N811AX

Part: TRANSMITTER — DEFECTIVE (NR 4 OIL PRESS) · airframe 61,858 hrs · 28,094 cycles

NR 4 ENGINE OIL PRESSURE BEGAN FLUXUATING IN CRUISE AND THEN WENT TO '0' PSI. NO LOW OIL PRESSURE LIGHT CAME ON. ALL OTHER ENG PARAMETERS NORMAL. SECURED NR 4 ENGINE AT 0340Z. REMOVED AND REPLACED ENGINE OIL STRAINER. NO CONTAMINATES NOTED. REPLACED MAIN ENGINE OIL FILTER IAW DC-8 MM 79-20-07. REPLACED OIL PRESSURE TRANSMITTER IAW DC-8 MM 79-32-01. PERFORMED ENGINE RUN. NO FLUXATION NOTED. SYSTEM LEAK CHECKED GOOD.

Part: SKIN — CORRODED (FUSELAGE) · airframe 61,670 hrs · 28,005 cycles

EXTERIOR LOWER FUSELAGE SKIN CRACKED AND BULGED AT LONGERON 35 RIGHT, FS 102. REMOVED END FITTING, SHEAR TIES AND DOUBLER IAW DC-8 SRM 51-1-21. REINSTALLED END FITTING, SHEAR TIES AND DOUBLER IAW DC-8 SRM 51-1-21 AND 51-1-20D. REPAIRED SKIN IAW REA D853-50299MR. ALODINED AND PRIMED REPAIR DOUBLER IAW DC-8 SRM 51-1-8.

Part: SKIN — CORRODED (FUSELAGE) · airframe 61,670 hrs · 28,005 cycles

FUSELAGE EXTERIOR SKIN BULGED AND FASTENERS HEAD SHEARED LEFT SIDE OF TAILSKID FAIRING. CUT OUT DAMAGED AREA AND INSTALLED FABRICATED DOUBLER REPAIR, TREATED, ALODINED AND PRIMED IAW DC-8 SRM 51-1-21, 53-2-1, 51-1-8, 51-1-20, AND REA D853-50297-MR.

Part: CUSP WEB — CORRODED (FUSELAGE) · airframe 61,670 hrs · 28,005 cycles

MAIN CABIN AT FS 1164 - 1170 AND LONGERON 21 RIGHT (CUSP) HAD CORROSION. REPAIRED AREA IAW DC-8 SRM 51-1-8 AND REA D853-50301-MR.

Part: SUPPORT — CORRODED (FUSELAGE) · airframe 61,670 hrs · 28,005 cycles

RIGHT FUSELAGE STA 915 - 935, SUPPORT BRACE OUTBOARD OF LONGERON 24 RIGHT, EXFOLIATED. REPAIRED AREA IAW REA D853-50298-MR.

Part: SKIN — CORRODED (FUSLEAGE) · airframe 61,670 hrs · 28,005 cycles

FORWARD CARGO RIGHT SIDE FROM STA 200 - 220, BETWEEN LONGERON 33 RIGHT - 34 RIGHT, SKIN CORRODED WITH BROKEN RIVETS. REMOVED SHEAR TIES, INSTALLED FINGER DOUBLERS, EXTERNAL DOUBLERS, FILLER AND INTERNAL DOUBLERS AND SHEAR TIES IAW REA D853-50304-MR AND DC-8 SRM 51-1-21 AND 51-1-20D. ALODINED AND PRIMED PARTS IAW DC-8 SRM 51-1-8. INSTALLED DRAIN COVER IAW DC-8 SRM 51-1-21.

Part: DOUBLER — CORRODED · corrosion level 2 · airframe 61,670 hrs · 28,005 cycles

AREAS OF CORROSION NOTED ON LOWER SKIN AROUND OUTFLOW VALVE (AFT ACCESSORY COMPARTMENT) FROM FLOOR FRAME 1620 - 1640, LONGERON 34 RIGHT TO 34 LEFT. REMOVED ALL SUBSTRUCTURE AND FASTENERS COMMON TO REPAIR AREA TO FACILITATE REPAIR. REMOVED ALL CORROSION IAW DC-8 SRM 53-2-0. COMPLIED WITH REA D853-50305-MR AND D853-50305-MR REV A. ALODINED AND PRIMED ALL PARTS IAW DC-8 SRM 51-1-8. REINSTALLED ALL SUBSTRUCTURE AND FASTENERS COMMON TO REPAIR AREA IAW DC-8 SRM 51-1-20D.

Part: WIRE — FRAYED (NR 3 ENGINE) · airframe 61,669 hrs · 28,004 cycles

DURING LINE MAINTENANCE, FOUND NR 3 ENGINE EPR WIRING HARNESS CHARRED AND FRAYED DUE TO PREVIOUS PNEUMATIC LEAK. REPLACED NR 3 ENGINE EPR WIRES 7E57SA24N AND 3E573A24N BETWEEN CONNECTOR P1-1449 AND GROUND 825.

Part: WIRE HARNESS — BURNED (EPR SYSTEM) · airframe 61,669 hrs · 28,004 cycles

DURING LINE MAINTENANCE INVESTIGATION OF NR 3 ENGINE EPR PROBLEM, FOUND THE EPR WIRING HARNESS, THRUST BRAKE WIRING AND THRUST REVERSER EMERGENCY DUMP VALVE WIRING CHARRED AND FRAYED DUE TO A PREVIOUS PNEUMATIC DUCT LEAK. REPLACED WIRE NR 3H406E24, 3H2156B24, 3E41L24, 3E379F24, 3E572A24N, 3E573A24N, 3E342K22-RD, 3E378D22-YE, 3E343K22-BL, 3K402C20, 3K404A20N, 3K405J20, 3K438A20N, 3K434A20N IN PYLON LEADING EDGE. ACCOMPLISHED ON ABX NON ROUTINES 105, 106, 107. ALL SYSTEMS OPS CHECKED GOOD IAW DC-8 MM.

