N496FE

Part: SWITCH — FAILED (NR 6 L/E FLAP) · airframe 33,609 hrs · 24,269 cycles

AFTER T/O NR 6 LED FAILED TO RETRACT. COMPLIED WITH QRH AND RETURNED TO MEM. REPEAT WRITEUP, NO DIRECTIONAL PROBLEMS. DURING CREW DEBRIEF, INDICATION WAS FOR NR 6 LEADING EDGE SLAT, NOT KRUEGER FLAP. AFTER TRANSLOAD, CYCLED FLAPS SEVERALTIMES AND FINALLY DUPLICATED PROBLEM WITH NR 6 SLAT AMBER {INTRANSIT} LIGHT ON BOTH FWD AND AFT PANELS. LEFT FLAPS EXTENDED FOR MORE T/S REF 727 MM 27-82-001-4. DURING T/S OPERATED L/E FLAPS AND SLATS APPROX 30 CYCLES. THE NR 6 FLAP IS THE ONLY LED THAT FAILED INDICATION, ABOUT 8 TIMES OUT OF TEN IT FAILED. AT NO TIME DID THE NR 6 SLAT FAIL INDICATION. INSTALLED FLAP POSITION SWITCH PER BOEING MM 27-82-0001-4. SYSTEM OPS CK OK.

Part: INDICATOR — FALSE INDICATION (NR 6 L/E FLAP) · airframe 33,609 hrs · 24,269 cycles

AFTER TAKEOFF NR 6 LED FAILED TO RETRACT, COMPLIED WITH QRH AND RETURNED TO MEM. JUMPER INSTALLED ON NR 6 KRUEGER FLAP. DETERMINED TO BE INDICATION PROBLEM, CYCLED FLAPS SEVERAL TIMES- INDICATIONS NORMAL, REF MM27-82-000-1. REMOVED JUMPER FROM NR 6 KRUEGER FLAP AND CONNECTED C/P CYCLED FLAPS PER MM 27-82-001-4, OPS CK NORMAL.

Part: ACCESSORY UNIT — FALSE INDICATION (E&E COMPARTMENT) · airframe 33,386 hrs · 24,067 cycles

DURING T/O GEAR RETRACTION, RED "RIGHT GEAR" LIGHT REMAINED ILLUMINATED. FOLLOWED RED TAB PROCEDURES BUT LIGHT REMAINED ON. NO OTHER LIGHTS OR INDICATIONS OBSERVED. REMOVED AND REPLACED LANDING GEAR ACCESSORY UNIT AND OPS CHECKED GOOD IAW M/M 32-09-122-5. RECHECKED R/H UP LOCK SENSOR. OPS CHECKED GOOD IAW M/M 32-61-081- 4 A/C OK FOR SERVICE.

Part: SUPPORT — CORRODED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

CORROSION ON BS 1176.9 REINFORCEMENT CHORD, RBL 50-70.5, WL 208. R&R CHORD PER SRM 51-30-2, 51-30-8, 51-30-5, 51-10-2 & MM 51-20-151-7.

Part: FRAME — CRACKED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

CRACK IN FRAME FAILSAFE CHORD BS 804, STR 14R. R&R FRAME PER SRM 51-40-3.

Part: FRAME — CRACKED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

CRACK IN FRAME FAILSAFE CHORD AT BS 804, STR 14R. R&R FRAME PER SRM 51-40-3.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

CORROSION LWR CHORD BS 720 FLOORBEAM, WL 208, LBL 55 - RBL 55. R&R CHORD PER SR 27-53-034.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

CORROSION LWR CHORD BS 1130, WL 200, LBL 55 - RBL 55. R&R CHORD PER EA 7-5310-62008.

Part: STRINGER — GOUGED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

STRINGER 7L, BS 720B+14 IS GOUGED. R&R STRINGER PER SRM 53-10-3 FIG 3.

Part: FRAME — DENTED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

DENTED FRAME AT BS 560, APPROX STR 24L. R&R FRAME PER EA 7-5310-65881.

Part: FRAME — DENTED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

DENTED FRAME AT BS 600 BETWEEN STR 24 LT & 25 LT. R&R FRAME PER EA 7-5310-65882.

