N540UA

Part: FAIRING — DAMAGED (LT AILERON) · airframe 73,001 hrs · 26,673 cycles

LT WING AILERON OTBD ACTUATOR FAIRING 56 1EB DAMAGED. ACCOMPLISHED INTERIM REPAIR TO THE LT AILERON OTBD FWD FAIRING IAW ITEM 100 IPC 57-51-1 1-001. SEAL HAS BEEN REMOVED IAW CDL ITEM DF469 CREATED. OPERATION CHECK OF AILERON ACCOMPLISHED IAW AMM 27-11-00-201 & CHECKED GOOD. ACCOMPLISHED INSPECTION AS CALLED OUT IN ECRA WITH NO DAMAGE.

Part: LIGHT — INOPERATIVE (R1 DOOR) · airframe 72,836 hrs · 26,615 cycles

DOOR 1R ARM LIGHT WILL NOT ILLUMINATE. REPLACED BULBS OPERATIONS CHECKED GOOD .

Part: LIGHT — MISSING (DOOR) · airframe 72,462 hrs · 26,496 cycles

DOOR 4L ARMING LIGHT MISSING. REPLACED DOOR 4R ARMING LIGHT, OPERATIONS CHECKED NORMAL.

Part: GUARD — MISSING (FIRE PANEL) · airframe 72,429 hrs · 26,485 cycles

CARGO FIRE PANEL MISSING LARGE COVER THAT SHOULD BE ATTACHED TO BTL1 SWITCH. REPLACED SWITCH GUARD PANEL & SWITCH NOT DISCONNECTED REF MM 26-11-02 & ESPM 2045-22. ESPM 2045-22 ENTERED IN ERROR, SHOULD READ SWPM20-84-14.

Part: LIGHT — OUT OF POSITION (CABIN) · airframe 72,129 hrs · 26,385 cycles

IN FLOOR LIGHT TRACK BEHIND SEAT 6B OUT OF TRACK. FLOOR LIGHTING WAS PULLED UP & TORN APART. SECURED LOOSE EMERGENCY EXIT LIGHTING DOWN & COMPLIED WITH MEL. ACCOMPLISHED EMERGENCY EXIT LIGHT TEST PRIOR TO DISPATCH, ONLY SMALL STRIP IN FRONT OF LAVATORY BY DR 2L INOPERATIVE. REST OF AIRCRAFT EMERGENCY EXIT LIGHTS FUNCTIONS PROPERLY. NEED SUPPORT IN FINDING EMERGENCY EXIT LIGHT STRIP, PINS BROKEN OFF. REPAIRED EMERGENCY EXIT LIGHT CABLE IAW MM 33-51-96. OPERATIONS CHECKED NORMAL.

Part: LIGHT — OUT OF POSITION (CABIN) · airframe 72,098 hrs · 26,375 cycles

IN FLOOR LIGHT TRACK BEHIND SEAT 6B OUT OF TRACK. FLOOR LIGHTING WAS PULLED UP & TORN APART. SECURED LOOSE EMERGENCY EXIT LIGHTING DOWN & COMPLIED WITH MEL. ACCOMPLISHED EMERGENCY EXIT LIGHT TEST PRIOR TO DISPATCH. ONLY SMALL STRIP IN FRONT OF LAVATORY BY DR 2L INOPERATIVE. REST OF AIRCRAFT EMERGENCY EXIT LIGHTS FUNCTIONS PROPERLY.

Part: LINER — LOOSE (EMERGENCY EXIT) · airframe 72,011 hrs · 26,346 cycles

RT FWD EMERGENCY DOOR EICAS ILLUMINATED AT APPROXIMATELY 13000' PRESSURE NORMAL, LIGHT OUT A 30,000'. FOUND DOOR LINING UPPER EDGE LOOSE. REMOVED PLUG DOOR, SECURED LINING & REINSTALLED PLUG DOOR. ALL INDICATIONS NORMAL.

Part: WINDOW FRAME — LOOSE (CABIN) · airframe 72,011 hrs · 26,346 cycles

26ABC WINDOW FRAME LOOSE. SECURED WINDOW FRAME.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 71,991 hrs · 26,338 cycles

REMOVE & REPLACE FUSELAGE SKIN REPAIR AT BS1580-1600 BETWEEN STRINGER 19R-20R. MAJOR REPAIR ACCOMPLISHED. WORK ACCOMPLISHED MCN ON NR 26146. RII ACCOMPLISHED. REPAIR IR PART MARKED IAW ECRA 5361-01065.

Part: DOOR — DENTED (CARGO BAY) · airframe 71,991 hrs · 26,338 cycles

DENT IN UPPER FORWARD CORNER OF FORWARD CARGO DOOR. DENT IN UPPER FORWARD CORNER OF FORWARD CARGO DOOR FOUND TO BE OUT OF LIMITS IAW SRM 52-30-01 FIG 101. REPAIRED DENT BY INSTALLING DOUBLER UPPER FORWARD CORNER OF FORWARD CARGO DOOR IAW SRM 52-30-01 FIG 201. WORK ACCOMPLISHED MCN ON NR25407. RII ACCOMPLISHED.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 71,991 hrs · 26,338 cycles

MULTIPLE LIGHTNING STRIKES (FIFTEEN) IN LOWER FUSELAGE EXTERIOR SKIN BS 526-529.5 RBL3-5. FIFTEEN LIGHTNING STRIKES ARE WITHIN LIMITS A 5"X2" AREA & FOUND TO BE OUT OF LIMITS IAW SRM 53-00-01 FIG101. REPAIRED MULTIPLE LIGHTNING STRIKES (FIFTEEN) IN LOWER FUSELAGE EXTERIOR SKIN BS526-BS529.5 RBL3-5 IAW ECRA 53 00-01761. WORK ACCOMPLISHED.

Part: PRESSURE PANEL — CORRODED (BS 1681-1720) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

CORROSION WAS FOUND ON THE AFT PRESSURE PLATE FROM BS 1681 TO 1720 RBL 38-57. REPAIRED IAW SRM 53-60-51 FIG 201.

Part: FLOOR SUPPORT — CORRODED (BS 1600-1681) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

CORROSION WAS FOUND ON THE FLOOR SUPPORT CHANNEL BETWEEN BS 1600 & 1681 LBL 57. CORROSION FOUND TO BE OUT OF LIMITS. REMOVED & REPLACED THE FLOOR SUPPORT IAW SRM 51-40-02 PAR 7D FIG 12.

Part: SENSOR — OBSTRUCTED (ENTRY DOOR) · airframe 74,742 hrs · 21,996 cycles

ENTRY DOOR SAFTY LOCK LIGHT INOPERATIVE. FOUND DEBRIS AT DOOR LOCK SENSOR. CLEANED & CYCLED DOOR LOCK. LIGHT OPERATIONS CHECKED NORMAL.

Part: ATTACH ANGLE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

CORROSION ON FLOOR ATTACH ANGLE BETWEEN BS 1640 - 1620 RBL 52. REMOVED FLOOR BOARD ATTACH BETWEEN BS 1640-BS 1620 IAW SRM 51-40-02 PAR 7 FIG 12, SRM 51-40-05 & BOEING DWG 146N5664. RII INSPECTION ACCOMPLISHED.

