N563AS

Part: SIGN — DETACHED (ZONE 200) · airframe 67,467 hrs · 20,322 cycles

MID CABIN "EXIT" SIGN FELL OFF. GROUNDED - YES. RE SECURED MID CABIN EXIT SIGN LENS. LIGHTS OPERATE NORMALLY.

Part: LENS — MISSING (ZONE 200) · airframe 66,247 hrs · 19,867 cycles

EXIT/SALIDA SIGN MISSING @17F. GROUNDED - YES. REPLACED EXIT/SALIDA SIGN COVER AT 17F AS REQ'D.

Part: COVER — DETACHED (ZONE 200) · airframe 65,999 hrs · 19,785 cycles

17F EXIT COVER CAME OFF. GROUNDED - YES. REINSTALLED EXIT LENS AT 17F AS REQ.

Part: SIGN — DETACHED (ZONE 200) · airframe 64,542 hrs · 19,288 cycles

OVERWING EXIT SIGN FELL OFF. GROUNDED - YES. RESECURED EMERGENCY EXIT SIGN AT ROW 15DEF, AS REQUIRED. NO FURTHER DEFECTS NOTED AT THIS TIME.

Part: POWER SUPPLY — INOPERATIVE (ZONE 200) · airframe 63,388 hrs · 18,881 cycles

INTERIOR EMERGENCY LIGHTS INOP AT ROWS 9ABC AND 11ABC. GROUNDED - YES. REMOVED AND INSTALLED SERVICEABLE POWER SUPPLY BATTERY PACK, OPS CHECK GOOD IAW B737-800 AMM 33-51-06-900-805.

Part: POWER SUPPLY — INOPERATIVE (ZONE 200) · airframe 63,388 hrs · 18,881 cycles

EXTERIOR EMERGENCY EXIT LIGHT AFT OF L2 DOOR INOP. GROUNDED - YES. REMOVED AND INSTALLED SERVIEABLE POWER SUPPLY, OPS CK GOOD, IAW B737-800 AMM 33-51-06-960-806.

Part: POWER SUPPLY — INOPERATIVE (ZONE 200) · airframe 63,388 hrs · 18,881 cycles

EXTERIOR EMRGENCY EXIT LIGHT INOP AFT OF FWD OVERWING ESCAPE, LEFT SIDE. GROUNDED - YES. REMOVED AND INSTALLED POWER SUPPLY BATTERY PACK OPS CK GOOD IAW B737-800 AMM 33-51-06-960-805.

Part: TRANSITION PANEL — CORRODED (ZONE 100) · airframe 63,385 hrs · 18,880 cycles

FWD PIT TRANSITION LH SIDE HAS CORROSION STA 500B TO 500E. GROUNDED - YES. REMOVED AND RELACED FWD PIT TRANSITION L/H SIDE IAW B737-800 SRM 51-40-02-0G-0.W= 1" O= .040 R= .034 L= 2" D= .006.

Part: TRANSITION PANEL — CORRODED (ZONE 100) · airframe 63,385 hrs · 18,880 cycles

AFT PIT R/H TRANSITION HAS CORROSION STA 767-727D. GROUNDED - YES. REMOVED AND REPLACED TRANSITION FROM STA 767-727D IAW B737-800 SRM 51-40-02-0G-0, AFT PIT R/H TRANSITION FROM STA 727E TO STA 727B FOUND TO BE IN LIMITS IAW B737-800 SRM 53-00-53-1A-2W= 1' O= .040" R= .035" L= 2" D= .006".

Part: CARGO TRACK — CRACKED (ZONE 100) · airframe 63,385 hrs · 18,880 cycles

AFT PIT R/H CARGO TRACK CRACKED AT STA 727H. GROUNDED - YES. REMOVED CRACKED SECTION OF CARGO TRACK AND REPAIRED WITH A NEW SECTION OF CARGO TRACK IN THE AFT PIT AT STA 727H IAW B737-800 SRM 53-00-53-2R-3.

Part: TRANSITION PANEL — CORRODED (AFT CARGO) · airframe 63,385 hrs · 18,880 cycles

AFT PIT L/H TRANSITION IS CORRODED FROM STA 727C-787. GROUNDED - YES. REMOVED AND REPLACED AFT PIT L/H TRANSITION FROM STA 727F TO 727C IAW B737-800 SRM 51-40-02-0G-0, TRANSITION FROM STA 727G TO STA 787 FOUND TO BE IN LIMITS IAW B737-800 SRM 53-00-53-1A-2W= 1" O= .040 R= .035 L= 1" D= .005.

Part: CARGO TRACK — CRACKED (ZONE 100) · airframe 63,385 hrs · 18,880 cycles

AFT PIT CARGO TRACK L/H SIDE CRACKED AT STA 727G. GROUNDED - YES. REMOVED DAMAGED SECTION OF CARGO TRACK AT L/H STA 727G AND REPAIRED WITH NEW SECTION FABRICATED AND INSTALLED IAW B737-800 SRM 53-00-53-2R-3.

Part: RIB — CRACKED (ZONE 300) · airframe 63,385 hrs · 18,880 cycles

LEFT HORIZONTAL STAB RIB AT STA. 120.30 IS CRACKED. MARKED. GROUNDED - YES. REPAIR LEFT HORIZONTAL STAB RIB AT STA 120.30 IAW B737-800 SRM 55-10-09-2R-4.

Part: RIB — CRACKED (HSS 102) · airframe 63,385 hrs · 18,880 cycles

LEFT HORIZONTAL STAB RIB AT STA 101.90 IS CRACKED. MARKED. GROUNDED - YES. REPAIRED LEFT HORIZONTAL STAB RIB AT STA 101.90 IAW B737-800 SRM 55-10-09-2R-4.

Part: RIB — CRACKED (ZONE 300) · airframe 63,385 hrs · 18,880 cycles

LEFT HORIZONTAL STAB RIB AT STA. 166.30 IS CRACKED. MARKED. GROUNDED - YES. REPAIR LEFT HORIZONTAL STAB RIB AT STA 166.30 IAW B737-800 SRM 55-10-09-2R-4.

Part: LENS — MISSING (EMERGENCY LIGHT) · airframe 63,293 hrs · 18,846 cycles

17F COVER FOR LIGHTING IS MISSING. GROUNDED - YES. REPLACED BROKEN EMERGENCY EXIT SIGN COVER AT SEAT 17F IN REF TO AMM 33-51-01. OPS-CHECK GOOD.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 61,762 hrs · 18,332 cycles

WHILE PERFORMING T/C 78233008 EMERGENCY LIGHTS, DISCOVERED R/H FWD OVERWING EMERGENCY LIGHT COVER POINTING TO WRONG DIRECTION. GROUNDED - YES. REMOVED AND REPLACED EMERGENCY OVERWING FWD R/H LIGHT COVER. COVER NOW POINTING TOWARDS EXIT. OPS CHECK GOOD. REF AMM 33-51-01.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 61,125 hrs · 18,124 cycles

FLIGHT DECK ZONE TEMP CONTROLLER ILLUMINATED ON RECALL. GROUNDED - YES. (RESOLVED ON W/O: 1975109 TASKCARD: N/R-00003 ) PERFORMED ZONE PACK CONTROLLER BITE REF AMM 21-61-00. NO FAULTS FOUND, NO HISTORY. THI CLEARS MEL 21-21G. C/N 29023563 REMOVED. NO CONFIG CHANGES. SEAMC SCOTT NOTIFIED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 60,941 hrs · 18,050 cycles

RT SIDE PACK ON AFTER START. RAN QRH WITH NO CHANGE. GROUNDED - YES. PERFORM PACK TEMP CONROL BITE REF FIM 21-60 TASK 801, NO 2 CONTROL SHOWS TVC FAULT THIS PACK, WAS ABLE TO RESET FAULT. BITE SHOWS NO CURRENT FAULTS. REF FIM 21-62 TASK 831. NO HISTORY 60 DAYS.

Part: LENS — DETACHED (MAIN PASSENGER C) · airframe 60,824 hrs · 18,009 cycles

EMERGENCY EXIT PLACARD IN 16 D,E,F FELL OFF. GROUNDED - YES. INSTALLED NEW EMERGENCY PLACARD ON AT ROW 16 DEF SIGN IS SECURED,.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 60,762 hrs · 17,988 cycles

ENG #2 BLEED TRIP CAUTION LIGHT ON AT 25,000 FT CLIMBING, CLEARED ON RESET. GROUNDED - YES. VERIFIED HISTORY NO FAULTS PREVIOUS 180 DAYS NO BLEED TRIP LIGHT PRESENT AFTER RESET REFERENCE FIM 36-10 TASK 801.

Part: BATTERY PACK — INOPERATIVE (CABIN) · airframe 60,736 hrs · 17,981 cycles

REF TC 78233001 - BATTERY PACK @ M1670 - EMERGENCY LIGHT POWR SUPPLY FAILED CAP CHECK. GROUNDED - YES. REPLACED BATTERY PACK @ M1670 - EMERGENCY LIGHT POWER SUPPLY WITH SERVICABLE UNIT, OPS CHECKS OK. REF AMM 33-51-06. 3 MIG 51A TAGS INSTALLED / REMOVED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 60,728 hrs · 17,977 cycles

F/O'S AUTO FLIGHT STATUS ANNUNCIATOR DOES NOT TEST IN POS #1. GROUNDED - YES. RESET A/C POWER. OPS TEST GOOD. REF AMM 22-11-32.

Part: SPINNER — WORN (#2 ENGINE) · airframe 60,702 hrs · 17,965 cycles

#2 ENGINE FWD SPINNER CONE MORE THAN 50% WORN. GROUNDED - YES. REPLACED AS REQUIRED PER TC 78472010#2 ENGINE FWD SPINNER CONE.

Part: CONTROL PANEL — FAULTY (FLIGHT DECK) · airframe 60,341 hrs · 17,836 cycles

FIRST OFFICER COURSE SELECT WINDOW SHOWS "UAU". GROUNDED - YES. CURRENT STATUS ALSO SHOWED MCP FAULTS.CYCLED POWER & RESTORED OPERATION.REMOVED & REPLACED MCP DUE TO REPEAT FAILURE.OP CK NORMAL.REF MM 22-11-34/401.NINE TAGS INSTALLED & REMOVED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 60,301 hrs · 17,821 cycles

F.O. SIDE COURSE SELECTOR WINDOW DISPLAY FROZEN. GROUNDED - YES. RESET POWER TO AUTOPILOT SYSTEM. F.O. COURSE SELECTOR DISPLAY RETURNED TO NORMAL OPERATION. OPS CHECK GOOD. REF AMM 22-11-00.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 60,278 hrs · 17,816 cycles

THROUGHOUT FLIGHT BOTH HF RADIOS HAVE POOR RECEPTION ON ALL FREQUENCIES. UNABLE TO RECEIVE SELCAL FROM BOTH HF RADIOS ON ALL FREQUENCIES. SAN FRANCISCO RADIO HAD NO REPORTS OF WIDE SPREAD HF RECEPTION ISSUES. GROUNDED - YES. ON DEFERRAL.

Part: CONTROL PANEL — FAULTY (FLIGHT DECK) · airframe 60,185 hrs · 17,780 cycles

AUTOTHROTTLES DISENGAGED INFLIGHT AND WILL NOT RE-ENGAGE. GROUNDED - YES. (RESOLVED ON W/O: 1963826 TASKCARD: N/R-00002 ) FOUND FAULT 22-31543 HIT 30 TIMES ON 2 DIFFERENT FLIGHT LEGS ON 08/03/2023. ACCOMPLISHED FIM 22-31 TASK 830. REPLACED MCP REF AMM 22-11-34/401. MCP INSTALLATION TEST PASSED WITH NO FAULTS FOUND REF AMM 22-11-34-740-801. LRU REPLACEMENT TEST FOR MCP REF AMM 22-11-34/501 AND LAND VERIFY TEST REF AMM 22-11-00/201 PASSED WITH NO FAULTS FOUND. ETOPS GROUND VERIFICATION SUCCESSFUL. THIS CLEARS MEL 22-4B AND MEL 22-99B. PLACARDS REMOVED C/N 03039563. SEAMC WILL NOTIFIED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 59,926 hrs · 17,672 cycles

RIGHT CENTER FUEL PUMP. LOW PRESSURE. GROUNDED - YES. ON DEFERRAL.

Part: CONTROL PANEL — FAULTY (FLIGHT COMPARTME) · airframe 59,897 hrs · 17,660 cycles

MCP LOCKUP OCCURED DURING DECENT AT APPROX 12,000'. ATTEMPTED TO RESET F/D INITIALLY WITH NO AFFECT, EVENTUALLY IT DID RESET. COMPLETED MCP LOCKUP QRC, OPS NORMAL ON APPCH. GROUNDED - YES. REMOVED & REPLACED DFCS MCP PER AMM 22-11-34.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 59,699 hrs · 17,579 cycles

ROW 16ABC EMERGENCY LIGHT IS OFF. GROUNDED - YES. REMOVED AND REPLACE EMERGENCY LIGHT ON ROW 16ABC IAW B737-800 AMM 33-51-00.

Part: VALVE — MALFUNCTIONED (#2 ENGINE) · airframe 59,401 hrs · 17,494 cycles

#2 ENGINE -ANTI-ICE HAD BRIGHT BLUE COWL VALVE LIGHT AND AMBER TAI INDICATION WHEN SELECTED ON IN ICING CONDITIONS WOULD NOT EXTINGUISH. REF MEL 30-3C ENG 2 NOSE COWL ANTI ICE VALVE INOP. GROUNDED - YES. REMOVED & REPLACED #2 ENG ANTI ICE VALVE IAW B737-800 AMM 30-21-11.

Part: SPRING — DEGRADED (RAM AIR DEFLECTO) · airframe 59,351 hrs · 17,482 cycles

ON DEPARTURE OGG ABOUT 12000FT, RIGHT PACK LIGHT ILLUMINATED. COMPLETED PACK OVERHEAT CHECKLIST. RIGHT PACK LIGHT ILL AGAIN. NO FURTHER ACTION - DIVERT TO HNL. GROUNDED - YES. ACCOMPLISHED B737-800 FIM 21-53 TASK 820 STEPS A THROUGH E (2)(B) AND STEPS F (3).(B) RADA OPS TEST FAILED THE R/H PACK INLET DEFLECTOR DOOR IS STUCK FULLY EXTENDED AND THE DOOR SHAFT SPRING IS BROKEN THE MODULATING PANELS FUNCTION NORMALLY. REPLACED DOOR SPRING REF B737-800 AMM 21-51-22.

Part: MOTOR — FAULTY (RT BOOST PUMP) · airframe 59,196 hrs · 17,433 cycles

DURING CLIMB THROUGH 17000 OBSERVED THE #2 MAIN FUEL TANK FWD LOW PRESSURE LIGHT ILLUMINATED. AT THE TIME THE ENGINES WERE FEEDING FROM CENTER TANK, THE #2 MAIN FUEL TANK WAS FULL AT 8.7. RAN FUEL PUMP LOW PRESSURE QRH. GROUNDED - YES. REMOVED AND REPLACED #2 FWD BOOST PUMP REF B737-800 AMM 28-22-41. OPS AND LEAK CHECK NORMAL. ETOPS GROUND VERIFICATION SUCCESSFUL.

Part: HARNESS — FAULTY (#1 ENGINE) · airframe 59,159 hrs · 17,423 cycles

#1 ENGINE CONTROL LIGHT ILLUMINATED AFTER #1 ENGINE START. GROUNDED - YES. REMOVED AND REPLACED J9 HARNESS. REF B737-800 AMM 73-21-06.

Part: HARNESS — FAULTY (#1 ENGINE) · airframe 59,140 hrs · 17,416 cycles

FOLLOWUP TO CHRONIC HISTORY TO #1 EEC LIGHT ILLUMINATING. GROUNDED - YES. R/R ENG #1 J5 HARNESS IAW B737-800 AMM 73-21-06.PERFORMED ENG RUN -EEC BITE CHECK IAW AMM TASK 71-00-00-700-808-F00. CHECK GOOD. PERFORMED ENG 1 ACTUATOR TEST IAW AMM TASK 71-00-00-700-807-F00. CHECK GOOD.FOUND NO RECENT FAULT/ NO FAULT HISTORY.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 59,140 hrs · 17,416 cycles

DURING ENG #1 START #1 ENGINE CONTROL LIGHT ILLUMINATED. GROUNDED - YES. PERFORMED ENG # 1 EEC BITE TEST IAW B737-800 AMM 73-00 TASK 801. FAULT CODE 75-20431 DISPLAYED. PERFORMED ACTUATOR TEST IAW AMM 71-00-00-700-807 ACTUATOR TEST PASSED, NO FAULT DISPLAYED. ENGINE CONTROL LIGHT OFF.

Part: HARNESS — FAULTY (#1 ENGINE) · airframe 59,124 hrs · 17,412 cycles

CREW REPORTS #1 ENGINE CONTROL AMBER LIGHT ILLUMINATED AFTER ENGINE START. GROUNDED - YES. #1 ENG EEC LOGGED FAULT 75-20431 VBV DEMAND & POSITION SIGNALS DISAGREE. REPLACED J10 HARNESS. EEC BITE SHOWS NO FAULTS. ACTUATORS TEST PASS, RAN ENGINE #1 WITH NO DISCREPANCIES, NO ENG CONT. LIGHT. ALL OPS NML, REF B737-800 AMM 73-21-06, 73-21-00, 71-00-00, B737-800 FIM 75-32/801.

Part: PROBE — FAULTY (#1 ENGINE) · airframe 59,124 hrs · 17,412 cycles

WHILE TROUBLESHOOTING (ASA LP 60513904), FOUND T49.5 (S4) PROBE INDICATION ALL DASHES, NO READING ON # 1 ENGINE. GROUNDED - YES. REMOVED AND REPLACED T49.5 (S4) PROBE REF B737-800 AMM 77-21-01/401.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 59,109 hrs · 17,404 cycles

R COWL ANTI ICE VALVE STUCK IN TRANSIT. AMBER TAI LIGHT. GROUNDED - YES. ACCOMPLISHED A #2 ENGINE COWL TAI VALVE OP-CHECK PER B737-800 AMM 30-21-11. ALL TESTS NORMAL. ALSO VERIFIED NO LEAKS AT VALVE. ALL INDICATIONS NORMAL DURING TEST. AC HAS NO SIMILAR HAS NO SIMILAR HISTORY WITHIN THE LAST 180 DAYS. OK FOR SERVICE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 59,109 hrs · 17,404 cycles

#1 ENGINE CONTROL LIGHT AFTER START. GROUNDED - YES. PERFORMED EEC BITE PROCEDURE REF B737-800 FIM 73-00 TASK 801. FOUND FAULT CODE 75-10431 VBV DEMAND AND POSITION SIGNALS DISAGREE. PERFORMED FIM 75-32 TASK 801 AND ACTUATOR TEST PER B737-800 AMM 71-00-00 FAULT CLEARED. ENG CONTROL LIGHT EXTINGUISHED. PERFORMED 2 #1 ENG STARTS AND IDLE CHECKS WITH NO FAULTS FOUND. REACCOMPLISHED EEC BITE WITH NO FAULTS NOTED. A/C OK FOR SERVICE.

Part: HARNESS — FAULTY (#1 ENGINE) · airframe 59,097 hrs · 17,399 cycles

ENG #1 EEC ILLUMINATED DURING TAXI OUT, MULTIPLE PREVIOUS WRITE UPS. ( AT LEAST 5). GROUNDED - YES. REMOVED AND REPLACED J6 HARNESS, REF B737-800 AMM 73-21-06-400-801-F00.

Part: HMU — FAULTY (#1 ENGINE) · airframe 59,054 hrs · 17,383 cycles

LEFT ENGINE CONTROL LIGHT ILLUMINATED ON TAXI CHECK THIS HAPPENED AT 58 MINUTES AFTER ENGINE START ENGINE START 2335Z, ENGINE CUTOFF 00592. GROUNDED - YES. REPLACED #1 ENG HMU REF ASA T/C'S N8473000 & N8473001.

Part: EEC — FAULTY (#1 ENGINE) · airframe 59,054 hrs · 17,383 cycles

#1 ENGINE CONTROL LIGHT ON @ TAXI OUT. GROUNDED - YES. REMOVED & REPLACED EEC IAW B737-800 AMM TASK 73-21-60-000-801-F00 AND AMM TASK 73-21-60-400-801-F00.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 59,054 hrs · 17,383 cycles

LEFT PACK LIGHT ON WITH RECALL. GROUNDED - YES. REVERSED MEL 21-5C MAINTENANCE PROCEDURES FROM LEFT RAM DOOR ACTUATOR; REMOVED CONNECTOR BAG AND RECONNECTED ACTUATOR CONNECTOR, REMOVED AND STOWED TR DEACTIVATION BOLT AND NUT FROM RIGGING PIN HOLE, AND REMOVED SAFETY WIRE SECURING ACTUATOR ROD TO BELLCRANK BOLT. PERFORMED ZONE TEMP CONTROLLER BITE REF B737-800 AMM 21-61-00. NO FAULTS FOUND. LEFT RAM DOOR ACTUATOR MOVES SMOOTHLY WITHOUT BINDING OR RESTRICTION. ETOPS VERIFICATION SUCCESSFUL.

Part: EEC — FAULTY (#1 ENGINE) · airframe 59,054 hrs · 17,383 cycles

#1 ENG CONTROL LIGHT ILLUMINATED ON TAXI. GROUNDED - YES. #1 EEC REMOVED AND REPLACED IAW B737-800 AMM TASK 73-21-60-000-801-F00 AND AMM TASK 73-21-60-400-801-F00.. (REF ASA LP 60501568)

Part: VALVE — FAULTY (#1 ENGINE) · airframe 58,980 hrs · 17,350 cycles

REPLACE #1 TBV DUE TO HISTORY OF FAULTS. GROUNDED - YES. REPLACED J6 HARNESS REF 73-21-06. REPLACED TBV IN REF TO B737-800 AMM 75-23-01 LEAK OPS CHECK GOOD.

Part: PROBE — OUT OF LIMITS (LT FUEL TANK) · airframe 58,793 hrs · 17,301 cycles

3 HOURS INTO FLT #2 MAIN FUEL INDICATED 800LBS > THAN #1 MAIN FUEL, ALL PUMPS ON & FUEL X-FEED VALVE WAS CLOSED. AFTER TURNING CTR PUMPS OFF WHEN ALL CTR TANK FUEL INDICATED ZERO, GOT A FUEL IMBALANCE LIGHT WITH 1.1 LB DIFFERENCE 1 HR AFTER ESTABLISHING BALANCED FUEL, ALL CTR PUMPS OFF, TANKS READ (L)5.39 (C) 0.00 5.31(R) TOTAL 10.7. GROUNDED. ACCOMP TANK 1 TANK & COMP UNITS RESISTANCE & CAP CHECK. FOUND TANK UNITS F4L & F6L CAP OUT OF LIMITS. IAW AMM 28-41-21. REPLACED F4 & F6 IAW AMM 28-41-21. INSTALLED 532DB, 5632FB MM 28-11-11. CROSSFEED VALVE FUNCL TEST PASS AMM 28-22-00-730-802. REPAIR CON FIM 28-21 TASK 803, UNWANTED XFER #1 TO CTR PASSED. REPAIR CON FIM 28-21 TASK 815, UNWANTED XFER CTR TO #2 PASSED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 58,612 hrs · 17,252 cycles

ON TAXI OUT ENGINE CONTROL LIGHT ILLUMINATED #1 ENGINE. GROUNDED - YES. ACCOMPLISHED EEC BITE FOUND FAULT 75-20581 (TBV DEMAND AND POSITION SIGNALS DISAGREE). ACCOMPLISHED ACTUATORS TEST NO CURRENT FAULTS NOTED. ENGINE CONTROL LIGHT EXTINGUISHED. REF B737-800 FIM 73-00 TASK 801 AND FIM 75-23 TASK 801.

Part: NOT REPORTED — NOT REPORTED (NOT REPORTED) · airframe 58,492 hrs · 17,220 cycles

BOTH RTP PANELS SHOW FAIL FOR HF1. GROUNDED - YES. PERFORMED HF COMMUNICATION SYSTEM BITE PROCEDURES PER B737-800 FIM 23-11 TASK 801, OPS CK GOOD OK FOR SVC.

Part: NONE — NONE (NONE) · airframe 58,472 hrs · 17,216 cycles

CONTROL CABIN ZONE TEMP LIGHT ILLUMINATES ON RECALL AND RESETS WITH MASTER CAUTION RESET. GROUNDED - YES. SYSTEM HAD CONTROL CABIN TRIM MODULATING VALVE FAULT. IT RESET & SYS BITE PASSED BUT THERE IS A PREVIOUS WRITE UP LAST WEEK. SAME FAULT & RESET WITH NO LRU CHANGE. CONT CAB ZONE TEMP LT DOES NOT SHOW ON MASTER RECALL. PERFORMED PZTC BITE IAW FIM 21-62 TASK 801, NO FAULTS PRESENT ON EITHER CONTLR 1 OR 2, BIT, PREV, OR VERIFY, GREEN ON VERIFY, RESET X2. AS PRECAUTION, CLEANED FLT DECK TEMP SENSOR IAW AMM 21-61-10-100-801. FILTER WAS EXTRA DUSTY. PERFORMED CABIN CONT AND INDICATION OPS TEST IAW AMM 21-61-00-700-807-002. BOTH PACKS RAN INDEPENDENTLY AND TOGETHER, HIGH AND LO, NO OBSERVED DEFECTS.

Part: NOT REPORTED — NOT REPORTED (NOT REPORTED) · airframe 58,477 hrs · 17,217 cycles

DATA LINK SHOWING DATA LINK FAIL. GROUNDED - YES. ACCOMPLISHED FMCS - CPDLC FUNCTIONAL TEST REF B737-800 AMM 34-61-00-720-899 WITH NO FAULTS FOUND. ALL TEST PASS. "DATA LINK READY" SHOWN ON "ATC" PAGE.

Part: FUEL CONTROL — FAULTED (APU) · airframe 58,326 hrs · 17,169 cycles

APU FAILED TO START FL34, APU FAULT LIGHT WITH 1000 EGT SPIKE. GROUNDED - YES. REMOVED AND REPLACED APU FUEL CONTROL UNIT IAW B737-800 AMM 49-31-11.

Part: PITOT HEAD — FAULTED (VERTICAL STAB) · airframe 58,321 hrs · 17,168 cycles

L ELEV PITOT CAUTION ILLUMINATED AFTER #2 ENGINE START. GROUNDED - YES. REPLACED L ELEVATOR PITOT TUBE. OPS NORMAL REF B737-800 AMM 27-31-94. SYSTEM LEAK TEST GOOD REF AMM 27-31-17.

Part: CIRCUIT BREAKER — TRIPPED (PITOT HEAT) · airframe 58,321 hrs · 17,168 cycles

AFTER LANDING, WHEN PROBE HEAT SWITCH TURNED TO AUTO, LT ELEV PITOT LIGHT ILLUMINATED. GROUNDED - YES. FOUND C/B P18-3 ROW C #4 ELEV PITOT HEAT LEFT TRIPPED. RESET THE C/B IAW AMM 20-60-01-860-801. VERIFIED CORRECT OPERATION IAW FIM 30-31 TASK 805.

Part: AUTOTHROTTLE SYS — FAULTED · airframe 58,249 hrs · 17,142 cycles

AUTO THROTTLE WILL NOT ARM. GROUNDED - YES. INITIAL EVALUATION, PERFORMED A/T BITE IAW FIM 22-31 TASK 801. PASSES CURRENT STATUS TEST AND INTERACTIVE SERVO MOTOR AND TORQUE TESTS, NO DEFECTS NOTED. INFLIGHT FAULT REVIEW SHOWS LEGS 6 & 7 HAVE MULTIPLE HITS ALL FOR MTX MSG 22-31543 A/T ENG 28VDC INV INDICATING AN MCP TO A/T SWITCH POWER ISSUE. DUE TO MCP JUST RECENTLY HAVING BEEN REPLACED, PERFORMED DFCS BITE, FAULT REVIEW, CURRENT STATUS/AUTO TEST IAW AMM 22-11-00-740-801, MCP TEST IAW AMM 22-11-00-740-806, & LAND VERIFY IAW AMM 22-11-00-700-801 AS PRECAUTIONARY, NO FAULTS FOUND. MCP CHECKS GOOD AT THIS TIME. FOLLOWING FIM 22-31 TASK 830, NO FAULTS ACTIVE AT THIS TIME. NO HISTORY FOR MTX MSG 22-31543. CAT III AUTOLAND APPROACH IS AUTHORIZED.

Part: FAN — CORRODED (NR 1 ENGINE) · airframe 58,243 hrs · 17,141 cycles

ENG. #1 S/N # 804749, FAN FRAME @ 12:00 O'CLOCK POSITION ( UNDER NUTPLATE) . PREVIOUS CORROSION BLENDED BEYOND LIMITS. REQUIRES ENGINEERING APPROVAL FOR DISPOSITION. GROUNDED - YES. REMOVED #1 ENGINE S/N # 804749, REPLACED WITH S/N # 890571 REF. ASA T/C # 78471000 W/O # 1934298. DEFECT TRANSFERRED TO ASA SHOP W/O# 1938112.

Part: SHUTOFF VALVE — FAILED (NR 2 ENGINE) · airframe 57,930 hrs · 17,055 cycles

ABORTED ENGINE START ENG #2. MAX MOTORING 22.4% - HUNG START AFTER START LEVER RAISED TO IDLE. COMPLIED WITH ASA QRH. GROUNDED - YES. FOUND #2 ENG PRSOV FAILED. REMOVED AND REPLACED #2 ENG PRSOV REF B737-800 AMM 36-11-04. OPS CK GOOD GROUND VERIFICATION SUCCESSFUL.

Part: MODULATING VALVE — FAULTED (RT ACM) · airframe 57,921 hrs · 17,051 cycles

ON RECALL ZONE TEMP ILLUMINATES FOR CONT CAB EXTINGUISHES ON MASTER CAUTION RESET. GROUNDED - YES. ACCOMPLISHED PACK ZONE TEMPERATURE CONTROLLER (PZTC) BITE PER B737-800 AMM 21-61-00-700-806-002 RH CONTROLLER FAULTED CONTROL CABIN TRIM VALVE. REMOVED ZONE TRIM VALVE V143 PER AMM 21-1-21-000-801. INSTALLED TRIM VALVE PER AMM 21-61-21-400-801 ACCOMPLISHED TRIM VALVE TEST PER AMM SUB TASK 21-61-21-400-801 PARA G.ALL TESTS PASSED.

Part: BLEED VALVE — OUT OF RANGE (NR 1 ENGINE) · airframe 57,921 hrs · 17,051 cycles

WHILE PERFORMING ASA T/C 78273000 FOUND #1 ENG FAULT 75-10591 THE TBV POSITION SIGNAL IS OUT OF RANGE. LONG TIME FAULT. GROUNDED - YES. TBV RECEPTACLE DP907 OUT-OF LIMITS REF. B737-800 FIM 75-23/802 STEP (4). REMOVED AND REPLACED TRANSIENT BLEED VALVE PER B737-800 AMM 75-23-01.

Part: DOOR — OUT OF RIG (UNKNOWN) · airframe 57,745 hrs · 16,994 cycles

FA REPORTS L1 DOOR VERY DIFFICULT TO CLOSE. GROUNDED - YES. PERFORMED HANDLE TORQUE TEST PER B737-800 AMM 52-11-00. FAILED DOOR HANDLE TORQUE TEST. TORQUE MEASUREMENT IS OUTSIDE SPECIFIED RANGE. ACCOMPLISHED DOOR RIG PER AMM 52-11-00-820-801.

Part: ACTUATOR — FAULTY (RIGHT RAM INLET) · airframe 57,415 hrs · 16,901 cycles

RIGHT PACK LIGHT ILLUMINATES WITH RECALL AND EXTINGUISHES WITH RESET. GROUNDED - YES. REMOVED & REPLACED R/H RAM AIR INLET ACTUATOR REF B737-800 AMM 21-51-21.

Part: LIGHT — INOPERATIVE (MAIN PASSENGER C) · airframe 57,406 hrs · 16,898 cycles

EMERGENCY LIGHTS ASSOCIATED WITH M1674 ARE INOP. GROUNDED - YES. REMOVED AND REPLACED M1674 IAW B737-800 AMM 33-51-06-960-806. TEST GOOD IAW B737-800 AMM 33-51-06-960-806.

Part: FLOOR PANEL — NONE · airframe 57,406 hrs · 16,898 cycles

LAV E FLOOR PANEL D72D41006-111 HAS DAMAGED CORNER.(RELEASED BY ASA FROM QC BOND). GROUNDED - YES. EVALUATED AND REMOVED DAMAGED MATERIALS,POTTED AND REFINISHED REPAIR AREA OF LAV E FLOOR PANEL D72D41006-111 IAW B737-800 SRM 53-00-50-01-1, 53-00-50-1A-1, 53-00-50-2R-10.

Part: FLOOR PANEL — DELAMINATED · airframe 57,406 hrs · 16,898 cycles

CABIN AFT WET AREA FLOOR PANEL 147A5810-90 HAS CORRODED INSERTS & PEELING FIBERS (PARTS RACK ITEM). GROUNDED - YES. REPAIRED DAMAGED INSERTS PEELING FIBERS IAW B737-800 SRM 53-00-50-2R-0.

Part: FLOOR PANEL — DELAMINATED · airframe 57,406 hrs · 16,898 cycles

CABIN AFT WET AREA FLOOR PANEL 147A5810-137 HAS CORRODED INSERTS, MISSING INSERTS, PEELING FIBERS & PUNCTURE DAMAGE. GROUNDED - YES. REPAIRED DAMAGED INSERTS AND MISSING INSERTS AND PEELING FIBERS AND PUNCTURE DAMAGE IAW B737-800 SRM 53-00-50-2R-0.

Part: FLOOR PANEL — NONE · airframe 57,406 hrs · 16,898 cycles

CABIN FWD WET AREA FLOOR PANEL 141A5810-236 HAS CORRODED INSERTS, BROKEN EDGE & PEELING FIBERS (PARTS RACK ITEM). GROUNDED - YES. REPAIRED DAMAGED INSERTS, BROKEN EDGE, AND PEELING FIBERS IAW B737-800SRM 53-00-50-2R-0.

Part: FLOOR PANEL — NONE · airframe 57,406 hrs · 16,898 cycles

CABIN FWD WET AREA FLOOR PANEL 141A5810-175 HAS CORRODED INSERTS & BROKEN EDGE (PARTS RACK ITEM). GROUNDED - YES. REPAIRED DAMAGED INSERTS AND BROKEN EDGE IAW B737-800 SRM 53-00-2R-0.

Part: FLOOR PANEL — DELAMINATED · airframe 57,406 hrs · 16,898 cycles

CABIN AFT WET AREA FLOOR PANEL 147A5810-123 HAS DAMAGED INSERT & PEELING FIBERS. GROUNDED - YES. REPAIRED DAMAGED INSERTS & PEELING FIBERS IAW B737-800 SRM 53-00-50-2R-0.

Part: FLOOR PANEL — DAMAGED · airframe 57,406 hrs · 16,898 cycles

CABIN AFT WET AREA FLOOR PANEL 147A5810-28 HAS CORRODED INSERTS, EDGE DAMAGE & PEELING FIBERS. GROUNDED - YES. REPAIRED DAMAGED INSERTS, EDGE DAMAGE, AND PEELING FIBERS IAW B737-800 SRM 53-00-50-2R-0.

Part: INSERT — DELAMINATED · airframe 57,406 hrs · 16,898 cycles

CABIN FWD WET AREA FLOOR PANEL 141A5810-286 HAS CORRODED INSERTS & MISSING INSERTS (PARTS RACK ITEM). GROUNDED - YES. REPAIRED CORRODED & MISSING INSERTS IAW B737-800 SRM 53-00-50-2R-0.

Part: FLOOR PANEL — NONE · airframe 57,406 hrs · 16,898 cycles

CABIN AFT WET AREA FLOOR PANEL 147A5810-27 HAS CORRODED INSERTS & PEELING FIBERS GROUNDED - YES. REPAIRED DAMAGED INSERTS AND PEELING FIBERS IAW B737-800 SRM 53-00-50-2R-0.

Part: FLOOR PANEL — DELAMINATED · airframe 57,406 hrs · 16,898 cycles

CABIN AFT WET AREA FLOOR PANEL 147A5810-136 HAS CORRODED INSERTS, MISSING INSERTS & PEELING FIBERS. GROUNDED - YES. REPAIRED DAMAGED INSERTS, MISSING INSERTS, AND PEELING FIBERS IAW B737-800 SRM 53-00-50-2R-0.

Part: FLOOR PANEL — NONE · airframe 57,406 hrs · 16,898 cycles

CABIN FWD WET AREA FLOOR PANEL 141A5810-189 HAS CORRODED INSERTS &PEELING FIBERS (PARTS RACK ITEM). GROUNDED - YES. REPAIRED DAMAGED INSERTS AND PEELING FIBERS IAW B737-800 SRM 53-00-50-2R-0.

Part: FLOOR PANEL — NONE · airframe 57,406 hrs · 16,898 cycles

CABIN FWD WET AREA FLOOR PANEL 141A5810-155 HAS CORRODED INSERTS & AND BROKEN EDGE (PARTS RACK ITEM). GROUNDED - YES. REPAIRED DAMAGED INSERTS AND BROKEN EDGE IAW B737-800 SRM 53-00-50-2R-0.

Part: FLOOR PANEL — DELAMINATED · airframe 57,406 hrs · 16,898 cycles

CABIN FWD WET AREA FLOOR PANEL 141A5810-454 HAS CORRODED INSERTS, MISSING INSERTS & PEELING FIBERS (PARTS RACK ITEM). GROUNDED - YES. REPAIRED DAMAGED INSERTS, MISSING INSERTS AND PEELING FIBERS IAW B737-800SRM 53-00-50-2R-0.

Part: WEB — NONE · corrosion level 2 · airframe 57,406 hrs · 16,898 cycles

FWD CARGO LOWER THRESHHOLD HAS CORR. GROUNDED - YES. REMOVED CORR. FROM FWD CARGO LWER THRESHOLD WEB ORIG THICKNESS .045 IAW B737-800 SRM 53-30-15.MAT. LOSSED .009REMAINING THICKNESS .036FOUND TO BE OUT OF LIMITS IAW B737-800 SRM 53-30-15TOOL#T8224M DUE DATE 10/18/22.REMOVED AND REPLACED WITH NEW THRESHOLD WEB IAW B737-800 SRM 51-40-02 AND BOEING DWG # 143A8330 REV A. LOCATED, DRILLED, COUNTERSUNK AND DEBURRED NEW THRESHOLD WEB IAW B737-800 SRM 51-40-05.

