21 AIR

Part: SKIN — DELAMINATED (ZONE 300) · airframe 105,639 hrs · 38,878 cycles

DELAMINATION LOCATED ON LEFT SIDE OF VERTICAL STABILIZER PANEL BETWEEN SPAR AND FRONT SPAR FSS 220.521 - 270-784 (MAJOR REPAIR)

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 105,639 hrs · 38,878 cycles

CORROSION FOUND ON SEAT TRACK AT STATION 1125 MAIN DECK AT LBL 11 AND RBL 11 (MAJOR REPAIR)

Part: SKIN — CORRODED (ZONE 600) · airframe 105,639 hrs · 38,878 cycles

CORROSION ON LOWER RH WING AT WS 314.30 - 372.20 STR 16-18

Part: SKIN — CORRODED (ZONE 100) · airframe 105,639 hrs · 38,878 cycles

CORROSION FOUND ON UPPER SURFACE OF CENTER SECTION AT BS 955.1 AT BL 0 (MAJOR REPAIR)

Part: FRAME — CRACKED (ZONE 100) · airframe 105,639 hrs · 38,878 cycles

CRACK FOUND IN CENTER WING REAR SPAR AT STATION 953 BBL 1R

Part: WINDOW FRAME — CRACKED (ZONE 200) · airframe 105,639 hrs · 38,878 cycles

WINDOW FRAME AT STATION 944 LH SIDE IS CORRODED AT CENTER OF LOWER EDGE. (MAJOR REPAIR)

Part: ENGINE — FAULTED (RIGHT) · airframe 99,696 hrs · 22,258 cycles

DURING TAKEOFF ROLL, BETWEEN 60-70 KNOTS, WE HEARD TWO LOAD BANGS AND TOWER CANCELED OUR TAKEOFF CLEARANCE FROM SEEING SPARKS FROM ENGINE AND HEARING A LOUD BANG FROM THE TOWER. FROM THE COCKPIT THEY HAD NORMAL ENGINE INDICATIONS AND NO FIRE WARNING. WE CLEARED RUNWAY, SHUT DOWN THE RIGHT ENGINE, AND REQUESTED FIRE CREW TO INSPECT THE JET WITH NO VISIBLE DAMAGE TO RIGHT ENGINE. WE RETURNED TO THE GATE SINGLE ENGINE TAXI, AFTER SHUT DOWN MAINTENANCE FOUND METAL PARTICLES IN THE RIGHT ENGINE. BOROSCOPE OF NR 2. ENGINE WAS ACCOMPLISHED TO SHOW DAMAGE OUT OF LIMITS

Part: SKIN — CRACKED (ZONE 200) · airframe 103,956 hrs · 22,078 cycles

CRACK ON R-1 DOOR CUTOUT LOWER AFT CORNER

Part: RIB — CRACKED (ZONE 600) · airframe 103,956 hrs · 22,078 cycles

CRACK ON L/E UPPER RIGHT WING AIRLOAD RIB

Part: CONTROLLER — FAULTED (FIRE DETECTION) · airframe 107,872 hrs · 23,636 cycles

ON APPROACH, RECEIVED WHEEL WELL FIRE EICAS MESSAGE. DECLARED EMERGENCY AND LANDED WITHOUT INCIDENT. INSPECTED AND FOUND NO EVIDENCE OF FIRE. REPLACED DETECTION CONTROL CARD.

Part: WARNING MESSAGE — FALSE ACTIVATION (TE FLAPS) · airframe 98,501 hrs · 25,612 cycles

ON APPROACH, SELECTED FLAPS TO 20. RECEIVED TE FLAP DISAGREE EICAS MESSAGE. DID GO AROUND, DECLARED EMERGENCY, AND LANDED WITHOUT INCIDENT. MAINTENANCE PERFORMED FIM PROCEDURE. NO DEFECTS NOTED.

Part: POWER SUPPLY — FAULTED (RT CSEU) · airframe 104,933 hrs · 38,633 cycles

AT FL 390 BEGAN TO EXPERIENCE DUTCH ROLLS WITH AUTO PILOT AND AUTO THROTTLES ENGAGED.DISCONNECTD AP BUT HAD TO HOLD THE YOKE TO THE RIGHT TO MAINTAIN CONTROL. DELCARED EMERGENCY AND DIVERTED TO ST. LOUIS. MAINTENANCE PERSONNEL REPLACED RIGHT CSEU POWER SUPPLY.

