N322AA

Part: CONTROL UNIT — FAULTY (ELECTRICAL SYS) · airframe 100,088 hrs · 19,183 cycles

JFK - CREW REPORTED DURING CLIMB, BOTH UTILITY BUSES DROPPED OFF LINE AND COULD NOT BE RE-INSTATED. EMERGENCY DECLARED FLIGHT RETURNED JFK LANDED WITHOUT INCIDENT. AFTER LANDING, BOTH UTILITY BUSES CAME BACK ON LINE WITHOUT THE CREW DOING ANYTHING. AIRCRAFT REMOVED FROM SERVICE. REPLACED BUSS CONTROL UNIT. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: HYDRAULIC LINE — LEAKING (HYDRAULIC SYS) · airframe 98,034 hrs · 18,767 cycles

ORD - INFLIGHT LAX-JFK. CREW REPORTED RAPID FLUID LOSS IN CENTER HYDRAULIC SYSTEM. FLIGHT DIVERTED ORD LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED HYDRAULIC LINE FOR TILT ACTUATOR. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: PRESSURE SWITCH — INOPERATIVE (HYDRAULIC SYS) · airframe 97,347 hrs · 18,628 cycles

JFK - CREW REPORTED CENTER HYDRAULIC SYSTEM LOW PRESSURE LIGHT CAME ON IN FLIGHT. NO OTHER INDICATIONS OR FAILURES NOTED. EMERGENCY DECLARED FLIGHT RETURNED JFK LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED S-35 CENTER LOW PRESSURE SWITCH. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: SPAR — CRACKED (LT PYLON) · airframe 97,339 hrs · 18,624 cycles

FOUND 2 CRACKS IN HTE LEFT PYLON STRUT FORWARD UPPER SPAR WEB AROUND THE POWER FEEDER CABLE CUTOUT. ACCOMPLISHED DOUBLER REPAIR PER BOEING SB 767-54-0090 REV 2 DATED JAN 28, 2010 AND MAJOR EA B767-54-018300.

Part: SKIN PANEL — DELAMINATED (HORIZ STAB) · airframe 97,339 hrs · 18,624 cycles

LEFT HORIZONTAL FORWARD TORQUE BOX UPPER SKIN PANEL AT AUXILIARY SPAR STATION 240 DELAMINATED. CUT OUT WAS 20.5 INCHES BY 20.25 INCHES. REPAIRED WITH METAL TRIPLER PER MAJOR EA B767-55-017991.

Part: FAN — MALFUNCTIONED (CABIN) · airframe 92,695 hrs · 17,679 cycles

JFK - CREW REPORTED LEFT RECIRCULATING FAN MESSAGE ON EICAS WITH SMOKE AND FUMES IN CABIN. EMERGENCY DECLARED LANDED JFK WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED LEFT RECIRCULATION FAN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SKIN — BULGED (FUSELAGE) · corrosion level 2 · airframe 92,115 hrs · 17,557 cycles

DURING THE CURRENT LIGHT C CHECK AAL MAINTENANCE FOUND A SLIGHT BULGE TO THE FUSELAGE SKIN AT THE LAP JOINT COMMON TO STR 37L JUST FORWARD OF STA 434. THE LAP JOINT IN THIS AREA WAS OPENED AND SEPARATED TO GAIN ACCESS TO REMOVE THE CORROSION. CORROSION WAS SUBSEQUENTLY FOUND TO BE LIMITED TO THE UNDERLYING SKIN 141T3231-3 OUTER FACING SURFACE. AFTER REWORK THE DAMAGE WAS FOUND TO EXCEED LIMITS 10 PERCENT AND WAS SUBSEQUENTLY TRIMMED OUT MEASURING 7.4€?X2.8€? AND FITTED WITH AN EXTERNAL LAP JOINT DOUBLER. EA B767-53-008735.

