N49082

Part: FLOOR SUPPORT — CORRODED (BS 488-501) · corrosion level 2 · airframe 118,904 hrs · 23,247 cycles

DURING ACCOMPLISHMENT OF TASK CARD SWF858 DETAILED VISUAL INSPECTION FOUND LEVEL 2 CORROSION ON FLOOR SUPPORT FRAME. REPLACED FLOOR ACA 7364-2 BEAM PER SRM VOL 2 51-30.

Part: SLIDE — UNWANTED DEPLOY (R2 DOOR) · airframe 117,855 hrs · 23,036 cycles

R2 DOOR INADVERTENTLY OPENED AFTER SLIDE WAS ARMED, SLIDE DID NOT DROP COMPLETELY OUT OF THE CASE TO THE POINT OF ACTUATING THE INFLATION SEQUENCE.

Part: SLIDE — UNWANTED DEPLOY (R2 DOOR) · airframe 117,855 hrs · 23,036 cycles

R2 DOOR INADVERTENTLY OPENED AFTER SLIDE WAS ARMED, SLIDE DID NOT DROP COMPLETELY OUT OF THE CASE TO THE POINT OF ACTUATING THE INFLATION SEQUENCE.

Part: MOTOR — FAILED (STAB TRIM) · airframe 116,114 hrs · 22,660 cycles

NR 1 SYSTEM HYDRAULIC FAIL LOST ALL FLUID IND ZERO. FOUND PRIMARY HORIZONTAL TRIM MOTOR LEAKING, REMOVED AND REPLACED PER 27-43 CHECKS NORMAL. REPLACED NR 1 HYD SYSTEM FILTERS ON EDPS AND ACMPS LEAK CHECK GOOD IAW 29-12.

Part: PROXIMITY SENSOR — INOPERATIVE (MLG) · airframe 115,762 hrs · 22,586 cycles

LANDING GEAR RED LIGHTS REMAIN ON ALL 4 RECYCLE GEAR NO HELP LIGHTS REMAINED ON FOR 15 MINUTES BEFORE GOING OUT.

Part: UNKNOWN — FUMES (MID-GALLEY) · airframe 113,932 hrs · 22,216 cycles

FLIGHT CREW REPORTED FUMES IN MID-GALLEY AREA AFTER TAKEOFF. AIRCRAFT DIVERTED TO MILDENHALL, ENGLAND AS A PRECAUTION. COULD NOT DUPLICATE ON THE GROUND. NO SMOKE WAS REPORTED OR SEEN. ACCOMPLISHED OPERATIONAL CHECKS OF ENTERTAINMENT SYSTEM, LIGHTS, GALLEY EQUIPMENT AND PNEUMATIC SYSTEM WITH ENGINES RUNNING. NO DEFECTS NOTED. FLIGHT CONTINUED TO ATL WITH NO FURTHER INCIDENT.

Part: CONNECTOR — DAMAGED (BRAKE SENSOR) · airframe 77,068 hrs · 11,828 cycles

DURING LANDING ROLLOUT, F/A NOTED SMOKE BRIEFLY EMITTING FROM VENTILATION SYSTEM OVERHEAD ROW 4 - 7 ON RT. F/E NOTED A HIGH BRAKE TEMP ON NR 5 WHEEL. PASSENGERS WERE CONCURRENTLY RELOCATED TO ZONES B & C. THE APPARENT SMOKE WAS LATER DISCRIBED AS FOGGY HAZE WHICH QUICKLY DISSIPATED. POST FLIGHT, MECHANICS FOUND NR 5 BRAKE TEMPERATURE SENSOR INDICATING ERRONEOUSLY HIGH DUE TO BENT PINS / SHORT CIRCUIT IN AN ELECTRICAL CONNECTOR WITH NO EVIDENCE OF OVERHEATING OR MALFUNCTION OF THE BRAKE SYSTEM. THE PRESUMPTIVE CAUSE OF THE SMOKE WAS CONDENSATION OF WATER VAPOR.

Part: GASKET — LEAKING (NR 3 ENGINE) · airframe 113,249 hrs · 22,088 cycles

NR 3 ENGINE OIL LOSS, APPROXIMATELY 2 QTS. PER HOUR. MX ADVISED CREW TO RETURN TO BWI FOR REPAIRS. REPLACED GASKET ON OIL VENT LINE FOR B-SUMP AND OIL TANK. RAN ENGINE AT POWER. NO FURTHER LEAKING NOTED.

Part: ENGINE — FLAMED OUT (NR3) · airframe 112,368 hrs · 21,894 cycles

NR 3 ENGINE FLAMED OUT AT TOP OF DECENT WITH THROTTLES AT IDLE. ACCOMPLISHED CHECKLIST IAW COM.