Part: TARGET — OUT OF POSITION (ZONE 500) · airframe 102,612 hrs · 21,501 cycles

AFTER LIFT OFF RECEIVED LE SLAT ASSYMETRY MESSAGE. RETURNED TO THE FIELD.

Part: WINGLET — DAMAGED (ZONE 600) · airframe 35,148 hrs · 8,984 cycles

PERFORMED PERMANENT REPAIR TO RH WINGLET LIGHTNING STRIKE DAMAGE PER IAAC EO 21A-250530.

Part: THRUST REVERSER — GOUGED (ZONE 400) · airframe 35,148 hrs · 8,984 cycles

PERFORMED GOUGE BLEN REPAIR ON #1 ENG TR INBOARD ANGLE AT 6 O'CLOCK POSITION PER IAAC EO 21A-250604.

Part: PROXIMITY SENSOR — OUT OF ADJUST (ZONE 500) · airframe 102,610 hrs · 21,498 cycles

ON APPROACH RECEIVED FLAP ASSYMETRY MESSAGE WHEN FLAP SET TO 5 DEGREES. DIVERTED TO IAD AND LANDED WITHOUT INCIDENT. CLEANED AND SET CLEARANCES ON LEADINF ESGE SLAT SENSORS.

Part: BATTERY — INOPERATIVE (ZONE 200) · airframe 107,578 hrs · 23,475 cycles

DURING SERVICE CHECK, L1 DOOR EMERGENCY LIGHT FAILED TO ILLUMINATE. REPLACED BATTERY ASSEMBLY.

Part: SUPPORT FITTING — DAMAGED (ZONE 500 FLAP) · airframe 93,397 hrs · 28,897 cycles

LH FAIRING SUPPORT #1 FLAP FITTING ASSY DAMAGED.

Part: SHEAR TIE — CORRODED (ZONE 100) · airframe 93,397 hrs · 28,897 cycles

ANGLE CONNECTING FRAME TO SKIN IN LH NOSE WHEEL WELL CORRODED.

Part: SUPPORT FITTING — DAMAGED (NR 1 FLAP) · airframe 93,397 hrs · 28,897 cycles

#1 FLAP SUPPORT FITTING FASTNER HOLE DAMAGED.

Part: SPLICE ANGLE — DAMAGED (ZONE 800) · airframe 93,397 hrs · 28,897 cycles

R1 DOOR CUTOUT REPAIR FASTENER HOLE OVAL.

Part: FITTING — DAMAGED (ZONE 600 FLAP) · airframe 93,397 hrs · 28,897 cycles

RH FAIRING SUPPORT #7 FLAP REPAIR.

Part: FITTING — CRACKED (ZONE 600 FLAP) · airframe 93,397 hrs · 28,897 cycles

RH FAIRING IB #7 FLAP SUPPORT CRACK REPAIR.

Part: VALVE — FAULTED (RT ENGINE) · airframe 104,349 hrs · 38,466 cycles

DURING CRUSIE RECEIVED FWD EQUIPMENT COOLING OVHT MESSAGE. DIVERTED TO OMAHA. REPLACED RH ENG PRVC.

Part: WARNING MESSAGE — FALSE ACTIVATION (ZONE 100) · airframe 104,345 hrs · 38,464 cycles

DURING CRUISE AT FL 370, RECEIVED EICAS MESSAGE "EQUIPMENT OVERHEAT" MESSAGE. DECENDED TO FL 310. DURING THIS DECENT, RECEIVED "CABIN ALT" MESSAGE. DECLARED EMERGENCY AND DIVERTED. MAINTENANACE PERSONNEL PLACED THE EQUIPMENT COOLING SYSTEM ON MEL AND ACCOMPLISHED A TEST OF THE CABIN ALTITUDE WARNING SYSTEM. NO DEFECT NOTED AND THE AIRCRAFT WAS RELEASED.

