N609DL

Part: DOOR — LACK OF LUBE · airframe 93,615 hrs · 43,540 cycles

DOOR CLOSED AND COULD NOT ARM. REMOVED AND REINSTALLED SLIDE LUBED DOOR.

Part: CONNECTOR — DAMAGED (EMERGENCY LIGHTS) · airframe 91,904 hrs · 42,932 cycles

EMERGENCY LIGHTS TEST RT SEATS 38 AND AFT WILL NOT COME ON. REPLACED POWER SUPPLY M9102 AND BATTERY PACK. REPLACED ADT LT EMERGENCY TEST SWITCH ABOVE LT PASS DOOR. REPAIRED GROUND WIRE CONNECTOR ON S10295-AFT EMERGENCY LIGHT TEST SWITCH. EMERGENCY LIGHTS TEST NORMAL. WDM 33-51.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 91,626 hrs · 42,848 cycles

ON SERVICE CHECK FOUND EMERGENCY LIGHTS FROM ROW 38AFT INOPERATIVE. FOUND BATTERY PACK FAILURE. REPLACED BATTERY PACK CHECKED NORMAL IAW AMM 33-52.

Part: STRUCTURE — DAMAGED (THRUST REVERSER) · airframe 91,422 hrs · 42,774 cycles

NR 1 ENGINE OTBD THRUST REVERSTER T/E HAS LIGHTNING DAMAGE. BETWEEN 630 AND 830. REPAIRED IAW SRM SRM 54-31-01.

Part: SKIN — DAMAGED (BS 1190) · airframe 91,422 hrs · 42,774 cycles

LIGHTNING STRIKE AT BS 1190, 2 INCHES BELOW STRINGER 9L. REPAIRED IAW SRM 53-00-01.

Part: SKIN — DAMAGED (BS 382 S17R) · airframe 91,171 hrs · 42,687 cycles

FOUND SKIN DAMAGE AT RT SIDE OF ACFT STRINGER 17, STATION 382. BURNISHED GOUGE IAW SRM 53-00-01. HFEC INSPECTED BURNISHED AREA IAW SRM 53-00-01. NO CRACKS INDICATED. FINISHED REPAIR SRM 53-00-01.

Part: STRUCTURE — PUNCTURED (THRUST REVERSER) · airframe 88,820 hrs · 41,849 cycles

DURING WALK AROUND MAINTENANCE DISCOVERED TWO PUNCTURES ON LT ENGINE REVERSER COWL INBD AT 4 O'CLOCK POSITION. COMPLIED WITH REPAIR PER SRM 54-31-01. TOUCHED UP PAINT PER AMM 51-21.

Part: DOUBLER — CORRODED (FUSELAGE) · airframe 78,326 hrs · 38,187 cycles

AFTER REMOVAL OF JAM NUT ON MID LAV PAN T- HANDLE CABLE FOUND LAV SERVICE PAN INTERNAL DOUBLER CORRODED AT STA 700 RBL 50 IN FWD PIT CP53-122-01I. C/W AT SAA - SAT ON N/R 122605 JOB 82876050001.

Part: FITTING — CORRODED (AFT CARGO BAY) · airframe 78,326 hrs · 38,187 cycles

AFT CARGO PIT FSTS 1376 S25L BOTTOM STOP PAN FITTING HAS SURFACE CORROSION CP53-153-03I/ C/W AT SAA - SAT ON N/R 108399 JOB 82873190001.

Part: SILL — CORRODED (AFT CARGO BAY) · airframe 78,326 hrs · 38,187 cycles

AFT CARGO DOOR LOWER SILL UPPER CHORD LOWER SURFACE FOUND CORROSION UNDER AND AROUND NUT PLATES STA 1380 TO 1440 (AFT CARGO DOOR CUTOUT) CP53-156-01I, C/W AT SAA- SAT ON N/R 122091 JOB 82874020001.

Part: SKIN — DENTED (LE SLAT) · airframe 78,326 hrs · 38,187 cycles

NR 10 SLAT HAS AREA OF HAIL DAMAGE, C/W AT SAA - SAT ON N/R 113285 JOB 82869040001.

Part: RESERVOIR — DAMAGED (L2 DOOR) · airframe 78,326 hrs · 38,187 cycles

DURING L2 DOOR RIG FOUND EMERGENCY ASSIST RESERVOIR DISCHARGED. REMOVED AND REPLACED EMERGENCY POWER ASSIST RESERVOIR PER AMM 52-11-404-013 AT SAA - SAT ON N/R 125725 JOB 82876300001.

