N517MC

Part: UNKNOWN — UNKNOWN · airframe 90,488 hrs · 15,493 cycles

AFTER BRAKE RELEASE FOR TAKEOFF AT ABOUT 20 KNOTS, ACFT TOOK ABRUPT RT TURN. ABORTED TAKEOFF. ACCOMPLISHED VISUAL INSP OF ALL 4 ENGINE INLETS AND EXHAUST. INSPECTED NOSE GEAR STEERING SYS, ALL NORMAL, CHECKED ANTI-SKID SYS AND ALL BRAKES, ALL NORMAL. NO ABNORMAILTIES NOTED.

Part: SLEEVE — CRACKED (EXHAUST NOZZLE) · airframe 90,300 hrs · 15,398 cycles

DURING MX WALKAROUND OF N517MC, MX FOUND 1 EA CRACK ON THE NR2 ENGINE EXHAUST NOZZLE OUTER SLEEVE, LOCATED AT APPROX 7 O'CLOCK POSITION. THE CIRCUMFERENTIAL CRACK IS APPROX 2.5 IN LONG. IAW AMM 78-11-01 THE LENGTH OF THE CRACK IS OUT OF LIMITS. (DISPOSITION IS TO STOP DRILL THE ENDS OF THE CRACK WITH A 0.125 IN. DIAMETER HOLE (DRILL BIT); DVI EVERY 3 FLIGHT CYCLES; AND REMOVAL/REPLACEMENT OF THE PART PRIOR TO THE ACCUMULATION OF 50 FC (FLIGHT CYCLES).

Part: CADC — INOPERATIVE (COCKPIT) · airframe 89,588 hrs · 15,322 cycles

AT FL 33.0 CAPT'S ALTIMETER READS 33,020. F/O ALTIMETER 32,520. AT FL 28.0 CAPT'S ALTIMETER READS 28000 F/O 27660. UNABLE TO CONTINUE INTO RVSM AIRSPACE. IAW ATC, CAPT'S & NBSP; ALTIMETER READS CORRECTLY. (FOUND NR 2 CADC AT FAULT. REPLACED NR2 CADC IAW MM 34-12-01. ALL REQUIRED CHECKS ACCOMPLISHED AND SYTEM CHECKS NROMAL IAW MM.)

Part: BLADE — DAMAGED (COMPRESSOR) · airframe 88,650 hrs · 15,075 cycles

ON POST FLT, FOUND NR1 ENGINE HAD BIRD STRIKE. 3EA FAN BLADES DAMAGED (INSP IAW MM 05-51-14 NO EVIDENCE OF FOD IN COMPRESSOR SECTION OF NR 1 ENG 3 BLADES REPLACED IAW AMM).

Part: STRINGER — CRACKED (BS 480-500 S38R) · airframe 87,026 hrs · 14,764 cycles

CRACK ON FWD CARGO STR 38 BS 480-500 RT. CRACKED AREA TRIMMED OUT, REINFORCED AREA WITH STRINGER SEGMENT PN N517MC-NRC624-1, IAW SRM 53-10-03 FIG 3 USING FASTENERS IAW SRM 51-30-02.

Part: FLOORBEAM — CRACKED (BS 1860) · airframe 87,026 hrs · 14,764 cycles

CRACK ON AFT CARGO FLOORBEAM UPPER CHORD BS 1860, LBL 47-48. TRIM THE UPPER FLANGE DAMAGED IAW SRM 51-40-04, FIG 3, REF EO 4753B236.

Part: LAP JOINT — DENTED (BS 500-520) · airframe 87,026 hrs · 14,764 cycles

DENT ON EXT FUSELAGE SKIN LAP JOINT AND STRINGER AREA BETWEEN STA 500-520 RT SIDE S44R. DENT AREA TRIMMED OUT REINFORCE AREA WITH DOUBLER AND FILLER P/N N517MC-NCR135-1/2 PER SRM 53-30-03 FIG. 26. USING FASTENER PER SRM 51-30-02.

Part: FRAME — CRACKED (BS 360 S2R) · airframe 87,026 hrs · 14,764 cycles

PERFORMED BOROSCOPE INSP AND FOUND CRACK ON FRAME BY LENGTH 3" AT BS 360, S-2R END OF CRACK STOPPED BY STOPPING HOLE. REINFORCED AREA WITH DOUBLER & ANGLE PN N517MC-NRC677-1/2 IAW SRM 53-10-04, FIG 18. PERMANENT REPAIR PRIOR TO 20,000 CYCLES IAW EO 4753B240 PART 2.

Part: FLOORBEAM — CRACKED (BS 460) · airframe 87,026 hrs · 14,764 cycles

CRACK ON UPPER DECK FLOORBEAM WEB BS 460 RBL 33-55. ACCOMPLISHED PER REA: MF00656R0008 AND RFTA: 00656-0008. CRACKED AREA TRIMMED OUT REINFORCE WITH EXTRUDED TEE AND SPLICE AND FILLERS (2EA) P/N N517MC-NRC178-1/2/3/4 PER SRM 53-10-07 FIG 11 USING FASTENER PER SRM 51-30-02. INITIAL DVI AT 6000 FC, REPEAT THEREAFTER AT 3000 FC PER EO NR 4753B238.

Part: CARRIAGE — DAMAGED (TE FLAP)

FOUND DURING MAJOR INSPECTION RIGHT INBD MID FLAP CARRIAGE SIDE (INBOARD POSITION) AFTER REMOVAL OF FAIL SAFE BOLT FOUND DAMAGE IN THE BORE. REPLACED RT INBD MID FLAP ASSY PER ATLAS EO REFERENCE NRC 795 AND 897.

Part: STRINGER — CORRODED (BS 1840-1920) · airframe 870,226 hrs · 14,764 cycles

LEVEL 1 CORROSION ON AFT CARGO BILGE STRINGER BS 1840-1920 S-50L. DAMAGED AREA TRIMMED OUT REINFORCED AREA WITH STRAP AND FILLER P/N N517MC-NRC187-1/2 PER SRM 53-10-03 FIG 9 USING FASTENERS PER SRM 51-30-02.

Part: STRINGER — CORRODED (BS 1860-1920) · airframe 87,026 hrs · 14,764 cycles

LEVEL 1 CORROSION ON AFT CARGO BILGE STRINGER BS 1860-1920 S-51L. DAMAGED AREA TRIMMED OUT REINFORCED AREA WITH DOUBLER AND STRAP P/N N517MC-NRC195-1/2 PER SRM 53-10-03 FIG 9. PROTECTED AREA PER SRM 51-10-02, INSTALLED RIVETS PER SRM 51-30-02.

Part: SKIN — CRACKED (MLG DOOR) · airframe 87,025 hrs · 14,764 cycles

DURING MAJOR INSPECTION FOUND, LT BODY INBD DOOR SKIN CRACKED. DAMAGED AREA TRIMMED OUT AREA REINFORCED WITH DOUBLER PER SRM 52-80-02. REFERENCE NON-ROUTINE 984. NO OTHER ACTION REQUIRED.

Part: STRINGER — CORRODED (BS 1715-1725) · airframe 87,026 hrs · 14,764 cycles

EXFOLIATION CORROSION ON INTERNAL SURFACE OF STRINGER BS 1715-1725 S-44L. DAMAGED AREA TRIMMED OUT REINFORCED AREA WITH STRAP AND FILLER P/N N517MC-NRC181-1/2 PER SRM 53-10-03 FIG 9 USING FASTENERS PER SRM 51-30-02.

Part: FLOOR PANEL — GOUGED (BS 780) · airframe 87,026 hrs · 14,764 cycles

DEEP ABRASION AT UPPER DECK FLOOR STRUCTURE BS 780 RBL 79. THE WORK ACCOMPLISHED PER REA: MF00656R0005 RFTA: REF: 00656-0005. FASTENER INSTALLED PER SRM 51-30-02.

Part: ANGLE — CORRODED (BS 2200 S38-40R) · airframe 87,026 hrs · 14,764 cycles

CORROSION ON ANGLE AFT TO BULK CARGO BEAM BS 2200 S38-40R. DAMAGED AREA TRIMMED OUT AREA REINFORCED WITH DOUBLER IAW SRM 51-40-03, FIG 1.

Part: SKIN — DAMAGED (BS 540-560) · airframe 87,026 hrs · 14,764 cycles

EXTERIOR FUSELAGE SKIN EXT. B/O BY 09" X 0.6" X 0.039" ON EXT FUSELAGE SKIN BETWEEN STA 540-560 AT STR 37/R. A SKIN REPAIR WAS ACCOMPLISHED AT DAMAGED IAW REA: MF00656R0010 REV A. REPEAT INSP PRIOR TO 20,000 CYCLES.

