N16709

Part: ENGINE — FAULTED · airframe 84,882 hrs · 31,149 cycles

RTO AT 63 KNOTS. NR 2 ENG STOPPED SPOOLING AT 75 PERCENT, LOG PAGE UPDATED CREW BRIEFED THAT THE 75 PERCENT STATED IN HIS WRITE-UP IS 75 % N1 PERFORMED FIM TASK # 73-05 TASK 814 ENGINE IS SLOW TO ACCELERATE. ALL PARAMETERS NORMAL WITH NO ERRATIC SIGNALS NOTED. ALSO TIMED NR 1 & 2 ENGINES FROM IDLE TO TAKE-OFF POWER. NR 2 ENGINE MADE TAKE-OFF POWER A HALF SECOND QUICKER THAN NR 1 ENGINE.

Part: MODULE — FAULTED (ZONE 700) · airframe 84,663 hrs · 31,060 cycles

LANDING GEAR FAILED TO RETRACT ON T/O. MANUAL GEAR EXT DOOR SWITCH DID NOT FIX ISSUE DEBREIFED FLIGHT CREW AND THEY REPORTED THAT ALL LANDING GEAR INDICATORS GREEN/RED WERE ILLUMINATED AFTER FIRST GEAR RETRACTION ATTEMPT. FOLLOWING EMERGENCY PROCEDURE THE GEAR RETRACTED AFTER CYCLING MANUAL GEAR EXT DOOR THEN PLACING HANDLE IN THE UP POSTION FOR THE THIRD ATTEMPT. THEY ALSO REPORTED THAT ON LANDING THE GEAR WAS SLUGGISH WHILE DEPLOYING. REPLACED LANDING GEAR CONTROL MODULE IAW AMM 32-31-11. PERFORMED MLG OPERATIONAL TEST REF 32-32-00-710-801. TEST PASS. GEAR CYCLED NORMAL WITH NORMAL INDICATION.

Part: GIRT BAR — UNRAVELED (ZONE 800) · airframe 84,298 hrs · 30,854 cycles

R1 GIRT BAR HAS ACCESS SLIDE MATERIAL SHOWING UPDATED MAA CODE FIX USING VENDOR MAA SCREEN PLEASE CONTACT TOMC BEFORE COMMENCING ANY WORK. UPDATED MAA CODE FIX USING VENDOR MAA SCREEN. UPDATED MAA CODE FIX USING VENDOR MAA SCREEN PLEASE CONTACT TOMC BEFORE COMMENCING ANY WORK. . MAC METER INITIATED FOR WITH VENDOR ID V928416 MAC RELATED WORK ORDER 000000003195976 AND PRTR MARTINY, JAMES (V928416) RESECURED Z-FOLD AT R1 DOOR REF AMM 25-66-01-400-804, OK FOR SERVICE. MARTINY, JAMES (V928416) RESECURED Z-FOLD AT R1 DOOR REF AMM 25-66-01-400-804, OK FOR SERVICE. ADD EMP: V928416

Part: OXYGEN MASK — NO TEST (ZONE 200) · airframe 84,044 hrs · 30,710 cycles

CREW OXYGEN MASK REGULATOR TEST. CAPTAIN MASK REGULATOR UNIT HEAD HARNESS LEAKS WHEN TESTED. REMOVED AND REPLACED CAPTAIN MASK REGULATOR IAW AMM 35-12-85. OPS AND LEAK CHECKED OK.

Part: BATTERY — INOPERATIVE (ZONE 200) · airframe 84,044 hrs · 30,710 cycles

EMERGENCY LIGHTING SYSTEM FUNCTIONAL CHECK - M1670 BATTERY FAILED FUNCTION CHECK. REMOVED AND REPLACED EMERGENCY LIGHT BATTERY PACK IAW AMM 33-51-06-960-805,. OPS CHECKED GOOD.

Part: SLIDE — NO DISCREPANCY (ZONE 800) · airframe 83,455 hrs · 30,395 cycles

1R DOOR SLIDE RAFT MATERIEAL IS OUT TOO FAR UPDATED MAA CODE FIX USING VENDOR MAA SCREEN PLEASE CONTACT TOMC BEFORE COMMENCING ANY WORK. M VERIFIED DOOR 1R Z FOLD FABRIC WITHIN LIMITS APPROXIMATELY 11 INCHES REF AMM TASK 25-66-01-400-804 OK FOR SERVICE VERIFIED DOOR 1R Z FOLD FABRIC WITHIN LIMITS APPROXIMATELY 11 INCHES REF AMM TASK 25-66-01-400-804 OK FOR SERVICE ADD EMP: V849650

Part: SLIDE — DISLODGED (ZONE 800) · airframe 82,549 hrs · 29,980 cycles

FWD ENTRY DOOR SLIDE IS PARTIALLY STICKING OUT OF CASE UPDATED MAA CODE FIX USING VENDOR MAA SCREEN PLEASE CONTACT TOMC BEFORE COMMENCING ANY WORK. MAC METER INITIATED FOR WITH VENDOR ID MAC RELATED WORK ORDER 000000003127480 AND PRTR RE-TUCKED LOOSE SLIDE MATER AND SLIDE CONDITION NORMAL IN REF WITH AMM 03-25-66-200-801. RE-TUCKED LOOSE SLIDE MATER AND SLIDE CONDITION NORMAL IN REF WITH AMM 03-25-66-200-801.

Part: SLIDE — DAMAGED (L1 DOOR) · airframe 82,373 hrs · 29,904 cycles

GIRT MATERIAL AT 1L HAS COME OUT OF SLIDE PACK COVER REMOVED AND REPLACED DOOR 1 LEFT SLIDE IAW REF 25-66-01-400-803 .PARTS USED: 29-2566-9-0006,QTY :1 ADD EMP:U260507,U416899 ROTABLE PARTS CHANGE WAS INDICATED - TT # 1334994 SN OFF 9434 SLIDE, FWD/AFT OFF 29-2566-9-0006 9434 ON 29-2566-9-0007 3724 ACCOMPLISHED RII INSPECTION OF DR 1L SLIDE PACK INSTALLATION REF AMM 25-66-01 AND GMM 09-25-05.

Part: PROXIMITY SENSOR — FAULTY (ZONE 700) · airframe 81,711 hrs · 29,592 cycles

RIGHT MAIN LANDING GEAR GREEN LIGHT REMAINED ILLUMINATED AFTER DEPARTURE. PROVIDED BY FLIGHT CREW PERFORMED BITE ON PSEU REF AMM 32-09 TASK 801 FOUND EXISTING FAULTS 2, MESSAGE 32-61005, LATCHED AND 32-61004 NOT LATCHED, RIGHT LAND GEAR DOWN LOCK FAULT. UPLOAD SOME PICTURES REF. SSM 32-61-11-101 & FIM 32-61 TSK 801 SENSOR RESISTANCE READS 799 OHMS W/ LCR METER OUT OF LIMITS, REQUIRES #1 RIGHT GEAR DOWN & LOCK SENSOR S0073 REPLACEMENT. FOUND RIGHT FWD DOWN LOCK SENSOR S0073 FAULTY, REPLACED SENSOR PER AMM 32-61-31-400-801, ALSO PERFORMED GEAR SWING REF AMM 32-32-00-710-801 4 TIMES FOUND NO FAULTS, INDICATION NORMAL.