Part: CIRCUIT BREAKER — TRIPPED (FLAP SYS) · airframe 88,349 hrs · 27,084 cycles

ON APPROACH GOT TE FLAP FAIL MESSAGE. CREW DECLARED AN EMERGENCY BUT LANDED WITHOUT INCIDENT. FOUND CD OUT. RESET BREAKER. SYSTEM TESTED GOOD.

Part: ENGINE — SURGES (RIGHT) · airframe 101,504 hrs · 39,103 cycles

RIGHT ENGINE SURGING. IT STOPPED WHEN THROTTLES REDUCED. THERE WERE NO EXCEEDENCES. ENGINE OPERATON BECAME NORMAL AGAIN. PERFORMED BORESCOPE INSPECTION. NO DEFECTS NOTED.

Part: WARNING MESSAGE — ILLUMINATED (TE FLAPS) · airframe 88,170 hrs · 27,014 cycles

ON APPROOACH RECEIVED TRAILING EDGE FLAP DISAGREE MESSAGE. PERFORMED GO AROUND, DECLARED EMERGENCY AND LANDED WITHOUT ANY INCIDENTS.

Part: SKIN — DENTED (ZONE 100) · airframe 103,604 hrs · 38,253 cycles

DURING HEAVY CHECK, DENTS AND CRACKS WERE FOUND BETWEEN FUSELAGE SKIN STA 347 AND 390 AT STR 19R TO 21R. WAS REPAIRED IAW FLIGT VEHICLES CONSULTING INC. EO# 24151-1.

Part: SKIN — DENTED (ZONE 100) · airframe 103,604 hrs · 38,253 cycles

DURING HEAVY CHECK, A DENT AND CREASE WERE FOUND AT FUSELAGE SKIN STA 1279.53 BETWEEN STR 33R AND 35R. WAS REPAIRED IAW FLIGHT VEHICLES CONSULTING, INC. EO # 24151-2.

Part: SKIN — CRACKED (ZONE 100) · airframe 103,604 hrs · 38,253 cycles

DURING HEAVY CHECK, FOUND CRACKED SKIN CRACKED 1 INCH FWD AND 2.5 INCHES AFT OF IAI PG STRAP. REPAIRED IAW FLIGHT VEHICLES CONSULTING, INC EO #24151-3.

Part: MODULE — FAULTED (MLG WW) · airframe 101,306 hrs · 38,884 cycles

ON APPROACH TO CVG SELECTED FLAPS AND GOT TRAINING EDGE FLAP DISAGREEE MESSAGE. LANDED WITH FLAPS AT 20 DEGREES.

Part: STRUCTURE — CORRODED (FWD CARGO DOOR) · airframe 96,103 hrs · 26,758 cycles

LOWER FWD CARGO DOOR INNER CHORD HAS EVIDENCE OF CORROSION AT APPROX. STA. 500, 530 & 590. REPAIRED CHORD.

Part: ATTACH BRACKET — DAMAGED (ZONE 400) · airframe 96,103 hrs · 26,759 cycles

#1 PYLON FAN COWL ATTACHING BRACKET DAMAGED. BLEND REPAIRED BRACKET.

Part: SKIN — CORRODED (RT WING) · corrosion level 3 · airframe 100,755 hrs · 38,683 cycles

CORROSION BEYOND LIMITS FOUND ON RH WING LOWER SKIN BETWEEN WS 1045.0 & WS 1070.59 AND THE REAR SPAR.

Part: SKIN — CORRODED (LT WING) · corrosion level 3 · airframe 100,755 hrs · 38,683 cycles

CORROSION FOUND ON LH WING UPPER SKIN BETWEEN STR U-2 AND U-4 AND SPLICE AND BODY STATION 97.42.

Part: WARNING MESSAGE — FALSE ACTIVATION (SLAT ASYM) · airframe 87,621 hrs · 26,654 cycles

ON APPROACH TO CVG AT 4,000 FEET SELECTED FLAPS TO POSITION 1 AND RECEIVED A LE SLAT ASYM MESSAGE. DECLARED AN EMERGENCY AND CONTINUED THE APPROACH. LANDED AIRCRAFT WITHOUT FURTHER INCIDENT. FLAP/SLAT SYSTEM OPERATED NORMALLY WITH NO MESSAGES AFTER LANDING.

