N480FE

Part: CABLE — DAMAGED (MLG DOOR) · airframe 39,088 hrs · 25,076 cycles

RED DOORS WARNING LIGHT ILLUMINATED ON GEAR RETRACTION S/O'S PANEL. NOSE GEAR DOOR LIGHT ALSO ILLUMINATED AFTER FOLLOWING QRH PROCEDURES. THE LIGHTS REMAINED ILLUMINATED. RETURN TO MEM. REMOVED AND REPLACED BOTH DOOR CABLE, ADJ AND RIGGED NOSE GEAR FWD DOORS. ALSO C/W GEAR SWING. NOSE DOOR LIGHT CHECK AND MANUAL EXTENSION ON NOSE GEAR C/W. ALL WORK ACCOMPLISHED PER AMM 727-200-32-22-001-5.

Part: SWITCH — FAILED (ZONE 800) · airframe 38,393 hrs · 24,527 cycles

MAIN CARGO DOOR LIGHT CAME ON INFLT . BOTH PACKS TURNED OFF . ALT 6000 FT PSI DIFF. 2.8 . LIGHT WENT OUT ONCE DEPRESS. COMPLIED WITH CHECKLIST RETURN TO MCO . OPERATED MCD OPEN/CLOSED SEVERAL TIMES. CLOSED DOOR AND PRESSURIZED A/C. WAS ABLE TO GET DOOR WARN RED TO COME ON WITH DOOR CLOSED AND BARBER POLE IN LINE. VISUALY INSPECTED AND CHECKED LOCKROD SWITCH AND ALL THE LATCH WARNING SWITCHES. MOST FWD LATCH SWITCH WAS CAUSING THE LIGHT TO COME ON WITH DOOR CLOSED. REPLACED AND ADJ FWD LATCH WARNING SWITCH. OPERATED DOOR OPEN/CLOSE SEVERAL TIMES. OPS CHECK OK. PRESSURIZED TO 3 PSID WITH NO MCD WARNING LIGHT.

Part: ROLLER — FAILED (PAX DOOR) · airframe 38,325 hrs · 24,471 cycles

DURING CLIMBOUT HEARD (LOUD) BANG AS IF SOMEONE HIT AIRCRAFT WITH HAMMER. SOUND OCCURRED AGAIN ABOUT 2 MINUTES LATER (BANG) WERE SO VIOLENT IT COULD BE FELT THROUGH SEATS. AFTER LANDING FOUND UPPER AFT ROLLER CAM ASSEMBLY ON FORWARD ENTRY DOOR BROKEN. BOTTOM ROLLER ALSO BROKEN. ** S/D ** COMING

Part: STRUCTURE — DAMAGED (PAX DOOR) · airframe 38,319 hrs · 24,465 cycles

PASSING APPROX 10,000 FT MSL NOTICED CABIN VVI FLUCTUATED BETWEEN CLIMB AND DESCENT. AROUND 13,000 FT HEARD AND FELT 2 LOAD BANGS COMING FROM VICINITY OF FORWARD ENTRY DOOR. DOOR WAS DIFFICULT TO CLOSE AND OPEN. *S/D* REPAIRED L1 DOOR UPPER AFT CORNER PER SRM 52-10-1 & 51-40-4. NO OTHER ACTION WILL BE REQUIRED.

Part: FRAME — GOUGED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

GOUGE IN 1176 CHORD AT RBL 28, WL 208. R&R CHORD PER EA 7-5310-67046.

Part: FRAME — DENTED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

BS 950C FRAME IS DENTED AT STR 25R UPPER FLANGE. R&R FRAME PER SRM 51-40-3 FIG 3 & EA 7-5310-67053.

Part: FRAME — DENTED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

FRAME IS BENT AT BS 1010, LBL 30, WL 146. REPAIRED FRAME BS 1010 LBL 30 WL 146 IAW EA 7-5310-67044 AND SRM 51-40-3 FIG 1.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

CORROSION AT BS 950C=12, STR 29R. REPAIRED KEELBEAM BS 950C+12 STR 29R IAW FEDEX DWG SR 27-53-023.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

CORROSION ON SHEAR TIE AT BS 950B, STR 29R.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

CORROSION ON SHEAR TIE AT BS 950B, STR 29R. R&R SHEAR TIE PER SRM 53-10-4 & EA 7-5310-67049.

