N791AX

Part: SKIN — CRACKED (NR 1 NACELLE) · airframe 68,488 hrs · 46,743 cycles

FOUND CRACK IN FWD SKIN ON #1 PYLON DURING EIGINE CHANGE.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 68,404 hrs · 46,710 cycles

#2 FLIGHT DECK EMERGENCY DESCENT DEVICE BLUE GROMET SEAL BROKEN. FAULT TRANSFERRED TO DEFERRAL MAINTENANCE ITEM (DMI)-46872 IAW ATI B767 MINIMUM EQUIPMENT LIST 25-61-01-01. DOWNLINE, #1 FLIGHT DESCENT DEVICE REMOVED AND REPLACED PER B767 AIRCRAFT MAINTENANCE MANUAL 25-61-03. DMI 46872 CLEARED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 68,404 hrs · 46,710 cycles

#1 FLIGHT DECK EMERGENCY DESCENT DEVICE BLUE GROMET SEAL BROKEN. FAULT TRANSFERRED TO DEFERRAL MAINTENANCE ITEM (DMI)-46870 IAW ATI B767 MINIMUM EQUIPMENT LIST 25-61-01-01. DOWNLINE, #1 FLIGHT DESCENT DEVICE REMOVED AND REPLACED PER B767 AIRCRAFT MAINTENANCE MANUAL 25-61-03. DMI 46870 CLEARED.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 67,788 hrs · 46,454 cycles

FOUND CRACK ON REPAIR R/H FWD BULKHEAD OUTER CORD FS 1809.5 FROM TOP AS PER SERVICE BULLETIN 767-53A0078 REV G.

Part: MEC — FAILED (NR 1 ENGINE) · airframe 66,319 hrs · 45,700 cycles

DESCENDING FROM 11,500 TO 7000 FT, LEFT ENGINE OIL PRESSURE FOLLOWED BY LEFT ENGINE BLEED OFF EICAS MESSAGE. OIL PRESSURE WAS INDICATING 8 PSI EVENTUALLY GOING TO 0 WITH N1 AT 20%. NO VIBRATION OR INDICATION OF FIRE. #1 ENGINE FLAMEOUT AND ALL INDICATIONS ROLLED BACK. CREW IN AIR RESTART ON #1 ENGINE RESTORED FUNCTIONALITY. START NORMAL, ENGINE PARAMETERS NOMINAL. FLIGHT CONTINUED UNAFFECTED. EMERGENCY DECLARATION WITH KILN ATC. LANDING UNEVENTFUL WITH NO ADDITIONAL PRECAUTIONARY ACTIONS. LH ENGINE BORESCOPE INSPECTION SATISFACTORY IAW B767 AMM 72-0-00. NO FAULTS NOTED. REMOVED AND REPLACED LEFT ENGINE FUEL PUMP AND FUEL, LUBE AND SCAVENGE OIL FILTERS. REMOVED AND REPLACED LEFT ENGINE MEC. CHANGED OIL. ALL OPERATIONAL AND LEAK CHECKS SATISFACTORY. INTERNALLY INSPECTED AND CLEANED MINIMAL FOD IN LEFT WING FUEL TANK. SECURED 2 EACH COUPLINGS IAW B767 28-11-01/007. LEAK CHECK GOOD. INSPECTION OF LEFT ENGINE SUPPLY SCAVENGE INLET SCREENS GOOD. FUEL TANK SUMPS SATISFACTORY. NO CONTAMINATION NOTED. TEST FLIGHT ATN791 WITH MAX POWER TAKE OFF GOOD. NO FAULTS NOTED.

Part: EICAS — FAULT MESSAGE · airframe 66,036 hrs · 45,541 cycles

ENROUTE FROM KTPA TO KCVG RIGHT PACK AND TEMP EICAS MESSAGE DISPLAYED. RIGHT PACK INOPERATIVE WITH LEFT PACK ON ACTIVE DEFERRAL. IN COMPLIANCE OF ATI QUICK REFERENCE HANDBOOK PROCEDURES, DIVERSION TO KATL WITH EMERGENCY DECLARATION. LANDING WAS UNEVENTFUL WITH NO ADDITIONAL PRECAUTIONARY ACTIONS. ON ARRIVAL, AIRCRAFT GROUNDED FOR UNSCHEDULED MAINTENANCE. REMOVED AND REPLACED COMPRESSOR OVERHEAT SWITCH IAW B767 AMM 21-51-00. OPERATIONAL CHECK SATISFACTORY. NO ADDITIONAL FAULTS NOTED. AIRCRAFT RELEASED TO SERVICE.

Part: BULKHEAD — CRACKED · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT. IN COMPLIANCE OF TASK CARD ATI-54-812-00-02, MAINTENANCE IDENTIFIED 3 INCH CRACK TO THE #2 PYLON BULKHEAD LOCATED AT NAC STA 163.50 DAMAGE FOUND TO BE OUT OF LIMITS IAW BOEING 767-200 SRM 54-50-07. REMOVED, FABRICATED AND REPLACED BULKHEAD.

