N904AW

Part: GIRT BAR — OBSTRUCTED (R4 DOOR) · airframe 103,672 hrs · 35,557 cycles

AIRCRAFT WAS GNDED. DOOR 4R WILL NOT ARM. REMOVED DEBRIS FROM GIRT BAR TRACKS IAW MM 52-11-00. 4R DOOR NOW ARMS PROPERLY.

Part: D-RING — OUT OF POSITION (L2 DOOR) · airframe 103,440 hrs · 35,503 cycles

DOOR 2L, D RING NOT PRESENT AFTER DOOR CLOSED. SECURED D RING TO CORRECT POSITION ON L2 DOOR SLIDE BUSSEL.

Part: LIGHT — LOOSE (CABIN) · airframe 103,306 hrs · 35,468 cycles

EMERGENCY LIGHT STRIP, FLOOR AT 15 ABC BOWING UP. SECURED EMER LIGHT IAW AMM 33-51-21.

Part: LIGHT — UNSECURE (CABIN) · airframe 102,857 hrs · 35,359 cycles

EMERGENCY LIGHT TAPE ON FLOOR BUCKLED AT 14C. SECURED EMER LIGHT TAPE AS REQUIRED.

Part: MEGAPHONE — INOPERATIVE (CABIN) · airframe 102,649 hrs · 35,317 cycles

FORWARD MEGA PHONE INOPERATIVE. R & R FWD MEGA PHONE IAW AMM 25-64-00. OPERATIONS CHECKED GOOD.

Part: BATTERY — DISCHARGED (FLASHLIGHT) · airframe 102,269 hrs · 35,237 cycles

FLIGHT ATTENDANT FLASHLIGHT INOPERATIVE AT DOOR 1L OTBD POSITION. REPLACED BATTERY IN FWD FLIGHT ATTENDANT SEAT EMER FLASHLIGHT. OPERATIONS NORMAL.

Part: PROXIMITY SWITCH — INOPERATIVE (GIRT BAR) · airframe 100,273 hrs · 34,847 cycles

L1 SLIDE LT INOPERATIVE. REPLACED FWD LT ENTRY DOOR L1 GIRT BAR PROXIMITY SWITCHES S10214 & S10215.

Part: HANDLE — BROKEN (R1 DOOR) · airframe 100,013 hrs · 34,791 cycles

ASSIST HANDLE ON DOOR 1R BROKEN. R & R R1 DOOR PULL ASSIST HANDLE, OPERATES NORMAL.

Part: INTERCOSTAL — CORRODED (BS 400) · corrosion level 2 · airframe 99,810 hrs · 34,756 cycles

CORROSION FOUND ON INTERCOSTAL WEB AT BS 400 LBL3. REPLACED INTERCOSTAL IAW SRM 51-40-02.

Part: FITTING — CRACKED (NR 2 NACELLE) · airframe 99,810 hrs · 34,756 cycles

CRACK IN NR 2 ENGINE PYLON AFT BULKHEAD ASSEMBLY LOWER BRACE FITTING NR 6 HOLE. REPAIRED LOWER BRACE FITTING NR 6 HOLE IAW EA 106219.

Part: FITTING — CRACKED (NR 2 NACELLE) · airframe 99,810 hrs · 34,756 cycles

CRACK IN NR 2 ENGINE PYLON AFT BULKHEAD ASSEMBLY LOWER BRACE FITTING NR 11 HOLE. REPAIRED LOWER BRACE FITTING IAW EA 106219.

Part: RESERVOIR — LOW PRESSURE (L4 DOOR) · airframe 99,847 hrs · 34,757 cycles

C3 CHECK EMER POWER RESERVOIR AT L4 DOOR READS 0 PRESS. REPLACED EMER POWER RESERVOIR AT L4 DOOR IAW JOB CARD 19C83652003.

Part: GIRT BAR — BROKEN (R1 DOOR) · airframe 99,311 hrs · 34,647 cycles

R1 DOOR SLIDE GIRT BAR HAS BROKEN SPRING CLIP. R & R R1 DOOR SLIDE GIRT BAR.

Part: GIRT BAR — DETACHED (L4 DOOR) · airframe 97,654 hrs · 34,304 cycles

PHX L4 DOOR GIRT BAR FWD SIDE DETACHED. REATTACHED L4 DOOR FWD SIDE GIRT BAR, OPERATIONS CHECKED GOOD.

Part: GIRT BAR — UNSECURE (L4 DOOR) · airframe 97,616 hrs · 34,297 cycles

FLIGHT ATTENDANT CANNOT GET ARMED LIGHT TO COME ON WHEN SLIDE ARMED AT DOOR 4L. SECURED DOOR 4L GIRT BAR PAW TO SLIDE, OPERATIONS CHECKED NORMAL.

Part: BATTERY — DISCHARGED (FLASHLIGHT) · airframe 97,496 hrs · 34,275 cycles

LIH FLIGHT ATTENDANT`S FLASHLIGHT INOPERATIVE AT L2 DOOR ACFT LT. REPLACED BATTERY IN FLASHLIGHT.

Part: BUSHING — WORN (L4 DOOR) · airframe 97,300 hrs · 34,232 cycles

PHX L4 DOOR DIFFICULT TO OPEN & CLOSED. R & R UPPER & LOWER BUSHING ON L4 DOOR GUIDE ARMS.

Part: ATTACH FITTING — LOOSE (L4 DOOR)

PHX L4 DOOR ARMING SHOE MECHANISM EXTREMELY LOOSE. L4 DOOR ARMING SHOE FWD MECHANISM ATTACHMENT FITTING PLATE REPLACED.

Part: ROD — LOOSE (L4 DOOR)

PHX L4 DOOR LOWER ARMING MECHANISM ROD EXTREMELY LOOSE. L4 DOOR LOWER ARMING MECHANISM ROD TIGHTENED.

Part: CHARGER — INOPERATIVE (EMERGENCY LIGHT) · airframe 96,333 hrs · 34,016 cycles

CABIN AFT LT EMERGENCY LIGHT INOPERATIVE. R & R BATTERY CHARGER POWER SUPPLY M737. OPS CHECKED GOOD.

Part: BEARING — SEIZED (APU) · airframe 95,638 hrs · 33,880 cycles

JUST PRIOR TO PUSHBACK, WITH CREW AND PAX ON BOARD, SMOKE BEGAN TO FILL THE COCKPIT & CABIN. SMOKE IN THE TAIL SECTION AND BRIEF FLAMES COMING FROM APU EXHAUST WERE OBSERVED. CREW EVACUATED THE ACFT USING ESCAPE SLIDES. PRIOR TO EXITING THE COCKPIT, CREW NOTED THAT THE APU INDICATED TO HAVE AUTOMATICALLY SHUTDOWN. MX REPLACED THE LT & RT PACK PRIMARY & SECONDARY HEAT EXCHANGERS, LT & RT RECIRC FILTERS DUE TO OIL CONTAMINATION. A/C DUCTS WERE CLEANED OUT & PACK BURN OUT PROCEDURE WAS PERFORMED. THE CAUSE OF THE SMOKE WAS DETERMINED TO BE THE APU, THE APU WAS REPLACED. THE LOAD COMPRESSOR THRUST BEARING SEIZED, CAUSING ROTATING GROUP TO SHIFT & COMPROMISE THE OIL SEALS.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 94,990 hrs · 33,745 cycles

C2 CHECK - CRACK ON INTERCOSTAL BETWEEN BS 1440 TO BS 1460 & JUST BELOW S23R. REPAIRED INTERCOSTAL BETWEEN BS 1440 TO BS 1460 & JUST BELOW S23R IAW B757 SRM 51-40-02, BOEING DRAWING 146N8544 & EA 104619.

Part: RESERVOIR — OUT OF LIMITS (R2 DOOR) · airframe 94,985 hrs · 33,746 cycles

C2 CHECK - R2 DOOR EMERGENCY POWER RESERVOIR OUT OF LIMITS PER CARD 19C84252003. REPLACED R2 DOOR EMERGENCY POWER RESERVOIR IAW JOB CARD 19C84252003.

