N68057

Part: SKIN — CRACKED (FUSELAGE) · airframe 64,082 hrs · 25,088 cycles

ON POST FLIGHT WALK AROUND FOUND FUSELAGE SKIN CRACKED AT NR 1 PACK DOOR CUT OUT UPPER AFT CORNER. INSTALLED DOUBLER, TRIPLER & FILLER IAW SRM 53-50-00 FIG 3A & EA.

Part: SKIN — CRACKED (RT WING) · airframe 64,004 hrs · 25,044 cycles

FOUND A CRACK ON RT WING SKIN AT NR 3 SLAT TRACK BETWEEN NR 1 & 2 SLATS. TRIMMED OUT DAMAGED AREA. PERFORMED INTERNAL & EXTERNAL VISUAL INSPECTION WITH NO ADDITIONAL DAMAGE NOTED. HFEC INSPECTION DONE WITH NO CRACKS NOTED. REPAIRED IAW EA 8-5730-T0308776 P1.

Part: SKIN — CRACKED (ZONE 600) · airframe 64,004 hrs · 25,044 cycles

FOUND TWO CRACKS ON RT WING TAI DUCT CUT OUT. VERIFIED CRACKS IAW NDT SPM PART 6. REPAIRED IAW EA 8-5710-T0308893 & SRM.

Part: SKIN — CRACKED (ZONE 500) · airframe 64,004 hrs · 25,044 cycles

DURING POST FLIGHT INSPECTION, FOUND POSSIBLE LT WING LE CRACK AT REFUEL DOOR INBD CORNER CUT OUT. CONFIRMED CRACK BY HFEC INSPECTION IAW NDTSPM PT 6 CRACK TERMINATES AT FASTENER. CUT OUT CRACKED AREA IAW SRM 57-10-00 FIG 68 SHEET 2. COMPLIED WITH HFEC ON CUT OUT AREA IAW NDT SPM, NO CRACKS FOUND. COMPLIED WITH EA TO REPAIR LT WING FIXED LEADING EDGE CRACK AT FUELING DOOR.

Part: SKIN — CRACKED (LT WING) · airframe 64,004 hrs · 25,044 cycles

FOUND TWO CRACKS IN LEFT WING TAI DUCT. VERIFIED CRACK IAW NDT SPM PART 6. REPAIRED IAW EA.

Part: TRANSMITTER — FAILED (FUEL FLOW) · airframe 63,321 hrs · 24,678 cycles

AT FL 320, NOTICED NR 2 FUEL FLOW 16150 PPH, ALL OTHER INDICATIONS NORMAL. FUEL USED SHOWED NR 2 HAD USED 2200 LBS MORE THAN 1 & 3. FUEL REMAINING WAS IN AGREEMENT WITH FUEL USED. WHEN THROTTLE RETARDED, FUEL FLOW REDUCED TO APPROXIMATELY 11000 PPH AT IDLE. R & R NR 2 ENGINE FUEL FLOW TRANSMITTER IAW MM 73-31-02-2, LEAK & OPS CHECKED GOOD.

Part: FITTING — CRACKED (CARGO DOOR FRAME) · airframe 62,465 hrs · 24,248 cycles

MAIN CARGO DOOR FRAME NR 1 SPOOL LOWER FITTING CRACKED IN FOUR LOCATIONS. VERIFIED WITH HFEC IAW NDT SPM93K0393, CRACK RUNS THOUGH FITTING. R & R MAIN CARGO DOOR FRAME SPOOL LOWER FITTING. IAW SRM 51-33-01, VOL II.

Part: STRUT — DAMAGED (NLG) · airframe 62,016 hrs · 24,042 cycles

AFTER T/O LDG GEAR HANDLE WOULD NOT RAISE. QRH C/W. HANDLE RAISED & ALL IN FLIGHT SYSTEMS OPERATED NORMALLY. R & R THE NLG ASSY, REF WC 32T2101 AND 32T2701.

Part: INTERCOSTAL — CORRODED (BS 1505-1521) · corrosion level 2 · airframe 61,992 hrs · 24,025 cycles

LEFT MLG WHEEL WELL AFT WALL LOWER SHELF HAS THE INTERCOSTAL JUST BELOW THE FLAP BUSS CABLE PULLEYS WITH A LARGE AREA BULGED. INSTALLED NEW INTERCOSTAL REF. SRM 51-31-01.

Part: CONTROL UNIT — MALFUNCTIONED (MLG) · airframe 61,977 hrs · 24,017 cycles

AFTER TAKEOFF LANDING GEAR HANDLE WOULD NOT RAISE. COMPLIED WITH QRH THEN GOT LEVEL 1 ANTI-SKID NO TEST ALERT. REMAINED ON UNTIL GEAR HANDLE DOWN. ANTI-SKID ALERT WENT OUT. ANTI-SKID WORKED ON LANDING ROLL OUT. LANDED WITHOUT INCIDENT. MX REMOVED AND REPLACED LANDING GEAR CONTROL MECHANISM. JACKED AIRCRAFT AND CYCLED ALL LANDING GEAR SIX TIMES PER MM 32-30-00-5, NO DEFECTS NOTED. PERFORMED ANTISKID ADJUSTMENT/TEST IN REF WITH AMM 32-45-01-5 & NO DEFECTS NOTED AT THIS TIME. ALSO WHILE SWINGING GEAR NO ANTISKID FAULTS OR ALERTS DISPLAYED. OK TO CONTINUE.

Part: SCAVENGE PUMP — LEAKING (ENGINE OIL) · airframe 61,592 hrs · 23,795 cycles

DURING CLIMB NR 1 OIL QUANTITY INDICATED '0'. ALL OTHER INDICATIONS NORMAL INITALLY. IN CRUISE NR 1 OIL PRESS DROPPED TO 14 PSI WITH AN AMBER INDICATION. CONFERRED WITH MAINT. THROUGHOUT, QRH COMPLIED WITH. DIVERTED. UPON ARRIVAL CHECKED NR 1 ENG. OIL, CONFIRMED THE OIL WAS EMPTY. OIL WAS WET AROUND THE OIL LUBE AND SCAVAGE PUMP. RAN NR 1 ENG. AND CONFIRMED LEAK AT QAD RING ON SCAVAGE PUMP. REPLACED NR 1 LUBE AND SCAVENGE PUMP REF AMM 79-20-4-2. RAN ENG TO TAKE OFF POWER REF JRH NO FURTHER LEAKS NOTED. ACFT OK FOR SERVICE.

