N809MC

Part: SKIN — DELAMINATED (NR 7 SPOILER) · airframe 106,028 hrs · 24,092 cycles

RIGHT WING SPOILER NR 7 HAS DELAMINATION. DISBONDED UPPER AND LOWER SURFACE 35" BY 25". REMOVED AND REPLACED THE NR 7 SPOILER IAW AMM 27-62-01 OPS CHECKED TRANS TO RUN UP AND LEAK CHECK SHEET 01-AA-74A ITEM NR 3.

Part: ACCESS PANEL — DELAMINATED (A/C BAY) · airframe 105,637 hrs · 24,008 cycles

AIR CONDITION ACCESS PANEL 192ER EXTERNAL SURFACE IS DELAMINATED. REPAIRED AS PER SRM 51-40-17 AND BOEING MESSAGE 1-638498164-2.

Part: BULKHEAD — CRACKED (BS 260) · airframe 105,637 hrs · 24,008 cycles

RIGHT SIDE NOSE WHEEL WELL BULKHEAD WEB CRACKED AT STATION 260, WL 182 RBL 38. WEB REPAIRED AS PER BOEING MESSAGE 1-636527780-4.

Part: FITTING — CORRODED (BS 230) · airframe 105,637 hrs · 24,008 cycles

BS 230 RBL 1 BILGE AREA BEAM WEB SUPPORT FITTING CORRODED. REPLACED FITTING AS PER SRM 51-10-01 AND BOEING MESSAGE 1-637033946-3.

Part: SKIN — CORRODED (NR 8 SPOILER) · airframe 105,637 hrs · 24,008 cycles

NR 8 SPOILER AREA OF UPPER SKIN AND REAR SPAR HAS AREA OF CORROSION. REPAIRED AS PER BOEING MESSAGE 1--638467931-2.

Part: BRACE — LOOSE (NR 1 PYLON) · airframe 105,637 hrs · 24,008 cycles

NR 1 PYLON DIAGONAL BRACE UNDERWING FITTING TENSION FASTENER HEAD SHEARED. REMOVED AND INSTALLED FASTENER AS PER 51-30-02.

Part: SPAR CAP — CORRODED (RT WING) · airframe 105,637 hrs · 24,008 cycles

RIGHT WING FRONT SPAR LOWER CHORD AREA FSSO 1356 CORRODED. CORROSION REMOVED AS PER SRM 51-10-01 AND BOEING MESSAGE 1-638497220-2.

Part: SPAR CAP — CORRODED (RT WING) · airframe 105,637 hrs · 24,008 cycles

RIGHT WING FRONT SPAR LOWER CHORD AREA BETWEEN FSSO 1322 AND 1340 CORRODED. CORROSION REMOVED AS PER SRM 51-10-01 AND BOEING MESSAGE 1-638497220-2.

Part: BRACE — CHAFED (NACELLE) · airframe 105,637 hrs · 24,008 cycles

NR 4 STRUT DIAGONAL BRACE FORWARD END CHAFED. CHAFING AREA DAMAGE BLENDED AS PER BOEING MESSAGE 1-636565614-4.

Part: FAIRING — DELAMINATED (FUSELAGE) · airframe 105,637 hrs · 24,008 cycles

FUSELAGE FAIRING 193C AREA OF DELAMINATION. DELAMINATED AREA REPAIRED AS PER SRM 51-40-12

Part: SKIN — DELAMINATED (ZONE 500) · airframe 105,356 hrs · 23,951 cycles

LT WING UPPER SURFACE TRAILING EDGE FIXED PANEL AT STATION 1224 HAS AN AREA OF 2.0 INCH LONG BY 15.0 INCH WIDE AREA OF DELAMINATION. PERMANENT REPAIR OF AREA WAS ACCOMPLISHED AS PER B747-200 SRM 51-40-09 FIG 2, SHEETS 4 & 5.

