N86425

Part: GEARBOX — LEAKING (NR 3 ENGINE)

AT APPROX 0730Z, THE CREW EXPERIENCED NR 3 ENG LOSS OF OIL QTY, FOLLOWED BY LOW OIL PRESS, HIGH ENG EMP AT FL 330. DECLARED AN EMER AT 0738Z & AIR RETURNED BACK SAFELY AT 0908Z. TROUBLESHOOTING IN PROGRESS. R & R NR 3 ENG GEARBOX IAW AMM 72-63-00. INSPECTED MAIN OIL FILTER. PERFORMED ENG RUN, LEAK CHECKED GOOD. MAIN OIL FILTER INSPECTION GOOD, NO DEBRIS NOTED. REQUIRES REPEAT INSPECTION & OIL ANALYSIS AFTER 1ST FLIGHT, 15 HRS, 25 HRS, 50 HRS, 75 HRS & 100 HRS FOR MONITOR. UPDATE PARTS INFORMATION.

Part: GEARBOX — UNKNOWN (NR 3 ENGINE)

AT APPROXIMATELY 0730Z, THE CREW EXPERIENCED NR 3 ENG LOSS OF OIL QTY FOLLOWED BY LOW OIL PRESS, HIGH ENG TEMP AT FL 330. THEY DECLARED AN EMERGENCY AT 0738Z & AIR RETURNED BACK TO HNL STATION SAFELY AT 0908Z. TROUBLESHOOTING IN PROGRESS. R & R NR 3 ENG GEARBOX IAW AMM 72-63-00. INSPECTED MAIN OIL FILTER, PERFORMED ENG RUN, LEAK CHECK GOOD. MAIN OIL FILTER INSPECTION GOOD, NO DEBRIS NOTED. REQUIRES REPEAT INSPECTION & OIL ANALYSIS AFTER 1ST FLIGHT, 15HRS, 25HRS, 50HRS, 75HRS & 100 HRS FOR MONITOR.

Part: FRAME — CORRODED (BS 720D) · airframe 69,193 hrs · 40,373 cycles

CORROSION WAS FOUND AT BS 720D FRAME BETWEEN S25-26R. CORROSION REMOVED IAW SRM 53-10-1, FIG 1.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 69,193 hrs · 40,373 cycles

DURING 7C CHECK & CPCP INSPECTION, INSPECTOR PERFORMED VISUAL INSPECTION AND FOUND CORROSION ON CENTER WING LOWER SURFACE BETWEEN STRINGER 4C & 5C, WING LBL 24 TO LBL 28, AFTER BLEND OUT OF CORROSION, FOUND OUT OF LIMITS IAW SRM 57-30-1, TABLE 1.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 69,193 hrs · 40,373 cycles

DURING CPCP INSPECTION, INSPECTOR PERFORMED VISUAL INSPECTION AND FOUND CORROSION ON FUSELAGE EXTERNAL SURFACE OF BS 640 TO 660, FOUND OUT OF LIMITS IAW SRM 53-30-1, FIG 2.

Part: BEAR STRAP — CORRODED (ZONE 800) · corrosion level 2 · airframe 67,847 hrs · 39,952 cycles

DURING PERFORMED 6C-CHECK, CORROSION WAS FOUND ON AFT ENTRY DOOR CUTOUT BEAR STRAP AT STATION BS 1067 TO 1073 BETWEEN S-12L AND S-15L (DIMENSIONS OF CORROSION AREA:8.750 × 2.250 AND 7.000 × 2.250). AFTER BLEND OUT CORROSION, THE PENETRATION DEPTH WAS OVER LIMIT IAW SRM 53-30-1, PAGE 2C.

Part: SPAR — CORRODED (ZONE 100) · corrosion level 2 · airframe 67,847 hrs · 39,952 cycles

DURING PERFORMED 6C CHECK, CORROSION WAS FOUND ON FUSELAGE WING CENTER SECTION REAR SPAR WEB BS 870 RBL 35 TO 43 WL 184. AFTER CORROSION REMOVED, THE CLEAN UP DEPTH WAS OVER LIMIT PER SRM 57-10-1 PAGE 12.

