N14524

Part: SMOKE DETECTOR — MALFUNCTIONED (ZONE 900) · airframe 694 hrs · 272 cycles

MOMENTARY LAV SMOKE DURING FLIGHT LESS THAN 5 SECONDS NO INDICAT ION OF SMOKE FLIGHT ATTENDANTS STRONGLY SUSPECT PASSENGER OF VAPING IN LAVATORY.FIGHT ATTENDANTS INSPECTED ALL LAVATORIES, NO SIGN OR SMELL OF SMOKE. PERFORMED TEST OF SDF 1 AND SDF 2, NO FAULTS CURRENT OR PREVIOUS.POST FLIGHT SHOWS NO FAULTS.LAST LEG SHOWS NO FAULTS.GROUND TEST SHOS NO FAULTS.

Part: BATTERIES — DISCHARGED (LT & RT NACELLE)

INSPECTION FOUND BOTH NACELLE EMERGENCY LIGHTS INOPERATIVE. THE BATTERIES WERE REMOVED AND REPLACED AND OPERATION CHECKED GOOD.

Part: WIRE — BROKEN (ROW 10)

INSPECTION FOUND THE OVERHEAD EMERGENCY LIGHT AT ROW 10 INOPERATIVE. MAINTENANCE FOUND LIGHT WIRE PULLED FROM SPLICE. THE WIRE WAS RESPLICED AND OPERATION CHECKED GOOD.

Part: BATTERIES — DISCHARGED (TAIL CONE)

INSPECTION FOUND THE TAIL CONE EMERGENCY EXIT FLOOD LIGHT INOPERATIVE. THE BATTERIES WERE REPLACED AND OPERATION CHECKED GOOD.

Part: WIRE — BROKEN (ROW 23)

THE AFT CEILING EMERGENCY LIGHTS WERE FOUND INOPERATIVE FROM ROW 23 TO TAIL SECTION. MAINTENANCE FOUND WIRING TO BATTERY POWER PACKS BROKEN. THE WIRING WAS REPAIRED AND OPERATION OF THE LIGHTS CHECKED GOOD IAW MM 33-50-0.

Part: WIRE — BROKEN (LT, RT EMER EXIT)

THE LEFT AND RIGHT AFT OVERWING EXIT EMERGENCY LIGHTS WERE FOUND INOPERATIVE. BROKEN WIRING WAS REPAIRED AND OPERATION OF THE LIGHTS CHECKED GOOD IAW MM 33-50-0, PAGE 501.

Part: WIRE — BROKEN (ROW 13)

THE CABIN EMERGENCY LIGHTS FROM COCKPIT TO ROW 13 WERE FOUND INOPERATIVE. BROKEN WIRING WAS REPAIRED AND OPERATION OF THE LIGHTS CHECKED GOOD IAW MM 33-50-0, PAGE 501.

Part: WIRE — LOOSE (CABIN)

THE AFT FLIGHT ATTENDANT STATION EMERGENCY LIGHT SWITCH WAS FOUND INOPERATIVE. MAINTENANCE FOUND A LOOSE WIRE ON SWITCH. THE LOOSE WIRE WAS TIGHTENED AND SYSTEM OPERATION CHECKED GOOD IAW MM 33-50-00, PAGES 203-204.

Part: CONNECTOR — DIRTY (L1 DOOR)

INSPECTION FOUND THE L-1 PORTABLE EMERGENCY LIGHT INOPERATIVE. THE CONNECTOR WAS CLEANED AND SECURED AND OPERATION OF THE LIGHT CHECKED GOOD.

Part: WIRE — BROKEN (CABIN)

INSPECTION FOUND THE ESCAPE PATH LIGHT INBOARD OF FORWARD FIRST CLASS COAT CLOSET INOPERATIVE. MAINTENANCE FOUND BROKEN WIRING. THE ESCAPE PATH LIGHT WIRING WAS REPAIRED AND OPERATION CHECKED GOOD IAW MM 33-50-0, PAGE 501.

Part: FITTING — CRACKED (CARGO DOOR)

INSPECTION FOUND AFT CARGO DOOR THIRD BEAM END FITTING CRACKED AT AFT SIDE OF DOOR. THE CRACK WAS .1875 INCH LONG. THE FITTING WAS REMOVED AND A NEW FITTING WAS INSTALLED IAW SRM 51-30-2.

