N604DL

Part: DOOR FRAME — DAMAGED (FUSELAGE) · airframe 84,078 hrs · 42,660 cycles

FASTENER HOLES ELONGATED IN FWD AND AFT FRAME OF CARGO DOOR CUTOUT.

Part: PILOT VALVE — FAILED (BLEED AIR SYS) · airframe 83,486 hrs · 42,422 cycles

FLIGHT RETURNED TO ATL DUE TO A LOSS OF CABIN PRESSURE. FLIGHT CREW ALSO REPORTED AN ELECTRIC SMELL AND SMOKE. CABIN OXYGEN MASKS WERE DEPLOYED. MAINTENANCE FOUND THE HIGH STAGE PILOT VALVE FAILED AND REPLACED IT. OXYGEN GENERATORS WERE REPLACED AND THE OXYGEN MASKS WERE CLEANED AND STOWED. ALL OPERATIONAL CHECKS WERE GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 82,763 hrs · 42,157 cycles

DURING A LAYOVER CHECK, MAINTENANCE FOUND THE FIRST CLASS SEATING EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REPLACED THE POWER SUPPLY. OPERATIONAL CHECK WAS GOOD.

Part: SKIN — CORRODED (FUSELAGE) · airframe 79,697 hrs · 40,816 cycles

OUTER FUSELAGE SKIN CORROSION OF AFT LAV PAN. REPAIRED AREA IAW ERA 483097-14, REV A, TIME LIMITED REPAIR.

Part: WIRE HARNESS — INOPERATIVE (EMERGENCY LIGHT) · airframe 79,310 hrs · 40,636 cycles

DURING AN A-CHECK, MX FOUND THE EMERGENCY PATH LIGHT AT SEAT 20DEF INOPERATIVE. MX REPLACED THE WIRING HARNESS. OPS CHECK WAS GOOD.

Part: WIRE — DAMAGED (CABIN) · airframe 79,179 hrs · 40,568 cycles

SEAT 4 C/D EMERGENCY EXIT SEAT LIGHT OUT. REPAIRED WIRING AND REPLACED M9101 EMERGENCY BATTERY BASE HOUSING CHECK GOOD PER MM.

Part: FAILSAFE — CORRODED (FS 900) · airframe 75,684 hrs · 38,741 cycles

FOUND FAILSAFE STRAP ON THE RT SIDE OF THE FS 900 BULKHEAD CORRODED. REMOVED AND REPLACED DAMAGED STRAP PER BLUEPRINT.

Part: FLAP TRACK — CORRODED (T/E FLAP) · airframe 75,684 hrs · 38,741 cycles

CORROSION ON MOUNT SURFACE OF NR 2 FLAP TRACK. DAMAGE WAS MACHINED AND RE-FINISHED.

Part: FRAME — CORRODED (BS 1661 S26-28R) · corrosion level 2 · airframe 71,216 hrs · 36,748 cycles

FOUND CORROSION IN AFT CARGO PIT LWR FRAME FWD FACE AT BS 1661 FROM S-26L TO S-28R. REPAIRED BY FABRICATING AND INSTALLING 3 SHEAR TIES 1.5 BY 4", 4" BY 4", 7.5" BY 3" FROM 7075-T6 .050 AND ONE 4.5" BY 5" FROM 7075-T6 .071 AND REPAIR DOUBLER 20 BY 6 FROM 7075-T6 .063" IAW BOEING DWG 146N1032 AND 140N202, DPS 900-2 NR 5, B757 SRM 53-00-07, 51-10-02, 51-40-02, 51-40-02, AND 51-20-01.

Part: FRAME — CORRODED (BS 1645 S27L) · corrosion level 2 · airframe 71,216 hrs · 36,748 cycles

FOUND CORROSION IN AFT CARGO PIT ON WASTE DRAIN LINE BOX FRAME AFT I/B CORNER BS 1645 S-27L. REPAIRED BY FABRICATING AND INSTALLING NEW INTERCOSTAL 21 BY 4.5 FROM, STRINGER REPAIR 39 BY 3 FROM BAC1498-204 7075-T62, STRINGER SPLICE 10 BY 3 FROM BAC1498-204 7075-T62, ATTACH ANGLE 5 BY 2 FROM 2024-T3 .063 AND WATER PAN P/N 146N3641-44 IAW BOEING DWG NR 146N3641 AND DPS 900-2 NR 5, B757 SRM 51-10-02, 51-40-02, 51-20-01, 51-20-05, 53-10-04, 53-00-03, 51-30-01 PG 8, AND 51-40-05.