Part: WEB — CORRODED · corrosion level 2 · airframe 57,406 hrs · 16,898 cycles

AFT CARGO THRESHOLD HAS CORR MARKED IN RED. GROUNDED - YES. REMOVED DAMAGE FROM THE AFT CARGO THRESHOLD WEB IAW B737-800 SRM 53-60-15-1A-1.2.D ORIG THICKNESS IS .045 IAW B737-800 SRM 53-60-15-0I-1TABLE 3REMOVED .007REMAINING THICKNESS IS .038 AND IS FOUND TO BE OUT OF LIMITS IAWB737-800 SRM 53-60-15-1A-1.4.G.(B)(L)TOOL # T8224M DUE DATE 10/18/22REMVOED AND REPLACED AFT CARGO THRESHOLD WEB IAW B737-800 SRM 51-40-02 AND B737-800 SRM 51-40-05 AND BOEING DWG: 146A8340 REV:--.

Part: UNKNOWN — CORRODED · corrosion level 2 · airframe 57,406 hrs · 16,898 cycles

MAIN CABIN AFT FLOOR STRUCTURE WET AREA, FLOOR BEAM FLANGE SURFACE CORROSION NOTED. GROUNDED - YES. REMOVED CORROSION, ORIGINAL THICKNESS 0.150. REMOVED 0.020,REMAINING THICKNESS 0.130. FOUND TO BE OUT OF LIMITS IAW B737-800 SRM 53-70-51-1A-1. T8224K CAL DUE 10/13/22. REMOVED AND REPLACED TEE CAP SECTION IAW B737-800 SRM 53-70-51-2R-4.TEE CAP SECTION REPLACED WAS FROM PREVIOUS REPAIR.

Part: POWER SUPPLY — INOPERATIVE (MAIN PASSENGER C) · airframe 57,406 hrs · 16,898 cycles

EMERGENCY LIGHT SYSTEM BATTERY PACK FAILED CAPACITY CHECK FOR AFT GALLEY AND AFT CABIN LH BIN LIGHTS. GROUNDED - YES. REMOVED AND REPLACED 4 EA POWER SUPPLY/ BATTERY PACKS M1672, M1673, M1676, AND M1694 IAW B737-800 AMM 33-51-06-960-806 EMERGENCY LIGHTS IN AFT GALLEY AND AFT CABIN TEST GOOD.

Part: CONTROL PANEL — FAILED (FLIGHT COMPARTME) · airframe 57,401 hrs · 16,897 cycles

WX RADAR RIGHT SIDE THAT CONTROL KNOB HAS BECOME UNCALIBRATED. IN MANUAL MODE, WITH THE KNOB ON THE 15 DEGREES DOWN SETTING, THE FO'S RADAR DISPLAY/ SHOWS 1 DEGREE DOWN. GROUNDED - YES. REMOVED AND REPLACED WEATHER RADAR CONTROL PANEL IN REFERENCE WITH BOEING 737-800 AMM 34-43-91. P

Part: A/C PACK — FALSE INDICATION · airframe 57,385 hrs · 16,894 cycles

ON RECALL AFTER START RIGHT PACK LIGHT ILLUMINATED. GROUNDED - YES. TROUBLESHOT IAW ASA B737-800 FIM 21-53 TASK 821, NO FAULTS NOTED, NO PACK LIGHT ON RECALL.

Part: FMC — INTERMITTENT (UNKNOWN) · airframe 57,224 hrs · 16,843 cycles

F/O VTK FLAG "SINGLE FMC OPERATIONS" IN SCRATCHPAD. GROUNDED - YES. ACCOMPLISHED B737-800 FIM 34-61 TASK 801 AND FOUND (2) INTERMITTENT FAULT FOR FMC TO CDU ON LEG G. DETERMINED TO BE INTERMITTENT PER THE FIM. OK FOR SERVICE. NO HISTORY 90 DAYS.

Part: MODULATING VALVE — FAULTY (UNKNOWN) · airframe 57,073 hrs · 16,791 cycles

CONTROL CABIN ZONE TEMP ILLUMINATED DURING MASTER CAUTION RECALL. RESET OK. GROUNDED - YES. PERFORMED BITE CK B737-800 AMM 21-61-00. FOUND TRIM VLV FLT DECK FAULT. RESET REPERFORMED BITE ALL PASS GO GREEN WITH NO FAULTS. NO HISTORY 30 DAYS.

Part: CIRCUIT BREAKER — POPPED (UNKNOWN) · airframe 57,072 hrs · 16,790 cycles

ENG # 1 DECLINED START WHEN START LEVER RAISED TO IDLE. GROUNDED - YES. FOUND ENG 1 IGNITION LEFT AND RIGHT C/B'S POPPED. RESET C/B'S AND PERFORMED ENG START.

Part: ACCESS DOOR — LEAKING (RIGHT WING) · airframe 56,984 hrs · 16,761 cycles

STEADY FUEL LEAK RIGHT WING FROM ACCESS PANEL OUT BOARD OF #2 ENGINE. GROUNDED - YES. FOUND RUNNING LEAK AT PANEL G32DB. REMOVED AND REPLACED FUEL PANEL G32DB, REF B737-800 AMM 28-11-11.

Part: EGT INDICATION — READS HIGH · airframe 56,827 hrs · 16,723 cycles

REF TSR712579 ENG # 1 HAD AN EGT EXCEEDANCE ON TAKEOFF PEAK 968 FOR 25 SEC AT AN ALT 5392. GROUNDED - YES. ACCOMP LPT-1 BORESCOPE PER B737-800 AMM 72-00-00-200-808-F00 NO DAMAGE NOTED. ACCOMPLISHED B737-800 FIM TASK 71-06 TASK 805 ENGINE OVERTEMPERATURE EGT OVER REDLINE FAULT ISOLATION STEP F (2) FOUND FAULT 75-10591 THE TBV POSITION SIGNAL IS OUT OF RANGE. REMOVED AND REPLACED THE AIR TRANSIENT BLEED VALVE REF AMM 75-23-01. OPS AND LEAK CHECK GOOD. ALSO ACCOMPLISHED BORO T/C'S 7847018 - COMBUSTION CHAMBER, 78472020 HPT NOZZLES, AND 78472022 - HPT BLADES WITH NO DEFECTS NOTED. ACCOMPLISHED TEST 5 POWER ASSURANCE CHECK REF AMM 71-00-00-700-813-F00. OAT 16 DEG C, N1 65.1%, EGT 571 DEG C WITHIN LIMITS.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 56,147 hrs · 16,542 cycles

A/P B DISCONNECTED W/ NO APPARENT CAUSE. RE-ENGAGED WITH NO FURTHER ISSUE. GROUNDED - YES. FOUND MSG 22-11607 IN FAULT HISTORY. NO CURRENT FAULTS NOTED. "B" AUTOPILOT OPS CHECK GOOD IAW B737-800 FIM 22-11 TASK 817.

Part: ACTUATOR — SEIZED (R FWD WING TO BO) · airframe 56,112 hrs · 16,533 cycles

RH RAM AIR DOOR ACTUATOR IS SEIZED. GROUNDED - YES. REMOVED AND REPLACED RH RAM AIR DOOR ACTUATOR IAW B737-800 AMM 21-51-21-000-801 AND AMM 21-51-21-400-801. ETOPS GROUND VERIFICATION CHECK GOOD IAW AMM 21-61-00-700-806-002. BOTH PACK/ZONE SYSTEMS FUNCTIONING PROPERLY AFTER RH RAM DOOR ACTUATOR CHANGE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 55,640 hrs · 16,423 cycles

AUTOPILOT B DISENGAGED TWICE AT 2HRS & 4.5 HRS INTO THE FLIGHT FL 360 & 380 SMOOTH AIR. WE WERE ABLE TO REENGAGE BOTH TIMES. GROUNDED - YES. PERFORMED B737-800 FIM 22-11 TASK 801, NO FAULTS NOTED AT THIS TIME.

Part: COUPLER — INOPERATIVE (VERTICAL FIN) · airframe 55,459 hrs · 16,377 cycles

UNABLE TO TRANSMIT ON HF 2. GROUNDED - YES. ACCOMPLISHED HF COMMUNICATION SYS BITE PROCEDURE PER B737-800 FIM 23-11 TASK 801 BITE TEST GOOD. FOR T/S SWAPPED TRANSCEIVER #1 TO #2 SLOT B737-800 AMM 23-11-21-400-801. NO HELP. SUGGESTED COUPLER CHANGE. RETURNED HF RT'S TO ORIGINAL POSITIONS, REF AMM 23-11-21. REPLACED HF #2 COUPLER REF AMM 23-11-61 OPS CHECK OK.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 55,410 hrs · 16,362 cycles

UNABLE TO TRANSMIT ON HF #2. WHEN KEYING THE MIC TO TALK THE SIDE TONE COMES ON AND STAYS ON. IT IS A CONTINUOUS TONE UNTIL THE RADIO IS TUNED TO ANOTHER FREQUENCY. GROUNDED - YES. ACCOMPLISHED OPS CHECK WITH NO FAULTS FOUND REF B737-800 AMM 23-11-00. HF #2 KEYS AND TRANSMITS NORMALLY. GROUND VERIFICATION TEST SUCCESSFUL.

Part: BULB — INOPERATIVE (L OVERWING EXIT) · airframe 55,311 hrs · 16,334 cycles

L/H AFT SLIDE/OVERWING LIGHT INOP. GROUNDED - YES. RELAMPED IAW B737-800 AMM 33-51-04-960-801. OPS CHECKS GOOD.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 55,187 hrs · 16,290 cycles

IN RECALL AFTER START, RECEIVED ZONE TEMP ON CONT CABIN. GROUNDED - YES. PERFORMED PTZ BITE PROCEDURES REF B737-800 FIM 21-62 TASK 801, FOUND FLT DECK TRIM VALVE FAULT LOGGED ON PZTC 2. FAULT CLEARED, PACK ZONE TEMP CONTROL GROUND VERIFICATION GOOD.

Part: EXCITER — INOPERATIVE (#2 ENGINE) · airframe 55,146 hrs · 16,272 cycles

NO EGT RISE ON START UP OF #2 ENGINE WHEN START LEVER RAISED TO IDLE. GROUNDED - YES. REMOVED AND REPLACED #2 ENG L IGNITION EXCITER IAW B737-800 AMM 74-11-01 AND REMOVED AND REPLACED #2 ENG L IGNITER IAW AMM 74-21-02 ON ENGINE START NO EGT RISE. REMAINS ON MEL. TROUBLESHOT #2 ENGINE L IGNITION LEAD. PERFORMED IGNITION SYSYTEM AUDIBLE TEST. TEST PASSED WITH NO FAULTS. STARTED ENGINE USING L IGN ONLY. ENGINE RAN NORMALLY AFTER STARTING. STARTED ENGINE SECOND TIME WITH NO ERRORS. L IGNITION OP CHECKS NORMAL AT THIS TIME. THIS CLEARS MEL 74-1C.

Part: APU — NOISE (APU COMPARTMENT) · airframe 55,104 hrs · 16,254 cycles

MX PERSONEL REPORTS THAT APU ABNORMALLY NOISY. GROUNDED - YES. REMOVED AND REPLACED THE APU REF TC 78349010. OPS CHECK GOOD. LEAK CHECK GOOD.

Part: BULB — INOPERATIVE (L MID FUSELAGE E) · airframe 55,094 hrs · 16,252 cycles

EMERGENCY SLIDE LIGHT AFT OF LH WING INOP. GROUNDED - YES. RELAMPED EMERGENCY SLIDE LIGHT AFT OF LH WING REF B737-800 AMM 33-51-04. OPS CHECK GOOD.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 54,927 hrs · 16,201 cycles

DUAL FMC FAILURE NO FMC ON BOTH CDU'S AND NAV DISPLAY VTK AND MAP DISAGREE ON BOTH NAVIGATIONAL DISPLAYS FOR APPROX 3 MINUTES FL350 2 HRS INTO FLT RESOLVED ITSELF W/ OUT ANY INPUT W/IN 3 MINUTES. GROUNDED - YES. ACCOMPLISHED FMC RESET PER B737-800 FIM 34-61 TASK 807 BOTH FMC'S LEFT AND RIGHT BACK TO NORMAL.

Part: VALVE — FAULTY (LEFT ECS BAY) · airframe 54,690 hrs · 16,151 cycles

CONT CAB TEMP CONTROL (ZONE TEMP) LIGHT ILLUMINATED AFTER PUSHPACK. RAN QRH. LOWERED TEMP PER QRH. LIGHT EXTINGUISHED. GROUNDED - YES. CONTROLLER IN E & E FAULTED WITH CONTROL CABIN TRIM VALVE FAULT. REMOVED AND REPLACED CONTROL CABIN TRIM MODULATING VALVE IAW B737-800 AMM 21-61-21-000-801 AND AMM 21-61-21-400-801, ETOPS GROUND FUNCTIONAL CHECK GOOD IAW AMM 21-61-00-700-002, SEAMC MITCH NOTIFIED OF ETOPS MAINTENANCE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 54,675 hrs · 16,148 cycles

HF2 RADIO WILL NOT TUNE (NO SIDE TONE) RADIO PANEL CHANGES BUT HF2 DOES NOT TRANSMIT NOR RECEIVE. SAT COM2 WORKS FINE. GROUNDED - YES. CYCLED HF2 CIRCUIT BREAKER PER B737-800 AMM 20-60-05, ETOPS VERIFICATION SUCCESSFUL.

Part: GUIDE VANE — DAMAGED (ENGINE) · airframe 54,617 hrs · 16,131 cycles

DURING ACCOMP T/C N8005010 #1 ENG ESN 804741 FOUND DAMAGE AT THE HPT NOZZLE GUIDE VANES OUTER PLATFORM. MISSING METAL OR BURING OF PAROSE METAL AT 6 O'CLOCK. GROUNDED - YES. REMOVED AND REPLACED # 1 ENGINE.

Part: PROCESSOR — FAULTY (FORWARD AREA OF) · airframe 54,365 hrs · 16,070 cycles

CDU MESSAGE "CHECK FUEL AND GW" ILLUMINATED 3 TIMES WITHIN 2 MIN. UPON CHECKING PERF PAGE NO FUEL AMOUNT WAS SHOWING. THEN RETURNED TO NORMAL EACH TIME AFTER 30 SEC. GROUNDED - YES. DE-BRIEFED CREW. THEY DID NOT NOTICE ANY QTY IND ISSUES OR MISSING FUEL TOTAL ON DU WHEN MESSAGE OCCURRED. BITE CHECKED FQIS - LAST 2 LEGS FAULTED PROCESSOR. RMVD & RPLCD FQIS PROCESSOR UNIT REF B737-800 AMM 28-41-81. OPS NML PER SAME. FMC SENSOR PAGE SHOWS OK FOR FQIS. ETOPS GND VERIFICATION TEST SUCCESSFUL.

Part: BATTERY — NONE (AFT CABIN CEILIN) · airframe 54,274 hrs · 16,039 cycles

DURING PERFORMING EMERGENCY BATTERY PACK CAPACITY FUNCTIONAL CHECK TASK CARD 78233001 FOUND AFT EMERGENCY SIGN AND L2 DOOR LIGHTS OFF. GROUNDED - YES. REPLACED EMERGENCY LIGHT BAT PACK AT AFT GALLEY CEILING PANEL LEFT SIDE- REF B737-800 MM 33-51-06-960-805. OPS NML.

Part: UNKNOWN — UNKNOWN (AUTOLAND SYSTEM) · airframe 54,192 hrs · 16,016 cycles

AUTOLAND AIII WITH HGS MONITOR EXCEEDED TOLERANCES 50' LEFT OF CENTER LINE AND DIVERGING. PILOT INTERVENTION NEEDED. FLAPS 40 TAIL WIND OF 5 KTS. GROUNDED - YES. PERFORMED DFCS BITE TEST PER B737-800 FIM 22-11 TASK 801. NO FAULTS IN CURRENT STATUS. IN FAULT HISTORY HAD FAULT 22-11063 MCP DATA ON LEG 11. PERFORMED FIM 22-11 817 INITIAL EVALUATION NO CURRENT FAULTS NOTED. PERFORMED MCP TESTS PER FIM 22-11 TASK 803 ALL MCP TEST PASSED. ACCOMPLISHED DFCS LAND VERIFY TEST BITE GROUP # 49 LAND VERIFY TEST PASSED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 54,166 hrs · 16,011 cycles

FMC DISAGREE-VERTICAL MESSAGE PRIOR TO TOP OF DESCENT. UPON DESCENDING VERTICAL PROFILE BOTH SIDES APPEARED THE CAM. RAN QRH, MESSAGE DID NOT RETURN. GROUNDED - YES. RAN B737-800 FIM 34-61 TASK 835, NO FAULT NOTED, CLEAN HISTORY, NO EXISTING FAULTS. A/C OK FOR CONTINIOUS SERVICE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 54,012 hrs · 15,977 cycles

AFTER EXITING THE RUNWAY AFTER LANDING THE GPWS INOP LIGHT ILLUMINATED FOR ABOUT 5 SECONDS AND BOTH CAPT AND FO CDU'S WENT BLANK FOR ABOUT 30 SECONDS. GROUNDED - YES. RAN B737-800 FIM 34-46 TASK 801 GPWS BITE & SHOWED NO FAILS AND TESTED OK. RAN FIM TASK 34-61 TASK 801 FMC LOGGED L/H FAIL. RAN FIM 34-61 TASK 836 CYCLED POWER TO FMC & CHECK OK.

Part: TRANSMITTER — FAULTED (LT WING SPOILER) · airframe 53,916 hrs · 15,948 cycles

DFCS BITE LIBRARY TEST 60.31 FAULT. AILERON SPOIL-4 SIG FAIL FCC B. FAULT MESSAGE 22-11158. SUSPECTED LRU SPOIL-4 POS SENSOR-2. GROUNDED - YES. REPLACED #4 SPOILER POSITION SENSOR REF B737-800 AMM 22-11-27-400-801. OPS NORMAL. BITE LIBRARY 60.31 ALL TESTS PASS CHANNEL A & B.

Part: CONTROL VALVE — FAULTED (LEFT ECS BAY) · airframe 53,913 hrs · 15,946 cycles

PRIOR TO PUSHBACK, WITH PACKS ON, AIRFLOW NOISE WAS EXTREMELY LOUD (WE HAD TO USE HEADSET TO COMMUNICATE). ON PUSHBACK AFTER PACKS WERE TURNED OFF, DUCT PRESSURE DROPPED TO 12 - 13 PSI. START NOT ATTEMPTED. GROUNDED - YES. THE DUCT PRESSURE DROP, AFTER PACKS TURNED OFF, IS NORMAL, NO DEMAND ON THE APU. SUPERVISION DEBRIEF OF THE PILOTS INDICATES EXCESSIVE COCKPIT AIRFLOW. INSPECTED DUCTING IN THE MIX CHAMBER AREA AND THE FWD E&E COMPARTMENTS. SECURED ONE LOOSE DUCT ABOVE THE VERY FWD DOOR WITH NO CHANGE IN COCKPIT AIR NOISE, NO OTHER DEFECTS NOTED. NOTED THAT THE LEFT PACK FCSOV IS FULL OPEN IN AUTO, SHOULD BE PARTIALLY OPEN REF B737-800 AMM 21-51-01-400-805-002 PARA. H. 28 VDC AVAILABLE AT SOLENOID B. RIGHT PACK FCSOV IS PARTIALLY OPEN IN AUTO (LEFT PACK OFF) BUT MOVES TO FULL OPEN WHEN LEFT PACK PLACED IN AUTO. REPLACED THE LEFT PACK FCSOV PER AMM 21-51-01. LK CK GOOD.

Part: CONTROL VALVE — FAILED (LT ECS) · airframe 53,913 hrs · 15,946 cycles

ON DEPARTURE AIRFLOW FROM PACKS WAS SO LOUD COMM WAS DIFFICULT TO IMPOSSIBLE. BOTH PACK CONTROLLERS UNRESPONSIVE. ALL WE COULD GET WAS VERY COLD AIR. CONT CAB @ 4C, FWD CABIN 12C, AFT CABIN 17 C. ALL STUCK/UNCONTROLLABLE. GROUNDED - YES. DIVERSION TIME 29 MINUTES - SUSPECT LEFT PACK FLOW CONTROL VALVE REMAINS IN APU HI-FLOW MODE. CHECKED WIRING FOR SHORT TO GROUND REF W/D 21-51-11-6, COULD NOT CONFIRM BAD WIRING. REPLACED L/H STANDBY TEMP CONT VALVE REF B737-800 MM 21-51-11-400-80, PACK ZONE TEMP CONT BITE TEST OPS NORMAL. BOTH PACK GREEN. REF AMM 21-61-00-200-806-002. NO LEAKS. REPLACED P5-10 PANEL OPS NORMAL REF AMM 21-51-65-400-801. RAN BOTH ENG.AT HIGH POWER WITH BOTH PACKS IN AUTO, TRIM AIR ON, TEMP CONTROL IN AUTO POSITION WOULD HEAT AND COOL A/C, OPS CK GOOD.

Part: ACTUATOR — FAULTED (APU FUEL SHTOFF) · airframe 53,735 hrs · 15,887 cycles

APU FAULT LIGHT ILLUMINATED WHEN APU SWITCH SELECTED OFF. GROUNDED - YES. VERIFIED FAULT 49-31001 STILL SHOWING AS CURRENT IN BITE CHECK. REMOVED & REPLACED APU FUEL SHUTOFF VALVE ACTUATOR, VERIFIED P/N FOR ETOPS. BOND CHECK GOOD, OPS CHECKED GOOD X3, APU STARTS UP AND RUNS UNDER FULL LOAD. AFTER SHUTDOWN VERIFIED FAULT CLEARED FROM CURRENT STATUS. APU SHUTDOWN GOOD. REF B737-800 AMM 28-25-02 AND AIPC 28-25-51-07 ITEM 45. THIS CLEARS MEL 49-1B. SEAMC FELIX NOTIFIED. PLACARDS REMOVED, C/B RESET.

Part: FMC — SLOW · airframe 53,555 hrs · 15,823 cycles

FMC FUNCTIONALITY IS VERY SLOW APPROX. 5 TIMES SLOWER THEN USUAL FUNCTIONALITY. THIS INCLUDES COMPUTING LATERAL AND VERITCAL NAVIGAITON AS WELL AS FUNCTIONS SUCH AS OBTAINING WX, FORWARDING OPERATIONAL REQUEST, LOADING OPERATIONAL DATA ETC. GROUNDED - YES. ACCOMPLISHED FMC BITE REF B737-800 FIM 34-61 TASK 801 NO INFLT FAULTS FOUND. VERIFIED ALL FMC SOFTWARE FOR BOTH FMC MATCHED. NO HISTORY PAST 90 DAYS, FMC OPERATIONAL TEST PASS REF B737-800 AMM 34-61-00-710-804.

Part: CONTROL VALVE — INOPERATIVE (LT A/C PACK) · airframe 53,517 hrs · 15,802 cycles

AFTER T/O POWER SET AN EXTREME AMOUNT OF AIRFLOW RUSHED IN TO COCKPIT SOUND OF RUSHING AIR WAS VERY LOUD ON CLIMB PRESSURIZATION NORMAL BUT AIRFLOW CONTINUED TO RUSH INTO FLIGHT DECK AND ALSO FWD GALLEY AREA AND JUMP SEAT BY F/A SEAT. AIR WAS VERY COLD. THIS CONTINUED THROUGH APPROX 18,000 FT WHEN WE STARTED TO GET A RESPONSE TO TEMP SELECTORS. AIR CONDITIONING PNL SWITCHES IN NORMAL CONFIGURATION, NO WARNING LIGHT OBSERVED. GROUNDED - YES. REMOVED AND REPLACED THE L/H PACK FLOW CONTROL AND SHUTOFF VALVE, OPS CHECK GOOD REF B737-800 AMM 21-51-01/401.

Part: LENS — DETACHED (EMERGENCY LIGHT) · airframe 53,464 hrs · 15,790 cycles

EXIT SIGN COVER IN ROW 16/17 CEILING NEEDS TO BE REACTACHED. GROUNDED - YES. REPLACED EXIT SIGN COVER WITH NEW FROM STOCK. NO OTHER DEFECTS NOTED.

Part: CONNECTOR — DIRTY (APU) · airframe 53,343 hrs · 15,752 cycles

APU SHUTDOWN AUTOMATICALLY WITH ASSOCIATED FAULT LIGHT DURING TAXI INTO GATE AFTER LANDING. GROUNDED - YES. PERFORMED B737-800 FIM 49-40 TASK 802 AND 49-60 TASK 801, RESOLVED FAULT CODE 49-61262 PERFORMED FIM 49-60 TASK 817 INSPECTED APU WIRE HARNESS. REMOVED AND CLEANED P-2 COMMON PLUG AND OIL PRESSURE COMMON PLUG RAN APU AND STARTED ON FIRST ATTEMPT.

Part: WIRE HARNESS — FAULTED (APU COMPARTMENT) · airframe 53,350 hrs · 15,754 cycles

APU HAS HISTORY OF AUTO SHUTDOWN WITH NO FLAME AND SPEED SENSOR FAULTS. REMOVE AND REPLACE APU WIRE HARNESS AND SPEED SENSOR. ETOPS SIGNIFICANT SYSTEM. ACCOMPLISHMENT OF LISTED MAINTENANCE TASKS WILL AFFECT APU ON DEMAND IN-FLIGHT START CAPABILITY. MEL 49-99A IS REQUIRED PRIOR TO FLIGHT. GROUNDED - YES. COMPLIED WITH TSR, REMOVED AND REPLACED APU WIRE HARNESS REF B737-800 AMM 49-11-01 AND SPEED SENSOR REF B737-800 AMM 49-61-21. OP CHECK GOOD. REF LOG PAGE 60193862 MEL 49-99A CURRENTLY INSTALLED. NO ADDITIONAL MEL NEEDED.

Part: GUIDE VANE — CRACKED (RT ENGINE) · airframe 53,187 hrs · 15,699 cycles

WHILE ACCOMPLISHING REINSPECT OF 1ST STAGE LPT NOZZLE ON #2 ENGINE LPT NOZZLE GUIDE VANES NOTED NEW DAMAGE, REF DEFECT 11749118. NEWER DAMAGE HAS 2 RADIAL CRACKS ON 1 AIRFOIL. PER AMM TASK 72-00-00-200-811-F00 15, F, 2) D) 5 EACH AIRFOIL CAN ONLY HAVE 1 RADIAL CRACK. ENGINE REQUIRES REPLACEMENT. GROUNDED - YES. REMOVED AND REPLACED #2 ENGINE. TRANSFERRED DEFECT TO EBU SHOP W/O # 1876569 N/R #00002.

Part: ACTUATOR — LEAKING (NR 2 ENG VSV) · airframe 53,187 hrs · 15,699 cycles

WHILE ACCOMPLISHING IDLE LEAK CHECK AFTER #2 ENGINE R&R FOUND R/H VSV ACTUATOR LEAKING FROM DRAIN MAST AT 4 DROPS PER MINUTE. GROUNDED - YES. LEAKAGE WITHIN ALLOWABLE LIMITS FOR 25 FLIGHT CYCLES PER B737-800 AMM 71-71-00-200-801-F00 FIGURE 605 SHEET 1. REMOVED #2 ENGINE RT VSV ACTUATOR REF AMM 75-31-01. INSTALLED RT #2 ENG VSV ACTUATOR REF AMM 75-31-01 OPS NORMAL REF AMM 75-31-01. LEAK CHECK GOOD.

Part: BULB — INOPERATIVE (EMERGENCY LIGHT) · airframe 52,635 hrs · 15,566 cycles

FOUND RH AFT OVERWING EMERGENCY LIGHT OUT DURING RON MTX. GROUNDED - YES. RELAMPED WITH NEW BULB FROM STOCK IAW B737-800 AMM 33-51-04-960-801. NEW BULB CHECKS GOOD.

Part: SEAL — LEAKING (NR 2 ENGINE) · airframe 52,499 hrs · 15,531 cycles

#2 ENGINE HAS A LARGE AMOUNT OF OIL DRIPPING FROM COWLING TO THE RAMP - PUDDLING ON RAMP. GROUNDED - YES. FOUND IDG PAD DRAIN AND FUEL PUMP PAD DRAIN LEAKING OUT OF LIMITS PER 71-71-00-200-801-FOO FIG 605 LEAK LIMIT TABLE 73245. 4/13/21 INIT MIG 2C 40-0013474, 40-0013475 REMOVED #2 ENG IDG AND FUEL PUMP PACKAGE. REMOVED AND REPLACED #2 ENG IDG & FUEL PUMP SEALOL. SEE MIG2C 40-0013474 FOR WORK ACCOMPLISHED REINSTALLED #2 ENG IDG AND FUEL PUMP REF B737-800 AMM 24-11-11 AND 73-11-01. NOTE: TEST 3B REQUIRED. ACCOMPLISHED 3B WITH IDG AND FUEL PUMP DRIVE PADS BAGGED. NO LEAKS NOTED. MIG 2C 40-0013474 AND 40-0013475 CLOSED.

Part: FMC — MALFUNCTIONED (RIGHT) · airframe 52,037 hrs · 15,415 cycles

RIGHT FMC FAIL INDICATED BY "MAP" ON FO ND AND "SINGLE FMC OPERATION IN SCRATCH PAD. GROUNDED - YES. PERFORMED B737-800 FIM 34-61 TASK 836 AND NO FAULTS FOUND. FLIGHT MANAGEMENT COMPUTER SYSTEM OPERATIONAL TEST GOOD, REF B737-800 AMM 34-61-00-710-801.

Part: CONNECTOR — LOOSE (NR 2 EEC) · airframe 51,998 hrs · 15,405 cycles

ENG #2 ESN 894276 FOUND BOTH WIRE BUNDLE CONNECTOR FOR THE EEC ALTERNATOR LOOSE (HEAT SHRINK OVER BACKSHELL). GROUNDED - YES. ON THE #2 ENG S/N 894276, REMOVED AND REPLACED J7 AND J8 HARNESS REF B737-800 AMM 73-21-06-000-801-F00 AND AMM 73-21-06-400-801-F00. ALL OPS TEST PASS. ETOPS GROUND VERIFICATION SUCCESSFUL.

Part: MODULATING VALVE — INOPERATIVE (CABIN TEMP) · airframe 51,777 hrs · 15,351 cycles

ON MASTER CAUTION RECALL CONTROL CAB LIGHT ILLUMINATED. RESETS ON RECALL. GROUNDED - YES. REPLACED THE CONTROL CABIN TCV REF B737-800 AMM 21-61-21/401. OP-CHECKS GOOD.

Part: ACTUATOR — LEAKING (NR 2 VSV) · airframe 51,689 hrs · 15,323 cycles

NR 2 ENGINE FUEL LEAK WITH REFUELER CONNECTED. WITH ENGINE NOT RUNNING IDENTIFIED 30 DROPS PER MINUTE COMING FROM THE NR 2 ENGINE DRAIN OF THE VSV LEFT AND RIGHT. AFTER ENGINE RUN NO LEAKS NOTED, REF B737-800 AMM 71-71-00-200-801. LEAKS WITHIN LIMITS. LEFT AND RIGHT VSV'S TO BE REPLACED WITH IN 25 CYCLES. GROUNDED-YES. REMOVED AND REPLACED BOTH LEFT AND RIGHT SIDE VSV ACTUATORS, B737-800 AMM 75-31-01. LEAK CHECK AND OPERATIONS CHECK GOOD.

Part: SLIDING WINDOW — CRACKED (COCKPIT) · airframe 51,613 hrs · 15,304 cycles

AT 1:10 INTO FLIGHT FL 394 FO'S R2 OUTER PANE SHATTERED WITH AN ASSOCIATED RT SIDE WINDOW OVERHEAT LIGHT. GROUNDED-YES. DIVERSION TIME 104 MINUTES. REMOVED W0210-1001-20 FROM TERMINAL NR 2 TO NR 1, PER B737-800 WDM 30-41-11 AND B737-800 AMM 56-12-11-400-801 STEP F(7). REMOVED AND REPLACED FO'S NR 2 OPENABLE WINDOW, REF B737-800 AMM 56-12-11-000-801, AMM 56-12-11-400-801 & 56-12-11-820-801. WINDOW HEAT TEST OPERATIONS TEST GOOD, REF AMM 30-41-00-710-801. PRESSURIZED CABIN TO 3.0 PSI. NO LEAKS NOTED AT R2 WINDOW. NO FURTHER DEFECTS NOTED.

Part: FMC — MALFUNCTIONED · airframe 51,559 hrs · 15,290 cycles

"FMC DISAGREE" LIGHT ON GROUND. GROUNDED-YES. ACCOMPLISHED RESET PER QRH.

Part: SEAL — MISSING (NR 1 ENG BLADES) · airframe 51,559 hrs · 15,290 cycles

NR 1 ENGINE FAN BLADE PLATFORMS MISSING OVER 39 INCHES OF ELASTOMER SEALS. GROUNDED-YES. REMOVED AND REPLACED NR 1 ENGINE PLATFORMS 23 EA, REF T/C 78472010.

Part: WARNING MESSAGE — FALSE INDICATION (WX RADAR SYS) · airframe 51,194 hrs · 15,190 cycles

''WXR FAIL CONT STAB" DISPLAYED ON BOTH MFD'S WHEN TRYING TO USE THE WEATHER RADAR. GROUNDED-YES. PERFORMED WEATHER RADAR SYSTEM BITE PROCEDURE, IAW B737-800 FIM 34-43 TASK 801, REF TEST PASS NO FAULT NOTED. AIRCRAFT OK FOR SERVICE.

Part: WARNING MESSAGE — FALSE ACTIVATION (COCKPIT TEMP) · airframe 51,107 hrs · 15,167 cycles

ON TAXI OUT IN SEA, WE GOT THE CONT CABIN "ZONE TEMP" LIGHT. RAN THE QRH AND THE LIGHT EXTINGUISHED. THEN ON CLIMBOUT, WE GET THE SAME "ZONE TEMP" LIGHT. RAN QRH AGAIN AND THE LIGHT EXTINGUISHED. THE LIGHT COMES BACK ON MASTER CAUTION RECALL. GROUNDED-YES. PERFORMED PACK TEMP. CONTROL BITE CHECK, REF B737-800 FIM 21-62 TASK 801. FOUND FLIGHT DECK TRIM VALVE LIGHT ON, ON TEMP CONTROL NR 2, RESET. PERFORMED BITE CHECK AGAIN. OPERATIONS CHECKED GOOD.

Part: BLEED VALVE — LEAKING (NR 2 ENGINE) · airframe 51,066 hrs · 15,150 cycles

WHILE PREPPING A/C FOR TOW FOUND 8 FT LONG BY 4 FT WIDE FUEL STAIN UNDER NR 2 ENGINE AND FUEL DRIPPING FROM BOTTOM OF COWL. GROUNDED-YES. FOUND NR 2 ENGINE TBV (TRANS BLEED VALVE) DRAIN DRIPPING APPROXIMATELY 67 DROPS, PER MIN. RAN NR 2 ENGINE AFTER ENGINE RUN TBV DRAIN HAD APPROXIMATELY 20 DRIPS OF FUEL A MINUTE, REF B737-800 AMM 71-71-00-801-F00. FUEL DRIPS WITHIN LIMITS. REMOVED AND REPLACED THE NR 2 ENGINE TBV, REF AMM 75-23-01/401. LEAK AND OPERATIONS CHECK GOOD, REF AMM 75-23-01-400-801-F00 STEP 3G.

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 50,980 hrs · 15,128 cycles

LT HORIZONTAL LOWER SKIN CRACKED AT STA 129, 18 INCHES FROM TRAILING EDGE. GROUNDED-YES. CUT OUT DAMAGE AND REPAIRED LT HORIZ LOWER SKIN, IAW B737-800 SRM 55-10-01-2R-11 REPAIR 11. THIS IS A CATEGORY B REPAIR WITH AN INSPECTION THRESHOLD OF 56,000 TOTAL FLIHGT CYCLES AND 9,000 FLIGHT CYCLE INTERVAL.

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 50,980 hrs · 15,128 cycles

LT HORIZONTAL LOWER SKIN CRACKED STA 129, 11 INCHES FROM TRAILING EDGE. GROUNDED-YES. REPAIRED DAMAGE TO LOWER SKIN AT STA 129, 11 INCHES FWD OF TRAILING EDGE. REPAIR ACCOMPLISHED IN CONJUNCTION WITH DAMAGE AT STA 129, 18 INCHES FWD OF TRAILING EDGE, IAW B737-800 SRM 55-10-01-2R-11 REPAIR 11. FOR ALL PARTIAL WORK ACCOMPLISHED SEE MIG-5 OK195757 W/O 1018821 000/0013. THIS IS C CATEGORY B REPAIR W/AN INSPECTION THRESHOLD AT 56,000 TOTAL FLIGHT CYCLES AND 9,000 FLIGHT CYCLE INTERVAL.

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 50,980 hrs · 15,128 cycles

LT HORIZONTAL LOWER SKIN CRACKED AT STA 175, 10 INCHES FROM TRAILING EDGE. GROUNDED-YES. CUT OUT DAMAGE AND REPAIRED LT HORIZ LOWER SKIN, IAW B737-800 SRM 55-10-01-2R-11 REPAIR 11. THIS IS A CATEGORY B REPAIR WITH AN INSPECTION THRESHOLD OF 56,000 TOTAL FLIGHT CYCLES AND 9,000 FLIGHT CYCLE INTERVALS.

Part: WARNING LIGHT — FALSE ACTIVATION (LT A/C PACK) · airframe 50,980 hrs · 15,128 cycles

L PACK LIGHT ILLUMINATES ON RECALL. GROUNDED-YES. PERFORMED L-PACK PACK LIGHT IS ON DURING MASTER CAUTION RECALL-FAULT ISOLATION AND FOUND NO DEFECTS IAW B737-800 FIM TASK 21-53 TASK 821 AND TASK 21-62 TASK 801.

