N269FE

Part: SKIN — DELAMINATED (RT AILERON) · airframe 840 hrs · 414 cycles

RH WING AILERON (113T7100-414G) HAS AS SPLIT IN THE TRAILING EDGE (WS 1114) WHICH WAS STARTING TO DELAM ONN UPPER SKIN (113T7112-6 SKIN) REPAIRED AILERON SKIN (UPPER 113T7112-6 SKIN, SIZE 5Ï¿½ X 6Ï¿½) USING 767 SRM 57-60-02-2R REPAIR 1, & 767 SRM 51-70-05 AS A MAJOR REPAIR. REBALANCE PROCEDRE CALCULATED REWORK MOMENT TO BE 1.347 USING 767 SRM 51-60-01-0G. EA RSC TRACKING ID IS H-2710- T0367440 (SEQ. 134 OF WO).

Part: SEAL — FAILED (L2 DOOR) · airframe 49,815 hrs · 31,068 cycles

AIRPLANE COULD ONLY HOLD STABLE CABIN PRESSURE UP TO 24,000 FT WITH AUTO PRESSURE CONTROLLER SET AT 24,000 FT, CABIN ALTITUDE SHOULD HAVE BEEN 1,000 FT BUT WAS 6,100 FT WITH A 6.2 DIFFERENTIAL AND CARGO HEAT OUTFLOW VALVE CLOSED. PERFORMED PRESSURIZATION CHECKS MM 5-51-01, FOUND L2 DOOR PREVIOUS SEALANT REPAIR BLOWN OUT AT UPPER FWD CORNER. REMOVED L2 DOOR LINING AND APPLIED SEALANT TO UPPER FWD CORNER, LINING STILL REMOVED FOR LEAK CHECK. SATISFACTORY TEST FLIGHT.

Part: UNKNOWN — UNKNOWN (CABIN PRESSURE) · airframe 49,807 hrs · 31,063 cycles

PRESSURIZATION SYS NOT FUNCTIONING PROPERLY. COULD NOT GET MORE THAN 6.0 PSID, 9600FT CABIN ALT AND SLOWLY CLIMBING AT FL330. DECENDED TO FL270, DIFFERENTIAL REDUCED TO 5.0 PSI CARGO HEAT VALVE CLOSED FULL TIME AT 10,000FT, CABIN ALT= 5500, DIFFERENTIAL 1.8 PSID, SLOW INCREASE. PERFORMED CABIN PRESSURE LEAKAGE TEST IAW MM 05-51-101-2. DECAY RATE WELL WITHIN LIMITS. R & R CABIN PRESSURE CONTROLLER & CABIN PRESSURE CONTROL PANEL AS A PRECAUTION IAW MM 21-31-010-4 & OPS CHECKED NORMAL IAW 21-31-000-2.

Part: SKIN — CORRODED (BS 720C-720D) · corrosion level 2 · airframe 49,403 hrs · 30,694 cycles

FWD PIT, REMOVED SOFT SEALANT BTW BS 720C - 720D BTW STR 28L - STR 28R EVIDENCE OF CORROSION. REMOVED CORROSION ON SKIN IAW B727 SRM 51-10-6. ORIGINAL MAT. 0.072", REMAINING MAT. 0.054", MAT. LOSS 0.018". FOUND TO BE WITHIN LIMITS IAW EA 7-5330-136797.

Part: SKIN — MISREPAIRED (BS 420-440) · airframe 49,403 hrs · 30,694 cycles

FUSELAGE SKIN HAS FASTENERS WITH IMPROPER SPACING, STA 420-440 BELOW STR 4L. TRIMMED UPPER AND LOWER SKIN AREA BETWEEN STA 420 TO STA 440, STR 4L, FABRICATED FREEZE PLUGS, DOUBLER, FILLER, TAPERED FILLER, TWO FILLER INTERNAL SKIN AND INSTALLED REPAIR PARTS IAW EA 7-5330-136790.

Part: SKIN — CORRODED (BS 720B S27L) · corrosion level 2 · airframe 49,403 hrs · 30,694 cycles

FUSELAGE SKIN AT BS 720B, 18" STR 27L HAS EXFOLIATION. CUT OUT DAMAGED AREA OF SKIN, FABRICATED REPAIR DOUBLER AND NEW TEE SUPPORT, AND INSTALLED NEW TEE SUPPORT AND DOUBLER IAW EA 7-5330-136797.

Part: SKIN — MISREPAIRED (BS 440-460) · airframe 49,403 hrs · 30,694 cycles

FUSELAGE SKIN HAS FASTENERS WITH IMPROPER SPACING, STA 440-460 BELOW STR 4L. TRIMMED UPPER AND LOWER SKIN AREA BETWEEN STA 440 TO STA 460, STR 4L, FABRICATED DOUBLER, FILLER , TWO FILLER INTERNAL SKIN AND INSTALLED REPAIR PARTS IAW EA 7-5330-136790.

Part: SUPPORT ANGLE — CORRODED (BS 740) · airframe 49,403 hrs · 30,694 cycles

FWD PIT BS 740 LOWER SUPPORT ANGLE HAS CORROSION, LOWER SURFACE AFT OF STR 27L. REMOVED AND REPLACED SUPPORT ANGLE AT BS 740 IAW SRM 51-30-5 AND 51-30-2 REV 103 AND DWG 69-43695.