Part: SKIN — DENTED (BS 1480-1500) · airframe 71,216 hrs · 36,748 cycles

FOUND EXTERNAL LOWER FUSELAGE SKIN BUCKLED AT S-26L AND BETWEEN BS 1480 TO 1500. REPAIRED BY CUTTING OUT BUCKLED/DENTED AREA, FABRICATED AND INSTALLED 2 REPAIR DOUBLERS 5 BY 5 FROM 2024-T3 .063 IAW DELTA SRM 53-00-01 FIG 101, 53-00-01 FIG 201, 51-10-02 PG 7 AND 51-40-02.

Part: SHEAR TIE — CORRODED (BS 1460) · corrosion level 2

FOUND CORROSION IN AFT PIT ON SHEAR CLIP AT BS 1460 S-25, 26R. REPAIRED BY REMOVING SHEAR CLIP, FABRICATING AND INSTALLING SHEAR CLIP 1 BY 1 BY 8 FROM 7075-T6 .050 IAW B757 SRM 53-00-07, 51-20-01, 51-40-02.

Part: SHEAR TIE — CORRODED (BS 1280) · corrosion level 2

FOUND CORROSION IN AFT PIT SHEAR TIE AFT SIDE BS 1280 S-28 - S-29L. REPAIRED BY FABRICATING AND INSTALLING SHEAR TIE 6 BY 2 FROM 7075-T6 .063 IAW B757 SRM 53-00-07, 51-40-2 AND 51-20-01.

Part: STRINGER — CORRODED (BS 1530 S28L) · corrosion level 2

FOUND CORROSION AFT PIT S-28L AT BS 1530 LT. REPAIRED BY CUTTING OUT CORRODED SECTION, FABRICATED AND INSTALLED REPAIR SPLICE 8.5 BY .090 FROM BAC1498-204 T62 EXTRUSION IAW B757 SRM 53-00-53, 51-20-01 AND 51-40-02.

Part: FITTING — CORRODED (BS 1400-1420) · corrosion level 2

FOUND CORROSION IN AFT PIT ON LOWER C2 DOOR SILL AREA FITTINGS AT BS 1400 AND 1420 S-27R. REPAIRED BY REMOVING AND REPLACING 2 FITTINGS P/N 69-45579-29 AND 2 P/N 69-45579-30 IAW B757 SRM 51-40-02 AND 51-20-01.

Part: STRINGER — CORRODED (BS 1460 S29L) · corrosion level 2

FOUND CORROSION AROUND RIVET IN AFT CARGO PIT JUST FWD OF BS 1460 AT S-29L. REPAIRED BY REMOVING AND REPLACING FABRICATED STRINGER SPLICE 12 BY 3 FROM 7075-T6 .090 IAW B757 SRM 53-00-02, 51-20-01 AND 53-60-03.

Part: STRINGER — CORRODED (BS 1500-1520) · corrosion level 2

FOUND CORROSION AFT PIT S-29R AT BS 1500 TO BS 1520 RT. REPAIRED BY CUTTING OUT CORRODED SECTION, FABRICATED AND INSTALLED REPAIR SPLICE 8.5 BY 3 .090 FROM BAC1498-204 EXTRUSION IAW B757 SRM 53-00-53, 51-20-01 AND 51-40-02.

Part: PLATE — CORRODED (LT WING) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND LT WING TANK PLATE 541EB CORRODED. REPAIRED BY REMOVING AND REPLACING WITH P/N 112N6101-1 IAW DELTA JOB CARD OPN 3512.

