N715AA

Part: WARNING HORN — FALSE ACTIVATION · airframe 65,612 hrs · 35,116 cycles

DURING TAKEOFF ROLL AT APPROX 60 KNOTS THE TAKEOFF WARNING HORN SOUNDED. THE TAKEOFF WAS ABORTED AND THE ACFT RETURNED TO THE BLOCKS WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED AND OPS CHECK OF THE TAKEOFF WARNING SYS WAS CONDUCTED NOTING NO DEFECTS. THE ACFT WAS RETURNED TO SERVICE.

Part: ACTUATOR — STICKING (NR 8 SLAT) · airframe 65,484 hrs · 35,030 cycles

AFTER TAKEOFF AND DURING CLIMB, THE NR 8 L/E SLAT IN TRANSIT LIGHT STAYED ON DURING FLAP RETRACTION AND ACFT ROLLED TO THE LT. THE ACFT RETURNED TO DEPARTURE, LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED, R & R THE NR 8 L/E ACTUATOR AND PERFORMED OPS CHECKS WITH NO DEFECTS. ACFT WAS RETURNED TO SERVICE.

Part: RELIEF VALVE — LEAKING (RUDDER LOAD) · airframe 65,403 hrs · 34,980 cycles

WHILE EN-ROUTE, THE CREW NOTED THAT THE B-SYSTEM HYD QUANTITY WAS DECREASING AND THE LOW LIGHT ILLUMINATED. ACFT DECLARED AN EMERGENCY AND LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED, NOTING THAT THE UPPER RUDDER LOAD LIMIT RELIEF VALUE WAS LEAKING. R & R RUDDER LOAD LIMITING VALUE AND PERFORMED OPS CHECKS WITH NO DEFECTS. ACFT WAS RETURNED TO SERVICE.

Part: CARRIAGE — BROKEN (TE FLAP) · airframe 65,307 hrs · 34,924 cycles

DURING CLIMB OPERATION, THE OTBD FLAPS FROZE AT 3 DEGREES ON CLIMBOUT, 9 UNITS OF AILERON TRIM WAS REQUIRED FOR LEVEL FLIGHT. THE ACFT RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED NOTING THAT BOTH RT OTBD FORE FLAP SEQUENCING HAVE NUMEROUS BROKEN BOLTS. R & R BOTH SEQUENCING CARRIAGES AND PERFORMED OPS CHECK. NO DEFECTS WERE NOTED AND THE ACFT WAS RETURNED TO SERVICE.

Part: FLAP SYSTEM — LACK OF LUBE (TE FLAPS) · airframe 65,235 hrs · 34,883 cycles

DURING DEPARTURE, ON FLAP RETRACTION THE OTBD FLAPS WOULD NOT RETRACT ABOVE 4 DEGREES. ACFT RETURNED TO DEPARTURE AND LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED, FLAP SYS WAS LUBRICATED AND OPS CHECK PERFORMED WITH NO DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: POWER SUPPLY — INOPERATIVE (FUEL FLOW) · airframe 65,216 hrs · 34,865 cycles

DURING TAKEOFF ROLL OUT, ALL 3 ENGINE FUEL FLOW INDICATIONS FLUXUATED BY + / - 5000 LBS. THE TAKEOFF WAS ABORTED AND THE ACFT RETURNED TO BLOCKS WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED NOTING FUEL FLOW POWER SUPPLY AT FAULT. R & R THE FUEL FLOW POWER SUPPLY PERFORMED OPS CHECKS, NO OTHER DEFECTS WERE IDENTIFIED. ACFT WAS RETURNED TO SERVICE.

Part: ENGINE — DAMAGED (ZONE 400) · airframe 65,209 hrs · 34,858 cycles

ON TAKEOFF DEPARTING, WHILE CLIMBING THROUGH 1000' A LOUD BANG EMERGED FROM THE NR1 ENGINE. AN EMERGENCY WAS DECLARED AND THE ACFT RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED NOTING THAT NR 1 ENGINE REQUIRES REPLACEMENT. ENGINE WAS R & R, OPS CHECKS GOOD. NO OTHER DEFECTS NOTED ACFT WAS RETURNED TO SERVICE.

Part: WEB — DENTED (ZONE 100) · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX PERFORMING INSPECTIONS IT WAS NOTED THAT THE FWD CARGO COMPARTMENT RT SIDE OF CARGO DOOR FRAME CUT-OUT AT BS 560 BETWEEN STR 23R & 25R. REMOVED DAMAGE AND FABRICATED WEB REPAIR FROM 7075 T6 .050 DIM. 15.5" X 5". INSTALLED REPAIR, NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FLOORBEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX INSP, IT WAS NOTED THAT THE FLOORBEAM FLANGE AT STA 1110 LBL 64. REMOVED CORROSION AND FABRICATED REPAIR ANGLES FROM 7075 T6, .090" DIM 13.5" X 4", 10.5" X 4" AND 4" X 1" FILLER INSTALLED REPAIR, NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FLOORBEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX IT WAS NOTED THAT THE MAIN CARGO FLOORBEAM IS CORRODED AT STA 1110 LBL 35. CORROSION WAS REMOVED, FABRICATED DOUBLER FROM 7075 T6 .090", FILLER FROM 7075 T6 .125. INSTALLED REPAIR, NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FITTING — CORRODED (ZONE 700) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX INSP IT WAS NOTED THAT THE RT MLG FWD TRUNION FITTING HAS CORROSION. REMOVED CORROSION AND REWORKED AREA AND INSTALLED 2 EA LOWER BUSHINGS. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: SHEAR TIE — CORRODED (ZONE 200) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX INSP IT WAS NOTED THAT THE AFT CARGO STA 1148, BL 0 SHEAR-TIE IS CORRODED. REMOVED SHEAR-TIE AND FABRICATED NEW FROM 2024 T3 .050". INSTALLED REPAIR, NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FLOORBEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX INSP IT WAS NOTED THAT THE AFT CARGO FLOORBEAM STAT 1010, LBL 10 IS CORRODED. CUT OUT DAMAGE, FABRICATED REPAIR PARTS FROM 7075 T6 .063" DIM 18" X 3", STRAP FROM 7075 T6 .100" DIM. 18" X 2" FILLER FROM BAC1505-100797 DIM. 7.25" X 2.25" AND INSTALLED REPAIR. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: BULKHEAD — CRACKED (RMLG WW) · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX, WHILE PERFORMING INSPECTIONS, IT WAS NOTED THAT THE RT INBD WHEEL WELL FWD BULKHEAD SKIN IS CRACKED AT APU OUTLET DUCT CUT-OUT LOWER. FABRICATED DOUBLER'S FROM 15-5PH .050". INSTALLED REPAIR, NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: WEB — DENTED (ZONE 100) · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX WHILE PERFORMING INSPECTIONS IT WAS NOTED THAT THE FWD CARGO DOOR FRAME AFT SIDE OF CUT-OUT AT BS 620 BETWEEN RBL 25-30 STRINGER 25R. REMOVED DAMAGE AND FABRICATED WEB REPAIR FROM 2024 T3 .040 DIM. 16.5" X 5". INSTALLED REPAIR, NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FITTING — CORRODED (ZONE 700) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX INSP, IT WAS NOTED THAT THE NLG RT TRUNNION FITTING HAVE CORROSION. REMOVED CORROSION AND REWORKED AREA. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX, WHILE PERFORMING INSPECTIONS, IT WAS NOTED THAT THE LT MLG WW INBD CTR CEILING AREA BL 0, STA 930 ABOVE APU SCREEN HAS CORROSION. REMOVED CORROSION AND FABRICATED DOUBLER FROM 2024 T3 .080" DIM 22" X 13". INSTALLED REPAIR, NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FLOORBEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX INSP IT WAS NOTED THAT THE AFT CARGO FLOORBEAM STA 1030, RBL 20 IS CORRODED. CUT OUT DAMAGE, FABRICATED AND INSTALLED REPAIR. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: DUCT — CORRODED (ZONE 200) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX, WHILE PERFORMING INSP, IT WAS NOTED THAT THE NR2 ENGINE "S" DUCT AT STATION 1203 6 O'CLOCK POSITION HAS CORROSION. REMOVED CORROSION AND FABRICATED REPAIR PARTS SPLICE STRAP FROM 301 1/2 HD , FABRICATED REPAIR DOUBLER FROM 7075 T6 .080". INSTALLED REPAIR, NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FITTING — CORRODED (ZONE 700) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX INSP IT WAS NOTED THAT THE NOSE LANDING GEAR LT TRUNNION FITTINGS HAVE CORROSION. REMOVED CORROSION AND REWORKED AREA. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FITTING — CORRODED (ZONE 700) · corrosion level 2 · airframe 64,623 hrs · 34,453 cycles

