N296SW

Part: LIGHT — INOPERATIVE (CABIN) · airframe 35,465 hrs · 49,160 cycles

EMERGENCY LIGHT ABOVE ROW 3 IS BURNED OUT. FLT 5291 RELAMPED.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 35,130 hrs · 48,727 cycles

EMERGENCY EXIT POD IN CEILING BURNED OUT. FLT#5441 RELAMPED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

FOUND A CRACK DEEPER THAN .40" & .5" IN LENGTH AT THE BOTTOM OF THE BELLY AT FS 11715.0 BETWEEN STRINGER 21L & 21R WITH CORROSION. C-CHECK REPAIRED CRACKED & CORRODED SKIN SECTION AT FS 11715.0 FRAME 35 BETWEEN STRINGER 21L & 21R IAW ETD.

Part: BUTTSTRAP — CORRODED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

CORROSION FOUND AT CARGO AREA 2ND BUTTSTRAP FROM ENTRANCE ALONG UNDERSIDE. C-CHECK REPLACED BUTTSTRAP AT CARGO AREA ENTRANCE IAW SRM.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

MAIN CABIN DOOR ENTRANCE LOWER THRESHOLD ANGLE HAS CORROSION. C-CHECK REPLACED MAIN CABIN DOOR ENTRANCE LOWER THRESHOLD ANGLE IAW SRM.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

FRAME 15 CRACKED ABOVE STRINGER 18 AT MAIN CABIN DOOR ENTRYWAY. C-CHECK REPAIRED FRAME 15 ABOVE STRINGER 18 AT MAIN CABIN DOOR ENTRY IAW SRM.

Part: SKIN — DAMAGED (RT NACELLE) · airframe 35,071 hrs · 48,642 cycles

RT NACELLE INBD SKIN NEAR FWD MLG DOOR CUT OUT HAS PULLED RIVETS DAMAGE TO SKIN OUT OF LIMITS. C-CHECK REPLACED INTERNAL SPLICE PLATE & INSTALLED DOUBLER AT RT NACELLE INBD SKIN NEAR FWD MLG DOOR CUT OUT IAW ETD.

Part: SUPPORT — CRACKED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

CARGO DOOR AFT TRACK MOUNTING BRACKET ATTACHMENT SUPPORT CRACKED ON RIB 44 BETWEEN STRINGERS 1R & 2R. C-CHECK REPLACED CARGO DOOR AFT TRACK MOUNTING BRACKET ATTACHMENT SUPPORT PN120-05151-001 ON RIB 44 BETWEEN STRINGERS 1R & 2R IAW SRM.

Part: SUPPORT — CRACKED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

CARGO DOOR AFT TRACK MOUNTING BRACKET ATTACHMENT SUPPORT CRACKED ON RIB 44 BETWEEN STRINGERS 3L & 4L. C-CHECK REPLACED CARGO DOOR AFT TRACK MOUNTING BRACKET ATTACHMENT SUPPORT PN120-06220-001 ON RIB 44 BETWEEN STRINGERS 3L & 4L IAW SRM.

Part: SUPPORT — CRACKED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

CARGO DOOR AFT TRACK MOUNTING BRACKET ATTACHMENT SUPPORT CRACKED ON RIB 44 BETWEEN STRINGERS 1L & 2L. C-CHECK REPLACED CARGO DOOR AFT TRACK MOUNTING BRACKET ATTACHMENT SUPPORT PN120-21326-001 ON RIB 44 BETWEEN STRINGERS 1L & 2L IAW SRM.

Part: SUPPORT — CRACKED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

CARGO DOOR FORWARD TRACK MOUNTING BRACKET ATTACHMENT SUPPORT CRACKED ON FRAME 40 BETWEEN STRINGERS 3L & 4L. C-CHECK REPLACED CARGO DOOR FWD TRACK MOUNTING BRACKET ATTACHMENT SUPPORT PN120-06218-001 ON FRAME 40 BETWEEN STRINGERS 3L & 4L IAW SRM.

Part: WEB — CHAFED (LT MLG WW) · airframe 35,071 hrs · 48,642 cycles

LT MLG INBD WW WEBBING CHAFED. C-CHECK REPLACED LT MLG INBD WW WEBBING IAW SRM.

Part: WEB — CRACKED (LT MLG WW) · airframe 35,071 hrs · 48,642 cycles

LT MLG WW OTBD WEBBING CHAFED, CRACKED, LOOSE RIVETS, MISSING BOLT. C-CHECK REPLACED LT MLG WW OTBD WEBBING IAW SRM.

Part: CLEAT — CRACKED (LT WING) · airframe 35,071 hrs · 48,642 cycles

LT WING SKIN CLEAT AT TOP NEAR FUEL LEVEL STICK NR 4 CRACKED. C-CHECK REPLACED LT WING UPPER SKIN CLEAT PN 120-17063-609 FWD OF NR 4 FUEL LEVEL DIP STICK IAW SRM.

