N68058

Part: FILLER — CRACKED (NACELLE) · airframe 51,427 hrs · 24,706 cycles

NR2 ENGINE SAIL TAIL FILLER AT EXHAUST NOZZLE HAS NUMEROUS CRACKS AS MARKED, 2 DEEP CHAF MARKS AND RIGHT FWD CORNER IS BROKEN. REMOVED SAIL TAIL FILLER IAW SRM 51-31-01. REPAIRED FILLER AS REQUIRED BY WELDING CRACKS AND CHAF MARKS ON MAE TRAVLER T6/593345.

Part: WEDGE — CRACKED (ZONE 500) · airframe 51,427 hrs · 24,706 cycles

LT WING I/B FLAP UPPER SKIN HAS A CRACK NEAR O/B END. CLEANED AREA IAW M/M 12-22-02-7, HFEC INSP PER NTM 51-00-00 CRACK FOUND 3 EA. REMOVED T/E SECTION IAW SRM 51-31-01. REMOVED DAMAGED AREA IAW SRM 57-10-00, FIG 85. FAB DOUBLER AND FILLER MAT THICKNESS 2024 T3 040 BATCH 1011107. LOCATED AND DRILLED REPAIR DOUBLER IAW SRM 57-10-00 FIG 85. INSTALLED ASSY PARTS IAW SRM 51-31-01. REINSTALLED T/E WEDGE IAW SRM 51-31-01. PREP AND PAINTED LT WING I/B FLAP UPPER O/B IAW SRM 51-21-02.

Part: CONNECTOR — DAMAGED (PAX DOOR) · airframe 51,322 hrs · 24,651 cycles

AT FL 290 A/C DOOR LIGHT ILLUMINATED ON SECOND OFFICERS PANEL. CREW RAN RED TAB CHECKLIST AND LANDED AT MEMPHIS. DOOR LIGHT EXT DESCENDING THROUGH 16,000 FT. AIR CONDITIONING DOOR CAUTION LIGHT SYSTEM(S) INOP. VERIFY AND RECORD IN AML/EAML THE AFFECTED AIR CONDITIONING DOOR(S) IS CLOSED AND LOCKED BY VISUAL INSPECTION PRIOR TO EACH DEPARTURE. REPLACED C/P CONNECTOR P1-1618 AND LIMIT SWITCH S1-257 NR 1 A/C COMPT DOOR IAW AMM 52-42-01-2 STEP 4, SUBTASK B AND SMP 20-30-02. ADJ TESTS AND IND NORMAL.

Part: WARNING LIGHT — ILLUMINATED (THRUST REVERSER) · airframe 50,693 hrs · 24,340 cycles

WHILE IN FLIGHT CLIMBING-OUT OF 15000 FT, THE NR 2 THRUST REVERSER UNLOCK LIGHT WAS FLICKERING ON AND OFF. THRUST REV CHECKLIST WAS COMPLETED AND RETURN AND LANDED ACN RELEASED FOR SERVICE PER MEL/CDL: 78-01-01-B

Part: SKIN — TORN (ZONE 100) · airframe 49,826 hrs · 23,900 cycles

INSPECTED DAMAGED AREA, FOUND A LARGE TEAR IN SKIN APPROX 16 X 6 INCH FWD OF FR959 L AND ABOVE STRINGER 41L. STOP DRILLED TEARS AND CUT OUT DAMAGE PER DC10 SRM 53-20-00 VOL 1 FIG 6 SHEET 7. UPON REMOVAL OF SKIN FOUND TEAR STRIP AT FR 959L/ STRINGER 41L CRACKED. REMOVED ADDITIONAL SKIN IN ORDER TO CUT THE DAMAGED SECTION OF TEAR STRIP. REMOVED DAMAGE SECTION OF TEAR STRIP PER DC10 SRM 53-20-00 VOL 1 FIG 18. REPAIR IS A CLASS 2 REPAIR AS PER SRM 53-20-0 FIG 6 SHEET 7, AND REQUIRES AN INITIAL INSPECTION AT 15,000 CYCLES, A REPETITIVE AT 9,800 AND REPLACEMENT AT 37,450 CYCLES.