DURING HEAVY MX INSP IT WAS NOTED THAT THE LT MLG FWD TRUNNION FITTING HAS CORROSION. REMOVED CORROSION AND REWORKED AREA AND INSTALLED 2EA LOWER BUSHINGS AND 2EA UPPER BUSHINGS. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRAP — CRACKED (BS 930) · airframe 64,116 hrs · 34,127 cycles

DURING A HEAVY MX EVENT THE LT WHEEL WELL STA 930 DECK STRAP WAS DISCOVERED CRACKED AND CORRODED JUST ABOVE THE HYD LINK CLUSTER. FABRICATED PRESSURE DECK STRAP FROM 2024-T3 .090 PO404503638 IAW SRM 53-1-02, FIG 5, SHEET 14, ITEM 164. ITEM WAS RETURNED TO SERVICE.

Part: ACTUATOR — MALFUNCTIONED (NR 7 SLAT) · airframe 63,663 hrs · 33,796 cycles

DURING CLIMB OPERATION THE NR 7 L/E SLAT FAILED TO RETRACT. CREW PERFORMED REQUIRED CHECKLISTS AND RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED, THE NR 7 SLAT ACTUATOR WAS DETERMINED TO BE AT FAULT. REMOVED AND REPLACED THE NR 7 SLAT ACTUATOR AND PERFORMED OPS AND LEAK CHECKS WITH NO DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: BEAM — CORRODED (HORIZONTAL STAB) · corrosion level 2 · airframe 63,555 hrs · 33,723 cycles

WHILE PERFORMING AN "A" MX CHECK, CORROSION WAS NOTED ON THE RT HORIZ STAB T/E UPPER BEAM APPROX 24" FROM HORIZ TIP. CORROSION WAS EVALUATED AND REMOVED, INSTALLED PERMANENT REPAIR 2024 T3 .063" DIM 3" X 12". NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: WIRE — CHAFED (NLG) · airframe 62,747 hrs · 33,211 cycles

FLT 715 FROM MEM TO BNA, DURING SHORT APPROACH THE NOSE LANDING GEAR DID NOT INDICATE DOWN AND LOCKED. THE RED LIGHT WAS ILLUMINATED AND THE GREEN LIGHT WAS OUT. THE CREW PERFORMED APPROPRIATE CHECK LIST AND LANDED WITHOUT INCIDENT IN BNA. POST FIGHT INSPECTION WAS PERFORMED, FOUND CHAFED WIRE ON NLG SWITCH. REPAIRED CHAFED WIRE AND PERFORMED OPS CHECK. NO OTHER DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (NLG) · airframe 62,748 hrs · 33,212 cycles

FLT 1740 FROM BNA TO CLT, DURING APPROACH THE NOSE LANDING GEAR FAILED TO INDICATE DOWN AND LOCKED. THE RED LIGHT WAS ILLUMINATED AND THE GREEN LIGHT WAS OUT. THE CREW PERFORMED APPROPRIATE CHECK LIST AND LANDED WITHOUT INCIDENT IN CLT. POST FIGHT INSPECTION WAS PERFORMED, FOUND CHAFED WIRE ON NLG SWITCH. REPAIRED BROKEN WIRE REROUTED AND CLAMPED NOSE GEAR SWITCH WIRE BUNDLE AND PERFORMED OPS CHECK. NO OTHER DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: ACCESSORY UNIT — DEFECTIVE (NLG) · airframe 62,743 hrs · 33,204 cycles

