N717AE

Part: FCU — INOPERATIVE (FUEL SYSTEM) · airframe 27,812 hrs · 24,854 cycles

ON FLIGHT 3291 THE CREW REPORTED THAT THEY DEPARTED TYR AND WERE HELD DOWN LOW AND VECTORED AWAY FROM DFW. THEY ADVISED ATC THEY WERE GETTING LOW ON FUEL AND DECLARED MINIMUM FUEL. FMS WAS PREDICTING 12 MINUTES OF FUEL REMAINING UPON LANDING AND BY THEIR CALCULATIONS USING THE LONG RANGE FUEL CHART 20 MINUTES WERE REMAINING. THE CREW DECLARED AN EMERGENCY AND WERE FINALLY CLEARED UP TO 12,000 FEET AND DIRECT TO DFW. THE AIRCRAFT LANDED WITHOUT INCIDENT. VERIFIED FCU CH 1 INOP, REMOVED AND REPLACED FCU IAW AMM II CH 28-41-01, OPS CHECK OK IAW AMM II CH 28-41-00. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FLASHLIGHT — BROKEN (COCKPIT) · airframe 27,647 hrs · 24,673 cycles

ON FLIGHT 3209 THE CREW REPORTED A LOUD "CLUNK" FROM UNDER FIRST OFFICER FLIGHT COLUMN FLOORBOARD AREA. NOISE OCCURED WHILE CONFIGURED FOR LANDING. NO OTHER DISCREPANCIES NOTED. THE AIRCRAFT WAS REMOVED FROM SERVICE. PERFORMED INSPECTION IN NOSE WHEEL COMPARTMENT, NOSE GEAR AND DOORS AND FORWARD AVIONICS COMPARTMENT. NO SIGNS OF DAMAGE NOTED, FOUND FIRST OFFICER’S EMERGENCY FLASHLIGHT IN COCKPIT BROKEN AND HOLDING CLIP ON HOLDER SNAPPED OFF AND ON THE COCKPIT FLOOR. REMOVED AND REPLACED THE FIRST OFFICER’S FLASHLIGHT ASSEMBLY IAW AMM 33-50-16. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: DETECTION SYS — MALFUNCTIONED (CARGO BAY) · airframe 27,254 hrs · 24,244 cycles

FLIGHT 3415, CARGO EXTINGUISHER BUTTON DOES NOT ILLUMINATE DURING FIRE TEST. AIRCRAFT REMOVE FROM SERVICE. PERFORMED TEST OF CARGO SMOKE IAW AMM 26-15-00. NORMAL INDICATION NOTED. AIRCRAFT RETURN TO SERVICE.

Part: FLASHLIGHT — INOPERATIVE (CABIN) · airframe 26,958 hrs · 23,928 cycles

DURING B INSPECTION FOUND THE FORWARD PASSENGER CABIN FLASHLIGHT LED WOULD NOT ILLUMINATE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE FLIGHTLIGHT ASSEMBLY IAW EMB 135 AMM 33-50-16. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FLASHLIGHT — DEFECTIVE (CABIN) · airframe 26,864 hrs · 23,813 cycles

DURING B INSPECTION FOUND THE CABIN FORWARD EMERGENCY FLASHLIGHT HAS INTERMITTENT CONTACT WITH CHARGER. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE FORWARD CABIN EMERGENCY FLASHLIGHT IAW EMB AMM 33-50-16. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 26,864 hrs · 23,813 cycles

DURING B INSPECTION FOUND THE CABIN EMERGENCY LIGHT OVER THE LEFT EMERGENCY EXIT INOPERABLE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE LAMP IN THE CABIN EMERGENCY LIGHT ABOVE THE LEFT EMERGENCY EXIT PER EMB 135 AMM 33-50-08. THE OPERATIONAL CHECK WAS GOOD PER EMB 135 AMM 33-50-00. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 26,827 hrs · 23,779 cycles

