N583AS

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHTS) · airframe 55,904 hrs · 16,356 cycles

RH AND LH AFT EXTERIOR OVERWING EMERGENCY EXIT LIGHTS DO NOT COME ON. GROUNDED - YES. REMOVED, REPLACED AND OP TEST ARE GOOD OF R/H AND L/H EXTERIOR OVERWING EMERGENCY EXIT LIGHTS IAW B737-900 AMM 33-51-06-960-805.

Part: BATTERY — INOPERATIVE (MAIN PASSENGER C) · airframe 55,904 hrs · 16,356 cycles

RH AND LH AFT EXTERIOR OVERWING EMERGENCY EXIT LIGHTS DO NOT COME ON. GROUNDED - YES. REMOVED, REPLACED AND OP TEST ARE GOOD OF R/H AND L/H EXTERIOR OVERWING EMERGENCY EXIT LIGHTS IAW B737-900 AMM 33-51-06-960-805.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 55,904 hrs · 16,356 cycles

CENTER ASILE CEILING EMERGENCY LIGHT NO WORKING PROPERLY. GROUNDED - YES. REMOVED AND REPLACED M1694 & M1695 EMERGENCY LIGHTS BATTERY PACKS MIDCABIN OPS CHECKS GOOD IAW B737-800 AMM 33-51-06-960-805 STEP 4.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 55,904 hrs · 16,356 cycles

CENTER ASILE CEILING EMERGENCY LIGHT NO WORKING PROPERLY. GROUNDED - YES. REMOVED AND REPLACED M1694 & M1695 EMERGENCY LIGHTS BATTERY PACKS MIDCABIN OPS CHECKS GOOD IAW B737-800 AMM 33-51-06-960-805 STEP 4.

Part: BATTERY — FAILED (MAIN PASSENGER C) · airframe 55,904 hrs · 16,356 cycles

R1 EMERGENCY EXIT LIGHT NOT WORKING PROPERLY. GROUNDED - YES. REMOVED, REPLACED AND OP CHECK GOOD R1 DOOR BATTERY PACK IAW B737-800 AMM 33-51-06-960-805.

Part: TRANSITION PANEL — CORRODED (UNKNOWN) · corrosion level 2 · airframe 55,904 hrs · 16,356 cycles

AFT PIT L/H TRANSITION HAS AREAS OF CORROSION ON UPPER AND LOWER SURFACES STA 727A TO 827. GROUNDED - YES. REMOVED CORROSION AND CHECKED LIMITS. FOUND TWO AREAS OUT OF LIMITS FS 727H - FS 727I AND FS 747-787. ALL OTHER AREAS ARE IN LIMITS IAW B737-800 SRM 53-00-53-1A-2. REFINISHED IN LIMITS AREAS IAW B737-800 SRM 53-00-53-1A-2. REPAIRED FS727H - FS787 IAW B737-800 SRM 53-00-53-2R-6W- 1.0" O- .040 R- .031 L- 20.0" D- .009.

Part: SKIN — CORRODED (UNKNOWN) · corrosion level 2 · airframe 55,904 hrs · 16,356 cycles

FOR CORROSION AND SDR REPORTING ONLY REF DEFECT 60708457 CORROSION AROUND LAV EXHAUST HOLE. GROUNDED - YES. REMOVED DAMAGE AND REPAIRED SKIN AT LAV EXHAUST HOLE FOR ALL WORK ACCOMPLISHED SEE DEFECT 60708457 ASA WO 1918839 N/R-00009W=2 O=.125 R=0 L-3 D=.125.

Part: SUPPORT — CORRODED (UNKNOWN) · corrosion level 2 · airframe 55,904 hrs · 16,356 cycles

AFT PIT RH TRANSITION HAS AEAS OF CORROSION STA 727B+12 TO 767. GROUNDED - YES. REMOVED CORROSION AND CHECKED LIMITS FOUND STA 727I OUT OF LIMITS ALL OTHER AREAS FOUND WITHIN LIMITS IAW B737-800 SRM 53-00-53-1A-2 REPAIRED OUT OF LIMITS AREA IAW B737-800 SRM 53-00-53-2R-6 REFINISHED WITHIN LIMITS AREAS IAW B737-800 SRM 53-00-53-1A-2W=1.0 O=.040 R=0.0 L=1.5 D=.040.

Part: FLOORBEAM — CORRODED (UNKNOWN) · corrosion level 2 · airframe 55,904 hrs · 16,356 cycles

AFT CABIN FLOORBEAM 986.3 CORRODED AROUND FASTENER HOLES LBL 45 TO RBL 45 NUMEROUS AREAS, MARKED. GROUNDED - YES. DAMAGE FOUND TO BE OUT OF LIMITS, REPAIRED FLOOR BEAM IAW B737-800 SRM 53-70-51-2R-6 W 1 O .150 R .126 L 2 D .024.

Part: SHIELD — CORRODED (UNKNOWN) · corrosion level 2 · airframe 55,904 hrs · 16,356 cycles

AFT PIT DOOR CUTOUT FWD SHIELD PANEL IS CORRODED 100% THROUGH. GROUNDED - YES. REMOVED AND REPLACED FWD SHIELD WITH NEW ONE IAW B737-800 SRM 51-40-02-0G-0W=1 O=.051 R=0 L=1 D=.051.

Part: CARGO TRACK — CRACKED (UNKNOWN) · airframe 55,904 hrs · 16,356 cycles

AFT PIT RH CARGO TRACK IS CRACKED IN FRAME ATTACH POINT RADIUS AT STA 727I, 727J 747 AND 767. GROUNDED - YES. REMOVED AND REPLACED AFT PIT R/H CARGO TRACK FROM STA 727I TO STA 767 IAW B737-800 SRM 53-00-53-2R-3.

Part: STRAP — CORRODED (UNKNOWN) · corrosion level 2 · airframe 55,904 hrs · 16,356 cycles

AFT PIT FLOOR STRUCTURE INBD OF DOORWAY SILL WEB HAS CORROSION ON UPPER SURFACE OF CHORD AT STA 800 FASTENER HOLE. GROUNDED - YES. REMOVED CORROSION AND CHECKED LIMITS FOUND CHORD UPPER SURFACE STRAP OUT OF LIMITS IAW B737-800 SRM 53-60-15-1A-1. REMOVED AND REPLACED STRAP IAW B737-800 SRM 51-40-02-0G-0 AND B737-800 SRM 51-40-05-0G-0 FIG 2W- 1.0 O- .100 R- .053 L- 1.25 D- .047.

Part: ANTI-ICE VALVE — FAILED (#1 ENGINE) · airframe 55,901 hrs · 16,355 cycles

#1 ENG. ANTI-ICE VALVE LIGHT REMAINED ON BRIGHT WHEN SELECTED OFF. GROUNDED - YES. REPLACED #1 ENGINE A/I VALVE PER MM 30-21-11-400, LEAK & OPS CHECK GOOD.

Part: REGULATOR — FAULTY (#1 ENGINE) · airframe 55,901 hrs · 16,355 cycles

#1 ENG. BLEED PRESSURE LOW AT IDLE. GROUNDED - YES. REPLACED BLEED AIR REGULATOR PER MM 36-11-03-400.REPLACED PRSOV FOUND TO BE LEAKING, PER MM 36-11-04-400-801.LEAK & OPS CHECK GOOD.

Part: IDG — FAULTED (#1 ENG) · airframe 55,904 hrs · 16,356 cycles

TECH SERVICES FOLLOW UP REQUEST IN FREQUENT #1 IDG SERVICING(#PRI2/ETOPS) ****** ETOPS SIGNIFICANT SYSTEM *******. GROUNDED - YES. (RESOLVED ON W/O: 1918839 TASKCARD: N/R-00011 ) NO MAINTENANCE ACTION REQUIRED SEE TECH SERVICE NOTE #1 IDG REPLACED 07/13/2023 WITH #1 ENG REPLACEMENT IDG SN AAAH005608 IS PART INSTALLED AT TIME OF TSR SUBMISSION SEAMC MIKE NOTIFIED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 55,835 hrs · 16,336 cycles

WHILE ACCOMPLISHING TC 78723000, ENG #2 HAD ECONOMIC FAULT 77-20862, BOTTOM LEFT EGT SIGNAL IS OUT OF RANGE. GROUNDED - YES. ON DEFERRAL.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 55,772 hrs · 16,312 cycles

WINDOW HEAT LIGHTS WON'T SHOW "ON" LIGHT DURING PREFLIGHT. GROUNDED - YES. PERFORMED WINDOW HEAT OPS CHECK. WINDOW OVERHEAT FUNCTION GOOD. WINDOW PWR FUNCTION GOOD. PERFORMED BITE OF WINDOW HEAT CONTROLLERS. BITE CHECK GOOD. NO FAULTS IAW B737-800 AMM 30-41-00. WINDOWS WERE IN DUN. SUSPECT THEY WERE PWR CYCLING AS NORMAL. OK FOR SERVICE. ONE BULB INOP ON INDICATOR. REMOVED AND REPLACED ONE BULB IN INDICATOR. LIGHTS CHECK GOOD.

Part: LUBRICATION UNIT — LEAKING (#1 ENGINE) · airframe 55,835 hrs · 16,336 cycles

#1 ENGINE OIL TREND DATA SHOWS OIL CONSUMPTION TO GREATER THAN EXPECTED. (#PRI2/ETOPS)ENGINE POWER RUN REQUIRED. GROUNDED - YES. ACCOMPLISHED TSR STEPS 8 THROUGH 13, STEP 9 OIL SUPPLY TUBE WAS SERVICABLE AND DOES NOT REQUIRE REPLACEMENT. STEP 10 ITEM 500 NIPPLE WAS FOUND BLOCKED AND WAS REPLACED. STEP 12 OIL INLET COVER IS REMOVED AND NEEDS TO BE REPLACED DUE TO EXCESSIVE COKING, STEP 13 NO DEFECTS/DAMAGE NOTED. OIL/AIR SEPARATOR WAS FOUND WITH ERROSION AROUND EDGES WHERE THE SCREEN IS, REF LP 60556335. INSTALLATION IS REQUIRED. REPLACED TRF OIL INLET COVER IAW AMM 72-56-00-400-801-F00 STEPS G(1) - H(2). LEAK CHECK REQ. ASA 41947 07/06/2023AFTER ACCOMPLISHING LK CK, FOUND OIL PUDDLING IN THE PRIMARY PLUG, SOURCE UNDETERMINED. REMOVED PLUG AND FLANGE. VERIFIED RTF CAVITY WAS DRY WITH NO LEAKS FROM THE TRF OR AFT SUMP DRAIN PORTS. OIL SOURCE IS FROM THE SHAFT AREA LEAKING OUT OF THE FLAME ARRESTOR. REPLACED THE LUBE UNIT REF MM 79-21-00. ALL LK AND OPS CKS GOOD. REINSTALLED FLANGE AND PLUG ASSY REF MM 72-56-00 AND MM 78-11-02. TSR COMPLETE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 55,717 hrs · 16,296 cycles

AFTER SHUTDOWN, SWITCH FOR EMERGENCY EXIT LIGHTING WAS PLACED "OFF" AND ALL THE EMERGENCY EXIT LIGHTING TURNED ON AND STAYED ON. GROUNDED - YES. AFT CABIN EMERGENCY LIGHT WAS STUCK IN THE ON POSITION. READJUSTED LIGHT COVER AND OPERATIONAL CHECK IS NORMAL. REF B737-800 AMM 33-51-00-720-801.

Part: ADAPTER — LEAKING (RIGHT WING) · airframe 55,597 hrs · 16,246 cycles

FUELING RECEPTACLE LEAKING WHEN FILLING ON #2 TANK. GROUNDED - YES. REMOVED AND REPLACED FUELING RECEPTACLE IAW AMM 28-21-11-400-801.

Part: VALVE — FAULTY (#1 ENGINE) · airframe 55,518 hrs · 16,226 cycles

TECH SERVICE REQUEST. GE DIAGNOSTICS IS REPORTING #1 ENGINE HPTACC FAULTS WITH COORESPONDING TREND SHIFTS. PRI2CNR 20230606039 ENG S/N 802957. GROUNDED - YES. ACCPMLISHED ACTUATORS TEST AND CHECK FAULT HISTORY NO FAULTS FOUND. REF AMM 71-00-00-700-807-F00. ALT. DEACTIVATION FOR ELECTRICAL POWER PER CHAPTER 5-07-01 PG3, TABLE 3 ITEM 1. REMOVED #1 ENG. HPTACC VALVE. REF. MM 75-21-01-000-001-F00 P YEELE 41581 06-27-2023. INSTALLED #1 ENG HPTACC VALVE IN REF TO AMM 75-21-01-400-801-F00 OPS AND LEAK CK GOOD THIS CLEARS TSR714464 SEAMC PAT NOTIFIED MIG2C INITIATED SN 40-0055038. MIG2C CLOSED 40-0055038.

Part: MODULATING VALVE — FAULTED (RIGHT ECS BAY) · airframe 55,496 hrs · 16,220 cycles

RH PACK H ILLUMINATED ON RECALL AND EXTINGUISHES WHEN MC RESET. GROUNDED - YES. BITE CHECK OF #1 & #2 PZTC. #1 NO FAULTS, #2 FAULTED TCV THIS PACK. VERIFY GREEN GO LT ILLUMINATED AND FAULT RESET. DUE HISTORY REPLACED RIGHT PACK TEMP CONTROL VALVE V141, LEAK AND OPS CHECKS OK. BITE #2 PZTC NO FAULTS. REF B737-800 FIM 21-53 TASK 821, 21-62 TASK 801 & 831, & B737-800 AMM 21-51-01.

Part: SEAL — LEAKING (#1 ENGINE OIL) · airframe 55,234 hrs · 16,145 cycles

#1 ENGINE OIL TREND DATA SHOWS OIL CONSUMPTION TO GREATER THAN EXPECTED. ENGINE POWER RUN REQUIRED. GROUNDED - YES. PERFORMED B737-800 AMM 71-00-00 TEST 3B WITH OIL DRAINS BAGGED. REMOVED BAGS AND COLLECTED 3CC/HR WORTH OF OIL FROM IDG PAD DRAIN SEALOL & CARBON SEAL REMOVED AND NEW INSTALLED UP TO STEP 6 REF AMM 72-60-00-400-802 FOO 49008 STEPS 6 AND 7 COMPLETED LEAK CHACK GOOD REF AMM 72-60-00.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 55,327 hrs · 16,172 cycles

RT PACK LT ILLUMINATED DURING RECALL, RESETS WITH MASTER CAUTION. GROUNDED - YES. ACCOMPLISHED PZTC #2 BITE AND HAD "THIS PACK TCV" FAULT ON PREV FLIGHT. FAULT CLEARED AND BITE PASS ON VERIFY REF B737-800 FIM 21-62 TASK 801.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 55,318 hrs · 16,170 cycles

AUTOTHROTTLE ARM (GREEN LIGHT) LIGHT INOP. GROUNDED - YES. MCP A/T LIGHT OPS NML REF B737-800 AMM 22-11-34. VERIFIED LIGHT INTENSITY CHANGES W/ CAPTAIN'S MAIN PANEL LT RHEOSTAT.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 54,950 hrs · 16,050 cycles

SPEED TRIM FAIL CAUTION LIGHT. GROUNDED - YES. ACCOMPLISHED B737-800 FIM 22-11 TASK 850. OPS TESTS PASSED. SPEED TRIM FAIL ON FCC-B ON FLT LEG 3. NO HISTORY IN LAST 30.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 54,929 hrs · 16,045 cycles

A/T ARM LIGHT INOP.A/T WORKS PROPERLY. GROUNDED - YES. PERFORMED INTENSITY CONTROL LIGHTING TEST OF MAIN CONTROL PANEL. B737-800 SSM 22-31-51. OPS CHK NORMAL.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 54,807 hrs · 16,008 cycles

AUTO THROTTLE GREEN ARM LIGHT INOP. GROUNDED - YES. ADJUSTED CAPT'S MAIN PANEL LIGHT RHEOSTAT, MCP A/T ARM LIGHT (GREEN) ON. A/T SYSTEM OPERATIONAL TEST NML REF B737-800 AMM 22-31-00-710-801.

Part: NOT REPORTED — NOT REPORTED (NOT REPORTED) · airframe 54,234 hrs · 15,850 cycles

LH FWD WINDOW OVERHEAT LIGHT ILLUMINATED. GROUNDED - YES. FOUND C/B AT P6-11, B-9 OPEN RESET C/B. REF B737-800 AMM-20-60-01 WINDOW HEAT OPS CHECK NORMAL REF AMM 30-41-11.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 54,099 hrs · 15,809 cycles

EMERGENCY SLIDE LIGHT BY R2 DOOR INOP. GROUNDED - YES. RELAMPED EMERGENCY SLIDE LIGHT BY R2 DOOR REF B737-800 AMM 33-51-04.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 54,078 hrs · 15,803 cycles

R PACK LIGHT ILLUMINATES WITH RECALL CHECK. GROUNDED - YES. PERFORMED PACK/ZONE TEMP. CONTROLLER BITE TEST REF. B737-800 AMM 21-61-00-700-806-002. BITE TEST GOOD. NO HISTORY FOR 30 DAYS. ORIG SUB DATE: 1/25/2023

Part: MODULATING VALVE — FAULTED (RIGHT ECS BAY) · airframe 54,010 hrs · 15,779 cycles

R PACK LIGHT - RESETS. GROUNDED - YES. FOUND FAULT THIS PACK TCV (V141). REMOVED AND REPLACED RIGHT TCV IAW B737-800 AMM 21-51-10.

Part: WARNING MESSAGE — FALSE ACTIVATION (COCKPIT TEMP) · airframe 53,662 hrs · 15,685 cycles

CONTROL ZONE CONTROL CAB LIGHT ON RECALL RESETS, TEMP CONTROLLABLE. GROUNDED - YES. VERIFIED FAULT, ACCOMP PACK ZONE TEMP CONTROL BITE, #1 CONT NO FAULTS, #2 FAULTS FLT DECK TRIM VALVE. CLEARED FAULT, REACCOMPLISHED PACK ZONE TEMP CONT BITE BOTH CONT SHOW NO FAULTS. REF B737-800 AMM 21-61-00-700-806-002. ACCOMP TRIM VALVE TEST, TEST PASS REF AMM 21-51-10-740-001.

Part: SEAL — LEAKING (#1 ENGINE) · airframe 52,880 hrs · 15,452 cycles

#1 ENGINE OIL TREND DATA SHOWS OIL CONSUMPTION TO GREATER THAN EXPECTED. ENGINE POWER RUN REQUIRED. GROUNDED - YES. FOUND EVIDENCE OF OIL LEAKING FROM IDG PAD DRAIN LINE. PERFORMED IDLE ENGINE RUN AND FOUND ACTIVE LEAK FROM IDG PAD DRAIN OF 7 DROPS PER MINUTE, WITH ENGINE AT IDLE. LEAKING IDG DRAIN PAD DEFECT. REMOVED & REPLACED #1 ENG IDG REF B737-800 AMM 24-11-11. REMOVED & REPLACED #1 ENG IDG SEALOL SEAL REF AMM 72-60-00. NO LEAKS NOTED OPS CHECK GOOD. (REF ASA L/P 60403486).

Part: A/C PACK — FAULTED (UNKNOWN) · airframe 52,329 hrs · 15,279 cycles

ON MASTER CAUTION RECALL AFTER START RIGHT HAND PACK LIGHT ILLUMINATED ,RESET WITH MASTER CAUTION RESET. GROUNDED - YES. INITIAL EVALUATION, RH PACK LT ON MASTER RECALL AT OVERHEAD. PERFORMED PZTC BITE IAW B737-800 FIM 21-62 TASK 801. PZTC #2 HAD TCV RED LT ON BIT, CLEARED GREEN ON VERIFY. OBSERVED RH PACK TCV MOVE AT TEST. SOUNDS SAME AS LEFT. RAN BOTH PACKS PER B737-800 AMM 21-61-00-700-807-002, BOTH PACKS RAN FULL WARM/FULL COLD TOGETHER AND INDEPENDENTLY 10-15 MINS, NO FAULTS. RH PACK LT NO LONGER PRESENT AT P5 OVERHEAD. NO A/C HISTORY FOR THIS DEFECT.

Part: SEAL — LEAKING (#2 ENGINE) · airframe 52,325 hrs · 15,277 cycles

#2 ENGINE CONTINUES TO SHOW GREATER THAN EXPECTED OIL CONSUMPTION. GROUNDED - YES. REMOVED AND REPLACED SEALOL SEAL IAW B737-800 AMM 72-60-00.

Part: CIRCUIT BREAKER — POPPED (UNKNOWN) · airframe 52,058 hrs · 15,191 cycles

FO COURSE SELECTOR WINDOW ON MCP NOT DISPLAYING SELECTED COURSE. GROUNDED - YES. FOUND POPPED BREAKER AFCS MCP DC1 GVI BREAKER AND ACCESSIBLE WIRING NO DEFECTS NOTED RESET CB REF B737-800 AMM 20.60.01 OPS RESTORED FO MCP COURSE WINDOW DISPLAY CHECKS OK REF B737-800 FIM 22-11 TASK 803.

Part: DRAIN LINE — LEAKING (#1 ENGINE) · airframe 51,995 hrs · 15,165 cycles

#1 ENG MAIN FUEL/OIL HEAT EXCHANGER PAD DRAIN LINE DRIPPING FUEL OUT OF LIMITS. GROUNDED - YES. REMOVED #1 MAIN FUEL/OIL HEAT EXCHANGER PER B737-800 AMM 79-21-02-00-801. REPLACED THE #1 ENG FUEL/OIL HEAT EXCHANGER REF AMM 79-21-02. LK AND OPS CHKS GOOD.

Part: O-RING — LEAKING (#2 ENGINE) · airframe 51,995 hrs · 15,165 cycles

#2 ENGINE OIL TREND DATA SHOWS OIL CONSUMPTION TO GREATER THAN EXPECTED. ENGINE POWER RUN REQUIRED RECOMMEND SEA ONLY. GROUNDED - YES. ACCOMPLISHED STEPS 1 THROUGH 5. FOUND SMALL PUDDLE OF OIL BELOW DEVE PAD COVER. REPLACED DRIVE PAD O-RINGS REF B737-800 AMM 72-63-01. NO LEAKS DETECTED. INSP. BAGGED OIL DRAINS FOR STEP 6. ACCOMPLISHED STEP 6. TEST 3B, NO DISCREPANCIES NOTED REMOVED BAGS.

Part: SEAL — LEAKING (#2 ENGINE) · airframe 51,839 hrs · 15,113 cycles

#2 ENGINE OIL CONSUMPTION IS HIGHER THAN DESIRED. CURRENT OIL CONSUMPTION .4. GROUNDED - YES. COMPLETED STEPS 1 AND 2 OF TSR AND BAGGED OIL DRAINS FOR STEP 3. FOUND IDG SEALOL SEAL LEAKING. REMOVED AND REPLACED #2 IDG SEALOL SEAL REF B737-800 AMM 72-60-00-400-802-F00. #2 ENG TEST 3B NEEDS ACCOMPLISHED DUE TO SEALOL SEAL CHANGE. ACCOMPLISHED PART POWER LEAK CHECK #2 ENG REF B737-800 AMM 71-00-00-700-823-F00, TEST 3B . NO LEAKS FOUND ALL BAGS WERE CLEAN & REMOVED. TSR COMPLETE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 51,541 hrs · 15,024 cycles

AUTO THROTTLES INOP. GROUNDED - YES. ACCOMPLISHED AUTOTHROTTLE BITE PER B737-800 FIM 22-31 TASK 801, CURRENT STATUS HAS NO FAULTS . IN FAULT HISTORY LEG 5 HAS FAULT MSG 22-31543 "A/T ENG 28 VDC INV" ACCOMPLISHED FIM 22-31 TASK 830 INITIAL EVALUATION NO CURRENT FAULTS NOTED.

Part: BULB — INOPERATIVE (R2 DOOR EXTERIOR) · airframe 51,281 hrs · 14,950 cycles

R2 DOOR EXTERIOR EMERGENCY LIGHT OUT. GROUNDED - YES. RELAMPED & TESTED R2 DOOR EMERG LT. OPS CHECK GOOD. REF B737-800 AMM 33-51-00.

Part: NONE — FAILED (E/E RACK E5) · airframe 51,272 hrs · 14,946 cycles

ABOUT ONE HOUR AFTER TAKEOFF WE GOT FOUR RIGHT FMC FAILURES OVER A SPAN OF ABOUT 10 MINUTES AS INDICATED BY VTK ON MAP DISPLAY AND "SINGLE FMC"IN SCRATCH PAD ON FO'S SIDE. PULLED OUT THE QRH BUT PROBLEM SELF CORRECTED EACH TIME BEFORE WE COULD ACCOMPLISH AND STEPS THEN ABOUT 5 MIN AFTER LAST FAILURE WE GOT A DUAL FMC FAILURE LASTING SEVERAL MINUTES BEFORE SELF CORRECTION AND CHECKLIST. GROUNDED - YES. DIVERSION TIME 110 MINUTES. DUE TO DUAL FMC FAILURE IN FLIGHT RESULTING IN AIR TURNBACK REPLACED #1+2 FMC REF AMM 34-61-02/401 ALL REQUIRED TESTS PASSED. BOTH FMC'S SHOW NO ACTIVE FAULTS. PERFORMED FMCS SYSTEM TEST REF AMM 34-61-00-730-801 ALL TEST PASS.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 51,201 hrs · 14,930 cycles

DURING CRUISE IN OCEANIC AIRSPACE, BOTH FMC'S FAILED THEN RECOVERED. GROUNDED - YES. PERFORMED #1 AND #2 FMC BITE/IN FLT FAULTS FOUND FMC-L PMG FAULT AND A CORRESPONDING FMC-R RESYNC WITH SAME TIME STAMP. L/H FMC WAS ONLY RESET/FAULT ON LEG 1 R/H FMC RESET WAS DUE TO L/H FAULT. PERFORMED FMC -L & R OPS CHECK. NO DEFECTS NOTED REF B737-800 AMM 34-61-00-710-801 & FIM 34-61 TASK 837. ETOPS SIGNIFICANT SYSTEM GROUND VERIFICATION SUCCESSFUL.

Part: LEAD — DAMAGED (#1 ENGINE) · airframe 51,174 hrs · 14,923 cycles

#1 ENG L/H IGNITION LEAD DAMAGED. GROUNDED - YES. REMOVED AND REPLACED #1 ENG IGNITION LEAD REF B737-800 AMM 74-21-01 OPS TEST GOOD.

Part: PRESSURE SWITCH — FAULTY (L LDG GEAR W/W) · airframe 50,819 hrs · 14,828 cycles

ETOPS MANAGER REQUESTS DUE TO RELIABILITY TO REPLACE CENTER TANK LH BOOST PUMP LOW PRESS SWITCH (S154) AND RELAY (R54). GROUNDED - YES. REMOVED AND REPLACED LEFT CENTER BOOST PUMP GFI RELAY R54 REF B737-800 AMM 28-22-18/401 AND B737-800 WDM 28-23-11 SHT.1. LEFT CENTER BOOST PUMP GFI OPERATIONAL TEST NORMAL. REF AMM 28-22-41-720-802. FUEL LEVELED IN WINGS FOR DISPATCH. 440 LBS REMAIN IN CENTER FUEL TANK. REMOVED AND REPLACED LEFT CENTER BOOST PUMP LOW PRESS SWITCH REF AMM 28-42-11. OPS CHECK GOOD NO LEAKS DETECTED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 50,661 hrs · 14,786 cycles

CONT CABIN ZONE TEMP INTERMITTENT LIGHT AFTER START RESETS WITH MASTER CAUTION RESET. GROUNDED - YES. PERFORMED PZTC BITE REF B737-800 FIM 21-62 TASK 801. CONTROLLER 2 FAULTED FLT DECK TRIM VALVE ON BIT AND PREV FLT. FAULT CLEARED WHEN PUSHED VERIFY. GREEN GO LIGHT ILLUMINATED. PERFORMED FLT DECK TEMP SENSOR CLEANING DUE TO DIRTY WITH DUST/ DEBRIS REF B737-800 AMM 21-61-10. OPERATED BOTH PACKS FOR 10 MIN. PERFORMED PZTC BITE AGAIN. NO FAULTS NOTED.

Part: MODULATING VALVE — INOPERATIVE (LEFT ECS BAY) · airframe 50,534 hrs · 14,746 cycles

CONT CAB ZONE TEMP LIGHT COMES ON WITH RECALL AND RESETS WITH MASTER CAUTION. GROUNDED - YES. PERFORMED PACK/ZONE TEMP CONTROLLER BITE TEST B737-AMM 21-61-00-700-802-002 FOUND FLT DECK TRIM VALVE. REMOVED AND REPLACED FLT DECK TRIM AIR MODULATING VALVE AS REQUIRED. OPS CKD AND LEAK CKD GOOD REF AMM 21-61-21-400-801. REACCOMPLISHED BITE TEST NO FAULTS FOUND.

Part: SENSOR — SHORTED (APU INLET) · airframe 50,425 hrs · 14,709 cycles

APU WONT START, FAULT LIGHT ON AFTER START ATTEMPT. GROUNDED - YES. PERFORMED BITE TEST AND FOUND MAINT MSG 49-61223. "INLET TEMPERATURE SENSOR SHOWS SHORT CIRCUIT". T/S TO INLET TEMP SENSOR IAW B737-800 FIM 49-60 TAK 812. REPLACED INLET TEMP SENSOR IN REF TO B737-800 AMM 49-61-31, OPS GOOD NO FAULT CODES NOTED.

Part: UNKNOWN — NONE (WATER SERVICE PA) · airframe 50,360 hrs · 14,691 cycles

AFTER TAKEOFF FA'S REPORT NO WATER AND NO WASTE OPERATION. GROUNDED - YES. DIVERSION TIME 27 MINUTES. PERFORMED B737-800 FIM 38-10 TASK 803. NO SYSTEM FAULTS. HAD RAMP RESERVICE POTABLE WATER CORRECTLY (PREVIOUSLY SERVICED INCORRECTLY). GROUND CHECKED LAVS AND SINKS, OPS CHECK GOOD. FOUND LAV SERVICE HANDLE BACKED OFF DUE TO MISSERVICING, RETURNED TO NORMAL POSITION.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 50,292 hrs · 14,673 cycles

L SIDE WINDOW OVERHEAT IN FLIGHT RAN QRH, OVERHEAT LIGHT STAYED ILLUMINATED. SWITCH LEFT IN OFF POSITION FOR REST OF FLIGHT. GROUNDED - YES. FOUND L2 WHCU SENSOR FAULT. SWAPPED TO SPARE SENSOR OP CK GOOD REF B737-800 FIM 38-41 TASK 811.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 50,277 hrs · 14,670 cycles

FMC FAIL. F.O. FMC FAILED THEN RAN QRH. THIS CAUSED DUAL FMC FAILURE. FMC'S BOTH CAME BACK. CONTINUED NORMAL OPS. CAPT'S RNP/AND WAS 10/9.92, GPS L&R O.O. IRS - L 340/1.0. IRS - R 300/1.2. CPDLC WAS LOST. GROUNDED - YES. RESET SYSTEM AND TESTED FMCS 1&2, GROUND FUNCTIONAL ETOPS TEST GOOD IAW B737-800 AMM 34-61-00-710-801 FOR FMCS 1&2.

Part: BLADE — DAMAGED (#1 ENGINE) · airframe 50,161 hrs · 14,644 cycles

WHILE ACCOMPLISHING T/C 78472010 FOUND BLADES 13,9,2,8,18,5,21 ON ENGINE #1 TO HAVE DAMAGE TO THE COATING THAT IS OUT OF LIMITS. GROUNDED - YES. REPLACED #1 ENGINE BLADES 1,2,5,6,8,9,13,14,18 AND 21 REF T/ 78472010.

Part: PLATFORM — OUT OF POSITION (NR 2 FAN BLADE) · airframe 50,123 hrs · 14,636 cycles

PER T/C 78472010 #2 FAN BLADE LUBE PLATFORM #14 P/N 340-001-817-0 NOT PAIRED 180 DEGREES APART. GROUNDED - YES. REMOVED AND REPLACED #2 ENGINE FAN BLADE PLATFORM #14 WITH P/N 340-001-816-0 REF TC 78472010.

Part: SPACER — DEBONDED (NR 2 FAN BLADE) · airframe 50,123 hrs · 14,636 cycles

PER T/C 78472010 #2 FAN BLANE LUBE SPACERS #(1-12),13,AND (17-24) ELASTOMERS ARE DISBONDED. GROUNDED - YES. REMOVED AN REPLACED #2 ENG FAN BLADE SPACERS 1-12,13,17-24 PER TC 78472010.

Part: SENSOR — INOPERATIVE (RH ECS BAY) · airframe 50,038 hrs · 14,614 cycles

DURING AIR CONDITIONING - PRESSURIZATION CHECKS, WITH TRIM AIR ON, CONT CAB, FWD & AFT CABIN TEMP SELECTORS AT 12 O'CLOCK POSITION. CABIN TEMPS WERE 21*-27* C-NORMAL. LEFT PACK TEMP WAS 30*C AND RIGHT PACK TEMP WAS 0*C - BOTTOM OF GAUGE. WHEN FWD & AFT TEMP CONTROLLERS WERE SET TO FULL WARM, SUPPLY DUCT TEMPS AND PASS CAB TEMPS ROSE. LEFT PACK TEMP ROSE. RIGHT PACK TEMP STAYED AT 0*C. GROUNDED - YES. REMOVED & REPLACED RH PACK TEMP SENSOR IAW B737-800 AMM 21-51-52 REMOVED & REPLACED RH PACK TEMP BULB IAW B737-800 AMM 21-51-60 ALL OPS CHECKS GOOD REF B737 AMM 21-51-60 & 21-51-52& 21-61-00.