Part: INDICATOR — INOPERATIVE (CABIN PRESSURE) · airframe 79,241 hrs · 28,480 cycles

AT 10000 CABIN ALT WAS -1000FT. CABIN RATE OF CLIMB APPEARED NORMAL AT 28000 DIFFPRES WAS8 VERIFIED QUICK DISCONNECT PROPERLY INSTALLED. ADDING PIC T/S PER FIM 21-33 TASK 803. REMOVED AND REPLACED CABIN ALT AND DIFFERENTIAL PRESSURE INDICATOR, REF AMM 21-33-02-400-801. IDT REQUIRED FOR QUICK DISCONNECT. PARTS USED: 29-3111-9-0001,QTY :1 ROTABLE PARTS CHANGE WAS INDICATED - TT # 1555755 SN OFF 1559 PERFORMED LOW LEVEL STATIC LEAK CHECK REF AMM 34-11-00-790-808 LEAK CHECK PASSED REPLACED #2 CABIN PRESSURE CONTROLLER PRE CAUTIONARY. PER AMM 21-31-01-000-801 AND AMM 21-31-01-400-801. OPS CK NORMAL. PARTS USED: 29-2131-9-0003,QTY :1 ROTABLE PARTS CHANGE WAS INDICATED - TT # 1521210 SN OFF 1916 INDICATOR, CABI OFF 29-3111-9-0001 1559 ON 0000 INDICATOR, CABI OFF 29-3111-9-0001 1559 ON 29-3111-9-0001 8678 IPC REFERENCE # 21-31-01-400-801 CONTROLLER, CAB OFF 29-2131-9-0003 1191 ON 0000 CONTROLLER, CAB OFF 29-2131-9-0003 1191 ON 29-2131-9-0003 1905 PERFORMED CABIN PRESSURE LEAK CHECK, TO VERIFIY OPERATION OF CABIN PRESSURE INDICATOR, REF AMM 05-51-91. CABIN PRESSURE INDICATOR OPERATES NORMALLY.

Part: CHARGER — INOPERATIVE (STA322) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK EMERGENCY LIGHTS CONNECTED TO BATTERY CHARGER M1675 STAY ON WITH FLIGHT DECK SWITCH IN OFF REF HAECO GSO NR 9282993 REMOVED AND REPLACED BATTERY CHARGER M1675 IAW B737 AMM 33-51-06-960-806 REF HAECO GSO.

Part: CHARGER — INOPERATIVE (STA 603) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK EMERGENCY LIGHTS CONNECTED TO BATTERY CHARGER M1668 STAY ON WITH FLIGHT DECK SWITCH IN OFF REF HAECO GSO NR 9282992. REMOVED AND REPLACED BATTERY CHARGER M1668 IAW B737 AMM 33-51-06-960-806 REF HAECO GSO

Part: WINDOW FRAME — CRACKED (STA 1217 WL258) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK CRACK FOUND IN LH NO. 1 WINDOW FRAME AT STA 1217 WL258 COMING OFF OF THE TOP LEFT INTERNAL FASTENER THAT ATTACHES STEEL CHORD DOUBLER. CRACK MARKED IN RED REF HAECO GSO NR 9282713 CYCLES PENDING THE RESULTS OF A DAMAGE TOLERANCE ANALYSIS (DTA). REMOVE THE AIRCRAFT FROM SERVICE ON OR BEFORE 50,000 TOTAL AIRCRAFT CYCLES, UNLESS ANOTHER 8100-9 FORM IS RECEIVED FINDING APPROVAL FOR DAMAGE TOLERANCE REQUIREMENTS - V901735 ACCOMPLISHED UNITED ECRA 5610-01529. DAMAGE CUTOUT AND REPAIR DOUBLER AND TRIPLER INSTALLED IAW ECRA 5610-01529. THE REPAIR INCORPORATED VIA ECRA 5610-01529 LH NO. 1 WINDOW FRAME CRACK APPROVED AS TIME LIMITED UNTIL 50,000 TOTAL AIRCRAFT FLIGHT

Part: BATTERY PACK — INOPERATIVE (M1669/ R/H OVERW) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK EMERGENCY BATTERY PACK M1669 NEEDS REPLACED REF HAE CO GSO NR 9282056 REMOVED AND REPLACED EMERGENCY LIGHT BATTERY M1669 RH OVERWING EXIT REF B737-700 AMM 33-51-06-960-805. EMERGENCY LIGHT BATTERY PACK CHECKS GOOD.

Part: PANEL — CRACKED (RH HORIZ STAB) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK- R/H HORIZONTAL STABILIZER, UPPER INBOARD PANEL LAND CRACKED AT NUTPLATE LOCATION. TRANSCRIBED FROM HAEC OGSO NRC# 9282697. ACCOMPLISHED UAL ECRA 5516-01043.

Part: DECK PLATE — CORRODED (STA 992.8) · airframe 79,014 hrs · 28,388 cycles

MAIN CABIN STA 992.8, RIGHT HAND DECK WEB PLATE HAS AREAS OF CORROSION. REMOVED .010" CORRODED MATERIAL FROM ORIGINAL .020" THICKNESS. R EMAINING .010" MATERIAL THICKNESS FOUND TO BE OUT OF LIMITS IAW SRM 53-70-51-01-1 AND DWG 147A5712 REV-. REMOVE D AND REPLACED DECK WEB PLATE IAW SRM 51-40-02 AND REMOVED .010" CORRODED MATERIAL FROM ORIGINAL .020" THICKNESS. R 147A5712 REV-. REMAINING .010" THICKNESS FOUND TO BE OUT OF LIMITS IAW SRM 53-70-51-01-1 AND DWG# 147A5712 REV-. REMOVED AND REPLACED DECK WEB PLATE IAW SRM 51-40-02 AND DWG#

Part: PANEL — CORRODED (AFT CARGO COMP) · airframe 79,014 hrs · 28,388 cycles

(B737-53-3-0785) AFT CARGO COMPARTMENT WAST TANK WHERE RINS FITTING HEATER TERMOSTAT ATTACHE TO IT THE PANAL IS CORRODED.

Part: DOOR SILL — CORRODED (R2 DOOR) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK: MAIN CABIN R-2 DOOR SILL APPROX STA 986 CHORD HAS CORROSION. TRANSCRIBED FROM HAECO GSO NRC# 9282250 REMOVED 50% CORRODED MATERIAL FROM ORIGINAL THICKNESS. FOUND TO BE OUT OF LIMITS IAW B737 SRM 53-70-15 AND BOEING DWG# 147A8501 REV C. REMOVED AND REPLACED CHORD IAW B737-700 SRM 51-40-02 AND BOEING DWG# 147A8501 REV C.

