N770NC

Part: WIRE — BROKEN (EMERGENCY LIGHTS) · airframe 78,154 hrs · 75,564 cycles

DURING LINE CHECK, MX FOUND THE EMERGENCY ESCAPE PATH LIGHTING AT SEAT 8D TO BE INOPERATIVE. MX FOUND A BROKEN WIRE, REPAIRED IT AND THE LIGHTS RETURNED TO AN OPS CONDITION. ACFT NOW OK FOR SERVICE.

Part: SKIN — CRACKED (BS 160) · airframe 78,004 hrs · 75,417 cycles

THREE CRACKS WERE FOUND IN THE FUSELAGE SKIN NEAR THE PED JAMB CUTOUT UPPER FORWARD CORNER AT STA 160. THE CRACKS WERE REPAIRED IAW ERA 504604-14AD, SECT I. MX TRIMMED THE INTERNAL DOUBLER TO REMOVE THE CRACK, EXTENDED THE TRIM OUT ONTO THE FUSELAGE SKIN, PERFORMED AN HFEC INSP AND INSTALLED THE REPAIR IAW SRM 53-05, FIG 114, SHEET 4, CONFIG -7005.

Part: SKIN — CRACKED (FUSELAGE) · airframe 78,004 hrs · 75,417 cycles

DURING L CHECK, A CRACK WAS NOTED IN THE FUSELAGE SKIN AT THE PASSENGER ENTRY DOOR CUTOUT, UPPER AFT CORNER, NR 1 DOOR STOP. COMPLIED WITH ERA 504606-14AD, REV ORIGINAL SECTION 1 ON FUSELAGE SKIN LT FWD PASSENGER DOOR JAMB/AFT UPPER CORNER, THIS IS A PERMANENT REPAIR.

Part: LONGERON — CRACKED (BS 1247-1258) · airframe 78,004 hrs · 75,417 cycles

CRACKED LONGERON RIGHT BELOW APU EXHAUST DUCTING L14R BETWEEN BS 1230 TO 1247, REMOVED LONGERON SPLICE, CUT OUT LONGERON AND REMOVED IAW SRM 53-02 FIG 18. REPAIRED LONGERON IAW SRM 53-02 FIG 18.

Part: PAN — CRACKED (CARGO DOOR) · airframe 78,004 hrs · 75,417 cycles

AD RELATED INSPECTION OF THE FORWARD CARGO DOOR UTILIZING HFEC, DETECTED A CRACK ON THE AFT SIDE DOOR PAN BEND RADII AT THE LOWER (5TH) DOOR STOP PAD APPROX .375 IN. IN LENGTH AND EXTENDS UNDER DOOR STOP PAD. ONE END OF CRACK IS MARKED UNABLE TO DETERMINE END OF CRACK UNDER DOOR STOP PAD. REMOVED 2 EA STOP PADS ON FWD LOWER CARGO DOOR AFT SIDE PAN, IAW SRM 52-03, FIG 8. FABRICATED REPAIR DOUBLER, LOCATED AND DRILLED REPAIR DOUBLER, TREATED AND PRIMED REPAIR DOUBLER. UPON FURTHER INVESTIGATION, FOUND REPAIR NOT FABRICATED TO STRUCTURE, HAS AREAS OF GAP/PRELOAD. FABRICATED SHIM AS REQUIRED TO RELIEVE PRELOAD. TREATED AND PRIMED SHIM AND INSTALLED REPAIR DOUBLER/SHIM ON FWD LOWER CARGO DOOR AFT SIDE DOOR PAN, IAW SRM 52-03, FIG 8.

Part: WIRE — BROKEN (EMERGENCY LIGHT) · airframe 77,996 hrs · 75,408 cycles

DURING LINE CHECK, MAINTENANCE FOUND THE EMERGENCY ESCAPE LIGHTING AT SEAT 6 DEF TO BE INOPERATIVE. MAINTENANCE REPAIRED THE BROKEN WIRE AND THE LIGHTS RETURNED TO AN OPERATIONAL CONDITION. AIRCRAFT NOW OKAY FOR SERVICE.

Part: FIRE WARNING — FALSE ACTIVATION (APU BAY) · airframe 77,757 hrs · 75,127 cycles

APU FIRE INDICATOR. RAN QRH PROCEDURE. CREW THEN DISCHARGED BOTH BOTTLES FOR APU. INSPECTED APU COMPARTMENT. NO FIRE DAMAGE OR EVIDENCE FOUND. RAN APU AND INSPECTED AREA. ALL CHECKS GOOD. REMOVED AND REPLACED BOTH FIRE BOTTLES.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 77,642 hrs · 74,979 cycles

DURING LINE CHECK, MAINTENANCE FOUND THE CEILING EMERGENCY LIGHTS AT ROWS 21 AND 23 TO BE INOPERATIVE. MAINTENANCE REPLACED THE BATTERY PACK AND THE LIGHTS RETURNED TO AN OPERATIONAL CONDITION.

Part: PAN — CRACKED (ENTRY DOOR) · airframe 3,391 hrs · 2,986 cycles

WHILE TROUBLESHOOTING DOOR CLOSURE ISSUE, A CRACK WAS NOTED IN THE DOOR PAN UNDER THE LOWER HINGE, APPROXIMATELY 1 INCH IN LENGTH. ERA 498996-14 APPLIED, AND SHIP NON-PRESSURIZED, MAINTENANCE FERRIED TO MSP. REPLACED L1 DOOR.

Part: SWITCH — DEFECTIVE (COCKPIT) · airframe 3,244 hrs · 2,854 cycles

WHILE PERFORMING THE SECURE CHECKLIST, PILOT PLACED EMERGENCY EGRESS LIGHT SWITCH IN OFF POSITION, AND ALL EMERGENCY EGRESS LIGHTS ILLUMINATED. REPLACED COCKPIT EMERGENCY EGRESS LIGHT SWITCH, CHECKS OK.

Part: CONNECTOR — DAMAGED (CABIN) · airframe 76,294 hrs · 73,617 cycles

MAINTENANCE FOUND EMERGENCY EXIT LIGHT AT 1R DOOR INOPERATIVE. MAINTENANCE REMOVED THE LIGHT ASSEMBLY, REPAIRED CONNECTOR, AND REPLACED THE POWER SUPPLY ASSEMBLY. OPERATIONAL CHECK WAS GOOD.