DURING B INSPECTIONS FOUND THE RIGHT AFT EMERGENCY LIGHT INOPERABLE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE RIGHT AFT EMERGENCY LIGHT IAW EBM 135 AMM 33-50-45. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 26,694 hrs · 23,639 cycles

DURING B INSPECTIONS, FOUND THE RIGHT EXTERIOR OVERWING EMERGENCY LIGHT INOPERATIVE. AIRCRAFT REMOVED FROM SERVICE. REMOVED AND REPLACED THE RIGHT EXTERIOR OVERWING EMERGENCY LIGHT BULB IAW AMM 33-50-07. OPS CHECKED GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 26,601 hrs · 23,537 cycles

DURING B INSPECTION FOUND THE CENTER AISLE EMERGENCY CEILING LIGHTS INOPERABLE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE FORWARD AND AFT CENTER CEILING EMERGENCY LIGHTS IAW EMB135 AMM 33-50-08. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CARBON SEAL — UNSERVICEABLE (LT ENGINE) · airframe 26,462 hrs · 23,400 cycles

ON FLIGHT 2669 THE CREW REPORTED THAT ON POST FLIGHT WITH BOTH ENGINES SHUTDOWN THEY NOTICED THE LEFT ENGINE HAD SMOKE COMING OUT OF EXHAUST. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE MAGNETIC CARBON SEAL OF ACCESSORY DRIVE GEARBOX LEFT ENGINE BREATHER VENT. THE LEAK CHECK WAS GOOD IAW ROLLS ROYCE MM 72-63-10. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: DOOR SEAL — MISINSTALLED (PAX DOOR) · airframe 26,333 hrs · 23,261 cycles

DURING MAINTENANCE INSPECTION FOUND THE MAIN PASSENGER DOOR SEAL INSTALLED INCORRECTLY. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND INSTALLED NEW RUBBER TRIM SEAL ON MAIN PASSENGER DOOR IAW EMB AMM 52-18-04. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: INVERTER — INOPERATIVE (EMERGENCY LIGHTS) · airframe 23,103 hrs · 20,383 cycles

DURING MAINTENANCE BASE VISIT FOUND THE EMERGENCY EXIT (ROW 9) FLOOR LIGHTS AND LEFT AND RIGHT LOWER EXIT SIGNS TO BE INOPERABLE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE NR 5 INVERTER IAW EMB 135 AMM 33-50-11. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BALLAST — DEFECTIVE (CABIN) · airframe 23,096 hrs · 20,378 cycles

ON FLIGHT 4500 THE CREW REPORTED A BURNING ODOR COMING FROM AROUND THE MAIN CABIN DOOR. THE AIRCRAFT WAS REMOVED FROM SERVICE. TROUBLESHOT AND FOUND THE BALLAST OVER SEAT 3A TO BE BAD (CAUSING ODOR). REMOVED AND REPLACED BALLAST OVER SEAT 3A IAW EMB AMM 33-21-05. THE OPERATIONAL CHECK WAS GOOD. NO FURTHER DEFECTS NOTED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: DISPLAY — MALFUNCTIONED (COCKPIT) · airframe 22,540 hrs · 19,885 cycles

ON FLIGHT 4558 THE CREW REPORTED THE FIRST OFFICER’S PRIMARY FLIGHT DISPLAY WENT BLANK, AND THEN THE CREW SMELLED AN ELECTRICAL BURNING ODOR. THE PRIMARY FLIGHT DISPLAY RETURNED FUNCTIONAL BUT THE ELECTRICAL BURNING ODOR REMAINED. THE CREW ELECTED TO RETURN TO LGA. THE AIRCRAFT LANDED WITHOUT INCIDENT. FOUND ODOR COMING FROM THE FIRST OFFICER’S PRIMARY FLIGHT DISPLAY. REMOVED AND REPLACED THE FIRST OFFICER’S PRIMARY FLIGHT DISPLAY IAW 133 MM 34-22-01. THE OPERATIONAL CHECK WAS GOOD AND NO DEFECTS WERE NOTED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (CABIN) · airframe 22,465 hrs · 19,819 cycles