Part: FITTING — CRACKED (CARGO DOOR)

INSPECTION FOUND A .5 INCH CRACK IN AFT CARGO DOOR BEAM END FITTING AT AFT SIDE OF DOOR. THE FITTING WAS REMOVED AND A NEW FITTING WAS INSTALLED IAW SRM 51-30-5, PAGE 4.

Part: RIB — CRACKED (WS 545)

RIB CRACKED THROUGH FASTENER HOLE INSIDE LEFT WING L/E XRS545 (.5) 12 INCES OUTSIDE OF NR 5 SLAT CENTER TRACK. REMOVED AND INSTALLED NEW RIB PER SRM 51-30-2.

Part: TAB — DEBOND (RT AILERON)

RIGHT AILERON INBOARD TAB HAS APPROXIMATELY 1 BY 10 DEBONDED LOWER SKIN. REMOVED AND REPLACED RIGHT AILERON PER MM 27-10-2.

Part: ANGLE — CRACKED (RT WING)

RIB TO LOWER LE ANGLE CRACKED INSIDE RIGHT WING APPROX 8 O/B OF VORTILON. REMOVED CRACKED ANGLE. FABRICATED AND INSTALLED NEW ANGLE PER SRM 51-30-5, 51-10-0, 51-10-3, AND 51-10-2.

Part: TERMINAL — FAILED (EMER EXIT)

AFT DOOR EMERGENGY EXIT LIGHT INOP. REPAIRED TERMINAL AT LIGHT AND OPS CHECK OK PER MM 33-53-01.

Part: SPAR — CRACKED (WS 164)

INSPECTION FOUND A .25 INCH CRACK IN RT WING AFT SPAR AT I/B ACTUATOR HINGE FORWARD FORGING FROM I/B LOWER BOLT AREA, APPROXIMATELY XRS 164. THE FASTENERS WERE REMOVED AND THE CRACKED SECTION OF SPAR WAS CUT OUT. A NEW SPAR SECTION WAS INSTALLED USING SPLICES INSIDE AND OUTSIDE IAW DRAWING J060165 AND EA 5761-01001.

Part: CONTROL — INOP (LT MLG)

THE LT MLG UNSAFE LIGHT ILLUMINATED ON UPLATCH CHECK AFTER TAKEOFF. WHEN THE SLATS AND FLAPS WERE EXTENDED TO FIVE DEGREES AND THE AIRCRAFT WAS SLOWED TO 210 KNOTS FOR A RETURN TO IAH, THE UNSAFE LIGHT EXTINGUISHED. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE PROXIMITY SWITCH CONTROL WAS REMOVED AND REPLACED. A SIMULATED GEAR RETRACTION GAVE NORMAL GEAR INDICATIONS.

Part: SPAR CAP — CRACKED (HORIZ STAB)

INSPECTION FOUND A 2 INCH CRACK AT OUTBOARD END OF RT HORIZONTAL STABILIZER LOWER SPAR CAP. THE OUTBOARD FITTING AND BULKHEAD WERE REMOVED IAW SRM 51-30-1. THE CRACKED SECTION OF SPAR WAS CUT OUT IAW SRM 55-02, FIGURE 8. A REPLACEMENT SPAR SECTION AND REPAIR ANGLES WERE FABRICATED AND INSTALLED IAW SRM 55-02, FIGURE 8. THE OUTBOARD FITTING AND BULKHEAD WERE INSTALLED IAW SRM 51-30-1.

Part: SPAR CAP — CRACKED (HORZ STAB)

INSPECTION FOUND A 2 INCH CRACK AT OUTBOARD END OF LT HORIZONTAL STABILIZER LOWER SPAR CAP. THE OUTBOARD FITTING AND BULKHEAD WERE REMOVED IAW SRM 51-30-1. THE CRACKED SECTION OF SPAR CAP WAS CUT OUT IAW SRM 55-02, FIGURE 8. A REPLACEMENT SECTION OF SPAR CAP WAS FABRICATED AND INSTALLED IAW SRM 55-02, FIGURE 8. THE FITTING AND BULKHEAD WERE INSTALLED IAW SRM 51-30-1.

Part: SKIN — DENTED (E/E DOOR)

INSPECTION FOUND DENTS IN E AND E COMPARTMENT DOOR EXTERIOR SKIN. THE SKIN WAS REMOVED, NEW SKIN WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 51-10-3.

Part: SUPPORT — CORRODED (CABIN)

INSPECTION FOUND FLOORBOARD SUPPORT AT FORWARD PASSENGER ENTRYWAY CORRODED BETWEEN NR 1 SEAT TRACK AND CENTERLINE FLOORBEAM. THE FLOOR SUPPORT WAS REMOVED, A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-10-1, 51-10-4, 51-10-3, AND 51-30-5.