Part: SEAT TRACK — CORRODED (BS 760-848) · airframe 49,403 hrs · 30,694 cycles

SEAT TRACK CORRODED STA 760-848, RBL 45.5. REMOVED SEAT TRACK, FABRICATED SEAT TRACK AND INSTALLED SEAT TRACK IAW SRM 51-10-6, 53-10-1 FIG 3, 51-10-2, 53-10-5 FIG 2 AND 51-30-2.

Part: SHEAR TIE — CORRODED (BS 720C S26-27R) · corrosion level 2 · airframe 49,403 hrs · 30,694 cycles

FWD PIT FRAME, BS 720C, AFT SHEAR TIE IS CORRODED BETWEEN STRINGERS 26-27R. REMOVED SHEAR TIE IAW SRM 51-30-2. LOCATED AND DRILLED NEW SHEAR TIE IAW SRM 51-30-2. INSTALLED NEW SHEAR TIE IAW SRM 51-30-2, REV 103.

Part: SUPPORT ANGLE — CORRODED (BS 740 S27-28R) · corrosion level 2 · airframe 49,403 hrs · 30,694 cycles

BS 740 ANGLE IS CORRODED WITH EXFOLIATION BETWEEN STRINGER 28R AND 27R. REMOVED SUPPORT ANGLE IAW SRM 51-30-2 REV 103. FABRICATED NEW ANGLE IAW SRM 51-20-1 FIG 7 AND 51-30-5. INSTALLED SUPPORT ANGLE IAW SRM 51-30-2 AND DWG 69-64841

Part: SHEAR TIE — CORRODED (BS 700 S28L) · corrosion level 2 · airframe 49,403 hrs · 30,694 cycles

CORROSION ON SHEAR TIE AT BS 700, INBD OF STRINGER 28L. CUT OUT DAMAGED SHEAR TIE IAW SRM 51-10-1. FABRICATED SHEAR TIE DOUBLER IAW SRM 53-10-4 FIG 15. INSTALLED SHEAR TIE REPAIR DOUBLER IAW SRM 53-10-4 FIG 15 REV 103.

Part: SKIN — GOUGED (BS 620 S8L) · airframe 49,403 hrs · 30,694 cycles

MCD INNER SURROUND SKIN GOUGED STA 620, STR 8L. REMOVED DAMAGED INNER SKIN, FABRICATED AND INSTALLED NEW INNER SKIN IAW SRM 53-10-2. FIG 3A AND SRM 51-30-2.

Part: SKIN — CORRODED (BS 440 S20R) · airframe 49,403 hrs · 30,694 cycles

SKIN BULGE STA 440, STR 20R. CUTOUT DAMAGED SKIN -DAMAGED AREA, FABRICATED REPAIR SKIN, REINFORCING STRAPS, SPLICE PLATE AND TAPERED FILLER AND INSTALLED REPAIR SKIN, REINFORCING STRAPS, SPLICE PLATE AND TAPERED FILLER IAW SRM 53-30-3 FIG 12.

Part: SPAR — CRACKED (FUSELAGE) · airframe 49,403 hrs · 30,694 cycles

CENTER TANK REAR SPAR UPPER WEB BL 0 TO LBL 2 HAS UT SHEAR WAVE CRACK INDICATION AND BL 0 TO RBL HAS HFEC CRACK INDICATION. STOP DRILLED HOLES AT CENTER TANK REAR SPAR UPPER WEB LBL 0-2 AND RBL 0-2 IAW SRM 51-10-1. LOCATED AND DRILLED HOLES AT REPAIR KIT AND INSTALLED REPAIR KIT PER EO 7-5710-7-3325 B3 PT 2.

Part: TORQUE BOX — CRACKED (BS 1223) · airframe 49,403 hrs · 30,694 cycles

AFT AIRSTAIR AREA - LIGHTNING HOLE IS CRACKED AT RT LOWER TORQUE BOX BS 1223. CUT OUT DAMAGED WEB IAW SRM 51-10-1 REV 103. FABRICATED REPAIR DOUBLER IAW SRM 51-40-2 FIG 1 AND 53-10-2 FIG 6. INSTALLED REPAIR DOUBLER IAW SRM 51-30-2 AND SRM 51-40-2.

Part: TORQUE BOX — CRACKED (BS 1233) · airframe 49,403 hrs · 30,694 cycles

AFT AIRSTAIR AREA - LIGHTNING HOLE IS CRACKED AT RT LOWER TORQUE BOX BS 1233. CUT OUT DAMAGED WEB IAW SRM 51-10-1 REV 103. FABRICATED REPAIR DOUBLER IAW SRM 51-40-2 FIG 1 AND 53-10-2 FIG 6. INSTALLED REPAIR DOUBLER IAW SRM 51-30-2

