N2FOR

Part: STATOR DISK — CRACKED (NR 1 BRAKE)

BRAKE NR 1 STATOR FAILED (CRACKED), JAMMING WHEEL BRAKE ASSEMBLY WHICH DAMAGED BOTH WHEEL AND BRAKE TORQUE TUBES.

Part: SCREW — FAILED (T/R BLADE BAL)

DURING REMOVAL OF T/R BLADE TIP SCREW, THE SCREW BROKE. SCREW IS LOCATED AT THE TIP OF TAIL ROTOR BLADE TO HOLD THE BALANCE WEIGHTS. THIS SCREW IS IN ALLOYED STEEL (CODE BC- STEEL 35NC6). REMOVING THE SCREW FROM THE TIP OF THE TAIL ROTOR BLADE IN FOR A NORMAL BALANCING CHECK, THE SCREW BROKE WITH A PART OF IT IN THE BLADE TIP. WHEN REMOVING THE SCREW AN EXTRACTOR BROKE ALSO IN THE BLADE TIP. THE BREAKING OF SCREW WAS DUE TO CORROSION. THERE IS NO WAY TO PREVENT CORROSION OF THIS SCREW INDICATED IN THE MM OF ASE350 AND MM AS355. AT THE INSTALLATION OF THE SCREW AS PRESCRIBED IN MM, IT IS PROHIBITED TO PROTECT THE SCREW WITH GREASE, MASTINOX, ETC.

Part: RISER — CORRODED (WING PLANK)

GULFSTREAM CUSTOMER BULLETIN NR CB 337 REQUIRES X-RAY INSPECTION OF INBOARD LOWER PLANK SPLICES AND ULTRASONIC INSPECTION OF THE ADJACENT RISERS. SUBSEQUENT DISASSEMBLY FOR REPAIRS REVEALED EXTENSIVE CORROSION IN SPLICES AND RISERS NOT DETECTABLE BY THE SPECIFIED TECHNIQUES. N-NR YV28CP.

Part: AIR CYC MACHINE — FAILED (CABIN AIR)

AIR CYCLE MACHINE FAILED TO COOL DUE TO OIL CONTAMINATION IN BLEED AIR CIRCUIT. ULTIMATELY, THE OIL CONTAMINATION CAUSED EXCESS FRICTION IN ROTATING GROUP CAUSING UNIT TO FAIL.

Part: TANK — DEFECTIVE (FUSELAGE)

BLIND RIVETS ON INNER WALL OF AFT FUSELAGE TANK SKIN TO FRAME WERE INCORRECTLY INSTALLED. RIVETS DID NOT EXTEND THROUGH SUFFICIENTLY TO FASTEN ALL MATERIAL. LEFT SIDE OF AIRCRAFT FR 22-25, STR 10-14. TT: 4,971.5 HOURS. LANDINGS: 3,301.

Part: WING PLANK — CORRODED (INBD LOWER)

GULFSTREAM CUSTOMER BULLETIN NR CB 337 REQUIRES X-RAY INSPECTION OF INBOARD LOWER PLANK SPLICES AND ULTRASONIC INSPECTION OF THE ADJACENT RISERS. SUBSEQUENT DISASSEMBLY FOR REPAIRS REVEALED EXTENSIVE CORROSION IN SPLICES AND RISERS NOT DETECTABLE BY THE SPECIFIED TECHNIQUES.

Part: HINGE — CRACKED (CABIN DOOR)

WHILE AIRCRAFT WAS UNDERGOING A SCHEDULED INSPECTION, NOTED THE RIVETS IN THE THE AFT LOWER CABIN DOOR HINGE APPEARED TO BE LOOSE. FURTHER VISUAL AND EDDY CURRENT INSPECTION SHOWED THE HINGE WAS CRACKED AT ALL THREE RIVET LOCATIONS. THE RIVETS HAD BEEN INSTALLED PREVIOUSLY IAW CESSNA BULLETIN PJN81-21. HINGE WAS REMOVED AND NEW PART INSTALLED.

Part: PLUG — LOOSE (CRANKSHAFT)

FLIGHT OVER THE GULF OF MEXICO. PROPELLER RPM STARTED TO DROP OFF. PROP CONTROL WAS ADVANCED, BUT AFTER ONE HOUR, PROPELLER WENT TO FEATHERED POSITION. AFTER SAFE LANDING, A VARIETY OF TESTS REVEALED THE PLUG, PN 71640, WAS LOOSE INSIDE THE CRANKSHAFT ALLOWING OIL TO BYPASS PROPELLER GOVERNOR. AFTER PLUG WAS PROPERLY SEATED, TESTING REVEALED NORMAL OPERATION ONCE AGAIN. NO METAL WAS FOUND IN FILTER OR SCREWS. OTHER ENGINE WAS CHECKED AND FOUND OK. NO RECOMMENDATION.

Part: SHAFT — CRACK (UPPER PIN HOLE)

DURING ROUTINE 100-HOUR EDDY CURRENT INSPECTION OF SHAFT PIN HOLES, A POSITIVE INDICATION WAS DETECTED. SHAFT WAS REMOVED FROM THE AIRCRAFT AND SENT TO THE SHOP FOR EVALUATION. MAGNETIC PARTICLE INSPECTION REVEALED A CRACK APPROXIMATELY 0.150 INCH LONG FROM ONE PIN HOLE. NO OTHER DEFECTS NOTED. PART IS BEING FORWARDED TO BOEING HELICOPTERS FOR FURTHER EVALUATION. (X)

Part: LEAD — DEFECTIVE (PROPELLER HEAT)

NEW PROPELLER DE-ICE HEAT LEADS WERE PURCHASED FROM DISTRIBUTER. THESE LEADS WERE IN THE ORIGINAL MANUFACTURER PACKAGING. WHEN THE PACKAGE WAS OPENED AND LEADS INSPECTED, FOUND OF THE 5 PACKAGED LEADS, 2 LEADS HAD LOOSE TERMINAL ENDS THAT WERE EASILY PULLED LOOSE FROM THE WIRE. DISTRIBUTER WAS INFORMED AND ADVISED TO CHECK THEIR STOCK. THEY INDICATED THEY WOULD ADVISE MANUFATURER.

Part: FIRE BOTTLE — DISCHARGED (APU)

AIRCRAFT WAS ON HELIPAD WHEN THE FIRE BOTTLE DISCHARGED. INVESTIGATION REVEALED THE THERMAL RELIEF VALVE HAD ACTIVATED AND BOTTLE PRESSURE WAS ZERO. THE SKIN OF THE ACFT IS VERY CLOSE TO THE BOTTLE AND IS PAINTED BLACK ON THE OUTSIDE AND IN A POSITION OF DIRECT SUNLIGHT IN THE A.M. THE OAT ON THE HELIPAD WAS 74 DEGREES FAHRENHEIT. THE FIRE BOTTLE COMPARTMENT INSIDE SKIN TEMP WAS 132 DEGREES FAHRENHEIT. THE INSIDE SKIN TEMP OF SKIN THAT HAS AN OUTSIDE PAINT OF WHITE NEAR SAME AREA WAS 107 DEGREES FAHRENHEIT. (A COMPANY CALIBRATED INSTRUMENT WAS USED.) MM, CHAPTER 26-20-00, PAGE 8, PARAGRAPH E, STIPULATES HIGH PRESSURE BLOW-OFF BETWEEN 208 DEGREES TO 220 DEREES FAHRENHEIT. (X)

Part: SWITCH — OUT OF RIG (UPLOCK)

AIRCRAFT IS EGYPTIAN REGISTERED. GEAR DOORS ON LANDING GEAR WOULD NOT RETRACT WHEN GEAR WAS RETRACTED. CHECKED UPLOCK SWITCHES AND FOUND THE NOSE GEAR UPLOCK SWITCH WOULD NOT CLOSE TO ALLOW THE GEAR DOORS TO CLOSE. ALSO, FOUND THE MECHANICAL UNLOCK CONTROLS MOVED TOO HARD. LUBED MECHANICAL UNLOCK AND MOVES OKAY. COMPLETED A RETRACT TEST AND GEAR PERFORMED PROPERLY.

Part: BLADE — FAILED (HPT AND LPT)

DURING TAKEOFF, ENGINE EXPERIENCED A CONTAINED FAILURE ON THE HPT AND LPT INCLUDING SEPARATION OF THE EXHAUST CONE. DURING INVESTIGATION, NUMEROUS PIECES OF THE TURBINE WERE FOUND IN THE ENGINE EXHAUST AREA AND RUNWAY. A METALLURGICAL EXAMINATION IS BEING ACCOMPLISHED BY PW FIELD REP. AN ENGINE BORESCOPE WAS ACCOMPLISHED A WEEK PRIOR TO FAILURE, NO DAMAGE REPORTED DURING THIS INSPECTION. ENGINE IS SCHEDULED FOR TEAR-DOWN AND CAUSE OF FAILURE WILL BE PROVIDED TO THE FAA.

Part: COMPUTER — MALFUNCTION (NR 1 AFCS)

A YAW KICK WAS FELT IN-FLIGHT. THE KICK WAS ISOLATED TO THE NR 2 AFCS SYSTEM. SUBSEQUENT TROUBLESHOOTING REVEALED THE PROBLEM TO BE THE NR 2 AFCS COMPUTER CAUSING THE YAW KICK. A SECOND SPARE COMPUTER WAS INSTALLED IN NR 2 POSITION AND THE SAME PROBLEM WAS THERE. ALSO, A LARGE ENGAGEMENT ERROR WAS NOTICED WHEN TURNING THE SYSTEM ON AND OFF. FINALLY, REPLACED THE NR 1 AFCS COMPUTER FOR TROUBLESHOOTING AND THE PROBLEM WAS GONE. (X)

Part: PISTON PIN — BROKEN (CYLINDER NR 5)

OPERATORS WERE NOTIFIED AIRCRAFT'S ENGINE CONTAINED A PISTON PIN FROM THE BATCH LISTED IN LYC SB 527C. AIRCRAFT WAS REMOVED FROM SERVICE AND ALL CYLINDERS REMOVED TO VISUALLY INSPECT FOR BATCH NR 17328. CYLINDER NR 5 REVEALED BROKEN PIN. NUMERS WERE NOT CLEARLY VISIBLE, SO ALL PINS WERE CHANGED WITH NEW PINS DIRECT FROM LYCOMING.

Part: HUB — CRACKED (M/R HEAD)

CRACK DISCOVERED DURING POST-FLIGHT INSPECTION. CRACK ON TOP SURFACE OF CENTER SECTION BETWEEN RESERVOIR MOUNT HOLE AND TIE BAR BOLT ACCESS HOLE. EXTENDS THROUGH RESERVOIR HOLE DOWN INTO WEB OF CENTER SECTION. ROTOR HUB OPERATED ON MJ022 IN 'LR' CONFIGURATION BY HELIKOPTER SERVICE NORWAY. ONLY OPERATED 7 DAYS AND 55 HOURS IN 'UT' LOGGING ENVIRONMENT. PART NEW FROM BOEING APRIL 1994, INSTALLED BY HS AT COMPONENT TT 6,928.9 HOURS. OVERHAULED BY HS JUNE 1995 AT COMPONENT TT 7,883.5 HOURS.

Part: BLADE — CRACKED (MAIN ROTOR)

SPAR IS CRACKED ON THE BOTTOM SIDE BACKWALL RADIUS APPROXIMATELY 112.1 INCHES FROM TIP END. SPAR AT CRACK LOCATION SHOWS NO OBVIOUS SIGNS OF DAMAGE ON THE EXTERIOR SURFACE.

Part: RIB — SEPARATION (WING SPAR)

INVESTIGATION FOR RIB SEPARATION FROM WING SPAR FOUND THE DESIGN OF LANDING GEARINSTALLATION TO BE A CAUSAL FACTOR. THIS INSTALLATION (EXTENDING FORWARD AND ATTACHED TO MAIN SPAR) INDUCES A TWISTING MOTION ON THE MAIN SPAR DURING LANDING. A HARD 3-POINT OR OFF-FIELD LANDING ATTEMPTS TO TWIST THE SPAR. THE TWISTING MOMENT IS ONLY RESTRAINED BY THE SECURITY OF THE GLUED RIBS. FAILURE MODE IS SUBTLE SHOWING UP AS SQUEEKS IN THE WING WHEN ROCKING THE WING DURING THE PRE-FLIGHT, BAGGINESS OR WRINKLES IN THE FABRIC, OR POSSIBLY WING LOW IF PROGRESSED FAIRLY FAR ALONG (NUMEROUS WING RIBS HAVING SEPARATED FROM THE SPAR).

Part: BOLT — FAILED (NLG DRAG LINK)

INVESTIGATION FOR NLG COLLAPSE ON LANDING FOUND BOLT CONNECTING DRAG LINK TO GEAR STRUT BROKEN. BOLT HAD A FATIGUE CRACK WHICH WORKED THROUGH BOLT DUE TO CYCLIC LOADING UNTIL BOLT FAILED DURING GEAR EXTENSION.

Part: SUNGEAR — FATIGUE (GEAR BOX)

ENGINE FAILED IN CRUISE. INVESTIGATION REVEALED THE FRACTURE OF THE RGB 1ST STAGE SUN GEAR FAILED DUE TO FATIGUE. THE ORIGINAL CAUSE OF THE FATIGUE COULD NOT BE DETERMINED. THE RGB DECOUPLING WAS CAUSED BY AN OVERSPEED CONDITION OF PT ROTOR RESULTING IN LIBERATION OF THE PT BLADES DUE TO TENSILE OVERLOAD. THE ENGINE WAS OVERHAULED AND RELEASED ON THE AUGUST 6, 1996 AND FAILED AT TSO 409 HOURS/1623 CSO.

Part: INDICATOR — MALFUNCTION (3 AXIS GYRO)

3 AXIS GYRO INDICATOR MALFUNCTION. AIRCRAFT UNDER FOREIGN REGISTRY, INSPECT AND EVALUATE AS REQUIRED.

Part: TRIM TAB — OUT OF BALANCE (ELEVATOR)

PARACHUTING FLIGHT - AFTER JUMP TRIMMED NOSE DOWN, IN DESCENT 150 MPH, ELEVATOR VIBRATION WHICH DISAPPEARED WHEN SPEED 130 MPH. TRIM TAB UNDERSIDE SKIN WAS DEFORMED UNDER BRACKET ASSEMBLY AND TRIM ACTUATOR WAS LOOSE FROM FASTENERS. ELEVATOR MASS BALANCE WAS FAR OUT OF LIMITS. ELEVATOR TRAILING EDGE AND TRIM TAB URETHANE CORE WERE WET WHICH WAS THE REASON FOR OUT OF BALANCE. SEVERAL OTHER CASES OF TRIM TABS AND TRAILING EDGES HEAVILY CORRODED BECAUSE OF WATER IN URETHANE. TOT: 2,800 HOURS.

Part: TRIM TAB — CORE SOAKED (ELEVATOR)

PARACHUTING FLIGHT - FL 100, AFTER JUMP IN DESCENT SPEED 100 MPH ELEVATOR FLUTTER, FAST AND HEAVY MOVEMENTS 2-3 SECONDS, DISAPPEARED WHEN SPEED 80 MPH. TRIM ACTUATOR WAS LOOSE FROM BROKEN STABILIZER BRACKET, FREE MOVEMENT 2 INCHES. NEARBY RIB WAS ALSO BROKEN. FREE PLAY OF ACTUATOR ITSELF WAS IN ORDER. TRIM TAB URETHANE CORE WAS WET, WHEN WEIGHED, THE TAB WAS TWICE AS HEAVY COMPARED WITH NEW SPARE. ALSO, THE ELEVATOR TRAILING EDGE URETHANE CORE WAS WET AND ELEVATOR FAR OUT OF MASS COMPENSATION VALUES BECAUSE OF WATER IN URETHANE. TOT: 4,983 HOURS.

Part: HUB — CRACKED (NR 2 SOCKET)

DURING EDDY CURRENT INSPECTION, TWO CRACKS FOUND IN NR 2 HOLE, 3RD AND 4TH THREADS IN AT 6 O'CLOCK.

Part: TAB LOCK — MISSING (COMP BLADE)

TAB LOCK FOUND MISSING WHEN ENGINE DISASSEMBLED. NO CONTACT NOTED BETWEEN BLADE AND 3RD STAGE STATOR. BROKEN PIECES OF THE TAB LOCK CONTACTED BLADES AND STATORS AFT OF THE 3RD STAGE CAUSING IMPACT DAMAGE. ENGINE WAS LAST OVERHAULED BY PRATT AND WHITNEY. (X)

Part: THERMOSTAT — FAILED (WINDSHIELD SW)

REMOVED FAILED SWITCHES, PURCHASED NEW FROM LEAR, TESTED AND FOUND FAILED, HAD SWITCHES TESTED BY LAB AND FAILED. REPLACEMENTS FROM LEAR FAILED, ONE OUT OF TWO, 2 TIMES. RECOMMEND LEAR RE-INITIATE TEST PROGRAM ON THEIR SWITCHES LIKE THEY USED TO DO.

Part: FRAME — CORRODED (FR 950A S19L)

DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS FOUND ON FUSELAGE FRAME 950A BETWEEN S19L AND S20L.

Part: WHEEL — CRACKED (OUTER HALF)

DURING ROUTINE INSPECTION, FOUND 50MM (2 INCH) LONG CRACK IN THE RADIUS OF THE OUTER WHEEL HALF DIRECTLY BELOW ONE OF THE THREE BOLTS WHICH HOLD THE TWO HALVES TOGETHER. (BOLT IS DIRECTLY OPPOSITE THE VALVE CORE HOLE.) NO OPINION AS TO CAUSE.

Part: DIAPHRAGM — RUPTURED (AFCU)

DURING DISASSEMBLY OF AFCU, FOUND DIAPHRAGM RUPTURED, P/N 2525013.

Part: STIFFENER — CORRODED (NLG BOX HORIZ)

DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON TOP NOSE GEARBOX HORIZONTAL SITFFENER, FROM END TO END, AT STA 294.5 (AS VIEW FROMT HE E/E BAY).

Part: STRINGER — CORRODED (BS 277 S33L)

DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON S23L FROM STA 277 TO STA 294.5.

Part: SPAR CAP — CORRODED (RT WS 560)

DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON LOWER FWD SPAR CAP AT RT WING STA 560 AT ATTACH POINT FOR LOWER LEADING EDGE ACCESS PANEL. APPARENTLY CAUSED BY INADEQUATE PREVENTIVE TREATMENT.

Part: STIFFENER — CORRODED (NLG BOX BS 312)

DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON TOP NOSE GEARBOX HORIZONTAL STIFFENER AT STA 312 (AS VIEWED FROM THE E/E BAY).

