N639FE

Part: BOLT — BROKEN (TRUNNION) · airframe 64,455 hrs · 14,952 cycles

ON VISUAL INSPECTION, 2 BOLT (PN 69B14786-2) HEADS WERE FOUND LOOSE ON TOP OF RT MLG BODY GEAR INBOARD TRUNNION SUPPORT FITTING. UPON REMOVAL OF SEALANT ON ATTACHING NUTS, NUTS WITH SHEARED SECTION OF BOLTS FELL FROM FITTING. BOLTS ARE OUTBOARD AND CENTER BOLTS OF 3 IN RT INBOARD FITTING. ONE BOLT HAD SURFACE CORROSION ON BOTH SECTIONS AT SHEAR POINT, INDICATIVE OF LONG PRE-EXISTING CONDITION. THE OTHER BOLT WAS RELATIVELY CLEAN. NO TORQUE WAS APPLIED TO EITHER BOLT AND LOWER HALF OF SHEARED BOLTS WITH NUTS HAD BEEN RETAINED BY ENCAPSULATION (SEALANT). (X)

Part: PANEL — DAMAGED (RT WING)

UPON LEVEL OFF FLT LEVEL 290, AIRFRAME VIB STARTED. AT THE SAME TIME THE NR 2 ENG LIGHT CAME ON. NO OTHER LIGHTS CAME ON. RAN THE ABNORMAL PROCEDURES CHECK. THE NR 2 CHECK THROTTLE RETARDED TO IDLE AND AIRSPEED REDUCED TO 290 KTS. RETURNED TO MIA. AS AIRSPEED SLOWED BUFFET/VIBRATION EASED, UPON SWITCH OVER TO MIA CENTER STARTED A SLOW DESCENT TO 10,000 FT AND SLOWED TO 270 KTS. VIBRATION STOPPED, OPTED TO LEAVE NR 2 THROTTLE IN IDLE AND FLEW AN UNEVENTFUL APPROACH AND LANDING. INSPECTION OF THE A/C AFTER BLOCKS, FOUND THE RIGHT WING INBOARD FLYING. PANEL DELAMINATED AND A PORTION MISSING.(M)

Part: BULKHEAD WEB — CRACKED (NR 3 PYLON)

AT NR 3 PYLON NAC. STA 286.0 BULKHEAD, AFTER REMOVAL OF OUTBOARD PYLON SKIN FOR REPAIR, INSPECTION REVEALED A CRACK IN THE AFT WEB OF THE 286.0 BULKHEAD. REPAIRED CRACKED WEB OF STA 286 BULKHEAD I.A.W. FED-EX ERA B-54-10-78 DATED 01/23/97.

Part: BULKHEAD WEB — CRACKED (NR 1 PYLON)

NR 1 PYLON NAC STA 286.0 BULKHEAD AFTER REMOVAL OF OTBD PYLON SKIN, CRACKS WERE DISCOVERD ON BOTH FWD AND AFT BULKHEAD WEBS. ALSO, EXTENSIVE CORROSION DAMAGE AND SIGNIFICANT MATERIAL LOSS IN STEEL FRAME. *S/D* REMOVED DAMAGED MEMBERS AND FABRICATED NEW PARTS PER SAMPLE ON MAE TRAY NR 66354 AND 66360. DRILLED AND INSTALLED NEW PARTS IAW REF SRM 51-30-02.

Part: PRESS DECK — CORROSION (LT MLG WW)

AFTER REMOVAL OF Z-ANGLE BECAUSE OF EXTENSIVE EXFOLIATION CORROSION, ADDITIONAL CORROSION WAS NOTED UNDER Z-ANGLE ON PRESSURE DECK WEB BS 1289 LT WW WITH SEVERAL AREAS. CORROSION WAS BEYOND ALLOWABLE LIMITS. FABRICATED DOUBLERS AS PER TRAVELER NR 51627, INSTALLED DOUBLERS IAW EA B53-10-328 AND INSTALLED NEW Z-ANGLE IAW SRM 55-10-01.

Part: SEAT TRACK — CORRODED (BS 1140-1260)

MAIN CARGO COMPT SEAT TRACK CORRODED BEYOND MANUFACTURER'S LIMITS AT LBL 75 STA 1140 TO 1260. REPLACED MAIN CARGO COMPT SEAT TRACK AT LBL 75 STA 1140 TO 1265 IAW SRM 51-10-01.

Part: SEAT TRACK — CORRODED (BS 1140-1260)

MAIN CARGO COMPT SEAT TRACK CORRODED BEYOND MANUFACTURER'S LIMITS AT LBL 33 STA 1140 TO 1260. REPLACED MAIN CARGO COMPT SEAT TRACK AT LBL 33 STA 1000 TO 1265 IAW SRM 51-10-01.

Part: FAIRING — DAMAGED (LT WING TE)

SYD - A/C HAS AN AERODYNAMIC VIBRATION STARTING AT APPROXIMATELY 220 KIAS AND CONTINUING ALL THE WAY TO NORMAL CRUISE. FOUND I/B T/E L/UPPER FAIRING DAMAGED BEYOND REPAIR. NEW FAIRING INSTALLED PER SRM 51-30-02 7, ADJ PER MM 57-22-01. ALSO, FOUND O/B DIAGONAL TIE ROD LWR CLEVIS BROKEN. NEW TIE ROD FITTED AND ADJ PER MM 57-22-01. FOUND FOREFLAP (L/I/B) UPPER AND LOWER SURFACES DAMAGED AND DELAMINATED ADJACENT TO FIXED PANEL DAMAGE. FOREFLAP ASSEMBLY REMOVED AND REPLACED PER MM 27-51-02. FOUND L/I/B ACCESS PANELS DAMAGED BEYOND REPAIR. PANELS REMOVED AND REPLACED PER MM 12-09-00, I/B T/E FLAPS OPS CHECKED SERVICEABLE.

Part: CLAMP — FAILED (NR 1 ENG TR DUCT)

DURING T/O ROLL, THE FIRE DETECTION LIGHT AND FIRE WARNING LIGHT ILLUMINATED ON NR 1 ENG. THE NR 1 ENG NACELLE OVERHEAT TEMP REACHED 9, THEN QUICKLY DROPPED TO ZERO. ABORTED T/O AT 60 KNOTS AND RETURNED TO RAMP. FOUND REVERSER DUCT CLAMP BLOWN. REMOVED AND REPLACED CLAMP, INSPECTED ENG AND PERFORMED GND ENG RUN. LK AND OPS CK GOOD.