N580FE

Part: HYDRAULIC LINE — LEAKING (NR 3 ENGINE) · airframe 71,579 hrs · 15,867 cycles

LEVEL ONE HYD 3 OFF PASSING FL 200 LEVEL TWO HYD 3 FAIL AT FL 370, LOWERED GEAR MANUALLY. FOUND HYD PRESS HOSE THAT CONNECTS FROM THE PYLON TO THE ENG HYD MANIFOLD BLOWN APART AT THE PYLON B NUT. REMOVED THE DAMAGED HOSE. DUE TO NR 3 SYS HYD AT 0 QTY, REQUIRES BOTH EDP & ENG FILTERS REPLACED. REMOVED THE RT EDP UP TO INSTALLATION IAW AMM CHAPTER 29-11-20-4-2. R & R NR 3 ENG HYD PRESS HOSE ASSEMBLY FROM PYLON TO HYD MANIFOLD ASSEMBLY IAW SMP.

Part: CONTROL UNIT — FAILED (FIRE DETECTION) · airframe 70,351 hrs · 15,500 cycles

ON TAXI OUT RECEIVED LVL 1, FIRE DET 2 FAIL. AFTER STOPPING ACFT, RAN A FIRE TEST & THEN RECEIVED LVL 3, ENG 2 FIRE, ALERT. RAN QRH PROCEDURES, FOR ENG FIRE SEVERE DAMAGE CHECKLIST. FIRED FIRST BOTTLE & ALERT REMAINED ON, AFTER 30 SEC STILL HAD FIRE ALERT ON. FIRED SECOND BOTTLE AFTER ABOUT 2 MINUTES ALERT WENT OUT, BOTH FIRE DET 2 FAIL & ENG 2 FIRE RETURN TO GATE. R & R NR 2 FDCU IAW AMM 26-11-02-4, FDCU CHECKED GOOD IAW AMM 26-11-02-5. R & R NR 2 LT & RT FIREX BOTTLE IAW MM 26-21-01-4. NO EVIDENCE OF FIRE, OK TO CONTINUE. INSTALLED 4 EA NEW FIREX DISCHARGE CARTRIDGES IAW AMM 26-21-05. RAN ENG JRH, OPERATIONS CHECKED GOOD NO FIRE WARN INDICATION. OK FOR SERVICE

Part: SKIN — MISREPAIRED (BS 979) · airframe 68,160 hrs · 14,780 cycles

FUSELAGE SKIN, BS 979, LONGERON 47-48R MISREPAIRED. REPAIRED IAW SRM 53-00-01, FIG 201, REPAIR 1 REV 52. EO 1-5100-7- 5001B3, PART 1. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SKIN — CORRODED (RT WING) · airframe 68,160 hrs · 14,780 cycles

RIGHT WING UPPER SURFACE FOUND CORROSION AT XORS 255 DURING SPOILER, UPPER SURFACE INSPECTION. CORROSION REMOVED AND FOUND EXCEED LIMITS IAW SRM 57-20-01, FIG 101, REV 52. DOUBLER REPAIR CARRIED OUT IAW EA 1-5730-167610. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: RIB — WORN (NR 4 SLAT) · airframe 68,160 hrs · 14,780 cycles

RT WING NR 4 L/E SLAT INBD SLAT TRACK RIB FWD HOLE FOUND WORN AFTER REMOVAL OF NR 3 SLAT. NR 4 SLAT REWORKED IAW SRM 57-40-02 REPAIR 10, FIGURE 201, REVISION 52. FINAL HOLE DIAMETER 1.125" AND THE CHAFING MARK STILL EXIST, REPAIR ACCOMPLISHED IAW EA 1-5750-166123. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SKIN — CRACKED (ZONE 100) · airframe 68,160 hrs · 14,780 cycles

NR 3 AIRCONDITIONING COMPARTMENT AFT UPPER CORNER CUT-OUT SKIN FOUND CRACKED. NR 3 AIRCONDITIONING COMPARTMENT AFT UPPER CORNER CUT-OUT SKIN CARRIED OUT REPAIR IAW SRM 53-20-15, REPAIR 3, FIG 201, REV 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: CAP — MISREPAIRED (ZONE 500) · airframe 68,160 hrs · 14,780 cycles

LT WING T/E LOWER ACCESS PANEL 541JB CUT-OUT FWD EDGE LOWER CAP MISREPAIRED. REPAIRED IAW EA 1-5710-167609. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SUPPORT FITTING — DAMAGED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

MAIN CARGO DOOR LOWER FRAME SUPPORT FITTING NR 6 HOLE DIAMETER (D ) ABOVE THE LIMIT (0.580). R & R IAW SRM 51-31-01, REV 52. REPAIR CLASSIFIED MAJOR IAW GMM 6-2-100, REV 116.

Part: SUPPORT FITTING — DAMAGED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

MAIN CARGO DOOR LOWER FRAME SUPPORT FITTING NR 7 HOLE DIAMETER (A & C ) ABOVE THE LIMIT (0.580). R & R IAW SRM 51-31-01, REV 52. REPAIR CLASSIFIED MAJOR IAW GMM 6-2-100, REV 116.

Part: SKIN — CRACKED (ZONE 100) · airframe 68,160 hrs · 14,780 cycles

NR 3 AIR CONDITIONING COMPARTMENT AFT UPPER CORNER CUT-OUT SKIN FOUND CRACKED. REPAIRED IAW SRM 53-20-15, REPAIR 3, FIG 201 REV 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REVISION 116.

Part: RIB — CRACKED (NR 5 SLAT) · airframe 68,160 hrs · 14,780 cycles

RIGHT WING NR 5 SLAT FOUND INBD INNER RIB CRACKED. NR 5 SLAT FABRICATED AND INSTALLED IAW EA 1-5750-166127, STEP 2 AND 3. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SUPPORT FITTING — DAMAGED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

MAIN CARGO DOOR LOWER FRAME SUPPORT FITTING NR 1 HOLE DIAMETER ABOVE THE LIMIT (0.580). R & R IAW SRM 51-31-01, REV 52. REPAIR CLASSIFIED MAJOR IAW GMM 6-2-100, REV 116.