Part: STRINGER — DAMAGED (BS 340-440) · airframe 87,026 hrs · 14,764 cycles

LIGHTING STRIKE ON FASTENER HEAD BS 340-440 STR-32AL. DRILLED OUT AND INSTALLED HI-LOCK HL63PB6-4 B/N 36457-01 IAW SRM 51-30-02, PERFORMED HFEC IAW D67170 PART 651-00-00 T-16 AND 23 NO CRACKS FOUND.

Part: STRINGER — CORRODED (BS 1840-1860) · airframe 87,026 hrs · 14,764 cycles

LEVEL 1 CORROSION ON AFT CARGO BILGE STRINGER BS 1840-1860 S-49R. DAMAGED AREA TRIMMED OUT REINFORCED AREA WITH STRAP AND FILLER P/N N517MC-NRC196-1/2 PER SRM 53-10-03 FIG 9 USING FASTENERS PER SRM 51-30-02.

Part: STRINGER — CORRODED (BS 1918-1927) · airframe 87,026 hrs · 14,764 cycles

DURING C-CHECK, CORROSION WAS FOUND ON THE 65B04483-13 STRINGER 51 LT AT BS 1918-1927. PART 1 - INTERIM REPAIR DO NOT SCHEDULE; THIS EO DOCUMENTS AN INTERIM REPAIR ACCOMPLISHED DURING THE JANUARY 2010 C-CHECK AT 14,764 TFC AND 87,026 TFH. INITIAL AND REPEAT INSP ACCOMPLISH PART 2 OF THIS EO PRIOR TO 20,764 TOTAL FLIGHT CYCLES. THEREAFTER, REPEAT PART 2 AT 3,000 CYCLE INTERVALS. THE CORROSION WAS BLENDED OUT IAW SRM 51-10-01 TO A MINIMUM REMAINING THICKNESS OF 0.068 INCH THICK. THE BLENDED AREA WAS THEN REINFORCED IAW NRC 195 AND SRM 53-10-03, FIGURE 9.

Part: STOP FITTING — CORRODED (ZONE 800) · airframe 87,026 hrs · 14,764 cycles

NR 1L ENTRY DOOR FITTING ON DOOR HAS CORROSION (AFT EDGE). WORK ACCOMPLISHED PER MF00656R0007 RFTA REF: 00656-007. REINFORCED AREA WITH SPLICE AND FILLER P/N N517MC-NRC0109-1/-2 PER SRM 51-40-03 FIG 2 USING FASTENER PER SRM 51-30-02.

Part: FORGING — CORRODED (WINDOW FRAME) · corrosion level 2 · airframe 87,026 hrs · 14,764 cycles

CORROSION ON M/D WINDOW FORGING BS1000-1040 LT BETWEEN STR 20-22 (CORROSION REMOVED IAW SRM 51-70-01 AND SRM 56-20-01, FIG 1 REWORK AREAS FOUND OUT OF LIMITS IAW SRM 56-20-01, FIG 1, WINDOW REPLACED WITH A NEW WINDOW IAW DWG 65B04122).

Part: LATCH — LOOSE (INSTRUMENT PANEL) · airframe 103,147 hrs · 20,765 cycles

CAPTAIN'S INSTRUMENT PANEL CAME OUT DURING TAKEOFF ACCELERATION. (RTO) AT APPROX 60 KNOTS. SECURED CAPT'S INSTRUMENT PANEL. REPAIRED PANEL HOLD DOWN LATCH IAW 31-11-11 PERFORMED INSPECTION 5-51-10 FOR RTO.

Part: PANEL — DELAMINATED (ZONE 500) · airframe 85,394 hrs · 14,429 cycles

LT WING, UPPER SURFACE FIXED L/E PANEL AT OLES 1210.5 AND 5.0 INCHES FROM FORWARD EDGE OF PANEL, SKIN HAS AN AREA OF 2.0 BY 3.0 INCHES OF DELAMINATION. PERMANENT REPAIR ACCOMPLISHED AS PER B747-200 SRM 51-40-09 FIG 18, SHEETS 4 AND 5, PREPREG 250 DEGREES F CURE PER SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO 4757A472.

Part: CONTROLLER — FAILED (RUDDER RATIO) · airframe 85,067 hrs · 24,484 cycles

RUDDER RATIO LIGHT CAME ON IN CLIMB PASSING THROUGH 5000FT. PROCEEDED AS PER FHB 3-27-24. REMOVED AND REPLACED LOWER REPLACED LOWER RUDDER RATIO CHANGER AND PERFORMED REQUIRED CHECKS PER MM 27-21-00

Part: SKIN — PUNCTURED (BS 430 S37R)

DURING GROUND OPERATION IN FUSELAGE SKIN, STA 430, STRINGER 37R NEAR THE GROUND POWER RECEPTACLE WAS STRUCK CAUSING DAMAGE CONSISTING OF A PUNCTURE MEASURING 3X6 INCHES. INTERIM REPAIR ACCOMPLISHED IAW EO 4753B209. (K)

Part: INU — FAILED (NR 1)

AIR TURN BACK, DURING CLIMBOUT BOTH INST WARNING LIGHTS WITH ATT LIGHT ILLUMINATED. CAPT`S ADI ATT AND COMPAS FLAG IN VIEW. CAPTS HSI HDG, FLAG IN VIEW. REMOVED AND REPLACED NR 1 INU IAW 34-41-03. COOLING SYSTEM TESTED OK AND INS NAV TEST OK. (K)

Part: FIRE DETECTOR — DIRTY (CARGO BAY) · airframe 84,048 hrs · 14,218 cycles

RETURN TO BLOCKS INTERMITTENT FIRE WARNING DURING TAXI. FOUND EVIDENCE OF DE-GERM IN CARGO SNIFFED TUBE. CLEANED SNUFFER TUBES WITH CONTACT CLEANER. SYSTEM OPS CHECK NORMAL AS PER MM 26-16-00. (A)

Part: STRINGER — CORRODED (BS 2357 S51R) · corrosion level 2 · airframe 83,301 hrs · 13,995 cycles

AFT PRESSURE BULKHEAD STRINGER END FITTING CORROSION AT STA 2357 STR 51R, STRINGER AND FITTING REPLACED PER SRM 51-30-02.

Part: SEAT TRACK — WORN (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1625 TO 1680 RBL 11 SEAT TRACK FOUND WORN. SEAT TRACK REPAIRED PER SRM 53-10-05.

Part: SEAT TRACK — BROKEN (BS 1720-1760) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK BS 1720 TO 1760 LBL 11 SEAT TRACK FOUND BROKEN AND WORN, SEAT TRACK REPAIRED PER SRM 53-10-05 FIG 14.

Part: FLOORBEAM — CRACKED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STATION 2020 RBL 21 FLOORBEAM SUPPORT FITTING FOUND CRACKED. REPLACED FLOORBEAM SUPPORT FITTING IAW SRM 51-10-01.

Part: SEAT TRACK — CHAFED (BS 1760-1890) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1760 TO 1890 LBL 11 SEAT TRACK FOUND CHAFED. SEAT TRACK SMOOTHED OUT PER SRM 51-10-01 AND REPROTECTED PER 51-10-02.

Part: REVEAL — CRACKED (R2 DOORWAY) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK R2 DOOR CUTOUT FWD LOWER REVEAL PANEL FOUND CRACKED. REPAIRED REVEAL IAW SRM 53-10-04.

Part: SKIN PANEL — CRACKED (LT WING) · airframe 83,301 hrs · 13,995 cycles

LEFT WING LEADING EDGE NOSE CAP UPPER CHORD FOUND CRACK JUST INBOARD OF NR 6 VARIABLE CAMBER FLAP UPPER STOP FITTING. FABRICATED AND REPAIRED DAMAGED AREA IAW SRM 57-20-03.

Part: FRAME — DEFORMED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1840 STRINGER 12R - 13R FRAME FOUND DEFORMED. FRAME REPAIRED PER ATLAS EO NR 4753A141.

Part: FRAME — CRACKED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1980 STRINGER 11R FRAME FOUND CRACKED. FRAME REPAIRED PER ATLAS EO NR 4753A141.

Part: FRAME — CRACKED (BS 1780) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1780 STRINGER 11R FRAME FOUND CRACKED. FRAME REPAIRED PER ATLAS EO NR 4753A141.

Part: SEAT TRACK — CRACKED (BS 1600-1615) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1600 TO 1615 RBL 99 SEAT TRACK FOUND CRACKED. SEAT TRACK REPAIRED PER SRM 53-10-05.

Part: FRAME — DEFORMED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1860 STRINGER 12R FRAME FOUND DEFORMED. FRAME REPAIRED PER ATLAS EO NR 4753B141.