Part: JAMB — CORRODED (BS 200)

INSPECTION FOUND DOOR JAMB AND SUB FLOOR CORRODED AT FS 200 BY R-1 DOOR. THE CORRODED DOOR JAMB PAN AND SUB FLOOR SECTIONS WERE REMOVED IAW SRM 53-05, FIGURE 55. FILLERS AND DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 53-05, 51-10-3, AND 51-30-5.

Part: FLOORBEAM — CORRODED (BS 965)

INSPECTION FOUND CORROSION ON FLOORBEAM NUT PLATE AT STA 965. A DOUBLER, FILLER, AND ANGLES WERE FABRICATED AND INSTALLED IAW SRM 51-10-3, 51-30-5, AND ECRA 5320-01488.

Part: SPAR CAP — CRACKED (HORZ STAB)

INSPECTION FOUND A 2 INCH CRACK AT OUTBOARD END OF RT HORIZONTAL STABILIZER UPPER SPAR CAP. THE OUTBOARD FITTING AND BULKHEAD WERE REMOVED IAW SRM 51-30-1. THE CRACKED SPAR SECTION WAS CUT OUT IAW SRM 55-02, FIGURE 8. A REPLACEMENT SPAR SECTION AND REPAIR ANGLES WERE FABRICATED AND INSTALLED IAW SRM 55-02, FIGURE 8. THE OUTBOARD FITTING AND BULKHEAD WERE INSTALLED IAW SRM 51-30-1.

Part: SKIN — DENTED (BS 323)

INSPECTION FOUND RT FUSELAGE SKIN DENTED AT FS 323, LONGERON 24. THE DENTED AREA WAS CUT OUT IAW SRM 53-04. A DOUBLER, FINGER DOUBLER, AND FILLER WERE FABRICATED AND INSTALLED IAW SRM 53-04, 51-10-3, 51-30-2, AND 51-30-5.

Part: FLOOR PANEL — CORRODED (COCKPIT)

INSPECTION FOUND FLOOR PANEL AND HAT CHANNEL CORRODED UNDER PILOT'S SEAT. A NEW PANEL AND HAT CHANNEL WERE FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 51-20-0.

Part: LONGERON — CRACKED (BS 1079)

INSPECTION FOUND A 1 INCH CRACK IN LONGERON 2L AT STA 1079. THE CRACKED SECTION OF LONGERON WAS CUT OUT IAW SRM 53-02. A REPAIR SECTION, SPLICE AND ATTACH BRACKET WERE FABRICATED AND INSTALLED IAW SRM 53-02, 51-30-5 AND ECRA 5310-03589.

Part: SKIN — DENTED (BS 360)

INSPECTION FOUND RT FUSELAGE SKIN DENTED AT FS 360 BETWEEN LONGERON 21R AND 22R. THE DENTED AREA WAS CUT OUT, A DOUBLER AND FILLER REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-10-3 AND 51-30-2.

Part: LONGERON — CORRODED (BS 218)

INSPECTION FOUND LONGERON 25R CORRODED IN FORWARD CARGO COMPARTMENT AT STA 218. THE LONGERON WAS REMOVED IAW SRM 53-10-03. A NEW LONGERON AND SPLICE SECTION WERE FABRICATED AND INSTALLED IAW SRM 53-02, 51-10-3 AND 51-30-2.

Part: COVER — CRACKED (RT ELEVATOR)

INSPECTION FOUND A 1 INCH CRACK IN RT ELEVATOR FLIGHT TAB MECHANISM CONTROL COVER AT STA XHS 95. THE CRACKED AREA WAS REMOVED, DOUBLER AND FILLER WERE FABRICATED AND INSTALLED IAW SRM 55-03, 51-10-3, 51-30-2, AND 51-30-8.

Part: DOUBLER — GOUGED (PAX DOOR)

INSPECTION FOUND GOUGED DOUBLER AT FORWARD PASSENGER DOOR CUTOUT FOR DOOR LATCH HOOK ASSEMBLY. THE OLD DOUBLER WAS REMOVED IAW SRM 51-30-2. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 52-05, 51-10-3, 51-30-1, AND 51-30-2.