Part: BULKHEAD — CANNING (BS 1401-1441) · airframe 68,160 hrs · 14,780 cycles

OIL CANNING AT CENTER LANDING GEAR LT VERTICAL WEB BETWEEN BS 1401 TO 1441, Z= -119 TO Z= -80. CARRIED OUT INSPECTION IAW EA 1-5310-167604, REPAIRED IAW EO 1-5100-7-5001B3 PART 1. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: BEAM — CORRODED (BS 1461-1490) · airframe 68,160 hrs · 14,780 cycles

CENTER WHEEL WELL BS 1461 TO 1490 RT DIAGONAL I-BEAM FOUND CORRODED. R & R WITH NEW FABRICATED I-BEAM IAW SRM 51-31-01, REV 52 AND EA 1-53-167608. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: BULKHEAD — CANNING (RT MLG WW) · airframe 68,160 hrs · 14,780 cycles

OIL CANNING AT CENTER LANDING GEAR RT VERTICAL WEB BETWEEN BS 1401 TO 1441, Z= -119 TO Z= -83. REPAIRED IAW EO 1-5100-7- 5001B3. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: DOOR FRAME — CRACKED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

R3 DOOR FORWARD FRAME WEB FOUND CRACKED. REPAIRED IAW SRM 53-40-15, FIG 201, REPAIR 3, REV 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SKIN — CRACKED (RT WING) · airframe 68,160 hrs · 14,780 cycles

RIGHT WING - L/E LOWER SURFACE NR 12 SLAT TRACK CUT-OUT SKIN FOUND CRACKED AT XOS 777. DURING OTBD SLAT DRIVE CABLES INSPECTION. REPAIRED IAW SRM 57-40-02, FIG 201, REPAIR 7 REV 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: DOOR FRAME — CRACKED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

L3 DOOR FORWARD FRAME LOWER WEB FOUND CRACKED. REPAIRED IAW SRM 53-40-15 FIGURE 201 REPAIR 3 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: FRAME — DENTED (BS 1661 L12R) · airframe 68,160 hrs · 14,780 cycles

BS 1661 LONGERON 12R FRAME FOUND DENTED. REPAIRED IAW SRM 53-00-07, FIG 201, REPAIR 2, REV 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: DOOR FRAME — CRACKED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

R3 DOOR AFT FRAME LOWER WEB FOUND CRACKED. REPAIRED IAW SRM 53-40-15, FIG 201, REPAIR 3, REV 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SKIN — LOOSE (LT WING TE FLAP) · airframe 68,160 hrs · 14,780 cycles

LEFT WING INBD FLAP UPPER SURFACE, SEVERAL FASTENERS AT XIFH 159 FOUND LOOSE. R & R WITH NEW FASTENERS IAW SRM 51-35-01, REV 52. REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 116.

Part: SKIN — CRACKED (LT WING TE FLAP) · airframe 68,160 hrs · 14,780 cycles

LEFT WING INBD FLAP UPPER SURFACE FOUND CRACKED AT XIFH 177 AND 58" FROM T/E. REPAIRED IAW EA 1-5750-166124. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REV 116.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

EXFOLIATION CORROSION FOUND ON SEAT TRACK BASE AT BS 491 TO 502, X= -27.5. REPAIRED IAW SRM 53-00-52, FIG 201, REPAIR 1, REV 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SKIN — MISREPAIRED (RT WING) · airframe 68,160 hrs · 14,780 cycles

RT WING FIXED L/E SURFACE TELESCOPIC DUCT CUT-OUT AREA MISREPAIRED. REPAIRED IAW SRM 57-40-01, REPAIR 10, FIGURE 201, REV 52 AND EA 1-5730-166121. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SKIN — DELAMINATED (ZONE 600) · airframe 68,160 hrs · 14,780 cycles

RIGHT WING OTBD FLAP T/E WEDGE INBD EDGE FORM DELAMINATED FROM XOFH 458.690 TO XOFH 468.690. REPAIRED IAW EA 1-5750-166120. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100 REVISION 116.

Part: SKIN — CRACKED (NR 5 SLAT) · airframe 68,160 hrs · 14,780 cycles

RT WING NR 5 SLAT LOWER SURFACE FOUND CRACK ABOUT 5 INCHES LONG AT XOS 717. REPAIRED IAW EA 1-5750-166127, REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: SKIN — CRACKED (LT WING TE FLAP) · airframe 68,160 hrs · 14,780 cycles

LT WING INBD FLAP UPPER SKIN AT XIFH= 171, 52" FROM T/E FOUND WITH 1 INCH CRACK. REPAIRED IAW EA 1-5750-166124. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: ACCESS PANEL — CORRODED (ZONE 600) · airframe 68,160 hrs · 14,780 cycles

RT WING T/E LOWER ACCESS PANEL 641JB CUT-OUT FWD EDGE LOWER CAP SURFACE FOUND CORRODED. REPAIRED IAW EA 1-5710-166116. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: FRAME — MISREPAIRED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

FRAME MISREPAIRED AT CABIN BS 535, L24L. REPAIRED IAW SRM 53-20-07, FIG 201, REPAIR 1, REV 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: FRAME — MISREPAIRED (ZONE 200) · airframe 68,160 hrs · 14,780 cycles

FRAME MISREPAIRED AT CABIN STATION 535, L19L. REPAIRED IAW SRM 53-20-07, FIG 202, REPAIR 1, REV 52. EO 1-5100-7-5001B3, PART 1. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 116.

Part: PRESSURE SWITCH — FAILED (ENGINE OIL SYS) · airframe 64,784 hrs · 13,796 cycles

MAX POWER TAKE OFF, NR 2 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED. OIL PRESSURE INDICATED NORMAL ON GAUGES. ABORT WAS ACCOMPLISHED AT 20 KIAS. LIGHT WENT OUT WHEN POWER MOVED TO IDLE. ALL OIL INDICATIONS REMAINED NORMAL. R & R LOW OIL PRESSURE SWITCH IAW MM 79-33-02-4-1. RAN NR 2 ENG AT HIGH POWER REF JRH AND MM 71-02-03-5-2 & MM 71-02-04-5-2. ALL PARAMETERS OK AND NO LOW OIL PRESSURE ALERT.

Part: HINGE — CRACKED (RT MLG DOOR) · airframe 63,565 hrs · 13,483 cycles

RIGHT MLG DOOR-CENTER HINGE ASSY FOUND CRACKED. CRACKED HINGE REMOVED AND REPLACED WITH NEW HINGE AT RIGHT HAND DOOR CENTER AREA AS PER SRM 51-35-01 REV 47. REPAIR CLASSIFIED MINOR AS PER GMM 6-2-100 REV 112.

