N12235

Part: CONNECTOR — SHORTED (APU TAILPIPE)

THE AIRCRAFT HAD A BRIEF HISTORY OF THE APU FIRE WARNING ACTIVATING DURING FLIGHT. NO EVIDENCE OF FIRE WAS FOUND. TROUBLESHOOTING FOUND APU TAILPIPE DETECTOR CONNECTORS SHORTING TO GROUND. THE CONNECTORS WERE REPLACED. IN ADDITION, THE FIRE DETECTION MODULE WAS REPLACED AS A PRECAUTIONARY MEASURE. OPERATIONAL CHECKS WERE GOOD.

Part: ANGLE — CORRODED (BS 727)

INSPECTION FOUND RT WING TO BODY ATTACH ANGLE AT STA 727 TO 727B CORRODED. THE ANGLE WAS REMOVED AND A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 53-50-1 AND 51-30-2.

Part: SKIN — CORRODED (BS 925)

INSPECTION FOUND FUSELAGE SKIN CORRODED AT STA 925, STRINGER 26L. THE CORRODED SECTION OF SKIN WAS REMOVED, A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-30-3 AND 53-10-3.

Part: FRAME — CRACKED (BS 500)

INSPECTION FOUND A .125 INCH CRACK IN FRAME AT STA 500A, STRINGER 20L AND 21L. THE CRACKED AREA WAS REMOVED, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-4 AND 51-10-2.

Part: DOUBLER — CORRODED (BS 837)

INSPECTION FOUND DOUBLER CORRODED AT FS 837, STRINGER 24L. THE DOUBLER WAS REMOVED AND A REPLACEMENT DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-40-2, 51-30-2, AND 53-10-2.

Part: SUPPORT — CORRODED (BS 986-1016)

INSPECTION FOUND CABIN FLOOR SUPPORT CORRODED AT STA 986 TO 1016, RBL 4 TO RBL 20. A FLOOR SUPPORT ANGLE WAS FABRICATED AND INSTALLED IAW SRM 53-10-2, FIGURE 7 AND 51-30-2.

Part: SUPPORT — CORRODED (BS 277-294)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 277 TO 294, LBL 50. THE SUPPORT WAS REMOVED, A REPLACEMENT SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 53-10-9 AND 51-30-2.

Part: FRAME — CORRODED (BS 480)

INSPECTION FOUND FRAME CORRODED AT FS 480, STRINGER 25L TO 22L. THE CORRODED SECTION OF FRAME WAS REMOVED, A NEW SECTION WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 53-10-4.

Part: FLOORBEAM — CORRODED (BS 1016)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1016. THE CORRODED AREA WAS REMOVED, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 51-30-1.

Part: ANGLE — CORRODED (BS 270-360)

INSPECTION FOUND SUPPORT ANGLE CORRODED AT STA 270 TO 360, RBL 52. THE CORRODED AREA WAS REMOVED, A SUPPORT ANGLE WAS FABRICATED AND INSTALLED IAW SRM 53-10-2, 51-30-2, AND 51-40-3.

Part: FLOOR — CORRODED (BS 994-1016)

INSPECTION FOUND AFT LAV FLOOR WEB CORRODED AT STA 994 TO 1016, LBL 37 TO LBL 46. THE CORRODED AREA WAS REMOVED, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-30-01 AND 51-30-2.

Part: CHANNEL — CORRODED (BS 1016)

INSPECTION FOUND AFT CABIN CLOSET TO FLOOR ATTACH CHANNEL CORRODED AT STA 1016 TO AFT PRESSURE BULKHEAD, RBL 2. THE CORRODED AREA WAS REMOVED, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 51-10-2.

Part: FRAME — CRACKED (BS 294)

INSPECTION FOUND A 2 INCH CRACK IN FORWARD FRAME OF R-1 DOOR AT STA 294, STRINGER 17R. THE CRACKED AREA WAS CUT OUT, A REPAIR WAS INSTALLED IAW SRM 51-40-3, 51-30-2, AND 51-10-6.

Part: FLOORBEAM — CORRODED (BS 986.5)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 986.5, LBL 24 TO RBL 24. THE FLOORBEAM WAS REPAIRED IAW SRM 53-10-9.

Part: ANGLE — CORRODED (BS 360)

INSPECTION FOUND TIE ANGLE CORRODED AT STA 360, STRINGER 28R. THE TIE ANGLE WAS REMOVED AND A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 53-10-2, 51-10-6, AND 51-30-2.

Part: ANGLE — CORRODED (BS 994)

INSPECTION FOUND SUPPORT ANGLES ATTACHED TO FLOORBEAM AT STA 994, LBL 17 TO LBL 44 AND RBL 17 TO RBL 44 CORRODED. THE SUPPORT ANGLES WERE REMOVED AND REPLACED IAW SRM 51-10-1, 51-30-2 AND 53-10-2.

