N183AW

Part: PUMP — INOPERATIVE (NR 2 ENGINE) · airframe 64,211 hrs · 51,999 cycles

ON CLIMB OUT OF PHX EN ROUTE FOR SJC LOST (A) SYS HYDS, TURNED BACK TO PHX & LANDED WITHOUT EVENT. MAINT R & R NR 2 EDP IAW T/C R5M29001. R & R (A) HYD SYS CASE DRAIN, PRESSURE, & RETURN FILTERS, FLUSHED SYSTEM IAW BMM 29-11-0, PG. 204. LEAK AND OPERATIONAL CHECK OF (A) HYD SYS WAS GOOD. CONFIRMED FAILURE OF EDP. VISUAL INSPECTION OF UNIT FOUND INTERNAL DRIVE SHAFT DAMAGED DUE TO BEARING FAILURE, PRETEST NOT ACCOMPLISHED. TEARDOWN OF UNIT FOUND O-RINGS HARD SET & WORN, CYLINDER BARREL, NOSE & FACE SEALS, HOLD DOWN & WEAR PLATES, PISTON & SHOE SUB ASSY DAMAGED BY BEARING FAILURE, & HANGAR TRUNNIONS, STROKING & RATE PISTONS, AND SPRING 195 WORN BEYOND LIMITS. REPLACED DAMAGED PARTS, MAINT & TEST ACCOMPLISHED.

Part: WIRE — BROKEN (SEAT ROW 13 LT) · airframe 64,102 hrs · 51,918 cycles

DURING INSPECTION THE EMERGENCY ESCAPE PATH LIGHT AT SEAT ROW 13 LT WAS FOUND INOPERATIVE. MAINTENANCE REPAIRED A BROKEN WIRE ON EMERGENCY ESCAPE PATH LIGHT AT SEAT ROW 13 LT, OPERATIONAL CHECK WAS GOOD.

Part: VALVE — BINDING (NR 1 ENGINE) · airframe 63,942 hrs · 51,813 cycles

EN ROUTE FROM ONT TO PHX AT CRUISE RECEIVED HIGH OIL TEMPERATURE LIGHT, FOLLOWED QUICK REFERENCE HANDBOOK AND SHUTDOWN THE NO. 1 ENGINE, LANDED AT PHX WITHOUT FURTHER EVENT. MAINTENANCE INSPECTED THE ENGINE AND FOUND THE FUEL HEAT VALVE STUCK IN THE OPEN POSITION, REMOVED AND REPLACED FUEL HEAT DEICING AIR VALVE IAW BMM 73-14-11, PG. 401, OPERATIONAL CHECK WAS GOOD. WIND-MILLING DETERMINED TO BE LESS THAN 30 MINUTES, INSPECTED CHIP DETECTORS, NO DEFECTS NOTE, REMOVED AND REPLACED OIL FILTER AND CHANGED OIL.

Part: WIRE — BROKEN (SEAT ROW 19) · airframe 63,224 hrs · 51,311 cycles

DURING INSPECTION MAINTENANCE FOUND THE EMERGENCY ESCAPE PATH LIGHTS AT SEAT ROWS 14 AND 19 LT INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE EMERGENCY ESCAPE PATH LIGHT ASSEMBLY AT SEAT ROW 14 LT, AND REPAIRED A BROKEN WIRE AT SEAT ROW 19 LT. OPERATIONAL CHECK OF EMERGENCY LIGHTING SYSTEM WAS GOOD. PART NAME; LIGHT ASSEMBLY, MFG; GRIMES, P/N; 10-1272-1, LOC; SEAT ROW 14 LT.

Part: INDICATOR — FAILED (ADI) · airframe 62,653 hrs · 50,903 cycles

ON CLIMB OUT FROM SLC EN ROUTE TO PHX THE CAPTAINS ATTITUDE DIRECTOR INDICATOR (ADI) "ATT" RED FLAG APPEARED, AND "PITCH" AND "ROLL" COMPARATOR LIGHTS ILLUMINATED. SWITCHED TO CAPTAINS ON AUX WITH NO HELP; TURNED BACK TO SLC. MAINTENANCE REMOVED AND REPLACED THE CAPTAINS ADI IAW BMM 34-26-11, OPERATIONAL CHECK WAS GOOD.

Part: TURBINE BLADES — FRACTURED (ENGINE) · airframe 62,646 hrs · 50,896 cycles

SLC - ABORTED TAKEOFF - FLT 0220 - ON TAKEOFF ROLL AT SLC EN ROUTE FOR PHX FELT STRONG VIBRATION FROM R/H SIDE OF AIRCRAFT AND IN R/H THRUST LEVER. ALL ENGINE INDICATIONS WERE NORMAL AT THIS POINT WITH NO WARNING INDICATIONS. REJECTED TAKEOFF AT 130 KTS INDICATED AIRSPEED. AS POWER WAS PULLED TO IDLE THE NO. 2 ENGINE DECELERATED FASTER THAN NO. 1. SHUTDOWN NO.2 ENGINE AND TAXIED TO GATE USING NO. 1 ENGINE. MAINTENANCE FOUND DAMAGE TO THE NO. 2 ENGINE LOW PRESSURE TURBINE SECTION. **SUPP** REMOVED AND REPLACED NO. 2 ENGINE IAW T/C R5M71003, AND R5M78002. STATIC RIG ACCOMPLISHED IAW T/C F5M76001, AND TRIM RUN PERFORMED IAW T/C F5M71002. **SUPP** TEARDOWN FINDINGS OF ENGINE S/N P708359 ATTRIBUTE ENGINE FAILURE TO

Part: ENGINE — MALFUNCTIONED (NR 2) · airframe 62,646 hrs · 50,896 cycles

ON TAKEOFF ROLL AT SLC EN ROUTE FOR PHX FELT STRONG VIBRATION FROM RT SIDE OF AIRCRAFT AND IN RT THRUST LEVER. ALL ENGINE INDICATIONS WERE NORMAL AT THIS POINT WITH NO WARNING INDICATIONS. REJECTED TAKEOFF AT 130 KTS INDICATED AIRSPEED. AS POWER WAS PULLED TO IDLE THE NR 2 ENGINE DECELERATED FASTER THAN NR 1. SHUTDOWN NR 2 ENGINE AND TAXIED TO GATE USING NR 1 ENGINE. MAINTENANCE FOUND DAMAGE TO THE NR 2 ENGINE LOW PRESSURE TURBINE SECTION. REMOVED AND REPLACED NR 2 ENGINE IAW T/C R5M71003, AND R5M78002. STATIC RIG ACCOMPLISHED IAW T/C F5M76001, AND TRIM RUN PERFORMED IAW T/C F5M71002.

Part: ACTUATOR — WORN (NR 6 SPOILER) · airframe 62,457 hrs · 50,777 cycles

SLC - AIR TURN BACK - ON CLIMB OUT FROM SLC EN ROUTE FOR PHX FLIGHT ATTENDANT REPORTED AN EXTREMELY LOUD NOISE AND VIBRATION IN FLOOR BOARDS OF AFT CABIN, TURNED BACK TO SLC AND LANDED WITHOUT FURTHER EVENT. MAINTENANCE PERFORMED GROUND INSPECTION OF FUSELAGE INCLUDING ALL SERVICE PANELS AND ACCESS DOORS. INSPECTED RUDDER POWER CONTROL UNITS FOR WEAR AND ABNORMAL CONDITIONS; INSPECTED THE STABILIZER, APU DOOR, AND APU MOUNTS. INSPECTED HELL HOLE AFT OF AFT PRESSURE BULKHEAD, NO DEFECTS WERE NOTED. INSPECTED THE AFT CARGO COMPARTMENT PANELS, THE ENGINE INLET & TURBINE BLADE AREAS, AND THE LANDING GEARS, NO DEFECTS NOTED. INSPECTED THE SLATS AND FLAPS FOR LOOSE FAIRINGS, AND ABNORMAL PLAY, NO DEFECTS FOUND. INSPE

Part: WIRE — BROKEN (SEAT ROW 16 LT) · airframe 62,183 hrs · 50,580 cycles

FLIGHT CREW REPORTED THE EMERGENCY ESCAPE PATH LIGHT AT SEAT ROW 16 LT WAS INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE EMERGENCY ESCAPE PATH LIGHT ASSEMBLY AT SEAT ROW 16 LT, LIGHT REMAINS INOPERATIVE. SUSPECT BAD SPLICE, PLACED EMERGENCY LIGHT AT SEAT ROW 16 LT ON MEL, COND. 1, (EMERGENCY LIGHT INOPERATIVE). ON 12/19/02 MAINTENANCE REPAIRED A BROKEN WIRE IN CONNECTOR AT EMERGENCY ESCAPE PATH LIGHT SEAT ROW 16 LT, OPERATIONAL CHECK WAS GOOD.