Part: FITTING — CRACKED (BS 600K)

SEVEN INCH LONG CRACK LT TERMINAL FITTING LOWER FORWARD CARGO AREA BS 600K, WL 170, LBL 50, INTERIOR P/N 50-5345-11. REF DWG. 50-2529 5H.3A ZNC2. THE FOLLOWING A/C HAS THE SAME CRACKS IN THE SAME AREA FROM 3.8 INCHES LONG TO 8 INCHES LONG. BOEING 707-338C S/N 19296 N6546L 65,300 HRS. BOEING 707-338C S/N 19293 N2178F 59,473 HRS. BOEING 707-321C S/N 20016 N870PA 52,582.24 HRS.

Part: BEAM — CORRODED (THRUST REV LT)

DURING 600-HOUR INSPECTION, FOUND INTERGRANULAR CORROSION OF BEAM AROUND NAS1154C5 ATTACH SCREW. BOTH OUTBOARD BEAMS OF THRUST REVERSERS HAD THIS CORROSION. BEAM IS EXTRUDED ALUMINUM. LEARJET RECOMMENDS BEAM REPLACEMENT. PART TOTAL CYCLES, 2,933.

Part: CRANKCASE — CRACKED (ALTERNATOR MT)

OIL LEAK. FOUND RIGHT CRANKCASE CRACKED IN THE MIDDLE OF THE REAR MOUNTING FLANGE OF THE ALTERNATOR. CRACK EXTENDED TOWARDS THE NR 4 MAIN BEARING 45MM (1.75 INCH). LOOKING FROM THE OUTSIDE, THE CRACK ALSO EXTENDS TOWARDS THE BACK 25MM (1 INCH) DIRECTLY UNDER THE 7TH STUD BOSS. TMC REMAN: 2771.0.

Part: TACH GENERATOR — EAR BROKEN (SHAFT FORK)

TACHOMETER GENERATOR AREA WAS OILY. TACHOMETER WAS REMOVED FOR INSPECTION. FOUND ONE OF THE EARS OF THE GENERATOR SHAFT FORK BROKEN OFF. NO OPINION AS TO CAUSE.

Part: HMU — MALFUNCTION (LT ENG)

INSTALLED HMU ON ENG FOR TEST AFTER C/W CFE 7388001. PERFORMED 2 NORMAL STARTS SATISFACTORILY. THE 3RD START ATTEMPT AND SUBSEQUENT ATTEMPTS FAILED. RE-INSTALLED ORIG HMU AND STARTS WERE NORMAL.

Part: SENSOR — RUSTED (TIP TANK QTY)

THE FUEL QTY SENDER IN THE TIP TANK (FLINT) CORRODED SEVERELY DUE TO THE TANK BEING LEFT EMPTY MOST OF THE TIME. CONDENSATION AND RUST TOTALLY DESTROYED THE SENDER. RECOMMEND KEEPING SOME FUEL IN THE TIP TANKS AT ALL TIMES. STC SA1335SO.

Part: ROCKER — BROKE (NR 2 CYL EXH)

THE NR 2 EXHAUST 'ROLLER ROCKER' BROKE MID-WAY BETWEEN THE PUSH ROD SOCKET AND THE ROCKER ARM SHAFT. STC 8594SW.

Part: BRAKE ASSY — LOCK UP (MLG)

BRAKE LOCKED UP. HIGH TEMPERATURE.

Part: BATERY PACK — SHORTED (CABIN)

THE NEW BATTERY PACKS USED BY GRIMES WHICH ARE MFG'D BY E.A.C., USE A METAL STRAP BETWEEN POSITIVE AND NEGATIVE TERMINALS WITH A SMALL PIECE OF HEAT SHRINK ON THEM. THE PROBLEM IS THE HEAT SHRINK SHRINKS AT TEMPERATURE AND THE STRAPS CUT THE HEAT SHRINK AND SHORT THE TERMINALS TO THE BATTERY CAUSING SHORTS AND THE PACKS OVERHEAT.

Part: TIRE — LEAK (MLG)

DUNLOP EQUIPPED BOEING 757 MAIN WHEEL ASSEMBLIES LEAKING. SUSPECT CAUSE WAS MICHELIN TIRE HAS A SMALL PROCESS CONTROL STICKER INSTALLED ON THE INSIDE TIRE WALL TO ENSURE PROPER CURE MOLD. THIS STICKER HAS DETERIORATED ONCE IN SERVICE AND MAY LODGE IN VALVE CORE SEAT WHEN TIRE PRESSURE IS CHECKED CAUSING SLOW LEAKAGE. TIRE IS MANUFACTURED BY MICHELIN FOR BFG.

Part: CYLINDER — SEAT WORN (NR 4 CYL EXH)

THE AIRCRAFT ARRIVED FOR 100-HOUR INSPECTION. COMPRESSION CHECK SHOWED NR 4 CYLINDER 55/80. ALL OTHER CYLINDERS WERE IN THE MID 70'S. THE CYLINDER WAS REMOVED. EXHAUST VALVE AND SEAT WERE WORN EXCESSIVELY. THIS IS A FACTORY RE-MANUFACTURED ENGINE. ALSO, FOUND, EXHAUST GUIDE WORN EXCESSIVELY, CYLINDER CHOKE AT MINIMUM SERVICE LIMIT, AND CYLINDER .0015 INCH OUT OF ROUND. ALL OTHER CYLINDERS APPEAR TO BE NORMAL.

Part: CROSS TUBE — CORRODED (LANDING GEAR)

SEVERE CORROSIONS FOUND UNDER THE CHAFING STRIPS OF THE LANDING GEAR CROSS TUBES.

Part: CROSS TUBE — CORRODED (LANDING GEAR)

SEVERE CORROSIONS FOUND UNDER THE CHAFING STRIPS OF THE LANDING GEAR CROSS TUBES.

Part: FUEL NOZZLE — DEFECTIVE (RT ENGINE)

AT CLIMB-OUT THE CREW NOTICED THE RT ITT CLIMBING PAST RED LINE. POWER LEVER WAS PULLED BACK UNTIL ITT WAS RED LINE. THERE WAS ONLY 1,200 POUNDS OF TORQUE NOTED. WHEN THE ENGINE HOT SECTION WAS REMOVED, THE CT VANE RING HAD ONE VANE WITH 99 PERCENT OF THE VANE AREA MELTED OR BURNED AWAY. THE CT BLADES WERE DISCOLORED DUE TO HIGH TEMP. AT THIS POINT OF THE INVESTIGATION, THE FUEL NOZZLE SET IS THE SUSPECTED CAUSE FOR FOR THE HOT SECTION DAMAGE.

Part: BLOCK — FAILED (OUTER WING SYS)

AUS - DURING INVESTIGATION OF A WRINKLE IN THE FABRIC COVERING ON THE TOP WING (INBOARD) TRAILING EDGE, THE DRAG/ANTI-DRAG WIRE REAR ATTACHMENT BLOCK AT REAR SPAR WAS FOUND BROKEN WHICH, IN TURN, CAUSED THE TRAILING EDGE TO CENTRE HOOP ATTACHMENT BLOCK TO FAIL.

Part: FILTER ADAPTER — WRONG CONN (WASTEGATE OIL)

EXPERIENCED INCONSISTENT MANIFOLD PRESS & FUEL FLOWS. LOOKED AT SOURCE OF OIL TO WASTEGATE FROM OIL PUMP HSNG P/N 643716, & FND PORT USED SUPPLIED UNFILTERED OIL. OIL PUMP HSNG IS NEW P/N WHICH USES FULL FLOW OIL FILTER. NEW HSNG HAS, BELOW FILTER BASE, A 2ND PORT THAT WILL PROVIDE FILTERED OIL. OLD P/N 632770 OIL PMP HSNG WHICH USES OTHER STYLE OF FILTER (CESSNA SUPPLIED OIL FILTER ADAPTER P/N 1250922-4) HAS 1 PORT FOR FILTERED OIL SUPPLY TO W/G. PORT IS IN SAME LOCALE AS UNFILTERED PORT ON NEW P/N HSNG. PROBLEM DEVELOPED WHEN REPLACING ENG WITH OLD HSNG WITH ENG HAVING NEW. ASSUMED FILTERED OIL WOULD COME OUT OF SAME LOCALE, PORT IS DIFFERENT INSIDE. PORT IS PLUGGED WITH ALLEN HEAD PLUG.

Part: BRACKET — ELONGATED HOLE (RT COWL FLAP)

WHILE INSPECTING RIGHT COWL FLAP FOR EXCESSIVE PLAY, FOUND IMPROPER BOLT USED WHICH ELONGATED HOLES ON ATTACH BRACKETS. REPLACED BRACKETS WITH NEW AND REPLACED BOLTS WITH PROPER CLEVIS PINS AND WASHERS PER PARTS BOOK.

Part: SEAL — DEBONDED (DRIVE SHAFT)

DRIVE SHAFT SEAL DEBONDED (2 EACH). REPLACED WITH NEW FIXTURE.

Part: COUPLING — PITTED (M/R DRIVE)

DRIVE COUPLING PITTED. REPLACED WTIH NEW FIXTURE.

Part: COUPLING — PITTED (M/R DRIVE)

INTER DRIVE COUPLING PITTED. REPLACED WITH NEW FIXTURE.

Part: SEAL — DEBONDED (DRIVE SHAFT)

DRIVE SHAFT SEAL DEBONDED. REPLACED WITH NEW FIXTURE.

Part: COUPLING — PITTED (M/R DRIVE)

DRIVE SHAFT COUPLING PITTED. REPLACED WITH NEW FIXTURE.

Part: COUPLING — PITTED (M/R DRIVE)

DRIVE SHAFT COUPLING HAS PITTED TEETH. REPLACED WITH NEW FIXTURE.

Part: BATTERY — DISCHARGED (CABIN)

HNL - AFT CABIN EMERGENCY LIGHTS INOP. REPLACED BATTERIES. OPS CHECK OK. (M)

Part: GEAR — FAILED (APU GRBOX)

APU RECEIVED AND AN INVESTIGATION CONDUCTED DUE TO OIL CONTAMINATION AND HARD TO ROTATE. UPON DISASSEMBLY OF THE GEARBOX ASSEMBLY, PN 160192-100, SN 5002-1206, THE INTERNAL GEAR WAS FOUND CRACKED AND SPLIT IN THREE PLACES FROM THE BASE TO THE HOLES. ALL THREE BEARINGS, PN 9524301, WERE SPINNING IN THE CARRIER HOUSING ASSY. THE PINION SHAFT, PN 44647-0, DID NOT SHEER, BUT THE TEETH WERE GROUND OFF. THE COVER DRAIN, PN 32896-1, WAS BENT/MANGLED AND THE BOTTOM THIRD WAS GROUND OFF. SUBMITTER STATED CAUSE IS UNKNOWN AT THIS TIME.

Part: TERMINAL BLOCK — FAILED (DC CONTACTOR BOX)

TPA/TLH - FLT 3448 - DURING AUTOFEATHER TEST, THE LEFT AND RIGHT ALTERNATE FEATHER ADVISORY LIGHTS WOULD NOT ILLUMINATE. REPLACED 2431-TB7 TERMINAL BLOCK IN DC CONTACTOR BOX. (X)

Part: APU — FAILURE (EMPENNAGE)

OGG - PRIOR TO TAKEOFF, UNKNOWN SMOKE FILLED THE COCKPIT AND PASSENGER CABIN. CONDUCTED EMERGENCY EVACUATION. MAINTENANCE INSPECTION DISCLOSED APU FAILURE RESULTED IN APU OIL TO ENTER BLEED AIR SYSTEM CAUSING SMOKE. APU WAS REPLACED AND ALL SYSTEM CHECK NORMAL.

Part: HYD MODULE — LEAKING (NLG WW)

AFTER TAKEOFF FROM OMA, LANDING GEARS WOULD NOT RETRACT RESULTING IN AN AIR TURN BACK. FOUND 'B' HYD SYSTEM MODULE UNIT (HOUSING) FAILED AT THE NR 5 PUMP PRESSURE SUPPLY PORT. REMOVED AND REPLACED MODULE PER MM 29-12-31. OPS AND LEAK CHECK GOOD. ALSO, FOUND NR 2 ENGINE DRIVEN HYD PUMP LEAKING. REMOVED AND REPLACED PUMP PER MM 29-12-00. REMOVED AND REPLACED NR 1 ENGINE DRIVER HYD PUMP FOR PRECAUTIONARY MEASURE. OPS AND LEAK GOOD.

Part: SPAR — FASTENER SHEARED (UNDER FLOOR)

INSPECTION FOUND SPAR WITH 2 FASTENERS BROKEN (SHEARED) APPROXIMATELY 14 INCHES FROM CENTER LINE UNDER LEFT SEAT IN COCKPIT AREA (FORWARD FLANGE).

Part: SEAL — SEPARATED (DRIVE SHAFT)

REPLACED WITH NEW FIXTURE. DRIVE SHAFT SEAL BOOT SEPARATION (2 EACH).

Part: VANE CONTROL — INOPERATIVE (NR 1 ENGINE)

ENGINE REPAIRED BY LUFTHANSA, FIRST FLIGHT AFTER INSTALLATION. NR 1 ENGINE STALL WHILE CLIMBING THROUGH 10,000 FEET. FLT NR GTI900/31, LUXEMBOURG-TURIN-ENGINE SHUT-DOWN. ENGINE RE-START ATTEMPT UNSUCCESSFUL. AIRCRAFT RETURNED TO LUXEMBOURG BORESCOPE HPC/HRT NORMAL, MAGNETIC PLUGS, OIL FILTERS, FUEL FILTER, INLET, EXHAUST - OK. INSPECT PT2/TT2 LINES, FUEL PUMP FP12, 3-WAY VALVE - OK. INSPECT VSV UNISON RINGS SPACERS - OK. REPLACE ENGINE VANE CONTROL, ACCOMPLISH TRIM RUN, POWER RUN - ENGINE OPS NORMAL.

Part: PUMP — PORT BLOCKED (ENGINE FUEL)

AN AUSTRALIAN BASED PA-34 PILOT REPORTED ENGINE FAILURE DUE TO FUEL STARVATION. CAUSE WAS A RUBBER WASHER BLOCKING THE FUEL OUTLET PORT OF A NEW TEXTRON FUEL PUMP. TEXTRON SB 525 ADDRESSES THE PROBLEM. NO AIRWORTHINESS DIRECTIVE HAS BEEN ISSUED TO DATE. SUBMITTER STATED THERE ARE 4 KNOWN FAILURES FROM SAME CAUSE. NOTE: SAME PROBLEM AS MOONEY M20J IN OCT '96 ALERTS.

Part: CONNECTOR — DIRTY (ISOLATION VALVE)

ON TAXIING, AFTER ENGINE START, FLIGHT CREW NOTED NR 1 AND NR 2 ISOLATION VALVES, PN DC26F14155, WOULD NOT CLOSE. FLIGHT CREW ELECTED TO RETURN TO GATE FOR CORRECTIVE ACTION. AIRCRAFT RETURNED TO GATE WITHOUT INCIDENT. DURING TROUBLESHOOTING, MAINTENANCE CREW IDENTIFIED INTERMITTENT CONTACT BETWEEN WIRING HARNESSES AND ISOLATION VALVES. CLEANED CANNON PLUG NR 1 AND NR 2 ISOLATION VALVES. OPS CHECKED BOTH ISOLATION VALVES. AIRCRAFT RETURNED TO SERVICE. (X)

Part: PACK VALVE — DIRTY (LT ENGINE)

STL - FLT 7180 - NR 1 PACK FAULTED WITH STRONG ELECTRICAL SMOKE SMELL ASSOCIATED, RETURNED TO GATE. MAINTENANCE CLEANED PACK VALVE CONNECTION SURFACE, GROUND RUN GOOD. (X)

Part: ECU — FAILED (RT ENGINE)

STL - FLT 7180 - NR 2 ECU FAULTED, COULD NOT RESET. MAINTENANCE REPLACED ECU, GROUND RUNS GOOD. ENGINE TT 14,383.1 HOURS. (X)

Part: FIRE DET UNIT — FAULTY (NR 1 ENGINE)

ENGINE NR 1 FIRE DURING LANDING ROLL OUT. ECL PROCEDURE COMPLETED(PAGE 34B). FIRE OUT AFTER A FEW SECONDS. MAINTENANCE VERIFIED ENGINE NR 1 DUCTING CONDITION AND FIRE LOOPS. ALL OK. PERFORMED RESISTANCE CHECK AT FDCU AT PINS J AND K PER FIM. ALL READINGS WITHIN NORMAL. MAINTENANCE CREW REMOVED AND REPLACED FIRE DETECTION CONTROL UNIT. RAN ENGINE AND NO FURTHER INDICATIONS EXPERIENCED. PART REMOVED AND REPLACED WAS FIRE DETECTION CONTROL UNIT, MFG PN 8038-02-03, AND SN 796. MFG DATE, 7-93. TRIGGERED BOTH LOOPS 'A' AND 'B' AND TESTED OK DURING GROUND CHECK.

Part: PROX CONTL BOX — MALFUNCTIONED (RT MLG/NLG)

HNL - FLT 516 - INFORMATION FROM LOG PAGE 149767-1. RED NOSE AND RT MAIN UNSAFE LIGHTS AFTER GEAR RETRACTION. RECYCLED, UNABLE TO EXTINGUISH ONE OR BOTH. CHECKED WIRING ON RT MAIN AND NOSE GEAR. FOUND OK. REPLACED PROXIMITY CONTROL BOX. RETRACTION CHECK OK. (X)

Part: WIRE — FAILED (CABIN)

STL - FLT 136 - DURING THE COURSE OF AN INSPECTION, IT WAS DISCOVERED THE EGRESS LIGHTING WAS INOPERATIVE. REPAIRED WIRING HARNESS TO THE EGRESS LIGHTING, OPERATION NORMAL. CHECK C-2D - 6-29-95 - MCI.

Part: WINDSHIELD — CRACKED (LT COCKPIT)

JFK - FLT 730 - IN CRUISE, L-1 WINDSHIELD OUTER PANE CRACKED RESULTING IN AN UNSCHEDULED LANDING AT ABQ. REPLACED L-2 WINDSHIELD, MFG PN 5912290505. CHECK C-1 - 6-27-95.