Part: SKIN — UNKNOWN (BS 108) · airframe 104,701 hrs · 23,818 cycles

RADOME SKIN HAS A 2.0 INCH BY 4.0 INCH PREVIOUS REPAIR FILLER ERODED AT 11 O'CLOCK POSITION. ACCOMPLISHED PERMANENT REPAIR AS PER 747-200 SRM 53-50-03 PAGE 23, PAR 15. ALSO REFERENCE ATLAS AIR XEO 53-061507-1.

Part: SKIN — DENTED (BS 660) · airframe 104,701 hrs · 23,818 cycles

LOWER FUSELAGE, RT SIDE AT STA 660 HAS A DENT BETWEEN S43 AND S44 RT CAUSED BY ACCIDENT DURING STORM. ACCOMPLISHED PERMANENT REPAIR OF EXTERIOR SKIN AS PER 747-200 SRM 53-30-03 FIG 17, ALSO, PERMANENT REPAIR OF BROKEN SHEAR TIE AT BS 660 S43R-S44R WAS REPAIRED PER SRM 53-10-04 FIG 3. ALSO, REFERENCE ATLAS AIR XEO 53-061507.

Part: SKIN — CRACKED (BS 789 S46R) · airframe 104,061 hrs · 23,674 cycles

FUSELAGE SKIN HAS A CRACK APPROX 400", AT BS 789 S46R AND RIVET PULLING THROUGH. REPAIRED ACCOMPLISHED AS PER XEO NR 53-032207.

Part: OIL FILTER — UNSERVICEABLE (NR 2 ENGINE) · airframe 103,912 hrs · 23,636 cycles

NR 2 OIL FILTER BY PASS LIGHT ILLUMINATED DURING DESCENT, LIGHT REMAINED AT IDLE THRUST, SHUT DOWN NR 2 ENGINE. REMOVED AND REPLACED NR 2 ENGINE OIL FILTER AS PER MM 79-21-04. PERFORMED ENGINE RUN NO LEAK NOTED.

Part: SEAT TRACK — BROKEN (BS 1960) · airframe 103,391 hrs · 23,536 cycles

MAIN CARGO COMPARTMENT SEAT TRACK AT STATION 1960 RT, RBL 11 HAS 1 EACH BROKEN CROWN LUG. REMOVED AND REPLACED SECTION OF SEAT TRACK FROM STATION 1946 TO 1969 RT AS PER 747 SRM 53-10-05 FIG 14.

Part: CIRCUIT CARD — FAILED (MLG) · airframe 102,896 hrs · 23,444 cycles

RED GEAR LIGHT CAME ON AFTER RETRACTION WITH AURAL WARNING ON IN UP POSITION, GEAR UNSAFE CHECK ACCOMPLISHED PER FHB PROCEDURES AND RETURNED FOR LANDING. T/S FOUND A-9 CARD IN ALT CONTROL BOX FAILED. REMOVED AND REPLACED CARD PER AMM 32-61-00.

Part: SKIN — CRACKED (BS 450) · airframe 102,766 hrs · 23,418 cycles

MAIN ENTRY DOOR L-1, LOWER, FORWARD HINGE CUT-OUT HAS A CRACK AT PREVIOUS REPAIR DOUBLER. PERMANENT EXTERNAL DOUBLER REPAIR WAS ACCOMPLISHED IAW SB 747-52-2144 REV 2 AND REFERENCE EO NR 4752A111.

Part: SKIN — DELAMINATED (RT WING TE FLAP) · airframe 102,098 hrs · 23,278 cycles

RT AFT IB FLAP UPPER AND LOWER SIDES OF SKIN HAVE AN AREA OF DELAMINATION. UPPER SIDE IS AT WBL 278.750 AND DAMAGE AREA IS 1.5 INCHES. LOWER SIDE IS AT WBL 272.00 AND DAMAGE IS 2.0 INCHES. ACCOMPLISHED PREPREG 250 DEGREES F. PERMANENT REPAIR OF BOTH AREAS IAW SRM 51-40-09 AND 51-40-12 ON FLAP P/N 65B02070-12, S/N 000171.