Part: HYDRAULIC SYSTEM — LOW · airframe 62,084 hrs · 5,049 cycles

AIR TURN BACK - FLT 0624 - SHORTLY AFTER TAKEOFF OBSERVED HYD QTY STARTING TO DROP, QUANTITY CONTINUED TO DROP TO 1.5 GALLONS. QUANTITY LEVEL WAS JUST ABOVE REFILL LINE PRIOR TO DEPARTURE, TURNED BACK TO OAK AND LANDED WITHOUT FURTHER EVENT. MAINTENANCE IN OAK FOUND NO VISUAL EVIDENCE OF LEAK, SERVICED HYD SYSTEM WITH 1 GALLON OF HYDRAULIC FLUID. OPERATED ALL FLIGHT CONTROL SURFACES AND THRUST REVERSES, NO EVIDENCE OF LEAKAGE NOTED. AS PRECAUTION AIRCRAFT WAS MAINTENANCE FERRIED BACK TO PHX. WHEN AIRCRAFT ARRIVED IN PHX FLUID LEVEL WAS NORMAL, AGAIN ALL FLIGHT CONTROL SURFACES WERE OPERATED WHILE LOOKING FOR EVIDENCE OF HYDRAULIC LEAK, NO LEAKS WERE NOTED.

Part: BATTERY PACK — DISCHARGED (COCKPIT) · airframe 61,410 hrs · 50,010 cycles

PHX - EEL - DURING INSPECTION OF EMERGENCY LIGHT SYSTEM THE COCKPIT EMERGENCY LIGHT WAS FOUND INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE BATTERY PACK AT THE COCKPIT EMERGENCY LIGHT, OPERATIONAL CHECK WAS GOOD.

Part: WEB — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 2" CRACK WAS FOUND ON TORQUE BOX WEB AT BS 1138 L/H. MAINTENANCE CUTOUT DAMAGE AT TORQUE BOX WEB, FABRICATED A REPAIR DOUBLER, AND INSTALLED REPAIR IAW B737-200 SRM 51-40-2, PG. 1-3, FIG. 1, SRM 51-10-2, PG.7 & 32, FIG. 2, SRM 53-10-2, PG. 53, FIG. 6, AND SRM 51-30-02, PG. 2.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A .5 INCH CRACK WAS FOUND ON INTERCOSTAL IN THE AFT CARGO COMPARTMENT AT BS 800, RBL 43, WL 164. MAINTENANCE REMOVED DAMAGED INTERCOSTAL AT BS 800, RBL 43, WL 164. FABRICATED A NEW REPLACEMENT INTERCOSTAL, AND INSTALLED REPAIR IAW 737-200 SRM 51-20-1, PG 10-11, 14 & 18A, FIG 3 & 7, SRM 51-30-5, PG 4-5, FIG 2 & 3, AND SRM 51-10-2, PG 32, FIG 32.

Part: FRAME — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 3/4" CRACK WAS FOUND ON THE R-1 DOOR FRAME AT INBOARD LOWER END, BS 300, RBL 55. MAINTENANCE REMOVED DAMAGED SECTION OF R-1 DOOR LOWER FORWARD STUB BEAM FRAME AND FOUND SILL CLIP ALSO CRACKED. REMOVED SILL CLIP, FABRICATED 2 EACH REPAIR ANGLES AND NEW SILL CLIP, AND INSTALLED REPAIR PARTS IAW B737-200 SRM 51-40-3, PG. 1-6, FIG. 1.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A .75 INCH CRACK WAS FOUND IN THE UPPER FLANGE OF LONGITUDINAL FLOORBEAM AT RBL 45 APPROXIMATELY 2 INCHES FROM BS 727B, WL 208.1. MAINTENANCE CUT OUT CRACK IN UPPER FLANGE OF LONGITUDINAL FLOORBEAM RBL 45 AND PERFORMED HFEC INSPECTION TO VERIFY NO CRACKS EXIST. FABRICATED A NEW TIE STRAP AND SHIM, AND INSTALLED REPAIR PARTS IAW AWA ER 15-5702-02234-TB5.

Part: WEB — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK HFEC INSPECTION INDICATED A 7/8" CRACK ON VERTICAL PRESSURE BEAM AT BS 663, RBL 32, WL 199. MAINTENANCE TRIMMED OUT DAMAGE AND PERFORMED A HFEC INSPECTION TO VERIFY NO CRACKS EXIST. FABRICATED 2 EACH REPAIR DOUBLERS, AND 3 EACH FILLERS, AND INSTALLED REPAIR PARTS IAW AWA E.R. 15-5702-02235-GF1.

Part: STRINGER — CORRODED · corrosion level 2 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK CORROSION WAS FOUND ON THE UPPER AFT END OF STRINGER 26 R/H, BS 380 (E&E COMPARTMENT). MAINTENANCE REMOVED 1 EACH STRINGER SPLICE BS 360, 2 EACH STRINGER CLIPS BS 360 & BS 380, AND CUTOUT DAMAGED SECTION OF STRINGER BS 363 TO BS 387. FABRICATED A NEW SECTION OF STRINGER, 2 EACH SPLICES, 2 EACH SHIMS, AND INSTALLED REPAIR PARTS AND 2 EACH (REMOVED) STRINGER CLIPS IAW B737-200 SRM 53-10-3, FIG. 1, PG. 3-9.

Part: WEB — CRACKED (R2 DOOR) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A .5 INCH CRACK WAS FOUND ON R-2 DOOR INTERCOSTAL WEB AT BS 954, WL 252. MAINTENANCE REMOVED 3 STRAPS AND CRACKED INTERCOSTAL WEB AT BS 954, WL 252. FABRICATED A NEW INTERCOSTAL WEB, AND INSTALLED NEW WEB AND 3 STRAPS IAW 737-200 SRM 51-30-2 PG 4, 33-34, FIG 8.

Part: ANGLE — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1/2" CRACK WAS FOUND ON TOP OF CABIN FLOOR BEAM SUPPORT ANGLE BS 344, LBL 12, WL 206. MAINTENANCE REMOVED DAMAGED FLOOR BEAM SUPPORT ANGLE BS 344, LBL 12. FABRICATED A NEW FLOOR BEAM SUPPORT ANGLE, AND INSTALLED REPAIR IAW 737-200 SRM 51-30-2, PG. 2-3, AND DWG 65-45815.

Part: SHEAR TIE — CORRODED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK CORROSION WAS FOUND ON THE AFT CARGO PIT FLOOR FRAME ON TOP OF THE FORWARD LEG OUTBOARD SIDE, INBOARD OF STR 27 L/H, WL 149, BS 807. MAINTENANCE REMOVED STIFFNER, STRINGER CLIP, AND CUTOUT DAMAGED SKIN ATTACHMENT (SHEAR TIE) BS 807, WL 149. FABRICATED REPAIR ANGLE AND NEW CLIP, AND INSTALLED STIFFNER AND REPAIR PARTS IAW B737-200 SRM 53-10-4, PG. 24 A, B, C, AND FIG. 9A.