Part: SPAR — CORRODED (ZONE 100) · corrosion level 2 · airframe 67,847 hrs · 39,952 cycles

DURING PERFORMED 6C CHECK, CORROSION WAS FOUND ON FUSELAGE WING CENTER SECTION REAR SPAR WEB BS 870 LBL 25 AND 35 TO 39 WL 184. AFTER CORROSION REMOVED, CLEAN UP DEPTH WAS OVER LIMITS PER SRM 57-10-1 PAGE 12.

Part: STRUCTURE — CORRODED (BS 348-351) · corrosion level 2 · airframe 67,847 hrs · 39,952 cycles

DURING PERFORMED 6C CHECK , LOWER FUSELAGE BS 348 TO 351 S27L WAS FOUND CORRODED. AFTER CORROSION REMOVED, CLEAN UP DEPTH WAS OUT OF LIMIT PER SRM 53-10-1 PAGE 1.

Part: STRUCTURE — CORRODED (ZONE 100) · corrosion level 2 · airframe 67,847 hrs · 39,952 cycles

DURING PERFORMED 6C CHECK, LOWER FUSELAGE BS 348 TO 351 S27R WAS FOUND CORRODED. AFTER CORROSION REMOVED, CLEAN UP DEPTH WAS OUT OF LIMIT PER SRM 53-10-1 PAGE 1.

Part: SPAR — CORRODED (HORIZONTAL STAB) · corrosion level 2 · airframe 67,847 hrs · 39,952 cycles

DURING PERFORMED 6C CHECK, FOUND RT HORIZONTAL STABILIZER REAR SPAR LOWER CHORD CORRODED AT ELEV STA 173 PER SRM 55-10-01 FIG 1 SHEET 3 ITEM 4, PENETRATED DEPTH OUT OF LIMITS. OPEN

Part: BEAM — CORRODED (HORIZ STAB) · corrosion level 2 · airframe 67,847 hrs · 39,952 cycles

DURING PERFORMED 6C CHECK (ASIA PACIFIC AIRLINES N86425), CARD NO. C55-300-10 PART 2 OF 2, FOUND RT HORIZONTAL STABILIZER T/E UPPER BEAM CORRODED AT ELEV STAT 17 & 68.5 PER B727 SRM 55-10-01 FIG 1 SHEET 3 ITEM 5 PENETRATED DEPTH OUT OF LIMIT. THE ITEM HAS BEEN REPORTED TO DER FOR REQUESTING THE REPAIR APPROVAL DATA.

Part: SKIN — CORRODED (RT WING) · corrosion level 2 · airframe 67,847 hrs · 39,952 cycles

DURING PERFORMED 6C CHECK. FOUND RT WING LWR SKIN CORRODED AT WS 196 TO WS 201 JUST UNDER FRONT SPAR, PER B727 SRM 57-30-1 PAGE 6 PENETRATED DEPTH OUT OF LIMIT. THE ITEM HAS BEEN REPORTED TO DER FOR REQUESTING THE REPAIR APPROVAL DATA.

Part: LINE — CRACKED (SCAVANGE SYS) · airframe 66,243 hrs · 39,418 cycles

AFTER 30 MINUTES OUT, CREW CALLED IN DUE TO RAPID LOSS OF OIL QUANTITY ON NR 1 ENGINE. ON LANDING, OIL QUANTITY INDICATED 1.5 GALLONS. MX RAN ENGINE, FOUND LEAK IN TAIL PIPE, FOUND SCAVENGE LINE NR6 BEARING LEAKING. REMOVED AND REPLACED SCAVENGE LINE. ALSO FOUND EXHAUST FAN DUCT STRUT BROKEN NR 5, REPLACED STRUT. RAN ENGINE, NO LEAKS, ACFT RELEASED.

