N456AA

Part: RIB — CRACKED (RT WING) · airframe 74,865 hrs · 40,112 cycles

RIGHT HAND NR 4 SLAT INBD SUPPORT RIB CRACKED. INSTALLED REPAIR DOUBLER IAW EA MD80-57-033891.

Part: RIB — CRACKED (LT WING) · airframe 74,865 hrs · 40,112 cycles

LEFT HAND NR 4 SLAT TRACK LE INBD SUPPORT RIB CRACKED. INSTALLED DOUBLER IAW EA MD80-57-033891.

Part: SLIDE — UNSERVICEABLE (R1 DOOR) · airframe 74,689 hrs · 40,011 cycles

RT NR 1 DOOR EVACUATION SLIDE FOUND UNPACKED WITH RELEASE PINS PULLED-OUT. REPLACED RT NR 1 DOOR SLIDE, OPERATIONS CHECKED NORMAL.

Part: TRIM MOTOR — INOPERATIVE (HORIZ STAB) · airframe 74,621 hrs · 39,974 cycles

DFW REPEAT ITEM, CREW REPORTED STABILIZER TRIM LIGHT ILLUMINATED. EMERGENCY DECLARED FLIGHT RETURNED DFW LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED ALTERNATE AUTOPILOT STAB TRIM MOTOR & RECTIFIER. SYS GND CHECKED NORMAL OPERATION CLOSED.

Part: TRIM MOTOR — INOPERATIVE (HORIZ STAB) · airframe 74,621 hrs · 39,974 cycles

DFW CREW REPORTED AIRCRAFT LOST PRIMARY STAB TRIM IN FLIGHT. EMERGENCY DECLARED FLIGHT RETURNED DFW. AIRCRAFT REMOVED FROM SERVICE. REPLACED HORIZONTAL STABILIZER PRIMARY TRIM MOTOR. SYSTEM GND CHECKED NORMAL OPERATION CLOSED.

Part: PORTABLE LIGHT — FAILED (CABIN) · airframe 74,118 hrs · 39,681 cycles

LT NR 1 DOOR PORTABLE EMERGENCY LIGHT FAILED. REPLACED PORTABLE LIGHT ASSEMBLY. OPERATIONS CHECKED NORMAL.

Part: CONTROLLER — INOPERATIVE (CABIN PRESSURE) · airframe 71,938 hrs · 38,441 cycles

ORD - INFLIGHT MKE-DFW. CREW REPORTED DIFFICULTY CONTROLLING CABIN PRESSURE AFTER TAKEOFF. CREW STATED THEY WERE IN MANUAL AND DID NOT EXPERIENCE ANY PACK PROBLEMS AND FLOW LIGHT WAS NOT ILLUMINATED. EMERGENCY DECLARED FLIGHT DIVERTED ORD LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED NUMBER TWO PRESSURE CONTROLLER. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 71,290 hrs · 38,078 cycles

CEILING EMERGENCY LIGHT AT SEAT 4B INOPERATIVE. REPLACED LAMP FOR CEILING EMERGENCY LIGHT AT SEAT 4B. OPS CHECK NORMAL.

Part: BATTERY — NOT SEATED (CATWALK) · airframe 71,290 hrs · 38,078 cycles

TAIL COMPARTMENT EMERGENCY LIGHTS ABOVE CATWALK ARE INOPERATIVE. RESEATED BATTERIES IN PACK FOR EMERGENCY LIGHTS IN CATWALK. OPS CHECK NORMAL.

Part: WEDGE — DENTED (TE FLAP) · airframe 70,744 hrs · 37,755 cycles

RIGHT WING TRAILING EDGE: DENT IN BOTTOM SIDE OF INBOARD FLAP, 9 INCHES FROM INBOARD END. INSTALLED PERMANENT FLUSH DOUBLER REPAIR PER SRM 57-01-00 FIGURE 5 SHEET 2.

