N768AX

Part: NONE — FAULTY (ZONE 400) · airframe 67,728 hrs · 47,083 cycles

RH ENG BLEED VALVE ON TAKE OFF PWR. CREW ABORTED TAKE OFF AT 70 KTS AND RETURNED TO BLOCK. AIRCRAFT GROUNDED BY MAINTENANCE. MAINTENANCE REMOVED AND REPLACED RH HIGH PRESSURE VALVE CONTROLLER IAW AMM 36-11-08. AIRCRAFT RETURNED TO SERVICE.

Part: FRAME — CRACKED (ZONE 100) · airframe 67,719 hrs · 47,080 cycles

DURING AIRCRAFT C-CHECK AT AIRBORNE (TAMPA), MAINTENANCE WAS REQUIRED TO INSPECT THE RIGHT INNER FRAME CHORD, LOCATED AT BS 883.5, LBL 89 PER ABX JOB CARD ABX-NEA-5350-0015-001 (AD 2012-22-17, SB 767- 53A0209 AND AD 2018-11-08, SB 767-53A0278). DURING INSPECTION OF THE RIGHT INNER CHORD A CRACK WAS FOUND IN THE STUB FRAME (PN 145T1381-4), COMMON TO THE #1 FASTENER HOLE. THE CRACK WAS ORIENTED IN THE 9 O’CLOCK POSITION AND THE CRACK LENGTH WAS NOT ABLE TO BE DETERIMINED. THE HOLE WAS REAMED TO 0.448 INCH WHICH EXCEEDS SB REPAIR LIMITS. THE SERVICE BULLETIN 767-53A0209, FIGURE 4, STEP (A) STATES TO CONTACT BOEING COMMERCIAL AIRCRAFT GROUP FOR FURTHER DIRECTION. BOEING WAS CONTACTED PER SERVICE REQUEST ID: 4-5553379008, AND REPAIR INSTRUCTIONS WERE PROVIDED. REPAIR ACCOMPLISHED PER ABX-REA-5353-64375-00. VENDOR DID NOT REPORT REPAIR TO ABX AIR. THIS WAS DICOVERED BY AN FAA AUDIT OF THE VENDOR.

Part: KEELBEAM — CRACKED (ZONE 100) · airframe 67,719 hrs · 47,080 cycles

DURING AN AIRCRAFT CURRENT CHECK AT AIRBORNE (TAMPA), MAINTENANCE DISCOVERED CORROSION AND A CRACK ON THE R/H SIDE KEEL BEAM CHORD, UPPER FLANGE AT STA 792. AFTER LOCAL FASTENERS IN THE CHORD UPPER FLANGE HAD BEEN REMOVED, A 4.75” CRACK WAS DISCOVERED. A SURFACE SCAN HAS IDENTIFIED THE END OF THE CRACK. A ROTO PROBE INSPECTION CONFIRMED THAT THE CRACK IS CONTAINED WITHIN THE KEEL CHORD FLANGE AND THAT THE KEEL BEAM WEB HAS NOT BEEN AFFECTED. THERE IS NO SRM REPAIR PROCEDURE FOR THIS LOCATION. AIRBORNE CONTACTED BOEING PER SERVICE REQUEST # 4-5543941743 AND WERE PROVIDED WITH PERMANENT REPAIR INSTRUCTIONS. REPAIR ACCOMPLISHED PER ABX-REA-5353-64377-00. VENDOR DID NOT REPORT REPAIR TO ABX AIR. THIS WAS DICOVERED BY AN FAA AUDIT OF THE VENDOR.

Part: NONE — NONE · airframe 67,487 hrs · 47,003 cycles

APU PNEUMATICS INOP, AIRCRAFT RETURNED TO BLOCK AND GROUNDED BY MAINTENANCE. MAINTENACE DEFERRED APU IAW MEL 49-11-1-1. AIRCRAFT RETURNED TO SERVICE.

Part: NONE — NONE · airframe 67,377 hrs · 46,964 cycles

A/C BLOCKED OUT MX WAS TOLD CREW COULD NOT START LH ENGINE AC WAS RETURNING TO GATE MX ON BOARD TALKED TO CREW SAID NO APU PRESSURE. AIRCRAFT BLOCKED AND GROUNDED BY MAINTENANCE. MAINTENANCE DEFERRED APU AIR IAW MEL 49-11-1-1 MBCB 05/21/22, MX PROCEDURES C/W. AIRCRAFT RETURNED TO SERVICE.

Part: ACTUATOR — FAILED (LEFT ENGINE) · airframe 67,085 hrs · 46,878 cycles

ON LEFT ENGINE START, ENGINE VALVE DID NOT EXTINGUISH, ABORTED START. AICRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. MAINTENANCE REMOVED AND REPLACED LEFT ENGINE CONDITION MOTOR. IAW 76-11-01 OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: NONE — NONE · airframe 66,638 hrs · 46,735 cycles

DURING TAXI OUT SHORT OF MIKE TAXIWAY ON SIERRA. MANUALLY TUNED FLM VOR MANUALLY IN BOTH VOR'S. CONFIRMED WITH ATC THAT THE FLM VOR IS OPERATIONAL! OFF FLAGS REMAINED IN VIEW . RETURNED TO GATE. AND GROUNDED BY MAINTENANCE. CONDUCTED TEST OF L/H AND R/H VOR, NO FAULTS. SWAPPED L/H AND R/H VOR LRUS, NO FAULTS PER AMM 34-51-00. SWAPPED L/H AND R/H VOR CONTROL PANELS, NO FAULTS PER AMM 34-51-02. ALL ITEMS RETURNED TO ORIGINAL POSIITONS A/C RELEASED CAT 1 PENDING 30/40 TEST. ALL VOR SYSTEMS TEST OK. AIRCRAFT RETURNED TO SERVICE.

