N640DL

Part: FITTING — CORRODED (FUSELAGE) · airframe 72,757 hrs · 31,837 cycles

TENSION TIE FITTING CORRODED AT STA 1723 STR 17R. REPAIR ACCOMPLISHED ON ERA 484045-14 REV A (DL757101931).

Part: FAN — INOPERATIVE (RT RECIRCULATION) · airframe 71,364 hrs · 31,355 cycles

CAPT REPORTED THAT WHEN THE RT RECIRC FAN WENT INOP IN TO BOG THE F/AS REPORTED A SMOKE SMELL. F/O REPORTS THAT SMELL WAS SIMILAR TO A FAN RUNNING HOT. SMELL DISSIPATED WITH FAN TURNED OFF. INSP RT RECIR FAN AND DETERMINED IT TO BE AT FAULT PLACED ON FCP.

Part: COOLING FAN — SEIZED (E&E BAY) · airframe 67,663 hrs · 30,305 cycles

BURNING SMELL IN COCKPIT AT CRUISE. RAN CHECKLIST, DIVERTED TO SJU. MTC FOUND THE FWD EQUIP COOLING SUPPLY FAN NR 1 SEIZED AND CAUSING THE SMELL. REPLACED THE FAN PER THE MM, ALL CHECKS OK.

Part: UNKNOWN — SMOKE (CABIN) · airframe 63,118 hrs · 28,921 cycles

ON TOP OF CLIMB-OUT FLT CREW REPORTED A SLIGHT SMOKE HAZE WITH A RUBBER SMELL LOC AROUND SEAT ROW 36. AFTER LANDING, FLT CREW TRIED TO DUPLICATE PROBLEM BY RUNNING ENGS/PACKS/BLEED SYS/LIGHTING/GALLEY EQUIP. UNABLE TO DUPLICATE PROBLEM. ALSO, PERFORMED AN OVERWEIGHT LANDING INSPECTION PER AMM.

Part: ENGINE — DAMAGED (NR 1) · airframe 62,926 hrs · 28,862 cycles

IRR:ON SELECTION OF TAKEOFF POWER, AT 31 DERATE-LEFT ENGINE EMITTED LOUD BANG. POWER-EPR/N1-DETERIORATED AND TAKEOFF WAS ABORTED-LESS THAN 10 KTS. MOMENTARY PUFF OF SMOKE. OTHER AIRCRAFT REPORTED FLASH AND SPARKS FROM TAILPIPE. ENGINE EGT AND OIL PRESSURE WENT RED. PERFORMED ENGINE SEVERE DAMAGE CHECKLIST AND SHUT DOWN ENGINE. FOUND METAL IN TAILPIPE. ENGINE CHANGE IN PROGRESS. REMOVED AND REPLACED NR 1 ENGINE PER TRANSMITTAL 6T103 UP T PREFLIGHT 605239. PREFLIGHT COMPLETE CK OK.

Part: SKIN — DENTED (BS 1685) · airframe 62,598 hrs · 28,772 cycles

FOUND DENT AT BS 1685 FROM S-16R TO S-14R ACROSS S-15R. REPAIRED BY CUTTING OUT DENTED AREA, HFEC CUT OUT PER B757 TM PT. 6-51-00-19, NO RELEVANT INDICATIONS NOTED. FABRICATED AND INSTALLED REPAIR DOUBLER 16-1/4 BY 15-1/40 BY 15-3/4" FROM 2024-T3 .080 AND FILLER FROM 2024-T3 .071 IAW DELTA ERA 461665-14 DATED 06-13-07 APPROVED PER FAA FORM 8100-9 (2 PAGES) BOEING. REPAIR APPROVAL IS LIMITED TO 12 MONTHS SERVICE ONLY. ADDITIONAL ENGINEERING AUTHORIZATION, (ERR/A REVISION) IS REQUIRED FOR CONTINUED SERVICE OF THIS REPAIR LONGER THAN 12 MONTHS FROM FAA FORM 8100-9 DATED (JUNE 8, 2007).

Part: SKIN — DENTED (FS 1690 S15R) · airframe 62,598 hrs · 28,772 cycles

DURING CURRENT HMV AT TIMCO LCQ, TWO DENTS WERE NOTED ON THE FUSELAGE SKIN BETWEEN BODY STATION 1681.8 AND 1701, BETWEEN S-14R AND S-16R. THE SUBJECT DAMAGE WAS BEYOND THE ALLOWABLE DAMAGE LIMITS OF THE SRM. EACH OF THE DAMAGED AREAS WAS TRIMMED OUT, AND A BOEING APPROVED REPAIR INSTALLED PER 461665-14.

