N463FE

Part: WINDOW — CRACKED (COCKPIT) · airframe 41,140 hrs · 28,891 cycles

L-1 WINDOW CRACKED AND ARCED AT FL 210 DURRING CLIMB OUT. NO WEATHER AS AN ISSUE. SMOOTH AIR AND CLEAR SKIES. 3-4 CRACKS ALL ON OUTER PANE. REMOVED AND REPLACED L-1 WINDOW IAW AMM 56-11-011-4. WINDOW HEAT TEST CHECKED NORMAL IAW 30-41-033-4 RII 236332 R/C AIRCRAFT OK FOR SERVICE.

Part: FRAME — CORRODED (ZONE 100) · corrosion level 2 · airframe 40,486 hrs · 28,316 cycles

NO. 2 CARGO DOOR AFT FRAME, STA 990, BETWEEN STR 24R & 25R, EXFOLIATION ON FRAME ABOVE DOOR FITTING. FABRICATED ANGLE REPAIR FROM 15-5 PH .080 PO 290342002 DIM: 18 1/4" X 3 1/2", FABRICATED REPAIR FILLER FROM BAC 1505-10046 PO 2901682 DIM: 3 1/8" X 1 1/8 & INSTALLED ANGLE PARTS AT C2 DOOR AFT FRAME BS 990 IAW FX EA 7-5310-126837.

Part: STIFFENER — CRACKED (ZONE 600) · airframe 40,486 hrs · 28,316 cycles

NR 7 SLAT ACT. ATTACH BRACKET I/B SIDE, INSIDE PLATE IS CRACKED. OPENED PANELS 7613, 7614, 7615 IAW MM 28-11-021-4 AND REMOVED STIFFNER AND PLATE ON NR 7 SLAT ACTUATOR IAW SRM 51-30-2. LOCATED AND DRILLED NEW STIFFNER PART 65-17240-24 IAW SRM 51-30-5 AND EA 7-5750-126841 AND FABRICATED STEEL DOUBLER FROM 301 1/2 HD .100 IAW EA 7-5750-126841, CAD PLATED DOUBLER IAW SRM 51-10-2, INSTALLED PARTS IAW EA 7-5750-126841. CLOSED PANELS 7613, 7614, AND 7615 IAW MM 28-11-021-4.

Part: SKIN — DAMAGED (ZONE 100) · airframe 40,486 hrs · 28,316 cycles

FUSELAGE OUTER SKIN HAS SCRATCHES AT STA 660 TO ST 700, STR 28L TO STR 28R. FABRICATED NEW REPAIR DOUBLER IAW SRM 53-30-2 FIG 2 SRM 53-30-3 FIG 1 CUT OUT DAMAGE AREA IAW SRM 53-30--2 FIG 2 SRM 53-30-3 FIG 1 INSTALLED REPAIR DOUBLER IAW SRM 53-30-3 FIG 1 53-30-2 FIG 2 SRM 51-30-2.

Part: DOUBLER — CRACKED (ZONE 500) · airframe 40,486 hrs · 28,316 cycles

LT MLG WING DOOR SKIN IS CRACKED FWD OF AFT HINGE AREA ABOVE SEAL RETAINER REMOVED DOUBLER AND FILLER IAW SRM 51-30-2 AND INNER PANEL IAW SRM 51-30-2 FABRICATED DOUBLER AND FILLER FROM 2024 T3 .050" PO NR 9008729 DIM 14.5" X 8" FOR DOUBLER AND 11" X 5.5" FOR FILLER IAW DWG 65C27128 ALODINED AND PRIMED PARTS IAW SRM 51-10-2. INSTALLED DOUBLER AND FILLER IAW DWG 65C27128. CLOSED INNER PANEL IAW SRM 51-30-2.

Part: KEELBEAM — CRACKED (BS 870) · airframe 40,486 hrs · 28,316 cycles

RT W/W KEEL BEAM CHORD ON RT SIDE IS CRACKED AT BS 870 RBL 6. REMOVED AND DISCARDED GUSSET PLATE AND REMOVED FASTENERS ON CHORD IAW EA 7-5310-126839 HFEC SHOWS HOLES ARE FREE OF CRACKS IAW NDTM 51-00- 00 FIG 23 PART 6 TRIMMED OUT DAMAGED CHORD AREA DIM 2 1/2" X 1" FABRICATED REPAIR DOUBLER, LOCATED AND DRILLED DOUBLER IAW EA 7-5310-126839 CADMIUM PLATED DOUBLER IAW 20-40-2 AND 20-24-05 ALODINED AND PRIMED CHORD AREA AND DOUBLER IAW B72751-10-2 INSTALLED DOUBLER REPAIR IAW EA 7-5310-126839

Part: ANGLE — CRACKED (NR 2 SLAT) · airframe 40,486 hrs · 28,316 cycles

NR 2 SLAT AFT LWR CHORD ANGLE PREVIOUS REPAIR IS CRACKED BELOW T-DUCT. REMOVED INNER ACCESS PANEL AT NR 2 SLAT IAW SRM 51-30-2. REMOVED CHORD ANGLE AT NR 2 SLAT IAW SRM 51-30-2. FABRICATED NR 2 SLAT AFT LWR CHORD ANGLE USING BAC 1514-1559 2024 T3511, PO NR 29057167, DIM 114" IAW SRM 57-50-2 FIG 2. TREATED AND PRIMED IAW SRM 51-10-2. INSTALLED NEW CHORD ANGLE IAW SRM 51-30-2 AND 57-50-2 FIG 2. CLOSED INNER ACCESS PANELS AT NR 2 SLAT IAW SRM 51-30-2.

Part: ANGLE — CRACKED (LT WING TE FLAP) · airframe 40,486 hrs · 28,316 cycles

RT WING INBD MID-FLAP, LOWER CHORD ANGLE IS CRACKED BELOW INBD MECHANISM, WBL 90. OPENED INBD MIDFLAP INNER PANEL IAW SRM 51-30-2. CUT OUT DAMAGED SECTION DIM 47" IAW SRM 51-10-1 AND 51-40-4 FABRICATED CHORD SECTION FROM BAC1503-100046, PO NR 9008728 DIM 47" AND SPLICE FROM BAC1503-100046 7075 T6 PO NR 9008728 DIM 8.5" IAW SRM 57-10-2 FIG 5 AND 51-40-4. ALODINED AND PRIMED PARTS IAW SRM 51-10-2. INSTALLED REPAIR PARTS IAW SRM 51-40-4 CLOSED PANEL IAW SRM 51-30-2.

Part: ANGLE — CRACKED (BS 870) · airframe 40,486 hrs · 28,316 cycles

RT WHEEL WELL VERTICAL ANGLE AT BS 870 IS CRACKED AT RBL 8. REMOVED VERTICAL ANGLE AT RT W/W BS 870 IAW SRM 51-30-2. FABRICATED NEW ANGLE IAW SRM 53-10-2 FIG 4, 51-30-5, 51-20-01 REMOVED KEELBEAM PANELS IAW SRM 51-30-2 ALODINED AND PRIMED ANGLE IAW SRM 51-10-2 INSTALLED ANGLE IAW SRM 51-30-2.

Part: STRUCTURE — CRACKED (LT WING TE FLAP) · airframe 40,486 hrs · 28,316 cycles

LT IB MIDFLAP LWR AFT CHORD IS CRACKED 4 PL. ON IB CARRIAGE TRACK CUT OUT AND IB ACT ROD CUT OUT. REMOVED INNER SKIN AND TEARDROP FAIRING IAW SRM 51-30-2. REMOVED PREVIOUS REPAIR SECTION DIM 48" IAW SRM 51-30-2, FABRICATED NEW ANGLE FROM BAC 1503 - 100046 PO NR 9008728 DIM 48" IAW SRM 57-50-2 AND 51-40-4 ALODINED AND PRIMED CHORD IAW SRM 51-10-2. INSTALLED NEW ANGLE IAW SRM 51-30-2 AND 51-40-4 CLOSED INNER SKIN PANEL AND INSTALLED TEARDROP FAIRING IAW SRM 51-30-2.

Part: FRAME — CRACKED (BS 540) · airframe 40,486 hrs · 28,316 cycles

FWD CARGO AREA, BS 540, STR 21L - 22L, CRACK ON STUB FRAME EXTENSION RADIUS. REMOVED GILLINER SUPPORT AND FRAME EXTENSION STUB IAW SRM 51-30-2. FORMED STUB FRAME WITH 7075 'O' .063" PO NR 9008655 IAW DWG 53FX 1350 REV A. HEAT TREATED PART FROM 'O' MATERIAL TO T6 CONDITION IAW FASI ENG REPORT NR 2-37153-801 REV A. LOCATED AND DRILLED PART IAW SRM 51-10-5. ALODINED AND PRIMED PART IAW SRM 51-10-2. INSTALLED FRAME STUB IAW SRM 51-30-2. INSTALLED SUPPORT IAW SRM 51-30-2.

Part: SUPPORT — CORRODED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

DURING PANEL CLOSE UP ON AFT BULKHEAD IN AFT PIT, CENTER LOWER PANEL, UPPER ANGLE CORRODED AROUND FASTENER HOLES. REMOVED CENTER BULKHEAD PANEL SUPPORT ANGLE, REPAIRED BY INSTALLING 2 ANGLES AND A FILLER. RE-INSTALLED PANEL SUPPORT ANGLE REF SRM 51-40-4/FIG NR 1 PGS 1-9.

Part: THRESHOLD — CRACKED (BS 950E-990) · airframe 38,775 hrs · 27,001 cycles

AFT LOWER CARGO PIT DOOR CUTOUT THRESHOLD HAS 2 CRACKS IN CURVED AREA BETWEEN 27" AND 32" AFT OF FWD EDGE WELD ACCOMPLISHED ON SHOP N/R 11841-8300-0001. VERIFIED MATERIAL WELDED AND SMOOTHED AREA REFERENCE FED EX DWG SR27-53-025C.

Part: CHANNEL — CRACKED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

AFT CARGO PIT RT "Z" CHANNEL CRACKED AT RIVET HEAD AT STA 1040 FRAME REPLACED Z-ANGLE REF SRM 51-30-2.

Part: ATTACH FITTING — CORRODED (LT WING TE) · airframe 38,775 hrs · 27,001 cycles

LT WING NR 1 KRUGER FLAP ALL 3 HINGES, HARDWARE HAS RUST CENTER CASTING AT ACTUATOR ATTACH, 1 HOLE IS CORRODED EDGE DAMAGED. REPLACED NR 1 KRUGER FLAP REFERENCE MM 27-81-001-4 ADJUSTMENT AND CHECK PERFORMED REF W/C70C007-00.

