N964AX

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 39,229 hrs · 41,828 cycles

LEFT AND RIGHT UPPER DOOR JAMBS ON AFT P-DOME WERE CRACKED. REPAIRED AREA IAW REA D953-54944.

Part: BATTERY — DISCHARGED (EMERGENCY LIGHTS) · airframe 39,142 hrs · 41,727 cycles

FOUND EMERGENCY LIGHTS VERY DIM. REPLACED EMERGENCY LIGHT POWER SUPPLY BATTERIES IAW DC9 MM 33-53-00-8-0001.

Part: BATTERY — DISCHARGED (EMERGENCY LIGHT) · airframe 38,841 hrs · 41,409 cycles

EMERGENCY LIGHTS DO NOT TEST. REPLACED EMERGENCY LIGHT POWER SUPPLY BATTERIES IAW DC9 AMM 33-53. OPS CHECK GOOD.

Part: COALESCER BAG — UNKNOWN (A/C PACKS) · airframe 38,725 hrs · 41,296 cycles

EN ROUTE RIGHT AC PACK MAINTAINED 13 PSI, AC PRESSURIZATION CONTROLLER WENT TO STBY/LOCKOUT AT TOP OF DESCENT, CABIN PRESSURE CONTROLLER FAILED, PERFORMED EMERGENCY DESCENT. PERFORMED BITE CHECK ON BOTH CABIN PRESSURE CONTROLLERS. NO FAULTS FOUND. SWAPPED NR 1 CONTROLLER WITH NR 2 FOR TROUBLESHOOTING. REPLACED BOTH LEFT AND RIGHT WATER SEPARATOR COALESCER BAGS. PRESSURIZED BOTH PACKS. NO LEAKS NOTED. SYSTEM OPS CHECKED OK IAW DC9 AMM 21.00.00.5. MANUAL OPERATION OF OUTFLOW VALVE CHECKED OK.

Part: CONTROLLER — DEFECTIVE (CABIN PRESSURE) · airframe 38,641 hrs · 41,233 cycles

CABIN PRESSURIZATION LOSS AT TOP OF DESCENT. CABIN PRESSURE EMERGENCY LIGHT ILLUMINATED, EMERGENCY PROCEDURE COMPLETED. NO FURTHER INCIDENT. PERFORMED BITE TEST PROCEDURES AND THE FOWARD CABIN PRESSURE CONTROLLER FAILED TEST. REPLACED FORWARD CABIN PRESSURE CONTROLLER IAW DC9 AMM 21-32-00-2-0501.

Part: FITTING — LEAKING (OXYGEN SYS) · airframe 38,536 hrs · 41,165 cycles

AT FLIGHT LEVEL 350, NOTICED CREW 02 BOTTLE WAS LOSING PRESSURE. DESCENDED TO LOWER ALTITUDE (170). REMAINDER OF FLIGHT, PRESSURE REMAINED AT 1000 PSI. SERVICED CREW 02 BOTTLE TO 1800 (WAS 1000) PSI. FOUND LINE FROM BOTTLE TO VALVE FITTING ON BULKHEAD LEAKING. REMOVED LINE, CLEANED FITTING. REINSTALLED LINE, NO LEAK NOTED. LEAK CHECKED SYS AT BACK OF ALL 3 02 REGULATORS. REMOVED SIDE PANEL ON F/O'S LOWER SIDEWALL & LEAK CHECKED FITTING BELTING PANEL. REINSTALLED PANEL & ALL 3 REGULATORS, LEAK CHECKED. ALL LINES LEAK CHECKED GOOD. ALL 3 MASKS AND REGULATRORS GOOD. PRESSURE HELD STEADY FOR 2.5 HRS AFTER MASK CHECKS & FIXING LEAK IN LINE 02 PRESSURE WAS 1750 PSI AT 16:15 GMT 10-08-05.

Part: DUCT — LOOSE (RT ACM) · airframe 38,444 hrs · 41,077 cycles

AT FL 350 LOST CABIN PRESSURE. LT PACK WAS NOT PROVIDING PRESSURIZATION BUT WAS IN AUTO AND INDICATED 160 PSI. ONLY ABLE TO MAINTAIN FL 210 WITH RIGHT PAC AT 260 PSI. BOTH PAC TEMPS NORMAL. FOUND RIGHT ACM DISCHARGE DUCT LOOSE AND RESECURED. REMOVED AND REPLACED LEFT WATER SEPERATOR BAG. OPS CHECKED GOOD IAW DC-9 AMM 21-00.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 37,516 hrs · 40,471 cycles

UPPER END OF SHEAR TIE CRACKED AT LONGERON 14 RIGHT, AFT OF FRAME 1056. REMOVED AND REPLACED SHEAR TIE IAW DC-9 SRM 51-30-5.

