N9403W

Part: WARNING LIGHT — INTERMITTENT (FUEL SYSTEM) · airframe 64,866 hrs · 31,847 cycles

ON CLIMB OUT, CTR FUEL LOW PRESS LIGHT ON WITH 9000 LBS IN CTR TANK. LIGHT WAS INTERMITTENT, & CTR TANK INTERMITTENTLY BURNED ON RETURN. UNCERTAIN IF FUEL WAS MIGRATING FROM CTR TANK TO WINGS. FLIGHT DECLARED AN EMER & RETURNED WITHOUT FURTHER INCIDENT. ACFT REMOVED FROM SERVICE. ACCOMPLISHED TEST OF FUEL FEED SYS IAW AMM 28-20-00-501 & UNWANTED FUEL TRANSFER CORRECTIONS PROCEDURE IAW MM 28-20-00-201, NO FAULTS FOUND.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 63,327 hrs · 30,968 cycles

EMERGENCY LIGHTS INOPERATIVE IN FWD ENTRY AREA. REPLACED BATTERY PACK 803900-1 IAW AMM 33-53-00. SYS CHECKED NORMAL.

Part: LINK — BROKEN (AFT STAIR) · airframe 63,327 hrs · 30,968 cycles

THE AFT STAIRWAY CEILING WALKWAY WILL NOT RETRACT WITH AIR STAIRS IN THE DOWN POSITION. R & R RT AFT LOWER LINK ASSEMBLY. PERFORMED OPERATIONAL CHECK IAW AMM 52-63-00. SYS CHECKED NORMAL.

Part: FRAME — CRACKED (FUSELAGE) · airframe 62,743 hrs · 30,639 cycles

FUSELAGE FRAME AT STATION 1510 IS CRACKED AT LT LOWER ALIGNMENT PIN HOLE. REPAIRED FRAME IAW SRM 53-01-00.

Part: SKIN — CRACKED (TE FLAP) · airframe 62,743 hrs · 30,639 cycles

RIGHT OTBD FLAP, LOWER INBD SKIN HAS A CRACK IN THE DENT BETWEEN XRS 324 & 330. REPAIRED IAW SRM 57-01-00-001, 51-10-03, 51-20-00 & 51-30-08.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 62,743 hrs · 30,639 cycles

RIGHT ENG STUB WING LOWER TE AT ROOT HAS LOOSE HARDWARE WEARING INTO SKIN. INSTALLED DOUBLER REPAIR IAW SRM 53-01-00-001.

Part: ENGINE — FAILED (RIGHT) · airframe 62,275 hrs · 30,383 cycles

RETURNED, EMER DECLARED & LANDING UNEVENTFUL. ACFT NOT OVERWEIGHT. DURING CLIMB THROUGH 6800 FEET A LOUD BANG OCCURRED ACCOMPANIED BY A YAW TO RIGHT. RT ENG INDICATIONS DROOPING. ENG SHUT DOWN. BORESCOPE OF ENG IAW 72-96-11-12-14 SHOWED DAMAGED STAGE 12 & 13 COMPRESSOR BLADES & STAGE 1 & 2 TURBINE BLADES. R & R ENG IAW WORK CARDS 71-91-99 & 71-91-03.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 61,051 hrs · 29,741 cycles

TAIL CONE CATWALK EMER LIGHT FAILED TESTS. REPLACED BATTERY PACK B5-28. OPERATIONS CHECKED NORMAL.

Part: ARU — MALFUNCTIONED (NR 1) · airframe 60,884 hrs · 29,641 cycles

DFW CREW REPORTED MULTIPLE INSTRUMENTS WENT BLANK & CARGO HEAT BREAKER POPPED. FLIGHT RETURNED DFW LANDED WITHOUT INCIDENT. ACFT REMOVED FROM SERVICE. REPLACED NR 1 ATTITUDE HEADING REFERENCE UNIT. SYS GND CHECKED NORMAL, OPERATION CLOSED.

Part: CASTING — CRACKED (RT WING) · airframe 59,361 hrs · 28,839 cycles

RT HAND WING FIXED LE CASTING AT INBD SIDE OF NR 4 SLAT TRACK CRACKED. INSTALLED CASTING IAW AARD 51-00-05-1 & DRAWINGS 5937484 & 9937489.