Part: SKIN — CORRODED (BS 2155-2164) · corrosion level 2 · airframe 63,565 hrs · 13,483 cycles

RT FUSELAGE BENEATH AFT BODY FAIRING (LOWER SIDE) FROM STA 2155 TO 2164 FOUND CORRODED AT SEVERAL LOCATIONS. CORROSION REMOVED, ORIGINAL THICKNESS 0.095", MATERIAL REMOVED 0.045", REMAINING THICKNESS 0.050". REPAIR CARRIED OUT IAW SRM 53-70-01, FIG 201, REPAIR 3, REV 47. MAJOR IAW GMM 6-2-100, REV 112.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 63,565 hrs · 13,483 cycles

RT FUSELAGE SKIN BENEATH AFT BODY FAIRING (UPPER SIDE) FROM BS 2155 TO 2164, FOUND CORRODED AT SEVERAL LOCATIONS. CORROSION REMOVED IAW SRM 51-70-01, FIG 201. REPAIR 3 REV 47. ORIGINAL THICKNESS 0.0125", MATERIAL REMOVED 0.085", REMAINING THICKNESS 0.040". REPAIR CARRIED OUT IAW SRM-70-01, FIG 201. REPAIR 3, REV 47. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: PROBE — FAILED (FUEL QTY) · airframe 60,608 hrs · 12,744 cycles

AT LEVEL OFF CALM AIR GOT A FUEL QTY/FUEL USED LEVEL 2 POSSIBLE FUEL LEAK ALERT. FOLLOWED QRH PROCEEDURE S AND ISOLATED PROBLEM TO NR 2 MAIN TANK ERRONEOUS QTY OF - 4500. QTY IN TANK 2 WOLD FLUCTUATE IN MANUAL AND AUTO. NO LEAK NOTED. REMOVED AND REPLACED NR 2 LT MJP AND NR 5 PROBE. OPS CHECK & LEAK CHECK GOOD.

Part: BRAKE — FAILED (NR 8) · airframe 59,462 hrs · 12,458 cycles

AFTER TAKEOFF NR 8 BRAKE TEMP CLIMBED TO OVER 400 DEGREES BEFORE DECREASING. AFTER LANDING NR 8 BRAKE RAN HOTTER THAN THE OTHERS. GEAR WAS LOWERED TO COOL BRAKE AND RETRACTED. ACFT LANDED OK WITHOUT INCIDENT. R & R NR 8 BRAKE IAW MM 32-43-20-4. OPS CHECK OK.

Part: SKIN — CORRODED (RT WING) · airframe 58,090 hrs · 12,149 cycles

CORROSION - RT UPPER WING SURFACE AT XORS197. REPAIRED IAW EA 1-5710-132215.

Part: SKIN — CORRODED (LT WING) · corrosion level 2 · airframe 58,090 hrs · 12,149 cycles

LT WING UPPER SKIN AT STA. XORS 402 TO XORS 433 FOUND CORROSIONS. REPAIR IAW EA 1-5710-132212.

Part: SKIN — CORRODED (LT WING) · corrosion level 2 · airframe 58,090 hrs · 12,149 cycles

LT WING UPPER SKIN AT STA, XORS 378 FOUND CORROSION. REPAIR IAW EA 1-5710-132212 TITLE: "WINGS-LT WING UPPER SKIN SURFACE CORROSION - REPAIR"

Part: SKIN — CORRODED (LT WING) · corrosion level 2 · airframe 58,090 hrs · 12,149 cycles

LT WING UPPER SKIN AT STA, XORS 130 TO XORS 197 FOUND CORROSIONS. REPAIR IAW EA 1-5710-132213 TITLE: "WINGS-LT WING UPPER SKIN SURFACE CORROSION - REPAIR"

Part: SKIN — CORRODED (RT WING) · airframe 58,090 hrs · 12,149 cycles

RIGHT UPPER WING SKIN HAS CORROSION, STA XORS 298. REPAIRED IAW EA 1-5710-132215. MAJOR REPAIR.

Part: SKIN — CORRODED (LT WING) · airframe 58,090 hrs · 12,149 cycles

LEFT UPPER WING SKIN STA XORS 317 TO 360 HAS CORROSION. REPAIR IAW EA 1-5750-132209.

Part: SKIN — CORRODED (RT WING) · airframe 58,090 hrs · 12,149 cycles

RIGHT UPPER WING SKIN HAS CORROSION AT STA XORS 150. REPAIRED IAW EA 1-5750-132215.

Part: LONGERON — CORRODED (ZONE 100) · airframe 58,090 hrs · 12,149 cycles

FWD CARGO - LONGERON 45R AT BS 879 LWR OTBD SURFACE CORRODED. COMPLIED WITH EA 1-5310-132210: FUSELAGE - LONGERON 45R CRACK AT APPROX STA 879 - REPAIR. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV. 107

Part: SKIN — CORRODED (RT WING) · airframe 58,090 hrs · 12,149 cycles

RIGHT UPPER WING SKIN HAS CORROSION, STA XORS 163. REPAIRED IAW EA 1-5710-132215.

Part: LONGERON — CORRODED (BS 879 L45R) · airframe 58,090 hrs · 12,149 cycles

LONGERON 45R BS879 LWR OTBD SURFACE CORRODED IN FWD CARGO. COMPLIED WITH EA 1-5310-132210: FUSELAGE - LONGERON 45R CRACK AT APPROX STA 879 - REPAIR. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 107.

Part: SKIN PANEL — CRACKED (LT WING) · airframe 58,090 hrs · 12,149 cycles

21 EA FASTENER HOLES FOUND CRACK INDICATION DURING HFEC OPEN HOLE INSPECTION AT LT W LWR SKIN ACCESS DOOR CUTOUT BETWEEN STA XORS=690 AND STA XORS=700. REPAIR IAW EA 1-5710-133857 TITLE: "AD2007-07-04 - WINGS - LT LWR SKIN PLANK CUTOUT AT 536AB - REPAIR TO ACCESS DOOR ATTACHMENT BORES WITH CRACK INDICATIONS PSE 57.23.01 ALI"

Part: SKIN PANEL — CRACKED (600) · airframe 58,090 hrs · 12,149 cycles

25EA FASTENER HOLES FOUND CRACK INDICATION DURING HFEC OPEN INSP AT RT LWR SKIN ACCESS DOOR CUTOUT BETWEEN STA XORS=690 AND STA XORS=700. REPAIR IAW EA 1-5710-133858 TITLE: "AD2007-07-04 - WINGS - RT LWR SKIN PLANK CUTOUT AT 636AB - REPAIR TO ACCESS DOOR ATTACHMENT BORES WITH CRACK INDICATIONS PSE 57.23.01 ALI"

Part: HINGE FITTING — CORRODED (TE FLAP) · corrosion level 2 · airframe 58,090 hrs · 12,149 cycles

LT WING FLAP SIDE INBD FLAP OTBD HINGE OTBD PIVOT HOLE FOUND CORROSIONS. REPAIRED IAW EA 1-5750-132206 (MAJOR REPAIR).

