N641DL

Part: BALLAST — SMOKE (CABIN LIGHTS) · airframe 71,337 hrs · 31,314 cycles

MULTIPLE ELECT FAILURE AND ELECTRICAL SMOKE OCCURED DURING APPROACH. F/C LIGHTS BLINKED REPEATEDLY DURING EVENT. SMOKE WAS FROM ROW 5 FWD. STRONGEST ON LT SIDE. LOWERED ALL PSU IN FIRST CLASS CABIN. INSPECTED WIRING AND PSU FOR DAMAGE AND EVIDENCE OF SMOKE. NON NOTED. OPENED O/H PANELS. NO DAMAGE OR EVIDENCE OF SMOKE. FOUND 2 EA LOWER SIDEWALL LIGHT BALLAST AT ROW 4 AND 6 HOT. R & R WITH SAME. RESECURED PSU AND OVERHEAD PANELS. OK FOR SERVICE MCO PLAC RMVD.

Part: WIRE — SHORTED · airframe 68,438 hrs · 30,523 cycles

WHILE TROUBLESHOOTING INBOUND WRITE UP, IRU DC FAIL MSG. FOUND WIRE BUNDLE W0072, W0066, AND W0074 ALL CHAFING AND SHORTED AGAINST SUPPORT BRACKET BEHIND P6-1 PANEL. AS PANEL WAS BEING CLOSED THE LAST TIME, THE BRACKET SHORTED BUNDLE AND CAUGHT FIRE. FIRE IMMEDIATELY EXTINGUISHED BY AMT.

Part: SENSOR — OUT OF ADJUST (PAX DOOR) · airframe 68,267 hrs · 30,479 cycles

REJECTED TO FOR RT AFT ENTRY DOOR LIGHT 90-100KTS. ABORT/ROLLOUT UNEVENTFUL. PERFORMED INSPECTION OF RT AFT ENTRY DOOR, NTF FWD TO MCO. PERFORMED HIGH ENERGY STOP INSPECTION. FOUND DOOR RT AFT SENSOR OUT OF ADJUSTMENT. ADJ PER AMM 52-71-00-825-001. MCO AND PLACARD REMOVED.

Part: STRINGER — CORRODED (BS 1710 S27L) · airframe 66,173 hrs · 29,794 cycles

STA 1710 STR 27L HAS EXFOLIATING CORROSION AFT CARGO BAY. REPLACED STR SECTION PER SRM 53-00-03 FIG 201 REF NR 78981650001.

Part: CHANNEL — CORRODED (BS 1720 S21L) · airframe 66,173 hrs · 29,794 cycles

AFT CARGO STA 1720 STR 21L IS CORRODED/SPLICED IN NEW HAT CHANNEL PER SRM 53-00-03 FIG 201 REF NR78980200001.

Part: STRINGER — CORRODED (BS 1710 S24L) · airframe 66,173 hrs · 29,794 cycles

AFT OF AFT CARGO BAY CORROSION AT STR 24L STA 1710/SPLICED STR HAT SECTION FROM STA 1690 TO 1720 PER SRM 53-00-03 FIG 201 AND 51-20-01 ON SAA N/R 78980240001.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 66,164 hrs · 29,792 cycles

STR 20L AT 1680 AND STA 1700 FOUND CRACKED AND CORRODED. REMOVED DAMAGE, FABRICATED STRINGER, SPLICED, TREATED, IAW 757 SRM 51-40-05 F 201,

Part: STRUCTURE — CORRODED (BULKHEAD) · airframe 66,164 hrs · 29,792 cycles

DURING HMV FOUND AFT CHORD CORRODED AROUND SEVERAL HOLES AFTER STR STR 27L TO 20L. REPLACED A SECTION OF THE CHORD PER SMR 53-80-08D REF SAA N/R 78986090001.

