N477FE

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 42,950 hrs · 30,230 cycles

FOUND STRINGER 27R TO BE CORRODED BS 1178.

Part: STRINGER — CRACKED (VERTICAL STAB) · airframe 42,950 hrs · 30,230 cycles

CRACKED STRINGER INSIDE VERTICAL STAB AT STRINGER 7 FIN STATION 157.2 LT. REPAIRED STRINGER PER SRM 55-30-4 FIG 1.

Part: STRINGER — CRACKED (RT WING) · airframe 42,950 hrs · 30,230 cycles

WHILE WORKING N00525, FOUND RT WING UPPER STRINGER NR 10 CRACKED AT WS 686.5 RIB BOLT. REPAIRED STRINGER PER FED EX EA 7-5710-86308.

Part: SKIN — DENTED (HORIZONTAL STAB) · airframe 42,950 hrs · 30,230 cycles

LEFT HORIZONTAL STAB UPPER SURFACE HAS DENT WITH GOUGE 17.5 INCHES FROM I/B END AND 16.5 INCHES FROM AFT END. REPAIRED PER FED EX EA 7-5510-86317.

Part: FRAME — CRACKED (FUSELAGE) · airframe 42,950 hrs · 30,230 cycles

EVIDENCE OF CRACK IN VERTICAL CHORD COMMON TO BS 870 BULKHEAD AND RIGHT KEELBEAM 6 INCHES UP FROM BOTTOM END OF CHORD. *S/D* REPLACED BS 870 CHORD PER SRM 51-30-2.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 42,950 hrs · 30,230 cycles

CORROSION ON FLOORBEAM UPPER AFT FLANGE, BS 344, RBL 10, TO LBL 20, WL 208. *S/D* REPAIRED FLOORBEAM AT BS 344 PER FED-EX DWG SR27-53-017A.

Part: PAN — CORRODED (FUSELAGE) · airframe 42,950 hrs · 30,230 cycles

CORROSION ON ANTENNA PAN IN AFT CARGO BILGE AT BS 1033, BETWEEN STR 30 AND STR 29R. REMOVED AND REPLACED IAW SRM 51-30-2, 51-20-1.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 42,487 hrs · 29,886 cycles

DURING "B" CHECK VISIT, LOWER AFT FUSELAGE FWD OF STATION 1183 HAS HI LOCK AND RIVETS MISSING. FURTHER INVESTIGATION REVEALED STRINGER 28R, STA 1166 HAD EXFOLIATION CORROSION OUT OF SRM LIMITS. SPLICED IN NEW SECTION OF STRINGER PER B727 SRM 53-10-3, FIG 1, SHEET 4, DETAIL 1.

Part: FIRE DETECTOR — FAILED (APU) · airframe 41,142 hrs · 28,823 cycles

TEN MIN AFTER TAKEOFF THE RED LIGHT IN THE APU FIRE SHUTOFF HANDLE ILLUMINATED. THERE WAS NO RINGING OF THE FIRE BELL IN ACCORDANCE WITH QRH. THE APU FIRE HANDLE WAS PULLED AND APU BOTTLE DISCHARGE BUTTON PUSHED. THE RED LIGHT IN THE APU FIRE HANDLE REMAINED ILLUMINATED. EGT WAS 100C WHEN THE LIGHT CAME ON AND SLOWLY DECREASED DURING THE FLIGHT. *S/D* REPLACED APU FIRE & OVERHEAT DETECTION POWER UNIT MM.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

FUSELAGE FRAME AT BS 540, HAS NUMEROUS EMPTY HOLES NEAR UPPER FLANGE BETWEEN STR 22 LT AND 26 LT.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

CORROSION ON AFT BAY SHEAR TIE AT BS 1010, LBL 9, WL 138.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

FOUND CRACK IN STR 21 LT AT BS 540.

Part: STRINGER — DENTED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

FUSELAGE STRINGER 24L HAS DENT DAMAGE AT BS 565.

Part: FRAME — DENTED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

FUSELAGE FRAME BS 520 UPPER FLANGE HAS SEVERAL DENTS RBL 33-42.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

STR 15R AT BS 720B+4 CRACKED. REPAIRED PER SRM 53-10-3 FIG 5.