Part: CHANNEL — CRACKED (CABIN DOOR) · airframe 35,071 hrs · 48,642 cycles

MAIN CABIN DOOR CRACK UNDER FWD CENTER STEP SUPPORT. C-CHECK REPLACED MAIN CABIN DOOR CHANNEL ASSEMBLY PN120-21058-003 AT BAY 15 IAW SRM.

Part: SUPPORT — CORRODED (CABIN DOOR) · airframe 35,071 hrs · 48,642 cycles

MAIN CABIN DOOR CORROSION IN BAY 15 BEHIND T BRACKET. C-CHECK REPLACED MAIN CABIN DOOR CROSS SUPPORT FROM BAY 15 THRU18 PN 120-21049-601 & T BRACKET AT BAY 15 PN120-21067-004 IAW SRM.

Part: CLEAT — CRACKED (RT WING) · airframe 35,071 hrs · 48,642 cycles

CRACKED UPPER SKIN CLEAT ABOVE RT WING NR 5 FUEL ACCESS PANEL. C-CHECK REPLACED UPPER SKIN CLEAT ABOVE RT WING NR 5 FUEL ACCESS PANEL PN120-17063-609 IAW SRM.

Part: SUPPORT FITTING — CORRODED (CABIN DOOR) · airframe 35,071 hrs · 48,642 cycles

MAIN CABIN DOOR CORROSION IN BAY 18 BETWEEN PLATES. C-CHECK REPLACED MAIN CABIN DOOR SUPPORT FITTING AT BAY 18 IAW SRM.

Part: BRACKET — CORRODED (CABIN DOOR) · airframe 35,071 hrs · 48,642 cycles

MAIN CABIN DOOR CORROSION IN BAY 10 BEHIND T BRACKET. C-CHECK REPLACED MAIN CABIN DOOR T BRACKET PN120-08303-001 AT BAY 10 IAW SRM.

Part: FRAME — CRACKED (RT NACELLE) · airframe 35,071 hrs · 48,642 cycles

RT NACELLE HAS A CRACKED FRAME UNDER INBD AFT EXHAUST MOUNT. C-CHECK REPLACED RT NACELLE AFT INBD EXHAUST MOUNT FRAME PN120-40442-002 IAW SRM.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

CORROSION FOUND ON STRINGER 19L FWD OF FS FRAME 14. C-CHECK SPLICED IN NEW SECTION OF STRINGER 19L IAW SRM.

Part: RIB — CRACKED (FUSELAGE) · airframe 35,071 hrs · 48,642 cycles

FOUND CRACK UNDER CAPTAINS SIDE DV WINDOW FRAME JUST OTBD OF THE TILLER HANDLE IN A RIB. C-CHECK INSTALLED NEW REINFORCING SECTION WITH SPLICE ATTACHING ANGLE DOUBLER IAW SRM.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 33,945 hrs · 47,069 cycles

ONE FLOOR LEVEL EMERGENCY LIGHT AT ROW 8 DOES NOT ILLUMINATE. (FLT 7388) REPLACED LIGHT ASSEMBLY.

Part: CABLE — LOOSE (COCKPIT) · airframe 33,730 hrs · 46,834 cycles

UNCOMMANDED RELEASE OF CAPTAINS SHOULDER HARNESS. HARNESS WILL NO LONGER STAY SECURED. (FLT 7398) TIGHTENED LOWER CABLE AT CONTROL LEVER.

Part: MODULE — FAULTY (GEAR HANDLE) · airframe 33,444 hrs · 46,478 cycles

AFTER MOVING GEAR HANDLE TO DOWN POSITION A 10-15 SECOND DELAY BEFORE GEAR MOVEMENT OCCURRED. (FLT 7777) REPLACED MLG GEAR HANDLE MODULE ASSY. P/N: 120-38594-501 S/N OFF: 141905-303

Part: LIGHT — UNSECURE (CABIN) · airframe 32,834 hrs · 45,804 cycles

FLOOR LEVEL EXIT PLACARD AT 6C, FELL OFF. (FLT 7359) REPLACED THE EMERGENCY EXIT LIGHT ASSEMBLY AT 6C.

Part: FIREWALL — DAMAGED (FUSELAGE) · airframe 32,570 hrs · 45,511 cycles

APU FIREWALL HAS A HOLE WHERE THE GROUNDING STRAPS MOUNT. (SERVICE) REPAIRED HOLE IN FIREWALL IN REFERENCE TO ETD.

Part: SIGN — BROKEN (CABIN) · airframe 32,541 hrs · 45,479 cycles

EXIT SIGN BROKEN AT SEAT 6A. (FLT 7780) REPLACED EMERGENCY EXIT IDENTIFIER ASSEMBLY IN REFERENCE TO AMM.

