N395AJ

Part: FRAME — CORRODED (BS 740) · airframe 83,096 hrs · 46,794 cycles

WING CENTER FRONT SPAR LOWER CHORD, CENTER WING WITH CORROSION BS 740.00 LT LBL 20,

Part: PLATE — CORRODED (BS 870) · airframe 83,096 hrs · 46,794 cycles

SPLICE PLATE ATTACHMENT UNDER WING TO BODY SHOW CORROSION AT BS 870, WLB 70.5.

Part: SPLICE — CORRODED (BS 870) · airframe 83,096 hrs · 46,794 cycles

WING TO BODY SPLICE PLATE ATTACH, UNDER WING TO BODY WITH CORROSION BS 870, WLB 70.5 LT REF N/R 0337.

Part: BEAM — CORRODED (HORIZONTAL STAB) · airframe 83,096 hrs · 46,794 cycles

LEFT HORIZONTAL STABILIZER T/E LOWER BEAM SHOWS CORROSION AT SEVERAL LOCATIONS.

Part: WARNING LIGHT — ILLUMINATED (COCKPIT) · airframe 82,883 hrs · 46,653 cycles

LEFT GEAR UNSAFE LIGHT.

Part: WARNING LIGHT — ILLUMINATED (COCKPIT) · airframe 82,883 hrs · 46,652 cycles

LEFT MAIN GEAR UNSAFE LIGHT ILLUMINATED.

Part: COMPRESSOR — STALLED (NR 3 ENGINE) · airframe 82,365 hrs · 46,286 cycles

AT 3500’ NR 3 ENG COMPRESSOR STALL. RETARDED THRUST, SLOWLY INCREASED THRUST, COMPRESSOR STALLED AGAIN. THRUST AT IDLE, RETURNED TO MIAMI.

Part: FLEX HOSE — RUPTURED (HYDRAULIC SYS) · airframe 82,001 hrs · 46,033 cycles

LOSS OF B SYS HYD FLUID IN FLIGHT. DECLARED EMERGENCY & RETURNED TO MIA.

Part: SKIN — CORRODED (LT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING UPPER SKIN NEAR REAR SPAR SHOWS CORROSION WS 601.5, REF NR 0258.

Part: FLAP TRACK — CORRODED (LT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING LOWER SURFACE INBD FLAP TRACK COUPLING SHOWS CORROSION WS 304.0, REF N/R 0250.

Part: STIFFENER — CORRODED (LT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING FRONT SPAR STIFFENER CORRODED, WS 198.

Part: STIFFENER — CORRODED (RT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING FRONT SPAR STIFFENER SHOWS CORROSION, WS 212.

Part: SKIN — CORRODED (BS 740) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, CARGO COMPARTMENT INNER UPPER SKIN SHOWS CORROSION BS 740, S1R.

Part: ANGLE — CORRODED (RT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING L/E FLAP HOUSING ANGLE CORRODED, WS 171.5, WS 198.0.

Part: STRUCTURE — CRACKED (LT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING LOWER CHORD (NEAR MLG SUPPORT BEAM) CRACKED 4 WS 244.5, REF N/R 0305.

Part: SPAR — CORRODED (LT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING FRONT SPAR LOWER CHORD SHOWS CORROSION WS 383.5.

Part: STIFFENER — CORRODED (LT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING FRONT SPAR STIFFENER SHOWS CORROSION, WS 224.5.

Part: FRAME — CORRODED (BS 1168) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, CARGO COMPARTMENT. FRAME SHOWS CORROSION AT STA 1168 NEAR STRINGER S16R.

Part: SKIN — CORRODED (BS 740) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, CARGO BAY UPPER INNER SKIN SHOWS CORROSION BS 740, STRINGER 1 LT.

Part: STIFFENER — CORRODED (RT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING FRONT SPAR STIFFENER SHOWS CORROSION WS 251.0.

Part: SKIN — CORRODED (NR 2 SLAT) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING NR 2 SLAT SKIN SHOWS CORROSION, WS 656.5, REF N/R 0440.

Part: SKIN — CORRODED (RT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING UPPER SKIN L/E SHOWS CORROSION L/E STA 130.7, REF NR 0183.

