N220FE

Part: FAN — FAILED (CABIN) · airframe 56,736 hrs · 35,795 cycles

SLIGHT ELECTRICAL ODOR WAS DETECTED APPROACHING DESTINATION. TURNED OFF GASPER FAN. ODOR WAS STILL DETECTED AND BECOMING STRONGER. DONNED OXYGEN MASKS RAN QRH SMOKE, FUMES, ODORS CHECKLIST. DECLARED ATC EMERGENCY LANDED AT RWY 9 WITH FIRE TRUCKS IN TOW. AT GATE, SHUTDOWN ACFT UNTIL ALL POWER OFF, LEFT ACFT. FLIGHT ENGINEER REPORTS VISUAL SMOKE NEAR FO`S LIDO BAG AFTER RUNNING QRH CKLIST. POSSIBLE OUT OF GASPER VENT BY LANDING, SMOKE CLEARED. AT CREW DEPARTURE STILL COULD DETECT SMOKE/ WIRE/ INSULATION BURN. GASPER FAN CAME APART, REMOVED AND REPLACED GASPER FAN IAW 21-23-001-4. CLOSED FINAL.

Part: GASPER FAN — MALFUNCTIONED (CABIN) · airframe 56,736 hrs · 35,795 cycles

AT FL 350 A SLIGHT ELECTRICAL ODOR WAS DETECTED APPROACHING MEMPHIS. TURNED OFF GASPER FAN. ODOR WAS STILL DETECTED AND BECOMING STRONGER. DONNED OXYGEN MASKS RAN QRH SMOKE, FUMES, ODORS CHECKLIST. DECLARED ATC EMERGENCY AND LANDED. AT GATE SHUTDOWN ACFT UNTIL ALL POWER OFF, LEFT ACFT. FLT ENGINEER REPORTS VISUAL SMOKE NEAR FIRST OFFICERS LIDO BAG AFTER RUNNING QRH CHECKLIST. POSSIBLE OUT OF GASPER VENT BY LANDING SMOKE CLEARED. AT CREW DEPARTURE STILL COULD DETECT SMOKE/WIRE/INSULATION BURN. GASPER FAN CAME APART, R/R GASPER FAN IAW 21-23-001-4

Part: BEAM — CORRODED (ZONE 100) · airframe 56,473 hrs · 35,606 cycles

KEEL BEAM END TOP ATTACH ANGLE ON BACK OF BULKHEAD AT FS 740 HAS CORROSION ON TOP SIDE OF ANGLE AT RBL 4, ABOVE CONTROL CABLE PULLEY WHEELS. REMOVED AND REPLACED ANGLE REF SRM 51-30-02. FABRICATED REPLACEMENT ANGLE ON N/R N00726. FLAP PEENED, ALODINED, PRIMED AND INSTALLED. REF SRM 51-10-2, SOPM 20-10-03. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: BEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

DELTA BEAM INTERIOR RT LOWER CHORD AT BS 747 - 749, RBL 5, IS CORRODED ON INNER SURFACE AT AND AROUND SPLICE. BLENDED CORROSION AT LOWER, FWD CHORD. FOUND TO BE OUT OF LIMITS, REF DWG 69-47111. REPLACED CHORD REF DWG 65-47111. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: FRAME — CORRODED (WING TO BODY) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

CORROSION ON TOP OF WING TO BODY FAIRING FRAME WORK AT TWO FWD ADF ANTENNA LEAD POSITION CLAMP ATTACH AT FS 730F, RBL 10, INBOARD OF RT RAM AIR DUCT REMOVED PANELS REF SRM 51-30-2, REMOVED CORROSION REF SRM 53-10-01. FOUND TO BE OUT OF LIMITS REF SRM 51-20-01. FABRICATED NEW Z-ANGLE REF SRM 53-10-1. REPLACED Z-ANGLE REF 51-30-02. REPLACED PANELS REF 51-30-02. THIS IS CLASSIFIED AS A MINOR.

Part: BEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

CORROSION INSIDE DELTA BEAM STA740, LBL 3, WL 148 CUT AWAY LWR WEB SECTION OF DELTA BOX TO FOM. REMOVED CORROSION FROM DELTA BEAM STA 740, LBL 3, WL 148. VERIFIED MATERIAL LOSS BY NDT, AND FOUND TO BE OUT OF LIMITS REF DWG 65-23555. REPLACED INTERCOSTAL REF DWG-23555. FABRICATED NEW WEB SECTION, VERIFIED MATERIAL FOR NEW WEB REF DWG .080. FABRICATED AND INSTALLED WEB. REF DWG 65-23555-7, SRM 51-4-02 PG 1-6, SRM 51-30-2 PG 1-6. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: BULKHEAD — CORRODED (BS 720) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

FWD PANEL RACK: BULKHEAD BS 720 FWD PIT FRAME CORROSION AROUND NUT PLATES (MKD) FABRICATED NEW FRAME ANGLE REF DAD DWG 65-82623. TREATED PRIMED RES AMM 51-20-021-7 PG 1-7 51-20-031-7 PG 1-7. MARKED PART REF FEDEX GMM 7-0-1001. THIS IS CLASSIFIED AS AMINOR REPAIR.

Part: PANEL — DELAMINATED (ZONE 100) · airframe 56,473 hrs · 35,606 cycles

RT A/C BAY PANEL 3456 R DELAMINATED REMOVED AND REPLACED PANEL 3456R WITH SERVICEABLE PANEL REF SRM 51-30-2 PG 13. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: BEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

RT A/C EQUIP BAY PANEL 3455 HAS CORROSION UNDER FWD HINGE PLATE ON FRAME REMOVED PNL NR 3453, 3358, 3465. SPLICED IN NEW BEAM ASSY P/N NR 65-58502-90. FABRICATED 4. REPAIR ANGLES, TREATED AND PRIMED AND INSTALLED. RE-INSTALLED A/C PANELS. REF SRM 51-30-02 PG5, 51-40-4 PG 14-17, 51-30-4 PG 1-2, RESTORED CIC REF SRM 51-10-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: MOUNT — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

CORROSION ON CARGO TIE DOWN MOUNT ON BOTTOM INBOARD FWD CORNER AT FS 720, LBL 22, WL 156. REMOVED AND REPLACED DAMAGED FITTING, REF SRM 51-30-02 PG 1-3. FITTING FOUND TO BE OUT F LIMITS, REF BOEING DWG 65-57848 ITEM NR 1, ORIG THK IS .110 INCH, MAT LOSS IS .035", MAT. REMAINING IS. 075 INCH, CAL TOOL NR IN 17-0213, DUE DATE 4/7/09. REINSTALLED ALL, REMOVED FASTENERS TO F.O.M. REF SRM 51-30-02 PG 1-3. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: DOOR FRAME — CRACKED (ZONE 800) · airframe 56,473 hrs · 35,606 cycles

REF SNRM N00174 JPF ITEM NR 1. MAIN DECK, 1L DOOR FRAME IS CRACKED UNDER REMOVED STOP FITTING, AT BOTTOM CROSS BEAM AFT END. REMOVED DAMAGED MATERIAL REF SRM 51-40-02. VERIFIED CRACK REMOVED REF. 727 NDT MAN. PT. 6 51.00-00 FIG 23. NO DEFECTS FOUND. INSTALLED FILLER AND DOUBLER REF SRM 51-40-02 PG. 1 & 2

Part: SKIN — CRACKED (MLG DOOR) · airframe 56,473 hrs · 35,606 cycles

NOSE LANDING GEAR RIGHT FWD DOOR, CRACK AT AFT END EDGE SKIN AT O/B STOP ANGLE SUPPORT REPAIRED, R NLG DOOR REF 51-40-3, 51-30-5, 51-10-02, AND MM 32-22-001-4 . PERFORMED ADJUSTMENT AND TEST OF DOOR REF MM 32-22-001-5. OPS CHECK GOOD. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

