CARIBBEAN SUN AIRLINES INC

Operated by Caribbean Sun Airlines Inc (per NTSB report)

the failure of the right main landing gear under normal loads due to fatigue cracking in an area subject to an FAA Airworthiness Directive that was not adequately inspected.

Sanction: $13,000 · case closed 2024-04-25

Part: LIGHT — INOPERATIVE (ZONE 200) · airframe 62,049 hrs · 41,515 cycles

DURING PREFLIGHT INSPECTION, FLIGHT CREW REPORTED THAT THE TAIL CONE LIGHT WAS INOPERATIVE. ADDITIONALLY, WHEN THE EMERGENCY LIGHTING SYSTEM WAS ACTIVATED, MULTIPLE CEILING LIGHTS DID NOT ILLUMINATE AS REQUIRED. THE EMERGENCY EXIT LIGHT AT THE L2 DOOR WAS ALSO FOUND INOPERATIVE. THE DISCREPANCIES WERE IDENTIFIED ON THE GROUND AND RECORDED IN THE AIRCRAFT MAINTENANCE LOG. MAINTENANCE PERFORMED TROUBLESHOOTING AND CORRECTIVE ACTIONS IN ACCORDANCE WITH APPLICABLE PROCEDURES, AND THE SYSTEM WAS RETURNED TO SERVICE AFTER SATISFACTORY OPERATIONAL CHECKS.

Part: PORTABLE LIGHT — INOPERATIVE (ZONE 200) · airframe 61,838 hrs · 41,316 cycles

DURING PRE-FLIGHT CHECK FOUND L1 DOOR EMERGENCY EXIT PORTABLE LIGHT INOPERATIVE.

Part: LENS — CRACKED (ZONE 200) · airframe 57,368 hrs · 32,889 cycles

DURING SERVICE CHECK FOUND DOOR R1 LIGHT EXIT LENS COVER IS CRACKED. REMOVED & REPLACED LENS IAW WITH AMM 33-60-98. LENS IS A CONSUMABLE ITEM.

Part: A/C PACK — NO DISCREPANCY (ZONE 200) · airframe 57,062 hrs · 32,610 cycles

BURNING SMELL REPORTED AFTER FLIGHT BY FLT ATTENDANTS SUSPECTED FROM LEFT PACK PER THEM. PERFORMED INSPECTION WITH L/H AND R/H A/C PACKS AND NO DISCREPANCY FOUND AS PER MD80 AMM 21-00-00: PERFORMED INSPECTION LEFT AND RIGHT ELECTRIC SYSTEMS NO DISCREPANCY FOUND AS PER MD80 AMM 24-20-00

Part: SKIN — CORRODED (ZONE 300) · airframe 46,484 hrs · 32,872 cycles

LEFT HORIZONTAL STABILIZER LEADING EDGE HAS CORROSION AT UPPER EDGE, ALL THRU THE LENGHT ALSO THE HARWARE OF LOWER EDGE IS RUSTY AND HAS CORROSION AROUND THE FASTENER HEAD. REPAIRED LEADING EDGE PER E.O.'S WAA-250220, WAA-250221, WAA-250222, WAA-250223, WAA-250224, WAA 250225 AND E.O. WAA-250615.

Part: SKIN — CORRODED (ZONE 300) · airframe 46,484 hrs · 32,872 cycles

RIGHT HORIZONTAL STABILIZER LEADING EDGE HAS CORROSION AT UPPER CENTER EDGE AREA AND LOWER SECTION. REPAIRED RIGHT HORIZONTAL STABILIZER LEADING EDGE PER E.O.'S WAA-250319, WAA-250623, AND E.O. WAA-250620.

Part: ANGLE — CORRODED (ZONE 200) · airframe 46,484 hrs · 32,872 cycles

MAIN CABIN AFT R/H LAVATORY HAS CORROSION ALL AROUND THE FLOOR BASE AND INCORRECT HOSE INSTALL. ACCOMPLISHED AFT R/H LAVATORY STRUCTURAL REPAIR IAW E.O. WAA-250503.