Part: ANGLE — CRACKED (NR 12 SPOILER) · airframe 38,775 hrs · 27,001 cycles

RT WING, TE LOWER PANEL, BELOW NR 12 SPOILER PANEL, OTBD ATTACH ANGLE, OF THE OTBD SET IS CRACKED AT SUPPORT ROD. REMOVED DAMAGE ANGLE, VERIFIED REPAIR MATERIAL AS 7075-T6 .050 REF IPC 57-30-00 FIG 16 AND DWG 65-21658. FABRICATED REPLACEMENT ANGLE REF FED EX GMM 7-0-1001 ITEM 7C AND SRM 51-41-2. TREATED REF 727 SRM 51-10-2 PG 7G, AND PRIMED REF 727 AMM 51-20-151-7 ITEMS 5 AND 6. INSTALLED REPLACEMENT PART REF 727 SRM 51-30-2.

Part: SKIN — DAMAGED (ZONE 200) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

EXT FUSELAGE BS 420 S-4R 2 PAIRS OF OVERLAPPPING RIVET HEADS AND SEVERAL RIVETS CLOSELY SPACED REMOVED 9 G NET ATTACH STRUCTURE BETWEEN S-4R AND S-5R CUT OUT DAMAGED AREA. FABRICATED REPAIR FILL AND REPAIR DOUBLER AND INSTALLED. REFERENCE EA NR 7-5330-106995 (REVISION DATE 16 MAR 2007).

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

LWR AFT PIT BILGE, STA 950A LBL 8" OB LWR FLANGE OF KEEL BEAM CHORD HAS APPROX 6 SQ INCHES OF CORROSION ON UPPER SURFACE. REMOVED CORROSION ON OUTBOARD FLANGE OF KEEL BEAM LWR AFT PIT BILGE STA 950A, 6" LBL 8" FOUND AREA OUT OF LIMITS. FABRICATED, TREATED AND PRIMED REPAIR, STRAP/FILLER AND INSTALLED REF EO NR 7-5310-7-2356C1 PART 3, NOTE 1 OF FIG 3, PG 2.

Part: WEB — CORRODED (ZONE 200) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

MAIN DECK FLOOR WEB UPPER SURFACE IS CORRODED BS 1147, LBL 52-63, WL 208. REMOVED DAMAGE AREA OF WEB REF SRM 51-40-2 FIG 1, STA 1147, LBL 62, THAT WAS OUT OF LIMITS REF 51-10-1, AFTER BLENDING, MFG AND INSTALLED REPAIR REF SRM 51-40-2 FIG 1 AT LBL 62

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIT BILGE, STA 950E 10, LBL 8" O/B LWR FLANGE OF KEEL BEAM CHORD HAS CORROSION, ON PREVIOUS STRAP REPAIR. REMOVED FLOOR SUPPORT AND SHEAR TIE FOR ACCESS, GROUND CORROSION ON EXISTING STRAP AND NDT FOR MATERIAL LOSS. FOUND TO BE OUT OF LIMITS. FABRICATED NEW REPAIR STRAP AND REPLACED SHEAR TIE AND FLOOR SUPPORT REF EA NR 7-5310-107011 PART 1.

Part: SKIN — CRACKED (ZONE 500) · airframe 38,775 hrs · 27,001 cycles

LEFT WING FAIRING NR 3343 VERIFIED MATERIAL AS 2024-0 .050 REF DWG 65-22555 AND SRM 51-40-2 PG 1. STOPPED DRILLED CRACK REF SRM 51-10-PG 13 ITEM 10, HFEC IAW 727NDT MAN PART 6, 51-00-00 FIG 23. TOOL NR IDM 0031 11-30-07. VERIFIED CRACK TO BE CONFINED BY STOP DRILL AND MADE REPAIR DOUBLER, REF SRM 51-40-2 PG 3 HEAT TREATED REF W/O 11841-5000-0011 ACP HARDNESS TEST, WITHIN ACCEPTABLE LIMITS FOR 2024 T4 REF BAC5946 REV 9 TREATED AND PRIMED DOUBLER/FAIRING REF SRM 51-10-2 PG 9 AND 11-12. INSTALLED DOUBLER AND FILLET SEALED REF SRM 51-40-2. PAINTED REF MM 51-20-151-7 REPAIR CLASSIFIED AS MINOR.

Part: BRACKET — CRACKED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

NR 6 FLAP TRACK OTBD FAIRING ATTACH BRACKET IS CRACKED REMOVED AND REPLACED NR 6 FLAP TRACK OTBD BRACKET REF SRM 5130-2 PGS 3, 4 AND 5 AND SRM 51-20-031-7 PGS 1, 3 AND 7.

Part: FLOORBEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

MAIN DECK FLOORBEAM UPPER FLANGE IS CORRODED AT BS 1110, RBL 22, WL 208 CORROSION DAMAGE REPAIRED REFERENCE EA NR 7-5310-106997.

Part: SKIN — CRACKED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT WING LEADING EDGE UPPER SURFACE CUTOUT AT NR 5 SLAT INBD GUIDE IS GOUGED AND CRACKED AT AFT EDGE REMOVED SLAT SEALS AND COVER FOR ACCESS, DAMAGE REMOVED REF SRM 57-30-2. HFEC FOR CRACKS REF B727 NDT MANUAL PART 6. FABRICATED PART AND INSTALLED REPAIR REF SRM 57-30-4 PG 26. REINSTALLED SLAT SEALS AND COVER REF SRM 51-30-02 PG 1.

Part: SKIN PANEL — GOUGED (ZONE 300) · airframe 38,775 hrs · 27,001 cycles

RT VERTICAL STAB SKIN/WEB HAS (2 EA) TOOLING GOUGES LOCATED UNDER PANEL 9706. GOUGES ARE LOCATED NEAR FASTENER ROW FOR L- ANGLE AND 23", 24" FROM FRONT OF PANEL. REMOVED DAMAGE PER EA I070144. VERIFY DAMAGED REMOVED BY HFEC IAW 727 NDT MAN, PART 6, 51-00-00, FIG 23. TOOL NR IDM-0031, 11/30/07 REF EA I070144 REV P2, PG 2 STEP 1. TREATED AND PRIMED BLENDED AREA REF 51-10-2 PG 7 AND EA I070144. FABRICATED DOUBLER, TREATED AND PRIMED DOUBLER, INSTALLED DOUBLER AND FILLET SEALED DOUBLER PER EA I070144 REV P2 PG 2 STEPS 3-7.

Part: CASTING — CRACKED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

MAIN DECK 2 RIGHT DOOR CUT OUT UPPER AFT CORNER SEAL DEPRESSOR CASTING IS CRACKED AT BS 1062 WL 271. REMOVED AND DRILLED UP R2 CORNER SEAL DEPRESSOR CASTING. INSTALLED CASTING REF 51-30-02.

Part: BRACKET — CORRODED (ZONE 800) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

MAIN ENTRY DOOR EMERG ESCAPE SLIDE, BACK PAN LWR LATCH HINGED RETAINER, MOUNT BLOCK HAS EXFOLIATION CORROSION. INSTALLED NEW BRACKET REF SRM 51-30-2 PG 2.

Part: FITTING — DAMAGED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

INTERNAL FUSELAGE AT STA 259.BL0 TO RBL 2, CASTING HAS TOOLING DAMAGE REMOVE FLIGHT DECK CEILING TO GAIN ACCESS TO CASTING. REMOVED INTERCOSTAL AND SURROUND STRUCTURE. REMOVED CASTING, DRILLED NEW CASTING AND INSTALLED. RE-INSTALLED ALL STRUCTURE AND CEILING PANELS REF SRM 51-30-2.

Part: SKIN — CRACKED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FUSELAGE UPPER LOBE INTERIOR SKIN IS CRACKED ON BOTH SIDES OF STRINGER AT SKATE ANGLE FASTENERS AT BS 1097, STR 1, LBL 1 - RBL 1. REMOVED DAMAGE AND INSTALLED DOUBLER IN REFERENCE TO SRM 53-30-3, PG 12.

Part: SKIN — CRACKED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

FOUND REPAIR AT FUSELAGE STA 1184, LBL 10. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. REMOVED REPAIR DOUBLER REF SRM 51-30-2. HFEC SKIN IAW 727 NDT MANUAL PART 6, 51-00-00 FIG 23. FOUND CRACKS AT 2 FASTENER HOLES. REMOVED DAMAGE REF SRM 53-30-3. FABRICATED REPAIR PARTS REF SRM 53-30-3. TREATED AND PRIMED REPAIR PARTS REF SRM 51-10-2. INSTALLED AND FILLET SEALED REPAIR REF SRM 53-30-3 PG 12, 155-159. THIS IS A CATEGORY C REPAIR REF PAGE 156. CLASSIFIED AS A MAJOR REPAIR.

Part: SUPPORT CHANNEL — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIT BILGE FWD SIDE OF STA 950A, VERTICAL SUPPORT CHANNEL AT 8" LBL HAS SMALL AMOUNT OF CORROSION AT LOWER OB. REPLACED VERTICAL SUPPORT AT STA 950A. REFERENCE SRM 51-30-2 PAGE 1 - 12.

Part: ATTACH ANGLE — CRACKED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT WING TE, LOWER PANEL BELOW NR 13 SPOILER PANEL OTBD ATTACH ANGLE OF THE INBD SET IS CRACKED AT SUPPORT ROD. FABRICATED REPLACEMENT ANGLE ON SHOP WO NR 11841-6300-0002. HEAT TREATED ON 8130- 3 TRACKING NR 2007-03-142. REPLACED ANGLE ATTACHMENT FOR LOWER PANEL REFERENCE SRM 51-40-3.

