N509MC

Part: INDICATOR — STICKING (COCKPIT) · airframe 116,279 hrs · 22,160 cycles

ON TAXI, OUTBOARD FLAP INDICATOR WITH 20 FLAPS SELECTED. RT FLAPS INDICATES 20 DEGREES, LT FLAP INDICATES 25 DEGREES. REPLACED FLAP INDICATOR PER AMM 27-58-00. OPS CHECK OK.

Part: INDICATOR — STUCK (AILERON) · airframe 116,011 hrs · 22,106 cycles

CREW REPORTED LEFT HAND AILERON INDICATOR STUCK IN FULL DOWN POSITION. TRANSFERRED TO DMI 35831 PER MEL 27-01.

Part: WARNING FLAG — FALSE INDICATION (INSTRUMENT PANEL) · airframe 115,845 hrs · 22,071 cycles

FLT CREW ADVISED F/O'S AIRSPEED IND HAS FLAG IN VIEW. CYCLED POWER, ALL OPS AND IND CHECK OK ATA 34-13-00. ALSO CLEANED CONNECTOR PINS.

Part: CONNECTOR — FAILED (AILERON POSITION) · airframe 115,683 hrs · 22,033 cycles

RIGHT OUTBOARD AILERON CONTROL SURFACE POSITION INDICATED DROOPING. PERFORMED VISUAL INSPECTION OF RIGHT OUTBOARD AILERON; VERIFIED PROPER MOVEMENT, ENTERED IN LOGBOOK. RELEASED ON MEL. REMOVED AND INSTALLED CONNECTOR DT488 AND RIGHT AILERON POSITION INDICATOR.

Part: STARTER — FAILED (NR 1 ENGINE) · airframe 115,428 hrs · 21,981 cycles

ABORTED START ON NR 1 ENGINE, DUE TO SLOW ACCELERATION AND SPARKS FROM STARTER EXHAUST. REMOVED AND REPLACED NR 1 ENGINE STARTER PER MM 80-40-07. FUNCTION CHECKS NORMAL.

Part: CIRCUIT BREAKER — TRIPPED (GENERATOR) · airframe 115,428 hrs · 21,981 cycles

GENERATORS NR 3 AND NR 4 SHOW NO GENERATOR LOAD AND NO VOLTS OF FREQ'S GENERATOR TEST SHOWS CSD RPM AND PMG FOR BOTH 3 AND 4. FOUND CIRCUIT BREAKERS FOR NR 3 AND NR 4 DISTRIBUTION METER POPPED, RESET BREAKERS AND RAN ENGINES PER MM 71-00-00. OPS CHECK NORMAL.

Part: PRESSURE SWITCH — FAILED (BOOST PUMP) · airframe 115,341 hrs · 21,960 cycles

NR 4 MAIN AFT BOOST PUMP FAILED. ITEM DEFERRED PER MEL 28-01-C. CHANGED NR 4 FUEL AFT BOOST PUMP PRESSURE SWITCH IAW MM 28-42-01. TEST OK.

Part: TRIM SYSTEM — MALFUNCTIONED (AUTOPILOT SYS) · airframe 115,277 hrs · 21,947 cycles

AUTOPILOT A DID NOT TRIM STABILIZER AND DID NOT CAPTURE ALTITUDE. REPLACED THE AUTOMATIC STABILIZER TRIM UNIT PER MM 22-14-01. TEST OK.

Part: PROXIMITY SWITCH — FAILED (LANDING GEAR) · airframe 115,200 hrs · 21,931 cycles

FLIGHT CREW REPORTED AFTER TAKEOFF, GROUND SAFE RELAY LIGHT CAME ON. ALTERNATE PROCEDURE ACCOMPLISHED. AUTO PRESS CONTROLLER NOT OPERATING NORMALLY, AURAL WARNING COULD NOT BE SILENCED. REPLACED LT BODY GEAR SWITCH AND TARGET. REPLACED LT WING GEAR ALT TILT SWITCH PER MM 32-61-00. ACCOMPLISHED GEAR SWING IAW MM 32-61-07. ALL OPS NORMAL.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 115,185 hrs · 21,929 cycles