Part: SKIN — SATURATED (NR 6 SPOILER) · airframe 94,990 hrs · 33,745 cycles

C2 CHECK - AREA OF DELAMINATION & WATER SATURATION ON NR 6 SPOILER SKIN UPPER SURFACE & CORE APPROX 12 INCHES FROM TRAILING EDGE. REPLACE NR 6 SPOILER PANEL IAW JOB CARD 19L55027003.

Part: SKIN — CRACKED (RUDDER) · airframe 94,990 hrs · 33,745 cycles

C2 CHECK - CRACK ON RUDDER LEADING EDGE AT RUDDER STA 245.00. REPAIRED RUDDER LEADING EDGE AT RUDDER STA 245.00 IAW B757 SRM 55-40-01, TABLE 1 & 51-70-05.

Part: SKIN — DELAMINATED (LT ELEVATOR) · airframe 94,990 hrs · 33,745 cycles

C2 CHECK - DELAMINATION ON LEFT ELEVATOR UPPER SURFACE AT ELEV STA 87, APPROX 51 INCHES FROM INBOARD END & 31 INCHES AFT OF SPAR. REPAIRED LEFT ELEVATOR UPPER SURFACE AT ELEV STA 87 IAW B757 SRM 55-20-01.

Part: SKIN — DEBONDED (LE SLAT) · airframe 94,990 hrs · 33,745 cycles

C2 CHECK - AREA OF DISBOND ON 4 SLAT TRAILING EDGE LOWER SURFACE APPROX 32 INCHES TO 33.25 INCHES FROM INBOARD EDGE & 1.75 INCHES FROM TRAILING EDGE OF WEDGE. REPAIRED 4 SLAT TRAILING EDGE LOWER SURFACE IAW B757 SRM 51-70-10, REPAIR 4.

Part: PANEL — DEBONDED (VERTICAL STAB) · airframe 94,270 hrs · 33,602 cycles

RON VISIT - AREA OF DISBOND ON VERTICAL STABILIZER FORWARD SPAR BOX PANEL BETWEEN BS 1729 TO BS 1786 & BEWTEEN FSS119 TO FSS191. REPLACED VERTICAL STABILIZER FORWARD SPAR BOX PANEL IAW B757 SRM 51-40-02 & BOEING DRAWING 175N2001.

Part: SLAT — DELAMINATED (LT WING) · airframe 94,131 hrs · 33,571 cycles

RON VISIT - REPAIR DELAMINATED ON NR 3 SLAT APPROX BETWEEN WS 492.1 TO WS 496.1. REPLACED NR 3 LEADING EDGE SLAT IAW B757 AMM 27-81-02-424-021.

Part: SLIDE — UNSECURE (L4 DOOR) · airframe 91,490 hrs · 33,040 cycles

CUN - EMERGENCY SLIDE IN DOOR 4L SAGGING AND NOT PROPERLY SECURED INDOOR. MAINTENANCE RE-SECURED SLIDE TO DOOR 4L.

Part: BATTERY — DISCHARGED (FLASHLIGHT) · airframe 91,319 hrs · 33,004 cycles

PHX - FWD FA POS FLASHLIGHT INOP. REPLACED BATTERY IN FWD F/A FLASHLIGHT. OPS CHECKED NORMAL.

Part: SLIDE — FAULTY (L4 DOOR) · airframe 91,296 hrs · 32,998 cycles

DCA - DOOR 4L WILL NOT COMPLETELY DISARM. INSTALLED NEW ESCAPE SLIDE AT DOOR 4L.

Part: GIRT BAR — BINDING (L4 DOOR) · airframe 91,296 hrs · 32,998 cycles

PHX - FLT 9030 DCA TO PHX. F/A REPORTED DOOR L-4 WAS HARD TO DISARM AFTER LANDING. REPLACED L4 DOOR SLIDE GIRT BAR.

Part: SKIN — DELAMINATED (HORIZ STAB) · airframe 91,200 hrs · 32,976 cycles

1C CHECK - AREA OF DELAMINATION ON LEFT UPPER HORIZONTAL STABILIZER SKIN & CORE AT FSS 56 THRU FSS 107 APPROX 12 INCHES FROM LEADING EDGE. REPAIRED LEFT UPPER HORIZONTAL STABILIZER SKIN & CORE IAW EA 103467.

Part: SKIN PANEL — DELAMINATED (HORIZ STAB) · airframe 91,200 hrs · 32,976 cycles

C3 CHECK - DELAMINATION ON HORIZONTAL STABILIZER UPPER SKIN PANEL AT STABILIZER STATION 176, BETWEEN FS 204.093 TO FS 155.849. REPAIRED HORIZONTAL STABILIZER UPPER SKIN PANEL AT STABILIZER STATION 176, BETWEEN FS 204.093 TO FS 155.849 IAW EA 103468.

Part: SKIN — DEBONDED (TE FLAP) · airframe 91,200 hrs · 32,976 cycles

C3 CHECK - DEBONDING ON RIGHT WING INBOARD MAIN FLAP UPPER SURFACE 39 INCHES OUTBOARD OF INBOARD END, 18 INCHES UP FROM AFT TRAILING EDGE. REPAIRED RIGHT WING INBOARD MAIN FLAP UPPER SURFACE IAW EA 103480.

Part: FLAP — DEBONDED (RT WING) · airframe 91,200 hrs · 32,976 cycles

C1 CHECK - DEBONDED ON RIGHT AFT OUTBOARD FLAP 3.7 INCHES FORWARD OF TRAILING EDGE, 70.5 INCHES INBOARD OF OUTBOARD EDGE. REPAIRED RIGHT AFT OUTBOARD FLAP IAW B757 SRM 51-70-04, 57-53-01.

Part: GUST LOCK — LACK OF LUBE (L2 DOOR) · airframe 90,758 hrs · 32,878 cycles

PHX - GUST LOCK DOOR 2L WILL NOT ENGAGE. LUBED L2 GUST LOCK MECHANISM, OPS CHECK GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

PHX - ROW 18 EMERGENCY LIGHT INOP. RELAMP DID NOT FIX. REMOVED AND REPLACED POWER SUPPLY AND BATTERY (L40) (M732).

Part: SLAT — DEBONDED (LT WING) · airframe 86,600 hrs · 32,079 cycles

PHX - PILOT REPORT - MAJOR REPAIR - NR 5 SLAT TRAILING EDGE DISBONDED AT WS 279. REPLACED NR 5 SLAT TRAILING EDGE AT WS 279 IAW EO 5794R074.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 86,514 hrs · 32,062 cycles

CLT - C1 - MAJOR REPAIR - CRACK IN FUSELAGE SHEAR TIE AT BS 310, S13R. REPLACED FUSELAGE SHEAR TIE AT BS 310, S13R IAW B757 SRM 51-40-02 & BOEING DRAWING 141N1314.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 86,514 hrs · 32,062 cycles

CLT - C1 - MAJOR REPAIR - CRACK ON FLOORBEAM AT BS 700, RBL 48. REPAIRED FLOORBEAM AT BS 700, RBL 48 IAW EA 101867.

Part: SUPPORT FITTING — CRACKED (FUSELAGE) · airframe 86,514 hrs · 32,062 cycles

CLT - C1 - MAJOR REPAIR - CRACK ON FORGED SUPPORT FITTING FORWARD OF MAIN LANDING GEAR DOORS IN KEEL BEAM AREA AT BS 1180, BL 0. REPLACED FORGED SUPPORT FITTING FORWARD OF MAIN LANDING GEAR DOORS IN KEEL BEAM AREA AT BS 1180, BL 0 IAW B757 SRM 51-10-02 & BOEING DRAWING 144N8110.

Part: SKIN PANEL — DELAMINATED (HORIZ STAB) · airframe 86,514 hrs · 32,062 cycles

CLT - C1 - MAJOR REPAIR - DELAMINATION ON LEFT HORIZONTAL STAB PANEL UPPER SKIN BETWEEN CLOSURE RIB & RIB 5 FROM FRONT SPAR TO AUX SPAR. REPAIRED LEFT HORIZONTAL STAB PANEL UPPER SKIN BETWEEN CLOSURE RIB & RIB 5 FROM FRONT SPAR TO AUX SPAR IAW EA 101813.