Part: INTERCOSTAL — CRACKED (BS 500)

INSPECTION FOUND A 2 INCH CRACK IN INTERCOSTAL IN FORWARD CARGO PIT AT STA 500A TO 500B, STRINGER 26R. THE CRACK WAS STOP DRILLED, A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-00-00, FIGURE 23, 51-40-2, AND 51-30-2.

Part: FLOORBEAM — CRACKED (BS 807)

INSPECTION FOUND A 1.5 INCH CRACK IN FLOORBEAM CHANNEL AT STA 807. THE CRACKED AREA WAS REMOVED, A NEW PART WAS FABRICATED AND INSTALLED IAW SRM 51-10-2, 53-10-2, AND 51-30-2.

Part: ANGLE — CORRODED (BS 267-277)

INSPECTION FOUND L-ANGLE CORRODED AT STA 267 TO 277, LBL 12 TO RBL 12. A REPLACEMENT ANGLE WAS FABRICATED AND INSTALLED IAW SRM 53-10-2 AND 51-30-2.

Part: SUPPORT — CRACKED (BS 770)

INSPECTION FOUND A .5 INCH CRACK IN SUPPORT AT FS 770 LT. THE CRACKED AREA WAS REMOVED AND A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-40-2, FIGURE 7.

Part: CHANNEL — CRACKED (VERTICAL FIN)

INSPECTION FOUND A 1 INCH CRACK IN SUPPORT CHANNEL AT BASE OF VERTICAL FIN. A REPAIR ANGLE WAS FABRICATED AND INSTALLED IAW SRM 53-10-2 AND 51-30-2.

Part: FLOOR — CRACKED (BS 986-995)

INSPECTION FOUND A 1.5 INCH CRACK IN FLOOR WEB AT STA 986 TO 995, RBL 43. THE CRACKED AREA WAS REMOVED IAW SRM 51-40-2, A REPAIR DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-40-3, 51-30-3, AND 51-10-3.

Part: INTERCOSTAL — CORRODED (BS 1006-1016)

INSPECTION FOUND FLOOR INTERCOSTAL CORRODED AT STA 1006 TO 1016. THE CORRODED AREA WAS REMOVED, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-2 AND 51-30-2.

Part: SKIN — CRACKED (NR 2 ENGINE)

INSPECTION FOUND A 0.4 CRACK IN NR 2 ENGINE FORWARD PYLON FAIRING SKIN. A REPAIR DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 54-10-2 AND 51-30-2.

Part: SKIN — CRACKED (R-2 DOOR)

INSPECTION FOUND A .5 INCH CRACK AT LOWER FORWARD CORNER OF R-2 DOOR SKIN. THE CRACK WAS STOP DRILLED, A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-10-1 AND 52-00-3.

Part: FRAME — CRACKED (BS 500)

INSPECTION FOUND A .125 INCH CRACK IN FRAME UPPER FLANGE IN FORWARD CARGO PIT AT FS 500A, STRINGER 23L. THE CRACKED AREA WAS REMOVED IAW SRM 53-10-4. FILLER AND DOUBLER WERE FABRICATED AND INSTALLED IAW SRM 53-10-4 AND 53-10-2.

Part: FLOORBEAM — CORRODED (BS 312)

INSPECTION FOUND FLOORBEAM UPPER CHORD CORRODED AT STA 312, LBL 20 TO RBL 20. THE CORRODED SECTION OF FLOORBEAM WAS REMOVED, A REPLACEMENT PART WAS FABRICATED AND INSTALLED IAW SRM 53-10-9 AND 51-30-01.

Part: PANEL — CRACKED (NR 2 ENGINE)

INSPECTION FOUND A 1 CRACK IN NR 2 ENGINE TO PYLON UPPER AFT PANEL. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 54-10-2, 51-40-2, AND 51-30-2.

Part: FLOORBEAM — CORRODED (BS 344)

INSPECTION FOUND UPPER CAP CORRODED AT STA 344, LBL 40 TO RBL 17. THE FLOORBEAM UPPER CAP WAS REMOVED IAW SRM 53-10-9, FIGURE 5. REPAIR ANGLES, SHIM, AND CHORD WERE FABRICATED AND INSTALLED IAW SRM 53-10-9 AND 51-10-2.

Part: FRAME — CRACKED (BS 767)

INSPECTION FOUND A 1 INCH CRACK IN BELTFRAME AT STA 767, STRINGER 13 AND 14R. THE CRACK WAS STOP DRILLED, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-4 AND 51-30-2.

Part: TEE — CRACKED (BS 342)

INSPECTION FOUND A 1.5 INCH CRACK IN FORMED TEE AT BS 342, LBL 12. THE CRACKED TEE WAS REMOVED AND A NEW TEE WAS FABRICATED AND INSTALLED IAW SRM 53-10-2 AND 51-30-2.

Part: FLOORBEAM — CRACKED (BS 328)

INSPECTION FOUND A 1 INCH CRACK IN FLOORBEAM SUPPORT TEE AT STA 328, LBL 48. THE TEE WAS REMOVED AND A NEW TEE WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 53-10-2.

