N14814

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND TWO .5 INCH CRACKS IN INTERCOSTAL IN MID CARGO COMPARTMENT AT STA 769 - 788, CENTERLINE. A NEW INTERCOSTAL WAS INSTALLED IAW SRM 51-30-2.

Part: FRAME — CORRODED (FUSELAGE) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND AFT SIDE OF BELT FRAME CORRODED IN AFT BAGGAGE BIN AT STA 1302, LONGERON 22L. THE CORRODED SECTION OF FRAME WAS CUT OUT AND A NEW SECTION WAS INSTALLED USING SPLICE ANGLES IAW SRM 53-03, FIGURE 2A.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND LT TIE DOWN RAIL CORRODED AT STA 1212 - 1322. A NEW SECTION OF TIE DOWN RAIL WAS INSTALLED IAW SRM 51-30.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND FLOORBEAM CORRODED AROUND NUT PLATE UNDER LT AFT LAV AT STA 1338. A REPAIR WAS INSTALLED IAW ECRA 5305-01051.

Part: PAN — GOUGED (CARGO DOOR) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND AFT BAGGAGE BIN DOOR STOP PAD FITTING ATTACH POINT SKIN GOUGED AT AFT LOWER LOCATION. A REPAIR DOUBLER WAS INSTALLED IAW ECRA 5230-01540.

Part: WEB — CORRODED (FUSELAGE) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND CUSP AT LT SIDE FLOOR LINE CORRODED AT STA 190 - 237. A REPAIR WAS INSTALLED IAW ECRA 5310-04066.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND LT MID SEAT TRACK CORRODED AT STA 1030 - 1200. REMOVED AND REPLACED SEAT TRACK SECTION IAW SRM 51-30-1 AND 51-30-2.

Part: CHANNEL — CORRODED (DOOR FRAME) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND AFT BAGGAGE BIN THRESHOLD Z-CHANNEL CORRODED. THE CHANNEL WAS REPLACED IAW SRM 53-05, FIGURE 63, SHEET 1.

Part: SEAT TRACK — CORRODED (CABIN) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND LEFT O/B SEAT TRACK CORRODED AT STA 1030 - 1132. THE SEAT TRACK SECTION WAS REPLACED IAW SRM 53-05.

Part: ATTACH ANGLE — CRACKED (VERTICAL STAB) · airframe 47,833 hrs · 37,169 cycles

INSPECTION FOUND A 1.125 INCH CRACK IN LT VERTICAL STABILIZER ATTACH ANGLE AT STA 1463. A REPAIR WAS INSTALLED IAW SRM 53-05, FIGURE 23.

Part: WIRE — LOOSE (NLG SENSOR)

THE NOSE GEAR RED UNSAFE LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION ON TAKEOFF FROM IAH. THE GEAR HANDLE WAS EXTENDED, BUT THE LIGHT REMAINED ON WITH THE GEAR DOOR OPEN LIGHT ILLUMINATING INTERMITTENTLY. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND WIRE PULLED FROM PIN AT CONNECTOR R5-1156. THE CONNECTOR WAS REPLACED. THE NOSE GEAR WAS SWUNG AND OPERATION CHECKED GOOD IAW MM 32-60-05.

Part: MANIFOLD — CRACKED (NR 2 ENGINE)

NUMBER 2 FUEL FLOW INDICATES HIGHER THAN NUMBER 1 ON TAKEOFF. AT CLIMB POWER NUMBER 2 FUEL FLOW IS 1000 POUNDS HIGHER AND AT CRUISE 500 POUNDS HIGHER. FUEL USED AND FUEL REMAINING VERIFY THE HIGHER FUEL FLOW. FOUND CRACKED FUEL MAINFOLD. REMOVED AND REPLACED ENGINE PER CITEXT WORK CARD 08-7100-1-9900 AND TRIMMED PER CITEXT WORK CARD 08-7100-1-8900.

Part: BELTFRAME — CORRODED (BS 1322)

INSPECTION FOUND BELTFRAME CORRODED AT STA 1322 BETWEEN LONGERON 29L AND 29R. THE CORROSION WAS REMOVED, FILLER AND DOUBLERS INSTALLED IAW SRM 53-03, FIGURE 2A.

Part: BEAM — CRACKED (SERVICE DOOR)

INSPECTION FOUND A 1 INCH CRACK IN FORWARD SERVICE DOOR NR 4 BEAM. THE DOOR BEAM WAS REPLACED IAW WORK CARD 99-5240-1-0002.

Part: FITTING — WORN (RT MLG ACTUATOR)

INSPECTION FOUND RT MLG RETRACT ACTUATOR UPPER ATTACH COKE BOTTLE FITTING WORN. A NEW COKE BOTTLE FITTING AND BUSHINGS WERE INSTALLED IAW MM 57-40-02.

Part: BELTFRAME — CORRODED (BS 1338)

INSPECTION FOUND BELTFRAME WEB CORRODED AT STA 1338 BETWEEN LONGERONS 25 AND 26. THE CORRODED AREA WAS CUT OUT, FILLER AND DOUBLER WERE INSTALLED IAW SRM 53-01, FIGURE 4.