Part: FAILSAFE — CORRODED (BS 900) · airframe 78,326 hrs · 38,187 cycles

FUSELAGE FAIL SAFE STRAP CORRODED RT SIDE AT STA900. C/W AT SAA - SAT ON N/R 114038 JOB 82866730001.

Part: SKIN — DENTED (BS 1310) · airframe 78,326 hrs · 38,187 cycles

LWR FUSELAGE STA 1310-1330 S29L TO S28R PREVIOUS BLENDOUTS MULTIPLE SHARP DENTS, NO TAG C/W AT SAA - SAT ON N/R 107953 JOB 82866150001.

Part: SUPPORT CHANNEL — CORRODED (BS 353) · airframe 78,326 hrs · 38,187 cycles

MAIN CABIN STA 353 LBL 60 AT L1 DOOR SUBFLOOR SUPPORT CHANNEL HAS HEAVY CORROSION (CP53-221-01I) C/W AT SAA - SAT ON N/R 122071 JOB 82874520001.

Part: CUSP WEB — CORRODED (BS 1030) · airframe 78,326 hrs · 38,187 cycles

CUSP WEB INNER CHORD CORRODED AT BS 1030 RBL 62 IN MAIN CABIN (CP53-242-01-02-02I) C/W AT SAA - SAT ON N/R 114200 JOB 82873320001.

Part: INTERCOSTAL — CORRODED (FS 1458) · airframe 78,326 hrs · 38,187 cycles

AFT CARGO CCOMPARTMENT FLOOR STRUCTURE AT STA 1458 TO 1472 INTERCOSTAL AND SUPPORT PLATE ARE CORRODED RBL 13.50, CP53-156-01I.

Part: ATTACH ANGLE — CORRODED (FS 740) · airframe 78,326 hrs · 38,187 cycles

CORROSION INTERCOSTAL AT ATTACH ANGLE TO SKIN AT FS 740 TO 760 IN FWD CARGO COMPARTMENT RBL10 ( CP53-127-01). C/W AT SAA, SAT ON N/R 122053 JOB 82874/840001.

Part: SHIM — MIGRATED (FLAP TRACK) · airframe 78,326 hrs · 38,187 cycles

R/W NR 8 FLAP TRACK CORRODED BETWEEN AFT SHIM AND TRACK. SHIM MIGRATED C/W AT SAA - SAT ON N/R 129961 JOB 82868960001.

Part: SEAT TRACK — CORRODED (BS 750-900) · airframe 78,326 hrs · 38,187 cycles

MAIN CABIN STA 750 -0900 SEAT TRACK SECTION AT LBL 45 HAS MODERATE CORROSION AT STA 800 -830 - 860 ( WORK WITH NR 108454 / C/W AT SAA - SAT ON N/R 108453 JOB 82874430001 AND N/R 108454.

Part: ANGLE — CRACKED (BS 1580-1600) · airframe 78,326 hrs · 38,187 cycles

AFT CARGO PIT AREA CRACKED INTERCOASTAIL UPPER ANGLE BETWEEN STA 1580-1600 BLO/ C/W AT SAA - SAT ON N/R 108393 JOB 82873280001.

Part: CREASE BEAM — CRACKED (BS 410 S17L) · airframe 78,326 hrs · 38,187 cycles

MAIN CABIN STA 410 STRINGER 17L AT CREASE BEAM. CREASE BEAM WEB IS CRACKED / C/W AT SAA - SAT ON N/R 122068 JOB 82874500001.

Part: SILL — CORRODED (BS 1380-1440) · airframe 78,326 hrs · 38,187 cycles

AFT CARGO COMPT. DOOR CUT OUT STRUCTURE LOWER SILL STA 1380 TO 1440 WEB HAS CORROSION ON MULTIPILE PLACES CP53 - 154 -01I/ C/W AT SAA - SAT ON N/R 122162 JOB 82873960001.

Part: INTERCOSTAL — DAMAGED (BS 860-880) · airframe 76,555 hrs · 37,589 cycles

INTERCOSTAL BS 860-880 BL 0 WL 208 HAS DAMAGED HOLES REMOVED AND REPLACED PER SRM 51-40-02 STEP 4.

Part: FLOOR PANEL — CORRODED (AFT CARGO BAY) · airframe 76,555 hrs · 37,589 cycles

CORROSION ON FLOOR PANEL AT STATION 1510 LBL 17 TO RBL 17. REPAIRED ON NR 00031 PER 53-00-53.

Part: STRINGER SPLICE — CORRODED (FUSELAGE) · airframe 76,555 hrs · 37,589 cycles

FWD CARGO CORROSION NOTED ON STRINGER SPLICE RADIUS STA 605 LBL 15. REPAIRED IAW SRM 53-00-03 FIG 201.