AFT CABIN, AT BS 1130 FLOORBEAM LOWER FLANGE, UPPER SURFACE CORRODED, BETWEEN LBL 22 AND LBL 35. REMOVED LOWER LT EXISTING T-CAP REPAIR, REF SRM 51-30-2. FABRICATED NEW T-CAP AND SPLICE ANGLES AND STRAP, REF SRM 53-10-8 FIG 10. INSTALLED REPAIR PARTS, REF SRM 53-10-8 FIG 10. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: FRAME — DAMAGED (ZONE 100) · airframe 56,473 hrs · 35,606 cycles

AFT PIT BILGE BODY FRAME UPPER FLG IS BUCKLED, BS 1070, STR 25R - 27R DAMAGE ON FRAME FLANGE FOUND TO BE OUT OF LIMITS PER SRM 53-10-1 PG 1-3 DETAIL 4 NOTE 5. REMOVED DAMAGE, NDT VERIFIED DAMAGE REMOVAL. VERIFIED MATERIAL FOR REPAIR DOUBLER, 7075 - O - .063" .A 03916 / PO 1035912. FABRICATED REPAIR DOUBLER ITEM 14. REPAIR DOUBLER FABRICATED IN ITEM NR 6 NOT USED. HEAT TREATED TO T-6. TREATED AND PRIMED AND INSTALLED REPAIR DOUBLER, REF SRM 53-10-1 PG 1-3, DETAIL 4, SRM 51-40-3 FIG 1 SRM 51-30-2 FIG 7 BOEING DWG 65-16344. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: STRINGER CLIP — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

AFT PIT BILGE BODY FRAME STR CLIP IS CORRODED BS 950F FWD, STR 29 R, O/B WL 139. REMOVED AND REPLACED STRINGER CLIP/CHANNEL REF SRM 51-30-2 PG 2. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: COVER — CRACKED (ZONE 100) · airframe 56,473 hrs · 35,606 cycles

C-2 PIT RT THRESHOLD COVER AT STA 950E IS CRACKED AT BOLT HOLE WITH LIGHT CORROSION ON BOTTOM SIDE OF PANEL TRANSFERRED HOLES, INSTALLED NUTPLATES, TREATED, PRIMED AND PAINTED NEW PANEL. REF; SRM 51-30-2 PG 1 - 3, FX 727 200 MM 51-20-151-7, AND FX727-200 MM 51-20-21-7 PG 1-3, THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SHEAR TIE — CHAFED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

AFT PIT BILGE BODY FRAME SHEAR TIE ASSY HAS DISBONDED LEVELING COMPOUND/CORROSION BS 1130 AFT, STR 29R - 30, WL 148. BLENDED CORROSION ON SHEAR TIE, FOUND TO BE OUT OF LIMITS. FABRICATED AND INSTALLED NEW PIECE. REF SRM 51-30-02 AND DWG NR 69-20813. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

CORROSION ON SKIN ATTACH ANGLE IN C-1 PIT, FS 700, BL 0, WL 148 REMOVED CORROSION AND FOUND TO BE OUT OF LIMITS. FABRICATED REPLACEMENT ANGLE FROM 7075- T6, .040' REF BOEING DWG 69-14871 AND PRINT NR 65-15938. REMOVED OLD ANGLE REF SRM 51-10-2 AND MM 51-30-0, THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

C-2 PIT Z - ANGLE FROM STA 960 TO 1036, RT SIDE, HAS SEVERAL LOOSE/MISSING NUT PLATES WITH AREAS OF LIGHT CORROSION ON PANEL REMOVED CORROSION, ORIGINAL THICKNESS, .062 INCH, REMOVED .037 INCH, REMAINING THICKNESS .025 INCH. OUT OF LIMITS. VERIFIED NEW PART 65-57568U26. TRANSFERRED HOLES TO NEW PART. TREATED AND PRIMED. ATTACHED SUPPORT TO NEW Z ANGLE REF SRM 53-10-1 PG 2 - 2A, SRM 51-30-5 PG 1, SRM 51-10-2 PG 7 AND 8, AND BOEING DWG 65-57567.

Part: FRAME — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

AFT PIT BILGE BODY FRAME UPPER FLG IS BUCKLED/CORRODED BS 1050, STR 26L-28L, WL 148 (MKD). REMOVED CORROSION ON AFT PIT BILGE BODY FRAME UPPER FLG STA 1050 STR 26L 28L WL148. ORIGINAL THICKNESS IS .063 REMAINING MATERIAL IS .061, .002 REMOVED FOUND TO BE IN LIMITS, TREAT, PRIMED. REMOVED BUCKLED AREA OF FRAME. FABRICATED TREATED, PRIMED AND INSTALLED REPAIR DOUBLER REF SRM 51-40-3 FIG 1, SRM 53-10-1 PG 1 DETAIL I. THIS REPAIR IS CLASSIFIED AS A MAJOR REPAIR.

Part: SEAL — DAMAGED (ZONE 800) · airframe 56,473 hrs · 35,606 cycles

LOWER NR 2 CARGO DOOR S/N BNW 506, AFT LWR CORNER, OF SEAL DEPRESSOR HAS NICKS. NR 2 CARGO DOOR SEAL DEPRESSOR, AFT CORNER FOUND TO BE OUT OF LIMITS. REMOVED AND REPLACED AFT CORNER SEAL DEPRESSOR PN NR 65-59948-502, REF 51-40-02 AND DWG 65-60234 THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: CHANNEL — DAMAGED (ZONE 100) · airframe 56,473 hrs · 35,606 cycles

FWD PIT STA 620 ABOVE STR 27L " U " CHANNEL SUPPORT ON FWD SIDE OF FRAME HAS 2 MISDRILLED HOLES AT LBL 26. REMOVED DAMAGE, FABRICATED 2 REPAIR ANGLES, HEAT TREATED TO T-6 CONDITION. FABRICATED FILLER. ALODINED AND PRIMED ALL REPAIR PARTS, INSTALLED REPAIR PARTS, REF FED EX EA NR 7-5310-118270. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 56,473 hrs · 35,606 cycles

MAIN CABIN SEAT TRACK CORRODED STA 1148 - 1170, RBL 45 WL 208 REMOVED CORROSION, FOUND TO BE OUT OF LIMITS, ORIGINAL THICKNESS .070 INCH, MATERIAL LOSS OF .030", REMAINING MATERIAL .040". REMOVED SEAT TRACK, REF SRM 53-10-1 PAGE 16 DET 5. SEAT TRACK FABRICATED ON N/R N00584. TREATED AND PRIMED REF SRM 51-10-2 PG 1. INSTALLED SEAT TRACK REF SRM 51-30-2 PG 1-10. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

MAIN DECK FLOOR, SEAT TRACK EXTRUSION IS CORRODED, BS 850 - 870, LBL 45, WL 208. REMOVED AND REPLACED TRACK WITH NEW TRACK. FABRICATED FROM BAC 1520-1466 EXTRUSION REF SRM 51-30-2 PG 2, SRM 51-10-2 PG -3, GMM7-0-1001, AMM 51-20-014. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SEAL — DIRTY (ZONE 800) · airframe 56,473 hrs · 35,606 cycles

LOWER FWD CARGO COMPARTMENT DOOR, UPPER AFT CORNER CRACKED FABRICATED PER BOEING DWG 65-57146 CARGO DOOR AFT UPPER CORNER REF SRM 51-30-2. INSTALLED NEW SEAL DEPRESSOR CORNER REF 51-30-2, RESTORED LEVELING COMPOUND TO AREA. REF AMM 51-40-000-0. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRINGER CLIP — DAMAGED (ZONE 100) · airframe 56,473 hrs · 35,606 cycles

FWD PIT BILGE BODY FRAME STRINGER CLIP IS MISDRILLED BS 720, STR 26L. INSTALLED STRINGER CLIP AT STA STA 720, STR 26L REF SRM 51-30-02.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

AFT CABIN, LBL 25 , SEAT TRACK IB AND OB UPPER FLANGES CORRODED ON LOWER SURFACE AT 1130. REMOVED AND REPLACED SEAT TRACK AT STA 1130, LBL 25, FOUND OLD SEAT TRACK OUT OF LIMITS. FABRICATED NEW AND INSTALLED REF BOEING DWG. 65-19606.