Part: STRAP — BROKEN (FUSELAGE) · airframe 86,514 hrs · 32,062 cycles

CLT - C1 - MAJOR REPAIR - FLOORBEAM STABILIZER TIE STRAP BROKEN BETWEEN BS 337.7 TO BS 365.2, LBL 45.5. REPAIRED FLOORBEAM STABILIZER TIE STRAP BETWEEN BS 337.7 TO BS 365.2, LBL 45.5 IAW EA 101852.

Part: SKIN — CORRODED (FUSELAGE) · airframe 86,514 hrs · 32,062 cycles

CLT - C1 - MAJOR REPAIR - CORROSION ON FUSELAGE SKIN AFT LOWER LOBE UNDER GTE ANTENNA BASE AT BS 1560, S29L. REPAIRED FUSELAGE SKIN AFT LOWER LOBE UNDER GTE ANTENNA BASE AT BS1560, S29L IAW EA 101841.

Part: BRACKET — CORRODED (FUSELAGE) · corrosion level 2 · airframe 86,514 hrs · 32,062 cycles

CLT - C1 - MAJOR REPAIR - LEVEL 2 EXFOLIATION CORROSION ON ANTENNA BRACKET AT BS 1560 BETWEEN S26R TO S26L. REMOVED ANTENNA BRACKET & REPAIRED FUSELAGE SKIN IAW ER 19-2310-04208-SS1.

Part: SKIN — DEBONDED (LE SLAT) · airframe 84,966 hrs · 31,446 cycles

PHX - DVI - MAJOR REPAIR - DISBONDING SURFACE ON LEFT WING NR 5 SLAT UPPER SURFACE LEADING EDGE WEDGE AT PREVIOUS REPAIR LOCATION BETWEEN ISS152 TO ISS169. REPAIRED LEFT WING NR 5 SLAT UPPER SURFACE LEADING EDGE WEDGE BETWEEN ISS152 TO ISS169 IAW B757 SRM 51-70-10.

Part: SUPPORT FITTING — CRACKED (TE FLAP) · airframe 83,717 hrs · 31,473 cycles

CLT - B13 - MAJOR REPAIR - CRACK ON RIGHT OUTBOARD MAIN FLAP AFT FLAP ROLLER SUPPORT FITTING ASSEMBLY. REPLACED RIGHT OUTBOARD MAIN FLAP AFT FLAP ROLLER SUPPORT FITTING ASSEMBLY IAW US AIRWAYS EA 101063 & BOEING DWG 113N3330.

Part: LANYARD — UNSECURE (EVAC SLIDE)

OGG FLT 432 PHX TO OGG. DOOR R4 WAS DIFFICULT TO ARM IN PHX. WHILE IN FLIGHT, THE "ARMED" LIGHT EXTINGUISHED. MAINTENANCE SECURED A LOOSE LANYARD ON THE R4 DOOR SLIDE.

Part: FITTING — CRACKED (FUSELAGE) · airframe 82,625 hrs · 31,224 cycles

MCN - MAJOR REPAIR - C12 CHECK - FRAME CLIP IS CRACKED AT BS 350, S7L AT THE UPPER SIDE OF L1 DOOR CUTOUT UPPER FRAME. REPLACED PER B757 SRM 51-40-02 AND BOEING DWG 141N8321.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 82,625 hrs · 31,224 cycles

MCN - MAJOR REPAIR - C12 CHECK - WEB REPAIR ANGLE CRACKED AT BS 860 - BS 878, BL 0, WL 207. REPLACED WEB REPAIR ANGLE CRACKED AT BS 860 - BS 878, BL 0, WL 207 IAW B757 SRM 51-40-02 AND 143N5157-8200.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 82,625 hrs · 31,224 cycles

MCN - MAJOR REPAIR - C12 CHECK - CRACKED WEB REPAIR ANGLE AT BS 790, BL 0, WL 207. REPLACED WEB REPAIR ANGLE AT BS 790, BL 0, WL 207 IAW B757 SRM 51-40-02.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 82,625 hrs · 31,224 cycles

MCN - MAJOR REPAIR - C12 CHECK - LEVEL 2 CORROSION ON FORWARD CARGO COMPARTMENT STRINGER AT BS 760, S20R. REPAIRED FORWARD CARGO COMPARTMENT STRINGER AT BS 760, S20R IAW US AIRWAYS EA 1301456 AND B757 SRM 53-00-03-2R1.

Part: STRINGER CLIP — CORRODED (ZONE 100) · corrosion level 2 · airframe 82,628 hrs · 31,224 cycles

MCN - MAJOR REPAIR - C12 CHECK - LEVEL 2 CORROSION ON STRINGER CLIP AT BS 751, S21R. REPAIRED STRINGER CLIP AT BS 751, S21R IAW EA 130156.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 82,625 hrs · 31,224 cycles

MCN - C12 - MAJOR REPAIR - WEB VERTICAL ANGLE CRACKED AT BS 680, RBL 45.5. REPAIRED WEB VERTICAL ANGLE AT BS 680, RBL 45.5 IAW B757 SRM 51-40-02-0G & BOEING DRAWING 143N5195.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 82,625 hrs · 31,224 cycles

MCN - C12 - MAJOR REPAIR - INTERCOSTAL WEB CRACKED AT BS 550, RBL 54.5. REPAIRED INTERCOSTAL WEB AT BS 550, RBL 54.5 IAW B757 SRM 51-70-10-0G.

Part: PANEL — CRACKED (LE SLAT) · airframe 82,625 hrs · 31,224 cycles

MCN - MAJOR REPAIR - C12 CHECK - RIGHT WING NR 9 SLAT COVE PANEL AT WS 653 CRACKED. REPLACED RIGHT WING NR 9 SLAT COVE PANEL AT WS 653 IAW BOEING DWG 114N4076.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 82,625 hrs · 31,224 cycles

MCN - MAJOR REPAIR - C12 CHECK - LEVEL 2 CORROSION ON FUSELAGE SKIN AT BS 749, S22R. REPAIRED FUSELAGE SKIN AT BS 749, S22R IAW EA 130154.

Part: ACTUATOR — MALFUNCTIONED (LT MLG)

PHL FLT 798 ENROUTE PHL TO AMS. THE STANDBY ATTITUDE INDICATOR FAILED ABOUT 45 MINUTES AFTER DEPARTURE. THE DECISION WAS MADE TO RETURN TO PHL. THE FLIGHT RETURNED WITHOUT FURTHER INCIDENT. MX REPLACED THE LT MAIN GEAR UP-LOCK ACTUATOR. OPS CHECK OK.

Part: SLIDE — LOW (R3 DOOR)

THE R3 DOOR EMERGENCY ESCAPE SLIDE PRESSURE WAS FOUND LOW. MX REPLACED THE R3 DOOR EMERGENCY ESCAPE SLIDE. OK FOR SERVICE.

Part: TRANSMISSION — BINDING (T/E FLAP)

PHX FLT 31 OGG TO PHX - DURING APPROACH, RECEIVED A TRAILING EDGE FLAP DISAGREE MESSAGE. THE CREW EMPLOYED THE ALTERNATE EXTENSION METHOD TO EXTEND THE TRAILING EDGE FLAPS. THE FLIGHT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE RESET THE NR 1 OVERLOAD INDICATOR. FLAPS OPERATIONALLY CHECKED OK. AIRCRAFT PLACED ON MONITOR STATUS TO INSPECT THE OVERLOAD INDICATOR FOR EXTENSION. MAINTENANCE REPLACED THE NUMBER ONE TRAILING EDGE FLAP TRANSMISSION. OPERATIONALLY CHECKS OK.

Part: IDG — INOPERATIVE (NR 2)

PHX - FLT 432 PHX TO OGG. DURING CLIMBOUT FROM PHX, THE RT GEN & RT GEN DRIVE LIGHTS ILLUMINATED, WITH GEN FAIL AND DRIVE LIGHTS ON IN EICAS. THE FLIGHT RETURNED TO PHX AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE NR 2 IDG. OPERATIONALLY CHECKS OK.