Part: HINGE BRACKET — CORRODED (ZONE 600) · airframe 58,090 hrs · 12,149 cycles

RT WING - WING SIDE OTBD FLAP OTBD HINGE LWR MOUNT OTBD HOLE FOUND CORRODED. REPAIRED IAW EA 1-5750-132208 (MAJOR REPAIR).

Part: STRINGER SPLICE — CRACKED (ZONE 200) · airframe 58,090 hrs · 12,149 cycles

CRACK FOUND DURING X-RAY INSP AT STA 6-100. LONGERON 3R STRINGER SPLICE CRACKED LENGTH APPROX 0.5 INCH. REPAIRED AS PER SRM51-31-01 REV41 AND DOUGLAS DRAWING A6A7112 REV A (MAJOR REPAIR).

Part: RIB — CRACKED (ZONE 500) · airframe 58,090 hrs · 12,149 cycles

LT WING - SLAT TRACK NR 16 INBD RIB FOUND CRACKED (APPROX 0.5 INCH) REPAIR IAW SRM51-33-01 REV41 (MAJOR REPAIR).

Part: HINGE BRACKET — CORRODED (ZONE 500) · airframe 58,090 hrs · 12,149 cycles

LT WING - WING SIDE OTBD FLAP INBD HINGE LWR MOUNT INBD HOLE FOUND CORRODED. REPAIRED IAW EA 1-5750-132207.

Part: CARGO TRACK — CRACKED (BS 755) · airframe 58,090 hrs · 12,149 cycles

CRACKED LOWER FLANGE OF FLOOR TRACK AT LT STA 755, X=27.5 IN MAIN DECK CARGO. REPAIRED AS PER SRM53-00-52 FIG201 REPAIR1 REV41 (MAJOR REPAIR).

Part: FITTING — CRACKED (BS 2164) · airframe 58,090 hrs · 12,149 cycles

CRACK FOUND APPROX 0.3 INCH DURING HFEC INSP AT RT LOWER VERTICAL STABILIZER BANJO FITTING ON THE FWD FLANGE, NR 3 LOWEST FASTENER AS MARKED. REPAIR IAW SRM55-30-02, FIG201, REV41. (MAJOR REPAIR).

Part: VALVE — INOPERATIVE (ANTI SKID SYS) · airframe 56,766 hrs · 11,822 cycles

ANTI-SKID FAIL DURING TAKEOFF AT 70 KTS, REJECTED TAKEOFF TIME 1335Z. RTRN TO GATE FOR 45 MIN BRAKECOOLING, BTM INOP. ASCU LAST LEG LOGGED SYS1 VALVE 2, NO CURRENT FAULT. CHK`D WIRING FROM ASCU TO NR 2 VALVE REF WDM 32-45-03 PG 501, RESISTANCE, CONTINUITY AND NO SHORT TO GRD CHK`D OK. REMOVED AND REPLACED SYS 1 ANTI-SKID VALVE NR 2 PER AMM 32-45-21-4, LEAK CHK OK. REMOVED AND REPLACED ASCU AND RTS OK PER AMM 32-45-01. ANTI-SKID OP TEST OK PER AMM 32-45-00-5. ACFT OK FOR SVC. R/I FROM FACT PREMATURE REMOVAL/INSTALLATION OFF MFG 6000189-4.

Part: SKIN — CORRODED (ZONE 200) · airframe 53,357 hrs · 11,063 cycles

L3 DOOR CUT-OUT LOWER AFT CORNER FOUND CORRODED. COMPLIED WITH EA 1-5310-112608. CLASSIFIED AS MAJOR REPAIR AS PER FEDEX GMM 6-2-100.

Part: FITTING — CRACKED (FUSELAGE) · airframe 53,357 hrs · 11,063 cycles

MAIN DECK CARGO DOOR, LOWER JAMB FITTING FOUND NR 1 MOUNT HOLE POSITION "A", "B", AND "D" CRACKED. COMPLIED WITH EA 1-5310-112601 PART 1. FITTING REMOVED AND REPLACED AS PER SRM 51-33-01 VOL.II. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: FITTING — CRACKED (ZONE 200) · airframe 53,357 hrs · 11,063 cycles

MAIN DECK CARGO DOOR, LOWER JAMB FITTING FOUND NR 7 HOLE POSITION "C" "A", "B", ":D" CORRODED. COMPLIED WITH EA 1-5310-112602 PART 1. FITTING REMOVED AND REPLACED AS PER SRM 51-33-01 VOL.II. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: STIFFENER — CRACKED (ZONE 300) · airframe 53,357 hrs · 11,063 cycles

AFT PRESSURE BULKHEAD BS 2007 AFT SIDE VERTICAL STIFFENER AT X = -10, FOUND 1/4 INCH CRACKED AT TOP CORNER AREA. COMPLIED WITH EA 1-5310-112588 PART 1. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: HINGE FITTING — CRACKED (T/E FLAP) · airframe 48,444 hrs · 9,956 cycles

RT WING O/B FLAP I/B HINGE SUPPORT FITTING SUSPECT CRACKED. RT WING O/B FLAP REMOVED AND REPLACED AS PER AMM 27-50-30-4. ADJUSTMENT AND TEST CARRIED OUT AS PER AMM 27-50-00-830-805 AND AMM 27-50-00-830-806, FOUND SATIS. REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: BRACKET — CORRODED (ZONE 600) · airframe 48,444 hrs · 9,956 cycles

DURING FLAP REPLACEMENT, RT WING O/B FLAP I/B HINGE FITTING O/B AFT BOLT HOLE FOUND CORRODED. REPAIR CARRIED OUT AT RH WING O/B FLAP I/B HINGE FITTING O/B AFT BOLT HOLE AS PER FEDEX EA 1-5750-103506, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: BEARING — CORRODED (ZONE 400) · airframe 48,444 hrs · 9,956 cycles

PYLON NR 3, UPON REMOVAL OF AFT BEARING FOUND CORROSION ON THE BEARING BORE. REPAIR CARRIED OUT AS PER FEDEX EA 1-5410-100698, REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: STRUT — CORRODED (ZONE 600) · airframe 48,444 hrs · 9,956 cycles

DURING FLAP REPLACEMENT RT WING O/B FLAP I/B HINGE FITTING AFT STRUT AFT BOLT HOLE FOUND CORRODED. REPAIR CARRIED OUT AT RH WING O/B FLAP I/B HINGE FITTING AFT STRUT AFT BOLT HOLE AS PER FEDEX EA 1-5750-103508, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: BEARING — CORRODED (NR 3 PYLON) · airframe 48,444 hrs · 9,956 cycles

ENGINE NR 3 PYLON AFT WING ATTACHMENT BEARING ASSEMBLY FOUND WITH CORROSION. REPAIR CARRIED OUT AS PER FEDEX EA NR 1-5410-100698, TITLE: "NACELLES AND PYLONS, NR 3 PYLON AFT BULKHEAD CORROSION, INTERIM (24 MONTH) REPAIR. REFER TO SNRM N01041 FOR WORK DETAILS.