Part: SKIN — CRACKED · airframe 50,038 hrs · 14,614 cycles

CRACKED INDICATION FOUND: L/H HORIZONTAL LOWER SKIN I/B OF STA.147.90, 16.5" AFT OF L/E, 2.150" FWD OF REPAIR DOUBLER, MARKED AT .320"L.DOT: A373 GROUNDED - YES. REPAIRED THE L/H HORIZONTAL LOWER SKIN AT APPROX. 147.9 USING DOUBLER MAT.100 2024-T3 AND FILLER MAT. .071 2024-T3 PER B737-800 SRM 55-10-01-2R-11. REPAIR IS A CATEGORY "B" REPAIR WITH INSPECTION THRESHOLD 56,000 TOTAL FLIGHT CYCLES PER B737-800 SRM 55-10-01-2R-11.5REMOVED DOT.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 49,987 hrs · 14,599 cycles

AFTER LANDING DUAL FMC FAILURE FOR APPROXIMATELY 20 SECONDS. GROUNDED - YES. PERFROMRED B737-800 FIM 34-61TASK 801 FLIGHT MANAGEMENT COMPUTER SYSTEM BITE TEST PROCEDURE. LEFT FMC LOGGED "PGM FAULT ON GROUND LEG (G). THIS IS A SOFTWARE ANOMALY. BOTH LEFT & RIGHT FMC'S RECOVERED AND OP CHECK NORMAL REF B737-800 AMM 34-61-00/501. SYSTEMS OK FOR SERVICE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 49,742 hrs · 14,529 cycles

"ZONE TEMP" LIGHT ILLUMINATES ON RECALL. GROUNDED - YES. BITE CK SHOWS FLT DECK TRIM VALVE. CW B737-800 FIM 21-62 TASK 832. FAULT CLEARED NOT ACTIVE.

Part: ACTUATOR — FAULTED (NR 2 ENG) · airframe 49,691 hrs · 14,515 cycles

DURING T/C 78273000 FOUND SHORT TIME FAULT 75-30542 ON ENGINE 2. GROUNDED - YES. REPLACED #2 ENG LEFT VBV ACTUATOR REF B737-800 AMM 75-32-02-400-801-F00 STEPS 3A-3H(7). PERFORMED IDLE LEAK CHECK AND ACTUATORS TEST. CHECK/TEST OK. REF AMM 75-32-02-400-801-F00 STEP 3I. B737-800 FIM 75-32 TASK 803 STEP H (REPAIR CONFIRMATION.)

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 49,556 hrs · 14,476 cycles

WINDOW HEAT L SIDE OVERHEAT CAUTION DURING DESCENT THROUGH 10,000. GROUNDED - YES. RAN QRH AND OVERHEAT REMAINED EXTINGUISHED.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 49,455 hrs · 14,437 cycles

OVERHEAD EMERGENCY EXIT LT @ ROW 1 IS INOP. GROUNDED - YES. RELAMPED ROW 1 EMERGENCY EXIT AREA LIGHT, OPS CHECKS OK. REF B737-800 AMM 33-51-03.

Part: ACM — SEIZED (LEFT) · airframe 48,815 hrs · 14,251 cycles

PACK TRIP OFF LIGHT ON TAXI OUT RESET AND CONTINUED TO OVERHEAT. GROUNDED - YES. PER B737-800 FIM 21-62 TASK 801 PERFORMED BITE OF PZTC 1 AND 2. NO FAULTS AND VERIFY PASSED. ATTEMPTED OPERATION OF LEFT PACK. PRESSURE SUPPLIED BUT ACM DID NOT TURN. REPLACED LT PACK ACM WITH NEW. OPS CK GOOD REF B737-800 AMM 21-51-04.

Part: COMPENSATOR — INOPERATIVE (FUEL QTY) · airframe 48,664 hrs · 14,209 cycles

TECH SERVICES REQUEST FOLLOW-UP TO RECENT #2 FUEL QTY GROUNDED - YES. ACCOMPLISHED A TANK AND COMPENSATOR UNITS TEST PER B737-800 AMM 28-41-21-710-801 ON THE #2 TANK AND FOUND COMPENSATOR PROBE AND TANK UNITS 2, 5, AND 6 OUT OF LIMITS. REMOVED AND REPLACED COMPENSATOR AND #2 PROBE. REMOVED AND REPLACED TANK UNIT PROBES 5 AND 6 REF AMM 28-41-21. PERFORMED SYSTEM TEST REF AMM 28-41-00. CHECKS GOOD. LEAK CHECK GOOD.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 48,643 hrs · 14,200 cycles

EMERGENCY LIGHT EXIT LOCATOR SIGN AT LEFT FORWARD OVERWING EXIT HAS SEVERAL LAMPS INOP. GROUNDED - YES. RELAMPED AND TESTER PER B737-800 AMM 3351-01-960-801 - OPS NORMAL.

Part: FMC — FAILED (CAPTAIN'S) · airframe 48,417 hrs · 14,113 cycles

AFTER LANDING ON TAXI BACK TO THE GATE THE CAPTAIN'S FMC FAILED THEN RESET BACK TO NORMAL WITHIN ABOUT 10 SECONDS. GROUNDED - YES. L/H FMC HAD PGM FAULT REBOOTED FMC & BITE CK OK. REF B737-800 FIM 34-61-00-860-801.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 47,871 hrs · 13,987 cycles

ON RECALL, RIGHT PACK LIGHT ILLUMINATED EXTINGUISHES WITH RESET OF MASTER CAUTION. GROUNDED - YES. FOUND RIGHT PACK ACTUATOR FAULT, A/C CHECKED AND RELEASED IAW MEL 21-32B, PRIMARY RIGHT PACK TEMP CONTROL INOP. PERFORMED PACK TEMP CONTROL BITE. NO FAULTS IN PREV FLTS AND VERIFY TEST PASSES. FAULT IS NOT ACTIVE. CLEARS MEL 21-32B.

Part: SPACER — DEBONDED (NR 1 ENGINE) · airframe 47,743 hrs · 13,957 cycles

PER T/C 78472010 #1 ENGINE FAN BLADE LUBE SPACER 2,5,8,9,10,11,12,17, AND 21 ELASTOMERS ARE DISBONDED. GROUNDED - YES. REMOVED AND REPLACED #1 ENGINE FAN BLADE SPACER 9 TOTAL REF. T/C # 78472010

Part: COMPENSATOR — FAILED (NR 1 FUEL TANK) · airframe 47,557 hrs · 13,902 cycles

FUEL QUANTITY INITIALLY 40.8 TOTAL 8.64 / 23.5 / 8.64. LESS THAN 5 MIN AFTER ENGINE START QTY WAS 7.68 / 22.6 / 8.6 (#1 QTY DROPPED NEARLY 1000 POUNDS). NO OTHER ABNORMAL INDICATIONS. ALL 6 PUMPS ON. NOTE "TOTAL" FUEL ALSO DROPPED (MIRRORED THE LOSS #1 QTY INDICATION). GROUNDED - YES. ACCOMPLISHED FQIS SYSTEM TEST #1 TANK COMP 59.03 406.9 TOTAL. REMOVED AND REPLACED #1 COMP AND 1-5 TANK UNITS IAW B737-800 AMM 28-41-21/401. REMOVED AND REPLACED FUEL PROBES 9-12 REF AMM 28-41-21/401. REMOVED AND REPLACED FUEL PROBES 7 AND 6 IAW AMM 28-41-21/401. REMOVED AND REPLACED FUEL PROBE #8 REF AMM 28-41-21. FQIS OPERATIONAL CHECK COMPLETE AND #1 MAIN FUEL TANK LEAK CHECK COMPLETE. OPS CHECK GOOD.

Part: FUEL SYS — MALFUNCTIONED · airframe 47,557 hrs · 13,902 cycles

MAIN TANK IMBALANCE OF 800# AT 4 HOURS INTO FLIGHT. LEFT TANK LOW. FUEL FLOW EVEN. BALANCED FUEL AT COMPLETION OF CENTER FUEL BURN. TANKS BURNED EVENLY UNTIL SEATTLE. GROUNDED - YES. FUELER REFUELED A/C 24.6 TOTAL FUEL ONBD. REFUEL DONE, NO PUMPS ON, CROSSFEED CLOSED, FUEL TRANSFERRED FROM CENTER TO LEFT WING TANK FUEL ENDED AT 9.1 IN LEFT WING TANK NO FUEL SPILLED OUTSIDE A/C, TRANSFERRED FUEL FROM LEFT WING TO CENTER TANK. LEFT WING TANK NOW AT 8.70 REF B737-800 FIM 28-21 TASK 814 UNWANTED FUEL XFER FROM CENTER TANK TO LEFT WING TANK. INITIAL EVAL STEPS 4 A TO G. ALL THESE STEPS GOOD. ACCOMPLISHED FIM TASK 28-21 TASK 814 STEPS 5 A TO G NO TRANSFER FROM CENTER TO LEFT TANK NOTED, VERIFIED FUEL QUANTITY USING THE FUEL STICK PER 737NG ALTERNATE FUELING PROCEDURES MANUAL INDICATIONS ARE GOOD, PER FIM TASK 28-21 TASK 814 STEP 6 IF THERE IS NO INDICATION OF UNWANTED FUEL TRANSFER ON SUBSEQUENT FLIGHTS, THEN THERE WAS AN INTERMITTENT PROBLEM.

Part: AUTOTHROTTLE SYS — DISENGAGED · airframe 47,489 hrs · 13,888 cycles

AUTOTHROTTLE DISENGAGED AT 100 FT, UNABLE TO RE-ENGAGE THROUGHOUT FLIGHT. GROUNDED - YES. ACCOMPLISHED AUTOTHROTTLE BITE IAW FIM 22-31 TASK 801. ALL TESTS PASSED. ACCOMPLISHED LRU REPLACEMENT TEST FOR DFCS IAW AMM 22-11-00-740-815. ALL TESTS PASSED. ACCOMPLISHED LAND VERIFY TEST IAW AMM 23-11-00-700-801. ALL TESTS PASSED.

Part: UNKNOWN — MALFUNCTIONED (SMOKE DETECTION) · airframe 47,312 hrs · 13,844 cycles

WHEN CARGO TEST BUTTON IS PRESSED EXT FWD GREEN LIGHT DOES NOT ILLUMINATE. GROUNDED - YES. RAN FIM 26-16 TASK 806 AND INSPECTED FWD CARGO SMOKE DETECTORS NO FAULTS FOUND OPS TEST GOOD.

Part: UNKNOWN — MALFUNCTIONED (EMERGENCY LIGHT) · airframe 47,161 hrs · 13,805 cycles

FWD CARGO EXT LIGHT DOES NOT ILLUMINATE DURING LIGHT TEST. GROUNDED - YES. PERFORMED B737-800 FIM 26-16-TASK 806. UPON INITIAL EVLAUATION CARGO FIRE CONTROL TEST CKS NORMAL. ALL REQURIED LIGHTS ILLUMINATE. NO OTHER DEFECTS NOTED.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 47,160 hrs · 13,804 cycles

AFTER LANDING, BOTH CDU'S BLANKED THEN CAME BACK ON "MENU" PAGE. NO FMC PROMPT FOR ABOUT 1 MIN. THEN IT CAME BACK. GROUNDED - YES. PERFORMED B737-800 FIM 34-61 TASK 801 AND FOUND FMC-L PGM FAULT. PERFORMED FIM 34-61 TASK 807 AND ALL NECESSARY PROMPTS SHOW. OPS TEST GOOD PER FIM 34-61 TASK 807.

Part: WARNING MESSAGE — FALSE ACTIVATION (COCKPIT TEMP) · airframe 46,854 hrs · 13,725 cycles

CONT CABIN ZONE TEMP LIGHT ILLUMINATED DURING RECALL. GROUNDED - YES. ACCOMPLISHED BIT CK ON BOTH CONTROLLERS B737-800 AMM 21-61-00, VERIFY GREEN LIGHT W/ NO REMAINING FAULTS.

Part: VALVE — NOT CLOSED (OVERFLOW) · airframe 46,695 hrs · 13,689 cycles

F/A REPORTS NO POTABLE WATER FOR COFFEE MAKER OR SINKS. GROUNDED - YES. AIR TURNBACK - DIVERSION TIME 30 MINUTES - TROUBLESHOOT IN REF TO B737-800 FIM 38-10 TASK 803 FOUND FILL/OVERFLOW VALVE NOT CLOSING COMPLETELY AND LEAKING WHEN SERVICE DOOR CLOSED. REMOVED AND REPLACED FILL/OVERFLOW VALVE, AS SUGGESTED BY FIM 38-10 TASK 803. REF B737-800 AMM 38-11-03. WATER FLOWS IN COFFEE MAKERS AND SINKS. A/C OK FOR SERVICE.

Part: SKIN — CRACKED (LT HORIZ STAB) · airframe 46,552 hrs · 13,648 cycles

CRACK INDICATION NOTED BETWEEN AT STAB STA 138.70 AND STAB STA 147.90 APROX .5 IN LENGTH. LOCATION IS APOX 5 INCHS FROM CENTERLINE OF FWD ROW OF FASTNER AFT SPAR AND 2 INCH AFT SIDE FROM DOUBLER ON THE STA 147.90 END POINTS OF CRACK ARE IDENTIFIED IN RED MARKER. L/H HORIZONTAL STAB. GROUNDED - YES. REPAIRED L/H HOIZ. STAB LOWER SKIN BETWEEN STAB STA 138.70 AND STAB 147.90 IAW B737-800 SRM 55-10-01-2R-11. TOPCOAT APPLIED IAW B737-800 AMM 51-21-99. REMOVED EXISTING REPAIR ON LOWER SURFACE OF THE LEFT HAND HORIZONTAL STABILIZER IAW B737-800 SRM 51-40-02. REMOVED DAMAGE AND ACCOMPLISHED HFEC INSPECTION OF CUT-OUT AREA IAW B737-NDTM 51-00-00 PART 6 PROC 4 WITH NO CRACK INDICATIONS. FABIRCATED DOUBLER TO INCORPORATE EXISTING REPAIR LOCATION AND INSTALLED CATEGORY B REPAIR IAW B737-800 SRM 55-10-01-2R-11. INSPECTION REQUIREMENTS, 56,000 TOTAL FLIGHT CYCLES.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 46,552 hrs · 13,648 cycles

FLOOR BEAM 986.5 APPROXIMATELY 4" FROM R/H INNER CHORD HAS CORROSION AROUND FASTENER HOLE. GROUNDED - YES. BLEND AND FOUND EDGE OF FASTENER HOLE TOO LARGE AMOUNT OF DAMAGE, ORIGINAL MATERIAL .150 MATERIAL REMOVED .072 REMAINING MATERIAL .078 FOUND TO BE OUT OF LIMIT IAW B737-800 SRM 53-70-15-1A-1, REMOVED T-CHORD RBL 7.9+10 RBL 54 IAW B737-800 SRM 53-70-51-2R-4 REPAIR 4, FABRICATED & LOCATED AND DRILLED. INSTALLED NEW T-CHORD IAW B737-800 SRM 53-20-51-2R-4 REPAIR 4.

Part: ELASTOMER — TORN (NR 1 ENGINE) · airframe 46,208 hrs · 13,559 cycles

WHILE ACCOMPLISHING TC 78472010 FOUND THAT ALL THE PLATFORMS RUBBER ON #1 ENG IS RIPPING. GROUNDED - YES. REPLACED ALL PLATFORMS ON #1 ENG REF TC 78472010 FAN BLADE LUBE.

Part: UNKNOWN — MALFUNCTIONED (FUEL SYSTEM) · airframe 45,506 hrs · 13,370 cycles

AT FLIGHT LEVEL 330, ONE CENTER TANK LOW PRESSURE ILLUMINATED. ASSOCIATED CENTER PUMP TURNED OFF AND CROSSFEED OPENED TO BALANCE FUEL. BOTH CTR PUMPS TURNED OFF AND CROSSFEED CLOSED. "FUEL IMBAL" ILLUMINATED WITH 1000 POUND IMBALANCE. CROSSFEED RE-OPENED AND FUEL REBALANCED. (NO MORE THAN 1000 POUND IMBALANCE.). GROUNDED - YES. PERFORMED FIM 28-22 TASK 801/802 INITIAL EVALUATION. PRIMED BOTH CENTER FUEL TANK BOOST PUMPS BY FILLING TANK WITH 14000 LBS OF FUEL. WHILE TRANSFERRING FUEL TO FILL WING TANKS, PERFORMED CENTER FUEL BOOST PUMP OPERATIONAL TEST REF AMM 28-22-41-710-801. BOTH CENTER TANK FUEL BOOST PUMPS OPS. NORMAL. BOTH LOW PRESSURE LIGHTS CAME ON INITIALLY THEN STAYED OFF. NO FAULTS NOTED.

Part: CONNECTOR — LOOSE (ANTI-ICE VALVE) · airframe 45,289 hrs · 13,310 cycles

#2 ENG ANTI ICE COWL VALVE OPEN LIGHT ON THE FWD OVERHEAD PANEL CYCLES ON AND OFF WITHOUT SWITCH ACTUATION, HISTORY OF CONNECTOR DP1303 BEING FOUND LOOSE PRI 2 ETOPS SIGNIFICANT SYSTEM. GROUNDED - YES. REMOVED AND REPLACED #2 ENGINE HARNESS MW0313 IAW B737-800 AMM 71-51-03. EEC TEST PASSED, NO FAULTS REF AMM 73-21-00-700-804-F00. TEST 12- ACTUATORS TEST PASSED REF AMM 71-00-00-700-807-F00.

Part: CONNECTOR — LOOSE (NR 2 ENGINE) · airframe 45,162 hrs · 13,265 cycles

WITH ENGINE ANTI ICE OFF RT ENGINE COWL VALVE OPEN FLICKERS ON AND OFF. GROUNDED - YES. FOUND CANNON PLUG LOOSE TO TAI VALVE ON #2 ENG. REMOVED CANNON PLUG, INSPECTED, REINSTALLED CANNON PLUG, PERFORMED ENG RUN AND OPERATIONAL TEST GOOD. REF: B737-800 AMM CH. 30-20-710-801.

Part: CONNECTOR — CONTAMINATED (NR 2 ENGINE) · airframe 44,927 hrs · 13,209 cycles

ENROUTE RT COWL VALVE OPEN BLUE LIGHT FLICKERING WITH ENG ANTI ICE SWITCH OFF. WHEN ENG ANTI ICE SWITCH SELECTED ON BRIGHT BLUE COWL OPEN LIGHT ILLUMINATED. LIGHT BRIGHT BLUE IN DESCENT REGARDLESS OF SWITCH POSITION. GROUNDED - YES. PERFORMED FIM 30-21 TASK 804, CONNECTOR DP1303 REMOVED CLEANED REINSTALLED TAI VALVE RIGHT SIDE OPS NRML.

Part: UNKNOWN — UNKNOWN (ELECTRICAL POWER) · airframe 44,765 hrs · 13,169 cycles

ENGINE CONTROL LIGHT ON #1 ENGINE AFTER START. EXTERNAL POWER FAILED ON PUSH. RELIED ON BATTERY POWER FOR APPROX. 15 MINUTES PRIOR TO STARTING ENGINE #1 AND ESTABLISHING AC ELECTRICAL POWER. GROUNDED - YES. THE AIRPLANE VOLTAGE INPUT TO EEC IS OUT OF RANGE. ACCOMPLISHED #1 ENG EEC TEST, NO EEC FAULTS, REF B737-800 AMM TASK 73-21-00-700-804-F00. ENG RUN AT GATE, NO FAULTS. GROUND VERIFICATION GOOD. #1 ENG. EEC BITE, NO FAULTS, REF AMM TASK 73-00-00-810-801-F00.

Part: OIL COOLER — LEAKING (APU) · airframe 44,765 hrs · 13,169 cycles

WHILE ACCOMPLISHING TSR FOR APU FREQUENT SERVICING FOUND A OIL LEAK NEAR THE AFT FITTING ON THE TURBINE SCAVENGE LINE. REF W/O 450930. GROUNDED - YES. REF FIM TASK 49-95 TASK 801 AND FOUND OIL COOLER LEAKING OIL COOLER REMOVED AND REPLACED OIL COOLER REF AMM 49-91-41 OPS CHECK GOOD.

Part: CONNECTOR — DAMAGED (SOLENOID VALVE) · airframe 44,428 hrs · 13,088 cycles

#2 ENGINE, CONNECTOR DP1103 AT GROUND WING THERMAL ANTI-ICE SOLENOID VALVE IS LOOSE. GROUNDED - YES. RESECURED #2 ENGINE CONNECTOR DP1103 BACKSHELL REF B737 SWPM 20-60-09.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 44,095 hrs · 13,007 cycles

ON RECALL CONT CAB ZONE TEMP LIGHT ILLUMINATED CLEARS ON RESET. GROUNDED - YES. FLIGHT PRIMARY TEMP CONT INOP. PERFORMED CABIN TEMP CONTROLLER BITE TEST PER AMM 21-61-00 SYSTEM OP CHECKS GOOD.

Part: CIRCUIT BREAKER — TRIPPED · airframe 44,024 hrs · 12,985 cycles

STANDBY POWER OFF LT ILLUMINATED IN FLIGHT ALSO NOTICED BATT BUS CB TRIPPED BEHIND FO SEAT SECT 2. GROUNDED - YES. RESET BUS SECTION 2 C/B REF B737-800 AMM 20-60-01-801, C/B REMAINS SET. PERFORMED OPS TEST OF THE STANDBY POWER SYS PER AMM 24-34-00-710-802 NO DEFECTS NOTED.

Part: SWITCH — INOPERATIVE (COCKPIT) · airframe 43,836 hrs · 12,942 cycles

CREW REPORTS V/S MODE SELECT SWITCH LIGHT PARTIALLY INOP. GROUNDED - YES. REMOVED AND REPLACED DFCS MODE CONTROL PANEL PER AMM 22-11-34. PERFORMED MODE CONTROL PANEL INSTALLATION TEST PER AMM 22-11-34-740-801 AND DFCS GROUP 49 (LAND VERIFY) TEST PER AMM 22-11-00-700-801 - ALL TESTS PASS.

Part: GUIDE ARM — OUT OF ADJUST (L1 DOOR) · airframe 43,464 hrs · 12,843 cycles

L1 DOOR HARD TO LATCH CLOSED. GVI PERFORMED. FOUND UPPER INBOARD ROLLER LATCH DEEPLY GOUGED. GROUNDED - YES. FOUND L1 DOOR GUIDE ARM OUT OF ADJUSTMENT PER AMM 52-11-00-820-801.

Part: HEATER — LEAKING (NR 1 ENGINE) · airframe 42,978 hrs · 12,714 cycles

NR 1 ENG FUEL HEATER SERVO LEAKING AT THE CAP. GROUNDED - YES. REMOVED AND REPLACED NR 1 ENG SERVO FUEL HEATER REF AMM 73-11-07. OPS & LEAK CK GOOD.

Part: B-NUT — LOOSE (NR 1 ENGINE) · airframe 42,978 hrs · 12,714 cycles

FUEL LEAKING AT 9 O’CLOCK STRUT ON NR 1 ENGINE. GROUNDED - YES. REMOVED 9:00 STRUT PANEL FOR ACCESS. SECURED & TORQUED, LOOSE VBV FUEL TUBE "B" NUT AT THE STRUT MOUNT, INSTALLED STRUT FAIRING AT THE 9 O’CLOCK POSITION, REF SHOP MANUAL 72-00-00 -ASSY 002. LEAK CHECK GOOD, NO LEAKS NOTED.

Part: WARNING MESSAGE — FALSE ACTIVATION (CABIN TEMP) · airframe 42,899 hrs · 12,692 cycles

AFTER START AND AFTER BLEED SWITCHES ON (AND PACK SWITCHES ON) WE HAD A "ZONE TEMP" LIGHT THAT CAME ON FOR THE CONTROL CABIN WITH MASTER CAUTION RECALL AND WENT OUT FO WITH RESET. GROUNDED - YES. INITIAL EVALUATION FOUND #2 PACK/ZONE TEMP CONTROLLER SHOWING FLT DECK TRIM VALVE FAULT. PERFORMED PACK/ZONE TEMP CONTROLLER BITE TEST REF B737-800 AMM TASK 21-61-00-700-806-002, NO DEFECTS NOTED, TEST PASSED AND FAULT WAS RESET. RAN BITE TEST 2 MORE TIMES NO DEFECTS NOTED.

Part: COMPENSATOR — OUT OF LIMITS (FUEL TANK) · airframe 42,889 hrs · 12,690 cycles

PROBES F15, 6 9 AND 10 IN THE NR 1 TANK ARE OUT OF LIMITS. GROUNDED - YES. REMOVED AND REPLACED COMPENSATOR PROBE F15 AND TANK UNITS F6, F9 AND F10 REF B737-28-41-21. NR 1 F/Q SYSTEM TEST GOOD REF AMM 28-41-00-730-801.

Part: COMPENSATOR — OUT OF LIMITS (FUEL TANK) · airframe 42,889 hrs · 12,690 cycles

PROBES F15, 2, AND 7 ARE OUT OF LIMITS IN THE NR 2 TANK. GROUNDED - YES. REMOVED AND REPLACED COMPENSATOR PROBE F15 AND TANK UNITS F2 AND F7 REF B737-28-41-21. NR 2 F/Q SYSTEM TEST GOOD REF AMM 28-41-00-730-801.

Part: NOZZLE — BURNED (NR 1 ENGINE) · airframe 42,820 hrs · 12,670 cycles

WHILE ACCOMPLISHING TASK CARD 78477022, FOUND #1 ENG S/N 894763. 3 LPT NOZZLES TOTAL AT 4 O CLOCK, 7 O CLOCK, AND 10 O CLOCK POSITION WITH BURN MARKS AND MISSING MATERIAL. GROUNDED - YES. ON DEFERRAL.

Part: APU — MALFUNCTIONED · airframe 42,451 hrs · 12,560 cycles

ATTEMPTED TO START APU, GOT CLIMBING HIGH EGT WITH NO SUCCESSFUL START, WITH REVERBERATING NOISE. CURRENT CODE 49-94226. LOW OIL PRESSURE SWITCH SHOWS OPEN CIRCUIT, NO FAULT LIGHTS ILLUMINATED. GROUNDED - YES. VISUALLY INSP TAILCONE, NO DEFECTS NOTED. OIL LEVEL FULL. ACFT RELEASED PER MEL 49-1B. PERFORMED START OF APU PER B737-800 AMM 49-11-00, OPS NORMAL. THIS CLEARS MEL 49-1B.

Part: EXCITER — FAILED (NR 1 ENGINE) · airframe 42,227 hrs · 12,490 cycles

ENGINE NR 1 HUNG START WITH RIGHT IGNITER SELECTED. STARTED NORMALLY WITH LEFT IGNITER SELECTED. GROUNDED - YES. REMOVED & REPLACED EXCITER UNIT REF AMM 74-11-01. AUDIBLE CHECKED GOOD REF AMM 74-00-00. POWER IDLE CHECKED NORMAL REF AMM 71-00-00.

Part: COUPLER — FAILED (HF ANTENNA) · airframe 42,046 hrs · 12,439 cycles

HF 2 WILL NOT TRANSMIT OR RECEIVE. ACFT GROUNDED. REMOVED AND REPLACED THE NR 2 HF ANTENNA COUPLER. OPS NORMAL IAW AMM 23-11-61-400-801.

Part: FILTER — DIRTY (TEMP SENSOR) · airframe 41,981 hrs · 12,408 cycles

FWD AND AFT CABIN TEMP HYPER-SENSITIVE TO INPUTS IN AUTO MODE. ACFT GROUNDED. FOUND THE CABIN TEMP SENSOR FILTERS DIRTY. REMOVED AND REPLACED THE CABIN TEMP SENSOR FILTERS IAW AMM 21-61-06. PERFORMED CABIN TEMP CONTROL AND IND OPERATIONAL TEST. OPS CHECKED NORMAL, IAW AMM 21-61-00, AND AMM 21-61-20.

Part: TRANSCEIVER — FAILED (NR 1 HF COMM) · airframe 41,976 hrs · 12,405 cycles

CANNOT TRANSMIT OR RECEIVE ON THE NR 1 OR 2 HF COMMS, WILL GET SIDE TONE ON INITIAL HF FREQ CHANGE. ACFT GROUNDED. VERIFIED CONNECTORS D8517 AND D345B AT E8-1 SHELF SECURE. PERFORMED HF 1 TRANSCEIVER BITE IAW FIM 23-11, TASK 801. BITE FAILED WITH KEYLOGGER LIGHT STAYING OFF DURING BITE. REMOVED AND REPLACED THE NR 1 HF TRANSCEIVER IAW AMM 23-11-21. BITE TEST PASSED.

Part: AUTOPILOT SYS — MALFUNCTIONED · airframe 41,954 hrs · 12,395 cycles

ON RNAV AT APPROXIMATELY 1500 MSL, VNAV PATH AND HUD GUIDANCE DEVIATE QUICKLY TO SHOW APPROXIMATELY 500' LOW ON PATH. AT THIS POINT THE AUTOPILOT FOLLOWS THIS GUIDANCE, PITCHES UP. AIRPORT WAS IN SIGHT, AUTOPILOT WAS DISCONNECTED AND GUIDANCE WAS IGNORED WITH WHITE OVER WHITE ON THE VASI. PATH CONTINUED TO DEVIATE APPROXIMATELY 700' ABOVE US. A STABLE APPROACH WAS REGAINED. INSIDE OF LINENUP AT APPROXIMATELY 300' GUIDANCE RETURNED TO NORMAL. NO WARNINGS GIVEN DURING EVENT. ACFT GROUNDED. FOUND FAULT CODE 22-11822 IN HISTORY, NO ACTIVE FAULTS. PERFORMED FIM 22-11 TASK 811, FAULT DID NOT RECUR. OPS CHECKS GOOD. COULD NOT DUPLICATE, NO HISTORY 30 DAYS.

Part: HF COMM — MALFUNCTIONED (NR 1) · airframe 41,941 hrs · 12,386 cycles

NR 1 HF DOES NOT TRANSMIT FROM EITHER PANEL. NO SIDE TONE, NO FREQUENCY CHANGE TONE. ACFT GROUNDED. AIR TURNBACK. RESET THE SYSTEM, NR 1 HF CHECKED GOOD IAW AMM 23-11-00-710-801.

Part: COMPUTER — FAILED (E&E BAY) · airframe 41,802 hrs · 12,351 cycles

AUTOPILOT DISCONNECTED WOULD NOT RECONNECT. GROUNDED - YES. REPLACED FCC-A PER AMM 22-11-33/401. LRU TEST GOOD PER SUBTASK 22-11-33-74-001. NO FAULTS NOTED. LAND VERIFY TESTS ALL PASS PER AMM 22-11-00/20. CHECKED SPOILER POS SENSORS PER AMM 22-11-27/401. ALL WITHIN LIMITS AND PASS.

Part: COMPUTER — FAILED (E&E BAY) · airframe 41,802 hrs · 12,351 cycles

AUTO THROTTLE DISENGAGED AND WOULD NOT RENGAGE ON T/O. GROUNDED - YES. A/P DISCONNECT, THE FCC-A WAS REPLACED. ACCOMPLISHED A/T SYS TEST PER AMM TASK 22-31-00-710-802. NO FAULTS NOTED.

Part: UNKNOWN — MALFUNCTIONED (HF COMM) · airframe 41,760 hrs · 12,342 cycles

HF NR 2 WILL NOT CHANNELIZE. GROUNDED - YES. ACCOMPLISHED HF COMM SYS BITE, NO BITE. CYCLED HF1 AND HF2 C/B'S. HF TRANSCEIVERS BITE TEST GOOD. HF1 AND HF2 COMM OPS NORMAL. PILOTS ACCOMPLISHED GROUND VERIFICATION REF FIM 23-11 TASK 801.

Part: AUTOTHROTTLE SYS — DISENGAGED (COCKPIT) · airframe 41,625 hrs · 12,303 cycles

AUTOTHROTTLES DISENGAGED, WILL NOT RE- ENGAGE. GROUNDED - YES. ON DEFERRAL.

Part: IRU — OUT OF ALIGNMENT · airframe 41,527 hrs · 12,274 cycles

WXR FAIL. GROUNDED - YES. REALIGNED IRU'S, PERFORMED WEATHER RADAR SYS BITE TEST PER FIM 34-43 TASK 801. NO FAULTS FOUND. WXR FAIL LIGHT GONE. OK FOR SERVICE.

Part: TRANSCEIVER — MALFUNCTIONED (NR 1 HF RADIO) · airframe 41,294 hrs · 12,216 cycles

NR 1 HF RADIO WILL NOT TRANSMIT, WILL RECEIVE. ACFT GROUNDED. CHECKED THE NR 1 HF RADIO, OPS CHECKED GOOD IAW AMM 23-11-00-730-801, NO DEFECTS NOTED. NO HISTORY IN THE LAST 30 DAYS.