Part: ACCESSORY UNIT — FAILED (MLG) · airframe 48,189 hrs · 29,674 cycles

AFTER TAKE OFF, THE LANDING GEAR LEVER LATCH FAILED TO RELEASE. LANDING GEAR LEVER COULD ONLY BE RAISED TO OFF POSITION. HORN SOUNDED WHEN FLAPS RETRACTED FROM 5 DEG. TO 2 DEG. REMOVED AND REPLACED M831 AIR SENSING SENSOR PER AMM 32-09-221-4 AND PERFORM TEST PER AMM 32-09-221-5. REMOVED AND REPLACED LANDING GEAR ELECTRONIC MODULE PER 32-09-121-4. LANDING GEAR ELECTRONIC MODULE TEST DUE. IN LIEU OF JACKING THE AIRPLANE AFTER LANDING GEAR SAFETY SENSOR PERFORMED EA 7-3210-132925 . ALTERNATE TEST PROCEDURE. SENSOR TEST OK. LANDING GEAR ELECTRICAL/ELECTRONIC MODULE ADJUSTMENT/TEST NORMAL PER AMM 32-09-121-5.

Part: DOOR FRAME — CRACKED (ZONE 100) · airframe 47,982 hrs · 29,500 cycles

CORRECTION OF SDR 09-0481 FWD CARGO DOORWAY STA 620 LOWER INNER CHORD CRACKED. FABRICATED CHORD ON MAE TRAVELER T9/778261. FABRICATED SPLICE ON MAE TRAVELER T9/779262. CHORD REMOVED AND NEW INSTALLED IAW SRM 51-30-2 AND SRM 51-40-4. MAJOR REPAIR, RII, RDR AND SDR.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 47,980 hrs · 29,496 cycles

FWD CARGO AREA BS 720F TO 740 S-26L STRINGER SEVERAL ROW OF RIVETS CORRODED REPAIRED STRINGER IAW SRM 53-10-3. FABRICATED STRINGER ON MAE TRAVILER T9/778825. MAJOR REPAIR, RII, RDR AND SDR.

Part: STRUCTURE — CRACKED (ZONE 100) · airframe 47,980 hrs · 29,496 cycles

FWD CARGO DOORWAY STA 620 LOWER INNER CHORD CRACKED. FABRICATED CHORD ON MAE TRAVELER T9/778261. FABRICATED SPLICE ON MAE TRAVELER T9/779262. REPAIRED CHORD IAW SRM 53-10-2. MAJOR REPAIR, RII, RDR AND SDR.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 47,980 hrs · 29,496 cycles

MCD SEAT TRACK FLANGE HAS CORROSION AT LBL24 APPROX FROM STA 370 TO 460. REMOVED AND REPLACED SEAT TRACK IAW SRM 53-10-5. FABRICATED TRACK AND SPLICES ON MAE TRAVELER T9/779235 AND T9/779236. MAJOR REPAIR, RII, RDR AND SDR.

Part: DOOR — UNSECURE (MAIN PAX) · airframe 46,796 hrs · 28,511 cycles

AFTER TAKEOFF IN IAD CABIN ALTITUDE WENT ABOVE 10,00 0' RAN QRH PROCEDURES CABIN ALTITUDE WENT TO 11,500' WENT ON O2 RETURNED TO IAD. NOTICE FORWARD ENTRY DOOR WAS NOT SEATED PROPERLY OPEN AND SECURED DOOR SEVERAL TIMES, PERFORMED FORWARD ENTRY DOOR INSPECTION REF: M/M 52-11-001-6 CHECKED NORMAL. A/C OK FOR SERVICE.

Part: FRICTION BRAKE — OUT OF ADJUST (THROTTLE) · airframe 46,490 hrs · 28,247 cycles

ON T/O AND CLIMB NR 2 THROTTLE CONSTANTLY CREEPS FORWARD 3-4% N1. THROTTLE NEEDS TO BE CONSTANTLY PULLED BACK NOT TO OVERSPEED ENGINE. ADJUSTED NR 2 ENG FRICTION BRAKE PER 727-200 M/M 76-11-001-8. OPS CHECKED NORMAL.

Part: THROTTLE — UNKNOWN (NR 2) · airframe 46,422 hrs · 28,186 cycles

AFTER LEVEL OFF AT FL 320, F/O NOTED THE NR 2 THROTTLE MOVED ITSELF TO FIREWALL POWER WHILE THROTTLES 1 AND 3 REMAINED AT CLIMB POWER. IMMEDIATELY RETARDED THE THROTTLE BACK TO MATCH 1 AND 3. EPR ON NR 2 WAS 2.57 AND TEMP EXCEEDED 650 DEG. OVERBOOST APPROX 5-10 SEC . N1 AND N2 NOT NOTED. CHECKED OPS OF NR 2 THROTTLE ASSY REF M/M 76-11-000-0 CHECKED NORMAL CHECKED THRUST LEVER FRICTION BRAKE ASSY REF M/M 76-11-001-8 CHECKED NORMAL WITH IN LIMITS WITH PUSH PULL SCALE DUE NO HISTORY

Part: ATTACH FITTING — CORRODED (NR 3 FLAP TRACK) · airframe 46,203 hrs · 27,997 cycles

CORROSION ON FWD ATTACH FITTING AT NR 3 FLAP TRACK.

Part: FRAME — MISDRILLED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

DOUBLE HOLE AT BS 500 STR 21L. COMPLIED WITH FED EX EA 7-5310-102255.