Part: FRAME — DEFORMED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1780 STRINGER 15R FRAME FOUND DEFORMED. FRAME REPAIRED PER ATLAS EO NR 4753B141.

Part: BOLT — SHEARED (MLG FITTING) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING GEAR WHEEL WELL CENTER WING REAR SPAR RIGHT BULKHEAD FITTING ONE BOLT SUSPECTED SHEARED. BOLT REPLACED IAW BOEING MESSAGE NUMBER 1-801292679-4.

Part: FAIRING — CRACKED (LE FLAP) · airframe 83,301 hrs · 13,995 cycles

LEFT WING VARIABLE CAMBER FLAP BULLNOSE FAIRING OUTBOARD FORWARD CORNER CRACKED. REPAIRED BULLNOSE PER SRM 57-50-03.

Part: BEAM — CRACKED (RT WING) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING LEADING EDGE CAVITY INBOARD OF NR 4 PYLON AT ABOUT WBL 830 FOUND WEB OF D-BEAM CRACKED. DAMAGED WEB REPLACED IAW SRM 57-20-03.

Part: SKIN — CORRODED (LWS 150-470) · airframe 83,301 hrs · 13,995 cycles

LEFT WING FROM WS 150 TO 470 UPPER SKIN CORROSION EVIDENT BETWEEN FRONT SPAR AND MID SPAR. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: WEB — CRACKED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 434 STR 26R FLOOR WEB CRACKED. FLOOR WEB REPLACED SRM 51-10-01.

Part: SKIN — CORRODED (ZONE 600) · airframe 83,301 hrs · 13,995 cycles

RT WING WBL 128 TO WS 510 FRONT SPAR TO REAR SPAR UPPER SKIN FOUND CORROSION. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — CORRODED (ZONE 600) · airframe 83,301 hrs · 13,995 cycles

RT WING WBL 470 TO WS 917 WING UPPER SKIN FROM FRONT SPAR TO REAR SPAR FOUND CORRODED. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — CORRODED (ZONE 500) · airframe 83,301 hrs · 13,995 cycles

LEFT WING FROM WBL 150 TO 470 UPPER SKIN CORROSION EVIDENT BETWEEN NR 1 BEAM TO THE REAR SPAR. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — DEFORMED (L1 DOOR) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK L-1 DOOR LOWER AFT CORNER OF EXTERNAL SKIN FOUND DEFORMED. DEFORMED AREA RE-WORKED AS PER SRM 51-10-01.

Part: SPAR — CORRODED (RWS 1392-1485) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING WS 1392 TO WS 1485 FROM (NR 24, AND 25 LEADING EDGE FLAP AREA) FRONT SPAR AREA SURROUNDING AND MID SPAR SURROUND AREA FOUND 8 AREAS OF CORROSION. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — CORRODED (LWS 1120-1540) · airframe 83,301 hrs · 13,995 cycles

LEFT WING UPPER SURFACE CORROSION FOUND FROM WS 1120-1540 BETWEEN FRONT SPAR AND REAR SPAR. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — CORRODED (RWS 1196-1392) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING WS 1196 TO WS 1392 FROM MID SPAR SURROUND AREA TO REAR SPAR HAS 15 AREAS OF CORROSION. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: PANEL — CORRODED (ZONE 600) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING LEADING EDGE FIXED PANEL AT WS 414 FOUND CORROSION/BULGE AT THE RABBET AREA. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — CORRODED (LWS 640-1120) · airframe 83,301 hrs · 13,995 cycles

LEFT WING FROM WS 1120 TO 640 UPPER SKIN CORROSION EVIDENT BETWEEN FRONT SPAR AND MID SPAR. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — CORRODED (LWS 640-1120) · airframe 83,301 hrs · 13,995 cycles

LEFT WS 640 TO 1120 HAS CORROSION EVIDENT BETWEEN MIDSPAR TO REAR SPAR. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — DEFORMED (L1 DOOR) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK L-1 DOOR LOWER FWD CORNER OF EXTERNAL SKIN FOUND DEFORMED. DEFORMED AREA RE-WORKED AS PER SRM 51-10-01.

Part: SPAR — CORRODED (RWS 1250-1392) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING WS 1250 TO WS 1392 FROM NR 23,AND 24 LEADING EDGE FLAP AREA, FRONT SPAR AREA SURROUNDING FOUND 7 AREAS OF CORROSION. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — CORRODED (RWS 917-834) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING WS 917 TO WBL 834 FROM MID SPAR SURROUND AREA TO REAR SPAR SURROUND AREA HAS CORROSION. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SKIN — CORRODED (RWS 470-510) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING WBL 470 TO WS 510 FROM FRONT SPAR TO REAR SPAR UPPER SKIN FOUND LIGHT CORROSION. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SEAT TRACK — CHAFED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1595 TO 1600 RBL 11 SEAT TRACK CHAFED, SEAT TRACK REPAIRED PER SRM 53-10-05 FIG 14.

Part: SKIN — CORRODED (LWS 150-470) · airframe 83,301 hrs · 13,995 cycles

LEFT WBL 150 TO 470 HAS CORROSION EVIDENT BETWEEN MIDSPAR TO NR 1 BEAM. BLENDED OUT CORROSION PER SRM 51-10-01, REPROTECTED PER SRM 51-10-02.

Part: SEAT TRACK — CHAFED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1595 TO 1600 RBL 11 SEAT TRACK FOUND CHAFED. SEAT TRACK SMOOTHED OUT PER SRM 51-10-01.

Part: LOCK PLATE — BROKEN (THRUST REVERSER) · airframe 83,301 hrs · 13,995 cycles

NR 4 ENGINE LEFT SIDE THRUST REVERSER FORWARD EDGE LOWER THRUST REVERSER LOCK PLATE POSITION TWO LOCK BOLTS HOLES BROKEN. REPAIRED PER CF6-50 ENGINE MANUAL 78-32-03.

Part: FLOOR SUPPORT — CORRODED (BS 440-460) · airframe 83,301 hrs · 13,995 cycles

STA 440 -460 LEFT OUTBOARD FLOOR SUPPORT HAS LEVEL 1 CORROSION. REMOVED CORROSION PER SRM 51-10-01, REPROTECTED PER 51-10-02.

Part: FLOOR SUPPORT — CORRODED (BS 440-460) · airframe 83,301 hrs · 13,995 cycles

STA 440 -460 RIGHT OUTBOARD FLOOR SUPPORT HAS LEVEL 1 CORROSION. REMOVED CORROSION PER SRM 51-10-01 AND REPROTECTED PER 51-10-02.

Part: LOCK PLATE — WRONG PART (THRUST REVERSER) · airframe 83,301 hrs · 13,995 cycles

NR 1 ENGINE RIGHT SIDE THRUST REVERSER FORWARD EDGE LOWER THRUST REVERSER LOCK PLATE POSITION FOUND WRONG LOCK BOLT HOLES. REPAIRED PER CF6-50 ENGINE MANUAL 78-32-03.

Part: SEAT TRACK — CHAFED (BS 1840-1860) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK BS 1840 TO 1860 RBL 75 SEAT TRACK CHAFED. CHAFED AREA SMOOTHED OUT AND REPROTECTED IAW SRM 51-10-01.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK BS 1700 TO 1740 RBL 75 SEAT TRACK FOUND CORRODED AND WORN. SEAT TRACK AREA CORROSION REMOVED AND SMOOTHED OUT IAW SRM 51-10-01.

Part: FLOORBEAM — CRACKED (BS 1200) · airframe 83,301 hrs · 13,995 cycles

MAIN DECK STA 1200 RBL 110 FLOORBEAM WEB FOUND CRACKED. FLOORBEAM WEB REPAIRED PER SRM 51-40-02.

Part: SKIN — DAMAGED (ZONE 600) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING REAR SPAR UPPER SKIN AT WS 1490 FOUND EXISTING EXCESSIVE BLEND OUT AS MARKED. CHECKED THE BLENDOUT AREA AND FOUND AS PER ATLAS EO 4757A338 THE BLENDOUT IS PERMITTED.

Part: SKIN — DAMAGED (RWS 1390) · airframe 83,301 hrs · 13,995 cycles

RIGHT WING REAR SPAR UPPER SKIN AT WS 1390 FOUND EXISTING EXCESSIVE BLEND OUT AS MARKED. CHECKED THE BLENDOUT AREA AND FOUND AS PER ATLAS EO 4757A338 THE BLENDOUT IS PERMITTED.

