N13624

Part: BEAM — CRACKED (L1 DOOR) · airframe 42,336 hrs · 22,575 cycles

L-1 DOOR FWD LOWER GATE BEAM IS CRACKED (MARKED). CUT & REMOVED THE DAMAGED PART OF THE LOWER GATE BEAM AND INSTALLED FILLER AND REPAIR DOUBLER PER ECRA 5210- 02217. INITIATED DIP TO READ: ON OR BEFORE 11/1/2012, PERFORM A PERMANENT REPAIR PER PART 3 OF ECRA 5210-02217. PLANNING TO CONT ACT ENG AFTER 9/1/2012 BEFORE 10/1/2012 FOR PERM REPAIR. ON OR BEFORE NOVEMBER 01, 2012, PERFORM A PERMANENT REPAIR PER PART 3 OF ECRA 5210-02217. PLANNING TO CONTACT ENGINEERING AFTER SEPT 01, 2012 BUT BEFORE OCTOBER 01, 2012 FOR PERMANENT REPAIR . DIP CTL NUMBER 07727.

Part: ATTACH BRACKET — CRACKED (FUSELAGE) · airframe 42,336 hrs · 22,575 cycles

SUPPORT TASK, WHEN PERFORMED ES 5310-04437 OP2 INSPECTION FOUND CRACKED ATTACHMENT CLIPS ON STA 360 AR STR 11LT. REPLACED DAMAGED ATTACH CLIP AT STA 360 STR 11LT PER ECRA 5311- 01510.

Part: SKIN — CRACKED (FUSELAGE) · airframe 42,336 hrs · 22,575 cycles

SUPPORT TASK - L-1 DOOR UPPER HINGE CUTOUT - FIRST HOLE BELOW SKIN TRIM PIECE REF ATTACHED DWG FIG 4 (SH2 OF 3) (HOLE MARKED NR 1) SHOWS HFEC CRACK INDICATION SEE ATTACHED 44.0008 - TRIMMED SKIN AND BEAR STRAP AND INSTALLED FILLERS, DOUBLER AND TRIPLER PER ECRA 5330-04078. INITIATED DIP T O READ: BEFORE THE ACCUM OF 77575 TOTAL AC CYCLES, PERFORM AN INSPECTION PER PART 2 OF ECRA5330-04078. PLANNING TO CONTACT ENGINEERING AFTER 70000 BUT BEFORE 71000 CYCLES FOR INSP DETAILS. INTERIM REPAIR ACCOMPLISHED PER ECRA 5330-04078, PART 1. BEFORE THE ACCUMULATION OF 77,575 TOTAL AIRCRAFT FLIGHT CYCLES, PERFORM AN INSPECTION PER PART 2 OF ECRA 5330-04078. PLANNING TO CONTACT ENGINEERING AFTER ACCUMULATION OF 70,000 TOTAL FLT CYCLES BUT BEFORE 71,000 TOTAL FLT CYCLES FOR INSP DETAILS.

Part: DOOR FRAME — GOUGED (FUSELAGE) · airframe 42,336 hrs · 22,575 cycles

SUPPORT TASK - C-2 COMP - GOUGE ON FWD FRAME CUTOUT UPPER CORNER (JUST BELOW LIGHT SWITCH). REMOVED AND REPLACED FRAME AT STA 794 (FWD FRAME AFT CARGO DOOR OPENING) PER ATTACHED FORM 44.0008 ITEMS, DWG 65-47959 AND SRM 51-40-02.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,336 hrs · 22,575 cycles

FLOOR SUPPORT BETWEEN STA 344 &360 12 INCHES LEFT C/L IS CRACKED REMOVED AND REPLACED FLOOR SUPPORT IN REF TO SRM 51-40-02.

Part: FRAME — CRACKED (FUSELAGE) · airframe 42,336 hrs · 22,575 cycles

SUPPORT TASK - WHEN PERFORMED EA 5310-04659 OP 2 INSPECTION FOUND CRACK ON FRAME WEB STA 303.9 AT STR 16L. REPAIR FRAME WEB AT STA 303.9 AT STRINGER 16L PER EA 5310-0465 9 OP 2.