Part: SUPPORT — CORRODED (BS 345-365) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

MAIN CABIN BS 345 TO BS 365 RBL 62 DRAIN HAD CORROSION. CORROSION OUT OF ALLOWABLE LIMITS IAW SRM. REMOVED AND REPLACED DRAIN SUPPORT IAW SRM 51-40-02 PARA 7D FIG 12 AND DWG 141N5160U78. MAJOR REPAIR.

Part: FLOOR SUPPORT — CORRODED (BS 1701-1712) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

CORROSION ON FLOOR SUPPORT BS 1701-1712 RBL 50. CORROSION OUT OF LIMITS IAW SRM 53-00-51 FIG 101. REMOVED AND REPLACED FLOOR SUPPORT IAW SRM 51-40-02 PARA 4 FIG 3 & 8 AND DWG 146N5300. MAJOR REPAIR.

Part: INTERCOSTAL — CORRODED (BS 1681-1700) · airframe 71,991 hrs · 26,338 cycles

INTERCOSTAL FROM BS 1681-1700 UNDER DECK PLATE IN AFT CABIN HAS CORROSION APPROX RBL 45. R & R INTERCOSTAL IAW SRM 51-0-02, PARA 7D FIG 12.

Part: CUSP WEB — CORRODED (BS 1720) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

CORROSION ON CUSP WEB TO AFT DECK BS 1720 RBL 59. REMOVED AND REPLACED CUSP WEB IAW SRM 51-40-02 PAR 7D FIG 12. MAJOR REPAIR.

Part: FLOORBEAM — DAMAGED (FUSELAGE) · airframe 71,991 hrs · 26,338 cycles

DOUBLE DRILLED HOLE IN FLOOR BEAM BS 1640 RBL28.5. REPAIRED FLOOR BEAM BS1640 RBL 28.5 IAW TYPICAL REPAIR ECRA 5310-05536.

Part: PLATE — CORRODED (BS 1681) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

CORROSION ON AFT PRESSURE PLATE BS 1681 LBL 17-10 AND LBL 17 GOES UNDER FLOORBOARD ATTACH PLATE. REPAIRED AFT PRESSURE PLATE IAW SRM.

Part: TEE FITTING — CORRODED (BS 1720) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

CORROSION ON -TEE FITTING IN AFT MAIN CABIN BS 1720 RBL 58. R & R TEE FITTING IAW SRM 51-40-02, PARA 7D, FIG 12 AND DWG 146N8722-156.

Part: CHANNEL — CORRODED (BS 310-324) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

FORWARD CABIN RBL 45 BETWEEN BS 310 AND 324, CHANNEL HAS CORROSION. R & R -CHANNEL IAW DWG 141N5160. REPLACED -CHANNEL IAW SRM 51-40-02, PARA 7D, FIG 12.

Part: CHANNEL — GOUGED (BS 1620-1640) · airframe 71,991 hrs · 26,338 cycles

BARE METAL IN FLOORBOARD ATTACH CHANNEL BETWEEN BS 1620-1640, RBL 11.5. GOUGES IN FLOORBOARD ATTACH CHANNEL FOUND TO BE OUT OF LIMITS IAW DWG 1508-255 & SRM 53-00-51, FIG 101, DETAIL 3. R & R CHANNEL IAW SRM 51-4 0-02, PAR 7D, FIG 12.

Part: CHANNEL — CORRODED (BS 1660-1681) · corrosion level 2 · airframe 71,991 hrs · 26,338 cycles

CORROSION ON FLOORBOARD ATTACH CHANNEL BETWEEN BS 1660-1681, BL 0. BLENDED CORROSION, FOUND TO BE OUT OF LIMITS IAW SRM 53-00-51, FIG 101. R & R FLOORBOARD ATTACH CHANNEL BS1660-1681, BL-0 IAW SRM 51-40-02, PAR 4, FIG 8 & PAR 7D, FIG 12.

Part: MICROPHONE — FAILED (OXYGEN MASK) · airframe 71,526 hrs · 26,188 cycles

FIRST OFFICER`S OXYGEN MASK HOT MIC. F/O'S MIC ON HOT JUST ON FLT INTERPHONE. F/O MIKES ARE ALSO HOT ON SERV INTERPHONE POS. REPLACED FIRST OFFICER`S OXYGEN MASK PER AMM. GROUND CHECKED OK. NO LEAKS NOTED.

Part: TRANSMITTER — FAILED (RT HYD PRESSURE) · airframe 71,508 hrs · 26,183 cycles

ON TAKEOFF AT FLAP RETRACTION, RT HYD SYS EICAS CAUTION MESSAGE. QTY AND OVERHEAD NORMAL. REPLACED RT HYD PRESSURE TRANSMITTER. LEAK CHECKED GOOD.

Part: FRAME — DENTED (BS 1500 S26L) · airframe 55,864 hrs · 20,438 cycles

AFT CARGO BAY FRAME DENTED BS 1500 S26L. CUT OUT DAMAGE, FABRICATED AND INSTALLED REPAIR PER SRM 53-00-07 REPAIR 5. MAJOR REPAIR.

Part: FRAME — DENTED (BS 1340 S25-26R) · airframe 55,864 hrs · 20,438 cycles

AFT CARGO BAY FRAME BS 1340 S25-26R DENTED. CUT OUT DAMAGE FABRICATED AND INSTALLED REPAIR IAW SRM 53-00-07 REPAIR 5. MAJOR REPAIR.

Part: FRAME — GOUGED (BS 1580 S26-27L) · airframe 55,864 hrs · 20,438 cycles

AFT CARGO BAY FRAME GOUGED AT BS 1580 BETWEEN S26-27L. CUT OUT DAMAGE FABRICATED AND INSTALLED REPAIR IAW SRM 53-00-07 REPAIR 5. MAJOR REPAIR.

Part: BALLAST — INOPERATIVE (LAVATORY LIGHTS) · airframe 70,903 hrs · 25,984 cycles

AFT LAVATORY FLUORESCENT LIGHT INOPERATIVE. REPLACED BALLAST. AFT LAVATORY LIGHTS OPERATE NORMALLY.

Part: STRAP — CRACKED (L1 DOOR) · airframe 70,800 hrs · 25,950 cycles

FOUND CRACK AT EDGE OF BEAR STRAP OF L1 DOOR CORNER, 4TH FASTENER UP FROM NR 1 DOOR STOP FITTING CENTERLINE. REPAIRED PER EA 5330-0421 3 OP3 AND EC RA 5330-04213.

Part: GALLEY MAT — DAMAGED (CABIN) · airframe 70,667 hrs · 25,903 cycles

AFT GALLEY FLOOR DAMAGED AND PREVENTING MOVEMENT OF LIQUOR CART. RUBBER TRANSITION STRIP IS TORN AND COMING UP FROM FLOORING. ACCOMPLISHED ECR 2533-0100 4 REV C. CENTER DIVIDING TRIP BETWEEN GALLEY PAN AND FLOOR MAT IS DAMAGED AND WILL REQUIRE REPLACEMENT. STRIP IS SECURE AND SEALANT IS TAPED OVER WITH MYLAR TAPE PER ECRA.

