N11641

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 33,942 hrs · 17,962 cycles

SUPPORT TASK - CORROSION ON FRAME SKIN CLIP STA 787 LBL 5. HEAT TREAT FORMS INSTALLED FRAME REPAIR PER SRM 53-00-07 REPAIR 3.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 33,942 hrs · 17,962 cycles

SUPPORT TASK, INTERCOSTAL CRACKED BETWEEN STA 344 AND 360 BL 0. REMOVED AND REPLACED INTERCOSTAL REF SRM 51-40-02.

Part: FITTING — CRACKED (L1 DOOR) · airframe 33,942 hrs · 17,962 cycles

SUPPORT TASK - REMOVE L-1 UPPER DOOR FITTING REMOVED AND REPLACED L-1 UPPER DOOR FITTING REF SRM 51-40-02.

Part: WASHER — INCORRECT (L2 DOOR) · airframe 31,217 hrs · 16,559 cycles

L-2 DOOR EMERGENCY ESCAPE SLIDE GIRT BAR LATCH CABLE HAS INCORRECT WASHERS INSTALLED IN THE ATTACHING HARDWARE. REPLACED L-2 DOOR LANYARD AND WASHERS PER MM 25-61-35,402007.

Part: CABLE ASSY — FRAYED (GIRT BAR) · airframe 31,217 hrs · 16,559 cycles

R-2 DOOR EMERGENCY ESCAPE SLIDE GIRT BAR LATCH CABLE HAS BROKEN STRANS. REMOVED AND REPLACED BROKEN CABLE P/N 65C19901-15, NUT BACN10R1OL AND WASHERS NAS1149C1165R. ARMED AND STOWED PER 737-3/5 MM 25-61-35-402-007.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 28,117 hrs · 14,941 cycles

INTERCOSTAL FWD WET AREA BETWEEN FLOORBEAM 328 & 344 LBL 46 CRACKED AT CLIP NUT HOLE. REMOVED & REPLACED INTERCOSTAL BETWEEN STATIONS 328 & 344 LBL 46 IAW SRM 51-40-02.

Part: FITTING — CRACKED (GIRT BAR) · airframe 28,117 hrs · 14,941 cycles

L1 ENTRY GIRT BAR ATTACH PTS (2) ARE CORRODED. L-1 GIRT BAR FITTING, STA 312, REMOVED CORROSION FOUND TO BE WITHIN LIMITS IAW B737 SRM 53-10-15. ALODINED, PRIMED AND PAINTED L-1 AFT GIRT BAR FITTING OUT OF LIMITS. REMOVED AND REPLACED WITH NEW GIRT BAR FITTING IAW B737 SRM 51-10-02. ALODINE, PRIME, AND PAINT IAW B737 SRM 51-20-01.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 28,117 hrs · 14,941 cycles

STRINGER TIE CLIP CRACKED STA 787 S-15R. REMOVED CRACKED TIE CLIP AT STA 787, STR 15R. LOCATED, DRILLED AND INSTALLED NEW STRINGER TIE CLIP P/N 69-35352-3 AT SAME LOCATION IAW B737-5 SRM 51-40-02.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 28,117 hrs · 14,941 cycles

Z-ANGEL AT L2 DOOR IS CORRODED IN SEVERAL AREAS. REMOVED CORRODED Z-ANGLE AND LOCATED AND DRILLED NEW Z-ANGLE AT L-2 DOOR PER B737 SRM 51-40-02. INSTALLED NEW Z-ANGLE AT L-2 DOOR PER B737 SRM 51-40-02, 51-10-02.

Part: ATTACH BRACKET — CRACKED (FUSELAGE) · airframe 28,117 hrs · 14,941 cycles

INTERCOSTAL ATTACH CLIP TO FRAME STA 348 AT STR 12 LT IS CRACKED. REPAIRED PER PACE EA 641-53-001CAL AND EC/RA 5310-04742.

Part: FRAME — DAMAGED (BS 348 S12L) · airframe 28,117 hrs · 14,941 cycles

TWO RIVET HEADS SHEARED OFF ON AFT SIDE OF FRAME STA 348 AND THE AREA OF STR 12 LT (MARKED). REPLACED 2 RIVETS THAT WERE SHEARED OFF ON AFT SIDE OF FRAME AT STA 348 AND STR 12 LT PER PACE EA 641-53-001 CAL AND EC/RA 5310-04742.

Part: ATTACH FITTING — CRACKED (BS 348 S13L) · airframe 28,117 hrs · 14,941 cycles

INTERCOSTAL ATTACH CLIP TO FRAME STA 348 AT STR 13 LT IS CRACKED (MARKED). REPAIRED PER PACE EA 641-53-001 CAL AND EC/RA5310-04742.

Part: INTERCOSTAL — MISSING (BS 348 S13L) · airframe 28,117 hrs · 14,941 cycles

INTERCOSTAL ATTACH POINT TO INBOARD FLANGE OF FRAME STA 348 AND STR 13 LT, MISSING FASTENERS 2 (MARKED). INSTALLED 2 FASTENERS AT INTERCOSTAL ATTACH POINT TO INBOARD FLANGE OF FRAME STA 348 AND STR 13 LT PER PACE EA 641-53-001CAL AND EC/RA5310-04742.

Part: INTERCOSTAL — MISSING (BS 348 S12L) · airframe 28,117 hrs · 14,941 cycles

INTERCOSTAL ATTACH POINT TO INBOARD FLANGE OF FRAME STA 348 AND STR 12 LT, MISSING FASTENERS 2 (MARKED). INSTALLED 2 FASTENERS AT INTERCOSTAL ATTACH POINT TO INBOARD FLANGE OF FRAME STA 348 STR 12 LT PER PACE EA 641-53-001CAL AND EC/RA5310-04742.