Part: ACTUATOR — DEFECTIVE (NR 3 SLAT) · airframe 66,987 hrs · 39,338 cycles

AIRCRAFT, AIR RETURN DUE TO NR 3 L/E SLAT REMAINED EXTENDED AND NR 3 SLAT REMAINED IN TRANSIT DURING FLAP RETRACTION. REMOVED AND REPLACED NR 3 L/E SLAT ACTUATOR THEN CLEANED AND RESEATED NR 2 L/E SLAT SWITCH. OPERATIONAL CHECK OK.

Part: STATIC LINE — KINKED (PITOT/STATIC SYS)

AC DEPARTED AT 1530L AND AIR RETURNED AT 1557L DUE TO CAPTS AND STANDBY A/S INDICATOR 40 TO 50 KNOTS LESS THAN COPILOTS (VERY SLOW TO RESPOND). UPON FURTHER TROUBLE SHOOTING, FOUND KINKED STATIC LINE BEHIND CAPTS VSI WHICH LINKS TO THE CAPT AND STANDBY A/S INDICATOR. REPOSITIONED AND STRAIGHTENED LINE AND R&R CADC AS PRECAUTION, CHECK GOOD. AFTER REVIEW FROM THE CAPTAIN AND FE ACFT WAS CLOSED OUT AND DEPARTED AT 0435L.

Part: ENGINE — INOPERATIVE (VIBRATION)

ON TAKEOFF, CREW EXPERIENCED A SLIGHT VIBRATION ON NR 3 ENGINE, VERIFIED ALL PARAMETERS NORMAL, CONTINUED WITH TAKEOFF CREW THEN NOTICED A LOSS OF OIL ON NR 3 ENGINE. SHUTDOWN ENGINE AND RETURN TO DEPARTURE. ON INSPECTION, FOUND BLADE DAMAGE, 2ND STAGE FAN BLADE.

Part: LINE — BROKEN (NR 1 ENGINE) · airframe 65,167 hrs · 39,054 cycles

AT FLIGHT LEVEL 30K FEET 263 NM OUT OF MAJURO, NR 1 OIL QUANTITY STARTED TO DECREASE FROM 4 GALLONS TO ZERO, CREW THEN SHUT DOWN ENGINE AND DESCENDED TO FL 26K FEET, RETURNED TO MAJURO. WINDMILLING OCCURRED FOR 43 MINUTES WITH OIL PRESSURE AT 17-18 PSI. ON INSPECTION FOUND NR 6 BEARING OIL PRESSURE LINE BROKEN. REPLACED LINE FULL POWER RUN NO LEAK, PERFORM TEST HOP SYSTEM OIL NO LEAK, RELEASED AIRCRAFT FOR SERVICE.

Part: WIRE — LOOSE (RT ADI)

FLT 992 - GUM - AIR RETURN DUE TO FIRSTI OFFICER ADI INOPERATIVE, DOES NOT RESPOND IN ROLL AND DOES NOT INDICATE A BANK. MAINTENANCE TROUBLESHOOT SYSTEM FOUND FAULTY WIRES. FOUND WIRES NR 27 AND NR 28 GROUNDING OUT AT VG CANNON PLUG. RESPLICED WIRES IAW WDM 34-22-03 PAGE 901. PERFORMED MANUAL VG 'ROLL', FO'S ADI CHECKS GOOD. AIRCRAFT BACK IN SERVICE. (M)

Part: HOSE — RUPTURED (HYD SERV COMPT)

KIX - EN ROUTE TO CTS DIVIRTED TO KIX DUR LOSS OF 'B' SYSTEM HYD FLUID DOWN TO 'ZERO'. 'B' HYD SYSTEM FAILED 'B' HYD QUANTITY AND PRESSURE INDICATE ZERO. PRIMARY LOSS OF FLUID TRACED TO FAILURE OF HYD 'B' PUMP TO RESERVOIR SUPPLY HOSE ASSY REFER IPC 29-14-06 ITEM 45. REPLACED HOSE ASSY. ALSO HAD SMALL LEAK AT NR 3 HYD SPOILER ACTUATOR FILTER BOWL SEAL. BUT DID NOT CONTRIBUTE TO PROBLEM REPLACED SEAL AND A/C RETURNED TO SERVICE. (M)