Part: FRAME — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIT BILGE, FRAME HAS APPROX 3 SQ INCHES OF CORROSION ON AFT LOWER FACE AT STA. 950A, LBL 8". REMOVED CORROSION REF 51-10-2 AND 53-10-1. NDT'D FOR MATERIAL LOSS, FOUND AREA OUT OF LIMITS REF SRM 53-10-1 FIG 1. REMOVED SUPPORT BRKT, VERT SUPPORT BRKT, FAST IN PNL 3522 FOR ACCESS, AND FASTENER IN REPAIR AREA REF SRM 51-30-2. CUTOUT DAMAGED SHEAR TIE AND FABRICATED NEW PART REF SRM 53-10-4, HEAT TREATED ON WO NR 11841-1000-0006. DRILLED UP REPAIR PARTS REF SRM 53-10-4. TREATED AND PRIMED REF SRM 53-10-4. INSTALLED SHEAR TIE REPAIR REF SRM 53-10-4. INSTALLED SUPPORT BRACKET, VERT BLKHD SUPPORT BRKT, AND PNL 3522 FAST, REF 51-30-2.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIT FLOORBEAM, VERTICAL CHANNEL HAS CORROSION AT LWR END AROUND FASTENER HEAD AT STA 950E, LBL 8 FABRICATED NEW FLOORBEAM VERTICAL CHANNEL AT STA 950E, LBL 8. HEAT TREATED AND HARDNESS TESTED FOR 7075 T6 CONDITION REF BAC DWG 69-44559 AND BAC 5602 REV AF 28AUG01 AND BAC 5946 REV AA 9JUL06, ON SHOP WO NR 11841-1600-0003. REINSTALLED FLOOR SUPPORT REF BOEING DWG 69-44559 AND SRM 51-30-2.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIT FWD BULKHEAD STA 950A, LBL 12, HORIZONTAL L-ANGLE AT BASE OF WALL SUPPORT HAS CORROSION AT INBD END. REMOVED L ANGLE FROM LBL 6 TO LBL 21, STA 950A. FABRICATED NEW L ANGLE ON AAR SHOP WO NR 11841-1600-0002, BY HEAT TREATING ANGLE REF DWG 65-67251. 8130 TRACKING NR 2007-03-069. INSTALLED L ANGLE REF SRM 51-30-02.

Part: NACELLE — CRACKED (ZONE 400) · airframe 38,775 hrs · 27,001 cycles

NR 1 ENGINE FIXED COWL UPPER SECTION CRACKED AT UPPER FWD CORNER. REPLACED FIXED COWL, NEW COWL INSTALLED ON WC 70T0001-01.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIR FWD BULKHEAD STA 950A, RBL 22, L ANGLE AT BASE OF WALL SUPPORTS HAVE CORROSION ON UPPER SURFACE (2 EACH) DAMAGE TO 2 L ANGLES OUT OF LIMITS. ORIGINAL MATERIAL WAS .050", REMAINING MATERIAL .035". FABRICATED 2 REPAIR ANGLES, HEAT TREATED TO T4 ON SHOP WO NR 11841-1600-0001, AND INSTALLED.

Part: SKIN — MISREPAIRED (ZONE 500) · airframe 38,775 hrs · 27,001 cycles

FOUND REPAIR AT LT WING NR 1 SLAT. FLUSH REPAIR IS 15" FROM OB END ON TOP SURFACE. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. FOUND REPAIR DID NOT MEET CRITERIA OF SRM 57-50-3 FIG 1. AFT END OF REPAIR NOT ATTACHED TO SKIN OF SLAT. REPLACED, ADJUSTED AND OPS CHECKED LT WING NR 1 LE SLAT REF MM 27-81-011-4 PAGES 1-5. NR 1 LE SLAT, OPS CHECKED GOOD.

Part: SKIN — DELAMINATED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT WING NR 9 SPOILER UPPER TE SURFACE HAS DELAM REMOVED NR 9 SPOILER PANEL. SPOILER REPAIRED ON SHOP WO NR 11841-6000-0003 REF SRM 51-40-20. INSTALLED NR 9 SPOILER PANEL REF MM 27-62-001-4 STEP 3-5. ADJUSTED SPOILER REF MM 27-62-001-5 PG 1 STEP 2A-2F AND STEP 3.

Part: SKIN — DELAMINATED (AILERON) · airframe 38,775 hrs · 27,001 cycles

LT WING OTBD AILERON IS DELAMINATED AT THE OTBD T/E. LT OB AILERON WAS REPAIRED ON SHOP WO NR 11841-5000-0003 REFERENCE SRM 51-40-20. LT OB AILERON IS INSTALLED AND RIGGED ON SNRM NR N00554.

Part: SKIN — MISREPAIRED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

FOUND EXTERNAL FUSELAGE REPAIR AT APPROX STA 1223, STR 25R. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. FOUND REPAIR DID NOT CONFORM TO SRM 53-30-3 FIG 3. REMOVED EXTERNAL DOUBLER FROM A/C REF SRM 51-30-2. MFG NEW REPAIR DOUBLER AND INSTALLED REF SRM 53-30-3 FIG 3.

Part: STRUCTURE — DELAMINATED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT WING NR 14 SPOILER T/E IS SPLIT REMOVED AND REINSTALLED NR 14 SPOILER FOR T/E REPAIR REF M/M 27-61-0001-4, M/M 27-61-001-5. SPOILER REPAIRED ON IDM WORK CARD ORDER NR 11841-6000-0004.

Part: SKIN — DELAMINATED (NR 13 SPOILER) · airframe 38,775 hrs · 27,001 cycles

RT WING NR 13 SPOILER T/E IS SPLIT NR 13 SPOILER REPAIRED ON WO NR 11841-6000-0005 REFERENCE SRM 51-40-20. INSTALLED NR 13 SPOILER REF MM 27-61-001-4 PG 2-3 STEP 5, TORQUE WRENCH AAR 20026 DATE 8-23-07. CTR BOLT 285 IN LB. OUTBD HINGE BOLT, 130 IN LB TORQUE WRENCH 23442 DATE 11-16-07. FLUKE KIT AAR 18259 DATE 10-5-06. FUNCTIONAL CHECK WILL BE PERFORMED ON WC 70C006-00.

Part: BATTERY BOX — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

E/E COMPARTMENT BATTERY TRAY AFT EDGE IS CORRODED. REMOVED, FABRICATED AND ACP HEAT TREAT PROCESS FOR 2024-T4, CONDITION FOR TRAY. REF BAC DWG 69-21649 REV C AND BAC5602 REV (AF) 28 AUG 01 AND BAC 5946 REV (AA) 9 JUL 01. IDENTIFIED TRAY AS FX-69-21649-1. W/O 11841-1000-0004 AND REINSTALLED REF SRM 51-30-02 PG 13.

Part: PANEL — DELAMINATED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT WING, UPPER SURFACE AT WBL 462, PNL, JUST O/B OF NR 14 SPOILER IS DELAMINATED. REMOVED PANEL AND SENT OUT FOR REPAIR. PANEL REPAIRED ON AAR WO NR 11841/6300/0003. REMOVED DAMAGE AND DELAMINATED SKIN, AND REPAIRED, REF SRM 51-40-20. INSTALLED PANEL REF SRM 51-30-02 PG 1.

Part: FLOORBEAM — CORRODED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FLIGHT DECK FLOORBEAM HAS CORROSION ON TOP OF BEAM LOCATED AT BS 277, RBL 10.5. REMOVED CORROSION, ALL WORK FOR BLEND WAS ACCOMPLISHED ON FED EX EA NR 7-5310-107004.

Part: SKIN — GOUGED (ZONE 800) · airframe 38,775 hrs · 27,001 cycles

FWD LOWER CARGO DOOR, FWD LOWER CORNER OF SKIN WORN, GOUGED. INSTALLED REPAIR DOUBLER REF 52-00-3 PG 2, FIG 4, DETAIL F. RESTORED LEVELING, COMPOUND REF SOPM 20-60-04 PG 7.

Part: PLUG — CORRODED (ZONE 200) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

THE SECOND WINDOW PLUG AFT OF THE LEFT AFT EMERGENCY ESCAPE HATCH HAS CORROSION UNDER THE SEAL AT THE FWD LOWER PLUG RETAINER REMOVED WINDOW PLUG, REF MM 56-20-000-4 PG 1. DRILLED HOLE IN THE WINDOW PLUG FOR JUMPER STRAP, REF EO NR 7-5620-7-4304. INSTALLED WINDOW PLUG REF MM 56-20-000-4 PG 2-4.

Part: BATTERY BOX — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

E/E COMPARTMENT BATTERY BOX CORRODED AT FOWARD RT AND LT CORNERS REMOVED CORROSION FROM BATTERY BOX. MATERIAL LOSS WAS OUT OF LIMITS, REF SRM 51-30-2 FIG. REPLACED WITH NEW BATTERY BOX REF MM 24-30-011-4.

Part: SKIN — DAMAGED (LT WING SLAT) · airframe 38,775 hrs · 27,001 cycles

LT WING LE, AT NR 4 SLAT OB HOOK CUTOUT CRACKED REMOVED DAMAGED AREA, REF SRM -30-4, NDT AREA AFTER BLEND OUT, NO DEFECTS NOTED REF B727NDT MANUAL PART 6. FABRICATED AND INSTALLED REPAIR REF SRM 57-30-4 AND SRM 51-30-2.

Part: SUPPORT — CRACKED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT WING INBD TE LOWER SURFACE FWD INNER SUPPORT CLIP IS CRACKED AT ATTACH TO REAR SPAR FLANGE OFF PANEL 10" O/B OF O/B END OF MLG BEAM REMOVED DAMAGED CLIP, VERIFIED REPAIR MATERIAL AS 2024-T3-.040 REF DWG NR 65-21656, AND FABRICATED REPLACEMENT CLIP REF DWG 65-21656 AND FED EX GMM 7-0-1001 ITEM 7C. TREATED REPLACEMENT CLIP REF 727 MM 51-10-2 PG 7G AND PRIMED REF 727 AMM 51-20-151-1 TMES 5 AND 6. INSTALLED REF 727 SRM 51-20-2.

Part: FAIRING — WORN (ZONE 400) · airframe 38,775 hrs · 27,001 cycles

NR 1 ENGINE S/N 700479 TAIL PIPE FAIRING HAS GROOVE WORN INTO IT AT 3 O'CLOCK POSITION FROM 1" AFT OF FWD EDGE TO 18" AFT OF FWD EDGE. REPLACED DAMAGED ENG NR 1 I/B TAILPIPE FAIRING REF SRM 51-30-2 ITEM 9.

Part: DOOR — WORN (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT IB FORE FLAP INBD UPPER HINGED LE DOOR HAS DEEP WEAR REMOVED AND REPLACED RT INBD FORE FLAP REF MM 27-51-001-4 PAGE 2. TQ WRNCH NR AAR 19624 DUE 8-19-07.

Part: SKIN — DENTED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

LOWER FUSELAGE SKIN IS GOUGED/CREASED AT BS 294-347 STR S-21R, 6" DENT WAS DETERMINED TO BE OUT OF LIMITS. REMOVED DAMAGE, FABRICATED AND INSTALLED EXTERNAL DOUBLER REPAIR REF SRM 53-30-3 FIG 1.

