N634DL

Part: WIRE — BROKEN (CABIN) · airframe 76,256 hrs · 35,886 cycles

FLIGHT ATTENDANT FOUND THE EMERGENCY PATH LIGHT AT SEAT 1C INOPERATIVE. MAINTENANCE FOUND A CONNECTOR WIRE BROKEN AND REPLACED THE TERMINAL PIN. OPERATIONAL CHECK WAS GOOD.

Part: CONTROL PANEL — FAILED (COCKPIT) · airframe 76,155 hrs · 35,849 cycles

AT FL380 RECEIVED CABIN ALT WARNING. CABIN ALTITUDE WAS AT APPROX. 12,000FT. NO FAULT LIGHTS OR OTHER INDICATIONS. DIFFERENTIAL PRESSURE WAS 6+. DONNED O2 MASKS AND PERFORMED EMERGENCY DESCENT TO 15,000FT AND THEN REGAINED CONTROL OF CABIN PRESSURE AT 15,000FT AND 4.6 DIFF PRESS. EMERGENCY WAS DECLARED. MAINTENANCE REPLACED CABIN PRESSURE CONTROL PANEL AND OUTFLOW VALVE ASSEMBLY. MAINTENANCE ALSO REPLACED THE AFT CARGO DOOR SEAL DUE TO TEARS AND A PIECE MISSING.

Part: WIRE — BROKEN (EMERGENCY LIGHT) · airframe 72,498 hrs · 34,226 cycles

DURING LAYOVER CHECK, MX FOUND EMERGENCY PATH LIGHT WIRES BROKEN AT ROW 5C. MX REPAIRED THE WIRES. OPS CHECK WAS OK.

Part: SKIN — DAMAGED (BS 310 L22R) · airframe 71,825 hrs · 33,877 cycles

FUSELAGE SKIN AT STA 310 AND L-22R WITH LIGHTNING STRIKE DAMAGE. REPAIR IAW ERA 478699-14.

Part: SKIN — DAMAGED (BS 235 L23R) · airframe 71,825 hrs · 33,877 cycles

FUSELAGE SKIN WITH LIGHTNING STRIKE DAMAGE THE FIRST LOCATION IS AT STA 235 AND L-23R. THE SECOND LOCATION IS AT STA 255 AND JUST ABOVE L-23R. THE THIRD LOCATION IS AT STA 278 AND JUST ABOVE L-23R. REPAIR IAW ERA 478695-14.

Part: MODULE — BROKEN (HYDRAULIC SYS) · airframe 70,941 hrs · 33,402 cycles

PTU AND LT LOW HYD QTY STATUS MSG ON EICAS. FOUND PTU PRESS MODULE FILTER BOWL BROKEN. REMOVED HYD PRESSURE PTU FILTER MODULE 239798 DUMPED HEAD. PRESSURE ON LEFT HYD SYSTEM 239798 NEEDS PTU PRESSURE FILTER MODULE ASSY REF IPC 29-22-02-01 ITEM 010J239798. INSTALLED PT PRESSURE MODULE PER M/M 29-22-02-404-020, CHECKS OK. MFG P/N INSTALLED 271N2009-3.

Part: SKIN — DAMAGED (VERTICAL STAB) · airframe 70,001 hrs · 32,980 cycles

LIGHTNING STRIKE DAMAGES ON THE FUSELAGE VERTICAL STABILIZER, RUDDER AND LT ELEVATOR. REPAIR IAW ERA 474515-14.

Part: SKIN — DAMAGED (BS 680 S26L) · airframe 69,341 hrs · 32,709 cycles

FUSELAGE SKIN WAS DAMAGED AT STA 680 TO 700 ABOVE S-26L. CUTOUT THE DAMAGED SKIN AND INSTALLED AN EXTERNAL REPAIR DOUBLER.

Part: LINE — BROKEN (LT HYD SYS) · airframe 65,961 hrs · 31,189 cycles

ON TAXI OUT, LT HYD QTY DROPPED TO .18 ASSOC LT HYD SYS PRESS EICAS LT ENG HYD PRESS AND LT ELEC HYD PRESS LIGHTS ALL CAME ON. FOUND RT OUTBD AILERON PCA PRESS LINE CRACKED. INST TEMP LINE PER AMM 20-10-09-801-001. NEEDS MFG P/N 2511242-17. TEMP LINE NEEDS TO BE INSP WITHIN 175 HRS AND REPLACED WITHIN 350 HRS. SERVICED LT HYD SYS TO FULL. LEAK CK AND OPS CK GOOD.