Part: SKIN — CORRODED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

FUSELAGE EXTERNAL SKIN CORROSION AT WING TO BODY PANEL ATTACHMENT FS 894-908, S26R-28R. REF LOG 0355872. PERMANENT REPAIR ACCOMPLISHED ON FUSELAGE SKIN AT WING TO BODY PANEL ATTACHMENT FS 894-908 S-26R-28R IAW ERA 493500-14 REV ORIGINAL. ALL WORK ACCOMPLISHED ON N/R 1A/68. REPETITIVE INSPECTION REQUIERED EVERY 8,000 CYCLES BY VISUAL METHOD IAW DC-9 SRM 53-04 FIG 57 PAGE 397.

Part: MEMBRANE — DAMAGED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

FOUND HOLES ON SUB FLOOR OF FLOOR PANEL NR 13 LBL 12 STA 160. REMOVED FABRICATED AND INSTALLED WEB UNDER FLOOR PANEL 13 AT STA 160 LBL 12 IAW DC9 SRM 51-30-1 AND DC9 SRM 51-30-2 PARA 7.

Part: WEB — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

FOUND CRACK UNDER FLOOR PANEL 13 BL 0 STA 160 WHILE GETTING OK TO INSTALL FLOOR PANEL. REMOVED FABRICATED AND INSTALLED NEW WEB UNDER FLOOR PANEL 13 STA 160 IAW DC9 SRM 51-30-1 PG 1 AND DC9 SRM 51-30-2 PAR 7.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

SEAT TRACK LBL 22 HAS AREAS OF CORROSION FROM STA 200 TO 318. REMOVED CORROSION ON SEAT TRACK LBL 22 AT STA 200 TO 318 PER DC9 SRM 51-10-3 PAGE 35 OUT OF LIMITS PER SRM 53-05 PAGE 24. LOCATED AND DRILLED PAGE 31 AND 40 INSTALLED SEAT TRACK LBL 22 AT STA 200 TO 318 PER DC9 SRM 51-10-5 PAGE 12.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

MAIN CABIN AT STA 1136 .091 FLOOR SUPPORTS ON LEFT AND RIGHT SIDES APPROXIMATELY 12" FROM BL 0 ARE CRACKED AT FWD O/B SIDES. REMOVED AND REINSTALLED CABIN FLOOR SUPPORTS ON LEFT AND RIGHT SIDE STA 1136.091 IAW DC9 SRM 51-30-1 PG 1. REPAIRED CRACKS IAW DC9 SRM 53-01 PG 13 FIG 1 SHEET 4. STOP DRILLED CRACKS. HFEC PER NDTSPM 06-10-01.0001 NO DEFECT NOTED. FABBED AND INSTALLED DOUBLERS IAW DC9 SRM 53-01 PG 13 FIG 2 SHEET 4.

Part: PLATE — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

EXTERNAL FUSELAGE NOSE SECTION LT AT HOOK PLATE OF THE FWD PAX DOOR AT FS 130 PLATE IS CRACKED AND DETERIORATED. REMOVED DOUBLER DAMAGED IAW SRM 51-70-2 PG 2 AND SRM 51-30-5 PG 29. LOCATED AND DRILLED NEW DOUBLER IAW SRM 53-04 FIG 24 AND INSTALLED NEW DOUBLER AT EXT FUSELAGE NOSE SECTION LT FS 130 IAW SRM 53-04 FIG 24 AND INSTALLED CONICAL WASHER OVER EXISTING COUNTERSINK.

Part: FLOOR PANEL — CORRODED (COCKPIT) · airframe 75,864 hrs · 73,207 cycles

COCKPIT FLOOR 15 PANEL CORROSION. REMOVED CORROSION PER DC9 SRM 51-10-3 PGS 46-48 OUT OF LIMITS PER DC9 SRM 53-01 PG 8. REMOVED ANGLE BRACKETS PER DC9 SRM 51-30-02 PG 24 PARA 7. LOCATED AND DRILLED NEW PNL PER DC9 SRM 51-10-4 PG 1. COUNTER SUNK PER DC 9 SRM 51-10-4 PG 21. REAMED BRACKET HOLES TO LINE UP WITH NEW PANEL PER DC9 SRM 51-10-4 PG 1. INSTALL BRACKETS PER DC9 SRM 51-30-1 PG 4, DC9 SRM 51-30-2 PGS 1-13 AND DC9 SRM 51-30-2 PGS 20 AND 22.

Part: FLOOR PANEL — CORRODED (COCKPIT) · airframe 75,864 hrs · 73,207 cycles

COCKPIT 13 FLOOR PANEL WITH CORROSION. UPON FURTHER EVALUATION FOUND PANEL TO BE EXFOLIATED AND CRACKED REMOVED 9 EA HAT CHANNEL FROM FLOOR PANEL 13, (1 EA) HAT CHANNEL FOUND TO BE CRACKED PER DC9 51-30-2. FABBED PANEL AND 1 EA HAT CHANNEL PER DC9 SRM 53-23-0 TREATED AND PRIMED PER DC9 SRM 51-10-3 PARA 31 PARA 14 AND PARA 21 PAGE 40. INSTALLED 9EA HAT CHANNELS ON FLOOR PANEL 13 AND ANGLE PER DC9 SRM 51-30-2 PG 2 FIG 1.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL 20 HAS CORROSION ON BOTTOM SIDE MARKED AND DAMAGED FASTENER HOLES MARKED DOUBLER WASHER NOT TO USE, FLOOR PANEL AND FLOOR PANEL 20 OUT OF LIMITS IAW SRM DC9 53-01 PAGE 8 REPLACED FLOOR PANEL IAW AMM DC9-A-53-20-01-201-925A-A. LOCATED AND DRILLED HOLES IAW SRM DC9 51-10-4 PG 1.

Part: WEB — CHAFED (RUDDER) · airframe 75,864 hrs · 73,207 cycles

RUDDER LOWER SURFACE WEB CHAFING ON NUT PLATE ATTACHMENT. BLENDED DAMAGE AREA OUT OF LIMITS PER SRM 55-40-0 FIG 4. REMOVED AND REPLACED RIB AT RUDDER LWR SURFACE PER SRM 51-30-2. REQUIRED BALANCING THAT SAME NEW PART WAS REPLACED AND THE SAME WEIGHT PER SRM 55-40-1 PG 1 STEP NOTED.

