N8923E

Part: DUCT — DEFECTIVE (ANTI-ICE SYS) · airframe 73,839 hrs · 78,465 cycles

ON APPROACH INTO YYZ AFTER FLIGHT CREW SET THE LEADING EDGE SLATS TO EXTEND, FLAPS AT ZERO, THE AMBER SLAT DISAGREEMENT LIGHT ILLUMINATED AND AN UNCOMMANDED ROLL OF THE ACFT TO THE LT OCCURRED. THE SLATS WERE RETRACTED WITHOUT DIFFICULTY, THE FLAPS EXTENDED TO 40 AND THE ACFT COMPLETED A NO SLAT LANDING WITHOUT FURTHER DIFFICULTIES. MX FUNCTIONALLY CHECKED THE SYSTEM AND REPLACED THE LT SIDE T-DUCT AS A RESULT. LEAK CHECK OF THE AIRFOIL ANTI-ICE SYSTEM AND FUNCTIONAL CHECKS OF THE SLAT AND FLAP SYSTEMS WERE ALL GOOD AND THE ACFT RETURNED TO SERVICE.

Part: CONNECTOR — CORRODED (CABIN) · airframe 73,681 hrs · 78,306 cycles

DURING LINE CHECK MX FOUND THAT 2 OF THE 3 EMERGENCY PATHWAY LIGHTS IN THE VENTRAL STAIRWAY WERE INOPERATIVE. MX FOUND THE CATWALK LIGHTS CONNECTOR BETWEEN THE SECOND AND THIRD EEPL WAS CORRODED. AFTER IT WAS CLEANED AND SECURED THE LIGHTS TESTED AS FUNCTIONAL.

Part: SWITCH — FAILED (TAXI LIGHT) · airframe 72,920 hrs · 77,577 cycles

DURING THE LANDING APPROACH INTO MBS, THE CREW SMELLED SMOKE AND WITNESSED SPARKS AND MOLTEN METAL COMING FROM UNDERNEATH THE INSTRUMENT PANEL. THE LANDING WAS ACCOMPLISHED WITHOUT FURTHER TROUBLE BUT CREW REQUESTED THAT CFR MEET UP WITH THE AIRCRAFT. AIRCRAFT TAXIED TO THE GATE UNDER ITS OWN POWER. FLIGHT ATTENDANTS ALSO REPORTED SMELLING BURNING ODORS IN THE CABIN AREAS. MAINTENANCE FOUND THAT THE NOSE TAXI LIGHT POWER SWITCH, S-109, WAS LOOSE IN ITS MOUNTING AND HAD A LOOSE WIRE CONNECTION WHICH ALLOWED THE WIRE TO SHORT OUT AGAINST ANOTHER CONTACT. THE SWITCH AND THE TERMINAL ENDS OF THE SHORTED WIRES WERE ALL REPLACED. THE FUNCTIONAL CHECK WAS GOOD.

Part: ACTUATOR — MALFUNCTIONED (STAB TRIM) · airframe 72,715 hrs · 77,403 cycles

AIRCRAFT RETURNED TO A SAFE LANDING AFTER PILOT EXPERIENCED HORIZONTAL STABILIZER PROBLEMS DURING CLIMB-OUT. FIRST OFFICER HAD SELECTED STABILIZER TRIM AND WAS UNABLE TO STOP THE STABILIZER FROM CONTINUOUSLY MOVING, OSCILLATING UP AND DOWN PAST THE DESIRED POINT. COM WAS COMPLIED WITH AND AFTER STABILIZER TRIM CUTOUT WAS SELECTED TO STOP, THE HUNTING OF THE STAB STOPPED BUT THE WARNING HORN CONTINUED. FLIGHT RETURNED TO AN UNEVENTFUL LANDING UNDER A DECLARED YELLOW EMERGENCY. MAINTENANCE REPLACED THE PRIMARY TRIM ACTUATOR MOTOR, PRIMARY TRIM UPPER RELAY R20-16 & LOWER RELAY R20-15, THE F/O’S PRIMARY TRIM YOKE SWITCH, AND CIRCUIT BREAKER B10-92. STOP ADJUSTMENTS WERE MADE, HARDWARE TORQUED, AND THE AIRCRAFT RETURNED TO SERVICE.

