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Part: TURBINE — DAMAGED (LT ENGINE) · airframe 14,727 hrs · 23,333 cycles

B757 A/C REG NR B-27007 ON TAKEOFF ROLL, JUST AS PILOT ADVANCED THROTTLES, A BANG WAS HEARD FROM LT ENG AND THEN EGT ROSE, RPM DROPPED. PILOT ABORTED TAKEOFF AND IAW QRH SHUT DOWN THE ENG. INITIAL INSPECTION REVEALED N1 IS SEIZED BUT N2 CAN BE ROTATED. BORESCOPE INSPECTION REVEALED FROM 1ST STAGE THRU 3RD STAGE TURBINE ARE ALL DAMAGED AND ONE OF 1ST STAGE TURBINE BLADE UNDER-PLATFORM FRACTURED. THIS ENG WILL BE SHIP TO P&W FOR REPAIR AND FURTHER INVESTIGATION.

Part: COMPRESSOR — DAMAGED (NR 2 ENGINE)

REGISTRATION NUMBER - B18703NR 2 ENGINE, NR 2 VIB IND 4.1 UNITS, ENGINE LOST POWER. IAW SOP SHUTDOWN ENGINE AND ENGINE EXPERIENCED 3 HOURS WINDMILL. BORESCOPE INSP FOUND NR 2 ENGINE ALL HPC 3RD STAGE BLADES DAMAGED SERIOUSLY. REPLACED NR 2 ENGINE AND RUN UP TEST NML. INITIAL INVESTIGATION: HPC BORESCOPE INSPECTION FOUND, STG 1 BLADE: 2 EA BALDES TIP CURL, STG 2 BLADE: SOME BLADES NICKS ON L/E. STG 3 THRU STG 5 BLADE: ALL BLADES FOUND SERIOUS DAMAGED (TEAR, LIBERATION, SEPARATION) ON AIRFOIL. NR 2 ENGINE WAS REMOVED AND REPLACED, ENGINE RUN UP NORMAL.

Part: FUEL CONTROL — MALFUNCTIONED (NR 2 ENGINE)

REGISTRATION NUMBER - B18771NR 2 ENGINE FLAME OUT AT FL330, TAT -4 DEGREES C, EGT 352 DEGREES C, EPR 1.02 AND DROPPING, ENGINE SHUTDOWN, WINDMILLED APPROX 1 MIN AT OIL PRESS 22 PSI, ENG WAS RESTARTED AND OPERATED NORMALLY. IAW AMM 71-00-43, MAIN FUEL FILTER AND EVBC FUEL FILTER INSPECTED NML AND REPLACED. CHECKED EVBC PT3 AND PS3 WATER TRAP, NO WATER EVIDENCE FOUND. PFMED FUEL TANKS WATER DRAINING. REPLACED FCU AND FUEL PUMP. REPLACED FUEL HEATER DUE TO MUNT BOLTS INSERT DAMAGED. PFMED WINDMILLING INSP MAIN OIL FILTER AND ALL MAGNETIC CHIP DETECTORS INSPED NML. ENG RUN UP TEST WITH TAKEOFF POWER SATISFACTORY.

Part: PUMP — MALFUNCTIONED (NR 2 ENGINE)

REGISTRATION NUMBER - B18771 NR 2 ENGINE FLAME OUT AT FL330, TAT -4 DEGREES C, EGT 352 DEGREES C, EPR W.02 DROPPING, ENGINE SHUTDOWN, WINDMILLED APPROX 1 MIN AT OIL PRESS 22 PSI, ENG WAS RESTARTED AND OPERATED NORMALLY. IAW AMM 71-00-43, MAIN FUEL FILTER AND EVBC FUEL FILTER INSPECTED NML AND REPLACED. CHECK EVBC PT3 AND PS3 WATER TRAP, NO WATER EVIDENCE FOUND. PFMED FUEL TANKS WATER DRAINING. REPLACED FUEL CONTROL UNIT AND FUEL PUMP ASSY. REPLACED FUEL HEATER DUE TO MOUNT BOLTS INSERT DAMAGEE. PFMED WINDMILLING INSP MAIN OIL FILTER AND ALL MAGNETIC CHIP DETECTORS INSPED NML. ENG RUN UP TEST WITH TAKEOFF POWER SATISFACTORY.