Part: CASTING — CRACKED (RT WING) · airframe 59,361 hrs · 28,839 cycles

RT WING FIXED LE CASTING AT INBD SIDE OF NR 4 SLAT TRACK CRACKED. REPLACED CRACKED CASTING.

Part: CASTING — CRACKED (LT WING) · airframe 59,361 hrs · 28,839 cycles

RT WING FIXED LE CASTING AT INBD SIDE OF NR 4 SLAT TRACK CRACKED. INSTALLED FABRICATED CASTING IAW AARD 51-00-05-1 & DRAWING 5937484 & 9937489.

Part: CASTING — CRACKED (LT WING) · airframe 59,361 hrs · 28,839 cycles

LT WING FIXED LE CASTING CRACKED ON TOP LUG NR 4 SLAT TRACK. REPLACED CRACKED CASTING.

Part: CSD — OVERSERVICED (LT ENGINE) · airframe 57,189 hrs · 27,694 cycles

ATL INFLIGHT TPA-ORD. CREW REPORTED LEFT ENGINE CONSTANT SPEED DRIVE FAILED AND UNABLE TO START AUXILIARY POWER UNIT. FLIGHT DIVERTED ATL LANDED WITHOUT INCIDENT. FOUND LEFT ENGINE CSD OVERSERVICED. SERVICED LEFT ENGINE CSD TO PROPER SERVICING LEVEL. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: CLAMP — LEAKING (AC BAY) · airframe 56,126 hrs · 27,141 cycles

DFW - CREW REPORTED DURING CLIMBOUT TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED WITH BOTH PACKS SHUT DOWN. EMERGENCY DECLARED FLIGHT RETURNED DFW LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. FOUND CLAMP ABOVE LEFT PACK SUPPLY TEMPERATURE SENSOR LEAKING DIRECTING HOT AIR TOWARD TAIL COMPARTMENT TEMPERATURE SENSOR. REPLACED CLAMP. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 55,330 hrs · 26,716 cycles

FRAME DAMAGED AT STATION 110 ABOVE AND JUST LEFT OF TRANSFER RELAY. INSTALLED REPAIR STRAP PER EA MD80-53-023136.

Part: CUSP WEB — CRACKED (ZONE 200) · airframe 55,330 hrs · 26,716 cycles

LEFT CUSP BUCKLED WITH CRACK AT STATION 257 NEAR GREEN FITTING. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — DAMAGED (BS 885) · airframe 55,330 hrs · 26,716 cycles

RIGHT CUSP WEB BS 885 DAMAGED FASTENER HOLE. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (ZONE 200) · corrosion level 2 · airframe 55,330 hrs · 26,716 cycles

RIGHT UPPER CUSP BS 1187 TO 1193 CORRODED. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (ZONE 200) · airframe 55,330 hrs · 26,716 cycles

CORROSION ON RIGHT CUSP FROM BS 503 TO 598. REPLACED CUSP SHEET PER AARD 51-10-00-5.

Part: STRUCTURE — CORRODED (ZONE 200) · corrosion level 2 · airframe 55,330 hrs · 26,716 cycles

SUBFLOOR HAS CORROSION UNDER G1 GALLEY DRAIN PAN. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: STRUCTURE — CORRODED (ZONE 200) · corrosion level 2 · airframe 55,330 hrs · 26,716 cycles

CORROSION ON FORWARD SUBFLOOR STATION 200 RIGHT BUTTLINE 55. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — CRACKED (ZONE 200) · airframe 55,330 hrs · 26,716 cycles

CRACK AT STATIONS 995 TO 997 LEFT CUSP. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 55,330 hrs · 26,716 cycles

RIGHT CUSP ANGLE CORRODED AT BS 200. INSTALLED REPAIR DOUBLER AND FILLER AT RIGHT CUSP ANGLE PER AARD 53-20-00-14.

Part: SKIN — BENT (PAX DOOR) · airframe 55,330 hrs · 26,716 cycles

CABIN FORWARD ENTRY DOOR SKIN IS BENT ALONG LOWER SIDE NEAR AFT LOWER CORNER. INSTALLED DOUBLER PER SRM 52-10-00-2 PAGE 2.

Part: LONGERON — CRACKED (BS 1309) · airframe 55,330 hrs · 26,716 cycles

LONGERON 18 LEFT CRACKED AT STATION 1309 AFT SIDE. REPAIRED LONGERON PER SRM 53-02-00 FIGURE 18.