Part: ESCAPE ROPE — MISMANUFACTURED (CABIN DOOR) · airframe 61,305 hrs · 27,790 cycles

CHECK EMERGENCY ROPE AT MAIN CABIN DOOR FOR PROPER LENGTH. ROBBED EMERGENCY ROPE FROM 826AX, CHECKED FOR PROPER LENGTH AND INSTALLED ON 811AX IAW DC-8 MM 25-60-02-0002. CANNIBALIZATION FORM WAS FILLED OUT.

Part: JACKSCREW — BINDING (STAB) · airframe 61,277 hrs · 27,779 cycles

DURING APPROACH TO GUA, STABILIZER JAMMED, WOULD NOT MOVE BOTH ELECTRIC OR HYDRAULIC. INDICATOR AT 5.2 DEGREES. FOUND GEARBOX SPROCKET SHEAR PINS SHEARED AND RIGHT JACKSCREW BINDING. INSTALLED NEW SHEAR PINS IAW DC8 OVHL MM 27-10-1. REPLACED LEFT AND RIGHT LONGITUDINAL TRIM JACKSCREWS ASSEMBLIES IAW DC8 MM 27-41-01-2. ACCOMPLISHED ADJ/TEST IAW DC8 MM 27-40-00-5, PARTS 1 THROUGH AND INCLUDING 3B. NO FURTHER DEFECTS NOTED. LUBRICATED BOTH LEFT AND RIGHT JACKSCREWS AFTER INSTALLATION IAW DC8 MM 12-82-01-3. CHECKED OIL LEVEL ON STAB TRIM GEARBOX. OIL LEVEL WAS WITHIN LIMITS IAW DC8 MM 27-41-05-21 AND 12-82-01-3.

Part: ENGINE — DEFECTIVE (NR 2) · airframe 60,995 hrs · 27,628 cycles

UPON INITIAL CLIMBOUT, NR 2 ENGINE OIL PRESSURE WARNING LIGHT ILLUMINATED. NR 2 ENGINE OIL PRESSURE WAS NOTED TO BE 28 PSI AND OIL QUANTITY DECREASING. SHUT DOWN ENGINE AT 0424Z. N1 AND N2 RPM'S NOTED: 22/35. ENGINE OIL PRESSURE IN CRUISE: 3 PSI. REPLACED NR 2 ENGINE.

Part: ACTUATOR — BYPASSING (YAW DAMPER) · airframe 60,983 hrs · 27,617 cycles

ON CLIMBOUT, THE AIRCRAFT EXPERIENCED A VIOLENT LATERAL FLUTTER. THE AUTOPILOT WAS OFF, YAW DAMPER ENGAGED. THE YAW DAMPER WAS DISENGAGED BY PILOT WITH NO NOTEABLE DIFFERENCE. DEPOWERED THE RUDDER HYDRAULICS AND THE FLUTTER STOPPED. FURTHER TROUBLESHOOTING VERIFIED THE RUDDER IN THE POWERED MODE CAUSED THE PROBLEM. ON PREFLIGHT, THE HYDRAULIC PRESSURE WITH AILERON AND RUDDER POWER OFF WAS 2920 PSI. WITH THE AILERON AND RUDDER POWER ON, THE PRESSURE WAS 2670 PSI. MAINTENANCE FOUND THE RUDDER HYDRAULIC POWER PACK BYPASSING FLUID. REPLACED THE RUDDER HYDRAULIC POWER PACK IAW DC8 MM 27-21-06.

Part: UPLOCK — DAMAGED (MLG) · airframe 60,951 hrs · 27,591 cycles

GEAR UPLATCH CHECK FAILED. RIGHT MAIN LANDING GEAR DOOR NOT LATCHED LIGHT ILLUMINATED WITH LANDING GEAR RED UNSAFE LIGHT. IAS DID NOT EXCEED 230 KTS. DEFERRED MAIN LANDING GEAR DOOR UPLATCH SYSTEM IAW DC-8 MEL 32-14, CAT A, CODE 1. PLACARD INSTALLED. MUST BE REPAIRED WITHIN 2 FLIGHT DAYS. REPLACED UPLATCH MECHANISM ON RIGHT MAIN LANDING GEAR IAW DC-8 AMM 32-31-04. PERFORMED ADJUSTMENT/TEST OF RIGHT MAIN LANDING GEAR DOOR UPLATCH MECHANISM IAW DC-8 MM 32-31-04-5, PARA. 3A THROUGH COMPLETION AND PERFORMED LANDING GEAR SWING IAW DC-8 MM 32-11-01. OPS CHECKED GOOD. NO UNSAFE LIGHT.

Part: LINK — LOOSE (MLG) · airframe 60,875 hrs · 27,543 cycles

UPLATCH CHECK FAILED ON INITIAL CHECK. GEAR WAS CYCLED THROUGH ONCE THEN UPLATCH CHECK WAS ACCOMPLISHED. UPLATCH CHECK WAS SATISFACTORY. FOUND LEFT MAIN LANDING GEAR LOWER SIDE BRACE LOWER LINK AND LOWER SIDE BRACE UPPER LINK WITH EXCESSIVE PLAY. REPLACE UPPER SIDE BRACE LOWER LINK AND LOWER BRACE LINK BOLT AND UNIVERSAL BLOCK BOLT IAW DC-8 MM 32-11-03-2-0001 AND DOUGLAS DRAWING 5753118. REPLACED UPPER SIDE BRACE UPPER LINK AND CENTER JOINT BOLT. ADJUSTED LINK IAW 32-11-03-2-0001 AND DOUGLAS DRAWING 5753118. LEFT MAIN LANDING GEAR SWING OPS CHECKED GOOD IAW DC-8 MM 32-11-03-2.