Part: NONE — NONE · airframe 66,499 hrs · 46,688 cycles

DURING RIGHT ENG START WHEN ADVANCING RT FUEL CONTROL , EICAS MESSAGE R ENG FUEL VALVE APPEARED AND DISAGREE ENGINE VALVE LIGHT ILLUMINATED. AIRCRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. MAINTENANCE FOUND DAMAGED WIRING IN FORWARD CARGO COMPARTMENT. WIRING REPAIRED IAW B767 STANDARD PRACTICE MANUAL 20-30-00. OPS CHECK OF VALVE NORMALIAW B767 AMM 76-11-00. AIRCRAFT RETURNED TO SERVICE.

Part: CABLE — BINDING (RT VSV) · airframe 65,821 hrs · 46,455 cycles

ON TAXI OUT, R ENG STARTED SURGE +/- 2% N2, +/- 100 FF, +/- 40 EGT, +/- 1% N1. AIRCRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. MAINTENANCE FOUND R/H ENG VSV FEEDBACK CABLE TO HAVE HIGH PULL FORCE.R&R RH ENG VSV FEEDBACK CABLE IAW AMM 75-31-03. AIRCRAFT RETURNED TO SERVICE.

Part: START VALVE — BINDING (LEFT ENGINE) · airframe 65,759 hrs · 46,436 cycles

LH ENGINE START VALVE FAILED TO OPEN. AIRCRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. FOUND L/H ENGINE START VALVE BINDING DURING MANUAL OPERATION. REMOVED OLD, THEN INSTALLED NEW L/H START CONTROL VALVE PER AMM 80-11-02. AICRAFT RELEASED FOR FLIGHT.

Part: STARTER — FAULTED (LEFT ENGINE) · airframe 65,751 hrs · 46,434 cycles

LEFT ENGINE FAILED TO START, N2 NEVER GOT ABOVE 8.7 DUCT PRESSURE WAS NORMAL. AICRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE. REMOVED AND REPLACED THE #1 ENGINE STARTER IAW B767 AMM 80-11-0. AIRCRAFT RELEASED FOR FLIGHT.

Part: PNEUMATIC SYSTEM — FAULTED (APU) · airframe 65,395 hrs · 46,322 cycles

APU PNEUMATIC PRESSURE WENT TO ZERO AFTER PUSHBACK AIRCRAFT BACK TO BLOCK AND GROUNDED BY MAINTENANCE, CYCLED APU. REGAINED DUCT PRESSURE AFTER RESTART. OPERATED BOTH PACKS. W/ PRESSURE BUILDING. IAW AMM 49-52-00. AIRCRAFT RELEASED FOR FLIGHT.

Part: SHUTOFF VALVE — STUCK (BLEED SYSTEM) · airframe 64,607 hrs · 46,038 cycles

RT ENG BLEED OFF LIGHT ON WITH ALSO THE RT PACK OFF LIGHT ON DURING TAXI. AIRCRAFT LINED UP FOR TAKE OFF AND RT ENG. BLEED LIGHT DID NOT EXTINGUISH DURING ENGINE ACCELERATION. AIRCRAFT ABORTED TAKEOFF AND RETURNED TO GATE. MAINTENANCE GROUNDED AIRCRAFT. REMOVED AND REPLACED RIGHT PRSOV IAW AMM 36-11-09. AIRCRAFT RELEASED FOR FLIGHT.

Part: CONTROL PANEL — DEFECTIVE (BLEED AIR SUPPLY) · airframe 64,140 hrs · 45,867 cycles

AFTER PUSH BACK, LEFT ENGINE WOULD NOT START DUE TO NO PNEUMATIC AIR. AIRCRAFT BTB AND GROUNDED. REMOVED AND REPLACED BLEED AIR SUPPLY CONTROL PANEL, IAW B767 AMM 36-11-26. OPERATIONS CHECK NORMAL, AIRCRAFT RELEASED.

Part: APU — UNKNOWN · airframe 63,957 hrs · 45,765 cycles

APU AUTO SHUTDOWN AFTER PUSH BACK, BTB AIRCRAFT GROUNDED BY MAINTENANCE. CHECKED APU ECU, IAW B767 FIM 49-11 FAULT TREE 958, AND FOUND NO MESSAGES. STARTED APU AND RAN FOR .75 HOURS, RAN BOTH PACKS, DRY MOTORED NR 1 ENGINE AND NO DISCREPANCIES NOTED, IAW B767 AMM 71-00-00. AIRCRAFT RELEASED.

Part: VALVE — BINDING (AFT CARGO) · airframe 63,653 hrs · 45,643 cycles

AFT CARGO OVERHEAT LIGHT AND EICAS MESSAGE. AIRCRAFT BACK TO BLOCK AND GROUNDED. MAINTENANCE INSPECTED AND DEFERRED SYTEM AIRCRAFT WAS RELEASED FOR FLIGHT.

