N285SC

Part: LIGHT — INOPERATIVE (CABIN) · airframe 66,159 hrs · 26,115 cycles

FWD CABIN EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED EMERGENCY LIGHT.

Part: CONTROL UNIT — FAILED (CABIN) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION THE ELECTRO PNEUMATIC FLOW CONTROL UNIT FAILS AUTOMATIC DROP TEST. REMOVED AND REPLACED FLOW CONTROL UNIT IAW B727 MM 352111. OPS CHECK NORMAL IAW B727 MM 352100.

Part: MANIFOLD — LEAKING (CABIN) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION THE OXYGEN MANIFOLD AT PSU 4L FAILS LEAK CHECK. REPLACED PSU OXYGEN MANIFOLD PER B727 MM 252131. LEAK CHECK AND OPS CHECK GOOD IAW B727 MM 352100.

Part: MANIFOLD — LEAKING (CABIN) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION THE OXYGEN MANIFOLD AT PSU 16R FAILS LEAK CHECK. REPLACED PSU OXYGEN MANIFOLD PER B727 MM 352131. LEAK CHECK AND OPS CHECK GOOD IAW B727 MM 352100.

Part: MANIFOLD — LEAKING (CABIN) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION THE OXYGEN MANIFOLD AT PSU 18RH FAILS LEAK CHECK. REPLACED PSU OXYGEN MANIFOLD PER B727 MM 352131. LEAK CHECK AND OPS CHECK GOOD IAW B727 MM 352100.

Part: MANIFOLD — LEAKING (CABIN) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION THE OXYGEN MANIFOLD AT PSU 3L FAILS LEAK CHECK. REPLACED MANIFOLD IAW B727 MM 352131. OPS AND LEAK CHECK NORMAL IAW B727 MM 352100.

Part: MANIFOLD — LEAKING (CABIN) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION THE OXYGEN MANIFOLD FAILS LEAK CHECK AT PSU 24RH. REPLACED MANIFOLD IAW B727 MM 352131, LEAK CHECK AND OPS CHECK GOOD IAW B727 MM 352100.

Part: MANIFOLD — LEAKING (CABIN) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION THE OXYGEN MANIFOLD FAILS LEAK CHECK AT PSU 20 LT. REPLACED MANIFOLD IAW B727 MM 352131. LEAK CHECK AND OPS CHECK GOOD IAW B727 MM 352100.

Part: MANIFOLD — LEAKING (CABIN) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION THE OXYGEN MANIFOLD AT PSU 24R FAILS LEAK CK. REPLACED PSU OXYGEN MANIFOLD PER B727 MM 352131. LEAK CHECK AND OPS CHECK GOOD IAW B727 MM 352100.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION CORROSION WAS FOUND OUT OF LIMITS ON SEAT TRACK AT STA 420 RBL 45.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION CORROSION WAS FOUND OUT OF LIMITS ON THE UPPER FLANGE OF THE FLOORBEAM AT BS 1130, RBL 28 TO RBL 36.

Part: BEAM — CORRODED (LT MLG) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE CHECK CORROSION WAS FOUND OUT OF LIMITS ON THE LEFT HAND MAIN LANDING GEAR SUPPORT BEAM. THE CORROSION WAS AT THE SITE OF THE HOLE FOR THE GEAR ACTUATOR SUPPORT PIN BUSHING. THE CORROSION WAS AT THE UPPER FORWARD END OF THE HOLE, EXTENDING APPROXIMATELY 0.14 INCH RADIALLY, AND APPROXIMATELY 0.80 INCH AFT INTO THE GEAR BEAM.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION CORROSION WAS FOUND OUT OF LIMITS ON FLOORBEAM AT STA 1070, LBL 58.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION CORROSION WAS FOUND OUT OF LIMITS ON THE SEAT TRACK AT STA 1070 TO 1135 LBL 22.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION CORROSION WAS FOUND OUT OF LIMITS ON SEAT TRACK AT STA 344 - 380 RBL 24.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION CORROSION WAS FOUND OUT OF LIMITS ON THE SEAT TRACK AT STA 380 TO 420 RBL 24.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION CORROSION WAS FOUND OUT OF LIMITS ON SEAT TRACK STA 420 - 440 RBL 24.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 65,116 hrs · 25,671 cycles

DURING HEAVY MAINTENANCE INSPECTION CORROSION WAS FOUND OUT OF LIMIT MAIN CABIN FLOOR STRUCTURE AT STATION 344 RBL 19, FLOORBEAM.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 64,347 hrs · 25,367 cycles

DURING A MAINTENANCE LINE CHECK THE EMERGENCY EXIT LIGHTS WERE FOUND INOPERATIVE. REMOVED AND REPLACED BATTERY POWER PACK FOR THE AFT EXIT EMERGENCY LIGHTS, OPERATIONAL CHECKS GOOD.

Part: COMPUTER — MALFUNCTIONED (NR 2 ENGINE) · airframe 63,611 hrs · 25,065 cycles

DURING TAKEOFF AT INITIAL POWER UP A SERIES OF COMPRESSOR STALLS OCCURRED ON THE NUMBER TWO ENGINE. THE TAKEOFF WAS ABORDED AND THE AIRCRAFT RETURNED TO GATE. REMOVED AND REPLACED THE PRBC, OPERATIONAL CHECKS GOOD. THE INLET AND EXHAUST OF NUMBER TWO ENGINE WERE INSPECTED, NO DEFECTS NOTED.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 62,974 hrs · 24,793 cycles

DURING A MAINTENANCE LINE CHECK, THE AFT AIRSTAIR EMERGENCY LIGHTING WAS FOUND INOPERATIVE. REMOVED AND REPLACED THE EMERGENCY EXIT LIGHTING ON THE AFT CABIN DOOR. OPERATIONAL CHECKS GOOD.

Part: FLOW VALVE — MALFUNCTIONED (CABIN PRESSURE) · airframe 62,911 hrs · 24,766 cycles

DURING CRUISE FROM JFK, THE CABIN RATE OF CLIMB WAS 1,000 FT/MIN, THE CABIN REACHED 9,000 FT. THE CREW CLOSED THE CARGO HEAT OUTFLOW AND THE CABIN DIFFERENTIAL AND ALTITUDE RETURNED TO NORMAL. THE RIGHT FLOW CONTROL VALVE WAS FOUND FAILED AND THE LEFT AND RIGHT FLOW CONTROL VALVES WERE REMOVED AND REPLACED. TROUBLESHOOTING ALSO FOUND FAULT WITH RELAYS R580, R588 AND THE AIR MANIFOLD RELIEF VALVES WERE REMOVED AND REPLACED.

Part: CONTROL PANEL — FAILED (CABIN PRESSURE) · airframe 62,794 hrs · 24,716 cycles

DURING CRUISE THE AIRCRAFT WAS UNABLE TO HOLD CABIN PRESSURE AT ALTITUDES ABOVE 10,000. REMOVED AND REPLACED THE R/L FLOW CONTROL VALVES. REMOVED AND REPLACED PRESSURE CONTROL PANEL, CHECKED ALL PRESSURE RELIEF VALVES FOR PROPER OPERATION. THE AIRCRAFT PRESSURIZED ON THE GROUND TO 8 PSI DIFFERENTIAL.

Part: VALVE — INOPERATIVE (CABIN PRESSURE) · airframe 62,599 hrs · 24,630 cycles

DURING CLIMBOUT FROM DTW, THE ALTITUDE WARNING HORN ACTIVATED AT 23,500 MSL. THE CREW INITIATED A DESCENT AND COMPLIED WITH EMERGENCY, AND COM CHECKLISTS. RETURNED TO POINT OF ORIGIN (DTW). REMOVED AND REPLACED THE RIGHT SAFETY VALVE, OPERATIONAL CHECK NOT REQUIRED DUE TO PART IS AN OVERHAULED PART.

Part: FIRE LOOP — CHAFED (NR 1 ENGINE) · airframe 62,594 hrs · 24,627 cycles

THE NUMBER ONE FIRE LIGHT AND BELL RANG MOMENTARILY AFTER LANDING. THE NUMBER ONE FIRE LOOP WAS FOUND CHAFING. REPOSITIONED FIRE LOOP. HIGH POWER ENGINE RUNS ACCOMPLISHED, REVERSE THRUST CYCLED. NUMBER ONE FIRE WARNING SYSTEM OPERATIONAL CHECKS OK IAW 261000.