Part: WIRE — CHAFED (FIRE LOOP)

PHX - FLT 45 EN-ROUTE PHX TO KOA. THE FLIGHT RECEIVED AN EICAS STATUS MESSAGE "R ENGINE FIRE LOOP 2" DURING CRUISE. THE FLIGHT RETURNED TO PHX AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED CHAFED WIRES BETWEEN CONNECTORS D1008P AND D1408. SYSTEM CHECKS OK.

Part: SLIDE — LOW PRESSURE (R2 DOOR)

PHX - THE R2 DOOR EMERGENCY ESCAPE SLIDE PRESSURE WAS FOUND TO BE IN THE RED. MAINTENANCE REPLACED THE R2 DOOR EMERGENCY ESCAPE SLIDE. OK FOR SERVICE.

Part: SWITCH — INOPERATIVE (EMERGENCY LIGHTS) · airframe 77,702 hrs · 30,017 cycles

MCN - EEL - C-11 CHECK - EMERGENCY EXIT LIGHTS TEST SWITCH LOCATED AT LEFT AFT EMERGENCY EXIT DOOR IS INOPERATIVE. DOES NOT ACTUATE EXIT LIGHT OVER DOOR. REPLACED EMERGENCY EXIT LIGHTS TEST SWITCH PANEL IAW B757-200 AMM 33-51-01.

Part: SHEAR TIE — CRACKED (ZONE 100) · airframe 77,702 hrs · 30,014 cycles

MCN - FOUND CRACKED SHEAR TIE, BS 1460, S29L - S30L. REPLACED SHEAR TIE, BS 1460, S29L - S30L IAW B757-200 SRM 51-40-05 AND 51-30-01.

Part: STRINGER — CRACKED (ZONE 200) · airframe 77,702 hrs · 30,017 cycles

MCN - MAJOR REPAIR - FOUND CRACKED STRINGER, BS 645, S16L. REPAIRED STRINGER BS 624 - BS 645, S16L IAW B757-200 SRM 53-00-03-2R1, FIGURE 201.

Part: INTERCOSTAL — CRACKED (BS 1240-1440) · airframe 77,702 hrs · 30,017 cycles

MCN - CRACKED INTERCOSTAL WEB, BS 1420 - BS 1440, S15R. REPLACED INTERCOSTAL WEB, BS 1420 - BS 1440, S15R IAW B757-200 SRM 51-40-02.

Part: BATTERY — DISCHARGED (CABIN) · airframe 77,702 hrs · 30,017 cycles

MCN - EEL - C-11 CHECK - RIGHT HAND MID AFT FLIGHT ATTENDANT SEAT EMERGENCY FLASHLIGHT BATTERY IS DISCHARGED. REPLACED AND OPERATIONAL CHECKED RIGHT HAND MID AFT FLIGHT ATTENDANT SEAT EMERGENCY FLASHLIGHT POWER UNIT.

Part: SKIN — CORRODED (ZONE 100) · airframe 77,702 hrs · 30,017 cycles

MCN - MAJOR REPAIR - CORROSION BULGE ON FUSELAGE SKIN, BS 1380, S29R. REPAIRED FUSELAGE SKIN, BS 1380, S29R IAW AWA ER 19-5361-07141-SS2.

Part: SKIN — CRACKED (ZONE 100) · airframe 77,702 hrs · 30,017 cycles

MCN - MAJOR REPAIR - CRACKED FUSELAGE SKIN, BS 1459, S26L - S27R. REPAIRED FUSELAGE SKIN, BS 1459, S26L - S27R IAW AWA ER 19-5361-07142-SS2.

Part: WIRE HARNESS — BROKEN (ZONE 200) · airframe 77,702 hrs · 30,017 cycles

MCN - EEL - C-11 CHECK - SEAT MOUNTED FLOOR PROXIMITY EMERGENCY WIRING HARNESS BROKEN IN SEVERAL PLACES. REPAIRED SEAT MOUNTED FLOOR PROXIMITY EMERGENCY WIRING HARNESS IAW B757-200 AMM 33-59-00.

Part: SKIN — CRACKED (RT WING) · airframe 77,702 hrs · 30,017 cycles

MCN - C-11 CHECK - RIGHT WING NR 9 SLAT COVE PANEL CRACKED, WS 639.1. REPLACED RIGHT WING NR 9 SLAT COVE PANEL, WS 639.1 IAW B757-200 SRM 51-40-02.

Part: WIRE — BROKEN (CABIN) · airframe 76,430 hrs · 29,673 cycles

PHX - EEL - EMERGENCY ESCAPE PATH LIGHTING INOP ROWS 1-8. FOUND CUT SPLICE AT ROW 5 MOVED SPLICE SO IT WOULD NOT SHORT. REMOVED AND REPLACED BATTERY CHARGER M9001. NO HELP. FURTHER T/S SHOWS PIN 9 AT CONNECTOR TO BE SHORTED TO GROUND. REPLACED THE SPLICE AT L9005D18 AND REPAIRED WIRE AT POWER SUPPLY M9001 REF SRM 33-041, OPS CHECK WAS GOOD.

Part: SUPPORT FITTING — CRACKED (T/E FOREFLAP) · airframe 75,245 hrs · 29,357 cycles

DURING A CHECK DISCOVERED THE LT OTBD T/E FLAP FORE FLAP CENTER TRACK, 2ND FROM OUTBOARD END SUPPORT FITTINGS, CRACKED ON THE INBOARD AND OUTBOARD HALVES. FLAP WILL BE REPLACED. NO MAJOR REPAIR FORM WILL BE COMPLETED. FLAP WAS REMOVED AND REPLACED. THE FOLLOWING INFORMATION WAS ADDED: PART NUMBER, TAT, TAC, AND WING STATION LOCATION.

Part: UNKNOWN — UNKNOWN (MLG) · airframe 73,937 hrs · 29,060 cycles

PHX - SMOKE - FLT 0708 - AFTER LANDING, TOWER REPORTED SMOKE COMING FROM THE LEFT MAIN GEAR. CREW REPORTED BRAKE TEMP INDICATORS AS NORMAL, INDICATING 1 & 2 AT THE MOST. EMERGENCY EQUIPMENT ESCORTED A/C TO THE GATE, CALLED OUT BY TOWER. MAINTENANCE INSPECTED TIRES AND BRAKES WITH NO INDICATION OF OVER TEMP. CHECKED BRAKE TEMP INDICATORS, ALL BEING WITHIN LIMITS. CHECKED FOR HYDRAULIC LEAKS IN THE LT WHEEL WELL AND HYDRAULIC QUANTITY INDICATIONS. ALL CHECKED NORMAL AND WAS RETURNED TO SERVICE. REPORTED FOR PRECAUTIONARY REASONS.

Part: SWITCH — SHORTED (L3 DOOR) · airframe 73,902 hrs · 29,045 cycles

GYR - EEL - DURING 8 DAY CHECK DISCOVERED THE L-3 DOOR EMERGENCY LIGHTS WERE INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE L3 DOOR LIGHT SWITCH IAW BOEING WDM 33-51-14. OPERATIONAL CHECKS WERE GOOD IAW BOEING 757-200 MM 33-51-00-5 STEP 3C(1).

Part: TRUNNION — CORRODED (LT MLG) · airframe 73,902 hrs · 29,045 cycles

GYR - DURING 8 DAY/ETOPS MOD DISCOVERED CORROSION AROUND THE UPPER OUTBOARD AND LOWER FUSE PINS AT THE LT MLG FORWARD TRUNNION SUPPORT FITTING AT WS 191.0L. REMOVED AND REPLACED THE LT MLG FORWARD TRUNNION SUPPORT FITTING, FUSE PINS AT WS 191.0L IAW EO 32-13-02 REV. A.

Part: BOTTLE — LOW PRESSURE (L2 DOOR) · airframe 73,837 hrs · 29,022 cycles

DURING OVERNIGHT INSPECTION MAINTENANCE FOUND THE L2 DOOR ASSIST BOTTLE PRESSURE LOW, 1300 PSI. REMOVED AND REPLACED THE L2 DOOR ASSIST BOTTLE IAW 52-11-33-4.