FLIGHT CREW REPORTED AFTER T/O, GEAR AND FLAPS UP, GOT T/O WARNING HORN THAT COULD NOT BE SILENCED. WARNING HORN C/B ON P-6 PULLED TO SILENCE. INDICATION WERE LEFT WING TILT LIGHT ON IN ALT. RIGHT HAND BODY GEAR TILT LIGHT ON IN ALT. LOW SPEED BRAKE RELEASE AND TOUCHDOWN PROTECTION LIGHTS ON TOUCHDOWN PROTECTION OFF LIGHTS ON. TD PROTECTION OFF LIGHT GOES OUT IF PRI GND TEST SWITCH IS SELECTED. DEFERRED PER MEL 32-13.

Part: WARNING HORN — ACTIVATED · airframe 115,173 hrs · 21,926 cycles

DURING CLIMB, AURAL WARNING SOUNDED AT 1000 FT - GEAR UP FLAPS AT 5 DEGREES ON F/E PANEL GEAR SAFE LIGHT ON. LEFT WING TILT LIGHT ON, RIGHT BODY TILT LIGHT ON, LOW SPEED BK REL LIGHT ON. T/O PROT OFF LT ON. LATER ALL LIGHTS EXCEPT RT BODY TILT EXTINGUISHED (RT ALT BODY TILT REMAINED ON DURING FLIGHT). CHECKED AS PER MM 32-61-04, ALL IND ON GROUND OK. RMS NOTIFIED.

Part: DRIVE ASSY — DAMAGED (ADP) · airframe 115,027 hrs · 21,894 cycles

ADP CHUGGING, REPORTING NO PRESSURE. OPENED MEL 29-2B

Part: STRUCTURE — CRACKED (RT ELEVATOR) · airframe 113,433 hrs · 21,571 cycles

RIGHT O/B ELEVATOR FOUND CRACKED AT LEADING EDGE AREA I/B OF ELEVATOR STATION 256.811 AND BRACKET CRACKED AT ELEVATOR STATION 256.811. RIGHT O/B ELEVATOR REPAIRED PER BOEING INSTRUCTIONS 1-1N575W AND FAA FORM 8100-9.

Part: SKIN — CRACKED (NR 4 NACELLE) · airframe 113,433 hrs · 21,571 cycles

CRACK AT NR 4 NACELLE STRUT TOP FORWARD CORNER OF PRECOOLER EXHAUST CUTOUT. PRECOOLER EXHAUST CUTOUT REPAIRED PER BOEING INSTRUCTIONS 1-1MNS9D AND FAA FORM 8100-9.

Part: PRESSURE PANEL — CRACKED (NLG WW) · airframe 113,433 hrs · 21,571 cycles

NOSE WHEEL WELL WEB AT STATION BS 400 STR 47R FOUND CRACKED AT RETRACT ACTUATOR CUTOUT. NOSE WHEEL WELL WEB REPAIRED AS PER BOEING MESSAGE 1-1MCB8E AND FAA FORM 8100-9.

Part: SKIN — WORN (NR 3 NACELLE) · airframe 113,433 hrs · 21,571 cycles

WORN/CHAFING NR 3 NACELLE STRUT SKIN AROUND CUTOUT NR 12. NR 3 NACELLE STRUT SKIN AROUND CUTOUT REPAIRED PER BOEING INSTRUCTIONS 1-1MNB95 AND FAA FORM 8100-9.

Part: VERTICAL BEAM — CRACKED (FUSELAGE) · airframe 113,433 hrs · 21,571 cycles

FOUND 2 CRACKS AT VERTICAL WEB BEAM BS 280 AND ONE CRACK AT BS 320. VERTICAL WEB BEAM REPAIR ACCOMPLISHED PER BOEING MESSAGE 1-1MEI6G AND FAA FORM 8100-9.

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 113,433 hrs · 21,571 cycles

LT FOUND 1 OFF STANDOFF HOLE WITH 2 OFF CRACKS APPROXIMATELY 3MM EACH AT BS 280 WEB. REPAIR CARRIED OUT IAW MFG MSG 1-1ME16G. REFER TO FAA FORM 8100-9 DATED JUNE 2, 2005. THIS REPAIR IS SUBJECT TO CONTINUE INSPECTION IAW SB 747-53A2293.