Part: CONTROL SYSTEM — OUT OF RIG (SLATS) · airframe 72,169 hrs · 76,933 cycles

WHEN THE SLATS WERE SELECTED TO EXTEND DURING THE APPROACH FOR LANDING, THE BLUE "SLAT DISAGREE" LIGHT ILLUMINATED AND WAS ACCOMPANIED BY AN AIRCRAFT ROLL TO THE RIGHT. THE FLAP/SLAT COMBINATION WAS RECYCLED AND THE FIRST OFFICER VISUALLY VERIFIED FLAPS HAD EXTENDED. AFTER A 5 MINUTE PAUSE THE SLATS EXTENDED EQUALLY, FULLY, AND ALL COCKPIT INDICATIONS WERE NORMAL. THE FLIGHT CREW PERFORMED AN UNEVENTFUL LANDING AT MBS. AIRCRAFT WAS FERRIED TO DTW WHERE MAINTENANCE REPLACED SLAT CONTROL CABLES AND PULLEYS, RIGGED THE CONTROL SYSTEM, AND FUNCTIONALLY CHECKED ALL WING DEVICES. THE AIRCRAFT HAS RETURNED TO SERVICE.

Part: SLAT SYSTEM — UNKNOWN (LE SLATS) · airframe 72,154 hrs · 76,916 cycles

ON APPROACH FOR LANDING AT ABOUT 200 KTS, THE YELLOW "SLAT DISAGREEMENT" LIGHT ILLUMINATED WHEN SLATS WERE SELECTED TO EXTEND. THE AIRCRAFT ALSO EXPERIENCED AN UNCOMMANDED ROLL TO THE RIGHT WHEN THE LEADING EDGE SLATS FAILED TO DEPLOY SYMMETRICALLY. AS THE AIRCRAFT SLOWED THROUGH 190 KTS AN AUDIBLE BANG WAS HEARD, BLUE "SLAT EXTEND" LIGHT CAME ON, AND THE "SLAT DISAGREEMENT" LIGHT EXTINGUISHED. LANDING WAS COMPLETED WITHOUT ANY FURTHER PROBLEM. MAINTENANCE INSPECTED THE SLAT SYSTEM BUT WAS UNABLE TO DUPLICATE THE FAULT OR TO FIND ANY PROBLEM AT ALL. THE T-DUCT O-RINGS AND SEALS WERE REPLACED PER MC DIRECTION. THE AIRCRAFT RETURNED TO SERVICE.

Part: SKIN — CRACKED (FUSELAGE) · airframe 71,725 hrs · 76,522 cycles

DURING "H" CHECK, FOUND CRACK IN FUSELAGE SKIN AT AFT UPPER CORNER OF FORWARD SERVICE DOOR JAMB . REPAIRED PER EA 99-209601 SECTION I SECTION II TO BE ACCOMPLISHED ON OR BEFORE TWO YEARS OR 3,000 CYCLES AFTER SECTION I ACCOMPLISHMENT.

Part: SKIN — CRACKED (FUSELAGE) · airframe 71,725 hrs · 76,522 cycles

DURING "H" CHECK FOUND CRACK IN RT FUSELAGE SKIN AT FORWARD UPPER CORNER OF THE FORWARD CARGO DOOR JAMB. REPAIRED PER EA 99-209598 SECTION I SECTION II TO BE ACCOMPLISHED ON OR BEFORE 2 YEARS OR 3000 CYCLES AFTER SECTION I ACCOMPLISHMENT.

Part: SKIN — CRACKED (FUSELAGE) · airframe 71,725 hrs · 76,522 cycles

DURING "H" CHECK FOUND CRACK IN RT FUSELAGE SKIN AT UPPER LEFT CORNER OF FORWARD CARGO DOOR JAMB. REPAIRED PER EA 99-209597 SECT I SECT II TO BE ACCOMPLISHED ON OR BEFORE TWO YEARS OR 3000 CYCLES AFTER SECTION I ACCOMPLISHMENT.

