N536MC

Part: SHEAR TIE — CRACKED (FUSELAGE)

FRAME 440, RT SIDE BETWEEN STRINGERS 10A AND 11 TOP HOLE OF FRAME TO FUSELAGE SKIN ATTACHMENT ANGLE HAS .2500 INCH CRACK GOING UPWARD AND .0625 INCH CRACK GOING DOWNWARD. CUTOUT CRACKED SECTION OF ATTACHMENT ANGLE IAW SRM. ACCOMPLISHED HFEC INSP OF CUTOUT OF DAMAGE IAW NDT. NO DEFECTS NOTED. INSTALLED REPAIR ANGLE IAW SRM. EO ISSUED TO DOCUMENT MAJOR REPAIR. (K)

Part: PYLON — CRACKED (NR 4)

NR 4 PYLON OB SKIN FOUND (2) CRACKS ON ACCESS DOOR 482AR CUTOUT CRACK 1INCH TO 1.5 INCH ON BOTH SKIN AND DOUBLER. (K)

Part: PAN — CRACKED (FUSELAGE)

LT SIDE CANTED BULKHEAD AT BS 1245, LBL 60 CLOSURE PAN FOR AILERON CONTROL CABLE FEED THROUGH TO PRESSURE DECK FOUND WITH (2) CRACKED LINES. CLOSURE PAN REPAIRED IAW MFG MM. (K)

Part: BULKHEAD — CRACKED (FUSELAGE)

BS 400 BULKHEAD WEB CUT OUT FOR NOSE GEAR RETRACT ACTUATOR PAN FOUND BOTH LOWER CORNERS CRACKED. (K)

Part: PYLON — CRACKED (NR 1)

LT WING NR 1 PYLON STRUT DOOR 453BL UPPER CORNER CRACKED. (K)

Part: PRECOOLER — CRACKED (ENGINE)

PYLONS NR1, 2, 3, AND 4, PRECOOLER EXHAUST CUT OUT LOWER EDGE CRACKED. REPAIRS ACCOMPLISHED IAW MM. (K)

Part: FRAME — CRACKED (FUSELAGE)

NOSE WHEEL WELL STRUCTURE ON INTERIOR OF FUSELAGE CHORD CRACKED AT BS 340, WL 200, LBL 10. REPAIRED IAW MFG MM. (K)

Part: PRESSURE PANEL — CORRODED (FUSELAGE)

BS 1408, LBL 78 WHEEL WELL PRESSURE DECK CORRODED AT FASTENERS LOCATIONS. PRESSURE DECK REPAIRED IAW MM. (K)

Part: SKIN — CRACKED (FUSELAGE)

NR 1 PYLON LT ACCESS DOOR 452BL CUT OUT LOWER EDGE CRACKED. REPAIRED ACCOMPLISHED IAW MFG MM. (K)

Part: FAIRING — MISSING (LT HORIZ STAB)

ON WALK AROUND CHECK, FOUND LT AFT TIP FAIRING OF HORIZONTAL STABILIZER MISSING. EO ISSUED TO ACCOMPLISH TIME-LIMITED REPAIR WORK TO BE DONE PRIOR TO FURTHER FLIGHT. FABRICATED A TIME LIMITED REPLACEMENT FAIRING FROM 0.040 INCH THICK 2024-T3 CLAD SHEET. PERMANENT REPAIR TO BE ACCOMPLISHED IAW EO WITH IN 25 FLIGHT CYCLES. (K)

Part: CONNECTOR — LOOSE (NR 4 SLAT)

NR 4 LEADING EDGE FLAP WOULD NOT RETRACT OR EXTEND NORMALLY OR ELECTRICALLY. JETTISONED 60.0 K FUEL. FOUND FORWARD CONNECTOR LOOSE ON L/E DRIVE UNIT. RESECURED CONNECTOR IAW MM. OPS CHECK OK, NORMAL. (K)

Part: SEAL — WORN (AIR DISTRIBUTION)

MXP-BOM - WITH NR 1 PACK ONLY ON OPERATION AT FL280 AND 310, CABIN ALTITUDE WILL CONTINUE TO CLIMB AT 10 TO 20 FPM. IN CRUISE WITH BOTH OUTFLOW VALVES FULL CLOSED AND DIFF PRESSURE DECREASING FROM 8.4 PSI WITH NO DROP IN DUCT PRESS, DUCT PRESSURE 42 PSI. AFTER TURNING NR 2 PACK ON, CABIN ALT WILL RETURN TO NORMAL. PERFORMED ENGINE BLEED DISTRIBUTION SYSTEM OPERATIONAL TEST IAW MM 36-11-00, FOUND AIR LEAK FROM NR 1 PACK AIR SUPPLY DUCT TO PACK CONTROL SHUTOFF VALVE. REPLACED DUCT SEALS AND LEAK CHECKED OK. PERFORMED CABIN PRESSURE LEAKGATE TEST IAW 5-51-08 ALL WITHIN LIMITS. (M)

