N15781

Part: HOUSING — CRACKED (RT MLG)

GUM - FLT 988 - EN ROUTE TO SPN, STARTED NOTICING A LOSS OF A-SYSTEM HYDRAULIC QUANTITY. REMOVED AND REPLACED MLG SEQUENCE VALVE PER MM 32-32-31. (X)

Part: T-CHORD — CORRODED (BS 950)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 3 SQUARE INCH IG CORROSION WAS FOUND ON BS 950 BULKHEAD LOWER TEE OF STRINGER 29L. THE CORRODED T-CHORD SECTION WAS TRIMMED AND REPAIRED PER CMI EC/RA NR 5310-0397. (M)

Part: CONTROL CABLE — FRAYED (BS 1070)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT ASIA, NR 3 ENGINE CONTROL CABLE (T3B) WAS FOUND FRAYED AT BS 1070. THE FRAYED CABLE WAS REMOVED AND REPLACED PER B727 MM CHAPTER 76-12-01 AND OPERATIONAL CHECK FOUND NORMAL. (M)

Part: FRAME — CORRODED (BS 303)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 2 INCH BY 5 INCH AREA IG CORROSION WAS FOUND ON NLG BAY FUSELAGE FRAME AT BS 303 BETWEEN STRINGER 25L AND STRINGER 26L. THE CORRODED FRAME WAS TRIMMED AND REPAIRED PER B727 SRM CHAPTER 53-30-03. (M)

Part: FITTING — CORRODED (TAIL SKID)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A IG CORROSION WAS FOUND ON TAIL SKID DRAG LEFT HINGE FITTING IN TAIL SKID BAY. THE CORRODED FITTING WAS REMOVED AND REPLACED WITH A NEW ONE (P/N 65-25614-11) PER B727 SRM CHAPTER 51-10-01 AND 51-30-02. (M)

Part: TEE — CORRODED (BS 294-312)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, IG CORROSION WAS FOUND ON NOSE WHEEL WELL TEE CHORD BETWEEN BS 294-312 AT STRINGER 26L. THE CORRODED T-CHORD WAS TRIMMED AND REPAIRED PER CMI EC/RA NR 5310-03937. (M)

Part: FLOORBEAM — CRACKED (BS 740)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 2 INCH LONG CRACK WAS FOUND ON PASSENGER CABIN FLOORBEAM UPPER CHORD AT BS 740 AND LBL 25. THE CORRODED SECTION WAS TRIMMED AND REPAIRED PER B727 SRM CHAPTER 51-40-04. (M)

Part: FLOORBEAM — CRACKED (BS 740)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 3 INCH LONG CRACK WAS FOUND ON PASSENGER CABIN FLOORBEAM UPPER CHORD AT BS 740. THE CORRODED SECTION WAS TRIMMED AND REPAIRED PER B727 SRM CHAPTER 53-30-02 AND 51-10-01. (M)

Part: STIFFENER — CRACKED (BS 1183)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 1.125 INCH LONG CRACK WAS FOUND ON BS 1183 BULKHEAD WEB FORWARD SIDE REINFORCEMENT BEAM INBOARD FLANGE AT LBL 36 AND WL 250. THE CORRODED SECTION WAS REPAIRED PER CMI EC/RA NR 5310-03930 USING KIT NR 65C34406-12 AND DWG NR 65C34406. (M)

Part: STIFFENER — CRACKED (BS 1183)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A .625 INCH LONG CRACK WAS FOUND ON BS 1183 BULKHEAD WEB FORWARD SIDE REINFORCEMENT BEAM OUTBOARD FLANGE AT LBL 37 AND WL 250. THE DAMAGED SECTION WAS REPAIRED PER CMI EC/RA NR 5310-03930 USING KIT NR 65C34406-12 AND DWG 65C34406. (M)

Part: BRACKET — CORRODED (PAX DOOR)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, AN IG CORROSION WAS FOUND ON L2 CABIN DOOR FORWARD STOP FITTING SUPPORT BRACKET. THE CORRODED FITTING WAS REMOVED AND REPAIRED PER B727 SRM CHAPTER 51-40-04. (M)

Part: FRAME — CRACKED (BS 1183)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, TWO 2 INCH AND 1.5 INCH LONG CRACKS WERE FOUND ON BS 1183 BULKHEAD FRAME INBOARD AND OUTBOARD FLANGE AT RBL 36 AND WL 238. THE DAMAGED SECTION WAS REPAIRED PER CMI EC/RA NR 5310-03930 USING KIT NR 65C34406-12 AND DWG 65C34406. (M)

Part: WEB — CORRODED (BS 1184)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CORROSION WAS FOUND ON TAIL SKID DRAG FORWARD WEB AT BS 1184. THE CORRODED WEB WAS TRIMMED AND REPAIRED PER B727 SRM CHAPTER 51-40-03. (M)

Part: STIFFENER — CORRODED (BS 930)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CORROSION WAS FOUND ON LEFT KEEL BEAM STIFFENER LOWER END AT WS 930. THE CORRODED STIFFENER SECTION WAS TRIMMED AND REPAIRED PER B727 SRM CHAPTER 51-40-04. (M)

