N645FE

Part: TRANSMITTER — INOPERATIVE (FUEL FLOW) · airframe 77,831 hrs · 13,557 cycles

SHORTLY AFTER BEGINNING TAKEOFF ROLL, NR 1 FUEL FLOW SHOWED AMBER X. REJECTED TAKEOFF AT ABOUT 60 TO 70 KTS. FUEL FLOW INDICATING NORMAL AGAIN WHILE TURNING OFF RUNWAY. TROUBLESHOOTING FOUND FUEL LEAK FROM THE FUEL FLOW TRANSMITTER. R & R NE 1 ENGINE FUEL FLOW TRANSMITTER IAW AMM 73-31-02-4-2, FUNCTIONAL TEST OF FUEL FLOW UNIT PASSED IAW AMM 73-31-03, AND LEAK CHECKED GOOD IAW AMM 71-02-03.

Part: SKIN — SEPARATED (RT WING AILERON) · airframe 77,827 hrs · 13,553 cycles

RIGHT WING INBD AILERON T/E FOUND SKIN SEPARATED. REPAIRED RIGHT WING INBOARD AILERON TRAILING EDGE AS PER SRM 57- 50-02 REPAIR 3 FIGURE 201 REVISION 52 AND EA 1-5750-T0301032 PART 1. REPAIR CLASSIFIED CLASSIFIED MAJOR AS PER GMM 6-2-100 REVISION 116.

Part: SKIN — DELAMINATED (LT WING TE FLAP) · airframe 77,827 hrs · 13,553 cycles

LEFT WING OTBD FLAP LOWER SURFACE T/E FOUND DELAMINATED XOFH 681.500 TO XOFH 689.500. REPAIRED IAW EA 1-5750-T0300982. REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 116.

Part: SKIN — DELAMINATED (ZONE 500) · airframe 77,827 hrs · 13,553 cycles

LEFT WING OTBD FLAP LOWER SURFACE T/E FOUND DELAMINATED XOFH 553.00 TO XOFH 568.00. REPAIRED IAW EA 1-5750-T0300982. REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100 REV 116.

Part: SKIN — DELAMINATED (RT WING TE FLAP) · airframe 77,827 hrs · 13,553 cycles

RIGHT WING OTBD FLAP LOWER SURFACE FOUND DELAMINATED XOFH 673.542 TO XOFH 667.542. REPAIRED IAW EA 1-5750-T0300985 PART 1. REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 116.

Part: SKIN — DELAMINATED (RT WING TE FLAP) · airframe 77,827 hrs · 13,553 cycles

RIGHT WING OTBD FLAP T/E, LOWER SURFACE FOUND DELAMINATED XOFH 527.690 TO XOFH 552.690. REPAIRED IAW EA 1-5750-T0300985, PART 1. REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REVISION 116.

Part: SKIN — DELAMINATED (RT WING TE FLAP) · airframe 77,827 hrs · 13,553 cycles

RIGHT WING OTBD FLAP T/E, UPPER SURFACE FOUND DELAMINATED AT XOFH 524.690 TO XOFH 554.690. REPAIRED IAW EA 1-5750-T0300985, PART 1. REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 116.

Part: SKIN — CRACKED (ZONE 600) · airframe 77,827 hrs · 13,553 cycles

TEN FASTENER HOLES FOUND TO HAVE CRACK INDICATIONS DURING OPEN HOLE HIGH FREQUENCY EDDY CURRENT INSPECTION, RT WING LOWER SKIN ACCESS DOOR CUT-OUT BETWEEN XORS= 683.4 AND 713.6. REPAIRED IAW SRM 57-20-02 REPAIR 5 FIGURE 201 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: SKIN — CRACKED (ZONE 500) · airframe 77,827 hrs · 13,553 cycles

EIGHT FASTENER HOLES FOUND TO HAVE CRACK INDICATIONS. DURING OPEN HOLE HIGH FREQUENCY EDDY CURRENT INSPECTION ONE LT WING LOWER SKIN ACCESS DOOR CUT-OUT BETWEEN STATION XORS= 683.4 AND 713.6. REPAIRED IAW SRM 57-20-02 REPAIR 5 FIGURE 201 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: FITTING — CORRODED (LT WING TE FLAP) · corrosion level 2 · airframe 77,827 hrs · 13,553 cycles

LEFT WING INBD FLAP DRIVE ARM SUPPORT BORE FOUND CORRODED. BORE REWORKED IAW SRM 51-21-01 REVISION 52 REPAIRED IAW EA 1-5750-T0300933A PART 1. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: HINGE BRACKET — CORRODED (LT WING TE FLAP) · corrosion level 2 · airframe 77,827 hrs · 13,553 cycles

LT INBD FLAP, OTBD HINGE (FLAP MOUNTED) PIVOT ATTACHMENT OTBD LUG, BORE FOUND CORRODED. BORE REWORKED FOUND EXCEED LIMITS IAW CMM 57-52-03 REVISION 76. REPAIRED IAW EA 1-5750-T0300889. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: HINGE — CORRODED (RT WING TE FLAP) · corrosion level 2 · airframe 77,827 hrs · 13,553 cycles