Part: STRINGER — CORRODED · corrosion level 2 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK EXFOLIATION CORROSION WAS FOUND ON CENTER INBOARD SIDE OF STRINGER 22 L/H, AFT OF DOME PLATE NUT AND ABOVE EMERGENCY LIGHT ASSEMBLY AT BS 776. MAINTENANCE REMOVED CORROSION AND FOUND MATERIAL LOSS OUT OF LIMITS. CUTOUT DAMAGED SECTION OF STRINGER 22 L/H; FABRICATED 2 EACH ANGLES AND A SPLICE CHANNEL; AND INSTALLED REPAIR PARTS IAW B737-200 SRM 53-10-3, PG. 3-10.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK EXFOLIATION WAS FOUND ON THE UPPER SURFACE OF TEE CHORD AT BS 986, LBL 21 TO RBL 40, WL 208. MAINTENANCE BLENDED DAMAGED SECTION OF TEE CHORD, MATERIAL LOSS OUT OF LIMITS. REMOVED FLOOR SUPPORTS BS 966 TO BS 986.5, AND TEE CHORD BS 986, LBL 21 TO RBL 48. FABRICATED -2 & -3 FLOOR SUPPORT ANGLES, A NEW SECTION OF TEE CHORD, 2 FRAME CLIPS, AND -4 & -5 STRAPS, AND INSTALLED REPAIR PARTS IAW AWA ER 15-5300-02234-TB4.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK EXFOLIATION CORROSION WAS FOUND ON THE UPPER SURFACE OF TEE CHORD BS 967, RBL 27 - 41, WL 208. MAINTENANCE BLENDED OUT CORROSION AND FOUND MATERIAL LOSS OUT OF LIMITS; REMOVED TEE CHORD BS 967 FROM BL 0 TO RBL 43. FABRICATED A NEW TEE CHORD, 4 REPAIR ANGLES, 4 STRAPS, AND INSTALLED REPAIR PARTS IAW B737-200 SRM 51-30-2, PG 8-9, & 13, AND SRM 53-10-9, FIG 2, PG 7-11.

Part: SKIN — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1/16" CRACK WAS FOUND ON EXTERNAL FUSELAGE SKIN EXTENDING FROM FASTENER HOLE AT BS 303, STR 17 R/H, WL 210. MAINTENANCE CUTOUT DAMAGED SKIN AND BONDED DOUBLER AND PERFORMED A HFEC INSPECTION TO VERIFY NO CRACKS EXIST. FABRICATED 3 EACH REPAIR DOUBLERS, A STRAP, A FILLER, AND TAPERED FILLER, AND INSTALLED REPAIR PARTS IAW AWA E.R. 15-5300-02236-ES2.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 2.7 INCH CRACK WAS FOUND ON THE LOWER SIDE OF FLOORBEAM UPPER CHORD AT BS 663, RBL 24, WL 202; VERIFIED BY HFEC INSPECTION. MAINTENANCE REMOVED CRACKED SECTION OF UPPER CHORD BS 663, RBL 24, WL 202. FABRICATED 2 REPAIR ANGLES, A STRAP, AND NEW SECTION OF CHORD. HFEC OF CHORD AND VERTICAL WEB IDENTIFIED 4 CRACKS PROTRUDING FROM UPPER AND LOWER HOLES ON VERTICAL WEB AT RBL 19 & 20.5 UPPER ROW, AND RBL 20.5 & 28 LOWER ROW. OVERSIZED CRACKED HOLES ON VERTICAL WEB TO .200 AND RE-ACCOMPLISHED HFEC INSPECTION TO VERIFY CRACKS CONTAINED. INSTALLED REPAIR PARTS FOR UPPER CHORD REPAIR IAW AWA ER 15-5715-02229-ES2.

Part: STRINGER — CORRODED · corrosion level 2 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK EXFOLIATION CORROSION WAS FOUND ON BOTH SIDES OF STRINGER 26 R/H BETWEEN BS 887 AND BS 927. MAINTENANCE BLENDED OUT CORROSION AND FOUND MATERIAL LOSS OUT OF LIMITS; REMOVED STRINGER 26 R/H FROM BS 885 TO BS 917, REMOVED TO FOM 1 EACH STRINGER CLIP & SPLICE BS 907, AND 1 EACH STRINGER CLIP BS 927. FABRICATED A FILLER, A REPAIR SPLICE, AND 4 EACH SHIMS; REINSTALLED STRINGER CLIPS AND SPLICE AT BS 907 AND BS 927, AND INSTALLED REPAIR PARTS IAW B737-200 SRM 53-10-3, FIG 1, PG. 3-10.

Part: FRAME — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1/2" CRACK WAS FOUND IN THE AFT CARGO DOORWAY FORWARD DOOR CUTOUT FRAME BS 827, RBL 43, WL 164. MAINTENANCE REMOVED THE THRESHOLD WEB, CLIP FROM STRINGER 27 R/H, INTERCOASTAL ASSEMBLY, 3 EACH STIFFNERS, AND THE CRACKED FRAME AT BS 827, RBL 43, WL 164. FABRICATED REPAIR FRAME, 2 EACH SPLICE ANGLES, INNER DOUBLER, 2 EACH TEE ANGLES, AND A SUPPORT ANGLE, AND INSTALLED REPAIR PARTS IAW AWA E.O. 53-10-01 (REV H).

Part: WEB — CRACKED (FUSELAGE) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A .5 INCH CRACK WAS FOUND IN CLOSE OUT WEB AT BS 1005, RBL 43, CORROSION WAS ALSO FOUND ON LOWER SIDE OF SAME WEB AT RBL 44. MAINTENANCE REMOVED THE DAMAGED CLOSE OUT WEB BS 986.5 TO 1016, RBL 44. FABRICATED A NEW CLOSE OUT WEB, AND INSTALLED REPAIR IAW B737-200 SRM 51-30-2, PG 2-3, 8-9, & 32, FIG 7, 11, &13 AND SRM 51-30-5, PG 4, FIG 2, 51-10-2, PG 1-2.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A .5 INCH CRACK WAS FOUND ON INTERCOSTAL AT BS 500A, STRINGER 25 RT. MAINTENANCE REMOVED INTERCOSTAL FROM BS 500A, STRINGER 25 RT, FABRICATED A NEW INTERCOSTAL PER DWG 69-41473, AND INSTALLED REPAIR IAW B737-200 SRM 51-30-2 PG 8-9 & 32.

Part: PLATE — CRACKED (FUSELAGE) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1 INCH CRACK WAS FOUND ON AFT CARGO COMPARTMENT FORWARD CORNER SCUFF PLATE. MAINTENANCE PREPARED, TREATED, AND WELDED THE CRACK ON FORWARD CORNER SCUFF PLATE IAW AWA ER 15-5333-01016-JS2.

Part: ANGLE — BROKEN · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A "T" ANGLE CLIP WAS FOUND BROKEN ON INBOARD SIDE OF THE #1 ENGINE FIXED FAIRING BETWEEN 2ND AND 3RD ATTACH FITTINGS FROM THE FORWARD END. MAINTENANCE REMOVED AND REPLACED THE "T" ANGLE CLIP ON INBOARD SIDE OF THE #1 ENGINE FIXED FAIRING IAW B737-200 SRM 51-30-2, FIG. 7, PG. 2-3, & 32.

Part: GUSSET — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1" CRACK WAS FOUND ON GUSSET AT AFT END OF NOSE GEAR ACTUATOR SUPPORT FITTING BS 240, BL 0, WL 190. MAINTENANCE REMOVED NOSE GEAR ACTUATOR SUPPORT FITTING AND THE CRACKED GUSSET BS 240, BL 0, WL 190. FABRICATED A NEW GUSSET, AND INSTALLED GUSSET AND NOSE GEAR ACTUATOR SUPPORT FITTING IAW B737-200 SRM 51-30-2, PG. 8-9.