Part: FRAME — WORN (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

BS 1352 T-CHORD AFT FLANGE IS WORN IN SEVERAL LOCATIONS FROM 3-9 O'CLOCK AND KNIFE EDGED AT 5 O'CLOCK. R&R BS 1352 T-CHORD PER SRM 51-30-2.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

CORROSION ON KEELBEAM AT BS 950D TO 950E, STR 29 LT. REPAIRED KEEL BEAM STA 950D TO 950I STR 29L IAW FEDEX DWG SR 27-53-023.

Part: FRAME — DENTED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

FRAME DENTED AT 970, LBL 30, STR 26L. R&R FRAME PER SRM 51-40-3 FIG & EA 7-5310-67055.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

BULGE IN COCKPIT FLOOR. R&R BEAM PER SRM 51-30-2, 51-30-5, 51-30-8.

Part: SKIN — DENTED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

EXTERNAL SKIN DENTED WITH TWO GOUGES AT BS 365, ABOVE STR 17L.

Part: FRAME — DENTED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

FRAME IS DENTED AT BS 990, LBL 30, WL 146. R&R FRAME PER SRM 53-10-1.

Part: FRAME — DENTED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

FRAME DENTED AT STR 950F, LBL 30, STR 26L. REPAIRED FRAME IAW SRM 51-40-3 FIG 1 SHEET 3 & EA 7-5310-67056.

Part: WEB — CORRODED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

CORROSION ON WEB AT BS 1166, RBL 10, WL 140. R&R WEB PER SRM 53-10-1, 51-30-2, 51-20-1.

Part: WEB — CORRODED (FUSELAGE) · airframe 38,149 hrs · 24,326 cycles

CORROSION ON WEB AT BS 1166, LBL 10, WL 140. R&R WEB PER SRM 53-10-1, 51-30-2, 51-20-1.

Part: RIB — CRACKED (NR 5 SLAT) · airframe 36,300 hrs · 22,737 cycles

DURING ROUTINE INSP, NR 5 L/E SLAT WAS FOUND CRACKED AT O/B ACTUATOR ATTACH RIB. STOP DRILLED CRACK, FABRICATED AND INSTALLED REPAIR IAW SRM 51-40-3 & 51-30-2.

Part: RIB — CRACKED (NR 4 SLAT) · airframe 36,300 hrs · 22,737 cycles

DURING INSPECTION, NR 4 L/E SLAT WAS FOUND CRACKED AT INBOARD ACTUATOR ATTACH RIB. STOP DRILLED CRACK, FABRICATED AND INSTALLED REPAIR IAW SRM 51-40-3 & 51-30-2.

Part: RIB — CRACKED (NR 5 SLAT) · airframe 36,300 hrs · 22,737 cycles

DURING INSPECTION, NR 5 L/E SLAT WAS FOUND CRACKED AT INBOARD ACTUATOR ATTACH RIB. STOP DRILLED CRACK, FABRICATED AND INSTALLED REPAIR IAW SRM 51-40-3 & 51-30-2.

Part: FITTING — CORRODED (DOOR JAMB) · airframe 36,300 hrs · 22,737 cycles

DURING ROUTINE INSPECTION, FITTING ON LWR SIDE DOOR JAMB AREA AT BS 620 BETWEEN STR 25R & 26R CORRODED BEYOND LIMITS. REMOVED AND REPLACED FITTING PER IAW SRM 51-30-2.

Part: ANGLE — CORRODED (FUSELAGE)

DURING ROUTINE INSPECTION, ANGLE ON LWR SIDE OF DOOR JAMB BS 620 CORRODED BEYOND LIMITS FROM STR 27R - 28R. REMOVED AND REPLACED PER IAW SRM 51-40-4.

Part: SKIN — CRACKED (VERTICAL STAB)

DURING ROUTINE INSPECTION, EXTERIOR SKIN LEFT SIDE VERTICAL STABILIZER CRACKED AT FIN STA 87, WL 290. REMOVED AND REPLACED PER IAW SRM 51-40-2 & SRM 51-30-2.

Part: ANGLE — CORRODED (FUSELAGE)

DURING ROUTINE INSPECTION, FLOOR SUPPORT ANGLE ABOVE STR 29R AT BS 642 CORRODED BEYOND LIMITS. REMOVED AND REPLACED PER IAW SRM 53-10-5 & SRM 51-40-3.

Part: FLOORBOARD — CRACKED (FUSELAGE)

DURING ROUTINE INSPECTION, CRACKS FOUND IN FLOOR WEB FWD BS 1183 BULKHEAD FROM BL 0 TO RBL 45. REMOVED, FABRICATED AND INSTALLED WEB IAW SRM 51-20-1 & 51-30-2.