Part: TRANSCEIVER — FAILED (WX RADAR SYS) · airframe 41,233 hrs · 12,200 cycles

DURING CLIMBOUT, WEATHER RADAR MESSAGES DISPLAYED. PWS FAIL, WXR RANGE DISAGREE, AND WXR FAIL. ACFT GROUNDED. REMOVED AND REPLACED THE WEATHER RADAR RECEIVER/TRANSMITTER IAW AMM 34-43-41. OPS TESTED IAW AMM 34-43-00-710-802-001, ALL TESTS GOOD.

Part: DISPLAY — INOPERATIVE (CAPTAIN'S) · airframe 41,049 hrs · 12,132 cycles

CAPTAIN`S MCDU INOPERATIVE. DOES NOT RESPOND TO KEY INPUTS. ACFT GROUNDED. ACCOMPLISHED FIM 34-61 TASK 804. CAPTAIN'S CDU OPS TESTED NORMAL. NO INFLIGHT FAULTS LOGGED.

Part: BLADES — DAMAGED (NR 2 ENGINE) · airframe 40,999 hrs · 12,121 cycles

IAW T/C 78472002, NR 2 ENGINE STEP 29 BLADES NR 1, 8, 13, 14, 15, 17, 18, 19, AND 20, HAVE MISSING CU-NI-IN COATING BEYOND LIMITS ON THE CONVEX SIDE. BLADES 6, 15, & 16 HAVE MISSING CU-NI-IN COATING BEYOND LIMITS ON THE CONCAVE SIDE. NR 2 BLADE CU-NI-IN COATING IS OUT OF LIMITS, CONCAVE SIDE. ACFT GROUNDED. REMOVED AND REPLACED THE BLADES IAW T/C 78472002, AND AMM 72-21-02-000-802-F00 STEPS J-L.

Part: ELASTOMER — DAMAGED (NR 2 ENGINE) · airframe 40,999 hrs · 12,121 cycles

IAW T/C 78472002, NR 2 ENG STEP 32, PLATFORM LOCATION 2, 8, 12, 13, 14, & 17 HAD MISSING, TORN OR UNBONDED ELASTOMERS. ACFT GROUNDED. REMOVED & REPLACED THE PLATFORMS IAW AMM 72-21-00 AND T/C 78472002.

Part: TIE ROD — CRACKED (NR 2 ENG CASE) · airframe 40,999 hrs · 12,121 cycles

NR 2 ENGINE FORWARD TIE ROD ON LOWER PNEUMATIC STARTER DUCT IS CRACKED THROUGH. ACFT GROUNDED. REMOVED AND REPLACED THE NR 2 ENGINE FORWARD TIE ROD IAW 71-00-02 FIG 25-1.

Part: PAD — DEBONDED (NR 1 ENGINE) · airframe 40,444 hrs · 11,967 cycles

NR 1 ENGINE FOUND VBV DOOR PAD SEAL DISBONDED ALF AT AROUND 8 O'CLOCK POSITION. ACFT GROUNDED.

Part: WIRE HARNESS — LOOSE (NR 1 ENGINE) · airframe 40,444 hrs · 11,967 cycles

NR 1 ENGINE OTBD WIRE HARNESS FOR STATOR GENERATOR LOOSE. ACFT GROUNDED. ENGINE WIRE HARNESS J7. R & R THE NR 1 J7 WIRE HARNESS IAW AMM 73-21-06. OPS TESTED GOOD.

Part: CONTROLLER — FAULTED (EE BAY) · airframe 40,302 hrs · 11,930 cycles

LEFT PACK LIGHT ILLUMINATED ON RECALL. EXTINGUISHED WITH MASTER CAUTION RESET. ACFT GROUNDED. ON PREVIOUS FLT, FOUND PACK ZONE RIGHT CONTROLLER FAULT, STANDBY. PERFORMED IAW FIM 21-62 / 803. PASSED SUSPECT M1443 RT TEMP ZONE CONTROLLER. REMOVED NR 2 RT PACK ZONE TEMPERATURE CONTROLLER IAW AMM 21-61-20-000-801. INSTALLED THE RT PACK ZONE TEMP CONTROLLER IAW AMM 21-61-20-400-801. ACCOMPLISHED PACK/ZONE TEMPERATURE CONTROLLER INSTALLATION TEST IAW AMM 21-61-20-400-801, PARA F, GROUND VERIFICATION TESTED GOOD.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 40,287 hrs · 11,927 cycles

LEFT PACK ILLUMINATED ON DESCENT WHEN RECALL WAS PRESSED. LIGHT CLEARED WHEN MASTER CAUTION PRESSED. GROUNDED - YES. PERFORMED PACK TEMPERATURE CONTROL-BITE PROCEDURE REF FIM 21-62 TASK 801. RESET AFTER VERIFIED. CHECKED GOOD ON SIX PACK. NO FAULT NOTED. OPS NORMAL.

Part: WARNING LIGHT — FALSE ACTIVATION (LT A/C PACK) · airframe 40,239 hrs · 11,913 cycles

LEFT PACK LIGHT ILLUMINATED ON RECALL, RESET WHEN MASTER CAUTION PUSHED. ACFT GROUNDED. RESET SYSTEM AND RAN PACKS FOR FIVE MINUTES. TESTED SYSTEM IAW AMM 21-61-00, NO FAULTS.

Part: CONTROLLER — FAILED (CABIN TEMP) · airframe 40,232 hrs · 11,910 cycles

RIGHT PACK, ZONE TEMP CONTROLLER M1443, ZONE LIGHT DOES NOT ILLUMINATE WITH LAMP TEST PRESSED. ACFT GROUNDED. REMOVED AND REPLACED THE RIGHT PACK, ZONE TEMP CONTROLLER, INSTALLATION TEST, PASSED, IAW AMM 21-61-20.

Part: WARNING LIGHT — FALSE ACTIVATION (CONTROL CABIN) · airframe 40,224 hrs · 11,908 cycles

CONTROL CABIN ZONE TEMP LIGHT ON TAXI OUT. LIGHT EXTINGUISHED WITH RESET. ACFT GROUNDED. ACCOMPLISHED THE LT AND RT PZTC BITE WITH NO FAULTS NOTED IAW AMM 21-61-00. ACCOMPLISHED AN EVALUATION IAW FIM 21-62 / 842, CONTROL CABIN ZONE TEMP LIGHT REMAINS EXTINGUISHED, FAULT IS INTERMITTENT WITH NO HISTORY LAST 30 DAYS.

Part: TRANSCEIVER — INTERMITTENT (NR 1 HF SYSTEM) · airframe 40,185 hrs · 11,895 cycles

FAIL DISPLAY ON BOTH ACTIVE AND STBY WINDOWS OF THE NR 1 HF. ACFT GROUNDED. DISCREPANCY WAS INTERMITTENT. NR 2 HF WAS NORMAL. REPLACED THE NR 1 HF TRANSCEIVER. OPS NORMAL IAW AMM 23-11-21.

Part: FMC — FALSE INDICATION (RIGHT) · airframe 40,150 hrs · 11,884 cycles

FMC SHUTDOWN AND RESTARTED DURING TAXI IN. ACFT GROUNDED. ACCOMPLISHED LEFT FMC SYSTEM OPS TESTED IAW AMM 34-61-00-710-801, TEST OK. ACCOMPLISHED RIGHT FMC SYSTEM OPS TESTED IAW AMM 34-61-00-710-801, TESTED OK.

Part: UNKNOWN — UNKNOWN (ACARS) · airframe 40,023 hrs · 11,848 cycles

ACARS/FMC WONT CLEAR FROM PREVIOUS FLIGHT. ACFT GROUNDED. TROUBLESHOT IAW FIM 34-61 TASK 837, ENSURED NR 1 & 2 FMC CIRCUIT BREAKERS WERE SET, THIS SUCCESSFULLY CLEARED PREVIOUS FLIGHT AND ALLOWED NEW FLIGHT PLAN ENTERED. CHECKED GOOD FOR SERVICE.

Part: COUPLER — FAULTY (HF COMM) · airframe 39,722 hrs · 11,750 cycles

AT CRUISE, UNABLE TO TRANSMIT ON HF. WHEN PUSH TO TALK SWITCH IN R/T POSITION, NO TRANSMISSION OCCURS WITH TRANSMITTER SELECTOR SWITCH ON HF. GROUNDED - YES. UNABLE TO DUPLICATE DEFECT. ACCOMPLISHED T/S PER B737-800 FIM 23-11 TASK 806 - INITIAL EVALUATION DID NOT CONFIRM FAULT BOTH HF 1 AND HF 2 TRANSMIT AND RECEIVE NORMALLY ON GROUND. DUE TO HISTORY OF 1 HF PROBLEMS, ACCOMPLISHED ENGINEERING REQUEST TSR701324, INCLUDING REPLACEMENT OF 1 HF COUPLER. ACCOMPLISHED HF OPERATIONAL TEST PER AMM 23-11-00-710-801 AND HF SYSTEM TEST PER AMM 23-11-00-730-801 - ALL TESTS PASS.

Part: COUPLER — FAULTY (HF COMM) · airframe 39,690 hrs · 11,744 cycles

FOLLOW-UP TO RECENT HISTORY WITH NR 1 HF UNABLE TO TRANSMIT, TECHNICAL SERVICES REQUEST ADDITIONAL TROUBLESHOOTING. GROUNDED - YES. ENGINEERING REQUEST - ACCOMPLISHED STATIC DISCHARGER INSPECTION PER AMM 23-61-00-210-801 - NO DEFECTS NOTED. ACCOMPLISHED GVI OF HF ANTENNA AND TAPE PER AMM 55-35-01-200-801 - NO DEFECTS NOTED. REMOVED, REPLACED, AND TESTED NR 1 HF COUPLER PER AMM 23-11-61-000-801 /AMM 23-11-61-400-801 - OPS NORMAL. CLEARS TSR DEFERRAL.

Part: TRANSCEIVER — MALFUNCTIONED (NR 1 HF) · airframe 39,641 hrs · 11,733 cycles

INTERMITTENT NR 1 HF, FAILED PRIOR TO GATEWAY, FIXED WHILE STILL IN VHF CONTACT. REGAINED DUAL HF RADIO CAPABILITY PRIOR TO ENTERING OCEANIC AIRSPACE WITH NO FURTHER ISSUES. ACFT GROUNDED. OPS CHECKED THE NR 1 HF IAW AMM 23-11-00. OPS CHECKED NORMAL.

Part: CONTROL VALVE — FAULTED (LT A/C PACK) · airframe 39,560 hrs · 11,713 cycles

LEFT PACK LIGHT ILLUMINATED ON RECALL. EXTINGUISHED WHEN MASTER CAUTION RESET. OPS NORMAL. ACFT GROUNDED. REMOVED AND REPLACED THE LEFT PACK TEMP CONTROL VALVE. LEAK CHECKED GOOD. OPS CHECKED GOOD IAW AMM 21-51-10. PERFORMED A BITE CHECK, NO FAULTS NOTED.

Part: ATTACH ANGLE — CRACKED (BS 663 BULKHEAD) · airframe 39,336 hrs · 11,636 cycles

RIGHT WING REAR SPAR VERTICAL PRESSURE DECK WEB IS CRACKED AT DRAIN HOLE LOCATED AT APPROXIMATELY RBL35 AND MEASURES .300 IN LENGTH. GROUNDED - YES. REPAIRED ATTACH ANGLE SEE TASK CARD SB737-57-1330-NG-2 FOR ALL DOCUMENTATION.

Part: CARGO TRACK — CRACKED (BS 727H) · airframe 39,336 hrs · 11,636 cycles

AFT PIT R/H CARGO TRACK IS CRACKED AT FRAME ATTACH POINT STA 727H. GROUNDED - YES. REPAIRED CARGO TRACK AT FRAME ATTACH POINT STATION 727H IAW B737 800 SRM 53 00 5 2R 3.

Part: TRANSITION PANEL — CRACKED (BS 727A-767) · airframe 39,336 hrs · 11,636 cycles

AFT PIT R/H TRANSITION PANEL IS CRACKED IN TWO PLACED STA 727J TO 747. GROUNDED - YES. REPAIRED TRANSITION PANEL IAW B737 800 SRM 53 00 53 2R 6 REPAIR 6.

Part: WEB — CORRODED (THRESHOLD) · corrosion level 2 · airframe 39,336 hrs · 11,636 cycles

AFT CARGO DOOR CUTOUT LOWER THRESHOLD WEB CORRODED IN NUMEROUS AREAS. GROUNDED - YES. REMOVED AND REPLACED AFT PIT LOWER SILL WEB IAW B737 800 SRM 51 40 02 0G 0 W 2 O .050 R .044 L 6 D .006.

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 39,336 hrs · 11,636 cycles

L/H HORIZ STABILIZER LOWER SKIN CRACKED I/B OF RIB AT STAB STATION 147.90 MARKED WITH RED GREASE PENCIL. GROUNDED - YES. REPAIRED SKIN IAW B737 800 SRM 55-10-01-2R-11, THIS IS A CATEGORY B REPAIR ENTRY MADE IN FILEMAKER PRO FOR CAT B REQUIREMENTS 74711 RTOWELL.

Part: SKIN — DENTED (BS 292-298) · airframe 39,336 hrs · 11,636 cycles

FOUND A DENT BELOW THE R1 DOOR BS 295, STRINGER 22R. ACFT GROUNDED. REPAIRED DAMAGE TO SKIN IAW B737 800 SRM 53 00 01 2R 1 THIS IS A CATEGORY B REPAIR WITH AN INSPECTION THRESHOLD OF 50,000 FLT. CYCLES, INTERVAL OF 3,440 FLT. CYCLES. REFER TO 737 800 APB SRM SUPPLEMENT 53 00 01 FOR INSPECTION REQUIREMENTS AND INTERVALS. ENTRY MADE IN FILEMAKER SUPPLEMENTAL DEFECT DATABASE FOR CAT B REQUIREMENTS 74711 RTOWELL.

Part: FMC — MALFUNCTIONED · airframe 39,251 hrs · 11,611 cycles

FMC MESSAGE ILLUMINATED ON FINAL. GROUNDED. ACCOMPLISHED FIM 34-61 TASK 835. OPS CHECKED GOOD.

Part: COUPLER — INTERMITTENT (HF COMMS) · airframe 39,240 hrs · 11,609 cycles

DURING OPERATIONAL TEST OF HF COUPLERS, THE NR 1 HF INTERMITTENTLY FAILED. ACFT GROUNDED. COULD NOT DUPLICATE FAILURE. CONTACTED ON 10.057, WAS RECEIVED 5 X 5 ON BOTH HF 1 & 2. TRANSCEIVER BITE SHOWED NO FAULTS.

Part: TRANSCEIVER — FAILED (HF SYS) · airframe 39,200 hrs · 11,595 cycles

UNABLE TO TRANSMIT ON HF 1. HAD DIFFICULTIES INITIALLY CONTACTING SFO RADIO AND HF1 TUNER TOOK A LONG TIME TO TUNE. LONG AUDIO TONE. THE TRAMSMIT FUNCTION BECAME COMPLETELY INOPERABLE USING CAPT AND FO AUDIO PANELS. GROUNDED - YES. UNABLE TO VERIFY DEFECT ON GROUND. REMOVED AND REPLACED #1 HF TRANSCEIVER REF B737-800 AMM TASK 23-11-21-000-801 AND AMM TASK 23-11-21-400-801. BITE TEST GOOD REF B737-800 FIM 23-11 TASK 801. OP'S CHECK TO SFO RADIO GOOD. REQUIRES NON-ETOPS REVENUE FVR TO VERIFY FUNCTIONALITY OF THE #1 HF COMM PER SEAMC. REF L/P 11763929 #1 HF OPS TEST VERIFICATION FLIGHT SATISFACTORY,THIS CLEARS FVR AND A/C IS ETOPS QUALIFIED.

Part: WARNING LIGHT — FALSE ACTIVATION (LT A/C PACK) · airframe 39,109 hrs · 11,561 cycles

LEFT PACK LIGHT ILLUMINATED ON RECALL. LIGHT GOES OUT ON RESET. ACFT GROUNDED. PERFORMED A PACK TEMP BITE PROCEDURE IAW FIM 21-62, TASK 801. LEFT RAM ACTUATOR FAULT LIGHT ON. PERFORMED FIM 21-62, TASK 837, RAM ACTUATOR FAULT ISOLATION, NO FAULTS NOTED. PERFORMED RAM AIR INLET ACTUATOR INSTALLATION TEST, GROUND VERIFICATION SUCCESSFUL. NO DEFECTS NOTED.

Part: KNOB — UNSECURE (COURSE SELECTOR) · airframe 39,064 hrs · 11,545 cycles

FIRST OFFICER`S COURSE SELECTOR KNOB TURNS BUT DOES NOT CHANGE DIGITS, INTERMITTENT. ACFT GROUNDED. TIGHTENED THE COURSE SELECTOR KNOB. OPS CHECKED NORMAL AND KNOB REPONDS TO DIGITS DETENT NORMAL. PERFORMED BITE DFCS IAW AMM 22-11-00-700-740-806. NO HISTORY IN LAST 30 DAYS.

Part: TRANSCEIVER — FAILED (HF 1) · airframe 38,852 hrs · 11,475 cycles

WHILE TRYING TO TUNE HF 1 TO NEW FREQUENCY, THERE WAS AN EXTENDED (APPROX 10-15 SECONDS) TONE AND WHEN IT STOPPED WERE UNABLE TO TRANSMIT ON HF 1. ATTEMPTED TO TRANSMIT ON VHF 1 OR 2 BUT WAS UNABLE. SELECTED ALTERNATE ON ACP NR 1 AND COULD COMMUNICATE ON VHF 1 WENT BACK TO NORMAL AND WAS ABLE TO TRANSMIT ON HF 2 BUT EVEN THAT SEEMED WEAK. ACFT GROUNDED. REMOVED AND REPLACED THE NR 1 HF TRANSCEIVER IAW AMM 23-11-21, SYSTEM OP CHECKED GOOD. GROUND VERIFICATION GOOD.

Part: WARNING MESSAGE — FALSE ACTIVATION (COCKPIT TEMP) · airframe 38,732 hrs · 11,433 cycles

CONTROL CABIN ZONE TEMP LIGHT ILLUMINATED ON RECALL. RESET ON CAUTION RESET. ACFT GROUNDED. PERFORMED PACK/ZONE TEMP CONTROL BITE MULTIPLE TIMES, INITIAL FAULT SHOWN FLT DECK TRIM VALVE , TEMP CONTROLLER NR 2 . RESET FAULT, FAULT DID NOT RETURN. RAN RT PACK HOT/COLD MULTIPLE TIMES, NO DEFECTS NOTED. BITE SHOWS NO FAULTS. CLEANED FLT DECK TEMP SENSOR FILTER IAW AMM 21-61-06. NO HISTORY NOTED 60 DAYS.

Part: WARNING LIGHT — FALSE ACTIVATION (CABIN PRESSURE) · airframe 38,730 hrs · 11,432 cycles

AT THE GATE, AUTO FAIL AND ALTERNATE ILLUMINATED ON PRESSURIZATION PANEL. ACFT GROUNDED. PERFORMED FIM 21-31 TASK 801. NO FAULT NOTED.

Part: CONNECTOR — UNSECURE (EGT) · airframe 38,648 hrs · 11,406 cycles

DIAGNOSTICS REPORTED A SPIKE IN EGT FOR THE NR 1 ENGINE. ACFT GROUNDED. ACCOMPLISHED TSR908608. PRIOR TO INSPECTION, ACCOMPLISHED T/C 78273000, NO CURRENT FAULTS OR FAULTS IN HISTORY. ON INITIAL GVI OF ENGINE HARNESSES, FOUND CJ10 CONNECTION LOOSE AND DIRTY. CLEANED ALL EGT CONNECTORS AND SECURED. EEC TEST PASSED. SYSTEM OPS NORMAL. ALL EGT T49.5 TEMPS WITH IN LIMITS. IAW FIM 77-05, TASK 801.

Part: FMC — MALFUNCTIONED (RIGHT) · airframe 38,539 hrs · 11,370 cycles

DURING TAXI-IN, VTK WARNING ON THE FIRST OFFICER`S ND INTERMITTENTLY WITH SINGLE FMC OPERATION SCRATCH PAD. ALSO RECEIVED A RAAS WARNING WHILE ON TAXI WAY. ACFT GROUNDED. FLT 6 SHOWS LEFT & RIGHT FMC WITH OPPOSITE FMC FCC DATA SYNC ERR FAULT. KNOWN FMC WITH U11.0 OPS SOFTWARE ANOMALY IAW FIM 34-61/837. OPS CHECKED BOTH FMC GOOD IAW AMM 34-61-00. ACFT GROUND VERIFICATION GOOD.

Part: DISPLAY — MALFUNCTIONED (FIRST OFFICER'S) · airframe 38,423 hrs · 11,344 cycles

ON SHORT FINAL, 4 NM, FIRST OFFICER MCDU FAILED. MCDU APPEARED TO GO THROUGH A RESTART WENT TO FMC ON LEFT AND CONTINUED. ACFT GROUNDED. FIRST OFFICER`S MCDU TESTED IAW AMM 34-61-01 AND OPS CHECKED GOOD, NO HISTORY 30 DAYS.

Part: IGNITION SYS — MALFUNCTIONED (LEFT ENGINE) · airframe 38,401 hrs · 11,339 cycles

DURING THE NR 1 ENG START, NO EGT RISE ON LEFT IGNITION. ATTEMPTED TO SWITCH IGNITION TO RIGHT AND ENGINE STARTED NORMAL. ACFT GROUNDED. ACCOMPLISHED GROUND VERIFICATION IAW FIM 74-21 TASK 806. PERFORMED A BITE CHECK, NO FAULTS FOUND. PERFORMED IGNITION SYSTEM AUDIBLE TEST, CHECKED GOOD IAW AMM 74-00-00-750-801-F00, RAN THE NR 1 ENGINE ON LT IGNITION SYSTEM, OP'S CHECKED GOOD, NO RECENT HISTORY.

Part: HF COMM — MALFUNCTIONED (NR 1 & 2) · airframe 38,385 hrs · 11,334 cycles

ACFT HF RADIO NR 1 INOPERATIVE. HF RADIO NR 2 STATIC BUILDS UP DURING TRANSMISSIONS AND CUTS OUT. ACFT GROUNDED. PERFORMED FIM 23-11, TASK 806, FOR BOTH NR 1 AND 2 HF RADIOS, NO FAULTS NOTED AT THIS TIME.

Part: LENS — BROKEN (EMERGENCY LIGHT) · airframe 38,281 hrs · 11,307 cycles

EMERGENCY LIGHT EXIT LOCATOR SIGN ADJACENT TO R1 DOOR HAS BROKEN LENS. ACFT GROUNDED. REMOVED AND REPLACED THE LENS AND TESTED LIGHT ASSEMBLY IAW AMM 33-51-01-960-801 - OPS NORMAL.

Part: LENS — BROKEN (EMERGENCY LIGHT) · airframe 38,281 hrs · 11,307 cycles

EMERGENCY LIGHT EXIT LOCATOR SIGN ADJACENT TO L2 DOOR HAS BROKEN LENS. ACFT GROUNDED. REMOVED AND REPLACED LENS AND TESTED LIGHT ASSEMBLY IAW AMM 33-51-01-960-801, OPS NORMAL.

Part: HOUSING — DETACHED (EMEGENCY LIGHT) · airframe 38,190 hrs · 11,272 cycles

R2 EXIT SIGN ABOVE DOOR LENS BROKEN OFF. ACFT GROUNDED. REMOVED AND REPLACED THE R2 DOOR EMERGENCY EXIT SIGN IAW AMM 33-51-01. OPS CHECKED NORMAL.

Part: PANEL — LOOSE (FAN DUCT) · airframe 38,184 hrs · 11,269 cycles

WHILE ACCOMPLISHING TC 78472000, THE NR 1 ENGINE FOUND FAN DUCT PANELS LOOSE AT THE 1:00 & 7:00 POSITIONS. ACFT GROUNDED. TORQUED THE NR 1 ENGINE DUCT PANELS AT 1:00 AND 7:00 POSITIONS IAW AMM 72-23-07.

Part: PRESSURE SWITCH — FAILED (FUEL SYSTEM) · airframe 37,973 hrs · 11,210 cycles

NR 2 FUEL FILTER BYPASS LIGHT ILLUMINATED AT FL 370, JUST AFTER CENTER PUMPS TURNED OFF. ACFT GROUNDED. REMOVED AND REPLACED THE NR 2 ENGINE FUEL DIFFERENTIAL PRESSURE SWITCH IAW AMM 73-34-01. OPS CHECKED GOOD.

Part: PRESSURE SWITCH — MALFUNCTIONED (FUEL SYSTEM) · airframe 37,887 hrs · 11,177 cycles

PERFORMED TASK CAR 78273000, #2 ENGINE HAD LONG TIME FAULT - 73-31072 - "THE FUEL FILTER SIGNALS DISAGREE". GROUNDED - YES. REFERENCE LOGPAGE 11803593, FUEL FILTER & DRAIN PLUG WERE REPLACED. LOG 11803589 THE FUEL DIFFERENTIAL PRESSURE SWITCH WAS REPLACED. A/C HAS FLOWN A MONTH WITH NO BYPASS FAULTS. NO CURRENT FAULTS IN #2 ENGINE HISTORY.

Part: PRESSURE SWITCH — MALFUNCTIONED (NR 2 ENGINE) · airframe 37,857 hrs · 11,169 cycles

NR 2 ENGINE FILTER BYPASS LIGHT ON DURING TAXI, AFTER LANDING. ACFT GROUNDED. REPLACED THE NR 2 ENGINE EEC IAW AMM 73-21-60-00-801-F00, & 73-21-60-400-801. FUEL BYPASS STILL ON AND OFF PRIOR TO STARTING. PERFORMED INDENT/CONFIG IAW 73-21-00-700-808-F00, TEST 12 ACTUATORS TEST IAW AMM 71-00-00-700-807-F00, EEC DISCRETES TEST IAW AMM 73-21-00-700-809-F00. THESE TESTS PASS PERFORMED EEC TEST IAW AMM 73-21-00-700-804-F00, TEST DID NOT PASS. MESSAGE 73-31072 IS STILL PRESENT. NR 2 ENGINE INPUT MONITORING OF FUEL FILTER SHOWS ALL FOUR CHANNELS OPEN. RANG OUT FUEL FILTER DIFFERENTIAL PRESSURE SWITCH, S241, FOUND NO CONTINUITY BETWEEN PINS 1 AND 2 IAW WDM 73-31-11. REMOVED AND REPLACED FUEL FILTER DIFFERENTIAL PRESSURE SWITCH IAW AMM 73-34-01/401. ALTERNATE DEACTIVATION PROCEDURES REVERSED. OPS AND LEAK CHECKED GOOD.

Part: PRESSURE SWITCH — FAILED (NR 2 FUEL) · airframe 37,804 hrs · 11,144 cycles

AT ROTATION NR 2 ENGINE FUEL FILTER BYPASS ILLUMINATED. STAYED ON FOR ABOUT 15 MINUTES. ACFT GROUNDED. ON ARRIVAL, THE NR 2 ENGINE FUEL BYPASS LIGHT NOT ILLUMINATED. REMOVED AND REPLACED THE FILTER, NO CONTAMINATION NOTED ON FILTER AND LEAK CHECKED GOOD IAW AMM 73-11-02-000-801. PERFORMED EEC BITE CHECK AND FOUND FUEL FILTER SIGNAL DISAGREE AND EEC TEST PASSED IAW AMM 73-21-00. REMOVED AND REPLACED THE NR 2 ENGINE FUEL DIFFERENTIAL PRESSURE SWITCH IAW AMM 73-34-01. OPS CHECKED GOOD.

Part: WARNING LIGHT — FALSE ACTIVATION (FUEL FILTER) · airframe 37,755 hrs · 11,131 cycles

AFTER TAKEOFF, THE RIGHT NR 2 ENGINE FUEL FILTER BYPASS LIGHT ILLUMINATED. FOLLOWED CHECKLIST. LIGHT WENT OUT APPROXIMATELY 8 MINUTES AFTER TAKEOFF. ACFT GROUNDED. PERFORMED EEC TEST IAW AMM 73-21-00, NO FAULTS FOUND. PERFORMED EEC BITE, NO FAULTS FOUND. SUSPECT INTERMITTENT FAULT. LIGHT NOW EXTINGUISHED.

Part: TRANSCEIVER — FAILED (NR 2 HF SYSTEM) · airframe 37,747 hrs · 11,129 cycles

DURING PREFLIGHT, FOUND THE NR 2 HF CIRCUIT BREAKER OPEN. ACFT GROUNDED. REMOVED, REPLACED, AND TESTED THE NR 2 HF TRANSCEIVER IAW AMM 23-11-21-400-801, TEST PASSED. ACCOMPLISHED HF COMMUNICATION SYSTEM TEST IAW AMM 23-11-00-730-801, TEST PASSED. ETOPS SIGNIFICANT SYSTEM GROUND VERIFICATION SUCCESSFUL.

Part: WARNING MESSAGE — FALSE INDICATION (FMC) · airframe 37,632 hrs · 11,092 cycles

ON LANDING, BOTH FMC BLANKED ALONG WITH A VTK FLAG ON BOTH DISPLAYS. BOTH FMC RESUMED AND VTK FLAG CLEARED AFTER APPROXIMATELY 45-60 SECONDS. ACFT GROUNDED. PERFORMED FIM 34-61, TASK 801, AMM 34-61-00-860-801. NUISANCE ERROR, NO FAULT NOTED. OPS NORMAL.

Part: SHROUD — CRACKED (APU DRAIN) · airframe 37,621 hrs · 11,090 cycles

APU DRAIN SHROUD APPEARS CRACKED ON TOP RADIUS/ FILLET. GROUNDED - YES. CONFIRMED CRACK , REMOVED AND REPLACED APU FUEL, HYD DRAIN MAST, REF B737-800 AMM 28-25-07-401

Part: DUCT — GOUGED (ANTI ICE) · airframe 37,579 hrs · 11,075 cycles

NR 2 ENGINE TAI VALVE DUCT AND BRACKETS HAD GOUGES FROM LINK ROD ENDS. GROUNDED - YES. REMOVED AND REPLACED #2 ENG TAI VALVE DUCT AND BRACKETS REF AMM CH. 30-21-11. LEAK CHECK GOOD.

Part: ROD END — WORN (STARTER DUCT) · airframe 37,579 hrs · 11,075 cycles

NR 2 ENGINE LOWER STARTER DUCT FWD ROD END WORN. ACFT GROUNDED. REMOVED AND REPLACED THE NR 2 ENGINE LOWER STARTER DUCT FWD ROD END IAW AMM 36-11-01-000-802(2)(E)(9), AND AMM 36-11-01-400-302(3)(F)(6).

Part: FMC — FALSE INDICATION · airframe 37,524 hrs · 11,056 cycles

AFTER LANDING, CAPTAIN'S DISPLAY SHOWED A VTK FLAG. WENT AWAY AFTER A MINUTE. ACFT GROUNDED. PERFORMED FIM 34-61, TASK 836. FMC RESET & GROUND FUNCTIONAL CHECKED GOOD. NO RECENT HISTORY OF FAULT.

Part: WARNING MESSAGE — ILLUMINATED · airframe 37,260 hrs · 10,977 cycles

ALL VNAV FUNCTIONS FAILED EN ROUTE. TIME ESTIMATES, FUEL ESTIMATES, EN ROUTE WIND, AND DESCENT PLANNING ALL DISAPPEARED. THE COST INDEX ENTRY DISPLAYED EMPTY BOXES. ATTEMPTS TO REENTER THE CI GAVE REPEATED MESSAGES OF VNAV INVALID, PERF OR INVALID MOD PLAN. A POSSIBLE CORRELATION IS THAT THIS ALL HAPPENED AFTER REQUESTING UPDATED EN ROUTE WINDS. ACFT GROUNDED. FMC IN FLIGHT FAULTS SHOW FMC L, ETHERNER-2, WRAP, I, FAULT. CURRENTLY THERE ARE NO FAULTS. OPS CHECK BOTH FMC GOOD IAW AMM 34-61-00.

Part: EXTINGUISHER — FAULTED (CARGO BAY) · airframe 36,972 hrs · 10,891 cycles

DURING CLIMBOUT, DISCHARGED LIGHT ILLUMINATED ON FIRE PANEL. TESTED NORMAL. LIGHT EVENTUALLY WENT OUT. ACFT GROUNDED. REPLACED THE NR 1 CARGO FIRE BOTTLE.

Part: WARNING LIGHT — FALSE ACTIVATION (FIRE) · airframe 36,939 hrs · 10,879 cycles

DURING CLIMBOUT, CARGO FIRE DISCHARGE LIGHT ILLUMINATED WITH NO PILOT INPUT. ACFT GROUNDED. CARGO FIRE TESTED GOOD. ALL INDICATIONS NORMAL IAW AMM 26-23-00.