Part: INTERCOSTAL — CORRODED (BS 680-699)

INSPECTION FOUND INTERCOSTAL CORRODED AT STA 680-699, LONGERON 16L. THE INTERCOSTAL WAS REMOVED IAW SRM 51-30-2. A NEW INTERCOSTAL WAS FABRICATED AND INSTALLED IAW SRM 53-11-3, 51-11-2, 51-10-3, AND 51-30-2.

Part: INTERCOSTAL — DENTED (BS 560-579)

INSPECTION FOUND INTERCOSTAL DENTED BETWEEN STA 560 AND 579 AT LONGERON 28R. THE INTERCOSTAL WAS REMOVED. A NEW INTERCOSTAL WAS FABRICATED AND INSTALLED IAW SRM 53-21-0, 51-10-3, AND 51-30-1.

Part: INTERCOSTAL — CRACKED (R-1 DOOR)

INSPECTION FOUND INTERCOSTAL CRACKED INSIDE R-1 DOOR AT CENTER OF DOOR BELOW LATCH MECHANISM. THE INTERCOSTAL WAS REMOVED AND REPLACED IAW SRM 51-30-2 AND 51-30-5.

Part: SKIN — DENTED (NR 1 LE SLAT)

INSPECTION FOUND RT WING NR 1 LEADING EDGE SLAT SKIN DENTED. THE DENTED AREA WAS CUT OUT. REPAIR DOUBLERS AND FILLERS WERE FABRICATED AND INSTALLED IAW SRM 57-06 AND 51-10-3.

Part: STIFFENER — CRACKED (AFT PRESS BLKHD)

INSPECTION FOUND A 2 CRACK IN HORIZONTAL STIFFENER ON FORWARD FACE OF AFT PRESSURE BULKHEAD AT L13R. THE STIFFENER WAS REMOVED. NEW PARTS WERE FABRICATED AND INSTALLED IAW SRM 51-30-5.

Part: SKIN — DENTED (BS 284)

INSPECTION FOUND RT FUSELAGE SKIN DENTED AT STA 284, LONGERON 24. THE DENTED AREA WAS CUT OUT. DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 53-04 AND 53-04, FIGURE 12.

Part: HYD LINE — LEAKING (RT TR VALVE)

THE RT HYDRAULIC SYSTEM LOST ALL QUANTITY DURING FLIGHT. ABNORMAL PROCEDURES WERE ACCOMPLISHED AND THE AIRCRAFT LANDED AT IAH WITHOUT INCIDENT. MAINTENANCE FOUND THE HYDRAULIC LINE ON RIGHT THRUST REVERSER VALVE LEAKING. THE LINE WAS REMOVED AND REPLACED. THE HYDRAULIC SYSTEM WAS SERVICED AND LEAK CHECKS WERE GOOD.

Part: DUCT — CRACKED (NR 2 ENGINE)

THE NR 2 ENGINE FIRE WARNING LIGHT AND BELL ACTIVATED SHORTLY AFTER TAKEOFF. THE FIRE WARNING CEASED AFTER THE ENGINE THROTTLE WAS RETARDED LESS THAN TEN PERCENT. BOTH FIRE LOOPS TESTED NORMAL AND ALL ENGINE INDICATIONS WERE NORMAL. THE FLIGHT CONTINUED AT NORMAL POWER SETTINGS WITH NO FURTHER OCCURANCE OF FIRE WARNING. MAINTENANCE FOUND THE NR 2 ENGINE 13TH STAGE SADDLE DUCT CRACKED AT ANTI-ICE FLANGE. THE DUCT WAS REPLACED AND LEAK CHECK WAS GOOD.

Part: PUSHROD — BENT (NLG GRD SENSE)

THE LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF. THE FLIGHT LANDED AT IAH WITHOUT INCIDENT. MAINTENANCE FOUND PUSHROD AT GROUND SENSE SECTOR BENT. THE PUSHROD WAS REMOVED AND REPLACED. THE NLG GROUND SENSE WAS TESTED IAW MM 32-23-1, PAGE 204A. THE LANDING GEAR WAS SWUNG SEVERAL TIMES AND OPERATION CHECKED GOOD.