Part: SILL — DAMAGED (THRESHOLD) · airframe 70,500 hrs · 25,852 cycles

AFT CARGO BAY STAINLESS STEEL BULLNOSE SILL PLATE DAMAGED AFT EDGE. REMOVED DAMAGED SILL PLATE. REPLACED SILL PLATE, FOUND SERVICEABLE.

Part: BLADE — DAMAGED (NR 1 ENGINE) · airframe 70,444 hrs · 25,832 cycles

DURING ACCOMPLISHMENT OF EC7601-2 FOUND ONE EACH T2 BLADE WITH BREAK THROUGH AND MATERIAL LOSS INTO CAVITY. MATERIAL LOSS EXTENDS INTO AREA 'A' OF BLADE. NO DAMAGE ALLOWED IN AREA A. REQUIRES ENGINE CHANGE ENGINE NR 1 07FEB13 . NR 4 BEARING SCAVENGE MANIFOLD, OIL FILTER DIFFERENTIAL PRESSURE SWITCH, MAGNETIC CHIP DETECTORS, AIR-OIL HEAT EXCHANGER, GEARBOX OIL SCAVENGE PUMP ASSEMBLY, OIL TANK AND ACCESSORIES, OIL PRESSURE TRANSMITTER, OR LOW OIL PRESSURE SWITCH (D). LEAK CHECK MAIN OIL FILTER, LAST CHANCE OIL FILTER, LEAK CHECKED NR 1 ENGINE NO LEAKS NOTED. CHG'D ENGINE.

Part: LOCK NUT — LOOSE (SEAT ROW 20 EF) · airframe 70,342 hrs · 25,793 cycles

20EF ENTIRE SEAT ROW LOOSE. REPLACED FORWARD LOCKING NUT. FIVE SEGMENTS LATER SECURED THE SEAT ASSY TO TRACK.

Part: GIRT BAR — DIRTY (R4 DOOR) · airframe 70,201 hrs · 25,742 cycles

UNABLE TO ARM DOOR 4R. CLEANED GIRT TRACK, OP CHECKED DOOR ARM SYSTEM OKAY.

Part: BULB — BURNED OUT (R2 DOOR SLIDE) · airframe 70,132 hrs · 25,717 cycles

SLIDE LIGHT AT R2 DOOR INOPERATIVE. REPLACED BURNED BULBS, CHECKED GOOD.

Part: SKIN — DAMAGED (NR 8 SLAT) · airframe 68,928 hrs · 25,310 cycles

NR 8 SLAT SKIN DAMAGE. SUPPLEMENTAL DATA UPDATE, LOOSE SKIN HAS BEEN TRIMMED AND AREA COVERED WITH SPEED TAPE PER ECRA. REMOVED LOOSE SKIN APPLIED SPEED TAPE PER ECRA 5470-02323, PERFORMED WALK AROUND ACFT IS IN A SAFE FLIGHT CONDITION FOR TYPE II FERRY FLT. FINISHED REMOVING NR 8 SLAT STARTING AT ITEM E2. REPLACED NR 8 LE EDGE SLAT. OPS TEST NORMAL. NO FAULTS.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 68,323 hrs · 25,105 cycles

EEL AT MID LAV IS INOP. REPLACED EEL AT MID LAV, OPS CHECKS GOOD.

Part: IDG — FAULTED (RIGHT) · airframe 67,994 hrs · 25,002 cycles

LOST RT GENERATOR, RT AC BUSS, RT BUSS TIE ISOLATION DURING TAKEOFF APPROX 110 KNOTS. REPLACED RT IDG PER MM24 11-01-401 OPS CHECKED NORMAL.

Part: IDG — FAILED (RIGHT) · airframe 67,994 hrs · 25,002 cycles

LOST RT GENERATOR, RT AC BUSS, RT BUSS TIE ISOLATION, DURING TAKEOFF APPROX 110 KNOTS. REPLACED RT IDG, OPS CHECKED NORMAL.

Part: ROLLER — BROKEN (L1 DOOR) · airframe 67,980 hrs · 24,998 cycles

L1 DOOR FWD UPPER CRANK ROLLER BROKEN. REPLACED BEARING, DOOR OPS NORMAL.

Part: COVER — LOOSE (CABIN) · airframe 67,327 hrs · 24,760 cycles

EMERGENCY FLOOR LIGHTING PEELING UP FROM WING EXIT TO AFT GALLEY. SECURED LOOSE COVER.

Part: SKIN — DENTED (FUSELAGE) · airframe 67,130 hrs · 24,681 cycles

DENT REPORTED ON LT FUSELAGE FORWARD OF DOOR 2L. DENT AT BS 620 STR 15L AND MEASURES 1 X 1 X .09 OPBLM. ACP EDDY CURRENT, NO CRACK PERFORMED INTERIM REPAIR PER ECRA 5330-04 194 PART 1 OK TO CONTINUE AND PERMANENT REPAIR OF THE FUSELAGE SKIN AND STRINGER AS REQUIRED WITHIN 5 CYCLES MARKED WITH DOT. RE-INSPECTION REQUIRED BY QC AT THE FIRST MAINTENANCE OPPORTUNITY WHERE GROUND TIME ALLOWS. BACK DRILLING DOUBLER AND TRIPLER. -RPR- :ACCOMPLISHED REPAIR PER ECRA: 5330-04199.

Part: SWITCH — DIRTY (R1 DOOR SLIDE) · airframe 67,017 hrs · 24,639 cycles

CREW REPORTS SLIDE ARM LIGHT AT DOOR 1R IS INOPERATIVE. CLEANED SWITCH AND OPS CHECKED NORMAL.

Part: CONTROL UNIT — MALFUNCTIONED (GALLEY) · airframe 66,630 hrs · 24,504 cycles

NO AFT GALLEY POWER. REPLACED ELCU M227 PER MM, OPS CHECKS NORMAL.

Part: CIRCUIT CARD — DEFECTIVE (FIRE DETECTION) · airframe 66,627 hrs · 24,503 cycles

EICAS MSG - L ENG FIRE LP 2. CREW COMMENTS: INTERMITTENT STATUS MSG. PROG TEXT: ACCOMPLISH CHRONIC REVIEW. NO TIME TO T/S. REPLACED FIRE DETECTION CARD M682, SYS GRND CHECKS GOOD.

Part: SKIN — DENTED (BS 465 S22-23R) · airframe 66,522 hrs · 24,456 cycles

WALK AROUND FLIGHT CREW FOUND A DENT EXTRUDING OUTWARD IN LINE WITH E/E DOOR ON RIGHT SIDE OF FUSELAGE. DENT LOCATION IS AT APPROX BS 465 BETWEEN S22-23R. DENT MEASURES APPROX 0.015' DEEP AND .25' IN DIA. REWORKED DENT PER SRM. PERFORMED EDDY CURRENT INSPECTION ON AFFECTED AREA. NO DISCREPANCIES FOUND.

Part: SKIN — DAMAGED (LT WING) · airframe 66,043 hrs · 24,286 cycles

LEFT WING L/E UPPER SKIN HAS 6 INCH LONG GOUGE FROM CONTACTING NR 3 SLAT OUTBOARD END BLADE SEAL SCREW. DAMAGE IS 12' FROM PANEL INBD EDGE, 5.250 FROM AFT EDGE,4.250" FROM NEAREST FASTENER, AND 13" FROM NEAREST REPAIR. REPAIRED IAW SRM 57-41-01 AND SB 757-57-0052. TAP TESTED DENTS AND PUNCTURES. COMPLIED WITH EG5879 CALL OUT. FILLED WITH SEALANT AND TAPED PUNCTURES IN ALL T/E FLAPS.