Part: NOZZLE — DAMAGED (EXHAUST) · airframe 113,229 hrs · 21,532 cycles

ON WALK AROUND, FOUND A HOLE APPROXIMATELY 1.5 INCH IN DIAMETER ON NR 3 ENGINE LONG FIXED CORE EXHAUST NOZZLE AT 8:00 O’CLOCK POSITION. REPAIRED NR 3 ENGINE LONG FIXED CORE COWL EXHAUST NOZZLE AS PER GE ENGINE MANUAL 78-11-01, REPAIR 010.

Part: WIRE — MISWIRED (AUTOPILOT) · airframe 113,141 hrs · 21,512 cycles

A-AUTOPILOT TOC F/L 320 SELECTED ALT HOLD A/C WENT 100 FT HIGH THEN DESCENDED TO 31500. DISENGAGED AUTOPILOT HAND FLEW A/C BACK TO F/L 320. SELECTED AUTOPILOT-B ALT HOLD. FOUND ALT HOLD JUMPER WIRES FROM AUTOPILOT-A PITCH COMPUTER AND NR 1 CADC PIN 64,65 SWAPPED. SWAPPED WIRES PER WDM 22-12-13. PERFORMED ALT HOLD SYSTEM PER MM 22-10-00.

Part: COMPUTER — INOPERATIVE (ALTITUDE) · airframe 113,006 hrs · 21,486 cycles

ALTITUDE ALERT SYSTEM INOP. REPLACED ALTITUDE ALERT COMPUTER AND TESTED OK PER MM 34-16-00.

Part: YAW DAMPER — MALFUNCTIONED (RUDDER) · airframe 112,999 hrs · 21,484 cycles

CREW REPORTED ON TAXI OUT UPPER RUDDER SHOWED 5 DEGREES LEFT AND LOWER RUDDER WAS CENTERED. AFTER TAXI IN, RUDDER POSITIONS WERE CONFIRMED BY MAINTENANCE. REPLACED YAW DAMPER COMPUTER AS PER MM 22-16-02. OPS CHECK PASSED ON GROUND.

Part: POWERPACK — FAILED (RUDDER) · airframe 112,985 hrs · 21,481 cycles

CREW REPORTED ON TAXI OUT UPPER RUDDER SHOWED 5 DEGREES LEFT AND LOWER RUDDER WAS CENTERED. AFTER TAXI IN, RUDDER POSITIONS WERE CONFIRMED BY MAINTENANCE. REPLACED RUDDER POWER PACK (UPPER) PER MM 27-21-16. NO HELP TRANSFERRED TO DMI 34039 MEL 22-3.

Part: CONNECTOR — LOOSE (TAWS INDICATOR) · airframe 112,982 hrs · 21,481 cycles

TAWS SYSTEM GIVES ERRONEOUS INFORMATION CALL OUTS TERRAIN. FOUND P-3 CONNECTOR LOOSE AT TAWS INDICATOR. FOUND NO POWER AT PIN 63 ON NR 1 CADC RACK PLUG. RESTORED 26V PER WDM 34-12-12. ALL OPS & LEAK CHECK OK.

Part: ACTUATOR — INOPERATIVE (FUEL CONDITION) · airframe 112,533 hrs · 21,394 cycles

DURING ENGINE START NR 3 ENGINE WOULD NOT LIGHT OFF. TROUBLESHOT, FOUND FUEL CONDITION ACTUATOR INOP. REMOVED & REPLACED CONDITION ACTUATOR PER MM 76-11-00. OPS NORMAL.

Part: VALVE — FAILED (NR 2 ENGINE) · airframe 112,514 hrs · 21,390 cycles

NR 2 PYLON VALVE FAILED TO OPEN ON ENGINE START. DEFERRED NR 2 ENGINE PYLON VALVE PER MEL 36-5-2. TRANSFERRED TO DMI 33793.

Part: CLAMP — LOOSE (THROTTLE) · airframe 112,533 hrs · 21,394 cycles

ON PREFLIGHT, NR 4 THROTTLE WOULDN’T ADVANCE FORWARD. T/S FOUND SHIELD SUPPORT BRACKET CLAMPS LOOSE AT PUSH PULL CABLE. SECURED PUSH PULL SHIELD SUPPORT BRACKET CLAMPS PER MM 76-11-05. OPS CHECK OK.