Part: HANDLE — DEFECTIVE (DOOR)

HANDLE WILL NOT LOCK.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY TRACKING LIGHTING INOP. MAINTENANCE REPLACED EMERGENCY BATTERY. (M)

Part: BRUSH BLOCK — FAILED (RT PROP)

STL - FLT NR 7417 - RIGHT PROP DE-ICE INOP. MAINTENANCE REPLACED RIGHT PROP DE-ICE BRUSH BLOCK. SYSTEM CHECK GOOD. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

PHX - FLT NR 604 - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY LIGHTS INOPERATIVE. REMOVED AND REPLACED BATTERY PACK ON LEFT SIDE AFT CARGO. OPS CHECKED NORMAL, OK FOR SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

PHX - FLT NR 604 - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY EXIT SIGNS AT OVERWING WILL NOT LIGHT. REMOVED AND REPLACED BATTERY PACK. OPS GOOD ON GROUND. (M)

Part: GEAR ASSY — BEARING FROZE (LE SLAT ACTUATOR)

NEEDLE BEARING FROZE IN PLANET GEAR ASSY CAUSING CARRIER TO BECOME INOPERATIVE. PIN ELONGATED MATING HOLES IN CARRIER. SUNSTRAND SB 27-15 REPLACES NEEDLE BEARING AND PIN WITH CORROSIVE RESISTANT MATERIAL. PRODUCT IMPROVEMENT. SUSPECT CAUSE, WATER IN ACTUATOR DUE TO ACTUATOR BEING VENTED DESIGN. DEFECT CAUSED SLAT LOCK-OUT.

Part: GEAR ASSY — BEARING FROZE (LE SLAT ACTUATOR)

NEEDLE BEARINGS FROZE CAUSING PINS IN 3 PLACES IN PLANET GEAR TO ELONGATE CARRIER HOLES BEYOND TOLERANCE. SCRAP COMPLETE ASSY. CURRENTLY, NEEDLE BEARINGS AND PIN BEING REPLACED WITH PRODUCT IMPROVEMENT CORROSIVE RESISTANT MATERIAL PER SUNDSTRAND SB 27-15. ALSO, CAUSED WEAR IN OUTPUT SHAFT CAUSING REPLACEMENT OF SAME. SUSPECT CAUSE IS WATER IN ACTUATOR WHICH IS VENTED CAUSING RUST TO FORM WHICH CAUSES LOCK-OUT OF SLATS.

Part: GEAR ASSY — WATER CONTAM (LE SLAT ACTUATOR)

GEAR SET CONTAMINATED WITH WATER DUE TO VENTED DESIGN OF ACTUATOR. ACTUATOR PREVIOUSLY HAD SB 27-15 ACCOMPLISHED. PLANET CARRIER ASSY IN GOOD CONDITION. REPLACED PART DUE TO WATER.

Part: GEAR ASSY — BEARING SEIZED (LE SLAT ACTUATOR)

NEEDLE BEARING FROZE TO PLANET GEAR. REMOVED BEFORE DAMAGE TO CARRIER OCCURRED, SUNSTRAND SB 27-15. REPLACES NEEDLE BEARINGS AND PINS WITH CORROSIVE RESISTANT MATERIAL. PRODUCT IMPROVEMENT. SUSPECT CAUSE, WATER IN ACTUATOR DUE TO BEING VENTED. CAUSED LOCK-OUT OF SLATS.

Part: HINGE — CRACKED (LT MLG DOOR)

IN S-CHECK, DURING ACCOMPLISHMENT OF AD 91-22-07, FOUND LEFT OUTBOARD GEAR DOOR HINGE HAD 3 CRACKED LOBES. REPLACED LEFT OUTBOARD GEAR DOOR HINGE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND FLOOR PROXIMITY EMERGENCY EXIT LIGHTS INOPERATIVE FROM ROW 7 THROUGH ROW 13. REMOVED AND REPLACED BATTERY PACK, OPS CHECK GOOD. (X)

Part: UPLOCK SW — OUT OF ADJUST (RT MLG)

LANDING GEAR TRANSIT LIGHT ILLUMINATED DURING FLIGHT. TROUBLESHOT AND ADJUSTED RIGHT UPLOCK PROX SWITCH. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: HYD PUMP — FAILED (NR 2)

ON TAKEOFF FROM BGM, NR 2 HYDRAULIC FAIL LIGHT ILLUMINATED UPON LANDING GEAR RETRACTION. AIRCRAFT RETURNED TO FIELD. TROUBLESHOT AND FOUND NR 2 ENGINE DRIVEN HYDRAULIC PUMP AT FAULT. REMOVED AND REPLACED PUMP, BLED SYSTEM. SUBSEQUENT TEST FLIGHT PROVED SATISFACTORY. AIRCRAFT RETURNED TO SERVICE. (M)

Part: PROX CONTL BOX — MALFUNCTIONED (NLG)

HNL - FLT NR 351 - AFT GEAR RETRACTION 'RIGHT GEAR UNSAFE' LIGHT REMAINED ON AFTER APPROX 1 MINUTE. 'GEAR DOOR OPEN' LIGHT CAME ON. RETURNED TO HILO FOR PRECAUTIONARY LANDING. DURING DESCENT SPEED BRAKE HANDLE WOULD NOT LOCK IN DETENTS. DURING DESCENT BOTH 'GEAR' AND 'DOOR' LIGHTS WENT OUT, NORMAL INDICATIONS. THEREAFTER, GEAR EXTENDED NORMALLY. LANDED WITHOUT INCIDENT. REPLACED MAIN LANDING GEAR PROXIMITY CONTROL BOX. LUBRICATED UPLOCK SWITCH. CLEANED SENSORS. GEAR SWING OPERATIONAL CHECK GOOD. OPERATIONAL CHECK OF SPEED BRAKE CHECKED NORMAL. (M)

Part: TARGET — OUT OF ADJUST (RT MLG)

FLT NR 441 - DEN - UPON ARRIVAL, FLIGHT CREW REPORTED THE RIGHT MAIN LANDING GEAR UNSAFE LIGHT ILLUMINATED. MAINTENANCE ADJUSTED TARGET ON THE PROXIMITY SWITCH AND SYSTEM CHECKED OK. (M)

Part: BATTERY — DISCHARGED (TAIL COMPT)

HNL - IN C-CHECK, TAIL COMPARTMENT EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED EMERGENCY LIGHT BATTERIES IN POWER SUPPLY B5-28. OPERATIONAL CHECK OK. (M)

Part: LAMP — FAILED (CABIN)

STL - FLT NR 7210 - EXTERIOR EMERGENCY LIGHT INOP. REPLACED LAMP. (M)

Part: FRAME — CORRODED (BS 1326)

HNL - IN C-CHECK, FOUND CANTED STATION 1326 FRAME RIGHT SIDE BOTTOM END SEVERELY CORRODED, REPAIRED PER SRM 53-01. CUT OUT LOWER RHS END OF FRAME AND REMOVED DAMAGE. FABRICATED REPAIR FILLER (.050, 7075-T6 CLAD). FABRICATED REPAIR SPLICE DOUBLER (.063, 7075-T6). INSTALLED REPAIR SPLICE DOUBLER USING HL 328-5 HI-LOCKS IN ADDED HOLES. (M)

Part: DOUBLER — CORRODED (LT MLG)

HNL - IN C-CHECK, FOUND LEFT WING LOWER MAIN LANDING GEAR DOUBLER HAS MODERATE CORROSION, REPAIRED PER SRM 57-03. CUT OUT BLENDED EDGE ON MLG DOUBLER. FABRICATED REPAIR FILLER (.125, 2024-T3). INSTALLED FILLER USING SAME SIZE AND TYPE AS THOSE REMOVED. (M)

Part: SKIN — GOUGED (AFT FUSELAGE)

HNL - DURING C-CHECK, GOUGE IN FUSELAGE APPROX 2.5 INCHES AFT OF FORWARD CARGO DOOR CUTOUT BELOW 2ND DOOR ADJUSTMENT SET SCREW. DEPTH CHECK SKIN REMAINING .023 INCH, 1 INCH BY 1 INCH. REPAIRED PER SRM 53-05, FIG 82. REMOVED DAMAGED SECTION. FABRICATED INTERNAL DOUBLER (.025 INCH TI-6AL-4V). FABRICATED EXTERNAL REPAIR DOUBLER (0.071 INCH 2024-T3 CLAD) INSTALLED REPAIR DOUBLER USING NAS1097AD5/6 RIVETS AND HLT435-6 HI-LOCKS IN EXISTING AND ADDED HOLES. (M)

Part: SKIN — CORRODED (BS 927)

HNL - IN C-CHECK DURING FUSELAGE MAPPING, FOUND EXFOLIATION ON FUSELAGE SKIN AT STATION 927, 1.5 INCH ABOVE LEFT LONGERON 26L. REPAIRED PER SRM 53-01. REMOVED DAMAGED SECTION. FABRICATED REPAIR FILLER (7075-T6 CLAD). FABRICATED INTERNAL REPAIR FILLER DOUBLER (0.032 INCH, TI-6AL-4V). INSTALLED REPAIR DOUBLER USING MS20470AD5 AND NAS1097AD5/6 RIVETS IN EXISTING AND ADDED HOLES. (M)

Part: COUPLING — PITTED (DRIVE)

DRIVE COUPLING PITTED. REPLACED WITH NEW COUPLINGS.

Part: COUPLING — PITTED (DRIVE)

DRIVE COUPLING PITTED. REPLACED WITH NEW COUPLINGS.

Part: FLANGE — CRACKED (ELEV TQ TUBE)

ELEV TQ TUBE FLANGE FOUND CRACKED DURING INSPECTION AFTER PILOT REPORT. PART REPLACED WITH NEW ASSEMBLY. OPS CHECK GOOD.

Part: TQ TUBE FLANGE — CRACKED (ELEVATOR)

TORQUE TUBE FLANGE FOUND CRACKED DURING INSPECTION AFTER PILOT REPORT. PART REPLACED WITH NEW ASSEMBLY.

Part: HEATER — MISREPAIRED (TERMINAL BLOCK)

CABIN HEAT WAS TOO HOT. NOT ABLE TO CONTROL HEAT. DURING TROUBLESHOOTING, FOUND THAT DURING SOME PREVIOUS 'REPAIR', JUMPER WIRES WERE ADDED TO TERMINAL BLOCKS TO MAKE HEATER RUN CONTINUOUSLY. THIS ACTION NEGATED ALL THE HEAT REGULATING SAFETY DEVICES, (THERMOSTAT, DUCT LIMIT SWITCH, AND OVERHEAT SWITCH); THUS, ALLOWING HEATER TO RUN TO VERY HIGH UNCONTAINED TEMPERATURES. SEVERE HEAT DAMAGE WAS FOUND TO HEATER AND HEAT DUCTING, (THERMOSTAT SENSOR SPRING HAD MELTED OFF). ADDITIONAL DAMAGE WAS FOUND TO SURROUNDING WIRING AND AIRCRAFT STRUCTURES. FOUND SEVERAL PLACES WHERE INSULATION HAD BEEN ON FIRE AND THEN SELF-EXTINGUISHED. REQUIRED EXTENSIVE REPLACEMENT OF COMPONENTS.

Part: BATTERY PACK — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND OVERHEAD MID-CABIN EMERGENCY EXIT LIGHT INOPERATIVE. REMOVED AND REPLACED BATTERY PACK, OPS CHECK GOOD. (X)

Part: PILOT TUBE — CRACKED (PROPELLER)

PROPELLER PILOT TUBE HAS AN APPROXIMATE .50 INCH LONG CRACK.

Part: STAIRS — CORROSION (VENTRAL DOOR)

HNL - INFORMATION FROM C-CHECK NR 142905. SEVERE CORROSION ON VENTRAL STAIRS EXTERIOR SURFACE, RIGHT SIDE APPROXIMATELY MIDWAY, LEVEL 2. REPAIRED PASSENGER AFT ENTRY STAIRWAY DOOR SKIN CUTOUT PER SRM 52-01. (X)

Part: CLAMP — CRACKED (321 SCREW HOLE)

PROPELLER CLAMP IS CRACKED WHERE THE 321 SCREW HEAD GOES THROUGH THE CLAMP.

Part: CONNECTOR — DISCONNECTED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND L2 DOOR EMERGENCY EXIT LIGHT INOPERATIVE. RECONNECTED LIGHT ASSEMBLY CONNECTOR. OPS CHECK GOOD. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY EXIT LIGHTS INOPERATIVE FROM ROW 3 THROUGH ROW 8. REMOVED AND REPLACED BATTERY PACK AT STA 500BR, OPS CHECK GOOD. (X)

Part: STATOR SET — LIBERATED SEAL (11TH STAGE)

CAUSE OF IN-FLIGHT SHUTDOWN FOUND TO BE LIBERATED BRAZED HONEYCOMB SEGMENT FROM THE 11TH STAGE STATOR INNER SHROUD.

Part: PROXIMITY SENSOR — FAILED (NLG)

UPON RETRACTION, NOSE GEAR (RED) INDICATION LIGHT WOULD FLICKER OFF AND ON, THEN FINALLY EXTINGUISHED. GEAR EXTENDED NORMALLY. AIRCRAFT RETURNED TO FIELD. AIRCRAFT FERRIED TO BGM FOR REPAIR. REMOVED AND REPLACED NOSE GEAR DRAG STAY PROXIMITY SENSOR. RETRACTION TEST PERFORMED SATISFACTORY. AIRCRAFT RETURNED TO SERVICE. ACTT: 11,502:24 HRS. ACTC: 11,818. (X)

Part: POWER SUPPLY — INOPERATIVE (CABIN)

FORWARD CABIN EEL POWER SUPPLY INOPERATIVE. CHANGED EEL POWER SUPPLY, OPS CHECK GOOD. (M)

Part: WIRE — CORRODED (FUEL COCK NR 2)

DURING C-CHECK, FOUND NR 2 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT AT CENTER AREA OF LT WING CORRODED. REPLACED CABLES. REFERENCE CONTROL NR A6WR95036, NR 95ZZZX6255, AND NR 95ZZZX6256.

Part: WIRE — CORRODED (FUEL COCK NR 3)

DURING C-CHECK, FOUND NR 3 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE CONTROL A6WR95040, NR 95ZZZX6263, AND NR 95ZZZX6265.

Part: WIRE — CORRODED (FUEL COCK NR 2)

DURING C-CHECK, FOUND NR 2 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT AT CENTER AREA OF LT WING CORRODED. REPLACED CABLES. REFERENCE CONTROL NR A6WR95036, NR 95ZZZX6256, AND NR 95ZZZX6257.

Part: WIRE — CORRODED (FUEL COCK NR 2)

DURING C-CHECK, FOUND NR 2 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT AT CENTER AREA OF LT WING CORRODED. REPLACED CABLES. REFERENCE CONTROL NR 95ZZZX6255, NR 95ZZZX6256, AND NR 95ZZZX6257. (X)

Part: CONTROL CABLE — CORRODED (LT AIL TRIM)

DURING C-CHECK, FOUND LT AILERON TRIM CABLE CIRCUIT CABLES CORRODED. REPLACED CABLES. (X)

Part: CONTROL CABLE — CORRODED (LT AIL TRIM)

DURING C-CHECK, FOUND LT AILERON TRIM CABLE CIRCUIT CABLES CORRODED. REPLACED CABLES.

Part: WIRE — CORRODED (FUEL COCK NR 1)

DURING C-CHECK, FOUND NR 1 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. ALL FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR 95ZZZX6258, NR 95ZZZX6259, AND NR 95ZZZX6260. (X)

Part: WIRE — CORRODED (FUEL COCK NR 4)

DURING C-CHECK, FOUND NR 4 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE CONTROL A6WR95046, NR 95ZZZX6267, AND NR 95ZZZX6268.

Part: WIRE — CORRODED (FUEL COCK NR 2)

DURING C-CHECK, FOUND NR 2 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT AT CENTER AREA OF LT WING CORRODED. REPLACED CABLES. REFERENCE CONTROL NR A6WR95036, NR 95ZZZX6255, AND NR 95ZZZX6257.

Part: WIRE — CORRODED (FUEL COCK NR 3)

DURING C-CHECK, FOUND NR 3 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE CONTROL NR 95ZZZX6263, NR 95ZZZX6264, AND NR 95ZZZX6265. (X)

Part: CONTROL CABLE — CORRODED (RUDDER TRIM)

DURING C-CHECK, FOUND RUDDER TRIM CABLES AT CENTER WING ROOT AREA CORRODED. REPLACED CABLES. REFERENCE OPERATOR CONTROL AND NR 95ZZZX6261. (X)

Part: CONTROL CABLE — CORRODED (LT ELEV CONTROL)

DURING C-CHECK, FOUND LT ELEVATOR MAIN CONTROL CABLES CORRODED AFT OF REAR PRESSURE BULKHEAD. REPLACED CABLES. REFERENCE CONTROL NR A6WR95039.

Part: CONTROL CABLE — CORRODED (LT ELEV CONTROL)

DURING C-CHECK, FOUND LT ELEVATOR MAIN CONTROL CABLES CORRODED AFT OF REAR PRESSURE BULKHEAD. REPLACED CABLES. REFERENCE CONTROL NR 95ZZZX6252. (X)

Part: WIRE — CORRODED (FUEL COCK NR 3)

DURING C-CHECK, FOUND NR 3 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE CONTROL A6WR95040, NR 95ZZZX6264, AND NR 95ZZZX6265.

Part: WIRE — CORRODED (FUEL COCK NR 3)

DURING C-CHECK, FOUND NR 3 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE CONTROL A6WR95040, NR 95ZZZX6263, AND NR 95ZZZX6264.

Part: WIRE — CORRODED (FUEL COCK NR 4)

DURING C-CHECK, FOUND NR 4 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE CONTROL A6WR95046, NR 95ZZZX6266, AND NR 95ZZZX6268.

Part: CONTROL CABLE — CORRODED (RT AIL TRIM)

DURING C-CHECK, FOUND RT AILERON TRIM CABLES CORRODED AT CENTER WING ROOT AREA. REPLACED CABLES. REFERENCE CONTROL NR 95ZZZX6262. (X)

Part: FAN FRAME — CORRODED (NR 1 ENGINE)

DURING C-CHECK, FOUND CORROSION ON NR 1 ENGINE MAIN FAN FRAME ON TRAILING EDGES OF STRUTS. REMOVED CORROSION, TREATED AND PAINTED AFFECTED SURFACES. (X)

Part: FAN FRAME — CORRODED (NR 2 ENGINE)

DURING C-CHECK, FOUND CORROSION ON NR 2 ENGINE MAIN FAN FRAME ON TRAILING EDGES OF STRUTS AND AT AFT FIREPROOF BULKHEAD SPLIT-LINE. REMOVED CORROSION, TREATED AND PAINTED AFFECTED SURFACES. (X)

Part: FAN SHROUD — CORRODED (NR 1 ENGINE)

DURING C-CHECK, FOUND NR 1 ENGINE FAN SHROUD ASSY TO HAVE CORROSION AND AREAS MISSING PLASMA COATING. REPLACE FAN SHROUD ASSY. (X)

Part: CONTROL CABLE — CORRODED (RT AIL TRIM)

DURING C-CHECK, FOUND RT AILERON TRIM CABLES CORRODED AT CENTER WING ROOT AREA. REPLACED CABLES. REFERENCE CONTROL NR A6WR95033.