Part: VALVE — INOPERATIVE (LT A/C PACK) · airframe 62,538 hrs · 24,602 cycles

DURING CLIMBOUT, THE LEFT MIX VALVE IN BOTH MANUAL AND AUTO, PACK TEMPERATURE STUCK AT 40 DEGREES. CABIN COULD NOT HOLD PRESSURE BELOW 10,000 FT WITH ONLY RIGHT PACK OPERATING IN AUTO OR STANDBY. THE CREW ELECTED TO RETURN TO POINT OF ORIGIN. REMOVED AND REPLACED THE LEFT PACK VALVE, PACK OPERATIONAL CHECKS NORMAL, LEAK CHECKS GOOD.

Part: FLOW VALVE — INTERMITTENT (CABIN PRESSURE) · airframe 62,438 hrs · 24,556 cycles

DURING CLIMB OUT FROM MSP, THE AIRCRAFT WAS SLOW TO PRESSURIZE. THE CREW CLOSED THE OUTFLOW VALVE, SOME HELP, ALL SWITCHES AND C/B''S NORMAL. CABIN ALTITUDE WOULD NOT LEVEL OFF. OUTFLOW VALVE INDICATION FULLY CLOSED. THE CREW RETURNED TO POINT OF ORIGIN. THE RIGHT FLOW CONTROL VALVE WAS FOUND TO BE INTERMITTANT. REMOVED AND REPLACED RIGHT FLOW CONTROL VALVE. OPERATIONAL CHECKS NORMAL.

Part: BATTERY PACK — INOPERATIVE (RT OVERWING) · airframe 62,344 hrs · 24,516 cycles

DURING A MAINTENANCE LINE CHECK, THE RT OVERWING EMERGENCY EXIT SIGN WAS FOUND INOPERATIVE.REMOVED AND REPLACED THE RIGHT BATTERY PACK FOR THE RIGHT OVERWING EMERGENCY EXIT SIGN, OPERATIONALLY CHECKED NORMAL.

Part: FUEL CONTROL — FAILED (NR 2 ENGINE) · airframe 62,331 hrs · 24,510 cycles

DURING THE TAKEOFF ROLL AT LAS, THE NUMBER TWO ENGINE WOULD NOT DEVELOP POWER ABOVE APPROXIMATELY IDLE POWER. THE TAKEOFF WAS ABORTED AT 60 KNOTS, RETURNED TO GATE. REMOVED AND REPLACED ENGINE NUMBER TWO FUEL PUMP AND FUEL CONTROL UNIT. OPERATIONAL AND LEAK CHECK GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 62,307 hrs · 24,500 cycles

DURING A MAINTENANCE LINE CHECK THE RED LIGHT IN THE EMERGENCY FLOOR TRACK LIGHTING AT SEAT ROW 18 ABC WAS FOUND INOPERATIVE. RE-WIRED NEW PIGTAIL INTO THE EMERGENCY FLOOR TRACK LIGHTING AT SEAT ROW 18 ABC.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 62,307 hrs · 24,500 cycles

DURING A MAINTENANCE LINE CHECK THE RED LIGHT IN THE EMERGENCY FLOOR TRACK LIGHTING AT SEAT ROW 30 DEF WAS FOUND INOPERATIVE. RE-WIRED NEW PIGTAIL INTO EMERGENCY FLOOR TRACK LIGHTING AT SEAT ROW 30 DEF.

Part: DUCT — LOOSE (AFT BODY) · airframe 62,298 hrs · 24,496 cycles

AFTER A HEAVY MAINTENANCE CHECK, DURING THE ACCEPTANCE FLIGHT, THE LOWER AFT BODY OVERHEAT LIGHT ILLUMINATED DURING CLIMB. THE AIRCRAFT COULD NOT MAINTAIN THE CABIN WITH ONE PACK. THE MAX AIRCRAFT ALTITUDE 19,000 FT AND THE MAX CABIN ALTITUDE 7,000 FT. REMOVED AND REPLACED THE NUMBER TWO BLEED DUCT AND CLAMPS. LEAK CHECKED GOOD, THE A/C PACKS OPERATIONALLY CHECKED GOOD.

Part: BATTERY — INOPERATIVE (CABIN) · airframe 62,077 hrs · 24,402 cycles

DURING A MAINTENANCE LINE CHECK THE EMERGENCY EXIT LIGHT AT THE AFT ENTRY DOOR WAS FOUND INOPERATIVE. THE BATTERIES AT THE AFT ENTRY DOOR WERE FOUND INOPERATIVE, AND WERE REMOVED AND REPLACED.

Part: BATTERY PACK — INOPERATIVE (CABIN)

DURING A LINE MAINTENANCE CHECK THE EXIT SIGN ABOVE THE R2 DOOR WAS FOUND INOPERATIVE WITH THE EMERGENCY LIGHTS ON. REMOVED AND REPLACED THE BATTERY PACK, OPERATIONALLY CHECKED NORMAL IAW 335071.

Part: LIGHT — INOPERATIVE (CABIN)

DURING A LINE MAINTENANCE CHECK, THE CENTER AISLE EMERGENCY LIGHT AT THE R2 DOOR WAS FOUND INTERMITTENT. REPINNED THE PIN 2 ON LIGHT ASSEMBLY L1023B. OPERATIONALLY CHECKS GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING A LINE MAINTENANCE CHECK, THE EMERGENCY EXIT SIGN ABOVE THE R2 DOOR WAS FOUND NOT ILLUMINATING. REMOVED AND REPLACED THE BATTERY PACK FOR THE EMERGENCY EXIT SIGN ABOVE THE R2 DOOR. OPERATIONALLY CHECKS GOOD.

Part: CONTROLLER — FAILED (CABIN PRESSURE)

DURING CLIMB, UNABLE TO CONTROL THE CABIN ALTITUDE. LEAK CHECKED AIR CONDITIONING SYSTEM, NO LEAKS NOTED. PRESSURIZED AIRCRAFT TO 3.0 PSI AND NO LEAKS NOTED. REMOVED AND REPLACED CABIN PRESSURE CONTROLLER PER MM 21310. SYSTEM OPERATIONALLY CHECKS NORMAL.

Part: EMER EXIT LIGHT — INOPERATIVE (R2 EXIT DOOR)

DURING A SCHEDULED MAINTENANCE CHECK, A FUNCTIONAL TEST OF THE EMERGENCY LIGHTS REVEALED THE AFT RIGHT R2 CABIN DOOR EXIT SIGN DID NOT ILLUMINATE. FOUND A BENT PIN ON BATTERY PACK CONNECTOR. STRAIGHTENED PIN AND LIGHT OPERATIONALLY CHECKS GOOD PER MM 335071.

Part: BATTERY PACK — INOPERATIVE (AFT ENTRY SIGN)

DURING A SCHEDULED MAINTENANCE CHECK, A FUNCTIONAL TEST OF THE EMERGENCY LIGHTS REVEALED THE AFT ENTRY DOOR CEILING EXIT SIGN LIGHT TO BE INOPERATIVE. REMOVED AND REPLACED THE BATTERY PACK. OPERATIONALLY CHECKS GOOD REF MM 335071.

Part: VALVE — INOP (EQUIP COOLING)

DURING CLIMB, THE CABIN PRESSURIZATION CONTINUED TO CLIMB BEYOND CABIN ALTITUDE SET. UNABLE TO CONTROL RATE OF CLIMB IN AUTO, STANDBY OR MANUAL MODES. REMOVED AND REPLACED THE FLOW CONTROL VALVE EQUIPMENT COOLING PER MM 215821. CABIN PRESSURIZATION CONTROL SYSTEM TESTED NORMAL PER 21310.

Part: LIGHT — INOP (ROW 17ABC)

DURING A LINE MAINTENANCE CHECK, THE EMERGENCY TRACK LIGHTING AT SEAT 17 ABC WAS FOUND WITH TWO LIGHTS INOPERATIVE. REMOVED AND REPLACED TWO EMERGENCY LIGHTS AT SEAT 17 ABC, OPERATIONALLY CHECKED GOOD.