Part: ANGLE — BROKEN · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A "T" ANGLE CLIP WAS FOUND BROKEN ON INBOARD SIDE OF THE #2 ENGINE FIXED FAIRING BETWEEN 2ND AND 3RD ATTACH FITTINGS FROM THE FORWARD END. MAINTENANCE REMOVED AND REPLACED THE "T" ANGLE CLIP ON INBOARD SIDE OF THE #2 ENGINE FIXED FAIRING IAW B737-200 SRM 51-30-2, FIG. 7, PG. 2-3, & 32.

Part: WEB — CRACKED (CARGO DOOR) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A .25 INCH CRACK WAS FOUND IN THE FORWARD END OF LOWER WEB ON FORWARD CARGO DOOR BS 446, STR 23 RT. MAINTENANCE REMOVED CRACKED SECTION OF WEB, FABRICATED 2 FILLERS, AND INSTALLED REPAIR PARTS IAW EO 52-31-04, FIG 2, PG 26, 36-37.

Part: SKIN — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,986 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1/4" CRACK WAS FOUND ON L-1 DOOR INTERNAL SKIN AT THE AFT UPPER CORNER DOOR STOP ADJUSTMENT CUTOUT, BS 346. MAINTENANCE CUTOUT CRACK AT L-1 DOOR AFT UPPER CORNER DOOR STOP ADJUSTMENT CUTOUT, BS 346. FABRICATED REPAIR DOUBLER AND INSTALLED REPAIR IAW B737-200 SRM 51-40-2, FIG. 1, PG. 1-3.

Part: LONGERON — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK THE #1 ENGINE FIXED FAIRING LOWER END "Z" ANGLE WAS FOUND CRACKED BETWEEN 1ST AND 2ND ATTACH FITTINGS FROM THE FORWARD END. MAINTENANCE REMOVED AND REPLACED THE LOWER END "Z" ANGLE ON THE #1 ENGINE FIXED FAIRING IAW B737-200 SRM 51-30-2, FIG. 7, PG. 2-3, 5, 8-11, & 32.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A .5 INCH CRACK WAS FOUND L-1 DOOR FRAME CUTOUT FORWARD LOWER STOP FITTING ATTACH PLATE WEB DOUBLER, BS 294.5, STR 16 LT. MAINTENANCE REMOVED THE L-1 DOOR FORWARD LOWER STOP FITTING ATTACH PLATE; REMOVED CLOSE OUT ANGLE AND FRAME STIFFENER PLATE TO FOM; CUT AND REMOVED DAMAGED SECTION OF WEB; FABRICATED A REPAIR DOUBLER, FILLER, AND LOWER STOP FITTING ATTACH PLATE AND INSTALLED ALL REMOVED PARTS AND REPAIR PARTS IAW B737-200 SRM 51-40-2, FIG 1 PG 3.

Part: WEB — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 3/8" CRACK WAS FOUND ON THE NOSE LANDING GEAR ACTUATOR SUPPORT BEAM WEB EXTENDING FROM UPPER CENTER RIVET HOLE, HFEC INSPECTION CONFIRMED CRACK. MAINTENANCE REMOVED NOSE LANDING GEAR ACTUATOR SUPPORT BEAM AND WEB, FABRICATED A NEW WEB, AND INSTALLED SUPPORT BEAM AND WEB IAW 737-200 SRM 51-30-2, PG. 8-9, FIG. 7, 11, & 13.

Part: ANGLE — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1" CRACK WAS FOUND ON FLOOR BEAM SUPPORT ANGLE BS 400, BL 0. MAINTENANCE REMOVED DAMAGED FLOOR BEAM SUPPORT ANGLE AT BS 400, BL 0. FABRICATED A NEW FLOOR BEAM SUPPORT ANGLE, AND INSTALLED REPAIR IAW B737-200 SRM 51-30-2, PG. 2-3.

Part: SKIN — CRACKED (RT WING) · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK .25 INCH CRACKS WERE FOUND ON RT WING LEADING EDGE AT THE NR 6 SLAT CENTER STOP FITTING CUTOUT, WS 557. MAINTENANCE BLENDED OUT CRACKS ON RT WING LEADING EDGE NR 6 SLAT CENTER STOP CUTOUT IAW AWA ER 15-5741-02232-SS1.

Part: SKIN — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1/4" CRACK WAS FOUND ON R-1 DOOR EXTERNAL SKIN AT UPPER AFT CORNER OF HINGE CUTOUT, CONFIRMED BY HFEC INSPECTION. MAINTENANCE CUTOUT DAMAGED AREA OF SKIN AT R-1 DOOR UPPER AFT CORNER OF HINGE CUTOUT AND PERFORMED HFEC INSPECTION TO ENSURE NO CRACKS EXIST. FABRICATED A REPAIR DOUBLER AND INSTALLED REPAIR IAW AWA ER 15-5241-02221-TB1.

Part: SKIN — DELAMINATED · corrosion level 0 · airframe 61,378 hrs · 49,988 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK THE R/H WING INBOARD FORE FLAP WAS FOUND TO HAVE DELAMINATION ON UPPER SKIN 6" INBOARD OF THE #3 FORE FLAP TRACK. MAINTENANCE CUTOUT DELAMINATED AREA OF SKIN ON R/H WING INBOARD FORE FLAP; BONDED AND POTTED REPAIR CORE; FABRICATED A REPAIR DOUBLER; BONDED AND SEALED REPAIR DOUBLER ON R/H WING INBOARD FOREFLAP IAW B737-200 SRM 51-40-20, FIG. 18, PG. 63-67.

Part: ATTACH ANGLE — CRACKED · corrosion level 0 · airframe 61,378 hrs · 49,986 cycles

MCN - MAJOR REPAIR - DURING C-18 CHECK A 1 1/2" CRACK WAS FOUND ON WEB UPPER CHORD (ATTACH ANGLE) AT FASTENER HOLES BS 500B TO BS 520, BL 0, WL 208.1. MAINTENANCE REMOVED WEB UPPER CHORD BS 500B TO BS 520, FABRICATED A REPAIR ANGLE AND INSTALLED REPAIR IAW DWG 69-41680, AND B737-200 SRM 51-30-2, FIG 7, PG. 32, SRM 51-10-2, FIG 2, PG. 7 & 32, AND SRM 51-10-1, PG. 10.

Part: FLASHLIGHT — DISCHARGED (CABIN) · airframe 61,278 hrs · 49,912 cycles

FLIGHT CREW REPORTED THE EMERGENCY FLASHLIGHT AFT LT INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE AFT LT EMERGENCY FLASHLIGHT.

Part: STRAP — CRACKED · airframe 59,697 hrs · 48,764 cycles

PHX - MAJOR REPAIR - "C" - CRACK FOUND ON FRAME RADIUS STRAP ON UPPER FLANGE ABOVE STRINGER 27R FOWARD PIT STA 492. MAINTENANCE REMOVED RADIUS STRAP FABRICATED STRAP AND FILLER AND INSTALLED IAW DWG 65-20723 AND SRM 50-30-2

Part: SKIN — CRACKED (FUSELAGE) · airframe 59,697 hrs · 48,746 cycles

PHX - MAJOR REPAIR - C - 9 CRACKS FOUND IN FUSELAGE SKIN .125 INCH LONG ORIGINATING FROM FASTENER HOLES ALONG STR 17L, STA 390 TO 415 VERIFIED BY HFEC. MAINTENANCE CUT OUT AND REMOVED DAMAGED AREA OF SKIN AND FABRICATED FILLER AND DOUBLER, INSTALLED IAW SRM 53-30-3, FIG 25, PG 88A.