Part: ANGLE — CORRODED (ZONE 200) · airframe 46,484 hrs · 32,872 cycles

FWD LAVATORY L/H SIDE HAS CORROSION ALL AROUND THE FLOOR BASE. ACCOMPLISH FWD LAVATORY L/H SIDE STRUCTURAL REPAIR IAW E.O. WAA-250303

Part: ANGLE — CORRODED (ZONE 200) · airframe 46,484 hrs · 32,872 cycles

MAIN CABIN L/H SIDE LAVATORY HAS CORROSION ALL AROUND FLOOR BASE ATTACHMENT AREA. ACCOMPLISH L/H SIDE LAVATORY STRUCTURAL REPAIR IAW E.O. WAA 250403.

Part: BATTERY PACK — DISCHARGED (ZONE 200) · airframe 46,484 hrs · 32,872 cycles

MULTIPLES INTERNAL AND EXTERNAL EMERGENCY LIGHTS INOP. REMOVED AND REPLACED BATTERY PACKS AND EMERGENCY LIGHTSPER MD-80 AMM 33-53-00 OPS CKECK OK.

Part: WINDOW FRAME — CORRODED (ZONE 200) · airframe 46,484 hrs · 32,872 cycles

MAIN CABIN LEFT SIDE WINDOW CUT OUT HAS SEVERAL CORROSION 4, 5, 13, 29, 43, 51. ACCOMPLISHED CORROSION REMOVAL AT MAIN CABIN LEFT SIDE WINDOW CUT OUT NBR 4,13, 29, 43, 51, FOUND WITHIN LIMITS AND REPAIR WINDOW AT # 5 POSITION PER E.O. WAA-250227, MD-80 SRM 53-05 FIG 111, SRM 51-10-3, 51-10-4 AND 51-30-01.

Part: WINDOW FRAME — CORRODED (ZONE 200) · airframe 46,484 hrs · 32,872 cycles

MAIN CABIN RIGHT SIDE WINDOW # 21 HAS CORROSION AROUND CUT OUT. ACCOMPLISHED REPAIR AT WINDOW # 21 R/H SIDE OF FUSELAGE BETWEEN BS 616 AND BS 636 PER E.O. WAA-250219

Part: SKIN — CORRODED (ZONE 300) · airframe 46,484 hrs · 32,872 cycles

LEFT HORIZONTAL STABILIZER LEADING EDGE HAS CORROSION AT UPPER EDGE, ALL THRU THE LENGHT ALSO THE HARDWARE OF LOWER EDGE IS RUSTY AND HAS CORROSION AROUND THE FASTENER HEAD. REPAIR DONE BY E.O. WAA-250220, 250221, 250222, 250223, 25024, 250225, 250615.

Part: LIGHT — BURNED OUT (ZONE 200) · airframe 56,743 hrs · 32,309 cycles

LOW LEVEL EMERGENCY LIGHTS ON SEATS ROWS 21-32 BURNED OUT

Part: ENGINE — FAILED (LEFT) · airframe 61,117 hrs · 40,663 cycles

LH ENGINE FAILURE AFTER TAKEOFF

Part: VALVE — FAILED (ZONE 700) · airframe 56,336 hrs · 31,855 cycles

AFTER TAKEOFF AND RISING LANDING GEAR, THE LANDING GEAR'S RED NOSE LIGHT WAS NOT EXTINGUISHED.

Part: LIGHT — INOPERATIVE (ZONE 200) · airframe 56,275 hrs · 31,790 cycles

EMERGENCY LIGHTS AT CABIN AFT DOOR INOP

Part: BATTERY PACK — DISCHARGED (ZONE 200) · airframe 56,275 hrs · 31,790 cycles

EMERGENCY LIGHTSAT L1 AND L2DOORS ARE INOP (NOT TESTING)

Part: CONTROL MODULE — INOPERATIVE (ZONE 200) · airframe 56,275 hrs · 31,790 cycles

EMERGENCY LIGHTS AT INBOARD OVERWING EXIT DOORS L/H AND R/H ARE INOP

Part: LIGHT — INOPERATIVE (ZONE 200) · airframe 56,206 hrs · 31,714 cycles

EMERGENCY EXIT LIGHT INOP

Part: FUEL SYS — INOPERATIVE (CENTER TANK) · airframe 46,324 hrs · 32,693 cycles

CENTER FUEL TANK NOT CONSUMING FUEL. REMAINED IN 14.3, DECLARED EMERGENCY DIVERTED TO KMIA.