Part: ANGLE — CRACKED (RT WING) · airframe 48,444 hrs · 9,956 cycles

RT WING NR 3 TANK ACCESS PANEL 634CT INTERIOR BETWEEN STR 8 AND STR 9 TEE ANGLE FOUND CRACKED. TEE ANGLE AT RHW NO. 3 TANK BETWEEN STRINGER 8 AND STRINGER 9 REMOVED AND REPLACED AS PER SRM 51-33-01 VOLUME II. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: TRUNNION — CRACKED (NLG) · airframe 48,444 hrs · 9,956 cycles

LT NOSE LANDING GEAR TRUNNION FOUND CRACK. REPAIR CARRIED OUT AS PER FEDEX EA 1-5310-103511, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 48,444 hrs · 9,956 cycles

CTR GEAR W/W FWD KEEL BEAM STA 1305.25 RT SIDE DOUBLER FOUND CRACKED. DOUBLER AT RT SIDE CTR GEAR WW FWD KEELBEAM, STA 1305.25 REMOVED AND REPLACED AS PER SRM 51-33-01 VOLUME II. REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 48,444 hrs · 9,956 cycles

CTR GEAR W/W FWD KEEL BEAM STA 1305.25 LT SIDE DOUBLER FOUND CRACKED. DOUBLER AT LH SIDE CTR GEAR W/W FWD KEEL BEAM, STA 1305.25 REMOVED AND REPLACED AS PER SRM 51-33-01 VOLUME II. REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: HINGE FITTING — CORRODED (T/E FLAP) · airframe 48,444 hrs · 9,956 cycles

DURING FLAP REPLACEMENT RT WING O/B FLAP O/B HINGE FITTING P/N ARC1991 I/B FWD BOLT HOLE FOUND CORRODED. REPAIR CARRIED OUT AT RH WING O/B FLAP O/B HINGE FITTING I/B FWD BOLT HOLE AS PER FEDEX EA 1-5750-103507, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: SPAR — CORRODED (LT WING) · airframe 48,444 hrs · 9,956 cycles

LT WING T/E REAR SPAR UPPER CHORD AROUND XORS 1020-1070 FOUND WITH CORROSION. REPAIR CARRIED OUT AS PER FEDEX EA 1-5710-103510, REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (LT WING) · airframe 48,444 hrs · 9,956 cycles

LT WING FIXED L/E BEADED DOUBLER FOUND CRACKED AT XOS 497. REPAIR CARRIED OUT AT LT WING FIXED L/E BEADED DOUBLER AT XOS 497 AS PER SRM 57-10- 00 FIGURE 25 VOLUME I. REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (LT WING) · airframe 48,444 hrs · 9,956 cycles

LT WING FIXED L/E BEADED DOUBLER FOUND CRACKED AT XOS 698-703. REPAIR CARRIED OUT AT LT WING FIXED L/E BEADED DOUBLER, XOS 698-703 AS PER FEDEX EA#1-5730-103490, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: FRAME — BENT (FUSELAGE) · airframe 48,444 hrs · 9,956 cycles

CARGO FRAME AT LT STA 1701, L12 FOUND BENT. REPAIR CARRIED OUT AT MAIN DECK CARGO FRAME LH STA 1701 L12 AS PER SRM 53-30-00 FIGURE 1 VOLUME I. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (RT WING) · airframe 48,444 hrs · 9,956 cycles

RT WING FIXED L/E BEADED DOUBLER FOUND CRACKED AT XOS 700. REPAIR CARRIED OUT AT RT WING FIXED L/E BEADED DOUBLER, XOS 700 AS PER FEDEX EA#1-5730-103492, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: FRAME — DENTED (FUSELAGE) · airframe 48,444 hrs · 9,956 cycles

CARGO FRAME AT LT STA 1761, L12 FOUND DENT. REPAIR CARRIED OUT AT MAIN DECK CARGO FRAME LT STA 1761 L12 AS PER SRM 53-30-00 FIGURE 1 VOLUME I. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (RT WING) · airframe 48,444 hrs · 9,956 cycles

RT WING FIXED L/E BEADED DOUBLER FOUND CRACKED AT XOS 753-759. REPAIR CARRIED OUT AT RT WING FIXED L/E BEADED DOUBLER, XOS 753-759 AS PER FEDEX EA 1-5730-103493, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (LT WING) · airframe 48,444 hrs · 9,956 cycles

LT WING FIXED L/E BEADED DOUBLER FOUND CRACKED AT XOS 639. REPAIR CARRIED OUT AS PER FEDEX EA 1-5730-103494, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: FRAME — BENT (FUSELAGE) · airframe 48,444 hrs · 9,956 cycles

M/D CARGO FRAME AT LT STA 1681, L12 FOUND BENT. REPAIR CARRIED OUT AT MAIN DECK CARGO FRAME LT STA 1681 L12 AS PER SRM 53-30-00 FIGURE 1 VOLUME I. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (RT WING) · airframe 48,444 hrs · 9,956 cycles

RT WING FIXED L/E BEADED DOUBLER FOUND CRACKED AT XOS 761. REPAIR CARRIED OUT AT RT WING FIXED L/E BEADED DOUBLER, XOS 761 AS PER FEDEX EA 1-5730-103493, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (ZONE 600) · airframe 48,444 hrs · 9,956 cycles

SNRM N00500: RT WING FIXED L/E BEADED DOUBLER FOUND CRACKED AT XOS 639. REPAIR CARRIED OUT AS PER FEDEX EA 1-5730-103491, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: SKIN — CORRODED (LT WING) · airframe 48,444 hrs · 9,956 cycles

LT WING UPPER SURFACE FOUND CORROSION AT XORS 270 STR 2 AREA. REPAIR CARRIED OUT AT LH WING UPPER SURFACE XORS 270 STR 2 AREA AS PER FEDEX EA 1-5710-103499.

