N758SA

Part: CARGO TRACK — CRACKED (ZONE 100) · airframe 104,725 hrs · 19,263 cycles

FORWARD CARGO TRACK FORWARD RIGHT CORNER WAS FOUND CRACKED. REPAIRED AS PER SRM 53-10-05 FIG 5 REV 120.

Part: SKIN — CRACKED (FUSELAGE) · airframe 104,725 hrs · 19,263 cycles

DURING REMOVING TWO ADDITIONAL DOUBLERS, THREE HOLE CRACK ON THE LEFT DOUBLER FUSELAGE SKIN AND TWO HOLE CRACK ON THE RIGHT DOUBLER FUSELAGE SKIN WERE FOUND. FOR EXISTING REPAIR DOUBLERS WHICH COMMON TO NOSE WHEEL WELL AFTER CORNER SKIN BETWEEN STA 400 TO STA 410, S-43R TO S-43L, SEVERAL CRACKED HOLES WERE FOUND. ONE HOLE WAS FOUND CRACKED AT LOWER SKIN (P/N:65B07661-5006) AND BULKHEAD LOWER CHORD (P/N:65B07936-2110). TWO HOLES WERE FOUND CRACKED AT RT LOWER SKIN (P/N:65B07661-5006). TRIM OFF THE LOWER SKIN (P/N:65B07661-5006) TO REMOVE THE CRACK. MAINTAIN MINUMUM 0.5 INCH TRIM RADIUS AND 1.7D EDGE MARGIN TO ADJACENT FASTENER HOLES.

Part: STRUCTURE — CORRODED (TE FLAP) · corrosion level 2 · airframe 104,725 hrs · 19,263 cycles

LT WING T/E INBOARD MID FLAP T/E LOWER CHORD WAS FOUND CORROSION. THREE CORROSION AREAS WERE FOUND ON LEFT T/E INBOARD MID FLAP (P/N:65B02025-35) T/E LOWER CHORD (P/N:65B02098-1) HORIZONTAL FLANGE LOWER SURFACE. THE REPAIR WAS CARRIED OUT PER BOEING MESSAGE NUMBER TEC-SOF-11-0106 AND SRM 51-10-01. THE REPAIR WAS APPROVED UNDER ODA-300064-NM FAA FORM 8100-9 DATED DECEMBER 16, 2011. THE INSPECTION REQUIREMENTS PER ODA-300064-NM FAA FORM 8100-9 DATED DECEMBER 16, 2011 ARE REQUIRED.

Part: MOUNT — CORRODED (NR 4 ENGINE) · airframe 104,725 hrs · 19,263 cycles

NR 4 ENG AFTER UPPER ENG MOUNT UPPER SURFACE WAS FOUND RUSTED HEAVILY. NR 4 ENGINE AFTER ENGINE MOUNT WAS REPLACED AS PER AMM 71-21-03 REV 86.

Part: LONGERON — CRACKED (RT COWLING) · airframe 104,725 hrs · 19,263 cycles

DURING INSPECTION OF NR 3 ENGINE RT SIDE COWL, ONE CRACK AND ONE DEEP CHAFING DAMAGE WERE FOUND AT LOWER LONGERON (P/N:65B94280-199). THE REPAIR WAS PERFORMED AS PER BOEING MESSAGE NUMBER TEC-SOF-11-0102.

Part: SKIN — DENTED (FUSELAGE) · airframe 104,725 hrs · 19,263 cycles

FUSELAGE SKIN (STA2200-STA2400,STR27-STR28) WAS FOUND ONE ORIGINAL REPAIR RIVET AND DENT. FUSELAGE SKIN DOUBLER WAS REPAIRED AS PER SRM 53-30-03 FIG 4 REV 120.