Part: BRACE — OUT OF LIMITS (NR 1)

FOUND NR 1 DIAGONAL BRACE ID 2.003 OUT OF LIMITS. REPAIRED OVERSIZED LUG ON NR 1 DIAGONAL BRACE BY HONING, FABRICATING AND INSTALLING BUSHINGS IAW DELTA ERA 461664-14AD DATED 6/7/07 APPROVED BY FAA FORM 8100-9 WITH AMOC TO PARAGRAPH (A) OF AD 2003-18-05.

Part: BULKHEAD — CHAFED (NR 1 NACELLE)

FOUND CHAFED LOWER OUTBOARD CORNER OF NR 1 PYLON AFT BULKHEAD. REPAIRED BY FABRICATING AND INSTALLING GUSSET 4.34 BY 2.88 BY 1.2 BY .100 FROM 7050-T7451 AND FILLER FROM 15-5PH.125 IAW DELTA ERA 461663-14AD DATED 6/7/07 REV ORIG APPROVED BY FAA FORM 8100-9, WITH AMOC TO PARAGRAPH (A) OF FAA AD 2003-18-05.

Part: BULKHEAD — CHAFED (NR 2 NACELLE)

FOUND CHAFED LOWER OUTBOARD CORNER OF NR 2 PYLON AFT BULKHEAD. REPAIRED BY FABRICATING AND INSTALLING GUSSET 4.34 BY 2.88 BY 1.2 BY .100 FROM 7050-T7451 AND FILLER FROM 15-5PH.125 IAW DELTA ERA 461663-14AD DATED 6/7/07 REV ORIG APPROVED BY FAA FORM 8100-9, WITH AMOC TO PARAGRAPH (A) OF FAA AD 2003-18-05.

Part: TORQUE TUBE — CORRODED (ZONE 500) · corrosion level 2

FOUND LT I/B FLAP I/B FAIL SAFE TORQUE TUBE CORRODED. REPAIRED CORRODED LT WING I/B FLAP FAIL SAFE TORQUE TUBE BY REMOVING AND REPLACE TORQUE TUBE WITH P/N’S 113N2105-1 AND 113N2108-1 IAW B757 MM 57-53-44.

Part: TORQUE TUBE — CORRODED (TE FLAP)

FOUND RUSTED RT I/B FLAP I/B TORQUE TUBE. REPAIRED BY REMOVING AND REPLACING TORQUE TUBE AND FAIL SAFE TUBE WITH P/N’S 113N2105-2 AND 113N2108-1 IAW B757 MM 57-53-44.

Part: BRACE — OUT OF LIMITS (ZONE 400)

FOUND NR 2 DIAGONAL BRACE ID 2.003 (OUT OF LIMITS). REPAIRED OVERSIZED LUG ON NR 2 DIAGONAL BRACE BY HONING, FABRICATING AND INSTALLING BUSHINGS IAW DELTA ERA 461664-14AD DATED 6/7/07 APPROVED BY FAA FORM 8100-9 WITH AMOC TO PARAGRAPH (A) OF AD 2003-18-05.

Part: BRACE — DAMAGED (NR 1 PYLON) · airframe 62,598 hrs · 28,772 cycles

DURING CURRENT HMV, THE NR 1 PYLON DIAGONAL BRACE REQUIRED OVERSIZING BEYOND THE EA LIMITS. AS SUCH, BOEING WAS CONTACTED FOR APPROVAL TO OVERSIZE BEYOND LIMITS DUE TO AD 2003-18-05, AND THE WORK IS DOCUMENTED IN ERA 461664-14AD.

Part: DRAG LINK — CORRODED (NLG) · corrosion level 2 · airframe 62,598 hrs · 28,772 cycles

FOUND CORRODED NLG LOWER DRAG LINK. REPAIRED BY REMOVING AND REPLACING P/N 162N2201-1 IAW B757 AMM 32-24-04.

Part: FRAME — DENTED (ZONE 400)

AFT PIT FRAME DENTED BS 1440, STR 27L. REMOVED OLD REPAIR, FABRICATED AND INSTALLED FRAME REPAIR 16"BY 3" BY 1" FROM 7075-T6 .071" IAW B757 SRM 51-40-02, 51-40-05, 51-70-11, 53-00-07, 51-20-01 AND 51-20-02.

Part: WEB — CORRODED (CARGO DOOR) · corrosion level 2 · airframe 62,598 hrs · 28,772 cycles

FOUND WEB CORRODED AT AFT CARGO DOOR LOWER FWD CORNER BS 1380 AND S-27R BY REMOVING WEB. REPAIRED BY FABRICATING AND INSTALLING REPAIR WEB 4-1/2 BY 22 FROM 7075-T6 .071 IAW B757 SRM 51-40-02 AND 51-30-01.