Part: NONE — NONE · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT. MAINTENANCE IDENTIFED #1 ENGINE INBOARD THRUST REVERSER LOWER INNER AIR BYPASS DUCT LOWER FAIRING IS DENTED AND GOUGED. REPAIRED GOUGE OF #1 ENGINE INBOARD THRUST REVERSER AT NAC 197.65 NAC 230

Part: NONE — CORRODED · corrosion level 2 · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT IN COMPLIANCE OF ATI TASK CARD 53-556-00-01 MAINTENANCE IDENTIFIED CORROSION AT AFT LOWER CARGO DOOR CUTOUT LOWER FAIL SAFE CORD AT APPROXIMATELY RBL 44 STA 1250-1275 CORROSION OUT OF LIMITS-LEVEL 2. REMOVED AND REPLACED AFT LOWER CARGO DOOR CUTOUT LOWER FAIL SAFE CHORD IAW ENGINEERING ORDER 47481FAB01.

Part: FORMER — CRACKED · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT. IN COMPLIANCE OF TASK CARD ATI-57-810-00-01 MAINTENANCE IDENTIFIED CORROSION AND A 1 INCH CRACK ON NOSE FORMER, LOCATED ON THE RIGHT WING LEADING EDGE AT OFSS 499.603. REMOVED, FABRICTED NEW NOSE RIB AND REINSTALLED.

Part: SPLICE — CRACKED · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT IN COMPLIANCE OF ATI TASK CARD 53-30-F28C1 MAINTENANCE IDENTIFIED CORROSION FS 436 STR 31L LOWER SURFACE OUTBOARD. IN THE COURSE OF REMOVING CORROSION, ADDITIONAL FAULTS WERE NOTED STRINGER SPLICE COMMON TO STA 436 AND 31L IN THE FORWARD LOWER CARGO CRACKED .380. REMOVED AND REPLACED SPLICE FITTING.

Part: NONE — CORRODED · corrosion level 2 · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT. IN COMPLIANCE OF TASK CARD ATI-53-556-00-01, IDENTIFIED CORROSION AT AFT LOWER CARGO LOWER DOOR CUTOUT LOWER SILL CORD AT APPROXIMATELY RBL44 STA 1270, CORROSION LEVEL 2. REMOVED AND REPLACED SILL CHORD. NO ADDITIONAL DEFECTS NOTED.

Part: SKIN PANEL — DELAMINATED · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT MAINTENANCE IDENTIFIED DELAMINATION ON THE UPPER LEFT HORIZONTAL STABILIZER SKIN PANEL LOCATED ON THE MOST INBOARD BONDED CORE SEGMENT OF THE INNER SKIN BETWEEN APPROXIMATELY AS STATION 240.701 AND AS STATION 290.274 DELAMINATION WAS CONTAINED TO THE INNER SKIN AND CORE ONLY. DAMAGES ARE BEYOND REPAIR INSTRUCTIONS REFERENCED IN 767-200 SRM 55-10-10 AND 51-70-10. REMOVED AND REPAIRED UPPER SKIN PANEL IAW ENGINEERING ORDER 47481REA11

Part: SKATE ANGLE — CHAFED · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT#2 PYLON FORWARD EDGE OF SKATE ANGLE IS CHAFFED AT 447AR PANEL.CHAFE BEYOND LIMITS IAW BOEING STRUCTURE REPAIR MANUAL 54-51-71. PREVIOUS BLEND NOTED. REMOVED AND REPLACED FORWARD END SKATE ANGLE.

Part: DOOR — GOUGED · airframe 64,800 hrs · 44,926 cycles

AIRCRAFT GROUNDED FOR SCHEDULED MAINTENANCE C CHECK VISIT IN COMPLIANCE OF ATI TASK CARD 52-410-00-01 MAINTENANCE IDENTIFIED AFT LOWER CARGO DOOR EXTERNAL SURFACE FORWARD LOWER CORNER DOOR SKIN BENT. REPAIRED GOUGE AT DOOR STATION 17.5. BEAM 10

Part: TRANSMITTER — ERRATIC (TE FLAP) · airframe 58,338 hrs · 42,502 cycles

ON APPROACH INTO DFW CREW DECLARED AN IFE FOR A TRAILING EDGE FLAP DISAGREE EICAS MSG. LANDING WAS CONTINUED SUCCESSFUL. MAINTENANCE COMPLETED FIM 27-51 FT 809. MAINTENANCE REMOVED AND REPLACED THE LEFT FLAP POSITION XMITTER AND PERFORMED OPERATIONAL CHECK PER AMM 27.

