N645DL

Part: DISPLAY — MALFUNCTIONED (COCKPIT) · airframe 72,366 hrs · 32,328 cycles

DURING FLIGHT, AN ELECTRICAL BURNING SMELL WAS EXPERIENCED IN THE COCKPIT ALONG WITH LEFT HSI FAILURE. MAINTENANCE REPLACED THE LEFT HSI DISPLAY UNIT. OPERATIONAL CHECK WAS GOOD.

Part: TRANSMISSION — MALFUNCTIONED (RT WING TE FLAPS) · airframe 68,565 hrs · 31,091 cycles

UPON SELECTING FLAPS 20, BECAME STUCK BETWEEN 15 AND 20 AND TE FLAP DISAGREE EICAS MSG APPEARED EXECUTED PROC WITH TE FLAP DISAGREE AND FLAPS 26. PERFORMED FSEU BITE NTF INSP FLAP TRANSMISSION, FOUND RT W/W SIDEWAYS TRANSMISSION OVERLOAD INDICATOR POPPED. RESET INDICATOR AND SERVICED TRANSMISSION IAW AMM RAN FLAPS SEVERAL TIMES CKS GOOD IAW AMM.

Part: UNKNOWN — ODOR (CABIN) · airframe 66,167 hrs · 30,246 cycles

AT 40K FEET FLT NOTIFIED FLT CREW OF RUBBERY/SULFUR ODOR AROUND ROWS 23-27 IN PASSENGER CABIN. THE ODOR WAS EMANATING FROM THE FLOOR AREA. CREW DECIDED TO DIVERT TO IAD, DECLARED AN EMERGENCY. AT APPROX 20K FT ODOR WAS DISSIPATING, ON LANDING ODOR WAS GONE. INSPECTED A/C INCLUDING ENG 1 AND INSPECTED LT AND RT PACK BAY, APU AND BOTH PACKS FOR 90 MINUTES, RECIRC FAN AREA. INSPECTED PAX CA ELECTRONIC BOXES. INSPECTED OVHD PSUS IN AFFECTED AREA. NO TROUBLE.

Part: WIRE HARNESS — BROKEN (RT OVRWG SLIDE) · airframe 63,904 hrs · 29,505 cycles

RIGHT OVERWING SLIDE DID NOT DEPLOY DURING SAMPLING EVENT. TROUBLESHOT PER WD 25-65-21. FOUND WIRE HARNESS W0624 ON P79 PANEL TIED TOO TIGHT CAUSING WIRE COMING FROM RELAY BASE K10536 TO BE VERY TAUGHT. THIS CAUSED WIRE TO BREAK FROM PIN B1. REPLACED B1 PIN IN RELAY BASE K10536. TESTED FOR 28 VOLTS DC AT RIGHT OVERWING SLIDE PRESSURE BOTTLE SQUIB. TEST GOOD.

Part: SKIN — CRACKED (NR 1 PYLON) · airframe 54,630 hrs · 26,420 cycles

APPROX 1 INCH CRACK IN PYLON TORQUE BOX INBOARD SIDE, UPPER FWD CORNER OF FWD ACCESS HOLE, PREVIOUSLY STOP DRILLED. REFERENCE NR CARD 291 PSV 17 CHECK. INSTALLED PERMANENT REPAIR PER SRM 54-51-01D FIG 203.

Part: CONTROLLER — MALFUNCTIONED (LT A/C PACK) · airframe 51,325 hrs · 25,189 cycles

RT CRUISE FL350 GOT CABIN ALT WARNING. CABIN CONTINUED TO CLIMB TO 12,500 FT BEFORE REVERSING. INITIATED DESCENT TO FL240. CABIN WILL NOT HOLD WITH LEFT THROTTLE AT OR NEAR IDLE BOTH DUCT PRESSURES APPEAR NORMAL (40-42 PSI) AT CRUISE FL280 CABIN ALT AT 280 = 4000 FT, NO RATE NOTED IE PRESS STEADY. FOUND LT PAC BITE MSG WOULD NOT ERASE. FOUND LT PAC CONTROLLER FAULTING LT PAC CONTROL VALVE. REMOVED AND REPLACED SAME PER MM, RAN PAC NOW CHECKS GOOD. RAN ENGINES PER PFHB PRESS CABIN TO 5 PSI DIFF PRESS, ALL CHECKS GOOD, NO MESSAGES.

Part: TRANSCEIVER — BURNED (RADAR UNIT) · airframe 50,563 hrs · 24,902 cycles

FAINT ELECTRICAL ODOR IN COCKPIT AFTER ENGINES SHUT DOWN. ISOLATED TO BAD WX RADAR R/T WHICH FAILED ON TAXI IN. DEACT R/T BY PULLING C/BS AND DISPATCHED WITH RADAR INOP PER MEL 34-43-01A. REPLACED R/T UNIT.

Part: LINE — RUPTURED (HYD SYSTEM) · airframe 50,319 hrs · 24,803 cycles

ON TOUCHDOWN GOT LEFT HYDRAULIC SYSTEM FAILURE, QUANTITY IS AT .07RF. THE AIRCRAFT WAS TOWED BACK TO THE GATE, INSPECTED THE LEFT LANDING GEAR AND FOUND THE DOWNLOCK ACTUATOR FWD HYDRAULIC LINE LEAKING. THE LINE WAS REPLACED AND THE HYDRAULIC SYSTEM WAS REFILLED AND PRESSURIZED WITHOUT INCIDENT.