Part: FRAME — MISDRILLED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

DOUBLE HOLE AT BS 520 STR 21L. COMPLIED WITH FED EX EA 7-5310-102255.

Part: FRAME — MISDRILLED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

DOUBLE HOLE AT BS 600 STR 21L. COMPLIED WITH FED EX EA 7-5310-102255.

Part: BEAM — CORRODED (RT SPOILER) · airframe 46,203 hrs · 27,997 cycles

WHILE WORKING CARD N00862, FOUND CORROSION AT WBL 206, LOWER CHORD OF SPOILER BEAM LOWER SURFACE, RIGHT WING. *S/D* REPAIRED CORROSION RIGHT WING LOWER CHORD OF SPOILER BEAM LWR SURFACE AT WBL 206 IAW FED EX EA 7-5710-100546.

Part: WEB — MISDRILLED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

WHILE WORKING CUST CARD N00346 FOUND LOWER SIDE OF THE FLOOR WEB AT BS 1175 RBL 26 WL 208 FASTENER HOLES -SNOWMANNED-. REPAIRED FLOOR WEB AT BS 1175, RBL 26, WL 208 IAW SRM 53-10-1 FIG 1.

Part: SKIN — DENTED (CARGO DOOR) · airframe 46,203 hrs · 27,997 cycles

MAIN CARGO DOOR EXTERNAL SKIN DENTED 20 INCHES FROM AFT EDGE AND 47 INCHES FROM BOTTOM EDGE. REPAIRED DENT PER FED EX EA 7-5230-102256.

Part: STRAP — CORRODED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

BS 950E STR 29 RT IS CORRODED. FOUND CORROSION TO BE ON REPAIR STRAP, REMOVED AND REPLACED REPAIR STRAP BS 950E STR 29R IAW SRM 51-30-2 AND FED EX DWG SR27-53-023 REV A.

Part: REPAIR — DAMAGED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

EXTERNAL DOUBLER REPAIR 12" X 37" ON LOWER FUSELAGE BETWEEN BS 680-BS 690 STR 26L-27R, REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. REMOVED AND REPAIRED DOUBLER AT BS 680 TO BS 720, STR 26L TO STR 27R IAW SRM 53-30-3.

Part: REPAIR — MISINSTALLED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

EXTERNAL REPAIR DOUBLER 22" BY 16" BS 700 STR 27L - 28R IS NOT PER SRM. REMOVED AND REPLACED DOUBLER AT BS 700 STR 27L TO STR 28R IAW SRM 53-30-3.

Part: REPAIR — MISINSTALLED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

EXTERNAL REPAIR DOUBLER 11" BY 17" ON LOWER FUSELAGE BS 720 STA 28L -28R IS NOT PER SRM. REMOVED AND REPAIRED DOUBLER BS 720 STR 28L TO 28R IAW SRM 53-30-3.

Part: SHEAR TIE — CORRODED (BS 1110) · airframe 46,203 hrs · 27,997 cycles

FOUND BS 1110 BETWEEN STRS 30 AND 29 RT SHEAR TIE IS CORRODED. REPAIRED SHEAR TIE IN AFT CARGO BAY AT BS 1110 BETWEEN S30 & 29R IAW SRM 51-40-03.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

FOUND SHEAR TIE AT BS 720, STRINGER 28 LT TO 28 RT CORRODED. REMOVED CORRODED SHEAR TIE AT BS 720 STR 28 RT - 28 LT, FORMED NEW SHEAR TIE AND INSTALLED IAW SRM 53-10-4 AND 51-30-2.

Part: DOUBLER — IMPROPER (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

EXTERNAL DOUBLER REPAIR 8" BY 14" ON LOWER FUSELAGE BS 1166, STR 19L-20L, REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. REMOVED AND REPLACED LOWER FUSELAGE SKIN REPAIR DOUBLER BS 1166 STR 19L-20L PER SRM 53-30-3, FIG 1, 51-30-2, 51-30-5, 51-30-8, 51-10-2, MAJOR REPAIR. AFTER INVESTIGATION OF PREVIOUS REPAIR AT BS 1166, STR 19L-20L WAS FOUND NOT TO BE PER APPROVED DATA.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

FOUND SHEAR TIE AT BS 700 STRINGER 27 LT TO 28 LT CORRODED. REMOVED CORRODED SHEAR TIE STR 27 LT - 28 LT. FORMED NEW SHEAR TIE & INSTALLED IAW SRM 53-10-4.

Part: DOUBLER — IMPROPER (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

EXTERNAL DOUBLER REPAIR 5" BY 18" ON LOWER FUSELAGE BS 1243, STR 22R, REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. INVESTIGATED REPAIR AT BS 1243 STR 22R, FOUND NOT TO BE PER APPROVED DATA. REMOVED AND REPLACED SKIN DOUBLER ON LOWER FUSELAGE BS 1243 STR 22 R TO COMPLY WITH SRM REPAIR 53-30-3, MAJOR REPAIR.

