N963TW

Part: PUMP — FAILED (HYD SYSTEM) · airframe 53,540 hrs · 26,654 cycles

DURING APPROACH, THE A HYDRAULIC SYSTEM WARNING . DECLARED EMERGENCY AND LANDED WITHOUT INCIDENT. THE RT ENGINE HYDRAULIC PUMP HAD FAILED. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPLACED THE HYDRAULIC PUMP IAW MM 29-10-05.

Part: PSEU — FAULTY (NLG) · airframe 52,993 hrs · 26,326 cycles

NOSE GEAR WOULD NOT RETRACT ON TAKE OFF. EMERGENCY DELCARED AND FLIGHT RETURNED TO RDU. LANDED WITHOUT INCIDENT. AIRCRAFT WAS GROUNDED. TROUBLESHOT NOSE GEAR IAW CARD 32-96-16, NO DEFECTS NOTED. CYCLED THE NOSE GEAR SEVERAL TIMES, GROUND CHECKED GOOD. REPLACED THE PROXIMITY SWITCH ELECTRONIC UNIT IAW AMM 32-60-04, ALL CHECKED NORMAL. ACFT OK FOR SERVICE.

Part: BEAM — CRACKED (BS 160-218) · airframe 52,858 hrs · 26,228 cycles

FORWARD ENTRY DOOR, NR 6 BEAM HAD A CRACK AT THE CENTER BEAM AREA. INSTALLED A REPAIRED DOUBLER IAW 52-10-00-03.

Part: SKIN — CRACKED (BS 100-110) · airframe 52,858 hrs · 26,228 cycles

FUSELAGE SKIN CRACKED ABOVE THE AFT NOSE LANDING GEAR DOOR. REPAIRED THE SKIN IAW SRM 53-05-00, FIGURE 158.

Part: COVER — MISSING (EMERGENCY LIGHT) · airframe 52,518 hrs · 26,006 cycles

FORWARD GALLEY DOOR EMERGENCY EXIT SIGN PLASTIC COVER MISSING. REPLACED THE COVER IAW MM 33-53-01.

Part: PIN — DISLODGED (SERVICE DOOR) · airframe 52,481 hrs · 25,984 cycles

AFT SERVICE DOOR HAD A GUIDE PIN DISLODGED WITH SPRING MECHANISM ON DOOR CATCH FOR DOOR BAYONETTE. MAINTENANCE REPLACED THE UPPER AND LOWER LINKS THAT HOLD GUIDE PIN IN PLACE ON THE SPRING MECHANISM OF AFT SERVICE DOOR IAW AMM 52-40-05 AND PERFORMED SATISFACTORY OPERATIONAL CHECK.

Part: PIN — DISLODGED (SERVICE DOOR) · airframe 52,481 hrs · 25,984 cycles

AFT SERVICE DOOR HAD GUIDE PIN DISLODGED WITH SPRING MECHANISM ON DOOR CATCH FOR DOOR BAYONETTE. MAINTENANCE REPLACED UPPER AND LOWER LINKS THAT HOLD GUIDE PIN IN PLACE ON THE SPRING MECHANISM OF AFT SERVICE DOOR IAW AMM 52-40-05 AND PERFORMED SATISFACTORY OPERATIONAL CHECK.

Part: WINDOW — DELAMINATED (L1) · airframe 52,481 hrs · 25,984 cycles

THE L1 WINDOW WAS FOUND DELAMINATED, 3 INCHES. REPLACED THE L1 WINDOW IAW AMM 56-10-01, LEAK CHECKED GOOD.

Part: SWITCH — FAULTY (FUEL SYSTEM) · airframe 51,996 hrs · 25,695 cycles

AIRCRAFT WAS GROUNDED: AFTER TAKEOFF CENTER FUEL PRESSURE LOW LIGHT ILLUMINATED. FOLLOWED QUICK REFERENCE HANDBOOK PROCEDURE. EMERGENCY WAS DECLARED AND FLIGHT RETURNED TO DFW WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED FORWARD CENTER PUMP SWITCH AND PERFORMED SATISFACTORY OPERATIONAL CHECK.

Part: SPRING — BROKEN (SERVICE DOOR) · airframe 51,888 hrs · 25,625 cycles

AIRCRAFT WAS NOT GROUNDED. AFT SERVICE DOOR GUST LOCK SPRING BROKEN. REMOVED & REPLACED SPRING IAW MM 52-42-01.

Part: GIRT BAR — INADEQUATE (R1 DOOR) · airframe 51,778 hrs · 25,560 cycles

R1 DOOR SLIDE GIRT BAR FLAP NOT FOLDED PROPERLY. REPLACED R1 DOOR SLIDE IAW AMM 25-62-00. OPERATIONS CHECK GOOD.

Part: SPRING — BROKEN (L2 DOOR) · airframe 51,424 hrs · 25,323 cycles

L2 DOOR HAS A BROKEN SPRING. REPLACED THE SPRING IAW AMM 20-10-01. OPS CHECKED GOOD. THE AIRCRAFT WAS GROUNDED.