Part: MEMBRANE — PUNCTURED (FUSELAGE) · airframe 55,330 hrs · 26,716 cycles

SUBFLOOR HAS A PUNCTURE AT STATION 194. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 55,330 hrs · 26,716 cycles

CORROSION ON BOTTOM OF LEFT CUSP AT STATION 532. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: WEB — CRACKED (FUSELAGE) · airframe 55,330 hrs · 26,716 cycles

FORWARD ENTRY DOOR JAMB- WEB TAB CRACKED AFT SIDE OF DOOR JAMB STATION 208 LONGERON 11 LEFT. INSTALLED REPAIR STRAP PER AARD 53-10-33-11.

Part: WEB — CRACKED (FUSELAGE) · airframe 55,330 hrs · 26,716 cycles

FORWARD ENTRY DOOR JAMB- WEB TAB CRACKED AFT SIDE OF DOOR JAMB STATION 208 LONGERON 15 LEFT. INSTALLED REPAIR STRAP PER AARD 53-10-00-11.

Part: SHROUD — BROKEN (CABIN) · airframe 55,218 hrs · 26,644 cycles

SEAT 12D EMERGENCY LIGHT SHROUD BROKEN. REPLACED SHROUD FOR SEAT 12D EMERGENCY LIGHT. OPS CHECK NORMAL.

Part: LENS — BROKEN (CABIN) · airframe 55,218 hrs · 26,644 cycles

THE 12D EMERGENCY LIGHT LENS BROKEN. REPLACED SEAT 12D EMERGENCY LIGHT LENS. OPS CHECK NORMAL.

Part: LIGHT — BROKEN (CABIN) · airframe 54,427 hrs · 26,288 cycles

PLASTIC EMERGENCY EXIT LIGHT COVER FROM FORWARD GALLEY FLOOR LIGHTING BROKEN. REMOVED AND REPLACED BROKEN EMERGENCY EXIT LIGHT.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 51,366 hrs · 24,756 cycles

LONGERON 2 LEFT CRACKED AFT OF STATION 1418. REMOVED DAMAGE AND INSTALLED LONGERON REPAIR PER SRM 53-02 FIGURE 18 AND EA MD80-53-013804.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 51,366 hrs · 24,756 cycles

LONGERON 20 IS CRACKED ABOVE INBOARD FLAP ACTUATOR RIGHT SIDE. REPAIRED LONGERON 20 PER AARD 53-10-00-18.

Part: AHRS — FAULTY (NR 1) · airframe 49,734 hrs · 23,962 cycles

DFW - INFLIGHT SJD-ORD. CAPTAIN REPORTED HIS NAVIGATION DISPLAY WAS NOT WORKING. EMERGENCY DECLARED FLIGHT DIVERTED DFW LANDED WITHOUT INCIDENT. FOUND NUMBER 1 HEADING HAD NUMBER 2 ATTITUDE FAILURES. REPLACED NUMBER 1 ATTITUDE HEADING REFERENCE SYSTEM UNIT. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: UNKNOWN — SMOKE (COCPKIT) · airframe 49,052 hrs · 23,642 cycles

CREW REPORTED AIRCRAFT LOAD SHOWED .7 LEFT NORMAL CENTER FUEL PRESSURE WARN ON FOR ABOUT 3 MINUTES THEN WENT OUT. CREW REPORTED ELECTRICAL BURNING SMELL AND THEN SMOKE IN COCKPIT AROUND THE THROTTLE QUADRANT AREA. RETURNED TO DFW AND LANDED WITHOUT INCIDENT. INSPECTED AND COULD NOT DUPLICATE. REPLACED AUTO THROTTLE SERVO M10-16 AS PRECAUTION.

Part: ACTUATOR — FAILED (LT MLG) · airframe 48,241 hrs · 23,293 cycles

DURING CLIMB AND GEAR RETRACTION THE AMBER GEAR DOOR OPEN LIGHT REMAINED ON AND LEFT MAIN INDICATOR WAS RED. GEAR LOWERED NORMALLY AND AIRCRAFT RETURNED TO BOSTON WITHOUT INCIDENT. REPLACED LEFT RETRACT ACTUATOR TO STRUT LINK. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: DUCT — DIRTY (CABIN) · airframe 47,653 hrs · 23,029 cycles

LFT - INFLIGHT FLL-DFW. CREW REPORTED ELECTRICAL SMOKE ODOR IN CABIN. EMERGENCY DECLARED, LANDED LFT WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. PERFORMED PACK AND HIGH PRESSURE PNEUMATIC DUCTING BURNOUT. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: FRAME — CRACKED (FUSELAGE) · airframe 47,494 hrs · 22,942 cycles

THE 1510 CANT FRAME CRACKED AT LOWER RIGHT HAND TAIL CONE ALIGNMENT. INSTALLED DOUBLER PER SRM 53-01-00 FIG 2 SHEET 3.

