N14334

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 57,278 hrs · 29,684 cycles

INSPECTION FOUND A 3 INCH CRACK IN SECTION 41 UPPER SKIN DOUBLER AT STA 178-196.5, S2L TO S2R. THE SKIN DOUBLER WAS REPLACED IAW SRM 51-40-02 AND 53-10-01.

Part: FRAME — CORRODED (FUSELAGE) · airframe 55,128 hrs · 28,623 cycles

INSPECTION FOUND STA 727 BULKHEAD FRAME FLANGE CORRODED BETWEEN LEFT AND RIGHT KEELBEAM AS SEEN FROM AFT CARGO COMPARTMENT, LBL 6.3. REPAIRED IAW ECRA 5311-01232.

Part: SKIN — CRACKED (NR 1 PYLON) · airframe 55,128 hrs · 28,623 cycles

INSPECTION FOUND A 0.5 IN CRACK AT EDGE OF NR 1 PYLON SKIN PANEL OPENING NR 5724L UPPER FORWARD CORNER. SKIN REPAIRED IAW ECRA 5430-01204.

Part: SKIN — CRACKED (NR 1 PYLON) · airframe 55,128 hrs · 28,623 cycles

INSPECTION FOUND 0.5 IN CRACK IN 2 PLACES ON NR 1 ENGINE PYLON SKIN ON EXTERNAL SURFACE ACCESS PANEL NR 5724 CUTOUT. PYLON SKIN REPAIRED IAW ECRA 5430-01204.

Part: KEELBEAM — CRACKED (FUSELAGE) · airframe 55,128 hrs · 28,623 cycles

INSPECTION FOUND 1.0 IN CRACK IN LT KEEL BEAM AT STA 727 ON O/B SIDE, LBL 6.5. CRACKED SECTION OF KEEL BEAM LOWER CHORD CUT OUT AND NEW SECTION SPLICED IN IAW ECRA 5311-01230.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 55,128 hrs · 28,623 cycles

INSPECTION FOUND CABIN FLOORBEAM CORRODED AT STA 967, RBL 38 TO LBL 0. REPLACED FLOORBEAM UPPER CHORD IAW ECRA 5311-01231.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 55,128 hrs · 28,623 cycles

INSPECTION FOUND 4 INCH CRACK IN FLOOR SUPPORT AT STA 328, LBL 11. CRACKED AREA CUT OUT AND REPAIRED IAW SRM 51-70-12, FIGURE 1, SHEET 6.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 51,690 hrs · 26,836 cycles

INSPECTION FOUND SHEAR TIE CORRODED AT STA 927 BETWEEN S27L AND S27R IN AFT CARGO AREA. THE SHEAR TIE WAS REMOVED AND REPLACED IAW SRM 53-00-07, FIGURE 210.

Part: SKIN — CORRODED (FUSELAGE) · airframe 51,690 hrs · 26,836 cycles

INSPECTION FOUND FUSELAGE SKIN CORRODED AT STA 927 BETWEEN S27L AND S27R. INSTALLED REPAIR IAW SRM 53-00-01, FIGURE 202.

Part: SKIN — CRACKED (NR 2 PYLON) · airframe 51,690 hrs · 26,836 cycles

INSPECTION FOUND A 1.25 INCH CRACK NR 2 PYLON PANEL NR 5842R. A DOUBLER WAS INSTALLED IAW ECRA 5430-01204.

Part: SKIN — CRACKED (NR 4 SLAT) · airframe 51,690 hrs · 26,836 cycles

INSPECTION FOUND A .5 INCH CRACK IN RT WING NR 4 SLAT SKIN LOWER SURFACE O/B OF ACTUATOR ATTACH. THE CRACKED AREA WAS CUT OUT AND FILLER AND DOUBLER WERE INSTALLED IAW SRM 57-43-01.

Part: INTERCOSTAL — CORRODED (FUSELAGE) · airframe 51,690 hrs · 26,836 cycles

INSPECTION FOUND INTERCOSTAL IN E&E COMPARTMENT CORRODED AT STA 227.8, BL 0 TO RBL 7. THE CORROSION WAS REMOVED AND THE INTERCOSTAL AND A STIFFENER WERE REMOVED AND REPLACED IAW SRM 51-10-2.

