N522MC

Part: NACELLE — CRACKED (NR 1) · airframe 106,920 hrs · 21,423 cycles

THE PURPOSE OF THIS EO 4771A096 & NBSP; IS TO DOCUMENT A MAJOR REPAIR. DURING WALK-AROUND INSPECTION AT RMS, MX FOUND THE NR 1 RT FAN COWL WITH DAMAGE; CRACK MEASURING 6.0 IN. LONG (REF FIG 1). THE DAMAGE IS BEYOND THE ALLOWABLE DAMAGE LIMITS IAW SRM 51-40-06, FIG 2, SHEET 2 (ALLOWABLE DAMAGE 1). (DISPOSITION WAS MADE TO PERFORM A TIME LIMITED REPAIR AS DESCRIBED IN PART 1 WORK INSTRUCTIONS, DVI INSPECTIONS AFTER EVERY 5 FLIGHT CYCLES UNTIL ACCOMPLISHMENT OF PERMANENT REPAIR PRIOR TO THE ACCUMULATION OF 1,000 FH (FLIGHT HOURS) AFTER PART 1.)

Part: CONDUIT — DAMAGED (NLG WW) · airframe 106,743 hrs · 21,389 cycles

DURING WALKAROUND INSP, MX FOUND THE ELECTRICAL CONDUIT AND CONNECTOR MOUNT HOUSING AT THE NOSE GEAR DAMAGED (REF FIG 1). DISPOSITION WAS MADE TO PERFORM TIME LIMITED REPAIR AS DESCRIBED IN PART 1 WORK INSTRUCTIONS, INITIATE REPEAT INSPECTIONS AT EVERY 5 FLIGHT CYCLES AND SCHEDULE PERMANENT REPAIR AT THE NEXT A CHECK AFTER PART 1 BY REPLACING THE DAMAGED CONDUIT AND NLG LIGHT HOUSING. THIS EO IS APPROVED VIA FAA 8110-3 FORM ISSUED ON 22OCT10; SINCE THE DAMAGE EXCEEDS THE AMM 20-11-05 LIMITS.

Part: ACTUATOR — DAMAGED (THRUST REVERSER) · airframe 105,981 hrs · 21,239 cycles

UPON ARRIVAL, THE NR2 RT THRUST REVERSER, MX FOUND THE T/R NOT COMPLETELY STOWED. AFTER INSP, MX FOUND THE CTR BALLSCREW SHEARED AND THE UPPER BALLSCREW ACTUATOR SUPPORT BRACKET DAMAGED. (DISPOSITION IS TO REPLACE THE CTR BALLSCREW WITH A SERVICEABLE UNIT, REMOVAL OF THE DAMAGED UPPER ANGLE GEARBOX ACTUATOR AND SUPPORT BRACKET, DEACTIVATE THE NR2 T/R IAW AMM 78-30-00, DVI EVERY FLIGHT CYCLE; AND REPLACEMENT OF A SERVICEABLE T/R WITHIN 10 CALENDAR DAYS. SUBSTANTIATION IS BASED ON THE INTEGRITY OF THE CTR AND LOWER ACTUATOR ASSEMBLIES, VERIFIED VIA INSPECTIONS PERFORMED, WHICH PROVIDES THE HOLDING FORCE TO PREVENT THE REVERSER FROM DEPLOYING IN FLIGHT.)

Part: FLOOR PANEL — DAMAGED (BS 1080) · airframe 105,405 hrs · 21,130 cycles

DURING CARGO LOADING AT DOV; MX FOUND DAMAGE TO THE MAIN DECK FLOORBOARD AT BS 1080, RBL 45. THE DAMAGE TO THE MD FLOORBOARD PANEL AT BS1080, RBL45 AIS S FOLLOWS: THE DAMAGE IS ABOUT 7 INCHES LONG AND ABOUT .5 INCH WIDE, AND .2500 INCH DEEP. (DISPOSITION WAS MADE TO PERFORM A TIME LIMITED REPAIR AS DESCRIBED IN PART 1 WORK INSTRUCTIONS, INITIATE REPETITIVE DVIS AT EVERY 5 FC AND PERMANENT REPAIR PRIOR TO/OR WITHIN 750 FH AFTER PART 1.)

Part: BLOWOUT DOOR — DAMAGED (THRUST REVERSER) · airframe 104,865 hrs · 21,026 cycles

REF EO 4778A150- NR 2 T/R ACCESS AMD BLOWOUT DOOR REPAIR. PART ONE TIME LIMITED REPAIR ACCOMPLISHED. PART TWO INSPECTION REQUIRED EVERY FLIGHT CYCLE (SCHEDULE WITHIN 10 CALENDAR DAYS AFTER ACCOMPLISHMENT PART 1).

Part: FAIRING — PUNCTURED (BS 1680) · airframe 104,289 hrs · 20,917 cycles

WING TO BODY FAIRING AT BS 1680 WITH A PUNCTURE/DAMAGE (HONEYCOMB EXPOSURE) MEASURING 2.5 IN. X 0.5 IN (REF FIG 1) (PERFORMED A TIME LIMITED REPAIR AS DESCRIBED IN PART 1 OF EO 4753B253 PART 1 OF WORK INSTRUCTIONS. SCHEDULE REPEAT INSP AT EVERY 3 FC AND PERMANENT REPAIR AT THE NEXT A CHECK AFTER PART 1.)

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, MAINTENANCE FOUND LEVEL 2 CORROSION IN THE 65B04369-175 STRINGER AT BS 1960, S-50R. EFFECTED AREA WAS REMOVED AND REPAIRED AS PER FAA FORM 8100-9 DATED 05 FEB 2010 AND EO 4753B249.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, MAINTENANCE FOUND CORROSION IN THE SKIN LAP JOINTS BETWEEN BS 1700 AND 1960 AND S-40L. CORROSION WAS BLENDED AS PER FAA FORM 8100-9 DATED 05 FEB 2010 AND EO 4753B248.

Part: FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, MAINTENANCE FOUND CORROSION IN THE 65B04331-165 AFT LOWER LOBE FRAME TEE CAP AT BS 1880, LBL 21-22. CORROSION WAS BLENDED AS PER FAA FORM 8100-9 DATED 04 FEB 2010 AND EO 4753B246.

Part: FRAME — CORRODED (MLG WW) · corrosion level 2 · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, MAINTENANCE FOUND CORROSION ON THE FLANGE OF THE OUTER CHORD 65B10365-10 OF FRAME 1265 IS WHEEL WELL S-30 R-S-31R. CORROSION WAS BLENDED AS PER FAA FORM 8100-9 DATED 05 FEB 2010 AND EO 4753B245.

Part: SKIN — CORRODED (BS 2020-2040) · corrosion level 2 · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, CORROSION WAS FOUND BETWEEN BS 2020 AND 2040 AT S-46L IN THE 65B04151-2 FUSELAGE SKIN. THE DENT WAS TRIMMED OUT AND A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-30-03, FIG 19. THE 65B04151-2 SKIN PANEL IS MADE FROM 0.063 INCH THICK 2024-T3 CLAD ALUMINUM IAW QQ-A-250/5. PART 1 OF THIS EO DOCUMENTS THE REPAIR OF THE DENT IAW SRM 53-30-03, FIG 19. THE REPAIR PART 1 OF THIS EO IS CATEGORY B AND REQUIRES REPETITIVE INSPECTION IAW PART 2 OF THIS EO.

Part: FRAME — CRACKED (FUSELAGE) · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, MAINTENANCE FOUND CRACKS IN THE 65B07415-5 FRAME WEB AT BS 720 BETWEEN S-42L AND S-44L. EFFECTED AREA WAS REMOVED AND REPAIRED AS PER EO 4753B243.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, MAINTENANCE FOUND LEVEL 2 CORROSION AT BS 1970 AT S46L IN THE 65B04151-2 FUSELAGE SKIN. AREA WAS TRIMMED OUT AND A REPAIR DOUBLER WAS INSTALLED AS PER EO 4753B244.

