N469AA

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 74,781 hrs · 39,455 cycles

FOUND CRACK IN UPPER PART OF CAPTAIN`S L1 WINDSHIELD. R & R CAPTAIN`S L1 WINDSHIELD IAW AMM 56-10-02. PERFORMED OPERATIONAL CHECKS IAW AMM 31-41-00 & 31-42-00. SYS CHECKED NORMAL.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 74,447 hrs · 39,252 cycles

CRACKED SHEAR TIE AT FRAME 1437 LONGERON 2 TO 3 LT. INSTALLED NEW SHEAR TIE IAW AARD 51-00-05-1.

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 74,447 hrs · 39,252 cycles

STATION 1437 CRACK AFT OF FASTENER BETWEEN LONGERON 3 & 4 RT. INSTALLED DOUBLER SRM 53-04-00-001 FIGURE 27 & EA MD80-53-036885.

Part: SKIN — CRACKED (FUSELAGE) · airframe 74,447 hrs · 39,252 cycles

FUSELAGE SKIN CRACKED AT STATION 1309 & LONGERON 7 LT. INSTALLED DOUBLER IAW SRM 53-04-00 FIGURE 32.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 74,352 hrs · 39,194 cycles

FORWARD ESCAPE PATH LIGHTS FOR ROWS 3 TO 20 WEAK DURING TEST USING AB5-2 CONTROLLER. REPLACED BATTERY FOR ESCAPE PATH LIGHTS CONTROLLER AB5-2. OPERATIONS CHECKED NORMAL.

Part: BATTERY — DISCHARGED (CABIN) · airframe 74,352 hrs · 39,194 cycles

AFT ESCAPE PATH LIGHTS DIM DURING TESTING AB5-3 CONTROLLER. REPLACED BATTERY FOR ESCAPE PATH LIGHTS CONTROLLER AB5-3. OPERATIONS CHECKED NORMAL.

Part: FORMER — CRACKED (LE SLAT) · airframe 74,293 hrs · 39,163 cycles

LEFT WING LE NR 4 SLAT TRACK INBD FORMER IS CRACKED. INSTALLED LT WING NR 4 SLAT INBD FORMER DOUBLER & HAT BUSHING IAW WORK CARD 57-98-05.

Part: FORMER — CRACKED (LE SLAT) · airframe 74,293 hrs · 39,163 cycles

RIGHT WING LE NR 4 SLAT TRACK INBD FORMER IS CRACKED. INSTALLED RT WING NR 4 INBD FORMER DOUBLER & HAT BUSHING IAW WORK CARD 57-98-06.

Part: FUEL FILTER — DEFECTIVE (APU) · airframe 73,925 hrs · 38,938 cycles

ON ROTATION, AUXILIARY POWER UNIT FAULT LIGHT & LOW OIL PRESS LIGHT ILLUMINATED & APU ROLLED BACK. LT ENG DRIVEN GEN WAS ON PLACARD. FLIGHT RETURNED & LANDED WITHOUT INCIDENT. ACFT REMOVED FROM SERVICE. REPLACED APU MAIN FUEL FILTER. SYS GND CHECKED NORMAL OPERATION CLOSED.

Part: BATTERY PACK — DISCHARGED (ZONE 200) · airframe 73,197 hrs · 38,521 cycles

LOWEST TAIL CONE SLIDE EMERGENCY LIGHT INOPERATIVE. R & R BATTERY PACK AT STATION 1322 RT, OPERATIONS CHECKED NORMAL.

Part: FAIRING — CRACKED (ZONE 300) · airframe 73,167 hrs · 38,501 cycles

ZFS=52.267 HAS CRACK INDICATION IN LOWER LE FAIRING ON LT SIDE 12TH HOLE FROM BOTTOM. FABRICATED & INSTALLED COUNTERSUNK REPAIR BUSHING IAW EA MD80-55-034271.

Part: INDICATOR — MALFUNCTIONED (TCAS) · airframe 71,406 hrs · 37,498 cycles

ELECTRICAL BURNING SMELL DETECTED IN COCKPIT. ACCOMPLISHED PACK BURN & REPLACED TCAS INDICATOR. SYSTEM GROUND CHECKED NORMAL.

Part: SHROUD — BROKEN (CABIN) · airframe 70,211 hrs · 36,827 cycles

EMERGENCY LIGHT ON SEAT 13C SHROUD IS BROKEN. REMOVED AND REPLACED SEAT 13C EMERGENCY LIGHT SHROUD.