Part: APU — FIRE (A/C TAIL) · airframe 50,945 hrs · 26,447 cycles

APU FIRE LT ILLUMINATED WHILE AT CRUISE FLT ENROUTE. FIRE BOTTLE WAS DISCHARGED, LT EXT. FLT CONTINUED W/O FURTHER PROBLEM. MAINT INSP APU AND FOUND EVIDENCE OF SMALL FIRE AT BOTTOM REAR OF APU (EXH AREA). FIRE APPEARED TO BE CONTAINED. WIRES FROM APU EGT PROBE, FIRE DETECTION LOOP WERE DAMAGED. REAR SEAL ON EXH BAFFLE WAS DAMAGED. APU SHROUD AND MOUNTS WERE INSP WITH NO FAULTS NOTED, NO EXT DAMAGE NOTED. APU TAIL PIPE OVERHEAT DET WAS REMOVED AND REPLACED IAW MM 26-15-14. WIRE HARNESS TO CONNECTOR D1876 AND D1878 WAS REPAIRED, MUFFLER DET WAS REPLACED. APU FIRE EXT BOTTLE WAS R AND R IAW MM 26-22-11, PAGE 401-406. APU WAS R AND R IAW MM 49-11-00. APU LEAK AND OPS CHECKS WERE GOOD.

Part: FLOORBEAM — CORRODED (STA 947.5) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 947.5, RBL 4 TO LBL 24. THE FLOORBEAM WAS REPAIRED IAW ECRA 5310-04187 AND SRM 53-00-51, FIGURE 202.

Part: FLOORBEAM — DAMAGED (FUSELAGE) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A NOTCH CUT INTO FLOORBEAM WEB AT STA 328, LOCATED JUST FORWARD OF RT HORIZONTAL STABILIZER PULLEY CABLE. A REPAIR DOUBLER WAS INSTALLED IAW ECRA 5320-01694.

Part: RIB — GOUGED (#4 SLAT) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND R/H WING L/E RIB GOUGED AROUND SCREW HOLE AT #4 SLAT(SLAT STA 30). THE SLAT RIB WAS REPAIRED IAW ECRA 5750-03584.

Part: PAN — CRACKED (L1 DOOR) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A 0.20 INCH CRACK IN L-1 DOOR PAN AT AFT SIDE OF DOOR AT STOP SCREW BELOW CENTERING GUIDE. A DOUBLER WAS INSTALLED IAW ECRA 5210-01398.

Part: FITTING — CORRODED (FUSELAGE) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND RT MLG SIDE STRUT FITTING LUG CORRODED AT STA 685. THE LUG WAS REPAIRED IAW ECRA 5340-01354.

Part: PANEL — DELAMINATED (#5 SLAT) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND O/B TRAILING EDGE OF #5 SLAT PANEL DELAMINATED. THE #5 SLAT ASSY WAS REMOVED AND REPLACED IAW MM 27-81-21.

Part: SLAT — DENTED (#3 POSN.) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND #3 SLAT LEADING EDGE DENTED APPROXIMATELY 30" FROM O/B END. REPAIRED SLAT IAW SRM 57-43-01.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED AT FASTENER HOLE AFT OF STA 787, BL 0. A REPAIR WAS INSTALLED IAW SRM 53-00-53.

Part: SKIN — DENTED (C-1 DOOR) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND C-1 DOOR SKIN DENTED 13 INCHES AFT OF FORWARD EDGE AND 12 INCHES FROM TOP. A DOUBLER WAS INSTALLED IAW SRM 52-00-01.

Part: PLATE — CRACKED (STA 847) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A 3" CRACK ON UPPER WEB OF DOOR THRESHOLD PLATE AT STA 847. A NEW THRESHOLD PLATE WAS INSTALLED IAW SRM 51-40-02.

Part: SEAT TRACK — CRACKED (STA 727B) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A 1/2" CRACK IN L/H I/B SEAT TRACK AT AFT HI-LOCK, STA 727B. STRAP AND FILLER WERE INSTALLED IAW ECRA 5310-04183.