Part: STIFFENER — CORRODED (BS 920)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CORROSION WAS FOUND ON LEFT KEEL BEAM STIFFENER LOWER END AT BS 920. THE CORRODED STIFFENER SECTION WAS TRIMMED AND REPAIRED PER B727 SRM CHAPTER 51-40-04. (M)

Part: SKIN — DAMAGED (PAX DOOR)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 1.5 INCH BY 1 INCH AREA DAMAGE WAS FOUND ON L2 CABIN DOOR SKIN FORWARD LOWER CORNER. THE DAMAGED AREA WAS TRIMMED AND REPAIRED PER B727 SRM CHAP 52-40-02. (M)

Part: FRAME — CRACKED (BS 783.9)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 2 INCH LONG CRACK WAS FOUND ON FUSELAGE FRAME BETWEEN STRINGER 16R AND 17R AT BS 783.9. THE DAMAGED SECTION WAS TRIMMED AND REPAIRED PER BOEING DRAWING NR 65C36280 USING REPAIR KIT NR 65C36280-24. (M)

Part: WEB — CRACKED (BS 1223-1243)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, FOUR CRACKS WERE FOUND ON RIGHT LOWER TORQUE BOX VERTICAL WEB LIGHTENING HOLES BETWEEN BS 1223 AND BS 1243. THE CRACK WAS STOP DRILLED AND REPAIRED PER B727 SRM CHAPTER 51-40-02. (M)

Part: STRINGER — CRACKED (WS 629)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A CRACK WAS FOUND ON RIGHT WING UPPER STRINGER S-9 ATTACHED TO WS 629 RIB. THE CRACK WAS STOP DRILLED AND REPAIRED PER CMI EA NR 5762-01050. (M)

Part: GUSSET — CORRODED (BS 950)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, AN IG CORROSION WAS FOUND ON GUSSET ATTACHED TO BS 950 BULKHEAD LOWER TEE CHORD AND STRINGER 29R INBOARD FLANGE. THE CORRODED GUSSET WAS REMOVED AND REPLACED WITH A NEW ONE PER B727 SRM CHAPTER 51-10-01 AND 51-30-02. (M)

Part: GUSSET — CORRODED (BS 950)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, IG CORROSION WAS FOUND ON GUSSET ATTACHED TO BS 950 LOWER TEE CHORD AND STRINGER 29L IN FLANGE. THE CORRODED GUSSET WAS REMOVED AND REPAIRED PER B727 SRM CHAPTER 51-10-01 AND 51-30-02. (M)

Part: RIB — CRACKED (WS 738.5)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A CRACK WAS FOUND ON RIGHT WING INSPAR WS 738.5 RIB UPPER FLANGE ATTACHED TO UPPER STRINGER 12. THE CRACK WAS STOP DRILLED AND REPAIRED PER B727 SRM CHAP 57-10-05 FIG 5. (M)

Part: STRINGER — CRACKED (WS 629)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A CRACK WAS FOUND ON RIGHT WING UPPER STRINGER S-13 ATTACHED TO WS 629 RIB. THE CRACK WAS STOP DRILLED AND REPAIRED PER CMI EA NR 5762-01050. (M)

Part: FITTING — CRACKED (LT WING)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CRACK WAS FOUND ON LEFT WING BOTTLE PIN. THE CORRODED FITTING WAS REMOVED AND REPLACED WITH A NEW ONE POWER SRM 53-30-02. (M)

Part: WEB — CRACKED (BS 1223)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, TWO CRACKS WERE FOUND ON LEFT LOWER TORQUE BOX VERTICAL WEB LIGHTENING HOLES AT BS 1223. THE CRACK WAS STOP DRILLED AND REPAIRED PER B727 SRM CHAPTER 51-40-02. (M)

Part: FITTING — CRACKED (TAIL SKID)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A CRACK WAS FOUND ON TAIL SKID ACTUATOR RIGHT HINGE ARM INBOARD SUPPORT BRACKET IN TAIL SKID BAY. THE CRACKED FITTING WAS REMOVED AND REPLACED WITH A NEW (P/N 65-57934-8) PER B727 SRM CHAPTER 51-10-01, 51-30-02. (M)

Part: FITTING — CRACKED (CARGO DOOR)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AIR ASIA, CRACK WAS FOUND ON C3 DOOR FORWARD LOWER CORNER STOP FITTING. THE DAMAGED STOP FITTING WAS REMOVED AND REPLACED WITH A NEW ONE (P/N 65-57768-6) PER CMI EA NR 5230-0185. (M)

Part: KEEL BEAM — CORRODED (BS 950)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 2 INCH BY .5 INCH AREA IG CORROSION WAS FOUND ON STRINGER29R KEEL BEAM OUTBOARD FLANGE AT BS 950 PLUS 14. THE CORRODED T-CHORD SECTION WAS TRIMMED AND REPAIRED PER B727 SB 53-0179. (M)

Part: SKIN — CRACKED (BS 730-734)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 4 INCH LONG CRACK WAS FOUND ON FUSELAGE SKIN AT STRINGER 17R BETWEEN BS 730 AND BS 734. THE DAMAGED SECTION WAS TRIMMED AND REPAIRED PER CML ECRA NR 5330-2891. (M)