Part: PLATE — CORRODED (RT WING) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND RT WING TANK PLATE 641EB CORRODED. REPAIRED BY REMOVING AND REPLACING WITH P/N 10-60031-83 IAW DELTA JOB CARD OPN 3612.

Part: SHEAR TIE — CORRODED (BS 1260) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION ON AFT PIT LWR ANGLE AND SHEAR TIE BS 1260 FWD SIDE OF MAIN FRAME BETWEEN S-28R AND S-29R. REPAIRED BY REMOVING CORRODED SHEAR TIE AND INSTALLING NEW SHEAR TIE P/N 140N2006-103 IAW B757 SRM 51-20-01 AND 51-40-02. FABRICATED AND INSTALLED SHEAR ANGLE 6 BY 22 FROM BAC1505-100962 IAW B757 DRAWING NR 140N2006.

Part: STRINGER — CORRODED (BS 1500-1520) · corrosion level 2

FOUND CORROSION IN AFT PIT S-29L O/B SIDE FROM BS 1500 TO BS 1520 LT. REPAIRED BY FABRICATING AND INSTALLING REPAIR DOUBLER 8 BY 3 BY FROM 7075-T6 .090 IAW 51-20-01, 53-40-02 AND 53-00-03.

Part: TORQUE TUBE — CORRODED (TE FLAP) · corrosion level 2

FOUND CORROSION INSIDE RT I/B T/E FLAP FAIL/SAFE TORQUE TUBE. REPAIRED BY REMOVING AND REPLACING TORQUE TUBE ASSY P/N 113N2106-1AND I/B AND O/B CARRIAGE HALVES IAW B757 AMM 27-51-05 AND DELTA EA 06-097981-14 REV A .

Part: FLOORBEAM — CORRODED (BS 324) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION AT FWD CABIN FLOORBEAM UPPER SURFACE BS 324 B/O RBL 50. REPAIRED BY REMOVING CORRODED T CAP, FABRICATED AND INSTALLED NEW T CAP 72 BY 3 BY 2 FROM AND10136-2409 EXTRUSION IAW B757 SRM 51-40-05, AND 53-10-08D.

Part: TORQUE TUBE — CORRODED (TE FLAP) · corrosion level 2

FOUND CORROSION INSIDE LT I/B T/E FLAP FAIL/SAFE TORQUE TUBE. REPAIRED BY REMOVING AND REPLACING TORQUE TUBE P/N 113N2108-1 AND 2 FITTINGS I/B AND O/B IAW B757 AMM 27-51-05 AND DELTA EA 06-097981-14 REV A.

Part: PLATE — CORRODED (RT WING) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND RT WING TANK PLATE 641JB CORRODED. REPAIRED BY REMOVING AND REPLACING WITH P/N 10-60031-83 IAW DELTA JOB CARD OPN 3612.

Part: PLATE — CORRODED (RT WING) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND RT WING TANK PLATE 641DB CORRODED. REPAIRED BY REMOVING AND REPLACING WITH P/N 10-60031-83 IAW DELTA JOB CARD OPN 3612.

Part: PLATE — CORRODED (RT WING) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND RT WING TANK PLATE 641AB CORRODED. REPAIRED BY REMOVING AND REPLACING WITH P/N 10-60031-83 IAW DELTA JOB CARD OPN 3612.

Part: PLATE — CORRODED (RT WING) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND RT WING TANK PLATE 641MB CORRODED. REPAIRED BY REMOVING AND REPLACING WITH P/N 10-60031-83 IAW DELTA JOB CARD OPN 3612.

Part: PLATE — CORRODED (RT WING) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND RT WING TANK PLATE 641FB CORRODED. REPAIRED BY REMOVING AND REPLACING WITH P/N 10-60031-83 IAW DELTA JOB CARD OPN 3612.

Part: SHAFT — CORRODED (L2 DOOR) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION ON L-2 DOOR LOWER HINGE ARM SHAFT INTERNAL UPPER NUT RUSTED. REPAIRED BY INSTALLING NEW UPPER AND LOWER BEARINGS. INSTALLED NEW LOWER HINGE ARM P/N 140N2651-49 IAW B757 CCM 52-11-15 AND SOPM 20-50-03.