Part: THRESHOLD — CORRODED (R2 DOOR) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK: MAIN CABIN R-2 DOOR THRESHOLD WEB RBL-39 HAS CORROSION. TRANSCRIBED FROM HAECO GSO NRC# 9282553 BOEING DWG# 147A8510 REV E. REMOVED .071" CORRODED MATERIAL FROM ORIGINAL .071" THICKNESS. R EMAINING 0 MATERIAL THICKNESS FOUND TO BE OUT OF LIMITS IAW B737 -700 SRM 53-70-15-1A-1 AND BOEING DWG# 147A8510 REV E. REMOVED AND REPLACED DOOR THRESHOLD WEB IAW B737-700 SRM 51-40-02 AND REMOVED .071" CORRODED MATERIAL FROM ORIGINAL .071" THICKNESS. DWG# 147A8510 REV E. REMAINING 0 MATERIAL THICKNESS FOUND TO BE OUT OF LIMITS IAW B737 -700 SRM 53-70-15-1A-1 AND BOEING DWG# 147A8510 REV E. REMOVED A ND REPLACED DOOR THRESHOLD WEB IAW B737-700 SRM 51-40-02 AND

Part: SKIN — DENTED (AFT CARGO DOOR) · airframe 79,014 hrs · 28,388 cycles

AFT CARGO DOOR SKIN DENTED. REMOVED AND REPLACED OUTER SKIN ASSY ON AFT PIT DOOR IAW SRM 52-30-01-2R-3.

Part: FLOORBEAM — CORRODED (STA 986.5) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK: MAIN CABIN STA 986.5 FLOOR BEAM UPPER SURFACE HAS CORROSION AT RBL-36, TRANSCRIBED FROM HAECO GSO N/R 9282552 REMOVED CORROSION FROM STA 986.5 FLOORBEAM AT RBL36 AND RBL5. ORIGINAL MATERIAL THICKNESS .150, REMOVED .015, REMAINING .135 OUT OF LIMITS IAW B737-700 SRM 53-70-51. FABRICATED AND INSTALLED T -CAP REPAIR FROM LBL10 TO RBL58 IAW B737-700 SRM 53-70-51-2R-4.

Part: FRAME — CORRODED (STA 727) · airframe 79,014 hrs · 28,388 cycles

SUPPORT TASK: MAIN CABIN STA 727 STR 1L TO 2L HAS AREA OF CORROSION, TRANSCRIBED FROM HAECO GSO N/R 9282437 REMOVED CORROSION IAW B737-700 SRM 51-10-02 ORIGINAL THICKNESS . 131 REMOVED .031 REMAINING .100. REPAIRED STA 727 FRAME INNER CHORD 51L-52L IAW UNITED EC/RA 5342-01137, REF HAECO GSO MECH V9 00579 REMOVED CORROSION IAW B737-700 SRM 51-10-02. ORIGINAL THICKNESS .131, REMOVED .031, REMAINING .100, REPAIRED STA 727 FRAME INNER CHORD S1L-S2L IAW UAL ECRA 5342-01137. HAECO GSO MECH V900579 INSP QC019

Part: WIRE — SEVERED (COMP C2 OF G7 GA) · airframe 78,906 hrs · 28,348 cycles

EMERGENCY LIGHTING SYSTEM OPERATIONAL CHECK {B737-33-3-0235} - FWD CLOSET AFT AISLE LIGHT INOP. REMOVED AND REPLACED LIGHT ASSY REF MM 33-51-14. NO HELP. SWPM20-30-11 AND REASSEMBLED TERMINAL BLOCK REF SWPM 20-30-00. REMOVED AND REPLACED PWR SUPPLY REF MM 33-51-06. NO HELP. FOUND OPS CK OK. PARTS USED: 29-3351-3-0031,QTY :1 TERMINAL END BROKEN OFF POWER SIDE WIRE IN CLOSET ASSY AT TERMINAL BLOCK IN COMP C2. REPLACED TERMINAL END REF REMOVED AND REPLACED LIGHT ASSY REF MM 33-51-14. NO HELP. REMOVED AND REPLACED PWR SUPPLY REF MM 33-51-06. NO HELP. FOUND TERMINAL END BROKEN OFF POWER SIDE WIRE IN CLOSET ASSY AT TERMINAL BLOCK IN COMP C2. REPLACED TERM.

Part: PANEL — MISSING (R MLG) · airframe 78,134 hrs · 27,936 cycles

PANEL MISSING JUST AFT OF R MLG SEE PICS ATTACHED. INSTALLED PANEL P/N 149A7654-8. CHECKS SECURE.OK TO CONT PARTS USED: 29-5351-3-0028,QTY :1

Part: FASTENER — MISSING (RT UPPER WING PA) · airframe 77,565 hrs · 27,694 cycles

PDA 3 RT UPPER WING PANEL MISSING 11 EACH FASTENERS. SEE PHOTO. ADDED PHOTO. INSPECTED NUT PLATES AND REPLACED MISSING SCREWS ON RT WING UPPER PANEL 651BT.

Part: NONE — NONE (SECTION 46 LOWER) · airframe 76,170 hrs · 27,121 cycles

AIRCRAFT LAV SERVICE DOOR FOUND MISSING ON INBOUND FLIGHT. SEE PICTURE. GVI WASTE TANK SERVICE PORT AND LH TAIL STRUCTURE. NO DAMEGE FOUND. REPLACED WASTE SERVICE PANEL. OPS CK GOOD.

Part: STRINGER — DAMAGED (STA 1088/STR5R) · airframe 75,987 hrs · 27,046 cycles

LONGITUDINAL ANGLE IN HORIZONTAL STABILIZER CENTER SECTION AREA, JUST ABOVE WHERE UPPER RH SLIDING SEAL AFT TRACK TURNS INWARD, IS WORN FROM CONTACT WITH SLIDING SEAL THAT WAS NOT BEING CAPTURED BY SEAL TRACK. SEE PICS. REMOVED UPPER R/H STAB SLIDING PLATE TO F.O.M. HORIZONTAL STAB TRIM SYSTEM HAS BEEN RE-ACTIVATED FOT OTHER MAINTENANE. WILL NEED DE-ACTIVATED AGAIN FOR SAFETY PRIOR TO CONTINUING WORK ON THIS L/P. REMOVED CLIP AT STA 1088 STR 5R. REF SRM 51-40-02. DAMAGE TO STRINGER 5R MEASURES 0.800 IN L BY 0.160 IN W BY 0.065 DAMAGE TO STRINGER 5R MEASURES 0.800 IN L BY 0.160 IN W BY 0.065 ADD MORE PHOTOS. IN D. SEE ATTACHED DRAWING AND PHOTOS. IN D. SEE ATTACHED DRAWING AND PHOTOS. REMOVED FRAME TIE AR STA 1156 TO FOM..MOVED STRINGER AFT TO FOM REMOVED FASTENERS AND BRACKET SECURING DAMAGED STRINGER. AND EVALUATE DAMAGE..PHOTOS ADDED MEASURE APPROX .070 DEEP .800 STRINGER REMAINS TRAPPED BEHIND FRAMES. LENGTH AND .200 WIDE REMOVED DAMAGE FROM STRINGER REF AVO 09957 REPAIR INSTRUCTIONS PERFORMED HFEC ON TRIM OUT PER 737 NDT PART6,51-00-00. NO CRACKS C/W AVO9957, STEP 4 HFEC, OK TO CONTINUE. COMPLETED REPAIR INSTRUCTIONS STEP 5 OF AVO 09957. REQUEST INSP COMPLIED WITH AVO9957 STEPS6 AND 7, PERFORMED HFEC HOLES AND TREATED AND PRIMED TRIMMED AREA OF STRINGER REF AVO9957 REPAIR STEPS A1-A3 COMPLETED. REQUEST INSP TO PERFORM HFEC REF STEP 4 NOTED. TO PERFORM HFEC OF HOLES AND COUNTERSINKS REF AVO REPAIR COUNTERSINK INSPECTION ON REMOVED FASTENER LOCATIONS PER 737 NDT INSTRUC