Part: FLOOR PANEL — CRACKED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PANEL 69 HAS A SMALL DENT WITH A CRACK IN SKIN, PNL IS OFF AIRCRAFT PART. CUT OUT DENTED CRACKED AREA ON CABIN FLOOR PANEL 69 IAW DC9 SRM 53-05 PG 10 FIG 7. FABRICATED AND INSTALLED REPAIR FILLER AND DOUBLER IAW DC-9 SRM 53-05 PG 10 FIG 1 AND DC9 SRM 51-30-2 PG 24 PAR 7. REPAIR ID TAG PER PSM 900-5-1 INSTALLED REPAIR ID TAG.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

MAIN CABIN, STA Y 775, LONG 2 RT WITH CRACK. RII: Y. CUT AND REMOVED DAMAGED SECTION MAIN CABIN 2 RT LONGERON AT STA 775 IAW DC9 SRM 53-02 FIG 18 FABRICATED LONGERON SECTION AND 2 EACH SPLICE SECTION SECTIONS IAW DC9 SRM 53-02 FIG 18 NR 2 RT LONGERON INSTALLED IAW DC9 SRM 53-02 FIG 18 AT STA 775 L-2R.

Part: FLOOR PANEL — CORRODED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL 26 HAS CORROSION ON UPPER SURFACE OF DOUBLER REPAIR AND ON THE BOTTOM SIDE OF PNL, PNL IS OFF AC PART. REMOVED CORRODED DOUBLER ON CABIN FLOOR PNL 26 IAW DC9 SRM 51-30-2 PG 1. FABRICATED AND INSTALLED DOUBLER ON CABIN FLOOR PANEL 26.

Part: FLOOR PANEL — PUNCTURED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL 89 SMALL PUNCTURE IN SKIN AND A 6 INCH LONG CREASE. REMOVED UPPER SKIN FROM CABIN FLOOR PANEL 89. INSTALLED UPPER SKIN TO CABIN FLOOR 89 IAW SRM 51-30-2 PG 24.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 75,864 hrs · 73,207 cycles

MAIN CABIN FLOOR PANEL 71C PUNCTURE TO FLOOR REMOVED DAMAGED FLOOR SKIN AND DAMAGED HAT CHANNEL FROM FLOOR PNL PER DC9 SRM 51-30-2, PG 1-3, FABBED FLOOR SKIN PER DC 9 SRM 53-21-0, PG 14A. FABBED HAT CHANNEL PER DC9 SRM 53-20-0, FIG 3, ITEM 16, TREATED AND PRIMED FLOOR SKIN AND HAT CHANNEL PER SRM DC9 51-10-3, PG 31 AND 40, INSTALLED HAT CHANNEL TO FLOOR SKIN PER DC9 SRM 51-30-2, PG 1-3.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

FLOOR SUPPORT STRUCTURE HAS AREAS OF CORROSION STA 160 BETWEEN LBL 53 AND BL-0. RII: Y. REMOVED CORROSION STA 160 BL-0 TO LBL 53, FOUND CRACK LBL 46. MECHANICALLY MEASURED FOUND MATERIAL LOSS .005. MATERIAL WITHIN LIMITS PER SRM 53-01 FIG 1 PG 8. CUT OUT DAMAGE STA 160 LBL 46 IAW DC-9 SRM 51-70-5 PG 4. FABRICATED & INSTALLED L-ANGLE DOUBLER AND FILLER IAW DC-9 SRM 51-30-5 PG 12.

Part: SKIN — DENTED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

FWD CARGO EXTERIOR SKIN SURFACE DENTED. RII: Y. REFORMED DENT AREA ON FWD CARGO DOOR EXTERIOR SKIN IAW SRM 51-10-02 PG:6 FIG 2. HFEC NOTED NO DEFECTS AT REWORK AREA REPAIRED DENT AREA WITH INTERNAL DOUBLER PER SRM 53-04 PG:218K FIG 38 SHEET 22. THIS IS IDENTIFIED AS A MAJOR REPAIR.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

MAIN CABIN STA Y 764, LONG 3RT WITH CRACK RII: Y. CUT AND REMOVED DAMAGED SECTION MAIN CABIN NR 3 RT LONGERON TO EXISTING SPLICE STA 764 IAW DC-9 SRM 53-02 FIG 18. FABRICATED LONGERON SECTION AND SPLICE IAW SRM 53-02 FIG 18 TO NR 3 RT LONGERON, INSTALLED IAW DC-9 SRM 53-02 FIG 18 AT STA 764 L-3 RT.

Part: FLOOR PANEL — CORRODED (COCKPIT) · airframe 75,864 hrs · 73,207 cycles

COCKPIT NR 14 FLOOR PANEL WITH CORROSION. RECEIVED NEW FLOOR PANEL 14 AT COCKPIT. LOCATED AND DRILLED NEW FLOOR PANEL 14 AT COCKPIT IAW DC-9 SRM 51-10-4 PARAGRAPH 2 PG:1.

Part: WEB — CRACKED (NR 2 PYLON) · airframe 75,864 hrs · 73,207 cycles

NR 2 PYLON AFT ENGINE MOUNT LWR SUPPORT STRUCTURE WEB AND EXISTING REPAIR CRACKED STA YN 174 VIEWED THRU ACCESS DOOR 8206A. NDT VERIFIED CRACK IN DOUBLER APPROX 2 INCHES LONG. REMOVED REPAIR DOUBLER PER DC9 SRM 51-30-2. STOP HOLE ON CRACK PER DC9 SRM 54-01 PG 9. FABBED DOUBLER REPAIR PER DC9 SRM 54-01 PG 9 NDT CHECKED NO CRACKS DETECTED BEYOND STOP DRILL HOLE. INSTALLED REPAIR DOUBLER PER DC9 SRM 54-01 PG 9 FIG 2.

Part: HINGE — EXCESS PLAY (TE FLAP) · airframe 75,864 hrs · 73,207 cycles

LT WING NR 4 FLAP HINGE O/B BUSHING HAS PLAY. REMOVED AND REPLACED LT WING NR 4 FLAP HINGE PER DC-9 AMM 20-17-00 -201 PG 1 & 2 AND DC-9 SRM 51-30-1 PG 15 AND 12. GAINED ACCESS PER DC-9 AMM 20-17-00-201. REMOVED AND REPLACED LT WING NR 4 FLAP HINGE PER DC-9 AMM 20-17-00-201 AND DC-9 SRM 51-30-1. RESTORED ACCESS PER DC-9 20-17-00-201 AND AMM 27-10-00-501. RIGGING OF CABLES TO BE ACCOMP ON TC 2710-9800M.

