N15774

Part: FLEX LINE — FAILED (ELEVATOR PCU)

THE A HYDRAULIC SYSTEM WAS LOST AFTER TAKEOFF FROM IAH. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND A HOLE IN ELEVATOR LEFT PCU PRESSURE FLEX LINE. THE FLEX LINE WAS REMOVED AND REPLACED. IN ADDITION, THE NR 2 ENGINE DRIVEN HYDRAULIC PUMP WAS REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE. THE HYDRAULIC SYSTEM WAS SERVICED TO FULL. OPERATIONAL CHECKS WERE GOOD WITH NO LEAKS NOTED.

Part: FRAME — CRACKED (L-2 DOOR)

INSPECTION FOUND A 1 INCH CRACK IN LOWER SIDE CORNER OF L-2 DOOR FRAME UPPER HINGE CUTOUT. THE L-2 DOOR FRAME WAS REPLACED IAW SRM 51-10-1.

Part: DOOR FRAME — CRACKED (C-2 DOOR)

INSPECTION FOUND A 1 INCH CRACK IN FORWARD LOWER EDGE OF C-2 DOOR FRAME. A NEW CORNER WAS INSTALLED ON FORWARD LOWER AREA OF C-2 DOOR IAW SRM 51-30-2 AND 51-10-2.

Part: HINGES — DAMAGED (LT AILERON)

INSPECTION FOUND LEFT OUTBOARD AILERON HINGES DAMAGED. THE HINGES WERE REMOVED AND REPLACED IAW SRM 51-30-2.

Part: WEB — CORRODED (BS 1150/1170)

INSPECTION FOUND RT AFT LAV FLOOR WEB CORRODED AT STA 1150 AND 1170. THE CORRODED SECTION OF FLOOR WAS CUT OUT IAW SRM 51-40-2. REPAIRS WERE FABRICATED AND INSTALLED IAW SRM 51-40-2 AND 51-10-2.

Part: ANGLE — CRACKED (BS 471)

INSPECTION FOUND A 1 INCH CRACK IN ANGLE AT FS 471, BBL 0. THE ANGLE WAS REMOVED. A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-10-1, 51-10-2, AND 51-40-5.

Part: DOUBLER — KINKED (BS 1263)

INSPECTION FOUND DOUBLER KINKED AND TORQUE BOX WEB CRACKED 1 AT STA 1263R BELOW AIRSTAIR ACTUATOR. THE CRACK WAS STOP DRILLED IAW SRM 51-10-1. THE DOUBLER WAS REMOVED IAW SRM 51-30-2. A NEW DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-10-1, 51-30-2, AND 51-40-2.

Part: RIB — CRACKED (LT WING)

INSPECTION FOUND A .75 INCH CRACK AT STIFFENER ON INBOARD SIDE OF LT WING LEADING EDGE RIB, WBL 92.0. A DOUBLER WAS INSTALLED IAW SRM 51-40-4 AND 51-30-2.

Part: RIB — CRACKED (NR 4 LE SLAT)

INSPECTION FOUND A 1 INCH CRACK IN LT WING NR 4 SLAT INBOARD END RIB. THE CRACKED AREA WAS REMOVED IAW SRM 51-30-2. A NEW PART WAS FABRICATED AND INSTALLED IAW SRM 51-30-2, 51-40-2, AND 51-10-2.

Part: ANGLE — CORRODED (BS 380-420)

INSPECTION FOUND CORROSION ON TOP AND BOTTOM OF CHORD AT FS 380-420, RBL 64. THE CORROSION AND CORRODED SPLICE ANGLE WERE REMOVED. A NEW SPLICE ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-10-1, 51-10-6, AND 51-10-1.

Part: SEAT TRACK — CORRODED (CABIN)

INSPECTION FOUND SEAT TRACK CORRODED AT FLOOR PANEL NR 104 AREA. THE SEAT TRACK WAS REMOVED AND A NEW SEAT TRACK WAS FABRICATED AND INSTALLED IAW SRM 53-10-5.