RIGHT INBD FLAP, OTBD HINGE (FLAP MOUNTED) PIVOT ATTACHMENT INBD LUG BORE FOUND CORRODED. BORE REWORKED AND FOUND EXCEED LIMITS IAW CMM 57-52-03 REVISION 76. REPAIRED IAW EA 1-5750-T0300874 B PART 1. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: HINGE — CORRODED (RT WING TE FLAP) · corrosion level 2 · airframe 77,827 hrs · 13,553 cycles

RIGHT INBD FLAP, OTBD HINGE (FLAP MOUNTED) PIVOT ATTACHMENT OTBD LUG BORE FOUND CORRODED. BORE REWORKED AND FOUND EXCEED LIMITS IAW CMM 57-52-03 REVISION 76. REPAIRED IAW EA 1-5750-T0300874 B PART 1. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: HINGE BRACKET — CORRODED (LT WING TE FLAP) · corrosion level 2 · airframe 77,827 hrs · 13,553 cycles

LEFT INBD FLAP, OTBD HINGE (FLAP MOUNTED) PIVOT ATTACHMENT INBOARD LUG BORE FOUND CORRODED. BORE REWORKED AND FOUND EXCEED LIMITS IAW CMM 57-52-03 REVISION 76. REPAIRED IAW EA 1-5750-T0300889. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: FRAME — DENTED (ZONE 200) · airframe 77,827 hrs · 13,553 cycles

FRAME BS 1761, LONGERON 12L FOUND DENTED. REPAIRED IAW SRM 53- 00-07 FIGURE 201 REPAIR 2 REVISION 52. REPAIR CLASSIFIED AS MAJOR AS IAW GMM 6-2-100 REVISION 116.

Part: FRAME — DENTED (BS 1701) · airframe 77,827 hrs · 13,553 cycles

FRAME, BS 1701, LONGERON 12R FOUND DENTED. REPAIR CARRIED OUT IAW SRM 53-00 07 FIGURE 201 REPAIR 2 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: FRAME — DENTED (BS 1721) · airframe 77,827 hrs · 13,553 cycles

FRAME BS 1721, LONGERON 12R, FOUND DENTED. REPAIR CARRIED OUT IAW SRM 53-00 07 FIGURE 201 REPAIR 2 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: FRAME — DENTED (ZONE 200) · airframe 77,827 hrs · 13,553 cycles

FRAME BS 1681, LONGERON 12L FOUND DENTED. REPAIRED IAW SRM 53-00-07 FIGURE 201 REPAIR 2 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: FRAME — DENTED (BS 1641) · airframe 77,827 hrs · 13,553 cycles

RIGHT FRAME BS 1641, LONGERON 12R FOUND DENTED. REPAIR CARRIED OUT IAW SRM 53-00 07 FIGURE 201 REPAIR 2 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: SKIN — CHAFED (LT AILERON) · airframe 77,827 hrs · 13,553 cycles

LEFT INBD AILERON LOWER SKIN CHAFED AT TWO LOCATIONS. DAMAGED SKIN REMOVED AND FABRICATED NEW SKIN AS PER EA 1-5750-T0300853 AND REPLACED. REPAIR CLASSIFIED AS MINOR AS PER GMM 6-2-100 REVISION 116.

Part: FRAME — CHAFED (BS 535) · airframe 77,827 hrs · 13,553 cycles

LEFT SUPPORT YOKE BS 535, LONGERON 21L FRAME FOUND CHAFED. REPAIRED IAW SRM 53-20-07 FIGURE 201 REPAIR 1 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: FRAME — DENTED (ZONE 200) · airframe 77,827 hrs · 13,553 cycles

FRAME BS 1701, LONGERON 12L FOUND DENTED. REPAIRED IAW SRM 53-00-07 FIGURE 201 REPAIR 2 REVISION 52. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100 REVISION 116.

Part: FRAME — CHAFED (BS 535) · airframe 77,827 hrs · 13,553 cycles

CABIN - LEFT SUPPORT YOKE, BS 535, LONGERON 19L, FRAME FOUND CHAFED. REPAIRED IAW SRM 53-20-07 FIGURE 202 REPAIR 1 REVISION 52. CLASSIFIED A MAJOR REPAIR IAW GMM 6-2-100 REVISION 116.

Part: UNKNOWN — UNKNOWN (FLAP SYSTEM) · airframe 77,076 hrs · 13,315 cycles

REJECT TAKE OFF AT 85 KTS FOR FLAP WARNING ON EAD. PERFORMED R-T-S OF NR 1 AND NR 2 FCC'S IAW MM 27-54-00-5. RAN FLAPS FULL TRAVEL DOWN AND UP ALL INDICATIONS NORMAL. BOTH FCC'S PASSED R-T-S.

