N37078

Part: GEAR HANDLE — BINDING (COCKPIT)

WHEN THE LANDING GEAR WAS EXTENDED ON APPROACH TO EWR, NO GREEN GEAR SAFE LIGHTS ILLUMINATED. THE GEAR WAS CYCLED THREE TIMES BEFORE RECEIVING GREEN DOWN AND LOCKED INDICATIONS. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE PERFORMED BITE ON PROX BOX AND ALL GEAR AND INTEGRITY TESTS PASSED. THE GEAR HANDLE ASSEMBLY WAS CLEANED AND LUBRICATED WITH NO OTHER DEFECTS NOTED.

Part: FRAME — CORRODED (CARGO DOOR)

CENTER CARGO BAY DOOR FRAME LOWER SECTION CORRODED. REPAIRED PER SRM 53-50-00.

Part: SKIN — CRACKED (LT LE SLAT)

NR 1 LEFT SLAT OUTER SKIN CRACKED. REPAIRED PER SRM 57-10-00, NR 6 LEADING EDGE RIB FOUND CRACKED. NEW RIBS FABRICATED PER DWG NRB6223 OP 3 AND ARB1583-405 OP 1.

Part: ANGLE — CRACKED (NR 2 ENGINE)

MAN - SUSPECT CRACK RIGHT DRAG ANGLE REPAIR PLATE AT LOWER END OF FIRST BANJO FITTING. AFTER NDT INSPECTION, CRACK CONFIRMED (1 INCH). CRACK STOP-DRILLED PER SRM 55-20-00, FIG 3. REPAIR PLATE REMOVED AND REPLACED PER SRM 55-20-00 FIG 3. (X)

Part: ANGLE — CRACKED (NR 2 ENGINE)

MAN - RIGHT HAND DRAG ANGLE AT LOWER END OF THIRD BANJO FITTING. SUBMITTER SUSPECTED CRACK. AFTER NDT, CRACK CONFIRMED (1 INCH). STOP-DRILLED CRACK PER SRM 55-20-00. REPAIR ANGLE MANUFACTURED, HEAT TREATED, AND FITTED PER SRM 55-20-00 FIG 3. (X)

Part: ANGLE — CRACKED (NR 2 ENGINE)

MAN - SUSPECT CRACK LT DRAG ANGLE AT LOWER END OF THIRD BANJO FITTING. AFTER NDT INSPECTION, CRACK CONFIRMED (1 INCH). CRACK STOP-DRILLED PER SRM 55-20-00. REPAIR PLATE MANUFACTURED, HEAT TREATED, AND FITTED PER SRM 55-20-00, FIG 3. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

THE EMERGENCY TRACK LIGHTING FAILED TEST. THE MID GALLEY BATTERY PACK WAS REMOVED AND REPLACED AND OPERATION CHECKED GOOD.

Part: ACTUATOR — DAMAGED (NLG)

A LOUD CLUNK WAS HEARD IN COCKPIT AREA ON GEAR RETRACTION, FOLLOWED BY UNSAFE NOSE GEAR INDICATION. FUEL WAS DUMPED AND THE AIRCRAFT WAS RETURNED TO LGW WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NOSE GEAR RETRACT ACTUATOR ROD END, GROUND SENSE CABLE SUPPORT AND MECHANISM BRACKET, AND NOSE GEAR RETRACTION LUG ON UPPER SECTION OF STRUT DAMAGED. ALL THE DAMAGED COMPONENTS WERE REMOVED AND REPLACED. THE NOSE GEAR STEERING WAS RIGGED IAW MM 32-50-00, PAGE 501-503. A GROUND SENSE RIG WAS COMPLIED WITH IAW MM 32-24-01. A GEAR SWING WAS PERFORMED AND OPERATION CHECKED GOOD.

Part: FUEL FILTER — CONTAMINATED (NR 3 ENGINE)

NR 3 ENG FLAMED OUT WHILE DESCENDING THRU FL 220 EN ROUTE. ENG FAILURE WAS ACCOMPANIED BY ILLUMINATION OF BOTH NR 3 GEN OFF LIGHT AND THE NR 3 ENG LOW OIL PRESS LIGHT. ENG WAS RESTARTED, A/C LANDED W/O INCIDENT. INSPECT FOUND THE NR 3 ENG FUEL FILTER AND NR 3 ENG FUEL PUMP DEBRIS SCREEN CONTAMINATED. FUEL TANKS WERE INSPECTED AND CLEANED. IN ADDITION, FUEL FILTERS AND SCREENS WERE R/R'D. A/C HAD COMPLETED A HEAVY MX CHECK AT VENDOR FACILITY ON 04/08/97. THE MX PROGRAM WAS ADJUSTED TO INCREASE THE FREQ OF FUEL FILTER INSPECTIONS.