Part: SEAT TRACK — CRACKED (STA 727B) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A 1/4" CRACK IN UPPER FLANGE OF L/H O/B SEAT TRACK AT HI-LOCK ATTACH POINT, STA 727B. A STRAP WAS INSTALLED IAW ECRA 5310-04183.

Part: STRINGER — CRACKED (STA 332) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A 4" CRACK IN STRINGER 10R AT STA 332. THE STRINGER WAS REMOVED AND REPLACED IAW EA 5363-01014.

Part: INTERCOSTAL — CRACKED (STA 332) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A 4" CRACK IN INTERCOSTAL AT STA 332, STRINGER 10R. THE INTERCOSTAL WAS REMOVED AND REPLACED IAW BOEING DRAWING 65C33288 AND EA 5363-01014.

Part: ANGLE — CORRODED (STA 1014) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND R/H LAV WALL & L/H LAV WALL ANGLES CORRODED AT STA 1014 RBL 4 AND LBL 4. THE ANGLES WERE REMOVED AND REPLACED IAW SRM 51-40-02.

Part: ANGLE — CORRODED (R/H W/W) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND ATTACH ANGLE FOR R/H AFT I/B WHEEL WELL FAIRING CORRODED ON FORWARD CURVED ATTACH POINTS. THE ATTACH ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: STRAP — CORRODED (AFT LAV) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND "H" STRAP IN AFT LAV AREA CORRODED. THE STRAP WAS REMOVED AND A NEW STRAP WAS INSTALLED IAW SRM 51-10-02.

Part: ANGLE — CORRODED (R-2 DOOR) · airframe 46,211 hrs · 23,915 cycles

INSPECTION R-2 DOOR Z-ANGLE CORRODED. THE Z-ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: ANGLE — CORRODED (L-2 DOOR) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND L-2 DOOR Z-ANGLE CORRODED. THE Z-ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND THREE FLOOR SUPPORTS CORRODED AT STA 950 FROM RBL 24 TO RBL 53. THE FLOOR SUPPORTS WERE REMOVED AND REPLACED IAW ECRA 5310-03585.

Part: BRACE — CORRODED (STA 1006-1016) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND L/H AND R/H DIAGONAL BRACES CORRODED AT STA 1006-1016. NEW DIAGONAL BRACES WERE INSTALLED IAW SRM 51-10-02.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT STA 947 - 967, RBL 30 AND STA 967-987, RBL 16. THE FLOOR SUPPORTS WERE REMOVED AND REPLACED IAW ECRA 5310-03585.

Part: MOUNT — CORRODED (RH AFT GALLEY) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND R/H AFT O/B GALLEY MOUNT CORRODED. THE GALLEY MOUNT WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: SEAT TRACK — CORRODED (STA 907-947.5) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND L/H I/B SEAT TRACK CORRODED AT STA 907-947.5. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: FLOORBEAM — CORRODED (STA 312) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND TOP OF FLOORBEAM CORRODED AT STA 312, LBL 24 TO RBL 23. THE CORRODED SECTION OF FLOORBEAM WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: ANGLE — CORRODED (STA 294-312) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND FLOOR SUPPORT ANGLE CORRODED AT STA 294-312, RBL 12. A NEW FLOOR SUPPORT ANGLE WAS INSTALLED IAW SRM 51-10-02.

Part: MOUNT — CORRODED (GALLEY) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND GALLEY FLOOR MOUNT CORRODED AT STA 292, RBL 12. A NEW GALLEY FLOOR MOUNT WAS INSTALLED IAW SRM 51-10-02.

Part: FLOORBEAM — CORRODED (STA 294) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND FLOORBEAM UPPER CHORD CORRODED AT STA 294, LBL 28 TO RBL 14. THE CORRODED SECTION OF CHORD WAS CUT OUT AND A NEW SECTION WAS SPLICED IN IAW SRM 53-10-51, FIGURE 205.

Part: STRINGER — CRACKED (STA 500C-500D) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A 1" CRACK IN STRINGER 16R AT STA 500C-500D. THE CRACKED SECTION OF STRINGER WAS REMOVED AND A NEW SECTION WAS INSTALLED IAW SRM 53-30-03.