Part: BULKHEAD — CRACKED (BS 178) · airframe 36,887 hrs · 19,723 cycles

STATION 178 BULKHEAD WL 207 LBL 4.5 FASTENER HOLE SHOWS CRACK INDICATION. REAMED HOLE TO .214 IAW ECRA 5310-04794 HFEC IAW B737 NDT MANUAL PT6-51-00-00 SIG.16 OF OPEN HOLE NO CRACKS NOTED. REAMED HOLE TO.246 FOR INSURANCE CUT IAW ECRA 5310-04794 INSTALLED FASTENER IAW ECRA 5310-04794.

Part: FRAME — CRACKED (BS 178) · airframe 36,887 hrs · 19,723 cycles

STATION 178 SIDE CHORD RIGHT-HAND SIDE AT WL 207 IS CRACKED. REMOVED AND REPLACED RIGHT-HAND SIDE CHORD IAW B737 SRM 51-40-02 AND EC/RA 5310-04794, EC/RA 5310-04794.

Part: STIFFENER — CRACKED (BS 178) · airframe 36,887 hrs · 19,723 cycles

STATION 178 VERTICAL BEAM WEB AT LBL 17 AND WL 234 CRACKED. REMOVED, FABRICATED AND INSTALLED UPPER WEB AT LBL 17 IAW ECRA 5310-04794.

Part: STIFFENER — CRACKED (BS 178) · airframe 36,887 hrs · 19,723 cycles

STATION 178 BULKHEAD RBL 17 WL 234 VERTICAL BEAM WEB CRACKED. REMOVED, FABRICATED AND INSTALLED UPPER WEB AT RBL 17 IAW ECRA 5310-04794.

Part: FRAME — CRACKED (BS 360 S8-9L) · airframe 36,887 hrs · 19,723 cycles

LEFT SIDE STATION 360 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET MOUNT HOLE CRACKED. REPAIRED FRAME AT BODY STATION 360 BETWEEN S-8 AND S-9 PER EA 624-53-002CAL AND EC/RA 5310-04793.

Part: FRAME — CRACKED (BS 827 S8-9R) · airframe 36,887 hrs · 19,723 cycles

RIGHTHAND SIDE STATION 827 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRAKCED. REPAIRED FRAME AT STATION 827 BETWEEN S-8 AND S-9R PER EA5310-04498.

Part: FRAME — CRACKED (BS 727B S8-9R) · airframe 36,887 hrs · 19,723 cycles

RIGHTHAND SIDE STATION 727B FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED FRAME AT STATION 727B BETWEEN S-8 AND S-9 PER EA5310-04498, OPERATION 02.

Part: FRAME — CRACKED (BS 907 S8-9R) · airframe 36,887 hrs · 19,723 cycles

RIGHTHAND SIDE STATION 907 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED FRAME AT STATION 907 BETWEEN S-8 AND S-9 PER EA 5310-04498.

Part: FRAME — CRACKED (BS 867 S8-9R) · airframe 36,887 hrs · 19,723 cycles

RIGHTHAND SIDE STATION 867 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED FRAME AT STATION 867 BETWEEN S8 AND S9R PER EA5310-04498.

Part: FRAME — CRACKED (BS 907 S8-9L) · airframe 36,887 hrs · 19,723 cycles

LEFTHAND SIDE STATION 907 FRAME BETWEEN S-8 AND S-9 AIRCONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED FRAME AT STATION 907 BETWEEN S-8 AND S-9 PER EA5310-04498 OPERATION 02.

Part: FRAME — CRACKED (BS 787 S8-9R) · airframe 36,887 hrs · 19,723 cycles

LEFTHAND SIDE STATION 787 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED CRACKED LEFTHAND FRAME STATION 787 BETWEEN S-8 AND S-9 A/C BRACKET MOUNT REF EA5310-04498 OP 02.

Part: FRAME — CRACKED (BS 747 S8-9R) · airframe 36,887 hrs · 19,723 cycles

RIGHTHAND SIDE STATION 747 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED FRAME AT STATION 747 BETWEEN S-8 AND S-9 PER EA5310-04498.

