USA Jet Airlines, Inc.

Operated by USA JET AIRLINES INC (per NTSB report)

The pilot's failure to adequately compensate for a wind shift while on short final approach which resulted in a higher than normal sink rate and a tailstrike.

Operated by USA JET AIRLINES INC (per NTSB report)

A short in the trim system’s wires and connector, which resulted in the elevator trim being in a full nose-down position.

Operated by USA JET AIRLINES INC (per NTSB report)

Sanction: $24,500 · case closed 2021-12-03

Sanction: $47,662 · case closed 2013-09-06

Sanction: $2,000 · case closed 2009-04-13

Sanction: 3000 · case closed 2000-04-18

Part: SWITCH — WORN (ZONE 700) · airframe 78,834 hrs · 57,795 cycles

FLIGHT CREW REPORTED DURING DESCENT, WHEN POWER LEVER PULLED TO IDLE, NR 2 ENG REMAINED AT A HIGHER POWER SETTING. CREW ATTEMPTED TO VERIFY FAILURE WITH AUTOTHROTTLE OFF & MONITORING DURING DESCENT. CONTACTED ATC DESCENDING THROUGH 10,000’ & REQUESTED DELAY VECTORS. AFTER CONSULTING WITH OPS & MX CONTROL, DETERMINED CLOSEST COM PROCEDURE WAS ENG FAILS TO RESPOND TO THROTTLE, ALTHOUGH THROTTLE DID RESPOND, IT COULD NOT ACHIEVE FLT IDLE. CREW DETERMINED THE SAFEST OPTION WAS TO PERFORM PRECAUTIONARY SHUTDOWN. CHKLIST PERFORMED & AFTER PROCEEDED TO CONDUCT A RNAV 18R & LANDED WITHOUT INCIDENT. MX IN KLRD PERFORMED NR 2 ENG RUN IAW AMM 71-00-00, OPS CHKD GOOD, ALL PARAMETERS WITHIN LIMITS. MX FOUND NLG DOWN SWITCH BAD IAW WDM 73-23-01. MX VISUALLY INSPD NR 2 ENG INLET, EXHAUST, & FUEL CONTROL RIGGING FOR DAMAGE, NO DAMAGE FOUND. MX R & R RT NLG DOWN SWITCH (S1-469) IAW WDM 73-23-01, AMM 32-60-05, & AMM 73-20-00. OPS CHKD GOOD. ENG RUN PERFORMED IAW AMM 71-00-00. NO DEFECTS NOTED.

Part: SKIN SPLICE — CORRODED (ZONE 500) · corrosion level 2 · airframe 59,904 hrs · 33,603 cycles

DISCREPANCY: WHILE AT C-CHECK IN KBQK, STAMBAUGH AVIATION FOUND CORROSION ON THE L/H WING LOWER SURFACE AT STR. 17 (SKIN SPLICE) AND AT XCW 85. BLENDED OUT THE DAMAGED AREA, PERFORMED HFEC OPEN HOLE INSPECTION AND FABRICATED A REPAIR DOUBLER USING 2024T3 .125” AND FILLER USING 7075T6 .063”. THEY PICKED UP THE HOLES, CLEANED, TREATED, PRIMED AND INSTALLED THE FILLER AND REPAIR DOUBLER IAW MD80 SRM 57-03 AND FLIGHT VEHICLES CONSULTING, INC. ENGINEERING ORDER 25095-1. REPAIR APPROVAL PROVIDED BY ROBERT MANASHI DERT 876272412. NO OTHER DEFECTS NOTED.

Part: BEAM — CORRODED (HORIZONTAL STAB) · corrosion level 2 · airframe 72,087 hrs · 38,682 cycles

WHILE AT C-CHECK IN KBQK, FOUND THE LT HORIZONTAL STABILIZER, UPPER SURFACE, OUTBOARD TRAILING EDGE BEAM TO BE CORRODED ABOVE THE #6 ELEVATOR HINGE. CUT OUT THE DAMAGED SECTION OF THE LH BEAM BETWEEN STATIONS 136.50-173.21, THEY FABRICATED A NEW BEAM SECTION FROM BAC 1520-1158. PICKED UP HOLES, CLEANED, TREATED, PRIMED, AND INSTALLED THE SPLICE REPAIR SECTION OF THE LT HORIZONTAL UPPER TRAILING EDGE BEAM IAW SRM 55-10-6 AND 51-30-2, NO OTHER DEFECTS NOTED AT THIS TIME

Part: RIB — CRACKED (LT WING) · airframe 72,087 hrs · 38,682 cycles

WHILE AT C- CHECK IN KBQK, DURING A HFEC INSPECTION OF THE RH RIB CHORD AT STATION BL 70.5 PER AD 14-04-09 S/B 57-0112 R5,A CRACK WAS FOUND IN HOLE MARKED ON THE RH SIDE AT STATION BL 70.5. STOP DRILLED CRACK, PERFORMED A HFEC INSPECTION OF ALL EXISTING HOLES, NO OTHER CRACKS FOUND AT THIS TIME, INSTALLED LARGE REPAIR KIT (65C33202-98) ON RT SIDE AT RBL 70.5,BS 760.95 IAW S/B 57- 0112 R5 AND SRM 51-30-2.

Part: ACM — FAILED (ZONE 200) · airframe 75,736 hrs · 56,282 cycles

THE CREW REPORTED WHEN ENGINE ANTI-ICE WAS TURNED ON, SMOKE FILLED COCKPIT. CREW RAN COM PROCEDURE. SMOKE DISSIPATED WHEN ENGINE ANTI-ICE TURNED OFF. CREW ADVISED OPS & MTX CONTROL, & CONTINUED ON TO ORIG DESTINATION. AIRCRAFT LANDED WITHOUT INCIDENT. MX IN KOAK FOUND RECIRCULATION FAN WITH SIGNS OF INTERNAL WEAR. MX R & R RECIRCULATION FAN IAW AMM 21-20-12. MX PERFORMED BORESCOPE INSPECTION OF #1 & #2 ENGINES. NO ENGINE OIL LEAKS WERE FOUND. MX INSPECTED LT & RT ACMS & ASSOCIATED DUCTS & FOUND OIL IN LT DUCTS. THE LT ACM R & R IAW AMM 21-51-01 & DUCTS CLEANED. OPS & LEAK CHECKED GOOD. BOTH LT & RT WATER SEPARATOR COALESCER BAGS R & R IAW AMM 21-20-02.

Part: FAN — FAULTED (ZONE 100) · airframe 75,700 hrs · 56,262 cycles

DISCREPANCY: THE FLIGHT CREW REPORTED THAT DURING CRUISE AT FL370 AFTER SWITCHING THE ENGINE ANTI-ICE ON THEY COULD SMELL SMOKE, FOLLOWED BY SIGNIFICANT SMOKE. THE CREW RAN THE SMOKE/FIRE FUMES CHECKLIST. THE CREW DONNED OXYGEN MASKS AND DECLARED EMERGENCY. THE CREW REPORTS THAT THE SMOKE CLEARED BY FL090. LANDED SAFELY IN KLBB WITH NO OTHER ISSUES. CORRECTIVE ACTION: USA JET MAINTENANCE IN KLBB INSPECTED THE RECIRCULATION FAN AND ASSOCIATED DUCTING. MAINTENANCE FOUND THE RECIRCULATION FAN TO BE MAKING GRINDING NOISE. MAINTENANCE REMOVED AND REPLACED THE RECIRCULATION FAN IAW MD88 AMM 21-20-12, OPERATIONAL AND LEAK CHECK GOOD. PERFORMED ENGINE GROUND RUN SYSTEM CHECK WITH AIR CONDITIONING SYSTEM CHECK GOOD IAW MD88 AMM 72-00-00.