Part: FITTING — CORRODED (RT WING LE FLAP) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING L/E FLAP FITTING CORRODED WS 188.0, REF NR 0392.

Part: STIFFENER — CORRODED (RT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING FRONT SPAR STIFFENER SHOWS CORROSION WS 222.0.

Part: SKIN — CORRODED (LT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING LOWER SURFACE SHOWS CORROSION WS 491.5 REF NR 0249.

Part: SKIN — CORRODED (BS 1343-1376) · airframe 81 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LOWER HALF FUSELAGE. RT UPPER AFT FUSELAGE SKIN SHOWS CORROSION FROM BS 1343 TO BS 1376.

Part: SKIN — CORRODED (LT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, LT WING UPPER SKIN T/E NEAR OTBD AILERON CORRODED WBL 492.0, REF NR 0257.

Part: ANGLE — CORRODED (RT WING) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING FRONT SPAR ANGLE CORRODED WS 198.0, REF N/R.

Part: INTERCOSTAL — CORRODED (BS 920) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT MLG INTERIOR UPPER PART INTERCOSTAL SHOWS CORROSION FS 920.

Part: FITTING — CORRODED (RT WING LE FLAP) · airframe 81,127 hrs · 45,469 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING L/E FLAP FITTING CORRODED, WS 198.0, WS 224.5 REF N/R 0393.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 80,809 hrs · 45,262 cycles

SEAT TRACK AT STA 360 TO 480 LBL 45.5 CORRODED.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 80,809 hrs · 45,262 cycles

SEAT TRACK AT STA 950 TO 950C LBL 24.7 CORRODED.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 80,809 hrs · 45,262 cycles

SEAT TRACK AT STA 689 CORRODED.

Part: SPLICE — CRACKED (FUSELAGE) · airframe 80,519 hrs · 45,052 cycles

FOUND 1.5 INCH CRACK AT STA 481 BETWEEN 13R AND 14R ON THE BUTT SPLICE.

Part: FIRE DETECTOR — UNSECURE (FIRE WARNING) · airframe 78,831 hrs · 43,930 cycles

NR 1 STRUT OVERHEAT LIGHT ILLUMINATES WITH NR 1 ENGINE BLEED AIR VALVE CLOSED. MECH FOUND FIRE DETECTOR UNIT UN-SECURED. RE-RACKED AND SECURED FIRE DETECTOR UNIT, OPS CHECK GOOD.

Part: WARNING LIGHT — ILLUMINATED (NR 1 PYLON) · airframe 78,609 hrs · 43,798 cycles

NR1 STRUT OVERHEAT LIGHT ILLUMINATED AT 33,000 FT. CLOSED NR 1 POWER LEVER AND LIGHT EXTINGUISHED. MX OPENED NR 1 PYLON, PRESSURIZED PNEUMATIC SYS CHECK FOR LEAKS, NONE NOTED IAW AMM 36-00-00. PERFORMED ENGINE RUN-UP AT PART POWER AND TAKEOFF. NO DEFECT NOTED IAW AMM 71-00-00.

Part: WARNING SYSTEM — ACTIVATED (OVERHEAT SYS) · airframe 78,525 hrs · 43,742 cycles

NR 1 STRUT OVERHEAT LIGHT ILLUMINATED DURING CRUISE WITH ENGINE ANTI-ICE ON. WHEN THE ANTI-ICE WAS TURNED OFF THE LIGHT WENT OUT.

Part: WARNING LIGHT — ILLUMINATED (COCKPIT) · airframe 78,477 hrs · 43,714 cycles

LOG ITEM LEFT ENGINE STRUT OVERHEAT LIGHT ILLUMINATED. REDUCED THRUST LEVER PER PROCEDURE. LIGHT EXTINGUISHED AFTER APPROX 30 SECONDS. RETURNED TO MIA. MAINTENANCE REMOVED THE PYLON PANELS. PERFORMED LEAK CHECK. NO LEAKS NOTED. PERFORMED ENGINE RUN-UP AT HIGH POWER. RE-INSTALLED PYLON PANELS AND PERFORMED RUN-UP PER AMM.