Part: FLOORBEAM — CORRODED (STA 1006) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1006, LBL 18. THE "T" CAP OF FLOORBEAM WAS REMOVED AND REPLACED IAW ECRA 5310-03851.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 294-312, LBL 12. A NEW FLOOR SUPPORT WAS INSTALLED IAW SRM 51-10-02.

Part: SPLICE — CRACKED (FUSELAGE) · airframe 46,211 hrs · 23,915 cycles

INSPECTION FOUND A .125 INCH CRACK IN STRINGER SPLICE 4L AT STA 907. THE STRINGER SPLICE WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: WIRE — DAMAGED (CABIN) · airframe 44,863 hrs · 23,247 cycles

THE FLOOR TRACK LIGHTS IN FIRST CLASS SECTION OF CABIN WERE FOUND INOPERATIVE. MAINTENANCE FOUND WIRES DAMAGED NEAR ROW 1 LEFT. THE WIRES WERE REPAIRED AND THE BLOWN FUSE IN POWER SUPPLY WAS REPLACED IAW MM 20-10-13.

Part: PANEL — DENTED (HORIZONTAL STAB) · airframe 43,283 hrs · 22,444 cycles

INSPECTION FOUND LEADING EDGE OF HORIZONTAL STABILIZER I/B RIGHT SIDE DENTED. THE LEADING EDGE WAS REPAIRED IAW SRM 55-10-01, PAGE 207-208.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT)

THE MASTER CAUTION LIGHT, OVERHEAT/DETECT LIGHT, AND CARGO DETECTION SUPRESSION FAIL LIGHT ILLUMINATED WHILE EN ROUTE FROM IAH TO SJC. THE AIRCRAFT WAS DIVERTED TO PHX WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND NO EVIDENCE OF FIRE. THE FIRE AND SMOKE DETECTION SYSTEM WAS TESTED IAW MM 26-16-10 AND FOUND TO BE WORKING NORMALLY.

Part: SENSOR — OUT OF ADJUST (LANDING GEAR)

THE LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF FROM IAH. THE OVERRIDE TRIGGER WAS USED PER QRH. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE AIR SAFETY SENSOR OUT OF RIG. THE SENSOR WAS ADJUSTED IAW MM 32-09-01. THE GEAR WAS SWUNG AND OPERATION CHECKED GOOD.

Part: SKIN — CRACKED (FUSELAGE)

INSPECTION FOUND A .25 INCH CRACK IN NR 1 LT WINDOW CUTOUT. REPAIRED IAW ECRA 5330-02877.

Part: SKIN — PITTED (BS 211-235)

FOUND EVIDENCE OF LIGHTNING STRIKE JUST BELOW CAPTAINS SLIDING WINDOW. BURNISHED DAMAGE PER SRM 53-00-01. ISSUED DIP FOR PERMANENT REPAIR.

Part: BEARING — FAILED (NR 2 ENGINE)

THE AIRCRAFT WAS DIVERTED TO SHV AFTER THE NR 2 ENGINE GAVE OFF TWO LOUD BANGS FOLLOWED BY AIRCRAFT VIBRATION AND WITH THE NR 2 ENGINE GOING TO IDLE. THE AIRCRAFT LANDED AT SHV WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 2 ENGINE GEARBOX AFT CHIP DETECTOR FULL OF METAL CHIPS AND THE COMPRESSOR COULD NOT BE TURNED. THE NR 2 ENGINE WILL BE REPLACED. TEARDOWN REVEALED NR 4 BEARING FAILURE.

Part: DOOR — CRACKED (CARGO COMPT)

INSPECTION FOUND A 1.875 INCH CRACK IN LOWER FORWARD CORNER OF FORWARD CARGO DOOR. THE FORWARD CARGO DOOR WAS REMOVED AND REPLACED. THE DOOR AND STOPS WERE ADJUSTED IAW MM 52-31-00, LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: SAFETY SENSOR — OUT OF ADJUST (MLG)

THE GEAR LEVER WOULD NOT RAISE PAST THE OFF POSITION ON FIRST ATTEMPT AFTER TAKEOFF. THE GEAR HANDLE RAISED TO THE UP POSITION AFTER SEVERAL ATTEMPTS AND THE FLIGHT PROCEEDED WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND THE MLG AIR SAFETY SENSOR OUT OF ADJUSTMENT. THE SENSOR WAS ADJUSTED AND TESTED IAW MM 32-09-01, PAGE 501. THE GEAR WAS SWUNG SEVERAL TIMES WITH NO DEFECTS NOTED.