Part: SKIN — CHAFED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

CHAFING ON SKIN LAP BS 720D PLUS 10 STR 19L. R&R SKIN PER SRM 53-30-3 FIG 14 & DWG SR 27-57-056.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

STR 15L IS CRACKED AT BS 720B+16. R&R STRINGER PER SRM 53-10-3.

Part: SKIN — CHAFED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

SKIN CHAFED AT BS 720D+10, STR 19R.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

STRINGER CLIP CRACKED AT BS 660, STR 6L. R&R STRINGER CLIP PER SRM 51-30-2, 51-30-5.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

STRINGER CLIP CRACKED AT BS 660, STR 9L. R&R STRINGER CLIP PER SRM 51-30-2, 51-30-5.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

STR CLIP CRACKED AT BS 660, STR 7L. R&R STRINGER CLIP PER SRM 51-30-2, 51-30-5.

Part: STRINGER CLIP — DAMAGED (FUSELAGE) · airframe 32,762 hrs · 23,572 cycles

STR 7R CLIP AT BS 720F HAS ELONGATED HOLE IN CLIP AND FRAME. R&R STRINGER CLIP PER SRM 51-30-2.

Part: WARNING HORN — ACTIVATED (COCKPIT) · airframe 32,658 hrs · 23,498 cycles

ON INITIAL CLIMBOUT FROM COS THE ALTITUDE WARNING HORN CAME ON PASSING APPROX 12,500 FT MSL. A CHECK OF THE CABIN PRESSURE GAUGE SHOWED CABIN ALTITUDE IN EXCESS OF 10,000 FT MSL WITH THE CABIN STILL CLIMBING. DESCENDED BACK TO 10,000 FT MSL AND RAN THE PROC FROM THE QRH BOOK WITH NO CHANGE. THE OUTFLOW VALVE WAS FULL CLOSED THE ENTIRE TIME, HAD CONTROL OF THE VALVE IN ALL POSITIONS OF THE AUTOMATIC CONTROLLER. RETURNED TO COS.

Part: ACCESSORY UNIT — FAILED (E&E COMPARTMENT)

02-36 AFTER DEPART LG WOULD NOT RETRACT. R&R LAND GEAR ACCESSORY BOX PER MM 32-09-112-5. GEAR HAD ICE ON ARRIVAL & DEICED.

Part: SENSOR — FAILED (UPLOCK)

01-304 RED L/GEAR LIGHT ON. R&R LMG UPLOCK SENSOR PER MM 32-61-081-4.

Part: FUEL CAP — FAULTY (#3 ENGINE)

01-204 AFT T/O #3 FUEL TANK GAUGE IND LOSS OF FUEL FROM THAT TANK. #3 BOOST PUMPS SHUTOFF & CROSSFEED #3 ENG FROM #1 FUEL TANK. INSTALL NEW FUEL CAP IN ACCORD WITH B727 MM 28-11-031-4. OK TO CONTINUE.

Part: CONNECTOR — CONTAMINATED (FEE L COMPUTER)

ON DEPARTURE, ELEV FEEL LIGHT CAME ON. *S/D* REMOVED AND REPLACED ELEV FEEL COMPUTER PITOT LINES CONNECTIONS. RIGGED STAB TRIM POTENTIMETER PER MM 22-11-061-4. BIRD NEST AND BIRD EGGS FOUND IN PNLS 9710, 9118, 9218.

Part: SEAL — BINDING (NLG DOOR)

NOSE GEAR DOOR LIGHT CAME ON WHEN GEAR DOWN. RECYCLE AND DOOR LIGHT CAME ON AGAIN. HYD PRESS NORMAL. FOUND SEAL BINDING THE LNG DOOR. REMOVED SEAL FROM AC 124 AND INSTALL ON THIS AC. AC OK TO CONTINUE.

Part: INDICATOR — INOPERATIVE (NLG DOOR)

UPON PUTTING GEAR DOWN, ALL GEAR GREEN, NOSE DOOR LIGHT RED. RECYCLED, NO CHANGE. *S/D* CREW REPORT ALL IND NORMAL. CK SWITCH DIMENSIONS AND OPS OF NOSE GEAR DOOR IND PER MM 32-62-11. ALL CK NORMAL.

