N484FE

Part: CASE — CRACKED (NR 1 ENGINE) · airframe 40,173 hrs · 27,011 cycles

NR 1 ENGINE IGV CASE CRACKED 3 PLACES ALONG FWD. AND AFT SIDE WELD BEAD. REMOVED NR 1 ENGINE IGV CASE ON WK CARD 7200-2002,N/R00937. REMOVED AND REINSTALLED ENGINE NOSE COWL ,NOSE DOME FOR ACCESS IAW MM 71-10-021-4, MM71-10- 041-4 LEAK AND OPS. CHECKED GOOD IAW 71-10-021.

Part: DOUBLER — CORRODED (BS 740) · airframe 40,173 hrs · 27,011 cycles

COMPLY WITH EA 7-5310-92343 FUSELAGE SKIN-STA 740 BKHD SUPPORT DOUBLER CORROSION. [OPEN]

Part: HINGE — CRACKED (AILERON) · airframe 40,173 hrs · 27,011 cycles

RT OB AILERON 2ND FROM I/B HINGE ASSY FLANGE SECTION MISSING. REMOVED AND REPLACED HINGE ASSY IAW SRM 51-30-2.

Part: FLAP TRACK — CORRODED (LT WING) · airframe 40,173 hrs · 27,011 cycles

LEFT WING FLAP TRACK NR 1 FWD ATTACH POINT INSIDE HAS CORROSION. REMOVED AND REPLACED NR 1 FLAP TRACK IAW MM 27-51-031-4.

Part: DOWNLOCK SENSOR — DIRTY (NLG) · airframe 38,424 hrs · 25,615 cycles

ON APPROACH, WHEN LANDING GEAR WAS SELECTED DOWN, THE NOSE GEAR, LEFT GEAR AND RIGHT GEAR ALL INDICATED (GREEN) DOWN AND LOCKED, AND THE RIGHT GEAR ALSO INDICATED (RED) GEAR UNSAFE. RECYCLED THE GEAR TO UP THEN DOWN, AND INDICATION WAS NORMAL. T/S DOWNLOCK SENSOR. PER 727 M/M 32-61-091-4. ALL INDICATIONS NORMAL. CLEANED SENSOR AND TARGET. LUBED UP LOCK PER 727 M/M 12-21-001-2.

Part: LIGHT — ILLUMINATED (AIRSTAIR DOOR) · airframe 38,150 hrs · 25,401 cycles

AFT AIRSTAIR LIGHT (AMBER) ILLUMINATED ON DEPARTURE WHILE PASSING 5000 FT -SLAT CLIMB POWER. REMAINED ON AT ALL POWER SETTINGS FOR REMAINDER OF FLIGHT. LIGHT EXTINGUISHED AT TOUCHDOWN.

Part: WARNING LIGHT — ILLUMINATED (DOORS) · airframe 38,039 hrs · 25,318 cycles

AMBER AFT STAIR LIGHT ILLUMINATED AFTER TAKEOFF, EXTINGUISHED AFTER LANDING. RAN RED TAB CHECKLIST AND TALKED TO GOCC LANDING OK. MEL 12JUN03 09:42 MEM U ACN RELEASED FOR SERVICE PER MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 22JUN03 MEL 52-06-B: AMBER AFT AIRSTAIR DOOR WARNING LIGHT - INOP.

Part: CONNECTOR — LOOSE (NR 3 ENGINE) · airframe 37,926 hrs · 25,238 cycles

ON DESCENT THE NR 3 ENGINE FIRE DETECTION WARNING LIGHT ILLUMINATED. UPON LANDING, THE LIGHT FLICKERED AND REMAINED ON. TROUBLESHOT IAW MM 26-11-000-1 FOUND CONNECTOR TO THE RESPONDER IN THE FWD SECTION LOOSE. INSPECTED CONNECTOR AND ALL OTHER COMPONENTS IN THE SYSTEM. TIGHTENED, REINSTALLED CONNECTOR AND OPS CHECK SYS, ALL TEST NORM IAW MM 26-11-000- 5, NO HISTORY 90 DAYS.