Part: FLASHLIGHT — INOPERATIVE (CABIN) · airframe 50,812 hrs · 24,938 cycles

AIRCRAFT WAS NOT GROUNDED. FLIGHT ATTENDANT EMERGENCY LED FLASHLIGHT BY THE L1 DOOR DOES NOT BLINK. REMOVED AND REPLACED FLASHLIGHT ASSEMBLY PER AMM 25-60-00. OPERATIONAL CHECK GOOD.

Part: CHANNEL — CRACKED (MLG DOOR FRAME) · airframe 50,572 hrs · 24,780 cycles

CRACK IN MAIN LANDING GEAR DOOR FRAME CHANNEL IN RIGHT WHEEL WELL. REPAIRED THE DOOR FRAME CHANNEL IAW 53-10-00-10.

Part: SWITCH — DEFECTIVE (COCKPIT) · airframe 50,209 hrs · 24,536 cycles

AFTER INITIAL GEAR RETRACTION ALL RED UNSAFE LIGHTS REMAINED ILLUMINATED WITH GEAR HANDLE UP. RECYCLED GEAR PER QRH PROCEDURE AND RED LIGHTS REMAINED ON. AS WE CONTINUED CHECK LIST, RED LIGHTS WENT OUT. CONTINUED CLIMB TO CRUISE ALL RED LIGHTS FLICKERED AND CAME ON BRIEFLY, THEN WENT OUT. WITH DISPATCH AND MAINTENANCE CONCURRENCE, CONTINUED TO DFW WHERE THE FLIGHT LANDED WITHOUT FURTHER INCIDENT. FOUND GEAR HANDLE SWITCH S1-89 BAD. REMOVED AND REPLACED SWITCH S1-89 IAW AMM 32-60-01 OPS CKS GOOD. ON GEAR SWING ALL INDICATIONS WORKED NORMAL. THE AIRCRAFT WAS GROUNDED.

Part: CONTROLLER — FAULTY (CABIN PRESSURE) · airframe 50,171 hrs · 24,517 cycles

BOTH PACK PRESSURE GAUGES WENT TO 0 AT 26,000. AUTO 1 AND 2 INOP LIGHTS AND AUTO INOP LIGHT ILLUMINATED. DECLARED AN EMERGENCY, PERFORMED RAPID DESCENT. WITH OUTFLOW VALVE FULLY CLOSED, CABIN STILL CLIMBING GREATER THAN 1500 FPM. THE FLIGHT DIVERTED TO MCI AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED BOTH CABIN PRESSURE CONTROLLERS AND OPERATIONALLY CHECKED GOOD IAW AMM 21-32-03. THE AIRCRAFT WAS GROUNDED.

Part: POWER SUPPLY — NO TEST (EMERGENCY LIGHT) · airframe 50,058 hrs · 24,448 cycles

RIGHT FORWARD OVERWING EMERGENCY EXIT MARKER FAILED TEST. REMOVED AND REPLACED BATTERY PACK AND POWER SUPPLY IAW AMM 33-60-98. OPERATIONAL CHECKED GOOD.

Part: BATTERY PACK — NO TEST (EMERGENCY LIGHT) · airframe 50,058 hrs · 24,448 cycles

RIGHT FORWARD OVERWING EMERGENCY EXIT MARKER FAILED TEST. REMOVED AND REPLACED THE BATTERY PACK AND POWER SUPPLY IAW AMM 33-60-98. OPERATIONAL CHECKED GOOD.

Part: BATTERY — FAILED (EMERGENCY LIGHTS) · airframe 50,058 hrs · 24,448 cycles

OVERHEAD EMERGENCY EXIT LIGHTS BY THE AFT FLIGHT ATTENDANT STATION CAME ON WHEN EXTERNAL POWER WAS DISCONNECTED. REMOVED AND REPLACED THE BATTERY ASSEMBLY B5-10-1 IAW AMM 33-53-00. OPERATIONAL CHECKED GOOD.

Part: BATTERY — NO TEST (EMERGENCY LIGHTS) · airframe 50,058 hrs · 24,448 cycles

EMERGENCY LIGHTS IN THE TAIL COMPARTMENT FAILED TEST. REMOVED AND REPLACED THE BATTERY ASSEMBLY IAW AMM 33-53-00. OPERATIONAL CHECKED GOOD.

Part: BATTERY — NO TEST (EMERGENCY LIGHTS) · airframe 50,058 hrs · 24,448 cycles

EMERGENCY EXIT LIGHTS IN THE TAIL COMPARTMENT FAILED TEST. REMOVED AND REPLACED THE BATTERY ASSEMBLY IAW AMM 33-53-00. OPERATIONAL CHECKED GOOD.

Part: OUTLET — FAULTY (CABIN) · airframe 49,856 hrs · 24,325 cycles

AIRCRAFT WAS NOT GROUNDED. PASSENGER IN SEAT 4F REPORTED HEARING A POP AND SMELLING ELECTRIC ODOR NEAR THE SIDEWALL. REMOVED AND REPLACED POWER PORT OUTLET UNIT AT SEAT 4F IAW AMM 25-23-00. OPERATIONAL CHECK GOOD.