Part: DUCT — RUPTURED (E/E COOLING) · airframe 63,073 hrs · 45,334 cycles

AFTER ENGINE START, OVERHEAT (OVERHEAD LIGHT) ILLUMINATED ON EQUIPMENT COOLING PANEL WITH ASSOCIATED EICAS MESSAGE FORWARD EQUIPMENT COOLING OVERHEAT. VERY LOW AIRFLOW THROUGH AC GASPERS. AIRCRAFT WAS GROUNDED.

Part: WARNING LIGHT — ILLUMINATED (FIRST OFFICER'S) · airframe 62,913 hrs · 45,259 cycles

AFTER ENG. START THE F/O PITOT DISCREET LIGHT REMAINED ILLUMINATED WITH F/O PITOT EICAS MESSAGE DISPLAYED. AIRCRAFT WAS GROUNDED.

Part: STRINGER — CORRODED (BS 428-434) · corrosion level 2 · airframe 62,893 hrs · 45,237 cycles

STR 38R CORRODED JUST FWD OF STA 434 FACTORY SPLICE. THE AIRPLANE WAS GROUNDED.

Part: DOOR SILL — CRACKED (EMERGENCY EXIT) · airframe 62,893 hrs · 45,237 cycles

LEFT EMER. EXIT HATCH LOWER SILL FRAME IS CRACKED AT STA.889. THE AIRPLANE WAS GROUNDED.

Part: STRINGER SPLICE — CORRODED (BS 752) · corrosion level 2 · airframe 62,893 hrs · 45,237 cycles

FLC STRINGER 39R APPROX. STA.752 CORROSION ON SPLICE PLATE. THE AIRPLANE WAS GROUNDED.

Part: SHEAR TIE — CRACKED (BS 368) · airframe 62,893 hrs · 45,237 cycles

FORWARD LOWER CARGO STA 368 BETWEEN S38L-S37L SHEAR TIE CRACKED FROM RIVET HOLE. THE AIRPLANE WAS GROUNDED.

Part: LONGERON SPLICE — CORRODED (BS 785) · corrosion level 2 · airframe 62,893 hrs · 45,237 cycles

LONGERON EXTENSION FITTING AT KEEL AT STA.785 S38L CORRODED. THE AIRPLANE WAS GROUNDED.

Part: CONTROLLER — MALFUNCTIONED (RT ENGINE) · airframe 61,088 hrs · 44,542 cycles

ON TAKEOFF/POWER UP, THE RIGHT ENGINE BLEED DISCRETE LIGHT ILLUMINATED. THE LEFT & RIGHT ENGINE BLEED EICAS & MASTER CAUTION LIGHTS ILLUMINATED AND THERE WAS A SMELL OF SOMETHING BURNING. THE TAKEOFF WAS ABORTED AT A SPEED OF LESS THAN 60 KNOTS. THE AIRPLANE WAS REMOVED FROM SERVICE (GROUNDED) AND A TAKEOFF POWER ENGINE RUN WAS PERFORMED ON THE RIGHT ENGINE. NO FAULTS OR MESSAGES WERE DISPLAYED. THERE WAS NOT A BURNING SMELL DURING THE ENGINE RUN. THE DEFECTIVE RIGHT ENGINE HIGH PRESSURE CONTROLLER WAS REPLACED. THE CAUSE OF THE BURNING SMELL IS UNKNOWN.

Part: WEB — CORRODED (FUSELAGE) · airframe 59,617 hrs · 43,997 cycles

CORROSION ON WEB AT RIGHT FORWARD WING TO BODY AREA AT FUSELAGE STATION 720. THE WEB WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: SUPPORT BEAM — CORRODED (RT WING) · airframe 59,617 hrs · 43,997 cycles

CORROSION ON THE CHORD AFT OF THE MAIN LANDING GEAR SUPPORT BEAM AT RIGHT WING STATION 336. THE CHORD WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: SUPPORT BEAM — GOUGED (TE FLAP) · airframe 59,617 hrs · 43,997 cycles

GOUGE IN THE NR 7 FLAP SUPPORT BEAM NR 1 HOLE AT THE 12:00 POSITION. THE GOUGE DAMAGE WAS REMOVED BY REAMING THE HOLE BEYOND THE MAXIMUM PRODUCTION SIZE. THE AIRPLANE WAS GROUNDED.

Part: SUPPORT — CORRODED (RT WING) · airframe 59,617 hrs · 43,997 cycles

CORROSION ON THE TRAILING EDGE PANEL SUPPORT UPPER CHORD AT RIGHT WING STATION 300. THE CHORD WAS REPLACED. THE AIRPLANE WAS GROUNDED.

Part: FAILSAFE — CRACKED (BS 955) · airframe 57,196 hrs · 43,004 cycles

RIGHT FAILSAFE STRAP BS 955 CRACKED AT LOWER ATTACH HOLE COMMON TO TEE FITTING. CRACKED AREA TRIMED OUT AND REPAIRED IAW SDR. AIRCRAFT WAS GROUNDED.