Part: RELIEF VALVE — LEAKING (FUEL SYSTEM) · airframe 111,660 hrs · 21,746 cycles

FUEL REPORTED LEAKING INFLIGHT FROM RIGHT AILERON AREA- FUEL QUANTITY LOSS CONFIRMED. AIR TURNBACK TO FRA.

Part: RELAY — INOPERATIVE (R3 DOOR) · airframe 106,432 hrs · 20,854 cycles

R3 DOOR WILL NOT OPEN ELECTRICALLY. REMOVED AND REPLACED RELAY R2-30.

Part: LONGERON — CORRODED (BS 1600 - 1620)

INSPECTION FOUND LONGERON 51L CORRODED BETWEEN STA 1600 AND 1620 AFTER REMOVAL OF ANTI-COLLISION BEACON LIGHT. THE CORRODED AREA WAS TRIMMED OUT AND REINFORCED WITH NEW PARTS IAW ECRA 5311-01092.

Part: CHARGER — INOPERATIVE (CABIN)

THE EMERGENCY LIGHT TEST LIGHT IN FLIGHT COMPARTMENT AT OVERHEAD CONTROL PANEL DID NOT ILLUMINATE IN TEST POSITION. THE EMERGENCY LIGHT CHARGER WAS REPLACED AND OPERATION CHECKED GOOD IAW MM 33-50-00.

Part: LIGHT — INOPERATIVE (SEAT 4 & 42)

INSPECTION FOUND EMERGENCY PATH LIGHTS ON SIDE OF SEATS 4B AND 42B INOPERATIVE. THE LIGHT ASSEMBLIES WERE REPLACED AND OPERATION CHECKED GOOD IAW MM 33-55-00.

Part: LIGHT — INOPERATIVE (SEAT 1)

INSPECTION FOUND ONE BULB NOT ILLUMINATED IN SEAT 1B AFT EMERGENCY PATH LIGHT. THE AFT LIGHT ASSEMBLY WAS REPLACED AND CHECKED GOOD IAW MM 33-55-00.

Part: FLOORBEAM — CRACKED (BS 575)

INSPECTION FOUND A 1 INCH CRACK IN FLOOR SUPPORT AT STA 575, RBL 65. THE FLOOR SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 53-60-01, 51-21-01, AND 51-31-01.

Part: FLOORBEAM — CORRODED (BS 1902 - 1921)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT UPPER LOBE UNDER CABIN FLOOR LAV/GALLEY AT STA 1902-1921 BETWEEN RBL 21 TO LBL 21. THE FLOOR SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 53-60-01, 51-21-01, AND 51-31-01.

Part: FLOORBEAM — CORRODED (BS 760 - 890)

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT GALLEY, STA 760-890, LBL 45 AND STA 780-880, RBL 45. NEW FLOOR SUPPORTS WERE INSTALLED IAW SRM 53-13-01, 53-70-00, FIGURE 13, AND 51-31-01.

Part: WEB — TORN (BS 1841)

INSPECTION FOUND LOWER LOBE CENTER CARGO BILGE TORN ON WEB AT STA 1841. THE TORN AREA WAS TRIMMED OUT AND A DOUBLER WAS INSTALLED WITH NEW RIVETS IAW SRM 51-31-01.

Part: FLOORBEAM — CORRODED (BS 1868 - 1884)

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT UPPER LOBE UNDER CABIN FLOOR LAV/GALLEY AT STA 1868-1884 BETWEEN LBL 5 AND RBL 5, BL 0 TO RBL 35, AND RBL 35-LBL 35. THE FLOOR SUPPORTS WERE REMOVED AND NEW SUPPORTS WERE INSTALLED IAW SRM 51-31-01.

Part: FLOORBEAM — CORRODED (BS 457 - 495)

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT UPPER LOBE UNDER LAV/GALLEY, STA 459-495, LBL 22 TO RBL 22 AND STA 457-495, LBL 52. NEW FLOOR SUPPORTS WERE INSTALLED IAW SRM 53-13-01, FIGURE 1, 53-60-01, 51-21-01, AND 51-31-01.

Part: SEAT TRACK — CORRODED (BS 820 - 840)

INSPECTION FOUND MAIN CABIN SEAT TRACK CORRODED AT STA 820-840, LBL 9. THE CORRODED AREA OF SEAT TRACK WAS TRIMMED OUT, REPAIRED WITH FILLER AND REINFORCEMENT IAW SRM 53-70-00, FIGURE 5.

