N14639

Part: SKIN — CRACKED (FUSELAGE) · airframe 34,487 hrs · 18,156 cycles

SUPPORT TASK FWD ENTRY DOOR LOWER HINGE CUTOUT HAS CRACKED INDICATION AT FASTENER HOLE JUST 3 INCHES BELOW STRINGER 13L AND FRAME STA 303.90 AREA REF B737 NDT MANUAL PART 6 CHAPTER 51-00- 00 FIG 16 OVERSIZED, HFEC INSPECTED, & ENDOSCOPE HOLE; CONFIRMED TO BE DRILLED THRU LWR SKIN; FABRICATED, DRILLED, & INSTALLED TRIPLER, DOUBLER, & FILLER; TREATED & PRIMED ALL REPAIR PARTS REF ECRA 5 330-04063.

Part: CASTING — CRACKED (FUSELAGE) · airframe 34,487 hrs · 18,156 cycles

L-1 DOOR UPPER HINGE CASTING CRACKED. INSTALLED NEW CASTING REF B737 SRM 51-10-02 AND 51-40-02.

Part: POWER SUPPLY — FAULTY (CABIN) · airframe 33,330 hrs · 17,559 cycles

F/C IN SEAT EMERGENCY EXIT LIGHTS INOP. FOUND POWER SUPPLY M1674 AT FAULT. REPLACED SAME PER MM REF 33-51-51. OPS NORMAL.

Part: FASTENER — LOOSE (ACCESSORY BAY) · airframe 31,789 hrs · 16,719 cycles

STABILIZER TRIM JAMMED. FOUND AFT RIGHT HI-LOK ON FORWARD STABILIZER TRIM DRUM MISSING NUT AND WASHER (REF IPC 27-41-61-01 ITEMS 40 AND 45) ALLOWING HI-LOK TO MIGRATE UPWARD, CONTACTING LOWER CABLE ATTACH LUG ON FORWARD STABILIZER CABLE DRUM. SUBSEQUENT UP AND DOWN TRIM ATTEMPTS RESULTED IN DAMAGE TO BOTH SIDES OF LOWER CABLE ATTACH LUG. REWORKED AREA, DYE PENETRATED, ALODINED, AND PRIMED DISCREPANT AREAS PER EC/RA 2741-01098. CHECKED CABLE TENSIONS STA AND STB AND CHAIN DEFLECTION REF AMM 27-41-00, ALL CHECKS NOMINAL. AFTER REVIEWING IPC WITH ENGINEERING SERVICE CENTER, EC/RA WAS ISSUED TO COVER CORRECT PHENOLIC SPACER STACK AND HI-LOK UTILIZATION. ASSEMBLED DRIP SHIELD WITH NEW HI-LOKS, WASHERS AND NUTS, REF L/P'S 8219505 AND 8219506 FOR ADJUSTMENT / TEST OF PRIMARY AND AUTOPILOT STAB TRIM ACTUATORS AND LAND VERIFY TEST, ALL TESTS PASSED.

Part: MEGAPHONE — INOPERATIVE (CABIN) · airframe 30,791 hrs · 16,230 cycles

AFT EMERGENCY MEGAPHONE WILL NOT TEST. REPLACED MEGAPHONE WITH SERVICEABLE UNIT, OPS CHECK GOOD.

Part: FRAME — CORRODED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

FRAME AT BILGE AREA AT STATION 767 LBL 9 IN AFT CARGO COMPARTMENT FOUND CORRODED. CORROSION FOUND TO BE OUT OF LIMITS PER B 737-500 SRM 53-00-07 AND 53-60-07. REMOVED CORROSION AND ACCOMPLISHED REPAIR PER B 737-500 SRM 53-00-07 REPAIR 8.

Part: FASTENER — MISSING (FUSELAGE) · airframe 28,809 hrs · 15,180 cycles

INTERCOSTAL INBOARD FRAME TO STIFFENER BRACKET AT STATION 354 S8L IS MISSING (4) FASTENERS. INSTALLED MISSING FASTENERS AT STATION 354 S8L PER EA639-6003CAL AND EC/RA 5310-04753.

