Narrative:

At cruise the 4R door developed a very significant air leak along the entire forward edge of the door. Daylight was visible through an approximately 1/4 inch gap between the door and aircraft structure. Communication with air carrier tech confirmed that this situation may indicate that door security is compromised. The flight was diverted to ZZZ. Due to landing limitations; 70000 pounds of fuel were dumped. Fuel dump was within the USA and between FL340 and 5000 ft. Subsequent discussion with tech revealed that this condition had been previously written up 11 times. Due to routine removal of pages from the aircraft log; the flight crew was aware of only 1 previous write-up. Callback conversation with reporter revealed the following information: reporter stated even though they could see daylight through the 1/4 inch visible gap at cabin door 4-RIGHT; fwd edge; no door 'open' or door 'not closed' warning indication(south) appeared in the cockpit. After a maintenance history search; he noticed the numerous flight logbook write-ups for door air leak. This is an outward opening door. He does not know when the last 'C' check or 'heavy maintenance' check was accomplished. Aircraft was ferried to maintenance facility.

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Original NASA ASRS Text

Title: A B-777 PILOT REPORTS OF A SIGNIFICANT PRESSURE LEAK AND APPROX 1/4 INCH VISIBLE GAP ALONG THE ENTIRE FWD EDGE OF CABIN DOOR 4-RIGHT. DOOR PREVIOUSLY WRITTEN-UP ELEVEN (11) TIMES.

Narrative: AT CRUISE THE 4R DOOR DEVELOPED A VERY SIGNIFICANT AIR LEAK ALONG THE ENTIRE FORWARD EDGE OF THE DOOR. DAYLIGHT WAS VISIBLE THROUGH AN APPROX 1/4 INCH GAP BTWN THE DOOR AND ACFT STRUCTURE. COM WITH ACR TECH CONFIRMED THAT THIS SITUATION MAY INDICATE THAT DOOR SECURITY IS COMPROMISED. THE FLT WAS DIVERTED TO ZZZ. DUE TO LNDG LIMITATIONS; 70000 LBS OF FUEL WERE DUMPED. FUEL DUMP WAS WITHIN THE USA AND BTWN FL340 AND 5000 FT. SUBSEQUENT DISCUSSION WITH TECH REVEALED THAT THIS CONDITION HAD BEEN PREVIOUSLY WRITTEN UP 11 TIMES. DUE TO ROUTINE REMOVAL OF PAGES FROM THE ACFT LOG; THE FLT CREW WAS AWARE OF ONLY 1 PREVIOUS WRITE-UP. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: REPORTER STATED EVEN THOUGH THEY COULD SEE DAYLIGHT THROUGH THE 1/4 INCH VISIBLE GAP AT CABIN DOOR 4-RIGHT; FWD EDGE; NO DOOR 'OPEN' OR DOOR 'NOT CLOSED' WARNING INDICATION(S) APPEARED IN THE COCKPIT. AFTER A MAINT HISTORY SEARCH; HE NOTICED THE NUMEROUS FLIGHT LOGBOOK WRITE-UPS FOR DOOR AIR LEAK. THIS IS AN OUTWARD OPENING DOOR. HE DOES NOT KNOW WHEN THE LAST 'C' CHECK OR 'HEAVY MAINT' CHECK WAS ACCOMPLISHED. ACFT WAS FERRIED TO MAINT FACILITY.

Data retrieved from NASA's ASRS site as of January 2009 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.