Part: LANDING GEAR — MALFUNCTIONED · airframe 76,810 hrs · 13,242 cycles

ON APPROACH, THE EAD DISPLAYED A WHITE BOX WITH "LANDING GEAR." THE "GEAR UNSAGE INDICATION WITH GEAR HANDLE DOWN," QRH CHECKLIST WAS ACCOMPLISHED. ON SECOND APPROACH ALL INDICATION NORMAL. PVG U CONSULTED WITH CREW, KNEW THAT SECOND L/G INDICATION ON LT GEAR FLASH RED WHEN THE WHITE BOX SHOWED UP, PRIMARY INDICATION WAS NORMAL ALL THE WAY.

Part: SKIN — CRACKED (LT WING) · airframe 73,567 hrs · 12,217 cycles

LT WING FIXED L/E TELESCOPIC DUCT DOOR CUTOUT CORNER FOUND CRACKED. REPAIRED IAW SRM 57-40-01 FIG 202, REV 46. REPAIR 10. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: SKIN — CORRODED (BS 1235) · corrosion level 2 · airframe 73,567 hrs · 12,217 cycles

MAIN DECK INTERIOR, FOUND UNDERFLOOR STRUCTURE AT STA 1235,RBL 51" WITH CORROSION. CORROSION REMOVED PER SRM51-21-01 REV 46. FOUND EXCEEDED LIMIT PER SRM 57-10-01 FIG 101 REV 46. CARRIED OUT ON REWORKED AREA FOUND NO CRACK & NO CORROSION. HFEC INSPECTION CARRIED OUT ON FASTENER HOLES FOUND NO CRACK. CARRIED OUT REPAIR PER EA 1-5730-152684. REPAIR CLASSIFIED AS MAJOR PER GMM6-2-100 REV 112.

Part: SKIN — CRACKED (RT WING) · airframe 73,567 hrs · 12,217 cycles

RT WING FIXED L/E TELESCOPIC DUCT DOOR CUTOUT CORNER FOUND CRACKED. REPAIRED IAW SRM 57-40-01, FIG 202. REPAIR 10, REV 46. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: SKIN — CORRODED (BS 1203) · airframe 73,567 hrs · 12,217 cycles

MAIN DECK INTERIOR, FOUND UNDERFLOOR STRUCTURE AT STA.1203", LBL 103" WITH CORROSION. CORROSION REMOVED PER SRM51-21-01 REV 46. EXCEEDED LIMIT PER SRM57-10-01 FIG 101 REV 46. HFEC INSPECTION FOUND NO CRACKS. FABRICATED & INSTALLED REPAIR PER EA 1-5730-152684. REPAIR CLASSIFIED AS MAJOR PER GMM6-2-100 REV 112.

Part: SKIN — CORRODED (BS 1230) · airframe 73,567 hrs · 12,217 cycles

MAIN DECK INTERIOR , FOUND UNDERFLOOR STRUCTURE AT STA. 1230, LBL 103" WTH CORROSION. EXCEEDED LIMIT PER SRM57-10-01 FIG 101 REV 46. HFEC INSPECTION FOUND NO CRACKS. MAIN DECK INTERIOR STA.1230 LBL 103 UNDERFLOOR DOUBLER / SHIM FABRICATED & INSTALLED PER EA 1-5730-152684 REPAIR CLASSIFIED AS MAJOR PER GMM6-2-100 REV 112.

Part: SKIN — DAMAGED (ZONE 200) · airframe 73,567 hrs · 12,217 cycles

CABIN - DOOR 4 LT AFT CUTOUT INBD SKIN BETWEEN LONGERON 20 LT TO 21 LT SKIN PUNCTURED. DAMAGED AREA TRIMMED OUT PER SRM53-00-00 FIG 204 REV 46. HFEC INSPECTION CARRIED OUT ON TRIMMED AREA, FOUND NO CRACK. REPAIR DOUBLER FABRICATED AND INSTALLED PER SRM53-00-00 FIG 204 REV 46. REPAIR CLASSIFIED AS MAJOR PER GMM6-2-100 REV 112.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 73,567 hrs · 12,217 cycles

CABIN - LT STRUCTURE UNDER DADO SUPPORT FROM FRAME 5-113 TO 1541 FOUND CORRODED. CARRIED OUT SEAT TRACK SECTIONAL REPAIR PER SRM53-00-52 FIG 101 REV 46. REPAIR CLASSIFIED AS MAJOR PER GMM6-2-100 REV 112.

Part: SHROUD — CRACKED (FUEL SYSTEM) · airframe 73,567 hrs · 12,217 cycles

AFT CARGO COMPARTMENT - TAIL TANK TRANSFER FUEL LINE SHROUD FOUND CRACKED AT STATION Y=2005 DURING CHECK. REPAIRED LINE, LEAK CHECK CARRIED OUT AS PER AMM 28-25-00-5 REV 70.0, NO LEAK FOUND. REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100 REV 112.

