N828BX

Part: PLUG — UNSECURE (NR 1 ENGINE OIL) · airframe 89,129 hrs · 37,202 cycles

DURING CRUISE, THE CREW SHUTDOWN NR 1 ENG DUE TO LOSS OF OIL QUANTITY. THEY LANDED WITHOUT FURTHER INCIDENT. MX INSPECTED AND FOUND THE STARTER FILLER PLUG OFF. THEY REINSTALLED FILLER PLUG AND LOCKED SERVICED ENGINE. OPS CHECK GOOD IAW AMM 80-10, AMM 12-10. ACFT WAS RETURNED TO SERVICE.

Part: FUEL CONTROL — OUT OF RIG (NR 4 ENGINE) · airframe 88,677 hrs · 36,981 cycles

DURING TAKEOFF, NR 4 ENG WOULD NOT MAKE PWR. ONCE AIRBORNE HAD TO PUSH THROTTLE PAST OTHER THROTTLES NR 4 EGT WENT TO 907 DEGREE. THE CREW RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. MX INSPECTED NR 4 ENG AND FOUND VSV'S AND VBV OUT OF RIG. MX ACCOMPLISHED VSV'S AND VBV'S RIGGING. OPS CHECK GOOD IAW MM 75-32-00, 73-21-00, AND ATI ERH 70.01.1. ACFT WAS RETURNED TO SERVICE.

Part: TEE FITTING — CRACKED (BULKHEAD) · airframe 88,673 hrs · 36,977 cycles

DURING INSP IAW AD2007-21-18 AND SB DC8-53A081 FOUND RT AFT PRESSURE BULKHEAD TEE FITTING CRACKED. STOP DRILLED CRACK IAW SRM 53-2-5.

Part: CONNECTOR — DEFECTIVE (ENGINE OIL SYS) · airframe 88,019 hrs · 36,652 cycles

DURING CRUISE FROM KTOL NUMBER THREE ENGINE OIL PRESSURE STABILIZED AT 50 PSI THEN FLUCTUATED BETWEEN 20-60 PSI FOR A SHORT TIME, THEN STABILIZED AGAIN AT 50 PSI. THE CREW RETURNED TO KTOL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED OIL PRESSURE ELECTRICAL CONNECTOR. OPERATIONAL CHECK GOOD IAW DACO MAINTENANCE MANUAL 20-50-1, AND ERH 70.01. AIRCRAFT WAS RETURNED TO SERVICE.

Part: COMPARATOR — DEFECTIVE (COCKPIT) · airframe 87,900 hrs · 36,598 cycles

DURING CLIMBOUT FROM KTOL, CAPT'S RMI, GYRO FLAG, AND F/O'S GLIDESLOPE IN HSI, FLIGHT DIRECTOR IN ASI FLAG ALL IN VIEW. THE CREW RETURNED TO KTOL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED SMART BOX. OPERATIONAL CHECK GOOD IAW DC8 MAINTENANCE MANUAL 34-20-0, 34-23-20, 34-31-0. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (SMART BOX) · airframe 87,900 hrs · 36,598 cycles

DURING TAKEOFF FROM KTOL F/O'S FLIGHT DIRECTOR FLAG IN ADI AND GYRO FLAG CAME IN VIEW. THE CREW REJECTED TAKEOFF AND RETURNED TO BLOCKS. MAINTENANCE SMART BOX WIRE NUMBER 2TN49B22 BROKEN AT R50-972 PIN 35. MAINTENANCE REPAIRED WIRE 2TN49B22. OPERATIONAL CHECK GOOD IAW DACO DC8 MAINTENANCE MANUAL 34-20-0. AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — DAMAGED (NR 2 FIRE LOOP)

DURING CRUISE, NR (2) FIRE WARNING LIGHT CAME ON STEADY, THE CREW SHUTDOWN NR (2) ENGINE AND DISCHARGED (1) FIRE BOTTLE, LIGHT WENT OUT. (20 MINUTES OUT, NR (2) FIRE WARNING LIGHT CAME BACK ON MOMENTARILY AND FIRE LOOPS WOULD ONLY TEST INTERMITTENTLY, THE CREW DISCHARGED THE (2ND) BOTTLE. THE CREW LANDED WITHOUT FURTHER INCIDENT. MAINT INSP AND FOUND (4) FIRE LOOPS CONNECTORS DAMAGED. MAINT REPLACED (2) ENGINE FIRE LOOPS AND BOTH FIRE BOTTLES. OPS CHECK GOOD IAW WDM 26-01-01. MM 26-10, AND ERH 70.01. ACFT WAS RETURNED TO SERVICE. (K)

Part: FIRE WARNING — ACTIVATED (NR 4 NACELLE) · airframe 87,593 hrs · 36,428 cycles

FLT NR ATN 819 / KDFW TO KTOL. DURING CLIMBOUT FROM KDFW NR 4 ENGINE FIRE WARNING LIGHT CAME ON, THE CREW DISCHARGED BOTH FIRE BOTTLES AND LIGHT REMAINED ON. THE CREW RETURNED TO KDFW AND LANDED WITHOUT INCIDENT. CORRECTIVE ACTION IN WORK. (A)

Part: FIRE DETECTOR — FALSE ACTIVATION (NR 4 NACELLE)

FLT ATN 819/KDFW TO KTOL/TAT 87593/TAC 36428. DURING CLIMBOUT FROM KDFW NR 4 FIRE WARNING LIGHT CAME ON, THE CREW SHUTDOWN NR 4 ENGINE AND DISCHARGED BOTH FIRE BOTTLES THE LIGHT REMAINED ON. THE CREW RETURNED TO KDFW AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED LT CORE, AND LT FAN PYLON FIRE SENSING ELEMENTS, AND BOTH FIRE BOTTLES, OPERATIONAL CHECK GOOD IAW MM 26-10-1, 26-21-09. AIRCRAFT WAS RETURNED TO SERVICE. (A)

Part: FIRE LOOP — LOOSE (NR 4 NACELLE) · airframe 87,323 hrs · 36,280 cycles

DURING CRUISE FROM KPHL TO KTOL, NUMBER FOUR ENGINE SHORT LIGHT CAME ON WITH NO FIRE TEST INDICATION, THE CREW ACCOMPLISHED EMERGENCY PROCEDURES AND SHUT DOWN NUMBER FOUR ENGINE. THE CREW LANDED AT KTOL WITHOUT INCIDENT. MAINTENANCE INSPECTED AND FOUND RIGHT FORWARD LOOP CONNECTOR LOOSE AND CORRODED. MAINTENANCE CLEANED AND RESECURED LOOP CONNECTOR OPERATIONAL CHECK WAS GOOD IAW DC8 MAINTENANCE MANUAL 26-10-1. AIRCRAFT WAS RETURNED TO SERVICE.

Part: FIRE LOOP — FALSE ACTIVATION (NR 4 NACELLE) · airframe 86,931 hrs · 36,058 cycles

DURING CRUISE FROM KTOL TO KMCI, NR 4 ENGINE WAS SHUT DOWN FOR A SHORT CIRCUIT LIGHT ON WITH NO FIRE LIGHT OR ALARM BELL DURING TEST. THE CREW LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED NUMBER 4 FIRE LOOPS, NO DEFECTS NOTED. OPERATIONAL CHECK WAS GOOD. AIRCRAFT WAS RETURNED TO SERVICE.

Part: RELAY — FAILED (ZONE 600) · airframe 86,929 hrs · 36,056 cycles

THIRTY MINUTES AFTER TAKEOFF FROM KTOL NR 4 FIRE WARNING LIGHT CAME ON, THE CREW DISCHARGED BOTH NR 4 ENGINE FIRE BOTTLES INTO ENGINE, THE FIRE WARNING LIGHT WENT OUT AFTER THE SECOND BOTTLE WAS DISCHARGED. 5 MINUTES LATER FIRE WARNING WAS INTERMITTENT, NR 4 GENERATOR WAS DISCONNECTED. THE CREW RETURNED TO KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND REPLACED UNIVERSAL RELAY, MAINTENANCE RECONNECTED THE GEN RAN ENGINE FOR 30 MINUTES AT 70 PERCENT POWER OPERATIONAL CHECK WAS GOOD BEFORE, DURING, AND AFTER RUN IAW DACO MAINTENANCE MANUAL 26-0, AND ATI DC8 ERH 70-01. AIRCRAFT WAS RETURNED TO SERVICE.

Part: FIRE LOOP — DEFECTIVE (NR 4 NACELLE) · airframe 86,928 hrs · 36,055 cycles

DURING CLIMB-OUT FROM KTOL, THE CREW NOTICED NUMBER 4 FIRE WARNING LIGHT WAS INTERMITTENT. THE CREW RETURNED TO KTOL WITHOUT INCIDENT. MAINTENANCE INSPECTED NUMBER FOUR FIRE WARNING SYSTEM AND REPLACED LEFT AFT FIRE LOOP, OPERATIONAL CHECK WAS GOOD IAW DC8 MAINTENANCE MANUAL 26-10-1. AIRCRAFT WAS RETURNED TO SERVICE.

Part: LONGERON — CRACKED (BS 1766-1794) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND FUSELAGE TAIL SECTION LONGERON 17 RIGHT HAND, WITH A CRACK AT STATION 1766.000 TO STATION 1794.000. REMOVED CRACKED LONGERON. CLEANED, TREATED AND PRIMED AREA. INSTALLED NEW LONGERON IAW DC8 SRM 53-5-1 PAGE 22 FIGURE 7 SHEET 1 ITEM "B", DC8 SRM 53-1-0 PAGE 1, DC8 SRM 51-1-20D, DC8 SRM 51-1-8B, DC8 SRM 51-2-0 PAGE 39 FIGURE 50 SHEET 37, DC8 SRM 51-1-21, AND DC8 SRM 51-3-1.

Part: FITTING — CORRODED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, IN MAIN CARGO COMPARTMENT, FOUND CORROSION ON FITTING ABOVE MAIN LANDING GEAR WHEEL WELL CEILING BETWEEN STATION 960.000 - 980.000 RIGHT BOTTOM LINE 40". REMOVED CORROSION. FOUND OUT OF LIMITS. REMOVED CORRODED FITTING. CLEANED, TREATED AND PRIMED AREA. INSTALLED NEW FITTING, IAW DC8 SRM 51-3-1,DC8 SRM 51-1-8, DC8 SRM 53-2-0 PAGE 2P, DC8 SRM 51-1-20D, AND DC8 SRM 51-1-8B.

Part: SKIN — MISREPAIRED (ZONE 500) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND LEFT WING CENTER LEADING EDGE LOWER SKIN HAD A NON STANDARD REPAIR AT STATION XFS 426.000. REMOVED EXISTING NON STANDARD REPAIR. REMOVED DAMAGED AREA PERFORMED NDT INSPECTION. NO CRACK OR CORROSION AFTER NDT TEST. FABRICATED NEW SKIN AND INTERNAL DOUBLER . CLEANED, TREATED AND PRIMED AREA AND NEW REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW FAA FORM 8110-3 NUMBER 07187 DATED 05-03-07, SEMAN DRAWING NUMBER ED-4529 DATED 04-20-07, DC8 SRM 51-1-21, DC8 SRM 51-3-0, DC8 NDT SPM PART 06-10-01-001,DC8 SRM 51-1-8B, DC8 SRM 51-1-11, 51-1-20D, AND 51-3-1.