Part: HOSE — SPLIT (ZONE 200) · airframe 49,699 hrs · 24,224 cycles

AIRCRAFT WAS GROUNDED. ORD-TPA FLIGHT RETURNED TO ORD ACCOUNT UNABLE TO PRESSURIZE AT 5000 FEET. LANDING UNEVENTFUL. REMOVED AND REPLACED COOLING TURBINE OUTLET HOSE AND CLAMPS(AALA20170118011) IAW AMM 21-51-00. OPERATIONAL CHECK GOOD.

Part: CLAMP — BROKEN (AC BAY) · airframe 49,699 hrs · 24,224 cycles

AIRCRAFT WAS GROUNDED. ORD-TPA FLIGHT RETURNED TO ORD ACCOUNT UNABLE TO PRESSURIZE AT 5000 FEET. LANDING UNEVENTFUL. REMOVED AND REPLACED COOLING TURBINE OUTLET HOSE (AALA20170114004) AND CLAMPS IAW AMM 21-51-00. OPERATIONAL CHECK GOOD.

Part: SWITCH — FAULTY (ZONE 200) · airframe 49,681 hrs · 24,214 cycles

AIRCRAFT WAS GROUNDED. EMERGENCY DECLARED. PRIOR TO ARRIVAL, THE CREW REPORTED THREE UNSAFE LANDING GEAR LIGHTS DURING LANDING GEAR RETRACTION. CREW RECYCLED GEAR AND LANDED WITHOUT INCIDENT. REMOVED AND REPLACED PROXIMITY SWITCH CONTROL ASSEMBLY IAW AMM 32-60-04. OPERATIONAL CHECK GOOD.

Part: BATTERY — DISCHARGED (CABIN) · airframe 49,537 hrs · 24,127 cycles

AIRCRAFT IN BASE MAINTENANCE. EMERGENCY PATHWAY LIGHTING FROM FUSELAGE STATION 243 TO 500 FAILED TEST. REMOVED AND REPLACED BATTERY ASSEMBLY. OPERATIONAL CHECK GOOD.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 49,537 hrs · 24,127 cycles

AIRCRAFT IN BASE MAINTENANCE. FORWARD CARGO DOOR AFT LOWER STOP PAD FITTING IS CRACKED. INSTALLED STOP PAD FITTING IAW AARD 51-00-05-1 AND DRAWING 5910141.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 49,537 hrs · 24,127 cycles

AIRCRAFT IN BASE MAINTENANCE. AFT CARGO DOOR AFT UPPER STOP PAD FITTING IS CRACKED. INSTALLED STOP PAD FITTING IAW AARD 51-00-05-1 AND DRAWING 5910141.

Part: BATTERY — DISCHARGED (CABIN) · airframe 49,537 hrs · 24,127 cycles

AIRCRAFT WAS IN BASE MAINTENANCE. EMERGENCY BATTERY ASSEMBLY B5-107 FAILED TEST. REMOVED AND REPLACED BATTERY ASSEMBLY IAW AMM 33-53-00.

Part: DOUBLER — CORRODED (BS 1312) · corrosion level 2 · airframe 49,537 hrs · 24,127 cycles

CORROSION ON INTERNAL ALUMINUM DOUBLER AT LOWER FORWARD CORNER AT AFT LAVATORY SERVICE PAN BS 1312. REMOVED CORROSION AND REPLACED DOUBLER IAW SRM 51-10-03 AND EA 265985.

Part: O-RING — LEAKING (APU) · airframe 47,614 hrs · 22,954 cycles

AIRCRAFT WAS GNDED. FUEL SMELL REPORTED IN ACFT CABIN. FOUND APU FUEL HEATER LEAKING AT BOTH END FITTING. R & R HEATER FITTING O RINGS IAW AMM 49-31-01. LEAK CHECKED GOOD.

Part: PUMP — INOPERATIVE (FUEL SYSTEM) · airframe 47,285 hrs · 2,250 cycles

AIRCRAFT WAS GNDED. AIR INTERRUPT, EMER DECLARED, LANDING UNEVENTFUL & ACFT NOT OVERWEIGHT. DURING CRUISE CTR TANK BOOST PUMP BECAME INOPERATIVE. R & R, OPERATIONALLY CHECKED THE CTR TANK FWD & AFT BOOST PUMPS IAW AMM 28-20-07-201. SEE ALSO AALA20151219005.

Part: PUMP — FAULTY (FUEL SYSTEM) · airframe 47,285 hrs · 22,750 cycles

AIRCRAFT WAS GNDED. AIR INTERRUPT, EMER DECLARED, LANDING UNEVENTFUL & ACFT NOT OVERWEIGHT. DURING CRUISE CTR TANK BOOST PUMP BECAME INOPERATIVE. R & R, OPERATIONALLY CHECKED THE CTR TANK FWD & AFT BOOST PUMPS IAW AMM 28-20-07-201. SEE ALSO AALA20151223004.