Part: BULKHEAD — MISREPAIRED (RT MLG WW) · airframe 73,567 hrs · 12,217 cycles

REPAIR FOUND AT RT MLG WW HORIZONTAL PANEL CTR AREA SPLICE PLATE. FOUND MISREPAIRED. CARRIED OUT REPAIR AS PER EA1-5310-147672 REPAIR CLASSIFIED MAJOR AS PER GMM 6-2-100 REV 112.

Part: INTERCOSTAL — CORRODED (BS 1341-1361) · airframe 73,567 hrs · 12,217 cycles

LONGERON NR 20R BETWEEN STA 1341 TO STA 1361 CORRODED INTERCOSTAL REMOVED. NEW INTERCOSTAL FABRICATED IAW DWG AEA0163 REV 'C'. FPI CARRIED OUT ON NEW FABRICATED INTERCOSTAL FOUND NO CRACK. NEW FABRICATED INTERCOSTAL HOLES TRANSFERRED, PROTECTED, PAINTED, PART MARKED & INSTALLED. REPAIR CLASSIFIED AS MINOR IAW GMM6-2-100, REV 112.

Part: STRUCTURE — CORRODED (FUSELAGE) · airframe 73,567 hrs · 12,217 cycles

UPON REMOVAL OF LT WINDSHIELD, CUTOUT AREA FOUND CORRODED. CARRIED OUT REPAIR IAW EA 1-5310-147652, REPAIR CLASSIFIED AS MINOR IAW GMM6-2-100, REV 112.

Part: SPAR — CRACKED (VERTICAL STAB) · airframe 73,567 hrs · 12,217 cycles

VERTICAL STABILIZER REAR SPAR NR 4 BANJO FITTING SUSPECT CRACK AT STA 2164 AND ZID 54.5 AREA. (REFER TO SRM 55-30-02, FIG 201). REPAIRED AS PER SRM 55-30-02 FIG 201 REPAIR 3 REV 46. THIS REPAIR CLASSIFIED AS MAJOR AS PER GMM 6-2-100 REV 112. TO CARRY OUT INITIAL INSPECTION AT 5,400 F.C AND REPETITIVE INSPECTION AT 2,700 F.C AS PER DWG SN10550000 REV NEW.

Part: LONGERON — CORRODED (BS 1059-1079) · airframe 73,567 hrs · 12,217 cycles

FWD CARGO COMPARTMENT, DURING REPAIR OF CORROSION LONG.48R STA 1059-1079 FOUND OUT CORROSION AT STA 1099 OF LONG 48R. CORRODED AREA REMOVED IAW SRM 51-21-01, REV 46. ORIGINAL THICKNESS : 0.080" & REMAINING THICKNESS : 0.00" FOUND EXCEEDED LIMIT IAW SRM 53-00-00 FIG 205, REV 46. REPAIRED IAW SRM 53-00-05, FIG 202, REV 46. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 73,567 hrs · 12,217 cycles

LT SEAT TRACK UNDER DADO SUPPORT FROM FRAME 5-53 TO 5-73 FOUND CORRODED. CARRIED OUT SEAT TRACK SECTION REPAIR. REPAIR CLASSIFIED AS MAJOR REPAIR IAW GMM 6-2-100, REV 112.

Part: HINGE FITTING — CORRODED (LT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

LEFT WING OTBD FLAP, INBD HINGE (WING SIDE) SIDE LINK HOLE SPOT FACE, FOUND CORRODED. REPAIRED IAW EA 1-5740-147655. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: HINGE FITTING — CORRODED (LT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

LEFT WING OTBD FLAP, OTBD HINGE (WING SIDE) UPPER OTBD MOUNT HOLE FOUND CORRODED. REWORKED IAW EA 1-5740-147654, PART 1(B). EXISTING HOLE: 0.881", FINAL HOLE: 0.947", MAX.HOLE: 0.944". NEW BUSHING FABRICATED AND INSTALLED IAW EA 1-5740-147654, PART 1(B). REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: HINGE FITTING — CORRODED (RT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

RT WING OTBD FLAP INBD HINGE (WING SIDE) SIDE LINK HOLE FOUND SURFACE CORRODED. REWORKED IAW CMM 20-11-02, REV 70. UPPER FACE EXISTING THICKNESS 0.481", MATERIAL REMOVED 0.003", REMAINING THICKNESS 0.478", LOWER FACE EXISTING THICKNESS 0.486" MATERIAL REMOVED 0.003", REMAINING THICKNESS 0.483". REPAIR EVALUATED AND FOUND 0.478" AND 0.483" IS STILL WITHIN THE DWG 0502 SHEET NR4 REV BN LIMITS AND CMM 57-44-08, FIG 604. REWORK LIMITS. REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 112.