Part: ARM — WORN (MLG DOOR) · airframe 60,775 hrs · 27,479 cycles

RED GEAR UNSAFE LIGHT CAME ON AFTER GEAR RETRACTION WITH RT GEAR DOOR LIGHT ON FLIGHT ENGINEER'S PANEL. RECYCLED GEAR, ALL INDICATIONS NORMAL. MAINTENANCE FOUND DOOR ROLLER OUT OF ADJUSTMENT AND AFT ARM WORN. REPLACED ARM, ADJUSTED MAIN GEAR DOOR UPLATCH MECHANISM IAW MM 32-31-04-4. PERFORMED ADJUSTMENT TEST IAW MM 32-31-04-5.

Part: PROXIMITY SENSOR — DIRTY (MGL) · airframe 60,774 hrs · 27,478 cycles

LANDING GEAR UNSAFE LIGHT ILLUMINATED IN CRUISE. NOT LATCHED LIGHT ON FLIGHT ENGINEER'S PANEL ILLUMINATED WITH SELECTION RT GEAR POSITION. PERFORMED ABNORMAL. LIGHTS EXTINGUISHED WHEN LANDING GEAR WAS CYCLED. MAINTENANCE FOUND RT MAIN LANDING GEAR DOOR NOT LATCHED PROXIMITY SWITCH SENSOR DIRTY. CLEANED PROX SWITCH SENSOR OF DIRT AND DEBRIS. PERFORMED OPERATIONAL CHECK OF MAIN LANDING GEAR DOOR PROX SWITCHES MM 32-60-00-2. ALL SYSTEMS CHECKED GOOD.

Part: SPRING — WORN (LT MLG) · airframe 60,537 hrs · 27,316 cycles

THE GEAR UNSAFE LIGHT ILLUMINATED INTERMITTENTLY ACCOMPANIED WITH LEFT DOOR NOT LATCHED LIGHT AT FLIGHT ENGINEER'S PANEL. PERFORMED ABNORMAL CHECK, UNSAFE LIGHT WOULD NOT REMAIN ILLUMINATED LONG ENOUGHT TO DETERMINE WHICH SWITCH MAY BE MALFUNCTIONING. REPLACED DOOR CONTROL VALVE SPRING. INSPECTED UPLATCH AREA, NO DEFECTS FOUND. INDICATION SYSTEM OPS CHECKED GOOD IAW DC8 MM 32-30-00-2.

Part: SEAL — TORN (MLG) · airframe 60,405 hrs · 27,229 cycles

GEAR UNSAFE LIGHT REMAINED ILLUMINATED WITH GEAR RETRACTED. CYCLED GEAR AND LIGHT WENT OUT. RIGHT MAIN LANDING GEAR DOOR IDENTIFIED ON FLIGHT ENGINEER'S LANDING GEAR AND DOOR LATCHING PANEL. CLEANED UP LATCH SWITCH. OPS CHECKED GOOD IAW DC-8 AMM 32-60-00-2. ON WALKAROUND, ALSO FOUND SEAL ON RIGHT MAIN LANDING GEAR TORN. REPLACED TORN SEAL IAW DC-8 MM 32-10-0.

Part: BATTERY — DISCHARGED (CABIN) · airframe 60,312 hrs · 27,176 cycles

MAINTENANCE FOUND EMERGENCY LIGHT VERY WEAK IN TEST. REPLACED EMERGENCY LIGHTS BATTERY RACK ASSEMBLY. OPS CHECKED GOOD IAW DC-8 MM.

Part: PROXIMITY SWITCH — DIRTY (MLG) · airframe 60,186 hrs · 27,098 cycles

ON CLIMBOUT, GEAR UNSAFE LIGHT STAYED ILLUMINATED AFTER GEAR RETRACTION. RIGHT GEAR DOOR INDICATED. RECYCLED GEAR TWICE. LIGHT WENT OUT. INSPECTED RIGHT GEAR DOOR AND INDICATING SYSTEM COMPONENTS. NO DEFECTS NOTED. DOOR FAIRED ON GROUND WITH HYDRAULIC PRESSURE AND INDICATED NORMALLY. CLEANED STRIKER AND PROX. SWITCH. FOUND PROX. SWITCH WITH CAKED ON GREASE.

Part: TRANSMITTER — FAILED (NR 1 ENG OIL) · airframe 60,145 hrs · 27,068 cycles

DURING CLIMBOUT, WHEN NR 1 ENGINE ANTI-ICE WAS TURNED OFF, NR 1 ENGINE COMPRESSOR STALLED ACCOMPANIED BY NR 1 OIL PRESSURE WENT TO 100 PSI AND OIL QUANTITY FLUCTUATED +/-2 GALLONS. SECURED ENGINE. ENGINE WINDMILLED ABOVE 25 PERCENT FOR 45 MINUTES. FOUND NR 1 OIL PRESSURE TRANSMITTER BAD. REPLACED OIL PRESSURE TRANSMITTER IAW DC-8 MM 79-32-01. OIL QUANTITY READ NORMAL. REMAINED STEADY ON ENGINE RUN. REMOVED AND INSPECTED NR 1 ENGINE OIL FILTER, FILTER WAS CLEAN IAW DC-8 MM 79-20-07. PERFORMED ENGINE RUN, CHECKED OPERATION OF PRBC. CHECKED GOOD. TESTED ENGINE ANTI-ICE VALVE UNDER AIRLOAD VALVES. CHECKED GOOD.

