N386FE

Part: ELEMENT — FAILED (NR 2 MANIFOLD) · airframe 75,330 hrs · 31,182 cycles

AFTER TAKEOFF, WITH NR 2 PACK OFF, CLIMBING PASSED 14000' MSL. RECEIVED NR 2 MANIFOLD FAILURE LEVEL ALERT, RTB LANDED WITHOUT INCIDENT. REMOVED AND REPLACED NR 2 ENGINE MANIFOLD SENSING ELEMENT IAW MM 36-23-02-4. RAN NR 2 ENGINE REF JRH AND PERFORMED PNEUMATIC SYSTEM TEST PER AMM 36-00-03/501. SYSTEMS OPS CHECKED GOOD.

Part: WARNING LIGHT — ILLUMINATED (BLEED SYS) · airframe 74,412 hrs · 30,697 cycles

CLIMBING THRU 13,000' GOT LVL 3" BLD AIR 1 TEMP HI", COMPLIED WITH QRH. PERFORMED RTS ON ALL 3 AIU'S, ALL TESTS PASSED. PERFORMED RTS ON PNEUMATIC SYS CONTROLLER NR 1. INSPECTED NR 1 ENGINE BLEED CONTROL VALVE SENSE LINES AND CONNECTORS, NO DEFECTS NOTED. INSPECTED NR 1 ENGINE FAN AIR CONTROL VALVE CONNECTOR AND SENSE LINES, NO DEFECTS NOTED. NO DEFECTS NOTED ON NR 1 ENGINE. REPLACED NR 1 PNEUMATIC SYS TEMP CONTROL SENSOR. SWAPPED NR 1 PNEUMATIC TEMP INDICATION SENSOR WITH NR 2 PNEUMATIC TEMP IND SENSOR. PERFORMED GROUND POWER RUN UP WITH CREW AND RE-CREATE POWER SETTING (N1 100 PERCENT) CONDITIONS WHEN FAULT OCCURED. ALL INDICATIONS NORMAL. (FINAL CLOSED)

Part: SKIN — CORRODED (BS 859 S43R) · airframe 74,393 hrs · 30,686 cycles

SKIN BULGING AT APPROX STA 859, STRINGER 43R FWD OF FWD CARGO DOOR, 6 INCHES IN LENGTH. INSPECTED, FOUND EXTERIOR SKIN OK. CORROSION FOUND UNDER SKIN AT RAIL AREA. REMOVED SKIN & DOUBLER TO GAIN ACCESS TO RAIL, REF SRM 51-21-00, VOL 2. BLENDED/REMOVED CORROSION ON RAIL REF SRM 51-21-00. VOL 2. PERFORMED UT THICKNESS FOUND GOOD, AREA .141" LOWEST AREA AFTER CORROSION REMOVED .063 IAW NDT SPM 93K0393. INSPECTION OF OPEN HOLES HFEC IAW NDT SPM CHP 06 FOUND NO INDICATIONS. TREATED & PRIMED SKIN CUTOUT & BLENDED AREA SRM 51-21-00, VOL 2. FABRICATED DOUBLER & TRIPLER , TREATED & PRIMED REF SRM 53-20-00, FIG 6,7 AND 8. INSTALLED WASHERS, SHIM, FILLERS, DOUBLER & TRIPLER, REF SRM 53-20-00, FIG 6,7 AND 8.

Part: FLOORBEAM — CORRODED (BS 1781) · airframe 74,393 hrs · 30,686 cycles

CENTER CARGO COMPARTMENT FLOORBEAM CORRODED/EXFOLIATED AT BS 1781, RBL 36.

Part: FITTING — CRACKED (ZONE 100) · airframe 74,393 hrs · 30,686 cycles

CAC COMPARTMENT FITTING AT THE PRESSURE DOME ADJACENT TO THE "SUGAR SCOOP" HAS A 2 IN CRACK IN THE LOWER LARGE RADIUS. (PN AYB7000-1) REMOVED CRACKED FITTING AND INSTALLED NEW FITTING PART NR AYB7000 IAW DWG NYB60472, SRM 51-31-01, SRM53-40-00. ACCOMPLISHED PART 3 OF EA WORK CARD T8-5340-121719 A P2, T8-5340-121719 A P3. REINSTALLED FASTENERS IN ARB 0323-1, REINSTALLED FASTENERS IN ARB 0322 IAW DWG NYB6042. REINSTALLED LONGERONS ADA 0158 AND ADA 0152 IAW SRM 51-31-01. INSTALLED BUSHING IN CORD NYS 6008 IAW CMM 20-20-07.