Part: UNKNOWN — SMOKE (GALLEY AREA) · airframe 81,952 hrs · 13,715 cycles

AT FL 380 (6.50 HOURS INTO FLIGHT) SMELLED ELECTRICAL SMOKE FROM UPPER DECK. COMPLETED ELECTRICAL SMOKE CHECKLIST LOCATED ODOR FROM GALLEY AREA. REMOVED POWER FROM GALLEY SMOKE ODOR WENT AWAY. INSPECTED GALLEY AREA FOR DEFECTS PERFORMED DETAILED WIRING INSPECTION PER 20-60-00. TURNED ON GALLEY EQUIPMENT FOR 2 HOURS AND WAS UNABLE TO DUPLICATE. ALL GALLEY EQUIPMENT OPERATED NORMAL.

Part: SEAT TRACK — BROKEN (BS 1872-1881) · airframe 81,308 hrs · 13,581 cycles

AFT CARGO COMPARTMENT HAS SEAT TRACK CROWN BROKEN BETWEEN STA 1872 AND STA 1881 LBL 47. REPAIRED SEAT TRACK IAW SRM 53-10-05.

Part: WEB — CRACKED (ZONE 100) · airframe 81,308 hrs · 13,581 cycles

AFT CARGO COMPARTMENT FLOOR WEB STA 1900 LBL 49 HAS SMALL CRACK. DAMAGED AREA OF WEB CUT OUT AND DOUBLER INSTALLED IAW SRM 53-10-04 FIG 71.

Part: DOOR — PUNCTURED (NR 1 NACELLE) · airframe 81,308 hrs · 13,581 cycles

NR 1 PYLON OUTBOARD TRAILING EDGE DOOR INNER FACE PUNCTURED BY HOLD OPEN ROD WHEN DOORS ARE CLOSED 1.5 BY 1.5. PERM REPAIR CARRIED OUT IAW SRM 51-40-20 PAGE 1 250 DEGREES F.

Part: UNKNOWN — UNKNOWN (NACELLE TEMP) · airframe 81,116 hrs · 13,541 cycles

RTO: T/O + 15 MINUTES NR 2 ENGINE NACELLE TEMPS WENT TO 9.2 "A" LOOP AND 8.1 "B" LOOP FAULT LIGHT CAME ON. FAULT LIGHT ON FWD PANEL WAS ON. ACCOMPLISHED FWB PROCEDURES. TOOK 20 MINUTES FOR OVERHEAT TO COOL AFTER NR 2 THROTTLE TO IDLE.

Part: ALTIMETER — OUT OF LIMITS · airframe 80,644 hrs · 13,447 cycles

A A/P PORPOISED 200-300' ABOVE AND BELOW SELECTED ALTITUDE AT FL 410 IN CRUISE. A/P OK. TRANSFERRED TO DMI M07-117IAW MEL 22-1-2B CAT C. A/C IS CAT II RESTRICTED.

Part: HOSE — BURST (NR 1 ADP) · airframe 80,324 hrs · 13,373 cycles

NR 1 ENGINE HAD VISIBLE SMOKE COMING FROM THE TAIL PIPE JUST PRIOR TO BLOCK IN. ALL INDICATIONS IN FLIGHT DECK WERE NORMAL. FOUND NR 1 ADP PRESS LINE BURST. REMOVED AND REPLACED THE LINE CLEANED RESIDUAL FLUID FROM THE COWLING AND SERVICED THE HYD FLUID. OPS AND LEAK CHECKED OKAY PER 29-11-40 AND 29-11-08.

Part: SKIN PANEL — DELAMINATED (LT WING) · airframe 79,966 hrs · 13,297 cycles

LT WING UPPER TRAILING EDGE SKIN PANEL HAS A 6.0 INCH BY 6.0 INCH AREA OF DELAMINATION AND FASTENERS ARE PULLING THRU THE SKIN, AT WBL 239.00 INBOARD OF NR 6 SPOILER AND 62.0 INCHES FROM AFT EDGE. PERMANENT REPAIR WAS ACCOMPLISHED AS PER 747-200 SRM 51-40-09, FIG 2, TABLE 1 AND 747-200 SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO NR 4757A352.

Part: SKIN PANEL — CRACKED (RT WING) · airframe 79,966 hrs · 13,297 cycles

RT WING UPPER TRAILING EDGE COMPOSITE PANEL HAS A 2.0 INCH CRACK, INBOARD OF INBOARD AILERON AT WBL 445.00, 10.0 INCHES FROM AFT EDGE. PERMANENT REPAIR WAS ACCOMPLISHED AS PER 747-200 SRM 51-40-09, FIG 2, TABLE 1 AND 747-200 SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO NR 4757A352.

Part: STRUCTURE — CRACKED (MLG DOOR) · airframe 79,950 hrs · 13,295 cycles

DURING WALK AROUND, FOUND LEFT WING GEAR INBOARD SHOCK STRUT DOOR DAMAGED ALONG THE LOWER 27" OF THE T/E WITH APPROX 7" DAMAGE ON DOOR FAIRING. LEFT WING GEAR INBOARD CHOCK STRUT DOOR ASSY REMOVED IAW CDL 32-12-1. REPLACED LOWER STRUT DOOR AND FAIRING AS PER AMM 32-12-05 AND 32-12-06, PERFORMED LOWER GEAR RETRACTION DOOR ADJUSTMENTS AND LOWER GEAR EXTENSION AS PER AMM 32-32-00 & 32-72-00, ALL OPS TEST WERE OK.

Part: VALVE — UNSERVICEABLE (NR 3 PYLON) · airframe 643,000 hrs · 12,415 cycles

WHEN "A" AUTOPILOT IS CONNECTED THE ACF GOES INTO A STEEP DIVE WITH STAB TRIM "A" LIGHT ON ALL ATTITUDE. WHEN AUTOPILOT "B" IS CONNECTED A/C PORPOISES + - 1,200 FRM WITH STAB TRIM "B" LIGHT ON. THIS HAPPENED ABOVE FL 27.0. IF FLYING AT 27.0 IT MAINTAINED A GOOD LEVEL CRUISE, TX DMI M07-028 PER MEL 22-1 PLACARD INSTALLED. REMOVED AND REPLACED AUTO STAB TRIM UNIT IAW 22-14-01, OPS CHECK OK. REMOVED AND REPLACED NR 3 PYLON VALVE IAW MM 36-11-04, OPS CHECK OK. PERFORMED OPS CHECK OF NR 4 PYLON VALVES AS PER MM 36-00-00, OPS CHECK NORMAL.

Part: PDU — FAILED (LE FLAPS) · airframe 79,344 hrs · 131,169 cycles

AIR TURN BACK, ON CLIMB NR 4 LEFT LEADING EDGE FLAP GROUP WOULD NOT RETRACT PNEUMATICALLY. THE GROUP WAS ALREADY ON DEFERRAL FOR BEING INOP ELECTRICALLY. CREW DUMPED 69000 KILOS OF FUEL. UPON RETURN MAINTENANCE REMOVED AND REPLACED NR 4 PDU, ALL OPS AND LEAK CHECKED OKAY.

Part: LINE — LEAKING (FUEL SYSTEM) · airframe 79,167 hrs · 13,130 cycles

UPON ARRIVAL, MAINTENANCE NOTICED A STRONG ODOR OF FUEL THROUGH OUT THE AIRCRAFT. INSPECTED THE FUEL TANKS FUEL LINES, ALL ENGINE FUEL LINES MAIN DECK AND LOWER CARGO AREAS NO TROUBLE FOUND. CHECKED APU AREA AND FOUND FUEL LEAKING AT APU FUEL TUBE FITTINGS FROM THE FUEL METERING VALVE TO THE FUEL PUMP. DEACTIVATED APU TRANSFERRED TO DMI M06-211 IAW DDPG 49-1. INSTALLED PLYCARD.

Part: DRIVE UNIT — UNSERVICEABLE (LE FLAPS) · airframe 78,935 hrs · 13,073 cycles

ON TAKEOFF ROLL AT APPROX 95 KNOTS AMBER L/E FLAP DISAGREEMENT LIGHT AND AMBER CAUTION L/E FLAP LIGHT. TAKE OFF WARNING HORN SOUNDED. REJECTED T/O. REMOVED AND REPLACED L1,L4 R2 AND R3 L/E FLAP DRIVE UNITS IAW AMM 27-81-03. DRIVE UNITS SERVICED IAW AMM 12-30-12. OPERATIONAL CHECK SATISFACTORY.

Part: SKIN — DELAMINATED (MID FLAP) · airframe 78,859 hrs · 13,062 cycles

RT INBOARD MID FLAP, BOTTOM SIDE SKIN AT WBL 195.750 HAS 1.250 BY 5.0 INCH AREA OF DELAMINATION. ACCOMPLISHED PREPREG LAYUP 250 DEGREES CURE PERMANENT REPAIR AS PER 747 SRM 51-40-09 FIG 2 AND 51-40-12.

