N14239

Part: HYD LINE — LEAKING (NR 1 ENGINE)

THE COCKPIT AND CABIN FILLED WITH SMOKE AFTER TAKEOFF FROM EWR. THE AIR CONDITIONING SMOKE CHECKLIST WAS ACCOMPLISHED AND A RETURN TO EWR WAS BEGUN. THE CREW NOTED A HYDRAULIC SYSTEM LOSS ON FINAL APPROACH. THE A/C LANDED WITHOUT INCIDENT. MX FOUND THE NR 1 ENGINE HYDRAULIC PUMP PRESSURE LINE LEAKING AND THE NR 1 ENGINE 8TH STAGE DUCT WAS LEAKING. BOTH THE HYDRAULIC LINE AND 8TH STAGE DUCT WERE REMOVED AND REPLACED. LEAK AND OP CHECKS WERE GOOD. A BURNOUT CHECK OF PACK AND BLEED SYSTEM FOR NR 1 ENGINE WAS PERFORMED AND ALL CHECKS WERE GOOD. BOTH WATER SEPARATOR BAGS WERE REMOVED AND REPLACED IAW MM 21-51-31.

Part: FLOORBEAM — CORRODED (STA 986)

INSPECTION FOUND FLOORBEAM AND SUPPORT CORRODED AT AFT CABIN L-2 DOOR THRESHOLD, STA 986. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-9, 51-10-2 AND 51-30-2.

Part: BULKHEAD — CRACKED (STA 178)

INSPECTION FOUND A 3.25 CRACK IN R/H SIDE OF PRESSURE BULKHEAD AT STA 178. THE BULKHEAD WAS REPAIRED IAW SRM 53-10-11 AND 53-10-2.

Part: FLOORBEAM — CRACKED (STA 684)

INSPECTION FOUND A 2 INCH CRACK IN FLOORBEAM AT STA 684, RBL 24.8. THE FLOORBEAM WAS REPAIRED IAW EA 5710-01638 AND SRM 51-40-4.

Part: STRINGER — CRACKED (STA 295)

INSPECTION FOUND A .75 INCH CRACK IN STRINGER 12L AT STA 295. THE STRINGER WAS REPAIRED IAW SRM 53-10-2.

Part: SKIN — CRACKED (FUSELAGE)

INSPECTION FOUND THREE .125 INCH CRACKS IN SECTION 41R, RT FORWARD FUSELAGE EXTERNAL SKIN PANEL. THE CRACKED AREA WAS CUT OUT, FILLERS AND DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 51-10-2 AND EA 5310-01188.

Part: STRINGER — CRACKED (CTR WING BOX)

INSPECTION FOUND A .75 INCH CRACK AT RT OUTBOARD END OF CENTER WING BOX UPPER STRINGER NR 3. THE CRACKED SECTION OF STRINGER WAS CUT OUT, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 57-10-4, FIGURE 4 FIGURE 8 AND SRM 57-10-2.

Part: BEAM — CRACKED (STA 685)

INSPECTION FOUND A 3 INCH CRACK IN RADIUS OF TRANSVERSE BEAM AT STA 685. THE CRACK WAS STOP DRILLED, REPAIR ANGLES AND RADIUS FILLERS WERE FABRICATED AND INSTALLED IAW SRM 51-10-1 AND BAC DRAWING NR 65C17103.

Part: STIFFENER — CRACKED (F.S. 295)

INSPECTION FOUND A .5 INCH CRACK IN STIFFENER BETWEEN STRINGER 10L AND 11L AT FS 295. THE CRACKED SECTION OF STIFFENER WAS REMOVED AND A NEW SECTION WAS FABRICATED AND INSTALLED IAW SRM 53-10-3 AND 51-10-2.

Part: ANGLE — CRACKED (STA 540)

INSPECTION FOUND A .5 INCH CRACK THROUGH RADIUS OF RT WING ROOT FORWARD FILLET PANEL SUPPORT ANGLE. THE CRACK WAS LOCATED AT STA 540, 10 INCHES BELOW LOWER CAP OF FORWARD SPAR ADJACENT TO FORWARD END OF HINGED RAM AIR DUCT ACCESS PANEL. THE ANGLE WAS REPAIRED IAW ECRA 5350-01227.

Part: FRAME — CRACKED (STA 947)

INSPECTION FOUND A 2.5 INCH CRACK IN FRAME AT STA 947, STRINGER 18R. THE FRAME WAS REPAIRED IAWS SRM 53-10-2, 53-10-4, 51-10-7, 51-10-2 AND 51-30-2.

Part: FLOORBEAM — CRACKED (BS 684)

INSPECTION FOUND A 1.5 INCH CRACK IN FLOORBEAM AT STA 684, LBL 24.8. THE FLOORBEAM WAS REPAIRED IAW EA 5710-01638 AND SRM 51-40-4.