Part: FLOORBEAM — CORRODED (BS 365) · corrosion level 2 · airframe 73,453 hrs · 28,863 cycles

GYR - DURING C10 CHECK DISCOVERED CORROSION LOCATED ON FLOORBEAM TEE CAP AT BS 365, FROM BL 35.5R TO BL 45.0R. REMOVED CORROSION AND FOUND TO BE OUT OF LIMITS IAW BOEING 757-200 SRM 53-00-51-1A. MAINTENANCE REMOVED UPPER T CAP IAW BOEING 757-200 SRM 51-40-02. FABRICATED NEW T CAP IAW BOEING G737-300 SRM 53-00-51 FIG 201. INSTALLED FABRICATED REPAIR PARTS IAW BOEING G757-200 SRM 51-00-51.

Part: SKIN — CORRODED (BS 1520-1540) · corrosion level 2 · airframe 73,453 hrs · 28,863 cycles

GYR - DURING C10 CHECK DISCOVERED CORROSION UNDER ANTENNA, ON FUSELAGE SKIN, FROM BS 1520 TO BS 1540 AND FROM STR 29L TO STR 30L, JUST AFT OF AFT CARGO PIT DOOR. REMOVED CORROSION FROM FUSELAGE SKIN AND FOUND TO BE OUT OF LIMITS IAW BOEING 757-200 4M 53-00-01-1A. MAINTENANCE CUT OUT DAMAGED SKI IAW BOEING 757-200 SRM 51-00-01-2R FIG 201. FABRICATED DOUBLER IAW BOEING 737-300 SRM 53-00-01-2R3. MAINTENANCE INSTALLED FABRICATED REPAIR PARTS ON FUSELAGE SKIN, FROM BS 1520 TO BS 1540 AND FROM STR 29L TO STR 30L, JUST AFT OF AFT CARGO PIT DOOR IAW BOEING 757-200 SRM 53-00-01-2R.

Part: FLOORBEAM — CORRODED (BS 345) · corrosion level 2 · airframe 73,453 hrs · 28,863 cycles

GYR - DURING C10 CHECK, DISCOVERED FLOORBEAM AT BS 345, WL 208.10 AND BL 60R CORRODED. MAINTENANCE REMOVED CORROSION AND FOUND TO BE OUT OF LIMITS. CUT OUT AND REMOVED FLOORBEAM AT STA 345, WL 208.10 AND BL 60R IAW BOEING 757-200 SRM 53-00-51. FABRICATED CHORD, ANGLES AND STRAPS IAW BOEING 757-200 SRM 53-00-51 FIG 201. INSTALLED FABRICATED REPAIR PARTS AT BS 345, WL 208.1 AND BL 60R IAW BOEING 757-200 SRM 53-00-51 FIG 201.

Part: SKIN — DELAMINATED (NR 3 SLAT) · airframe 73,453 hrs · 28,863 cycles

DURING C10 CHECK DISCOVERED SMALL AREA OF DELAMINATION ON THE LOWER SURFACE OF THE NO. 3 SLAT TRAILING EDGE WEDGE AT WS 460L. MAINTENANCE REMOVED DELAMINATION AREA ON THE NR 3 SLAT IAW BOEING 757-200 SRM 51-70-10-2R. FABRICATED DOUBLER AND FILLER IAW BOEING 757-300 SRM 51-40-10-2R. BONDED REPAIR PARTS TO THE NR 3 SLAT TRAILING EDGE WEDGE AT WS 460L IAW BOEING 757-200 SRM 51-70-10-2R.

Part: SKIN — GOUGED (NR 4 SLAT) · airframe 73,453 hrs · 28,863 cycles

GYR - DURING C10 CHECK, DISCOVERED GROOVES WORN INTO PREVIOUS REPAIR DOUBLER ON THE LOWER SURFACE OF THE T/E WEDGE SKIN, FOR THE NR 4 LEADING EDGE SLAT. DAMAGE WAS CAUSED BY CONTACT WITH FIXED LEADING EDGE DURING EXTENSION AND RETRACTION. MAINTENANCE REMOVED THE EXISTING REPAIR DOUBLER AND FABRICATED REPLACEMENT DOUBLER IAW BOEING 757-200 SRM 51-70-10-2R. INSTALLED FABRICATED REPAIR DOUBLER AT WS 390L, ON THE NR 4 LEADING EDGE SLAT IAW BOEING 757-200 SRM 51-70-10-2R PAR 15, 18, 20 AND 21.

Part: LIGHT — INOPERATIVE (R1 DOOR SLIDE) · airframe 73,066 hrs · 28,708 cycles

BWI - EEL - DURING A CHECK INSPECTION IN BWI, FOUND THE R1 DOOR SLIDE LIGHT INOPERATIVE. MAINTENANCE ISSUED AN MEL.

Part: ENGINE — SURGES (LEFT) · airframe 72,952 hrs · 28,663 cycles

DURING CLIMB, LT ENG SURGED. A/C DIVERTED. LANDED WITHOUT INCIDENT. SEVERAL COMPONETS CHANGED INCLUDING NR 1 EEC, BVCU, AND SEVERAL OPERATIONAL TESTS PREFORMED. DISCOVERED TUBE MISSING FROM PF RAKE ON THE NR 1 ENGINE. A/C FERRIED FOR REPAIR. R & R PF RAKE ON NR 1 ENG. OPS TEST GOOD. COULD NOT CONFIRM FAILURE OF ESC. UNIT TESTED ONLY & PASSED ALL TESTS IAW CMM. NO FAULTS FOUND. BLEED VALVE CONTROLLER FAILED INCOMING TESTS. FOUND H1 FAULTY ON SIGNAL PROCESSOR BOARD. ALSO FOUND FATIGUED JOINTS ON TR4 & TR9 ON PUS2 BOARD. H1 PROCESSOR BOARD REPLACED & UNITED REPAIRED. UNIT PASSED OPS CHKS. ALL WORK ACCOMPLISHED IAW CMM.

Part: BOTTLE — EMPTY (L1 DOOR) · airframe 72,559 hrs · 28,485 cycles

FOUND L-1 DOOR ASSIST BOTTLE EMPTY. MAINTENANCE REMOVED AND REPLACED THE L-1 DOOR ASSIST BOTTLE IAW BOEING 757 MM 52-11-30-4.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 72,347 hrs · 28,382 cycles

DURING ROTATION EN ROUTE FROM PHX TO EWR PILOTS SUSPECTED A BLOWN TIRE DURING ROTATION. ACFT CONTINUED & LANDED WITHOUT FURTHER INCIDENT. MX INSPECTED ALL TIRES AND FOUND NO EVIDENCE OF DAMAGE. UPON FURTHER INSPECTION OF ACFT, MX FOUND DAMAGE TO AFT BELLY OF THE AIRCRAFT DUE TO AN APPARENT OVER ROTATION DURING TAKEOFF. MX REMOVED DAMAGED SKIN PANEL & REPLACED AFT SKIN PANEL FROM STA 1720 TO STA 1787 AND BLENDED AREAS FROM STA 1825 TO STA 1862 IAW AM WEST ENGINEERING REPAIR 19-5361-05147. MX ALSO REMOVED DAMAGED SHEAR TIE AT STA 1740 ON LOWER FLANGE BETWEEN STRINGER 29L TO STRINGER 29R. FABRICATED A NEW SHEAR TIE AND INSTALLED AT STA 1740 ON LOWER FLANGE BETWEEN STRINGER 29L TO STRINGER 29R IAW BOEING 757

Part: WIRE — BROKEN (SEAT ROW 23 LT) · airframe 71,691 hrs · 28,108 cycles

PHX - EEL - DURING A-01 CHECK, FOUND THE EMERGENCY ESCAPE PATH LIGHT AT SEAT ROW 23 LT INOPERATIVE. MAINTENANCE REPAIRED A BROKEN WIRE AT EMERGENCY ESCAPE PATH LIGHT SEAT ROW 23 LT. OPERATIONAL CHECK WAS GOOD.