Part: CLAMP — LOOSE (AC BAY) · airframe 68,024 hrs · 35,624 cycles

STL - INFLIGHT ORD-TUS. CREW REPORTED LEFT PACK FAILED ON CLIMBOUT. FLIGHT DIVERTED STL LANDED WITHOUT INCIDENT. FOUND CLAMP LOOSE FOR BOOT AT LEFT FORWARD HEAT EXCHANGER OUTLET. REPOSITIONED DUCT AND SECURED BOOT AT LEFT FORWARD HEAT EXCHANGER OUTLET. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: LONGERON — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,063 hrs · 35,089 cycles

AFT CARGO STATION 1287 LONGERON 28 RIGHT CORRODED. INSTALLED LONGERON SPLICE ON LONGERON 28 RIGHT AT STATION 1287 PER SRM 53-00-00-05.

Part: STIFFENER — CRACKED (FUSELAGE) · airframe 67,063 hrs · 35,089 cycles

STIFFENER CRACKED ABOVE VAULT DOOR ON 1338 BULKHEAD, LEFT NUMBER 1 DOOR. ACCOMPLISHED DOUBLER REPAIR PER EA MD80-53-020676 AND SRM 51-70-5.

Part: DOUBLER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,063 hrs · 35,089 cycles

AFT CARGO EXISTING BEAM DOUBLER LOWER LEG RIPPLED UP BETWEEN STATIONS 1155 TO 1212. REMOVED CORROSION AND INSTALLED DOOR BEAM AARDS 53-10-00-3, 51-10-00-5, SRMS 51-10-03, 51-30-05, 51-30-01 AND BOEING DRAWING 5936038.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,063 hrs · 35,089 cycles

LEFT CUSP FRAME STATIONS 302 TO 303 CORRODED. REMOVED CORROSION AND INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 67,063 hrs · 35,089 cycles

FORWARD CABIN ENTRY DOOR JAMB AFT SIDE TANG CRACKED AT FRAME STATION 208 LONGERON 15 LEFT. REMOVED CRACK BY CUTTING OFF TAB AND INSTALLED DOUBLER PER AARD 53-10-00-11.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,063 hrs · 35,089 cycles

RIGHT CUSP SHEET FROM STATIONS 1250 TO 1308 CORRODED. INSTALLED NEW CUSP FROM STATIONS 1250 TO 1308 RIGHT SIDE PER AARD 53-20-00-16 AND SRM 51-30-05, 51-30-01.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,063 hrs · 35,089 cycles

DAMAGED TO CUSP AT STATION 1250 BETWEEN SEAT TRACKS 1 AND 2. COMPLETED INSULATION OF DOUBLER PER AARD 53-20-00-16.

Part: PAN — CRACKED (WINDOW) · airframe 67,063 hrs · 35,089 cycles

CRACK AT LEFT WINDOW PAN LOWER FORWARD CORNER, STATION 1022. ACCOMPLISHED NESTED ANGLE REPAIR PER AARD 53-10-00-25.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 67,063 hrs · 35,089 cycles

SHEAR TIE CRACKED AFT SIDE LONGERON 2 LEFT. REPLACED SHEAR TIE PER SRM 53-01-00.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,063 hrs · 35,089 cycles

LEFT CUSP STATIONS 302 TO 303 CORROSION OUT OF LIMITS. ACCOMPLISHED DOUBLER REPAIR PER AARD 53-20-00-16.

Part: LIGHT — INOPERATIVE (FUSELAGE) · airframe 66,796 hrs · 34,934 cycles

CEILING EMERGENCY LIGHT AT SEAT 27B INOPERATIVE. REPLACED LAMP FOR SEAT 27B EMERGENCY LIGHT. OPS CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 66,796 hrs · 34,934 cycles

RIGHT AND CENTER CEILING EMERGENCY LIGHTS BETWEEN AFT LAVATORIES INOPERATIVE. REPLACED RIGHT AFT LAVATORY FORWARD BATTERY PACK. OPS CHECK NORMAL.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 66,796 hrs · 34,934 cycles

CEILING EMERGENCY LIGHT AT SEAT 23D INOPERATIVE. REPLACED LAMP FOR SEAT 23D EMERGENCY LIGHT. OPS CHECK NORMAL.

