N823AX

Part: LIGHT — INOPERATIVE (COCKPIT) · airframe 72,095 hrs · 20,274 cycles

THE EMERGENCY LIGHT AMBER LIGHT WOULD NOT ILLUMINATE. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY LIGHT AMBER LIGHT BULBS IAW DC-8 MM 33-00-00.

Part: BOLT — BROKEN (RT MLG) · airframe 71,750 hrs · 20,066 cycles

AFTER GEAR RETRACTION THE LANDING GEAR UNSAFE LIGHT REMAINED ILLUMINATED WITH GEAR HANDLE UP. GEAR WAS CYCLED WITH SAME INDICATIONS. AN UPLATCH CHECK WAS PERFORMED AND WITH THE GEAR HANDLE TO THE UPLATCH POSITION THE NOT LATCHED LIGHT ILLUMINATED. IN RIGHT DOOR AND RIGHT MAIN LANDING GEAR POSITIONS A VIBRATION WAS NOTED. FOUND RIGHT AFT ATTACH BOLT ON BOGIE TRIM CYLINDER BROKEN. REPLACED BOLT AND ATTACH CLEVIS IAW DC8 MM 20-16-0. PERFORMED POSITION AND WARNING SYSTEM CHECK ON THE RIGHT MAIN LANDING GEAR. OPS CHECKED GOOD IAW DC8 MM 32-60-00.

Part: STRUT — FAILED (NLG)

LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF. GEAR HANDLE WOULD NOT MOVE OUT OF DOWN POSITION. AIR TURN BACK TO ILN. REPACKED NOSE LANDING GEAR STRUT IAW DC8 MM 32-21-2 AND CHECKED LANDING CONTROL LEVER AND ANTI-RETRACTION LATCH IAW DC8 MM 32-31-1. OPS CHECKED OK.

Part: SELECTOR — LACK OF LUBE (LANDING GEAR)

DURING CLIMB, UNSATISFACTORY GEAR UPLATCH CHECK WITH NOSE GEAR NOT LATCHED LIGHT ILLUMINATED. PERFORMED ALTERNATE UPLATCH CHECK PROCEDURE. FOUND LANDING GEAR LEVER STIFF AND HARD TO GO IN UPLATCH DETENT. CLEANED AND LUBED LEVER MECHANISM. OPS CHECKED GOOD. PERFORMED ADJ/TEST NOSE LANDING GEAR CONTROL VALVE IAW DC-8 MM 32-32-11. OPS CHECKED GOOD. PERFORMED GEAR SWING IAW DC-8 SMM 32-60-0. OPS CHECKED GOOD.

Part: INSULATION — OUT OF POSITION (LANDING GEAR)

UNABLE TO RAISE LANDING GEAR HANDLE AFTER TAKEOFF. NOSE GEAR HAD MOVED PAST CENTER, RESET GROUND CONTROL RELAY CIRCUIT BREAKER. MAIN GEAR SPOILER INOP LIGHT ILLUMINATED. RESET LOCKOUT CIRCUIT BREAKER AND LIGHT WENT OUT. GEAR THEN RETRACTED NORMALLY. INSPECTED GEAR AND GEAR LINKAGE, NO DEFECTS NOTED. FOUND INSULATION INTERFERING WITH LANDING GEAR CONTROL LINKAGE. REMOVED INSULATION. OPS CHECKED GOOD.

Part: PLATE — CRACKED (LT WING)

LEFT WING TRAILING EDGE SUPPORT STRUCTURE PLATE CRACKED, AFT OF NR 3 SPOILER ACTUATOR. REPAIRED IAW DC8 SRM 57-5-3 AND 57-2-0.

Part: LONGERON — CORRODED (BS 660)

HEAVY CORROSION ON LONGERON 28R AT STATION 66O. REPAIRED IAW DC8 SRM 51-1-20D AND DWG 3750342.

