N2829W

Part: CLAMP — BROKEN (CARGO BAY) · airframe 75,088 hrs · 44,882 cycles

A/C PERFORMED AIR TURNBACK DUE TO AFT CARGO DETECTION OVERHEAT/FIRE. REPLACED BROKEN CLAMP ON PNEUMATIC DUCT IN AFT BAG BIN.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 74,883 hrs · 44,747 cycles

FUSELAGE BULKHEAD STA 1183 RBL 8, A 3/8 INCH CRACK WAS FOUND IN THE FS 1183 BULKHEAD WEB UNDER THE LOWER END OF THE RBL VERTICAL STIFFENER NEAR WL 182. THE CRACK IS TYPICAL OF BAC S/B 727-53-0175. THE CRACK WAS REMOVED AND REPAIR INSTALLED PER ER/A 382099-14.

Part: ATTACH ANGLE — CRACKED (L/E SLAT) · airframe 74,883 hrs · 44,747 cycles

FOUND ON F1 CK NR 8 SLAT INBD STOP ATTACH ANGLE CRACKED. REPAIRED PER MM 57-54-000-8.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 73,248 hrs · 43,647 cycles

RT OVERWING EMERGENCY EVAC LIGHT INOP. REPLACED BATT PACK OPS NML.

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 72,189 hrs · 42,973 cycles

NUMBER ONE ENG EPR ERRATIC AROUND 1.8. RAN ENGINES. UNABLE TO DUPLICATE. INSPECTED SYSTEM - NTF.

Part: STIFFENER — CRACKED (NR 2 SLAT) · airframe 71,714 hrs · 42,654 cycles

L/E SPAR STIFFENER CRACKED AT NR 2 SLAT O/B TRACK O/B SIDE. TPA E-1 LETTER CHECK. REPLACED STIFFENER PER M/M 57-20-21 NR 14.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 71,183 hrs · 42,292 cycles

THE FS 1183 BULKHEAD WAS FOUND WITH A TYPICAL .75 INCH LONG CRACK AT RBL 30 AND WL 169. THE CRACK IS TYPICAL OF BAC S/B 727-53-0215. THE CRACK WAS CUTOUT OF THE WEB AND REPAIRED WITH AN ALUMINUM DOUBLER PER S/B AND ER/A 377664-14

Part: LIGHT — INOPERATIVE (CABIN) · airframe 70,938 hrs · 42,122 cycles

EMERGENCY LIGHT ABOVE R1 DOOR WOULD NOT ILLUMINATE WHEN OPERATED BY COCKPIT SWITCH. RELAMPED, NO HELP. REPLACED LIGHT ASSY, CKS OK.

Part: CHARGER — INOP (CABIN)

DURING L/O CK, FOUND EXTERIOR OVERWING EXIT AFT EMERGENCY LIGHT INOP ON LEFT SIDE. REPLACED CHARGER ASSY. OPS CKS GOOD.

Part: BATTERY — DISCHARGED (EMER EXIT DOOR)

CENTER LT OVERWING EMERG LIGHT INOP. REPLACED BATTERY AT M954, OPS CHKS GOOD.

Part: BATTERY — SHORTED (ROW 1-26)

EMERGENCY EXIT LIGHTS ILLUMINATE WHEN ARMED SEAT 1 TO 26. FOUND LIGHTS ILLUM INTERMITTENTLY. ISOLATED PROBLEM TO RT CONTROL SYSTEM, FOUND POWER AT PIN 4 AT FWD BATTERY PACK. INSPECTED WIRE BUNDLE IN CEILING, AT ALL BATTERY PACKS. FOUND AFT AIRSTAIR LIGHT AND BATTERY ASSY SHORTED INTERNALLY. REPLACED AFT AIRSTAIRS EMERGENCY EXIT LIGHT ASSY. ALL LIGHTS CHECK NORMAL.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

EMERGENCY EXIT LIGHTS ILLUMINATED IN FLIGHT, CHECKED COCKPIT SWITCH. REPLACED AFT EMERGENCY LIGHTS POWER SUPPLY.

Part: POWER SUPPLY — INOP (CABIN)

EMERGENCY EXIT LIGHTING FLICKERED ON AND OFF DURING FLIGHT. REPLACED F/C EMER LIGHT POWER SUPPLY AND BATTERY TEST OK.

Part: POWER SUPPLY — INOP (CABIN)

ALL EMER LIGHTS TURN ON AND OFF WITHOUT CONTROL SWITCH TURNED ON. REPLACED EMERGENCY LIGHT POWER SUPPLY.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERG EXIT LIGHT SIGN ON FACE OF LIFE RAFT COMPARTMENT, MAIN CABIN INOP ON TEST. REPLACED RACK AND BATTERY PACK, OPN CKS OK.