Part: PAN — CRACKED (ZONE 200) · airframe 56,473 hrs · 35,606 cycles

AFT MAIN DECK FLOOR DITCHING PAN ASSY IS CRACKED WITH INTERIM COMPOSITE REPAIR BS 1176 - 1183, RBL 18-27, WL 208 REMOVED OLD DITCHING PAN. FABRICATED NEW DITCHING PAN OUT OF 6061-O, HEAT TREATED TO T-6, DRILLED TRIMMED, TREATED PRIMED AND INSTALLED. REF BAC DWG 65- 29548, FED EX GMM 7-0-1001, THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: DOOR — CRACKED (ZONE 800) · airframe 56,473 hrs · 35,606 cycles

NOSE LANDING GEAR LEFT DOOR, CRACK AT AFT END EDGE SKIN AT B-STOP ANGLE SUPPORT REMOVED DAMAGE, NDT FOR CRACKS REMOVAL, FABRICATED FILLER AND DOUBLER REPAIR PARTS. INSTALLED FILLER AND DOUBLER REF SRM 51-30-2 PG 1, SRM 51-40-3 PG 1-3, SRM 52-80-1 ITEM 3, SRM 51-10-2, PG 7-15. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FRAME — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

AFT PIT BILGE BODY FRAME UPPER FLG IS CORRODED BS 103, STR 26R - 28R, WL 147 REMOVED .007 INCH FROM ORIGINAL MATERIAL OF .063 INCHES WITH .056 INCH REMAINING AND FOUND FRAME TO BE OUT OF LIMITS. HEAT TREATED, DRILLED TREATED, PRIMED AND PAINTED, REPAIR DOUBLER. INSTALLED REPAIR DOUBLER REFERENCE SRM 53-10-1/PAGE NR 2 SRM 51-30-2 PAGES 2, 8, 9. CLASSIFED AS A MAJOR REPAIR.

Part: PAN — CRACKED (FUSELAGE) · airframe 56,473 hrs · 35,606 cycles

AFT MAIN DECK FLOOR DITCHING PAN ASSY IS CRACKED WITH INTERIM / DISBONDED. COMPOSITE REPAIR, BS 1176 - 1183, RBL 27-37, WL 208. REMOVED CRACKED DITCHING PAN. FABRICATED NEW DITCHING PAN, HEAT TREATED TO T-6 CONDITION, TREATED AND PRIMED, AND INSTALLED. REF SRM 51-30-2 PG 5, 51-20-021 PG 7 AND DWG 65-29548 THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FAIRING — CRACKED (FLAP TRACK) · airframe 56,473 hrs · 35,606 cycles

NR 4 T/E FLAP TRACK FWD FAIRING, HAS CRACK AT FWD END CUTOUT REMOVED EXISTING DOUBLER, CUT OUT DAMAGE, NDT CHECKED FAIRING AND FOUND CRACK TO BE TERMINATED. MADE ADDITIONAL CUT FINALE CUT. FABRICATED REPAIR DOUBLER AND FILLER. TREATED AND PRIMED. INSTALLED REPAIR PARTS. PAINTED IN REF TO SRM 57-20-4 PG 5-12, SRM 57-20-2 PG 4, SRM 51-10-2 PG 1-7, MM 51-20-151-7, THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: PAN — CRACKED (ZONE 200) · airframe 56,473 hrs · 35,606 cycles

AFT MAIN DECK FLOOR DITCHING PAN ASSY IS CRACKED BS 1176 - 1183, LBL 27 - 37, WL 208. REPLACED DITCHING PAN AT STA 1176 - 1183, LBL 27 - 37, WL 208 REF BOEING DWG 65-29548 AND SRM 51-30-2 AND 51-30-2 PG 1-10. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: PAN — CRACKED (FUSELAGE) · airframe 56,473 hrs · 35,606 cycles

AFT MAIN DECK FLOOR DITCHING PAN ASSY IS CRACKED WITH INTERIM COMPOSITE REPAIR BS 1176-1183, RBL 37-47 WL 208 (MKD). FABRICATED NEW DITCHING PAN, HEAT TREATED, ALODINED AND PRIMED, INSTALLED IAW SRM 51-10-2, PG 1, 51-30-2, PG 1, 51-30-5 PG 1. BOEING DWD: 65-29548. HEAT TREATED, TRACKING NR: 2008-05-068. THIS IS CLASSIFIED AS A MINOR REPAIR. REF: GMM 6-2-100 PG 2 AND 3.

Part: PAN — CRACKED (ZONE 200) · airframe 56,473 hrs · 35,606 cycles

AFT MAIN DECK FLOOR DITCHING PAN ASSY IS CRACKED BS 1176 - 1183, LBL 27 - 37, WL 208 REPLACED DITCHING PAN AT STA 1176 - 1183, LBL 27 - 37, WL 208 REF BOEING DWG 65-29548 AND SRM 51-30-2 AND 51-30-2 PG 1-10. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: PAN — CRACKED (ZONE 200) · airframe 56,473 hrs · 35,606 cycles

DITCHING PAN FWD ATTACH ANGLE BS 1166, RBL 38 - 47, IS CRACKED AT RBL 45 - 4. REMOVED DAMAGED PART (ANGLE) FABRICATED NEW, TREATED AND PRIMED AND INSTALLED IAW SRM 51-10-02 PG 1, 51-30-02, PG 1 AND DWG 65-29548. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: ANGLE — CORRODED (ZONE 100) · airframe 56,473 hrs · 35,606 cycles

AFT PIT BS 950E BULKHEAD RIGHT FWD BLOW OUT PANEL FRAME HAS CORROSION AROUND NUTPLATES. REMOVED DAMAGED Z-ANGLE, REPLACED WITH FABRICATED Z-ANGLE. INSTALLED ON BULKHEAD PANEL STA 950E IAW DWG 65-57172 AND SRM 51-40-02. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: DOUBLER — CRACKED (COWLING) · airframe 56,473 hrs · 35,606 cycles

NR 3 ENG LOWER COWL, I/B SIDE EDGE, 3RD LATCH CUTOUT FROM FWD END, LOWER CUTOUT AREA, DOUBLER CRACKED OUT. REMOVED AND REPLACED DOUBLER, REF SRM 51-30-2 PG 2, THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FLOOR PANEL — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

C-2 PIT FLOOR PANELS NR 3 HAS CORROSION ALONG ONE SIDE EDGE FABRICATED NEW C-2 NR 3 PIT FLOOR PANEL REF DRAWING 65-67245 AND SRM 51-30-05 PG 13-21. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: PAN — CRACKED (ZONE 200) · airframe 56,473 hrs · 35,606 cycles

AFT MAIN DECK FLOOR DITCHING PAN ASSY HAS 2 CRACKS AND A MISSING FASTENER COLLER, BS 1176 - 1183,LBL 18 - 27, WL 208. REPLACED DITCHING PAN AT STA 1176 - 1183, LBL 18 - 27 REF BOEING DWG 65-29548 AND SRM 51-30-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

AFT PIT BILGE BODY FRAME INTERCOSTAL UPPER CHORD IS CORRODED BS 1050 - 1070 STR 27L OB, WL 149. REMOVED ATTACHED UPPER CHORD ANGLE. FABRICATED NEW ANGLE REF DWG 69-44884 PG 1. TREATED AND PRIMED UPPER CHORD ANGLE. INSTALLED REF SRM 51-30-20 PG 1-10. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

CORROSION ON I/B SIDE OF STR 28L AT FS 661, LBL6, WL 149 REPAIRED STRINGER AT 292 AT FS 661 LBL 6, WL 149. REF SRM 53-10-3, PG 3 -4, FIG 1, DETAIL 1, THIS IS CLASSIFIED AS MAJOR REPAIR.