Part: STRUCTURE — CORRODED (BS 50-60)

COCKPIT SUBFLOOR STATION -60 TO -50, LBL 24-30, SHEARED RIVETS AND INTERNAL CORROSION. REPAIRED IAW ABX REA D853-24900 AND DC8 SRM 51-1-20D.

Part: RIB — CRACKED (WS 520.168)

RIGHT WING OUTBOARD STUB WING LEADING EDGE RIB CRACKED, 7 INCHES FORWARD OF FRONT SPAR AT STATION XS 520.168. REPAIRED IAW DC8 SRM.

Part: FRAME — CORRODED (BS 1580)

BELTFRAME CORRODED AT STATION 1580 BETWEEN LONGERON 36R AND 35R. REPAIRED IAW DC8 SRM 51-1-21 AND 53-2-0.

Part: RIB — CRACKED (WS 610)

RIGHT WING LEADING EDGE RIB AT STATION XFS 610 IS CRACKED AT THE AFT UPPER END. REPAIRED IAW ABX DWG K05056, DC8 SRM 51-1-8 AND 51-1-20D.

Part: FITTING — CRACKED (BS 680)

CRACKED INTERCOSTAL FITTING AT STATION 680 LONGERON 18L. REPAIRED IAW DC8 SRM 51-1-20D AND DWG 3179874.

Part: BULKHEAD BRACKET — CRACKED (BS 640)

STATION 640 BULKHEAD TO FUSELAGE ATTACH BRACKET CRACKED BETWEEN LONGERON -26L AND -27L FORWARD ACCESSORY COMPARTMENT. REPAIRED IAW DC8 SRM 53-2-0.

Part: FITTING — CORRODED (BS 1180)

BATH TUB FITTING AT STATION 1180 BETWEEN LONGERON 35R AND 36R CORRODED. REPAIRED IAW DC8 SRM 53-2-0.

Part: RIB — CRACKED (WS 520)

LEFT WING LEADING EDGE RIB CRACKED AT STATION XS520.168. REPAIRED IAW DC8 51-1-21, 51-1-20D AND DWG 5769523.

Part: DOUBLER — CRACKED (NR 1 PYLON)

LEFT WING NR 1 PYLON STUB WING LOWER SURFACE REPAIR DOUBLER CRACKED BETWEEN 2 RIVETS. REPAIRED IAW DC8 SRM 51-1-26.

Part: RIB — CRACKED (WS 622.5)

RIGHT WING LEADING EDGE RIB STATION XFS 622.5 IS CRACKED AT THE AFT LOWER END. REPAIRED IAW DWG K05056 AND DC8 SRM 51-1-20D.

Part: ANGLE — CRACKED (BS 1750)

ELEVATOR UP CABLE FEED THROUGH BRACKET CRACKED AT RBL 24, STATION 1750. REPAIRED IAW ABX REA D853-24898MR.

Part: FITTING — CRACKED (BS 200-220)

LONGERON 31L SPLICE CRACKED STATION 200 TO 220. REPLACED SPLICE IAW DC8 SRM 53-1-0 AND 51-1-20D.

Part: RIB — CRACKED (WS 766.25)

LEFT WING LEADING RIB UPPER ARM CRACKED BY AFT FASTENER AT STATION XFS 766.250. REPAIRED IAW ABX DWG K05056.

Part: RIB — CRACKED (WS 778.75)

LEFT WING LEADING EDGE RIB UPPER ARM CRACKED BY AFT FASTENER AT STATION XFS 778.750. REPAIRED IAW ABX DWG K05056.

Part: RIB — CRACKED (WS 628.75)

RIGHT WING LEADING EDGE RIB STATION 628.75 IS CRACKED AT THE AFT UPPER END. REPAIRED IAW DWG K05056 AND DC8 SRM 51-1-20D.

Part: RIB — CRACKED (WS 772.5)

LEFT WING LEADING EDGE RIB CRACKED STATION SFX 772.500. REPAIRED IAW ABX DWG K05056.

Part: ANGLE — CRACKED (WS 454)

RIGHT WING LEADING EDGE, INBOARD OF STATION XW454 RIB, VERTICAL ANGLE CRACKED AT LOWER END. REPAIRED IAW DC8 SRM 51-1-21, 51-3-0 AND DWG 9755297.