Part: STRUCTURE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, MAINTENANCE FOUND CORROSION BETWEEN BS 2020 AND 2040 AT S 46L. CORROSION WAS BLENDED OUT AS PER EO 4752B242.

Part: SKIN — CORRODED (RT WING) · corrosion level 1 · airframe 104,134 hrs · 20,886 cycles

DURING C-CHECK, MAINTENANCE FOUND CORROSION ON THE INTERSPAR SKIN AFT OF REAR SPAR. CORROSION WAS BLENDED OUT AS PER EO 4757A493 AND FAA 8100-9 DATED 1 FEB 2010.

Part: ACTUATOR — FAILED (MLG DOOR) · airframe 103,276 hrs · 20,789 cycles

AIR TURN BACK DUE TO RED GEAR LIGHT ILLUMINATED AFTER GEAR RETRACTION . F/E PANEL RIGHT WING GEAR DOOR OPEN ON BOTH PRIMARY AND ALTERNATE . AFTER FHB CHECK WITH GEAR EXTENDED LIGHTS EXTINGUISHED. RIGHT WING GEAR DOOR ACTUATOR REPLACED, GEAR SWING ACCOMPLISHED PER AMM 32-32-27, ALL OPERATION NORMAL.

Part: SKIN — CRACKED (ZONE 200) · airframe 103,032 hrs · 20,669 cycles

FUSELAGE SKIN RT SIDE ABOVE STABILIZER CUT-OUT AT STA 2589.5 TO 2598, SKIN MISSING CRACKED AND MISSING MATERIAL. PERMANENT REPAIR ACCOMPLISHED IAW SRM 53-30-03 FIG 1A. ALSO, REFERENCE EO 4753B229.

Part: SKIN — PUNCTURED (RT WING TE FLAP) · airframe 103,032 hrs · 20,669 cycles

RT WING INBD FLAP HAS 0.500 INCH DIAMETER PUNCTURED HOLE AT LWR SURFACE, WBL 188.30 AND 4.0 INCHES FROM L/E. PERMANENT REPAIR ACCOMPLISHED IAW SRM 51-40-09 FIG. 5, SHEETS 4 AND 8, 250* F CURE IAW SRM 51-40-12. REF: EO 4757A485.

Part: PANEL — CRACKED (ZONE 600) · airframe 101,539 hrs · 20,370 cycles

RT WING UPPER L/E PANEL HAS A 19 INCH COMPOSITE CRACK AT ILES 657.22, 5.0 INCHES FROM PANEL FRONT EDGE. PERMANENT REPAIR ACCOMPLISHED AS PER SRM 51-40-09 FIG 18, SHEETS 2 AND 5 AND SRM 51-40-12. REF ATLAS AIR EO 4757A467.

Part: PANEL — DELAMINATED (ZONE 100) · airframe 101,539 hrs · 20,370 cycles

RT WING PREVIOUS REPAIR ON UPPER WING SURFACE L/E PANEL AN AREA OF 6.0 BY 38.0 INCHES IS DELAMINATED AT ILES 522.06 AND 7.5 INCHES FROM PANEL FRONT EDGE. PERMANENT REPAIR ACCOMPLISHED AS PER B747-200 SRM 51-40-09 FIG 18, SHEETS 2, 5 AND SRM 51-40-12. REF. ATLAS AIR EO 4757A467.

Part: PANEL — CRACKED (RT WING)

RT WING UPPER LEADING EDGE PANEL HAS A 20.0 INCH COMPOSITE CRACK AT ILES 522.56 AND IS 26 INCHES FROM FORWARD END OF PANEL. PERMANENT REPAIR ACCOMPLISHED AS PER 747-200 SRM 51-40-09 FIG 18, SHEETS 2 AND 5, PREPEG LAYUP 250 DEGREES F CURE PER SRM 51-40-12. REFERENCE ATLAS AIR EO 4757A457. (S)

Part: PANEL — CRACKED (RT WING)

RT WING UPPER AFT TRAILING EDGE PANEL, OUTBOARD OF INBOARD AILERON HAS 2 EACH SMALL COMPOSITE CRACKS AT WBL 445.00. FORWARD CRACK IS .500 INCH LONG AND AFT CRACK IS 1.0 INCH LONG. PERMANENT REPAIR ACCOMPLISHED AS PER 747-200 SRM 51-40-09 FIG 2, SHEETS 2 AND 5, PREPREG LAYUP 250 DEGREES F CURE PER SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO 4757A456. (S)

Part: ENGINE — VIBRATION (NR 2)

BLOCK TURNBACK NR 2 ENGINE EGT FLAG IN VIEW WITH UNUSUAL NOISE (RUMBLING) HEARD AND FELT DURING THROTTLE MOVEMENT FROM NR 2 ENGINE. REPLACED ENGINE IAW WORK CARD E2008. (A)

Part: FLOORBEAM — CRACKED (ZONE 200) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK FLOORBEAM WEB FOUND CRACKED AT STA 1200 LBL 120. MAIN DECK FLOOR WEB CRACKED AREA REPAIRED PER EO 4753B154.

Part: FLOORBEAM — CRACKED (BS 1180) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK FLOORBEAM WEB FOUND CRACKED AT STA 1180 RBL 123. MAIN DECK FLOOR WEB CRACKED AREA REPAIRED PER EO 4753B153.

Part: FRAME — CRACKED (ZONE 200) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK STA 1740 STRINGER 13R - 14R FRAME FOUND CRACKED. FRAME CRACKED AREA REPAIRED PER EO NR 4753B152.

Part: PANEL — CRACKED (BS 800) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK L-2 DOOR FWD UPPER INNER REVEAL PANEL FOUND CRACKED. CRACKED AREA REPAIRED IAW EO NR 4753B148.

Part: FLOORBEAM — CRACKED (ZONE 200) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK FLOORBEAM WEB FOUND CRACKED AT STA 1180 LBL 120. MAIN DECK FLOOR WEB CRACKED AREA REPAIRED PER EO 4753B153.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

CABIN AND FLIGHT DECK UPPER DECK STA 540 LBL 10 SEAT TRACK FOUND WITH MINOR CORROSION. CORROSION REMOVED AND RETREATED PER SRM 53-10-01 AND 51-10-02.

Part: SEAT TRACK — CRACKED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

SEAT TRACK AT STA 1440 LBL 11 FOUND CRACKED. SEAT TRACK REPAIRED AS PER SRM 53-10-05 AND 51-30-02.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

FWD CARGO STA 640 LBL 20 FLOORBEAM UPPER CHORD FOUND CRACKED. FWD CARGO STA 640 LBL 20 FLOORBEAM UPPER CHORD CRACKED AREA REPAIRED AS PER SRM 51-40-04.

Part: DOOR FRAME — CRACKED (R5 DOOR) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK R5 DOOR FORWARD LOWER CORNER EDGE FRAME FOUND CRACKED. CRACKED AREA REPAIRED PER SRM 52-10-02.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK STA 980 RBL 33 SEAT TRACK OUTBOARD FLANGE FOUND CORRODED. CORROSION REMOVED PER SRM 51-10-01 AND 51-10-02.

Part: SEAT TRACK — CHAFED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK STA 935 LBL 33 SEAT TRACK FOUND CHAFED. REPAIRED SEAT TRACK PER SRM 51-10-02.

Part: SKIN — CORRODED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

AFT CARGO STA 1860 STR 45R- 46R FUSELAGE SKIN FOUND WITH LEVEL 1 CORROSION. CORROSION REMOVED PER SRM 51-10-02 AND 51-30-01.

