N624DL

Part: FAILSAFE — MISINSTALLED (BS 1540 S21-22R) · airframe 73,725 hrs · 35,706 cycles

DURING WIFI RACK INSTALLATION THE FUSELAGE FRAME FAILSAFE WAS MISDRILLED AT FS 1540 BETWEEN S21R AND S22R IN THE AFT CARGO BIN RIGHT LOWER LOBE. REPAIR ACCOMPLISHED PER ERA 475918-14_REV 2 DTD 11JUL09/1300.

Part: SKIN PANEL — PUNCTURED (RUDDER) · airframe 73,642 hrs · 35,669 cycles

RUDDER STA 115, LT SKIN PANEL PUNCTURED. REPAIRED IAW ERA 475576-14.

Part: GEAR — DEFECTIVE (FLAP TRANS) · airframe 70,287 hrs · 34,012 cycles

TRAILING EDGE FLAP TRANSMISSION GEAR REPLACED IAW EA 06-097281-03, ME02, ME04.

Part: WIRE HARNESS — SPARKS (L1 WINDOW) · airframe 69,102 hrs · 33,470 cycles

CLIMBING THROUGH 17000 FEET NOTICED A STRONG ELEC SMELL. CAPT NOTICED SPARKING IN LOWER LEFT SIDE OF WINDOW L1. FOUND L1 WINDOW J5 WINDOW HEAT CONNECTION LOOSE. REPLACED J5 WIRE HARNESS AND HARDWARE.

Part: UNKNOWN — ODOR (CABIN) · airframe 69,090 hrs · 33,461 cycles

AFTER DESCENT, PILOTS SMELLED ELECTRICAL ODOR IN COCKPIT. RAN ENGINES TO TAKEOFF POWER WITH FULL ELECTRICAL LOAD. NO ODORS NOTED, RELAMP SWITCH LIGHTS RT ENG BLEED AND RT RECIR FAN. ALL CKS NML.

Part: ROLLER — DAMAGED (MLG DOOR SWITCH) · airframe 67,163 hrs · 32,660 cycles

AFTER TAKEOFF WHEN GEAR WAS RETRACTED DOOR LIGHT REMAINED ON WITH ASSOC EICAS GEAR MESSAGE. RTN TO CVG WITH UNEVENTFUL LANDING. FLT CREW REPORTED FLT ATTENDANT NOTED NOISE AT FWD NOSE OF ACFT. T/S IAW MM AND FOUND NOSE DOORS WOULD NOT CLOSE WITH GRD SW. FOUND ROLLER ON S10362 FLAT SPOTTED. REPLACED SAME. JACKED AND CYCLED NOSE GEAR. OPS CKS GOOD.

Part: SKIN — WORN (BS 508 S28L) · airframe 66,251 hrs · 32,268 cycles

THE FUSELAGE SKIN WAS BURNISHED OUT OF SRM LIMITS AT STA 508 APPROX 3.5" INBOARD OF STR 28L. THE DAMAGED SKIN WAS CUT OUT AND A REPAIR DOUBLER WAS INSTALLED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 64,757 hrs · 31,700 cycles

A CRACK WAS FOUND AT THE UPPER FORWARD L1 DOOR OPENING IN THE FUSELAGE SKIN. THE DAMAGED SKIN WAS CUT OUT AND A REPAIR DOUBLER WAS INSTALLED.

Part: SKIN — CORRODED (FUSELAGE) · airframe 64,673 hrs · 31,672 cycles

LOWER FUSELAGE SKIN PANEL BS 495, B/L 0 ANTENNA OPENING PAD CORROSION REPAIRED IAW ERA 099979-14.

Part: RELIEF VALVE — MALFUNCTIONED (CABIN PRESSURE) · airframe 63,122 hrs · 31,138 cycles

CREW ON FLT 1148/12 SLC-BWI RADIOED THAT AT FL340 CABIN ALTITUDE WARNING SOUNDED AND CREW REALIZED CABIN ALTITUDE WAS 11K AND CLIMBING AT 1000FT/MIN. REPLACED LOWER PRESSURE RELIEF VALVE.

Part: ENGINE — FAILED (NR 1) · airframe 62,765 hrs · 30,999 cycles

CREW SHUT ENGINE DOWN IN FLIGHT. EICAS L ENG STATOR, ENG FAILED W/ PWR REDUCTION. REPLACED STATOR VANE ACTUATOR.

Part: FLOORBEAM — CORRODED (CABIN)

CORROSION RUNNING UNDER REPAIR DOUBLER AT STA. 377.7 LBL 59.