Part: SKIN — DENTED (FS 570, S-16L) · airframe 44,849 hrs · 22,498 cycles

FUSELAGE / SKIN / FS 570-660 / STRG. 14L-19L : GROUND DAMAGE SPLICE REPAIR THE FUSELAGE SKIN WAS FOUND WITH 2 DENTS IN CLOSE PROXIMITY TO AN EXISTING SKIN REPAIR DOUBLER. TO REMOVE ALL DAMAGE AND ACCOMPLISH A REPAIR, THE SKIN WAS CUT AT FS 570 BETWEEN THE SKIN LAP JOINTS AT STRG. 14L & 19L AND THE AFT SECTION OF SKIN REMOVED. A NEW SKIN SECTION WAS SPLICE IN WITH AN INTERNAL AND EXTERNAL ALUMINUM SPLICE DOUBLER PER ER/A 383226-14, REV A.

Part: HARNESS — OPEN (CARGO DOOR) · airframe 43,342 hrs · 21,793 cycles

EMERGENCY LIGHT ON C-2 CARGO DOOR INOP. DOOR HARNESS HAS OPEN. REPLACED SAME.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 42,620 hrs · 21,450 cycles

EMERGENCY LIGHT INOP. AT SEAT 20DEF. REPLACED EMERGENCY LIGHT ASSY. AT 20DEF; OPS CHECK GOOD. DELTA PART NUMBER 333201532 INSTALLED.

Part: HARNESS — DAMAGED (ROW 21)

SEAT 21 D, E, F EMERGENCY LIGHT INOP. FOUND WIRE HARNESS DAMAGED. REPLACED WIRE HARNESS, OPS NORMAL.

Part: RADOME — BROKEN (FWD FUSELAGE)

ON CLIMBOUT ABOUT 13,000 FT, HEARD TWO LOUD BANGING NOISE FOLLOWED BY LOUD AIR NOISE IN NOSE GEAR AREA. FOUND RADOME AND RADAR ANTENNA DAMAGED. MAINT IN PROGRESS.

Part: FAIRING — GAPPED (LT HORIZ STAB)

AIRFRAME BUFFET AFTER TAKEOFF. WORSE WITH INCREASE IN ALT AND SPEED FELT THROUGH CONTROLS FIRST THEN UP THROUGH SEAT. F/A FELT ALL THE WAY TO BACK OF PLANE. INSPECTED FUSELAGE AND WINGS INCLUDING FLT CONTROLS AND FLAPS AND ALSO EMPENNAGE. FOUND LT LWR STAB FAIRING GAPPED, SHIMMED FAIRING. PERFORMED TEST FLT PER SP 4080, NO DISCREPANCIES NOTED BY FLT CREW OR INSPECTOR DURING TEST FLT.

Part: OUTFLOW VALVE — FAILED (CABIN)

BOTH 1 AND 2 AUTO PRESS SYSTEMS INOP. REPLACED OUTFLOW VLV.

Part: PSUS — MALFUNCTIONED (CABIN)

THE FOLLOWING PSUS DID NOT OPEN WHEN O2 SYS ACTIVATED PASSING 36,000 FT, WHEN CABIN LOST PRESSURIZATION 2AB, 2CD, 23DEF, 24ABC, 34DEF, 37DEF. DNTC REPLACED ABOVE LISTED PSUS.

Part: SEAL — FAILED (CARGO DOOR)

WHILE PASSING THRU 36,000 FT, LOST CABIN PRESSURIZATION. MADE EMERGENCY DESCENT, O2 MASKS AUTO DEPLOYED AT 14,000 FT CABIN ALTITUDE. A 2 FT SECTION OF C2 CARGO DOOR SEAL MISSING ON ARRIVAL ATL. REPLACED DOOR SEAL.

Part: WEDGE — DELAMINATED (NR 9 LE SLAT TE)

THE NR 9 LEADING EDGE SLAT WEDGE WAS DELAMINATED. REPLACED SLAT.

Part: WIRE — BROKEN (CABIN)

F/C TRACK LIGHTS INOP. REPAIRED BROKEN WIRES AT FLOOR TRACK, OPN NORM.

Part: VALVE — FAILED (LT MLG)

ON TAKEOFF, EICAS PROBE HEAT ADVISORY DISPLAYED. EICAS STATUS NOSE A/G DISAGREE. UNABLE TO RAISE GEAR. RETURNED DFW. FOUND LEFT TRUCK SHUTTLE VALVE FAULTY. REPLACED VALVE, SWUNG GEAR RETURNED TO SERVICE.

Part: PUMP — CRACKED (NR 2 ENGINE)

DURING CRUISE, NR 2 ENGINE OIL QUANTITY STEADILY DECREASED. INSPECTION OF NR 2 OIL SYSTEM FOUND THE ENGINE SCAVANGE OIL PUMP WITH A CRACKED PUMP CASE. REPLACED OIL PUMP, OPERATION NORMAL.