Part: CONTROL BOX — FAILED (LANDING GEAR) · airframe 70,517 hrs · 37,587 cycles

SAT - (REPEAT ITEM) CREW REPORTED UPON GEAR RETRACTION, RIGHT MAIN LANDING GEAR RED LIGHT INDICATION REMAINED ILLUMINATED. EMERGENCY DECLARED FLIGHT RETURNED SAT LANDED WITHOUT INCIDENT. REPLACED PROXIMITY SWITCH CONTROL BOX AND CHECKED TARGET GAP. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: PROXIMITY SENSOR — INOPERATIVE (RT MLG) · airframe 70,517 hrs · 37,586 cycles

SAT - CREW REPORTED ON DESCENT LANDING GEAR DOOR WARNING LIGHT ILLUMINATED. LANDING GEAR DOORS WERE EXTENDED MANUALLY. EMERGENCY DECLARED FLIGHT LANDED SAT WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED GEAR UP AND DOOR LATCH PROXIMITY SENSOR AND RIGHT MAIN GEAR DOOR OPEN PROXIMITY SENSOR. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 70,164 hrs · 37,381 cycles

LONGERON 23 LEFT CRACKED AT STATION 200. REPLACED SECTION OF LONGERON 23 LEFT PER SRM 53-02-00.

Part: CONTROLLER — INOPERATIVE (CABIN PRESSURE) · airframe 69,304 hrs · 36,862 cycles

MTY - CREW REPORTED UNABLE TO PRESSURIZE AIRCRAFT. EMERGENCY DECLARED FLIGHT RETURNED MTY LANDED WITHOUT INCIDENT. BOTH CABIN AUTO PRESSURE CONTROLLERS PLACARD PER MEL 21-32-03-2. FLIGHT CONTINUED TO DESTINATION. REPLACED BOTH CABIN CONTROLLERS AT DFW ON 02/09/2012. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 67,181 hrs · 35,443 cycles

CRACK IN LONGERON 4 LEFT AT STATION 200. INSTALLED NUMBER 4 LONGERON FROM STATIONS 172 TO 227 LEFT PER SRM 53-02-00.

Part: MEMBRANE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,181 hrs · 35,443 cycles

CORROSION ON SUBFLOOR INBOARD OF FORWARD SERVICE DOOR STATIONS 160 TO 200. INSTALLED SUBFLOOR DOUBLER INBOARD OF FORWARD SERVICE DOOR STATIONS 160 TO 200 PER AARD 53-20-00-16.

Part: PAN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,181 hrs · 35,443 cycles

CORROSION ON SUB-FLOOR UNDER G1 GALLEY DRAIN PAN. INSTALLED DOUBLER UNDER G1 GALLEY DRAIN PAN PER AARD 53-20-00-16.

Part: CARGO TRACK — CORRODED (CARGO BAY) · corrosion level 2 · airframe 67,181 hrs · 35,443 cycles

CORROSION ON TIE-DOWN TRACK, STATIONS 1174 TO 1212 LEFT SIDE. INSTALLED NEW LEFT TIE DOWN TRACK FROM STATIONS 1007 TO 1217 PER AARD 51-10-00-5, IPC 25-52-00-03L AND SRM 51-30-01.

Part: SKIN — DAMAGED (CARGO DOOR) · airframe 67,181 hrs · 35,443 cycles

FORWARD CARGO DOOR HAS PREVIOUS STATIC BURN ON OUTER SKIN ON UPPER CORNER 7 INCHES DOWN AND 4 INCHES AFT. INSTALLED INTERNAL DOUBLER PER SRM 53-04-02.

Part: STRAP — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,181 hrs · 35,443 cycles

CORROSION ON WEB STATION 1193 LONGERONS 28 TO 29 RIGHT. INSTALLED SERVICEABLE STRAP PER AARD 51-10-00-5.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,181 hrs · 35,443 cycles

CORROSION ON BOTTOM OF CUSP ON TOP OF FLOORBEAM AT STATION 655 ABOVE MID CARGO DOOR. INSTALLED NEW CUSP SHEET RIGHT SIDE STATIONS 598 TO 712 PER AARD 53-20-00-16.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 67,181 hrs · 35,443 cycles

CRACK IN CUSP STATION 326. INSTALLED REPAIR DOUBLER IN ACCORDANCE WITH AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,181 hrs · 35,443 cycles

CORROSION UNDER LEFT CUSP STATIONS 585 TO 595. INSTALLED REPAIR DOUBLER PER AARD 53-20-00-16.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 67,181 hrs · 35,443 cycles

CRACK IN ANGLE, CENTER OF PRESSURE BULKHEAD, ABOVE AFT ENTRY DOOR CUTOUT AT STATION 1338. INSTALLED REPAIR DOUBLER PER AARD 53-10-00-15.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 67,181 hrs · 35,443 cycles

FORWARD ENTRY DOOR JAMB WEB AT STATION 208 LONGERON 15 LEFT IS CRACKED. INSTALLED REPAIR STRAP PER AARD53-10-00-11.