Part: PANEL — CRACKED (LT WING) · airframe 78,859 hrs · 13,062 cycles

LT WING TOP T/E PANEL AT WBL 235.65 HAS A 1.750 INCH CRACK 17.0 INCHES FROM FORWARD EDGE OF PANEL. ACCOMPLISHED PREPREG LAYUP 250 DEGREES CURE PERMANENT REPAIR AS PER 747 SRM 51-40-09 FIG. 2 AND SRM 51-40-12.

Part: PANEL — DELAMINATED (RT WING) · airframe 78,859 hrs · 13,062 cycles

RT WING TOP L/E PANEL AT ILES 559.72 HAS AREA OF 4.0 BY 7.0 INCH OF DELAMINATION. ACCOMPLISHED PREPREG LAYUP 250 DEGREES F CURE PERMANENT REPAIR AS PER 747 SRM 51-40-09 FIG 2 AND 747 SRM 51-40-12.

Part: UNKNOWN — MALFUNCTIONED · airframe 78,188 hrs · 12,919 cycles

UPON THROTTLE ADVANCE AND BRAKE RELEASE, AIRCRAFT VEERED SHARPLY TO THE RIGHT. FULL LEFT RUDDER WAS APPLIED ACFT CONT, TO VEER RT. TAKEOFF ABORTED. OPS CHECKED BRAKES, AS PER MM 32-41-15 OPS CK NORMAL. OPS CHECKED BODY GEARS STEERING AS PER MM 32-53-00. OPS CHECKED NOSE GEARS STEERING AS PER 32-51-00 ALL SYS OPS CHECKED NORMAL OK TO PROCEED.

Part: BEARING — MIGRATED (NR 4 PYLON) · airframe 78,180 hrs · 12,917 cycles

PYLON NR 4 DIAGONAL BRACE LOWER SPAR FITTING BEARING MIGRATED. BEARING WAS REMOVED AND REPLACED WITH NEXT AVAILABLE OVERSIZED BEARING P/N KSC273624B-090 AS PER SRM 54-41-03 AND MM 54-10-03.

Part: AIR DATA MODULE — INOPERATIVE (NR 1) · airframe 77,615 hrs · 12,803 cycles

CAPT'S MACH METER YELLOW FLAG IN VIEW AFTER TAKE OFF. REMOVED AND REPLACED NR 1 CADC IAW AMM 34-12-01. OPS CHECKED OKAY. RII PERFORMED.

Part: CLAMP — BROKEN (ENGINE) · airframe 77,407 hrs · 12,754 cycles

FIRE WARNING AT 70KTS. A/C RETURNED TO BLOCKS. ON POST FLIGHT INSPECTION FOUND NR 3 BOTTOM DOOR OPEN, & INBOARD PYLON DOOR OPEN. FOUND HP VALVE LOWER CLAMP OFF POSITION, ADJUSTED DUCTS AND REPLACED LOWER CLAMP AS PER MM 36-11-05. LEAK CHECK OK.

Part: LINE — BROKEN (PR VALVE)

AFTER TAKEOFF NR 4 ENGINE FIRE WARNING SOUND. PEAK EGT 976 FOR 11 SECONDS. GOT A RED BALL, SHUTDOWN THE ENGINE IAW FHB FIRE INDICATION WENT OUT WHEN NR 4 ENGINE FIRE SWITCH WAS PULLED. PERFORMED NR 4 ENGINE VISUAL INSPECTION NO EVIDENCE OF FIRE. PERFORMED BOROSCOPE INSPECTION OF BLADES OF HPC STAGES 1-7-12-13 AND 14. HPT STAGE 1 AND 2, LPT STAGE 1 AND 2, FOUND ALL SATISFACTORY IAW AMM 72-00-00. REMOVED AND REPLACED ENGINE NR 4 IAW AMM 71-00-02. PERFORMED ENGINE TEST RUN IAW AMM 71-00-00. FINDINGS WERE VARIABLE BLEED VALVE FEED BACK CABLE TO MEC FAILED CAUSING PRESSURE RELIEF VALVE TO DUMP BLEED LOAD CAUSING FIRE WARNING. ALSO, FOUND SENSE LINE TO PRV BROKEN ON INITIAL INSPECTION. (M)

Part: RELIEF VALVE — LEAKING (NR 1 ENGINE)

RHI/MXP - NR 1 ENGINE WOULD NOT ATTAIN REQUIRED THRUST FOR T/OFF. WOULD ONLY ATTAIN 108.5 AGAINST THE STOP. ALL OTHER INDICATIONS NORMAL. NR 3 ENG WOULD NT ATTAIN REQUIRED THRUST FOR T/OFF. WOULD ONLY ATTAIN 110.0 AGAINST THE STOP. ALL OTHER INDICATIONS NORMAL. REJECTED TAKEOFF. NR 1 ENGINE PERFORMED PNEUMATIC LEAK CHECK. NOTED RELIEF VALVE WITH EXCESSIVE LEAK. R & R ENG NR 1 RELIEF VALVE UNIT IAW MM 36-12-00. PERFORMED NR 1 THRUST CONTROL CABLE CHECK IAW MM 76-71-00. NR 3 PERFORME PNEUMATIC LEAK, NOTED PVR CLAMP LEAKING, RETORQUED CLAMP. PERFORMED NR 3 THRUST CONTROL CABLE CHECK IAW AMM 76-11-00. PER MCC ADJUSTED MAIN ENG CONTROL PART POWER TRIM 1-TURN CW IAW MM 71-00-00 TEST 5. (M)

Part: CONNECTOR — DAMAGED (NR 4 ENGINE)

AFTER TAKEOFF, NR 4 ENGINE INTERMITTENT FIRE WARNING 'A' LOOP FLUCTUATED. HOWEVER, 'B' LOOP DMI INOPERATIVE. SHUTDOWN NR 4 ENGINE JETTISION FUEL AND RETURNED. CLEANED AND CHECKED ALL CONNECTOR OF NR 4 ENGINE 'A' LOOP. NO FAULT FOUND AND GROUND TEST OK AS PER MM 26-11-00. REPAIRED CONNECTOR AS PER MM 26-11-00 AND GROUND TEST OK. (M)

Part: ACM — UNSERVICEABLE (NR 3)

AFTER TAKEOFF, NR 3 AIR CONDITIONING PACK STARTED MAKING LOW RUMBLING SOUND. SMELLED BURNING ODOR, TURNED NR 3 PACK OFF FOR REMAINDER OF FLIGHT. REMOVED AND REPLACED NR 3 AIR CYCLE MACHINE. GROUND OPERATION CHECK NORMAL IAW MM.

Part: HANDLE — MALFUNCTIONED (LT MLG DOOR)

DUE TO GEAR DOOR OPEN INDICATION: AFTER GEAR RETRACTION, RED DOOR OPEN LIGHT REMAINED ILLUMINATED. RAN SECTION 3 PROCEDURES, LT WING GEAR DOOR OPEN LIGHT ILLUMINATES WITH PRIMARY AND ALTERNATE DOOR SELECTION SWITCHES. DOOR IS OPEN WITH AIRCRAFT RUMBLE. UP ON INSPECTION OF LT WING GEAR DOOR, FOUND LT DOOR RELEASE HANDLE NOT FULLY ENGAGED IN THE UP AND CLOSED POSITION. POSITIONED DOOR HANDLE PROPERLY, LT WING DOOR CLOSED, CYCLED HANDLE 3 TIMES. DOOR OPERATION CHECK NORMAL IAW MM. NOTE: NO FUEL DUMPED.

Part: BEAM — CRACKED (LT WING LE)

LT WING FIXED LEADING EDGE NOSE BEAM UPPER CHORD AND LOWER CHORD AND WEB CRACKED AT ILES 1116.00. REMOVED FASTENERS IAW SRM, REMOVED DAMAGED UPPER AND LOWER CHORD BY CUTOUT METHOD IAW SRM REMOVED WEB IAW SRM. FABRICATED UPPER, AND LOWER CHORDS FROM SRM. FABRICATED WEB FROM SRM, TREATED AND PRIMED IAW SRM. INSTALLED PARTS IAW SRM.

