N775AX

Part: ESCAPE REEL — UNWANTED DEPLOY (CABIN) · airframe 59,420 hrs · 43,325 cycles

WHILE PERFORMING INSPECTION OF THE DESCENT DEVICES, TWO DESCENT DEVICES FELL TO THE FLOOR, BREAKING THE SEALS. THE AIRPLANE WAS REMOVED FROM SERVICE (GROUNDED) UNTIL THE DESCENT DEVICES WERE REWOUND, RESEALED, AND RESTOWED. THE CAUSE FOR THE DESCENT DEVICES FALLING TO THE FLOOR IS UNKNOWN.

Part: ESCAPE ROPE — INOPERATIVE (CABIN) · airframe 59,315 hrs · 43,270 cycles

ONE DESCENT DEVICE WAS FOUND NOT PROPERLY STOWED AND INOPERATIVE DURING THE FLIGHT CREW’S PRE-FLIGHT INSPECTION. THE AIRPLANE WAS REMOVED FROM SERVICE (GROUNDED) UNTIL THE DESCENT DEVICE WAS DEFERRED. THE NEXT DAY, THE AIRPLANE WAS REMOVED FROM SERVICE (GROUNDED) WHILE THE DESCENT DEVICE WAS REPLACED WITH A SERVICEABLE DESCENT DEVICE. THE CAUSE FOR THE DESCENT DEVICE BECOMING INOPERATIVE WAS BECAUSE IT WAS UNSTOWED.

Part: TEE FITTING — CORRODED (FUSELAGE) · corrosion level 2 · airframe 58,843 hrs · 43,066 cycles

RIGHT T FITTING IS CORRODED AT THE FWD BOLT HOLES. NEW T FITTING DRILLED IAW SRM 57-40-05. NEW T FITTING TO BE INSTALLED ON DOCUMENT 47008ORD04. CORRODED LEVEL 2, PN 100T1440V4, PART NAME T FITTING, EXACT FS & BS LOCATION ON ACFT 955, EXACT STRINGER & WS LOCATION ON ACFT STRINGER 20R. ACFT WAS GNDED.

Part: TEE FITTING — CORRODED (FUSELAGE) · corrosion level 2 · airframe 58,843 hrs · 43,066 cycles

LEFT T FITTING IS CORRODED AT THE FWD BOLT HOLES. MATCH DRILLED THE NEW T FITTING IAW SRM 51-40-05. T FITTING TO BE INSTALLED ON JC DOCUMENT 47008ORD03. CORRODED LEVEL 2, PN 100T1440V3, PART NAME T FITTING, SN NSN, EXACT FS & BS LOCATION ON ACFT 955, EXACT STRINGER & WS LOCATION ON ACFT STRINGER 20L. ACFT WAS GNDED.

Part: FAILSAFE — CRACKED (FUSELAGE) · airframe 58,843 hrs · 43,066 cycles

LEFT WW FAILSAFE STRAP AT STATION 955 IS CRACKED AT LOWER FASTENER HOLE. REFERENCE DOCUMENT 47008ORD01 STEP 21. PERFORMED CUT OUT OF CRACKED FAILSAFE IAW DOCUMENT 47008ORD03. REASSEMBLY TO BE ACCOMPLISHED ON DOCUMENT 47008ORD03. CRACKED LENGTH .500". PN 145T2524U21, SN NSN, PART NAME FAILSAFE STRAP, EXACT FS & BS LOCATION ON ACFT FROM 955 TO EXACT STRINGER & WS LOCATION. ACFT WAS GNDED.

Part: FAILSAFE — CRACKED (FUSELAGE) · airframe 58,843 hrs · 43,066 cycles

RIGHT WW FAILSAFE STRAP AT STATION 955, IS CRACKED AT LOWER FASTENER HOLE. REFERENCE DOCUMENT 47008ORD02 STEP 21. PERFORMED CUT OUT OF FAILSAFE IAW DOC 47008ORD04. CRACKED LENGTH 1.100", PN 145T2524U22, SN NSN, PART NAME FAILSAFE STRAP, EXACT FS & BS LOCATION ON ACFT FROM 955 TO EXACT STRINGER & WS LOCATION ON ACFT FROM STRINGER 20R. ACFT WAS GNDED.