Part: SKIN — PUNCTURED (AILERON) · airframe 66,043 hrs · 24,286 cycles

LT WING AILERON UPPER SURFACE HAS NUMEROUS PUNCTURES TO COMPOSITE SKIN.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 65,558 hrs · 24,113 cycles

CORROSION ON FWD PIT ANGLE ASSY 143N5368-939 DETERMINED TO BE LEVEL 2 CORROSION. REPAIRED ANGLE.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHTS) · airframe 64,870 hrs · 23,860 cycles

ABOUT 1-3 OF EMERGENCY EXIT LIGHTS ON WITH SWITCH OFF. FOUND AFT ATTENDANT PANEL SWITCH ON. LIGHTS DISCHARGED FOR GREATER THAN 10 MIN. PER MM. CHECKED EMERGENCY LIGHTS, ALL LIGHTS OP CHECKED NORMAL, NO BATTERY PACKS NEEDED. A 16 HOUR CHARGE COMPLETE AT 2300 ON 15MAR. ACCOMPLISHED TEST, OPS CHECKED NORMAL.

Part: GIRT BAR — DIRTY (R1 DOOR SLIDE) · airframe 64,729 hrs · 23,810 cycles

EMERGENCY SLIDE LIGHT AT DOOR 1R INOP. CLEANED GIRT BAR FLOOR FITTINGS AND LUBED ARMING MECHANISM. OPS NORMAL.

Part: GIRT BAR — UNSECURE (R1 DOOR) · airframe 64,023 hrs · 23,549 cycles

DOOR 1R GIRT BAR LOOSE AND OUT OF HOLDERS. SECURED GIRT BAR.

Part: SILL — DIRTY (R1 DOOR) · airframe 63,533 hrs · 23,366 cycles

DOOR 1R WILL NOT DISARM. CLEANED DOOR 1R DOOR SILL. REMOVED SLIDE COVER TO INSPECT OPERATION OF GIRT BAR MECHANISM. NORMAL ARMING FUNCTION NOTED.

Part: FAN — ODOR (COCKPIT) · airframe 63,386 hrs · 23,313 cycles

COCKPIT ODOR ISSUE, FLIGHT DIVERTED. ACCOMPLISHED PACK RUN WITH APU. NO UNUSUAL ODORS. CHECKED E&E COMPARTMENT FOR UNUSUAL ODORS, NONE NOTED. NO ELECTRICAL OR OVERHEAT EVIDENCE OF ANY KIND NOTED ON THE ACFT. INSPECTED AND REPLACED RECIRC FAN FILTERS. REPLACED EQUIPMENT COOLING FAN. RAN PACKS (ISOLATED) HI-PWR, NO ODOR NOTED.

Part: NOSE COWL — DAMAGED (LT ENGINE) · airframe 62,980 hrs · 23,166 cycles

ACFT TAXIED INTO JETWAY DAMAGING LT ENGINE NOSE COWL. FOUND DAMAGE AT 12 O'CLOCK POS. DAMAGE 2 DENT ONE IS 12 IN WIDE X 8 IN LONG X 2 IN DP. THE OTHER IS 18 IN LONG X 4 IN WIDE X 1 IN DP. ENG 1 INLET L/E BEYOND ALLOWABLE DAMAGE LIMITS OF SRM. REPLACED INLET COWL.

Part: WINDSHIELD — DAMAGED (COCKPIT) · airframe 62,668 hrs · 23,046 cycles

LOWER EDGE OF CAPTS WINDSHIELD SHOWS POSSIBLE SIGNS OF OVERHEATING. NR 1L WINDSHIELD HAS TOTAL 9 INCHES OF UNEVEN BROWNING ALONG THE BOTTOM EDGE, 1-8 TO 3-8 WIDE, WITH SMALL MOISTURE DELAMINATION. NEED TO REPLACE WINDOW WITHIN 150 FLIGHT HOURS. REPLACED WINDSHIELD.

Part: SQUIB — UNDERSERVICED (CARGO BAY) · airframe 62,284 hrs · 22,903 cycles

CARGO FIRE EXT BOTTLE 2 AFT SQUIB UNDERSERVICED. REPLACED SQUIB IAW MM.

Part: VALVE — BINDING (LAV DUMP) · airframe 62,251 hrs · 22,893 cycles

WHILE DUMPING WATER OUT OF GALLEY BINS AN ICE SCOOP FELL INTO TOILET OF LAV 136. WHILE ATTEMPTING TO REMOVE ICE SCOOP FOUND DUMP CABLE BROKEN OFF IN TANK. THIS IS THE AFT CABIN AFT LAV THAT IS INOP. WILL REQUIRE SHROUD TO BE REMOVED AND DUMP VALVE MANUALLY OPERATED EACH TIME TOILETS ARE SERVICED. REPLACED DUMP VALVE & GASKET UNDER VALVE AND REPLACED TOILET SEAT. CREW WOULD NOT TAKE AIRCRAFT UNLESS TOILET REPAIRED. OLD DUMP VALVE WAS JAMMED & COULD NOT BE MANUALLY DUMPED.

Part: GUIDE ARM — BINDING (R1 DOOR) · airframe 61,164 hrs · 22,486 cycles

DOOR 1R BINDS WHEN OPENING. HINGE ARM FOUND TO BE CONTACTING GUIDE ARM. ADJUSTED SERRATED PLATE AND GUIDE ARM. DOOR OPS GREAT.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 60,607 hrs · 22,266 cycles

EXT EVAC LIGHT ON AFT CARGO DOOR INOP. RELAMPED CARGO DOOR LIGHT.

Part: LAMP — INOPERATIVE (EXTERIOR) · airframe 60,607 hrs · 22,266 cycles

EXT EVAC LIGHT AT DOOR 4 LT INOP. RELAMPED EXT EVAC LIGHT.

Part: LIGHT — UNSECURE (ROW 13) · airframe 60,273 hrs · 22,127 cycles

EMERGENCY FLOOR LIGHTING LOOSE AT ROW 13. SECURED AND TESTED FLOOR LIGHTING AT ROW 13.

Part: OXYGEN MASK — FAULTY (COCKPIT) · airframe 60,176 hrs · 22,093 cycles

THE O2 MASK CAPT SIDE SEEMS TO HAVE A HOT MIC. REPLACED CAPTAINS OXYGEN MASK, RADIO MANAGEMENT PANEL (P/N 5031-1-2 SERIAL NUMBER 511) AND OXYGEN STORAGE BOX. OPERATION CHECKS OKAY.

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 59,699 hrs · 21,920 cycles

FOUR (4) RT MED EXTERIOR EMERGENCY EXIT LIGHT INOPERATIVE. RELAMPED, OPS GOOD P/N 767.

Part: LIGHT — UNSECURE (ROWS 29-30) · airframe 59,641 hrs · 21,896 cycles

EMERGENCY TRACK LIGHTING BETWEEN ROWS 29 - 30 LOOSE AND COMING UP. SECURED TRACK.