Part: SKIN — CRACKED (ZONE 100) · airframe 48,444 hrs · 9,956 cycles

SNRM N00430: CTR CARGO DOOR AFT LOWER CUT OUT FOUND EDGE DAMAGED. REPAIR CARRIED OUT AT DAMAGED EDGE OF CENTER CARGO DOOR AFT LOWER CUTOUT AS PER SRM 53-50-00 FIGURE 16 VOLUME I. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: SPAR — CORRODED (LT WING) · airframe 48,444 hrs · 9,956 cycles

LT WING T/E REAR SPAR LOWER CHORD AROUND XORS 1020-1070 FOUND WITH CORROSION. REPAIR CARRIED OUT AS PER FEDEX EA 1-5710-103505, REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (ZONE 600) · airframe 48,444 hrs · 9,956 cycles

SNRM N00501: RT WING FIXED L/E BEADED DOUBLER FOUND CRACKED AT XOS 613. REPAIR CARRIED OUT AS PER FEDEX EA 1-5730-103491, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: STRINGER — CRACKED (LT WING) · airframe 48,444 hrs · 9,956 cycles

HFEC INSPECTION CARRIED OUT AND FOUND CRACK ON LHW STRINGER 16.

Part: STRINGER — CRACKED (LT WING) · airframe 48,444 hrs · 9,956 cycles

HFEC INSPECTION CARRIED OUT AND FOUND CRACK ON LHW STRINGER 10.

Part: SKIN — DENTED (T/E FLAP) · airframe 48,444 hrs · 9,956 cycles

RT WING I/B FLAP LOWER SURFACE FOUND DENT. REPAIR CARRIED OUT AT RH WING I/B FLAP LOWER SURFACE AS PER SRM 57-10-00 FIGURE 3 VOLUME I. REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: STRINGER — CRACKED (RT WING) · airframe 48,444 hrs · 9,956 cycles

HFEC INSPECTION CARRIED OUT AND FOUND CRACK ON RHW STRINGER 13. REPAIR CARRIED OUT AT STRINGER 13 RT WING STA XORS 577 AS PER SRM 57-20-00 FIGURE 10 VOLUME I. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: STRUCTURE — CRACKED (LT WING) · airframe 48,444 hrs · 9,956 cycles

LT WING FIXED L/E TELESCOPING DUCT CUTOUT FOUND CRACK. REPAIR CARRIED OUT AS PER FEDEX EA1-5730-103486, REPAIR CLASSIFIED AS MINOR AS PER GMM 6- 2-100.

Part: STRINGER — CRACKED (LT WING) · airframe 48,444 hrs · 9,956 cycles

HFEC INSPECTION CARRIED OUT AND FOUND CRACK ON LHW STRINGER 14.

Part: STRUCTURE — CRACKED (RT WING) · airframe 48,444 hrs · 9,956 cycles

RT WING FIXED L/E TELESCOPING DUCT CUTOUT FOUND CRACK. REPAIR CARRIED OUT AS PER FEDEX EA 1-5730-103485, REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: LONGERON — CORRODED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

FUSELAGE-CORROSION OBSERVED IN CENTER ACCESSORY COMPARTMENT ON LONGERON 49R BETWEEN STATION 6-70 TO 6-90. REMOVED AND REPAIR CARRIED OUT AS PER FEDEX EA NR 1-5310-86604.

Part: SKIN — GOUGED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

FUSELAGE GOUGE MARK FOUND ON RIGHT HAND FUSELAGE STATION 1959 BETWEEN LONGERON 31 AND 32. TRIMMED OUT AND CARRIED OUT REPAIR AS PER SRM 53-20-00 VOLUME I FIGURE 6. REPAIR ACCOMPLISHED UNDER CATEGORY 'B' AND REQUIRE REPETITIVE INSPECTION AS PER FEDEX EA NR 1-5330-86627.

Part: SPAR CAP — CORRODED (ZONE 600) · airframe 44,365 hrs · 9,045 cycles

RT WING REAR SPAR UPPER CAP FOUND CORROSION AT XORS 450. REPAIRED AS PER FEDEX EA NR 1-5710-86608. THIS REPAIR CLASSIFIED AS MAJOR REPAIR AS PER GMM 6-2-100.

Part: ACCESS PANEL — CORRODED (ZONE 600) · airframe 44,365 hrs · 9,045 cycles

RT WING LEADING EDGE ACCESS PANEL 626FB INSIDE LOWER SURFACE FOUND CORROSION. REMOVED AND REPAIRED AS PER FEDEX EA NR 1-5710-86606. REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100.

Part: SPAR CAP — CORRODED (ZONE 300) · airframe 44,365 hrs · 9,045 cycles

NR 36R BORE FOUND EXCEEDED LIMIT AFTER CORROSION REMOVAL. EMPENNAGE NR 36R BORE REWORKED AS PER FEDEX EA NR 1-5510-83129. HORIZONTAL STABILIZER, BARREL NUT BORE 36R. REWORKED BEYOND S/B MD11-55-023 REV 2 LIMITS. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: SKIN — DAMAGED (ZONE 200) · airframe 44,365 hrs · 9,045 cycles

UPON REMOVAL OF DOME NUT STRAP TO FACILITATE SATCOM MOD AT STA 949 FUSELAGE SKIN ADJACENT TO LONGERON 1L 1 EACH FASTENER HOLE FOUND ELONGATED. REPAIRED AS PER FEDEX EA NR 1-5330-86609. THIS REPAIR CLASSIFIED AS MINOR REPAIR AS PER GMM 6-2-100.

Part: SPAR CAP — CORRODED (ZONE 600) · airframe 44,365 hrs · 9,045 cycles

RT WING REAR SPAR UPPER CAP FOUND CORROSION AT XORS 470. REPAIRED AS PER FEDEX EA NR 1-5710-83099 THIS REPAIR CLASSIFIED AS MAJOR REPAIR AS PER GMM 6-2-100.

Part: PANEL — BULGED (RT WING) · airframe 44,365 hrs · 9,045 cycles

RIGHT WING TRAILING EDGE UPPER PANEL LEADING EDGE FOUND BULGING AT XORS 1042. REMOVED AND REPAIR CARRIED OUT AS PER FEDEX EA NR 1-5710-86607.