Part: FLOORBEAM — CORRODED (BS 1884)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT UPPER LOBE UNDER CABIN FLOOR LAV/GALLEY AT STA 1884 BETWEEN RBL 90 AND LBL 90. THE FLOOR SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 53-60-01, 51-21-01, AND 51-31-01.

Part: FRAME — CRACKED (CARGO DOOR)

AFT CARGO DOOR HAS INTERNAL STRUCTURE CRACKED. PERFORMED REPAIR PER EC/RA 5230-01461.

Part: WIRE — DISCONNECTED (R1&R3 DOOR)

DOOR 1 AND 3 RT LOW PRESSURE LIGHT SLIDE BOTTLES DONT WORK. REINSTALLED TERMINALS WIRE LIGHT SLIDE ON DOOR 1 AND 3 RIGHT SIDE. PERFORMED TEST PER MM 25-60-00.

Part: BATTERY — DISCHARGED (MEGAPHONES)

FWD AND AFT MEGAPHONES HAVE BATTERY DISHARGED. REPLACED BATTERY AND PERFORMED CHECK PER MM 25-60-00.

Part: BATT CHARGER — INOPERATIVE (CABIN)

THE EMERGENCY EXIT LIGHTS WOULD NOT TEST, NO GREEN WHEN BUTTON PUSHED. THE LEFT AFT BATTERY CHARGER AND PACK WERE REMOVED AND REPLACED.

Part: STRINGER — CRACKED (BS 1953-1964)

INSPECTION FOUND A 1 INCH CRACK WITH CORROSION ON STRINGER 51L BETWEEN STA 1953 AND 1964 IN AFT CARGO BILGE AREA. CORROSION WAS REMOVED. THE CRACKED AREA WAS REMOVED. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-16-01, FIGURE 7, 51-20-00, AND 51-31-01.

Part: FLOORBEAM — TORN (BS 1841)

INSPECTION FOUND WEB IN AFT CARGO BILGE AREA TORN AND DISTORTED AT FLOORBEAM, STA 1841, STRINGER 44L. THE DAMAGED AREA OF WEB WAS TRIMMED AND BLENDED OUT. THE AREA WAS REINFORCED WITH DOUBLER IAW SRM 53-00-01, 51-21-01, AND 51-31-01.

Part: STIFFENER — CRACKED (LT MLG WW)

INSPECTION FOUND A 1 CRACK IN STIFFENER AT LT MLG WHEEL WELL AFT WALL. THE STIFFENER WAS REMOVED AND A NEW STIFFENER WAS FABRICATED AND INSTALLED IAW SRM 53-53-01, 51-20-00, AND 51-31-01.

Part: BOLT — FAILED (NR 2 ENGINE)

NR 2 ENG FIRE WARNING ACTIVATED AFTER T/O. FUEL WAS DUMPED AND THE ACFT WAS RETURNED TO LGW WHERE IT LANDED WITHOUT INCIDENT. THE NR 2 ENG WAS REMOVED AND REPLACED. A POWER ASSURANCE RUN WAS PERFORMED AND ALL PARAMETERS WERE NORMAL. *S/D* ENG DISASSEMBLY IDENTIFIED THE PRIMARY CAUSE OF THE LPT CASE PENETRATION TO BE FAILURE OF A NUMBER OF STAGE 1 LPT BLADES. THE CAUSE OF THE IMPACT TO THE LPT BLADES WAS IDENTIFIED AS LIBERATION OF TWO STAGE 1 LPT NOZZLE SEGMENT SECURING BOLTS. THE BOLT LIBERATION IS BELIEVED TO HAVE BEEN CAUSED BY BOLT HOLE CRACKING IN THE NOZZLE SUPPORT FLANGE. PARTS HAVE BEEN SENT TO GE AIRCRAFT ENGINES FOR FURTHER INVESTIGATION.

Part: BATTERY CHARGED — INOPERATIVE (CABIN)

THE EMERGENCY LIGHTS WOULD NOT TEST DURING A PREFLIGHT CHECK. THE AFT EMERGENCY CHARGER AND BATTERY WERE REMOVED AND REPLACED, OPERATIONAL CHECKS WERE GOOD.

Part: SKIN — CRACKED (LT ELEVATOR)

INSPECTION FOUND THE LEFT OUTBOARD ELEVATOR TRAILING EDGE CRACKED IN TWO PLACES. THE CRACK LENGTHS WERE NOT IDENTIFIED. THE ELEVATOR TRAILING EDGE WAS REPAIRED IAW SRM 55-30-00, FIGURE 1 AND BALANCED IAW SRM 55-20-00.