Part: WARNING MESSAGE — FALSE ACTIVATION (COCKPIT TEMP) · airframe 50,978 hrs · 15,127 cycles

CONT CABIN ZONE TEMP ILLUMINATES ON RECALL. GROUNDED-YES. PERFORMED ZONE TEMP LIGHTS COME ON DURING MASTER CAUTION RECALL-FAULT ISOLATION AND FOUND NO DFECTS, IAW B737-800 FIM TASK 21-62 TASK 848 AND 21-62 TASK 801.

Part: BLEED VALVE — FAILED (NR 2 ENGINE) · airframe 50,980 hrs · 15,128 cycles

REF TASK CARD NR AD20201651-NG-36-2. NR 2 ENG 5TH STAGE BLEED AIR CHECK VALVE FAILED INSPECTION, VALVE REMOVED. GROUNDED-YES. REMOVED NR 2 ENG 5TH STAGE BLEED AIR CHECK VALVE, IAW B737-800 AMM 36-11-02-000-801. INSTALLED NR 2 ENG 5TH STAGE BLEED AIR CHECK VALVE, REF AMM 36-11-02-400-801. OPS CHECK GOOD. NO LEAKS NOTED.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 50,929 hrs · 15,112 cycles

FMC CDU FAULTS: ENGINE #1, 73-31741 (DEU 1 LEFT FLAP AND RIGHT FLAP POSITION DATA DISAGREE) SHORT TIME FAULT. ENGINE #1, 73-31751 (DEU 2 LEFT FLAP AND RIGHT FLAP POSITION DATA DISAGREE) SHORT TIME FAULT. ENGINE #2, 73-31742 (DEU 1 LEFT FLAP AND RIGHT FLAP POSITION DATA DISAGREE) SHORT TIME FAULT. ENGINE #2, 73-31752 (DEU 2 LEFT FLAP AND RIGHT FLAP POSITION DATA DISAGREE) SHORT TIME FAULT. GROUNDED - YES. NO MORE FAULTS IN NEW LEGS 1-6. CW B737-800 FIM 73-24 TASK 810 FOUND FCC B FAULT 31-67340 IN HISTORY CW FIM 31-63 TASK 809 FCC B LLM TESTS CHECKED GOOD INTERMITTENT FAULT. COMPLETED REPAIR CONFIRMATION IN FIM 73-24 TASK 810 AND ALL TESTS NORMAL.

Part: ACTUATOR — FAILED (AUTOPILOT SYS) · airframe 50,816 hrs · 15,084 cycles

AUTOPILOT B WILL NOT CONNECT. GROUNDED - YES. REMOVED AND REPLACED ELEV A/P B ACTUATOR REF B737-800 AMM 22-11-26. LEAK CHECK GOOD. AUTOPILOT ELEVATOR ACTUATOR ADJUSTMENT AND TEST PASSED REF AMM 22-11-216-820-801. NO ADJUSTMENTS MADE. AUROPILOT ELEVATOR ACTUATOR TEST GOOD REF AMM 22-11-26-710-801. REMOVED AND REPLACED ELEV A/P B ACTUATOR HYDRAULIC SWITCH REF AMM 22-11-40. INSTALLATION TEST GOOD. ALL LLM TESTS PASSED REF EXTENDED MAINT BITE GROUP #60 AMM 22-11-26/501.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 50,766 hrs · 15,071 cycles

CAPTAIN DISPLAY VTK NO FD NO LNAV OR VNAV. BOTH MAPS ONLY DISPLAYED THE MAGENTA LINE BOTH CDU WENT TO MENU DISPLAY / FO SIDE HAD A FLIGHT DIRECTOR. SWITCHED AUTO PILOT TO B SIDE AND HEADING SELECT LNAV + VNAV THEN WORKED SO I SWITCHED EVERYTHING BACK TO THE CAPTAIN'S SIDE AND EVERYTHING WORKED BEFORE SWITCHING TO THE FO SIDE, THE AUTO THROTTLE RETARDED PAST 75% SO I DISENGAGED IT + RE-ENGAGED IT AND THEN IT WORKED. GROUNDED - YES. PERFORMED FMC RESET PER B737-800 FIM 34-61-836. OPS CHECK NORMAL.

Part: IDG — FAILED (NR 1 ENGINE) · airframe 50,666 hrs · 15,043 cycles

DURING DESCENT GEN 1 SOURCE OFF LIGHT ILLUMINATED, FOLLOWED QRH. SOURCE OFF LIGHT WOULD NOT STAY EXTINGUISHED. GROUNDED - YES. FOUND IDG FAULT ON GCU. REMOVED AND REPLACED #1 ENG IDG PER B737-800 AMM 24-11-11. FILTERS ON OLD IDG WERE CLEAN. #1 IDG OPS CHECKS GOOD. NO MORE IDG FAULT ON GCU.

Part: HEATER — LEAKING (NR 1 FUEL SERVO) · airframe 50,395 hrs · 14,976 cycles

WHILE ACCOMPLISHING TEST 9 AFTER #1 ENGINE R&R #1 ENGINE SERVO FUEL HEATER IS LEAKING. GROUNDED - YES. REMOVED AND REPLACED #1 ENG SERVO FUEL HEATER. REF B737-800 AMM 73-11-07-000-801-F00 & AMM 73-11-07-400-801-F00. OPS & L/C'D GOOD.

Part: CONTROL PANEL — FAILED (WEATHER RADAR) · airframe 50,241 hrs · 14,937 cycles

WEATHER RADAR WILL NOT GO INTO AUTO MODE WHEN AUTO SELECTED. MANUAL MODE WORKS. GROUNDED - YES. VERIFIED DISCREPANCY. FOUND AUTO/MANUAL INTERMITTENT. REMOVED AND INSTALLED A NEW WEATHER RADAR CONTROL PANEL IAW AMM 34-43-91/401. PERFORMED SYS INSTALLATION TEST IAW AMM TASK 34-43-91-400-801. SYS OPS NORMAL.

Part: PLATFORM — DAMAGED (NR 2 FAN BLADES) · airframe 50,231 hrs · 14,932 cycles

WHILE ACCOMPLISHING FAN LUBE LUBRICATION TASK CARD 78472010, FOUND A TOTAL OF 13 PLATFORMS UNSERVICEABLE DUE TO TOOLING MARKS, ON ENGINE NUMBER 2. GROUNDED - YES. REPLACED THIRTEEN PLATFORMS PER B737-800 AMM TASK 72-21-02-400-F00.

Part: WARNING MESSAGE — FALSE ACTIVATION (COCKPIT TEMP) · airframe 50,168 hrs · 14,919 cycles

CONT CAB ZONE TEMP. EXTINGUISHES UPON RECALL. GROUNDED - YES. NR 2 ZTC LOGGED FLT DECK TRIM VALVE. BITE TESTED GOOD. FAULT RESET.

Part: CONNECTOR — LOOSE (NR 2 ENGINE) · airframe 50,099 hrs · 14,903 cycles

NR 2 FUEL FILTER BYPASS ILLUMINATED AFTER LANDING. GROUNDED - YES. DURING INITIAL EVALUATION FOUND FUEL FILTER DIFFERENTIAL PRESSURE SWITCH ELECTRICAL CONNECTOR DP0803 LOOSE. RE-CONNECTED CONNECTOR REF AMM 73-34-01. PERFORMED EEC 2 BITE TEST REF FIM 73-00 TASK 801. TEST PASSED. REMOVED AND REPLACED FUEL FILTER IAW AMM 73-11-02/ 401. INSPECTED FILTER WITH NO DEFECTS FOUND. C/W ENGINE RUN AND LEAK CHECK NO DEFECTS NOTED. NR 2 FUEL FILTER BYPASS LIGHT DID NOT ILLUMINATE OPS CK GOOD.

Part: RESOLVER — WORN (THRUST LEVER) · airframe 50,093 hrs · 14,901 cycles

NR 2 THRUST LEVER HAS EXCESSIVE PLAY. GROUNDED - YES. REPLACED NR 2 THRUST LEVER ANGLE RESOLVER ASSY REF AMM 76--11-05 PB 401. COMPLETED NR 2 THRUST LEVER ANGLE RESOLVER ADJUSTMENT REF AMM 76-11-05-820-801 THRU STEP 2.F. NR 2 ENG THRUST LEVER FREE PLAY ELIMINATED. PERFORMED LANDING WARNING SYS TEST AMM 31-51-00-730-802. OPS NORMAL. GROUND CONFIRMATION CK OPS NORMAL.

Part: FMC — MALFUNCTIONED (FIRST OFFICER'S) · airframe 49,357 hrs · 14,728 cycles

F/O'S FMC DISPLAYED A MAP FLAG ON THE ND, WITH SINGLE FMC OPERATION DISPLAYED IN THE SCRATCH PAD. GROUNDED - YES. REBOOTED R/H FMC REF. FIM 34-61 TSK 835 OPENED & CLOSED 1 C/B NORM OPS RESTORED. OPS OK REF B737-800 FIM 34-61 TSK 801. "ETOPS GROUND VERIFICATION COMPLETE".

Part: STARTER GEN — FAILED (APU) · airframe 49,153 hrs · 14,672 cycles

APU FAILED TO START AFTER LANDING FAULT LIGHT ILLUMINATED. GROUNDED - YES. REMOVED & REPLACED APU STARTER-GENERATOR IAW B737-800 AMM 49-41-21, LEAK CHECK & OPS CHECK GOOD.

Part: AUTOTHROTTLE SYS — MALFUNCTIONED · airframe 49,083 hrs · 14,657 cycles

AUTO THROTTLES DISENGAGED DURING TAKEOFF AND WILL NOT REENGAGE. GROUNDED - YES. ON DEFERRAL.

Part: FMC — FAULTED (COCKPIT) · airframe 49,027 hrs · 14,642 cycles

WHILE AT CRUISE, FL380, LNAV VNAV ENGAGED, VTK DISPLAYED ON CAPT ND, FOLLOWED BY BOTH CDU'S BLANKING, 15 SECONDS LATER #1 FMC RESTORED TO NORMAL OPS BY ITSELF - DID NOT POSITION FMC SWITCH TO BOTH ON R. GROUNDED - YES. REF B737-800 FIM 34-61 TASK 836. INITIAL EVALUATION SHOWS INTERMITTENT FAULT. FAULT LEG 01 SHOWS CDU POWER SUPPLY 85214.3. ACCOMPLISHED FMCS BITE PROCEDURE TASK 801. NO FAULTS CURRENT. ACCOMPLISHED FMCS OPERATIONAL TEST IAW B737-800 AMM 34-61-00-710-801. GROUND VERIFICATION TEST IS GOOD.

Part: EXCITER — INTERMITTENT (APU) · airframe 49,008 hrs · 14,636 cycles

APU "FAULT" LIGHT WHEN ATTEMPTED TO START APU AFTER LANDING. GROUNDED - YES. FOUND "NO FLAME SHUTDOWN" FAULT. ACCOMPLISHED B737-800 FIM 49-40 TASK 802. ACCOMPLISHED 2 SUCCESSFUL STARTS, NO FAULTS FOUND. REMOVED AND REPLACED APU EXCITER ASSY AND IGNITER PLUG, PER B737-800 AMM 49-41-31 AND AMM 49-41-51. OPS TEST NORMAL.

Part: OVERHEAT SENSOR — DEFECTIVE (APU) · airframe 48,774 hrs · 14,561 cycles

APU DET INOP ILLUMINATED AT CRUISE, APU WAS NOT RUNNING. GROUNDED - YES. FIRE DETECTION MODULE SHOWS APU-TAILPIPE. ACCOMPLISHED FIM 26-10 TASK 808. TAIL PIPE DETECTOR READS 25K OHMS. PER FIM 26-10 TASK 802 REMOVED AND REPLACED APU TAILPIPE OVERHEAT DETECTOR ELEMENT IAW AMM 26-15-01. INSTALLATION TEST GOOD. FIRE DETECTION CONTROL MODULE BITE CHECK GOOD. NO FAULTS.

Part: CARD — NOT SEATED (SATCOM) · airframe 48,684 hrs · 14,529 cycles

SAT LOG MODEM STATUS PAGE IN ACARS DISPLAYS LBT-2 AS NOT READY AND SIGNAL STRENGTH 0. GROUNDED - YES. ON SAT CONFIG PAGE. LBT-2 SIM NUMBER WAS BLANK. RESEATED IRIDIUM CONFIG ID MODULE SIM CARDS PER AMM 23-15-00-400-802. ONE MIG-51A INSTALLED/ REMOVED. LBT-2 SIM NUMBER NOW SHOWS AND LBT-2 SHOWS READY ON SAT LOG PAGE.

Part: CONTROL PANEL — INOPERATIVE (COCKPIT) · airframe 48,220 hrs · 14,397 cycles

F/O SIDE COURSE KNOB INOP. GROUNDED - YES. CYCLED POWER-NO HELP. FO COURSE SELECTOR INOP. REMOVED & REPLACED MCP. OP CK NORMAL. REF AMM 22-11-34-000-801 & 22-11-34-400-801, BITE GROUP 32 & 49.

Part: TURBINE — DENTED (NR 1 ENGINE) · airframe 48,150 hrs · 14,381 cycles

#1 ENGINE REAR TURBINE FLANGE DENTED @ 3&9 OCLOCK POSITION. GROUNDED - YES. REMOVED AND REPLACED #1 ENG REAR TURBINE FLANGE REF. AMM 72-56-00-000-802-F00 STEPS (E) AND (F) 1, 2 AND 4 AND AMM 72-56-00-400-801-F00 F(2), (3) AND G(1) AND (2).

Part: PUMP — INOPERATIVE (FUEL BOOST) · airframe 47,761 hrs · 14,273 cycles

MAIN TANK #1 FORWARD FUEL PUMP INOP. GROUNDED - YES. REF B737-800 AMM 28-22-41-000-801/-400-801 REMOVED AND REPLACED #1 TANK FWD BOOST PUMP IMPELLER, #1 BOOST PUMP OPS AND LEAK CHECK GOOD.

Part: INDICATOR — INACCURATE (NR 1 FUEL QTY) · airframe 47,051 hrs · 14,076 cycles

#1 FUEL QUANTITY INDICATOR SHOWS IMBALANCE. GROUNDED - YES. CYCLED A/C POWER #1 FUEL IMBALANCE AMBER LIGHT EXTINGUISHED PERFORMED B737-800 FIM TASK 28-41-00-810-801 NO FAULTS FOUND.

Part: PUMP — FAILED (LT WING) · airframe 46,943 hrs · 14,039 cycles

THE AFT FUEL PUMP ON THE LEFT MAIN TANK FAILED DURING CRUISE. GROUNDED - YES. REMOVED AND REPLACED LEFT AFT TANK FUEL BOOST PUMP PER AMM 28-22-41. CLEARED MEL 28-1C.

Part: CIRCUIT BREAKER — TRIPPED (FUEL SYSTEM) · airframe 46,938 hrs · 14,038 cycles

LEFT AFT MAIN TANK FUEL PUMP SWITCH ILLUMINATED. GROUNDED - YES. FOUND TANK 1 AFT FUEL BOOST CB OPEN ON P92 PANEL NO DEBRIS FOUND. INSPECTION OF P92 PANEL GOOD. RESECURED P92 PANEL RESET BOOST PUMP CB. OPERATED BOOST PUMP FOR 10 MINS, TURNED OFF AND OPERATED FOR 5 MINS, CHECKS GOOD IAW FIM 28-22 TASK 803. DETERMINED TO BE INTERMITTENT FAULT.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 46,774 hrs · 13,999 cycles

HF RADIO NR 1 FAIL. GROUNDED - YES. PERFORMED BITE PROCEDURE ON NR 1 HF TRANSCEIVER PER FIM TASK 23-11-00-810-801, OPS CHECK GOOD, FAIL LIGHT EXTINGUISHED.

Part: UNKNOWN — MALFUNCTIONED (CABIN TEMP) · airframe 46,727 hrs · 13,988 cycles

CON CAB & FWD CAB ZONE TEMP CONTROLLERS INOP. GROUNDED - YES. RAN PACK/ZONE TEMP CONT TEST PER AMM 21-61-00 SYSTEM OP CHECKS GOOD NO DEFECTS NOTED. CABIN AND FLIGHT DECK SENSOR FILTERS REPLACED FOR THE "A" CHECK THIS CLEARS MEL 21-19G AND 21-21G.

Part: INDICATOR — INOPERATIVE (FUELING PANEL) · airframe 46,710 hrs · 13,981 cycles

NR 2 TANK FUELING PANEL GAUGE INOP. GROUNDED - YES. REMOVED AND REPLACED NR 2 TANK FUELING PANEL GAUGE REF AMM 28-41-61. OPERATIONAL CHECK IS NORMAL CLEARS MEL 28-12B.

Part: START VALVE — INOPERATIVE (NR 2 ENGINE) · airframe 46,683 hrs · 13,974 cycles

ENG NR 2 AFTER START SWITCH TO GROUND START VALVE OPEN BUT NO N2 ROTATION. GROUNDED - YES. REMOVED & REPLACED N2 ENG START VALVE IN REF TO AMM 80-11-03 PERFORMED PNU LEAK CHECK AMM TASK 71-00-00-700-809-F00 OPS NORMAL AC IS GOOD FOR SERVICE.

Part: WARNING LIGHT — FALSE ACTIVATION (COCKPIT TEMP) · airframe 46,590 hrs · 13,950 cycles

AFTER ENGINE START CONT CAB ZONE TEMP LITE ILLUMINATED WILL NOT EXTINGUISH AFTER FOLLOWING QRH. GROUNDED - YES. REF B737-800 FIM 21-61 TASK 801, #1 PZTC BITE TEST PASSED NO FAULT NOTED, #2 PZTC BITE TEST FAULTED FLT DECK TRIM VALVE, NO ACTIVE FAULT SHOWS AFTER #2 PZTC RESET, BOTH PACKS OPS TES NORMAL REF B737-800 AMM 21-61-00, CLEARS MEL 21-21G.

Part: SHIM — WORN (NR 2 ENGINE) · airframe 46,287 hrs · 13,880 cycles

DURING FAN LUBE ALL NR 2 ENGINE FAN BLADE SHIMS HAVE WEAR. GROUNDED - YES. REPLACED ALL NR 2 ENGINE SHIMS PER T/C 78472010.

Part: BLADE — CRACKED (NR 2 ENGINE) · airframe 46,287 hrs · 13,880 cycles

WHILE ACCOMP T/C SBCFM56-7B-72-1033-1, FAN BLADE ROOT ULTRASONIC INSPECTION FOUND BLADE NR 3 S/N DD453914-J 32% INDICATION 5.25" FROM LE CONVEX SIDE. BLADE NR 11 S/N DD454177-5 31% INDICATION 1.25" FROM LE CONVEX SIDE. ALL BEYOND 30% REJECT, ENGINE NR 2 S/N 894276. GROUNDED - YES. REPLACED NR 2 ENGINE FAN BLADES NR 3 & NR 11 AND THEIR PAIR NR 15 & NR 23 PER AMM 72-21-02-000-802 & T/C 78472010.

Part: SMOKE DETECTOR — FAILED (CARGO BAY) · airframe 46,293 hrs · 13,881 cycles

AFT LOWER CARGO FIRE SWITCH LOOP A TEST INOP. GROUNDED - YES. REPLACED (3) SMOKE DETECTORS IN AFT CARGO PIT A SYS M2242, M2243, M2244 PER AMM 26-16-01-400-801. OPS CK PER AMM 26-16-00-730-801.

Part: SEAL — MISSING (NR 2 ENGINE) · airframe 46,287 hrs · 13,880 cycles

REF T/C 78472010 NR 2 ENGINE FAN BLADE LUBRICATION. FOUND PLATFORMS MISSING RUBBER SEALS BEYOND LIMITS. P/N: 340-001-816-0. 24 EACH. GROUNDED - YES. REPLACED ALL PLATFORMS ON NR 2 ENGINE FAN PER T/C 78472010.

Part: ELECTRONIC UNIT — FAILED (CARGO BAY) · airframe 46,179 hrs · 13,848 cycles

CARGO SMOKE/FIRE DETECTION AFT LOOP "A" WILL NOT TEST. GROUNDED - YES. DUE TO HISTORY, REMOVED AND REPLACED AFT CARGO CEU. OPS TEST GOOD. REF AMM 26-16-02. AFT CARGO DETECTOR SWITCH TO NORMAL POSITION.

Part: UNKNOWN — MALFUNCTIONED (DETECTION SYS) · airframe 46,105 hrs · 13,832 cycles

AFT CARGO DETECTOR LOOP A WON'T TEST. GROUNDED - YES. PERFORMED AMM TASK 26-16-00-710-801. CHECKED GOOD. NO HISTORY IN 30 DAYS. OPS NORMAL.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 46,062 hrs · 13,812 cycles

WHILE IN THE CLIMB, VTK APPREARED ON FO'S ND. FMA WENT FROM LNAV TO CWS AND SCRATCHPAD MESSAGE SINGLE FMC OPERATION WAS DISPLAYED. CONSULTED QRH 11.3 AND BEFORE WE COMPLETED THE CHECKLIST THE RIGHT FMC WAS RESTORED AND WORKING AGAIN. ENTERED PER FLIGHT HANDBOOK PAGE 6. 110 P.23. GROUNDED - YES. ACCOMPLISHED FIM 34-61 TASK 836. FMC BITE SHOWED NO CURRENT FAULTS. INTERMITTENT SOFTWARE RESET FAULT.

Part: UNKNOWN — MALFUNCTIONED (FUEL SYSTEM) · airframe 46,016 hrs · 13,800 cycles

SHORTLY AFTER LEVEL AT CRUISE SAW LEFT MAIN FUEL QUANTITY DECREASING WITH ALL 6 FUEL PUMPS ON WITH CENTER TANK FUEL, LEFT TANK SHOWED A 500 LBS DIFFERENCE FROM RIGHT MAIN TANK. RAN QRH FUEL LEAK CHECK LIST. DETERMINED NO LEAK WAS PRESENT. QUANTITY STOPPED DECREASING FROM LEFT TANK. AFTER CENTER TANK WAS USED GOT ABOUT A 700LB IMBALANCE FROM LEFT AND RIGHT TANK. BALANCED FUEL REST OF FLIGHT NORMAL. GROUNDED - YES. REFERENCE FIM 28-41 TASK 801. PERFORMED FUEL FQIS BITE CHECK. FOUND NO INFLIGHT FAULTS. FOUND NO CURRENT STATUS FAULTS. GROUND TEST PASS - NO FAULTS, REF AMM 28-22-00-730-802. PERFORMED CROSS FEED VALVE TEST - TEST PASSED NO FAULTS. REFERENCE AMM 28-41-00-720-801, PERFORMED FQIS COMPARISON CHECK - FOUND INDICATION WITHIN LIMITS.

Part: COMPENSATOR — FAILED (FUEL SYSTEM) · airframe 46,026 hrs · 13,802 cycles

IN FLIGHT MAIN TANK NR 1 WAS 600 LBS LOW WHILE USING CENTER TANK FUEL. ON LANDING MAIN TANK NR 1 300 LBS LOW. GROUNDED - YES. ON DEFERRAL. PERFORMED A TANK AND COMP UNITS TEST ON THE NR 1 TANK PER AMM 28-41-21-710-801. FOUND PROBES F15, F4, F5, F6, F7, AND F9 OUT OF LIMITS. REMOVED AND REPLACED F15L COMPENSATOR AND F4L, F5L, F6L, F7L, F8L, AND F9L TANK UNITS ON NR 1 MAIN TANK PER AMM 28-41-21/401. TANK AND COMPENSATOR UNITS TEST GOOD PER AMM 28-41-21-710-801. GROUND VERIFICATION GOOD.

Part: IDG — INOPERATIVE (NR 1 GENERATOR) · airframe 45,918 hrs · 13,774 cycles

DRIVE LIGHT ILLUMINATED. DISCONNECTED DRIVE. GROUNDED - YES. REMOVED/REPLACED/TESTED #1 ENGINE IDG PER B737-800 AMM 24-11-11-000/400-801, 71-00-00-800-811-F00. GROUND VERIFICATION REPAIR CONFIRMATION SUCCESSFUL PER FIM 24-11-801. LIBERATION OF VALVE CAP LIKELY RESULTED FROM EXCESSIVE CAP SCREW TORQUE. NO DEFECTS NOTED.

Part: FITTING — SEPARATED (NR 2 ENGINE BOSS) · airframe 45,830 hrs · 13,754 cycles

FOUND TEST PIN FITTING TO HAVE SEPARATED FROM BOSS # 2 ENGINE 1 O'CLOCK POSITION LOOKING FWD. GROUNDED - YES. ON DEFERRAL

Part: VALVE — INTERMITTENT (NR 2 ANTI ICE) · airframe 45,830 hrs · 13,754 cycles

#2 ENGINE ANTI-ICE BLUE (COWL VALVE OPEN) LIGHT DOES NOT STAY DIM WHEN ENGINE ANTI ICE SELECTED ON (LT INTERMITTENTLY SWITCHES BACK AND FORTH) (DIM TO BRIGHT). GROUNDED - YES. REF B737-800 WDM'S 30-21-11/30-21-21 PG1, W/DP1303 OFF VALVE, SW ON, AND SHOWS BRIGHT TILL PINS 8+9 ON SAME CONN JUMPERED AND GOES DIM. SUSPECT BAD VALVE (V4). REMOVED AND INSTALLED #2 ENGINE COWL TAI VALVE REF B737-800 AMM 30-21-11. OPS CHK GOOD.

Part: OVEN — ODOR (GALLEY) · airframe 45,702 hrs · 13,720 cycles

AIRCRAFT RIGHT AFT RIGHT HAND OVEN BEGAN TO HEAT UP AND EMIT A HOT ELECTRICAL SMELL AFTER HAVING BEEN TURNED OFF FOR 45 MINUTES HOT ELECTRICAL SMELL STOPPED AFTER PULLING OVEN CIRCUIT BREAKERS. GROUNDED - YES. RESET C/B'S FOR AFT GALLEY OVENS. TURNED ON OVEN AND PERFORMED OPS CHECK ON OVENS. REF B737-800 AMM 25-32-01. DID NOT NOTE ANY SMELLS OF ELECTRICAL SMELL. OVENS OPS NORMAL WITH NO DEFECTS NOTED. OK FOR SERVICE.

Part: SMOKE DETECTOR — INTERMITTENT (CARGO BAY) · airframe 45,688 hrs · 13,717 cycles

CARGO FIRE TEST AFT FAIL. GROUNDED - YES. UNABLE TO DUPLICATE DEFECT, DUE TO HISTORY REMOVED AND REPLACED AFT CARGO A3 LOOP DETECTOR REF AMM 26-16-01, OPS CHECK NORMAL.

Part: EEC — INOPERATIVE (NR 1 ENGINE) · airframe 45,697 hrs · 13,719 cycles

ENGINE CONTROL LIGHT ILLUMINATED AFTER LANDING. GROUNDED - YES. FOUND FAULTS CODE 73-20131 & 73-21281. FURTHER INSPECTION REVEALED ENG #1 ALTN PWR CHANNEL "A" C/B OPENED. INSPECTED C/B PER B737-800 AMM 20-60-01 NO DEFECTS NOTED. C/B WOULD NOT RESET. DISCONNECTED CONNECTOR DP0101 AT EEC. RESET C/B & C/B REMAINS SET. REMOVED & REPLACED #1 ENG EEC IAW AMM 73-21-60. OPS CHECK GOOD.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 45,581 hrs · 13,691 cycles

FLT CREW REPORTS FAULT LIGHT ILLUMINATED ON AFT CARGO FIRE DETECTION TEST. GROUNDED - YES. PERFORMED FIRE AND OVERHEAT DETECTION CHECK REF AMM 26-10-00-710-801, NO FAULTS FOUND. PERFORMED CARGO FIRE CONTROL PANEL BITE CHECK, NO FAULTS FOUND REF FIM 26-23 TASK 801.

Part: TRANSCEIVER — FAILED (HF COMM) · airframe 45,456 hrs · 13,661 cycles

NR 2 HF DID NOT TEST. GROUNDED - YES. ACCOMPLISHED FIM 23-11 TASK 801. FOUND NUMBER 2 HF TRANSCEIVER WOULD NOT POWER UP FOR BITE TEST. CYCLED A/C POWER OPS AND BITE CHECK GOOD. REMOVED AND REPLACED NR 2 HF TRANSCEIVER PER AMM 23-11-21. OPS AND BITE CK GOOD. OK FOR SVC.

Part: MODULATING VALVE — FAILED (AC BAY) · airframe 45,344 hrs · 13,622 cycles

CONT CABIN ZONE TEMP ILLUMINATED AFTER ENG START. RAN QRH AND COMPLIED WITH INSTRUCTIONS ZONE LIGHT EXTINGUISHED AFTER MASTER CAUTION WAS RESET. TALKED TO MAINT, AND SAID GOOD TO PROCEED. GROUNDED - YES. BITE CHK NR 2 TEMP CONTROLLER, SHOWED FLT DECK TRIM VALVE FAULT. REMOVED AND REPLACED CONTROL CABIN TRIM VALVE REF AMM 21-61-21. BITE TEST AND LEAK CK GOOD.

Part: TRANSCEIVER — INOPERATIVE (E&E BAY) · airframe 45,279 hrs · 13,605 cycles

HF RADIO NR 1 INOPERATIVE, RADIO DOES NOT TRANSMIT OR RECEIVE. ANTENNA DOES NOT INDICATE TUNING WHEN MICROPHONE IS KEYED. NO SIDETONE IS HEARD WHEN ATTEMPTING TO TRANSMIT. TWO BEEPS ARE HEARD EVER 12 SECONDS WHEN MONITORING RADIO. USE OF DIFFERENT TUNING HAD, MICROPHONE, OR HEADSET MAKES NO DIFFERENCE. GROUNDED - YES. NONE OF THE INDICATION LIGHTS OPERATIONAL ON FRONT PANEL OF HF TRANSCEIVER DURING BITE REMOVED AND REPLACED HF NR 1 TRANSCEIVER REFERENCE AMM 23-11-21-000-801 AND 23-11-21-400-801. INSTALLATION AND BITE TEST PASS.

Part: INTERCOSTAL — CRACKED (NOT REPORTED) · airframe 45,190 hrs · 13,571 cycles

INTERCOSTAL BETWEEN STA. 312 AND 328 LBL 45 CRACKED AT FASTENER HOLE. GROUNDED - YES. REMOVED AND REPLACED CRACKED INTERCOSTAL IAW B737-800 SRM 51-40-02-06-0.

Part: TRANSITION PANEL — CORRODED (FUSELAGE) · airframe 45,190 hrs · 13,571 cycles

UPON REMOVAL OF GEL TAPE FOUND CORR ON TRANSITIONAL PANEL FROM LT STA 727D+10 TO 727I+10 IN AFT PIT. GROUNDED - YES. REMOVED DAMAGE FOUND TO BE OUT OF LIMITS IAW SRM 53 00 53 1A 2. FABRICATED NEW TRANSITION PNL IAW SRM 53 00 53 2R 5 STEPS 4D AND INSTALLED IAW SRM 53 00 53 2R 5 W 3 O .040 R .00 L 240. D .040.

Part: GUSSET — CORRODED (FUSELAGE) · airframe 45,190 hrs · 13,571 cycles

UPON REMOVAL OF GEL TAPE AT STA 767 ABOVE STR 25R GUSSET IS CORRODED. GROUNDED - YES. REMOVED AND REPLACED RT STR 25 GUSSET AT BS 767 IAW SRM 51 40 02 0G 0. GUSSET FOUND TO BE OUT OF LIMITS IAW SRM 53 00 53 1A 2 W 1 1/4 O .063 R .051 L 1 1/2 D .012.

Part: TRANSITION PANEL — CORRODED (FUSELAGE) · airframe 45,190 hrs · 13,571 cycles

UPON REMOVAL OF GEL TAPE FOUND CORR ON RT TRANSITION PANEL AFT PIT FROM STA 727E TO STA 767. GROUNDED - YES. REMOVED DAMAGE FOUND TO BE OUT OF LIMITS IAW SRM 53 00 53 1A 2 FIG 103 DETAIL D. FABRICATED NEW TRANSITION PNL IAW SRM 53 00 53 2R 5 AND INSTALLED IAW SRM 53 00 53 2R 5 W 3 O .040 R 0 L 216 D .040.

Part: ANGLE — CORRODED (BS 986) · airframe 45,190 hrs · 13,571 cycles

UPON REMOVAL OF ANGLE AT STA. 986 LBL45, CORROSION ON LOWER SURFACE (PR). GROUNDED - YES. REMOVED CORROSION ON ANGLE AT STA 986 LBL 45, FOUND TO BE OUT OF LIMITS IAW B737-800 SRM 53-70-51-1A-1 FIG 104 DETAIL F, LOCATED + DRILLED NEW ANGLE IAW B737-800 SRM 51-40-05-06-0 FIG 2.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 45,190 hrs · 13,571 cycles

DRY AREA FLOOR STRUCTURE ANGLE CRACKED IN RADIUS AT STA 540 RBL 2. GROUNDED - YES. REMOVED AND REPLACED DRY AREA FLOOR STRUCTURE ANGLE AT STA 540 RBL2 IAW B737 800 SRM 51 40 02 0G 0.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 45,190 hrs · 13,571 cycles

DRY AREA FLOOR STRUCTURE ANGLE CRACKED FWD SIDE OF STA 520 FLOORBEAM BL0. GROUNDED - YES. REMOVED AND REPLACED WITH NEW ANGLE AT DRY AREA FLOOR STRUCTURES AT STA 520 BL0 IAW SRM 51 40 02 0G 0.

Part: DOOR SILL — CORRODED (FUSELAGE) · airframe 45,190 hrs · 13,571 cycles

AFT PIT CARGO THRESHOLD SILL HAS CORR. GROUNDED - YES. REMOVED CORR REMAINING MATL FOUND TO BE OUT OF LIMITS, REMOVED AND REPLACED THRESHOLD SILL IAW SRM 51 40 02 0G 0 W 1 O .05 R .043 L 24 D .007.

Part: CARGO TRACK — WORN (CARGO BAY) · airframe 45,190 hrs · 13,571 cycles

AFT PIT CARGO NET TIE DOWN AT STA 787 LT LUGS ARE WORN. GROUNDED - YES. AFT PIT CARGO TRACK AND LUG WERE REPAIRED AND REFINISHED IAW EA 800 53EA 20761 AND SRM 53 00 53 2R 3.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 45,190 hrs · 13,571 cycles

DRY AREA FLOOR STRUCTURE ANGLE CRACKED IN RADIUS AT STA 54O LBL 2. GROUNDED - YES. REMOVED AND REPLACED DRY AREA FLOOR STRUCTURE ANGLE AT STA 540 LBL 2 IAW SRM 51-40-02-00-0.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 45,190 hrs · 13,571 cycles

FWD WET AREA INTERCOSTAL BETWEEN STA 277 AND 294 BL0 IS CRACKED AT FASTENER HOLE. GROUNDED - YES. REMOVED CRACKED INTERCOSTAL BETWEEN STA 277 AND 294 BL0 AND INSTALLED NEW INTERCOSTAL IAW SRM 51 40 05 0G 0 AND 51 40 02 0G 07.

Part: FLOORBEAM — CORRODED (BS 947) · corrosion level 2 · airframe 45,190 hrs · 13,571 cycles

AFT WET AREA FLOOR BEAM STA. 947 HAS A CORROSION PIT O/B OF RH LAV. MOUNT. GROUNDED - YES. REPAIRED FLOOR BEAM HORIZONTAL FLANGE IAW 737-800 SRM 53-70-51-2R-5.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 45,190 hrs · 13,571 cycles

AFT WET AREA FLOORBEAM STA. 986 HAS CORROSION ALONG TOP CAP. GROUNDED - YES. REPAIRED 986 FLOORBEAM UPPER HORZ. FLANGE IAW SRM 53-70-51-2R-4.

Part: INTERCOSTAL — CRACKED · airframe 45,190 hrs · 13,571 cycles

FWD WET AREA INTERCOSTAL BETWEEN STA 312 AND 328 RBL 30 IS CRACKED. GROUNDED - YES. REMOVED AND REPLACED CRACKED INTERCOSTAL IAW B737-800 SRM 51-40-02-06-0.

Part: FEEDER CABLE — NOT REPORTED (L2 WINDOW) · airframe 45,146 hrs · 13,554 cycles

L2 WINDOW OVERHEAT LIGHT ILLUMINATED DURING CLIMB. REMAINED OUT AFTER QRH. ACFT GROUNDED. REMOVED AND REPLACED THE COIL CORD AT THE L2 WINDOW IAW AMM 30-41-00. OPS TESTED GOOD.

Part: CONTROLLER — FAILED (CABIN PRESSURE) · airframe 45,127 hrs · 13,548 cycles

PRESSURIZATION SELECTOR SWITCH WAS IN AUTO POSITION & GREEN ALTERNATE LIGHT ON. ACFT GROUNDED. REMOVED AND REPLACED THE NR 2 CABIN PRESSURE CONTROLLER, OPS NORMAL IAW AMM 21-31-01.

Part: WARNING LIGHT — FALSE ACTIVATION (LT WINDOW) · airframe 45,127 hrs · 13,548 cycles

LEFT SIDE WINDOW OVERHEAT ILLUMINATED IN FLIGHT. ACFT GROUNDED. COMPLETED QRH OPS NORMAL.

Part: INDICATOR — INOPERATIVE (FUEL QTY) · airframe 45,090 hrs · 13,534 cycles

NR 2 REFUELING PANEL, QTY GAUGE WAS INOPERATIVE. ACFT GROUNDED.

Part: UNKNOWN — UNKNOWN (DISPLAY) · airframe 45,084 hrs · 13,533 cycles

CAPTAIN`S CDU WENT BLANK DURING CRUISE, MOMENTARILY AND RETURNED TO NORMAL OPS. ACFT GROUNDED. PERFORMED FIM 34-61 TASK 804. OPS CHECK OK.

Part: INDICATOR — INTERMITTENT (FUEL QTY) · airframe 44,965 hrs · 13,502 cycles

LEFT MAIN TANK REFUEL PANEL QUANTITY INDICATOR WAS INTERMITTENT. ACFT GROUNDED. REPLACED THE FUEL PANEL NR 1 INDICATOR IAW AMM 28-41-61.