Part: UFI — FAULTY (FUEL SYSTEM) · airframe 47,022 hrs · 22,586 cycles

AIR INTERRUPT, EMER DECLARED, LANDING UNEVENTFUL & ACFT NOT OVERWEIGHT. DURING CRUISE, RECEIVED CTR TANK LOW FUEL PRESS INDICATION & FUEL WOULD NOT FEED FROM TANK. R & R CTR TANK FWD & AFT UNIVERSAL FAULT INTERRUPTER ASSEMBLIES IAW AMM 28-20-28. SYS CHECKED NORMAL. SEE ALSO AALA20151105006.

Part: UFI — FAULTY (FUEL SYSTEM) · airframe 47,022 hrs · 22,586 cycles

AIR INTERRUPT, EMER DECLARED, LANDING UNEVENTFUL & ACFT NOT OVERWEIGHT. DURING CRUISE, RECEIVED CTR TANK LOW FUEL PRESS INDICATION & FUEL WOULD NOT FEED FROM TANK. R & R CTR TANK FWD & AFT UNIVERSAL FAULT INTERRUPTER ASSEMBLIES IAW AMM 28-20-28. SYS CHECKED NORMAL. SEE ALSO AALA20151103016.

Part: PRESSURE SWITCH — MALFUNCTIONED (FUEL) · airframe 46,652 hrs · 22,349 cycles

DURING CLIMB THE CTR FUEL PRESS LOW LIGHT ILLUMINATED. AIR INTERRUPT, EMERGENCY NOT DECLARED, LANDING UNEVENTFUL. R & R FWD CENTER FUEL PRESSURE SWITCH IAW AMM 28-41-01. OPS & LEAK CHECKED OK.

Part: BRACKET — CRACKED (FUSELAGE) · airframe 46,360 hrs · 22,168 cycles

MID CARGO COMPARTMENT BRACKET AT AFT OTBD END OF RT TIE DOWN TRACK IS CRACKED AT FS 788. R & R BRACKET IAW AARD 51-00-05-1 & DWG 5956034.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 46,360 hrs · 22,168 cycles

CUSP UNDER SEAT TRACK NR 6 IS CORRODED AT FS 215. INSTALLED DOUBLER 2" X 1" IAW AARD 53-20-00.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 46,360 hrs · 22,168 cycles

CUSP UNDER SEAT TRACK NR 4 IS CORRODED AT FS 218. INSTALLED DOUBLER IAW AARD 53-20-00.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 46,360 hrs · 22,168 cycles

NUMBER 6 SEAT TRACK IS CORRODED BETWEEN FS 215 & 304. R & R SEAT TRACK SECTION IAW SRM 53-05-00-001 FIGURE 4.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 46,360 hrs · 22,168 cycles

NUMBER 4 SEAT TRACK IS CORRODED BETWEEN FS 200 & 256. R & R SEAT TRACK SECTION IAW SRM 53-05-00 & MPSM 09-01-62.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 46,360 hrs · 22,168 cycles

SUB FLOOR AT FWD SERVICE DOOR AREA, RBL 54.5, IS CORRODED AT FS 215. REMOVED DAMAGE & INSTALLED DOUBLER IAW AARD 53-20-00-16.

Part: FRAME — CRACKED (FUSELAGE) · airframe 46,360 hrs · 22,168 cycles

FRAME CRACKED AT STATION 1401 & LONGERON 1. INSTALLED DOUBLER IAW AARD 53-10-00-17.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 46,360 hrs · 22,168 cycles

CRACK IN THE LONGERON 20L AT FS 993. STOP DRILLED CRACK & INSTALLED AN EXTERNAL DOUBLER IAW AARD 53-10-00-18.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 46,360 hrs · 22,168 cycles

AFT CARGO COMPARTMENT RT TIE DOWN TRACK IS CORRODED BETWEEN STATIONS 1117 & 1155. R & R TIE DOWN TRACK FROM 1117 TO 1155 IAW SRM 51-01-00-001.

Part: PORTABLE LIGHT — MISSING (CABIN) · airframe 46,218 hrs · 22,083 cycles

L1 DOOR PORTABLE EMER LIGHT UPPER MOUNT IS MISSING. REPLACED L1 DOOR EMER LIGHT IAW AMM 33-53-00. SYS CHECKED NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 45,183 hrs · 21,502 cycles

EMERGENCY LIGHTS IN FWD GALLEY AREA INOPERATIVE. REPLACED BATTERY PACK IAW MM 33-53-00. OPERATIONS CHECKED GOOD.

Part: CONTROL MODULE — FAILED (CABIN) · airframe 45,183 hrs · 21,502 cycles

ESCAPE PATH SYS CAME ON WHEN FLIGHT ATTENDANT SWITCH MOVED TO THE ON POSITION. PROPER OPERATION REQUIRES SWITCH BE MOVED TO ARM & THEN RELEASED TO THE ON POSITION. REPLACED AISLE PATH LIGHTING CONTROL MODULE IAW AMM 20-20-01. OPERATIONS CHECKED GOOD.

Part: SUPPORT RIB — CRACKED (RT WING) · airframe 43,413 hrs · 20,583 cycles

RIGHT WING NR 4 SLAT TRACK INBD SUPPORT RIB CRACKED. INSTALLED REPAIR DOUBLER IAW MCM CARD 57-98-06 & EA MD 80-57-034991.