Part: ACTUATOR — LEAKING (ZONE 700) · airframe 27,280 hrs · 21,260 cycles

CREW STATED THAT WHILE ON FINAL FOR RUNWAY 19L, THE GEAR DID NOT COME DOWN. THEY REQUESTED DELAY VECTORS TO RUN PROCEDURE. THEY PERFORMED PROCEDURE A SUCCESSFULLY, GEAR EXTENDED. THEY DECLARED AN EMERGENCY AND LANDED WITHOUT FURTHER INCIDENT. FOUND THE RH MAIN LANDING GEAR BRACING CYLINDER LEAKING. THEY REMOVED AND REPLACED THE RH MLG BRACING CYLINDER WITH A SERVICEABLE UNIT IAW MM32-30-11. LEAK CHECK WAS NORMAL, HOWEVER THEY WERE UNABLE TO PERFORM THE REQUIRED OPERATIONAL CHECK. LANDING GEAR LOCKS WERE INSTALLED AND THE AIRCRAFT WAS INSPECTED AND FERRIED TO KYIP IN ORDER TO PERFORM THE OPS CHECK. UPON ARRIVAL IN KYIP THE LANDING GEAR LOCKS WERE REMOVED AND SEVERAL LANDING GEAR EXTENSION AND RETRACTION TESTS WERE PERFORMED IAW MM 32-30-00. OPS AND LEAK CHECKS WERE BOTH NORMAL AT THIS TIME

Part: TRANSFER PUMP — LOW PRESSURE (ZONE 100) · airframe 19,305 hrs · 13,920 cycles

CREW REPORTED THAT PREFLIGHT-TAXI-TAKEOFF-CLIMB-THROUGH CRUISE CHECK AT FL320 ALL FUEL INDICATIONS WERE NORMAL. 30 MINUTES LATER FO NOTICED THAT THERE WERE LESS THAN 500 LBS. INDICATING ON THE R/H FUEL GAUGE AND THE L/H FUEL GAUGE SHOWED 3500 LBS. THE CAPTAIN DIRECTED THE FO TO RUN THE “FUEL ASYMMETRY PROCEDURE. THE CAPTAIN LOOKED FOR A POSSIBLE DIVERSION AIRPORT FIRST, THEN ASKED ATC FOR THE CLOSEST AIRPORT WITH AT LEAST A 6000 FT RUNWAY. ATC INFORMED THEM THAT KARG WAS 70 MILES OUT. THE FO INITIATED CROSS FEED TO SEE IF THEY COULD KEEP THE RH FUEL TANK FROM DEPLETING TO 0. THE CAPTAIN DECLARED AN EMERGENCY DESCENT INTO KARG. THE AIRCRAFT LANDED SAFELY WITH 0 LBS. FUEL IN THE RH WING, 300 LBS. IN THE RH FEEDER TANK. AND 3200 LBS.IN THE LH WING. MAINTENANCE IN KARG FOUND THE WING PRE INTERCONNECT OUT OF ADJUSTMENT. THEY ADJUSTED THE WING PRE INTERCONNECT IAW MM 28-10-33. LEAK AND OPS. CHECKS NORMAL. THEY ALSO REMOVED AND REPLACED THE RH TRANSFER PUMP IAW MM 28-10-32. LEAK AND OPS. CHECKS BOTH NORMAL. NO OTHER DEFECTS NOTED AT THIS TIME

Part: VALVE — BINDING (ZONE 100) · airframe 27,178 hrs · 21,201 cycles

DISCREPANCY: CREW REPORTED THAT THE CABIN ALTITUDE LIGHT AND HORN WENT OFF UPON REACHING CRUISE ALTITUDE. THEY DONNED MASKS AND RAN POH PROCEDURE. THEY COULD NOT REDUCE CABIN ALTITUDE WITH AUTO OR MANUAL SYSTEMS. THEY EXECUTED EMERGENCY DESCENT. THEY EXECUTED AN EMERGENCY DESCENT, COORDINATED A DIVERSION TO KDAL WITH ATC AND OPS. UPON REACHING 10000 FEET, THEY STOWED MASKS. THE REST OF THE TRIP WAS UNEVENTFUL. CORRECTIVE ACTION: USA JET MAINTENANCE IN KDAL FOUND THE CABIN CONDITIONING CIRCUIT BREAKER POPPED. THEY REMOVED AND REPLACED THE AIR CONDITIONING SHUT-OFF VALVE IAW DA20 MM21-20-1, NO HELP. THEY FOUND THE RH P3 VALVE BINDING, CAUSING THE CABIN CONDITIONING CIRCUIT BREAKER TO POP THEY REMOVED AND REPLACED THE RH P3 VALVE, OPS AND LEAK CHECKS BOTH NORMAL IAW USA JET WORK CARD N36-01. THEY PERFORMED AN OPS. CHECK OF THE AIRCRAFT PRESSURIZATION SYSTEM IAW DA20 MM 21-30-5. OPS CHECK NORMAL WITH NO OTHER DEFECTS NOTED AT THIS TIME

Part: SEAL — FAILED (ZONE 400) · airframe 19,286 hrs · 13,909 cycles

DISCREPANCY: THE CREW REPORTED ON DEPARTURE, CLIMBING THROUGH 8,000 FEET THE ENGINE #2 FIRE WARNING WENT OFF. THE CREW LEVELED THE AIRPLANE AT 9,000 FEET TO RUN THE RED BOARDER CHECKLIST PROCEDURE. DURING STEP 1 OF THE CHECKLIST PROCEDURE (THRUST LEVER-VERIFY IDLE) THE ENGINE FIRE LIGHT WENT OUT. FLIGHT WAS CONTINUED WITH #2 ENGINE AT IDLE. ATC PROVIDED PRIORITY HANDLING INTO KDAL AIRPORT AT THE CREW’S REQUEST FOR THE LONG RUNWAY AND EMERGENCY SERVICES. AIRCRAFT LANDED SAFELY. CORRECTIVE ACTION: USA JET MAINTENANCE IN KDAL INSPECTED THE #2 ENGINE AND FOUND LARGE SECTION OF SEAL BLOWN OFF ON FUEL HEATER DUCT CAUSING FIRE WARNING. MAINTENANCE REMOVED AND REPLACED SEAL IAW DA20 AMM 73-10-0, PERFORMED LEAK CHECK AT IDLE AND T/O POWER WITH CREW IAW DA20 AMM 71-00-0. NO LEAKS NOTED. USA JET MAINTENANCE ALSO PERFORMED #2 ENGINE FIRE TEST IAW DA20 AMM 26-10-0, OPERATIONAL CHECK GOOD.

