 20-44-04 PG3. INSTALLED NEW INTERCOSTAL AT STA 294-312, RBL 41, WL 208 REF SRM 51-30 02 PG 1-12. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: ANGLE — CRACKED (ZONE 200) · airframe 33,009 hrs · 19,197 cycles

DITCHING PAN ANGLE, JUST OTBD OF AIRSTAIR DOOR, LEFT SIDE IS CRACKED AT ALL FASTENER HOLES. REPLACED ANGLE REF DWR 65-29548. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRAP — CHAFED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN CARGO FLOOR, CHAFING ON "I" BEAM FLOORBEAM AT STA 740 FROM BL 0 TO BL 50. REPLACED STRAP AT 740, LBL 50 TO RBL 50 REF EA 7-5310-118310, WORKED WITH N/R N00390, THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SKIN — MISREPAIRED (FUSELAGE) · airframe 33,009 hrs · 19,197 cycles

FOUND EXTERNAL FUSELAGE REPAIR LOCATED AT APPROX BS 1164-1178 STR 17R- STR 18R. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA REMOVED OLD REPAIR REF SRM 51-30-2 PG 1-6. FABRICATED REPAIR DOUBLER REF SRM 53-30-2 FIG 3. TREATED AND PRIMED REF SRM 51-10-2 PG 1-6. INSTALLED REF SRM 53-30-3 FIG 1. PAINTED TO MATCH REF MM 51-20-151-7 (CLASSIFIED AS A MAJOR REPAIR).

Part: BRACKET — CRACKED (FLAP TRACK) · airframe 33,009 hrs · 19,197 cycles

NR 4 FLAP TRACK FAIRING BRACKET CLIP IS CRACKED LOCATED ON OTBD SIDE, 20 INCHES FROM FWD END VERIFIED MATERIAL AS 7075-T6-.063 REF DWR 69- 22882. REPLACEMENT MATERIAL SAME AS ORIGINAL, FABRICATED BRACKET FOR OTBD SIDE OF NR 4 FLAP TRACK PER DWR 69-22882. TREATED BRACKET REF MM 51-20-021-7 AND PRIMED REF MM 51-20-031-7 AND INSTALLED BRACKET ON FLAP TRACK REF SRM 51-30-2. MARKED BRACKET WITH FX 69-22882-21 REF GMM 7-0-001. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: BRACKET — CRACKED (TE FLAP) · airframe 33,009 hrs · 19,197 cycles

NR 5 FLAP TRACK FAIRING BRACKET CLIP IS CRACKED LOCATED ON INBD SIDE, 20 INCHES FROM FWD END VERIFIED MATERIAL AS 7075-T6-.063 REF DWR 69-22882. REPLACEMENT MATERIAL SAME AS ORIGINAL, FABRICATED BRACKET FOR INBD SIDE OF NR 5 FLAP TRACK PER DWR 69-22882. TREATED BRACKET REF MM 51-20-021-7 AND PRIMED REF MM 51-20-031-7 AND INSTALLED BRACKET ON FLAP TRACK REF SRM 51-30-2. MARKED BRACKET WITH FX 69-22882-21 REF GMM 7-0-1001. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRAP — CHAFED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

MAIN CABIN FLOOR CHAFING ON "I" BEAM FLOORBEAM AT STA 740 FROM BL 0 TO RBL 50. REMOVED DAMAGED STRAP REF 51-30-02, FABRICATED REPLACEMENT STRAP REF EA 7-5310-118310. TREATED AND PRIMED REF AMM 51-20-151. INSTALLED NEW STRAP REF EA 7-5310-118310, WORKED WITH N/R N00389. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: INTERCOSTAL — CRACKED (ZONE 200) · airframe 33,009 hrs · 19,197 cycles