Part: SKIN — DENTED (LT ELEVATOR) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND LEFT ELEVATOR. UPPER SKIN DENT WITH CRACK AT STATION XE 156.468 AND STATION XE 161.375. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED DAMAGED AREA. FABRICATED NEW SKIN AND INTERNAL REPAIR PARTS. BONDED PARTS AS NEEDED WITH HYSOL. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED REPAIR PART AND NEW FASTENERS. PERFORMED BALANCED FOUND WITHIN MOMENT 1443.36 IN LBS IAW DC8 SRM 55-2-1 FIGURE 8 TR NUMBER 55-1 DATED 11-03-00, DC8 SRM 51-1-21, DC8 SRM 55-2-1 FIGURE 8 TR NUMBER 55-1 SHEET 1 AND 2, DC8 SRM 51-1-9 TR NUMBER 51-142 DATED 04-05-06, DC8 SRM 51-1-9A TR NUMBER 51-141 DATED 04-03-06, DC8 SRM 51-1-8B, AND DC8 SRM 51-4-4 PAGES 1 AND 2.

Part: FLOORBEAM — CORRODED (ZONE 200) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND MAIN CARGO COMPARTMENT FLOORBEAM WEB CORRODED AT STATION 960.000 RT BOTTOM LINE 40". REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR, REMOVED CORROSION. FOUND OUT OF LIMIT. FABRICATE REPAIR ANGLES OF EXTRUSION. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW DC8 SRM 51-2-1 FIGURE 1 SHEET 1, 2, 3 AND 12 T/R 51-130 DATED 01-26-04, SRM 51-1-20D, DC8 SRM 51-1-8 PAGE 17-18, DC8 SRM 53-2-0 PAGE 2P, DC8 SRM 53-7-1 FIGURE 13 ITEM R, DC8 SRM 51-2-0 FIGURE 50 SHEET 76, DC8 SRM 51-1-8B, DC8 SRM 51-1-11, AND DC8 SRM 51-3-1.

Part: SKIN — MISREPAIRED (BS 1699 L27L) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR AT AFT FUSELAGE SKIN PANEL AND SKIN SPLICES OF LONGERON 27 LEFT AT STATION 1699. REMOVED EXISTING EXTERNAL REPAIR DOUBLER. PERFORMED NDT INSPECTION. NO CRACK OR CORROSION FOUND. FABRICATED NEW SKIN, EXTERNAL DOUBLER, AND INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACES. DEACTIVATED UAL DRAIN FOR CUSTOMER REQUEST. INSTALLED REPAIR PARTS IAW FAA FORM 8100-9 DATED 04-23-07, MESSAGE BOEING NUMBER 1-317422975-5 DATED 04-23-07, AIRWORTHINESS DIRECTIVE 2007-02-02, SERVICE BULLETIN DACO DC8-53A80, DOUGLAS DRAWING SR08530032, SEMAN DRAWING NUMBER ED-4519 DATED 04-17-07, DC8 SRM 51-1-21, DC8 SRM 51-1-20D, DC8

Part: LONGERON — MISREPAIRED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR INSTALLED AT A-PIT BASKET DOOR, RIGHT FORWARD JAMB CORNER AT STATION 293 LONGERON 30 RIGHT. REMOVED EXISTING REPAIR. FABRICATED REPAIR DOUBLER, TRIPLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW DC8 SRM 51-1-20D, DC8 SRM 53-2-0 FIGURE 19 T/R NUMBER 53-136 AND 53-186, DC8 SRM 51-1-8B, DC8 SRM 51-1-11, DC8 SRM 51-1-21, AND DC8 51-3-1,AD 2005-18-07, DACO SERVICE BULLETIN DC8-53-078, AND DOUGLAS DRAWING SR08530019 AND 5750776.

Part: LONGERON — MISREPAIRED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR INSTALLED AT A-PIT BASKET DOOR, RIGHT AFT JAMB CORNER AT STATION 327 LONGERON 30 RIGHT. REMOVED EXISTING REPAIR. FABRICATED DOUBLER, TRIPLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW DC8 SRM 51-1-20D, DC8 SRM 53-2-0 FIGURE 19 T/R NUMBER 53-136 AND 53-186, DC8 SRM 51-1-8B, DC8 SRM 51-1-11, 51-1-21, AND AD 2005-18-07, DACO SERVICE BULLETIN DC8-53-078 AND DOUGLAS DRAWING SR08530019 AND 5750776.

Part: SKIN — MISREPAIRED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR AT AFT FUSELAGE SKIN PANEL AND SKIN SPLICES OF LONGERON 28 RIGHT AT STATION 1690. REMOVED EXISTING EXTERNAL REPAIR DOUBLER. PERFORMED NDT INSPECTION. NO CRACK OR CORROSION FOUND. FABRICATED NEW SKIN, EXTERNAL DOUBLER, AND INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACES. INSTALLED REPAIR PARTS IAW FAA FORM 8100-9 DATED 04-23-07, MESSAGE BOEING NUMBER 1-317422975-5 DATED 04-23-07, AIRWORTHINESS DIRECTIVE 2007-02-02, SERVICE BULLETIN DACO DC8-53A80, DOUGLAS DRAWING SR08530032, SEMAN DRAWING NUMBER ED-4519 DATED 04-17-07, DC8 SRM 51-1-21, DC8 SRM 51-1-20D, DC8 NDT SPM PART 06-10-01-001, DC8 SRM 51-

Part: FITTING — CORRODED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND BATH TUB FITTING CORRODED, BETWEEN STATION 70.000 AND STATION 80.000 LONGERON 35 RIGHT. REMOVED CORROSION, FOUND OUT OF LIMITS. REMOVED CORRODED FITTING. CLEANED TREATED AND PRIMED AREA. INSTALLED NEW FITTING IAW DC8 SRM 51-1-8 PAGES 17 AND 18, DC8 SRM 53-2-0 PAGES 2P, DC8 SRM 51-1-21, DC8 SRM 51-1-20D, DC8 SRM 51-1-8B, AND 51-3-1.

Part: FITTING — CORRODED (ZONE 500) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND LEFT WING INBOARD SLOT VANE FITTING WITH CORROSION AT STATION XILD 0.7095. REMOVED CORROSION. FOUND OUT OF LIMITS. REMOVED CORRODED FITTING. FABRICATED NEW FITTING. CLEANED, TREATED AND PRIMED AREA AND FITTING. APPLIED SEALANT TO FAYING SURFACE. INSTALLED NEW FITTING IAW DC8 SRM 57-3-1 FIGURE 8 PAGE 15, DC8 SRM 51-1-8, PAGES 17-18, DC8 SRM 57-2-0, PAGE 16, DC8 SRM 57-1-0, PAGE 1, AND DC8 SRM 51-1-21, DC8 SRM 57-3-1, FIGURE 8 PAGE 15 ITEM D, DC8 SRM 51-2-0 PAGE 75 FIGURE 50, AND SHEET 73, DC8 SRM 51-1-8B, AND DC8 SRM 51-1-11.

Part: SKIN — MISREPAIRED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR AT AFT FUSELAGE SKIN PANEL AND SKIN SPLICES OF LONGERON 28 LEFT AT STATION 1690. REMOVED EXISTING EXTERNAL REPAIR DOUBLER. PERFORMED NDT INSPECTION. NO CRACK OR CORROSION FOUND. FABRICATED NEW SKIN, EXTERNAL DOUBLER, AND INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACES. INSTALLED REPAIR PARTS IAW FAA FORM 8100-9 DATED 04-23-07, MESSAGE BOEING NUMBER 1-317422975-5 DATED 04-23-07, AIRWORTHINESS DIRECTIVE 2007-02-02, SERVICE BULLETIN DACO DC8-53A80, DOUGLAS DRAWING SR08530032, SEMAN DRAWING NUMBER ED-4519 DATED 04-17-07, DC8 SRM 51-1-21, DC8 SRM 51-1-20D, DC8 NDT SPM PART 06-10-01-001, DC8 SRM 51-

Part: SKIN — CORRODED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR AT AFT FUSELAGE SKIN PANEL AND SKIN SPLICES OF LONGERON 28RIGHT AT STATION 1690. REMOVED EXISTING EXTERNAL REPAIR DOUBLER. PERFORMED NDT INSPECTION. NO CRACK OR CORROSION FOUND. FABRICATED NEW SKIN, EXTERNAL DOUBLER, AND INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACES. DEACTIVATED UAL DRAIN FOR CUSTOMER REQUEST. INSTALLED REPAIR PARTS IAW FAA FORM 8100-9 DATED 04-23-07, MESSAGE BOEING NUMBER 1-317422975-5 DATED 04-23-07, AIRWORTHINESS DIRECTIVE 2007-02-02, SERVICE BULLETIN DACO DC8-53A80, DOUGLAS DRAWING SR08530032, SEMAN DRAWING NUMBER ED-4519 DATED 04-17-07, DC8 SRM 51-1-21, DC8 SRM 51-1-20

Part: SKIN — CRACKED (ZONE 500) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND LEFT WING INBOARD FLAP CRACKED ON UPPER PART EXTERNAL COATING AT STATION XW 104.00. REMOVED DAMAGED SKIN. FABRICATED NEW SKIN AND INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACES. INSTALLED REPAIR PARTS IAW DC8 SRM 57-7-1 PAGE 2 FIGURE 1, DC8 SRM 57-1-0 PAGE 1, DC8 SRM 51-1-21,DC8 SRM 57-7-1 PAGE 2 FIGURE 1 ITEM "D’, DC8 SRM 51-1-8B, DC8 SRM 51-1-11, AND DC8 SRM 51-3-0, DC8 SRM 51-3-1.

Part: LONGERON — MISREPAIRED (FUSELAGE) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR LOCATED AT STATION 1.600 LONGERON 28 RIGHT. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. PERFORMED NDT INSPECTION. NO CRACK OR CORROSION FOUND. FABRICATED NEW SKIN, EXTERNAL DOUBLER, INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW DC8 SRM 51-1-21, 51-1-20D, SEMAN DRAWING NUMBER ED-4520, DC8 NDT SPM PART 06-10-01.001, DC8 SRM 51-1-8B, DC8 SRM 51-1-11, AND 51-3-1.

Part: FRAME — CRACKED (BS 1260 L34R) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND AFT CARGO COMPARTMENT FRAME WITH A CRACK AT STATION 1260.000 LONGERON 34 RIGHT TO LONGERON 35 LEFT. REMOVED CRACKED FITTING. FABRICATED FRAME FITTING, SPLICES, AND DOUBLER. PERFORMED HEAT TREATMENT. PERFORMED NDT INSPECTION NO CRACK OR CORROSION FOUND. TRIMMED OUT NEW FRAME FITTING TO FACILITATE INSTALLATION. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED REPAIR PARTS IAW DC8 SRM 53-2-0 FIGURE 8 SHEET 2, 5, 6, AND 8, DC8 SRM 51-1-8 PAGES 17 AND18, DC8 SRM 53-2-0 PAGE 2P, DC8 SRM 53-2-0 FIGURE 8 SHEET 2 AND 6, DC8 SRM 51-1-20D, ATI REPAIR SPECIFICATION NUMBER 2003-05, DOUGLAS DRAWING NUMBER 3646956,DC8 SRM 51-1-1 PAGES 1, 13 AND 17, NDT SPM PART 08-00

Part: FITTING — CORRODED (ZONE 700) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND RIGHT MAIN LANDING GEAR WHEEL WELL JOINT FITTING WITH CORROSION AT STATION 940.000 LONGERON 24 RIGHT. REMOVED CORROSION. FOUNDED OUT OF LIMITS REMOVED CORRODED FITTING. FABRICATED FRAME FITTING, SPLICES AND DOUBLER. PERFORMED HEAT TREATMENT PERFORMED NDT INSPECTION. NO CRACK OR CORROSION FOUND. TRIMMED OUT NEW FRAME FITTING TO FACILITATE INSTALLATION. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED REPAIR PARTS IAW DC8 SRM 53-2-0 FIGURE 8 SHEET 2, 5, 6, AND8, DC8 SRM 51-1-8 PAGES 17 AND 18, DC8 SRM 53-2-0 PAGE 2P, DC8 SRM 51-1-20D,DC8 SRM 51-1-1 PAGES 1, 13, AND 17,NDT SPM PART 08-00-02 TO 07,DC-8 SRM 53-2-0 FIGURE 8 SHEET 2 AND 6, DC-8 SRM 51-1-8B,

Part: FRAME — CRACKED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND MAIN CARGO COMPARTMENT FRAME FLANGE WITH A CRACK AT STATION 1580.000 LONGERON 21LEFT. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED CRACKED FRAME SEGMENT. FABRICATED NEW FRAME SEGMENT. PERFORMED HEAT TREATMENT TO FRAME SEGMENT AND ANGLES. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACES. INSTALLED REPAIR PARTS IAW DC8 SRM 53-2-0 FIGURE 2 SHEETS 4 AND 6, DC8 SRM 51-1-21, DC8 SRM 53-4-1 FIGURE 51 SHEET 21 ITEM A, DC8 SRM 53-2-0 FIGURE 2 SHEET 1, DC8 SRM 53-2-0 FIGURE 2 SHEETS 7 AND 8, T/R NUMBER 53-110 DATED 11-10-00,DC8 SRM 51-1-1 PAGES 1, 13, 17,DC8 SRM 51-1-8B, DC8 SRM 51-1-11, DC8 SRM 51-1-20D, AND DC8 SRM 51-3-1.