Part: FLOOR SUPPORT — CRACKED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

FWD CARGO PIT FLOOR SUPPORT AT SRA 717 ABOVE STR 27R IS CRACKED FABRICATED FLOOR SUPPORT REF DWG BAC 1517-1507 REV A. NDT REF BAC 5423, HEAT TREATED AND TESTED HARDNESS REF BAC 5602 AND BAC 5946 FEF TRACKING NR 2007-03-150. REMOVED DAMAGED SECTION OF CARGO FLOOR SUPPORT AND SPLICED IN NEW SECTION OF SUPPORT REF SRM 53-10-05 FIGURE 4 PAGES 9 AND 10.

Part: PANEL — DELAMINATED (ZONE 300) · airframe 38,775 hrs · 27,001 cycles

VERTICAL STABILIZER PANEL 9511 IS DELAMINATED REMOVED DAMAGE AND REPAIRED PANEL, THEN APPLIED CONDUCTIVE COAT, PRIMED AND PAINTED REFERENCE SRM 51-40-09 PAGE 4, AND MM 51-21-121-7.

Part: ANGLE — CRACKED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIT LOWER LT SIDEWALL ATTACH CLIP IS CRACKED AT STA 950F ABOVE STR 26L. FABRICATED AND REPLACED BROKEN CLIP REF BOEING DRAWING 66-12821 AND SRM 51-30-2.

Part: COWLING — CRACKED (ZONE 400) · airframe 38,775 hrs · 27,001 cycles

NR 3 ENGINE FIXED COWL AFT UPPER LATCH CUTOUT IS CRACKED AT AFT END NEW COWL ASSY RECEIVED AND REPLACED REF MM 71-10-031-4 AND REF WC 74C300-01.

Part: SKIN — DELAMINATED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT OTBD AILERON OTBD T/E UPPER AND LOWER SURFACE IS DELAMINATED FROM CORE. REMOVED AND REPLACED RT OTBD AILERON REF MM 27-10-031-2.

Part: SKIN — DELAMINATED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

NR 5 SLAT FENCE IS DELAMINATED ON LEADING EDGE REMOVED DAMAGE AND REPAIRED AREA REF SRM 51-40-09 PG 3-7. APPLIED CONDUCTIVE COATING REF MM 51-20-051-7. PRIMED AND PAINTED REPAIR REF MM 51-20-151-7.

Part: SPLICE — CORRODED (ZONE 100) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIT FLOOR STRUCTURE FLOOR PANEL SPLICE STRAP AT STA 980 4" HAS CORROSION ON UNDERSIDE AT MANY NUTPLATES AND CRACKED AT RBL 8. MANUFACTURED STRAP PER BOEING DWG 65-57567. REMOVED AND REPLACED AFT PIT FLOOR SPLICE STRAP REF SRM 51-30-07.

Part: SKIN — DENTED (BS 277 S29R) · airframe 38,775 hrs · 27,001 cycles

NLG CUTOUT FWD EDGE SKIN BENT/CREASED, REMOVED DAMAGE AREA. FABRICATED REPAIR DOUBLER AND INSTALLED REF SRM 53-30-3 FIG 1. THIS REPAIR IS A CATEGORY '"B" REPAIR. INSPECTION THRESHOLD IS 45,000 CYCLES REF SRM 53-30-3 FIG TABLE 3.

Part: TAB — DELAMINATED (ZONE 500) · airframe 38,775 hrs · 27,001 cycles

LT WING IB AILERON TAB CONTROL ARM FAIRING IS DISBONDED AT AFT EDGE CLEANED AREA, REPAIRED FAIRING REFERENCE SOPM 20-50-12 PAGE 11 PARA 4.

Part: SKIN — DENTED (ZONE 400) · airframe 38,775 hrs · 27,001 cycles

FOUND REPAIR AT THE TE OF THE NR 1 ENG PYLON STUB FRAME UPPER SURFACE EXISTING. REPAIR DID NOT CONFORM TO SRM 54-30-2. REMOVED EXISTING REPAIR ON UPPER SURFACE. REMOVED DAMAGE SKIN, REMOVED DAMAGE ON LOWER SURFACE T/E SKIN. REPAIRED UPPER AND LOWER T/E WEDGE SKIN REF WO NR 35851/EA NR 7-5480-107016, THIS REQUIRES RE-INSPECTION OF BLIND FASTENERS EVERY C-CHECK FOR CONDITION.

Part: SKIN — MISREPAIRED (BS 1223) · airframe 38,775 hrs · 27,001 cycles

FOUND EXTERNAL FUSELAGE REPAIR AT APPROX STA 1223, STR 25R. REPAIR DOES NOT CONFORM TO SRM 53-30-3 FIG 3. REMOVE EXTERNAL DOUBLER FROM A/C REF SRM 51-30-2. MFG NEW REPAIR DOUBLER REF SRM 53-30-3 FIG 3. INSTALLED NEW REPAIR DOUBLER REF SRM 53-30-3 FIG 3.

Part: FLOORBEAM — DAMAGED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

UPPER MAIN CARGO FLOOR STRUCTURE HAS DEEP SCRIBE ON UPPER SURFACE TEE AT STA 720D, RBL 27" TO RBL 44" STR 17R. REMOVED UPPER TEE FROM RBL 14 TO RBL 65 AND REPAIRED WITH SUPPORT ANGLES AND REINFORCEMENT STRAP AT SPLICE REF SRM 53-10-8/ FIG NR 3 PAGES 18-23.

Part: SKIN — MISREPAIRED (BS 1223 S25R) · airframe 38,775 hrs · 27,001 cycles

FOUND EXTERNAL FUSELAGE REPAIR AT APPROX STA1223, STR 25R. REPAIR DOES NOT CONFORM TO SRM 53-30-3 FIG 3. REMOVE EXTERNAL DOUBLER FROM A/C REF SRM 51-30-2. MFG NEW REPAIR DOUBLER REF SRM 53-30-3 FIG 3. INSTALLED NEW REPAIR DOUBLER REF SRM 53-30-3 FIG 3.

Part: SKIN PANEL — DAMAGED (RT WING) · airframe 38,775 hrs · 27,001 cycles

RT WING PANEL NR 8505 OUTER SURFACE FWD EDGE I/B IS DAMAGED REMOVED PANEL REF SRM 51-30-02. REPAIRED PANEL REF SRM 51-40-20 PAGES 12, 46, 53 THRU 62. PRIMED AND PAINTED, REF MM 51-20-151-7. INSTALLED PANEL REF 20-10-023-4 PARA 4B (2).

Part: BRACKET — CRACKED (RT MLG WW) · airframe 38,775 hrs · 27,001 cycles

RT MLG WW BULB SEAL SUPPORT BRACKET ON KEEL BEAM IS CRACKED 10 INCHES FORWARD OF SAFETY BAR. REMOVED DAMAGED BRACKET AND FABRICATED NEW BRACKET. HEAT TREATED REF BOEING DWG 65-57990. TREATED, PRIMED AND INSTALLED NEW BRACKET REF SRM 51-40-2. INSTALLED NUT PLATE REF SRM 51-30-2.

Part: ANGLE — CRACKED (ZONE 400) · airframe 38,775 hrs · 27,001 cycles

AIR STAIRS AREA LT SIDE, STA 1342 INBD DUCT SUPPORT ANGLE IS CRACKED LOWER END AT LBL 40. REMOVED AND REPLACED LT SIDE STA 1342 IB DUCT SUPPORT ANGLE REF SRM 51-30-02 PAGE 1.

Part: DUCT — CRACKED (ZONE 400) · airframe 38,775 hrs · 27,001 cycles

NR 2 ENGINE 6TH STAGE SADDLE DUCT IS CRACKED AT THE RIGHT DUCT TO ENGINE MOUNT FLANGE AREA AFT OUTBD END OF DUCT. REMOVED AND REPLACED CRACKED DUCT WITH SERVICEABLE UNIT REF 727 AMM 36-00-001-2 PG 1 - 6 FIG'S 201 AND 202, 727 AMM 20-80-001-2 FIG'S 203 AND 209 AND 727 AMM 20-10-023. LEAK CHECK PERFORMED ON WORK CARD 70C005-00.

Part: TAB — DELAMINATED (ZONE 300) · airframe 38,775 hrs · 27,001 cycles

LT HORIZONTAL STAB ELEVATOR TAB UPPER SURFACE HAS SPOT OF CRUSH WITH DELAM AT 9.5" OB OF INBD EDGE, ALSO SMALL DELAM ON UPPER 1" O/B. RECEIVED SERVICEABLE TAB ASSY WAS REMOVED AND WILL BE REINSTALLED ON WC E7-5520- 7-3307, WO NR 35851.

Part: SHELF — CRACKED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

E/E COMPARTMENT MIDDLE EQUIPMENT RACK LT SIDE VHF SHELF CRACKED AT LT AFT ATTACH POINT BELOW COMPARATOR WARN UNIT. FABRICATED AND INSTALLED NEW SHELF SUPPORT ANGLE REF BOEING DRAWING 69-15989, SRM 51-10-02 PAGE 7 AND SRM 51-30-02. SYSTEM OPS CHECKED GOOD REF MM 34-31-001-5, AND 34-63-011-4.

Part: ANGLE — CRACKED (LT MLG DOOR) · airframe 38,775 hrs · 27,001 cycles

LT WING GEAR DOOR LOWER AFT EDGE OF DOOR, ANGLE IS CRACKED REMOVED AND REPLACED AFT LOWER EDGE ANGLE REF SRM 51-30-02 AND REPLACED SEAL REF MM 32-10-03.

Part: SEAT TRACK — CORRODED (BS 1094-1101) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

MAIN DECK FLOOR SEAT TRACK CROWN IS GOUGED/CORRODED AT BS 1094 - 1101, RBL 25, WL 208. FABRICATED AND INSTALLED REPAIR ON SEAT TRACK, STA 1094 - 1101, RBL 25, WL 208 REF B 727 SRM 53-10-5 PG 1 FIG 1.

Part: THRESHOLD — CRACKED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

FOUND FORWARD LOWER CARGO DOOR, AFT THRESHOLD IS CRACKED ON FWD END. RECEIVED REPAIRED THRESHOLD, REPAIRED REF DRAWING SR27-53-025 REV. C BY IDENTIFYING BASE METAL, PREPPED, WELDED AND INSPECTED REF WO NR 11841-1000-0001. FWD LOWER CARGO DOOR AFT THRESHOLD WILL BE INSTALLED ON W/C 71C201-02.

Part: PANEL — DELAMINATED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

LOWER FUSELAGE PANEL NR 3622 (ADF NR 2 SENSE ANTENNA) PANEL HAS MULTIPLE LARGE AREAS OF DELAM, MULTIPLE ELONGATED FASTENER HOLES AND PANEL IS EXCESSIVELY HEAVY. REMOVED DAMAGED PANEL ASSY AND INSTALLED SERVICEABLE PANEL ASSY REF SRM 51-30-2 PAGE 9. VERIFIED ADF SENSE ANTENNA WAS HOOKED UP.