Part: FUEL FILTER — DIRTY (APU) · airframe 45,753 hrs

ORD INFLIGHT - AT TOP OF CLIMB RIGHT AND LEFT INLET FUEL PRESSURE LOW LIGHT ILLUMINATED INTERMITTENTLY. AFTER LEVEL OFF APU SHUT DOWN. NUMBER TWO ENGINE GENERATOR ON PLACARD. APU RESTARTED AT 10,000 FEET. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. REPLACED APU LOW PRESSURE FUEL FILTER AND APU COMBUSTION LINER. ALSO, REPLACED GENERATOR CONTROL UNIT AS A PRECAUTION. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: START VALVE — FAILED (NR 1 ENGINE) · airframe 45,725 hrs

DFW INFLIGHT - NUMBER ONE ENGINE START VALVE INDICATION. RETURNED TO DFW AND LANDED WITHOUT INCIDENT. REPLACED NUMBER ONE ENGINE START VALVE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: FLOOR PANEL — CORRODED (CABIN) · airframe 43,910 hrs · 21,407 cycles

TUL - FOUND CORROSION ON CABIN SUB FLOOR, AREA OF DISCREPANCY IS 18 BY 18 INCHES AT STATION 218. INSTALLED REPAIR DOUBLER PER AARD 53 20 00 16.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 43,514 hrs

LGA - EMERGENCY LIGHTS AT OVERHEAD SEAT ROWS 27 TO 29 INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS AT OVERHEAD SEAT ROWS 27 TO 29. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 43,514 hrs

LGA - EMERGENCY LIGHTS IN AFT CABIN INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS IN AFT CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 43,514 hrs

LGA - EMERGENCY LIGHTS AT OVERHEAD FIRST CLASS INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS AT OVERHEAD FIRST CLASS. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 43,514 hrs

LGA - EMERGENCY LIGHTS IN AFT CABIN INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS IN AFT CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 43,514 hrs

LGA - EMERGENCY EXIT SIGN LIGHTS AT OVERWING INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY EXIT SIGN LIGHTS AT OVERWING. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 43,514 hrs

LGA - EMERGENCY LIGHTS AT OVERHEAD FIRST CLASS INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS AT OVERHEAD FIRST CLASS. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SENSOR — DAMAGED (MLG)

GEAR UNSAFE LIGHT ILLUMINATED ON EXTENSION. DIFFICULTY MOVING EMERGENCY EXTENSION HANDLE. LANDED MSP WITHOUT INCIDENT. FOUND SMALL ROCK LODGED BETWEEN RIGHT MAIN LANDING GEAR DOWN LOCK SENSOR AND TARGET. SENSOR DAMAGED. REPLACED RIGHT MAIN LANDING GEAR DOWN LOCK SENSOR. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SWITCH — INOPERATIVE (RT A/C PACK)

AIRCRAFT UNABLE TO PRESSURIZE AT 29000 DURING CLIMB THE RIGHT PACK SHOWED 0 PSI AND CABIN SUPPLY TEMPERATURE GAUGE WAS PEGGED AT 150. THE LEFT PACK PRESSURE GAUGE SLOWLY REDUCED TO LESS THAN 10 PSI AND THE CABIN ALTITUDE CLIMBED THROUGH 10,000 TO JUST UNDER 15,000. AN EMERGENCY DESCENT WAS INITIATED WHEN THE CABIN ALTITUDE PASSED 10,000. LEVELED AT 14,000 AND THE PACKS BOTH CAME BACK ON. THE PACKS REMAINED BACK ON THROUGH THE LANDING AND TAXI BACK TO THE GATE. LANDED SJD WITHOUT INCIDENT. AIRCRAFT WAS FERRIED TO DFW. REPLACED LEFT AND RIGHT SINGLE ENGINE SECOND SEGMENT PRESSURE SWITCHES. REPLACED OXYGEN MASKS AND CANISTERS. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