FLT 716 FROM BNA TO MEM, WHILE ON APPROACH INTO MEM THE NOSE GEAR FAILED TO INDICATE DOWN AND LOCKED. THE GREEN NOSE GEAR LIGHT WAS OUT, AND THE RED LIGHT WAS ILLUMINATED. AN ABORTED APPROACH WAS ACCOMPLISHED, CHECKLIST FOLLOWED AND AIRCRAFT LANDED IN MEM WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED. THE MLG ACCESSORY UNIT WAS REMOVED AND REPLACED. OPERATIONAL CHECKS WERE PERFORMED AND NO FURTHER DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SKIN — CORRODED (ZONE 100) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS IT WAS NOTED THAT FUSELAGE SKIN IS CORRODED BELOW STR 28R AT BS 490-510.CORROSION OUT OF LIMITS. CUT OUT DAMAGE, FABRICATED DOUBLER, FABRICATED 2 FILLERS. INSTALLED REPAIR IAW SRM 53-30-3. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: VENT LINE — CHAFED (ZONE 500) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING TANK VENT LINE IS CHAFED AT CLAMP WBL 519. REPAIRED LT WING TANK FUEL VENT LINE AT WBL 519 IAW COTNEY ED NR EDAG52-1. FABRICATED DOUBLER FROM 2024 0.040 INCH DIM 1.625 INCH BY 4.250 INCH. INSTALLED DOUBLER AND PERFORMED LEAK CHECK, GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: STRUCTURE — CRACKED (NR 3 SLAT) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE NR 3 SLAT OTBD STOP CUTOUT CORNER CRACKED. STOP DRILLED CRACK, PERFORMED HFEC WITH NO DEFECTS. FABRICATED DOUBLER FROM 2024 T3 .063 INCH DIM 9 INCH BY 9 INCH. INSTALLED REPAIR IAW SRM 57-30-4. NO OTHER DEFECT NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: FITTING — CORRODED (BS 307) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE AFT I BEAM SUPPORT SHACKLE FITTING HAS EXFOLIATING CORROSION AT BS 307-0. REMOVED FITTINGS AND FABRICATED 2 NEW FITTINGS. INSTALLED NEW FITTINGS IAW DWG NR 69-45947-1-1 AND 51-30-1. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: VENT LINE — CHAFED (ZONE 500) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING TANK VENT LINE IS CHAFED AT CLAMP WBL 601.50. REPAIRED LT WING TANK FUEL VENT LINE AT WBL 601.50 IAW COTNEY ED NR EDAG52-1. FABRICATED DOUBLER FROM 2024 0.040 INCH DIM 1.625 INCH BY 4.250 INCH. INSTALLED DOUBLER AND PERFORMED LEAK CHECK, GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: STIFFENER — CORRODED (WING BOX) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE WING CENTER SECTION LOWER FORWARD STIFFENER ON FORWARD CHORD AT BS 740 LBL-45 CORRODED. CORROSION TO BE OUT OF LIMITS, REMOVED STIFFENER, FABRICATED NEW FROM 7075 T6 DIM 15 INCH AND INSTALLED STIFFENER. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: VENT LINE — CHAFED (ZONE 500) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING TANK VENT LINE IS CHAFED AT CLAMP WBL 686.50. REPAIRED LT WING TANK FUEL VENT LINE AT WBL 686.50 IAW COTNEY ED NR EDAG52-1. FABRICATED DOUBLER FROM 2024 0.040 INCH DIM 1.625 INCH BY 4.250 INCH. INSTALLED DOUBLER AND PERFORMED LEAK CHECK, GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: INTERCOSTAL — BROKEN (ZONE 100) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS IT WAS NOTED THAT THE INTERCOSTAL SKIN ATTACH FLANGE WAS BROKEN AT BS 950A - 950B STR 28L. REMOVED BROKEN INTERCOSTAL AND FABRICATED NEW. INSTALLED FABRICATED INTERCOSTAL IAW SRM 53-10-2 AND 51-20-1. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: VENT LINE — CHAFED (ZONE 500) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING TANK VENT LINE IS CHAFED AT TOP OF CLAMP WBL 348.00. REPAIRED LT WING TANK FUEL VENT LINE AT WBL 348 IAW ED NR EDAG52-1. LEAK CHECK GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SKIN — DENTED (ZONE 100) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS 2 EA DENTS WERE NOTED AT BS 575-583 BETWEEN STR. 26R-27R. CUT OUT 2 EA DAMAGED AREAS, FABRICATED DOUBLER, AND SHIMS. PERFORMED HFEC INSPECTION NO DEFECTS NOTED. INSTALLED REPAIR IAW DWG AG52-53-101. NO OTHER DEFECTS NOTED. ACFT RETURNED TO SERVICE.

Part: INTERCOSTAL — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE INTERCOSTAL WEB AT BS 490-510 STR 28R HAS CORROSION. REMOVED INTERCOSTAL AND FABRICATED ANGLE FROM 7075 T6 DIM 18.5". INSTALLED INTERCOSTAL AND FABRICATED ANGLE IAW B727 SRM 53-10-2, 51-30-5. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SKIN — CRACKED (LT WING) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING L/E WS 530 AT HOOK CUTOUT AFT REPAIR HAS CRACK. REMOVED PREVIOUS REPAIR, FABRICATED NEW PLATE FROM AISI 301 1/2 HARD .020 INCH DIM 8 INCH BY 6 INCH. INSTALLED REPAIR IAW SRM 57-30-4. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: VENT LINE — CHAFED (ZONE 500) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING TANK VENT LINE IS CHAFED AT CLAMP WBL 383.50. REPAIRED LT TANK FUEL VENT LINE AT WBL 383.50 IAW COTNEY ED NR EDAG52-1. FABRICATED DOUBLER FROM 2024 0.040 INCH DIM 1.625 INCH BY 4.250 INCH. INSTALLED DOUBLER AND PERFORMED LEAK CHECK, GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: VENT LINE — CHAFED (ZONE 500) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING TANK VENT LINE IS CHAFED AT TOP CLAMP WBL 442. REPAIRED LT WING TANK FUEL VENT LINE AT WBL 442 IAW COTNEY ED NR EDAG52-1. FABRICATED DOUBLER FROM 2024 0.040 INCH DIM 1.625 INCH BY 4.250 INCH. INSTALLED DOUBLER AND PERFORMED LEAK CHECK, GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: VENT LINE — CHAFED (ZONE 500)