Part: TRANSCEIVER — INTERMITTENT (E&E BAY) · airframe 44,583 hrs · 13,379 cycles

NR 2 HF RADIO SHOWS FAIL/FAIL WHEN SELECTED, WHEN THE FREQ. TRANSFER SWITCH IS PUSHED, THE RADIOS WORK NORMALLY, BUT THEN SHOW FAIL. GROUNDED - YES. ACCOMPLISHED FIM TASK 23-11 TASK 801 BITE TEST PASS. PRECAUTIONARY CHANGED HF TRANSCEIVER NR 2 LRU REF AMM 23-11-21-400-801. BITE TEST GOOD. GROUND VERIFICATION SUCCESSFUL.

Part: UNKNOWN — MALFUNCTIONED (AUTOPILOT SYS) · airframe 44,518 hrs · 13,364 cycles

HGS AIII AND AUTOLAND FAILED. ON LOC CAP, BOTH AUTOPILOTS DISCONNECTED. MOMENTARY FMC DISAGREE ON FO'S SIDE ILLUMINATED. MOMENTARY RA FAIL FLAG AT 5000' / FO'S FD DROPPED OFF. IN THE FLARE USING HGS ONLY, THE FLIGHT PATH CUE DISAPPEARED. GROUNDED - YES. RESET SYSTEM AND RAN LAND VERIFY TEST IAW B737-800 AMM 22-11-00/201, OPS CHECK GOOD. RAN HGS TEST IAW MM 34-36-00, OPS CHECK GOOD. AIRCRAFT IS AUTOLAND AND HGS CAT III QUALIFIED.

Part: FITTING — DETACHED (EVAC SLIDE) · airframe 44,483 hrs · 13,356 cycles

R1 DOOR GIRT BAR CLIP, LEFT SIDE IS HALF DETACHED -SWINGS SIDEWAYS WHEN BAR IS NOT CLIPPED IN. GROUNDED - YES. REMOVED SLIDE FROM DOOR, OPENED SLIDE SHROUD TO REMOVE SHEARED FASTENER, REMOVED FASTENER AND INSTALLED NEW, REINSTALLED SLIDE ON R1 DOOR REF SRM 51-40-02 AND AMM 25-66-01.

Part: AUTOTHROTTLE SYS — MALFUNCTIONED · airframe 44,358 hrs · 13,317 cycles

AUTOTHROTTLE WILL NOT ARM. ACFT GROUNDED. ACCOMPLISHED FIM 22-31, TASK 801. NO FAULTS IN CURRENT STATUS OR IN FLIGHT FAULTS. ACCOMPLISHED AUTOTHROTTLE SYSTEM OPS TEST IAW AMM 22-31-00-710-801. OPS CHECKED NORMAL.

Part: BULB — FAILED (RT A/C PACK TEMP) · airframe 44,174 hrs · 13,271 cycles

TEMPERATURE INDICATION NOT CORRECT FOR THE RIGHT PACK, ALL SUPPLY & PASSENGER TEMPS APPEAR NORMAL. LEFT PACK TEMP WAS NORMAL. ACFT GROUNDED. REMOVED AND REPLACED THE PACK TEMPERATURE BULB T489 IAW AMM 21-51-60. OPS CHECKED GOOD.

Part: UNKNOWN — MALFUNCTIONED (HF COMM) · airframe 44,027 hrs · 13,233 cycles

ON PREFLIGHT FOUND HF NR 2 FAIL LIGHTS ILLUMINATED. GROUNDED - YES. REF FIM 23-11 TASK 801. PERFORMED NR 2 HF SYSTEM BITE. CYCLED BREAKER SYSTEM RESTORED. BITE CHECK OPS NORMAL. NO FAULT FOUND NO HISTORY PAST 30 DAYS. OK TO CONTINUE SERVICE.

Part: INDICATOR — FAILED (REFUEL PANEL) · airframe 43,915 hrs · 13,202 cycles

FUELER REPORTED THE NR 1 TANK INDICATOR ON REFUEL PANEL HAS A DIGIT BURNT OUT. FLT DECK GAUGE READS NORMAL. ACFT GROUNDED. REMOVED AND REPLACED THE NR 1 TANK REFUEL INDICATOR IAW AMM 28-41-61. OPS CHECKED GOOD.

Part: CONTROL VALVE — FAULTED (LT A/C PACK) · airframe 43,875 hrs · 13,191 cycles

LEFT PACK LIGHT ILLUMINATED DURING MASTER CAUTION RECALL. EXTINGUISHED WHEN MASTER CAUTION SYSTEM WAS RESET. ACFT GROUNDED. PERFORMED A NR 1 PZTC BITE IAW AMM 21-51-00. FOUND LEFT PACK TCV FAULT. REMOVED AND REPLACED THE LT TEMP CONTROL VALVE IAW AMM 21-51-10. NR 1 PZTC BITE CHECKED GOOD AFTER THE REPLACEMENT. PERFORMED CABIN TEMP CONTROL AND INDICATION OPS TEST IAW AMM 21-61-00. NO NEW FAULTS FOUND, LT & RT PACKS OPS CHECKED GOOD. ETOPS SIGNIFICANT SYSTEM, GROUND VERIFICATION SUCCESSFUL.

Part: CONNECTOR — DIRTY (EGT) · airframe 43,611 hrs · 13,127 cycles

DIAGNOSTICS REPORTED THE NR 1 ENGINE TREND DATA SHOWS A SHIFT IN EGT HOT DAY MARGIN ALL OTHER PARAMETERS NORMAL. EGT INDICATION ERRORS ARE SUSPECT PRI 2 ETOPS SIGNIFICANT SYSTEM. ACFT GROUNDED. ACCOMPLISHED EGT INDICATION SYSTEM TROUBLESHOOTING AND CONNECTOR CLEANING IAW AMM 77-21-00-140-801. NUMBERS BEFORE CLEAN, S1 - 228, S2 - 219, S3 - 222, S4 - 238. NUMBERS AFTER CLEAN S1 - 68, S2 - 35, S3 - 36, S4 - 86. SYSTEM OPS CHECK GOOD WITH ACTUATORS TEST, EEC TEST, AND RECENT FAULTS.

Part: VANE — CRACKED (NR 1 NOZZEL) · airframe 42,082 hrs · 12,640 cycles

REPEAT BOROSCOPE INSPECTION ON #1 ENGINE WITH ONE LPT STAGE 1 NOZZLE VANE WITH FULL CRACK AND MISSING MATERIAL LESS THAN .039 SQ IN AT 3 O'CLOCK ALF PER B737-800 AMM 72-00-00-200-811-F00 FOUND RADIAL CRACKS FROM HOLE HAS PROGRESS, BUT REMAINS IN LIMITS. BURNED MATERIAL HAS PROGRESS FROM .0318"SQ TO .0393"SQ. GROUNDED - YES. REMOVED AND REPLACED #1 ENGINE REF W/O 1042103.

Part: WARNING LIGHT — FALSE ACTIVATION (A/C PACK) · airframe 42,587 hrs · 12,813 cycles

DURING CLIMB OUT, LEFT PACK ILLUMINATED, COMPLIED WITH QRH, TURNED LEFT PACK SWITCH TO OFF, CLOSED ISOLATION VALVE. PRESSURIZATION NORMAL AT CRUISE. ACFT GROUNDED. VERBAL FROM CREW LEFT PACK WOULD NOT RESET LIGHT ILLUMINATED WITH NO ASSOCIATED PACK OR M/C LIGHTS. ON ARRIVAL, LT A/C PACK LIGHT WAS NOT ILLUMINATED, DEPRESSED RECALL AND LEFT PACK LIGHT ILLUMINATED AND WILL RESET WITH RECALL, RAN PACKS WITH NO PACK LIGHT ILLUMINATED IAW FIM 21-53, TASK 803. ACCOMPLISHED PTZ OF BOTH CONTROLLERS, NR 1 ON BIT & PREVIOUS FLT PACK TCV FAULTED WITH A GREEN ON. VERIFY NR 2 HAD NO FAULTS IAW FIM 21-62, TASK 801. RAN PACKS AND PTZ BITE WITH NO FAULTS NOTED, ACCOMPLISHED LEFT TCV IAW FIM 21-62, TASK 803, NO FAULTS, ALL GROUND TESTS PASSED. ACCOMPLISHED MASTER DIM & TEST OPS TEST IAW AMM 33-18-00. ALL LIGHTS OPERATE NORMAL, NO HISTORY 60 DAYS.

Part: TRANSFER VALVE — MALFUNCTIONED (FUEL SYSTEM) · airframe 42,461 hrs · 12,766 cycles

FUEL IMBALANCE. ACFT GROUNDED. ACCOMPLISHED CROSSFEED VALVE ALIGNMENT IAW AMM 28-22-21-820-801. REMOVED AND REPLACED THE ENGINE FUEL CROSSFEED VALVE BODY IAW AMM 28-22-21-000-803, AND AMM 28-22-21-400-803. COMPLETED ALL OPS AND LEAK CHECKS. NO UNWANTED FUEL TRANSFER NOTED.

Part: CONTROL PANEL — FAULTED (FIRE SUPPRESSION) · airframe 42,216 hrs · 12,689 cycles

"DISCHARGE" LIGHT ON CARGO FIRE PANEL CAME ON AND OFF IN FLIGHT. GROUNDED - YES. REMOVED, REPLACED CARGO FIRE CONTROL PANEL PER B737-800 AMM 26-00-02-400-801 OPS NML PER AMM 26-23-00-730-802. REMOVED & REPLACED CARGO FIRE BOTTLE #1 REF ASA T/C 78226001. OPS CHECKED GOOD

Part: WARNING LIGHT — ILLUMINATED (EXTINGUISHER) · airframe 42,216 hrs · 12,689 cycles

ON PREFLIGHT NOTED DISCHARGE LIGHT ON CARGO FIRE PANEL. GROUNDED - YES. VERIFIED DISCHARGE LIGHT ILLUMINATED, WENT OUT ON ITS OWN WITH - NO - ACTION BY FLIGHT CREW. REMOVED #1 & #2 CARGO FIRE BOTTLES PER TASK CARD # 78226001. INSTALLED #1 & #2 CARGO FIRE BOTTLES REF TASK CARD 78226001. OPS CHECKS GOOD.

Part: EXCITER — FAILED (APU) · airframe 42,082 hrs · 12,640 cycles

APU FAULT LIGHT ILLUMINATED DURING APU START. APU DID NOT START. GROUNDED - YES. VERIFIED APU WILL NOT ACCELERATE PAST 12% DURING START. REMOVED & REPLACED APU IGNITION EXCITER. OPS CHECK NORMAL, REF B737-800 FIM 49-40 TASK 805 & AMM 49-41-31-000-801, 49-41-31-400-801, & 49-11-00-860-801.

Part: SENSOR — DIRTY (CABIN TEMP) · airframe 42,023 hrs · 12,628 cycles

THE CONTROL CABIN TEMPERATURE SELECTOR ON THE AIR CONDITIONING PANEL DOES NOT FUNCTION PROPERLY. WHEN POSITIONED TO FULL WARM OR OFF THE FLIGHT DECK IS ESTIMATED TO BE 50 DEG F OR LESS. THIS CONDITION BECAME NOTICEABLE 4 HOURS INTO FLIGHT AT 36,000 FT AND OUTSIDE AIR TEMP OF -54 DEG. C. FOLLOWING ARE THE INDICATIONS ON THE AIR TEMP INDICATOR: CONT CAB SELECTOR AT 3 O'CLOCK POSITION DUCT SUPPLY =28 DEG. C. FWD CAB SECTOR AT 12 O'CLOCK POSITION = 26 DEG. C. AFT CAB SELECTOR AT 12 O'CLOCK = 12 DEG. C. FWD AND AFT CAB TEMP = 23 DEG. C. RT PACK = 0 DEG. C. LT PACK = 13 DEG. C. ACFT GROUNDED. ACCOMPLISHED CABIN TEMP CONTROLLER BITE PROCEDURE IAW FIM 21-61 TASK 801. NO CURRENT FAULTS OR PREVIOUS FAULTS NOTED. PERFORMED CABIN TEMP SENSOR CLEANING IAW AMM 21-61-00 AND CABIN TEMPERATURE SENSOR ASSEMBLY FILTER REPLACEMENT FOR CONTROL CABIN IAW AMM21-61-06. RAN PACKS IAW AMM 21-00-00 AND OBSERVED CABIN TEMP INDICATIONS. ALL CONDITIONS NORMAL. CONTROL CABIN HEATED AND COOLED PROPERLY.

Part: FMC — MALFUNCTIONED (NR 1) · airframe 41,464 hrs · 12,448 cycles

NR 1 FMC FAILED AFTER LANDING, REBOOTED AFTER ONE MINUTE. ACFT GROUNDED. NO HISTORY LAST 30 DAYS. PERFORMED FIM 34-61, TASK 836, & FMC OPS CHECKED GOOD. GROUND FUNCTIONAL TEST PASSED.

Part: ACTUATOR — LEAKING (NR 1 VSV) · airframe 41,400 hrs · 12,418 cycles

DURING A LEAK CHECK FOR T/C 78472040, FUEL WAS LEAKING OUT OF THE NR 1 ENGINE RIGHT VSV DRAIN. ACFT GROUNDED. REMOVED AND REPLACED RT VSV ACTUATOR IAW AMM 75-31-01-400-802-F00. ACTUATOR LEAK TEST PERFORMED IAW AMM 75-31-01-790-801-F00.

Part: TERMINAL — BROKEN (FIRE LOOP) · airframe 41,077 hrs · 12,316 cycles

NR 2 FIRE BOTTLE DISCHARGE HANDLE WILL NOT LIGHT UP DURING TEST. ACFT GROUNDED. REPLACED CORE FIRE LOOP HARNESS MW326 DUE TO BROKEN TERMINALS TO RIGHT CORE FIRE DETECT ASSEMBLY. OPS NORMAL IAW AMM 26-11-02.

Part: IDG — LEAKING (NR 2) · airframe 40,830 hrs · 12,248 cycles

FOUND THE NR 2 IDG WITH NO OIL VISIBLE IN SIGHT GLASS WINDOW. ACFT GROUNDED. FOUND OIL LEAKING AROUND IDG SEAL ON THE CASE SECTIONS OF IDG, DUE TO EXCESSIVE OIL SERVICING IN HISTORY REMOVED AND REPLACED THE NR 2 IDG ASSY IAW AMM 24-11-11. FOUND NO OIL CONTAMINATION IN IDG FILTERS. OPS & LEAK CHECKED GOOD.

Part: GUIDE VANE — CRACKED (NR 2 ENGINE) · airframe 40,776 hrs · 12,236 cycles

WHILE ACCOMPLISHING HPT BLADE BOROSCOPE IAW T/C 78472022 ON THE NR 2 ENGINE, FOUND 2 LPT STAGE 1 NOZZLE GUIDE VANES WITH AN AXIAL CRACK .075 INCH, 14 VANE SEGMENTS IN FROM S17, VIEWING CONCAVE SIDE OF LPT VANES. ACFT GROUNDED.

Part: ACTUATOR — FAULTED (RAM AIR) · airframe 40,671 hrs · 12,202 cycles

LEFT PACK RAM DOOR FULL OPEN LIGHT REMAINED ILLUMINATED IN CRUISE AT FL380. ACFT GROUNDED. PERFORMED PACK/ZONE TEMP CONTROL NR 1 BITE IAW FIM 21-62 TASK 801. TEST SHOWED FAULT FOR RAM AIR ACTUATOR AND FAULT FOR RAM AIR SENSOR. FOR THE RAM AIR ACTUATOR FAULT, REMOVED, REPLACED, ADJUSTED, AND TESTED LEFT RAM AIR ACTUATOR IAW AMM 21-51-21-000-801 AND AMM 21-51-21-400-801, OPS NORMAL, AND FOR THE PACK/ZONE TEMP CONTROLLER BITE IAW AMM 21-61-00-700-806-002, NO LONGER SHOWS RAM AIR ACTUATOR FAULT. FOR THE RAM AIR SENSOR FAULT, ACCOMPLISHED FIM 21-62 TASK 821 AND VERIFIED THAT T481 LEFT RAM AIR SENSOR READS OPEN AT PINS 1 AND 2 OF SENSOR. REMOVED, REPLACED, AND TESTED T481 LEFT RAM AIR SENSOR IAW AMM 21-51-50-000-801, AND AMM 21-51-50-400-801. PACK/ZONE TEMP CONTROLLER BITE IAW AMM 21-61-00-700-806-002, NO LONGER SHOWS RAM AIR SENSOR FAULT AND SHOWS NO FAULTS.

Part: ACTUATOR — FAULTED (RAM AIR) · airframe 40,651 hrs · 12,191 cycles

ON RECALL NR 1 PACK LIGHT ILLUMINATED RESETS WITH CAUTION LIGHT RESET. ACFT GROUNDED. REVERSED CONFIGURATION CHANGE FOR MEL 21-5C AND PERFORMED PACK/ZONE TEMP CONTROL 1 BITE IAW FIM 21-62, TASK 801. VERIFY TEST SHOWED FAULT FOR RAM AIR ACTUATOR AND FAULT FOR RAM AIR SENSOR. FOR RAM AIR ACTUATOR FAULT. REMOVED, REPLACED, ADJUSTED, AND TESTED LEFT RAM AIR ACTUATOR IAW AMM 21-51-21-000-801, AND AMM 21-51-21-400-801, OPS NORMAL AND PACK/ZONE TEMP CONTROLLER BITE IAW AMM 21-61-00-700-806-002. NO LONGER SHOWS RAM AIR ACTUATOR FAULT. FOR RAM AIR SENSOR FAULT. ACCOMPLISHED FIM 21-62, TASK 821, AND VERIFIED THAT T481 LEFT RAM AIR SENSOR READS OPEN AT PINS 1 AND 2 OF SENSOR. REMOVED, REPLACED, AND TESTED T481 LEFT RAM AIR SENSOR IAW AMM 21-51-50-000-801 AND AMM 21-51-50-400-801. PACK/ZONE TEMP CONTROLLER BITE IAW AMM 21-61-00-700-806-002. NO LONGER SHOWS RAM AIR SENSOR FAULT AND SHOWS NO FAULTS.

Part: WARNING MESSAGE — INTERMITTENT (LT A/C PACK) · airframe 40,624 hrs · 12,184 cycles

LEFT PACK LIGHT ILLUMINATED ON RECALL, RESETS WITH MASTER CAUTION RESET. ACFT GROUNDED. LEFT PACK/ZONE TEMP CONTROLLER BITE SHOWED NO CURRENT FAULTS, BUT PREV FLT SHOWED FAULT FOR LEFT PACK RAM AIR TEMP SENSOR. VERIFY TEST DID NOT CONFIRM FAULT. DUE TO HISTORY, REMOVED AND REPLACED LEFT PACK RAM AIR TEMP SENSOR T481 IAW AMM 21-51-50-000-801, AND AMM 21-51-50-400-801. OPERATED PACK FOR 15 MINUTES AND PERFORMED BITE OF LEFT PACK/ZONE TEMP CONTROLLER IAW AMM 21-61-00-700-806-002 - ALL TESTS PASS.

Part: HOSE — SEVERED (CABIN AIR) · airframe 40,615 hrs · 12,180 cycles

EXCESSIVE AIR NOISE IN COCKPIT AT HIGH POWER SETTINGS. COCKPIT TO ATC AND PILOT TO PILOT COMMUNICATIONS WERE AFFECTED. ACFT GROUNDED. DIVERTED, RAN ENGINES AT HIGH POWER SETTINGS IAW AMM 71-00-00, NO AIR NOISE NOTED. ACCOMPLISHED ON TSR 818575. FOUND Y HOSE SEVERED.

Part: WARNING LIGHT — ILLUMINATED (LT A/C PACK) · airframe 40,587 hrs · 12,171 cycles

LEFT PACK LIGHT ILLUMINATED ON RECALL. GOES AWAY DURING RESET. ACFT GROUNDED. OPEN

Part: WARNING LIGHT — FALSE ACTIVATION (LT A/C PACK) · airframe 40,564 hrs · 12,166 cycles

LEFT PACK LIGHT ILLUMINATED ON RECALL. GOES OUT WITH MASTER CAUTION RESET. ACFT GROUNDED. PERFORMED PACK/ZONE TEMP CONTROLLER BITE TEST IAW AMM 21-51-00-700-803. NO FAULTS INDICATED.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 40,178 hrs · 12,041 cycles

ELECTRIC LIGHT ILLUMINATED. ACFT GROUNDED. VERIFIED DEFECT. ACCOMPLISHED FIM 24-31 TASK 801, ALL FAULTS CLEARED. REACCOMPLISHED BITE TEST, NO FAULTS. NO HISTORY PAST 30 DAYS.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 39,865 hrs · 11,951 cycles

RT WHEEL WELL FWD BULKHEAD CRACK NOTED BELOW CEILING PANEL AT RBL 43. GROUNDED - YES. REPAIRED WING CENTER SECTION REAR SPAR VERTICAL PRESSURE DECK WEB AT BS 663, RBL 25 - RBL 48 IAW SRM 57-10-10-2R-3 REPAIR 3 ALTERNATIVE 2. WORK ACCOMPLISHED ON TASK CARD 7675, SB737-57-1330-NG-2.

Part: WINDOW — MALFUNCTIONED (WINDOW HEAT) · airframe 39,405 hrs · 11,831 cycles

ACARS AND VERBAL FROM CAPTAIN`S R1 WINDOW HEAT, ON LEFT THIRD. INOPERATIVE DURING CRUISE AND ICED UP. RIGHT 2/3 WINDOW HEAT FEELS NORMAL. ACFT GROUNDED. ACCOMPLISHED WINDOW HEAT SYSTEM OPERATIONAL TEST IAW AMM 30-41-00-710-801, R1 WINDOW OPERATED NORMAL. ACCOMPLISHED WINDOW HEAT CONTROL UNIT SYSTEM TEST WITH NO FAULTS ON BITE IAW AMM 30-41-11-710-801. R1 WINDOW DUE TO ICE UP DURING CRUISE, REMOVED AND REPLACED THE R1 WINDOW IAW AMM 56-11-11/401, OPS AND LEAK CHECKED GOOD. CHECKED WINDOW TAP WIRING IAW WDM 30-41-12 AS H12.

Part: ACTUATOR — FAULTED (RAM AIR EXHAUST) · airframe 39,242 hrs · 11,784 cycles

DURING DESCENT RECALL CHECK, MASTER CAUTION, AIR CONDITIONER, RT PACK LIGHT ILLUMINATED. RESET AND ALL LIGHTS EXTINGUISHED. ACFT GROUNDED. PERFORMED NR 2 PACK ZONE TEMP CONTROL BITE IAW AMM 21-61-00. FOUND RT RAM AIR DOOR ACTUATOR FAULTED IN CURRENT HISTORY AND VERIFY. REMOVED AND REPLACED THE RT RAM AIR DOOR ACTUATOR IAW AMM 21-51-21. ALL TESTS PASSED.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 39,197 hrs · 11,771 cycles

RT PACK LIGHT ILLUMINATED ON RECALL. GOES OUT WITH MC RESET. GROUNDED - YES. PERFORMED CONTROLLER BITE IAW FIM 21-62 TASK 801. FAULT ON NR 2 RAM AIR ACTUATORON BITE, UNABLE TO VERIFY.

Part: NUT PLATE — BROKEN (EXIT LIGHT) · airframe 38,733 hrs · 11,649 cycles

LT FWD OVERWING EMERGENCY EXIT LIGHT LENS COVER HAS 2EA SPINNING FASTENERS. NUTPLATES ARE BROKEN. ACFT GROUNDED. REPAIRED IAW AMM 33-51-04-960-802 PARAGRAPH F(3) THROUGH (9). COMPLETED STEP F(10) THROUGH G(1). LIGHT OPS TEST GOOD, IAW AMM 33-61-04.

Part: DOOR — DAMAGED (RT RAM AIR) · airframe 38,714 hrs · 11,643 cycles

RT RAM AIR INLET ACTUATOR DEFLECTOR DOOR SPONGY. ACFT GROUNDED. PERFORMED BITE TEST AMM TASK 21-61-00-700-806-002, NO DEFECTS NOTED. DEFLECTOR DOOR OPS NORMAL AND SECURE IN DEPLOYED POSITION. OK FOR CONTINUED SERVICE.

Part: STARTER GEN — FAILED (APU) · airframe 38,726 hrs · 11,645 cycles

APU GENERATOR NO FREQ OR VOLTS-GENERATOR FAILED. GROUNDED - YES. REMOVED AND REPLACED APU STARTER GENERATOR, REF AMM 49-41-21. OPS TEST GOOD, BITE TEST NO FAULTS FOUND. THIS CLEARS MEL 49-1B.

Part: COMPENSATOR — NO TEST (NR 1 FUEL TANK) · airframe 38,656 hrs · 11,628 cycles

DURING ACCOMPLISHMENT OF TASK CARD NG-28FCD-18088-1. FOUND A TOTAL SEVEN BAD FUEL PROBES, F15, F1, F2, F3, F7, F8 AND F10. ACFT GROUNDED. NR 1 TANK IS SUMPED AND NR 1 BUSSING PLUG IS DISCONNECTED. REPLACED THE NR 1 TANK COMPENSATOR F15 AND PROBES F1, F2, F3, F7, F8 AND F10 IAW AMM 28-41-21-400-801 THRU STEP E (10).

Part: PROBE — NO TEST (NR 2 FUEL TANK) · airframe 38,656 hrs · 11,628 cycles

DURING ACCOMPLISHMENT OF TASK CARD NG-28FCD-18090-1. FUEL QTY INDICATION SYSTEM NR 2 TANK AND COMPENSATOR UNITS TESTING. FOUND SIX FUEL PROBES OUT OF TOLERANCE F1, F2, F3, F4, F6 AND F8. ACFT GROUNDED. 2 TANK IS SUMPED AND NR 2 BUSSING PLUG IS DISCONNECTED. REPLACED THE NR 2 TANK PROBES F1, F2, F3, F4, F6, AND F8 IAW AMM 28-41-21-400-801. SYSTEM TEST NORMAL AND PASSED IAW AMM 28-41-00. COMPARISON CHECK PASSED IAW AMM 28-41-00.

Part: PROBE — FAILED (FUEL TANKS) · airframe 38,654 hrs · 11,627 cycles

AT PUSHBACK, FUEL TANKS READ LEFT 8.5, RIGHT 8.6, CENTER 25.9. DURING CRUISE, MAIN TANKS SLOWLY DECREASED TO LEFT 7.93, RIGHT 8.17 BY THE TIME THE CENTER TANK REACHED ZERO. OUTSIDE TEMP -64C. FUEL TEMP GOT TO -30C. ACFT GROUNDED. ACCOMPLISHED TASK CARDS NG-28 FCD -18090-1 & NG-28FCD-18088-1. FOUND THE NR 1 TANK HAD SEVEN BAD PROBES & NR 2 TANK HAD SIX BAD PROBES. PROBES REMOVED & REPLACED.

Part: LENS — DAMAGED (EXIT SIGN) · airframe 38,631 hrs · 11,622 cycles

EMERGENCY LIGHT EXIT LOCATOR SIGN AT RIGHT FORWARD OVERWING EXIT HAS DAMAGED LENS. GROUNDED - YES. REMOVED AND REPLACED LENS AND TESTED LIGHT ASSEMBLY PER AMM 33-51-01-960-801 - OPS NORMAL.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 38,503 hrs · 11,587 cycles

RIGHT PACK ANNUNICATED ON RECALL. EXTINGUISHED WHEN SYSTEM WAS RESET. ACFT GROUNDED. PERFORMED CONTROLLER BITE IAW FIM 21-62 TASK 801. FAULT ON RAM AIR ACTUATOR NR 2, UNABLE TO VERIFY, CLEARED AND RETESTED, NO FAULTS. INTERMITTENT, OK FOR SERVICE,

Part: INDICATOR — FAILED (FUELING PANEL) · airframe 38,182 hrs · 11,505 cycles

NR 1 FUEL INDICATOR IN WING FUELING PANEL INOP. GROUNDED - YES. REMOVED AND REPLACED NR 1 REFUEL QTY INDICATOR IAW AMM 28-41-61. INDICATORS OPS TESTED GOOD. FQIS BITE GND TESTED GOOD. REMOVED MEL 28-12B.

Part: FMC — MALFUNCTIONED (COCKPIT) · airframe 38,177 hrs · 11,504 cycles

IN CRUISE THE LEFT FMC FAILED BRIEFLY THEN RECOVERED AUTOMATICALLY WITHOUT ANY PILOT INPUT. DURING THE INTERMITTENT FAILURE, THE FOLLOWING INDICATIONS WERE OBSERVED. THE FMC ALERT LIGHT ILLUMINATED, THE MENU PAGE APPEARED ON BOTH CDU'S, VTK APPEARED ON THE LEFT NAVIGATION DISPLAY. GROUNDED - YES. ACCOMPLISHED FLIGHT MANAGEMENT COMPUTER SYS BITE PROCEDURE. NO ACTIVE FAULTS NOTED. PERFORMED BITE ON ADIRS NO CURRENT FAULTS NOTED NO INFLT FAULTS NOTED REF B737-800 FIM 34-61 TASK 801. NO HISTORY IN 30 DAYS BOTH FMC INDICATIONS NORMAL.

Part: SEAL — OUT OF POSITION (L1 DOOR) · airframe 37,870 hrs · 11,421 cycles

ON TAKE OFF RIGHT AFTER GEAR RETRACTION, FORWARD FLIGHT ATTENDANTS REPORTED L1 DOOR HAD A GAP WITH A LOT OF WIND NOISE, FLIGHT ATTENDANTS REPORTED SEEING DAYLIGHT. ACFT GROUNDED. AIR TURNBACK, FOUND LOWER ENTRY DOOR FLAPPER SEAL NOT SEATED PROPERLY TO L-1 DOOR. ADJUSTED FLAPPER SEAL TO CORRECT POSITION AND CLEANED AWAY DEBRIS AND LUBED FLAPPER SEAL SPRING IAW AMM 52-11-00-420. PRESSURIZED A/C WITH APU TO 6 PSI DIFF, NO DEFECTS NOTED, OPS CHECK NORMAL IAW AMM 36-00-00-860.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 37,854 hrs · 11,414 cycles

AFTER TWO ENGINE STARTS, RECALL DISPLAYED ELEC ON OVERHEAD PANEL. RAN QRH, RETURNED TO GATE. ACFT GROUNDED. COMPLIED WITH FIM TASK 24-34 TASK 802. RAN BOTH ENGINES. BITE PROCEDURE FIM 24-31 TASK 801 PASSES. OPS CHECKED NORMAL.

Part: AUTOLAND SYS — MALFUNCTIONED · airframe 37,809 hrs · 11,396 cycles

UNSUCCESFUL AUTOLAND. JUST PRIOR TO FLARE, RECEIVED A APPROACH WARNING WITH ROLLOUT CAUTION. TOWER CONFIRMED THE APPROACH AREA WAS PROTECTED. ACFT GROUNDED. PERFORMED LANDING DFCS BITE GROUP 20 FAULT REVIEW IAW FIM 22-11 TASK 801, NO FAULTS AND NO CURRENT FAULTS. PERFORMED DFCS LANDING VERIFY TEST DFCS BITE GROUP 49 IAW AMM 22-11-00-700-801 LANDING VERIFY TEST PASSED.

Part: FMC — MALFUNCTIONED · airframe 37,762 hrs · 11,382 cycles

DUAL FMC FAILURE DURING CRUISE. BOTH FMCS RESTORED THEMSELVES WITHIN TWO MINUTES. ACFT GROUNDED. PERFORMED FIM TASK 34-61 TASK 801. NO ACTIVE FAULTS NOTED. OPS CHECKED GOOD PER SAME.

Part: INTERCOSTAL — DAMAGED (FUSELAGE) · airframe 37,707 hrs · 11,366 cycles

FLOOR SUPPORT ANGLES BETWEEN STA 312 TO STA 294, BL 12L, LAV ANCHOR, TOP SURFACE HAS SCRIBE LINE FORWARD OF MOUNT. ACFT GROUNDED. R & R 141A569041 FLOOR SUPPORT INTERCOSTAL BETWEEN BS 294-BS 312, LBL12 IAW SRM 51-40-02 AND BAC DWG 141A5600, REV N. REMOVED AND REINSTALLED FLOOR STRUCTURE AND EXISTING REPAIR ADJACENT TO 141A5690U1 TO FOM IAW SRM 51-40-02, DWG 141A5600, REV N, REMOVED DOT.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 37,707 hrs · 11,366 cycles

CORROSION ON TOP OF FLOORBEAM AT STA 328, RBL 54. ACFT GROUNDED. REMOVED CORROSION AT RBL 54, ORIGINAL THICKNESS 0.125 IAW DWG 15189-1210, REMAINING THICKNESS 0.094, REMOVED 0.031, BLENDED AREA IS OUT OF ALLOWABLE LIMITS IAW SRM 53-10-51-1A-1, PAR 4, FIG 105. REPAIRED BS 328 UPPER CHORD OF FLOORBEAM IAW SRM 53-10-51-2R-7, REPAIR NR 7.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 37,707 hrs · 11,366 cycles

STA 294, FLOORBEAM, WL208 UPPER T-CAP HAS CORROSION AT 3 LOCATIONS BLO+1R, BL0+6L, BL012L. ACFT GROUNDED. FOUND CORROSION TO BE OUT OF LIMITS, REPAIRED REF: EA 800-53EA-17749 AND REO-G20248, REV B, DOT REMOVED.

Part: SKIN — CRACKED (RT HORIZ STAB) · airframe 37,707 hrs · 11,366 cycles

FOUND 2.5" CRACK ON RT HORIZONTAL LOWER SKIN AT THE REAR SPAR, STABILIZER STA 96. ACFT GROUNDED. CUTOUT DAMAGE ON LOWER SKIN IAW SRM 55-10-01-2R-11 MATERIAL ID FOR REPAIR FILLER 2024-T3 .071, PO 870187.1 AND 2024-T3, .100, PO 871757.1. FABRICATED REPAIR FILLER AND DOUBLER IAW SRM 55-10-01-2R-11 ALODINED IAW SRM 51-20-01, PRIMED IAW SOPM 20-44-04. INSTALLED IAW SRM 55-10-01-2R-11, PAINTED IAW AMM 51-21-73.

Part: FLOORBEAM — CORRODED (BS 772) · airframe 37,707 hrs · 11,366 cycles

AFT CARGO BAY FLOORBEAM TEE AT BS 772 HAS EVIDENCE OF CORROSION ON TOP AND BOTTOM SURFACE. ACFT GROUNDED. REMOVED THE CORROSION IAW SRM 51-10-02 AND FOUND TO BE OUT OF LIMIITS IAW SRM 53-00-53, REPLACED IAW SRM 51-40-02 & DWG 146A7500 REV B.

Part: SHIELD — CORRODED (FUSELAGE) · corrosion level 2 · airframe 37,707 hrs · 11,366 cycles

AFT CARGO COMPARTMENT FLOOR TRANSITION PANEL BETWEEN BS 796 AND BS 794.37 HAS EVIDENCE OF CORROSION AROUND FASTENER HOLE, MARKED. ACFT GROUNDED. REMOVED CORROSION FROM TRANSITION SHIELD ASSY AT BS 767-794 IAW SRM 51-10-02 AND FOUND TO BE OUT OF LIMITS IAW SRM 53-60-15-1A FIG 103. ORIGINAL THICKNESS IS .050, REMOVED .012 REMAINING THICKNESS IS .038. REMOVED SHIELD ASSY IAW SRM 51-40-02. INSTALLED NEW SHELF, PO:875423.2 IAW SRM 51-40-02 AND DWG 146A0081, REV: CIC WAS APPLIED TO INTERNAL AND EXTERNAL AREAS IAW AMM 51-05-01-701 UT GAUGE USED T8225V . REMOVED DOT.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 37,707 hrs · 11,366 cycles

AFT CARGO COMPARTMENT CROSS TEE ATTACH POINT TO RAIL RBL 13.84 AT BS 772 HAS EVIDENCE OF CORROSION ON TOP SURFACE OF RAIL. MARKED AND STREAMER ATTACHED. ACFT GROUNDED. REMOVED CORROSION ON FLOOR SUPPORT IAW SRM 51-10-02 AND CPM 20-40-00 ORIGINAL THICKNESS IS .063. REMAINING THICKNESS IS .040 LOSS OF MATERIAL .023 FOUND TO BE OUT OF LIMITS IAW SRM 53-00-53-1A-2, FABRICATED TRACK REPAIR SPLICES 2 EA IAW SRM 53-00-53-1A-3, ALODINED IAW SRM 51-20-01, PRIMED IAW SOPM 20-41-02, INSTALLED TRACK REPAIR AND SPLICES, 2 EA IAW SRM 53-00-53-2R-3. DOT REMOVED AND STREAMER. .

Part: FLOORBEAM — CORRODED (BS 500I) · corrosion level 2 · airframe 37,707 hrs · 11,366 cycles

FWD CARGO AFT SECTION , JUST BEFORE THE A/C BAY, FLOORBEAM HAS CORROSION AT SEVERAL SPOTS. BS 500I LBL 21 - RBL 21. ACFT GROUNDED. REMOVED CORROSION IAW SRM 51-10-02, FOUND TO BE OUT OF LIMITS IAW SRM 53-00-53-1A FIG 103 DETAIL D. REMOVED AND REPLACED IAW SRM 51-40-02.

Part: FLOOR SUPPORT — DAMAGED (FUSELAGE) · airframe 37,707 hrs · 11,366 cycles

FLOOR SUPPORT AT STA 277 TO FLIGHT DECK FLOOR, BL 12L HAS SCRIBE LINE ON TOP SURFACE. ACFT GROUNDED. R & R 141A5670Y12 FLOOR SUPPORT TEE AT BS 277 LBL12 IAW SRM 51-40-02 AND DWG 141A5600, REV N. REMOVED AND REINSTALLED PULLEY BRACKETS ADJACENT TO FLOOR SUPPORT TEE TO FOM IAW AMM 20-10-09, REMOVED DOT.

Part: FLOORBEAM — CORRODED (BS 500I) · corrosion level 2 · airframe 37,707 hrs · 11,366 cycles

FWD PIT, AFT SECTION , JUST BEFORE THE A/C BAY, FLOOR SUPPORT CHANNEL HAS CORROSION AT SEVERAL SPOTS. BS 500I LBL 21 - RBL 21. GROUNDED - YES. REMOVED CORROSION FROM FLOOR SUPPORT AT 500I, LBL 21 - RBL 21 IAW ASA B737-800 SRM 51-10-02, FLOOR SUPPORT FOUND TO BE OUT OF LIMITS IAW ASA B737-800 SRM 53-00-53-1A FIG 103 DETAIL D. ORIGINAL THICKNESS IS .080, REMOVED .013 REMAINING .067. REMOVED CORRODED SUPPORT AND INSTALLED NEW SUPPORT IAW ASA B737-800 SRM 51-40-02. APPLIED CIC IAW ASA B737-800 AMM 51-05-01, UT GAUGE USED T8225S. NEW SUPPORT PO:869104.8 REMOVED DOT.