Part: DOORS — LEAKING (CARGO COMPT)

UNABLE TO CONTROL CABIN PRESSURE DURING CLIMB. STOPPED ASCENT THEN BEGAN DESCENT TO MAINTAIN CABIN ALTITUDE BELOW 10,000 FEET. CABIN CONTROLLER DIDN'T HAVE ANY EFFECT IN AUTO, STANDBY OR MANUAL MODES. AIRCRAFT DOORS WERE LEAK CHECKED AND FOUND OVERWING EMERGENCY EXITS AND FORWARD AND AFT CARGO DOORS LEAKING. ALSO, FOUND SUPPLY DUCT GASPER FAN DUCT LEAKING. CORRECTED ALL LEAKS AND PRESSURIZED AIRCRAFT. NO LEAKS NOTED AND AIRCRAFT TEST FLOWN TO OPERATIONALLY CHECK SYSTEM.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING A LINE MAINTENANCE CHECK, THE FWD CENTER AISLE OVERHEAD EMERGENCY LIGHT WAS FOUND INOPERATIVE. REMOVED AND REPLACED BATTERY PACK. LIGHT OPERATIONALLY CHECKED GOOD REF MM 335071.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING HEAVY MAINTENANCE CHECK, AFT SECTION OF FORWARD LEFT ESCAPE PATH LIGHTING WAS FOUND INOPERATIVE. REMOVED AND REPLACED LIGHT BATTERY PACK AND CHARGER ASSEMBLY IAW B727 MM 335051. OPS CHECK GOOD IAW B727 MM 335001.

Part: FRAME — CORRODED (BS 280)

DURING HEAVY MAINTENANCE CHECK, CORROSION WAS FOUND OUT OF LIMITS AT STA 280 LEFT HAND AT STR 27L AFT SIDE OF LWR FRAME T IAW B727 SRM 531001. REMOVED T CHORD IAW B727 SRM 513002. TRANSFERRED FASTENER LOCATIONS TO NEW T CHORD IAW SRM 511001. FABRICATED STRINGER SPLICE IAW B727 SRM 531003 FROM BAC 1498124 FOR STRINGER 25L. TREATED AND PRIMED IAW B727 SRM 511002. INSTALLED SPLICE IAW B727 SRM 513002. FABRICATED SPLICES FOR STR 26L IAW SRM 514004 FROM BAC 14902734. TREATED AND PRIMED SPLICE IAW SRM 511002 MM 512002. INSTALLED PER B727 SRM 513002. INSTALLED NEW T 6516312145 IAW 513002 AND 511002 SRM B727.

Part: RIB — CORRODED (RT WING)

DURING HEAVY MAINTENANCE CHECK, THE RIGHT WING LEADING EDGE CAVITY AT FSS 605, RIB HAS CORROSION AT ADELL CLAMP ATTACH POINT. REMOVED LEADING EDGE RIB IAW B727 SRM 513002. CORROSION WAS FOUND OUT OF LIMITS IAW SRM B727 571001. FABRICATED NEW RIB PER SAMPLE FROM 2024 T3 .050. TREATED AND PRIMED IAW SRM B727 511002 AND MM 512002. INSTALLED IAW SRM B727 513002.

Part: SIGN — FAILED TEST (LT EMER EXIT)

DURING HEAVY MAINTENANCE CHECK, THE LEFT HAND AFT OVERWING EXIT EMERGENCY AND PULL SELF LUMINOUS EXIT SIGNS FAILED INTENSITY INSPECTION. REMOVED AND REPLACED LEFT HAND AFT OVERWING EMER EXIT AND PULL SELF LUMINOUS EXIT SIGNS IAW MM 335031.

Part: SIGN — FAILED TEST (LT EMER EXIT)

DURING HEAVY MAINTENANCE CHECK, THE LEFT HAND FWD OVERWING EXIT EMERGENCY AND PULL SELF LUMINOUS EXIT SIGNS FAILED INTENSITY INSPECTION. REMOVED AND REPLACED LEFT HAND FWD OVERWING EXIT EMERGENCY AND PULL SELF LUMINOUS EXIT SIGNS IAW MM 335031.

Part: SIGN — FAILED TEST (RT EMER EXIT)

DURING HEAVY MAINTENANCE CHECK, THE RIGHT HAND FWD OVERWING EXIT PULL SELF LUMINOUS EXIT SIGN FAILED INTENSITY INSPECTION. REMOVED AND REPLACED RIGHT HAND FWD OVERWING EMER EXIT PULL SELF LUMINOUS EXIT SIGN IAW MM 335031.

Part: SIGN — FAILED TEST (RT EMER EXIT)

DURING HEAVY MAINTENANCE CHECK, THE RIGHT HAND AFT OVERWING EXIT EMERGENCY AND PULL SELF LUMINOUS EXIT SIGNS FAILED INTENSITY INSPECTION. REMOVED AND REPLACED RIGHT HAND AFT OVERWING EXIT EMERGENCY AND PULL SELF LUMINOUS EXIT SIGNS IAW MM 335031.

Part: SUPPORT — CORRODED (BS 294)

DURING HEAVY MAINTENANCE CHECK, CORROSION WAS FOUND OUT OF LIMITS IN THE LOWER NOSE COMPARTMENT STA 294 STR 28R, INSIDE RT FORWARD NOSE LANDING GEAR WALKWAY, FRAME SUPPORT ANGLE ON THE UPPER SURFACE IAW B727 SRM 531001. REMOVED FRAME FORMER IAW B727 SRM 513002. REMOVED CORROSION IAW B727 SRM 511006. CUT STRINGERS 25R AND 26R TO FACILITATE INSTALLATION. FABRICATED STRINGER SPLICE IAW B727 SRM 531003 FROM BAC 1498124 FOR STRINGER 25R. TREATED AND PRIMED IAW B727 SRM 511002. INSTALLED SPLICE IAW B727 SRM 513002. FAB SPLICES FOR STR 26R FROM BAC 14902734 IAW SRM 514004. TREATED AND PRIMED SPLICE IAW B727 SRM 511002, MM 512002. INSTALLED NEW T 6516312146 IAW SRM 513002 AND 511013.

Part: ANGLE — CORRODED (BS 330)

DURING HEAVY MAINTENANCE CHECK, CORROSION WAS FOUND OUT OF LIMITS IN THE LOWER NOSE COMPARTMENT STA 330 S28L, INSIDE LT NOSE LANDING GEAR WALKWAY, FRAME SUPPORT ANGLE PER B727 SRM 531001. REMOVED T CHORD IAW B727 SRM 513002. FIT AND TRANSFERRED HOLES TO NEW CHORD PART NUMBER 65198617. INSTALLED NEW T CHORD IAW B727 SRM 511001 AND 513002.

Part: SPAR — CORRODED (LT HORZ STAB)

DURING HEAVY MAINTENANCE CHECK, CORROSION WAS FOUND OUT OF LIMITS AT THE AFT UPPER SPAR CHORD OF THE LEFT HORIZONTAL STABILIZER IAW B727 SRM 571001 FIG 2. FABRICATED NEW CHORD FROM 2024 T3511 PER SAMPLE. FABRICATED REPAIR ANGLES AND STRAPS FROM 101381203 7075 T6511 .063 7075 T6 IAW B727 SRM 551005. TREATED AND PRIMED IAW B727 SRM 511002 AND MM 512002. INSTALLED IAW B727 SRM 551005 AND 513002.

Part: BATTERY PACK — DISCHARGED (R2 DOOR)

DURING A LINE MAINTENANCE CHECK, THE R2 OVERHEAD EMERGENCY LIGHT WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED THE R2 OVERHEAD EMERGENCY LIGHT BATTERY PACK. LIGHT OPERATIONALLY CHECKS GOOD IAW MM 335071.

Part: BATTERY CHARGER — INOPERATIVE (CARGO DOOR)

DURING A LINE MAINTENANCE CHECK, THE EMERGENCY LIGHT ON THE AFT CARGO DOOR WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED THE BATTERY CHARGER M957. SYSTEM OPERATIONALLY CHECKS NORMAL.

Part: WARNING — SOUNDED (COCKPIT)

DURING START OF TAKEOFF ROLL, THE TAKEOFF WARNING SOUNDED WITH POWER SET ABOVE 1.4 EPR. FLAPS, TRIM AND SPEED BRAKES AT SET IN OPERATING/TAKEOFF SETTINGS. RETURNED AIRCRAFT TO GATE. RESET TAKEOFF WARNING CIRCUIT BREAKERS, MOVED STABILIZER TRIM ALL THE WAY UP AND ALL THE WAY DOWN, RECYCLED FLAPS UP AND DOWN, CHECKED EPR TEST CARDS AND ALL CHECKED GOOD.

