N919TW

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHT) · airframe 51,770 hrs · 27,179 cycles

THE EGRESS LIGHTS AT THE OVERWING EMERGENCY EXITS, CAME ON IN FLIGHT WITH THE SWITCH IN ARM POSITION. REPLACED THE BATTERIES IN THE BATTERY PACK. CHECK-C 3-28-03 STL.

Part: GENERATOR — MALFUNCTIONED (LEFT) · airframe 46,075 hrs · 23,672 cycles

AT FL 330 CAPT INSTRUMENTS WENT DEAD AND FLT GUIDANCE CONTROL PANEL FROZE. LT AND RT GEN VOLTS AND FREQS NORMAL. MADE UNSCHEDULED LANDING AT TPA. AFTER LANDING NOTICED LT CSD TEMP WAS LOW. TURNED OFF LT GEN AND INDICATIONS RETURNED TO NORMAL. REPLACED THE LT GEN. ALSO REPLACED PRECAUTIONARY THE RT DC BUS SENSING RELAY P/N 9227-10127, THE LT GENERATOR CONTROL UNIT P/N 947F945-3, AND THE DC EMERGENCY POWER TRANSFER RELAY P/N EP-410. CHECK-C 5-12-00 MCI.

Part: SMOKE — DETECTED (CABIN) · airframe 45,870 hrs · 23,558 cycles

ON SHORT FINAL SMOKE APPEARED IN THE CABIN WHEN ANTI-ICE WAS TURNED ON. ACCOMPLISHED PACK BURN OUT AND DEACTIVATED APU PER MEL. CHECK-C 5-12-00 MCI.

Part: MOTOR — DAMAGED (OUTFLOW VALVE) · airframe 44,093 hrs · 22,535 cycles

DURING DESCENT HAD A CABIN PRESSURIZATION PROBLEM. PASSENGER OXYGEN MASKS DROPPED. FERRY TO MCI FOR CORRECTIONS. AC04 01-28-00 DFW. REPLACED THE OUTFLOW VALVE MOTOR. FOUND THE TACH WINDINGS OF THE MOTORS WERE OPEN.

Part: FRAME — CORRODED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, FOUND FORMER FOOT CORRODED AT STA 1287, AT LONGERON 20L. REMOVED CORROSION PER SPM 6-80-01.

Part: INTERCOSTAL — CORRODED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT INTERCOSTAL AT RBL 16 BETWEEN STA 1307 AND 1323, HAD CORROSION AT BOTH ENDS. REMOVED AND REPLACED INTERCOSTAL AT STA 1322, RBL 15. INSTALLED WITH HI-LOKS PER SRM 51-30-5, AND AD RIVETS PER SRM 51-30-2. INTERCOSTAL FABRICATED PER DAC DRAWING 5936667. TREATED PER SRM 51-30-3.

Part: FRAME — CORRODED (FUSELAGE) · airframe 94,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, FOUND CORROSION ON LOWER FLANGE OF FORMER STA 1307, LONGERON 25L TO 28R. SPLICED IN NEW FORMER PER DOUGLAS DRAWING 9912243 AND SRO 9530057.

Part: OUTFLOW VALVE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 44,003 hrs · 22,485 cycles

DURING CC24C, FOUND INTERGRANULAR CORROSION ON THE OUTFLOW VALVE CASTING (SUGAR SCOOP) LOWER AFT SIDE. REPLACED DOUBLER MANUFACTURE NUMBER 5914558-5012 VING TWA NUMBER 163497 PER MDC PRINT NUMBER 5936021. CC24C MCI 04-27-00.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, THE RT AFT CARGO COMPT TIE DOWN TRACK HAD NUMEROUS PLACES OF CORROSION AT TOP AND BOTTOM OF CLIP NUT LOCATIONS FROM STA 1212 TO 1320. REMOVED AND REPLACED TIE DOWN FLOOR TRACK FROM STA 1212 TO 1320, INSTALLED WITH NAS 7103 SCREWS PER SRM 51-30-01.

Part: FRAME — CORRODED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, FOUND CORROSION IN LOWER FLANGE OF FORMER 1271, BETWEEN LONGERON 28L AND 30. REMOVED CORROSION PER SRM 53-10-03. REPAIRED PER SRM 53-03, PAGE 4A. PRIMED PER SRM 51-10-3B.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, FOUND CORROSION BEYOND LIMITS ON FLOOR SUPPORT STA 1322, LONGERON 23R TO 23L. FABRICATED NEW FLOOR SUPPORTS FROM 0.040 2024 PER SPM 6-70-01 AND SRM 51-10-2A. INSTALLED FASTENERS PER SRM 51-30-2.

Part: SKIN — DAMAGED (PAX DOOR) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, THE FWD LT PAX DOOR SKIN ALONG THE BOTTOM EDGE WAS DISTORTED. REPAIRED SKIN ALONG BOTTOM EDGE BY STRENGHTENING AND REPAIRED PER SRM 52-05, FIG 32 SHEET 1 AND 3.