Part: CABLE — DETERIORATED (LT ENGINE) · airframe 56,577 hrs · 41,925 cycles

ON DESCENT INTO KCVG, LT ENG STUCK AT IDLE AND WOULD NOT ACCELERATE AS COMMANDED. EMERGENCY DECLARED. IN ACCORDANCE WITH ENGINE FAILURE CHECKLIST, COMPLIED WITH IN FLIGHT SHUTDOWN WITH A RESTART. ENGINE RESTARTED NORMALLY, BUT STILL AT IDLE. APPROACH AND LANDING INTO DESTINATION AIRPORT KCVG WITHOUT INCIDENT. AIRCRAFT WAS GROUNDED FOR UNSCHEDULED MAINTENANCE. INSPECTION OF LT ENG MEC REVEALED BROKEN VSV CABLE BELLCRANK. REMOVED AND REPLACED VSV FEEDBACK BELLCRANK, CABLES AND VAR STATOR ACTUATOR. OPERATIONAL ENG RUNS SATISFACTORY. LEAK CHECK SATISFACTORY. NO FURTHER DEFECTS NOTED. AIRCRAFT RELEASED TO SERVICE.

Part: BELLCRANK — BROKEN (LT ENGINE) · airframe 56,577 hrs · 41,925 cycles

ON DESCENT INTO DESTINATION STATION KCVG, LT ENG STUCK AT IDLE AND WOULD NOT ACCELERATE AS COMMANDED. EMERGENCY DECLARED. IN ACCORDANCE WITH ENGINE FAILURE CHECKLIST, COMPLIED WITH IN FLIGHT SHUTDOWN WITH A RESTART. ENGINE RESTARTED NORMALLY, BUT STILL AT IDLE. APPROACH AND LANDING INTO DESTINATION AIRPORT KCVG WITHOUT INCIDENT. AIRCRAFT WAS GROUNDED FOR UNSCHEDULED MAINTENANCE. INSPECTION OF LT ENG MEC REVEALED BROKEN VSV CABLE BELLCRANK. REMOVED AND REPLACED VSV FEEDBACK BELLCRANK, CABLES AND VAR STATOR ACTUATOR. OPERATIONAL ENG RUNS SATISFACTORY. LEAK CHECK SATISFACTORY. NO FURTHER DEFECTS NOTED. AIRCRAFT RELEASED TO SERVICE.

Part: FAILSAFE — CRACKED (BS 955) · airframe 56,265 hrs · 41,767 cycles

IN COMPLIANCE OF TASK CARD S53-050-04-1/AD 2012-09-04, THE FOLLOWING FINDING WERE NOTED, LOWER WHEEL WELL BS 955 FAILSAFE STRAP HAD A CRACK INDICATION AT LOWER BOLT HOLE COMMON TO THE TEE FITTING AND FAILSAFE. REMOVED AND REPLACED THE LEFT WHEEL WELL FAILSAFE STRAP IAW 47008ORD11. AIRCRAFT GROUNDED

Part: STRUT — CORRODED (NR 1 SLAT TRACK) · corrosion level 2 · airframe 56,247 hrs · 41,748 cycles

NUMBER ONE SLAT INBOARD AUX TRACK ATTACH FITTING INBOARD LOWER STRUT CORRODED AROUND NUTPLATE. REMOVED AND REPLACED STRUT IAW DRAWING 114T2226. AIRCRAFT GROUNDED

Part: STRAP — CORRODED (LT WING SPAR) · corrosion level 2 · airframe 56,255 hrs · 41,757 cycles

LEFT WING FRONT SPAR LOWER STRAP CORRODED, 7 INCHES OUTBOARD OF PYLON. REMOVED AND REPLACED LOWER STRAP IAW SRM 51-90-02 REA 4727REA04. AIRCRAFT GROUNDED.

Part: SPAR WEB — CORRODED · corrosion level 2 · airframe 56,225 hrs · 41,757 cycles

AIRCRAFT GROUNDED FOR HEAVY MAINTENANCE. FRONT SPAR WEB HAS CORROSION AT THE BOTTOM FASTENER ROWS LES 418. REPAIRED CORRODED AREA IAW ENGINEERING 47273REA06.

Part: STRAP — CORRODED (LT WING) · corrosion level 2 · airframe 56,247 hrs · 41,748 cycles

THE LEFT WING FRONT SPAR LOWER STRAP CORRODED 7 INCHES OUTBOARD OF PYLON. REMOVED AND REPLACED THE STRAP IAW SRM 51-90-02. AIRCRAFT GROUNDED

Part: FLOOR SUPPORT — CRACKED (BS 1518-1519) · airframe 56,225 hrs · 41,757 cycles

AIRCRAFT GROUNDED FOR HEAVY MAINTENANCE. BULK CARGO FLOOR PANEL ATTACH CHANNEL AT BS 1518, LBL 30 FOUND CRACKED. REMOVED THE DAMAGE. FABRICATED A REPAIR CHANNEL AND INSTALLED IAW SRM 51-70-11, DETAIL 1, AND SRM 51-40-02.

Part: FRAME — CRACKED (BS 859) · airframe 56,247 hrs · 41,748 cycles

DURING ACCOMPLISHMENT OF EO 53-767-5353 FOUND THE FRAME AT BS 859.5 CRACKED. REPAIRED THE FRAME EO 53-767-5353, REVISION 3. AIRCRAFT GROUNDED

Part: FRAME — CRACKED (FUSELAGE) · airframe 56,253 hrs · 41,755 cycles

AIRCRAFT GROUNDED FOR HEAVY MAINTENANCE. FRAME INNER CHORD AT RIGHT SIDE RBL 89 STA 883.5 CRACKED. FRAME CHORD REPAIRED IAW ENGINEERING ORDER 53-767-5353.

