N73444

Part: CASTING — CRACKED (LE SLAT) · airframe 65,900 hrs · 34,731 cycles

PULLEY BRACKET SUPPORT CASTING CRACKED INBOARD OF NUMBER 8 SLAT TRACK FRONT SPAR LEFT WING. REMOVED AND REPLACED CASTING PER BOEING DRAWING 9930529 SRM 51-60 AND EA MD80-57-009274.

Part: PAN — CRACKED (DOOR) · airframe 65,005 hrs · 34,236 cycles

HIGH FREQUENCY EDDY CURRENT INSPECTION DETECTS CRACK IN PAN AT FORWARD LOWER STOP. DYE CHECKED AND STOP DRILLED CRACK, FABRICATED AND INSTALLED DOUBLER PER SRM 52-05-00 FIG 8-1.

Part: FITTING — BROKEN (EVAC SLIDE) · airframe 64,466 hrs · 33,924 cycles

FOUND RIGHT NUMBER 1 DOOR SLIDE COVER CLIP BROKEN DURING OVERNIGHT MAINTENANCE. REMOVED AND REPLACED RIGHT NUMBER 1 DOOR SLIDE COVER.

Part: LIGHT — DISCHARGED (CABIN) · airframe 63,060 hrs

LGA - PORTABLE EMERGENCY LIGHT AT LEFT NUMBER ONE DOOR INOPERATIVE. REPLACED PORTABLE EMERGENCY LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHT) · airframe 63,060 hrs

LGA - EMERGENCY LIGHT AT LEFT NR 2 DOOR INOPERATIVE. REPLACED BATTERY PACK. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (CABIN) · 62,159 cycles

LGA EMERGENCY LIGHT AT FORWARD CABIN INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHT AT FORWARD CABIN. SYSTEM GROUND CHECKED NORMAL OPS.

Part: WIRE — DAMAGED (CABIN) · 62,159 cycles

LGA EMERGENCY LIGHT AT FORWARD GALLEY DOOR INOPERATIVE. REPAIRED WIRING AT CONNECTOR FOR EMERGENCY LIGHT AT FORWARD GALLEY DOOR. SYSTEM GROUND CHECKED NORMAL OPS.

Part: ENGINE — MAKING METAL (NR 1)

PHL - INFLIGHT T1415/11JUL - CREW REPORTED LT ENG OIL CLOG INDICATION DURING CLIMB FOLLOWED BY ENG UNCOMMANDED SHUTDOWN. RETURNED TO PHL AND LANDED WITHOUT INCIDENT. SINGLE ENG TIME 15 TO 17 MINUTES. REPLACED NR 1 ENG ON 13 JUL AT PHL DUE TO OIL LEAK AND METAL FOUND IN OIL. SYSTEM GROUND CHECKED NORMAL OPERATION. (S)

Part: CYLINDER — DEFECTIVE (NLG)

MSP INFLIGHT T1231/29 OCT - AFTER TAKEOFF NOSE GEAR RED LIGHT REMAINED ON. ALL OTHER LIGHTS WERE OUT. PUT LANDING GEAR DOWN AND ALL LANDING GEAR LIGHTS WERE GREEN. LANDING GEAR HANDLE LOCKED IN THE DOWN POSITION. RETURNED TO MSP AND LANDED WITHOUT INCIDENT. REPLACED AND REPACKED NOSE LANDING GEAR INNER CYLINDER. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LENS — BROKEN (EMERGENCY LIGHT)

DFW - EMERGENCY LIGHT AT SEAT 29D HAS BROKEN LENS SHROUD. REPLACED LENS SHROUD FOR EMERGENCY IGHT AT SEAT 29D. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LENS — BROKEN (EMERGENCY LIGHT)

DFW - EMERGENCY LIGHT AT SEAT 20D HAS BROKEN LENS SHROUD. REPLACED LENS SHROUD FOR EMERGENCY LIGHT AT SEAT 20D. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