Part: ENGINE — FAILED (RIGHT) · airframe 64,679 hrs · 33,769 cycles

DFW - CREW REPORTED GENERATOR FAILED MESSAGE FOLLOWED BY A FIRE WARNING ON RIGHT ENGINE. PULLED FIRE HANDLE AND DISCHARGED BOTH FIRE BOTTLES. RIGHT ENGINE SHUTDOWN (SINGLE ENGINE TIME 16 MINUTES) EMERGENCY DECLARED FLIGHT LANDED DFW WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED RIGHT ENGINE AT DFW ON 12/26/2010. REPLACED BOTH FIRE BOTTLES. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: CONTROLLER — FAULTY (CABIN PRESSURE) · airframe 63,284 hrs · 33,004 cycles

PHX - INFLIGHT TUS-ORD. CREW REPORTED MULTIPLE PRESSURIZATION FAULTS DURING CLIMBOUT. EMERGENCY DECLARED DIVERTED PHX LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED BOTH PRESSURIZATION CONTROLLERS AND PRESSURIZATION CONTROL PANEL. TIGHTENED THREE UNIONS AND B-NUTS ON LEFT AUGMENTATION VALVE THAT WERE LOOSE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SKIN — CRACKED (FUSELAGE) · airframe 63,281 hrs · 33,001 cycles

FUSELAGE SKIN CRACKED AT FASTENER STATION 196 LONGERON 22 LEFT. INSTALLED DOUBLER AND FILLER PER EA 010892.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 61,873 hrs · 32,288 cycles

SEAT MOUNTED EMERGENCY LIGHTS FROM SEAT 21DEF AFT ARE DIM. REPLACED BATTERY PACK.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 61,873 hrs · 32,288 cycles

EMERGENCY EXIT SIGNS AT SEAT ROW 21 INOPERATIVE. REPLACED BATTERY PACK FOR AFT OVERWING EMERGENCY EXIT SIGNS.

Part: LIGHT — NOT SEATED (CABIN) · airframe 60,536 hrs

EWR - RIGHT AISLE FORWARD ENTRY EMERGENCY LIGHTS ON INTERMITTENTLY. RESEATED FORWARD REMOVABLE EMERGENCY LIGHT UNIT.

Part: LENS — MISSING (CABIN) · airframe 60,362 hrs

LGA SEAT MOUNTED EMERGENCY EXIT LIGHT AT SEAT 13D MISSING LENS. REPLACED LENS FOR SEAT MOUNTED EMERGENCY EXIT LIGHT AT SEAT 13D.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 60,362 hrs

LGA FORWARD CEILING BY AFT GALLEY EMERGENCY LIGHT INOPERATIVE. REPLACED LAMP FOR EMERGENCY LIGHT AT FORWARD CEILING BY AFT GALLEY.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 60,362 hrs

LGA SEAT MOUNTED EMERGENCY EXIT LIGHT AT SEAT 13D INOPERATIVE. REPLACED LAMP FOR SEAT MOUNTED EMERGENCY EXIT LIGHT AT SEAT 13D.

Part: PUMP — INOPERATIVE (FUEL BOOST) · airframe 60,327 hrs · 31,457 cycles

INFLIGHT TPA-DFW. LEFT HAND FUEL BOOST PUMP FAULT. EMERGENCY DECLARED LANDED TLH WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED LEFT AFT FUEL BOOST PUMP. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: SKIN — CRACKED (ZONE 100) · airframe 68,673 hrs · 30,471 cycles

CRACK AT FASTENER HOLE STATION 191 LONGERON 22 LEFT. DAMAGE CUTOUT AT REPAIRED PER ESO 80559 DATED 10/3/08 AND BOEING SERVICE REWORK DRAWING SRO9530219.

Part: LONGERON — CORRODED (ZONE 100) · airframe 56,290 hrs · 29,030 cycles

CORROSION IN LONGERON 29 RIGHT. REPLACED LONGERON AND SPLICED IN NEW PART PER 53-02-00.

Part: INTERCOSTAL — CRACKED (ZONE 100) · airframe 56,290 hrs · 29,030 cycles

CRACK IN CEILING INTERCOSTAL AT STATION 1297 AFT CARGO. REPLACED INTERCOSTAL FROM STATION 1297- 1309 AT CENTER FLOORBOARD.