Part: CONNECTOR — DIRTY (R1 DOOR) · airframe 49,314 hrs · 23,682 cycles

AFTER TAKEOFF R1 DOOR LIGHT CAME ON AND WOULD NOT PRESSURIZE. ATB TO MEM. MEL 52-04-02: FWD CABIN DOOR CAUTION LIGHT INOPERATIVE. CHECKED WIRING ON R-1 DOOR, CLEANED CONNECTOR TO ACTUATOR. PRECAUTIONARY, ACTUATED DOOR MULTIPLE TIMES INSIDE AND OUT, CLEANED OUT SIDE SWITCH. DOOR OPS CHECKED NORMALLY AS PER M/M 52-10-01-2, OK TO CONTINUE.

Part: FITTING — MIGRATED (ZONE 300) · airframe 49,035 hrs · 23,532 cycles

LEFT HORIZONTAL STABILIZER INBOARD TRAILING EDGE, STABILIZER TO STABILIZER BOX SAFETY LINK, OUTBOARD ATTACH CLEVIS BUSHING WORN AND MIGRATED THROUGH STABILIZER LOWER INBOARD ACCESS PANEL 334MB. REMOVED FITTING FOR INSTALLATION OF REPAIR BUSHING IAW FEDEX DC10 SRM 55-10-00 VOL 1. REMOVED AND REINSTALLED BEARING, HAND STAKED IAW FEDEX EA 8-5510-81489, HORIZONTAL STABILIZER SIDE LOAD SUPPORT FITTING. REINSTALLED FITTING IAW FEDEX DC10 SRM 51-31-01 VOL II, REMOVED AND REINSTALLED FORWARD BULKHEAD ACCESS PANEL AND HORIZONTAL STABILIZER LEADING EDGE IAW FEDEX DC10 SRM 51-31-01 VOL II AND DC10 MM 55-30-01-2. REFERENCE NONROUTINE N02092.

Part: LONGERON — CORRODED (ZONE 100) · corrosion level 2 · airframe 49,035 hrs · 23,532 cycles

LOWER FUSELAGE UNDERWING LONGERON 49R IS CORRODED FROM STATION 1368 TO 1521. REMOVED CORROSION LONGERON 49R, FOUND TO BE OUT OF LIMITS. REMOVED LONGERON 49R FROM STATION 1330 TO 1521. FABRICATED LONGERON 49R IAW DAC DWG 7013 AND SPLICE REPAIR IAW DC10 SRM 53-00-01 VOL 1 PAGE 30. INSTALLED NEW END FITTING LONGERON AND REPAIR SPLICES IAW DAC DWG AYB 7020, 7013 AND DC10 SRM 53-00-01 VOL II, REFERENCE NON-ROUTINE N00937.

Part: PANEL — DELAMINATED (ZONE 300) · airframe 49,035 hrs · 23,532 cycles

LEFT HORIZONTAL STABILIZER 1 EACH PANEL AT STATION XE122 COMPOSITE PANEL AT AFT SPAR TOP SIDE IS DELAMINATED. REPAIRED PANEL BY FABRICATING AND BONDING NEW OUTER SKIN, INNER SKIN, INNER DOUBLER AND CORE IAW DWG ALC7429 AND EA 8-5510-81439 AND TPS 1001 REV E. REFERENCE NON-ROUTINE N01578.

Part: LONGERON — CORRODED (ZONE 100) · corrosion level 2 · airframe 49,035 hrs · 23,532 cycles

LOWER FUSELAGE UNDERWING LONGERON 48R IS CORRODED FROM STATION 1368 TO STATION 1521. REMOVED CORROSION, FOUND TO BE OUT OF LIMITS IAW DC10 SRM 53-00-01 VOL I PAGE 8, FIGURE 1B. REMOVED DAMAGE SECTION OF LONGERON 48R FROM STATION 1330 TO 1521. INSTALLED LONGERON 48R PART NUMBER AYB 7016-2 IAW DAC DWG 7020 AND SPLICE FITTING IAW DC10 SRM 53-00-01 VOL 1. REFERENCE NON-ROUTINE N00938.