Part: RADOME — OUT OF TOLERANCE (NOSE) · airframe 36,088 hrs · 39,440 cycles

RADAR PAINTS STREAK OF GROUND RETURNS AT 60 DEGREES RIGHT OF NOSE ON COUNTER CLOCKWISE SWEEP. SOUNDS LIKE RADAR HITS DOME ON CLOCKWISE SWEEP. FOUND RADAR DRIVE PLATE BINDING AGAINST RADOME STATIC DISCHARGE STRIP PLASTIC NUT PLATES. REPLACED THE RADOME ASSEMBLY.

Part: ATTACH ANGLE — CRACKED (VERTICAL STAB) · airframe 35,897 hrs · 39,296 cycles

VERTICAL STAB TO FUSELAGE ATTACH ANGLE CRACKED, LEFT SIDE OF VERTICAL AFT END. REPAIRED ANGLE IAW DC-9 SRM 53-05.

Part: SENSOR — FAILED (MLG DOOR) · airframe 35,662 hrs · 39,127 cycles

AFTER LANDING GEAR RETRACTION, THE NOSE GEAR UNSAFE LIGHT REMAINED ON. AFTER CYCLING GEAR, THE LIGHT REMAINED ON FOR ONE MINUTE, THEN WENT OUT. REMOVED AND REPLACED THE NOSE LANDING GEAR LOCK SENSOR IAW DC-9 MM 32-60-01-2.

Part: FUEL CONTROL — MALFUNCTIONED (NR 1 ENGINE) · airframe 35,012 hrs · 38,614 cycles

NR 1 ENGINE WOULD NOT DECELERATE FROM FULL POWER TO IDLE, WOULD NOT RESPOND AFTER THE THROTTLE WAS RETARDED. IN-FLIGHT SHUTDOWN AND DID AN AIR TURN BACK. REPLACED THE FUEL CONTROL AND MAIN FUEL PUMP IAW DC-9 MM 73-20-01-2.

Part: PACKING — DEFECTIVE · airframe 34,348 hrs · 38,051 cycles

RIGHT ENGINE LOST OIL PRESSURE ON CLIMBOUT, FOR DURATION OF 9 MINUTES ENGINE WINDMILLED. OIL PRESSURE DECREASED AS OIL QUANTITY DECREASED. IN FLIGHT SHUT-DOWN. REPLACED THE MAIN OIL FILTER HOUSING CAP O-RING AND INSPECTED THE MAIN OIL FILTER, NO METAL FOUND, IAW DC-9 MM 72-20-06.

Part: DOUBLER — CORRODED · corrosion level 2 · airframe 34,314 hrs · 38,002 cycles

CORROSION SPOTS WERE NOTED BELOW FRAME AT FUSELAGE STATION 617L AND LONGERON 29L. MAINTENANCE REPLACED THE INTERNAL DOUBLER IAW DC-9 SRM 51-30-5 AND 51-30-1.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 33,530 hrs · 37,352 cycles

OVERHEAD EVACUATION LIGHTS INOPERATIVE. MAINTENANCE INSPECTED AND CLEANED THE EVACUATION LIGHT BATTERY CONTACTS, IAW DC-9 MAINTENANCE MANUAL. OPERATIONAL CHECKED GOOD.

Part: FRAME — CORRODED (BS 1041)

FUSELAGE FRAME AT STA 1041 CORRODED BETWEN LONGERON 28 LEFT SIDE TO 28 RIGHT SIDE IN AFT BAG BIN. REPAIRED FRAME IAW DC9 SRM 53-03 FIGURE 2A.

Part: PAN — CRACKED (CABIN)

LEFT MAIN ENTRY DOOR PAN CRACKED AT TOP HINGE CUT OUT. FABRICATED DOOR REPAIR ANGLE IAW DC9 SRM 52-05 FIGURE 47. INSTALLED DOOR REPAIR ANGLE IAW DC9 SRM 51-30-5 AND 51-30-1 AND 52-05 FIGURE 4.

Part: SUPPORT — CRACKED (RT WING)

RIGHT WING INBOARD SPOILER OUTBOARD SPOILER SUPPORT CRACKED. REPLACED SUPPORT FITTING IAW DC9 SRM 51-30-1.

Part: BRACKET — CRACKED (RT WING)

RIGHT WING OUTBOARD SPOILER OUTBOARD SUPPORT CRACKED. REPLACED OUTBOARD SPOILER SUPPORT BRACKET IAW 51-30-2 AND 51-30-5.