Part: ANGLE — CRACKED (WS 130)

INSPECTION FOUND A 1 INCH CRACK IN CURVED ANGLE INSIDE LT WING INBOARD FIXED LEADING EDGE AT STA 130. A DOUBLER WAS INSTALLED IAW SRM 51-40-3.

Part: SEAT TRACK — CORRODED (CABIN)

INSPECTION FOUND SEAT TRACK CORRODED IN FLOOR PANEL NR 97 INBOARD AFT AREA. THE SEAT TRACK WAS REMOVED. A NEW SEAT TRACK WAS FABRICATED AND INSTALLED IAW SRM 53-10-5.

Part: ANGLE — CRACKED (NR 2 SLAT ACT)

INSPECTION FOUND A 1.5 INCH CRACK IN INBOARD SUPPORT ANGLE AT UPPER SURFACE OF COVER BELOW LT WING NR 2 SLAT ACTUATOR. THE ANGLE WAS REMOVED AND A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-40-3.

Part: ANGLE — CRACKED (BS 722)

INSPECTION FOUND A 1 CRACK IN ANGLE AT FS 722, BBL 0. THE ANGLE WAS REMOVED. A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-10-1, 51-10-6, AND 51-40-1.

Part: SUPPORT — CORRODED (BS 640)

INSPECTION FOUND FLOOR SUPPORT CORRODED UNDER NUT PLATES IN FORWARD CARGO COMPARTMENT AT STA 640, STRINGER 28R. THE CORRODED AREA WAS CUT OUT. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-4-4, 51-10-2, AND 51-30-2.

Part: INTERCOSTAL — CRACKED (BS 380)

INSPECTION FOUND A .5 INCH CRACK IN INTERCOSTAL AT UPPER FLANGE RIVET, FS 380, LBL 12. THE CRACK WAS STOP DRILLED IAW SRM 51-10-1. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-40-2, 51-10-2, AND 51-30-2.

Part: FRAME — CRACKED (BS 1049)

INSPECTION FOUND A 2 INCH CRACK IN FLOOR SUPPORT FRAME IN AFT BAGGAGE BIN AT STA 1049, SRTINGER 27R. THE FLOOR SUPPORT FRAME WAS REMOVED, AN INTERCOSTAL WAS FABRICATED AND INSTALLED IAW SRM 51-10-1.

Part: SKIN — DENTED (NR 5 LE SLAT)

INSPECTION FOUND NR 5 SLAT SKIN DENTED BETWEEN NR 9 AND 10 RIB FROM INBOARD END. THE SKIN WAS REPAIRED IAW SRM 57-50-3.

Part: SPAR — CRACKED (RT ELEVATOR)

INSPECTION FOUND 2 CRACKS IN REAR SPAR RT ELEVATOR AT TAB CENTER HINGE FITTING. THE SPAR WAS REPLACED IAW SRM 51-80-1.

Part: FLOORBEAM — CORRODED (BS 1070)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1070, BL 0 TO RBL 42. THE FLOORBEAM WAS REPAIRED BY INSTALLING ANGLES ON BOTH FORWARD AND AFT FLOORBEAM FLANGES IAW SRM 53-10-8, FIGURE 8.

Part: DOOR ACTUATOR — CRACKED (RT MLG)

FLT 281 - EWR - ON TAKEOFF AFTER RAISING GEAR HANDLE, SYSTEM 'A' HYDRAULIC QUANTITY DROPPED TO ZERO AND PRESSURE FLUCTUATED BETWEEN 0/3000 PSI RAN APPROPRIATE CHECK LISTS AND RETURNED TO EWR. OPERATED HYDRAULIC SYSTEM AND FOUND RIGHT GEAR DOOR ACTUATOR HOUSING CRACKED, REPLACED PER MM 32-32-81 AND CHECKED GOOD. CYCLED ALL SYSTEMS AND FILLED RESERVOIR TO FULL. (M)

