N371CM

Part: ESCAPE ROPE — UNSECURE (ZONE 200) · airframe 91,836 hrs · 31,907 cycles

CAPTAIN'S ESCAPE ROPE WILL NOT STAY STOWED. STOWED CAPTAINS ESCAPE ROPE IAW B767 AMM 25-61-02.

Part: WARNING LIGHT — ILLUMINATED (ZONE 800) · airframe 91,648 hrs · 31,827 cycles

MAIN CARGO DOOR LIGHT ILLUMINATED DURING CLIMB. ACFT AIR TURN BACK TO CVG. (ATB) DEFERRED SYSTEM IAW MEL C ABX-52-71-1-2. AIRCRAFT RETURNED TO SERVICE.

Part: ACTUATOR — FAULTED (ZONE 500 SLAT) · airframe 91,644 hrs · 31,825 cycles

DURING APPROACH, LE SLAT ASSYM. EICAS MSG ILLUMINATED, ABORTED APPROACH. (AAP). A/C IS CURRENTLY IN WORK. WILL SEND AN UPDATED SDR REPORT WHEN WORK IS COMPLETE. AMENDED: FOUND #4 SLAT ASKEW, REMOVED AND REPLACED #4 OUTBD SLAT ROTART ACTUATOR AND OFFSET GEARBOX IAW AMM 27-81-20, REMOVED AND REPLACED #3 AND 4 TAI DUCTS AND INTERSTITIAL DUCT SECTIONS BETWEEN SLAT #3-4 AND SLATS #4-5 IAW AMM 30-11-06. OPERATED SLATS MANUALLY, ELECTRICALLY AND HYDRAULICALLY, REF AMM 27-81-00. OPS CHECKS GOOD, NO ASSYMETRY OBSERVED OR FAULT LIGHTS AND MESSAGES. AIRCRAFT RETURNED TO SERVICE.

Part: WARNING MESSAGE — ILLUMINATED (CABIN TEMP) · airframe 91,561 hrs · 31,787 cycles

ON ENGINE START, FWD CABIN TEMP EICAS MSG ACCOMPLISHED. AIRCRAFT RETURNED TO BLOCKS (BTB). MAINTENANCE DEFERRED FWD CABIN CONTROL SYSTEM PER MEL 21-61-1-2 PLACARDS INSTALLED. A/C REMAINS NO ETOPS. MBCB 9-27-25. AIRCRAFT RETURNED TO SERVICE.

Part: PITOT HEAD — MALFUNCTIONED (ZONE 200) · airframe 91,372 hrs · 31,667 cycles

CAPTAIN PITOT EICAS MSG AFTER ENGINE START, A/C RETURNED TO GATE (BTB) AND MTX GROUNDED A/C .T/S AS PER WDM 30-31-11, FOUND CAPT PITOT PROBE SHORTED.], AND PROBE CB HT POPPING OUT DURING TEST. REMOVED /REPLACED CAPT. PITOT PROBE. OPS OK PER AMM 30-31-00. PERFORMED LOW AND HIGH RANGE LEAK TEST OPS OK PER AMM 34-11-00. AIRCRAFT REMAIN ETOPS 180/ AIRCRAFT REMAN RVSM.AND RETURNED A/C TO SERVICE .

Part: BRAKE — OVERTEMP (ZONE 700) · airframe 91,332 hrs · 31,646 cycles

UPON LANDING AFTER TURNING OFF OF RUNWAY ANOTHER PLANE REPORTED SMOKING RIGHT BRAKE. RIGHT BRAKE TEMP VALUES WERE 2-2 ON TOP AND 3-3 ON BOTTOM. CFR FOLLOWED PLANE INTO PARKING AND SMOKE QUICKLY DISSIPATED AND STOPPED ALTOGETHER. NORMAL TAXI IN. BRAKE PEDALS FELT NORMAL WITH NO SQUISHINESS. BRAKES 2 UNSED FOR LANDING. PERFORMED GVI OF ALL AIRCRAFT BRAKE ASSEMBLIES AS PER AMM 32-41-08. INSPECTED LANDING GEAR BAYS AND LANDING GEAR ASSEMBLIES FOR LEAKAGE, PERFORMED TEMPERATURE SCAN OF BRAKE ASSEMBLIES. ALL FOUND TO BE BETWEEN 160 F AND 188 F. PERFORMED TEST OF BRAKE TEMP MONITOR AS PER AMM 32-46-00. NO LEAKS FOUND. ALL TEMPERATURES INDICATED ARE WITHIN NORMAL LIMITS. ALL ITEMS CHECKED GOOD AS PER AMM REFERENCES. AIRCRAFT RELEASED NO ETOPS CAT 1.

Part: ROD BEARING — BROKEN (ZONE 700) · airframe 91,324 hrs · 31,643 cycles

DURIING LUBE, MAINTENANCE IN LAX (LOS ANGELES, CA), FOUND THE RH MLG RETRACT ACTUATOR ROD END BEARING BROKEN. ABX AIR MAINTENACE CONTROL CONTACTED AMES EMGINEERING FOR ANALYSIS AND DISPOSITION FOR A GEAR DOWN FERRY FLIGHT TO CVG, PER ABX-REA-3200-65748-02. AFTER FERRY FLIGHT A/C WAS GROUNDED. CURRENTLY IN WORK FOUND RT MLG FWD LUG WHERE RETRACT ACTUATOR ATTACHES WAS DAMAGED. AN AMENDED SDR WILL BE SENT WHEN WORK IS COMPLETED.

