N8925E

Part: BATTERY — DISCHARGED (CABIN) · airframe 76,803 hrs · 79,022 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE EMERGENCY PATHWAY LIGHTING IN ROWS 5-11 OF THE CABIN WERE INOPERATIVE. MAINTENANCE REPLACED THE BATTERIES IN THE POWER SUPPLY AND THE LIGHT RETURNED TO AN OPERATIONAL CONDITION.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHTS)

DURING LINE CHECK, MX FOUND THAT ALL THREE OF THE EMERGENCY PATHWAY LIGHTING FOR THE CATWALK IN THE TAIL COMPARTMENT WERE INOPERATIVE. MX REPLACED THE EMERGENCY LIGHT POWER SUPPLY AND OPERATIONALLY CHECKED THE SYS. (K)

Part: ACTUATOR — INTERMITTENT (SPOILER)

ON APPROACH, AS THE FLIGHT CREW WAS CONFIGURING THE ACFT FOR LANDING, AN UNCOMMANDED ROLL OF THE ACFT TO THE LT OCCURRED WHEN THE SPEED BRAKES WERE USED. THE ACFT COMPLETED A NORMAL LANDING WITHOUT FURTHER DIFFICULTIES. MX FUNCTIONALLY CHECKED THE SPOILER SYS AND FOUND THE RT WING INBD SPOILER WAS INTERMITTENT. THE RT WING INBD SPOILER ACTUATOR WAS REPLACED AND FUNCTIONAL CHECK OF THE SYS WAS PERFORMED SUCCESSFULLY. THE ACFT HAS RETURNED TO SERVICE. (K)

Part: SKIN — CORRODED (FUSELAGE) · airframe 68,539 hrs · 71,734 cycles

DURING M-CHECK FOUND CRACK IN SKIN AT NR 6 FORWARD STOP OF DOOR 1L. REPAIRED PER EA 99-196420.

Part: SKIN — WRINKLED (FUSELAGE) · airframe 63,532 hrs · 67,275 cycles

DURING AN H-CHECK AT ATLANTA, WAVINESS AND SKIN MISMATCH WERE FOUND IN THE AREA OF THE ALTERNATE STATIC PORT. IN ORDER TO CORRECT THE DISCREPANCY, THE FUSELAGE SKIN WAS TRIMMED OUT. HOWEVER, THE FLUSH SKIN REPAIR PER THE DC-9 SRM, CHAPTER 53-04, FIGURE 12C COULD NOT BE ACCOMPLISHED DUE TO THE CLOSE PROXIMITY WITH OTHER REPAIRS. THE SUBJECT SKIN PANEL HAD BEEN PREVIOUSLY REPLACED. THE EA 99-181020 LOG PAGE 1583873 PROVIDES AUTHORIZATION TO ACCOMPLISH AN ALTERNATE FLUSH SKIN REPAIR. HOWEVER, DUE TO THE IMPENDING REPAIR ASSESSMENT PROGRAM, IT WAS DECIDED TO CONSIDER THIS REPAIR A INTERIM.

Part: BATTERY PACK — DISCHARGED (TAIL) · airframe 77,327 hrs · 81,411 cycles

DURING LINE MAINTENANCE INSPECTION, FOUND CATWALK EMERGENCY LIGHTS IN TAIL COMPARTMENT INOPERATIVE. REPLACED BATTERY PACK. OPERATIONAL CHECK OK.

Part: CONNECTOR — DIRTY (TAIL COMPT)

DURING PERIODIC CHECK, FOUND TAIL COMPARTMENT EMERGENCY LIGHTS ON CATWALK INOPERATIVE. CLEANED CORROSION FROM CATWALK STRIP CONNECTOR, OPERATIONAL CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (TAIL COMPT)

DURING LINE MAINTENANCE INSPECTION, FOUND CATWALK EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACK. OPERATIONAL CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (TAIL COMPT)

DURING LINE MAINTENANCE INSPECTION, FOUND CATWALK EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACK. OPERATIONAL CHECK NORMAL.