Part: DOUBLER — GOUGED (TE FLAP VANE) · airframe 75,864 hrs · 73,207 cycles

GOUGE ON REPAIR DOUBLER AT LEFT WING FLAP, INBD FIXED VANE, STA XF-154. REMOVED REPAIR DOUBLER ON LEFT WING FLAP INBD FIXED VANE LEADING EDGE STA XF 154 IAW DC-9 SRM 51-70-2 PAGE 11 PARA6A. INSTALLED DOUBLER AND FILLER PER DC-9 SRM 57-03 PAGE 27, BONDED REPAIR PER DC-9 51-70-2 PAGE 21, 91-101 TABLE 7 PARA 18, APPLIED ALODINE TO REPAIR.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL NR 53 TWO SCREWS ARE PULLED THRU SKIN. FABRICATED TREATED AND PRIMED AND INSTALLED REPAIR DOUBLER WASHER AT FLOOR PNL NR 53 PER SRM 51-10-3 PGS 31, 32, 40, AND 42 AND SRM 53-05 PG 12 FIG 3.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PANEL NR 91 THREE SCREWS PULLED THRU SKIN. FABRICATED, TREATED, PRIMED, AND INSTALLED 3 REPAIR DOUBLER WASHERS AT FLOOR PANEL NR 91 PER SRM 51-10-3 PGS 31, 32, 40, AND 42 AND SRM 53-05.

Part: SKIN — GOUGED (TE FLAP) · airframe 75,864 hrs · 73,207 cycles

RT WING FIX VANE MID PANEL FWD SECTION HAS A DEEP GOUGE ON SKIN TO BARE METAL, LOOSE EYE BOLT. CUT OUT GOUGE ON SKIN, IAW SRM 51-70-2, FABBED DOUBLER AND FILLER PER SRM 51-70-2, SRM 57-03, APPLIED ALODINE PER DC9 SRM 51-10-3, PRIMER PER SRM 51-10-3, PG 31-32, PARA 14 AND SEALANT PER SRM 51-70-2, PG 114. RE-SECURED EYEBOLT PER SRM 51-30-1, PAGE 11 (BONDED DOUBLER AND FILLER ON RT WING FIXED VANE MID PANEL FWD SECTION IAW SRM 51-70-2.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

CABIN OVERWING STRUCTURE FLOOR SUPPORT CRACKED AT STA 775 AND X-15. REMOVED FLOOR SUPPORT ON MAIN CABIN AT STA 775 AND X-15 IAW DC9 SRM 51-30-02, FABRICATED FLOOR SUPPORT IAW DC9 SRM 53-13-3, PG 26, FIG 11. INSTALLED FLOOR SUPPORT AT STA 775 AND X-15 IAW DC9 SRM 51-30-02.

Part: FLOOR PANEL — PUNCTURED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL 52, ONE SMALL PUNCTURE ON SKIN 861-KK-82. FABBED & INSTALLED DOUBLER AS PER DC9 SRM 51-30-2, PG 1, 24-26B, PAR 7, MARKED USING REPAIR IDENTIFICATON REQUIREMENTS USING PROCESS STANDARD 900-5-1, NR 4, PG 1-6. INSTALLED REPAIR DOUBLER ON CABIN FLOOR PNL 52.

Part: FLOOR PANEL — BENT (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL 79, FWD END IS BENT UP AND THERE ARE THREE MIS-DRILLED HOLES ALONG I/B AFT EDGE FABED NEW FLOOR PANEL PER DC9 SRM 53-21-0, PG 14B, 14D, SHEET 1-3, AND SRM DC9 51-30-2. TREATED AND PRIMED PER DC9 SRM 51-10-3. ASSEMBLED FLOOR PANEL BY INSTALLING HAT CHANNELS ONTO SKIN, REF DC9 SRM 51-30-1, PG 1 & DC9 SRM 51-30-2, PG 1.

Part: DOUBLER — CRACKED (LT WING) · airframe 75,864 hrs · 73,207 cycles

LEFT WING REAR SPAR WEB DOUBLER O/B SIDE OF AFT DOUBLER IS CRACKED, REF: EM 5710-00028, SECTION 03 UPON FURTHER INVESTIGATION, ALL WORK TO BE COMPLIED WITH ON WORK CARD 5710-00028-08A (LEFT WING SPAR AND/OR DOUBLER TRIM REPAIR) JOB 000-0009, WO 87938350001.

Part: FLOOR PANEL — CORRODED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL HAS SURFACE CORROSION AT FWD END. REMOVED AND FABRICATED REPLACEMENT FLOOR PANEL WITH SHT 7075T6 .032, BATCH 0002057150 IAW DC9 SRM 51-01 PG 3 AND DC9 SRM 51-20-0 PG 4, AND DC9 SRM 51-30-02.

Part: FLOOR PANEL — DENTED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL 80 IS BOWED UP IN THE CENTER AND HAS MANY DENTS. 861-KK-84. RII: Y. FABRICATED NEW SKIN, REMOVED 2EA HAT CHANNELS FROM OLD SKIN, FLOOR PANEL 80, AND INSTALLED ON NEW SKIN FLOOR PANEL 80, IAW DC9 SRM 51-30-2, PG 1-4.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

CORROSION ON MOUNTING TRACK FOR RIGHT AFT LAVATORY AT STA 1174, RBL 25. REMOVED MOUNTING TRACK FROM IAW DC9 SRM 51-30-2 & DC9 SRM 51-30-5, PAR 8, FIG 16, FABBED INTERCOSTAL PER REF DWG 94FS481223. TREATED AND PRIMED MOUNTING TRACK AS PER DC9 SRM 51-10-3. LOCATED AND DRILLED HOLES IAW DWG 94FS481223. INST PER DC9 SRM 51-30-2, AND SRM 51-30-5, AND DWG 99FS634222.

Part: PAN — DETERIORATED (CARGO DOOR) · airframe 75,864 hrs · 73,207 cycles

FWD CARGO DOOR OUTER PAN AREA UNDER PRESSURE SEAL PRIMER COATING DETERIORATED, PEELING UP, LIGHT CORROSION AND AREAS OF PROTECTIVE FINISH MISSING ALL THE WAY AROUND DOOR PAN. FWD CARGO DOOR OUTER PAN FOUND TO BE OUT OF LIMITS IAW DC-9 SRM 52-01 FIG 1 P66. RECEIVED NEW DOOR STOCK 09-5230-9-0001 BATCH 0002065418 TO BE INSTALLED ON TO #5230-0203 SR 00648.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 75,864 hrs · 73,207 cycles

ELONGATED 7 HOLES AT FLOOR PANEL 99. FABRICATED AND INSTALLED 07 EA. FABRICATED REPAIR WASHERS IN MAIN CABIN FLOOR PANEL 99 PER DC9 SRM 53-05, PG 12, FIG 3, PER DC9 SRM 51-60-0, PG 6, FIG 1 AND DC9 SRM 51-30-1.

Part: FORMER — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

CRACK ON FUSELAGE FORMER AT STA 1151, BELOW LONGERON 14L. REMOVED FORMER ON STA 1151 BELOW LONGERON 14L, REMOVED 4 ANGLES STA 1151, LONGERONS 13,14,15,16, & 1 EA SPLICE PER DC9 SRM 51-30 -5, PG 30, 29. LOCATED AND DRILLED NEW FORMER PER DC9 SRM 51-10-4, PG 1, OK TO INSTALL.