Part: BATTERY — FAILED (EVAC SLIDE)

DURING C-CHECK, FORWARD PASSENGER DOOR EVACUATION SLIDE BATTERY FAILED EFFICIENCY CHECK DUE TO LOW VOLTAGE. REPLACED BATTERY. (X)

Part: BARRIER — SEAM OPEN (CENTER TANK)

DURING C-CHECK, FOUND CENTER FUEL TANK VAPOR BARRIER FORWARD RT SEAM DETERIORATED OPEN. REPLACED VAPOR BARRIER. (X)

Part: CONTROL CABLE — CORRODED (RUDDER TRIM)

DURING C-CHECK, FOUND RUDDER TRIM CABLES AT CENTER WING ROOT AREA CORRODED. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR A6WR95034.

Part: LIGHT ASSY — DEFECTIVE (EVAC SLIDE)

DURING C-CHECK, FOUND AFT SERVICE DOOR EVAC SLIDE LAMP CIRCUIT AMPERAGE LOW DURING LAMP HARNESS TEST. REPLACE LIGHT ASSY. CIRCUIT TESTED WITHIN REQUIRED AMPERAGE PARAMETERS. (X)

Part: BRACKET — CORRODED (AIL SERVO TAB)

DURING COMPLIANCE WITH SB 57-47, FOUND 2 EACH AILERON SERVO TAB BRACKETS CORRODED IN SPOT FACE AREA. REPLACED BRACKETS. (X)

Part: CONTROL CABLE — CORRODED (NR 2 ENG THRUST)

DURING C-CHECK, FOUND NR 2 ENGINE THRUST CONTROL CABLE CORRODED NEAR PULLEY AT WING LEADING EDGE. REPLACED CABLE. (X)

Part: WIRE — CORRODED (FUEL COCK NR 1)

DURING C-CHECK, FOUND NR 1 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. ALL FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR A6WR95035, NR 95ZZZX6258, AND NR 95ZZZX6259.

Part: WIRE — CORRODED (FUEL COCK NR 4)

DURING C-CHECK, FOUND NR 4 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE CONTROL A6WR95046, NR 95ZZZX6266, AND NR 95ZZZX6267.

Part: WIRE — CORRODED (FUEL COCK NR 4)

DURING C-CHECK, FOUND NR 4 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE CONTROL NR 95ZZZX6266, NR 95ZZZX6267, AND NR 95ZZZX6268. (X)

Part: CONTROL CABLE — CORRODED (ELEVATOR TRIM)

DURING C-CHECK, FOUND ELEVATOR TRIM CABLE CIRCUIT IN CENTER WING AREA CORRODED. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR 95ZZZX6269. (X)

Part: CONTROL CABLE — CORRODED (ELEVATOR TRIM)

DURING C-CHECK, FOUND ELEVATOR TRIM CABLE CIRCUIT IN CENTER WING AREA CORRODED. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR A6WR95047.

Part: CONTROL CABLE — CORRODED (RT ELEV CONTROL)

DURING C-CHECK, FOUND RT ELEVATOR MAIN CONTROL CABLES CORRODED AFT OF REAR PRESSURE BULKHEAD. REPLACED CABLES. REFERENCE CONTROL NR 9ZZZX6253. (X)

Part: CONTROL CABLE — CORRODED (RT ELEV CONTROL)

DURING C-CHECK, FOUND RT ELEVATOR MAIN CONTROL CABLES CORRODED AFT OF REAR PRESSURE BULKHEAD. REPLACED CABLES. REFERENCE CONTROL NR A6WR95038.

Part: CONTROL CABLE — CORRODED (RUDDER CONTROL)

DURING C-CHECK, FOUND MAIN RUDDER CONTROL CABLES CORRODED AFT OF REAR PRESSURE BULKHEAD. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR A6WR95037.

Part: CONTROL CABLE — CORRODED (RUDDER CONTROL)

DURING C-CHECK, FOUND MAIN RUDDER CONTROL CABLES CORRODED AFT OF REAR PRESSURE BULKHEAD. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR 95ZZZX6254. (X)

Part: WIRE — CORRODED (FUEL COCK NR 1)

DURING C-CHECK, FOUND NR 1 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. ALL FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR A6WR95035, NR 95ZZZX6259, AND NR 95ZZZX6260.

Part: WIRE — CORRODED (FUEL COCK NR 1)

DURING C-CHECK, FOUND NR 1 ENGINE LOW PRESSURE FUEL COCK CABLE CIRCUIT CORRODED. ALL FOUR CABLES FROM FUSELAGE FRAME 18 TO L.P. COCK. REPLACED CABLES. REFERENCE OPERATOR CONTROL NR A6WR95035, NR 95ZZZX6258, AND NR 95ZZZX6260.

Part: TEMP SWITCH — FAILED (RT WING)

STL - FLT NR 7162 - THE RIGHT BLEED FAULTED. MAINTENANCE REMOVED AND REPLACED TEMP SWITCH, PERFORMED GROUND RUN, OPS CHECK GOOD. (M)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY EXIT LIGHTS INOPERATIVE FROM ROW 9 THROUGH ROW 13. REMOVED AND REPLACED BATTERY PACK AT ROW 11, OPS CHECK GOOD. (M)

Part: BELLCRANK — MISINSTALLED (CONTROL)

BELLCRANK IMPROPERLY INSTALLED. REPLACED WTIH NEW BELLCRANK.

Part: SLIDE — DEFECTIVE (FWD ENTRY DOOR)

LAX - DURING SHOP TEST DEPLOYMENT, EMERGENCY EVACUATION SLIDE HAD SEAM DEFECTS AND POROSITY LEAKS. EMERGENCY EVACUATION SLIDE SCRAPPED. (M)

Part: BEARING — FAILED (LT ENGINE)

CREW NOTED REDUCED TORQUE INDICATED ON TAKEOFF. CLIMB TORQUE INDICATED NORMAL. PCU AND FCU WERE CHANGED WITH NO EFFECT. WET TAKEOFF POWER NORMAL. ENGINE WAS REMOVED AND SENT TO ROLLS ROYCE CANADA. TEAR DOWN INDICATES FAILURE OF LAY SHAFT FRONT BEARING ROLLERS AND INNER TRACKS. ALL FILTERS IN OTHER ENGINES IN FLEET INSPECTED WITH NO EVIDENCE OF TROUBLE WITH OTHER ENGINES.

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

CEILING EMERGENCY LIGHTS FROM ROW 7-11 ARE INOPERATIVE. REPLACED EMERGENCY CEILING LIGHT BATTERY PACK. OPERATIONAL CHECK GOOD. (M)

Part: EEL WIRE — BROKEN (CABIN)

MX - LIGHT OUT AT MID CABIN ON CABIN EMERGENCY ESCAPE PATH LIGHTING. MAINTENANCE REPAIRED BROKEN WIRE ON EMERGENCY LIGHTS AT LEFT MID CABIN ROW 8AB. (M)

Part: FEED BACK SPRING — FAULTY (RT BRAKE)

STL - FLT NR 7487 - RIGHT BRAKE IS SOFT EXCESSIVE TRAVEL THEN BITES HARD. MAINTENANCE REPLACED RIGHT BRAKE FEED BACK SPRING. TAXI CHECK GOOD. (M)

Part: MOTOR — FAILED (MLG)

NOTE MLG MOTOR FAILURE AT 4.5 HRS AFTER OVERHAUL. MOTOR WOULD NOT MOVE LANDING GEAR. SUBMITTER RECOMMENDS CLOSER FINAL OPERATIONAL TEST PRIOR TO RETURN TO SERVICE FROM TEST BENCH.

Part: EEL WIRING — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND L1 DOOR, R1 DOOR AND FIRST FOUR ROWS OF EMERGENCY EXIT LIGHTS INOPERATIVE. REMOVED AND REPLACED BASE WIRING OF FIRST FOUR ROWS. OPS CHECK GOOD. (M)

Part: EEC — MALFUNCTIONED (RT ENGINE)

BGR - DURING CRUISE SHUT DOWN RIGHT ENGINE, S/N 4704, DUE TO SURGING WITH ACCOMPANYING VIBRATION. FOUND ENGINE ELECTRONIC CONTROL COMPUTER, MFG P/N 791100-4-087, AND FUEL METERING UNIT, MFG P/N 801000-3, MALFUNCTIONING. REPLACED ENGINE ELECTRONIC CONTROL COMPUTER AND FUEL METERING UNIT, AND ENGINE OPERATION CHECKED NORMAL.

Part: CONTROL CABLE — BROKEN (MACH TRIM)

FLT NR 530 - HNL - MACH TRIM INDICATOR WENT FULL FORWARD ON ITS OWN FOLLOWED BY A BANG. REPLACED CABLE RUN NR 129E. RIGGED CABLE PER MM 27-40-0. ADJUSTEMENT AND TEST GOOD, CLOSE UP COMPLETE PER MM 27-40-0. (M)

Part: BRAKE — REQ'D SERVICE (RT MLG)

STL - FLT NR 7231 - RIGHT BRAKE LIGHT EXCESSIVELY SENSITIVE AND GRABS RESULTING IN ERRATIC BRAKING. MAINTENANCE BLED BRAKES. TAXI CHECK GOOD. (M)

Part: LINE — BOGUS (FUEL VENT)

REMOVED RUBBER HOSE (GARDEN HOSE) FROM THE FUEL VENT LINE AND INSTALLED PROPER PLUMBING PER CITATION PARTS MANUAL.

Part: EEL BATTERY — DISCHARGED (CABIN)

STL - EMERGENCY TRACK LIGHTS INOP. MAINTENANCE REPLACED EMERGENCY LIGHT BATTERIES AT ROW 5CD. (M)

Part: EEL BATTERY — DISCHARGED (CABIN)

STL - EMERGENCY TRACK LIGHTS INOP. MAINTENANCE REPLACED EMERGENCY LIGHT BATTERIES AT ROW 2AB. (M)

Part: HUB — CRACKED (NR 1 SOCKET)

PROPELLER INSPECTION FOUND CRACK IN BLADE SOCKET NR 1, 4TH THREAD.

Part: EEL STRIP — WET (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY EXIT LIGHTS INOPERATIVE IN FRONT SECTION. CLEANED UP A WATER SPILL ON TRACK AT ROWS 1 AND 2, OPS CHECK GOOD. (M)

Part: EXHAUST SYSTEM — CRACKED (ENGINE)

DURING ANNUAL AND ROCKET MSB 95-305-01 INSPECTION: FOUND TAIL PIPES, HEADERS, TRANSITION PIPES CRACKED AT WELDS AND WHERE BAFFLING RUBS. EXHAUST SYSTEM IS HARD MOUNTED, PLACING STRAIN ON ALL COMPONENTS. SYSTEM ASSEMBLY INSTALLATION REQUIRES FORCE TO PUT IN PLACE. ENGINE TO LORD MOUNT BOLTS - UNTHREADED BOLT SHANK TOO LONG; THUS, ALLOWING ENGINE TO FURTHER VIBRATE. BAFFLING CRACKED AND BROKEN. ENGINE EXHAUST STAINS THROUGHOUT COMPARTMENT. STC SA5891NM (SEA).

Part: TRIM TAB — CORRODED (ELEVATOR)

ELEVATOR TRIM TAB CORRODED AT PUSH/PULL ROD ATTACHMENT. SAME CONDITION AS MENTIONED ON AC 43-16, ALERT NR 200, PAGE 6.

Part: PSEU — FAILED (LANDING GEAR)

FLT NR 3053 - MIA-JAX - NOSE GEAR GREEN AND RED LIGHTS AND GEAR HANDLE LIGHT ILLUMINATED IN FLIGHT. AIRCRAFT CONTINUED ON TO JAX AND LANDED WITHOUT INCIDENT. REMOVED AND REPLACED THE PROXIMITY SENSING ELECTRONIC UNIT. (M)

Part: BOLT — LOOSE (CTR FUEL TANK)

AFTER TAKEOFF ORY-JFK, FUEL FUMES VERY STRONG IN FLIGHT DECK AREA. FUMES DISSIPATED AT 3.0 TO 4.0 FEET DURING CLIMB. DURING INSPECTION FOUND FUEL LEAK AT BOW TIE FITTING. REMOVED AND REPLACED BOLTS, RESEALED FITTING, IAW EA 57-112. LEAK CHECK OK. (M)

Part: EEL BULB — FAILED (CABIN)

STL - FLT NR 7531 - RIGHT FORWARD TOP EMERGENCY EXIT LIGHT INOP. MAINTENANCE REPLACED EMERGENCY LIGHT BULB. (M)

Part: EXHAUST DUCT — CRACKED (ENG EXHAUST)

OPERATOR COMPLAINED OF SUPPORT BRACKET FAILURES. AT 390.6 HOURS, CRACK IN ENGINE EXHAUST DUCT 24 INCHES LONG, SPLIT ON WELD SEAM. AIRCRAFT IS CORPORATE CONFIG NOT CARGO CONFIG.

Part: CLAMP — CRACKED (BLADE)

INSPECTION FOUND BLADE CLAMP BACK HALF CRACKED. SUSPECT POSSIBLE ENGINE VIBRATION.

Part: TSCU — FAILED (NR 1 ENGINE)

PBY/TPA - FLT 3031 - ON TAKEOFF, THE NR 1 ENGINE PROPELLER FEATHERED. THE CREW ABORTED THE TAKEOFF AND RETURNED TO THE GATE WITHOUT INCIDENT. REMOVED AND REPLACED THE NR 1 TORQUE SENSOR CONTROL UNIT AND CLEANED BOTH TSCU CONNECTORS.

Part: CONNECTOR — FAILED (LT MLG)

MIA/JAX - FLT 3053 - EN ROUTE TO JAX, THE WEIGHT-ON-WHEELS LIGHT ILLUMINATED, THE GEAR WARNING HORN SOUNDED, THE ROLL OUTBOARD GROUND AND GROUND SPOILER CAUTION LIGHT ILLUMINATED AND THE APU INLET DOOR WOULD NOT OPEN. REMOVED AND REPLACED LEFT OUTBOARD WEIGHT-ON-WHEELS CANNON PLUG AT LANDING GEAR JUNCTION TO NACELLE.

Part: CONNECTOR — DIRTY (LT ENGINE)

STL - FLT 7128 - LEFT ENGINE DID NOT MAKE TARGET TORQUE. MAINTENANCE CLEANED LEFT EEC CANNON PLUG. AIRCRAFT TT, 11,503.0. ENGINE TT, 121,021.0. (X)

Part: COOLING FAN — FAILED (LT PACK)

STL - FLT 7001 - NR 1 PACK FAULTS WITH ELECT SMOKE MASTER. MAINTENANCE REPLACED NR 1 GROUND COOLING FAN. AIRCRAFT TT, 12,613.0. (X)

Part: EEL STRIP — WET (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY EXIT LIGHTS INOPERATIVE AT R2 DOOR AND IN THE AFT SECTION OF AIRCRAFT. FLOOR TRACK FOUND TO BE WET. DRIED TRACK AND REINSTALLED LIGHT STRIPS. AIRCRAFT OK FOR SERVICE. (M)

Part: EEL POWER SUPPLY — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND THE FIRST SIX ROWS OF EMERGENCY EXIT LIGHTS INOPERATIVE. REMOVED AND REPLACED POWER SUPPLY, OPS CHECK GOOD. (M)

Part: EEL LEAD STRIP — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY EXIT LIGHTS INOPERATIVE FROM ROW 16 BACK. REMOVED AND REPLACED EMERGENCY LEAD STRIP AT ROW 16. OPS CHECK GOOD. (M)

Part: ENGINE — MALFUNCTIONED (LEFT)

STL - FLT NR 7524 - ELECTRICAL SMOKE LIGHT ILLUMINATED. MAINTENANCE REPLACED LEFT ENGINE. ENGINE PERFORMANCE RUNS REVEALED ALL ENGINE PARAMETERS TO BE NORMAL. NO SMOKE NOTED. (M)

Part: BATTERY — LEAK (ELT)

AIRTEX BATTERY INSIDE ELT CASE FOUND LEAKING AND CORROSION FORMING. SUSPECT HIGH FUSELAGE TEMPERATURE AS THE CAUSE OF FAILURE. ASSEMBLY IS MOUNTED IN AFT EQUIPMENT BAY WITH VERY LITTLE AIR FLOW WHEN AIRCRAFT IS STATIC.

Part: SWITCH — BROKE (NR 1 ENGINE)

DURING REMOVAL OF ENGINE SCREEN AND NOSE BOX COWL, NOTICED NR 1 ENGINE TRANSMISSION TEMP SWITCH WAS HANGING BY THE CANNON PLUG WHERE IT HAD BROKEN IN HALF AT THE WELDED SEAM. NO SIGN OF LEAKAGE. CAUSE UNKNOWN. (X)

Part: FIRE LOOP — FAILED (NR 1 ENGINE)

PHX-IAH - FLT NR 273 - DURING CRUISE AT FL 330, NR 1 FIRE HANDLE LIGHT ILLUMINATED WITH FIRE WARNING BELL. NR 1 ENGINE WAS SHUTDOWN IAW QRH PROCEDURES, BOTH FIRE BOTTLES WERE DISCHARGED. LIGHT WENT OUT FOR APPROXIMATELY THREE MINUTES AND THEN WENT ON AND OFF SPORADICALLY. AIRCRAFT DIVERTED TO MAF, LIGHT REMAINED OUT FOR REMAINDER OF FLT. AIRCRAFT LANDED UNEVENTFULLY. MX REPLACED RT AND LT ENG FIRE BOTTLES IAW MM 26-21-11, CARD R4L26001. OPS CHECK OK PER A4L26003. ALSO, PLACED NR 1 ENGINE NORMAL POSTION ON MEL 26-02 UNTIL AIRCRAFT ARRIVED AT PHX BASE MAINTENANCE. PHX MAINTENANCE REPLACED NR 1 ENGINE LOWER FIRE DETECTION SYSTEM. OPS CHECK GOOD. MEL REMOVED. AIRCRAFT RETURNED TO SERVICE. (M)

Part: EEL BATT PACK — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND AFT EMERGENCY EXIT LIGHT SIGN INOPERATIVE. REMOVED AND REPLACED BATTERY PACK, OPS CHECK NORMAL. (M)

Part: GYRO — FAILED (COCKPIT ADI)

GYRO TUMBLES FOR 30-40 MINUTES.

Part: BRACKET — CRACKED (TAILBOOM)

RECEIVED NEW HANGER BEARING BRACKET WITH CRACKED, AFT VERTICAL FLANGE IN CENTER OF BRACKET.

Part: EEL POWER SUPPLY — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND FLOOR MOUNTED EMERGENCY EXIT LIGHTS INOPERATIVE IN FWD CABIN. REMOVED AND REPLACED POWER SUPPLY AT FWD CABIN POSITION. OPS CHECK NORMAL. (M)

Part: GYRO — INOPERATIVE (COCKPIT TARSYN)

INOPERATIVE TARSYN GYRO. REMOVED AND REPLACED.