Part: WIRE — BROKEN (CABIN) · airframe 32,436 hrs · 45,361 cycles

CABIN FLOOR EMERGENCY LIGHT AT CENTER ROW 6 IS OUT. (SERVICE) REPAIRED BROKEN WIRE AT CONNECTER AT ROW 6.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 32,361 hrs · 45,256 cycles

FLOOR ESCAPE PATH WHITE FLOOR EMERGENCY LIGHT AT 9A IS OUT. (FLT 5432) RELAMPED EMERGENCY LIGHT.

Part: HINGE — LACK OF LUBE (CABIN DOOR) · airframe 31,273 hrs · 43,924 cycles

MAIN CABIN DOOR HARD TO OPEN. (FLT 1301) LUBED MAIN CABIN DOOR HINGE ARM.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 32,195 hrs · 45,065 cycles

STRINGER 18L HAS CORROSION BELOW FORWARD PASSENGER DOOR ACTUATOR. (C-CHECK) REPAIRED STRINGER 18L.

Part: SIGN — BROKEN (CABIN) · airframe 30,937 hrs · 43,491 cycles

EMERGENCY "EXIT" SIGN BY MAIN CABIN DOOR HAS FALLEN OFF. (FLT 7786) REPLACED THE EMERGENCY EXIT LIGHT ASSEMBLY NEAR MCD.

Part: LIGHT — BROKEN (CABIN) · airframe 30,054 hrs · 42,463 cycles

EMERGENCY LIGHT AT MAIN CABIN DOOR IS BROKEN. (FLT 7791) REPLACED PAX DOOR LOWER EMERGENCY EXIT LIGHT ASSEMBLY.

Part: B-NUT — LOOSE (APU FUEL CONTROL) · airframe 29,825 hrs · 42,209 cycles

FUEL FUMES IN COCKPIT DURING APU OPERATIONS WITH PACKS ON. (FLT 6947) TIGHTENED "B" NUT ON APU FUEL CONTROL.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 29,557 hrs · 41,877 cycles

FLOOR LEVEL EMERGENCY LIGHT AT ROW 8 IS INOPERATIVE. (FLT 6820) RELAMPED EMERGENCY LIGHT.

Part: SIGN — BROKEN (CABIN) · airframe 29,355 hrs · 41,650 cycles

EMERGENCY LIGHT EXIT SIGN BROKEN AT FORWARD BOARDING DOOR. (FLT 7767) REMOVED AND REPLACED THE EMERGENCY LIGHT ASSEMBLY.

Part: WIRE — BROKEN (CABIN) · airframe 28,538 hrs · 40,686 cycles

EXIT SIGN AT ROW 9B IS INTERMITTENT WHEN TESTED. (FLT 7764) REPAIRED BROKEN WIRE.

Part: WIRE — BROKEN (CABIN) · airframe 28,393 hrs · 40,521 cycles

EMERGENCY EXIT SIGN ON OVERHEAD BIN AT ROW 9 FLICKERS WHEN TESTED. (FLT 6237) REPAIRED BROKEN WIRE.

Part: SHIM — BENT (CABIN DOOR) · airframe 28,366 hrs · 40,481 cycles

MAIN CABIN DOOR DIFFICULT TO OPEN. (FLT 7780) REPLACED SHIMS.

Part: ARM — OUT OF ADJUST (CABIN DOOR) · airframe 28,286 hrs · 40,391 cycles

MAIN CABIN DOOR WILL NOT OPEN FROM OUTSIDE. (FLT 1002) REPLACED BOTTOM AFT SHIMS AND ADJUSTED MAIN CABIN DOOR HINGE ARMS.

Part: BUTTSTRAP — CORRODED (FUSELAGE) · airframe 28,462 hrs · 40,604 cycles

BUTTSTRAPS CORRODED UNDER LEFT AFT ROW OF SEATS, UNDER LAV FLOOR, INSIDE PASSENGER DOOR ENTRY AND IN AREA OF AIR CONDITIONING MUFFLER. (C CHECK) REPLACED BUTTSTRAPS PER SRM.

Part: SEAT TRACK — CORRODED (CABIN) · airframe 28,462 hrs · 40,604 cycles

LEFT CABIN SEAT TRACK CORRODED. (C CHECK) REPLACED TRACK PER SRM.

Part: ANGLE — CRACKED (RT WING) · airframe 28,482 hrs · 40,627 cycles

RIGHT INBOARD WING FUEL TANK LOWER ANGLE CRACKED FORWARD OF DEFUEL PANEL. (C CHECK) REPLACED ANGLE PER SRM.