Part: POWER SUPPLY — FAILED (EMERGENCY LIGHTS) · airframe 61,091 hrs · 23,501 cycles

DURING PREFLIGHT EMERGENCY LIGHT TEST FAILED. R & R EMERGENCY LIGHTS POWER SUPPLY IAW MM 33-51-01-4, OPS CHECKS NORMAL.

Part: SENSOR — FAILED (NR 1 ENGINE) · airframe 60,490 hrs · 23,184 cycles

ON TAKEOFF ROLL N2 VIA FAIL. REJECT AT 60 KTS. R & R NR 1, ENG N1 SENSOR.

Part: SENSOR — FAILED (NR 3 ENGINE) · airframe 60,490 hrs · 23,184 cycles

NR 3 ENGINE N1 GAUGE FAILED ON DEPARTURE ROLL ALONG WITH AUTOTHROTTLE OFF - "VIA 1 FAIL" AND "VIA 2 FAIL" LEVEL 1 ALERTS. VIA 1 FAULT HISTORY SHOWED NR 3 ENGINE N1 DISAGREE AND VIA 2 SHOWED NR 3 ENGINE N1 INTERMITTANT. FCC'S 1 & 2 LIST NR 3 ENG TACH FAULT ALSO. RAN NR 3 ENGINE IAW JRH CHAP 6 AND N1 BLANK THEN STARTED TO WORK. SWAPPED VIA 1 AND VIA 3 FOR TROUBLESHOOTING. OPS CHECKED GOOD ON RTS IAW AMM 31-43-01-5. DURING ENGINE RUN, SHOOK DOWN WIRING FRON THE N1 SENSOR TO TERMINAL BOARD S3-800, NO FLUXUATIONS. SWAPPED N1 TACH FROM NR 1 ENG TO NR3 ENG AND OP CHECKED GOOD ON ENGINE RUN. RETURNED TACH GENERATORS TO ORIGINAL POSITIONS. REF WDM 77-11-01. R & R NR 3 ENGINE N1 FAN SPEED SENSOR T2-69 & OP CHECKED GOOD ON ENGINE RUN IAW JRH CHAP 6. REF AMM 77-11-01-2-0. FAILED OPS CHECK & REPLACED WITH SERVICABLE UNIT.

Part: WINDSHIELD — FAILED (COCKPIT) · airframe 60,362 hrs · 23,107 cycles

CAPT'S WINDSHIELD ARCING & SHATTERED. SHORTED IN WINDOW AT 18000 FT. REPLACED THE CAPT'S WINDSHIELD REF MM 56-11-00-2.

Part: FLOORBEAM — CRACKED (BS 1156 L29R) · airframe 60,033 hrs · 22,948 cycles

FLOORBEAM TEE CRACKED THROUGH ALL SIDES AT STA 1156 L29R. REPAIRED CRACKED FLOORBEAM REF SRM 53-30-00 FIG 7. COMPLIED WITH EA 8-5310-147795.

Part: LAMP — INOPERATIVE (R1 DOOR) · airframe 59,236 hrs · 22,528 cycles

R1 DOOR PRESSURE, PRESS TO TEST INDICATOR INOP. FOUND P/N 387 HIGH VOLTAGE LAMPS IN DOOR SLIDE PUSH BUTTON SWT. INSTALED P/N 368 LAMPS PER IPC. GRD OPS CHECKS OK.

Part: ACTUATOR — DAMAGED (LT WING TE FLAP) · airframe 57,633 hrs · 21,748 cycles

DURING WALK AROUND, FOUND LT OTBD FLAP INBD ACT BROKEN. INSPECTED FLAP FOR ANY PULLED RIVETS AND NONE FOUND. INSPECTED OTBD FLAP ACT"S ATTACKING POINTS TO MAKE SURE NO OTHER DAMAGE TO FLAPS, NONE FOUND. INSPECTED ALL OTHER FLAPS AND NO DAMAGE FOUND IAW AMM-27-50-02-6. REMOVED AND REPLACED RT OTBD FLAP INBD ACTUATOR IAW AMM 27-52-01-2, OPS AND LEAK CHECK NORMAL IAW AMM 27-52-01-2.

Part: SMOKE DETECTOR — MALFUNCTIONED (CARGO BAY) · airframe 57,229 hrs · 21,535 cycles

DECENDING THRU 14,000` RECEIVED "CARGO FIRE ALERT" COMPLIED WITH QRH AND DISCHARGED BOTH FIRE BOTTLES. NEVER HAD ANY SECONDARY INDICATIONS OF FIRE. REMOVED AND REPLACED ALL LOWER CARGO COMPARTMENT SMOKE DETECTOR PER MM 26-14-01-4. INSTALLED NR 2 CARGO FIRE BOTTLE PER 26-22-01-4 THROUGH STEP J. OK FOR SERVICE.

Part: SEAL — WORN (WINDOW) · airframe 56,017 hrs · 20,980 cycles

LOUD NOISE THAT APPEARED TO COME FROM THE CAPT'S SLIDING WINDOW AREA. A VIBRATION COULD BE FELT ON THE POST IN THE WINDOW ARM. BUT COMMUNICATION WAS NEARLY IMPOSSIBLE WITH ATC. EVENTUALLY AN EMERGENCY WAS DECLARED. LOWER ALTITUDE AND LOWER AIRSPEED HELPED. NOISE REMAINED UNTIL DESCENT BELOW 19,000 FT AND FL 270. REMOVED AND REPLACED CAPTS SLIDING WINDOW FRAME INNER SEAL.