Part: DOUBLER — IMPROPER (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

EXTERNAL DOUBLER REPAIR 7" BY 7" ON LT SIDE OF FUSELAGE AFT OF MLG WHEEL WELL AT BS 950A, STR 25L, REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. REMOVED REPAIR DOUBLER, FABRICATED, DRILLED, TRIMMED, ALODINED AND PRIMED FABRICATED DOUBLER. INSTALLED REPAIR DOUBLER LT SIDE OF FUSELAGE AFT OF MLG WHEEL WELL BS 950A STR 25L INSIDE SYSTEM "B" HYD COMPARTMENT. WORK DONE PER SRM 51-30-2, 51-10-2, 53-30-3 FIG 1, MINOR REPAIR, PREVIOUS REPAIR BS 950A STR 25 WAS FOUND TO NOT BE PER APPROVED DATA.

Part: REPAIR — IMPROPER (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

EXTERNAL DOUBLER REPAIR 14" BY 16" ON LOWER FUSELAGE CENTERLINE AT BS 660, REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. EXISTING REPAIR IS NOT PER SRM, REMOVED EXISTING REPAIR, FABRICATED AND INSTALLED REPAIR DOUBLER IAW SRM 53-30-3.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

FOUND SHEAR TIE AT BS 700 STRINGER 28 LT TO 28 RT CORRODED. REMOVED CORRODED SHEAR TIE STR 28 LT - 28 RT BS 700, FORMED NEW SHEAR TIE AND INSTALLED IAW SRM 53-10-4.

Part: FLAP TRACK — CORRODED (T/E FLAP) · airframe 46,203 hrs · 27,997 cycles

NR 3 FLAP TRACK UPPER SURFACE CORRODED FWD ATTACH PT OB HOLE. REMOVED AND REPLACED NR 3 FLAP TRACK IAW TASK CARD 27X5705-03.

Part: FLAP TRACK — CORRODED (NR 6) · airframe 46,203 hrs · 27,997 cycles

FOUND CORROSION ON NR 6 FLAP TRACK AFT MOUNT PAD. REMOVED AND REPLACED NR 6 FLAP TRACK IAW TASK CARD 27X5708-03.

Part: STRINGER — CORRODED (BS 680-700 S28R) · airframe 46,203 hrs · 27,997 cycles

FOUND STRINGER 28 RT TO BE CORRODED AT BS 680-700. REMOVED S28R BS 680-700 RT & PRODUCTION SPLICES AND REINSTALLED NEW STRINGER PER FED EX SRM 51-30-2.

Part: STRINGER — CORRODED (BS 680-700 S28R) · airframe 46,203 hrs · 27,997 cycles

FOUND STRINGER 28 LT TO BE CORRODED AT BS 680-700. REMOVED S28R AND PRODUCTION SPLICES BS 680-700 AND REINSTALLED NEW STRINGER IAW FED EX SRM 51-30-2.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 46,203 hrs · 27,997 cycles

FOUND BS 1130 FLOORBEAM TO BE CORRODED AT RBL 7 TO RBL 9 WL 208. REPAIRED BS 1130 FLOOR BEAM RBL 7 - 9 IAW SRM 53-10-8 FIG 11 DETAIL II.

Part: SPACER — LOOSE (NR 1 ELEVATOR) · airframe 46,203 hrs · 27,997 cycles

RIGHT ELEVATOR, NR 1 ELEVATOR RUB BLOCK SPACER IS LOOSE IN LOWER TRAILING EDGE BEAM. REPAIRED R/H ELEVATOR NR 1 RUB BLOCK SPACER IN T/E BEAM IAW FED-EX EA 7-5510-100547.

Part: SHEAR TIE — CORRODED (BS 1148 S29-30R) · airframe 46,203 hrs · 27,997 cycles

FOUND BS 1148 BETWEEN STRS 30 AND 29 RT SHEAR TIE IS CORRODED. REMOVED SHEAR TIE BS 1148 STR 29 & 30 R/H PER SRM 51-30-2. BLENDED CORROSION 3 X 3 .030. ORIG THICKNESS .063. FOUND TO BE OUT OF LIMITS. FABRICATED NEW SHEAR TIE USING 7075T6 .063 LOT #500810 PER SRM 51-20-1 ALODINE, PRIME & PAINTED PER 51-10-2. INSTALLED NEW SHEAR TIE PER SRM 51-30-2 BS 1148 STR 29 & 30.

Part: FRAME — CRACKED (BS 1176) · corrosion level 2 · airframe 46,203 hrs · 27,997 cycles

FOUND CORROSION AT STA 1176 RBL 2 WL 208 FRAME IS CORRODED AND CRACKED. REMOVED AND REPLACED FRAME IAW SRM 51-30-2 AT BS 1176, LBL 68 - RBL 68.

Part: WARNING LIGHT — ILLUMINATED (AIRSTAIR DOOR) · airframe 45,157 hrs · 27,164 cycles

CLIMBING THROUGH FL200, AFT AIRSTAIR LIGHT ILLUMINATED. DIVERTED TO EWR ACCORDING TO QRH. MEL 12MAR05. RELEASED FOR SERVICE PER MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 22MAR05 MEL 52-06-B: AMBER AFT AIRSTAIR DOOR WARNING LIGHT INOP. C/W MX PROCEDURES PRIOR TO DEPARTURE. FOUND AFT STAIRS UPLOCK SWITCH (S268) FUNCTIONS OK, ALSO SWITCH WAS REPLACED ON 2/17/05. FOUND STAIRS UPPER HANDLE DETENT SWITCH OUT OF ADJUSTMENT. REPLACED HANDLE SWITCH (S395), AND ADJUSTED PER AWW 52-70-001-5. AFT STAIR INDICATOR SYS OPS GOOD, 52-70-001-5. RII:094451.