Part: STRINGER — CORRODED (BS1710 S26L) · airframe 66,164 hrs · 29,792 cycles

STR 26L AT STA 1710 WAS FOUND TO HAVE CORROSION UNDER STRINGER. REPAIRED PER SRM 53-80-08 FIG 201.

Part: SKIN — DENTED (BS 192) · airframe 66,164 hrs · 29,792 cycles

DENT ON STR BETWEEN STR 28R AND 29R AT STA 192. REPAIRED DENT PER SRM 53-00-01 REF SAA N/R 78986200001.

Part: STRINGER — CORRODED (BS 1460-1480) · airframe 66,164 hrs · 29,792 cycles

STR 28 L HAS 2 AREAS OF CORROSION BETWEEN STA 1460 AND 1480/SRM 51-40-05. REPAIR REPORTED PER SRM 53-00-03.

Part: STRINGER — CORRODED (BS 1700 S23L) · airframe 66,164 hrs · 29,792 cycles

STR 23L AT STA 1700, FOUND CORROSION. REPAIRED PER SRM 53-00-03 FIG 201.

Part: STRINGER — CORRODED (BS 1720 S22L) · airframe 66,164 hrs · 29,792 cycles

STR 22L AT STA 1710, FOUND CORROSION. REPAIRED PER SRM 53-00-03 FIG 201.

Part: STRUCTURE — CORRODED (BS 1720 S19L) · airframe 66,164 hrs · 29,792 cycles

DURING HMV AT SAA, CORROSION WAS FOUND ON THE HORIZONTAL AFT CHORD OF THE AFT PRESSURE BULKHEAD, FORWARD SIDE AT STA 1720, S-19L. THE CORROSION WAS REPAIRED PER BOEING INSTRUCTIONS AS DOCUMENTED IN ER/A 06-468363-14.

Part: BULKHEAD — WORN (NR 1 PYLON) · airframe 66,146 hrs · 29,786 cycles

THE NR 1 PYLON AFT BULKHEAD O/B VERTICAL FLANGE AT NAC STA 203 WAS FOUND WITH WEAR. THIS WEAR WAS CAUSED BY THE RUBBING OF THE PYLON AFT FAIRING UPPER SPAR FLANGE. THIS WEAR WAS FOUND DURING ACCOMPLISHMENT OF THE SIP MOD, S/B B757-54-0034. REPAIR WAS ACCOMPLISHED WITH INSTALLATION OF A GUSSET AND FILLER. AFTER BLENDOUT THE MAXIMUM WEAR DIMENSIONS WERE 1.7" X 1.25" X 0.140" DEEP. AD 2003-18-05 APPLIES.

Part: FITTING — DAMAGED (NR 2 PYLON) · airframe 66,148 hrs · 29,787 cycles

DURING HMV AT SAA, A HOLE WAS MISDRILLED COMMON TO THE NR 2 PYLON MIDSPAR FITTING, WEB, CHORD AND DOUBLER. THE HOLE WAS REAMED, BUSHED, AND REDRILLED PER BOEING INSTRUCTIONS.

Part: FITTING — DAMAGED (NR 2 PYLON) · airframe 66,148 hrs · 29,787 cycles

DURING ACCOMPLISHMENT OF THE SIP MOD PER S/B 757-54-0034 REV 1, THE NR 2 PYLON MID SPAR FITTING UPPER HORIZONTAL TANGE WAS MISDRILLED IN A FORWARD MOST HOLE LOCATION. THE FINAL CLEANUP SIZE HOLE WAS 0.704". A BUSHING AND RETENTION WASHER WERE INSTALLED AS A REPAIR. AD 2003-18-05 APPLIES.

Part: BRACE — DAMAGED (NR 1 PYLON) · airframe 66,148 hrs · 29,787 cycles

DURING ACCOMPLISHMENT OF THE SIP MOD, S/B 757-54-0034 REV 1, THE DIAGONAL BRACE LOWER/FWD I/B LUG WAS INADVERTENTLY OVERSIZED TO 2.003" INSTEAD OF THE REQUIRED 2.000" MAXIMUM. AN OVERSIZED BUSHING WAS INSTALLED. AD 2003-18-05 APPLIES.