Part: INTERCOSTAL — CRACKED (ZONE 100) · airframe 56,290 hrs · 29,030 cycles

INTERCOSTAL UNDER FLOORBOARD C-18 BETWEEN STATION 1271-1287 CRACKED AT MOUNT HOLES TO FLOORBOARD. INSTALL NEW INTERCOSTAL 1271 -1287 STATION PER SRM 51-01-00.

Part: BATTERY PACK — DISCHARGED (CABIN) · 58,772 cycles

PHX CREW REPORTED EMERGENCY EXIT SIGN NOT ILLUMINATED AT OVERWING EXITS. REPLACED BATTERY PACK IN AFT POSITION STATION 1100, FOR EMERGENCY SIGN AT AFT OVERWING EXIT. SYSTEM GROUND CHECKED NORMAL OPS.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

SFO - EMERGENCY EXIT SIGN LIGHT AT FORWARD OVERWING EXIT DOOR INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY EXIT SIGN LIGHT AT FORWARD OVERWING EXIT DOOR. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SEAL — LEAKING (LT TANK ACCESS)

SFO INFLIGHT T1514/06FEB SJC TO DFW - AFTER TAKEOFF FELT WING INBALANCE. FUEL GAGE HAD LEFT MAIN 450, RIGHT MAIN 9250 AND CENTER 14700. UNWANTED FUEL TRANSFER FROM LEFT WING TO CENTER TANK. LANDED SFO WITHOUT INCIDENT. FOUND FUEL LEAK FROM LEFT WING FUEL BOOST PUMP COVER PLATE. REPLACED TANK ACCESS COVER SEAL. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: COMPRESSOR — STALLED (RIGHT ENGINE)

ORD - DURING CLIMB ABOUT 2000 ABOVE GROUND LEVEL AIRCRAFT EXPERIENCED VIBRATION. CREW HEARD GRINDING SOUND FOLLOWED BY A SECOND JOLT. RIGHT ENGINE INSTRUMENTS DROPPED THEN WENT BACK UP. RETARDED AUTO THROTTLE TO IDLE AND JOLTS STOPPED. CAPTAIN SHUT DOWN RIGHT ENGINE. SINGLE ENGINE TIME APPROXIMATELY SEVEN MINUTES. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. REPLACED NUMBER TWO ENGINE DUE TO COMPRESSOR STALLS ON 18 DEC 2006 AT ORD. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

SFO - CEILING EMERGENCY LIGHTS ABOVE SEATS 23, 24, AND 26 INOPERATIVE. REPLACED BATTERY PACK AT ROWS 23 VOR CEILING EMERGENCY LIGHTS ABOVE SEATS 23, 24, AND 26. SYSTEM GROUND CHECKED NORMAL OPERATION. (CLOSED)

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

ATL - EMERGENCY LIGHT AT ROWS 20 THROUGH 31 INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS AT ROWS 20 THROUGH 31. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: ENGINE — FAILED (RIGHT)

TPA - FLT 1525 - AT TPA ON TAKEOFF ROLL, ENGINES APPROACHING TAKEOFF THRUST, RIGHT ENGINE FAILED. EGT EXCEEDED 700 C DEGREES. FIRE BOTTLE NR 2 WAS USED. REPLACED NR 2 ENGINE. ACCOMPLISHED TRIM RUN UP AND LEAK CHECK. REPLACED NR 2 FIRE BOTTLE. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONNECTOR — LOOSE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, FIRST CLASS CEILING EMERGENCY EXIT LIGHTS INOPERATIVE. TIGHTENED EMERGENCY EXIT LIGHT BATTERY CONNECTOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: BATTERY — NOT SEATED (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, OVERHEAD EMERGENCY EXIT LIGHTS AT ROW 13-16 INOPERATIVE. RESEATED EMERGENCY EXIT LIGHT BATTERY CONTACTS. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: ANGLE — CRACKED (FUSELAGE)

TUL - FOUND RIGHT STAB TO FUSELAGE ATTACH ANGLE CRACKED BETWEEN FASTENERS AT AFT END. REPAIRED BY INSTALLATION OF A REPAIR DOUBLER PER MD80 AARD 53-10-00-2. (M)

Part: COMPRESSOR — STALLED (LT ENGINE)

SFO - FLT 892 - EN ROUTE SFO-DFW, DURING TAKEOFF ROLL, CREW REPORTED A LEFT SIDE COMPRESSOR STALL. ABORTED TAKEOFF. RETURNED SFO GATE WITHOUT FURTHER INCIDENT. ACCOMPLISHED BORESCOPE INSPECTION IAW THE MM. NO DEFECTS FOUND. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: O-RING — LEAKING (NLG)