Part: FITTING — GOUGED (RT HORIZ STAB)

INSPECTION FOUND THE RT HORIZONTAL STABILIZER UPPER AFT SPAR INBOARD ATTACH FITTING GOUGED. THE ATTACH FITTING WAS REPAIRED IAW ECRA 5510-01338.

Part: SKIN — DENTED (B.S. 890)

INSPECTION FOUND A 3 BY 5 INCH AREA OF FUSELAGE SKIN DENTED AT BS 890, LT SIDE, TOP OF WINDOW BELT. THE DENTED AREA WAS CUT OUT, DOUBLER AND FILLER WERE FABRICATED AND INSTALLED IAW SRM 53-30-2, 51-10-2 AND SRM 51-30-2.

Part: CHORD ANGLE — CRACKED (STA 673)

INSPECTION FOUND A 3.25 INCH CRACK IN MAIN CABIN FLOORBEAM LOWER CHORD ANGLE AT STA 673, BL 0. THE AREA WAS REPAIRED IAW BOEING DRAWING 65-45410, CAL ENGINEERING ORDER 031-5710-01322, SRM 51-40-4 AND 51-30-2.

Part: FLANGE — GALLED (BS 663-727)

INSPECTION FOUND RT KEEL BEAM FAYING FLANGE FROM BS 663 TO BS 727 GALLED ON LOWER SURFACE AND WORN AROUND FASTENER HOLES ON UPPER SURFACE. A REPAIR STRAP WAS FABRICATED AND INSTALLED IAW SRM 51-10-2, 51-30-2 AND ECRA 5310-03324.

Part: FLOORBEAM — CRACKED (BS 724)

INSPECTION FOUND A 1 INCH CRACK IN MAIN CABIN FLOORBEAM AT STA 724, BL 0. THE WEB AND STIFFENER WERE REMOVED IAW SRM 51-30-2. A WEB AND DOUBLER WERE FABRICATED AND INSTALLED IAW SRM 51-10-2, 51-20-4, 57-30-2, ECRA 5710-01755 AND REO 02209.

Part: STRINGER — CRACKED (F.S. 837)

INSPECTION FOUND A 1.125 INCH CRACK IN STRINGER 17R BELOW CABIN FLOOR AT FS 837. REPAIR DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 51-40-4, 51-10-2 AND 51-30-2.

Part: FLOORBEAM — CORRODED (STA 360)

INSPECTION FOUND FLOORBEAM CORRODED BETWEEN SEAT TRACK ROW D AND CUSP LINE AT STA 360. A NEW FLOORBEAM WAS FABRICATED AND INSTALLED IAW SRM 53-10-9, 51-10-2 AND 51-30-3.

Part: SKIN — CORRODED (AFT LAV)

INSPECTION FOUND SKIN BULGED/CORRODED WITH POPPED FASTENERS AT FORWARD INBOARD CORNER OF AFT LAV DUMP CHUTE DOOR CUTOUT. THE CORRODED AREA OF SKIN WAS REMOVED IAW SRM 53-30-3. SKIN FILLER, DOUBLER AND SHIMS WERE FABRICATED IAW SRM 53-30-2. STRINGER 26R WAS REMOVED AND A NEW STRINGER WAS DRILLED IAW SRM 51-30-2. THE REPAIR WAS INSTALLED IAW SRM 51-30.

Part: KEEL BEAM — GALLED (BS 663-727)

INSPECTION FOUND LT KEEL BEAM FAYING FLANGE FROM BS 663 TO 727 GALLED ON LOWER SURFACE AND WORN AROUND FASTENER HOLES ON UPPER SURFACE. EXISTING HOLES WERE OVERSIZED AND 3 EACH PRESS FIT BUSHINGS WERE INSTALLED. A REPAIR STRAP WAS FABRICATED AND INSTALLED. ALL WORK WAS PERFORMED IAW SRM 51-10-2, 51-30-2, ECRA 5310-03324, AND REO 02234.

Part: SKIN — CRACKED (FUSELAGE)

INSPECTION FOUND FOUR .125 INCH CRACKS IN SECTION 41, LT FORWARD FUSELAGE EXTERNAL SKIN PANEL. THE CRACKED AREA WAS CUT OUT, FILLERS AND DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 51-10-2 AND EA 5310-01188.

Part: STRINGER — CRACKED (W.S. 6R)

INSPECTION FOUND A 1.25 INCH CRACK IN WING SUPPORT STRINGER AT RIGHT WBL 70.85, WS 6. THE CRACKED SECTION OF STRINGER WAS CUT OUT, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 57-10-4, FIGURE 8 AND SRM 57-10-2.