SFO OVERHEAD EMERGENCY LIGHTS AT ROWS 23, 24B, AND 26 INOPERATIVE. REPLACED BATTERY PACK FOR OVERHEAD EMERGENCY LIGHTS AT ROWS 23, 24B, AND 26. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: WIRE — SHORTED (EMERGENCY LIGHTS)

EMERGENCY EXIT LIGHTS AT SEAT 20D AND BACK INOPERATIVE. FOUND WIRE SHORTED AT 280. REPLACED LIGHT ASSEMBLY FOR EMERGENCY EXIT LIGHTS AT SEAT 20D AND BACK. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (CABIN)

PHX - EMERGENCY LIGHT AT AFT FLIGHT ATTENDANT POSITION INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHT AT AFT FLIGHT ATTENDANT POSITION. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: APU — LEAKING (APU BAY) · airframe 31,141 hrs · 15,658 cycles

CREW REPORTED HAZE IN CABIN AND HAD ODOR, MOST NOTICEABLE ON THE GROUND. REPLACED THE APU DUE TO INTERNAL OIL LEAK. CHECK-C 9-11-02 STL.

Part: ACM — OVERSERVICED (LEFT) · airframe 30,894 hrs · 15,510 cycles

DURING PREFLIGHT SMOKE IN CABIN DUE TO OVERSERVICE OF AIR CONDITIONING PRESSURIZATION LT ACM. REPLACED LT ACM PER MM 21-51-01 AND COMPLETED MD9-49-06. CHECK-C 9-11-02 STL.

Part: LAMP · airframe 30,696 hrs · 15,394 cycles

THE EGRESS LIGHTS WERE INOPERATIVE AT CABIN ROWS 6-7. REPLACED THE LAMP AT SEAT 6. CHECK-C 9-11-02 STL. --CLOSED--

Part: BRAKE ASSY — CONTAMINATED (MLG) · airframe 30,515 hrs · 15,291 cycles

DURING LANDING ROLL ANOTHER AC REPORTED SMOKE FROM LEFT GEAR AREA. SMOKE QUICKLY DISSIPATED NO EVIDENCE OF HYD FLUID ON GEAR. FIRE DEPT CALLED AS PRECAUTION. NO SYS FAULTED BUT EVIDENCE OF ICE-DEICE FLUID RESTING ON NR 1 BRAKE ASSY AND STRUT. REMOVED ICE. BRAKE OPS WAS NORMAL. CHECK-C STL 9-11-02.

Part: BATTERY — DISCHARGED (CABIN) · airframe 30,311 hrs · 15,181 cycles

DEPLETED BATTERIES IN EMERGENCY LIGHTING. REPLACED BATTERIES AND CHECKS MADE PER MM33-59-00.

Part: ODOR — DETECTED (CABIN) · airframe 29,538 hrs · 14,721 cycles

A VERY STRONG FUEL ODOR WAS REPORTED IN COCKPIT AND SLIGHTLY IN C ABIN. FLIGHT RETURNED TO STL. UNABLE TO FIND ANY FUEL LEAK. CHANGED THE WATER SEPERATORS AND ACCOMPLISHED A PACK BURN OUT TO ELIMINATE THE ODOR.

Part: MODULE · airframe 27,858 hrs · 13,680 cycles

THE EGRESS LIGHTS WERE INOPERATIVE AT ROWS 7, 8, 9, 19, 27, 29, AND 31. REPLACED THE LAMP ASSEMBLY/MODULE AT EACH LOCATION. CHECK-C 9-10-01 STL. --CLOSED--

Part: BELTFRAME — CRACKED (FUSELAGE) · airframe 26,939 hrs · 13,154 cycles

DURING CHECK-C MAINT THE BELT RING AT STATION, 1418 LONGERON 2L, HAD A .5 INCH CRACK. BELT RING REPAIRED PER ARA 17916, AND SRM 53-20.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 26,939 hrs · 13,154 cycles

DURING CHECK-C MAINT THE NUMBER 2L LONGERON WAS CRACKED ABOVE THE Y DUCT ALONG LONGERON END. REPLACED LONGERON SECTION PER SRM 53-02.

Part: MOUNT BRACKET — CRACKED (CARGO DOORWAY) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT THE AFT CARGO DOOR, AFT SIDE, THE SECOND FROM TOP AND UPPER DOOR STOP MOUNT BRACKETS WERE CRACKED. REPLACED BOTH BRACKETS PER SPM 6-70-01.