Part: WINDOW FRAME — DAMAGED (COCKPIT WINDOW) · airframe 56,017 hrs · 20,980 cycles

LOUD NOISE THAT APPEARED TO COME FROM THE CAPT'S SLIDING WINDOW AREA. A VIBRATION COULD BE FELT ON THE POST IN THE WINDOW ARM. BUT COMMUNICATION WAS NEARLY IMPOSSIBLE WITH ATC. EVENTUALLY AN EMERGENCY WAS DECLARED. LOWER ALTITUDE AND LOWER AIRSPEED HELPED. NOISE REMAINED UNTIL DESCENT BELOW 19,000 FT AND FL 270. R&R CAPTS SLIDING WINDOW FRAME INNER SEAL.

Part: SKIN — DAMAGED (ZONE 200) · airframe 55,383 hrs · 20,674 cycles

FUSELAGE SKIN AND FRAME AT STA 642 HAVE OVERSIZED FASTENER HOLE. REPAIRED IAW EA 8-53-109196-FUSELAGE-EXISTING BUSHINGS FOUND AT STA 641.5 MCD, LOWER SILL-REPAIR. MAJOR REPAIR.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

AFT CABIN BULKHEAD FLOOR TEE ANGLE SUPPORT CORRODED UNDER FLOOR PANEL SUPPORT AT RBL 20 REMOVED CORROSION IAW MD10 SRM 53-40-00 VOL1 FIG 18. ORIGINAL THICKNESS .125 IAW MD10 SRM 53-40-00 VOL 1 FIG 18, REMAINING .094 MATERIAL REMOVED .031. REPAIRED IAW MD10 SRM 53-40-00 FIG 16 VOL 1 AT AFT PRESSURE BULKHEAD STA 2007 RBL 10-30.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

MAIN CABIN SEAT TRACK HAS CORROSION AT STA.720 AT LBL 107. REMOVED, FABRICATED AND INSTALLED SPLICED PLATE, SPLICE HAT AND SEAT TRACK IAW MD/DC10 SRM 53-70-00 VOL I PGE 3-4,51-31-01 VOL II PGE 1-10,53-70-00 PG E51 VOL I AND PART MARKED IAW FED EX GMM 7-0-1000. MAJOR REPAIR MECH 111258 QC 348.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

CENTER W/WELL AREA L48L END FITTING CORRODED IN AREAS STA 1509 TO 1521. REMOVED, FABRICATED AND INSTALLED FITTING P/N AYB7020-1 STA 1509-1521 L48L IAW DC/MD10 SRM 51-33-01 VOL II, 53-00-01 FIG 1B VOLII , 51-21-01 VOL1, 51-21-02 VOLII AND DAC DWG AYB 7020.

Part: SEAT TRACK — CRACKED (ZONE 200) · airframe 55,383 hrs · 20,674 cycles

CABIN SEAT TRACK FLANGE IS CRACKED AT STA 449 LBL 28.5 REMOVED SEAT TRACK AT STA 449 LBL 28.5 IAW DC-10 SRM 51-31-01 VOL 2 PG 1-10. FABRICATED IAW DC-10 SRM 53-70-00 PG 51 VOL 1. INSTALLED SEAT TRACK AT STA 449LBL 28.5 IAW DC 10 SRM 51-51-01 VOL 2 PG 1-2 .

Part: SEAT TRACK — GOUGED (ZONE 200) · airframe 55,383 hrs · 20,674 cycles

GOUGED CABIN SEAT TRACK SCALLOPS AT STA 879 TO 899 LBL 85 REMOVED AND REPLACED SEAT TRACK IAW DC-10 SRM 53-70-00 VOL 1 PG 51. FABRICATED SPLICE PLATES AND SPLICE HATS IAW DC-10 SRM 53-70-00 PG 4 VOL 1. INSTALLED SEAT TRACK SPLICE PLATE AND SPLICE HAT IAW DC10 SRM 51-31-01 VOL 2 PG 1-10. [08-29-07] REPAIR CLASSIFIED AS MAJOR. PART MARKED IAW GMM 7-0-1000.

Part: SPAR — CRACKED (ZONE 300) · airframe 55,383 hrs · 20,674 cycles

RT HORIZONTAL STAB REAR SPAR CAP CRACKED ON AFT SIDE NEAR RT UPPER AFT BARREL NUT AT STA XE 48.500 CRACK EXTENDS APPROX 3.0", HORIZONTALLY FROM INBD END OF FITTING PER EDDY CURRENT TEST. ACCOMPLISHED EA 8-5510-109187"STABILIZER-HORIZ- AD92-22-10-RH UPPER AFT SPAR SPLICE-REPAIR. MAJOR REPAIR MECH 7198 QC227

Part: DOOR FRAME — CORRODED (ZONE 200) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

FOUND MAIN CARGO LOWER DOOR JAMB HAS CORROSION ON LOWER BEAM AT STA 750. 09-04-07 REMOVED AND REPLACED MAIN CARGO DOOR JAMB LOWER DOOR JAMB LOWER BEAM IN REF TO DC/MD10 SRM 51-33-01 VOL II PAGE 1, AND DAC DRAWING ACA7224 REV.G. MAJOR REPAIR.

