N978TW

Part: APU — LEAKING (APU BAY) · airframe 43,647 hrs · 21,286 cycles

SMOKE & FUMES IN CABIN WHILE IN BLOCKS. FOUND OIL IN APU INLET. PERFORMED PACK BURN IAW 21-92-12. REMOVED AND REPLACED APU IAW 49-96-83. SYSTEM CHECKED NORMAL.

Part: CHARGER — FAULTY (MAIN BATTERY) · airframe 41,016 hrs · 19,939 cycles

SJC CREW REPORTED EMERGENCY AC BUSS RELAY CIRCUIT BREAKER K7 POPPED IN FLIGHT. EMERGENCY DECLARED FLIGHT RETURNED SJC LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED BATTERY CHARGER & BOTH SHIPS BATTERIES. SYSTEM GND CHECKED NORMAL OPERATION CLOSED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 40,454 hrs · 19,626 cycles

FS SKIN ON RT SIDE CRACK EXTENDING FROM FASTENER HOLE TO BS 1380 JUST ABOVE LONGERON 14 RT. REMOVED DAMAGE & INSTALLED DOUBLER IAW SRM 53-01-00 FIGURE 4.

Part: ACTUATOR — INOPERATIVE (LE SLAT) · airframe 40,209 hrs · 19,471 cycles

ORD CREW REPORTED AUTO FLAP FAIL LIGHT ILLUMINATED WITH MASTER CAUTION. EMERGENCY DECLARED FLIGHT LANDED ORD WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED AUTO SLAT ACTUATOR NR 1. SYSTEM GROUND CHECKED NORMAL OPERATION CLOSED.

Part: COMPUTER — INOPERATIVE (STALL WARNING) · airframe 39,895 hrs · 19,303 cycles

SLAT DISAGREE LIGHT ILLUMINATED ALONG WITH AUTO SLAT FAIL LIGHT. EMERGENCY DECLARED FLIGHT LANDED DFW WITHOUT INCIDENT. REPLACED NR 1 STALL WARNING COMPUTER. SYSTEM GROUND CHECKED NORMAL.

Part: PROXIMITY SENSOR — INOPERATIVE (LE SLAT) · airframe 37,960 hrs · 18,312 cycles

OKC - CREW REPORTED SLAT DISAGREE INDICATION. EMERGENCY DECLARED FLIGHT LANDED OKC WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED PROXIMITY BOX. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: SKIN — CRACKED (FUSELAGE) · airframe 36,589 hrs · 17,617 cycles

STATION 1380 ON LEFT SIDE HAS CRACK IN SKIN AT SHEAR TIE AREA JUST ABOVE PYLON. INSTALLED DOUBLER PER SRM 53-01-00.

Part: STRUT — FAULTY (NLG) · airframe 35,698 hrs · 17,155 cycles

LAX - CREW REPORTED AFTER TAKEOFF NOSE GEAR RED LIGHT ON WITH GEAR HANDLE UP. CYCLED GEAR PER QRH AND STILL NO INDICATION. EMERGENCY DECLARED FLIGHT RETURNED LAX LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. ACCOMPLISHED STRUT REPACK AND GEAR SWING. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: ACTUATOR — FAILED (OUTFLOW VALVE) · airframe 35,011 hrs · 16,819 cycles

LGA - CREW REPORTED BOTH AUTO PRESSURE CONTROLS FAILED. EMERGENCY DECLARED FLIGHT RETURNED LGA LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED OUTFLOW VALVE ACTUATOR. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: APU — FAILED (APU BAY) · airframe 34,330 hrs · 16,458 cycles

MCI - INFLIGHT STL-LAX. CREW REPORTED AUXILIARY POWER UNIT FAILED WITH RIGHT GENERATOR ON PLACARD. EMERGENCY DECLARED FLIGHT DIVERTED MCI LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED AUXILIARY POWER UNIT. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: REGULATOR — LEAKING (AC BAY) · airframe 34,306 hrs · 16,446 cycles