Part: HINGE FITTING — CORRODED (LT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

LEFT WING OTBD FLAP, OTBD HINGE (WING SIDE) LOWER INBD MOUNT HOLE SPOT FACE FOUND CORRODED. REPAIRED IAW EA 1-5740-147654. EXISTING THICKNESS: 0.439", MATERIAL REMOVED: 0.003"(FWD), MATERIAL REMOVED: 0.050"(AFT). REMAINING THICKNESS : 0.386",MINIMUM THICKNESS 0.408". REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: HINGE FITTING — CORRODED (RT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

RT WING OTBD FLAP, OTBD HINGE (WING SIDE) SIDE LINK HOLE, FOUND SURFACE CORRODED. REWORKED IAW EA 1-5740-147651. EXISTING THICKNESS 0.3845", MATERIAL REMOVED 0.003", REMAINING THICKNESS 0.3815". REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 112.

Part: HINGE FITTING — CORRODED (LT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

LEFT WING OTBD FLAP, OTBD HINGE (WING SIDE) SIDE LINK HOLE SPOT FACE, FOUND CORRODED. REWORKED IAW CMM 20-11-02 REV 70. REMOVED: 0.003", FOUND THE REMAINING THICKNESS OF 0.460" AND 0.464" IS WITHIN DWG ARC 503 SHEET 2 BG LIMITS AND CMM 57-44-09 REV 70 FIG.601 AND 601 IN SERVICE REWORK LIMIT. REPAIR CLASSIFIED AS MINOR PER GMM 6-2-100 REV 112.

Part: SUPPORT — CORRODED (ZONE 200) · airframe 73,567 hrs · 12,217 cycles

LEFT STRUCTURE UNDER DADO SUPPORT FROM STATION 1481 TO STATION 1501, FOUND CORRODED. CORROSION REMOVED IAW SRM 51-21-01, REV 46. ORIGINAL THICKNESS : 0.080", MATERIAL REMOVED 0.026" & REMAINING THICKNESS : 0.054" FOUND EXCEEDED LIMIT IAW SRM 53-00-52 FIG 101, REV 46. TRIMMED OUT & REMOVED IAW SRM 53-00-52, FIG 101, REV 46 & SRM 51-31-01, REV 46. HFEC INSP CARRIED OUT ON TRIMMED AREA FOUND NO CRACK. SEAT TRACK & SPLICE FABRICATED IAW SRM 53-00-52, FIG 201, REV 46 & REINSTALLED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: FLOOR SUPPORT — CORRODED (ZONE 200) · airframe 73,567 hrs · 12,217 cycles

RT FLOOR STRUCTURE BELOW DADO PANEL SUPPORT FROM STATION 1501 TO STATION 1521 FOUND CORRODED. REPAIRED IAW SRM 53-00-52, FIG 101, REV 46.

Part: HINGE FITTING — CORRODED (LT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

LEFT WING OTBD FLAP, OTBD HINGE (WING SIDE) PIVOT HOLE FOUND CORRODED. REWORKED IAW EA 1-5740-147654 PART 1 A. EXISTING HOLE 2.251", FINAL HOLE 2.352", NEW BUSHING FABRICATED AND INSTALLED IAW EA 1-5740-147654, PART 1 A. REPAIR CLASSIFIED MAJOR IAW GMM 6-2-100, REV 112.

Part: HINGE FITTING — CORRODED (RT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

RT WING OTBD FLAP INBD HINGE (WING SIDE) PIVOT HOLE FOUND CORRODED. REPAIRED IAW EA1-5740-147656. EXISTING HOLE: 2.252" FINAL HOLE: 2.3185" MAX HOLE: 2.3135" . NEW BUSHING FABRICATED AND INSTALLED IAW EA 1-5740-147656. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: SKIN — MISREPAIRED (BS 1695-1701) · airframe 73,567 hrs · 12,217 cycles

REPAIR AT FUSELAGE SKIN AT STA 1695 TO STA 1701 BETWEEN LONGERON 31 TO LONGERON 33 LT. FOUND NOT REPAIR IAW APPROVED DATA. FUSELAGE SKIN AT STA 1695 TO STA 1701 BETWEEN LONGERON 31 TO 33 LT CARRIED OUT REPAIR IAW EA 1-5330-150352, PART 1.

Part: SKIN — CRACKED (LT WING) · airframe 73,567 hrs · 12,217 cycles

DURING HFEC OPEN HOLE INSPECTION, 4 EA CRACK INDICATION FOUND AT LT WING STA XORS=698.730 FUEL CUTOUT FASTENER HOLES. HOLES REAMED IAW DWG SG11570004, REV 'A'. HFEC OPEN HOLE INSP CARRIED OUT ON REWORKED FASTENER HOLES 4EA FOUND NO CRACK. NEW BUSHINGS 4EA FABRICATED BY MACHINING IAW DWG NR SG11570004 REV 'A'. NEW FABRICATED BUSHINGS 4EA REPROTECTED & INSTALLED. REPAIR CLASSIFIED AS MINOR IAW GMM6-2-100, REV 112.