Part: SWITCH — INOP (HORIZ STAB)

DURING TAKEOFF ROLL, THE TAKEOFF WARNING HORN SOUNDED WHEN ENGINES NR 1 AND NR 3 REACHED 1.4 EPR. ABORTED TAKEOFF AND RETURNED AIRCRAFT TO THE RAMP. REMOVED AND REPLACED THE STABILIZER UPPER TAKEOFF WARNING SWITCH S532 IAW MM 312624. OPERATIONALLY CHECKS GOOD.

Part: BATTERY — DISCHARGED (R2 DOOR)

DURING A LINE MAINTENANCE CHECK, THE EMERGENCY LIGHT ABOVE THE R2 DOOR WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED THE BATTERY M1093, SYSTEM OPERATIONALLY CHECKS NORMAL.

Part: SWITCH — FROZEN (HORIZ STABILIZER)

DURING TAKEOFF ROLL, THE TAKEOFF WARNING HORN SOUNDED. ABORTED TAKEOFF. FOUND THE STABILIZER POSITION SWITCH S532 FROZEN. DEICED THE SWITCH AND CLEANED. PERFORMED A TAKEOFF WARNING SYSTEM CHECK WITH NO FAULTS NOTED. ALL SYSTEMS CHECK NORMAL AND OK FOR SERVICE.

Part: VALVE — MALFUNCTIONED (NR 2)

AT LEVEL OFF AT 31,000 FEET, NOTICED TANKS 1 AND 3 WERE DECREASING BETWEEN 9,000 AND 10,000 POUNDS EACH. TANKS 1 AND 3 CONTINUED TO DECREASE CREATING A FUEL LIMITATION PROBLEM WITH THE BOOST PUMP ON TANKS 1 AND 3 ON OR OFF. UNABLE TO STOP IMBALANCE SO ELECTED TO RETURN TO MSP. DUMPED FUEL FOR LANDING LIMITATIONS. FOUND NUMBER TWO FUEL MANIFOLD CROSSFEED VALVE INTERMITTENT. REMOVED AND REPLACED NUMBER TWO CROSSFEED VALVE PER 727 MAINTENANCE MANUAL 282211. OPERATIONALLY CHECKED GOOD.

Part: BULB — FAILED (RT OVERWING)

DURING A LINE MAINTENANCE CHECK, THE RIGHT FORWARD OVERWING EMERGENCY LIGHTS WERE INOPERATIVE. RELAMPED THE LIGHT ASSEMBLY, OPERATIONALLY CHECKS GOOD.

Part: BATTERY PACK — DISCHARGED (R2 DOOR)

DURING A LINE MAINTENANCE CHECK, THE EMERGENCY LIGHT ABOVE THE R2 DOOR WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED THE BATTERY PACK. LIGHT OPERATIONALLY CHECKS GOOD REFERENCE MM 335071.

Part: RT UNIT — FAILED (FWD FUSELAGE)

DURING CLIMB, THE RADAR LOST PICTURE. PICTURE CAME BACK FIVE MINUTES PRIOR TO LANDING. DIVERTED AIRCRAFT TO IAH. REMOVED AND REPLACED THE RADAR RECEIVER/TRANSMITTER. RADAR SYSTEM OPERATIONALLY CHECKS GOOD IAW MM 340000.

Part: INDICATOR — FAILED (LT COCKPIT)

ON CLIMBOUT, CAPTAIN'S AIRSPEED INDICATOR FAILED. RETURNED TO MSP FOR CHANGE. REMOVED AND REPLACED CAPTAIN'S AIRSPEED INDICATOR IAW MM 341221. OPERATIONALLY CHECKED NORMAL IAW MM 34120.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING A LINE MAINTENANCE CHECK, RIGHT AFT OVERWING EMERGENCY EXIT LIGHT WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED THE BATTERY PACK FOR THE LIGHT. OPERATIONALLY CHECKS GOOD PER MAINTENANCE MANUAL 335022.

Part: FIRE BELL — INOPERATIVE (COCKPIT)

DURING A LINE MAINTENANCE CHECK, THE FIRE WARNING BELL IN THE COCKPIT WAS FOUND TO BE INOPERATIVE DURING A FIRE TEST. REMOVED AND REPLACED THE ENGINE FIRE DETECTION UNIT. OPERATIONALLY CHECKS GOOD PER MAINTENANCE MANUAL CHAPTER 261101.

Part: DOOR — OPEN (CABIN)

AFTER TAKEOFF, THE AIRCRAFT WOULD NOT PRESSURIZE. FOUND THE R1 DOOR TOP CORNER NOT LATCHED PROPERLY. RECLOSED DOOR AND PERFORMED OPERATIONAL CHECK OF DOOR AND PRESSURIZATION. OPERATIONALLY CHECKED GOOD IN ACCORDANCE WITH MAINTENANCE MANUAL 2100 AND 5200.

Part: MODULATING VALVE — FAILED (NR 1 ENGINE)

THE NUMBER ONE ENGINE STRUT OVERHEAT LIGHT ILLUMINATED. LIGHT EXTINGUISHED FOLLOWING COM PROCEDURES AND AIRCRAFT DIVERTED TO ATL. THE NUMBER ONE ENGINE PYLON INSPECTED FOR LEAKS WITH NONE FOUND. BLEED VALVE AT 13TH STAGE FOUND CLOSED. REMOVED AND REPLACED NUMBER ONE ENGINE 13TH STAGE MODULATING VALVE, OPERATIONAL AND LEAK CHECK GOOD IN ACCORDANCE WITH MAINTENANCE MANUAL 361242.

Part: FRAME — CRACKED (BS 303.9)

DURING A HEAVY MAINT CHECK, A CRACK 3 INCHES LONG RUNNING FORE TO AFT WAS FOUND IN THE MAIN CABIN FLOORBOARD FRAME AT STA 303.9 LBL 55. MATERIAL WAS VERIFIED AS 7075 T6 .040. FABED FLOORBOARD FRAME PER SRM 512002. TREATED PER SRM 511002, PRIMED PER MM 512000, INSTALLED.

Part: SUPPORT — CRACKED (BS 303.9)

DURING A HEAVY MAINT CHECK, A CRACK 4 INCHES LONG WAS FOUND ON THE FLOOR SUPPORT WEB IN THE UPPER ANGLE RADIUS IN THE MAIN CABIN FLOOR STRUCTURE AT STATION 303.9 LBL 41. NDT VERIFIED CRACK IAW BOEING NDT MANUAL D6 48875 510000. MATERIAL VERIFIED AS 7075 T6 .032. FABRICATED REPAIR ANGLE IAW SRM 514003. TREATED AND PRIMED ANGLE PER SRM 511002. INSTALLED PER SRM 514002 AND MM 512000.

Part: OVERHEAT LIGHT — ILLUMINATED (AFT BODY)

LOWER AFT BODY OVERHEAT LIGHT ILLUMINATED AT FL370. SHUT OFF NUMBER ONE BLEED VALVE AND LEFT PACK. COULD NOT HOLD PRESSURIZATION SO THE NUMBER ONE BLEED VALVE AND PACK TURNED BACK ON AND A DESCENT INITIATED DOWN TO FL250. DURING THE DESCENT THE LOWER AFT OVERHEAT LIGHT EXTINGUISHED. PERFORMED MEG CHECK OF ENGINE FIRE LOOPS WITH NO TROUBLE FOUND. KEEL BEAM AND AFT PIT PANELS CHECKED FOR LEAKS AT TAKEOFF AND PART POWER WITH NO DISCREPANCIES NOTED. LEFT AND RIGHT PACK OPERATED NORMALLY WITH NO DISCREPANCIES NOTED. FUNCTIONALLY TESTED GOOD.

Part: ANTI-ICE VALVE — LEAKING (NR 2 ENGINE COWL)

ON DESCENT, TURNED ON ENGINE ANTI-ICE AND APPROXIMATELY TWO MINUTES LATER GOT ENGINE NUMBER TWO FIRE WARNING. SHUT DOWN NUMBER TWO ENGINE AND BLEW BOTH FIRE BOTTLES. FOUND NUMBER TWO COWL ANTI-ICE VALVE LEAKING. REMOVED AND REPLACED NUMBER TWO COWL ANTI-ICE VALVE AND BOTH ENGINE FIRE BOTTLES AND SQUIBS.