Part: ACTUATOR — BROKEN (ZONE 700) · airframe 91,324 hrs · 31,643 cycles

DURING LUBE, MAINTENANCE IN LAX, FOUND RT MLG RETRACT ACTUATOR ROD END BEARING BROKEN. AFTER FERRY FLIGHT A/C WAS GROUNDED. CURRENTLY IN WORK FOUND RT MLG FWD LUG WHERE RETRACT ACTUATOR ATTACHES WAS DAMAGED. PREVIOUS DESCRIPTION INDICATED GEAR DOWN FERRY FLIGHT. THIS SHOULD HAVE STATED GEAR DOWN NON-REV REPOSITION FLIGHT TO CVG. AMENDED: OPENED WO# 14446227, REMOVED & REPLACED R MLG RETRACT ACTUATOR IAW AMM 32-32-01. AND REMOVED & REPLACED RT MAIN LANDING GEAR DUE TO LUG DAMAGE IN WO # 14499551 IAW J/C ABX-32-045-01-02-M. ALL NON-ROUTINES C/W. ACFT NOT RETURNED TO SERVICE, UNSERVICABLE GEAR INSTALLED. GEAR WAS REPAIRED AND REINSTALLED. ACFT RETURNED TO SERVICE.

Part: EICAS — INOPERATIVE (ZONE 200) · airframe 91,318 hrs · 31,639 cycles

DURING TAXI LOWER EICAS UBIT WAS INOPERATIVE. A/C RETURNED TO THE GATE (BTB) AND MTX GROUNDED A/C . MTX DEFERRED EICAS FOR DEPARTURE AIAW MEL ABX 31-41-1-1. AND RETURNED A/C TO SERVICE .

Part: WARNING MESSAGE — ILLUMINATED (CARGO DOOR) · airframe 91,007 hrs · 31,527 cycles

CARGO DOOR INDICATION, PRESSURIZATION NORMAL, LIGHT WENT OUT AFTER FLIGHT DESCENDED BELOW FL240. FLIGHT DIVERT TO KATL WHILE AT FL180,A/C LANDED SAFELY AND MTX GROUNDED A/C THEN DEFERRED MAIN CARGO DOOR INDICATION IAW MEL ABX-52-71-1-2 AND RETURNED AC TO SERVICE.

Part: VALVE — LEAKING (ZONE 700) · airframe 90,834 hrs · 31,454 cycles

DURING TAXI OUT ON THE GROUND PRIOR TO DEPARTURE WITH BRAKES SET RT HYD QTY EICAS MESSAGE WITH QTY READING 0.0. AC RETURNED TO GATE(BTB) AND MTX GROUNDED AC. MTX FOUND R BRAKE METERING VALVE LEAKING AT BODY. REMOVED AND REPLACED R METERING VALVE PER AMM 32-41-02, SERVICED R HYD SYSTEM PER AMM 12-12-01, OPS AND LEAK CHK -OK PER AMM 32-41-00. AIRCRAFT REMAINS ETOPS 180. AND RETURNED AC TO SERVICE.

Part: WARNING MESSAGE — FALSE ACTIVATION (LT BLEED) · airframe 90,770 hrs · 31,428 cycles

DURING TAXI UPON COMPETITION OF ENGINE START WE RECEIVED AN EICAS L ENG BLEED OFF ,AC REURNED TO THE GATE (BTB) AND MTX GROUNDED AC , EXERCISED PRSOV VALVE (L/H) CYCLED CARD LH ENG BLEED AIR, OPERATIONAL TEST GOOD IAW AMM 36-11-00. RAN LH ENGINE NO FAULTS NOTED OPS CHECK GOOD IAW AMM 71-00-00 A/C REMAINS NO ETOPS AND RETURNED AC TO SERVICE

Part: ISOLATION VALVE — DAMAGED (STARTER) · airframe 90,714 hrs · 31,408 cycles

DURING TAXI , R ENG STARTER CAUTION MSG ON ENG START , AC RETURNED TO GATE(BTB) AND MTX GROUNDED AC . TROUBLE SHOT AND REPLACED R/H ISOL CHECK VALVE IAW AMM 36-11-05 DUE TO BROKEN SPRING OPS CHECKS GOOD A/C REMAINS NO ETOPS MTX REPERUNED AC TO SERVICE.

Part: APU — FAULTED (ZONE 100) · airframe 90,659 hrs · 31,384 cycles

AFTER DE-ICE APU WOULD NOT PRODUCE ENOUGH AIR FOR START AC RETURNED TO GATE (BTB) AND MTX GROUNDED AC . AND DEFERRED APU IAW MEL ABX-49-11-1A AC REMAINS NO ETOPS . AC WAS RETURNED TO SERVICE .

Part: WARNING MESSAGE — FALSE INDICATION (CABIN PRESSURE) · airframe 90,160 hrs · 31,156 cycles

DURING TAXI CABIN AUTO INOP EICAS MSG DISPLAYED AND A/C RETURNED TO GATE AND MTX GROUNDED A/C MTX PERFORMED RESET OF THE CABIN PRESSURE 1 AND CABIN PRESSURE 2 CONTROLLERS IAW B767 FIM 21-31 FAULT TREE #803 . FAULTS CLEARED AND DID NOT RETURN. A/C REMAINS NO ETOPS. MTX RETURED A/C TO SERVICE.

