N68065

Part: SKIN — CRACKED (LEFT WING)

INSPECTION FOUND AN 8 INCH CRACK IN LEFT WING SKIN PANEL NR 517CT. NEW SKIN WAS INSTALLED IAW SRM 57-31-01, FIGURE 1A AND SRM 51-31-01.

Part: BATTERY PACK — DISCHARGED (ROW 29-35)

INSPECTION FOUND THE EMERGENCY ESCAPE PATH LIGHTS FROM SEAT 29AB TO SEAT 35AB INOPERATIVE. REPLACED BATTERY PACK AND OPERATION CHECKED GOOD IAW MM 33-51-00.

Part: FRAME — CRACKED (CARGO DOOR)

INSPECTION FOUND A 3 CRACK ON AFT CARGO DOOR FRAME AT AFT CORNER. A REPAIR WAS INSTALLED IAW SRM 52-10-00, FIGURE 7.

Part: HINGES — BROKEN (RT NLG DOOR)

A LOUD VIBRATION WAS OBSERVED WHILE ON DESCENT. THE VIBRATION SEEMED TO WEAKEN WHEN SLOWED TO 250 KNOTS. THE GEAR OPERATED NORMAL UPON LANDING WITH LESS VIBRATION. MAINTENANCE REMOVED AND REPLACED THE RT FORWARD NLG DOOR DUE TO BROKEN HINGES. THE RT FORWARD NLG DOOR DRIVE LINK WAS REPLACED DUE TO A BROKEN ROD END AND HOUSING DAMAGE. THE LT AFT NLG DOOR STRUT BRACKET WAS REPLACED DUE TO DAMAGE. THE DOORS WERE RIGGED AND OPERATIONAL CHECKS WERE GOOD IAW MM 32-23-01.

Part: FUEL OIL COOLER — RUPTURED (NR 2 ENGINE)

FUEL SMELL REPORTED IN COCKPIT AND CABIN DURING TAXI OUT. RETURN TO GATE, FIRE DEPART REPORTED FIRE COMING FROM NR 2 ENG. NR 2 ENG WAS SHUT DOWN. EMERG EVAC SLIDES WERE DEPLOYED AND PAX EXITED A/C VIA SLIDES. FIRE DEPART EXTINGUISHED ENG FIRE. L-3 DOOR SLIDE DID NOT FULLY DEPLOY. NR 2 ENG WILL BE REPLACED. PRELIMINARY INVESTIGATION FOUND FUEL MIGRATED INTO OIL SYS WHICH WOULD EXPLAIN REPORTED FIRE IN EXHAUST AREA. FURTHER INVESTIGATION, THE FUEL OIL HEAT EXCHANGER FAILED INTERNALLY. ALLOWING FUEL, THAT OPERATES AT SIGNIFICANTLY HIGHER PRESS THAN OIL, TO MIGRATE INTO OIL SYS. DISASSEMBLY OF FUEL OIL HEAT EXCHANGER REVEALED CRACKED OIL DIVIDER PLATE WHICH HAD BEEN DISPLACED AND CAUSED FRETTING OF FUEL T

Part: ENGINE — FIRE (NR 2)

A FUEL SMELL WAS REPORTED IN THE COCKPIT AND CABIN DURING TAXI OUT AT MAN. WHILE RETURNING TO THE GATE THE FIRE DEPARTMENT REPORTED FIRE COMING FROM THE NR 2 ENGINE. THE NR 2 ENGINE WAS SHUT DOWN. EMERGENCY EVACUATION SLIDES WERE DEPLOYED AND PASSENGERS EXITED THE AIRCRAFT VIA THE SLIDES. THE FIRE DEPARTMENT EXTINGUISHED THE ENGINE FIRE. THE L-3 DOOR SLIDE DID NOT FULLY DEPLOY. THE NR 2 ENGINE WILL BE REPLACED. THE SDR WILL REMAIN OPEN FOR FINDINGS ON L-3 DOOR SLIDE.

Part: SLIDE — LOW PRESSURE (L-3 DOOR)

INSPECTION FOUND THE L-3 DOOR EMERGENCY SLIDE PACK PRESSURE LOW. THE L-3 DOOR EMERGENCY SLIDE WAS REMOVED AND REPLACED.

Part: SLIDE — LOW PRESSURE (L-1 DOOR)

INSPECTION FOUND THE L-1 DOOR EMERGENCY SLIDE PACK PRESSURE LOW. THE L-1 DOOR EMERGENCY SLIDE WAS REMOVED AND REPLACED.

Part: FIREWALL — CRACKED (NR 3 PYLON)

INSPECTION FOUND A 7 CRACK IN NR 3 PYLON UPPER SURFACE SKIN FIREWALL AT STA YN222. THE AREA WAS REPAIRED IAW SRM 51-31-01 AND 54-20-00, FIGURE 5.

Part: O-RING — LEAKING (NR 3 HYD SYSTEM)

AIRCRAFT DIVERTED TO LONDON DUE TO LOSS OF HYDRAULIC QUANTITY. FOUND NUMBER THREE PRESSURE TRANSMITTER LEAKING AT O-RING. REPLACED O-RING.

Part: CHANNEL — CORRODED (BS 1910-2007)

INSPECTION FOUND CORROSION ON CHANNEL AT STA 1910 TO 2007, LBL 22 AND AT STA 1910 TO 1920, RBL 22. NEW PARTS WERE FABRICATED AND INSTALLED USING FASTENERS IAW SRM 51-31-01.