Part: STOP FITTING — BROKEN (L3 DOOR) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK L3 DOOR AFT SIDE NR 2 COUNTED FROM BOTTOM STOP FITTING BROKEN. REPLACED STOP FITTING PER SRM 51-10-01.

Part: SEAT TRACK — CRACKED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK STA 1770 LBL 75 SEAT TRACK FOUND CRACKED. SEAT TRACK REPAIRED PER SRM 53-10-05.

Part: DOOR FRAME — CRACKED (L3 DOOR) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK L3 DOOR AFT UPPER CORNER EDGE FRAME FOUND CRACKED. CRACKED AREA REPAIRED PER SRM 52-10-02.

Part: SKIN — CHAFED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

FUSELAGE LOWER LOBE STA 220 - 240 LEFT SIDE STR 36L - 37L FOUND CHAFING. CHAFED AREA SMOOTHED OUT PER SRM 51-10-01.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

COCKPIT STA 330 RBL 65 FLOORBEAM UPPER CHORD CRACKED. REPAIRED FLOORBEAM CHORD AS PER SRM 51-40-04 FIG 2.

Part: SKIN — DENTED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

BODY STATION 220 STRINGER 28L FOUND AREA DENTED AS MARKED. DENTED AREA RE-WORKED AS PER SRM 51-10-01.

Part: BEAM — CRACKED (LT WING) · airframe 100,114 hrs · 20,082 cycles

LEFT WING LEADING EDGE "D" BEAM UPPER CHORD CRACKED ILES 1120. D' BEAM UPPER CHORD FABRICATED AND REPLACED IAW DRAWING 65B07895-139.

Part: REVEAL — CRACKED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK L4 DOOR CUTOUT FORWARD LOWER REVEAL PANEL FOUND CRACKED. REVEAL CRACKED AREA REPAIRED PER SRM 53-10-04.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

STATION 2160 STRINGER 44L FOUND LEVEL 1 CORROSION. CORROSION CLEANED UP IAW SRM 53-10-03.

Part: ACCESS DOOR — CORRODED (LT WING) · airframe 100,114 hrs · 20,082 cycles

NR 1 MAIN TANK ACCESS DOOR 552CB CUT OUT LOWER SURFACE CORROSION EVIDENT. BLENDED OUT CORROSION IAW SRM 57-30-03 AND REPROTECTED AREA IAW SRM 51-10-02.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK STA 980 RBL 45 TO RBL 55 FLOORBEAM UPPER CHORD FOUND WITH LEVEL 1 CORROSION. CORROSION REMOVED PER SRM 53-10-01, 51-10-01, 51-10-02.

Part: SEAT TRACK — CRACKED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

AFT CARGO STA 1590 LBL 45.5 SEAT TRACK FOUND CRACKED. AFT CARGO SEAT TRACK REPAIRED PER SRM 53-10-05.

Part: WEB — CRACKED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK STA 140 TO 150 RIGHT SIDE OUTBOARD WEB FOUND CRACKED. WEB REMOVED AND REPLACED PER SRM 51-10-01.

Part: SKIN — DEFORMED (L4 DOOR) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK L4 DOOR FORWARD LOWER CORNER EXTERNAL SKIN FOUND DEFORMED. L4 DOOR EXTERNAL SKIN REPAIRED AS PER SRM 51-10-01.

Part: FRAME — DEFORMED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK STA 1900 STRINGER 13R TO 14R FRAME FOUND DEFORMED. REPAIRED FRAME PER SRM 53-10-04.

Part: DOOR FRAME — DEFORMED (L5 DOOR) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK 5L DOOR FORWARD UPPER EDGE FRAME FOUND DEFORMED. PERFORMED DOOR EDGE RE-WORK AS PER SRM 51-10-01.

Part: SKIN — DEFORMED (R4 DOOR) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK 4R DOOR AFT LOWER CORNER EXTERNAL SKIN FOUND DEFORMED. PERFORMED EXTERNAL SKIN RE-WORK AS PER SRM 51-10-01.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

UPPER DECK STA 560-580 LBL 81 OUTBOARD FLOOR SUPPORT FOUND CORROSION. LEVEL 1, CORROSION REMOVED AS PER SRM 51-10-01.

Part: INTERCOSTAL — CRACKED (BS 1700-1720) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK 4R DOOR CUTOUT BS 1700 TO 1720 STRINGER 14R TO 15R INTERCOSTAL FOUND CRACKED. REPLACED INTERCOSTAL IAW 51-10-01.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 100,114 hrs · 20,082 cycles

COCKPIT STA 340 - 360 RIGHT SIDE OUTBOARD FLOORBEAM FOUND TO HAVE MINOR CRACK. WEB MINOR CRACK TRIMMED OFF PER SRM 51-10-01.

Part: DOOR FRAME — DEFORMED (L5 DOOR) · airframe 100,114 hrs · 20,082 cycles

MAIN DECK 5L DOOR AFT UPPER EDGE FRAME FOUND DEFORMED. PERFORMED DOOR EDGE RE-WORK AS PER SRM 51-10-01.

Part: CONTROL CABLE — BINDING (THROTTLE) · airframe 99,841 hrs · 20,089 cycles

AIR TURN BACK, NR 4 ENGINE THROTTLE ON REDUCED TAKEOFF, THRUST LEVER WAS BINDING AND HAD TO PUSH THROTTLE LEVER 1.5 KNOBS ABOVE THE OTHER THROTTLES TO SET POWER AND STILL COULD NOT REACH CLIMB THRUST. REMOVED AND REPLACED THROTTLE PUSH PULL CABLE AND PLA SENSOR IAW AMM 76-11-05 AND OPS CHECKED IAW 76-11-00. ALSO, PERFORMED TEST 4 PER AMM 71-00-00, OPS CHECKED NORMAL.

Part: PANEL — CRACKED (LWS 744) · airframe 99,574 hrs · 19,968 cycles

LT WING UPPER FIXED T/E PANEL AT WS 744.0 HAS A CRACK 6 INCHES FROM AFT EDGE OF PANEL. PERMANENT REPAIR ACCOMPLISHED AS PER B747-200 SRM 51-40-09, FIG 2, SHEET 1, 2 AND 5 PREPREG 250 DEGREES F CURE PER SRM 51-40-12. REF: ATLAS AIR EO NR 4757A420.

Part: SPOILER PANEL — DELAMINATED (ZONE 500) · airframe 99,574 hrs · 19,968 cycles

LT WING NR 2 SPOILER UPPER SURFACE HAS A PREVIOUS REPAIR DISBONDING AT I/B FWD END OF SPOILER. PERMANENT REPAIR ACCOMPLISHED AS PER B747-200 SRM 51-40-06, FIG 1, SHEET 2, FIG 4 SHEET 1, ALUMINUM HONEYCOMB REPAIRS, 250 DEGREES F CURE PER SRM 51-40-20. REFERENCE ATLAS AIR EO NR 4757A419.

Part: SEAT TRACK — CRACKED (ZONE 200) · airframe 99,574 hrs · 19,968 cycles

FOUND MAIN DECK CARGO SEAT TRACK AT BS 1920, LBL99 IS CRACKED. PERMANENT REPAIR ACCOMPLISHED AS PER B747-200 SRM 53-10-05, FIG 1A, REFERENCE ATLAS AIR EO NR 4753B118.

Part: GEARBOX — CRACKED (ZONE 400) · airframe 99,406 hrs · 19,929 cycles

NR 4 ENGINE GEAR BOX WAS FOUND WITH A 3.0 INCH CRACK ON INBOARD SIDE OF FUEL PUMP DRIVE PAD AREA. ENGINE CHANGE IS CURRENTLY IN PROGRESS.

Part: SELECTOR PANEL — FAILED (AUTOPILOT) · airframe 99,127 hrs · 19,870 cycles

A/P F/D SYSTEM "A" ROLL DC CIRCUIT BREAKER POPPED, PREVIOUSLY DETECTED ELECTRICAL ODOR MOMENTARILY.