FOR FLIGHT 4588 DURING MAINTENANCE CHECK FOUND THE SERVICE DOOR EXTERNAL EMERGENCY LIGHT TO BE INOPERABLE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPLACED BULB IN FIXTURE, EMB AMM 33-50-10, AND REPAIRED WIRING AT SERVICE DOOR EXTERNAL EMERGENCY LIGHT SPLICES SP7376/SP7377, EMB SWPM 20-21-00. THE SERVICE DOOR EMERGENCY LIGHT OPERATIONAL TEST WAS GOOD IAW EMB AMM 33-50-00. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WARNING LIGHT — FALSE ACTIVATION (ANTI ICE SYSTEM) · airframe 21,393 hrs · 18,883 cycles

ON FLIGHT 4608 ON APPROACH THE CREW REPORTED, RECEIVED A STABILIZER ANTI ICE FAIL MESSAGE FOLLOWED BY ANTI ICE CONDITIONS. THE ANTI ICE WAS INOPERABLE. THE AIRCRAFT WAS IN ICING CONDITIONS AND THE CREW DECLARED AN EMERGENCY. THE AIRCRAFT LANDED SAFELY WITHOUT INCIDENT. THE AIRCRAFT WAS REMOVED FROM SERVICE. PERFORMED CONTROL REPORT WORKSCOPE FOUND NO FAULTS IAW AMM 30-00-00 AND 36-00-00. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: IGNITER — DAMAGED (NR 1 ENGINE)

ON TAKEOFF CREW REPORTED AIRCRAFT YAWED TO THE RIGHT AND THEN ON THE CLIMB, RIGHT ENGINE ITT WAS FLUXING/SPIKING ANY WHERE FROM 800 TO 838. BOTH PACKS WERE RUNNING AND ONLY AFTER RETARDING POWER, (N1 65) THE PACKS HAD TO BE RESET A FEW TIMES AFTER POWER WAS RETARDED BUT WERE NEVER TURNED OFF. WHEN CREW WAS TURNED OVER FROM TOWER TO DEPARTURES THEY WERE TOLD THERE WAS FLAMES COMING OUT OF THE NR 1 ENGINE ON TAKEOFF. CREW DECLARED AND EMERGENCY AND RETURNED SAFELY TO DTW. AIRCRAFT REMOVED FROM SERVICE. UPON REMOVAL THE TOP AND BOTTOM IGNITER WAS FOUND TO BE SEVERELY ERODED AT ITS TIP WITH EVIDENCE OF FROTTAGE. THE BOTTOM IGNITER HAD A MUSHROOM SHAPE, WHICH EXPLAINS THE JAMMING CONDITION. AC RETURNED.

Part: BALLAST — DEFECTIVE (CABIN) · airframe 19,068 hrs · 16,886 cycles

CREW REPORTED ON FLIGHT 4869 DURING CLIMBOUT SMOKE SMELL IN CABIN AT ROWS 1-9. CREW DIVERTED TO BUF. AIRCRAFT REMOVED FROM SERVICE. REMOVED AND REPLACED BALLAST AT ROW 4A IAW EMB 135 AMM33-21-03. OPERATIONAL CHECK GOOD IAW EMB 135. AIRCRAFT RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT OUTBORAD SEAT TRACK CORRODED BETWEEN FRAMES 47 TO 53. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-01-06. OPERATIONAL CHECK GOOD. RETURNED AIRCRAFT TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

RIGHT INBORAD SEAT TRACK CORRODED BETWEEN FRAMES 36 TO 47. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-01-06. OPERATIONAL CHECK GOOD. RETURNED AIRCRAFT TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