Part: FRAME — CRACKED (BS 727B S8-9L) · airframe 36,887 hrs · 19,723 cycles

LEFTHAND SIDE STATION 727B FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED FRAME AT STATION 727B BETWEEN S-8 AND S-9 PER EA5310-04498, OPERATION 02.

Part: FRAME — CRACKED (BS 827 S8-9L) · airframe 36,887 hrs · 19,723 cycles

LEFTHAND SIDE STATION 827 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED FRAME AT STATION 827 BETWEEN S-8 AND S-9 A/C BRACKET MOUNT PER EA5310-04498, OPERATION 02.

Part: FRAME — CRACKED (BS 747 S8-9L) · airframe 36,887 hrs · 19,723 cycles

LEFTHAND SIDE STATION 747 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED FRAME AT STATION 747L BETWEEN S-8 AND S-9 PER EA5310-04498 OPERATION 02.

Part: FRAME — CRACKED (BS 867 S8-9R) · airframe 36,887 hrs · 19,723 cycles

LEFTHAND SIDE STATION 867 FRAME BETWEEN S-8 AND S-9 AIR CONDITIONING (A/C) BRACKET INBOARD MOUNT HOLE CRACKED. REPAIRED LEFTHAND SIDE STATION 867 FRAME BETWEEN S-8 AND S-9 PER EA 5310-04498 OPERATION 02.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 36,887 hrs · 19,723 cycles

SIGNS OF CORROSION ON T-CAP STATION 1016 BL29RT. BLENDED CORROSION ON BS 1016 FLOORBEAM AT RBL 29 DAMAGE FOUND TO BE BEYOND LIMITATIONS PER 737-500 SRM 53-60-51 FIG 101, FABRICATED AND INSTALLED REPAIR PER 737-500 SRM 53-00-51 FIG 201.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 36,887 hrs · 19,723 cycles

DOOR Z-ANGLE STRAP AT BODY STATION 227 TO 294 CORRODED. REMOVED AND REPLACED Z-ANGLE AND STRAP AT R-1 DOOR IAW B737 SRM 51-40-02.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 36,887 hrs · 19,723 cycles

AFT CARGO STATION 767 TO 787 RIGHT TRANSITION ANGLE TOP AND BOTTOM SURFACES ARE CORRODED. REMOVED CORRODED TRANSITION ANGLE FROM AFT CARGO STATION 767 TO 787 AND INSTALLED NEW TRANSITION ANGLE IAW SRM 51-40-02.

Part: MOUNT FITTING — CORRODED (CABIN) · airframe 36,887 hrs · 19,723 cycles

AFT GALLEY LOWER MOUNT FITTING CORRODED AT BODY STATION 1016 LBL 28. FABRICATED NEW FLOOR PAN IAW BAC DWG 65C33582, FABRICATED T-CAP REPAIR STRAP IAW SRM 53-00-51. ALODINED AND PRIMED IAW SRM 51-20-01, INSTALLED FLOOR PAN DIP PAN GALLEY MOUNTS T-ANLGE AND REPAIR STRAP IAW B737 SRM 51-40-02.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 36,887 hrs · 19,723 cycles

FLOORBEAM AT BODY STATION 1016 LBL 37 HAS CORROSION ON UPPER FLANGE. FABRICATED NEW FLOOR PAN IAW BAC DWG 65C33582 FABRICATED T-CAP REPAIR STRAP IAW SRM 53-00-51, ALODINED AND PRIMED IAW SRM 51-20-01, INSTALLED FLOOR PAN DIP PAN GALLEY MOUNTS T-ANGLE AND REPAIR STRAP IAW SRM 51-40-02.