Part: SKIN — CRACKED (NR 1 NACELLE) · airframe 56,225 hrs · 41,757 cycles

AIRCRAFT GROUNDED FOR HEAVY MAINTENANCE. NR 1 PYLON INBOUND SKIN HAS A CHAFE MARK AT THE UPPER CONTACT POINT WITH THE WING LEADING EDGE. REMOVED AND REPLACED THE NR 1 PYLON INBOUND SKIN IAW DRAWING 313T200 AND SRM 51-40-02, PARAGRAPH 7.

Part: TRACK — CORRODED (NR 8 SLAT) · corrosion level 2 · airframe 56,225 hrs · 41,757 cycles

AIRCRAFT GROUNDED FOR HEAVY MAINTENANCE. CORROSION AROUND NUTPLATE ON NR 8 SLAT OUTBOARD AUX TRACK INBOARD LOWER STRUT. REMOVED CORROSION AROUND NUTPLATE ON NR 8 SLAT OUTBAORD AUX TRACK AND FOUND TO BE OUT OF LIMIT IAW SRM 57-41-09. REMOVED AND REPLACED IAW SRM 51-40-02 PARA 9.

Part: SKIN — CRACKED (BS 1654) · airframe 56,247 hrs · 41,748 cycles

LEFT FUSELAGE SKIN CRACKED BETWEEN RIVETS BS 1654.5 BETWEEN STRINGERS 4L-5L. REPAIRED THE SKIN. AIRCRAFT GROUNDED.

Part: FRAME — CRACKED (FUSELAGE) · airframe 56,247 hrs · 41,748 cycles

AIRCRAFT GROUNDED FOR HEAVY MAINTENANCE. FRAME INNER CHORD AT RIGHT SIDE STA-859.5 CRACKED. REPAIRED IAW ENGINEERING ORDER 53-767-5353 REVISION 03.

Part: STRINGER — CRACKED (BS 676-678) · airframe 56,225 hrs · 41,757 cycles

AIRCRAFT GROUNDED FOR HEAVY MAINTENANCE. STRINGER 12L CRACKED AT BS 676. SPLICED IN REPLACEMENT SECTION IAW SRM 53-00-03, FIG 201, REPAIR 1 AND SB 368-53-038.

Part: BEAM — CORRODED (LT WING) · corrosion level 2 · airframe 56,225 hrs · 41,757 cycles

VERTICAL PANEL ON WING LEADING EDGE BETWEEN NR 9 SLAT INBOARD AND OUTBOARD AUX TRACKS CORRODED AROUND NUTPLATE AT LES .595. BLENDED CORROSION AND FOUND TO BE OUT OF LIMITS. FABRICATED NOSE BEAM IAW DWG 114T2300. INSTALLED IAW SRM 51-40-02, PARA 4.7.10.

Part: SKIN — CRACKED (BS 1724) · airframe 56,225 hrs · 41,757 cycles

EXTERNAL SKIN CRACKED AROUND FASTENER HEAD AT BS 1725.5 RIGHT SIDE. REPAIRED THE SKIN IAW SRM 53-80-01. REPAIR 6. ACFT GROUNDED.

Part: TRACK — CORRODED (NR 1 SLAT) · corrosion level 2 · airframe 56,225 hrs · 41,757 cycles

NUMBER 1 SLAT INBOARD AUX TRACK ATTACH FITTING INBOARD LOWER STRUT CORRODED AROUND NUTPLATE. REMOVED AND REPLACED STRUT IAW B767 DRAWING 114T2226. AIRCRAFT GROUNDED.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 54,562 hrs · 41,165 cycles

DURING DAILY CHECK, FOUND ALL EMERGENCY LIGHTS INOPERATIVE. AIRCRAFT GROUNDED. REMOVED AND REPLACED EMERGENCY LIGHTS BATTERY PACK M736. OPS SATISFACTORY IAW AMM 33-51-00. ACFT RELEASED TO SERVICE.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 54,562 hrs · 41,165 cycles

DURING DAILY CHECK FOUND ALL EMERGENCY LIGHTS INTERIOR AND EXTERIOR INOPERATIVE. AIRCRAFT GROUNDED. REMOVED AND REPLACED EMERGENCY LIGHTS BATTERY PACK IN POSITION M735. OPERATIONAL CHECK IAW 757 AMM 33-51-00 SATISFACTORY. ACFT RELEASED TO SERVICE.

Part: BRACKET — CORRODED (FUSELAGE) · corrosion level 2 · airframe 54,250 hrs · 41,071 cycles

CORRODED BRACKETS IN ACCESS PANELS OF APU DOOR ACTUATOR. FOUR CLIPS WERE FABRICATED IAW SRM DIAGRAM 353T0115 REV D. INSTALLED CLIPS IAW SRM 51-40-02. NO FURTHER DEFECTS NOTED.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 54,325 hrs · 41,093 cycles

THREE EMER LAMPS DO NOT ILLUMINATE DURING TEST, INSIDE ENTRYWAY CEILING CTR & TWO LT OVERHEAD FIXTURES.