Part: SKIN — CORRODED (CARGO DOOR)

CORROSION ON BELLY SKIN JUST AFT OF MEC DOOR.

Part: STRINGER — CORRODED (FUSELAGE)

CORROSION AT STR. 28R AT BS 650. S/O 283001, DELTA N//R NR 22590

Part: CLIP — CORRODED (FUSELAGE)

CORROSION, AFT CARGO ACCS AREA SHEAR CLIP BS 1681 S-22-S-23. S/O 283001, DELTA N//R NR 21000.

Part: SEAT TRACK — CORRODED (FUSELAGE)

CORROSION ON SEAT TRACKS LT SIDE IB AND OB AT BS 780 - 800. S/O 283001, DELTA NR NR21386.

Part: THRESHOLD — CORRODED (FUSELAGE)

CORROSION AT STA. 1440 ON MAIN STRUCTURE UNDER THRESHOLD Z-ANGLE CORROSION AT 6 FASTENERS. S/O 283001, DELTA N//R NR22456

Part: SHEAR WEB — CORRODED (FUSLEAGE)

CORROSION ON SHEAR WEB SURFACE FROM BS 1681.8 TO 1720 BL 0 TO BL60L INCLUDING FASTENER HOLES. S/O 283001, DELTA N//R NR 21000.

Part: SHEAR WEB — CORRODED (FUSELAGE)

CORROSION IN SHEAR WEB SURFACE FROM BS 1681.8 - 1720 BL 0 - BL 60R INCLUDING FASTENERS.

Part: FRAME — CRACKED (FUSELAGE)

CRACK IN FRAME UPPER SURFACE IN AFT CARGO COMPARTMENT BS 1540.

Part: FRAME — DENTED (FUSELAGE)

DENT IN AFT CARGO COMPARTMENT BS 1520 FRAME UPPER FLANGE BETWEEN S-25 TO S-26L.

Part: CREASE BEAM — CORRODED (FUSELAGE)

CORROSION ON CREASE BEAM AT 364 - 371 RBL 65.

Part: FRAME — DENTED (FUSELAGE)

AFT CARGO BAY LT BS 1340 AT S-25L MAIN FRAME HAS DENT.

Part: DOOR FRAME — CRACKED (PAX DOOR)

RT NR 2 DOOR ON FRAME 27 IS CRACKED.

Part: FRAME — CRACKED (FUSELAGE)

AFT BAG PIT LT BS 1500 AT S-26L MAIN FRAME HAS DENT/CRACK.

Part: SHEAR WEB — CORRODED (FUSELAGE)

CORROSION IN SHEAR WEB SURFACE FROM BS 1681.8 - 1720 BL 0 - BL 60R INCLUDING FASTENERS.

Part: SUPPORT — CRACKED (FUSELAGE)

CRACKED/TORN METAL SUPPORT IN CABIN FUSELAGE AT BS 1040 - 1060 JUST AFT OF FLOORBOARD 1020A.

Part: FLOORBEAM — CRACKED (FUSELAGE)

CRACKED CAP ON FLOORBEAM AT BS 900 BL 54L TO 64L WL 208.1.

Part: DOOR — DENTED (R4)

R-4 DOOR IS DENTED ON THE LOWER AFT CORNER.

Part: FRAME — DENTED (FUSELAGE)

AFT CARGO BAY LT BS 1480 AT S-25L MAIN FRAME HAS DENTS.

Part: SEAL — LEAKING (ESCAPE HATCH) · airframe 60,448 hrs · 30,118 cycles

CABIN ALTITUDE DISCRETE ON EICAS AND OVERHEAD PANEL AT FL335. FOUND RT AFT OVERWING EXIT HATCH SEAL LEAKING. REPLACED SEAL.

Part: PUMP — FAILED (FUEL SYSTEM) · airframe 55,557 hrs · 28,268 cycles

DURING ROUTINE DISASSEMBLY OF A FAILED FUEL BOOST PUMP, SEVERE BEARING AND HOUSING WEAR WAS DISCOVERED, TO THE EXTENT THAT END CAP FAILURE WAS IMMINENT. ROTOR AND STATOR HAD CONTACTED EACH OTHER AND EVIDENCE OF HEAT WAS PRESENT. PUMP P/N 60-75504, S/N 048910657A. C/A NONE. PART WAS ALREADY REMOVED FROM AIRCRAFT AND IN REPAIR PROCESS.