Part: VALVE — FAILED (NR 3 A/C PACK) · airframe 112,514 hrs · 21,390 cycles

NR 3 PACK HAD NO CONTROL FROM FLIGHT ENGINEERS STATION. PACK STAYS ON AND WILL NOT SHUT DOWN. REMOVED AND REPLACED FLOW CONTROL VALVE PER MM 21-51-00.

Part: RELIEF VALVE — FAILED (NR 1 ENGINE) · airframe 115,219 hrs · 21,935 cycles

CREW REPORTED NR 1 ENGINE NACELLE TEMP WENT TO TOP END OF SCALE. RETARDED THROTTLES, TEMP DECREASED. RETURNED TO RMS. FOUND NR 1 ENGINE PRESSURE RELIEF VALVE FAILED. REPLACED PER AMM 36-11-03. OPS OK.

Part: FUEL CELL — OVERSERVICED (RT WING) · airframe 111,512 hrs · 21,188 cycles

FUEL SPILL RIGHT WING. FOUND NR 4 MAIN OVER FILLED. DRAINED RIGHT SURGE TANK IAW 28/21/00, RESET SYSTEM & CONTINUED FUELING. CHECK OF VOLUMETRIC SYSTEM IAW 28-21-00 SATISFACTORY.

Part: HEATER — ODOR (WINDSHIELD) · airframe 110,094 hrs · 20,882 cycles

F/O NR 1 WINDOW LOWER RIGHT CORNER OVERHEATING AND CAUSING BURNT WIRE SMELL. TURNED OFF AND C/B PULLED. DEFERRED R-1 WINDOW HEAT PER MEL 30-11-1.

Part: MEC — FAILED (NR 1 ENGINE) · airframe 11,055 hrs · 20,874 cycles

AFTER ENGINE START, NR 1 ENGINE HAD NO RESPONSE TO THROTTLE MOVEMENT, IDLE PARAMETERS NORMAL. REPLACED MEC PER AMM 73-21-01.

Part: INDICATOR — INOPERATIVE (ADI)

ON TAKEOFF ABORTED FOR CAPTAINS AND FIRST OFFICER INSTRUMENT WARNING, ATT, AND MONITOR LIGHT WITH ASSOCIATED BELL. ALSO, ATT FLAG, WITH ADI INDICATOR ON CAPTAINS SIDE FULL DOWN. ABORT SPEED WAS APPROXIMATELY 85 KNOTS. REMOVED AND REPLACED CAPTAINS ADI, ACCOMPLISHED PER MM 34-21-00, AND INTERCHANGED INU POSITION LAND 3. ACCOMPLISHED MM 34-41-00. FUNCTIONAL CHECKED SATISFACTORY. NR 5 TIRE BLEW DURING ABORTED TAKEOFF. (M)

Part: WEB — DAMAGED (FWD CARGO DOOR)

LOWER FORWARD CARGO DORO HAS WEB DAMAGED AT TWO LOCATIONS, FORWARD AND AFT, ADJACENT TO POWER DOOR LOCK PUSH PULL RODS. REMOVED DAMAGED WEB FABRICATED NEW WEB AND INSTALLED NEW WEB AS PER SRM 51-30-02, 51-10-02 AND 52-30-02. (M)

Part: FIRE LOOP — MALFUNCTIONED (NR 2 ENGINE)

DURING DESCENT INTO ANC, NR 2 ENGINE HAD A FIRE WARNING PASSING THROUGH 16000 FT AT IDLE POWER. NR ENGINE (A) LOOP IS PLACARDED INOPERATIVE. PERFORMED EMERGENCY FIRE CHECK LIST AND SHUTDOWN ENGINE. FIRE HANDLE WAS PULLED AT 1946Z, TT EDP IN DEPRESSURIZE MODE WAS 19 MIN. DUCT PRESSURE DROPPED TO 10 PSI AND NO ADP RUN LIGHT. EVENTUALLY DUCT PRESSURE CAME BACK TO NORMAL. NACELLE TEMPERATURE WAS NORMAL. FOUND PYLON DETECTOR FORWARD SECTION LOOSE, RETORQUED FASTENERS IAW MM 70-51-01, GROUND OPS CHECK 2A, B LOOPS OK IAW MM 26-11-00.(K)