Part: PAN — CRACKED (WINDOW) · airframe 67,181 hrs · 35,443 cycles

WINDOW PAN CRACKED UPPER FORWARD CORNER STATION 886 LEFT SIDE. INSTALLED REPAIR DOUBLER IN ACCORDANCE WITH AARD 53-10-00-25.

Part: PAN — CRACKED (WINDOW) · airframe 67,181 hrs · 35,443 cycles

CRACK IN WINDOW PAN UPPER AFT CORNER STATION 1060 RIGHT SIDE. INSTALLED REPAIR DOUBLER PER AARD 53-10-00-25.

Part: GENERATOR — FAILED (RT ENGINE) · airframe 66,730 hrs · 35,197 cycles

IAD - INFLIGHT LGA-DFW. CREW REPORTED RIGHT ENGINE GENERATOR FAILED AND AC CROSSTIE LOCKOUT LIGHT ILLUMINATED. UNABLE TO START APU UNTIL DESCENT TO LOWER ALTITUDE. ABLE TO POWER RIGHT BUS AFTER APU WAS RUNNING. EMERGENCY DECLARED FLIGHT DIVERTED IAD LANDED WITHOUT INCIDENT. DEFERRED RIGHT ENGINE GEN INOP PER MEL 24-1A AUTH 2-581DC-B. REPLACED RIGHT ENGINE GENERATOR AT DFW ON 02/08/2011. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: SLAT — DAMAGED (LT WING) · airframe 66,013 hrs · 34,810 cycles

MFE - CREW REPORTED BIRD STRIKE TO LEFT WING ROOT, ENGINE VIBRATION EGT SEEMED NORMAL. REDUCED VIBRATION WITH REDUCED THRUST. EMERGENCY DECLARED RETURNED MFE LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. ACCOMPLISHED BIRD STRIKE INSPECTION. FOUND DENT IN LEFT WING ROOT SLAT. AIRCRAFT FERRIED TO DFW FOR SLAT CHANGE. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: TUBE — BLOWN (NR 1 ENGINE) · airframe 65,884 hrs · 34,744 cycles

AUS - CREW REPORTED ABOUT 4 MINUTES AFTER TAKEOFF THE FIRE DETECTOR LOOP AND THE B-LOOP LIGHT ON THE LEFT ENGINE ILLUMINATED. EMERGENCY DECLARED RETURNED AUS LANDED WITHOUT INCIDENT. DURING APPROACH BACK TO THE AIRPORT THE LIGHT ON THE FIRE HANDLE EXTINGUISHED AND THE LOOP LIGHTS ALSO WENT OUT. AIRCRAFT REMOVED FROM SERVICE. REPLACED ANTI-ICE TUBE ON LEFT ENGINE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: TRIPLER — CRACKED (FUSELAGE) · airframe 63,739 hrs · 33,580 cycles

AFT FUSELAGE FRAME 1463 TRIPLER CRACKED AT LONGERON 18 LEFT. REMOVED CRACKED TRIPLER AND INSTALLED NEW REPAIR DOUBLER AND TRIPLER.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 63,113 hrs · 33,227 cycles

FOUND GALLEY/COCKPIT AND FORWARD AISLE WHITE EMERGENCY LIGHTING INOPERATIVE DURING FUNCTIONAL CHECK. REPLACED BATTERY POWER SUPPLY IN FORWARD AISLE OF AIRCRAFT.

Part: SHROUD — BROKEN (CABIN) · airframe 62,873 hrs

MSP - EMERGENCY LIGHT SHROUD AT SEAT 24D BROKEN. REPLACED EMERGENCY LIGHT SHROUD AT SEAT 24D.