Part: FLOOR WEB — CRACKED (BS 83.55/89.05)

IAH - INSPECTION FOUND A 1 INCH CRACK IN COCKPIT FLOOR WEB AT BS 89.050 AND A 2 INCH CRACK FOUND AT BS 83.550. THE FLOOR WEB WAS REPAIRED IAW ECRA 5310-03193 AND ECRA 531003031. (X)

Part: LONGERON — CORRODED (BS 945-960)

HOU - INSPECTION FOUND CORROSION ON LONGERON 26L BETWEEN STATION 945-960. THE CORROSION WAS REMOVED AND TREATED IAW SRM 51-10-3 AND RIVETS WERE INSTALLED IAW SRM 51-30-2. (M)

Part: LONGERON — CORRODED (BS 937-945)

HOU - INSPECTION FOUND CORROSION ON LONGERONS 26L TO 28L IN AFT BAGGAGE BIN BETWEEN STATION 937-945. THE CORROSION WAS REMOVED AND TREATED IAW SRM 51-10-3 AND RIVETS WERE REPLACED IAW SRM 51-30-2. (M)

Part: RIB — CRACKED (WS 501)

HOU - INSPECTION FOUND THREE .25 INCH CRACKS IN WING LEADING EDGE RIB AT STATION XRS 501. A DOUBLER, FILLER, AND CLIP WERE FABRICATED AND INSTALLED IAW ECRA 5720-01260. (M)

Part: SKIN — CRACKED (NR 2 PYLON)

HOU - INSPECTION FOUND A .5 INCH CRACK IN SKIN ON TOP SIDE OF NR 2 ENGINE PYLON. THE CRACK WAS STOP DRILLED. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 54-02. (M)

Part: PROX CONTROL BOX — INOPERATIVE (MLG)

IAH - FLT 1536 - THE LEFT GEAR UNSAFE LIGHT ILLUMINATED DURING THE GEAR UPLATCH CHECK AFTER DEPARTING IAH. CYCLING THE GEAR AND REPEATING THE UPLATCH CHECK GAVE NO CHANGE. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. THE LANDING GEAR PROXIMITY SWITCH CONTROL BOX WAS REMOVED AND REPLACED. A CHECK OF THE LT MLG UPLATCH SENSOR SHOWED PROPER CLEARANCE. SEVERAL GEAR RETRACTIONS AND EXTENSIONS WERE PERFORMED AND ALL GEAR INDICATIONS WERE NORMAL. (X)

Part: SEAL — FAILED (HEAT EXCHANGER)

FLT NR 1781 - GSO - THE CABIN BEGAN TO FILL WITH SMOKE DURING TAXI OUT FOR DEPARTURE. THE AIRCRAFT BEGAN A RETURN TO THE GATE AND WAS ACCOMPANIED BY EMERGENCY VEHICLES AS A PRECAUTIONARY MEASURE. NO EVIDENCE OF FIRE WAS OBSERVED. THE PASSENGERS WERE DEPLANED AT THE GATE WITHOUT INCIDENT. MAINTENANCE FOUND OIL IN THE RIGHT WATER SEPARATOR BAG AND THE REAR SEAL ON SECONDARY HEAT EXCHANGER PROTRUDING. THE HEAT EXCHANGER SEAL WAS REINSTALLED AND BOTH THE LEFT AND RIGHT WATER SEPARATOR BAGS WERE REMOVED AND REPLACED. (M)

Part: S/O VALVE — LEAK (RUDDER)

FLT NR 1581 - IAH - UPON LANDING FOUND HYDRAULIC FLUID LEAKING AT RUDDER. FOUND RUDDER POWER SHUTOFF VALVE LEAKING. REPLACED SHUTOFF VALVE NO FURTHER ACTION. (W)

Part: BUNGEE CYL — INOPERATIVE (LT MLG)

FLT NR 1647 - CLE - THE LEFT MLG RED UNSAFE LIGHT AND GEAR DOOR OPEN LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION. THE GEAR WAS CYCLED AND BOTH RED LIGHTS EXTINGUISHED WITH THREE GREEN GEAR LIGHTS INDICATED. THE AIRCRAFT WAS DIVERTED TO CLE WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LEFT MLG BUNGEE CYLINDER AT FAULT. THE LEFT MLG BUNGEE CYLINDER WAS REMOVED AND REPLACED. GEAR OPERATION AND INDICATIONS CHECKED GOOD. (Z)

Part: EEL BATT — DISCHARGED (CABIN)

JAX - FLT 1521 - THE FWD OVERWING EMERGENCY EXIT LIGHT WAS FOUND INOPERATIVE DURING A PREFLIGHT CHECK. THE BATTERIES FOR THE FWD OVERWING EMERGENCY EXIT LIGHT WERE REMOVED AND REPLACED. OPERATION OF THE EMERGENCY EXIT LIGHT WAS RESTORED. (W)