Part: SKIN — CRACKED (RT ELEVATOR)

INSPECTION FOUND RIGHT OUTBOARD ELEVATOR TRAILING EDGE SPLIT WITH A 2 INCH CRACK AT INBOARD END. THE ELEVATOR WAS REPAIRED IAW SRM 55-30-00, FIGURE 1 AND BALANCED IAW SRM 55-20-00.

Part: DOOR FRAME — CORRODED (BS 893)

INSPECTION FOUND FORWARD CARGO DOOR FRAME CORRODED AT STA 893. THE CORRODED SECTION OF FRAME WAS REMOVED. A FRAME AND SPLICE REPAIR WAS FABRICATED AND INSTALLED IAW ECRA 5310-03424.

Part: TEE CAP — CORRODED (BS 1521)

INSPECTION FOUND T-CAP CORRODED AT STA 1521. THE T-CAP WAS REPAIRED IAW ECRA 5330-02489.

Part: SUPPORT — CRACKED (LT AILERON)

INSPECTION FOUND A 2 INCH CRACK IN T-SUPPORT TWELVE INCHES FORWARD OF LEFT INBOARD AILERON OUTBOARD HINGE. THE T-SUPPORT WAS REMOVED AND A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM'S 51-10-00, 57-22-01, AND 51-31-01.

Part: FLOORBEAM — CORRODED (BS 860)

INSPECTION FOUND CORROSION ON FLOOR BEAM UPPER CAP AT F.S. 860, RBL 72 BETWEEN 242EF AND 242FF. THE FLOOR BEAM WAS REMOVED AND REPLACED IAW 51-21-01.

Part: ANGLE — CORRODED (CARGO COMPT)

INSPECTION FOUND SIDEWALL TO FLOOR SPLICE ANGLE CORRODED AT CENTER CARGO COMPARTMENT RT SIDE AFT OF THE DOOR CUT-OUT. A NEW SPLICE ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-10-00, 53-42-01, AND 51-31-01.

Part: BRACKET — BROKEN (BS 879)

INSPECTION FOUND FORWARD CARGO BAY BRACKET BROKEN WHERE FLOORBOARD IS ATTACHED JUST LEFT OF BUTT LINE AT STA 879. THE BRACKET WAS REMOVED. A REPLACEMENT BRACKET WAS FABRICATED AND INSTALLED IAW SRM 51-10-00, 51-31-01, 53-13-01, 51-21-01, AND 51-10-01.

Part: WINDOW FRAME — CORRODED (L3 DOOR)

INSPECTION FOUND L-3 DOOR WINDOW FRAME CORRODED. THE WINDOW FRAME WAS REMOVED. A REPLACEMENT WINDOW FRAME WAS FABRICATED AND INSTALLED IAW SRM 51-31-01.

Part: BULKHEAD FITTING — CRACKED (BS 595)

INSPECTION FOUND A 1 INCH CRACK IN T-FITTING ON BULKHEAD AT F.S. 595, LBL 35. A NEW T-FITTING WAS INSTALLED IAW SRM 51-10-00, 51-31-01, AND 53-12-01.

Part: SKIN — CORRODED (BS 470)

INSPECTION FOUND FUSELAGE SKIN CORRODED AT F.S. 470, LONGERON 8. THE CORRODED AREA WAS REMOVED. THE AREA WAS REPAIRED USING FINGER DOUBLERS, SKIN, DOUBLER AND TRIPLER IAW SRM 53-20-00, FIGURE 6.

Part: SUPPORT — CORRODED (BS 1921-1962)

INSPECTION FOUND FLOOR SUPPORT CORRODED FROM F.S. 1921 TO 1962, BL ZERO. A REPLACEMENT FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 53-16-01.

Part: SUPPORT — CORRODED (BS 1887)

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT STA 1887, LBL 17 TO LBL 5 AND LBL 61 TO LBL 80. REPLACEMENT FLOOR SUPPORTS WERE FABRICATED AND INSTALLED IAW SRM 51-31-01.

Part: SUPPORT — CRACKED (BS 824)

INSPECTION FOUND A 1 INCH CRACK IN FLOOR SUPPORT AT F.S. 824, LBL 72. A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-30-00.

Part: ANGLE — CRACKED (WS 1381)

INSPECTION FOUND A 2 INCH CRACK IN LT WING ROOT L-ANGLE SUPPORT AT STA 1381. THE ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-1.

Part: ANGLE — CRACKED (BS 1360)

INSPECTION FOUND A 2 INCH CRACK IN L-ANGLE WING BODY FAIRING SUPPORT AT LT WING ROOT, STA 1360. THE ANGLE WAS REPLACED IAW SRM 51-30-101 AND 53-53-01, FIGURE 3A.