Part: FLAP — ACTIVATED (WING) · airframe 101,834 hrs · 23,218 cycles

AFTER CLIMB-OUT AND FLAP RETRACTION FROM 5*-1*, FLAPS STAYED IN FLAPS 5* POSITION, ACCOMPLISHED ALT FLAP OPERATION SECT III FLAPS MOVED TO APPROX 3*, THEN STOPPED NO OTHER MOVEMENT WAS POSSIBLE INITIAL CK FOR OPEN C/B'S AND FURTHER INVESTIGATED PROBLEM. NO SPLIT OR ASYMMETRIC COND EXISTED. ATTEMPTED SPLIT FLAP CHECKLIST IN ATTEMPT TO MOVED FLAPS, FLAPS THEN MOVED TO ON POSITION TO FLAPS 30*. REMOVED PLUG FROM M14 ASYMMETRY DETECTOR FLAP POSITION, INDICATION SYSTEM NORMAL IAW DDPG 27-27 OPERATED FLAPS IN NORMAL AND ALTERNATE, ALL INDICATIONS NORMAL. NORMAL AND ALT T/E FLAPS AND PNEUMATIC AND ELECTRIC L/E FLAPS OPS CHECK OK WITH NORMAL INDICATIONS TRF TO DMI LOG PAGE 88020 IAW DDPG 27-27. DMI M06-084.

Part: STEERING SYS — MALFUNCTIONED (NLG) · airframe 101,765 hrs · 23,203 cycles

RTO AT 30 KTS AIRCRAFT DRIFTED LEFT WITH NO EFFECTIVE CONTROL, W/NOSE WHEEL STEERING. NOSE WHEEL STEERING APPEARS TO BE INOP. TRANSF TO DMI M06-076 PER MEL 32-18 CAT 'C'.PLACARD. VERIFIED OPS RUDDER PEDAL NORMAL. VERIFIED OPS TILLER STEERING NORMAL.

Part: PANEL — CRACKED (HORIZONTAL STAB) · airframe 104,701 hrs · 23,818 cycles

LT HORIZONTAL STABILIZER, LOWER T/E ACCESS PANEL 334 GBL HAS 2 EACH CRACKS ON INBOARD SIDE OF PANEL. CRACKS ARE 2.0 INCH IN LENGTH. ACCOMPLISHED PERMANENT REPAIR AS PER 747-200 SRM 51-40-09 FIG 13, 747-200 SRM 51-40-12. ALSO REFERENCE ATLAS AIR XEO 55-061507.

Part: APU — MALFUNCTIONED (APU BAY) · airframe 96,449 hrs · 16,542 cycles

APU FIRE BOTTLE WAS DISCHARGED DUE TO HEAVY BLACK SMOKE COMING FROM INLET, TAILPIPE, AND COWLING OF APU. APU INOP DUE TO FIRE BOTTLE PREVIOUSLY DISCHARGED. FIRE BOTTLE TRANSFERRED TO DI PG 88002 CAT C, PER MEL 26-8 M06-056. INSPECTED APU PER MM 49-11-00 PG601. TRANSFERRED TO DI PG CAT C, PER MEL 49-1 DMI M06-057.

Part: SKIN — DENTED (BS 660) · airframe 101,549 hrs · 23,156 cycles

FOUND DENTS AT BS 660 BETWEEN S-46L AND S-45R. REPAIR ACCOMPLISHED AS PER BOEING MESSAGE 1-17408378 AND FAA FORM 8100-9.