Part: ANGLE — CORRODED (BS 1176)

DURING INSPECTION, FOUND BS 1176 CHORD LBL 27.5 LEFT LAV INBOARD WALL LOWER ATTACH ANGLE HAS CORROSION. REMOVED CORROSION FABRICATED, REPAIR INSTALL PER IAW B727 SRM 51-10-2, 51-30-2, MM 51-40-5. (M)

Part: FLANGE — CORRODED (BS 360)

DURING INSPECTION, FOUND AT BS 360 FORWARD LOWER FUSELAGE S-26R UPPER OUTBOARD FLANGE HAS 1 INCH SECTION CORRODED. REMOVED CORROSION REPAIRED, FABRICATED, ALODINED PRIMED AND INSTALLED PER IAW B727 SRM 51-10-6, 53-10-3, 51-10-2, 53-10-3. (M)

Part: SEAT TRACK — CORRODED (BS 380-420)

DURING INSPECTION, FOUND CORROSION AT BS 380 TO 420 BL 24R AND BL 48R SEAT TRACK. FABRICATED SEAT TRACK SEC BS 380 TO 420 PER IAW B727 SRM 53-10-5. TREATED AND PRIMED PER SRM 51-10-2. (M)

Part: ANGLE — CORRODED (DOOR L-1)

DURING INSPECTION, FOUND CORROSION AT L-1 DOOR SILL L-ANGLE. FABRICATED REPAIR ANGLE, CUT OUT CORRODED AREA HEAT TREATED MATERIAL, DRILLED AND COUNTER SUNK HOLES, ALODINED AND PRIMED, INSTALLED DOUBLER PER SRM 51-40-3 AND INSTALLED FILLER 51-40-3. (M)

Part: SUPPORT — CORRODED (BS 312-344)

DURING INSPECTION, FOUND CORROSION AT MAIN CABIN INTERIOR FLOOR SUPPORT. FABRICATED SUPPORT ANGLES, ALODINED, PRIMED AND INSTALLED PER SRM 51-10-2, 51-30-2 AND 53-10-2. (M)

Part: SEAT TRACK — CORRODED (BS 340-480)

DURING INSPECTION, FOUND CORRODED SEAT TRACK. REMOVED SEAT TRACK FROM RBL 48 STATION 340 TO 480. FABRICATED AND INSTALLED NEW SEAT TRACK SEC. (M)

Part: STRINGER — CORROSION (BS 422)

DURING INSPECTION, FOUND CORROSION BEYOND LIMITS AT BS 422A STRINGER 26R. REMOVED CORRODED STRINGER IAW SRM 53-10-3, FABRICATED NEW PART PER IAW B727 SRM 53-10-3 ALODINED AND PRIMED PART PER IAW B727 SRM 51-10-6, INSTALLED PART PER SRM 53-10-3. (M)

Part: FLOOR BEAM — CORROSION (BS 344)

DURING INSPECTION, FOUND CORROSION AT MAIN CABIN FLOOR BEAM UPPER CAP. REMOVED CORRODED T-CAP, FABRICATED, TREATED, PRIMED. INSTALLED NEW T-CAP PER SRM 51-20-01 AND 53-10-04. (M)

Part: ANGLE — CORROSION (BS 580)

DURING INSPECTION, FOUND CORROSION AT BS 580 STRINGER 28R AND STRINGER 28L FORWARD CARGO CIRCUMFERENTIAL SHEAR TIE. CUT OUT CORRODED SHEAR TIE, FABRICATED ANGLE DOUBLER, SHEAR TIE REPAIR, TREATED, PRIMED AND INSTALLED PER IAW B727 SRM 53-10-4, 51-10-2 AND MAINTENANCE MANUAL 51-20-31. (M)

Part: BULKHEAD ANGLE — CORROSION (BS 340)