Part: SMOKE DETECTOR — FALSE ACTIVATION (ZONE 900) · airframe 58,019 hrs · 42,535 cycles

SERVICE AREA SMOKE ALARM SOUNDED, NO SMOKE OBSERVED. CLEANED GRILL & DETECTOR UNIT. OPERATION CHECKED GOOD.

Part: SMOKE DETECTOR — FALSE ACTIVATION (LAVATORY) · airframe 58,016 hrs · 42,533 cycles

LAVATORY SMOKE ALARM SOUNDED. NO SMOKE OBSERVED. LAVATORY SMOKE DETECTOR OPERATION CHECKED GOOD.

Part: BEAM — CRACKED (NR 1 PYLON) · airframe 56,014 hrs · 41,427 cycles

NUMBER 1 PYLON SKIRT BEAM ON OTBD SIDE IS CRACKED & CHAFED AROUND FASTENER HOLES. R & R NR 1 PYLON SKIRT BEAM OTBD SIDE IAW B767 SRM 51-40-02, PN 313T1380-241, NSN. BEAM CHAFED 1/4 INCHES, BEYOND REPAIR & CRACKED, NAC 298.93 TO 365.4 NAC WL 120. ACFT WAS GNDED.

Part: GUSSET — CORRODED (NR 1 PYLON) · airframe 56,014 hrs · 41,427 cycles

NUMBER 1 ENG PYLON FWD EDGE UPPER STRUCTURE HAS CHAFED AREA TO BARE METAL, WITH INLET REMOVED. R & R -36 CHAFFED GUSSET ON NR 1 ENG PYLON FWD UPPER EDGE IAW B767 SRM 51-40-2, PN 311T1510-36, NSN, GUSSET CHAFED FROM NAC STATION 144.5. ACFT WAS GNDED.

Part: STIFFENER — CRACKED (NR 1 PYLON) · airframe 56,014 hrs · 41,427 cycles

NR 1 PYLON FWD OF PANEL 437DB INSIDE STRUCTURE LOWER CROSS BRACE HILOCK LOOSE. R & R NEW FABRICATED PADS ON ALL AREAS DAMAGED. PN 313T3380-303 WEB & FRAME 1INCH CRACK, PN 313T1355-169 SPLICE 2 1/2 INCHES CRACK, PN 313T1355-181 1 INCH CRACK 313T3380-244 & 313T3380-193 CHANNEL STIFFENER ELONGATED HOLES. FROM NAC 353-34 TO NAC 410.59, FROM NAC WL120. AIRCRAFT WAS GROUNDED.

Part: SKIN PANEL — CORRODED (LT WING) · airframe 56,014 hrs · 41,427 cycles

UPPER TRAILING PANELS FWD OF OTBD AILERON RAISED IN TWO SPOTS ON PANEL LE. R & R UPPER TE PANELS IAW B767 SRM 51-40-02 PARA 4 & PARA 7. REPAIRED CORRODED SKIN IAW ABX REA B657-60785-MR REV IR DATED 11-14- 13. PN 112T3101, PN SKIN PANEL, SN NSN, CORRODED, A/C LOS STINGER & WS 1031. AIRCRAFT WAS GROUNDED.

Part: CHANNEL — CORRODED (RT WING) · airframe 56,014 hrs · 41,427 cycles

REAR SPAR TO TE PANEL ATTACH CHANNEL AT WING STATION 1046 SPLIT ON EDGE. FABRICATED NEW CHORD ON RFA B657-60757 REMOVED OLD CHORD & INSTALLED NEW CHORD IAW B767-200 SRM 51-40-02. CORRODED PN 113T1683-14 PN CHORD RIGHT WING LOWER TE EXACT STRINGER & WS LOCATION ON A/C WS 1146 TO WS 1146. AIRCRAFT WAS GROUNDED.

Part: SPAR — CORRODED (HORIZ STAB) · airframe 54,270 hrs · 40,377 cycles

CORROSION SPOT ON TOP OF REAR SPAR OF LEFT HORIZ STAB REPAIRED ON REA B655-59696-MR, AWG

Part: SPAR — CORRODED (HORIZ STAB) · airframe 54,270 hrs · 40,377 cycles

SPOT OF CORROSION ON TOP OF REAR SPAR OF LEFT HORIZ STAB REPAIRED ON REA B655-59696-MR, A/W/G.