Part: WARNING LIGHT — FALSE ACTIVATION (FIRE BOTTLE) · airframe 36,925 hrs · 10,876 cycles

DURING PREFLIGHT, OBSERVED DISCHARGE LIGHT ILLUMINATED ON CARGO FIRE PANEL. ACFT GROUNDED. PERFORMED FIM 26-23 TASK 802. AFTER DISCONNECTING CONNECTOR FROM NR 1 BOTTLE PRESSURE SWITCH, LIGHT EXTINGUISHED. INSPECTED CONNECTOR WITH NO FAULTS FOUND. INSTALLED THE CONNECTOR AND DISCHARGE LIGHT REMAINED EXTINGUISHED. PERFORMED CARGO FIRE CONTROL PANEL TEST IAW AMM 26-00-02, SYSTEM OPS CHECKED NORMAL. ACFT OK FOR SERVICE.

Part: PUMP — FAILED (FUEL SYSTEM) · airframe 36,900 hrs · 10,868 cycles

BEING AWARE OF PREVIOUS FUEL IMBALANCE WRITE UP, WE MONITORED FUEL TANK LEVEL. AT 4 HOURS AND 10 MINUTES INTO FLIGHT AT 38,000 FEET NR 2 FUEL TANK WAS 800 LBS. LOWER THAN NR 1 TANK (LEFT SIDE). TO PREVENT A LIMIT FUEL IMBALANCE OF 1,000 LBS. WE CROSSFEED THE TANKS. THERE WAS STILL CENTER (1250 LB) FUEL. SUSPECT NR 2 MAIN TANK PUMPS GREATER PRESSURE THAN CENTER PUMP RIGHT. GROUNDED - YES. REF LOGPAGE 11749408: REMOVED AND REPLACED RIGHT CENTER TANK FUEL BOOST PUMP, REF AMM 28-22-41-000-801 AND TASK 28-22-41-400-801. OPS AND LEAK TEST GOOD.

Part: UNKNOWN — MALFUNCTIONED (FUEL SYSTEM) · airframe 36,890 hrs · 10,866 cycles

AT CRUISE 360 ALL FUEL PUMPS ON CENTER TANK FUEL DEVELOPED 1000 IMBALANCE ON THE RIGHT TANK. SHUT OFF RT PUMPS, BURNED OFF LEFT TO BALANCE 1 & 2 AND HAD NO FURTHER PROBLEMS. GROUNDED - YES. ACCOMPLISHED GVI AROUND EXTERNAL A/C LOOKING FOR FUEL LEAKS, NONE FOUND. FQIS BITE PER FIM 28-41 TASK 801 SHOWED NO FAULTS IN CURRENT STATUS. FUEL X- FEED VALVE FUNCTIONAL TEST PER AMM 28-22-00 TESTED NORMAL. ACCOMPLISHED FUEL STICK TO FLIGHT DECK INDICATION COMPARISON CHECK PER AMM 28-41-00. PRIOR TO FUELING BOTH LT AND RT TANK WITHIN LIMITS. REFUEL A/C AND DID COMPARISON CHECK AGAIN, BOTH TANKS STILL WITHIN LIMITS. FUEL QUANTITY SYSTEM GROUND TEST NORMAL.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 36,445 hrs · 10,749 cycles

AIR CONDITIONING LIGHT & RT PACK LIGHT ILLUMINATED DURING RECALL, LIGHTS GO OUT WITH RESET. ACFT GROUNDED. RAN RT PACK ON AUTO & HIGH SETTINGS. NO FAULTS INDICATED. COULD NOT DUPLICATE DISCREPANCY. OK FOR SERVICE.

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 36,145 hrs · 10,668 cycles

DURING ENGINE START OF THE NR 1 ENGINE. THE ENGINE N2 ROSE VERY SLOWLY AND HUNG AT 19% AT ABOUT 40 SECONDS INTO THE START. ACFT GROUNDED. PERFORMED FIM 80-05, TASK 806, ENGINE STARTED SLOW N2 ACCELERATION TO IDLE OR HUNG START WITH NO DEFECTS NOTED. VERIFIED LT ENGINE FLOW CONTROL VALVE OPENED FULLY IAW AMM 21-51-00. CHECKED FOR LEAKS AND WING ANTI-ICE VALVE, NO LEAKS NOTED IAW AMM 30-11-11 AND AMM 30-21-00. REMOVED & REPLACED THE LEFT FLOW CONTROL VALVE IAW AMM 21-51-01. OPS AND LEAK CHECKED GOOD. REMOVED & REPLACED THE NR 1 START VALVE AMM 80-11-03. OPS TESTED GOOD. REMOVED & REPLACED AIR CONDITIONING MODULE IAW AMM 21-51-65-400-801. ACCOMPLISHED PACK ZONE TEMPERATURE CONTROLLER BITE TEST IAW AMM 21-51-00-700-803. CLEARED INDUCED FAULTS. OPS CHECKED NORMAL. INSTALLATION TESTED, CHECKED GOOD IAW AMM 21-51-65-400-801. PERFORMED FIM 36-10 TASK 806 TABLE 201, OPS NORMAL, NO DEFECTS NOTED. STARTED BOTH ENGINES 3 TIMES IAW AMM 71-00-00. BOTH ENGINES OPERATE AND STARTED NORMAL.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 36,130 hrs · 10,661 cycles

APPROXIMATELY 1 MINUTE AFTER LANDING THE NR 1 ENGINE OIL FILTER BYPASS LIGHT ILLUMINATED (WITH POWER AT IDLE THRUST) ENGINE WAS THEN SHUTDOWN. GROUNDED - YES. ACCOMPLISHED FIM 79-05 TASK 817 UP TO E(2)(C)1). ACCOMPLISHED REPAIR CONFIRMATION PART POWER LEAK CHECK PER STEP F, FIM 79-05 TASK 817. LIGHT REMAINED OUT.

Part: UNKNOWN — UNKNOWN (NR 1 ENGINE) · airframe 36,130 hrs · 10,661 cycles

ENGINE START IN SJC NR 1 ENGINE N2 WAS VERY SLOW IN SPOOLING UP MAX ROTATION WAS 21.2 % AFTER APPROXIMATELY 35 SECONDS WITH START LEVER STILL IN CUTOFF. AFTER LEVER RAISED TO IDLE N2 AND N1 CONTINUED TO RISE SLOWLY BUT CONSISTENTLY ACHIEVING CUTOUT W/ NORMAL PARAMETERS 1 MINUTE +55 SECONDS AFTER ENGAGING STARTER. FUEL FLOW AND EGT AND OIL PRESSURE INDICATIONS WERE WITHIN NORMAL PARAMETERS THROUGHOUT START MAX EGT APP 420 DEG. GROUNDED - YES. PERFORMED MULTIPLE ENGINE (NORMAL STARTS) WITH NO DEFECTS NOTED. STARTING APU PRESSURE WHILE STARTING ENGINES AT 35 PSI. N2 INCREASED AT NORMAL RATE WITH NO DEFECTS NOTED. AS A PRECAUTIONARY REMOVED AND REPLACED THE R/H FLOW CONTROL AND SHUTOFF VALVE IAW AMM 21-51-01-000/400-802. LEAK TEST GOOD NO LEAKS NOTED. OPS TEST GOOD NO DEFECTS. NORMAL START IAW AMM 71-00-00-800-808. MAX MOTORING REACHED 29% N2 ON ALL ENGINE STARTS.

Part: UNKNOWN — MALFUNCTIONED (AC PACK) · airframe 36,127 hrs · 10,659 cycles

ON STARTING ENGINE NR 2 IN LAS, ENG START INDICATIONS WERE VERY SLOW TO INCREASE. START PSI WAS BELOW 30 AND AT REACHING 20% N2, MOVED START LEVER TO RUN. ENGINE CONTINUED TO START BUT VERY SLOWLY. EXHAUST FUMES ENTERED AIRCRAFT DURING START. START COMPLETED WITH NO ANOMALIES NOTED. ENGINE NR 1 START WAS THE SAME AS NR 2 EXCEPT THERE WAS NO FUMES ENTERING THE AIRCRAFT. GROUNDED - YES. WHILE PERFORMING PRE START CHECK LIST WITH APU AIR, SWITCH TURNED TO ON, FOUND PACKS RUNNING WITH PACK SWITCHES IN OFF POSITION. OPS CHECK OF LT PACK NORM. RT PACK WOULD NOT SHUT OFF TILL RT PACK SWITCH CYCLED 3 TIMES. STARTED BOTH ENGINES MULTIPLE TIMES, NO DEFECTS NOTED, DUCT PRESSURE REMAINED OVER 30 PSI, N1 REACHED 25% IN NORMAL TIME. PACK OPERATION NORMAL WITH SWITCHES. PRECAUTIONARY REPLACED P5-10 AIR CONDITIONING MODULE REF MM 21-51-65-000-801 AND 36-21-02-600-802 FOR DUCT PRESSURE TRANSMITTER TRANSFER. OPS CHECK GOOD. GROUND VERIFICATION ACCOMPLISHED REF 21-51-65-000-801, SEAMC NOTIFIED.

Part: FMC — MALFUNCTIONED (LEFT) · airframe 36,111 hrs · 10,654 cycles

LEFT FMC FAILED IN CRUISE FL 380, CHECKLIST FOLLOWED CONTINUED WITH SINGLE FMC OPS. ACFT GROUNDED. PULLED AND RESET THE NR 1 FMCS COMPUTER CIRCUIT BREAKER. TEST SUCCESSFUL IAW AMM 34-61-00-710-801. FMC OPS CHECKED NORMAL.

Part: RELAY — FAILED (AUTOPILOT SYS) · airframe 36,098 hrs · 10,649 cycles

AUTOPILOT NR 1 & 2 WOULD NOT ENGAGE. ACFT GROUNDED. PERFORMED DFCS BITE, IAW FIM 22-11 TASK 801, FOUND MAINTENANCE MESSAGE 22-11176. STAB TRIM RELAY ISSUE. REPLACED THE STAB TRIM RELAY R64, IAW FIM 22-13 TASK 818. ALL TESTED GOOD.

Part: PUMP — FAILED (FUEL TANK) · airframe 35,972 hrs · 10,619 cycles

NR 2 FUEL TANK, AFT PUMP, LOW PRESSURE LIGHT ILLUMINATED WITH SWITCH ON AND QUANTITY IN TANK READING 8.56. GROUNDED - YES. REMOVED AND REPLACED NR 2 FUEL TANK AFT PUMP WITH SERVICEABLE UNIT, REF AMM 28-22-41. OPS CHECKS GOOD, REF AMM 28-22-41.

Part: COMPENSATOR — NO TEST (NR 1 WING TANK) · airframe 35,972 hrs · 10,619 cycles

DURING ACCOMPLISHMENT OF FUEL QUANTITY INDICATION SYSTEM, NR 1 TANK AND COMPENSATOR UNITS TESTING IAW TASK CARD NG-28FCD-18088-1, FOUND COMPENSATORS, F1, F7 AND F8 BAD. ACFT GROUNDED. REPLACED THE PROBES IAW AMM 28-41-21-000/400-801. ALL PROBES CHECKED GOOD. SYSTEM TEST GOOD IAW AMM 28-41-00-730-801. COMPARISON CHECK GOOD IAW AMM TASK 28-41-00-720-801. OK FOR SERVICE.

Part: COMPENSATOR — NO TEST (NR 2 WING TANK) · airframe 35,972 hrs · 10,619 cycles

WHILE ACCOMPLISHING T/C NG-28FCD-18090-1, FOUND #2 MAIN TANK FUEL TANK TOTAL TANK CAPACITANCE AND COMPENSATOR CAPACITANCE OUT OF LIMITS. GROUNDED. MIG-2C INITIATED. REMOVED AND REPLACED #2 TANK COMPENSATOR PROBE AND TANK UNITS F1,F3,F8 AND F9 IAW B737-800 AMM 28-41-21. OPS CHECK NORMAL. DEFECT CLEARED.

Part: CONTROL UNIT — FAULTED (FLIGHT DECK) · airframe 35,954 hrs · 10,612 cycles

WARNING LIGHT ON OVERHEAD PANEL DURING TAXING OUT. ACFT GROUNDED. SPCU FAULT ON BITE, WILL NOT CLEAR. REMOVED & REPLACED SPCU IAW AMM 24-34-11. OPS NORMAL, AFTER FAULT CLEARED.

Part: INDICATOR — FAILED (FUEL QTY) · airframe 35,920 hrs · 10,598 cycles

FUELER REPORTED NR 1 TANK INDICATION FLUCTUATING AT WING. ACFT GROUNDED. FOUND NR 1 REFUEL PANEL FUEL QUANTITY INDICATOR BLANK. REMOVED AND REPLACED IAW AMM 28-41-61-000/400-801, OPS NORMAL.

Part: TRANSCEIVER — FAILED (NR 1 HF) · airframe 35,645 hrs · 10,541 cycles

NR 1 HF INAUDIBLE AND EXTREMELY GARBLED AND UNUSABLE FOR RECEPTION. SEEMS TO TRANSMIT FROM EITHER CAPT OR FO PANEL. MULTIPLE FREQUENCIES WERE ATTEMPTED WITH NO IMPROVEMENT IN RECEPTION. ACFT GROUNDED. ACCOMPLISHED T/S IAW FIM 23-11 TASK 806. REPLACED NR 1 HF TRANSCEIVER IAW AMM 23-11-21. OPS CHECK NORMAL. DEFECT CLEARED.

Part: HF COMM — MALFUNCTIONED (NR 1) · airframe 35,640 hrs · 10,540 cycles

HF 1 RADIO RECEIVES ONLY, UNABLE TO TRANSMIT. HF 2 RADIO WORKS FINE. ACFT GROUNDED. PERFORMED FIM TASK 23-11 TASK 806. PERFORMED HF COMM SYSTEM TROUBLESHOOTING GROUND VERIFICATION CHECK SUCCESSFUL. NO HISTORY PAST 30 DAYS.

Part: BLADE — WORN (NR 2 ENGINE) · airframe 35,614 hrs · 10,532 cycles

NR 2 ENGINE, PLATFORMS WORN WITH MISSING ELASTOMERS. FAN BLADE SPACERS WORN. GROUNDED - YES. REMOVED AND REPLACE ALL 24 PLATFORMS WITH P/N 340-001-816-0 AND ALL 24 SHIMS WITH P/N 340-252-307-0 ON NR 2 ENG.

Part: MODULE — FAILED (CABIN PRESSURE) · airframe 35,166 hrs · 10,393 cycles

OUTFLOW VALVE POSITION INDICATOR LED POSITION DISPLAY IS INOPERATIVE. ACFT GROUNDED. REMOVED & REPLACED CABIN PRESSURE CONTROL MODULE, IAW AMM 21-31-02. OPS NORMAL.

Part: MODULE — MALFUNCTIONED (ALTITUDE) · airframe 35,142 hrs · 10,387 cycles

FLT ALT SELECTOR ON OVHD PANEL IS STUCK ON 37,000 FEET. ACFT GROUNDED. REMOVED AND REPLACED CPC MODULE IAW AMM 21-31-02, ALL TESTS PASSED.

Part: FUEL NOZZLE — FAILED (NR 1 ENGINE) · airframe 35,068 hrs · 10,366 cycles

AFTER SHUTDOWN NR 1 ENGINE EGT RED BOX ILLUMINATED INDICATING EGT EXCEEDANCE ON NR 1 ENGINE ON TAKEOFF. ACFT GROUNDED. REMOVED AND REPLACED THE NR 1 ENGINE UPPER SEGMENT FUEL NOZZLES PER T/C PWRPL-73CMPT-07267-2.

Part: EGT INDICATION — READS HIGH (NR 1 ENGINE) · airframe 35,038 hrs · 10,358 cycles

NR 1 ENGINE ECONOMIC FAULT FOUND DURING LL-2 CHECK ON CDU T/C MSG 73-3171 UPPER EGT SECTORS READING HIGH. ACFT GROUNDED. BITE CHECK OF NR 1 ENGINE T49.5. INSPECTED AND CLEANED EGT TEMP PROBE CONNECTORS. RING OUT OF PROBES WAS WITHIN LIMITS. INSPECTED CJ10 AND CJ9 HARNESS CONNECTORS WITH NO DISCREPANCIES NOTED. RING OUT OF J9 AND J10 HARNESS GOOD. CHECKED T49.5 TEMPS, ALL WITHIN LIMITS. EEC TESTED GOOD, IAW AMM 77-21-00, 77-21-01 AND FIM 73-11 TASK 801.

Part: HEATER — LEAKING (NR 1 FUEL) · airframe 34,992 hrs · 10,347 cycles

WHILE ACCOMPLISHING TEST 3A-LEAK CHECK ON THE NR 1 ENGINE FOR HPTCC VAVE REPLACEMENT, FOUND LEAK COMING FROM SERVO FUEL HEATER. ACFT GROUNDED. REMOVED AND REPLACED THE NR 1 ENGINE SERVE FUEL HEATER IAW AMM 73-11-07-000-801-F00 & 73-11-07-400-801-F00. OPS & LEAK CHECKS OK.

Part: ACTUATOR — LEAKING (NR 1 VSV) · airframe 34,992 hrs · 10,347 cycles

NR 1 ENGINE RT VSV DRAIN LEAKING > 30 DPM. ACFT GROUNDED. REMOVED AND REPLACED THE NR 1 VSV ACTUATOR IAW AMM 75-31-01-000-802, AND AMM 75-31-01-400-802.

Part: WARNING LIGHT — FALSE ACTIVATION (LT A/C PACK) · airframe 34,803 hrs · 10,287 cycles

DURING AFTER START CHECKLIST ON "RECALL" LEFT PACK, ILLUMINATED - RESETS WITH MASTER CAUTION PRESSED. ACFT GROUNDED. PERFORMED PACK ZONE/TEMP CONTROLLER BITE TEST IAW AMM 21-51-00-700-803. PACK FAULT CLEARED AND DID NOT ILLUMINATE ON SECOND TESTING. CONSIDERED AN INTERMITTENT FAULT.

Part: TRANSCEIVER — FAILED (E&E BAY) · airframe 34,529 hrs · 10,205 cycles

NR 1 HF RADIO INOPERATIVE. ACFT GROUNDED. VERIFIED FAULT UNIT WOULD NOT BITE TEST. R & R HF TRANSCEIVER IAW AMM 23-11-21, GROUND VERIFICATION OK.

Part: AUTOLAND SYS — MALFUNCTIONED · airframe 34,463 hrs · 10,186 cycles

DURING AUTOLAND AND HGS APPROACH SURVEY AIRCRAFT DRIFTED AND TOUCHED DOWN APPROXIMATELY 40 FEET LEFT OF CENTERLINE. CRITICAL AREA WAS CLEAR AND WINDS WERE REPORTED WITHIN LIMITS AND ND WIND DISPLAY SHOWED WINDS IN LIMIT. TOUCH DOWN OCCURRED SMOOTHLY BUT WAS NOT CORRECTING UNTIL DONE SO MANUALLY. HGS WAS USED AND DID NOT ISSUE APPROACH WARNING. ACFT GROUNDED. ACCOMPLISHED DFCS BITE FAULT REVIEW, FIM 22-11 TASK 801. CHANNEL A LOGGED FAULT MESSAGE 22-11822 LEG 02 AND CHANNEL B LOGGED FAULT MESSAGE 22-11391 LEG 06. ACCOMPLISHED FMCS BITE, FIM 34-61 TASK 801 AND MMR BITE, FIM 34-31 TASK 801. BITE TESTS PASSED WITH NO CURRENT FAULTS. PERFORMED DFCS GROUP 49 (LAND VERIFY) TEST PER AMM 22-11-00 AND HGS OPERATIONAL AND SYSTEM TEST PER HGS SMM 34-36-00. ALL TESTS PASS.

Part: DISPLAY — MALFUNCTIONED (FMC) · airframe 34,372 hrs · 10,159 cycles

DURING TOUCHDOWN, FUEL READOUT IN FMC BLANKED OUT, FMC SHOWED "INSUFFICIENT FUEL" AND THE YELLOW FMC LIGHT ILLUMINATED. ACFT GROUNDED. PERFORMED BITE OF FMCS IAW FIM 34-61-00-810-801. NO FAULTS NOTED. PERFORMED OPS CHECK OF FQIS IAW AMM 28-41-00-710-801. NO DEFECTS NOTED. PERFORMED FQIS BITE IAW AMM 28-41-00-810-801. NO FAULTS NOTED. ACCOMPLISHED FIM TASK 34-61-00-810-826. NO FAULTS OR WIRING DEFECTS NOTED DURING GROUND VERIFICATION.

Part: ENGINE — UNKNOWN (NR 1) · airframe 34,236 hrs · 10,119 cycles

NR 1 ENGINE DID NOT LIGHT OFF DURING START. ACCOMPLISHED ABORT PROCEDURE. ACCOMPLISHED QRC. STRONG ODOR OF FUMES. ACFT GROUNDED. ACCOMPLISHED IGNITION SYSTEM AUDIBLE TEST FOR THE NR 1 ENGINE LT & RT IGNITION CHECK. BOTH LEFT AND RIGHT IGNITERS PASSED WITH NO FAULTS DETECTED IAW AMM 74-00-00-750-801-F00. ALSO PERFORMED NR 1ENGINE IDLE RUN FOR FIVE MINUTES ENGINE START NORMAL WITH ALL PARAMETERS SHOW NORMAL IAW AMM 71-00-00-800.

Part: KEYBOARD — FAILED (FLIGHT DECK) · airframe 33,845 hrs · 10,006 cycles

FLIGHT CREW REPORTS THAT THE F/O'S CDU KEYPAD IS MISSING THE O-KEY. ACFT GROUNDED. R & R F/O'S CDU KEYBOARD REF AMM 34-61-01. OPS NORMAL, GROUND VERIFCATION ACCOMPLISHED.

Part: WARNING LIGHT — FALSE ACTIVATION (LT A/C PACK) · airframe 33,817 hrs · 9,999 cycles

LEFT PACK ILLUMINATES ON MASTER CAUTION RECALL AFTER ENGINE START AND EXTINGUISHES AFTER MASTER CAUTION RESET. ACFT GROUNDED. COMPLIED WITH TEMPERATURE CONTROLLER BITE TEST IAW AMM 21-51-00-700-803, BITE CHECK RESET GOOD . OPS TEST IAW AMM TASK 21-51-00-700-802, OPS CHECK GOOD.

Part: PACKING — FAILED (NR 1 ENGINE) · airframe 33,793 hrs · 9,994 cycles

WHILE PERFORMING TASK CARD 78472040 FOUND FWD MAINTENANCE, AGT/TGB SPOOL VALVE INNER NOT FULLY SEALING. ACFT GROUNDED. ACCOMPLISHED TASK AMM 79-21-01-400-804-F00, OPS AND LEAK CHECKS GOOD. INNER, PN J221P019 AND OUTER PN 335-299-401-0SD, SPOOL SEALS REPLACED.

Part: FAULT CODE — ACTIVATED (ENGINE) · airframe 33,783 hrs · 9,992 cycles

WHILE PERFORMING TASK CARD 78273000, FOUND FAULT CODE 73-31371, UPPER EGT SECTORS READING HIGH, FOR ENGINE NR 1 ECONOMIC FAULT. ACFT GROUNDED. RE-CHECKED FOR FAULT CODE 73-31371 ON NR 1 ENGINE. NO RECENT FAULTS FOUND.

Part: FMC — MALFUNCTIONED · airframe 33,447 hrs · 9,889 cycles

ON TAXI IN "VTK" DISPLAYED ON LEFT NAV DISPLAY, THEN CLEARED ITSELF. ACFT GROUNDED. CREW REPORTS THAT FAULT HAPPENED WHEN THEY SWITCHED POWER SOURCE FROM APU TO EXTERNAL POWER. BITE CHECK OF FMC'S REVEALS LEFT FMC FAULT ON GROUND LEG, PGM FAULT, REF FIM 34-61, TASK 801. SUSPECT FAULT LOGGED DUE TO POWER INTERRUPTION. FMCS SENSOR STATUS NORMAL, REF FIM 34-61, TASK 801 & 807.

Part: SATCOM — MALFUNCTIONED · airframe 33,334 hrs · 9,853 cycles

SAT SECTION MISSING FROM THE MCDU MENU PAGE AND NO SATCOM PAGES AVAILABLE. PERFORMED SATCOM LOCK-UP PROCEDURE FROM QRH, SAT PROMPT REAPPEARED IN MCDU PAGE AS WELL AS SAT PAGES. SATCOM OPS NORMAL. ACFT GROUNDED. VERIFIED SATCOM AVAILABLE, REF FIM 23-15-00.

Part: SATCOM — LOCKED · airframe 33,319 hrs · 9,849 cycles

SATCOM LOCKUP AFTER POWER TRANSFER. OPS NORMAL AFTER RESETTING CB IAW QRH. ACFT GROUNDED. VERIFIED SATCOM AVAILABLE AND OPS NORMAL, REF FIM TASK 23-15-00.

Part: FIRE DETECTOR — FAILED (NR 2 NACELLE) · airframe 32,928 hrs · 9,738 cycles

FIRE TEST INCONCLUSIVE ON NR 2 ENGINE. FOUND B LOOP TO BE INOPERATIVE IN OVERHEAT SYSTEM. ACFT GROUNDED. R & R NR 2 ENGINE M1757 UPPER FAN ENGINE FIRE DETECTOR ELEMENT IAW AMM 26-11-01-000-801 AND AMM 26-11-01-400-801, OPS CHECK GOOD.

Part: PROBE — FAILED (NR 1 ENGINE) · airframe 32,861 hrs · 9,717 cycles

NR 1 ENGINE ELECTRONIC ENGINE CONTROL BITE SHOWS FAULT CODE 77-20871, THE TOP LT EGT SIGNAL, T495S4 IS OUT OF RANGE. FAULT IS A LONG TERM FAULT AND IS LOGGED FOR 6 OUT OF THE LAST 10 STARTS. ACFT GROUNDED. ACCOMPLISHED T/S FOR FAULT 77-20871 IAW FIM 77-21, TASK 804. PERFORMED EGT CONNECTOR CLEANING IAW AMM 77-21-00-140-801, ALL CONNECTORS IN TABLE 2 CLEANED. AFTER CLEANING, T495S4 READINGS WERE STILL OUT OF LIMITS. R & R T495S4 PROBE IAW AMM 77-21-01-000-801, AMM 77-21-01-400-801. OPERATED ENGINE AND FOUND T495 READINGS WITHIN LIMITS WITH ENGINE RUNNING AND NOT RUNNING. PERFORMED EEC TEST IAW AMM 73-21-00-700-804-F00. NO FAULTS NOTED. EGT READINGS BEFORE CLEANING: S1-89.70; S2 - 53.32; S3-61.75; S4-119.59. AFTER CLEANING, AND PROBE REPLACEMENT: S1-116.28; S2-79.96; S3 - 84.98; S4-118.80.

Part: LENS — DAMAGED (EMERGENCY LIGHT) · airframe 32,830 hrs · 9,707 cycles

LIGHT COVER ADJACENT TO R2 DOOR HAS FALLEN OFF. ACFT GROUNDED. FOUND LT COVER ATTACHMENT POINTS DAMAGED. REPLACED DAMAGED R2 EMERGENCY EXIT LIGHT COVER REF AMM 33-51-01.

Part: MODULE — FAILED (FIRE DETECTION) · airframe 32,680 hrs · 9,665 cycles

APU FIRE HANDLE ILLUMINATED WITHOUT EITHER FIRE WARNING LIGHTS OR FIRE BELL, QRH FOR APU FIRE WAS RUN, BOTTLE FOR APU DISCHARGED, LIGHT REMAINED ILLUMINATED, NOTE APU WAS NOT RUNNING AND NO EGT INDICATION. ACFT GROUNDED. DIVERSION TIME, 25 MINUTES. FOUND APU FIRE HANDLE WAS NOT ILLUMINATED. PERFORMED OPS TEST OF FIRE AND OVERHEAT DETECTION SYS AT P8-1 MODULE IAW AMM 26-10-00-710-801 PARA F AND APU FIRE HANDLE OPERATED NORMALLY DURING TEST AND REMAINED OUT AFTER TEST. PERFORMED TEST OF M279 ENGINE/APU FIRE DETECTION CONTROL MODULE IAW FIM 26-10, TASK 801. ALL TESTS PASSED BUT APU FIRE HANDLE WAS ILLUMINATED AFTER M279 BITE AND REMAINED ILLUMINATED. REMOVED AND REINSTALLED M279 MODULE AND HANDLE WAS NOT ILLUMINATED. PERFORMED M279 BITE AND HANDLE AGAIN ILLUMINATED. R & R M279 ENGINE AND APU FIRE DETECTION MODULE IAW AMM 26-10-01-000-801 AND 26-10-01-400-801. PERFORMED ENGINE FIRE DETECTION OPERATIONAL TEST IAW AMM 26-11-00-710-801 AND APU FIRE DETECTION OPS TEST IAW AMM 26-15-00-710-801. ALL TESTS PASS. BITE TEST OF M279 MODULE NO LONGER CAUSES APU FIRE HANDLE TO ILLUMINATE.

Part: DISPLAY — MALFUNCTIONED · airframe 32,650 hrs · 9,655 cycles

MCP ALT WINDOW WILL NOT CHANGE. ACFT GROUNDED. AFTER LOSS OF EXT POWER AND RE-ESTABLISHING EXT POWER, DFCS MODE CONTROL PANEL ADJ/TEST NORMAL IAW AMM 22-11-34.

Part: FUEL CONTROL — FAILED (APU) · airframe 32,546 hrs · 9,626 cycles

APU HAS PREVIOUS HISTORY OF OVERTEMP SHUTDOWN AND REPORT OF APU INOPERATIVE WITH NO FAULT FOUND. ACFT GROUNDED. STEP 1 OF TSR FOUND MAINT MSG 49-52284, 49-52219, 49-41250, 49-41253. FAULT HISTORY SHOW 49-41012, 49-41010, 49-31016, 49-11023, 49-11021. R & R MAIN AND AUXILIARY BATTERIES, INSTALLATION TEST GOOD REF AMM 24-31-11. REPLACED APU LUBE MODULE REF AMM 49-91-11. REPLACED APU FUEL CONTROL UNIT REF AMM 49-31-11. BOTH OPS & LEAK CHECK GOOD. APU BITE CHECK GOOD.

Part: IDG — FAILED (NR 2 GENERATOR) · airframe 32,544 hrs · 9,625 cycles

NR 2 ENGINE IDG WOULD NOT COME ON LINE. ACFT GROUNDED. R & R NR 2 ENGINE IDG REF AMM 24-11-11. OPS & LEAK CHECKED GOOD, REF AMM 24-11-00-700-803.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 32,535 hrs · 9,623 cycles

TRIED APU WITH BATTERY, FAULT LIGHT ILLUMINATED & FAULT CODE 49-41010. THIS APPEARS TO BE INTERMITTENT FAULT. ACFT GROUNDED. HOOKED -UP EXT GPU, APU STARTED NORMAL. NO FAULT NOTED.

Part: APU — INOPERATIVE · airframe 32,531 hrs · 9,619 cycles

APU INOPERATIVE. ACFT GROUNDED. RAN APU SEVERAL TIMES LOADED APU AND MONITORED APU OPERATION, GROUND FUNCTIONAL CHECKS NORMAL. ACFT APU FAULT HISTORY ADDED AS FOLLOWS: 49-41012, 49-31016, & 49-41010. MAINTENANCE HISTORY WAS 49-52284.

Part: WIRE HARNESS — FAILED (FIRE DETECTOR) · airframe 32,523 hrs · 9,616 cycles

FOLLOW-UP TO RECENT HISTORY OF NR 2 ENGINE FIRE, O/H B LOOP FAULTS. ACFT GROUNDED. R & R FIRE LOOP HARNESS MW0326, REF AMM 26-11-00. OPS CHECK OK.

Part: WARNING FLAG — FALSE ACTIVATION (FLT DIRECTOR) · airframe 32,446 hrs · 9,590 cycles

FLIGHT DIRECTOR FLAG ON CAPTAINS EADI. ACFT GROUNDED. FOUND FCC "A" WOULD NOT ENTER BITE. PERFORMED FIM TASK 22-11, TASK 826. DFCS CURRENT STATUS NORMAL, NO CURRENT FAULTS, NO FLAGS REF AMM 22-11-00-810-801.

Part: APU — MALFUNCTIONED · airframe 32,446 hrs · 9,590 cycles

STARTING APU AT GATE, AFTER EXTERNAL POWER FAIL, GOT HOT START AT 900-950 EGT/FAULT LIGHT FOLLOWED/FAULT LIGHT EXTINGUISHED. ACFT GROUNDED. PERFORMED FIM 49-30, TASK 803, STEP A-G, 1-2. PERFORMED GVI OF THE INLET DUCT, NO DEFECT NOTED. PERFOMED GVI OF COMPRESSOR INLET PLENUM, FOUND DEBRIS AT COMPRESSOR INLET. REMOVED DEBRIS AND GVI COMPRESSOR INLET SURROUNDING, NO DEFECT NOTED. PERFORMED APU OPERATION; APU STARTING, OPERATION, AND SHUTDOWN NORMAL. PERFORMED APU BITE TEST, NO CURRENT FAULT LOGGED.

Part: ACTUATOR — FAILED (RAM AIR) · airframe 32,427 hrs · 9,582 cycles

RT PACK LT ILLUMINATED LIGHT GOES OUT WHEN RESET MASTER CAUTION. ACFT GROUNDED. R & R RT RAM AIR ACTUATOR IAW AMM 21-51-21-400-801. OPS CK NORMAL. PERFORMED BITE CHECK NR 2 CONTROLLER NO DEFECTS.