Part: CASTING — CRACKED (LT WING) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, THE LT WING FWD END OF GROUND SPOILER ATTACH CASTING WAS CRACKED BOTH I/B AND O/B SIDE OF ACT ATTACH FWD END. STOP DRILLED CRACKS PER SRO 9570010-5. INSTALLED DOUBLER FILLER AND STIFFENER PER SRO 9570010-5, FIG 6 PAGE 45-62.

Part: ACTUATOR — CRACKED (SPOILER) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, THE RT WING FWD END OF GROUND SPOILER ACTUATOR ATTACH CASTING WAS CRACKED I/B AND O/B SIDE AT FWD END, PER BOEING DAC SB 57-180 VIEW DD CONDITION 4. ACCOM HIGH FREQ EDDY CURRENT PER TWA NDT 51-00-01 PART 6 FOR CRACK CONTAINMENT. STOP DRILLED AND INSTALLED DOUBLER PER SB 57-180 REV 02, AND DRAWING SR0 9570010.

Part: STRUCTURE — BENT (PAX DOOR) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, THE FWD ENTRY DOOR WAS BENT AT THE BOTTOM FWD AND AFT ENDS. REPAIRED SKIN PER SRM 52-05 PAGE 32, AND 52-03 PAGE 1.

Part: DOME NUT — CORRODED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, FOUND RT FUSELAGE CORROSION AROUND DOME NUT HOLES AT STA 769 TO 807, AREA OF LONGERON 28R. REMOVED CORROSION PER SPM 6-80-01. CHECKED MATERIAL LOSS 45 PER CENT BY NDT. REPAIRED PER SRM 53-04 FIG 53 SHEET 1 TO 5. TREATED PER SRM 51-10.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING CHECK-C MAINT, THE RT CHAIR TRACK HAD CORROSION FROM STA 1079 TO 1155, WL 200. REMOVED CORRODED TRACK AND INSTALLED NEW TRACK USING SCREWS NAS 7103, WASHERS (P/N NAS1252-10H), NUTS (P/N MS21042L3), AND RIVETS MS 20426AD6.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING C CHECK, THE LT OTBD SEAT TRACK WAS BLENDED BEYOND LIMITS, STA 1231 TO 1240, LONGERON 54. REPLACED SEAT TRACK AT STA 1231 TO 1309 PER DRAWING 5930566. ---CLOSED---

Part: FLOOR SUPPORT — CORRODED (CARGO BAY) · airframe 44,003 hrs · 22,485 cycles

DURING C CHECK, IN AFT CARGO BAY, STA 1211, LONGERON 29 LT, AFT FACE OF SUPPORT HAD CORROSION ON FLOOR SUPPORT AT STA 1211, LONGERON 29 RT TO 30 RT. REPLACED FLOOR SUPPORT WITH NEW PER SRM 51-10-4. ---CLOSED---

Part: FORGING — CRACKED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING C CHECK, AT CABIN STA 1338, LONGERON 18 RT, WHERE 3 LEGGED FORGING ATTACHES TO FRAME TO FLOORBEAM, THE VERTICAL LEG WAS CRACKED AND CORRODED. REPLACED FITTING PER SPM 6-70-01. INSTALLED FASTENERS PER SRM 51-10-5B. PAINTED PER SRM 51-10-3B. ---CLOSED---

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 44,003 hrs · 22,485 cycles

DURING C CHECK, MAINT FOUND CRACK IN FLOORBEAM CAP AT STA 237, RBL 4, CARGO CEILING AREA. FABRICATED NEW FLOORBEAM CAP PER SPM 6-70-01 AND SRM 51-10-03. ---CLOSED---

Part: LINK — BROKEN (RT MLG DOOR) · airframe 43,888 hrs · 22,424 cycles

ON LANDING GEAR RETRACTION, THE RT GEAR UNSAFE LIGHT AND GEAR DOOR WARNING LIGHT WERE ON. SLOWED TO 180 KTS AND CYCLED GEAR, NO HELP. FLIGHT RETURNED TO STL. REPLACED THE LOWER ACTUATOR LINK ON THE RT MAIN GEAR. CHECK-C 5-5-99 MCI.

Part: LIGHT — INOPERATIVE (CABIN)

THE LEFT SIDE FORWARD CABIN DOOR PORTABLE EMERGENCY LIGHT ON-OFF SWITCH WAS BROKEN. REPLACED THE LIGHT ASSY. CHECK-C 5-5-99 MCI.

Part: LINK — BROKEN (LT MLG DOOR)

AFTER TAKEOFF AND GEAR RETRACTION THE LEFT GEAR RED UNSAFE LIGHT AND GEAR DOOR OPEN LIGHT REMAINED ON. RECYCLED THE GEAR, NO HELP. FLIGHT RETURNED TO STL. FOUND THE LEFT GEAR DOOR ACTUATOR UPLINK BROKEN. REPLACED THE LINK ASSEMBLY. CHECK-C 4-19-99 MCI.