Part: PAN — CRACKED (CARGO DOOR)

FORWARD LOWER CARGO DOOR INNER PAN CRACKED IN TWO AREAS JUST ABOVE BEAM NR 1 FORWARD SIDE OF DOOR. REPAIRED EXTERNAL CRACK IAW DC9 SRM 52-05 PAGE 110A. MATERIAL 2024-T3-.063. EDDY CURRENT INTERNAL MARKED AREA. NO CRACK FOUND.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING SERVICE CHECK, FOUND EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACK, OPS CHECKED GOOD.

Part: PROX CONTROL — MALFUNCTION (E/E COMPT)

AFTER LANDING GEAR RETRACTION, RIGH GEAR UNSAFE LIGHT REMAINED ILLUMINATED. RECYCLED GEAR, LIGHT REMAINED ON. REPLACED PROX CONTROL BOX, OPS CHECKED GOOD IAW DC9 MM 32-60-00.

Part: FLOORBEAM — CRACKED (BS 718)

WHILE COMPLYING WITH C-INSPECTION, FOUND A FLOORBEAM AT FS 718 CRACKED AT RBL 48. REPLACED FLOORBEAM IAW DC9 SRM CHAPTERS 51-30-1, 51-30-2 AND 51-30-5.

Part: LONGERON — CRACKED (BS 1041)

WHILE COMPLYING WITH C-INSPECTION, FOUND LONGERON 16 LEFT CRACKED AT PYLON UPPER ATTACH BOLT AT FS 1041. REPAIRED LONGERON IAW DC9 SRM CHAPTER 53-02.

Part: LONGERON — CRACKED (BS 1052)

WHILE COMPLYING WITH C-INSPECTION, FOUND LONGERON 17 RIGHT CRACKED AT UPPER FASTENER HOLE ATTACHING IT TO BULKHEAD AT FS 1052. REPLACED LONGERON SECTION IAW DC9 SRM CHAPTER 53-02.

Part: SHEAR TIE — CRACKED (BS 1041)

WHILE COMPLYING WITH C-INSPECTION, FOUND THE LEFT ENGINE PYLON SHEAR-TIE CRACKED AT LONGERON 14 LEFT AND FS 1041. REPLACED SHEAR-TIE IAW DOUGLAS DC9 SRM CHAPTERS 53-12-3, 51-30-1, 51-30-2 AND 51-30-5.

Part: LONGERON — CRACKED (BS 1041)

WHILE COMPLYING WITH C-INSPECTION, FOUND LONGERON 17 LEFT CRACKED AT PYLON ATTACH BOLT AT FS 1041. REPAIRED LONGERON IAW DC9 SRM CHAPTER 53-02.

Part: SPAR CAP — CORRODED (WS 160)

WHILE COMPLYING WITH C-INSPECTION, FOUND LEVEL 2 CORROSION ON THE LEFT WING REAR SPAR UPPER T-CAP AT STATION XRS 160. REPAIRED LEFT WING REAR SPAR UPPER CAP IAW ABX REA D957-23974 MR.

Part: UPLATCH ASSY — OUT OF ADJUST (RT MLG DOOR)

RIGHT MAIN GEAR UNSAFE LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTED. RECYCLED GEAR, LIGHT REMAINED ON. ADJUSTED DOOR UPLATCH ASSY AND ROLLER. OPS CHECKED GOOD IAW DC9 MM 32-31-4.

Part: UPLIMIT SWITCH — WORN HARDWARE (RT MLG)

RIGHT GEAR UNSAFE LIGHT ILLUMINATED AFTER TAKE OFF AND DURING FLIGHT. GEAR UPLATCH CHECKED GOOD. REPLACED WORN HARDWARE ON RIGHT MAIN LANDING GEAR UP-LIMIT SWITCH. PERFORMED ADJUSTMENT AND TEST IAW DC9 MM 32-60-00. OPS CHECKED GOOD.

Part: SKIN — CORRODED (LT TE WING)

FOUND LEFT FLAP UPPER AND LOWER SKINS CORRODED. REPLACED SKINS (P/N 9957578-15, 995757-503) IAW DC9 SRM 51-30-1.

Part: RIB — CRACKED (RT TE FLAP)

FOUND RIGHT FLAP OUTBOARD HINGE INBOARD AND OUTBOARD RIBS CRACKED. REPLACED FITTINGS (P/N 9957600-7, 9957600-15) IAW DC9 SRM 51-30-2.

