N841AL

Part: SKIN — CRACKED (BS 802 S18L) · airframe 68,502 hrs · 71,593 cycles

DURING SERVICE CHECK FOUND AN APPROX 2" CRACK ON THE LT SIDE FUSELAGE AT BS 802, ABOVE STRINGER 18L. REPAIRED IAW SRM 53-30-3, FIG. 48.

Part: SKIN — CRACKED (BS 887) · airframe 68,129 hrs · 70,744 cycles

DURING SERVICE CHECK, FOUND AN APPROXIMATELY 2 INCH CRACK ON THE LT SIDE FUSELAGE AT BS 887, ABOVE STRINGER 17L. REPAIRED CRACK IAW SRM 53-30-3, FIG 48, DETAIL XI.

Part: STRINGER CLIP — CRACKED (BS 277 S15R) · airframe 67,719 hrs · 69,876 cycles

STRINGER CLIP CRACKED AT FUSELAGE BS 277 AT STRINGER 15R. REMOVED DAMAGED STRINGER CLIP IAW SRM 51-30-02. FABRICATED NEW STRINGER CLIP IAW SRM 51-30-06. INSTALLED NEW STRINGER CLIP IAW SRM 51-30-2.

Part: SKIN — CORRODED (HORIZONTAL STAB) · corrosion level 2 · airframe 67,719 hrs · 69,876 cycles

LT HORIZONTAL STABILIZER UPPER SURFACE REAR SPAR HAS A BROKEN RIVET HEAD AND A BULGE IN SKIN AROUND BROKEN RIVET AT STABILIZER STATION 66.5. REMOVED T/E SKIN FASTENERS. DISCOVERED CORROSION AROUND AFT SPAR OF HORIZONTAL STABILIZER. REMOVED CORROSION ON AFT SPAR OF LT HORZ STAB. FABRICATED REPAIR DOUBLER AND FILLER MATERIALS IAW SRM 5510-3. INSTALLED ALL REPAIR PARTS IAW SRM 51-30-2.

Part: FLOORBEAM — CORRODED (BS 787) · corrosion level 2 · airframe 67,719 hrs · 69,876 cycles

CORROSION ON FLOORBEAM AT STA 787 AND RBL 40 THROUGH 55. REMOVED CORROSION IAW SRM 51-30-2. FABRICATED FLOORBEAM REPAIR IAW ECO 53-04407-1. INSTALLED FABRICATED FLOORBEAM IAW DWG 53-04407-1.

Part: STRINGER SPLICE — CORRODED (BS 907 S26L) · corrosion level 2 · airframe 67,719 hrs · 69,876 cycles

CORROSION ON STRINGER SPLICE AT STA 907 AT STRINGER 26L. FOUND STRINGER SPLICE TO BE EXFOLIATED OUT OF LIMITS. REMOVED STRINGER SPLICE IAW SRM 51-30-2. FABRICATED STRINGER SPLICE FILLER MATERIAL IAW SRM 53-10-3 AND INSTALLED REPAIR PARTS IAW SRM 51-30-2.

Part: PLATE — GOUGED (NR 2 NACELLE) · airframe 67,719 hrs · 69,876 cycles

NR 2 ENGINE CROSSBEAM LOWER INBD ENGINE TO WING FAIRING HAS GOUGES ON CROSSBEAM FACE. REMOVED DAMAGED PLATE FROM CROSSBEAM IAW 51-30-2. FABRICATED NEW PLATE IAW SRM 51-20-1. INSTALLED NEW PLATE ON CROSSBEAM FACE SRM 51-30-2.

Part: SHEAR TIE — CORRODED (ZONE 100) · corrosion level 2 · airframe 67,719 hrs · 69,876 cycles

CORROSION AT FUSELAGE STA 400 AND STRINGER 26R, FUSELAGE FRAME. REMOVED CORRORED SHEAR TIE IAW SRM 51-30-02, FABRICATED AND ISTALLED A NEW SHEAR TIE IAW SRM 51-10-02 AND 51-30-02.

Part: SUPPORT — CRUSHED (BS 727) · airframe 67,719 hrs · 69,876 cycles

BS 727 AT STRINGER 19R HORIZONTAL BULKHEAD PANEL SUPPORT FRAME IS CRUSHED IN AFT PIT. REMOVED HORIZONTAL BULKHEAD PANEL SUPPORT FRAME AT FUSELAGE STATION 727 IAW SRM 51-30-2. FABRICATED NEW SUPPORT FERAME IAW SRM 51-20-01. INSTALLED NEW SUPPORT FRAME IAW SRM 51-30-02

Part: STRINGER — CORRODED (BS 1016 S24L) · corrosion level 2 · airframe 67,719 hrs · 69,876 cycles

CORROSION AT BS 1016 AT AFT PRESSURE BULKHEAD AT STRINGER 24L. REMOVED STRINGER END FITTING AND ALSO FOUND END OF STRINGER WAS ALSO CORRODED. FABRICATED NEW STINGER END FITTING AND STRINGER SPLICE, ALL REPAIR PARTS INSTALLED IAW SRM 53-10-3.