Part: POWER SUPPLY — FAILED (EMERGENCY LIGHTS) · airframe 74,269 hrs · 30,625 cycles

EMERGENCY LIGHT TEST FAIL MEL 04FEB11. RELEASED FOR SERVICE IAW MEL: 33-50-02, CATEGORY: C. R & R EMERGENCY EXIT LIGHTS POWER-SUPPLY IAW AMM 33-51-01-4. OPS CHECKS GOOD IAW AMM. OK FOR SERVICE.

Part: NONE — NONE (NONE) · airframe 71,531 hrs · 29,248 cycles

AT BEGINNING OF TAKEOFF ROLL, LEVEL 1 'UNABLE RNP'. DURING TAX IN, RNP INDICATED 4.1 NM. UPON RETURN TO BLOCKS, TROUBLESHOT THE CFDS/ MCDU: NO FAULTS PERFORMED RTS ON ADIRU 1,2, AND 3; MMR 1,2, AND 3, NO FAULTS FOUND. ALL TESTS PASS POS REF SHOWS 6 SAT'S, GOOD REFS. REF AMM 34-35-01-5/34-58-00-5/34-43-00-5. ALL 3 IRU AND BOTH GNS SHOWED SAME LATITUDE AND LONGITUDE. ACFT OK AT THIS TIME.

Part: SPAR CAP — CRACKED (LT WING) · airframe 71,486 hrs · 29,221 cycles

FUEL LEAK LT WING LOWER REAR SPAR CAP AT WS XORS 346, INDICATION OF CRACK AT THE POINT OF LEAK. REAR SPAR REPAIRED AS PER E.A. 8-5710-126158. SEQ.#924.

Part: WINDOW FRAME — CRACKED (COCKPIT) · airframe 71,486 hrs · 29,221 cycles

CAPTAIN SLIDING VIEW WINDOW FRAME AIRPLANE SIDE CRACKED OUTSIDE (MARKED).

Part: CONTROL VALVE — MALFUNCTIONED (MLG) · airframe 69,586 hrs · 28,343 cycles

ON INITIAL GEAR EXTENSION GOT ALL RED AND NO GREEN ON LIGHTS AND CONFIG PAGE. SAME ON SECOND ATTEMPT. NO WIND NOISE ON 1ST AND SECOND TIME, THIRD TIME ALL GREEN INDICATIONS. CHECKED MECHANICAL CONTROL TO LANDING GEAR CONTROL VALVE NO FAULTS FOUND. CHECKED CABLE TENSION ON CABLES 109,110,111,112A FOUND OK PER MD10-10 MM 32- 31-01-5. REMOVED AND REPLACED LANDING GEAR CONTROL VALVE REF MD10-10 M/M 32-31-03-2. RIGGED VALVE PER MD10-10 PERFORMED FUNCTIONAL TEST REF MD10-10 M/M 32-30-00- 5. LEAK AND OPS CHECK GOOD, NEEDS PLUMB BOB REMOVED AFTER A/C IS DOWN JACKED.

Part: ENGINE — DAMAGED (NR 1) · airframe 69,347 hrs · 28,222 cycles

CLIMBING THROUGH FL190 AIRCRAFT SHUDDERED TWICE WITH SLIGHT YAW TO LEFT. LOOKED DOWN AND "ENG 1 EXCEEDENCE" ALERT AND RED BOXED ENG 1 EGT "951". PULLED ENG 1 TO IDLE AND RAN ENG FIRE SEVERE DAMAGE CHECKLIST. SHUTDOWN NR 1, PULLED NR 1 FIRE HANDLE AND RTBED TO KJAX. BORESCOPED NR 1 ENG COMPRESSOR, HAS 3RD STAGE TIP CLANG (B1-3 PORT ). REQUIRES ENG CHANGE PER 72-00-00-6. REMOVED AND REPLACED NR 1 ENGINE, REF MD-10 WORK CARD 71T0101-1. OK FOR SERVICE.

Part: ENGINE — FAILED (NR 3) · airframe 68,005 hrs · 27,576 cycles

ON CLIMBOUT TO CRUISE ALTITUDE PASSING 28,000 FT HEARD A THUD & EXPERIENCED AIRCRAFT YAW TO THE RIGHT. ENGINE INSTRUMENTS INDICATED NR 3 ENGINE FAILURE. SHUT DOWN ENGINE IN ACCORDANCE WITH QRH. FIRED NR 3 ENGINE FIRE EXTINGUISHER PER QRH. RETURNED TO MEM, LANDED RWY 36C. EXPERIENCED SEVERE AIRCRAFT VIBRATION DURING DESCENT UNTIL ENGINE APPEARED TO HAVE SEIZED OR STOPPED ROTATING. PERFORMED SLAT RETRACTED/FLAPS 22 LANDING. ROLLOUT WAS NORMAL. EVACUATED THE A/C USING QRH CHECKLIST. FIRED EXTINGUSHING AGENT TO ALL ENGINES. ITEM IN WORK.