Part: DOWNLOCK SENSOR — FAILED (ZONE 100) · airframe 69,547 hrs · 27,156 cycles

ON CLIMBOUT RECEIVED EICAS MESSAGE MLG MONITOR DISPLAYED MLG UP & LOCKED. MLG HANDLE IN UP/OFF POSITION & LT HALF OF NLG INDICATOR GREEN. TURNED OFF PAX ENTERTAIN EQUIP, LIGHT REMAINED ILLUM. TURNED BACK & LANDED W/O EVENT. MX ERASED EICAS MESSAGE. MESSAGE DID NOT RETURN. NO IN-FLT FAULTS DETECTED ON PSEU, BITE CHECK SYSTEM 2, MLG DID HAVE 006 CARD FAULT, SYS 1 OK. R & R NLG DOWNLOCK SENSOR, NO HELP. R & R PSEU IAW BMM & SWUNG MLG SEVERAL TIMES, OPS CK GOOD. CONFIRMED FAILURE OF UNIT. PBC CARD 006 FAILED TEST FOR DRIVER 106 (L6GA), RESEATED BOARDS & FAULT CLEARED. CARD 007 ALSO FAILED, PERFORMED CONTINUITY TEST & FOUND HIGH RESISTANCE AT PINS J7-B11, J11-C40, J12-B9 C4, AND J13-A11 C39.

Part: WIRE — BROKEN (CABIN) · airframe 69,169 hrs · 26,995 cycles

LCQ - EEL - DURING C-09 CHECK FOUND THE L-4 & R-4 DOOR EMERGENCY EXIT LIGHTS INOPERATIVE. MAINTENANCE RE-TERMINATED A TERMINAL AT THE AFT CABIN EMERGENCY LIGHT TEST SWITCH IAW SWPM 20-30-15, OPERATIONAL CHECK WAS GOOD.

Part: WIRE — BROKEN (SEAT ROW 35 LT) · airframe 68,783 hrs · 26,854 cycles

DURING 8-DAY CHECK, MAINTENANCE FOUND THE EMERGENCY ESCAPE PATH LIGHT AT SEAT ROW 35 LT INOPERATIVE. REPAIRED BROKEN WIRE FOR THE EMERGENCY ESCAPE PATH LIGHT UNDER SEAT ROW 35 LT, OPERATIONAL CHECK WAS GOOD.

Part: ACTUATOR — DEFECTIVE (ZONE 200) · airframe 66,930 hrs · 26,124 cycles

DURING EMERGENCY DESCENT AFTER MANUAL DEPLOYMENT OF OXYGEN MASKS, SEVERAL MASKS FAILED TO DEPLOY. FLIGHT ATTENDANT MANUALLY DEPLOYED MASKS AT SEAT ROW 2, 4 & 12 AND LAVATORIES A & C. MAINTENANCE REPLACED SOLENOIDS (ACTUATORS) AT SEAT ROWS 2, 4 & 12 AND LAVATORIES A & C; PERFORMED OXYGEN MASK DEPLOYMENT TEST IAW BMM 35-21-00 PG 501 AND T/C F1C35601.

Part: DUCT — BLOWN (ZONE 126) · airframe 66,930 hrs · 26,124 cycles

ON CLIMBOUT AT FL 190 HEARD A LOUD BANG AND FELT AIRCRAFT SHUDDER. CHECKED PRESSURIZATION AND FOUND OUTFLOW VALVE WAS IN FULL CLOSED POSITION, CABIN PRESSURE WAS CLIMBING. MANUALLY DEPLOYED OXYGEN MASKS & MADE EMERGENCY DESCENT. DECLARED EMERGENCY & TURNED BACK TO PHX. MX FOUND A BLOWN DUCT IN RT A/C PACK BAY, REMOVED & REPLACED DUCT ASSEMBLY IN RT PACK BAY, LEAK CHECK WAS GOOD. THE CHECK VALVE THAT PREVENTS REVERSE AIRFLOW FROM THE MIX MANIFOLD ALSO FAILED, FLAPPER DISK WAS TORN OFF HINGES & FOUND WEDGED IN DUCTING. REMOVED & REPLACED CHECK VALVE ASSEMBLY, OPERATIONAL CHECK GOOD. REPLACED ALL OXYGEN MASKS & GENERATORS.

Part: POWER SUPPLY — DISCHARGED (EMERGENCY LIGHTS) · airframe 66,100 hrs · 25,765 cycles

PHX - EEL - EMERGENCY LIGHTS AT THE L-2 DOOR, AND JUST AFT OF L-2 DOOR REMAIN ON. MAINTENANCE REMOVED AND REPLACED THE EMERGENCY LIGHT POWER SUPPLY AND BATTERY AT THE L-2 DOOR POSITION, OPERATIONAL CHECK WAS GOOD.

Part: LIGHT — INOPERATIVE (SEAT ROW 25) · airframe 65,723 hrs · 25,586 cycles

PHX - EEL - DURING INSPECTION THE EMERGENCY ESCAPE PATH LIGHT AT SEAT ROW 25 L/H WAS FOUND INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE EMERGENCY ESCAPE PATH LIGHT ASSEMBLY AT SEAT ROW 25 L/H, OPERATIONAL CHECK WAS GOOD.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 64,727 hrs · 25,149 cycles

PHX - EEL - DURING INSPECTION THE EMERGENCY EXIT LIGHT OVER R1 DOOR WAS FOUND TO COME ON INTERMITTENTLY. MAINTENANCE REMOVED AND REPLACED THE BATTERY PACK, POWER SUPPLY, AND R1 DOOR EMERGENCY EXIT LIGHT ASSEMBLY IAW BMM 33-51-07 AND BMM 33-51-01, OPERATIONAL CHECK WAS GOOD.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK A 1.25 INCH CRACK WAS FOUND ON FLOORBEAM SUPPORT ANGLE BETWEEN BS 660 - 680. MAINTENANCE REMOVED CRACKED FLOORBEAM SUPPORT ANGLE, FABRICATED A NEW FLOOR SUPPORT ANGLE, AND INSTALLED REPAIR IAW B757-200 SRM 51-10-02, PG 15 AND SRM 51-40-02, PG 8, 11-12.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK CORROSION WAS FOUND ON INBOARD SEAT TRACK FLOOR SUPPORT AT BS 1300 TO 1320, LBL 24. MAINTENANCE REMOVED CORRODED FLOOR SUPPORT AT BS 1300 TO 1320, LBL 24; FABRICATED A NEW FLOOR SUPPORT, AND INSTALLED REPAIR IAW B757-200 SRM 51-40-02, PG. 4-5, & 11.

Part: CREASE BEAM — CORRODED · corrosion level 2 · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK CORROSION WAS FOUND ON CREASE BEAM AT ATTACHMENT HOLE BS 1340, RBL 65. MAINTENANCE CLEANED CORROSION AND FOUND MATERIAL LOSS OUT OF LIMITS, REMOVED CREASE BEAM CHORD FROM BS 1290 TO BS 1400, FABRICATED A NEW CREASE BEAM AND INSTALLED REPAIR IAW B757-200 SRM 51-40-02, PG. 11-12, & 39.

Part: TIE CLIP — CRACKED · corrosion level 0 · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK A 3/4" CRACK WAS FOUND ON FLOOR BEAM SUPPORT TIE CLIP BS 1280, AFT CARGO COMPARTMENT. MAINTENANCE REMOVED CRACKED FLOOR BEAM SUPPORT TIE CLIP BS 1280, FABRICATED A NEW FLOOR SUPPORT TIE CLIP, AND INSTALLED REPAIR IAW B757-200 SRM 51-20-00, PG. 1, AND SRM 51-40-05, PG. 1.

Part: TIE CLIP — CRACKED · corrosion level 0 · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK A 5/8" CRACK WAS FOUND ON FLOOR BEAM SUPPORT TIE CLIP BS 1320, AFT CARGO COMPARTMENT. MAINTENANCE REMOVED CRACKED FLOOR BEAM SUPPORT TIE CLIP BS 1320, FABRICATED A NEW FLOOR SUPPORT TIE CLIP, AND INSTALLED REPAIR IAW B757-200 SRM 51-40-02, PG. 1.