Part: PANEL — CRACKED (LT WING) · airframe 98,936 hrs · 19,829 cycles

DURING ROUTINE INSPECTION FOUND LT WING L/E FIXED FIBERGLASS PANEL UPPER SURFACE AT WS 577/586 CRACKED LONGITUDINAL AND AT WS 752 PREVIOUS REPAIR DELAMINATED. PERMANENT REPAIRS ACCOMPLISHED IAW 51-40-09 AND 51-40-12, DOCUMENTED ON EO 4757A406.

Part: PANEL — CRACKED (RT WING) · airframe 98,936 hrs · 19,829 cycles

DURING ROUTINE INSPECTION FOUND RT WING L/E FIXED FIBERGLASS PANEL UPPER SURFACE CRACKED LATERAL 4" AT WS 1322. PERMANENT REPAIRS ACCOMPLISHED IAW SRM 51-40-09 AND 51-40-12. DOCUMENTED ON EO 4757A407.

Part: SKIN — DAMAGED (RT AILERON) · airframe 98,199 hrs · 19,674 cycles

RT OUTBOARD AILERON HAS A 5.250 INCH SCRATCH/GROOVE AT UPPER LEADING EDGE. PERMANENT REPAIR WAS ACCOMPLISHED AS PER B747-200 SRM 51-40-02 FIG 1, SHEETS 1, 2 AND 3. TOTAL WEIGHT OF MATERIAL USED FOR THIS REPAIR IS 0.15 LBS AND DOES NOT REQUIRE BALANCE ADJUSTMENT AS PER B747-200 SRM 51-80-02. ALSO, REFERENCE ATLAS AIR XEO NR 57-092107-1.

Part: PANEL — DELAMINATED (LT WING) · airframe 98,199 hrs · 19,674 cycles

LT WING, UPPER LEADING EDGE FIXED PANEL AT WING STATION 766 HAS AN AREA OF 12.0 INCH BY 12.0 INCH OF DELAMINATION. PERMANENT REPAIR WAS ACCOMPLISHED AS PER B747-200 SRM 51-40-09 FIG 18, SHEETS 1, 3 AND 5, AND SRM 51-40-12. ALSO, REFERENCE ATLAS AIR XEO NR 57-092107.

Part: DOOR — ERODED (LT MLG) · airframe 97,503 hrs · 19,523 cycles

RT AND LT WING GEAR UPPER STRUT DOORS HAS EROSION AND MATERIAL SEPARATING ON FORWARD LEADING EDGE. PERMANENT REPAIR WAS ACCOMPLISHED PER 747-200 SRM 51-40-09 FIG 18, SHEET 4, TABLE II AND 51-40-12 FIG 16 SHEET 1. ALSO, REFERENCE ATLAS AIR XEO NR 57-062707.

Part: ACCESS PANEL — DELAMINATED (RT WING) · airframe 97,503 hrs · 19,523 cycles

RT WING LOWER SIDE FUELING BAY ACCESS PANEL HAS 2 EACH AREAS OF INNER SKIN DELAMINATION. INBOARD SIDE AREA IS 4.0 BY 5.0 INCHES AND OUTBOARD SIDE IS 8.0 BY 10.0. PERMANENT REPAIR WAS ACCOMPLISHED ON AREAS AS PER 747-200 SRM 51-40-09 FIG 18, SHEET 1, 3 AND 5, TABLE 1, PREPEG 250 DEGREE F CURE. ALSO, REFERENCE ATLAS AIR XEO NR 57-062807.

Part: FLT CONTROLS — BINDING · airframe 96,575 hrs · 19,299 cycles

AT T/O WITH FLAP 20 DEGREES THE YOKE WOULD STICK AT ABOUT THE POINT OF 2 UNITS OF RIGHT AILERON TRIM. AFT FLAP WERE AT 10 DEGREES THE YOKE WOULD STICK AT THE SAME POINT, BUT TAKE LESS PRESSURE TO OVERCOME THE PROBLEM, ON APPROACH NO INDICATION OF STICKING WITH FLAPS UP OR AT NIL FLAPS SETTING DOWN TO 30 DEGREES. VERIFIED YOKE AND AILERONS, NOT BINDING PRIOR TO DEPARTURE WITH FLAPS UP AND FLAPS DOWN IAW MM 27-11-00.

Part: STRINGER — CORRODED (BS 1700 S46L) · corrosion level 2 · airframe 96,210 hrs · 19,219 cycles

AFT CARGO BS 1700 STRINGER S-46L FOUND CORRODED. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-272065605 AND FAA FORM 8100-9.

Part: FLOORBEAM — CRACKED (BS 400) · airframe 96,210 hrs · 19,219 cycles

BS 400 RT UPPER DECK FLOORBEAM UPPER CHORD FOUND HOLES AND CRACKED. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-271227292 AND FAA FORM 8100-9.

Part: SKIN — DAMAGED (BS 2300) · airframe 96,210 hrs · 19,219 cycles

FUSELAGE BS 2300 S-23 EXISTING DOUBLER FOUND DAMAGED. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-274437619.

Part: FLOORBEAM — CRACKED (BS 260) · airframe 96,210 hrs · 19,219 cycles

M/DECK STA 260 RBL90 FLOORBEAM UPPER CHORD FOUND CRACKED. REPAIRED ACCOMPLISHEED AS PER BOEING SR ID NR 1-273725179 AND FAA FORM 8100-9.

Part: FLOORBEAM — CRACKED (BS 380) · airframe 96,210 hrs · 19,219 cycles

UPPER DECK FLOOR BEAM UPPER CHORD LT STA 380 FOUND CRACKED. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-271217089 AND FAA FORM 8110-9.

Part: SHEAR WEB — CRACKED (BS 840) · airframe 96,210 hrs · 19,219 cycles

M/DECK STA 840 RT TENSION TIE ATT SLOPING WEB AT FWD CORNER FOUND CRACKED. REPAIRED ACCOMPLISHED AS PER SRM 51-30-02.

Part: SHEAR WEB — CRACKED (BS 840) · airframe 96,210 hrs · 19,219 cycles

M/DECK STA 840 LT TENSION TIE ATT SLOPING WEB FWD CORNER FOUND CRACKED. REPAIRED ACCOMPLISHED AS PER SRM 51-30-02.

Part: BEARING — MIGRATED (FLAP TRACK) · airframe 96,210 hrs · 19,219 cycles

RT WING NR 6 FLAP TRACK FWD ATTACH FITTING BEARING FOUND MIGRATED. REPAIRED ACCOMPLISHED AS PER SB747-57-2325.

Part: BEARING — MIGRATED (FLAP TRACK) · airframe 9,621 hrs · 19,219 cycles

LT WING NR 3 FLAP TRACK FWD ATTACH FITTING BEARING FOUND MIGRATION. REPAIRED ACCOMPLISHED AS PER SB747-57-2325.

Part: SHEAR TIE — CORRODED (BS 1800) · corrosion level 2 · airframe 96,210 hrs · 19,219 cycles

AFT CARGO STA 1800 FRAME SHEAR TIE S-50R TO S-51L FOUND CORRODED. AFT CARGO STA 1800 FRAME SHEAR TIE REPAIRED AS PER SRM 53-10-04 FIG 3A.

Part: SKIN — CHAFED (NR 3 NACELLE) · airframe 96,210 hrs · 19,219 cycles

NR 3 PYLON RT ACCESS PANEL 473AR CUTOUT AT NAC STA 286 TO STA 300 FOUND CHAFING. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-272049267 AND FAA FORM 8110-9.

Part: FRAME — CRACKED (BS 800) · airframe 96,210 hrs · 19,219 cycles

RT NR 2 MED FWD CUTOUT MIDDLE AREA FOUND CRACKED AT TWO LOCATIONS. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-272479981 AND FAA FORM 8110-9.