Part: SKIN — DENTED (FS221 S23L) · airframe 72,519 hrs · 36,337 cycles

DENTS IN FUSELAGE SKIN NEAR RADOME AT FS 220, LT SIDE, S-23L. CUTOUT DENTS AND INSTALLED DOUBLER.

Part: STRUCTURE — DENTED (FUSELAGE) · airframe 72,519 hrs · 36,337 cycles

MAJOR REPAIR ER/A 463313-14. THREE DENTS NEAR A/C NOSE REPAIRED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 68,165 hrs · 34,856 cycles

CRACKS WERE FOUND IN THE FUSELAGE SKIN AT THE EDGE OF THE L1 DOOR OPENING UPPER FORWARD CORNER. A DOUBLER WAS INSTALLED, REF. AD 2004-09-32, 2001-20-12.

Part: OUTFLOW VALVE — LEAKING (CABIN PRESSURE) · airframe 67,891 hrs · 34,766 cycles

AT FL410 - CABIN ALT WARNING, CABIN ALT EXCEEDED 10,000 FT. OUTFLOW VALVE CLOSED. ALL BLEEDS AND PACKS NORM. RECIRC FAN ON. C/W QRH PROCEDURES. DIVERTED TO MCO. BITE OF CABIN PRESSURE CONTROLLERS 1 AND 2 SHOW NO FAULTS. AMM TASK 05-51-24-702-001 HAS EXCESSIVE PRESSURE LEAK RATE OUT OF LIMITS. FOUND LEAKS AT E/E COOLING VALVE, FWD CARGO DOOR AND OUTFLOW VALVE. REPLACED OVBD EXHAUST VALVE AND RT AND LT FLOW CONTROL VALVES. FWD CARGO DOOR FWD LWR CORNER SEAL OUT OF TRACK.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 59,329 hrs · 31,669 cycles

ON L/O FOUND EMERGENCY EXIT LIGHTS INOP AT RT OVERWING EXIT, RT AISLE, RIGHT AFT WING ILUM, AND RIGHT MID WING ILLUM POSITIONS. REPLACED PWR SUPPLY M10568 AND BATTERY. EMERGENCY LIGHTS NOW CHECK GOOD.

Part: BATTERY — DISCHARGED (MEGAPHONE) · airframe 58,476 hrs · 31,277 cycles

MEGAPHONE L1 CLOSET INOPERATIVE. REPLACED BATTERIES

Part: SKIN — CORRODED (FUSELAGE) · airframe 58,426 hrs · 31,256 cycles

FUSELAGE SKIN WAS FOUND WITH CORROSION DAMAGE COMMON TO THE VHF ANTENNA CUTOUT AND THE REINFORCING DOUBLERS AT FS 1470 AND BL 0. THE EXISTING DOUBLERS WERE REMOVED AND THE ANTENNA CUTOUT ENLARGED TO REMOVE THE CORROSION. TWO LARGER ALUMINUM EXTERNAL DOUBLERS WERE INSTALLED TO REPAIR THE AREA PER ER/A 384844-14, REV A.

Part: SKIN — DENTED (FUSELAGE) · airframe 58,424 hrs · 31,255 cycles

DENT CUTOUT REPAIR. THE FUSELAGE SKIN WAS FOUND WITH MULTIPLE DENT LOCATIONS BETWEEN FS 1570 & 1615 AND BETWEEN STRINGERS 18L & 22L. THE DENTS WERE REMOVED WITH CUTOUTS TO THE SKIN AND REPAIRED WITH A SINGLE EXTERNAL ALUMINUM REPAIR DOUBLER PER ER/A 384846-14, REV A.

Part: SKIN — DENTED (FUSELAGE) · airframe 58,424 hrs · 31,255 cycles

THE FUSELAGE SKIN WAS FOUND DENTED AT FS 1710 JUST BELOW THE STRINGER 14R SKIN LAP JOINT. THE DENT WAS REMOVED WITH A CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER ER/A 384813-14, REV A.

Part: SKIN — DENTED (FUSELAGE) · airframe 58,424 hrs · 31,255 cycles

THE SKIN WAS FOUND WITH 4 DENTS BETWEEN FS 601 & 630 AND BETWEEN STRINGERS 15L & 16L. THE DENTS WERE REMOVED WITH 4 SMALL CUTOUTS AND REPAIRED WITH A SINGLE EXTERNAL ALUMINUM REPAIR DOUBLER PER ER/A 384778-14, REV A.