COCKPIT FLOOR SUPPORT INTERCOSTAL IS CRACKED BS 304, LBL 10, WL 208. REMOVED FIRE EXTINGUISHER BRACKET TO FOM REF SRM 51-30-2 P. 1. REMOVED DAMAGED INTERCOSTAL REF SRM 51-30-2. INSTALLED REPLACEMENT INTERCOSTAL REF SRM 51-30-2. REINSTALLED FIRE EXTINGUISHER BRACKET. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SHEAR TIE — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LOWER AFT CARGO AREA, CORROSION ON SHEAR TIE AT RBL 11 BS 990, REMOVED CORROSION REF SRM 51-10-6 PG 5. MEASURED ORIGINAL "T" .043, .038 REMAINING REF NDT PART 4 51-00-00 FIG 2. REMOVED .005 OUT OF LIMITS REF SRM 53-10-1 DETAIL IV. REMOVED DAMAGE, FABRICATED SHEAR TIE REF SRM 53-10-4 DETAIL I. HEAT TREATED SHEAR TIE TO THE T-6 CONDITION. TREATED AND PRIMED REF SRM 51-10-2 PG 7 AND MM 51-20-151-7. INSTALLED SHEAR TIE REF SRM 51-51-10-4 PG 58-60. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: STRINGER CLIP — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

LOWER AFT CARGO AREA, CORROSION ON STRINGER CLIP AT KEEL BEAM CHORD STA 950E 3. REMOVED STRINGER CLIP, LOCATED AND DRILLED TO SIZE, TREATED AND PRIMED BARE METAL ON KEEL BEAM. INSTALLED NEW STRINGER CLIP REF SRM 51-30-2 PG 1, 51-10-2 PG 1. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: STRAP — CRACKED (ZONE 200) · airframe 33,009 hrs · 19,197 cycles

MAIN DECK FLOORBEAM STABILIZER STRAP IS CRACKED BS 344 LBL 23 WL 200 STOP DRILLED CRACK. INSTALLED REPAIR DOUBLER REF SRM 53-10-08 PG 36, FIG 6. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: INTERCOSTAL — CORRODED (ZONE 200) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN DECK FLOOR INTERCOSTAL IS CORRODED BS 312-328, LBL 30, WL 208. REMOVED CORROSION AND INTERCOSTAL AT STA 312 ORIGINAL THICKNESS .075 MATERIAL LOSS .025 REMAINING MATERIAL .050, FOUND OUT OF LIMITS. FABRICATED NEW INTERCOSTAL, INSTALLED NEW INTERCOSTAL AND SHIM REF BOEING DWR 65-26173, SRM 51-30-2 PG 1-3. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: RIB — CRACKED (ZONE 500) · airframe 33,009 hrs · 19,197 cycles

LT WING LE RIB LWR CHORD IS CRACKED FSS 119, 17 INCH FROM SPAR REMOVED CRACKED AREA OF RIB FLANGE, FABRICATED AND INSTALLED REPAIR ANGLE REF SRM 51-40-3 FIG 1. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 33,009 hrs · 19,197 cycles

MAIN DECK FLOOR SUPPORT INTERCOSTAL IS CORRODED BS 304-312, LBL 30, WL 230 REMOVED CORROSION ON INTERCOSTAL AT BS 304-312 ORIGINAL THICKNESS .062, MATERIAL LOSS .012 REMAINING MATERIAL .050 OUT OF LIMITS. REMOVED INTERCOSTAL AND FABRICATED NEW INTERCOSTAL INSTALLED NEW INTERCOSTAL AND SHIM. REF BOEING DRW 65-26173, SRM 51-30-2 PG 1-3.

Part: FLANGE — CRACKED (ZONE 100) · airframe 33,009 hrs · 19,197 cycles

MAIN DECK FLOOR E/E RACK STANTION SUPPORT INTERCOSTAL VERT FLANGE IS CRACKED BS 371 RBL 2 WL 199. REMOVED ANGLE VERIFIED MATERIAL ID FABRICATED NEW ANGLE INSTALLED NEW ANGLE AND WIRE BUNDLE CLAMP, REF SRM 51-30-2 PG 2, REF DWR 65-24297, REF MM 51-20-151 PG 1- 6, REF SRM 51-30-2 PG 8, 13-14. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRAP — CRACKED (FUSELAGE) · airframe 33,009 hrs · 19,197 cycles