Part: BEAM — CORRODED (CARGO DOOR) · corrosion level 2 · airframe 92,115 hrs · 17,557 cycles

CORROSION WAS FOUND ON THE AFT CARGO DOOR NUMBER 4 BEAM INNER CHORD AT APPROXIMATELY DOOR STATION 170. THE CORROSION IS LOCATION ON THE INNER SURFACE OF THE UPPER HORIZONTAL FLANGE COMMON TO THE FACTORY NUT PLATE. REMOVED CORROSION AND PERFORMED HIGH FREQUENCY EDDY CURRENT INSPECTION WITH NO FINDINGS. ENGINEERING AUTHORIZATION COMP-52-008732.

Part: MODULE — INOPERATIVE (CABIN) · airframe 91,819 hrs · 17,496 cycles

EMERGENCY AISLE LIGHTS IN COACH CABIN INOPERATIVE. REPLACED MODULE M9029.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHTS)

LAX - EXTERIOR EMERGENCY LIGHT AT LEFT NUMBER FOUR DOOR INOPERATIVE. REPLACED BATTERY PACK AT LEFT NUMBER FOUR DOOR. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHTS) · airframe 88,326 hrs

LAX - EXTERIOR EMERGENCY LIGHT AT LEFT NUMBER FOUR DOOR INOPERATIVE. REPLACED BATTERY PACK AT LEFT NUMBER FOUR DOOR. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: CONNECTOR — LOOSE (EMERGENCY LIGHT)

JFK EMERGENCY LIGHT AT SEAT 11H INOPERATIVE. SECURED CONNECTOR FOR EMERGENCY LIGHT AT SEAT 11H. SYSTEM GROUND CHECKED NORMAL OPS.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · 87,421 cycles

JFK EMERGENCY LIGHT EXIT SIGN AT OVERHEAD SEAT 20H INOPERATIVE. REPLACED BATTERY PACK M732 FOR EMERGENCY LIGHT EXIT SIGN AT OVERHEAD SEAT 20H. SYSTEM GROUND CHECKED NORMAL OPS.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 85,649 hrs

LAX - EMERGENCY EXIT SIGN LIGHTS AT LEFT AND RIGHT OVERWING INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY EXIT SIGN LIGHTS AT LEFT AND RIGHT OVERWING. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (CABIN)

LAX - EMERGENCY LIGHT AT SEAT 31AB INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS AT SEAT 31AB. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

LAX - SEAT MOUNTED EMERGENCY LIGHTS AT LEFT CABIN INOPERATIVE. REPLACED BATTERY PACK FOR SEAT MOUNTED EMERGENCY LIGHTS AT LEFT CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: MODULE — INOPERATIVE (CABIN)

SFO - EMERGENCY SEAT LIGHTS AT ROWS 20 TO 30AB INOPERATIVE. REPLACED MODULE FOR EMERGENCY SEAT LIGHTS AT ROWS 20 TO 30AB. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LIGHT — INOPERATIVE (CABIN)

JFK - RIGHT FORWARD OVERWING EMERGENCY EXIT LIGHT INOPERATIVE. SECURED WIRING ON LIGHT ASSEMBLY FOR RIGHT FORWARD OVERWING EMERGENCY EXIT LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LIGHT — INOPERATIVE (CABIN)

JFK - EMERGENCY LIGHT AT MID GALLEY RIGHT IS BROKEN. REPLACED EMERGENCY LIGHT ASSEMBLY FOR EMERGENCY LIGHT AT MID GALLEY RIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: KEELBEAM — CORRODED (BS 790)

AFW - RIGHT HAND KEEL BEAM OUTBOARD FLANGE AT STATION 790 HAD FLANGE REMOVED DUE TO CORROSION. A 3.6 INCH BY 1 INCH SECTION OF KEEL BEAM CHORD FLANGE WAS REMOVED AT APPROXIMATELY STATION 790. PERFORMED OPEN HOLE HIGH FREQUENCY EDDY CURRENT INSPECTION ON ALL REMOVED FASTENER HOLES. PERFORMED EDDY CURRENT INSPECTION ON EDGES AND BLENDS TO VERIFY CORROSION COMPLETELY REMOVED. ROTOPEEN EDGES AND BLENDS IN AREA OF THE CUTOUT. FABRICATED A REPAIR ANGLE FROM 7075 T6511 EXTRUSION. FABRICATED FILLER FROM 7075 T6 AND INSTALLED ANGLE AND FILLED WET WITH SEALANT AND FASTENED WITH BACB30MY6. HI-LOKS AND FASTENERS INSTALLED WET MAINTAINING 1.7 DIAMETER EDGE DISTANCE. APPLIED CORROSION INHIBITING COMPOUND.