Part: SEAT TRACK — DAMAGED (BS 899-919) · airframe 55,383 hrs · 20,674 cycles

ELONGATED SCALLOPS AT CABIN SEAT TRACK, STA 899 TO 919, RBL47.5. [08-29-07] CHECKED LIMITS, MAX ALLOW BETWEEN EDGE OF SCALLOP IS .500. FOUND TO BE GREATER THAN .500. OUT OF LIMITS IAW DC/MD-10 SRM 53-70-00 VOL 1 PG 21. DIAL CALIPER T8878F REMOVED AND REINSTALLED (2) FLR BOARDS AT STA 819-879 RBL 27-76 IAW MD-10 MM 53-21-08-2 REMOVED OLD SEAT TRACK AND INSTALLED NEW SEAT TRACK IAW DC/MD-10 SRM 51-31-01 VOL 2 PG1. MAT ID AND FABED SEAT TRACK IAW DC/MD-10 SRM 53-42-01 VOL 3 PG 13&14 AND 53-70-00 VOL 1 PG 3. ALODINED AND PRIMED IAW DC/MD-10 SRM 51-21-01 VOL 2 PG 1&21, PART MARKED IAW FED-EX GMM 7-0-10-00. MAJOR REPAIR

Part: SEAT TRACK — GOUGED (BS 1039) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

GOUGED, CABIN SEAT TRACK AT STA 1039 TO 1059, LBL 27.5 CHECKED LIMITS, GAP BETWEEN SCALLOPS FOUND TO BE GREATER THAN .500 (MAX ALLOWED) OUT OF LIMITS IAW DC/MD-10 SRM 53-70-00 VOL 1 PG 21. REMOVED DAMAGE SEAT TRACK SECTION AND INSTALLED FAB`D SEAT TRACK SECTION IAW DC/MD-10 SRM 53-70-00 VOL 1 PG 3 AND 51-31-01 VOL 2 PG 1. MAT ID SECTION IAW DC/MD-10 SRM 53-42-01 VOL 3 PG 13 AND 14. ALODINED AND PRIMED IAW DC/MD-10 SRM 51-21-01 VOL 2 PG 1 AND 21. MAJOR REPAIR.

Part: SEAT TRACK — GOUGED (BS 1199-1219) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

GOUGED/SCUFFED SCALLOPS ON CABIN SEAT TRACK AT STA 1199, TO 1219, RBL 47.5 REMOVED SEAT TRACK SECTION AT STA 1209-1269 RBL 47 IAW DC-10/MD-10 SRM 51-31-01, VOL2, PG 1. MAT ID FOR SEAT TRACK SECTION IS S4929405 PO 571558.2 IAW DC-10/MD10 SRM 53-42-01, VOL 2 PG 13 AND 14. INSTALLED SEAT TRACK SECTION AT STA 1209-1269 RBL 47 IAW DC-10/MD-10 SRM 51-31-01, VOL 2 PG 1. THIS REPAIR IS CLASSIFIED AS MAJOR.

Part: SEAT TRACK — DAMAGED (BS 939-1019) · airframe 55,383 hrs · 20,674 cycles

ELONGATED SCALLOPS AT CABIN SEAT TRACK LBL 47.5, STA 939 TO 1019 (2-PLACES) REMOVED SEAT TRACK AT STA 879-1019 IAW DC10-SRM 53-70-00 VOL 1 PG5. SEAT TRACK WAS OUT OF LIMITS IAW DC10 SRM 53-20-00 PG 21. REPLACED SEAT TRACK IAW DC10 SRM 53-70-00 VOL 1 PG 1-10, AT STA 879-1019 LBL 47.5. REPAIR CLASSIFIED AS MAJOR.

Part: SEAT TRACK — GOUGED (BS 1099-1159) · airframe 55,383 hrs · 20,674 cycles

GOUGED, CABIN SEAT TRACK SCALLOPS AT STA 1159 TO STA 1099, RBL 27.5 STA 1099-1119, RBL 27.5 REMOVED GOUGE, REMAINING .434, FOUND TO BE WITHIN LIMITS IAW DC10/MD10 SRM 53-70-00, FIGURE 5 VOL 1 STA 1119-1159 RBL 27.5. REMOVED GOUGE AND FOUND TO BE OUT OF LIMITS. FABBED NEW SEAT TRACK IAW DC10/MD10 SRM 53-70-00, VOL1, PG 3 P.O: 571947.1. INSTALLED THE NEW SEAT TRACK IAW DC10/MD10 SRM 51-31-01, VOL 2, PAGE 1-5. THIS REPAIR IS CLASSIFIED AS MAJOR.

Part: SEAT TRACK — DAMAGED (BS 700-815) · airframe 55,383 hrs · 20,674 cycles

BROKEN SCALLOPS ON CABIN SEAT TRACK AT STA 755 REMOVED FLOOR PANEL IAW DC10/MD10 SRM 51-31-01 VOL 2 PGS 1-5. REMOVED SEAT TRACK AT STA 700-760 LBL 47.5 IAW DC10/MD10 SRM 51-31-01 VOL 2 PG 1-5, MAT ID 54929405 AND PO NR 570769.5 FOR SEAT TRACK IAW DC10/MD10 SRM 53-42-01 VOL 3. FABRICATED AND INSTALLED SEAT TRACK IAW FEDEX DC10/MD10 SRM 53-70-00 VOL 1 PG 21-22. FABRICATED SPLICE AND SPLICE PLATE AND INSTALLED IAW FEDEX DC10/MD10 SRM 53-70-00 VOL1 PG 3 AND 4. ALODINED AND PRIMED IAW FEDEX DC10/MD10 SRM 51-21-01 VOL 2 PG 25 AND 21. INSTALLED FLOOR PANEL IAW FEDEX DC10/MD10 SRM 51-30-01, MAJOR REPAIR.

Part: SEAT TRACK — WORN (BS 1019-1039) · airframe 55,383 hrs · 20,674 cycles

ELONGATED SCALLOPS ON CABIN SEAT TRACK AT RBL 47.5, STA 1019 TO 1039 CHECKED LIMITS, SEAT TRACK HAS SEVERAL BROKEN SCALLOPS OUT OF LIMITS IAW DC/MD10 SRM 53-70-00 VOL 1 PG 21. REMOVED OLD TRACK AND INSTALLED NEW TRACK IAW MD-DC10 SRM 53-42-01 VOL 3 PG 13/14 AND 53-70-00 VOL 1 PG 3 AND 4. ALODINED AND PRIMED TRACK IAW DC/MD-10 SRM 51-21-01 VOL 2 PG 1 AND 4.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

CENTER WHEEL AREA L48L END FITTING CORRODED IN AREAS STA1509 TO 1521. [08-21-07] ALL WORK ACCOMPLISHED ON SDR 07-3006 -W/O 37284.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