Part: MECHANISM — MISWIRED (AILERON FEEL) · airframe 53,618 hrs

THE LATERAL TRIM ACTUATOR,(PART OF THE ELEVATOR FEEL MECHANISM ASSEMBLY) RUNS THE OPPOSITE OF THE DIRECTION COMMANDED WHEN OPERATED. SDR WAS FILED PER THE REQUEST OF THE FAA.

Part: ESCAPE ROPE — DISLODGED (CABIN) · airframe 53,029 hrs · 40,465 cycles

WHILE PERFORMING MX ON EMER DESCENT DEVICE IN NR 1 POSITION, NR 5 DESCENT DEVICE DEPLOYED. REMOVED & INSTALLED EMERGENCY DESCENT DEVICE IAW AMM 25-61-03. NO ADDITIONAL FAULTS WERE NOTED AT THIS TIME. ACFT RELEASED TO SERVICE.

Part: ESCAPE ROPE — DISLODGED (CABIN) · airframe 53,029 hrs · 40,465 cycles

ONE EACH DESCENT DEVICE DISLODGED FROM HOLDER. DEFERRED MX ITEM INITIATED IAW AMM 25-61-01-01, CAT C. REMOVED & INSTALLED EMER DESCENT DEVICE IAW AMM 25-61-03. DMI CLEARED & ACFT RELEASED TO SERVICE.

Part: ESCAPE ROPE — DISLODGED (CABIN) · airframe 53,021 hrs · 40,458 cycles

DURING LANDING, TWO DESCENT DEVICES DISLODGED FROM EMER ESCAPE. R & R TWO DISLODGED EMER DESCENT DEVICES IAW AMM 25-61-03. NO ADDITIONAL DEFECTS WERE NOTED, ACFT RELEASED TO SERVICE.

Part: ESCAPE ROPE — DISLODGED (CABIN) · airframe 53,021 hrs · 40,458 cycles

DURING THE LANDING TWO DESCENT DEVICE DISLODGED FROM EMER ESCAPE. R & R TWO DISLODGED & ACTIVATED EMER DESCENT DEVICES IAW AMM 25-61-03. NO ADDITIONAL DEFECTS NOTED. ACFT RELEASED TO SERVICE.

Part: STOP FITTING — CORRODED (AILERON) · corrosion level 2 · airframe 52,055 hrs · 39,903 cycles

OUTBOARD AILERON AT GND STOP ON AIRPLANE GND POINT SIDE CORRODED. OTBD AILERON FITTING R & R IAW SRM 51-40-02.

Part: BEAM — CRACKED (NR 1 PYLON) · airframe 52,055 hrs · 39,903 cycles

NUMBER 1 PYLON INBOUND LOWER BEAM INSIDE ACCESS DOOR 437BL IS WORN THROUGH AT FWD END & FASTENER HOLES ARE WORN. NR 1 PYLON INBOUND LOWER BEAM R & R IAW DWG 313T1380.

Part: SKIN — CRACKED (NR 1 PYLON) · airframe 52,055 hrs · 39,903 cycles

NUMBER 1 PYLON SKIN CRACKED AT ACCESS PANEL 436AL AT THE 7 O'CLOCK POSITION. REPAIRED ACCESS PANEL SKIN IAW REA47107REA05.

Part: SKIN — CRACKED (FUSELAGE) · airframe 52,055 hrs · 39,903 cycles

UPPER RT SIDE OF FUSELAGE SKIN IS CRACKED AT APPROXIMATELY BS 1654, STRINGER 3 - 5R. DAMAGED AREA WAS R & R IAW SRM 53-80-01 FIG 201.

Part: SEAT TRACK — CRACKED (COCKPIT) · airframe 52,055 hrs · 39,903 cycles

CAPTAIN'S FWD & OTBD SEAT TRACK IS CRACKED. R & R CAPTAIN'S SEAT TRACK IAW AMM 20-11-00.

Part: STRUT — CORRODED (LE SLAT) · corrosion level 2 · airframe 52,055 hrs · 39,903 cycles

NUMBER 9 SLAT OTBD AUX TRACK ATTACH FITTING LOWER INBD STRUT CORRODED AROUND NUTPLATES. IAW SRM 51-40-05 & 51-40-02 LOWER INBD STRUT R & R.

Part: ATTACH FITTING — CORRODED (SLAT TRACK) · corrosion level 2 · airframe 52,055 hrs · 39,903 cycles

NR 11 SLAT OTBD AUX TRACK ATTACH FITTING. OTBD LOWER STRUT SPLIT ON EDGE AT FWD END. R & R SLAT OTBD AUX TRACK ATTACH FITTING OTBD LOWER STRUT IAW REA 7107REA04.