Part: MANIFOLD — BROKEN (NR 2 ENGINE) · airframe 65,846 hrs · 29,687 cycles

RT ENG OIL QTY AT ZERO AND OIL PRESSURE DROPPING WITH OIL PRESS LIGHT FLICKERING AT CRUISE. MX FOUND THE MAIN BEARING BREATHER MANIFOLD BROKEN. REPLACED SAME, RAN ENGINE LEAK CHECKS GOOD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 59,662 hrs · 27,780 cycles

THE FUSELAGE SKIN HAS A 4 INCH CRACK RUNNING FROM THE FORWARD UPPER CORNER OF HTE L-1 DOOR OPENING. THE CRACK IS IN THE SKIN AND BEARSTRAP. THE CRACKED SKIN WAS CUT OUT AND A REPAIR DOUBLER WAS INSTALLED.

Part: SKIN — FATIGUED (FUSELAGE) · airframe 59,662 hrs · 27,780 cycles

FOUR INCH CRACK IN FUSELAGE SKIN AND BEAR STRAP AT THE UPPER FWD CORNER OF L1 DOOR OPENING. EXTERNAL DOUBLER/TRIPLER/QUADRUPLER INSTALLED PER DELTA ERA 456338-14.

Part: WIRE — DAMAGED (EMERGENCY LIGHT) · airframe 54,823 hrs · 26,112 cycles

EMERGENCY LIGHT AT 23D INOP. FOUND BROKEN WIRE UNDER SEAT 23F. REPAIRED WIRE.

Part: BATTERY — UNSERVICEABLE (EMERGENCY LIGHT) · airframe 53,114 hrs · 25,506 cycles

EMERGENCY ESCAPE LIGHTING IN F/C VERY DIM ON TEST. REPLACED BATTERY PACK IN EMERGENCY ESCAPE PATH PWR SUPPLY M9101 IAW AMM. CKS GOOD.

Part: GARLOCK SEAL — LEAKING (NR 1 ENGINE) · airframe 45,670 hrs · 22,360 cycles

LEFT ENG OIL QTY DECREASING DURING FLIGHT. DECREASED TO -0- ON APPROACH. REPLACED NUMBER 5 BEARING COVER GARLOCK SEAL.

Part: SKIN — GOUGED (FS 1708, S-17L) · airframe 45,662 hrs · 22,356 cycles

FUSELAGE / SKIN / FS 1708 / STRG. 17L : GOUGE CUTOUT REPAIR THE FUSELAGE SKIN WAS FOUND GOUGED AT FS 1708 JUST BELOW STRINGER 17L. THE GOUGE WAS REMOVED WITH A CUTOUT TO THE SKIN. THE CUTOUT WAS REPAIRED WITH 2 EXTERNAL ALUMINUM DOUBLERS PER ER/A 382720-14, REV A.

Part: SIGN — BROKEN (CABIN) · airframe 43,383 hrs · 21,299 cycles

FOUND DURING LAYOVER EMERGENCY EXIT IDENTIFIER AT R2 DOOR F/A SEAT BROKEN REPLACED SIGN BASE AND LENS COVER. OPERATIONAL CK OK.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 43,383 hrs · 21,299 cycles

SEAT MOUNTED ESCAPE PATH LIGHTING INOP AT SEAT 1CD. RELAMPED SAME, NO HELP. REMOVED/REPLACED ILLUMINATOR ASSY OPS CKS OK.

Part: LIGHT — MISSING (CABIN) · airframe 43,383 hrs · 21,299 cycles

SEAT MOUNTED ESCPAPE PATH LIGHTING COMPLETELY MISSING AT SEAT 2CD REPLACED ILLUMINATOR ASSY. OPS CKS OK.