Part: COVER — CRACKED (EMERGENCY LIGHT) · airframe 59,633 hrs · 21,893 cycles

EMERGENCY LIGHT COVER CRACKED AT SEAT 31C AREA. LIGHT WORKS. MADE INTERIM REPAIR WITH CLEAR TAPE. REPLACED BROKEN SECTION OF EMERGENCY LIGHT COVER.

Part: FEEDER CABLE — FAULTY (CABIN) · airframe 59,626 hrs · 21,891 cycles

EXIT PATH LIGHTING BETWEEN ROWS 31 AND 33 IS INOP. FOUND EEL STRIP UNPLUGGED AT ROW 31. ALSO FOUND EEL LIGHTING INOP BETWEEN ROWS 16 AND 21. REPLACED EEL FEEDER AT ROW 16, TESTS OKAY.

Part: SMOKE GOGGLES — WORN (COCKPIT) · airframe 59,150 hrs · 21,693 cycles

F/O SMOKE GOGGLE HEAD BAND WORN. REPLACED GOGGLES.

Part: COVER — UNSECURE (EMERGENCY LIGHT) · airframe 59,075 hrs · 21,665 cycles

EMERGENCY LIGHTING STRIP AT ROW 31 IS LOOSE. SECURED COVER PLATE.

Part: LIGHT — DETACHED (CABIN) · airframe 58,917 hrs · 21,612 cycles

EMERGENCY LIGHTS DETACHED AT FLOOR LEVEL NEAR ROW 31C. SECURED EMERGENCY LIGHT STRIP, OPS CHECKS NORMAL.

Part: COVER — UNSECURE (EMERGENCY LIGHT) · airframe 58,813 hrs · 21,571 cycles

EMERGENCY EXIT LIGHT ON FLOOR DISLODGED FROM FLOOR. SECURED COVER.

Part: GAUGE — LEAKING (EVAC SLIDE)

SLIDE PRESSURE LOW. LEAKING AROUND GAUGE FACE. REMOVED AND REPLACED GAUGE.

Part: GCU — MALFUNCTIONED (RT GENERATOR) · airframe 57,209 hrs · 20,921 cycles

LOST RIGHT GENERATOR. FLIGHT DIVERTED. REPLACED GCU. OK FOR SERVICE.

Part: SKIN — DELAMINATED (THRUST REVERSER) · airframe 57,072 hrs · 20,868 cycles

NR 2 ENGINE RT OUTBOARD REVERSER UPPER BIFURCATION PANEL INNER SKIN DELAMINATED FROM FWD END TO AFT END EDGE TO EDGE. REPLACED REVERSER HALF.

Part: SKIN — DELAMINATED (THRUST REVERSER) · airframe 57,072 hrs · 20,868 cycles

NR 2 ENGINE LT INBOARD REVERSER UPPER BIFURCATION PANEL IS DELAMINATED INNER SKIN ABOUT 60 PERCENT OF PANEL LENGTH FROM EDGE TO EDGE. REPLACED REVERSER HALF.

Part: FEEDER CABLE — INOPERATIVE (EMERGENCY LIGHT) · airframe 56,788 hrs · 20,762 cycles

EMERGENCY LIGHT STRIP INOP AT DOOR 2L. FOUND SUPPLY CABLE PINCHED/SHORTED. REPLACED SUPPLY CABLE, OPS CHECKED OK.

Part: SCAVENGE PUMP — MALFUNCTIONED (ENGINE OIL SYS) · airframe 56,377 hrs · 20,620 cycles

NR 2 ENG HIGH OIL TEMPERATURE INDICATION. RTFL. REPLACED LUBE SCAVENGE PUMP AS WELL AS CHECKED ALL WIRING FROM PYLON DOWN ENG. ALSO REPLACED EEC AS PRECUATIONARY.

Part: VALVE — OPEN (POTABLE WATER) · airframe 56,091 hrs · 20,524 cycles

VIBRATION IN THE AFT CABIN FLOOR LED TO DIVERSION. WATER FILL VALVE AND PANEL LEFT OPEN SUSPECT ALL ISSUES ARE RELATED TO WATER FILL VENT VALVE NOT BEING CLOSED, BLEEDING HEAD PRESSURE. CAUSING WATER COMPRESSOR TO VIBRATE FLOOR AND CLUNKING WATER LINE DUE TO AIR IN SYSTEM PERFORMED VISUAL SEARCH OF EXTERIOR OF A/C - OK. CLOSED VALVE AND ACCESS DOOR. FURTHER FLIGHTS WERE CLEAN.

Part: GIRT BAR — OBSTRUCTED (L2 DOOR) · airframe 56,031 hrs · 20,499 cycles

SLIDE LIGHT 2L ON W-DOOR DISARMED. DEBRIS UNDER GIRT BAR. REMOVED DEBRIS, PERFORMED OPS CHECKS, ALL NORMAL.

Part: ARM — CRACKED (L2 DOOR HINGE) · airframe 55,864 hrs · 20,438 cycles

L2 DOOR UPPER HINGE ARM CUTOUT HAS CRACKS. MAJOR REPAIR ACCOMPLISHED: REMOVED DAMAGE. FABRICATED & INSTALLED A REPAIR ANGLE & TAPERED FILLERS.

Part: DOOR FRAME — GOUGED (FUSELAGE) · airframe 55,864 hrs · 20,438 cycles

FUSELAGE DOOR FRAME GOUGED DUE TO LATCH ON ACCESS DOOR 113AL. TRIMMED OUT DAMAGE AND ACP 'D HFEC INSPECTION PER NDT 6-51-00-19, AND FABRICATED A REPAIR A NGLE AND FILLER AND INSTALLED PER REO G12327, REV. B ON NO N ROUTINE 28814. PER EVA 71516,

Part: SKIN — DAMAGED (R2 DOOR) · airframe 55,864 hrs · 20,438 cycles

R2 DOOR UPPER HINGE ARM CUT-OUT HAS DAMAGE. SUPPLEMENTAL DATA UPDATE MAJOR REPAIR ACCOMPLISHED: RMV'D DAMAGE. FABRICATED & INSTALLED A REPAIR ANGLE & TAPERED FILLERS.

Part: FEEDER CABLE — DAMAGED (EMERGENCY LIGHTS) · airframe 55,864 hrs · 20,438 cycles

BULL NOSE LIGHT AT STA 1370R AND FLOOR LIGHT AT K LAV INOP. FOUND CABLE DAMAGE TO LIGHT ASSY. R EPAIRED LIGHT CABLE ASSY AND RELAMPED. OPS NORMAL

Part: STRINGER — DAMAGED (BS 1400 S26L) · airframe 55,864 hrs · 20,438 cycles

AFT PIT STA 1400 STR 26L HAS ENLONGATED HOLES IN SIDES OF STRINGERS DUE TO REPLACEMENT STRINGER CLIPS ON FRAME REPAIR. MAJOR REPAIR ACCOMPLISHED, CUTOUT DAMAGE, STA 1390 TO 1410. INSTALLED NEW SECTION AND FILLER AND REPAIR SPLICES.