Part: LONGERON — MISREPAIRED (BS 445 L27R) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR AT STATION 445, LONGERON 27.5 RIGHT. REMOVED EXISTING REPAIR. FABRICATED NEW SKIN, EXTERNAL DOUBLER AND INTERNAL DOUBLER, CLEANED TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW DC8 SRM 53-2-1 FIGURE 7 SHEET 1 AND 3, DC8 SRM 51-1-21 AND 51-1-20D,DC8 SRM 53-4-1 FIGURE 1 ITEM "B" AND DC8 SRM 51-9-0 FIGURE 68A, DC8 SRM 51-1-8B, AND DC8 SRM 51-1-11.

Part: SKIN — MISREPAIRED (ZONE 200) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND IMPROPER REPAIR LOCATED AT FS 1725 LONGERON 16.5 RIGHT. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. FABRICATED NEW SKIN, AND INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW DC8 SRM 53-2-1 FIGURE 7 SHEET 1, 3 AND 5, DC8 SRM 51-1-20D, DC8 SRM 53-2-1 FIGURE 7 SHEET 1, 3 AND 5, DC8 SRM 53-5-1 FIGURE 1 ITEM "D", DC8 SRM 51-1-8B, DC8 SRM 51-1-11, DC8 SRM 51-1-21, DC8 SRM 51-1-20D, AND DC8 SRM 51-3-1.

Part: FITTING — CORRODED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND MAIN CARGO COMPARTMENT HAD CORROSION ON FITTING ABOVE MAIN LANDING GEAR WHEEL WELL CEILING BETWEEN STATION 960.000 - 980.000 LEFT BOTTOM LINE 40”. REMOVED CORROSION. FOUND OUT OF LIMITS. REMOVED CORRODED FITTING. CLEANED TREATED AND PRIMED AREA. INSTALLED NEW FITTING IAW DC8 SRM 51-1-8 PAGE 17 AND 18, DC8 SRM 53-2-0 PAGE 2P DC8 SRM 51-1-21, DC8 SRM 51-1-20D, DC8 SRM 51-1-8B, AND 51-3-1.

Part: HOOK — CRACKED (PAX DOOR) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND EXTERIOR FUSELAGE AT NOSE SECTION FORWARD PAX DOOR HOLD OPEN HOOK, WAS CRACKED AT STATION 15.000 LONGERON 16 LEFT. REMOVED FASTENERS AS NEEDED TO PERFORM THE REPAIR. REMOVED DAMAGED AREA. PERFORMED INSPECTION NDT INSPECTION. NO CRACK OR CORROSION FOUND. FABRICATED EXTERNAL AND INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS AND NEW FASTENERS IAW FAA FORM 8110-3 NUMBER 07187 DATED 05-03-07, AND SEMAN DRAWING NUMBER ED-4522 DATED 04-20-07, DC8 SRM 51-1-21, 51-3-0, DC8 NDT SPM PART 06-10-01-001, DC8 SRM 51-1-8B, DC8 SRM 51-1-11, 51-3-0, 51-1-20D, AND 51-3-1.

Part: LONGERON — CRACKED (BS 1766-1794) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND FUSELAGE TAIL SECTION LONGERON 17 LEFT HAND, WITH A CRACK AT STATION 1766.000 TO STATION 1794.000. REMOVED CRACKED LONGERON. CLEANED, TREATED AND PRIMED AREA. INSTALLED NEW LONGERON IAW DC8 SRM 53-5-1 PAGE 22 FIGURE 7 SHEET 1 ITEM "B", DC8 SRM 53-1-0 PAGE 1, DC8 SRM 51-1-20D, DC8 SRM 51-1-8B, DC8 SRM 51-2-0 PAGE 39 FIGURE 50 SHEET 37, DC8 SRM 51-1-21, AND DC8 SRM 51-3-1.

Part: LONGERON — MISREPAIRED (BS 1581 L26R) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, IMPROPER REPAIR LOCATED AT STATION 1581 LONGERON 23 RIGHT. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. PERFORMED NDT INSPECTION. NO CRACK OR CORROSION FOUND. FABRICATED NEW SKIN, EXTERNAL DOUBLER, AND INTERNAL DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW DC8 SRM 51-1-21, 51-1-20D,SEMAN DRAWING NUMBER ED-4521,DC8 NDT SPM PART 06-10-01.001,DC8 SRM 51-1-8B,DC8 SRM 51-1-11, AND 51-3-1.

Part: DOUBLER — CRACKED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND EXTERNAL FUSELAGE NOSE SECTION RIGHT AFT PRIMARY HEAT INTERCHANGER AFT LOWER CORNER DOUBLER CRACKED AT STATION -12 LONGERON 27 RIGHT. REMOVED EXISTING REPAIR. FABRICATED REPAIR DOUBLER. CLEANED TREATED AND PRIMED AREA AND REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACE. INSTALLED REPAIR PARTS IAW DC8 SRM 51-1-20D, DC8 MM 53-30-09 PAGES 201, 202, 206 AND 209, DC8 SRM 51-1-8B, DC8 SRM 51-1-11,DC8 SRM 51-1-20D, AND DC8 SRM 51-3-1.

Part: FITTING — CRACKED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND AFT LOWER CARGO BILGE INTERIOR FITTING CRACKED AT STATION 1260.000 LONGERON 35 RIGHT. REMOVED CRACKED FITTING. FABRICATED FITTING PERFORMED NDT. NO CRACK OR CORROSION FOUND. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FITTING IAW DC8 SRM 51-1-20D, DC8 SRM 51-1-8B, ATI REPAIR SPECIFICATION NUMBER 2003-05, DOUGLAS DRAWING NUMBER 3750277, DC8 NDT SPM PART 08-00-02 TO 07, AND 51-3-1.

Part: FITTING — CRACKED (ZONE 100) · airframe 86,484 hrs · 35,828 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND AFT LOWER CARGO BILGE INTERIOR FITTING CRACKED AT STATION 1260.000 LONGERON33 RIGHT. REMOVED CRACKED FITTING. FABRICATED FITTING. PERFORMED NDT INSPECTION. NO CRACKS OR CORROSION FOUND. CLEANED TREATED AND PRIMED AREA AND FITTING. INSTALLED NEW FITTING IAW DC8 SRM 51-1-20D, ATI REPAIR SPECIFICATION NUMBER 2003-05 AND DOUGLAS DRAWING NUMBER 3750277,NDT SPM PART 08-00-02 TO 07, DC8 SRM 51-1-8B, AND DC8 SRM 51-3-1.

Part: OIL FILTER — DIRTY (NR 2 ENGINE) · airframe 86,014 hrs · 35,563 cycles

DURING CRUISE FROM KTOL TO KSJC, NUMBER 2 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED ALL OTHER PARAMETERS WERE NORMAL. THE CREW SHUTDOWN THE ENGINE AND CONTINUED TO KSJC WHERE THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED THE ENGINE AND FOUND THE SCAVENGE FILTER BYPASS BUTTON POPPED. THE SUPPLY AND SCAVENGE FILTER WERE REPLACED. NO ABNORMAL CONTAMINATION WAS FOUND. THE ENGINE WAS RAN AND THE SCAVENGE FILTER WAS REINSPECTED WITH NO CONTAMINATION FOUND. THE AIRCRAFT WAS RETURNED TO SERVICE IAW CFM MM 79-00-00, AND ATI ERH.

Part: FIRE DETECTOR — SHORTED (NR 3 ENGINE) · airframe 84,843 hrs · 35,097 cycles

AT CRUISE FL 36.0 NR 3 ENGINE SHORT CIRCUIT LIGHT BEGAN FLASHING. FIRE WARNING WOULD NOT TEST, ENGINE SHUTDOWN PER COM PROCEDURE. THE CREW ELECTED TO RETURN THE AIRCRAFT TO TOL AND LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED CONNECTOR FROM FORWARD SIDE OF RIGHT HAND FAN FIRE LOOP, SHORT LIGHT REMAINED ILLUMINATED. REMOVED CONNECTOR FROM AFT SIDE OF RIGHT HAND FAN LOOP AND SHORT LIGHT EXTINGUISHED. REMOVED AND REPLACED RIGHT HAND FAN FIRE ELEMENT AND AFT CONNECTOR. NR 3 ENGINE FIRE WARNING TEST AND SHORT CIRCUIT LIGHT OPS CHECK GOOD. RAN NR 3 ENGINE, SHORT LIGHT DID NOT ILLUMINATE AND FIRE TEST GOOD. WORK WAS DONE PER ALL APPLICABLE MANUALS AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — CORRODED (FIRE LOOP) · airframe 84,792 hrs · 35,079 cycles

DURING FLIGHT 834 FROM TOL TO SJC APROX 50 MIN INTO FLIGHT, NR 3 ENG SHORT CIRCUIT AMBER LIGHT CAME ON. PERFORMED ABNORMAL CHECK LIST. THE LIGHT DID NOT EXTINGUISH, NOR DID THE FIRE WARNING TEST. PERFORMED ENGINE SHUTDOWN OTHER THAN FIRE DAMAGE. THE CREW ELECTED TO RETURN THE AIRCRAFT TO TOL AND LANDED WITH OUT INCIDENT. MAINTENANCE INSPECTED ALL FIRE LOOPS IN COLD SECTION OF NR 3 ENGINE AND FOUND LOWER OUTBOARD AFT CONNECTOR CORRODED. CLEANED AND REINSTALLED, LIGHT WENT OUT. RAN ENGINE TO PART POWER FOR 15 MINUTES PER ALL APPLICABLE MANUALS NO DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SENSING ELEMENT — DEFECTIVE (NR 3 ENGINE) · airframe 84,593 hrs · 34,986 cycles

ON FLIGHT ATN833 FROM KSJC TO KRFD, NR 3 ENGINE FIRE WARNING LIGHT AND BELL CAME ON DESCENT TO KRFD. COMPLY WITH COMPANY PROCEDURES WIND MILLING TIME 30 MINUTES AND OIL PRESSURE WAS 20 PSI. CREW ELECTED TO LAND AT KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE SHOOK DOWN WIRING ON NR 3 ENGINE, NO DEFECTS NOTED. REMOVED AND REPLACED ALL 5 FIRE WARNING SENSING ELEMENTS ON NR 3 ENGINE, RAN NR 3 ENGINE, AND PERFORMED BLEED CHECK. ALL WORK WAS DONE PER ALL APPLICABLE MANUALS AND OPS CHECK WAS GOOD. AIRCRAFT WAS RETURNED TO SERVICE.