Part: LIGHT — SHORTED (L1320 FWD CLOSET) · airframe 75,586 hrs · 26,897 cycles

R1 DOOR EMERGENCY LIGHTS NOT WORKING. TROUBLESHOT SYSTEM IAW AMM 33-51-14 AND FOUND SHORTED EMERGENCY LIGHT JUST FORWARD OF SEAT 1A/B VERIFIED ALL RII REQUIREMENTS MET

Part: STRAP — LOOSE (1 AND 2) · airframe 74,474 hrs · 26,483 cycles

BOTH NAV1 AND NAV2 SHOW FAIL. NAV1 THRU 10K FT NAV2 15 MIN LATER TS PER FIM 22-15-00 TASK 813. MULTIPLE FAULTS FOUND DURING BITE AFTER CONFERRING WITH TOMC IN REGARDS TO THE NAV TUNING PANEL LIBRARY TEST. FAILURE 1 AND 2, ACMP FIM 34-31 TASK 801 WITH PARTICULAR ATTENTION TO THE GROUNDING OF THE P5. IF NO DEFECTS FOUND REPLACE THE P5-28 MODULE. PERFORMED BONDING CHECK AND FOUND GRD STUD GD604AC TO SEAT TRAC FOUND SECOND STRAP LOOSE . RESECURED STRAP AND BONDING CHECKED THE FINAL READING ON THE OVERHEAD PANEL WAS .15 MILL OHMS. PLEAS K GOOD , BUT FROM STRAP TO PANEL 230 MIIL OHMS .CLEANED STRAP ON GOOD. E PERFORM FIM 34-31 TASK808 PART F (1)THROUGH(D). GRD STUD AND READIND WAS.15 MILL OHMS.THEN CHECKED OVERHEAD PAN EL RAIL AND FOUND IT OVER RANGE . REF FIM 34-31 TASK 808 STEPS F(1)A-D CHECKED GND BLOCKS AND SWITCHING PNL GNDS, NO STRAY VOLTAGE NOTED. NO FAIL INDICATIONS ON EITHER NAV CNTRL PNLS.

Part: SEAL — MISSING (#6TE FLAP) · airframe 74,045 hrs · 26,323 cycles

PDA 3 #6 T/EFGE FLAP FAIRING OUTBD SIDE CENTER SEAL COMPLETELY MISSING -- SEE PHOTO PHOTO ADDED REPLACED MISSING SEAL. REF SRM 57-53-70-2R-2. REPAIR 2 PAR 4 ALTERNATIVE 1 REPAIR.

Part: SENSOR — MALFUNCTIONED (LE FLAP SYSTEM) · airframe 72,827 hrs · 25,867 cycles

*EMERGENCY DECLARED* LEADING EDGE SLAT 7 ILLUMINATED. LE FLAP TRANSIT LIGHT ON FWD I LLUMINATED. PER CREW, SELECTED FLAPS 5, LEADING EDGE TRANSIT AND OVERHEAD SLAT 7 STAYED ILLUMINATED FOR APPROX 5 MIN THEN EXTINGUISHED. SELECTED FLAPS 15, SAME... DECLARED EMERGENCY. BOTH LIGHTS EXTINGUISED AGAIN AFTER A FEW MINUTES. CAPT DECIDED TO GO TO FLAPS 30, ALL INDICATIONS NORMAL, LANDING NORMAL. FLAPS RAISED NORMAL. NO ABNORMAL FLIGHT CONTROL, CREW SUSPECTED ONLY INDICATION SEE LOG 6689986, SENSOR S1007 RPL ACCOMP SYSTEM TEST 27-88-11-700-801 & FIM 27-51 TASK 801, ALL LIGHT INDICATION OVERHEAD GO ON AND OFF SIMULTANEOUSLY THRU ALL FLAP POSITION CHANGES. ALL TESTS PASSED. SEE PIC.

Part: COMPUTER — MALFUNCTIONED (STALL WARNING) · airframe 70,844 hrs · 25,157 cycles

YAW DAMPER OFF AFTER TAKEOFF. WHEN RE-SELECTED RUDDER ENGAGED ABRUPTLY. FOUND POSITION 1 SMYD FAILED SELF TEST. REMOVED AND REPLACED POSITION 1 SYMD, PER AMM 27-32-42. ALL TESTS PASSED. S/N OFF 0869 COMPUTER, STALL OFF 29-2732-9-0003 0869 ON 29-2732-9-0003-0762, REF LOG PAGE 5328251 FOR COMPLETE T/S AND SIGNOFF.

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 70,824 hrs · 25,148 cycles

RT HORIZONTAL STAB HAS CRACK INDICATION AT STAB STA 147.90 APPROX. 25" FROM AFT EDGE, MARKED. SEE FLEET CYCLE N/R 9752929 FOR WORK PERFORMED, PER SRM 55-10-01 REPAIR 11. INSP THRESHOLD 56000 TOTAL FLT CYLCLES, DVI 9000 FLT CYCLES; EXTERNAL LFEDC AT 9000 FLT CYCLES SRM 55-10-01 TABLE 204 ADD EMP:U242511 TOMC APPROVED TO PLACE ON DIP TO INSP THRESHOLD 56000 TOTAL FLT CYLCLES, DVI 9000 FLT CYCLES; EXTERNAL LFEDC AT 9000 FLT CYCLES SRM 55-10-01 TABLE 204 TOMC-APPROVAL FROM SC1ELBYC COMMENT INSPECTIONS CREATED BY AUTODIP, PENDING AIRCRAFT RECORDS AUDIT UPDATE.

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 70,824 hrs · 25,148 cycles

RT HORIZONTAL STAB HAS CRACK INDICATION AT STAB STA 138.70 APPROX 10 1/4" FROM AFT EDGE. REPAIRED RT HORIZONTAL STAB LOWER SKIN AT STA 138.70 AND 10 1/4" FWD OF AFT EDGE, REF SRM 55-10-01 REPAIR 11 FIGURE 204 DETAIL "F". WORK PERFORMED ON FLEETCYCLE N/R 9752928.

Part: LIGHT — MALFUNCTIONED (CABIN) · airframe 70,627 hrs · 25,061 cycles

EMERGENCY LIGHTS WILL ONLY TURN OFF IN ARM, IN OFF LIGHTS STAY ON

Part: FITTING — CRACKED (BS 540) · airframe 69,868 hrs · 24,739 cycles

SHEAR FITTING AT BS 540 RBL 15.04 WAS CRACKED. REMOVED AND REPLACED THE SHEAR FITTING IAW SRM 51-40-02, AND EC / RA 57-14-01044.