Part: OVERHEAT SENSOR — FAILED (TAIL COMP)

TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED AFTER TAKEOFF. FLIGHT RETURNED TO MSY AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE TAIL COMPARTMENT OVERHEAT SENSOR. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: WIRE — BROKEN (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND FLOOR PROXIMITY EMERGENCY LIGHTS BETWEEN ROWS 12, 13, AND 14 INOPERATIVE. REPAIRED BROKEN WIRING, OPERATIONAL CHECK NORMAL.

Part: BRACKET — CRACKED (BS 639)

DURING H-CHECK, FOUND SHEAR TIE FITTING CRACKED AT FS 639 AT LONGERON 29L. REPLACED SHEAR TIE FITTING PER SRM 51-30-2.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND AFT CEILING AND TAIL CONE EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERIES IN PACK, OPERATIONAL CHECK NORMAL.

Part: AIR CYCLE MACH — LEAKING (LEFT)

TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED AT 29,000 FEET. CREW SHUT DOWN LEFT PACK AND CABIN PRESSURE BEGAN TO RISE. CREW DECLARED AN EMERGENCY AND DESCENT WAS MADE TO 10,000 FEET. FLIGHT WAS DIVERTED TO MEM, AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND LEFT AIR CYCLE MACHINE LEAKING. DEFERRED LEFT PACK PER MEL 21-1A.

Part: GASKET — BLOWN (AC TEMP SENSOR)

TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED AFTER TAKEOFF. CAPTAIN DECLARED AN EMERGENCY AND FLIGHT WAS DIVERTED TO BNA. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED BLOWN GASKET AT AIR CONDITIONING SUPPLY TEMPERATURE HIGH SENSOR, OPERATIONAL CHECK NORMAL.

Part: ANTI ICE VALVE — MALFUNCTIONED (TAIL)

AIRFOIL ICE PROTECTION PRESSURE ABNORMAL AND PRESSURE HIGH LIGHTS ILLUMINATED WITH TAIL DEICE SELECTED AFTER TAKEOFF. FLIGHT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED TAIL ANTI-ICE VALVE. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: TAILCONE — OUT OF ADJUST (AFT FUSELAGE)

DURING PERIODIC CHECK, TAILCONE RELEASE FORCE EXCEEDED MAXIMUM LIMITS ON FUNCTION DROP CHECK. ADJUSTED PER CITEXT 09-5350-1-0021, SECOND TEST WAS WITHIN LIMITS.

Part: FRAME — ELONGATED HOLE (BS 1038)

DURING PERIODIC CHECK, FOUND FRAME AT FS 1038 BETWEEN LONGERONS 13L AND 14L WITH AN ELONGATED HOLE FROM BRACE ROD ATTACH FITTING. REPAIRED FRAME PER EA 99-111-14.

Part: GEN CONTL PNL — FAILED (RT COCKPIT)

RIGHT GENERATOR DROPPED OFF LINE ACCOMPANIED BY AC CROSSTIE LOCKOUT AFTER TAKEOFF. FLIGHT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED RIGHT GENERATOR CONTROL PANEL. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: DOOR TRACK — DIRTY (E/E DOOR)

AFTER TAKEOFF RECEIVED AN E/E DOOR WARNING INDICATION, LIGHT EXTINGUISHED AFT PRESSURIZATION. RETURNED TO SDF WITHOUT FURTHER INCIDENT. RECYCLED THE DOOR, CLEANED DEBRIS FROM THE DOOR TRACK AND RESET THE PLUG ON THE SWITCH, CHECKED OK.