Part: RADIO — MALFUNCTIONED (HF SYSTEM) · airframe 84,495 hrs · 34,963 cycles

ON FLIGHT 362 FROM KTOL TO KEWR NR 1 HF CONTINOUSLY ATTEMPTED TO TUNE ON ALL FREQUENCES WITH THE SAME RESULTS. THEN HF RADIO NR 2 WAS KEYED TO TUNE, THE AUTOPILOT KICKED OFF CAUSING THE AIRCRAFT TO YAW AND PITCH. DUE TO INTENDED FLIGHT PLAN, CREW ELECTED TO RETURN TO DEPARTURE STATION KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE CHECKED NR 1 HF, NO DEFECTS WERE NOTED. CALLED AIR INC ON NUMEROUS FREQUENCIES AND CHECKED GOOD. CHECKED NR 2 HF WITH AUTOPILOT ON AND OFF, NO DEFECTS WERE NOTED. CALLED AIR INC ON NUMEROUS FREQUENCIES AND CHECKED GOOD. WORK WAS PERFORMED PER ALL APPLICABLE MANUALS AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: BULB — LOOSE (ENGINE INDICATOR) · airframe 84,372 hrs · 34,907 cycles

DURING A TAKEOFF ROLLOUT AT 110KTS, NR 3 ENGINE OIL PRESSURE LIGHT CAME ON. TAKEOFF WAS REJECTED. OIL PRESSURE AND QUANTITY INDICATED NORMAL BUT LIGHT REMAINED ON UNTIL THE ENGINE WAS SHUTDOWN. CREW RETURNED TO BLOCKS. MAINTENANCE DEFERRED THIS IAW MEL 79-6 (CAT B) WITH A NO FLY DATE OF 11/26/05. MAINTENANCE CHECKED NR 3 ENGINE OIL PRESSURE WARNING LIGHT SWITCH AND DIFFERENTIAL SWITCH AND ASSOCIATED WIRING, NO DEFECTS WERE NOTED. FOUND BULB IN LIGHT SOCKET LOOSE. REPLACED BULB AND RAN THE NR 3 ENGINE AND THE OIL PRESSURE LIGHT CHECKS NORMAL WITH NO DEFECTS NOTED IAW ALL APPLICABLE MANUALS.

Part: BLADE — LEAKING (NR 2) · airframe 83,912 hrs · 34,740 cycles

NR 2 ENG SHUTDOWN FOR LOSS OF OIL QTY. OIL PRESS DROPPED. OIL TEMP STABLE. SHUTDOWN NR 2 ENG. WINDMILL OIL PRESS DROPPED & QTY INCREASED. TEMP STABLE. NO WINDMILLING PRESS. LOW PRESS LIGHT ILLUM. LANDED W/OUT INCIDENT. R&R NR 2 ENG, OPS & LEAK CHK GOOD. ACFT RTS. AN FITTING & FLARE OF TUBE INCOMPATIBLE. OIL LINE CLAMP LOOSE. FORWARD OIL TANK MOUNT LOOSE. BORESCOPE REVEALED HALF OF A HPT BLADE MISSING. LOOSE HARDWARE CAUSED BY CORE VIBRATIONS (N2). ENG HAS BEEN RETURNED TO VENDOR FOR REPAIR & ROOT CAUSE ANALYSIS OF BLADE FAILURE. OVERTEMP ANALYSIS RESULTS NEG. ENG BEYOND REPAIR. METALLURGICAL EVALUATION REPORT, HPT BLADE FAILED IN THERMAL FATIGUE MODE DUE TO SEGREGATION OF TITANIUM-HAFNIUM DURING CASTING.

Part: ENGINE — MALFUNCTIONED (NR 2) · airframe 83,904 hrs · 34,737 cycles

DURING CRUISE FROM KPHL TO KTOL THE NR 2 ENGINE FLUCTUATED EGT FOLLOWED BY A INSTANTANEOUS EGT TEMPERATURE INCREASE. OIL PRESSURE FLUCTUATED BUT NO LOSS. THE CREW PERFORMED A PRECAUTIONARY ENGINE SHUTDOWN THEN LANDED IN KTOL WITHOUT INCIDENT. AN INSPECTION IS ON GOING. AS SOON AS INFORMATION IS AVAILABLE IT WILL BE PROVIDED.

Part: TUBE — BROKEN (ENGINE OIL) · airframe 83,903 hrs · 34,736 cycles

!DURING CLIMBOUT FROM KTOL TO KPHL THE NR 2 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED. PRESSURE WAS AT 14 PSI AND FLUCTUATING AND OIL QUANTITY DEPLETING SLOWLY. THE CREW PERFORMED A PRECAUTIONARY ENGINE SHUTDOWN. CREW LANDED IN KPHL WITHOUT INCIDENT. MAINTENANCE FOUND OIL PRESSURE TRANSMITTER OIL SUPPLY TUBE BROKE AT FLANGE. MAINTENANCE REMOVED AND REPLACED TUBE. THE OPERATIONAL CHECK AND LEAK CHECK WERE GOOG PER ALL APPLICABLE MANUALS AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LINE — BROKEN (OIL PRESSURE) · airframe 89,301 hrs · 34,735 cycles

DURING CRUISE FROM KBFI TO KTOL THE NR 2 ENGINE HAD LOSS OF OIL QUANTITY FOLLOWED BY LOSS OF OIL PRESSURE. CREW PERFORMED A PRECAUTIONARY ENGINE SHUTDOWN. AIRCRAFT MAINTAINED OIL PRESSURE DURING DURATION OF FLIGHT AND THE CREW LANDED IN KTOL WITHOUT INCIDENT. MAINTANENCE FOUND BROKEN LINE AT OIL TRANSMITTER. MAINTENANCE REMOVED AND REPLACED THE OIL PRESSURE TRANMSMITTER LINE AND THEN RAN ENGINES. THE OPERATIONAL AND LEAK CHECK WERE GOOD IN ACCORDANCE WITH THE ERH AND GMM. AIRCRAFT WAS RETURNED TO SERVICE

Part: LINE — BROKEN · airframe 83,892 hrs · 34,731 cycles

DURING CRUISE FROM KDFW TO KTOL CREW SHUTDOWN THE #2 ENGINE DUE TO LOSS OF OIL QUANTITIY PRESSURE. CREW LANDED IN KTOL WITHOUT INCIDENT. MAINTENANCE FOUND A BROKEN LINE AT THE OIL PRESSURE TRANSMITTER. THEY REMOVED AND REPLACED THE PRESSURE TRANSMITTER LINE AND PERFORMED A LOSS OF OIL PRESSURE INSPECTION CHECK. THE OPERATIONAL AND LEAK CHECK WAS GOOD IN ACCORDANCE WITH THE ERH AND GMM. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — DAMAGED (NR 2 ENGINE) · airframe 83,877 hrs · 34,724 cycles

DURING CLIMB & CRUISE NR 2 ENGINE FUEL FLOW & EGT FLUCUATED FROM 811 TO 875, OTHER ENGINES AT 830 TO 835. EGT THEN PEAKED AT 1000 (FLASHING). ALSO WITH STANDARD POWER SET FOR CLIMB, THE EGT & FF FOLLOWED THE THROTTLE & THEN THE FUEL FLOW & EGT WENT HIGH & DID NOT FOLLOW THROTTLE. CREW PERFORMED AN ENGINE SHUTDOWN CHECKLIST IAW QRH AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED THE LEFT AND RIGHT EGT HARNESS AND THE THERMOCOUPLES. THE PLUG RECEPTACLE WAS CLEANED AT PYLON. THE EGT HARNESS WAS REMOVED & REPLACED AND A RUN-UP WAS PERFORMED OF NR 2 ENGINE IAW ATI ERH 70.01. NR 2 ENGINE EGT OPS CHECK GOOD. NO FLUCTUATION NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE HARNESS — DEFECTIVE (NR 2 EGT) · airframe 83,772 hrs · 34,678 cycles

DURING TAKEOFF FROM KTOL BOTH EGT INDICATIONS ON NR 2 ENG BECAME ERRATIC. INFLT-ANALOG WENT OFF SCALE HIGH AND DIGITAL SHOWS 1000 INTERMITTENTLY. THE CREW RETURNED THE AIRCRAFT TO KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED EGT HARNESS, RAN ENGINES AND THE OPERATIONAL TEST WAS GOOD ON GROUND PER ALL APPLICABLE MANUALS. NO OTHER DEFECTS WERE NOTED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE HARNESS — DEFECTIVE (NR 2 EGT) · airframe 83,768 hrs · 34,674 cycles

DURING TAKEOFF FROM KTOL TO KATL AFTER V1 NR 2 EGT STARTED TO FLUX FROM 860 TO MAX EGT 1000 (DIGITAL AND POINTER) CONTINUED TO FLUX ON CLIMB-OUT. ALL OTHER ENGINE INDICATIONS WERE NORMAL. THE CREW ELECTED TO OVERFLY INTERIM STOP ATL AND FLY DIRECT TO KMCO. MAINTENCE FOUND THE NR 2 ENGINES EGT HARNESS READING HIGH RESISTANCE. REMOVED AND REPLACED THE EGT HARNESS. ENGINE RUN WAS COMPLETE AND NO OTHER DEFECTS WERE NOTED PER ALL APPLICABLE MANUALS AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: FITTING — CRACKED (HORIZONTAL STAB) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, LT HORIZONTAL STABILIZER FITTING CRACKED 1 IN., XFS 47.000 - XFS 60.000 (LWR PART). REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. CLEANED, TREATED AND PRIMED AREA IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9, DC-8 SRM 51-1-21 PAGE 1. TORQUED IAW DC-8 RM 51-3-1.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY END FITTING CRACKED, STA 680.000, L-4R. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 3779762. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED DC-8 SRM 51-3-1.

Part: SKIN — DENTED (HORIZONTAL STAB) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, EVALUATE FOR REPAIR DENT OF RT HORIZ STAB. PERFORMED MAJOR REPAIR IAW DC-8 SRM 55-2-1 FIG 4. FABRICATED REPAIR DOUBLER IAW DC-8 SRM 55-2-1 FIG 4. CLEANED, TREATED AND PRIMED REPAIR DOUBLE INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED REPAIR DOUBLER IAW DC-8 SRM 51-2-1 FIG 1, DC-8 SRM 51-1-21 PAGE 1.

Part: ATTACH FITTING — CRACKED (HORIZONTAL STAB) · airframe 83,496 hrs · 34,569 cycles

LT HORIZONTAL STABILIZER FAIRING SUPPORT AFT FITTING CRACKED STA 1880.000 LT. REMOVED CRACKED FITTING IAW DC-8 SRM. FABRICATED NEW FITTING IAW DWG NR 3702464. PERFORMED HEAT TREATMENT IAW DC-8 SRM. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM. INSTALLED NEW FITTING IAW DC-8 SRM. TORQUED IAW DC-8 RM 51-3-1.

Part: SKIN — CRACKED (RT WING) · airframe 83,496 hrs · 34,569 cycles

RT WING, LE LWR SKIN WITH 03 CRACKS , XW 422.750. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3. REMOVED EXISTING REPAIR DOUBLER IAW SEMAN DWG ED-3950, DC-8 SRM. REMOVED DAMAGED AREA IAW SEMAN DWG ED-3950. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. FABRICATED REPAIR DOUBLER, FILLERS IAW SEMAN DWG ED-3950. CLEANED, TREATED AND PRIMED REPAIR PARTS IAW DC-8 SRM. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM.

Part: SKIN — CRACKED (ZONE 600) · airframe 83,496 hrs · 34,569 cycles

RT WING CTR L/E OUTER PLATING UPPER SURFACE CRACKED STA. XFS 430.000. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3, SEMAN DWG ED-3937. REMOVED FASTENERS IAW DC-8 SRM. REMOVED DAMAGED AREA IAW SEMAN ED-3937. PERFORMED NDT INSPECTION IAW NDT SPM PART 06-10-01-001. FABRICATED REPAIR DOUBLER, FILLER IAW SEMAN DWG ED-3937. CLEANED, TREATED AND PRIMED AREA+ REPAIR PARTS INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED REPAIR PART IAW SEMAN DWG ED-3937, DC-8 SRM 51-1-21 PAGE 1, DC-8 SRM 51-3-0 PAGE 1, DC-8 SRM 51-1-20D APGE9. TORQUED IAW DC-8 RM 51-3-1.