Part: FITTING — CRACKED (BS 540) · airframe 69,868 hrs · 24,739 cycles

SHEAR FITTING AT BS 540, LBL 15.04 WAS CRACKED. REMOVED AND REPLACED THE SHEAR FITTING IAW SRM 51-40-02, AND DWG 111A2000.

Part: FITTING — CRACKED (STA 540 LBL 6) · airframe 69,868 hrs · 24,739 cycles

SHEAR FITTING AT BS 540, LBL 6.14 WAS CRACKED. REMOVED AND REPLACED THE SHEAR FITTING IAW SRM 51-40-02, AND ECRA 5714-01044.

Part: FITTING — CRACKED (BS 540) · airframe 69,868 hrs · 24,739 cycles

SHEAR FITTING AT BS 540, RBL 6.14 WAS CRACKED. REMOVED AND REPLACED THE SHEAR FITTING IAW SRM 51-40-02, AND DWG 111A2000.

Part: FITTING — CRACKED (BS 540) · airframe 69,868 hrs · 24,739 cycles

SHEAR FITTING AT BS 540, LBL 40.87 WAS CRACKED. REMOVED AND REPLACED THE SHEAR FITTING IAW SRM 51-40-02, AND ECRA 5714-01044.

Part: WINDOW FRAME — CRACKED (CABIN) · airframe 69,067 hrs · 24,386 cycles

CRACK AT TOP OF WINDOW POST BETWEEN R-1 AND R-2 WINDOWS. NEED INSPECTION TO PERFORM HFEC ON R1 WINDOW POST FOR CRACK VERI FICATION PERFORMED HFEC PART 6 51-00-00, PROCEDURE 23, CONFIRMED EXISTING CRACK. PER AVO8019 COMPLIED WITH STEPS A1 THRU A6. PER AVO8019 STEP B1, REQUIRES A HFEC INSPECTION OF THE AREA ABOVE AND BELOW THE TYPICAL CRACK LOCATIONS ON THE RIGHT SIDE #1 WINDOW FRAME IN ACCORDANCE WITH FIGURE 9. C/W AVO8019 REV A STEPS B. AND C. AND FOUND CRACK CONDITION 1 AS CRACK MEASURES APPROXIMATELY 1" IN LENGTH HORIZONTALLY AND VERFIED BY HFEC THAT IT EXTENDS TO THE WINDOW SIDE OF THE.... CONT''D CONT''D ... FRAME APPROXIMATELY 1" ALSO AND DOES NOT TRANSITION INTO THE WINDOW FRAME RADIUS. SEE LP 3411134. C/W STEP C.1 REF AVO# ESC190928-709-1 C/W WINDOW FRAME CUT STEP D.1 REF. AVO# ESC190928-0709-1 VERIFIED STEPS C.1. AND D.1 OF REF AVO# ESC190928-0709-1 DRILLED AND COUNTERSUNK TRIPLER AND DOUBLER REF. AVO # ESC190928 -0709-1 STEPS-1 THRU-20 OF FIG.24. VERIFIED STEPS 1-20 OF FIG 24 OF AVO NO:ESC190928-0709-1 C/W NEED INSPECTION TO PERFORM STEP E1 AND E2 REF AVO NO ESC190928-0 709-1. PERFORMED STEP E1 AND E2 PER AVO NUMBER ESC190928-0709-1, NO DEF ECTS NOTED AT THIS TIME. INSTALLED COUNTERSINK WASHERS AND INTERFACE SEALANT REF AVO ESC1 90928-0709-1 FIG 24 STEPS 21, 22, & 23. 22 & 23 OK TO INSTALL REPAIR PARTS REF AVO ESC190928-0709-1 FIG 24 STEPS OK TO INSTALL ACCOMPLISHED DOUBLER/TRIPLER INSTALLATION STEPS 21-23 FIGURE 24 REF AVO-ESC190928-0709-1. -0709-1. VERIFI

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 69,067 hrs · 24,386 cycles

FO FWD WINDSHIELD CRACKED C/W STEP A THRU STEP D(2) REF AMM 56-11-11-000-0801. NEW R1 WINDOW IS DESIGNATED H13. FOUND WINDOW HEATER RESISTANCE TO BE 33.7 OHMS. MOVED TERMINAL BOARD TAP FROM TB5012 TAP 2 TO TAP 1 AMM 30-41-21-000-801 INSTALLED NEW WINDSHIELD REF AMM 56-11-11-400-801 PRESSURIZATION LEAK CK COMPLIED WITH ON L/P 3404731 ROTABLE PARTS CHANGE WAS INDICATED - TT # 1014215 SN OFF 6468 WINDSHIELD, B73 OFF 99-5611-9-9001 6468 ON 99-5611-9-9001 7590

Part: LENS — LOOSE (EVAC SLIDE) · airframe 63,763 hrs · 22,218 cycles

L2 DOOR SLIDE COVER CLEAR VIEW BOTTLE PRESSURE LENS LOOSE. REMOVED & REPLACED L2 DOOR SLIDE ASSY, AMM REF 25-66-01-000-801 AND 25-66-01-400-801; RENDER SAFE C/L C/W; REINSTALLED CLEAR VIEW LENS ON SLIDE PACK COVER FOR SLIDE BOTTLE PRESSURE GAGE.

Part: SWITCH — FAULTY (COCKPIT) · airframe 62,488 hrs · 21,702 cycles

EMERGENCY LIGHT SWITCH ON P5 PNL IN COCKPIT, LIGHT STAYS ON WHEN SWITCH IS IN THE ON POSITION. REMOVED AND REPLACED AFT F/A PANEL LIGHTING SWITCH REF WD 33-51- 11, OPS CHECK EMERGENCY LIGHTS REF AMM 33-51-00-720-801, OPS CHECK WORK LIGHT REF AMM 33-26-01-710-001, OPS CHECK ENTRY LIGHT REF AMM 33-29-710-001, ALL OPS CHECK GOOD.

Part: FRAME — CORRODED (FUSELAGE) · airframe 62,486 hrs · 21,701 cycles

FRAME 992.8 IS CORRODED ABOVE STR 19R (MARKED). INSTALLED INTERIM REPAIR TO FRAME AT STA 992.80 ABOVE STR S-21R IN REFERENCE TO EC/RA 5310-07240.

Part: FLOOR SUPPORT — CORRODED (BS 323) · airframe 62,486 hrs · 21,701 cycles

CABIN FLOOR SUPPORT CORRODED AT BS 323. REMOVED AND REPLACED.

Part: SENSOR — FAULTY (TE FLAPS) · airframe 62,471 hrs · 21,694 cycles

FLAP FAILED TO EXTEND LT & RT NEEDLE GAUGE SPLIT COMPLIED WITH QRH. LANDED FLAPS UP. EMERGENCY DECLARED. ACP TS PROCEDURE FIM 27-51-00-810-826, FOUND SKEW SENSOR 4 FAILED, WITH PARAMETERS READINGS OUT OF LIMITS, AFTER FSEU INTERROGATIONS. REPLACED FLAP SKEW SENSOR POS 4 IAW AMM 27-59-01-000-8 02 AND 27-59-01-400-802, OPS CHECKED GOOD IAW AMM 27-51-00-810-802.