Part: SKIN — PILOT ERROR (ZONE 100) · airframe 75,857 hrs · 56,665 cycles

DURING A TAIL-STRIKE INSPECTION IN KYIP, C.A.S. MAINTENANCE FOUND A DRAG MARK ON THE FUSELAGE SKIN AT APPROXIMATELY F.S. 1322 L30, AND THE SKIN GOUGED BETWEEN F.S. 1334 TO 1338, L29L – L29R. MAINTENANCE IN KYIP PERFORMED A HFEC INSPECTION OF THE DAMAGE AREA AND VERIFIED NO CRACKS AND NOM THICKNESS OF 0.061” AND MIN THICKNESS OF 0.044” IN THE DAMAGED AREA. C.A.S MAINTENANCE FABRICATED A REPAIR DOUBLER FROM DMS 1592 0.025” MATERIAL, DOUBLER WAS TREATED, PRIMED AND INSTALLED IAW DC9/MD80 SRM 53-04-1 PARA. C PAGE 8 AND DRAWING # 5911429

Part: SKIN — DENTED (ZONE 100) · airframe 75,857 hrs · 56,665 cycles

DURING A TAIL-STRIKE INSPECTION IN KYIP, C.A.S. MAINTENANCE FOUND THE SKIN GROUND DOWN AND DENTED BETWEEN L29L-L29R AT F.S. 1338-1363. MAINTENANCE IN KYIP PERFORMED CUTOUT OF DAMAGED AREA, MAINTENANCE PERFORMED A HFEC INSPECTION OF THE AREA AND VERIFIED NO FURTHER DAMAGE EXISTED. C.A.S. MAINTENANCE FABRICATED A REPAIR SKIN FROM A NEW SKIN P/N 5911429-151. REPAIR SKIN SECTION WAS TREATED, PRIMED AND INSTALLED IAW DC9/MD80 SRM 53-01, PARA. 2B

Part: TEE FITTING — SEVERED (ZONE 100) · airframe 75,857 hrs · 56,665 cycles

DURING A TAIL-STRIKE INSPECTION IN KYIP, C.A.S. MAINTENANCE FOUND THE AFT PRESSURE BULKHEAD TEE SEVERED AND BENT BETWEEN F.S. 1334-1338 AT BL 0. . MAINTENANCE IN KYIP REMOVED THE DAMAGED APB TEE AND INSTALLED A NEW TEE IAW SRM 53-03, FIGURE 33.

Part: SKIN — DAMAGED (ZONE 100) · airframe 75,857 hrs · 56,665 cycles

DURING A TAIL-STRIKE INSPECTION IN KYIP, MAINTENANCE FOUND THE SKIN IS GROUND OFF BETWEEN F.S. 1331-1338, BETWEEN L29L AND L29R. MAINTENANCE IN KYIP REMOVED AND CUT OUT DAMAGED SKIN BETWEEN F.S. 1331-1338, L29L- L29R, MAINTENANCE PERFORMED A HFEC INSPECTION OF THE AREA AND VERIFIED ALL DAMAGE WAS REMOVED. FABRICATED A INTERNAL DOUBLER FROM 2024 T3 0.025”, FILLERS FROM 2024 T3 0.063 AND AN EXTERNAL DOUBLER FROM 7075 T6 0.071”. THEY TREATED, PRIMED AND INSTALLED REPAIR PARTS IAW SRM 53-04 PARA. 8, FIGURE 9

Part: SKIN PANEL — GOUGED (ZONE 100) · airframe 75,857 hrs · 56,665 cycles

DURING A TAIL-STRIKE INSPECTION IN KYIP, C.A.S. MAINTENANCE FOUND A SKIN PANEL IS GROUND DOWN AT F.S. 1381, L23R-L28R. . MAINTENANCE IN KYIP REMOVED AND CUT OUT DAMAGE. USA JET MAINTENANCE PERFORMED A HFEC INSPECTION OF THE AREA AND VERIFIED NO CRACKS PRESENT. CAS FABRICATED A FILLER AND A DOUBLER FROM TITANIUM 0.025” REPAIR PARTS WERE TREATED, PRIMED AND INSTALLED IAW SRM 53-04, SHEET 4

Part: FRAME — CRACKED (ZONE 100) · airframe 75,857 hrs · 56,665 cycles

DURING A TAIL-STRIKE INSPECTION IN KYIP, C.A.S. MAINTENANCE FOUND A CRACK ON THE R/H OUTER FRAME, OUTER FRAME CAP AT F.S. 1380, L22R-L23R. MAINTENANCE IN KYIP REMOVED AND CUT OUT DAMAGE. USA JET MAINTENANCE PERFORMED A HFEC INSPECTION OF THE AREA AND VERIFIED ALL DAMAGE WAS REMOVED. CAS FABRICATED 2 EA. REPAIR ANGLES FROM 7075-T6 0.063”, 1 EA. FILLER FROM 7075-T6 0.090” AND 2 EA. REPAIR STRAPS FROM 7075-T6 0.063”.ALL REPAIR PARTS WERE TREATED , PRIMED AND INSTALLED IAW TD # 0079-CAS-201 IR AND FAA FORM 8110-3 DATED 7/26/2023.

Part: SKIN PANEL — DENTED (ZONE 100) · airframe 75,857 hrs · 56,665 cycles

DURING A TAIL-STRIKE INSPECTION IN KYIP, C.A.S. MAINTENANCE FOUND THE APB WEB DENTED AND CRACKED, L=20” W=58” DEPTH=0.050” AT F.S 1334-1338. MAINTENANCE IN KYIP PERFORMED THE DAMAGE CUTOUT OF THE APB SKIN, MAINTENANCE PERFORMED A HFEC INSPECTION AND VERIFIED ALL DAMAGE WAS REMOVED. FABRICATED A NEW REPAIR SKIN FROM P/N 5910130-285, REPAIR Y-CHORD FROM P/N 5910130-387, REPAIR SPLICE -5 FROM 2024-T3, REPAIR SPLICE -7 FROM 2024-T3 0.063”, REPAIR PLATE -13 FROM 2024-T3 0.063”AND REPAIR DOUBLER -11 FROM 7075-T6 0.080”. ALL REPAIR PARTS WERE TREATED, PRIMED AND INSTALLED IAW SRM 53-03 PARA. 7 FIG. 33-PAGE 2B AND 53-03 FIGURE 37.