CLT - (REPEAT ITEM) CREW REPORTED TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED DURING CLIMBOUT. ACCOMPLISHED QRH PROCEDURES AND LIGHT EXTINGUISHED. FLIGHT RETURNED CLT LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED RIGHT PRESSURE REGULATOR THAT WAS LEAKING AND GASKET ON RIGHT A/C SUPPLY HIGH SENSOR THAT WAS LEAKING. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: DUCT — DAMAGED (AC BAY) · airframe 34,095 hrs · 16,328 cycles

LAS - CREW REPORTED TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED DURING CLIMBOUT. EMERGENCY DECLARED FLIGHT RETURNED LAS LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED LEFT FLOW CONTROL VALVE AND RIGHT AC PACK DUCT FROM FLOW CONTROL VALVE TO HEAT EXCHANGER. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: PUMP — INOPERATIVE (FUEL SYSTEM) · airframe 33,002 hrs · 15,778 cycles

SAT - INFLIGHT GDL-DFW. CREW REPORTED UNABLE TO GET FUEL OUT OF THE CENTER TANK WITH ASSOCIATED CENTER FUEL PRESS LOW LIGHT. FLIGHT DIVERTED SAT LANDED WITHOUT INCIDENT. FORWARD AND AFT CENTER FUEL BOOST PUMPS PLACARD. FLIGHT RE-DEPARTED PLANNED FOR WING FUEL TANKS ONLY. REPLACED BOTH CENTER FUEL TANK BOOST PUMPS ON 02/14/2011 AT DFW. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

CORROSION OUT OF LIMITS RIGHT CUSP STATION 396. INSTALLED NEW CUSP DOUBLER PER AARD 53-20-00-16.

Part: SKIN — DAMAGED (ENTRY DOOR) · airframe 32,602 hrs · 15,586 cycles

FORWARD ENTRY DOOR HAS DAMAGE AROUND HOLD OPEN HOOK CUTOUT ON OUTER SKIN. BLENDED TO REMOVE DAMAGE FABRICATED AND INSTALLED DOUBLER PER SRM 52-05-02 FIGURE 20A.

Part: DOOR FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

EMERGENCY EQUIPMENT COMPARTMENT. THE CUTOUT FOR FORWARD STAIR DOOR CONTROL ROD IS BENT AND CRACKED AFT SIDE OF FRAME 160. THIS CUTOUT IS AT THE CABIN FLOOR LEVEL. INSTALLED DOUBLER PER EA MD80-53-014436 REVISION A.

Part: CUSP WEB — CORRODED (FUSELAGE) · airframe 32,602 hrs · 15,586 cycles

CORROSION OUT OF LIMITS ON LEFT CUSP STATIONS 1020 TO 1025. CUT OUT CORROSION AND INSTALLED DOUBLER IAW AARD 53-20-00-16.

Part: CUSP WEB — DAMAGED (FUSELAGE) · airframe 32,602 hrs · 15,586 cycles

CORROSION OUT OF LIMITS ON RIGHT CUSP STATIONS 1202 TO 1207. INSTALLED DOUBLER REPAIR RIGHT CUSP STATION 1202 AS PER AARD 53-20-00-16.

Part: BEAM — CRACKED (ENTRY DOOR) · airframe 32,602 hrs · 15,586 cycles

FORWARD ENTRY DOOR NUMBER 1 BEAM ON FORWARD END HAS NOT HAD MOD PERFORMED. FOUND CRACK IN BEAM END. STOP DRILLED CRACK AND INSTALLED DOUBLER PER ESO 80172.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

MID CARGO HAS CORROSION ON LOWER SURFACE OF LEFT CUSP AT STATION 725. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: BEAM — CRACKED (ENTRY DOOR) · airframe 32,602 hrs · 15,586 cycles

FORWARD ENTRY DOOR NUMBER 1 BEAM ON AFT END HAS NOT HAD MOD PERFORMED. FOUND CRACK AT END OF BEAM. STOP DRILLED CRACK AND INSTALLED MOD DOUBLER PER ESO 80172.