Part: OVEN — SPARKS (GALLEY) · airframe 60,762 hrs · 21,013 cycles

OVEN SMOKING OR SPARKING 222. THE OVEN WAS REPLACED, OPS CHECKED NORMAL.

Part: BATTERY — DISCHARGED (CABIN) · airframe 56,555 hrs · 19,354 cycles

FORWARD ESCAPE SLIDE LIGHT WILL NOT ILLUMINATE. REMOVED & INSTALLED NEW EMER LIGHT BATTERY IAW AMM 33-51-06. OPERATION CHECKED GOOD. POWER SUPPLY SN OFF 4119, SN ON 7367. BATTERY PACK SN OFF 64327, SN ON 160162.

Part: SKIN — CRACKED (FUSELAGE) · airframe 55,318 hrs · 18,866 cycles

FUSELAGE STATION 540 SKIN AT STRINGER 22L & 23L, TWO CRACKS AT CHORD HOLES & ONE AT SKIN HOLE. PERFORMED PART 1 INTERIM REPAIR, INSTALLED FREEZE PLUG HOLE A & OPENING HOLE TO .2455 IAW ECRA 5310-06438 REV A. INITIATE DIP TO ACCOMPLISH A PERMANENT REPAIR ON OR BEFORE 12 MONTHS. PLANNING TO CONTACT ENGINEERING AFTER 10 MONTHS BUT BEFORE 11 MONTHS FOR THE PERMANENT REPAIR.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 53,860 hrs · 18,363 cycles

EMERGENCY LIGHTS ROW 3 TO 11 DIM DURING TEST. REPLACED BATTERY PACK MM 33-31-06. CHECKED OK SDR REQUIRED & SUBMITTED.

Part: PUMP — FAILED (NR 2 ENGINE) · airframe 53,409 hrs · 18,187 cycles

AFTER LEVEL OFF, TAKEOFF +30 MIN B HYD SYS FAILED. FOUND HYD PUMP ON NR 2 SEIZED. R & R NR 2 ENG HYD PUMP IAW AMM 29-11-11-401. OPERATIONS & LEAK CHECKED GOOD. FLUSH & FILTER REPLACEMENT SCHEDULED.

Part: CONNECTOR — LOOSE (NR 1 ENGINE) · airframe 52,003 hrs · 17,638 cycles

ENG 1 VIBRATION WENT AS HIGH AS 5.6 & DEBRIS NOTED ON FAN BLADES. ENG 1 VIB INDICATOR PLACARD MEL. PILOT REPORTED AFTER LANDED ALL OTHER PARAMETER NORMAL INSP INLET & EXHAUST NO DAMAGE NOTED TO FAN BOOSTER OR TURBINE DEBRIS FOUND TO BE FAN LUBE WHICH WAS CLEANED. COMPLY WITH EEC BITE, AVM BITE. NO FAULTS. NO 1403 288. DFD REPORTED ALL NORM ENG VIBE ERRATIC. ON INSPECTION FOUND NR 1 ENG FAN FRAME COMPRESSOR CASE SENSOR CONNECTOR LOOSE, DP1101-1. INSPECTED, CLEANED & RECONNECT CONNECTOR DP 1101-1, NO DEFECTS NOTED. HIGH POWER ENG RUNS CHECKED OK. MEL CLEARED, PLACARD REMOVED.

Part: RING — WORN (THRUST REVERSER)

INSPECTION FOUND TWO LOOSE, BOLTS. AREAS OF MATERIAL DISPLACEMENT AND CRACKING IN THE LOWER OTBD SURFACE OF THE CASCADE RING.

Part: FRAME — CRACKED (BS 706) · airframe 47,241 hrs · 15,886 cycles

LT FRAME BS 706 SHOWS CRACK IND HFEC INBD FASTENER BETWEEN STR 7L AND STR 8L. REPAIRED LT FRAME STA 706 IAW EC/RA 5310-05590.

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 47,241 hrs · 15,886 cycles

LT STAB LOWER SKIN, FOUND CRACK .7500 INCH LONG AT STA 129.50 AND ABOUT 3" AFT FROM PREVIOUS REPAIR. REPAIRED IAW SRM 55-10-01. ACCOMPLISHED FOR OTHER WORK COMPLETED WORK PERFORMED BY N4531. DIP ISSUED PRE SRM 55-10-01 REPAIR 11, STEP TABLE 204 TO READ INSPECTION THRESHOLD 56,000 FLT CYCLES AND REPEAT INSPECTIONS EVERY 9000 FLIGHT CYCLES THEREAFTER "Q/C" ACCOMPLISH A DV INSP AT 56,000 FLT CYC THRESHOLD AFTER INST OF REPAIR USING LFEC INSP IAW NDT PART 6, 53-30-00, FIG 5. REPEAT INSP AT EACH 9,000 FLT CYC INTERVAL. SRM 55-10-01, REPAIR 11. DIP C/N 17445.

Part: FRAME — GOUGED (BS 294.5) · airframe 47,241 hrs · 15,886 cycles

BOTTOM OF FRAME GOUGED. FRAME 294.5 AT S-3L. REPAIR FRAME STA 294.5 AT S3L REF SRM 53-00-07, REPAIR 1.

Part: FRAME — CRACKED (BS 380) · airframe 47,241 hrs · 15,886 cycles

LEFT FRAME STA 380 SHOW CRACK IND MFEC & HFEC INBD FASTENER. REPAIRED FRAME DAMAGE AT BS 380 LT IAW EA 5310-04716.

Part: FRAME — CRACKED (BS 480) · airframe 47,241 hrs · 15,886 cycles

LEFT FRAME BS 480 HAS A CRACK INDICATION, MFEC & HFEC INBD FASTENER. REPAIRED FRAME DAMAGE AT BS 480 LT EA5310-04716.

Part: FLOORBEAM — CORRODED (BS 986) · airframe 47,241 hrs · 15,886 cycles

BS 986-5 CABIN FLOORBEAM, LBL 30 HAS CORROSION AROUND NUTPLATE HOLE. REPAIRED IAW SRM 53-00-51.

Part: FRAME — CRACKED (BS 727D) · airframe 47,241 hrs · 15,886 cycles

RT FRAME 727D SHOWS A CRACK INDICATION MFEC & HFEC INBD FASTENER REPAIRED DAMAGE IAW EA 5310-04716.

Part: FRAME — CRACKED (BS 727D) · airframe 47,241 hrs · 15,886 cycles

FRAME BS 727D SHOWS A CRACK INDICATION MFEC & HFEC INBD FASTENER PERFORMED REPAIR TO LT FRAME BS 727D, REF EA 5310-04716.

Part: FRAME — CRACKED (BS 827) · airframe 47,241 hrs · 15,886 cycles

RT FRAME BS 827 SHOW CRACK INDICATIONS MFEC AND HFEC INBD FASTENER. INSTALLED REPAIR ANGLES IAW EA 5310-04716.

Part: FRAME — CRACKED (BS 747) · airframe 47,241 hrs · 15,886 cycles

RT FRAME BS 747 SHOW CRACK INDICATION MFEC AND HFEC INBD FASTENER REPAIRED DAMAGE IAW EA 5310-04716.