Part: SUPPORT — CRACKED (LT WING) · airframe 28,482 hrs · 40,627 cycles

LEFT LEADING EDGE INBOARD WEB CRACKED. (C CHECK) REPLACED WEB RIB SUPPORT PER SRM.

Part: MECHANISM — LACK OF LUBE (MAIN DOOR) · airframe 28,242 hrs · 40,340 cycles

MAIN CABIN DOOR DIFFICULT TO OPEN FROM INSIDE. (FLT 5947) LUBED LATCHING MECHANISM AND HANDLE.

Part: LINKAGE — LACK OF LUBE (CABIN DOOR) · airframe 28,242 hrs · 40,340 cycles

MAIN CABIN DOOR DIFFICULT TO OPEN. (FLT 6063) LUBRICATED DOOR HANDLE LINKAGE.

Part: HANDLE — LACK OF LUBE (CABIN DOOR) · airframe 28,242 hrs · 40,340 cycles

MAIN CABIN DOOR DIFFICULT TO OPEN AND CLOSE. (FLT 6817) LUBED MAIN CABIN DOOR HANDLE.

Part: BUSHING — LACK OF LUBE (DOOR HANDLE) · airframe 28,188 hrs · 40,263 cycles

FLT 6269 - MAIN CABIN DOOR HANDLE HARD TO OPERATE. LUBED DOOR HANDLE BUSHINGS.

Part: TERMINAL — LOOSE (EMERGENCY LIGHT) · airframe 28,158 hrs · 40,221 cycles

FLT 6241 - EMERGENCY EXIT LIGHT ON BULKHEAD INOP. RESECURED TERMINAL ON BACK SIDE OF LIGHT FIXTURE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 27,738 hrs · 39,709 cycles

THIRD WHITE EMERGENCY FLOOR LIGHT INOP. (FLT 5830) RELAMPED EMERGENCY LIGHT.

Part: CONNECTOR — NOT SEATED (CABIN) · airframe 27,183 hrs · 38,983 cycles

EMERGENCY ESCAPE PATH MARKING LIGHT INOP. (FLT 6288) RESEATED CONNECTOR.

Part: SKIN — CORRODED (PAX DOOR) · airframe 26,937 hrs · 38,673 cycles

MAIN DOOR HAS CORROSION AND PIN HOLE IN EXTERIOR SKIN APPROX 5 INCHES FROM BOTTOM AND 12 INCHES FROM AFT SIDE OF DOOR. (SVC CHECK) REPAIRED PER SRM.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 26,912 hrs · 38,642 cycles

FLOOR EXIT ROW LIGHTING INOP. (FLT 6077) RELAMPED FLOOR LIGHTING.

Part: WIRE — BROKEN (EMERGENCY LIGHT) · airframe 26,860 hrs · 38,572 cycles

FLT 6328 - RED EMERGENCY LIGHTS AT CABIN DOOR INOP. REPAIRED WIRE.

Part: HANDLE — LACK OF LUBE (PAX DOOR) · airframe 26,453 hrs · 38,023 cycles

FLT 5568 - MAIN CABIN DOOR HARD TO OPEN. LUBED DOOR HANDLE ASSEMBLY.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 26,002 hrs · 37,464 cycles

FLT 7813 - AFT SECTION EMERGENCY LIGHTS INOP. OPS CHECKED GOOD.

Part: FRAME — CRACKED (RT NACELLE) · airframe 25,496 hrs · 36,842 cycles

RIGHT NACELLE FRAME NR 1 CRACKED AT TENSION MOUNT AREAS IB AND OB. C-CHECK, REPLACED NACELLE FRAME NR 1.

Part: STRINGER — CRACKED (LT WING) · airframe 25,496 hrs · 36,842 cycles

LT IB WING STRINGER NR 10 CRACKED. C-CHECK, RE-WORKED STRINGER "RAMPS" FABRICATED AND INSTALLED.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 25,496 hrs · 36,842 cycles

RT FLOORBOARD PROP ANGLE IS CRACKED UNDER JUMPSEAT FLOORBOARD. C-CHECK, REPLACED RT FLOORBOARD PROP ANGLE.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 25,496 hrs · 36,842 cycles

LT FLOORBOARD PROP ANGLE CRACKED UNDER JUMPSEAT FLOORBOARD. C-CHECK, REPLACED LT FLOORBOARD PROP ANGLE.

Part: RADIO — MALFUNCTIONED (NAVIGATION) · airframe 25,128 hrs · 36,384 cycles

BOTH NAV RADIOS WENT INOP. REPLACED FIRST OFFICERS VIR32 AND VOR ANTENNA COUPLER. OPERATIONAL CHECKS ARE GOOD.