Part: SKIN — MISREPAIRED (BS 907-917) · airframe 67,719 hrs · 69,876 cycles

LOWER FUSELAGE PRESSURIZATION LEAK AT EXTERNAL REPAIR FWD EDGE AT STA 907 AT STRINGER 20L AT LAP SEAM AND BUTT SPLICE DOWN TO STR 25L LAP SEAM. REMOVED FASTENERS IN EXISTING REPAIR AT STR 20L STA 907 - 917. REAMED HOLES TO PROPER SIZE IAW SRM 51-30-05, FIG 3 & 4. NDT INSP WAS PREFORMED ON THE HOLES, NO CRACKS DETECTED IAW NDT MANUAL 51-00-00. INSTALLED FASTENERS WET WITH SEALANT IAW SRM 51-30-2. PRESSURIZATION LEAK WAS DUE TO IMPORPER SEALING WHEN REPAIR WAS INSTALLED ON ACFT AT A PREVIOUS DATE.

Part: SKIN — MISREPAIRED (BS 312 S19R) · airframe 67,719 hrs · 69,876 cycles

LOWER FUSELAGE, PRESSURIZATION LEAK AT EXTERNAL REPAIR (APPROX 30 RIVETS) BELOW R-1 DOOR. STA 312 AT STRINGER 19R LAP SEAM. REMOVED FASTENERS AT LOWER FUSELAGE AT STA 312 STR 19R AT LAP SEAM. PERFORMED NDT INSP OF FASTENER HOLES, NO DEFECT NOTED. FOUND WHEN DOUBLER WAS APPLIED TO ACFT, NOT ENOUGH SEALANT WAS USED. CLEANED THE ENTIRE AREA AND REINSTALLED FASTENERS WET WITH SEALANT IAW SRM 51-20-4.

Part: STRINGER SPLICE — CORRODED (BS 907) · corrosion level 2 · airframe 67,719 hrs · 69,876 cycles

CORROSION AT FUSELAGE STA 907 AT STR 27L AT STRINGER SPLICE. REMOVED STRINGER SPLICE AND STRINGER CLIP DUE TO CORROSION FOUND TO BE OUT OF LIMITS IAW SRM 51-30-02. FABRICATED REPAIR COMPONENTS IAW SRM 53-10-03. INSTALLED REPAIR COMPONENTS IAW SRM 51-30-02.

Part: FRAME — CORRODED (ACCESS DOOR) · corrosion level 2 · airframe 67,719 hrs · 69,876 cycles

AFT TAIL CONE ACCESS DOOR PANEL NR 3802 FRAME HAS CORRODED RIVET HEADS AND RUB PADS. REMOVED RIVETS AND RUB PADS FROM TAIL CONE ACCESS DOOR IAW SRM 51-30-2. FABRICATED NEW RUB PADS AND INSTALLED RUB PADS AND NEW FASTENERS AS IAW SRM 51-30-2.

Part: FAIRING — DAMAGED (NR 3 FLAP) · airframe 67,719 hrs · 69,876 cycles

NR 3 FLAP FAIRING FORWARD LOWER L/E IS DAMAGED. REPAIRED IAW SRM`S 51-30-2, & 51-40-3.

Part: SKIN — CRACKED (BS 360 S15R) · airframe 67,034 hrs · 68,460 cycles

DURING SERVICE CHECK, FOUND A 2 INCH CRACK ON THE RT SIDE FUSELAGE AT BS 360+5.5, ABOVE STRINGER 15R. THE CRACK WAS REPAIRED IN ACCORDANCE WITH ECO 3826, SB 737-53A1177 REVISION 6 & SRM 53-30-03 FIGURE 48.

Part: SKIN — CRACKED (BS 259.5) · airframe 66,411 hrs · 67,154 cycles

DURING THE DAILY SERVICE CHECK, A 2 IN CRACK AT BODY STA 259.5, 1 IN ABOVE STRINGER 16R WAS DISCOVERED DURING THE VISUAL CHECK OF THE FUSELAGE. THE CRACK WAS CONFIRMED WITH HFEC INSP AND WAS REPAIRED IAW SRM 53-30-3, FIG 48 DETAIL VIII. THE ACFT WAS RETURNED TO SERVICE.