Part: SUPPORT FITTING — DAMAGED (NLG) · airframe 43,915 hrs · 26,203 cycles

COMPLY WITH EA 7-3220-73848 LANDING GEAR - NLG - ELONGATED HOLES IN 69-16339-5 SUPPORT FITTING. COMPLIED WITH EA 7-3220-73848 LANDING GEAR - NLG - ELONGATED HOLES IN 69-16339-5 SUPPORT FITTING, AT MAE.

Part: SUPPORT FITTING — DAMAGED (NLG) · airframe 43,915 hrs · 26,203 cycles

COMPLY WITH EA 7-3220-73848 LANDING GEAR - NLG - ELONGATED HOLES IN 69-16339-5 SUPPORT FITTING. COMPLIED WITH EA 7-3220-73848 LANDING GEAR - NLG - ELONGATED HOLES IN 69-16339-5 SUPPORT FITTING, AT MAE.

Part: SUPPORT FITTING — DAMAGED (NLG) · airframe 43,915 hrs · 26,203 cycles

COMPLY WITH EA 7-3220-73848 LANDING GEAR - NLG - ELONGATED HOLES IN 69-16339-5 SUPPORT FITTING. COMPLIED WITH EA 7-3220-73848 LANDING GEAR - NLG - ELONGATED HOLES IN 69-16339-5 SUPPORT FITTING, AT MAE.

Part: BRAKE — OUT OF ADJUST (HORIZ STAB) · airframe 43,915 hrs · 26,203 cycles

COMPLY WITH EA 7-2740-72134 FLIGHT CONTROLS - HORIZONTAL STAB BRAKE CONTROL, ADJUST NUMBER OF REQUIRED WASHERS. CLOSING ACTION ON 10/31/03 ON N/R S00027. COMPLIED WITH EA 7-2740-72134.

Part: STRUCTURE — CORRODED (BULKHEAD) · airframe 43,915 hrs · 26,203 cycles

COMPLY WITH EA 7-5310-73206 FUSELAGE - MAIN FRAME - BS 950 BULKHEAD LOWER STRUCTURE CORROSION REPAIR, P/N 65-16338-7. COMPLIED WITH EA 7-5310-73206 FUSELAGE - MAIN FRAME - BS 950 BULKHEAD LOWER STRUCTURE CORROSION REPAIR P/N 65-16338-7, AT MAE.

Part: FITTING — CHAFED (NLG) · airframe 43,915 hrs · 26,203 cycles

COMPLY WITH EA 7-5310-73211 FUSELAGE - MAIN FRAME - NLG DRAG BRACE SUPPORT CHAFE REPAIR P/N 65-17673. COMPLIED WITH EA 7-5310-73211 FUSELAGE - MAIN FRAME - NLG DRAG BRACE SUPPORT CHAFE REPAIR P/N 65-17673, AT MAE.

Part: HINGE — CHAFED (CARGO DOOR) · airframe 43,915 hrs · 26,203 cycles

COMPLY WITH EA 7-5230-73214 DOORS - MAIN CARGO - WEAR/CHAFING ON 2 EACH LOBES OF MCD HINGE ASSY. COMPLIED WITH EA 7-5230-73214 DOORS - MAIN CARGO - WEAR/CHAFING ON 2 EACH LOBES OF MCD HINGE ASSY.

Part: SKIN — MISREPAIRED (FUSELAGE) · airframe 43,915 hrs · 26,203 cycles

FUSELAGE SKIN PRE-EXISTING OPEN HOLES NEAR MAIN CARGO DOOR CUTOUT. FUSELAGE SKIN PRE-EXISTING OPEN HOLES NEAR MAIN CARGO DOOR CUTOUT. (INITIAL ACTION, PART 1 COMPLIED WITH ONLY).

Part: KEELBEAM — DAMAGED (FUSELAGE) · airframe 43,915 hrs · 26,203 cycles

COMPLY WITH EA 7-5310-73207 FUSELAGE - MAINFRAME - KEEL BEAM T-ANGLE REPAIR. COMPLIED WITH EA 7-5310-73207 FUSELAGE - MAIN FRAME - KEEL BEAM T-ANGLE REPAIR AT MAE.

Part: WARNING LIGHT — ILLUMINATED (BODY OVERHEAT) · airframe 43,558 hrs · 25,900 cycles

PASSING FL230, 330 KIAS, EPR 2.01/2.07/2.01, LOWER AFT BODY OVERHEAT LIGHT ILLUMINATED. LEVELED OFF AT FL 260 AND PRIOR TO COMPLETING RED TABS , LOWER AFT BODY OVERHEAT LIGHT EXTINGGUISHED. RED TABS COMPLETED AND SYSTEM TEST GOOD. AT LEVEL OFF FL260 THROTTLES WERE REDUCED, SWITCH POSITION CARGO HEAT OUTFLOW-NORMAL, BLEED AIR 1/3 OPEN, BLEED 2 CLOSED, RIGHT AND LEFT PACK ON. INSPECTED PNUEMATIC DUCTING FOR LEAKS NONE NOTED AT THIS TIME REF. 26-14-001-2.