Part: INSTRUMENT PANEL — MULTIPLE FAIL (COCKPIT) · airframe 73,543 hrs · 32,012 cycles

DURING ADVERSE WEATHER LOST MULTIPLE NAV GUIDANCE INSTRUMENTS, AUTO THROTLE AND AUTO PILOT, DECLARED EMERGENCY DIVERTED TO KIAH. UPON LANDING EVERTHING RETORNED TO NORMAL.

Part: LIGHT — DAMAGED (CABIN) · airframe 72,953 hrs · 31,856 cycles

FWD FLIGHT ATTENDANT EMERGENCY EXIT LIGHT WILL NOT HOLD A CHARGE. REMOVED AND REPLACED FWD FLIGHT ATTENDANT EMERGENCY LIGHT IAW MD80 AMM 33-53-00. OPS CHECK NORMAL.

Part: WIRE — BROKEN (FIRE LOOP) · airframe 52,917 hrs · 29,319 cycles

LT ENGINE LOOP A AND FIRE HANDLE INTERMITTENT ILLUMINATION DURING APPROACH WITHOUT FIRE BELL FOR THE ENGINE FIRE AND NO CAWS ALERT. OPS CHECK LT ENGINE FIRE DETECTION LOOP A FOUND TO BE NORMAL IAW AMM 26-10-00. DURING APPROACH, THE LT ENGINE DETECTION LOOP A ND LT FIRE HANDLE INTERMITTENT ILLUMINATION. WHEN TESTING LOOP A IAW QRH, ONLY TWO LOOP LIGHTS CAME ON INSTEAD OF THREE. RT ENGINE AND APU ILLUMINATED, THE LT ENGINE FIRE LOOP A LIGHT AND FIRE HANDLE LIGHT DID NOT ILLUMINATE, FIRE WARNING WAS NOT ACTIVATED IN LT ENGINE, NO CAWS, NO FIRE BELL. TEST WAS NOT SATISFACTORY. PERFORMED TROUBLESHOOTING OF THE NR 1 ENGINE FIRE DETECTION SYSTEM IAW AMM 26-10-00 WDM 26-26-31-01, 26-11-00. FOUND A BROKEN WIRE AT LOOP B OF THE LOWER PYLON DETECTOR ELEMENT THAT WAS CORRECTED. ALSO FOUND SWAPPED ELEMENT WIRES AT UPPER PYLON ELEMENT SENSOR SECURED PER WDM 26-11-00. PERFORMED OPS CHECK. OPS CHECK NORMAL IAW AMM MD-80 26-10-00. NO FAULTS NOTED.

Part: WINDOW — BROKEN (ROW 11) · airframe 57,508 hrs · 37,842 cycles

DURING WALK-AROUND, DISCOVERED PASSENGER CABIN WINDOW AT ROW 11 R/H WAS DAMAGED AND ENTERED THE #2 ENGINE. R/R PASSENGER CABIN WINDOW AT ROW 11 RH IAW MD-80 AMM 56-20-00