Part: WINDOW — CRACKED (COCKPIT) · airframe 66,385 hrs · 67,096 cycles

NON-ETOPS FLIGHT 54 HNL-ITO. ON DESCENT, THE CAPTAIN’S NR 2 WINDOW OUTER PANE CRACKED. GLASS REMAINED INTACT AND THERE WAS NO LOSS OF PRESSURIZATION. CREW RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. MX R & R THE CAPTAIN’S NR 2 WINDOW IAW AMM 56-12-11 AND OPS CHECK WAS SATISFACTORY. THE ACFT WAS RETURNED TO SERVICE.

Part: OIL FILTER — SEPARATED (NR 2 ACSORY G/B) · airframe 66,192 hrs · 66,690 cycles

FLT 40. AFTER ADVANCING THE THROTTLES THE CREW NOTED THE NR 2 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATE FOLLOWED BY A DECREASE IN NR 2 ENGINE OIL QUANTITY. THE CREW ABORTED THE TAKE-OFF AND SHUTDOWN THE NR 2 ENGINE AND RETURNED TO THE CARGO RAMP. MAINTENANCE FOUND ONE OF THE THREADED INSERTS FOR THE BOLTS THAT SECURE THE OIL FILTER COVER FAILED AND THE COVER SEPARATED FROM THE ENGINE ACCESSORY GEARBOX. MAINTENANCE REMOVED AND REPLACED THE ENGINE ACCESSORY GEARBOX IN ACCORDANCE WITH FORM M-230. OPERATIONAL AND LEAK CHECK FOUND SATISFACTORY. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: INDICATOR — FAILED (TE FLAPS) · airframe 65,818 hrs · 65,885 cycles

DURING CLIMB, THE CREW SELECTED FLAPS UP AND NOTED A SPLIT-FLAP INDICATION, WITH NO ROLL ENCOUNTERED. CREW ATTEMPTED TO SELECT FLAPS 1 WITH NO EFFECT. CREW DECLARED AN EMERGENCY, ACCOMPLISHED T/E FLAPS DISAGREE CHECK LIST WITH FLAPS 15. ACFT LANDED WITHOUT FURTHER INCIDENT. MX R & R THE T/E FLAP POSITION INDICATOR AND TEST CYCLED FLAPS IAW AMM 27-58-41. OPS CHECK WAS FOUND SATISFACTORY AND THE ACFT WAS RETURNED TO SERVICE.

Part: STRUCTURE — CORRODED (BS 540 BULKHEAD) · airframe 65,574 hrs · 65,398 cycles

FWD CARGO COMPARTMENT BULKHEAD BS 540 BTWN STR 22L AND 23L CHORD HORIZ FLANGE WITH CORROSION (THE CORROSION REQUIRES A MAJOR REPAIR).

Part: STRINGER — CRACKED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

TAIL COMPARTMENT, STA 1132, STRINGER 5 RIGHT WITH CRACK. THE CRACK REQUIRES A MAJOR REPAIR.

Part: BULKHEAD — CORRODED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

LOWER FUSELAGE, FWD CARGO COMPARTMENT, STA 540 BULKHEAD BETWEEN STRINGER 22 LT AND 23 LT CHORD HORIZONTAL FLANGE WITH CORROSION. THE CORROSION REQUIRES A MAJOR REPAIR.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

TAIL COMPARTMENT STA 1132 STRINGER 5 LT WITH CRACK. THE CRACK REQUIRES A MAJOR REPAIR.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

UPPER FUSELAGE, FLOORBEAM WITH CORROSION AT UPPER FLANGE AT STA 344 BETWEEN LBL 43 & RBL 11. THE CORROSION REQUIRES MAJOR REPAIR.

Part: FLOORBEAM — CORRODED (ZONE 200) · airframe 65,574 hrs · 65,398 cycles

UPPER FUSELAGE, FLOORBEAM LOWER FLANGE WITH CORROSION AT STA 867 BETWEEN RBL 26 AND RBL 56. THE CORROSION REQUIRES A MAJOR REPAIR.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

UPPER FUSELAGE, FLOORBEAM LOWER FLANGE WITH CORROSION AT STA 847 BETWEEN RBL 42 AND RBL 59. THE CORROSION REQUIRES A MAJOR REPAIR.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

UPPER FUSELAGE, BS 787 FLOORBEAM, LOWER FLANGE CORRODED. THE DAMAGE REQUIRES A MAJOR REPAIR.