Part: KEELBEAM — CORRODED (FUSELAGE)

FOUND RIGHT WING GEAR WHEEL WELL KEELBEAM TOP SURFACE AT BS 1265, CORRODED AROUND FASTENERS LOCATION. KEEL BEAM CORRODED TOP WEB SURFACE REPLACEMENT CARRIED OUT AS PER SRM 51-10-01 AND SRM 51-30-02. (M)

Part: SKIN — CORRODED (LT WING)

FOUND LEFT WING TOP SIDE SKIN CORRODED WSTA 1454 STRINGER 15. SKIN CORROSION WAS BLENDED OUT WITHIN LIMITS OF SRM 57-30-01 FIG 1. AREA WAS REPROTECTED AND PRIMER APPLIED IAW SRM 57-30-01. (M)

Part: SKIN — CORRODED (LT WING)

FOUND LEFT WING LOWER SKIN CORROSION AROUND SURGE TANK SUMP DRAIN VALVE AT WS 1487. CORROSION BLENDED OUT AND REPAIRED AS PER FAA FORM 8110-3 DATED 19 JAN 2004, COPY ATTACHED FOR DETAILS OF HFEC INSPECTION REF COPY OF ATTACHED SJC A00064. (M)

Part: RIB — CRACKED (NR 3 NACELLE)

FOUND INTERIOR RIB CRACKED AT NAC STA 300 LEFT SIDE NR 3 PYLON LOWER AREA. DEFECT RECTIFIED AS PER TRANSIT W/O 71181467000001 IAW BOEING DRAWING 65B94117 REV E, 65B89043 REV D, 65B89044 REV B, AND BOEING SEP-SIN-04-00049H. (M)

Part: ANGLE — CRACKED (RT WING TE)

FOUND RT WING T/E UPPER FIXED PANEL LONGITUDINAL SUPPORT BEAM FORWARD L-ANGLE CRACK AT WBL 130.0. REPLACED CRACKED SUPPORT ANGLE WRT SRM 51-30-02. (M)

Part: SKIN — CORRODED (FUSELAGE)

FOUND LEFT WING TOP SIDE SKIN CORRODED WSTA 1392 STRINGER 15. SKIN CORROSION WAS BLENDED OUT WITHIN LIMITS OF SRM 57-30-01 FIG 1. AREA WAS REPROTECTED AND PRIMER APPLIED IAW SRM 57-30-01. (M)

Part: RIB — CRACKED (NR 3 PYLON)

FOUND INTERIOR RIB CRACKED AT NAC STA 318.20 RIGHT SIDE NR 3 PYLON LOWER AREA. DEFECT RECTIFIED AS PER TARNSIT W/O 71181467000001 IAW BOEING DRAWING 65B94117 REV E, 65B89043 REV D, 65B89044 REV B, AND BOEING SEP-SIN-04-00049H. (M)

Part: SKIN — CORRODED (LT WING)

FOUND WING TOP SIDE SKIN CORROSION WSTA 440.62 STRINGER 19. SKIN CORROSION WAS BLENDED OUT WITHIN LIMITS OF SRM 57-30-01 FIG 1. AREA WAS REPROTECTED AND PRIMER APPLIED IAW SRM 57-30-01. (M)

Part: ANGLE — CRACKED (RT WING TE)

FOUND RT WING T/E LOWER ACCESS PANEL SUPPORT BEAM AFT L-ANGLE CRACK AT WS 670. REPLACED CRACKED PANEL SUPPORT BEAM ATTACH CLIP 'L' ANGLE WRT SRM 51-30-02. (M)

Part: SKIN — CORRODED (LT WING)

FOUND LEFT WING TOP SIDE SKIN CORROSION WS 1434 STRINGER 13. SKIN CORROSION WAS BLENDED OUT WITHIN LIMITS OF SRM 57-30-01 FIG 1. AREA WAS REPROTECTED AND PRIMER APPLIED IAW SRM 57-30-01. (M)

Part: FRAME — CORRODED (BULKHEAD)

FOUND RT WING GEAR WHEEL WELL BS 1350 BULKHEAD LOWER CHORD HORIZONTAL FLANGE AT RBL 50, LOWER SURFACE CORRODED. CORROSION REMOVED IAW SRM 51-10-01 FOUGN TO BE WITHIN LIMITS IAW SRM 53-10-01 FIG 1. AREA REPROTECTED IAW SRM 51-10-02. REMAINING THICKNESS 1.140 INCH. ORIGINAL THICKNESS 1.225 INCH. MATERIAL REMOVED .085 INCH. (M)

Part: SKIN — CORRODED (LT WING)

FOUND LEFT WING TOP SIDE SKIN CORROSION WSTA 697 STRINGER 27. SKIN CORROSION WAS BLENDED OUT WITHIN LIMITS OF SRM 57-30-01 FIG 1. AREA WAS REPROTECTED AND PRIMER APPLIED IAW SRM 57-30-01. (M)

Part: ANGLE — CRACKED (RT WING)

FOUND RIGHT WING T/E UPPER FIXED PANEL HORIZONTAL SUPPORT BEAM L-ANGLE CRACKED AT WING STATION 400. REPLACED CRACKED ANGLE WRT SRM 51-30-02. (M)

Part: PANEL — CORRODED (LT WING)

FOUND LEFT WING STATION 715, WBL 433, BULGE ON THE T/E F/G PANEL RABBET AREA AT REAR SPAR WING STOP SKIN. CORROSION FOUND ON WING TOP SKIN AFT OF REAR SPAR CORROSION BLENDED OUT WITHIN LIMITS OF SRM 57-30-01. AREA REPORTECTED AND PRIMER APPLIED IAW 57-30-01. (M)

Part: STRINGER — CORRODED (FUSELAGE)

FOUND AFT CARGO STRINGER AT STATION 1750 RIGHT SIDE STRINGER 44 FOUND CORRODED. STRINGER REPAIRED AT STATED LOCATION CARRIED OUT AS PER SRM 53-10-03 FIG 1. (M)

Part: RIB — CRACKED (FUSELAGE)

FOUND KEELBEAM VERTICAL SUPPORT ANGLES AT STATION 1000 LT AND RT SIDES CRACKED. SUPPORT ANGLES REPLACED IAW SRM 51-10-01 AND SRM 51-30-02. (M)

Part: SKIN — CORRODED (LT WING)

FOUND LEFT WING TOP SKIN CORROSON WS 323.82.00 STRINGER 27. SKIN CORROSION WAS BLENDED OUT WITHIN LIMITS OF SRM 57-30-01 FIG 1 AREA WAS REPROTECTED AND PRIMED IAW SRM 57-30-01. (M)

Part: RIB — CRACKED (NR 3 PYLON)

FOUND INTERIOR RIB CRACKED AT NAC STATION 220 RIGHT SIDE. DEFECT RECTIFIED AS PER TRANSIT W/O 71181467000001 IAW BOEING DRAWING 65B94117 REV E, 65B89043 REV D, 65B89044 REV B, AND BOEING RES SIN-04-00049H. (M)

Part: SKIN — CORRODED (LT WING)

FOUND LEFT WING TOP SKIN CORROSION WS 1280 STRINGER 18. SKIN CORROSION WAS BLENDED OUT WITHIN LIMITS OF SRM 57-30-01 FIG 1 AREA WAS REPROTECTED AND PRIMED IAW SRM 57-30-01. (M)

Part: PANEL — CORRODED (LT WING)

FOUND LEFT WING STATION 715, WBL 433, BULGE ON THE T/E F/G PANEL RABBET AREA AT REAR SPAR WING TOP SKIN. CORROSION FOUND ON WING TOP SKIN AFT OF REAR SPAR CORROSION BLENDED OUT WITHIN LIMITS OF SRM 57-30-01. AREA REPROTECTED AND PRIMER APPLIED IAW 57-30-01. (M)

Part: BUSHING — CRACKED (LT WING)

FOUND LEFT WING WALKING BEAM SUPPORT FITTING ASSEMBLY. FORWARD BEARING HOUSING OUTBOARD UPPER/FWD BOLT HOLE LOCATION ON REAR SPAR STIFFENER WAS FOUND WITH A CRACKED BUSHING HOLE AND BUSHING WAS ALSO FOUND WORN. CRACKED HOLE REPAIRED AS PER SB 747-57-2226 REV 6. CRACKED HOLE REAMED TO REMOVED CRACK. HOLE HFEC INSPECTED AND COLD WORKED TO .748 INCH AND NEW BUSHING INSTALLED. (M)

Part: SKIN — CORRODED (LT WING)

FOUND LT WING TOP SKIN CORROSION WS 1280 STRINGER 14. SKIN CORROSION WAS BLENDED OUT WITHIN LIMITS OF SRM 57-30-01 FIG 1 AREA WAS REPROTECTED AND PRIMED IAW SRM 57-30-01. (M)

Part: RIB — CRACKED (LT WING LE)

FOUND LEFT WING LE PARTIAL RIB AT ILES 414.5 HAS A 4.5 INCH CRACK LONGITUDAL ACROSS ITS WEB JUST BEHIND THE FORWARD RIB SECTION. CRACKED WEB REPAIRED PER SRM 51-40-02. (M)

Part: SEAT TRACK — DAMAGED (FUSELAGE)

UPPER DECK SEAT TRACK CROWN HAS 2 OF THE LIPS SHEARED OFF AT STATION 660 LBL 46.65. DAMAGED SEAT TRACK SECTION TRIMMED OUT AND REPAIR SECTION SPLICED ON IAW SRM 53-10-05. (M)