Part: WEB — CRACKED (BS 1243)

REF SHIP 576 TPA LTR CHK C2 12-03-98, .25 INCH CRACK IN TORQUE BOX VERT WEB RT SIDE STA 1243, .5 INCH CRACK IN TORQUE BOX VERT WEB LT SIDE STA 1323. REPAIRED BOTH ITEMS PER MM 53-11-0.

Part: BATTERY PACK — DISCHARGED (OVERWING EXIT)

LT CTR OVERWING EMER LIGHT INOP. REPLACED BULB AND BATT PACK, NO HELP. REPLACED CHARGING RACK, CKS OK.

Part: RACK — INOPERATIVE (CABIN)

LT OVERWING EMERGENCY LIGHT INOP. REPLACED RACK.

Part: BATTERY PACK — DISCHARGED (CABIN)

LT WING CTR EMER EXIT LIGHT INOP. REPLACED RACK AND BATTERY M956.

Part: SKIN — CRACKED (RT ELEVATOR)

FOUND ON C1 LETTER CK, TWO .75 INCH CRACKS IN THE RT ELEVATOR LOWER SKIN LOWER FWD EDGE OF ELEVATOR. REPAIRED PER SRM 55-20-3.

Part: BRACKET — CRACKED (NR 1 LE SLAT ACT)

NR 1 SLAT ACTUATOR MOUNT BRACKET CRACKED 1.5 INCH VISIBLE O/B END. REPAIRED PER M/M 57-20-21.

Part: CONNECTOR — LOOSE (CABIN)

ON LAYOVER CK, FOUND 2 AFT LEFT OVERWING EMERG EXIT LIGHTS INOP. FOUND CONNECTOR PLUG OFF OF BATTERY PACK FOR AFT O/W BATTERY PACK. REINSTALLED CONNECTOR CHECKS GOOD. REPLACED BATTERY FOR MIDDLE O/W EXIT LIGHT, NO HELP. REPLACED BATTERY PACK, OPS CKS GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

RIGHT FORWARD EMERGENCY LIGHT INOP. REPLACED BATTERY PACK.

Part: BATTERY PACK — DISCHARGED (CABIN)

LEFT AFT OVERWING EMERGENCY LIGHT INOP. REPLACED BATTERY PACK.

Part: SILL — CORRODED (BS 950)

C2 DOOR SILL WAS FOUND CORRODED ON THE OUTBD FLANGE. CORROSION CONFINED TO THE UPPER SURFACE OF OUTBD FLANGE. CUT OUT IN FLANGE IS 6.125 BY 1.625. REPAIRED PER ERA 330801-14.

Part: SKIN — CORRODED (BS 1010)

FUSELAGE SKIN BUTT SPLICE AND STRINGER WERE FOUND CORRODED AT S29R AND FS 1010. REPAIRED PER ERA 330802-14.

Part: SILL — CORRODED (BS 980)

C2 DOOR SILL WAS FOUND CORRODED AT THE OUTBD CHORD AT FS 980. REPAIRED PER ERA 330800-14.

Part: FRAME — CRACKED (C 2 DOORWAY)

WHILE ACCOMPLISHING EO 4-61247-12AD, A 0.75 CRACK WAS FOUND IN THE WEB OF THE NR 2 CARGO DOORWAY AFT FRAME. REPAIRED PER ERA 330827-14AD.

Part: RIB — CRACKED (LE FLAP)

RIB IS CRACKED AT ACTUATOR ATTACH HOLE I/B RIB. PLATE AT ATTACH HOLE IS WORN ON SAME RIB. SMALL LEG ON RIB IS MISSING THAT ATTACHES CHORD ANGLE. REPAIRED PER MM 57-54-00 PG 805 ITEM 2, REPLACED PLATE PER SRM 51-00.

Part: RIB — CRACKED (NR 4 LE SLAT)

RIB IS CRACKED AT NUT PLATE O/B RIB AT ACTUATOR ATTACH HOLE ON NR 4 SLAT. REPAIR DOUBLER IS CRACKED ON SAME RIB. REPAIRED PER MM 57-54-0 PG 805.

Part: FRAME — CRACKED (BS 930)

FUSELAGE FRAME CRACKED AT STA 930 STR 13 AND 14 LT SIDE. REPAIRED PER M/M 53-10-4 FIG 25 AND ERA 330775-14.

Part: SPAR — CRACKED (LT TE MIDFLAP)

CRACK AFT SPAR 53 FROM I/B END OF FLAP. REPAIRED PER MM 57-52-0.

Part: ACT BRACKET — CRACKED (NR 5 LE FLAP)

NR 5 L/E FLAP ACTUATOR ATTACH BRACKET CRACKED AT O/B UPPER CORNER. INSTALLED DOUBLER PER M/M 57-20-21.