Part: SHROUD — BROKEN (CABIN) · airframe 62,873 hrs

MSP - EMERGENCY LIGHT SHROUD AT SEAT 32D BROKEN. REPLACED EMERGENCY LIGHT SHROUD AT SEAT 32D.

Part: STRUT — INOPERATIVE (NLG)

ORD INFLIGHT T1659/16DEC - NOSE LANDING GEAR DID NOT RETRACT AFTER TAKEOFF. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. FOUND STRUT FLAT. REPACKED NOSE LANDING GEAR STRUT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LIGHT — INOPERATIVE (CABIN)

SFO EMERGENCY LIGHT AT SEAT 6E INOPERATIVE. RELAMPED EMERGENCY LIGHT AT SEAT 6E. SYSTEM GROUND CHECKED NORMAL OPERATION. (CLOSED)

Part: HEAT EXCHANGER — INOPERATIVE (AIR CONDITIONING)

ORD INFLIGHT T366/25JAN - REPORTED FUMES IN COCKPIT AND FLIGHT ATTENDANTS REPORTED BLUISH GREY SMOKE COMING OUT OF VENTS. HIGH TEMPERATURE PACK LIGHT ILLUMINATED. SMOKE SUBSIDED WHEN PACK TURNED OFF. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. REPLACED RIGHT MOTOR PRIMARY AND SECONDARY HEAT EXCHANGER. ACCOMPLISHED PACK SYSTEM BURN OUT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: STARTER — LEAKING (APU)

ORD INFLIGHT, SMOKE AND FUMES REPORTED AFTER TAKEOFF. ENGINE ANTI ICE ON PACKS MEDIUM SETTING. SMOKE DISSIPATED WITH REDUCTION IN POWER AND TEMPERATURE CONTROLLERS SET TO FULL COLD. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. REPLACED AUXILIARY POWER UNIT DUE TO OIL LEAK AT MATING SURFACE OF STARTER. PERFORMED PACK BURN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: ACM — LEAKING

ORD INFLIGHT T1392/16JAN - DURING CLIMB SMOKE AND FUMES IN CABIN COMING FROM AIR CONDITIONING SYSTEM. TURNED OFF PACKS AND RECIRCULATION SWITCH AND BREAKERS. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. FOUND LEFT PACK AIR CYCLE MACHINE LEAKING OIL. REPLACED AIR CYCLE MACHINE FOR LEFT PACK. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: ENGINE — MAKING METAL (RIGHT)

BOS - INFLIGHT JUST AFTER ROTATION A STRANGE RUBBING NOISE WAS HEARD FROM THE COCKPIT FOLLOWED BY A THUMP. A STRONG VIBRATION WAS FELT IN THE REAR OF THE AIRCRAFT. RETURNED TO BOS AND LANDED WITHOUT INCIDENT. FOUND METAL IN OIL FILTER. REPLACED RIGHT ENGINE. FLIGHT DATA RECORDER DOWNLOAD REQUESTED FROM ENGINEERING.

Part: SOCKET — DEFECTIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHT INOPERATIVE AT SEAT 22D. REPLACED LIGHT SOCKET. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONNECTOR — INOPERATIVE (EMERGENCY LIGHT)

DURING OVERNIGHT MAINTENANCE, FORWARD TAIL CONE EMERGENCY EXIT LIGHTS INOPERATIVE. SECURED EMERGENCY EXIT LIGHT CONNECTOR AT BATTERY. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: SWITCH — OUT OF ADJUST (NLG)

ORD - FLT 2034 - EN ROUTE ORD-BOS - AFTER TAKEOFF, LANDING GEAR FAILED TO RETRACT. THEN THE CABIN PRESSURE DUMPED, RECEIVED STALL INDICATION FAILURE AND AUTO SPOILER DO NOT USE LIGHTS ON. RETURNED TO ORD WITHOUT FURTHER INCIDENT. FOUND NOSE GEAR OLEO SWITCHES OUT OF ADJUSTMENT. ADJUSTED SWITCH CABLE AND CABLE TENSION. ACCOMPLISHED LANDING GEAR FUNCTIONAL CHECKS. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: BATTERY — INOPERATIVE (CABIN)