Part: SUPPORT — CORRODED (FUSELAGE) · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK CORROSION WAS FOUND UNDER NUT PLATES FOR LOWER FASTENERS ON FLAP CUTOUT SUPPORT CHORD AT RT UPPER WHEEL WELL, BS 1147 TO BS 1180. MAINTENANCE REMOVED FLAP CUTOUT SUPPORT CHORD BS 1147 TO BS 1180. FABRICATED A NEW CUTOUT SUPPORT CHORD AND INSTALLED REPAIR IAW B757-200 SRM 51-40-02, PG 4 & 11.

Part: CREASE BEAM — CORRODED · corrosion level 2 · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK CORROSION WAS FOUND ON THE LOWER SIDE OF CREASE BEAM AND FLOOR PAN AT BS 1348, LBL 66. MAINTENANCE CLEANED CORROSION AND FOUND MATERIAL LOSS OUT OF LIMITS, CUTOUT DAMAGED AREA OF FLOOR PAN AND PERFORMED HFEC INSPECTION TO VERIFY NO CRACKS EXIST. FABRICATED A REPAIR DOUBLER AND FILLER, AND INSTALLED REPAIR PARTS IAW B757-200 SRM 51-70-13, PG. 1-2. REMOVED CREASE BEAM FROM BS 1290 TO BS 1400, FABRICATED A NEW CREASE BEAM AND INSTALLED REPAIR IAW B757-200 SRM 51-40-02, PG. 4-7.

Part: RIB — CRACKED · corrosion level 0 · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK A CRACK WAS FOUND AT L/H AFT WING TO BODY FAIRING SUPPORT RIB BS 1300. MAINTENANCE REMOVED CRACKED AREA OF SUPPORT RIB, FABRICATED 2 EACH REPAIR ANGLES, AND INSTALLED REPAIR PARTS IAW B757-200 SRM 53-60-71, PG. 201-204.

Part: ANGLE — CORRODED · corrosion level 0 · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK CORROSION WAS FOUND ON REPAIR ANGLE AT LOWER FLOOR BEAM BS 377, LBL 02. MAINTENANCE REMOVED REPAIR ANGLE AT LOWER FLOOR BEAM BS 377, LBL 02, FABRICATED A NEW REPAIR ANGLE, AND INSTALLED REPAIR IAW B757-200 SRM 53-00-51, PG. 209-210.

Part: SEAT TRACK — CHAFED · corrosion level 0 · airframe 64,658 hrs · 25,117 cycles

LCQ - MAJOR REPAIR - DURING C-08 CHECK SEVERAL CHAFE MARKS WERE FOUND ON SEAT TRACK AT BS 377-400, LBL 45. MAINTENANCE REMOVED DAMAGED SECTION OF SEAT TRACK AT BS 377-400, LBL 45. FABRICATED A NEW SECTION OF SEAT TRACK AND INSTALLED REPAIR IAW B757-200 SRM 53-00-52, PG. 101, FIG. 101.

Part: CHARGER — FAILED (CABIN) · airframe 64,438 hrs · 25,016 cycles

DURING INSPECTION ALL FIRST CLASS SEAT EMERGENCY ESCAPE PATH LIGHTS WERE FOUND INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE BATTERY CHARGER , OPERATIONAL CHECK WAS GOOD.

Part: CHARGER — INOPERATIVE (CABIN) · airframe 64,112 hrs · 24,876 cycles

PHX - EEL - DURING INSPECTION THE R-3 DOOR EXTERIOR EMERGENCY EXIT LIGHT WAS FOUND INOPERATIVE. RELAMPED 3 TIMES, NO HELP. MAINTENANCE REMOVED AND REPLACED THE BATTERY CHARGER ASSEMBLY FOR THE R-3 DOOR, OPERATIONAL CHECK WAS GOOD IAW BMM 33-51-00, PG 501.

Part: PSEU — UNRELIABLE · airframe 61,213 hrs · 23,756 cycles

D: Phx- Air turnback - Flt 494 - Shortly after take off EICAS displayed Air/ Ground Disagree message, FRM code 32-09-03-00, and the aircraft returned to Phx. C: In Phx maitenance trouble shot and performed a bite test of the PSEU which showed no faults when faults should have existed. The PSEU was replaced. As a precaution both NLG not compressed sensors were replaced as well.Part name: Sensor(2ea) MFG: ELDEC Corp. P/N:8-345-01 Part Loc: NLG Part condition: Good (Precautionary)

Part: DOOR FRAME — CHAFED (CARGO DOOR)

FWD cargo door LWR frame edge beam has chafe marks along entire length - 43 inches. removed damaged edge beam; FABBED replacement beam IAW BAC DWG 143N6621; installed IAW SRM 51-40-02.

Part: FLOOR SUPPORT — CHAFED (FUSELAGE)

FWD cargo pit floorboard support at FS 610 RBL 6 has chafed area. cut out damaged section; FABBED and installed floor support IAW SRM 53-30-53 fig 1; treated and primed IAW SRM 51-20-01.

Part: DOOR — OUT OF RIG (L4 DOOR) · airframe 60,930 hrs · 23,648 cycles

PHX - air turnback - 5/31/01 - FLT 49 - on climbout at 10000 ft the left aft entry door light illuminated. the door handle was observed not fully closed and had a small air leak (L4 door); the aircraft returned to PHX making an uneventful landing. in PHX the L4 door was rigged IAW AMM 52-11-13 and operational and pressurization checks were good; no further discrepancies.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

FWD CARGO PIT FLOOR SUB STRUCTURE FLOOR SUPPORT FOR FLOOR BOARD RT SIDE RBL 25 FS 590-650 HAS CORROSION. REMOVED AND REPLACED DAMAGED FLOOR SUPPORT IAW SRM 51-40-02.

Part: WEB — CORRODED (FUSELAGE)

MAIN CABIN FLOORD STRUCTURE AFT DECK SHEAR WEB HAS CORROSION AT STA 1710-1720 RBL 65-60 AND RBL 6.5-17. CUT OUT DAMAGED AREA; FABBED AND INSTALLED FILLER, DOUBLER AND SHIMS IAW SRM 53-60-51 FIG 203, AFT CABIN DECK PLATE IAW SRM 51-40-02 AND SRM 53-60-51 FIG 203.

Part: LINE — BROKEN (EPR TRANSMITTER) · airframe 58,588 hrs · 22,687 cycles

AIR TURNBACK, LEFT ENGINE DEVELOPING PARTIAL THRUST ON CLIMBOUT. FOUND P1 LINE, NR 1 ENGINE, BROKEN IN TWO PIECES. REPLACED LINE IAW MM 77-11-00.

Part: CHARGER — INOPERATIVE (CABIN) · airframe 58,771 hrs · 22,770 cycles

NR 4 RT EXIT DOOR EMERGENCY LIGHT INOP. REMOVED AND REPLACED BATTERY CHARGER, OPS CK GOOD.

Part: CHARGER — INOPERATIVE (CABIN) · airframe 58,276 hrs · 22,551 cycles

NON-ROUTINE, AFT CABIN FLOOR PROXIMITY EMERGENCY LIGHTS INOP. REMOVED AND REPLACED BATTERY CHARGER UNIT.

Part: UNKNOWN — ODOR (CABIN) · airframe 56,841 hrs · 21,967 cycles

SEWER SMELL IN AFT OF AIRCRAFT, FLT ATTENDANTS NAUSEOUS HAD TO BE REPLACED. DRAINED AND SERVICED ALL LAVS, INSPECTED AFT LAV DUMP TUBE FROM FLOOR LEVEL TO SERVICE PANEL, INSPECTED AREA BEHIND AFT WALL AND FWD WALL OF AFT PIT. NO DEFECTS NOTED. NO EVIDENCE OF LAV LEAKS, NO SEWER SMELL NOTED. CURRENT HISTORY: LIKE DISCREPANCY 3/21/00 AND LAV ODORS 2/20/00. RECOMENDATION: REMAIN OPEN AND MONITOR.

Part: WARNING LIGHT — ILLUMINATED (TE FLAP)

EMERGENCY LANDING-- ON APPROACH WHEN SELECTING FLAPS, TRAILING EDGE ASYMMETRY MESSAGE CAME ON UPPER EICAS. PERFORMED CK PER FIM 27-51-00. BITE C/W NO FAULTS NOTED, OPS CK OF FLAPS WAS NORMAL.