Part: FRAME — CHAFED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

MAIN DECK CABIN RIGHT STATION 1701 LONGERON 12R FRAME, FOUND CHAFED AS MARKED. REPAIR CARRIED OUT AS PER SRM 53-30-00 FIGURE I VOLUME I.

Part: LONGERON — CORRODED (ZONE 100) · airframe 44,365 hrs · 9,045 cycles

FUSELAGE-CORROSION OBSERVED IN CENTER ACCESSORY COMPARTMENT ON LONGERON 47R STATION 6-90. REPAIRED AS PER SRM 53-10-00 FIGURE 2 VOLUME I.

Part: FRAME — DENTED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

MAIN DECK CABIN LEFT STATION 1641 LONGERON 12L FRAME FOUND DENTED AS MARKED. REPAIRED IAW SRM 53-30-00 FIGURE I VOLUME I.

Part: FRAME — DENTED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

MAIN DECK CABIN LEFT STATION 1661 LONGERON 12L FRAME FOUND DENTED AS MARKED. REPAIRED IAW SRM 53-30-00 FIGURE I VOLUME I.

Part: RIB — CRACKED (ZONE 600) · airframe 44,365 hrs · 9,045 cycles

RT WING LEADING EDGE SLAT TRACK NR 16 INBOARD RIB FOUND CRACKED. CRACKED RIB REMOVED AND REPLACED AS PER SRM 51-33-01 AND SRM 51-35-01 VOLUME II. THIS REPAIR CLASSIFIED AS MAJOR REPAIR AS PER GMM 6-2-100.

Part: FRAME — DENTED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

MAIN DECK CABIN RIGHT HAND STATION 1681 LONGERON 12R FRAME FOUND DENTED AS MARKED. REPAIRED AS PER SRM 53-30-00 FIGURE I VOLUME I.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 44,365 hrs · 9,045 cycles

MAIN DECK STATION 839 AND STATION 859 X=-8 SEAT TRACK FOUND CORRODED. TRIMMED OUT AND REPAIRED AS PER SRM 53-70-00

Part: FRAME — DENTED (ZONE 200) · airframe 44,365 hrs · 9,045 cycles

MAIN DECK LEFT STATION 535 "Z"= 24 FRAME FOUND DENTED AS MARKED. REPAIR CARRIED OUT AS PER DRAWING SRZ-53-503.

Part: FRAME — DENTED (ZONE 200) · airframe 44,365 hrs · 9,045 cycles

MAIN DECK LEFT HAND STATION 535 "Z"= 50 FRAME FOUND DENTED AS MARKED. REPAIR CARRIED OUT AS PER DRAWING SRZ-53-503.

Part: FITTING — CRACKED (ZONE 100) · airframe 44,365 hrs · 9,045 cycles

FORWARD CARGO COMPARTMENT,FOUND BILGE LOCATION AT STATION 1130, LONGERON 51L WITH SPLICE CRACKED AS MARKED. NEW SPLICE FITTING MACHINED AS PER DRAWING NO.ADA 8424. FORWARD CARGO COMPARTMENT AT STATION 1130, LONGERON 51L CRACKED SPLICE FITTING REMOVED AND NEW SPLICE FITTING INSTALLED AS PER SRM 51-31-01 VOLUME II. THIS REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: BRACKET — CRACKED (ZONE 300) · airframe 44,365 hrs · 9,045 cycles

TAILCONE FORWARD SECTION: LT UPPER DOOR TEE BRACKET BELOW THE HINGE ASSEMBLY FORWARD MOST EDGE FOUND CRACKED AS MARKED. CRACKED AREA REPAIRED AS PER FEDEX EA NR 1-5350-86610.

Part: SKIN — CORRODED (ZONE 500) · airframe 44,365 hrs · 9,045 cycles

LT WING UPPER SURFACE FOUND CORROSION AT XORS 77 STRINGER 21. CORRODED AREA REPAIRED AS PER FEDEX EA NR 1-5710-86605. THIS REPAIR CLASSIFIED AS MINOR REPAIR AS PER GMM 6-2-100.

Part: FITTING — CORRODED (ZONE 100) · airframe 44,365 hrs · 9,045 cycles

AFT CARGO COMPARTMENT FOUND BILGE LOCATION LONGERON-48R STA 1851 SPLICE FITTING WITH CORROSION. NEW SPLICE END FITTING MACHINED AS PER DRAWING NR AGA7438. AFT CARGO COMPARTMENT STA 1851, LONGERON-48R SPLICE END FITTING REMOVED AND NEW SPLICE END FITTING INSTALLED AS PER SRM 51-31-01 VOLUME II. THIS REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: CLIP — CRACKED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

AFT FUSELAGE COMPARTMENT DOGHOUSE NR 2 AFT TOP FRAME TO CROWN ATTACHMENT CLIP SUSPECT CRACK. REMOVED AND REPLACED AS PER SRM 51-35-01 AND SRM 51-33-01 VOLUME II.

Part: FITTING — CRACKED (ZONE 100) · airframe 44,365 hrs · 9,045 cycles

CENTER CARGO COMPARTMENT FOUND SUMP LOCATION WITH SPLICE CRACKED AT STA 1710, L-51L. CARRIED OUT REMOVAL AS PER SRM 51-33-01 VOL II AND NEW SPLICE FITTING FABRICATED BY MACHINING AS PER DRAWING NR AFA7102 AND INSTALLED AS SRM 51-33-01 VOL II. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: LONGERON — CORRODED (ZONE 100) · airframe 44,365 hrs · 9,045 cycles

CENTER CARGO COMPARTMENT FOUND BILGE LEVEL L-49R, STA 1541 WITH STRINGER CORRODED. CARRIED OUT REPAIRED AS PER SRM 53-10-00 FIGURE 2 VOLUME 1. THIS REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

LANDING GEAR, CENTER LANDING GEAR LEFT HAND FORWARD BULKHEAD SIDE DOUBLER CRACKED. DOUBLER REMOVED AND NEW DOUBLER INSTALLED AS PER SRM 51-33-01 VOLUME II. THIS REPAIR CLASSIFIED AS MAJOR REPAIR AS PER GMM 6-2-100.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 44,365 hrs · 9,045 cycles

LANDING GEAR, CENTER LANDING GEAR RIGHT HAND FORWARD BULKHEAD SIDE DOUBLER CRACKED. DOUBLER REMOVED AND NEW DOUBLER INSTALLED AS PER SRM 51-33-01 VOLUME II.