Part: SKIN — GOUGED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

GOUGE IN SKIN BS 1070, STR 25R, WAS FOUND OUT OF LIMITS. REPAIRED SKIN AT BS 1070, STR 25R PER SRM 53-30-3, FIGURE 3.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

FOUND CORROSION ON STR 27L BS 965. REPAIRED DAMAGED STRINGER 27L BS 965 PER SRM 53-10-3 FIG 1

Part: SKIN — CORRODED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

FOUND CORROSION ON INNER SURFACE OF SKIN BS 965 LBL 17 WL 139.

Part: CREASE BEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 40,642 hrs · 28,433 cycles

N00836 CORROSION C53-224-02 CREASE BEAM BS 500 RBL 67. CORROSION ON CREASE BEAM AT BS 600, RBL 67, WL208 FOUND TO BE OUT OF LIMITS IAW SRM 53-10-1. REMOVED CREASE BEAM BS 445-525, RBL 67,WL 208. FABRICATED REPLACEMENT CREASE BEAM FROM BAC 1515-531 7075-T6 LOT NR 391371 IAW SRM 51-30-5. INSTALLED CREASE BEAM BS 445-525, RBL 67, WL 208 IAW SRM 51-30-2 AND SOPM 20-50-01.

Part: FRAME — DENTED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

FUSELAGE FRAME BS 500 UPPER FLANGE HAS SEVERAL DENTS LBL 33-47. REMOVED EXISTING FRAME SPLICE BS 500, LBL 33. CUT OUT DAMAGED AREAS AT LBL 33 TO LBL 47. FABRICATED AND DRILLED UP NEW FRAME SPLICE. INSTALLED NEW FRAME SPLICE AND FASTENERS IAW B727 SRM AND EA.

Part: FRAME — BENT (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

FUSELAGE FRAME BS 500 UPPER FLANGE IS BENT RBL 33 WL 160. REMOVED DAMAGE AND REPAIRED IAW SRM.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

CORROSION AT STA 617-624, WL 151, RBL 15, ON STRINGER 27 RT. INSPECTION OF STRINGER 27 RT, WL 151, BS 617 - 624 FOUND IT TO BE OUT OF LIMITS PER BOEING SRM REMOVED DAMAGED AREA AND REPLACED PER BOEING SRM 53-10-3.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 40,642 hrs · 28,433 cycles

CORROSION ON FLOORBEAM, BS 720D, LBL 5. BLENDED CORROSION ON FLOORBEAM, FOUND TO BE OUT OF LIMITS IAW SRM. CUT OUT DAMAGE FROM BS 720-720F, BL 0. FABRICATED AND INSTALLED REPAIR IAW EA.

Part: SENSOR — FAILED (RT MLG) · airframe 40,381 hrs · 28,247 cycles

DURING TAKEOFF ROLL THE RIGHT GEAR RED LIGHT CAME ON AFTER GEAR RETRACTION THE RED GEAR LIGHT REMAINED ON WITH ALL OTHER GEAR LIGHTS EXTINGUISHED (GEAR WAS RE-CYCLED). REPLACED RT MAIN GEAR UPLOCK SENSOR PER M/M 32-61-081-4. ALSO REPLACED THE LANDING GEAR ACCESSORY UNIT PER M/M 32-09-121-4. ALL CHECKS OK.

Part: SWITCH — DIRTY (GEAR DOOR LIGHT)

00-340 DURING CLIMB, AMBER NOSE GEAR DOOR 2ND OFF PANEL & FWD PANEL LIGHTS ILLUM. PERF RED TABS. COULD NOT DUPLICATE, FOUND LT SWITCH DIRTY AND LOOSE. CLEANED & SECURED SWITCH PER STANDARD MAINTENANCE PRACTICES.

Part: FILTER — DIRTY (NR 3 ENGINE)

99-175 - NR 3 OIL QUANTITY DECREASED STEADY TO 0 GAL. LOST ENG OIL PRESSURE AND SHUTDOWN ENGINE IN ACCORD WITH RED TABS. REMOVED AND REPLACED MAIN ENG OIL FILTER PER MM 79-20-03 CK GOOD. PERF LP6 BOSS THREAD REPAIR. LEAK CK GOOD. A/C OK FOR SERVICE.

Part: SENSOR — BENT (LT MLG)

LEFT MAIN GEAR INDICATED UNSAFE GROUND OUT RED ON WARN HORN SOUND. REMOVED AND REPLACED MAIN DOWN LOCK SENSOR PER 727 MM 32-61-91. ALSO, JACK AC PER 727 MM 07-11-000-2, OP CK GOOD.