Part: SWITCH — OUT OF ADJ (NLG)

NOSE GEAR DOOR LIGHT CAME ON DURING LANDING, CYCLED GEAR. CLEANED AND CHECKED ADJUSTMENT PER MM 32-62-11 PAGES 402 & 403. ADJUST NORM AND NO 90 DAY HISTORY. OK TO CONTINUE.

Part: WEB — CRACKED (BS 228)

DURING ROUTINE MAINTENANCE, THE UPPER WEB OF THE NOSE WHEEL WELL WAS FOUND CRACKED FROM FASTENER HOLE TO EDGE OF WEB AT THE AFT SIDE OF THE LT ACCESS PNL CUT OUT, BS 288, LBL 10. REMOVED AND REPLACED IAW SRM 51-40-2.

Part: SWITCH — MISWIRED (B HYD SYST)

98-293 AT FLT LVL 330 HAD KW SPIKE TO 40 KW ON ALL 3 GEN. AUTOPILOT DISCONN AND CAPT ADC FAILED MOMENTARILY. COCKPIT LIGHT DIMMED DURING FLUXES. REWIRED B SYS HYD SWITCH. RAN MOTOR WITH LOAD APLIED. GEN IND NORM.

Part: ACTUATOR — INOP (RT MLG DOOR)

ON DEPARTURE, GEAR RAISED NORMALLY IND LEVER TURN OFF, RED DOOR LIGHT ON FWD PNL AND RT GEAR DOOR, LT ON S/O'S PNL ILLUM. RAISED GEAR HANDLE TO UP AND RED DOOR LT. USING MANUAL LEVER-OPER RT GEAR DOOR NUMEROUS TIMES. DOOR LOCKED OK, NO HYD LEAK NOTE IND. REPLACED RT GEAR DOOR ACTUATOR PER MM 32-32-8, OPS AND LEAK CK OK.

Part: EPR TRANSMITTER — MALFUNCTION (NR 3 ENGINE)

98-0154 STA-IND, ON T/O AIRCRAFT ROLL WAS EXTREMELY LONG. AIRBORNE WITH STANDARD T/O EPR'S SET NR 1 AND NR 3 N1'S WERE APPROXIMATELY 82 PERCENT AND NR 2 N1 WAS APPROX 91 PERCENT. A/C BLEED SWITCHES WERE NR 1 OPEN NR 2 AND NR 3 WERE CLOSED. CHECKED ANTI-ICE BLEEDS ALL WERE CLOSED. OTHER ENGINE INSTRUMENTS SEEMED TO MATCH N1 SETTINGS. REMOVED AND REPLACED NR 3 PRESS RATIO TRANSMITTER EPR OPER CHECK NORMAL ON GROUND AT THIS TIME. SEE A/C MAINTENANCE LOG PAGE 972220 FOR NR 1 EPR DEFERRAL. FOUND INSECT NEST (MUD DAUBER) IN PT 2 PORT NR 1 AND NR 3 ENGINE. CLEANED OUT NEST AND BLEW OUT PT 2 PORT. RAN ENGINES PER JET RUN HANDBOOK CHAPTER 6. ALL PARAMETERS NORMAL.

Part: FLOORBEAM — CORRODED (BS 1070)

NR 0682 72 C 237-02 BS 1070, RBL 60 TO LBL 24 LOWER FORWARD FLANGE CORRODED. REMOVED CORRODED AREA OF FLOORBEAM FLANGE AND REPAIRED WITH FLOORBEAM REPAIR PER SRM 53-10-8.

Part: ANTI-ICE DUCT — BLOWN (NR 2 ENGINE)

ON CLIMBOUT AT 3000, LWR AFT BODY OVERHEAT LIGHT ILLUM. RAN CHECK LIST AND AFTER RETARD NR 2 THROTTLE LIGHT WENT OUT. ENG ANTI-ICE WAS OPENED JUST PRIOR TO ILLUM OF LWR AFT BODY OVERHEAT LIGHT. DECLARED EMERGENCY AND RETURN TO MEM. FOUND NR 2 ENG COWL THERMAL ANTI-ICE DUCT BLOWN. REMOVED AND REPLACED FIREWALL COUPLING, DUE VALVE INSTALLATION. DUCT REPLACEMENT AND SEALANT ON NR 2 ENGINE SIDE OF FIREWALL BRACE ROD IN AFT STAIRWELL REMOVED. REMOVED PANEL LEFT SIDE VERTICAL STABILIZER, PANEL ON TRUCK. REINSTALL THERMAL ANTI-ICE VALVE AND DUCT. SEALED FIREWALL SIDE OF COUPLING. RAN NR 2 ENG, NO LEAKS NOTED AND OPERATION NORMAL. REINSTALL PANEL ON STAB AND SUPPORT ROD, OK FOR SERVICE.

