N68046

Part: ACTUATOR — INOPERATIVE (NLG)

THE NLG WOULD NOT RETRACT AFTER TAKEOFF. THE GEAR WARNING HORN WAS ALSO ON. COMPLYING WITH ABNORMAL PROCEDURES WAS NO HELP. THE AIRCRAFT WAS RETURNED TO NGO WHERE IT LANDED WITHOUT INCIDENT. THE NLG RETRACT AND UNLOCK CYLINDERS WERE REMOVED AND REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD. *S/D* SUPPLEMENT IS ISSUED TO REFLECT THE FACT THAT THE AIRCRAFT FERRIED TO NRT BEFORE THE NLG RETRACT AND UNLOCK CYLINDERS WERE REPLACED AS A PRECAUTIONARY MEASURE. THE NLG UNLOCK CYLINDER PART NUMBER IS: ACG73305501. IN ADDITION, THE PART TOTAL CYCLES SHOULD BE: 28, 893.

Part: AOA SENSOR — INOPERATIVE (BS 369)

BOTH ADI'S DISPLAYED SPEED WARNING FLAG FOR 5 TO 10 SECONDS ON SLAT. THE STICK SHAKER ACTIVATED CONTINUOUSLY. THE CHECKLIST WAS COMPLIED WITH AND THE STICK SHAKER STOPPED, BUT SLAT WOULD NOT RESET. ALSO, THE AUTO SLAT EXTEND AND SLAT DISAGREE WERE ON. THE AIRCRAFT WAS RETURNED TO GUM WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE RT ANGLE OF ATTACK SENSOR AT FAULT. THE RT ANGLE OF ATTACK SENSOR WAS REMOVED AND REPLACED IAW MM 22-33-01, OPERATIONAL CHECKS WERE GOOD. ALSO, THE R2-5244 AUTO SLAT EXTEND RELAY WAS FOUND BAD. THE RELAY WAS REPLACED.

Part: RIB — CORRODED (BS 1360)

INSPECTION FOUND CORROSION ON RIB OF LOWER WING TO FUSELAGE FAIRING AT STA 1360. THE RIB WAS REMOVED AND A NEW RIB WAS FABRICATED AND INSTALLED IAW SRM 53-00-01.

Part: INTERCOSTAL — CORRODED (BS 1820-1830)

INSPECTION FOUND AFT CARGO INTERCOSTAL CORRODED AT STA 1820-1830, STRINGER 45L. THE INTERCOSTAL WAS REMOVED AND A NEW INTERCOSTAL WAS FABRICATED AND INSTALLED IAW SRM 53-00-01.

Part: FRAME — CORRODED (BS 1964)

INSPECTION FOUND CORROSION ON FRAME IN AFT CARGO COMPARTMENT AT STA 1964, STRINGER 42-43L AND 48-52. THE CORRODED SECTION OF FRAME WAS REMOVED. THE CORRODED PART WAS REMOVED AND A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-30-00, FIGURE 5.

Part: FLANGE — CORRODED (BS 1902)

INSPECTION FOUND CORROSION ON LOWER FLANGE CHORD IN AFT CARGO COMPARTMENT AT STA 1902, STRINGER 52-50. THE CORROSION WAS REMOVED AND A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-00-01.

Part: INTERCOSTAL — CORRODED (BS 1800-1820)

INSPECTION FOUND AFT CARGO INTERCOSTAL CORRODED AT STA 1800-1820, STRINGER 44L. THE INTERCOSTAL WAS REMOVED AND A NEW INTERCOSTAL WAS FABRICATED AND INSTALLED IAW SRM'S 53-00-01 AND 51-33-01.

Part: TR COWL — FAILED (NR 3 ENGINE)

THE NR 3 ENGINE REVERSER UNLOCK LIGHT AND REVERSER 3 VALVE OPEN LIGHT ILLUMINATED DURING LANDING ROLL. MAINTENANCE FOUND THE TRANSLATING COWL HAD SEPARATED FROM THE ENGINE AND FELL ON THE RUNWAY. THERE WAS DAMAGE TO THE COWL AND FAN REVERSER. THE NR 3 THRUST REVERSER RT HALF TRANSLATING COWL AND FAN REVERSER WERE REMOVED AND REPLACED. *S/D* INVESTIGATIVE FINDINGS REVEALED THAT THE PRIMARY CAUSE OF THE TRANSLATING COWL ASSEMBLY LOSS WAS DUE TO A SEPARATION OF THE FORWARD OUTER COWL TO THE AFT COWL, ALONG THE AFT COWL FORWARD CLOSE-OUT Z-CHANNEL BONDING ZONE.