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING TANK VENT LINE IS CHAFED AT CLAMP WBL 656.50. REPAIRED L/WING TANK FUEL VENT LINE AT WBL 656.50 IAW COTNEY ED NR EDAG52-1. FABRICATED DOUBLER FROM 2024 0.040 INCH DIM 1.625 INCH BY 4.250 INCH. INSTALLED DOUBLER AND PERFORMED LEAK CHECK, GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: VENT LINE — CHAFED (ZONE 500) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT THE LT WING TANK VENT LINE IS CHAFED AT CLAMP WBL 601.50. REPAIRED LT WING TANK FUEL VENT LINE AT WBL 601.50 IAW COTNEY ED NR EDAG52-1. FABRICATED DOUBLER FROM 2024 0.040 INCH DIM 1.625 INCH BY 4.250 INCH. INSTALLED DOUBLER AND PERFORMED LEAK CHECK, GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP, IT WAS NOTED THAT STRINGER 29L STA 950C - 1000 IS CORRODED. REMOVED AND REPLACED STRINGER 29L P/N 65-56441-7. INSTALLED STRINGER IAW SB 727-53-0179. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT STR. 27R LOCATED AT BS. 1010-1030 HAD EXFOLIATED CORROSION. REMOVED CORROSION, CORROSION AFTER CLEAN UP FOUND TO BE BEYOND LIMITS. FABRICATED DOUBLER. INSTALLED REPAIR AT BS 950E-1010 PER EA EAAG52-2. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT STRINGER 29R WAS CORRODED UNDER BS 950E FRAME EXTENDING TO BS 1000. CORROSION AT STR. 29R WAS OUT OF LIMITS. CUT OUT DAMAGED STR 29R AT BS 950 TO 1006. INSTALLED NEW STRINGER P/N 65-56441-8. WORK PERFORMED IAW SB 727-53-0179. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRUCTURE — CRACKED (ZONE 200) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS IT WAS NOTED THAT THE LOWER CHORD RUNNING ALONG STR 27R BY THE C2 DOOR IS CORRODED AND CRACKED AT BOTH ENDS, STA 950E-1010. CUT OUT DAMAGED AREA, PERFORMED HFEC INSPECTION AND FABRICATED REPAIR ANGLE FROM 7075-T6 .080 INCH 14 INCH BY3 3/8 INCH, 7075-T6 .063 INCH 10 INCH BY 3 INCH. INSTALLED REPAIR IAW DWG AG52-53-100. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: INTERCOSTAL — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS SURFACE CORROSION WAS NOTED ON INTERCOSTAL BS 695 STR 27R. DAMAGED INTERCOSTAL WAS REMOVED, A NEW INTERCOSTAL WAS FABRICATED. INSTALLED REPAIR IAW SRM 53-10-2 AND 51-10-3. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: FRAME — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY PERFORMING INSPECTIONS IT WAS NOTED THAT THE FRAME WAS DENTED AT BS 1110 JUST ABOVE STR 26R CUT OUT DAMAGED FRAME AND FABRICATED NEW FRAME FROM 7075-O .063 INCH 23 INCH BY 4.5 INCH. HEAT TREATED FRAME TO T6. INSTALLED REPAIR IAW SRM 53-10-2 AND 51-40-3. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SUPPORT ANGLE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT THE SUPPORT ANGLE LOCATED ABOVE STRINGER 26R AT BS 558 HAS SURFACE CORROSION. REMOVED CORRODED SUPPORT ANGLE AND FABRICATED SUPPORT ANGLE FROM 7075 O -.040 INCH (9 INCHES X 4.5 INCHES) HEAT TREATED TO T6. INSTALLED SUPPORT ANGLE. IAW SRM 53-10-2, 51-30-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: SHEAR TIE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS IT WAS NOTED THAT SHEAR TIE LOCATED AT STATION 580 STRINGER 26R-27R WAS CORRODED. REMOVED DAMAGED SHEAR TIE. FABRICATED NEW SHEAR TIE FROM 7075-O .071 INCH (8 INCHES X 2 INCHES) HEAT TREATED TO T6. INSTALLED NEW SHEAR TIE IAW 51-40-2, 53-10-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT STRINGER 22L STA, 1183 ATTACH FITTING HAS EXFOLIATION CORROSION. REMOVED AND REPLACED ATTACH FITTING. PN 65-24276-29 IAW SRM 51-30-2. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTION IT WAS NOTED THAT STRINGER 22L WAS CORRODED AT B.S. 1177. DAMAGE WAS OUT OF LIMITS. CUT OUT DAMAGED AREA AT STR. 22L AT B.S 1177, FABRICATED 2 EA STR. REPAIR MATERIALS FROM BAC 1498-143 7075T6 (14 3/8" & 9 1/4"). FABRICATED 2 EA SPLICES FROM BAC 1498-132. INSTALLED REPAIR IAW SRM 53-10-2, 53-10-3 AT STR. 22L STATION 1165-1189. NO OTHER DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: ANGLE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT THE L-ANGLE LOCATED BETWEEN STRINGER 27L - 28L IS CORRODED AT STA 740. REMOVED CORRODED L-ANGLE AND FABRICATED NEW FROM 7075 O -.090" (10.6250 INCH X 7.6258 INCH)HEAT TREATED TO T6. INSTALLED (L) ANGLE. IAW DRAWING NR 65-15940 AND SRM 51-30-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: ANGLE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX, PERFORMING INSP IT WAS NOTED THAT AN L-ANGLE LOCATED AT STA 740 STR 27R-28R WAS CORRODED. REMOVED DAMAGED ANGLE AND FABRICATED NEW ANGLE FROM 7075-O .190 INCH (12 INCH X 10.5 INCH) HEAT TREATED TO T6. INSTALLED L-ANGLE IAW 727 DRAWING NR 65-15940 AND 51-30-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT STRINGER 28L STA 492 HAD CORROSION. CUT OUT DAMAGE AT STA 492 FABRICATED NEW ANGLE SUPPORT FROM 7075 T6 18, .5 INCH, FABRICATED STRINGER REPAIR STA. 480 -510 FROM P/N BAC 1498-141 7075 T6, FABRICATED 2EA SPLICES FROM BAC 1498-132 7075 T6. INSTALLED SUPPORT ANGLE AND REPAIR IAW SRM 53-10-2, 53-10-3. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS IT WAS NOTED THAT STR 28R LOCATED AT BS. 490-510 HAD CORROSION. REMOVED DAMAGED SECTION OF STR 28R FROM BS 480-508. FABRICATED NEW STRINGER, FABRICATED 2 EA SPLICES. INSTALLED NEW PARTS IAW SRM 53-10-3, 51-30-5 NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SHEAR TIE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT SHEAR TIE LOCATED AT STA 990 STRINGER 29R WAS CRACKED. REMOVED DAMAGED SHEAR TIE. FABRICATED NEW SHEAR TIE FROM 7075-O .063 INCH (4.380 INCH X 2 INCH) HEAT TREATED TO T6. INSTALLED NEW SHEAR TIE IAW 53-10-4, 51-10-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP, IT WAS NOTED THAT STRINGER 26L STATION 540 - 560 IS CORRODED. CUT OUT DAMAGE AT STA 533-550. FABRICATED STRINGER FROM BAC 1498-143 7075T6, 16 INCH, FABRICATED 2 EA SPLICE PLATES FROM BAC 1498-132 7075 T6, 13 INCHES INSTALLED STRINGER IAW SRM 53-10-2 & 53-10-3. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT RIVETS WERE PULLING THROUGH THE SKIN EXTERIOR AT BS 1010 STR 28R. CORROSION ON STR 28R TO BE OUT OF LIMITS. CUT OUT DAMAGED STR 28R AT B.S 1010 TO + 11.375. FABRICATED NEW STRINGER REPAIR SPLICE FROM BAC 1498-131 7075 T6 (12 INCHES), BAC 1498-147 .090 INCH 7075 T6 (11.375 INCHES). INSTALLED STRINGER REPAIR IAW 53-10-3, 53-10-2 AND 51-10-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS IT WAS NOTED THAT THE MAIN CABIN SEAT TRACK LOCATED AT BS. 760-850, LBL 45.5 HAD CORROSION. REMOVED SEAT TRACK FROM STATION 760-850, FABRICATED NEW SEAT TRACK, INSTALLED NEW SEAT TRACK IAW SRM 53-10-2, 53-10-5 & 51-10-2. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SHEAR TIE — CORRODED (FUSELAGE) · corrosion level 2

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT SHEAR TIE LOCATED AT STA 620 STRINGER 26L-27L WAS CORRODED. REMOVED DAMAGED SHEAR TIE. FABRICATED NEW SHEAR TIE FROM BAC 1506-1630 7075-T6 (6.75 INCHES) INSTALLED SHEAR TIE IAW 51-30-2, 53-10-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: SHEAR TIE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT SHEAR TIE LOCATED AT STA 640 STRINGER 26L-27L WAS CORRODED. REMOVED DAMAGED SHEAR TIE. FABRICATED NEW SHEAR TIE FROM BAC 1506-1630 7075-T6 (6.75 INCH) INSTALLED SHEAR TIE IAW 51-30-2, 53-10-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: SHEAR TIE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MX PERFORMING INSP IT WAS NOTED THAT SHEAR TIE LOCATED AT STA 660 STRINGER 26R-27R WAS CORRODED. REMOVED DAMAGED SHEAR TIE. FABRICATED NEW SHEAR TIE FROM BAC 1506-1630 7075-T6 (6.5 INCH) INSTALLED SHEAR TIE IAW 51-30-2, 51-10-2. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS IT WAS NOTED THAT STR 25R LOCATED AT BS 720E +4 , HAD EXFOLIATED CORROSION. REMOVED DAMAGED SECTION OF STR. FABRICATED NEW STRINGER, FABRICATED SPLICE, INSTALLED NEW PARTS IAW SRM 53-10-3, 53-10-2 NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 62,202 hrs · 32,810 cycles

WHILE IN HEAVY MAINTENANCE PERFORMING INSPECTIONS IT WAS NOTED THAT THE MAIN CABIN SEAT TRACK LOCATED AT BS. 760-850, LBL 45.5 HAD CORROSION. REMOVED SEAT TRACK FROM STATION 760-850, FABRICATED NEW SEAT TRACK, INSTALLED NEW SEAT TRACK IAW SRM 53-10-2, 53-10-5 & 51-10-2. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: ACM — INOPERATIVE (LEFT)