Part: SKIN — DAMAGED (LT PYLON)

AFW - LT PYLON INBOARD SIDE STRUT SKIN HAS GOUGE WHICH WAS REWORKED BEYOND LIMIT. DAMAGE WAS INDUCED BY INTERFERENCE FROM THE UPPER FIRE SEAL BRACKET. BLENDED DAMAGE AT SINGLE FASTENER LOCATION. PERFORMED HIGH FREQUENCY EDDY CURRENT INPSECTION. INSTALLED NEW FASTENER AND REMOVED THE SOURCE OF WEAR BY TRIMMING BRACKETS. RESTORED FIRE SHIELD.

Part: O-RING — LEAKING (HYD SYSTEM)

CENTER HYDRAULIC QUANTITY LOSS INDICATION. AIRCRAFT DIVERTED AND LANDED ORD WITHOUT INCIDENT. REPLACED O-RING ON HEX NUT FOR FILTER SCREEN ON NR 10 SPOILER. SERVICED HYDRAULIC SYSTEM. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONNECTOR — INOPERATIVE (CABIN)

DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT SEAT LIGHT AT 20AB INOPERATIVE. REPAIRED EMERGENCY EXIT LIGHT WIRE CONNECTOR SEAT 20AB. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: GENERATOR — FAILED (CENTER SYSTEM)

MIA - FLT 789 - REPLACED CENTER SYSTEM GENERATOR AND OPS CHECK OR BUT 5 MINUTES LATER IT FAILED SHOWING FAIL CODE 200. REMOVED AND REPLACED CENTER SG, OPS CHECKED NORMAL FOR SHTS, IAW MM ALL TESTS NORMAL. (M)

Part: IDG — FAILED (RIGHT ENGINE)

EICAS GEN DRIVE LIGHT AND ASSOCIATED RIGHT GEN CONTROL LIGHT ILLUMINATED WHILE CLIMBING TO FLIGHT LEVEL 370 GENERATOR DRIVE DISCONNECTED PER OP MANUAL. REMOVED AND REPLACED RIGHT IDG. NEEDS LEAK AND OPS CHECK AND DISCONNECT CHECK. OPS CHECK AND LEAK CHECK OK. (M)

Part: LIGHT — INOPERATIVE (CABIN)

SFO - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT FLOOR LIGHT AFT OF MID GALLEY ON RIGHT SIDE INOPERATIVE. REPLACED LIGHT ASSEMBLY. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONNECTOR — FAILED (CABIN)

SFO - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHT AT SEAT 25 A/B INOPERATIVE. REPAIRED EMERGENCY EXIT LIGHT CONNECTOR AT 25 A/B. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: SOCKET — INOPERATIVE (CABIN)

BOS - DURING OVERNIGHT MAINTENANCE, SEAT MOUNTED EMERGENCY EXIT LIGHT AT 23H INOPERATIVE. REPLACED EMERGENCY EXIT LIGHT SOCKET AT SEAT 23H. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONNECTOR — DISCONNECTED (CABIN)

SFO - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHT AT SEAT 21H INOPERATIVE. RE-CONNECTED EMERGENCY EXIT LIGHT CONNECTOR AT SEAT 31H. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONNECTOR — LOOSE (CABIN)

SFO - FOUND DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT ESCAPE PATH LIGHT AT SEAT 23H INOPERTIVE. RECONNECTED CONNECTOR AT SEAT 23H. SYSTEM GROUND CHECK NORMAL OPERATION. (M)

Part: LIGHT — INOPERATIVE (L2 DOOR)

SFO - DURING OVERNIGHT MAINTENANCE, L2 LOWER EMERGENCY EXIT SIGN LIGHT INOPERATIVE. REPLACED 1.2 LOWER EMERGENCY EXIT SIGN LIGHT. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: LIGHT — MALFUNCTIONED (CABIN)