Part: LG HANDLE — LACK OF LUBE (COCKPIT)

WHEN GEAR WAS LOWERED ON APPROACH, THE THREE GEAR RED UNSAFE LIGHTS ILLUMINATED. ALTERNATE GEAR EXTENSION WAS PERFORMED AND THREE GREEN LIGHTS WERE INDICATED FOR A NORMAL LANDING AT EWR. A SELF TEST OF THE PROXIMITY SWITCH ELECTRONIC BOX WAS PERFORMED WITH NO FAULT LIGHTS INDICATED. THE LANDING GEAR HANDLE ASSEMBLY WAS LUBRICATED, THE GEAR HANDLE WAS CYCLED SEVERAL TIMES WITH OPERATION AND INDICATIONS CHECKING GOOD.

Part: HANDLE — LACK OF LUBE (LANDING GEAR)

ON GEAR EXTENSION CREW REPORTED THREE GEAR UNSAFE LIGHTS. USED EMERGENCY EXTENSION HANDLE TO GET THREE GREEN LIGHTS. AFTER NORMAL LANDING, UNABLE TO RESTOW ALTERNATE GEAR HANDLE. RESECURED ALTERNATE GEAR HANDLE. CLEANED AND LUBRICATED LANDING GEAR HANDLE AND CYCLED SEVERAL TIMES, NO DEFECTS WERE NOTED.

Part: ROLLER — BINDING (LG HANDLE)

WHEN LANDING GEAR WAS EXTENDED ON APPROACH, NO GREEN GEAR LIGHTS WOULD ILLUMINATE. ABNORMAL PROCEDURES WERE COMPLIED WITH AND A VISUAL INSPECTION CONFIRMED GEAR WAS EXTENDED. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE GEAR HANDLE ROLLER JAMMED. THE ROLLER AND HANDLE MECHANISM WAS CLEANED AND OPERATION CHECKED GOOD.

Part: GRD SENSE MECH — OUT OF ADJUST (LANDING GEAR)

EWR - FLT 0088 - THE LANDING GEAR HANDLE WOULD NOT RAISE TO UP POSITION AND ON TAKEOFF FROM SFO, THE OVERRIDE BUTTON WAS USED AND THE GEAR RETRACTED. THE AIRCRAFT CONTINUED FLIGHT TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE PERFORMED A GEAR SWING AND THE GEAR RETRACTED NORMALLY. THE AIRCRAFT WAS OBSERVED TO BE STUCK IN THE AIR MODE WITH AUTO SLATS EXTENDED AND WOULD NOT RETRACT. A GROUND SENSING CONTROL MECHANISM AND ADJUSTMENT TEST WAS PERFORMED IAW MM 32-24-01, PAGE 202, AND OPERATION CHECKED GOOD. (X)

Part: FRAME — CORRODED (BS 1997)

INSPECTION FOUND CORROSION ON LOWER FRAME CHORD AT STA 1997, BETWEEN STRINGERS 51R AND 51L. THE AREA WAS REPAIRED IAW ECRA 5330-02386.

Part: CONTROL CABLE — BROKEN (LANDING GEAR)

FLT NR 0970 - NGO - THE LANDING GEAR WOULD NOT RETRACT WHEN GEAR WAS SELECTED TO UP POSITION AFTER TAKEOFF FROM NGO. THE AIRCRAFT WAS RETURNED TO NGO WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE PUSH-PULL CABLE BEHIND THE GEAR SELECTOR HANDLE BROKEN. THE CABLE WAS REMOVED AND REPLACED. THE CABLE WAS ADJUSTED AND OPERATION CHECKED GOOD IAW MM 32-31-02. (M)

Part: COMPRESSOR — STALLED (NR 1 ENGINE)