Part: RIB — CRACKED (ZONE 300) · airframe 56,473 hrs · 35,606 cycles

LT HORIZ STAB TRAILING EDGE ELEVATOR HINGE SUPPORT RIB CRACKED 2 AREAS AT ELEVATOR STA 99.79 AFT INBOARD SIDE. REPAIRED LT HORIZONTAL TRAILING EDGE HINGE SUPPORT RIB AT STA 99.79 REF SRM 55-10-4. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: ANGLE — CRACKED (ZONE 400) · airframe 56,473 hrs · 35,606 cycles

NR 3 ENGINE LOWER COWL, O/B SIDE EDGE, COWL STRUCTURE AREA CRACKED OUT, JUST AFT OF THE 4TH LATCH CUT OUT FROM FWD END REMOVED AND REPLACED ANGLE REF DWG 65- 19507. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRUCTURE — CRACKED (LAVATORY) · airframe 56,473 hrs · 35,606 cycles

FWD LAV SINK CABINET WASTE DISPOSAL FIBERGLASS SHOOT IS CRACKED. REPAIRED LAV SINK CABINET WASTE DISPOSAL CHUTE REF SRM 51-40-9 PAR 7, THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: FRAME — DAMAGED (ZONE 100) · airframe 56,473 hrs · 35,606 cycles

AFT PIT, BILGE BODY FRAME, HAS A DRILL START ON UPPER FLANGE AND CORRODED WEB BS 1143, FWD AND AFT SIDE, STR 26R - 27R, WL 153 - 156 LEVEL 1 CORROSION BLENDED AREA, FLAP PEENED AREA, APPLIED ALODINE AND PRIMER TO AREA APPLIED CORROSION INHIBITOR TO AREA, REF EA 7-5310-118267. ORIGINAL T .080 INCH REMOVED .055 INCH, .025 INCH REMAINING.

Part: PAN — CRACKED (ZONE 200) · airframe 56,473 hrs · 35,606 cycles

AFT MAIN DECK FLOOR DITCHING PANS PAN ASSY IS CRACKED BS 1176 - 1183, LBL 37-47, WL 208. REMOVED DITCHING PAN, FABRICATED, HEAT TREATED TO T-6 CONDITION, ALODINED AND PRIMED AND INSTALLED NEW PAN, REF SRM 51-30-2 PG 1, CWG 65-29549, MM 51-30-05 PG1, SRM 51-10-2 PG 7, MM 51-20-151-07 PG 1, SRM 51-20-04 PG1-4. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: STRAP — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

C-2 PIT NR 3 AND NR 4 TIE STRAP HAS AREA OF LIGHT CORROSION ON BACK OF STRAP. FABRICATED NEW STRAP REF 65-67245, TREATED AND PRIMED STRAP REF SRM 51-10-2. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

CORROSION ON AFT SKIN IN C-1 PIT AT FS 683 LBL 11, WL 148 REMOVED CORROSION, FOUND TO BE OUT OF LIMITS. ORIINAL "T" IS .045" REMAINING 'T' IS .024. MATERIAL LOSS OF .021 REF SRM 53-30-1 FIG 1. FABRICATED DOUBLER AND FILLER, TREATED AND PRIMED, INSTALLED DOUBLER AND FILLER REF SRM 53-30-3 FIG A AND SRM 51-10-2 THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,473 hrs · 35,606 cycles

FWD PANEL RACK, FWD PIT FRAME BS 720 CORROSION AROUND NUTPLATES REMOVED CORROSION IAW SRM 51-10-6, ORIGINAL "T'' .040 INCH, MAT. REMOVED IS .012. MAT REMAINING .028 INCH IS OUT OF LIMITS IAW SRM 53-1031. FABRICATED NEW LINER SUPPORT ANGLE FROM 7075-0 .050' AND HEAT TREATED TO T-6. LOCATED NEW ANGLE, TREATED AND PRIMED IAW SRM 51-20-2 AND INSTALLED NUT PLATES IAW SRM 51-30-02 THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: ANGLE — CRACKED (ZONE 500) · airframe 56,473 hrs · 35,606 cycles

LEFT WING INBD LE CAVITY NR 2 FLAP ACTUATOR AFT MOUNT, UPPER CORNER ANGLE IS CRACKED REMOVED AND REPLACED WEB REF SRM 51-30-2. OPS CHECKED ACCOMPLISHED ON W/C 70C003-00 THIS CLASSIFIED AS A MINOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 200) · airframe 56,473 hrs · 35,606 cycles

BS 1148 FLOORBEAM UPPER T-CAP, AFT FLANGE LWR SURFACE IS CORRODED, RBL 43 BLENDED CORROSION, ROTO- PEENED BLENDED AREA, ALODINED AND PRIMED AND APPLIED BMS 3-23, REF EA 7-5310-118266. ORIGINAL THICKNESS OF .130 INCH, .109 INCH REMAINING AT DEEPEST AREA. THIS IS CLASSIFIED AS A MINOR REPAIR. LEVEL 1 CORROSION.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 56,473 hrs · 35,606 cycles

RT Z- ANGLE UNDER AUX TANK HAS SEVERAL LOOSE/MISSING NUT PLATES WITH AREAS OF LIGHT CORROSION ON LOWER SIDE OF PANEL VERIFIED MATERIAL THICKNESS, BLENDED OUT CORROSION, VERIFIED Z ANGLE THICKNESS WAS OUT OF LIMITS AFTER BLEND OUT ORIGINAL THICKNESS WAS .056", AFTER BLEND OUT .036, LOSS OF .020". VERIFIED MATERIAL ID, FABRICATED REPAIR PARTS, TREATED AND PRIMED REPAIR ANGLES, INSTALLED REPAIR ANGLE, REPLACED NUT PLATES. REF DWG 65-57568-6, SRM 53-10-1 PG 1-2, SRM 51-40-4 PG 14-17. TOL ID IN 17-0236 CAL DUE DATE 1-8-09. THIS IS CLASSIFIED AS A MINOR REPAIR, LEVEL 1 CORROSION.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 56,473 hrs · 35,606 cycles

LOWER FWD CARGO COMPARTMENT, FLOOR SUPPORT ANGLE AT STA 580 15, STRINGER 29L IS CRACKED BEYOND STOP DRILL. REMOVED DAMAGE, FABRICATED REPAIR, REF SRM 51-40-04 PAGE 1-9. INSTALLED FLOOR SUPPORT ANGLE REPAIR PARTS REF SRM 51-40-4 PAGE 8. THIS IS CLASSIFIED AS A MINOR REPAIR.

Part: ARM — FAILED (ZONE 800) · airframe 55,785 hrs · 35,085 cycles

FORWARD ENTRY DOOR OPENED UPON TOUCHDOWN. AFTER FURTHER INSP FOUND THE UPPER GUIDE ARM WORN CAUSING THE DOOR OPEN LOCK NOT TO WORK AND DOOR HARD TO CLOSED. REMOVED AND REPLACED THE UPPER GUIDE ARM IAW 727 M/M 52-11-001-5. OPS CHECK GOOD OF THE DOOR OPERATION A/C OK FOR CONT SERVICE.

Part: SKIN — OUT OF LIMITS (CARGO DOOR) · airframe 54,701 hrs · 34,215 cycles

NR 3 LOWER CARGO DOOR REQUIRES TRIMMING OF CIRCUMFERENCE FOR FIT AFTER SKIN REPLACEMENT. REMOVED AND REINSTALLED CARGO DOOR SEAL, TRIMMED CARGO DOOR, OPERATIONAL CHECK,LEAK GOOD IAW FED EX MM B727-200 52-35-071-4, 52-35-051, 33-30-000-0 AND 05-51-101-2. MINOR REPAIR MECH 4714 QC321.

Part: FLOORBEAM — CRACKED (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

FOUND STA BS1179, 3 EACH ELONGATED NUTPLATE FASTENER HOLES; LBL 2 IS ELONGATED AND CRACKED, AND RBL 3.5 AND RBL 10.5 ARE ELONGATED. COMPLIED WITH FEDEX EA# 7-5321-92600 "FUSELAGE FLOOR CHORD AT STA BS 1179 HAS DAMAGED FLANGE - REPAIR ".