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 69,655 hrs · 39,128 cycles

DISCREPANCY: DURING C-CHECK AT BQK, STAMBAUGH AVIATION FOUND CORROSION ON THE LH KEEL BEAM IN THE AFT LOWER CARGO PIT BETWEEN FUSELAGE STATIONS 950-1010.CORRECTIVE ACTION: STAMBAUGH AVIATION IN BQK, REMOVED AND REPLACED THE LH KEEL BEAM BETWEEN STATIONS 950-1010 IAW B727 SRM 51-30-2. THEY PERFORMED AN HFEC INSPECTION OF THE NEW INSTALLED LH KEEL BEAM IAW B727 NDT MANUAL PARAGRAPH 6 51-00-00 PROCEDURE 23. NO DEFECTS NOTED AT THIS TIME

Part: FLOOR SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 75,266 hrs · 55,993 cycles

WHILE AT C-CHECK, CORROSION WAS FOUND ON CUSP WEB AT APPROXIMATELY BS 209 BETWEEN LBL 44 AND LBL 54. N REMOVED THE CORROSION AND FOUND AREA TO BE OUT OF LIMITS. THE DAMAGED AREA WAS REMOVED AND AN HFEC INSPECTION WAS PERFORMED OF THE TRIMMED-OUT AREA AND THE EXISTING FASTENER HOLES COMMON TO THE REPAIR. NO DEFECTS NOTED. THEY FABRICATED A REPAIR FILLER FROM 7075-T6 0.020 AND A REPAIR DOUBLER FROM 7075-T6 0.025. REPAIR PARTS WERE DRILLED, DEBURRED, TREATED AND PRIMED IAW SRM 51-10-3. REPAIR PARTS WERE INSTALLED ON REPAIR AREA BETWEEN BS 200 AND 215 BETWEEN LBL 44 AND LBL 54 IAW AEI EO 18734. EO 18734 .

Part: LONGERON — CORRODED (BS 1003-1050) · corrosion level 2 · airframe 75,266 hrs · 55,993 cycles

WHILE AT C-CHECK, THE AFT CARGO BILGE AREA BETWEEN BS 1003-1050 AT LONGERON 30 WAS FOUND TO BE CORRODED. REMOVED CORROSION AND FOUND THE AREA TO BE OUT OF LIMITS. THEY TRIMMED OUT THE DAMAGED AREA AND PERFORMED A HFEC SURFACE TRIM PROBE INSPECTION OF ALL THE TRIMMED AREA AND ACCOMPLISHED A HFEC OPEN HOLE INSPECTION OF ALL THE OPEN FASTENER HOLES COMMON TO THE REPAIR. NO CRACK INDICATIONS NOTED. FABRICATED A REPAIR SECTION FOR LONGERON, A SPLICE ANGLE, 2 SPLICE STRAPS AND A FILLER. REPAIR PARTS WERE DRILLED, DEBURRED, TREATED AND PRIMED IAW SRM 51-10-03. ALL REPAIR PARTS WERE INSTALLED WET AND CORROSION INHIBITING COMPOUND WAS APPLIED TO THE REPAIR AREA IAW AEI EO 18918. EO 18918.

Part: LONGERON — CORRODED (ZONE 100) · corrosion level 3 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND LONGERON 22L CORRODED BETWEEN STATIONS 1271 AND 1338 IN THE AFT LOWER CARGO COMPARTMENT CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE AREA AND FOUND THE CORRODED AREAS OUT OF LIMITS IAW DC9/MD80 SRM 51-30-5. THEY REMOVED 3 SECTIONS OF LONGERON 22L BETWEEN F.S. 1271-1338.THEY CUT, DRILLED AND DEBURRED LONGERON SECTIONS FROM 5242886-7075T6511 AND CUT, DRILLED AND DEBURRED REPAIR SPLICES FROM 52642454-7075T6 SPLICE EXTRUSION. TREATED AND PRIMED LONGERON SECTIONS AND SLICE REPAIR PARTS IAWDC9/MD80 SRM 51-10-3. THEY INSTALLED LONGERONS AND SPLICES IN THE AFT CARGO COMPARTMENT BETWEEN F.S. 1271 AND 1338 IAW DC9/MD80 SRM 51-30-5 AND SRM 51-30-2

Part: FRAME — CORRODED (ZONE 100) · corrosion level 2 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: WHILE AT C-CHECK IN KDHN, COMMERCIAL JET FOUND A FRAME CORRODED AT F.S. 1322 AND LONGERON 30 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN FOUND THE FRAME AT F.S. TO BE CORRODED OUT OF LIMITS. THEY CUT OUT DAMAGED SECTION OF THE FRAME AT F.S. 1322BETWEEN LONGERONS 27L AND 27R IAW DC9/MD80 SRM 53-03 FIG. 2A. THEY FABRICATED NEW FRAME FROM .063” 7075-0 AND ALSO FABRICATED 4 EACH SPLICES FROM .071” 7075-0 IAW DC9/MD80 SRM 53-03 FIG. 2A..REPAIR PARTS WERE HEAT TREATED FROM 0 TO T6 CONDITION. THEY FABRICATED FORWARD AND AFT PLATE REPAIR PIECES FROM .063” 7075-T6. IAW DC9/MD80 SRM 53-03 FIG. 2A. THEY LOCATED, DRILLED AND DEBURRED, TREATED AND PRIMED THE FRAME, FRAME SPLICES AND FORWARD AND AFT PLATE REPAIR. THEY INSTALLED REPAIR PARTS (FRAME, FRAME SPLICES AND FWD. AND AFT PLATES REPAIR) IAW DC9/MD80 SRM 53-033 FIG. 2A

Part: LONGERON — CORRODED (ZONE 100) · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND LONGERON 25L CORRODED AT STATION 1287 IN THE AFT LOWER CARGO COMPARTMENT CORRECTIVE ACTION: CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE AREA AND FOUND THE CORRODED AREA OUT OF LIMITS IAW DC9/MD80 SRM 51-30-5. THEY REMOVED THE SECTION OF LONGERON 25L BETWEEN F.S. 1280 AND 1300.THEY CUT, DRILLED AND DEBURRED LONGERON SECTION FROM 2912727-7075T6511 AND CUT, DRILLED AND DEBURRED REPAIR SPLICE FITTINGS FROM 3913291U501. TREATED AND PRIMED LONGERON SECTION AND SLICE FITTING PARTS IAWDC9/MD80 SRM 51-10-3. THEY INSTALLED LONGERONS AND SPLICES IN THE AFT CARGO COMPARTMENT BETWEEN F.S. 1280 AND 1300 IAW DC9/MD80 SRM 51-30-5 AND SRM 51-30-2

Part: LONGERON — CORRODED (ZONE 100) · corrosion level 3 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND LONGERON 24L CORRODED BETWEEN STATIONS 1287 AND 1309 IN THE AFT LOWER CARGO COMPARTMENT CORRECTIVE ACTION: CORRECTIVE ACTION: CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE AREA AND FOUND THE CORRODED AREA OUT OF LIMITS IAW DC9/MD80 SRM 51-30-5. THEY REMOVED THE SECTION OF LONGERON 24L BETWEEN F.S. 1280 AND 1300.THEY CUT, DRILLED AND DEBURRED LONGERON SECTION FROM 2912727-7075T6511 AND CUT, DRILLED AND DEBURRED REPAIR SPLICE FITTINGS FROM 3913291U501. TREATED AND PRIMED LONGERON SECTION AND SLICE FITTING PARTS IAWDC9/MD80 SRM 51-10-3. THEY INSTALLED LONGERONS AND SPLICES IN THE AFT CARGO COMPARTMENT BETWEEN F.S. 1280 AND 1300 IAW DC9/MD80 SRM 51-30-5 AND SRM 51-30-2