Part: BUSHING — MISSING (ZONE 700) · airframe 37,879 hrs · 25,190 cycles

TEST FLIGHT. UPON RAISING LANDING GEAR, NOSE GEAR RED LIGHT AND RED DOOR LIGHT STAYED ON. AIR CREW COULD HEAR SOMETHING STILL IN AIRSTREAM. LOG BOOK ENTRY REQ. UPON FURTHER INVESTIGATION, FOUND BUSHING FROM LOCK & POSITION SWITCH CONTROL ARM TO BE MISSING. INSTALLED BUSHING IN CONTROL ARM. PERFORMED OPERATIONAL TEST ON NLG IAW FED-EX M/M 32-61-071-5. FUNCTIONAL CHECKED GOOD.

Part: SWITCH — LOOSE (CARGO DOOR)

ON CLIMBOUT, PASS 5000 FT MAIN CARGO DOOR LIGHT ILLUMINATED. LIGHT FLICKERED OCCASIONALLY. DEPRESS CABIN AND LIGHT WENT OUT. CK ALL LATCH SWITCHES, FOUND S9039 LATCH SW LOOSE. TIGHTENED MOUNTING SCREWS, PRESS A/C. OPS CHECK GOOD.

Part: FRAME — CRACKED (FUSELAGE)

FWD GALLEY DOORWAY LWR FWD FRAME SEGMENT IS CRACKED AT THE BOTTOM I/B TWO FASTENERS. *S/D* REMOVED AND REPLACED PER SRM 51-40-3 & FEDEX EA 7-5310-53810.

Part: SKIN — CORRODED (FUSELAGE)

BS 687 AROUND STR 28R LEVELING COMPOUND CRACKED AND MISSING. INSP NEEDS TO CK FOR POSSIBLE CORROSION WHEN REMOVED C53-111-01-2. *S/D* REMOVED AND REPLACED PER IAW FEDEX SRM 53-30-3.

Part: FRAME — CORRODED (FUSELAGE)

CORROSION ON LWR CHORD BS 1130 BEAM LBL 38-RBL 50, WL 200. *S/D* REMOVED AND REPLACED PER FEDEX EA 7-5310-53818.

Part: FLOORBEAM — CORRODED (FUSELAGE)

CORROSION ON LWR CHORD OF FLOORBEAM BS 1070, RBL 2 - RBL 50, WL 200. *S/D* REMOVED AND REPLACED PER FEDEX SRM 53-10-1, 53-10-8.

Part: STIFFENER — CORRODED (FUSELAGE)

CORROSION (C53-111-01-1) VERTICAL CHORD BS 312 COMMON TO LT LWR NOSE CHORD. *S/D* REMOVED AND REPLACED PER FEDEX 51-30-2, 57-10-1 AND DWG 65-18415.

Part: STRINGER CLIP — CORRODED (FUSELAGE)

CORROSION (C53-224-01-, 1) ON STRINGER CLIP AT BS 720C, STR 7L. *S/D* REMOVED AND REPLACED PER IAW FEDEX SRM 51-30-2.

Part: FRAME — CORRODED (FUSELAGE)

VERTICAL SUPPORT FITTING ON FWD FACE OF NR 2 FIREWALL IS RUSTED BS 1342, LBL 25, WL 210 - 260. *S/D* REMOVED AND REPLACED PER FEDEX SRM 51-31-2, 51-10-6, 51-20-4 AND DWG 65-17508.

Part: CABLES — LOOSE (TE AFT FLAP)

A/C STARTED AIRFRAME VIBRATION. FOUND EDGE FLAPS AFT FLAP FOLLOW UP CABLES LOOSE. RIGGED CABLES PER 727 MM 27-51-5-4, OPS CK GOOD.