Part: INDICATOR — FAILED (FUEL QTY) · airframe 32,412 hrs · 9,579 cycles

FUEL PANEL TANK 2 QTY "TEST GAUGES" FUNCTION INOPERATIVE. CHECKS OK, FLT DECK. ACFT GROUNDED. R & R NR 2 REFUEL QTY INDICATOR REF AMM 28-41-61. GROUND VERIFICATION TEST PASSED REF AMM 28-41-61.

Part: TERMINAL — LOOSE (NR 2 FIRE DETECT) · airframe 32,403 hrs · 9,575 cycles

ON FIRE TEST NR 2 ENGINE FIRE TEST FAILED. ACFT GROUNDED. PERFORMED NR 2 ENGINE/APU FIRE DETECTION MODULE BITE PROCEDURE, REF FIM 26-10, TASK 801. NO FAULTS FOUND. ACCOMPLISHED LOW DETECTORS RESISTANCE, REF FIM 26-10, TASK 810. FOUND M1757 UPPER FAN DETECTOR WITHIN RESISTANCE LIMITS OF 5921 OHMS. FURTHER INSPECTION FOUND DETECTOR M1759 HAD LOOSE HW. TIGHTENED AS REQUIRED. PERFORMED DETECTOR OPS TEST REF AMM 26-11-00. SYS CHECKS NORMAL.

Part: PROBE — FAILED (NR 1 ENGINE) · airframe 32,390 hrs · 9,571 cycles

NR 1 ENGINE, PERFORMED TC 78273000, FOUND FAULT 73-31371. UPPER EGT SECTORS READING HIGH, ECONOMIC FAULT, REPAIR WITHIN 500 HOURS. ACFT GROUNDED. UNABLE TO DUPLICATE DEFECT. NR 1 ENGINE ELECTRONIC ENGINE CONTROL BITE IAW T/C 78273000 SHOWED NO INSTANCES OF FAULT 73-31371 IN THE LAST TEN STARTS. ACCOMPLISHED T/S FOR FAULT 77-20871 IAW FIM 77-21, TASK 804. PERFORMED EGT CONNECTOR CLEANING IAW AMM 77-21-00-140-801, ALL CONNECTORS IN TABLE 2 CLEANED. AFTER CLEANING, T495S4 READINGS WERE STILL OUT OF LIMITS. R & R T495S4 PROBE IAW AMM 77-21-01-000-801, 77-21-01-400-801. OPERATED ENGINE AND FOUND T495 READINGS WITHIN LIMITS WITH ENGINE RUNNING AND NOT RUNNING. PERFORMED ELECTRONIC ENGINE CONTROL TEST IAW AMM 73-21-00-700-804-F00. NO FAULTS NOTED.

Part: FIRE LOOP — MALFUNCTIONED (NR 2 NACELLE) · airframe 32,367 hrs · 9,563 cycles

REQUEST VISUAL INSPECTION OF NR 2 ENGINE OVERHEAT/FIRE UPPER FAN DETECTOR LOOP AND OPS TEST OF ENGINE FIRE AND OVERHEAT DETECTION SYSTEM. ACFT GROUNDED. MOVED NR 2 ENGINE LOOP FIRE SWITCH BACK TO NORMAL. ENGINE FIRE WARNING OPS TEST NORMAL. USED IAW CHAP 5-07-01, TABLE 3, ITEM 9. INSPECTED WIRING AND TERMINALS TO UPPER FAN LOOP ASSY. NO DEFECTS NOTED. REPLACED UPPER FAN LOOP ASSY DUE TO PREVIOUS FAULTS LOGGED. GROUND VERIFICATION GOOD. ALL TEST PASS, REF MM 26-11-01 AND MM 26-11-00.

Part: FIRE HANDLE — NO TEST · airframe 32,361 hrs · 9,562 cycles

DURING OVERHEAT/FIRE TEST, NR 2 FIRE HANDLE DOES NOT ILLUMINATE AND ENGINE 2 OVERHEAT CAUTION LIGHT DOES NOT ILLUMINATE. ACFT GROUNDED. PERFORMED ENGINE/APU FIRE DETECTION BITE FOUND FAULT NR 2 ENGINE LOOP B UPPER FAN DETECTOR FAULT IAW-800 FIM 26-10-801. REMOVED ENGINE/APU FIRE DETECTION CONTROL MODULE M279. INSPECTED RACK CONNECTORS, NO DEFECTS NOTED. REINSTALLED M279 INOPERATIVE NORMAL IAW AMM 26-10-01. PERFORMED BITE, ALL FAULTS CLEARED. ENGINE FIRE AND OVERHEAT DETECTOR SYS OPS TEST PASSED.

Part: LAMP — INOPERATIVE (EMERGENCY LGIHT) · airframe 32,285 hrs · 9,542 cycles

FOUND R2 DOOR EMERGENCY SLIDE LIGHT INOPERATIVE. ACFT GROUNDED. REPLACED THE LAMP. OPS CHECKED GOOD, IAW AMM 33-51-04.

Part: STARTER — FAILED (NR 2 ENGINE) · airframe 32,282 hrs · 9,541 cycles

NR 2 ENGINE FAILED TO START. START VALVE OPEN LIGHT WAS ILLUMINATED. NO INDICATION OF N2 OR N1. ACFT GROUNDED. R & R NR 2 ENGINE STARTER, REF MM 80-11-01. OPS CK GOOD.

Part: WARNING LIGHT — ILLUMINATED (RT A/C PACK) · airframe 32,280 hrs · 9,539 cycles

RIGHT PACK LIGHT ILLUMINATES WITH MASTER RECALL. LIGHT EXTINGUISHES WITH RESET. ACFT GROUNDED. PERFORMED PACK TEMP CONTROL BITE TEST REF FIM 21-62, TASK 801. RAM AIR ACT. CAME UP ON BIT AND PREV FLT. THEN GREEN LIGHT CAME ON TO VERIFY. RESET BITE NO HISTORY 30 DAYS.

Part: DISPLAY — FAILED (FLIGHT DECK) · airframe 32,204 hrs · 9,520 cycles

LEFT MCDU PUSHBUTTON L-2 INOPERATIVE MOST OF THE TIME. ACFT GROUNDED. R & R LT FMC MCDU REF AMM 34-61-01-400-802 AND GROUND FUNCTIONAL TEST PASSED.

Part: HEATER — MALFUNCTIONED (PROBE) · airframe 32,193 hrs · 9,518 cycles

CREW REPORTS SOME FMC DATA WILL NOT LOAD. ACFT GROUNDED. FOUND PROBE HEAT ON & TEMP WITH DASHED LINES. AFTER PROBE COOLED, ALL OPS NORMAL.

Part: IDG — LEAKING (NR 1 GENERATOR) · airframe 32,156 hrs · 9,509 cycles

NR 1 ENGINE IDG OIL LEAK. ACFT GROUNDED. R & R NR 1 ENGINE IDG REF AMM 24-11-11. SERVICED OIL TO FULL. PERFORMED IDG OPS TEST, PASSED REF AMM 24-11-00-700-802. LEAK CHECK ON IDG GOOD.

Part: FLOORBEAM — CORRODED (BS 500I) · corrosion level 2 · airframe 32,121 hrs · 9,499 cycles

FWD CARGO COMPARTMENT, AFT BULKHEAD TO FLOOR LOWER SUPPORT ANGLE HAS CORROSION INTERGRANULAR. ACFT GROUNDED. REMOVED CORROSION IAW SRM 53-00-53, ORIGINAL MATERIAL 0.071, MATERIAL LOSS .0.019 FOUND TO BE OUT OF LIMITS IAW SRM 53-00-53. REMAINING MATERIAL 0.052, UT GAGE, T8225U. REMOVED SUPPORT ANGLE IAW SRM 57-40-02. INSTALLED POSITIONED DRILLED AND DEBURRED IAW SRM 57-40-05 AND 51-40-02, NEW ANGLE PO 853691.3.

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 32,121 hrs · 9,499 cycles

CRACK INDICATION, STABILIZER BS 101, APPROXIMATELY 10" FROM FRONT SPAR, APPROXIMATELY .5 " IN LENGTH, MARKED IN RED. ACFT GROUNDED. REMOVED RIGHT HORIZONTAL STABLIZER L/E AND TIP TO ACCESS REPAIR IAW AMM 27-41-21. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR FILLER AND DOUBLER IAW SRM 55-10-01, REPAIR 11. REINSTALLED RT HORIZONTAL STABILIZER L/E AND TIP IAW AMM 27-41-21.

Part: WARNING LIGHT — FALSE ACTIVATION (A/C PACK) · airframe 31,982 hrs · 9,467 cycles

AT CRUISE, SINGLE CHANNEL FAILURE OF RT PACK RECALL. CANCELS WITH MASTER CAUTION RESET. ACFT GROUNDED. PERFORMED FIM TASK 21-62-801, CLEARED FAULTS, FAULT DID NOT RETURN.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 31,970 hrs · 9,464 cycles

AFTER ENGINE START, FMC DISAGREE MESSAGE APPEARED IN SCRATCHPAD. ACFT GROUNDED. PERFORMED QRH RESET PROCEDURE. DISAGREE MESSAGE CLEARED.

Part: HEATER — FAILED (NR 2 FUEL) · airframe 31,896 hrs · 9,444 cycles

NR 2 ENGINE FUEL SERVO HEATER LEAKING. ACFT GROUNDED. R & R NR 2 ENGINE SERVO FUEL HEATER REF MM 73-11-07-400-801-F00 AND 73-11-07-000-801-F00. ACCOMPLISHED POWER PLANT TEST REF TABLE 3A, SERVO LEAK CHECKS GOOD.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 31,899 hrs · 9,445 cycles

ON FINAL, WHEN RECALL CHECKED, RT PACK LIGHT ILLUMINATED. LIGHT EXTINGUISHED WHEN MC RESET PUSHED. ACFT GROUNDED. BITE TEST OF NR 2 TEMP CONTROLLER SHOWS "RAM AIR ACT" FAULT ON "BITE" TEST ONLY. RESET FAULT. FAULT DID NOT RETURN. RAN RT PACK. FAULT DID NOT RETURN. BITE TEST, NR 2 TEMP CONTROLLER AND OPS CHECK RT PACK GOOD.

Part: WARNING LIGHT — FALSE ACTIVATION (AIR CON) · airframe 31,845 hrs · 9,431 cycles

UPON RECALL, AIR CONDITIONER & CONTROLLER CAB ZONE TEMP LIGHT ILLUMINATED, LIGHT EXTINGUISH ON RESET. ACFT GROUNDED. PERFORMED A PACK/ZONE CONTROLLER BITE TEST REF AMM 21-51-00. NO FAULTS FOUND.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 31,687 hrs · 9,390 cycles

ELECTRIC FAULT LIGHT ON DURING PREFLIGHT. LIGHT REMAINED ON AFTER SWITCHING FROM GROUND POWER TO APU. POWERED OK WN A/C + LIGHT REMAINED ON. ACFT GROUNDED. PERFORMED FIM TASK 24-31, TASK 801 FAULT RESET, ELECTRIC FAULT LIGHT EXTINGUISHED, ACFT OK FOR SERVICE.

Part: AUTOPILOT SYS — MALFUNCTIONED · airframe 31,666 hrs · 9,382 cycles

B-AUTOPILOT AND B-CWS INOP. ACFT GROUNDED. ACCOMPLISHED DFCS BITE REF FIM 22-11, TASK 801. FAULT REVIEW FOR LAST LEG LOGGED CHANNEL B, A/P DISC SW INPUT INV FAULT MSG 22-11282. PERFORMED AUTOPILOT LRU TEST GROUP 11, 20 AND DFCS GROUP NR 49 LAND VERIFY TEST IAW MM 22-11-00 AND HGS SYS TEST IAW SMM 34-36-00. ALL TESTS PASS. ACFT REMAINS QUALIFIED CAT 111A AUTOLAND AND HGS OPS. STATUS PLACARD SCREW REFLECTS SAME. ACFT APPROACH SURVEY COMPLETED. NO HISTORY 30 DAYS.

Part: SATCOM — LOCKED · airframe 31,628 hrs · 9,366 cycles

SATCOM LOCKUP. ACFT GROUNDED. FOLLOWED QRH TO RESET NORMAL, OPS RESTORED.

Part: CONTROL VALVE — FAILED (A/C BAY) · airframe 31,553 hrs · 9,349 cycles

FWD CABIN ZONE TEMP LIGHT ILLUMINATED ON PUSHING MASTER CAUTION RECALL BUTTON, LIGHT EXTINGUISHED WHEN PRESSING MASTER CAUTION RESET BUTTON. ACFT GROUNDED. WHILE ON DEFERRAL, UNABLE TO MAKE FWD/AFT CABIN CONTROL ADJUST TEMP. R & R THE FWD TRIM MODULATING VALVE REF AMM 21-51-10. INSPECTED CABIN SENSORS, R & R ALL FILTERS AS WELL. AS CLEANED, BOTH FWD & AFT GALLEY VENTILATION GRILLS.

Part: CONTROL VALVE — MALFUNCTIONED (TEMP) · airframe 31,447 hrs · 9,312 cycles

FWD CABINE ZONE TEMP LIGHT ILLUMINATES ON RECALL AND EXTINGUISHES WITH MASTER CAUTION RESET. ACFT GROUNDED. ACCOMPLISH BITE FOUND PACK TCV FAULT ON ZONE TEMP CONTROLLER 1 REF AMM 21-61-00. R & R TEMP CONTROL VALVE. OPS CK, BITE CHECK, LEAK CK OK, REF MM 21-51-10.

Part: CONTROL VALVE — MALFUNCTIONED (LT A/C PACK) · airframe 31,390 hrs · 9,292 cycles

AFTER ENGINE START DURING RECALL, MASTER CAUTION & AIR CONDITION LIGHT ILLUMINATED WITH FWD CABIN ZONE TEMP LIGHT ILLUMINATED. LIGHT EXTINGUISHED WITH MASTER CAUTION RESET. ACFT GROUNDED. ACCOMPLISHED LT PACK TEMP CONTROLLER BITE TEST REF 21-61-00. FOUND LT CONTROLLER TCV FAULT 2 X'S, REQ'S LT TCV REPLACEMENT. REPLACED LT TCV REF MM 21-51-10, OPS & LK CK GOOD. REACCOMPLISHED BITE CK REF MM 21-61-00, NO FAULTS.

Part: WARNING LIGHT — FALSE ACTIVATION (CABIN TEMP) · airframe 31,386 hrs · 9,290 cycles

AFTER ENGINE START, DURING RECALL, FWD CAB ZONE TEMP LIGHT ILLUMINATED, LIGHT EXTINGUISHED WITH MASTER CAUTION RESET. ACFT GROUNDED. RESET PACK, ZONE TEMP CONTROLLER IAW FIM 21-62, TASK 801. GROUND VERIFICATION SUCCESSFUL.

Part: WARNING MESSAGE — FALSE ACTIVATION · airframe 30,854 hrs · 34,083 cycles

DURING TAXI OUT, ZONE TEMP FWD CABIN ILLUMINATED WITH AND RESETS WITH MASTER CAUTION PUSHED. WHEN RECALL IS PUSHED, ZONE TEMP LIGHT ILLUMINATES. TEMP CONTROLLER DOESN`T CONTROL ZONE DUCT TEMP. ACFT GROUNDED. ACCOMPLISHED PACK TEMP CONTROL BITE TEST IAW FIM 21-62, TASK 801. FWD CABIN TRIM AIR VALVE LIGHT RESET & 3 BITE CHECKED, NO RECURRENCE NOTED. ALL COMPONENTS FUNCTION NORMAL. NO HISTORY 30 DAYS.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 30,795 hrs · 9,097 cycles

FMC DISAGREE, ACFT GROUNDED. RESOLVED IAW QRH.

Part: SWITCH — MALFUNCTIONED (THRUST REVERSER) · airframe 30,574 hrs · 9,032 cycles

AFTER LANDING, THE THRUST REVERSER LIGHT ON OVERHEAD PANEL ILLUMINATED AND STAYED ON, NR 1 ENGINE. ACFT GROUNDED. REPLACED NR 1 AUTOTHROTTLE SWITCH PACK ASSY IAW AMM TASK 76-11-07-020-802-F00 AND 76-11-07-400-802-F00. ACCOMP AUTOTHROTTLE SWITCH PACK ASSY TEST IAW AMM 76-11-07-400-802-F00, STEP (H) 1 THROUGH 7. ALL TEST PASSED.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 30,283 hrs · 8,947 cycles

DURING APPROACH, WITH RECALL RT PACK LIGHT ILLUMINATED AND RESETS. ACFT GROUNDED. ACCOMPLISHED BITE CHECK ON BOTH TEMP CONTROLLERS, NO FAULTS LOGGED. SYS GROUND VERIFICATION TEST NORMAL.

Part: ACTUATOR — FAILED (RT RAM AIR DOOR) · airframe 30,287 hrs · 8,949 cycles

RIGHT PACK LIGHT ILLUMINATED DURING LANDING ON "RECALL". ACFT GROUNDED. WHILE ON DEFERRAL, RT PACK LIGHT ILLUMINATES ON RECALL AND EXTINGUISHES WITH MASTER CAUTION RESET. REMOVED OLD RAM AIR DOOR ACTUATOR, RT SIDE & INSTALLED NEW. ALL OPS CHECKED GOOD IAW AMM 32-00-01. ZONE TEMP NR 2 CONTROLLER INTERROGATION CLEAN/ GOOD IAW AMM 21-61-00.

Part: FAULT CODE — FALSE ACTIVATION (RAM AIR ACTUATOR) · airframe 30,261 hrs · 8,940 cycles

ON RECALL, THE RT PACK LIGHT ILLUMINATED. ACFT GROUNDED. BITE TESTED NR 2 CONTROLLER AND FOUND FAULT. RAM AIR ACTUATOR. CLEARED FAULT. RAN FIM TASK 21-53-804. NO CURRENT FAULTS, OPS NORMAL. NO HISTORY LAST 30 DAYS.

Part: PRESSURE SWITCH — FAILED (NR 2 FUEL) · airframe 30,117 hrs · 8,899 cycles

NR 2 ENGINE FILTER BYPASS ILLUMINATED AFTER ENGINE START. ACFT GROUNDED. REMOVED FUEL FILTER IAW MM 73-11-02 AND INSTALLED NEW FUEL FILTER NO CONTAMINATION NOTED. REPLACED FUEL FILTER DIFFERENTIAL PRESSURE SWITCH IAW MM 73-34-01. RAN ENGINE, NO LEAKS NOTED.

Part: WINDOW — FAILED (COCKPIT) · airframe 29,961 hrs · 8,858 cycles

LEFT SIDE WINDOW HEAT, CAUTION LIGHT CAME ON DURING CRUISE, RAN QRH, LIGHT DID NOT EXTINGUSH, CONTINUED WITH SWITCH OFF IAW QRH. ACFT GROUNDED. FOUND LT NR 2 WINDOW SENSOR BAD, REPLACED LT NR 2 WINDOW ASSY, REF AMM 56-12-11. WINDOW LEAK AND OPS CHECK GOOD.

Part: SENSOR — FAILED (L2 WINDOW HEAT) · airframe 29,955 hrs · 8,857 cycles

LEFT SIDE WINDOW HEAT IS SHOWING OVERHEAT. ACFT GROUNDED. CHECKED WINDOW HEAT SENSOR. FOUND OUT OF LIMITS. SWAPPED TO SPARE SENSOR IAW 30-41-760-801 WINDOW HEAT TEST OK, REF 30-41-00-710-801.

Part: COVER — DETACHED (EMERGENCY LIGHT) · airframe 29,666 hrs · 8,781 cycles

LOWER EXIT SIGN CAME OFF NEEDS TO BE REINSTALLED AT 17A. GROUNDED - YES. RESECURED LOWER EXIT SIGN COVER.

Part: TERMINAL — CORRODED (NR 2 FIRE DETECT) · airframe 29,624 hrs · 8,773 cycles

NR 2 ENGINE, RT CORE FIRE DETECTOR HARNESS AFT TERMINALS CORRODED, MW0326. ACFT GROUNDED. R & R MW 0326 HARNESS ON NR 2 ENGINE IAW AMM 26-11-02. OPS CHECK NORMAL.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 29,612 hrs · 8,770 cycles

RT PACK LIGHT CAME ON WITH RECALL. ACFT GROUNDED. RT PACK BIT FAULTED RAM ACT. RESET FAULT, PACK / ZONE TEMP CONTROLLED, RT. GROUND VERIFICATION TEST SUCCESSFUL IAW MM 21-61-00-700-806-002.

Part: PROBE — FAULTED (NR 2 ENGINE) · airframe 29,557 hrs · 8,756 cycles

WHILE ACCOMPLISHING T/C 78273000, FOUND NR 2 ENGINE ECONOMIC FAULT 73-31372 ON LEG 2 & 10. UPPER EGT SECTORS READING HIGH. ACFT GROUNDED. ACCOMPLISHED T49.5 PROBE AND EGT SYS INSPECTION IAW AMM 77-21-01-200-801-F00. FOUND RESISTANCE TO S4 PROBE MEASURING EXCESSIVE RESISTANCE. R & R S4 49.5 EGT PROBE IAW AMM 77-21-01. CLEANED EGT HARNESESS IAW AMM 77-21-00. OPS CHECKED IAW AMM 73-21-00-700-804-F00. EEC TEST PASSED. NO FAULTS INDICATED.

Part: INDICATOR — INOPERATIVE (FUEL QTY) · airframe 29,545 hrs · 8,754 cycles

QTY INDICATOR INOPERATIVE, NR 1 TANK. ACFT GROUNDED. OPS CKD FQI ON RE-FUEL ALL OPS NML 28-40-00.

Part: INDICATOR — FAILED (FUEL QTY) · airframe 29,466 hrs · 8,737 cycles

REFUELING NR 2 FUEL QUANTITY INDICATION SHOWING 8'S, AS IF IN A TEST MODE. ACFT GROUNDED. REPLACED NR 2 FUELING FUEL QUANTITY INDICATOR, OPS NORMAL, REF AMM 28-41-61-400-801.

Part: VALVE — MALFUNCTIONED (RT A/C PACK) · airframe 29,476 hrs · 8,739 cycles

AFTER ENGINE START AND MASTER CAUTION RECALL THE RIGHT PACK LIGHT ILLUMINATED. COMPLIED WITH QRH AND LIGHT RESET. ACFT GROUNDED. TEMPERATURE CONTROL VALVE HARD FAULT ON TEMP CONTROLLER NR 2. R & R NR 2 TEMPERATURE CONTROL VALVE IAW AMM 21-51-10-000-801 AND 21-51-10-400-801, OPS CHECK GOOD.

Part: HF COMM — MALFUNCTIONED (NR 1) · airframe 29,387 hrs · 8,719 cycles

HF1 SHOWS "FAIL". ACFT GROUNDED. ACCOMPLISHED FOLLOWING: CYCLED POWER AND RADIOS RECOVERED. ACCOMPLISHED "HF COMM SYS OPS TEST." AMM 23-11-00-710-801. ACFT GROUND VERIFICATION SUCCESSFUL, NO HISTORY 60 DAYS.

Part: SCUFF PLATE — GOUGED (BS 440-492) · airframe 29,303 hrs · 8,700 cycles

RAMP REPORTED A GOUGE AT FWD CARGO FLOOR. ACFT GROUNDED. REMOVED FWD CARGO SCUFF PLATES IAW AMM 53-11-02. REMOVED LOWER SILL WEB AND INSTALLED NEW WEB IAW SRM 51-10-02 PARA 9, SRM 51-40-02, AND BAC DWG 143A8330, REV A. ACCOMPLISHED PERMANENT WELD REPAIR TO SCUFF PLATE THRESHOLD PANEL IAW EA 5320-01456, REV D. INSTALLED FWD CARGO SCUFF PLATES IAW AMM 53-11-02. IN REFERENCE TO DISCREPANCY AS WRITTEN, DAMAGE LOCATION IS DESCRIBED AS SCUFF PLATE, NOT FLOOR, IAW SRM.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 29,292 hrs · 8,698 cycles

AFTER ENGINE START CHECKLIST RECALL, RT A/C PACK LIGHT ILLUMINATED & EXINGUISHED WHEN MASTER CAUTION RESET WAS PUSHED. ACFT GROUNDED. PERFORMED PACK/ZONE TEMP CONTROLLER BITE TEST IAW AMM 21-51-00. VERIFY TEST SHOWS NO FAULTS. NO HISTORY FOR PAST 90 DAYS.

Part: SATCOM — MALFUNCTIONED · airframe 29,279 hrs · 8,694 cycles

"SAT" NOT DISPLAYED ON MCDU MENU. ACFT GROUNDED. PULLED AND RESET CB IAW QRH. "SAT" REAPPEARED.

Part: INDICATOR — FAILED (FUEL QTY) · airframe 29,178 hrs · 8,666 cycles

NR 1 REFUEL GAUGE IN FUEL PANEL IS BLANK. ACFT GROUNDED. CHANGED NR 1 REFUEL IND, OPS NORMAL, REF MM 28-41-61.

Part: INDICATOR — INOPERATIVE (FUEL QTY) · airframe 29,093 hrs · 8,629 cycles

NR 1 TANK FUEL QUANTITY GAUGE ON REFUEL PANEL IS BLANK. ACFT GROUNDED. ACCOMPLISHED FQIS BITE IAW MM 28-41, TASK 801. OPS GOOD. CLEANED NR 1 TANK IND. CONNECTOR CONTACTS. NO HISTORY LAST 90 DAYS.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 29,031 hrs · 8,609 cycles

FMC DISAGREE AFTER ENGINE START. ACFT GROUNDED. RAN QRH, ISSUE RESOLVED.

Part: SATCOM — MALFUNCTIONED · airframe 28,969 hrs · 8,595 cycles

SAT PHONE ABLE TO MAKE CONNECTION OTBD AND INBD. COULD HEAR DISPATCH, BUT DISPATCH COULD NOT HEAR US. USED SATPHONE NR 2. ACFT GROUNDED. OPS CK GOOD, IAW MM 23-15-00. NO HISTORY 30 DAYS.

Part: GENERATOR — MALFUNCTIONED (APU) · airframe 28,920 hrs · 8,583 cycles

APU ELECTRICAL DEAD WITH APU RUNNING. APU GENERATOR SHOWS ZERO VOLTS. ACFT GROUNDED. RESET SYSTEM, GROUND FUNCTIONAL CHECKED GOOD IAW AMM 24-21-00-700-803, PARAGRAPH E, NO HISTORY LAST 90 DAYS.

Part: INDICATOR — INOPERATIVE (NR 1 FUEL QTY) · airframe 28,708 hrs · 8,527 cycles

NR 1 FUEL TANK QUANTITY INDICATOR IS BLANK UPSTAIRS IS OK. ACFT GROUNDED. PERFORMED FIM TASK 28-21, TASK 804. NO FAULT NOTED. OPS CHECKED NORMAL. NO HISTORY IN 30 DAYS.

Part: AUTOPILOT SYS — MALFUNCTIONED · airframe 28,629 hrs · 8,510 cycles

AUTOPILOT NR 2 WOULD NOT ENGAGE AFTER ABANDONING APPROACH DUE TO ACFT ON RUNWAY-IT WAS WORKING FINE UNTIL CIRCLING BACK FOR NEXT APPROACH. ACFT GROUNDED. FFR LOGGED A/P DISC SW INV & MAIN ELECTRICAL TRIM. COULD NOT DUPLICATE MALFUNCTION. BITE GROUP NR 20 NORMAL. LAND VERIFY NORMAL IAW BITE GROUP NR 49. HOUSINGS RTS NORMAL REF SMM 34-36-00. LWMP STATUS REMAINS "AUTOLAND & HOUSINGS" QUALIFIED. SCREW REFLECTS SAME.

Part: SENSOR — FAILED (L2 WINDOW) · airframe 28,624 hrs · 8,509 cycles

L2 WINDOW OVERHEAT LIGHT ILLUMINATED. ACFT GROUNDED. ACCOMP FIM TASK 30-40, NR 801. SHOWS LT SIDE WINDOW FAULT ACCOMPLISH TASK 30-41, NR 811 SWAPPED TO SPARE SENSOR WINDOW. HEAT OPS CK OK, REF AMM 30-41-00-710-801, GROUND VERIFIED CK OK.

Part: WARNING LIGHT — INOPERATIVE (RAM AIR) · airframe 28,558 hrs · 8,495 cycles

ON FINAL WITH FLAPS EXTENDED LT RAM AIR FULL OPEN LIGHT DID NOT ILLUMINATED THROUGHOUT APPROACH. BULB, AND CIRCUIT BREAKERS CHECKED. ACFT GROUNDED.

Part: CONTROL VALVE — FAILED (A/C PACK) · airframe 28,398 hrs · 8,452 cycles

AFTER ENGINE START ON RECALL, "MASTER CAUTION" ILLUMINATED AND "ZONE TEMP" ILLUMINATED ON CABIN CONTROL "CONT CAB". FOLLOWED QRH. MASTER CAUTION RESETS BUT TRIP RESET DOES NOT RESET. ACFT GROUNDED. VERIFIED NR 2 CONTROLLER SHOWS FLT DECK TRIM VALVE FAULT ON BIT/PREV. FLT TEST. REPLACED ZONE TRIM AIR MODULATING VALVE CONTROL CABIN IAW MM 21-61-21-000-801 AND 21-61-21-400-801. OPS CHECK GOOD.

Part: CONTROL VALVE — MALFUNCTIONED (LT A/C PACK) · airframe 28,358 hrs · 8,442 cycles

PRIOR TO DEPARTURE LT PACK ILLUMINATED ON RECALL EXTINGUISHED WITH M/C RESET. ACFT GROUNDED. CONFIRMED FAULT, LT PACK ZONE TEMP CONTROLLER BITE FAILS TCV 1 (V139), FOUND TCV 1 OVERHEATED AND LEAKING FLUID. R & R TCV 1 (V139) REF AMM 21-51-10, GROUND FUNCTIONAL CKS/ BITE NORMAL REF AMM 21-61-00-700-806-002.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 28,293 hrs · 8,419 cycles

RIGHT FMC DISAGREE. ACFT GROUNDED. UNABLE TO DUPLICATE DEFECT. NO IN-FLIGHT FAULTS LOGGED FOR FMC. NO FLAG WHEN FMC SELECT SWITCH PLACED ON BOTH. GROUND VERIFICATION TEST PASSED, REF MM 34-61-00.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 27,918 hrs · 8,309 cycles

FMC DATALINK FULL. ACFT GROUNDED. FOLLOWED CHECKLIST. ANOMALY CLEARED.

Part: WARNING MESSAGE — ILLUMINATED (NR 2 ENGINE) · airframe 27,719 hrs · 8,256 cycles

FOUND NR 2 ENG FAULT MSG 77-20862 BOTTOM LT EGT SIGNAL OUT OF RANGE, LONG TIME FAULT. FOUND NR 2 ENG FAULT MSG 77-20872, TOP LT EGT SIGNAL IS OUT OF RANGE, LONG TIME FAULT. ACFT GROUNDED. CONFIRMED FAULT, NR 2 ENGINE BOTTOM LEFT EGT (T495 S3) AND TOP LT EGT, T495 S4, SHOW NO READING, DASHES, ON CDU PAGE. EEC BITE SHOWS MSG 77-20862 BOTTOM LT EGT SIGNAL OUT OF RANGE AND MSG NR 77-20872, TOP LT EGT SIGNAL OUT OF RANGE. FLIGHT FAULT REVIEW SHOWS FAULTS AT ALL 10 LEGS. FOUND DP1001 LOOSE, CLEANED DP1001 & SECURED CONNECTOR. ALSO, CLEANED BOTTOM LT AND TOP LT EGT PROBES REF AMM TASK 77-21-00-140-801 & SECURED TOP AND BOTTOM LT EGT PROBE CONNECTORS. ACCOMPLISHED FIM 77-21 TASK 803, CDU PAGE NOW SHOWS S2 AT 26.50 & S3 AT 26.80. ACCOMPLISHED FIM 77-21, TASK 804, CDU PAGE SHOWS S1 51.62 & S4 52.12. REACCOMPLISHED TC 78273000 AND GROUND FUNCTIONAL CHECKED NORMAL.

Part: PROBE — MALFUNCTIONED (NR 2 ENGINE) · airframe 27,530 hrs · 8,196 cycles

DIAGNOSTIC REPORTS NR 2 ENGINE CONTINUES TO SHOW GREATER THAN EXPECTED DATA SCATTER AND MARGIN LOSS. INDICATION ERRORS STILL SUSPECT. ACFT GROUNDED. ACCOMPLISHED T49.5 PROBE AND EGT SYSTEM INSPECTION, REF TASK 77-21-01-200-801-F00. FOUND RESISTANCE FOR T49-5 S2 PROBE HIGH. R & R S2 T49-5 PROBE IAW AMM TASK 77-21-01-000-801-F00 AND 77-21-01-400-801-F00. FOR ENG NR 2. PERFORMED NR 2 EEC TEST REF AMM TASK 73-21-00-70-804-F00. TEST PASSED. NO FAULTS LOGGED.