DFW - EMERGENCY LIGHTS AT CEILING FROM SEAT ROWS 28 TO 30 INOPERATIVE. REPLACED BATTERY PACK B5107 FOR EMERGENCY LIGHTS AT CEILING FROM SEAT ROWS 28 TO 30. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LENS — MISSING (EMERGENCY LIGHT)

DFW - EMERGENCY LIGHTS AT CEILING AT LEFT ROW 21 HAS MISSING LENS. REPLACED LENS FOR EMERGENCY LIGHTS AT CEILING AT LEFT ROW 21. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

DFW - EMERGENCY LIGHTS IN CEILING AT ROW 8 INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS IN CEILING AT ROW 8. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: CONNECTOR — DISCONNECTED (EMERGENCY LIGHT)

DFW AFT AIRSTAIR LEFT HAND UPPER SIDEWALL MOUNTED EMERGENCY LIGHT INOPERATIVE. RESECURED CONNECTION FOR EMERGENCY LIGHT AT AFT AIRSTAIR LEFT HAND UPPER SIDEWALL. SYSTEM GROUND CHECKED NORMAL OPERATION. (CLOSED)

Part: CYLINDER — INOPERATIVE (NLG)

DURING APPROACH INTO BWI, UNABLE TO EXTEND NOSE GEAR. ACCOMPLISHED EMERGENCY GEAR EXTENSION PROCEDURES. LANDED BWI WITHOUT INCIDENT. AIRCRAFT INSPECTED AND FERRIED TO DCA FOR REPAIRS. REPLACED NOSE LANDING GEAR BUNGEE CYLINDER. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: GASKET — WORN (OIL CAP)

INFLIGHT BLUE HAZE AND FAINT SMOKE IN CABIN ON TAKEOFF. HAZE SOON DISSIPATED. AFTER LANDING DURING TAXI IN, SMOKE AND ODOR APPEARED AGAIN. PACKS SHUT DOWN AND SMELL AND HAZE DISSIPATED AGAIN. FOUND APU OIL SERVICE CAP WITH WORN GASKET. REPLACED APU OIL SERVICE CAP AND PERFORMED PACK BURN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

DEN - EMERGENCY LIGHTS AT MID CABIN OVERHEAD INOPERATIVE. REPLACED BATTERY PACK AT LOCATION B5-105 FOR EMERGENCY LIGHTS AT MID CABIN OVERHEAD. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (CABIN)

DFW - EMERGENCY LIGHTS AT FORWARD ENTRY INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS AT FORWARD ENTRY. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: CONNECTOR — FAULTY (CABIN)

EMERGENCY LIGHT ON SEAT 27D INOPERATIVE. REPLACED CONNECTOR. SYSTEM GROUND CHECKED NORMAL OPERATION.--CLOSED--

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY EXIT LIGHT AT AFT RT OVERWING INOPERATIVE. RESEATED BATTERY PACK. SYSTEM GROUND CHECKED NORMAL OPERATION.--CLOSED--

Part: BATTERY PACK — DISCHARGED (CABIN)

FORWARD GALLEY AND COCKPIT EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACK FOR FORWARD GALLEY AND COCKPIT EMERGENCY LIGHTS. SYSTEM GROUND CHECKED NORMAL OPERATION.--CLOSED--

Part: CONNECTOR — LOOSE (FIRE LOOPS)

MEX - FLT 1111 - EN ROUTE DFW-MEX, DURING DESCENT FIRE DETECTOR LOOP LIGHT ON ANNUNCIATOR PANEL FLASHED ON AND OFF, ALSO MASTER CAUTION LIGHT FLASHING. LOOP LIGHTS ON OVERHEAD PANEL DID NOT ILLUMINATED. LANDED MEX WITHOUT INCIDENT. TIGHTENED CONNECTIONS AT LOOP DETECTORS ON BOTH ENGINES. RE-RACKED MASTER WARNING AND CAUTION CONTROLLER, RAN UP ENGINES AT DIFFERENT POWER SETTINGS UNABLE TO DUPLICATE, PERFORMED FIRE AND LOOP FUNCTIONAL TEST. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: LIGHT — INOPERATIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, SEAT MOUNTED EMEGENCY EXIT PATH LIGHTING AT SEAT 9B INOPERATIVE. REPLACED SEAT MOUNTED EMERGENCY EXIT PATH LIGHTING AT SEAT 9B ASSEMBLY. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: GROUND WIRE — LOOSE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHT AT AFT FLIGHT ATTENDANT SEAT. RESECURED EMERGENCY EXIT LIGHT FIXTURE GROUND WIRE IN TAIL CONE AREA. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — LOOSE (CABIN)