Part: AIR DISTRIBUTION — ODOR (COCKPIT)

98-0166 STA-IND: SMOKE FUMES IN COCKPIT AT GEAR CONFIGURATION. SMOKE EMANATED INTO COCKPIT. SMOKE AND FUMES CHECKLIST RUN SMOKE NOTED IN COCKPIT AROMA LIKE WOOD BURNING. GASPER FAN SECURED. SMOKE MAY HAVE DECREASED. AIRCRAFT STOPPED AND EMERGENCY EQUIP RESPONDED. AIRCRAFT INSP BY FIRE DEPT, FAA OFFICIALS AND LINE AIRCRAFT MAINTENANCE NO SOURCE FOUND. SUSPECT AIRCRAFT FLEW THROUGH A HEAVY SMOKE AREA DUE TO HEAVY BURNING IN AREA BECAUSE OF THUNDER STORM THE DAY BEFORE 6/30/98. ALL AIRCRAFT SYSTEMS WORKING NORMALLY.

Part: DOOR LIGHT — ILLUMINATED (CARGO DOOR)

98-0161 - STA-PIT - CLIMBING THROUGH FLIGHT LEVEL 290, MAIN CARGO DOOR LIGHT ON CAUTION LIGHT PANEL ILLUMINATED AND REMAINED ILLUMINATED DURING DIVERSION TO PIT. ACCOMPLISHED RED TAB PROCEDURES. FOUND BUS SUPPLY AND BATTERY CHARGER CIRCUIT BREAKERS POPPED. OPENED AND CLOSED DOOR AFTER CLOSING CIRCUIT BREAKERS. ALL DOOR LIGHT EXTINGUISHED INDICATIONS SHOW DOOR CLOSED AND LOCKED. OK FOR SERVICE.

Part: SKIN — CORRODED (BS 720-724)

CORROSION ON SKIN BS 720 - 724 BETWEEN STR 28L - 28R WL 148. REMOVED CORROSION ON SKIN BS 720-724 STR 28L - 28R WL 148. FOUND CORROSION TO BE OUT OF LIMITS PER FEDEX 727 SRM 5-10-1. REMOVED DAMAGED, FABRICATED REPAIR AND INSTALLED PER FEDEX 727 SRM 53-30-3.

Part: SILL — CORRODED (BS 340-343)

CORROSION (C53-224-06) ON FWD ENTRY DOOR MOPSILL BS 340-343 LBL 60 WL 208.

Part: SHEAR TIE — CORRODED (BS 720)

NR-0408, WHILE WORKING NR0384, FOUND SHEAR TIE BS720 STR 28L - 28R, WL 148 TO BE CORRODED. REMOVED CORROSION ON SHEAR TIE BS 720 STR 28L - 28R, WL 138. FOUND CORROSION TO BE OUT OF LIMITS PER FEDEX 727 SRM 53-10-1. FABRICATED, LOCATED BACKDRILLED AND INSTALLED NEW SHEAR TIE PER FEDEX SRM 51-30-2.

Part: PACK VALVE — MALFUNCTIONED (LEFT PACK)

ON CLIMBOUT OF DSM PASSING 3,000 FT, THE NR 5 MAIN CARGO SMOKE DETECTOR ILLUMINATED. DETECTOR REMAINED ON APPROXIMATELY 2 MINUTES, THEN EXTINGUISHED. APPROXIMATELY 4 MINUTES LATER THE NR 5 LIGHT ILLUMINATED AGAIN. FOUND PACK C/B TRIPPED. REMOVED AND REPLACED L/PACK VALVE. REPAIRED BLEED AIR LEAK AT CHECK VALVE. RAN PACKS, OPS NORMAL AFTER DUCTS PURGED.

Part: T CHORD — CRACKED (BS 760)

ON BL 70.5 RT RIB UPPER CHORD, NOTED CORROSION AND/OR CRACK IN FWD UPPER HOLE AND NOTED DAMAGE AND/OR CRACK IN AFT UPPER HOLE. ALL NOTED INDICATIONS MARKED ON A/C. (CORROSION IN ENTIRE HOLE, DAMAGE IN T-CHORD) BS 760.