Part: HOSES — FAILED (B-HYD SYSTEM)

B-SYSTEM FLIGHT CONTROL AND BOTH B-PUMP LOW PRESSURE LIGHTS CAME ON THEN SLOWLY LOST QUANTITY. DIVERTED TO DENVER. REMOVED AND REPLACED TWO HYDRAULIC HOSES IN B-SYSTEM BAY AND CHANGED FILTERS. SERVICED HYDRAULIC SYSTEM AND FUNCTIONAL CHECK GOOD.

Part: ALERT PANEL — INOPERATIVE (RT COCKPIT)

DURING CRUISE FLIGHT, ALL MASTER AND WARNING LIGHTS ILLUMINATED. DIVERTED AIRCRAFT TO MCO. REMOVED AND REPLACED ALTITUDE ALERT PANEL AND FUNCTIONAL CHECK GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

THE FORWARD FLOOR TRACK LIGHT WERE FOUND TO BE INOPERATIVE. REMOVED AND REPLACED FORWARD TRACK EMERGENCY LIGHTS BATTERY PACK IAW B727 MM 33-50-51, LIGHTS CHECKED GOOD.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY EXIT SIGN FOUND INOPERATIVE AT R-2 DOOR. REMOVED AND REPLACED EMERGENCY EXIT BATTERY PACK, LIGHT CHECKED GOOD.

Part: FITTING — CRACKED (LT MLG UPLOCK)

DURING SCHEDULED INSPECTION, FOUND THE LEFT MAIN LANDING GEAR UPLOCK SUPPORT FITTING CRACKED AT THE LOWER FORWARD LUG. REMOVED AND REPLACED FITTING PER SUN COUNTRY EA 53-7398.

Part: LAMP — FAILED (CABIN)

THE EXTERNAL EMERGENCY EXIT LIGHT AFT OF THE 2R DOOR WAS FOUND INOP. REMOVED AND REPLACED LAMP AND FUNCTIONALLY TESTED.

Part: LIGHT — INOPERATIVE (CABIN)

THE CEILING MOUNTED EMERGENCY AREA LIGHT AT OVERHEAD CEILING PANEL 24ABC WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED AREA LIGHT, OPS CHECKED NORMAL.

Part: LIGHT — FAILED (AIRSTAIR)

THE AFT AIRSTAIR OVERHEAD EMERGENCY LIGHT WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED LIGHT ASSEMBLY, LIGHT OPS CHECKED GOOD IAW B727 MM 33-50-01.

Part: BATTERY PACK — DISCHARGED (CABIN)

THE FORWARD CABIN TRACK LIGHTS WERE FOUND TO BE INOPERATIVE. REMOVED AND REPLACED BATTERY PACK, LIGHT CHECKED GOOD.

Part: FRAME — CRACKED (BS 760)

DURING HEAVY MAINTENANCE VISIT, THE RIGHT PORTION OF THE 760 FRAME REQUIRED REPAIR IAW BOEING INSTRUCTIONS AND REPAIR KIT 65C33202-94. INCORPORATED REPAIR IAW BOEING INSTRUCTIONS AND VIA ENGINEERING ORDER.

Part: SEAT TRACK — CORRODED (COCKPIT)

DURING HEAVY MAINTENANCE VISIT, FOUND CORROSION AND GOUGES ON THE FLIGHT ENGINEERS CENTER AND AFT SEAT TRACKS. REMOVED AND REPLACED SEAT TRACK IAW B727 MM 53-40-00.

Part: SUPPORT — CORRODED (BS 395)

DURING HEAVY MAINTENANCE VISIT, FOUND CORRODED FLOOR SUPPORT AT STATION 395, LBL 12.09. REMOVED, FABRICATED AND INSTALLED NEW ANGLE IAW B727 SRM 51-10-2, 51-10-6, 51-30-1, AND 51-40-3.

Part: SUPPORT — CORRODED (BS 328-344)

DURING HEAVY MAINTENANCE VISIT, THE FLOOR SUPPORT U ANGLE CHANNEL WAS FOUND WITH ELONGATED FASTENER HOLES WITH CORROSION PRESENT. REMOVED, FABRICATED AND INSTALLED NEW SUPPORT IAW B727 SRM 51-10-6, 51-40-4, 53-10-1 AND MM 51-20-11.

Part: BRACKET — CORRODED (BS 1166)

DURING HEAVY MAINTENANCE VISIT, THE TENSION TIE SUPPORT ROD ATTACH BRACKET MOUNTED TO THE AFT SIDE OF STATION 1166 FRAME BETWEEN STRINGER 27L AND 28L WAS FOUND WITH EXFOLIATED CORROSION. REMOVED CORRODED BRACKET, FABRICATED AND INSTALLED NEW BRACKET IAW B727 SRM 51-402, 51-30-2 AND MM 51-20-11.

Part: SEAT TRACK — CORRODED (BS 370)

DURING HEAVY MAINTENANCE VISIT, FOUND CORROSION ON FLOORBEAM AT STATION 950F BETWEEN STRINGERS 27 AND 28 LEFT. CUT OUT CORRODED SECTION OF FRAME, FABRICATED AND INSTALLED FILLER AND DOUBLER IAW B727 SRM 53-10-3, 53-10-4, AND 51-30-2.

Part: SUPPORT — CORRODED (BS 303)

DURING HEAVY MAINTENANCE VISIT, THE FLOOR SUPPORT ANGLE AT STATION 303 RBL 44 WAS FOUND CORRODED. REMOVED, FABRICATED, AND INSTALLED NEW ANGLE IAW B727 SRM 51-40-3, 51-10-2, 51-30-2, AND MM 51-20-11.

Part: SUB FLOOR — CORRODED (BS 312)

DURING HEAVY MAINTENANCE VISIT, THE UNDER FLOOR PANEL FOR THE RIGHT FORWARD LAV WAS FOUND CORRODED BEYOND LIMITS AT STATION 312, RBL 44. REMOVED, FABRICATED, AND INSTALLED NEW SUB FLOOR IAW B727 SRM 51-30-2, 53-10-10, AND MM 51-20-11.

Part: SUPPORT — CORRODED (BS 324-348)

DURING HEAVY MAINTENANCE VISIT, THE FLOOR SUPPORT EXTRUSION WAS FOUND CORRODED AT STATION 324-348, RBL 42. REMOVED, FABRICATED, AND INSTALLED NEW SUPPORT IAW B727 SRM 51-30-2 AND 51-40-3.

Part: ANGLE — CORRDED (BS 312)

DURING HEAVY MAINTENANCE VISIT, THE FLOOR SUPPORT EXTRUSION WAS FOUND CORRODED AT STATION 312 RBL 34. REMOVED, FABRICATED, AND INSTALLED NEW ANGLE IAW B727 SRM 53-10-1, 51-10-6, 51-10-2, 51-30-2.

Part: STRINGER — CORRODED (BS 344)

DURING HEAVY MAINTENANCE VISIT, STRINGER 21R WAS FOUND WITH EXCESSIVE CORROSION ON THE END WHERE IT TERMINATES AFT OF FUSELAGE FRAME 344. REMOVED CORRODED SECTION, FABRICATED AND INSTALLED REPAIR SPLICE AND FILLERS IAW B727 SRM 51-30-2, 53-10-3 FIGURE 1 DETAIL 2.

Part: STIFFENER — CORRODED (BS 303-312)

DURING HEAVY MAINTENANCE VISIT, FOUND THE FLOORING UNDER THE RIGHT FORWARD LAV CORRODED FROM STATION 303 TO 312, RBL 45. REMOVED CORRODED STIFFENER, FABRICATED AND INSTALLED NEW STIFFENER IAW B727 SRM 53-10-2, 53-10-1, 51-40-3, 51-30-2, AND MM 51-20-11.

Part: FRAME — CORRODED (BS 72O)

DURING HEAVY MAINTENANCE VISIT, THE FORWARD CARGO COMPARTMENT FRAME AT STATION 720E BETWEEN STRINGERS 27 AND 28 LEFT WAS FOUND WITH CORROSION. REMOVED CORROSION, FOUND TO BE OUT OF LIMITS, FABRICATED AND INSTALLED REPAIR ANGLE IAW B727 SRM 53-10-4, 51-40-2 AND MM 51-20-11.