Part: WEB — CRACKED (STA 727)

D: S-18A R/H shear beam web cracked.C: Replaced web 65-46877-82 per DWG 65-46877 - 76 INST. IAW SRM 51-10-1 page 8,9,10

Part: SKIN

D: Fuselage R/H Skin STA 727-777 STR 14R-20R found to have several existing skin repairs adjacent to each other.C: repaired per ER 15-5331-01206-SS3

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

AFT CABIN - CORROSION ON FLOOR SUPPORT BEAMS BETWEEN STN 1000-1010 LBL 45. REPLACED BOTH FLOOR SUPPORT PER DRAW 65-46812 PART NUMBER 65-46812-87 AND 65-46812-91 IAW SRM 51-10-1 PAGE 8, 9, 10.

Part: SEAT — CORRODED (STA 1006-1016)

D: Aft cabin R/H track F.STN.1006-1016 RBL 45 corroded.C: R/H floor track F.STN.1006-1016 RBL 45 DRAW 65C80735 - part no. 65C80735-115 and IAW SRM 51-10-1 Page 8,9,10

Part: SKIN — CRACKED (FUSELAGE)

FWD ENTRY DOORWAY AFT LWR CORNER OF CUTOUT IS CRACKED. HFEC INSP OF HOLES ACCOMPLISHED PER 737 NDT MAN PT 6 51-00-00. ACCOMPLISHED SB 737-53-1083R FOG .2 & FIG 4.

Part: DOOR FRAME — CRACKED (ENTRY DOOR)

FWD ENTRY DOOR AFT FRAME AND INNER WEB CRACKED. REPAIRED DOOR AFT FRAME AS PER SRM 51-40-3 PG 1-6. REPAIRED DOOR WEB AS PER SRM 51-40-2 PG 1-3.

Part: SKIN — CORRODED (FUSELAGE)

LIGHT CORROSION ON SURFACE FOUND UNDERNEATH VHF ANTENNA COVER AT BS 777 & BL 0. CORROSION REMOVED PER SRM 53-30-1 FIG 1 PG 1. MADE AND INSTALLED NEW ANGLES PER DWG 65-49917 P/N 65-49917-11 AND 65-49917-12. INSTALLED NEW DOUBLERS AND FILLER PER SRM 53-30-3 FIG 1 SHT 1-A & SRM 51-30-2 PG 2-3.

Part: BULKHEAD — CRACKED (FUSELAGE)

NDT FOUND CRACKS AT BS 178 WL 222 LBL 3 AND BS 178 WL 222 RBL 3. DAMAGED REPAIRED PER ER 15-5313-01212-DD1.

Part: SKIN — CRACKED (AFT SERV.CUT OUT)

D: Aft service doorway Fwd Lwr corner cutout is cracked.C: Crack repaired as per SRM 53-30-3 Fig 24 pg 83-86H

Part: SEAT TRACK

D: Seat track @ RBL 24-75 STA 360-947 Nicked at Various Locations.C: Track blended at various locations and Assessed Per SRM 53-10-1 Pg 18. Track repaired per SRM 51-30-2 PG 8, SRM 53-10-5 pg 2, SRM 53-10-1 pg 8, SRM 53-10-5 PG 8

Part: SEAT TRACK — NICKED (STA 360-947)

D: Seat track RBL 45-50 STA 360-947 is nicked @ various locations.C: Track blended and protected per SRM 53-10-1 pg 18. STA 520-540 track replaced per SRM 51-30-2 Pg * STA 827 track repaired per SRM 53-10-5 pg 3, and SRM 51-30-2 PG 8

Part: STRINGER — CORRODED (STA 727 -727A)

D: S-26L STA 727-727A +10 corroded beyond limits.C: S-26L STA 727-727A +10 repaired per SRM 53-10-3 Fig 1 pg 2 and SRM 51-30-2 pg 2 & 8

Part: SEAT TRACK — NICKED (STA 360-947)

D: Various nicks found along seat track LBL 45-50 STA 360-947C: Nicks dressed and assessed per SRM 51-10-1 Pg 18 STA 540-564 track repaired per SRM 53-10-5 Fig 2 Pg 2-5

Part: SEAT TRACK — NICKED (STA 360-947)

D: Nicks on LBL 24.75 seat track at various locations from STA 360-947C: Nicks blended and assessed per SRM 53-10-1 pg 18 STA 520-540 track replaced per SRM 51-30-2 pg 8

Part: WEB — CRACKED (WL 207)

D: Bulkhead 178 intercostal on LH side cracked @ WL 207 aft side chord NDT confirmed.C: Web replaced per ref DWG 65-45833-40 & SRM 51-30-2 Pg 5 alodine & primed per SRM 51-10-2 Pg 7

Part: STIFFENER — CRACKED (FUSELAGE)

BULKHEAD 178 VERTICAL CHORD AT LBL 5.7 CRACKED IN RADIUS AT WL 190 NDT CONFIRMED. REPAIRED PER REF SRM 53-10-11 FIG 8 SMT 1-20 HFEC PER 737 NDT PT.6 51-00-00. PARTS CAD PLATED ON WIP R445976 REPROTECT PARTS PER SRM 51-10-2. SEALED PER SRM 51-20-4 PG 4, INSTALLED REPAIR PARTS PER SRM 51-30-2 PGS 2-3 & 5.

Part: FRAME — CRACKED (FUSELAGE)

BULKHEAD 178 CHORD CRACKED AT WL 207 LT SIDE ABOVE AND BELOW FLOOR -NDT- CONFIRMED. LEFT LWR CHORD P/N 65-16300-86 REPLACED PER REF DWG 65-16300 & SRM 51-30-2 PG 2-3. RESTORED SURFACE FINISH PER AWA 51-21-0 PG 1 & SRM 51-20-4 PG 4.

Part: BULKHEAD — CRACKED (FUSELAGE)

INSP OF STA 178 BLKHD FWD FACE REVEALS SEVEN CRACK INDICATIONS. LOCATIONS ARE AS FOLLOWS LBL 8/WL 228, LBL 4/WL 216, RBL 12/WL 216, LBL 12/ WL 216, LBL 1/WL 200, RBL 1/WL187, & LBL 1/WL 187. REPAIRED PER ER NR 15-5313-01212-DD1 HFEC PER 737 NDT MAN, PT 6 51-00-00 REP SRM 51-30-2 PGS 2-3 & 5 SRM 51-20-4 PG 4 & PER MM 51-21-0 PG 1.

Part: INTERCOSTAL — CRACKED (WL 195)

D: E.T. INSP reveals cracks in intercostal on both LH & RH sides @ WL 195, just AFT 178 Each intercostal has one crack.C: LH & RH intercostal replaced per ref DWG 65-16300 SHT.3 & SRM 51-30-2 pg 2-3

Part: ACM — OVERSERVICED (AC BAY) · airframe 58,090 hrs · 47,522 cycles

PHX - AIR TURNBACK - 2/25/01 - AFTER LEVELING OFF AT FL 310, FLIGHT ATTENDANTS REPORTED A BURNING SMELL IN THE CABIN; THE CREW STARTED A DESCENT AND TURNED OFF THE GRASPER FAN AND THE SMELL SEEMED TO GO AWAY; THE FLIGHT RETURNED TO PHX. IN PHX, MAINTENANCE FOUND OIL DRIPPINGS ON THE RT AIR CYCLE MACHINE (ACM); BOTH THE LT AND RT ACM''''S APPEARED TO BE OVERSERVICED; BOTH ACM''''S WERE DRAINED AND REFILLED; THE AIR CONDITIONING PACKS WERE RUN FOR 30 MIN AT MAX TEMPERATURE AND NO ODORS NOTED.