Part: FLOORBEAM — CORRODED (BS 1681 S17L) · corrosion level 2

CORROSION UNDER NUTPLATES AFT PIT MAIN CABIN FLOOR STRUCTURE BS 1681.8 FROM LBL 30 TO LBL 50 (3 EA.) REPAIRED CORROSION UNDER NUT PLATES IN AFT PIT MAIN CABIN FLOOR STRUCTURE BS 1681.8 FROM LBL 30 TO LBL 50. CUT OUT CORRODED SECTION OF CABIN FLOORBEAM, FABRICATED AND INSTALLED L ANGLE 19.250 BY 1.750 BY 1.250 AND 15.75 BY 1.750 BY 1.125 AND STRAPS 19 BY 1.25 AND 16.750 BY 1.25 ALL FROM 7075-T6 .040. FABRICATED AND INSTALLED 1 U CHANNEL FROM 7075-T6 .125 AND 1 EA FROM 7075-T6 .063, AND FABRICATED SHEAR WEB FROM 7075-T6 .025 IAW B757 DWG #146N5190, AND B757 SRM 53-00-51 FIG 201.

Part: SEAT TRACK — CORRODED (BS 810-830) · corrosion level 2

LT O/B SEAT TRACK CORRODED AT BS 810 AND 830. CUT OUT SECTION OF TRACK FROM BS 780 TO BS 879. FABRICATED AND INSTALLED REPAIR TRACK SECTION BAC1520-792 IAW DWG NR 143N5116, 53-00-52 AND 51-40-02.

Part: SKIN — DENTED (FUSELAGE)

LEFT LWR FUSELAGE HAS A DENT AT BS 640 S-17L. CUT OUT DENTED AREA. FABRICATED AND INSTALLED DOUBLER REPAIR 9.20" BY 8.75" BY 11.10" BY 5.10" FROM CLAD 2024-T3 .050" AND 2 SHIMS 8.5" BY 4.5" BY 10.6" AND 9.7" BY 1.45" BY 10.7" FROM CLAD 2024-T3 .040" IAW B757 SRM 53-00-01 FIG 201.

Part: HOSE — CRACKED (OXYGEN MASK) · airframe 62,611 hrs · 29,800 cycles

ON CLIMB OUT HEARD A POP AND HISSING SOUND UN VICINITY OF CAPT O2 MASK. ALSO NOTED A DROP IN CREW O2 QUANTITY TO ZERO. POSSIBLE LEAK UNDER CAPT O2 COMPARTMENT. FOUND FLEX LINE BROKEN UNDER CAPTS O2 MASK BOX. REPLACED SAM REPLACED O2 BOTTLE REF MM. LK CKS GOOD.

Part: CONNECTOR — FAILED (FUEL PUMP) · airframe 54,719 hrs · 27,028 cycles

WORKING MCO RT AFT MAIN FUEL PUMP INOPERATIVE. FOUND RT AFT SPAR MOUNTED CONNECTOR D40930P BURNED AND ARCING. REPLACED CONNECTOR D40930P, OPS CHECK OK.

Part: DUCT — BURST (A/C BAY) · airframe 53,072 hrs · 26,382 cycles

BLEED AIR Y-DUCT IN RT A/C BAY BURST CAUSING PNEUMATIC AIR ACCESS DOOR TO BE RIPPED FROM ITS HINGES DEPARTING ACFT. REPLACED DUCT AND DOOR.

Part: FAN — SEIZED (E/E BAY) · airframe 51,082 hrs · 25,558 cycles

RETURNED TO IAD AFTER ELECTRICAL FUMES IN COCKPIT AND THROUGHOUT CABIN ON APPROACH, GOT EQUIPMENT COOLING OVERHEAT LIGHT WITH EFI SYMBOLS DEGRADING. FOUND NR 1 FORWARD EQUIPMENT COOLING FAN C/B POPPED AND FOUND NR 1 FAN SEIZED. REPLACED FAN EQUIPMENT COOLING, OP CHECKS NORMAL.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 47,959 hrs · 24,094 cycles

LEFT ENGINE HIGH STAGE LIGHT ON TAKEOFF ROLL. ABORT AT 100 KTS. PERFORMED HIGH EMER STOP/ RTO INSP PER AMM 05-51-14-2. NO DEFECTS FOUND. LOCKED HPPRSOV PER MEL 36-11-02. REMOVED, CAPPED & SECURED CANNON PLUG PER SAME. FWD TO MCO/PLC PER MEL 36-11-02. CLSD/ SECURED COWLS.