Part: STRINGER — DAMAGED (BS 1400 S25L) · airframe 55,864 hrs · 20,438 cycles

AFT PIT STA 1400 STR 25L HAS ELONGATED HOLES IN SIDES OF STRINGER DUE TO REPLACEMENT STRINGER CLIPS ON FRAME REPAIR. MAJOR REPAIR ACCOMPLISHED, CUTOUT DAMAGE. INSTALLED FILLER AND 2 REPAIR SPLICES.

Part: INTERCOSTAL — CRACKED (BS 1400-1420) · airframe 55,864 hrs · 20,438 cycles

INTERCOSTAL AT STA 1400-1420 AND RBL 3 IS CRACKED. MAJOR REPAIR ACCOMPLISHED, INSTALLED ANGLE REPAIR WITH FILLER.

Part: FRAME — DENTED (BS 1340) · airframe 55,864 hrs · 20,438 cycles

AFT PIT FUSELAGE FRAME AT STA 1340 BETWEEN STRINGERS 25R AND 26R DENTED. CUT OUT DAMAGE FABRICATED AND INSTALLED REPAIR IAW SRM 53-00-07 RPR 5. PER SRM 53-00-07 RP R 5 TABLE II THIS RPR REQUIRES SUPPLEMENTAL INSPECTIONS STARTING AT 50,000 TOTAL FLIGHT CYCLES AND 12,000 FC THERE AFTER THIS IS A CAT B RPR. INSPECTIONS ARE BOTH VISUAL AND NDT.

Part: FRAME — GOUGED (BS 1580) · airframe 55,864 hrs · 20,438 cycles

AFT PIT LEFT SIDE FRAME HAS GOUGE AT BS 1580 BTWN STRS 27L AND 26L. CUT OUT DAMAGE FABRICATED AND INSTALLED REPAIR IAW SRM 53-00-07 RPR 5. PER SRM 53-00-07 RP R 5 TABLE II THIS RPR REQUIRES SUPPLEMENTAL INSPECTIONS STARTING AT 50,000 TOTAL FLIGHT CYCLES AND 12,000 FC THERE AFTER THIS IS A CAT B RPR. INSPECTIONS ARE BOTH VISUAL AND NDT.

Part: SLIDE — DAMAGED (LT OVERWING) · airframe 55,864 hrs · 20,438 cycles

LT OVERWING ESCAPE SLIDE FOUND UNLACED. REPLACED EMERGENCY SLIDE.

Part: FLOOR SUPPORT — CORRODED (BS 1440-1460) · airframe 55,864 hrs · 20,438 cycles

CABIN FLOOR SUPPORT CORRODED AT FS 1440-1460 RBL 64-60. MAJOR REPAIR ACCOMPLISHED: REMOVED SUPPORT. FABRICATED AND INSTALLED.

Part: INTERCOSTAL — CORRODED (BS 1600-1620) · airframe 55,864 hrs · 20,438 cycles

AFT PIT INTERCOSTAL HAS CORROSION BETWEEN BS 1600 AND 1620 STR 29L AND 30. MAJOR REPAIR ACCOMPLISHED, REMOVED EXISTING INTERCOSTAL AND INSTALLED NEW INTERCOSTAL AT STA 1600 TO 1620 BTWN STR S29L AND 30.

Part: FRAME — DENTED (BS 1500 S26L) · airframe 55,864 hrs · 20,438 cycles

AFT PIT LEFT SIDE FRAME HAS DENT AT BS 1500 ABOVE STR-26L. ACCOMPLISHED MAJOR REPAIR. CUT OUT DAMAGE, FABRICATED AND INSTALLED REPAIR PER SRM. THIS IS A CAT B REPAIR AND REQUIRES SUPPLEMENTAL INSPECTIONS STARTING AT 50,000 TOTAL FLT CYCLES AND 12,000FC THERE AFTER.

Part: STIFFENER — CRACKED (BS 377) · airframe 55,864 hrs · 20,438 cycles

CABIN FLOORBEAM STIFFENER CRACKED, STA 377.7, BL 0. MAJOR REPAIR ACCOMPLISHED: FABRICATED & INSTALLED NEW STIFFENER.

Part: FLOORBEAM — CORRODED (BS 365) · airframe 55,864 hrs · 20,438 cycles

MAIN CABIN BS 365 TEE CAP HAS CORROSION AT RBL 42. MAJOR REPAIR ACCOMPLISHED: CUTOUT DAMAGE, 1" X 2" FWD EDGE OF TEE CAP. INSTALLED FILLER & ANGLE REPAIR.

Part: FLOOR SUPPORT — CORRODED (BS 1640-1660) · airframe 55,864 hrs · 20,438 cycles

CABIN FLOOR SUPPORT INTERCOSTAL CORRODED BETWEEN STA 1640 - 1660, RBL 57. MAJOR REPAIR ACCOMPLISHED: INSTALLED NEW INTERCOSTAL (P/N 146N5246-8).

Part: LINER — CRACKED (NR 1 ENGINE) · airframe 54,617 hrs · 20,002 cycles

RTFL DUE TO NR 1 ENGINE HIGH OIL TEMPERATURE INDICATIONS. BOROSCOPE SHOWS A CRACK IN THE CRACK OF INNER LINER NR 4 PANEL. AIR/OIL HEAT EXCHANGER ALSO BELIEVED TO BE FAULTY. REMOVED ENGINE AND REPLACED WITH A NEW ENGINE. ENG 726661 SENT TO SHOP FOR OVERHAUL.

Part: FEEDER CABLE — FAULTY (EMERGENCY LIGHTS) · airframe 54,452 hrs · 19,940 cycles

EMERGENCY ESCAPE PATH LIGHTING AFT OF DOOR 2L BETWEEN SEATS 9-13 INOPERATIVE. REPLACED EEL LAMP CABLE. OPS CHECKED OKAY.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHTS) · airframe 54,452 hrs · 19,940 cycles

EMERGENCY LIGHT BETWEEN SEAT 3-4 LH UNDER STOW BIN INOP. RELAMPED. OPS CHECKED OKAY.

Part: SQUIB — BLOWN (RT ENGINE) · airframe 53,711 hrs · 19,661 cycles

RIGHT ENGINE SQUIB TEST LIGHT WILL NOT LIGHT UP DURING TEST POSITION 2. AS PART OF TROUBLESHOOTING VERIFIED SQUIB CIRCUIT, AND DURING TEST FOUND RIGHT ENGINE SQUIB BOTTLE BLOWN. REPLACED SQUIB.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 53,483 hrs · 19,578 cycles

FWD OVERWING EMERGENCY SLIDE LIGHT INOP AT LEFT OVERWING HATCH. RELAMPED.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 53,483 hrs · 19,578 cycles

EEL LIGHT INOP AT FWD CLOSET. REPLACED LAMP, TRACK BASE, HOUSING COVER AND END CAPS. OP CKS GOOD.

Part: LEVER — STIFF (L1 DOOR SLIDE) · airframe 53,382 hrs · 19,541 cycles

THE 1L ARMING LEVER IS VERY STIFF.

Part: CONTROLLER — FAULTY (WINDOW HEAT) · airframe 53,378 hrs · 19,539 cycles

WINDOW EICAS MSG DISPLAYED, POSITION 4.(1=L FWD, 2=L SIDE, 3=R FWD, 4=R SIDE) INOP LIGHT ILLUM. INOP LIGHT DID NOT EXTINGUISH WHEN SWITCH WAS RECYCLED TO OFF THEN ON. CREW COMMENTS: IT HAPPENED AGAIN.