Part: SUPPORT — CORRODED (BS 1887)

INSPECTION FOUND CORROSION ON FLOOR SUPPORTS AT STA 1887, LBL 30 TO LBL 50 AND RBL 33 TO RBL 53. NEW SUPPORTS WERE FABRICATED AND INSTALLED USING FASTENERS IAW SRM 51-31-01.

Part: CHANNEL — CORRODED (BS 1887-1942)

INSPECTION FOUND CORROSION ON CHANNEL AT STA 1887 TO 1942, RBL 25. A NEW PART WAS FABRICATED AND INSTALLED USING FASTENERS IAW SRM 51-31-01.

Part: CHANNEL — CORRODED (BS 1887-2007)

INSPECTION FOUND CORROSION ON CHANNEL AT STA 1887 TO 2007, LBL 25 AND LBL 60. NEW PARTS WERE FABRICATED AND INSTALLED USING FASTENERS IAW SRM 51-31-01.

Part: CHANNEL — CORRODED (BS 1871-1887)

INSPECTION FOUND CORROSION ON CHANNEL AT STA 1871 TO 1887, RBL 33 TO LBL 35. A NEW PARTS WERE FABRICATED AND INSTALLED USING FASTENERS IAW SRM 51-31-01.

Part: CHANNEL — CORRODED (BS 1820-1887)

INSPECTION FOUND CORROSION ON CHANNEL AT STA 1820 TO 1887, LBL 30. A NEW PART WAS FABRICATED AND INSTALLED USING FASTENERS IAW SRM 51-31-01.

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND EMERGENCY EXIT LIGHTS AT L-1, L-2, AND L-4 DOORS INOPERATIVE. THE BATTERY PACKS WERE REMOVED AND REPLACED AND OPERATION OF THE EMERGENCY EXIT LIGHTS WAS RESTORED.

Part: CHARGER — INOPERATIVE (CABIN)

THE EMERGENCY LIGHT SYSTEM WOULD NOT TEST DURING A PRE-FLIGHT TEST. INSPECTION FOUND FORWARD, MID, AND AFT BATTERY CHARGERS INOPERATIVE. THE BATTERY CHARGERS WERE REMOVED AND REPLACED. THE EMERGENCY LIGHT SYSTEM TESTED GOOD.

Part: CONTROL CABLE — BROKEN (RT TE FLAP)

CREW HAD A FLAP ASYMMETRY FLAG AFTER TAKEOFF. TAPES SHOWED FLAP TRAVELING SYMMETRICALLY, RIGHT FLAP WAS LEADING LEFT APPROXIMATELY 5 DEGREES. THE FLIGHT CONTINUED TO EWR WHERE IT LANDED WITH FLAPS OPERATING NORMALLY. MAINTENANCE CYCLED FLAPS SEVERAL TIMES AND VERIFIED RT INBOARD FLAP LOCKED IN UP POSITION. THE FLAP FOLLOW-UP CABLE ON RT INBOARD FLAP WAS FOUND BROKEN. THE CABLE WAS REPLACED AND ADJUSTED IAW MM 27-50-00, PAGE 503, ITEM 3, OPERATION CHECKED GOOD. IN ADDITION, THE RT I/B FLAP INBOARD ACTUATOR WAS REPLACED DUE TO BINDING.

Part: Y-DUCT — RUPTURED (NR 3 ENGINE)

THE NR 3 ENGINE FIRE WARNING ACTIVATED MOMENTARILY WHILE EN ROUTE. THE FIRE WARNING SYSTEM OF ALL ENGINES WAS TESTED AND ALL SYSTEMS CHECKED GOOD. THE FLIGHT WAS CONTINUED TO LGW WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 3 ENGINE 8TH STAGE BLEED Y-DUCT FAILED WITH RESULTANT DAMAGE TO THE 10TH STAGE BLEED AND B-A VENT COOLING DUCTS. THE DUCTS WERE REPLACED AND LEAK CHECKS DURING ENGINE RUN WERE GOOD.

Part: SUPPORT BEAM — CORRODED (UNDER LAV 'B')

KUL - INSPECTION FOUND CABIN FLOOR BOARD SUPPORT BEAM CORRODED UNDER LAV 'B'. THE SUPPORT BEAM WAS REPLACED IAW SRM 53-22. (M)

Part: SUPPORT BEAM — CORRODED (UNDER GALLEY NR2)

KUL - INSPECTION FOUND CABIN FLOOR BOARD SUPPORT BEAM CORRODED UNDER GALLEY NR 2. A REPAIR WAS PERFORMED IAW SRM 53-22. (M)

Part: OVEN — DIRTY (GALLEY)

FLT NR 0050 - FRA - THE FORWARD GALLEY OVEN NEXT TO LEFT AISLE BEGAN PRODUCING SMOKE IN FLIGHT. THE SMOKE CEASED SHORTLY AFTER OVEN POWER WAS REMOVED. THE FLIGHT WAS CONTINUED WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND FOOD CONTAMINATING THE HEATING ELEMENT OF THE FORWARD GALLEY OVEN AT POSITION 308. THE OVEN WAS PLACARDED INOPERATIVE. (M)

Part: UNLOCK CYLINDER — JAMMED (NLG)

FRA - FLT 0059 - THE NLG WOULD NOT RETRACT AFTER TAKEOFF FROM FRA. FUEL WAS DUMPED AND THE AIRCRAFT WAS RETURNED TO FRA WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND A .1875 INCH DIAMETER BOLT JAMMED IN THE UNLOCK CYLINDER AT THE PIVOT POINT. THE BOLT WAS REMOVED. AN INSPECTION FOUND NO EVIDENCE OF DAMAGE OR MISSING BOLTS. (X)