CENTER WHEEL WELL AREA L51R END FITTING HAS CORROSION IN AREAS STA 1509 TO 1521. [08-21-07] REMOVED, FABRICATED, AND INSTALLED FITTING P/N AYB 7020-1 STA.1509 TO 1521 L51R IAW DC/MD10 SRM 51-33-01 VOLII,53-00-01 FIG. 1B VOLII,51-21-01 VOLII,51-21-02 VOLII AND DAC DWG AYB 7020. MAJOR REPAIR.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

CENTER WHEEL WELL AREA L52 END FITTING HAS CORROSION IN AREAS STA1509 TO 1521. [08-21-07] RMEOVED, FABRICATED, INSTALLED FITTING P/N AYB7020-2 IAW DC/MD10 SRM 51-33-01 VOLII, 53-00-01FIG 1B VOLII, 51-21-01 VOLII, 51-21-02 VOL II AND DAC DWG AYB 7020. MAJOR REPAIR.

Part: DOOR FRAME — CORRODED (ZONE 200) · corrosion level 2 · airframe 55,383 hrs · 20,674 cycles

MAIN CARGO DOOR CUT-OUT LOWER JAMB TOP SIDE, JUST FWD OF NR 3 LATCH SPOOL FITTING WEB CORRODED. 09-04-07 REMOVED AND REPLACED MAIN CARGO DOOR JAMB UPPER BEAM ACA7226-1 IN REF TO DC/MD10 SRM 51-33-01 VOL II PAGE1 AND DAC DRAWING ACA7224 REV G. MAJOR REPAIR.

Part: FITTING — CRACKED (ZONE 200) · airframe 55,383 hrs · 20,674 cycles

MAIN CARGO DOOR FITTING NR 7 BORES A, B, C AND D SHOW CRACK INDICATIONS WITH BHEC BORES MARKED IN BLACK. 09-04-07 REMOVED AND REPLACED FITTING NR 7 IN REF TO DC/MD10 SRM 51-33-01 VOLI PAGE 1. MAJOR REPAIR MECH 3934 QC348

Part: FITTING — CRACKED (ZONE 200) · airframe 55,383 hrs · 20,674 cycles

MAIN CARGO DOOR FITTING NR 3 BORES A, C AND D SHOWS CRACK INDICATION WITH BHEC BORES MARKE DIN BLACK. 09-04-07 REMOVED AND REPLACED NR 3 DOOR FITTING AT STA 666 IN REF TO DC/MD10 SRM 51-33-01 VOL II PAGE 1. MAJOR REPAIR.

Part: BOLT — CORRODED (LT MLG) · airframe 54,715 hrs · 20,384 cycles

LT MAIN LANDING GEAR SUPPORT FITTING-FWD TRUNNION BOLT DOES NOT TAKE GREASE AND IS FROZEN. UPON REMOVAL, FOUND BOLT CORRODED. REPAIRED BOLT PER SEQ NR 13 EA 8-5710-10593 "LT MLG SUPPORT FITTING, FWD TRUNNION BOLT (FROZEN)".

Part: ENGINE — MAKING METAL (NR 3) · airframe 54,320 hrs · 20,218 cycles

SHUT DOWN NR 3 ENGINE IN FLIGHT BECAUSE OF LEVEL 2 ALERT, ENG NR 3 OIL FILTER. BEFORE SHUT DOWN OIL PRESS WAS NORMAL. OIL TEMP WAS 20 PERCENT HIGHER THAN OTHER ENGINES. AFTER SHUT DOWN IT WIND MILLED FOR 25 MIN WITH SOME OIL PRESS. CHECKED AIU FAULTS LAST FLT LEG IAW FIM, FAULT 314125, ENG OIL STRN CLOG SW 3. REMOVED MASTER CHIP DETECTOR, FOUND LARGE CHUNKS ON IT. PROCEEDED PULLING SCAVENGE CHIP DETECTORS, FOUND MORE LARGE CHUNKS ON THE TRANSFER GEARBOX CHIP DETECTOR. PICTURES POSTED ON INTRANET BY DAYSHIFT MANAGER. ACCOMPLISHED IAW FIM 79-35. REMOVED AND REPLACED NR 3 ENG PER FEDEX WORKCARDS 71T0101-3, 71T0701-3, 7100J2009. OPS CHECKS NORMAL RII:236332

Part: CYLINDER — FAILED (MLG DOWNLOCK) · airframe 53,801 hrs · 19,989 cycles

RT MAIN GEAR DOWN ON RETRACTION AFTER T/O. LIGHT WENT RED AND STAYED RED UNTIL GEAR HANDLE PLACED DOWN. RECYCLED, SAME THING. LANDED @ KOAK. PER CREW DEBRIEF, APPARENTLY THE RT MLG NEVER MOVED FROM THE DOWN AND LOCKED POSITION. SUSPECT RT MAIN DOWNLOCK CYCLINDER BYPASSING. JACKED A/C REF MM 07-11-00-2. ACCOMPLISHED LT AND RT MLG SWING REF MM 32-10-00-5. LT OPS AND INDICATIONS NORMAL; CONFIRMED RT NO UNLOCK/MOTION. DOOR SEQUENCING APPEARS NORMAL. REPLACED RT MLG DOWNLOCK CYLINDER REF MM 32-33-02-2. ACCOMPLISHED MULTIPLE MLG GEAR SWINGS, OPS AND INDICATIONS NORMAL REF MM 32-10-00-5.

Part: DIMMER — FAILED (COCKPIT LIGHTS) · airframe 52,957 hrs · 19,637 cycles

APPROACHING TOP OF DESCENT A SLIGHT ELECTRICAL ODOR WAS NOTED IN COCKPIT. UNABLE TO LOCATE SOURCE, BUT A BRIEF SQUEAL WAS HEARD NEAR COCKPIT DOOR, FOLLOWED SHORTLY AFTER BY UNCOMMAND IRCD OPENING. DEACTIVATED IRCD AS A PRECAUTION. CONFIRMED ELECTRICAL ODOR DESCRIBED BY CREW. FOUND O/H INSTRUMENT PANEL BACKGROUND LIGHTING INOP. CONFIRMED THE DIMMER IS INOP WHICH CREATED THE ODOR. REMOVED AND REPLACED LIGHT DIMMER. ALL LIGHTING NOW WORKS NORMAL. ALSO PERFORMED OPS CK OF FORTIFIED COCKPIT DOOR. NO DEFECTS NOTED.