Part: OIL FILTER — LEAKING (NR 3 ENGINE)

A +25 ENG OIL QUANTITY DECREASED. FILTER BYPASS LIGHT OUT. REMOVED AND REPLACED NR 3 MAIN OIL STRAINER IAW MM 79-00-00-3, NEEDS LEAK CK FOR FILTER CHIP DETECTOR AND CONSUMPTION. REMOVED AND REPLACED O-RING BEHIND BOSS FITTING ON LP6 PER MM 70-00. LEAK CK OK.

Part: SKIN — DAMAGED (RUDDER)

TAIL, UPPER RUDDER NR 2 RUDDER TAB HINGE CUTOUT BRACKETS AND COVER FAIRING DAMAGED LT SIDE, AS IS RUDDER LT T/E FRAME IN SAME AREA. INSTALLED DOUBLER PER AA SRM 55-20-0 AND AA SRM 55-40-3.

Part: STRINGER — CORRODED (BS 1026-1030)

CORROSION ON RT SIDE OF STRINGER 30, BS 1026 TO 1030 IN AFT CARGO. REMOVED DAMAGED SECTION OF STRINGER 30. INSTALLED STRINGER SPLICE AND DOUBLERS PER SRM 53-30-3.

Part: BELTFRAME — DENTED (BS 1090)

UPPER LOBE BELT FRAME DENTED AT RIVET INSTALLATION BS 1090, O/B OF STR 2R. REMOVED DAMAGED AREA AND INSTALLED DOUBLER PER SRM 51-40-3.

Part: LAV SERV PANEL — CORRODED (BS 1173)

LOWER FUSE LT SIDE BS 1173L AFT LAV SERV PANEL HAS CORROSION BETWEEN PANEL INSERT AND FUSE STRUCTURE. ACCOMPLISHED LAV PANEL MOD PER E/A 7-5310-29355.

Part: SKIN — CORRODED (BS 1148R)

LOWER FUSE SKIN BULGE BETWEEN STR 26R AND STR 25R, BS 1148R. REMOVED ALL CORROSION AND INSTALLED FRAME SHEAR TIE REPAIR AT SKIN ATTACHMENT PER SRM 53-10-4 FIG 11.

Part: FLOORBEAM — CORRODED (BS 344)

BS 344, LBL 44 TO RBL 25 FLOORBEAM HAS CORROSION AROUND NUTCLIP HOLES (TOP AND BOTTOM) AND ON TOP OF FLOORBEAM. REMOVED CORROSION ON TOP AND BOTTOM OF 344 FLOORBEAM AS PER SRM 51-10-6. INSTALLED NEW TOP CHORD FROM LBL 50 TO RBL 67 PER SR 27-53-007.

Part: SKIN — CORRODED (BS 1165)

FUSELAGE SKIN BULGED AT BS 1165 JUST OUTBOARD AND FORWARD OF RT STATIC PORT. INSTALLED REPAIR PER SRM 53-30-3.

Part: STRINGER — CRACKED (BS 720)

STRINGER CRACKED AT FWD END FASTENER BS 720C + 12 (JUST AFT OF ICE LIGHT HOUSING). REPAIRED CRACKED STR PER SRM 53-10-3, FIG 5.

Part: BELLFRAME — DENTED (BS 660)

BS 660L, STR 23L, 22L, 24L AND 25L IS DENTED (BELLFRAME) AND HOLES DRILLED IN RADIUS. REMOVED DAMAGED AREA AND INSTALLED DOUBLER PER SRM 51-40-3.

Part: BELLFRAME — DENTED (BS 520)

BS 520L BETWEEN STR 22 TO 25L BELL FRAME DENTED SEVERAL PLACES. REMOVED DAMAGED AREA AND INSTALLED DOUBLER PER SRM 51-40-3.

Part: SKIN — CORRODED (BS 1148)

LWR FUSE SKIN BULGE BETWEEN STR 26R AND STR 25R, BS 1148R. REMOVED ALL CORROSION AND INSTALLED FRAME SHEAR TIE REPAIR AT SKIN ATTACHMENT PER SRM 53-10-4 FIG 11.

Part: FRAME — CRACKED (BS 930)

INSPECTED FRAME AT BS 930, STR 14R, CRACK FOUND. INSTALLED DOUBLER AS PER EO 7-5310-7-4330.

Part: STRINGER — CRACKED (BS 720)

NR 0502 72C235-02, UPPER LOBE BS 720B - 720C, STR 15L CRACKED AT AFT FASTENER FWD OF ICE LIGHT HOUSING. REPAIRED CRACKED STRINGER PER SRM 53-10-3 FIG 5.