Part: TEE — CORRODED (BS 950)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 2 INCH LONG IG CORROSION WAS FOUND ON BS 950 BULKHEAD LOWER TEE CHORD BETWEEN STRINGER 29R AND S29L. THE CORRODED SECTION WAS TRIMMED AND REPAIRED PER B727 SRM CHAPTER 51-10-01 AND 51-30-02. (M)

Part: TEE — CORRODED (BS 950)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 2 INCH BY 1 INCH AREA CORROSION WAS FOUND ON BS 950 BULKHEAD LOWER T-CHORD AT RIGHT SIDE OF STRINGER 29R. THE CORRODED T-CHORD WAS TRIMMED AND REPAIRED PER CMI EC/RA NR 5310-3928. (M)

Part: SKIN — CORRODED (CARGO DOOR)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 1.5 INCH LONG IG CORROSION WAS FOUND ON NR 3 CARGO DOOR FORWARD EDGE BETWEEN NR 3 AND NR 4 STOP FITTING. THE CORRODED AREA WAS TRIMMED OUT AND REPAIRED PER B727 SRM CHAPTER 51-40-03 FIG 1. (M)

Part: KEEL BEAM — CORRODED (BS 950)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 3 INCH BY .5 INCH AREA CORROSION WAS FOUND S-29L KEEL BEAM OUTBOARD FLANGE AT BS 950 PLUS 14. THE CORRODED KEEL BEAM OUTBOARD FLANGE WAS TRIMMED AND REPAIRED PER B727 SB 53-0179. (M)

Part: SPAR — CORRODED (WS 401)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A IG CORROSION WAS FOUND ON LEFT WING FRONT SPAR LOWER CHORD VERTICAL LEG AT FSS 401. THE CORRODED SECTION WAS CLEANED UP AND REPAIRED PER CMI EC/RA NR 5710-01975. (M)

Part: SKIN — BULGED (RUDDER)

TNN - DURING D-CHECK INSPECTIN ON AIRCRAFT AT AIR ASIA, A 7 INCH BY 3 INCH AREA BULGE WAS FOUND ON UPPER RUDDER SKIN AT FIN STATION 270. THE DAMAGED AREA WAS TRIMMED OUT AND REPAIRED PER B727 SRM CHAPTER 55-40-02, 55-20-03. (M)

Part: SKIN — BULGED (RUDDER)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 2 INCH BY 4 INCH AREA BULGE WAS FOUND ON UPPER RUDDER SKIN AT FIN STATION 213. THE BULGED AREA WAS TRIMMED OUT AND REPAIRED PER B727 SRM CHAPTER 55-40-02 FIG 1 AND 55-20-03 FIG 1. (M)

Part: CONTROL CABLE — FRAYED (BS 1186)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AIR ASIA, NR 1 ENGINE START CONTROL CABLE (ESS1A) WAS FOUND FRAYED AT BS 1186. THE FRAYED CABLE WAS REMOVED AND REPLACED PER B727 MM CHAPTER 76-12-01 AND OPERATIONAL CHECK FOUND NORMAL. (M)

Part: BEAM — CORRODED (ELEVATOR)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A 2 INCH LONG IG CORROSION WAS FOUND ON LEFT STABILIZER UPPER T/E BEAM AT ELEV STAB 146. THE CORRODED AREA WAS REMOVED AND REPAIRED PER B727 SRM CHAP 55-10-06. (M)

Part: SPAR — CORRODED (WS 221)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CORROSION OWAS FOUND ON LEFT WING FRONT SPAR WEB ABOVE FUEL BYPASS VALVE ACTUATOR. THE DAMAGED AREA WAS BLENDED OUT AND REPAIRED PER CMI EC/RA NR 5710-01978. (M)

Part: FITTING — CRACKED (AIRSTAIR)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A CRACK WAS FOUND ON AFT AIRSTAIR RIGHT LOWER STRUT END TO AIRSTAIR FITTING. THE CRACKED FITTING WAS REMOVED AND REPLACED WITH A NEW ONE (P/N 65-26651-18) PER B727 SRM CHAPTER 51-10-01. (M)

Part: FITTING — CRACKED (AIRSTAIR)

TNN - DURING D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, A CRACK WAS FOUND ON AFT AIRSTAIR LEFT LOWER STRUT END TO AIRSTAIR FITTING. THE CRACKED FITTING WAS REMOVED AND REPLACED WITH A NEW ONE (P/N 65-26651-17) PER B727 SRM CHAPTER 51-10-01. (M)

Part: SKIN — CORRODED (CARGO DOORWAY)

INSPECTION FOUND THE NR 3 CARGO DOOR CUTOUT SKIN CORRODED AT AFT LOWER CORNER. REPAIRED IAW ECRA 5330-02818.

Part: SKIN — CRACKED (FUSELAGE)

INSPECTION FOUND A 9 INCH CRACK IN FUSELAGE SKIN JUST UNDER FORWARD END OF NR 3 ENGINE PYLON. REPAIRED IAW SRM 53-30-3, FIGURE 3 SHEET 1.