Part: ENGINE — FAILED (NR 3) · airframe 68,005 hrs · 27,576 cycles

ON CLIMB-OUT TO CRUISE, ALTITUDE PASSING 28000' HEARD A "THUD" AND EXPERIENCED AIRCRAFT YAW TO THE RIGHT. ENGINE INSTRUMENTS INDICATED NR 3 ENGINE FAILURE. SHUT DOWN ENGINE IN ACCORDANCE WITH QRH. FIRE EXTINGUSHING AGENT TO NR 3 ENGINE PER QRH, RETURNED TO MEMPHIS, LANDED RWY 36C. EXPERIENCED SEVERE AIRCRAFT VIB DURING DESCENT UNTIL ENGINE APPEARED TO HAVE SEIZED OR STOPPED ROTATING. UPON INSPECTION OF ENGINE NOTED THE LOW PRESSURE TURBINE (LPT) WAS MISSING. DAMAGED TO WING AND FUSLAGE AND 3 PYLON.

Part: FLOORBEAM — DAMAGED (ZONE 200) · airframe 64,918 hrs · 26,194 cycles

FLOORBEAM AT FUSELAGE STATION 1921, LBL 50, FOUND DAMAGED ON EDGE OF CUTOUT, AT CABLE LOCATION. COMPLIED WITH FEDEX EA 8-5310-77598, FUSELAGE STATION 1921, X=-50, FLOORBEAM LIGHTENING HOLE REPAIR.

Part: DOOR FRAME — CORRODED (ZONE 100) · airframe 64,918 hrs · 26,194 cycles

FORWARD PIT, FORWARD DOOR FRAME STATION 886 HAS CORROSION. DOOR FRAME FOUND TO BE OUT OF LIMITS. CUT AND REMOVED CORRODED FRAME SECTION, CUT WEB TO FOM. FABRICATED -15, -13 AND WEB REPAIR DOUBLER AND INSTALLED REPAIR COMPONENTS IAW DC10 SRM 51-31-01 VOL II, PERCENT 3-50-00 VOL I, 53-00-01, 51-21-01 VOL II AND 51-35-01 VOL III. FABRICATION OF FRAME SECTION ADA 0055-3 TO BE ACCOMPLISHED ON N/R 00727. FABRICATION OF -11 SPLICE ANGLE TO BE ACCOMPLISHED ON N/R N00728. REFERENCE N/R 00060.

Part: PANEL — DENTED (ZONE 600) · airframe 64,918 hrs · 26,194 cycles

RIGHT HAND WING TRAILING EDGE INBOARD LOWER PANEL NUMBER 641 BB HAS NUMEROUS DENTS IN ITS UPPER SURFACE. REPAIRED BY FABRICATING AND BONDING NEW METAL OUTER SKIN, CORE, INNER SKIN AND INNER DOUBLER IAW TPS 1001 REV E AND DWG ARC 2067 AND EA 8-5710-77592. REFERENCE N/R N00699.

Part: CONTROL CABLE — CROSSED (ZONE 200) · airframe 64,918 hrs · 26,194 cycles

AFT PIT BEHIND STATION 1967, 36 INCHES, LEFT BUTT LINE CABLES CROSSED BELOW MAIN CABIN FLOOR. OPENED CEILING PANELS AND REMOVED LEFT HAND VERTICAL ACCESS PANELS. REMOVED AND REPLACED PULLEYS AND 2 EACH CABLES, RIGGED AND OPS CHECKED GOOD, ROUTE CHECKED AND INSTALLED AND REMOVED CABLE BLOCKS IAW MD 10 MM 27-20-00 AND 20-50-02. REFERENCE N/R N00946

Part: SKIN — DENTED (FUSELAGE) · airframe 64,918 hrs · 26,194 cycles

SEVERAL DENTS IN REPAIR DOUBLER, JUST AFT OF LOWER FWD CARGO DOOR. REMOVED DOUBLER AND TRIPLER. FABRICATED AND INSTALLED DOUBLER AND TRIPLER IAW DC10 SRM 53-20-00 VOL 1 AND 51-21-01 VOL 2.