Part: SKIN — CRACKED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

RT WING NR 6 MOVEABLE FAIRING SKIN FWD OB EDGE IS CRACKED. REPAIRED FAIRING REF SRM 51-10-1, 57-20-2, 51-40-2 AND MM 51-20-151-7.

Part: SKIN — DELAMINATED (AILERON) · airframe 38,775 hrs · 27,001 cycles

LT WING O/B AILERON LOWER T/E SKIN IS DELAMINATED JUST O/B OF TAB. REMOVED, REPAIRED AND REINSTALLED LT O/B AILERON REF MM 27-10-031-2. REPAIR ACCOMPLISHED ON WO NR 11841-5000-0002. REMOVED TAB, REPAIRED DELAMINATED SKIN ON AILERON TE AND REINSTALLED TAB REF MM 27-10-041-4 AND SRM 51-40-20.

Part: ATTACH FITTING — CRACKED (ZONE 300) · airframe 38,775 hrs · 27,001 cycles

NR 2 ENG INLET DOGHOUSE AT BASE OF VERTICAL LEADING EDGE, VERTICAL WEB ATTACH CLIP CRACKED AT INTERIOR STA 1274 LT SIDE. REMOVED AND REPLACED VERTICAL WEB ATTACH CLIP, AT STA 1274 INSIDE VERTICAL STABILIZER ABOVE S-DUCT ON LT SIDE. REF B727 SRM 51-30-02 PG 2.

Part: ATTACH FITTING — CRACKED (ZONE 500) · airframe 38,775 hrs · 27,001 cycles

LT WING PANEL NR 8240 CLIP IS CRACKED REMOVED DAMAGED CLIP, VERIFIED MATERIAL AS 2024 T3-.032 REF DWG 65-19280 AND FABRICATED REPLACEMENT CLIP REF DWG 65-19280 AND FED EX 7-0-1001 ITEM 7C. TREATED REPLACEMENT PART REF SRM 51-10-2 PG 7. PRIMED REF AMM 51-20-151-7 ITEMS 5 AND 6 AND INSTALLED REF SRM 51-30-2.

Part: FLOORBEAM — CORRODED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

MAIN DECK AT FS 480 FLOORBEAM CORRODED BETWEEN LBL 26 AND LBL 45. REMOVED CORROSION REF SRM 53-10-01. ORIGINAL MATERIAL MEASURED AT .125 BLEND OUT MATERIAL LOSS AT DEEPEST LOCATION MEASURES .016. REMAINING MATERIAL AFTER BLEND IS .109 AND IS STRUCTURALLY ACCEPTABLE PER EA 7-5310-106996. ACCOMPLISHED HFEC INSPECTION TO EFFECTED AREA REF EA AND SOPM 20-10-03 WAS USED TO ACCOMPLISH FLAP PEEN TO AREA.

Part: BRACKET — CRACKED (ZONE 600) · airframe 38,775 hrs · 27,001 cycles

NR 5 FLAP TRACK OTBD AFT BRACKET FOR CENTER FAIRING IS CRACKED. REMOVED AND REPLACED NR 5 FLAP TRACK OTBD AFT BRACKET. REF SRM51-30-2 PG 4 REF BOEING DRAWING 69-22882 REF SRM 51-10-2 PG 3, 4 AND 5, REF MM 51-20-031-07 PGS 1, 2, & 3.

Part: ATTACH ANGLE — CRACKED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

LOWER AFT PIT FORWARD BULKHEAD VERTICAL WALL SUPPORT LOWER CLIP ANGLE IS CRACKED THAT ATTACHES TO FLOOR STRINGER AT STA 950A, RBL 12. REMOVED AND REPLACED AFT PIT FWD BULKHEAD VERTICAL WALL SUPPORT LOWER CLIP ANGLE AT STA 950A, RBL 12, REF DWG NR 66-24895 AND 727 SRM 51-30-02 PG 2.

Part: BULLET — CRACKED (FLAP TRACK) · airframe 38,775 hrs · 27,001 cycles

NR 1 FLAP TRACK FAIRING ASSY BULLET IS CRACKED REMOVED AND REPLACED NR 1 FAIRING BULLET REF MM 27-31-031.

Part: FLOOR SUPPORT — WORN (BS 740-760) · airframe 38,775 hrs · 27,001 cycles

CABIN FLOOR SUPPORT WORN AT FWD END FROM CONTACT WITH SPACER BLOCK UNDER SEAT TRACK AT BS 744, RBL 63. REPLACED CABIN FLOOR SUPPORT AT STA 740-760 RBL 63 REF SRM 51-30-2.

Part: FLOOR SUPPORT — WORN (BS 740-760) · airframe 38,775 hrs · 27,001 cycles

CABIN FLOOR SUPPORT WORN AT FWD END FROM CONTACT WITH SPACER BLOCK UNDER SEAT TRACK AT BS 744, RBL 63. REPLACED CABIN FLOOR SUPPORT AT STA 740-760 RBL 63 REF SRM 51-30-2.

Part: STRINGER — DAMAGED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

MAIN CABIN FS 360 AT STR 7L HAS A MIS DRILLED HOLE AT END OF STRINGER. REMOVED DAMAGE SECTION OF STRINGER 7L. FABRICATED AND INSTALLED STRINGER REPAIR. REINSTALLED ITEMS THAT WERE REMOVED IAW SRM 53-10-3 PG 3-4, FIG 1 AND SRM 51-30-2.

Part: SKIN — MISREPAIRED (BS 1148-1166) · airframe 38,775 hrs · 27,001 cycles

FOUND EXTERNAL FUSELAGE REPAIR AT APPROX STA 1148-1166, STR 29L-29R. REPAIR REQUIRED EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. DOUBLER HAS NUMEROUS AD RIVETS WHICH WERE REPLACED WITH D RIVETS TO CONFORM TO SRM 53-30-3 FIG 3. A MINOR REWORK TO A MAJOR REPAIR.

Part: SHEAR TIE — DAMAGED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

MAIN DECK BODY FRAME WEB AND SHEAR TIE HAVE 2 SHORT PITCH (0.25') MISDRILLED FASTENER HOLES BS 640, STR 5R. REF SNRM N00674. REMOVED DAMAGE FROM WEB, FABRICATED AND INSTALLED REPAIR AND NEW SHEAR TIE. TREATED AND PRIMED REPAIR PARTS IAW EA 7-5310-107003. CLASSIFIED AS A MAJOR REPAIR.

Part: CREASE BEAM — MISREPAIRED (BS 740-760) · airframe 38,775 hrs · 27,001 cycles

CABIN FLOOR CREASE BEAM RT INNER CHORD HAS 7 PLUGGED HOLES BS 740-760, REPLACED CABIN FLOOR CREASE BEAM ANGLE AT CREASE BEAM STA 740-760 ON RT SIDE AT RBL 63" REFERENCE SRM 51-30-2.

Part: FRAME — DAMAGED (BS 640 S5R) · airframe 38,775 hrs · 27,001 cycles

MAIN DECK BODY, FRAME WEB AND SHEAR TIE HAVE 2 EA SHORT PITCH (0.25 INCH) MISDRILLED FASTENER HOLES BS 640, STR 5R. REMOVED DAMAGE FROM WEB, FABRICATED AND INSTALLED REPAIR AND NEW SHEAR TIE. TREATED AND PRIMED REPAIR PARTS REF EA 7-5310-107003.

Part: ATTACH FITTING — CRACKED (ZONE 300) · airframe 38,775 hrs · 27,001 cycles

NR 2 ENGINE INLET DOGHOUSE AT BASE OF VERTICAL LEADING EDGE VERTICAL WEB ATTACH CLIP CRACKED RT SIDE INTERIOR AT STA 1274. REMOVED AND REPLACED VERTICAL WEB ATTACH CLIP AT STA 1274 INSIDE VERTICAL STABILIZER ABOVE S DUCT ON RT SIDE, REF B727 SRM 51-30-2 PAGE 2.

Part: SKIN — CRACKED (ELEVATOR) · airframe 38,775 hrs · 27,001 cycles

LT HORIZONTAL STAB, ELEVATOR LWR SURFACE SKIN HAS CRACKS COMING OUT OF FWD AND AFT EDGES OF FASTENER HOLES, 38.5" OB OF INBD EDGE AND 13.5" FWD OF AFT EDGE. REPAIRED BONDED SKIN REF SRM 51-40-20 PG 59, 60, COOK TICKET ATTACHED TO N00129. PRIMED/PAINTED EXTERIOR, PROTECTIVE FINISH, REF MM 51-20-151-7.

Part: RETAINER — CRACKED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

RIGHT AFT EMERGENCY EXIT HATCH AFT LOWER SECTION HAS CRACKED SEAL RETAINER. REMOVED RETAINER REF SRM 51-20-2. FABRICATED NEW SEAL RETAINER REF BAC DWG 50-07978-53. INSTALLED NEW SEAL REF SRM 51-20-2 PG 4.

Part: SKIN — DAMAGED (ZONE 500) · airframe 38,775 hrs · 27,001 cycles

FOUND REPAIR AT LT WING FIXED LE AT IB END OF NR 3 SLAT. REPAIR REQUIRES EVALUATION FOR MAJOR/MMINOR DETERMINATION AND IF REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. FOUND EXISTING REPAIR DAMAGED. REMOVED DAMAGED REPAIR FILLER, FABRICATED NEW FILLER AND INSTALLED. REFERENCE SRM 57-30-4/FIGURE 4/PAGES 6-7. ALSO BLENDED GOUGE AFT OF REPAIR FILLER AND IS WITH IN LIMITS. REFERENCE SRM 57-20-1. CLASSIFIED AS A MINOR REPAIR.

Part: CREASE BEAM — DAMAGED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

CABIN LT CREASE BEAM INNER CHORD HAS 5 EA PLUGGED HOLES WL 208, BS 740 - 760. REMOVED SUPPORT ANGLE, AND INSTALLED NEW SUPPORT ANGLE, REFERENCE SRM 51-30-02. CLASSIFIED AS MAJOR REPAIR.

Part: STRINGER CLIP — DAMAGED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

MAIN CABIN FS 640, STR 3R STRINGER CLIP IS DAMAGED. FABRICATED STRINGER CLIP, TREATED, PRIMED AND INSTALLED CLIP REF SRM 51-10-2 PG 3, SRM 51-30-2 PG 3, AND DWG 65-15935-16. CLASSIFIED AS A MAJOR REPAIR.