Part: FAILSAFE — CRACKED (BS 955) · airframe 57,196 hrs · 43,004 cycles

LEFT FAILSAFE STRAP BS 955, CRACKED AT LOWER ATTACH HOLE COMMON TO TEE FITTING. REMOVED AND REPLACED THE FAILSAFE STRAP IAW JOB CARD EA 53500013-007 AND INSTALLED A NEW FAILSAFE AIRCRAFT WAS GROUNDED.

Part: STRUCTURE — CORRODED (BS 995) · corrosion level 2 · airframe 57,196 hrs · 43,004 cycles

AFT SPAR WEB HAS CORROSION ON THE PAD UP AREA COMMON TO MULTIPLE HOLES. REMOVED CORROSION, SPOT FACED CORROSION NEAR HOLES NDT CHECKED NO FURTHER DEFECTS NOTED ROTO PEENED BLENDED AND SPOT FACED AREAS REPAIRED BLENDED AND SPOT FACED AREAS IN ACCORDANCE WITH REA B657-62379-MR. SDR INFO: PART NUMBER: 111T1003-4, PART NAME: SPAR WEB, S/N: NSN, CORRODED: LEVEL 2, EXACT FS/ BS LOC ON AC: STA 955 TO LH. AIRCRAFT WAS GROUNDED.

Part: FRAME — CORRODED (BS 955) · corrosion level 2 · airframe 57,196 hrs · 43,004 cycles

TWO HOLES IN LEFT HAND SIDE FRAME FITTING (PICKLE FORK) COMMON TO FUSELAGE SKIN SIZE .309" HAVE DEFECT INDICATION FROM HFEC HOLE SCAN. REAMED HOLES UP UNTIL NO FURTHER DEFECTS WERE NOTED REA WAS GIVEN TO REPAIR THE HOLES. HOLES REPAIRED IN ACCORDANCE WITH REA B653-62378-MR.

Part: FRAME — CORRODED (BS 955) · corrosion level 2 · airframe 57,196 hrs · 43,004 cycles

CORROSION FOUND ON FORWARD LOWER FACE OF LEFT HAND SIDE FRAME FITTING (PICKLE FORK) AROUND SEVEN FASTENER HOLES COMMON TO MATING SURFACE OF REAR SPAR WEB PAD UP AREAS. REMOVED CORROSION SPOT FACED COMMOMON TO BOLT HOLES. NDT CHECKED NO DEFECTS REMAINING ROTO PEENEDBLENDED AND SPOT FACED AREAS, TREATED AND PRIMED AND REPAIRED IN ACCORDANCE WITH REA B653-62378-MR. SDR INFO: PART NUMBER: 145T2520-9, PART NAME: SIDE FRAME FITTING, S/N: NSN, CORRODED: LEVEL 2, EXACT FS/BS LOC ON A/C: FS 955LBL AREA AROUND HOLE 10-22. AIRCRAFT WAS GROUNDED.

Part: FAILSAFE — CRACKED (BS 955) · airframe 57,196 hrs · 43,004 cycles

LEFT FAILSAFE STRAP AT BS 955 IS CORRODED AND CRACKED PAST TRIM OUT LIMITS. REPLACED THE FAILSAFE.

Part: BULKHEAD — CORRODED (FUSELAGE) · airframe 56,731 hrs · 42,813 cycles

FOUND UNACCOUNTED OIL CAN REPAIR NEAR THE OUTER EDGE STIFFENER. REMOVED UNACCOUNTED REPAIR STIFFENER IAW SRM 51-40-02, FABRICATED NEW STIFFENER IAW SRM 53-80-08, REPAIR 8, STEP 3, LOCATED IAW SRM 53-80-08. TREATED IAW SRM 51-20-01 AND INSTALLED IAW SRM 51-40-02 AND 53-80-08 LOCATED AT APB AT LOWER OUTER EDGE BETWEEN RS14 AND RS15. APB WEB, LOCATION LOWER OUTER EDGE BETWEEN RS14 AND RS15. CORRODED, PN: 148T2610-111. ACFT WAS GROUNDED.

Part: CHANNEL — CRACKED (FUSELAGE) · airframe 56,731 hrs · 42,813 cycles

AFT FUSELAGE COMPARTMENT. REMOVED REPAIR CHANNEL IAW SRM 51-40-02. FABRICATED NEW REPAIR CHANNEL IAW SRM 53-80-08, REPAIR 3, PG 203, LOCATED CHANNEL IAW SRM 53-80-08. TREATED CHANNEL IAW SRM 51-20-01 AND INSTALLED IAW SRM 51-40-02 AND 53-80-08. REF REO G20134 AND REA 8653-62039. WEB STA 1582 BETWEEN S18R AND S19R, OUTER EDGE OF TS1, REPAIR SIZE 15.7500" X 1", ACFT WAS GROUNDED.

Part: KEELBEAM — CORRODED (BS 990-1015) · airframe 56,731 hrs · 42,813 cycles

CORROSION AT BS 990 - 1010 LEFT SIDE OF KEEL BEAM ALONG THE UPPER SIDE. FOUND TO BE OUT OF LIMITS IAW SRM 53-50-12. REPAIRED IAW SRM 53-50-12 REPAIR 1, REO-G20121 REV. A, AND REA B653-62037MR.