Part: DOOR — NOT SEATED (E/E COMPT)

AIRCRAFT WOULD NOT PRESSURIZE AFTER TAKEOFF. WIND NOISE WAS ALSO COMING FROM NOSE GEAR AREA. FLIGHT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. NOTE: FORWARD ACCESSORY COMPARTMENT DOOR LIGHT ILLUMINATED SEVERAL TIMES ON FINAL. MAINTENANCE FOUND E/E COMPARTMENT DOOR NOT COMPLETELY CLOSED. ALSO, FOUND CANNON PLUG DISCONNECTED AT E/E DOOR SWITCH. RESEATED DOOR AND RECONNECTED PLUG TO SWITCH. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: BLEED AIR — LEAKING AIR (APU)

DURING CLIMBOUT, PASSENGERS REPORTED A FUEL LIKE SMELL IN CABIN. FLIGHT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THAT APU WAS BLEEDING RESIDUAL OIL INTO AIR CONDITIONING SYSTEM, APU WAS CHANGED ON 10JUL96. REPLACED COALESCER BAGS, LEAK AND OPERATIONAL CHECK WAS NORMAL.

Part: SCHRADER VALVE — FAILED (NLG STRUT)

DURING CLIMBOUT, THE AIRCRAFT WOULD NOT SHIFT FROM GROUND MODE TO FLIGHT MODE. AIRCRAFT WAS UNABLE TO PRESSURIZE AND NOSE WHEEL WAS STEERABLE. FLIGHT RETURNED TO MSP AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND NOSE LANDING GEAR STRUT FLAT. REPLACED SCHRADER VALVE AND SERVICED STRUT TO PROPER LEVELS.

Part: PRESS REG VLV — MALFUNCTIONED (AIRFOIL DE-ICE)

DURING FLIGHT, THE AIRFOIL ICE PROTECTION PRESSURE ABNORMAL LIGHT ILLUMINATED DURING WING ANTI-ICE. FOLLOWED COCKPIT OPERATING MANUAL PROCEDURES AND LIGHT REMAINED ILLUMINATED. AIRCRAFT DIVERTED TO CLE AND LANDED WITHOUT INCIDENT. REPLACED ICE PROTECTION PRESSURE REGULATOR VALVE, OPERATIONAL CHECK GOOD.

Part: THERMAL SWITCH — FAILED (LT PACK)

DURING CLIMB, THE LEFT PACK OVERHEATED AND SMOKE ACCUMULATED IN THE FLIGHT DECK AND CABIN. DEACTIVATED THE LEFT PACK. FLIGHT RETURNED TO ROC AND LANDED WITHOUT INCIDENT. REPLACED THE THERMAL SHUTOFF SWITCH. OPERATIONAL CHECK OK.

Part: INDICATION — MALFUNCTIONED (LE FLAPS)

DURING APPROACH INTO MSP, AFTER SLATS AND FLAPS WERE EXTENDED FOR LANDING, SLAT DISAGREEMENT LIGHT ILLUMINATED WITH NO BLUE SLAT EXTENDED LIGHT. SLATS WERE VISUALLY CONFIRMED TO BE IN EXTENDED POSITION AND AIRCRAFT LANDED WITHOUT INCIDENT. EMERGENCY EQUIPMENT WAS CALLED OUT ON STANDBY AS A PRECAUTION. REPLACED SWITCH S1-298 AND CONNECTORS P1-373, P1-374. OPERATIONAL CHECK OK AND AIRCRAFT RETURNED TO SERVICE.

Part: RETRACT MECH — MALFUNCTIONED (LE FLAPS)

DURING SLAT EXTENSION ON APPROACH INTO MSP, SLAT EXTEND LIGHT BEGAN FLICKERING, THEN EXTINGUISHED AND SLAT DISAGREEMENT LIGHT ILLUMINATED. PERFORMED MISSED APPROACH AND CAPTAIN DECLARED AN EMERGENCY. SUCCESSFUL LANDING WAS ACCOMPLISHED ON SECOND ATTEMPT WITH FLAPS AT 40 DEGREES AND NO SLATS. CYCLED SLATS AND FLAPS SEVERAL TIMES AND DISCREPANCY COULD NOT BE DUPLICATED. AIRCRAFT RETURNED TO SERVICE.