Part: PAN — CORRODED (FUSELAGE) · airframe 36,887 hrs · 19,723 cycles

CORROSION FOUND ON UNDERSIDE OF FLOORBEAM PAN AT BODY STATION 1016 LBL 37. FABRICATED NEW FLOOR PAN IAW BAC DWG 65C33582, FABRICATED T-CAP REPAIR STRAP IAW SRM 53-00-51, ALODINED AND PRIMED IAW SRM 51-20-01, INSTALLED FLOOR PAN DRIP PAN GALLEY MOUNTS T-ANGLE AND REPAIR STRAP IAW SRM 51-40-02.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 36,887 hrs · 19,723 cycles

SIGNS OF CORROSION ON Z-ANGLE FORWARD AREA OF R1 DOOR LOWER FRAME. REMOVED AND REPLACED Z-ANGLE AND STRAP AT R-1 DOOR IAW SRM 51-40-02.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 36,887 hrs · 19,723 cycles

FORWARD PIT STATION 380 S26L WEB ATTACH CLIP IS CRACKED. REPLACED CRACKED CLIP AT STATION 380 S28L WITH FABRICATED CLIP 7075-T6 .032 IAW SRM 51-40-02.

Part: FLOORBEAM — CORRODED (STA 947) · airframe 30,159 hrs · 16,130 cycles

INSPECTION FOUND THE FLOORBEAM AFT FLANGE CORRODED AT STA 947, RBL 4 TO RBL 12. A STRAP REPAIR WAS INSTALLED IAW SRM 53-00-51.

Part: FLOORBEAM — CORRODED (STA 947) · airframe 30,159 hrs · 16,130 cycles

INSPECTION FOUND FLOORBEAM FORWARD FLANGE CORRODED AT STA 947, LBL 10.5. A REPAIR STRAP WAS INSTALLED IAW SRM 53-00-51.

Part: FLOORBEAM — CORRODED (STA 947) · airframe 30,159 hrs · 16,130 cycles

INSPECTION FOUND FLOORBEAM FORWARD FLANGE CORRODED AT STA 947, RBL 10.5, S18R. REPAIRED IAW SRM 53-60-51.

Part: FLOORBEAM — CORRODED (BS 986.5) · airframe 30,159 hrs · 16,130 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 986.5, RBL 7 TO LBL 49. REPAIRED IAW ECRA 5310-04494.

Part: FLOORBEAM — CORRODED (BS 986.5) · airframe 30,159 hrs · 16,130 cycles

INSPECTION FOUND FLOORBEAM UPPER CHORD CORRODED AT STA 986.5, RBL 28 TO RBL 45.5 (RIGHT I/B OF R-2 DOOR Z-ANGLE). A REPAIR WAS INSTALLED IAW SRM 53-00-51, FIGURE 201.

Part: BATTERY — INOPERATIVE (FWD CABIN) · airframe 29,476 hrs · 15,763 cycles

THE EMERGENCY LIGHTS IN FORWARD CABIN WOULD NOT ILLUMINATE DURING TEST WHILE IN SERVICE CHECK. THE BATTERY PACK WAS REMOVED AND REPLACED IAW MM 33-51-51.

Part: SENSOR — OUT OF ADJUST (MLG) · airframe 24,502 hrs · 13,199 cycles

THE LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF FROM HOU. THE AIRCRAFT WAS RETURNED TO HOU WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE ADJUSTED AND TESTED THE MLG SAFETY SENSORS IAW MM 32-09-01. AN OPERATIONAL CHECK OF THE GEAR WAS PERFORMED IAW MM 32-32-04 AND 32-33-00 AND THE GEAR RETRACTED NORMALLY.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 24,502 hrs · 13,198 cycles

INSPECTION FOUND A .5 INCH CRACK IN INTERCOSTAL AT NUT PLATE HOLES BETWEEN STA 344 AND 360, BL 0. THE INTERCOSTAL WAS REMOVED AND REPLACED IAW SRM 51-10-40.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 24,502 hrs · 13,198 cycles

INSPECTION FOUND A 2 INCH CRACK IN CENTER FLOOR SUPPORT AT STA 540 LEFT OF CENTER. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 24,502 hrs · 13,198 cycles

INSPECTION FOUND A .5 INCH CRACK IN INTERCOSTAL AT NUTPLATE HOLES BETWEEN STA 344 AND 360, LBL 10. THE INTERCOSTAL WAS REMOVED AND REPLACED IAW SRM 51-10-40.