Part: FITTING — BROKEN (FWD CARGO BAY) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FWD CARGO COMPARTMENT FITTING BROKEN, 70.000 L-31L. REMOVED BROKEN FITTING IAW DC-8 SRM 51-120D PAGE 21. CLEANED, TREATED AND PRIMED AREA IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 SRM 51-3-1.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY RT WING SECTION INTERIOR FITTING CRACKED, STA 781.000 - RBL 23. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 4646547. PERFORMED HEAT TREATMENT IAW DC-8 SRM 51-1-1 PAGES 1, 13, 17. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 SRM 51-3-1.

Part: TEE FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY FWD TYPE I DOOR INNER JAMB FITTING CRACKED, STA 384.000 L-11 AND L-12R. REMOVED DAMAGED TEE IAW DC-8 SRM 53-1-0, DC-89 SRM 51-1-20D PAGE 21. FABRICATED NEW TEE IAW DGW 9755815. PERFORMED NDT INSPECTION TO TEE IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA AND NEW TEE IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLAED NEW TEE IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 SRM 51-3-1.

Part: SKIN — CORRODED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

EXT FS RT FUSELAGE FWD CTR SECTION PLATING CORRODED AND HOLES ELONGATED, STA 260.000 L-3. MAJOR REPAIR IAW FAA 8110-3 NR 05168 AND SEMAN DWG ED-3951. REMOVED CORROSION IAW DC-8 SRM 51-1-8. FOUND OUT OF LIMITS IAW DC-8 SRM 53-2-0. REMOVED EXISTING DOUBLER DC-8 SRM 51-1-21 AND DC-8 SRM 51-1-20D. REMOVED DAMAGED AREA IAW SEMAN DWG ED-3951. PERFORMED NDT INSP IAW DC-8 NDT SPM PART 06-10-01-001. FAB NEW SEGMENT OF SKIN, EXTERNAL SPLICE DOUBLER , INTERNAL FINGER DOUBLERS , FINGER DOUBLER , FILLER , INTERNAL DOUBLER S, AND STRAPS IAW SEMAN DWG ED-3951. CLEANED, TREATED, PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY, STA 857.000 L-19L AFT FITTING CRACKED. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 4750423. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: ATTACH FITTING — CORRODED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY INTERNAL FUSELAGE FITTING CORRODED, STA 1614.000 L-21L. REMOVED CORROSION IAW DC-8 SRM 51-1-8 PAGE 17-18. FOUND OUT OF LIMITS IAW DC-8 SRM 53-2-0 PAGE 2P. REMOVED CORRODED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 9750448. PERFORMED NDT INSPECTION IAW NDT DC-8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED DC-8 SRM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FWD CARGO COMPT - INTERIOR SPLICE FITTING CRACKED, STA 440.000 - STA 460.00, L-34L 3. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING (ALCLAD 7075 T6 51) IAW DWG 3750330. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA + NEW FITTING IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 SRM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, AFT CARGO COMPT SPLICE FITTING CRACKED 9 IN., L-31L , STA 1040.00 - STA 1060.000. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG 3750257. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, AFT CARGO COMPARTMENT SPLICE FITTING CRACKED 3 IN., STA 1040.000, STA 1060.00, L-31R. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG 3750330. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED, PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: SKIN — CRACKED (RT WING AILERON) · airframe 83,496 hrs · 34,569 cycles

RT WING INBD AILERON UPPER SKIN CRACKED 0.5 IN., STA. XA 610.000. MAJOR REPAIR IAW DC-8 SRM 57-1-0 PAGE 1 IAW DC-8 SRM 57-8-1 FIG 1, DWG DACO 5705334. REMOVED DAMAGED PANEL IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21 PAGE 1. REMOVED DAMAGED AREA IAW DC-8 SRM 57-2-5 FIG 1 SHEET 2. FABRICATED NEW PANEL AND FINGER DOUBLER IAW DC-8 SRM 57-8-1 FIG 1 ITEM B, K, DWG DACO 5705334. BONDED FINGER DOUBLER ON NEW PANEL IAW DC-8 SRM 51-1-9 PAGE 1, DC-8 SRM 51-1-9D PAGE 1, DPS 1.950, REV. AR R-1. CLEANED, TREATED, PRIMED AREA AND NEW PANEL INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9, DPS 2.50 REV BB. INSTALLED NEW PANEL IAW DACO 5705334, DC-8 SRM 51-1-21 PAGE 1.

Part: SKIN — CORRODED (OVERWING EXIT) · airframe 83,496 hrs · 34,569 cycles

FUSELAGE EXTERIOR SKIN LOCAL CORROSION, STA 700.000 STA 708.000, L-32R. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NR 05163 DATE 04-28-05; SEMAN DWG ED-3961 DATED 04-20-05. REMOVED DAMAGED PLATING SEGMENT IAW SEMAN DWG ED-3961. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. FABRICATED REPAIR DOUBLER STRAP (ALCLAD 7075 T6 0.090”), REPAIR TRIPLER STRAP (ALCLAD 7075 T6 0.100”), PLATING SEGMENT (ALCLAD 7075 T6 0.125”) IAW SEMAN DWG ED-3961. CLEANED, TREATED AND PRIMED REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED REPAIR PARTS IAW SEMAN DWG ED-3961, DC-8 SRM 51-1-20D PAGE 9, DC-8 SRM 51-3-1 PAGE 1, DC-8 SRM 51-3-0 PAGE 1.

Part: SKIN — CORRODED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

FUSELAGE SKIN CORRODED STA 700.00 STA 708.000 L-32L. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NR 05163 DATE 04-28-05; SEMAN DWG ED-3961 DATED 04-20-05. REMOVED DAMAGED PLATING SEGMENT IAW SEMAN DWG ED-3961. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. FABRICATED REPAIR DOUBLER STRAP (ALCLAD 7075 T6 0.090”), REPAIR TRIPLER STRAP (ALCLAD 7075 T6 0.100”), PLATING SEGMENT (ALCLAD 7075 T6 0.125”) IAW SEMAN DWG ED-3961. CLEANED, TREATED AND PRIMED REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED REPAIR PARTS IAW SEMAN DWG ED-3961, DC-8 SRM 51-1-20D PAGE 9, DC-8 SRM 51-3-1 PAGE 1, DC-8 SRM 51-3-0 PAGE 1.

Part: SKIN — CORRODED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FUSELAGE L-35L CORRODED, STA 690.000 STA 781.000. REMOVED LEVEL I CORROSION IAW DC-8 SRM 51-1-8 PAGES 17-18. PERFORMED BLEND OUT 0.003”. MATERIAL THICKNESS 0.160”, REMAINING MATERIAL 0.157 FOUND WITHIN ALLOWABLE LIMITS IAW DC-8 SRM 53-2-0 FIG 11 SHEET 3 PAGE 2P. CLEANED, TREATED AND PRIMED IAW DC-8 SRM 51-1-8B.

Part: SKIN — CORRODED (OVERWING) · airframe 83,496 hrs · 34,569 cycles

FUSELAGE SKIN CORRODED, STA 722.000 781.000, L-35L TO L-35R. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NR 05163 DATE 04-28-05; SEMAN DWG ED-3961 DATED 04-20-05. REMOVED DAMAGED PLATING SEGMENT IAW SEMAN DWG ED-3961. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. FABRICATED REPAIR DOUBLER STRAP (ALCLAD 7075 T6 0.090”), REPAIR TRIPLER STRAP (ALCLAD 7075 T6 0.100”), PLATING SEGMENT (ALCLAD 7075 T6 0.125”) IAW SEMAN DWG ED-3961. CLEANED, TREATED AND PRIMED REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED REPAIR PARTS IAW SEMAN DWG ED-3961, DC-8 SRM 51-1-20D PAGE 9, DC-8 SRM 51-3-1 PAGE 1, DC-8 SRM 51-3-0 PAGE 1.

Part: LONGERON — CORRODED (AFT CARGO BAY) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, AFT CARGO COMPARTMENT CORROSION ON LONGERON 36 BETWEEN STA FS 1380.000 AND 1420.000. PERFORMED BLEND OUT 0.015, MATERIAL THICKNESS 0.150, REMAINING MATERIAL 0.135 ON LWR RADIO AREA AND BLEND OUT 0.011, MATERIAL THICKNESS 0.135, REMAINING MATERIAL 0.124 ON LONGITUDINAL HORIZONTAL LWR AREA FOUND WITHIN ALLOWABLE LIMITS IAW DC-8 SRM 53-2-0 FIG IF SHEET 3 PAGE 2P. APPLIED ALODINE AND REPAINTED AREA IAW DC-8 SRM 51-1-8B.

Part: SKIN — CRACKED (CARGO DOOR) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, CARGO DOOR EXTERNAL SKIN HAS 0.25 IN. CRACKS ON EDGES STA 1160.000 TO STA 1220.000, L-31R TO L-31L. PERFORMED MAJOR REPAIR IAW DC-8 SRM 52-1-0 PAGE 1, DC-8 SRM 52-4-1 FIG 1. REMOVED EXISTING DAMAGED SKIN IAW DC-8 SRM 51-1-21 PAGE 1. FABRICATED NEW SKIN (ALCLAD 2024 T6 0.050”) IAW DC-8 SRM 52-4-1 FIG. 1 ITEM Q CLEANED, TREATED AND PRIMED NEW SKIN AND AREA IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW SKIN IAW DC-8 SRM 51-1-21 PAGE 1, DC-8 SRM 51-3-0 PAGE 1. TORQUED IAW DC-8 SRM 51-3-1.

Part: FITTING — CRACKED (CARGO BAY) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, MAIN CARGO BAY STA 781.000 L-14R AFT FITTING CRACKED 1 IN STA 781.000. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 3779970. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, AFT CARGO BAY LT TRACK STA 980.000 - 1160.000 CORRODED. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-8 PAGES 17-18. FOUND OUT OF LIMITS IAW DC-8 SRM 53-2-3 FIG 12. REMOVED CORRODED TRACK IAW DC-8 SRM 51-3-0 PAGE 1. CLEANED, TREATED AND PRIMED AREA IAW DC-8 SRM 51-1-8B. INSTALLED NEW TRACK IAW DC-8 SRM 51-3-0 PAGE 1. TORQUED IAW DC-8 SRM 51-3-1.

Part: DOUBLER — CRACKED (RT WING) · airframe 83,496 hrs · 34,569 cycles

RT WING CTR L/E INTERNAL DOUBLER CRACKED. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 AND SEMAN DWG ED-3953. REMOVED FASTENERS FROM REPAIR AREA IAW DC-8 SRM. REMOVED DAMAGED AREA IAW SEMAN ED-3953. PERFORMED NDT INSPECTION TO AREA IAW NDT SPM PART 06-10-01-001. FABRICATED REPAIR DOUBLER , SHIM, FILLER, INTERNAL REPAIR DOUBLER IAW SEMAN DWG ED-3953. CLEANED, TREATED AND PRIMED AREA, SHIM, FILLER REPAIR DOUBLER, REPAIR DOUBLER INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED REPAIR PART IAW SEMAN DWG ED-3953, DC-8 SRM 51-1-21 PAGE 1, DC-8 SRM 51-3-0 PAGE 1. TORQUED IAW DC-8 RM 51-3-1.