Part: STATIC PORT — FAILED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

LEFT PRIMARY STATIC PORT FAILS WAVINESS CHECK. REMOVED LEFT HAND STATIC PORT AND REPLACED HEAT SINK IAW FEDEX DC10 MM 34-11-01-2. REMOVED STATIC PORT AND BLENDED OUT GOUGE ON LEFT HAND RUB PLATE IAW DC10 SRM 53-00-02 VOL 1 AND DC10 SRM 51-71-00 VOL II. INSTALLED LEFT HAND PRIMARY STATIC PORT AND HEAT SINK IAW DC10 MM 34-34-11-01-2. INSTALLED LEFT HAND PRIMARY STATIC PORT HEATER ASSEMBLY IAW DC10 MM 34-11-01-2. PERFORMED CONVECTIVITY AND WAVINESS INSPECTION, WITHIN LIMITS IAW FEDEX DC10 MM 34-11-01-2. PERFORMED STATIC LEAK CHECK IAW DC10 MM 34-11-00-2. BOTH CAPTAINS AND FIRST OFFICERS PORTS CHECK GOOD.

Part: SKIN PANEL — CORRODED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

LOWER FUSELAGE CENTER SKIN REQUIRES REMOVAL DUE TO CORROSION FROM STATION 1350 TO 1521, L48L TO L48R. COMPLIED WITH FEDEX EA 8-5330-77624, SKIN SPLICE REPAIR AT STATION 1350-1521 REPAIR. REFERENCE NON-ROUTINE N01775.

Part: VENTILATOR PANEL — CRACKED (ZONE 400) · airframe 49,035 hrs · 23,532 cycles

NR 3 PYLON TOP PANEL 487DR HAS THREE AREAS OF CRACKS. REPAIRED VENTILATOR ASSY P/N AUB7054-501 IAW FEDEX EA 8-5480-77611. LOCATED AND DRILLED VENTILATOR ASSY IAW DC10 SRM 51-31-01 VOL II. VENTILATOR ASSEMBLY TO BE INSTALLED UNDER FEDEX OPS 43R-FIT. REFERENCE NON-ROUTINE N00166.

Part: PANEL — DELAMINATED (ZONE 600)

PANEL 66CT HAS SEVERAL AREAS OF DELAMINATION. REPAIRED BY REMOVING DAMAGE, FABRICATING AND BONDING NEW SKIN, CORE AND DOUBLERS IAW DAC DWG ARC0627 AND EA 8-5710-77619, REFERENCE NON-ROUTINE N00129.

Part: PANEL — DELAMINATED (ZONE 600) · airframe 49,035 hrs · 23,532 cycles

PANEL 641CR HAS SEVERAL AREAS OF DELAMINATION. REPAIRED PANEL IAW FEDEX EA 8-5710-77617. REFERENCE NON ROUTINE N00169.

Part: PANEL — DELAMINATED (ZONE 300) · airframe 49,035 hrs · 23,532 cycles

LEFT HORIZONTAL STABILIZER, 1 EACH PANEL AT STA XE203.5, COMPOSITE PANEL AT AFT SPAR TOP DELAMINATED. REPAIRED BY FABRICATION AND BONDING NEW OUTER AND INNER SKIN, DOUBLERS AND CORE IAW TPS 1001 REV E AND FEDEX EA 8-5510-81441. REFERENCE NON-ROUTINE N00148.

Part: PANEL — DELAMINATED (ZONE 500) · airframe 49,035 hrs · 23,532 cycles

PANEL 541EB HAS SEVERAL AREAS OF DELAMINATION. REPAIRED PANEL IAW FEDEX EA 8-5710-77620, REFERENCE NON ROUTINE N00125.

Part: PANEL — DELAMINATED (ZONE 600) · airframe 49,035 hrs · 23,532 cycles

PANEL 636HL HAS SEVERAL AREAS OF DELAMINATION. REPAIRED PANEL IAW FEDEX EA 8-5710-77614. REFERENCE NON ROUTINE N00323.

Part: SKIN — CORRODED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

LOWER FUSELAGE CENTER SKIN REQUIRES REMOVAL DUE TO CORROSION, FROM STATION 1350 TO 1521 L48L TO L48R. COMPLIED WITH FEDEX EA 8-5330-77624, SKIN SPLICE REPAIR AT STATION 1350-1521. REFERENCE NON ROUTINE N01775.