Part: FLOORBEAM — CORRODED (BS 1016)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1016, LBL 10 TO LBL 30. REPAIRED FLOORBEAM IAW SRM 53-00-51.

Part: FOREFLAP — DELAMINATED (LT TE FOREFLAP)

INSPECTION FOUND LT INBOARD TRAILING EDGE FOREFLAP DELAMINATED ON UPPER SURFACE. THE LT INBOARD TRAILING EDGE FOREFLAP WAS REMOVED AND REPLACED IN REFERENCE TO SRM 51-70-10.

Part: FLOORBEAM — CORRODED (BS 1006)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1006, LBL 14 TO LBL 20. THE FLOORBEAM WAS REPAIRED IAW SRM 53-00-51.

Part: FLOORBEAM — CORRODED (BS 967)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 967, RBL 40 TO LBL 40. THE UPPER T-CHORD SECTION WAS REMOVED AND REPAIR WAS INSTALLED IAW ECRA 5310-03570 AND 5310-03450.

Part: FLOORBEAM — CORRODED (BS 986)

INSPECTION FOUND CORROSION ON FLOORBEAM UPPER CHORD AT STA 986, LBL 24 TO RBL 24. THE FLOORBEAM UPPER CHORD WAS REPLACED IAW SRM 53-00-51.

Part: BATTERY PACK — DISCHARGED (CABIN)

THE EMERGENCY LIGHT CAPACITY CHECK FAILED AT BS 662 ON RT SIDE. THE BATTERY CHARGER AND BATTERY PACK WERE REMOVED AND REPLACED.

Part: FLOORBEAM — CORRODED (BS 312)

INSPECTION FOUND FLOORBEAM UPPER CHORD CORRODED AT STA 312, LBL 8 TO RBL 24. THE CORRODED AREA WAS REMOVED, A NEW SECTION OF BEAM WAS FABRICATED AND INSTALLED IAW SRM 53-10-51, FIGURE 205.

Part: FLOORBEAM — CORRODED (BS 947)

INSPECTION FOUND CORROSION ON FLOORBEAM AT STA 947, RBL 4. THE FLOORBEAM UPPER CHORD WAS REPLACED IAW SRM 53-00-51.

Part: SKIN — DENTED (CARGO DOOR)

A DENT IN THE AFT CARGO DOOR SKIN THAT HAD BEEN DEFERRED WAS REPAIRED PERMANENTLY. THE DENT WAS REMOVED AND A DOUBLER WAS INSTALLED IAW SRM 52-00-01.

Part: FLOORBEAM — CORRODED (BS 328)

INSPECTION FOUND FLOORBEAM UPPER CHORD CORRODED AT STA 328, RBL 7 TO 63. THE CORRODED SECTION OF FLOORBEAM WAS REMOVED AND REPLACED IAW SRM 53-10-51.

Part: SKIN — SCRATCHED (BS 460)

INSPECTION FOUND A SCRATCH IN LT FUSELAGE SKIN AT STA 460, STRINGER 23L. THE SCRATCHED AREA WAS ROUTED OUT. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 53-00-01.

Part: FIRE DETECTOR — INOPERATIVE (APU TAILPIPE)

FLT NR 1603 - DCA - THE APU FIRE WARNING LIGHT AND BELL ACTIVATED IN FLIGHT. THE FIRE BOTTLE WAS DISCHARGED, BUT THE FIRE WARNING LIGHT REMAINED ILLUMINATED. THE AIRCRAFT WAS RETURNED TO DCA WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND NO EVIDENCE OF FIRE. MAINTENANCE FOUND THE M717 APU TAILPIPE OVERHEAT DETECTION ELEMENT AT FAULT. THE FIRE BOTTLE WAS REMOVED AND REPLACED. THE APU FIRE DETECTION SYSTEM WAS TEMPORARILY PLACARDED INOPERATIVE, PENDING REPLACEMENT OF THE FAULTY OVERHEAT DETECTION ELEMENT. (M)