Part: WIRE — CHAFED (EMERGENCY LIGHT) · airframe 68,628 hrs · 73,637 cycles

EMERGENCY LIGHTS REMAIN ON WHEN SWITCHED OFF AND C/B POPS. FOUND WIRING CHAFED BEHIND OVERHEAD BINS. REPAIRED WIRING AND RECHARGED BATTERY PACKS. CHECKS GOOD.

Part: FRAME — CRACKED (FUSELAGE) · airframe 66,629 hrs · 71,708 cycles

DURING M-CHECK FOUND CRACK IN FRAME AT BS 598 L24L. REPAIRED PER EA 99-199088.

Part: DUCT — LACK OF LUBE (LT & RT WINGS) · airframe 64,899 hrs · 70,146 cycles

DURING SLAT EXTENSION ROLL, SLAT DISAGREEMENT ANNUNCIATOR STAYED ON. COMPLIED WITH COM PROCEDURE AND SLATS RETRACTED NORMALLY. AN UNEVENTFUL LANDING WAS MADE AT MKE. MAINTENANCE INSPECTED THE SLAT SYSTEM BUT FOUND NO DEFECTS AND COULD NOT DUPLICATE THE PROBLEM AFTER 15 SLAT EXTENSIONS. THE T-DUCT WAS LUBRICATED AND SYSTEM WAS DEFERRED FOR 5 CYCLES. BOTH LEFT AND RIGHT T-DUCTS WERE REPLACED BY 27JUN03. AIRCRAFT RETURNED TO SERVICE.

Part: DUCT — LACK OF LUBE · airframe 63,958 hrs · 69,317 cycles

When the slats were extended the aircraft rolled and the "Slat Disagreement" light illuminated. After about 2 minutes the light extinguished and the aircraft flew normally. Landing at YYG was without incident. No mention of COM procedures. Maintenance found no discrepencies with either wing slat system. The right T-Duct was lubricated and will be replaced within 5 cycles. The aircraft has been returned to service.

Part: DUCT · airframe 63,946 hrs · 69,307 cycles

During approach the aircraft rolled left on slat extension. "Slat Disagreement" light was illuminated. COM procedures were performed and the aircraft landed uneventfully. Maintenance replaced a T-Duct in the left wing. The aircraft was returned to service.

Part: FLANGE — CRACKED · airframe 61,727 hrs · 67,374 cycles

EO 5230-01119 installs a hold open latch on the fwd end of the fwd cargo door to minimize the the possibility of inadvertant closure. However, investigation has revealed cracking of the cargo door flange. EA 99-186086

Part: SLAT — STUCK (RT WING) · airframe 59,811 hrs · 65,719 cycles

SLAT DISAGREEMENT ANNUNCIATOR ILLUMINATED ON APPROACH TO MEM. THE AIRCRAFT ROLLED TO THE LEFT WHEN RIGHT SLAT EXTENDED BEFORE THE LEFT, THEN ROLLED TO THE RIGHT WHEN THE LEFT SLAT CAUGHT UP RESULTING IN A SAFE LANDING. MAINTENANCE DETERMINED THAT A LEFT ''T'' DUCT WAS STICKING. REPLACED THE LEFT ''T'' DUCT. AIRCRAFT RETURNED TO SERVICE.

Part: ANGLE — CRACKED (VERTICAL STAB) · airframe 58,898 hrs · 64,910 cycles

VERTICAL STABILIZER LOWER ATTACH ANGLE CRACKED AT RIGHT SIDE, NEAR AFT END. REPAIRED DAMAGED AREA AND CONFIRMED. REPAIRED IAW SRM 53-05 AND EA 99-175537. LP''S 1424295, 1423937

Part: DUCT — LACK OF LUBE (LEFT WING)

ON APPROACH INTO CLT, SLAT DISAGREEMENT LIGHT ILLUMINATED WITH ROLL TO THE LEFT ON SLAT EXTENSION. FLIGHT CREW DECLARED A YELLOW EMERGENCY AND AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE LUBRICATED LEFT SLAT T DUCT. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: CLIPS — OUT OF ADJUST (TAIL CONE)

DURING TAIL CONE FUNCTIONAL CHECK, FOUND THAT INADEQUATE FORCE WAS REQUIRED TO REMOVE BOTH THE INTERIOR AND EXTERIOR TAIL CONE RELEASE HANDLES FROM THE RETAINING CLIPS. ADJUSTED CLIPS, FUNCTIONAL CHECK OK.