Part: FIRE — DETECTED (NR 2 ENGINE) · airframe 51,585 hrs · 26,383 cycles

DURING ENGINE START ON RT ENG, FLT ATT REPORTED A FIRE ON THE RIGHT ENG. REPORTED SMOKE AND FLAMES OUT THE RIGHT TAIL PIPE. SMOKE IN CABIN. ENG FUEL WAS CUT OFF, MOTORED FOR 30 SECS AND STARTER WAS TURNED OFF. NO COCKPIT INDICATION OF ENG FIRE. OPEN ENG VERIFIED SVA AND 2.5 BLEED FULL OPEN. REPLACED NR 1 AND NR 2 IGNITORS AS PRECAUTION. INSPECTED INLET AND EXHAUST, NO TROUBLE FOUND. RAN ENG WITH PACKS, NO TROUBLE FOUND.

Part: LIGHT — INOPERATIVE (R3 DOOR) · airframe 49,193 hrs · 25,255 cycles

FOUND ON L/O, R-3 EMERGENCY DOOR LIGHT INOP. RELAMPED SAME.

Part: HEATER — MALFUNCTIONED (GALLEY WATER) · airframe 46,622 hrs · 24,101 cycles

F/A REPORTED LIGHT SMOKE WITH ELECTRICAL BURNING ODOR COMING FROM MID GALLEY AREA. WALL ALSO REPORTED TO BE HOT AND WATER DISPENSER PRODUCING BOILING WATER. SMOKE AND SMELL WAS CONFIRMED. DIVERTED TO KLAS. FOUND MID GALLEY COFFEEMAKER BAD. REPLACED SAME.

Part: PANEL — ODOR (COCKPIT) · airframe 46,339 hrs · 23,972 cycles

PA IN USE LIGHT APPEARED TO BE INOP, EMITTED ODOR WHEN PUSHED. FOUND PA CAPSUL PIN BURNED. REPLACED PANEL, NO FURTHER ODOR PRESENT. UNIT OPS CHECK NORMAL.

Part: MODULE — INOPERATIVE (OVERHEAD) · airframe 45,354 hrs · 23,497 cycles

INTERIOR AFT CABIN SEAT EMERGENCY LIGHTS INOP. REPLACED LIGHT MODULE.

Part: SKIN — DELAMINATION (RT ELEVATOR)

RT ELEVATOR LOWER L/E SKIN, FS 52, 112, 136, 160, 170 AND 220: DELAMINATION. MULTIPLE INTER-PLY DELAMINATION AREAS WERE FOUND AT THE ABOVE STATION LOCATIONS TYPICALLY AROUND HINGE-ATTACH BOLT HOLES IN THE LOWER L/E SKIN. AUTHORIZED TIME-LIMITED WET LAYUP REPAIRS. PERMANENT REPAIR TO BE SCHEDULED WITHIN NEXT 12 MONTHS.

Part: MEGAPHONE — INOPERATIVE (CABIN)

BOTH CABIN MEGAPHONES INOP. FOUND BY CABIN CREW ON PREDEPARTURE CHECK, P/N 237702242 (2) EACH.

Part: FITTING — WORN (NR 3 FLAP TRACK)

THE SIX BOLTS THAT ATTACH THE NR 3 FLAP INBD FLAP TRACK FWD SUPPORT FITTING TO THE MLG BEAM WERE FOUND TO BE LOOSE CAUSING THE BOLTS TO WEAR INTO THE BEAM AND THE FITTING. ALL SIX HOLES IN BOTH THE BEAM AND THE FITTING WERE FOUND TO BE EGG SHAPED. THE ORIG FASTENERS WERE .25 DIAMETER BOLTS. THE SIX HOLES IN THE BEAM WERE OVERSIZED TO 0.313 MAX DIAMETER ON CENTER WHILE ALL SIX HOLES IN THE FITTING WERE OVERSIZED TO 0.314 MAX DIAMETER. THE MLG BEAM IS M/F FROM TI-6AL-4V FORGING WITH LOCAL THICKNESS OF 0.90. THE FITTING IS M/F 7075-T73 FORGING WITH LOCAL THICK OF 0.19

Part: RATIO MODULE — FAILED (RUDDER CONTROL)

ON CLIMB-OUT RUDDER RATIO EICAS MSG AND RUDDER RATIO OVERHEAD LIGHT ILLUMINATED WITH UNCOMMANDED RUDDER MOVEMENT. FOUND PCA FAULT BALL SET ON RT RUDDER RATIO MODULE. REPLACED MODULE AND PERFORMED BITE. CKS GOOD.