N279

Part: BLADES — DAMAGED (NR 2 ENGINE)

JFK/BRU AIR TURNBACK DUE TO ENGINE VIBRATION HIGH ALERT ON NR 2 ENGINE AT 700 FT ON TAKEOFF NR 2 ENGINE COMPRESSOR READS 5.8 VIBRATION AND SOUND PRESENT. WHEN THROTTLE RETARDED VIBRATION CEASED. DUMPED FUEL AND RETURNED BACK FOR LANDING AT JFK. NR 2 ENGINE BOROSCOPED AT AP-2 & AP-3, NO DAMAGE OBSERVED. ALL FAN BLADES REPLACED DUE TO 17 BLADES DAMAGED. ENGINE VIBRATION SURVEY ACCOMPLISHED PER MD-11 MM 71-02-08.

Part: SEAT TRACK — CORRODED (STA 1811-1871)

DURING ACCOMPLISHEMENT OF CARGO MOD J/C SP11530505-7014, FOUND TRACK P/N AFA7795-11 CORRODED (REF STA 1811-1871, X=-8.5). TRACK SECTION REMOVED AND REPLACED WITH TRACK P/N WSP0826-527 IWA DWG SP11530505-7013.

Part: SEAT TRACK — CORRODED (FUSELAGE)

DURING C-CHECK IN NAP FOUND CORROSION ON THE CHANNEL SUPPORT PN NBA6000-926 ON CABIN SEAT TRACK. REPLACED PN ABA8225-503 SUPPORT AND REWORK IAW DWG SP11530511-7025

Part: SUPPORT — CORRODED (BS 392-421)

DURING CARGO MOD FOUND CABIN SEAT TRACK REF STA 392-421 CHANNEL SUPPORT P/N NBA 6000-926 CORRODED. REPLACED CABIN SEAT TRACK SUPPORT WITH P/N ABA8225-503 IAW DWG SP11530511-7025.

Part: CARGO TRACK — CORRODED (FUSELAGE)

DURING ACCOMP OF CARGO MOD J/C SP11530505-7014-1F, FOUND TRACK P/N AFA7795-11 MADE FROM P/N SG9291-47 CORRODED (REF STA 1811-1871). REPLACED AFFECTED TRACK WITH NEW TRACK P/N WSP0826-527 IAW DWG SP 11530505-7013.

Part: INDICATOR — MALFUNCTIONED (FUEL QTY)

AIRCRAFT DIVERTED TO CHA DUE TO IN CRUISE NR 2 ENGINE FUEL QUANTITY LOW ALERT CAME ON, FUEL INDICATIONS WERE: NR 1 ENGINE 700 LBS, NR 2 ENGINE 0 LBS AND NR 3 ENGINE 600 LBS. MANIFOLD DRAIN ALERT CAME ON. SWAPPED CONTROLLERS BUT INDICATIONS REMAINED. PROBED FUEL LEVEL STICKS IAW MD11 AMM 12-11-07, NR 1 TANK STICK NR 4: 27", NR 2 TANK STICK NR 1: 14" & STICK NR 3: 14", NR 3 TANK STICK NR 4: 27". FUEL STICKS CORRESPOND WITH ASSOCIATED FUEL QUANTITY ON AIRCRAFT. PERFORMED FUEL QUANTITY BITE TEST IAW MM 28-42-00, SYSTEM OPERATIONS CHECKS GOOD.

Part: CONTROL PANEL — INOPERATIVE (EMERGENCY LIGHT) · airframe 10,545 hrs · 8,213 cycles

UPON ENTERING THE AIRCRAFT THE EMERGENCY LIGHTS WERE COMING ON AND OFF ON THEIR OWN. TROUBLESHOT TO FLIGHT ATTENDANT CONTROL PANEL. REMOVED AND REPLACED FLIGHT ATTENDANT CONTROL PANEL IAW EMB 145 MM 25-27-09. OPS CHECK GOOD.

Part: FITTING — CORRODED (MLG)

DURING C2 CHECK FOUND CORROSION IN CENTER LANDING GEAR FITTING. CLEANED UP CORROSION BY MACHINING FAYING SURFACE, ENLARGED HOLE DIAMETER OF TURNION FITTING AND INSTALLED BUSHING. THE DIMENSIONS OF REWORK AREA ARE WITHIN LIMITS PER SRM 53-40-00 VOL 1 FIG 15.