Part: WARNING MESSAGE — FALSE ACTIVATION (CARGO DOOR) · airframe 90,051 hrs · 31,104 cycles

DURING TAXI WHILE AFTER STARTING L ENG MASTER WARN AND MAIN CARGO DOOR WARNING LIGHT CAME ON AC RETURNED TO GATE AND MTX GROUNDED AC . MTX PERFORMED MAIN DECK CARGO DOOR SYSTEM TEST PERFORMED REF AMM 52-32-00 AND SAMM 52-71-09 OP CHECK GOOD. MTX RETURNED AC TO SERVICE AND DEPARTED

Part: WIRE — BROKEN (FLAP/SLAT SYSTEM) · airframe 89,812 hrs · 30,993 cycles

LE FLAP SLAT DISAGREE AFTER START CHECKLIST. AC RETURNED TO BLOCK AND MAINTENANCE GROUNDED AC T/S IAW WDM 27-81-11, REPLACED RELAY K624 NO HELP. FOUND THE INBD SLAT BYPASS VALVE IN POS 1 NO POWER FOUND ON PIN 2 CONN D1515 FOUND OPEN. CK FROM CONN D5316P PIN 42 TO D5712J PIN 1. FOUND BROKEN WIRE AT STA 700 BRACKET R/M CEILING, SPLICE IT RE-DO BOTH ENDS TERMINATIONS AT CONN D5316P AND D5712J PIN 42 & PIN 1 IAW SWPM 20-10-13 AND 20-60-00 .PERFORMED LE FLAPS OPS CK FOUND NORMAL FROM ALT TO NORMAL LEVER MOVES TO CORRECT POS AT THE BYPASS VALVE R/H SIDE AMM 27-81-00 AC RETURNED TO SERVICE.

Part: SHUTOFF VALVE — MALFUNCTIONED (RT ENGINE) · airframe 89,767 hrs · 30,972 cycles

R HPSOV VALVE MESSAGE APPEARED IN CRUISE CREW DIVERTED FROM SJO TO MIA. DESTINATION WAS CVG. MAINTENANCE GROUNDED AC AND DEFERRED RH HPSOV AND LOCK OUT IAW MEL 36-11-2 .AND RETURNED AC TO SERVICE TO CONTINUE TO FLY TO CVG . WHERE THEY REPLACED THE PRSOV AND CLEARED THE DEFERRAL.

Part: MODULE — MALFUNCTIONED (RUDDER) · airframe 89,761 hrs · 30,969 cycles

RUDDER RATIO EICAS MSG & DISCRETE LIGHT CAME ON TAXI OUT AC RETURNED TO GATE AND MAINTENANCE GROUNDED AC . MAINTENANCE DEFERRED RUDDER RATIO SYSTEM . IAW ABX-MEL -27-21-1. AND REMOVED/REPLACED CSEU M538 1 RIGHT, PERFORMED RUDDER RATIO OPS OK PER AMM 27-21-00. DI 51456 CONTINUE OPEN PART EFF VERIFIED. NEXT NEXT LEG ACCOMPLISHED RUDDER RATIO BITE IAW FIM 27-09. FT 814. MODULE FAULT WAS SET ON RIGHT MODULE, FULT CLEARED. ACCOMPLISHED TEST MULTIPLE TIME, NO FAULTS NOTED. THIS ACTION CLOSES DI, PLACARD REMOVED. NO MEL RE-ACTIVATION APPLIED.

Part: WIRE HARNESS — DAMAGED (HYD SYSTEM) · airframe 89,570 hrs · 30,899 cycles

RT HYD QUANTITY LIGHT ON OVER HEAD, RT HYD EICAS MESSAGE (RT.00 RF) LIGHT. DEFERRED. T/S WIRING, CK NORMAL. INTERMITTENT IND AFTER HYD PLACED ON OFF POSITION. FOUND CONNECTOR D60 QTY ASSY LOCKING MECHANISM DAMAGED IAW WDM 29-33-11. REMOVED AND REPLACED CONN D60 IAW SWPM 20-61-00 R/O CK FROM D60 TO M122 CONN D2704B GOOD AND NO SHORT TO GROUND, NO SHORT IN THE SHIELD'S READING ON EICAS IN BLANK NO READING, CHECKED AND R/O FROM 122 TO EICAS WIRE CK GOOD AND NO SHORT. CHECKED POWER AND GROUND AT M122 CK GOOD. NO DEFECT FOUND AFTER POWER RESET PULLING CB HYD QTY C1101 TWICE READING WORK NORMAL REF. W.D. 29-33-11. THIS DI REMAIN OPEN. NEEDS AMENDED AFTER CORRECTIVE ACTIONPERFORMED MEG CHECKS OF D60 PIN 7 TO SHIELD GROUNDS PIN 1 AND 6 FOUND CONTINUITY FROM 7 TO BOTH SHIELDS. PERF HARNESS SHAKE DOWN AND FOUND DAMAGED WIRING W394-11-20 REPAIRED DAMAGED WIRE W394-11-20 PER BWSPM 20-30-12 REINSTALLED WIRING AND CONTINUITY CHECKS GOOD PER BSWPM 20-10-11, 20-61-11, AND WDM 29-33-11. RE-INSTALLED HYD QTY MONITOR PER AMM 29-33-01 OPS CHECK GOOD THIS CLEARS DI PLACARDS REMOVED NO MEL REACTIVATION PROCEDURES APPLIED. LP 38607-02/1

Part: HYDRAULIC SYSTEM — WARNING MESSAGE (RIGHT) · airframe 89,334 hrs · 30,799 cycles

DURING TAXI OUT PIOLITS REPORT RIGHT HYD QTY INDICATION. AC RETURENED TO GATE AND MAINTENANCE GROUNDED AC . AND DEFERRED THE AC FOR DEPARTURE. IAW MEL 29-33-2 .MAINT. ACTIONS COMPLIED WITH AND AC WAS RETURNED TO SERVICE AND DEPARTED.