Part: FILTER — DIRTY (E/E BAY) · airframe 56,775 hrs · 46,490 cycles

AIR TURNBACK, F/A REPORTS SMELLING SMOKE. REMOVED AND REPLACED COALESCER FILTERS.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, CORROSION OUT OF LIMITS ON STR 28R BS 325. REMOVED DAMAGED SECTION OF STRINGER, AND REPAIRED STRINGER IAW 737 SRM 53-10-1 AND 53-10-3.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, CORROSION ON SEAT TRACK AT BS 328 - 344 RBL 45. REMOVED AND REPLACED SEAT TRACK (NEW PART) IAW 737 SRM 53-10-1 AND 51-30-2.

Part: WEB — CRACKED (CARGO DOOR) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, LOWER WEB INSIDE FWD CARGO DOOR CRACKED BS 486 RBL 3L WL 160. REMOVED DAMAGED SECTION OF LOWER WEB, FABRICATED NEW REPAIR DOUBLER, ALODINED, PRIMED, AND INSTALLED IAW 737 SRM 51-40-03 AND 51-10-02.

Part: FITTING — CORRODED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, RIGHT 685 FITTING CORRODED AROUND LOWER BUSHING. REMOVED AND REPLACED FITTING (NEW) IAW DWG 65C36758 SHEET 1, 3 AND 4.

Part: CARGO TRACK — CRACKED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, WHILE WORKING CARD 5250058 FOUND AFT CARGO BAY RT CARGO TRACK CRACKED. REMOVED CARGO TRACK, LOCATED AND DRILLED NEW CARGO TRACK, FABRICATED SPLICES AND INSTALLED PARTS IAW 737 SRM 51-30-2 AND SRM 53-10-05.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, CORROSION OUT OF LIMITS AT BS 480 RBL 1 TO 6 WL 149 1 X 5 X .013. REMOVED DAMAGED SHEAR TIE, FABRICATED REPAIR PART, INSTALLED PARTS IAW 737 SRM 53-10-1, 53-10-4 FIG 9A, AND 51-30-2.

Part: CHANNEL — CRACKED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, CRACK FOUND ON LOWER VHF ANTENNA SUPPORT STRINGER BS 500+11 LBL 1 WL 149. REMOVED AND REPLACED ANTENNA SUPPORT WITH NEW PART IAW 737 SRM 51-30-2 AND 737 MM 23-21-11.

Part: FRAME — CORRODED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, LEFT BS 685 FRAME HAS CORROSION IN THE FRAME BORE AND ON LUG FACES. REMOVED CORROSION AND REPAIRED LEFT BS 685 FRAME IAW ER 15-5364-00146-DL2.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, CRACKED INTERCOSTAL AT BS 278 STR 14 RT. REMOVED AND REPLACED CRACKED INTERCOSTAL IAW 737 SRM 51-30-2 PGS 1 - 4, 8 - 9. FABRICATED INTERCOSTAL AND SUPPORT ANGLE IAW 737 SRM 51-20-1, 51-10-2 PG 7.

Part: CLIP — CRACKED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, FRAME SUPPORT CLIP AT BS 707 RBL 65 WL 254 CRACKED. REMOVED CRACKED CLIP, FABRICATED AND INSTALLED REPLACEMENT CLIP IAW 737 SRM 51-30-02 AND 51-20-01, ALODINED AND PRIMED IAW 737 SRM 51-21-41.

Part: BEAM — GALLED (RT MLG WW) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, RIGHT MLG INBOARD STABILIZER SUPPORT BEAM GALLED ON LUG FACES (BOTH ENDS). REMOVED AND REPLACED RIGHT MLG STABILIZER SUPPORT BEAM IAW 737 MM 57-15-0 PG 408.

Part: TRACK — CRACKED (HORIZONTAL STAB) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, RT HORIZ STAB UPPER AFT SLIDING SEAL TRACK CRACKED. REMOVED AND REPLACED RT HORIZONTAL STAB UPPER AFT SLIDING SEAL TRACK IAW 737 SRM 51-30-02.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, CORROSION ON GALLEY TRACK BS 290 TO 295, RBL 42. REMOVED AND REPLACED SEAT TRACK IAW 737 SRM 51-30-02.

Part: FITTING — GALLED (RT MLG) · airframe 56,111 hrs · 45,904 cycles

C-CHECK, RIGHT INBOARD AFT MLG SUPPORT BEAM FITTING GALLED ON LUG FACE. REMOVED AND REPLACED RT MLG SUPPORT BEAM STABILIZER FITTING IAW 737 MM 57-15-0 PG 408.

Part: FLOORBEAM — CORRODED (BS 986.5)

CORROSION ON BEAM FS 986.5 LBL 42-46. REMOVED DAMAGED CAP, FABRICATED NEW CAP, TREATED PRIMED AND INSTALLED IAW SRM 53-10-9, SRM 51-10-2.

Part: FRAME — CRACKED (APU DOORWAY)

APU COWL DOOR RIGHT AFT LATCH MOUNT STRUCTURE FRAME IS BROKEN AND CRACKED ON BOTH THE FORWARD AND AFT FRAMES. REMOVED CRACKED FRAMES, FABRICATED AND INSTALLED REPAIRED FRAMES PER SRM 52-40-1, 51-30-2, 51-10-2.

Part: SILL — CORRODED (L1 DOORWAY)

CORROSION ON FWD LT DOOR SILL, I/B OF L-1 DOOR. REMOVED CORRODED AREA, FABRICATED AND INSTALLED FILLER AND DOUBLER PER SRM 53-10-2, 51-40-3, 51-10-2.

Part: SUPPORT — CORRODED (BS 947)

CORROSION ON THRESHOLD SUPPORT FOR L-2 DOOR FS 947 LT BL 54-55. REMOVED DAMAGED PART AND INSTALLED NEW PART PER SRM 51-30-2.

Part: STRINGER — CRACKED (BS 607 & 787)

RT SKIN AT STR 17R BETWEEN STA 787 AND 607 HAD TWO CRACKS VERIFIED BY HFEC. CUT OUT CRACK, VERIFIED WITH HFEC. FABRICATED AND INSTALLED REPLACEMENT DOUBLER IAW SRM 53-30-3, QQA-250/5.

Part: BULKHEAD DOUBLER — MISREPAIRED (AFT PRESS BLKHD)

AFT PRESSURE BULKHEAD, FUSELAGE STATION 1016, RBL 20, EXISTING REPAIR DOES NOT CONFORM TO SRM 53-10-4 FIG 3. REMOVED DOUBLER, FABRICATED AND INSTALLED REPLACEMENT DOUBLER PER SRM 53-10-4 FIG 3.

Part: FLOORBEAM — CORROSION (BS 1016)

CORROSION ON BEAM FS 1016 LT BL 6 12 AFT LAV GALLEY FLOOR. CUT OUT CORROSION, FABRICATED NEW PARTS, TREATED, PRIMED AND INSTALLED IAW SRM 53-10-09, 51-30-2.

Part: CLIP — CRACKED (FUSELAGE)

IN MAINTENANCE, FOUND CRACKS, STRINGER CLIPS AT THE FOLLOWING LOCATIONS ARE CRACKED CABIN FS 947.6 STR 25R, FS 787 STR 1, FS 767 STR 5L, 6R, 6L, 7R, FS 727A STR 4L, 7R, FS 727B STR 5R, FS 688 STR L2, FS 639 STR L2. REMOVED AND REPLACED STRINGER CLIPS PER SRM 51-30-02.

Part: DOUBLER — CORRODED (BS 967-986.5)

FLOOR SUPPORT, MAIN CABIN FS 967 - 986.5, RBL 18 TOP OF FLOOR SUPPORT HAS CORROSION. REMOVED FLOOR SUPPORT DOUBLER, FABRICATED, ALODINED AND PRIMED DOUBLER IAW SRM 53-10-2 FIG 7 AND SRM 51-10-2.