Part: FIRE WARNING — MALFUNCTIONED (APU) · airframe 77,928 hrs · 43,128 cycles

AFTER GEAR RETRACTION RECEIVED APU FIRE WARNING. FOLLOWED AMJ PRECEDURES. MAINTENANCE ACCOMPLISHED AN APU INSPECTION. NO SIGNS OF FIRE NOTICED. OPERATIONAL AND FUNCTION CHECKS WERE PERFORMED PER THE AMM ALL OK. THE APU FIRE BOTTLE WAS REPLACED.

Part: SENSOR — OUT OF POSITION (NR 1 NACELLE) · airframe 77,169 hrs · 42,430 cycles

NR1 STRUT OVERHEAT LIGHT ILLUMINATED IN FLIGHT. SHUTDOWN NR1 ENGINE AND RETURNED TO DEPARTURE. WINDMILLING 15 MINUTES, OIL PRESSURE WITHIN LIMITS. MX FOUND NR 1 STRUT SENSING ELEMENT OUT OF POSITION. THE ELEMENT WAS REPOSITIONED AND A PNEUMATIC LEAK CHECK WAS PERFORMED. NO EXTERNAL LEAKS WERE NOTED. 3 BUSHINGS ON THE NR 1 STRUT SENSING ELEMENT WERE CONSIDERED WORN AND REPLACED AND THE NR 1 ENGINE PRECOOLER WAS REPLACED FOR AN INTERNAL LEAK. THE ACFT WAS RETURNED TO SERVICE.

Part: ACTUATOR — LEAKING (NR 7 LE SLAT)

LOST A HYDR SYS AFTER FLAP RETRACTION DEPARTING. ON APPROACH TO POS NR 7 L/E SLAT FAILED TO EXTEND. LANDING GEARS WERE EXTENDED MANUALLY, THE AC LANDED SAFELY AND WAS TOWED FROM THE RUNWAY. MAINT DISCOVERED THE NR 7 L/E ACTUATOR BODY HAD FAILED CAUSING A LOSS OF A SYS HYDR FLUID, A SYS FAILURE AND CONSEQUENT LOSS OF NOSE WHEEL STEERING. (K)

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 75,097 hrs · 41,064 cycles

FLIGHT 861 DEPARTED SJU AND DURING THE TOP OF THE CLIMB THE CREW REPORTED THE NUMBER 1 ENGINE OIL PRESSURE DROPPED TO ZERO, THE NUMBER 1 ENGINE WAS SHUTDOWN AND THE AIRCRAFT CONTINUED TO MIA AND LANDED WITHOUT INCIDENT. THE NUMBER 1 ENGINE WAS REMOVED AND REPLACED IAW AMERIJET WORKCARDS B-48, B-49, B-41. THE NUMBER 1 ENGINE WAS LEAK CHECKED AND OPERATIONALLY CHECKED GOOD, THE AIRCRAFT WAS RETURNED TO SERVICE. A FOLLOW-UP SUPPLEMENT SDR WILL BE SUBMITTED WITH THE ENGINE TEARDOWN REPORTS WHEN AVAILABLE.

Part: FUEL TANK — LEAKING (NR 2)

DURING THE MAINTENANCE WALK AROUND INSPECTION, A FUEL LEAK WAS DISCOVERED AT THE REAR SPAR OF THE NR 2 FUEL TANK (WING BOX CENTER SECTION). FURTHER INSPECTION REVELED CORROSION BEYOND LIMITS IN THE NR 2 FUEL TANK AT THE REAR SPAR. REPAIR WEB DOUBLER AND STIFFENER REPAIR OF THE NR 2 TANK REAR SPAR WAS ACCOMPLISHED ON WORK ORDER NR 16052, IAW EO SIE-727-57-395-06 AND SRM-51-10-2 AND 51-30-2. AT COMPLETION OF REPAIRS THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ENGINE — DAMAGED (NR 1)

FLIGHT 848 AFTER PUSHBACK FROM PAP, THE CREW REPORTED WHEN POWER WAS ADDED THE NUMBER ONE ENGINE EXPERIENCED A VIBRATION. THE AIRCRAFT RETURNED TO THE GATE WITHOUT ANY FURTHER INCIDENT. FURTHER INSPECTION OF THE NUMBER ONE ENGINE INLET FOUND THE C-1 BLADES HAD SUSTAINED DAMAGE. MAINTENANCE IS PREPARING THE AIRCRAFT FOR A TWO ENGINE FERRY TO MIA FOR FURTHER NUMBER ONE ENGINE INSPECTION AND REPAIR.