Part: TRANSITION PANEL — CORRODED (FUSELAGE) · corrosion level 2 · airframe 37,707 hrs · 11,366 cycles

AFT PIT, RT TRANSITION PANEL HAS CORROSION AT SEVERAL SPOTS, BS 727-BS 727H. ACFT GROUNDED. REMOVED CORROSION FROM AFT CARGO RT TRANSITION PANEL IAW SRM 51-10-02, ORIGINAL THICKNESS .040 REMOVED .007 REMAINING THICKNESS .033" FOUND TO BE OUT OF LIMITS IAW SRM 53-00-53-1A-2. MATERIAL ID BAC1496-377, PO 875640.2, FABRICATED NEW TRANSITION PANEL IAW SRM 53-00-53-2R-6 ALODINED IAW AMM 51-21-41 PRIMED IAW AMM 51-21-72 INSTALLED IAW SRM 51-40-02, REMOVED DO L641.

Part: SKIN — CRACKED (LT HORIZ STAB) · airframe 37,707 hrs · 11,366 cycles

FOUND 1.5" CRACK ON LT HOROZONTAL LOWER SKIN AT STAB STA 138.7, 24.5" AFT OF FORWARD SPAR. GROUNDED - YES. REMOVED DAMAGED SECTION OF SKIN, FABRICATED AND INSTALLED REPAIR FILLER AND DOUBLER IAW SRM 55-10-01-2R-11. APPLIED TOPCOAT TO REPAIR AREA IAW AMM 51-21-99.

Part: CHANNEL — CORRODED (BS 500-500I) · corrosion level 2 · airframe 37,707 hrs · 11,366 cycles

FWD CARGO BAY RIGHT TRANSITION PANEL HAS CORROSION AT SEVERAL SPOTS. BS 500 - 500I, RBL 21. ACFT GROUNDED. REMOVED CORROSION IAW 51-10-02, FOUND TO BE OUT OF LIMITS IAW 53-00-53-1A, FIG 103 DET D. REPAIRED IAW SRM 51-10-02, SRM 53-00-53-2R, SRM 53-30-53-01, SRM 53-00-53-1R-5, SRM 51-20-01, AND AMM 51-21-00

Part: PUMP — FAILED (NR 1 FUEL) · airframe 37,595 hrs · 11,336 cycles

FUEL DRIPPING FROM THE BOTTOM COWL OF NR 1 ENGINE. ACFT GROUNDED. WHILE ACCOMPLISHING ENGINE DRAINS AND VENTS INSPECTION WITH ENGINE RUNNING FUEL STARTED TO LEAK OUT FROM THE HMU ATTACHMENT TO THE FUEL PUMP AT STEADY RATE AND ALSO FROM THE FUEL PUMP PAD DRAIN AT A RATE OF 1 DROP PER 10 SECONDS. REPLACED THE FUEL PUMP, DIFFERENTIAL SWITCH, & OIL/FUEL HEAT EXCHANGER.

Part: CONTROLLER — MALFUNCTIONED (CABIN PRESSURE) · airframe 37,569 hrs · 11,323 cycles

AUTO FAIL AMBER LIGHT ILLUMINATED AND ALTN GREEN ON PREFLIGHT. ACFT GROUNDED. RESET THE CABIN PRESSURE CONTROLLER IAW AMM 21-31-TASK 801 B ITEM C. BITE PROCEDURE FOR EXISTING FAULT CLEARED.

Part: FMC — MALFUNCTIONED · airframe 37,503 hrs · 11,303 cycles

DURING TAXI IN, BOTH FMC S SHOWED VTK AND FMC WAS REMOVED FROM CDU MENU. AFTER SEVERAL SECONDS ALL FUNCTIONS RETURNED TO NORMAL. ACFT GROUNDED. FMC LANDING & TAXI VTK MAP NUISANCE ERROR, IAW AMM 34-51-00. AIRCRAFT OKAY FOR CONTINUED SERVICE.

Part: CONTROL PANEL — FAILED (ALTITUDE) · airframe 37,489 hrs · 11,297 cycles

MCP ALTITUDE SELECTORS IS NOT WORKING PROPER AND CHANGING ALTITUDE ON ITS OWN. DIFFICULT OR IMPOSSIBLE TO MAKE SELECTIONS. ACFT GROUNDED. ACCOMPLISHED DFCS BITE TEST, NO FAULTS LOGGED. REMOVED & REPLACED DFCS MCP AS A PRECAUTION, IAW AMM 22-11-34/401. ACCOMPLISHED DFCS LRU INTERFACE TEST FOR MCP, IAW AMM 22-11-34/501 (GP 32), DFCS LAND VERIFY TEST, IAW AMM 22-11-00/201 (GP 49), AND HGS SYSTEM/SENSOR TEST, IAW SMM 34-36-00, OPS CHECKED NORMAL. ACFT LWMP STATUS REMAINS UPGRADED AT CAT3A AUTOLAND & HGS, CAT STATUS SCREW REFLECT SAME.

Part: SATCOM — MALFUNCTIONED (COCKPIT) · airframe 37,485 hrs · 11,296 cycles

SATCOM LOCKUP GROUNDED. ACCOMPLISHED RESET PROCEDURE IAW QRH. SATCOM RESTORED NORMAL.

Part: SENSING ELEMENT — FAULTY (L1 WINDOW) · airframe 37,446 hrs · 11,280 cycles

R1 WINDOW OVERHEAT LIGHT ILLUMINATED ON APPROACH. DID NOT RESET. ACFT GROUNDED. ACCOMPLISHED BITE CHECK IAW FIM 30-41, TASK 801. FOUND WHCU RT FORWARD WINDOW SENSOR FAULT. SWITCHED ALT SENSOR IAW FIM 30-41, TASK 812.

Part: SATCOM — LOCKED (COCKPIT) · airframe 36,996 hrs · 11,157 cycles

SATCOM LOCKUP. ACFT GROUNDED. ACCOMPLISHED RESET PROCEDURE IAW QRH. SATCOM RESTORED NORMAL.

Part: CDU — FAILED (COCKPIT) · airframe 36,974 hrs · 11,152 cycles

F/O`S FMC CDU HAS A PURPLE LINE ON THE RT SIDE. ACFT GROUNDED. ON INITIAL POWER UP NO PURPLE LINE WAS VISIBLE. WHEN SCREEN WAS TOUCHED, SEVERAL PURPLE LINES APPEARED AND SCREEN WAS DISTORTED. REPLACED FMC CDU, ALL OPS NORMAL, REF AMM 34-61-01.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 36,970 hrs · 11,151 cycles

TEMPORARY FMC FAILURE ON CAPTS SIDE VTK DISPLAYED FOLLOWED BY MAP FAILURE FLAGS. RETURNED TO NORMAL AFTER ABOUT 60 SECONDS, QRH REFERENCED BUT RETURNED TO NORMAL BEFORE SWITCHES WERE MOVED. ACFT GROUNDED. REF FIM 34-61, TASK 801, PERFORMED FMC BIT TEST. NO FAULTS FOUND. GROUND VERIFICATION WAS SUCCESSFUL.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 36,949 hrs · 11,144 cycles

LOST BOTH FMC, VTK FLAG BOTH SIDES, FOLLOWED BY A/T LIMIT. AFTER 30 SECONDS, LT AND RT FMC CAME BACK. ACFT GROUNDED. VERIFIED NR 1 AND NR 2 FMC RESET ON FLT LEG 1 DURING NR 1 AND NR 2 FMC BITE, REF FIM 34-61,TASK 801. NO CURRENT FAULTS ON NR 1 OR NR 2 FMC. PERFORMED NR 1 AND NR 2 FMC SYS AND OPS TEST, REF AMM 34-61-00. NO FAULTS FOUND, ALL SOFTWARE EFFECTIVE FOR ACFT NR 1 AND NR 2 FMC.

Part: SHIM — WORN (NR 2 ENGINE) · airframe 36,852 hrs · 11,115 cycles

REF TASK CARD 78472002, FAN BLADE SHIMS WORN ON NR 2 ENGINE. ACFT GROUNDED. R & R NR 2 ENGINE FAN BLADE SHIMS IAW TASK CARD 78472002.

Part: CONTROL PANEL — FAILED (FLIGHT DECK) · airframe 36,679 hrs · 11,067 cycles

MC PANEL, F/O'S COURSE DIGITAL READOUT FIRST DIGIT SHOWS SEGMENTS OF OTHER NUMBERS WHEN ON 1 & 3. ACFT GROUNDED. REMOVED, REPLACED, AND TESTED DFCS MODE CONTROL PANEL IAW AMM 22-11-34-400-801, TEST PASSED. ALSO ACCOMPLISHED DFCS LRU REPLACEMENT TEST FOR MCP IAW AMM 22-11-34/501, DFCS LAND VERIFY TEST IAW AMM 22-11-00/201, AND HGS SENSOR TEST FOR FCC/AT IAW SMM 34-36-00. ALL TESTS PASS. ACFT REMAINS CAT IIIA AUTOLAND & HGS, SCREW REFLECTS SAME. ETOPS SIGNIFICANT SYS GROUND VERIFICATION SUCCESSFUL.

Part: SATCOM — LOCKED · airframe 36,543 hrs · 11,030 cycles

SATCOM LOCKUP, ACFT GROUNDED. ACCOMPLISHED RESET PROCEDURE IAW QRH. SATCOM RESTORED NORMAL.

Part: WARNING LIGHT — FALSE ACTIVATION (CABIN TEMP) · airframe 36,468 hrs · 11,002 cycles

ZONE TEMP FOR CONTROL CABIN ILLUMINATES WITH RECALL AND EXT WITH MASTER CAUTION RESET. CHECKED & REL IAW MEL 21-21F FLIGHT DECK PRI TEMP CONTROL INOPERATIVE. ACFT GROUNDED. PERFORMED FIM 21-62, TASK 832 AND FAULT CLEARED. GROUND FUNCTIONAL CK GOOD REF FIM 21-62, TASK 801. CLEARS MEL 21-21F.

Part: SATCOM — MALFUNCTIONED · airframe 36,293 hrs · 10,950 cycles

HAD SATCOM LOCKOUT IN FLIGHT. PERFORMED QRH PROCEDURES. REGAINED SATCOM. ACFT GROUNDED. ACCOMPLISHED FIM 23-15, TASK 801, STEP 4B. SYSTEM CHECKS NORMAL.

Part: COMPENSATOR — FAILED (NR 2 FUEL TANK) · airframe 36,204 hrs · 10,922 cycles

REF FQIS BITE GROUND TEST SHOWS HARD FAULT MSG 28-41208 FOR NR 2 TANK. DUE TO FAULT HISTORY, REQUIRES SYS DEFERRAL. ACFT GROUNDED. R & R COMPENSATOR UNIT, REF AMM 28-41-21-400-801. COMPENSATOR CAPACITY IS 57.8 PF. THIS CLEARS MEL 28-6B. LEAK CHECK GOOD, REF AMM 28-11-00-400-801.

Part: SATCOM — LOCKED · airframe 36,163 hrs · 10,910 cycles

SATCOM LOCKUP DURING POWER TRANSFER. ACFT GROUNDED. ACCOMPLISHED SATCOM RESET PROCEDURE IAW QRH, SATCOM OPS NORMAL.

Part: STARTER — FAILED (NR 2 ENGINE) · airframe 36,097 hrs · 10,895 cycles

NR 2 ENGINE NO ROTATION ON START. ACFT GROUNDED. R & R NR 2 ENGINE STARTER REF AMM 80-11-01. OPS GOOD. LEAK CHECKS GOOD.

Part: WARNING LIGHT — FALSE ACTIVATION (CABIN TEMP) · airframe 35,961 hrs · 10,861 cycles

CONTROLLER CABIN ZONE TEMP LIGHT ILLUMINATED AFTER ENGINE START AND BLEEDS ESTABLISHED. ACFT GROUNDED. RELEASED IAW MEL 21-21F. PRIMARY FLIGHT DECK CONTROLLER INOPERATIVE. COMPLIED WITH AMM TASK 21-61-00-700-806-002. FAULT RESET AND CABIN ZONE TEMP LIGHT NO LONGER ILLUMINATES.

Part: FMC — FAILED (LEFT) · airframe 35,954 hrs · 10,856 cycles

AFTER LANDING BOTH MCDU'S DISPLAYED THE MENU PAGE WITHOUT AN FMC PROMPT. FMC PROMPT LATER RETURNED WITH ALL DATA LOST. ACFT GROUNDED. FMC BITE LT & RT FAULTED LT FMC, WHILE ATTEMPTING OPS CHECK, LT FMC FAILED AGAIN. R & R LT FMC COMPUTER REF AMM 34-61-02. ALL SOFTWARE CROSSLOADED FROM RT FMC & VERIFIED EFFECTIVE. FMC OPS TEST PASSED.

Part: AUTOLAND SYS — MALFUNCTIONED · airframe 35,917 hrs · 10,843 cycles

REQUESTED AUTOLAND HGS APPROACH UNSUCCESSFUL, AUTOPILOT DISENGAGED AT 5 FT APPROXIMATELY. ACFT GROUNDED. ACCOMPLISHED FAULT REVIEW IAW FIM 22-11, TASK 801, GP 20, NO FAULTS LOGGED. ALSO ACCOMPLISHED DFCS LAND VERIFY TEST, GP 49, IAW AMM 22-11-00/201 AND HGS SYSTEM, SENSOR TEST IAW SMM 34-36-00, OPS CHECKED NORMAL.

Part: INDICATOR — FAILED (FUEL QUANTITY) · airframe 35,900 hrs · 10,839 cycles

FUELER REPORTED RIGHT HAND PANEL RIGHT HAND INDICATOR NUMBER FLASHING. GROUNDED - YES. REMOVED AND REPLACED NR 2 REFUEL QTY INDICATOR IAW AMM 28-41-61/401. FUELING INDICATION, OPS TESTED NORMAL.

Part: SATCOM — LOCKED · airframe 35,817 hrs · 10,822 cycles

SATCOM LOCK-UP. ACFT GROUNDED. ACCOMPLISHED SATCOM RESET PROCEDURE IAW QRH. SATCOM OPS NORMAL.

Part: FMC — MALFUNCTIONED (RIGHT) · airframe 35,721 hrs · 10,797 cycles

RT FMC FAILED MOMENTARILY THEN RESTORED ITSELF PRIOR TO ANY ACTION. ACFT GROUNDED. RT FMC OPS TEST OK. REF AMM 34-61-00-710-801, NO DEFICIENCIES NOTED IN FAULT HISTORY EITHER. ETOPS GROUND VERIFICATION COMPLETE.

Part: WARNING MESSAGE — ILLUMINATED · airframe 35,713 hrs · 10,795 cycles

FQIS SHOW NR 2 TANK DEGRADE ATA 28-41208, REF AMM 28-41-00. ACFT GROUNDED. TRANSFERRED FUEL AND BARREL DRAINED NR 2 TANK. REMOVED LARGE QTY OF WATER VIA SUMP. RETESTED FQIS WITH NO DISCREPANCIES NOTED. NO FAULTS. GROUND TEST PASS. SYS OPS NORMAL, REF AMM 28-41-00.

Part: LAMP — FAILED (EMERGENCY LIGHT) · airframe 35,713 hrs · 10,795 cycles

LEFT FWD OVERWING EXIT, EMERGENCY LIGHT INOPERATIVE. ACFT GROUNDED. R & R LT FWD OVERWING EXIT EMERGENCY LIGHT, OPS CHECK GOOD.

Part: SATCOM — MALFUNCTIONED · airframe 35,682 hrs · 10,785 cycles

NO SATCOM INDICATION ON MENU PAGE FOLLOWING POWER CHANGE. ACFT GROUNDED. ACCOMPLISHED SATCOM RESET PROCEDURES IAW QRH. SATCOM OPS NORMAL.

Part: CONTROL UNIT — FAILED (NR 1 ENGINE) · airframe 35,645 hrs · 10,774 cycles

NR 1 ENGINE WOULD NOT START. ACFT GROUNDED. NO IGNITOR WAS HEARD DURING TEST REF AMM 74-00-00-750-801-F00. R & R NR 1 ENGINE LT AND RT INGITOR BOXES, DURING OPS TEST RT IGNITOR FAILED CHANNEL B TEST. R & R NR 1 ENGINE ELECTRONIC ENGINE CONTROL REF AMM 73-21-60. ALL OPS CHECKS NORMAL REF AMM 73-21-60. ACFT RETURN TO SERVICE.

Part: SATCOM — MALFUNCTIONED · airframe 35,643 hrs · 10,773 cycles

ON CLIMBOUT OF OGG NOTED NO, SATCOM, PROMPT IN MCDU. ACFT GROUNDED. ACCOMPLISHED SATCOM RESET PROCEDURES IAW QRH. ALL OPS NORMAL.

Part: ENGINE — MALFUNCTIONED · airframe 35,580 hrs · 10,759 cycles

NR 1 ENGINE WOULD NOT START, WHEN START LEVER RAISED TO IDLE FF APPROXIMATELY 1.75, BOTH FUEL SHUTOFF LIGHTS GO OUT. AFTER A FEW SECONDS THE ENGINE VALVE CLOSED ILLUMINATED, NO LIGHT OFF. ACFT GROUNDED. PERFORMED ELECTRONIC ENGINE CONTROL BITE PROCEDURE IAW FIM TASK 73-00, TASK 801, NO FAULTS NOTED ON NR 1 ENGINE. PERFORMED NR 1 ENGINE IGNITION AUDIBLE TEST IAW AMM 74-00-00, OPS CHECK GOOD FOR LT & RT IGNITORS. STARTED NR 1 ENGINE ON LT & RT IGNITION POSITION INDIVIDUALLY IAW AMM 71-00-00, ENGINE STARTS NORMALLY, GROUND VERIFICATION OF ENGINE START SUCCESSFUL.

Part: SENSOR — DIRTY (CABIN TEMP) · airframe 35,555 hrs · 10,752 cycles

CONTROLLER CABIN ZONE TEMP ON RECALL. ACFT GROUNDED. PERFORMED NR 2 PACK TEMP ZONE BITE AND FOUND TRIM AIR MOD VALVE FAULT ON FLIGHT HISTORY BUT COULD NOT DUPLICATE FAULT IN VERIFY MODE OF BITE, NUMEROUS ATTEMPTS. FOUND CONTROL CABIN TEMP SENSOR AND FILTER DIRTY. CLEANED CONTROL CABIN TEMP SENSOR AND FILTER REF AMM 21-61-06. RESET FAULTS ON PACK ZONE TEMP CONTROL BITE. CONTROL CABIN PRIMARY TEMP CONTROL. OPS CHECKS GOOD MULTIPLE TIMES REF AMM 21-61-00. BITE CHECKS WITH NO FAULTS REF FIM 21-62, TASK 801. GROUND VERIFICATION SUCCESSFUL.

Part: SATCOM — LOCKED · airframe 35,393 hrs · 10,718 cycles

SATCOM LOCK UP. ACFT GROUNDED. ACCOMPLISHED SATCOM RESET PROCEDURES IAW QRH. SATCOM RESTORED NORMAL.

Part: WARNING MESSAGE — FALSE ACTIVATION (CABIN TEMP) · airframe 35,340 hrs · 10,704 cycles

DURING MASTER CAUTION RECALL CONTROLLER CABIN ZONE TEMP LIGHT ILLUMINATED. RESETS WITH MASTER CAUTION RESET. ACFT GROUNDED. ACCOMPLISHED PACK/ZONE TEMP CONT BITE TEST. FAULT RESET AND DID NOT RECUR AMM 21-61-00-700-806-002. GROUND VERIFICATION SUCCESSFUL.

Part: WARNING MESSAGE — FALSE ACTIVATION · airframe 35,340 hrs · 10,704 cycles

WHILE PERFORMING DFCS BITE, LIBRARY 32, FAULT CODE 22-11126 FOUND. ACFT GROUNDED. ACCOMPLISHED FIM 22-12, TASK 812, NO FAULTS. ACCOMPLISHED LANDING, VERIFY NO FAULTS. GROUND VERIFICATION SUCCESSFUL, IAW AMM 22-00-01-730-801.

Part: VALVE — FAILED (LT A/C PACK) · airframe 35,324 hrs · 10,700 cycles

ON MASTER CAUTION RECALL CONTROLLER CABIN ZONE TEMP ILLUMINATES, RESETS WITH MASTER CAUTION RESET. ACFT GROUNDED. NR 2 PACK/ZONE TEMP CONT BITE INDICATES FLT DK TRIM VALVE FAULT, REF AMM 21-61-00. REPLACED FLIGHT DECK TRIM VALVE, INSTALLATION TEST NORMAL REF AMM 21-61-21.

Part: SENSOR — FAILED (WINDOW HEAT) · airframe 35,252 hrs · 10,676 cycles

R2 WINDOW OVERHEAT LIGHT ILLUMINATED AND WOULD NOT EXTINGUISH. CYCLED SWITCH MULTIPLE TIMES TO ALLOW COOLING, OVERHEAT LIGHT WOULD ALWAYS COME BACK ON AFTER COOLING PERIOD WHEN R2 WINDOW HEAT SWITCH RESELECTED ON. ACFT GROUNDED. FOUND PRIMARY WINDOW HEAT SENSOR BAD, OPEN CIRCUIT, REF AMM 30-41-21-760-801. SWAPPED LEAD TO SPARE SENSOR, R2 WINDOW HEAT OPS CHECKS NORMAL. BITE CHECKED R2 WHCU, NO FAULTS IAW FIM 30-41, TASK 801.

Part: SATCOM — MALFUNCTIONED · airframe 35,226 hrs · 10,671 cycles

NO SATCOM PROMPT ON MCDU MENU PAGE GROUNDED. FOLLOWED QRH PROCEDURE AND SAT PROMPT RETURNED.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 35,167 hrs · 10,657 cycles

FMC DIAGREE ON GROUND. ACFT GROUNDED. CLEARED WITH QRH PROCEDURE.

Part: WARNING LIGHT — FALSE ACTIVATION (CABIN TEMP) · airframe 34,989 hrs · 10,608 cycles

ON RECALL CONTROLLER CABIN ZONE TEMP ILLUMINATES, EXTINGUISHES ON RECALL. ACFT GROUNDED. ON ZONE TEMP CONTOLLER 2, BIT, SHOWED, TRIM VALVE, FLT DECK, PREV FLGHT, SHOWED, TRIM VALVE, ZONE TEMP CONTROLLER 1 BIT SHOWED, GO, PREVIOUS FLIGHT SHOWED GO AND BOTH ZONE TEMP CONTROLLERS SHOWED, GO, AFTER VERIFY. RESET BOTH ZONE TEMP CONTROLLERS IAW FIM TASK 21-62, TASK 801. CONTROLLER CAB ZONE TEMP LIGHT NO LONGER ILLUMINATES ON RECALL.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 34,922 hrs · 10,591 cycles

OBSERVED, FMC DISAGREE, MEASSAGE AFTER LANDING. MESSAGE EXTINGUISHED AFTER 2-3 MINUTES. ACFT GROUNDED. ACCOMPLISHED FIM 34-61, TASK 835. SYS CHECKS NORMAL. NO FAULT FOUND.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 34,878 hrs · 10,582 cycles

FMC DISAGREE RECEIVED AFTER SELECTING FLAPS, PRIOR TO TAXI. ACFT GROUNDED. ACCOMPLISHED RESET PROCEDURE IAW QRH. RESTORED NORMAL.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 34,875 hrs · 10,581 cycles

ON GROUND FMC ANOMALY, DATALINK FULL MESSAGE. ACFT GROUNDED. ACCOMPLISHED RESET PROCEDURE IAW QRH. RESTORED NORMAL.

Part: SATCOM — LOCKED · airframe 34,819 hrs · 10,566 cycles

SATCOM LOCKUP, ACFT GROUNDED. ACCOMPLISHED QRH RESET PROCEDURE. SATCOM RESTORED NORMAL.

Part: IGNITION UNIT — FAILED (APU) · airframe 34,771 hrs · 10,551 cycles

APU FAULT LIGHT REMAINS ON AFTER APU START. SWITCH IN OFF. ACFT GROUNDED. R & R APU IGNITION UNIT REF AMM 49-41-31. OPS CHECKS GOOD.

Part: FIRE DETECTOR — DAMAGED (NR 2 NACELLE) · airframe 34,682 hrs · 10,532 cycles

NR 2 ENGINE FIRE SWITCH, PULL HANDLE, LIGHT DOES NOT ILLUMINATE ON TEST WITH FAULT LIGHT ILLUMINATED. ACFT GROUNDED. ACCOMPLISHED FIRE DETECT BITE AND FOUND ENGINE 2, LOOP B CORE LT FAULTED. FOUND TERMINAL LUG BROKEN OFF, FIRE DETECTOR, RE-TERMINATED LUG AND REINSTALLED IAW SWPM 20-30-11. REACCOMPLISHED BITE, NO FAULTS NOTED REF FIM 26-10, TASK 801. FIRE DETECTION SYS TEST NORMAL.

Part: SATCOM — MALFUNCTIONED · airframe 34,624 hrs · 10,513 cycles

SATCOM INOPERATIVE NOT LISTED ON MENU OF MCDU. ACFT GROUNDED. ACCOMPLISHED FIM 23-15, TASK 801, SATCOM, OPS NORMAL.

Part: SATCOM — LOCKED · airframe 34,527 hrs · 10,482 cycles

SATCOM LOCKUP DURING POWER TRANSFER. ACFT GROUNDED. FOLLOWED QRH SATCOM RESTORED.

Part: SATCOM — LOCKED · airframe 34,255 hrs · 10,402 cycles

SATCOM LOCKUP, ACFT GROUNDED. SAT LOCKUP CHECKLIST COMPLETED, NORMAL OPS RESTORED.

Part: EXCITER — FAILED (NR 1 ENGINE) · airframe 34,228 hrs · 10,396 cycles

STARTING NR 1 ENGINE WITH IGNITION IN RT IGNITION, THERE WAS NO FUEL FLOW NO EGT, START WAS NORMAL IN LT IGNITION. ACFT GROUNDED. R & R NR 1 ENG RT IGNITION EXCITER REF AMM 74-11-01-400-801-FOO. R & R NR 1 ENGINE BOTH MAIN IGNITER PLUGS REF AMM 74-21-02. IGNITION SYS AUDIBLE TEST PASS, REF AMM 74-00-00750-801-F00.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 34,218 hrs · 10,393 cycles

DURING PRE-FLIGHT, FOUND PRESSURIZATION "AUTO FAIL" AND "ALTN" LIGHTS ILLUMINATED. ACFT GROUNDED. PERFORMED DIGITAL CABIN PRESSURE CONTROLLER BITE PROCEDURE ON NR 1 AND NR 2 CONTROLLERS. OPS CHECKED GOOD, NO FAULT NOTED. REF FIM TASK 21-31, TASK 801.

Part: INDICATOR — INTERMITTENT (FUEL QUANTITY) · airframe 34,216 hrs · 10,392 cycles

NR 1 REFUEL INDICATOR FAILED INTERMITTENTLY. ACFT GROUNDED. R & R NR 1 REFUEL QTY INDICATOR IAW AMM 28-41-61, OPS TEST GOOD.

Part: SATCOM — MALFUNCTIONED · airframe 34,185 hrs · 10,383 cycles

SATCOM COULD NOT TRANSMIT. COULD RECEIVE VOICE BUT WE COULD NOT TRANSMIT ON SAT 1 OR SAT 2. ACFT GROUNDED. ACCOMPLISHED SATCOM COMMUNICATION TEST. OPS CK GOOD. REF AMM 23-15-00-730-801.

Part: EXCITER — FAILED (NR 2 ENGINE) · airframe 34,180 hrs · 10,382 cycles

NR 1 ENGINE, RT IGNITION INOPERATIVE. ACFT GROUNDED. PERFORMED IGNITION SYS AUDIBLE TEST ON RT AND LT SEVERAL TIMES. FOUND RT IGNITER INTERMENT. SOUNDED DIFFERENT EVERY TIME REF74-00-00-750-801-F00. REMOVED RT MAIN IGNITER PLUG AND INSPECTED IT. FOUND THE TIPS HAVE CRACKS AND DAMAGED REF MM 74-21-02. INSTALLED NEW MAIN RT IGNITER PLUG. OPS CK NORMAL. STARTED ENG NR 1 SEVERAL TIMES ON RT IGNITION REF MM 74-21-02-200-801-F00.

Part: SATCOM — LOCKED · airframe 34,160 hrs · 10,376 cycles

SATCOM LOCKUP. ACFT GROUNDED. CHECKLIST ACCOMPLISHED, SATCOM RESTORED.

Part: PRESSURE SWITCH — FAILED (NR 2 FUEL) · airframe 34,107 hrs · 10,362 cycles

ON CLIMB OUT NR 2 FILTER BYPASS ILLUMINATED. ACFT GROUNDED. ACCOMPLISHED FIM TASK 73-05, TASK 801, FUEL FILTER BYPASS LIGHT ON. R & R RT ENGINE FUEL FILTER REF AMM TASK 73-11-02-000-801-FOO. NO CONTAMINATION FOUND. REPLACED FUEL FILTER DIFFERENTIAL PRESSURE SWITCH REF AMM TASK 73-34-01-000-801-F00 AND 73-34-01-400-801-F00. POWER PLANT TEST 71-00-00-700-801-F00, OPS. AND LEAK. CK. GOOD FILTER AND SWITCH AND 73-21-00-700-804-F00. NO EEC FAULTS FOUND. CHECKED ALL HISTORY. OK.

Part: EXCITER — FAILED (NR 1 ENGINE) · airframe 34,087 hrs · 10,357 cycles

NR 1 LT ENGINE DID NOT START ON PUSHBACK. ENGINE START WAS IN RT POSITION IAW MCSEA, STARTED ON LT POSITION SUCCESSFUL. ACFT GROUNDED. REPLACED RT IGNITION EXCITER BOX NR 1 ENGINE IAW AMM 74-11-01, AND REPLACED RT IGNITION LEAD NR 1 ENGINE IAW AMM 74-21-01. RT IGNITION, OPS CKS GOOD.

Part: TERMINAL — BROKEN (NR 2 NACELLE) · airframe 34,065 hrs · 10,349 cycles

NR 2 ENGINE WIRE HARNESS HAS A BROKEN TERMINAL LUG. ACFT GROUNDED. REPLACED TERMINAL LUG AT NR 3 DETECTOR OF MW0325 ON NR 2 ENGINE, REF MM 26-11-02. ENGINE FIRE DETECTION, OPS TEST NORMAL, REF MM 26-11-00.

Part: FUEL NOZZLE — FAULTED (NR 2 ENGINE) · airframe 34,060 hrs · 10,347 cycles

NR 2 ENGINE LOGGED FAULT 77-10842, TOP RT EGT SIGNAL OUT OF RANGE, REF T/C78273000. ACFT GROUNDED. R & R NR 2 ENGINE, TOP 11 FUEL NOZZLES. ACCOMPLISHED GROUND VERIFICATION REPAIR CONFIRMATION IAW FIM 77-21, TASK 801G. NO RECENT FAULTS NOTED.

Part: ENGINE — FAULTED (NR 2) · airframe 33,877 hrs · 10,293 cycles

NR 2 ENGINE, WHILE PERFORMING T/C 78273000, HAD FAULT 73-31372, UPPER EGT SECTORS READING HIGH, ECONOMIC FAULT, 500 HR PLT, ONLY ON FLIGHT LEG 3. ACFT GROUNDED. ON DEFERRAL.

Part: DRAIN MAST — CRACKED (APU) · airframe 33,862 hrs · 10,289 cycles

POSSIBLE CRACK ON APU/HYDRAULIC SHROUD DRAIN, AFT UPPER DRAIN MOUNT. ACFT GROUNDED. REPLACED APU SHROUD DRAIN/HYD VENT DRAIN MAST REF MM 28-25-07. APPLIED STENCIL TO DRAIN MAST REF MM 51-21-99, EXTERIOR MARKING MANUAL SECT.3, PG16.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 33,831 hrs · 10,275 cycles

FMC DISAGREE LIGHT ILLUMINATED ON TAXI OUT. ACFT GROUNDED. CHECKLIST COMPLETED LIGHT EXTINGUISHED.

Part: SATCOM — MALFUNCTIONED · airframe 33,801 hrs · 10,269 cycles

NO SATCOM PROMPT. ACFT GROUNDED. CYCLED "SATCOM" BREAKER TO RESTORE SATCOM IAW QRH.

Part: FAULT CODE — ACTIVATED (NR 1 ENGINE) · airframe 33,752 hrs · 10,257 cycles

UPON ACCOMPLISHING TASK CARD 78273000, FMC CDU FOR ENGINE FAULTS ENGINE NR 1 HAS FAULT 77-20871, TOP LT EGT SIGNAL OUT OF RANGE. TERM OF FAULT ECONOMIC. FLT LEGS 1, 2, 3, 8, 9. ACFT GROUNDED. ON DEFERRAL.

Part: CONTROL VALVE — FAILED (LT A/C PACK) · airframe 33,752 hrs · 10,257 cycles

LEFT PACK LIGHT LLUMINATES ON RECALL, GOES OUT WITH MASTER CAUTION RESET IAW QRH. ACFR GROUNDED. R & R LT TEMPERATURE CONTROL VALVE REF AMM 21-51-10. OPS CK OK.

Part: SATCOM — MALFUNCTIONED · airframe 33,650 hrs · 10,231 cycles

NO SATCOM PROMPT ON TAXI. ACFT GROUNDED. PERFORMED SATCOM LOCK UP PROCEDURE. SATCOM PROMPT RESTORED.

Part: SENSOR — FAULTED (EGT) · airframe 33,608 hrs · 10,216 cycles

FAULT CODE MESSAGE NR 73-31372, UPPER EGT SECTORS READING HIGH "ECONOMIC FAULT" FLIGHT LEG 3 ACCOMPLISHING TC 78273000, NR 2 ENGINE. ACFT GROUNDED.

Part: CONTROL PANEL — BURNED (COCKPIT) · airframe 33,618 hrs · 10,218 cycles

ALTITUDE WINDOW ON MCP HAS SIGNIFICANT BURN IN. TOUGH TO SEE SELECTED ALTITUDE. ACFT GROUNDED. REPLACED DFCS MODE CONTROL PANEL IAW AMM 22-11-34/401. MODE CONTROL PANEL INSTALLATION TESTS PASSED.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 33,580 hrs · 10,207 cycles

FMC DISAGREE ON TAXI. ACFT GROUNDED. PERFORMED QRH PROCEDURE. MESSAGE NO LONGER DISPLAYED.

Part: FMC — FAILED (RIGHT) · airframe 33,305 hrs · 10,124 cycles

IN ETOPS AIRSPACE, JUST PASSED LP. RECEIVED FMC MESSAGE "SINGLE FMC", RT FMC FAILED, AT TIME OF FAILURE LT, IRS DRIFT 1.6 AND RT- IRS DRIFT 3.7, BOTH LT & RT GPS OPS NORMAL, QRH FOLLOWED, UNABLE TO RESTORE DUAL FMC OPERATION. ACFT GROUNDED. REPLACED RT FMC IAW AMM 34-61-02-400-801.

Part: ENGINE — FAULTED (NR 2) · airframe 33,217 hrs · 10,100 cycles

WHILE ACCOMPLISHING TC 7827300, FOUND ECONOMIC FAULT 73-3137, UPPER EGT SECTORS READING HIGH. ONLY ON FLIGHT LEG NR 4, ENGINE NR 2. ACFT GROUNDED. ON DEFERRAL.

Part: SATCOM — MALFUNCTIONED · airframe 33,124 hrs · 10,069 cycles

NO SATCOM PROMPT. ACFT GROUNDED. PERFORMED SATCOM LOCK OUT PROCEDURE IAW QRH. OPS NORMAL.

Part: AUTOTHROTTLE SYS — MALFUNCTIONED · airframe 33,110 hrs · 10,064 cycles

AUTOTHROTTLE INOPERATIVE. ACFT GROUNDED. ACCOMPLISHED AUTOTHROTTLE SYSTEM OPS TEST IAW MM 22-31-00-710-801, TEST PASSED NO FAULTS WERE INDICATED, NO HISTORY 90 DAYS.

Part: BUTTON — INOPERATIVE (KEYBOARD) · airframe 32,947 hrs · 10,007 cycles

F/O MCDU R6 BUTTON INOPERATIVE. ACFT GROUNDED. REF AMM 34-61-01, REMOVED AND INSTALLED NEW KEYBOARD. PERFORMED SYS TEST REF AMM 34-61-01-400-801. STEP D ALL TESTS PASSED.

Part: SATCOM — LOCKED · airframe 32,939 hrs · 10,004 cycles

SATCOM LOCKUP ENROUTE. ACFT GROUNDED. FOLLOWED QRH PROCEDURE AND SATCOM RESTORED.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 32,898 hrs · 9,995 cycles

DATALINK FULL MESSAGE IN FMC. ACFT GROUNDED. COMPLIED WITH QRH. OPS NORMAL

Part: ACARS — MALFUNCTIONED (SATCOM) · airframe 32,786 hrs · 9,965 cycles

NO SATCOM ON ACARS PAGE. ACFT GROUNDED. FOLLOWED QRH AND SATCOM PROMPT RESTORED.

Part: SATCOM — MALFUNCTIONED · airframe 32,780 hrs · 9,963 cycles

NO SATCOM ON ACARS. ACFT GROUNDED. FOLLOWED QRH, SATCOM RESTORED.

Part: FMC — FAILED (EE BAY) · airframe 32,739 hrs · 9,953 cycles

DURING CLIMBOUT, FMC SCRATCHPAD SHOWED FOLLOWING MESSAGE "CHECK FMC POSITION FMC-FMC." RETURNED TO SEATTLE. ACFT GROUNDED. DIVERSION TIME: 39 MINUTES. CREW DEBRIEF REPORTS RT FMC POS SHIFT PAGE DATA BLANK AND WOULD NOT WORK IN VNAV. WHEN SWITCHED TO BOTH ON LEFT VNAV FUNCTIONED NORMAL. REPLACED RT FMC COMPUTER. RT FMC OPS AND SOFTWARE CONFIGURATION NORMAL. REF MM 34-61-02 AND 34-61-0. GROUND VERIFICATION SUCCESSFUL.