Part: SKIN — CRACKED (ZONE 400) · airframe 101,549 hrs · 23,156 cycles

DURING A C-CHECK, CRACK DAMAGE WAS FOUND IN THE 65B94052 SKIN ASSEMBLY NR 3 STIFFENER AND PRE-COOLER EXHAUST CUT OUT EDGE ADJACENT TO N.S. 248 NR 2 PYLON. INTERIM REPAIR AS AN AMOC TO AD 95-13-07, ON THE RIGHT SIDE OF THE STRUT STRUCTURAL ASSEMBLIES OF THE NR 2 PYLON AS PER BOEING MESSAGE 1-1780134626 AND FAA FORM 8100-9.

Part: SKIN — CRACKED (NR 1 NACELLE) · airframe 101,549 hrs · 23,156 cycles

NR 1 PYLON RIGHT SIDE SKIN ASSEMBLY WAS FOUND CRACKED IN THE AREA COVERED BY TITANIUM DOUBLERS. INTERIM REPAIR FOR THE NR 1 PYLON 65B94100 SKIN ASSEMBLY, WAS ACCOMPLISHED AS PER BOEING MESSAGE 1-178658112 AND FAA FORM 8100-9.

Part: SKIN — CRACKED (NR 2 NACELLE) · airframe 101,549 hrs · 23,156 cycles

THE CRACKS WERE FOUND IN THE SUBJECT STRUT CAP SKIN ASSEMBLY AND ADJACENT BULKHEAD STRAP AT STA-286 BULKHEAD INSTALLATION CROWN AREA AT B-L. 0-0. THE AFT EDGE OF CAP SKIN ASSEMBLY. THE BULKHEAD STRAP IN AREA COMMON TO CAP SKIN. INTERIM REPAIR OF THE 65B94053-27 CAP SKIN ASSEMBLY AND THE ADJACENT 65B89049-38. UPPER BULKHEAD ASSEMBLY, AT NAC STA 286 IN THE 65B94051-1 STRUT STRUCTURE ASSEMBLY FOR NR 2 PYLON ACCOMPLISHED AS PER BOEING MESSAGE 1-176887932 AND FAA FORM 8100-9.

Part: SKIN — CRACKED (NR 3 NACELLE) · airframe 101,549 hrs · 23,156 cycles

CRACK DAMAGE WAS FOUND IN THE 65B94052 SKIN ASSEMBLY NR 3 STIFFENER, AND PRE-COOLER EXHAUST CUT OUT ADJACENT TO THE AFT CORNER AT N.S.248, ON THE RIGHT SIDE OF THE STRUT STRUCTURAL ASSEMBLIES FOR NR 3 AND NR 4 PYLONS. INTERIM REPAIR FOR THE NR 3 AND NR 4 STRUT. STRUCTURE ACCOMPLISHED AS PER BOEING MESSAGE 1-178658174 AND FAA FORM 81-00-9.

Part: SKIN — CORRODED (BS 555-560) · airframe 101,549 hrs · 23,156 cycles

CORROSION IN THE INTERNAL BEAR STRAP AT THE RT AFT CORNER OF THE FORWARD LAVATORY SERVICE DOOR CUT-OUT, BS 560, STR 46R. REPAIR ACCOMPLISHED AS PER BOEING MESSAGE NR 1-177290023 ANF FAA FORM 8100-9.

Part: BULKHEAD — CRACKED (BS 2598) · airframe 101,549 hrs · 23,156 cycles

BS 2598 BULKHEAD AFT OUTER CHORD ATTACH FASTENER CRACKS AT STR 12L,LBL 50-55, WL 310-315. REPAIR ACCOMPLISHED AS PER BOEING MESSAGE 1-17563784 AND FAA FORM 8100-9.

Part: FLOORBEAM — CORRODED (BS 500) · airframe 101,549 hrs · 23,156 cycles

REPORTED CORROSION ON THE MAIN DECK FLOORBEAM UPPER T-CHORD HORIZONTAL FLANGE AT STA 500 BETWEEN APPROXIMATELY LBL 50.0 AND LBL 60.0. THE UPPER CHORD WAS REPLACED WITH SPLICES AT LBL 21.37.5 AND LBL 78.5, SIMILAR TO 747 SRM 53-10-07 FIG 12. REPAIR ACCOMPLISHED AS PER BOEING MESSAGE 1-182888881 AND FAA FORM 8100-9. SUPPLEMENTAL INSPECTION REQUIRED FOR EVERY C-CHECK OR 24 MONTHS WHICH EVER OCCURS EARLIER.