Part: TUBE — CRACKED (ZONE 400) · airframe 49,035 hrs · 23,532 cycles

LEFT WING LEADING EDGE UPPER PYLON FUEL SAXAPHONE LINE IS CRACKED AT MOUNTING POINT. REMOVED, REPAIRED, REINSTALLED FUEL LINE IAW FEDEX EA 8-2822-77635.

Part: HINGE — CORRODED (ZONE 500) · airframe 49,035 hrs · 23,532 cycles

LEFT HAND INBOARD FLAP OUTBOARD SUPPORT PIVOT ATTACH POINT OUTBOARD BORE CORRODED. CORROSION EXCEEDS CMM 57-52-01 LIMITS. REPAIRED IAW FEDEX EA 8-5750-77622. REFERENCE NON ROUTINE N00490.

Part: PANEL — CORRODED (ZONE 300) · airframe 49,035 hrs · 23,532 cycles

RIGHT HORIZONTAL STABILIZER PANEL 344JB HAS CORROSION ON NUMEROUS SPOTS ON INTERIOR SURFACE. REPAIRED PANEL IAW FEDEX EA 8-5510-81466.

Part: PANEL — DELAMINATED (ZONE 600) · airframe 49,035 hrs · 23,532 cycles

RIGHT WING TRAILING EDGE PANEL 641BB DELAMINATED. REPAIRED PANEL IAW FEDEX EA 8-5710-77621, REFERENCE NON ROUTINE N00419.

Part: BEAM — DAMAGED (ZONE 700) · airframe 49,035 hrs · 23,532 cycles

DURING REMOVAL OF ZERT FITTING BUSHING ON LEFT HAND MAIN LANDING GEAR TRUCK BEAM, FOUND BUSHING TO BE THREADED BUSHINGS, NOT PRESS BUSHING. INSTALLED NEW ZERK FITTING IAW FEDEX EA 8-3212-81257 PART 1 DC10 LANDING GEAR MAIN LANDING GEAR TRUCK BEAM BORE REPAIR AUTHORIZATION. REFERENCE NON-ROUTINE N01937.

Part: PANEL — DELAMINATED (WING) · airframe 49,035 hrs · 23,532 cycles

PANEL 541EB HAS SEVERAL AREAS OF DELAMINATION. REPAIRED PANEL BY FABRICATING AND BONDING NEW INNER SKIN, OUTERSKIN, DOUBLER AND CORE IAW DC10 DRAWING ARC0264 AND EA8-5710-77620.

Part: LINER — PUNCTURED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

AFT PIT DOOR JAMB AFT SIDE THRESHOLD PANEL HAS HOLE PUNCTURES ON IT. WELD REPAIRED IAW FEDEX EA 8-5320-77632, REFERENCE NON-ROUTINE.

Part: FRAME — CORRODED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

MAIN CABIN FUSELAGE STATION 1821 HAS CORROSION AT LOWER FRAME END, AS SEEN FROM BULK PIT UPPER TORQUE BOX. CORROSION EXCEEDS LIMITS IAW DC10 SRM 53-00-01 VOL 1. FABRICATED AND INSTALLED REPAIR IAW DC10 SRM 50-30-00 FIGURE 5, VOLUME 1. REFERENCE NON ROUTINE N01499.

Part: PANEL — DELAMINATED (ZONE 500) · airframe 49,035 hrs · 23,532 cycles

PANEL 541CR HAS MANY AREA OF DELAMINATION. REPAIRED PANEL 541CR BY FABRICATING AND BONDING NEW SKINS, DOUBLERS AND CORE IAW TPS 1001 REV E, DAC DWG ARC2906 AND FEDEX EA 8-5710-77618. REFERENCE NON-ROUTINE N00163.

Part: PANEL — CORRODED (ZONE 300) · airframe 49,035 hrs · 23,532 cycles

RIGHT HORIZONTAL STABILIZER PANEL 344JB HAS CORROSION ON NUMEROUS SPOTS ON INTERIOR SURFACE. REPAIRED PANEL BY FABRICATING AND BONDING NEW OUTER SKIN, INNER SKIN, INNER DOUBLER, OUTER DOUBLER AND CORE IAW TPS 1001 REV E AND FEDEX EA 8-5510-81466. RIGHT HAND HORIZONTAL STABILIZER TRAILING EDGE FAIRING PANEL. REFERENCE NON-ROUTINE N00138.