Part: SPLICE — CORRODED (BS 1135-1137)

INSPECTION FOUND STRINGER SPLICE CORRODED AT STA 1135 TO 1137. THE SPLICE WAS REMOVED AND A NEW SPLICE WAS INSTALLED IAW SRM 51-31-01.

Part: SPLICE — CORRODED (BS 1120)

INSPECTION FOUND STRINGER 27R SPLICE CORRODED AT STA 1120. THE SPLICE WAS REMOVED AND REPLACED IAW SRM 51-33-01 AND 51-10-00.

Part: SPLICE — CRACKED (BS 1521-1541)

INSPECTION FOUND A .5 INCH CRACK IN STRINGER SPLICE BETWEEN STA 1521 AND 1541, STRINGER 1L. THE SPLICE WAS REMOVED AND REPLACED IAW SRM 51-31-01.

Part: ANGLE — CORRODED (BS 464)

INSPECTION FOUND T-ANGLE CORRODED AT STA 464, X= -4 INSIDE OF NLG WHEEL WELL FORWARD BULKHEAD. THE T-ANGLE WAS FABRICATED AND INSTALLED IAW SRM 53-40-00, 51-11-01, 51-31-01 AND 51-21-01.

Part: MOUNT — CRACKED (BS 1099)

INSPECTION FOUND A 3 INCH CRACK IN FILLET FAIRING MOUNT AT STA 1099, LONGERON 36. THE MOUNT WAS REMOVED AND REPLACED IAW SRM 51-31-01.

Part: SUPPORT — CRACKED (BS 1887)

INSPECTION FOUND FLOORBOARD SUPPORT CRACKED IN SIX PLACES AT STA 1887, X = 38-57. THE CRACKS WERE 1 OR LESS IN LENGTH. THE FLOOR SUPPORT WAS REMOVED AND A NEW FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-31-01 AND 51-21-01.

Part: SUPPORT — CORRODED (BS 497)

INSPECTION FOUND CORROSION ON FLOOR SUPPORT AROUND GALLEY FLOOR SPACER AT STA 497, X+22. THE FLOOR SUPPORT WAS REMOVED AND A NEW FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-21-01 AND 51-31-01. TWO EACH BOSSES WERE REMOVED AND REPLACED IAW SRM 51-31-01. THE DOME NUTS WERE REPLACED IAW SRM 51-31-01.

Part: PANEL — GOUGED (VERT STAB)

INSPECTION FOUND A GOUGE AT CORNER EDGE OF VERTICAL STABILIZER ACCESS PANEL NR 373EL. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 55-00-01, FIGURE 3 AND 51-21-01.

Part: PANEL — CRACKED (NR 1 PYLON)

INSPECTION FOUND A 1 INCH CRACK AT CUTOUT OF NR 1 ENGINE PYLON PANEL NR 437DR. THE CRACK WAS STOP DRILLED AND A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 54-00-01, FIGURE 1 AND 2.

Part: ANGLE — CRACKED (BS 1341)

INSPECTION FOUND A 1.5 INCH CRACK ON SUPPORT ANGLE UNDER BODY FILLET JUST ABOVE WING AT FS 1341R. THE CRACKED AREA WAS REMOVED AND A NEW PART WAS FABRICATED AND INSTALLED IAW SRM 51-31-01, 51-21-01 AND 53-53-01.

Part: LONGERON — CORRODED (BS 1119-1139)

INSPECTION FOUND LONGERON 4L CORRODED BETWEEN BS 1119 TO 1139. THE CORRODED SPLICE WAS REMOVED AND A NEW ONE WAS FABRICATED AND INSTALLED IAW SRM 53-10-00 FIGURE 3, 53-13-01 FIGURE 33 AND 51-21-01.

Part: SUPPORT — CORRODED (BS 1915/2004)

INSPECTION FOUND LAV TIE DOWN FLOOR SUPPORT CORRODED AT STA 1915 AND 2004, LBL X+55. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 53-70-00.

Part: SUPPORT — CRACKED (BS 1921)

INSPECTION FOUND A .20 INCH CRACK IN FLOORBOARD SUPPORT AT STA 1921, X + 1 TO 16. TWO CRACKS UP TO .30 INCH LONG WERE FOUND IN FLOORBOARD SUPPORT AT STA 1921, X - 1 TO 16. NEW FLOOR SUPPORTS WERE FABRICATED AND INSTALLED IAW SRM 51-21-01 AND 51-31-01.

Part: SUPPORT — CRACKED (BS 1986)

INSPECTION FOUND TWO CRACKS APPROXIMATELY .5 INCH LONG IN FLOORBOARD SUPPORT AT STA 1986, X + 1 TO 16. A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-21-01 AND 51-31-01.

Part: SUPPORT — CRACKED (BS 1943)

INSPECTION FOUND THREE CRACKS UP TO .30 INCH LONG IN FLOORBOARD SUPPORT AT STA 1943, X - 11 TO 16. A NEW FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-21-01 AND 51-31-01.