Part: RIB — CRACKED (RT WING LE)

FOUND RT WING LEADING EDGE RIB AT ILES 330 FOUND WITH A 1.25 INCH LONG CRACK ON THE WEB ALONG THE LOWER ANGLE AT AFT EDGE. REPLACED CRACKED LEADING EDGE RIB WEB WRT SRM 51-30-02. (M)

Part: CAP — CRACKED (RT WING LE)

FOUND RT WING LEADING EDGE NOSE CAP AT LES 1042 FOUND 4.25 INCH LONG SPANWISE CRACK PROPERGATED FROM WING ANTI-ICE DUCT. RIGHT WING LEADING EDGE NOSE BEAM CRACKED WEB REPAIRED AS PER FAA FORM 8110-3 REF SJC NR A00063. (M)

Part: PANEL — CORRODED (LT WING)

FOUND LEFT WING TOP SKIN FIXED T/E FIBERGLASS PANEL BULGING AT RABBET AREA AFT OF REAR SPAR BETWEEN WBL 198.6 TO 204.6. CORROSION FOUND ON WING TOP SKIN AFT OF REAR SPAR CORROSION BLENDED OUT WITHIN LIMITS OF SRM 57-30-01. AREA REPROTECTED AND PRIMER APPLIED IAW SRM 57-30-01. (M)

Part: STRUT — CRACKED (NR 2 PYLON)

DURING D-CHECK AT SIN, DURING ZONAL INSPECTION IT WAS DISCOVERED THAT NR 2 ENGINE PYLON STRUT PRECOOLER EXHAUST VENT WITH CRACKS ON THE RIGHT SIDE OF THE STRUT. THE REPAIRS WERE MADE ON THE RIGHT SIDE OF THE STRUT STRUCTURE ASSEMBLY. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW LOWER REPAIR ANGLE FROM NAC STATION 235 TO STATION 254. THE RIB INSTALLATION AT NAC STA 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLES INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: STRUT — CRACKED (NR 4 PYLON)

DURING ZONAL INSPECTION IT WAS DISCOVERED THE NR 4 ENGINE PYLON STRUT PRECOOLER EXHAUST VENT WITH CRACKS ON THE RIGHT SIDE OF THE STRUT. THE REPAIRS WERE MADE ON THE RIGHT SIDE OF THE STRUCT STRUCTURE ASSEMBLY. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW LOWER REPAIR ANGLE FROM NACELLE STATION 235 TO STATION 254. THE RIB INSTALLATION AT NACELLE STATION 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLES INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: STRUT — CRACKED (NR 3 PYLON)

DURING D-CHECK AT SIN, DURING ZONAL INSPECTION IT WAS DISCOVERED THAT NR 3 ENGINE PYLON STRUT PRECOOLER EXHAUST VETN WITH CRACKS ON THE RIGHT SIDE OF THE STRUT. THE REPAIRS WERE MADE ON THE RIGHT SIDE OF THE STRUT STRUCTURE ASSEMBLY. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW LOWER REPAIR ANGLE FROM NAC STATION 235 TO STATION 254. THE RIB INSTALLATION AT NAC STATION 248 WAS MODIFIED TO ACCOMODATE THE NEW STEEL REPAIR ANGLES INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: STRUT — CRACKED (NR 1 PYLON)

DURING D-CHECK AT SIN, DURING ZONAL INSPECTION IT WAS DISCOVERED THAT NR 1 ENGINE PYLON STRUT PRECOOLER EXHAUST VENT HAD CRACKS ON THE RIGHT SIDE OF THE STRUT. THE REPAIRS WERE MADE ON THE RIGHT SIDE OF THE STRUT STRUCTURE ASSEMBLY. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW LOWER REPAIR ANGLE FROM NAC STATION 235 TO STATION 254. THE RIB INSTALLATION AT NAC STATION 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLES INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: ATTACH FITTING — CRACKED (NR 1 PYLON)

DURNG D-CHECK AT SIN ON NR 1 PYLON DIAGONAL BRACE ATTACH FITTING, HFEC INSPECTOIN FOUND CRACK IN HOLE LOCATION REF 'A'. HOLE OVERSIZED TO .0405, BUT CRACK REMAINS. THE DEFECT WAS COMPLETELY REMOVED BY OVERSIZING THE HOLE TO .434 INCHES PRIOR TO FURTHER OVERSIZING TO .4521-0 .4541 INCHES. A SAME TYPE FASTENER WAS INSTALLED AT THE DISCREPANT LOCATION. ALL OTHER FITTING REWORK AND REFINISH WAS ACCOMPLISHED IAW TERMINATING ACTION. (M)

Part: SKIN — WRINKLED (NR 3 PYLON)

DURING D-CHECK AT SIN, FOUND NR 3 PYLON HAS A WRINKLE CONDITION ON RIGHT SIDE. SKIN ASSEMBLY WAS TRIMMED TO REMOVE THE WRINKLED AREA. NDT INSPECTION OF THE REPAIR AREA, INCLUDING HFEC INSPECITON OF SKIN TRIMMED EDGES AND REPAIR FASTENER HOLES WAS PERFORMED TO ENSURE ABSENCE OF CRACKS, CORROSION AND ANY OTHER DAMAGE. A NEW SKIN REPAIR DOUBLER ASSY WAS INSTALLED FROM FS 286-316. THE NEW SKIN REPAIR DOUBLER ASSY WAS MADE FROM TWO STAGGERED LAYERS OF TITANIUM SHEET AND INSTALLED IMMEDIATELY AFT OF THE TITANIUM SIN DOUBLER EXTENSION. THE NEW SKIN REPAIR DOUBLER ASSEMBLY FORWARD END WAS ATTACHED TO THE EXISING TITANIUM DOUBLER EXTENSION WITH A NEW TRIPLER MADE FROM TITANIUM SHEET. (M)

Part: SKIN — WRINKLED (NR 2 PYLON)

DURING D-CHECK AT SIN, FOUND NR 2 PYLON HAS A WRINKLE CONDITION ON RIGHT SIDE. SKIN ASSY WAS TRIMMED TO REMOVED THE WRINKLED AREA. NDT INSPECTION OF THE REPAIR AREA, INCLUDING HFEC INSPECTION OF SKIN TRIMMED EDGES AND REPAIR FASTENERS HOLES WAS PERFORMED TO ENSURE ABSENCE OF CRACKS, CORROSION AND ANY OTHER DAMAGE. A NEW SKIN REPAIR DOUBLER ASSEMBLY WAS INSTALLED FROM STATION 286-300. THE NEW SKIN REPAIR DOUBLER ASSY WAS MADE FROM TWO STAGGERED LAYERS OF TITANIUM SHEET AND INSTALLED IMMEDIATELY AFT OF THE TITANIUM SKIN DOUBLER EXTENSION. THE NEW SKIN REPAIR DOUBLER ASSEMBLY FORWARD END WAS ATTACHED TO THE EXISTING TITANIUM DOUBLER EXTENSION WITH A NEW TRIPLER MADE FROM TITANIUM SHEET. (M)

Part: PANEL — DELAMINATED (TE FLAP)

DURING D-CHECK AT SIN, FOUND TOP PANEL P/N 65B08540-202 DELAMINATED. AREA AFFECTED EXCEED SRM REPAIR LIMITS. THE DAMAGED SKIN WAS REMOVED AND DISCARDED. A METAL TO METAL HOT BOND REPAIR WAS ACCOMPLISHED PER 747 SRM 51-40-06 SECTION 3 REQUIREMENTS. DETAIL VISUALLY INSPECT AND TAP TEST THE REPAIR AREA FOR SIGNS OF DEGRADATION AT 2A CHECK INTERVALS, AND REPLACED THE PANEL WITHIN 18 MONTHS. ATLAS MCI A062 ISSUED TO REPLACE PANEL AT NEXT C-CHECK. (M)

Part: SPAR — CORRODED (TE FLAP)

DURING DC-CHECK AT SIN, FOUND CORROSION ON THE LOWER SECTION OF THE UPPER T-CHORD OF SPAR NR 1 AND NR 2 OF RIGHT INOARD MID FLAP. FOUND ON ROUTINE CARD 12FM40010. CORROSION LEVEL 1. LOCALLY BLEND OUT CORROSION DAMAGE FROM THE EFFECTED CHORD FLANGE LOWER SURFACE. BOTH NR 1 AND NR 2 SPARS. NDT INSPECT TO ENSURE CRACK AND DEFECT FREE CONDITION. REFINISH CHORDS TO DESIGN STANDARD. REASSEMBLED MID-FLAP WITH OVERSIZE FASTENERS AT LOCATIONS COMMON TO CORROSION REWORK. (M)

Part: STIFFENER — CRACKED (KRUEGER FLAP)