Part: RELAY — MALFUNCTIONED (BRAKE SYS) · airframe 89,114 hrs · 30,706 cycles

DURING TAXI OUT RSV BRAKE VAL EICAS MEESAGE CAME ON . AC RETURNED TO GATE AND MAINTENACE GROUNDED AC AND T/S PER FIM 29-11 FT 828. VERIFIED NO PWR TO C2 ISOLATED ACMP SUPPLY SOV. K1 RELAY ON M1216 PANEL BAD. REPLACED PANEL PER WDM 29-21-32. OPS CHECK GOOD AND RETURNED AC TO SERVICE .

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 89,114 hrs · 30,706 cycles

RIGHT ENGINE VALVE LIGHT ILLUMINATED DURING START SEQUENCE,ON TAXI OUT NO N2 ROTATION.AC RETURNED TO GATE AC MAINTENACE GROUNDED AC AND DEFERRED RIGHT HAND START VALVE IAW MEL-ABX-80-00-2-1, RETURNED AC TO SERVICE AND MANUALLY STARTED ENGINE FOR DEPARTURE.

Part: CIRCUIT — UNSERVICEABLE (BLEED SYS) · airframe 89,109 hrs · 30,704 cycles

L ENG BLEED OFF EICAS AND DISCREET LIGHT OFF IS ON AFTER STARTING LEFT ENGINE RETURN TO GET MAINTENANCE GROUNDED AC .TROUBLE SHOT AND REMOVED / REPLACED LEFT ENG BLEED CARD M859 IAW AMM 36-11-12, ACCOMPLISHED ENG IDLE RUN PER AMM 71-00-00 OPS OK AIRCRAFT RELEASED NO ETOP RETURNED AC TO SERVICE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 88,967 hrs · 30,639 cycles

BOTH THRUST LEVERS ARE DIFFICULT TO PUSH FORWARD TOGETHER  AC RETURNED TO GATE AND GROUNDED BY MAINTENANCE. TROUBLESHOT .C/W FIM 76-11 FT 806 BLOCK 23. SYS CKS OK. VERIFIED A/C REMAINS ETOPS 180 AC RETURNED TO SERVICE .

Part: UNKNOWN — UNKNOWN (ZONE 200) · airframe 88,591 hrs · 30,476 cycles

DURING C18 CHECK FOUND CORROSION AT LH FWD EMERGENCY EXIT CUTOUT AT BS883.5 AND STRG 16AL AND L 7L PIN 145T8320-15 AS SHOWN IN FIGURE 1. ADDITIONALLY DOUBLE DRILLED WAS FOUND DURING FASTENER REMOVED ON THE SKIN AREA. 767-300 SRM HAS NO REPAIR FOR THIS AREA. FLIGHT VEHICLES CONSULTING INC. WAS CONTACTED WITH REPAIR PROPOSAL, AND PERMANENT REPAIR INSTRUCTIONS WERE APPROVED. AIRCRAFT TYPE MODEL: 767-338ER, TC: 30,476 &TH: 88,591:1 REPAIRED IAW ABX-REA-5355-64964-00

Part: SKIN — CORRODED (ZONE 600) · corrosion level 2 · airframe 88,591 hrs · 30,476 cycles

DURING AIRCRAFT CURRENT CHECKC18 AT AIRBORNE (TAMPA), MAINTENANCE DISCOVERED CORROSION ON THE LOWER SURFACE OF THE RIGHT WING BOTTOM SKIN PANEL #2 (PIN L L2T4702-2) BETWEEN RIBS 31-32 AT THE REAR SPAR. THE CORROSION WA REMOVED BY BLENDING PER B767-300 SRM 57-20-01, AND FOUND TO BE OUT OF SRM ALLOWABLE LIMITS. AN ULTRASONIC (UT) INSPECTION WAS ACCOMPLISHED TO DETERMINE THE MINIMAL REMAINING MATERIAL THICKNESS A,,T.)D RESULT WERE RECORDED IN A 0.5'' X 0.5'' GRID PATTERN. INSPECTION REPORTED 0.076" REMAINING MATERIAL THICKNE. SAT THE THINNEST LOCATION FROM 0.200" NOMINAL (REMOVED 0.124") AS SHOWN IN FIGURE 2. ALL FASTYNERS COMMON TO REWORKED AREAS WERE REMOVED AND HFEC ROTA-PROBE INSPECTED(NO FINDINGS). AN HFEC URFACE CAN INSPECTION WAS ACCOMPLISHED PER 767 NDT MANUAL PART 6, 51-00-00 WITH NO DEFECTS NOTED. THIS REA PRNVIDES REPAIR INSTRUCTIONS FOR THE SUBJECT LOCATION, AND APPROVED BY FLIGHT VEHICLES CONSULTING.REPAIRED IAW ABX REA-5725-65145-00.