Part: ACCESS PANEL — WORN (NR 2 PYLON) · airframe 96,210 hrs · 19,219 cycles

NR 2 PYLON RT ACCESS PANEL 463AR CUTOUT FOUND WORN AT TWO POSITIONS. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-272049267 AND FAA FORM 8110-9.

Part: STRINGER — CORRODED (BS 2200-2220) · corrosion level 2 · airframe 96,210 hrs · 19,219 cycles

BULK CARGO STA 2200-2220 STR 49L FOUND CORRODED. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-271194583 AND FAA FORM 8110-9.

Part: BULKHEAD — CRACKED (BS 260) · airframe 96,210 hrs · 19,219 cycles

FUSELAGE STA 260 BULKHEAD LT LBL60 CANTED BULKHEAD WEB FOUND CRACKED. BULKHEAD STA 260 WEB REPAIRED AS PER SRM 53-10-04 FIG 47.

Part: SHEAR TIE — CORRODED (BS 1760) · corrosion level 2 · airframe 96,210 hrs · 19,219 cycles

AFT CARGO STA 1760 FRAME SHEARTIE S-50L TO S-51L FOUND CORRODED. AFT CARGO STA 1760 FRAME SHEAR TIE REPAIRED AS PER SRM 53-10-04 FIG 3A.

Part: ANGLE — DAMAGED (THRUST REVERSER) · airframe 96,210 hrs · 19,219 cycles

NR 2, NR 3 AND NR 4 LT FAN T/REV ACCESS DOOR CLOSEOUT ASSY ANGLE FOUND DAMAGED. REPAIR ACCOMPLISHED AS PER EO NR 4778A091 AND FAA FORM 8110-3.

Part: RING — DAMAGED (THRUST REVERSER) · airframe 96,210 hrs · 19,219 cycles

NR 3 ENGINE RT T/REV OUTER SUPPORT RING AFT I/B EDGE DAMAGED. REPAIRED ACCOMPLISHED AS PER EO NR 4778A090 AND FAA FORM 8110-3.

Part: SKIN — DEBONDED (NR 1 NACELLE) · airframe 96,210 hrs · 19,219 cycles

NR 1 ENGINE RT T/REV TRANSLATING COWL UPPER EDGE SKIN FOUND DEBOND. REPAIR ACCOMPLISHED AS PER EO NR 4778A088 AND FAA FORM 8110-3.

Part: TRANSFER TUBE — WORN (RT WING) · airframe 96,210 hrs · 19,219 cycles

RT WING NR 3 RESERVE TANK AT WS 1454 TRANSFER TUBE ASSY 2 COTTER PINS HOLES FOUND WORN. REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-276113094 AND EO NR 4728A027.

Part: FITTING — CRACKED (HORIZONTAL STAB) · airframe 96,210 hrs · 19,219 cycles

CRACKS FOUND ON RT HORIZ STAB AT HOLE 15 IN THE SPLICE PLATE AND HOLE 28 IN THE HINGE FITTING. REPAIRED ACCOMPLISHED AS PER BOEING SRM ID NR 1-273714301 AND FAA FORM 8110-9.

Part: RIB — CRACKED (LT WING LE) · airframe 96,210 hrs · 19,219 cycles

LT WING INBOARD FIXED LEADING EDGE RIB AT ILES 1024.45 FOUND CRACKED IN THE INTEGRAL STIFFENER ATTACHING THE UPSTOP FITTING INTERCOSTAL. INTERIM REPAIRED ACCOMPLISHED AS PER BOEING SR ID NR 1-271219411 AND FAA FORM 8100-9.

Part: COWLING — CRACKED (THRUST REVERSER) · airframe 96,210 hrs · 19,219 cycles

AS PER N/R 746, NR 3 ENG RT T/REV TRANSLATING COWL UPPER FAIRING (BEAVER TAIL) INTERIOR SKIN FOUND CRACKED. REPAIRED ACCOMPLISHED AS PER EO NR 4778A089 AND FAA FORM 8110-3 DATED 12 JAN, 2007.

Part: CREASE BEAM — CRACKED (BS 940-960) · airframe 96,210 hrs · 19,219 cycles

M/DECK STA 940-960 S-7R TO S-8R CREASE BEAM WEB FOUND CRACKED. REPAIRED ACCOMPLISHED AS PER SRM 51-10-01.

Part: SEAT — CRACKED (COCKPIT) · airframe 96,210 hrs · 19,219 cycles

CRACK AND GOUGES WERE FOUND ON 2ND OBSERVER SEAT. REPAIR ACCOMPLISHED AS PER EO NR 4725A223 AND FAA FORM 8110-3 DATED 17 JAN 2007.

Part: FRAME — CRACKED (ZONE 200) · airframe 96,210 hrs · 19,219 cycles

CABIN BS 2231 RT FRAME INNER CHORD S-25R FOUND CRACK ON FASTENER HOLE AT STRAP. REPAIR ACCOMPLISHED AS PER SRM 53-10-04 FIG 115.

Part: FRAME — CRACKED (BS 488) · airframe 96,210 hrs · 19,219 cycles

NR 1R BS 488 CUTOUT FRAME WEB AT STOP NR 1 FOUND CRACKED. NR 1R BS 488 FRAME REPAIRED PER SRM 53-10-04 FIG 92.

Part: FRAME — CRACKED (BS 2231) · airframe 96,210 hrs · 19,219 cycles

CABIN BS 2231 LT FRAME UPPER STRAP AND INNER CHORD FOUND CRACKED. CABIN BS 2231 LT FRAME UPPER STRAP AND INNER CHORD REPAIRED AS PER SRM 53-10-04 FIG 115.

Part: FRAME — CRACKED (BS 488) · airframe 96,210 hrs · 19,219 cycles

DURING PERFORMANCE OF EO NR 4753A531 AS PER AD 2005-22-06, AS PER NON ROUTINE CARD NR 212 CRACK FOUND DURING HFEC AT BS 488 MAIN ENTRY DOOR 1R CUT OUT FRAME WEB AT STOP 9. BS 488 MED FRAME REPAIRED AS PER SRM 53-10-04 FIG 121.

Part: DOOR FRAME — CRACKED (L1 DOORWAY) · airframe 96,210 hrs · 19,219 cycles

AT XMN UNDER C-1 CHECK, DURING PERFORMING EO NR 4753A531 AS PER AD 2005-22-06.AS PER NR NR 215, CRACK FOUND DURING HFEC AT BS488 ME DOOR 1L CUT OUT FRAME WEB AT STOP 9. RECTIFICATION, BS 488 MED 1L DOOR FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 121.

Part: ENGINE — FAILED (NR 4) · airframe 95,619 hrs · 19,061 cycles

AIR TURN BACK AFTER NR 4 ENGINE FLAMED OUT WHEN CLIMBING OUT, WHEN CLIMBING THROUGH F/L 260 INCH, A COUGH WAS HEARD PRIOR TO FLAME OUT. ENGINE WAS FOUND WITH METAL IN TAIL PIPE, ENGINE WAS REPLACED IAW CF6-50E2 POWERPLANT REMOVAL AND INSTALLATION FORM NR 01-AA-45. OPERATIONAL TEST GOOD IAW 747-MM 71-00-00.

Part: TRANSPONDER — UNSERVICEABLE (NR 1 AND 2) · airframe 95,246 hrs · 18,982 cycles

TRANSPONDER NR 1 AND NR 2 ALT REPORTING INCORRECTLY ABOVE 12,000 FT, AMBER "FAIL" LIGHT ON STEADY. ATC REPORTED ALTITUDE FROM 7,000 TO FL 250 MOSTLY 7,000. ON DESCENT AT APPROX 15,000 THE ATC READOUT STARTED, CLIMBING AND AT APPROX 12,000 FT MATCHED THE AIRPLANE ALTITUDE. TWAS FMS 1 "FAIL" MSG DISPLAYED WITH GREEN LIGHTED X. REMOVED AND REPLACED NR 1 AND NR 2 ATC XPONDER IAW AMM 34-53-02, OPS CHECK NORMAL. SECURED CONNECTOR ON TAWS INDICATOR, OPS CHECK NORMAL IAW AMM 34-46-30.