Part: SKIN — CRACKED (ZONE 600) · airframe 83,496 hrs · 34,569 cycles

RT WING CTR L/E LOWER OUTER PLATING CRACKED. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3, SEMAN DWG ED-3944. REMOVED FASTENERS FROM REPAIR AREA IAW DC-8 SRM. REMOVED DAMAGED AREA IAW SEMAN DWG ED-3944. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. FABRICATED REPAIR DOUBLER, FILLER IAW SEMAN DWG ED-3944. CLEANED, TREATED AND PRIMED AREA, FILLER AND REPAIR DOUBLER INTERIOR IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED REPAIR PARTS IAW SEMAN DWG ED-3944, DC-8 SRM 51-1-20D PAGE 9, DC-8 SRM 51-1-21 PAGE 1. TORQUED IAW DC-8 SRM 51-3-1.

Part: ATTACH FITTING — CRACKED (HORIZONTAL STAB) · airframe 83,496 hrs · 34,569 cycles

LT HORIZ STAB FAIRING SUPPORT AFT FITTING CRACKED STA 1870.000. REMOVED CRACKED FITTING IAW DC-8 SRM 51-3-0 PAGE 1. FABRICATED NEW FITTING IAW DWG NR 3702408. PERFORMED HEAT TREATMENT IAW DC-8 SRM 51-1-1 PAGES 1, 13, 17. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-3-0 PAGE 1. TORQUED IAW DC-8 RM 51-3-0 PAGE 1, DC-8 SRM 51-3-1 PAGE 2A.

Part: FITTING — CRACKED (CARGO BAY) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY FITTING INTERNAL SKIN CRACKED, STA 700.000 L-21 - L-22R. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 3616948. PERFORMED HEAT TREATMENT IAW DC-8 SRM 51-1-1 PAGES 1, 13, 17. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED DC-8 SRM 51-3-1.

Part: ATTACH FITTING — CORRODED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY INTERNAL FUSELAGE FITTING CORRODED, STA 41520.000 L-21L. REMOVED CORROSION IAW DC-8 SRM 51-1-8 PAGE 17-18. FOUND OUT OF LIMITS IAW DC-8 SRM 53-2-0 PAGE 2P. REMOVED CORRODED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 4640162. PERFORMED NDT INSPECTION IAW NDT DC-8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED DC-8 SRM 51-3-1.

Part: RIB — CRACKED (LT WING) · airframe 83,496 hrs · 34,569 cycles

LT NR 1 STUB WING FORMER CRACKED, STA XFS 526.000. PERFORMED MAJOR REPAIR IAW DWG 9753247. REMOVED CRACKED RIB IAW DC-8 SRM 54-1-0 PAGE 1, DC-8 SRM 51-1-21 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW RIB IAW DWG 9753297, DC-8 SRM. DPS 369-4 REV AM. PERFORMED HEAT TREATMENT IAW DC-8 SRM. CLEANED, TREATED AND PRIMED AREA AND RIB IAW DC-8 SRM 51-1-8B. INSTALLED NEW RIB IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 SRM 51-3-1.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY STA 680.000 L-11L AFT FITTING CRACKED. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 4751625. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY RT WING CTR SECTION FITTING CRACKED, STA 759.000 RBL 23. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 4646547. PERFORMED HEAT TREATMENT IAW DC-8 SRM 51-1-1 PAGES 1, 13, 17. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

MAIN CARGO BAY FWD SERVICE DOOR INTERNAL JAMB FITTING CRACKED, STA 474.000 L-11R. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG NR 9755586. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: MOUNT — CRACKED (ANTENNA) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, 2 CRACKS ON DOPPLER ANTENNA FRAME, STA -99.000 TO STA -131.000. REMOVED CRACKED CAP IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-21 PAGE 1, IAW DWG 5616101. PERFORMED HEAT TREATMENT IAW DC-8 SRM 51-1-1 PAGES 1, 13, 17. CLEANED, TREATED, PRIMED AREA AND NEW CAP IAW DC-8 SRM 51-1-8B. INSTALLED NEW CAP IAW DC-8 SRM 51-1-21 PAGE 1.

Part: SKIN — CORRODED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

EXT FUSELAGE RT FUSELAGE CTR SECTION PLATING TCAS DOUBLER MOD CORRODED. ELONGATED HOLES AND DENT DAMAGE (STA 220.000 - 260.000, L-29R TO L-31R). PERFORMED MAJOR REPAIR IAW FAA 8110-3 NR 05168, SEMAN DWG ED-3951. REMOVED CORROSION IAW DC-8 SRM 51-1-8. FOUND OUT OF LIMITS IAW DC-8 SRM 53-2-0. REMOVED EXISTING DOUBLER DC-8 SRM 51-1-21. DC-8 SRM 51-1-20D. REMOVED DAMAGED AREA IAW SEMAN DWG ED-3951. PERFORMED NDT INSP IAW DC-8 NDT SPM PART 06-10-01-001. FAB NEW SEGMENT OF SKIN, EXT SPLICE DOUBLER, INT FINGER DOUBLERS, FINGER DOUBLER, FILLER , AND INT DOUBLER M STRAPS IAW SEMAN DWG ED-3951. CLEANED, TREATED, PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO SURFACES IAW DC-8 SRM 51-1-11.

Part: FITTING — CRACKED (FWD CARGO BAY) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FWD CARGO BAY FITTING CRACKED 1 IN., STA 240.000. L-31R. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1. CLEANED, TREATED AND PRIMED AREA IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: FITTING — CRACKED (NLG) · airframe 83,496 hrs · 34,569 cycles

NOSE SECTION RT TUNNEL FITTING CRACKED STA 8.000. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-3-0 PAGE 1. FABRICATED NEW FITTING IAW DWG NR 4640117. PERFORMED HEAT TREATMENT IAW DC-8 SRM 51-1-1 PAGES 1, 13, 17. PERFORMED NDT INSPECTION IAW NDT SPM PART 08-00-02 TO 07. ENCLOSED SMN FORM 242-4. CLEANED, TREATED AND PRIMED AREA AND FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1 PAGE 2A.

Part: FITTING — CRACKED (RT WING) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, RT WING L/E INBOARD STUB WING UPPER SURFACE SCREWS OXIDIZED, XW 257.000. REMOVED OXIDIZED SCREWS IAW DC-8 SRM 51-3-0 PAGE 1. INSTALLED NEW SCREWS ON RT L/E INBOARD STUD WING UPPER SURFACE, XW 257.000 IAW DC-8 SRM 51-3-0 PAGE 1. TORQUED FASTENERS IAW DC-8 SRM 51-3-1.

Part: FITTING — CRACKED (HORIZONTAL STAB) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, RT HORIZONTAL STABILIZER FITTING CRACKED 1 IN., XFS 47.000 - XFS 60.000 (LWR PART). REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. CLEANED, TREATED AND PRIMED IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9, DC-8 SRM 51-1-21 PAGE 1. TORQUED IAW DC-8 RM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FWD CARGO COMPT INTERIOR. SPLICE FITTING CRACKED, STA 600.00 - STA 620.000, L-31R. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING (ALCLAD 7075 T6 51) IAW DWG 3750257. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA + NEW FITTING IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 SRM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FWD CARGO COMPARTMENT INTERIOR SPLICE FITTING CRACKED 8 IN., STA 440.000 - STA 460.000 , L-31L. REMOVED CRACKED FITTING IAW DC-8 SRM 53-1-0 PAGE 1, DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG 3750257. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA + NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FWD CARGO COMPT INTERIOR SPLICE FITTING CRACKED 3 IN., STA 440.000 - STA 460.000, L-31R. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG 3750257. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: SCREW — CORRODED (RT WING) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C CHECK INSPECTION, RT WING, L/E INBD STUB WING UPPER SURFACE SCREWS OXIDIZED, XW 257.000. REMOVED OXIDIZED SCREWS IAW DC-8 SRM 51-3-0 PAGE 1. INSTALLED NEW SCREWS ON RT L/E INBD STUD WING UPPER SURFACE, XW 257.000 IAW DC-8 SRM 51-3-0 PAGE 1. TORQUED FASTENERS IAW DC-8 SRM 51-3-1.

Part: FITTING — COCKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FWD CARGO COMPT - INTERIOR SPLICE FITTING CRACKED, STA 440.000 - STA 460.00, L-34L 3. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING (ALCLAD 7075 T6 51) IAW DWG 3750330. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA + NEW FITTING IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 SRM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSPECTION, FWD CARGO COMPT - INTERIOR SPLICE FITTING CRACKED, STA 440.000 - STA 460.00, L-34L 3. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING (ALCLAD 7075 T6 51) IAW DWG 3750330. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA + NEW FITTING IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 83,496 hrs · 34,569 cycles

DURING ROUTINE C-CHECK INSP, FWD CARGO COMPARTMENT INTERIOR, SPLICE FITTING CRACKED 3 IN, STA 440.000 - STA 460.000 L-35L. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D PAGE 21. FABRICATED NEW FITTING IAW DWG 3750330. PERFORMED NDT INSPECTION TO FITTING IAW NDT SPM PART 08-00-02/07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO IAW DC-8 SRM 51-1-11 PAGE 9. INSTALLED NEW FITTING IAW DC-8 SRM 51-1-20D PAGE 9. TORQUED IAW DC-8 RM 51-3-1.

Part: GASKET — LEAKING (ENGINE) · airframe 83,115 hrs · 34,375 cycles

DURING TAKEOFF ROLL NR 2 ENGINE GOT TO ABOUT 78 PERCENT N1 AND BEGAN TO ROLL BACK. AFTER THE TAKEOFF WAS ABORTED THE ENGINE CONTINUED TO ROLLBACK BELOW IDLE RPM. ENGINE WAS SHUTDOWN AT THAT POINT. EGT WAS NORMAL, FUEL FLOW WAS FLUCUATING BETWEEN -0- AND -1000- PPH. ALL OTHER INDICATIONS WERE NORMAL. MAINTENANCE REMOVED AND REPLACED FUEL FLOW TRANSMITTER GASKET. OPERATIONAL AND LEAK CHECK WERE GOOD PER ALL APPLICABLE MANUALS AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: ACTUATOR — CRACKED (ZONE 500) · airframe 82,286 hrs · 34,000 cycles

AIR RETURN, AFTER T/O SLOT LIGHT REMAINED ON AFTER FLAP RETRACTED. CYCLED, SLOT LIGHT OUT WHEN EXTENDED, ON WHEN RETRACTED. THEN 10 MIN INTO FLT SLOT LIGHT WENT OUT WITH FLAPS RETRACTED. NEVER EXCEEDED 230 KTS, LIGHT CAME BACK ON WHEN ON THE GROUND, WHILE TAXIING INTO PARKING LOST HYD SYSTEM. MAINTENANCE INSPECTION OF FLAPS FOUND BROKEN LEFT I/B ACTUATOR ASSY BRACKET. HYDRAULIC LEAK COMING FROM BROKEN HYDRAULIC ELBOW ON SAME ACTUATOR ASSY. REMOVED AND REPLACED ACTUATOR ASSY PER DACO M/M 27-51-9, RESERVICED HYDRAULIC SYSTEM PER DACO 12-30-1, FLAPS AND HYDRAULIC SYSTEM OPS AND LEAK GOOD. SLOT LIGHTS OP CHECK GOOD.