Part: STRUT — CORRODED (LE SLAT) · corrosion level 2 · airframe 52,055 hrs · 39,903 cycles

NUMBER 2 SLAT OTBD AUX TRACK FITTING INBD LOWER STRUT CORRODED AT FWD END UNDER NUT. R & R AIRLOAD STRUT IAW REA 4710REA01.

Part: ACCESS DOOR — CORRODED (APU) · corrosion level 2 · airframe 52,056 hrs · 39,903 cycles

LEFT APU ACCESS DOOR 315AL CORROSION AT THE FWD & OTBD CORNER. CORROSION FOUND OUT OF LIMITS. PERMANENT REPAIR FABRICATED ON LT APU ACCESS DOOR, 315AL IAW SRM 51-70-11.

Part: WEB — CRACKED (RT WING) · airframe 52,055 hrs · 39,903 cycles

RIGHT WING LE OTBD OF NR 9 SLAT DRIVE ROD LES650 SPLIT ON EDGE UNDER NUTPLATE. IAW SRM 51-70-11 RT WING LE WEB REPAIRED ON NR 9 SLAT AT LES650.

Part: WEB — CORRODED (LE SLAT) · corrosion level 2 · airframe 52,055 hrs · 39,903 cycles

LEADING EDGE WEB CORRODED AT NR 4 SLAT AREA NEAR INBOUND AUX TRACK. FABRICATED & INSTALLED NEW WEB IAW DWG & SRM 51-40-02.

Part: PANEL SUPPORT — CORRODED (WING) · corrosion level 2 · airframe 52,055 hrs · 39,903 cycles

PANEL SUPPORT FOR PANEL 655CB IS CORRODED BY INBOUND FLAP FWD SUPPORT. R & R SUPPORT BEAM IAW DWG 113T1634-22 & SRM 51-40-02.

Part: BEAM — CRACKED (LT WING) · airframe 52,055 hrs · 39,903 cycles

WING LE INBD OF NR 12 SLAT OTBD AUX TRACK LES 1071 CRACKED IN RADIUS. IAW SRM 51-40-02 & DWG 114T2300 NOSE BEAM PN 114T2300-170 WAS R & R.

Part: ESCAPE ROPE — DEPLOYED (CABIN) · airframe 52,015 hrs · 39,879 cycles

FOUND 1 EA DESCENT DEVICE EMERGENCY CABLE DEPLOYED. IAW AMM 25-61-03 EMERGENCY DESCENT DEVICE WAS R & R.

Part: AILERON SYS — MALFUNCTIONED · airframe 51,814 hrs · 39,797 cycles

AFTER THREE HOURS IN CRUISE FLIGHT AND DISENGAGING AUTOPILOT, AILERONS VERY STIFF. AFTER ACTUATING ON GROUND SEVERAL CYCLES, RETURNED TO NORMAL OPERATION. ACCOMPLISHED FIM PROCEDURE 27-11, FAULT TREE 808, PAGE 119, BLOCKS 1, 21 AND 41. LUBED LEFT LATERAL CENTRAL CONTROL ACTUATORS TORQUE TUBE. SYS OPS CHECKS NORMAL.

Part: J-BOX — FAILED (LT ENGINE EGT) · airframe 51,689 hrs · 39,751 cycles

LEFT ENGINE EGT FLUXUATES FROM NORMAL TO 70C ON EICAS AND ALTERNATE SYS. ACFT RETURNED TO STATION. ACCOMPLISHED FIM PROCEDURE 77-21 FAULT TREE 103, BLK 1,2,21. R & R LT ENGINE EGT JUNCTION BOX IAW AMM 77-21-02. OPS CHECKS NORMAL ON ENGINE RUN UP IAW ERH B767 01-01-1.

Part: PROXIMITY SWITCH — MALFUNCTIONED (TE FLAPS) · airframe 51,540 hrs · 39,687 cycles

EICAS FLAP MESSAGE ON TAKEOFF ROLL. TAKEOFF REJECTED AT 70 KTS. ACCOMPLISHED TAKEOFF WARNING ALERT TEST IAW MM 31-51-00, PARA 2 AND TESTED THE FLAP SLAT ELECTRONICS UNIT IAW MM 27-51-00, PARA 3E AND 3F. TESTED THE PROXIMITY SWITCH ELECTRONICS UNIT OF L/E IAW AMM 27-88-00, NR 507. NO FAULTS FOUND.

Part: DOOR — UNSECURE (CARGO BAY) · airframe 51,501 hrs · 39,673 cycles

ON DEPARTURE, ACFT WOULD NOT PRESSURIZE. EICAS MESSAGE CARGO DOORS INDICATED AND CARGO DOORS LIGHT ILLUMINATED. ACFT RETURNED TO STATION. DURING INSPECTION FOUND AFT CARGO DOOR NOT CLOSED AND LOCKED. MANUALLY CLOSED AND LOCKED DOOR. OPERATED THE DOOR ELECTRICALLY TWO TIMES. OPS CHECKED NORMAL IAW AMM 52-35-00/201. NO FAULTS NOTED.