Part: SHAFT — SHEARED (STARTER) · airframe 27,396 hrs · 8,146 cycles

UNABLE TO START NR 1 ENGINE NR 1 START VALVE OPEN LIGHT CAME ON, NO ENGINE ROTATION. ACFT GROUNDED. UPON FURTHER INVESTIGATION FOUND LT STARTER SHAFT SHEARED. REPLACED DEFECTIVE STARTER, REF AMM 80-11-01. SERVICE STARTER OIL FULL. ACFT GROUND VERIFICATION CHECK SUCCESSFUL.

Part: PUMP — LEAKING (NR 2 ENGINE) · airframe 27,315 hrs · 8,127 cycles

DURING IDLE LEAK CHECK FOUND FUEL LEAKING FROM FUEL PUMP DRAIN PAD, 32 DROPS IAW MINUTE, ON NR 2 ENGINE. ACFT GROUNDED. REPLACED FUEL PUMP PACKAGE. INSTALLATION, LEAKAGE AND OP'S CHECK GOOD, REF 73-11-01, T/C N8473000 & N8473001.

Part: SPACER — MISSING (FAN DUCT) · airframe 27,181 hrs · 8,073 cycles

FOUND UPPER AFT INSERT MISSING ON 10 O'CLOCK FAN DUCT PANEL, NR 2 ENGINE. ACFT GROUNDED. REMOVED INSERT SHELL AND INSTALLED NEW INSERT IAW SPM 70-42-13, TASK 70-42-13-350-014. REINSTALLED 10 O`CLOCK FAN DUCT PANEL IAW AMM 72-23-07-400-801-F00.

Part: ACTUATOR — LEAKING (NR 2 VSV) · airframe 27,165 hrs · 8,066 cycles

AFTER ENGINE START, NR 2 ENGINE OBSERVED WITH FUEL LEAK. ACFT GROUNDED. R & R NR 2 ENG INBD VBV ACTUATOR, IAW AMM 75-32-02-400 UP TO STEP 3-H-4.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 26,681 hrs · 7,924 cycles

"FMC DISAGREE" ON THE GROUND. ACFT GROUNDED. CHECKLIST RUN AND DISAGREE CLEARED.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 26,603 hrs · 7,894 cycles

FMC DISAGREE ILLUMINATED AFTER PUSH BACK/ ENGINE START. ACFT GROUNDED. COMPLETED QRH, NORMAL OPS RESTORED.

Part: FIRE WARNING — MALFUNCTIONED (CARGO BAY) · airframe 26,435 hrs · 7,842 cycles

CARGO FIRE AFT ARM LIGHT NOT ARMING ON TEST. ACFT GROUNDED. PERFORMED SQUIB TEST LIGHT IAW FIM 26-23, TASK 812. PASSED, NO DEFECT NOTED. NO HISTORY 30 DAYS.

Part: PROBE — OUT OF LIMITS (NR 2 ENGINE) · airframe 26,222 hrs · 7,776 cycles

DIAGNOSTICS REPORTS NR 2 ENGINE TREND DATA SHOWS A SHIFT IN DELTA CRUISE AND TAKEOFF MARGIN INDICATIVE OF EGT INDICATION ERRORS. ACFT GROUNDED. ACCOMPLISHED TSR, FOUND S2 PROBE OUT OF LIMITS, R & R RE FMM 77-21-01.

Part: ANTI-ICE VALVE — MALFUNCTIONED (NR 1 ENGINE) · airframe 26,139 hrs · 7,743 cycles

NR 1 ENGINE ANTI-ICE COWL LIGHT AT FIRST INTERMITTENT THEN STEADY, BRIGHT BLUE WHEN ANTI-ICE SWITCH SELECTED ON. ACFT GROUNDED. PERFORMED 30-21, TASK 805. OPS CHECKED NR 1 ENGINE ANTI-ICE VALVE. OPEN, CLOSED, BRIGHT ANN LIGHT NUMEROUS TIMES, OPS NORMAL IAW FIM INTERMITTENT FAULT. CONSULTED SEAM C NR 1 ENGINE COWL TAI VALVE IS TO BE REPLACED. REPLACED ENGINE COWL ANTI ICE VALVE IAW AMM 30-21-11 IAW STEP, F, 1. PROVIDED SECONDARY TORQUE CHECK. VALVE REPLACED AS PRECAUTIONARY. VERIFICATION FLIGHT SATISFACTORY.

Part: WARNING LIGHT — FALSE ACTIVATION (ANTI ICE SYS) · airframe 25,973 hrs · 7,688 cycles

LEFT COWL ANTI-ICE POSITION LIGHT INOPERATIVE. ACFT GROUNDED. PERFORMED NR 1 ENGINE COWL ANTI-ICE OPS TEST IAW AMM 30-21-00-710-801. OPS CHECK NORMAL.

Part: FMC — MALFUNCTIONED · airframe 25,748 hrs · 7,618 cycles

NO L NAV DATA IN FMC. ACFT GROUNDED. CYCLED ACFT POWER AND AOC CMU CIRCUIT BREAKER, NORMAL DATA RESTORED.

Part: IGNITER — FAILED (NR 1 ENGINE) · airframe 25,661 hrs · 7,595 cycles

NO LIGHT OFF AFTER NR 1 START LEVER RAISED TO IDLE. IGNITION SWITCH ON RT POSITION. ACFT GROUNDED. REPLACED LT AND RT MAIN IGNITER PLUGS ON ENGINE NR 1 IN REF TO AMM 74-21-02. PERFORMED IGNITION SYS AUDIBLE TEST IN REF TO AMM 74-00-00. OPS CHECKS NORMAL, NO FAULTS FOUND, NO DEFECTS NOTED.

Part: UNKNOWN — UNKNOWN (ENGINE) · airframe 25,656 hrs · 7,594 cycles

DURING ENGINE START, RAISED START LEVER TO IDLE FUEL FLOW NO LIGHT OFF ON NR 1 ENGINE, IGNITION SWITCH IN RT POSITION. ACFT GROUNDED. AFTER RETURNING TO GATE ACCOMPLISHED ENGINE IGNITION TEST IAW AMM 74-00-00-750-801-FQQ, NO FAULTS FOUND. STARTED NR 1 ENGINE WITH LT AND RT IGNITION SYS, STARTS WERE NORMAL. NO HISTORY 30 DAYS. GROUND FUNCTIONAL TEST NORMAL.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 25,628 hrs · 7,583 cycles

RIGHT PACK LIGHT ILLUMINATED DURING MASTER RECALL. EXTINGUISHES ON RESET. ACFT GROUNDED. ACCOMPLISHED FIM 21-53 TASK 804. OPERATED RT AIR CONDITIONING PACK REF AMM 21-00-00-800-803. PACK LIGHT REMAINS OFF. PERFORMED PACK / ZONE TEMP CONTROLLER BITE REF FIM 21-62 TASK 801. NO FAULTS LOGGED. NO HISTORY 30 DAYS.

Part: RIVET — MISSING (OIL COOLER) · airframe 25,509 hrs · 7,550 cycles

WHILE ACCOMPLISHING NR 1 INLET INSPECTION T/C 78472000, FOUND CSD OIL COOLER WITH FWD OTBD FASTENER MISSING. ACFT GROUNDED. INSTALLED FASTENER-FWD OTBD-CSD OIL COOLER REF AMM 73-11-06.

Part: WARNING LIGHT — MALFUNCTIONED (A/C PACK) · airframe 25,291 hrs · 7,483 cycles

FAILED OPS TEST, A/C PACK LIGHT STAYED ILLUMINATED. ACFT GROUNDED. PERFORMED TROUBLESHOOTING IAW FIM TASK 21-62, TASK 801, LT PACK CONTROL SHOWED NO FAULTS AND GREEN GO LIGHT AFTER ACCOMPLISHING FIM. RT LIGHT EXTINGUISHES, A/C PACK OPS PROCEDURES PASSED SUCCESSFUL, GROUND VERIFICATION PASSED. ACFT OK FOR SERVICE.

Part: CONTROL VALVE — MALFUNCTIONED (RT A/C PACK) · airframe 25,286 hrs · 7,482 cycles

DURING LANDING CHECKLIST, PUSHED RECALL RT PACK LIGHT ON. ACFT GROUNDED. REPLACED AND TESTED RT PACK TEMPERATURE CONTROL VALVE IAW MM 21-51-10-000-801, MM 21-51-10-400-801. OPS NORMAL, NO LEAKS NOTED. PERFORMED NR 2 PACK/ZONE TEMPERATURE CONTROLLER BITE TEST IAW MM 21-61-00-700-806-002. ALL TESTS PASS.

Part: CONTROL VALVE — FAULTED (A/C BAY) · airframe 25,172 hrs · 7,451 cycles

RT PACK LIGHT ILLUMINATES ON MC RECALL, GOES OUT ON MC RESET. ACFT GROUNDED. ACCOMPLISHED FIM 21-62, TASK 801 R/T PACK-ZONE TEMP CONTROLLER BITE. FURTHER TROUBLESHOOTING FOUND NUMEROUS "ZONE TRIM VALVE" FAULTS & FAILS. ACCOMPLISHED FIM 21-62, TASK 834 FORWARD CABIN TRIM AIR VALVE FAULT ISOLATION, PATCHED IN ANOTHER KNOWN GOOD NR 2 CABIN TEMP CONTROLLER, M1443, NO HELP. REINSTALLED ORIGINAL NR 2 CABIN TEMP CONTROLLER (M1443) IAW AMM 21-61-20. SUSPECT INTERMITTENT "FORWARD CABIN TRIM AIR VALVE" FAULT V144. REPLACED ZONE TRIM AIR VALVE, V144, FWD CABIN AS REQUIRED. PRESSURE CHECKED WITH NO LEAKS NOTED. PERFORMED BITE TEST ON PACK/ZONE TEMP CONTROLLER NO FAULTS FOUND.

Part: RADAR — MALFUNCTIONED (WX SYS) · airframe 25,056 hrs · 7,422 cycles

THE MULTI-SCAN RADAR UNIT IN THE AUTO MODE IS NOT SHOWING ANY RETURNS OVER AN AREA OF OBVIOUS CONGESTIVE ACTIVITY INCLUDING LIGHTNING AND OTHER PILOT REPORTS. GC MODE WHEN ACTIVATED SHOWS NORMAL TEST RESULT. IN THE MANUAL MODE ABLE TO IDENTIFY CELLS. GAIN MODE SET AT 12 O'CLOCK POSITION WHICH IS NORMAL. ACFT GROUNDED. PERFORMED WEATHER RADAR TEST IAW AMM 34-43-00, OPS CHECKED NORMAL. AUTO MODE OPS NORMAL. NO HISTORY 30 DAYS. ALL GROUND FUNCTIONAL TESTS PASS.

Part: WARNING LIGHT — FALSE ACTIVATION (WINDOW HEAT) · airframe 24,844 hrs · 7,365 cycles

LEFT SIDE, FWD WINDOW, OVERHEAT LIGHT ILLUMINATED. ACFT GROUNDED. FOUND LT FWD WINDOW HEAT CIRCUIT BREAKER TRIPPED. INSPECTED CIRCUIT BREAKER & ASSOCIATED WIRING. FOUND NO DEFECTS. RESET CIRCUIT BREAKER. ACCOMPLISHED OPS CHECK OF WINDOW HEAT. OPS CHECKED GOOD WITH NO OVERHEAT LIGHT IAW AMM 20-60-01 & 30-41-00. NO HISTORY.

Part: CONTROLLER — LOOSE (CABIN PRESSURE) · airframe 24,820 hrs · 7,359 cycles

SEVERAL INTERMITTENT PRESSURE CONTROLLER AUTO FAIL/ALTN LIGHTS COME ON. TWO SECONDS THEN WENT OUT. ACFT GROUNDED. PERFORMED FIM 21-31, TASK 827. BITE CHECK PRESSURE CONTROLLER NR 1 & NR 2 IAW FIM 21-31, TASK 801. NO CURRENT FAULTS AND NO FAULT HISTORY FOR FLT LEG 01. ALSO PERFORMED ADIRU NR 1 & NR 2 BITE CHECK IAW FIM 21-31 TASK 806. NO CURRENT FAULTS AND NO FAULT HISTORY. PRESSURIZATION SYSTEM GROUND TEST REF AMM TASK 21-31-00-700-802. DURING TEST CONTROLLER NR 1 FAULTED. TIGHTENED CONTROLLER NR 1 IN RACK AND PERFORMED OPS CHECK WAS GOOD. NO FAULTS FOR CONTROLLER NR 1 OR NR 2.

Part: CONTROL PANEL — MALFUNCTIONED (WX RADAR SYS) · airframe 24,780 hrs · 7,349 cycles

WEATHER RADAR CONTROL PANEL TEST BUTTON STICKS IN THE ON POSITION. ACFT GROUNDED. REPLACED WEATHER RADAR CONTROL PANEL IAW AMM 34-43-91-000-801 AND 34-43-91-400-801. SYSTEM OPS CHECKED GOOD IAW AMM 34-43-91-400-801.

Part: CONTROLLER — FAILED (CABIN PRESSURE) · airframe 24,782 hrs · 7,350 cycles

WITH PRESSURIZATION MODE CONTROLLER IN AUTO, AUTO FAIL AND ALT ANNUNCIATORS ILLUMINATED. ACFT GROUNDED. FOUND NR 2 CPC WILL NOT TEST OR DISPLAY. REPLACED NR 2 IAW AMM 21-31-01. NR 2 CPC TESTED GOOD IAW AMM 21-31-700-802. TROUBLESHOOTING ACCOMPLISHED IAW FIM 21-31, TASK 827.

Part: FLOOR SUPPORT — CRACKED (BS 312-328) · airframe 24,780 hrs · 7,349 cycles

MAIN CABIN FLOOR SUPPORT CRACKED BS 312 - 328, RBL 31.6. R & R FLOOR SUPPORT IAW SRM 51-40-02.

Part: FLOOR SUPPORT — CRACKED (BS 277-294.5) · airframe 24,780 hrs · 7,349 cycles

MAIN CABIN FLOOR SUPPORT CRACKED BS 277-294.5, BL 0. ACFT GROUNDED. R & R FLOOR SUPPORT IAW SRM 51-40-02.

Part: INTERCOSTAL — CRACKED (BS 328-344) · airframe 24,780 hrs · 7,349 cycles

E & E COMPARTMENT INTERCOSTAL CRACKED BS 328-344, LBL 48. R & R INTERCOSTAL IAW SRM 51-40-02.

Part: TRANSITION PANEL — CORRODED (CARGO BAY) · corrosion level 2 · airframe 24,780 hrs · 7,349 cycles

AFT CARGO BAY, RT TRANSITION PANEL HAS CORROSION FROM BS 780-BS 800, RBL 19-RBL 22, STR 25R-STR 26R. REMOVED CORROSION FROM AFT CARGO BAY RT TRANSITION PANEL. FOUND TO BE OUT OF LIMITS IAW SRM 53-00-53-1A-2, DETAIL 2F. R & R WITH NEW PANEL SHIELD 146A81271112 IAW SRM 51-40-02.

Part: SEAT TRACK — GOUGED (BS 520) · airframe 30,724 hrs · 9,631 cycles

SEAT TRACKS IN THE MAIN CABIN AT BS 520, LBL-24.75 GOUGED. ACFT GROUNDED. REPAIRED SEAT TRACK AT BS 520, LBL 24.75 IAW SRM 53-00-52, REPAIR 4.

Part: SEAT TRACK — GOUGED (BS 520) · airframe 24,780 hrs · 7,349 cycles

SEAT TRACKS IN THE MAIN CABIN AT BS-520, RBL-24.75 GOUGED. ACFT GROUNDED. REPAIRED SEAT TRACK AT BS 520, RBL 24.75 IAW SRM 53-00-52, REPAIR 4.

Part: VALVE — MALFUNCTIONED (NR 2 CONTROLLER) · airframe 24,414 hrs · 7,242 cycles

ZONE TEMP AMBER LIGHT FOR CONTROL CAB ILLUMINATES ON RECALL. EXTINGUISHES ON RESET. ACFT GROUNDED. NR 2 TEMP CONTROLLER LOGGED FLT DECK TRIM AIR VALVE. SYS TESTS GOOD, FAULT RESET.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 24,344 hrs · 7,220 cycles

DURING MASTER CAUTION RECALL, RT PACK LIGHT CAME ON. ACFT GROUNDED. GROUND TEST PASSED WITH NO FAULTS NOTED IAW AMM 21-51-00-700-803 AND NO MAINTENANCE HISTORY FOUND WITHIN THE PAST 30 DAYS.

Part: KEYBOARD — FAILED (DISPLAY UNIT) · airframe 24,335 hrs · 7,217 cycles

LSK 1 AND 2 ON CAPT MCDU INOPERATIVE. ACFT GROUNDED. REPLACED MCDU KEYPAD. SYS TESTS GOOD, REF TASK 34-61-01-400-801.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 24,335 hrs · 7,217 cycles

FMC DISAGREE ALERT MESSAGE, DISPLAYED ON THE GROUND. ACFT GROUNDED. PERFORMED QRH PROCEDURE AND FMC DISAGREE MESSAGE CLEARED.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 24,172 hrs · 7,171 cycles

ON PUSHBACK FROM ANC C1. FMC DISAGREE MESSAGE DISPLAYED. ACFT GROUNDED. QRH 11.2 ACCOMPLISHED. NORMAL FMC OPS RESTORED.

Part: CHARGER — FAULTED (MASTER) · airframe 23,990 hrs · 7,120 cycles

BATTERY DISHCHARGE LIGHT ILLUMINATED ON PUSHBACK. ACFT GROUNDED. PERFORMED BATTERY DISCHARGE FIM 24-31, TASK 833. FAULT WILL NOT RESET. REF FAULT ISOLATION PROCEDURE, R & R BATTERY CHARGER M5, REF MM 24-31-21. GROUND VERIFICATION CHECKS NORMAL.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 23,903 hrs · 7,096 cycles

FMC LIGHT ILLUMINATED ON THE GROUND. ACFT GROUNDED. DISAGREE CHECK LIST PERFORMED, OPS NORMAL.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 23,852 hrs · 7,080 cycles

RIGHT PACK LIGHT ILLUMINATED DURING TAXI OUT, RESET WITH MASTER CAUTION RESET. ACFT GROUNDED. ACCOMPLISHED BITE TESTS ON BOTH CONTROLLERS IAW TASK 21-61-20-860-005. NO FAULTS FOUND ON PREVIOUS FLIGHTS. BOTH CONTROLLERS PASSED. RAN PACKS FOR 10 MIN. NO FAULTS.

Part: WARNING MESSAGE — FALSE ACTIVATION (FMC) · airframe 23,542 hrs · 7,000 cycles

FMC DISAGREE ILLUMINATED, ACFT GROUNDED. QRH PROCEDURE PERFORMED. OPS NORMAL.

Part: CIRCUIT BREAKER — TRIPPED (WINDOW HEAT) · airframe 23,458 hrs · 6,975 cycles

NR 3 WINDOW HEAT CIRCUIT BREAKER OPEN. ACFT GROUNDED. FOUND RT FORWARD WINDOW HEAT CIRCUIT BREAKER ON P6-12 OUT. RESET IAW AMM 20-60-01. OPS CHECKED NORMAL IAW AMM 30-40-01.

Part: INDICATOR — TRIPPED (APU OIL FILTER) · airframe 23,232 hrs · 6,912 cycles

DURING ETOPS PDC CHECK, FOUND OIL FILTER APU DPI POPPED. ACFT GROUNDED. PERFORMED OIL FILTER INDICATOR INSPECTION IAW MM 49-91-13, R & R FILTER IAW 49-91-12, NO DEBRIS FOUND IN FILTER. OIL FILTER INDICATOR RESET. APU STARTED, OPS CHECKED GOOD.

Part: FMC — FAILED (EE BAY) · airframe 22,883 hrs · 6,805 cycles

SCRATCH PAD NOTIFICATION OF SINGLE FMC INOPERATIVE, FOLLOWED BY F/O LT DU DISPLAYING YELLOW MAP BOX AND YELLOW VTK. ACFT GROUNDED. REPLACED RT FLIGHT MANAGEMENT COMPUTER IAW MM 34-61-02-000-801/ MM 34-61-02-400-801. MM 34-61-00-470-805 LOADED FOLLOWING FMC SOFTWARE USING MEDIA TYPE 1- OPS 549849-018; OPC BCG-01J-H5; LDDB 557362-P; ADDB ASA1005A; MEDB BCG-014-V9; NAV DATA ASA1130701. PERFORMED FMCS OPERATIONAL TEST IAW MM 34-61-00-710-801 - ALL TESTS PASS.

Part: CONTROL PANEL — INOPERATIVE (AUTO PILOT) · airframe 22,683 hrs · 6,745 cycles

AUTOPILOT COMMAND B BUTTON WILL NOT ILLUMINATE AUTOPILOT FUNCTIONS NORMALLY. ACFT GROUNDED. REPLACED MASTER CONTROL PANEL IAW AMM TASK 22-11-34-400-801/22-11-34-000-801. PERFORMED MASTER CONTROL PANEL INSTALLATION TEST IAW AMM TASK 22-11-34-74-801.

Part: UNKNOWN — UNKNOWN (AUTOPILOT B) · airframe 22,649 hrs · 6,728 cycles

AUTOPILOT B, INOPERATIVE. ACFT GROUNDED. PERFORMED DFCS BITE IAW FIM 22-11, TASK 801, CURRENT STATUS TEST PASSED, NO FAULTS NOTED. PERFORMED DFCS LAND VERIFY TEST IAW MM 22-11-00-700-801, GROUP 49.00 LAND VERIFY TEST PASSED. COULD NOT DUPLICATE MALFUNCTION.

Part: PROBE — OUT OF LIMITS (NR 1 ENGINE) · airframe 22,518 hrs · 6,691 cycles

DIAGNOSTICS REPORTS NR 1 ENGINE TREND DATA SHOWS A SHIFT IN DELTA CRUISE AND TAKEOFF MARGIN INDICATIVE OF EGT INDICATION ERRORS. ACFT GROUNDED. ACCOMPLISHED TSR, REF MM 77-21-01 FOUND THE T49.5 S4 EGT PROBE OUT OF LIMITS, REPLACED S4 PROBE REF MM 77-21-01, OPS CK GOOD REF MM 73-21-00-700-804-F00.

Part: LIGHT — INOPERATIVE (A/P BUTTON) · airframe 22,493 hrs · 6,684 cycles

A/P ENGAGE LIGHT IN CMD B-BUTTON INOPERATIVE. ACFT GROUNDED. REVIEW DFCS FFR, NO RELATED FAULTS NOTED. PERFORMED MCP INTERFACE TEST NR 32, REF MM 22-00-01-730-801, TEST PASSED.

Part: HOUSING — GOUGED (CARGO DOOR) · airframe 222,219 hrs · 6,598 cycles

FOUND AFT CARGO DOOR HANDLE HOUSING GOUGED AND PREVIOUSLY BLENDED ON. ACFT GROUNDED. AFTER BLENDING EXISTING GOUGES, HOUSING IS BEYOND LIMITS OF .060 MAX REF AMM 52-31-15-801. REQUIRES REPLACEMENT. REMOVED AFT CARGO DOOR HANDLE MECHANISM IAW MM 52-31-14-000-801. REMOVED RIVETS FROM HOUSING REF SRM 51-40-02. REMOVED HOUSING FROM ACFT PICKED UP HOLES IN NEW HOUSING REF SRM 51-40-02, ALODINED AND PRIMED NEW HSG REF SRM 51-20-01, INSTALLED SPRING HINGE DOOR ON NEW HSG REF SRM 51-40-02. COMPLETED INSTALLATION OF DOOR HANDLE HOUSING REF SRM 51-40-02.

Part: GENERATOR — MALFUNCTIONED · airframe 22,097 hrs · 6,568 cycles

APU GENERATOR HAS NO VOLTS OR FREQS. ACFT GROUNDED. GROUND POWER WAS PULLED DURING START SEQUENCE, FULL POWERED DOWN ACFT & RESTARTED APU. VOLTS & FREQS GOOD AND HOLD LOAD. SYS CKS NORMAL REF 24-21-00, GROUND VERIFICATION SUCCESSFUL.

Part: FMC — MALFUNCTIONED · airframe 21,996 hrs · 6,538 cycles

FMC DISAGREE ON GROUND. QRH PERFORMED, OPS NORMAL.

Part: TRANSCEIVER — FAILED (NR 1 HF SYSTEM) · airframe 21,954 hrs · 6,523 cycles

HF 1 WILL NOT TRANSMIT ON 5547, NOR 6673. ACFT GROUNDED. REPLACED NR 1 HF TRANSCEIVER. OPS CK GOOD. REF AMM 23-11-21/401 & 23-11-00-730-801.

Part: WARNING LIGHT — FALSE ACTIVATION (FCC) · airframe 21,918 hrs · 6,514 cycles

WHILE ACCOMPLISHING LAND VERIFY TEST FCC B FAILED SPEED/ STAB TEST, MSG 22-00026 S154 ELV POS TRIED TEST SEVERAL TIMES. COULD NOT DUPLICATE. PERFORMED FIM22-12/812, FOUND FAULT NOT ACTIVE. ACCOMPLISHED DFCS FLT FAULT REVIEW, CURRENT STATUS NR 10 CK, EXTENDED MAINT TEST NR 60.30, 32, & 35 SEVERAL TIMES, AND LAND VERIFY NR 49 TEST TWICE. ALL TEST NORMAL, & NO FAULT LOGGED, REF MM22-11-00. NO HISTORY 30 DAYS.

Part: FUEL CELL — CONTAMINATED (CENTER CELL) · airframe 21,314 hrs · 6,356 cycles

WHILE BURNING CENTER TANK FUEL, THE LT FUEL QUANTITY DROPPED TO 8.6K FOR APPROX 20 MINUTES AT CRUISE, THEN RETURNED TO 8.94K. THE RT FUEL QUANTITY REMAIN AT 8.94 DURING THIS TIME. REMOVED ICE AND RESIDUAL WATER FROM LT FUEL TANK. NR 1 FUEL QTY OPS NORMAL REF AMM 28-41-00. FQIS SHOWS NR 2 TANK DEGRADED ACC ATA 28-41208. REMOVED ICE AND RESIDUAL WATER FROM RT FUEL TANK. NR 2 FUEL QTY OPS NORMAL REF AMM 28-41-00.

Part: INDICATOR — MALFUNCTIONED (FUEL QTY) · airframe 21,284 hrs · 6,349 cycles

LT FUEL TANK DIGITAL QUANTITY INDICATOR WENT BLANK FOR 10 SECONDS, THEN CAME BACK ON. TOTALIZER SHOWED CORRECT AMOUNT OF FUEL. STABLE CRUISE AT FL 380. FUEL QUANTITY INDICATION SYS PASSED GROUND TEST REF MM 28-41-00-710-801. NO HISTORY PAST 30 DAYS.

Part: BUSS — MALFUNCTIONED (APU) · airframe 20,975 hrs · 6,265 cycles

STARTED APU ON LANDING ATTEMPTED TO BRING APU ELECTRICAL POWER ON BUSSES AND WOULD NOT HOLD AFTER 2ND BUSS ATTEMPTED ON TWO ATTEMPTS, ATTEMPTED TO PROVIDE APU BLEED AIR AT GATE ALSO AND THERE WAS ZERO APU BLEED DUCT PRESSURE. APU BITE PROCEDURE AMM TASK 49-60-801, FAULT 49-31171 INDICATED, PAGE 6 OF 16 49-60, TASK 801 LED TO TASK 49-31, TASK 808 PERFORMED FIM TASK 49-31-808A. -F 910 10 APU OPS NORMAL - ACCEPTS ALL BLEED AIR LOADS AND ELECTRICAL LOADS, INSPECTION OF TAIL PIPE PERFORMED.

Part: WARNING LIGHT — FALSE ACTIVATION (RT A/C PACK) · airframe 20,870 hrs · 6,230 cycles

RT PACK LIGHT ILLUMINATES ON RECALL. ACCOMPLISHED CABIN TEMP CONTROLLER BITE IAW AMM REF 21-61-00, OPS CHECKED NORMAL. GROUND VERIFICATION SUCCESSFUL.

Part: WARNING LIGHT — FALSE ACTIVATION (GENERATOR) · airframe 20,759 hrs · 6,202 cycles

AFTER LANDING, STARTED APU WHICH STARTED NORMALLY AND THE BLUE APU GENERATOR BUSS LIGHT ILLUMINATED BUT THE APU WOULD NOT TAKE AN ELECTRICAL LOAD. VOLTS AND FREQUECY BOTH SHOW ZERO (BLANK). PERFORMED OPS TEST FOR THE APU AC GENERATION AND CONTROL IAW AMM TASK 24-21-00-700-803. OPS CHECKED GOOD, UNABLE TO DUPLICATE, NO HISTORY IN THE PAST 30 DAYS.

Part: CONTROL PANEL — INOPERATIVE (WX RADAR SYS) · airframe 20,028 hrs · 6,029 cycles

ROTARY KNOB BACKGROUND LIGHTING INOPERATIVE ON RADAR CONTROL PANEL. PANEL WILL ILLUMINATE TEMPORARILY AFTER PANEL IS TAPPED. ACFT GROUNDED. REPLACED WEATHER RADAR CONTROL PANEL. OPS CHECKED GOOD. REF AMM 34-43-91.

Part: BOLT — LOOSE (NR 1 ENGINE) · airframe 19,673 hrs · 5,933 cycles

NR 1 ENGINE FAN DUCT PANEL AT 500 POS, LPT COOLING INTAKE SCOOP LOC, HAS TWO BOLTS LOOSE ON LOWER MIDDLE LOWER FWD LOCATION. R & R TWO BOLTS ON LOWER MIDDLE NR 1 ENGINE FAN DUCT PANEL AT 500 72-23-07-400-801.

Part: APU — MALFUNCTIONED · airframe 19,566 hrs · 5,904 cycles

APU WOULD NOT ACCEPT AIR OR ELECTRIC LOADS. PERFORMED STEPS 1-4 ON T101. NO REACURRING FAULTS NO CURRENTS FAULTS. DATA PARAMATERS ARE ALL 0. PERFORMED OPS CHECK IAW AMM 49-11-00-710-801. OPS CHECKED NORMAL ON ALL TESTS.

Part: CIRCUIT BREAKER — MALFUNCTIONED (WX RADAR SYS) · airframe 19,134 hrs · 5,779 cycles

WEATHER RADAR FAIL FLAG ANNUNCIATED. ACFT GROUNDED. CYCLED WEATHER RADAR RT CIRCUIT BREAKER. PERFORMED WEATHER RADAR SYS OPS TEST, NO DEFECTS NOTED REF MM 34-43-00-710-802-001.

Part: PROBE — FAILED (NR 1 ENGINE) · airframe 19,163 hrs · 5,786 cycles

DIAGNOSTICS REPORTS NR 1 ENGINE TREND DATA SHOWS A SUDDEN SHIFT IN EGT HOT DAY MARGIN. ACFT GROUNDED. PERFORMED FIM TASK 77-05-00-810-801-F00, STEP E (8) (B). RESULTS ARE S-1 83.56, S-2 63.34, S-3 62.51, S-4 109.20. TASK PERFORMED ON 3 HRS AFTER ENG NR 1 SHUTDOWN. FOUND S-4 READING FLICKERING, HIGHER AND OUT OF LIMITS. REPLACED S-4 PROBE REF MM 77-21-01. READING AFTER REPLACEMENT S-1 51.89, S-2 30.88, S-2 32.38, S-4 57.68. S-4. READING STEADY AND WITHIN LIMITS.

Part: SEAL — TORN (ENGINE FAN) · airframe 19,339 hrs · 5,838 cycles

DIAGNOSTICS REPORTS, NR 2 ENGINE TREND DATA SHOWS A SUDDEN INCREASE IN LOW PRESSURE ROTOR VIBRATION LEVELS. DATA INDICATES HARDWARE INSPECTION AND FAN RELUBE REQUIRED. ACFT GROUNDED. FOUND EXCESSIVE LUBE ON FAN BLADE. FOUND ALL PLATFORMS HAD TORN SEALS. R & R ALL PLATFORMS. FOUND ALL SHIMS TO HAVE COATING LOSS/WORN. NEW SHIMS INSTALLED. PERFORMED VIBE SURVEY IAW TEST 7. MM TASK NR 71-00-00-700-814-F00. FAN BLADE LUBE T/C 78472002 COMPLETE. VIBES WERE LESS THAN 1.0 UNITS AT ALL POWER SETTINGS. GROUND VERIFICATION OF SIG, SYS VERIFIED.

Part: BATTERY PACK — FAILED (EMERGENCY LIGHT) · airframe 18,797 hrs · 5,685 cycles

WHILE ACCOMPLISHING EMERGENCY LIGHTS OPS CHECK. FOUND LEFT AFT BATTERY PACK INOP/FAILED TEST. R & R LEFT AFT BATTERY PACK. OPS CHECKED GOOD. REF AMM 33-51-06-960-805.