Part: FRAME — CRACKED (BS 827) · airframe 47,241 hrs · 15,886 cycles

LT FRAME, BS 827 SHOWS CRACK INDICATIONS MFEC AT HFEC INBD FASTENER. REPAIRED FRAME IAW 5310-04716- REV C.

Part: FRAME — CRACKED (BS 867) · airframe 47,241 hrs · 15,886 cycles

LT FRAME BS 867 SHOW CRACK INDICATIONS. MFEC & HFEC INBD FASTENER. REPAIRED LT FRAME IAW EA5310-04716.

Part: FRAME — CRACKED (BS 400) · airframe 47,241 hrs · 15,886 cycles

LT FRAME STA 400 SHOWS CRACK INDICATION, MFEC INBD FASTNER. REPAIRED LT FRAME AT STA 400 IAW EA 5310-04716, REV C 44.0008 FROM FOR WORK PERFROMED.

Part: FRAME — CRACKED (BS 599) · airframe 47,241 hrs · 15,886 cycles

LT FRAME BS 559 SHOWS CRACK IND MFEC INBD FASTENER FRAME. REPAIRED LT STA 559 IAW EA 5310-04716, REV C.

Part: FRAME — CRACKED (BS 727) · airframe 47,241 hrs · 15,886 cycles

RT FRAME BS 727A SHOW CRACK IND. INBD FASTENER. REPAIRED IAW EA 5310-04716 REV C FOR WORK ACCOMPLISHED.

Part: FRAME — CRACKED (BS 500) · airframe 47,241 hrs · 15,886 cycles

LT FRAME BS 500A SHOWS CRACK INDICATION. INSTALLED FRAME REPAIR IAW EA 5310-04716, REV C.

Part: FRAME — CRACKED (BS 597) · airframe 47,241 hrs · 15,886 cycles

LT FRAME BS 597 SHOWS CRACK INDICATIOIN. INSTALLED REPAIR FRAME DOUBLERS IAW EA 5310-0471 6, REV C.

Part: FRAME — CRACKED (BS 747) · airframe 47,241 hrs · 15,886 cycles

SUPPORT TASK LT FRAME BS 747 SHOWS CRACK IND MFEC INBD FASTENER ACCOMPLISHED PERMANENT REPAIR ON LT FRAME IAW ECRA 5310-04 716.

Part: FRAME — CRACKED (BS 500) · airframe 47,241 hrs · 15,886 cycles

RT FRAME BS 500C SHOWS CRACK INDICATION. REPAIRED FRAME IAW EA 5310-04716, REV C, FIG 3.

Part: FRAME — CRACKED (BS 787) · airframe 47,241 hrs · 15,886 cycles

LT FRAME BS 787 SHOW CRACK INDICATION, REPAIRED FRAME IAW EA 5310-04716, REV C.

Part: FRAME — CRACKED (BS 500) · airframe 47,241 hrs · 15,886 cycles

RT FRAME BS 500A SHOWS CRACK INDICATION, INSTALLED REPAIR DOUBLER IAW EA 5310-04716.

Part: FRAME — CRACKED (BS 787) · airframe 47,241 hrs · 15,886 cycles

RT FRAME BS 787 SHOWS CRACK INDICATION. REPAIRED DAMAGE FRAME IAW EA5310-04716, REV C.

Part: FRAME — CRACKED (BS 520) · airframe 47,241 hrs · 15,886 cycles

RT FRAME BS 520 SHOWS CRACK INDICATION. REPAIRED DAMAGE FRAME IAW EA 5310-04716, REV C.

Part: FRAME — CRACKED (BS 500) · airframe 47,241 hrs · 15,886 cycles

LT FRAME BS 500C SHOW CRACK INDICATION. REPAIRED DAMAGE FRAME IAW EA5310-04716, REV C.

Part: CONTROL MODULE — FAILED (COCKPIT) · airframe 43,824 hrs · 14,673 cycles

AFTER TAKEOFF OUT OF DFW LANDING GEAR LEVER STIFF TO GO FROM UP TO OFF AND STIFF TO LATCH OFF. R&R LANDING GEAR CONTROL LEVER MODULE IAW AMM 32-31-11. PERFORMED GEAR SWING IAW AMM 32-32-00. OPS CHECK NORMAL. ROTABLE PARTS CHANGE WAS INDICATED - TT 1407483 SN OFF 00100 IPC REFERENCE NUMBER.

Part: TURBINE BLADES — MISSING (LPT STG-1) · airframe 15,389 hrs · 2,087 cycles

(B-16709) RT ENGINE HIGH VIBRATION DURING CLIMB AFTER FL210- 4.3 MAX FELT NEAR R4 DOOR AND ADJACENT CABIN, AIR TURN BACK. PERFORM BSI ON NR2 ENGINE FOUND LPT-1, STG-1 BLADE MISSING AND LPT STG-1 TO STG-4 BLADES DAMAGED, R & R NR2 ENGINE.

Part: SKIN — CRACKED (HORIZ STAB) · airframe 40,128 hrs · 13,333 cycles

SUPPORT TASK CRACK FOUND ON RIGHT HORIZONTAL STAB LOWER SKIN AT STAB STA 129.50 AND 25.5"AFT OF FWD SPAR WHILE PERFORMING FCD 5510-02034. CRACK MEASURES 1.375 INCH IN LENGTH. INSTALLED INTERIM REPAIR DOUBLER AND ISSUED DIP TO ACCOMPLISH INITIAL INSPECTIONS PER PART 2 WITHIN 9000 FLIGHT CYCLES FROM 07/09/2010 AND PERFORM REPETITIVE INSPECTIONS AT INTERVALS NOT TO EXCEED 9000 FLIGHT CYCLES AFTER THE INITIAL HAS BEEN ACCOMPLISHED REF ECRA 5510-02106 STEPS 1 THRU 20. INTERIM REPAIR ACCOMPLISHED PER ECRA 5510-02106, PART 1. ACCOMPLISH INITIAL INSPECTION PER PART 2 WITHIN 9000 FLIGHT CYCLES FROM 07/09/2010 AND PERFORM REPETITIVE INSPECTIONS AT INTERVALS NOT TO EXCEED 9000 FLIGHT CYCLES AFTER THE INITIAL HAS BEEN ACCOMPLISHED. RIR: W/I EVERY 9000 F/C STARTING FROM 09JUL2010.

Part: SKIN — CRACKED (HORIZ STAB) · airframe 40,128 hrs · 13,333 cycles

SUPPORT TASK CRACK FOUND ON LEFT HORIZONTAL STAB LOWER SKIN AT STAB STA 129.50 AND 9 INCHES AFT OF FWD SPAR WHILE PERFORMING FCD 5510-02034. CRACK MEASURES 0.750 INCH IN LENGTH. INSTALLED INTERIM REPAIR DOUBLER AND ISSUED DIP TO ACCOMPLISH INITIAL INSPECTIONS PER PART 2 WITHIN 9000 FLIGHT CYCLES FROM 07/09/2010 AND PERFORM REPETITIVE INSPECTIONS AT INTERVALS NOT TO EXCEED 9000 FLIGHT CYCLES AFTER THE INITIAL HAS BEEN ACCOMPLISHED REF ECRA 5510-02105 STEPS 1 THRU 20. INTERIM REPAIR ACCOMPLISHED PER ECRA 5510-02105, PART 1. ACCOMPLISH INITIAL INSPECTION PER PART 2 WITHIN 9000 FLIGHT CYCLES FROM 07/09/2010 AND PERFORM REPETITIVE INSPECTIONS AT INTERVALS NOT TO EXCEED 9000 FLIGHT CYCLES AFTER THE INITIAL HAS BEEN ACCOMPLISHED. RIR: W/I EVERY 9000 F/C STARTING FROM 09JUL2010.