Part: INDICATOR — DAMAGED (OUTBD TE FLAPS)

97-204 - ON CLIMB-OUT O/B T/E FLAPS ASSYMETRIC (SPLIT) ONE (1) NEEDLE WIDTH. (RETRACTION) RAN CHECKLIST AND LANDED WITHOUT INCIDENT, WAS ABLE TO DUPLICATE ON GROUND WITH ORIGINAL OUTBOARD FLAP POSITION INDICATOR INSTALLED. REMOVED AND REPLACED OUTBOARD FLAP POSITION INDICATOR IN ACCORDANCE MAINTENANCE MANUAL WITH 27-52-21. RAN FLAPS THROUGH FULL TRAVEL, OUTBOARD FLAPS OPERATIONALLY CHECKED NORMAL. REINSTALLED FLAP HANDLE STOP.

Part: TERMINAL PIN — CORRODED (RT WING)

RT WING REAR TERMINAL PIN CORRODED. REPLACED RT WIG REAR TERMINAL PIN PER M/M 57-41-1.

Part: FLOORBEAM — CORRODED (CABIN)

REMOVED CORROSION CAP OF FLOORBEAM OUT OF LIMITS. REPLACED FLOORBEAM CAP PER SRM 27-53-007.

Part: ANGLE — CORRODED (BS 740-780)

NR1315 71C131-02, A/C BAY AREA - T ANGLE SUPPORT STRUCTURE CORRODED FROM BS 740-780 LT INBD AND FORWARD OF LT HEAT EXCHANGER. REMOVED CORRODED T ANGLE AND INSTALLED NEW SECTION OF T ANGLE PER SRM 51-10-1. INSTALLED SPLICE DOUBLER AT BS 790 PER SRM 51-40-4.

Part: FLOORBEAM — CORRODED (BS 480)

UPPER LOBE CORROSION ON FLOORBEAM TOP AND BOTTOM OF UPPER FLANGE BS 480, RBL 12 TO 16. INSTALLED DOUBLER PER AARD 53-10-07-02.

Part: SKIN — DAMAGED (BS 970)

DEEP WEAR MARK IN FUSE SKIN AT BS 970 BETWEEN STR 24L AND 25L. CUT OUT DAMAGE TO APPROXIMATELY 1.5 BY 2 AND INSTALLED .090 202473 DOUBLER PER SRM 53-30-3 PG 8.

Part: DOUBLER — CORRODED (BS 720)

FWD CARGO, CORROSION ON BELLY SKIN AT AND AROUND NUT PLATE BS 720+3 BETWEEN STR 28L AND 28R AND AT BS 715 O/B OF STR 28R. INSTALLED DOUBLER PER SRM 53-30-3.

Part: BULKHEAD — CRACKED (BS 1183)

CRACK IN 1183 BULKHEAD LBL 10, WL 172. CUT OUT CRACK FINAL APPROX 1 BY 1.5 AND INSTALLED A .063202473 DOUBLER PER EA 7-5310-29205. DATED 9/3/97.

Part: FRAME — DAMAGED (BS 660)

FWD CARGO BELT FRAME AT BS 660 DENTED JUST ABOVE STR 24L. REMOVED DAMAGED AREA OF FRAME AND REPAIRED WITH TYPICAL FORMED SECTION REPAIR PER SRM 51-40-3 PG 1, FIG I.

Part: SKIN — CORRODED (BS 720)

NR 0300 71C209-02, FWD CARGO, CORROSION ON BELLY SKIN UNDER LEVELING COMPOUND JUST AFT OF BS 720C BETWEEN STR 28L AND 28R. INSTALLED DOUBLER PER SRM 53-30-3.

Part: T-ANGLE — CORRODED (BS 740-780)

NR1299 71C131-02, A/C BAY AREA - T ANGLE SUPPORT STRUCTURE CORRODED FROM BS 740-780 RT INBD AND FORWARD OF RT HEAT EXCHANGER. REMOVED CORRODED T ANGLE AND INSTALLED NEW SECTION OF T ANGLE PER SRM 51-10-1. INSTALLED SPLICE DOUBLER AT BS 790 PER SRM 51-40-4.