Part: PANEL — DELAMINATED (ZONE 600) · airframe 49,035 hrs · 23,532 cycles

RIGHT WING TRAILING EDGE PANEL 641 EB HAS MANY AREA OF DELAMINATION. REPAIRED RIGHT WING TRAILING EDGE PANE 641EB BY FABRICATING AND BONDING INNER AND OUTER SKIN, HONEYCOMB CORE AND INNER DOUBLER IAW EA 8-5710-7763, DAC DWG ARC0264 AND TPS 1001 REV E, REFERENCE N/R N00882.

Part: PAN — GOUGED (ZONE 400) · airframe 49,035 hrs · 23,532 cycles

NR 2 ENGINE RT FAN COWL INTERIOR HAS RUBBING APPROXIMATELY 8 INCHES ABOVE CENTER U-BOLT. REMOVED CENTER U-BOLT FITTING TO FOM. REMOVED DAMAGED SECTION OF PAN IAW SRM 51-35-01, VOL II. WELD REPAIRD IAW EA 8-5410-81450. INSTALLED PAN IAW SRM 51-31-01 VOL II. INSTALLED CENTER U-BOLT AND FITTING IAW SRM 51-31-01 VOL II. REFERENCE N/R N00899.

Part: PANEL — DELAMINATED (ZONE 600) · airframe 49,035 hrs · 23,532 cycles

PANEL 636 DL HAS SEVERAL AREA OF DELAMINATION. REPAIRED PANEL P/N ARC0566-2 BY FABRICATING AND BONDING NEW SKIN, DOUBLERS AND CORE IAW FEDEX EA 8-5710-77513, DAC DWG ARC0566 AND TPS 1001 REV E, REFERENCE N/R N00321.

Part: SKIN — DAMAGED (ZONE 500) · airframe 49,035 hrs · 23,532 cycles

LEFT WING TRAILING EDGE SKIN AFT OF MAIN LANDING GEAR LOWER SURFACE REQUIRES FABRICATION. FABRICATED DOUBLER AND SKIN IAW DAC DWG ARC0468, BONDED SKIN AND DOUBLER IAW TPS 1001 REV E AND DAC DWG ARC0468 AND EA 9-5710-81448. ALODINED AND PRIMED CONTACT UPPER SURFACE IAW DC 10 SRM 51021-01 VOL II, MARKED FX ARC0468-9 FOR SKIN PART AND FX ARC0468 DOUBLER PART IAW FEDEX GMM 7-0-1001. REFERENCE N/R N01745.

Part: PAN — GOUGED (ZONE 400) · airframe 49,035 hrs · 23,532 cycles

NR 2 ENGINE RIGHT HAND FAN COWL INTERIOR HAS RUBBING APPROXIMATELY 8 INCHES ABOVE CENTER "U" BOLT. REMOVED CENTER "U" BOLT FITTING TO FOM. REMOVED DAMAGED SECTION OF PAN IAW DC10 SRM 51-35-01 VOL II. WELD REPAIRED IAW FEDEX EA 8-5410-81450. INSTALLED PAN IAW DC10 SRM 51-31-01 VOL II. INSTALLED CENTER "U" BOLT AND FITTING IAW DC10 SRM 51-31-01 VOL II, REFERENCE N/R N00899.

Part: FLOORBEAM — CORRODED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

AFT PIT, FLOORBEAM CAP BEAM AT STATION 1887.0 HAS EXFOLIATION. REMOVED FLOORBEAM IAW SRM 51-33-01 VOL II. INSTALLED NEW FLOORBEAM AGA 3849-15, (FABRICATED ON NON-ROUTINE N01875) IAW DWG AGA 3849 AND SRM 51-33-01 VOL II. REFERENCE NON-ROUTINE N01814.

Part: DUCT — GOUGED (ZONE 400) · airframe 49,035 hrs · 23,532 cycles

SEVERAL GOUGES ON FORWARD COMPARTMENT COOLING DUCT INSIDE NR 1 OUTBOARD THRUST REVERSER AT NR 1 ENGINE, (NR 1 OUTBOARD THRUST REVERSER UPPER COOLING DUCT). REMOVED DUCT, REPAIRED IAW EA 8-7830-77634, AND DC10 SRM 51-21-01 VOL 2, AND REINSTALLED IAW DC10 MM 20-50-02. REFERENCE NON-ROUTINE N00929.