Part: SKIN — CRACKED (BS 681-740)

AN INSPECTION OF THE LOWER SKIN OUTER SURFACE ALONG THE LOWEST ROW AT STRINGER 4R LAP SPLICE FROM BS 681 TO BS 740 FOUND CRACKS IN THE ENTIRE LENGTH OF THE PANEL. THE CRACKS MEASURED FROM .0625 INCH TO .25 INCH LONG. THE AREA WAS REPAIRED IAW ECRA 5330-02785. A DIP WAS ISSUED STATING THAT ENGINEERING WOULD PROVIDE FINAL DISPOSITION OF THE REPAIR WITHIN 23 MONTHS OF THIS REPAIR, AND UNTIL FINAL DISPOSITION LFEC INPECTION OF THE REPAIR WOULD BE PERFORMED IAW EA 5330-02762.

Part: ACCESSORY UNIT — INOP (E & E COMPT)

BOTH RT MLG RED AND GREEN ANNUNCIATOR LIGHTS ILLUMINATED DURING DESCENT. THE GEAR HANDLE WAS CYCLED FROM UP TO OFF AND THE GEAR DOOR LIGHT CAME ON. WHEN GEAR WAS SELECTED TO DOWN, GOT THREE GREEN AND LANDING WAS NORMAL. THE LANDING GEAR AND DOORS WERE INSPECTED WITH NO DEFECTS NOTED. THE LANDING GEAR ACCESSORY UNIT WAS REPLACED. SLUGGED GEAR AND CHECKED INDICATIONS IN UP, OFF, AND DOWN AND ALL WERE NORMAL. GEAR DOOR OPERATION CHECKED GOOD.

Part: ACTUATOR — INOPERATIVE (LT MLG DOOR)

THE LT MLG DOOR WOULD NOT RETRACT AFTER TAKEOFF FROM SFO. THE AIRCRAFT WAS RETURNED TO SFO WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE LT MLG DOOR ACTUATOR IAW MM 32-32-81. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: COMPRESSOR — STALLED (NR 1 ENGINE)

AS AIRCRAFT LEVELING AT FL 350 THE POWER REDUCTION CAUSED HEAVY COMPRESSOR STALLS IN THE NUMBER ONE ENGINE. LARGE FLUCTUATION IN N1, EGT, N2, AND FUEL FLOW. RAN NR 1 ENGINE PER MM 71-00-87 TO TAKEOFF POWER FOR THREE MINUTES, REDUCED POWER. NO STALLS NOTICED. CHECKED BLEED SCHEDULE. TESTS PERFORMED SEVERAL TIMES WITHOUT FAULTS.

Part: SPAR — CORRODED (VERT STAB)

INSPECTION FOUND VERTICAL STABILIZER FRONT SPAR FIN STA 87 TO 100 CORRODED ON RT SIDE. THE CORRODED AREA WAS CUT OUT, A REPAIR ANGLE AND STRAP WERE FABRICATED AND INSTALLED IAW ENGINEERING ORDER 98-833.

Part: CHORD — CORRODED (BS 1179)

INSPECTION FOUND CHORD CORRODED AT FS 1179, LBL 20. THE CHORD WAS REMOVED AND A NEW CHORD WAS FABRICATED AND INSTALLED IAW SRM 53-30-2 AND 51-10-1.

Part: FLOORBEAM — CORRODED (BS 1130)

INSPECTION FOUND UPPER CAP OF FLOORBEAM CORRODED AT FS 1130, LBL 60 TO RBL 60. THE FLOORBEAM WAS CORRODED IAW ECRA 5310-03707.

Part: CHORD — CORRODED (BS 950-1010)

INSPECTION FOUND AFT CARGO THRESHOLD LOWER CHORD CORRODED AT FS 950E TO 1010. THE AREA WAS REPAIRED IAW ECRA 5310-03710.

Part: FLOORBEAM — CORRODED (BS 1070)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1070, RBL 20 TO 60. THE CORRODED SECTION OF FLOORBEAM WAS REMOVED. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8, FIGURE 3.

Part: SEAT TRACK — CORRODED (BS 1130)

INSPECTION FOUND SEAT TRACK CORRODED AT STA 1130, LBL 24. THE SEAT TRACK WAS REMOVED. A NEW SEAT TRACK WAS FABRICATED AND INSTALLED IAW SRM 53-10-5.

Part: FLOORBEAM — CORRODED (BS 1110)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1110, RBL 0 TO 60. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8, FIGURE 3.

Part: SEAT TRACK — CORRODED (BS 1090-1130)

INSPECTION FOUND RT AFT LAV SEAT TRACK CORRODED BETWEEN STA 1090 TO 1130, RBL 24. A NEW SECTION OF SEAT TRACK WAS FABRICATED AND INSTALLED IAW SRM 53-10-5, PAGE 1 FIGURE 1, 51-10-2 AND MM 51-20-0.

Part: SEAT TRACK — CORRODED (BS 1010-1030)

INSPECTION FOUND SEAT TRACK CORRODED AT STA 1010 TO 1030, RBL 48. A NEW SEAT TRACK WAS FABRICATED AND INSTALLED IAW SRM 53-10-5, FIGURE 1, 51-10-2 AND MM 51-20-11.

Part: SUPPORT — CORRODED (BS 1110-1130)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT FS 1110 TO 1130, LBL 12. THE FLOOR SUPPORT WAS REMOVED. A NEW FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-40-4 AND 51-30-2.

Part: SEAT TRACK — CORRODED (BS 970-1130)

INSPECTION FOUND SEAT TRACK CORRODED AT FS 970 TO 1130, RBL 24. A SEAT TRACK REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-05, FIGURE 7, 51-10-2 AND MM 51-30-11.