Part: HYD LINE — RUPTURED (A-HYD SYST)

THE A-SYSTEM HYDRAULIC QUANTITY WAS LOST APPROXIMATELY 15 MINUTES INTO FLIGHT. THE LOSS WAS ACCOMPANIED BY ILLUMINATION OF THE NR 1 AND NR 2 PUMP LOW PRESSURE LIGHTS. THE LOSS OF HYD SYSTEM-A QTY CHECKLIST WAS COMPLETED AND THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND A-SYSTEM PRESSURE HYDRAULIC FLEX LINE IN THE LT FLAP WELL INBOARD OF ENGINE PYLON RUPTURED. THE LINE WAS REMOVED AND REPLACED AND LEAK CHECK WAS GOOD.

Part: OIL PRESS SW — CRACKED (NR 2 ENGINE)

THE NR 2 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED AND THE ENGINE OIL QUANTITY DROPPED WHILE ON APPROACH. THE 2 ENGINE WAS SHUT DOWN AND THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 2 ENGINE OIL PRESSURE SWITCH CASE CRACKED AND LEAKING OIL. THE NR 2 ENGINE OIL PRESSURE SWITCH WAS REMOVED AND REPLACED. THE ENGINE WAS SERVICED WITH OIL AND RUN AT VARIOUS POWER SETTINGS WITH NO LEAKS NOTED.

Part: FRAME — CRACKED (CARGO DOOR)

INSPECTION FOUND A 3.75 INCH CRACK BELOW UPPER STOP FITTING OF FORWARD CARGO DOOR AFT FRAME. THE CRACKED SECTION OF FRAME WAS CUT OUT, A FRAME SPLICE REPAIR WAS INSTALLED IAW ECRA 5365-01042.

Part: ADC — INOPERATIVE (E/E RACK)

THE CAPTAIN'S ALTIMETER, COMPASS FLAG IN HSI, OFF FLAG IN ALT SELECT WINDOW, AUTO PILOT, MACH TRIM, GPWS, MODE-C AND CAPTAIN'S DME INSTRUMENTATION ALL WENT INOPERATIVE INTERMITTENTLY WHILE EN ROUTE. THE USABILITY OF THE INSTRUMENTATION WOULD RETURN EVERY 10 TO 15 MINUTES. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE AIR DATA COMPUTER AT FAULT. THE COMPUTER WAS REMOVED AND REPLACED. A PITOT/STATIC CHECK WAS PERFORMED ON THE COMPUTER IAW MM 34-12-11, PAGES 401 AND 402 AND ALL CHECKED GOOD.

Part: SKIN — CRACKED (L 2 DOOR CUTOUT)

INSPECTION FOUND A .75 INCH CRACK IN EXTERNAL SKIN AT FORWARD LOWER CORNER OF L-2 DOOR CUTOUT. THE CRACKED AREA WAS CUT OUT, REPAIR DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 53-30-3, 51-30-2 AND 51-10-2.

Part: DOUBLER — CRACKED (BS 675)

INSPECTION FOUND THREE EACH CRACKS IN T-CHORD AND WEB DOUBLER AT STA 675, RBL 24.8. THE CRACKS WERE .25 INCH OR SMALLER. THE DOUBLER WAS REMOVED AND A NEW DOUBLER WAS INSTALLED IAW SRM 51-30-2. THE EDGE CRACKS ON T-CHORD WERE TRIMMED OUT AND THE REPAIR WAS DETERMINED GOOD IAW SRM 53-10-2.

Part: FLOORBEAM — CRACKED (BS 665)

INSPECTION FOUND A .5 INCH CRACK IN FLOORBEAM WEB AT STA 665, BBL 0. THE AREA WAS REPAIRED IAW EA 5710-01322, SRM 51-30-09 AND SRM 51-30-02.

Part: SKIN — CRACKED (RT WING LE)

GSO - INSPECTION FOUND A 1 INCH CRACK EXTENDING BEYOND STOP HOLE IN RT WING UPPER SURFACE FIXED LEADING EDGE. THE ADJACENT SKIN AT O/B TRACK FOR NR 5 SLAT WAS WARPED. THE DAMAGED AREA WAS ROUTED OUT IAW SRM 57-30-4. REPAIR DOUBLER AND FILTER WERE FABRICATED AND INSTALLED IAW SRM 51-10-2 AND 51-30-2. (W)

Part: SKIN — CRACKED (BS 188-251)

GSO - INSPECTION FOUND SEVERAL FASTENER HOLES CRACKED IN RT FUSELAGE SKIN AT BS 188 TO 251 BETWEEN WL 207 AND WL 234. THE CRACKS WERE ALL APPROXIMATELY .1 INCH LONG. THE CRACKED SKIN SECTIONS WERE CUT OUT. REPAIR DOUBLERS AND FILLERS WERE FABRICATED AND INSTALLED IAW ECRA 5310-01188. (W)