Part: SKIN — CRACKED (BS 1418)

INSPECTION FOUND A .375 INCH CRACK IN FUSELAGE SKIN AT STA 1418, LONGERON 2R. REPAIRED IAW SRM 53-04, FIGURE 40.

Part: B NUT — LEAKING (RT MLG BRAKE)

THE RT HYDRAULIC SYSTEM FLUID QUANTITY DROPPED TO 1.5 QUARTS ON CLIMB-OUT OF DCA EN ROUTE TO EWR. THE RIGHT PUMP AND AUX PUMP WERE TURNED OFF. THE GEAR WAS MANUALLY EXTENDED AND THE AIRCRAFT LANDED AT EWR WITH GEAR DOORS OPEN. THE RIGHT GEAR DOOR SUSTAINED DAMAGE. THE RIGHT GEAR DOOR WAS REPLACED IAW MM 32-31-04. MAINTENANCE FOUND B NUT LOOSE ON HYDRAULIC LINE TO RIGHT SYSTEM BRAKE ACCUMULATOR. THE B NUT WAS TIGHTENED AND LEAK CHECK WAS GOOD. THE RT HYDRAULIC SYSTEM WAS SERVICED TO FULL. GEAR DOOR OPERATION AND INDICATION CHECKED GOOD.

Part: WIRE — BROKEN (NLG)

THE NLG INDICATED RED UNSAFE WHEN GEAR WAS EXTENDED, BUT THE COCKPIT INDICATOR PIN SHOWED DOWN AND LOCKED ON APPROACH TO EWR. A GO-AROUND WAS PERFORMED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND A BROKEN WIRE ON NLG DOWNLOCK SENSOR. THE WIRE WAS SPLICED. A GEAR SWING WAS PERFORMED IAW MM 32-31-00 WITH OPERATION AND INDICATIONS CHECKING GOOD.

Part: FUEL CONTL UNIT — MALFUNCTIONED (APU)

THE APU AUTO SHUT DOWN INFLIGHT AND THE HIGH OIL TEMP LIGHT ILLUMINATED. ALSO, THE NR 2 FIRE BOTTLE LOW AGENT LIGHT ILLUMINATED. THE AIRCRAFT LANDED AT EWR WITHOUT INCIDENT. MAINTENANCE FOUND NR 2 FIRE BOTTLE APU SQUIB BLOWN. THE APU WAS PLACARDED INOPERATIVE. THE NR 2 FIRE BOTTLE WAS REMOVED AND REPLACED. THE NR 2 FIRE BOTTLE APU SQUIB WAS REMOVED AND REPLACED. THE APU PLACARD WAS REMOVED, A TEST OF THE FIRE DETECTION SYSTEM WAS PERFORMED AND OPERATION CHECKED GOOD. *S/D* THE APU CONTINUED TO HAVE A HISTORY OF THE OIL TEMP HIGH LIGHT ILLUMINATING. THE APU FUEL CONTROL UNIT AND TEMP SENSOR WERE REPLACED. THE APU WAS RUN AND OPERATION CHECKED GOOD.

Part: THRESHOLD — CORRODED (LAV SERVICE DOOR)

INSPECTION FOUND LT AFT SERVICE DOOR THRESHOLD WEB AT AFT LOWER CORNER CORRODED. THE CORRODED WEB SECTION WAS REMOVED. A NEW WEB REPAIR SECTION WAS FABRICATED AND INSTALLED IAW SRM 51-10-03 AND 53-01, FIGURE 2.

Part: SUPPORT — CORRODED (BS 150-200)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED FROM STA 150 TO 200, RBL 7. THE FLOOR SUPPORT WAS REMOVED. A REPLACEMENT PART WAS FABRICATED AND INSTALLED IAW SRM 53-14-1 AND 51-30-1.

Part: SUPPORT — CORRODED (BS 200-204)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED AT STA 200-204, LBL 56. THE FLOORBOARD SUPPORT WAS REMOVED AND A REPLACEMENT PART WAS FABRICATED AND INSTALLED IAW SRM 51-30-2.

Part: SUPPORT — CORRODED (BS 150-200)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED FROM STA 150-200, LBL 7. THE FLOOR SUPPORT WAS REMOVED. A REPLACEMENT PART WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 53-14-1.

Part: SUPPORT — CORRODED (BS 218-238)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED FROM STA 218 TO 238, LBL 14. THE FLOOR SUPPORT WAS REMOVED. A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-10-2 AND 53-18-1, FIGURE 11.

Part: SUPPORT — CORRODED (BS 160-200)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED FROM STA 160 TO 200, LBL 44. THE FLOOR SUPPORT WAS REMOVED. A REPLACEMENT PART WAS FABRICATED AND INSTALLED IAW SRM 53-14-1 AND SRM 51-30-2.

Part: SUPPORT — CORRODED (BS 168)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED AT STA 168 FROM RBL 10 TO RBL 43. THE FLOOR SUPPORT WAS REMOVED AND A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-10-3 AND SRM 51-10-2.