Part: UNKNOWN — ODOR (CABIN) · airframe 52,040 hrs · 19,063 cycles

NOTICED BURNING PLASTIC ODOR ON DESCENT OUT OF 240. TURNING OFF RIGHT RECIRC FAN NO CHANGE. PER CREW, ODOR IN FLT DECK AREA, WENT AWAY AT APPROX 8000 FT. [SUP 05-18-07] CHECKED MEC FOR ELEC MODULE FAULTS OR ODOR IN AREA AND NONE FOUND. CHECKED WINDOW HEAT CONNECTIONS FOR EVIDENCE OF LOOSE OR OVERHEATING AND ALL CHECKED OK. NO PROTECTIVE CAPS MELTED. NO EICAS MESSAGES FOUND. RIGHT HALF OF THE VNAV SWITCH IS BURNED OUT. RELAMPED.

Part: GIRT BAR — OUT OF ADJUST (L2 DOOR) · airframe 51,624 hrs · 18,923 cycles

L-2 CABIN DOOR, ARM HANDLE HARD TO ENGAGE. ADJUSTED GIRT BAR MECHANISM WHICH FIXED THE DISCREPANCY. NO COMPONENTS NEEDED TO BE REPLACED.

Part: FRAME — DAMAGED (BS 879 S21R) · airframe 50,487 hrs · 18,504 cycles

STATION 879 J-SECTION FRAME IS DAMAGED NEAR S21R. MAJOR REPAIR ACCOMPLISHED AT STA 879 FRAME S-21R. NEW FRAME INSTALLED. THIS IS A 12 MONTH CF ITEM PENDING DTA FROM BOEING.

Part: FRAME — DAMAGED (BS 880 S21R) · airframe 50,480 hrs · 18,504 cycles

FRAME AT STA 880 STR 21R HAS HEAT DAMAGE. MAJOR REPAIR ACCOMPLISHED. CONDUCTIVITY CHECK FOUND HEAT DAMAGE APPROX 3 INCH FROM EITHER SIDE OF BURNT THRU AND THE FRAME SUPPORT BRACKET ALSO HAS HEAT DAMAGE AT THAT LOCATION. UPON FURTHER INSPECTION FOUND STRINGER BURNT THRU, STRINGER LOCATED UNDER RECIRC FAN APPROX 40 INCHES AFT OF BHD 845. ALSO FOUND FRAME BURNED THROUGH AT STA 880 STR 21R. CLEANED UP DAMAGE AREA. MFG FRAME REPAIR SECTION AND SPLICE DOUBLER FOR REPAIR AT STA 880 STR 21R FROM 7075-O AND HEAT TREATED. ACP ROCKWELL HARDNESS TEST OF REPAIR FRAME SECTION AND SPLICE DOUBLER.

Part: WIRE HARNESS — MISINSTALLED (FAN) · airframe 50,480 hrs · 18,504 cycles

DURING REMOVAL OF RT RECIRC FAN FOUND RECIRC FAN CONNECTOR WIRES BURNED. UPON FURTHER INSPECTION FOUND STRINGER BURNED. INCORRECT INSTALLATION OF WIRE HARNESS ALLOWING RUBBING OF WIRES AGAINST THE STRUCTURE, THIS CAUSED SHORT CIRCUIT OF AT LEAST ONE OF THE WIRES LEADING TO ARCING. AS PART OF CORRECTIVE ACTION, AN EG CALLOUT HAS BEEN ISSUED TO INSPECT THE REST OF THE FLEET TO INSURE HARNESSES ARE CORRECTLY INSTALLED WITH CLAMPS AND STANDOFFS.

Part: VALVE — FAILED (HYD SYSTEM) · airframe 50,431 hrs · 18,484 cycles

BRAKE & ANTI-SKID MESSAGES ON TAXI. THE DISCREPANCY WAS DIAGNOSED AS A FAILED TWO PORT MOTOR OPERATED HYDRAULIC VALVE ASSY. REPLACED PARK VALVE, AND THE MESSAGE CLEARED.

Part: ODOR — DETECTED (GALLEY) · airframe 50,039 hrs · 18,334 cycles

BURNING ODOR IN AFT GALLEY WHEN COFFEEMAKERS TURNED ON. REMOVED AND INSPECTED WIRING AND RECEPTACLES BEHIND CABIN MODULES. CM'S HAD ELEC SMELL WHEN REMOVED. NO PREVIOUS HISTORY FOUND. REPLACED COFFEEMAKER.

Part: WIRE — BURNED (FUSELAGE) · airframe 47,351 hrs · 17,382 cycles

WORKING INOP BLD FOUND CB'S FOR WATER HEATERS & DRAIN MAST POPPED. FOUND BURNED WIRES. *S/D* WIRES BURNED THRU AT STA 1681 , WL 208 DUE TO CHAFE THRU BY HOSE BAND CLAMP FROM IMPROPERLY ROUTED WIRES AND VENT HOSES WHICH LED TO ARCING AND BURN-THRU OF WIRES. BOEING NOTIFIED, AND NO PREVIOUS OCCURRENCES WERE NOTED. STRICTLY DUE TO IMPROPER ROUTING OF VENT HOSES AND WIRING BUNDLE WITH IMPROPER STAND-OFFS, AS VERIFIED IN IPC 38-31-56-004, FIG G. THREE OTHER AIRCRAFT INSPECTED FOR PROPER ROUTING, AND WERE IN ACCORDANCE WITH IPC ABOVE.

Part: WIRE — BURNED (WATER SYSTEM) · airframe 47,351 hrs · 17,382 cycles

FOUND C/B'S FOR WATER HEATERS & DRAIN MAST POPPED. FOUND BURNED WIRES. WIRES BURNED THRU AT STA 1681 , WL 208 DUE TO CHAFE THRU BY HOSE BAND CLAMP FROM IMPROPERLY ROUTED WIRES AND VENT HOSES WHICH LED TO ARCING AND BURN-THRU OF WIRES. BOEING NOTIFIED, AND NO PREVIOUS OCCURANCES WERE NOTED. STRICTLY DUE TO IMPROPER ROUTING OF VENT HOSES AND WIRING BUNDLE WITH IMPROPER STAND-OFFS, AS VERIFIED IN IPC 38-31-56-004, FIG G. 3 OTHER AIRCRAFT INSPECTED FOR PROPER ROUTING, AND WERE IN ACCORDANCE WITH IPC.

Part: SKIN — DELAMINATED (NR 9 SLAT) · airframe 42,929 hrs · 15,716 cycles

DURING WALK AROUND, FOUND SLAT NUMBER 9 DELAMINATED AT TRAILING EDGE WEDGE. *S/D* REPLACED NUMBER 9 SLAT. DURING DISASSEMBLY OF THE SLAT WEDGE FOR REPAIR, THE SHOP FOUND THAT INADEQUATE FILM ADHESIVE (RESIN) WAS USED DURING THE PERVIOUS REPAIR WHICH LEAD TO POROSITY AND VOIDS IN THE BOND LINE BETWEEN THE UPPER SKIN AND CORE MATERIAL. IN ADDITION, HAIL DAMAGE WAS FOUND ON THE REPLACED SKIN WHICH MAY HAVE CAUSED OR ACCELERATED THE DISBOND PROCESS.