Part: SUPPORT RIB — CRACKED (LT WING) · airframe 43,413 hrs · 20,583 cycles

LEFT NR 4 SLAT TRACK INBD SUPPORT RIB CRACKED. INSTALLED DOUBLER REPAIR IAW MCM CARD 57-98-05 & EA MD80-57-034736.

Part: CASTING — CRACKED (LT SPOILER) · airframe 43,413 hrs · 20,583 cycles

LEFT WING GND SPOILER CTR CASTING IS CRACKED AT FWD OTBD ACTUATOR MOUNT. INSTALLED NEW GND SPOILER CASTING IAW AARD 51-00-05-1.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 43,413 hrs · 20,583 cycles

CARGO DOOR FWD SIDE, LOWER STOP PAD FITTING CRACKED. INSTALLED NEW STOP PAD FITTING IAW AARD 51-00-05-1.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 43,413 hrs · 20,583 cycles

CARGO DOOR FWD SIDE, CTR STOP PAD FITTING CRACKED. INSTALLED NEW STOP PAD FITTING IAW AARD 51-00-05-1.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 43,413 hrs · 20,583 cycles

CARGO DOOR AFT UPPER STOP PAD FITTING IS CRACKED. INSTALLED NEW STOP PAD FITTING IAW AARD 51-00-05-1.

Part: PROXIMITY SENSOR — DEFECTIVE (LT MLG) · airframe 42,745 hrs · 20,259 cycles

DFW CREW REPORTED LT MLG RED LIGHT ILLUMINATED AFTER GEAR RETRACTION & LT HAND GENERATOR FAIL. EMERGENCY DECLARED FLIGHT RETURNED DFW LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED D1 26 PROXIMITY SENSOR. SYS GND CHECKED NORMAL OPERATION CLOSED.

Part: TRIM PANEL — BROKEN (CABIN) · airframe 42,243 hrs · 20,009 cycles

TRIM PIECE AT SEAT 20D BROKE OFF & EXPOSED WIRES FOR EMERGENCY LIGHTS DUE TO PASSENGER DAMAGE. REINSTALLED SIDE OF SEAT TRIM PIECE & REHOOKED UP EMERGENCY LIGHTS SEAT MOUNTED AT SEAT 20D. OPERATIONS CHECKED NORMAL

Part: PORTABLE LIGHT — INOPERATIVE (CABIN) · airframe 39,792 hrs · 18,722 cycles

LEFT NUMBER 1 DOOR EMERGENCY LIGHT WILL NOT ILLUMINATE. REPLACED PORTABLE EMERGENCY PORTABLE LIGHT AT LEFT NUMBER 1 DOOR. OPS CHECK NORMAL.

Part: SENSOR — INOPERATIVE (NLG) · airframe 35,672 hrs · 16,604 cycles

DFW - CREW REPORTED NOSE LANDING GEAR GREEN LIGHT ON APPROACH WENT TO RED WITH AURAL WARNING. ACCOMPLISHED GO AROUND AND TOWER CONFIRMED GEAR WAS DOWN. EMERGENCY DECLARED FLIGHT LANDED DFW WITHOUT INCIDENT. REPLACED NOSE GEAR UP/DOWN SENSOR. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: CONTROLLER — INOPERATIVE (CABIN PRESSURE) · airframe 35,366 hrs · 16,448 cycles

IAD - CREW REPORTED UNABLE TO PRESSURIZE CABIN. EMERGENCY DECLARED FLIGHT RETURNED IAD LANDED WITHOUT INCIDENT. PLACARD NUMBER 2 CABIN PRESSURE CONTROLLER PER MEL. REPLACED NUMBER 2 PRESSURE CONTROLLER AT DFW ON 07/23/2011. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

AFT ACCS LONGERON 2 LEFT CRACKED AFT OF STATION 1418. INSTALLED LONGERON SPLICE PER SRM 53-02 FIGURE 18 SHEET 2 AND EA MD53-017911 REVISION B DATED 7/13/2011.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

CRACK IN LEFT CUSP MEMBRANE STATION 1184, OUTBOARD OF NUMBER 2 SEAT TRACK. INSTALLED DOUBLER ON CUSP MEMBRANE STATION 1184 LEFT SIDE PER AARD 53-20-00-16.

Part: STRAP — GOUGED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

WEB STRAP STATION 1150 HAS A SCREW GOUGE LONGERON 28 RIGHT. INSTALLED NEW WEB STRAP PER AARD 51-10-00-5.

Part: WEB — CRACKED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

TAB ON FORWARD PASSENGER DOOR WEBBING IS CRACKED STATION 207 LONGERON 15 LEFT. INSTALLED REPAIR DOUBLER AND FILLER AS PER AARD 53-10-00-11.

Part: MEMBRANE — CORRODED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

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

Part: SKIN — DENTED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

TWO SCRATCHES FOUND AT STATION 220 BETWEEN LONGERONS 18 AND 19 LEFT. INSTALLED DOUBLER PER REPAIR DRAWING SG09530008 CLASS I REPAIR AND SRM 53-04-05, 51-30-05 AND 51-60-00.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

FRAME DAMAGE AT FORWARD FLANGE STATION 1401. REPAIR STRAP DOUBLER INSTALLED PER EA MD80-53-017853.