Part: CARGO TRACK — CORRODED (CARGO BAY) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

HEAVY CARGO/AFT- CORROSION ON TIEDOWN TRACK, AT ATTACH POINTS, CENTER OF TRACK, RIGHT SIDE STATIONS 1212 TO 1287. INSTALLED NEW TIE-DOWN TRACK PER SRM 51-30-01.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

CORROSION OUT OF LIMITS LEFT CUSP STATION 681 PER SRM 51-10-03. INSTALLED REPAIR DOUBLER LEFT CUSP STATION 681 AS PER AARD 53-20-00-16.

Part: DOOR FRAME — CORRODED (FUSELAGE) · airframe 32,602 hrs · 15,586 cycles

CORROSION ON DOOR CUTOUT BEAM WEB STATIONS 1174 TO 1212. INSTALLED NEW WEB PER EA NUMBER MD80-51-014446 DATED 12/13/2010 AND AARD 51-10-00-5.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

CORROSION OUT OF LIMITS ON RIGHT CUSP STATION 1064 LOWER SURFACE. INSTALLED CUSP DOUBLER FROM APPROXIMATELY STATION 1062 TO STATION 1077 PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

RIGHT CUSP HAS CORROSION ON OUTBOARD EDGE STATIONS 360 TO 379. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

CORROSION OUT OF LIMITS ON RIGHT CUSP STATION 1064 LOWER SURFACE. INSTALLED CUSP DOUBLER RIGHT STATION 1064 PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 32,602 hrs · 15,586 cycles

CORROSION BOTTOM OF LEFT CUSP AT STATION 1174 BELOW NUMBER 1 SEAT TRACK. INSTALLED NEW CUSP DOUBLER AT STATION 1174 TO 1190 LEFT SIDE PER AARD 53-20-00-16.

Part: CUSP WEB — DAMAGED (FUSELAGE) · airframe 32,602 hrs · 15,586 cycles

CORROSION ON RIGHT CUSP SHEET AT STATION 600. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: BEAM — CRACKED (ENTRY DOOR) · airframe 32,602 hrs · 15,586 cycles

NUMBER 7 DOOR BEAM IS CRACKED AT THE AFT END. OLD BEAM END DOUBLER REMOVED, CRACK STOP DRILLED AND DYE CHECKED. INSTALLED NEW BEAM END DOUBLER.

Part: CUSP WEB — CORRODED (FUSELAGE) · airframe 32,602 hrs · 15,586 cycles

LEFT CUSP HAS CORROSION ON BOTTOM SIDE AT STATION 725. REMOVED CORROSION AND INSTALLED DOUBLER REPAIR PER AARD 53-20-00-16.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 29,176 hrs · 13,984 cycles

EMERGENCY BATTERY PACK STATION 1336 IS INOPERATIVE. REPLACED BATTERY PACK.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 29,176 hrs · 13,984 cycles

EMERGENCY BATTERY PACK STATION 1098 IS INOPERATIVE. REPLACED BATTERY PACK.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 29,176 hrs · 13,984 cycles

EMERGENCY LIGHT BATTERY PACK AT STATION 1057 INOPERATIVE. REPLACED BATTERY PACK.

Part: SKIN — CRACKED (FUSELAGE) · airframe 29,166 hrs · 13,978 cycles

FUSELAGE SKIN CRACKED AT A RIVET AT CANT FRAME 1474 AND LONGERON 15 RIGHT. INSTALLED EXTERNAL DOUBLER REPAIR UNDER SRM 53-01-00.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 29,167 hrs · 13,978 cycles

FORWARD CENTER DOOR STOP BRACKET CRACKED ON CARGO DOOR. REMOVED AND REPLACED STOP BRACKET FITTING PER ESO 80174.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 28,426 hrs · 13,612 cycles

LEFT AFT OVERWING INTERIOR EMERGENCY EXIT LIGHT STAYS ON WITH SWITCH OFF. REPLACED EMERGENCY LIGHT BATTERY PACK B5-105. OPS CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 28,426 hrs · 13,612 cycles

RIGHT AFT OVERWING INTERIOR EMERGENCY EXIT LIGHT STAYS ON WITH SWITCH OFF. REPLACED EMERGENCY LIGHT BATTERY PACK B5-105. OPS CHECK NORMAL.