Part: SUPPORT — CORRODED (BS 1138)

DURING HEAVY MAINTENANCE VISIT CORROSION WAS FOUND ON THE FLOOR SUPPORT AT STATION 1138, LBL 0 TO 15. REMOVED, FABRICATED, AND INSTALLED NEW FLOOR SUPPORT IAW B727 SRM 51-40-4, 51-30-2, AND MM 51-20-11.

Part: ANGLE — CORRODED (E EXIT DOORWAY)

DURING HEAVY MAINTENANCE VISIT, THE RIGHT FORWARD EMERGENCY EXIT HATCH HAS TWO CORRODED ANGLES. REMOVED, FABRICATED, AND INSTALLED NEW ANGLES IAW B727 SRM 51-10-2, 51-10-6, 51-20-01, 51-30-2 AND 51-30-8.

Part: ANGLE — CORRODED (E EXIT DOORWAY)

DURING HEAVY MAINTENANCE VISIT, FOUND CORRODED BOTTOM WEB AND RETAINER ANGLES ON THE LEFT AFT EMERGENCY EXIT HATCH. REMOVED CORROSION ON WEB AND FOUND TO BE WITHIN LIMITS, REPLACED BOTH RETAINER ANGLES.

Part: ANGLE — CORRODED (E EXIT DOORWAY)

DURING HEAVY MAINTENANCE VISIT, FOUND CORROSION ON THE BOTTOM WEB AND RETAINER ANGLE FOR THE LEFT FORWARD EMERGENCY EXIT HATCH. CORROSION REMOVAL ON WEB WAS WITHIN LIMITS, BUT REMOVED AND REPLACED RETAINER ANGLE IAW B727 SRM 51-10-2, 51-10-6, AND 51-30-2.

Part: SUPPORT — CORRODED (BS 380)

DURING HEAVY MAINTENANCE VISIT, FLOOR SUPPORT AT STATION 380, RBL 12.09 WAS FOUND CORRODED. REMOVED, FABRICATED, AND INSTALLED NEW SUPPORT IAW B727 SRM 51-40-4, 51-10-2, AND MM 51-20-11.

Part: HAT SECTION — CORRODED (BS 1138)

DURING HEAVY MAINTENANCE VISIT, CORROSION WAS FOUND ON HAT SECTION AT STATION 1138 RBL 42 TO RBL 60. FABRICATED AND INSTALLED NEW HAT SECTION IAW B727 SRM 51-40-3.

Part: FLOOR BEAM — CORRODED (BS 380)

DURING HEAVY MAINTENANCE VISIT, FLOORBEAM AT STATION 380, RBL 10 TO RBL 24 WAS FOUND CORRODED ON THE UPPER PORTION. REMOVED ALL CORROSION, FABRICATED AND INSTALLED REPAIR ANGLES IAW B727 SRM 53-10-8, 51-30-2, 51-10-06, AND MM 51-20-31.

Part: SEAT TRACK — CORRODED (BS 1025-1090)

DURING HEAVY MAINTENANCE VISIT, THE SEAT TRACK BETWEEN STATIONS 1025 TO 1090, LBL 46 TO 47, WAS FOUND CORRODED. REMOVED, FABRICATED, AND INSTALLED NEW SEAT TRACK IAW B727 SRM 53-10-02 AND 53-10-03.

Part: SEAT TRACK — CORRODED (BS 1070-1130)

DURING HEAVY MAINTENANCE VISIT, SEAT TRACK AT THE FOLLOWING LOCATIONS WERE FOUND CORRODED: STATION 1070 TO 1130 LBL 56, STATION 1070 LBL 25, AND STATION 1110 TO 1130 LBL 46. REMOVED, FABRICATED, AND INSTALLED NEW SEAT TRACK IAW B727 SRM 51-20-2, 51-30-2, AND MM 51-20-11.

Part: SEAT TRACK — CORRODED (BS 370)

DURING HEAVY MAINTENANCE VISIT, FOUND CORRODED SEAT TRACK AT STATION 370, LBL 42.8. REMOVED, FABRICATED, AND INSTALLED NEW SEAT TRACK IAW B727 SRM 53-10-1, 51-30-2, AND MM 51-20-11.

Part: FLOORBEAM — CORRODED (BS 344)

DURING HEAVY MAINTENANCE VISIT, THE FLOORBEAM AT STATION 344 FROM ENTRY DOOR TO RBL 20 WAS FOUND WITH SURFACE CORROSION. REMOVED CORRODED T CAP, FABRICATED, AND INSTALLED NEW CAP IAW B727 SRM 53-10-1 AND 53-10-8.

Part: FLOORBEAM — CORRODED (BS 1110)

DURING HEAVY MAINTENANCE VISIT, CORROSION WAS FOUND ON THE FLOORBEAM AT STATION 1110, RBL 10. CUT-OUT CORROSION, FABRICATED, AND INSTALLED REPAIR ANGLES AND STRAPS PER B727 SRM 53-10-8 FIGURE 3.

Part: ANGLE — WORN (BS 1070)

DURING HEAVY MAINTENANCE VISIT, FLOOR SUPPORT ANGLE AT STATION 1070, LBL 45 TO 63, WAS FOUND WITH ELONGATED HOLES BY THE L-2 DOOR. REMOVED, FABRICATED AND INSTALLED NEW SUPPORT IAW B727 SRM 51-30-02, 53-10-1, AND B727 MAINTENANCE MANUAL 51-20-11.

Part: SUPPORT — CORRODED (BS 1050-1130)

DURING HEAVY MAINTENANCE VISIT, FLOOR SUPPORT BETWEEN STATIONS 1050 TO 1070 AND 1110 TO 1130, LBL 12 WAS FOUND CORRODED. REMOVED, FABRICATED AND INSTALLED NEW SUPPORT IAW B727 SRM 51-30-02, 53-10-3, 51-40-4 AND B727 MAINTENANCE MANUAL 51-20-11.

Part: SUPPORT — CORRODED (BS 1070-1110)

DURING HEAVY MAINTENANCE VISIT, FLOORBEAM SUPPORTS AT THE FOLLOWING LOCATIONS WERE FOUND CORRODED: STATION 1050 TO 1110 LBL12, STATION 1070 LBL 45 - 63, AND STATION 1110 TO 1130 BL 0 - LBL 12. REMOVED, FABRICATED, AND INSTALLED NEW SUPPORTS IAW B727 SRM 53-10-01 AND MM 51-20-11.

Part: ANGLE — CORRODED (BS 405)

DURING HEAVY MAINTENANCE VISIT, THE FLOOR SUPPORT AT STATION 405, BL 12.09 WAS FOUND CORRODED. REMOVED, FABRICATED, AND INSTALLED NEW ANGLE IAW B727 SRM 53-10-1.

Part: SUPPORT — CORRODED (BS 1030-1148)

DURING HEAVY MAINTENANCE VISIT, THE CABIN FLOOR SUPPORT ANGLE AT STATION 1030- 1148 LBL 12 WAS FOUND CORRODED. FABRICATED AND INSTALLED NEW FLOOR SUPPORT IAW B727 SRM 53-10-8.

Part: SEAT TRACK — CORRODED (BS 420-460)

DURING HEAVY MAINTENANCE VISIT, THE SEAT TRACK AT STATION 420-460 RBL 55 WAS FOUND CORRODED. REMOVED, FABRICATED, INSTALLED AND NEW SEAT TRACK IAW B727 SRM 53-10-2, 51-30-2 AND MM 51-20-11.

Part: ANGLE — CRACKED (BS 400-420)

DURING HEAVY MAINTENANCE VISIT, THE CABIN FLOOR SUPPORT INTERCOSTAL WAS FOUND CRACKED BETWEEN FRAMES AT STATION 400 TO 420, LBL 5. REMOVED, FABRICATED AND INSTALLED NEW ANGLE IAW B727 SRM 51-20-1, 51-30-2 AND MAINTENANCE MANUAL 51-20-11.

Part: ANGLE — CORRODED (BS 1030-1148)

DURING HEAVY MAINTENANCE VISIT, FLOOR SUPPORT ANGLE AT STATION 1030 TO 1148, LBL 12 WAS FOUND CORRODED. REMOVED, FABRICATED AND INSTALLED A NEW FLOOR SUPPORT IAW B727 SRM 53-10-8.