Part: ANGLE — DAMAGED (BS 760)

FOUND MECHANICAL DAMAGE IN FWD UPPER HOLE IN ANGLE AT RBL 70.5, WL 210, BS 760. REPAIRED DAMAGED HOLE PER FEDEX EO 7-5710-25977.

Part: SKIN — DENTED (BS 360)

DENT IN SKIN, BS 360, STR 17L. CUT OUT SKIN AND INSTALLED EXTERNAL DOUBLER PER FEDEX EA 7-5330-25929.

Part: SKIN — CREASED (BS 328)

CREASE IN SKIN AT BS 328 BETWEEN STR 17-18L. CUT OUT DAMAGED SKIN AND REPAIRED PER FEDEX EO NR 7-5330-25992. DUE TO PROXIMITY OF DAMAGE, THIS REPAIR INCORPORATED DAMAGE DOCUMENTED ON FEDEX NR 0167.

Part: SKIN — CREASED (BS 312)

CREASE IN SKIN AT BS 312 BETWEEN STR 17-18L. CUT OUT DAMAGED SKIN. DUE TO PROXIMITY OF DAMAGE, INCORPORATED THIS REPAIR WITH REPAIR DOCUMENTED ON FEDEX NR 0168. REPAIR WAS ACCOMPLISHED PER FEDEX EO NR 7-5330-25992.

Part: STRINGER — DAMAGED (BS 278)

MECHANICAL DAMAGE TO STR 16L, BS 278. CUT 3 SECTIONS FROM FRAME AT BS 277 ABOVE STR 16L FOR ACCESS. REMOVED STR FROM BS 259 - 294. FABRICATED NEW SECTION OF STR AND SPLICED NEW STR AT BS 264. (NEW STR INSTALLED FROM BS 264 - 294). INSTALLED REPAIRED STR FROM BS 259 - 294. REPAIRED FRAME AND FRAME CHORDS PER FEDEX SRM 51-40-4, 51-40-3, 51-40-2. STR REPAIRED PER FEDEX EO NR 7-5310-26104.

Part: CHORD — CRACKED (BS 760)

ON BL 70.5 LT RIB UPPER CHORD NOTED CRACKS IN THE FOLLOWING HOLES, FWD UPPER AND LOWER CRACKS APPROX 0.040 INCH LENGTH. NOTED DAMAGE AND/OR CRACK IN AFT LOWER HOLE. ALL NOTED IND MARKED ON A/C, CRACKS IN T-CHORD BS 760, LBL 70.5 WL 204. REPAIRED DISCREPENT HOLE PER FEDEX EO NR 7-5310-25982.

Part: KEEL BEAM — CORRODED (BS 950-1000)

CORROSION (71C712-00), AFT CARGO BAY NUMEROUS CORROSION FOUND ON KEEL BEAM FLANGE BS 950 TO 1000 STR 29R. REMOVED RT KEEL BEAM STR 29 RECEIVED NEW KEEL BEAM, DRILLED AND INSTALLED PER EO 7-5310-7-2356C PART 1 AND 7, FEDEX EA 7-5310-25739.

Part: KEEL BEAM — CORRODED (BS 1000)

CORROSION IN AFT CARGO BAY, CORROSION FOUND ON SIDE OF STR 29, KEEL BEAM STA 1000 LBL 9. REMOVED AND REPLACED KEEL BEAM PER FEDEX EO NR 7-5310-7-2356 REV C PART 5.

Part: STUB BEAM — CRACKED (BS 760)

CRACK IN WEB OF 760 STUB BEAM, WL 206 RBL 65 BS 760. STOP DRILLED CRACK AND INSTALLED REPAIR PARTS PER FEDEX EO NR 7-5310-25928.

Part: FRAME — DENTED (BS 950)

DENT IN FRAME AT BS 950F LT BETWEEN STR 23 TO 26, AFT CARGO BIN. CUT OUT DAMAGED SECTION OF FRAME, FABRICATED REPAIR FRAME AND INSTALLED IAW SRM 51-40-5.