Part: SIGN — DAMAGED (EMERGENCY LIGHTS) · airframe 24,095 hrs · 34,992 cycles

FLT 3687 - FORWARD FLOOR EMERGENCY LIGHT SIGN BROKEN. REPLACED LIGHT ASSEMBLY. OPS CHECK GOOD.

Part: LIGHT — BROKEN (CABIN) · airframe 23,539 hrs · 34,249 cycles

FLIGHT NR 3697, EMERGENCY EXIT LIGHT AT ROW 9 IS BROKEN. REPLACED EMERGENCY EXIT SIGN WITH A SERVICEABLE LIGHT. OPS CHECK GOOD.

Part: CONNECTOR — ODOR (COFFEEMAKER) · airframe 22,328 hrs · 32,706 cycles

FOUND OVERHEATED ELECTRICAL SMELL IN CABIN. REPLACED CONNECTOR ON HOT JUG. OPERATIONAL CHECKS GOOD.

Part: LIGHT — BROKEN (CABIN) · airframe 22,006 hrs · 32,312 cycles

ROW 6 SEAT C LOWER EMERGENCY EXIT LIGHT IS BROKEN. REPLACED ROW 6 FLOOR LEVEL EMERGENCY EXIT SIGN WITH SERVICEABLE UNIT. OPERATIONAL CHECKS GOOD.

Part: SIGN — MISSING (CABIN) · airframe 21,887 hrs · 32,184 cycles

"EXIT" ROW SIGN MISSING NEAR SEAT 6A. REPLACED EXIT ROW SIGN NEAR SEAT 6A. OPS CHECK GOOD, PN 10-1301-15.

Part: STRAP — CORRODED (FUSELAGE) · airframe 21,642 hrs · 31,859 cycles

CORROSION ON CENTER BUTT STRAP FORWARD OF BIFFY, DISCOVERED DURING C-CHECK INSPECTION. REPLACED BUTT STRAP CENTER INTERIOR FUSELAGE FORWARD OF BIFFY IAW SRM 120 51-10-02 PG 3 SEC 3A.

Part: RIB — CRACKED (RT WING) · airframe 21,642 hrs · 31,859 cycles

RIGHT INBOARD LEADING EDGE RIB IS CRACKED IN 2 PLACES, DISCOVERED DURING C-CHECK INSPECTION. REPLACED LEADING EDGE RIB IAW EMB-120 SRM 51-40-02.

Part: SUPPORT — CRACKED (PAX DOOR) · airframe 21,642 hrs · 31,859 cycles

PAX DOOR AFT STEP SUPPORT STRUCTURE CRACKED, DISCOVERED DURING C-CHECK INSPECTION. REPLACED PAX DOOR AFT STEP SUPPORT STRUCTURE IAW SRM 120 51-10-02 PG 3 SEC 3A AND RII 52-800-1000.

Part: STRUCTURE — CRACKED (PAX DOOR) · airframe 21,642 hrs · 31,859 cycles

PAX DOOR INTERNAL STRUCTURE CRACKED AT 3 PLACES, DISCOVERED DURING C-CHECK INSPECTION. APPLIED DOUBLERS AT FORWARD AND AFT FRAMES BELOW STOPS IAW SRM 120 52-10-02 PGS 207 AND 208 AND RII 52-800-1000. REPLACED INTERNAL FRAME IAW SRM 120 51-10-02 PG 3 SEC 3 B AND IAW RII 52-800-1000.

Part: LIGHT — FAILED (CABIN) · airframe 20,780 hrs · 30,717 cycles

WHITE FLOOR LEVEL EMERGENCY LIGHT BY SEAT 8A IS INOP. REPLACED LIGHT AT SEAT 8A. OPERATIONAL CHECKS GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 20,697 hrs · 30,590 cycles

TWO CONSECUTIVE EMERGENCY FLOOR LEVEL LIGHTS INOP. REPLACED TRACK LIGHTING ASSY. OPERATIONAL CHECK GOOD.

Part: WIRE — BROKEN (EMERGENCY LIGHT) · airframe 20,434 hrs · 30,201 cycles

EMERGENCY EXIT ROW NR 9 EMERGENCY EXIT SIGN WILL NOT ILLUMINATE. REPAIRED A BROKEN WIRE. OPERATIONAL CHECK GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 20,284 hrs · 29,971 cycles

ALL 3 FWD BULKHEAD EMERG EXIT LIGHTS. FAIL TO ILLUMINATE. REPLACED FWD BATTERY PACK. OPERATIONAL CHECK GOOD.

Part: WIRE — BROKEN (EMERGENCY LIGHT) · airframe 19,457 hrs · 28,688 cycles

EMERGENCY EXIT SIGN ON OVERHEAD BIN AT SEATS 9B/9C DOES NOT LIGHT UP. REPAIRED BROKEN WIRE AT EMERGENCY SIGN OF SEAT 9BC, OPERATIONAL CHECK GOOD.