Part: FUSE — BLOWN (BATTERY PACK) · airframe 24,502 hrs · 13,198 cycles

INSPECTION FOUND THE LAST FOUR ROWS OF EMERGENCY ESCAPE PATH LIGHTING INOPERATIVE. THE RT AFT BATTERY PACK 5 AMP FUSE WAS REMOVED AND REPLACED IAW MM 33-51-51 AND OPERATION OF THE LIGHTS WAS RESTORED.

Part: SKIN — DENTED (FUSELAGE) · airframe 18,506 hrs · 9,868 cycles

INSPECTION FOUND A DENT IN FUSELAGE SKIN AT STA 396, JUST ABOVE STRINGER 18L. A REPAIR WAS INSTALLED IAW ECRA 5330-03031.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 18,506 hrs · 9,868 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 312, RBL 42. A STRAP REPAIR WAS INSTALLED IAW SRM 53-00-51.

Part: FRAME — CRACKED (FUSELAGE) · airframe 18,506 hrs · 9,868 cycles

INSPECTION FOUND A 7 INCH CRACK IN AFT CARGO COMPARTMENT CENTER BELT FRAME TO SKIN ATTACH AREA AT STA 807, S27L TO S27R. THE CRACKED FRAME WAS REMOVED AND A NEW BOTTOM FRAME WAS INSTALLED IAW SRM 51-10-02.

Part: GIRT BAR — CORRODED (ESCAPE SLIDE) · airframe 18,506 hrs · 9,868 cycles

INSPECTION FOUND L-1 DOOR ESCAPE SLIDE FORWARD AND AFT GIRT BAR SUPPORTS CORRODED AT STA 312 AND STA 344. THE GIRT BAR SUPPORTS WERE REMOVED AND REPLACED IAW SRM 51-10-2.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 18,506 hrs · 9,868 cycles

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT STA 907 - 927, RBL 17, STA 927 - 947.5, RBL 17, STA 947 - 967, LBL 17, AND AT STA 967 - 986,5, LBL 17. THE FLOOR SUPPORTS WERE REPLACED IAW SRM 51-10-2 AND ECRA 5310-03585.

Part: BATTERY — INOPERATIVE (MEGAPHONE) · airframe 18,390 hrs · 9,809 cycles

THE AFT CABIN MEGAPHONE WAS FOUND INOPERATIVE. THE MEGAPHONE BATTERIES WERE REMOVED AND REPLACED AND OPERATION CHECKED GOOD.

Part: SUPPORT FITTING — WORN (HORIZONTAL STAB) · airframe 17,487 hrs · 9,347 cycles

LEFT ELEVATOR OUTBOARD ATTACH BOLT BUSHING IS PULLED OUT OF CASTING. REMOVED AND REPLACED CASTING AND ATTACH FITTINGS ON ELEVATOR PER MM 27-31-11 AND EC/RA 5550-01205.

Part: SEAL — BROKEN (NR 1 ENGINE)

SMOKE APPEARED IN THE COCKPIT AND CABIN DURING CLIMB-OUT OF EWR. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. A BOROSCOPE INSPECTION OF THE NR 1 ENGINE HPC 1ST, 2ND, AND 3RD STAGES FOUND EVIDENCE OF OIL LEAK IN ALL STAGES. THE NR 1 ENGINE WAS REMOVED AND REPLACED. THE ENGINE WAS RUN AT TAKEOFF POWER WITH NO SMOKE OR DEFECTS NOTED. ENGINEERING INVESTIGATION REVEALED THE NR 3 BEARING STATIONARY AFT AIR/OIL SEAL HAD BROKEN INTO THREE PIECES AND WAS THE PRIMARY CAUSE OF ENGINE OIL LEAK.

Part: HYD LINE — LEAKING (TE FLAPS)

THE AIRCRAFT HAD ASSYMETRIC LOCKOUT BETWEEN FLAPS 2 AND 5 ON APPROACH TO IAH. THE ALTERNATE FLAP SYSTEM WAS USED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND FLAP HYDRAULIC LINE LEAKING IN LT FORWARD AIR CONDITIONING BAY. THE HYDRAULIC LINE WAS REPAIRED AND LEAK CHECK WAS GOOD. NO OTHER DEFECTS WERE NOTED.