Part: SEAT TRACK — CORRODED (BS 420-460)

DURING HEAVY MAINTENANCE VISIT, THE SEAT TRACK BETWEEN STATIONS 420 TO 460, RBL 55 WAS FOUND CORRODED. REMOVED, FABRICATED AND INSTALLED NEW SEAT TRACK IAW B727 SRM 53-10-2, 51-30-2, AND MAINTENANCE MANUAL 51-20-11.

Part: SUPPORT — CORRODED (BS 1070)

DURING HEAVY MAINTENANCE VISIT, THE FLOOR SUPPORT AT STATION 1070 LBL 26 TO LBL 43 WAS FOUND WITH SURFACE CORROSION. REMOVED AND REPLACED FLOOR SUPPORT ANGLE IAW B727 51-30-2 AND 53-10-1.

Part: FLOORBEAM — CRACKED (BS 950)

DURING HEAVY MAINTENANCE VISIT, THE FLOORBEAM WEB AT STATION 950A TO 950B WAS FOUND CRACKED. REMOVED, FABRICATED AND INSTALLED NEW WEB IAW B727 SRM 51-20-1, 51-30-6, 51-10-2 AND MAINTENANCE MANUAL 51-20-11.

Part: FLOORBEAM — CRACKED (BS 950)

DURING HEAVY MAINTENANCE VISIT, THE FLOORBEAM WEB AT STATION 950A TO 950B WAS FOUND CRACKED. REMOVED CRACKED ANGLE, FABRICATED AND INSTALLED NEW ANGLE IAW B727 SRM 51-20-1, 51-30-6, 51-10-2, AND MM 51-20-11.

Part: ANGLE — CORRODED (LT WING TIP)

DURING HEAVY MAINTENANCE VISIT, THE LEFT WING OTBD EDGE WING TIP SUPPORT ANGLE WAS FOUND CORRODED AT THE UPPER AND LOWER SURFACE. REMOVED AND REPLACED 4 SPLICES AND 1 STIFFENER IAW B727 SRM 57-20-05, 51-30-02, AND 51-20-01.

Part: INTERCOSTAL — CRACKED (BS 400-420)

DURING HEAVY MAINTENANCE VISIT, THE CABIN FLOOR SUPPORT INTERCOSTAL WAS CRACKED BETWEEN FRAMES AT STATION 400-420 LBL 5. REMOVED, FABRICATED AND INSTALLED NEW ANGLE IAW B727 SRM 51-30-2, 51-20-1 AND MM 51-20-11.

Part: SEAT TRACK — CORRODED (BS 786-847)

DURING HEAVY MAINTENANCE VISIT, SEAT TRACK AT STATION 786 TO 847, RBL 45 WAS FOUND CORRODED. REMOVED, FABRICATED, AND INSTALLED NEW SEAT TRACK IAW B727 SRM 51-30-2, 51-10-2, 53-10-5 AND MAINTENANCE MANUAL 51-20-11.

Part: SHEAR TIE — CORRODED (BS 560)

DURING HEAVY MAINTENANCE VISIT, FOUND THE SHEAR TIE AT STATION 560, RBL 2, WBL 148 IN THE FORWARD CARGO COMPARTMENT CORRODED. REMOVED, FABRICATED, AND INSTALLED NEW SHEAR TIE IAW B727 SRM 53-30-3, 53-10-4 FIGURE 15 AND MM 51-20-11.

Part: SEAT TRACK — CORRODED (BS 1025-1090)

DURING HEAVY MAINTENANCE VISIT, CORRODED SEAT TRACKS WERE LOCATED IN THE FOLLOWING AREAS: STATION 786 - 847 RBL 45 AND STATION 1025 - 1090 LBL 46. REMOVED, FABRICATED AND INSTALLED SEAT TRACK IAW B727 53-10-2 AND 53-10-3.

Part: SKIN — DAMAGED (BS 377)

DURING HEAVY MAINTENANCE VISIT, LIGHTNING STRIKE WAS FOUND AT STATION 377, STRINGER 5 LEFT. CUT OUT HOLE, FABRICATED AND INSTALLED REPAIR IAW B727 SRM 53-30-3 FIGURE 3A AND FIGURE 20.

Part: SKIN — DENTED (BS 294)

DURING HEAVY MAINTENANCE VISIT, THE FUSELAGE SKIN WAS FOUND DENTED BEYOND LIMITS AT STATION 294, STRINGER 21R. CUT OUT DENT, FABRICATED AND INSTALLED REPAIR DOUBLER IAW B727 SRM 51-20-2, 53-30-3, AND 53-10-3 FIGURE 1.

Part: BRACKET — CRACKED (BS 720)

DURING HEAVY MAINTENANCE VISIT, CRACK WAS FOUND ON UPPER CAP AT THE LOWER WING TO BODY FAIRING SUPPORT STRUCTURE ON THE EXTERIOR OF THE AIRCRAFT. A PREVIOUS REPAIR (PER THE SRM) IN THE AREA WAS ALSO FOUND CRACKED. REMOVED, FABRICATED, AND INSTALLED NEW DOUBLERS AND SUPPORT STRUCTURE PER B727 SRM 51-40-2 AND 51-30-2.

Part: BUSHING — CORRODED (BS 870)

DURING HEAVY MAINTENANCE VISIT, THE RIGHT MAIN LANDING GEAR OTBD FORWARD ATTACH FITTING BUSHING AREA WAS FOUND CORRODED. REMOVED CORROSION, FABRICATED AND INSTALLED NEW BUSHING IAW ENGINEERING ORDER INSTRUCTIONS.

Part: FITTING — CORRODED (HORIZ STAB)

DURING HEAVY MAINTENANCE VISIT THE LEFT PORTION OF THE HORIZONTAL STABILIZER WAS FOUND TO HAVE PITTING CORROSION IN TWO OF THE TENSION TIE ATTACH FITTING HOLES AND DEEP GOUGE IN ONE OF THE HOLES. REAMED HOLES TO REMOVE CORROSION AND GOUGE PER B727 SERVICE BULLETIN 727-55-0071.

Part: BATTERY CHARGER — INOPERATIVE (CABIN)

FOUND BATTERY CHARGER BAD FROM STOCK. REMOVED AND REPLACED BATTERY CHARGER.

Part: BATTERY CHARGER — INOPERATIVE (CABIN)

FOUND AFT RIGHT OVERWING EMERGENCY EXIT LIGHT INOP. REMOVED AND REPLACED BATTERY CHARGER AND FUNCTIONALLY CHECKED GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

FOUND EMERGENCY FLOOR TRACK LIGHTING INOP IN ROWS 19 THROUGH 26. REMOVED AND REPLACED BATTERY POWER SUPPLY AND OPS CHECKED NORMAL.

Part: DOOR — NOT LATCHED (CABIN)

CABIN WOULD NOT PRESSURIZE, L-2 DOOR WAS NOT SEALED PROPERLY. DUMPED FUEL AND RETURNED TO CUN. VISUALLY INSPECTED DOOR L-2 AND FRAME AND NO DAMAGE WAS FOUND. SECURED DOOR AND DISPATCHED AIRCRAFT.

Part: DOOR SEAL — NOT SEATED (L2 DOOR)

UNABLE TO MAINTAIN PRESSURIZATION IN AUTO, STANDBY, OR MANUAL MODE. PERFORMED ALL APPROPRIATE CHECKLISTS IN COM AND RETURNED TO SLC. CHECKED AND RESEATED L-2 DOOR, RAN ENGINE AND PRESSURIZED TO 4 PSI DIFFERENTIAL AND NO LEAKS NOTED.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

FOUND L2 OVER DOOR EMERGENCY EXIT LIGHT WILL NOT TEST. REMOVED AND REPLACED POWER SUPPLY AND OPS CHECKED GOOD IN ACCORDANCE WITH MM 33-50-71.

Part: SENSOR — INTERMITTENT (NLG)

ON GEAR RETRACTION, NOSE GEAR RED WARNING LIGHT REMAINED ON, RECYCLED GEAR AND OPS NORMAL. CLEANED NOSE GEAR POSITION AND LOCK SWITCHES, SWUNG NOSE GEAR AND OPS CHECKED NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

FOUND RIGHT OVERWING EMERGENCY EXIT LIGHTS INOP. REMOVED AND REPLACED RIGHT OVERWING EMERGENCY EXIT LIGHT BATTERY PACK, OPS CHECKED GOOD.