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND A MAIN CABIN FLOOR BEAM CORRODED ON THE UPPER AND LOWER SURFACE AT F.S. 1322, LBL54 TO RBL54 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE FLOOR BEAM AND FOUND THE CORROSION TO BE OUT OF LIMITS. THEY TRIMMED OUT SECTION OF FLOOR BEAM IAW EO18214. PERFORMED HFEC OF THE TRIMMED-OUT AREA AND FOUND NO CRACK INDICATIONS. THEY FABRICATED A REINFORCEMENT ANGLE P/N EO18214-11 FROM .100” 7075-T6, A FILLER P/N EO18214-13 FROM.100” 7075-T6 AND A STRAP P/N EO18214-15 FROM >100” 7075-T6. ALL REPAIR PARTS WERE DRILLED, DEBURRED, TREATED AND PRIMED IAW DC9/MD80 SRM 51-10-03. REPAIR PARTS WERE INSTALLED IAW EO18214. REPAIR 8110-3 APPROVED BY RICARDO FERNANDEZ DERT-834363-CE

Part: NONE — CORRODED (ZONE 100) · corrosion level 2 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND A MAIN CABIN FLOOR BEAM CORRODED ON THE UPPER AND LOWER SURFACE AT F.S. 1338, LBL54 TO RBL54 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE FLOOR BEAM AND FOUND THE CORROSION TO BE OUT OF LIMITS. THEY TRIMMED OUT SECTION OF FLOOR BEAM IAW EO18212. PERFORMED HFEC OF THE TRIMMED-OUT AREA AND FOUND NO CRACK INDICATIONS. THEY FABRICATED A REPAIR FILLER P/N EO18212-11 FROM .100” 7075-T6, A REPAIR STRAP P/N EO18212-13 FROM.100” 7075-T6 IAW EO18212. ALL REPAIR PARTS WERE DRILLED, DEBURRED, TREATED AND PRIMED IAW DC9/MD80 SRM 51-10-03. REPAIR PARTS WERE INSTALLED IAW EO18212. REPAIR 8110-3 APPROVED BY RICARDO FERNANDEZ DERT-834363-CE

Part: FRAME — CRACKED (ZONE 200) · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND THE FUSELAGE FRAME AT F.S. 110 LH CRACKED BELOW FLIGHT DECK WINDOW CORRECTIVE ACTION: COMMERCIAL JET IN KDHN VERIFIED CRACKED FRAME. THEY CUTOUT CRACKED SECTION OF FRAME SECTION IAW DC9/MD80 SRM 51-70-5. THEY FORMED FRAME REPAIR SECTION FROM .063” 7075-0 AND REPAIR DOUBLER FROM .071” 7075-0 IAW DC9/MD80 SRM 51-10-2 AND 51-70-5. HEAT TREATED REPAIR PARTS FROM 0 TO T6. THEY DRILLED, DEBURRED, AND TREATED AND PRIMED FORMED FRAME REPAIR SECTION AND REPAIR DOUBLER IAW DC9/MD 80 SRM 51-10-3. THEY INSTALLED FRAME REPAIR SECTION AND REPAIR DOUBLER ON FRAME AT STATION 110 LH BELOW FLIGHT DECK WINDOW IAW DC9/MD80 SRM 51-70-5 FIG. 1 AND SRM 51-30-5

Part: LONGERON — CORRODED (ZONE 100) · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND HOLE DAMAGE ON L8L UPPER INBOARD FLANGE BETWEEN FRAMES 1401 AND 1418 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN, INSPECTED DAMAGE AND FOUND TO BE OUT OF LIMITS. THEY CUTOUT DAMAGE SECTION OF L8L BETWEEN F.S. 1392 AND 1428. THEY FABRICATED, DRILLED AND DEBURRED NEW SECTION OF L8L FROM 2777922-3-7075-T6. THEY ALSO FABRICATED DRILLED AND DEBURRED SPLICE REPAIR FROM 7637813-3-7075-T6. ALL REPAIR PARTS WERE TREATED AND PRIMED IAW DC9/MD80 SRM 51-10-3. THEY INSTALLED NEW LONGERON SECTION AND LONGERON REPAIR SPLICES ON L8L BETWEEN STATIONS 1392 AND 1428 IAW DC9/MD80 SRM 53-14-4 AND SRM 53-02 FIG.18

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 3 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL FOUND AREAS OF CORROSION ON THE SEAT TRACK IN THE MAIN CABIN BETWEEN F.S. 218 AND 788 LBL 54.00 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE AREAS AND FOUND THEM TO OUT OF LIMITS. THEY REMOVED DAMAGED SEAT TRACK FROM F.S. 218 TO 370 AND F.S. 560 TO 797 IAW DC9/MD80 SRM 53-40-00. THEY FABRICATED, DRILLED AND DEBURRED SEAT TRACK SECTIONS FROM F.S. 218-370 AND F.S. 560-797 FROM S00482-7075T76511 AND FABRICATED, DRILLED AND DEBURRED 5 EACH SPLICES FROM .125” 7075-T6. TREATED AND PRIMED ALL REPAIR PARTS IAW DC9/MD80 SRM 51-10-3. THEY INSTALLED 2 EACH SEAT TRACKS AND 5 EACH SPLICES BETWEEN F.S.218 AND 370 AND F.S. 560-797 IAW DC9/MD80 SRM 53-05 AND SRM 51-10-3

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 3 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND NUMEROUS AREAS OF CORROSION ON THE MAIN CABIN SEAT TRACK BETWEEN STATIONS 275 AND 797 RBL 54.5 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE AREA AND FOUND THE AREA FROM F.S. 537-788 TO BE OUT OF LIMITS. THEY REMOVED CORROSION FROM SEAT TRACK BETWEEN STATIONS 275-537(.015”) AND 789—797 (.010”), ORIGINAL THICKNESS .080”,THESE AREAS FOUND TO BE WITHIN LIMITS, AREAS WERE TREATED AND PRIMED IAW DC9/MD80 SRM 51-10-3. THEY REMOVED THE DAMAGED SEAT TRACK BETWEEN STATIONS 537-788 IAW DC9/MD80 SRM 53-05 FIG.4F.THEY FABRICATED, DRILLED AND DEBURRED SEAT TRACK FROM S00482-7075T76511 AND REPAIR SPLICES FROM.063” 7075-T6 AND .100” 7075-T6. ALL REPAIR PARTS WERE TREATED AND PRIMED IAW DC9/MD80 SRM 51-10-3. THEY INSTALLED SEAT TRACK AND REPAIR PARTS BETWEEN F.S. 537 AND 788 RBL 54.5 IAW DC9/MD80 SRM 53-05 FIG. 4F

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 3 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND AREAS OF CORROSION ON THE MAIN CABIN SEAT TRACK BETWEEN F.S. 200 -275 RBL 54.5 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE SEAT TRACK AND FOUND IT TO BE OUT OF LIMITS. THEY REMOVED THE CORRODED SEAT TRACK BETWEEN F.S. 200-275 RBL 54.5 IAW DC9/MD80 SRM 53-05. THEY FABRICATED, DRILLED AND DEBURRED THE SEAT TRACK FROM S00482-7075T76511 AND REPAIR SPLICE PARTS FROM 3925837-501, .063” 7075-T6 AND .100” 7075-T6.REPAIR PARTS WERE TREATED AND PRIMED IAW DC9/MD80 SRM 51-10-3.THEY INSTALLED THE SEAT TRACK AND REPAIR PARTS BETWEEN F.S. 200-275 RBL 54.5 IAW DC9/MD80 SRM 53-05