Part: WINDSHIELD — DELAMINATED (LEFT COCKPIT)

LEFT COCKPIT WINDSHIELD CRACKED EN ROUTE DFW TO MSP. CAPTAIN DECLARED AN EMERGENCY AND FLIGHT WAS DIVERTED TO STL, AN UNEVENTFUL LANDING WAS ACCOMPLISHED. FOUND CAPTAIN'S WINDSHIELD DELAMINATED ON ALL SIDES. REPLACED WINDSHIELD AND TEMPERATURE CONTROLLER. AIRCRAFT RETURNED TO SERVICE.

Part: BRACKET — CRACKED (VERTICAL STAB)

DURING LINE CHECK, FOUND CRACK IN VERTICAL STABILIZER TO FUSELAGE ATTACH ANGLE REPAIR, RIGHT SIDE ABOVE THE RUDDER LEADING EDGE. REPAIRED PER XEA X9-53-82.

Part: STRUT — DEFLATED (NLG)

LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF DUE TO GROUND SHIFT FAILURE. FLIGHT RETURNED TO MSP AND LANDED WITHOUT INCIDENT. INSPECTED GROUND SHIFT LINKAGE AND CABLES WITH NO PROBLEMS FOUND. PERFORMED FULL SERVICE OF NOSE LANDING GEAR STRUT. AIRCRAFT RETURNED TO SERVICE.

Part: STUDS — CORRODED (NR 2 FLAP HINGE)

DURING PERIODIC CHECK, FOUND CORROSION ON NR 2 FLAP HINGE ATTACH STUDS. REPAIRED PER XEA X9-27-9.

Part: HINGE — CORRODED (WS 251)

DURING PERIODIC CHECK, FOUND CORROSION IN NR 3 FLAP HINGE MOUNTING HOLES, WS 251. REPLACED HINGE FITTING PER CITEXT 09-5740-1-9800.

Part: BULKHEAD — CORRODED (FS 110)

DURING PERIODIC CHECK, FOUND CORROSION IN FS 110 BULKHEAD TUNNEL AT LONGERON 27R, 6 INCHES UP FROM BOTTOM CORNER. REPAIRED PER XEA X9-53-50.

Part: HINGE FITT — CORRODED (LT TE FLAP)

DURING PERIODIC CHECK, FOUND CORROSION IN THE LEFT WING NR 2 FLAP HINGE FITTING OUTBOARD FASTENER BORES. REPAIRED PER XEA X9-9-27-9.

Part: HINGE — CORRODED (NR 3 TE FLAP)

DURING PERIODIC CHECK, FOUND CORROSION IN NR 3 FLAP HINGE FASTENER BORES. REPAIRED PER XEA X9-27-12.

Part: KEEL BEAM — CRACKED (FS 604-637)

DURING PERIODIC CHECK, FOUND 10 INCH CRACK AND CORROSION IN RIGHT SIDE KEEL BEAM FS 604 - 637 BETWEEN LONGERON 28R - 29R. REPLACED BEAM PER SRM 51-30-2.

Part: FITTING — CRACKED (WS 0)

DURING PERIODIC CHECK, FOUND CRACK IN CENTER WING TANK FITTING XCW O, BETWEEN WING STRINGERS 17 - 18. REPLACED FITTING PER SRM 51-10-4.

Part: FITTING — CRACKED (FS 996)

DURING PERIODIC CHECK, FOUND CRACKS IN ATTACH FITTINGS FS 996 AT LONGERONS 27R, 24L, AND AT INTERCOSTAL BETWEEN LONGERON 27L AND 28L. REPLACED ALL FITTINGS PER SRM 51-30.

Part: SPAR CHORD — CRACKED (HORIZ STAB)

DURING PERIODIC CHECK, FOUND CRACKS IN THE HORIZONTAL STABILIZER AFT SPAR 'T' CAPS LEFT SIDE LOWER (XHS 205-211) AND RIGHT SIDE UPPER (XHS 188). REPAIRED BOTH PER SRM 55-02.