Part: FUEL HEATER — MALFUNCTIONED (NR 2 ENGINE)

REGISTRATION NUMBER - B18771NR 2 ENGINE FLAME OUT AT FL330, TAT -4 DEGREES C, EGT 352 DEGREES C, EPR 1.02 AND DROPPING, ENGINE SHUTDOWN, WINDMILLED APROX 1 MIN AT OIL PRESS 22 PSI, ENG WAS RESTARTED AND OPERATED NORMALLY. IAW AMM 71-00-43, MAIN FUEL FILTER AND EVBC FUEL FILTER INSPECTED NML AND REPLACED. CHECKED EVBC PT3 AND PS3 WATER TRAP, NO WATER EVIDENCE FOUND. PFMED FUEL TANKS WATER DRAINING. REPLACED FULE CONTROL UNIT AND FUEL PUMP ASSY. REPLACED FUEL HEATER DUE MOUNT BOLTS INSERT DAMAGED. PFMED WINDMILLING INSP MAIN OIL FILTER AND ALL MAGNETIC CHIP DETECTORS INSPED NML. ENG RUN UP TEST WITH TAKEOFF POWER, SATISFACTORY.

Part: HOUSING — DEFECTIVE

RELEVANT INDICATION ON TOP OF GOVERNOR BODY. (X)

Part: BEARING — GROOVED

RELEVANT INDICATION IN BEARING GROOVE. (X)

Part: LIGHT — INOPERATIVE (ROW 15)

CLE - REF DMI 830 EMERGENCY PATH LIGHT AT ROW 15 INOPERATIVE. REPLACED BULB AT ROW 15 EMERGENCY LIGHT. OPS CHECK GOOD DMI 830 REMOVED. (X)

Part: REEL — DAMAGED (PHONE)

PHONE REEL MELTED.

Part: BOLT — MISMANUFACTURED (RT MLG)

DURING REPLACEMENT OF RT MLG ATTACH FITTING (TRUNNION) WHILE INSTALLING LOWER REAR AUXILIARY SPAR CAP TO TRUNNION, 'NEW CONDITION' BOLT, P/N NAS-638-39, CRACKED WHILE TURNING INTO POSITION. THIS BOLT WAS ONLY BEING RUN IN AT TIME OF FAILURE, NOT TORQUED. ACFT N NR HK-4176X.

Part: BRACE — DAMAGED (NLG)

UPON GEAR EXTENSION INTO MIAMI, HEARD STRANGE NOISE FROM NOSE WHEELWELL AREA. GEAR EXTENDED NORMALLY WITH 3 GREEN INDICATIONS. POST-FLIGHT SIDE BRACE ATTACH LUG FOR RETRACT CYLINDER ATTACHMENT CRACKED. ACFT N NR HK-3785X.

Part: SWITCH — MISINSTALLED (FUEL CUT OFF)

THIS PART, NR 1 FIREWALL SHUT-OFF VALVE PULL SWITCH, HAD AT SOME POINT BEEN DISMOUNTED AND THEN REMOUNTED USING A SCREW THAT WAS LONGER THAN THE REQUIRED NAS387-1032-10. THE REQUIRED SCREW LEAVES ALMOST NO CLEARANCE BETWEEN THE END OF THE SCREW AND THE HOUSING OF A MICROSWITCH IN THE ASSEMBLY. THE LONGER THAN ALLOWED SCREW BROKE THE HOUSING AND THE RESULTING DEBRIS CAUSED THE MICROSWITCH TO ACTUATE ERRATICALLY GIVING FALSE READINGS ON THE ANNUNCIATORS. (X)