Part: VALVE — MALFUNCTIONED (NR 4 ENGINE)

MXP-ALA - AT 1741Z ON TAKEOFF ROLL AT APPROXIMATELY 120 KNOTS EXPERIENCED THE NR 4 ENGINE FIRE INDICATION. N1 SET AT 106.0. PERFORMED A REJECTED IAW THE FHB. ONCE STOPPED, THE ENGINE FIRE CHECKLIST WAS ACCOMPLISHED. JUST PRIOR TO ROLLING, NR 4 ENGINE FIRE SWITCH FIRE LIGHT DID EXTINGUISH. AT 1741Z AFTER THE REJECT, THE BRAKE OVERHEAT LIGHT ILLUMINATED FOR ALL WING AND BODY GEAR. ALL OVERHEAT METERS INDICATED IN THE RED ZONE. TOW WAS 319.0 KGS, REJECT SPEED WAS 120 KTS. DURING NR 4 ENGINE INSPECTED NO SIGN OF FIRE NOTE. FIRE WARNING WAS INITIATED BY HEAT CAUSED BY LOOSE CLAMP ON HIGH STAGE VALVE DUCT AND CONSEQUENT AIR LEAK. CLAMP REPSOITIONED AND SECURED PROPERLY INSTALLED. PERFORMED NR 4 ENGINE PNEU

Part: VALVE — ERRATIC (NR 4 ENGINE)

NR 4 ENGINE SHUTDOWN DURING DECENT: NR 4 ENGINE SHUTDOWN RUMBLE AND EGT RISING. AFTER RISING RELIGHT IS STARTED SURGING. SHUTDOWN AGAIN. NR 4 HIGH STAGE VALVE DEACTIVATED, CLOSE AND PERFORMED ENGINE RUN UP, CHECK NORMAL, ENGINE RUN BY FLT CREW AND NR 4 ENGINE INSPECTED OK IAW MM 72-00-00, ITEM DEFFERED TO MEL 36-1. CONF NR M04-163. DMI M04-163 IS CLOSED 7/12/04 AT ORD.

Part: BLEED VALVE — MALFUNCTIONED (NR 2 ENGINE)

DURING CLIMB-OUT, NR 2 ENGINE COMPRESSOR STALLED. NR 2 ENGINE SUSTAINED 6 OR MORE HARD COMPRESSOR STALLS WHILE CLIMBING THROUGH 18,000 FT TO 24,000 FT. INSPECTED INTAKE/EXHAUST AREAS, NIL DISCREPANCIES. CHIP DETECTORS CLEAN REMOVED AND REPLACED SAME 8TH STAGE CHECK VALVE AFTTER INSPECTION. ALL OK. CHECKED ALL DUCTS ENGINE AREA FOR LEAKS/CHECKED DUCTS ETC. NIL DISCREPANCIES NOTED. STALL INSPECTIONS COMPLETED PER L/P 522816 NR 1. AIRCRAFT WAS DIVERTED TO FCO/PIK. (M)

Part: ENGINE — MALFUNCTIONED (NR 3)

PRIOR TO TAKEOFF, DUE TO ANTI-ICE ON, STAT 'C' RUN AT 60 PERCENT. N1 WAS NORMAL. WITH BRAKE RELEASE, TAKEOFF THRUST SET, ROLLING DOWN RUNWAY 13, ASI BELOW 60 KNOTS, NR 3 ENGINE HAD 'BACKFIRED WITH A LOUD NOISE', WITH REDUCTION IN N1 RPM OF ABOUT 10-15 PERCENT AND PEAK EGT OF APPROX 920 DEG C WHILE OTHER ENGINE EGT WERE APPROX 800 DEGREES CELSIUS DISCONNECT THE TAKEOFF, AND S/D THE ENGINE ON WAY BACK TO RAMP. CHECKED INLET AND EXHAUST AREAS FOR DAMAGE AND FOD, NONE FOUND. VISUALLY INSPECTED SVS/VBV RIG CHECK IAW MM 75-30-00/75-31-02. NIL DISCREPANCIES. LOCKED OUT HIGH STAGE VALVE FOR TROUBLE. SHOOTING PERFORMED TAKEOFF POWER ROLL TO 80 KTS. ENGINE PERFORMANCE TO 112 PERCENT N1 NORMAL ON TWO RUNS.