Part: SMOKE DETECTOR — ACTIVATED (LAVATORY) · airframe 19,166 hrs · 28,217 cycles

ON TAKEOFF FROM LAS VEGAS, THE LAV SMOKE ALARM WENT OFF. SMOKE WAS NOT VISIBLE. RAN BOTH PACKS OFF APU FOR 34 MINS AND NO SIGN OF SMOKE/SMOKE ODOR WAS PRESENT. OPERATIONAL CHECK GOOD.

Part: CONNECTOR — DIRTY (TE FLAPS) · airframe 18,899 hrs · 27,815 cycles

IN CRUISE FLIGHT, RECEIVED CONTROL FAULT ON FLAPS. REPLACED STALL WARNING TEST PANEL ON CENTER PEDESTAL. CLEANED LEFT WING OUTBOARD FLAP CONNECTOR. OPERATIONAL CHECK GOOD.

Part: LIGHT — BURNED OUT (EMERGENCY EXIT) · airframe 18,799 hrs · 27,653 cycles

EMERGENCY LIGHT ABOVE SEAT 9C NOT ILLUMINATED. RELAMPED EMERGENCY EXIT LIGHT ABOVE 9C. OPERATIONAL CHECK GOOD.

Part: CONTROL UNIT — MALFUNCTIONED (TE FLAP) · airframe 17,174 hrs · 25,181 cycles

DURING CRUISE, FLAP AND ADVANCED SWS LIGHTS ILLUMINATED. REMOVED AND REPLACED FLAP CONTROL UNIT. OPERATIONAL CHECK GOOD IAW 27-50-06.

Part: ACTUATOR — LEAKING (TE FLAPS) · airframe 16,656 hrs · 24,396 cycles

ENROUTE, AT ALTITUDE, FLAP SYSTEM EXPERIENCED A CONTROL FAULT ON THE OUTBOARD SEGMENT. WHEN LANDING, FLAPS 45 DEGREES, WE EXPERIENCED ANOTHER CONTROL FAULT. WE RESET THE SECOND ONE AFTER LANDING. BOTH WERE ON THE OUTBOARD SEGMENTS. REPLACED RIGHT OUTBOARD FLAP ACTUATOR DUE TO CONTROL FAULTS AND HYDRAULIC FLUID ON ROD END AREA. OPS CHECKED GOOD. DONE IAW MM 27-50-09. S/N OFF: 0294.

Part: ANNUNCIATOR — MALFUNCTIONED (TE FLAPS) · airframe 15,498 hrs · 22,666 cycles

FLAP'S FAULT COULD NOT BE CLEARED (IT WOULDN'T GO TO ''M'' MODE). REPLACED FLAP ANNUNICIATOR. OPS CHECK GOOD.

Part: CONTROL UNIT — MALFUNCTIONED (T/E FLAP) · airframe 15,396 hrs · 22,514 cycles

WHEN RETRACTING FLAPS ON CLIMBOUT, RECEIVED A CONTROL FAULT AND THE OVERHEAD PAIR OF FLAP BARS FLASHING. RESET VIA QRH PROCEDURE; WORKED FINE REST OF FLIGHT. REMOVED AND REPLACED FLAP CONTROL UNIT IAW 27-50-06. OPS CHECKS GOOD.

Part: WIRE — LOOSE (PROP DE-ICE SYS) · airframe 15,334 hrs · 22,408 cycles

LEFT PROP HEAT FAILED IN CRUISE WITH SUBSEQUENT SMELL OF ELECTRONICS FAILURE ALTERNATED BETWEEN LEFT 'PROP HEAT' AND 'MONITOR' WITH SMELL BECOMING STRONGER. PROP HEAT WAS TURNED OFF AND CONTINUES FOR APPROX 30 SECONDS TO INDICATE INOP. INSPECTED LEFT PROP DEICE SYSTEM. FOUND LOOSE WIRES ON RELAYS K0063 AND K0065. TIGHTENED WIRES AS NEEDED. OPERATED PROP DEICE SYTEM FOR 20 MINUTES. NO DEFECTS NOTED. OPS CHECK OK AT THIS TIME.

Part: BRACKET — CRACKED (LT NACELLE FLAP) · airframe 14,923 hrs · 21,799 cycles

LT NACELLE FLAP BRACKET CRACKED INSIDE. (DISCOVERED DURING C-CHECK.) REPLACED INSIDE OUTBOARD BRACKET ON LEFT NACELLE FLAP.

Part: CLIP — CRACKED (LT WING NACELLE) · airframe 14,923 hrs · 21,799 cycles

LT WING OB NACELLE RIB NR 15 LOWER CENTER CLIP CRACKED. (DISCOVERED DURING C-CHECK.) INSTALLED NEW LEFT WING OB NACELLE RIB NR 15 LOWER CENTER CLIP IAW MM 28-10-00.