Part: SUPPORT — CORRODED (BS 1130-1150)

INSPECTION FOUND CABIN FLOOR SUPPORT CORRODED AT FS 1130 TO 1150, LBL 12. THE FLOOR SUPPORT WAS REMOVED. A NEW FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-40-4 AND 51-30-2.

Part: FLOORBEAM — CORRODED (BS 1070)

INSPECTION FOUND LOWER CAP OF FLOORBEAM CORRODED AT FS 1070 FROM LBL 39 TO RBL 48. THE LOWER CAP WAS CUT OUT, L-ANGLES, FILLER AND A STRAP WERE FABRICATED AND INSTALLED IAW SRM 53-10-8, FIGURE 8.

Part: SEAT TRACK — CORRODED (BS 1110-1130)

INSPECTION FOUND SEAT TRACK CORRODED FROM STA 1110 TO 1130, LBL 45. A NEW SECTION OF SEAT TRACK WAS FABRICATED AND INSTALLED IAW SRM 53-10-2, 51-10-2 AND MM 51-20-0.

Part: FLOORBEAM — CORRODED (BS 1130)

INSPECTION FOUND LOWER CHORD OF FLOORBEAM CORRODED AT STA 1130, RBL 0 TO RBL 60. A REPAIR WAS FABRICATED AND INSTALLED IAW ECRA 5310-03707.

Part: SKIN — CORRODED (WS 250)

INSPECTION FOUND SCREW HOLE ON TOP OF LT WING FIXED LEADING EDGE CORRODED AT WS 250. THE CORROSION WAS REMOVED IAW SRM 57-20-1. THE CORRODED AREA OF SKIN WAS CUT OUT. REPAIR PARTS WERE FABRICATED AND INSTALLED IAW AEROCORP ENGINEERING ORDER 04884.

Part: SEAT TRACK — CORRODED (BS 480)

INSPECTION FOUND SEAT TRACK CORRODED AT STA 480, RBL 48. A SEAT TRACK REPAIR WAS FABRICATED AND INSTALLED IAW 53-10-5, 51-10-2, 51-30-2, AND MM 51-20-11.

Part: SUPPORT — CRACKED (BS 714)

INSPECTION FOUND CRACKS IN FORWARD PIT FLOOR SUPPORT AT STA 714, LBL 2. THE CRACKS WERE STOP DRILLED IAW SRM 51-10-1, PAGE 6. REPAIR ANGLES WERE FABRICATED AND INSTALLED IAW SRM 51-10-2, 51-30-2, AND 51-40-3.

Part: SKIN — DENTED (NR 1 LE SLAT)

INSPECTION FOUND A DENT IN LT WING LEADING EDGE NR 1 SLAT. THE DENTED AREA WAS REMOVED. THE AREA WAS REINFORCED WITH A NEW DOUBLER WHICH WAS FABRICATED AND INSTALLED IAW SRM 57-10-00 FIGURE 18A 51-20-00 AND 51-31-01.

Part: BULKHEAD — CRACKED (BS 1183)

INSPECTION FOUND A 3 INCH CRACK AROUND FASTENERS ON STA 1183 BULKHEAD AT RBL 7, WL 192 ABOVE TAIL SKID AT SECOND ANGLE FROM TOP. THE CRACK WAS ROUTED OUT IAW ECRA 5310-01473. A DOUBLER WAS FABRICATED AND INSTALLED IAW ECRA 5310-01473, SRM 51-30-2, AND 51-10-2.

Part: BULKHEAD — CRACKED (BS 1183)

INSPECTION FOUND A 6 INCH CRACK ON AFT SIDE OF STA 1183 BULKHEAD AT RBL 7, WL 192 JUST ABOVE TAIL SKID ATTACH UPPER L-ANGLE TO LOWER L-ANGLE. THE CRACK WAS ROUTED OUT IAW ECRA 5310-01473. A DOUBLER WAS FABRICATED AND INSTALLED IAW ECRA 5310-01473, SRM 51-30-2, AND 51-10-2.

Part: FLOORBEAM — CORRODED (BS 480)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 480, RBL 48. THE CORRODED AREA WAS REMOVED, A FLOORBEAM REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8, FIGURE 1.

Part: SEAT TRACK — CORRODED (BS 440-480)

INSPECTION FOUND SEAT TRACK CORRODED AT STA 440 TO 480, RBL 24. A NEW SEAT TRACK WAS FABRICATED AND INSTALLED IAW SRM 51-10-5, 53-10-5, 51-30-5, 51-30-8, 51-10-2, 51-30-2 AND MM 51-20-11.

Part: SUPPORT — CORRODED (BS 1130-1170)

INSPECTION FOUND AFT LAV LT SUB FLOOR SUPPORT CORRODED AT STA 1130 TO 1170, LBL 25 TO 60. THE CORROSION WAS REMOVED IAW SRM 51-10-6. A NEW FLOOR SUPPORT PANEL WAS FABRICATED AND INSTALLED.

Part: SUPPORT — CORRODED (BS 1070-1050)

INSPECTION FOUND CABIN FLOOR SUPPORT CORRODED AT FS 1070 TO 1050, LBL 12. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-40-4, 51-10-2, 51-30-5, AND MM 51-20-0.