UPPER MAIN DECK FLOORBEAM STABILIZER STRAP CRACKED AT STA 324 LBL 23 WL 200. STOP DRILLED CRACK, INSTALLED REPAIR DOUBLER REF SRM 53-10-08 PG 36 FIG 6. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: TRANSMITTER — MALFUNCTIONED (NR 3 ENGINE) · airframe 30,967 hrs · 17,845 cycles

NR 3 EPR GAUGE PEGGED HIGH IN EXCESS OF 2.5 EPR DURING INITIAL POWER ADVANCEMENT FOR TAKEOFF ROLE, ABORTED TAKEOFF PRIOR TO AIR SPEED INDICATION, REVIEWED AND COMPLIED WITH MEL/CDL DIRECTIONS. CONTINUED TO DESTINATION AND NR 3 EPR GAUGE APPEARED TO WORK NORMALLY, REPEAT WRITE UP. REMOVED AND REPLACED NR 3 ENGINE EPR TRANSMITTER IAW AMM 77-11-011-4, RAN ENGINE PER JRH CHAPTER 5 EPR INDICATION NORMAL. NO OSCILLATIONS OR PEGGED WITH POWER, MOCC NOTIFIED. A/C OK FOR SERVICE.

Part: FUEL CONTROL — MALFUNCTIONED (NR 1 ENGINE) · airframe 29,991 hrs · 17,246 cycles

NO THROTTLE RESPONSE ON NR 1 ENGINE ON TAKEOFF. REMOVED AND REPLACED NR 1 ENGINE FUEL CONTROL IAW FX B 727-200 MM 73-20-001-2. PERFORMED ENGINE RUN AND TRIM MED IAW FX B727-200 MM 71-00-030 AND 71-00-097 AND OPS AND LEAK CHECK GOOD. ALSO REMOVED AND REPLACED NR 1 ENGINE FUEL PUMP IAW FX B727-200 MM 73-12-001-2. OPS CHECK AND LEAK CHECK GOOD IAW FX B727-200 MM 73-12-0 01-2 SIGNED BY TIMCO MECH NR 7342 AND QC281.

Part: ANGLE — CRACKED (ZONE 100) · airframe 29,989 hrs · 17,241 cycles

CRACKED, NOSE LANDING GEAR WHEEL WELL TOP-AFT ANGLE, BS 351.2, LBL 4 TO RBL 4, WL 181 (CRACKED AFT UPPER CHORD) FX SNRM N00174. REMOVED, FABRICATED, ALODINED, PRIMED AND INSTALLED NEW CHORD ALL IAW BAC DWG 65-18417 AND FX B727 SRM'S 51-30-2, 51-10-2.

Part: SKIN — GOUGED (ZONE 100) · airframe 29,989 hrs · 17,241 cycles

GOUGE IN FUSELAGE SKIN AT STA 294 AT STRINGER 25R. FX SNRM N00075. REMOVED DAMAGED AREA OF SKIN, FABRICATED, ALODINED, PRIMED AND INSTALLED REPAIR DOUBLER ALL IAW FX B727 SRM 53-30-3 FIG 1 & 4, 53-30-1 FIG 1, 53-30-2 FIG 4, 51-30-2 AND 51-10-2.

Part: UNKNOWN — FUMES (CABIN/COCKPIT) · airframe 28,994 hrs · 16,614 cycles

CREW REPORTS THAT AT PASSING THRU 8000 FT, HAD UNKNOWN FUMES IN THE COCKPIT. DECLARED AN EMERGENCY AND C/W WITH CHECKLIST. RETURNED TO RNO. RAMP UNLOADED AND INSPECTED HAZ CONTAINER ALL OK. REMAINDER OF FREIGHT UNLOADED NO SIGNS OF LEAKAGE. RAN ENGINES AND PRESSURIZED A/C TO 4 PSID PER JRH, NO ODORS DETECTED.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 28,915 hrs · 16,570 cycles