Part: BRACKET — CRACKED (FUSELAGE) · airframe 56,731 hrs · 42,813 cycles

AFT CARGO STA 1087 UNDER STR 38L JUST AFT OF FORWARD BULKHEAD HAS EVALUATED BLEND ON STR 38L IN AFT CARGO STA 1087 AFT OF FORWARD BULKHEAD, ORIGINAL MATERIAL THICKNESS .125", REMOVED .048", REMAINING THICKNESS .077". FOUND TO BE OUT OF LIMITS IAW SRM 53-00-15. REPLACED CLIP AT STA 108, STR 38 IAW SRM 51-40-01. BRACKET, PN: 96FS667603-16, PART LOCATION: STA 1087, LBL 11, DAMAGE SIZE: 1.0" X .5X .048. ACFT WAS GROUNDED.

Part: SEAT TRACK — CORRODED (BS 530-660) · airframe 56,731 hrs · 42,813 cycles

MAIN CABIN SEAT TRACK, BS 530 - 660 LBL 54.75 HAS CORROSION. REMOVED CORROSION, AND FOUND TO BE OUT OF LIMIT IAW SRM 53-00-52 FIGURE 101. REMOVED AND REPLACED THE SEAT TRACK IAW SRM 5140-02 DWG 368-53-13-909-08 REV A, AND DWG 368-53-13-90899.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 56,731 hrs · 42,813 cycles

MAIN CABIN, SEAT TRACK, STA 440-STA 660, LBL11 HAS SEVERAL AREAS OF CORROSION. REMOVED CORROSION .090" MATERIAL LOSS, FOUND TO BE OUT OF LIMITS IAW SRM 53-00-52, FIG 101. REMOVED CORRODED SEAT TRACK, STA 440-660, LBL11 IAW SRM 51-40-02. FABRICATED SEAT TRACK IAW DWG 368-53-13-90908 AND REO-G20087, REV A. ALODINED AND PRIMED IAW SRM 51-20-01 AND 53-00-52. PAINTED SEAT TRACK IAW DWG 368-53-13-90908. INSTALLED SEAT TRACK IAW DWG 36-13-90899. FINAL REF REO-G20087, REV C AND REA B653-62028DE, REV IR. SEAT TRACK, PN 368-53-13-90901-101, STA 440-660, LBL11. ACFT WAS GROUNDED.

Part: BEAM — CORRODED (FUSELAGE) · airframe 56,731 hrs · 42,813 cycles

FORWARD CARGO DOOR LOWER SILL BEAM UPPER SURFACE CORRODED AT AFT REPAIRED FORWARD CARGO DOOR LOWER SILL BEAM UPPER SURFACE, HIGH FREQUENCY, NO CRACKS NOTED. INSTALLED NEW FASTENERS IAW SRM 51-40-02. INNER CHORD, PART LOCATION: FLC STA 624-628 AT RBL44, PN: 143T8004-2, DAMAGE SIZE-2.5" INBD-OTBD 4.0" FWD-AFT, .045 IN DEPTH. WORK ACCOMPLISHED IAW REO-G20085 AND REA 8653-62033MR. ACFT WAS GROUNDED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 56,731 hrs · 42,813 cycles

CRACK INDICATION FOUND L-1 DOOR CUTOUT LOWER FORWARD CORNER. REPAIRED FUSELAGE SKIN STA 287 TO STA 347, S18L TO S24L BELOW L-1 DOOR IAW REO-G20052, REV B AND NR-B653-62038MR. SDR INFO: PART NAME: FUSELAGE SKIN, PN: 141T3331-5, SN: NSN, STA 287-347, LT BELOW L-1 DOOR. CRACK SIZE: 0.125". ACFT WAS GROUNDED.

Part: KEELBEAM — CORRODED (BS 955-977) · airframe 56,731 hrs · 42,813 cycles

LEFT MAIN WHEEL WELL KEEL BEAM BETWEEN BS 955 - 977. REMOVED CORROSION IAW SRM 51-10-02 AND FOUND TO BE WITHIN LIMITS IAW REO G20083 REVA.

Part: UNKNOWN — ODOR (COCKPIT) · airframe 55,563 hrs · 42,189 cycles

AFTER STARTING APU & TURNING ON PACK, STRONG ODOR OF JET FUEL NOTICED ON FLIGHT DECK. RESTARTED APU & CHECKED SYS WITH PACK ON IAW AMM 49-11-00. NO ODORS NOTICED. INSPECTED APU FOR OIL CONTAMINATION & INSPECTED WING ROOT AREAS FOR FUEL LEAKS. NO CAUSE OF ODOR FOUND.

Part: RIB — CORRODED (LT WING) · corrosion level 2 · airframe 54,654 hrs · 41,662 cycles

CORROSION FOUND AT NR 8 SLAT OTBD AUXILIARY TRACK LOWER STRUT RIB. REMOVED, FABRICATED & INSTALLED NEW AIR LOAD STRUT RIB IAW REA B657-61133 & DWG 114T2204. SDR INFO LEVEL 2 CORROSION, PN 114T2204-8, PART NAME STRUT AIR LOAD RIB, SN NSN, LOC OSS484.054. AIRCRAFT WAS GNDED.

Part: RIB — CORRODED (LT WING) · corrosion level 2 · airframe 54,654 hrs · 41,662 cycles

NUMBER 3 SLAT OTBD AUXILIARY TRACK ATTACH FITTING INBD LOWER STRUT SPLIT ON EDGE. R & R LOWER STRUT IAW REA B657-61134 & DWG 14T2217. SDR INFO LEVEL 2 CORROSION PN 114T2217-7, PART NAME, AIRLOAD RIB LOWER STRUT, SN NSN, LOC LES 780. ACFT WAS GNDED.