Part: SKIN — CREASED (BS 235)

CREASE IN SKIN BS 235 AT STR 20R. CUT OUT DAMAGE AT BS 235 STR 14R, FABRICATED NEW REPAIR DOUBLER AND INSTALLED AT BS 235 STR 20R PER FEDEX SRM 53-3-3 FIG 1.

Part: STRINGER — DAMAGED (BS 1070)

DRILL START / DOUBLE HOLE AT AFT SIDE OF 1070 FRAME ON STR 7L (LOWER SIDE OF STR). BLENDED DAMAGED STR AND FABRICATED REPAIR PARTS. BS 1070, STR 7L. INSTALLED PARTS AND FASTENER WET WITH SEALANT IAW FEDEX 727 SRM 53-10-3 FIG 3.

Part: STRINGER — CRACKED (VERT STAB)

THE NR 8 STR CRACKED ON RT SIDE OF VERTICAL FIN AT FIN STA 180.6. CUT OUT CRACKED AREA OF NR 8 STR ON RT SIDE OF VERTICAL FIN AT FIN STA 180.6, FABRICATED AND INSTALLED REPAIR PARTS PER FEDEX SRM 55-30-4.

Part: FRAME — CRACKED (BS 580)

BS 580 ABOVE STR 28R FRAME CRACKED UNDER FLOOR SUPPORT. STOP DRILLED CRACK, FABRICATED PATCH DRILLED IN PLACE REMOVED DEBURRED, ALODINED PRIMED AND PAINTED. INSTALLED WET WITH SEALANT AT BS 580 STR 28R, ALL WORK DONE IAW FEDEX SRM 53-10-2, 51-40-3.

Part: STRINGER — CRACKED (VERT STAB)

THE NR 9 STR CRACKED ON RT SIDE OF VERTICAL FIN AT FIN STA 180.6. CUT OUT CRACKED AREA OF NR 9 STR ON RT SIDE OF VERTICAL FIN AT FIN STA 180.6, FABRICATED AND INSTALLED REPAIR FILLERS AND DOUBLERS IAW FEDEX SRM 55-30-4.

Part: FLOORBEAM — CORRODED (BS 360)

CORROSION ON TOP OF BEAM, BS 360 LBL 8 WL 208. REMOVED CORRODED SECTION OF FLOORBEAM LBL 6 TO 9 BS 360. FABRICATED REPAIR PARTS, ALODINED, PRIMED, PAINTED AND INSTALLED PARTS PER FEDEX SRM 53-10-8 FIG 5.

Part: STRINGER — CRACKED (VERT STAB)

THE NR 9 STRINGER CRACKED ON RT SIDE OF VERTICAL FIN AT FIN STA 157.2. CUT OUT CRACKED AREA OF NR 9 STR ON RT SIDE OF VERTICAL FIN AT FIN STA 157.2, FABRICATED AND INSTALLED REPAIR PARTS PER FEDEX SRM 55-30-4.

Part: STRINGER — CRACKED (VERT STAB)

THE NR 9 STRINGER CRACKED ON LT SIDE OF VERTICAL FIN AT STA 180.6. CUT OUT CRACKED AREA OF NR 9 STR ON LT SIDE VERTICAL FIN AT FIN STA 180.6, FABRICATED AND INSTALLED REPAIR FILLERS AND DOUBLERS IAW FEDEX SRM 55-30-4.

Part: FRAME — CRACKED (BS 600)

FRAME CRACKED UNDER FLOOR SUPPORT ABOVE STR 28R BS 600. STOP DRILLED CRACK, FABRICATED REPAIR DOUBLER AND INSTALLED PER FEDEX SRM 51-40-3.

Part: FRAME — CRACKED (BS 520)

FRAME BENT WITH POSSIBLE CRACK AT BS 520 STR 25R. CUT OUT DAMAGE, FABRICATED DOUBLER AND INSTALLED PER FEDEX SRM 51-40-03.