Part: RIB — CORRODED (HORIZ STAB) · airframe 54,270 hrs · 40,377 cycles

CORROSION SPOT ON TOP OF RIB AT LEFT HORIZ STAB REAR SPAR TO TRAILING EDGE AT STA 226. REPAIRED ON REA B7655-59696-MR, AWG.

Part: SPAR — CORRODED (ZONE 300) · airframe 54,270 hrs · 40,377 cycles

CORROSION SPOT ON REAR SPAR UPPER CAP ON LT HORIZONTAL STAB AT SS 238. REPAIRED ON REA B655-59696-MR.

Part: SPAR — CORRODED (HORIZ STAB) · airframe 54,270 hrs · 40,377 cycles

CORROSION SPOT ON TOP OF REAR SPAR OF LEFT HORIZ STAB STA 318 TO 335. REPAIRED ON REA B655-59696-MR, A/W/G.

Part: SPAR — CORRODED (HORIZ STAB) · airframe 54,270 hrs · 40,377 cycles

CORROSION SPOT MARKED NR 4 ON TRAILING EDGE UPPER SPAR OF LEFT HORIZ STAB AT STA 287. REPAIRED IAW REA B655-55695-MR, A/W/G.

Part: SPAR — CORRODED (HORIZ STAB) · airframe 54,270 hrs · 40,377 cycles

CORROSION SPOT ON RIB OF LEFT HORIZ STAB FROM REAR SPAR TO TRAILING EDGE AT STA 335. REPLACED "T" CORD IAW B767 SRM 51-40-02, AWG.

Part: SPLICE PLATE — CRACKED (LT WING) · airframe 54,270 hrs · 40,377 cycles

LEFT WING OUTBD UPPER L/E SPLICE PLATE CRACKED AT APPOX LWS 564. REPAIRED IAW REA B651-59661, AIRCRAFT WAS GROUNDED.

Part: RIB — CORRODED (HORIZ STAB) · airframe 54,270 hrs · 40,377 cycles

CORROSION SPOT ON RIB AT REAR SPAR TO TRAILING EDGE OF LEFT HORIZ STAB AT STA 323. REPLACED "T" CORD B767 SRM 51-40-02, A/W/G.

Part: SKIN — GOUGED (FUSELAGE) · airframe 54,270 hrs · 40,377 cycles

FUSELAGE SKIN IS GOUGED AT FLC DOOR CUTOUT AREA LOWER FWD. REPAIRED IAW REA B653-59680.

Part: SHIM — CORRODED (HORIZ STAB) · airframe 54,270 hrs · 40,377 cycles

RT HORZ STAB TRAILING EDGE UPPER SURFACE BONDED PANEL BULGED AROUND FASTENER, LOCATED AFT OF RIB 13. REPLACED CORRODED SHIM AT RIB 13 IAW B767-200 SRM 51-20-11. ELEVATOR STA 335.109 AIRCRAFT WAS GROUNDED.

Part: FITTING — DENTED (LT PYLON) · airframe 54,270 hrs · 40,377 cycles

LEFT ENGINE BACK UP FITTING OUTBOARD OF RIB 8 HAS 3 SMALL TOOLING MARKS. REMOVED TOOLING MARKS IAW REA B657-59674, AIRCRAFT WAS GROUNDED.

Part: WEB — CRACKED (VERTICAL STAB) · airframe 542,701 hrs · 40,377 cycles

VERT STAB PANEL 324CLX ACCESS, LWR LT FWD ANGLE CRACKED INSIDE AUX BOX. REMOVED WEB AND ANGLE, FABRICATED ANGLE IAW BOEING DWG 173T1215. RE-INSTALLED FABRICATED ANGLE AND ORIGINAL WEB IAW 767 SRM 51-40-2.

Part: ESCAPE REEL — DEPLOYED (CABIN) · airframe 54,082 hrs · 40,265 cycles

FOUR ESCAPE REELS DEPLOYED AFTER LANDING. INSTALLED 4 EMERGENCY ESCAPE REELS PER B767 AMM 25-61- 03-4. PART EFFECTIVITY VERIFIED, AIRCRAFT WAS NOT GROUNDED.

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 53,612 hrs · 39,962 cycles

EXTERIOR EMERGENCY LIGHT AT LOWER AFT CORNER OF MED DOES NOT ILLUMINATE WHEN EMERGENCY LIGHT SWITCH IS PLACED TO "ON". RELAMPED, OP CHECK GOOD.