Part: BULKHEAD WEB — CORRODED (ZONE 600) · airframe 88,591 hrs · 30,476 cycles

DURING AIRCRAFT CIIRRENT C 18 CHECK AT AIRBORNE (TAMPA), A GENERAL VISUAL INSPECTION OF THE CENTER WING REAR SPAR BULKHEAD WEB (111 TI 003-14) IDENTIFIED EXTENSIVE CORROSION AT THE RH SIDE FITTING ( L 45T2523-8) SEE FIGURE I. AFTER SIDE FITTING REMOVAL PER REA 65147, LIGHT PITTING CORROSION WAS FOUND ON THE FWD FACE OF THE SIDE FITTING(MATING SURFACE COMMON TO REAR SPAR WEB). THIS REA PROVIDES REPAIR INSTRUCTIONS FOR THE RH SIDE FITTING. THIS REA IS ASSOCIATED TO REA 65 I 46UACKING/SHORING) & 6514 ?(REMOVALS/EVALUATION). SEE REA 65148 FOR REPAIR OF THE REAR SPAR WEB. BOEING WAS CONTACTED PER BMN PEF-ABX-23-0 I 06 ANS! PERMANENT REPAIR INSTRUCTIONS WERE PROVIDED. AC WAS REPAIRED IAW ABX-REA-5353-65150-00

Part: UNKNOWN — CORRODED (ZONE 100) · corrosion level 2 · airframe 88,591 hrs · 30,476 cycles

DURING C18 CHECK AT AIRBORNE TAMPA EXFOLIATION WAS FOUND ON N371CM AT FWD DOOR CUTOUT LO??ER SILL INNER CHORD PIN 143T8204-L APPROX. AT STA 544. THE CORROSION WAS REMOVED PER 767-300 S·RM 51-10-02, GRID MAP WITH UT ACCOMPLISHED SEE FIGURE 1. THE MINIMUM DEEPEST POINT IS .096". THE DAMAGE IS OUT OF LIMITS PER 767-300 SRM 53-00-15 ALLOWABLE DAMAGE 1. BOEING WAS CONTACTED VIA SR 4-5876205052 WITH REPAIR PROPOSAL, AND PERMANENT REPAIR INSTRUCTIONS WERE APPROVED. AIRCRAFT TYPE MODEL: 767-338ER, TC: 30,476 &TH: 88,591:1 REPAIRED IAW ABX-REA-5331-65144-00.

Part: FORK — CORRODED (ZONE 600) · airframe 88,591 hrs · 30,476 cycles

DURING AIRCRAFT CURRENT C18 CHECK AT AIRBORNE (TAMPA), A GENERAL VISUAL INSPECTION OF THE CENTER WING REAR SPAR BULKHEAD WEB (111 TL003-14) IDENTIFIED EXTENSIVE CORROSION AT THE RH SIDE FITTING (145T2523-8) SEE FIGURE 1. CORROSION WAS FOUND UNDER THE SIDE FITTING AND CORROSION REMOVAL WAS ACCOMPLISHED BY REA 6514 7. THIS REA PROVIDES REPAIR INSTRUCTIONS FOR THE REAR SPAR WEB CORROSION LOCATIONS UNDER THE SIDE FITTING. THIS REA IS ASSOCIATED TO REA 65 L 46(JACKING/SHORING) & 6514 ?(REMOVALS/EVALUATION). SEE REA 65150 FOR REPAIR OF THE RH SIDE FITTING. BOEING WAS CONTACTED PER BMN PEF-ABX-23-0105 AND PERMANENT REPAIR INSTRUCTIONS WERE PROVIDED. AC WAS REPAIRED IAW ABX-REA-5712-65148-00.AND ABX-REA-5712-65148-01

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 88,360 hrs · 30,387 cycles

UNABLE TO MAKE CONTACT ON RIGHT HF. FLIGHT CREW ELECTED TO DIVERT TO EMA DUE TO COMM. REQIREMENTS FOR ETOPS ROUTING. AIRCRAFT LANDED AND WAS GROUNDED BY MAINTENANCE. MAINTENANCE DEFERRED RIGHT HF COMM. IAW ABX MEL 23-11-1-2A. AIRCRAFT RETURNED TO SERVICE.

Part: DOWNLOCK — BYPASSING (LT MLG) · airframe 87,795 hrs · 30,181 cycles

GEAR DISAGREE MSG ON CLIMB OUT OF CVG. CREW ELECTED TO RETURN TO DEPARTURE AIRPORT. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE GROUNDED AIRCRAFT. MAINTENANCE ACCOMPLISHED THERMAL IMAGING TEST ON LH MLG IAW 20-10-75. FOUND DRAG BRACE GETTING HOT, BYPASSING. REMOVED AND REPLACED LH DRAG BRACE ACTUATOR IAW B767 AMM 32-30, OPS CHECK GOOD. ACCOMPLISHED MLG+NLG SWINGS IAW B767 AMM 32-32-00 + 32-34-00. ALL SYSTEMS OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 87,795 hrs · 30,180 cycles

ON INITIAL TAKEOFF WHEN N1/EPR BUTTON PUSHED AUTO THROTTLE DISCONNECT EICAS AND LIGHTS LOW SPEED ABORT (FLIGHT CREW DEFERRED PER MEL 22-30-1A) AIRCRAFT DEPARTED WITHOUT FURTHER INCIDENT.

Part: TRANSCEIVER — WEAK (RT HF COMMS) · airframe 87,170 hrs · 29,948 cycles

RIGHT HF WAS WEAK ON GROUND BUT WORKS IN FLIGHT WHEN IRO OR CAPT TRIED TO XNIT NO TRANSMISSION OVERRED AND NO SIDE TONE WAS HEARD. INITIALLY FO HAD SIDE TONE BUT SOON AFTER HE DID NOT HAVE SIDE TONE. AIRCRAFT DID NOT HAVE ENOUGH FUEL TO CONTINUE ROUTE VIA VHF COVERAGE. AIRCRAFT RETURNED TO EMA. AIRCRAFT WAS GROUNDED BY MAINTENANCE. MAINTENANCE REMOVED AND REPLACED RIGHT HF TRANSCEIVER AND FUNCTION TEST SATIS. IAW AMM 23-11-03 AIRCRAFT REMAINS ETOPS 180. AIRCRAFT RETURNED TO SERVICE.