DURING LIFT TRUCK POSITIONING STRUCK A/C ON LT SIDE AND CAUSED HORIZONTAL SCRATCH/HOLES APPROXIMATELY 14 INCHES IN LENGTH AT BS 300 TO 314 AND 18 INCHES BELOW WL 208 CHORD (FLOORBEAM). REPAIRED NOTED DAMAGE PER BOEING 727 SRM 53-30-3. THIS REPAIR WAS DEEMED A CAT-B IN REF TO SRM 53-30-3 PAGE 6. THE SKIN THICKNESS DID NOT MEET THIS CRITERIA AND THEREFORE CAUSED THE REPAIR TO BE A CATAGORY B REPAIR, FEDEX SRM 53-30-3.

Part: FIRE LOOP — MALFUNCTIONED (APU BAY) · airframe 28,640 hrs · 16,401 cycles

APU FIRE WARNING LIGHT IN HANDLE AND FIRE WARNING ON GLARESHIELD CAME ON. PULLED FIRE HANDLE, LIGHT STAYED ON. DISCHARGED APU BOTTLE, LIGHT STAYED ON. LIGHT EXTINGUISHED ON DESCENT INTO IAH 10 MIN LATER. LIGHT CONTINUED TO FLICKER IN HANDLE INTERMITTENT IN DESCENT & ON GROUND. CHECKED APU FIRE SENSOR LOOP AND SHOOK DOWN CONNECTORS ON APU. NO FAULTS NOTED. CLEANED C/P D4858P AND R421 PER WDM. REMOVED AND REPLACED APU FIRE DET OPERATION UNIT PER MM 26-15-003-4. REMOVED AND REPLACED FIRE BOTTLE PER MM 26-23-001-4.

Part: BRAKE — BLOWN (MLG) · airframe 27,716 hrs · 15,883 cycles

ON BLOCK, FOUND NR 1 BRAKE ASSY BLOWN APART.

Part: ACTUATOR — FAILED (ZONE 500) · airframe 26,954 hrs · 15,495 cycles

ON PUSHBACK MEM AFTER DISCONNECT WITH A PUMPS ON, L/E FLAPS REMAINED UNSAFE. CYCLED FLAPS 2-5 DEGREES WENT GREEN. CYCLED FLAPS BACK UP, UNSAFE WENT OUT. PASSING 10K UNSAFE L/E FLAPS RE-ILLUMINATED. CYCLED DOWN AND BACK LIGHT WENT OUT. PASSING 19K, UNSAFE L/E FLAP RE-ILLUMINATED RETURNED TO MEM. LOWERING FLAPS FOR LANDING, L/E FLAP UNSAFE OUT SELECTING FLAPS 5. REMAINS UNSAFE FLAPS 2 OPERATED L/E SEVERAL TIMES. L/E FLAP LIGHT REMAINED LIT WHEN SLATS WERE UP. CHECKED LED PANEL AND CONFIRMED NR 4 SLAT NOT UP INDICATION. T/S PER WDM AND DETERMINED NR 4 SLAT ACT SW IS BAD. REMOVED AND REPLACED NR 4 SLAT ACT REF 727-200MM 27-81-032-4, OPS CHECKS GOOD AT THIS TIME.

Part: ACCESSORY UNIT — FALSE ACTIVATION (E&E BAY) · airframe 26,589 hrs · 15,304 cycles

DURING CONFIGURATION TO LAND AFTER PLACING LANDING GEAR LEVER DOWN ALL LIGHTS REMAINED ILLUMINATED ON GEAR ANNUNCIATOR PANEL, REDS AND GREENS. RECYCLED GEAR IAW QRH AND AGAIN ALL LIGHTS REMAINED ILLUMINATED. RECYCLED AGAIN AND GOT A SAFE 3 GREEN INDICATION AND LANDED UNEVENTFULLY. TROUBLESHOT PER MM 32-61-001-1, NEEDS LANDING GEAR ACCESSORY UNIT P/N 65-60211-23 NIS GTF/LINE. REMOVED AND REPLACED LANDING GEAR ACCESSORY UNIT PER FEDEX 727-200 M/M 32-09-121-4. PERFORMED TEST OF LANDING GEAR ACCESSORY UNIT PER FEDEX 727-200 M/M 32-09-122-5. TEST CHECKS GOOD.