Part: FLANGE — CRACKED (NR 1 EXHAUST) · airframe 32,738 hrs · 9,952 cycles

LT ENGINE TURBINE EXHAUST FLANGE ASSY HAS CRACKS AT BOLT LOCATIONS. ACFT GROUNDED. REMOVED NR 1 ENGINE TURBINE EXHAUST FLANGE IAW 72-56-00-000-802. INSTALLED TURBINE EXHAUST FLANGE IAW 72-56-00-400-801, STEP F. 2, A-G + 3 A- C, INSTALLED PRIMARY PLUG IAW 78-11-02-400-802 ITEM 3. F.

Part: WIRE HARNESS — MALFUNCTIONED (NR 1 ENGINE) · airframe 32,677 hrs · 9,933 cycles

NR 1 ENGINE HAS HISTORY OF HPTACC FAULTS. POSITION SIGNAL DISAGREE AND SIGNAL OUT OF RANGE FAULTS BEING SET. ACFT GROUNDED. VERIFIED HPTACC FAULTS ARE STILL ACTIVE. ACCOMPLISHED FIM 75-21/802, STEP F, NO OBVIOUS DISCREPANCIES NOTED. ACCOMPLISHED AND REVERSED ALT PROCEDURES 05-07-01, TABLE 3, ITEM 1. REPLACED J10 HARNESS. CLEARED FAULTS AND ACCOMPLISHED ELECTRONIC ENGINE CONTROL DISCRETES TEST, ELECTRONIC ENGINE CONTROL TEST, AND ACTUATORS TEST. NO FAULTS ON ELECTRONIC ENGINE CONTROL BITE. ALL OPS NORMAL. REF MM 71-00-00,73-21-00, FIM 75-21/802, WDM 75-31-11.

Part: LIGHT — INOPERATIVE (LT OVERWING) · airframe 32,626 hrs · 9,916 cycles

AFT LT SLIDE OVERWING EMERGENCY LIGHT INOPERATIVE. ACFT GROUNDED. R & R SLIDE OVERWING EMERGENCY LIGHT IAW AMM 33-51-04-960-801. OPS CHECKED GOOD.

Part: ENGINE — FAULTED (NR 2) · airframe 32,626 hrs · 9,916 cycles

NR 2 ENGINE FMC CODE LOGGED ECONOMIC FAULT NR 73-31372 UPPER EGT SECTORS READING HIGH. ACFT GROUNDED.

Part: SATCOM — LOCKED · airframe 32,605 hrs · 9,908 cycles

SATCOM LOCK-UP. ACFT GROUNDED. SATCOM LOCK-UP RESET IAW QRH PROCEDURE.

Part: EEC — FAULTED (NR 1 ENGINE) · airframe 32,583 hrs · 9,904 cycles

ON T/C 78273000, ECONOMIC FAULT MSGS: MSG 75-30411, #75-20361 #1 ENG. HPTACC POSITION SIGNAL OUT OUT OF RANGE, MSG #75-20411 #1 ENG HPTACC POSITION SIGNAL DISAGREE, #75-10411 #1 ENG. HPTACC POSITION SIGNAL DISAGREE, 75-20361 #1 ENG HPTACC SIGNAL IS OUT OF RANGE GROUNDED - YES. REPLACED #1 ENG EEC REF MM 73-21-60, GROUND VERIFICATION TEST PASSED.

Part: ENGINE — FAULTED (NR 2) · airframe 32,541 hrs · 9,890 cycles

ON T/C 78273000 #2 ENG HAS FAULT 73-31372 UPPER EGT SECTORS READING HIGH. GROUNDED - YES. ACCOMPLISHED T/C 78273000, NO FAULTS LOGGED.

Part: SATCOM — LOCKED · airframe 32,521 hrs · 9,882 cycles

SATCOM LOCK-UP. ACFT GROUNDED. QRH PERFORMED SUCCESSFULLY.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 32,290 hrs · 9,826 cycles

FMC DATA LINK FULL MESSAGE. ACFT GROUNDED. QRH PROCEDURE CLEARED MESSAGE.

Part: PROBE — FAILED (PITOT) · airframe 32,188 hrs · 9,796 cycles

DURING CRUISE FLIGHT, F/O PITOT LIGHT ILLUMINATED FOUND THAT CB OPEN, LABELED F/O PITOT HEATER P18,3,D5. ACFT GROUNDED. REPLACED F/O PITOT PROBE IAW 34-11-01-400-801 AND LEAK TEST OK, REFERENCE 34-11-00-740-811. PROBE HEAT CHECKS GOOD REF 30-31-00-730-801.

Part: WARNING MESSAGE — FALSE ACTIVATION · airframe 32,188 hrs · 9,796 cycles

DATALINK FULL MESSAGE ON GROUND. ACFT GROUNDED. CLEARED IAW QRH.

Part: SATCOM — LOCKED · airframe 31,823 hrs · 9,696 cycles

SATCOM LOCK UP ON GROUND, ACFT GROUNDED. FOLLOWED QRH, ISSUE RESOLVED.

Part: SATCOM — LOCKED · airframe 31,784 hrs · 9,686 cycles

SATCOM LOCKUP. ACFT GROUNDED. ACCOMPLISHED QRH PROCEDURE, PS 3. SATCOM PROMPT RESTORED ON MCDU MENU PAGE AFTER 3 MINUTES.

Part: SEAL — OUT OF LIMITS (APU) · airframe 31,789 hrs · 9,687 cycles

APU SIGMA SEAL HEIGHT IS OUT OF LIMITS IAW TC 78349000. ACFT GROUNDED. R & R SIGMA SEAL IAW AMM 49-15-11-000-801 & 49-15-11-400-801.

Part: SATCOM — LOCKED · airframe 31,767 hrs · 9,683 cycles

SATCOM APPEARS TO HAVE LOCKED UP. NO SATCOM SELECTION ON MCDU PAGE. ACFT GROUNDED. ACCOMPLISHED FIM 23-15, TASK 801. NO LOCK UP CONDITION PRESENT WITH NORMAL OPERATION IAW THIS REF, THERE'S A KNOWN PROBLEM WITH SATCOM EQUIPED PLANES HAVING THIS ISSUE.

Part: SATCOM — LOCKED · airframe 31,697 hrs · 9,660 cycles

SATCOM LOCKED UP IN FLIGHT. ACFT GROUNDED. RESET IAW QRH PROCEDURE.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 31,613 hrs · 9,639 cycles

FOUND AUTO FAIL & ALTN LIGHT ON AT PREFLIGHT ON PRESSURIZATION PANEL. ACFT GROUNDED. SELECTED CONTROL PANEL TO MANUAL THEN RETURNED TO AUTO AND ALL FAULT INDICATIONS EXTINGUISHED. BITE CHECKS OF PRESSURE CONTROLLER 1 AND 2 SHOWS NO CURRENT FAULTS. NO HISTORY LAST 30 DAYS, REF 21-31-827 AND 21-31-801.

Part: EGT INDICATION — READS HIGH (NR 2 ENGINE) · airframe 31,570 hrs · 9,619 cycles

NR 2 ENGINE HAS FAULT 73-31372, UPPER EGT SECTORS READING HIGH. ACFT GROUNDED. ACCOMPLISHED FIM 73-11, TASK 801. S1 AND S4 ARE READING NORMAL IN RELATION TO S2 AND S3 WITH NO DEFECTS NOTED FOR FLIGHT LEG 0.

Part: APU — MALFUNCTIONED · airframe 31,527 hrs · 9,607 cycles

APU CT5ATP EGT TREND DATA SHOWS EGT HAS SHIFTED ABOVE THE ESTABLISHED 605 DEGREE THRESHOLD. ACFT GROUNDED. ON DEFERRAL.

Part: FUSE — FAILED (EMERGENCY LIGHT) · airframe 31,478 hrs · 9,596 cycles

WHILE PERFORMING TASKCARD 78233008, FOUND LT EMERGENCY AISLE LIGHT AT ROW INOPERATIVE. ACFT GROUNDED. R & R EMERGENCY AISLE LIGHT ASSY AT ROW 16 LT IAW AMM 33-51-03, NO HELP. R & R POWER SUPPLY FUSE TO ROW 16 LT AISLE LIGHT IAW AMM 33-51-06. OPS CKS GOOD.

Part: EGT INDICATION — READS HIGH (NR 2 ENGINE) · airframe 31,440 hrs · 9,586 cycles

FOUND FAULT CODE 73-31372 LOGGED DURING ACCOMPLISHMENT OF T/C 78273000, NR 2 ENGINE UPPER EGT SECTORS READING HIGH ESN894276. ACFT GROUNDED. PERFORMED TASKCARD 78273000. FAULT CODE 73-31372 WAS NOT FOUND.

Part: SHIM — WORN (NR 2 ENGINE) · airframe 31,440 hrs · 9,586 cycles

FOUND NR 2 ENGINE FAN BLADE SHIMS MISSING 100 PERCENT MOLYDAG COATING MISSING AND WEAR INTO BASE METAL IN PRESSURE FACE CONTACT AREA. REF T/C 78472002. ACFT GROUNDED. NO WEAR TO FAN BLADES NOTED. R & R SHIMS IAW T/C 78472002.

Part: WARNING MESSAGE — FALSE ACTIVATION (NR 2 ENGINE) · airframe 31,329 hrs · 9,550 cycles

NR 2 ENGINE ECONOMIC FAULT MESSAGE 77-10842, FLT LEG 2, THE TOP RT EGT SIGNAL IS OUT OF RANGE. ACFT GROUNDED. RETESTED NR 2 ENGINE FMC/CDU IAW TC 78273000. FAULT MESSAGE NR 77-10842 DID NOT APPEAR.

Part: SATCOM — MALFUNCTIONED · airframe 31,308 hrs · 9,545 cycles

NO SATCOM PROMPT ON TAXI. ACFT GROUNDED. PERFORMED SATCOM LOCKUP PROCEDURE. QRH 5.3, ON GROUND. ACARS PROMPT APPEARED AND SYS RESTORED.

Part: LIGHT — INTERMITTENT (ROW 16) · airframe 31,220 hrs · 9,514 cycles

LEFT EMERGENCY EXIT LIGHT AT ROW 16 INOPERATIVE, AISLE LIGHT. ALL OTHER LIGHTS WORK. ACFT GROUNDED. COMPLETED OPS CHECKS OF EMERGENCY LIGHT SYSTEM IAW MM 33-51-00. NO DEFECTS NOTED. COULD NOT DUPLICATE.

Part: SATCOM — LOCKED · airframe 31,180 hrs · 9,503 cycles

SATCOM LOCKED UP. ACFT GROUNDED. CYCLED POWER AND BOTH SATCOM PROMPT CAME ON BOTH MCDU. SATCOM GROUND VERIFICATION TEST, OPS CK GOOD. REF FIM TASK 23-15, TASK 801.

Part: SATCOM — MALFUNCTIONED · airframe 31,138 hrs · 9,493 cycles

ON GROUND KOA "SAT", SATCOM, MISSING. ACFT GROUNDED. QRH RESET C/B, SATCOM RE-ESTABLISHED.

Part: SATCOM — LOCKED · airframe 31,069 hrs · 9,475 cycles

SATCOM LOCKED UP ON GROUND. ACFT GROUNDED. SUCCESSFULLY RESET IAW QRH PROCEDURE.

Part: WIRE — DETACHED · airframe 30,998 hrs · 9,458 cycles

LEFT "ENGINE VALVE CLOSED" LIGHT ILLUMINATED BRIGHT AFTER ENGINE SHUTDOWN. ACFT GROUNDED. FOUND WIRE W2508-6025-20 AT TB261Y NOT SEATED AT A9. RESEATED WIRE IN TERMINAL BLOCK. ALL OPS NORMAL. REF WDM 76-21-11.

Part: INDICATOR — MALFUNCTIONED (SATCOM) · airframe 30,991 hrs · 9,456 cycles

SAT OPTION NOT PRESENT ON CDU WHEN MENU BUTTON PUSHED. ACFT GROUNDED. FOUND SATCOM PROMPT ON BOTH FMC MCDU'S. PERFORMED SATCOM VOICE TEST IAW MM 23-15-00. CHECKED GOOD, IAW FIM 23-15, TASK 801 C.1, E.

Part: LENS — DETACHED (EMERGENCY LIGHT) · airframe 30,974 hrs · 9,452 cycles

F/A REPORTED LEFT AFT- EMERGENCY LIGHT COVER AT AFT LAV NEEDS TO BE REINSTALLED. ACFT GROUNDED. REATTACHED LIGHT LENS COVER. AFT LT LAV OK FOR SERVICE.

Part: SATCOM — LOCKED · airframe 30,813 hrs · 9,414 cycles

SATCOM LOCKUP ON GROUND. ACFT GROUNDED. QRH PROCEDURES RESTORED.

Part: SATCOM — LOCKED · airframe 30,788 hrs · 9,406 cycles

SATCOM LOCKUP ON GROUND, ACFT GROUNDED. PERFORMED QRH 5.3. OPS NORMAL.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 30,750 hrs · 9,393 cycles

EMERGENCY EXIT LIGHTS ABOVE SEAT 8C AND SEAT 16C WILL NOT ILLUMINATE. ACFT GROUNDED. REPLACED THE LAMPS, OPS CHECKED GOOD IAW MM 33-51-03.

Part: CHANNEL — DAMAGED (727D) · airframe 30,750 hrs · 9,393 cycles

AFT CARGO BAY RT SIDEPLATE CHANNEL HAS OVERSIZED HOLES FROM FASTENERS PULLING THROUGH AT STA 727F, 727G, AND 727H. ACFT GROUNDED. REMOVED DAMAGE AREA IAW SRM 53-00-53-2R. FABRICATED NEW SIDEPLATE SECTION AND SIDEPLATE SPLICE IAW SRM 53-00-53-2R. ALODINED REPAIR PARTS IAW SRM 51-20-01. PRIMED REPAIR PARTS IAW SOPM 20-41-02 INSTALLED NUT PLATES AND REPAIR PARTS IAW SRM 53-00-53-2R-5. REMOVED AND REINSTALLED FLOOR PANEL 140EF FOR ACCESS IAW AMM 25-52-10.

Part: CHANNEL — CORRODED (BS 727D-727H) · corrosion level 2 · airframe 30,750 hrs · 9,393 cycles

AFT CARGO BAY RT SIDEPLATE CHANNEL IS CORRODED, STA 727D-727H+10. ACFT GROUNDED. REMOVED CORROSION FROM STA 727D-727E AND FOUND TO BE WITHIN LIMITS IAW SRM 53-00-53, ORIGINAL THICKNESS .040 MATERIAL REMOVED .002. MATERIAL REMAINING .038. ALODINED REWORKED AREA IAW SRM 51-20-01. PRIMED REWORKED AREA IAW SOPM 20-41-02. MARKED BLENDOUT AREA AND APPLED CIC IAW AMM 51-05-01. REMOVED CORROSION FROM STA 727E-727H AND FOUND TO BE OUT OF LIMITS. REPAIR PERFORMED ON CUSTOMER CARD G346354 COPY ATTACHED. AT STA 727E-727H, ORIGINAL MATERIAL THICKNESS IS 0.040 IN, MATERIAL THICKNESS REMAINING IS 0.028IN, MATERIAL THICKNESS REMOVED IS 0.012 IN. BEYOND ALLOWABLE LIMITS, 10 PERCENT THICKNESS MAX, IAW SRM 53-00-53-1A-2, FIG 103, DETAIL D, TOOL ID T8225Y. REPAIR ACCOMPLISHED IAW SRM 53-00-53-2R-5 .

Part: INJECTOR — FAILED (APU) · airframe 30,724 hrs · 9,385 cycles

APU CT5 ATP EGT TREND DATA SHOWS EGT HAS SHIFTED ABOVE THE ESTABLISHED THRESHOLD. ACFT GROUNDED. R & R ALL APU FUEL NOZZLE IAW AMM 49-31-14/401. OPS CHECKED NORMAL. NO LEAKS NOTED.

Part: CIRCUIT BREAKER — MALFUNCTIONED · airframe 30,723 hrs · 9,383 cycles

AT N8, AFTER GROUND POWER SURGE AND DISRUPTION, STARTED APU AND A "TR UNIT" REMAINS ILLUMINATED. ACFT GROUNDED. ACCOMPLISHED FIM 24-31-810-826. FOUND TR 1, 2 & 3 C/B'S OUT ON P91 & P92. ACCOMPLISHED C/B RESET PROCEDURE. NO DEFECTS NOTED. C/B RESET. OPS & GROUND VERIFICATION CHECKS NORMAL REF 24-32-400-801.

Part: WEB — WORN (FUSELAGE) · airframe 30,658 hrs · 9,360 cycles

HIGH PRESSURE CONNECTOR DOOR WORN AT LAND AREAS HINGE ARE EXTREMELY LOOSE. ACFT GROUNDED. REMOVED HIGH PRESSURE CONNECTOR DOOR BUILD UP HINGE MARKS REF 53-30-71-1A1, AD1 POINT IS .098. OUT OF LIMITS. INSTALLED FILLER TO STRAP UNDER DOOR HINGE REF EA800-53EA-13474. R & R HINGES OPS CHK GOOD NG53EO-09660-1.

Part: WARNING LIGHT — ILLUMINATED · airframe 30,605 hrs · 8,341 cycles

CHECKING MASTER CAUTION IN CRUISE, AIR CONDITION AND RT PACK LIGHTS ILLUMINATED. HITTING MASTER CAUTION. AGAIN CAUSED BOTH LIGHTS TO GO OUT. ACFT GROUNDED. TESTED RT PACK ZONE CONTROLLER IAW AMM 21-31-00. NO FAULTS FOUND AND NO MAINTENANCE HISTORY WITHIN THE PAST 10 DAYS.

Part: WARNING MESSAGE — FALSE ACTIVATION · airframe 30,566 hrs · 9,328 cycles

DURING PREFLT, PRESSURIZATION AUTO FAIL AND ALTN ILLUMINATED. ACFT GROUNDED. PERFORMED PRESSURIZATION SYSTEM TEST NO NR 1 AND NR 2 CONTROLLER. OPS CHECKED NORMAL. REF AMM 21-31-00-700-802. NO HISTORY LAST 30 DAYS. AUTO FAIL AND ALTN LIGHT OFF.

Part: WIRE HARNESS — MALFUNCTIONED · airframe 30,536 hrs · 9,319 cycles

WHILE COMPLETING T/C 78273000, 75-30411 HPTASS SIGNAL DISAGREE. ACFT GROUNDED. PERFORMED HPTACC VALVE, EEC AND WIRE HARNESS J10, CH B AND J9, CH A, ALL RESISTANCE CK WITHIN LIMITS, AND RECEPTACLE ARE IN GOOD CONDITION, REF FIM 75-21, TASK 802. IAW PG A, STEP 5 SAME FIM FADEC 3, CH B EXCITATION CIRCUIT FOR (HPTACC) POSITION LVDT AND THE (TBV) POSITION ARE FROM A COMMON SOURCE IN THE EEC. T/S (TBV) FOUND TO BE OUT OF LIMITS IAW FIM 75-23, TASK 802. DUE TO FAULT HISTORY, CLEARED ALL FAULTS FROM NR 1 ENG EEC. BITE TEST AND VERIFIED NO FAULTS ARE CURRENT REF MM 73-21-00-740-803-F00. WE PERFORMED THE FOLLOWING TASK IN ORDER TO VERIFY NO FAULTS ON ENGINE FROM EEC. WE FIRST DID AN ACTUATORS TEST WITH NO DEFECTS NOTED REF MM 71-00-00-700-807-F00. THEN WE DID AN EEC BITE TEST REF MM 73-21-00-740-803-F00. NO DEFECTS FOUND. THEN WE PERFORMED AN ENG IDLE RUN FOR 5 MIN REF MM 71-00-00-800-808-F00. THEN WE PERFORMED ECC BITE TEST AND NO DEFECTS FOUND REF MM 73-21-00. WE DID THIS PROCEDURES THE FOLLOWING NR OF TIMES, A TOTAL OF 3 ACTUATORS TEST REF MM 71-00-00-700-807-F00, A TOTAL OF 2 ENGINE IDLE RUN 5, MIN AT A TIME, RE MM 71-00-00-800-808-F00 AND A TOTAL OF 7 EEC BITE TEST REF MM 73-21-00-740-803-F00. AT THIS TIME AND AFTER ALL TESTS, THERE HAS NOT BEEN 1 INSTANCE OF A FAULT FOR HPTACC TESTING EE REPLACEMENT AND WIRE HARNESS TESTING. ACCOMPLISHED EA -800-75, EA-13416.

Part: SATCOM — MALFUNCTIONED · airframe 30,410 hrs · 9,276 cycles

NO SATCOM PROMPT DURING TAXI, ACFT GROUNDED. SATCOM RESET PROCEDURE PERFORMED IAW QRH.

Part: EEC — FAULTED (NR 1) · airframe 30,266 hrs · 9,234 cycles

ON FMC TAKEOFF REF PAGE, LT N1 INDICATING 101.7. RT N1 INDICATING 102.6. ACFT GROUNDED. ACCOMPLISHED FIM TASK 75-21, TASK 802 AND 803. FOUND HPTACC VALVE AND HARNESS GOOD. REPLACED NR 1 ENGINE EEC. RAN ENGINE WITH NO DISCREPANCIES NOTED. ALL OPS NORMAL. NO FAULTS ON EEC BITE, EEC TEST GOOD, ACTUATORS TEST GOOD, IAW MM 73-21-60, 71-00-00, FIM 75-21, TASK 802 AND 803, 73-00 TASK 801.

Part: INDICATOR — MALFUNCTIONED (CONTROL PANEL) · airframe 30,262 hrs · 9,232 cycles

PRESSURIZATION PANEL, FLT ALT WINDOW. THE 100'S AND 1 DIGITS HAVE BURNED OUT SEGMENTS. ACFT GROUNDED. R & R CABIN PRESSURE CONTROL SELECTOR REF AMM 21-31-02-400-801, OPS CK'S GOOD IAW STEP E.

Part: CONNECTOR — LOOSE (LT A/C PACK) · airframe 30,266 hrs · 9,234 cycles

LEFT PACK LIGHT ILLUMINATED ON RECALL. ACFT GROUNDED. DURING GVI OF ACFT BAY, FOUND PACK VALVE CONNECTOR TO BE BACKING OFF AND LOOSE. SECURED CONNECTOR, ALL OPS NORMAL IAW WDM 21-51-11.

Part: SWITCH — MALFUNCTIONED (A/C PACK) · airframe 30,257 hrs · 9,231 cycles

AFT CABIN ZONE TEMP LIGHT ILLUMINATEED ON RECALL. ACFT GROUNDED. DUCT OVERHEAT SWITCH S1077 TURNS ON THE AFT CABIN ZONE TEMP LIGHT IAW AMM 21-60-00-823. R & R DUCT OVERHEAT SWITCH IAW AMM 21-61-05-401. OPS CHECKED GOOD. RAN PACK WITH NO AFT ZONE LT ON RECALL.

Part: CONTROLLER — FAILED (CABIN TEMP) · airframe 30,223 hrs · 9,223 cycles

AFTER PUSH BACK, AFT ZONE TEMP LIGHT CAME ON WHEN PRESSING THE RECALL. LIGHT WENT OUT WHEN RESET. ACFT GROUNDED. PRESSED MASTER CAUTION RECALL. NO AFT ZONE TEMP LIGHT OR PACK REF FIM 21-62 TASK 848. PERFORMED BITE CK OF CONTROLLERS. FOUND RT CONTROLLER LOGGED STANDBY PACK REF FIM 21-62, TASK 801. ACCOMPLISHED PACK/ZONE TEMP CONTROLLER BITE PROCEDURE AND NR 2 CONTROLLER STILL SHOWS CONTROLLER FAULT, STANDBY PACK, IAW FIM 21-62, 803. REMOVED & REPLACED NR 2 TEMP CONTROLLER REF AMM 21-61-20-401, OPS CK GOOD.

Part: SATCOM — LOCKED · airframe 30,211 hrs · 9,220 cycles

SATCOM LOCKED UP ON GROUND. ACFT GROUNDED. QRH CHECKLIST USED CLEARED, OPS NORMAL, OK FOR SERVICE.

Part: WARNING LIGHT — FALSE ACTIVATION (LT A/C PACK) · airframe 30,196 hrs · 9,216 cycles

DURING RECALL, LEFT PACK LIGHT ILLUMINATED, EXTINGUISHES WHEN MASTER CAUTION RESET IS PULLED. ACFT GROUNDED. PERFORMED OPERATIONAL CHECK IAW MM 21-61-00, NO DEFECTS NOTED. NO HISTORY LAST 60 DAYS. OK FOR SERVICE.

Part: SATCOM — LOCKED · airframe 30,191 hrs · 9,215 cycles

SAT COM LOCKED UP ON GROUND. ACFT GROUNDED. ACCOMPLISHED QRH PROCEDURE TO RESET. OPS NORMAL.

Part: FILTER — DIRTY (TEMP SENSOR) · airframe 30,149 hrs · 9,199 cycles

DURING RECALL, AFT CABIN ZONE LIGHT ILLUMINATED. RESETS WITH MASTER CAUTION RESET. ACFT GROUNDED. PERFORMED PACK/ZONE TEMPERATURE CONTROLLER BITE TEST REF MM21-51-00. FOUND STANDBY PACK CONTROLLER FAULT LOGGED ON NR 2 TEMP CONTROLLER. RESET FAULT AND OPERATED BOTH PACKS FOR 20 MIN +. RECHECKED NR 2 TEMP. CONTROLLER FOR FAULTS, PERFORMED PACK/ZONE TEMP CONTROLLER BITE SEVERAL TIMES. OPS NORMAL. NO FAULTS NOTED. ALSO FOUND AFT CABIN TEMP SENSOR FILTER DIRTY. REPLACED FILTER REF MM21-61-06.

Part: WARNING LIGHT — ILLUMINATED (LT A/C PACK) · airframe 30,145 hrs · 9,197 cycles

ON LANDING RECALL, AFT CABIN ZONE TEMP ILLUMINATED. ACFT GROUNDED. BITE TESTED ZONE TEMP CONTROLLERS IAW AMM 21-61-20, ON BITE NR 2 ZONE TEMP CONTROLLER SHOWED STANDBY LT PACK, FAULT RESET. NO HISTORY PAST 30 DAYS.

Part: START VALVE — FAILED (NR 1 ENGINE) · airframe 30,140 hrs · 9,195 cycles

NR 1 ENGINE START VALVE FAILED TO OPEN. ACFT GROUNDED. REPLACED NR 1 ENGINE START VALVE, OPS CHECKED GOOD, IAW AMM 80-11-03.

Part: INDICATION SYS — MALFUNCTIONED (SATCOM) · airframe 29,865 hrs · 9,117 cycles

SATCOM PROMPT MISSING. ACFT GROUNDED. QRH PROCEDURE RESTORED SATCOM.

Part: SENSOR — MALFUNCTIONED (INLET TEMP) · airframe 29,842 hrs · 9,108 cycles

ENGINEERING REPORTS APU CT5ATP TEMPERATURE IS APPROACHING ESTABLISHED THRESHOLD. ACFT GROUNDED. REPLACED INLET TEMPERATURE SENSOR IAW AMM 49-61-31-000-801 AND 49-61031-400-801, GROUND FUNCTIONAL TEST GOOD AMM 49-61-31-400-801, PARA G.

Part: SATCOM — LOCKED · airframe 29,852 hrs · 9,110 cycles

SATCOM LOCKED UP ON GROUND. ACFT GROUNDED. QRH PROCEDURE PERFORMED. SATCOM OPS RESTORED.

Part: SATCOM — MALFUNCTIONED · airframe 29,737 hrs · 9,079 cycles

SATCOM LOCKED UP ON GROUND. ACFT GROUNDED. FOLLOWED QRH PROCEDURE AND SAT RECOVERED.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 29,727 hrs · 9,077 cycles

FMC DISAGREE MESSAGE ON GROUND. ACFT GROUNDED. COMPLIED WITH QRH - MESSAGE NO LONGER DISPLAYED.

Part: EEC — OUT OF LIMITS (NR 1 ENGINE) · airframe 29,632 hrs · 9,046 cycles

FOUND FAULT CODES 73-31351. THE APL VOLTAGE INPUT TO THE EEC IS OUT OF RANGE, LONG TERM FAULT, AND FAULT CODE 74-30971. THE APL INPUT VOLTAGE FOR THE LT EXCITER LT IGN IS OUT OF RANGE, LONG TERM FAULT. FOUND WHILE PERFORMING TASK CARD 78273000 ON NR 1 ENGINE. ACFT GROUNDED. ON DEFERRAL.

Part: WARNING MESSAGE — INTERMITTENT (FMC) · airframe 29,586 hrs · 9,033 cycles

FMC DATA LINK FULL. ACFT GROUNDED. PERFORMED FIM 34-61-810-839 FOUND TO BE AN INTERMITTENT FAULT. OK FOR CONTINUED SERVICE, IAW BULLETIN 11-7. THIS IS A RARE ANOMALY AND DOES NOT IMPACT THE FUNCTIONALITY OF ACARS OR DATALINK UPLOADS.

Part: HEATER — LEAKING (FUEL SERVO) · airframe 29,444 hrs · 8,985 cycles

WHILE WORKING TC QA07 PNC, NR 2 ENG FUEL FILTER DIFFERENTIAL PRESSURE SWITCH REPLACEMENT, FOUND FUEL HEATER SERVO LEAKING FROM UPPER SEAM. GROUNDED. REPLACED SERVO FUEL HEATER IAW AMM 73-11-07. SERVO FUEL HEATER INSTALLATION TEST AND LEAK CHECK GOOD REF 71-00-00.

Part: ANTI-ICE VALVE — INTERMITTENT (NR 1 ENGINE) · airframe 29,402 hrs · 8,974 cycles

LEFT ENGINE ANTI-ICE VALVE STUCK CLOSED, RAN QRH EXERCISED SWITCH BECAME INTERMITTENT. ACFT GROUNDED. PERFORMED FIM TASK 30-21-00-810-805 AND FOUND VALVE TO BE INTERMITTENT. REMOVED LT ENGINE COWL TAI VALVE REF MM 30-21-11. INSTALLED LT ENG COWL TAI VALVE REF AMM 30-21-400-801. PERFORMED 3RD TORQUE OF COUPLINGS. PERFORMED ENG COWL ANTI-ICING, OPS TEST. REF AMM 30-21-00-710-801 OPS TEST GOOD.

Part: INDICATOR — TRIPPED (APU OIL FILTER) · airframe 29,386 hrs · 8,971 cycles

ON ETOPS PDC WALKAROUND FOUND APU LUBE OIL FILTER DPI BUTTON EXTENDED. ACFT GROUNDED. REF AMM 49-91-13-600-801 INSPECTED CHIP DETECTOR AND NO DEBRIS FOUND. INSPECTED OIL FILTER, NO DEFECTS NOTED. REPLACED OIL FILTER. PERFORMED OPS CHECK OF APU. NO LEAKS NOTED AT THIS TIME. GROUND VERIFICATION CHECK SUCCESSFUL.

Part: CONNECTOR — DAMAGED (NR 1 ENGINE) · airframe 29,283 hrs · 8,936 cycles

FMC & CDU, FOUND FAULT CODE 75-20361 HPTACC POSITION SIGNAL IS OUT OF RANGE. ACFT GROUNDED. TROUBLESHOT FAULT CODE FOUND EEC J-9 PUSHED PIN. REF FIM 75-21, TASK 802 & 75-34-TASK 816. REPLACED NR 1 ENG EEC WITH NEW REF AMM 73-21-60 ALL TEST ACCOMP/ PASSED AS DIRECTED BY POWERPLANT TEST, REF TASK 71-00-00-800-811-F00.

Part: FMC — FAULTED · airframe 29,230 hrs · 8,923 cycles

FMC DATALINK FULL. ACFT GROUNDED. PERFORMED FIM 34-61-810-839 FOUND TO BE AN INTERMITTENT FAULT. OK FOR CONTINUED SERVICE.

Part: COMPUTER — FAILED (EE BAY) · airframe 28,983 hrs · 8,854 cycles

SPEED TRIM FAILED, MACH TRIM FAILED SINGLE CHANNEL ONLY. ACFT GROUNDED. TROUBLESHOT IAW FIM 22-11, TASK 801. REPLACED FCC "A" IAW MM 22-11-33. FCC A BITE 35 NORMAL. PERFORMED SPEED TRIM BITE 60.32 & MACH TRIM BITE 60.33. BOTH TEST NORMAL. PERFORMED LAND VERIFY BITE 49 & HGS SENSOR TEST FOR FCC. ACFT STATUS & PLACARD REMAIN THE SAME CAT IIIA AUTOLAND & HGS.

Part: CONTROLLER — FAILED (NR 2 A/C PACK) · airframe 28,815 hrs · 8,806 cycles

AFT CABIN ZONE LIGHT DURING RECALL. ACFT GROUNDED. NR 2 CONTROLLER LOGGED STANDBY PACK CONTROLLER FAULT. R & R NR 2 PACK TEMP CONTROLLER. OP CHECKED NORMAL IAW MM 21-61-20.

Part: SCREEN — CLOGGED (TEMP SENSOR) · airframe 28,782 hrs · 8,793 cycles

ON RECALL, AFT CABIN ZONE TEMP LIGHT ILLUMINATED. RAN CHECKLIST, LIGHT STAYED ON. ACFT GROUNDED. PERFORMED FIM 21-61, TASK 801 T/S. ALL BITE CHECKS ON ZONE TEMP CONTROLLER AND PASSED. FOUND AFT CABIN TEMP SENSOR INLET SCREEN CLOGGED, CLEANED SCREEN. RAN PACKS IAW AMM TASK 21-00-00-800-803, CHECKS GOOD.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 28,703 hrs · 8,773 cycles

FMC DISAGREE ON TAXI OUT. ACFT GROUNDED. QRH PROCEDURE ACCOMPLISHED, OPS NORMAL.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 28,664 hrs · 8,763 cycles

"FMC DISAGREE" ON GROUND. ACFT GROUNDED. PERFORMED QRH PROCEDURE. CHECKS OK.

Part: IDG — MALFUNCTIONED (NR 1 ENGINE) · airframe 28,591 hrs · 8,743 cycles

NR 1 IDG REQUIRES FREQUENT SERVICING. ACFT GROUNDED. R & R NR 1 IDG IAW 24-11-11. OPS CHECKED GOOD IAW MM 24-11-00. LEAK CHECKED GOOD IAW MM 71-00-00.

Part: DISPLAY — FAILED (FLIGHT DECK) · airframe 28,422 hrs · 8,700 cycles

FO'S MCDU FLASHES ON AND OFF WITH AN INTERMITTENT " FAIL " LIGHT. ACFT GROUNDED. CONFIRMED DEFECT - RT MCDU HAS CONTINUOUS FAIL/REBOOT CYCLE. R & R AND TESTED RT MCDU IAW MM 34-61-01-000-802/ MM 34-61-01-400-802. OPS NORMAL. VERIFIED MCDU OPS SOFTWARE 3463-SMI-001-02 INSTALLED.

Part: AUTOTHROTTLE SYS — MALFUNCTIONED · airframe 28,409 hrs · 8,696 cycles

DURING CRUISE, AUTOTHROTTLE LIM BOX APPEARED AS N1 LIMIT ANNUNCIATION ON UPPER DU. SYSTEM HANDBOOK STATES: WHEN DISPLAYED INDICATES THE FMC IS NOT PROVIDING THE AUTOTHROTTLE SYSTEM WITH N1 LIMIT VALUES. THE AUTOTHROTTLE IS USING A DEGRADED N1 THRUST LIMIT FROM THE RELATED EEC. ACFT GROUNDED. FMC BITE FOR AUTOTHROTTLE SHOWS 12 FAULTS LAST FLIGHT. FAULTS 22-31413 & 22-31513. EEC INFO CH A & B. AUTOTHROTTLE BITE TESTED GOOD IAW TASK 22-31, TASK 801. ACCOMPLISHED FIM TASK 22-31, TASK 806 FOR FAULT CODES. NO FAULTS NOTED. SUSPECT INTERMITTENT FAULT.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 28,359 hrs · 8,675 cycles

EMERGENCY LIGHT IN FORWARD LOWERED CEILING PANEL IS INOPERATIVE. ACFT GROUNDED. IAW WDM 33-51-12, REPLACED LAMP L1417 AND TESTED IAW MM 33-51-00-710-801. OPS NORMAL.

Part: WARNING LIGHT — ILLUMINATED (FUEL BALANCE) · airframe 28,271 hrs · 8,652 cycles

JUST BEFORE TOP OF DESCENT, FUEL IMBALANCE ANNUNCIATION ILLUMINATED. COULD NOT CONFIRM LEAK. APPEARED TO BE DUE TO HIGHER FUEL FLOW ON LT ENGINE, 200 LBS OR SO MORE THAN THE RIGHT. IMBALANCE WAS STABLE AT 1000-1100 LBS THROUGH LANDING. ACFT GROUNDED. FQIS & CDS TESTED GOOD, NO FAULTS. TRANSFERRED FUEL BETWEEN NR 1 & NR 2 TANKS. APPEARED NORMAL. NO LEAKS NOTED. NO FUEL IMBALANCES NOTED.

Part: CONTROLLER — FAULTED (NR 2 TEMP) · airframe 28,240 hrs · 8,644 cycles

DURING RECALL, LANDING CHECKLIST, AFT CABINE ZONE TEMP LIGHT ILLUMINATED AND EXTINGUISHED WITH MASTER CAUTION RESET. ACFT GROUNDED. NR 2 TEMP CONTROLLER LOGGED "CONTROLLER FAULT". REPLACED NR 2 TEMP CONTROLLER. SYSTEM BITES NORMAL IAW MM 21-62-20. GROUND VERIFICATION SUCCESSFUL.

Part: WARNING LIGHT — ILLUMINATED (CABIN TEMP) · airframe 28,229 hrs · 8,642 cycles

CONTROL CABIN ZONE TEMP LIGHT ILLUMINATED ON RECALL, EXTINGUISHED ON MASTER CAUTION RESET. ACFT GROUNDED.