DFW - FLT 1318 - EN ROUTE DFW-CMH, ON TAKEOFF, DETECTED NOSE GEAR LIGHT ILLUMINATE AT COCKPIT. RETURNED DFW AND LANDED WITHOUT INCIDENT. REPLACED O-RING AT NOSE LANDING GEAR SCHRADER VALVE. SERVICED STRUT. SWUNG NOSE LANDING GEAR PER THE MM. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: STRUT — DISCHARGED (NLG)

DFW - FLT 1571 - EN ROUTE DFW-TUS, SHORTLY AFTER TAKEOFF ATTEMPTED TO RAISE LANDED GEAR. LANDING GEAR WOULD NOT RETRACT. RETURNED DFW AND LANDED WITHOUT FURTHER INCIDENT. SERVICED NOSE LANDING GEAR STRUT. ACCOMPLISHED GEAR RETRACTION PER THE MM. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: LATCH — DIRTY (MLG DOOR)

ORD - FLT 0066 - AFTER TAKEOFF, LEFT GEAR DOOR LIGHT (RED) ILLUMINATED. PROCEDURE FOLLOWED AND FLIGHT CONTINUED IN MANUAL. DURING CRUISE, THE AMBER GEAR DOOR LIGHT ILLUMINATED WITH ASSOCIATED NOISE AND YAW. INCREASED HYDRAULIC PRESSURE TO EXTINGUISH THE AMBER DOOR OPEN LIGHT. RED LEFT GEAR LIGHT REMAINED ILLUMINATED. CLEANED DEBRIS FROM LEFT MAIN GEAR DOOR LATCH. LUBRICATED LATCH MECHANISM ON BOTH GEAR DOORS. CYCLED GEAR SEVERAL TIMES. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: SEAT TRACK — CORRODED (BS 483)

TUL - FOUND CORROSION ON NR 6 SEAT TRACK. INSTALLED SEAT TRACK PLUG PER AARD 53-20-00-10. (M)

Part: PUMP — FAILED (NR 1 ENGINE)

RDU - FLT 1547 - EN ROUTE BOS-MCO - AT 35,000 FT LEFT INLET LOW FULE PRESSURE LIGHT ILLUMINATED. LEFT FUEL QTY DECREASED NORMALLY. FIFTEEN MINUTES LATER LEFT ENGINE FLAMED OUT. RESTARTED ENGINE WITH X FEED OPEN. CREW DECLARED AN EMERGENCY, AIR INTERRUPTED, AND LANDED RDU WITHOUT INCIDENT. REPLACED LEFT ENGINE FUEL PUMP AND FUE CONTROL. PERFORMED LEAK AND TRIM CHECKS. REPLACED LEFT ENGINE FUEL PUMP AND FUEL CONTROL. PERFORMED LEAK AND TRIM CHECKS. REPLACED FORWARD AND AFT NR 1 FUEL TANK BOOST PUMPS. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: PIN — INSTALLED (MLG)

ORD - FLT 1731 - AFTER TAKEOFF DTW, UNABLE TO RAISE MAIN LANDING GEAR. LANDED ORD WITHOUT INCIDENT. REMOVED MAIN LANDING GEAR DOWNLOCK PINS. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: SLIDE — DEFECTIVE (TAILCONE)

ORD - DURING OVERNIGHT MAINTENANCE CHECK, FOUND TAIL CONE EVACUATION SLIDE PRESSURE INDICATOR IN THE RED BAND. REPLACED TAIL CONE EVACUATION SLIDE. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: SENSOR — DEFECTIVE (RT MLG)

ORD - FLT T1716 - DURING APPROACH TO ORD WHEN LANDING GEAR EXTENDED, RT MLG RED LIGHT REMAINED ILLUMINATED. RECYCLED LANDING GEAR AND RED LIGHT EXTINGUISHED AFTER 2 MINUTES. AIRCRAFT LANDED ORD WITHOUT INCIDENT. REPLACED RT MLG DOWNLOCK SENSOR. ACCOMPLISHED LANDING GEAR RETRACTION CHECK WITH NO DEFECTS FOUND. SYSTEM GROUND CHECKED NORMAL OPERATION. (X)