Part: WEB — CORRODED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT CORROSION WAS FOUND ON MEMBRANE AT LONGERON 18R, BETWEEN STA 636 TO 653. REMOVED CORRODED SECTION OF MEMBRANE AND INSTALLED DOUBLER PER SRM 53-01, FIG 4.

Part: WEB — CORRODED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT ON RT SIDE OF CABIN FLOOR, CORROSION WAS BETWEEN STA 617 TO 636 ON FLOOR MEMBRANE AT LONGERON 18R. REMOVED CORRODED SECTION OF MEMBRANE AND INSTALLED DOUBLER PER SRM 53-01, FIG 4.

Part: CARGO TRACK — CORRODED (AFT CARGO BAY) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT THE SLANTED SIDE WALL ATTACH FLANGE ON AFT CARGO BIN RT FLOOR TIE DOWN FROM STA 1111 TO 1155 WAS CORRODED. REPLACED TIE DOWN TRACK FROM STA 1111 TO 1155 PER SRM 53-05, PAGE 10R FIG 4G.

Part: CARGO TRACK — CORRODED (AFT CARGO BAY) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT IN AFT CARGO BIN, SLANT SIDE LINING ATTACH FLANGE ON THE LT CARGO BIN FLOOR TIE DOWN WAS CORRODED FROM STA 1117 TO 1174. REPAIRED TRACK PER SRM 53-05, FIG 4G. PRIMED AND SEALED PER SRM 51-10-05.

Part: BRACKET — CRACKED (CARGO DOORWAY) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT THE MID CARGO DOOR, FWD SIDE, THE TOP AND BOTTOM DOOR STOP BRACKETS WERE CRACKED. REPLACED BOTH BRACKETS PER SRM 51-34-5 AND DRAWING 5910141.

Part: WEB — CORRODED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT CABIN MEMBRANE WAS CORRODED AT STA 503 TO 597, RT SIDE CABIN FLOOR AT STA 18R AREA. REMOVED CORROSION PER SPM 6-80-01. REPAIRED MEMBRANE PER SRM 53-01 FIG 4 SHEET 3 FIG 7. INSTALLED RIVETS PER SRM 51-30-02. REPAIR MATERIAL 7975-T6, 0.020 MATERIAL.

Part: DOOR FRAME — CORRODED (FWD SERVICE DOOR) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT THE FWD SERVICE DOOR, CORROSION WAS FOUND AT DOOR FRAME OPENING AT LOWER FWD CORNER, STA 160, APPROX RBL 58 INCHES. REMOVED CORROSION PER SPM 6-80-01. TREATED AND PAINTED PER SRM 51-10-32. INSTALLED REMOVED FASTENERS PER SRM 51-30.

Part: BRACKET — CRACKED (CARGO DOORWAY) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT ON THE AFT CARGO DOOR FWD SIDE, THE UPPER AND SECOND FROM TOP DOOR STOP BRACKETS WERE CRACKED. REPLACED BOTH BRACKETS PER SPM 6-70-01.

Part: CASTING — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT AT STA 845, LBL 58, CASTING WAS CRACKED BELOW FLOOR AT FUSELAGE FORMER TO FLOORBEAM TIE, LT. INSTALLED NEW CASTING PER DOUGLAS DRAWING 3920341 AND SPM 6-70-01. INSTALLED HI-LOKS PER SRM 51-60-0 PAGE 36 FIG 4 PIN SUBSTITUTION TABLE AND PER SRM 51-3-0 PAGE 12 HI-LOK INSTALLATION. TORQUED HI-LOKS PER SRM 51-30-1 PAGE 11 TO 13.

Part: WEB — CORRODED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT FOUND CORROSION ON DIAPHRAM STA 448 TO 503, RT SIDE AT STRINGER 18. REPAIRED MEMBRANE PER SRM 53-01, PAGE 18.

Part: WEB — PUNCTURED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT FOUND HOLE IN MEMBRANE UNDER LAV TIE DOWN, STA 200 AND LBL 44 INCHES. REMOVED TORN EDGE OF PUNCTURE TO 1/2 IN DIAMETER HOLE. INSTALLED REPAIR DOUBLER AROUND HOLE PER SRM 53-01, FIG 4.

Part: STOP FITTING — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT ON THE FWD SIDE OF THE FWD CARGO DOOR, TWO DOOR STOP SUPPORT BRACKETS WERE CRACKED. REPLACED CASTINGS PER DRAWING 4920233. INSTALLED NEW FASTENERS AND HARDWARE PER SRM 51-30.