Part: BEAR STRAP — CRACKED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

MAIN CARGO DOOR, FWD UPPER CORNER CUTOUT, FUSELAGE SKIN, BEAR STRAP WITH CRACK. THE CRACK REQUIRES A MAJOR REPAIR.

Part: BEAR STRAP — CRACKED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

UPPER FUSELAGE, FWD ENTRY DOOR, LOWER HINGE CUTOUT AT BS 304.5 WL 235, INTERNAL BEAR STRAP WITH CRACK. THE CRACK REQUIRES MAJOR REPAIR.

Part: BULKHEAD — DENTED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

FUSELAGE BULKHEAD BS 1016, AFT FACE, WEB DENTED AT WBL 166, RBL 7. THE DENT REQUIRES A MAJOR REPAIR.

Part: SPAR — CORRODED (RT WING) · corrosion level 2 · airframe 65,574 hrs · 65,398 cycles

RIGHT WING LEADING EDGE FRONT SPAR LOWER CHORD WITH CORROSION ON LOWER FLANGE. THE CORROSION REQUIRES A MAJOR REPAIR.

Part: SKIN PANEL — DENTED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

LOWER EXTERNAL FUSELAGE AT BS 727A+6.25 BETWEEN STR 22R AND STR 23R SKIN WITH DENT. THE DENT REQUIRES MAJOR REPAIR.

Part: SKIN PANEL — DENTED (FUSELAGE) · airframe 65,574 hrs · 65,398 cycles

LOWER FUSELAGE, AT BS 727+12.5 BETWEEN STRINGER 20 RT AND STRINGER 21 RT SKIN WITH DENT. THE DENT REQUIRES MAJOR REPAIR.

Part: STRINGER — CRACKED (BS 490-510 S22R) · airframe 65,227 hrs · 64,799 cycles

DISCOVERED 1" CRACK DURING SCHEDULED INSP AT BS 492.4, S-22R (AFT SIDE OF FWD CARGO DOOR CUTOUT FWD END OF STRINGER). R & R STRINGER ASSY IAW SRM 53-10-3, FIG 1, APPLIED CORROSION INHIBITOR.

Part: PROXIMITY SENSOR — FAILED (LE FLAP) · airframe 65,151 hrs · 64,533 cycles

DURING CLIMB, AFTER THE FLAPS WERE RETRACTED, THE FLIGHT CREW NOTED THE LE FLAPS TRANSIT ANNUNCIATOR REMAINED ILLUMINATED. CREW ACCOMPLISHED THE QRH PROCEDURES AND ELECTED TO RETURN TO DEPARTURE. THE ACFT LANDED WITHOUT ANY FURTHER INCIDENT. MX R & R THE NR3 L/E FLAP RETRACT PROXIMITY SENSOR IAW AMM 27-88-11 WITH THE OPS CHECK SATISFACTORY. THE ACFT RETURNED TO SERVICE.

Part: FIRE DETECTOR — FALSE ACTIVATION (NR 2 NACELLE) · airframe 64,934 hrs · 64,080 cycles

NON-ETOPS. DURING CLIMB THE CREW NOTED A FIRE INDICATION ON THE NR 2 ENG. CREW ACCOMPLISHED ALL RELATED QRH AND CHECKLIST PROCEDURES AND SHUTDOWN THE NR 2 ENGINE AND DISCHARGED ENGINE FIRE EXTINGUISHERS. CREW RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. THE ACFT REMAINS OUT OF SERVICE AWAITING REPLACEMENT FIRE EXTINGUISHER BOTTLES.

Part: DUCT — CRACKED (NR 1 ENGINE) · airframe 64,907 hrs · 64,021 cycles

FLT NR 58 (HNL ITO)- ON CLIMB OUT, NR 1 ENG FIRE WARNING LIGHT STARTED TO FLICKER AND BELL STARTED TO RING. PULLED BACK TO IDLE CONTINUED TO FLY AT IDLE, LIGHT AND BELL WENT OUT. R & R NR1 NOSE COWL DUCT DUE TO CRACK. PERFORMED HIGH POWER ENGINE RUN LEAK AND OPS CK GOOD IAW AMM 75-11-61 PG 401. ACFT RETURNED TO SERVICE.

Part: SKIN — CRACKED (BS 440-450, S-16)

DURING SCHEDULED INSP A 3" CRACK WAS DISCOVERED AT BS 440, 450, S-16R FUSELAGE SKIN. REPAIRED SKIN BY REMOVING CRACK DEFECT, CONDUCTED HFEC INSP, ENLARGED TRIM BY 0.040" INSURANCE CUT, INSTALLED DOUBLER/ TRIPLER, MAINTAINED A 0.5" MIN. CORNER RADIUS, MAINTAINED 2D MIN EDGE MARGIN AND 63 RA OR BETTER SURFACE ROUGHNESS IAW ECO 3804. ACFT RETURNED TO SERVICE. CLOSED.