Part: MEC — MALFUNCTIONED (NR 1 ENGINE)

RMS/FRU - REJECTED TAKEOFF, ON TAKEOFF ROLL, NR 1 ENGINE WOULD PRODUCE ONLY 108.0 N1 WITH FIREWALL THRUST. 113.0 N1 WAS THE DESIRED POWER SETTING. ABORTED TAKEOFF AT 80 KTS, NR 1 N1 APPEARED TO SPIN UP SLOWER THAN THE REST. ALL OTHER ENGINES APPEARED NORMAL. REMOVED AND REPLACED NR 1 ENGINE MEC PER MM 73-21-01. OP AND LEAK CHECKS OK. OK FOR SERVICE. REMOVED AND REPLACED NR 1 ENGINE FUEL PUMP PER MM 73-11-01. OPS AND LEAK CHECKS OK. OK FOR SERVICE. FUEL PUMP P/N 9039M45P14. (M)

Part: RIB — CRACKED (LT WING)

DURING CURRENT C CHECK, FOUND LT WING LEADING EDGE RIB CRACKED, WING STATION ILES1024 AT THE VERTICAL STIFFENER COMMON TO THE UP STOP INTERCOSTAL. DAMAGED AREA TRIMMED OUT. HFEC INSPECTED TRIMMED AREA. NO ADDITIONAL CRACKING FOUND. FABRICATED REPAIR DOUBLER, FILLER AND SHIM.

Part: GASKET — UNSECURE (FUEL OIL HEAT EX)

NR 2 ENGINE SHUTDOWN DURING CLIMB OUT, DUE TO OIL CONTENT LOSS AND LOW OIL PRESSURE. DUMPED 28,000 KGS OF FUEL TO MAX LANDING WEIGHT. ENGINE WINDMILLED AT 24 PERCENT N1 UNITIL LANDING. C/A: SERVICED ENGINE OIL SYSTEM. FOUND GASKET AT FUEL OIL HEAT EXCHANGER NOT SECURED. LOWER TWO BOLTS NOT TIGHT. REMOVED GASKET AND FOUND UNSERVICEABLE DUE SEAL DAMAGED. INSTALLED NEW GASKET IAW MM. REMOVED AND REPLACED ENGINE OIL FILTER IAW MM. FILTER INSPECTION FOUND OK. REMOVED AND INSPECTED CHIP DETECTORS IAW MM. NO DEFECTS NOTED. ENGINE RUN SATISFACTORY. OIL TANK SERVICED. LEAK CHECK GOOD.

Part: SKIN — CRACKED (NR PYLON)

DURING INSPECTION FOUND PYLON SKIN NR 4 POSITION CRACKED AT ACCESS DOOR R/S BETWEEN NAC 211.42 AND 222.50. TRIMMED OUT CRACKED AREA. HFEC AREA FOR ADDITIONAL CRACKING, NO CRACKS FOUND. FABRICATED FILLER AND REPAIR DOUBLER, INSTALLED SAME PER STANDARD PRACTICES SRM 51-30. (M)

Part: BEAM — CRACKED (CARGO DOOR)

DURING INSPECTION OF LOWER AFT CARGO COMPARTMENT DOOR, FOUND CRACK 1.5 INCHES LONG ON LOWER FORWARD END OF LOWER EDGE BEAM. STOP DRILLED CRACK. FABRICATED REPAIR DOUBLER. INSTALLED PER STANDARD PRACTICES IAW SRM 51-30. (M)

Part: DOOR FRAME — CRACKED (FUSELAGE)

DURING HFEC INSPECTION PER SB 747-53A2488 FOUND UPPER AFT CARGO COMPARTMENT DOOR CUT OUT WITH CRACK INDICATION OF .5MM AT FASTENER HOLE UNDER AFT HINGE, AFT HOLE, LOWER ROW (SECOND LAYER). FASTENER IS OUT OF THE SB INSPECT AREA AND NOT SUBJECT TO REWORK PER ABOVE SB. INSTEAD, PER BOEING TELEX, FASTENER HOLE OVERSIZED UNTIL INDICATION DISAPPEARED. INSURANCE CUT BY REAMING HOLE TO .375 INCH DIAMETER. INSTALLED BACB30NN6K BOLT, NAS1805-6L NUT, BACW30BP6DP WASHER. (M)