Part: SKIN — DAMAGED (CARGO DOOR) · airframe 26,401 hrs · 15,195 cycles

WHILE WORKING FOUND AREA OF OIL CANNING ON FWD CARGO DOOR LOWER SKIN 10 INCHES FROM FRONT. REPAIRED FWD CARGO DOOR LOWER SKIN IAW SRM 52-00-3 FIG 3.

Part: FLOORBEAM — CHAFED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

BS 740 FLOORBEAM IS CHAFED IN AREAS FROM LBL-45 RBL 45 WL 208. REPAIRED FLOORBEAM IAW EA 7-5310-54878.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

N00460 CRACKED FRAME SHEAR TIE STA 580 ABOVE 18L ** SD ** COMING

Part: FRAME — CRACKED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

CRACKED FRAME SHEAR TIE STA 540 ABOVE STR 18L. REPAIRED SHEAR TIE BS 540 ABOVE STR 18L IAW SRM 51-40-3.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

N00459 CRACKED FRAME SHEAR TIE AT STA 500 ABOVE STR 18 LT. ** SD ** COMING

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

N00461 SHEAR TIE CRACKED BS 560 ABOVE STR 18L. ** S/D ** COMING

Part: FRAME — CRACKED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

CRACKED FRAME SHEAR TIE STA 580 ABOVE STR 18L. REPAIRED SHEAR TIE CLIP AT BS 580 ABOVE 18L PER SRM 51-40-3.

Part: FRAME — DENTED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

N00368 970 FRAME DENTED AT S25L. REPAIRED FRAME AT BS 970 STR 25L IAW SRM 51-40-3, FIG 1, BS 970 FRAME DENT AT STR 25L OUT OF LIMITS IAW SRM 53-10-1.

Part: FRAME — DENTED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

N00367 950F FRAME DENTED BETWEEN S26L AND S25L. REPAIRED FRAME AT BS 950F BETWEEN STR 26L AND STR 25L IAW SRM 51-40-3 FIG 1, BS 950F FRAME DENT BETWEEN STR 25L AND STR 26L OUT OF LIMITS IAW SRM 53-10-1.

Part: FRAME — GOUGED (FUSELAGE) · airframe 26,401 hrs · 15,195 cycles

N00369 990 FRAME GOUGED BETWEEN S25L - S26L. REPAIRED FRAME AT BS 990 BETWEEN STR 25L - STR 26L PER SRM 51-40-3 FIG 1, BS 990 FRAME GOUGE OUT OF LIMITS IAW SRM 53-10-1 AT STR 25L - STR 26L.

Part: SWITCH — FAULTY (L/E FLAP)

L/E FLAP NR 5 IND INTRANSIT LIGHT ON FWD INSTRUMENT PANEL AND AUX PANEL. REMOVED AND REPLACED FLAP POS SW FOR NR 5 KRUEGER FLAP PER MM 27-82-001-4. OPS CHECK GOOD.

Part: SOLENOID — FAILED (COCKPIT)

LANDING GEAR FAILED TO RETRACT ON DEPART. REMOVED AND REPLACED LANDING GEAR LEVER LOCK SOLENOID IN REF 727-200 MM 32-31-016-4. CHECK GOOD.

Part: FIRE LOOP — FAULTY (NR 1 ENGINE)

ON CLIMB FIRE WARNING SYS (WITH BELL) ACTUATED FOR 2 SEC. FIRE SYS TEST OK. *S/D* REMOVED AND REPLACED NR 1 ENG AND FIRE WALL LOOPS PER MM 26-11-012-4. OPS CK OK FOR SERVICE.

Part: FIRE DETECTOR — FAULTY (ENGINE)

AFT T/O ENG FIRE LIGHT ILLUM. BOTTLES 1 AND 2 DISCHARGED LIGHT REMAIN ILLUM. *S/D* REMOVED AND REPLACED FIRE DETECTION UNIT AND FIRE BOTTLES AND DISCHARGE IND DISK PER STANDARD PRACTICE AND MM 26-21-001-4, MM 26-11-001-5. GOOD FOR SERVICE.