RIGHT OUTBOARD SEAT TRACK CORRODED BETWEEN FRAMES 23 TO 36. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-01-06. OPERATIONAL CHECK GOOD. RETURNED AIRCRAFT TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

RIGHT INBOARD SEAT TRACK CORRODED BETWEEN FRAMES 47 TO 53. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-01-06. OPERATIONAL CHECK GOOD. RETURNED AIRCRAFT TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT INBOARD SEAT TRACK CORRODED BETWEEN FRAMES 47 TO 53. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-10-06. AIRCRAFT RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT OUTBOARD SEAT TRACK CORRODED BETWEEN FRAMES 36 TO 47. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-01-06. OPERATIONAL CHECK GOOD. RETURNED AIRCRAFT TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT OUTBOARD SEAT TRACK CORRODED BETWEEN FRAMES 23 TO 36. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-10-06. AIRCRAFT RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT INBOARD SEAT TRACK CORRODED BETWEEN FRAMES 23 TO 36. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-10-06. AIRCRAFT RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT OUTBOARD SEAT TRACK CORRODED BETWEEN FRAMES 36 TO 47. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-01-06. OPERATIONAL CHECK GOOD. RETURNED AIRCRAFT TO SERVICE

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

RIGHT INBOARD SEAT TRACK CORRODED BETWEEN FRAMES 53 TO 55. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-10-06. AIRCRAFT RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT OUTBORAD SEAT TRACK CORRODED BETWEEN FRAMES 53 TO 55. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-01-06. OPERATIONAL CHECK GOOD - RETURNED AIRCRAFT TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT INBOARD SEAT TRACK CORRODED BETWEEN FRAMES 36 TO 47. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-10-06. AIRCRAFT RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 15,889 hrs · 14,307 cycles

LEFT OUTBOARD SEAT TRACK CORRODED BETWEEN FRAMES 17 TO 23. REMOVED AND REPLACED SEAT TRACK IAW EMB AMM 53-01-06. OPERATIONAL CHECK GOOD. RETURNED AIRCRAFT TO SERVICE.

Part: SERVO — FAILED (AUTOPILOT SYS)

WHILE CRUISING AT FLIGHT LEVEL 280, FLIGHT CONTROLS VIOLENTLY FLUTTERED ACCOMPANIED BY A BURNING SMELL IN THE COCKPIT. WHEN SPEED DROPPED BELOW 250KIAS AND AUTOPILOT MANUALLY DISENGAGED FLUTTERING OF CONTROLS ENDED. CREW DECLARED EMERGENCY AND DIVERTED TO JFK LANDED WITH NO OTHER PROBLEMS. RAI AUTO PILOT SERVO, OPS CHECK GOOD. REMOVED RAG FROM F/O YOKE CHAIN AND SPROCKET ASSY, PERFORMED VIBRATION WORKCARD AND RUDDER ENGINEERING ORDER, RETURNED AIRCRAFT TO SERVICE. (M)

Part: SILL — CORRODED (FUSELAGE)

DURING CPCP INSPECTION FOUND FLOORBEAM AT FRAME 22 ABOVE SERVICE DOOR AFT SILL IS CORRODED. REPLACED (Z) PROFILE AT FRAME 22 ABOVE SERVICE DOOR AFT SILL IAW SRM. AIRCRAFT WAS RETURNED TO SERVICE. (SW21200600538) (K)

Part: DOUBLER — CORRODED (FLOOR SUPPORT)

DURIN CPCP INSPECTION FOUND LT OMEGA BEAM DOUBLER AT FRAME 20 IS CORRODED. REPLACED LT OMEGA BEAM DOUBLER AT FRAME 20 IAW SRM. AIRCRAFT WAS RETURNED TO SERVICE. (K)

Part: BEAM — CORRODED (FR 18-22)

DURING CPCP INSPECTION, FOUND PROFILE ON CENTER HAT BEAM BETWEEN FRAMES 18-22 CORRODED. REPLACED CENTER HAT BEAM PROFILE IAW SRM. AIRCRAFT WAS RETURNED TO SERVICE. (SW21200600538) (K)