Part: FLOORBEAM — CORRODED (BS 620) · airframe 101,549 hrs · 23,156 cycles

REPORTED CORROSION ADJACENT TO AN EXISTING REPAIR ANGLE AT THE MAIN DECK FLOORBEAM UPPER T-CHORD HORIZONTAL FLANGE AT STA 620. REPAIR ACCOMPLISHED AS PER BOEING MESSAGE 1-178210650 AND FAA FORM 8100-9.

Part: SKIN — CRACKED (RT ELEVATOR) · airframe 101,549 hrs · 23,156 cycles

CRACKED RT OUTBOARD ELEVATOR PANEL AT ELEV STA 244 AND 306, P/N 65B05730-2. REPAIR ACCOMPLISHED AS PER BOEING MESSAGE 1-174409992 AND FAA FORM 8100-9.

Part: SPAR — CORRODED (TE FLAP) · airframe 101,549 hrs · 23,156 cycles

CORROSION DAMAGE FOUND IN SUBJECT SPAR AFT FLANGE AT WBL 770. INTERIM REPAIR TO OUTBOARD TRAILING EDGE MIDFLAP, NR 3 SPAR LOWER CHORD ACCOMPLISHED AS PER BOEING MESSAGE 1-177581561 AND FAA FORM 8100-9. DETAIL VISUAL INSPECTION THE EXPOSED AFFECTED AREA, FOR DEGRADATION, INCLUDING CORROSION, CRACKS AND LOOSE FASTENERS EVERY C-CHECK NOT TO EXCEED 24 MONTHS.

Part: WEB — CRACKED (HORIZONTAL STAB) · airframe 101,549 hrs · 23,156 cycles

CRACKED WEB AND LOWER CHORD AT THE RT HORIZONTAL STABILIZER STA BL 421.50. WEB AND LOWER CHORD REPAIR CARRIED OUT AS PER BOEING MESSAGE 1-17410726 AND FAA FORM 8100-9.

Part: FRAME — CRACKED (BS 300) · airframe 101,549 hrs · 23,156 cycles

RT STA 300 FRAME WEB AT STA 14D CUT OUT FOUND CRACKED 7.1". CRACKS WERE FOUND ON FRAME WEB. REPAIR DOUBLER AND WAS INSTALLED IAW BOEING MESSAGE 1-175762603.

Part: WEB — CRACKED (FUSELAGE) · airframe 101,549 hrs · 23,156 cycles

CRACKED WEB AND UPPER CHORD AT THE LT HORIZONTAL STABILIZER STA BL421.50. TRIMMED OUT WEB AND UPPER CHORD CRACKS. HFEC INSPECTED AREA, NO ADDITIONAL FINDINGS. FABRICATED REPAIR DOUBLERS, SUPPORT ANGLES AND STRAPS. WET INSTALLED ALL PARTS IAW BOEING MESSAGE 1-174107926 AND 1-17601239. FORM 8100-9 ISSUED.

Part: WEB — CRACKED (HORIZONTAL STAB) · airframe 101,549 hrs · 23,156 cycles

LT HORIZONTAL STAB, UPPER CHORD AT STAB BL 421.5 FOUND 1/2" CRACK AT AFT END. CHORD REPAIR CARRIED OUT AS PER BOEING MESSAGE 1-176012397 AND FAA FORM 8100-9.