Part: FAILSAFE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 104,725 hrs · 19,263 cycles

DURING DATUM AIRCRAFT INPUT,A CORROSION (SIZE ABOUT:3.3"*0.8") WAS FOUND ON BULK CARGO FRAME LOWER LOBE FAIL SAFE CHORD (P/N:65B04347-149,STA2200) HORIZONTAL FLANGE AT STR 40R. THE REPAIR WAS PERFORMED PER BOEING MESSAGE NUMBER TEC-SOF-11-0099. THE REPAIR WAS APPROVED UNDER BOEING SR 1-2054920594 ON ODA-300064-NM FAA FORM 8100-9 DATED DECEMBER 16, 2011. THE INSPECTION REQUIREMENTS PER SB747-53A2500 REV 1 ARE REQUIRED. DETAILS OF THE REPAIR ARE RECORDED IN EN EA-53-1315.

Part: DOUBLER — CRACKED (SPOILER) · airframe 104,725 hrs · 19,263 cycles

NR 9 SPOILER HINGE DOUBLER AND NR 11 SPOILER HINGE DOUBLER WERE FOUND CRACKED. NR 9 SPOILER AND NR 11 SPOILER WERE REPLACED AS PER AMM 27-61-02 REV 86.

Part: SKIN — DENTED (CARGO DOOR) · airframe 104,725 hrs · 19,263 cycles

BULK CARGO DOOR SKIN FORWARD LOWER CORNER WAS FOUND A DENT. THE SKIN SMOOTHED OUT WAS FOUND OUT LIMITS. BULK CARGO DOOR SKIN DENT AREA WAS REPAIRED AS PER SRM 52-00-03 FIG 9 REV 120.

Part: ENGINE — FAILED (NR 3)

FLIGHT MAS6145, WHILE PREPARING FOR TAKEOFF, EXPERIENCED AN UNCONTAINED ENGINE FAILURE.

Part: ACTUATOR — MISSING (MLG)

ACFT 795 DEPARTED AS FLT SOO113, BOTH TAXI & TAKEOFF OPS WERE NORMAL. MLG HANDLE SELECTED TO "UP" POSITION AFTER LIFTOFF. BOTH RED "DOOR OPEN" & "RED "GEAR" LIGHTS REMAINED ILLUMINATED. FO CONTINUED FLYING & CLIMBED ON COURSE. CAPTAIN & FE COMPLETED QRH PROCEDURES. UPON COMPLETION OF PROCEDURES, RT MLG STILL EXTENDED. DIVERTED TO NEAREST AIRPORT. ALL SPEED LIMITATIONS, & NORMAL OPERATING PROCERDURES COMPLIED WITH. DESCENT, APPROACH, AND SUBSEQUENT LANDING MADE WITHOUT INCIDENT. IT WAS DISCOVERED THE RT MLG RETRACTION ACTUATOR WAS COMPLETELY MISSING. RT MLG DOOR HINGE FOUND TO HAVE NUMEROUS CRACKS & MISSING BOLTS.

Part: ENGINE — LEAKING (NR 1)

DURING THE TAKEOFF ROLL IN OMDB NR 1 EGT GAUGE BRIEFLY WENT TO 0, THEN RETURNED TO NORMAL. DURING THE CLIMB TO FL 300 IT WAS NOTICED, NR 1 EGT WAS RUNNING SIGNIFICANTLY HOTTER (APPROXIMATELY 80 DEG C) THAN THE OTHERS. AT THE TOP OF CLIMB, THE NR 1 EGT KEPT CREEPING HIGHER BUT THE OTHER ENGINE PARAMETERS CLOSELY MATCHED THE OTHERS. SHORTLY AFTER REACHING CRUISE, IT WAS NOTICED THAT NR 1 OIL QUANTITY WAS SLOWLY DECREASING, AS WAS THE OIL PRESSURE. OIL TEMPERATURE WAS INCREASING TO 150 DEGREES. IT WAS OBVIOUS THE ENGINE READINGS WERE NORMAL AND WOULD EXCEED LIMITS IF THERE WAS NO INTERVENTION, SO IT WAS DECIDED TO DO A PRECAUTIONARY SHUTDOWN BEFORE ANY SERIOUS DAMAGE WAS DONE. THE INFLIGHT ENGINE SHUTDOWN CHECKLIST WAS ACCOMPLISHED. FUEL WAS DUMPED DOWN TO APPROXIMATELY 87,000 LBS DURING THE TURN BACK TO OMSJ. A THREE ENGINE DESCENT, APPROACH AND LANDING WAS CONDUCTED TO RUNWAY 12 AT OMSJ WITHOUT INCIDENT. MAINTENANCE PERFORMED AT OMSJ, FOUND NR 1 FAN CASE SOAKED WITH OIL. REMOVED AND REPLACED NR 1 ENGINE IAW SAI RNR 4771001, OPS CHECK AND LEAK CHECK NORMAL. MPA RUN ACCOMPLISHED IAW SAI RNR 4771002 R3, NO DEFECTS NOTED.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 101,362 hrs · 18,589 cycles