Part: STRUCTURE — CRACKED (RT NACELLE) · airframe 51,400 hrs · 39,635 cycles

NR 2 ENGINE-RT CORE COWL CRACKED 1.5", STA NAC. 272.30 AND STA NAC 261.000. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3, DEC 3, 2012. DWG NR ED 5544, NOVEMBER 07,2012. REMOVED FASTENERS IAW SRM 51-40-02. TRIMMED OUT DAMAGED AREA IAW DWG NR ED 5544 NOV 07,2012, SRM 51-11-00. FABRICATED DOUBLER, TRIPLER, FILLER AL 2024T3 0.071" IAW DWG NR 5544 NOV 07,2012, SRM 51-30-01. CLEANED, TREATED AND PRIMED AREA, DOUBLER, TRIPLER AND FILLER IAW SRM 51-21-01. INSTALLED REPAIRED PARTS IAW SRM 51-40-02, SRM 51-40-4, DWG NR ED 5544.

Part: STRUCTURE — CRACKED (NLG WW) · airframe 49,852 hrs · 38,814 cycles

LEFT NWW CHORD AT STA 287 LBL 25 IS CRACKED APPROX 1 INCH IN LENGTH REQUIRES REPAIR. LT NWW CHORD AT STA 287 LBL 25 REPAIRED IAW B767 SRM 51-70-12.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 49,383 hrs · 38,513 cycles

BOTH EMERGENCY LIGHT BATTERIES ARE DEAD. REMOVED AND REPLACED BOTH EMERGENCY LIGHT BATTERY PACKS IAW B767 AMM 33-51-07-2.

Part: STRUCTURE — CORRODED (WING) · airframe 49,042 hrs · 38,347 cycles

TWO SPOTS OF EXFOLIATION ON UPPER L/E STRUCTURE APPROX LES 466. REPAIRED IAW REA B625-58391.

Part: RIB — CORRODED (WING) · airframe 49,042 hrs · 38,347 cycles

L/E RIB HAS EXFOLIATION O/B SIDE BY TAI DUCT APPROX LES 456. REMOVED AND REINSTALLED NEW RIB IAW B767 SRM 51-40-02.

Part: BALLSCREW — DAMAGED (HORIZ STAB) · airframe 48,973 hrs · 38,293 cycles

JACKSCREW HAS BRINELLING IN THREAD IN AREA OF TRAVEL. REMOVED AND REPLACED STABILIZER TRIM BALLSCREW ASSY IAW B767 M/M 27-41-10-4. UPPER BUSHING REWORKED PER ST-61664-01, W/O 600306164.

Part: SPINNER — LEAKING (NR 1 ENGINE) · airframe 48,390 hrs · 37,960 cycles

EXHAUST FUMES IN COCKPIT DURING HIGH THRUST SETTINGS. GROUND RAN ENGINES AND FOUND LEFT ENGINE PRODUCING SMOKE EXHAUST FUMES FROM VENTS WITH LEFT BACK ON. FOUND OIL IN NR 1 ENGINE SPINNER. RESEALED NR 1 BEARING MANIFOLD AND FAN ROTOR SPINNER IAW AMM 72-31-00-2 AND 72-31-01-4. (K)

Part: ENGINE — DEFECTIVE (NR 1) · airframe 46,935 hrs · 37,277 cycles

LEFT ENGINE HAD LOUD BANG, LOTS OF YAW AND THE ODOR OF SMOKE. EGT REACHED 1100 AFTER SHUTDOWN, HAPPENED AT 14000FT, AIR TURNBACK TO ILN. REMOVED AND REPLACED NR 1 ENGINE IAW JOB CARD 7010, WORKPACK WO 600274113, L/P 034277-13/1.

Part: SKIN — CORRODED (LT WING) · airframe 45,503 hrs · 36,695 cycles

LEFT LEADING EDGE AT STA 740 WAS CORRODED IN 3 SPOTS. REMOVED AND REPLACED NOSE BEAM IAW B767 SRM 51-40-02.

Part: CONNECTOR — CORRODED (EMERGENCY LIGHT) · airframe 43,726 hrs · 36,025 cycles

EMERGENCY LIGHT AT L1 POSITION (EXTERNAL) INOPERATIVE (GROUND ILLUM) L388. CLEANED CORROSION AT CONNECTOR IAW B767 MM 33-51-06. OPS CHECKED GOOD.

Part: BATTERY — DISCHARGED (CABIN) · airframe 38,861 hrs · 34,324 cycles

DURING PREDEPARTURE CHECK, FOUND COCKPIT OVER THE DOOR REMOVABLE EMERGENCY LIGHT BARELY GLOWING WHEN TESTED. REPLACED INTERNAL BATTERIES IN EMERGENCY EXIT LIGHT. OPS CHECKED GOOD IAW B767 MM 33-51-0.