Part: FLOORBEAM — CORRODED (CORRODED) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION AT CABIN FWD FLOORBEAM UPPER SURFACE AROUND NUTPLATE HOLES AT BS 345 B/L 0 RBL 56. REPAIRED BY REMOVING CORROSION, FABRICATED AND INSTALLED REPAIR SECTION 32-1/2 FROM BAC1505-100617 IAW B757 53-00-51, 51-20-01 AND 51-10-2.

Part: FLOORBEAM — CORRODED (CORRODED) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION AROUND HOLES AT BS 345 LBL 6 AND LBL 12 W/L 0 AROUND 2 HOLES AND B/L, TO RBL 56. REPAIRED BY REMOVING CORROSION, FABRICATED AND INSTALLED REPAIR SECTION 32-1/2 FROM BAC1505-100617 IAW B757 53-00-51, 51-20-01, 51-10-2 AND DRD 53-10-51D.

Part: SHEAR TIE — CORRODED (BS 1400) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION IN AFT PIT ON SHEAR CLIP (AFT SIDE) BS 1400 S-29L AND S-30. REPAIRED BY REMOVING SHEAR CLIP. FABRICATED AND INSTALLED NEW SHEAR TIE FROM 7075-T6 .063 4.7" BY 1.2" IAW B757 SRM 51-40-02 BOEING DWG 146N1011 AND 146N1603.

Part: SKIN — DENTED (BS 418 S16L) · airframe 71,216 hrs · 36,749 cycles

FOUND DENT IN EXTERIOR SKIN AT BS 418 S-16L. REPAIRED BY IAW B757 SRM 53-00-01 FIG 207 BY CUTTING OUT DENTED SKIN. HFEC CUTOUT, NO CRACKS INDICATED. FABRICATED AND INSTALLED DOUBLER 12" BY 7" FROM 2024-T3 .071 AND FILLER FROM 2024-T3 .063 IAW B757 DELTA SRM 53-00-01 FIG 201, 53-10-01 FIG 1, 51-20-01.

Part: ROD END — CORRODED (L1 DOOR) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION ON L-1 DOOR RUST ON LATCH CONTROL ROD, 2 ROD ENDS. REPAIRED BY REMOVING AND REPLACING ROD ENDS WITH P/N 140N2725-9 IAW BOEING CMM 52-11-07.

Part: BEARING — CORRODED (L2 DOOR) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION ON L-2 DOOR, RUST ON FWD AND CRANK ROD, ROD END. REPAIRED BY REMOVING AND REPLACING ROD END WITH P/N 60B10024-4 IAW BOEING SOPM 20-50-03.

Part: ROD END — CORRODED (R1 DOOOR) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION ON R1 DOOR INTERNAL UPPER END CENTER CONTROL ROD WITH RUSTED ROD END. REPAIRED BY REMOVING AND REPLACING ROD END WITH P/N 10-60779-8A IAW BOEING CMM 52-11-05.

Part: ROD — CORRODED (R1 DOOR) · corrosion level 2 · airframe 71,216 hrs · 36,749 cycles

FOUND CORROSION ON R-1 DOOR LOWER GATE GIRT BAR CRANK PUSH ROD. REPAIRED BY REMOVING CORRODED ROD, ADJUSTED AND INSTALLED NEW ROD P/N 140N2751-4 ON GIRT BAR MECHANISM IAW CMM 52-11-05.

Part: FRAME — GOUGED (FS 1720 S25L-25R) · airframe 70,814 hrs · 36,596 cycles

REPLACEMENT FUSELAGE CHORD SECTIONS WERE FABRICATED TO REPLACE DAMAGED FRAME SECTIONS. REPLACEMENT PARTS WERE MADE AND INSTALLED.

Part: BULKHEAD — DAMAGED (BS 1720) · airframe 70,814 hrs · 36,596 cycles

DURING WALK AROUND, THE FLIGHT CREW FOUND DAMAGE TO THE TAIL AREA STA 1720 BY THE P-DOME FERRY A/C TO ATL. REPAIRED P-DOME LOWER WEB.