Part: RIB — CRACKED (LT WING)

LEFT WING LEADING EDGE RIB UPPER ARM CRACKED BY AFT FASTENER AT STATION FS 785. REPAIRED IAW DWG K05056.

Part: RIB — CRACKED (LT WING)

LEFT WING LEADING EDGE RIB UPPER ARM CRACKED BY AFT FASTENER AT STATION XFS591.250. REPAIRED IAW SRM 51-1-20D.

Part: SPLICE — CRACKED (BS 380-400)

LONGERON 31L SPLICE CRACKED BETWEEN STATION 400 AND 380. REPAIRED IAW DC8 SRM 51-1-20D.

Part: TEMP PROBE — STRIPPED (NR 2 ENGINE)

INFLIGHT SHUTDOWN OF NR 2 ENGINE DUE TO LOW OIL PRESSURE. FOUND OIL TEMP PROBE BACKED OUT OF OIL FILTER HOUSING. THREADS WERE STRIPPED.

Part: LONGERON — CORRODED (BS 450-610)

DURING C-CHECK, FOUND CORROSION ON LONGERON 36L AT STA 450 TO 610. *S/D* REPAIRED IAW DC8 SRM 51-1-200 AND ABX REA D853-19137MR.

Part: PRESSURE WEB — CORROSION (BS 12)

DURING C-CHECK, CORROSION FOUND ON PRESSURE PANEL WEB RUNNING UNDER FLOORBEAM, COCKPIT FLOOR FS 12.00. *S/D* REPAIRED IAW ABX REA D853-19472MR.

Part: FRAME — CORRODED (CABIN)

CORROSION ON FRAME 12, LOWER LEG AT L30L. *S/D* REPAIRED IAW DC8 SRM 51-1-20A AND ABX REA D853-19476MR.

Part: SKIN — CORRODED (BS 400)

DURING C-CHECK, FUSELAGE SKIN WAS FOUND BULGED AT STA 400 LONGERON 34L. REMOVED CORRODED SKIN AND REPAIRED IAW DC8 SRM 53-4-1 AND ABX REA D853-19125MR.

Part: LONGERON — CRACKED (BS 500-540)

DURING C-CHECK, FOUND LONGERON 35L, STA 500 TO 540 CRACKED. *S/D* REPAIRED IAW DC8 SRM 51-1-8 AND ABX REA 853-19130MR.

Part: SKIN — CORRODED (RT TE FLAP)

RIGHT FLAP, TOP SIDE, INBOARD EDGE FOUND CORRODED DURING C-CHECK. REMOVED CORROSION, FABRICATED FILLER AND DOUBLER AND INSTALLED IAW DC8 SRM 51-1-8 AND 57-2-1.

Part: SKIN — CORRODED (WS 285)

DURING C-CHECK, FOUND CORROSION ON LEFT WING LEADING EDGE AT XFS 285 ON UPPER SURFACE. INSTALLED FILLER AND DOUBLER IAW DC8 SRM 51-1-8.

Part: SUPPORT — CRACKED (BS 759/875)

FLOOR SUPPORT CRACKED AT STA 759 AND 875.375, BETWEEN SEAT TRACKS C AND D. FABRICATED SUPPORT ANGLES AND INSTALLED IAW DC8 SRM 51-1-8 AND ABX REA 853-19470.

Part: ANGLE — CORRODED (SERVICE DOOR)

DURING C-CHECK, FOUND RIGHT FWD SERVICE DOOR FWD LOWER ANGLE AT CUSP CORRODED. FABRICATED AND INSTALLED NEW ANGLE IAW DC8 SRM 51-1-24 AND ABX REA D853-19482.

Part: SKIN — CORRODED (RT STUB WING)

DURING C-CHECK, FOUND CORROSION IN STUB-WING AT SPAR CAP ATTACH EDGE ON RIGHT HAND LEADING EDGE . *S/D* FABRICATED REPAIR DOUBLER AND INSTALLED IAW DC8 SRM 51-1-8 AND ABX REA D823-19144MR.