FWD CARGO LOWER FUSELAGE SKIN AT STA 1000 WAS CORRODED LEVEL 2.

Part: STIFFENER — CRACKED (NR 1 PYLON) · airframe 101,362 hrs · 18,589 cycles

PYLON NR 1, INBD NR 3, STIFFENER CRACK.

Part: HINGE FITTING — CRACKED (HORIZONTAL STAB) · airframe 101,362 hrs · 18,589 cycles

HORIZ STABILIZER LT 2 PLACES 0.9 INCH AND 0.8 INCH & RT 2 PLACES 1.1 INCH AND 0.85 INCH, HINGE FITTING CRACKED.

Part: DOUBLER — CRACKED (ZONE 800) · airframe 101,362 hrs · 18,589 cycles

MAIN ENTRY DOOR NR 1 UPPER OUTER SKIN DOUBLER CRACK, 0.35 INCH AT UPPER HINGE DOOR.

Part: STIFFENER — CRACKED (NR 2 PYLON) · airframe 101,362 hrs · 18,589 cycles

PYLON NR 2 INBD NR 3 STIFFENER CRACK 0.67 INCH BETWEEN NAC STA 248 AND NAC STA 259 ON THE RT SIDE.

Part: STIFFENER — CRACKED (NR 1 PYLON) · airframe 101,362 hrs · 18,589 cycles

PYLON NR 1 INBOARD NR 3 STIFFENER CRACK.

Part: DOUBLER — CRACKED (ENTRY DOOR) · airframe 101,362 hrs · 18,589 cycles

MAIN ENTRY DOOR NR 1 UPPER OUTER SKIN DOUBLER CRACK AT UPPER HINGE DOOR.

Part: A/C PACK — VIBRATION (NR 1) · airframe 100,136 hrs · 18,337 cycles

DEPARTURE FROM VAKK TO VMCC: AFTER TAKEOFF NR 1 AIR CONDITIONING PACK STARTED SEVERE RUMBLING NOISE AND EMITTED AN ODOR. AIRCRAFT QUICK HANDBOOK PROCEDURE ACCOMPLISHED. REMOVED AND REPLACED ACM AND DUCT ASSEMBLY. OPERATIONAL AND LEAK CHECK ACCOMPLISHED AND FOUND TO BE SATISFACTORY PER AMM 21-51-04 (11-25-09). THIS MAINTENANCE ACTION CLEARS DI 20658.

Part: FUEL FILTER — FAILED (NR 1 ENGINE) · airframe 99,959 hrs · 18,308 cycles

ON TAKEOFF CLIMBOUT OF KJFK, ENGINE NR 1 AND ENGINE NR 4 FUEL FILTER BYPASS INDICATION LIGHTS CAME ON AND STAYED ON, CREW ELECTED TO TERMINATE FLIGHT, DUMPED 156,000 LBS OF FUEL, RETURNED TO KJFK AND LANDED SAFELY. AFTER LANDING MAINTENANCE CREW IN KJFK REPLACED THE MAIN FUEL FILTER ELEMENT ON ENGINE NR 1 AND ENGINE NR 4 AND PERFORMED AN ENGINE RUN UP TEST ON BOTH ENGINES IN ACCORDANCE WITH THE AMM 73-11-02 AND 71-00-00, ENGINE PARAMETERS NORMAL AND NO FUEL LEAK NOTED ON BOTH ENGINE NR 1 AND ENGINE NR 4. AIRCRAFT RESTORED TO NORMAL.