Part: INTERCOSTAL — CRACKED (BS 344-360) · airframe 28,570 hrs · 15,045 cycles

INTERCOSTAL BETWEEN STA 344 AND 360 BL 0 CRACKED. REMOVED AND REPLACED INTERCOSTAL PART NUMBER 65C33970-53 STA 344-360, BL 0, REF SRM 51-40-02 & BOEING INSTALLATION DWG 65C33970.

Part: SKIN — CRACKED (FUSELAGE) · airframe 64,651 hrs · 33,211 cycles

LEFT AFT FUSELAGE- 8" AFT OF EMERGENCY LIGHT, 2.5 INCH LONG CRACK IN SKIN. REPAIRED PER SRM 53-00-01 REPAIR 31, PROCEDURE 5, INITIATED DIP TO INSPECT EVERY 4,000 FLIGHT CYCLES AFTER INITIAL SCHEDULED INSPECTION.

Part: BRACKET — CORRODED (BS 344) · airframe 28,570 hrs · 15,045 cycles

BRACKET AT STA 344, LBL 58" FOUND CORRODED. REMOVED & REPLACED 65C16121-6 GIRT BAR MOUNT BRACKET REF 51-10-02 & 51-40-02 (STA 344, LBL 58").

Part: BRACKET — CORRODED (BS 312) · airframe 28,570 hrs · 15,045 cycles

BRACKET AT STA 312 LBL 54" FOUND CORRODED. REMOVED & REPLACED 65C16121-5 GIRT BAR FITTING BRACKET REF SRM 51-10-02 & 51-40-02 (STA 312, LBL 54").

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

STATION 747 LT SIDE BETWEEN S8LT AND S9LT AT AC BRACKET I/B FASTENER CRACKED. REPAIRED CRACKED FRAME AT STATION 747 LT SIDE BETWEEN S8LT & S9LT AT AC BRACKET IAW EA 5310-04498.

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

STATION 440 LT SIDE BETWEEN S8LT AND S9LT AT AC BRACKET I/B FASTENER HOLE IS CRACKED. CUT OUT DAMAGED HOLE AT STATION 440 LT BETWEEN S9LT & S8LT, REPAIRED DAMAGED FRAME PER EA5310-04498.

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

STATION 787 RT SIDE BETWEEN S8RT AND S9RT AT AC BRACKET I/B FASTENER HOLE IS CRACKED. ACCOMPLISHED REPAIR AT STA 787 RT SIDE BETWEEN S8RT & S9RT AC BRACKET I/B FASTENER HOLE PER EA 5310-04498.

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

CRACK IN FRAME AT STATION 360 ABOVE S8LT. REPAIRED CRACKED FRAME AT STATION 360 ABOVE S8LT IAW EA 5310-0 498 CAL EC/RA5310-04752.

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

STATION 869 RT SIDE BETWEEN S8RT AND S9RT AT AC BRACKET I/B FASTENER CRACKED. ACCOMPLISHED FRAME REPAIR PER CAL EC/RA 5310-04755.

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

STATION 867 LT SIDE BETWEEN S8LT AND S9LT AT AC BRACKET I/B FASTENER HOLE IS CRACKED. REMOVED A/C BRACKET IAW B737 SRM 51-40-02. MADE ID FOR REPAIR ANGLES "A" & "B" 7075-0 040 IAW EA5310-04498, HEAT TREATED ANGLES TO 7075T6 IAW BAC5602. ALODINED & PRIMED IAW B737 SRM 51-20-01, INSTALLED ANGLES & BRACKET IAW EA5310-04498.