Part: FUEL DUMP VALVE — FAILED (LT/RT)

WHILE EN ROUTE TO SBCF, A PASSENGER SUFFERED A MEDICAL EMERGENCY. CAPTAIN ELECTED TO DUMP FUEL AND DIVERT TO SAN JUAN BUT NEITHER DUMP VALVE WOULD OPEN DURING BEGINNING OF DESCENT. CREW PERFORMED TROUBLESHOOTING PROCEDURES BUT STILL UNSUCCESSFUL IN DUMPING FUEL. CAPTAIN ELECTED TO RETURN TO MIAMI. ARRIVED MIAMI WITHOUT FURTHER INCIDENT. MAINTENANCE PERSONNEL REMOVED AND REPLACED BOTH DUMP VALVES. OPS CHECK PERFORMED AND AIRCRAFT RETURNED TO SERVICE.

Part: FIRE LOOP — BROKEN (LOWER)

NR 2 ENGINE FIRE WARNING STARTED FLICKERING AND EVENTUALLY CAME ON STEADY. CAPTAIN PULLED BACK THROTTLE, NO HELP. SHUT DOWN ENGINE, NO HELP. FIRED ONE FIRE BOTTLE, NO HELP. DURING DESCENT, LIGHT FLICKERED AGAIN AND WENT OUT. FOUND BOTTOM FIRE LOOP FORWARD LOWER CONNECTOR BROKEN LOOSE FROM MOUNTING AND LOOP WAS TOUCHING CASE, CAUSING FALSE WARNING. REPLACED LOWER FIRE LOOP ASSY AND FIRE BOTTLE ASSY. (M)

Part: DN LOCK ACT — BROKEN (NLG)

NOSE GEAR WOULD NOT EXTEND NORMALLY, MANUALLY EXTENDED OK. GOOD DOWN AND LOCKED INDICATION. DOWN LOCK ACTIVATOR WAS BROKEN. (M)

Part: FLOOR BEAM — CORRODED (BS 1016)

PHX - DURING SCHEDULED C8 INSPECTION, FOUND MAIN FLOOR BEAM AT STATION 1016 BL 0 CORRODED BEYOND LIMITS. INSTALLED REPAIR ANGLE AND REPAIRED PER SRM 51-40-4, FIGURE 1. (M)

Part: ROTATING BEACON — DEFECTIVE (FS 570)

WHILE PUSING BACK FROM GATE AT JAX, FLIGHT ATTENDANT REPORTED SMOKE FROM OVERHEAD BIN AROUND ROW NR 9. AIRCRAFT WAS TOWED BACK TO THE GATE AND PASSENGER DEPLANNED. ALL POWER WAS REMOVED, UPPER BEACON CIRCUIT BREAKER WAS FOUND POPPED. MAINTENANCE IN JAX FOUND UPPER ANTI-COLLISION BEACON DEFECTIVE. ITEM WAS DEFERRED PER MEL 33-6. REMOVED AND REPLACED UPPER ANTI-COLLISION LIGHT, OPS CHECK OK. (M)

Part: EEL — INOP (SERVICE DOOR)

EMERGENCY LIGHT AT SERVICE DOOR INOP. REPLACED LIGHT. (W)

Part: FIRE LOOP — MALFUNCTIONED (NR 2 ENGINE)

MIA/PIE - ON CLIMB-OUT OF MIA TO PIE, CREW GOT A NR 2 ENGINE FIRE INDICATION. C/W SPECIAL PROCEDURE, SHUT DOWN ENGINE, AND FIRED BOTTLE. LANDED IN PIE. INSPECTED, FOUND LOWER LOOP DETECTOR BAD. REPLACED LOOP, FIRE BOTTLE, AND SQUIBS.

Part: FLOOR PANEL — CORRODED (FUSELAGE RT AFT)

WHILE PERFORMING A SHEET METAL INSPECTION, FOUND SKIN CORRODED AND SEPARATED AROUND PERIMETER OF FLOOR PANEL. INADEQUATE (PRO-SEAL) AROUND PERIMETER OF PART.

Part: FLOOR PANEL — CORRODED (LT FUEL CELL)

WHILE PERFORMING A SHEET METAL INSPECTION, FOUND SKIN CORRODED AND SEPARATED AROUND PERIMETER OF LT CELL FLOOR PANEL. INADEQUATE (PRO-SEAL) AROUND PERIMETER OF PART.

Part: FLOOR PANEL — CORRODED (FUSELAGE LT OTBD)

WHILE PERFORMING A SHEET METAL INSPECTION, FOUND SKIN CORRODED AND SEPARATED AROUND PERIMETER OF FLOOR PANEL. INADEQUATE (PRO-SEAL) AROUND PERIMETER OF PART.

Part: FLOOR PANEL — CORRODED (FUSELAGE RT OTBD)

WHILE PERFORMING A SHEET METAL INSPECTION, FOUND SKIN CORRODED AND SEPARATED AROUND PERIMETER OF FLOOR PANEL. INADEQUATE (PRO-SEAL) AROUND PERIMETER OF PART.

Part: EEL COVER — MISSING (FORWARD)

DURING AN INSPECTION, THE EMERGENCY FLOOR LIGHTING AT FORWARD GALLEY WAS MISSING APPROXIMATELY A 10 INCH STRIP PLASTIC COVER DUE TO PASSENGER STEPPING ON IT. INSTALLED AND SECURED FLOOR STRIP. FLOOR LIGHT OPS CHECKED GOOD PER M/M 33.

Part: ESCAPE SLIDE — TORN (L1 DOOR)

ESCAPE SLIDE AT POSITION L1 FRAYED AND TORN AT THE GIRT AREA. REMOVED AND REPLACED SLIDE, NOT RUBBING NOTED ON SCUFF PLATE.

Part: LATCH CABLE — MISROUTED (ESCAPE SLIDES)

ALL EMERGENCY ESCAPE SLIDES LATCH CABLE NOT PROPERLY ROUTED. REMOVED AND REPOSITIONED CABLE.

Part: PBE — TORN (FWD/AFT GALLEY)

FORWARD AND AFT GALLEYS HAVE ONE EACH PBE'S UNSERVICEABLE DUE TO HOLE TORN IN CASE ONE AND LATCH BROKEN ON OTHER. REMOVED AND REPLACED PBE'S AND SECURED WELL WITH VELCRO STRAP.

Part: ACTUATOR — FAILED (LT MLG)

FLT 3064 - PBI-TPA - LEFT FORWARD MAIN GEAR DOOR REMAINED OPEN AFTER TAKEOFF. AIRCRAFT CONTINUED ON TO TPA AND LANDED WITHOUT INCIDENT. REMOVED AND REPLACED THE LEFT MAIN FORWARD GEAR DOOR ACTUATOR.

Part: FILTER BYPASS SW — FAILED (NR 2 ENGINE)

MCI - DURING CRUISE, SHUT DOWN NR 2 ENGINE DUE TO OIL FILTER BYPASS LIGHT CAME ON. REPLACED OIL FILTER AND OIL FILTER BYPASS SWITCH, MFG P/N 42D109-1A. ENGINE OPERATION CHECKED NORMAL.

Part: EEL SOCKET — INOP (CABIN)

DURING INSPECTION, FOUND THE EMERGENCY PASSENGER LIGHTING SYSTEM WHITE LIGHT INOP BETWEEN ROWS 1 AND 2. BAD SOCKET WAS FOUND AND REPLACED. OPS CHECKED GOOD.

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

HNL - INFORMATION FROM M71 LOG PAGE 148957-2. FLOOR EMERGENCY LIGHTS INOPERATIVE FROM THE OVERWING EXITS TO THE AFT OF THE AIRCRAFT CABIN. REPLACED AFT CONTROL MODULE AND BATTERY PACK. OPERATIONAL CHECK GOOD. (X)

Part: VALVE — GASKET FAILED (ENGINE FUEL)

NEWLY INSTALLED OVERHAULED ENGINE AFTER 20 HOURS OF FLYING TIME. FUEL DISTRIBUTION VALVE ON TOP OF ENGINE HAD A BLOWN GASKET WHICH SPRAYED RAW FUEL ALL OVER THE ENGINE WHILE IN FLIGHT. ENGINE OVERHAULED BY TELEDYNE CONTINENTAL MOTORS.

Part: POWER SUPPLY — FAILED (COCKPIT)

PHX\MCI - FLT 592 - ONE HOUR OUT OF PHX, THE STANDBY HORIZON FLAGGED AND THE CIRCUIT BREAKER TRIPPED. DUE TO MEL RESTRICTIONS, AIRCRAFT RETURNED TO PHX AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE POWER SUPPLY FAILED. REPLACED POWER SUPPLY AND INDICATOR. AIRCRAFT RETURNED TO SERVICE. REF CONTROL NR AWXA9500421. (X)

Part: STANDBY HORIZON — MALFUNCTIONED (COCKPIT)

PHX\MCI - FLT 592 - ONE HOUR OUT OF PHX, THE STANDBY HORIZON FLAGGED AND THE CIRCUIT BREAKER TRIPPED. DUE TO MEL RESTRICTIONS, AIRCRAFT RETURNED TO PHX AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE POWER SUPPLY FAILED. REPLACED POWER SUPPLY AND INDICATOR. AIRCRAFT RETURNED TO SERVICE. REF CONTROL NR 95ZZZX3455. (X)

Part: ENGINE — MALFUNCTIONED (NR 2)

PHX-ABQ - FLT 205 - ON TAKEOFF, THE E2 EGT REACHED 940 FOR 45 SECONDS, THE NR 2 TRUST LEVER WENT TO FIREWALL AND N1 2 PERCENT LESS THAN TARGET. AFTER REDUCING POWER ESTABLISHED IN CLIMB, THE NR 2 N2 STARTED INCREASING AND REACHED APPROXIMATELY 103 PERCENT BEFORE SWITCHING AUTO THROTTLE OFF. PILOT RETURNED AC TO PHX WITHOUT FURTHER INCIDENT. MX PERFORMED TAKEOFF SIMULATION, BLEEDS ON PACKS ON, PMC'S ON, AUTO/THROTTLE ACTIVATED NR 2 ENGINE, ACHIEVED TAKEOFF POWER TARGET WITH ALL PARAMETERS WITHIN LIMITS AND MATCHED WITH NR 1 ENGINE. SWITCHED PMC'S OFF, ALL PARAMETERS STABLE. NR 2 ENGINE HAD 1 INCH CUSHION FROM FIREWALL AT TAKEOFF POWER SETTING. (W)

Part: FIRE LOOP — FAILED (APU)

PHX - FLT 742 - ELP TO LAS DURING CRUISE, APU FIRE LIGHT AND BELL CAME ON. APU PREVIOUSLY PLACARDED, FIRE EXTINGUISHING SYSTEM INOP. CREW PULLED FIRE HANDLE AND WARNINGS CEASED. CREW ELECTED TO RETURN TO PHX. MAINTENANCE FOUND LOOP-M 334 OUT OF TOLERANCE, REPLACED M 334 AND CLEANED PLUG D 4816. SYSTEM OPS CHECKED OK, AC RETURNED TO SERVICE. (W)

Part: PLANK — CORRODED (RT WING)

DURING A ROUTINE 72-MONTH INSPECTION OF THE UPPER RIGHT WING SURFACE UNDER THE 'WING WEDGE', A FAIRLY LARGE (5.5 INCH BY 1.0 INCH) AREA OF INTERGRANULAR, EXFOLIATION-TYPE CORRISION WAS FOUND. THIS AREA IS SUPPOSED TO BE TREATED WITH A CORROSION INHIBITING COMPOUND (COSMOLINE), HOWEVER, THIS AREA WAS DRY. SUBMITTER STATED THIS WOULD APPEAR TO BE THE APPARENT CAUSE OF THE PROBLEM. GULFSTREAM HAS BEEN NOTIFIED AND IS ASSISTING IN REPAIRS.

Part: EEL BULB — FAILED (CABIN)

HNL - INFORMATION FROM M-71 LOG PAGE 148514. THREE SETS OF CABIN EMERGENCY FLOOR LIGHTS ARE OUT. REPLACED 3 EACH EMERGENCY FLOOR LIGHT BULBS. OPERATIONAL CHECK GOOD. (X)

Part: EEL BATTERY — DISCHARGED (CABIN)

INFORMATION FROM M-71 LOG PAGE 148403-1. AFT EMERGENCY FLOOR LIGHTS INOPERABLE. REMOVED AND REPLACED BATTERY PACK. OPERATIONAL CHECK GOOD. (X)

Part: OVERHEAT — DEFECTIVE (NR 2 ENGINE)

NR 2 ENGINE OVERHEAT LIGHT ILLUMINATED EN ROUTE TO PIE FROM MIA. FOUND DEFECTIVE OVERHEAT LOOP NR 2 ENGINE. REMOVED AND REPLACED OVERHEAT LOOP NR 2 ENGINE, OPS CHECKED GOOD. (M)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

HNL - INFORMATION FROM M-71 LOG PAGE 142429-4. OVERHEAD EMERGENCY LIGHTS BETWEEN ROW 6 AND ROW 12 ARE INOPERABLE. REPLACED EMERGENCY BATTERY POWER SUPPLY ABOVE ROW 10R. OPERATIONAL CHECK GOOD. (X)

Part: EEL BATT PACK — DISCHARGED (CABIN)

DURING DAILY SERVICE, FOUND EVAC LIGHTS BATTERY PACK DEPLEATED AT ROW 50ABC. REMOVED AND REPLACED BATTERY PACK, OPS CHECK OK. (M)

Part: EEL — INOP (CABIN)

DURING DAILY SERVICE, FOUND EVAC LIGHT AT ROW 19A BROKEN. REMOVED AND REPLACED LIGHT ASSEMBLY, OPS CHECK OK. (M)

Part: COMPUTER — FAILED (AVIONICS BAY)

STL - FLT 7230 - NR 2 AHRS FAILED IN-FLIGHT. MAINTENANCE REPLACED NR 2 AHRS COMPUTER. (X)

Part: EEL STRIP — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERENCY EXIT LIGHTS INOPERATIVE ROW 1 THROUGH ROW 5. REPLACED LIGHT STRIP AT ROW 1, OPS CHECK GOOD. (M)

Part: EEL — INOP (CABIN)

DURING DAILY SERVICE, FOUND EVAC LIGHT MISSING AT ROW 60A. REMOVED AND REPLACED LIGHT ASSEMBLY, OPS CHECK OK. (M)

Part: MOUNT — FAILED (ENGINE)

ISOLATOR COMING APART AND ISOLATOR SAGGING IN MOUNT. FOUND DURING ENGINE CHANGE. MOUNT INSTALLED BY THIS REPAIR STATION 21.0 HRS AGO.

Part: COMP BLADES — DAMAGED (NR 1 ENGINE)

OGG - FLT 559 - AFTER LANDING IN MAUI, NR 1 ENGINE FOUND WITH 11 BLADES DAMAGED. LARGEST DAMAGED BLADE WAS .5937 INCH BY .50 INCH LONG. REPLACED LEFT ENGINE ASSEMBLY PER HAWAIIAN AIRLINES STANDARD PRACTICE DC-9, HAL M143 DC-9-50 INSTALLATION REV 59 DATED 1-11-95. (X)

Part: EEL BULB — FAILED (CABIN)

STL - AFT CABIN EMERGENCY EXIT SIGN ABOVE FLIGHT ATTENDANT SEAT IS INOP. MAINTENANCE REPLACED AFT CABIN EMERGENCY EXIT SIGN LIGHT BULB. (M)

Part: EEL CABLE ASSY — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY EXIT LIGHTS INOPERATIVE FROM ROW 19 THROUGH ROW 22. REMOVED AND REPLACED CABLE ASSEMBLY, OPS CHECK GOOD. (M)

Part: SWITCH — STICKING (RT YOKE)

STL - FLT 7478 - FLIGHT OFFICERS PUSH TO TALK SWITCH IS STICKING. MAINTENACNE REPLACED FLIGHT OFFICERS PUSH TO TALK SWITCH. OPERATIONAL CHECK GOOD. (M)

Part: FRAME — CORROSION (FS 17734)

STL - MAINTENANCE DISCOVERED CORROSION ON RT FRAME 36 BTW STRINGER 14 AND 16. MAINTENANCE REPAIRED FRAME 36 CORRODED AREA AS PER TRANS STATES AIRLINES DER APPROVAL 8110-3 AND ATR DWG 16S536R0052. (Z)

Part: FRAME — CORROSION (FS 17734)

STL - MAINTENANCE DISCOVERED CORROSION ON RT FRAME 37 BTW STRINGER 14 AND 16. MAINTENANCE REPAIRED FRAME 37 CORRODED AREA AS PER TRANS STATES AIRLINES DER APPROVAL 8110-3 AND ATR DWG 16S536R0052. (Z)

Part: EEL BATTERY — DISCHARGED (CABIN)

STL - BOTH FWD EMERGENCY EXIT SIGNS ARE INOP. MAINTENANCE REPLACED FWD LOWER EMERGENCY LIGHTING BATTERY. (Z)

Part: EEL HARNESS — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND FLOOR MOUNTED EMERGENCY EXIT LIGHTS INOPERATIVE, ROWS 1 THROUGH 5. REMOVED AND REPLACED FEEDER HARNESS FROM SIDEWALL TO FLOOR TRACK, OPS CHECK GOOD. (M)

Part: SHUTOFF VALVE — SHORTED (NR 2 ENGINE)

PHX-DFW - FLT 544 - DURING CRUISE, THE NR 2 BLEED VALVE CIRCUIT BREAKERS POPPED AND WOULD NOT RESET. PILOT ELECTED TO RETURN TO PHX DUE TO KNOWN ICING CONDITIONS. AC LANDED WITHOUT FURTHER PROBLEMS. MX REMOVED AND REPLACED NR 2 ENGINE BLEED AIR SHUTOFF VALVE PER MM 36 11 11 PG 401. OPS CHECK GOOD, AC RETURNED TO SERVICE. (Z)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND FLOOR MOUNTED EMERGENCY EXIT LIGHTS INOPERATIVE, ROWS 13 THROUGH 17 RIGHT SIDE. REMOVED AND REPLACED BATTERY PACK, OPS CHECK GOOD. (M)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND FORWARD CEILING EMERGENCY EXIT LIGHT INOPERATIVE. REMOVED AND REPLACED BATTERY PACK, OPS CHECK NORMAL. (M)

Part: SELECTOR VALVE — INOP (MLG)

FLT BVA777 - MQY-IAB - NOSE GEAR EXTENDS NORMALLY, BUT BOTH MAIN GEARS WOULD NOT EXTEND. EMERGENCY GEAR EXTENSION USED. NO EMERGENCY DECLARED. REMOVED AND REPLACED MLG SELECTOR VALVE IAW MM 4-21-127. NO JACKS AVAILABLE IAB FOR GEAR SWING. FERRY FLIGHT TO MQY FOR GEAR SWING. AIRCRAFT JACKED AND GEAR SWING ACCOMPLISHED IAW MM 7-00 AND 32-00. ALL OPERATIONS CHECKED NORMAL. (M)

Part: FLOORBEAM — CORROSION (FS 344)

HEAVY CORROSION AT MAIN CABIN FLOORBEAM FS 344, BETWEEN LBL 65 TO RBL 10. REPAIRED FLOORBEAM PER SRM 51-70-12, PAGES 2-6. (W)

Part: SKIN — DELAMINATION (LT TE FOREFLAP)

LT WING OUTBOARD FOREFLAP DELAMINATED ON UPPER OUTBOARD EDGE. REPAIRED FLAP PER SRM 51-70-10.