DURING CLIMB OPERATION, THE AC WAS UNABLE TO MAINTAIN CABIN ALTITUDE BELOW 10000 FEET WITH ONE PACK OPERATION. AC RETURNED TO DEPARTURE, WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP REVEALED LT ACM INOPERATIVE. REMOVED AND REPLACED LT ACM AND LT PACK SHUTOFF VALVE, OPS CHECK GOOD. NO OTHER DEFECTS NOTED. AC WAS RETURNED TO SERVICE

Part: ACM — FAILED (LEFT) · airframe 61,797 hrs · 32,555 cycles

FLT 711 FOR DEN TO TOL. DURING CLIMB OPERATION FROM DEN THE AIRCRAFT WAS UNABLE TO MAINTAIN CABIN ALTITUDE BELOW 10000 FEET WITH ONE PACK OPERATION. AIRCRAFT RETURNED TO DEN WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION REVEALED LEFT ACM INOP. REMOVED AND REPLACED LEFT ACM AND LEFT PACK SHUTOFF VALVE, OPS CHECK GOOD. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: LINE — LEAKING (HYD SYSTEM) · airframe 61,033 hrs · 32,116 cycles

FLT 811 FROM SJU TO MCO - DURING CLIMB OPERATION, THE AIRCRAFT EXPERIENCED NR 2 ENGINE "A" SYSTEM HYDRAULIC FAILURE/FLUID LOSS. THE AIRCRAFT RETURNED TO SJU WERE AN EMERGENCY WAS DECLARED. THE AIRCRAFT LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION REVEALED AN ELEVATOR POWER CONTROL UNIT FLEX LINE LEAKING. THE FLEX LINE WAS REMOVED AND REPLACE, HYDRAULIC SYSTEM SERVICED, OPS AND LEAK CHECKED GOOD.

Part: PITOT TUBE — OBSTRUCTED · airframe 59,179 hrs · 31,273 cycles

FLT 719 FROM MCO. TO TOL. DURNING TAKEOFF ROLL FO'S AIRSPEED INDICATION INOP AT 80 KNOTS, NO AIRSPEED INDICATION. CREW ABORTED TAKEOFF AND RETURNED TO THE BLOCK WITHOUT INCIDENT. ON POST FLIGHT INSPECTION FOUND BUG OBSTRUCTING THE FO'S PITOT TUBE. OBSTRUCTION WAS REMOVED FROM THE FO'S PITOT TUBE, OPERATIONAL CHECK PERFORMED. NO DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WARNING LIGHT — FALSE ACTIVATION (SMOKE DETECTOR) · airframe 59,182 hrs · 31,276 cycles

DURING CLIMB AT APPROXIMATELY 1000 AGL THE LOWER AFT CARGO FIRE WARNING LIGHT AND BELL CAME ON. AN EMERGENCY WAS DECLARED AIRCRAFT RETURNED TO AIRPORT AND LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION FOUND LOWER AFT CARGO COMPARTMENT WITH BOXES STACKED TO THE CEILING AND IN VERY CLOSE PROXIMITY OF THE SMOKE DETECTORS. ADJUSTED LOAD, AND PERFORMED SYSTEM CHECK OF FIRE/SMOKE DETECTION SYSTEM NO DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: GENERATOR — MALFUNCTIONED (NR 2) · airframe 59,126 hrs · 31,229 cycles

FLT 717 FROM STL TO TOL. ON TAKEOFF ROLL, NR 2 GENERATOR TRIPPED OFF LINE AND UNDER VOLTAGE LIGHT ILLUMINATED. AIRCRAFT RETURNED TO BLOCKS. PLACED NR 2 GENERATOR/CSD ON MEL 24-1. AIRCRAFT RETURNED TO SERVICE. ON 8/17/06, COULD NOT DUPLICATE DISCREPANCY. INSPECTED WIRING, REPOSITIONED GENERATOR LEADS, SERVICED CSD, AND RAN ENGINES. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: DRAG LINK — DAMAGED (DOOR) · airframe 57,777 hrs · 30,625 cycles

FLT 5201FROM MIA TO CCS. AFTER TAKEOFF, AND UPON GEAR RETRACTION, TAIL SKID LIGHT REMAINED ON. CYCLED GEAR NO AFFECT. CREW DUMPED FUEL, RETURNED TO MIA, AND LANDED WITHOUT INCIDENT. FOUND TAIL SKID HEEL MISSING AND BOLTS SHEARED. REPLACED DRAG LINK DOOR ASSEMBLY AND TAIL SKID ENERGY ABSORBER CARTRIDGE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: OVERHEAT SENSOR — INOPERATIVE (ANTI ICE DUCT) · airframe 56,746 hrs · 30,178 cycles

AFTER TAKEOFF, AT 4500 FT, ANTI-ICE DUCT OVERHEAT LIGHT ILLUM. LOWER CARGO FIRE LIGHT ILLUM WITH FIRE WARNING BELL. MX DISPLAY ANNUNCIATOR READING "AFT CARGO". CREW DECLARED AN EMERGENCY, DUMPED FUEL, & RETURNED TO MOTTO. DURING FUEL DUMP, BOTH WARNING LIGHTS EXTINGUISHED. ON FINAL, BOTH WARNING LIGHTS ILLUMINATED & WARNING BELL SOUNDED. AT 1000 FT GAL, ALL WARNING LIGHTS EXTINGUISHED. CREW COMPLETED EMERGENCY & NORMAL CHECKLISTS & LANDED WITHOUT FURTHER INCIDENT. FOUND THERMAL ANTI-ICE OVERHEAT SENSOR INOP. REPLACED SENSOR. OPS CHK GOOD. PERFORMED INSP OF LOWER CARGO BAY. NO EVIDENCE OF FIRE OR OVERHEAT NOTED. LOWER CARGO FIRE DETECTION SYS OPS CHK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: WIRE — BROKEN (NLG POS SWITCH) · airframe 56,632 hrs · 30,133 cycles

FLT 202 FROM SDQ TO MIA, ON APPROACH TO MIA, WITH GEAR EXTENDED, NOSE GEAR RED WARNING LIGHT ILLUMINATED WITH NO GREEN OR AURAL WARNING. RECYCLED GEAR NO HELP. EXECUTED MISSED APPROACH AND COMPLETED ABNORMAL CHECKLIST. F/E VISUALLY CONFIRMED NOSE GEAR DOWN AND LOCKED WITH CONFIRMATION FROM TOWER THAT ALL GEAR WERE DOWN AND VISIBLE. AIRCRAFT LANDED WITHOUT INCIDENT. FOUND BROKEN WIRE AT NOSE GEAR POSITION SWITCH. REPAIRED WIRE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE

Part: ENGINE — LEAKING (NR 2) · airframe 56,463 hrs · 30,051 cycles

FLT 202 FROM SVMI TO KMIA - ON CLIMB-OUT, NR 2 ENGINE OIL QUANTITY DECREASED. AT 1.8 GALLONS INDICATED, NOTICEABLE DECREASING INDICATION. RETURNED TO SVMI AND LANDED WITHOUT INCIDENT. FERRIED AIRCRAFT TO JAX AND CHANGED NR 2 ENGINE. OPS AND LEAK CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: PROXIMITY SWITCH — FAILED (MLG) · airframe 56,141 hrs · 29,903 cycles