Part: EYEBOLT — WORN (LR MLG) · airframe 60,139 hrs · 27,065 cycles

LT MLG WAS MAKING LOUD NOISE DURING RETRACT. ON SERVICE CHECK, FOUND LT MLG RETRACT CYLINGER EYE BOLT HAD EXCESSIVE PLAY. REWORKED PIN IAW 32-13-0001-001 NEA ON SHOP TRAVELER 5816-01.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 60,136 hrs · 27,062 cycles

CLEAN, TREAT AND PRIME SKIN UNDER C4 SCUFF PLATE. CLEANED CORROSION, TREATED, PRIMED SKIN. FABRICATED AND INSTALLED FILLERS, DOUBLERS AND TRIPLERS IAW DC-8 REA D853-46013-MR, AND THE SRM.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 60,136 hrs · 27,062 cycles

LONGERON 24 RIGHT CRACKED JUST UNDER BOTTLE BOLT IN BATH TUB AREA. ACCOMPLISHED LONGERON 24 RIGHT REPLACEMENT IAW ABX REA D853-46001-MR AND JOB CARD 90453100 (TIMCO).

Part: SKIN — CRACKED (FUSELAGE) · airframe 60,136 hrs · 27,062 cycles

AFT PAX DOOR UPPER AFT CORNER HAD 4 CRACKS FOUND WITH NDT L-2. REMOVED DAMAGE IAW DC-8 SRM 53-2-0, FABRICATED AND INSTALLED DOUBLERS AND FILLERS IAW DC-8 SRM 53-2-0, 51-1-20D, AND 51-1-21.

Part: ACTUATOR — BROKEN (RT WING) · airframe 59,920 hrs · 26,933 cycles

HYD QTY LOSS ON LANDING. MAINTENACE FOUND THE RT INBOARD FLAP ACTUATOR CRANK ASSEMBLY BROKEN ALONG WITH A BROKEN HYD LINE TO THE ACTUATOR AND ASSOCIATED ATTACHING HARDWARE BROKEN. OPEN: CORRECTIVE ACTION IS NOT COMPLETE.

Part: WARNING SYSTEM — MALFUNCTIONED (MLG) · airframe 59,930 hrs · 26,940 cycles

DURING CLIMB, AFTER GEAR UPLATCH CHECK, AIRCRAFT HAD LIGHT TURBULANCE. THE RED GEAR UNSAFE LIGHT CAME ON CAUSED BY THE RT MAIN GEAR DOOR UPLATCH LIGHT ILLUMINATED. RECYCLED GEAR TWICE BEFORE LIGHT WENT OUT. PERFORMED ADJUSTMENT ON UPLATCH. OPS CHECKED UPLATCH AND LIGHTS OPS CHECKED GOOD IAW DC-8 MM 32-31-05.

Part: PUMP — DEFECTIVE (HYD SYSTEM) · airframe 59,893 hrs · 26,914 cycles

MANUAL REVERSION LIGHTS CAME ON DURING FINAL APPROACH. RAN LOSS OF HYDRAULIC PROCEDURES. REPLACED BOTH LT AND RT ENGINE DRIVEN HYDRAULIC PUMPS IAW DC-8 MM 29-10-12-02 AND 29-10-12. SERVICED SYSTEM IAW DC-8 AMM 12-00. LEAK AND OPS CHECKED GOOD.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 59,610 hrs · 26,742 cycles

GEAR UNSAFE LIGHT ILLUMINATED AFTER GEAR RETRACTION. CYCLED GEAR, LIGHT WENT OUT. LOUD GRINDING NOISE HEARD ON 2ND ROTATION.

Part: CONNECTOR — LOOSE (HYD SYSTEM) · airframe 59,457 hrs · 26,642 cycles

AIR RETURN TO MIA DUE TO LOSS OF HYDRAULIC FLUID. AIRCRAFT DUMPED FUEL IN PREPARATION FOR RETURN TO MIA. FOUND CONNECTOR ON HYDRAULIC QUANTITY TRANSMITTER LOOSE. CLEANED AND RESECURED. SYSTEM OPS CHECKED GOOD. CHECKED FUEL DUMP SYSTEM AFTER USE, FOUND ALL NORMAL IAW DC-8 MM 28-30-0.

Part: FLAP — OUT OF RIG (WING) · airframe 59,401 hrs · 26,608 cycles

ON TAKEOFF WITH FLAPS SELECTED TO 18 DEG, THE INDICATOR INDICATED 15 DEG, THEN INCREASED TO 20 DEGREES. ON APPROACH, FLAP INDICATION WAS AS FOLLOWS, 12 SELECTED, 10 INDICATED - 23 SELECTED, 23 INDICATED - 35 SELECTED, 40 INDICATED. AIRCRAFT WAS FERRIED FROM MIA TO ILN. MAINTENANCE RIGGED THE RIGHT FLAP FOLLOW-UP SYSTEM AND RELATED SYSTEM IAW DC-8 MM 27-50-00-5. LUBRICATED LEFT AND RIGHT WING FLAPS IAW DC-8 MM 12-82-01-3.