Part: PBE — UNSERVICEABLE (CABIN) · airframe 53,401 hrs · 40,891 cycles

PBE (PERSONAL BREATHING EQUIPMENT) HOOD CONTAINER LOST VACUUM SEAL. REMOVED AND REPLACED IAW AMM 25-64-00-0, ACFT WAS GROUNDED.

Part: STRUT — CORRODED (LT WING) · airframe 52,976 hrs · 40,615 cycles

NUMBER 5 SLAT INBOARD AUX TRACK LOWER OUTBOARD PANEL ATTACH STRUT HAS CORROSION BETWEEN PANEL ATTACH POINT NUT PLATES. ATTACH STRUT PANEL WAS FOUND TO BE OUT OF LIMITS. REMOVED AND REPLACED IAW B767 SRM 51-40-02. ACFT WAS GROUNDED.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 52,976 hrs · 40,615 cycles

LEFT KEEL BEAM STA 1000 TO 1010 HAS CORROSION ON LOWER HORIZONTAL LEG UPPER SURFACE. REPAIRED LEFT KEEL BEAM STA 1000-1010 ON LOWER HORIZONTAL LEG IAW REA B653-60410-MR. ACFT WAS GROUNDED.

Part: FLANGE — CORRODED (LT WING) · airframe 52,976 hrs · 40,615 cycles

LEFT WING TRAILING EDGE UPPER PANEL ATTACH FLANGE AT WS 807 HAS A SPOT OF CORROSION (1"). REPAIRED PER REA B657-60409-MR LEFT WING TRAILING EDGE UPPER PANEL ATTACH FLANGE AT WS 807. ACFT WAS GROUNDED.

Part: STRINGER — CORRODED (HORIZ STAB) · airframe 52,976 hrs · 40,615 cycles

HORIZONTAL STABILIZER CENTER SECTION, RIGHT OUTBOARD LOWER STRINGERS CORRODED; NR 10, 9, 7, 6, 5, 4, AND 2. REPAIRED AREAS IAW REA B655-60408-MR, ALL ARE BETWEEN RIBS 1R-2R. ACFT WAS GROUNDED.

Part: RIB — CORRODED (LT WING) · airframe 52,976 hrs · 40,615 cycles

NUMBER 5 SLAT INBOARD AUX TRACK LOWER PANEL AT INBOARD ATTACH STRUT IS CORRODED ON INBOARD FORWARD SIDE OF STRUT. REMOVED AND REPLACED INBOARD AUX TRACK RIB FOR NR 5 SLAT IAW B767 SRM 51-40-02. ACFT WAS GROUNDED.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 52,976 hrs · 40,615 cycles

CORROSION ON KEEL BEAM IN LEFT WHEEL WELL AT STA 982 LBL 10. REPAIRED KEEL BEAM IN LEFT WHEEL WELL AT STA 982 LBL 10 IAW REA B653-60411-MR. ACFT WAS GROUNDED.

Part: STRUT — CORRODED (LT WING) · airframe 52,976 hrs · 40,615 cycles

NUMBER 4 SLAT INBOARD AUX TRACK OUTBOARD LOWER PANEL ATTACH STRUT HAS SPOT OF CORROSION ON INBOARD SIDE UNDER AUX TRACK ATTACH FITTING. STRUT CORROSION OUT OF LIMITS. FABRICATED NEW AND INSTALLED IAW B767 SRM 51-40-2.

Part: RIB — CORRODED (RT WING) · airframe 52,976 hrs · 40,615 cycles

NUMBER 9 SLAT INBOARD AUX TRACK LOWER PANEL ATTACH STRUT CORRODED BETWEEN NUT PLATES. REPLACE LOWER LEADING EDGE STRUT RIB IAW B767 SRM 51-40-02 PARA 7, ACFT WAS GROUNDED.

Part: SPAR CAP — CORRODED (RT WING) · airframe 52,976 hrs · 40,615 cycles

CORROSION AROUND OVER RIGHT WING FUELING GROUND POINT ON LOWER SURFACE OF UPPER FRONT SPAR T-CAP AFT OF NUMBER 10 SLAT OUTBOARD DRIVE ROD ACTUATOR. REMOVED GROUND STUD. REMOVED CORROSION. GRAPHED RIGHT WING WS 802 UPPER .146" THINNEST AREAS. COMPLIED WITH THICKNESS CHECK. REPAIRED AS REQUIRED. RESTORED FINISH. INSTALLED PLACARD AND SEALED, ACFT WAS GROUNDED.

Part: RIB — CHAFED (LT WING) · airframe 52,976 hrs · 40,615 cycles

NR 5 LEADING EDGE SLAT OUTBOARD MAIN TRACK CHAFING FIXED LEADING EDGE STRUCTURE ON OUTBOARD SIDE. REPAIRED NR 5 LEADING EDGE SLAT OUTBOARD MAIN TRACK LEADING EDGE RIB IAW REA#B657-60396-MR, ACFT WAS GROUNDED.