Part: CONNECTOR — DISCONNECTED (EXTERIOR LIGHT) · airframe 45,334 hrs · 22,867 cycles

EXTERIOR EMERGENCY LIGHT AFT OF R-1 DOOR WILL NOT TEST OR ILLUMINATE. REMOVED PART OF GALLEY AND GAINED ACCESS TO BACK OF THE EMERGENCY LIGHT. FOUND PLUGS D4474 AND D4476 DISCONNECTED. RECONNECTED BOTH PLUGS AND LIGHT OPER IS NORMAL. PLACED GALLEY BACK IN PLACE.

Part: ACTUATOR — FAILED (NR 1 SLAT) · airframe 42,066 hrs · 21,358 cycles

AFTER TAKEOFF, GOT L/E SLAT DISAGREE, L/E SLAT LIGHT, EICAS MSG FLAP/SLAT ELECT. SLATS WOULD NOT RETRACT USING POM PROCEDURE. FLAPS/SLATS EXTENDED TO 20 DEG FOR RETURN/LANDGING. REPLACED O/B ROTARY ALT PER M/M, OPS CKS NORMAL.

Part: AIR DIST — ODOR (CABIN)

SMOKE SMELL IN CABIN STARTED AT ROW 27 AND STARTED DRIFTING AFT IN CABIN. SMELL ONLY NO VISABLE SMOKE. REPLACED RECIRC FILTERS RT SIDE. LT RECIRC FILTERS FOUND CLEAN. INSP PSU'S AND CABIN LIGHTING COMPONENTS. INSP OVERHEAD BINS. RAN ENGS AND OPERATED PACKS PER PFHB NO ODORS OR VAPORS PRESENT. INSP BAG BINS REVEALED NOTHING. ALSO, INSP PAX BAGS CARRY ON AND IN BINS NO ODORS. THIS IS A DIVERSION W/EMERG UNITS CALLED.

Part: SWITCH — BENT (EMER EXIT SLIDE)

TAKEOFF ABORTED AT 100 KIAS DUE TO RT WING SLIDE LIGHT ON EICAS. FOUND RT OVERWING SLIDE PACK PROX SWITCH TARGET BENT. ADJUSTED SAME AND LIGHT CKS GOOD.

Part: SKIN — CRACKED (NR 2 NACELLE)

DURING INSPECTION OF A PREVIOUSLY ACCOMPLISHED REPAIR, AN ADDITIONAL CRACK WAS FOUND EMANATING FROM A PREVIOUS CUTOUT AT THE FWD UPPER CORNER OF THE ACCESS HOLE ON THE NR 2 ENGINE STRUT SKIN, AT THE OUTBD SIDE OF NAC STA 107.7. REPAIRED PER ERA 365391-14.

Part: GIRT BAR CLIPS — DAMAGED (R2 DOOR)

THE R2 DOOR GIRT BAR WOULD NOT ARM / DISARM CORRECTLY. FOUND METAL CLIPS AT ENDS OF GIRT BAR TO BE DAMAGED. INSTALLED NEW GIRT BAR ASSEMBLY. GIRT BAR NOW ARMS AND DISARMS CORRECTLY.

Part: TE WEDGE — DELAMINATED (NR 8 LE FLAP)

DURING INSPECTION, NR 8 L/E SLAT TRAILING EDGE WEDGE WAS FOUND DELAMINATED. REPLACED WEDGE PER SRM 57-43-07.

Part: EEL TRACK — LOOSE (CABIN)

DURING INSPECTION, SEVERAL EMERGENCY TRACK LIGHT MODULES FOUND LOOSE AND OUT OF TRACK IN FWD CABIN. SECURED TRACK MODULES RETURNED TO SERVICE.