Part: FLAP TRACK — CORRODED (ZONE 500) · airframe 54,701 hrs · 34,215 cycles

LEFT WING I/B FLAP O/B TRACK FWD MOUNT HOLE-D HAS PITTING IN INNER BORE. REMOVED PITTING AND CORROSION IAW BAC OHM 57-40-01. FABRICATED AND INSTALLED IAW BAC OHM 57-40-01 AND FED EX EA 7-5710-91314, LT INBOARD FLAP OUTBOARD TRACK OVERSIZE HOLE-D. MINOR REPAIR, TIMCO MECH 1281 QC280.

Part: REPAIR — UNKNOWN (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

FOUND REPAIR LOCATED AT FUSELAGE RIGHT SIDE STA 1174-1203 STR19-20. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. COMPLIED WITH FED EX EA 7-5330-92597 PART 1, FUSELAGE SKIN, REWORK OF EXISTING REPAIR. MAJOR REPAIR TIMCO MECH NR 1985 QC 227.

Part: SKIN — CORRODED (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

AFT PIT HAS EXFOLIATED SKIN AT STA 1044 TO 1050 STR 29R-28R. REMOVED DAMAGE IAW B727 SRM 53-30-3 FIG 3 SHEET 1. FABRICATED AND INSTALLED DOUBLER IAW B727 SRM 53-30-3 FIG 3, 51-10-2 AND 51-30-2, MECH NR 7990 QC 362, MAJOR REPAIR.

Part: SHEAR TIE — CORRODED (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

AFT PIT SHEAR TIE CORRODED AT STA 955.0E STRINGER 28R TO 29R. REMOVED AND INSTALLED DOUBLER, SHEAR TIE AND RAILS 1AW B727 SRM 51-10-2, 51-30-02, 51-10-6 AND 53-10-4. MINOR REPAIR SIGNED BY TIMCO MECH.33 NR 7921 QC 362.

Part: SKIN — DAMAGED (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

RESKIN C-3 DOOR DUE TO, TOO MANY REPAIRS ON OUTER SKIN. REMOVED AND REPLACED SKIN P/N 65-56927-2 IAW B727 SRM 51-10-2,51-30-2 AND 51-30-5. MINOR REPAIR SIGNED BY NR 1560 QC334.

Part: REPAIR — UNKNOWN (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

FOUND REPAIR LOCATED AT FUSELAGE, RIGHT SIDE STA 1174-1203 STR 19-20. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. INSTALLED NEW REPAIR IAW FED EX B727 P-F SRM 53-30-3 FIG.1A.

Part: REPAIR — UNKNOWN (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

EXISTING REPAIR DOUBLER ON C-1 CARGO DOOR FORWARD LOWER CORNER IS NOT PER SRM DATA. REMOVED AND REPLACED REPAIR DOUBLER IAW B727 SRM 52-00-3, FIG 3.

Part: REPAIR — IMPROPER (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

EXISTING REPAIR AT STA 1148-1166 STR 25L IS NOT PER SRM DATA. INSTALLED EXTERNAL REPAIR DOUBLER IAW B727 SRM 53-30-3 FIG 3.

Part: FLAP TRACK — CORRODED (ZONE 500) · airframe 54,701 hrs · 34,215 cycles

LEFT WING OUTBOARD FLAP OUTBOARD TRACK, FORWARD MOUNT HOLE "D" HAS PITTING IN INNER BORE. REMOVED ALL PITTING FROM BORE "D ", FABRICATED AND INSTALL REPAIR BUSHING AND FINAL REAM ID, IAW BOEING OHM 57-40-01 SIGNED BY TIMCO MECH NR 4951 AND QC 280, CARD N00841.

Part: FLOORBEAM — CORRODED (ZONE 200) · airframe 54,701 hrs · 34,215 cycles

FOUND MAIN CABIN FLOORBEAM T-CAP CORROSION BS 560 LBL 3 TO LBL 24. COMPLIED WITH FLOORBEAM UPPER CHORD REPAIR AT STA 560 LBL 3 TO LBL 24, IAW B727 SRM 53-10-8 FIG 3, SIGNED BY TIMCO MECH NR 5154 AND QC 321.

Part: FLAP TRACK — CORRODED (ZONE 600) · airframe 54,701 hrs · 34,215 cycles

RIGHT WING INB FLAP OUTB TRACK FORWARD MOUNT HOLE "D" HAS PITTING IN INNER BORE. REMOVED PITTING , FABRICATED AND INSTALLED REPAIR BUSHING AND FINAL REAM ID IAW BAC OHM57-40-01.

Part: REPAIR — IMPROPER (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

EXISTING REPAIR AT STA 1148-1166 STR 25L IS NOT PER SRM DATA. INSTALLED EXTERNAL REPAIR DOUBLER IAW B727 SRM 53-30-3 FIG 3.

Part: REPAIR — CORRODED (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

AFT CARGO, DOUBLER CORRODED, BETWEEN STR 21 AND 22L, STA 1165. ALL WORK ACCOMPLISHED ON FED EX N/R N00243, ENTERED IN ERROR.

Part: SKIN — CORRODED (ZONE 100) · airframe 54,701 hrs · 34,215 cycles

AFT PIT HAS EXFOLIATED SKIN AT STA 1044 TO 1050 STR 29R TO STR 28R. ALL WORK ACCOMPLISHED ON SDR 05-4182.

Part: FLOORBEAM — CORRODED (BS 620) · airframe 54,701 hrs · 34,215 cycles

MAIN CABIN FLOORBEAM TEE CAP CORRODED STA 620 RBL 10 AND RBL15. REMOVED DAMAGED AREA AND INSTALLED FILLER AND 2 (EA.) REPAIR ANGLES IAW B727 SRM 53-10-8 FIG 8. ALODINED AND PRIMED SAME IAW B727 SRM 51-10-2.

Part: DOUBLER — CORRODED (BS 1165) · airframe 54,701 hrs · 34,215 cycles

AFT CARGO DOUBLER CORRODED, BETWEEN STR 21L AND 22L STA 1165. COMPLIED WITH FED EX EA 7-5330 91316-FUSELAGE- CORROSION AT AFT LAV SERVICE DOOR CUTOUT-REPAIR . TIMCO MECH #2891 QC227 MAJOR REPAIR

Part: CLAMP — OUT OF POSITION (PRECOOLER) · airframe 54,692 hrs · 34,208 cycles

DURING CLIMB-OUT ENG NR 1 STRUT OVHT LIGHT ILLUMINATED ACCOMPLISHED ABNORMAL CHK LIST AFTER BLEED AND PACK SW'S CLOSED AND THRUST LEVER TO IDLE LIGHT OUT. INSPECT ALL THE CLAMPS ON THE NR 1 STRUT. PRESSURIZING THE DUCTS USING APU AIR FOUND CLAMP ADJACENT TO PRECOOLER LEAKING AND BLOWING HOT AIR ONTO OVHT SENSOR. REPOSTION CLAMP AND TIGHTENED, NO LEAK NOTED. STILL NEEDS HIGH POWER RUN FOR PROPER LEAK CHK. AFTER REPOSITIONING CLAMP DECIDED TO REMOVED AND REPLACED SAME CLAMP AS PRECAUTIONARY. RAN ENGINE AT TAKEOFF POWER SETTING FOR APPROX 5 MIN AS PER JRH. NO LEAKS NOTED A/C OK FOR SERVICE.

Part: UNKNOWN — MALFUNCTIONED (NR 3 ENGINE) · airframe 54,086 hrs · 33,838 cycles

ENGINE NR 3 EPR SETTING WOULD NOT GO TO 2.13 WHEN SET TO MAX POWER FOR T/O. REJECTED T/O BELOW 60 KTS. MAX EPR ONLY REACHED 2.05 AT MECHANICAL STOPS. EXECUTED THE RTO PROCEDURES FROM THE QRH IN ACCORDANCE WITH PROCEDURES. PERFORMED WET MOTORED DRY MOTORED, AND IDLE LEAK CHECK, PERFORMED RICK CHECKED FOUND OK. AS PER M/M 73-21-000-4; PERFORMED HIGH POWER RUN ON NR 3 ENGINE, ALL PARAMETERS NORMAL AS PER JRH 6-39. ALL TEST NORMAL.