Part: FUEL CONTROL — FAILED (NR 4 ENGINE) · airframe 58,962 hrs · 26,355 cycles

DURING DESCENT, THE NR 4 ENGINE FAILED TO ACCELERATE. EPR, EGT, RPM AND F/F DECAYED. OIL PRESSURE WAS NORMAL (WINDMILLING). PERFORMED CHECKLIST - NO HELP. DURING LEVEL OFF WITH INCREASED AIRSPEED - NEGATIVE RELIGHT. PERFORMED ENGINE SHUTDOWN ACTIONS CHECKLIST. REPLACED PRESSURE RATIO BLEED CONTROL VALVE IAW DC-8 MM 75-31-1. REPLACED NR 4 ENGINE DRIVEN FUEL PUMP IAW DC-8 MM 73-10-02, NO HELP. ENGINE DRIVEN FUEL PUMP SAFTIED. INSTALLED FUEL CONTROL UNIT IAW DC-8 MM 73-21-1. OPS AND LEAK CHECKED GOOD.

Part: ACTUATOR — BROKEN (SPOILER) · airframe 58,790 hrs · 26,266 cycles

ON SERVICE CHECK, FOUND BOTH CRANK ASSEMBLIES TO THE RIGHT WING INBOARD SPOILER RODS BROKEN. REPLACED BOTH INBOARD SPOILER REAR SPAR ACTUATOR CRANK ASSEMBLIES IAW DC-8 MM 27-61-01-2-0001.

Part: SEAT TRACK — DIRTY (COCKPIT) · airframe 58,195 hrs · 25,960 cycles

AFTER MOVING THE CAPTAIN'S SEAT FORWARD OR AFT, THE HANDLE DID NOT LOCK DOWN ALLOWING THE SEAT TO MOVE. CLEANED AND LUBRICATED THE SEAT TRACK. CHECKED GOOD IAW DC-8 MM 25-11-01.

Part: BRAKE — MALFUNCTIONED (MLG) · airframe 58,191 hrs · 25,958 cycles

ON LANDING, 5 MAIN LANDING GEAR TIRES BLEW. MECHANICS FOUND THAT THE EMERGENCY AIR BRAKE BOTTLE WENT OFF. REPLACED AFT AIR BRAKE MECHANICAL CONTROL CABLE. REF CABLE RUN 81B, 82B, IAW DC-8 MM 32-45-00. SERVICED AIR BRAKE BOTTLE. OPS CHECK OF AIR BRAKE SYSTEM GOOD IAW DC-8 MM 32-44-00. WHEEL ASSEMBLIES REPLACED: 1, 2, 3, 4, 5, 6, 7, 8. REPLACED DAMAGED BRAKE ASSEMBLIES 3 AND 4. COMPLIED WITH REA D832-41587. REPLACED DAMAGED WHEEL SPEED TRANSDUCERS 4 AND 7. BOTH OPS CHECKED GOOD IAW DC-8 MM 32-43-02.

Part: LOCK — LACK OF LUBE (CAPTAIN SEAT) · airframe 58,076 hrs · 25,908 cycles

CAPTAIN'S SEAT WOULD NOT REMAIN IN SELECTED POSITION. INTERMITTENTLY CAUSED SEAT TO SLIDE BACK ON TRACK. LUBRICATED CAPTAIN'S SEAT TRACKS AND LOCKING MECHANISM. SEAT NOW STAYS IN SELECTED POSITION.

Part: DOOR — FAULTY (COCKPIT) · airframe 58,067 hrs · 25,904 cycles

COCKPIT DOOR WAS DIFFICULT TO KEEP CLOSED. UNSAFE AS IS REF, UNABLE TO KEEP CLOSED DURING EMERGENCY PROCEDURE. COCKPIT SMOKE REMOVAL, STEP 6. NOTE: DOOR CAME OPEN SEVERAL TIMES DURING FLIGHT. OPEN AND CLOSED COCKPIT DOOR SEVERAL TIMES BY USING THE COCKPIT DOOR HANDLE AND FOUND NO DEFECTS. AFTER CLOSING DOOR, MAINTENANCE ATTEMPTED SEVERAL TIMES TO MAKE DOOR COME OPEN AND COULD NOT.

Part: LONGERON — CORRODED (FUSELAGE) · airframe 58,057 hrs · 25,899 cycles

FORWARD CARGO COMPARTMENT LONGERON 28 LEFT CORRODED AT FS 280 INSIDE TORQUE BOX. REPAIRED AREA IAW DC-8 SRM 51-3-0, 51-1-21, 51-1-20D, AND REA D853-40780MR.

Part: LONGERON — CORRODED (FUSELAGE) · airframe 58,055 hrs · 25,896 cycles

LEFT MAIN LANDING GEAR WHEEL WELL LONGERON 24 HAD CORROSION ON UPPER SURFACE BETWEEN STATION 879 - 902. CORROSION ALSO RUNS UNDER FITTING AT STATION 902. REPLACED LEFT LONGERON 24 IAW DAC DWG 5750198.

Part: LONGERON — CORRODED (FUSELAGE) · airframe 58,055 hrs · 25,896 cycles

FORWARD CARGO COMPARTMENT CORROSION ON LONGERON 34 RIGHT AT FS 280 INSIDE TORQUE BOX. REPAIRED AREA IAW DC-8 SRM 51-3-0, 51-1-20D, 53-2-2, AND REA D853-40226MR.

Part: STIFFENER — CRACKED (FUSELAGE) · airframe 58,055 hrs · 25,896 cycles

LEFT MAIN LANDING GEAR STATION 940 STIFFENER CRACKED ADJACENT TO CABLE PULLEY ON OUTBOARD WEB. REPAIRED AREA IAW DC-8 DAC DWG 5643402, DC-8 SRM 53-2-0, 51-1-8, 51-1-11, 51-1-21A, AND 51-1-20D.