Part: FLOORBEAM — CORRODED (BS 1166)

INSPECTION FOUND FLOORBEAM CORRODED AT FS 1166 RBL 45. THE CORRODED SECTION OF FLOORBEAM WAS REMOVED, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8 AND 51-30-2.

Part: FLOORBEAM — CORRODED (BS 1090)

INSPECTION FOUND FLOORBEAM CORRODED AT FS 1090, RBL 24. THE CORRODED AREA WAS CUT OUT, TWO ANGLES WERE FABRICATED AND INSTALLED IAW SRM 53-10-8, FIGURE 8.

Part: BULKHEAD WEB — CRACKED (BS 1183)

INSPECTION FOUND TWO 2 CRACKS IN STA 1183 BULKHEAD WEB ON FORWARD SIDE AT WL 188, RBL 32 AND RBL 35.5. THE CRACKS WERE STOP DRILLED, A REPAIR WAS INSTALLED IAW SRM 53-00 AND BOEING DRAWING 65C31446.

Part: SEAT TRACK — CORRODED (BS 1090)

INSPECTION FOUND SEAT TRACK CORRODED AT STA 1090, LBL 55 AND AT STA 970 TO 1130, RBL 24. THE SEAT TRACKS WERE REMOVED AND REPLACED IAW SRM 53-10-2, 51-10-2, AND 51-20-11.

Part: CABLE — FRAYED (ESCAPE SLIDE)

KUL - NRC 826112. R1 CABIN DOOR ESCAPE SLIDE LATCH ASSY CABLE FRAYED. REMOVED AND REPLACED ESCAPE SLIDE CABLE ASSY IAW MM 25-60-15. (X)

Part: CABLE — FRAYED (ESCAPE SLIDE)

KUL - NRC 826113. L1 CABIN DOOR ESCAPE SLIDE LATCH ASSY CABLE FRAYED. REMOVED AND REPLACED ESCAPE SLIDE LACH ASSY IAW MM 25-60-15. (X)

Part: DUCT — FAILED (BS 1223)

FLT 840 - NRT - DURING CRUISE, A LOUD BANG WAS HEARD FROM THE AFT CABIN IN CONJUNCTION WITH BODY OVERHEAT LIGHT ILLUMINATING AND LOSS OF EPR IND AT NR 2 ENG. PULLED THROTTLE TO IDLE PER CHECKLIST PROCEDURE AND LIGHT WENT OFF. DIVERTED TO NRT. MX FOUND THE RT WING ANTI-ICE AIR DUCT ATTACHMENT FLANGE FAILED, AT BS 1223. THE RT WING ANTI-ICE SYSTEM WAS PLACARDED PER MEL 30-02 AND ACCOMP DDP. ALSO, THE NR 2 ENG EPR SYS WAS PLACARDED PER MEL 77-01. MX REPLACED THE RT ANTI-ICE DUCT AND THE ANTI-ICE AIR VALVE. SYS CHECKED GOOD. MX FOUND A EPR LINE BROKEN. THE EPR LINE WAS REPLACED AND THE SYSTEM CHECKED GOOD. (M)

Part: HYD LINE — RUPTURED (ON DOOR ACT)

FLT 864 - GUM - LOST ALL 'A' SYSTEM HYDRAULIC FLUID DURING GEAR AND FLAP RETRACTION AFTER TAKEOFF. FOUND RIGHT GEAR DOOR ACTUATOR PRESSURE LINE BLOWN. REPLACED LINE AND PERFORMED LEAK CHECK. REPLACED 'A' SYSTEM HYDRAULIC PUMP ON NR 1/2 ENGINES. CHECKED BOTH CASE DRAIN FILTERS. RAN ENGINES AND PERFORMED LEAK CHECK. (M)

Part: TURBINE — FAILED (NR 1 ENGINE)

FLT NR 915 - GUM - ON TAKEOFF HEARD LOUD EXPLOSION, THEN CAW NR 1 ENGINE FAIL LIGHT CAME ON. EPR WENT TO ZERO, HOWEVER, EGT, N1 AND N2 APPEARED NORMAL. LOUD RUMBLE HEARD FROM NR 1 ENGINE WHEN AT IDLE. FOUND TURBINE SECTION FAILED. REMOVED AND REPLACED NR 1 ENGINE PER WORKCARD 07-7100-1-8001. (M)

Part: WINDSHIELD — AIR LEAK (RT COCKPIT)

FLT NR 958 - GUM - AIR TURN BACK, NOTED AIR LEAK ON T/O (RT SIDE F/O'S WINDOW AREA) AS DIFFERENTIAL INCREASED NOISE TURNED TO SQUEL AND INCREASED AT 5 PSI. NOISE WAS DEAFENING AND CREW/RADIO COMMUNICATIONS BECAME IMPOSSIBLE, DUMPED 9000 LBS OF FUEL OFFSHORE AND RETURNED TO GUAM, LANDING WEIGHT 134,000 LBS. FOUND FLIGHT OFFICERS WINDSHIELD (R1) PEELING ON OUTSIDE. REMOVED ALL OUTER SEALANT, RETORQUED, RESEALED PER MM 56-11-11. (M)

Part: BALL NUT — NICKED (NLG)