Part: SKIN — DAMAGED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

RIGHT HAND PRIMARY STATIC PORT HAS EXTERNAL DOUBLER WITHIN 18 INCHES OF CONTROLLED AREA AT FOUR O'CLOCK POSITION AT FUSELAGE STATION 869 AT LONGERON 48 RIGHT. REMOVED AND REPLACED SKIN AND DOUBLERS IAW FEDEX EA 8-5330-81438, FUSELAGE SKIN SPLICE REPAIR AT STA 913 L48R TO CARGO DOOR CUTOUT REPAIR. REFERENCE NON-ROUTINE N00312.

Part: FITTING — CORRODED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

LOWER SFT WING TO CENTER BOX ATTACH SKI FITTING IS EXFOILATED. RIGHT WHEEL WELL STATION 1341 TO 1360 AT XCW 118. REMOVED ATTACHED STRUCTURE IAW DC10 SRM 51-33-01, 51-35-01 VOL II, REMOVED FITTING P/N ANB7015-2. INSTALLED NEW P/N ANB7015-2 IAW DAC DWG ANB7014, REMOVED AND REINSTALLED 2 EACH CENTER WING PANELS IAW DC10 SRM 51-31-01 VOL II, REMOVED AND REINSTALLED CROSSFEED TUBE IAW DC10 MM 28-00-01-2. REINSTALLED ATTACH STRUCTURE IAW DC10 SRM 51-33-01 AND 51- 35-01.

Part: FITTING — CORRODED (ZONE 100) · corrosion level 2 · airframe 49,035 hrs · 25,532 cycles

CORROSION AT THE INTERIOR OF AFT CARGO DOOR UPPER BOX AT LONGERON 27L FITTING AND SEVERAL HARDWARE, STA 1787 TO STA 1841, LONGERON 27L, LBL 101.0 TO LBL 106.0. REMOVED CORROSION, EXCEEDS LIMITS IAW DC10 SRM 53-00-01 VOL I, REMOVED AND REPLACED HEADER BEAM, REMOVED AND REINSTALLED SHROUD, TORQUE BOX WEBS, AFT TORQUE BOX, BATHTUB FITTING, ATTACH ANGLES, TEE FITTING, STUB FRAMES, INTERCOSTALS, END FITTING, SCUFF FITTING, STIFFNER, RACK, STOP PAD, CONTROL ARM FITTING, SEAL RETAINER, GILL LINER AND CLOSEOUT PANELS REMOVED TO FOM IAW DC10 SRM 51-31-01 VOL II, 51-33-01 VOL II, 53-00-01 AND 51-35-01 VOL II.

Part: FITTING — CRACKED (ZONE 100) · airframe 49,035 hrs · 23,532 cycles

CRACKED FITTING, CENTER WING SECTION TO FUSELAGE SPLICE, STATION 1157, LEFT HAND SIDE AT LONGERON 37L, EXTERNAL FITTING. REMOVED DAMAGED FITTING IAW DC10 SRM 51-33-01 VOL II. NEW FITTING FABBED ON FEDEX CARD N00880. LOCATED AND DRILLED FITTING IAW DC10 SRM 51-33-01 VOL II. INSTALLED FITTING IAW DC10 SRM 51-33-01 VOL. II.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 49,035 hrs · 23,532 cycles

LOWER FUSELAGE UNDER WING BARREL SKIN IS CORRODED FROM STATION 1368 TO 1288 FROM LONGERON 47R TO 52R. REMOVED CORROSION IAW DC10 SRM 51-21-01 VOL II. ORIGINAL THICKNESS IS .090 IAW DWG AYB7030. AFTER BLENDOUT MATERIAL IS AT .080, WITHIN LIMITS IAW DC10 SRM 51-21-01 VOL II. (OPEN)

Part: AUDIO PANEL — BURNT (RT COCKPIT)

AIR TURNBACK, RETURNED TO DFW. SMOKE IN COCKPIT, APPEARS TO BE COMING FROM SECOND OFFICER'S AUDIO PANEL. ALL FIRE AND SMOKE CHECK LIST DONE. FOUND SECOND OFFICER'S AUDIO CONTROL PANEL BURNT INSIDE. USED AUDIO PANEL FROM ELECTRONIC COMPARTMENT, FUNCTIONAL CHECKS OK.