Part: O-RING — GOUGED (BURNER HOSE)

VISUAL INSPECTION REVEALED GOUGES IN SURFACE OF O-RING IN FEMALE QUICK DISCONNECT FUEL TANK TO BURNER HOSE COUPLING. CAUSE IS SUSPECTED TO BE IMPROPER ALIGNMENT OF COUPLING DURING MATING. SUBMITTER RECOMMENDS VISUAL INSPECTION DURING EVERY PRE-FLIGHT INSPECTION. THESE O-RINGS ARE LOCATED IN A FEMALE TEMA 3800 COUPLING PN 10105, MFG SKOVDE, SWEDEN.

Part: SPLICE — CORROSION (FS 907)

FS 907, STRINGER 23L SPLICE HEAVY CORROSION. REPLACED STRINGER SPLICE PER SRM 51-30-2. (W)

Part: SKIN — DELAMINATION (LT AILERON TAB)

LEFT AILERON TAB DELAMINATED ON UPPER AND LOWER SURFACES. REPAIRED TAB PER SRM 57-61-01. (W)

Part: LOCK SWITCH — FAILED (ELECT SYS)

INSTALLED LOCK SWITCH. TOT LIGHT ILLUMINATED, TRIED TO RESET SWITCH, DID NOT RESET, SWITCH WOULD JUST TURN. BROKEN INTERNALLY.

Part: DUCT — DELAMINATION (LT ENGINE)

THE NR 1 ENGINE FAN COWL INNER DUCT SKIN DELAMINATED AT 3 O'CLOCK POSITION. REPAIRED PER DALFORT AVIATION XEA NR X2-78-6.

Part: EEL — BROKEN (CABIN)

EMERGENCY EXIT LIGHTS ABOVE AFT ENTRY AND SERVICE DOORS HAVE BROKEN LENSES. REPLACED BOTH LIGHT ASSEMBLIES PER SRM 51-40-0. (W)

Part: SKIN — CRACKED (FS 727)

TWO CRACKS IN FUSELAGE SKIN BETWEEN FS 727B-727D, LONGERON 23R. REPAIRED SKIN PER DALFORT AVIATION XEA NR X2-53-114, REVISION 1. (W)

Part: ENGINE — MALFUNCTIONED (NR 1)

PHX-IAH - AT ROTATION, THE WIND SHEAR ALERT CAME ON. PILOT ADVANCED THROTTLES. NR 1 ENG EGT WENT TO 640 DEGREES FOR APPROXIMATELY 5 SECONDS AND NR 2 ENG EGT WENT TO 620 DEGREES FOR APPROXIMATELY 5 SECONDS. AIRCRAFT RETURNED TO PHX AND LANDED WITHOUT INCIDENT. MAINTENANCE COMPLIED WITH OVER TEMP INSPECTION AND BORESCOPE OF NR 2 ENG AND FOUND NO EVIDENCE OF DISTRESS, ENG TO CONTINUE IN SERVICE. MAINTENANCE REMOVED AND REPLACED THE NR 1 ENGINE. AIRCRAFT RELEASED FOR SERVICE. (W)

Part: FIRE LOOP — MALFUNCTIONED (APU)

PHX-OMA - ON FINAL APPROACH CREW ATTEMPTED APU START AND APU FIRE WARNING ILLUMINATED. FIRE HANDLE PULLED AND WARNING SILENCED. CREW DECLARED AN EMERGENCY AND LANDED WITHOUT FURTHER PROBLEMS. CONTRACT MAINTENANCE REMOVED APU SHROUD AND CONFIRMED NO EVIDENCE OF FIRE. UNMANNED STATION RELEASE WAS ISSUED AND AIRCRAFT CONTINUED IN SERVICE TO LAS. LAS MAINTENANCE PLACARDED APU INOPERATIVE. MAINTENANCE REMOVED AND REPLACED LOWER FIRE LOOP. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (W)

Part: ANGLE — CRACKED (LT PYLON)

LT PYLON ANGLE HAS 1 INCH LONG CRACK ON LOWER SIDE, 6 INCHES OF AFT CONE BOLT. REPLACED ANGLE PER SRM 51-40-12.

Part: FLOORBEAMS — CORROSION (FS 294\312\328)

HEAVY CORROSION AT FLOORBEAMS FS 294, 312, AND 328, JUST BELOW FWD LAVATORY AND GALLEY. REPAIRED BEAMS PER SRM 51-70-12.

Part: DOOR FRAME — CRACKED (CARGO COMPT)

FORWARD CARGO DOOR OUTER FRAME HAS A .375 INCH LONG CRACK AT LOWER FORWARD CORNER. REPAIRED FRAME PER SRM 51-70-11.

Part: BEARING — MISMANUFACTURED (GRIP)

BEARING CAGE SPOT WELD, EXTENDING TOO HIGH.

Part: BEARING — MISMANUFACTURED (GRIP)

BEARING CAGE SPOT WELD, EXTENDING TOO HIGH.

Part: ACTUATOR — FAULTY (TAIL)

MDW - FLT 7017 - PITCH TRIM ASYMMETRY FAILED INFLIGHT. MAINTENANCE REPLACED PITCH TRIM ACTUATOR. OPERATIONAL TEST OF SYSTEM CHECK GOOD. (W)

Part: EEL BATT PACK — DISCHARGED (CABIN)

HNL - FLOOR EMERGENCY EVACUATION LIGHTS ARE VERY DIM. REPLACED AFT BATTERY PACKS AND OPERATIONAL CHECK WAS GOOD. (Z)

Part: EEL WIRE STRIP — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND ROW 13 THROUGH 15 FLOOR MOUNTED EMERGENCY EXIT LIGHTS INOPERATIVE. MAINTENANCE REPLACED SECTIONAL WIRE STRIP FROM CABIN SIDE WALL TO FLOOR TRACK, OPS CHECK NORMAL. (M)

Part: ACCESSORY UNIT — MALFUNCTION (E/E COMPT)

PHX-SFO - FLT 605 - AFTER TAKEOFF, THE TAKEOFF WARNING HORN WOULD NOT SHUT OFF. AIRCRAFT RETURNED TO GATE WITHOUT INCIDENT. MAINTENANCE PERFORMED TAKEOFF WARNING TEST PER AWA TASK CARD A1B31007, NO DEFECTS WERE NOTED. MAINTENANCE ALSO REPLACED ENGINE ACCESSORY UNIT AS A PRECAUTION. OPERATIONALLY TESTED ACCESSORY UNIT PER BMM 78-34-91, NO DEFECTS NOTED. AIRCRAFT RELEASED FOR SERVICE. (W)

Part: SKIN — CRACKED (NR 3 SLAT)

DURING WALKAROUND INSPECTION A CRACK WAS NOTED ON THE RIGHT WING NR 3 SLAT. THE CRACK WAS LOCATED ON THE UPPER SURFACE OUTBOARD TRAILING EDGE CORNER. THE CRACK WAS 6 INCHES IN LENGTH IN ADDITION, THE SLAT UPPER SKIN WAS DELAMINATED APPROXIMATELY 10 PERCENT. REPLACED DAMAGED SLAT WITH SERVICEABLE UNIT. AIRCRAFT RETURNED TO SERVICE. (W)

Part: VLV — INOPERATIVE (E/E COOLING)

PHX-SNA - FLT 661 - AIR TURNBACK, CREW UNABLE TO PRESSURIZE AIRCRAFT ON CLIMB-OUT. AIRCRAFT RETURNED TO PHX AND LANDED WITHOUT FURTHER PROBLEMS. MAINTENANCE REMOVED AND REPLACED E/E COOLING VLV. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — DENTED (CARGO DOOR)

C-1 B/B DOOR DENTED AND OIL CANNING. REPAIR REF ERA 301714-14.

Part: SKIN — CRACKED (FS 764)

THE FUSELAGE SKIN AT STA 764 HAS A 4 CRACK JUST BELOW STR 17L. EXTERNAL REPAIR DOUBLER WILL BE INSTALLED PER THE SRM.

Part: BATTERY PACK — INOPERATIVE (CABIN EEL)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND FLOOR MOUNTED EMERGENCY EXIT LIGHTS IN FORWARD SECTION INOPERATIVE. REMOVED AND REPLACED BATTERY PACK, OPS CHECK GOOD. (W)

Part: SKIN — CORROSION (FS 1314-1339)

SBA - DURING D-CHECK, FOUND LEVEL 2 CORROSION AROUND FASTENERS ON EXTERIOR FUSELAGE STA 1314 TO 1339 STR 20L TO 25L. REMOVED CORROSION AND INSTALLED REPAIR PER 51-10-3, 53-01 AND 52-01 FIG 3 SHEET 3. (Z)

Part: VALVE — MALFUNCTION (PACK FLOW)

PHX-ABQ - FLT NR 200 - NR 1 PACK TRIP RESET TWICE. AIRCRAFT RETURNED TO PHX WITH ALL TEMPS AND PRESSURE NORMAL, LANDING WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED NR 1 PRIMARY HEAT EXCHANGER AND NR 1 PACK FLOW CONTROL VALVE DUE TO LOW FLOW. LT PACK SYSTEM OPS AND LEAK CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. REFERENCE 95ZZZW669.

Part: HEAT EXCHANGER — FAILED (NR 1 LT PRIMARY)

PHX-ABQ - FLT NR 200 - NR 1 PACK TRIP RESET TWICE. AIRCRAFT RETURNED TO PHX WITH ALL TEMPS AND PRESSURE NORMAL, LANDING WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED NR 1 PRIMARY HEAT EXCHANGER AND NR 1 PACK FLOW CONTROL VALVE DUE TO LOW FLOW. LT PACK SYSTEM OPS AND LEAK CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. REFERENCE AWXA9500244.

Part: EEL BULB — FAILED (CABIN)

TWO EMERGENCY LIGHTS INOP. REPLACED BULBS. (W)

Part: FAIRING — CORRODED (NR 2 PYLON)

SBA - DURING D-CHECK, FOUND RT PYLON AFT FAIRING HAS LEVEL 2 CORROSION AT FUSELAGE ATTACH HOLES AND IN BETWEEN SKIN LAYERS. CUT OUT CORRODED AREA AND INSTALLED DOUBLER REPAIR PER SRM 54-01 FIG 4. (Z)

Part: UPLOCK ACT — FAILED (RT MLG)

RT MAIN GEAR UNSAFE INDICATION WHEN GEAR WAS EXTENDED. REMOVED AND REPLACED RT UPLOCK ACTUATOR, OPS CHECK OKAY. LUBED UPLOCK ROLLER IAW MM. AIRCRAFT RETURNED TO SERVICE. ACTC: 14298.(X)

Part: STIFFENER — CORROSION (FS 1292)

SBA - DURING D-CHECK, FOUND AFT TAIL COMPARTMENT INTERNAL STRUCTURE HAS LEVEL 2 CORROSION ON FRAME STIFFENER AT STA 1292 STR 13L. FABRICATED AND INSTALLED STIFFENER PER SRM 51-01 AND 51-30-2. (Z)

Part: STRINGER — CORROSION (FS 699 RBL 13)

SBA - ITEM FROM SBA NR 18N00907 C-CHECK, LEVEL 2 CORROSION ON STRINGER AND AROUND FASTENERS STA 699 - STA 770, RBL 13 (KEEL BEAM AREA). REMOVED CORROSION, CLEANED AND TREATED PER SRM 51-10-3. INSTALLED REPAIRED SPLICE PER SRM 53-02. (X)

Part: SKIN — CORRODED (FS 927)

SBA - DURING D-CHECK, FOUND LEVEL 2 CORROSION ON LT FUSELAGE SKIN AT STATION 927 TO 851 STR 18 TO 22 AROUND FAIRING ATTACH POINTS. REMOVED CORROSION AND INSTALLED DOUBLER REPAIR PER SRM 53-09 FIG 53. (Z)

Part: SKIN — CORRODED (FS 1258)

SBA - ITEM FROM SBA N/R NR 827. DURING C-CHECK FOUND LEVEL 2 CORROSION ON FUSELAGE SKIN AT BUTT JOINT, FS 1258, STR 24R-24L. REMOVED AND REPLACED THE SKIN PER SRM 51-10-0. (X)

Part: ANGLE — CORRODED (RUDDER)

SBA - ITEM FROM SBA N/R NR 1144. DURING C-CHECK, FOUND CORROSION ON CASTING AND ANGLE INTERNAL RIB OF RUDDER AT STA ZR-30 AND STA ZR-40. REMOVED AND REPLACED THE CASTING PER SRM 51-10-04. REF CONTROL NR 95ZZZX2358. (X)

Part: RIB — CORRODED (RUDDER)

SBA - ITEM FROM SBA N/R NR 1144. DURING C-CHECK, FOUND CORROSION ON CASTING AND ANGLE INTERNAL RIB OF RUDDER AT STA ZR-30 AND STA ZR-40. REMOVED AND REPLACED THE CASTING PER SRM 51-10-04. REF CONTROL NR HAL95043.

Part: SPAR — CORRODED (NR 2 TE FLAP)

SBA - DURING D-CHECK, FOUND LEVEL 2 CORROSION UNDER NUT CHANNELS AND 4 BROKEN SCREWS ON LT FLAP AFT SPAR NR 2 TRAILING EDGE. REMOVED CORROSION AND INSTALLED STRAP PER ENGINEERING DRAWING NR SKB0038N00531 AND SRM 51-10-3 AND 51-01. (Z)

Part: THRESHOLD — CRACKED (FS 370-427)

SBA - ITEM FROM SBA N/R NR 18N01242. DURING C-CHECK, FOUND LEVEL 2 CORROSION AT FORWARD CARGO PIT, THRESHOLD AREA AT DOOR CUT-OUT, THRESHOLD CHANNEL FROM STA 370 TO STA 427. ALSO, FOUND CRACK AT NT-PLATE TABS. FABRICATED AND INSTALLED NEW CHANNEL PER SRM 51-30-02 AND SRM 51-10-02. (X)

Part: FITTING — CRACKED (FS 775 LBL 45)

DURING C-CHECK, FOUND FLOOR SUPPORT CRACKED AT UPPER SURFACE OF THE CENTER WING SECTION STAION 775 LBL 45 OUTBOARD SIDE. INSTALLED A NEW FITTING PER SRM 51-30-2. (W)

Part: STIFFENER — CORROSION (FS 868 STR 21R)

SBA - ITEM FROM SBA NR 18N00882 C-CHECK, LEVEL 2 CORROSION EXTERNAL SKIN STIFFENER STA 868, AT STR 21R. REMOVED DAMAGED STIFFENER AND REINSTALLED NEW STIFFENER PER SRM 51-30-2 AND SRM 51-10-03. (X)

Part: FITTING — BROKEN (RT TE FLAP)

SBA - ITEM FROM SBA N/R NR 18N01049. DURING C-CHECK, FOUND BROKEN CASTING INSIDE RT TRAILING EDGE FLAP AT THE INBOARD CORNER. REMOVED AND REPLACED THE FITTING PER SRM 51-30-92. (X)

Part: SKIN — CORROSION (FS 851-860)

SBA - DURING D-CHECK, FOUND WIDE SPREAD LEVEL 2 CORROSION ON FUSELAGE SKIN INCLUDING BRACKET AT STATION 851 TO 860 STR 30. INSTALLED STRAP AND DOUBLER REPAIR PER ENGINEERING DRAWING NR SKB003818N00253. (Z)

Part: FRAME — CORROSION (FS 1320)

SBA - DURING D-CHECK, FOUND AFT TAIL COMPARTMENT INTERNAL STRUCTURE HAS LEVEL 2 CORROSION ON FRAME WEB JUST BELOW AIRSTAIR ACTUATOR CONTROL VALVE STA 1320 STR 26L. FABRICATED WEB AND CLIP PER SRM 53-01 FIG 4 AND INSTALLED PER SRM 51-30-2 AND 51-30-5. (Z)

Part: NOSE CAP — CORRODED (RT WING T/E FLAP)

SBA - ITEM FROM SBA NR 310, C-CHECK, LEVEL 2 WIDESPREAD CORROSION AND DISBONDING OF BONDED DOUBLER ON INTERIOR AND EXTERIOR SURFACES OF RT WING TRAILING EDGE FLAP, TRAILING EDGE PANEL. REMOVED AND REPLACED LEADING EDGE CAP ON WORK ORDER B00380900018. (X)

Part: SKIN — CORRODED (FS 674 STR 29L)

SBA - ITEM FROM SBA NR 18N00094 C-CHECK, D.P.M. P061002, SEVERE CORROSION, FUSELAGE SKIN STA 674 BETWEEN LONGERON 30 AND LONGERON 29 LEFT. REMOVED TEMPORARY REPAIR, REMOVED CORROSION AND TREATED. FABRICATED AND INSTALLED FILLER AND DOUBLER PER SRM 51-10-1 AND SRM 53-04, FIGURE 43, PAGE 251. (X)

Part: SKIN — DISBOND (FS 747)

PHX - DURING C6 INSPECTION, FOUND DELAMINATION IN WINDOW BELT AREA, STA 747 RT AND LT AND STA 847 RT. LOCATED AND REPAIRED PER EO 53-30-14. (Z)

Part: FRAME — CRACKED (FS 597)

PHX - DURING C6 INSPECTION, FOUND STA 597 STR 17R FRAME CRACKED. INSTALLED REPAIR FILLER AND ANGLE PER ER 2 53 34 06. (Z)

Part: RIB — CRACKED (RT HORIZ STAB)

PHX - DURING C6 INSPECTION, FOUND RT HORIZONTAL STABILIZER LE RIB 3RD, 4TH AND 9TH FROM I/B END CRACKED. FABRICATED AND INSTALLED DOUBLER REPAIR PER SRM 51-40-3. (Z)

Part: FLOORBEAM — CRACKED (FS 597)

PHX - DURING C6 INSPECTION, FOUND FLOORBEAM CRACKED, STA 400 STR 27. SPLICED IN NEW REPAIR SECTION PER SRM 51-40-4. (Z)

Part: SUPPORT — CORRODED (BS 987)

PHX - DURING C6 INSPECTION, FOUND CORROSION BEYOND LIMITS ON LT LAV DOOR THRESHOLD SUPPORT, STA 987 TO 1006. FABRICATED NEW SUPPORT INTERCOSTAL PER SRM 51-10-1. (Z)

Part: FRAME — CRACKED (BS 639)

PHX - DURING C6 INSPECTION, FOUND STA 639 STR 17L FRAME WEB CRACKED. REPAIRED WITH DOUBLER REPAIR PER SRM 51 40 2 AND SRM 51 30 2. (Z)

Part: ANGLE — CORRODED (BS 987)

PHX - DURING C6 INSPECTION, FOUND LT LAV FWD WALL SUPPORT ANGLE CORRODED BEYOND CLEAN UP LIMITS. FABRICATED AND INSTALLED NEW SUPPORT ANGLE PER SRM 51-30-2. (Z)

Part: ANGLE — CRACKED (BS 294)

PHX - DURING C6 INSPECTION, FOUND FWD ENTRY DOOR INTERCOSTAL SUPPORT ANGLE BETWEEN STA 294 STR 10L AND 11L CRACKED. FABRICATED AND INSTALLED NEW ANGLE PER SRM 51-30-2. (Z)

Part: RIB — CRACKED (LT HORIZ STAB)

PHX - DURING C6 INSPECTION, FOUND LT HORIZONTAL STABILIZER LE RIB 4TH AND 9TH FROM I/B END CRACKED. INSTALLED DOUBLER REPAIR PER SRM 51-40-3. (Z)

Part: BEARING — MISMANUFACTURED (GRIP)

BEARING CAGE SPOT WELD EXTENDING TOO HIGH.