Part: FRAME — DENTED (FUSELAGE)

FOUND DENT MAIN FRAME UPPER CAP IN FWD PIT BS 720 AT B/L 0. REPAIRED BY FABRICATING AND INSTALLING DOUBLER 5-5/8 BY 1-7/8 BY 1 FROM 7075-T6 .063 IAW B757 SRM 51-40-05, 51-40-02 AND 51-20-01.

Part: SKIN — DENTED (FUSELAGE)

FOUND DENTED STRINGER 15L ON EXTERNAL SKIN AT BS 569. REPAIRED BY CUTTING OUT DENT IAW B757 SRM 53-00-01 SECTION OF FRAME HFEC CUT OUT EDGES HFEC DENT IAW B757 D634N301, PT 6-51-00-19, NO DEFECTS NOTED. FABRICATED AND INSTALLED DOUBLER 10.5 BY 9.25 FROM 2024-T3 .063”, FILLER FROM 2024-T3 .071" IAW B757 SRM 53-00-01 FIG 201 AND 51-20-02.

Part: BEARING — CORRODED (LT MLG) · corrosion level 2 · airframe 62,598 hrs · 28,772 cycles

FOUND OUTER HOUSING OF LT MLG AFT TRUNNION CORRODED. REPAIRED BY REMOVING AND REPLACING WITH P/N S113N103-5 IAW B757 MM 57-54-07.

Part: BEARING — CORRODED (RT MLG) · corrosion level 2 · airframe 62,598 hrs · 28,772 cycles

FOUND RIGHT MLG AFT TRUNNION BEARING HOUSING CORRODED AT RACE AND AFT TANG FWD OF THREADS. REPAIRED BY REMOVING AND REPLACING BEARING P/N S113N103-5 IAW B757 MM 57-54-07.

Part: FRAME — BENT (BS 660)

FOUND BENT MAIN FRAME UPPER SURFACE IN FWD PIT BS 660 AT S-24L. REPAIRED BY CUTTING OUT BENT SECTION OF FRAME. FABRICATED AND INSTALLED DOUBLER 11-1/2 BY ¼ BY 1 BY 2 FROM 7075-T6 .063 IAW B757 SRM 53-00-07 AND 51-20-01.

Part: SKIN — DAMAGED (BS 310)

FOUND LIGHTNING STRIKE AT BS 310 BETWEEN S-2R AND S-3R. REPAIRED BY CUTTING OUT STRIKE AREA, HFEC INSPECTED IAW B757 NTM PT6 51-00-01, 51-00-19 NO RELEVANT INDICATIONS NOTED. FABRICATED AND INSTALLED REPAIR DOUBLER 8.0 BY 7.75 FROM 2024-T3 .071 IAW B757 SRM 53-00-01 FIG 201.

Part: CHARGER — INOPERATIVE (EMERGENCY LIGHTS) · airframe 61,596 hrs · 28,488 cycles

FOUND EMERGENCY LIGHT INOP OVERHEAD SEAT 23D BY 2R DOOR. REMOVED AND REPLACED EMERGENCY BATTERY PACK ASSY. OPS OK.

Part: BRACE — CORRODED (NR 1 ENGINE) · airframe 57,164 hrs · 26,989 cycles

NR 1 ENGINE UPPER DIAGONAL BRACE FUSE PIN INNER BORE CORRODED. REPAIRED SAME.

Part: PITOT TUBE — UNRELIABLE · airframe 54,945 hrs · 26,300 cycles

ON CLIMBOUT FROM JFK IN ICING CONDITIONS LOST BOTH CAPT AND F/O AIRSPEED INDICATORS, AIRSPEED COMMAND BUGS WERE UNRELIABLE, AND LOST ALL ENGINE POWER SETTINGS INSTRUMENTS EPR N1, N2. EMERGENCY DECLARED. ONCE VFR EVERYTHING CAME BACK EXCEPT FOR EPR INDICATIONS. THOROUGHLY TESTED PITOT-STATIC SYSTEM - NTF.

Part: LINE — LOOSE (NR 1 ENGINE) · airframe 49,965 hrs · 24,459 cycles

ON TAKEOFF ROLL LT ENGINE WAS RUNUP TO 1.12..WHEN THROTTLES ADVANCED TO TO POWER THE LT ENGINE EPR ROLLED BACK TO 1.06. FOUND P4.9 LINE LOOSE. TIGHTENED SAME

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 47,635 hrs · 23,438 cycles

DURING LAYOVER FOUND AFT RIGHT F/A EMERGENCY FLASHLIGHT INOP. REPLACED BATTERY PACK.

Part: SKIN — DAMAGED (L/E SLAT) · airframe 44,509 hrs · 21,964 cycles

NR 7 SLAT HAS OVERSIZED HOLES COMMON TO THE TRAILING EDGE WEDGE, SKIN, AND RIB. REPAIR PER ER/A 401937-14AD.