Part: MEMBRANE — CORRODED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

SUB-FLOOR AT FORWARD SERVICE DOOR ENTRY HAS HEAVY CORROSION STATIONS 180 TO 200, 7 INCHES INBOARD FROM DOOR JAMB. INSTALLED REPAIR DOUBLER ON DIAPHRAGM FROM RIGHT BUTTLINES 43 TO 57 STATIONS 160 TO 200 PER AARD 53-20-00-16.

Part: DOUBLER — CORRODED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

FACTORY DOUBLER STATIONS 160 TO 180 RIGHT BUTTLINES 44 TO 57 CORRODED. INSTALLED NEW FACTORY DOUBLER STATIONS 160 TO 180 RIGHT BUTTLINES 44 TO 57 PER AARD 51-10-00-5.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

CRACK IN CUSP STATION 1184 OUTBOARD NUMBER 2 SEAT TRACK. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: SKIN — DENTED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

DENT IN FUSELAGE AT STATION 190 LONGERONS 20 TO 21 LEFT. INSTALLED SKIN REPAIR DOUBLER PER SG0953002 CLASS 1. REPAIR AND SRM 53-04-03 AND EA MD80-53-017855.

Part: CARGO TRACK — CORRODED (CARGO BAY) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

AFT CARGO CORROSION ON RIGHT TIE DOWN TRACK AT CLIP NUT TABS STATIONS 1220 TO 1280. INSTALLED NEW RIGHT AFT TIE DOWN TRACK PER AARD 51-10-00-5.

Part: SKIN — DENTED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

DENT IN FUSELAGE SKIN STATION 208 2 INCHES BELOW LONGERON 4 LEFT. INSTALLED DOUBLER, FILLER, FINGER DOUBLERS AT STATIONS 204 TO 211 FROM ABOVE LONGERON 4 DOWN TO ABOVE LONGERON 5 LEFT PER DWG SG09530002 VIEW G1.

Part: CUSP WEB — CORRODED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

RIGHT CUSP CORRODED STATIONS 731 TO 734. REMOVED DAMAGE CUSP SECTION AND INSTALLED NEW CUSP SHEET PER AARD 51-10-00-5.

Part: SPLICE — CORRODED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

CORROSION ON LEFT TIE DOWN TRACK SPLICE AT STATIONS 1212 TO 1222. INSTALLED NEW OUTBOARD SPLICE PIECE PER AARD 51-10-00-5.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

CORROSION ON CUSP, JUST AFT OF AFT THRESHOLD SUPPORT, AT AFT SERVICE DOOR. CUT OUT DAMAGE AND INSTALLED SPLICE REPAIR PER AARD 53-20-00-16 AND BOEING DRAWING SG09530019.

Part: DOOR FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

AFT CARGO DOOR JAMB LOWER BEAM UPPER FRAME WEB CORRODED. INSTALLED WEB SPLICE PER AARD 53-10-00-24.

Part: SKIN — DENTED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

DENT IN FUSELAGE AT STATION 239, LONGERONS 17 TO 18 LEFT. CUT OUT DAMAGED SKIN AND INSTALLED DOUBLERS AND FILLERS, STATIONS 220 TO 239 LONGERONS 17 TO 18 PER BOEING DRAWING SG09530008.

Part: MOUNT — CORRODED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

CORROSION ON G2 GALLEY MOUNT JUST RIGHT OF CENTER FLOORBEAM AROUND STATION 207. INSTALLED NEW SERVICEABLE G2 GALLEY MOUNT PER SRM 51-01-00.

Part: FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

AFT CARGO, CORROSION ON STATION 1322 FRAME, FORWARD SIDE, AT LONGERON 30. CUT OUT DAMAGE AND INSTALLED "J" ANGLE REPAIR PER AARD 53-10-00-17.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

CORROSION ON CUSP BELOW OUTBOARD EDGE OF FORWARD GIRT BAR SUPPORT, AT AFT SERVICE DOOR. CUT OUT CORRODED AREA AND INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: WEB — CRACKED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

AFT ACCS WEB CRACKED 1463 CANT FRAME ABOVE LEFT LOUVER BOX. INSTALLED FORWARD AND AFT DOUBLER AND FILLER PIECE PER EA MD80-53-017720.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

INTERCOSTAL ABOVE CARGO CEILING PANEL, STATIONS 1287 TO 1309 BUTTLINE 0 CRACKED AROUND FLOORBOARD ATTACH FASTENER HOLES. INSTALLED NEW INTERCOSTAL PER AARD 51-10-00-5.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

RIGHT CUSP SHEET STATIONS 1174 TO 1250 CORRODED. INSTALLED RIGHT CUSP SHEET AT STATIONS 1174 TO 1250 PER AARD 51-10-00-05.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

SEAT TRACK NUMBER 6: CORROSION REMOVAL RESULTED IN GRINDING THE MATERIAL BEYOND LIMITS AT STATIONS 546 TO 548. INSTALLED SEAT TRACK PLUG PER AARD 53-20-00-10.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

RIGHT CUSP SHEET CORRODED STATIONS 845 TO 905. REPLACED RIGHT CUSP SHEET FROM STATIONS 845 TO 905 PER AARD 51-10-00-05.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 35,357 hrs · 16,440 cycles

RIGHT CUSP SHEET CORRODED STATIONS 807 TO 845. REPLACED RIGHT CUSP SHEET STATIONS 807 TO 845 PER AARD 51-10-00-5.