Part: VANE — DELAMINATED (LT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

LEFT WING INBD FLAP VANE LWR SURFACE BETWEEN INBD AND MID VANE TRACKS FOUND SEVERAL DELAMINATED. REPAIR COMPLIED WITH EA 1-5750-147649. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 73,567 hrs · 12,217 cycles

CRACK FOUND APPROX 1.2500" DURING X-RAY INSPECTION AT STA 6-100 LONGERON 1R FWD & AFT SECTION EDGE OF THE SPLICE.

Part: SEAT TRACK — CORRODED (BS 1888) · airframe 73,567 hrs · 12,217 cycles

UPON REMOVAL OF DOOR 4R DRAIN COVER FOR ACCESS, SEAT TRACK AT RT X=107.25 STA 1888 FOUND TO BE CORRODED. CORRODED SEAT TRACK REMOVED & TRIMMED IAW SRM53-00-52, FIG 101, REV 46. HFEC INSPECTION CARRIED OUT ON TRIMMED AREA FOUND NO CRACK. SEAT TRACK & SPLICE FABRICATED IAW SRM 53-00-52, FIG 201, REV 46. SEAT TRACK & SPLICE INSTALLED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: SEAT TRACK — CORRODED (BS 1341-1361) · airframe 73,567 hrs · 12,217 cycles

CABIN - SEAT TRACK LT X=8.5 STA 1341 TO 1361 CORRODED. CORROSION REMOVED IAW SRM 51-21-01, REV 46. ORIGINAL THICKNESS : 0.100", MATERIAL REMOVED : 0.014" & REMAINING THICKNESS : 0.086" FOUND EXCEEDED LIMIT IAW SRM 53-00-52, FIG 101, REV 46. SEAT TRACK CUT & REMOVED IAW SRM 53-00-52, FIG 201, REV 46 & SRM 51-31-01, REV 46. HFEC INSP CARRIED OUT ON TRIMMED AREA FOUND NO CRACK. REPAIR SEAT TRACK & NEW FABRICATED SPLICES 2EA / SPLICE PLATES 2EA PROTECTED, PAINTED & INSTALLED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: LONGERON — CORRODED (BS 1321-1341) · airframe 73,567 hrs · 12,217 cycles

LONGERON 25R BETWEEN STA 1321-1341 CORRODED. CORROSION REMOVED IAW SRM51-21-01, REV 46. ORIGINAL THICKNESS : 0.200", MATERIAL REMOVED : 0.090" & REMAINING THICKNESS : 0.110" FOUND EXCEEDED LIMIT SRM53-00-00, FIG 205, REV 46. LONGERON REMOVED AND REPLACED IAW SRM 51-31-01, REV 46. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: LONGERON — CORRODED (BS 1461-1481) · airframe 73,567 hrs · 12,217 cycles

LONGERON 25R BETWEEN STA 1461-1481 CORRODED. CORRODED AREA REMOVED IAW SRM 51-21-01, REV 46. ORIGINAL THICKNESS : 0.200", MATERIAL REMOVED : 0.060" & REMAINING THICKNESS : 0.140" FOUND EXCEEDED LIMIT IAW SRM 53-00-00, FIG 205, REV 46. CORRODED LONGERON NR 25R REMOVED. LONGERON REMOVED. NEW LONGERON FABRICATED IAW DWG AEA0303, REV 'J'. FPI CARRIED OUT ON NEW FABRICATED LONGERON FOUND NO CRACK. NEW LONGERON INSTALLED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: TRUNNION — CRACKED (CRACKED) · airframe 73,567 hrs · 12,217 cycles

LOWER FUSE NLG RT TRUNNION FITTING FOUND CRACKED. HFEC INSP CARRIED OUT ON CRACKED AREA FOUND CRACK APPROX 1" IN LENGTH. TRIMMED OFF IAW SRM 53-10-14, FIG 201. REPAIR NR 2 REV 46. HFEC INSP CARRIED OUT ON TRIMMED AREA FOUND NO CRACK. REPAIR DOUBLER & FILLER FABRICATED IAW SRM 53-10-14, FIG 201. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: VANE — DELAMINATED (RT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

RT WING INBB FLAP VANE LWR SURFACE BETWEEN MID AND OTBD VANE TRACKS FOUND SEVERAL DELAMINATED. R & R IAW AMM 27-50-22-4, REV 70. REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 112.

Part: SKIN — CRACKED (RT WING) · airframe 73,567 hrs · 12,217 cycles

DURING HFEC OPEN HOLE INSPECTION 8 EA CRACK INDICATION FOUND AT RT WING STA XORS=698.730 FUEL CUTOUT FASTENER HOLES. HOLES REAMED IAW DWG NR SG11570004, REV 'A'. HFEC OPEN HOLE INSP CARRIED OUT ON REWORKED FASTENER HOLES 8EA. FOUND NO CRACK. NEW BUSHINGS 8EA FABRICATED BY MACHINING IAW DWG NR SG11570004 REV 'A'. NEW FABRICATED BUSHINGS 8EA REPROTECTED & INSTALLED. REPAIR CLASSIFIED AS MINOR IAW GMM6-2-100, REV 112.