Part: BEAM — CORRODED (RT WING) · airframe 52,976 hrs · 40,615 cycles

RIGHT WING LEADING EDGE NOSE BEAM WS 410 HAS CORROSION AREA ON TOP OF BEAM WHERE SKIN ATTACHES. REPAIRED RIGHT WING LEADING EDGE NOSE BEAM STA 410, ON TOP OF BEAM WHERE SKIN ATTACHES, USED 7075-T6 .063" AND 7075-T6 .050" IAW B767-200 SRM 51-70-11. ACFT WAS GROUNDED.

Part: RIB — CORRODED (RT WING) · airframe 52,976 hrs · 40,615 cycles

NUMBER 8 SLAT THERMAL ANTI-ICE (TAI) DUCT INBOARD LOWER RIB WHERE DUCT ATTACHES CORRODED AT LOWER END DIM: 2.5" X 1.3". REMOVED AND REPLACED LOWER RIB STRUT BY NR 8 SLAT TAI DUCT INBOARD RIB IAW B767 SRM 51-40-05, 51-40-02. ACFT WAS GROUNDED.

Part: ANGLE — CRACKED (NR 1 PYLON) · airframe 52,976 hrs · 40,615 cycles

NR 1 PYLON AT HYDRAULIC BAY NAC STATION 313 FOUND WITH T-ANGLE CRACKED. REMOVED AND REPLACED ANGLE IAW B767-200 SRM 51-40-02. ACFT WAS GROUNDED.

Part: RIB — CORRODED (RT WING) · airframe 52,976 hrs · 40,615 cycles

NUMBER 8 SLAT OUTBOARD AUX TRACK INBOARD LOWER PANEL ATTACH STRUT CORRODED AROUND NUT PLATES. REMOVED AND REPLACED STRUT RIB, IAW B767 SRM 51-40-02. ACFT WAS GROUNDED.

Part: ANGLE — CRACKED (PYLON) · airframe 52,976 hrs · 40,615 cycles

LEFT OUTBOARD SIDE OF PYLON HAS A ANGLE BRACKET BELOW PANEL 437ELX & ABOVE EXHAUST NOZZLE CRACKED. REMOVED AND REPLACED ANGLE IAW B767-200 51-40-02. ACFT WAS GROUNDED.

Part: DOOR FRAME — CORRODED (FUSELAGE) · airframe 52,976 hrs · 40,615 cycles

FORWARD LOWER CARGO AFT LOWER DOOR JAMB CORNER HAS CORROSION MARKED. REPAIRED FORWARD LOWER CARGO AFT LOWER DOOR JAMB CORNER IAW REA N653-60393-MR, ACFT WAS GROUNDED.

Part: STRUT — CORRODED (RT WING) · airframe 52,976 hrs · 40,615 cycles

RIGHT WING TRAILING EDGE INBOARD OF AUX TANK VENT HAS 2 EACH PANEL SUPPORTS WITH SEVERAL RUSTED NUT PLATES AND POSSIBLE CORROSION ON SUPPORTS. BLENDED PANEL SUPPORT BEAM & FOUND TO BE OUT OF LIMITS IAW B767 SRM 57-51-02. BEAM 0.080 MATERIAL REMOVED 0.020. REMOVED AND REPLACED PANEL SUPPORT STRUT IAW B767 SRM 51-40-02. REMOVED AND REPLACED NUT PLATES IAW B767 SRM 51-40-02. ACFT WAS GROUNDED.

Part: ENGINE — FAILED (LEFT) · airframe 51,837 hrs · 39,952 cycles

LEFT ENGINE FAILURE DURING CLIMB, LOUD BANG FOLLOWED BY ENGINE SHUTDOWN. N1 EXCEEDANCE OBSERVED. NO ENGINE RESTART ATTEMPTED. REMOVE AND REPLACE ENGINE, AWG.

Part: HARNESS — MISSING (COCKPIT) · airframe 51,305 hrs · 39,629 cycles

ESCAPE HARNESS 3 EA MISSING FROM FLIGHT DECK. REF B767-2A ITEM NR 7D. DEFERRED: 68733 DEFERRED IAW 767 MEL 25-61-1-2. PLACARD INSTALLED. MUST BE CLEARED BY 5/27/11 CODE 11. AIRCRAFT WAS NOT GROUNDED.

Part: PANEL — MISSING (RT WING) · airframe 51,053 hrs · 39,438 cycles

PANEL MISSING ON RT WING. REPLACED RT WING ANTI-ICING DUCT DOOR IAW 767 MM 57-41-58.

Part: UNKNOWN — ODOR (CABIN) · airframe 48,876 hrs · 38,487 cycles

SMELL OF SMOKE DETECTED ON FLIGHT DECK AND MAIN CARGO DECK WITH LEFT PACK ON. SHUT PACK OFF, SMELL CONTINUED. SMELL APPEARED OF ELECTRICAL ORIGIN. INSPECTED LOWER E&E COMPARTMENT, UPPER AND LOWER CARGO COMPARTMENTS WITH PACKS ON AND OFF. INSPECTED BOXES AND ASSOCIATED WIRING AND CIRCUIT BREAKER PANEL. INSPECTED LEFT AND RIGHT PACK COMPONENTS. NO DEFECTS NOTED. RAN PACK FOR 1/2 HOUR WITH NO SMELL NOTICED. COULD NOT DUPLICATE.