Part: BEARING — MISMANUFACTURED (GRIP)

BEARING CAGE SPOT WELD EXTENDING TOO HIGH.

Part: BEARING — MISMANUFACTURED (GRIP)

BEARING CAGE SPOT WELD EXTENDING TOO HIGH. REPLACE BEARINGS.

Part: BEARING — MISMANUFACTURED (GRIP)

BEARING CAGE SPOT WELD EXTENDING TOO HIGH. REPLACE BEARINGS.

Part: RELIEF VALVE — MISSING (NR 1 ENGINE)

DURING ROUTINE A-3 CHECK, NR 1 ENGINE MAIN OIL FILTER CHANGE, DISCOVERED OIL PRESSURE RELIEF VALVE ASSEMBLY WAS NOT INSTALLED. REPLACED PRESSURE RELIEF VALVE, PN 710170, RETAINING RING, PN 728373, KEY WASHER, PN 695395, AND GASKET, PN 6-961.

Part: HIGH STAGE VALVE — INOPERATIVE (NR 1 ENG)

FLT 66 - SNA-LAS - AIR TURNBACK, UNABLE TO PRESSURIZE A/C DURING TAKEOFF/CLIMB. A/C RETURNED TO SNA. A/C WAS MX FERRIED UNPRESSURIZED TO PHX. PHX MX RESEALED OUTFLOW VLV, REINSTALLED SEALED AROUND POTABLE WATER TANK DRAIN, AND RECONNECTED UPPER AND LOWER HALVES OF NOSE GEAR VIEWING PORT ASSY. MX ALSO REMOVED AND REPLACED FAN AIR VALVE TO BLEED REGULATOR LINE, NR 1 ENG BLEED AIR REG HIGH STAGE VLV, AND 490 DEGREE THERMOSTATIC SWITCH. COMPLIED WITH A/C BLEED DOWN TEST IAW MM 05-51-91, SYS TEST OK. PERFORMED OPS CK OF CABIN PRESS CONTROLLER PER MM 21-31-00, PAGE 201/205. OPS CHECK GOOD. POST INSTALLATION TEST ACCOMPLISHED PER MM 36-11-16, TEST OK. A/C RETURNED TO SERVICE. (W)

Part: SEAL — LOOSE (CARGO DOOR)

FLT 2806 - SNA-LAS - AIR TURNBACK, CREW UNABLE TO PRESSURIZE AIRCRAFT DURING TAKEOFF/CLIMB. AIRCRAFT RETURNED TO SNA AND LANDED WITHOUT FURTHER INCIDENT. CONTRACK MX FOUND A 24 INCH SEGMENT OF AFT CARGO DOOR SEAL PULLED LOOSE FROM ITS TRACK. REINSTALLED SEAL, PRESSURIZED AIRCRAFT USING THE APU AND/OR RT ENGINE BLEED, AND PERFORMED THE PRESSURIZATION CONTROL SYSTEM OPERATIONAL TEST. NO FURTHER FAULTS NOTED AT THIS TIME. SEAL TO BE INSPECTED AT LAS. AIRCRAFT RETURNED TO SERVICE. (W)

Part: THERMOSTATIC — INOPERATIVE (NR 1 ENG)

FLT 66 - SNA-LAS - AIR TURNBACK, UNABLE TO PRESSURIZE A/C DURING TAKEOFF/CLIMB. A/C RETURNED TO SNA. A/C WAS MX FERRIED UNPRESSURIZED TO PHX. PHX MX RESEALED OUTFLOW VLV, REINSTALLED SEALED AROUND POTABLE WATER TANK DRAIN, AND RECONNECTED UPPER AND LOWER HALVES OF NOSE GEAR VIEWING PORT ASSY. MX ALSO REMOVED AND REPLACED FAN AIR VALVE TO BLEED REGULATOR LINE, NR 1 ENG BLEED AIR REG HIGH STAGE VLV, AND 490 DEGREE THERMOSTATIC SWITCH. COMPLIED WITH A/C BLEED DOWN TEST IAW MM 05-51-91, SYS TEST OK. PERFORMED OPS CK OF CABIN PRESS CONTROLLER PER MM 21-31-00, PAGE 201/205. OPS CHECK GOOD. POST INSTALLATION TEST ACCOMPLISHED PER MM 36-11-16, TEST OK. A/C RETURNED TO SERVICE. (W)

Part: BLEED AIR REG — INOPERATIVE (NR 1 ENG)

FLT 66 - SNA-LAS - AIR TURNBACK, UNABLE TO PRESSURIZE A/C DURING TAKEOFF/CLIMB. A/C RETURNED TO SNA. A/C WAS MX FERRIED UNPRESSURIZED TO PHX. PHX MX RESEALED OUTFLOW VLV, REINSTALLED SEALED AROUND POTABLE WATER TANK DRAIN, AND RECONNECTED UPPER AND LOWER HALVES OF NOSE GEAR VIEWING PORT ASSY. MX ALSO REMOVED AND REPLACED FAN AIR VALVE TO BLEED REGULATOR LINE, NR 1 ENG BLEED AIR REG HIGH STAGE VLV, AND 490 DEGREE THERMOSTATIC SWITCH. COMPLIED WITH A/C BLEED DOWN TEST IAW MM 05-51-91, SYS TEST OK. PERFORMED OPS CK OF CABIN PRESS CONTROLLER PER MM 21-31-00, PAGE 201/205. OPS CHECK GOOD. POST INSTALLATION TEST ACCOMPLISHED PER MM 36-11-16, TEST OK. A/C RETURNED TO SERVICE. (W)

Part: INVERTER — FAILED (EE COMPT)

PRIMARY INVERTER CAUTION LIGHT ILLUMINATED AND COCKPIT FILLED WITH SMOKE. REMOVED AND REPLACED PRIMARY INVERTER AND PARALLEL CONTROL BOX. PERFORMED FUNCTION TEST OF INVERTER SYSTEM IAW MM. OPS OKAY. ACFT RETURNED TO SERVICE. (X)

Part: FILTER — DEFECTIVE (ENGINE OIL)

WHEN REMOVING OIL FILTER AFTER APPROXIMATELY 10 HOURS OF SERVICE CHANGE, DISCOVERED THE OIL FILTER CAN PORTION WAS SPINNING/ROTATING IN THE BASE PLATE. NO LEAKS HAD OCCURRED DURING SERVICE.

Part: EEL BULB — FAILED (CABIN)

STL - EMERGENCY LIGHT IN CABIN DOOR IS INOP. MAINTENANCE REPLACED EMERGENCY LIGHT BULB. (W)

Part: EEL BULB — FAILED (LT FWD DOOR)

LEFT FORWARD ENTRY DOOR (EXTERIOR) EMERGENCY SLIDE LIGHT INOP. RELAMPED BURNED OUT BULB, OPS CHECK NORMAL IAW MM 33-51-11 AND 33-51-21. (W)

Part: COOLING FAN — OVERHEATED (LT)

SMOKE COMING OUT OF GROUND COOL FAN INLETS. LEFT GROUND FAN SIDE OF 'Y' DUCT EXTREMELY HOT. SUSPECT ELECTRICAL SHORT AT FAN. REMOVED AND REPLACED THE LEFT GROUND COOLING FAN ASSEMBLY. THE OPERATIONAL CHECK WAS GOOD AND THE LEAK CHECK GOOD. NO SMOKE NOTED ON OPS CHECK. SYTEM OPERATING NORMALLY. (W)

Part: MOUNT — CRACKED (ENGINE)

ENGINE MOUNT ASSEMBLY SHOWING A CRACK AND SEPARATION ON THE LOWER PART. THIS WAS FOUND DURING A 100-HOUR INSPECTION. THE RUBBER ENGINE MOUNTS THAT WERE INSTALLED ARE NOT THE ORIGINALS, THEY WERE MADE IN BRAZIL. THE PROPELLER SPINNER HAD BEEN REPAIRED, BUT WAS NOT DYNAMICALLY BALANCED.

Part: EEL HARNESS — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND FLOOR MOUNTED EMERGENCY EXIT LIGHTS IN FORWARD CABIN INOPERATIVE. REMOVED AND REPLACED LIGHT HARNESS ASSEMBLY, OPS CHECK GOOD. (W)

Part: BOLT — MISSING (RT MLG)

ON THE CLEVELAND BRAKE, 6 BOLTS ARE REMOVED EVERY 100 HOURS TO REMOVE THE WHEEL TO LUBE THE BEARINGS. ON PERFORMING 100-HOUR INSPECTION, FOUND 2 EACH BOLTS MISSING AND 1 BOLT LOOSE. BRAKE PAD WAS RUBBING ON TIRE. SECOND SUCH INCIDENT IN 1 MONTH. SUGGEST REPLACING BOLTS WITH SAFETY WIRE-CAPABLE BOLTS.

Part: ATTACH PLATE — LOOSE (LT ELEVATOR)

DURING C-INSPECTION, THE LEFT OUTBOARD ELEVATOR HINGE ATTACH PLATES WERE FOUND LOOSE AND FRETTING, WHERE THEY ATTACH TO THE AFT END OF THE STABILIZER RIB AT STATION 213.32. THE HINGE ATTACH PLATES WERE REPLACED AND THE RIB END FITTING REPAIRED PER S/B 737-55-1054. (W)

Part: ENGINE — REQ SERVICING (RTG ENGINE)

SGF - FLT 7020 - RT ENGINE OIL PRESSURE DROPPED TO 40 PSI. MAINTENANCE SERVICED RT ENGINE WITH OIL. GROUND RUNS REVEALED NO LEAKS. ENGINE PLACED AN OIL CONSUMPTION WATCH. (X)

Part: HEAT EXCHANGER — CRACKED (LEFT)

PHX - DURING SCHEDULED C8 INSPECTION, FOUND LT PRIMARY HEAT EXCHANGER CRACKED AT WELD IN AFT LOWER INBOARD CORNER. REMOVED AND REPLACED HEAT EXCHANGER PER AWA TASK CARD R2C21004. LEAK CHECK COMPLIED WITH. (W)

Part: FLOORBEAM — CORRODED (FS 328)

PHX - DURING SCHEDULED C8 INSPECTION, FOUND CORROSION ON UPPER CAP OF FLOORBEAM, STA 328 RBL 12 TO R1 DOORWAY. INSTALLED NEW T-CAP PER BOEING STRUCTURAL REPAIR MANUAL 53-10-9 PG 29. (W)

Part: FLOORBEAM — CORRODED (FS 312)

PHX - DURING SCHEDULED C8 INSPECTION, FOUND CORROSION ON TOP CAP OF FLOORBEAM, STA 312 LBL 12 TO RBL 12. INSTALLED REPAIR PER BOEING STRUCTURAL REPAIR MANUAL 51 10 9. (W)

Part: THRESHOLD — CORRODED (R1 DOOR)

PHX - DURING SCHEDULED C8 INSPECTION, FOUND R1 DOOR THRESHOLD CHORD CORRODED BEYOND LIMITS. FABRICATED NEW ANGLE PER BOEING DRAWING AND INSTALLED REPAIR PER BOEING SRM 51-30-2. (W)

Part: SEAT TRACK — CORRODED (FS 312)

PHX - DURING SCHEDULED C8 INSPECTION, FOUND CORROSION BEYOND LIMITS ON SEAT TRACK AT STA 312, RBL 18 AND RBL 45. REMOVED, FABRICATED AND INSTALLED NEW SEAT TRACK PER BOEING SRM 51-10-1 AND SRM 51-30-2. (Z)

Part: SEAT TRACK — CORRODED (FS 328)

PHX - DURING SCHEDULED C8 INSPECTION, FOUND CORROSION ON GALLEY SUPPORT TRACK, STA 328 RBL 55, RBL 45 AND RBL 24. REMOVED AND REPLACED DAMAGED SECTION OF TRACK WITH NEW TRACK PER BOEING SRM 51-10-1 AND SRM 51-30-2. (Z)

Part: PCU — MALFUNCTIONED (RUDDER)

WITH REFERENCE TO AD T95-06-53. AIRTRAN AIRWAYS, INC., RECEIVED RUDDER PCU PN 65-44861-5, SN 855A OVERHAULED BY NORTEK REPAIR CENTER, INC., FAA. , REPAIR STATION NR YA4R667M. THE RUDDER PCU ON AIRCRAFT EI-CJW (TAT 36,134.6 AND TAC 44104) WAS REMOVED AND REPLACED WITH SERVICEABLE UNIT. ON 3-16-95, PERFORMED ADJUSTMENT TESTS AND LEAK CHECKED PER BOEING 737-200 MM CHAPTER 27-21-91. FUNCTIONAL CHECK FLIGHT ACCOMPLISHED, NO DISCREPANCIES NOTED. AIRCRAFT EI-CJW WAS RETURNED TO SERVICE.

Part: PROX SW — FAILED (RT MLG)

HNL - FLT NR 508 - AFTER TAKEOFF, RIGHT GEAR UNSAFE LIGHT ON. NORMAL GEAR EXTENSION. ON RETURN TO HONOLULU GEAR DOOR OPEN LIGHT ON WHEN UPLATCH CHECK. CHECKED GEAR SWITCH WIRE AND FOUND OK. INSPECTED GEAR AND UPLOCK AND FOUND OK. REPLACED PROXIMITY BOX. GEAR SWING CHECKED OK. (W)

Part: EEL — MISSING (CABIN)

STL - ESCAPE PATH LIGHTING MISSING. MAINTENANCE REPLACED ESCAPE PATH LIGHTING. (W)

Part: RELAY — INOP (L/G MODULE)

PHX - FLT 445 - AFTER TAKEOFF AND DURING CLIMB, THE LANDING GEAR CONTROL LEVER WOULD NOT RAISE PAST THE OFF DETENT TO RETRACT THE GEAR. CREW MADE NO ATTEMPT TO OVERRIDE THE LOCKOUT AND ELECTED TO RETURN TO PHOENIX. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE K3 RELAY, OPERATIONAL CHECK WAS SATISFACTORY. AIRCRAFT RETURNED TO SERVICE. (W)

Part: EEL CONNECTOR — LOOSE (CABIN)

DURING DAILY SERVICE, FOUND MAIN CABIN INTERVAL LIGHT EXIT LIGHT AT L-5 DOOR INOPERATIVE. FOUND CONNECTOR LOOSE IN LIGHT ASSEMBLY. SECURED CONNECTOR, OPS CHECK OK. (W)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

DURING DAILY SERVICE, FOUND MAIN CABIN INTERVAL EMERGENCY EXIT LIGHT AT L-1 MAIN ENTRY DOOR (SYSTEM INDICATOR LED) INOPERATIVE. DURING TROUBLESHOOTING, FOUND THE BATTERY PACK AT FAULT. REMOVED AND REPLACED THE BATTERY PACK, OPS CHECK OK. (W)

Part: CONNECTOR — CORRODED (NR 2 ENG)

RETURN TO GATE DUE NR 2 ENGINE WOULD NOT ACCELERATE. CLEANED LOW IDLE CANNON PLUG ON MAIN ENGINE CONTROL. OPERATIONAL CHECKED OK. (W)

Part: LOWER TUBE — FAILED (LIFE RAFT)

DURING A DITCHING DRILL EXERCISE, AT THE LONG BEACH RECREATION CENTER, THE 25 MAN LIFE RAFT (P/N 14D23041) USED DURING THE DRILL, FAILED TO DEPLOY PROPERLY. THE LOWER BUOYANCY TUBE FAILED TO INFLATE FULLY. THIS TYPE LIFE RAFT IS NOT INSTALLED ON ANY TOWER AIRCRAFT. (W)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

DURING DAILY SERVICE, FOUND MAIN CABIN INTERVAL EMERGENCY EXIT LIGHT AT L-3 MAIN ENTRY DOOR INOPERATIVE. DURING TROUBLESHOOTING, FOUND THE BATTERY PACK AT FAULT. REMOVED AND REPLACED THE BATTERY PACK, OPS CHECK OK. (W)

Part: EXTINGUISHER — DISC FAILED (NR 1 ENGINE)

AIRCRAFT WAS PARKED. FIRE EXTINGUISHER DISCHARGED. UPON REMOVAL, FOUND FRANGIBLE DISC RUPTURED. THE SQUIB WAS NOT DISCHARGED. THE FRANGIBLE DISC FAILED. THE FIRE EXTINGUISHER WAS HYDROSTATICALLY TESTED AND SERVICED JANUARY, 1990.