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

STATION 827 LT BETWEEN S8LT AND S9LT AT AC BRACKET I/B FASTENER HOLE IS CRACKED. REMOVED AC BRACKET IAW B737 SRM 51-40-02, CUT OUT DAMAGED HOLES IAW EA5310-04498, MATERIAL ID FOR REPAIR ANGLES "A" & "B" 7075-0 .040 IAW B73753-60-07 AND EA5310-04498, HEAT TREATED REPAIR ANGLES TO 70 75T6 IAW BAC5602 LOAD NUMBERS 354+360, INSTALLED REPAIR IAW EA5310-04498, COLD WORKED & INSTALLED FASTENERS IN REQUIRED HOLES.

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

STATION 787 LT SIDE BETWEEN S8LT AND S9LT AT AC BRACKET I/B FASTENER HOLE IS CRACKED. REPAIRED CRACKED FRAME AT STA 787 LT SIDE BETWEEN S8LT AND S9LT AT AC BRACKET IAW EA 5310-04498.

Part: FRAME — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

STATION 400 LT BETWEEN S8LT & S9LT AT AC BRACKET I/B FASTENERS ARE CRACKED. REPAIRED CRACKED FRAME AT STATION 400 BETWEEN S8LT AND S9LT AT AC BRACKET IAW EA5310-04498.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

CORROSION ON INTERCOSTAL BETWEEN BS 947.5 TO BS 967 AT LBL 52", DRAIN GOES THROUGH THIS INTERCOSTAL. REMOVED AND REPLACED INTERCOSTAL REF 737-500 SRM 51-40-02; LOCATED BETWEEN BS 947.5 & 967 AT LBL 52.

Part: STRINGER CLIP — CRACKED (BS 663 S10R) · airframe 28,570 hrs · 15,045 cycles

MAIN CABIN STRINGER CLIP CRACKED AT STA 663 AND S10R. REPLACED STRINGER TIE CLIP AT STA 663R AND STR 10R IAW SRM 51-10-2 (B737-500) AND SRM 51-40-02 (B737-500).

Part: INTERCOSTAL — CRACKED (BS 344-360) · airframe 28,570 hrs · 15,045 cycles

INTERCOSTAL FOUND CRACKED BETWEEN BS 344 TO BS 360 AT LBL 10". REPAIRED INTERCOSTAL AT STA 344-360 LBL 10 IAW EC/RA 5310-03585 (REV C).

Part: INTERCOSTAL — CRACKED (BS 312-328) · airframe 28,570 hrs · 15,045 cycles

INTERCOSTAL FOUND CRACKED BETWEEN BS 312 TO BS 328 AT LBL 44". REMOVED AND REPLACED DAMAGED INTERCOSTAL BS 312-328, REF SRM 51-40-02 & BOEING INSTALLATION DWG 65C33970.

Part: ANGLE — CORRODED (R2 DOOR) · airframe 28,570 hrs · 15,045 cycles

R2 DOOR Z-ANGLE CORRODED AT SILL AREA. REMOVED R-2 DOOR Z-ANGLE IAW B737 SRM 51-40-02. LOCATED AND DRILLED NEW Z-ANGLE IAW B737 SRM 51-40-02. INSTALLED Z-ANGLE IAW B737 SRM 51-40-02.

Part: INTERCOSTAL — DAMAGED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

INSTALLED SRM REPAIR AT BS 178-188 RBL 24.67 FLOORBEAM WEB FOR ACCESS. REMOVED EXISTING WEB & STIFFENER, MODIFIED WEB & FABRICATED NEW STIFFENER & REPAIR PARTS FOR SRM REPAIR BS 178-188 RBL 24.67 FOR FLOORBEAM FOR ACCESS IAW SRM 53-10-51.

Part: INTERCOSTAL — DAMAGED (FUSELAGE) · airframe 28,570 hrs · 15,045 cycles

INSTALLED SRM REPAIR AT BS 178-188 LBL 24.67 FLOORBEAM WEB FOR ACCESS. REMOVED EXISTING WEB & STIFFENER, MODIFIED WEB & FABRICATED NEW STIFFENER & REPAIR PARTS FOR SRM REPAIR BS 178-188 LBL 24.67 FOR FLOORBEAM FOR ACCESS, IAW SRM 53-10-51.