Part: BATTERY PACK — DISCONNECTED (EMERGENCY LIGHTS) · airframe 27,069 hrs

LGA - CEILING EMERGENCY LIGHTS FROM ROW 23 THRU 27 INOPERATIVE. CLEANED AND RECONNECTED BATTERY PACK FOR CEILING EMERGENCY LIGHTS FOR ROW 23 THRU 27.

Part: CONNECTOR — LOOSE (EMERGENCY LIGHTS) · airframe 27,069 hrs

LGA - EMERGENCY LIGHTS IN TAIL COMPARTMENT BELOW WATER SEPARATORS INOPERATIVE. RECONNECTED LOOSE CONNECTOR FOR EMERGENCY LIGHTS IN TAIL COMPARTMENT BELOW WATER SEPARATORS.

Part: OXYGEN BOTTLE — LOW (ZONE 200) · airframe 26,964 hrs · 12,960 cycles

ELP INFLIGHT ORD TO SJD. CREW REPORTED CREW OXYGEN BOTTLE LOW. LANDED ELP WITHOUT INCIDENT. REPLACED CREW OXYGEN BOTTLE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: DUCT — BLOWN (A/C BAY) · airframe 25,002 hrs

ORD INFLIGHT T2079/07MAY - TAIL COMPARTMENT TEMPERATURE HIGH INDICATION ILLUMINATED DURING CLIMB. LIGHT EXTINGUISHED IN ABOUT FIVE MINUTES. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. FOUND WATER SEPARATOR DUCT AT FORWARD RIGHT SIDE OF AFT TAIL COMPARTMENT BLOWN. REPLACED BLOWN DUCT ON FORWARD RIGHT SIDE OF AFT TAIL COMPARTMENT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: STRUT — DAMAGED (NLG)

YUL INFLIGHT T761/02OCT - UNABLE TO RETRACT NOSE GEAR. RECEIVED RED LIGHT INDICATION. LANDED YUL WITHOUT INCIDENT. AIRCRAFT OUT OF SERVICE FOR REPAIR. 10-16-07 FOUND NOSE GEAR PISTON DAMAGE. REPLACED NOSE GEAR STRUT ASSEMBLY. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LENS — MISSING (EMERGENCY LIGHTS)

LGA - EMERGENCY EXIT LIGHT AT SEAT ROW 7C MISSING LENS. REPLACED LENS FOR EMERGENCY EXIT LIGHT AT SEAT ROW 7C. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: DUCT — DISCONNECTED (ACM)

DFW - ON CLIMB FLIGHT ATTENDANT REPORTED SMELL OF FUMES IN CABIN FOLLOWED BY LEFT ENGINE VALVE LIGHT ILLUMINATED FOLLOWED BY PRESSURE ABNORMAL LIGHT AND AIR FRAME VIBRATIONS. CAPTAIN SECURED WING AND ENGINE ANTI-ICE AND VIBRATIONS DECREASED. RETURNED TO DFW AND LANDED WITHOUT INCIDENT. FOUND CABIN AIR SUPPLY DUCT FOR RIGHT AIR CYCLE MACHINE DISCONNECTED. CONNECTED DUCT TO RIGHT AIR CYCLE MACHINE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SENSOR — INOPERATIVE (MLG)