DURING D-CHECK AT SIN, FOUND NR 16 KRUEGER FLAP INBOARD STIFFENER CRACKED. TRIMMED OUT CRACKED SEGMENT OF STRINGER FLANGE TO REMOVE DAMAGE. NDT INSPECT STRINGER TO INSURE CRACK AND DEFECT FREE CONDITION. INSTALLED ALUMINUM REPAIR ANGLE AND ALUMINUM FILLER TO COMPENSATE FOR MATERIAL REMOVED. REFINISHED TRACK TO DESIGN CONDITION. (M)

Part: SKIN — CORRODED (FUSELAGE)

DURING D-CHECK AT SIN, CENTER WING TANK, LOWER SKIN ABOVE NR 1 ACM FOUND CORRODED. LEVEL 1. CORROSION WAS BLENDED OUT WITH A MACHINED FINISH. THE BLENDED AREA WAS HFEC INSPECTED AND FLAP/SHOP PEENED. ALODINE PRIMER AND BMS 3-23 CORROSION INHIBITING COMPOUND WAS APPLIED TO THE BLENDED AREAS PER 747 SRM 57-10-01 FIGURE 2. (M)

Part: SKIN — CORRODED (LT WING)

DURING (D) CHECK, WING LOWER SKIN CORROSION FOUND AROUND SURGE TANK SUMP DRAIN VALVE AT WING STA 1487, BETWEEN STRINGERS S-5 AND S-6 LT SIDE. CORROSION DAMAGE IS REPAIRED BY BLEND OUT. REPAIR AREA IS SHOP PEENED AND HFEC INSPECTED. APPLIED ALODINE 1200 AND BMS 10-11 TYPE PRIMER. BLEND OUT AREA AROUND DRAIN VALVE FASTENER HOLE IS SPOT FACED. BACB30NW8 HILOK WITH BACC30N8 COLLAR IS INSTALLED WET WITH BMS 5 26 SEALANT IN .2460 TO .2480 INCHES DIAMETER HOLE. BMS 5 26 SEALANT IS APPLIED IN THE BLENDED CAVITY.

Part: BEAM — CRACKED (RT WING)

DURING (D) CHECK AT SIN, RT WING LEADING EDGE NOSE BEAM WEB FOUND WITH 4.2500 CRACK AT ILES 1042. REPAIR, TRIM OUT SECTION OF CRACKED WEB TO REMOVE DAMAGE. NDT INSPECTED TO ENSURE CRACK AND DEFECT FREE CONDITION. SPLICE IN REPLACEMENT WEB REPAIR SECTION WITH ALUMINUM SPLICE DOUBLERS. REFINISH BEAM TO DESIGN STANDARD. REPAIR ACCOMPLISHED AT (C) CHECK INTERVALS NOT TO EXCEED 18 MONTHS FOR SIGNS OF CRACKS OR LOOSE FASTENERS.

Part: DUCT — LEAKING (NR 3 ENGINE)

ON CLIMB-OUT, NR 3 ENGINE NACELLE TEMPERATURE WENT TO 6.0, LOOPS A/B. WITH POWER PULLED BACK TO CRUISE TEMPERATURE DROPPED TO 3.5 - 4.0. REMOVED AND REPLACED FORWARD 8TH STAGE DUCT ASSEMBLY AS PER MM 36, ACCOMPLISHED LEAK CHECK ON ABOVE IDLE RUN UP, ALL NORMAL. (M)

Part: METERING VALVE — LEAKING (APU)

STRONG SMELL OF FUEL AFTER SUPPLYING A/C PACK WITH AIR FROM THE APU. SUSPECT FUEL LEAK. FOUND FUEL DROP FROM THE FORWARD FUSELAGE DRAIN. APU RENDERED INOPERATIVE. REMOVED AND REPLACED FUEL METERING VALVE PER MM 49-31-07. OPS AND LEAK CHECK OK. (M)

Part: TRANSPONDER — FAILED (NR 1 MODE)

DURING INITIAL CLIMB, TRANSPONDER FAIL LIGHT ILLUMINATED WITH NR 1 SET SELECTED. SELECTED NR 2 TO NO AVAIL. CIRCUIT BREAKER CHECKED OK. DIVERTED. C/A: REPLACED MODE S TRANSPONDER IAW MM. TEST CARRIED OUT. OPS CHECK SATISFACTORY. ALSO ATC TRANSPONDER NR 2 TRANSFERRED TO DMI.

Part: SKIN — CRACKED (RT WING)

DURING CURRENT C-CHECK AT SIAEC, FOUND RT WING L/E STATIONS NR ILES 378, 400, 446, 467, AND 546 NOSE CAP POSITIONS CRACKED AND CORRODED AT TOP ROW OF RIVETS. SIX CRACKED/ CORRODED AREAS TRIMMED OUT. ALL AREAS HFEC INSPECTED FOR ADDITIONAL CRACKS. NONE FOUND. FABRICATED FILLER, INTERNAL REPAIR DOUBLER AND TAPERED SHIMS FOR EACH AREA. OVERSIZED EXISTING HOLES. INSTALLED REPAIR SECTIONS IAW SRM 57-30-04 FIG 2 AT ILES 378, 400, 446, 467, 515 AND 546. (M)

Part: BEAM — CRACKED (BS1344,1354)

DURING CURRENT (C) CHECK AT SIAEC FOUND LOWER KEEL BEAM CHORD INBOARD VERTICAL FLANGE CRACKED 10 INCH FROM BS 1344 TO 1354 AT LBL 9.0. LEVEL 1 CORROSION PRESENT IN CRACKED AREA OF VERTICAL WEB THROUGH ABOUT 50 PERCENT OF THE ORIGINAL THICKNESS. CRACKED/ CORRODED AREA TRIMMED AWAY. AREA VISUALLY INSPECTED FOR ADDITIONAL CRACKS/CORROSION. NONE FOUND. FABRICATED FILLER AND REPAIR DOUBLER. INSTALLED IAW SRM.

Part: PANEL — CRACKED (LT WING)

DURING CURRENT (C) CHECK AT SIAEC FOUND CRACKED CLOSURE PANEL ON LT WING LE NR12 KRUGER FLAP FOLDING NOSE SECTION OF THE CENTER ATTACH BRACKET AT ILES 480. TRIMMED OUT CRACKED SECTION OF CLOSURE WEB. FABRICATED NEW SECTION OF WEB AND ASSOCIATED SLICE DOUBLERS. INSTALLED PER STANDARD SRM.

Part: SKIN — CORRODED (RH STAB STA343)

DURING CURRENT (C) CHECK AT SIAEC FOUND RIGHT HORIZONTAL STABILIZER BOTTOM SKIN AT STA 343 OUTER SURFACE CORRODED (LEVEL 2). FASTENERS REMOVED IN THE AFFECTED AREA. ALL HOLES CHECKED FOR CORROSION, OVER-SIDED AND HFEC INSPECTED FOR CRACKS. NO ADDITIONAL CORROSION ON CRACKING FOUND. CORROSION AREA BLENDED, MEASURED, FLAP PEENED, ALODINE TREATED AND PRIME PAINTED. ORIGINAL SKIN MEASURED 0.120, AFTER BLENDING 0.091 REMAINS. REPAIRS CARRIED OUT IAW SRM. REPAIR IS TIME LIMITED WITH PERMANENT REPAIRS TO BE CARRRIED OUT WITHIN 18 MONTHS OR NEXT (C) CHECK.

Part: FLOORBEAM — CRACKED (FUSELAGE)

DURING SB747-53A2416 INSPECTION OF BS 1265, A CRACK WAS DISCOVERED EMANATING FROM A FRAME WEB FASTENER HOLE ON THE MAIN DECK FLOORWEB AT WL 199, LBL 120. REPAIRED ACCOMPLISHED BY INSTALLING A FRAME WEB DOUBLER, INTERCOSTAL DOUBLER AND AN ATTACHING ANGLE IAW AMOC LETTER TO AD 2000-02-10 STATION 1265 LEFT FRAME WEB CRACK DATED 4/10/2000. (M)

Part: TURBINE — FAILED (NR 2 ENGINE)

ANC - AFTER TAKEOFF AT FL 310, NR 2 ENGINE FLAMED OUT IN CRUISE. ATTEMPTED RE-START ENGINE AND NO HELP. NO N2 INDICATION. AIRCRAFT DUMPED FUEL AND HAD UNEVENTFUL RETURN TO ANC. DURING INSPECTION OF ENGINE AT ANC, FOUND EVIDENCE OF METAL IN THE TAIL PIPE AND DAMAGE TO 4TH STAGE LOW PRESSURE TURBINE BLADES. ENGINE REPLACED. S/N OFF 517482, S/N ON 530304. (X)