Part: CUSP WEB — CORRODED (ZONE 100) · corrosion level 3 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND CORROSION ON A CUSP WEB ANGLE AT F.S. 218 LBL 54 IN THE DOOR JAMB AREA. CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE AREA AND FOUND THE CORROSION TO BE OUT OF LIMITS. THEY TRIMMED OUT DAMAGED SECTION OF THE DOOR JAMB. THEY PERFORM A HFEC INSPECTION OF THE TRIMMED SECTION OF THE REPAIR, NO CRACK INDICATIONS OR ANY OTHER DAMAGE INDICATIONS NOTED. THEY FABRICATED A EO18667-11 CUSP ANGLE FROM .063” 7075-T6, A EO18667-13 FILLER FROM .040” 7075-T6 AND A EO18667-15 TAPERED SHIM FROM 7075-T6. ALL REPAIR PARTS WERE DRILLED, DEBURRED, TREATED AND PRIMED IAW DC9/MD80 SRM 51-10-03. ALL REPAIR PARTS WERE INSTALLED AT F.S. 218 LBL IAW FIG. 3 OF EO18667 IR. REPAIR WAS APPROVED BY 8110-3 DATED 8/17/22 BY RICARDO FERNANDEZ DERT-834363-CE

Part: CUSP WEB — CORRODED (ZONE 100) · corrosion level 3 · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND CORROSION ON THE CUSP WEB AND FLOOR WEB AT F.S. 215 RBL 58 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN INSPECTED THE AREA AND FOUND IT TO BE OUT OF LIMITS. THEY TRIMMED OUT DAMAGED SECTION OF THE CUSP ANGLE IAW EO18305 FIGURE 2. THEY FABRICATED A EO18305-11 CUSP ANGLE FROM .071” 7075-T6, A EO18305 -13 UPPER DOUBLER ANGLE FROM .080” 7075-T6, A EO18305-15 LOWER FILLER FROM .090” 7075-T6, A EO18305-17 LOWER DOUBLER FROM .080” 7075-T6 AND EO18305-19 FILLER FROM .071” 7075-T6 IAW FIG 3 OF EO18305. ALL REPAIR PARTS WERE DRILLED, DEBURRED, TREATED AND PRIMED IAW DC9/MD80 SRM 51-20-03. ALL REPAIR PARTS WERE INSTALLED WET IAW FIG. 3 OF EO18305. REPAIR APPROVED BY 8110-3 DATED 8/4/2022 BY RICARDO FERNANDEZ DERT-834363-CE

Part: SKIN — CRACKED (ZONE 100) · airframe 74,652 hrs · 55,584 cycles

DISCREPANCY: DURING C-CHECK IN KDHN, COMMERCIAL JET FOUND A PLUGGED HOLE AT STATION 315 L16L CORRECTIVE ACTION: COMMERCIAL JET IN KDHN PERFORMED A HFEC INSPECTION OF THE AREA AND FOUND THE HOLE TO BE CRACKED. THEY TRIMMED OUT THE DAMAGE AREA IAW FIG 3 OF EO17365. THEY PERFORMED A HFEC INSPECTION OF THE TRIMMED-OUT AREA AND FOUND NO CRACK INDICATIONS OR OTHER DAMAGE. THEY FABRICATED 2 EACH EO17365-11 DOUBLERS FROM .050” 2024-T3, 2 EO17365-13 FILLERS FROM .050” 2024-T3, A EO17365-15 FREEZE PLUG FROM .050” 7075-T6 AS SHOWN IN FIG 2 AND STEP 13 OF EO17365 AND EO17365-17 FILLER FROM .050” 7075-T6. ALL REPAIR PARTS WERE DRILLED, DEBURRED, TREATED AND PRIMED IAW DC9/MD80 SRM 51-10-03.REPAIR PARTS WERE INSTALLED IAW FIG 2 OF EO17365. REPAIR APPROVED BY 8110-3 DATED 6/12/0222 BY RICARDO FERNANDEZ DERT-834363-CE

Part: ENGINE — FLAMED OUT (ZONE 400) · airframe 26,496 hrs · 20,763 cycles

DISCREPANCY: CREW REPORTED THAT WHILE CONDUCTING ENGINE ACCELERATION CHECKS ON THE #1 ENGINE, THE #1 ENGINE FLAMED OUT AT FL290. THE CREW DECLARED AN EMERGENCY WITH CLEVELAND CENTER TO OBTAIN LOWER ALTITUDE, THEY DESCENDED AND PERFORMED A SUCCESSFUL RELIGHT AT FL260. THE CREW CANCELLED EMERGENCY AND RETURNED TO KYIP AND LANDED WITHOUT FURTHER INCIDENT. CORRECTIVE ACTION: USA JET MAINTENANCE IN KYIP REMOVED THE #1 ENGINE AND SENT IT TO INTERNATIONAL TURBINE INC. FOR EVALUATION. THEY INSTALLED A SERVICEABLE #1 ENGINE IAW USA JET GMM VOLUME 3 CHAPTER 72.00.3 CF700 CHECKLIST, OPS, LEAK AND TRIM RUNS ALL NORMAL.

Part: LATCH — CRACKED (ZONE 800) · airframe 58,477 hrs · 32,875 cycles

DISCREPANCY: DURING C-CHECK AT COMMERCIAL JET IN KDHN, THE MAIN CARGO DOOR LATCH BASE LUG FITTINGS 3,4,5,6 AND 7 WERE FOUND TO BE CRACKED AT FASTENER HOLES DURING THE ACCOMPLISHMENT OF AD 2004-11-07 (PSE 52.80.FC3) HFEC INSPECTION OF THE MAIN CARGO DOOR LATCH BASE LUG CORRECTIVE ACTION: COMMERCIAL JET AT KDHN REMOVED AND REPLACED 4 EACH LATCH ASSEMBLIES P/N AE5000-100 AND 1 EACH LATCH ASSEMBLY P/N AE5000-200 WITH NEW LATCH ASSEMBLIES IAW MD80 MM SUPPLEMENT 52-33-05. OPS CHECKS ALL NORMAL IAW MD80 MM SUPPLEMENT 52-33-05

Part: FLAP — CORRODED (ZONE 600) · corrosion level 2 · airframe 58,477 hrs · 32,875 cycles