Part: APU — NO INDICATION · airframe 86,901 hrs · 29,857 cycles

APU NO PNEUMATICS INDICATION. AIRCRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. MAINTENANACE DEFERRED APU IAW MEL 49-11-1-1. MAINTENANCE PROCEDURES COMPLIED WITH. AIRCRAFT RETURNED TO SERVICE.

Part: BUSS — MALFUNCTIONED · airframe 86,756 hrs · 29,805 cycles

ABORTED T/O AT 40 KTS WITH R GEN OFF AND L & R UTILITY BUSS OFF LIGHTS. RAN CHECKLIST AND GEN RESET ATTEMPTED ANOTHER T/O @ 30 KTS GEN OFF LIGHT AGAIN ABORTED T/O. AIRCRRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. MAINTENANCE TRANSFERRED TO DEFERRAL IAW ABX MEL 24-00-1-1, MAINTENANCE PROCEDURES COMPLIED WITH. AIRCRAFT RETURNED TO SERVICE.

Part: TRANSMITTER — INTERMITTENT (RT PYLON) · airframe 86,623 hrs · 29,756 cycles

RH HYD SYSTEM INDICATION FLUCTUATING. AIRCRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. MAINTENANCE FOUND NO HYDRAULIC FLUID LEAKING, RT HYD. QTY. DEFERRED PER MEL 29-33-2. AIRCRAFT RETURNED TO SERVICE.

Part: GENERATOR — FAILED (RIGHT) · airframe 86,275 hrs · 29,620 cycles

R GEN FAILURE PRIOR TO 80 KNOTS ON TAKE OFF. ABORTED TAKE OFF AND RETURNED TO GATE. AIRCRAFT GROUNDED BY MAINTENANCE. MAINTENANCE DEFERRED RT GEN. IAW MEL 24-00-1-1. PLACARD INSTALLED, AIRCRAFT RELEASED ETOPS 120. MAINTENANCE PROCEDURES C/W MBCB 08.25/22. AIRCRAFT RETURNED TO SERVICE.

Part: NONE — NONE (ZONE 400) · airframe 85,998 hrs · 29,509 cycles

LEFT HYDRAULIC PRIMARY PUMP APPEARS INOP. AIRCRAFT RETURNED TO GATE AND WAS GROUNDED BY MAINTENANCE. MAINTENANCE REPLACED LEFT ACMP, LEFT ACMP PRESS/CASE DRAIN FILTER MODULE AND LEFT EDP PRESSURE/CASE DRAIN FILTER MODULE IAW B767 AMM 29-11-01, 29-11-17 AND 29-11-18, PRESS AND TEMP NORMAL, LEAK CK OK.AIRCRAFT RETURNED TO SERVICE.

Part: NOT REPORTED — NOT REPORTED · airframe 85,099 hrs · 29,199 cycles

LEFT ENGINE EEC EICAS MESSAGE AND LEFT ENG EEC SWITCH INOP. AIRCRAFT BACK TO GATE AND GROUNDED BY MAINTENANCE. MAINTENANCE DEFERRED LT EEC IAW B767 MEL 73-21-22. PLACARDS INSTALLED; A/C RELEASED ETOPS 180. NO MAINT. DEACTIVATION REQUIRED. AIRCRAFT RETURNED TO SERVICE.

Part: SKIN — CORRODED · corrosion level 2 · airframe 92,713 hrs · 31,288 cycles

DURING AIRCRAFT C-CHECK AT AIRBORNE (TAMPA). AMES NR 0148 - LH WING, LOWER SURFACE, I/B WING AREA, CORROSION IN TWO SPOTS AROUND FASTENERS, AFT OF FUEL PNLS 531AB AND 531BB. DURING AIRCRAFT CURRENT CHECK AT AIRBORNE (TAMPA), MAINTENANCE DISCOVERED CORROSION ON THE LOWER SURFACE OF THE LEFT-HAND WING BOTTOM SKIN PANEL #2 (P/N 112T4702-1) AT RIB NO. 2 AND STRINGER 6. THE CORROSION WAS REMOVED BY BLENDING PER B767-300 SRM 57-20-01 AND FOUND TO BE OUT OF SRM ALLOWABLE LIMITS. AN ULTRASONIC (UT) INSPECTION WAS ACCOMPLISHED TO DETERMINE THE MINIMAL REMAINING MATERIAL THICKNESS AND RESULTS WERE RECORDED IN A 0.5” X 0.5” GRID PATTERN. INSPECTION REPORTED 0.203” REMAINING MATERIAL THICKNESS AT THE THINNEST LOCATION FROM 0.265” NOMINAL (REMOVED 0.062”) AS SHOWN IN FIGURE 1. ALL FASTENERS COMMON TO REWORKED AREAS (AS REQUIRED) WERE REMOVED AND HFEC OPEN-HOLE AND SURFACE SCAN INSPECTIONS WERE ACCOMPLISHED PER 767 NDT MANUAL PART 6, 51-00-00 WITH NO DEFECTS NOTED. THIS REA PROVIDES REPAIR INSTRUCTIONS FOR THE SUBJECT LOCATION, AS APPROVED BY FLIGHT VEHICLES CONSULTING, INC. (FVCI).