Part: COMPUTER — MALFUNCTIONED (E&E COMP)

MULTIPLE TERRAIN WARNINGS IN FLIGHT IN IMC CONDITIONS, TERRAIN AVOIDANCE PROCEDURES ACCOMPLISHED. PERFORMED T/S IAW FIM 34-46-00 AND REMOVED AND REPLACED GPWS COMPUTER, OPS CHECKED OK IAW TASK CARD F1B34601.

Part: STOP PINS — OUT OF ADJUST (PAX DOOR)

ON CLIMBOUT AT APPROX 8000 FT, EICAS MSG L AFT ENTRY DOOR AND OVERHEAD ENTRY DOOR LIGHT. FLIGHT ATTENDANT REPORTED DOOR HANDLE POPPED UP UNABLE TO CLOSE PRESSURIZATION NORMAL. ADJUSTED LEFT AFT ENTRY DOOR STOP PINS PER 757 MM 52-11 P 512 ITEM NR 4 PRESSURIZED CABIN, OPS CK GOOD.

Part: PUMP — FAILED (LT ENGINE)

INBOUND TO BOSTON LEFT HYDRAULIC ENGINE DRIVEN PUMP LOW OIL PRESSURE LIGHT ILLUMINATED. PUMP WAS TURNED OFF. LEFT SYSTEM QUANTITY WENT TO ZERO. REPLACED LEFT ENGINE DRIVEN PUMP. REPLACED PRESS AND SUPPLY QUICK DISCONNECT. REPLACED FILTERS ON EDP AND ACMP. REPLACED LEFT HYDRAULIC SYSTEM PRESS TUBE ABOVE LEFT PYLON PRESS MODULE, LEAK CHECKS GOOD. SERVICED LEFT HYDRAULIC RESERVOIR.

Part: BATTERY — DISCHARGED (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY EXIT LIGHTS ON A/C RIGHT AFT INOP. RESET BATTERY, LIGHT OPS GOOD.

Part: SKIN — CRACKED (BS 405)

DURING SCHEDULED C-5 INSPECTION, FOUND LOWER FUSELAGE SKIN CRACKED AT STA 405, STR 276 (LBL 14). FOUND BY HFEC. INSTALLED RIVET REPAIR PER SRM 53-00-01.

Part: LENS — MISSING (CABIN)

EMERGENCY LIGHT LENS ON BULL NOSE AT ROW 18R MISSING. REPLACED LENS.

Part: WIRE — BROKEN (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY LIGHT AT ROW 19 HAS TORN WIRE UNDER SEAT TRACK. REPAIRED BROKEN WIRE, OPS CHECK GOOD.

Part: LIGHT — INOPERATIVE (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY LIGHT AT ROW 11 A, B, C INOP. REPLACED LIGHT ASSEMBLY, OPS CHECK GOOD.

Part: FUEL PUMP — INOPERATIVE (LT ENGINE)

LEFT ENGINE SHUT DOWN ON APPROACH WITH STATUS MESSAGE LEFT ENGINE LOW PRESSURE PUMP. REMOVED AND REPLACED LOW PRESSURE FUEL PUMP AND LOW PRESSURE FUEL FILTER, OPS CHECK GOOD.

Part: BATTERY — DISCHARGED (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND MID CABIN CSR EMERGENCY FLASHLIGHT INOP. REPLACED BATTERY, OPS CHECK OK.

Part: HYDRAULIC LINE — LEAKING (LANDING GEAR)

AIR TURNBACK, LEFT HYDRAULIC QUANTITY DECREASED TO .02. REMOVED AND REPLACED GEAR DOWNLOCK ACTUATOR RETRACT LINE, LEAK CHECKED GOOD.

Part: CONNECTOR — DISCONNECTED (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND ROW 11 EMERGENCY LIGHT INOP. RECONNECTED CONNECTOR, OPS CHECK GOOD.

Part: WIRE — FAILED (APU GENERATOR)

PRYOR TO PUSHBACK AND DURING PAX BOARDING, SMOKE WAS OBSERVED IN FORWARD CABIN AREA. BOARDING WAS DISCONTINUED AND REMAINING PAX WERE DEPLANED. APU FEEDER CABLE DAMAGED IN FIRST CLASS FORWARD CABIN RIGHT SIDE OVERHEAD BIN AREA. CABLES BURNED DUE TO CHAFED WIRING. PLACARDED APU GENERATOR INOP, MEL 24-00-02. APU GENERATOR FEEDER CANNON PLUG DISCONNECTED AT APU FIRE WALL. REPAIRED FEEDER CABLE BY SPLICING IN A NEW SECTION OF WIRE IAW BOEING STANDARD WIRING PRACTICES MANUAL 20-30-13. OPS CHECK GOOD, MEL CLEARED.

Part: WIRE — BROKEN (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND ROW 19C EMERGENCY LIGHT INOP. REPAIRED BROKEN WIRE AT ROW 19. OPS CHECK OK.

Part: FLOOR BEAM — CORRODED (BS 365.5)

PAE - FLT 7803 - DURING ROUTINE SCHEDULED C-4 MAINTENANCE CHECK, FOUND CORROSION ON FLOOR BEAM BS 365.25, RBL 30 RBL 65. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED NEW UPPER CHORD, IAW 53-00-51. (M)

Part: FRAME — GOUGED (CARGO DOOR)

PAE - FLT 7803 - DURING ROUTINE SCHEDULED C-4 MAINTENANCE CHECK, FOUND AFT CARGO DOOR GOUGED. REMOVED AND REPLACED LOWER DOOR FRAME PER SRM 51-40-02. (M)

Part: FLOOR BEAM — CORRODED (BS 377.7)

PAE - FLT 7803 - DURING ROUTINE SCHEDULED C-4 MAINTENANCE CHECK, FOUND CORROSION ON FLOOR BEAM STATION 377.7, LBL 6-65. REMOVED DAMAGE AND REPAIRED FLOOR BEAM BY SPLICING IN A NEW TOP CHORD, IAW 53-00-51. (M)

Part: FLOOR BEAM — CORRODED (BS 324)

PAE - FLT 7803 - DURING ROUTINE SCHEDULED C-4 MAINTENANCE CHECK, FOUND CORROSION ON FLOOR BEAM BS 324, RBL 46 - RBL 63. REMOVED AND INSTALLED FABRICATED T-CHORD ON FLOOR BEAM BS 324, ER 5-53-32-07. (M)

Part: SHEAR TIE — CORRODED (BS 1300)

DURING ROUTINE SCHEDULED C-4 MAINTENANCE CHECK, FOUND CORROSION ON SHEAR TIE BETWEEN STRINGER 18R AND 19R, BS 1300. FABRICATED AND INSTALLED NEW SHEAR TIE, IAW, SRM 51-40-02. (M)

Part: SILL — CORRODED (BS 318)

DURING ROUTINE SCHEDULED C-4 MAINTENANCE CHECK, FOUND CORROSION ON R1 MOPSILL BS 318 TO 324, RBL 65. REMOVED AND REPLACED MOPSILL, IAW, SRM 51-40-02, 51-30-01, 53-10-15. (M)

Part: FLOORBEAM — CORRODED (FS 1661)

PHX - FOUND DURING C-4 INSPECTION, CORROSION UPPER AND LOWER SURFACE OF TOP CHORD FLOORBEAM STA 1661, LBL 2 TO LBL 22. REPAIRED FLOORBEAM PER SRM 51-70-12. (X)

Part: FLOORBEAM — CORRODED (FS 1661)

FOUND DURING C-4 INSPECTION, CORROSION UPPER AND LOWER SURFACE TOP CHORD OF FLOOR BEAM, STA 1661, LBL 24.5 TO LBL 36. REPAIRED FLOORBEAM PER SRM 51-70-12. (X)

Part: FLOORBEAM — CORRODED (FS 1640)

PHX - FOUND DURING C-4 INSPECTION, MAIN CABIN FLOORBEAM UPPER CHORD TOP CAP CORRODED, STA 1640, BL ZERO TO RBL 40. REPAIRED BEAM PER 53-00-51. (X)