Part: CONNECTOR — DISCONNECTED (CABIN) · airframe 39,986 hrs · 13,279 cycles

L-1 MAIN CABIN DOOR OVERHEAD EMERGENCY EXIT LIGHT INOP WHEN EMERGENCY LIGHTS TURNED ON. FOUND DISCONNECTED AND RE-SECURED WIRE CONNECTOR D3658 TO L1 MAIN CABIN DOOR OVERHEAD EMERGENCY EXIT LIGHT, REF B737 WD33-51-21, L1 MAIN CABIN DOOR OVERHEAD EMERGENCY EXIT LIGHT TESTED NORMAL REF B737 MM 33-51-00.

Part: DOUBLER — MISLOCATED (FUSELAGE) · airframe 39,931 hrs · 13,261 cycles

SUPPORT TASK - LIVE TV FEED THRU DOUBLER WAS POSITIONED ONE INCH TO FAR FROM ORIGINAL POSITION AS PER DRW 737N2200 REV B PAGE 16 TO 18, PART 22007-091. CORRECTED DISCREPANCY IN ACCORDANCE WITH ECRA 5310-05210 AND AAR RES 2002494-16 IR STEPS 1 THRU 10.

Part: FRAME — CRACKED (FUSELAGE) · airframe 32,279 hrs · 10,488 cycles

FRAME CRACKED AT STA 727B BETWEEN 9 & 9R. REPAIRED PER ECRA 5310-04717.

Part: FRAME — CRACKED (FUSELAGE) · airframe 32,279 hrs · 10,488 cycles

FRAME CRACKED AT STA 480 BETWEEN STRINGER 8 & 9R. REPAIRED PER ECRA 5310-04717.

Part: FRAME — CRACKED (FUSELAGE) · airframe 32,279 hrs · 10,488 cycles

FRAME CRACKED AT STA 440 BETWEEN 8 & 9R. REPAIRED PER SRM 5210-04717.

Part: FRAME — CRACKED (FUSELAGE)

FRAME CRACKED AT STA 440 BETWEEN STRINGER 8 AND 9L. REPAIRED PER ECRA 5310-04717.

Part: FRAME — CRACKED (FUSELAGE) · airframe 32,279 hrs · 10,488 cycles

FRAME CRACKED STA 380 BETWEEN STRINGER 8R AND 9R. REPAIRED PER ECRA 5310-04717.

Part: FRAME — CRACKED (FUSELAGE) · airframe 32,279 hrs · 10,488 cycles

FRAME CRACKED AT STA 400 BETWEEN STRINGER 8R AND 9R. REPAIRED PER ECRA 5310-04717.

Part: OUTFLOW VALVE — MALFUNCTIONED (CABIN PRESSURE) · airframe 29,496 hrs · 9,576 cycles

IN ALT PRESSURIZATION MODE AUTO FAIL LIGHT ILLUMINATED CABIN CLIMBING/DESCENDING ERRATICALLY. PSID IN ORANGE RANGE. REMOVED AND REPLACED OUTFLOW VALVE IAW TASK 21-31-03-000-801, 21-31-03-400.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 24,774 hrs · 8,063 cycles

INSPECTION FOUND FORWARD FLOOR STRUCTURE T-CAP (FLOORBEAM) CORRODED AT STA 344. REPAIRED IAW ECRA 5321-01324.

Part: STRUCTURE — CORRODED (STA 312-328) · airframe 24,774 hrs · 8,063 cycles

INSPECTION FOUND R-1 DOOR CUTOUT AREA CHORD CORRODED ON AFT SIDE BETWEEN STA 312 AND 328, RBL 56. A NEW CHORD ANGLE WAS INSTALLED IAW SRM 51-40-02.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 24,774 hrs · 8,063 cycles

INSPECTION FOUND FORWARD FLOOR STRUCTURE T-CAP (FLOOR SUPPORT) CORRODED AT STA 328, RBL 64. REPAIRED IAW ECRA 5321-01326.

Part: INTERCOSTAL — CORRODED (STA 947.5-967) · airframe 24,774 hrs · 8,063 cycles

INSPECTION FOUND INTERCOSTAL AT STA 947.5 TO 967, LBL 46 CORRODED. THE INTERCOSTAL WAS REMOVED AND REPLACED IAW SRM 51-10-02 AND 51-40-02.

Part: FLOORBEAM — CORRODED (STA 951) · airframe 24,774 hrs · 8,063 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED ON SCREW HOLES AT STA 951, LBL 12 TO LBL 46. ALL LOCATIONS OF CORROSION WERE EITHER REPAIRED OR REPLACED IAW SRM 51-10-02 AND GMM 10-900-01 AND 51-40-02.

Part: FLOORBEAM — CORRODED (STA 947.5) · airframe 24,774 hrs · 8,063 cycles

INSPECTION FOUND AFT CABIN LT FLOORBEAM CORRODED AT STA 947.5, LBL 51. A REPAIR WAS INSTALLED IAW ECRA 5321-01325.

Part: FLOORBEAM — CORRODED (STA 986) · airframe 24,774 hrs · 8,063 cycles

INSPECTION FOUND FLOORBEAM FORWARD FLANGE CORRODED AT SCREW HOLE, STA 986, RBL 30. THE FLOORBEAM WAS REPAIRED IAW SRM 53-00-51, REPAIR 1.

Part: FLOORBEAM — CORRODED (STA 312) · airframe 24,774 hrs · 8,063 cycles

INSPECTION FOUND FORWARD FLOOR STRUCTURE T-CAP (FLOORBEAM UPPER CHORD) CORRODED AT STA 312, LBL 29 APPROXIMATELY 24 INCHES O/B OF L-1 DOOR THRESHOLD. THE FLOORBEAM UPPER CHORD WAS REPAIRED IAW ECRA 5321-01323.

Part: CAPACITOR — FAILED (VIDEO SYS) · airframe 10,948 hrs · 3,608 cycles

FLIGHT ATTENDANT'S REPORTED SMOKE IN THE FORWARD GALLEY AREA WHILE EN ROUTE FROM EWR TO MEX. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE IDENTIFIED THE SOURCE OF SMOKE TO BE FROM THE VIDEO SYSTEM CONTROL UNIT (SCU) BASED ON THE BURN SMELL NOTED INSIDE THE UNIT. THE SCU WAS REMOVED AND REPLACED. SCU BITE TEST CHECKED GOOD. NO OTHER FAULTS WERE FOUND. TEARDOWN REVEALED THAT THE HEAT DAMAGE AND RESULTANT SMOKE WAS DUE TO FAILURE OF A CAPACITOR IN THE SCU.