AFTER TAKE-OFF, TAKE-OFF WARNING SOUNDED WHEN FLAPS SELECTED FROM 5 TO 2 DEGREES. HORN SILENCED WHEN CYCLED BACK TO 5 DEGREES. CYCLED GEAR AND GEAR HANDLE STUCK IN DOWN POSITION. AIRCRAFT RETURNED TO AIRPORT. TAKE-OFF HORN SOUNDED AGAIN WHEN FLAPS SELECTED FROM 25 TO 30 DEGREES. AIRCRAFT LANDED WITHOUT INCIDENT. FOUND GEAR AIR SENSE PROXIMITY SWITCH FAILED. REPLACED PROXIMITY SWITCH. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: ENGINE — LEAKING (ZONE 400) · airframe 55,981 hrs · 29,804 cycles

DURING CLIMB, NR 1 ENGINE LOST 1.5 GALLONS OF OIL IN THE FIRST 10 MINUTES. AIRCRAFT RETURNED TO TOL AND LANDED WITHOUT FURTHER INCIDENT. FOUND EXCESSIVE AMOUNT OF OIL LEAKING FROM THE NR 4.5 TO NR 6 BEARING DRAIN. REPLACED THE NR 1 ENGINE. OPS AND LEAK CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: GARLOCK SEAL — LEAKING (NR 1 ENGINE) · airframe 55,974 hrs · 29,801 cycles

DURING CLIMB, AT APPROXIMATELY FL210, NR 1 ENGINE OIL QUANTITY BEGAN DROPPING RAPIDLY FOLLOWED BY OIL PRESSURE DROP AND WARNING LIGHT. PERFORM ENGINE INFLIGHT SHUT DOWN PROCEDURE. AIRCRAFT RETURNED TO TOL AND LANDED WITHOUT INCIDENT. FOUND GARLOCK SEAL LEAKING AT THE ENGINE DRIVEN HYDRAULIC PUMP. REPLACED SEAL. ENGINE RUN AND LEAK CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: SWITCH — DEFECTIVE (NR 1 ENGINE) · airframe 55,844 hrs · 29,725 cycles

DURING TAKEOFF ROLL, THE NR 1 ENGINE LOW OIL PRESSURE LIGHT CAME ON AT 80 KNOTS. ABORTED TAKEOFF AND RETURNED TO RAMP WITH NO FURTHER INCIDENT. DMI THE NR 1 ENGINE LOW OIL PRESSURE LIGHT UNDER MEL 79-4. AIRCRAFT RETURNED TO SERVICE. CLEARED MEL 79-4 ON 7/8/2004 UPON ARRIVING IN KFLL BY REPLACING THE LOW OIL PRESSURE LIGHT SWITCH IAW B727 MM 79-33-0. OPERATIONAL SYSTEM CHECKED GOOD IAW B727 MM 79-32-0 AND THE AIRCRAFT RETURNED TO SERVICE.

Part: LINE — RUPTURED (HYD SYSTEM) · airframe 55,278 hrs · 29,431 cycles

FLT 202 FROM MDSD TO KMIA. ENROUTE TO KMIA OBSERVED A COMPLETE LOSS OF "B" SYSTEM HYDRAULIC FLUID FOLLOWED BY BOTH "B" SYSTEM LOW-PRESSURE LIGHTS ILLUMINATING. BRAKE PRESSURE BEGAN A SLOW DROP TO 1400 POUNDS. A PHONE PATCH WAS MADE TO COMPANY, ADVISED ATC IN MIAMI AND DECLARED AN EMERGENCY. THE AIRCRAFT LANDED AT OUR FINAL DESTINATION IN KMIA WITHOUT INCIDENT. AIRCRAFT WAS INSPECTED AND FOUND A RUPTURE FLEX LINE TO HYD POWER UNIT FOR THE RIGHT HAND ELEVATOR. REPLACED FLEX HOSE ASSEMBLY AT ELEVATOR POWER UNIT, SERVICED “A” AND “B” HYDRAULIC SYSTEMS AND SYSTEM LEAK CHECK GOOD IAW B727 MM 12-12-0, 29-00 AND 27-30-81. AIRCRAFT RETURNED TO SERVICE.

Part: WIRE — BROKEN (OIL TEMP BULB) · airframe 54,532 hrs · 29,104 cycles

FLT 800 FROM KMIA TO MMUN. AFTER TAKE-OFF CLIMBING THROUGH 1,000 FT AGL, THE NR 3 ENGINE OIL TEMPERATURE BEGAN TO FLUCTUATE BETWEEN 100 DEGREES AND OFF SCALE HIGH. AT APPROXIMATELY 15,000 FT, THE NR 3 ENGINE STAYED OFF SCALE HIGH. REFERENCE AOM CHECKLIST FOLLOWED BY NR 3 ENGINE IN-FLIGHT SHUTDOWN AS PRECAUTIONARY, ADVISED ATC AND DECLARED EMERGENCY. AIRCRAFT AIR TURN BACK TO KMIA AND LANDED WITHOUT INCIDENT. AIRCRAFT WAS INSPECTED AND FOUND A BROKEN WIRE/PIN AT THE NR 3 ENGINE OIL TEMP BULB CONNECTOR. REPAIRED AND REPINNED BROKEN WIRE AT CONNECTOR, PERFORMED ENGINE RUN AND SYSTEM CHECK GOOD IAW MM 79-32-0 AND 20-11-1. AIRCRAFT RETURNED TO SERVICE.

Part: ACTUATOR — FAILED (NLG DOOR) · airframe 53,515 hrs · 28,602 cycles

FLIGHT 002 FROM PTO TO MIA. ON APPROACH TO MIA, THE NOSE LANDING GEAR DOORS OPEN AND THE NOSE GEAR FAILED TO LOWER. RECYCLED SYSTEM TWICE BEFORE THE NOSE GEAR CAME DOWN. NO EMERGENCY ACTION WAS TAKEN AND AIRCRAFT LANDED WITHOUT INCIDENT. AIRCRAFT WAS INSPECTED AND THE NOSE GEAR UNLOCK ACTUATOR, TRANSFER CYLINDER AND TWO WAY RESTRICTOR WERE REPLACED. OPERATED THE NOSE LANDING GEAR SYSTEM SEVERAL TIMES AND NO DEFECTS WERE NOTED. ALL WORK DONE IAW MM 32-33-11, 32-33-41, 32-33-0, AND 32-34-0. AIRCRAFT RETURNED TO SERVICE.

Part: TIRE — FAILED (MLG) · airframe 53,479 hrs · 28,580 cycles

FLIGHT 002 FROM MPTO TO MIA. AFTER NORMAL LANDING AND NORMAL TOUCHDOWN, AND WITHOUT APPLICATION OF BRAKES ON TOUCHDOWN THE MAIN TIRES BLEW AND AIRCRAFT CAME TO A COMPLETE STOP. THE MIA TOWER INFORMED US OF FIRE OR SMOKE COMING FROM RIGHT WHEEL WELL AND WE REQUESTED EMERGENCY ASSISTANCE. FIRE DEPARTMENT RESPONDED AND AIRCRAFT WAS SECURE. THE AIRCRAFT WAS INSPECTED AND PREPARED FOR A SPECIAL MAINTENANCE FERRY FLIGHT FROM MIA TO JAX TO BE WORK AT THE FLIGHTSTAR REPAIR FACILITY IN JACKSONVILLE, FLORIDA.