Part: FITTING — CRACKED (RIGHT WING) · airframe 46,965 hrs · 37,756 cycles

RIGHT WING HAD BROKEN FITTING LOCATED BETWEEN AFT MAIN LANDING GEAR TRUNNION AND FALSE SPAR OUTBOARD OF RIGHT MAIN LANDING GEAR PIVOT POINT. REMOVED AND REPLACED FITTING IAW B767 SRM 51-40-2.

Part: BEAM — CRACKED (NR 2 PYLON) · airframe 46,965 hrs · 37,756 cycles

NR 2 PYLON OUTBOARD BEAM WAS CRACKED AT AFT LATCH PIN RECEPTACLE. REPAIRED AREA IAW REA B654-53516-MR.

Part: SKIN — DAMAGED (RT ELEVATOR) · airframe 46,965 hrs · 37,756 cycles

RIGHT OUTBOARD ELEVATOR: HOLE RUBBED IN LEADING EDGE. REPAIRED AREA IAW REA B655-53514.

Part: BATTERY — DISCHARGED (EMERGENCY LIGHT) · airframe 46,192 hrs · 37,454 cycles

AIRCRAFT EMERGENCY LIGHTING SYSTEM INOPERATIVE (SPARE BATTERY). REMOVED AND REPLACED EMERGENCY LIGHT SPARE BATTERY PACK. OPS CHECKED GOOD IAW B767 MM 33-56-35.

Part: BATTERY — DISCHARGED (EMERGENCY LIGHT) · airframe 45,576 hrs · 37,221 cycles

DURING AM CHECK, FOUND EMERGENCY LIGHT WOULD NOT STAY ON FOR MORE THAN 5 MINUTES. SWAPPED BATTERIES, NO HELP. CHECKED VOLTAGE AT CHARGER IAW AMM 33-51-07-2, CHECKED GOOD. CHARGED BATTERIES FOR MORE THAN 4 HOURS. OPS CHECKED GOOD.

Part: WARNING LIGHT — ILLUMINATED (MLG) · airframe 45,198 hrs · 37,077 cycles

EICAS MESSAGE GEAR DISAGREE DISPLAYED AND GEAR AMBER LIGHT ILLUMINATED WITH GEAR DOWN LIGHTS ILLUMINATED. INITIALLY THERE WAS NO RIGHT MAIN GREEN LIGHT DOWN. THE LIGHT CAME ON DURING RETURNING FOR APPROACH. PERFORMED BITE OF PSEU AND FOUND LANDING GEAR LEVER SWITCH SYSTEM NR 1 AND NR 2 FAULTED. PUT HANDLE IN FULLY DOWN POSITION AND LANDING POSITION INDICATING OPS CHECKED GOOD IAW B767 MM 32-61-00. PERFORMED FIM 32-30-00. INSPECTED GEAR SWITCHES AND NO DEFECTS NOTED. NOTE: THIS FLIGHT PERFORMED A GO-AROUND. THE CREW SPECIFICALLY REPORTED THAT THEY DID NOT RECYCLE THE GEAR. FLIGHT CONTROL REPORTED THAT THE CREW DID DECLARE AN EMERGENCY ON THEIR FINAL APPROACH.

Part: BATTERY — DISCHARGED (CABIN) · airframe 41,641 hrs · 35,878 cycles

EMERGENCY LIGHTS INOPERATIVE. REPLACED POWER SUPPLY BATTERY ASSEMBLY IAW B767 MM. OPS CHECKED GOOD.

Part: FITTING — DEFECTIVE (T/E FLAP) · airframe 39,675 hrs · 35,224 cycles

WHILE PERFORMING AD 2002-01-15, THE RIGHT OUTBOARD, OUTBOARD 3-10 LINK, AFT FITTING, WILL NOT TAKE GREASE. REMOVED AND REPLACED THE FITTING IAW B767 MM 27-51-274.

Part: LIGHT — INOPERATIVE (COCKPIT) · airframe 39,096 hrs · 35,059 cycles

EMERGENCY EXIT LIGHT IN COCKPIT WAS INOPERATIVE. MAINTENANCE REPLACED THE EMERGENCY EXIT LIGHT ASSEMBLY IAW B767 MM 33-51-00. OPERATIONAL CHECKS WERE COMPLETED AND WERE SATISFACTORY.

Part: ACTUATOR — DEFECTIVE (NLG) · airframe 36,794 hrs · 34,358 cycles

NOSE GEAR GREEN DOWN LIGHT FAILED TO ILLUMINATE WITH GEAR HANDLE DOWN. GEAR DISAGREE MESSAGE DISPLAYED, DOOR AMBER LIGHT EXTINGUISHED AND GEAR LIGHT ILLUMINATED. RE-CYCLED GEAR. REPLACED NOSE LANDING GEAR DOWNLOCK ACTUATOR IAW B767 MM 32-34-02-04. OPS CHECKED GOOD.

Part: LINKAGE — LACK OF LUBE (NLG DOOR)

WHEN LANDING GEAR WAS RETRACTED, THE 'DOORS' LIGHT REMAINED ILLUMINATED. RETURNED TO DFW. FOUND LEFT NOSE GEAR DOOR DOWN AND NOT LATCHED. INSPECTED DOOR AND LINKAGE. FOUND DOOR RELEASE STICKING. LUBRICATED LATCH AND RESECURED DOOR, OPS CHECKED GOOD.