Part: VALVE — INOPERATIVE (NR 3 ENGINE)

AZ9051 PVG/HKG NR 3 ENG BLEED OVERHEAT LIGHT CAME ON DURING TAKEOFF. FOLLOWED CHECKLIST IAW 3.36.5, NR 3 THRUST LEVER BACK TO IDLE LIGHT WILL EXTINGUISH. BUT LIGHT WILL COME BACK ON IF PUSH THRUST LEVER FORWARD MORE THAN 70 PERCENT N1. NR 3 THRUST LEVER USED IN IDLE FOR REMAINING OF FLIGHT. NR 3 ENGINE PNEUMATIC DUCT LEAK CHECK CARRIED OUT, NIL LEAKS. FAN AIR MODULATING VALVE SENSE LINES LEAK CHECK NIL. FAN AIR MODULATING VALVE REPLACED IAW AMM. TEMPERATURE SENSOR BODY AND PLUG CLEANED. HIGH POWER RUN CARRIED OUT ALL NORMAL. DUMPED 30.0 KG FULE TO MEET MAX LANDING WEIGHT.

Part: CLAMP — BROKEN (RN 2 BLEED VALVE)

LEFT WING OVERHEATED TWICE ON CLIMB-OUT AND THEN IN CRUISE. COMPLETED CHECKLIST TO ISOLATE LEFT WING WITH ONLY NR 2 ENGINE PYLON VALVES OFF, AND ISOLATION VALVE OPEN. FOLLOWING CLIMB FL320 TO FL350 WITH NR 1 AND NR 2 ENGINES BLEED VALVES CLOSED AND LEFT AND RIGHT ISOLATION VALVES OPEN WITH BOTH AIRCRAFT PACKS VALVES OPEN, LEFT WING OVERHEAT REOCCURRED. AS PER CHECKLIST COMPLETELY ISOLATED LEFT BLEED MANIFOLD FOR REMAINDER OF FLIGHT. FOUND NR 2 PYLON BLEED AIR VALVE AFT CLAMP BROKEN, BLEED AIR LEAKING. REMOVED AND REPLACED CLAMP IAW MM 36-11-04. LEAK CHECK GOOD. NO OVERHEAT INDICATION NOTED AND NO OVERHEAT DAMAGE NOTED. OVERHEAT TESTED IAW MM 36-22-01, OPERATION CHECK GOOD. (M)

Part: CONTROL CABLE — ICED (NR 3 THROTTLE)

NR 3 ENGINE THROTTLE UNABLE TO SELECT IDLE DURING DESCENT. THROTTLE STUCK AT 4 DEGREE THROTTLE ANGLE AND 80 PERCENT N1. ENGINE SHUTDOWN USING ENGINE FAILURE/SHUTDOWN CHECKLIST. PERFORMED INSPECTION IAW 73-21-01 AND 76-11-03 THRUST CONTROL CABLE INSPECTED ALL NORMAL. SUSPECT MOISTURE ICING BUILD INSIDE. RUN ENGINE ALL NORMAL. (M)

Part: CLAMP — LOOSE (BLEED AIR)

NR 1 ENGINE FIRE WARNING LIGHT ILLUMINATED & FIRE BELL ACTIVATED DURING CLIMB THROUGH 3000 FT. NR 1 ENGINE NACELLE TEMP INDICATES 'F' FOR BOTH 'A' AND 'B' LOOPS. ENG FIRE CHECKLIST ACCOMPLISHED. 80,000 KGS OF FUEL DUMPED. AFTER PULLING FIRE HANDLE LIGHT WENT OUT IMMEDIATELY. FIRE BOTTLE WAS NOT DISCHARGED. NR 1 ENGINE TEMP LOOPS STILL IN THE 'F' RANGE. A/C ARRIVED WITH NR 1 ENGINE T/R DEPLOYED. EXTERNAL CHECKS, NO SIGN ON O/H OR DAMAGE. T/R STOWED AND FUNCTION CHECKED USING PNEUMATICS FROM APU SAT. ENGINE DUCT SEPARATION/RUPTURE INSPECTION ACTIONED IAW MM 5-51-86. PNEUMATIC TEST ACTIONED IAW MM 71-00-00. PNEUMATIC LEAK FOUND AT CLAMP DOWN STREAM OF HIGH STAGE BLEED VALVE & BEFORE PRV. CLAMP TAPPED

Part: FIRE WARNING — ACTIVATED (COCKPIT)

FLT GT020 - FIRE WARNING BELL AND LIGHT SOUNDED ON FORWARD COCKPIT LIGHT FOR CARGO AREA, BUT WENT OUT TOO FAST TO CHECK F/E PANEL. CHECK CARGO AREA FIRE TEST AND INDICATION AND NO ABNORMALITIES NOTED. (M)

Part: FRAME — CORRODED (BS 1319)

INSPECTION OF STA 1319 FRAME REVEALED CORROSION ABOVE THE LEFT HAND LONGERON BEAM. THE AREA WAS REPAIRED IAW ATLAS AIR EO 4753A085. (X)