Part: CONTROL VALVE — FAILED (RT A/C PACK) · airframe 18,965 hrs · 5,731 cycles

ON RECALL RT PACK LIGHT ILLUMINATED WITH AIR CONDITION LIGHT ON SIX PACK ALL CLEAR WITH MASTER CAUTION RESET. PERFORMED PACK ZONE TEMPERATURE CONTROL BITE PR FIM 21-62 TASK 801 NR 2 (RT) ZONE TEMP CONTROLLER FAULTED THIS PACK TCV. PERFORMED FIM 21-61, TASK 831 A - F1. REMOVED RT PACK TEMPERATURE CONTROL VALVE IAW 21-51-10-000-801. INSTALLED RT PACK TEMPERATURE CONTROL VALVE IAW AMM 21-51-10-400-801. ACCOMPLISHED TEMPERATURE CONTROL VALVE INSTALLATION TEST IAW AMM 21-51-10-400-801 PARA-E CONTROL VALVE INSTALLATION TEST IS GOOD.

Part: SMOKE DETECTOR — MALFUNCTIONED (AFT CARGO BAY) · airframe 19,019 hrs · 5,748 cycles

DETECTOR FAULT LIGHT ILLUMINATES DURING CARGO FIRE TEST, AFT LIGHT REMAINS EXTINGUISHED. R & R AFT A3 AFT CARGO SMOKE DETECTOR. OPS NORMAL, REF 26-16-01.

Part: INTERCOSTAL — CRACKED (BS 312-328) · airframe 18,102 hrs · 5,490 cycles

INTERCOSTAL, BS 312 TO BS 328, WL 201, LBL 40 CRACKED AT SCREW HOLE. ACFT GROUNDED. R & R INTERCOSTAL.

Part: AUTOTHROTTLE SYS — MALFUNCTIONED · airframe 18,086 hrs · 5,483 cycles

AUTOTHROTTLES DISENGAGED AFTER TAKE OFF AND WOULD NOT RE-ENGAGE. ACFT GROUNDED. INFLIGHT FAULT REVIEW SHOWS FLIGHT LEG 09 ASM NR 1 FAULT. NO OTHER A/T FAULTS LOGGED WITHIN PREVIOUS 20 FLIGHT LEGS. ACCOMPLISHED A/T SERVO MOTOR TEST. OPS NORMAL WITH NO FAULTS. ADDITIONALLY ACCOMPLISHED BG 43, DFCS LRU REPLACEMENT TEST FOR A/T. ALL TESTS PASS.

Part: FMC — MALFUNCTIONED · airframe 18,011 hrs · 5,464 cycles

ON TAXI OUT FMC DISAGREE IT ILLUMINATED. ACFT GROUNDED. QRH PROCEDURE ACCOMPLISHED. LIGHT WENT OUT.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 17,453 hrs · 5,286 cycles

APU OVERSPEED LIGHT ILLUMINATED ON CLIMB (~FL290 NON ETOPS AIRSPACE). DIVERSION TIME 35 MINUTES. PERFORMED APU BITE TASK 49 60 FOUND MAINT MSG 49 31014 APU OVERSPEED. PERFORMED TASK 49 30 00 810 802. NO FAULTS FOUND. PERFORMED APU OPERATIONAL TEST PER AMM 49 11 00 710 801. APU OPS CHECK NORMAL.

Part: APU — OVERSPEED (APU BAY) · airframe 17,454 hrs · 5,287 cycles

APU OVERSPEED LIGHT ILLUMINATED ON CLIMBOUT AT FL 290 NON ETOPS AIRSPACE. DIVERSION TIME: 14 MINUTES.PERFORMED APU BITE FOUND MAINT MESSAGE 49 31014 APU OVERSPEED 2 OCCURENCES. REPLACED APU ASSY PER TASK CARD 78349001 & AMM 49 11 00 APU OPS & LEAK CK OK.

Part: PANEL — DAMAGED (NR 1 ENGINE FAN) · airframe 17,384 hrs · 5,267 cycles

NR 1 ENGINE TWO FAN STRUT PANELS AT ONE O`CLOCK AND FIVE O`CLOCK POSITION, FASTENERS PULLED THRU PANEL AND SCREW HEAD LOOSE. REPLACED NR 1 ENGINE FAN STRUT PANEL IAW AMM 72-23-07-000-801-F00.

Part: PIN — LOOSE (ANTI-SKID SYS) · airframe 17,198 hrs · 5,212 cycles

AFTER TAKEOFF ANTISKID INOP LIGHT ILLUMINATED. DIV TIME: 16 MINUTES. T/S AND FOUND PIN AT J32 NOT SECURED. RESECURED PIN AT J32. RAN BITE CHECK PER AMM 32 42 00 810 801, ALL FAULTS CLEARED. ACFT OK FOR SERVICE. ALL ITEMS RESECURED.

Part: LENS — BROKEN (EXIT SIGN) · airframe 17,193 hrs · 5,211 cycles

EMERGENCY EXIT LIGHT LENSE COVER BROKEN AT R1 DOOR. REF WDM 33 51 21 PAGE 8. REPLACED AND TESTED L1186 EMERGENCY EXIT LOCATOR SIGN AT R1 DOOR PER MM 33 51 01 960 802, OPS NORMAL.

Part: UNKNOWN — MALFUNCTIONED (FMC) · airframe 16,499 hrs · 5,004 cycles

"FMC DISAGREE" LEFT ON GROUND AT SAN. FOLLOWED QRH PROCEDURE AND SITUATION CORRECTED. DID FIM 34 61 00 810 835 AND FMC BITE REF FIM 34 61 TASK 801. NO FAULTS NOTED AND ALL FMC INDICATIONS NORMAL ON BOTH LEFT AND RIGHT FMC'S. A/C OK FOR SERVICE. GROUND VERIFICATION COMPLETE.

Part: LENS — BROKEN (EMERGENCY LIGHT) · airframe 16,375 hrs · 4,970 cycles

L2 EMERGENCY EXIT LIGHT LENS BROKEN. LENS COULD NOT BE REMOUNTED. REPLACED LIGHT ASSY REF 33 51 01. OP'S CHECK GOOD.

Part: AUTOLAND SYS — MALFUNCTIONED (COCKPIT) · airframe 16,061 hrs · 4,868 cycles

AUTOLAND / HGS APPROACH AIRCRAFT WAS OFFSET TO THE LEFT OF CENTERLINE ABOUT 1/4 THE WIDTH OF THE RUNWAY. CONDITIONS WERE CAT 1 THEREFORE AUTOLAND WAS ABORTED. ACCOMPLISHED FIM 22 11 00 TASK 825 AND AMM 22 11 00 DFCS GP 49 LAND VERIFY TESTS OPS CHECK NORMAL. FFR AND CURRENT FAULTS SHOWS NO FAULTS. ACCOMPLISHED HGS TESTS REF 34 36 00 OPS CHECK NORMAL. CHECKED FOR REPETITIVE AND CHRONIC MALFUNCTION LAST 10 DAYS NO FAULTS.

Part: UNKNOWN — MALFUNCTIONED (ELECTRICAL SYS) · airframe 16,010 hrs · 4,856 cycles

AMBER "ELEC" LIGHT ILLUMINATED. CONFIRMED. SHOWS AUX BAT CHARGR FAULT. WOULD NOT CLEAR. AUX BAT CHGR SHOWS BATT FAULT. COMPLETED FIM 24 31/T825 WITH NO DISCREPANCIES FOUND. AFTER PWR RE APPLIED TO A/C FAULT RESET. BITE TEST GOOD. REF FIM 24 31/T801. GND VERIFICATION TEST GOOD. REF MM 24 31 31/501.

Part: UNKNOWN — MALFUNCTIONED (FMC) · airframe 15,930 hrs · 4,832 cycles

FMC DISAGREE LIGHT ILLUMINATED ON TAXI OUT. PERFORMED QRH ISSUE RESOLVED. AS A PRECAUTION CHECKED BOTH FMC FOR "FMC DISAGREE" NO DEFECTS NOTED. OK FOR CONT SERVICE.

Part: UNKNOWN — MALFUNCTIONED (AUTOPILOT SYS) · airframe 15,896 hrs · 4,823 cycles

AUTOLAND UNSUCCESSFUL LANDED TOO FAR LEFT OF CENTERLINE, ALSO AIRCRAFT PITCHED OVER IN LAST 50 FEET EXCESSIVELY. BUT DID MANAGE TO CORRECT. WINDS WERE CALM CRITICAL AREA CLEAR. UNABLE TO CONFIRM FAULT. 2 FAULTS RECORDED ON DATE OF DISCREPANCY ONE ADIRU FAULT & ONE FMS FAULT. SUSPECTED LRU TESTS FOR BOTH FAILURES SHOW NO FAILURES. PERFORMED FIM TASKS 22 11 00 810 806 & 22 11 00 810 811 NO FAULTS FOUND. PERFORMED LAND VERIFY BITE GP 49 NO FAILURES.

Part: MOTOR — INOPERATIVE (STAB TRIM) · airframe 15,795 hrs · 4,794 cycles

ON TAKEOFF LEG ATTEMPTED TO TRIM STAB WITH CAPT YOKE SWITCHES NO EFFECT. HAD F/O TRY ON HIS YOKE NO RESPONSE. STAB TRIM WORKED FOR SETTING STAB TRIM FOR TAKEOFF. DIVERSION TIME: 14 MINUTES. UNABLE TO DUPLICATE DEFECT STAB TRIM OPS NORMAL WITH CAPT'S & F/O'S YOKE SWITCHES & AP/ REF MM 27 41 71. REPLACED STAB TRIM MOTOR PRECAUTIONARY REF MM 27 41 71, OPS CHECK NORMAL.

Part: APU — OIL CONSUMPTION (APU BAY) · airframe 15,822 hrs · 4,800 cycles

APU OIL CONSUMPTION CONTINUES TO BE GREATER THAN EXPECTED. REPLACED APU IAW AMM 49 11 0.

Part: SEAL — OUT OF LIMITS (APU) · airframe 15,666 hrs · 4,757 cycles

PER T/C 78349000 SIGMA SEAL OUT OF LIMITS FOR COMPRESSION CHECK AT 1.1 INCHES. REPLACED SIGMA SEAL ON APU REF MM 49 15 11.

Part: APU — MALFUNCTIONED (APU BAY) · airframe 15,590 hrs · 4,730 cycles

APU EGT ABOVE THE THRESHOLD, APU REMOVED & REPLACED IAW MM 49-11-00-400-803 THRU STEP L(7).

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 15,427 hrs · 4,678 cycles

ELEC LIGHT ON OVERHEAD PANEL ILLUMINATED ON RECALL. ELEC PANEL SHOWED STATIC INV. I FAULT. PERFORMED FIM 24 24 TASK 801 FAULT CLEARED. STATIC INV OPS CHECK GOOD REF MM 24 31 21 GND VERIFICATION FOR ETOPS PASSED.

Part: COVER — CRACKED (HORIZ STAB) · airframe 15,098 hrs · 4,577 cycles

RT HORIZONTAL STAB HINGE COVER PNL 344JB CRACKED. REPLACED RT HORIZONTAL STAB HINGE COVER PNL.

Part: CIRCUIT BREAKER — LOOSE (MAIN BUSS) · airframe 14,788 hrs · 4,484 cycles

A WARM ELECTRICAL ODOR ON CLIMBOUT IN COCKPIT AND FOWARD CABIN. TURNED OFF RIGHT RECIRC FAN AND ODOR WENT AWAY, NO FURTHER PROBLEMS. ACFT GROUNDED, FOUND C2 CONNECTION ON CIRCUIT BREAKER C817 "MAIN BUSS 2" LOOSE. (CIRCUIT BREAKER IS IN P92 PANEL) SCREW HAD WORKED ITS WAY LOOSE. REMOVED P92 PANEL AND TIGHTENED C2 CONNECTION ON CIRCUIT BREAKER C817 "MAIN BUS 2". RAN SYSTEMS AFFECTED AFTERWARDS GALLEYS APU FUEL PUMPS POTABLE WATER PRESSURE EQUIP COOLING FANS ELECTRIC HYDRAULIC PUMPS 1&2 RT RECIRCULATION FAN (RAN FOR OVER 1 HOUR WITH NO PROBLEMS) AND BATTERY CHARGER. OPS CHECK GOOD. DURING RT RECIRCULATION FAN OPERATION DID NOT NOTICE ANY COCKPIT OR CABIN ODORS.

Part: INDICATION SYS — FALSE ACTIVATION (COCKPIT) · airframe 14,788 hrs · 4,484 cycles

ON TOUCHDOWN OVERHEAD ELECTRICAL PANEL ELEC LIGHT CAME ON. PERFORMED BITE TEST ON OVERHEAD ELEC PANEL AND CLEARED FAULT. FAULT DID NOT RETURN REF AMM 24 21 53. NO HISTORY 90 DAYS.

Part: TIE BOLT — BROKEN (WHEEL) · airframe 14,240 hrs · 4,332 cycles

DURING MAINTENANCE WALK AROUND FOUND NR 2 MLG WHEEL/TIRE ASSY WITH A BROKEN TIE BOLT. REPLACED WHEEL/TIRE ASSY IAW B737 800 AMM 32 45 11.

Part: IDG — MALFUNCTIONED (NR 1 GENERATOR) · airframe 14,043 hrs · 4,270 cycles

NR 1 ENG IDG DPI FILTER INDICATOR POPPED OUT. REPLACED BOTH IDG FILTERS IAW AMM 24-11-41-000-801 AND AMM 24-11-400-801. ACCOMPLISHED INSP AND CHECK IAW AMM 24-11-41-200-801. NO VISIBLE CONTAMINATION NOTED. TSR ISSUED REPLACED NR 1 ENGINE IDG IN REF AMM 24-11-11 AND LEAK CHECKED, NO LEAK NOTED. OPS CHECKED GOOD.

Part: COMPUTER — FAILED (E&E BAY) · airframe 14,004 hrs · 4,254 cycles

FMC DISAGREE MESSAGE ON BOTH DU'S (ON INITIAL SETUP). REPLACED FMCS CONTROL DISPLAY UNIT NR 2 IAW MM 34 61 01, OPS CHECK GOOD. REPLACED NR 1 FMCS COMPUTER IAW MM 34 61 02, OPS CHECK GOOD. VERIFICATION TEST GOOD IAW MM 34 61 01.

Part: UNKNOWN — MALFUNCTIONED (FMC) · airframe 14,000 hrs · 4,253 cycles

FMC DISAGREE LIGHT ILLUMINATES ON THE GROUND. NO DISAGREE MESSAGE WHEN FMC SELECT SWITCH PLACED TO BOTH ACCOMPLISHED FIM 34 61TASK 835 OPENED AND RESET FMC NR 1&2 C/B'S. NO FAULTS LOGGED ON BOTH FMC'S.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 13,935 hrs · 4,230 cycles

AFTER PUSH BACK ON ENG START RT PACK LIGHT ILLUMINATED ON RECALL. PERFORMED GROUND VERIFICATION BITE TEST OF RT PACK TEMP CONTROLLER. NO FAULTS NOTED AND RESET. NO HISTORY PAST 30 DAYS.

Part: FMC — MALFUNCTIONED (E&E BAY) · airframe 13,924 hrs · 4,228 cycles

VTK FLAG FMC NR 1. PERFORMED FIM TASK 34 61 TASK 801 'VTK FLAG SHOWS CAPTAINS'. FMCS IN FLIGHT FAULTS INDICATED L FMC FAULTS DETECTED BY BOTH FMC'S. A/C HAS PREVIOUS HISTORY OF VTK FLAG. REQUIRES LEFT FMC REPLACEMENT. REPLACED LEFT FMC REF MM34 61 02. OPS NORMAL.

Part: WINDOW — OVERHEATED (COCKPIT) · airframe 13,667 hrs · 4,156 cycles

RIGHT SIDE WINDOW OVERHEAT. WINDOW PRIMARY TEMP SENSOR CHECKS NML PER FIM 30 41 TASK 811. WINDOW HAS CONCENTRATED HOT SPOTS AS WELL AS COOL. REQUIRES R2 WINDOW CHANGE PER FIM 30 41 TASK 809. REPLACED R2 WINDOW OPS CHECKS NORMAL REF M/M 56 12 11 400 801.

Part: UNKNOWN — MALFUNCTIONED (FMC)

AT 2057Z FL 370 M.78 "VTK" APPEARED ON CAPTAINS MFD. FMC DATA WAS LOST ON BOTH FMC'S. IAW QRC, SELECTED FMC "BOTH ON 2 GOT THE " SINGLE FMC OPERATION" MESSAGE. PULLED & RESET FMCS COMPTR 1 C/B. P 18 2 A 6. NR 1 FMC SYSTEM OPS CHECK GOOD. REF M/M 34 61 00 810 801. LAND VERIFY TESTS PASS. REF 22 00 01 M/M. LWMP STATUS REMAINS CAT IIIA AUTOLAND & HGS.

Part: BLEED VALVE — FAILED (APU) · airframe 13,357 hrs · 4,055 cycles

AFTER ENGINE START AND AFTER START CHECKLIST "DUAL BLEED" LIGHT REMAINED ILLUMINATED. REMOVED AND REPLACED APU BLEED CONTROL VLV GROUND TEST VERIFICATION OF APU BLEED CONTROL CHECKED NORMAL APU BITE CHECK SHOWS NO CURRENT FAILURES.

Part: SKIN — CORRODED (FUSELAGE) · airframe 13,214 hrs · 4,010 cycles

CORRODED RIVET HEAD APPROX 10 INCHES AFT OF VACUUM TOILET DISCHARGE HOLE. CORROSION LT FUSELAGE AT 1016 BULKHEAD. REMOVED CORROSION FROM AREA 10 INCHES AFT OF VACUUM TOILET DISCHARGE HOLE. BLENDOUT WITHIN LIMITS PER SRM 53 00 01 AD1 FIG 103 DETAIL C. REMOVED CORROSION LT FUSELAGE AT STA 1016 BULKHEAD DAMAGE REMOVAL WITHIN LIMITS PER SRM 53 00 01 AD1 FIG 103 DETAIL C. INSTALLED BLIND HUCKBOLTS PER 800 53EA 04657. INSPECT HUCKBOLTS EVERY 500 HOUR FOR SECURITY. REPLACE AS REQUIRED. AT NEXT HEAVY MAINTENANCE CHECK REPLACE HUCKBOLTS WITH SOLID RIVETS PER SRM GUIDELINES PER 800 53EA 04657.

Part: FILTER — DIRTY (COCKPIT) · airframe 12,867 hrs · 3,916 cycles

RIGHT PACK LIGHT ON DURING RECALL. WILL RESET. UNABLE TO DUPLICATE DEFECT. FOUND FLIGHT DECK TEMP SENSOR FILTER CLOGGED AND SENSOR DIRTY. REMOVED CLEANED AND INSTALLED TEMP SENSOR FILTER PER MM 21 61 05 AND TEMP SENSOR PER MM 21 61 10. OPS NORMAL.

Part: STARTER GEN — FAILED (APU) · airframe 12,614 hrs · 3,830 cycles

WHILE PRESSURIZING WATER SYSTEM FOR OPERATION APU SHUT ITSELF DOWN. STARTED APU AND AFTER 30 SECONDS THE APU SHUT ITSELF DOWN WITH A FAULT LIGHT PERFORMED BITE CHECK AND FOUND FAULT CODE 49 94299 PERFORMED FIM 49 90 00 810 809. REMOVED AND REPLACED OIL FILTERS ON APU FOUND THAT THE STARTER/GENERATOR SCAVANGE FILTER WAS VERY CONTAMINATED WITH SOME TYPE OF MATERIAL AND VERY BLACK IN COLOR ALSO THE FILTER FOR THE LUBE UNIT WAS ALSO VERY BLACK AND A LARGE AMOUNT OF WHAT SEEMED TO BE CARBON WAS BUILT UP IN THE FILTER BOWLS. WITH THE ADVICE OF TECH SERVICES AND SEAMC REMOVED AND REPLACED THE STARTER/GENERATOR REF MM 49 41 21. REPLACED THE APU OIL REF MM 12 13 31 OPS & LEAK CHECK GOOD. THEN REMOVED & REPLACED THE OIL FILTERS ONCE AGAIN REF MM 49 91 12 ALL OPS & LEAK CHECK GOOD.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 12,576 hrs · 3,819 cycles

FMC NR 2 GO TO INDEX POS PAGE 2 CANNOT SELECT L1 L5 WHEN ON THIS PAGE TO CAPTURE A POSTION REPORT. LONG/LAT KEYS WORK ON ALL OTHER PAGES. PERFORMED INSTALLATION TEST PER MM 34 61 01 SYSTEM OP CHECKS GOOD TESTED FMC CDU LEFT SELECT KEYS 1 5 WHILE CHECKING DIFFERENT TEST IN THE MAINT BITE AND INIT REF INDEX PGS. LEFT SELECT KEYS 1 5 OP CHECK GOOD. SYSTEM OP CHECKS GOOD. VERIFICATION FLIGHT SUCCESSFUL.

Part: CONNECTOR — DIRTY (APU) · airframe 12,360 hrs · 3,761 cycles

MAINT MESSAGE 49 52284 SURGE VALVE POSITION DISAGREES WITH COMMAND FAULT FOUND ON APU BITE CK. ACCOMP FIM TASK 49 53 00 810 806. FAULT CORRECTED AFTER WIRE HARNESS CONNECTION WAS CLEANED. OPTS CHECK GOOD NO FAULTS FOUND AFTER MULTIPLE STARTS. SUCCESSFUL GROUND VERIFICATIONS OF CORRECTION ACCOMP REF FIM TASK 49 53 00 810 806.

Part: UNKNOWN — MALFUNCTIONED (AC BAY) · airframe 12,284 hrs · 3,739 cycles

ON CLIMBOUT OF SEATTLE GOING THROUGH 18000FT RIGHT PACK LIGHT ILLUM. FOLLOWED QRH PROCEDURE PACK LIGHT RESET PRESS ALL NORMAL WHEN TEMP SEL POSITIONED TO RIGHT PACK PER QRH THE PACK TEMP WAS APPROX 40 CALL CABIN ZONE CONTROL TEMP SELECTORS WERE IN APPROX THE 12 O`CLOCK POSITION. PERFORMED FIM TASK 21 53 00 801 808 NO DEFECTS NOTED, OPS CHECKED NORMAL. SEAMC NOTIFIED, NO HISTORY.

Part: FMC — FAILED (E&E BAY) · airframe 11,958 hrs · 3,644 cycles

VTK (RIGHT FMC) ALERT ON FIRST OFFICER DISPLAY SELECTED FMC BOTH ON L. PERFORMED FIM TASK 34 61 00 NO HELP. RT FMC COMP IS DEAD. REPLACED RIGHT FMC COMPUTER PER MM 34 61 02. INSTALLED THE FOLLOWING SOFTWARE VIA CROSSLOAD: FMC OPC BCG 016 C9 ACARS DATABASE ASA1004A LDDB 557362P MEDB BCG 014 V9 NDB ASA1101001. FMCS OPERATIONAL TEST PER MM 34 61 00 740 801 ALL TESTS PASS.

Part: FLOORBOARD — CRACKED (CARGO BAY) · airframe 11,932 hrs · 3,631 cycles

CRACK IN AFT PIT FLOORBOARD. REMOVED AND INSTALLED NEW NR 2 FLOOR PANEL.

Part: BRACKET — CRACKED (LT WING) · airframe 11,932 hrs · 3,631 cycles

LT WING TRAILING EDGE SEAL RETAINER BRACKET CRACKED. REMOVED AND REPLACED BRACKET.

Part: DISPLAY — DEFECTIVE (COCKPIT) · airframe 11,623 hrs · 3,540 cycles

F/O SIDE FMC R6 BUTTON IS COMING APART. REMOVED AND REPLACED F/O'S MCDU REF MM 34 61 01. OPS NORMAL. GROUND VERIFICATION SUCCESSFUL.

Part: FILTER — POPPED (NR 1 IDG) · airframe 11,551 hrs · 3,521 cycles

NR 1 ENG IDG PIN POPPED. FIM 24 11 803 REF WORK ORDER 85103 COMPLETED TASK CARDS 78424000 IDG FILTER AND OIL CHANGE AND TASK CARD 78273000 INTERROGATE FMC CDU FOR ENG FAULTS. OPS NORMAL.

Part: STARTER GEN — FAILED (APU) · airframe 11,342 hrs · 3,455 cycles

APU FAULT LIGHT ILLUMINATED ON UNSUCCESSFUL APU START. SHUT APU DOWN FAULT LIGHT EXTINGUISHED IN 30 SECONDS. FAULT LIGHT ILLUMINATED ON 2ND + 3RD START ATTEMPTS. APU DID NOT START. REF AMM 49 41 21 000 801 TASK 49 41 21 400 801 INSTALLED NEW STARTER GENERATOR. PERFORMED OPS CHECK OF SYSTEM OPERATION NORMAL LEAK CHECK OK, NO LEAKS NOTED. GROUND VERIFICATION SUCCESSFUL.

Part: LIGHT — EXTINGUISHED (COCKPIT) · airframe 11,306 hrs · 3,446 cycles

NR 2 IDG LOW PRESSURE LIGHT EXTINGUISHED WITH ENG SHUTDOWN. PERFORMED FIM 24 11 TASK 801. MOTORED NR 2 ENG & DRIVE LT OPS NORMAL. GROUND VERIFICATION PASSED.

Part: FMC — MALFUNCTIONED (RIGHT) · airframe 11,055 hrs · 3,362 cycles

RT FMC FAILED MAP FAIL LIGHT ON CO-PILOTS ND. FOLLOWED QRH SYSTEM RESTORED. RE-INITIALIZED RT FMC BY CYCLING TRANSFER SWITCH. OPERATION RESTORED TO NORMAL REF FIM 34 61 00. SYS OPERATION CHECKS GOOD.

Part: PROBE — FAILED (NR 2 ENGINE) · airframe 10,665 hrs · 3,248 cycles

DURING ACCOMPLISHMENT OF TASK CARD 78273000 ENGINE FMC CDU FAULTS NR 2 ENGINE FAULTED 75 10802 T25 SIGNALS DISAGREE. GROUNDED YES. REPLACED NR 2 ENG PT25 SENSOR REF 2MM73 21 02 000 801 F00 & 73 21 02 400 801 F00. OPS NORMAL.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 10,611 hrs · 3,232 cycles

RIGHT PACK LIGHT CAME ON AFTER ENGINE START LIGHT DOES RESET AFTER RECALL. PERFORMED BITE CHECK ON PACK ZONE TEMP CONTROLLER NO FAULTS LOGGED OR NOTED, OPS NORMAL. RAN APU AND PERFORMED PACK FLOW CONTROL VALVE OPS TEST, OPS NORMAL. SUCCESSFUL GROUND VERIFICATION NO DEFECTS NOTED. OK FOR CONTINUED SERVICE. REF MM 21 51 00 700 802 21 51 00 700 803.

Part: FMC — FAULTED (NR 2 ENGINE) · airframe 10,605 hrs · 3,230 cycles

WHILE PERFORMING T/C 78273000 FOUND MAINT FAULT CODE 75 10802 FOR FMC CDU T25 SIGNALS DISAGREE SHORT TERM FAULT NR 2 ENG. REPLACED EEC ON THE NR 2 ENGINE. OPS CHECKED GOOD REF MM 73-21-60-400-801-F00.

Part: PLUG — BROKEN (NR 2 STARTER) · airframe 10,169 hrs · 3,101 cycles

NR 2 ENG AIR STARTER MAGNETIC PLUG BROKEN FOUND DURING A CHECK MAINTENANCE. NO CONTAMINATION NOTED. REMOVED AND REPLACED NR 2 ENGINE STARTER PER MM 80 11 01 000 801 F00. OPS CHECK AND LEAK CHECK GOOD.

Part: OIL SYSTEM — LOW (NR 2 ENGINE) · airframe 10,087 hrs · 3,076 cycles

RIGHT ENG OIL QTY 14 QTS AT TOP OF DESCENT. SERVICED RIGHT ENGINE TO FULL PER MM 12 13 11. OIL ADDED 3 QTS.

Part: OIL SYSTEM — LOW (NR 1 ENGINE) · airframe 10,087 hrs · 3,076 cycles

LEFT ENG OIL QTY 13 QTS AT TOP OF DESCENT. SERVICED LEFT ENGINE TO FULL PER MM 12 13 11. OIL ADDED 3 QTS.

Part: ACTUATOR — OUT OF RIG (AC BAY) · airframe 9,910 hrs · 3,028 cycles

FOUND LT AIR CONDITIONING RAM AIR DEFLECTOR DOOR THAT APPEARS OUT OF RIG. DOOR CAN BE DEFLECTED UPON BEING PUSHED ON. ADJUSTED THE LT RAM AIR DEFLECTOR DOOR TO WITHIN LIMITS REF MM 21 51 22 400 803 STEP F (7) THROUGH (8) (B), OPS CHECK GOOD.

Part: ACTUATOR — OUT OF ADJUST (AC BAY) · airframe 9,910 hrs · 3,028 cycles

RIGHT RAM AIR DEFLECTOR DOOR WILL NOT ACTUATE. ADJUSTED THE RT RAM AIR DEFLECTOR DOOR TO WITHIN LIMITS REF MM 21 51 22. OPS CHECK GOOD.

Part: FILTER — FAULTY (NR 1 IDG) · airframe 8,661 hrs · 2,624 cycles

NR 1 ENG IDG DELTA "P" INDICATOR EXTENDED. REMOVED AND REPLACED NR 1 ENG IDG SCAVENGE AND CHARGE FILTERS. NO CONTAMINATION / OIL DISCOLORATION NOTED. RESET DELTA "P" INDICATOR AND GEN DISC NR 1 C/B. IDLE RAN LEAK CHECK GOOD. DPI DECAL INSTALLED AT IDG AND 1ST OCCURRENCE ANNOTATED. REF AMM 24 11 41 200 801 AND 24 11 41 400 801.

Part: TRANSCEIVER — MALFUNCTIONED (WEATHER RADAR) · airframe 8,454 hrs · 2,559 cycles

RADAR HAS 2 4 SPOKES AT 10:00 O'CLOCK POSITION INTERMITTENTLY ON CAPTS DU F/O SIDE OK RADAR APPEARS TO PAINT NORMALLY. FOUND SPOKES ON BOTH DU'S INTERMITTENTLY APPEAR. DUE TO PREVIOUS TROUBLESHOOTING REMOVED AND REPLACED WXR R/T REF M/M 34 43 41. GROUND VERIFICATION SUCCESSFUL REF M/M 34 43 00. VISUALLY INSP'D QUICK DISCONNECT OK FOR CONTINUED SERVICE.

Part: WINDOW — DEFECTIVE (COCKPIT) · airframe 8,222 hrs · 2,472 cycles

L1 WINDSHIELD OVERHEAT LIGHT ILLUMINATED. VERIFIED FAILURE SENSOR (TEMP) FAULT ON WINDOW HEAT CONTROL UNIT. BOTH SENSORS FOR LEFT FRONT WINDSHIELD READ OPEN AT WINDOW. WINDOW REMOVED PER MM 56 11 11 000 801. INSTALLED NEW L1 WINDSHIELD GROUND VERIFICATION SUCCESSFUL REF MM 56 11 11.

Part: FMC — MALFUNCTIONED (COCKPIT) · airframe 8,170 hrs · 2,454 cycles

"INFO ONLY" FMC DISAGREE ON GROUND. CLEARED DURING PROCEDURE IN QRH. INFO NOTED. OPS NORMAL.

Part: FMC — MALFUNCTIONED (E&E BAY) · airframe 7,997 hrs · 2,396 cycles

LEFT FMC FAILED AT CRUISE. APPLIED LEFT FMC FAIL CHECKLIST. UNABLE TO RESTORE DUAL OPERATIONS. KNOWN SOFTWARE FAULT. PULLED NR 1 FMCS CMPTR & MCDU C/B'S FOR 30 SECS & RESET. OPS CHECK NR 1 FMCS GOOD. REF MM 34 61 02/101. MCF INFORMED.

Part: TRANSCEIVER — FAULTY (E&E BAY) · airframe 7,904 hrs · 2,368 cycles

NR 2 HF RADIO UNABLE TO VOICE TRANSMIT OR RECEIVE. NO SQUELCH BREAK OR FEEDBACK ON BOTH AUDIO PANELS AND CAPT STANDBY HAND MIC. DATA FUNCTION TRANSMIT AND RECEIVE WORKS WHEN IN VHF RANGE BUT NOT WHEN USING HF2. CONFIRMED FAULT WITH NR 2 HF RADIO. REMOVED & REPLACED NR 2 HF RT PER MM 23 11 21 400 801. OPS CHECK NORMAL. PERFORMED OPS CHECK OF NR 2 RADIO PER MM 23 11 00 710 801. NO DEFECT NOTED. RECEIVED & TRANSMITTED NORMAL.

Part: OVERHEAT SENSOR — FAULTY (APU TAILPIPE) · airframe 7,821 hrs · 2,338 cycles

APU DET INOP ILLUMINATED ON FINAL. ACCOMPLISHED QRH APU WAS NOT RUNNING. VERIFIED FAULT STILL CURRENT. VERIFIED P/N WITH SEAMC. REPLACED TAILPIPE OVERHEAT DETECTOR ASSEMBLY WITH SERVICEABLE ONE. ACCOMP INST, TEST PASS REF M/M 26 15 01 400 802.

Part: INLET BULLET — WORN (NR 2 ENGINE) · airframe 7,538 hrs · 2,261 cycles

NR 2 ENG FRONT CONE WORN. REMOVED AND REPLACED NR 2 ENG FRONT CONE REF MM 72 21 01 400 801.