Part: WARNING SYSTEM — UNSERVICEABLE (TE FLAPS) · airframe 51,662 hrs · 27,997 cycles

WHEN FLAPS SET TO 1 DEG T/E FLAP LIGHT CAME ON, WOULD NOT RESET. WENT THROUGH PROCEDURE USED ALT FLAP 20 DEG FOR LANDING. WHEN ALT SELECTED TO 20 DEG, ON FINAL SLAT DIS AGREE LIGHT CAME ON NO ABNORMAL CONTROL. CHECKED T/E FLAPS FOR DAMAGE-NONE FOUND. BITE OF BOX SHOWS-NR 1 BOX ASSY/NO MOTION. NR 2 BOX ASSY/NO MOTION. NR 3 BOX- NO FAULT. CHECKED ALL GEAR BOX FLUID LEVELS ALL FULL. SWAPPED NRS 1 AND 3 FSEU'S. FLAP OPS CHECK OK.

Part: SKIN — GOUGED (BS 1550)

THE UPPER SKIN OF THE STRINGER 26L SKIN LAP SPLICE WAS FOUND GOUGED AT FS 1150. THE DAMAGED AREA OF UPPER SKIN WAS CUT OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER. INSTALLED PER ER/A 367340-14.

Part: SKIN — DENTED (BS 1580-1600)

THE FUSELAGE SKIN BETWEEN FS 1580 AND 1600 BETWEEN STR 18L AND 22L WAS BADLY TORN AND DENTED FROM GROUND EQUIPMENT. THE DAMAGE WAS CUT OUT AND A SKIN DOUBLER WAS INSTALLED PER ER/A 364067-14, REV A. THE UNDERLYING STRINGERS WERE REPAIRED PER THE B757 SRM.

Part: RADOME — DAMAGED (NOSE)

RADOME CAVED IN DURING DESCENT. SHOP INSPECTION FOUND WHITE AND YELLOW MARKS OF PAINT IN CAVED AREA. THIS AREA SEEMED TO BE HIT. REBUILD RADOME COMPLETE USING 757 MOLD AND BOEING SPEC MATERIAL.

Part: WEIGHT — CRACKED (RT AILERON)

AT HMV, THE LWR L/E AT THE O/B END OF THE I/B WEIGHT ON THE RT AILERON WAS FOUND CRACKED. THIS WAS REPAIRED PER SRM 57-60-01.

Part: FLOORBEAM — CORRODED (FS 324)

AT HMV, CORROSION WAS FOUND ON FLOORBEAM BL0 TO RT FUSELAGE SKIN STA 324. REMOVED CORR AND CK LIMITS PER SRM 53-10-8 FIG 101. DRILLED REPAIR SPLICE ANGLES PER SRM 53-10-8 AND INSTALLED PER SAME.

Part: FLOORBEAM — CORRODED (FS 700)

AT HMV, THE CABIN FLOORBEAM UPPER CAP WAS FOUND TO BE CORRODED FROM LBL 10 TO 16. REPAIRED PER SRM 53-30-51 FIG 202.

Part: WEDGE — WORN (NR 4 LE FLAP)

LOWER AFT EDGE IS WORN ON NR 4 SLAT. REPLACED WEDGE PER SRM 57-43-02 REF AD 90-23-06. FOUND AND REPAIRED DURING HMV.

Part: FLOORBEAM — CORRODED (FS 760)

AT HMV, THE FLOORBEAM WAS FOUND TO BE CORRODED AT STA 760 FROM LBL 15 TO RBL 15. THE CORROSION WAS REMOVED AT BL0 TO RBL 15 WITHIN LIMITS PER SRM 53-00-51 FIG 101. CORR REM AT LBL 5 TO BL 0 NOT IN EXCESS OF .040 DEPTH. REPAIR FABRICATED PER SRM 53-30-51 FIG 203. REPAIR INSTALLED PER ABOVE SRM.

Part: SKIN — DAMAGED (NR 2 ENGINE)

AT HMV, PERM REPAIR OF NR 2 ENG NACELLE STRUT SKIN I/B WAS SCHEDULED. THE DAMAGE WAS ROUTED OUT, INSP FOR CRACKS (NONE DETECTED), AND DOUBLER AND TRIPLER WERE FABRICATED AND INSTALLED PER SRM 54-51-01.

Part: FLAP — GOUGED SKIN (RT WING)

DURING LETTER CHECK, RIGHT WING NR 4 AFT FLAP LOWER SKIN WAS FOUND GOUGED BETWEEN THE NR 7 AND NR 8 FLAP FAIRING. REPAIRED PER SMR 57-70-05.