Part: FITTING — CRACKED (FUSELAGE) · airframe 58,055 hrs · 25,896 cycles

FITTING AT STA 980 IN LEFT MAIN LANDING GEAR WHEEL WELL ABOVE LONGERON 24 IS CRACKED. MAINTENANCE INSPECTED AND REPAIRED THE AREA IAW DC-8 SRM.

Part: FITTING — CRACKED (FUSELAGE) · airframe 58,055 hrs · 25,055 cycles

CORROSION FOUND ON LONGERON 24 BACK UP FITTING AT STA 879, LEFT MAIN LANDING GEAR WHEEL WELL. FOUND TO BE CRACKED AFTER CORROSION REMOVAL.

Part: SKIN — CORRODED (FUSELAGE) · airframe 58,055 hrs · 25,896 cycles

FS 660 - 680 LONGERON 36 - 35 RIGHT AIRCRAFT SKIN WAS CORRODED UNDER ACCELEROMETER BRACKET INSIDE AND OUTSIDE AIRCRAFT. REPAIRED AREA IAW DC-8 SRM 51-1-21, 51-1-8, 53-2-0, 51-1-20D, AND 53-2-1.

Part: FITTING — CORRODED (RT MLG WW) · airframe 58,055 hrs · 25,896 cycles

RIGHT MAIN LANDING GEAR WHEEL WELL HAD CORROSION ON INBOARD UPPER CHAMBER ON TRAP FITTING. BLENDED AND REMOVED CORROSION FOUND WITHIN LIMITS IAW DC-8 SRM 53-2-0, FIGURE 1, SHEET 3. ALODINED AND PRIMED IAW DC-8 SRM 51-1-8.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 58,055 hrs · 25,896 cycles

LONGERON 24L WAS FOUND TO BE CRACKED AT FS 960.

Part: BRAKE — DEFECTIVE (MLG) · airframe 58,055 hrs · 25,896 cycles

THE BRAKES WERE SPONGY AND INEFFECTIVE ON LANDING.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 58,055 hrs · 25,896 cycles

AFT LOWER CARGO STRINGER 35 RIGHT CORRODED CAUSING CRACK TO APPEAR. REPAIRED AREA IAW DC-8 SRM 53-2-0, 53-2-1, 51-1-8, 51-1-20D, 51-1-21, 51-3-0, DAC DWG 5759639, AND REA D853-40796MR.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 58,055 hrs · 25,896 cycles

LOWER T-CAP DOUBLER STA 980 AFT CARGO PIT WAS CRACKED FROM LONGERON 35L TO 35R. MAINTENANCE INSPECTED AND REPLACED THE T-CAP DOUBLER IAW DC-8 SRM 51-1-24.

Part: SPLICE — CRACKED (FUSELAGE) · airframe 58,054 hrs · 25,895 cycles

SPLICE FITTING AT FS 1050 LONGERON 31L IS CRACKED.

Part: FITTING — CRACKED (FUSELAGE) · airframe 58,054 hrs · 25,895 cycles

A FITTING AFT OF THE PRODUCTION SPLICE IS CORRODED.

Part: FITTING — CRACKED (FUSELAGE) · airframe 58,054 hrs · 25,895 cycles

FITTING IS CRACKED AND CORRODED AT FS 1690 LONGERON 34R AFT SIDE OF SPLICE.

Part: FITTING — CRACKED (FUSELAGE) · airframe 58,054 hrs · 25,895 cycles

FITTING CRACKED AND CORRODED AT FS 1690 LONGERON 36 AFT SIDE OF SPLICE.

Part: LONGERON — CORRODED (FUSELAGE) · corrosion level 2 · airframe 58,054 hrs · 25,895 cycles

LONGERON 24 IN LEFT MAIN LANDING GEAR WHEEL WELL HAS CORROSION ON UPPER SURFACE, BETWEEN STA 879 AND 902.

Part: LONGERON — CORRODED (FUSELAGE) · corrosion level 2 · airframe 58,054 hrs · 25,895 cycles

CORROSION FOUND ON UPPER SURFACE OF LONGERON 24 AT FS 920. CORROSION EXTENDS UNDER FITTING IN LEFT MAIN LANDING GEAR WHEEL WELL.

Part: BRACKET — CORRODED (LT MLG WW) · airframe 58,055 hrs · 25,896 cycles

BRACKET FOR FLAP CABLE GUIDE WHEEL HAD CORROSION AFT OF STATION 902 FITTING LEFT MAIN LANDING GEAR WHEEL WELL. REPLACED FLAP BUS CABLE BRACKET IAW DC-8 MM 27-50-00 AND 20-17-00.

Part: SPLICE — CRACKED (FUSELAGE) · airframe 58,054 hrs · 25,895 cycles

FITTING AT PRODUCTION SPLICE FS 1690 32R WAS CRACKED.

Part: CONTROL UNIT — FAILED (RUDDER) · airframe 57,842 hrs · 25,785 cycles

DURING TAXI WHILE PERFORMING THE FLIGHT CONTROL CHECK, THE RUDDER WAS REPORTED TO BE BINDING NEAR THE LAST 1/3 OF RIGHT INPUT TRAVEL. MAINTENANCE INSPECTED AND CYCLED THE RUDDER NUMEROUS TIMES. THE RUDDER POWER CONTROL UNIT AND PRESSURE REDUCER VALVE WAS INSPECTED IAW DC-8 MM 27-21-07. NO DEFECTS OR BINDING WAS FOUND. OPS CHECKED GOOD.