Part: FLOORBEAM — CRACKED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FLIGHT DECK FLOOR SUPPORT CHANNEL IS CRACKED ON TOP OF CHANNEL LOCATED AT BS 285, LBL 6.5. INSTALLED NEW SUPPORT CHANNEL PER SRM 51-30-2 PG 2. CLASSIFIED AS A MAJOR REPAIR.

Part: SKIN — MISREPAIRED (FUSELAGE) · airframe 38,775 hrs · 27,001 cycles

FOUND EXTERNAL FUSELAGE REPAIR AT APPROX STA 1110-1130, AT S-20L DID NOT CONFORM TO SRM 53-30-3 FIG 5. REMOVED EXISTING REPAIR, EXTENDED FILLER AT LAP AND INSTALLED DOUBLER REF SRM 53-30-3 FIG 5.

Part: SKIN — CORRODED (RT WING) · airframe 38,775 hrs · 27,001 cycles

RIGHT WING LOWER SURFACE HAS CORROSION AT NR 6 FLAP TRACK MID ATTACH POINT. ACCOMPLISHED REPAIR OF ATTACH POINT, REF EA 7-5730-107001, WRI 57309127.

Part: SKIN — MISREPAIRED (FUSELAGE) · airframe 38,775 hrs · 27,001 cycles

FOUND FLUSH REPAIR AT APPROX FUSELAGE STATION 1110-1130 BETWEEN STR 13L-14L DID NOT CONFORM TO EA NR 7-5330-107007. REMOVED EXISTING INTERNAL PLUG DOUBLER PER EA NR 7-5330-107007. FABRICATED .090" INTERNAL DOUBLER TO COMFORM TO EA TREATED AND PRIMED, AND INSTALLED PLUG AT AFT GALLEY VENT LOCATION.

Part: BEAM — CORRODED (BS 745-765) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

AC BAY LBL 13 BEAM LOWER CHORD HAS CORROSION AROUND GROUND STUDS AND CLAMP SCREW BS 745-765, WL 140 ACCOMPLISHED REPAIR AT A/C BAY LBL 13 BEAM LOWER CHORD BS 745-765 REF SRM 51-40-3 PG 1-6. CLASSIFIED AS A MAJOR REPAIR.

Part: SKIN — MISREPAIRED (BS 720C-720D) · airframe 38,775 hrs · 27,001 cycles

FOUND EXTERNAL REPAIR APPROX BETWEEN STA 720C AND 720D, BETWEEN STR 7R-8R, TO BE INSTALLED WITH BLIND FASTENERS, AND DOUBLER ENDS ON STRUCTURE. REMOVED AND REPLACED DOUBLER BETWEEN STA 720C AND 720D. SEALED AND PAINTED. REF SRM 53-30-3 FIG 1.

Part: STRUCTURE — CRACKED (ZONE 500) · airframe 38,775 hrs · 27,001 cycles

FOUND LMLG WING DOOR LWR AFT EDGE ANGLE IS CRACKED. REPAIRED LMLG WING DOOR LWR AFT EDGE ANGLE REF SRM 51-40-3 FIGURE 1.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

MAIN DECK FLOOR SEAT TRACK OTBD FLANGE IS CORRODED AT BS 950 ,10 TO 950A 8, LBL 25, WL 208. BLENDED CORROSION AND FOUND TO BE OUT OF LIMITS REF SRM 53-10-1 FIG 3. REPAIRED SEAT TRACK REF SRM 53-10-5 FIG 7. CLASSIFIED AS A MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN DECK FLOOR SUPPORT SEAT TRACK OUTBD FLANGE IS CORRODED AT BS 1080 - 1090, RBL 1, WL 208. REMOVED DAMAGED/CORRODED OUT OF LIMIT SEAT TRACK FROM STA 1010 TO STA 1130, BL0 AND INSTALLED NEW SEAT TRACK REF SRM 53-10-2 FIGURE 7A SHEET 16 PAGE 16 AND SRM 51- 30-02. CLASSIFIED AS MAJOR REPAIR.

Part: SKIN — DENTED (ZONE 100) · airframe 38,775 hrs · 27,001 cycles

LOWER FUSELAGE AT BS 1148 TO 1170 BETWEEN STR 19R AND 20R, SKIN IS CREASED. REMOVED DAMAGE AND MANUFACTURED REPAIR PARTS REF SRM 53-30-3, PG 5. TREAT AND PRIMED REPAIR PARTS AND REPAIR AREA ON A/C SKIN REF SRM 51-10-2 PG 7. INSTALLED FASTENERS REF SRM 51-30-02 PG 8 AND SRM 53-30-3 PG 5, ITEM 12.

Part: FITTING — DAMAGED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

MAIN CABIN FS 340 STR 8L DOOR STOP FITTING FOR FWD ENTRY HAS A MISDRILLED HOLE. REMOVED OLD FITTING, DRILLED AND INSTALLED NEW STOP FITTING REF SRM 51-30-02 PG 4, MM 52-11-011-8 PG 1, POLY PAINTED FITTING REF MM 51-20-103-7, PG 1.

Part: FRAME — CRACKED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FRAME 277 IS CRACKED IN THE RADIUS OF CUT OUT FOR STRINGER 16R DISPLACED WIRING FOR ACCESS. VERIFIED CRACK, REMOVED FASTENERS AND DAMAGE, VERIFIED DAMAGE REMOVED AND MATERIAL LOSS. FABRICATED, TREATED AND INSTALLED DOUBLER, FILLER AND CLIP REF SRM 51-40-2 FIG 1 AND SRM 51-30-2. RESECURED DISPLACED WIRING FOR ACCESS.

Part: ANGLE — CRACKED (ZONE 800) · airframe 38,775 hrs · 27,001 cycles

FOUND LT FWD EMERGENCY EXIT UPPER FWD SEAL RETAINER ANGLE IS CRACKED AT FASTENER HOLE. REMOVED LT FWD EMERGENCY EXIT UPPER FWD SEAL RETAINER ANGLE AND INSTALLED NEW RETAINER ANGLE PER SRM 51-30-02 PG 2. REMOVED LINER AND REINSTALLED LINER PER SRM 51-30-02 PG 4.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN DECK FS 500 AND FS 525, LBL 26 SEAT TRACK CORRODED, DUE TO BEING PREVIOUSLY BLENDED AND NO PROTECTIVE FINISH APPLIED. REMOVED SEAT TRACK. FABRICATED NEW SEAT TRACK FROM BAC 1520-792, 7178T6511. INSTALLED NEW SEAT TRACK FROM BS 480-680 10 AT LBL 26, REF SRM 51-30-2, 53-30-2, 51-30-5 AND FX GMM 7-0-1001. FASTENER HOLES FOR INTERCOSTAL WEB AT BS 560-580 TO BE DRILLED ON WEB INSTALLATION ON SNRM NR N01084.

Part: STRINGER CLIP — CRACKED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN DECK BODY FRAME STRINGER CLIP IS CRACKED AT BS 950D, STR 9L. REMOVED DAMAGED CLIP REF SRM 51-30-2. INSTALLED NEW CLIP REF SRM 51-30-2.

Part: DOOR — CORRODED (ZONE 700) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

FOUND NLG LEFT FORWARD DOOR, INBOARD INNER CHORD IS CORRODED THRU AT AFT END REPLACED LEFT FWD NLG DOOR. REF MM 32-22-001-4, PG 1. DOOR ADJUSTMENT AND TEST ACCOMPLISHED ON ROUTINE CARD 71C130-00 SEQ# 98.

Part: STRINGER CLIP — CRACKED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN DECK BODY FRAME STR CLIP IS CRACKED AT BS 970, STR 9L REMOVED AND REPLACED CRACKED STRINGER ATTACH CLIP AT STRINGER 9L, BS 970 PER SRM 51-30-02 PG 8.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN DECK BODY FRAME STRINGER CLIP IS CRACKED AT BS 970, STR 9R. REMOVED CRACKED STRINGER CLIP, DRILLED UP NEW CLIP AND INSTALLED REF SRM 51-30-2.

Part: STRINGER CLIP — DAMAGED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN CABIN FS 540, STR 3 R STRINGER CLIP HAS NO RADIUS AND HAS SHARP EDGES ON TOP SIDE. REPLACED STRINGER CLIP AT STA 540, STR 3R REFERENCE SRM 51-30-2. CLASSIFIED AS MAJOR REPAIR.

Part: STRINGER CLIP — CRACKED (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN DECK BODY FRAME STRINGER CLIP IS CRACKED AT BS 950D, SRT 9R. REPLACED STRINGER CLIP REF SRM 51-30-2. CLASSIFIED AS A MAJOR REPAIR.

Part: STRINGER CLIP — DAMAGED (FUSELAGE) · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN CABIN STATION 620, STR 3R, STRINGER CLIP IS DAMAGED REPLACED STRINGER CLIP REF SRM 51-30-2.

Part: DOOR — CRACKED (NLG) · airframe 38,775 hrs · 27,001 cycles

FOUND NLG RT FWD DOOR INNER SKIN IS CRACKED AT INBD EDGE, FORWARD END CUT OUT DAMAGE. INSTALLED TYPICAL WEB REPAIR, REF SRM 51-40-2 FIG 1.

Part: SKIN — MISREPAIRED (FORE FLAP) · airframe 38,775 hrs · 27,001 cycles

FOUND REPAIR AT LT WING INBD FOREFLAP LE SKIN 21" FROM IB END (EXTERNAL REPAIR). REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. EVALUATED REPAIR, FOUND NOT TO CONFORM TO SRM 57-50-4 FIG 1. REMOVED EXISTING REPAIR, PICKED UP ONE ADDITIONAL ROW OF FASTENERS TO CONFORM TO SRM REPAIR 57-50-4 FIG 7. REPAIR CLASSIFIED AS MAJOR.

Part: SKIN — WORN (ZONE 200) · airframe 38,775 hrs · 27,001 cycles

FUSELAGE AT LT WING LEADING EDGE ROOT AT BS 720D, 10" - 14" AT STRINGER 19L, LAP AREA IS WORN FROM PANEL CONTACT. BLENDED DAMAGED AREA REF 53-30-1 PAGE 2A. FOUND TO BE OUT OF LIMITS REF SRM 53-30-1 PG 2C. REPAIRED AREA WITH DOUBLER AND FILLER REF SRM 53-30-3 FIG 5. CLASSIFIED AS A MAJOR REPAIR.

Part: STRINGER CLIP — DAMAGED (BS 540 S1L) · airframe 38,775 hrs · 27,001 cycles

FOUND MAIN CABIN STRINGER CLIP DAMAGED AT FS 540 STR 1. REPLACED STRINGER CLIP REF SRM 51-30-2 AND SRM 51-30-5. CLASSIFIED AS A MAJOR REPAIR.