Part: SUPPORT — CORRODED (BS 200)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED AT STA 200, LBL 7 TO RBL 5. THE CORRODED SECTION WAS REMOVED. A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 53-14-1 AND SRM 51-30-2.

Part: SUPPORT — CORRODED (BS 541)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED AT FORWARD BULKHEAD OF MID CARGO COMPARTMENT, STA 541, STRINGER 29L TO 28L. THE FLOOR SUPPORT WAS REMOVED IAW SRM 51-30-2. A REPLACEMENT FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 53-24-0, FIGURE 9A, SHEETS 2 AND 3, AND SRM 51-30-2.

Part: SUPPORT — CORRODED (BS 1155)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT F.S. 1155, LBL 18 - 40. THE FLOOR SUPPORT WAS REMOVED AND A SUPPORT ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 51-10-3.

Part: BRACE — CRACKED (LT MLG DOOR)

INSPECTION FOUND A 1.5 INCH CRACK IN LT MLG DOOR CENTER BRACE. THE CENTER BRACE WAS REMOVED IAW SRM 51-30-1. A REPAIR WAS INSTALLED AND THE BRACE WAS REINSTALLED IAW SRM 51-30-1.

Part: SUPPORT — CORRODED (BS 200)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED AT STA 200, RBL 10 TO RBL 44. THE FLOOR SUPPORT WAS REMOVED. A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-10-3.

Part: SUPPORT — CORRODED (BS 221)

INSPECTION FOUND FLOORBOARD SUPPORT CORRODED AT STA 221, LBL 3. THE FLOOR SUPPORT WAS REMOVED IAW SRM 51-30-2. A REPLACEMENT PART WAS FABRICATED AND INSTALLED IAW SRM 53-14-1, FIGURE 11 AND 51-30-2.

Part: SKIN — CRACKED (BS 258)

INSPECTION FOUND A 1.5 INCH CRACK AND DENT IN FUSELAGE SKIN AT STA 258 JUST BELOW STRINGER 21R. THE DENT WAS REWORKED AND THE CRACKED AREA WAS CUT OUT. A FILLER AND DOUBLER WERE FABRICATED AND INSTALLED IAW SRM 53-04, FIGURE 38, SHEET 21, VIEW I.

Part: HYD LINE — LEAKING (TAIL COMPT)

THE RT HYDRAULIC SYSTEM QUANTITY BEGAN TO DECREASE DURING CLIMB. THE R/H HYDRAULIC QUANTITY CONTINUED TO DROP SLOWLY WHILE AT CRUISE. THE TRANSFER PUMP, RT HYDRAULIC PUMP AND AUX PUMP WERE TURNED OFF. THE PUMPS WERE RETURNED TO NORMAL ON APPROACH WITH THE RT HYDRAULIC QUANTITY AT 2 GALLONS. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND A PINHOLE LEAK IN RT HYDRAULIC SYSTEM PRESSURE LINE LOCATED IN TAIL COMPARTMENT. THE HYDRAULIC LINE WAS REMOVED AND REPLACED. THE RT HYDRAULIC SYSTEM WAS SERVICED TO FULL AND LEAK CHECKS WERE GOOD.

Part: FIRE DET MODULE — INOPERATIVE (NR 1 ENGINE)

FLT NR 421 - IAH - THE NR 1 ENGINE LOOP 'B' FIRE DETECTOR LIGHT AND MASTER CAUTION LIGHT ILLUMINATED DURING CLIMB-OUT AT 18,000 FEET. THE NR 1 ENGINE LOOP SWITCH WAS MOVED TO LOOP 'A' AND TEST WAS NORMAL. THE NR 1 ENGINE FIRE DETECTION MODULE WAS REMOVED AND REPLACED. THE NR 1 ENGINE FIRE DETECTION SYSTEM CHECKED GOOD. (M)

Part: FUEL PUMP — LEAKING (NR 1 ENGINE)

DFW - FLT 0140 - THE NR 1 FUEL QUANTITY DECREASED FROM 6500 TO 1350 WITHIN 15 MINUTES WHILE ENROUTE FROM LAS TO IAH. THE CROSSFEED PROCEDURE WAS USED AND THE NR 2 FUEL QUANTITY DECREASED FASTER THAN FUEL QTY DISPLAYS COULD INDICATE. THE AIRCRAFT WAS DIVERTED TO DFW FOR AN UNEVENTFUL LANDING. AFTER LANDING, PERSONNEL ON THE GROUND REPORTED FUEL LEAKING FROM THE NR 1 ENGINE. PASSENGERS WERE DEPLANED ON THE TAXIWAY AS A PRECAUTIONARY MEASURE. MAINTENANCE FOUND THE FITTING FOR FUEL INLET PRESSURE LINE BLOWN OUT OF MANIFOLD ON NR 1 ENGINE FUEL PUMP. THE NR 1 ENGINE FUEL PUMP WAS REMOVED AND REPLACED IAW MM 73-12-01. LEAK AND OPERATIONAL CHECKS WERE NORMAL. (X)