Part: SHEAR PIN — BROKEN (CARGO DOOR) · airframe 95,173 hrs · 18,967 cycles

AIR TURNBACK DUE TO SIDE CARGO DOOR OPEN INDICATION ILLUMINATED. MAINTENANCE FOUND SHEAR PIN BROKEN. SHEAR PIN REPLACED IAW AMM 52-11-11, ALL CHECK OK.

Part: COMPRESSOR — STALLED (NR 2 ENGINE) · airframe 94,971 hrs · 18,928 cycles

RTO: NR 2 ENGINE COMPRESSOR STALL ON T/O ROLL. EGT 1111 DEGREES FOR 4 SECONDS. FOUND METAL IN TAIL PIPE. LOCKED OUT ENGINE PER GMM 3.23.8. ENGINE TO BE REPLACED.

Part: SKIN PANEL — DELAMINATED (RT WING) · airframe 94,908 hrs · 18,917 cycles

RIGHT WING TOP LEADING EDGE PANEL AT ILES 682.50 HAS AN AREA OF 20 INCHES BY 12 INCHES OF DELAMINATION, 28 INCHES FROM FORWARD EDGE OF PANEL. ACCOMPLISHED PERMANENT REPAIR AS PER B747 SRM 51-40-09 AND 51-40-12. ALSO, REFERENCE ATLAS EO 4757A312.

Part: BULKHEAD — CRACKED (BS 1000) · airframe 94,219 hrs · 18,764 cycles

RT SIDE BS 1000 BULKHEAD CHORD AREA, CRACK REVEAL AT BULKHEAD CHORD HEEL AREA APPROX, 2" IN LENGTH JUST BELOW STR 38R. BS 1000 BULKHEAD CHORD BETWEEN STR 36/37R TO STR 40/41R CHORD SEGMENT REPAIRED AS PER SB 747-53A2471 R1. REPEAT INSPECTION IS REQUIRED AS PER SB 747-53A2471 R1 FIG 1.

Part: FLOORBEAM — DAMAGED (BS 340) · airframe 94,219 hrs · 18,764 cycles

BS 340 FLOORBEAM UPPER CHORD AFT FLANGE 3 HOLE AT LBL 29, 31 AND 32 FOUND CRACKS. BS 340 FLOOR BEAM UPPER CHORD AFT FLANGE LBL 29" OVERSIZE TO .309" AND GAGE DISTANCE .440" E/D = 1.423, WITHIN BS53A2431 PART 3 TABLE 1. REQUIREMENT, REPAIR IS NOT REQUIRED. U/D BS 340 FLOORBEAM UPPER CHORD AFT FLANGE LBL 31" AND 32" REPAIRED AS PER SB 53A2431 FIG 9. CONTINUED INSPECTION IS REQUIRED AS PER BS 53A2431 PART 3.

Part: FLOORBEAM — CRACKED (ZONE 200) · airframe 94,219 hrs · 18,764 cycles

BS 340 FLOORBEAM UPPER CHORD AFT FLANGE 1 HOLE AT RBL 41 FOUND CRACK RUNNING AFT. FLOORBEAM UPPER CHORD AFT FLANGE AT RBL 41" AREA HOLE OVERSIZED BY INCREMENT TO FINAL HOLE SIZE .309" GAGE DISTANCE IS 0.500". E/D= 1.618" WITHIN SB 53A2431 PART 3, TABLE 1 REQUIREMENT. NO REPAIR IS REQUIRED, CONTINUE INSPECTION IS REQUIRED AS PER SB 53A2431 PART 3.

Part: FLOORBEAM — CRACKED (BS 360) · airframe 94,219 hrs · 18,764 cycles

U/D BS 360 FLOORBEAM UPPER CHORD AFT FLANGE 1 HOLE AT RBL 43 FOUND CRACK RUNNING FWD. U/DECK BS 360 FLOORBEAM UPPER CHORD AFT FLANGE AT RBL 43" AREA. REPAIRED AS PER SB 53A2431 FIG 9. CONTINUE INSPECTION IS REQUIRED AS PER SB 53A2431 PART 3.

Part: BULKHEAD — CRACKED (BS 1000) · airframe 94,219 hrs · 18,764 cycles

LT SIDE BS 1000, BULKHEAD CHORD AREA, CRACK REVEALED AT BULKHEAD CHORD HEEL AREA APPROX, 1-1/4" IN LENGTH, JUST BELOW STR 38L. BS 1000 BULKHEAD CHORD BETWEEN STR 36/37L TO STR 40/41L CHORD SEGMENT REPAIRED AS PER SB 747-53A2474 R1. REPEAT INSPECTION IS REQUIRED AS PER SB 747-53A2471 R1 FIG-1.

Part: FLOORBEAM — CRACKED (BS 380) · airframe 94,219 hrs · 18,764 cycles

BS 380 FLOORBEAM UPPER CHORD FWD FLANGE 1 HOLE AT RBL 66 FOUND CRACK RUNNING FWD AND AFT. U/DECK BS 380 FLOORBEAM UPPER CHORD FWD FLANGE AT RBL 66" AREA REPAIRED AS PER SB 53A2431 FIG 9. CONTINUE INSPECTION IS REQUIRED AS PER SB 53A2431 PART 3.

Part: FLOORBEAM — CRACKED (BS 380) · airframe 94,219 hrs · 18,764 cycles

U/D BS 380 FLOORBEAM UPPER CHORD AFT FLANGE, 1 HOLE AT LBL 60 FOUND CRACK RUNNING AFT. U/DECK BS 380 FLOORBEAM UPPER CHORD AFT FLANGE AT LBL 60" AREA REPAIRED AS PER BS 53A2431 FIG 8. CONTINUE INSPECTION IS REQUIRED AS PER SB 53A2431 PART 3.

Part: FLOORBEAM — CRACKED (BS 360) · airframe 94,219 hrs · 18,764 cycles

U/D BS 360 FLOORBEAM UPPER CHORD FWD FLANGE, 2 HOLE AT RBL 48 AND 53 FOUND CRACK RUNNING AFT. BS 360 FLOORBEAM UPPER CHORD FWD FLANGE AT RBL 48" AND RBL 53". REPAIRED AS PER SB 53A2431 FIG 9. CONTINUE INSPECTION IS REQUIRED AS PER SB 53A2431 PART 3.

Part: STRUCTURE — CRACKED (PAX DOOR)

LOUD AIR LEAK FROM AROUND DOOR ON MAIN CARGO DECK. AREA BY PALLET POSITION LR-MR. AFT OBSERVATION WINDOW DOOR. REMOVED AND INSTALLED NR 4 MAIN ENTRY DOOR IAW AMM. LEAK CHECK IAW AMM. NO LEAK NOTED. CABIN PRESSURIZATION LEAKAGE TEST ACCOMPLISHED IAW MM. (K)

Part: FRAME — CRACKED (PAX DOOR)

DURING DESCENT, CABIN STILL CLIMBS APPROX 800 PER MINUTE WITH THROTTLES AT IDLE. REPEAT ITEM, SEE LOG PAGE 548463 ITEM 1. REMOVED AND REPLACED R2 DOOR ASSEMBY DUE TO CRACK IN DOOR FRAME PER MM 52-11-01. PER BOEING TELECOM 1-195VDL CONVERTED DOOR TO CARGO FROM PAX CONFIG. FUNCTIONAL CHECK NORMAL PER MM 52-11-09 AND 52-11-02, LEAK CHECK AND OPS CHECK NORMAL. REMOVED DOOR S/N 000901. (M)

Part: MECHANISM — BROKEN (L1 DOOR)

AFTER TAKEOFF AT APPROX 2,500 FT, THE LT ENTRY DOOR (L1) DOOR LIGHT CAME ON. ACCOMPLISHED CHECK LIST. THEN HEARD A LOAD NOISE WITH AIRCRAFT PRESS CLIMBING. RETURNED TO SFO. AFTER LANDING, FOUND DOOR LOCKING LUG BROKEN OFF. ACCOMPLISHED DETAILED INSPECTION OFF L1 DOOR MM. REPLACED UPPER AND LOWER AFT LATCH ROLLER CRANKS. ACCOMPLISHED ADJUSTMENT CHECK AND LEAK CHECK OF L1 DOOR. PERFORMED PRESSURE CHECK OF L1 DOOR. PRESSURE CHECK GOOD.