Part: POWER SUPPLY — DISCHARGED (EMERGENCY LIGHT)

BOS - FLT 4592 - EMERGENCY LIGHT STRIP AT ROW 7 AND 8 INOPERATIVE. REPLACED NR 3 EMERGENCY LIGHT POWER SUPPLY. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

FORWARD BULKHEAD EMERGENCY LIGHT FAILS TO ILLUMINATE. REPLACED LIGHT ASSEMBLY. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHT)

EMERGENCY EXIT SIGN AT ROW 2 NOT ILLUMINATED. REPLACED NR 2 EMERGENCY LIGHT BATTERY ASSEMBLY IAW EMB 135 AMM 33-50-04. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: PITOT TUBE — MALFUNCTIONED (RIGHT)

ABI - FLT 9806 - CREW REPORTED THE STANDBY ALTIMETER OFF BY 200 FEET FROM PRIMARY AT 10,000 FEET AND BACKLIGHTING ON THE THRUST RATING PANEL IS BLINKING ON AND OFF. AIRCRAFT RETURNED TO ABI AND LANDED SAFELY WITH NO FURTHER INCIDENTS REPORTED. MAINTENANCE REMOVED AND REPLACED THE RIGHT PTITO TUBE IAW EMB MM. OPERATIONAL CHECK WAS GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: ECU — INOPERATIVE (AVIONIC BAY)

DURING APPROACH, CREW REPORTED FLAPS FAILED TO DEPLOY WHEN LEVER SELECTED TO NINE DEGREES. AN EMERGENCY WAS DECLARED AND AIRCRAFT WAS LANDED WITH ZERO FLAPS. MAINTENANCE REMOVED AND REPLACED THE FLAP ELECTRONIC CONTROL UNIT IAW EMB MM. OPERATIONAL CHECK WAS SATISFACTORY AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

ABI - DURING AN IMBV INSPECTION, THE CENTER OMEGA BEAM AT FRAME 25 WAS FOUND CORRODED BELOW SRM LIMITS. CUT OUT SECTION OF THE OMEGA BEAM. FABRICATED AN EXTERNAL ANGLE, FILLER AND TWO SHIMS. REPAIR DONE IAW EMB REPAIR STATEMENT IC2003-145/2917. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

ABI - DURING AN IMBV INSPECTION, THE GALLEY FLOOR CENTER BEAM WAS FOUND TO BE CORRODED BELOW SRM LIMITS. REMOVED EXISTING CENTER BEAM AND INSTALLED NEW BEAM. REPAIR DONE IAW EMB 145 SRM, SRM EMB 145/1142 REV 22, 51-40-02, AND 51-40-04 AND CPM 51-21-04. (M)

Part: STRINGER — CHAFED (FUSELAGE)

ABI - DURING AN IMBV INSPECTION, FOUND STRINGER 19R WAS FOUND TO BE CHAFED BEYOND SRM LIMITS AFT OF FRAME 52. COMPLETELY REMOVED CHAFED BY BLENDING AREA. PERFORMED EDDY CURRENT INSPECTION OF THE BLENDED AREA. NO DEFECTS NOTED. FABRICATED ONE REPAIR ANGLE, TWO SHIMS. REPAIR DONE IAW EMB REPAIR STATEMENT IC2003-145/2917 AND STANDARD SRM PRACTICES. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

ABI - DURING AN IMBV INSPECTION, THE LEFT OMEGA BEAM BETWEEN FRAMES 24 AND 25 WAS FOUND TO BE CORRODED BELOW SRM LIMITS. REMOVED THE DAMAGED SECTION OF THE LEFT OMEGA BEAM, THE CUTOUT OF THE FLANGED AREA WAS EXTENDED BEYOND THAT OF THE WEB TO EMCOMPASS THE REPAIR SHIMS. FABRICATED AN EXTERNAL ANGLE, FILLER AND TWO SHIMS. REPAIR DONE IAW EMB REPAIR STATEMENT IC2003-145/2917, PRINCIPLES CONTAINED IN THE EMB SRM, SRM EMB 145/1142 REV 22, CHAPTERS 53-21-10 FIG 202, SHEET 1 AND STANDARD SRM AND CPM PRACTICES. (M)