Part: ENGINE — FAILED (NR 2) · airframe 57,508 hrs · 37,842 cycles

1. RIGHT ENGINE FAILURE DURING CRUISE, FOLLOWED QRH PROCEDURES AND DIVERTED TO BRO, DECLAIRED EMERGENCY UNEVENTFUL LANDING. 2. DURING WALK-AROUND, DISCOVERED PASSENGER CABIN WINDOW AT ROW 11 R/H WAS DAMAGED. 1. DURING T/S FOUND #2 ENGINE HAD CONSIDERABLE FOD DAMAGE. R/R # 2 ENG IAW W.O. #4863, TC 71-900-01-01. PERFORMED ADJUSTMENT/TEST ENG GROUND RUN-UP ENG CHANGE IAW TC 71-900-02-01. ITEMS S,A,B, +C, SYNCHRONIZATION SYSTEM TEST 6, ELECTRICAL SYSTEM CHK + ITEM, ENGINE GENERATOR FIELD DISCONNECT + OPERATIONAL CHECK COULD NOT BE ACCOMPLISHED DUE TO R/H GENERATOR FAILURE TO COME ONLINE. ADJUSTED PART POWER TRIM AND ENG LOW IDLE TRIM IAW MD80 AMM 71-00-00. ALL PARAMETERS WITHIN LIMITS. C/W BOEING TC 76-021-01-02, ENG EMERGENCY SHUTDOWN SYSTEM. OPS CHK IS SATISFACTORY. 2. R/R PASSGENER CABIN WINDOW AT ROW 11 R/H IAW MD80 AMM 56-20-00.

Part: BALLAST — SMOKE (CABIN LIGHTS) · airframe 72,790 hrs · 31,773 cycles

SMOKE COMING FROM OVERHEAD BIN #3 A/C RH. R/R CABIN SIDEWALL LIGHTING BALLAST IAW MD-80 AMM 33-21-03. OPS CHECK NORMAL.

Part: PUMP — MALFUNCTIONED (FUEL SYSTEM) · airframe 42,460 hrs · 30,074 cycles

DURING CRUISE FWD CENTER PUMP STOPPED WORKING. DIVERSION TO MMUN. PERFORMED AIRCRAFT FUEL SUMP IAW MD-80 AMM 12-11-08. FUEL NORMAL. PERFORMED OPS CHK OF FUEL BOOST PUMP IAW MD-80 AMM 28-20-07 OPS CHK NORMAL. COULD NOT DUPLICATE ON GROUND. THIS ACTION CLEARS DMI 4725. PLACARD REMOVED.

Part: NUT — BACKED OUT (THROTTLE) · airframe 85,737 hrs · 38,861 cycles

AT TOP OF CLIMB LH ENGINE STUCK IN CLIMB SETTING NO THROTTLE RESPONSE BE IT FULL OR IDLE. COMPLETED QRH IDLE 12.2.5 AND 12.2.10 ENGINE. NORMAL SHUTDOWN. LANDING WEIGHT 122.2. DURING T/S DISCOVERED LH THROTTLE PUSH PULL CABLE ROD HAD COME LOOSE FROM FCU. POWER LEVER CRANK. SECURED THROTTLE PUSH-PULL TO FUEL CONTROL UNIT POWER LEVER CRANK IAW M80 76-11-00. FUNCTIONAL CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 57,181 hrs · 37,647 cycles

FWD CABIN EMERGENCY LIGHT BATTERY PACK INOP. R/R FWD CABIN EMERGENCY LIGHT BATTERY PACK IAW AMM 33-53-00.

Part: CONTROL UNIT — MALFUNCTIONED (FIRE DETECTION) · airframe 52,230 hrs · 28,919 cycles

DURING APPROACH LT ENGINE FIRE INDICATION INTERMITTENT AND THEN WENT OFF. MTX T/S ENGINE FIRE DETECTION STSYEM. FOUND LT FIRE LOOP "A" TEST SYSTEM FAILED. TRANSFERRED TO DMI 4568. IN REFRENCE TO DMI 4568: RERACKED LT ENGINE FIRE DETECTOR CONTROL UNIT AS PER AMM 26-10-03. OPS CHECK NORMAL AS PER AMM 26-10-00. THIS ACTION CLEARED DMI 4568.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 41,765 hrs · 29,701 cycles

FOUND BOTH RIGHT SIDE LOWER EMERGENCY EXIT LIGHT INOP.