Part: FRAME — DAMAGED (NR 2 COWL) · airframe 37,847 hrs · 34,009 cycles

ENGINE NR 2 RIGHT CORE COWL FRAME NAC STA 304.60, NAC WL 75, FOUND DAMAGE ON FRAME. FABRICATED REPAIR PARTS, INSTALLED AND REPAIRED AREA IAW REA B671-42172MR.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 37,847 hrs · 34,009 cycles

DAMAGED AREA NEAR AN EXISTING FASTENER HOLE AT STATION 435, BETWEEN STR 13 LEFT TO STR 14 LEFT, LEFT SIDE ON OUTER SKIN. REPAIRED AREA IAW REA B653-41430MR.

Part: SKIN — GOUGED (NR 1 STRUT) · airframe 37,847 hrs · 34,009 cycles

ENGINE NR 1 STRUT, RIGHT SKIN PANEL OUTER SURFACE, DEEP GOUGE WITH SKIN PUNCTURE WAS FOUND NEAR AN ACCESS DOOR CUT OUT, STA 237, WL 135. FABRICATED REPAIR PARTS AND INSTALLED IAW REA B654-42153MR.

Part: SKIN — DENTED (FUSELAGE) · airframe 37,847 hrs · 34,009 cycles

DENT WAS FOUND ON FUSELAGE SKIN BETWEEN STATION 1373 TO STATION 1395 AND BETWEEN STRINGER 25 LEFT TO STRINGER 26 LEFT AT LONGITUDINAL LAP SPLICE, LEFT SIDE. REPAIRED AREA IAW REA B653-41399MR.

Part: SKIN — CRACKED (NR 1 PYLON) · airframe 37,847 hrs · 34,009 cycles

GOUGE AND CRACK ON P/N 313T1200-3 FAIRING SKIN PYLON NR 1 RIGHT SIDE. FABRICATED REPAIR PARTS AND REPAIRED AREA IAW REA B654-42136MR.

Part: BOLT — IMPROPER (LT STRUT) · airframe 37,847 hrs · 34,009 cycles

STRUT FASTENERS INSTALLATION GRIP LENGTH NOT PER DWG, LEFT STRUT. REPAIRED AREA IAW REA B654-42145MR.

Part: BOLT — IMPROPER (RT STRUT) · airframe 37,847 hrs · 34,009 cycles

STRUT FASTENERS INSTALLATION GRIP LENGTH NOT PER DRAWING, RIGHT STRUT. REPAIRED AREA IAW REA B654-42146MR.

Part: CHANNEL — CORRODED (FUSELAGE) · airframe 37,847 hrs · 34,009 cycles

FORWARD CARGO LOWER LOBE BETWEEN STATION 610 AND STATION 632, LEFT BUTT LINE 6.5, CORRODED FLOOR CHANNEL, P/N 143T5000-80, LEFT SIDE. FABRICATED NEW PART AND REPAIRED AREA IAW REA B653-41896MR.

Part: STRINGER — DAMAGED (FUSELAGE) · airframe 37,847 hrs · 34,009 cycles

AFTER REMOVAL OF 140T015-22 SPLICE FITTING, STRINGER 34 RIGHT AT STATION 434, DAMAGE WAS FOUND ON TWO ENDS OF STRINGER 34 RIGHT. FABRICATED NEW PART AND REPAIRED AREA IAW REA B653-41910MR.

Part: SKIN — CRACKED (RT WING) · airframe 37,847 hrs · 34,009 cycles

UPPER LINK PITCH FITTING REWORK. UPPER WING SKIN CRACKS, RIGHT WING. REPAIRED AREA IAW REA B657-41905MR.

Part: FITTING — DAMAGED (RT WING) · airframe 37,847 hrs · 34,009 cycles

DURING THE SIDE LINK FITTING REPLACEMENT ON THE RIGHT WING, DISCOVERED THAT TWO EXISTING ATTACHMENT HOLES WERE ALREADY SECOND OVERSIZED, WHILE SERVICE BULLETIN ALLOWED THE HOLES TO BE ENLARGED (AFTER COLDWORK) TO A MAXIMUM OF SECOND OVERSIZE. ONE OF THE HOLES WAS ELONGATED. REPAIRED AREA IAW REA B653-41461MR.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 37,847 hrs · 34,009 cycles

THREE OVAL HOLES WERE FOUND IN THE 143T1052-29 FRAME AND IN THE EXISTING ANGLE AT THE AFT SIDE OF FRAME, AT STATION 456, BETWEEN STRINGER 7 RIGHT AND STRINGER 8 RIGHT. FABRICATED NEW PART AND REPAIRED AREA IAW REA B653-41426DE.

Part: STRINGER — DAMAGED (FUSELAGE) · airframe 37,847 hrs · 34,009 cycles

ONE ELONGATED HOLE WAS FOUND AT STATION 434, STRINGER 9, LEFT SIDE ON STRINGER, LOWER SIDE. FABRICATED REPAIR PART AND REPAIRED AREA IAW REA B653-41421MR.

Part: SKIN — GOUGED (CARGO DOOR) · airframe 37,847 hrs · 34,009 cycles

A GOUGE WAS FOUND IN THE 146T6334-1 INNER SKIN, NEAR STATION 1439, WATER LINE 131, LOWER SIDE ON BULK CARGO DOOR INNER SKIN. REPAIRED THE AREA IAW REA B652-41387MR.