Part: TIRE — DEFECTIVE (NLG) · airframe 54,027 hrs · 33,799 cycles

RTO DUE TO VIBRATION ON T/O ROLL. MINOR VIBRATION AT 60 KTS INCREASING IN INTENSIVE TO MODERATE VIBRATION AS SPEED INCREASED RTO AT 110 KTS. RTO AT 0815Z WITH 49 MIN COOL TIME. AFTER DEBRIEF WITH FLIGHT CREW IT WAS DETERMINED THAT VIBRATION WAS WORSE WHEN YOKE WAS PUSHED FWD. CHANGED BOTH NOSE GEAR TIRES. REMOVED AND REPLACED NOSE GEAR TIRE REF 727-200 MM 32-45-011-4. SWAP COMPONENT POSITIONS MPN: 65-72762-15 MSN: 388 TO POS: NRH MSN: A0117 TO POS: NLH. SWAPPED COMPONENTS DUE TO ERROR UPON INITIAL POSITION LOCATION. SWAPPED ON MAXI ENTRY ONLY.

Part: RIB — CRACKED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

CRACK INDICATION NOTED AT BS 760 WL 208 RBL 70.5 IN THE FWD UPPER HOLE COMMON TO THE RIB CHORD UPPER VERTICAL FLANGE IN THE RIB CHORD LAYER AT THE 12 O'CLOCK POSITION. REPAIRED PER EA 7-5710-54691 AND EO 7-5710-7-2308 I PT 3.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

MAIN CARGO DOOR STUB FRAME IS CRACKED AT O/B FLANGE THRU FASTENER HOLE 49 INCHES AFT OF FWD FRAME, 3 INCHES BELOW UPPER FRAME. REMOVED AND REPLACED PER SRM 51-30-2.

Part: STRUCTURE — CORRODED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

CORROSION ON STRUCTURE IN NLG BAY AT BS 284 RBL 18 INSIDE TORQUE BOX O/B OF STRUT DOOR FWD HINGE. REMOVED AND REPLACED PER SRM 51-30-2.

Part: SKIN — DENTED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

DENT ON SKIN BS 359 BETWEEN STR 19-20 LT. REPAIR PER ER 03-3244 AND EA 7-5330-72319.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

MAIN CARGO DOOR STUB FRAME IS CRACKED AT O/B FLANGE THRU FASTENER HOLE, 69 INCHES AFT OF FWD FRAME 3 INCHES BELOW UPR FRAME. REPLACED PER SRM 51-30-2.

Part: STIFFENER — CHAFED (LT NACELLE) · airframe 51,736 hrs · 32,435 cycles

AFT STIFFNER IS CHAFED AT NR 6 LT NACELLE, ATTACH POSITION ABOVE NR 2 ENGINE BS 1456. REMOVED AFT STIFFENER, FABRICATED, DRILLED, ALODINED, PRIMED AND RE-INSTALLED RIBS AND STIFFENER AT BS 1456 AND 1459 AT NR 6 LT COWL ATTACH POSITION ABOVE NR 2 ENGINE.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 51,736 hrs · 32,435 cycles

CORROSION ON BS 1130 FLOORBEAM UPPER CHORD AROUND HOLES AND UNDER NUT PLATES, LBL 48, WL 208. CORROSION WAS FOUND TO BE OUT OF LIMITS PER SRM 53-10-1. REPAIRED FLOORBEAM AT BS 1130, LBL 48, WL 208 FWD UPPER FLANGE PER SRM 53-10-8.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 51,736 hrs · 32,435 cycles

A/C BAY LT SIDE, ABOVE PANEL 3355L, CORROSION ON TORQUE BOX LWR FLANGE NUT CLIPS FOUND DAMAGE TO LOWER FLANGE TO BE .066 MATERIAL LOSS ORIGINAL THICKNESS .125. FOUND TO BE OUT OF LIMITS. REMOVED DAMAGED CHORD. DRILLED UP NEW CHORD. ALODINED, PRIMED & INSTALLED LOWER CHORD FOR TORQUE BOX IN A/C BAY LT SIDE. WORK DONE PER SRM 53-10-1, 51-10-3, 51-30-2, 51-30-5, WORK DONE FROM BS 740-870, LBL 10, WL 145.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 51,736 hrs · 32,435 cycles

CORROSION AT NUT PLATES BS 351 TO 341, LBL 18 TO RBL 18, W/L 152. REMOVED CORROSION ON T-CHORD AT VARIOUS LOCATIONS 1 X 1 X .077 INCH FROM ORIGINAL THICKNESS OF .097 INCH AT BS 341-351, LBL 18, RBL 18, WL 152 AND IS FOUND TO BE OUT OF LIMITS IAW SRM 53-10-1. REMOVED AND INSTALLED NEW CHORD AT BS 340, LBL 18 - RBL 18, WL 152 IAW SRM 51-30-2.

Part: FRAME — DENTED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

FWD CARGO BAY, DENT IN FRAME, BS 500, AT STR 24L. REMOVED, REPLACED AND INSTALLED FRAME SECTION BS 500 AT STR 21L TO STR 25L. ALL WORK DONE IAW SRM 51-30-5, SRM 51-30-2, SRM 51-10-2 AND MM 51-20-151-7 PG 1.

Part: SKIN — DENTED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

STA 720A STR 24L SKIN HAS A DENT. REMOVED DAMAGED SKIN AT 720A, STR 24L AND REPAIRED. WORK DONE IAW BOEING 727 SRM 53-30-3 FIG 3.

Part: SUPPORT FITTING — CORRODED (BULKHEAD) · corrosion level 2 · airframe 51,736 hrs · 32,435 cycles

CORROSION ATTACH FITTING ON BS 228 BULKHEAD, AFT SIDE, LBL 10, 6 INCHES BELOW UPPER PRESSURE DECK IS CORRODED ON UPPER SIDE. REMOVED AND REPLACED SUPPORT FITTING PER SRM 51-30-5 & 51-30-2.

Part: FRAME — DENTED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

FWD CARGO BAY, DENTS IN FRAME, BS 520, AT STR 23L TO STR 25L. REMOVED FRAME SECTION, BS 520, STR 21-25, INSTALLED NEW FRAME SECTION BETWEEN SPLICES. ALL WORK DONE PER SRM 51-30-2, SRM 51-30-5, SRM 51-10-2 & MM 51-20-151-7 PG 1.

Part: STIFFENER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 51,736 hrs · 32,435 cycles

STIFFENER INSIDE DELTA BEAM AT BS 789, RBL 3, WL 154 IS CORRODED. REMOVED AND REPLACED STIFFENER IAW SRM 51-30-2.

Part: FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 51,736 hrs · 32,435 cycles

CORROSION ON CHORDS IN NLG BAY AT B/S 284, LBL 18 INSIDE TORQUE BOX O/B OF STRUT DOOR FWD HINGE. REMOVED AND REPLACED LT CHORD AT B.S. 284, LBL 18 PER SRM 51-30-02. PERFORMED FUNCTIONAL TEST OF NLG PER M/M 32-22-001-5. FUNCTIONAL TEST GOOD.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 51,736 hrs · 32,435 cycles

CORROSION (C53-113-01) ON FLOOR FUSELAGE SKIN STA 703 BL 0 WL 148. REPAIRED SKIN B.S 703, WL 148, BL 0, IAW SRM 53-30-3 FIG 1.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 51,736 hrs · 32,435 cycles

CORROSION (C53-224-03(1/2) AT BS 344, LBL 40, WL 208, ON TOP OF FLOORBEAM. REMOVED CORROSION BS 344, WL 208, LBL 40. FOUND TO BE OUT OF LIMITS. REMOVED FLOORBEAM UPPER CHORD BS 344, BL 0 TO LBL 70 & INSTALLED REPAIR. ALL IAW SRM 53-10-1 & 53-10-8, FIG 9.

Part: FRAME — CHAFED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

CHORD AT BS 1352 IS CHAFED ALONG ENTIRE CIRCUMFERENCE AND RUB STRIPS ARE MISSING. FOUND FLANGE ON 1352 CHORD TO BE OUT OF LIMITS. REMOVED DAMAGED CHORD, DRILLED UP AND INSTALLED NEW 1352 CHORD IAW SRM 53-10-1, 51-30-2, 51-30-5.