Part: CLAMP — LOOSE (HEAT EXCHANGER)

NR 1 ENG FIRE IND ON CLIMBOUT. SHUTDOWN ENG DID NOT FIRE BOTTLE. *S/D* REINSTALLED AIR HEAT EXCHANGER EXHAUST DUCT CLAMP PER MM 36-11-051-4. ALL IND NORMAL, OK FOR SERVICE.

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

AFT T/O NORM CLIMBOUT WENT TO RAISE GEAR HANDLE. GEAR WOULD NOT GO BEYOND OFF POS. PERFORMED OPS TEST ON SOLENOID. CK GOOD. REMOVED AND REPLACED LG ELECTRONIC MODULE PER 32-09-122. OK FOR SERVICE.

Part: DUCT CLAMP — LOOSE (NR 1 ENGINE)

ON FINAL NR 1 FIRE WARN ILLUM. ENG SHUTDOWN. FIRE BOTTLE DISCHARGED. FOUND DUCT CLAMP LOOSE WITH AIR LEAK. TIGHTENED CLAMP PER STANDARD MAINTENANCE PRACTICES. RAN ENG, NO LEAKS NOTED. REMOVED AND REPLACED OIL FILTER PER P&W MM 72-61-55, RAN ENG PER JET RUN HDBK. NO LEAKS NOTED.

Part: DOOR — MALFUNCTIONED (NLG) · airframe 23,131 hrs · 13,406 cycles

WHEN GEAR WAS EXTENDED MANUALLY HAD RED DOOR LIGHT BUT NO GREEN LIGHT. CK VIEW PORT AND CONFIRM NOT DOWN. PERF OPS CK OF NOSE GEAR MANUAL EXT, BOTH POWER ON AND OFF. CYCLED 5 TIMES, NO DEFECT NOTED. OPS CK GOOD PER IAW MM 32-34-000-5 AND MM 7-11-000-2.

Part: COMPUTER — FAILED (E/E BAY)

00-345 AUTO PILOT DISCONNECTED ON 2 ATTEMPS CAT 3 ILS 16R AT SEA. ** S/D ** R&R B PITCH COMPUTER, CK OK PER MM 22-11-121.

Part: WARNING SYSTEM — ACTIVATED (CABIN PRESSURE)

CABIN PRESS ALT WARN HORN CAME ON. RAN RED TABS. CHANGED CABIN PRESSURE CONTROLLER PRECAUTIONARY. NO FUSELAGE LEAKS NOTED. NO PACK LEAKS NOTED. ALL SYS CK NORMAL ON GROUND. WORK ACCOMP PER MM 21-31-0, 21-31-10 & JRH.

Part: ACTUATOR — LEAKING (TE FLAPS)

NR 1 A SYS LOW PRESSURE LIGHT CAME ON. NR 2 A SYS LIGHT OUT. RAN HYD LEAK OR LOSS CKLIST, SHUTOFF A SYS PUMP AND FLUID. *S/D* REMOVED AND REPLACED NR 1 & 2 A SYS HYD PUMPS, CASE DRAIN AND PRESSURE FILTERS AND I/B FLAP DRIVE MOTOR PER MM 29-11-0, 29-11-41, 29-11-62, 29-11-33, AND 27-51-62. HYD SYS AND FLAP MOTOR OPS CK NORMAL. OK FOR SERVICE.

Part: DUCT — FAILED (NR 3 ENGINE COWL)

ENGINE NR 3 FIRE WARNING LIGHT ON CLIMBOUT 100 AGL. FOLLOWED RED TAB PROCEDURES. WARNING LIGHT WENT OUT WHEN THRUST LEVER RETARDED. FIRE WARNING SYSTEM CHECKED OK. RETURNED TO STL. *S/D* REMOVED TUBE PART NUMBER 777790, DUCT PART NUMBER 1211318-002, FLANGE PART NUMBER 259-1068-501. INSTALLED TUBE, DUCT, AND DUCT FLANGE. LEAK CHECKS GOOD. DUE TO DUCT BREAK NR 3 UPPER COWL DAMAGED. REMOVED AND REPLACED SAME.