Part: NONE — NONE · airframe 84,556 hrs · 29,026 cycles

LH SIDE WINDOW EICAS MESSAGE ILLUMINATED ON TAXI. AIRCRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. MAINTENANCE DEFERRED THE L/H SIDE WINDOW HEAT IAW MEL 30-41-1-2. MAINTENANCE PROCEDURES COMPLIED WITH; PLACARD INSTALLED. AIRCRAFT REMAINS ETOPS 180. AIRCRAFT RETURNED TO SERVICE.

Part: VALVE — FAULTED (RIGHT ENGINE) · airframe 84,519 hrs · 29,008 cycles

R ENG HPSOV EICAS AND STATUS MSG DURING FLIGHT. AFTER DEPARTING FROM C-CHECK. CREW ELECTED TO DO AN AIR TURN BACK TO TAMPA. MAINTENANCE GROUNDED THE AIRCRAFT, RIGHT HPSOV WAS REPLACED IAW 36-11-07 AMM. AIRCRAFT RETURNED TO SERVICE.

Part: CAM — CORRODED (ZONE 800) · airframe 84,519 hrs · 29,008 cycles

WHILE IN C-CHECK AT TAMPA, MAIN CARGO DECK#2 LATCH CAM PAWL WAS FOUND TO HAVE CORROSION. REMOVED AND REPLACED #2 LATCH CAM IAW ABX 767 AMM 52-32-11.

Part: NONE — NONE · airframe 84,453 hrs · 28,978 cycles

RIGHT ENG LOW OIL PRESSURE EICAS MSG AND RIGHT ENGINE LOW OIL PRS DISCREET LIGHT CAME ON AFTER ENGINE START. AIRCRAFT RETURNED TO BLOCK AND WAS GROUNDED BY MAINTENANCE. MAINTENANCE DEFERRED LOW OIL SYSYEM IAW MEL 79-33-1-1. VERIFIED OIL PRESSURE GAUGE,OIL TEMP AND OIL QUANTITY NORMAL. AIRCRAFT RELEASED FOR FLIGHT.

Part: WARNING MESSAGE — FALSE ACTIVATION (FUEL PUMP) · airframe 82,288 hrs · 28,085 cycles

EICAS MESSAGE RT FWD FUEL PUMP (ADVISORY) SHOWS ON THE RT FWD PUMP PRESS LIGHT IS ON WITH THE SWITCH ON. AIRCRAFT RETURNED TO GATE. AIRCRAFT WAS GROUNDED WHILE MAINTENANCE INSPECTED PROBLEM. MAINTENANCE DEFERRED ITEM, EXAMINED CANNON PLUG CONNECTOR D3986 AT RT FWD FUEL BOOST PUMP FOR CORROSION & CONTAMINATION NO DAMAGE FOUND. PERFORMED GFI CONTROL RELAY OPS TEST, IAW AMM 28-22-00, CHECKED OK. OPERATED RT FWD FUEL BOOST PUMP WHILE WIGGLED WIRING ON P 141 D17314P & D17326P COULD NOT DUPLICATE FAULT. DEACTIVATED BY MAINT PROCEDURE DI REMAINS OPEN A/C NO ETOPS.

Part: GASKET — LEAKING (FCU) · airframe 82,247 hrs · 28,061 cycles

RT ENG FAILED AS RT THROTTLE WAS BEING RETARDED AFTER PLANNED GO AROUND, ENG WAS NORMAL PRIOR TO FAILURE. UNCOMMANDED IFSD. AIRCRAFT DECLARED AN EMERGENCY, LANDED SAFELY AND WAS SUBSEQUENLY GROUNDED. MAINTENANCE FOUND A LEAKING GASKET IN ENGINE FUEL CONTROL SYSTEM. AIRCRAFT WAS REPAIRED AND RETURNED TO SERVICE.

Part: STARTER — MALFUNCTIONED (NR 1 ENGINE) · airframe 81,685 hrs · 27,805 cycles

NO INDICATIONS DURING NR 1 ENGINE START SECOND TIME. DURING FIRST START NR 1 ENGINE EGT WAS RISING AND N2 WAS GOING DOWN, NO EXCEEDANCE. AIRCRAFT WAS GROUNDED.

Part: SUPPORT BRACKET — CRACKED (ENGINE MOUNT) · airframe 80,865 hrs · 27,417 cycles

CRACK IN THE LEFT PYLON AFT ENGINE MOUNT SUPPORT BULKHEAD, AFT SIDE UPPER BRACKET AT OUTBOARD SIDE FORWARD OF THE WIRE BUNDLE. THE BRACKET WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: SKIN — DAMAGED (BS 325-347) · airframe 80,865 hrs · 27,417 cycles

DAMAGE IN THE FUSELAGE SKIN AT THE LEFT FORWARD DOOR CUTOUT, AFT LOWER CORNER, STRINGER 20L, BETWEEN FUSELAGE STATIONS 325 AND 347. THE SKIN WAS REPAIRED. THE AIRPLANE WAS GROUNDED.

Part: SKIN — CORRODED (LT WING) · airframe 80,865 hrs · 27,417 cycles

CORROSION ON THE LEFT WING LOWER SKIN NUMBER 3 PANEL ON THE LOWER SURFACE AT STRINGER L10 BETWEEN WING STATIONS: 668 AND 746, 759 AND 792, 800 AND 820, AND 825 AND 916. THE SKIN WAS REPAIRED. THE AIRPLANE WAS GROUNDED.