Part: FILTER — CLOGGED (LT ENGINE) · airframe 51,537 hrs · 28,664 cycles

DURING ATTEMPTED TAKE OFF AS THRUST LEVERS WERE BEING ADVANCED TO T/O THRUST SETTINGS "L OIL FILTER CLOGGING" WARNING LIGHT ILLUMINATED. THRUST LEVERS WERE RETARDED TO IDLE POSITION AND ABOVE WARNING LIGHT EXTINGUISHED. ANOTHER T/O THRUST SETTING WAS ATTEMPTED WITH SAME "L OIL FILTER CLOGGING" WARNING LIGHT ILLUMINATED. ABORTED TAKE OFF WAS ACCOMPLISHED. A/C RETURNED TO GATE. MT FOUND LT ENGINE MAIN OIL FILTER CONTAMINATED. FILTER WAS R/R. PERFORMED LEAK CHECK AND ENGINE RUN UP. OPS CHECK NORMAL NO LEAKS NOTED. ITEM WAS PLACED ON DMI TO ACCOMPLISH REPETITIVE INSPECTION OF OIL FILTER IN 50 FH.

Part: HEAT EXCHANGER — CRACKED (AC BAY) · airframe 56,422 hrs · 37,225 cycles

AFTER TAKE OFF RED "TAIL COMPARTMENT TEMP HIGH" AND "MASTER WARNING" LIGHT ILLUMINATED. INSPECTED TAIL COMPARTMENT FOUND AIR LEAK AT LT PACK PNEUMATIC DUCT. PERFORMED INSPECTION AND CHECK OF LT SECONDARY HEAT EXCHANGER AND FOUND CRACKED. R&R LT SECONDARY HEAT EXCHANGER. OPS CHECK NORMAL. NO LEAKS NOTED.

Part: SPRING — LOOSE (TRIM SYSTEM) · airframe 41,487 hrs · 29,577 cycles

PRIMARY TRIM COMPENSATOR DID NOT WORK AFTER TAKE OFF AND DURING CLIMB. LT TRIM HANDLE NO CABLE TENSION. T/S FOUND PRIMARY LONGITUDINAL TRIM MANUAL OVERRIDE AND SHUTOFF CONTROL SYSTEM DETENT ROLLER SPRING LOOSE. SECURED ROLLER SPRING. OPS CHECK NORMAL ON GROUND CHECK.

Part: NOT REPORTED — MALFUNCTIONED (RT ENGINE) · airframe 56,375 hrs · 37,195 cycles

ON TAKE OFF RT ENGINE APPROACHED CAUTION ZONE EGT. AFTER TAKE OFF RT ENGINE EGT 75 DEGREES CELSIUS HIGHER THAN LT ENGINE 560 DEGREES CELSIUS OIL TEMP EXCEEDED 130 DEGREES CELSIUS. FUEL FLOW RT ENGINE 1000 PPH HIGHER THAN LT ENGINE

Part: DUCT — LEAKING (AC BAY) · airframe 56,352 hrs · 37,181 cycles

DURING CLIMB THRU FL270 TAIL COMPARTMENT TEMP HIGH ANNUNCIATOR LIGHT ON. FOUND PRIMARY HEAT EXCHANGER DUCT LEAKING. R&R PRIMARY HEAT EXCHANGER DUCT. NO LEAKS NOTED. OPS CHECK NORMAL.

Part: PUMP — FAULTY (FUEL SYSTEM) · airframe 41,372 hrs · 29,512 cycles

FUEL NOT PUMPING OUT OF CENTER TANK.

Part: PUMP — MALFUNCTIONED (FUEL SYSTEM) · airframe 56,342 hrs · 37,175 cycles

AFT CENTER FUEL PUMP IS NOT PASSING TEST DURING PREFLIGHT.