Part: RUDDER — BINDING (TAIL) · airframe 57,842 hrs · 25,785 cycles

DURING TAXI WHILE PERFORMING THE FLIGHT CONTROL CHECK, THE RUDDER WAS REPORTED TO BE BINDING NEAR THE LAST 1/3 OF RIGHT INPUT TRAVEL. MAINTENANCE INSPECTED AND CYCLED THE RUDDER NUMEROUS TIMES. THE RUDDER POWER CONTROL UNIT AND PRESSURE REDUCER VALVE WAS INSPECTED IAW DC-8 MM 27-21-07. NO DEFECTS OR BINDING WAS FOUND. OPS CHECKED GOOD.

Part: VALVE — LEAKING (HYDRAULIC SYS) · airframe 57,333 hrs · 25,595 cycles

AIRCRAFT HAD A LOSS OF HYDRAULIC QUANTITY ON TAKEOFF, DOWN TO STANDPIPE. CREW ELECTED TO USE AIR BRAKES UPON LANDING. REPLACED BRAKE CONTROL VALVE AND O-RINGS IAW DC8 MM.

Part: LIGHT — FAILED (COCKPIT) · airframe 56,610 hrs · 25,258 cycles

CAPTAIN''S BRIEFCASE LIGHT WAS SMOKING. REPOSITIONED WIRES INSIDE LIGHT ASSY.

Part: SKIN — CRACKED (BS 8)

THE FUSELAGE SKIN WAS CRACKED IN THE RIGHT AFT WHEEL WELL CORNER OF THE NOSE LANDING GEAR. REPAIRED FUSELAGE SKIN AT STATION 8.0, RIGHT AFT CORNER OF NOSE LANDING GEAR CUTOUT, IAW ABX REA D853-34755-MR, REVISION A.

Part: WINDOW — OUT OF ADJUST (RT COCKPIT)

FIRST OFFICER'S CLEARVIEW WINDOW (EMERG EXIT) WOULD NOT OPEN. ADJUSTED WINDOW MECHANISM IAW DC8 MM 56-10-3.

Part: FRAME — CORRODED (BS 1140)

CORROSION ON UNDERSIDE OF FRAME AT STATION 1140 BETWEEN LONGERONS 33 AND 34 RIGHT. REPAIRED IAW ABX REA D853-31948MR.

Part: SKIN — CRACKED (WS 404)

RIGHT WING LEADING EDGE LOWER SKIN CRACKED AT STATION XW-404. REPAIRED IAW ABX REA D857-31905MR.

Part: SKIN — CRACKED (RUDDER)

LEFT LOWER RUDDER SKIN CRACKED. REPAIRED IAW ABX REA D827-31901.

Part: SWITCH — DAMAGED (LT MLG)

ON GEAR RETRACTION RED LIGHT EXTINGUISHED BUT CAME BACK ON DURING UPLATCH CHECK. RECYCLED GEAR, WHEN GEAR WAS RETRACTED, RED INTRANSIT LIGHT REMAINED ON. REPLACED LEFT UPLATCH PROXIMITY SWITCH, OPS CHECKED GOOD IAW DC8 MM 32-60-00.

Part: FRAME — CORRODED (BS 1040)

ZEE-FRAME AT STATION 1040 CORRODED BEYOND LIMITS. REPAIRED IAW ABX REA D853-0229 AND DC8 SRM 51-1-20.

Part: FRAME — CORRODED (BS 1120)

FRAME CORRODED BEYOND LIMITS AT STATION 1120, LONGERON 36. REPAIRED IAW ABX REA D853-21894MR AND DC8 SRM 53-2-0.

Part: BRACKET — BROKEN (RT SPOILER)

DURING PREFLIGHT INSPECTION, FOUND THE RIGHT WING SPOILER SYSTEM WHEEL WELL PULLEY BROKEN. REPLACED SPOILER PULLEY BRACKET, RIGGED AND PERFORMED SPOILER OPERATIONAL CHECK IAW DC-8 MM 27-60-0.

Part: O-RING SEAL — DEFECTIVE (NR 2 HYD PUMP)

DURING DESCENT, HYDRAULIC FLUID QUANTITY DROPPED TO STANDPIPE LEVEL. REPLACED O-RING SEAL ON THE NR 2 HYDRAULIC PUMP PRESSURE LINE FITTING, LEAK CHECK GOOD.

Part: DRIVE LINK — FAILED (LT SPOILER)

DURING GEAR EXTENSION ON APPROACH, THE SPOILER EXTEND LIGHT ILLUMINATED; NO BUFFET WAS FELT. EXTENDED SPOILERS MANUALLY, LIGHT REMAINED ON AFTER THEY WERE RETRACTED. FOUND LT MOST INBOARD SPOILER PANEL DRIVE LINK AND OUTBOARD TOP DRIVE LINK BROKEN. ALSO, LT SPOILER SWITCH WAS BROKEN. REPLACED LINKS AND SWITCH IAW DC 8MM. SYSTEM OPS CHECKED GOOD.

Part: LINK — FAILED (LT SPOILER)

DURING GEAR EXTENSION ON APPROACH, THE SPOILER EXTEND LIGHT ILLUMINATED; NO BUFFET WAS FELT. EXTENDED SPOILERS MANUALLY, LIGHT REMAINED ON AFTER THEY WERE RETRACTED. FOUND LT MOST INBOARD SPOILER PANEL DRIVE LINK AND OUTBOARD TOP DRIVE LINK BROKEN. ALSO, LT SPOILER SWITCH WAS BROKEN. REPLACED LINKS AND SWITCH IAW DC 8MM. SYSTEM OPS CHECKED GOOD.