Part: SKIN — DENTED (RT TE AFT FLAP)

A DENT ON RT INBOARD AFT FLAP UPPER SKIN 2 INCHES DIAMETER AT WBL 123 RT INBOARD AFT FLAP. TRIMMED OUT THE DENTED AREA OF SKIN. PERFORMED FIBERGLASS CLOTH OVERLAY REPAIR. (M)

Part: FITTING — CORRODED (NLG)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, PITTING CORROSION WAS FOUND ON NLG RT AND LT TRUNNING SUPPORT FITTING. THE CORRODED TRUNNION SUPPOR T FITTING WAS CLEANED UP AND BEARING HALVES REPLACED PER B727 SRM 53-40-1 FIGURE 2. (M)

Part: RIB — CRACKED (NR 6 LE SLAT)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, 2 SUB-STANDARD REPAIR WERE FOUND IN RT WING L/E NR 6 SLAT ACTUATOR OUTBOARD RIB. THE DAMAGED SLAT ACTUATOR OUTBOARD RIB WAS REMOVED AND REPLACED WITH NEW RIB PER B727 SRM 57-50-2 AND 51-30-2. (M)

Part: ROLLER — FROZEN (LT/RT MLG DOOR)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, ROLLERS FROZEN WERE FOUND ON RT AND LEFT MLG DOOR EMERGENCY MANUAL RELEASE CRANK. THE DEFECTED ROLLERS WERE REMOVED AND REPLACED NEW ROLLERS PER BOEING SRM 20-50-03. (M)

Part: SKIN — DENT (LT TE AFT FLAP)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DENT WAS FOUND ON RT WING T/E INBOARD AFT FLAP UPPER SKIN AT WBL 123. THE DAMAGED SKIN 2 INCH DIAMETER WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. (M)

Part: LATCH ASSY — BROKEN (R2 SERVICE DOOR)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, EXCESSIVE BROKEN WIRES WERE FOUND ON R2 SERVICE DOOR ESCAPE SLIDE LATCH CABLE. THE DAMAGED ESCAPE SLIDE LATCH ASSEMBLY WAS REMOVED AND REPLACED PER B727 MM 25-60-16. (M)

Part: SKIN — CORRODED (LT TE AFTFLAP)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CORROSION AND DENT WAS FOUND ON LEFT WING T/E INBOARD AFTFLAP UPPER SKIN AT WBL 90 AND WBL 94 RESPECTIVELY. THE DAMAGED SKIN 1.5 INCH DIAMETER AND 2.5 INCHES DIAMETER WERE TRIMMED OUT AND REPAIRED PER B727 RM 51-40-6. (M)

Part: SKIN — DELAMINATED (LT TE FOREFLAP)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DELAMINATION WAS FOUND ON LEFT WING T/E INBOARD FORE FLAP UPPER SKIN AT WBL 88 JUST ABOVE FLAP FRONT SPAR CAP. THE DAMAGED SKIN 2.5 INCH BY 1.5 INCH IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. (M)

Part: SKIN — DELAMINATED (LT TE MIDFLAP)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DELAMINATION WAS FOUND ON LEFT WING INBOARD T/E MIDFLAP T/E LOWER SKIN AT WBL 133. THE DAMAGED SKIN 5 INCH BY 4.5 INCH IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. (M)

Part: SKIN — DELAMINATED (LT TE MIDFLAP)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DELAMINATION WAS FOUND ON LEFT WING INBOARD T/E MIDFLAP T/E SKIN LOWER SURFACE AT WBL 181. THE DAMAGED SKIN 5.5 INCH BY 4.5 INCH IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. (M)

Part: SKIN — DELAMINATED (LT TE FOREFLAP)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DELAMINATION WAS FOUND ON LEFT WING T/E INBOARD FORE FLAP T/E LOWER SKIN AT WBL 187. THE DAMAGED SKIN 9.5 INCHES BY 4 INCHES IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. (M)