Part: VALVE — UNKNOWN (NR 1 IDG) · airframe 28,205 hrs · 8,634 cycles

NR 1 ENGINE IDG REQUIRED FREQUENT SERVICING. ACFT GROUNDED. RAN NR 1 ENGINE FOR 10 MIN, AMM 71-00-00-800-808-FOO. NO LEAKS FOUND. REPLACED NR 1 IDG PUSH TO VENT VALVE REF TASK 24-11-00-700-804 AND IDG SERVICE FITTING REF CMM 24-11-85.

Part: WARNING MESSAGE — UNKNOWN (A/C PACK) · airframe 28,125 hrs · 8,611 cycles

AFT CABIN ZONE TEMP ILLUMINATES ON RECALL. ACFT GROUNDED. PERFORMED PACK-ZONE TEMP CONTROLLER BITE PROCEDURE. FOUND STANDBY PACK FAULT LIGHT ILLUMINATED DURING THE BITE PROCEDURE ON THE NR 2 PACK - ZONE TEMP CONTROLLER. FAULT NOT PRESENT DURING THE VERIFY PROCESS. FAULT CODE CLEARED. NO HISTORY PAST 60 DAYS. REF AMM 21-61-00-700-806--002.

Part: FMC — MALFUNCTIONED (LEFT) · airframe 28,123 hrs · 8,610 cycles

LT FMC FAILED SINGLE OPERATION. ACFT GROUNDED. REBOOTED LT FMC REF FIM TASK 34-61, TASK 807. FMC OPS RESTORED. BITE CK OK.

Part: SENSOR — MALFUNCTIONED (WINDOW HEAT) · airframe 28,087 hrs · 8,601 cycles

LEFT SIDE WINDOW OVERHEAT LIGHT ILLUMINATED. THE LIGHT EXTINGUISHED AFTER RESTORING POWER IAW THE QRH PROCEDURE. APPROXIMATELY 1 HR LATER, THE SAME OVERHEAT LIGHT ILLUMINATED. ACFT GROUNDED. PERFORMED THE FIM TASK 30-41, TASK 801 WINDOW HEAT CONTROL UNIT BITE CHECKED. BITE CHECK PASSED. HISTORY SHOWS SENSOR FAULTS. SWAPPED SENSOR TAP TO SPARE SENSOR ON L2 WINDOW. WINDOW HEAT OPS CHECKED IAW AMM 30-41-00-710-801. OPS CHECKED OK.

Part: SATCOM — MALFUNCTIONED · airframe 28,087 hrs · 8,601 cycles

SATCOM LOCKED UP. ACFT GROUNDED. RESET IAW QRH. OPS NORMAL.

Part: SATCOM — MALFUNCTIONED · airframe 28,065 hrs · 8,593 cycles

ON GROUND, SATCOM FAILED DURING POWER TRANSFER. ACFT GROUNDED.. SYSTEM RESET NORMALLY USING QRH PROCEDURE.

Part: SATCOM — MALFUNCTIONED · airframe 28,064 hrs · 8,592 cycles

SATCOM FAILED DURING POWER TRANSFER ON GROUND. ACFT GROUNDED. RESET USING QRH PROCEDURE. OPS NORMAL.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 27,801 hrs · 8,528 cycles

ON TAXI OUT FMC DISAGREE DISPLAYED. ACFT GROUNDED. RAN CHECKLIST, MESSAGE NO LONGER DISPLAYED.

Part: FUEL NOZZLE — MALFUNCTIONED (APU) · airframe 27,713 hrs · 8,506 cycles

APU DATA IS TRENDING ABOVE ESTABLISHED THRESHOLD. ACFT GROUNDED. REPLACED ALL APU FUEL NOZZLE FOR PRECAUTIONARY MEASURES. REF AMM 49-31-14/401. OPS CHECKS OF APU NORMAL. NO LEAKS NOTED.

Part: FILTER — CLOGGED (APU OIL SYS) · airframe 27,687 hrs · 8,499 cycles

DURING A-CHECK, FOUND APU OIL LUBE FILTER DELTA P INDICATOR POPPED. ACFT GROUNDED. R & R APU OIL FILTER ELEMENTS, AND LEAK CK OK IAW AMM 49-91-12/401.

Part: CONTROL VALVE — FAULTED (A/C BAY) · airframe 27,333 hrs · 8,418 cycles

LEFT PACK LIGHT & AIR CONDITION ILLUMINATED ON RECALL. FOLLOWED QRH. LIGHT EXTINGUISHES ON RESET. ACFT GROUNDED. IAW FIM TASK 21-53, TASK 803 PACK LIGHT DID NOT COME ON WHEN RUNNING PACK. INTERMITTENT FAULT. CHECKED LT PACK ZONE TEMP CONTROLLER, FOUND TCV LIGHT ILLUMINATED ON BIT AND PREVIOUS FLT. REPLACED LEFT PACK TCV IAW AMM 21-51-10. LEFT PACK ZONE TEMP CONTROLLER FOUND NO FAULTS.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 26,734 hrs · 8,241 cycles

FMC DISAGREE ON THE GROUND. ACFT GROUNDED. RESET SUCCESSFULLY IAW QRH.

Part: ANGLE — WORN (DOOR) · airframe 30,658 hrs · 9,360 cycles

HIGH PRESSURE DOOR OTBD ANGLE DAMAGED AT STRIKER PLATE. ACFT GROUNDED. FOUND OUT OF LIMITS. REMOVED AND REPLACED THE ANGLE IAW SRM 51-40-02 AND SRM 51-40-02

Part: UNKNOWN — UNKNOWN (APU) · airframe 26,578 hrs · 8,192 cycles

APU STARTED, AIR OK. NO ELECTRIC, NO FREQ/VOLTS. ACFT GROUNDED. ACCOMPLISHED OPS TEST FOR APU AC GENERATION, TEST PASS REF MM 24-21-00-700-803, STEP E. GROUND VERIFICATION CHECKED GOOD IAW MM 24-21-00-700-803.

Part: FMC — FAILED (EE BAY) · airframe 26,193 hrs · 8,064 cycles

NR 2 FMC/CDU ERRORS ACFT GROUNDED. REPLACED NR 2 FMC COMPUTER. OPS CHECKED GOOD IAW MM 34-61-02. GROUND VERIFICATION TESTED GOOD.

Part: FMC — FALSE INDICATION · airframe 26,193 hrs · 8,064 cycles

FMC DISAGREE ON PUSH BACK, ON RETURN TO GATE, FMC DISAGREE WARNING WENT AWAY. ACFT GROUNDED. ACCOMP FIM 34-61-T835. FMC DISAGREE DOES NOT SHOW. INTERMITTENT FAULT. NO FAULTS AT THIS TIME.

Part: RESOLVER — WORN (THROTTLE STAND) · airframe 26,150 hrs · 8,053 cycles

NR 2 THROTTLE LEVER LOOSE, PLAY APPROX .2500". ACFT GROUNDED. APPEARS TO HAVE PLAY IN RT THROTTLE PACK. FOUND RT AUTOTHROTTLE BRAKE & THRUST LEVER RESOLVER TO HAVE EXCESSIVE PLAY. REPLACED RT AUTOTHROTTLE GEARBOX REF MM 22-31-91-400-801. ACCOMPLISHED AUTOTHROTTLE BRAKE ASSY TEST REF MM 76-11-05-820-802-F00 WITHIN LIMITS.

Part: SHIM — WORN (NR 2 ENGINE) · airframe 25,947 hrs · 7,994 cycles

FAN BLADE SHIMS REQUIRE REPLACEMENT DUE MISSING MOLYDAG. FAN RETAINING FLANGE AXIAL STOP PINS DETERIORATED. FAN DISK / RETAINING RING ELASTOMER SPACERS DETERIORATED. ACFT GROUNDED. REPLACED FAN BLADE SHIMS REF TASK CARD 78472002 FOR INSTALLATION. REPLACED FAN RETAINING FLANGE AXIAL STOP PINS AS A FULL SET REF AMM SUB TASK 72-21-01-30-001 F00 FOR REMOVED AND SUB TASK 72-21-01-430-00-F00 FOR INSTALL. REPLACED FANDISK / RETAINING RING ELASTOMER SPACERS REF TASK CARD 7872002.

Part: WARNING LIGHT — FALSE ACTIVATION (FMC) · airframe 25,851 hrs · 7,963 cycles

AFTER POWER TRANSFER FROM APU TO GEN DURING AFTER START CHECKLIST - RECEIVED AN FMC DISAGREE LIGHT. ACFT GROUNDED. RAN QRH CHECKLIST, OPS NORMAL.

Part: OVERHEAT SENSOR — FAILED (TAILPIPE) · airframe 25,851 hrs · 7,964 cycles

AFTER TAKE OFF WITH APU OFF. RECEIVED AN OVERHEAT DETECTOR AND WITH APU DETECTOR INOPERATIVE LIGHT. RETURNED TO DEPARTURE. ACFT GROUNDED. VERIFIED FAULT. REPLACED APU TAIL PIPE OVERHEAT DETECTOR ASSY WITH SERVICEABLE ONE. ACCOMP APU FIRE DETECTION OPS TEST, TEST PASS REF MM 26-15-00-710-801 & 26-15-01-400-802.

Part: CONTROL VALVE — INOPERATIVE (LT A/C PACK) · airframe 25,777 hrs · 7,944 cycles

PRIOR TO TAXI THE LT PACK OVER HEAT LIGHT ILLUMINATED. ACFT GROUNDED. REPLACED LT PACK TEMP CONTROL VALVE IAW AMM 21-51-10-400-801, OPS & BITE CK GOOD IAW AMM 21-61-00-700-806-002.

Part: FMC — UNKNOWN · airframe 25,745 hrs · 7,935 cycles

ON THE GROUND, FMC DISAGREE DISPLAYED. ACFT GROUNDED. PERFORMED QRH 11-2, OPS NORMAL.

Part: FMC — FALSE INDICATION · airframe 25,741 hrs · 7,932 cycles

FMC DISAGREE LIGHT CAME ON. ACFT GROUNDED. ACCOMPLISHED QRH CHECK LIST. SYS RESET.

Part: RADIO — UNKNOWN (HF SYS) · airframe 25,661 hrs · 7,910 cycles

NR 1 & 2 HF RADIOS GARBLED IN RECEIVE MODE ONLY. TRANSMIT OK, DATA OK JUST WEAK TO RECEIVE. ACFT GROUNDED. PERFORMED BITE CHECK OF HF SYS, NO FAULTS FOUND IAW AMM TASK 23-11, TASK 801. PERFORMED OPS CHECK OF HF SYS IAW AMM TASK 23-11.

Part: PANEL — LOOSE (NR 1 FAN DUCT) · airframe 25,566 hrs · 7,874 cycles

NR 1 ENGINE FAN DUCT PANELS LOOSE, 1130 -1200 O`CLOCK POSITION AND 230- 300 POSITION AFT LOOKING FORWARD. ACFT GROUNDED. REMOVED PANELS AS REQUIRED, INSTALLED SERVICEABLE PANELS IAW AMM 72-23-07-400-801-F00.

Part: PROBE — DIRTY (NR 1 ENGINE) · airframe 25,500 hrs · 7,855 cycles

DIAGNOSTICS REPORTS NR 1 ENGINE TREND DATA SHOWS A SHIFT IN DELTA CRUISE AND TAKE-OFF MARGIN INDICATIVE OF EGT INDICATION ERRORS. ACFT GROUNDED. FOUND T 49.5 SENSORS (EGT) S1 AND S4 TO BE HIGH (BEFORE READINGS) S1- 92.88, S2-48.40, S3-52.09, AND S4-108.96 CLEANED T 49.5 PROBES, SYS OP CHECKS GOOD, (AFTER READINGS) S1 57.92, S2-34.14, S3-42.27, S4-73.14.

Part: TRANSCEIVER — FAILED (WX RADAR SYS) · airframe 25,497 hrs · 7,854 cycles

BOTH SCREENS (MAP) SHOW PWS FAIL. ACFT GROUNDED. WXR FAIL LIGHT ILLUMINATED ON BOTH PANELS. REPLACED WEATHER RADAR R/T REF AMM 34-43-41. OPS CHECK NORMAL.

Part: SLAT SYSTEM — FAILED (NR 4 SLAT) · airframe 25,357 hrs · 7,809 cycles

AFTER LEVEL OFF AND APPROACHING OCEANIC AIRSPACE NR 4 L/E FLAP TRANSIT LIGHT (AMBER) BLINKED AT LEAST 3 TIMES AT FL350 AMD 0.79 MACH. ACFT GROUNDED. DIVERSION TIME - 45 MINS. R & R NR 4 L/E SLAT RETRACT PROXIMITY SENSOR REF 27-88-11. PERFORMED L/E PROXIMITY SENSOR TEST, TESTED NORMAL REF MM 27-88-11.

Part: WARNING LIGHT — ILLUMINATED · airframe 25,288 hrs · 7,789 cycles

AUTO FAIL & ALTN CAUTION LIGHTS ON OVHD PRESS CONTROL ILLUMINATED. ACFT GROUNDED. CYCLED PRESSURIZATION MODE SELECTOR SWITCH TO MANUAL AND BACK TO AUTO, AUTOFAIL & ALT LIGHT STAYS EXTINGUISHED. OK FOR SERVICE.

Part: INDICATOR — FALSE INDICATION (APU OIL FILTER) · airframe 25,241 hrs · 7,777 cycles

APU OIL FILTER DELTA-P INDICATOR EXTENDED, ACFT GROUNDED. R & R APU OIL FILTER & RESET INDICATOR BUTTON REF AMM TASK 49-91-13-600-801.

Part: FMC — MALFUNCTIONED · airframe 24,684 hrs · 7,631 cycles

FMC DISAGREE AFTER START. PERFORMED QRH PROCEDURE - OPS NORMAL.

Part: VALVE — INTERMITTENT (FUEL CROSSFEED) · airframe 24,678 hrs · 7,630 cycles

FUEL CROSSFEED VALVE LIGHT ILLUMINATED INTERMITTENTLY DURING FLIGHT WITHOUT SELECTING THE OPEN POSITION. WHEN THE LIGHT IS ILLUMINATED, IT IS IN THE BRIGHT MODE. LIGHT CYCLES FROM BRIGHT TO OFF THROUGHOUT THE FLIGHT. ACFT GROUNDED. INBOUND CREW REPORTS FUEL BURN NORMAL. VALVE OPERATION NORMAL IAW AMM 28-22-21. INSPECTED VALVE & CONNECTOR. ALL CHECKS GOOD. VISUALLY CONFIRMED VALVE OPERATION. OK FOR SVC.

Part: ACTUATOR — FAILED (FUEL CROSSFEED) · airframe 24,684 hrs · 7,631 cycles

ON APPROACH INTO PORTLAND, THE FUEL CROSSFEED LIGHT ILLUMINATED BRIGHT AND REMAINED ON TO THE GATE. REPLACED FUEL CROSSFEED ACTUATOR REF MM 28-22-21-00-804 AND 28-22-21-400-804. OPS LEAK CHECKS GOOD.

Part: CONTROL MODULE — INOPERATIVE (CABIN PRESSURE) · airframe 24,485 hrs · 7,579 cycles

ON THE PRESSURIZATION CONTROL PANEL,THE FLIGHT ALTITUDE DISPLAY IS INOPERATIVE, ONLY RANDOM LINE SEGMENTS ARE ILLUMINATED. R & R CABIN PRESSURE CONTROL MODULE REF 21-31-02-400-801, OPS CK OK, GROUND VERIFICATION CK OK.

Part: SATCOM — MALFUNCTIONED · airframe 24,485 hrs · 7,579 cycles

SATCOM, THERE IS NO SAT PROMPT AVAILABLE AT 4L ON THE MCDU. ACCOMPLISHED SATCOM COMMUNICATION SYS TEST IAW AMM TASK 23-15-00-730-801. VERIFIED OUTGOING CALL AND INCOMING CALL VOICE TEST GOOD WITH DISPATCH-A IN DIRECTORY.

Part: VALVE — FAILED (NR 1 ENGINE) · airframe 24,447 hrs · 7,570 cycles

ENGINE ANTI ICE NR 1 COWL VALVE OPEN LIGHT REMAIN BRIGHT BLUE. WHEN SELECTED TO ON. SELECTION AT FL260, BRIGHT BLUE, DURING DESCENT WENT DIM AT FL180. AT 10000 FT WENT BRIGHT AGAIN WHILE IN CLOUDS. REMAINED BRIGHT BLUE UNTIL LANDING. REPLACED NR 1 ENG TAI VALVE, LEAK AND OPS CHECKED GOOD IAW MM 30-21-11. VERIFIED THAT LIGHTS WORKED NORMALLY IAW MM 30-21-11.

Part: CONTROL VALVE — FAULTED (A/C BAY, LT PAC) · airframe 24,382 hrs · 7,557 cycles

LT PACK LIGHT ILLUM AFTER START DURING SYS RECALL. ACFT GROUNDED. REPLACED LT PACK TEMP CONTROL VALVE REF MM 21-51-10. OP CHECK GOOD. BITE CHECKED LT PACK TO VERIFY FAULT CLEARED REF MM 21-61-00 BITE CHECK GOOD. RESET PACK CONTROLLER, OK FOR SERVICE.

Part: UNKNOWN — UNKNOWN (SATCOMM) · airframe 24,265 hrs · 7,524 cycles

SATCOMM PROMPT IS NOT AVAILABLE IN THE MCDU. ACFT GROUNDED. UNABLE TO DUPLICATE DEFECT, ALL LIGHTS WERE GREEN. R & R SATCOM TRANSCEIVER, REF MM 23-15-00, OPS CHECK NORMAL.

Part: SATCOM — MALFUNCTIONED · airframe 24,233 hrs · 7,518 cycles

NO SATCOM PROMPT ON MCDU MENU PAGE. SATCOM PROMPT ON MCDU ILLUMINATED AFTER TRANSCEIVER FROM EXTERNAL POWER TO APU ELECT POWER SATCOM, OPS NORMAL IAW 23-15-00-730-801. GROUND VERIFICATION TEST SUCCESSFUL.

Part: ACTUATOR — LEAKING (NR 2 VSV) · airframe 24,205 hrs · 7,512 cycles

ON PDC WALKAROUND, FOUND FUEL LEAKING UNDER NR 2 ENGINE. REMOVED NR 2 VSV ACTUATOR IAW MM 75-31-01-00-8025. A-F. INSTALLED NR 2 ENG VSV ACTUATOR IAW AMM 75-31-01-400 LEAK AND ACTUATORS TEST GOOD IAW AMM 71-00-00-700.

Part: WARNING LIGHT — FALSE ACTIVATION (FMC) · airframe 23,663 hrs · 7,359 cycles

FMC DISAGREE ILLUMINATED DURING TAXI. CLEARED IAW QRH PROCEDURE.

Part: WARNING LIGHT — INTERMITTENT (LT A/C PACK) · airframe 23,626 hrs · 7,350 cycles

WHEN PRESSING MASTER RECALL, LT PACK LIGHT ILLUMINATES. WHEN PRESSED AGAIN, PACK LIGHT EXTINGUISHES, REF CHECKLIST. PERFORMED PACK ZONE TEMP CONTROLLER BITE REF MM 21-62, TASK 801. BITE CHECKED OK. RAN LT PACK THEN REACCOMPLISHED BITE, BITE PASSES, INTERMITTENT FAULT. NO HISTORY 30 DAYS.

Part: IGNITION UNIT — FAULTED (APU) · airframe 23,556 hrs · 7,332 cycles

DURING MX TROUBLESHOOTING, CSS FAILED, FAULT LIGHT. FOUND FAULT CODE 49-41011. NO FLAME SHUTDOWN. MADE 2 START ATTEMPTS WITH NO EGT RISE NOTED, FAULT LT ILLUM AND FAULT CODE 349-41011. LATCHED ON EACH ATTEMPT. ACCOMP. FIM TASK 49-40, TASK 802, FOR MAINT. MESSAGE 49-41011, STEPS A- F (3). REPLACED IGNITER PLUG, REF STEP F(4), NO HELP. REPLACED IGNITER LEAD, REF STEP F(5), NO HELP. REPLACED IGNITION UNIT REF STEP F(6). APU STARTS SUCCESSFUL, MAINT MESSAGE DOES NOT SHOW FOR LAST APU CYCLE. STARTED APU AGAIN, NO MESSAGE. GROUND OPERATION CHECKED GOOD.

Part: SHUTOFF VALVE — FAILED (NR 1 ENGINE) · airframe 23,549 hrs · 7,330 cycles

LEFT DUCT PRESSURE BELOW 18 PSI (AT 16PSI) WITH IDLE POWER DURING HIGH STAGE CROSSOVER CHK. ACFT GROUNDED. R & R NR 1 ENG PRSOV AND LEAK AND OPS CHECKED GOOD IAW MM 36-11-04 ACP ENG BLEED AIR CROSSOVER OPS TEST IAW MM 36-11-00 TEST GOOD.

Part: INTERCOSTAL — CRACKED (BS 394) · airframe 23,549 hrs · 7,330 cycles

MAIN CABIN INTERCOSTAL AT BS 394 AND RBL 10 IS CRACKED AT FASTENER HOLE. R & R INTERCOSTAL UPPER ANGLE BS 394RBL10 IAW SRM 51-40-02.

Part: FLOORBEAM — CORRODED (BS 312) · corrosion level 2 · airframe 23,549 hrs · 7,330 cycles

MAIN CABIN, TOPSIDE OF FLOORBEAM CORRODED AT BS 312, RBL 12. CUTOUT DAMAGED AREA, FABRICATED AND INSTALLED REPAIR IAW REO-G15772, REV B. PERFORMED FPI ON NEW UPPER CHORD IAW SOPM 20-20-02, ACCOMPLISHED HFEC INSPECTION OF CUTOUT IAW SRM 53-10-51 AND 737 NDT MAN 51-00-00. ALODINED AND PRIMED IAW SRM 51-20-01.

Part: FLOOR PANEL — CORRODED (BS 340) · corrosion level 2 · airframe 23,549 hrs · 7,330 cycles

MAIN CABIN, FLOOR STRUCTURE CORRODED ON TOP AT BS 340 LBL 12. REMOVED OLD PANEL BREAK IAW SRM 51-40-02. LOCATED AND DRILLED NEW PANEL BREAK IAW SRM 51-40-02 AND DWG 141A5410, REV -INSTALLED NEW PANEL BREAK IAW SRM 51-40-02.

Part: FLOOR PANEL — CORRODED (BS 322) · corrosion level 2 · airframe 23,549 hrs · 7,330 cycles

MAIN CABIN, FLOOR STRUCTURE CORRODED ON TOP AT BS 322, LBL. 12. GROUNDED. REMOVED FLOOR PANEL IAW SRM 51-40-02. LOCATED AND DRILLED NEW FLOOR PANEL IAW SRM 51-40-02 AND DWG 141A5410. REV -. INSTALLED NEW FLOOR PANEL IAW SRM 51-40-02.

Part: INTERCOSTAL — CRACKED (BS 394) · airframe 23,549 hrs · 7,330 cycles

MAIN CABIN INTERCOSTAL AT BS 394 AND BL 0 IS CRACKED AT FASTENER HOLE. ACFT GROUNDED. R & R INTERCOSTAL UPPER ANGLE AT BS 394, BL 0 IAW SRM 51-40-02.

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 23,548 hrs · 7,330 cycles

R1 WINDOW REMOVED DUE TO SCRATCHES AND FOUND LOWER WINDSHIELD GLASS CRACKED ADJACENT TO FASTENER LOCATIONS. R & R R-1 WINDOW ASSY IAW MM 56-11-11-400-801. LEAK AND OPS CHECKED GOOD.

Part: WARNING LIGHT — FALSE ACTIVATION (CABIN PRESSURE) · airframe 23,320 hrs · 7,269 cycles

AUTO FAIL AND ALTERNATE ILLUMINATED ON PRESSURIZATION CONTROL PANEL. PERFORMED DCPC BITE REF FIM 21-31, TASK 801. NO EXISTING FAULTS DCPC 1 AND 2. DCPC 2 SHOWS FAULT HISTORY LEG 00 FC 001. INITIAL EVAL NO EXISTING FAULTS (TASK 804). NO HISTORY 30 DAYS. AUTO FAIL AND ALTN LIGHTS EXTINGUISHED.

Part: UNKNOWN — UNKNOWN (COWL VALVE) · airframe 23,205 hrs · 7,232 cycles

WHEN RT ENGINE ANTI-ICE IS TURNED ON, COWL VALVE OPEN LIGHT COMES ON, THEN AFTER A FEW SECONDS FLICKER BETWEEN BRIGHT TO DIM OR STEADY BRIGHT. THIS TAI INDICATES GREEN. PERFORMED GROUND VERIFICATION OPS TEST 30-21-00-710-801. ALL TESTS SUCCESSFUL. ACFT GOOD FOR CONTINUE SERVICE.

Part: INDICATOR — ACTIVATED (NR 1 IDG) · airframe 23,179 hrs · 7,225 cycles

NR 1 ENG IDG DPI EXTENDED. VERIFIED NR 1 ENG IDG DPI EXTENDED THIRD EXTENSION DECAL REFLECTS THE SAME. R & R FILTERS AND OIL, CHECKED GOOD IAW FIM TASK 24-11-803 LEAK CHECKED GOOD IAW AMM 24-11-00-700-802.

Part: WARNING LIGHT — FALSE ACTIVATION (TEMP CONTROL) · airframe 22,891 hrs · 7,140 cycles

ON RECALL, LT PACK LIGHT ILLUMINATED. BITE SHOWS TEMP CONTROL VALVE FAULT ON NR 1 ZONE TEMP CONTROLLER. RAN BITE REF AMM 2-61-00, FAULT CLEARS AND OPS NORMAL.

Part: DRIVE UNIT — FAILED (WX RADAR) · airframe 22,767 hrs · 7,106 cycles

ON TAXI OUT TURNED WEATHER RADAR TO WX-T. PWS AND WEATHER RADAR INOPERATIVE. OPS TEST IAW MM TASK 34-43-00-710-802-001 SHOWS PWS AND WEAHTER RADAR INOPERATIVE FAULTING ANTENNA. R & R WEATHER RADAR ANTENNA DRIVE UNIT IAW MM 34-43-11-000-802. OPS TEST NORMAL IAW SAME REF. GROUND VERIFICATION SUCCESSFUL.

Part: HOSE — LEAKING (NR 2 ENGINE) · airframe 22,649 hrs · 7,069 cycles

DURING REMOVAL AND REPLACEMENT OF (TIME CHANGE UNIT) NR 2 ENG PRECOOLER CONTROL VALVE FAILED INSTALLATION TEST IAW AMM 36-12-02 (PART G) VALVE IS OPENING HALFWAY. ACFT GROUNDED. PERFORMED LEAK CHECK OF NR 2 ENG BLEED AIR SYS SENSE LINES IAW AMM 36-11-00. FOUND PRECOOLER CONTROL VALVE CONTROL PRESSURE FLEX SENSE LINE LEAKING. R & R FLEX LINE. OPS AND LEAK TEST OF PRECOOLER CONTROL VALVE CHECKS GOOD IAW AMM 36-12-02.

Part: ANTENNA — FAILED (WX RADAR) · airframe 22,273 hrs · 6,956 cycles

AFTER POWER UP, GRINDING NOISE HEARD FROM NOSE CONE AREA. WEATHER RADAR FAIL RT AND PWS FAIL MESSAGES SHOWN ON ND DISPLAY. ACFT GROUNDED. CONFIRMED WEATHER RADAR FAIL RT AND PWS FAIL MESSAGE ON ND. REPLACED WEATHER RADAR ANTENNA FLAT PLATE IAW 34-43-11-000-801/400-801 AND WX RADAR DRIVE UNIT IAW MM 34-43-11-000-802/400-802. WXR SYS OPS TEST NORMAL IAW 34-43-00-710-802-001.

Part: COMPUTER — MALFUNCTIONED (FMC) · airframe 22,404 hrs · 6,998 cycles

ON TAXI OUT, FMC DISAGREE MESSAGE. ACFT GROUNDED. CYCLED FMCS COMPUTER NR1 CB AND FMCS COMPUTER NR2 CB, IAW QRH 11.2- OPS CHECK NORMAL.

Part: TRANSCEIVER — FAILED (WX RADAR SYS) · airframe 22,099 hrs · 6,900 cycles

DURING CRUISE FLIGHT WHILE USING RADAR GOT AMBER WEATHER RADAR FAIL WARNING ON NAV DISPLAY. SHUT RADAR OFF. WEATHER RADAR SYSTEM TEST PASSED. R & R WEATHER RADAR TRANSCEIVER IAW MM 34-43-41, GROUND VERIFICATION TEST PASSED.

Part: TRANSCEIVER — DIRTY (WX RADAR) · airframe 22,081 hrs · 6,895 cycles

ON DESCENT, TURNED WEATHER RADAR ON, WX FAIL APPEARED ON MFD. TURNED OFF THEN ON RECEIVED WEATHER RADAR FAIL & NO PWS, TURNED OFF AND AS EXPECTED NO PWS REAPPEARED BELOW 1600. ACFT GROUNDED. ACCOMPLISHED GVI OF WEATHER RADAR TRANSCEIVER, FOUND TO COVERED IN DUST. REMOVED WEATHER RADAR TRANSCEIVER. VACUUMED DUST . VERIFIED BLOWER OPS NORMAL. INSTALLED ORIGINAL TRANSCEIVER, ACCOMPLISHED OPS TEST, TEST PASSES. REF MM 34-43-00-710-802-001 & 34-43-41-400-801.

Part: CONTROLLER — MALFUNCTIONED (CABIN PRESSURE) · airframe 22,040 hrs · 6,882 cycles

ON PREFLIGHT, FOUND AUTO FAIL ILLUMINATED WITH SWITCH IN AUTO MANUAL LIGHT WAS ALSO ILLUMINATED. GROUNDED ACFT. FOUND CABIN PRESSURE CONTROL FAULT TO BE A RECOVERABLE FAULT REF MEL 21-14C.

Part: FILTER — CLOGGED (NR 1 IDG) · airframe 22,040 hrs · 6,882 cycles

FOUND NR 1 ENGINE IDG DPI POPPED DURING S/C. ACFT GROUNDED. PERFORMED FIM TASK 24-11-00-810-803. REPLACED FILTER AND RESET DPI. DPI DIDN`T POP AGAIN. THIS WAS THE FIRST TIME POPPED AND WAS MARKED ACCORDINGLY ON DECAL.

Part: SEAL — UNBONDED (NR 1 ENGINE) · airframe 21,695 hrs · 6,788 cycles

NR 1 ENGINE, PLATFORM AT BLADE NR 4 HAS ELASTOMER SEAL UNBONDED. ACFT GROUNDED. R & R NR 4 & NR 16 BLADE PLATFORM IAW T/C 78472002, STEP 46. C/W ENG NR 1, TEST 7, VIBRATION SURVEY IAW T/C 78472002, STEP 53. VIBRATION SURVEY WITHIN LIMITS.

Part: SHIM — WORN (FAN BLADES) · airframe 21,695 hrs · 6,788 cycles

NR 1 ENGINE FAN BLADE SHIMS WORN, ACFT GROUNDED. R & R NR 1 ENG FAN BLADE SHIMS, REF T/C 78472002, STEP 44.

Part: FMC — FAILED (EE BAY) · airframe 21,701 hrs · 6,790 cycles

NR 2 FMC SINGLE OPS, F/OS PFD HAS VTK AND MAP FLAGS. ACFT GROUNDED. REMOVED NR 2 FMCS COMPUTER IAW AMM 34-61-02-000-801. INSTALLED NR 2 FMCS COMPUTER IAW AMM 34-61-02-400-801. LOADED SOFTWARE INTO LT AND RT FMCS COMPUTERS IAW 34-61-00-470-805. PERFORMED SOFTWARE CONFIGURATION CHECK ON LT AND RT FMCS COMPUTERS IAW AMM 34-61-00-750-801. CONFIGURATION IS GOOD ON LT AND RT COMPUTERS. PERFORMED ZERO FUEL WEIGHT SETTING IAW AMM 34-61-00-400-801, ZERO FUEL SETTING IS GOOD. PERFROMED FMCS OPS TEST IAW AMM 34-61-00-710-801. OPS TEST IS GOOD.

Part: CONTROL PANEL — ARCED (FLIGHT DECK) · airframe 21,485 hrs · 6,714 cycles

DURING SERVICE CHECK, FOUND MCP VERTICAL SPEED LCD WINDOW HAS A WHITE ARC DISPLAY. ACFT GROUNDED. R & R DFCS MCP REF AMM TASK 22-11-34/401. ACCOMPLISHED DFCS LRU INTERFACE MCP TEST GP32 REF AMM TASK 22-11-34/501 AND LAND VERIFY TEST GP49 REF AMM TASK 22-11-00/201. OPS CK NORMAL. ALSO ACCOMPLISHED HGS TESTS REF SMM 34-36-00, OPS CK NORMAL.

Part: SEAL — MISSING (NR 2 ENGINE) · airframe 21,485 hrs · 6,714 cycles

WHILE PERFORMING FAN BLADE LUBE TASK CARD 78472002. FOUND NR 16 PLATFORM MISSING RUBBER SEALS. ACFT GROUNDED. R & R NR 16 PLATFORM IAW TASK CARD NR 7847002. NR 2 ENG REQUIRES TEST 7. VIBRATION SUEVEY REF AMM 71-00-00, PB 501. COMPLETED NR 2 ENG ENGINE RUN. VIBRATION SURVEY IS WITHIN LIMITS REF AMM 71-00-00.

Part: POSITION SWITCH — FAULTED (APU DOOR) · airframe 21,242 hrs · 6,643 cycles

DURING ACCOMPLISHEMENT OF APU INTERROGATION, CURRENT STATUS FAULTED 49-15218, INLET DOOR DID NOT CLOSE. ACFT GROUNDED. R & R AIR INLET DOOR POSITION SWITCH IAW AMM TASK 49-15-41-000-801 AND 49-15-41-400-801.

Part: FILTER — CLOGGED (PAX CABIN) · airframe 21,225 hrs · 6,639 cycles

F/A REPORTS ABOUT CABIN TEMPERATURE, SUGGEST THAT "FWD CABIN" AND "AFT CABIN" CONTROL KNOBS ARE PRODUCING ERRATIC SUPPLY TEMPS THAT ARE INCONSISTENT WITH KNOB POSITION. FOR INSTANCE "FWD CAB" AT 11 O'CLOCK PRODUCES 20 DEG SUPPLY TEMP CONT FROM FLIGHT DECK DIFFICULT/INCONSISTENT WITH ALL TEMP SELECTORS OFF LT PACK TEMP AT 28 DEG RT PACK 23 DEG C. ACFT GROUNDED. FOUND BOTH FWD & AFT CABIN TEMP SENSOR FILTERS COMPLETELY CLOGGED. CLEANED & REINSTALLED FILTERS REF MM 21-61-06. OPS CK OK RAN PACKS NO ERRATIC FLUCTUATIONS NOTED. NO HISTORY 90 DAYS.

Part: ACTUATOR — FAILED (RAM AIR DOOR) · airframe 20,989 hrs · 6,569 cycles

AIR CONDITIONER ON RECALL AND "PACK" LT ILLUMINATED. EXTINGUISH ON RESET. GROUNDED, YES. PERFORMED BITE TEST TO VERIFY THE FAULT. FOUND RAM AIR ACTUATOR TO BE INOPERATIVE. R & R LT RAM AIR ACTUATOR IAW AMM 21 51 21. PERFORMED BITE CHECK IAW AMM 21 51 21. CHECK NORMAL.

Part: WARNING LIGHT — ILLUMINATED (LT A/C PACK) · airframe 20,895 hrs · 6,538 cycles

ON LANDING RECALL "AIR COND" LIGHT ILLUMINATED WITH LEFT PACK LIGHT. LEFT PACK LT WENT OUT DURING RESET. RAN PACK / ZONE TEMP CONTROLLER BITE FOR NR 2 PACK. OPS CHECKED GOOD. INITIALLY THE "RAM AIR ACT" IS WHAT FAULTED BUT AFTER RESET AND TESTING SEVERAL TIMES THE FAULT DID NOT RETURN. GROUND FUNCTIONAL TEST GOOD AMM 21-62-00-810-801.

Part: WARNING LIGHT — ILLUMINATED (FMC) · airframe 20,322 hrs · 6,385 cycles

"FMC DISAGREE" ANNUNCIATION ILLUMINATED ON TAXI OUT. ACCOMPLISHED QRH PROCEDURE. ANNUNCIATOR REMAINED OFF.

Part: WARNING LIGHT — FALSE ACTIVATION (A/C PACK) · airframe 20,302 hrs · 6,378 cycles

RT PACK LIGHT ILLUMINATED AFTER START RESETS WITH MASTER CAUTION. REMOVED AND REPLACED RT PACK TEMPERATURE CONTROL VALVE. TEMP CONTROLLER BITE TEST COMPLIED WITH. CHECKED GOOD, NO FAULTS IAW AMM 21-51-10-000-801.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 20,291 hrs · 6,375 cycles

RT PACK LIGHT ILLUMINATES ON MASTER CAUTION RECALL. THE LIGHT GOES ON MASTER CAUTION RESET. ACCOMPLISHED BITE ON NR 2 PACK ZONE TEMP CONT PER FIM TASK 21-62-00, OPS CHECKED NORMAL. GROUND VERIFICATION SUCCESSFUL.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 20,274 hrs · 6,371 cycles

ON PRESSING RECALL AT EEP. FOR A SYSTEMS CHECK, THE RIGHT PACK AMBER LIGHT ILLUMINATED ON OVERHEAD PER DIRECTION OF QRH. LIGHT EXTINGUISHED ON MASTER CAUTION CLEAR. PER QRH NO FURTHER ACTION REQUIRED. PERFORMED PACK/ZONE TEMP CONTROLLER BITE TEST FOR RT PACK REF MM 21-61-00. CONTROLLER FAULTED FOR RT PACK TRIM CONTROL VALVE. REPLACED RT PACK TRIM CONTROL VALVE PER AMM 21-51-10-400-801. PERFORMED BITE CHECK 21-61-00-700-806-002 TO CLEAR FAULTS. OPERATED RIGHT PACK NO LEAKS AT VALVE NOTED. OPS NORMAL. PERFORMED BITE NO FAULTS FOUND.