Part: FORMER — DAMAGED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

CRACK ON FUSELAGE FORMER AT STA 1151, BELOW LONGERON 14R, REMOVED AND REPLACED FORMER, P/N J060119-40, BATCH 0002054712 IAW DC9 DRAWING J060119, REMOVED AND REINSTALLED ACCESS PANEL 820 2A AT RT LOWER PYLON IAW DC9 SRM 51-30-1. FORMER WAS REMOVED AND REPLACED AT STA 1151, BELOW LONG 14R.

Part: FORMER — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

CRACK ON FUSELAGE FORMER AT STA 1151, BELOW LONGERON 14L (093-31). REMOVED FORMER, REMOVED 4 ANGLES, LONGERONS 13, 14, 15, 16 AND 1 SPLICE. OK TO INSTALL FORMER, 4 EA ANGLES, AND SPLICE. INSTALLED FORMER ON STA 1151, BELOW LONGERON 14L, INSTALLED 4 EA ANGLES ON STA 1151, LONGERONS13, 14, 15, 16 AND 1 EA SPLICE ALL PER DC-9 SRM 51-30-5 PG 1 AND DRAWING J060116.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

CRACK ON INTERNAL DOUBLR REPAIR AT FUSELAGE SKIN STA 1163, BELOW LONGERON 14R (093-29). RII: Y. REMOVED LONGERON ATTACH BRACKET BY FOM AT STA 1163, STR 14R IAW DC9 SRM 51-30-5, PG 29. REMOVED INTERNAL DOUBLER REPAIR AT FUSELAGE SKIN STA 1163, STR 14R IAW DC9 SRM 51-30-5, PG 29. FABRICATED AND INSTALLED REPAIR DOUBLER AND FILLER AND LONGERON ATTACH BRACKET AT STA 1163, STR 14R IAW DC9 SRM 51-30-5, PG 1-22, INSTALLED ID TAG PER DC9 PS 900-5-1, NR 4.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

FLOOR SUPPORT ANGLE CRACKED, BENT, AND HAS LIGHT CORROSION, STA 180 BETWEEN BL-0 AND RBL-44. REMOVED DAMAGED FLOOR SUPPORT ANGLE AT STA 180, BETWEEN BL 0 AND RBL 44 IAW DC9 SRM 51-30-2, PG 26. FABRICATED NEW SUPPORT ANGLE IAW SRM DC9 53-13-1, PGS 25-26, INSTALLED NEW FABRICATED ANGLE AT STA 180, BL 0 AND RBL 44 IAW DC9 SRM 51-30-2, PGS 1-4.

Part: FLOOR PANEL — DENTED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL 75 HAS A DENT, PNL IS OFF A/C PART 861-KK-74. RII: Y. FABBED & INSTALLED REPAIR DOUBLER AS PER DC9 SRM 51-30-2, PG 24-26B, PAR 7 ON CABIN FLOOR PNL 75, MARKED USING REPAIR IDENTIFICATION REQUIREMENTS USING PROCESS STANDARD 900-5-1, NR 4, PG 1-6.

Part: PAN — CRACKED (WINDOW) · airframe 75,864 hrs · 73,207 cycles

MAIN CABIN, STA Y794, LONG 12LT, WINDOW PAN WITH CRACK. CUT OUT DAMAGE MAIN CABIN WINDOW RING PAN AT STA Y794, LONGERON 12LT PER DC9 SRM 53-05, FIG 122. FABRICATED REPAIR DBLR MAIN CABIN WINDOW RING PAN USING FABBED SHIM, FABBED REPAIR WASHER, TREATED AND PRIMED ALL PARTS PER DC9 SRM 51-10-3, (PG 31 & 40). INSTALL PARTS PER DC9 SRM 53-05, FIG 122 PER DC9 SRM 51-30-2 AND SRM DC9 51-30-5.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 75,864 hrs · 73,207 cycles

CABIN FLOOR PNL 102A, THREE EA FASTENER HOLES SHOWING WEAR AND PITTING. REMOVED CABIN FLOOR PANEL 102A ON TASK CARD 0590-0020-8M, CORROSION REMOVED IAW DC9 SRM 53-01, IN LIMITS PER DC9 SRM 53-02, PG 8. FABBED REPAIR DOUBLERS IAW DC9 SRM 53-05, PG 12, TREATED AND PRIMED FLOOR PANEL AND REPAIR DOUBLERS PER DC9 SRM 51-10-3, PG 30-31, INST FLOOR PANEL 102A & REPAIR DOUBLERS IAW SRM 53-05 PG 12.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

SEAT TRACK RBL 44 HAS AREAS OF CORROSION FROM STA 200 TO 318. REMOVED CORROSION FROM SEAT TRACK PER DC9 SRM 51-10-3, PG 47, FOUND TO BE OUT OF LIMITS AT STA 200 TO 203 RBL 44 PER DC9 SRM 53-05, FIG 4B. REMOVED AND REPLACED SEAT TRACK SECTION AT STA 200 TO 266.5 RBL 44 PER DC9 SRM 51-30-5, PG 24, TRAVELER 87929350001, DC9 SRM 51-30-4, PARA 2, FIG 3A, DC9 SRM 51-30-5, PARA 7, PG 12.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 75,864 hrs · 47,758 cycles

FLOOR SUPPORT ANGLE HAS CORROSION STA 200 BETWEEN RBL 22 AND RBL 44. REMOVED OUT OF LIMITS FLOOR SUPPORT ANGLE IAW DC9 SRM 51-10-3, PG 46. FOUND TO BE OUT OF LIMITS IAW DC9 SRM 53-01 PG 8. FABRICATED FLOOR SUPPORT ANGLE AT STA 200, RBL 22 RBL 24 IAW DC9 SRM 53-13-1 PG 25/26. INSTALLED FLOOR SUPPORT ANGLE IAW DC9 SRM 51-30-5 PG 12.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

SEAT TRACK LBL 44 HAS AREAS OF CORROSION FROM STA 200 TO 318. REMOVED CORR PER DC9 SRM 51-10-3, PG 3, 5. ORIGINAL .070 PER DC9 SRM 51-10-1, SRM 53-23-0, FIG 4 OUT OF LIMITS PER DC9 SRM 53-05, PG 28, REMOVED SEAT TRACK DC9 SRM 51-30-5, PG 29. FABBED SEAT TRACK PER DWG 5910754. LOCATED & DRILLED SEAT TRACK PER DC9 SRM 51-10-4, PG 1, TREATED & PRIMED SEAT TRACK PER DC9 SRM 51-10-3, INSTALLED SEAT TRACK, IAW SRM 51-30-5, PG 12.