Part: WEB — CRACKED (FUSELAGE) · airframe 35,357 hrs · 16,440 cycles

TAB ON WEB AFT OF FORWARD ENTRY DOOR STATION 207 IS CRACKED. INSTALLED DOUBLER REPAIR PER AARD 53-10-00-11.

Part: PAN — CRACKED (WINDOW) · airframe 35,357 hrs · 16,440 cycles

WINDOW PAN CRACKED AT UPPER AFT CORNER AT STATION 1022 LEFT SIDE. INSTALLED REPAIR ANGLE PER AARD 53-10-00-25.

Part: PAN — CRACKED (WINDOW) · airframe 35,357 hrs · 16,440 cycles

WINDOW PAN IS CRACKED AT STATION 1060 RIGHT LOWER FORWARD. INSTALLED REPAIR ANGLE DOUBLER PER AARD 53-10-00-25.

Part: PAN — CRACKED (WINDOW) · airframe 35,357 hrs · 16,440 cycles

WINDOW PAN IS CRACKED AT STATION 1193 RIGHT LOWER FORWARD. INSTALLED REPAIR ANGLE DOUBLER PER AARD 53-10-00-25.

Part: ANTICIPATOR — LEAKING (AC BAY) · airframe 35,353 hrs · 16,435 cycles

DFW - CREW REPORTED TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED JUST AFTER TAKEOFF. ACCOMPLISHED QRH CHECKLIST AND LIGHT WENT OUT. EMERGENCY DECLARED FLIGHT RETURNED DFW LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. FOUND LEFT ANTICIPATOR LEAKING. REPLACED ANTICIPATOR AND DUCT FROM RIGHT AIR CYCLE MACHINE TO WATER SEPARATOR, SYSTEM GROUND CHECK NORMAL OPERATION.

Part: LENS — MISSING (CABIN) · airframe 34,770 hrs · 16,143 cycles

EMERGENCY LIGHT ROW 7 MISSING LENS. REPLACED LENS FOR EMERGENCY LIGHT AT ROW 7. OPS CHECK NORMAL.

Part: LIGHT — MISSING (CABIN) · airframe 34,770 hrs · 16,143 cycles

EMERGENCY LIGHT ROW 7 MISSING LAMP. REPLACED LAMP FOR EMERGENCY LIGHT ROW 7. OPS CHECK NORMAL.

Part: LATCH — BROKEN (O2 PANEL) · airframe 33,754 hrs · 15,652 cycles

FLIGHT ATTENDANT AFT JUMPSEAT O2 PANEL DOOR LATCH BROKEN. REPLACED LATCH. OPS CHECK NORMAL.

Part: DUCT — INOPERATIVE (AC BAY) · airframe 33,605 hrs · 15,574 cycles

LAX - INFLIGHT SAN-DFW. CREW REPORTED RIGHT PACK FAILED AND LEFT PACK WAS ALREADY ON PLACARD. EMERGENCY DECLARED FLIGHT DIVERTED LAX LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED RIGHT AIR CYCLE MACHINE COOLING DUCT. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: SWITCH — MALFUNCTIONED (CABIN) · airframe 32,474 hrs · 15,054 cycles

OVERHEAD EMERGENCY LIGHTS AT ROWS 23 AND AFT CAME ON WHEN POWER ON SHIP REMOVED. RECYCLED EMERGENCY EXIT LIGHT SWITCH AND MAIN AIRCRAFT BATTERY SWITCH. OPS CHECKED NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 31,329 hrs · 14,560 cycles

EMERGENCY LIGHT BATTERY PACK B5-106 AT STATION 1057 RIGHT FAILED FUNCTION TEST. REPLACED BATTERY PACK.

Part: FITTING — CRACKED (SPOILER) · airframe 31,329 hrs · 14,560 cycles

RIGHT GROUND SPOILER FITTING CRACKED. SPOILER FITTING REPLACED.

Part: START VALVE — FAULTED (NR 1 ENGINE) · airframe 27,881 hrs

INFLIGHT - RIGHT AFTER TAKEOFF LT ENGINE START VALVE LIGHT STARTED FLICKERING. REDUCED ENGINE TO IDLE AND LIGHT STOPPED FLICKERING. REPLACED NUMBER ONE ENGINE START VALVE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 27,596 hrs

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

Part: GENERATOR — MALFUNCTIONED (NR 1 ENGINE)

PHX INFLIGHT T1406/17JUN. CAPTAIN AND FIRST OFFICERS ELECTRONIC FLIGHT INSTRUMENT SYSTEM (EFIS) SCREENS CYCLED ON AND OFF FOR 60 TO 90 SECONDS FOLLOWED BY NR ONE GENERATOR TRIPPING. RESET NR ONE GENERATOR. EFIS CONTINUED TO CYCLE BUT THE NUMBER ONE GENERATOR REMAINED ON. REPLACED NR ONE CONSTANT SPEED DRIVE AND GENERATOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (A)