Part: UNKNOWN — MALFUNCTIONED (AC BAY) · airframe 20,017 hrs · 6,311 cycles

RIGHT PACK COMES ON WHEN RECALL IS PUSHED GOES OUT WHEN RESET IS PUSHED. PERFORMED BITE CHECK ON NR 1 & NR 2 PACK ZONE TEMP CONTROLLERS PER FIM TASK 21 62 00 810 801 NR 2 PACK ZONE CONTROLLER HAD A PACK SENSOR FAULT RESET FAULT PER SAME REFERENCE. PERFORMED BITE CHECK ON NR 2 CONTROLLER OPS CHECK GOOD. NO FAULTS NOTED.

Part: DRAIN MAST — CRACKED (APU) · airframe 19,700 hrs · 6,204 cycles

APUR SHROUD AND HYD DRAIN MAST AFT OF LT W/W APPEARS CRACKED AT THE BASE ON THE T/E. VERFIED CRACK USING HFEC 2.0 IN ON OTBD SIDE AND 3.0 IN ON INBD SIDE PER BOEING NDT MANUAL 51 00 00 FIG 23 PART 6. REPLACED APU FUEL FEED LINE SHROUD DRAIN MAST REF MM 25 25 070 420 801. USED BMS 1826B 1/4 SEALANT FOR FILLET SEAL PER TYP EA 5100 01004.

Part: APU — MAKING METAL (APU BAY) · airframe 19,272 hrs · 6,067 cycles

APU WILL NOT START FAULT LIGHT ILLUMINATED. DURING T/S OF APU FAULT FOUND THE MAGNETIC DRAIN PLUG COVERED WITH MAGNETIC SILVER COLORED PARTICLES. IAW FIM TASK 49 91 81 200 801 APU REPLACEMENT IS REQUIRED. APU CHANGE COMPLETED. NO DEFECTS NOTED.

Part: UNKNOWN — MALFUNCTIONED (FMC) · airframe 19,189 hrs · 6,037 cycles

ON TAXI GOT FMC DISAGREE WARNING. ACCOMPLISHED QRH PROCEDURE. OPS CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 18,831 hrs · 5,928 cycles

WHILE PERFORMING MAINT IAW TC 78233001 BATTERY PACK AND POWER SUPPLY AT M1675 PERFORMED UN SAT. REPLACED BATTERY PACK AND POWER SUPPLY AT M1675 TESTS GOOD. REF AMM 33 51 06.

Part: UNKNOWN — MALFUNCTIONED (FMC) · airframe 18,786 hrs · 5,916 cycles

"SINGLE FMC OPERATION" MSG DISPLAYED ON BOTH FMC'S. FMC RETURNED TO NORMAL AFTER PWR SWITCHING. OPS NORMAL.

Part: POWER UNIT — FAULTY (E&E BAY) · airframe 18,729 hrs · 5,899 cycles

DURING APU START ON EXT PWR O/BS'D BATTERY DISCHARGE LT "ON". VIS INSP'D START CONVERTER & START POWER UNITS IN E & E. OBS'D APU START CONV UNIT C/B ON P91 115VAC TRANSFER BUS 1 OUT (A 11). REPLACED START POWER UNIT MM 49 41 71 000 801 & 400 801. APU START & OPS CHECK PASS MM TASK 49 41 00 860 801.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 18,680 hrs · 5,875 cycles

BATTERY DISCHARGE LIGHT ILLUMINATED DURING APU START DC AMPS SHOWED 295 AMPS AND 22 VOLTS LIGHT WENT OUT AFTER APU START. GROUND FUNCTIONAL CHECK OF APU REF FIM49 45 00, OPS CHECK NORMAL.

Part: IDG — FAULTY (NR 2 ENGINE) · airframe 17,521 hrs · 5,495 cycles

DRIVE LIGHT ON ENG NR 2 NOT ILLUMINATED WITH ENG NOT RUNNING. REPLACED NR 2 ENG IDG OPS & LEAK CHECK GOOD REF MM 24 11 11 PG 401. OPS CHECK GOOD.

Part: WARNING SYSTEM — ACTIVATED (BLEED AIR SYS) · airframe 16,982 hrs · 5,317 cycles

AFTER 27K BUMP TAKEOFF FROM MEX NR 2 BLEED TRIP OFF LIGHT ILLUMINATED. QRH PROCEDURE WAS FOLLOWED & THE LIGHT EXTINGUISHED. PRESSURIZATION RETURNED TO NORMAL. ONCE LEVEL AT FL 340 CABIN PRESSURIZATION ON SCHEDULE AT 6800 FT CABIN ALTITUDE & LEFT PACK STABLE AT 40 PSI. RIGHT STABLE AT 43 PSI. CABIN RATE OF CLIMB STABLE AT ZERO. PERFORMED PNEUMATIC T/S PER AMM 36 00 00. ALL OPS CHECKS NORMAL. A/C GOOD FOR SERVICE. VERIFICATION FLIGHT SUCCESSFUL.

Part: TRANSCEIVER — MALFUNCTIONED (E&E BAY) · airframe 16,769 hrs · 5,247 cycles

HF 2 FAILED ON PREFLIGHT. PROBLEM CONFIRMED RERACKED NR 2 HF TRANSCEIVER GROUND FUNCTION CHECK GOOD IAW MM 23 11 00 AIRCRAFT OKAY FOR ETOPS OPERATIONS. PULLED NR 2 HF CIRCUIT BREAKER AND RESET SAME P6 1 D 2 MIG 51A 37062.

Part: UNKNOWN — MALFUNCTIONED (FMC) · airframe 16,752 hrs · 5,242 cycles

GOT "FMC DISAGREE" MESSAGE ON TAXI OUT IN SAN. FOLLOWED QRH 11.2. RESET NORMALLY.

Part: APU — MALFUNCTIONED (TAIL) · airframe 16,517 hrs · 5,166 cycles

STRONG UNPLEASANT ODOR FROM AIR CONDITIONING SOON AS PACKS TURNED ON. USING BLEED AIR FROM APU A/C AIR HAS LIGHT ODOR. FOUND OIL ODOR IN APU BLEED AIR DUCT DOWNSTREAM OF BLEED AIR VALVE. REPLACED APU REF 49 11 00 400 803 STEP L PG 10. COMPLETED INSTALL OF APU IAW 49 0 400 803. OPS AND LEAK CHECK GOOD IAW 49 11 0 400 803.

Part: SEAL — UNBONDED (NR 2 ENGINE) · airframe 16,159 hrs · 5,057 cycles

WHILE PERFORMING T/C 78472002 (NR 2 ENGINE FAN BLADE LUBRICATION) FOUND NR 22 PLATFORM'S SEAL UNBONDED (4 INCHES IN LENGTH). REMOVED LOOSE SEAL SECTION. RE-INSTALLED THE NR 22 PLATFORM REF T/C 78472002. REPLACED NR 2 ENGINE NR 22 FAN BLADE PLATFORM REF AMM 72-21-02-000-802-F00.

Part: INDICATION SYS — MALFUNCTIONED (CABIN PRESSURE) · airframe 16,083 hrs · 5,038 cycles

FLIGHT ALTITUDE WINDOW ON PRESSURIZATION PANEL UNRESPONSIVE WILL NOT CHANGE. PERFORMED FIM TASK 21 31 00 810 801 NO DEFECT NOTED. NO FAULTS FOUND, NO HISTORY PAST 30 DAYS. ACFT OK FOR SERVICE. SEAMC NOTIFIED.

Part: UNKNOWN — MALFUNCTIONED (ELECTRICAL SYS) · airframe 15,997 hrs · 5,011 cycles

DURING ENGINE START APU POWER FAILED AFTER START COMPLETE HAD AN EEC ALTN LIGHT ON ENG NR 1. PERFORMED FIM TASK 73 05 00 810 811 F00 ENG NR 1 ALTN LIGHT ON. ALL LOGGED FAULTS APPEAR RELATED TO LOSS OF APU ELECTRICAL POWER. APU GENERATOR SYSTEM CHECKED & RELEASED PER MEL 24 2B. PERFORMED FIM 24 21 00 810 801. NO FAULTS. PERFORMED OPERATIONAL TEST OF AC GEN & CTRL SYSTEM. OPS CHECK GOOD.

Part: FMC — FAILED (E&E BAY) · airframe 15,963 hrs · 5,002 cycles

VTK/MAP ON NR 1 CDU UNABLE TO RESTORE NR 1 FMC SINGLE FMC OPS. DIVERSION TIME 58 MINUTES. CONFIRMED DEFECT NR 1 FMCU INOP R FMC LOGGED L FMC FAIL. CYCLED PWR TO L FMCU DISPLAY RETURNED L FMC SHOWS FAIL LAST FLT. REPLACED NR 1 FMC COMP L FMC CKS OK. GRD FUNCT CHECK SUCCESSFUL REF 34 61 02 PB401.

Part: UNKNOWN — MALFUNCTIONED (HF COMM) · airframe 15,814 hrs · 4,963 cycles

UNABLE TO TRANSMIT OR RECEIVE ON HF1 RETURNED AT LEAST 4 TIMES. DATA SEEMED TO WORK INTERMITTANTLY. "NO COMM" MESSAGE DISPLAYED OFTEN DURING FLIGHT. HF2 WORKED FINE ON ALL FREQUENCIES. PERFORMED HF COMM SYSTEM TEST 23 11 00 NO FAULTS FOUND PERFORMED HF COMM OPS TEST 23 11 00 NO FAULTS FOUND. PERFORMED TASK 23 11 00 810 806 IN FIM NO FAULTS FOUND. SFO REPORTS 5X5 RADIO CHECK. NO HISTORY OF FAULT IN TRAX. CONFIRMED HF 1 OPERATING CORRECTLY.

Part: FILTER — DEFECTIVE (NR 2 IDG) · airframe 15,476 hrs · 4,850 cycles

NR 2 IDG DELTA P POPPED. PERFORMED IDG DIFFERENTIAL PRESSURE INDICATOR TASK REF FIM 24 11 00 810 803 OPS & LEAK CHECK GOOD.

Part: DISPLAY — DAMAGED (COCKPIT) · airframe 14,626 hrs · 4,588 cycles

THE RUBBER PAD IS COMING OFF THE F/O`S 6R LINE SELECT KEY ON THE FMC. REMOVED AND REPLACED F/O'S MCDU, OPS CHECK GOOD REF MM 34 61 01.

Part: PRESSURE SWITCH — FAULTY (NR 2 ENGINE) · airframe 14,492 hrs · 4,529 cycles

AT 1500FT ON FINAL RIGHT ENGINE "FILTER BYPASS" LIGHT ILLUMINATED. ALL ENG PARAMETERS APPEARED NORMAL. PERFORMED FIM 73 05 00 010 801 F00. NR 2 ENGINE EEC TESTED, TEST PASSED. FUEL FILTER REPLACED IAW 73 11 02 000 801 F00. NO CONTAMINATION NOTED. ENGINE RAN FOR 5 MINS. FILTER BYPASS LIGHT ILLUMINATED AFTER 1.5 MINS INTO ENGINE RUN. DIFFERENTIAL PRESSURE SWITCH REPLACED IAW 73 34 01 400 801 F00. REQUIRED IDLE POWER LEAK CHECK DUE TO PRESSURE SWITCH REPLACEMENT. ENG IDLE RUN CUTOUT FILTER BYPASS LIGHT REMAINED OUT, LEAK CHECK ACCOMPLISHED, NO LEAKS FOUND.

Part: OIL COOLER — CLOGGED (APU) · airframe 14,452 hrs · 4,516 cycles

APU LOW OIL PRESSURE CAUTION LIGHT ON OVERHEAD PANEL ILLUMINATED. APU SHUT DOWN AUTOMATICALLY. TOTAL RUN TIME FROM START AT GATE ABOUT 2+45 HOURS. FOUND APU OIL COOLER CLOGGED. REPLACED IAW AMM 49 91 41 400 801. PRECAUTIONARY REPLACED APU LUBE MODULE IAW 49 91 11 400 802. RAN APU FOR APPROX 10 MINUTES OPS AND LEAK CHECK OK.

Part: PRESSURE SWITCH — DEFECTIVE (APU) · airframe 14,434 hrs · 4,507 cycles

WHEN REQUIRED EN ROUTE SHUTTING DOWN APU LOW OIL PRESSURE LIGHT WAS ILLUMINATED. AFTER SHUT DOWN LIGHT WENT OUT. NO MASTER CAUTION LIGHT ILLUMINATED. PERFORMED FIM TASK 49 90 00 810 803. THRU STEPS F (3). REMOVED AND REPLACED LOW OIL PRESSURE SWITCH REF MM 49 94 22. OPS CHECK LEAK CHECK OK. NO FAULTS LOGGED.

Part: SWITCH — FAULTY (COCKPIT) · airframe 14,247 hrs · 4,452 cycles

WHILE PERFORMING TASK CARD 78273000 FMC CDU ENG FAULTS FOUND MSG 73 30311 START SWITCH SIGNAL AND ARINC BUS DATA DISAGREE. SHORT TERM FAULT. FAULT VERIFIED REF FIM 73 24 00 810 813 F00 FOUND NR 1 ENGINE START SWITCH FAULTY. REMOVED AND REPLACED SWITCH, OPS CHECK GOOD. REF AMM 80 11 00 FOR R&R/OPS CHECK. FMC CDU FAULT VERIFIED CORRECTED REF AMM 73 21 00 EEC TEST, SEAMC NOTIFIED.

Part: BLOWER — INOPERATIVE (WEATHER RADAR) · airframe 13,968 hrs · 4,367 cycles

JUST INSIDE SEDAR (OUTSIDE ETOPS AIRSPACE) THE WEATHER RADAR BEGAN TO INTERMITTENTLY BLANK OUT AND DISPLAY ONLY THE UPPER RIGHT QUADRANT OR THE RIGHT HALF OF DISPLAY FRC 34409031/34409032. CONFIRMED WRX FAULT. FOUND RT BLOWER INOP. REMOVED WRX RT & REPLACED RT BLOWER ASSEMBLY WITH NEW ONE. BLOWER TEST TEST PASS. RE-INSTALLED WXR RT. ACCOMP WXR SYS. OPS TEST, PASS GROUND VERIFICATION SUCCESSFUL. REF M/M'S34 43 51 400 801 34 43 41 400 801 & 34 43 00 710 802 001.

Part: PRESSURE SWITCH — MALFUNCTIONED (APU) · airframe 13,902 hrs · 4,343 cycles

POST A CHECK FLIGHT VERIFICATION FAILED APU STARTED NORMALLY AT 41000 RAN FOR APPROX 5 MINUTES THEN SHUT DOWN WITH OIL LOW PRESS LIGHT ILLUMINATED. REPLACED LOW OIL PRESSURE SWITCH PER MM 49 94 22 400 801. PERFORMED OPERATION AND BITE CHECK. OPERATION NORMAL, NO LEAKS AND NO NEW FAULTS.

Part: SENSE LINE — LEAKING (RT ACM) · airframe 13,834 hrs · 4,317 cycles

FOUND SENSE LINE LEAKING FROM RT ACM. REMOVED AND REPLACED SENSE LINE ON RT ACM, LEAK CHECK GOOD REF 21 51 05 802 002 PARG E STEP 3C AND 21 51 05 802 002 PARG H STEP 4C.

Part: COFFEEMAKER — MALFUNCTIONED (GALLEY) · airframe 13,806 hrs · 4,304 cycles

AT 1.5 HRS INTO FLIGHT AFT F/A REPORTED STRONG ODOR COMING FROM AFT GALLEY. A/C RT NO SMOKE OR HAZE SIMILAR TO PREVIOUS WRITE UP AS A METALLIC SMELL. ODOR REPORTED BY PASSENGER AS FAR FORWARD AS ROW 19. ODOR REMAINED STRONG FOR APPROX 40 MIN THEN STARTED TO DISSIPATE. RECIRC FANS & GALLEY POWER TURNED OFF NO IMMEDIATE CHANGE. DIVERSION TIME 83 MINUTES. PERFORMED CABIN ODOR T/S PER AMM 05 60 00 280 801C1, NO DEFECTS NOTED. ALL AREAS OF INSP FOUND CLEAN. PERF AFT DOOR AREA HEATER OPS TEST PER AMM 21 45 00 700 802. SYSTEM OPS NORMAL WITH NO SMELLS. RAN ENGS AND APU FOR BLEED SOURCES FOR PACKS. NO SMELLS NOTED FROM PACKS WITH 3 DIFF BLEED SOURCES. OPERATED ALL AFT OVENS COFFEEMAKERS AND LIGHTING FOR EXTENSIVE AMOUNT OF TIME. FOUND RT COFFEEMAKER WITH SUSPECT SMELL. REPLACED C/M PER AMM 25 32 02. OPS NORMAL WITH NO SMELLS NOTED. REMOVED AND INSP AREA BEHIND ALL AFT GALLEY OVENS AND COFFEEMAKERS. NO DEFECTS NOTED REF AMM 25 32 02. INSP ALL CABIN LIGHTING FOR OPS & OBVIOUS DEFECTS. ALL LIGHTS OP NORMAL WITH NO BURNT BALLAST. A/C OK FOR SERVICE. SEAMC NOTIFIED.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 13,360 hrs · 4,173 cycles

WHILE PERFORMING T/C 78273000 (ENGINE FMC CDU FAULTS) FOUND MAINT MSG NR 73 30312 (START SWITCH AND ARINC BUS DATA DISAGREE) FOR NR 2 ENGINE. PERFORMED FIM TASK 73 24 00 810 813 F00 STEPS A THRU E.2.I.1. AND STEPS G 1. THRU G.3.G. NO DISCREPANCIES NOTED AT THIS TIME. PERFORMED ENGINE FMC T/C 78273000, NO FAULTS LOGGED FOR PAST 5 LEGS.

Part: ANTENNA — MALFUNCTIONED (WEATHER RADAR) · airframe 13,105 hrs · 4,101 cycles

WHEN WEATHER RADAR TURNED ON A VIBRATION PLUS NOSE FELT AND "WX FAIL" ILLUMINATED. REPLACED WEATHER RADAR ANTENNA WITH SERVICEABLE ONE. OPERATIONAL TEST PASS PER AMM 34 43 11 400 802 & 34 43 00 710 802 001.

Part: FLOAT SWITCH — INOPERATIVE (FUEL SYSTEM)

WHEN OUTSIDE PERFORMING PREFLIGHT IT WAS DISCOVERED THAT FUEL WAS STREAMING OUT OF THE RIGHT WING FUEL VENT. UPON DISCUSSION WITH THE FUELER, HE REPORTED "THE SHUTOFF VALVE IS NOT WORKING". WHEN LOOKING AT THE FUEL INDICATOR PANEL ON THE WING THE RIGHT TANK QUANTITY WAS FLASHING. REPLACED RIGHT FUEL TANK FUELING SHUT OFF FLOAT SWITCH REF MM 28-21-71-020 801 AND 400-802, OPS NORMAL. TORQUES ON MOUNTING NUT AND ON BOTH CAPTIVE NUTS ON FLOAT SWITCH CONDUIT IS 280 IN/LBS. LEAK CHECK IS ALSO GOOD.

Part: TRANSCEIVER — DEFECTIVE (HF COMM) · airframe 12,742 hrs · 3,992 cycles

NR 2 HF SIDE TONE QUALITY IS BAD AND BARELY READABLE IN RECEIVE MODE. TRANSMIT IS NORMAL. UNABLE TO VERIFY SIDE TONE DISCREPANCY WITH NR 2 HF SIDE TONE REMOVED AND REPLACED HF NR 2 TRANSCEIVER IAW MM 23 11 21 AS PRECAUTIONARY PERFORMED SUCCESSFUL GROUND VERIFICATION CHECK.

Part: TRANSCEIVER — FAULTY (HF COMM) · airframe 12,723 hrs · 3,988 cycles

UNABLE TO XMIT ON HF1 ALL FREQS CAN RECEIVE ON 5574 ONLY. C/B'S ALL IN. VERIFIED FAULT BITE CHECK ON HF1 TRANSCEIVER HAS LRU FAULT. REMOVED AND REPLACED HF1 TRANSCEIVER IAW MM 23 11 21. OPS NORMAL.

Part: REGULATOR — INOPERATIVE (NR 2 BLEED SYS) · airframe 12,696 hrs · 3,979 cycles

ON CLIMBOUT, RT PACK LIGHT ILLUMINATED. QRH CHECKLIST ACCOMPLISHED & PACK RESET BUT FOR ONLY ABOUT 1 MINUTE. RAN CHECKLIST 1 MORE TIME & THIS CAUSED BLEED TRIP OFF LIGHT TO ILLUMINATE. RAN QRH & BLEED TRIP RESET BUT CAUSED PACK TO TRIP AGAIN. AT THAT POINT RAN QRH & ISOLATED RT PACK. DUCT PRESSURE NORMAL EXCEPT DURING BLEED TRIP OFF. FOUND BAD, R & R NR 2 ENGINE PRECOOLER CONTROL VALVE. FOUND BAD, R & R NR 2 ENGINE BLEED AIR REGULATOR. ALT PROCEDURE: POWER REMOVED FROM ACFT & THEN RE-INSTALLED W/OPS AND LEAK CHECK GOOD. R & R PRECOOLER CONTROL VALVE SENSOR

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 12,372 hrs · 3,890 cycles

NR 2 ENG FMC CDU FAULT CODE FOUND 76 31362. THE START LEVER SIGNAL DISAGREE. LONG TERM FAULT. ON DEFERRAL.

Part: CDU — MALFUNCTIONED (COCKPIT) · airframe 12,372 hrs · 3,890 cycles

NR 2 ENG FMC CDU FAULT CODE FOUND 76 31362. THE START LEVER SIGNAL DISAGREE. LONG TERM FAULT. ON DEFERRAL.

Part: FILTER — DIRTY (CABIN) · airframe 12,261 hrs · 3,858 cycles

UNABLE TO MODULATE AFT CABIN TEMPERATURE. PULLED CB'S P6 4 B2 B3 A3. CLEANED COCKPIT TEMP SENSOR FILTER AND REPLACED FWD AND AFT CABIN TEMP SENSOR FILTERS PER MM 21 61 06. VERIFIED FAULT AND AFTER FILTER CLEAN / CHANGE, PERF CABIN TEMP CONTROL AND INDICATION OPERATIONAL TEST REF MM 21 61 00 700 807 002. TESTS GOOD.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 11,830 hrs · 3,730 cycles

DURING ENGINE FMC CDU FAULT T/C 78273000 ENGINE NR 2 SHOWED A FAULT 76 31362. START LEVER SIGNAL DISAGREE (LONG TERM FAULT). NO FAULTS LOGGED LAST FOUR LEGS OF FLIGHTS. ACCOMPLISHED EEC TEST NO FAULTS LOGGED OPS NORMAL REF AMM TASK 73 21 00 700 804 F00. THIS CLEARS PLT NOTIFIED SEAMC. ACCOMPLISHED T/C 78273000 NO FAULTS RECORDED.

Part: FMC — MALFUNCTIONED · airframe 11,734 hrs · 3,704 cycles

ON INITIAL CLIMB FMC SCRATCH PAD MESSAGE CHECK PO IRS/IRS RECEIVED. POSITION PAGE 3 SHOWS L IRS DRIFTED 7.3 MILES R IRS DRIFTED 4.3 MILES. GPS POSITION AND FMC SOLUTION 0.0. ACFT GROUNDED. DIVERSION TIME 16 MINUTES. ACCOMP'D FIM TASKS 34 21 NR 836 801AND 802. RADIAL POS ERR AND RES G/S WITHIN LIMITS. NO FAULTS LOGGED EITHER DFCS ADIRU'S HGS FMC'S. ADIRU'S CK OK REF LWMP CKLIST 22-00-01. HGS TEST AND DFCS TEST OK REF SAME. ACFT REMAINS CATIIIA A/L AND HGS QUAL.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 11,600 hrs · 3,672 cycles

GOT FMC DISAGREE MESSAGE. PERFORMED QRH PROCEDURE. FMC DISAGREE MESSAGE WENT AWAY. ACCOMPLISHED FIM 34 61 00, NO FAULTS NOTED. OPS CHECKED FMC IAW MM 34 61 00 OPS NORMAL GND VERIFICATION TEST PASSES SEAMC.

Part: CDU — MALFUNCTIONED (COCKPIT) · airframe 11,536 hrs · 3,646 cycles

FMC FUNCTIONS BUTTONS INOP NO INPUT AVAILABLE ALL BUTTONS STUCK ON CRZ PAGE. REMOVED AND REPLACED CAPT'S CDU REF MM 34 60 01, OPS CHECK NORMAL.

Part: FMC — MALFUNCTIONED (COCKPIT) · airframe 11,531 hrs · 3,643 cycles

CAPT FMC/CDU BUTTONS ARE INOP. FMC SEEMS TO BE FUNCTIONING NORMALLY. A/P 1 WORKING NORMALLY. INPUT FROM F/O SIDE ON CDU IS NORMAL. JUST UNABLE TO INPUT OR CHANGE MODE OF FMC FROM CAPT CDU. COULD NOT DUPLICATE NO HISTORY. CAPTS FMC CDU OPS CHECKS NORMAL PER FIM 34 60 00 810 802. NO 1 FMC OPS CHECKS NORMAL PER MM 34 60 00 710 801. DFCS LRU INTERFACE GRP 34 BITE CHECKS NORMAL.

Part: TRANSCEIVER — FAULTY (HF COMM) · airframe 11,408 hrs · 3,601 cycles

HF NR 1 WILL NOT TRANSMIT. RECEIVES OK DATA TRANSMIT OK. VERIFIED NR 1 HF RADIO INOP. REPLACED NR 1 HF TRANSCEIVER PER MM 23 11 21 400 801. REPLACED NR 1 HF ANTENNA COUPLER PER MM 23 11 61 400 801. BOTH OPS CHECK NORMAL. PART NUMBERS VERIFIED BY SEAMC REF IPC 23 11 61 01 AND IPC 23 11 21 11.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 11,277 hrs · 3,566 cycles

OVERHEAD PANEL ELEC INDICATOR LIGHT ILLUMINATED. VERIFIED ELEC IND LIGHT ON. PERFORMED FIM PROCEDURE 24 31 00 810 801. CLEARED TRANSIENT FAULTS. BITE TEST GOOD. NO CURRENT FAULTS. GROUND TEST VERIFICATION GOOD. NO HISTORY 2 WEEKS. NOTIFIED SEAMC.

Part: INDICATION SYS — MALFUNCTIONED (NR 1 ENGINE) · airframe 11,250 hrs · 3,558 cycles

GE DIAGNOSTICS REPORTS NR 1 ENGINE TREND DATA SHOWS A SUDDEN DECREASE IN CRUISE DELTA EGT WITH A CORRESPONDING INCREASE IN TAKEOFF HOT DAY MARGIN. INDICATION ERRORS ARE SUSPECT. LONG TERM FAULT 77 10841 TOP RIGHT EGT SIGNAL OUT OF RANGE NR 1 ENG. ACCOMPLISHED TSR 904861 WO 44572 TC 78273000, ACCOMPLISHED CLEANED EGT CONNECTORS REF MM 77-21-00 NO HELP. REPLACED S1 EGT PROBE REF MM 77-21-01 NO HELP. PERFORMED EEC BITE TEST FOR ENG 1 CHA + CHB NO RECENT FAULTS AND NO RECORDED FAULTS LOGGED.

Part: WARNING LIGHT — ILLUMINATED (NR 1 ENGINE) · airframe 11,064 hrs · 3,487 cycles

LEFT SPAR VALVE ILLUMINATED (BRIGHT) NEAR THE ETOPS EXIT POINT AT 0400Z APPROX 4 +20 INTO FLIGHT. FL 380 TEMP 53C CENTER PUMPS OFF & X FEED CLOSED. DIVERSION TIME 27 MINS. UNABLE TO VERIFY DISCREPANCY. ACCOMPLISHED FIM 28 22 TASK 809. INITIAL EVALUATION SHOWED NO FAULTS. REMOVED INSPECTED AND REINSTALLED CONNECTORS D 788 & D 626 FROM ACTUATOR ASSY AND P5 2. NO FAULTS FOUND. REMOVED AND REPLACED NR 1 SPAR VLV ACTUATOR PER MM 28 22 11 AND FUEL SYSTEM MODULE P5 2 PER MM 28 22 43. VERIFICATION FLIGHT SATISFACTORY. OPS NORMAL.

Part: FILTER — LEAKING (NR 1 ENGINE) · airframe 11,064 hrs · 3,487 cycles

NUMBER 1 ENGINE MAIN FUEL FILTER LEAKING AT CAP. REMOVED AND REPLACED NR 1 ENG MAIN FUEL FILTER REF AMM 73 11 02 000 801 AND 73 11 02 400 801 FILTER AND O-RING P/NS VERIFIED BY SEAMC, RAN ENG LEAK CHECKED GOOD. OK FOR SERVICE.

Part: WARNING LIGHT — FALSE ACTIVATION (LT ENGINE) · airframe 11,053 hrs · 3,483 cycles

LEFT ENGINE "SPAR VALVE CLOSED" BLUE LIGHT CAME ON BRIGHT ON FINAL APPROACH STAYED BRIGHT UNTIL AT THE GATE. AT ENGINE SHUT DOWN (WITH THE START LEVER) VALVE LIGHT WENT TO DIM BLUE AGREEMENT POSITION. PERFORMED FIM TASK 28-22-00-810-809 NO DISCREPANCIES NOTED. MANUAL STATES THIS TO BE "INTERMITTENT FAULT". A/C GOOD FOR CONTINUED SERVICE.

Part: DRIVE UNIT — NOISY (WEATHER RADAR) · airframe 10,999 hrs · 3,463 cycles

WEATHER RADAR ANTENNA SHUTTERS DURING SWEEP MAKES NOISE AUDIBLE IN COCKPIT AND FORWARD GALLEY. NAV DISPLAY SHOWS WX RADAR FAIL AND PWS FAIL. ACCOMPLISHED FIM 34 43 TASK 815. UNABLE TO DUPLICATE DISCREPANCY. PRECAUTIONARY REPLACED WXR ANTENNA DRIVE UNIT REF MM34 43 11. OPS NORMAL. SUCCESSFUL GROUND VERIFICATION REF MM34 43 00 710 802 001. NO AUDIBLE NOISE NOTED DURING ANTENNA DRIVE.

Part: UNKNOWN — MALFUNCTIONED (WINDOW HEAT) · airframe 10,897 hrs · 3,436 cycles

DURING FLT DECK PREFLIGHT BOTH L (SIDE & FWD) WINDOW HEAT OVERHEAT LIGHTS WERE ILLUMINATED. PER QRH TURNED OFF L SIDE & FWD WINDOW HEAT FOR 5 MINS AND THEN TURNED BACK ON. OVERHEAT LIGHTS DID NOT ILLUMINATE UNTIL APPROX 10 MINS LATER. UNABLE TO DUPLICATE FAULT. PRECAUTIONARY REPLACED P5 9 MODULE WINDOW/PITOT HEAT REF MM30 41 41. OPS NORMAL. VERIFICATION FLIGHT SUCCESSFUL.

Part: SKIN — DENTED (BS 400) · airframe 10,879 hrs · 3,428 cycles

DENT IN RVSM AREA. REPAIRED DENT IN LT RVSM AREA.

Part: SKIN — DELAMINATED (TE FLAP) · airframe 10,879 hrs · 3,428 cycles

LEFT WING TRAILING EDGE FLAP LWR SKIN IS DELAMINATED AT PREVIOUS REPAIR 18 INCHES FROM I/B EDGE. REPAIR AFT FLAP LOWER SKIN.

Part: BRACKET — CRACKED (LT WING) · airframe 10,879 hrs · 3,428 cycles

LEFT WING FIXED T/E HAS A CRACKED BRACKET AT THE SEAL BULKHEAD RS 279 FWD SIDE OF BULKHEAD. REPLACED LEFT WING FIXED TRAILING EDGE PANEL SEAL RETAINER AT RS 279 FWD SIDE OF BULKHEAD.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 10,879 hrs · 3,428 cycles

INTERCOSTAL CRACKED BS 312 328 LBL 55 WL 208. REMOVED AND REINSTALLED NEW INTERCOSTAL.

Part: SUPPORT — CORRODED (FUSELAGE) · corrosion level 2 · airframe 10,879 hrs · 3,428 cycles

SEVERAL AREAS OF CORROSION FOUND ON FLOOR TO SIDEWALL SUPPORT INTERCOSTAL RIGHT BS 768 - 791. REMOVED AND REPLACED FLOOR TO SIDEWALL SUPPORT.

Part: DISPLAY — FAULTY (COCKPIT) · airframe 10,820 hrs · 3,406 cycles

LEFT CDU SCREEN INOP (BLANK). REMOVED & REPLACED LT FMC CDU REF MM 34 61 01 000 802. OPS NORMAL PER SAME. VERIFIED CDU P/N WITH SEAMC ETOPS. GROUND VERIFICATION TEST SUCCESSFUL.

Part: SENSE LINE — LEAKING (AC PACK) · airframe 10,824 hrs · 3,408 cycles

FLIGHT ATTENDANTS REPORT LOW AIRFLOW FROM ALL PASSENGER COMPARTMENT GASPER VENTS. COCKPIT AIRFLOW FROM GASPERS IS LOW AS WELL. ALL PRESSURIZATION INDICATIONS ARE NORMAL. FOUND SENSE LINES LEAKING SIGNIFICANTLY. REMOVED & REPLACED LT & RT ACM SENSE LINES IN BOTH A/C BAYS, OPS CHECK GOOD REF AMM 20 10 52.

Part: VALVE — INTERMITTENT (LT WING) · airframe 10,760 hrs · 3,386 cycles

ON DESCENT BETWEEN 18000 AND 12000 THE NR 1 ENGINE FUEL SPAR VALVE CLOSED LIGHT ILLUMINATED BRIGHT AND REMAINED ON FOR DURATION OF FLIGHT. NO OTHER NEGATIVE INDICATION WITH NR1 NOTED. LIGHT WENT DIM ON NR1 START LEVER CUTOFF. GROUNDED YES. PERFORMED FIM TASK 78-22-00-810-809. DETERMINED FAULT TO BE INTERMITTENT. REPLACED LT WING SPAR VALVE AS PRECAUTION REF MM 28-22-11. OPS NORMAL. VERIFICATION FLIGHT SUCCESSFUL.

Part: SHROUD — DAMAGED (NR 1 ENGINE) · airframe 10,731 hrs · 3,380 cycles

WHILE ACCOMPLISHING FAN BLADE LUBE T/C NR 78472002 ON NR 1 ENG, FOUND 2 AREAS OF ABRADABLE SHROUD DAMAGE AT 9:30 AND 10 O'CLOCK LOOKING AFT DAMAGE TO PARENT MATERIAL. GROUNDED YES. ACCOMPLISHED LOCAL RECONDITIONING OF MISSING SHROUD MATERIAL IAW MM 72 24 02. NO DAMAGE FOUND OF PARENT METAL OR OXIDE FILM COATING.

Part: SHIM — WORN (FAN BLADE) · airframe 10,731 hrs · 3,380 cycles

WHILE ACCOMPLISHING FAN BLADE LUBE ON NR 1 ENG T/C NR 78472002 FOUND ALL SHIMS WORN. GROUNDED YES. INSTALLED 24 EA. FAN BLADE SHIMS MFG. PN 340 252 307 0 ON NR1 ENGINE. REF T/C 78472002.

Part: BUTTON — STICKING (FMC) · airframe 10,735 hrs · 3,381 cycles

F/O'S FMC NOT RESPONSIVE TO BUTTON PRESS. ACFT GROUNDED. FOUND CLEAR BUTTON STUCK ON MCDU CLEANED AND FREE BUTTON RESET RT FMC COMPUTER AND MCDU BREAKERS ACCOMPLISHED RT MCDU KEY TEST IAW FIM 34-61-802 AND FMC BITE IAW 34-61-801. OPS NORMAL.

Part: MODULE — FAULTED (BATTERY CHARGER) · airframe 10,570 hrs · 3,338 cycles

ELEC FAULT LIGHT DISCOVERED ON PREFLIGHT GROUNDED YES. FOUND "AUX BAT CHGR INOP" FAULT IN P5 13 MODULE. PERFORMED FIM 24-31-00-810-801 GROUND VERIFICATION SUCCESSFUL. OPS NORMAL SEAM C, CONSULTED.

Part: UNKNOWN — MALFUNCTIONED (FUEL SYSTEM) · airframe 10,553 hrs · 3,330 cycles

ON CLIMBOUT FROM SEA, FUEL IMBALANCE OF 1260 LBS, DUE TO PILOT ACTIONS CORRECTED TO WITHIN LIMITS. INITIAL IMBALANCE LEFT 7.330 RIGHT 8.59 OK AFTER CORRECTING. PERFORMED CK OF FUEL CROSSFEED VALVE FUNCTIONAL TEST IN REF TASK 28 22 00 730 802. NO FUEL MIGRATION NOTED, ACFT OK FOR FLIGHT.

Part: WIRE — LOOSE (COCKPIT) · airframe 10,548 hrs · 3,328 cycles

LOOSE SPRING WIRE ON CARGO FIRE DISCHARGE SWITCH. REMOVED AND REPLACED CARGO FIRE CONTROL MODULE PER 26 00 02, OPS CHECK NORMAL PER SAME.

Part: DRIVE UNIT — DEFECTIVE (WEATHER RADAR) · airframe 10,498 hrs · 3,310 cycles

WX RADAR SPOKING IN WX AND WXT 1 WITH STAB ON AND IN CAL GROUNDED YES. PERFORMED WXR SYS SELF TEST START REF AMM 34 43 00 PG SET 023 OPS CHECK GOOD. VERIFICATION FLIGHT FAILED. DUE TO HISTORY REMOVED AND REPLACED RADAR ANTENNA DRIVE UNIT. REF MM 34 43 11 000 802/400 802. PERFORMEDOPS CK REF MM 34 43 00 710 802 0011. SYS CKS NML. VERIFICATION FLIGHT SUCCESSFUL.

Part: STRINGER — DAMAGED (FUSELAGE) · airframe 9,743 hrs · 3,068 cycles

STR 25R HAS THREE OVERSIZED HOLES. REMOVED & REPLACED DAMAGED SECTION OF STR PER SRM 53 00 03 REPAIR 1.

Part: FITTING — DAMAGED (FUSELAGE) · airframe 9,743 hrs · 3,063 cycles

STR 25R HAS ELONGATED HOLE IN STR END FITTING. REPLACED STR END FITTING.

Part: FRAME — CRACKED (FUSELAGE) · airframe 9,743 hrs · 3,068 cycles

BS 1088 FRAME LOWER CHORD CRACKED. REPAIRED PER ER 09-2021 & EA 800-53EA-00963.