Part: MODULE — MALFUNCTIONED (STALL WARNING)

ON DEPARTURE, CREW REPORTED STALL WARNING STICK SHAKER CAME ON AT ROTATION. CREW DUMPED FUEL, RETURNED AND LANDED WITHOUT ANY FURTHER INCIDENT. MAINTENANCE TROUBLESHOT STALL WARNING SYSTEM. OPERATIONAL CHECK NORMAL IAW B-727 MM CH 34-18-01, UNABLE TO DUPLICATE DISCREPANCY. AS A PRECAUTION, MAINTENANCE REMOVED AND REPLACED STALL WARNING MODULE IAW B-727 MM CH 34-18-41, OPERATIONAL CHECK GOOD IAW B-727 MM CH 34-18-01. AIRCRAFT RETURNED TO SERVICE.

Part: OIL SYSTEM — LEAKING (NR 3 ENGINE)

DURING CRUISE NR 3 ENGINE OIL TEMP WAS BETWEEN 125 & 130 DEG FOR 15 MINUTES. PERFORMED ALT PROCEDURES, RETARDED THROTTLE, DIDN'T HELP. SHUTDOWN NR 3 ENGINE, ENGINE WINDMILLED FOR 45 MIN. OIL PRESSURE STAYED ABOVE 25 PSI. DIVERTED & LANDED AT SJU. MX INSPECTED NR 3 ENGINE & FOUND AN OIL LEAK COMING FROM MAIN OIL FILTER PACKING. ENGINE MAIN OIL FILTER & PACKINGS WERE REMOVED INSPECTED & REPLACED. OIL FILTER INSPECTION REVEALED NO CONTAMINATION NOTED. NR 3 ENGINE WAS RUN AT TAKEOFF POWER FOR 5 MIN, ENGINE OIL TEMP STAYED BELOW 125 DEG. ALL PERAMETERS NORMAL. NO LEAKS NOTED, ALL WORK ACCOMPLISHED IAW BOEING MM CH-71-00 PG 609 & 71-00 PG 212A & AMERIJET ENGINE RUN FORM B-41. AIRCRAFT RETURNED TO SERVICE.

Part: COVER — LEAKING (FILTER)

DURING CLIMB CREW REPORTED LOSS OF HYDRAULIC (A) SYSTEM. AIRCRAFT WAS DIVERTED AND LANDED WITH NO FURTHER INCIDENT. MAINTENANCE FOUND FEEL COMPUTER FILTER COVER LEAKING HYDRAULIC FLUID. REMOVED AND REPLACED FEEL COMPUTER FILTER CAP AND O-RING IAW MM CH 20-10-11, SERVICED HYDRAULIC SYSTEM IAW MM CH 12-12-0, NO LEAKS NOTED. REMOVED A & B CASE DRAIN FILTERS, INSPECTED FOR CONTAMINATION AND REPLACED FILTERS IAW MM. NO CONTAMINATION NOTED. CYCLED FLAPS AND FLIGHT CONTROLS, PRESSURIZED HYDRAULIC SYSTEM AND LEAKED CHECK GOOD, AND RECHECKED HYDRAULIC QTY. HYDRAULIC SYSTEM PRESSURE CHECKED AND LEAK CHECK NORMAL IAW MM CH-29-11-41 AND 29-12-21. AIRCRAFT RETURNED TO SERVICE.

Part: FRAME — CORRODED (FUSELAGE)

RT MAIN GEAR WHEEL WELL, STA 950 WL 201, FORGING FRAME, HORIZONTAL FLANGE, LOWER SURFACES CORRODED.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN, BS 1110, FLOORBEAM, LOWER CHORD CORRODED.

Part: SKIN — CORRODED (LT WING)

LT WING, LOWER SKIN, LOWER SURFACE, ACCESS DOOR CUTOUT CORRODED. (K)

Part: FRAME — CORRODED (FUSELAGE)

RT MAIN GEAR WHEEL WELL, STA 940 WL 201, FORGING FRAME, VERTICAL FLANGE, NBOARD SURFACES CORRODED.