Part: DOUBLER — DENTED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

LT EXTERIOR FUSELAGE EXTERNAL DOUBLER REPAIR IS DENTED AT BSTA Y235 AND BETWEEN LONGERONS 17L AND 18L (MAJOR REPAIR). RII: Y. REMOVED EXISTING DOUBLER, TRIMMED SKIN DAMAGE, HFEC NO DAMAGE NOTED, FABRICATED AND, INSTALLED REPAIR PARTS FROM STA 229 TO STA 249, STR 18L TO S16L IAW DC9 SRM 53-04, FIG 12B, PAGE 60F, AND INSTALLED ID TAG PER PS 900-5-1, NO 4.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

FLOOR SUPPORT ANGLE HAS AREAS OF CORROSION BL 0 FROM STA 160-318 BL 0. REMOVED CORROSION OUT OF LIMITS PER DC9 SRM 53-01, FIG 1, PG 8. REMOVED AND FABBED (2EA) FLOOR SUPPORTS SECTION PER DC9 SRM 53-13-1, FIG 11, PG 25-26 AND INST NEW FLOOR SUPPORTS IAW DC9 SRM 51-30-5, PG 12, PARA 7. TREATED AND PRIMED FLOOR SUPPORTS IAW DC9 SRM 51-10-3 STA 160 TO 318, BL 0.

Part: PANEL — GOUGED (TE FLAP) · airframe 75,864 hrs · 73,207 cycles

RT WING T/E FLAP PANEL 1860NW HAS DEEP GOUGE CA415 (MAJOR REPAIR) RII: Y. CUT OUT DAMAGED AREA AT R/WING T/E PANEL, FABRICATED & INSTALLED DOUBLER REPAIR AND FILLER AT R/W T/E PANEL 1680NW IAW DC9 SRM 51-30-2, PAGE 8. RE-INSTALLED T/E PANEL, INSTALLED ID TAG IAW DC9 PROCESS STANDARD 900-5-1, NR 4.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

MAIN CABIN STA Y851, LONG 4 RT WITH CRACK GM007 (MAJOR REPAIR) RII: Y. REMOVED AND REPLACED LONGERON AT MAIN CABIN BETWEEN STA 851-870 S-4R PER DC9 SRM 53-02, FIG 18, PG 51 AND DC9 SRM 51-30-5. CUT AND REMOVED 20 INCH SECTION OF LONGERON 4 RT, FROM STA 851-870 PER DC-9 SRM 53-02, FIG 18.

Part: SKIN — DENTED (FUSELAGE) · airframe 75,864 hrs · 73,207 cycles

EXTERIOR FUSELAGE RT BETWEEN L-16 AND L-17 AT FS 200 IS DENTED. MEASURED SKIN DENT DUE TO PROXIMITY OF FRAME, OUT OF LIMITS IAW DC9 SRM 53-04, PG 217. CONDITION 1B. FABBED DOUBLER REPAIR IAW DC9 SRM 53-04, PG 218K. TREATED AND PRIMED DOUBLER REPAIR IAW DC9 SRM 51-10-3, PG 31-40, INSTALLED IAW DC9 SRM 53-04, PG 218K, FIG 38, INSTALLED ID TAG PROCESS STANDARD 900-5-1, NR 4.

Part: SEAL — CRACKED (SLATS) · airframe 75,706 hrs · 73,068 cycles

METAL SEAL BETWEEN NR 2 & NR 3 LT WING SLATS CRACKED. NO DAMAGE PROGRESSION FOUND. REPAIRED LT NR 2 SLAT SEGMENT SEAL IAW ER/A491825-14, OK FOR SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 75,453 hrs · 72,852 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE OVERHEAD EMERGENCY ESCAPE LIGHTING IN THE A SECTION OF THE CABIN WAS INOPERATIVE. MAINTENANCE REPLACED THE BATTERY PACK AND THE LIGHTS RETURNED TO AN OPERATIONAL CONDITION.

Part: CONNECTOR — DISCONNECTED (CABIN) · airframe 74,432 hrs · 71,978 cycles

DURING LINE CHECK, MX FOUND THAT THE EMERGENCY PATHWAY LIGHTING AT SEAT 17D IN THE CABIN IS INOPERATIVE. MX FOUND A CONNECTOR IN THE WIRE HARNESS UNPLUGGED, RECONNECTED IT, AND FUNCTIONALLY CHECKED THE SYS.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 74,156 hrs · 47,758 cycles

DURING LINE CHECK FOUND 1 FOOT GASH AND 1 INCH SKIN PUNCTURE APPROXIMATELY 5 FEET IN FRONT OF FORWARD CARGO DOOR. REPAIRED PER DWG SG09530002 AND ERA 483946-14 RII CLASS II REPAIR ACCOMPLISHED. INITIAL 20,000 CYCLE INSPECTION, WITH FOLLOW UP INSPECTIONS AT 15,000 CYCLE INTERVALS.

Part: CHANNEL — CRACKED (MLG WW) · airframe 73,411 hrs · 71,101 cycles

DURING "L" CHECK FOUND U CHANNEL CRACKED, AT 1B/6 NLG WHEEL WELL 3.5" AFT OF FWD RT LOWER CORNER U CHANNEL. REPAIRED IAW SRM 51-72-01, SRM 51-10-5, AND SRM 51-30-5.

Part: LONGERON — CRACKED (BS 1230-1247) · airframe 73,411 hrs · 71,101 cycles

DURING "L" CHECK FOUND CRACK IN LONGERON AT BS 1230-1247 L12R. REPAIRED IAW SRM 53-02-18, SRM 51-30-2, SRM 51-30-5.

Part: FRAME — CRACKED (BS 1209) · airframe 73,411 hrs · 71,101 cycles

DURING "L" CHECK FOUND FRAME WEB AT STA 1209, FRL12L, WAS CRACKED, AT LIGHTING HOLE. REPAIRED IAW SRM 51-70-4.