Part: ANGLE — CRACKED (LT PYLON)

DURING ACCEPTANCE INSPECTION FOUND THE LEFT ENGINE PYLON TO FUSELAGE ATTACH ANGLE CRACKED IN TWO PLACES. REPAIRED LEFT PYLON ATTACH ANGLE IAW ABX REA D954-16868-MR.

Part: BULKHEAD CLIP — CRACKED (AFT PRESS BLKHD)

DURING ACCEPTANCE INSPECTION FOUND THE AFT PRESSURE BULKHEAD LATERAL STIFFENER CRACKED AT LONGERON 16L. REMOVED AND REPLACED END CLIPS AT LONGERON 16L IAW DC-9 SRM CHAPTERS 51-30-1 AND 51-30-2.

Part: ANGLE — CRACKED (RT PYLON)

DURING ACCEPTANCE INSPECTION, FOUND THE RIGHT ENGINE PYLON UPPER FUSELAGE ATTACH ANGLE CRACKED. REPLACED THE RT UPPER PYLON TO FUSELAGE ATTACH ANGLE IAW DC-9 SRM CHAPTER 51-30-2 AND 51-30-5 AND REPAIRED ONE CRACK IAW ABX REA D954-16695-MR.

Part: SPAR CAP — CORRODED (VERT STAB)

DURING ACCEPTANCE INSPECTION, FOUND THE VERTICAL STABILIZER REAR SPAR CAPS CORRODED AT STATIONS ZRS 4, 8 AND 10. REPAIRED VERTICAL STAB REAR SPAR CAPS IAW ABX REA D957-16873-MR.

Part: SKIN — ERODED (HORIZ STAB)

DURING ACCEPTANCE INSPECTION, FOUND THE LEFT HORIZONTAL STABILIZER LEADING EDGE SKINS ERODED. REPAIRED LEFT HORIZONTAL STAB LEADING EDGE SKINS IAW ABX REA D955-16859-MR.

Part: ANGLE — CRACKED (RT PYLON)

DURING ACCEPTANCE INSPECTION, FOUND THE RIGHT ENGINE PYLON UPPER FUSELAGE ATTACH ANGLE CRACKED AT FS 1095. REPAIRED THE RIGHT PYLON UPPER ATTACH ANGLE IAW ABX REA NR D954-16695-MR.

Part: BULKHEAD CLIP — CRACKED (AFT PRESS BLKHD)

DURING ACCEPTANCE INSPECTION, FOUND THE AFT PRESSURE BULKHEAD LATERAL STIFFENER CRACKED AT LONGERON 15L. REPLACED END CLIP AT LONGERON 15L IAW DC-9 SRM CHAPTERS 51-30-1 AND 51-30-2.

Part: KEEL BEAM — CORRODED (BS 660)

DURING ACCEPTANCE INSPECTION, FOUND THE BUTT LINE O KEEL BEAM UPPER CAP SEVERELY CORRODED AT FS 660. REPAIRED KEEL BEAM UPPER CAP IAW ABX REA D953-16673-MR.

Part: PANEL — CORRODED (WS 690)

DURING ACCEPTANCE INSPECTION, FOUND THE RIGHT WING LOWER TRAILING EDGE BONDED PANEL JUST INBOARD OF MLG CORRODED. REPLACED RIGHT WING LOWER INBOARD TRAILING EDGE PANEL IAW DC9 SRM 51-30-1.

Part: RIB — CRACKED (WS 509.5)

DURING ACCEPTANCE INSPECTION, FOUND THE OUTBOARD LEFT WING LEADING EDGE RIB AT SLAT TRACK NR 10 CRACKED. REMOVED AND REPLACED LEADING EDGE RIB IAW DC-9 SRM CHAPTERS 51-30-2 AND 51-30-5.

Part: JAMB — CRACKED (BS 756)

DURING ACCEPTANCE INSPECTION, FOUND THE RIGHT MLG WHEEL WELL DOOR JAMB CRACKED INBOARD OF HYDRAULIC SUMP JAR. REPAIRED RIGHT MLG DOOR JAMB IAW ABX REA D953-16723.

Part: PANEL — DELAMINATED (WS 509)

WHILE COMPLYING WITH ACCEPTANCE INSPECTION, FOUND THE RIGHT WING UPPER TRAILING EDGE BONDED PANEL FORWARD OF AILERON DELAMINATED AND CORRODED. REMOVED AND REPLACED RIGHT WING TRAILING EDGE PANEL IAW DC-9 CHAPTERS 51-30-1 AND 51-30-2.