Part: INDICATOR — MALFUNCTIONED (HSI)

DURING CLIMB, WHEN CLEARED INS WAYPOINT AND SELECTING INS MDU, CDI ON C/A AND F/O HSI WOULD NOT CENTER X WHEN CLEARED VOR AND SELECTING ON INS MDU, HSI SHOWED ABOUT 30 DEGREE DIFFERENCE IN UPDATE. EXCESSIVE DIFFERENCE IN DRIFT ON ARRIVAL . 23400 FUEL DUMPED. AC RETURNED. INS CHECKED OUT IAW 34-41-00. HSI/ADI INTERFACE CHECKED ALL INDICATION IS NORMAL W/OUT REMARKS.

Part: BUSHING — WORN (WING)

(D) CHECK, DURING SCHEDULE MAINTENANCE, NR 8 MOVEABLE CANOE AFT SECTION SECONDARY DOOR ASSEMBLY LOWER BEARING FOUND MIGRATED. THE LUG BORES ARE OVERSIZED TO 0.7827 INCH DIAMETER TO REMOVE DAMAGE. NDT INSPECTED TO ENSURE CRACK AND DEFECT FREE. AN ALUMINUM REPAIR SLEEVE WAS INSTALLED, COMPLETE WITH A NEW DESIGN TYPE BEARING.

Part: SKIN — CRACKED (ACCESS CUT OUT)

D CHECK, DURING SCHEDULE MAINTENANCE. CRACKS WERE FOUND ON NR 1 PYLON PERCOOLER EXHAUST CUTOUT AFT LOWER CORNER. ON THE RT SIDE OF STRUT STRUCTURE ASSY, THE OUTER SKIN WAS TRIMMED. NDT INSPECTION WAS ACCOMPLISHED TO ENSURE CRACK AND DEFECT FREE CONDITION. INSTALLED AN ALUMINUM FILLER OF 2024-T3. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEAL LOWER REPAIR ANGLE FROM STA 235 TO STA 254. THE RIB INSTALLATION AT NAC STA 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLES INSTALLATION ON THE NR 3 STIFFENER. FORM 8110-3 ISSUED.

Part: SKIN — CRACKED (NR 2 PYLON)

D CHECK, DURING SCHEDULE MAINTENANCE. CRACKS WERE FOUND ON NR 2 PYLON PRECOOLER EXHAUST CUTOUT AFT LOWER CORNER. ON THE RT SIDE OF STRUT STRUCTURE ASSY, THE OUTER SKIN WAS TRIMMED. NDT INSPECTION WAS ACCOMPLISHED TO ENSURE CRACK AND DEFECT FREE CONDITION. INSTALLED AN ALUMINUM FILLER OF 2024-T3. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEAL LOWER REPAIR ANGLE FROM STA 235 TO STA 254. THE RIB INSTALLATION AT NAC STA 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLES INSTALLATION ON THE NR 3 STIFFENER. FORM 8110-3 ISSUED.

Part: SKIN — CRACKED (NR 4 PYLON)

D CHECK, DURING SCHEDULE MAINTENANCE. CRACKS WERE FOUND ON NR 4 PYLON PRECOOLER EXHAUST CUTOUT AFT LOWER CORNER. ON THE RT SIDE OF STRUT STRUCTURE ASSEMBLY, THE OUTER SKIN WAS TRIMMED. NDT INSPECTION WAS ACCOMPLISHED TO ENSURE CRACK AND DEFECT FREE CONDITION. INSTALLED AN ALUMINUM FILLER OF 2024-T3. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEAL LOWER REPAIR ANGLE FROM STA 235 TO STA 254. THE RIB INSTALLATION AT NAC STA 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLES INSTALLATION ON THE NR 3 STIFFENER. FORM 8110-3 ISSUED.

Part: SKIN — CRACKED (NR 3 PYLON)

D CHECK, DURING SCHEDULE MAINTENANCE. CRACKS WERE FOUND ON NR 3 PYLON PRECOOLER EXHAUST CUTOUT AFT LOWER CORNER. ON THE RT SIDE OF STRUT STRUCTURE ASSY, THE OUTER SKIN WAS TRIMMED. NDT INSPECTION WAS ACCOMPLISHED TO ENSURE CRACK AND DEFECT FREE CONDITION. INSTALLED A ALUMINUM FILLER OF 2024-T3. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEAL LOWER REPAIR ANGLE FROM STA 235 TO STA 254. THE RIB INSTALLATION AT NAC STA 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLES INSTALLATION ON THE NR 3 STIFFENER. FORM 8110-3 ISSUED.

Part: STIFFENER — CRACKED (NR 1 PYLON)

D CHECK, DURING SCHEDULE MAINTENANCE OF NR 1 PYLON, THE LHS NR 5 STIFFENER END WAS FOUND CRACKED AT NAC STA 288.0 WL 146.5. TRIMMED OFF THE CRACKED STIFFENER END. FABRICATED A REPAIR PLATE TO MATCH THE TRIMMED OFF PORTION OF THE STIFFENER ATTACHING FLANGE. FABRICATED TWO REPAIR ANGLES AND A HORIZONTAL WEB FILLER. THE REPAIR PARTS WERE INSTALLED WITH HI-LOK FASTENERS. FORM 8110-3 ISSUED.

Part: BEAM — CRACKED (RT WING)

D CHECK, CRACKS WERE FOUND AT RT WING LE LOWER OUTBOARD BEAM LOCATIONS AT ILES 414.50 AND 543.93. TRIMMED OUT CRACKED PORTIONS OF BEAM NDT INSPECTED TO ENSURE CRACK AND DEFECT FREE CONDITION. SPLICED IN REPLACEMENT SECTIONS OF BEAM BETWEEN TRIM LINES AND PRODUCTION SPLICES. REFINISHED BEAM TO DESIGNED CONDITION. FORM 8110-3 ISSUED.

Part: SKIN — DENTED (NR 2 PYLON)

DURING A MAINTENANCE INSPECTION, WRINKLED SKIN/ DENTS WERE FOUND ON THE EXTERIOR SKIN ASSEMBLY OF NR 2 PYLON JUST AFT OF THE TITANIUM DOUBLER, BETWEEN THE MID SPAR CHORD AND NR 5 STIFFENER. AFFECTED SKIN ASSEMBLY WAS TRIMMED TO REMOVE DAMAGE. NDT INSPECTION, INCLUDING HFEC OF SKIN TRIMMED EDGES AND REPAIR FASTENER HOLES WAS ACCOMPLISHED TO ENSURE DAMAGE FREE CONDITION. A NEW SKIN REPAIR DOUBLER ASSEMBLY WAS INSTALLED FROM STA 286 TO STA 300. THE REPAIR DOUBLER ASSY IS MADE FROM TWO STAGGERED LAYERS OF TITANIUM SHEET AND INSTALLED JUS AFT OF THE TITANIUM SKIN DOUBLER EXTENSION. THE REPAIR TITANIUM DOUBLERS ARE ATTACHED TO THE EXISTING TITANIUM DOUBLER EXTENSION WITH A NEW TITANIUM TRIPLER.