Part: SKIN — CRACKED (FUSELAGE) · airframe 38,775 hrs · 27,001 cycles

FOUND LOWER FUSELAGE AT BS 178, LBL 0 - LBL 1 SKIN EDGE IS BENT, CRACKED AND KNIFE EDGED. REPAIRED DAMAGED LOWER FUSELAGE SKIN AT BS 178, LBL 0 - LBL 1 REF SRM 53-30-1, FIGURE 1.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 38,775 hrs · 27,001 cycles

MAIN DECK BODY FRAME STRINGER CLIP IS CRACKED AT BS 950C STR 9R. REPLACED STRINGER CLIP REFERENCE SRM 51-30-2. CLASSIFIED AS A MAJOR REPAIR.

Part: BUSHING — MIGRATED (T/E FLAP) · corrosion level 2 · airframe 38,775 hrs · 27,001 cycles

NR 6 FLAP TRACK FWD ATTACH FITTING HAS MIGRATING BUSHING AND INBD FACE HAS CORROSION (BORE ALSO CORRODED) WBL 203. REMOVE BUSHING, REAMED BORE, MPI BORE, FABRICATE BUSHING, CAD PLATE BUSHING, ROTOPEEN BORE AND FACES, CAD PLATE LUG AND INSTALLED BUSHING REF FED EX DWG SR 27-57-020 REV A., NOTES 1-9.

Part: UNKNOWN — UNKNOWN · airframe 38,703 hrs · 26,937 cycles

AFTER APPLICATION OF STANDARD TAKEOFF POWER AT APPROXIMATELY 60KTS A LOUD HIGH PITCH WHINE ACCOMPANIED WITH SOUND OF RUSHING AIR WAS HEARD. TAKEOFF WAS REJECTED AT 80KTS. CHECKED CARGO AND ENTRY DOOR SEALS FOR DAMAGE, NONE FOUND. PRESSURIZED AC IAW JRH CHAP 8. NO ABNORMAL LOUD NOISE HEARD. RAN NR 1 ENG IAW JRH, FOUND BLEED SYSTEM TO FUNCTION NORMALLY. AIRCRAFT OK FOR SERVICE.

Part: SAFETY SWITCH — DIRTY (NLG) · airframe 38,256 hrs · 26,574 cycles

ON LANDING AT APPROX 60 KTS, BRAKE PEDALS WERE FULLY DEPRESSED DID NOT NOTICE ANY CYCLING OF ANTISKID BRAKES, AND AIRCRAFT DID NOT APPEAR TO HAVE NORMAL AMOUNT OF BRAKING. ANTISKID LIGHT REMAINED OFF. OPERATED BRAKES, FOUND THAT NR 2 AND NR 3 BRAKES WOULD NOT ENGAGE MANUALLY WHEN AUTO BRAKE SELECTOR SWITCH WAS IN OFF POSITION. BRAKES WOULD ENGAGE MANUALLY. WHEN AUTO BRAKE SELECTOR WAS PLACED IN THE -DISARM- POSITION. PERFORMED AUTO BRAKE SYSTEM T/S 32-46-00. COULD NOT PASS STEP 1A. CLEANED & LUBED THE NOSE LANDING GEAR SAFETY SWITCH ACTUATOR PER STANDARD PRACTICE, OPS CKED ANTI-SKID SYSTEM PER B727-200 MM 32-42-001-5 SYSTEM OPS CKS GOOD AT THIS TIME.

Part: INDICATOR — MALFUNCTIONED (AIRSPEED) · airframe 38,159 hrs · 26,498 cycles

CAPT HAD NO AIRSPEED INDICATION ON TAKEOFF. REJECTED AT 80 KTS. REMOVED AND REPLACED CAPT'S AIRSPEED INDICATOR PER MM 34-12-021-4. OPS CHECKED GOOD IAW MM 34-12-00.

Part: DUCT — LEAKING (NR 1 PYLON) · airframe 38,116 hrs · 26,462 cycles

ENGINE NR 1 STRUT OVERHEAT LIGHT ILLUMINATED DURING CLIMB. COMPLETED QRH AND LIGHT RE-ILLUMINATED. NEW CLAMP DID NOT HELP 8TH STAGE DUCT APPEARS TO BE LEAKING IN PYLON. ALSO, REPLACED SENSE BRAIDED LINE, FOUND BLOWN COMING OFF T-FITING PER BOEING SPM. INSTALLED DUCT CLAMP RAN ENGINE PER JRH NO LEAKS DETECTED INSTALLED PYLON PANELS.

Part: COMPRESSOR — STALLED (NR 2 ENGINE) · airframe 38,054 hrs · 26,408 cycles

DEPARTING 23R IND USING STD PWER, EXPERIENCED COMPRESSOR STALLS ON NR 2 ENGINE. REJECTED TAKEOFF AT 50KTS AND EXITED RWY. ENGINE GAUGES WERE NORMAL EXCEPT NR 2 EPR, WHICH BARELY CLIMBED WHEN POWER WAS APPLIED. LEARN FROM THE MISTAKES OF OTHERS. REMOVED AND REPLACED NR 2 ENGINE PRBC, REF B727-200 AMM 75-31-011-4. PERFORMED TAKEOFF EPR TEST, ENGINE ACCELERATION TEST AND BLEED VALVE OPERATION CHECK OF THE NR 2 ENGINE PER JRH. ALL ENGINE PARAMETERS NORMAL FOR TESTS.

Part: ENGINE — FAILED (NR 2) · airframe 38,020 hrs · 26,380 cycles

PRECAUTIONARY SHUTDOWN NR 2 ENGINE DUE TO VIBRATION. AIRCRAFT ON GROUND REPORTED SEEING SPARKS COMING FROM NR 1 ENGINE, HOWEVER HAD SEVERE VIBRATION ON NR 2 ENGINE. FAN HAS FOD AND BLADES BROKEN IN HALF, SECOND STAGE DAMAGED, THIRD STAGE IS ALSO DAMAGED, METAL IN TAILPIPE ALL FINDINGS IN NR 2 ENGINE. STILL NEED TO INSPECT NR 1 ENGINE. R & R NR 2 ENGINE PER WORK CARD 70T0002. OK FOR SERVICE.

Part: INDICATOR — INOPERATIVE (NR 2 EPR) · airframe 37,893 hrs · 26,276 cycles

NR 2 EPR WOULD NOT REACH TAKEOFF EPR, NR 2 GAUGE WOULD ONLY REACH APPROXIMATELY 1.55 SETTING. ALL OTHER ENGINE GAUGES READ NORMAL. RELEASED FOR SERVICE PER MEL. NR 2 ENGINE EPR INDICATOR, INOP. RAN NR 2 ENGINE TO TEST EPR INDICATOR AND INDICATOR CHECKS GOOD IAW 727 JRH. REMOVED AND REPLACED NR 2 EPR INDICATOR IAW 727 SMP.

Part: INDICATOR — INOPERATIVE (NR 3 EPR) · airframe 37,860 hrs · 26,249 cycles

NR 3 EPR GAUGE DID NOT MOVE WHEN THROTTLES ADVANCED FOR TAKEOFF. RELEASED FOR SERVICE PER MEL/CDL: 77-01-01 CATEGORY: A EXPIRATION: 23DEC05 "MEL 77-01-01: NR 3 ENGINE EPR INDICATOR INOP."

Part: AUTOPILOT SYS — MALFUNCTIONED (COCKPIT) · airframe 36,067 hrs · 24,808 cycles

AT ALTITUDE FL280 CREW NOTICED AN UNUSUAL VIBRATION OF AIRCRAFT. ALL ENGINES / INSTRUMENTS INDICATED NORMALLY. ELECTED TO DIVERT TO SDF. VIBRATION / SHUTTER CONTINUED DURING TAXI IN. ACN RELEASED FOR SERVICE PER MEL/CDL: 22-06-A CATEGORY: C EXPIRATION: 18NOV03 MEL 22-06-A: UPPER YAW DAMPER INOP. FOUND UPPER RUDDER SHUTTERING BACK AND FORTH. TURNED UPPER YAW DAMPER OFF SHUTTERING STOP. DEFERRED UPPER YAW DAMPER. SWAPPED YAW DAMPER COUPLERS, NO HELP RETURNED TO ORIGINAL POSITIONS. REF B727-200 MM 22-11-131-4, NEEDS CONTINUED T/S.

Part: SWITCH — FALSE INDICATION (ZONE 400) · airframe 35,943 hrs · 24,701 cycles

ENGINE NR 3 OVERHEAT LIGHT ILLUMINATED ON CLIMB OUT REFRENCED JRH AND CLOSED THE RIGHT WING ANTI-ICE SWITCH. LIGHT WENT OUT AND STAYED OUT FOR REMAINDER OF FLIGHT. CHECKED DUCTS AND CLAMPS ON NR 3 ENGINE OPS CHECK SYSTEM USING APU POWER IAW SMP. COULD NOT DUPLICATE PROBLEM.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 35,787 hrs · 24,581 cycles

MDIS 463 53-30 0005661 26JUN03 BFM CLOSE R COMPLY WITH EA NR 7-5330-70964 FUSELAGE-SKIN-PRE-EXISTING ELONGATED HOLES UNDER MCD HINGE (AD 2002-16-19).. FACT 29JUN03 17:38 BFM U COMPLIED WITH EA NR 7-5330-70964 FUSELAGE-SKIN-PRE-EXISTING ELONGATED HOLES UNDER MCD HINGE (AD2002-16-19 ). CLOSED ON 06/29/2003

Part: TRIPLER — WORN (FUSELAGE) · airframe 35,787 hrs · 24,581 cycles

MDIS 463 53-30 0005660 25JUN03 BFM CLOSER COMPLY WITH EA 7-5330-70962; MAIN CARGO DOOR TRIPLER WEAR. FACT 27JUN03 13:59 BFM R COMPLIED WITH EA NR 7-5330-70962, FUSELAGE-MAIN CARGO DOOR TRIPLER WEAR, P/N 53FX1301-7/-9.

Part: FITTING — GOUGED (MAIN CARGO DOOR) · airframe 35,787 hrs · 24,581 cycles

MDIS 463 53-10 0005658 24JUN03 BFM CLOSE R COMPLY WITH EA NR 7-5310-70960, FUSELAGE - MAIN CARGO DOOR ACTUATOR FITTING GOUGE REPAIR P/N 53FX1428-1. FACT 27JUN03 13:57 BFM R COMPLIED WITH EA NR 7-5310-70960,FUSELAGE-MAIN CARGO DOOR ACTUATOR FITTING GOUGE REPAIR P/N 53FX1428-1.