Part: ENGINE — MALFUNCTIONED (NR 2) · airframe 70,002 hrs · 36,223 cycles

ON T/O ROLL RT ENG OIL PRESS LIGHT FLICKERED FOLLOWED BY OIL QTY DROPPING TO 3 AND RT ENG OIL PRESS LIGHT ILLUMINATED, ABORTED T/O AT 90-100 KTS/ T/S OIL PRESS SYSTEM REPLACED RT ENG MAIN OIL PRESS T.X. AS PRECAUTION. OPS CHECKS AND LEAK CHECK GOOD. DRAINED NR 1 AND NR 2 ENG GEARBOXES AND CHECK FOR EXCESSIVE OIL. APPROX 1 QT EA ENG. PERFORMED TEST 11 MA OIL PRESS TX ON BOTH ENGS IAW M/M. NO PROBLEMS FOUND.

Part: WINDOW — CRACKED (COCKPIT) · airframe 68,885 hrs · 35,827 cycles

FLIGHT DIVERED TO DEN WITH CRACKED L1 WINDOW. INSTALLED NEW CONTROLLER, NEED OP CK AND BITE. REMOVED AND REPLACED L1 WINDOW PER MM. WILL REQUIRE 3RD TORQUE. WIN HEATING SYS CK. WIPER OP CK AND WINDOW HEAT CONTROLLER BITE OK. ALL CK GOOD. APPLIED FINAL TORQUE PER MM.

Part: SCAVENGE PUMP — FAILED (LT ENGINE) · airframe 68,127 hrs · 35,567 cycles

DURING FLT AT 41,000 FT LEFT ENGINE OIL TEMP WAS IN AMBER BAND. OIL TEMP THEN WENT TO RED BAND, FOLLOWED ENGINE SHUTDOWN LIST PER QRH. DIVERTED FLT TO LAS. REPLACED SCAVENGE PUMP AND INTERNAL LUBE PUMP. REPLACED EJECTOR PUMP. RAN ENGINE AT T/O PER PFHB. NO FAULTS NOTED, NO LEAKS DURING LEAK CHECK.

Part: UPLOCK SENSOR — MALFUNCTIONED (MLG) · airframe 66,124 hrs · 34,822 cycles

AFTER TAKEOFF, GEAR DISAGREE ON EICAS ILLUMINATED ALONG WITH GEAR LIGHT ABOVE HANDLE. RETURNED TO CVG WHEN GEAR LOWERED ALL INDICATIONS RETURNED TO NORMAL. FOUND FAULT CARD ON SYS 2 069 ON PSEU. REPLACED PSEU PER M/M CHKS GOOD. GEAR SWING CKS OK. REPLACED RT GEAR UP SENSORS S10069 AND S10239. SWUNG GEAR SEVERAL TIMES OPS NORMAL EACH TIME. NO EICAS MSG, NO FAULTS ON PSEU AFTER GEAR SWING.

Part: BATTERY PACK — INOPERATIVE (EMERGNECY LIGHT) · airframe 61,340 hrs · 33,002 cycles

FOUND ON LAYOVER, F/C RIGHT UPPER EMERGENCY LIGHTS AND R1 EXIT LIGHT INOP. REPLACED POWER SUPPLY.

Part: SKIN — DENTED (FUSELAGE) · airframe 61,005 hrs · 32,890 cycles

THE FUSELAGE SKIN WAS FOUND DENTED BETWEEN FS 627 & 639 AND BETWEEN STRINGERS 15L & 16L. THE DAMAGE WAS REMOVED WITH A 9 X 12.5 INCH CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER ER/A 385913-14, REV A.

Part: ANTENNA — FAILED (WX RADAR SYS) · airframe 59,548 hrs · 32,287 cycles

WX RADAR FAIL DISPLAYED ON HSI. WX RADAR TEST DISPLAYS ANT FAIL ON HSI AND ON WX RADAR INDICATOR. DIVERTED TO MCO. REPLACED RADAR ANTENNA AND TRANCEIVER PER MM, OPN TEST NORMAL.