Part: FRAME — CRACKED (BS 300) · airframe 101,549 hrs · 23,156 cycles

RT STA 360 FRAME WEB AT STR 14E CUT OUT FOUND CRACKED 7.5". CRACKS WERE FOUND ON FRAME WEB. REPAIR DOUBLERS WERE INSTALLED IAW BOEING MESSAGE NR 1-175762603, AND FAA FORM 8100-9.

Part: FITTING — SHEARED (NR 4 PYLON) · airframe 101,174 hrs · 23,140 cycles

FOUND SHEARED HI-LOKS IN NR 4 PYLON AFT DIAGONAL BRACE FITTING.

Part: RELAY — FAILED (LE FLAPS)

AFTER TAKE OFF, LEADING EDGE FLAPS NR 1 AND NR 3 WOULD NOT RETRACT. PRIMARY LEADING EDGE C/B OPEN. REPLACED R1102 RELAY IAW WDM 27-81-01. INSPECTED PDU`S DAMAGE, NONE FOUND. CLEANED ALL CONNECTORS AND RESEATED C/B. OPS CHECK CARRIED OUT SEVERAL TIMES IAW AMM. OPS CHECK GOOD. (K)

Part: MODULE — FAILED (NLG WW)

FLT 8452 - AFTER TAKEOFF WITH GEAR RETRACTED, ANTI-SKID HYD LIGHT AND RED PARK LIGHT ILLUMINATED. A/C DIVERTED TO FRA. CLEANED CANNON PLUG AT PARKING BRAKE VALVE. SYSTEM CHECKS NORMAL. ALL INDICATIONS NORMAL PER MM 32-41-00. AS PRECAUTION MCC ISSUED ITEM TO REPLACE PARKING BRAKE VALVE AT ORD. PARKING BRAKE MODULAR REPLACED PER AMM 32-44-04. OPS AND LEAK CHECK GOOD. REF LOG PAGE 554769, S/N OFF DA365. (M)

Part: SKIN — CORRODED (RT WING)

DURNG FA02 A-CHECK ACCOMPLISHGIN ATLAS AIR ROUTINE WORK CARD 12M15002 INSPECTION OF RIGHT WING FOUND BULGE AT LOWER FRONT SPAR CAP, CORROSION IS REPORTED AS LEVEL 1 AND IS LOCAL. (M) T64R

Part: BRACE — CRACKED (NR 4 CANOE FAIR) · airframe 96,908 hrs · 22,176 cycles

DURING A-CHECK ACCOMPLISHING ATLAS AIR ROUTINE WORK CARD 11FM15002 INSPECTION OF LEFT WING FOUND NR 4 FLAP CANOE FAIRING TO TRACK FORWARD OUTBOARD FITTING CRACKED IN HALF. JETIIIB WORK ORDER 1063 NON-ROUTINE NR 132.

Part: BRACE — CRACKED (FLAP FAIRING)

DURING FA02 A-CHECK ACCOMPLISHING ATLAS AIR ROUTINE WORK CARD 11FM15002, INSPECTION OF LEFT WING FOUND NR 4 FLAP CANOE FAIRING TO TRACK FORWARD OUTBOARD FITTING CRACKED IN HALF. (M) T64R

Part: DUCT — MISALIGNED (COOLING EXHAUST)

AIR TURNBACK DUE TO NR 3 ENGINE FIRE WARNING. NOTICED EGT AT 850 DEGREES, ON TAKEOFF AT 100 DEGREE HIGHER THAN NR 2 AND NR 4 ENGINES. REMOVED AND REPLACED T/R DRIVE DUCT ASSEMBLY IAW MM, PERFORMED PNEUMATIC LEAK TEST IAW MM, NO LEAKS FOUND. DISCOVERED TURBINE CASE COOLING EXHAUST DUCT MISALIGNED, CORRECTED INSTALLATION IAW MM AND SECURED DUCT. ACCOMPLISHED ENGINE RUN UP IAW MM; ENGINE RUN UP CHECKS GOOD. NO FUEL DUMPED.