Part: ACT BRACKET — CRACKED (NR 8 LE SLAT)

A 2 INCH CRACK AT NR 8 L/E SLAT ACTUATOR ATTACH BRACKET O/B SIDE. INSTALLED DOUBLER PER M/M 57-20-21.

Part: STIFFENER — CORROSION (BS 1183)

CORROSION WAS DISCOVERED AT THE LOWER END OF LBL 17.8 VERTICAL STIFFENER, JUST BELOW THE SUPPORT ROD END AT STA 1183. CORROSION IS ON THE O/B FACE OF THE VERTICAL WEB WHICH RUNS FWD-AFT. THIS DAMAGE HAS BEEN REPAIRED IN ACCORDANCE WITH S/B 727-53-0202.

Part: WEB — CRACKED (BS 1235)

LT TORQUE BOX VERTICAL WEB LIGHTENING HOLE CRACKED 2 PLACES AT STA 1235, MARKED. REPAIRED PER M/M 53-11-0 PG 828.

Part: WEB — CRACKED (BS 1235)

LT TORQUE BOX VERTICAL WEB LIGHTENING HOLE CRACKED 2 PLACES AT STA 1235. INSTALLED DOUBLER PER MM 53-11-0 PG 828.

Part: SKIN — CORROSION (BS 1050)

THE FUSELAGE SKIN HAS A 2 BY 2 CUTOUT AT FS 1050, NEAR STR 28R. THE SKIN IS MANUFACTURED FROM CLAD 2024-T3 CHEM-MILLED WITH A LOCAL THICKNESS OF 0.050 AND 0.070. UPON REMOVAL OF TIME-LIMITED REPAIR AT HMV, ADDITIONAL DAMAGE HAS BEEN DISCOVERED, STR 28R AT FS 1050 HAS EXTENSIVE CORROSION AND WILL REQUIRE INSTALLATION OF A SPLICE SECTION. ADDITIONAL CORROSION DAMAGE IS LOCATED APPROXIMATELY 2 INCHES INBOARD AND 2 INCHES FWD OF THE EXISTING CUTOUT. THE RESULTING CUTOUT IS 4 BY 5 INCH, 0.050 AND 0.070 2024-T3 CLAD SKIN.

Part: STRINGER — CORROSION (FS 1050-1070)

UPON REMOVAL OF TIME-LIMITED REPAIR AT HMV, ADDITIONAL DAMAGE HAS BEEN DICOVERED. STRINGER 28R AT STATION 1050 HAS EXTENSIVE CORROSION AND WILL REQUIRE INSTALLATION OF A SPLICE SECTION. ADDITIONAL CORROSION DAMAGE IS LOCATED APPROXIMATELY 2 INCHES INBOARD AND 2 INCHES FORWARD OF THE EXIST, IN CUTOUT. THE RESULTING CUTOUT IS 4 INCHES BY 5 INCHES BY 0.050 AND LOCATED APPROXIMATELY 15 INCHES AFT OF THE ORIGINAL DAMAGE LOCATION.

Part: ANGLE — CORRODED (BS 400)

AT MID VISIT FASTENER HOLES WERE FOUND CORRODDED AT STA 400 RBL 33. CAP AND ANGLES REPLACED PER SRM 53-10-8.

Part: SKIN — CORROSION (FS 1065)

THE FUSELAGE SKIN HAS A 2 BY 2 CUTOUT AT FS 1050, NEAR S-28R. THE SKIN IS 2024-T3 CLAD CHEM-MILLED SKIN WITH A LOCAL THICKNESS OF 0.050 AND 0.070. UPON REMOVAL OF TIME-LIMITED REPAIR AT HMV, ADDITIONAL DAMAGE HAS BEEN DICOVERED. S-28R AT STATION 1050 HAS EXTENSIVE CORROSION AND WILL REQUIRE INSTALLATION OF A SPLICE SECTION. ADDITIONAL CORROSION DAMAGE IS LOCATED APPROXIMATELY 2.0 I/B AND 2.0 FWD OF THE EXISTING CUTOUT. THE RESULTING CUTOUT IS 4.0 BY 5.0 IN 0.050 AND 0.00 2024-T3 CLAD SKIN. IN ADDITION, AN EXISTING REPAIR, INSTALLED PER ER/A 259545, ADD DAMAGE AFT OF FWD CUTOUT.

Part: FUEL CONTL UNIT — FAILED (NR 1 ENGINE)

NR 1 ENGINE FLAMED-OUT AS TAKEOFF POWER WAS BEING APPLIED. C/A: REPLACED FCU AND FUEL PUMP. LEAK CHECKED AND RIGGED PER PFHB. OPS CKS OK.

Part: RIB — CRACKED (NR 6 SLAT)

SLAT NR 6, RIB NR 10 AND 12 CRACKED. REPAIRED PER M/M 57-54-0 FIG 814.