Part: FRAME — CRACKED (FS 560, S-22R) · airframe 59,372 hrs · 32,205 cycles

THE INNER STRUCTURE AND WEB OF THE C1 DOOR CUTOUT FWD FRAME AT FS 560 WERE FOUND CRACKED BETWEEN STRINGERS 21R & 22R. THE CRACKS ARE TYPICAL OF AD 2002-24-02 AND BAC S/B 757-53A0080.THE OUTER CHORD WAS DAMAGED DURING THE REPAIR. ALL CRACKS AND DAMAGES WERE TRIMMED OUT. THE CHORDS WERE REPAIRED WITH ALUMINUM REPAIR ANGLES AND THE WEB WITH A DOUBLER. THEREPAIRS WERE ACCOMPLISHED PER ER/S 384900-14AD.

Part: CIRCUIT BREAKER — FAILED (E/E BAY) · airframe 58,313 hrs · 31,703 cycles

C/B "VIDEO SYS AC UTILITY" IN E/E COMPARTMENT FUSED CLOSED. ALSO ALL 5 VIDEO MONITOR C/B'S POPPED AND WON'T RESET. CAUSING C/B TO CATCH ON FIRE. REPLACED C/B AND RELAY.

Part: SEAT — BROKEN (CABIN) · airframe 58,053 hrs · 31,563 cycles

SEAT FRAME BROKE ON TOURIST SEAT 22DEF ON TAKEOFF IN PHL. REPLACED SEAT.

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 57,251 hrs · 31,143 cycles

EMERGENCY LIGHT OUTSIDE OF L-2 DOOR INOP. RELAMPED EMERGENCY LIGHT, CHECK GOOD.

Part: BULB — BURNED OUT (RIGHT FUSELAGE) · airframe 55,502 hrs · 30,253 cycles

DURING LAYOVER INSP FOUND R3 DOOR OUTSIDE EMERG LIGHT INOP. RELAMPED, OPS CHECKS OK. AIRCRAFT LOC DNTC. TAYLOR

Part: LIGHT — DAMAGED (CABIN) · airframe 55,211 hrs · 30,110 cycles

LIGHT ASSY DAMAGED. REPLACED LIGHT ASSY.

Part: LIGHT — BURNED OUT (CABIN) · airframe 53,709 hrs · 29,426 cycles

BURNING SMELL BY AFT GALLEY JUMPSEAT READING LIGHT. LIGHT WAS TURNED OFF AND SMELL DISSIPATED. INSPECTED SWITCH ASSY LIGHT ASSY WIRES AND ALL ATTACHING PIECES FOR CONDITION AND SECURITY. NO DEFECTS FOUND. INSPECTED BULB. FOUND BULB AT END OF SERVICE LIFE. FOUND ADJACENT BUGEYE HOSE LOOSE IN CEILING. REATTACHED HOSE. REBULBED AND OPERATED LIGHT. NOW CKS OKAY.

Part: SKIN — GOUGED (FUSELAGE) · airframe 53,249 hrs · 29,209 cycles

THE FUSELAGE SKIN WAS FOUND WITH SEVERAL DENTS AND GOUGES AROUND THE LOWER PORTION OF THE R4 DOOR CUTOUT. THERE WERE ALSO SEVERAL EXISTING REPAIRS IN THE AREA. TO REMOVE THE DAMAGE AND ELIMINATE THE EXISTING REPAIS, THE ENTIRE SKIN PANEL WAS REMOVED. A NEW SKIN PANEL WAS INSTALLED PER ER/A 380033-14.

Part: SKIN — DENTED (FUSELAGE) · airframe 53,249 hrs · 29,209 cycles

THE FUSELAGE SKIN AND UNDERLYING BUTT SPLICE STRAP WERE FOUND DENTED AT FS 297 BELOW STRINGER 17L. THE DAMAGED AREA OF SKIN WAS REMOVED WITH A CUTOUT AND THE BUTT SPLICE STRAP WAS CUT NEAR WL 216 AND A NEW SECTION INSTALLED. THE SKIN WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND THE NEW BUTT STRAP WAS SPLICED TO THE ORIGINAL WITH AN ALUMINUM DOUBLER PER ER/A 380006-14, REV A.