Part: GCU — INOPERATIVE (P6 PANEL)

THE LEFT BUS OFF LIGHT COME ON SHORTLY AFTER TAKEOFF. THE LIGHT WAS ACCOMPANIED BY AN ELECTRICAL ODOR OR AIR CONDITIONING PACK SMELL AND A CLICKING SOUND, LIKE THAT OF A RELAY OPENING AND CLOSING, THE SOUND WAS HEARD COMING FROM BEHIND THE SECOND OFFICER'S SEAT. THE LIGHT EXTINGUISHED AND THE ODOR DISSIPATED ABOUT 10 MINUTES LATER. THE AIRCRAFT LANDED AT ATL WITHOUT INCIDENT. MAINTENANCE CHECKED THE ELECTRICAL OPERATION OF BOTH ENGINE GENERATORS AND FOUND BOTH GOOD. THE LEFT GCU WAS REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE, AN OPERATIONAL CHECK OF THE APU GENERATOR WITH MAXIMUM LOAD GAVE ALL NORMAL PARAMETERS.

Part: HYD LINE — LEAKING (NLG D/L ACT)

THE A-SYSTEM HYDRAULIC QUANTITY BEGAN TO DROP SHORTLY AFTER TAKEOFF. THE AIRCRAFT WAS RETURNED TO CLE WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NOSE GEAR DOWNLOCK ACTUATOR UPPER LINE LEAKING. THE LINE WAS REMOVED AND REPLACED, LEAK CHECK WAS GOOD.

Part: DNLOCK ACTUATOR — BROKEN (RT MLG)

FLT NR 1249 - EWR - THE RIGHT MLG WOULD NOT RETRACT AFTER DEPARTING BDL FOR CLE. THE GEAR WAS VISUALLY CONFIRMED DOWN AND LOCKED AND THE AIRCRAFT WAS DIVERTED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE RIGHT MLG DOWNLOCK ACTUATOR BROKEN. THE ACTUATOR WAS REMOVED AND REPLACED IAW MM 32-32-51. AN ADJUSTMENT/TEST WAS PERFORMED IAW MM 32-32-00, PAGE 501. SYSTEM OPERATION CHECKED GOOD WITH NO LEAKS NOTED. (M)

Part: FRAME — CRACKED (BS 440L)

GSO - INSPECTION FOUND A .5 INCH CRACK IN FRAME AT STATION 440L BETWEEN STRINGERS 19L-20L. THE CRACKED FRAME SECTION WAS CUT OUT. A NEW FRAME AND CHORD SPLICES WERE FABRICATED AND INSTALLED IAW SRM 51-30-2 AND BOEING DRAWING NR 65C27113. (M)

Part: FRAME — CRACKED (BS 420)

GSO - INSPECTION FOUND A .5 INCH CRACK IN FRAME AT STATION 420L BETWEEN STRINGERS 20L-21L. THE DAMAGE WAS CUT OUT AND A NEW FRAME, CHORD, AND SPLICES WERE INSTALLED IAW SRM 51-30-2 AND BOEING DRAWING 65C25113. (M)

Part: FRAME — CRACKED (GALLEY DOOR)

GSO - INSPECTION FOUND A .75 INCH CRACK IN FORWARD GALLEY DOOR LOWER SIDE OF FRAME AT LOWER FORWARD STOP FITTING. THE CRACKED SEGMENT OF FRAME WAS REMOVED. A NEW SEGMENT WAS INSTALLED PER ECRA 5240-01089 AND BAC DRAWING 69-69680. (M)

Part: FRAME — CRACKED (BS 460)

GSO - INSPECTION FOUND A .75 INCH CRACK IN FRAME AT STATION 460L AND STRINGERS 21L-22L. CUT OUT DAMAGE AND INSTALLED A NEW FRAME, CHORD AND SPLICES IAW SRM 51-30-2 AND BOEING DRAWING 65C25113. (M)

Part: FLOOR BEAM — CORRODED (BS 250)

GSO - INSPECTION FOUND CORROSION ON FLOOR BEAM UNDER COCKPIT FLOOR PANEL AT STATION 250, BBL 0. A WEB AND FILLER REPAIR WERE FABRICATED AND INSTALLED IAW SRM 51-40-2 AND 51-40-4. (M)

Part: FRAME — CRACKED (BS 639)

GSO - INSPECTION FOUND A .5 INCH CRACK IN FRAME AT BS 639R, STRINGER 16. REMOVED CRACKED UPPER CHORD AND FRAME WEB AND INSTALLED REPAIR PARTS IAW BOEING DRAWING NR 65C31658 AND SRM 51-30-2. (M)