Part: STRINGER — CORRODED (BS 967-1016)

CORROSION OUT OF LIMITS ON STRINGER 27L AT FRAME 967. REMOVED STRINGER 27L AT STA 967 TO 1016. FABRICATED 3 EA STRINGERS 6 EA SPLICE ANGLES 2 EA N CHANNELS. TREATED PRIMED AND INSTALLED NEW PARTS PER SRM 51-30-2, 51-10-2, 57-30-3 FIG 1 AND TORQUED 2 EA STRINGER END FITTING BOLTS IAW SRM 51-40-4N

Part: KEEL BEAM — CRACKED (BS 700)

STATION 700 KEEL BEAM CLOSEOUT PANEL BOTTOM SIDE OF FUSELAGE AT MLG HAS 1.5 INCH CRACK. REMOVED CRACKED SKIN, FABRICATED AND INSTALLED REPLACEMENT SKIN PER SRM 51-10-2, 51-30-2, 53-10-2 FIG 4.

Part: SUPPORT — CORRODED (BS 992)

CORROSION ON SECONDARY SUPPORT STRUCTURE AT FS 992 LT BL 15-20. REMOVED CORRODED SUPPORT IAW SRM 51-10-3 FIG 2, ALODINED AND PRIMED IAW 51-10-2, AND INSTALLED PER SRM 51-30-02.

Part: FLOORBEAM — CORRODED (BS 968.5)

EXISTING FLOORBEAM REPAIR AT STA 968.5 RBL 49 CORRODED BEYOND LIMITS. REMOVED EXISTING T-CHORD PER SRM 51-30-2, FABRICATED T-CHORD REPLACEMENT PER SRM 53-10-9 FIG 2, TREATED AND PRIMED PARTS PER SRM 51-10-6 AND INSTALLED REPAIR IAW SRM 51-30-2.

Part: SKIN — CRACKED (BS 787 & 607)

NORMAL OPS, SKIN CRACK. SKIN AT STRINGER 17R BETWEEN STA 787 AND STA 607 HAS 2 CRACKS. VERIFIED WITH HFEC. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED EXTERNAL DOUBLER PER SRM 53-30-3 FIG 1. PLACED ON MCK. INSPECT EVERY 3000 CYC'S, TERM AT C-CK.

Part: SKIN — CRACKED (L2 DOORWAY)

D-POSSIBLE CRACK REPORTED L2 LWR FWD CORNER OF LOWER HINGE CUTOUT OF SKIN, CONFIRMED BY EDDY CURRENT INSPECTION. C-REMOVED DAMAGE PORTION OF SKIN AND BONDED DOUBLER INSTALLED DOUBLER PER 53-30-03 FIG 34.

Part: AIR DISTRIBUTION — SMOKE (CABIN)

SMOKE IN THE CABIN, RETURNED TO AIRPORT. CHECKED PACKS RAN A/C, RECIRC FAN, EYEBALL VENTS, COULD NOT DUPLICATE.

Part: AIR DISTR — SMOKE (CABIN)

CREW REPORTED, SMOKE IN THE CABIN. A/C RETURNED TO DEN ATBC. CONTRACT MX CHECKED BOTH PACKS, RECIR FAN, LIGHT BALLAST, EYEBALL VENTS, RAN PACKS WITH ENGINES AND APU, PRESSURIZED THE A/C. MX COULDN'T DUPLICATE THE PROBLEM, CREW REFUSED, A/C FLIGHT WAS CANCELLED. STC NR SA3432NM.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND ROW 1 THROUGH 5 AISLE EMERGENCY LIGHTS INOP. REMOVED AND REPLACED POWER SUPPLY UNIT UNDER ROW 3L, OPS CHECK GOOD. STC - SA3432NM

Part: WIRE — BROKEN (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY LIGHT AT ROW 2 A, B INOP. REPAIRED BROKEN WIRE, OPS CHECK GOOD. STC - SA3432NM.

Part: LIGHT — LOOSE (CABIN)

DURING ROUTINE MAINTENANCE CHECK, FOUND EMERGENCY AISLE LIGHT AT ROW 14C NOT SECURELY ATTACHED TO SEAT. REMOVED AND REPLACED LIGHT ASSEMBLY, OPS CHECK GOOD. STC - SA3432NM

Part: OIL FILTER STUD — LOOSE (NR 1 ENGINE)

APPROXIMATELY 4 MINUTES AFTER TAKEOFF, THE NR 1 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED. PRESSURE DROPPED TO APPROXIMATELY 20 PSI, QUANTITY WENT TO ZERO. ACCOMPLISHED ENGINE SHUTDOWN, EMERGENCY LANDING DECLARED. INTERIM REPAIR OF NR 1 ENGINE OIL FILTER COVER. INSPECTED FILTER AND REMAINING 3 STUDS. RAN ENGINE AT HIGH POWER, NO LEAKS NOTED. SAFE FOR FERRY FLIGHT. DURING FERRY FLIGHT, NR 1 ENGINE OIL QUANTITY DROPPED. DIVERTED TO ICT. INSTALLED HELICOIL INSERT PER PRATT AND WHITNEY MM CHAPTER 72, NR 1 ENGINE OIL FILTER COVER FWD LOWER STUD. RAN ENGINE AT 85 PERCENT POWER, NO LEAKS NOTED.

Part: RELAY — SHORTED (NR 1)

IN CRUISE AT FL 310, TWO CLICKS WERE HEARD FROM BEHIND CAPTAIN'S SEAT (ELECTRICAL). ALL INSTRUMENTS ON FORWARD PANEL FLASHED OFF THEN ON THEN WENT BLACK. SEVERAL ORANGE LIGHTS ON THE OVERHEAD. LASTED ABOUT 30 SECONDS, THEN REPEATED ABOUT 4 MINUTES LATER. APU WAS SWITCHED AFTER FIRST EVENT. AT 1,000 FT SMELLED BURNING WHICH CONTINUED UNTIL TAXI-IN. REMOVED AND REPLACED NR 1 TRANSFER BUS RELAY. SYSTEM OPS CHECKS NORMAL.

Part: STRINGER — CORRODED (BS 785)

DURING ROUTINE MAINTENANCE CHECK, FOUND CORROSION ON STR 26R, BS 785 WHILE WORKING N/R 00372822. REMOVED CORRODED SECTION OF STRINGER FROM BS 783 TO 786, FABRICATED REPAIR PARTS AND INSTALLED STR REPAIR PER SRM 53-10-3.

Part: SKIN — DAMAGED (BS 353-357)

DURING ROUTINE MAINTENANCE CHECK, FOUND PUNCTURE, DENTS, GOUGES AND A PULLED FASTENER IN SKIN BS 353 - 357 INBOARD OF STR 28R. REPAIRED DAMAGED SKIN AT BS 352A - 380 PER ER 2-53-32-20, TCO-PAN-97-0511RR, 8110-3.

Part: STRINGER — CORRODED (BS 1006-1016)

DURING ROUTINE MAINTENANCE CHECK, FOUND STRINGER 26R AT BS 1006 TO 1016 CORRODED. REMOVED CORRODED SECTION OF STRINGER 26R FROM BS 1006 TO BS 1016 AND REPLACED WITH FABRICATED STRINGER, IAW, SRM 53-10-3.

Part: STRINGER — CORRODED (BS 947-967)

DURING ROUTINE MAINTENANCE CHECK, FOUND STR 27L JUST AFT OF BS 947 TO 967, WL 145 CORRODED. REMOVED STR 27L FROM BS 928 - 954, FABRICATED REPAIR PARTS AND INSTALLED PER SRM 53-10-3.

Part: STRINGER — CORRODED (BS 818)

DURING ROUTINE MAINTENANCE CHECK, FOUND STR 27 RT CORRODED IN CENTER CHANNEL AT BS 818 REMOVED STR 27 RT FROM BS 807 TO BS 855 AND SPLICED IN NEW SECTION IAW, SRM 53-10-3.

Part: SKIN — CORRODED (BS 808)

DURING ROUTINE MAINTENANCE CHECK, FOUND SKIN PILLOWING AROUND FASTENERS AT BS 808 1 INBOARD OF STR 26. REMOVED FASTENERS, CUT OUT 4 BY 4 OF SKIN AND REPAIRED IAW, SRM 5A3-30-3.