Part: AOA SENSOR — FAILED (RIGHT)

AT 8,000 FT SLAT EXTENDED SPOILER DEPLOYED 200 STOWED AT 210 BUG WAS 197 AUTO SLAT EXTENSION + STICK SHAKER. SLAT DISAGREE LIGHT CYCLED TO T/O AND SLAT DISAGREE 3X. 35 LANDING WITH SLATS WAS ACCOMPLISHED SLAT SPEED 230. INSTALLED LT SYS OPS NORMAL AND RT AOA SENSOR HTR CUR TEST FAILED - INOP. *S/D* CORRECTED WIRING ON RT AOA SENSOR PER WIRING DIAGRAM AND REPLACED SENSOR, O/C NORMAL.

Part: BULKHEAD FTG — CRACKED (BS 1156)

SNRM 1067. CENTER ASSY COMPT - 1156 BULKHEAD - OUTER CAP ANGLE FITTING ON LEFT SIDE HAS A 1.75 INCH CRACK ACROSS THE RADIUS BETWEEN STR 35 - STR 36L. ***S/D***** NDT VERIFIED END OF CRACK/ACCOMPLISHED REPAIR PER SRM 53-40-00, FIG 8.

Part: FITTING — CORRODED (LT MLG)

SNRM 5054, LEFT MLG FITTING EXHIBITS EXFOLIATION CORROSION APPROX 2 SQ IN AT LEFT LWR INTERNAL SURFACE. *S/D* CLEAN AND TREAT CORROSION, REMOVED AND REPLACED LT LWR FWD AUX SPAR SPLICE PER EA 8-5710-28974.

Part: BEAM — CORROSION (LT WING)

SNRM 5046 LT WING - AFT I BEAM, DIRECTLY BELOW AND 20 I/B OF NR 1 SPOILER, EXHIBITS HEAVY INTERGRANULAR CORROSION. *S/D* REMOVED CORROSION AND INSTALLED DOUBLER PER SRM 57-00-1, CLOSED 6/16/96.

Part: COWL WEB — CRACKED (NR 2 ENGINE)

SNRM 4206, NR 2 ENG NOSE COWL CRACK AT AFT BULKHEAD AS VIEWED THROUGH ACCESS PANEL 361 KL. *S/D* REMOVED AND REPLACED WEB SECTION AS PER SRM 54-00-01.

Part: SPRING — MISSING (RUDDER CONTROLS)

PRESSURE REQUIRED TO MOVE RUDDER PEDALS IS CONSIDERABLY LESS THAN ON OTHER DC-10-A/C. FOUND UPPER RUDDER LOAD FEEL MECHANISM SECOND STAGE SPRING PRELOAD MISSING. INSTALLED SAME, OPS CKS GOOD IAW MM 27-20-00 ON (P/N AMH7002-1).

Part: PROX SWITCH — LOOSE (LT MLG)

LT MLG IND LIGHT REMAINED RED AFTER INT RETRACTION, BOTH PANELS. GEAR WAS RECYCLED PER PG 2-6-2 OF OTHER EMERGENCY ANDABNORMAL PROCEDURE HANDBOOK AND BOTH REMAINED RED. ONE MORE RECYCLE WAS ACCOMP WITH THE SAME RESULTS. FLT CONTINUED AT 260 KTS OR LESS FOR THE REMAINDER OF FLT PER CKLIST. FUELCONSUMPTION AND DRAG IND THAT THE GEAR WAS UP, LIGHTS REMAINED ON THROUGHOUT FLT, LIGHTS SHOWED GREEN EACH TIME. FOUNDPROX SW TARGET LOOSE, REPLACE SAME, FOUND EXCESSIVE GAP BETWEEN TARGET AND PROX SW ADJ SAME PER 32-34-03. DURING T/S FE LDG IND WENT INOP. REMOVED AND REPLACED PROX ELECTRONIC UNIT. BITE CK SAME, ALL POS CK NORMAL, PERFORMED GEAR SW ANDALL IND NORMAL. OK FOR SERVICE.