Part: BUTTSTRAP — CORRODED (FUSELAGE) · airframe 14,923 hrs · 21,799 cycles

CORROSION ON RT FLOOR SUPPORT BUTT STRAP AND OUTBOARD FLOOR CHANNEL UNDER TOILET APPROX. FS 13500. (DISCOVERED DURING C-CHECK.) REMOVED BUTT STRAP AND CHANNEL ADJACENT TO LAV. INSTALLED TWO NEW BUTT STRAPS IAW SRM 51-10-02. P/N: 120-06158-002, 120-06159-501

Part: CLIP — DAMAGED (WING CLIP) · airframe 14,923 hrs · 21,799 cycles

WING CLIP JUST IN FRONT OF NR 2 FUEL LEVEL STICK AT RT WING IS CRACKED. (DISCOVERED DURING C-CHECK.)REMOVED DAMAGED WING CLIP AS REQUIRED. INSTALLED NEW WING CLIP IN RH WING . NO LEAKS NOTED AT THIS TIME.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 13,424 hrs · 19,478 cycles

ONE RED LIGHT OF FORWARD PAIR OF FLOOR EMERGENCY LIGHTS IS INOP. RELAMPED FORWARD EMERGENCY FLOOR LIGHT AS REQUIRED. OPS CHECKS GOOD.

Part: EJECTOR VALVE — FAILED (LT ENGINE) · airframe 12,793 hrs · 18,464 cycles

LEFT ENGINE AIR INLET INOP INFLIGHT. RETURNED TO SFO. UPDATE: LEFT ENGINE AIR INLET REPORTED INOP BY CREW ON FLIGHT TO PDX. INSTALLED SERVICEABLE PRESSURE SWITCH ON LEFT ENGINE INLET. OPS CHECK GOOD. REMOVED AND REPLACED LEFT ENGINE EJECTOR VALVE IAW 30-20-04. OPS CHECK GOOD.

Part: RELIEF VALVE — MALFUNCTIONED (LEFT) · airframe 12,750 hrs · 18,398 cycles

ON CLIMBOUT, DUCT LEAK LIGHT ILLUMINATED AND WOULD NOT GO OUT. ENGINE SHUT DOWN. RETURNED TO PDX. REMOVED AND REPLACED LEFT BLEED PRESSURE RELIEF VALVE IAW MM 30-10-00. OPS CHECK GOOD.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 12,598 hrs · 18,158 cycles

ON INITIAL TAKEOFF ROLL, TAKEOFF AUTO FEATHER AURAL WARNING WAS HEARD WITH AUTO FEATHER SWITCH ON. TAKEOFF WAS ABORTED. RETURNED TO THE GATE. PERFORMED SIMULATED TAKEOFF ENGINE RUNS. COULD NOT DUPLICATE. OPS CHECK GOOD AT THIS TIME.

Part: WIRE — SHORTED (CABIN) · airframe 12,316 hrs · 17,721 cycles

FORWARD OF ROW 3, MOST OF THE EMERGENCY LIGHTS ARE INOP OR VERY DIM. FOUND FORWARD SECTION OF LIGHTS DIM AT PIN-H OF FORWARD BATTERY ISOLATED TO WIRE W220-0316-24 AND REMOVED SHORT TO GROUND. ALSO FOUND COURTESY LIGHT AND OVERHEAD EMERGENCY LIGHT POSITION SWITCHED. RESTORED TO ORIGINAL CONFIGURATION. GROUND CHECK NORMAL.

Part: WIRE — BROKEN (FLIGHT CONTROL) · airframe 12,269 hrs · 17,644 cycles

ON TAKEOFF ROLL, CONTROL DISENGAGE MAP LIGHT ILLUMINATED. ABORTED TAKEOFF. REPAIRED BROKEN WIRE ON CONTROL DISENGAGE CONNECTOR 2P1421. OPS CHECK GOOD. PLACARD REMOVED.

Part: PROXIMITY SENSOR — OUT OF ADJ (LT MLG) · airframe 11,869 hrs · 17,102 cycles

AFTER TAKEOFF LEFT MAIN GEAR RED LIGHTS WON'T EXTINGUISH. COULD FEEL GEAR NOT RETRACTING. FOLLOWED QRH PROCEDURES AND RECYCLED WITH SAME RESULTS. ADJUSTED LEFT MAIN LANDING GEAR PROXIMITY SENSOR. CYCLED GEAR SEVERAL TIMES. SYSTEM OPS CHECK GOOD.