Part: SEAL — LEAKING (COCKPIT WINDOW) · airframe 52,814 hrs · 19,578 cycles

1 40 INTO FLIGHT AT FL370, WINDOW SEAL ON CAPT SIDE DEVELOPED LOUD SQUEAL. TOO LOUD TO CONTINUE FLIGHT. NOISE DISSIPATED UPON DESCENT THRU 15,000'. REMOVED AND REPLACED LEFT SLIDING CLEAR WINDOW PER MD-10-10 AMM 56-12-00-4. PRESSURIZED A/C PER MD10-10 AMM 21-31-00-5, NO LEAKS NOTED, WINDOW OK FOR SERVCICE.

Part: REPAIR — NONE (ZONE 100) · airframe 52,741 hrs · 19,541 cycles

REPAIR DOUBLER STATION 1059 - 1085 L51 - L52 MARKED NR 15 REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. VISUALLY INSPECTED REPAIR LOCATED AT STA 1059 - 1085 L51 - L52. ACCOMPLISHED PART 1 OF EA 8-5330-96453 - FUSELAGE REPAIR EVALUATION AGING AIRPLANE PROGRAM-EXISTING REPAIR AT STA 1059 - 1085 LONG L51 - L51R. MINOR REPAIR MECH 1941 QC 139.

Part: REPAIR — UNKNOWN (ZONE 500) · airframe 52,741 hrs · 19,541 cycles

REPAIR LT OB FLAP UPPER SKIN,STA.XOF 587 MARKED NR 71. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. VISUALLY INSPECTED REPAIR AT LT OB FLAP UPPER SKIN, FOUND TO BE WITHIN SRM 57-20-00 FIG 11 VOL. 1 LIMITS WITH RESPECT TO SIZE, SHAPE, SPACING AND EDGE DISTANCE.REMOVED SEVERAL LOOSE FASTENERS AND INSTALLED NEW FASTENERS IAW SRM 51-35-02 VOL 2. MINOR REPAIR.

Part: DOUBLER — OUT OF LIMITS (LT WING) · airframe 52,741 hrs · 19,541 cycles

REPAIR LT WING IB FLAP IB LWR FAIRING FWD END MARKED NR 51. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. N00719, EVALAUATED REPAIR IAW FAA DATA FOUND REPAIR WAS NOT IN COMPLIANCE. FABBED DOUBLER, ALODINED, PRIMED AND INSTALLED DOUBLER IAW SRM 57-00-01 VOL.1 FIG 4,51-21-01 VOL 2.MATERIAL ID 2024-T3-05 IAW DWG. ARC 2787. MINOR REPAIR.

Part: DOUBLER — INCORRECT (RT WING) · airframe 52,741 hrs · 19,541 cycles

R/W IB FLAP IB LOWER FAIRING FWD EDGE SIDE AFT OF FWD END MARKED NR 49. REPAIR REQUIRES EVALUATION FOR MAJOR/MINOR DETERMINATION AND IF THE REPAIR WAS ACCCOMPLISHED USING FAA APPROVED DATA. N00717, EVALUATED DOUBLER FAA APPROVED DATA, FOUND DOUBLER WAS NOT IN COMPLIANCE. FABBED NEW DOUBLER IAW SRM 57-00-01 VOL 1 FIG. 4. MATERIAL ID 2024-T3 .O50 IAW DAC DWG.ARC2787 ALODINED AND PRIMED, AND INSTALLED DOUBLER IAW SRM 51-21-01 VOL.2 AND 57-00-01 VOL.1 FIG.4.

Part: REPAIR — MISINSTALLED (T/E FLAP) · airframe 52,741 hrs · 19,541 cycles

REPAIR DOUBLER RT I/B FLAP LOWER T/E SKIN STA XIFH 311 MARKED NR 41 REPAIR REQUIRES EVALUATION FOR MAJOR/ MINOR DETERMINATION AND IF THE REPAIR WAS ACCOMPLISHED USING FAA APPROVED DATA. REPAIR DOUBLER FOUND TO BE NOT IN COMPLIANCE WITH THE FAA APPROVED DATA. MAT ID FOR REPAIR S3913181-72 IAW DC 10 SRM 57-20-00 VOL I FIG 10 PO# 57-6080.1, POSITIONED DRILLED AND INSTALLED REPAIR WEDGE IAW DC-10 SRM 57-20-00 VOL I AND 57-31-01 VOL II, MINOR REPAIR.

Part: CONDUIT — UNSECURE (LT MLG SENSOR) · airframe 52,291 hrs · 19,334 cycles

AFTER T/O & GEAR RETRACTION, UNSAFE (RED) ON RT & LT MAINS ON BOTH PRIMARY & CONFIG DISPLAYS. RAN CHECKLIST CYCLED GEAR. GOOD UP INDICATION ON LEFT MAIN BUT STILL UNSAFE ON RIGHT MAIN. RETURNED, LANDED AT KORD. FOUND NO PSEU LAST LEG FAULTS, PERFORMED RT MLG UPLTCH ADJ/TEST, FOUND THE CONDUIT FOR THE UPLATCH SENSORS CLAMPED IMPROPERLY, NOT ALLOWING SENSORS TO MOVE TO THE NEAR STATE. ADJ CONDUIT & RE-CLAMPED. ADJ/TEST OF RIGHT UPLATCH SENSOR GAP GOOD PER AMM. PERFORMED RT & LT MAIN UPLATCH SENSOR INDUCTANCE TEST PER AMM. FOUND THE LT SENSORS CONDUIT IMPROPERLY CLAMPED. RE-ADJUSTED CONDUIT & CHECKED LEFT SENSOR GAP GOOD PER AMM. PERFORMED PSEU RTS GOOD PER AMM.