Part: CONNECTOR — DISCONNECTED (CABIN) · airframe 73,065 hrs · 70,812 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE EMERGENCY PATHWAY LIGHTING AT ROW 16 OF THE CABIN WAS INOPERATIVE. MAINTENANCE FOUND A CONNECTOR IN THE WIRE HARNESS UNPLUGGED, RECONNECTED IT, AND FUNCTIONALLY CHECKED THE SYSTEM.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 71,974 hrs

DURING LINE CHECK, MAINTENANCE FOUND THAT THE LEFT OVERWING EMERGENCY EXIT SIGN WAS INOPERATIVE. MAINTENANCE REPLACED THE BATTERIES. OPERATIONAL CHECK WAS GOOD.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

DURING LINE CHECK, MAINT FOUND THAT THE EMERGENCY PATHWAY LIGHTING FOR THE CATWALK IN THE TAIL COMPARTMENT WAS INOPERATIVE. MAINT REPLACED THE BATTERIES IN THE POWER SUPPLY AND THE LIGHTS RETURNED TO AN OPERATIONAL CONDITION. (K)

Part: ANGLE — CRACKED (WINDOW FRAME) · airframe 78,004 hrs · 75,417 cycles

DURING H CHECK, THE RT STA 83 ANGLE WAS FOUND CRACKED WHILE PERFORMING AN INSPECTION IAW EM5300-01041-08B. ACCOMPLISHED PERMANENT REPAIR AT COCKPIT WINDOW SILL BS 83.550 RT ANGLE FASTENERS REPLACEMENT IAW ERA 498419-14AD REV ORIGINAL SECTION 1.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 70,123 hrs · 68,246 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE EMERGENCY FLOOD LIGHT FOR THE AFT EVACUATION SLIDE WAS NOT FUNCTIONAL. MAINTENANCE FOUND THE BATTERY PACK B5-28 FAULTY AND REPLACED IT. OPERATIONAL CHECK WAS GOOD.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHTS) · airframe 69,973 hrs · 68,123 cycles

DURING LINE CHECK, THE EMERGENCY OVERWING EXIT SIGNS AT ROWS 10, 11, AND 12 WERE FOUND TO BE INOPERATIVE. MAINTENANCE REPLACED THE EMERGENCY EXIT LIGHT POWER SUPPLY AND OPERATIONALLY CHECKED THE SYSTEM.

Part: FLOORBEAM — TOOL DAMAGE (BS 148) · airframe 67,454 hrs · 65,996 cycles

DURING "L" CHECK, FOUND DRILL START IN THE UPPER FLANGE OF THE FLOORBEAM AT BS 148 RBL 13. REPAIRED PER EA 98-208456.

Part: UNKNOWN — UNKNOWN (FLT CONTROLS) · airframe 67,378 hrs · 65,842 cycles

CREW REPORTED FLIGHT CONTROL PROBLEMS DURING CRUISE AT ALTITUDE. AIRCRAFT DECLARED AN EMERGENCY, WAS CLEARED TO LOWER ALTITUDE IN ATTEMPT TO THAW ANY POSSIBLE ICING OF CABLES, AND DIVERTED TO BUF. THE LANDING WAS NORMAL AND WITHOUT FURTHER INCIDENT. MAINTENANCE DID INSPECT THE AIRCRAFT UPON ARRIVAL BUT DID NOT FIND ANY EVIDENCE OF ICE PROBLEMS.

Part: HYDRAULIC LINE — RUPTURED (HYDRAULIC SYS)

AT ABOUT 6000 FEET ON APPROACH FOR LANDING THE AIRCRAFT LOST ALL HYDRAULIC FLUID IN THE RIGHT SYSTEM. COM PROCEDURES WERE COMPLIED WITH AND THE CREW DECLARED AN EMERGENCY WITH AIR TRAFFIC CONTROL. THE LANDING WAS UNEVENTFUL AND THE AIRCRAFT WAS TOWED TO THE GATE. MAINTENANCE FOUND THE AUXILIARY PUMP PRESSURE LINE RUPTURED AND REPLACED IT. ALSO REPLACED THE RIGHT ENGINE DRIVEN HYDRAULIC PUMP AND THE ELECTRIC DRIVEN HYDRAULIC PUMP. SYSTEM WAS SERVICED, LEAK CHECKED, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONTROL CABLE — OUT OF RIG (NR 1 & 2 SLATS) · airframe 60,680 hrs · 59,682 cycles

ON INITIAL SLAT EXTENSION THE AIRCRAFT ROLLED TO THE RIGHT AND THE BLUE SLAT DISAGREEMENT ANNUNCIATOR LIGHT ILLUMINATED AND THE SLAT EXTEND INDICATOR DID NOT ILLUMINATE. AFTER ABOUT 45 SECONDS THE EXTEND DID LIGHT UP AND THE DISAGREE EXTINGUISHED. FLIGHT CONTROL WAS NORMAL AFTER THAT AND THE LANDING WAS UNEVENTFUL. MAINTENANCE FOUND THE SLAT CONTROL CABLES HAD LOW TENSION AND THE NR 2 SLAT DRIVE STOP WAS HITTING. ALL OF THE SLAT CABLES WERE RIGGED AND THE STOPS ADJUSTED. OPERATIONAL CHECK WAS GOOD AND THE AIRCRAFT HAS RETURNED TO SERVICE.

Part: BULKHEAD — CRACKED · airframe 58,572 hrs · 57,802 cycles

During Mck in ATL, a .65" crack was found in the upper bend radius of the APB channel.Repaired per EA 98-189685.

Part: SKIN — CORRODED · corrosion level 2 · airframe 58,572 hrs · 57,802 cycles

During MCK in ATL, corrosion was found in a temporary repair in the lower forward VHF antenna between stations 465-484 and longeron 30. After removal of repair several cracks were found. Repaired per EA 98-189679.

Part: INTERCOSTAL — CRACKED · airframe 58,572 hrs · 57,802 cycles

During MCK in ATL, a crack was found on intercostal 991157-3 at sta. 148.5 to 160. approx. z 44. Repaired per EA 98-189671.

Part: INTERCOSTAL — CRACKED · airframe 58,572 hrs · 57,802 cycles

During MCK in ATL, At sta 180 a crack found on the 9923484 intercostal at X=20. Repaired per EA 98-189693.

Part: POWER SUPPLY — INOPERATIVE (OVERWING EXIT) · airframe 55,436 hrs · 54,990 cycles

DURING L-CHECK, FOUND NACELLE EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REPLACED THE BATTERY POWER PACKS. OPERATIONAL CHECK NORMAL.

Part: BATTERY — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND EMERGENCY LIGHTING INOPERATIVE IN THE FIRST CLASS SECTION CEILING. MAINTENANCE REPLACED BATTERIES. OPERATIONAL CHECK NORMAL.

Part: BATTERY — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND FORWARD OVERWING EMERGENCY EXIT LIGHTS INOPERATIVE. MAINTENANCE REPLACED BATTERIES, OPERATIONAL CHECK OK.