Part: SUPPORT — CRACKED (BS 1965)

INSPECTION FOUND TWO CRACKS UP TO .35 LONG IN FLOORBOARD SUPPORT AT STA 1965, X -1 TO 16. ALSO, TWO CRACKS UP TO .20 INCH LONG WERE FOUND IN FLOORBOARD SUPPORT AT STA 1965, X + 1 TO 16. NEW FLOOR SUPPORTS WERE FABRICATED AND INSTALLED IAW SRM 51-21-01 AND 51-31-01.

Part: SUPPORT — CRACKED (BS 1943)

INSPECTION FOUND A .35 INCH CRACK IN FLOORBOARD SUPPORT AT STA 1943, X-1 TO 16. A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-21-01 AND 51-31-01.

Part: SUPPORT — CORRODED (BS 2004)

INSPECTION FOUND CORROSION ON LAV TIE DOWN FLOOR SUPPORT AT STA 2004, X-55. THE FLOOR SUPPORT WAS REPAIRED IAW SRM 53-70-01, FIGURE 13.

Part: CASTING — CORRODED (BS 1321-1341)

INSPECTION FOUND STRINGER 24R CASTING CORRODED BETWEEN STA 1321 AND 1341. THE CASTING WAS REMOVED AND REPLACED IAW SRM 51-33-01.

Part: SUPPORT — CRACKED (BS 420)

INSPECTION FOUND FLOORBOARD SUPPORT CRACKED IN THREE PLACES AT STA 420, X-13 TO X-22. THE CRACKS WERE .125 INCH LONG. THE FLOOR SUPPORT WAS REMOVED, A NEW FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-31-01, 51-21-01 AND 51-35-01.

Part: BULKHEAD ANGLE — CRACKED (BS 1521)

INSPECTION FOUND A 1 INCH CRACK IN FLOOR SUPPORT L-ANGLE AT CENTER CARGO FORWARD BULKHEAD FS 1521, RBL 19. THE CRACK WAS STOP DRILLED, AN L-ANGLE AND DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 53-00-01, FIGURE 2 AND 51-31-01.

Part: SKIN — RIPPLED (NR 1 LE SLAT)

INSPECTION FOUND RIPPLING ONE FOOT IN DIAMETER IN RT WING NR 1 SLAT AT INBOARD END. THE RIPPLED AREA WAS CUT OUT, A SKIN INSERT, SPLICE STRAPS, DOUBLERS AND FILLERS WERE FABRICATED AND INSTALLED IAW SRM 51-10-00, FIGURE 43 AND 51-31-01.

Part: SKIN — DENTED (NR 3 SLAT)

INSPECTION FOUND A 5 INCH DIAMETER BY 0.060 DEEP DENT IN OUTBOARD RT WING NR 3 SLAT. A SKIN AND DOUBLER REPAIR WAS INSTALLED IAW SRM 57-10-00, FIGURE 11.

Part: WING TIP — CREASED (WS 988)

INSPECTION FOUND A 3L BY .5W BY 0.080D CREASE IN RT WING TIP AT XW 988, BETWEEN TIP LEADING EDGE AND TRAILING EDGE. A FILLER AND DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW SRM 57-00-01, FIGURE 4 AND SRM 57-31-01 FIGURE 3.

Part: PANEL — DENTED (RT WING)

INSPECTION FOUND FOUR DENTS ON UPPER SURFACE OF RT WING TRAILING EDGE PANEL 641HB. A DOUBLER AND FOUR FILLERS WERE FABRICATED AND INSTALLED IAW SRM 51-71-00, FIGURE 33.

Part: SUPPORT — CORRODED (BS 879/899)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 879 AND 899, Y= -44. CHANNEL FLOOR SUPPORT ANGLES AND BOSSES WERE FABRICATED AND INSTALLED IAW SRM 51-31-01, 51-21-01 AND 53-70-00.

Part: ANGLE — CORRODED (ADF ANTENNA)

INSPECTION FOUND L-ANGLE CORRODED AT FORWARD ADF LOOP ANTENNA. AN L-ANGLE WAS FABRICATED AND INSTALLED WITH NUT PLATES IAW SRM 53-00-01, FIGURE 2, SHEET 2, 51-11-01, 51-31-01, 51-21-01 AND 51-30-00.

Part: FRAME — CORRODED (BS 1781)

INSPECTION FOUND FORWARD SIDE OF FRAME CORRODED IN AFT CARGO BILGE AREA AT STA 1781 FROM LONGERON 50L TO 50R. THE CORRODED SECTION WAS CUT OUT, AN L-ANGLE DOUBLER AND FILLER WERE FABRICATED AND INSTALLED IAW SRM 53-30-00, FIGURE 8, 51-21-01 AND 53-30-01 FIGURE 8.