MIA - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT AFT TAIL CONE LIGHT LEFT SIDE INOPERATIVE. SECURED EMERGENCY EXIT PATH LIGHT GROUND WIRE. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — INOPERATIVE (EMER EXIT SYST)

DURING OVERNIGHT MAINTENANCE EMERGENCY EXIT LIGHT ABOVE AFT FLIGHT ATTENDANT SEAT INOPERATIVE. SPLICED WIRES OVER AFT LAVATORY EMERGENCY EXIT LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SKIN — CRACKED (WING)

TUL - FOUND 3 INCH CRACK IN FIXED LEADING EDGE SKIN ABOVE NR 8 SLAT TRACK. REPAIRED CRACK PER SRM 57-01 FIG 3 SHEET 2 PAGE 8. (M)

Part: SEAT TRACK — CORRODED (FUSELAGE)

TUL - FOUND CORROSION ON NR 6 SEAT TRACK IN CHANNEL AND ON LUGS. REMOVED DAMAGED AREA FROM SEAT TRACK. INSTALLED REPAIR PLUG PER AARD 53-20-00-10 PAGE 1 REPAIR NR 10. (M)

Part: WEB — CORRODED (FUSELAGE)

TUL - FOUND RIGHT CUSP CORRODED AFT OF LIGHTENING HOLE STATION 558 LOWER SIDE. INSTALLED DOUBLER PER SRM 53-01. (M)

Part: SOCKET — INOPERATIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHT AT SEAT 9D INOPERATIVE. REPLACED EMERGENCY EXIT LIGHT SOCKET AT SEAT 9D. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: SPLICE — CHAFED (TAILCONE)

DFW - DURING OVERNIGHT MAINTENANCE, TAILCONE EMERGENCY EXIT LIGHT WIRE CHAFED. REPLACED EMERGENCY EXIT LIGHT WIRE SPLICE. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: ENGINE — STALLED (NR 1)

DEN - FLT 1220 - EN ROUTE DEN-ORD, ON TAKEOFF, DETECTED NR 1 ENGINE COMPRESSOR STALL. RETURNED DEN AND LANDED WITHOUT FURTHER INCIDENT. REPLACED NR 1 ENGINE. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — BROKEN (STAIRWELL)

DFW - DURING OVERNIGHT MAINTENANCE, STAIRWELL EMERGENCY LIGHT INOPERATIVE. REPAIRED BROKEN WIRE. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: WARNING LIGHT — ILLUMINATED (CABIN)

DFW - FLT 499 - DURING DESCENT AT FL330, CABIN ALTITUDE LIGHT ILLUMINATED. CREW EXPEDITED DESCENT AND AT FL12 ALL OXYGEN MASKS DEPLOYED. AIRCRAFT LANDED DFW WITHOUT FURTHER INCIDENT. MAINTENANCE ACCOMPLISHED RATE CHECK AND GROUND PRESSURIZED AIRCRAFT IN AUTOMATIC/MANUAL MODE WITH NO ABNORMAL CONDITIONS NOTED. ALL REQUIRED CHECKS WERE PERFORMED WITH NORMAL OPERATION. UNABLE TO DUPLICATE FAULT. REPLACED OXYGEN GENERATORS AND REPACKED MASKS. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: JAMB — CORRODED (CARGO DOORWAY)