Part: SKIN — CHAFED (FUSELAGE)

DURING INSPECTION OF LOWER FORWARD CARGO COMPARTMENT DOOR CUT OUT, FOUND FUSELAGE SKIN CHAFFED IN TWO AREAS AT THE AFT LOWER CORNER BETWEEN STRINGER 38/39R. POLISHED SKIN, HFEC INSPECTED, NO CRACKS. FABRICATED REPAIR DOUBLERS. INSTALLED PER STANDARD PRACTICES IAW SRM 51-30. (M)

Part: FLAP TRACK — CORRODED (T/E FLAP)

DURING INSPECTION FOUND, NR 1 FLAP TRACK AFT INBOARD REAR SPAR ATTACH MOUNT HOLE CORRODED. REAMED HOLE OVERSIZE TO 1.139 FEET, FABRICATED BUSHING. INSTALLED BUSHING PER STANDARD PRACTICES. REINSTALLED WITH STANDARD SIZE HARDWARE. NR 3 FLAP TRACK BOTH REAR SPAR ATTACH HOLES CORRODED. REAMED HOLES OVERSIZED TO 1.285 INCH. FABRICATED BUSHINGS. INSTALLED PER STANDARD PRACTICES. REINSTALLED WITH STANDARD SIZE HARDWARE. (M)

Part: FRAME — GOUGED (FUSELAGE)

DURING INSPECTION FOUND BS 360 FRAME DEEPLY GOUGED BETWEEN STRINGER 2L AND 2AL. CUT AWAY DAMAGED AREA. FABRICATED REPAIR FILLER, DOUBLERS AND SPLICE PLATES. INSTALLED PER STANDARD PRACTICES IAW BOEING TELEX. MODIFICATION SB 747-53-2272 PREVIOUSLY ACCOMPLISHED. (M)

Part: DOUBLER — CORRODED (BULKHEAD)

DURING INSPECTION, FOUND BONDED DOUBLER CORRODED ON CANTED BULKHEAD BS 1241 AT LBL 11.33. USED GUN BARREL REAMER, REMOVED LAYER OF CORRODED SKIN OF BONDED DOUBLER. FABRICATED FILLER AND REPAIR DOUBLERS. INSTALLED PER STANDARD PRACTICES PER BOEING TELEX. (M)

Part: PRESSURE PANEL — CRACKED (FUSELAGE)

DURING INSPECTION OF PRESSURE DECK NUMEROUS AREAS WERE FOUND WITH SPOT CORROSION BETWEEN BS 1460/1480 AT RBL 6, RBL 26.5; LBL 6, LBL 20, LBL 39, LBL 47.5. MOST AREAS BLENDED TO SRM LIMITS, TREATED AND FINISHED PER STANDARD PRACTICES. THE FOLLOWING AREAS WERE REPAIRED BY TRIMMING OUT THE CORRODED AREAS AT LBL 39, LBL 48. AT RBL 6; LBL 6 AND 20 CORROSION CRACK WAS REMOVED BY STEP DRILLING AND SUBSEQUENTLY FREEZE PLUGS INSTALLED. FILLER SECTIONS AND REPAIR DOUBLERS WERE FABRICATED FOR ALL ABOVE AREA. INSTALLED REPAIR FILLERS AND DOUBLERS PER STANDARD PRACTICES. (M)

Part: STRINGER — CORRODED (FUSELAGE)

DURING INSPECTION,FOUND STRINGER 51L AT BS 1480 CORRODED. TRIMMED OUT CORRODED AREA. FABRICATED NESTED CHANNEL REPAIR AND FILLER. INSTALLED NEW STRINGER END FITTING ALONG WITH FILLER AND NESTED CHANEL PER STANDARD PRACTICES. (M)

Part: SKIN — CRACKED (FUSELAGE)