SYD - FLT 0909 - NR 1 ENGINE EXPERIENCED COMPRESSOR STALLS AT 37,000 FEET AFTER DEPARTING SYD. THE NR 1 ENGINE WAS SHUT DOWN AND THE AIRCRAFT WAS RETURNED TO SYD WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE READIED THE AIRCRAFT FOR FERRY FLIGHT TO GUM WHERE THE NR 1 ENGINE WILL BE REMOVED AND REPLACED. SUPPLEMENT - THE STALLS WERE CAUSED BY HIGH PRESSURE BLEED AIR REVERSE FLOW INTO THE 8TH STAGE BLEED AIR DUCT. THE ENGINE WAS NOT DAMAGED, IT WAS REMOVED AS A PRECAUTION FOR POST-STALL BORESCOPE. IT IS BELIEVED THAT FAILURE OF 1 OR ALL 3 OF THE FOLLOWING COMPONENTS COULD HAVE RESULTED IN THE REVERSE FLOW CONDITION: LOWER PRESS CHECK VALVE, PRESS REGULATOR VALVE, AND FAN REVERSER OVERPRESS VALVE. (W)

Part: DISK — DECOUPLED (NR 2 ENGINE)

FLT NR 960 - NRT - THE NR 2 ENGINE FIRE WARNING ACTIVATED ACCOMPANIED BY ENGINE POWER LOSS DURING TAKEOFF AT 40 KNOTS. THE TAKEOFF WAS ABORTED AND THE ENGINE FIRE/FAILURE CHECKLIST WAS COMPLETED. THE A/C WAS RETURNED TO THE GATE. MX FOUND THE NR 2 ENGINE TURBINE HAD FAILED WITH RESULTANT DAMAGE TO BOTH THE LEFT AND RIGHT CORE COWLS. THE LEFT AND RIGHT CORE COWLS WERE REPLACED. THE NR 2 ENGINE WAS REMOVED AND REPLACED. INVESTIGATION REVEALED LPT ROTOR DISK DECOUPLING AS THE PRIMARY CAUSE OF FAILURE. ANALYSIS WAS UNABLE TO CONFIRM REASON FOR DECOUPLING. SUBMITTER STATES, THE PREVIOUS SUPPLEMENT STATED, THERE WAS 'DISK SEPARATION', RATHER THAN 'DISK DECOUPLING'. (M)

Part: EGT WIRE — CHAFED (NR 2 ENG)

FLT NR 0963 - GUM - THE NR 2 ENGINE EGT CIRCUIT BREAKER POPPED IN FLIGHT. WHEN THE CIRCUIT BREAKER WAS RESET, THE LEFT EMERGENCY BUS WAS LOST. APPROPRIATE CHECKLIST PROCEDURES WERE COMPLIED WITH, AND THE AIRCRAFT WAS RETURNED TO GUM WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND WIRE TO PIN 'J' OF THE EGT INDICATOR CHAFED AND IN CONTACT WITH THE INDICATOR CAUSING A SHORT. THE WIRE WAS INSULATED WITH SHRINK TUBING AND OPERATION CHECKED GOOD. (W)

Part: FIRE LOOP — CRUSHED (NR 3 ENGINE)

GUM - FLT 0973 - THE NR 3 ENGINE 'B' LOOP FIRE WARNING LIGHT ILLUMINATED WHILE IN-FLIGHT. THE CREW WENT TO 'A' LOOP AND TEST FAILED ON 'A'. THE NR 3 ENGINE WAS SHUT DOWN AND THE AIRCRAFT WAS RETURNED TO GUM WHERE IT LANDED WITHOUT INCIDENT. THE NR 3 ENGINE HAD A HISTORY OF FALSE FIRE WARNINGS. MAINTENANCE FOUND NO EVIDENCE OF FIRE. THE NR 3 ENGINE AFT PYLON 'B' FIRE LOOP DETECTOR WAS FOUND CRUSHED. THE DETECTOR WAS REPLACED. IN ADDITION, THE LOWER FORWARD 'A' LOOP WAS FOUND BENT. THE 'A' LOOP WAS SECURED IN PROPER POSITION AND CHAFED WIRES AT UPPER AFT SECTION WERE REPAIRED. AN OPERATIONAL TEST OF BOTH LOOPS CHECKED NORMAL. (X)