Part: PMC — OUT OF LIMITS (NR 2) · airframe 81,432 hrs · 33,593 cycles

DURING CRUISE NR 2 ENGINE EGT INCREASED FROM 730 DEGREES APPROXIMATELY TO 830 DEGREES. CREW REDUCED POWER TO IDLE AND EGT STABILIZED AT 640 DEGREES. PRECAUTIONARY ENGINE SHUTDOWN WAS ACCOMPLISHED AND CREW LANDED IN KTOL WITHOUT INCIDENT. MAINTENANCE INSPECTED EGT HARNESS AND NO DEFECTS WERE NOTED. MAINTENANCE RAN ENGINES AND FOUND PMC DROP CHECK OUT OF LIMITS. ADJUSTED POWER TRIM AND OPERATIONAL CHECK WAS GOOD PER ALL APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: BRACKET — CRACKED (AILERON CONTROL) · airframe 81,430 hrs · 1,292 cycles

DURING A ROUTINE B-CHECK INSPECTION MAINTENANCE FOUND RT AILERON INBOARD CONTROL TAB CABLE BRACKET CRACKED. AS MORE INFORMATION BECOMES AVAILABLE IT WILL BE PROVIDED. MAINTENANCE REMOVED AND REPLACED INBOARD AILERON, RT AILERON MANUAL REVERSION CONTROL ROD, 5 EACH RT AILERON BUS CABLE, RT INNERCONNECT EYEBOLT AND RT AILERON CONTROL ACTUATOR PER ALL APPLICALBE MANUALS. OPERATIONAL CHECK GOOD AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: FITTING — CRACKED (FLAP) · airframe 81,430 hrs · 33,592 cycles

DURING A ROUTINE "B" CHECK INSPECTION, MAINTENANCE FOUND LT FLAP SUPPORT FITTING CRACKED AT STATION 219. AS MORE INFORMATION BECOMES AVAILABLE IT WILL BE PROVIDED. MAINTENANCE REMOVED AND REPLACED L/H FLAP OUTBOARD SECTION PER ALL APPLICABLE MANUALS. OPERATIONAL CHECK GOOD. AIRCRAFT WAS RETURNED TO SERVICE.

Part: UPLOCK — INOPERATIVE (MLG) · airframe 81,183 hrs · 33,469 cycles

AFTER TAKEOFF FROM KTOL TO KBNA UPLATCH CHECK POSITION OF GEAR HANDLE DURING CLIMBOUT THE (LANDING GEAR UNSAFE) LIGHT CAME ON. CYCLED GEAR DOWN AND BACK UP TWICE BEFORE GETTING A SATISFACTORY UPLATCH CHECK. AN INSPECTION IS ONGOING. AS INFORMATION BECOMES AVAILABLE IT WILL BE PROVIDED.

Part: ENGINE — FLAMED OUT (NR 3) · airframe 81,134 hrs · 33,450 cycles

AFTER LEVEL OFF AT CRUISE ALTITUDE FROM KTOL NR3 ENGINE FLAMED OUT. CREW COMPLIED WITH CFM-56 FLAME OUT/INFLIGHT START CHECKLIST AND HAD A SUCCESSFUL RESTART WITH NO FURTHER PROBLEMS NOTED. AIRCRAFT RETURNED TO KTOL AND LANDED WITHOUT INCIDENT. AN INVESTIGATION IS ONGOING. WHEN MORE INFORMATION IS AVAILABLE IT WILL BE PROVIDED. MAINTENANCE PERFORMED FLAMEOUT INSPECTION IAW CFM MM 71-00-00. THEY REMOVED AND REPLACED FUEL FILTER IAW CFM MM 73. ENGINE WAS RUN AT TAKEOFF POWER IAW ATI ERH 70.01 TABLE 91.01.4 SUMPED TANK AND NO DEFECTS NOTED. OPERATIONAL CHECK GOOD, AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: SCREW — MISSING (NLG WW PANEL) · airframe 81,077 hrs · 33,416 cycles

AFTER TAKE OFF FROM KPHL TO KTOL AND DURING GEAR RETRACTION CREW EXPERIENCED A NOISE AND VIBRATION COMING FROM THE NOSE GEAR AREA. THE GEAR WAS LEFT DOWN FOR THE REMAINDER OF FLT AND MADE AN UNEVENTFUL LANDING IN KTOL. MAINTENANCE FOUND SCREWS MISSING FROM RIGHT AFT PANEL IN NOSE WHEEL WELL. MAINTENANCE REPLACED SCREWS IAW ALL APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE

Part: CURTAIN — UNSECURE (NLG WW) · airframe 81,049 hrs · 33,406 cycles

AFTER TAKEOFF FROM KBDL AND AFTER GEAR RETRACTION, THERE WAS A VIBRATING NOISE COMING FROM NOSE WHEEL WELL. CREW RETURNED TO KBDL AND LANDED WITHOUT INCIDENT. DURING INSPECTION OF THE NOSE GEAR AREA MAINTENANCE FOUND NOSE WHEEL CURTAIN UNSNAPPED. MAINTENANCE INSPECTED THE NOSE GEAR WHEEL ASSEMBLY FOR EXCESSIVE PLAY, NONE WAS FOUND. THE CURTAIN WAS SECURED IN ACCORDANCE WITH ALL APPLICABLE MANUALS AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: PLUG — LOOSE (FUSELAGE) · airframe 81,006 hrs · 33,373 cycles

AFTER TAKEOFF FROM KMCO AND GEAR RETRACTION, THERE WAS A VIBRATION ASSOCIATED WITH NOISE COMING FROM THE NOSE WHEEL WELL AREA. GEAR WAS CYCLED AND NOISE AND VIBRATION CONTINUED. CREW DECIDED TO RETURN AND LAND AT KMCO. MAINTENANCE FOUND NOSE CURTAIN LOOSE AND RESECURED. INSPECTED AND FOUND WINDOW PLUG LOOSE. MAINTENANCE RESECURED PLUG IN ACCORDANCE WITH ALL APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: COUPLING — SEPARATED (DUCT) · airframe 81,002 hrs · 33,368 cycles

AFTER TAKE OFF FROM KPHL TO KTOL, DURING GEAR RETRACTION A NOISE AND VIBRATION OCCURRED. WHEN GEAR WAS LOWERED NOISE AND VIBRATION DISSIPATED SLIGHTLY. GEAR WAS CYCLED AND NO CHANGE OCCURRED. MAINTENANCE FOUND DUCT SEPERATED AT COUPLING. RESECURED DUCT, RESECURED CANVAS CURTAIN IN NOSE WHEEL WELL, IAW MM. INSPECTION OF NOSE WHEEL FRICTION BRAKES FOUND NO DEFECTS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: MECHANISM — BROKEN (MLG) · airframe 80,986 hrs · 33,359 cycles

AFTER TAKEOFF AND GEAR RETRACTION, CREW EXPERIENCED A VIBRATION AND NOISE COMING FROM NOSE GEAR AREA. THE CREW ELECTED TO RETURN BASE. MAINTENANCE FOUND GROUND SHIFT ARM BROKEN. AS MORE INFORMATION BECOMES AVAILABLE IT WILL BE PROVIDED. MAINTENANCE REMOVED AND REPLACED GROUND SHIFT MECHANISM, THEY ALSO FOUND THE NOSE WHEEL STEERING OUT OF RIG. NOSE WHEEL STEERING WAS RIGGED, OPERATIONAL CHECK GOOD. ALL WORK PERFORMED IAW APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WING — CRACKED (R/H UPPER) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE UPPER RIGHT WING, INBOARD OF FUEL PANEL 505F AT THE UPPER AFT PLANK. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGE, FABRICATION AND INSTALLATION OF REPAIR FILLERS AND DOUBLERS IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: LONGERON — CORRODED (STATION 36) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS DETECTED ON LONGERON 36 AT STATION 380. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGED LONGERON FROM STATION 360 TO 450, FABRICATION AND INSTALLATION OF NEW LONGERON IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: LONGERON — CRACKED (LONGERON 33R) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE LONGERON 33R AT STATION 350 AFT OF THE C-1 DOOR CUT OUT. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGED LONGERON FROM STATION 340 TO 450, FABRICATION AND INSTALLATION OF NEW LONGERON IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: DOUBLER — CORRODED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, CORRODED DOUBLERS WERE DISCOVERED ON THE FUSELAGE BY STA 340 AND 360 AFT OF THE C-1 DOOR. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGE, FABRICATION AND INSTALLATION OF REPAIR FILLERS AND REPAIR SPLICE DOUBLERS IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING AUTHROIZATION R12-R04.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, FOUND A TEMPORARY REPAIR ON FUSELAGE FRAME STATION 340. REPAIR ACCOMPLISHED, REMOVAL OF TEMPORARY REPAIR, FABRICATION AND INSTALLATION OF REPAIR DOUBLERS IAW THE DOUGLAS SRM AND ENGINEERING DRAWING R12-R04.

Part: SKIN — DAMAGED (DOOR CUTOUT) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A HOLE WAS DISCOVERED IN THE MAIN CARGO DOOR RT AFT LOWER FORWARD CUT OUT AREA. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGE, FABRICATION AND INSTALLATION OF REPAIR DOUBLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: DOUBLER — INADEQUATE (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A TEMPORARY REPAIR WAS DISCOVERED ON THE LOWER FORWARD CARGO COMPARTMENT FORWARD DOOR CUT OUT FORWARD SIDE AT FS 280 STRINGER 36. REPAIR ACCOMPLISHED, REMOVAL OF THE TEMPORARY REPAIR, FABRICATION AND INSTALLATION OF REPAIR FILLER AND DOUBLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: FRAME — CORRODED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS DETECTED ON THE LOWER FORWARD CARGO COMPARTMENT FRAME CLOSE TO AFT DOOR CUT OUT OF FUSELAGE STATION 520 LONGERON 27R. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGED FRAME SECTION, FABRICATION AND INSTALLATION OF REPAIR FILLER AND REPAIR CHANNELS IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: DOOR — DAMAGED (FWD CARGO) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A TEMPORARY REPAIR WAS DISCOVERED ON THE LOWER FORWARD CARGO COMPARTMENT FORWARD DOOR CUT OUT ON THE RIGHT HAND SIDE FORWARD AND AFT CORNERS @ FUSELAGE STATION 280 LONGERON 30R. REPAIR ACCOMPLISHED, REMOVAL OF TEMPORARY REPAIR, FABRICATION AND INSTALLATION OF REPAIR DOUBLERS AND TRIPLERS IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: DOUBLER — DENTED (FUSELAGE SKIN) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A DENT WAS DISCOVERED UNDER AN EXISTING REPAIR ON THE CENTER SECTION OF THE LOWER FORWARD CARGO COMPARTMENT FUSELAGE STATION 335. REPAIR ACCOMPLISHED, REMOVAL OF PREVIOUS REPAIR, REMOVAL OF DAMAGE, FABRICATION AND INSTALLATION OF REPAIR ANGLE IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING AUTHORIZATION R12-R04.

Part: SKIN — CORRODED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS DETECTED UNDER AND EXISTING REPAIR DOUBLER AFT OF THE C-1 DOOR LONGERON 36, FS 333 TO FS 450. REPAIR ACCOMPLISHED, REMOVAL OF REPAIR DOUBLER, CORROSION AND SKIN PANEL, FABRICATION AND INSTALLATION OF NEW SKIN PANEL IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING DRAWING 5755271.

Part: DOUBLER — INADEQUATE (FUSELAGE SKIN) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A TEMPORARY REPAIR AT FUSELAGE STATION 45 LONGERON 29L WAS DETECTED. REPAIR ACCOMPLISHED, REMOVAL OF TEMPORARY REPAIR, DAMAGE. FABRICATION AND INSTALLATION OF REPAIR DOUBLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: SKIN — CORRODED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS DETECTED ON THE FUSELAGE SKIN. FUSELAGE STATION 8 LONGERON 28R. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGE, FABRICATION AND INSTALLATION OF REPAIR FILLER AND DOUBLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING AUTHORIZATION R12-R05.

Part: SKIN — CRACKED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE FUSELAGE AT FS 490 LONGERON 11R UPPER AFT CORNER OF THE FORWARD SERVICE DOOR CUT OUT. REPAIR ACCOMPLISHED, REMOVED DAMAGE, FABRICATION AND INSTALLATION OF REPAIR DOULBER AND TRIPLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING AUTHROIZATION EAR12-01.