Part: TRIPLER — WORN (MAIN CARGO DOOR) · airframe 43,541 hrs · 25,888 cycles

MAIN CARGO DOOR TRIPLER WEAR. COMPLIED WITH EA 7-5330-70376 BLENDED AREA, EDDY CURRENT INSP, NO CRACKS NOTED. OK FOR SERVICE.

Part: LINK — BINDING (L/E FLAP)

ON TAKEOFF LEAD EDGE W/N RAISE WHEN MOVING FLAP HANDLE FROM 5 DEG TO 2 DEG. REMOVED AND REPLACED LINK ASSY PER MM 27-51-051-4. OPS CHECK NORMAL.

Part: DUCT — MISSING (E&E COMPARTMENT)

01-214 WHILE CHECKING RUDDER CONTROLS NOSE GEAR VIEWING TUBE SECTION MISSING. INSTALL NEW VIEWING TUBE. FUNCIONAL CK GOOD PER B727-200 MM 56-40-000-0. AC OK FOR SERVICE.

Part: STIFFENER — WORN (BS 1330)

01-215 STIFFENER BS 1330, THAT HYDRAULIC LINE CLAMPS TO IS WORN COMPLETELY THROUGH HALF OF ITS SPAN BY HYD LINE. R&R PER B727 STRUCTURAL REPAIR MANUAL 51-40-4.

Part: CONTROLLER — INOP (E&E COMP)

AUTO PRESSURIZATION FAILURE IN FLT. COULD NOT CONTROL CABIN ALT IN ANY PRESSURIZATION MODE. REMOVED AND REPLACED PRESSURE CONTROLLER PER MM 21-31-010-4. OPER CHECK NORM.

Part: WINDSHIELD — CRACKED (RT COCKPIT)

99-191 - AFT T/O R1 WINDOW HEAT ARCED TOP RIGHT TO TOP LEFT 2 MIN LATER OUTER WINDSCREEN CRACKED FROM UPPER RIGHT TO LWR LEFT. REMOVED AND REPLACED R1 WIND PER 727 MM 56-11-011, WIND HEAT CONTROL PER 727 MM 30-41-013. SEAL WIND, INSTALL WINDSHIELD WIPER. WINDSHIELD CONTROLLER INSTALLED. OPS CK NORM.

Part: ENGINE — FAILED (NR 2)

ON T/O FROM MEM, 18L WINDS 160118625 NR 2 ENG FAILED WITH LOUD BANG. *S/D* NR 2 ENG CHANGE ACCOMPLISHED PER WC 70T0002. LEAK AND OPS CK GOOD.

Part: CONNECTOR — CORRODED (NLG)

98-0030 - AFTER TAKEOFF GEAR UP: RED NOSE GEAR LIGHT REILLUMINATED AFTER HANDLE PLACED TO OFF. RED TABS, NO HELP. RED LIGHT COMES ON AFTER DELAY, NOT IMMEDIATELY WHEN PLACING HANDLE TO OFF. REMOVED AND REPLACED NOSE GEAR LOCK SWITCH S96 AND NOSE LANDING GEAR POSITION SWITCH S93. WOULD NOT PASS ADJUSTMENT AND TEST PROCEDURES. FOUND PINS A AND C SHORTED IN CANNON PLUG D300. REMOVED CANNON PLUG AND PINS D300. PASSED ADJUSTMENT AND TEST PER MAINTENANCE MANUAL 32-61-71 OK FOR SERVICE.

Part: CONTROL MODULE — MALFUNCTIONED (E/E COMP)

98-0029 NOSEGEAR UNSAFE, LANDING GEAR HANDLE UP DOOR LIGHTS OUT. REPLACED LANDING GEAR ACCESSORY CONTROL MODULE PER MAINTENANCE MANUAL 32-09-121 PAGE 401 TEST PER 32-09-122 PARAGRAPH 6A, PAGE 505.

Part: CONNECTOR — CORRODED (NLG)

NOSE GEAR UNSAFE LIGHT (RED) WITH LANDING GEAR HANDLE UP. ALL DOOR LIGHTS OUT. (CYCLED GEAR AND PROBLEM REMAINS, RED NOSE GEAR LIGHT ON) NOTE: NORMAL GEAR DOWN, NORMAL HYDRAULICS. AFTER 45 MINUTES, GREEN NOSE GEAR LIGHT ALSO ILLUMINATED AT THE SAME TIME, BUT RATHER DIM. *S/D* INSTALL 3 GEAR PINS. WHILE CHECKING POSITION AND LOCK SWITCHES PER M/M 32-61-71 DUPLICATED PROBLEM. FOUND CORROSION IN CANNON PLUG FOR POSITION SWITCH. CLEANED CORROSION FROM SWITCH AND CANNON PLUG. SYSTEM FUNCTIONAL CHECK OK, PER M/M 32-61-71. GEAR PINS REMOVED.