DURING HFEC INSPECTIN PER SB 747-53A2488 FOUND LOWER LOBE CARGO COMPT UPPER FORWARD DOOR CUT-OUT CRACKED 2MM. TRIMMED OUT CRACK. FABRICATED FILLER AND REPAIR DOUBLER. INSTALLED IAW SRM 53-30-03 TYPE 1 (SKIN CRACK ONLY). (M)

Part: BULKHEAD — CRACKED (FUSELAGE)

DURING INSPECTION OF AFT PRESSURE BULKHEAD BS 2360 PER SB 747-53A2275 FOUND CRACK .75 INCH LONG ORIGINATING FROM FASTENER HOLE FROM WEB TO Y-RING LAP JOINT BETWEEN STRINGER 24 AND 25R. CUT OUT CRACKED AREA. FABRICATED FILLER AND DOUBLER. OVERSIZED FASTENER HOLES AS NEEDED. INSTALLED FILLER AND DOUBLER PER STANDARD PRACTICES. (M)

Part: ANGLE — CRACKED (BS 980)

MAIN DECK, CREASEBEAM ATTACHED ANGLE AT BS 980 STRINGER 5L AND 5R FOUND CRACK. THE CRACKED FLANGE WAS TRIMMED OUT AND REPAIR DOUBLER AND ANGLE WERE INSTALLED IAW BOEING TELEXS. (M)

Part: SPAR WEB — CORROSION (WS 1314-1322)

LEFT WING FRONT SPAR WEB CORRODED BETWEEN FSSO 1314 TO FSSO 1322. TRIMMED OUT CORRODED AREAS, NDT WEB NO CRACK INDICATION. REPAIRED IAW BOEING TELEXS. (M)

Part: DOUBLER — CRACKED (NR 1 PYLON)

NR 1 PYLON CAP SKIN MOD MO 54-0074 AREA FOUND WITH EXISTING DOUBLER, BULKHEAD FRAME CRACK AT STATION 270. THE CRACKED FRAME FLANGE WAS TRIMMED TO REMOVED DAMAGE, NDT PERFORMED TO VERIFY NO OTHER CRACKS. NEW REPAIR ANGLES AND NEW DOUBLER INSTALLED IAW BOEING TELEXS. (M)

Part: DRIVE LINK — CHAFED (TE FLAPS)

NR 3 FLAP TRACK MOVEABLE CANOE FAIRING FIXED DRIVE LINK CHAFED, BLENDED OUT DAMAGE AND NDT INSPECTED. SHOT PEENED AND REPAIRED IAW BOEING TELEX. (M)

Part: STRAP — CRACKED (PYLON)

NR 1, 2, 3, 4, PYLONS EXTERIOR RIGHT PRE-COOLER EXHAUST CUTOUT FOUND WITH CRACK,AND NR 3 STIFFENER CRACK. REPAIRS CARRIED OUT IAW BOEING TELEXS AND SB 747-54-2163 R1 AND SB 747-54A2158 R2. THE SB REVS HAVE BEEN APPROVED ALTERNATE METHOD OF COMPLIANCE. (M)

Part: STRAP — CRACKS (NR 4 PYLON)

NR 4 PYLON INTERIOR, LEFT BULKHEAD STRAP AT NAC STATION 286 FOUND CRACKED. REPAIRED IAW BOEING TELEXS, TO BE RE-INSPECTED EVERY C-CHECK NOT TO EXCEED 18 MONTHS OR 1000 FLTS. (M)

Part: FITTING — OVERSIZE (NR 1/4 PYLONS)

NR 1 AND NR 4 PYLONS FOUND FASTENER HOLE SIZE TO EXCEED TOLERANCE PER SB 747-54A2152 IN SPRINGBEAM SUPPORT FITTINGS IN 3 HOLE LOCATIONS. HOLES WERE OVERSIZED, NDT PERFORMED TO VERIFY NO CRACKS. NO INSURANCE CUT WAS PERFORMED AND FASTENERS INSTALLED. THIS IS A TIME LIMITED REPAIR APPROVED AS AN ALTERNATE METHOD OF COMPLIANCE BY BOEING. PERMANENT REPAIR TO BE ACCOMPLISHED PRIOR TO MARCH 28, 2000. (M)

Part: SPAR WEB — CRACKED (WS 385-400)