Part: SKIN — CORRODED (ZONE 600) · airframe 64,918 hrs · 26,194 cycles

RIGHT HAND WING INBOARD AILERON LOWER SKIN BULGED/CORRODED AND I EACH FASTENER POPPED. REMOVED AND REPLACED INBOARD AILERON LOWER SKIN PER FEDEX EA 8-5750-77595. REMOVE AND REPLACE LEADING EDGE SKIN PER FEDEX DC10-10 SRM 51-35-01 VOL 2.

Part: BEAM — CRACKED (ZONE 600) · airframe 64,918 hrs · 26,194 cycles

RIGHT WING INBOARD AILERON LOWER BEAM CRACKED AT END. REMOVE TEE-CAP IAW DC10 SRM 51-35-01 VOL I, FABRICATED -4 TEE CAP IAW DCA DWG ARC 3012 AND DC10 SRM 51-10-01 FIG 13 VOL 3. TRIMMED, LOCATED, DRILLED AND DEBURRED -4 TEE CAP IAW DC10 SRM 57-31-01 VOL 2 AND DAC DWG ARC 3102. RE-ASSEMBLED TEE CAP IAW DAC DWG ARC 3102 AND DC10 SRM 51-31-01 VOL 2. INSTALLATION TO BE ACCOMPLISHED ON NR N00307.

Part: SKIN — DENTED (FUSELAGE) · airframe 64,918 hrs · 26,194 cycles

SEVERAL DENTS IN REPAIR DOUBLER, JUST AFT OF LOWER FWD CARGO DOOR. REMOVED DOUBLER AND TRIPLER. FABRICATED AND INSTALLED DOUBLER AND TRIPLER IAW DC10 SRM 53-20-00 VOL 1 AND 51-21-01 VOL 2.

Part: STATIC PORT — DAMAGED · airframe 64,918 hrs · 26,194 cycles

RIGHT PRIMARY STATIC PORT FAILS RVSM CONVEXITY AND CONCAVITY AND WAVINESS INSPECTION IAW WORK CARD 34C1501 STEP 9 AND 10. REMOVED AND REPLACED RIGHT HAND PRIMARY STATIC PORT IAW FEDEX MD10-10 MM 34-11-01-2, PERFORMED WAVINESS INSPECTION IAW FEDEX MD10-10 MM 34-11-01, CHECKED GOOD, PERFORMED PITOT/STATIC CHECK OF CAPT'S, F.O. AND AUX SYSTEMS IAW FEDEX MD10-10 MM 34-16-00-5, ALL SYSTEMS LEAK CHECKED GOOD. PERFORMED OPERATIONAL CHECK OF RIGHT HAND STATIC PORT HEATER IAW FEDEX MD10-10 MM 34-16-00-5, OPERATIONAL CHECK GOOD.

Part: WARNING SYSTEM — ACTIVATED (FUEL QTY) · airframe 64,392 hrs · 25,951 cycles

AT 6000 FT ON DOWN WIND LEG WITH SLATS EXTENED AND 180 KTS,THE LEVEL 2 FUEL USED ALERT CAME ON. FUEL USED AND FUEL REMAINING EQUALLED DEPARTURE FUEL. APPROXIMATELY 5 MIN LATER, GOT A TANK NR 3 FUEL QTY LO ALERT. DECLARED AN EMERGENCY AND LANDED UNEVENTFULLY. ALL ALERTS WENT AWAY AT 2500 FT ON FINAL. AT SHUTDOWN FUEL USED =17.7, 17.8, 18.0 FUEL TANKS 6.4, 6.7, 6.4 DEPARTURE FUEL WAS 73.0. PERFORM FUEL SYSTEM TEST ON ENTIRE FUEL SYSTEM WITH AIRCRAFT SYSTEM COMPUTER TWICE, ALL SYSTEM PASSED. PER MAINT PRACTICES. NO PREVIOUS HISTORY.

Part: SELECTOR VALVE — FAILED (MLG) · airframe 63,920 hrs · 25,732 cycles

AT 180 KTS ON FINAL DROPPED LANDING GEAR AND GOT UNSAFE ON BOTH PRI-SEC. CYCLED GEAR WITH SAME RESULT. INITIATED GO-AROUND. AT 210 KTS ON VECTORS CYCLED GEAR AND GOT 3 GREEN. REMOVED AND REPLACED LANDING GEAR SELECTOR VALVE PER AMM 32-31-03-2 OPS CHECK NORMAL PER AMM 32-30-00-5. LEAK CHECKED NORMAL.