Part: EEL BATTERIES — DISCHARGED (CABIN)

HNL - THE EMERGENCY EXIT LIGHT AT BOTH AFT OVERWING EXITS (ROW 18) IS OUT. REPLACED THE EMERGENCY POWER SUPPLY BATTERIES ABOVE THE OVERWING EXITS. THE OPERATIONAL CHECK WAS GOOD. (Z)

Part: ACTUATOR — BROKEN (NLG DOWNLOCK)

NOSE GEAR DOWNLOCK ACTUATOR UPPER ATTACH FITTING BROKEN. REMOVED AND REPLACED DOWNLOCK ACTUATOR IAW MM 32-33-21. (W)

Part: DOOR — OBSTRUCTED (CARGO COMPT)

AIR RETURN DUE AIRCRAFT WOULD NOT PRESSURIZE. INSPECTION FOUND CARGO NET P/N 657896640 OBSTRUCTING AFT CARGO DOOR PRESSURE SEAL. REMOVED OBSTRUCTION AND PRESSURIZED AIRCRAFT PER MM 21-21-00. AIRCRAFT RETURNED TO SERVICE. (W)

Part: EEL POWER SUPPLY — FAILED (CABIN)

HNL - THE EMERGENCY CEILING LIGHT AT ROWS 16-18 WILL NOT COME ON. REPLACED THE BATTERIES IN THE EMERGENCY PACK AND IT WAS NO HELP. REMOVED AND REPLACED THE BATTERY POWER SUPPLY AND THE OPERATIONAL CHECK WAS GOOD. (Z)

Part: SENSOR — INOP (NR 1 ENG)

MEM - FLT 7146 - ON CLIMB, THE NR 1 ENGINE WOULD NOT MAKE TORQUE. MAINTENANCE REPLACED THE LT ENG OIL IMMERSED THERMAL SENSOR. (W)

Part: AIR MIX VALVE — STUCK (LEFT)

PHX\LAS - FLT 2807 - AIR TURNBACK, DUAL DUCT OVERHEAT DURING TAKEOFF. AIRCRAFT RETURNED TO GATE WITHOUT FURTHER INCIDENT. MX FOUND LEFT AIR MIX VALVE STUCK IN MID-POSITION, NOT MOVING IN MANUAL OR AUTO. MX REMOVED AND REPLACED LT AIR MIX VALVE, OPERATION CHECK NORMAL IAW AWA CARD R2C21003. REPLACED CABIN TEMP REGULATOR PN 548376, SN 076C2423, AS PRECAUTIONARY, OPERATIONAL CHECK NORMAL PER BMM 21 61 00. ACFT RETURNED TO SERVICE. AIR MIX VALVE, MFG PN 3981161 1, SN 38 3985. CONDITION STUCK OPEN, LOCATION ONLY. (X)

Part: EEL BULB — FAILED (CABIN)

STL - THE RT FWD EMERGENCY LIGHT INOP. MAINTENANCE REPLACED RT FWD EMERGENCY LIGHT BULB. (W)

Part: NUT — FAILED (T/R BELLCRANK)

THE T/R SUDDENLY DEVELOPED A SEVERE VIBRATION IN-FLIGHT. THE AIRCRAFT WAS LANDED IMMEDIATELY. EVIDENCE INDICATES THE NUT WHICH SECURES THE COUNTERWEIGHT BELLCRANK TO THE T/R CROSS-HEAD FAILED ALLOWING THE C/W BELLCRANK TO COME OFF STRIKING THE T/R BLADE AS IT DEPARTED THE AIRCRAFT. THE THREADS ON THE T/R CROSS-HEAD WERE STILL IN GOOD CONDITION. PIECES OF THE COTTER KEY WERE STILL IN PLACE WHICH INDICATES THAT THE NUT FAILED AND THE FORCE OF THE COUNTERWEIGHT BELLCRANK SHEARED OFF THE COTTER KEY. THE BELLCRANK WAS NOT RECOVERED. SUBMITTER STATED NUT IS TOO LIGHT-WEIGHT TO BE USED IN SUCH A SAFETY SENSITIVE APPLICATION HAD THE PILOT NOT BEEN ABLE TO LAND IMMEDIATELY. THIS COULD HAVE BEEN A CATASTROPHE.

Part: CONTROL CABLE — BROKEN (RT MLG DOOR)

HNL - FLT 127 - CORRECTED SDR TO REFLECT CORRECT FLT NR. RIGHT MAIN GEAR DOOR CAME DOWN DURING LANDING ROLL AT 80 TO 90 KNOTS. ALL CONDITIONS NORMAL DURING TOUCH DOWN AND DURING GEAR DOWN CHECK, NO GEAR DOOR OPEN LIGHT SEEN UNTIL SCRAPING SOUND AS AIRCRAFT DECELERATED. FOUND RT GEAR DOOR POSITION SEQUENCE CABLE TUBE ASSY SPOT WELD BROKEN AND SHIFTED TO THE RIGHT APPROXIMATELY 2 INCHES. REMOVED DOOR AND INSPECTED HINGE. NO DEFECTS NOTED. INSTALLED SERVICEABLE DOOR PER MM 32-12-1. INSTALLED MLG PUSH/PULL CABLE PER MM 32-31-0. ADJUSTMENT/TEST PER MM 32-31-0. GEAR SWING AND FREE-FALL CHECK OKAY. INSPECTED NR 2 ENGINE INLET FOR FOD AND NO DAMAGE NOTED. (X)

Part: SKIN — CRACKED (BS 953)

PHX - DURING ACCOMPLISHMENT OF LOWER LAP SKIN INSPECTION PER BSB 737 53A1177, SKIN CRACKS WERE IDENTIFIED AT BS 953 STR 10R, REMOVED WITH .0625 INCH OVERSIZE. ALL AREAS WERE REPAIRED IAW AWA EO 53-30-16 AND ER 2-53-33-08. REF 95ZZZW197, 95ZZZW198, 95ZZZW199, AWXA9500093.

Part: SKIN — CRACKED (BS 845)

PHX - DURING ACCOMPLISHMENT OF LOWER LAP SKIN INSPECTION PER BSB 737 53A1177, SKIN CRACKS WERE IDENTIFIED AT BS 845 STR 4L, .125 INCHES IN LENGTH. ALL AREAS WERE REPAIRED IAW AWA EO 53-30-16 AND ER 2-53-33-08. REF 95ZZZW197, 95ZZZW199, 95ZZZW200, AWXA9500093.

Part: SKIN — CRACKED (BS 510)

PHX - DURING ACCOMPLISHMENT OF LOWER LAP SKIN INSPECTION PER BSB 737 53A1177, SKIN CRACKS WERE IDENTIFIED AT BS 510 STR 10L, .200 INCHES IN LENGTH. ALL AREAS WERE REPAIRED IAW AWA EO 53-30-16 AND ER 2-53-33-08. REF 95ZZZW198, 95ZZZW199, 95ZZZW200, AWXA9500093.

Part: SKIN — CRACKED (BS 492)

PHX - DURING ACCOMPLISHMENT OF LOWER LAP SKIN INSPECTION PER BSB 737 53A1177, SKIN CRACKS WERE IDENTIFIED AT BS 492 STR 10L, .125 INCHES IN LENGTH. ALL AREAS WERE REPAIRED IAW AWA EO 53-30-16 AND ER 2-53-33-08. REF 95ZZZW197, 95ZZZW198, 95ZZZW199, 95ZZZW200.

Part: SKIN — CRACKED (BS 909)

PHX - DURING ACCOMPLISHMENT OF LOWER LAP SKIN INSPECTION PER BSB 737 53A1177, SKIN CRACKS WERE IDENTIFIED AT BS 909 STR 20R, REMOVED WITH .0625 INCH OVERSIZE. ALL AREAS WERE REPAIRED IAW AWA EO 53-30-16 AND ER 2-53-33-08. REF 95ZZZW197, 95ZZZW198, 95ZZZW200, AWXA9500093.

Part: EEL BULB — FAILED (CABIN)

STL - FLT 7126 - FORWARD RT EMERGENCY LIGHT OVER THE EMERGENCY HATCH IN THE CABIN IS INOP. MAINTENANCE REPLACED EMERGENCY LIGHT BULB. (Z)

Part: ROD END — LOOSE (RT ELEVATOR)

OGG - FLT 258 - VIBRATION FELT INFLIGHT THROUGH WHOLE AIRPLANE BUT, MOSTLY THROUGH CONTROL YOKE. PITCH TRIM SEEMED TO CHANGE CONSTANTLY. STABILIZER TRIM SYSTEM WORKED FINE, MADE AIR TURNBACK. FOUND RT ELEVATOR BOOST CYLINDER AFT ROD-END NUT BACKED OFF. REPLACED EYE BOLT ASSEMBLY PER MM FOR PRECAUTION. LT ELEVATOR BOOST CYLINDER CONDITION AND SECURITY CHECK OKAY. ELEVATOR OPERATION CHECK OKAY. RT ELEVATOR ROD-END RETAINER TO BE REPLACED AFTER ACFT FERRIED TO HNL. (W)

Part: TEMP MONT — FAILED (BATT COMPT)

MAIN BATTERY HOT AND AUX BATTERY HOT LIGHTS ILLUMINATED, ALSO NO TEMP INDICATION. REMOVED AND REPLACED BATTERY TEMP MONITOR OP CHECKS GOOD. INSPECTED BATTERIES FOUND TO BE COOL. ACFT RETURNED TO SERVICE. (W)

Part: INVERTER — FAILED (NR 2)

STL - FLT 7146 - NR 2 INVERTER FAULTED. MAINTENANCE REPLACED NR 2 INVERTER. OPERATIONAL CHECK GOOD. (X)

Part: STIFFENER — CRACKED (FS 1217)

HNL - TWO STIFFENERS (T ANGLE) WERE FOUND SEVERELY CRACKED AND CORRODED AT THE CANTED BULKHEAD FWD FACE FS 1217. REPLACED STIFFENERS. REF 95ZZZW117.

Part: ATTACH FITTING — CRACKED (VERT STAB LE)

HNL - VERTICAL STABILIZER LEADING EDGE, RT FRONT SPAR ATTACH FITTING WAS FOUND CRACKED WHILE ACCOMPLISHING NON-ROUTINE MAINTENANCE. REPLACED FITTING. (W)

Part: STIFFENER — CRACKED (FS 1217)

HNL - TWO STIFFENERS (T ANGLE) WERE FOUND SEVERELY CRACKED AND CORRODED AT THE CANTED BULKHEAD FWD FACE FS 1217. REPLACED STIFFENERS. REF HAL95016.

Part: LANYARD — FAILED (OXYGEN SYSTEM)

LANYARD FOR ACTIVATING PASSENGER CHEMICAL OXYGEN SYSTEM FAILED DURING ACTIVATION TEST. INSPECTION OR OTHER LANYARDS ON THE ACFT RESULTED IN APPROXIMATELY 50 PERCENT FAILURE RATE. ALL LANYARDS REPLACED WITH NEW SERVICEABLE LANYARDS. OXYGEN ASSEMBLY MANUFACTURER PURITAN BENNETT WAS NOTIFIED AND IS PERFORMING FAILURE ANALYSIS ON REMOVED LANYARDS. BOEING AIRCRAFT HAS BEEN NOTIFIED AND IS INVESTIGATING THE PROBLEM.

Part: CRANKSHAFT — BROKE (NR 3 JOURNAL)

WHILE IN-FLIGHT, CATASTROPHIC FAILURE -- CRANKSHAFT BROKE CLEAN IN HALF AT NR 3 CONN ROD JOURNAL. SUSPECT HEAT/FATIGUE CRACK, OR IMPROPER UNDERSIZING PROCESS.

Part: EEL BATTERY — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND GALLEY EMERGENCY BATTERY PACK AT FAULT. REMOVED AND REPLACED BATTERY ASSEMBLY, OPS CHECK GOOD. (W)

Part: INSERT — WORN THREADS (NR 1 ENG GEAR BX)

LAS-ELP - FLT 976 - AIR TURNBACK - ON CLIMB-OUT AIRCRAFT LOST NR 1 ENGINE OIL PRESSURE. CREW SHUT ENGINE DOWN AND RETURNED TO LAS WITHOUT FURTHER PROBLEMS. MAINTENANCE FOUND STRIPPED THREADS ON BANJO FITTING OF GEAR BOX, JUST ABOVE THE MAIN OIL FILTER. MAINTENANCE REMOVED AND REPLACED FITTING LP5 BOSS AND BANJO FITTING. LEAK CHECK ON RUNUP NORMAL. AIRCRAFT RETURNED TO SERVICE. (Z)

Part: STEP — CORROSION (PAX DOOR)

MAINTENANCE DISCOVERED SURFACE CORROSION ON PAX DOOR STEP BOX. CORROSION DEFINED AS FILIFORM TYPE. MAINTENANCE CLEANED AND TREATED AREAS OF CORROSION IAW ATR42 SRM 51-21-42 FOR PAINTING AND CORROSION PREVENTION AND INSPECTION MM 52-10-00. (W)

Part: SKIN — CRACKED (FS 1209)

HNL - FOUND APPROX .25 INCH CRACK AT RIVET ON FUSELAGE SKIN STATION 1209 LEFT SIDE APPROXIMATELY 8 INCHES UP FROM ENGINE PYLON. MADE FILLER AND DOUBLER REPAIR PER HAL M105 FILE NR 61044. (Z)

Part: SKIN — CRACKED (FUSELAGE)

PHX - DURING LFEC INSPECTION OF LOWER SKIN LAPS, CRACKS WERE FOUND AT THE FOLLOWING LOCATIONS, STA 381 14R, STA 400 14L, STA 490 14L, STA 597 4L, STA 628 4L, STA 756 14R, STA 777 14L, STA 787 20L, STA 877 20L. ALL AREAS REPAIRED PER EO 53-30-16. (Z)

Part: SKIN — CRACKED (FS 727B)

PHX - DURING SCHEDULED INSPECTION, FOUND FUSELAGE SKIN CRACKED AT STATION 727B STRINGER 17R. REPAIRED DAMAGE PER SRM 53-30-3. (Z)

Part: SKIN — CRACKED (FS 1247)

HNL - DURING S-CHECK, FOUND APPROXIMATELY 1.0625 INCH CRACK BETWEEN LONGERON 3R AND LONGERON 4R AT FUSELAGE STATION 1247. MADE FILLER AND INTERNAL DOUBLER REPAIR PER HAL FORM M 105 FILE NR 61038. (Z)

Part: SKIN — CRACKED (FS 1247)

HNL - DURING S-CHECK, FOUND APPROXIMATELY 1.25 INCH CRACK BETWEEN LONGERON 3L AND LONGERON 4L AT FUSELAGE STA 1247. MADE FILLER AND INTERNAL DOUBLER REPAIR PER HAL FORM M 105 FILE NR 61037. (W)

Part: DETECTOR — LOOSE (RT WING)

THE RT WING BODY OVERHEAT LIGHT FLICKERED SEVERAL TIMES, THEN STAYED ON STEADY IN FLIGHT. CHECKED RESISTANCE AT D742, AND REPOSITIONED OVERHEAT DETECTOR DUE TO PULLED FROM SUPPORT. OPERATIONAL CHECKED OK FOR CONTINUED SERVICE. (W)

Part: CONNECTOR — LOOSE (RT WING)

THE RT WING BODY OVERHEAT LIGHT ILLUMINATED DURING FLIGHT. FOUND LOOSE CANNON PLUG ON THERMAL ANTI-ICE SENSOR, AND RT WING LOOP RUBBING ON FLUID LINE UNDER WING LEADING EDGE. SECURED CANNON PLUG AND REPOSITIONED OVERHEAT WARNING DETECTOR. RAN ENGINE AND WING ANTI-ICE SYSTEM. OPS CHECKED NORMAL. (W)

Part: WHEEL BEARING — FAILED (NR 3 MLG)

THE NR 3 O/B BEARING FAILED ON LANDING IN CANCUN. REPLACED LOWER STRUT, WHEELS AND NR 3 BRAKES. (W)

Part: OVERHEAT LIGHT — ILLUMINATED (RT WING)

THE RT WING BODY OVERHEAT LIGHT INTERMITTENT IN FLIGHT. OPERATED RT PACK WITH NO FAULTS NOTED. SYSTEM CHECKED NORMAL. OK FOR CONTINUED SERVICE. (W)

Part: PT7 TUBE — FRACTURED (NR 2 ENGINE)

NR 2 ENGINE EPR INDICATION APPEARS LOW DURING GROUND RUN-UP. INVESTIGATION FOUND PT7 TUBE ASSEMBLY WAS BROKEN ON B-NUT. REPLACED TUBE ASSEMBLY PER PRATT AND WHITNEY MM 78-22-00.

Part: VALVE — INOP (LT PACK)

FLIGHT RETURNED TO GATE, DUE TO RT AIR CONDITIONING PACK DEFERRED AND LT AIR CONDITIONING PACK OVERHEAT TRIPPED AND WOULD NOT RESET. REMOVED AND REPLACED WING ISOLATION VALVE DUE TO STUCK OPEN. OPS CHECK OK. (W)

Part: LUBE UNIT — FAILED (NR 2 ENGINE)

FLIGHT RETURNED TO GATE, DUE TO NR 2 ENGINE OIL PRESSURE AND TEMPERATURE NOT WITH IN LIMITS. REMOVED AND REPLACED NR 2 ENGINE LUBRICATION UNIT IAW MM 79-21-01. OPS CHECKED OK. (W)

Part: BREATHER — ICE BLOCKED (ENGINE OIL)

AIRCRAFT DEPARTED INL ON A MINUS 9 DEGREES FAHRENHEIT DAY. OIL BREATHER PLUGGED WITH ICE, FRONT OIL SEAL BLOW-OUT ALONG WITH ALL THE ENGINE OIL. AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING 'OFF FIELD' LANDING. AD 64-17-05 IS NOT APPLICABLE BECAUSE BREATHER HAS A 'NICKLE SLOT' CUT IN IT DURING MANUFACTURE, BUT SLOT WAS FILLED WITH ICE. SUBMITTER RECOMMENDS MOVING BREATHER LINE AND AIR/OIL SEPARATOR TO A WARMER PART OF THE ENGINE COWLING. IT IS CURRENTLY MOUNTED IN THE FRONT NOSE COWL WHICH PROVIDES NO PROTECTION FROM THE ELEMENTS.

Part: BREATHER — ICE BLOCKED (FRONT NOSE COWL)

AIRCRAFT DEPARTED INL ON A MINUS 9 DEGREE FAHRENHEIT DAY. OIL BREATHER PLUGGED WITH ICE, FRONT OIL SEAL BLEW OUT ALONG WITH ALL THE ENGINE OIL. AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING 'OFF-FIELD' LANDING. AD 64-17-05 IS NOT APPLICABLE BECAUSE BREATHER HAS A 'NICKLE SLOT' CUT IN IT DURING MANUFACTURE, BUT SLOT WAS FILLED WITH ICE. SUBMITTER RECOMMENDS MOVING BREATHER LINE AND AIR/OIL SEPARATOR TO A WARMER PART OF THE ENGINE COWLING. IT IS CURRENTLY MOUNTED IN THE FRONT NOSE COWL WHICH PROVIDES NO PROTECTION FROM THE ELEMENTS.

Part: EEL — INOP (CABIN)

THE FLOOR LEVEL EMERGENCY LIGHTS AND MID CABIN EXIT SIGNS INOP. FERRIED ACFT TO LGA FOR REPAIR. CREW REPORTS CONDITION NO LONGER EXITS. ACFT RETURNED TO SERVICE. (W)

Part: EEL BULB — FAILED (CABIN)

LAST AFT RED SECTION OF FLOOR PROXIMITY LIGHTING INOP. RELAMPED BURNED OUT BULB. OPS CHECK NORMAL. (W)