Part: RIB — CRACKED (NR 4 LE SLAT)

DURING SHOP INSPECTION, NR 4 L/E SLAT WAS FOUND WITH RIB NR 12 CRACKED PAST PREVIOUS STOP DRILL. REPAIRED PER MM 57-54-00.

Part: PACK VALVE — MALFUNCTIONED (LT)

ON CLIMBOUT, A/C WOULD NOT HOLD PRESSURIZATION. DESCENDED AND CABIN STILL CLIMBED, LT DUCT PRESS 20 LBS HIGHER THAN RT. CA REPLACED LT PAC VALVE, CLEANED TRASH FROM LWR AFT CORNER OF C2 BIN DOOR AND A/C PRESSURE CHECK OK.

Part: BEAM — CRACKED (FS 1273)

THERE IS A 1 INCH CRACK IN THE FWD TRANSVERSE BEAM OF THE RT TORQUE BOX AT FS 1273 AND A 3 INCH CRACK IN THE AFT SIDE GUSSET. THE INBD UPPER CHORD HAS A 4 INCH LONGITUDINAL CRACK. THESE AREAS OF THE TORQUE BOX ARE THE SUBJECT OF AIRWORTHINESS DIRECTIVE 94-07-08, WHICH REQUIRES INSPECTION PER S/B 53-0129. THIS ER/A WILL REPLACE/REPAIR THE DAMAGED PARTS IN ACCORDANCE WITH THE S/B. IN ADDITION, THE INBD WEB WILL BE CUT TO FACILITATE PART REPLACEMENT.

Part: WEB — CRACKED (FUSELAGE)

A .375 INCH CRACK IN LT LWR TORQUE BOX VERTICAL WEB AT UPPER FWD LIGHTENING HOLE ADJACENT TO DOUBLER. FOUND DURING F-2 LETTER CHECK TPAMM, REPAIRED PER M/M 53-11-0.

Part: RIB — CRACKED (NR 4 LE SLAT)

UPON ROUTINE INSPECTION, A CRACK WAS FOUND ON THE 17TH RIB FROM O/B END OF NR 4 L/E SLAT. REPAIRED AS PER MM 57-54-0, FIG 805.

Part: RIB — CRACKED (NR 4 LE FLAP)

UPON ROUTINE INSPECTION, A CRACK WAS FOUND ON THE 5TH RIB FROM THE O/B END NR 4 L/E SLAT. REPAIRED AS PER 57-54-0, FIG 805.

Part: SLAT — CRACKED (NR 7)

FOUND DURING F-1 LETTER CHECK, .75 INCH CRACK AT NR 7 SLAT UNDER I/B STOP FITTING. REPAIRED PER MM 57-54-0.

Part: SKIN — LIGHTNING STRIKE (FS 904-946)

FOUND DURING F-1 LETTER CHECK - 3 EACH LIGHTNING STRIKES ON TOP OF FUSELAGE BETWEEN STA 905-946 AND BETWEEN STRINGERS 5 AND 6R. REPAIRED PER SRM 53-04, FIG 38.

Part: FOREFLAP — CRACKED (NR 4 TE FLAP)

FOUND DURING F-1 LETTER CHECK - ONE CRACK AT NR 4 FOREFLAP ABOVE NR 8 FLAP TRACK AT CUTOUT AREA. REPAIRED PER SRM 57-50-4 FIG 1.

Part: SKIN — CRACKED (NR 7 SLAT)

FOUND DURING F-1 LETTER CHECK, .375 INCH CRACK ON COVE SKIN SUPPORT ANGLE, NR 7 SLAT AT THERMAL ANTI-ICE DUCT. REPAIRED PER MM 57-54-0.

Part: FWD TRUNNION — CORROSION (RT MLG)

RT/MLG FWD TRUNNION ATTACH FITTING HAS CORROSION IN UPPER AND LOWER BOLT HOLES. REPAIRED PER M/M 57-43-0 PAGE 803 FOUND ON CV-3 TRIPLE GEAR CHANGE.

Part: TRUNNION FITTING — CORROSION (RT MLG)

RT MLG FWD ATTACH FITTING LT/UPPER/LOWER BUSHINGS CORRODED. REPAIRED PER ERA 301600-14. FOUND ON CV-3, TRIPLE GEAR CHANGE.

Part: TRUNNION FITTING — CORROSION (RT MLG)

R/MLG FWD TRUNNION ATTACH FITTING. CORROSION OTBD FITTING UPPER AND LWD BOLT HOLES. REPAIRED PER M/M 32-43-0. FOUND ON CV-3 TRIPLE GEAR CHANGE.

Part: TRUNNION FITTING — CORROSION (LT MLG)

LT MLG FWD TRUNNION ATTACH FITTING. LT LOWER BUSHING HAS CORROSION. LOWER RT BUSHING HAS CORROSION. REPAIRED PER M/M 57-43-0 PG 804.