Part: SKIN — DELAMINATED (LT TE FOREFLAP)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DELAMINATION WAS FOUND ON LEFT WING T/E INBOARD FORE FLAP T/E LOWER SKIN AT WBL 117. THE DAMAGED SKIN 10 INCH BY 4 INCH IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. (M)

Part: FLOOR PANEL — CORRODED (BS 1136)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, SEVERE CORROSION WAS FOUND ON RT AFT LAVATORY FLOOR PANEL AT BS 1136, RBL 26. THE CORRODED FLOOR PANEL 3 INCH BY 4 INCH IN SIZE WAS CUTOUT AND INBOARD PARTITION LOWER SUPPORT CHANNEL WERE REPAIRED PER B727 SRM 53-20-2 AND 51-40-4 RESPECTIVELY. (M)

Part: SKIN — DELAMINATED (LT TE FOREFLAP)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DELAMINATION WAS FOUND ON LEFT WING T/E INBOARD FORE FLAP LOWER SKIN BETWEEN WBL 93 AND WBL 103. THE DAMAGED SKIN 10 INCH BY 8 INCH IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. (M)

Part: SKIN — CRACKED (NR 6 LE SLAT)

TNN - DURING 'S' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A SUB-STANDARD EXTERNAL REPAIR WAS FOUND ON RT WING NR 6 SLAT NOSE AREA AT SS 122. THE EXISTING EXTERNAL REPAIR WAS REMOVED AND REPLACED WITH NEW STANDARD EXTERNAL REPAIR PER B727 SRM 57-50-3 FIGURE 1. (M)

Part: VALVE — STUCK (LT PACK)

FLT 937 - GUM - RIGHT PACK OVERHEAT LIGHT CAME ON. RESET PACK AS PER CHECKLIST. STILL UNABLE TO CONTROL AIRMIX VALVE. DUCT OVERHEAT LIGHT CAME ON AGAIN. PACK TURNED OFF. TROUBLESHOT RIGHT PACK SYSTEM, FOUND T415 TEMP SENSOR AT FAULT. REPLACED SAME, PER SYS CHECK PER 21-61-21, GOOD. LEFT PACK WILL NOT PRESSURIZE WITH RT PC OFF. REF TO WRITE UP 79277853, CABIN WILL NOT CLIMB AND DESCEND WITH A/C RATE OF CLIMB. FOUND LT PACK VALVE STUCK CLOSED, REPLACED SAME. CHANGED VALVE PER MM 21-56-61. ALL CHECKS GOOD. ROTABLE PARTS CHANGE WAS INDICATED. (M)

Part: CLAMP — LEAKING (NR 1 ENGINE)

GUM - FLT 958 - L/P 7916635 AND 7916636. ON FIRST OCCURRENCE DURING CLIMB AT 1,000 FEET, NR 1 ENG STRUT OVERHEAT LIGHT ILLUMINATED. CREW AIR RETURN TO GUM. MTX FOUND SECONDARY AIR FLEX DUCT AT GENERATOR SHROUD BLOWN. THE DUCT WAS REPLACED. ENG RUN FOUND NO FURTHER AIR LEAK. AIRCRAFT WAS RELEASED FOR FLIGHT. ON SECOND OCCURRENCE DURING CLIMB AT 1,000 FEET, NR 1 ENG OVERHEAT LIGHT ILLUMINATED. LIGHT WOULD NOT GO OUT WITH BLEED SWITCH OFF, BUT HAD TO REDUCE POWER TO IDLE TO GET OVERHEAT LIGHT OUT. MTX REPLACED CLAMP AT 6TH STAGE DUCT FWD OF ANTI-ICE VALVE. ALSO ADJUSTED LEAKING CLAMP ON 8TH STAGE DUCT. PERFORMED HIGH POWER RUN FOR 5 MINUTES. DUCT PRESSURE NORMAL AND LEAK CHECK GOOD. (X)