Part: SMOKE DETECTOR — FALSE ACTIVATION (CARGO BAY) · airframe 53,022 hrs · 39,592 cycles

DETECTED FIRE/SMOKE IN MAIN CARGO COMPARTMENT. DECLARED EMERGENCY AND RETURNED TO LAND AT CVG. COMPLIED WITH OVERWEIGHT LANDING INSPECTION IAW 05-51-35-2 PHASE 1 OPTION A. NO DEFECTS FOUND. INSPECTED MAIN AND LOWER CARGO COMPARTMENTS, NO DEFECTS OR SMOKE NOTED. INSPECTED MEC COMPARTMENT AND INSIDE P31, P32, P33, P34, P36 AND P37 PANELS, NO DEFECTS NOTED. CHECKED TRASH CONTAINERS IN LAV AND GALLERY AREA. NO DEFECTS NOTED. OPERATED APU AND OPERATED AIR CONDITIONING PACKS. RAN BOTH ENGINES TO APPROXIMATELY 80 PERCENT N1 WITH AIRCRAFT PACKS OPERATING. NO SMOKE NOTED. CHECKED ALL CIRCUIT BREAKERS IN COCKPIT AND MEC. NO BREAKERS POPPED AND NO STATUS MESSAGES ON EICAS. PRESSURIZED AIRCRAFT AND NO FAULTS NOTED. PULLED DOWN CEILING PANELS IN SUPERNUMERARY AND INSPECTED THE TWO ELECTRIC HEATERS, LIGHT ASSYS AND WIRING. CHECKED WIRING AROUND OUTFLOW VALVE. AIRCRAFT RELEASED FOR EVAL FLIGHT. COMPLIED WITH EVAL FLIGHT, NO SMOKE NOTED.

Part: FIRE WARNING — FALSE ACTIVATION (COCKPIT) · airframe 52,535 hrs · 39,293 cycles

WHEEL WELL FIRE ANNUNCIATOR LIGHT ON FORWARD PANEL COME ON DURING CRUISE. COMPLIED WITH ABNORMAL, FIRE TEST NORMAL. DEFERRED. WHEEL WELL LIGHT WILL NOT STAY ON WITH WHEEL WELL FIRE TEST OR LAMP TEST. TRIED NEW KORRY SWITCH & RELAY K693 - NO HELP.

Part: SLAT TRACK — CORRODED (LE SLAT) · airframe 52,298 hrs · 39,116 cycles

NR 11 SLAT I/B AND O/B MAIN TRACKS HAVE SURFACE CORROSION ON UPPER AND LOWER SURFACES. REMOVED AND REPLACED NR 11 SLAT MAIN TRACKS IAW B767 AMM 27-81-54-4. REMOVED AND REPLACED NR 11 SLAT IAW B767 AMM 27-81-02-4, OPS CHECK GOOD.

Part: SUPPORT — DAMAGED (TE FLAP) · airframe 52,298 hrs · 39,116 cycles

NR 2 FLAP SUPPORT ACTUATOR FASTENER HOLES 3 EACH, 2 FWD UPPER SMALL DIA AND 1 LARGE AFT UPPER CENTER HOLE HAVE EDDY CURRENT INDICATION USING HOLD SCAN IAW 50-04 AND 51-00-16 PART 6 767 NDT. REWORKED HOLES AND INSTALLED FREEZE PLUGS IAW REA B657-58806-MR.

Part: SUPPORT — CORRODED (LT WING) · airframe 52,298 hrs · 39,116 cycles

LT WING L/E SUPPORT CORRODED ABOVE WING FUEL PANEL. REMOVED CORROSION. FOUND LT WING L/E SUPPORT TO BE OUT OF LIMITS. REPAIRED LT WING L/E SUPPORT IAW 767-200 SRM 57-41-09.

Part: CHANNEL — CRACKED (FUSELAGE) · airframe 52,298 hrs · 39,116 cycles

BULK CARGO COMPARTMENT FLOOR PANEL ATTACH HAT CHANNEL HAS VERTICAL ATTACH ANGLE CRACKED AT STA 1417 RBL 8. REMOVED AND REPLACED ATTACH ANGLE IAW B767 SRM 51-40-02.