Part: CABLES — OUT OF ADJUST (LT LE SLAT)

AIRCRAFT ROLLED TO THE LEFT UPON SLAT EXTENSION. SLAT EXTEND TOOK LONGER THAN NORMAL TO ILLUMINATE. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND LEFT SLAT CABLES OUT OF RIG. RIGGED SLAT SYSTEM CABLES, OPERATIONAL CHECK NORMAL.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND AFT OVERWING EMERGENCY EXIT LIGHTS INOPERATIVE. REPLACED BATTERIES, OPERATIONAL CHECK NORMAL.

Part: RELEASE MECH — OUT OF ADJUST (TAIL CONE)

DURING L-CHECK, FOUND THAT EXCESSIVE FORCE WAS REQUIRED TO DEPLOY TAIL CONE. ADJUSTED TAIL CONE RELEASE LATCHES, OPERATIONAL CHECK OK.

Part: BULKHEAD — CRACKED (BS 110)

DURING L-CHECK, FOUND A CRACK IN THE NOSE LANDING GEAR WHEEL WELL HORIZONTAL PRESSURE BULKHEAD FS 110 AT RIGHT INBOARD FITTING. REPAIRED PER EA 99-112886.

Part: BULKHEAD — CRACKED (BS 110)

DURING L-CHECK, FOUND CRACK IN NOSE LANDING GEAR WHEEL WELL HORIZONTAL PRESSURE BULKHEAD AT FS 110 AT RIGHT OUTBOARD FITTING. REPAIRED PER EA 99-112886.

Part: BULKHEAD — CORRODED (BS 110)

DURING L CHECK, FOUND CORROSION ON THE HORIZONTAL FLANGE AT THE T-CAP FS 110 BETWEEN LONGERONS 26L AND 27L. REPAIRED PER EA 99-112892.

Part: BULKHEAD — CRACKED (BS 110)

DURING L-CHECK, FOUND A CRACK IN THE NOSE LANDING GEAR WHEEL WELL HORIZONTAL PRESSURE BULKHEAD FS 110 AT LEFT OUTBOARD FITTING. REPAIRED PER EA 99-112886.

Part: SKIN — CORRODED (BS 310)

DURING L CHECK, FOUND CORROSION ON FUSELAGE SKIN AT FS 310 BETWEEN AFT MOUNT HOLES ON UPPER AFT LOOP ANTENNA. REPAIRED PER EA 99-112904.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND OVERWING EMERGENCY EXIT LIGHT DIM. MAINTENANCE REPLACED BATTERY PACK. OPERATIONAL CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND BOTH AFT OVERWING EXIT EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACK, OPERATIONAL CHECK NORMAL.

Part: SWITCH — MALFUNCTIONED (TE FLAP)

FLAP/RUDDER STOP INOPERATIVE, LIGHT ILLUMINATED AFTER TAKEOFF. FLIGHT RETURNED TO MSP AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED FLAP POSITION SWITCH S1-351. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND OVERWING EXIT EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERIES IN BATTERY PACK, OPERATIONAL CHECK NORMAL.

Part: FUEL LINE — DISCONNECTED (RT BOOST PUMP)

FUEL BEGAN VENTING FROM LEFT WING EN ROUTE DCA-MSP. FLIGHT DIVERTED TO PIT AND LANDED WITHOUT INCIDENT. FORWARD AND AFT RIGHT FUEL PRESSURE LIGHTS WOULD NOT EXTINGUISH AFTER LANDING. MAINTENANCE FOUND FUEL LINE AT FORWARD RIGHT FUEL BOOST PUMP DISCONNECTED AT UNION. LINE WAS RECONNECTED AND A NEW O-RING WAS INSTALLED. LEAK AND OPERATIONAL CHECK NORMAL, AIRCRAFT RETURNED TO SERVICE.