TNN - DURING '1/2D' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, NLG MANUAL EXTENSION BALL NUT AND SCREW ASSEMBLY PATH WAS FOUND NICKED. THE DAMAGED BALL NUT AND SCREW ASSY, PN 10-60744-1, WAS REMOVED AND REPLACED PER B727 MM 32-35-0, AND OPERATIONAL CHECK FOUND SATISFACTORY. REF: HANGAR NON-ROUTINE REPAIR ITEM CARD NR 819170 (SEQ NR 01154). (X)

Part: SUPPORT PLATE — CRACKED (R1 GALLEY DOOR)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, 6 INCH LONG CRACK WAS FOUND ON R1 GALLEY DOOR LOWER FORWARD DOOR STOP BOLT FITTING SUPPORT PLATE. THE CRACK WAS STOP DRILLED AND REPAIRED PER B727 SRM 51-40-2. HANGAR NON ROUTINE REPAIR ITEM CARD NR 807054 (SEQ NR 02260). (M)

Part: SEAT TRACK — CRACKED (BS 720)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, 1 INCH LONG CRACK WAS FOUND ON PASSENGER CABIN SEAT TRACK LOW PORTION AT BS 720D, RBL 45.5. THE DAMAGED SEAT TRACK FROM BS 720C TO BS 720D WAS TRIMMED OUT AND REPAIRED PER B727 SRM 53-10-5. HANGAR NON ROUTINE REPAIR ITEM CARD NR 818897. (M)

Part: SUPPORT — CRACKED (CABIN)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, 2 INCH LONG CRACK WAS FOUND ON PASSENGER CABIN FLOOR PANEL SUPPORT 'L' ANGLE BETWEEN BS 720A AND 720B, BL 0. THE DAMAGED FLOOR PANEL SUPPORT 'L' ANGLE FROM BS 720A TO 720B WAS REMOVED AND REPLACED WITH NEW 'L' ANGLE. HANGAR NON ROUTINE REPAIR ITEM CARD NR 818863. (M)

Part: STRINGER — CRACKED (WS 686.5)

TNN - DURING '1/2D' CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, 0.5 INCH LONG CRACK FOUND ON LEFT OUTER WING UPPER VENT STRINGER TO RIB ATTACHMENT AT S12, WS 686.5. THE CRACKED TAB WAS STOP DRILLED AND REPAIRED PER EA 5762-1050 (SB 727-57A159R5). REF: HANGAR NON-ROUTINE REPAIR ITEM CARD NR 806515 (SEQ NR 05065). (X)

Part: CHANNEL — CORRODED (BS 380-400)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, SEVERE CORROSION WAS FOUND ON PASSENGER CABIN FLOOR PANEL SUPPORT 'J' CHANNEL AT BS 395, RBL 15. THE CORRODED 'J' CHANNEL FROM BS 380 TO 400 WAS REMOVED AND REPLACED WITH NEW 'J' CHANNEL. HANGAR NON ROUTINE REPAIR ITEM CARD NR 818889. (M)

Part: SEAT TRACK — CORRODED (BS 344-380)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, SEVERE CORROSION WAS FOUND ON PASSENGER CABIN SEAT TRACK UPPER FLANGE AT BS 350, RBL 45.5. THE DAMAGED SEAT TRACK FROM BS 344 TO BS 380 WAS TRIMMED OUT AND REPAIRED PER B727 SRM 53-10-5. HANGAR NON ROUTINE REPAIR ITEM CARD NR 818882. (M)

Part: INTERCOSTAL — CRACKED (BS 950)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, 1 INCH LONG CRACK WAS FOUND ON PASSENGER CABIN FLOORBEAM INTERCOSTAL BETWEEN BS 950A AND 950B, BL 0. THE DAMAGED INTERCOSTAL FROM BS 950A AND 950B WAS REMOVED AND REPLACED WITH NEW CHANNEL. HANGAR NON ROUTINE REPAIR ITEM CARD NR 818860. (M)

Part: GUSSET — CRACKED (BS 823)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, 1.5 INCH LONG CRACK WAS FOUND ON BS 823 FRAME FORWARD GUSSET AT RBL 62.5. THE CRACK WAS STOP DRILLED AND REPAIRED PER SRM 51-40-3. HANGAR NON ROUTINE REPAIR ITEM CARD NR 818598. (M)

Part: SPAR — CORRODED (RT WING)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, SEVERE CORROSION WAS FOUND ON RIGHT WING FRONT SPAR LOWER CHORD PLATE BELOW NR 5 SLAT ACTUATOR. THE CORRODED CHORD PLATE WAS CLEAN UP AND REPAIRED PER B727 51-10-6 AND 51-40-4. HANGAR NON ROUTINE REPAIR ITEM CARD NR 819631 (SEQ NR 06031). (M)