Part: STRUCTURE — CRACKED (THRUST REVERSER) · airframe 52,298 hrs · 39,116 cycles

#1 ENG I/B THRUST REVERSER #13 CASCADE HAS 3 CRACKS. REMOVED AND REPLACED #13 CASCADE IAW B767 AMM 78-31-16-4

Part: SUPPORT — CORRODED (NR 3 SLAT) · airframe 52,298 hrs · 39,116 cycles

LT WING LE NR 3 SLAT INBD AUX TRACK HAS CORROSION ON INBD & OUTBD SUPPORTS. REMOVED CORROSION ON I/B SUPPORT IAW SRM51-10-02. REMOVED AND REPLACED SUPPORT IAW SRM 51-47-02

Part: RIB — CORRODED (ZONE 500) · airframe 52,298 hrs · 39,116 cycles

LT WING L/E SUPPORT HAS CORROSION JUST INBD OF OUTBD AUX TRACK NR 3 SLAT. REMOVED AND REPLACED RIB IAW SRM 51-40-2

Part: RIB — DAMAGED (WING) · airframe 52,298 hrs · 39,116 cycles

CLOSE OUT NOSE RIB AT LES 568 IS DAMAGED. REMOVED DAMAGED NOSE RIB FABRICATED NEW NOSERIB IAW B767 DWG 114T2512. INSTALLED NOSE RIB IAW B767-200 SRM 51-40-02

Part: RIB — CRACKED (LT WING) · airframe 52,298 hrs · 6,529 cycles

OUTBOARD NOSE RIB CRACKED AT NR 5 SLAT OUTBOARD DRIVE ROD CUTOUT. CRACK IS .75 INCH LONG. REMOVED AND REPLACED NOSE RIB IAW B767 SRM 51-40-02 AT NR 5 SLAT OUTBOARD DRIVE ROD CUTOUT.

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 52,298 hrs · 39,116 cycles

CRACK EMANATING FROM RIVET AT BS 1702 BETWEEN S7L TO S8L. CRACK IS .1250 INCH IN LENGTH. REPAIRED AREA IAW B767 SRM 53-80-01-FIG 201.

Part: STRUCTURE — CRACKED (NLG WW) · airframe 52,298 hrs · 39,116 cycles

THE NWW VERTICAL CHORD AT LBL 25 IS CRACKED APPROX .625 INCH IN LENGTH IN FLANGE LOCATED 11.5 INCHES BELOW CEILING PANEL. REPAIRED CRACKED CHORD AT LL25 IAW B767 SRM 51-70-12 FIG 1.

Part: RIB — CRACKED (LT WING) · airframe 52,298 hrs · 39,116 cycles

LEADING EDGE RIB AT STA OSS574.05 IS CRACKED ON THE FORWARD ENG AT CLOSEOUT RIB ATTACH HOLE. REMOVED DAMAGE AND INSTALL BUSHING IAW 767 SRM 51-20-07.

Part: FIRE DETECTOR — MALFUNCTIONED (LT NACELLE) · airframe 52,173 hrs · 39,049 cycles

26-11-05-01 FIRE PROTECTION SYSTEM FAIL LIGHT ILLUM EICAS MSG: FIRE/OVHT SYS DISPLAYED, ENG FIRE LP2 DISPLAYED. "OCCASIONALLY INTERMITTENT FIRE WARNING IN TURBULENCE." REMOVED AND REPLACED L ENGINE DETECTOR CARD ASSY IAW MM 26-10-1-4. REMOVED AND REPLACED AFT LOWER FIRE ELEMENT ASSY IAW 26-11-2-4. FIRE DETECTION SYSTEM CHKS GOOD OK FOR SERVICE.

Part: DUCT — LEAKING (BLEED AIR SYS) · airframe 52,179 hrs · 39,052 cycles

09/16/09 - 26-11-02-01 L ENG FIRE LP2 - TROUBLESHOT, NO FAULTS FOUND - RESISTANCE GOOD FOR ALL LOOP 2 DETECTORS. FWD LWR LOOP CHAFING, REPOSITIONED LOOP. 09/17/09 - 26 11 02 01 L ENG FIRE LP2 - DEFERRED. T/S SWAPPED FIRE DETECT CIRCUIT CARD. 09/18/09 WORKING DI T/S STATUS MSG FIRE LOOP EICAS INTERMITTENT. 09/19/09 - CREW REPORTS EICAS MESSAGE OF L ENG FIRE LP1 OR L ENG FIRE LP2. EICAS MSG L ENG LP2 MSG CAME ON AT T/O, STEADY AT CRUISE, MSG WENT OUT AT TOP OF DESCENT. NOTED BY MAINT. 09/22/09 - DI IN WORK LT ENG FIRE LOOP 2. CLR INSP ENGINE PNEUMATIC DUCTS FOUND DUCT LEAK AT FLEXIBLE BALL JOINT FOR 8TH STAGE AIR GOING TO PRECOOLER. REPOSITIONED PNEUMATIC DUCTS IAW B767 AMM 36-11-01-4. LEAK CHECK GOOD.