Part: T/O WARNING — SOUNDED (COCKPIT)

TAKEOFF WARNING HORN SOUNDED DURING TAKEOFF ROLL AT 30 KNOTS. ABORTED TAKEOFF AND RETURNED TO GATE. HORN WAS SILENCED AFTER SPOILERS WERE CYCLED. MAINTENANCE PERFORMED TAKEOFF WARNING SYSTEM TEST PER MAINTENANCE MANUAL 27-00, CODE 4, PG 215, SYSTEM CHECKED NORMAL. DISCREPANCY COULD NOT BE DUPLICATED.

Part: BATTERY PACK — DISCHARGED (TAIL CONE)

DURING LINE MAINTENANCE INSPECTION, FOUND TAIL CONE EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK, OPERATIONAL CHECK NORMAL.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND ALL OVERWING EXIT EMERGENCY LIGHTS DIM. REPLACED BATTERIES AND OPERATIONAL CHECK NORMAL.

Part: POWER SUPPLY — INOPERATIVE (TAILCONE)

DURING LINE CHECK, FOUND TAILCONE EMERGENCY LIGHTS INOPERATIVE. REPLACED POWER SUPPLY AND BATTERIES, OPERATIONAL CHECK GOOD.

Part: BATTERY — DISCHARGED (TAILCONE)

DURING LINE CHECK, FOUND EMERGENCY LIGHTS IN TAILCONE INOPERATIVE. REPLACED BATTERIES AND OPERATIONAL CHECK GOOD.

Part: WINDSHIELD — CRACKED (COCKPIT)

MSP-YQR - DURING CRUISE AT FL350, THE FIRST OFFICER'S OUTER WINDSHIELD CRACKED. ACFT RETURNED TO MSP WITHOUT FURTHER INCIDENT. REPLACED THE WINDSHIELD AND WINDOW HEAT CONTROLLER, CHECKED OK.

Part: BOOST PUMP — MALFUNCTIONED (FUEL SYST)

DURING CLIMB, FUEL WAS PUMPING INTO RIGHT FUEL TANK AND WAS UNABLE TO CROSSFEED FUEL WITH FUEL IN CENTER TANK. AIRCRAFT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. INSTALLED NEW BOOST PUMP VOLUTE AND OPERATIONAL CHECK GOOD.

Part: ENGINE — LOW POWER (NR 1 ENGINE)

DURING TAKEOFF, THE NR 1 ENGINE DID NOT REACH TAKEOFF POWER. ABORTED TAKEOFF AND RETURNED TO THE GATE. RERIGGED AND TRIMMED BOTH ENGINES AND OPERATIONAL CHECK GOOD.

Part: CIRCUIT BREAKER — POPPED (LT INST TRNSFMR)

DURING APPROACH INTO DTW, FLAPS INDICATED AN ASYMMETRICAL CONDITION ON FLAP EXTENSION. CAPTAIN DECLARED AN EMERGENCY AND ACCOMPLISHED AN UNEVENTFUL LANDING USING SLATS ONLY. FOUND LEFT INSTRUMENT TRANSFORMER CIRCUIT BREAKER POPPED. RESET CIRCUIT BREAKER, CYCLED FLAPS SEVERAL TIMES AND ALL INDICATIONS WERE NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: DOUBLER — CORRODED (PAX DOOR)

DURING ACCEPTANCE CHECK AND PRIOR TO SERVICE, FOUND CORROSION IN THE MAIN CABIN DOOR CUTOUT, LOWER INTERNAL DOUBLER BENEATH THE SEAL DEPRESSOR. REPAIRED PER EA 99-94734.

Part: SKIN — CRACKED (FS 197)

DURING ACCEPTANCE CHECK AND PRIOR TO SERVICE, FOUND A .25 INCH CRACK IN THE FUSELAGE SKIN FS 197 AT LONGERON 22L. REPAIRED SKIN PER EA 99-94700.

Part: LONGERON — CORRODED (FS 813)

DURING ACCEPTANCE CHECK AND PRIOR TO SERVICE, FOUND CORROSION IN LONGERON 30 AT FS 813. REPAIRED LONGERON PER EA 99-97390.