Part: SILL — CORRODED (FUSELAGE) · airframe 53,249 hrs · 29,209 cycles

THE C1 DOOR OPENING LOWER SILL WAS CORRODED, REQUIRING REPLACEMENT OF THE SILL OUTER CHORD. TO FACILITATE INSTALLATION OF A NEW CHORD, THE FS 620 CLOSING FRAME OUTER CHORD AND WEB WERE CUT BETWEEN STRINGERS 25R & 26R AND A SECTION TEMPORARILY REMOVED FOR ACCESS. THE SECTIONS WERE REINSTALLED WITH ALUMINUM ANGLE CHORD SPLICES AND AN ALUMINUM DOUBLER WEB SPLICE INSTALLED PER ER/A 380263-14.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 53,249 hrs · 29,209 cycles

THE UPPER CAP OF THE FS 1681 FLOOR BEAM WAS FOUND WITH NUMEROUS AREAS OF CORROSION ALONG ITS LENGTH. THE UPPER CAP WAS TRIMMED OFF ALONT ITS FULL LENGTH FROM LBL 60 TO RBL 60. A NEW CAP WAS FABRICATED FROM AN ALUMINUM EXTRUSION AND INSTALLED PER ER/A 380020-14, REV A.

Part: DOOR FRAME — CORRODED (FUSELAGE) · airframe 53,249 hrs · 29,209 cycles

IN ORDER TO REPLACE A CORRODED C2 DOOR SILL CHORD, THE FS 1440 OPENING FRAME WAS CUT AND REMOVED BETWEEN THE LOWER DOOR SILL AND STRINGER 26R. THE FRAME CHORDS WERE SPLICED WITH ALUMINUM REPAIR ANGLES AND THE WEB WITH AN ALUMINUM DOUBLER. THE REPAIR WAS ACCOMPLISHED PER ER/A 379988-14, REV A.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 53,249 hrs · 29,209 cycles

DOUBLER REPAIR AT HMV, AND EXISTING REPAIR DOUBLER WAS REMOVED FROM THE VHF ANTENNA CUTOUT AREA BETWEEN FS 720 & 740 AND BETWEEN STRINGERS 28L & 28R. THE CUTOUT AND FASTENER HOLES WERE HFEC INSPECTED TO ENSURE NO CRACKS. THE BAC S/B 757-53A0053MOD DOUBLER WAS INSTALLED WITH DEVIATIONS TO ACCOUNT FOR THE PREVIOUS REPAIR. THE MOD/REPAIR WAS ACCOMPLISHED PER ER/A 379686-14, REV B.

Part: DOOR FRAME — CORRODED (CARGO DOOR) · airframe 53,249 hrs · 29,209 cycles

ADDITIONAL DAMAGE FOUND AT EXISTING REPAIR ON C-2 DOOR SURROUND AFT FRAME INNER CHORD. EXISTIND REPAIR WILL BE REMOVED AND REPLACED WITH A NEW REPAIR SCHEME. THIS ER/A SUPERCEDED BY ER/A 379988-14.

Part: FITTING — TOOL DAMAGE (NR 1 PYLON) · airframe 53,249 hrs · 29,209 cycles

NR 1 PYLON / NACELLE ATTACH SUPPORT SIDE LINK FITTING MISDRILLED HOLE AT NR 2 ATTACH HOLE THROUGH SIDE LINK FITTING, WING LOWER SKIN AND WING FRONT SPAR LOWER CHORD.

Part: SKIN — GOUGED (FUSELAGE) · airframe 53,249 hrs · 29,209 cycles

THE FUSELAGE SKIN WAS FOUND DENTED AND GOUGED BETWEEN FS 519& 531 AND BETWEEN STRINGERS 27L & 28L. THE DAMAGED WAS REMOVED WITH A 10.5 INCH X 4 INCH CUTOUT IN THE SKIN. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 380176-14, REV A.