DISCREPANCY: : DURING C-CHECK AT COMMERCIAL JET IN KDHN, EXFOLIATION CORROSION FOUND ON RH WING INBOARD FLAP AT APPROXIMATELY XRS 69 INNER SURFACE EMANATING FROM UNDER RIB JUST BELOW 3RD FROM INBOARD FLAP VANE MOUNT CORRECTIVE ACTION: COMMERCIAL JET IN KDHN BLENDED OUT DAMAGE AND PERFORMED HFEC INSPECTION OF THE REPAIR AREA. FABRICATED REPAIR STRAP FROM 0.032” 301 CRES, REPAIR STRAP FROM 0.040” 2024-T3 AND A REPAIR SHIM FROM 0.032” 301 CRES. DEBURRED, TREATED, PRIMED AND INSTALLED REPAIR PARTS IAW CJS EO 18600. ALL WORK APPROVED BY 8110-3 DATED 7/27/2022. DER-T VICTOR BURNETT 039923400

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 58,477 hrs · 32,875 cycles

DISCREPANCY: DURING C-CHECK AT COMMERCIAL JET IN KDHN, CORROSION FOUND ON FUSELAGE SKIN INTERNAL DOUBLER AT DRAIN VALVE MOUNTING SURFACE AT STATION 157 CORRECTIVE ACTION: : COMMERCIAL JET IN KDHN TRIMMED OUT DAMAGE AND PERFORMED AN HFEC INSPECTION OF REPAIR AREA, FABRICATED A REPAIR DOUBLER FROM 2024-T3 0.071” AND FILLER FROM 2024-T3 0.063”. DEBURRED, TREATED, PRIMED AND INSTALLED REPAIR PARTS IAW FVC EO 22121-1. ALL WORK APPROVED BY 8110-3 DATED 8/4/2022 ROBERT M. MANASHI DERT 710167-SW

Part: SKIN PANEL — CRACKED (ZONE 100) · airframe 75,543 hrs · 56,419 cycles

DISCREPANCY: WHILE AT C-CHECK AT COMMERCIAL JET IN KDHN THE AREA OF THE AFT FUSELAGE STATION 1401 AND LONG 1L, THE REPAIR DOUBLER AND SKIN ON THE FUSELAGE CROWN AREA WAS FOUND CRACKED CORRECTIVE ACTION: COMMERCIAL JET IN KDHN, REMOVED EXISTING DOUBLER, PERFORMED NDT OF CRACK IN THE SKIN AND DETERMINED IT TO BE 4.9”. AEI ENGINEERING ISSUED EO 17404. THEY TRIMMED OUT CRACK AREA AND PERFORMED A HFEC OF THE AREA AND FOUND NO CRACK INDICATIONS. THEY FABRICATED A FILLER FROM 2024T3 .050, AN INTERNAL DOUBLER FROM 7075 T6 032”, AN EXTERNAL DOUBLER FROM 6AL-4V .032” ANNEALED TITANIUM AND 2 TAPERED SHIMS FROM 2024 T3 .032” IAW EO17404. THEY TREATED, PRIMED AND INSTALLED ALL REPAIR PARTS IAW EO17404.REPAIR APPROVAL FROM RICARDO FERNANDEZ DERT-834363-CE

Part: FLOOR PANEL — CORRODED (ZONE 100) · corrosion level 2 · airframe 75,543 hrs · 56,419 cycles

DISCREPANCY: WHILE AT C-CHECK AT COMMERCIAL JET IN KDHN, A FLOOR PAN WAS FOUND CORRODED AT DRAIN HOLE IN THE MAIN CABIN AT F.S. 207 LBL-50 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN REMOVED THE CORROSION AT MAIN CABIN F.S. 207 LBL-50 IAW MD80 SRM 51-10-3 AND DETERMINED THE AREA TO OUT OF LIMITS IAW MD80 SRM 53-01. THEY FABRICATED A REPAIR DOUBLER FROM 7075 T6 .025”, TREATED AND PRIMED REPAIR DOUBLER IAW MD80 SRM 51-10-3.THEY INSTALLED THE REPAIR DOUBLER AT THE MAIN CABIN F.S. 207 LBL-50 IAW MD80 SRM 51-70-4

Part: ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 75,543 hrs · 56,419 cycles

DISCREPANCY: WHILE AT C-CHECK AT COMMERCIAL JET IN KDHN A FLOOR BEAM UPPER ANGLE WAS FOUND CORRODED IN MULTIPLE PLACES IN THE AFT CABIN @ F.S. 1338 RBL 24- RBL 44 CORRECTIVE ACTION: COMMERCIAL JET IN KDHN REMOVED CORROSION FROM THE FLOOR BEAM UPPER ANGLE AT F.S. 1338 AND FOUND AREAS TO BE OUT OF LIMITS IAW MD80 SRM 53-01.. THEY REMOVED THE FLOOR BEAM UPPER ANGLE AND FABRICATED A NEW ANGLE FROM 7075-T6511 EXTRUSION. THE NEW ANGLE WAS DRILLED AND DEBURRED IAW MD80 SRM 51-10-4, THE ANGLE WAS TREATED AND PRIMED IAW MD80 SRM 51-10-3. NEW ANGLE WAS INSTALLED AT F.S. 1338 IAW MD80 SRM 51-30-5

Part: ENGINE — POWER LOSS (ZONE 400) · airframe 26,217 hrs · 21,415 cycles

DISCREPANCY: CREW REPORTED THAT EN-ROUTE DPA-HQA FL 350 HEARD NOISE AND FELT LOW RUMBLING THEN CHECKED ENGINE PARAMETERS. SAW OIL PRESSURE LOW ON GAUGE JUST AT RED LINE WITHOUT ASSOCIATED WARNING LIGHT. HEADING STARTED TO DRIFT TO THE LEFT WITH AN ASSOCIATED RPM DROP SEEN ON ENGINE GAUGES. DECLARED EMERGENCY ON CURRENT ATC FREQUENCY AND ASKED FOR VECTORS AND DESCENT TO A SUITABLE AIRPORT. THEY PERFORMED OIL PRESSURE LIGHT ON CHECKLIST WHICH LEADS TO ENGINE FAILURE SHUTDOWN IN FLIGHT THEN LANDING WITH LEFT ENGINE SHUTDOWN WINDMILLING N1 AND HYDRAULIC PRESSURE THEN GEAR DOWN PROCEDURE A. LANDED WITHOUT INCIDENT AT KLEX. AFTER PARKING NOTED OIL LEAKING FROM DRAIN AND OPENED THE AFFECTED ENGINE COWL AND NOTED THE ENGINE WAS COVERED IN OIL. RELAYED INFORMATION TO FLIGHT OPS. AND MAINTENANCE DEPARTMENTS.CORRECTIVE ACTION: USA JET MAINTENANCE IN KLEX REMOVED AND REPLACED THE #1 ENGINE IAW USA JET AIRLINES GMM VOL # CHAPTER 72 ENGINE CHANGE CHECKLIST. LEAK AND OPS. CHECKS NORMAL, NO DEFECTS NOTED AT THIS TIME. REMOVED ENGINE TO BE SENT TO ITI FOR EVALUATION.