Part: PANEL — DELAMINATED (WS 531)

DURING ACCEPTANCE INSPECTION, FOUND THE RIGHT WING OUTBOARD TRAILING EDGE PANEL FORWARD OF AILERON DELAMINATED AND CORRODED. REPLACED RIGHT WING OUTBOARD TRAILING EDGE PANEL IAW DC-9 SRM CHAPTERS 51-30-1 AND 51-30-2.

Part: SPOILER — CORRODED (RT WING)

THE RIGHT WING OUTBOARD SPOILER HAD SEVERAL AREAS OF CORROSION. REPLACED ALL HONEYCOMB CORE, DOUBLERS AND SKINS IAW DC-9 SRM.

Part: SPAR CAR — CORRODED (WS 137.5)

DURING ACCEPTANCE INSPECTION, FOUND THE LEFT WING REAR TEE CAP DOUBLER CORRODED. REPAIRED LEFT WING REAR SPAR CAP IAW ABX REA D957-16504-MR.

Part: SPOILER — CORRODED (RT WING)

THE RIGHT OUTBOARD SPOILER HAD WIDESPREAD CORROSION. REPLACED ALL HONEYCOMB CORE, DOUBLERS AND SKIN IAW DC-9 SRM.

Part: SPAR CAP — CORRODED (WS 137)

DURING ACCEPTANCE INSPECTION FOUND THE LEFT WING UPPER SPAR CAPS CORRODED ON THE AFT TANG AT WS XRS 137. REPAIRED IAW ABX REA D957-16496-MR.

Part: RIB — CRACKED (WS 111.5)

DURING ACCEPTANCE INSPECTION, FOUND THE LEFT WING LEADING EDGE RIB AT SLAT TRACK NR 2 CRACKED. REMOVED AND REPLACED RIB IAW DC-9 SRM CHAPTERS 51-30-2 AND 51-30-5.

Part: SPAR CAP — CORRODED (WS 137)

DURING ACCEPTANCE INSPECTION, FOUND THE RIGHT WING UPPER SPAR CAPS CORRODED ON THE AFT TANG AT WS XRS 137. REPAIRED IAW ABX REA 957-16496-MR.

Part: VANE — CORRODED (LT TE FLAP)

THE LEFT FORWARD FLAP VANE HAS WIDE SPREAD CORROSION AND PITTING ALONG THE TRAILING EDGE. REPLACED ALL HONEYCOMB CORE, DOUBLERS AND SKINS IAW DC-9 SRM.

Part: CLIP — CRACKED (AFT PRESS BLKHD)

DURING ACCEPTANCE INSPECTION, FOUND THE AFT PRESSURE BULKHEAD LATERAL STIFFENER CRACKED AT LONGERON 17L. REMOVED AND REPLACED END CLIPS AT LONGERON 17L IAW DC-9 SRM CHAPTERS 51-30-1 AND 51-30-2.

Part: PAN — CRACKED (EMER EXIT DOOR)

FOUND EMERGENCY EXIT DOOR PAN CRACKED. REPAIRED IAW ABX REA D952-16416-MR.

Part: TAB — DELAMINATED (RT AILERON)

THE RIGHT AILERON TAB HAD 3 AREAS OF DELAMINATION BOTH UPPER AND LOWER, 20 PERCENT OVERALL. REPLACED ALL HONEYCOMB CORE, DOUBLERS AND SKINS IAW DC-9 SRM.

Part: PAN — CRACKED (EMER EXIT DOOR)

FOUND EMERGENCY EXIT DOOR PAN CRACKED. REPAIRED IAW ABX REA D952-16415-MR.

Part: PANEL — DELAMINATED (WS 509)

DURING ACCEPTANCE INSPECTION, FOUND THE LEFT WING UPPER TRAILING EDGE BONDED PANEL OUTBOARD OF SPOILER DELAMINATED. REPLACED TRAILING EDGE PANEL IAW DC-9 SRM CHAPTERS 51-30-1 AND 51-30-2.

Part: LONGERON — CRACKED (BS 237)

DURING ACCEPTANCE INSPECTION FOUND LONGERON 17 RIGHT CRACKED AT FS 237. REMOVED AND REPLACED LONGERON AND SPLICE SECTION IAW DC-9 SRM CHAPTER 53-02, FIGURE 2.

Part: SPOILER — CORRODED (LT WING)

LEFT WING SPOILER LOWER SURFACE CORRODED. REPLACED HONEYCOMB CORE, DOUBLERS AND SKIN.

Part: SPOILER — CORRODED (RT WING)

RIGHT SPOILER LOWER SURFACE CORRODED. REPLACED HONEYCOMB CORE DOUBLERS AND SKIN.