Part: LANDING GEAR — LACK OF LUBE (MAINS) · airframe 53,440 hrs · 28,562 cycles

DURING APPROACH, THE NOSE GEAR DID NOT EXTEND WHEN THE GEAR WAS LOWERED. GEAR WAS RECYCLED AND NOSE GEAR EXTENDED NORMALLY AND AIRCRAFT LANDED WITHOUT INCIDENT. AIRCRAFT WAS INSPECTED, CLEANED AND LUBED NOSE GEAR MOUNTS, LINKS AND ACTUATOR MOUNTS. TROUBLESHOOT BY EXTENDING AND RETRACTING HYDRAULIC COMPONENT SYSTEMS. JACKED AIRCRAFT NOSE FOR GEAR EXTENSION AND RETRACTION TEST. CYCLED GEAR SIX FULL TIMES RETRACT AND EXTEND. OBSERVED NORMAL OPERATIONS FOR ALL TEST AND NO DEFECTS NOTED IAW B727 MM 32-33-0 AND THE AIRCRAFT RETURNED TO SERVICE.

Part: CARRIAGE — DAMAGED (LE FLAP) · airframe 53,018 hrs · 28,348 cycles

FLT 041 FROM MIA TO AUA. AFTER TAKEOFF DURING CLIMB, THE OUTBOARD TRAILING EDGE FLAPS WOULD NOT RETRACT, STUCK BETWEEN TWO AND FIVE DEGREES. AIRCRAFT RETURNED TO MIA AND LANDED WITHOUT INCIDENT. UPON LANDING, DURING INSPECTION FOUND A BROKEN BOLT AND MISSING BEARING ON LEFT FORE FLAP SEQUENCING CARRIAGE. REPLACED BOLT AND BEARING AND CHECKED FLAP RIGGING. ALL FLAPS OPERATIONAL CHECKED GOOD IAW MM 27-50-00 AND AIRCRAFT RETURNED TO SERVICE.

Part: SMOKE DETECTOR — DEFECTIVE (CARGO BAY) · airframe 52,470 hrs · 28,083 cycles

FLT 713 FROM DEN TO TOL. DURING CRUISE LEVEL, THE LOWER AFT CARGO FIRE WARNING LIGHT CAME ON INFLIGHT. APPROPRIATE CHECK LIST WERE ACCOMPLISHED, NOTIFIED ATC, DECLARED EMERGENCY AND AIR TURNBACK TO DEN AND LANDED WITHOUT INCIDENT. UPON LANDING INSPECTED THE LOWER AFT CARGO COMPARTMENT AND FOUND NO INDICATION OF FIRE. MEL THE LOWER AFT CARGO COMPARTMENT AREA DETECTION SYSTEM PER 26-19-1A. AIRCRAFT RETURNED TO SERVICE. MEL 26-19-1 WAS CLEARED UPON ARRIVAL IN TOL 8/29/2002 BY REPLACING A SMOKE DETECTOR AND TWO SMOKE DETECTOR BATTERIES.

Part: SMOKE DETECTOR — DEFECTIVE (CARGO BAY) · airframe 52,405 hrs · 28,043 cycles

FLT 2220 FROM PHX TO TOL. DURING CRUISE LEVEL, THE FORWARD CARGO COMPARTMENT FIRE LIGHT CAME ON. APPROPRIATE CHECK LIST WERE ACCOMPLISHED AND THE LIGHT EXTINGUISHED, THEN THE SMOKE LOWER FORWARD DETECTOR SYSTEM INOPERATIVE MAINTENANCE LIGHT CAME ON. NOTIFIED ATC, DECLARED EMERGENCY AND DIVERTED TO KICT AND LANDED WITHOUT INCIDENT. INSPECTED FORWARD CARGO PIT AND FIRE WARNING SYSTEM AND FOUND TWO SMOKE DETECTORS INOPERATIVE. MEL THE FORWARD LOWER CARGO DETECTION SYSTEM PER 26-19-1. AIRCRAFT RETURNED TO SERVICE. MEL 26-19-1 WAS CLEARED 8/8/2002 BY REPLACING TWO SMOKE CARGO DETECTORS. SYSTEMS OPERATIONAL CHECKED GOOD PER SECURAPLANE ST3000 MANUAL.

Part: LIGHT — INOPERATIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT SIGN ABOVE R1 DOOR INOPERATIVE. REPLACED EMERGENCY EXIT SIGN ABOVE R1 DOOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: SKIN — CORRODED (FUSELAGE)

TUL - FOUND CORROSION ON BELLY SKIN STATION 950F STRINGER 28L. CUT OUT CORRODED SKIN AND FABRICATED DOUBLER, TRIPLER AND FILLERS IAW ESO 11697 DATED 3-21-2000 AND SRM 53-30-3 FIG 3 AND INSTALLED. (M)

Part: FRAME — DAMAGED (FUSELAGE)

TUL - INSTALLED BELL FRAME DOUBLER PER SRM 51-40-3. (M)

Part: STRINGER — CORRODED (FUSELAGE)

TUL - FOUND CORROSION ON STRINGER 30 ADJACENT OT DRAIN MAST STATIN 1154. REMOVED CORRODED SECTION OF STRINGER AND SPLICE AND INSTALLED NEW STRINGER SECTION AND SPLICE AS PER SRM 53-10-3 FIG 1. (M)

Part: FRAME — DENTED (FUSELAGE)

TUL - FOUND BELL FRAME DENTED STATION 990 STRINGER 25L. INSTALLED TYPICAL FORMED SECTION REPAIR DOUBLER PER SRM 51-40-3. (M)

Part: FRAME — CRACKED (FUSELAGE)

TUL - FOUND BELL FRAME CRACKED RIGHT STATION 500 STRINGER 24R. INSTALLED FRAME DOUBLER PER SRM 51-40-3, DOUBLER MATERIAL .063 7075 T-6 FASTENED WITH STANDARD HI-LOKS. (M)

Part: FRAME — DENTED (FUSELAGE)

TUL - FOUND DENT ON FRAME AT STRINGER 25 LEFT, PER SRM 51-40-3 WITH MS20470D RIVETS. (M)

Part: STRUCTURE — CRACKED (FUSELAGE)

TUL - FOUND RBL 8 VERTICAL CRACKED AT LOWER END, PER SB 727-53-0175 REV 3. (M)

Part: SKIN — CORRODED (FUSELAGE)

TUL - FOUND SKIN BULGED AND FASTENER PULLING THROUGH SKIN AT STATION 640 STRINGER 27L. FABRICATED AND INSTALLED SKIN REPAIR IAW SRM 53-30-3 FIG 3 AND STRINGER REPAIR IAW SRM 53-10-3 FIG 1. (M)

Part: FRAME — DENTED (FUSELAGE)