Part: TE WEDGE — TORN (NR 7 LE SLAT)

NR 7 SLAT T/E WEDGE IS TORN ABOVE I/B GUIDEHOOK. REPAIRED NR 7 SLAT T/E WEDGE IAW EA NR 7-5710-25887.

Part: FITTING — CRACKED (RT ELEVATOR)

RT ELEVATOR AFT SPAR AT CONTROL TAB CUTOUT SUPPORT FITTING CRACKED. REMOVED RT ELEVATOR CONTROL TAB CUTOUT SUPPORT FITTING, REPAIRED CRACK IN ELEVATOR REAR SPAR PER FEDEX SRM 51-40-3. REPLACED NEW RT ELEVATOR CONTROL TAB CUTOUT SUPPORT FITTING. RECALCULATED ELEVATOR REPAIR MOMENT, NEW MOMENT IS 127.91 IAW FEDEX SRM 51-80-7.

Part: CLIP — CRACKED (BS 440)

CRACKED STR CLIP NR 1 AT BS 440. REMOVED CRACKED STR CLIP AT BS 440 STR 1. BACK DRILLED NEW CLIP AND INSTALLED WET WITH FAYING SURFACE SEALANT IAW FEDEX SRM 51-30-2, 51-10-1 AND MM 51-30-0.

Part: CLIP — CRACKED (BS 950)

CRACKED STRINGER CLIPS AT STA 950C, STR 6 AND 7R. REMOVED CRACKED STR CLIPS AT BS 950C, STR 6 AND 7R. BACK DRILLED NEW STR CLIPS AND INSTALLED WET WITH FAYING SURFACE SEALANT IAW FEDEX SRM 51-30-2, 51-10-1 AND FEDEX MM 51-30-0.

Part: CLIP — CRACKED (BS 750)

MECH DAMAGE FOUND ON STR CLIP AND AT STA 750F, STR 7R. REMOVED DAMAGED STR CLIP AT STA 950F, STR 7R. BACK DRILLED NEW CLIP AND INSTALLED WET WITH FAYING SURFACE SEALANT IAW FEDEX SRM 51-30-2, 51-10-1, MM 51-30-0.

Part: FLOOR BEAM — CORRODED (BS 344)

CORROSION (C53-224-01) AROUND FASTENER HOLES ON TOP CHORD OF BEAM BS 344, RBL 16-LBL 60, WL 208. REMOVED UPPER T-CHORD, FIXED NEW CHORD IN PLACE AND DRILLED, REMOVED DEBURRED, ALODINED, PRIMED AND INSTALLED WET WITH SEALANT. ALL WORK DONE IAW FEDEX SR 27-53-007, AT BS 344, RBL 16 - LBL 60, WL 208.

Part: STRINGER — PUNCTURED (BS 480)

STR 22R PUNCTURED BS 480 PLUS 8.5 INCHES. REMOVED DAMAGED SECTION OF STR 22R, BS 480 PLUS 8.5 INCHES. FABRICATED REPAIR PARTS AND INSTALLED WET WITH SEALANT IAW FEDEX 727 SRM 53-10-3, FIG 1.

Part: FRAME — CRACKED (BS 640)

FRAME CRACKED UNDER FLOOR SUPPORT, BS 640, STR 27R, RBL 18. CUT OUT DAMAGE AND REPAIRED PER FEDEX SRM 51-40-3.

Part: FRAME — CRACKED (BS 600)

FRAME CRACKED UNDER FLOOR SUPPORT, BS 600 ABOVE STR 28L LBL 10. CUT OUT DAMAGE AND REPAIRED PER FEDEX SRM 51-40-3.

Part: FRAME — CRACKED (BS 500)

FRAME BENT AND CRACKED AT BS 500 STR 25L. CUT OUT DAMAGE AND REPAIRED PER FEDEX SRM 51-40-03.