MIA - FLT 2198 - EN ROUTE MEX-MIA - CABIN EMERGENCY LIGHTS ILLUMINATED FOR ONE MINUTE THEN EXTINGUISHED. ALL SWITCHES WERE IN NORMAL (ARMED) POSITION. FLIGHT CONTINUED AND LANDED MIA WITHOUT INCIDENT. INSPECTED EMERGENCY LIGHTING SYSTEM COULD NOT DUPLICATE FAULT. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — BROKEN (L1 DOOR)

SFO - FLT 0041 - DURING MAINTENANCE, EMERGENCY EXIT SIGN AT L1 DOOR FOUND INOPERATIVE. REPAIRED EMERGENCY EXIT SIGN BROKEN WIRE AT L1 FLIGHT ATTANDANT SEAT. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: IDG — FAILED (NR 1 ENGINE)

JFK - FLT 1786 - LEFT GENERATOR FAILED AFTER DESCENT FOR APPROACH. LEFT GENERATOR DRIVE LIGHT ILLUMINATED. DISCONNECTED LEFT GENERATOR IAW PROCEDURE. STATUS - L IDG OIL TEMP. REMOVED AND REPLACED NR 1 ENGINE IDG PER MM. ACCOMPLISHED RUN-UP AND LEAK CHECK. ACCOMPLISHED DISCONNECT. ALL CHECKS OK. NO MESSAGE FOUND. 32224FBB1/0350.02JAN.JFK. (X)

Part: CONNECTOR — LOOSE (CABIN)

SFO - DURING OVERNIGHT CHECK, EMERGENCY EXIT LIGHT AT PAX SEAT 22B INOPERATIVE. RESECURED LOOSE EMERGENCY EXIT LIGHT CONNECTOR AT PAX SEAT 22B. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONNECTOR — LOOSE (CABIN)

SFO - DURING OVERNIGHT CHECK, EMERGENCY EXIT LIGHT AT PAX SEAT 24H INOPERATIVE. RESECURED LOOSE EMERGENCY EXIT LIGHT CONNECTOR AT PAX SEAT 24H. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: BOARD — DEFECTIVE (LT MLG)

BOS - FLT 147 - DURING APPROACH TO BOS WHEN LANDING GEAR EXTENDED, LEFT MAIN LANDING GEAR GREEN LIGHT DID NOT ILLUMINATE WITH EICAS AND ALL OTHER INDICATIONS NORMAL. ACCOMPLISHED TOWER FLY-BY AND CONFIRMED ALL LANDING GEAR EXTENDED. AIRCRAFT LANDED BOS WITHOUT INCIDENT. REPLACED INTEGRATED CIRCUIT MODULE BOARD FOR LEFT MAIN LANDING GEAR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: MODULE — DEFECTIVE (CABIN)

SFO - DURING OVERNIGHT CHECK, FOUND THAT THE EMERGENCY LIGHTS AT SEATS 10H AND 11J STAY ON WHEN SWITCH IS IN OFF POSITION. REPLACED EMERGENCY LIGHTS MODULE AND BATTERY. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: FLOOR BEAM — GOUGED (BS 814-955)

AFW - FOUND AND BLENDED OUT GOUGES ON THE UPPER SURFACE OF THE MAIN CABIN FLOORBEAM. THE BLEND-OUT EXCEEDS SRM LIMITS. ROTO-PEENED, DYE CHECKED, ALODINED, PRIMED, AND PAINTED DAMAGED AREAS. APPROVED FOR CONTINUED SERVICE BY ENGINEERING PER SRB 767-1142. TST: 41,252.20 HRS. CYCLES, 7,600. (X)

Part: SKIN — CORRODED (WS 955)

AFW - CENTER WING UPPER SKIN PREVIOUSLY BLENDED. LIGHT CORROSION AGAIN. BLEND-OUT WAS PREVIOUSLY BEYOND SRM LIMITS AND ADDRESSED ON MRB 767-424. SHOT-PEENED BLEND OUT PER SRM. TREATED, PRIMED, AND APPLIED FUEL BARRIER COMPOUND SEALED WITH BM55-95. APPLIED DINOLTROL. APPROVED FOR CONTINUED SERVICE BY ENGINEERING PER MRB 767-1140. TST: 41,252.20 HRS. CYCLES, 7,600. (X)