Part: LONGERON — CRACKED (FUSLEAGE) · airframe 73,567 hrs · 12,217 cycles

CRACK FOUND APPROX .7500" LENGTH DURING X-RAY INSPECTION AT STA 6-100, LONGERON 6R CENTER SECTION OF THE SPLICE. CRACKED LONGERON REMOVED. NEW LONGERON FABRICATED IAW DWG A6A7112 REV 'A'. FPI CARRIED OUT ON NEW FABRICATED LONGERON SPLICE FOUND NO CRACK. FABRICATED LONGERON SPLICE REWORKED IAW DWG A6A7112 REV 'A'. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100 REV 112.

Part: LONGERON — CHAFED (BS 575-595) · airframe 73,567 hrs · 12,217 cycles

LONGERON 24R BETWEEN FRAME 575 AND 595 CHAFED. LONGERON BLENDED, FOUND WITHIN LIMIT IAW SRM 53-00-00, FIG 205, REV 46. HFEC INSP CARRIED OUT ON REWORKED AREA FOUND CRACK APPROX 0.75". LONGERON FABRICATED IAW DWG ACA3017 REV 'L'. FPI CARRIED OUT ON NEW FABRICATED LONGERON FOUND NO CRACK. LONGERON HEAT TREATED, & INSTALLED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: SEAT TRACK — CORRODED (BS 475) · airframe 73,567 hrs · 12,217 cycles

CABIN - SEAT TRACK RT X=27.5 STA 475 CORRODED. CORROSION REMOVED IAW SRM 51-21-01, REV 46. ORIGINAL THICKNESS : 0.100", MATERIAL REMOVED : 0.018" & REMAINING THICKNESS : 0.082" FOUND EXCEEDED LIMIT IAW SRM 53-00-52, FIG 101, REV 46. REMOVED IAW SRM 51-31-01, REV 46. NEW REPAIR SEAT TRACK FABRICATED IAW SRM 53-00-52, FIG 201. REPAIR NR 1 REV 46. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: SUPPORT — CORRODED (FUSELAGE) · airframe 73,567 hrs · 12,217 cycles

LONGITUDINAL SUPPORT UNDER GALLEY CORRODED. SUPPORT REMOVED IAW SRM 51-33-01 REV 46. NEW SUPPORT FABRICATED AND INSTALLED IAW SRM 51-31-01, REV 46. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: LONGERON — CORRODED (BS 1059-1079) · airframe 73,567 hrs · 12,217 cycles

LOWER FWD CARGO COMPT BILGE AREA, STA 1059-STA 1079, LONG 48R FOUND WITH CORROSION. CORROSION REMOVED IAW SRM 51-21-01, REV 46. ORIGINAL THICKNESS : 0.080", MATERIAL REMOVED: 0.075" & REMAINING THICKNESS : 0.005" FOUND EXCEEDED LIMIT IAW SRM 53-00-00, FIG 205, REV 46. DAMAGED LONGERON TRIMMED OUT IAW SRM 53-00-05, FIG 202, REV 46. HFEC INSPECTION CARRIED OUT ON TRIMMED AREA FOUND NO CRACK. DAMAGED LONGERON REMOVED. NEW LONGERON FABRICATED IAW DWG ADA3065, REV 'H'. REPAIR SPLICE FABRICATED IAW SRM 53-00-05, FIG 202, REV 46. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: LONGERON — CORRODED (L51R) · airframe 73,567 hrs · 12,217 cycles

LOWER FUSE CAC COMPT AT STA Y6-70 LONGERON 51R FOUND CORRODED. CORROSION REMOVED IAW SRM 51-21-01, REV 46. ORIGINAL THICKNESS : 0.063", MATERIAL REMOVED : 0.016" & REMAINING THICKNESS : 0.047" FOUND EXCEEDED LIMIT IAW SRM 53-00-00, FIG 205, REV 46. LONGERON REMOVED & TRIMMED OUT IAW SRM 53-00-05, FIG 202, REV 46. HFEC INSP C/OUT ON TRIMMED AREA FOUND NO CRACK. LONGERON & REPAIR SPLICE FABRICATED IAW SRM 53-00-05, FIG 202 REV 46 AND INSTALLED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: STOP FITTING — CRACKED (LT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

LT WING OTBD FLAP NR 2 SECONDARY UP STOP BOLT FITTING FOUND CRACKED. DAMAGED FITTING REMOVED IAW SRM 51-31-01, REV 46 AND INSTALLED NEW FITTING IAW DWG ARC 4125, REV G. THIS REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 112.