Part: DOOR — MALFUNCTIONED (RT MLG) · airframe 35,591 hrs · 24,418 cycles

DURING GEAR RETRACTION, THE RT GEAR DOOR LIGHT AND PILOTS GEAR DOOR WARNING LIGHT REMAINED ILLUMINATED. RECYCLED GEAR IAW RED TABS AND LIGHTS EXTINGUISHED. OPERATED RIGHT DOOR FOR MAIN GEAR WITH GROUND RELEASE HANDLE OPERATES NORMAL IAW M/M 32-62-011-5.

Part: SWITCH — FAULTY (HYD SYSTEM) · airframe 35,039 hrs · 23,981 cycles

HYD A-SYSTEM OVERHEAT LIGHT ILLUMINATED ON TAXI OUT. RAN THE CHECKLIST AND LIGHT EXTINGUISHED. TALKED WITH MX T/O. DURING CLIMBOUT HYD A-SYSTEM OVERHEAT LIGHT RE-ILLUMINATED. RAN THE CHECKLIST AND RETURNED TO MEM. REMOVED AND REPLACED NR 1 & NR 2 ENG HYD CASE DRAIN FILTER, OLD FILTERS WERE CLEAN. REMOVED AND REPLACED OVERHEAT SWITCH, RAN ENGINES LIGHT DID NOT COME ON. ALL WORK WAS DONE USING A STANDARD MAINTENANCE PRACTICE.

Part: FRAME — DENTED (FUSELAGE)

DENTS IN FRAME BS 580, STR 22 - 23 LT. REMOVED AND REPLACED FRAME PER SRM 51-30-2.

Part: STRUCTURE — CORRODED (L/E FLAP) · corrosion level 2

NR 5 K-FLAP OUTBOARD LWR BONDING JUMPER UPPER ATTACH POINT IS CORRODED. REMOVED AND REPLACED FLAP PER DWG SR 27-97-010.

Part: FRAME — GOUGED (FUSELAGE)

FRAME GOUGED AT BS 620, STR 6R. REMOVED AND REPLACED FRAME PER SRM 53-10-4.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2

CORROSION ON UPPER FLANGE OF FLOORBEAM BS 312, LBL 3-19. REMOVED AND REPLACED FLOORBEAM PER DWG SR 27-53-017A.

Part: STRINGER — CHAFED (FUSELAGE)

N 1101 STRINGER 7 LT MID SPAR IS CHAFED 4 INCHES IN FRONT OF SLIDING SEAL. R&R STRINGER PER E.A. 7-5530-54204.

Part: FLOORBEAM — DAMAGED (FUSELAGE)

HOLES IN FLOORBEAM AT BS 400, RBL 60-65, WL 208. REMOVED AND REPLACED FLOORBEAM PER SRM 53-10-8 FIG 3 & EA 7-5335-54192.

Part: FLOORBEAM — DAMAGED (FUSELAGE)

HOLE UPPER FWD FLANGE OF FLOORBEAM BS 480, RBL 49, WL 208. REMOVED AND REPLACED FLOORBEAM PER EA 7-5335-54192 & SRM 53-10-8 FIG 3.

Part: FLOORBEAM — DAMAGED (FUSELAGE)

HOLES IN FLOORBEAM AT BS 380, RBL 60-65, WL 208. REMOVED AND REPLACED FLOORBEAM PER EA 7-5335-54192 & SRM 53-10-8 FIG 3.

Part: FLOORBEAM — DAMAGED (FUSELAGE)

HOLES IN FLOORBEAM AT BS 420, RBL 60-65, WL 208. REMOVED AND REPLACED FLOORBEAM PER EA 7-5335-54192.

Part: FLOORBEAM — DAMAGED (FUSELAGE)

HOLES IN FLOORBEAM AT BS 400, RBL 60-65, WL 208. REMOVED AND REPLACED FLOORBEAM PER EA 7-5335-54192 & SRM 53-10-8 FIG 3.

Part: WEB — DAMAGED (FUSELAGE)

HOLES IN WEB AT BS 372 TO 415, RBL 65 TO 70, WL 208. REMOVED AND REPLACED WEB PER SRM 51-30-2, 53-10-1, 51-10-3, 51-10-2, 51-20-1.

Part: PIN — CORRODED (WING)

CORROSION AT FLANGE BASE OF TERMINAL PIN. REMOVED AND REPLACED PIN PER 75C012-00.

Part: PIN — CORRODED (WING)

CORROSION AT FLANGE BASE OF TERMINAL PIN. REMOVED AND REPLACED PIN PER 75C011-00.

Part: FLOORBEAM — DAMAGED (FUSELAGE)

FOUND HOLES IN FLOORBEAM BS 440, RBL 60-65, WL 208. REMOVED AND REPLACED FLOORBEAM PER EA 7-5335-54192 & SRM 53-10-8 FIG 3.

Part: FRAME — CRACKED

N 852 CRACKED FRAME AT FASTENER HOLE AT BS 540, RBL 3, WL 155. ** S/D ** COMING

Part: FRAME — CORRODED (FUSELAGE)

CORROSION (C53-224-01) AND TOOLING DAMAGE ON FRAME I/B FLANGE BS 372, WL 212, RBL 64. REMOVED AND REPLACED FRAME PER SRM 51-4-3.

Part: SHEAR TIE — CRACKED (FUSELAGE)

FRAME TO SKIN SHEAR TIE CRACKED AT BS 990, L29L. REMOVED AND REPLACED PARTS FOR SHEAR TIE PER SRM 51-10-4 FIG 13.

Part: FRAME — CRACKED

N 321 DRILL START IN BS 700 FRAME BETWEEN STR 24 & 35 R. ** S/D ** R&R FRAME PER SRM 51-40-03.

Part: ACCESSORY UNIT — FALSE INDICATION (EE BAY)

WHILE RAISING THE GEAR THE LEFT GEAR RED LIGHT STAY ILLUM. DID PROC AND LIGHT REMAIN ON. CONT FLT IN ACCORD WITH FLT MANUAL. CLEAN UPLOCK PROXIMITY SENSOR AND SENSOR TARGET. PERF LAND GEAR ASSY UNIT FUNCTION TEST PER MM 32-09-122-5. ALL STEPS PASSED. REMOVED AND REPLACED LG ASSY UNIT PER MM 32-09-121-4. PERF GEAR SWING PER MM 32-32-000-5. OPS NORM PER MM 32-61-001-5.

Part: SWITCH — CLOSED (RT WING ANTI-ICE)

AT 800 FEET CLIMBING OUT, ANTI-ICE DUCT OVERHEAT LIGHT ON, WHEN CORRESPONDING BLEED AIR SWITCHES CLOSED, NO HELP. WHEN NR 3 ENGINE POWER RETARDED LIGHT WENT OUT. RAN NR 3 ENGINE PER JET RUN, HANDBOOK CHAPTER 5 OPERATIONAL CHECK GOOD. FOUND RIGHT WING ANTI-ICE SWITCH IN OPEN POSITION AFTER LANDING, SUSPECT CAUSE OF OVERHEAT. CHECKED WING LEADING EDGE SURFACES, NO FAULTS NOTED PER STANDARD MAINTENANCE PRACTICES.

Part: SWITCH — LACK OF LUBE (LT MLG DOOR)

CONFIGURED AC WITH GEAR AND 15 DEG FLAPS DURING APPROACH. GEAR EXTENSION NORMAL, BUT DOOR LIGHT AND LEFT GEAR DOOR LIGHT REMAINED ILLUMINATED. LUBED DOOR WARNING SWITCH, GEAR DOOR WARNING SYS CK GOOD PER MM 32-62-011.

Part: SENSOR — MALFUNCTIONED (RT MLG)

RT MAIN GEAR UNSAFE LIGHT DURING T/O. RETRACT GEAR AND GOT GOOD UP IND. LOWERED GEAR AND GOT RT MAIN UNSAFE. CK RT MAIN FOR GOOD DOWN IND WITH GEAR CRANK AND IT CK GOOD. FIVE MIN AFTER LANDING GOT UNSAFE RT MAIN IND AGAIN WHILE IN CHOCKS, IN ALL CASES WHEN RED UNSAFE LIGHT CAME. REMOVED AND REPLACED LANDING GEAR ASSY PER MM 32-09-121 AND RMG DOWNLOCK SENSOR PER M/M 32-61-91. ALL CKS WERE NORM.

Part: FLOORBEAM — CORRODED (BS 400)

CORROSION AT NUT PLATE HOLE AT EDGE OF FLOORBEAM BS 400, RBL 35. REMOVED CORROSION PER SRM 53-10-01, INSTALLED DOUBLER REPAIR PER SRM 53-10-1.

Part: FLOORBEAM — CORRODED (BS 344)

HEAVY CORROSION BS 344 FLOORBEAM RBL 10. CUTOUT DAMAGED SECTION OF FLOORBEAM CHORD AND REPLACED WITH NEW CHORD USING BS 344 CHORD SPLICE PER FED-EX DRAWING NR SR 27-53-007.

Part: FLOORBEAM — CORRODED (BS 344)

CORROSION ON FLOORBEAM UNDERSIDE AT MISSING NUT PLATE AREA BS 344, RBL 35 FWD SIDE OF BEAM. CUT OUT DAMAGED SECTION OF FLOORBEAM CHORD AND REPLACED WITH NEW CHORD USING BS 344 CHORD SPLICE PER FED-EX DRAWING NR SR 27-53-007.

Part: SPAR — CRACKED (RT TE MID FLAP)

RT WING, IN/BD MIDFLAP, T/EDGE SPAR LWR CHORD CRACKED, APPROX 4 FT FROM IN/BD END OF FLAP. REMOVED DAMAGED SECTION, FABRICATED NEW SECTION AND INSTALLED PER SRM 51-50-2 AND 51-40-3.

Part: FLOORBEAM — CORRODED (BS 400)

CORROSION AT NUT PLATE HOLE TO EDGE OF FLOORBEAM BS 400, RBL 35 FWD SIDE OF BEAM. CUT OUT CORROSION AND INSTALLED FLOORBEAM REPAIR PER 53-10-01.

Part: TR SWITCH — FAILED (NR 3 ENGINE)

AFTER ROTATION NR 3 REVERSER OPERATING LIGHT ILLUMINATED, PERFORMED APPROPRIATE CHECKLIST AND SHUTDOWN NR 3 ENG. REPLACED NR 3 ENG REVERSER SWITCH PER MM 78-30-00. OPS CHECKED NORMAL, PANELS SECURED.