Part: SUPPLY DUCT — BURNT SMELL (NR 1 ENGINE)

BURNT OIL SMELL FROM AIR CONDITIONING WHEN NR 1 BLEED USED FOR PACK AIR SOURCE ON DESCENT. REPEAT GRIPE. RAN NR 1 AND NR 3 ENGINES TOGETHER AND SEPARATELY AS AIR SOURCE . RAN LEFT AND RIGHT PACKS TOGETHER AND SEPARATELY WITH BOTH PACKS ON. USING NR 1 BLEED, ABLE TO GET A HOT PACK SMELL (VERY SLIGHT) , BUT WERE UNABLE TO DUPLICATE DISCREPANCY. FOUND OIL IN NR 1 ENGINE 6TH STAGE SUPPLY DUCT AT PYLON. ENGINE REMOVED PER WORK CARD 70T005. REMOVED AND REPLACED ENGINE NR 1 PER WORK CARD 70T0005 AND 70T0301. RAN ENGINE. OPERATIONAL AND LEAK CHECK GOOD. OK FOR SERVICE.

Part: GASPER FAN — FAILED (COCKPIT)

CREW HAD AIR RETURN DUE SMOKE IN COCKPIT, ODOR POSSIBLY OIL/HYD CMA SMOKE AND FUMES. T/S A/C SYSTEM FOUND CONDENSOR/WATER SEPARATOR BAGS BLACK COLOR WITH BAD SMELL. GASPER FAN HAD OIL ON BLADES WITH BAD SMELL. REMOVED AND REPLACED CONDENSOR/WATER SEPARATOR BAGS PER MM 21-23-51. REMOVED AND REPLACED GASPER FAN PER MM 21-23-11, OPS CHK NORMAL. RAN APU OPERATED LT AND RT PACKS, OPENED ALL GASPER AIR VENTS IN COCKPIT, NO SMOKE OR FUMES. RAN ENGINES OPERATED LT AND RT PACKS, ALL GASPER AIR VENTS OPEN IN COCKPIT NO SMOKE OR FUMES.

Part: RIB CHORD — CRACKED (BS 760.75)

REPAIR WING RIB UPPER CHORDS BS 760.75, RBL AND LBL 70.5, IAW FEDEX EA 7-5710-26265 AND 7-5710-26266. REPAIRED LT RIB UPPER CHORD, BS 760.95 IAW FEDEX EA 7-5710-26266. ALSO, REPAIRED RT RIB UPPER CHORD BS 760.95 IAW FEDEX EA 7-5710-26265.

Part: CHORD — CRACKED (TE MID FLAP)

RIGHT INBOARD MID-FLAP AFT LOWER CHORD CRACKED AT INBOARD AFT FLAP ACTUATOR RUDDER CUT-OUT. REMOVED NR 5 FLAP TRACK AFT FAIRING. REMOVED DAMAGED PORTION OF AFT LOWER CHORD ON RT INBD MID-FLAP AND REPAIRED IAW FEDEX SRM 51-40-4, FIG 1. REINSTALLED NR 5 FLAP TRACK AFT FAIRING PER FEDEX MM 27-51-31.

Part: TURBINE — FAILED (NR 2 ENGINE)

ABORT ON RUNWAY FOR ENGINE FAILURE ABOUT 80K, #2 ENG MAXIMUM POWER T/O. FOUND NR 2 ENG TURBINE FAILURE. REMOVED NR 2 ENG AS PER WORKCARD 70T0002, INSTALLED NR 2 ENG PER WORKCARD 70T0002. COMPLIED WITH HOOKUPS OPERATIONAL AND LEAK CHECKS PER WORKCARD 70T0002 AND 70T0301, OPS CK GOOD. REQUIRED ITEMS INSPECTION COMPLIED WITH.