Part: WARNING LIGHT — FALSE INDICATION (TE FLAPS) · airframe 51,479 hrs · 18,954 cycles

ON APPROACH, GOING FROM FLAPS 22 TO FLAPS 35, GOT LEVEL 2 ALERT SLATS DISAGREE. AFTER GO AROUND, FOUND SLAT HANDLE SCREW LOOSE. EXTENDED FLAPS AND SLATS. VISUAL INSPECTION OF FLAPS AND SLATS BOTH SIDES. NO DEFECTS FOUND. RAN FLAPS AND SLATS SEVERAL TIMES AND COULD NOT DUPLICATE FAULT. TEST FLAP POSITION IND PER MM NR 27-50-00-5 PAR F. C/W RETURN TO SERVICE ON THE FCC NR 1 AND NR 2. ALL TEST PASSED. NO FAULTS FOUND ON BOTH FCC FAULT REVIEW.

Part: SPAR CAP — CRACKED (ZONE 500) · airframe 49,711 hrs · 18,178 cycles

DURING C-CHECK AT OAN, INSPECTION FOUND A CRACK IN THE REAR SPAR LOWER CAP AT XORS 412. THE CRACK EXTEND INTO THE VERTICAL LAG AND FWD HORIZONTAL LAG, AND IS CONSISTENT WITH CRACKING DESCRIBED IN S/B DC10-57A137.

Part: SPAR CAP — CRACKED (ZONE 500) · airframe 49,711 hrs · 18,178 cycles

WING LEFT REAR SPAR AFT LOWER CAP CRACK AT XORS 412. THE CRACK EXTENDS INTO THE VERTICAL LEG AND FWD HORIZONTAL LEG. PERFORM PERMANENT REPAIR SIMILAR IN CONCEPT TO DWG SR10570019 WITH DIFFERENT FASTENER CALL OUTS TO COMPENSATE FOR PREVIOUS REWORK IAW EA 8-5710-78175.

Part: SKIN — CRACKED (ZONE 300) · airframe 49,711 hrs · 18,178 cycles

DURING ACCOMPLISHMENT -F- TO -ACF- AT OAN, INSPECTION FOUND CRACKS IN 2 LWR CONSTANT SECTION SKINS OF THE HORIZONTAL STAB. THE CRACKS WHERE WITHIN FLYLABLE LIMITS. HOWEVER, DUE TO SHORT INSPECTION REQUIREMENTS IT WAS DECIDED TO REPLACE ALL CRACKED PLANKS AND CONTINUE INSPECTION OF THE SKINS PER EO 8-5510-7-2307 PART 1 AT 24 MONTH INTERVALS. THE WORK IS BEING ACCOMPLISHED PER SB 55-16 FOR GROUP 1 A/C.

Part: SKIN — CRACKED (ZONE 300) · airframe 49,711 hrs · 18,178 cycles

DURING ACCOMPLISHMENT -F- TO -ACF- AT OAN, INSPECTION FOUND CRACKS IN 2 LWR CONSTANT SECTION SKINS OF THE HORIZONTAL STAB. THE CRACKS WHERE WITHIN FLYLABLE LIMITS. HOWEVER, DUE TO SHORT INSPECTION REQUIREMENTS IT WAS DECIDED TO REPLACE ALL CRACKED PLANKS AND CONTINUE INSPECTION OF THE SKINS PER EO 8-5510-7-2307 PART 1 AT 24 MONTH INTERVALS. THE WORK IS BEING ACCOMPLISHED PER SB 55-16 FOR GROUP 1 A/C.

Part: STRUT — DAMAGED (NLG) · airframe 49,504 hrs · 18,090 cycles

AFTER T/O LAX, RAISED GEAR & GOT NOSE GEAR UNSAFE UP BOTH POSITIONS. PER RED TABS LOWERED GEAR HANDLE & GOT 3 GREEN. ATTEMPTED TO RAISE GEAR HANDLE & WERE UNABLE. RAN RED TABS FOR GEAR HANDLE, WOULD NOT RAISE. RETURNED TO KLAX. JACKED AIRCRAFT REF DC-10-10 AMM 07-11-00-2. PERFORMED EXTENSION RETRACTION TEST IAW DC-10-10 AMM 32-30-00-5. OBSERVED NLG STRUT EXTENDING SLOW. STRUT NEEDS SERVICE. OBSERVED BLACK FLUID WHILE DRAINING STRUT. SUGGEST STRUT SEAL INSPECTION/CHANGE. C/W DC10 W/C 32T2401 NOSE GEAR STRUT REPACK. OP'D CK NOSE RETRACTION & EXTENSION PER MM 32-30-00-5.

Part: GASKET — BLOWN (NR 3 ENGINE) · airframe 48,871 hrs · 17,828 cycles

AT TOP OF DESCENT GOT INTERMITTENT THEN STEADY LOOP A LT NR 3 ENG FOLLOWED RED TABS TESTED LOOP-B TEST FAILED FOLLOWED ENG FIRE SEVERE DAMAGE CHECKLIST SHUTDOWN NR 3 ENG FIRE INDICATIONS CONTINUED UNTIL AFTER SHUTDOWN. FOUND 9TH STAGE METAL GASKET BLOWN OUT, WHICH CAUSED HOT AIR TO BE BLOWN ON THE -A- AND -B- FIRE LOOPS. REMOVED AND REPLACED GASKET PER STANDARD MAINT PRACTICES. FOUND NO FAULTS WITH -B- LOOP, OPS CHECK NORM PER M/M 26-10-00-5. INSP TIN FOIL ON DUCT JOINTS, NO DAMAGE FOUND. NR 3 ENG WAS RAN PER JRH, NO FAULTS NOTED ON IDLE ENG RUN. REOPENED ENG AND INSP DUCTS, NO FAULTS NOTED, ENG COWLINGS ARE CLOSED PER M/M 71-00-00-2. OK FOR SVC.