DFW - AFTER TAKEOFF AND GEAR UP SELECTION RIGHT GEAR UP AND UNSAFE RED LIGHT ILLUMINATED. LIGHT EXTINGUISHED AFTER APPROXIMATELY 20 MINUTES AND DISPLAYED INTERMITTENTLY. RETURNED TO DFW AND LANDED WITHOUT INCIDENT. REPLACED RIGHT MAIN UP AND LOCKED SENSOR. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

LGA - CEILING EMERGENCY LIGHTS AT ROWS 2 TO 6 INOPERATIVE. REPLACED BATTERY PACK FOR CEILING EMERGENCY LIGHTS AT ROWS 2 TO 6. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

ORD - OVERHEAD EMERGENCY LIGHTS AT ROWS 18 THROUGH 21 INOPERATIVE. REPLACED BATTERY PACK AT B4104 FOR OVERHEAD EMERGENCY LIGHTS AT ROWS 18 THROUGH 21. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

DFW TAIL CONE EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACKS FOR TAIL CONE EMERGENCY LIGHTS. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHT) · airframe 9,910 hrs · 5,472 cycles

BOTH UPPER LAMPS AT EMERGENCY LIGHT TRIPLE FIXTURE IN CONE SLIDE AREA, THE EMERGENCY OVERHEAD LIGHT ON RT SIDE OF TAIL CONE SLIDE, AND THE EMERGENCY OVERHEAD LIGHT IN CATWALK IN TAIL CONE, WERE ALL INOPERATIVE. REPLACED BATTERIES IN BATTERY PACK. CHECK-C 8-17-02 MCI.

Part: BULB — INOPERATIVE (EMERGENCY LIGHT) · airframe 9,910 hrs · 5,472 cycles

THE EGRESS LIGHT JUST AHEAD OF CABIN ROW 6, AND THE EGRESS LIGHT JUST FORWARD OF ROW 31, WERE INOPERATIVE. REPLACED BOTH BULBS. CHECK-C 8-17-2002 MCI.

Part: BULB — LOOSE (EMERGENCY LIGHT) · airframe 9,535 hrs · 5,262 cycles

THE EGRESS LIGHT WAS INOPERATIVE AT ROW 21 AND 28. SECURED LOOSE BULB AT BOTH LOCATIONS. CHECK-C 8-17-2002 MCI.

Part: CONTROL HANDLE — DIRTY (COCKPIT) · airframe 8,218 hrs · 4,466 cycles

THE FLAP/SLAT SELECTOR HANDLE WAS DIFFICULT TO MOVE. FLIGHT RETURNED TO STL. FOUND THE HANDLE MECHANISM WAS DIRTY. CLEANED AND LUBRICATED THE FLAP/SLAT HANDLE MECHANISM.

Part: PUMP — FAILED (HYD SYSTEM) · airframe 8,086 hrs · 4,391 cycles

LOST HYDRAULIC PRESSURE FROM NUMBER TWO HYDRAULIC PUMP DUE TO SHEARED SHAFT. REPLACED NUMBER TWO HYDRAULIC PUMP.

Part: COVER (SEAT 21A) · airframe 5,107 hrs · 2,750 cycles

AT SEAT 21A THE EMERGENCY EXIT SIDEWALL LIGHT COVER WAS MISSING. REPLACED THE COVER. CHECK-C 10-27-00 STL. --CLOSED--

Part: LIGHT — INOPERATIVE (CABIN) · airframe 2,223 hrs · 1,240 cycles

THE EMERGENCY LIGHT AT THE FORWARD LT SIDE CABIN DOOR WAS INOPERATIVE. REPLACED THE LIGHT ASSEMBLY. NO CHECK-C.

Part: FLASHLIGHT — DISLODGED (CABIN) · airframe 1,263 hrs · 713 cycles

THE EMERGENCY FLASHLIGHT AT THE L-1 DOOR IS FALLING OUT OF THE HOLDER. REMOVED AND REPLACED THE FLASHLIGHT ASSY AT THE L-1 DOOR. CHECKS MADE TO ASSURE NORMAL OPERATION PER MM 33. AC 02 03-08-00 DFW.