Part: INLET BULLET — WORN (NR 1 ENGINE) · airframe 7,538 hrs · 2,261 cycles

NR 1 ENG FRONT CONE WORN. REMOVED AND REPLACED NR 1 ENG FRONT CONE REF MM 72 21 01 400 801.

Part: SENSOR — DEFECTIVE (L1 WINDOW) · airframe 7,021 hrs · 2,088 cycles

FWD LEFT WINDOW OVERHEAT LIGHT ILLUMINATED. VERIFIED L1 WINDOW PRIMARY TEMP SENSOR BAD SPARE TEMP SENSOR GOOD, S1078 S/W POSITIONED FOR SPARE SENSOR REF MM TASK 30 41 00 810 812. WINDOW HEAT OPS NORMAL REF MM TASK 30 41 00 710 801.

Part: FMC — MALFUNCTIONED (NR 2) · airframe 6,902 hrs · 2,054 cycles

NR 2 FMC INOP. PERFORMED FMC GND VERIFICATION TEST PER M/M 34 61 00 710 801, TEST OK. NO HISTORY LAST 30 DAYS. A/C RETAINS CURRENT CAT STATUS.

Part: FUEL SYS — MALFUNCTIONED · airframe 6,786 hrs · 2,017 cycles

INADVERTENT FUEL IMBALANCE GREATER THAN 1000 LBS LEFT TANK 7.35 RIGHT TANK 8.40. BALANCE WAS RESTORED. NO EVIDENCE OF FUEL LEAK. ACCOMPLISHED FIM TASK 28 41 810 820 NO DISCREPANCIES FOUND. FUEL QUANTITY TEST PASSED. GROUND TEST VERIFICATION PASSED. NO FAULTS, NO HISTORY PREVIOUS 60 DAYS CONTACTED SEAMC.

Part: FUSE — BLOWN (BATTERY PACK)

RT AFT SERVICE DOOR EMERGENCY ESCAPE SLIDE LIGHT INOP (EXTERIOR LIGHT. REPLACED BATT PACK PICO FUSE. OPS CHECK RT AFT SERVICE DOOR EMERG EXIT SLIDE LIGHT GOOD.

Part: CONTROL VALVE — FAILED (RT AC PACK) · airframe 6,604 hrs · 1,956 cycles

AFTER STARTING ENGINES, CHECKED MC LIGHT AND GOT RIGHT PACK LIGHT. REMOVED AND REPLACED RIGHT PACK TEMP CONTROL VALVE REF MM 21 61 00, OP CHECK AND BITE CHECK GOOD REF MM 21 61 20. GROUND VERIFICATION ACCOMPLISHED PER ETOPS MANUAL. RT PACK TEMP CONTROL VALVE VERIFIED BY SEAMC.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 6,439 hrs · 1,906 cycles

WHEN MASTER CAUTION RECALL CHECK ACCOMPLISHED RT "PACK" LT ILLUMINATED. LT EXTINGUISHED WHEN MASTER CAUTION PUSH TO RESET BUTTON PUSHED. TROUBLESHOT PER FIM 21 62 00 810 828. RT PACK TCV FAULT LIGHT CLEARS AFTER TEMP CONTROLLER BITE. PAC OPS NORMAL RT "PACK" LIGHT REMAINS EXTINGUISHED ON RECALL. ETOPS SEAMC CONSULTED.

Part: CONTROL UNIT — OVERSPEED (APU) · airframe 6,432 hrs · 1,904 cycles

FVR UNSATISFACTORY APU OVERSPEED AT FL 390 AUTO SHUTDOWN INITIATED. REMOVED AND REPLACED APU FUEL CONTROL UNIT REF MM 49 31 11 000 801 AND 49 31 11 400 801 STEPS A THROUGH AND INCLUDING H(2) OF INSTALLATION. REMOVED AND REPLACED APU ELE CONT UNIT REF MM 49 61 12 400 801, ACCOMPLISHED LEAK AND OPS CHECK REF MM 49 61 12 AND MM 49 31 11, OPS CHECK GOOD. VERIFICATION FLIGHT SUCCESSFUL.

Part: SENSOR — MALFUNCTIONED (APU) · airframe 6,427 hrs · 1,902 cycles

AFTER LEVELING FL 340 APU OVERSPEED ILLUMINATED FOLLOWED BY A SHUTDOWN OF THE APU. DIVERSION TIME 83 MINUTES. PERFORMED APU BITE CHECK FOUND FAULT MSG 49 31014 (APU OVERSPEED SHUTDOWN). PERFORMED FIM 49 30 TASK 802. REMOVED AND REPLACED APU SPEED SENSOR P/N 3876223 1 (PART AFFECTIVITY VERIFIED) REF MM 49 61 21 000 801 PG 1 3 AND MM 49 61 21 400 801 PG 14. APU OPERATIONAL CHECK AND APU BITE CHECK SHOW NO CURRENT FAULTS AT THIS TIME.

Part: UNKNOWN — MALFUNCTIONED (COCKPIT) · airframe 6,334 hrs · 1,873 cycles

JUST AFTER TAKEOFF AT 1000 AGL RECEIVED CDU SCRATCH PAD MESSAGE "VERIFY POSITION IRS FMC" FMC L 299' /0.0 FMC R 123' /0.0 GPS L 122'/0.1 IRS L068'/12 IRSR 070"/12.0 RADIO: BLANK RADIO POS 041'/0.0 DME UPDATE ON NAV STATUS PAGE NORMAL ACTIVE NAV SCR GPS 2 IRS 2 RPN 2.0/ ANP 0.03 RAW DATA CHECKED GOOD. ACCOMPLISHED RADIAL POSITION ERROR CHECK TASK 34 21 00 200 801 WITHIN LIMITS FOR 4.5 HR TIME IN NAV MODE L 7.4 M R 6.5M REALIGNED IRS GROUND SPEED IS 0 REF IRS GROUND SPEED TEST REF MM 34 21 0 200 802. FME BITE CHECKS GOOD NO FAULTS. DFGS LRU REPLACEMENT TEST CHECKS GOOD HGS SENSOR TEST FOR THE ADIRU IR AND ADIRU ADR CHECKS GOOD.

Part: OIL FILTER — DIRTY (NR 1 ENGINE) · airframe 6,319 hrs · 1,870 cycles

NR 1 ENG FOUND SMALL AMOUNT OF COKE PARTICLES IN AFT SUMP CHIP DETECTOR. REMOVED AND REPLACED SCAVENGE OIL FILTER PER MM 79 21 06, NO PARTICLES FOUND IN SCAVENGE FILTER. LEAK CHECK GOOD.

Part: EEC — FAILED (NR 1 ENGINE) · airframe 6,145 hrs · 1,832 cycles

NO EGT AFTER START LEVER TO IDLE (ENG 1). REMOVED & REPLACED NR 1 EEC PER MM 73 21 60, OPS CHECK GOOD PER MM 71 00 00, PART VERIFICATION PER ETOPS PROGRAM VERIFIED WITH SEAMC.

Part: RETAINER — CRACKED (RT WING) · airframe 5,996 hrs · 1,792 cycles

RT WING TE PANEL 671BB SEAL RETAINER ANGLE IS CRACKED. REMOVED FABICATED NEW AND INSTALLED RETAINER ANGLE.

Part: FAIRING — CHAFED (FUSELAGE) · airframe 5,996 hrs · 1,792 cycles

WING TO BODY FAIRING DAMAGE 193AR CHAFFED THROUGH. REPAIRED PER SRM 51 70 05.

Part: BRACKET — CRACKED (RT WING) · airframe 5,996 hrs · 1,792 cycles

RT WING FIXED TE SEAL BRACKET WS 289 CRACKED. R&R WITH NEW BRACKET PER SRM 51 40 02.

Part: SKIN — DENTED · airframe 5,996 hrs · 1,792 cycles

SKIN DAMAGE DENT. REPAIRED PER ASA EA 53EA00526.

Part: BRACKET — CRACKED (WS 289) · airframe 5,996 hrs · 1,792 cycles

LT WING FIXED TE SEAL BRACKET AT WS 289 IS CRACKED FWD WEB AFT BRACKET. R&R LT WING FIXED TE SEAL BRACKET AT WS 289 PER SRM 51 40 02.

Part: CONNECTOR — DIRTY (APU) · airframe 5,932 hrs · 1,778 cycles

ENROUTE APU OVERSPEED LIGHT ILLUMINATED ALONG WITH MASTER CAUTION. APU CONTROL SWITCH SELECTED TO OFF. OVERSPEED LIGHT EXTINGUISHED 5 MIN AND 40 SECONDS LATER. EGT WENT FROM 200* TO 0* WHEN LIGHT WENT OUT GROUNDED YES. PERFORMED APU BITE PER AMM 49 60 00 FOUND MSG 49 31014. PERFORMED FIM TASK 49 30 00 REMOVED CANNON PLUG ON SPEED SENSORS AND CLEANED. CHECKED CHIP DETECTOR NO DEFECT. INSPECTED WIRE HARNESS NO DEFECTS. PERFORMED APU OPS TEST PER MM 49 11 00 NO HISTORY NOTED. SEAMC MIKE NOTIFIED FAA NR 2786424 IN LIH

Part: SENSOR — MALFUNCTIONED (APU) · airframe 5,837 hrs · 1,779 cycles

APU OVERSPEED LIGHT ILLUMINATED WITH MASTER CAUTION. HAPPENED AT FL350 ABOUT 2 1/2 HOURS INTO FLIGHT. SHUT DOWN APU OVERSPEED LIGHT EXT PER QRH GROUNDED YES. PERFORMED APU BITE TEST MX MSG NR 49 31014 APU OVERSPEED PRESENT. REF FIM 49 60 00 810 801. VERIFIED APU BITE SHOWN FAULT CODE 49 31014. ACCOMPLISHED FIM TASK 49 30 00 810 802. REPLACED APU SPEED SENSOR PER AMM 49 61 21 PB 401. APU OPS CHECK NORMAL ON GROUND. ETOPS PART VERIFICATION ACCOMPLISHED BY SEAMC JERRY.

Part: FILTER ELEMENT — POPPED (APU) · airframe 5,887 hrs · 1,767 cycles

APU LUBE FILTER ELEMENT DELTA-P EXTENDED, GROUNDED, YES. APU LUBE FILTER REMOVED AND REPLACED IAW AMM 49 91 13 MAGNETIC CHIP DETECTOR, CHK GOOD. LEAK CHECK ON MCD AND FILTER BOWL GOOD.

Part: PACKING — LOOSE (OIL CAP) · airframe 5,783 hrs · 1,740 cycles

WHILE SERVICING NR 2 ENG OIL SERVICING CAP PACKING VERY LOOSE GROUNDED YES. R&R PACKING OIL CAP P NR M83248 1 226

Part: GENERATOR — UNKNOWN (APU) · airframe 5,721 hrs · 1,727 cycles

APU GENERATORS DROPPED OFFLINE WITHOUT WARNING GROUNDED YES. NO CIRCUIT BREAKERS OPEN NO FAULTS IN COMPUTER STARTED APU SWITCHED TO APU POWER LOADED UP SYSTEM NO DEFECTS NOTED. GOOD FOR SERVICE. SEAMC BILL NOTIFIED.

Part: PCU — MALFUNCTIONED (COCKPIT) · airframe 5,721 hrs · 1,727 cycles

`ELEC` LIGHT ILLUMINATED ON OVERHEAD PANEL GROUNDED YES. TRIED TO CLEAR THE FAULT AND NO HELP. CYCLED NORMAL AND STANDBY SPCU C/B AND CLEARED FAULT REF MM FIM 24 34 00 810 802 SPCU. OPS CK GOOD.

Part: VALVE — FAULTED (RT A/C PACK) · airframe 5,646 hrs · 1,709 cycles

ON MASTER CAUTION RECALL GOT MASTER CAUTION AIR COND AND RT PACK LIGHT. IT EXTINGUISHES ON RESET GROUNDED YES. PERFORMED PACK/ZONE TEMP CONTROL BITE TEST PER FIM TASK 21-62 TASK 801. FOUND FAULT WITH TRIM CONTROL VALVE RT. R&R RT TRIM VALVE PER FIM TASK 21-62 TASK 828. CONFIRMED PROPER ETOPS PN W/ ROB. PERFORMED PACK/ZONE TEMP CONTROL TEST SECOND TIME. NO FAULTS NOTED. OK FOR ETOPS. NO LEAKS NOTED.

Part: SENSOR — FAILED (COCKPIT WINDOW) · airframe 5,529 hrs · 1,682 cycles

RIGHT SIDE WINDOW OVERHEAT CONDITION 10 MIN AFTER TAKEOFF TURNED HEAT OFF FOR 5 MINUTES PER QRH UPON TURNING HEAT ON THE OVERHEAT LAMP ILLUMINATED IMMEDIATELY. TURNED HEAT OFF FOR REMAINDER OF FLIGHT. RT SIDE WHCU FAULTS SENSOR. W/RT SIDE WINDOW HEATED FOUND PRIMARY SENSOR AT 364 OHMS. SPARE AT 352 OHMS. MAX IS 330 OHMS PER MM 30-41-21-760-801 TABLE 502. CHECK OF HEAT FILM RESISTANCE GOOD PER MM 30-41-21-000-801. VERIFIED WINDOW IS TAPPED PROPERLY REF WD 30-41-11 PG 3. REMOVED AND REPLACED R2 WINDOW.

Part: CONTROLLER — FAULTED (WINDOW HEAT) · airframe 5,524 hrs · 1,680 cycles

WHILE EN ROUTE RIGHT SIDE WINDOW OVERHEAT LIGHT CAME ON FOLLOWED QRH PROCEDURE AND OVERHEAT LIGHT CAME BACK ON BITE CHECKED WHCU CURRENT BIT PASSED. RT SIDE WHCU LOGGED SENSOR FAULT FOR PAST 7 LEGS. MEASURED RESISTANCE OF SENSOR REF MM 30 41 21 760 801 PRIMARY 320 OHM SPARE 317 OHM WITH IN LIMITS. ALSO MEASURED WINDOW HEAT FILM REF MM 30 41 21 CHECKED NORMAL. WINDOW HARNESS CHECKED NO FAULT NOTED. DUE TO HISTORY REMOVED AND REPLACED RT SIDE WHCU REF MM 30 41 11. OPS NORMAL, PART VERIFIED WITH SEAMC ROB.

Part: CONTROLLER — INTERMITTENT (WINDOW HEAT) · airframe 5,517 hrs · 1,678 cycles

WHILE EN ROUTE RIGHT SIDE WINDOW HEAT OVERHEAT LIGHT CAME ON CYCLED IT OFF PER THE CHECKLIST (AND BACK ON) BUT OVERHEAT WOULD NOT EXTINGUISH. SWITCH REMAINS OFF PER THE CHECKLIST. OPS CHECK BITE CHECK INTERMITTENT SENSOR FAULT OPS CK IAW FIM 30 41 00 810 801 30 41 00 760 801. VERIFICATION NO FURTHER FAULTS NOTED. OK FOR CONTINUED SERVICE.

Part: CONTROLLER — FAULTY (E&E BAY) · airframe 5,051 hrs · 1,546 cycles

DURING LANDING CHECK, "RIGHT PACK" LIGHT ILLUMINATED ON RECALL ACCOMPLISHED FIM TASK 21 53 810 & ZONE TEMP CONTROLLER BITE PER 21 61 00. RT CONTROLLER SHOWED PACK TEMP SENSOR FAULT. RESET & RAN PACK FOR 1 2 HOUR ON GROUND WITH NO FURTHER FAULTS.

Part: PROBE — MALFUNCTIONED (NR 1 ENGINE) · airframe 4,910 hrs · 1,508 cycles

GE DIAGNOSTICS REPORTS NR 1 ENGINE CRUISE DELTA EGT SHOWS GREATER THAN NORMAL SCATTER AND MOVEMENT. EGT INDICTION IS SUSPECT: PRI: 1 PERFORMED EGT PROBES CLEANING PER MM 77 21 00 201 PINS AND SOCKETS TENSION CHECKED NORMAL. VALUES S1 S4 PRE 205 176 176 214 POST 130 83 83 142 DURING RUN AFTER 3 MIN 380 430 415 410. NO FAULTS LOGGED.

Part: STARTER GEN — FAILED (APU) · airframe 4,812 hrs · 1,475 cycles

BLUE MAINT LIGHT ON APU ILLUMINATED. PERFORMED FIM TASK 49 40 00 810 806 CONFIRMED FAULT REMOVED AND REPLACED STARTER GENERATOR REF MM 49 41 21 OPS & LEAK CHECK GOOD. CONFIRMED FAULT CORRECTED W CDU AND FIM TASK 49 40 00 810 806.

Part: OIL FILTER — FAULTY (APU) · airframe 4,778 hrs · 1,462 cycles

WHILE ACCOMPLISHING TC 78349013 FOUND APU OIL FILTER DELTA P INDICATOR EXTENDED. REMOVED AND REPLACED APU OIL FILTER, NO CONTAMINATION NOTED. INSPECTED MAGNETIC DRAIN PLUG, NO CONTAMINATION NOTED. RAN APU FOR 15 MINS. NO LEAKS NOTED. GROUND VERIFICATION SUCCESSFUL. REF AMM'S49 91 13 & 49 91 81 & EMM 05 00 05.

Part: POSITION SENSOR — OUT OF ADJUST (SPOILER) · airframe 4,590 hrs · 1,408 cycles

AUTOPILOT HAD SPOIL 4 SIQ FAILURE INDICATION. ADJUSTED SPOILER POSITION SENSOR.

Part: PROCESSOR — FAULTED (FUEL SYS) · airframe 4,568 hrs · 1,402 cycles

DURING CRUISE DEVELOPED 1000 LBS FUEL IMBALANCE WITH ASSOCIATE "IMBAL" ANNUNCIATOR FOR NO OBVIOUS REASON. ACFT WAS NOT BALANCED, FUEL CROSS FEED CLOSED. CENTER TANK EMPTY WITH CENTER BOOST PUMPS OFF. ALL MAIN TANK PUMPS ON. LT QTY REACHED 7100 LBS RT WAS 8100 LBS. RAN QRH PROCEED REST ABLIL BAL. NO EVIDENTS OF LEAK. FUEL REMAINED IN BALANCE REST OF FLT. CROSS FEED HAD BEEN OPEN BRIEFLY LAST OF CENTER FUEL WAS USED EARLIER IN FLT. EMBALANCE LIGHT CAME ON WENT OFF NORMALLY REF FIM 28-41-00-810. FQIS HAS NO HISTORY OR CURRENT FAULTS AND BITE TEST OK. NO FAULTS IN CDS BITE AS WELL REM FIM 28-41-00-801. REF FAULT ISOLATION MANUAL 28-21-00-810-815 INITIAL EVALUATION CHECK COMPLETED WITH NO DISCREPANCY NOTED. FOUND TO BE AN INTERMITTENT FAULT. OK FOR SERVICE.

Part: OIL FILTER — ACTIVATED (IDG) · airframe 4,517 hrs · 1,386 cycles

NR 1 ENG IDG DPI FOUND EXTENDED ARCTIC VERIFIED 1ST OCCURRENCE LAST 365 DAYS. ACCOMP FIM 24 11 TASK 803. REMOVED INSP & REPLACED CHG & SCAVENGE FILTERS REF MM 24-11-41. RESET DPI LK & OPS NORMAL REF MM 24-11-41. GROUND VERIFICATION SUCCESSFUL.

Part: FMC — MALFUNCTIONED (FLT MANAGE) · airframe 4,492 hrs · 1,379 cycles

FMC DISAGREE LIGHT ILLUMINATED. ACCOMPLISHED FMC DISAGREE QRH ON THE GROUND. PERFORMED "FMC DISAGREE MESSAGE ON CDU" FIM TASK 34 61 00 810 835. GROUND VERIFCATION SUCCESSFUL.

Part: FMC — MALFUNCTIONED · airframe 4,454 hrs · 1,367 cycles

DURING CLIMB SPEED BUG DROPPED TO CLEAN SPEED WITH V NAV ENGAGED FMC READS GOOD FOR CLIMB SPEED. AT CRUISE V NAV AND BUG APPEAR TO BE WORKING OKAY. PERFORMED FMC BITE TEST PER MM 34-61-00. PERFORMED DFGS BITE TEST PER MM 22-11-00. NO FAULTS NOTED. NO HISTORY NOTED. GROUND VERIFICATION SUCCESFUL.

Part: CONTROLLER — INOPERATIVE (WINDOW HEAT) · airframe 4,413 hrs · 1,356 cycles

LT FWD WINDOW OVERHEAT LIGHT ILLUMINATED FOUND LEFT FRONT HEAT POWER C/B ON P6 11 OUT. RESET C/B REF PROCEDURE MM 20 60 01. BITE CHECK ON WHCU OPS NORMAL REF MM FIM 30 41 00 TASK 801. GROUND VERIFICATION CHECKS GOOD.

Part: FMC — FAULTED (FLT MANAGE) · airframe 4,378 hrs · 1,345 cycles

AT LIM ILLUMINATED IN FLIGHT ABOVE N1'S. AFTER LANDING DASHES ABOVE N1'S CURRENT STATUS & BITE CHECKS GOOD REF FIM 22 31 710 801 FMS CHECKS GOOD REF FIM 34 61 00 810 807 & FIM 73 00 00 810 801 F00, NO PREVIOUS HISTORY. GROUND VERIFICATION SUCCESSFUL.

Part: IDG — FAILED (NR 2 ENGINE) · airframe 4,310 hrs · 1,316 cycles

NR 2 GEN OFF BUSS LIGHT ILLUMINATED FOLLOWED SHORTLY BY NR 2 DRIVE LIGHT ILLUMINATION. DISCONNECTED DRIVE AND PUT APU ON BUSS. REMOVED AND REPLACED THE NR 2 ENG IDG REF MM 24 11 11 000 801 AND MM 24 11 11 400 801 LEAK CHECK AND OPS CHECKS GOOD REF MM 24 11 00 700 803.

Part: TRANSCEIVER — FAULTED (WX RADAR SYS) · airframe 4,120 hrs · 1,263 cycles

DURING LANDING ROLL "PWS FAIL" ILLUMINATED ON BOTH CAPT AND FO NAV DISPLAY. WEATHER RADAR OPERATED NORMAL INFLIGHT. VERIFED DISCREPANCY PWS FAIL ANNUNCIATED ON BOTH CAPT'S & FO'S DISPLAY. CYCLED WRX CB GROUND VERIFICATION TEST PASSED REF MM 34-43-00.

Part: CONTROLLER — FAULTED (CABIN PRESSURE) · airframe 4,018 hrs · 1,236 cycles

AUTO FAIL LIGHT ALONG WITH ALTN LIGHT ILLUMINATED CLEARED NUISANCE MSG FROM NR 2 PRESS CONT SYSTEM OPS CHECK NORMAL IAW AMM 21 31 00 700 802. (GROUND TEST)

Part: FMC — FAULTED (FLT MANAGE) · airframe 4,018 hrs · 1,236 cycles

UPON TAXI OUT FMC DISAGREE CAME ON BOTH FMC'S STAYED ON FOR 6-8 MINUTES AND BOTH WENT OFF AS WE TAXIED IN. FMC DISAGREE EXTINGUISHED BEFORE AIRCRAFT RETURNED TO GATE. PERFORMED FIM TASK 34-61-00-810-835 FOR PRECAUTIONARY PURPOSES. DETERMINED TO BE INTERMITTENT NUISANCE MSG. NO 30 DAY HISTORY.

Part: START VALVE — MALFUNCTIONED (NR 2 ENGINE) · airframe 3,835 hrs · 1,170 cycles

WHILE TRYING TO START ENG NR 2 MOVED START SWITCH TO GND DID NOT GET A "START VALVE OPEN" LIGHT OR N2 INDICATION COMPLETED FIM TASK 80 70 00 810 804 F00. DRY MOTORED ENGINE SUCCESSFUL, TWO ATTEMPTS NO FAULTS IN BITE CHECK RECENT OR HISTORICAL. NO HISTORY 30 DAYS IN ARCTIC. BVI OF NR 2 STARTER AND VALVE NO FAULTS NOTED PER ETOPS MANUAL E05 00 05.

Part: OIL SYSTEM — LOW (NR 1 ENGINE) · airframe 3,740 hrs · 1,140 cycles

NR 1 OIL AT 13 ADDED 4QTS OIL TO NR 1 AND 4QTS OIL TO NR 2.

Part: FMC — FAULTED (E/E BAY) · airframe 3,711 hrs · 1,124 cycles

FMC DISAGREE FLAG DISPLAYED ON TAXI OUT CONFIRMED FAULT FMC DISAGREES MONITORING PARAMETERS. RESET BOTH FMC'S AND TEST NML PER FIM 34 61 00 810 807. INSPECTION ACCOMPLISHED FOR SIMULTANEOUS MAINTENANCE.

Part: OIL SYSTEM — LOW (NR 1 ENGINE) · airframe 3,476 hrs · 1,056 cycles

NR 1 ENG QTY AT 13 NR 2 ENG QTY AT 15 SERVICED NR 1 ENG OIL TO FULL 5.5 QTS SERVICED NR 2 ENG TO FULL.

Part: CHARGER — MALFUNCTIONED (E/E BAY) · airframe 3,465 hrs · 1,051 cycles

AUX BATTERY SHOWS A 2 AMP CHARGE AND HAS NOT DECREASED TO ZERO. DC VOLTS SHOWS 27 CKD AUX BATT AND AUX BATT CHGR REF 24 31 31, OPS CKS OK WITHIN.

Part: FILTER — CLOGGED (CABIN) · airframe 3,000 hrs · 896 cycles

WITH FWD & CONT CABIN PACK CONTROLLERS IN 12:00 AFT CABIN CONTROLLER REQUIRED 4:00 POSITION TO MAINTAIN AFT CABIN TEMP AT 26 DEGS C. NO FAULTS LOGGED IN NR 1, 2 CONTROLLERS. FOUND AFT CABIN TEMP SENSOR FILTER CLOGGED. CLEANED FILTER. GROUND VERIFICATION PASSED. ACCOMPLISHED ZONE TEMP BITE CHECK. NO FAULTS LOGGED 1&2. RAN BOTH PACKS TEMP IN FWD AFT CABIN PAIRED UP AT ALL SETTINGS.

Part: MODULATING VALVE — MALFUNCTIONED (RT A/C PACK) · airframe 2,936 hrs · 880 cycles

CABIN ZONE TEMPERATURE ANNUNCIATION OCCURRED. BITE TEST INDICATED RIGHTHAND PACK TRIM MODULATING VALVE AT FAULT. RESET, OP CHECKED OK.

Part: SWITCH — FAULTY (AUTOPILOT SYS) · airframe 2,772 hrs · 825 cycles

AUTOPILOT "A" WILL NOT ENGAGE. COULD NOT GET AUTOPILOT "A" TO ENGAGE. PERFORMED DFCS BITE SHOWED MULTIPLE DISCONNECT FAILURES. FOUND F/O'S DISCONNECT SWITCH BAD. THE "A" SIDE OF SWITCH STICKS OPEN REQUIRES NUMEROUS PRESSES OF SWITCH TO CLOSE AND ENGAGE AUTOPILOT. REPLACED F/O'S AUTOPILOT DISCONNECT SWITCH. OPS NORMAL.

Part: AUTOPILOT SYS — MALFUNCTIONED (COCKPIT) · airframe 2,761 hrs · 821 cycles

THE "A" AUTOPILOT WILL NOT ENGAGE. UNABLE TO DUPLICATE. RAN LAND VERIFY TEST WITH NO FAILURES.

Part: DOOR — STICKS (L1) · airframe 2,730 hrs · 811 cycles

FLIGHT ATTENDANT REPORTS L1 IS STICKY. COULD NOT DUPLICATE PROBLEM. OPENED & CLOSED L1 DOOR SEVERAL TIMES OPERATES SMOOTHLY. OP CHECKS NORMALLY, OK FOR SERVICE.

Part: SENSE LINE — LEAKING (NR 2 ACM) · airframe 2,704 hrs · 798 cycles

WHILE WORKING RT PACK ISSUE, FOUND SENSE LINE LEAKING IN 3 SPOTS. REPLACED RT ACM SENSE LINE WITH TEMPORARY FLEX LINE. REPLACED TEMPORARY FLEX LINE WITH PERMANENT LINE.

Part: VALVE — FAULTY (A/C PACK) · airframe 2,687 hrs · 792 cycles

RIGHT "PACK" LIGHT ILLUMINATED WITH RECALL PUSHED DURING LANDING CHECKLIST, RAN CHECKLIST ON TAXI IN PACK RESET. PERFORMED FIM 21 62 TASK 801 NR 2 LOGGED "THIS PACK TCV". REPLACED RT PACK TEMP CONTL VLV. PERFORMED LEAK CHECK, NO LEAKS NOTED. PERFORMED OP CHECK, CHECKED GOOD. PERFORMED BITE CHECK, NO FAULTS NOTED.

Part: SWITCH — FAULTY (GLARESHIELD) · airframe 2,629 hrs · 779 cycles

AUTOPILOT A WILL NOT ENGAGE. CAPT'S DISCONNECT SWITCH BAD. REPLACED AND CHECKED PER MM 22 11 41, TASK 000 801, NORMAL.

Part: VALVE — MALFUNCTIONED (TEMP) · airframe 1,948 hrs · 600 cycles

AFT CABIN TEMPERATURE CONTROLLER WOULD NOT HOLD SET TEMPERATURE. REPLACED TRIM MOD VALVE.

Part: EEC — FAULTY (NR 2 ENGINE) · airframe 1,736 hrs · 540 cycles

DURING TASKCARD 78273000 NR 2 ENGINE FAULT 73 20012 WAS FOUND. REPLACED NR 2 EEC (REF 73 21 60 PG 401 408 & MM SUPP 73 21 60 PG 401&408). ALL OP CHECKS GOOD. NO FAULTS.

Part: EEC — FAULTY (NR 1 ENGINE) · airframe 1,463 hrs · 468 cycles

NR 1 ENGINE SHOWS EEC FAULT CODE 73 20011 AS A CURRENT SHORT TERM FAULT. REPLACED EEC AND UPLOADED NEW SOFTWARE. NR 1 ENGINE EEC SYSTEM TEST PASSED.

Part: KNOB — LOOSE (ALTITUDE SELECT) · airframe 1,351 hrs · 437 cycles

SELECTOR KNOB ON ALTITUDE SELECT MCP IS LOOSE. TIGHTENED LOOSE KNOB.

Part: ANTENNA — INTERMITTENT (WX RADAR) · airframe 1,136 hrs · 383 cycles

WITH WX SELECTED WEATHER RADAR DISPLAYS RETURN ON LEFT SIDE OF SCREEN WITH GREATER INTENSITY THAN ON RIGHT SIDE AS IF THE ANTENNA IS TILTED TO LEFT. ALSO TWO GHOST RETURNS ABOUT 2 MILES LEFT AND RIGHT AHEAD OF ACFT POSTION. ALL GAIN LEVELS. ACCOMPLISHED WXR SYSTEM OPERATIONAL TEST NO DISCREPANCIES. ACCOMPLISHED FIM 34 43 TASK 814, NO FAULTS. REPLACED WXR ANTENNA ASSY PRECAUTIONARY.

Part: SWITCH — FAULTY (AUTOPILOT SYS) · airframe 967 hrs · 329 cycles

THE "A" AUTO PILOT WILL NOT ENGAGE. FFR SHOWS CHANNEL AAP DISCONNECT SWITCH INPUT INVALID. REPLACED S231 SWITCH IAW 22-11-41.

Part: PRESSURE SWITCH — INTERMITTENT (FUEL BOOST)

LEFT MAIN FUEL TANK AFT FUEL PUMP LIGHT IS ON INTERMITTENTLY WITH THE SWITCH IN THE ON POSITION. REPLACED NR 1 AFT FUEL BOOST PUMP PRESSURE SWITCH.

Part: PUMP — LOW PRESSURE (NR 1 FUEL TANK) · airframe 853 hrs · 297 cycles

NR 1 AFT MAIN FUEL PUMP LOW PRESSURE LIGHT ILLUMINATED AT CRUISE WITH ALL 6 PUMPS ON. PUMP WAS TURNED OFF & LEFT OFF PER QRH. VERIFIED PUMP, OPS NORMAL DURING FUEL TRANSFER (FIM 28 77 802).

Part: PUMP — LOW PRESSURE (NR 1 FUEL TANK) · airframe 814 hrs · 287 cycles

NR 1 AFT FUEL LOW PRESSURE LIGHT ILLUMINATED ON DESCENT. LIGHT WAS ON DIM, WENT BRIGHT WHEN PUMP TURNED OFF. 3,900LBS OF FUEL IN TANK. PERFORMED FIM TASK 28 22 TASK 803. NO FAULTS FOUND. SUMPED NR 1 TANK, NO WATER FOUND. INSPECTED CONNECTOR ON PRESSURE SWITCH, NO DAMAGE FOUND.

Part: CONTROL UNIT — INOPERATIVE (E&E BAY) · airframe 799 hrs · 282 cycles

ELECT WARNING LIGHT ON OVERHEAD PANEL ILLUMINATED. BITE TEST SHOWS SPCU INOP. REPLACED SPCU, OP CHECKS NORMAL.