Part: INBOARD WEB — OIL CANNING (AFT AIRSTAIR)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, OIL CANNING WAS FOUND ON AFT AIRSTAIR RT/LT TORQUE BOX INBOARD WEB AT THE FOLLOWING AREAS; RT SIDE BETWEEN BS 1213 AND 1223. RT SIDE BETWEEN BS 1243 AND 1253. RT SIDE BETWEEN BS 1263 AND 1273. RT SIDE BETWEEN BS 1283 AND 1293. RT SIDE BETWEEN BS 1303 AND 1313. RT SIDE BETWEEN BS 1313 AND 1323. LT SIDE BETWEEN BS 1213 AND 1223. LT SIDE BETWEEN BS 1233 AND 1243. LT SIDE BETWEEN BS 1253 AND 1263. LT SIDE BETWEEN BS 1313 AND 1323. THE AFT AIRSTAIR RT/LT TORQUE BOX INBOARD WEB OIL CANNING AREAS WERE INSTALLED REINFORCEMENT STIFFENER ANGLES PER B727 SRM 53-30-1. HANGAR NON ROUTINE REPAIR ITEM CARD NR 819390 THROUGH 819399. (M)

Part: INBOARD WEB — CRACKED (AFT AIRSTAIR)

TNN - DURING 1/2D CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CRACKS WERE FOUND ON AFT AIRSTAIR TORQUE BOX INBOARD WEB LIGHTENING HOLE CUTOUT, AT THE FOLLOWING AREA; 1 INCH LONG CRACK AT BS 1238 LEFT SIDE, 2 INCHES LONG CRACK AT BS 1218 RIGHT SIDE, 4 INCHES LONG CRACK AT BS 1238 RIGHT SIDE. THE CRACKS WERE STOP DRILLED AND REPAIRED PER B727 SRM 51-40-2. HANGAR NON ROUTINE REPAIR ITEM CARD NR 819400, 819401 AND 819431. (M)

Part: ACTUATOR — LEAKING (NR 5 L/E SLAT)

AFTER TAKEOFF ON CLIMB-OUT FROM SPN, LOST ALL A-SYSTEM HYDRAULIC QUANTITY. FLIGHT CONTINUED TO GUM AND GEARS EXTENDED MANUALLY FOR LANDING. MAINTENANCE FOUND NR 5 L/E SLAT ACTUATOR LEAKING EXCESSIVELY. REMOVED AND REPLACED ACTUATOR ASSY. ALSO REPLACED BOTH A-SYSTEM HYDRAULIC PUMPS AND FILTER ASSEMBLIES. SLAT SYSTEM OPERATION CHECK GOOD. HYDRAULIC SYSTEM OPERATION CHECK AND LEAK CHECK GOOD. AIRCRAFT RETURNED BACK TO SERVICE. (X)

Part: HYD PUMP — FAILED (NR 1 ENG)

GUM - FLT 965 - AIRCRAFT LOST 'A' SYSTEM HYDRAULIC QUANTITY WHILE EN ROUTE FROM OSAKA, JAPAN TO SAIPAN, CNMI. FLIGHT WAS DIVERTED TO GUAM. MAINTENANCE FOUND NR 1 ENGINE DRIVEN HYDRAULIC PUMP FAILED. MECHANIC REMOVED AND REPLACED NR 1 ENGINE DRIVEN HYDRAULIC PUMP PER MM 29-11-31. SYSTEM OPERATIONAL AND LEAKAGE CHECK GOOD. (W)

Part: OIL CAP — LOOSE (NR 2 ENGINE)

TNN - FLT 858 - DURING POST-MAINTENANCE CHECK FLIGHT ON AIRCRAFT AT AIR ASIA, OIL LOSS FOUND ON NR 2 ENGINE DUE TO OIL TANK FILLER CAP NOT PROPERLY SECURED. THE OIL WAS REFILLED AND OIL TANK FILLER CAP WAS PROPERLY SECURED PER B727 MM 70-11-0 AND OPERATIONAL CHECK FOUND SATISFACTORY. REF: LINE NON-ROUTINE REPAIR ITEM CARD NR 7917132. (X)

Part: SMOKE DETECTOR — INOPERATIVE (LAVATORY)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, FORWARD AND RT AFT LAVATORY SMOKE DETECTORS FOUND INOPERATIVE. THE DEFECTIVE SMOKE DETECTORS REMOVED AND REPLACED PER B727 MM 26-10-0 AND OPERATIONAL CHECK FOUND SATISFACTORY. REF: HANGAR NON-ROUTINE REPAIR ITEM CARD NR 0726932 AND NR 0726933 (SEQ. NR. 02142 AND NR 02143). (X)

Part: EXIT SIGN — CRACKED (AFT ENTRY DOOR)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CRACK FOUND ON PASSENGER CABIN AFT ENTRY DOOR EXIT SIGN COVER. THE DAMAGED EXIT SIGN ASSEMBLY REMOVED AND REPLACED WITH PN BR9279-105 ASSEMBLY PER B727 MM 33-50-11 AND OPERATIONAL CHECK FOUND SATISFACTORY. REF: HANGAR NON-ROUTINE REPAIR ITEM CARD NR 0729535 (SEQ NR 02045). (X)

Part: BEARING — SEIZED (NR 4 FLAP LT)

FLT 821 - GUM - AIRCRAFT AIR RETURNED AFTER TAKEOFF CREW ADVISED THAT DURING FLAP RETRACTION, INBOARD FLAPS STUCK BETWEEN 2 AND 5 DEGREES. FOUND LEFT FLAP THRUST BEARING FROZEN. REPLACED THRUST BEARING AND SYSTEM OPERATIONAL CHECKED SATISFACTORY. (Z)