Part: CASTING — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT FOUND IN MID CABIN, STA 864 AND RBL 58 INCHES, CASTING CRACKED BELOW FLOOR AT FUSELAGE FORMER TO FLOOR BEAM TIE RT. INSTALLED NEW FITTING PER SRM 51-30-5.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT FOUND CORROSION ON NR 1 CHAIR TRACK, LBL 54 INCHES, FROM STA 1041 TO 1090. REPLACED TRACK PER SPM 6-70-01, FROM STA 1003 TO 1136.

Part: CASTING — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT FOUND IN MID CABIN AT STA 905, LBL 58 INCHES, CASTING CRACKED BELOW FLOOR AT FUSELAGE FORMER TO FLOOR BEAM TIE, LT. REPLACED BRACKET PER SRM 51-30-5 AND SRM 51-60-0.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT TRACK LBL 22 INCHES WAS CORRODED AT STA 1155 TO 1231, TRACK LBL 22 IN WAS CORRODED AT STA 1260 TO 1276, AND CORROSION WAS FOUND ON NUMBER 3 TRACK 22 INCHES LBL STA 1090 TO 1155. REMOVED AND REPLACED CHAIR TRACK FROM STA 1089 TO 1307, AND SLICED NEW TRACK AT STA 1089 PER SRM 53-05 FIG 4F.

Part: SEAT TRACK — DAMAGED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT CORROSION WAS FOUND ON FLOOR TRACK NUMBER 2 AND FLOOR PANEL ATTACH LUGS BROKEN OFF, NUMBER 2 TRACK OTBD SIDE STA 1146 TO STA 1166. REPLACED CHAIR TRACK NUMBER 2 FROM STA 1032 TO 1221 PER SPM 6-70-01.

Part: WEB — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT FOUND MEMBRANE CRACKED OUT AROUND LIGHTNING HOLES AND BRACKET LOOSE AT INBD ATTACH AREA, LT SIDE BETWEEN STA 1294 AND 1301, STRINGER 18. REMOVED DAMAGE PER SRM 53-05 PAGE 345 VIEW B. REPAIRED WITH DOUBLER SRO 9530189-3 PER SRM 53-05, PAGE 345 TO 359.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT A T-ANGLE WAS CRACKED AT STA 807, LONGERON 16R. FABRICATED AND INSTALLED NEW T-ANGLE PER SPM 6-70-01 PAGE 2 AND 3, AND DRAWING 291387-1.

Part: CASTING — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT, AT STA 905, RBL 58 INCHES, A CASTING WAS CRACKED BELOW FLOOR AT FUSELAGE FORMER TO FLOOR BEAM TIE, RT SIDE. REPLACE BRACKET PER SRM 51-60-0 AND 51-30-5.

Part: CHANNEL — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT FOUND ON RT WING A CRACK AT FWD INBD SECTION OF CHANNEL AT FWD WHEEL WELL OPENING. FABRICATED DOUBLER PER SRM 53-14-3 FIG 2 AND SRM 53-01 FIG 2. SEALED AND INSTALLED WITH AD RIVETS AND HI-LOKS PER 51-30-3 AND SRM 51-30-5.

Part: WEB — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT THE WEB WAS CRACKED AT STA 1309 TO 1322, RBL 58 INCHES. INSTALLED REPAIR PER SRM 53-05, PAGE 317. PAINTED PER SRM 51-10-05.

Part: SKIN — CORRODED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT THE FWD CARGO DOOR JAMB HAD CORROSION UNDER THE SCUFF PLATE, AIRCRAFT OUTER SKIN FROM LONGERON 28 TO 26, AND FROM STA 370 TO 427. REMOVED SURFACE CORROSION PER SPM 6-80-01.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT THE FLOOR SUPPORT BRACKET WAS CRACKED AT STA 370, RBL 4 INCHES. REPLACED SUPPORT BRACKET PER SRM 51-30-2.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 25,057 hrs · 12,178 cycles

DURING CHECK-C MAINT STATION 1155 FLOOR BEAM CAP HAD CORRODED FROM 22 INCHES LBL TO 44 IN LBL. FABRICATED NEW PART PER SAMPLE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 24,869 hrs · 12,070 cycles

THE EGRESS LIGHTS WERE INOPERATIVE AT THE FWD GALLEY, SEAT ROWS 8D, 15D, 21D AND THE LAST RED LIGHT. REPLACED MODULES 0105606-002, 0105606-003, AND 0105606-004. ALSO REPLACED LAMP (P/N 7732). CHECK-C 9-25-99 STL.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 24,790 hrs · 12,027 cycles

THE EMERGENCY LIGHTS WERE INOPERATIVE AT THE AFT ENTRY DOOR AND IN THE AFT AIRSTAIR. REPLACED THE POWER SUPPLY. CHECK-C 9-25-99 STL.