Part: SKIN — CRACKED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE FUSELAGE STATION 1660 LONGERON 11L UPPER AFT CORNER ON THE AFT ENTRY DOOR CUTOUT. REPAIR ACCOMPLISHED, REMOVED DAMAGE, FABRICATION AND INSTALLATION OF REPAIR FILLER, DOUBLER AND TRIPLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: SKIN — CRACKED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE FUSELAGE, AT FS 1620 LONGERON 11R ON THE UPPER AFT CORNER OF THE AFT SERVICE DOOR CUT OUT. REPAIR ACCOMPLISHED, CUT OUT DAMAGED AREA, FABRICATION AND INSTALLATION OF REPAIR FILLER, DOUBLER AND TRIPLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: SKIN — CRACKED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE FUSELAGE, FS 1620 LONGERON 21L BY THE AFT ENTRY DOOR CUT OUT ON THE LOWER FORWARD CORNER. REPAIR ACCOMPLISHED, REMOVED DAMAGE, FABRICATION AND INSTALLATION OF REPAIR FILLER, DOUBLER AND TRIPLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: SKIN — CRACKED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE FUSELAGE UPPER FORWARD CORNER OF THE FORWARD SERVICE DOOR CUT OUT. REPAIR ACCOMPLISHED, REMOVED DAMAGE, FABRICATION AND INSTALLATION OF REPAIR FILLER, DOUBLER AND TRIPLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND DRAWING R12-R03.

Part: SKIN — CRACKED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, TWO CRACKS WERE DECTECTED ON THE FUSELAGE SKIN AT STATION 490 ON THE LOWER AFT CORNER OF THE FORWARD ENTRY DOOR CUT OUT. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGE, FABRICATION AND INSTALLATION OF REPAIR DOULBER AND TRIPLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING AUTHORIZATION R12-R03

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DISCOVERED ON THE FUSELAGE BY THE LEFT HINGE OF THE RADOME. REPAIR ACCOMPLISHED, REMOVAL OF DAMAGE, FABRICATION AND INSTALLATION OF REPAIR FILLER AND DOUBLER, IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL.

Part: WING — CRACKED (LOWER L/E) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE LEFT WING LOWER LEADING EDGE SCREW HOLE. REPAIR ACCOMPLISHED, REMOVAL OF PREVIOUS REPAIR, REMOVAL OF DAMAGE, FABRICATION AND INSTALLATION OF FILLER AND DOUBLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING AUTHORIZATION R12-R01

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED UNDER A TEMPORARY REPAIR OF THE FORWARD FUSELAGE, STATION 45 AT LONGERON 9L ADJACENT TO L-1 DOOR FRAME. REPAIR ACCOMPLISHED, REMOVAL OF THE TEMPORARY REPAIR AND DAMAGE, FABRICATION AND INSTALLATION OF REPAIR FILLER, DOUBLER AND TRIPLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING AUTHORIZATION R12-R03.

Part: SKIN — CRACKED (LT WING) · airframe 80,111 hrs · 32,890 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK ALONG WITH CORROSION WAS DETECTED ON THE LT WING UPPER AFT SKIN ABOVE THE LT GEAR TRUNNION AREA. REAPIR ACCOMPLISHED, REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF REPAIR DOUBLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING AUTHORIZATION R12-R01.

Part: ROD — MALFUNCTIONED (NLG) · airframe 77,934 hrs · 31,811 cycles

EN ROUTE FORM LRD TO TOL, WHEN THE LANDING GEAR WAS RETRACTED THE FLIGHT CREW NOTICE A VIBRATION IN THE NOSE OF THE AIRCRAFT. THE FLIGHT CREW CYCLED THE LANDING GEAR BUT THE VIBRATION REMAINED PRESENT. THE AIRCRAFT RETURN TO LRD FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED THE LEFT NOSE LANDING GEAR DOOR OPEN. MAINTENANCE CLEANED, LUBRICATED AND SECURED THE TELESCOPING DOOR ROD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: VALVE — DEFECTIVE (WHEEL WELL) · airframe 77,161 hrs · 31,434 cycles

DURING APPROACH INTO TOL, THE FLIGHT CREW NOTICED THE MAIN HYDRAULIC QUANTITY DECLINING. THE FLIGHT CREW FOLLOWED COMPANY EMERGENCY PROCEDURES, DECLARED AN EMERGENCY AND CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT LOCATING A DEFECTIVE BRAKE CONTROL VALVE AT FAULT. MAINTENANCE REPLACED THE CONTROL VALVE IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE. (X)

Part: BOLT — MISMANUFACTURED (ENGINE MOUNT)

DURING INSTALLATION AND TIGHTENING OF BOLTS THAT SECURE THE FORWARD ENGINE MOUNT TO THE PYLON, ONE BOLT BROKE IN TWO AND ANOTHER BOLT STRIPPED. THIS OCCURRED PRIOR TO THE BOLTS REACHING FINAL TORQUE. THIS IS CURRENTLY BEING INVESTIGATED BY BOEING AND IS ALSO BEING TRACKED BY GEES SAFETY PRODUCT MANAGEMENT TEAM (SPMT).

Part: ACM — DEFECTIVE (LT PACK)

EN ROUTE FROM PDX TO TOL, THE FLIGHT CREW NOTICE SMOKE EMMITTING INTO THE COCKPIT, ACCOMPANIED WITH LEFT PACK TEMPERATURE INCREASING. THE FLIGHT CREW FOLLOWED COMPANY EMERGENCY PROCEDURES, SECURED THE LEFT PACK, SMOKE SUBSIDED. THE FLIGHT RETURNED TO PDX FOR AN UNEVENTUL LANDING. MAINTENANCE INSPECTED THE PACK SYSTEM WHICH REVEALED THE LEFT AIR CYCLE MACHINE DEFECTIVE. MAINTENANCE PLACED THE PACK ON DEFERRAL AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: RELAY — DEFECTIVE (COCKPIT)

DURING CLIMBOUT, THE NR 1 ENG FIRE WARNING SOUNDED WITH THE MASTER FIRE WARNING LIGHT ILLUMINATED. THE FLT CREW SECURED THE ENG FOLLOWING COMPANY PROCEDURES AND DISCHARGED THE FIRE BOTTLE. THE FIRE WARNING LIGHT EXTINGUSHED FOLLOWING FIRE BOTTLE DISCHARGE. THE FLT RETURNED TO DFW FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE ENG AND FOUND NO EVIDENCE OF A FIRE. THE FIRE WARNING LOOPS AND ASSOCIATED WIRING WERE INSPECTED LOCATING CORROSION ON THE FIRE WALL CANNON PLUG AND A DEFECTIVE RESET RELAY. THE RELAY WAS REPLACED AND THE CANNON PLUG WAS CLEANED. MAINTENANCE PERFORMED A SUCCESSFUL OPERATIONAL TEST IN ACCORDANCE WITH THE MAINTENANCE MANUAL.

Part: COWL — DAMAGED (LT ENGINE)

DURING LANDING, THE NUMBER ONE ENGINE SUSTAINED A GROUND STRIKE WITH MINOR DAMAGE TO THE FORWARD FAN COWLINGS, DRAIN MAST AND THE ACCESSORY GEARBOX COVER. A MANUFACTURER SUPPORT TEAM WAS CALLED IN TO PERFORM AN ENGINE BORESCOPE AND GEARBOX FPI INSPECTION, WHICH REVEALED NO DISCREPANCIES. A MAX POWER ASSURANCE CHECK WAS ACCOMPLISHED. RECOMMENDED CHIP DETECTOR INSPECTION EVERY FIFTY HOURS FOR THE NEXT TWO HUNDRED HOURS WAS SCHEDULED. THE AIRCRAFT IS WILL RETURN TO SERVICE FOLLLOWING FAN COWL REPLACEMENT.

Part: WIRE — FAILED (NR 4 BUSS)

EN ROUTE FLIGHT LEVEL 330, SMOKE EMANATED FROM AFT ELECTRICAL POWER CENTER. CREW ACCOMPLISHED COMPANY PROCEDURES FOR SMOKE IN COCKPIT AND ELECTED TO RETURN TO OAK. FURTHER ASSESSMENT OF THE PROBLEM DURING COURSE REVERSAL FOUND THAT WHEN THE NR 1 LOAD MONITOR RELAY WAS OPENED THE SMOKE STOPPED. FLIGHT CONTINUED TO OAK WITH NR 1 LMR OFF WITH AN UNEVENTFUL LANDING. MAINTENANCE FOUND AND REPAIRED THE NR 4 BUS TIE RELAY WIRING. THE WIRING WAS REPORTED AS BURNT AS IT EXITED THE CONDUIT IN THE AREA.

Part: TELESCOPING LINK — NOT LATCHED (RT NLG DOOR)

ON DEPARTURE OUT OF BFI, THE RIGHT NLG DOOR DID NOT CLOSE AFTER GEAR RETRACTION. THE GEAR WAS CYCLED, BUT THE PRESENCE OF THE BUFFETING FROM THE DOOR INDICATED THAT IT WAS STILL OPEN. THE AIRCRAFT RETURNED TO BFI FOR MAINTENANCE. AT BFI THE NOSE GEAR DOORS WERE INSPECTED AND OPERATIONALLY CHECKED IAW THE DC-8MM 32-22-1, AND FOUND TO BE NORMAL. THE RIGHT NLG DOOR DID NOT CLOSE ON TAKEOFF EITHER BECAUSE THE TELESCOPING LINK WAS NOT FULLY LATCHED, OR BECAUSE IT WAS NOT LATCHED AT ALL. (M)

Part: TURNBUCKLE — SPLIT (RT MLG DOOR)

DFW - ON DEPARTURE, GEAR DOOR LIGHT WOULD NOT GO OUT WITH THE LANDING GEAR HANDLE IN THE 'UP' POSITION. CYCLING THE GEAR RESULTED IN NO CHANGE. THE AIRCRAFT RETURNED TO DFW FOR MAINTENANCE. MAINTENANCE FOUND THE RT MLG DOOR ACTUATOR FOLLOW-UP CABLE WAS OUT OF RIG DUE TO A TURNBUCKLE IN THAT CABLE RUN WHOSE BARREL HAD SPLIT LONGITUDINALLY. THE TURNBUCKLE BARREL WAS REPLACED, THE RT DOOR FOLLOW-UP SYSTEM RIGGED IAW THE DC-8 MM, THE LANDING GEAR OPERATIONALLY CHECKED IAW DC-8 MM, AND THE AIRCRAFT RETURNED TO SERVICE. (X)

Part: CONNECTOR — LOOSE (RT MLG DOOR)

ON TAKEOFF OUT OF ONT, THE FLT CREW OBSERVED A LANDING GEAR DOOR UNSAFE INDICATION AFTER GEAR RETRACTION. THE LANDING GEAR WAS CYCLED, AND THE WARNING LIGHT EXTINGUISHED. TOL MAINTENANCE INSPECTED THE LANDING GEAR DOOR WARNING SYSTEM AND FOUND THE ELECTRICAL CONNECTOR ON THE RIGHT DOOR UPLATCH SWITCH LOOSE. THE CONNECTOR WAS SECURED AND THE INDICATION SYSTEM OPS CHECKED. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: CONTL VALVE — SEAL EXTRUDED (LE FLAPS)

DFW/TOL - DURING CRUISE BETWEEN DFW AND TOL, THE AIRCRAFT EXPERIENCED AN HYDRAULIC SYSTEM FAILURE OF BOTH PRESSURE AND QUANTITY. AFTER AN UNEVENTFUL LANDING, MAINTENANCE FOUND THE RIGHT HYDRAULIC MANIFOLD SLOT CONTROL VALVE O-RING EXTRUDED BETWEEN THE MANIFOLD AND THE VALVE. MAINTENANCE REPLACED THE O-RING, SERVICED THE HYDRAULIC SYSTEM, RAN THE AIRCRAFT, ALL SYSTEMS OPERATIONALLY CHECKED GOOD IAW MM. THE AIRCRAFT WAS RETURNED TO SERVICE. (X)