Part: SILL — CORRODED (FUSELAGE)

ABI - DURING AN IMBV INSPECTION, THE SERVICE DOOR CENTER SILL WAS FOUND TO BE CORRODED BELOW SRM LIMITS. REMOVED EXISTING CENTER SILL AND INSTALLED A NEW SILL. REPAIR DONE IAW EMB 145 SRM, SRM 145/1142 REV 22, 51-40-02 AND EMB REPAIR STATEMENT IC2003-145/0818. (M)

Part: CIRCUIT BOARD — INOPERATIVE (PSU)

DURING CRUISE FLIGHT, THE CREW REPORTED THE OVERHEAD LIGHT AT 12C FLASHING OFF AND ON WITH A BURNING ELECTRICAL ODOR. MAINTENANCE REMOVED AND REPLACED DIODE BOARD FOR THE PASSENGER SERVICE UNIT AT SEAT 12C IAW CMM. OPS CHECK WAS GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: CONNECTOR — DISCONNECTED (CABIN)

DCA - FLT 4562 - CREW REPORTED THE EMERGENCY LIGHT BY FLIGHT ATTENDANT STATION TO BE INOPERATIVE. MAINTENANCE RECONNECTED LOOSE CANNON PLUG ON THE BATTERY PACK ABOVE CEILING PANEL. OPERATIONAL CHECK WAS GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: TRIM SWITCH — FAULTY (COCKPIT)

PITCH TRIM 1 INOPERATIVE WARNING APPEARED ON EICAS USED STANDBY TRIM FOR REMAINDER OF THE FLIGHT. DECLARED EMERGENCY AND RETURNED TO BOS. REMOVED AND REPLACED CAPTAIN YOKE PITCH TRIM SWITCH IAW EMB135 AMM 27-40-02-001-400-801-A, OPS CHECK GOOD. (M)

Part: LIGHT — NOT SEATED (CABIN)

FLOOR EMERGENCY LIGHT ROW 5 INOPERATIVE. C/A SEATED FLOOR EMERGENCY STRIP IN ROW 5 OPS CHECKED GOOD.

Part: CAP — CORRODED (RT MLG)

ABI - DURING MBV INSPECTION, MAINTENANCE FOUND CORROSION ON THE RIGHT MAIN LANDING GEAR BEARING CAP. MAINTENANCE REMOVED AND REPLACED THE BEARING CAP IAW EMB MM. (M)

Part: CAP — CORRODED (LT MLG)

ABI - DURING MBV INSPECTION, MAINTENANCE FOUND THE LEFT MAIN LANDING GEAR BEARING CAP TO BE CORRODED. BEARING CAP WAS REMOVED AND REPLACED IAW EMB MM. (M)

Part: WINDSHIELD — CRACKED (COCKPIT)

BWI - FLT 4756 - CREW REPORTED DURING CLIMB, THE RIGHT FRONT WINDSHIELD HEATING ELEMENT STARTED TO GLOW. A FEW SECONDS AFTER THAT THE WINDSHIELD SHATTERED. REMOVED AND REPLACED FRONT RIGHT WINDSHIELD IAW EMB 135 AMM. OPERATIONALLY CHECKED GOOD. (M)

Part: RELAY — BURNED (COCKPIT)

CHO - FLT 4139 - TAT 2 HEAT INOPERATIVE FOLLOWED BY SMOKE IN COCKPIT. REMOVED AND REPLACED RELAYS AND RELAY SOCKET IAW AMM. OPS CHECK GOOD. 9M)