DURING OVERNIGHT MAINTENANCE, EMERGENCY LIGHTS IN AFT ACCESSORY COMPARTMENT INOPERATIVE. RESEATED EMEGENCY EXIT LIGHT BATTERY. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: PUMP — FAILED (FUEL BOOST)

DFW - FLT 1023 - EN ROUTE DFW-BUR - PASSING 7,000 FEET ON CLIMB NOTICED CENTER TANK NOT FEEDING. FOUND FORWARD CENTER FUEL TANK CIRCUIT BREAKER POPPED. RETURNED TO DFW AND LANDED WITHOUT INCIDENT. CIRCUIT BREAKERS WERE CHECK ON PREFLIGHT AND WERE IN BOTH CAPTAIN AND FIRST OFFICER. CHECKED CENTER PUMPS ON PREFLIGHT AND THE CHECK WAS NORMAL. REPLACED BOTH CENTER AFT AND FORWARD FUEL BOOST PUMPS. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: LONGERON — CRACKED (FUSELAGE)

TUL - FOUND LONGERON NR 2 RIGHT CRACKED AT FLANGE OF FRAME, AFT SIDE OF FRAME, STATION 1418. INSTALLED NEW SECTION OF LONGERON NR 2 RIGHT SIDE, STATION 1418 PER AARD 53-30-00-02. (M)

Part: FRAME — CRACKED (FUSELAGE)

TUL - FOUND CRACK IN CANT FRAME, FS 1474. INSTALLED DOBLER PER ESO 80559 DATED 12-27-02. (M)

Part: WEB — CORRODED (FUSELAGE)

TUL - FOUND CORROSION ON TOP SURFACE. INSTALLED NEW WEB/SUPPORT STATION 1211 L29R TO L28L. (M)

Part: BEAM — CORRODED (FUSELAGE)

TUL - FOUND CORROSION ON VERTICAL AND HORIZONTAL LEGS, AREA HAD PREVIOUS DOUBLER INSTALLED. REMOVED AND REPLACED WITH NEW BEAM AND REINSTALLED ATTACHING PARTS IAW AARD 53-10-00-3 AND SRM 51-30-5 SHT 2 AND 51-30-2 FIG PAR 3. (M)

Part: SKIN — DENTED (FUSELAGE)

TUL - FOUND DENT AND CREASE IN FUSELAGE SKIN AT STATION 21, L18 TO L19 LEFT. COLD WORKED DENT AND DYE CHECKED. NO CRACKS FOUND. INSTALLED .063 INCH 7075-T6 ALUMINUM EXT DOUBLER PER AARD 53-30 PAGE 1 REF 53-04 FIG 38 AND FIG 12B. (M)

Part: SKIN — CRACKED (FUSELAGE)

TUL - FOUND FUSELAGE SKIN HAS TWO SMALL CRACKS, APPROX .050 INCH LONG EACH, AT RIVET THROUGH SKIN AND SHEAR TIE ABOVE LONGERON 14R AT STATION 1380. INSTALLED DOUBLER PER SRM 53-01-00. (M)

Part: WEB — CORRODED (FUSELAGE)

TUL - FOUND CORROSION ON CUSP BETWEEN STATION 700-712 RIGHT SIDE. INSTALLED DOUBLER PER AARD 53-00-00-02. (M)

Part: WEB — CRACKED (FUSELAGE)

TUL - FOUND CUSP CRACKED AT FASTENER HOLE STATION 712 RIGHT. INSTALLED DOUBLER PRE AARD 53-00-00-02. (M)

Part: WEB — CRACKED (FUSELAGE)

TUL - FOUND CUSP CRACKED OUTBOARD OF SEAT TRACK NR 1, FORWARD OF STATION 1309, APPROX 6 INCHES. CORROSION ON CUSP BETWEEN SEAT TRACK NR 1 AND NR 2 JUST FORWARD OF STATION 1309. OLD CUSP, REMOVED AND REPLACED WITH NEW CUSP MATERIAL, STAITON 1250-1309. (M)

Part: WEB — CRACKED (FUSELAGE)