Part: ENGINE — MALFUNCTIONED (NR 3) · airframe 63,192 hrs · 25,326 cycles

CRUISE ALT (FL370) ANC -- SEA 2+19 ENROUTE TIME "ENG NR 3 OIL PRESS LOW" ALERT. FOLLOWED APPROPRIATE CHECKLIST & LANDED AT DESTINATION. EMERGENCY DECLARED. FOUND ANGLE GEARBOX LOOSE ON HORIZONTAL SHAFT ANGLE GEARBOX CASE SEALS BLOWN, SEVERAL OIL LINES SHEARED FROM VIBRATION. TOWER SHAFT SHEARED FROM ANGLE GEARBOX AND VERTICAL SHAFT HOUSING DISINTERGRATED. ALSO NOTED METAL ON A,G & D SCAVANGE MAG PLUGS. REMOVED AND REPLACE THE #3 ENGINE.

Part: BEARING — WORN (TE FLAP CARRIAGE) · airframe 62,496 hrs · 25,048 cycles

RT WING OUTBOARD FLAP CARRIAGE ASSY HAS 2 SMALL ROLLER BEARINGS WORN. REMOVED AND REPLACED 2 SMALL ROLLER BEARINGS.

Part: MOTOR — FAILED (PAX DOOR) · airframe 62,496 hrs · 25,048 cycles

R1 ENTRY DOOR HARD TO OPEN, MOTOR SOUNDS LIKE IT SPINS, CLUTCH SLIPS. REMOVED AND REPLACED R1 DOOR ELECTRIC MOTOR, SHAFT, BEARINGS, AND PNEUMATIC MOTOR REF MM.

Part: BRAKE ASSY — DAMAGED (MLG) · airframe 62,496 hrs · 25,048 cycles

NUMBER 2 BRAKE BINDING. DURING TIRE CHANGE, FOUND FIRST THREE SETS OF ROTORS FROZEN & STUCK. REMOVED OLD DEFECTIVE NR 2 BRAKE AND INSTALLED NEW BRAKE IAW MM.

Part: DUCT — OVERHEATED (E/E BAY) · airframe 62,496 hrs · 25,048 cycles

RADIO RACK FAN EXHAUST DUCT EXHIBITS SIGNS OF FIRE AND OVERHEATING, INSULATION BLANKETS AND FOAM MATERIAL FROM INSIDE OF DUCT BELOW MAIN CABIN FLOORING AT BS 475 THRU BS 495. R&R DUCT ASSY, BLACK FOAM DETERIORATED. INSPECTION FOUND NO EVIDENCE OF FIRE.

Part: MOTOR — FAILED (R1 DOOR) · airframe 62,496 hrs · 25,048 cycles

DOOR HARD TO OPEN. MOTOR SOUNDS LIKE SPINS, CLUTCH SLIPS. R/R R1 DOOR ELECTRIC MOTOR, SHAFT, BEARINGS AND PNEU MOTOR REF MM 52-11-01-02.

Part: O-RING — DAMAGED (HYD SYSTEM) · airframe 62,348 hrs · 24,981 cycles

NR 3 HYDRAULIC QUANTITY DROPPED TO 4.9 GAL. WITH HYDRAULIC 3 ELEVATOR OFF LEVEL 2 ALERT, DECLARED EMERGENCY. APPROACH, LANDING AND TAXI NORMAL. ON BLOCK IN NR 3 HYDRAULIC QUANTITY WAS DOWN TO 3.4 GAL. FOUND PRESSURE TRANSDUCER LEAKING AT SEALS (O-RINGS). MANIFOLD NR 3 LOCATED RIGHT WHEEL WELL. REMOVED AND REPLACED 2 EACH O-RINGS ON HYDRAULIC SYSTEM 3 MANIFOLD PRESSURE TRANSDUCER IAW MD, MM SERVICED NR 3 HYDRAULIC RESERVOIR IAW MD. OPERATIONAL AND LEAK CHECK GOOD, AIRCRAFT CONTINUED SERVICE.

Part: FITTING — CORRODED (NR 1 P6YLON)

SNRM 042 STA-LAX - CORROSION FOUND TO EXCEED LIMITS ON NR 1 PYLON AFT MOUNT BULKHEAD FITTING. REMOVED AND REPLACED NR 1 PYLON AFT BULKHEAD FITTING PER SRM 51-00-01.

Part: FITTING — CRACKED (NR 3 PYLON)

STA-LAX - NR 3 PYLON HAS A HIGH FREQUENCY EDDY CURRENT CRACK INDICATION IN THE OUTBOARD ENGINE TRUSS FITTING AS PER FED-EX EO 8-5410-7-3323 PT W. COMPLIED WITH REPAIR AND TERMINATING MOD EO 8-5410-7-3323 PT 4.