DURING INSPECTION, FOUND CORROSION AT LOWER L-ANGLE. REMOVED ATTACH ANGLE FROM AFT BLKHD FABRICATED SHIM FOR ANGLE, ALODINED, PRIMED AND INSTALLED PER IAW 727 SRM 51-30-2, 51-10-1 AND 53-10-2. (M)

Part: LINER — CRACKED (L-1 DOOR)

DURING INSPECTION, FOUND NUMEROUS CRACKS AROUND OUTER EDGES AND AROUND ASSISTS HANDLE. FABRICATED INTERNAL DOUBLER ALODINED, PRIMED, AND INSTALLED PER IAW B727 SRM 52-10-2, 51-30-2 AND 52-20-11, CRACKS STOP DRILLED 51-10-1 EDDY CURRENT REVEALED NO FURTHER CRACKING. (M)

Part: STRINGER — CORROSION (BS 740)

DURING INSPECTION, FOUND BS 740 FORWARD CARGO COMPARTMENT STRINGER-27L AND ENDING FITTING HAS CORROSION. REMOVED CORROSION ON END FITTING .002 TO FALL WITHIN LIMITS AT STRINGER 27L BS 740. CUT OUT FABRICATED NEW STRINGER SEC AT STRINGER 27L AND STRAP FOR STRINGER REPAIR, TREAT INSTALLED PER SRM 51-10-2, 6 AND 51-30-2. (M)

Part: SKIN — CRACKED (R-1 DOOR)

DURING INSPECTION, FOUND R-1 DOOR SKIN LOWER AFT CORNER HAS APPROX 1 INCH CRACK THROUGH SCREW HOLE. REPAIRED IAW B727 SRM 52-20-2 FABRICATED WITH 2024-T3 .050 CLAD. PRIMED AND TREATED IAW B727 SRM 51-10-2. INSTALLED DOUBLER (4 INCH BY 4 INCH) PER SRM 51-30-2 CRACK STOP DRILLED SRM 51-10-1. (M)

Part: ANGLE — CORROSION (BS 1130)

DURING INSPECTION, FOUND CORROSION AT BS 1130 WEB BETWEEN STRINGER 30 AND STRINGER 29R. REMOVED CORROSION AND CORRODED REINFORCEMENT ANGLE FABRICATED REPAIR ANGLE FOR WEB AND REINFORCEMENT ANGLE SRM 51-10-6 AND B727 MM 51-20-11 AND INSTALLED PER SRM 51-30-2. (M)

Part: HYD MODULE — LEAKING ('A' HYD SYSTEM)

FLT NR 0299 - EWR - THE 'A' HYD SYSTEM OVERHEAT LIGHT ILLUMINATED IN FLIGHT. THE 'ABNORMAL' PROCEDURES WERE COMPLIED WITH, BUT HAD NO EFFECT. A RETURN TO EWR WAS INITIATED AND ON FINAL APPROACH THE 'A' SYSTEM PRESSURE WENT TO 500 PSI ACCOMPANIED BY ILLUMINATION OF BOTH HYDRAULIC 'A' SYSTEM LOW PRESSURE LIGHTS. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE 'A' SYSTEM HYDRAULIC MODULE LEAKING. THE MODULE WAS REMOVED AND REPLACED AND LEAK CHECK WAS GOOD. (M)

Part: DUCT — RUPTURED (NR 2 ENGINE)

FLT NR 0238 - SFO - THE NR 2 ENGINE FIRE WARNING LIGHT AND BELL ACTIVATED AFTER TAKEOFF FROM SFO. WHEN THE THROTTLE WAS REDUCED THE WARNING CEASED, BUT UPON INCREASING POWER THE WARNING WOULD ACTIVATE AGAIN. THE AIRCRAFT WAS RETURNED TO SFO WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 2 ENGINE HIGH PRESSURE SUPPLY DUCT RUPTURED. THE DUCT WAS REMOVED AND REPLACED. THE NR 2 ENGINE WAS RUN AND LEAK AND OPERATIONAL CHECKS WERE GOOD. (W)