Part: BULB — BURNED OUT (ROW 2AB) · airframe 56,320 hrs · 37,162 cycles

SMOKE REPORTED IN CABIN. FOUND ROW 2AB SIDEWALL UPPER LIGHT WALL SOCKET HAD AN ELECTRICAL ODOR AND SMOKE. REMOVED A BURNED OUT BULB AT SECTION 2AB IAW 33-21-03. SMOKE WAS CLEARED AND NO ODOR.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 41,365 hrs · 29,507 cycles

RT ENGINE OIL PRESSURE LIGHT ILLUMINATED. RT ENGINE OIL QTY INDICATE "0" PERFORMED QRH.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 71,840 hrs · 31,122 cycles

AT 25,000 FT NOTICED RT ENGINE OIL/FUEL TEMP HIGH PERFORMED QRH AND SHUT DOWN RT ENGINE RETURNED TO KBRO SINGLE ENGINE LANDING.

Part: NOT REPORTED — MALFUNCTIONED (CABIN PRESSURE) · airframe 41,342 hrs · 29,493 cycles

AIR RETURN TO MGGT. AIRCRAFT WILL NOT PRESSURIZE WITH BOTH PACKS ON AND INDICATING NORMAL.

Part: PUMP — FAILED (CENTER TANK) · airframe 56,180 hrs · 37,084 cycles

FWD & AFT CENTER FUEL TANK BOOST PUMP CIRCUIT BREAKER TRIPPED DURING FLIGHT. TROUBLESHOT THE FUEL PUMP CONTINUITY AND RESISTANCE, CHECKED UNSATISFACTORY IAW AMM 28-20-07. REMOVED AND REPLACED THE FUEL BOOST PUMPS FWD AND AFT IAW AMM 28-20-07. OPS CHECKED THE BOOST PUMPS AND FOUND NORMAL IAW AMM 28-20-07.

Part: PUMP — FAILED (FUEL BOOST) · airframe 56,180 hrs · 37,084 cycles

FWD & AFT CENTER FUEL BOOST PUMP CIRCUIT BREAKER TRIPPED DURING FLIGHT. TROUBLESHOT THE FUEL PUMPS CONTINUITY AND RESISTANCE CHECKED UNSATISFACTORY IAW AMM 28-20-07. REMOVED AND REPLACED THE FUEL BOOST PUMPS FWD AND AFT IAW AMM 28-20-07. OPS CHECKED NORMAL IAW AMM 28-20-07.

Part: LANDING GEAR — COLLAPSED (RIGHT) · airframe 43,724 hrs · 39,539 cycles

RIGHT MAIN LANDING GEAR COLLAPSED AFTER LANDING.

Part: SLIDE — NO TEST (L1 DOOR) · airframe 43,724 hrs · 39,539 cycles

L1 DOOR ESCAPE SLIDE FAILED TO INFLATE DURING DEPLOYMENT PROCESS.

Part: OIL SYSTEM — LEAKING (APU) · airframe 84,358 hrs · 38,172 cycles

ON LANDING, WHITE SMOKE IN THE CABIN. SUSPECTED AND INSPECTED APU, FOUND APU OIL ENTERING APU AIR INLET.

Part: APU — LEAKING (APU BAY) · airframe 55,716 hrs · 36,923 cycles

AFTER LANDING AIRCRAFT WITH APU RUNNING AND 1 PACK ONLINE (RIGHT), SMOKE WAS PRESENT IN CABIN. APU TEMPERATURE RED LINE. REMOVED AND REPLACED APU IAW AMM 49-10-00. OPS CHECK NORMAL.

Part: CLAMP — LOOSE (PNEUMATIC SYS) · airframe 43,121 hrs · 39,375 cycles

TAIL COMPARTMENT TEMP HIGH WARNING LIGHT CAME ON DURING CLIMB. DURING TROUBLESHOOTING, FOUND THE RT COOLING TURBINE OUTLET DUCT CLAMP LOOSE. REPOSITIONED THE PNEUMATIC DUCT AND SECURED THE CLAMP. PERFORMED AN OPS & LEAK CHECK, NO LEAKS NOTED IAW AMM 21-51-01. PERFORMED OPS CHECK OF THE TAIL COMPARTMENT OVERHEAT SENSORS AND ALERTS AND FOUND SATISFACTORY IAW AMM 36-20-02.