Part: LINK — FAILED (LT SPOILER)

DURING GEAR EXTENSION ON APPROACH, THE SPOILER EXTEND LIGHT ILLUMINATED; NO BUFFET WAS FELT. EXTENDED SPOILERS MANUALLY, LIGHT REMAINED ON AFTER THEY WERE RETRACTED. FOUND LT MOST INBOARD SPOILER PANEL DRIVE LINK AND OUTBOARD TOP DRIVE LINK BROKEN. ALSO, LT SPOILER SWITCH WAS BROKEN. REPLACED LINKS AND SWITCH IAW DC 8MM. SYSTEM OPS CHECKED GOOD.

Part: SPRING — BROKEN (CAPT SEAT)

CAPTAIN'S SEAT WOULD NOT STAY LOCKED IN POSITION, KEPT SLIDING BACK. FOUND SPRING TO LOCKPIN BROKEN. REPLACED SPRING IAW DC 8 MM CHAPTER 25, SYSTEM OPS CHECKED GOOD.

Part: LINE — DEFECTIVE (LEFT)

AFTER LIFT OFF, LOST ALL HYDRAULIC PRESSURE, RESERVOIR LOW PRESSURE AND AILERON MANUAL CONTROL LIGHTS ILLUMINATED. HYDRAULIC QUANTITY INDICATED FULL, WAS NOT ABLE TO RECOVER PRESSURE WITH AUX PUMP. REPAIRED .5 INCH STEEL HYDRAULIC LINE BEHIND ACCESS PANELS 525 AND 562 IN LEFT FLAP WELL, OUTBOARD NR 5 MAIN WHEEL IAW GMM, CHAPTER 3, 29-01-01. SYSTEM LEAK CHECKED GOOD. SERVICED HYDRAULIC RESERVOIR IAW DC-8 MM 12-08.

Part: ENGINE — FAILED (NR 3)

EN ROUTE TO FLL, CREW SHUTDOWN NR 1 ENGINE AS PRECAUTIONARY DUE TO LOW OIL PRESSURE INDICATION, LIGHT, AND HIGH OIL TEMPERATURE INDICATION. VERIFIED ENGINE FAILURE, LOSS OF OIL OUT TAIL PIPE AND METAL IN THE FILTER SCREEN. INSPECTED AND PREPARED AIRCRAFT FOR THREE ENGINE FERRY TO ILN. REPLACED THE NR 3 ENGINE, SYSTEMS OPS CHECKED GOOD IAW DC 8 MM.

Part: CYLINDER — SHEARED PIN (MLG)

UPON CLIMB-OUT OF PDX GEAR UNSAFE LIGHT, RIGHT MLG DOOR, AND RIGHT MLG UNSAFE LIGHTS ILLUMINATED. RECYCLED GEAR SEVERAL TIMES. DURING UPLATCH CHECK, THE LIGHT STAYED ON. PERFORMED ABNORMAL PROCEDURES AND UPLATCH CHECK DOOR LIGHT WENT OUT; GEAR UNLATCHED AND UNSAFE LIGHT STAYED ON. CONTINUED AT REDUCED AIRSPEED TO ILN. FOUND MLG ACTUATOR ATTACH PIN TO GEAR SHEARED AT THE STRUT. REMOVED AND REPLACED THE ATTACH PIN IAW REA0832-11273-MR AND DC 8 OVH MANUAL CHAPTER 32. REMOVED AND REPLACED THE RIGHT MLG ACTUATOR AS PRECAUTIONARY IAW DC 8 MM CHAPTER 32. GEAR INDICATION AND OPERATIONS CHECKED GOOD.

Part: TARGET — LOOSE (RT MLG DOOR)

AFTER TAKEOFF AND GEAR RETRACTION, GEAR 'UNSAFE' LIGHT STAYED ON. SELECTOR INDICATED THAT THE RIGHT MLG DOOR WAS NOT LATCHED. ON THE THIRD GEAR RECYCLE 'UNSAFE' LIGHT EXTINGUISHED AND GEAR DOOR INDICATED UP AND LOCKED. FOUND LOOSE STRIKER PLATE AT RIGHT MLG DOOR PROXIMITY SWITCH. TIGHTENED STRIKER. MLG GEAR UPLATCH AND DOOR CLOSED PROXIMITY SWITCH TEST OPS CHECKED GOOD IAW DC 8 MM CHAPTER 32.

Part: CONTROL CABLE — OUT OF ADJ (RT MLG)

UPON CLIMB-OUT OF ILN RIGHT MAIN GEAR DOOR 'UNLATCHED' LIGHT ILLUMINATED. RECYCLED GEAR AND HAD SAME INDICATION. REDUCED AIRSPEED AND CONTINUED TO EWR. PERFORMED MAIN GEAR DOOR CLOSED PROXIMITY SWITCH TEST. RIGHT MAIN LANDING GEAR DOOR 'UNLATCHED' LIGHT REMAINED ON. REPLACED RIGHT PROXIMITY SWITCH STRIKER AND SPRING. ADJUSTED MAIN LANDING GEAR DOOR FOLLOW-UP CABLE. PERFORMED GEAR RETRACTION TEST, AND OPS CHECKED GOOD IAW DC-8 MM CHAPTER 32.

Part: RECIRC FAN — ODOR (LEFT)

EN ROUTE TO BOS, CREW REPORTED LEFT RECIRCULATING FAN CAUSED AN OILY SMELL IN THE COCKPIT. OPS CHECKED LEFT RECIRCULATING FAN AND ALL FOUR CTC'S IAW DC 8 MM CHAPTER 21. NO OILY SMELL OR ABNORMAL ODORS NOTICED.