Part: SLIDE — UNWANTED DEPLOY (ZONE 200) · airframe 99,344 hrs · 18,106 cycles

PRIOR TO DEPARTURE FROM KJFK, LEFT UPPER DECK EMERGENCY EXIT SLIDE INADVERTENTLY DEPLOYED. REMOVED SLIDE IN ACCORDANCE WITH AMM 25-68-02. TRANSFERRED TO DEFERRED MAINTENANCE ITEM NR 18844 PER MEL 25-11, CAT. C. PLACARD INSTALLED.

Part: PMS — INACTIVE (ZONE 200) · airframe 99,136 hrs · 18,062 cycles

CLIMB-OUT OF EBLG, PERFORMANCE MANAGEMENT SYSTEM (PMS) LIGHT ILLUMINATED IN FLIGHT AND AUTOPILOTS "A" AND "B" WOULD NOT FOLLOW FLIGHT MANAGEMENT SYSTEM (FMS) COMMAND. AIR TURN BACK TO EBLG. NO FUEL DUMPED. OPERATIONALLY CHECKED IN ACCORDANCE WITH DELCO OPERATIONS MANUAL, P/N 7891920-415. COULD NOT DUPLICATE FAULT.

Part: THRUST REVERSER — DEPLOYED (ZONE 400) · airframe 98,870 hrs · 18,002 cycles

ON CLIMB-OUT FROM ADDIS ABABA, ETHIOPIA (HAAB), AIRCRAFT PERFORMED AN AIR TURN BACK DUE TO INDICATION OF NR 4 ENGINE THRUST REVERSER TRYING TO DEPLOY IN FLIGHT. CREW WAS ALERTED BY THRUST REVERSER VALVE LIGHT AND TRANSIT LIGHT ILLUMINATING. CREW RETURNED TO HAAB WITH REVERSER PARTIALLY DEPLOYED. NO FUEL WAS DUMPED. MAINTENANCE TOOK ACTION TO LOCK OUT THRUST REVERSER AND SCHEDULE FOR APPROVED DEFERRED MAINTENANCE ACTION.

Part: ENGINE — DAMAGED (NR 3) · airframe 98,533 hrs · 17,930 cycles

DURING TAKEOFF AFTER V1 FROM HAAB, BIRD INGESTION INTO NR 3 ENGINE. AIR TURNBACK TO HAAB. FUEL DUMP OF 50,000 LBS. INSPECTION AFTER LANDING CONFIRMED DAMAGE TO NR 3 ENGINE FAN BLADES, AS WELL AS EVIDENCE OF BIRD STRIKE ON NR 2 ENGINE. NR 1, 3, 4, 6, 11, 13 AND 15 MAIN WHEEL ASSEMBLIES THERMALLED.

Part: ACCESS PANEL — CRACKED (NR 1 NACELLE) · airframe 97,564 hrs · 17,734 cycles

POST FLIGHT WALK-AROUND, FOUND HYDRAULIC ACCESS PANEL ON NR 1 ENGINE SAIL BOAT FAIRING OPEN. FOUND CRACK AT NR 1 ENGINE INBOARD SAIL BOAT DOOR, AT THE FORWARD HINGE. HYDRAULIC ACCESS PANEL OPENED IN FLIGHT.

Part: TRIM SYSTEM — FAILED (AUTOPILOT) · airframe 92,993 hrs · 16,993 cycles

ASTU WAS ON DEFERRAL. REMOVED AND REPLACED ASTU PRIOR TO DEPARTURE OUT OF PANC IAW AMM 22-14-01. AFFECTED BOTH AUTOPILOT A AND B SYSTEMS AND COULD NOT ENGAGE BOTH AUTOPILOT IN FLIGHT. RETURNED TO PANC. ASTU OPERATIONAL CHECK ACCOMPLISHED ON GROUND AND FAILED IAW AMM 22-14-01. REPLACED WITH PREVIOUSLY REMOVED ASTU. DEFERRAL REMAINS OPEN. RERACKED AUTOPILOT MONITOR AND LOGIC UNIT. OPERATIONAL CHECK NORMAL ON GROUND IAW AMM 22-11-07.