Part: SEAL — MISSING (SURVIVAL KIT) · airframe 43,383 hrs · 21,299 cycles

SURVIVAL KIT FOR 2L DOOR MISSING LEAD SEAL. REMOVED AND REPLACED SURVIVAL KIT FOR 2L DOOR.

Part: BATTERY — DISCHARGED (FLASHLIGHT) · airframe 42,686 hrs · 20,983 cycles

FWD FLIGHT ATTENDANT EMERGENCY FLASHLIGHT HAS WEAK BATTERY. REPLACED BATTERY, OPS NORMAL.

Part: HEATER — INOPERATIVE (WINDOW HEAT) · airframe 39,921 hrs · 19,712 cycles

SMOKE AND FUMES IN COCKPIT COMING FROM UNDER F/O GLARESHIELD. DIVERTED TO KIAH. FOUND LOWER TERMINAL R-1 WINDOW BURNED AND BROKEN OFF. REPLACED WINDSHIELD AND CONTROLLER.

Part: BULB — FAILED (COCKPIT)

WHEN GEAR EXTENDED LEFT MAIN DID NOT GO GREEN. ALTERNATE GEAR EXTENSION PER POM, NO HELP. RELAMPED INDICATOR.

Part: ENGINE — FAILED (NR 1)

ON CLIMB-OUT, FL 260, LT ENG STALLED AND QUIT ALL ENG IND WENT BLANK CLB 2 SELECTED SHUTDOWN CK LIST C/W RETURNED TO CVG. REPLACED NR 1 ENG PMA AND ROTOR SHAFT CKS, OK.

Part: STATOR — FAILED (NR 1 ENGINE)

NR 1 ENG STALLED AT V1 AND AUTO SHUT DOWN HARD CARD AND POM EMERGENCY PROCEDURES FOLLOWED RETURNED TO RUNWAY 9L. BORESCOPED OK OF 6TH STAGE LPT - 16TH STAGE HPC CKS OK, CKD WIRING BETWEEN EEC AND SVA ALL OK. REPLACED EEC AND SVA AS PRECAUTION DUE TO EICAS MSG. FOUND PMA ROTOR AND STATOR BAD. REPLACED SAME, OP CKS OK. RAN ENG PER PFHB, CKS OK.

Part: ECU — FAILED (APU COMPT)

APU FLAMED OUT IN FLT FOLLOWED PROCEDURES AND GOT APU FAULT LIGHT, NO START ALLOWED. ONE ENG GEN PREV DEFERRED, ROBBED APU CONTROL ECU FROM A/C 628. INSTALLED BITE CK OK. OPERATED APU W/AIR AND ELECTRIC OPS NML.

Part: WEDGE — DELAMINATED (LE SLATS TE)

NUMBER 1, 6, 7 AND 9 SLAT WEDGE DELAMINATED. REPLACED ALL FOUR SLATS.

Part: BULB — FAILED (LT MLG)

ON GEAR EXT LEFT MAIN DID NOT GO GREEN. TOWER THOUGHT LEFT GEAR WAS UP. USED ALT EXT, NO GREEN. FOUND BOTH LEFT GEAR IND LIGHTS INOP. RELAMPED SAME, OPN NORM ON TEST FLIGHT.

Part: TE WEDGE — DELAMINATED (NR 2 LE SLAT)

T/E WEDGE DELAMINATED. COMPLIED WITH AD 90-23-06 PER SRM 57-54-02 FIG 202, FOR NR 2 L/E SLAT AT SHOP INSPECTION.

Part: SKIN — DELAMINATED (NR 3 LE SLAT)

TRAILING EDGE WEDGE DELAMINATED. REPLACED TRAILING EDGE WEDGE PER SRM 57-43-02 FIG. 202, DURING SHOP INSPECTION OF NR 3 L/E SLAT.