Part: BATTERY — DISCHARGED (CABIN) · airframe 51,769 hrs · 38,777 cycles

EMERGENCY LIGHTS WERE INOPERATIVE. REPLACED EMERGENCY LIGHT BATTERY, P/N 2013-1A IAW 767 AMM 33-51-07-2.

Part: FLAP — MALFUNCTIONED (WING) · airframe 51,669 hrs · 38,715 cycles

AFTER TAKEOFF, GEAR UP EICAS MSG TRAILING EDGE FLAP DISAGREEMENT LIGHT ILLUMINATED WITH FLAP LEVER IN UP DETENT. FLAPS INTO APPROX 3 DEGREE EXTENSION. FLAPS RETRACTED OK USING ALTERNATE PROCEDURE. FLAPS EXTENDED OK USING ALTERNATE PROCEDURE FOR LANDING FLAPS 20 DEGREE'S. C/W B767 FIM 27-51-00-1. NO DEFECTS NOTED, CYCLED FLAPS SEVERAL TIMES. CHECK GOOD.

Part: PRESSURE PANEL — CRACKED (RT MLG) · airframe 50,606 hrs · 38,223 cycles

RIGHT CANTED PRESSURE DECK IN RIGHT WHEEL WELL HAD APPROXIMATELY 6 INCH CRACK. REPAIRED CANTED PRESSURE DECK IN RIGHT WHEEL WELL IAW B767 SRM. CRACK LENGTHS WERE: 7 AND 3 INCHES.

Part: PRESSURE PANEL — CRACKED (LT MLG) · airframe 50,606 hrs · 38,223 cycles

LEFT CANTED PRESSURE DECK IN LEFT WHEEL WELL HAD APPROXIMATELY 4 INCH CRACK. REPAIRED CANTED PRESSURE DECK IN LEFT WHEEL WELL IAW B767 SRM 53-50-51.

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 50,606 hrs · 38,223 cycles

CRACK IN LOWER AFT CORNER OF THE FORWARD SERVICE DOOR CUTOUT. REPAIRED R1 LOWER AFT DOOR CORNER IAW REA B653-57148-MR.

Part: INTERCOSTAL — CORRODED (AFT CARGO DOOR) · airframe 50,606 hrs · 38,223 cycles

CORRODED INTERCOSTAL AT DOOR STA 181 BETWEEN BEAM NR 3 AND NR 4 AFT LOWER CARGO DOOR. REPAIRED AREA IAW B767 SRM 51-70-11.

Part: BEAM — CORRODED (AFT CARGO DOOR) · airframe 50,606 hrs · 38,223 cycles

AFT LOWER CARGO DOOR BEAM CORRODED JUST BELOW PRESSURE DOOR. REMOVED AND REPLACED BEAM IAW B767 SRM 51-40-02.

Part: BEAM — CORRODED (FWD CARGO DOOR) · airframe 50,606 hrs · 38,223 cycles

FORWARD CARGO DOOR BEAM CORRODED JUST BELOW PRESSURE DOORS. REMOVED AND REPLACED BEAM IAW B767 SRM 51-40-2.

Part: LIGHT — INOPERATIVE (COCKPIT) · airframe 49,569 hrs · 37,816 cycles

ON APPROACH AT ILN, RIGHT GEAR GREEN DOWN LIGHT FAILED TO ILLUMINATE WITH GEAR HANDLE DOWN. EICAS MESSAGE GEAR DISAGREE DISPLAYED, DOOR AMBER LIGHTS WERE EXTINGUISHED AND GEAR LIGHTS ILLUMINATED. EMERGENCY DECLARED. INDICATION NORMAL AFTER ALTERNATE GEAR EXTENSION. TESTED RIGHT MAIN LANDING GEAR POSITION INDICATION SYSTEM, LANDING GEAR MONITOR AND POSITIONER / GROUND CIRCUIT BREAKER IAW B767 AMM 32-61-00-5 PARA 3 H, K, J. NO FAULTS NOTED. REPLACED RIGHT MAIN LANDING GEAR KORRY LIGHT BULB RECEPTICAL. JACKED AIRCRAFT, CYCLED LANDING GEAR SEVERAL TIMES, NO DEFECTS NOTED. PSEU BITE CHECK OKAY, MEMORY CLEARED.