Part: FLOORBOARD — CRACKED (FUSELAGE)

DURING ROUTINE INSPECTION, CRACKS FOUND IN FLOOR WEB FWD OF BS 1183 BULKHEAD BL 0 TO LBL 45. REMOVED AND REPLACED WEB PER IAW SRM 51-20-1 AND SRM 51-30-2.

Part: BELTFRAME — CRACKED (FUSELAGE)

DURING ROUTINE INSPECTION, CRACK IN FWD UPPER FLANGE BELTFRAME BS 1010 BETWEEN STR 26L AND 27L. REMOVED AND REPLACED PER IAW SRM 51-40-3.

Part: FITTING — CORRODED (DOOR JAMB) · airframe 36,300 hrs · 22,737 cycles

DURING ROUTINE INSPECTION, FITTING ON LOWER SIDE OF DOOR JAMB AREA AT BS 620 BETWEEN STR 25R AND 26R. REMOVED AND REPLACED PER IAW SRM 51-30-2.

Part: SKIN — GOUGED (AIRSTAIR)

DURING ROUTINE INSPECTION, AFT AIRSTAIR EXTERIOR SKIN FOUND GOUGED BEYOND LIMITS AT BS 1300. REMOVED AND REPLACED PER IAW SRM 52-10-2.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 36,300 hrs · 22,737 cycles

DURING ROUTINE INSPECTION, ANGLE FOUND CRACKED AT BS 560, FROM STR 25R IN DOOR JAMB AREA. REMOVED, FABRICATED AND INSTALLED PER IAW SRM 51-20-1 & SRM 51-30-2.

Part: ANGLE — CORRODED (FUSELAGE)

DURING ROUTINE INSPECTION, FLOOR SUPPORT ABOVE STR 30 AT BS 1035 CORRODED BEYOND LIMITS. REMOVED AND REPLACED PER IAW SRM 51-40-3.

Part: SKIN — CRACKED (FUSELAGE) · airframe 36,300 hrs · 22,737 cycles

DURING ROUTINE INSPECTION, FUSELAGE SKIN FOUND CRACKED AT FWD ENTRY DOOR LOWER HINGE CUTOUT APPROX 0.4 INCH. REMOVED AND REPLACED PER IAW FEDEX EO 7-5330-7-2345.

Part: ENGINE — DAMAGED (NR 1 ENGINE)

ADVANCED POWER FOR TAKEOFF AND HAD LARGE AIRFRAME VIBRATION. THROTTLES RETARDED AND TAKEOFF ABORTED. EPR MADE IT AS FAR AS 1.3, BUT NOT UP TO 1.4. SUBSEQUENT POST FLIGHT INSPECTION REVEALED DAMAGE TO THE NUMBER ONE ENGINE. REMOVED AND REPLACED THE NUMBER ONE ENGINE PER WORK CARD 70T0001, 70T0003 AND 70T0301. OPERATIONS AND LEAK CHECK GOOD ON GROUND RUNS. REQUIRED INSPECTION ITEMS HAVE BEEN COMPLIED WITH.

Part: STRINGER — CRACKED (BS 530-540)

STR 7R CRACKED IN 2 PLACES BETWEEN STA 530 TO 540R. INSTALLED STR REPAIR AS PER SRM 53-10-3.

Part: STRINGER — CORRODED (BS 490-500)

STR 28R IS CORRODED IN 2 PLACES BETWEEN STA 490 TO 500. REPAIRED DAMAGED AREA PER SRM 53-30-3 PG 140 AND 53-10-3 PG 1.

Part: SEAT TRACK — WORN (BS 740)

SEAT TRACK WORN STA 740 LBL 45. SPLICED IN NEW SECTION OF SEAT TRACK PER SRM 53-10-5 PG 1 TO 4.

Part: RIB CHORD — CRACKED (BS 760)

FS 760 RT RIB CHORD UPPER VERTICAL FLANGE FWD UPPER FASTENER HOLE AND FWD LOWER FASTENER HOLE HAVE CRACKS UP AND DOWN FROM HOLES. REMOVED END OF CRACK PER 51-10-1, NFRC INSP SPOTFREE OF CRACK REMOVED, REPAIRED BY INSTALLING DOUBLER PER EO 7-5710-7-23084 PART 1 AND 3 PER SB 727-S7-0112 REV 4.

Part: SEAT TRACK — CORRODED (BS 740)

CORROSION TOP LT FLANGE OF NR 3 TRACK LBL 25 STA 740. THE NR 3 TRACK STA 740 IS OUT OF LIMITS 53-10-1 PG 616. REPLACED SEAT TRACK PER SRM 53-10-5.