Part: CONNECTOR — DAMAGED (NR 3 ENGINE)

OKO/SUU - NR 3 ENGINE FILTER BYPASS LIGHT CAME ON DURING CLIMB. RETARDING THROTTLE DID NOT OUT IT OUT. ENGINE SHUTDOWN PER FHB AT 0633Z. LIGHT REMAINED ON. REMOVED AND REPLACED OIL FILTER AND INSPECTED, NO CONTAMINATION FOUND. INSTALLED NEW FILTER, LEAK AND OPERATION CHECK NORMAL PER MM 79-21-07. CONFIRMED INDICATOIN PROBLEM, ITEM TRANSFERRED TO DMI M04-004 PER MEL 79-03 D1 PAGE 50807. TROUBLESHOT FOUND CONNECTOR BACK SHELL LOOSE, SECURED BACK SHEELL PER CHAP 20 MAINTENANCE PRACTICES MANUAL. OPERATION CHECK NORMAL. DMI CLEARED AND PLACARD REMOVED. (M)

Part: FITTING — CRACKED (WING)

DURING C-CHECK, FOUND RT KICK FITTING BOLT HOLES POSITION A, B AND K STILL SHOWING CRACK INDICATION AFTER 2ND OVERSIZE REAMING. PERMANENT REPAIR WITH DEVIATION TO REF 'A' SB PER REF 'B', 'C', AND 'D' BY OVERSIZING HOLE 'A', 'B'B AND 'K' THROUGH ALL COMPONENTS IN THE STACKUPS AT EACH LOCATION ON THE RIGHT SIDE SPLICE BEYOND THE LIMITS OF REF 'A' SB TO HOLE DIAMETERS OF 1.00, 1.040 AND .8750 INCH RESPECTIVELY. A SLEEVED BOLT WAS INSTALLED IN HOLE 'B'.

Part: FITTING — CRACKED (FUSELAGE)

DURING C-CHECK AT SIN, FOUND LT NOSE CARGO DOOR PORTAL FRAME CRACKED ON FUSELAGE AT BS 281, WL 312 AND LBL 40, REF SRM 53-10-04 FIG 97. THE NOSE CARGO DOOR PORTAL FRAME CRACK WAS REPAIRED BY MODIFYING SRM 747-53-10-04 FIGURE PER REF TO MATCH THE REPAIR GEOMETRY. THE REASON FOR DEVIATION FROM SRM, IS WHEN INSTALLING THE REPAIR SRM STEEL ANGLE, SHORT EDGE MARGINS WERE ENCOUNTERED AND TWO FASTENER HOLES WERE NOT FOUND ACCORDING TO THE SRM. AT THE TWO MISSING FASTENER HOLES, INSTALLED BACB30NX6K INSTEAD OF THE CALLED FOR BACB30NX8K PER SRM. AT THE SHORT EDGE MARGIN LOCATIONS, IT IS ACCEPTABLE TO INSTALL 5 REPAIR FASTENERS INSTEAD OF 6. THE REPAIR WAS CONFIRMED BY REF B AND C. (M)

Part: FLOOR PANEL — DELAMINATED (FUSELAGE)

DURING C-CEHCK AT SIN, FOUND FLOOR PANEL DELAMINATED AT FS 2040 TO STATION 2140, RIGHT SIDE RBL 33.00-75.00. REPAIR BOND A 2024-T3 REPAIR DOUBLER TO THE UNDERSIDE OF THE FLOOR PANEL, PER REF'A'. REPAIR PER REF 'A' IS TIME LIMITED. DER APPROVAL OF REF 'A' ENGINEERING INSTRUCTIONS FOR THE SUBJECT TIME LIMITED REPAIR. REPLACE FLOOR PANEL WITH A NEW PANEL, THAT IS EQUIVALENT TO THE PRODUCTION PANEL, WITHIN 90 DAYS. ISSUED MCI A130 TO CHANGE FLOOR PANEL. (M)

Part: SKIN — DAMAGED (NR 2 PYLON)