Part: SLIDE — MALFUNCTIONED · airframe 48,174 hrs · 37,315 cycles

EMERGENCY ESCAPE SLIDE WOULD NOT ARM. CHECKED RAILS AND HANDLE FOR OBSTRUCTIONS, NONE FOUND. OPERATED DOOR AND SLIDE, OPS CHECKED GOOD.

Part: ROD — DAMAGED (THRUST REVERSER) · airframe 47,865 hrs · 37,195 cycles

AIRCRAFT HAS ROUGH VIBRATION SHAKES LEFT TO RIGHT. INSPECTED LEFT AND RIGHT WING FLAPS AND FAIRINGS, AILERONS, SLATS, ELEVATORS. PERFORMED VISUAL INSPECTION OF NR 1 ENGINE AND CHIP DETECTOR, NO FINDINGS. INSPECTED NR 2 ENGINE, CHIP DETECTOR (MASTER) AND COWLING & T/R HOLD OPEN RODS. REMOVED AND REPLACED NR 2 ENG T/R OUTBOAD HOLD ROD IAW B767 MM 78.31.00. MAINTENANCE EVALUATION FLIGHT REQUESTED. EVALUATION FLIGHT SATISFACTORY.

Part: SKIN — CRACKED (BS 441 S32L) · airframe 47,752 hrs · 37,138 cycles

5/16 INCH CRACK IN PRESSURIZED SKIN AT STA. 441, LONGERON S32L. CRACK EXTENDED OUT OF RIVET HEAD. FURTHER INVESTIGATION REVEALED LONGERON S32L CRACKED BEHIND SKIN CRACK FROM RIVET TO RIVET. TRANSFERRED TO DAMAGE WO 600252246. OPEN: TEMP REPAIRED IAW REA B653-54324-MR. WATCH ITEM 52284 CREATED TO INSPECT CRITICAL ROW OF FASTENERS. CARRY OVER ITEM 52285 CREATED TO PERMANTLY REPAIR BY NEXT 'C' CHECK. DDD 9-19-06. REPAIRED IAW B767 SRM 53-00-03 AND REA B653-54331.

Part: GIRT BAR — CONTAMINATED (ENTRY DOOR) · airframe 47,288 hrs · 36,956 cycles

ENTRY DOOR SLIDE WILL NOT ARM. CLEANED METAL SHAVING FROM GIRT BAR: DOOR CLOSED AND LOCKED NORMALLY, METAL SHAVING WAS FROM "C" CONTAINER.

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 45,906 hrs · 36,431 cycles

L1 DOOR EMERGENCY EXTERIOR LIGHT WAS INOP. RELAMPED AND SEALED LENS TO L1 DOOR EMERGENCY LIGHT. OPS CHECKED GOOD.

Part: WEDGE — DELAMINATED (LT WING SLAT) · airframe 45,463 hrs · 36,274 cycles

WHILE PERFORMING LINE MAINTENANCE, FOUND LEFT WING NR 4 SLAT WEDGE DELAMINATED BEYOND LIMITS AT INBOARD END. REPLACED NR 4 SLAT IAW B767 MM 27-81-02-4.

Part: WIRE — LOOSE (EMERGENCY LIGHT) · airframe 44,994 hrs · 36,120 cycles

CABIN ENTRY LIGHTS FLICKERED ACCOMPANIED BY ARCING IN THE AREA OF SWITCH. INSPECTED WIRE ON BACK SIDE OF SWITCH, FOUND LOOSE WIRE. REINSTALLED WIRE ON SWITCH, OPS CHECKED GOOD.

Part: SPLICE — CRACKED (HORIZONTAL STAB) · airframe 43,136 hrs · 35,418 cycles

CRACK INDICATION ON RT UPPER INBOARD HORIZONTAL STABILIZER PIVOT FITTING DURING X-RAY. REMOVED AND REPLACED PLATE IAW REA B655-48039-MR.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 41,904 hrs · 35,004 cycles

EMERGENCY LIGHTS INOPERATIVE. REMOVED AND REPLACED SPARE BATTERY PACK FOR EMERGENCY LIGHTS. OPS CHECKED GOOD IAW MM.