Part: SKIN — GOUGED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

AFT AIRSTAIR, HAS A GOUGE ON THE EXTERNAL SKIN, 40 INCHES FROM THE LOWER END. EVALUATED GOUGE ON AFT AIRSTAIR EXTERNAL SKIN 40 INCHES FROM LOWER END. FOUND GOUGE TO BE .012 INCHES DEEP. ORIGINAL THICKNESS IS .040. FOUND TO BE OUT OF LIMITS PER SRM 52-00-2. REMOVED DAMAGE IN AN AREA OF 2.25 X 4.25 INCHES. FABRICATED, ALODINED, PRIMED AND INSTALLED REPAIR DOUBLER PER SRM 52-10-2.

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 51,736 hrs · 32,435 cycles

BS 1225 RBL 20 WL 185 STRUCTURE UNDER AIRSTAIR ACTUATOR MOUNT IS CRACKED. REMOVED, DRILLED UP & INSTALLED REPLACEMENT "L" ANGLE SUPPORT BS 1265, WL 185, RBL 20-45 IAW SRM 51-30-2, 51-30-5.

Part: UPLOCK SENSOR — FAILED (ZONE 700) · airframe 51,691 hrs · 32,400 cycles

AFTER TAKEOFF LEFT GEAR UNSAFE LIGHT REMAINED ILLUMINATED. COMPLIED WITH QRH AND LIGHT REMAINED ILLUMINATED. REMOVED AND REPLACED LEFT MAIN GEAR UP AND LOCKED PROX SENSOR (M827) IAW 727 WDM 32-60-01 SENSOR NEEDS TO BE REINSTALLED AND OP'S CHECKED. REPLACED LEFT MAIN GEAR UPLOCK SENSOR IAW 727 MM 32-61-081-4. OPS CHECK GOOD. OK FOR SERVICE.

Part: DOOR — MISSING (HYD SERVICE) · airframe 51,660 hrs · 32,379 cycles

HYDRAULIC SERVICE AREA ACCESS PANEL MISSING FROM A/C. REPLACED DOOR IAW SMP. OK FOR SERVICE.

Part: MOTOR — FAILED (ZONE 600) · airframe 51,387 hrs · 32,241 cycles

AFTER T/O FLAP RETRACTION - OUTBOARD T/E FLAPS STAYED AT 5 DEG WHEN FLAPS WERE RETRACTED TO 2 DEGREES. USED ALT FLAP MASTER SWITCH TO RETRACT FLAPS PER QRH PROCEDURE. PERF T/S AND FOUND OUTBOARD FLAP STUCK FROM 5 TO 2, RESET USING ALTERNATE. COULD NOT GET IT STUCK AGAIN BUT THEN WAS VERIFIED THAT THE MOVEMENT FROM 5 UP TO ZERO WAS NOT CONSISTENT; THE TORQUE TUBE WAS MOVING AS IT WAS GRABING. VERIFIED BY-PASS VLV AND FOUND WORKING PROPERLY. REMOVED AND REPLACED FLAP POWER UNIT HYD MOTOR AS PER B727-200 MM 27-51-062-4. RAN SYS SEVERAL TIMES AND NOW IT'S WORKING CONSISTENTLY. ACFT IS OKAY TO FLY.

Part: CLAMP — LOOSE (NR 3 ENG NACELLE) · airframe 51,211 hrs · 32,165 cycles

1 HR INTO FLIGHT SELECTED ENGINE THEN WING A/I (FL310 .82M) ALMOST INMEDIATELY ENG 3 STRUT OVERHEAT LIGHT ILLUMINATED. NO CHANGE AFTER QRH PROCEDURES ACCOMPLISHED. NR 3 ENGINE SHUTDOWN AS PER QRH . LIGHT REMAINED ILLUMINATED FOR 5 MORE MINUTES, THEN EXTINGUISHED , NO OTHER PROBLEM NOTED. FOUND CLAMP MISPLACED AT ENGINE NACELLE ANTI-ICE DUCT AT FWD STUD WIND, REINSTALLED CLAMP PROPERLY, CKD OK NOW.

Part: CONNECTOR — FAULTY

01-337 ASSYMETRICAL INBD T/E FLAP BETWEEN 2 & 5 DEG AFT T/O. R&R RIGHT INBD FLAP POS TRANSMITTER ELECTRICAL CONNNECTOR.

Part: INDICATOR — INOPERATIVE (COCKPIT)

01-237 INBD TRAILING EDGE FLAP ASYMMETRY OCCURRED DUR FLAP EXT WITH OTBD 30 DEG, INBD LOCK OUT AT LESS THAN 2 DEG. R&R INBD FLAP POSITION IND PER MM 7-52-021-2. OPS CK GOOD.

Part: WARNING LIGHT — ILLUMINATED (COCKPIT)

NR 2 OIL PRESSURE/FILTER BYPASS LIGHT STAY ON LONGER THAN NORM. INFLT ENGINE SHUTDOWN ACCOMPLISHED.

Part: LINE — LEAKING (NR 2 ENGINE)

NR 2 LOW OIL PRESSURE BYPASS LIGHT CAME ON. FOLLOWED BY LOSS OF OIL QUANTITY SHUT DOWN NR 2 IN FLT PER CKLIST. *S/D* FOUND MAIN SCAVENGE OIL LINE LEAKING AT COUPLING NUT PACKINGS DETERIORATING. REMOVED AND REPLACED PACKINGS PER MM 79-20-002-2, MAIN OIL FILTER PER MM 79-00-000-3 AND OIL FILTER BYPASS SWITCH PER MM 7+-33-002-4.

Part: RELIEF VALVE — STUCK (NR 2 ENGINE)

NR 2 OIL BYPASS LIGHT ILLUMINATED. SECURE ENG PER RED TAB PROC. REMOVED AND REPLACED MAIN OIL SCREEN, FOUND FILTER PRESSURE RELIEF VALVE STUCK. REMOVED AND REPLACED VALVE PER PW JT8D72-009G518C-518D. INSP OIL SCREEN PER MM 79-00-000-2. NONE NOTED. LEAK AND OPS CK GOOD.

Part: SWITCH — OUT OF ADJ (DOOR ACTUATOR)

UPON GEAR EXTENSION RIGHT GEAR DOOR ON 2ND OFF PANEL REMAIN ILLUM. ADJUSTED RIGHT GEAR DOOR ACTUATOR SWITCH AS PER MM 727-200 32-62-11. RETURN TO SERVICE.

Part: DUCT — LEAKING (LT ENGINE)

99-131 - NR1 ENGINE STRUT OVERHEAT LIGHT CAME ON. REMOVED AND REPLACED LEFT HEAT EXCHANGER DUCT PER MM 36-12-12-042-4. LEAK CK NORM.

Part: DRIVE MOTOR — FAILED (TE FLAPS)

98-236 - AFTER T/O DUR NORM FLAP RETRACTION. OTBD TRAIL EDGE FLAPS STUCK AT 15 DEG. ACCOMPLISH ABNORMAL CKLIST FLAPS OTBD STILL DID NOT MOVE. RETURN FOR LAND. REMOVED AND REPLACED OTBD FLAP BYPASS VALVE PER MM 27-51-151. TROULBE SHOT AS PER MM. REMOVED AND REPLACED HYD FLAP DRIVE MOTOR PER MM 27-51-62.

Part: ENGINE — MALFUNCTIONED (NR 2)

NR 2 ENGINE JUST AFTER LIFTOFF OIL PRESSURE WENT TO 5 PSI WITH GOOD OIL QUANTITY. OIL FILTER BYPASS/LOW OIL PRESSURE LIGHT CAME ON. *S/D* REMOVED ACCESSORY DRIVE GEARBOX OIL FILTER AND MAIN OIL PUMP. REMOVED AND REPLACED NR 2 ENG FIREWALL PLUG AND NR 2 ENG PER WORK CARD 70T0002. ENG RUN AND LEAK CK GOOD.