Part: BATTERY PACK — LOOSE (CABIN)

RIGHT EXTERIOR OVERWING EMERGENCY LIGHT INOP. FOUND BATTERY PACK LOOSE, RESEATED AND SECURED BATTERY PACK, OPS CHECK GOOD.

Part: HYDRAULIC LINE — LEAKING (A-HYD SYSTEM)

ON FINAL, LOST SYSTEM-A FLUID. MANUALLY EXTENDED GEAR AND LANDED NORMALLY. REMOVED AND REPLACED HYDRAULIC LINE, PERFORMED OPERATIONAL AND LEAK CHECK.

Part: FIRE LOOP WIRE — DAMAGED (NR 3 ENGINE)

THE NUMBER 3 ENGINE FIRE WARNING LIGHT ILLUMINATED AND HORN SOUNDED. PERFORMED ENGINE FIRE/FAILURE CHECKLIST, DECLARED EMERGENCY, DUMPED FUEL TO LANDING WEIGHT AND LANDED. FOUND FRAYED WIRE AT PIN-X OF D400P, REPINNED WIRE AND OPS CHECKS GOOD.

Part: BATTERIES — DISCHARGED (CABIN)

THE AFT AIRSTAIR OVERHEAD SELF CONTAINED EMERGENCY EXIT LIGHT WAS FOUND INOP. REPLACED BATTERIES AND OPS CHECK OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

FOUND LEFT FORWARD OVERWING EXTERIOR EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED THE BATTERY PACK, OPS CHECK GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

LEFT FORWARD OVERWING EXTERIOR EMERGENCY LIGHT WAS FOUND INOPERATIVE. REMOVED AND REPLACED THE BATTERY POWER SUPPLY. OPS CHECKS OK.

Part: FITTING — ELONGATED HOLE (RT MLG BEAM)

DURING HEAVY MAINTENANCE VISIT, THE RIGHT HAND MAIN LANDING GEAR BEAM OUTBOARD SUPPORT FITTING RETAINER BOLT HOLE WAS FOUND ELONGATED. REPAIRED SUPPORT FITTING PER SUN COUNTRY ENGINEERING ORDER 57-5242-1.

Part: ACTUATOR BRACKET — CRACKED (NR 8 SPOILER)

DURING HEAVY MAINTENANCE VISIT, THE NUMBER 8 SPOILER ACTUATOR SUPPORT FITTING WAS FOUND CRACKED ON THE VERTICAL FLANGE OF THE RIGHT TRAILING EDGE BEAM. INSTALLED REPAIR IAW LOCKHEED ENGINEERING ORDER NUMBER 3753.

Part: BATTERY — DISCHARGED (CABIN)

THE FORWARD EMERGENCY EXIT AREA LIGHT COMES ON AND THEN GOES OUT. REMOVED AND REPLACED BATTERY IAW MM 33-50-71 AND LIGHT TESTED NORMAL.

Part: SHOCK ABSORBER — DAMAGED (TAIL SKID)

AFTER GEAR RETRACTION, TAIL SKID LIGHT ILLUMINATED. INSTALLED NEW SHOCK ABSORBER ASSEMBLY IAW MM 32-71-81 AND OPS TESTED GOOD IAW 32-71-01.

Part: BATTERY — DISCHARGED (CABIN)

THE FORWARD CEILING MOUNTED EMERGENCY AREA LIGHT TESTED DIM. REMOVED AND REPLACED BATTERIES IN AREA LIGHT, TESTED NORMAL IAW MM 33-50-81.

Part: EEL POWER SUPPLY — FAILED (CABIN)

THE FORWARD OVERHEAD EMERGENCY EXIT LIGHT WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED FORWARD OVERHEAD EMERGENCY EXIT LIGHT POWER SUPPLY AND LIGHT TESTED GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

THE EMERGENCY EXIT LIGHT ABOVE THE L-2 DOOR TESTED DIMLY. REMOVED AND REPLACED BATTERY PACK FOR THE L-2 DOOR EMERGENCY EXIT LIGHT IAW MM 33-50-71 AND LIGHT TESTED GOOD.

Part: EEL BATT CHARGER — FAILED (L-2 DOOR)

THE L-2 DOOR OVERHEAD EMERGENCY EXIT LIGHT WAS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED BATTERY PACK AND CHARGER, LIGHT TESTED GOOD.

Part: BATTERIES — DISCHARGED (CABIN)

MID CABIN OVERHEAD EMERGENCY EXIT LIGHT WAS FOUND TO BE DIM. REPLACED THE EMERGENCY EXIT LIGHT BATTERIES AND LIGHT OPS CHECKED GOOD PER MM 33-50-01.

Part: EEL BATTERY — DISCHARGED (CABIN)

FOUND THE OVERHEAD EMERGENCY LIGHT AT SEAT 11 INOPERATIVE. REMOVED AND REPLACED BATTERIES IN OVERHEAD EMERGENCY LIGHT AND UNIT TESTED GOOD.

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

FORWARD LEFT AND AFT OVERWING EMERGENCY LIGHTS FOUND TO BE INOPERATIVE. REMOVED AND REPLACED BATTERY PACK M1090 PER MM 33-50-22 PAGE 22. LIGHTS OPS CHECKED GOOD.

Part: SKIN — DAMAGED (BS 340)

DURING C-CHECK, FOUND A HOLE IN THE FUSELAGE, 2 INCHES BELOW STRINGER 19 RIGHT AT BODY STATION 340. CUT OUT DAMAGED AREA, FABRICATED AND INSTALLED FILLER AND DOUBLER REPAIR IAW SRM 53-30-3.

Part: FLOORBEAM — CORRODED (BS 34O)

DURING C-CHECK, TWO BULGES WHERE FOUND IN THE FLOOR BOARDS AT BODY STATION 340. UPON REMOVAL, THE FLOOR BOARD CORROSION WAS FOUND ON THE UNDERLYING FLOORBEAM. CUT OUT DAMAGED SECTION FOR FLOORBEAM, FABRICATED AND INSTALLED REPAIR MEMBERS PER AERO CORP ENGINEERING ORDER 95-154.

Part: EEL BULB — FAILED (CABIN)

L2 DOOR EMERGENCY EXIT LIGHT HAD TWO BULBS INOPERATIVE. RELAMPED L2 EMERGENCY EXIT LIGHT AND OPS CHECKED GOOD IAW 33-50-00.

Part: EEL BULB — FAILED (L 1 DOOR)

L-1 DOOR EMERGENCY EXTERIOR SLIDE LIGHT INOPERATIVE. RELAMPED L-1 SLIDE LIGHT. OPS CHECK GOOD.

Part: L-2 WINDOW — NOT CLOSED (COCKPIT)

ON INITIAL ACCELERATION AT HUX, L-2 WINDOW CAME OPEN. ABORTED TAKEOFF, RESHUT WINDOW, AND ALL INDICATION WERE NORMAL ON SECOND TAKEOFF (PACKS OFF TAKE-OFF). OPENED L-2 WINDOW AND INSPECTED TRACK AND LOCKING MECHANISM, CYCLED WINDOW SEVERAL TIMES AND FOUND IT TO LOCK NORMALLY. NO OTHER DEFECTS NOTED. OK FOR SERVICE.

Part: EEL BATT CHARGER — FAILED (L-2 DOOR)

L-2 DOOR EMERGENCY EXIT LIGHTS INOPERATIVE. REMOVED AND REPLACED BATTERY CHARGER M1092, AND BATTERY PACK AT L-2 DOOR. OPS CHECK GOOD.

Part: EEL — FAILED (CABIN)

AFT OVERHEAD SELF-CONTAINED EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED AFT OVERHEAD EMERGENCY LIGHT. OPS CHECK GOOD IAW 33-50-01.

Part: EEL — FAILED (CABIN)

FORWARD OVERHEAD SELF-CONTAINED EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED EMERGENCY LIGHT AND OPS CHECK GOOD PER MM 33-50-81.

Part: EEL BATT CHARGER — FAILED (CABIN)

L-2 DOOR EMERGENCY EXIT SIGN DOES NOT ILLUMINATE DURING TEST. REMOVED AND REPLACED BATTERY CHARGER AT L-2 DOOR, M1092. ALSO, REMOVED AND REPLACED L-2 DOOR BATTERY PACK. OPS CHECK GOOD.