Part: LENS — MISSING (EMERGENCY LIGHTS) · airframe 25,420 hrs

LGA - EMERGENCY LIGHT AT SEAT 14D MISSING LENS. REPLACED LENS FOR EMERGENCY LIGHT AT SEAT 14D. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHTS) · airframe 25,420 hrs

LGA - EMERGENCY LIGHT AT SEAT 14D INOPERATIVE. REPLACED LAMPS FOR EMERGENCY LIGHT AT SEAT 14D. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (CABIN)

ORD - SEAT MOUNTED EMERGENCY LIGHTS AT SEAT ROW 20 DEF FORWARD INOPERATIVE. REPLACED BATTERY PACK FOR SEAT MOUNTED EMERGENCY LIGHTS AT SEAT ROW 20DEF FORWARD. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

IAH - EMERGENCY LIGHT BATTERY SWITCH WAS LEFT IN ARMED POSITION ON OVERNIGHT TERMINATOR BY CREW. REPLACED BATTERY PACKS FOR INOPERATIVE EMERGENCY LIGHTS IN CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

IAH - EMERGENCY LIGHT BATTERY SWITCH ON TERMINATOR WAS LEFT IN THE ARM POSITION BY FLIGHT CREW. REPLACED BATTERY PACKS FOR EMERGENCY LIGHTS. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

ORD - EMERGENCY INTERIOR OVERWING LIGHT INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY INTERIOR OVERWING LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: ENGINE — FAILED (RIGHT)

INFLIGHT, SHORTLY AFTER LEVEL OFF AT FL320, RIGHT ENGINE FAILED. RIGHT HAND ENGINE OIL QUANTITY AND PRESSURE WERE NORMAL. EXHAUST GAS TEMPERATURE REACHED 800 DEGREES BEFORE SHUTDOWN. NO FIRE INDICATION OCCURRED. LANDED ORD WITHOUT INCIDENT. REPLACED NUMBER TWO ENGINE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

AUS - OVERWING EMERGENCY LIGHTS IN CABIN INOPERATIVE. REPLACED BATTERY PACK AT B5 49 FOR OVERWING EMERGENCY LIGHTS IN CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: CONTACTOR — DIRTY (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, CEILING EMERGENCY EXIT LIGHTS FROM SEAT ROW 18 THROUGH 21 INOPERATIVE. CLEANED CEILING EMERGENCY EXIT LIGHTS BATTERY CONTACTS. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: LIGHT — INOPERATIVE (CABIN) · airframe 10,733 hrs · 5,662 cycles

EGRESS LIGHTS INOP IN ROW 16 THROUGH 25. REPLACED SEVERAL LAMPS IN EGRESS LIGHT SYSTEM AND OPS CHECK NORMAL PER MM. LAST CHECK-C STL 5-20-02. --CLOSED--

Part: WIRE — DAMAGED (CABIN) · airframe 10,557 hrs · 5,575 cycles

THE EGRESS LIGHTS IN THE FIRST CLASS CABIN WERE INOPERATIVE. REPAIRED WIRE AT SPLICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 7,218 hrs · 3,554 cycles

THE FORWARD OVERWING EMERGENCY EXIT LIGHTS WERE INOPERATIVE. REPLACED THE POWER SUPPLY PN 60-0304-51LB, AND LAMPS PN 1315.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 4,895 hrs · 2,511 cycles

THE AFT OVERWING EXIT LIGHTS FOR THE TOP LT AND RT DOORS WERE INOPERATIVE. REPLACED THE BATTERY PACK. CHECK-C 5-24-00 JFK.

Part: CONTROLLER — MALFUNCTIONED (ELEVATOR) · airframe 4,443 hrs · 2,277 cycles

SEVERE PITCH OSCILLATIONS WERE REPORTED IN DESCENT AT 300 KNOTS, CAUSING THE CREW PROBLEMS CONTROLLING THE AIRCRAFT. LASTED FOR APPROXIMATELY 2 MINUTES. NO ABNORMAL INDICATIONS IN THE COCKPIT. LANDED NORMALLY. CHECK-C 5-24-00 JFK. AFTER EXTENSIVE CHECKS OF NUMEROUS AIRCRAFT SYSTEMS NO AIRCRAFT MALFUNCTION WAS FOUND AND NO EVIDENCE WAS FOUND TO LINK THE REPORT TO AN AIRCRAFT MALFUNCTION. THE AIRCRAFT WAS ALSO TEST FLOWN.

Part: BOTTLE — DISCHARGED (ESCAPE SLIDE) · airframe 3,535 hrs · 1,841 cycles

WHILE CLOSING THE FORWARD LEFT CABIN DOOR THE EVACUATION SLIDE BOTTLE DISCHARGED. THE SLIDE DID NOT DEPLOY. BOTTLE REPORTEDLY WAS CRACKED. REPLACED THE SLIDE ASSEMBLY. CHECK-C 5-24-00 JFK. ---CLOSED---