Part: BELLFRAME — DENTED (BS 560)

NR 0172 71C209-02, BELLFRAME DENTED BS 560L BETWEEN STRINGERS 22-25L. REMOVED DAMAGED AREA AND INSTALLED DOUBLER PER SRM 51-40-3 FIG 1.

Part: BEAM — CORRODED (LT MLG)

NR 0794 7-5750-7-231, LEFT MLG BEAM CORRODED ON UNDERSIDE WHERE NR 4 FLAP TRACK CONTACTS IT. REMOVED CORROSION BLENDED AREA PER EA 7-5730-29358 EA - DATE 2/10/98.

Part: RETRACT MECH — MALFUNCTIONED (SPOILER SYST)

DURING DESCENT WITH SPOILER DEPLOYMENT, JET WANTED TO ROLL LT. TOOK FULL AILERON INPUT TO THE RT ABOVE 300-350 KTS. NOT AS PRONOUNCED BELOW 250 KTS. ON LANDING, LT WING WANTED TO DROP WHEN SPOILERS DEPLOYED. HAPPENED BOTH AUTO-PILOT ENGAGED OR DISENGAGED, CHECKED SPOILERS FOR DEPLOYMENT, LOCKING UP AND DOWN. UNABLE TO HEAR BYPASSING FLUID. CHECKED FOR SHEARED RIVETS, NONE FOUND. RAN SPOILERS, FLAPS DOWN AND UP, RAN AILERONS, ALL CHECKED NORM. CHECKED INBD AND OTBD SPOILER DEPLOYMENT PER MM 27-61-1 STEPS 3 THROUGH 6. ALL IND NORM. COULD NOT DUP. ADJUSTED SPOILERS PER MM 27-61-91.

Part: VOLTAGE REG — INOPERATIVE (E/E COMPARTMENT)

97-0129 AFTER CLIMB POWER WAS SET NR 1 BUS TIE. NR 1 GENERATOR SWITCH, AND NR 1 FIELD RELAY TRIPPED OFF. PERFORMED RED TABS. FIELD RELAY WOULD NOT COME BACK ON LINE. DISCONNECTED NR 1 CONSTANT SPEED DRIVE AND RETURNED. RECONNECTED NR 1 CONSTANT SPEED DRIVE. REMOVED AND REPLACED NR 1 VOLTAGE REGULATOR AND NR 1 GENERATOR CONTROL PANEL. PERFORMED NR 1 ENGINE RUN PER JET RUN HANDBOOK 8-3. NR 1 GENERATOR FUNCTION TESTS NORMAL.

Part: SWITCH WIRE — FAILED (RT MLG DOOR)

RT MLG DOOR LIGHT ILLUMINATED INTERMITTENTLY IN FLIGHT, 3 TIMES. REMOVED AND REPLACED WIRING FROM D752 TO SPLICES SP578 AND SP576. REMOVED AND REPLACED D752 FOR RT MLG DOOR LOCK SW. FUNCTIONAL CHECKS GOOD PER FEDEX MM 32-62-11.

Part: BEAM — ELONGATED (LT HORIZ STAB)

BOLT HOLE ON LT HORIZONTAL STAB TRAILING EDGE BEAM AT NR 2 RUB BLOCK IS ELONGATED. REMOVED HORIZONTAL STAB TRAILING EDGE BEAM, FABRICATED AND INSTALLED PARTS PER FEDEX EA 7-5510-25555.

Part: CHORD — CRACKED (BS 760)

BS 760 LBL 70.5 WL 208, 1 EA FWD, LOWER HOLE IN CHORD IS CRACKED. REPAIRED PER FEDEX EA 7-5710-25565.

Part: STRINGER — CRACKED (BS 1174)

CRACKED STR AND RIVETS PULLING THROUGH STR 29R BS 1174 WL 154. CUT OUT DAMAGED SECTION OF STR AND REPAIRED PER SRM 53-10-03 FIG 1.

Part: SKIN — DENTED (ENTRY DOOR)

FWD ENTRY DOOR HAS A LARGE DENT IN AFT EDGE OF SKIN, AFT LOWER CORNER. REPAIRED FWD ENTRY DOOR, LARGE DENT IN AFT EDGEIN SKIN AFT LOWER CORNER PER FEDEX SRM 52-00-3, 52-00-2, 51-30-8, 51-10-2, 51-30-2, 52-10-1.