Part: SWITCH — MALFUNCTIONED (CARGO DOOR)

AT FLIGHT LEVEL 290 CLIMBING TO FLIGHT LEVEL 310, PRESSURIZATION NORMAL, MAIN CARGO DOOR LIGHT ILLUMINATED. PRECAUTIONARY DESCENT TO 10,000 FT, SLOWED TO 250 KNOTS PER RED TAB PROCEDURES. ALSO, DEPRESSURIZED THE AIRCRAFT, HAD BULKHEAD CARGO DOOR UNLOCKED LIGHT ILLUMINATED, PRESSURIZATION WAS NORMAL DURING ENTIRE PROCEDURE. DOOR LIGHT REMAINED ON DURING THE REST OF FLIGHT LEVEL. TROUBLESHOT DOWN TO S9035 LATCH WARNING PROXIMITY SENSOR. INSTALLED NEW SWITCH ADJUSTED PER MAINTENANCE MANUAL 52-34-9 PAGE 513, OPERATIONAL CHECK GOOD.

Part: WEB — CRACKED (BS 1330)

LIGHTENING HOLE ON TORQUE BOX VERTICAL WEB IS CRACKED .5 INCH LONG BS 1330 RBL 20 WL 185. STOP DRILLED CRACK ON TORQUE BOX WEB AT BS 1330 RBL 20 WL 185. FABRICATED REPAIR AND INSTALLED REPAIR WORK IAW FEDEX SRM 51-10-1 AND 51-40-2.

Part: WEB — CRACKED (BS 1230)

LIGHTENING HOLE ON TORQUE BOX VERTICAL WEB IS CRACKED .5 INCH LONG BS 1230 LBL 20 WL 185. STOP DRILLED CRACK IN TORQUE BOX WEB AT BS 1230 LBL 20 WL 185. FABRICATED REPAIR DOUBLER AND INSTALLED IAW FEDEX 51-40-2 AND 51-10-1.

Part: SKIN — DAMAGED (AFT SRV DOOR)

WHILE REMOVING SCUFF PLATES FROM LT AFT SERVICE DOOR ON CARD NR 72C200-01, FOUND DAMAGED HOLE ON OUTER SKIN AFT UPPER CORNER WHERE SCUFF PLATE FASTENER ATTACH POINT. REPAIRED DAMAGED HOLE ON OUTER SKIN AFT UPPER CORNER WHERE SCUFF PLATE FASTENER ATTACH POINT PER FEDEX EA 7-5310-28242. WHILE WORKING REPAIR FOUND DRILL START ON STR 17L, REPAIRED PER FEDEX SRM 51-40-4.

Part: KEEL BEAM — CRACKED (BS 950-1010)

RT KEEL BEAM CRACKED AT BS 990 PLUS 1 TO PLUS 4 W/L. REPAIRED RT KEEL BEAM AT BS 990 PLUS 1 TO PLUS 4, PER FEDEX EO 7-5310-7-2356C PT 5 AND EA 7-53-10-27778.

Part: STRINGER — DOUBLE DRILLED (BS 540)

FOUND DOUBLE DRILLED HOLE IN STRINGER AT BS 540 STR 15R. REMOVED DAMAGE PER FEDEX SRM 53-10-03 FIG 1, DETAIL 1. FABRICATED AND REPAIRED SPLICES AND FILLER PER FEDEX SRM 53-10-03, FIG 1 DETAIL 1. ALODINE AND PRIMERED PER FEDEX SRM 51-10-2 AND INSTALLED FASTENERS PER FEDEX SRM 53-10-3, FIG 1 SHEET 3.

Part: FLAP ASSY — CORRODED (NR 5 LE FLAP)

NR 0130 AND 003, DUE TO NUMEROUS CORROSION DISCREPANCIES, NR 5 K-FLAP ASSY REQUIRES REPLACEMENT.

Part: SKIN — LIGHTNING STRIKE (BS 650)

LIGHTNING STRIKE BS 650 STR 6R. CUT OUT DAMAGED AREA, FABRICATED FILLER AND DOUBLER PARTS AND INSTALLED. TREATED, PRIMED AND PAINTED REPAIR PARTS AND AREA AT BS 650 STR 6R, ALL WORK DONE IAW FEDEX SRM 53-30-3.

Part: HINGE LUG — CORROSION (NR 2 LE FLAP)

NR 0381 AND 004, NR 2 K-FLAP O/B HINGE LUG O/B UPPER BOLT HAS CORROSION AROUND IT. REPLACED NR 2 K-FLAP PER FEDEX MM 27-81-01, DUE TO CORROSION BEING EXCESSIVE.

Part: PRESSURE PAN — CRACKED (BS 757)

UPON REMOVAL OF PRESSURE PAN, FOUND TWO CRACKS AT BS 757 RBL 65 TO 68 WL 207. REMOVED DAMAGE ON PRESSURE PAN, FABRICATED AND INSTALLED REPAIR PARTS AT BS 757 RBL 65 TO 68 WL 207 PER FEDEX SRM 51-40-2.