Part: SHUTOFF VALVE — INOPERATIVE (PARKING BRAKE) · airframe 64,509 hrs · 63,164 cycles

ON TAXI-OUT, THE "ANTI-SKID INOP" LIGHT ILLUMINATED AND THE "FAIL WARN AND PARK BRAKE" CIRCUIT BREAKER POPPED. RETURNED TO RAMP. MX REMOVED AND REPLACED THE PARKING BRAKE SHUT OFF VALVE IAW MM 32-44-21. OPS AND LEAK CHECK OK. ACFT RETURNED TO SERVICE.

Part: FIRE LOOP — MALFUNCTIONED (NR 1 ENGINE)

FLT 42, ENG NR 1 (OVERHEAT WARN) LIGHT FLICKERING DURING TAXI. RETURNED TO BLOCK. TRIED FIRE CONTROL MODULE, FIRE DETECTION UNIT AND DISCONNECTED NR1 ENG FIREWALL CONNECTOR, LIGHT STILL FLICKERING. RE-INSTALLED ORIGINAL COMPONENTS AND CONNECTOR. REMOVED AND REPLACED THE NR 1 ENGINE LWR FIRE WARN LOOP IAW MM26-11-11. OPS CK GOOD ON GROUND. REMOVED AND REPLACED ENG/APU FIRE DETECTION CONTROL UNIT IN THE EE BAY. OPS CHECKED GOOD ON GROUND. ACFT RETURNED TO SERVICE.

Part: TRANSMITTER — FAILED (OIL QTY) · airframe 62,310 hrs · 58,198 cycles

FLIGHT 913 HNL-LIH. DURING TAKEOFF, THE NR 2 ENGINE OIL QUANTITY DECREASED. ELECTED TO ABORT TAKEOFF. INDICATIONS RETURNED TO NORMAL DURING ABORT; ALL ENGINE PARAMETERS WERE NORMAL. MX REMOVED AND REPLACED THE NR 2 ENGINE OIL QUANTITY TRANSMITTER. OPS AND LEAK CHECK OKAY. AIRCRAFT WAS RETURNED TO SERVICE. (A)

Part: CONTROLLER — MALFUNCTIONED (RAM AIR DOOR) · airframe 62,837 hrs · 59,505 cycles

FLIGHT 48 HNL-ITO - DURING CLIMB THE CREW NOTED THE RIGHT SUPPLY DUCT PRESSURE READING 100 PSI (FULL SCALE). THE CREW LANDED IN HNL WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE LEFT RAM AIR DOOR CONTROL AND PERFORMED AN ENGINE RUN WITH ALL OPERATIONAL CHECKS SATISFACTORY PER AMM 36-11-00. THE AIRCRAFT RETURNED TO SERVICE.

Part: FDAU — FAILED · airframe 62,554 hrs · 58,810 cycles

NON-ETOPS FLIGHT 278 HNL-KOA, AT 5000 FT, THE CREW NOTED THE FLIGHT RECORDER OFF LIGHT ILLUMINATED. THE CREW RETURNED TO HNL WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE FLIGHT DATA ACQUISITION UNIT PER AMM 31-24-11 WITH ALL CHECKS SATISFACTORY. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SWITCH — FAILED (ACCESSORY UNIT) · airframe 62,310 hrs · 58,198 cycles

NON-ETOPS FLIGHT 62 HNL - OGG - DURING CLIMB-OUT OF HNL, THE CREW REPORTED THE LANDING GEAR HANDLE STAYED IN THE DOWN POSITION WHEN THEY ATTEMPTED TO RAISE IT TO THE UP POSITION. THE CREW USED THE QRH PROCEDURES AND RAISED THE GEAR HANDLE USING THE OVER-RIDE SWITCH. CREW CONTINUED TO OGG WITHOUT FURTHER INCIDENT. MAINTENANCE INSPECTED THE LANDING GEAR AND INSTALLED THE LANDING GEAR LOCK PINS. THE AIRCRAFT FLEW TO HNL WITH THE GEAR DOWN WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE S1 TEST SWITCH ON THE LANDING GEAR ACCESSORY UNIT WITH ALL CHECKS NORMAL PER CMM 32-66-44. AIRCRAFT WAS RETURNED TO SERVICE.