Part: TAB — DELAMINATED (RUDDER)

RUDDER TAB WAS FOUND TO BE DELAMINATED. REPLACED SKIN, HONEYCOMB CORE AND INTERNAL DOUBLERS.

Part: AILERON — BROKEN (RIGHT)

AIRCRAFT REQUIRED 2 UNITS OF LEFT AILERON TRIM AND 1 UNIT OF LEFT RUDDER TRIM TO MAINTAIN STRAIGHT FLIGHT DURING CLIMB AND CRUISE. REPLACED RIGHT INBOARD AILERON IAW DC-8 MM 27-10-1.

Part: SKIN — DAMAGED (BS 28)

DURING SORT OPERATIONS, A CARGO LOADER WAS DRIVEN INTO THE AIRCRAFT PUTTING A HOLE IN THE FUSELAGE SKIN AT STATION 28 LEFT. REPAIRED IAW ABX REA D853-17575.

Part: ENGINE — DEFECTIVE (NR 4)

DURING SERVICE CHECK, FOUND NR 4 ENGINE C1 COMPRESSOR BLADE HAD RUBBED A .75 BY 2.25 INCH HOLE; HOUSING BETWEEN C1 AND C2 HAD A .25 BY 3 INCH GAP, BOTH AT THE 4 O'CLOCK POSITION. THREE ENGINE FERRIED AIRCRAFT BACK TO ILN. REPLACED NR 4 ENGINE IAW JOB CARD J7002.

Part: BOLT — LOOSE (NR 3 ENGINE)

DURING CLIMB, NR 3 ENGINE COULD NOT BE CONTROLLED WITH THROTTLE INPUTS. ENGINE REMAINED AT MAX CONTINUOUS THRUST WITH THE THROTTLE LEVER PULLED BACK TO IDLE. ENGINE WAS SHUTDOWN AND MAINTAINED A POSITIVE OIL PRESSURE DURING SHUTDOWN PROCEDURES. SECURED AND SAFETIED THE NR 3 ENGINE POWER LEVER LINKAGE AT THE FCU INPUT CLEVIS. GROUND RAN ENGINE, ALL CONTROLS AND PARAMETERS CHECKED GOOD.

Part: C1 DISK — CRACKED (NR 2 ENGINE)

DURING COMPLIANCE OF AD 80-12-51, PRATT AND WHITNEY SB 5136, FOUND CRACK INDICATIONS IN C-1 DISK, FIRST STAGE FAN BLADES. REPLACED C-1 DISK, FIRST STAGE FAN BLADES IAW ABX TEST AND MAINTENANCE RECORD WORK SHEETS, BS374A, BS375A, BS376A AND BS377A.

Part: HEAT SYST — ODOR (COCKPIT)

EN ROUTE TO EWR, WITH SUPPLEMENTAL HEAT ON, A BURNING ODOR WAS REPORTED IN THE COCKPIT. THE ODOR DISSIPATED WHEN THE HEAT WAS TURNED OFF. COULD NOT DUPLICATE. THE SUPPLEMENTAL HEAT WAS OPERATED FOR SEVERAL MINUTES ON THE GROUND AND NO ODOR WAS NOTED. HEATER OPS CHECKED GOOD.

Part: PROXIMITY BOX — DEFECTIVE (LT MLG)

LEFT MAIN GEAR DOOR LATCH LIGHT ILLUMINATED. RECYCLED LANDING GEAR 3 TIMES, LIGHT REMAINED ILLUMINATED. AIRCRAFT REDUCED AIRSPEED AND CONTINUED TO ILN. REMOVED AND REPLACED FAULTY PROXIMITY CONTROL BOX. REPLACED BENT PROXIMITY SWITCH PADDLE FOR LEFT GEAR DOOR. SYSTEM OPS CHECKED GOOD IAW DC 8 MM CHAPTER 32.