Part: FRAME — CORRODED (BS 767) · airframe 28,568 hrs · 15,045 cycles

FRAME AT BILGE AREA AT STA 767 RBL 10" IN AFT CARGO FOUND CORRODED. CORROSION FOUND TO BE OUT OF LIMITS PER B737-500 SRM 53-00-07 & 53-60-07. REMOVED CORROSION PER B737-500 SRM 53-00-07, ACCOMPLISHED REPAIR PER 13-737-500 SRM 53-00-07 REPAIR 8.

Part: SHUTOFF VALVE — SHORTED (NR 1 ENGINE) · airframe 18,556 hrs · 9,833 cycles

THE AUTOTHROTTLE DISCONNECTED AND THE NR 1 ENGINE AUTO SHUTDOWN ON FINAL APPROACH TO IAH. NO RESTART WAS ATTEMPTED. THE AIRCRAFT LANDED AT IAH WITHOUT INCIDENT. MAINTENANCE FOUND CANNON PLUG D05162P SHORTED WHICH CAUSED THE NR 1 ENGINE FUEL S/O VALVE TO POWER CLOSED. THE FUEL S/O MOTOR WAS ALSO SHORTED. THE FUEL S/O VALVE WAS REPLACED IAW MM 28-22-11. THE D05162P AND D05162J CANNON PLUGS WERE REMOVED AND REPLACED IAW STANDARD PRACTICES WIRING MANUAL 20-00-01. ALL OPERATIONAL CHECKS WERE GOOD.

Part: SKIN — DENTED (HORIZONTAL STAB) · airframe 16,499 hrs · 8,724 cycles

INSPECTION FOUND A DENT WITH GOUGE IN LT HORIZONTAL STABILIZER UPPER SPAR SKIN. THE DENT WAS LOCATED 51 INCHES O/B FROM I/B EDGE AND 3.5 INCHES AFT OF FORWARD SPAR. THE DENTED AREA WAS CUTOUT AND A DOUBLER WAS INSTALLED IAW SRM 55-10-01, FIGURE 207.

Part: ATTACH ANGLE — CORRODED (DOORWAY) · airframe 16,499 hrs · 8,724 cycles

INSPECTION FOUND Z-ATTACH ANGLE CORRODED AT L-2 DOOR ENTRYWAY. THE Z-ANGLE WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: CREASE BEAM — DENTED (STA 360-380) · airframe 11,015 hrs · 5,664 cycles

THE FUSELAGE SKIN WAS FOUND DENTED COMMON TO THE CREASE BEAM BETWEEN STA 360 TO STA 380. FURTHER INSPECTION FOUND THE CREASE BEAM OUTBOARD CHORD AND SHEAR WEB DAMAGED. THE SKIN DENT WAS WITHIN SRM LIMITS. THE DAMAGE WAS REPAIRED IAW ECRA 5310-04100. A DIP WAS ISSUED TO PERFORM A PERMANENT REPAIR WITHIN 24 MONTHS 0R 3000 CYCLES, WHICHEVER COMES FIRST.

Part: SOLENOID — INOPERATIVE (LANDING GEAR)

THE AIRCRAFT HAD A BRIEF HISTORY OF THE LANDING GEAR LEVER BINDING DURING GEAR RETRACTION. MAINTENANCE REMOVED AND REPLACED THE LANDING GEAR LEVER LATCH SOLENOID IAW MM 32-31-31 AND OPERATIONAL CHECKS WERE GOOD.

Part: LOGIC CARD — INOPERATIVE (E/E COMPT)

THE AIRCRAFT HAD A BRIEF HISTORY OF THE LANDING GEAR HANDLE BINDING IN THE OFF POSITION DURING GEAR RETRACTION. CYCLING THE GEAR HANDLE REMEDIED THE PROBLEM. MAINTENANCE REMOVED AND REPLACED THE M991 LOGIC CARD AND RELAY R276. A GEAR SWING WAS PERFORMED AND OPERATION CHECKED GOOD.