Part: BEAM — CRACKED (R1 DOOR)

FOUND THE FORWARD RIGHT CABIN DOOR HAD THE BOTTOM DOOR BEAM CRACKED. INSTALLED NEW DOOR BEAM PER SRM 51-30-2. CHECK-C 8-27-98 STL.

Part: BATTERIES — DISCHARGED (FWD CABIN)

OVERHEAD EMERGENCY EXIT LIGHTS AND COCKPIT EMERGENCY LIGHTS WERE REPORTED INOPERATIVE. REPLACED BATTERIES IN FWD POWER SUPPLY. CHECK-C 8-27-98 STL.

Part: BULKHEAD TEE — CREASED (BS 1338)

DURING CHECK-C MAINT, FOUND CREASE ON BULKHEAD TEE STA 1338, BETWEEN LONGERON 29R AND 29L. REMOVED AND REPLACED TEE PER SRM 53-03, FIG 37A.

Part: COMPRESSOR — STALLED (RT ENGINE)

DCA - FLT 797 - AT FL 330 TO 350 RT ENGINE HAD SEVERAL STALLS. REDUCED THROTTLE TO IDLE AND STALLS STOPPED. DECLARED EMERGENCY AND DIVERTED TO DCA. REPLACED ENGINE. (M)

Part: OVEN — MALFUNCTIONED (AFT GALLEY)

STL - FLT 100 - DURING CRUISE, THE COACH GALLEY OVEN L2 EMITTED STRONG ELECTRICAL FUMES. REPLACED THE AFT GALLEY L2 OVEN MFG P/N 50381. (M)

Part: TARGET — MISSING (CARGO COMPT)

OMA - FLT 38 - AFT CARGO DOOR LIGHT ILLUMINATED AFTER TAKEOFF. RETURNED TO OMA. DOOR INDICATION PLACARDED PER MEL. ON ACFT LAYOVER, THE DOOR SENSOR WAS REPLACED AND THE MISSING DOOR SENSOR TARGET WAS INSTALLED. SENSOR PART NR 8-340-02. CHECK-C 8-9-97 MCI. (X)

Part: BEARING — FAILED (LT ENGINE)

MEM - FLT 1226 - DURING FLIGHT, THE LEFT ENGINE, SPOOLED DOWN. MADE UNSCHEDULED LANDING AT MEM. REPLACED ENGINE. ENGINE WAS DISASSEMBLED AND FOUND NR 3 BEARING WAS THE INITIAL FAILURE. IT THEN CAUSED OTHER FAILURES. (M)

Part: PRESSURE REG — FAILED (LT COCKPIT)

JFK - FLT 783 - AFTER TAKEOFF ROTATION, RIGHT AIRCONDITIONING TEMPERATURE SUPPLY HIGH INDICATION LIGHT CAME ON. REPLACED THE PILOT PRESSURE REGULATOR. (M)

Part: FRAME — DAMAGED (BS 1380)

MCI - DURING OP 15 MAINTENANCE CHECK, FOUND FORMER RING STATION 1380 BELOW LONGERON 4L WITH GOUGE WORN INTO FORMER BY IMPROPERLY INST AIR VALVE. REMOVED DAMAGED AREA AND APPLIED FILLER AND DOUBLER PER SRM 53-01 PAGE 9. (M)

Part: LONGERON — CORRODED (BS 200-218)

MCI - DURING OP 15 MAINTENANCE CHECK, FOUND CORROSION AT STATION 200 TO 218, LONGERON 18L FORWARD AND AFT OF LAV VENT. CLEANED CORROSION PER SRM 51-10-3, PAR 31-42, AND INSTALLED NEW MEMBRANE PER SRM 53-05, FIG 96. (M)

Part: FILTER — DIRTY (NR 1 ENGINE)

ICT - FLT 65 - DURING CRUISE, SHUT DOWN NR 1 ENGINE, SN 1206, DUE TO HIGH OIL PRESSURE AND INCREASING OIL TEMPERATURE. REPLACED ENGINE OIL FILTER AND ENGINE OIL PRESSURE RELIEF VALVE. ENGINE OPERATION AND LEAK CHECK NORMAL. ENGINE TOTAL TIME: 21,726 HOURS; 10,984 CYCLES. OP-16 - 8-17-94 - MCI.

Part: ENGINE — FAILED (LEFT)

JFK - FLT 481 - DURING CLIMB, SHUT DOWN LEFT ENGINE DUE TO LOUD BANG AND INCREASING EGT. FOUND METAL PARTICLES IN TAILPIPE. REPLACED ENGINE, SN 3218. GROUND RUN-UP AND OPERATION CHECKED NORMAL. ENGINE TOTAL TIME: 27,663 HOURS; 14,695 CYCLES. CHECK OP-16 - 8-17-94 - MCI.