Part: FASTENER — MISSING (INTERCOSTAL) · airframe 28,117 hrs · 14,941 cycles

INTERCOSTAL ATTACH POINT TO INBOARD FLANGE OF FRAME STA 348 AND STR 14 LT FASTENERS (2) MISSING (MARKED). INSTALLED 2 FASTENERS AT BS 348 STR 14 LT AT INTERCOSTAL ATTACH POINT TO INBOARD FLANGE OF FRAME PER PACE EA 641-53-0001 CAL AND EC/RA 5310-04742.

Part: INTERCOSTAL — MISSING (BS 348-360) · airframe 28,117 hrs · 14,941 cycles

INBOARD ATTACH BRACKET FOR STIFFENERS ON TOP AND BOTTOM OF INTERCOSTAL, BETWEEN FRAMES STA 348 & 360, AT STR 8 LT LOCATION, FASTENERS (4) MISSING (MARKED). INSTALLED 4 FASTENERS AT INBOARD ATTACH BRACKET FOR STIFFENERS ON TOP & BOTTOM OF INTERCOSTAL BETWEEN FRAMES 348 & 360 AT STR 8LT PER PACE EA 641-53-001 CAL AND EC/RA 5310-04742.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 28,117 hrs · 14,941 cycles

INTERCOSTAL FWD WET AREA BETWEEN FLOORBEAM 312 AND 328 LBL 46 IS CRACKED AT CLIP NUT HOLE. REMOVED AND INSTALLED NEW INTERCOSTAL FWD WET AREA BETWEEN FLOORBEAM 312 AND 328 LBL 46 IAW B737-500 SRM 51-40-02.

Part: BATTERY — DISCHARGED (CABIN) · airframe 25,219 hrs · 13,410 cycles

EMERGENCY LIGHTS FOUND ON. REPLACED BATTERIES IAW 33-51-51.

Part: CHARGER — INOPERATIVE (EMERGENCY LIGHT) · airframe 20,014 hrs · 10,644 cycles

THE EMERGENCY LIGHTS ON SEAT ROWS 5-9 DID NOT ILLUMINATE DURING TEST. THE EMERGENCY EXIT LIGHT BATTERY CHARGER AT RT OVERWING EXIT WAS REMOVED AND REPLACED IAW MM 33-51-51.

Part: GATE — CORRODED (L-1 DOOR) · airframe 16,474 hrs · 8,768 cycles

INSPECTION FOUND CORROSION AND GOUGES ON EXTERIOR OF L-1 DOOR LOWER GATE. THE LOWER GATE WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: BEAM — CRACKED (CARGO DOOR) · airframe 16,474 hrs · 8,768 cycles

INSPECTION FOUND A 1 INCH CRACK IN C-1 DOOR T-BEAM. A REPAIR WAS INSTALLED IAW SRM 51-70-12.

Part: SKIN — DENTED (AFT CARGO DOOR) · airframe 16,474 hrs · 8,768 cycles

INSPECTION FOUND AFT CARGO DOOR SKIN DENTED 39 INCHES FROM FORWARD EDGE AND 19 INCHES FROM TOP. REPAIRED IAW SRM 52-00-01.

Part: SKIN — DENTED (AFT CARGO DOOR) · airframe 16,474 hrs · 8,768 cycles

INSPECTION FOUND THE AFT CARGO DOOR EXTERNAL SKIN DENTED 21 INCHES FROM FORWARD DOOR EDGE AND 40 INCHES FROM TOP EDGE. A REPAIR DOUBLER WAS INSTALLED IAW SRM 52-00-01, FIGURE 203.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 16,474 hrs · 8,768 cycles

INSPECTION FOUND A .25 INCH CRACK IN INTERCOSTAL AT STA 344-360, RBL 3. THE INTERCOSTAL WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: ANGLE — CORRODED (R-2 DOOR) · airframe 16,474 hrs · 8,768 cycles

INSPECTION FOUND R-2 DOOR THRESHOLD Z-ANGLE CORRODED AT AFT AREA OF DOOR CUTOUT. THE Z-ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-2.

Part: OUTFLOW VALVE — MALFUNCTIONED (AFT/TAIL)

THE AIRCRAFT PRESSURE COULD NOT BE CONTROLLED IN AUTO, ALTERNATE, OR MANUAL AFTER TAKEOFF FROM MEX. THE OXYGEN MASKS WERE DEPLOYED AND THE AIRCRAFT WAS RETURNED TO MEX WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE AFT OUTFLOW VALVE AND BOTH CABIN PRESSURE CONTROLLERS. MAINTENANCE FOUND THAT THE 02 GENERATORS IN LAVS AND SEAT ROWS 1AB, 3AB, 3EF, AND 19L HAD NOT FIRED. ALL O2 GENERATORS WERE REMOVED AND REPLACED AND THE O2 MASKS WERE REPACKED.

Part: GEARBOX — FAILED (NR 1 ENGINE)

THE NR 1 ENGINE FLAMED OUT WHILE ON DESCENT INTO OMA. ENGINE RESTART ATTEMPT WAS UNSUCCESSFUL. THE A/C LANDED WITHOUT INCIDENT. THE NR 1 ENGINE IS BEING REPLACED. INVESTIGATION FOUND GEARBOX FAILURE. SHOP FINDINGS REVEALED GEAR FAILURE CAUSED BY IMPROPER CONCENTRATION OF HYDROCHLORIC ACID USED DURING MANUFACTURING PROCESSES PRIOR TO BLACK OXIDE COATING.