Part: CHORD — CORRODED (BS 539.5)

AFW - BLENDED OUT CORROSION ON THE INNER SURFACE OF THE FAIL-SAFE CHORD. BLENDED OUT IS BEYOND SRM LIMITS. INSTALLED NEW FASTENERS, ROTO-PEENED, ALODINED, AND PRIMED. APPROVED FOR CONTINUED SERVICE WITH NOTED CONDITION BY ENGINEERING PER MRB 767-1151. TST: 41,252.20 HRS. CYCLES, 7,600. (X)

Part: TRUNNION TAB — CORRODED (RT MLG)

AFW - DURING REINSTALLATION OF THE RT MLG AFTER REWORK OF THE AFT TRUNNION, REMOVED THE FWD TRUNNION HOUSING DUE TO LOOSENESS. AFTER REMOVAL, FOUND AND BLENDED CORROSION ON THE INNER SURFACE OF THE 3 O'CLOCK POSITION TAB. AFTER BLENDED, APPLIED PRIMER AND REINSTALLED HOUSING WITHOUT SHOT-PEENING OR CAD PLATING THE BLENDED AREA. APROVED BY ENGINEERING WITH NOTED CONDITION UNTIL NEXT SCHEDULED LANDING GEAR OVERHAUL PER MRB 767-1159. TST: 41,252.20 HRS. CYCLES, 7,600. (X)

Part: TRUNNION — CORRODED (RT MLG)

AFW - DURING REINSTALLATION OF THE RT MLG AFTER REWORK AT THE AFT TRUNNION, REMOVED THE FWD TRUNNION HOUSING DUE TO LOOSENESS. AFTER REMOVAL, FOUND AND BLENDED OUT CORROSION IN THE CHAMFER ON THE THRUST FACE IN QUADRANT 2. APPLIED PRIMER AND REINSTALLED HOUSING WITHOUT SHOT-PEENING OR CAD PLATING THE BLENDED AREA. APPROVED FOR CONTINUED SERVICE BY ENGINEERING WITH NOTED CONDITION UNTIL NEXT SCHEDULED LANDING GEAR OVERHAUL PER MRB 767-1156. TST: 41,252.20 HRS. CYCLES, 7,600. (X)

Part: SHEAR TIE — CORRODED (BS 1562)

AFW - FOUND AND BLENDED OUT CORROSION ON THE AFT SIDE OF THE SHEAR-TIE. FOUND BLEND-OUT EXCEEDS SRM LIMITS. ALODINED AND PRIMED AREA. REPLACED FASTENERS. APPROVED FOR CONTINUED SERVICE BY ENGINEERING PER MRB 767-1152. TST: 41,252.20 HRS. CYCLES, 7,600. (X)

Part: SKIN — DAMAGED (RT HORIZ STAB)

AFW - DAMAGE ON THE LOWER SURFACE AT FS 127 WAS REPAIRED PER SMM/AFW 1371 AND ESO 9196 13DEC95. APPROVED FOR CONTINUED SERVICE WITH NOTED CONDITION BY ENGINEERING PER MRB 767-1138. TST: 41,252.20 HRS. CYCLES, 7,600. (X)

Part: SKIN — CORRODED (WS 955)

AFW - AREA PREVIOUSLY BLENDED. LIGHT CORROSION FOUND AGAIN IN THIS LOCATION. BLENDED, FLAP PEENED, REFINISHED AND FILLED WITH BM55-55 PER ENGINEERING MRB 767-1140. TST: 41,252.20 HRS. CYCLES, 7,600. (X)

Part: EEL CONNECTOR — DEFECTIVE (CABIN)

SFO - DURING OVERNIGHT CHECK, FOUND EMERGENCY EXIT FLOOR PATH LIGHTS AT SEAT 35H AND INOPERATIVE. REPLACED PINS ON SEAT CONNECTOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)