Part: FLAP TRACK — WORN (LT WING) · airframe 87,614 hrs · 26,650 cycles

OUTBOARD FLAP TRACK SUPPORT BEAMS NO.'S 1, 2, 7, AND 8 ATTACHMENT HOLES BUSHING REPAIR.

Part: FLOORBEAM — CORRODED (BS 228 LBL11-26) · corrosion level 3 · airframe 87,614 hrs · 26,650 cycles

FUSELAGE SECTION 41, FLOOR BEAM AROUND F.S. 228 BETWEEN LBL 11-26 CORROSION FOUND OUT OF LIMITS.

Part: FLOORBEAM — CORRODED (BS 347 RBL55-89) · airframe 87,614 hrs · 26,650 cycles

FUSELAGE SECTION 41, FLOOR BEAM AROUND F.S. 347 BETWEEN RBL 54.75 - 88.5 CORROSION OUT OF LIMITS.

Part: SKIN — DAMAGED (BS 632-654 S25L) · airframe 87,614 hrs · 26,650 cycles

FUSELAGE SECT 43 AT FUSLEAGE SKIN BETWEEN F.S. 632-654 AT STR 25 LH ELONGATED HOLE.

Part: PRESSURE BLKHD — DENTED (BS 1582) · airframe 87,614 hrs · 26,650 cycles

FUSELAGE SECT 48, AFT PRESSURE BULKHEAD AT F.S. 1582 AROUND 9 O'CLOCK POSITION DENT REPAIR.

Part: FITTING — DAMAGED (RT WING TE FLAP) · airframe 87,614 hrs · 26,650 cycles

RH WING INBOARD FLAP-OUTBOARD LINKAGE FITTING BLEND OUT REPAIR.

Part: FRAME — DAMAGED (NACELLE) · airframe 87,614 hrs · 26,650 cycles

ENG INBD COWLING FRAME DAMAGE

Part: STRUT — CRACKED (ZONE 400) · airframe 87,614 hrs · 26,650 cycles

ENG NO. 2 PYLON RH STRUT SIDE AFT TRAPEZOIDAL ACCESS DOOR CRACKED.

Part: STIFFENER — WORN (NACELLE) · airframe 87,614 hrs · 26,650 cycles

ENG NO. 2 LH INBOARD THRUST REVERSER STIFFENER DAMAGED

Part: FLT CONTROLS — ABNORMAL (UNKNOWN) · airframe 100,567 hrs · 38,594 cycles

AFTER TAKEOFF PASSING 5,000 FT, EXTREMELY LOUD BANGING NOISE ON RH SIDE OF AIRCRAFT. AIIRCRAFT WAS YAWING BACK AND FORTH. FLIGHT CONTROLS FELT LOOSE. DISCONNECTED AUTOPILOT AND RETURNED TO FIELD WITHOUT INCIDENT. MAINTENANCE PERSONNEL INSPECTED THE AIRCRAFT WITH NO DEFECTS FOUND. A FUNCTIONAL CHECK FLIGHT WAS ACCOMPLISHED WITH NO ISSUES NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: STIFFENER — CRACKED (ZONE 700) · airframe 90,877 hrs · 27,713 cycles

DURING ACCOMPLISHMENT OF AD 2005-02-02. CRACK INDICATION WAS FOUND EXTENDING BELOW WL 160. REPAIR WAS ACCOMPLISHED PER BOEING.

Part: FRAME — CORRODED (ZONE 200) · airframe 90,877 hrs · 27,713 cycles

CORROSION FOUND ON AFT LOWER SIDE OF PRESSURE DECK FRAME AT STA 977, RBL 97. REPAIRED PER KALITTA DWG 53502301.1-OR

Part: STRINGER — CORRODED (ZONE 300) · corrosion level 3 · airframe 90,877 hrs · 27,713 cycles

FOUND SURFACE CORROSION ON HORIZONTAL STABILIZER UPPER STRINGER S-10R AND RBL 39 ON LOWER FLANGE. REPAIRED PER KALITTA DWG 55102304-1.