TUL - FOUND CUSP CRACKED OUTBOARD OF NR 5 SEAT TRACK, FS 218-219. INSTALLED DOUBLER PER AARD 53-00-002. (M)

Part: CHANNEL — CORRODED (FUSELAGE)

TUL - FOUND FLOORBOARD SUPPORT CHANNEL BETWEEN NR 2 AND NR 3 SEAT TRACK AT STATION 254 CORRODED. REPLACED SUPPORT CHANNEL WITH NEW CHANNEL PER SRM 51-00-00. (M)

Part: FRAME — CRACKED (FUSELAGE)

TUL - FOUND FRAME CRACKED AT STATION 1174 LONGERON 6L IN VERTICAL LEG. INSTALLED DOUBLER PER AARD 53-10-00-30. (M)

Part: LONGERON — CRACKED (FUSELAGE)

TUL - FOUND LONGERON NR 2 LEFT SIDE CRACKED AT ATTACH RADIUS. INSTALLED LONGERON SPLICE AT STATION 148-172 PER SRM 53-02-00, FIG 18. (M)

Part: SEAT TRACK — CORRODED (FUSELAGE)

TUL - FOUND CORROSION ON NR 1 SEAT TRACK AT STATION 672. INSTALLED SEAT TRACK PLUG PER SRM 53-05. (M)

Part: FRAME — WORN (FUSELAGE)

TUL - FOUND LANDING WORN, RIGHT SIDE, ALONG FRAME 1380 FOR ARM DOOR. INSTALLED A DOUBLER PER AARD 53-10-00-34 PAGE 1 TO REPAIR A WEAR AREA WORN LESS THAN 50 PERCENT IN DEPTH. (M)

Part: SEAT TRACK — CORRODED (FUSELAGE)

TUL - FOUND CORROSION INSIDE SEAT TRACK NR 1, BEYOND MANUAL LIMITS, TRACK EAR TOO THIN. INSTALLED PLUGPER AARD 53-20-00-10, REPAIR NR 10. (M)

Part: COALESCER BAG — DIRTY (A/C BAY)

SAN - FLT 418 - EN ROUTE SAN-DFW, HEAVY SMOKE IN THE CABIN. DECLARED EMERGENCY AND RETURNED TO SAN WITHOUT INCIDENT. ACCOMPLISHED MAINTENANCE CHECK MANUAL CARD 21-96-01 AND FOUND NO DISCREPANCIES. ACCOMPLISHED PACK BURN OUT PER MM 21-20-02-2 AND REPLACED COALESCER BAGS. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: BATTERY — DISCHARGED (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHTS AT SEAT 19 INOPERATIVE. REPLACED EMERGENCY EXIT LIGHTS BATTERY. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — LOOSE (AIRSTAIRS)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHT AT AFT AIRSTAIRS INOPERATIVE. RE-SECURED EMERGENCY EXIT LIGHT WIRE AT CONNECTOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — DAMAGED (TAILCONE)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHT AT TAILCONE DIM. REPAIRED EMERGENCY EXIT LIGHT WIRE AT TAILCONE. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: INDICATOR — MALFUNCTIONED (COCKPIT)

SDF - FLT 0899 - DURING FLIGHT FROM BJF/DFW, CREW REPORTED LEFT FUEL USED INDICATION HIGH AND ERRATIC. ENGINE SHUT DOWN AS PRECAUTION AND CREW DECLARED EMERGENCY. DIVERTED AND LANDED SDF WITHOUT INCIDENT. REPLACED FUEL FLOW INDICATOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (X)

Part: WIRE — CHAFED (CABIN)

DFW - DURING MAINTENANCE CHECK, EMERGENCY EXIT FLOOR PATH LIGHTS IN FRONT HALF OF COACH CABIN WERE INOPERATIVE. REPAIRED EMERGENCY FLOOR PATH LIGHTING WIRE IN COACH CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — DEFECTIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, FORWARD CABIN EMERGENCY EXIT FLOOR PATH LIGHTING INOPERATIVE. REPLACED EMERGENCY EXIT FLOOR PATH LIGHT STRIP JUMPER WIRE IN FORWARD CABIN. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)