Part: SEAT TRACK — CORRODED (BS 635) · airframe 73,567 hrs · 12,217 cycles

CABIN SEAT TRACK STA 635 X=8, CORRODED. CORROSION REMOVED IAW SRM 51-21-01, REV 46. ORIGINAL THICKNESS : 0.100", MATERIAL REMOVED : 0.035" & REMAINING THICKNESS : 0.065" FOUND EXCEEDED LIMIT IAW SRM 53-00-52, FIG 101 REV 46. SEAT TRACK CUT & REMOVED IAW SRM 53-00-52, FIG 101, REV 46 & SRM 51-31-01, REV 46. HFEC INSP CARRIED OUT ON TRIMMED AREA FOUND NO CRACK. SEAT TRACK, SPLICE & SPLICE PLATE FABRICATED IAW SRM53-00-52, FIG 201. REPAIR NR1 REV 46. TRIMMED AREA REPROTECTED. NEW FABRICATED REPAIR SEAT TRACK, SPLICE & SPLICE PLATE PROTECTED, PAINTED & INSTALLED. REPAIRED AREA PAINTED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: STOP FITTING — CRACKED (RT WING TE FLAP) · airframe 73,567 hrs · 12,217 cycles

RT WING OTBD FLAP NR2 SECONDARY UP STOP FITTING FOUND CRACKED. DAMAGED FITTING REMOVED IAW SRM 51-31-01, REV 46 AND INSTALLED NEW FITTING IAW DWG ARC4125, REV G, THIS REPAIR CLASSIFIED AS MINOR IAW GMM 6-2-100, REV 112.

Part: SEAT TRACK — CORRODED (BS 806) · airframe 73,567 hrs · 12,217 cycles

CABIN SEAT TRACK STA 806 X=-8, CORRODED. CORROSION REMOVED IAW SRM51-21-01, REV 46. ORIGINAL THICKNESS : 0.100", MATERIAL REMOVED: 0.038" & REMAINING THICKNESS : 0.062" FOUND EXCEEDED LIMIT IAW SRM 53-00-52, FIG 101, REV 46. STA 815 & STA 909 SEAT TRACK CORRODED SECTION CUT OFF IAW SRM 53-00-52, FIG 101, REV 46. CORRODED SEAT TRACK REMOVED. HFEC INSPECTION CARRIED OUT ON TRIMMED OFF AREA. FOUND NO CRACK. NEW REPAIR SEAT TRACK, SPLICE & SPLICE PLATE FABRICATED IAW SRM 53-00-52, FIG 201, REV 46. NEW FABRICATED REPAIR SEAT TRACK, SPLICE & SPLICE PLATE PROTECTED, PAINTED & INSTALLED. REPAIRED AREA PAINTED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.

Part: RIB — CRACKED (LT WING) · airframe 73,567 hrs · 12,217 cycles

LT WING L/E RIB NR16 FOUND CRACKED. REMOVED IAW SRM 51-33-01, REV 46 AND NEW RIB INSTALLED IAW DWG ARB 7565, REV C. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: RIB — CRACKED (RT WING) · airframe 73,567 hrs · 12,217 cycles

RT WING L/E RIB NR16 FOUND CRACKED. CRACKED RIB REMOVED IAW SRM 51-33-01, REV 46 AND INSTALLED NEW RIB IAW DWG, ARB 7565, REV C. REPAIR CLASSIFIED AS MAJOR IAW GMM 6-2-100, REV 112.

Part: SKIN — MISREPAIRED (BS 989) · airframe 73,567 hrs · 12,217 cycles

REPAIR AT FWD CARGO DOOR CUTOUT AFT JAMB STA.989 LONGERON 40 TO 41R EVALUATED & FOUND CHAFING MARKS ON REPAIR DOUBLER. SCUFF PLATE, HEAT SHIELD PANEL, TUBINGS, FWD CARGO ENTRY DOOR GUIDE AFT ROLLER FITTING ASSY REMOVED FOR ACCESS. CHAFED REPAIR DOUBLER REMOVED. HFEC INSP CARRIED OUT ON CUTOUT AREA FOUND NO CRACK. NEW REPAIR DOUBLER FABRICATED IAW SRM53-00-15, FIG 202 REPAIR NR 8, REV 46. NEW FABRICATED REPAIR DOUBLER PROTECTED, PAINTED & INSTALLED. REPAIRED AREA PAINTED. SCUFF PLATE, HEAT SHIELD PANEL, TUBINGS, FWD CARGO ENTRY DOOR GUIDE AFT ROLLER FITTING ASSY REINSTALLED. INITIAL INSPECTION TO BE CARRIED OUT AT 12,600 FLIGHT CYCLES & REPETITIVE INSP AT 6,300 FLIGHT CYCLES IAW ALI PSE NR 53.10.06.1. EO 1-5100-7-5001 A5 PT 1 TITLE : STRUCTURES - REPAIR CATALOG - REPAIR ID & TRACKING REQUIREMENTS 14 CFR 121.707 ACCOMPLISHED. REPAIR CLASSIFIED AS MAJOR IAW GMM6-2-100, REV 112.