DURING C-CHECK SERVICE IN SIAEC, NR 2 PYLON EXTERNAL SKIN FOUND WRINKLED AT INBOARD SIDE AREA OF PYLON VALVE FROM STATION 286 TO STATION 300, BETWEEN THE MID SPAR AND NR 5 STIFFENER. NDT AND CONDUCTIVITY CHECKS WERE ACCOMPLISHED AS PER CARDS A00043 AND A00044. PYLON EXTERNAL SKIN REPAIR CARRIED OUT AS PER TLS-SIN-03-063H, TLS-SIN-03-0053F, AND TLS-SIN-03-0002H. (M)

Part: ACTUATOR — FAILED (AILERON)

FLT 64 - AIRCRAFT DIVERTED TO ATL DUE ON CLIMB-OUT WITH AILERONS AND RUDDER TRIM SET TO ZERO, REQUIRED 3.5 UNITS OF LEFT AILERON TO MAINTAIN LEVEL FLIGHT AND 6 UNITS OF RUDDER TRIM TO NEUTRALIZE AILERONS. MAINTENANCE AT ATL FOUND TWO RIVETS SHEARED IN THE AILERON PROGRAM MECHANISM OF THE CCA IN THE LEFT WHEEL WELL. REPLACED RIVETS AND FOUND LEFT INBOARD AILERONS DROOPS 3 DEGREES. CHECK RIGGING AND FOUND SAME NORMAL. DETERMINED THAT LEFT INBOARD AILERON PACKAGE (P/N 3170120-8) FAULTY. REPLACED LEFT CCA, SYSTEM OPERATION NOW NORMAL. (M)

Part: FRAME — SEVERED (FUSELAGE)

DURING C-CHECK AT AMS DISCOVERED CIRCUMFERENTIAL FRAME SEVERED AT STATION 2240 BETWEEN STRINGER 38R AND 39R. ACCOMPLISHED PERMANENT REPAIR TO FRAME STATION 2240 PER SRM 53-10-04 FIG 66. (M)

Part: FRAME — CORRODED (FUSELAGE)

DURNG C-CHECK AT AMS, FOUND STATION 400 BULKHEAD UPPER CHORD LBL 40 WL 200 CORRODED (MAIN DECK LEVEL). CORROSION REMOVED BY TRIMMING THE FLOOR ANGLE. REPAIRED BY SPLICING IN REINFORCEMENT STRAPS AND ANGLES IAW KLM REPAIR 747-2000-019 AND BOEING ENGINEERING. (M)

Part: ENGINE — FAILED (NR 4)

CREW REPORTS: FLT NR LAU 322/28, BOG/MIA - DEPARTED BOG ON 9-28-97 AND EXPERIENCED AN ABORTED TAKEOFF DUE NR 4 ENGINE FAN BLADE SEPARATION (2 EACH). IN ADDITION, EXHAUST TAIL PLUG EXITED THE ENGINE AND WAS RECOVERED FROM THE RUNWAY. FAN EXIT GUIDE VANES EXHIBIT DAMAGE AND SEVERAL MISSING. ALL FAN BLADES EXHIBIT DAMAGE. REPLACED NR 4 ENGINE, SN ON 662439. OPERATIONAL CHECK SATISFACTORY. (X)

Part: FRAME — CRACKED (BS 320 STR 39)

AD 96-26-04. INSPECTION OF FRAME, RIGHT BS 320, STR 39R, CRACK FOUND. INTERIM REPAIR CARRIED OUT IAW SRM 53-10-04, FIGURE 85.

Part: FRAME — CRACKED (BS 300-320)

AD 96-26-04. INSPECTION OF LEFT FRAME BS 300 AND BS 320. BS 300, STR 39 - STR 40, LEFT, CRACKED. BS 320, STR 41 - STR 42, LEFT, CRACKED. REPAIRED IAW ATLAS E.O. 4753A031.