Part: LONGERON — CORRODED (FUSELAGE)

IDURING "C2" CHECK INSPECTION, FOUND CORROSION AT LONGERON 50R FROM STA 1884 TO STA 1975. REMOVED THE CORRODED LONGERON AND INSTALLED NEW PART PER MD11 SRM VOL II 51-33-01. APPLIED PROTECTIVE COATING.

Part: DRAIN — CORRODED (WASTE TANK)

DURING C2 CHECK INSPECTION FOUND CORROSION IN WASTE TANK DRAIN PAN AT STA 1970 BETWEEN L50L AND L50R. REMOVED WASTE TANK DRAIN PAN AND INSTALLED NEW PART PER MD11 SRM 51-33-01 VOL II REV 36. APPLIED PROTECTION COATING.

Part: SHEAR TIE — CORRODED (FUSELAGE)

ITEM: DURING "C2" CHECK INSPECTION, FOUND SHEAR CLIP CORROSION AT STA 1953, STA 1959 AND STA 1975 BETWEEN L48L AND L52R. REMOVED THE CORROSION SHEAR CLIP AND INSTALLED NEW PARTS PER MD11 SRM VOL II 51-35-01. APLIED PROTECTION COATING.

Part: FITTING — CORRODED (FUSELAGE)

DURING "C2" CHECK INSPECTION, FOUND CORROSION IN LONGERONS FITTING AT STA 1970 BETWEEN L52L, L51L AND L51R.

Part: SHEAR TIE — CORRODED (FUSLEAGE)

DURING C2-CHECK INSPECTION, FOUND SHEAR TIE CORROSION AT STA 1741 BETWEEN L51L TO L51R. CUT OUT THE CORROSION AREA AND MADE REPAIR PARTS PER SRM 53-30-00 VOL 1 FIG 5. PERFORMED NDT INSP NO DEFECT FOUND. INSTALLED REPAIR PARTS PER MD11 SRM 51-33-01 VOL II REV35 AND APPLIED PROTECTION COATING.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE)

DURING C2 CHECK INSPECTION, FOUND CRACK IN TWO FLOOR PANEL SUPPORT ABOVE 1 INCH AND 1.5 INCH AT STA 1541 RBL 0 TO RBL 30, LBL 0 TO LBL 30. REPAIRED CRACKED AREA USING REPAIR DOUBLERS PER MD11 SRM53-00-01 FIG 5,VOL1 REV 36.

Part: ENGINE — MAKING METAL (NR 2) · airframe 10,159 hrs · 7,890 cycles

DURING CRUISE ON FLT 3103 FROM LGA TO SDF, THE FLIGHT CREW HEARD A LOUD BANG. THE ITT DROPPED TO THE AMBER RANGE, AN EICAS E2 OUT MESSAGE APPEARED, AND THE ENGINE SHUTDOWN. THE QRH WAS RAN AND ABOUT 35 MINUTES OUT FROM SDF, AN EMERGENCY WAS DECLARED. DURING LANDING AN EICAS E2 EXCEEDED MESSAGE AND AN E2 SHORT DISPATCH MESSAGE APPEARED. MAINTENANCE INSPECTED THE ENGINE AND FOUND METAL SHAVINGS IN THE EXHAUST SECTION. REMOVED AND REPLACED NR 2 ENGINE. MAINTENANCE PERFORMED GROUND RUNS OF NR 2 ENGINES WITH NO LEAKS NOTED. OPS CHECK GOOD.

Part: CLAMP — LEAKING (NR 1 PYLON) · airframe 5,950 hrs · 4,483 cycles

LAV SMOKE WARNING (AURAL, VISUAL, EICAS) ON CLIMB OUT. ALSO HAD NR 1 BLEED LEAK WARNING. EMERGENCY WAS DECLARED AND LANDED WITHOUT INCIDENT. FIRE DEPT MET WITH AIRCRAFT. NO SMOKE WAS NOTED. UPON INVESTIGATION, FOUND 2 CLAMPS LEAKING IN NR 1 PYLON BY PRECOOLER IAW MM 36-11-04. NO DEFECTS NOTED DURING GROUND RUN.

Part: APU — FAILED (APU BAY) · airframe 4,955 hrs · 3,715 cycles

APU SHUTDOWN, SMOKE AND BURNING ODOR FILLED AFT CABIN. DEFERRED.

Part: FLAP — MALFUNCTIONED (WING) · airframe 1,016 hrs · 759 cycles

UNKNOWN FLAP PROBLEM. PILOT DECLARED EMERGENCY. MAINTENANCE NOTIFIED BY DISPATCH.