Part: SKIN — DENTED (FS 620, S-17L) · airframe 43,869 hrs · 21,664 cycles

FUSELAGE / SKIN / FS 615-630 / STRG. 17L : SKIN CUTOUT REPAIR THE FUSELAGE SKIN WAS FOUND WITH AN EXISTING BLIND FASTENER REPAIR AND A DENT BETWEEN FS 615 & 630 AT STRINGER 17L. THEREPAIR WAS REMOVED AND ALL FASTENER HOLES COMMON TO THE REPAIR AND THE DENT REMOVED WITH A SINGLE 14" X 8 " CUTOUT. THE CUTOUT WAS REPAIRED WITH 2 EXTERNAL ALUMINUM DOUBLERS INSTALLED PER ER/A 381112-14, REV A.

Part: SKIN — GOUGED (FUSELAGE) · airframe 43,869 hrs · 21,664 cycles

THE FUSELAGE SKIN WAS FOUND WITH A GOUGE AT FS 283 ABOVE THE STRINGER 20R SKIN LAP SPLICE.

Part: IDG — MAKING METAL (NR 2 ENGINE) · airframe 42,947 hrs · 21,234 cycles

RIGHT GEN DRIVE LIGHT CAME ON DURING CLIMB. DISCONNECTED RIGHT DRIVE PER POM. FOUND METAL ON CHIP DETECTOR REPLACED IDG PER MM.

Part: SKIN — CRACKED (NR 2 PYLON)

THREE CRACKS WERE FOUND IN THE INBD STRUT SKIN OF THE NR 2 ENGINE PYLON. THE CRACKS WERE IN THE TYPICAL CUTOUT AREA AT NAC STA 107. THE CRACKS WERE CUTOUT AND REPAIRED WITH A TITANIUM DOUBLER AND TRIPLER PER DAL B757 SRM 54-51-01, FIG 203 AND DOCUMENTED PER ER/A 363804-14.

Part: CONTROLLERS — FAILED (CABIN)

BOTH AUTO PRESS CONTROLLER FAILED DURING CLIMBOUT. BITE CHECKED BOTH CONTROLLERS AND RESET BOTH. THEY BOTH HAD AC MOTOR, AC POWER OFF. VERIFIED EACH TWO TIMES, NO FAULTS. A/C RETURNED TO SERVICE I/A/W FIM 21-30-00 PG 108 FIG 104.

Part: POWER SUPPLY — INOPERATIVE (R2 DOOR)

C/B 11N36 EMERG CHARGER POPPED AND WOULD NOT RESET. EMERG EXIT LIGHTS ILLUM ON RT SIDE. REPLACED PWR SUPPLY M732 AND M10568. EMERG LIGHT OPS CK OK.

Part: OVEN — FAILED (MID GALLEY)

AT CRUISE, F/A REPORT ODOR OF OVERHEATED PLASTIC SMELL AT MID-GALLEY. ODOR PARTICULARLY STRONG AT MID-GALLEY VENT. REMOVED ALL POWER AND ODOR DISSIPATED IN APPROXIMATELY 1 HOUR. INSPECTED AREA FOR SHORTS AND CHAFES - N0NE NOTED. REPLACED SUSPECTED OVERHEATED/DEFECTIVE FWD FACING MID-GALLEY OVEN.

Part: LIGHT — INOPERATIVE (2R DOOR)

DOOR 2R SLIDE LIGHT INOP. REPLACED S10220 AND S10221 DOOR 2R SLIDE LIGHT, CHECKS NORMAL.

Part: SLIDE BOTTLE — LOW PRESSURE (R 2 DOOR)

DURING SERVICE CHECK, FOUND R-2 SLIDE BOTTLE PRESSURE BELOW LIMITS. REPLACED SAME.

Part: BULB — FAILED (CABIN)

LT AFT OVERWING EMERG LIGHT INOP. RELAMPED. OPERATION NORMAL.

Part: BULB — FAILED (CABIN)

DURING INSPECTION FOUND EMERGENCY FLOOR TRACK LIGHT AT ROW 34DEF INOP, RELAMPED, OPERATION NORMAL.

Part: BULB — FAILED (CABIN)

EMERG LIGHT SEAT 32ABC INOP, RELAMPED, OPERATION NORMAL.

Part: PANEL — DELAMINATED (LE SLAT)

DURING SHOP INSPECTION, SLAT PANEL WAS FOUND WITH T/E WEDGE DELAMINATED. WEDGE WAS REPLACED PER SRM 57-43-02.

Part: TE WEDGE — DELAMINATED (NR 10 LE SLAT)

DURING INITAL INSP THE TRAILING EDGE WEDGE WAS FOUND TO BE DELAMINATED. A NEW TRAILING EDGE WEDGE WAS INSTALLED IAW SRM 57-43-02, AND E/A NR 274662-14AD FOT THE RIGHT WING NR 10 L/E SLAT.