Part: FITTING — CRACKED (ZONE 100) · airframe 44,365 hrs · 9,045 cycles

CENTER CARGO COMPARTMENT, FOUND BILGE LOCATION L-49R STA 1531 SPLICE FITTING CRACKED. REMOVED AS PER SRM 51-33-01 VOLUME II AND NEW SPLICE FITTING FABRICATED AS PER DRAWING NR A5A7114 AND INSTALLED AS PER SRM 51-33-01 VOLUME II. THIS REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100.

Part: WARNING LIGHT — FALSE ACTIVATION (MLG BRAKES) · airframe 43,689 hrs · 8,895 cycles

BRAKE OVERHEAT ALERT ON T/O. PUT GEAR BACK DOWN LIGHT WENT OUT. BRAKE NR 9 INITIALLY BLANK THEN 130 DEGREES WHEN LIGHT WENT OUT. T/O ROLL WAS NORMAL. NO CURRENT FAULT SHOWN IN BTMTP. PERFORMED RTS OF BTMTPI IAW MM 32-46-00-700,TEST PASSED. PERFORMED VISUAL INSPECTION OF BRAKE NR 9 IAW MM 32-43-20. NO DAMAGE FOUND.

Part: ENGINE — FAILED (NR 2) · airframe 43,138 hrs · 8,770 cycles

NR 2 ENGINE VIBRATION AT TAKEOFF ROTATION FOLLOWED BY A BANG AT ROTATION. COMPRESSOR STALL REPORTED BY ANOTHER AIRCRAFT. EXCEEDENCE WENT AMBER TO 5.3 ON CLIMB & 4.4 IN CRUISE AT 10K FT, VIBRATION NOTICABLE IN CRUISE WITH ENGINE & WING ANTI-ICE ON & IGNITION OVERRIDE, ENGINES WERE DE-ICE & ANTI-ICE IN GATE FOLLOWED 30 SECOND RUN UP ON RUNWAY. DUE TO TAKEOFF COMPRESSOR STALL ABOVE 1.25 EPR THIS ENGINE IS APPROVED FOR REMOVAL PER PP/ENGINEERING. COMPLETED ENGINE CHANGE 1/1/05.

Part: SENSOR — MALFUNCTIONED (MLG BRAKE) · airframe 41,170 hrs · 8,318 cycles

AFTER T/O & GEAR RETRACTION, PASSING 6000 FT, BRAKE DIFF TEMP ALERT APPEARED. TEMP ON BRAKE NR 6 WAS 400 & RISING. ALL OTHER BRAKE TEMPS WERE LESS THAN 50. LANDING GEAR WAS EXTENDED TO COOL & STOP THE RISING TEMP ON BRAKE NR 6. BRAKE DIFF TEMP ALERT WENT AWAY AFTER TEMP DECREASE BELOW 300. AFTER LANDING BRAKE TEMP IS AT 656 DEG. REMOVED AND REPLACED BRAKE TEMP SENSOR PER MM 32-46-01-4.

Part: SUPPORT BRACKET — MISSING (NR 3 PYLON) · airframe 41,015 hrs · 8,286 cycles

NR 3 PYLON ENGINE FIREX SUPPLY LINE IS RIDING HARD AND WORN THROUGH AGAINST PYLON STRUCTURE AFT OF PYLON FWD BULKHEAD LOOKING THRU ACCESS PANEL 487FL. THE DAMAGE IS MEASURED AS 1.125 X .125 INCHES ). REMOVED AND REPLACED A SECTION OF FIREX PERMANENT LINE BETWEEN FIRE BOTTLE AND UPPER PILLOW CONNECTION PER M/M 20-10-01-2. BLENDED BULB SEAL SUPPORT BRACKET. FOUND THAT DAMAGE TO FIREX LINE WAS DUE TO MISSING SUPPORT BRACKET HARDWARE.

Part: TRUCK — BROKEN (RT MLG) · airframe 41,015 hrs · 8,286 cycles

RT MLG TRUCK BEAM HAS BROKEN PIVOT BORE SLEEVE AS VIEW THRU RT OUTBOARD AFT LUBE HOLE. UPON FURTHER INVESTIGATION NO DAMAGE WAS FOUND.OK TO CONTINUE SERVICE. RT MLG TRUCK WAS REMOVED & REINSTALLED IAW M/M 32-12-20-4.

Part: WARNING LIGHT — FALSE ACTIVATION (COCKPIT) · airframe 38,178 hrs · 7,607 cycles

DURING CLIMB SHOWED LEVEL ONE AIR SYS 2 OFF, ALERT FOLLOWED SHORT LAG BY LEVEL THREE MANF 2 FAIL ALERT. RAN CHECKLIST AND RETURNED TO NRT WITH ENGINE 2 AT IDLE THRUST. WITH ENGINE AT IDLE, ALERT WAS REMOVED. FACT 18JUL03 10:04 NRT R, REPLACED MANIFOLD FAILURE SENSING ELEMENT (35625-4-255) AT ZONE 14A PER AMM36-23-7. SOMETIMES MFC ABORT DURING ACCESS, REMOVED AND REPLACED MFC AND R-T-S TEST PASSED PER AMM36-23-01. CHECKED ALL ELEMENT A&B, FOUND NO SHORT TO GROUND. PERFORMED ENG RUN PER MD11JRH WITH NR 135532. DECAY C'K PASSED 27 SEC. FOUND NO DEFECT.

Part: CONTROLLER — FAILED (MANIFOLD) · airframe 37,833 hrs · 7,526 cycles

AIR MANFOLD NR 2 FAIL ALERT- COMPLIED WITH QRC PROCEDURES RETURNED TO KEWR- NORMAL LDG 4L. FOUND AIR LEAK AT CLAMP ON AFT END OF PRECOOLER ASSY. REPLACED CLAMP AT NR 2 PYLON PRECOOLER AFT END PER MM 36-13-01-2 LEAK CHECK GOOD WITH AIR FROM AIR START. REPLACED MANIFOLD FAILURE DETECTION CONTROLLER AS PER 36-23-01-4 - OPS AND RTS NORMAL. RAN NR 2 ENG PER JRH AT POWER, NO FAULTS, PERFORMED DECAY CHECK PER JRH 7-10, PASSED. MANIFOLD PRESSURE DROPPED FROM 40 PSI TO 30 PSI IN 25 SEC WITH A TEMP OF 105C. CHECKED MFC AFTER RUN, NO CURRENT FAULTS, NO FAULTS IN REVIEW AND PASSED RTS.