Part: LIGHT — FAILED (ROW 29) · airframe 24,425 hrs · 11,819 cycles

THE ESCAPE PATH LIGHTING WAS INOPERATIVE AT CABIN ROW 29. REPAIRED WIRING AND REPLACED BULBS. CHECK-C 9-25-99 STL.

Part: COVER — LOOSE (CABIN) · airframe 23,957 hrs · 11,560 cycles

FLIGHT CALLED INBOUND PLASTIC COVER CAME OFF OF EGRESS LIGHT STRIP. REPLACED COVER. AC03 05-20-00 JFK.

Part: BATTERY — INOPERATIVE (COCKPIT) · airframe 23,577 hrs · 11,356 cycles

THE OVERHEAD EMERGENCY LIGHT IN THE COCKPIT WAS INOPERATIVE. REPLACED THE BATTERIES. CHECK-C 9-25-99 STL.

Part: LIGHT — FAILED (ROW 19 & 24)

THE CABIN EGRESS LIGHTS WERE INOPERATIVE AT ROW ONE, FORWARD LT CABIN DOOR, ROW 19 AND ROW 24. REPLACED THE WIRE SEGMENTS AT EACH LOCATION. CHECK-C 9-25-99 STL.

Part: POWER SUPPLY — DISCHARGED (ROW 8DEF)

THE EMERGENCY LIGHTS WERE INOPERATIVE AT SEAT ROWS 8, 9, AND 10. REPLACED THE POWER SUPPLY. CHECK-C 9-1-99 STL.

Part: WIRE — BROKEN (ROW 25)

THE EGRESS LIGHTS WOULD NOT COME ON FROM CABIN ROW 25 TO THE AFT CABIN DOORS. REPLACED BROKEN POWER WIRES IN THE TRACK. CHECK-C 11-3-98 MCI.

Part: LAMP — FAILED (ROW 9-22-27-28)

THE EGRESS LIGHTS WERE INOPERATIVE AT CABIN ROWS 9, 22, 27, AND 28. REPLACED THE LAMP FOR EACH OF THE INOPERATIVE LIGHTS. CHECK-C 11-3-98 MCI.

Part: LAMP — FAILED (CABIN)

STL - DURING MAINTENANCE CHECK, FOUND EGRESS LIGHTS BURNED OUT AT ROWS 1, 4, 5, 22, 25, 28, AND 30. REPLACED LAMPS. CHECK-C 11-6-97 LAX. (X)

Part: PT2 LINE — LOOSE (NR 2 ENGINE)

LAS - FLT 501 - DURING CLIMB, THE NR 2 ENGINE, S/N 1405, LOST POWER. THE PT2 LINE WAS FOUND LOOSE, RESECURED LINE. OPERATIONAL CHECKS AND ENGINE RUN NORMAL. (M)

Part: PUMPS — OUT OF HIGH MODE (HYD SYSTEM)

STL - DURING APPROACH, NOSE LANDING GEAR FAILED TO FULLY EXTEND. FLIGHT CREW REPORTED HYDRAULIC PUMPS WERE NOT IN THE HIGH MODE. AIRCRAFT WAS JACKED AND NUMEROUS GEAR SWINGS PERFORMED. NOSE GEAR TRUNNION WERE LUBE AND INSPECTION. FUNCTIONAL CHECKS NORMAL. (M)

Part: TRANSDUCER PINS — LOOSE (BRAKE SYSTEM)

SEA - FLT 350 - DURING THE TAKEOFF ROLL AT APPROXIMATELY 40 KNOTS, THE 'WHEEL NOT TURNING' LIGHT ILLUMINATED. THE TAKEOFF WAS ABORTED. REINSTALLED TRANSDUCER PINS. OPERATIONAL CHECK AND BITE CHECK NORMAL. CHECK C-1D - 11/3/95 - JFK.