Part: BUSHING — SHEARED (T/E FLAP) · airframe 47,332 hrs · 17,165 cycles

RIGHT INBOARD FLAP OUTBOARD HINGE BUSHING ATTACHMENT FOUND SHEARED DURING REMOVAL OF FLAP PANEL ASSY. EVIDENCE LACK OF LUBRICATION. REF EA 8-5750-60767 SEQ 760. C/W EA 8-5750-60767 SEQ 760.

Part: RESERVOIR — LEAKING (RT MLG WW)

97-0098, HYD SYS 3 ELEVATOR OFF LT ILLUMINATED. HYD QTY DROPPED TO 1 GAL. ACCOMPLISHED RED TAB PROCEDURE. PRESSURE DROPPED ONLY AFTER PUMPS WERE SHUT OFF. HYD FLUID FOUND ON POST FLT IN RT WHEEL WELL. REMOVED AND REPLACED NR 3 RESERVOIR TO STEP B5, M/M 29-12-09. GRD TEST PRESSURE FILTER INDICATOR POPPED. REMOVED AND REPLACED FILTER PER M/M 29-12-02. NEEDS LEAK CHECK. COMPLETED INSTALLATION OF RESERVOIR PER M/M 29-12-09-4. PRESSURIZED SYSTEM, NO LEAKS DETECTED.

Part: CONNECTOR — LOOSE (LE SLAT)

RECEIVED SLAT DISAGREE LIGHT, AIRBORNE AT FLAPS 15 DEGREES, NO FLAP LANDING ACCOMP EWR. FOUND SLAT HANDLE LAND LIMIT SWITCH S1-380 PLUG LOOSE. RESECURED SAME, OPERATED SLATS/FLAPS SEVERAL TIMES AND ALL OPS CKS NORMAL.

Part: SLAT HANDLE — WORN (LE FLAPS)

SLAT DISAGREE LIGHT AIRBORNE PAST FLAPS 0 EXT APPROACH AND LANDING IN 0 EXT SLAT. SEVERAL DISAGREE LIGHTS EVEN AT SLAT EXTEND. WIGGLING SLAT HANDLE FIXED THIS EACH TIME. CHECKED LEADING EDGE SLATS PER TAFI 27-80-00 FAULTS CODE AD. BITE CHECKED PROXIMITY ELECTRONIC UNIT CHANNELS 1-6, CHECKED NORMAL. T/S TO SLAT HANDLE T/O LIMIT SWITCH. REMOVED AND REPLACED BOTH SLAT HANDLE, T/O RETRACT (S1-379) AND SLAT HANDLE LIMIT (S1-380) IAW MM 27-84-02. OPS CHECKED SLAT LIGHTS, OPS NORMAL.

Part: BUSHING — MIGRATED (RT MLG TRUNNION)

RT MAIN LANDING GEAR WING TRUNNION AFT FITTING, AFT LUG BUSHING MIGRATED FWD OUT OF LUG. FOUND THAT AFT LUG BUSHING WAS A SPACER AND NOT A TRUNNION BUSHING MIGRATING OUT, REF DAC B/P 3800, DC10 MM 32-11-01 FIG 106, OK'ED FOR SERVICE. RESEALED SPACER PER DAC B/P ARB 3800.

Part: BUSHING — MIGRATED (RT MLG TRUNNION)

RT MAIN LANDING GEAR WING TRUNNION AFT FITTING, AFT LUG BUSHING MIGRATED FWD OUT OF LUG. FOUND THAT AFT LUG BUSHING WAS A SPACER AND NOT A TRUNNION BUSHING MIGRATING OUT, REF DAC B/P 3800, DC10 MM 32-11-01 FIG 406, OK'ED FOR SERVICE. RESEALED SPACER PER DAC B/P ARB 3800.

Part: BELLFRAME — CORRODED (BS 1841)

CENTER CARGO COMPARTMENT CORROSION ON BELLFRAME, STA 1841 STRINGER 50R THROUGH 506 AFT SIDE OF BELLFRAME. CUT AND REMOVED DAMAGED SECTION OF BELLFRAME, REMOVED LIGHT REMAINING CORROSION. ALODINED AND PRIMED AREA, FABRICATED, SPLICE AND DOUBLER INSTALLED SPLICE AND DOUBLER PER SRM NR 53-00-01.

Part: BUSHING — MIGRATED (RT MLG)

RT MAIN LANDING GEAR WING TRUNNION AFT FITTING, AFT LUG BUSHING MIGRATED FWD OUT OF LUG. FOUND THAT AFT LUG BUSHING WAS A SPACER AND NOT A TRUNNION BUSHING MIGRATING OUT, REF DAC B/P 3800, DC10 MM 32-11-01 FIG 409, OK'ED FOR SERVICE. RESEALED SPACER PER DAC B/P ARB 3800.

Part: FRAME — CRACK (TAIL CONE)

TAIL CONE FWD FRAME CRACKED LT SIDE AT TOP GUIDE PIN HOLE. STOP DRILLED CRACK IN FRAME, INSTALLED FRAME DOUBLER PER TAIL CONE FRAME CRACK REPAIR SRM 53-30-00 FIG 3 PAGE 2. VERIFIED FOR CRACK INDICATION BEYOND STOP DRILL HOLES WITH H/FEC, NO INDICATION, REF SRM NR 3096.

Part: BUSHING — MIGRATED (RT MLG TRUNNION)

RIGHT MLG WING TRUNNION FWD FITTING FWD LUG BUSHING MIGRATED FWD/OUT OF LUG.

Part: BUSHING — MIGRATED (RT MLG TRUNNION)

RIGHT MLG WING TRUNNION FWD FITTING AFT LUG BUSHING MIGRATED FWD/OUT OF LUG.

Part: BUSHING — MIGRATED (RT MLG TRUNNION)

RIGHT MLG STRUT AFT TRUNNION FITTING BUSHING MIGRATED FWD/OUT OF FITTING.