Part: FRAME — CORRODED (BS 747)

DURING ROUTINE MAINTENANCE CHECK, FOUND CORROSION ON FRAME BOTH FWD AND AFT AT BS 747, RBL 4. REPAIRED FRAME IAW, SRM 53-10-4.

Part: STRINGER — CORRODED (BS 848)

DURING ROUTINE MAINTENANCE CHECK, FOUND CORROSION ON STR 27R, BS 848. REMOVED .5 BY .75 DAMAGED STR, INCLUDED REPAIR FROM BS 807 - 855. INSTALLED REPAIR PARTS PER SRM 53-10-3.

Part: STRINGER — CORRODED (BS 815)

DURING ROUTINE MAINTENANCE CHECK, FOUND CORROSION ON STR 27 RT BS 815 AROUND FASTENERS. REMOVED STR 27R FROM BS 807 TO 855. INSTALLED REPAIR PARTS PER SRM 53-10-3.

Part: LIGHT — INOP (CABIN)

PHX - FLT 2267 - FOUND EMERGENCY EXIT LIGHT ON SEAT AT OVERWING EMERGENCY EXIT IS INOPERATIVE. REMOVED AND REPLACED LIGHT ASSEMBLY. OPERATIONS CHECK GOOD. (M)

Part: WIRE — DISCONNECTED (CABIN)

PHX - FLT 2062 - DURING ROUTINE MAINTENANCE CHECK, FOUND SEAT MOUNTED EMERGENCY LIGHTS ON DIM, ROW 1-5, AT ALL TIMES. RECONNECTED WIRE. REPAIRED SHORT IN WIRING. OPERATIONS CHECK OK. (M)

Part: ENGINE — OVERTEMP (NR 2)

PHX - FLT 1195 - AIR TURNBACK FOR ENGINE NR 2 OVERTEMP. REMOVED AND REPLACED ENGINE NR 2 FOR HIGH EGT. PART TOTAL CYCLES: 33,896. (X)

Part: EGT — OVERTEMP (NR 2 ENGINE)

LAS/SFO - FLT 2603 - AIR TURNBACK. ON TAKEOFF, THE NR 2 ENGINE HAD AN OVERTEMP OF EGT. THE PILOT REPORTED A TEMPERATURE OF 635 DEGREES FOR A PERIOD OF 20-30 SECONDS. HE SAID IT WAS A BLEEDS-OFF TAKEOFF. PER MM 71-09-100, PAGE 218F, THE ENGINE WILL REQUIRE A BORESCOPE INSPECTION. COMPLIED WITH BORESCOPE INSPECTION PER CARD 15M72014. Q.C. PERFORMED BORESCOPE REQUIRED PER 72-00, PAGE 530W-532. TROUBLESHOOTING PRIOR TO BORESCOPE PER P AND W MM 72-00, PAGE 127-139. PERFORMED TRIM RUN PER F5M71002. TAKEOFF POWER AND EGT GOOD. (X)

Part: NR 6 HEAT SHIELD — FAILED (NR 2 ENGINE)

ABQ- FLT 343 - EN ROUTE IAH-LAS, THE NR 2 ENGINE OIL QUANTITY BEGAN DECREASING RAPIDLY. CREW ELECTED TO DIVERT AIRCRAFT TO ABQ. AIRCRAFT ARRIVED AT GATE WITHOUT FURTHER INCIDENT. MAINTENANCE NOTED LESS THAN 1 QT OIL ON QUANTITY GAUGE, AND ALSO FOUND A PUDDLE OF OIL IN EXHAUST DUCT. MAINTENANCE ELECTED TO CHANGE ENGINE. TEARDOWN OF ENGINE FOUND FOD IMPACTED THE NR 6 BEARING HEAT SHIELD CAUSING IT TO CRACK AND COME INTO CONTACT/CHAF THE NR 6 BEARING PERSSURE TUBE. (M)

Part: EEL BATTERY PACK — INOPERATIVE (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND THE OVERWING EMERGENCY EXIT LIGHT STAYS ON IN FLIGHT AND IS INOPERATIVE ON GROUND. REMOVED AND REPLACED POWER SUPPLY AND BATTERY PACK, OPS CHECK GOOD. (X)

Part: EEL BATT PACK — DISCHARGED (CABIN)

PHX - DURING ROUTINE MAINTENANCE CHECK, FOUND R2 DOOR EMERGENCY EXIT LIGHT INOPERATIVE. REMOVED AND REPLACED BATTERY PACK, OPS CHECK GOOD. (M)

Part: INTERCOSTAL — CORRODED (FS 967)

PHX - DURING SCHEDULED C11 INSPECTION, FOUND CORROSION ON NUT PLATE CLIP OF INTERCOSTAL BETWEEN FS 967 AND FS 986.5 RBL 18. REMOVED DAMAGED PARTS, FABRICATED SHIM AND REINSTALLED ON INTERCOSTAL PER SRM 51-10-1. (W)

Part: FLOOR BEAM — CORRODED (FS 967)

PHX - DURING SCHEDULED C11 INSPECTION, FOUND CORROSION AROUND FASTENER HOLES ON FLOOR BEAM AT FS 967 RBL 12 TO RBL 24. REMOVED DAMAGED AND REPAIRED WITH TOP CAP SPLICE PER SRM 53-10-9. (W)

Part: SKIN — CRACKED (FS 360)

PHX - DURING SCHEDULED C11 INSPECTION, FOUND FUSELAGE SKIN CRACKED AT FORWARD ENTRY DOOR LOWER HINGE CUTOUT. REPAIRED DAMAGE WITH DOUBLER REPAIR PER SRM 53-30-3. (W)

Part: INTERCOSTAL — CORRODED (FS 1006)

DURING SCHEDULED C11 INSPECTION, FOUND LAV THRESHOLD SUPPORT INTERCOSTAL CORRODED FROM FS 1006 TO FS 1016 LBL 22. REMOVED, FABRICATED AND INSTALLED NEW INTERCOSTAL PER SRM 51-10-1. (W)

Part: FLOOR BEAM — CORRODED (FS 947)

DURNIG SCHEDULED C11 INSPECTION, FOUND CORROSION AROUND FASTENER HOLES ON FLOOR BEAM AT FS 947, RBL 32 TO RBL 49. REMOVED DAMAGE AND INSTALLED ANGLE REPAIR PER SRM 53-10-1 AND SRM 51-40-4. (W)

Part: SPLICE — CORRODED (FS 907)

DURING SCHEDULED C11 INSPECTION, FOUND STRINGER SPLICE AT FS 907 STRINGER 28R CORRODED BEYOND LIMITS. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED NEW STRINGER SPLICE PER SRM 51-32-2 AND SRM 51-10-1. (W)

Part: SKIN — CRACKED (FS 960)

PHX - DURING SCHEDULED C11 INSPECTION, FOUND FUSELAGE SKIN CRACKED AT FORWARD LOWER CORNER OF AFT ENTRY DOOR CUTOUT. REPAIRED DAMAGE WITH DOUBLER REPAIR PER SRM 53-30-3. (W)

Part: THRESHOLD — CORRODED (FS 947)

DURING SCHEDULED C11 INSPECTION, FOUND R2 DOOR THRESHOLD CHORD CORRODED FROM FS 947 TO FS 1006. REMOVED, FABRICATED AND INSTALLED NEW CHORD ANGLE PER SRM 51-10-1. (W)

Part: SCUFF PLATE — CRACKED (CARGO COMPT)

PHX - DURING SCHEDULED C11 INSPECTION, FOUND FORWARD CARGO DOORWAY THRESHOLD CRACKED IN TWO PLACES. REMOVED AND WELDED REPAIR PER ER 1-53-30-02D AND INSTALLED THRESHOLD. (W)