Part: FRAME — DAMAGED (ZONE 200) · airframe 69,970 hrs · 37,616 cycles

DISCREPANCY WHILE AT C-CHECK AT COMMERCIAL JET IN KDHN THE FOLLOWING DAMAGE WAS FOUND AT STATION 783 WL 213RBL AND LBL63 HAVE PILOT HOLES WITH NO PITCH FROM EXISTING HOLES, CHAFE DAMAGE AND A DRILL STRIKE ON THE INBOARD FREE FLANGE OF THE FRAME. CORRECTIVE ACTION: COMMERCIAL JET IN KDHN FABRICATED 4 EACH FREEZE PLUGS FROM 7075-T651, A CIRCULAR FILLER FROM 7075-T6 .090, STRAP FROM 7075-T6 .071 AND A REPAIR DOUBLER FROM 7075-T6 .071 IAW AEI EO# EO12870, TREATED AND PRIMED PARTS AND INSTALLED PARTS IAW AEI EO NO EO12870. WORK APPROVED BY AEI 8110-3 DATED 2/15/2021 BY ROLF D. HAMERQUIST DERT-636371-NM

Part: GEARBOX — LEAKING (RT ENGINE) · airframe 79,211 hrs · 90,866 cycles

CREW REPORTED THAT IN CRUISE AT FL 340, RT OIL PRESSURE LOW LIGHT CAME ON, GAUGE INDICATIONS BACKED UP LIGHT INDICATION, OIL PRESSURE ZERO, OIL TEMP WENT TO ZERO, OIL QUANTITY DROPPED FROM 16 QTS TO APPROX.. 5 QTS. THEY PERFORMED COM PROCEDURE THROUGH PRECAUTIONARY SHUTDOWN, DECLARED EMERGENCY WITH ATC, DIVERTED TO KLIT, SENT MESSAGE TO OPS. KLIT WEATHER WAS VMC ILS 22R APPROACH AND LANDING WERE WITHOUT INCIDENT. CORRECTIVE ACTION: USA JET MAINTENANCE AT KLIT INSPECTED ENGINE AND CHECKED OIL QUANTITY LEVEL AND FOUND LOW. THEY REMOVED AND REPLACED THE NR 2 ENGINE WITH A SERVICEABLE ENGINE IAW USA JET GMM VOL 2 72.00.1. PERFORMED OPS AND LEAK CHECKS BOTH GOOD. TRIM RUNS COMPLIED WITH IAW USA JET GMM 72.00.18 AND DC9 MM 71-00. AND FOUND NO DEFECTS AT THIS TIME. REMOVED ENGINE WAS SENT TO OSCODA ENGINE SERVICES FOR TEARDOWN AND ANALYSIS. PRELIMINARY TEARDOWN REPORT INDICATES THAT THE FORWARD BEARING ON THE MAIN GEARBOX FOR THE STARTER SHAFT FAILED.

Part: BEAM — CRACKED (L1 DOOR) · airframe 81,719 hrs · 90,946 cycles

DISCREPANCY: DURING C-CHECK AT KDHN A CRACK WAS FOUND ON L1 DOOR AFT BEAM NR 3. CORRECTIVE ACTION: COMMERCIAL JET IN KDHN STOP DRILLED CRACK AND VERIFIED BY NDT. THEY INSTALLED NEW REPAIR DOUBLER AND GUSSET FITTING ON L1 DOOR NR 3 BEAM AFT AREA, IAW DC9 SRM 52-05 FIGURE 85 SHEET 4.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 81,719 hrs · 90,946 cycles

DISCREPANCY: DURING C-CHECK IN KDHN CORROSION WAS FOUND AT FS 724 BETWEEN L27R AND L28R ON FUSELAGE SKIN. CORRECTIVE ACTION: COMMERCIAL JET IN KDHN REMOVED DAMAGED AREA AT FS 724 BETWEEN L27R AND L28R. PERFORMED A HFEC INSPECTION OF THE AREA. THEY INSTALLED REPAIR DOUBLERS -69 AND -71 AND FILLER -75, IAW EO 12254 AND 8110-3.

Part: DOOR FRAME — CHAFED (ZONE 100) · airframe 81,719 hrs · 90,946 cycles

DISCREPANCY: DURING C-CHECK IN KDHN THE FORWARD BAGGAGE COMPARTMENT FS 322 CARGO DOOR LOWER JAMB WAS FOUND TO BE CHAFED AT LONGERON 28. CORRECTIVE ACTION: COMMERCIAL JET IN KDHN REMOVED DAMAGED AREA AND PERFORMED A HFEC INSPECTION OF THE AREA. THEY FABRICATED A NEW REPAIR DOUBLER USING .050 THICK CLAD 2024-T3 ALUMINUM. DRILLED, TREATED, PRIMED AND INSTALLED -003 DOUBLER, IAW EO 2020-1118 AND 8110-3.

Part: ENGINE — FOD (NR 3) · airframe 69,816 hrs · 37,544 cycles

DISCREPANCY: CREW REPORTED THAT AFTER DEPARTURE FROM KLRD AND CLIMBING THROUGH 10000 FEET, THE NR 3 ENGINE FAILED WITH ASSOCIATED VIBRATIONS. THEY DECLARED AN EMERGENCY AND PERFORMED THE ENGINE FIRE, SEVERE DAMAGE OR SEPARATION CHECKLIST AND LANDED AT THE DEPARTURE AIRPORT WITHOUT FURTHER INCIDENT. CORRECTIVE ACTION: USA JET MAINTENANCE IN KLRD INSPECTED THE ENGINE AND FOUND ALL FOUR STAGES OF THE TURBINE SECTION TO HAVE FOD. THEY REMOVED AND REPLACED THE NR 3 ENGINE, IAW USA JET GMM VOLUME 4 CHAPTER 72.01.1 TO 72.01.26. ALL OPERATIONS AND LEAKS NORMAL DURING ENGINE TRIM RUN.

Part: BEAM — CORRODED (BS 579) · corrosion level 2 · airframe 57,348 hrs · 56,315 cycles

DISCREPANCY: DURING C-CHECK AT KDHN, CORROSION WAS FOUND ON THE FORWARD CARGO LOWER FUSELAGE BEAM AT STATION 579R – 579L ON THE FORWARD AND AFT ENDS. CORRECTIVE ACTION: COMMERCIAL JET CUT OUT THE DAMAGED SECTION OF THE FLOOR BEAM AT STATION 579 RBL 38.0 TO RBL 41.2, FABRICATED, LOCATED, DRILLED, DEBURRED, TREATED, PRIMED AND INSTALLED -1 REPAIR ANGLE, -2 REPAIR ANGLE, -3 FILLER AND -4 FILLER IAW ED20161 REV A AND DC9 SRM 51-10-4, 51-10-3 AND 51-60-0. FAA APPROVED PER 8110-3 ROBERT MANASHI DERT-710167-SW STRUCTURES DATED 5/22/2020.

Part: SPAR CAP — CORRODED (LT WING) · corrosion level 3 · airframe 57,348 hrs · 56,315 cycles

DURING C-CHECK AT KDHN 3 NDT CONFIRMED CRACKS FOUND ON L/H WING XRS 267 UPPER SPAR CAP DURING ACCOMPLISHMENT OF AD05-07-03, S/B 57-179. REMOVED AND REPLACED DISCREPANT AREA OF THE LT WING UPPER REAR SPAR CAP FROM XRS 167.15 TO XRS 319.5 IAW DC9 S/B 57-179 AND DRAWING J060214.