Part: CONTROLLER — MALFUNCTIONED (CABIN PRESSURE)

CREW REPORTED, UNABLE TO PRESSURIZE AIRPLANE AFTER TAKEOFF. FLIGHT CREW RETURNED AIRCRAFT TO TJSJ AND LANDED WITHOUT FURTHER INCIDENT. A GROUND PRESSURIZATION CHECK WAS PERFORMED, NO DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: FIRE DETECTOR — FALSE ACTIVATION (CARGO BAY)

CAPTAIN REPORTED DURING CLIMB OUT, FIRE INDICATION IN AFT CARGO ILLUMINATED. CREW NOTED THE INDICATION OCCURRED AFTER SELECTING ON THE WING ANTI-ICING. AIRCRAFT RETURNED BACK WITHOUT FURTHER INCIDENT. MAINTENANCE CLEANED AFT CARGO COMPARTMENT PNEUMATIC DUCTS AND DETECTION LOOPS EXTERNALLY OF DINATROL RESIDUE. PERFORMED ENGINE RUNS AT BLAST FENCE AND CHECKED SYSTEM IAW MM. OPS CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: CLAMP — FAILED (NR 1 STRUT)

CREW REPORTED NR 1 STRUT OVERHEAT LIGHT ILLUMINATED PASSING FL220. AIRCRAFT RETURNED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED CLAMP AT STARTER DUCT CONNECTION NEAR 13TH STAGE BLEED VALVE, OPERATED ENGINE AT HEIGHT POWER FOR 15 MINUTES. OPS CHECK GOOD IAW MM. AIRCRAFT RETURNED TO SERVICE.

Part: SKIN — CORRODED (WING)

WING CENTER SECTION UPPER SKIN CORRODED. LOCATION BS 783.95, RBL 63.0, BTWN S-14 AND S-16.

Part: STRINGER — CRACKED (FUSELAGE)

AFT CARGO COMPARTMENT, STRINGER 30 CRACKED AT BS 950.

Part: SKIN — CORRODED (FUSELAGE)

SECTION 43-STA720E+11/STA720D+3, S26R AND ST720E+5.25 S26L. INTERNAL FUSELAGE SKIN CORRODED.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 950C FLOORBEAM UPPER CHORD CORRODED, BETWEEN RBL 62 IN AND LBL 62 IN.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 380 FLOORBEAM UPPER CHORD CORRODED, BETWEEN RBL 62 IN AND LBL 62 IN, WL 208.

Part: SKIN — CORRODED (RT WING)

RT WING, LOWER SURFACE AT WS 320, STRINGER 8 SKIN CORRODED.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 1130 FLOOR BEAM LOWER CHORD CORRODED, BETWEEN RBL 45 INCHES AND LBL 45 INCHES.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 720A FLOOR BEAM UPPER CHORD CORRODED, BETWEEN RBL 60 INCHES AND LBL 60 INCHES, WL 208.

Part: SKIN — CORRODED (FUSELAGE)

LOWER FUSELAGE, SKIN CORRODED BETWEEN BS 117B TO BS 1183 BETWEEN STR 25L AND STR 26L.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 1110 FLOORBEAM UPPER CHORD CORRODED, BETWEEN RBL 61 IN AND LBL 61 INCHES, WL 208.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 720D FLOORBEAM UPPER CHORD CORRODED, BETWEEN 45 IN AND LBL 60 IN, WL 208.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 1030 FLOORBEAM UPPER CHORD CORRODED, BETWEEN RBL 62IN AND LBL 62 IN, WL 208.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 1070, FLOORBEAM UPPER AND LOWER CHORD CORRODED, BETWEEN RBL 61 IN AND LBL 61 IN, WL 208.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN, BS 950F, FLOORBEAM UPPER CHORD CORRODED, BETWEEN RBL 62 IN AND LBL 62 IN, WL 208.

Part: PS4 LINE — BROKEN (NR 2 ENGINE)

AFTER TAKEOFF DURING CLIMB NR 2 ENGINE FLAMED OUT, ENGINE RESTARTED BUT WOULD NOT ACCELERATE FROM IDLE. AIRCRAFT RETURNED TO DEPARTURE AIRPORT. AFTER TROUBLESHOOTING, FOUND PS4 LINE ON TOP OF ENGINE BROKEN. REPLACED LINE, OPS CHECK OK.