Part: SUPPORT — CORRODED (NR 2 ADF ANTENNA)

NR 0879 71C131-02 A/C BAY AREA, - NR 2 ADF ANTENNA SUPPORT STRUCTURE IS CORRODED AROUND FRAME. REMOVED AND REPLACED SUPPORT STRUCTURE FRAME AT BS 760, BLO AS PER SRM 51-10-1.

Part: PROX SWITCH — FAILED (LANDING GEAR)

GEAR FAILED TO RETRACT AFTER TAKEOFF. HANDLE WOULD NOT RAISE ABOVE OFF POSITION. COMPLIED WITH APPROPRIATE CHECKLIST PG 2-6-2 AND RETURNED FOR LANDING. REMOVED AND REPLACED AIR SENSE PROX SWITCH IAW MFG M/M 32-09-221. ALSO, REPAIRED OPEN CIRCUIT IN SAME, OPS CHK PER M/M 32-02-221. PERFORMED GEAR SWING DUE TO AIR TURNBACK, OPS CHK OK.

Part: GEAR INDICATION — MALFUNCTIONED (NOSE GEAR)

ON LANDING INTO OAK, DID NOT GET NOSE GEAR LIGHT, DOWN AND LOCKED.

Part: GEAR MODULE — MALFUNCTIONED (NLG)

NOSE WHEEL GEAR LIGHT WOULD NOT GIVE DOWN AND LOCKED INDICATION AFTER PUTTING GEAR HANDLE DOWN. THE TEST WOULD NOT TEST NORMAL. NOSE GEAR BULB WORKED NORMALLY. DOWN AND LOCKED VERIFIED BY VIEWING PORT AND RUNNING THE CHECKLIST. REMOVED AND REPLACED LANDING GEAR ELECTRICAL/ELECTRONIC MODULE. OPS TEST PER MM 32-09-121 PAGE 401 AND TESTED PER 32-09-121 PAGE 501. ALL SYSTEM CHECKS NORMAL.

Part: IND LIGHT — MALFUNCTIONED (NLG)

DID NOT GET NOSE GEAR LIGHT DURING NORMAL EXTENSION, RECYCLED AND TESTED AND DID NOT CHECK NORMAL, WENT AROUND AND ON GROUND, THE NOSE GEAR LIGHT TESTED NORMAL, LEFT GEAR DOWN IN PATTERN AND LANDED. INSPECTED NOSE GEAR POSITION SWITCH AND FOUND WATER IN CANNON PLUG, CLEANED MOISTURE FROM CANNON PLUG - CHECKED LINKAGE FOR DEFECTS, FOUND NONE, SYS GROUND CHECK NORMAL.

Part: OVERHEAT LIGHT — ILLUMINATED (NR 1 ENGINE)

NR 1 ENG STRUT OVERHEAT LIGHT CAME ON PASSING 10,000 FEET CLIMBING OUT. ENG ANTI-ICE HAD JUST BEEN SHUTOFF, BOTH PACS ON, BLEEDS OPEN ON NR 1 AND NR 3. ABNORMAL PROCEDURES IN RED TABS COMPLIED WITH/ACCOMPLISHED. LIGHT STAYED OUT AS NR 1 THROTTLE READVANCED TO CLIMB SETTING. IAW CHECKLIST NR 1 BLEED AND PAC SHUTDOWN. INSPECTED NR 1 ENG STRUT AREA FOR PNEU LEAKS AND RUBBING OF SENSING ELEMENT. OK FOR SERVICE.

Part: WIRE — CHAFED (NR 3 ENGINE)

NR 3 FUEL ICING LIGHT CAME ON AT LEVEL OFF. ABNORMAL PROCEDURES COMPLIED WITH HOWEVER THE LIGHT REMAINED ON. WE WERE BURNING FROM TANK NR 2 AT THE TIME. FOUND CHAFED WIRE GROUNDED TO ENG CASE NEAR FUEL FITLER PRESSURE SWITCH REPAIRED SAME. NR 3 ENG FUEL DE-ICING SYSTEM OPS CKS OK PER MM 73-14-0.