Part: IMPELLER — OUT OF BALANCE (AIR DISTRIBUTION) · airframe 41,959 hrs · 15,380 cycles

SMOKE IN THE FLT DECK AND CABIN ON TAXI. THE ROTOR-IMPELLER WAS FOUND TO BE OUT OF BALANCE, ALLOWING IT TO RUB AGAINST THE FAN HOUSING. BURNED RESIDUE WAS DISCOVERED WITHIN THE ASSEMBLY. RIGHT RECIRCULATION FAN REPLACED.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 41,489 hrs · 15,211 cycles

BS 620 AT STR 18L-19L, SHEAR TIE CRACKED ON BOTH ENDS. MAJOR REPAIR ACCOMPLISHED. REPLACED SHEAR TIE.

Part: SKIN — DENTED (FUSELAGE) · airframe 41,489 hrs · 15,211 cycles

EXTERNAL FUSELAGE STA 600-620 HAS 3 DENTS OUT OF LIMITS BETWEEN STR 16L-17L. MAJOR REPAIR ACCOMPLISHED. REPLACED EXISTING REPAIRED SKIN SPLICE.

Part: SMOKE — DETECTED (LAVATORY) · airframe 38,769 hrs · 14,196 cycles

FLASH REPORTED NEAR MID-LAV, THEN SMOKE COMING OUT OF LAV. NO FLAME OR FIRE REPORTED.

Part: VALVE — FAILED (CABIN TEMP) · airframe 37,428 hrs · 13,688 cycles

COCKPIT VERY HOT, TEMPERATURE UNCONTROLLABLE. NO EVAC OCCURRED. NO OVERWEIGHT LANDING IN DTW. REPLACED TRIM AIR PRESSURE REGULATING VALVE.

Part: SKIN — DENTED · airframe 37,132 hrs · 13,571 cycles

LEFT HAND FUSELAGE STATION 600-640 STRINGER 13L-18L HAS MULTIPLE DENTS. SUPPLEMENTAL DATA UPDATE MAJOR REPAIR ACCOMPLISHED. INSTALLED FLUSH REPAIR, DOUBLERS AND TRIPLERS.

Part: STRINGER — DENTED · airframe 37,132 hrs · 13,571 cycles

STRINGER 14L AT STATION 620 HAS A DENT. MAJOR REPAIR ACCOMPLISHED. SPLICED IN HAT CHANNEL REPAIR.

Part: FLOORBEAM — ELONGATED (FUSELAGE) · airframe 37,132 hrs · 13,571 cycles

FORWARD CABIN FLOOR BODY STATION 395 LBL 2 T-CAP FASTENER HOLE IS ELONGATED. MAJOR REPAIR ACCOMPLISHED. INSTALLED 10 INCH STRAP AND NESTED ANGLE.

Part: INTERCOSTAL — CORRODED · airframe 37,132 hrs · 13,571 cycles

FORWARD CABIN FLOOR INTERCOSTAL AT STATION 301 TO 310.5 RBL 40 HAS EXCESSIVE MATERIAL REMOVED DURING CLEANUP. MAJOR REPAIR ACCOMPLISHED. REPLACED INTERCOSTAL.

Part: SKIN — DENTED · airframe 37,132 hrs · 13,571 cycles

CABIN AFT PRESSURE DECK SKIN BLENDED BEYOND LIMITS STATION 1693, RBL 51 AND STATION 1685, RBL 51.5. MAJOR REPAIR ACCOMPLISHED. FABRICATED AND INSTALLED DOUBLER.

Part: SKIN — DENTED · airframe 37,132 hrs · 13,571 cycles

FUSELAGE SKIN HAD DENT AT FRAME AT STA.288 APPROX. TO STRINGER 19R. MAJOR REPAIR ACCOMPLISHED. INSTALLED DOUBLER.

Part: FRAME — GOUGED · airframe 37,132 hrs

STATION 338.5 DOOR 1L SURROUND STUB FRAME WL 278 HAS A GOUGE. SUPPLEMENTAL DATA UPDATE MAJOR REPAIR ACCOMPLISHED. BLENDED GOUGE, INSTALLED REPAIR ANGLE AND MODIFIED DOOR STOP.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 37,132 hrs · 13,571 cycles

CABIN FLOORBEAM HAD EXCESS CORROSION AT STATION 740 RBL 62 STRINGER 17L, ALSO GUTTER UNDER STRUCTURE L-CHANNEL WAS CORRODED STATION 740, 62 RBL. MAJOR REPAIR ACCOMPLISHED. INSTALLED NEW SECTION OF INNER CREASE BEAM FROM 664 TO 756. A NEW UNDER GUTTER L-CHANNEL WAS FABRICATED, ALSO U-CHANNEL FOR BETWEEN STATION 720-740.

Part: AXLE — FRACTURED (RT MLG) · airframe 30,277 hrs · 11,130 cycles

THE RT MLG WHEEL TRUCK AFT AXEL WAS FOUND BROKEN. *S/D* NR 7 AXLE WAS FOUND COMPLETELY FRACTURED APPROX 18 INCHES FROM AXLE END. CAUSE IS DUE TO STRESS CORROSION CRACKING. THERE MAYBE A POSSIBLE CHROME PLATING ADHESION ISSUE RELEVANT TO OTHER AXLES THAT HAVE SIMILAR TYPE STRESS CORROSION. BOEING HAS BEEN INCLUDED IN THE ANALYSIS PROCESS.

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 29,836 hrs · 10,959 cycles

DIVERTED TO ORD DUE TO A PROBLEM WITH THE CAPTAIN''S WINDOW. *S/D* CAPTAIN''S WINDSHIELD (1L) WAS FOUND CRACKED AND ARCHING AT THE BUS BAR. CAPTAIN''S WINDSHIELD AND WINDOW HEAT CONTROLLER WERE REPLACED.

Part: FOOD CART — MALFUNCTIONED (GALLEY)

AFT GALLEY ELECTRICAL PIGTAIL GAVE OFF SPARKS AND ODOR. *S/D* INSPECTED CABLES AT ALL POSITIONS AND FOUND NO EVIDENCE OF BURNED, BENT, DAMAGED. SUSPECT BAD CARTS. REMOVED AND REPLACED FOOD CARTS.

Part: LIGHT — INOPERATIVE (CABIN)

EXTERIOR EMERGENCY LIGHTS INOP AT LEFT AFT ENTRY, RIGHT AFT ENTRY, LEFT OVERWING AFT LAMP, AND RIGHT OVERWING FORWARD LAMP. *S/D* RELAMPED.

Part: COMPRESSOR — FAILED (ENGINE)

DURING CLIMBOUT, HAD TWO COMPRESSOR STALLS. DIVERTED TO JFK. NORMAL LANDING. REPLACED ENGINE FOR HIGH PRESSURE COMPRESSOR DAMAGE. ON DISASSEMBLY FOUND 7 EACH 9TH STAGE BLADES FAILED AT MID SPAN. ADDITIONAL DOWN STREAM DAMAGE TO HIGH PRESSURE COMPRESSOR.