Part: SKIN — DENTED (FUSELAGE) · airframe 53,249 hrs · 29,209 cycles

THE FUSELAGE SKIN WAS FOUND DENTED AT FS 1598 JUST BELOW THE STRINGER 20L SKIN LAP SPLICE. THE DENT WAS REMOVED WITH A CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 380096-14, REV B.

Part: SMOKE DETECTOR — INOP (CARGO COMPT)

IMMEDIATELY AFTER TAKEOFF OUT OF RDU, RECEIVED A SMOKE CAUTION LIGHT ON EQUIP COOLING PANEL. STATUS MESSAGE OVERBOARD EXHAUST VALVE OPEN AND LEFT RECIRC FAN INOP LIGHT. CREW ELECTED TO RETURN TO RDU. CONTRACT MTC FOUND BAD SMOKE DETECTOR. REPLACED DETECTOR AND ALL CHECKED GOOD.

Part: SYMBOL GENERATOR — MALFUNCTIONED (E & E COMPT)

DURING T/O ROLL CREW LOST ALL PRIMARY FLIGHT INSTRUMENTS, BOTH EADI'S AND BOTH EHSI'S. FLIGHT CREW ELECTED TO REJECT TAKEOFF AT 90 KTS. ALL INDICATIONS RETURNED TO NORMAL WITHIN 5 SECS. CONTRACT MAINTENANCE INSPECTED AIRCRAFT AND TESTED ALL SYMBOL GENERATORS WITH NO TROUBLE FOUND.

Part: EXTINGUISHER — DEPLETED (AFT LAV)

LAV AFT LEFT H2O EXTINGUISHER USED, CONT NR C05229076. REPORTED VIA ACARS AND DISPATCHER TO MTC. F/A SUSPECTED PASSENGER SMOKING IN AFT LEFT LAVATORY AND USED H2O BOTTLE. REPLACED H2O EXTINGUISHER AND SMOKE DETECTOR.

Part: SLIDE — DISCHARGED (R1 DOOR)

DURING GROUND SERVICING, R-1 DOOR SLIDE FELL OUT OF HOLDER DUE TO FLIGHT ATTENDENT NOT DISARMING DOOR SLIDE AND DOOR WAS OPENED FROM OUTSIDE BY CATERING. THE OUTSIDE HANDLE DID NOT DISARM THE DOOR EITHER. THE DOOR DISARM CABLE WAS RIGGED PER MAINTENANCE MANUAL AND NEW SLIDE AND DOOR ASSIST BOTTLE WAS REPLACED.

Part: BATTERY — DISCHARGED (MID GALLEY)

EMERGENCY FLASH LIGHT BATTERY LOW. REPLACED BATT.

Part: TE WEDGE — DELAMINATED (NR 7 LE FLAP)

T/E DELAMINATED, REPLACED WEDGE PER SRM 57-43-02. FOUND DURING SHOP INSPECTION FOR NR 7 SLAT.

Part: TERMINAL — BURNED (P6-3 PANEL)

DURING L/O, FWD EQUIP COOLING FAN C/B POPPED WITH NUMEROUS UNASSOCIATED MTC AND STATUS MSGS. FOUND TERMINAL STRIP TB5012 IN P6-3 PANEL AND BOTH TERMINALS NR 1 PHASE WIRE BURNED. REPLACED TB5012 AND COVER WITH MFG P/N MS27212-3-3 AND MS18029-353. REPLACED WIRE TERMINALS. ALL CHECKS NORMAL.

Part: TE WEDGE — CRACKED (NR 5 LE FLAP)

THE UPPER SKIN OF THE TRAILING EDGE WEDGE OF THE NR 5 L/E SLAT IS DELAMINATED AT ISS 109.00. THE DELAMINATION MEASURES 1 INCH ALONG THE EDGE OF THE PANEL AND PROGRESSES 0.25 INCH FORWARD FROM THE EDGE OF THE PANEL. DAMAGE FOUND AT LETTER CHECK, REPAIRS WERE ACCOMPLISHED PER DL ERA 301604-14AD.