Part: CONNECTOR — NOT SEATED (CABIN) · airframe 41,309 hrs · 34,815 cycles

EMERGENCY LIGHTS WOULD NOT STAY ON. FOUND EMERGENCY BATTERIES DEPLETED. CHARGED USING AIRCRAFT POWER. TROUBLESHOT WIRES IAW B767 WD 33-51-11. CHECKED GOOD. RESEATED PLUG D5124P. OPS CHECKED GOOD IAW B767 MM 31-51-00. EMERGENCY LIGHTS CHECKED GOOD.

Part: SPAR — CRACKED (RT WING) · airframe 40,501 hrs · 34,533 cycles

RIGHT WING, FRONT SPAR, OUTBOARD HOLES, HOLE NR 10 FROM TOP, HAD A CRACK INDICATION WITH NDT. REAMED HOLE SIZE TO .387, NO CRACKS FOUND IAW B767 NDT MANUAL PT6 51-00-19. INSTALLED OVERSIZED FASTENERS IAW REA B657-43120MR.

Part: SPAR — CRACKED (RT WING) · airframe 40,501 hrs · 34,533 cycles

RIGHT WING FRONT SPAR OUTBOARD HOLES, HOLE NR 12, FROM TOP HAD A CRACK INDICATION WITH NDT. REAMED HOLE SIZE TO .387, NO CRACKS FOUND IAW B767 NDT MANUAL PT6 51-00-19. INSTALLED OVERSIZED FASTENERS IAW REA B657-43120MR.

Part: SPAR — CRACKED (RT WING) · airframe 40,501 hrs · 34,533 cycles

RIGHT WING, FRONT SPAR, OUTBOARD HOLES, HOLE NR 4 FROM TOP, HAD A CRACK INDICATION WITH NDT. REAMED HOLE SIZE TO .387, NO CRACKS FOUND IAW B767 NDT MANUAL PT6 51-00-19. INSTALLED OVERSIZED FASTENERS IAW REA B657-43120MR.

Part: FITTING — CRACKED (LT. HORIZ. STAB.) · airframe 40,500 hrs · 34,532 cycles

LEFT UPPER HORIZONTAL STABILIZER FITTING HAD 2 EACH FORWARD FASTENER HOLES CRACKED. REPAIRED AREA IAW B767 SRM 57-40 AND REA B655-43116MR.

Part: FITTING — CRACKED (LT. HORIZ. STAB.) · airframe 40,500 hrs · 34,532 cycles

LEFT HORIZONTAL, LOWER HORIZONTAL STABILIZER FITTINGS HAD 3 EACH FORWARD FASTENER HOLES CRACKED. REPAIRED AREA IAW B767 SRM 51-40-05 AND REA B766-43116MR.

Part: FITTING — CRACKED (RT. HORIZ. STAB.) · airframe 40,500 hrs · 34,532 cycles

RIGHT UPPER HORIZONTAL STABILIZER FITTING HAD INBOARD FORWARD FASTENER HOLE CRACKED. REPAIRED AREA IAW B767 REA B655-43116MR.

Part: GEARBOX — DEFECTIVE (COCKPIT) · airframe 39,006 hrs · 34,026 cycles

FIRST OFFICER'S OPENABLE WINDOW, HAND CRANK WOULD NOT OPEN OR CLOSE WINDOW. REPLACED FIRST OFFICER'S OPERATING GEARBOX IAW B767 56-11-04-4. OPS CHECKED GOOD.

Part: RELIEF VALVE — LEAKING (HYD SYSTEM) · airframe 38,637 hrs · 33,898 cycles

THE RIGHT HYDRAULIC QUANTITY DECREASED TO .67. THE ENGINE DRIVEN PUMP DE-PRESSURIZED AND THE ALTERNATING CURRENT MOTOR PUMP WAS SELECTED OFF. MAINTENANCE INSPECTED AND REPLACED THE FILTER MODULE RELIEF VALVE IAW B767 29-11-17. OPS AND LEAK CHECKS WERE COMPLETED, AND THE AIRCRAFT WAS RETURNED TO SERVICE.