Part: RETAINER — CRACKED (LT PYLON) · airframe 80,865 hrs · 27,417 cycles

CRACK IN THE LEFT PYLON PANEL 437BR AFT SEAL RETAINER. THE SEAL RETAINER WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: ANGLE — CORRODED (LT PYLON) · airframe 80,865 hrs · 27,417 cycles

CORROSION IN THE LEFT PYLON FAIRING PANEL 437BL BONDING WIRE ATTACH POINT (ANGLE). THE ANGLE WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: ANGLE — CRACKED (RT PYLON) · airframe 80,865 hrs · 27,417 cycles

CRACK IN THE RIGHT PYLON PANEL 437BR CUT-OUT, INNER AFT SUPPORT ANGLE. THE SUPPORT ANGLE WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: STIFFENER — DENTED (BS 1016) · airframe 80,865 hrs · 27,417 cycles

DENT ON THE OVER WING PRESSURE DECK LONGITUDINAL STIFFENER ON THE UPPER INBOARD FLANGE AT FUSELAGE STATION 1016. THE STIFFENER WAS REPAIRED. THE AIRPLANE WAS GROUNDED.

Part: ANGLE — CORRODED (LT PYLON) · airframe 80,865 hrs · 27,417 cycles

CORROSION IN THE LEFT PYLON PANEL 437BR CUT-OUT, INNER AFT SUPPORT ANGLE. THE SUPPORT ANGLE WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: PLATE — CORRODED (RT PYLON) · airframe 80,865 hrs · 27,417 cycles

CORROSION IN THE RIGHT PYLON, UNDER PANEL 437BR, AFT SIDE UPPER CUT-OUT INNER SUPPORT PLATE. THE SUPPORT PLATE WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: RETAINER — CRACKED (LT PYLON) · airframe 80,865 hrs · 27,417 cycles

CRACK IN THE LEFT PYLON HYDRAULIC BAY CUT OUT LOWER ZEE ANGLE SEAL RETAINER. THE ZEE ANGLE SEAL RETAINER WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: CROSSBEAM — GOUGED (RT WING) · airframe 80,865 hrs · 27,417 cycles

GOUGE IN THE RIGHT WING REAR SPAR TO WALKING BEAM CROSSBEAM. THE CROSSBEAM WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: WEB — CRACKED (RT PYLON) · airframe 80,865 hrs · 27,417 cycles

CRACK IN THE RIGHT PYLON, UNDER PANEL 437BR, AFT SUPPORT WEB. THE WEB WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: SKIN — GOUGED (CARGO DOOR) · airframe 80,865 hrs · 27,417 cycles

GOUGES IN THE BULK CARGO DOOR SKIN, LOWER AFT CORNER AND LOWER FORWARD CORNER. THE SKIN WAS REPAIRED. THE AIRPLANE WAS GROUNDED.

Part: SKIN — DAMAGED (BS 325-347) · airframe 80,865 hrs · 27,417 cycles

DAMAGE IN THE FUSELAGE SKIN AT THE RIGHT FORWARD DOOR CUTOUT, AFT LOWER CORNER, STRINGER 20R, BETWEEN FUSELAGE STATIONS 325 AND 347. THE SKIN WAS REPAIRED. THE AIRPLANE WAS GROUNDED.

Part: STIFFENER — CRACKED (LT PYLON) · airframe 80,865 hrs · 27,417 cycles

CRACK IN THE LEFT PYLON FAIRING INBOARD STIFFENER. THE STIFFENER WAS REPAIRED. THE AIRPLANE WAS GROUNDED.

Part: ANGLE — CRACKED (RT PYLON) · airframe 80,865 hrs · 27,417 cycles

CRACK IN THE RIGHT PYLON INBOARD AFT FAIRING SUPPORT ANGLE. THE FAIRING SUPPORT ANGLE WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: STIFFENER — CRACKED (LT PYLON) · airframe 80,865 hrs · 27,417 cycles

CRACK IN THE LEFT PYLON, INBOARD AFT FAIRING, INBOARD STIFFENER. THE STIFFENER WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: SKIN — CORRODED (LT WING) · airframe 80,865 hrs · 27,417 cycles

CORROSION IN THE LOWER LEFT WING SKIN NUMBER 3 LOWER SURFACE AT FRONT SPAR BETWEEN RIBS 26 AND 27. THE SKIN WAS REPAIRED. THE AIRPLANE WAS GROUNDED.

Part: FRAME — CORRODED (LT PYLON) · airframe 80,865 hrs · 27,417 cycles

CORROSION IN THE LEFT PYLON FAIRING, INBOARD FRAME, AT PYLON STATION 376. THE FRAME WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: SKIN — DENTED (FUSELAGE) · airframe 80,473 hrs · 27,231 cycles

DENT ON THE FUSELAGE SKIN AT FUSELAGE STATION 329, STRINGER 37R. THE SKIN WAS REPAIRED. THE AIRPLANE WAS GROUNDED.

Part: STIFFENER — CRACKED (BS 246) · airframe 76,844 hrs · 25,540 cycles

CRACK IN TOP OUTBOARD CORNER OF A STIFFENER AT BS 246. THE STIFFENER WAS REPLACED. THE ACFT WAS GROUNDED.

Part: STRINGER — CRACKED (BS 654) · airframe 76,844 hrs · 25,540 cycles

CRACK IN RADIUS OF STRINGER 25L, BS 654+22. THE STRINGER WAS REPAIRED. THE ACFT WAS GROUNDED.

Part: BEAM — CORRODED (RT WING TE FLAP) · airframe 75,745 hrs · 24,997 cycles

NR 8 FLAP SUPPORT 1-2-3 BEAM HAS FOUR HOLES SHOWING DEFECTS. REPAIRED IAW REA CO57-62458-MR. AIRCRAFT WAS GROUNDED.