Part: PROXIMITY SENSOR — OUT OF ADJ (LT MLG) · airframe 11,906 hrs · 17,138 cycles

AFTER TAKEOFF LEFT MAIN GEAR RED LIGHTS WON'T EXTINGUISH. COULD FEEL GEAR NOT RETRACTING. FOLLOWED QRH, RECYCLED - SAME RESULT. ADJUSTED LEFT GEAR PROXIMITY SENSOR. CYCLED GEAR SEVERAL TIMES. SYSTEM OPS CHECK GOOD.

Part: VALVE — LEAKING (RT ENGINE) · airframe 11,401 hrs · 16,444 cycles

AFTER TAKE OFF, RIGHT DUCT LEAK LIGHT CAME ON. FOLLOWED QRH PROCEDURE AND AFTER 3 MINUTES WE SHUT DOWN THE RIGHT ENGINE IN FLIGHT. RETURNED TO FAT REPLACED RIGHT PRESSURE REGULATING VALVE. OPS CHECK GOOD. PERFORMED EXTENSIVE GROUND RUNS, NO DUCT LEAK LIGHT NOTED.

Part: UPLOCK SWITCH — OUT OF ADJ (RT MLG) · airframe 10,165 hrs · 14,643 cycles

WHEN LANDING GEAR WAS SELECTED UP THE RIGHT GEAR INDICATOR TWO RED LIGHTS, NO GREEN, AND WE COULD HEAR THAT A GEAR DOOR WAS OPEN. NORMAL INDICATIONS WHEN GEAR SELECTED DOWN. RETURNED TO MRY. ADJUSTED RIGHT MLG UPLOCK SWITCH IAW MM 32-61-01. SWUNG GEAR SEVERAL TIMES. OPS CHECK GOOD AT THIS TIME.

Part: ACTUATOR — FAILED (ELEVATOR TRIM) · airframe 9,506 hrs · 13,679 cycles

DURING LEVEL OFF AT FL 240 FROM 250 ELEVATOR TRIM WHEELS MOVED FORE AND AFT RAPIDLY AND APPEARED TO BE JAMMED. THEN GOT A TRIM FAIL MAP WARNING. DISENGAGED THE AUTO PILOT AND CONFIRMED TRIM WHEELS WERE FROZEN. CONSULTED QRH AND HAND FLEW TO BELOW THE FREEZING LEVEL. TRIM WORKED OK ABOVE FREEZING TEMPS. REMOVED AND REPLACED BOTH ELEVATOR TRIM ACTUATORS IAW MM 27-32-02. OPS CHECKS GOOD. S/N: 633, S/N OFF: 824 RT, S/N: 631, S/N OFF: 339 LT.

Part: CONTROL UNIT — FAILED (TE FLAP)

FLAP CONTROL FAULT ILLUMINATED IN FLIGHT AND WOULD NOT RESET. RETURNED TO LAX. REPLACED FLAP CONTROL UNIT. OPS CHECKS GOOD, SN ON 0057, SN OFF 0031.

Part: PANEL — LOOSE (ENGINE)

ENGINE PANEL ON TOP WAS NOT SECURE. RETURNED TO FAT. INSPECTED AREA AROUND ENGINE COWL ACCESS PANEL AND OBSERVED NO DAMAGE. SECURED PANEL.

Part: FRAME — CORRODED (CABIN)

CORROSION PITTING ON CROSS FRAME JUST AFT OF RIGHT AFT SEAT TRACK. REPLACED CROSS FRAME UPPER MEMBER SRM 51-40-02.

Part: STRAP — CORRODED (CABIN)

NUMEROUS AREAS OF CORROSION ON RIGHT AFT FLOOR BUTT STRAP, REPLACED STRAP. REPLACED RIGHT AFT BUTT STRAP SRM 51-40-02.

Part: STRAP — CORRODED (CABIN)

NUMEROUS AREAS OF CORROSION IN AFT CENTER FLOOR BUTT STRAP. REPLACED AFT CENTER FLOOR BUTT STRAP IAW SRM 51-40-02.

Part: BULBS — FAILED (SERVICE DOOR)

SERVICE DOOR LIGHT REMAINS LIT AFTER TAKEOFF. RETURNED TO FIELD. MEL 52-70-1. INSTALLED NEW BULBS IN SERVICE DOOR LIGHT. LIGHT CHECKS GOOD AT THIS TIME.

Part: BRUSH — FAILED (START/GEN)

START/GEN BRUSHES FAILED AFTER 277.0 HOURS OF FLIGHT TIME. THE BRUSH SHUNT LEADS WERE BURNED AND BROKEN OFF. THIS WAS A NEW AIRCRAFT, THIS WAS A NEW STARTER GENERATOR WITH ONLY 277.0 HOURS SINCE NEW. SUBMITTER RECOMMENDS RE-DESIGNING DEFECTIVE BRUSHES. NOTE: THIS REPAIR STATION HAS SEEN MANY OF THESE BRUSH FAILURES IN THE PAST. (X)