Part: SKIN — DENTED (NR 3 PYLON)

D CHECK, DURING A MAINTENANCE INSP, WRINKLED SKIN/ DENTS WERE FOUND ON THE EXTERIOR SKIN ASSEMBLY OF NR 3 PYLON JUST AFT OF THE TITANIUM DOUBLER, BETWEEN THE MID SPAR CORD AND NR 5 STIFFENER. AFFECTED SKIN ASSEMBLY WAS TRIMMED TO REMOVE DAMAGE. NDT INSP, INCLUDING HFEC OF SKIN TRIMMED EDGES AND REPAIR FASTENER HOLES WAS ACCOMPLISHED TO ENSURE DAMAGE FREE CONDITION. A NEW SKIN REPAIR DOUBLER ASSEMBLY WAS INSTALLED FROM STA 286 TO STA316. THE REPAIR DOUBLER ASSEMBLY IS MADE FROM TWO STAGGERED LAYERS OF TITANIUM SHEET AND INSTALLED JUST AFT OF THE TITANIUM SKIN DOUBLER EXTENSION. THE REPAIR TITANIUM DOUBLERS ARE ATTACHED TO THE EXISTING TITANIUM DOUBLER EXTENSION WITH A NEW TITANIUM TRIPLER.

Part: FRAME — CRACKED (NR 3 PYLON)

D CHECK, DURING SCHEDULE MAINTENANCE INSPECTION OF NR 3 PYLON, THE BULKHEAD UPPER ASSEMBLY RHS FORWARD ANGLE FRAME FLANGE WAS FOUND CRACKED AT THE END FASTENER HOLE COMMON TO THE FRONT SPAR FITTING AND STRUT CAP SKIN ASSY. FABRICATED A REPAIR ANGLE TO RESTORE THE DAMAGED ANGLE SECTION, EXCEPT EXTENDED IT TO MATCH THE EXISTING FRAME ANGLE. FORM 8110-3 ISSUED.

Part: SKIN — DENTED (FUSELAGE)

DURING D CHECK, SKIN DENT FOUND ON FWD CARGO DOOR CUTOUT. A SKIN GOUGE ON THE SKIN OF THE FORWARD CARGO DOOR CUTOUT AFT SKIN EDGE, BS670, BETWEEN S-37 AND S-38 WAS REPAIRED BY TRIMMING OUT THE GOUGE. A HFEC AND DETAILED VISUAL INSPECTION WITHIN 20 INCHES WAS ACCOMPLISHED. FORM 8110-3 ISSUED.

Part: FLOORBEAM — DAMAGED (FUSELAGE)

DURING D CHECK, FOUND UPPER DECK FLOORBEAM, ONE ELONGATED HOLE WITH A SHORT EDGE MARGIN WAS FOUND COMMON TO STA 360 UPPER DECK FLOORBEAM UPPER CORD. THIS AIRCRAFT WAS MODIFIED TO A SPECIAL FREIGHTER CONFIGURATION. OVERSIZED SME HOLE TO 0.250 INCH DIAMETER (CLOSE REAM ACCEPTABLE) USED OPEN-HOLE HFEC INSPECTION TO CONFIRM ALL HOLES COMMON TO THE MODIFICATION/ REINFORCING STRAP ARE CRACK FREE. FORM 8110-3 ISSUED.

Part: HOUSING — CORRODED (TE FLAP CARRIAGE)

DURING D CHECK AT SIN, PITTED CORROSION FOUND OUTBOARD TRAILING EDGE MID-FLAP IB CARRIAGE BRG HOUSING. REMOVED LOCAL SURFACE DAMAGE FROM THE AFFECTED AREA OF HOUSING. NDT INSPECTED TO INSURE CRACK AND DEFECT FREE CONDITION. SMOOTH, BLENDED AND REFINISHED HOUSING TO DESIGN CONDITION. INSTALLED OVERSIZED BUSHING IAW REQUIREMENTS OF OHM 57-52-55.

Part: HINGE FITTING — WORN (LT COWLING)

DURING CURRENT C-CHECK AT SIAEC, FOUND NR 3 ENGINE LEFT AFT FAN COWL HINGE SUPPORT FITTING WITH WEAR DAMAGE IN THE LUG BORE HOLE. REAMED LUG BORE HOLE OVERSIZED TO .610 INCH. PERFORMED MAGNETIC PARTICLE INSPECTION FOR CRACKING. NO CRACKS FOUND. FABRICATED INTERFERENCES BUSHING. INSTALLED BUSHING PER STANDARD SHRINK FIT METHOD IAW BOEING STANDARD OVERHAUL PRACTICES 71-11-21 REV 2. (M)

Part: DAMPER — MALFUNCTIONED (AUTOPILOT SYS)

DURING CLIMB-OUT FROM MIA PASSING FL 33, FELT ABRUPT UNCOMMANDED YAW OF AIRCRAFT. LOWER RUDDER INDICES SHOWED DISPLACEMENT 5 DEGREES RIGHT OF CENTER. UPPER RUDDER INDICES SHOWED CENTERED. TURNED OFF LOWER YAW DAMPER, CONDITION STOPPED. INITIATED RETURN TO MIA. (M)

Part: FRAME — CRACKED (FUSELAGE)

AT C-CHECK WHILE CONDUCTING A THROUGH VISUAL STRUCTURES INSPECTIONS, FOUND VERTICAL SUPPORT FRAMES OF RADAR SUPPORT ANTENNA CRACKED AT BS 140. LEFT SIDE CRACKED 3 INCHES FROM LOWER CLIP AREA. RIGHT SIDE CRACKED .5 INCH THROUGH ONE FASTENER AT LOWER CLIP. REPLACED FRAMES PER SRM 51-30-02. BOEING ADVISED AND ACCOMPLISHED RADAR ALIGNMENT PER SRM REPAIR INSTRUCTIONS. BOEING MAINTENANCE RELEASE DOCUMENT ISSUED. (M)

Part: AIRSPEED — DEFECTIVE (LT/RT COCKPIT)

FLT TG891 - BTB - DURING TAKEOFF ROLL, F/O'S AIRSPEED INDICATOR DID NOT MOVE AND CAPTAINS AIRSPEED INDICATOR JUMPED FROM 70 TO 80 KNOTS. RETURNED TO BLOCKS AND DURING TROUBLESHOOTING CONFIRMED THAT BOTH AIRSPEED INDICATORS WERE DEFECTIVE. REPLACED CAPTAINS AND F/O'S AIRSPEED INDICATOR P/N A4321710016. PERFORMED PITOT/STATIC TEST AND BOTH SYSTEMS NOW OPERATE NORMAL. (M)

Part: AIR DISTRIBUTION — ODOR (COCKPIT)

FRA/SHJ - FLT TG891 - AFTER TOP OF DESCENT, A STRONG ELECTRICAL SMELL WAS NOTED. FLIGHT DECK FAN WAS ON AT THE TIME FOR APPROX 10 MINUTES. FAN SWITCHED OFF. P6 CIRCUIT BREAKER PANEL (FRONT, BACK, AND UNDER F/E TABLE) WERE CHECKED FOR SMOKE AND ODORS. THE SMELL SEEMED PREDOMINANTLY TO COME FROM F/O SIDE, MORE FROM TOP OF HIS GLARESHIELD THAN UNDER. SMELL DISSIPATED APPROX 5 MINUTES AFTER TURNING FLT DECK FAN OFF. FAN RAN ON GROUND FOR APPROX 10 MINUTES WITH NO RECURRENCE. (X)