LEFT WING MID SPAR AND UPPER CHORD, FASTENER HOLES ELONGATED AND CRACKED. ALSO, EXISTING REPAIR DOUBLER FASTENER HOLE CHIPPED FROM WS 400 TO WS 385. AT 12 HOLE LOCATIONS BETWEEN WS 388 AND 407 OVERSIZE HI-LOCKS WERE INSTALLED AND AT ONE LOCATION SEPARATE FREEZE PLUGS WERE INSTALLED COMMON TO THE WEB AND UPPER SPAR CHORD AND HI-LOCK INSTALLED. AT MSS 400, THE CRACKED HOLE WAS TRIMMED OUT AND A PERMANENT REPAIR WAS INSTALLED IAW BOEING TELEXS. (M)

Part: FRAME — CRACKED (BS 1265)

FUSELAGE FRAME AT BS 1265 LEFT SIDE FOUND WEB CRACK AND SEVERAL FASTENER HOLES ELONGATED. INTERIM REPAIR IAW BOEING TELEXS TO BE INSPECTED EVERY 2000 FLIGHTS. (M)

Part: SPAR WEB — CRACKED (WS 382-411)

RIGHT WING FUEL TANK INTERIOR WS 382 TO WS 411 MID SPAR AFT UPPER WEB SURFACE FOUND CRACK PROPAGATING FROM EXISTING REPAIR. MID SPAR WEB CRACK AT MSS 400 WAS TRIMMED OUT AND A PERMANENT REPAIR INSTALLED. AT MSS 394 A FREEZE PLUG WAS INSTALLED COMMON TO THE WEB AND A HI-LOCK WAS INSTALLED AT THE LOCATION IAW BOEING TELEXS. (M)

Part: FRAME — CRACKED (NR 3 PYLON)

NR 3 PYLON INTERIOR AFT MOUNT BULKHEAD WEB AFT SIDE AT NAC STATION 286 FOUND WITH CRACK. DAMAGED AREA WAS TRIMMED OUT, NDT INSPECTED, REPAIRED IAW BOEING TELEXS. (M)

Part: MANIFOLD — CRACKED (NR 1 ENGINE)

FLT 322 - BOG/MIA-IFSD - NR 1 ENGINE FUEL FLOW FLUCTUATED ERRATICALLY, NO OTHER ENGINE PROBLEMS. AFTER APPROX 5 MINUTES ENGINE FLAMED UNEVENTFULLY. DECIDED NOT TO ATTEMPT A RELIGHT. CONTINUED TO MIA, DECLARED AND EMERGENCY AND LANDED. DURING TROUBLESHOOTING MAINTENANCE FOUND FUEL MANIFOLD LINE GOING TO P/D VALVE FROM FUEL FLOW TRANSMITTER CRACKED BY FLANGE WELD. ALSO, FOUND OIL LINE GOING TO GEAR CASE DAMAGED ALONG WITH BRACKET, REF IPC 73-11-01, FIG 1, PAGE OC, ITEM 5, P/N 9068M44G01. REPLACED NR 1 ENGINE, OPERATIONAL CHECK SATISFACTORY. (M)

Part: BLADE — FRACTURE (HPT)

ENGINE, SN 455833, TEAR DOWN REVEALED CONSIDERABLE TURBINE DAMAGE. HPT STAGE 1 BLADES METALLURGICAL ANALYSIS FOR PRIMARY FAILURE MODE. ONE BLADE FOUND WITH FAILURE PATTERNS IN THE TRAILING EDGE AREA. BLADE, PN 9299M30G09R, SN KTWD2263, REPAIR HISTORY M1K-M2K-M3K-M4H, TSN/CSN, 24,031 HOURS/5,199 CYCLES. BLADES EXHIBITED 2 FAILURE MODES - 1 TRAILING EDGE CRACKING AND SEPARATION, 2 INTERGRANULAR OXIDATION (IGO) ON INNER PASSAGE WALLS. BLADE ANALYSIS REVEALED PRESENCE OF MISLOCATED COOLING HOLE ON BLADE CONVEX SIDE WITHOUT INTERSECTING BLADE INNER OR OUTER WALLS. THE PRIMARY BLADE FAILURE ATTRIBUTED MORE TO INTERGRANULAR OXIDATION DUE TO LACK OF INTERNAL COATING. (X)