TUL - FOUND CORROSION ON MID CARGO LOWER DOOR SILL FRAME. CORROSION REMOVAL EXCEEDS MANUAL LIMITS. INSTALLED DOUBLER PER AARD 53-10-00-3 FIG 2. INSTALLED DOUBLER PER AARD 53-10-00-3 FIG 2. (M)

Part: SWITCH — OUT OF ADJUST (TAIL CONE)

ORD - FLT 485 - DURING GROUND OPERATIONS, TAIL CONE MISSING LIGHT ILLUMINATED ON OVERHEAD PANEL. MAINTENANCE FOUND SWITCHES TO BE OUT OF ADJUSTMENT. ADJUSTED TAIL CONE SWITCHES PER MM. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — FAILED (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT FLOOR PATH LIGHTS BETWEEN FIRST CLASS AND COACH INOPERATIVE. REPLACED JUMPER WIRE. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: LIGHT — DEFECTIVE (CABIN)

DFW - DURING OVERNIGHT CHECK, EMERGENCY LIGHT AT FORWARD ENTRY DOOR INOPERATIVE. REPLACED EMERGENCY LIGHT AT FORWARD ENTRY DOOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: HYD LINE — CRACKED (LT OUTBD SPOILER)

DFW - FLT 871 - AFTER TAKEOFF DFW DURING CLIMB-OUT, RIGHT HYDRAULIC SYSTEM PRESSURE WENT TO ZERO. ACCOMPLISHED MANUAL GEAR EXTENSION AND AIRCRAFT RETURNED TO DFW, LANDING WITHOUT INCIDENT. REPLACED LEFT OUTBOARD SPOILER LINE. REPLACED RIGHT ENGINE DRIVEN HYDRAULIC PUMP AND ALL SYSTEM FILTERS. ACCOMPLISHED SYSTEM LEAK AND GROUND CHECK WITH NO DEFECTS FOUND. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: TURBINE BLADE — FAILED (NR 2 ENG)

ORD - FLT 1853 - EN ROUTE ROC/ORD - DURING CRUISE, LOUD BANG FOLLOWED BY LOSS OF POWER FROM NR 2 ENGINE AND NO EPR OR N1 INDICATIONS. ACCOMPLISHED SHUTDOWN OF NR 2 ENGINE AND AIRCRAFT PROCEEDED SINGLE ENGINE TO ORD, LANDING WITHOUT INCIDENT. REPLACED NR 2 ENGINE AND ACCOMPLISHED LEAK AND GROUND ENGINE RUN CHECKS WITH NO DEFECTS FOUND. ENGINE SHUTDOWN WAS THE RESULT OF 3RD AND 4TH STAGE TURBINE FAILURE. ALL 3RD AND 4TH STAGE TURBINE BLADES WERE BROKEN AT OR NEAR THE AIRFOIL ROOT. NO DEFINITIVE CAUSE OF FAILURE HAS BEEN DETERMINED. ENGINE ROUTED TO SHOP FOR REPAIR AND RETURN TO SERVICE. REFERENCE AALA960375.

Part: TURBINE BLADES — FAILED (NR 2 ENG)

ORD - FLT 1853 - EN ROUTE ROC/ORD - DURING CRUISE, LOUD BANG FOLLOWED BY LOSS OF POWER FROM NR 2 ENGINE AND NO EPR OR N1 INDICATIONS. ACCOMPLISHED SHUTDOWN OF NR 2 ENGINE AND AIRCRAFT PROCEEDED SINGLE ENGINE TO ORD, LANDING WITHOUT INCIDENT. REPLACED NR 2 ENGINE AND ACCOMPLISHED LEAK AND GROUND ENGINE RUN CHECKS WITH NO DEFECTS FOUND. ENGINE SHUTDOWN WAS THE RESULT OF 3RD AND 4TH STAGE TURBINE FAILURE. ALL 3RD AND 4TH STAGE TURBINE BLADES WERE BROKEN AT OR NEAR THE AIRFOIL ROOT. NO DEFINITIVE CAUSE OF FAILURE HAS BEEN DETERMINED. ENGINE ROUTED TO SHOP FOR REPAIR AND RETURN TO SERVICE. (M)