Part: FUEL PUMP — FAILED (LT ENGINE)

AS TAKEOFF POWER WAS APPLIED, THE LEFT ENGINE WAS UNRESPONSIVE TO THROTTLE MOVEMENT. CREW ABORTED TAKEOFF AND RETURNED TO THE GATE. MAINTENANCE REPLACED THE LEFT ENGINE FUEL PUMP ASSEMBLY, OPERATIONAL CHECK OK.

Part: FRAME — CRACKED (BS 1314)

DURING L CHECK, FOUND A CRACK IN TAIL INTERIOR LEFT SIDE FRAME AT FS 1314 AFT SIDE 10 O'CLOCK POSITION. REPAIRED PER EA 98-151768.

Part: PRESSURE VALVE — MALFUNCTIONED (LT ENGINE)

AS TAKEOFF POWER WAS APPLIED, THE LEFT ENGINE EXPERIENCED COMPRESSOR STALLS. CREW ABORTED TAKEOFF AND SHUT DOWN THE LEFT ENGINE. MAINTENANCE INSPECTED THE LEFT ENGINE INLET AND REPLACED THE PRESSURE AND DUMP VALVE. ENGINE OPERATIONAL CHECK OK.

Part: OVERHEAT SENSOR — FAILED (TAIL COMPT)

TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED INTERMITTENTLY DURING CLIMB-OUT OF MSP. FLIGHT RETURNED TO MSP AND LANDED WITHOUT INCIDENT. REPLACED BOTH OVERHEAT SENSORS IN TAIL COMPARTMENT. OPERATIONAL CHECK OK.

Part: TRANSMITTER — FAILED (LT ENGINE)

EN ROUTE, NR 1 ENGINE OIL QUANTITY INDICATION BEGAN DECREASING. THE FLIGHT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE OIL QUANTITY TRANSMITTER AND INDICATOR WITH SERVICEABLE UNITS. OIL QUANTITY SYSTEM OPERATION SATISFACTORY.

Part: GUIDE PINS — WORN (TAILCONE)

DURING LINE CHECK, FOUND THAT IT TOOK EXCESSIVE FORCE TO DEPLOY TAILCONE. ALSO, FOUND FOUR GUIDE PINS WORN. REPLACED GUIDE PINS AND ADJUSTED INTERIOR HANDLE RELEASE PRESSURE.

Part: BATTERY — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND CEILING EMERGENCY LIGHTS INOPERATIVE FROM ROW 25 AFT. REPLACED BATTERIES, OPERATIONAL CHECK OK.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING LINE CHECK, FOUND AFT OVERWING EMERGENCY EXIT LIGHTS INOPERATIVE. REPLACED POWER SUPPLY AND BATTERIES. OPERATIONAL CHECK GOOD.

Part: FLOOR BEAM — CORRODED (FS 1136)

DURING H-CHECK, FOUND CORROSION ON THE FS 1136 FLOOR BEAM UPPER CAP UNDER THE RIGHT LAV INBOARD FLOOR SUPPORT. REPAIRED BEAM (P/N 9912243-55) PER EA 98-109466.

Part: FITTING — CRACKED (PAX DOOR)

DURING H-CHECK, FOUND A CRACK IN THE AFT ENTRY DOOR UPPER BEAM FITTING. REPLACED FITTING PER SRM 51-10-04.

Part: FLOOR BEAM — CORRODED (FS 1167)

DURING H-CHECK, FOUND CORROSION ON THE FS 1167 FLOOR BEAM UPPER CAP FROM THE RIGHT CUSP TO THE RIGHT INBOARD LAV WALL. REPAIRED BEAM (P/N 9915561-1) PER EA 98-109486.

Part: FLOOR BEAM — CORRODED (FS 1151)

DURING H-CHECK, FOUND CORROSION ON THE FLOOR BEAM UPPER CAP AT FS 1151 LEFT SIDE. REPAIRED BEAM (P/N 9958188-1) PER EA 98-109489.

Part: REGULATOR — MALFUNCTIONED (PASS OXY SYST)

DURING CHECK OF PASSENGER OXYGEN SYSTEM IN MANUAL POSITION, PRESSURE ROSE TO 60 PSI AND OXYGEN MASKS WERE DEPLOYED THROUGHOUT THE CABIN. REPLACED THE PASSENGER OXYGEN BOTTLE AND REGULATOR, RE-STOWED ALL MASKS. OPERATIONAL CHECK NORMAL AND AIRCRAFT RETURNED TO SERVICE.

Part: STRUT — UNDERSERVICED (NLG)

LANDING GEAR HANDLE WOULD NOT RAISE AND AIRCRAFT FAILED TO SHIFT FROM GROUND MODE TO FLIGHT MODE AFTER TAKEOFF. FLIGHT RETURNED TO YWG AND LANDED WITHOUT INCIDENT. FOUND NOSE STRUT UNDERSERVICED. SERVICED STRUT TO PROPER LEVELS. OPERATIONAL CHECK NORMAL AND AIRCRAFT RETURNED TO SERVICE.

Part: SPRING ROD — FAILED (NLG)

LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF. THE NOSE WHEEL STEERING WAS OPERATIONAL AND THE AIRCRAFT WOULD NOT PRESSURIZE. THE FLIGHT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. FOUND SPRING ROD TO GROUND SHIFT MECHANISM HAD FAILED. REPLACED THE SPRING ROD. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE.

Part: HYD PUMP — LEAKING (LT ENGINE)

DTW - ON APPROACH, LOSS OF LEFT HYDRAULIC FLUID AND PRESSURE OCCURRED AFTER AUXILIARY AND ALTERNATE PUMPS WERE ACTIVATED. FOLLOWED COCKPIT OPERATING PROCEDURES AND LANDED WITHOUT INCIDENT. FOUND LEFT ENGINE HYDRAULIC PUMP LEAKING FROM SCREW HOLE AT BOTTOM OF PUMP. HOLE THREADS WERE STRIPPED WITH SCREW HANGING FROM SAFETY WIRE. REPLACED THE LEFT ENGINE HYDRAULIC PUMP AND OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE.

Part: CONTROL UNIT — MALFUNCTIONED (RIGHT)

RIGHT ICE PROTECTION TEMPERATURE LOW LIGHT REMAINED ON AFTER TAKEOFF. LIGHT EXTINGUISHED AFTER WORKING WITH CROSSFEED. LEFT SUPPLY TEMPERATURE HIGH LIGHT THEN ILLUMINATED. FLIGHT RETURNED TO MSP AND LANDED WITHOUT INCIDENT. REPLACED THE RIGHT THERMAL CONTROL UNIT AND RIGHT LOW TEMPERATURE SENSOR. OPERATIONAL CHECK OK, AND AIRCRAFT RETURNED TO SERVICE.