Part: FIRE LOOP — MALFUNCTION (NR 3 ENGINE)

NR 3 FIRE LIGHT ILLUMINATED WITH BELL AT FL 290. AFTER SWITCHING ESSENTIAL POWER, LIGHT AND BELL WENT OUT NEVER TO COME ON AGAIN. NEVER ANY INDICATION OF FIRE VISUALLY INSPECTED NR 3 ENGINE AND FIRE LOOP. LOOKED GOOD, OPS CHECKED GOOD.

Part: B-LOOP — INOPERATIVE (NR 2 ENGINE)

NR 2 ENGINE FIRE DETECTION LIGHT ILLUMINATED IN FLIGHT ACCOMPLISHED RED TAB PROCEDURES AND LIGHT REMAINED ON. GOOD FIRE PROTECTION VERIFIED THROUGH RED TABS AND MINIMUM EQUIPMENT LIST (WARNING, FIRE WARNING TEST GOOD). IDENTIFY B-LOOP INOPERATIVE NR 2 ENGINE. PULL B-LOOP CIRCUIT BREAKER. SELECTED A-LOOP ON PANEL OK TO CONTINUE PER MINIMUM EQUIPMENT LIST 26-6B, CONTROL. NR 28206 CAT C ITEM EXPIRES 19JAN98.

Part: TAILSKID — DAMAGED (AFT FUSELAGE)

97-0133 TAILSKID DID NOT RETRACT AFTER TAKEOFF. CYCLING GEAR HAD NO EFFECT. REPLACED TAILSKID LOWER HOUSING WITH CARTRIDGE IN ACCORDANCE WITH MAINTENANCE MANUAL 32-71-00. FUNCTIONAL CHECKED OK IN ACCORDANCE WITH MAINTENANCE MANUAL 32-71-01.

Part: FRAME — CORRODED (BS 1070)

NR 0261 CORROSION ON TOP OF LWR FLANGE OF UPPER LOBE FLOOR FRAME AT STA 1070, RBL 10-16, IN AFT CARGO COMP AT FASTENER PLATE NUTS. REMOVED CORROSION AND SECTION OF FLANGE AND INSTALLED FLOORBEAM REPAIR PER SRM 53-10-8 AT STA 1070 FROM LBL 5 TO RBL 45.

Part: FLOORBEAM — CORRODED (BS 1070)

NR 0260 CORROSION ON LOWER FLANGE OF UPPER LOBE FLOORBEAM AT STA 1070, RBL 26-30 IN AFT CARGO COMP. REMOVED CORRODED FLANGE AND INSTALLED FLOORBEAM REPAIR PER SRM 53-10-8 AT STA 1070 FROM LBL 5 TO RBL 45.

Part: SKIN — CRACKED (TE MID FLAP)

NR 1109 76C003-00 RT WING, OUTBD MID FLAP UPPER SKIN CRACKED, (3 EA.) AT INBD END OF FLAP, ABOVE REAR SPAR. HFEC'D MARKED ENDS OF CRACKS. CUT OUT DAMAGED AREA OF UPPER SKIN. FABRICATED AND INSTALLED DOUBLER AND FILLER PER SRM 57-50-4, FIG 8.

Part: SKIN — CRACKED (BS 984)

NR 0246 71C721-03 FUSELAGE SKIN DENTED AND CRACKED AT NR 2 LWR CARGO DOOR CUT OUT, IN THE LWR AFT CORNER, STA 984, BETWEEN STR 26R-27R. CUT OUT DAMAGE AND TRIMMED AREA. VISUALLY INSPECTED FOR CORROSION OF THE BONDED DOUBLER. NO CORROSION NOTED. FABRICATED AND INSTALLED FILLERS, DOUBLER AND TRIPLER PER FED-EX EA NR 7-5330-29067, DATED MAY 12, 1997.

Part: RADAR DRIVE — FAILED (RADOME)

RADAR ANTENNA FAIL LIGHT CAME ON AFTER TAKEOFF AND ANTENNA WOULD NOT SWEEP. REPEATED CYCLES ON AND OFF THE RADAR, DID NOT HELP. REMOVED AND REPLACED RADAR ANTENNA DRIVE UNIT PER MAINTENANCE MANUAL 34-41-21. OPERATIONAL CHECKED WEATHER RADAR PER MAINTENANCE MANUAL 34-41-0, OPERATIONAL CHECKED GOOD.

Part: ACTUATOR — FAILED (NR 13 SPOILER)

A SYSTEM HYDRAULIC PRESSURE WENT TO ZERO IN FLIGHT. A SYSTEM LOW PRESSURE LIGHT ILLUMINATED. PERFORMED EMERGENCY PROCEDURES, HAND CRANKED GEAR DOWN. CLOSED HYDRAULIC FLUID SHUTOFF VALVES, USED ALTERNATE FLAPS AND SHUT OFF ALL A-SYSTEM COMPONENTS. TOWED BACK INTO THE PARKING AREA. FOUND NR 13 SPOILER ACTUATOR HAD A CUT ON RING. REPLACED SAME, LEAK AND OPERATIONAL CHECKED GOOD.

Part: FUEL CONTROL — FAILED (NR 3 ENGINE)

AT IDLE POWER NR 3 ENGINE FAILED TO RESPOND TO THROTTLE MOVEMENT. CONTINUED OPERATION UNTIL NR 3 GEN FAILED. ACCOMP ENGINE SHUTDOWN PROCEDURES IAW CHECKLIST PROCEDURES AND LANDING UNEVENTFUL. REMOVED AND REPLACED MAIN FUEL PUMP AND FUEL CONTROL UNITS AS PER MM 73-11-1 AND 73-21-1. TRIM RUN AND LEAK CHECK GOOD. RII COMPLIED WITH E/E NR 1208 FUEL PUMP (P/N 378200) (S/N NR OFF 1201M).

Part: DETECTION UNIT — FAILED (E/E COMPT)

FSD - ON CLIMBOUT PASSING 15,000 MSL, THE LOWER AFT BODY OVERHEAT LIGHT STARTED FLASHING. BLEEDS WERE NR 1 ON, LT PACKON, NR 2 RT ON, RT PACK ON, NR 3 OFF, OVERHEAT LIGHT EXTINGUISHED WITHIN 5 SECONDS OF TURNING NR 3 BLEED ON AND SYSTEM TESTED GOOD. NO FURTHER ACTION TAKEN, LEFT BOTH PACKS ON WITH NR 1, 2 RT AND 3 BLEEDS ON. REPLACED FIRE AND OVERHEAT DECTECTOR CONTROL BOX PER MM, OPS CHECKS GOOD.

Part: FLOW CONTL VALVE — LEAKING (AFT BODY)

LWR AFT BODY HEAT CAME ON DURING CLIMB-OUT PASSING THROUGH FL 320. NR 2 LEFT AND NR 3 BLEEDS OPEN BOTH PACKS ON, WENT THROUGH THE EMERGENCY PROCEDURE. THE LIGHT WENT OUT WHEN WE TURNED LEFT PACK OFF. CHECKED DUCTS AND CLAMPS IN AFT STAIRS WELL AREA FOUND OK. FOUND LEFT FLOW CONTROL VALVE WEEP HOLE BLOWING A HIGH PRESSURE STREAM OF AIR IN DETECTOR AREA. REMOVED AND REPLACED VALVE CABIN AIR FLOW AS PER MM 36-12 PRESSURE CHECKED AND GROUND CHECKED GOOD.

Part: WINDOW — CRACKED (FLIGHT DECK)

DURING CLIMB-OUT, R-1 WINDOW BEGAN ARCING FOLLOWED BY CRACKING OF THE OUTER PANE OF THE R-1 WINDOW. REMOVED R-1 WINDOW AND TAGGED PARTS, INSTALLED R-1 WINDOW PER MM 56-11-11. CHECK FOR CORRECT R-1 TERMINAL AND R-1 WINDOW CONTROL TO BE REPLACED. TERMINAL CK OK. REMOVED AND REPLACED WINDOW HEAT CONTROL.