TUL - FOUND DENT IN FRAME AT STRINGER 24R. REPAIRED FRAME WITH MATERIAL 7075-T6 .063, FASTENER, .25 INCH 0 HI-LOCKS 18 EACH, 22 EACH .1875 INCH 0 HI-LOCKS, AND 16 EACH .1875 0 NAS8603 SCREWS WITH APPROPRIATE COLLARS AND NUTS/WASHERS, 5 FASTENERS REQ''D BOTH SIDES OF DAMAGE PER SRM 51-40-3 FIG 1 SHEET 3. (M)

Part: FRAME — GOUGED (FUSELAGE)

TUL - FOUND GOUGE IN BELT FRAME DOUBLER. REMOVED AND REPLACED BELT FRAME SPLICE DOUBLER AT STATION 580 STRINGER 25L PER SRM 51-10-1. (M)

Part: CONNECTOR — DEFECTIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT FLOOR PATH LIGHTS INOPERATIVE FROM AFT OF FIRST CLASS CABIN TO FORWARD OVERWING EXIT DOOR. REPLACED CONNECTOR TO EMERGENCY EXIT FLOOR PATH LIGHTING BETWEEN FIRST CLASS CABIN AND FORWARD OVERWING EXIT DOOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: FRAME — CRACKED (BS 312)

TUL - FOUND OUTBOARD FLANGE CRACKED OF BELLFRAME STATION 312 AND STRINGER 13. INSTALLED DOUBLER PER SRM 51-40-3 USING .071 MATERIAL AND .875 HI-LOCKS 3 ON TOP FLANGE AND 4 ON BOTTOM FLANGE AND 2 ROWS ON WEB TOTAL 26 FASTENERS. (M)

Part: STRINGER — CORRODED (BS 585-592)

TUL - STRINGER CORRODED AT 28L, STATION 585-592. FABRICATED/INSTALLED STRINGER REPAIR FILLER AND 2 SPLICES AT STATION 570-592 SRM 53-10-3 FIG 1. (M)

Part: SKIN — CORRODED (BS 585-592)

TUL - FUSE SKIN HAS CORROSION BELOW STRINGER 28L AT STATION 585 - STATION 592. FABRICATED AND INSTALLED REPAIR DOUBLER AND FILLER PER SRM 53-30-3. (M)

Part: SKIN — CORRODED (BS 1070-1090)

TUL - FOUND CORROSION BELOW STRINGER 29L BETWEEN STATION 1070 TO STATION 1090. INSTALLED SKIN DOUBLER AT STATION 1077 TO STATION 1087 AS PER SRM 53-30-3 FIG 3 AND INSTALLED STRINGER REPAIR DOUBLER STATION 1070 TO STATION 1090 AS PER SRM 53-10-3 FIG 1. (M)

Part: CONNECTOR — LOOSE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT FLOOR PATH LIGHTING IN FRONT HALF OF COACH CABIN INOPERATIVE. REPAIRED LOOSE CONNECTORS AT ROWS 7 AND 18. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: ANGLE — CRACKED (WS 275)

TUL - FALSE SPAR LOWER CHORD ANGLE IS CRACKED APPROXIMATELY 8 INCHES LONG UNDER NR 7 SPOILER SUPPORT CASTING. REPAIRED LOWER CHORD ANGLE ON FALSE SPAR UNDER NR 7 SPOILER PER ESO 11697 DATED 5-17-97 FOR A/C 715. TAT: 42,252 HOURS. CYCLES: 22,908. (X)

Part: TRACK DOOR — CORRODED (NR 4 LE SLAT)

TUL - NR 3 L/E SLAT OUTBOARD TRACK DOOR HAS CORROSION. REMOVED CORROSION AND INSTALLED DOUBLER (PER 57-50-1 SRM). TST: 42,252. CYCLES: 22,908. (X)

Part: TRACK DOOR — CORRODED (NR 2 LE SLAT)

TUL - NR 3 LEADING EDGE SLAT INBOARD TRACK DOOR IS CRACKED. STOP DRILLED CRACK AND INSTALLED DOUBLER PER SRM 57-50-1. TST: 42,252. CYCLES: 22,908. (X)

Part: LIGHT — DEFECTIVE (CABIN)

DFW - DURING OVERNIGHT CHECK, EMERGENCY FLOOR LIGHTS AT FORWARD PART OF FIRST CLASS CABIN INOPERATIVE. REPLACED EMERGENCY FLOOR LIGHT STRIP AT FORWARD PART OF FIRST CLASS CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONNECTOR — LOOSE (CABIN)

MIA - DURING OVERNIGHT CHECK, EMERGENCY FLOOR LIGHTS IN AFT SECTION OF MAIN CABIN INOPERATIVE. RESECURED LOOSE CANNON PLUG AT AFT CABIN BATTERY PACK. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CARRIAGE JOURNAL — CORRODED (LT WING)

ATL - DURING CONTRACT MAINTENANCE AT DALA FOR HEAVY C-CHECK, THE OUTBOARD CARRIAGE LARGE JOURNAL OF THE LT INBOARD FLAP WAS FOUND CORRODED. MAINTENANCE MACHINED THE OUTER DIAMETER DOWN TO 2.957 INCH AND THE INNER DIAMETER OUT TO 2.010 INCH ON THE TAPERED SECTION. THE DAMAGE DOES NOT EXTEND INTO THE TAPERED SECTION OF THE CARRIAGE JOURNAL. REPAIR APPROVAL PER DL ERA 357260-14. ACFT TT: 39,457 HRS. ACFT TOTAL CYCLES: 21,587. (X)

Part: SKIN — DAMAGED (FUSELAGE)

ATL - DURING CONTRACT MAINTENANCE AT DALA, THE UPPER FORWARD CORNER OF THE C-2 DOOR OPENING HAS HAD DAMAGE REMOVED FROM THE OUTER LAYER OF SKIN. THE RESULTING CUT-OUT IS 1.5 INCHES BY .75 INCH IN THE OUTER LAYER OF SKIN. ACCOMPLISHED REPAIRS PER DL ERA 303435-14. ACFT TT: 39,457 HRS. ACFT TOTAL CYCLES, 21,587. (X)

Part: WING CHORD — CRACKED (BS 760)

ATL - DURING CONTRACT MAINTENANCE AT DALA FOR HEAVY C-CHECK, CRACKS WERE DISCOVERED IN THE VERTICAL FLANGE OF THE LBL AND RBL 70.5 WING CHORD AT FS 760.95. REPAIRS WERE ACCOMPLISHED PER SB 727-57-0112, REV B. ACFT TT: 39,457 HRS. ACFT TOTAL CYCLES: 21,587. (X)

Part: STRINGER — CORRODED (FS 1000)

ATL - DURING CONTRACT MAINTENANCE AT DALA, FOUND STR 29L WITH SEVERAL AREAS OF CORROSION ON THE OUTBOARD SKIN ATTACH FLANGE. THE DAMAGE WAS LOCATED AT FS 950C TO FS 1000. ACCOMPLISHED REPAIRS PER DL ERA 303390. ACFT TT: 39,457 HRS. ACFT TOTAL CYCLES: 21,587. (X)

Part: LIGHT — DEFECTIVE (AFT AIRSTAIR EEL)

MIA - DURING OVERNIGHT CHECK, AFT AIRSTAIRS EMERGENCY OVERHEAD LIGHT INOPERATIVE. REPLACED AFT AIRSTAIRS EMERGENCY LIGHT ASSEMBLY. SYSTEM GROUND CHECKED NORMAL OPERATION. (Z)