N235WA

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 42,952 hrs · 37,451 cycles

THE UPPER CAP OF THE BL 0.07 LONGITUDINAL FLOORBEAM WAS FOUND WITH CRACKS COMMON TO THE FLOOR PANEL ATTACH HOLES BETWEEN FS 660 & 664. THE CRACKS ARE TYPICAL OF BAC S/B 737-57-1210. THE CAP CRACKS WERE REPAIRED WITH ALUMINUM REPAIR ANGLES PER THE S/B AND PER ER/A 379246-14.

Part: SWITCH — MALFUNCTIONED (TAKEOFF WARNING) · airframe 42,811 hrs · 37,344 cycles

AS POWER WAS PUSHED UP FOR TAKEOFF ABOVE 1.4 EPR TAKEOFF WARNING HORN SOUNDED INTERMITTENT TONE. TAKEOFF WAS DISCONTINUED AT AROUND 20 - 30 KTS. A CHECK SHOWED AIRCRAFT CONFIGURATION PERFECTLY NORMAL, FLAPS 5, SPEEDBRAKE DOWN, TRIM 5.0 ETC. AFTER DEPARTING RUNWAY SPEEDBRAKE WAS CYCLED UP AND DOWN, THEN TWO RUNUPS WERE MADE UP TO 1.5 EPR WITH NO WARNING HORN. REPLACED SPOILER TAKEOFF WARNING SWITCH PER M/M. PERFORMED TAKEOFF WARNING TEST PER M/M 31-26-0.

Part: SKIN — CRACKED (FUSELAGE)

THE LOWER AFT CORNER OF THE R1 DOOR CUTOUT WAS FOUND WITH A 1.75 INCH TYPICAL CRACK IN THE SKIN AND BONDED DOUBLER AND A 1.5 INCH CRACK IN THE UNDERLYING BEAR STRAP. THE CRACK WAS ROUTED OUT OF THE SKIN STACK UP AND REPAIRED WITH 3 EXTERNAL ALUMINUM DOUBLER PER THE PROCEDURES OF B737 SRM 53-30-3 FIG 26 AND ER/A 369206-14, REV A.

Part: OVERHEAT DET — INOPERATIVE (APU)

APU LIGHT ILLUMINATED ON T/O. PULLED HANDLE, LIGHT CONTINUED TO ILLUMINATE ON TAXI BACK. REJECTED TAKEOFF. REPLACED APU TAILPIPE OVERHEAT DET CONNECTOR D1878 AND WIRE W765-451-18R DUE TO HIGH RESISTANCE SHORT. OPS TEST AND RUN TEST CHECK GOOD. CONNECTOR (P/N 878581-01).

Part: LIGHT — INOP (L1 DOOR)

EMERGENCY EXIT LIGHT ABOVE L1 DOOR INOP. REPLACED LIGHT ASSY, OP CKS GOOD.

Part: LIGHT — INOP (ROW 12D)

EMERGENCY LIGHT ASSY SEAT 12D INOP. REPLACED LIGHT ASSY, TEST GOOD PER MM.

Part: ACTUATOR — BROKEN (NR 8 SPOILER)

ON TAXI IN, A-SYS HYD WENT TO ONE GALLON. REPLACED NR 8 SPOILER ACTUATOR.

Part: ENGINE — OVER TEMP (NR 2)

ENGINE IN FLIGHT, SHUT DOWN DUE TO OIL TEMP EXCEEDED RED LINE. ENGINE WAS REPLACED.

Part: STRUCTURE — CORRODED (BS 807)

SKIN, FRAME AND STRINGERS 27 LT AND RT WERE FOUND WITH CORROSION AT STA 807. REPAIRED PER ERA 330955-14.

Part: FLOORBEAM — CRACKED (BS 520)

FLOORBEAM AT FS 520 WAS FOUND CRACKED AT RBL 25 AND LBL 45. REPAIRED PER SB 737-53-1120, R 1.

Part: KEEL BEAM — CRACKED (BS 680/696)

TWO 1.5 INCH CRACKS FOUND IN THE KEEL BEAM LWR SKIN AT STA 680 AND TWO ADDITIONAL AT STA 696. CRACKS LOCATED AT L/RBL 5. REPAIR PER ERA 363005-14, REV A.

Part: FRAME — CRACKED (BS 334)

R1 DOOR FRAME INTERCOSTAL AT STGR 8A WAS CRACKED IN TYP MANNER SHOWN IN SB 737-53A1108, R5, AT APPROX FS 334. ALSO, THE INTERCOSTAL AT STGR 11 WAS CRACKED. REPAIRED PER SB 737-53A1108, R5.

Part: SKIN — CRACKED (BS 727)

CRACK FOUND IN THE FUSELAGE SKIN AT STA 727A AND STR 16R. REPAIR PER ERA 330976-14.

Part: SKIN — CRACKED (C2 DOORWAY)

FUSELAGE SKIN FOUND WITH A SMALL CRACK IN THE UPPER AFT CORNER OF THE C2 DOOR CUTOUT. REPAIRED PER ERA 330960-14.

Part: SKIN — CRACKED (BS 747-767)

THE RT FUSELAGE SKIN BETWEEN FS 747 AND 767 AND S-18R AND S-19R WAS FOUND WITH TWO CRACKS. REPAIRED PER DELTA ER/A 362945-14 AND B737 SRM 53-30-3, FIG 6.

Part: TEST MODULE — INOPERATIVE (NR 2 ENGINE)

NR 2 GENERATOR WOULD NOT HOOK UP TO BUS DUE TO NO VOLTAGE. FREQUENCY WAS NORMAL. REPLACED POWER TEST MODULE, OPS CK OK FOR SERVICE.

Part: MAIN TIRE — FAILED (NR 3)

SHORTLY AFTER TAKEOFF, A HYD SYS PRESS FAILED AND QTY WENT TO ZERO. ACCOMPLISHED CHECKLIST AND RETURNED FOR LANDING. AFTER LANDING FOUND NR 3 MAIN TIRE HAD COME APART AND DAMAGED 2 HYDRAULIC LINES. ALSO, TIRE DAMAGED RT WING AND I/B SPOILER ABOVE RT MAIN GEAR.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY PATH LIGHTS BATTERY PACK INOP. REPLACED, CHECKS GOOD.

Part: BULKHEAD WEB — CRACKED (BS 178)

BULKHEAD 178 WAS FOUND CRACKED BENEATH THE VERTICAL STIFFENERS AT LBL 5.7 AND RBL 5.7. DAMAGE REMOVAL RESULTED IN CUT OUTS ON THE LT SIDE 3.5 AND 6 ABOVE WL 195, SAME FOR THE RT SIDE. THE WEB IS MANUFACTURED FROM 0.040 CLAD 2024-T3. ACCOMPLISHED REPAIRS PER DL ERA 303381-14.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LAYOVER, EMERGENCY LIGHTS FOR OVERWING EMERGENCY EXITS FAILED TEST. REPLACED BATTERY PACK, OPERATION NORMAL.

Part: SKIN — DAMAGED (FS 380-400)

THE FUSELAGE SKIN WAS GOUGED BETWEEN FS 380 AND FS 400. THE DAMAGE CUT OUT MEASURES APPROX 4.9 BY 23.1. THE NEWLY DAMAGED SECTION IS BETWEEN 2 PREVIOUSLY DAMAGED SKIN SECTIONS, REPAIRS ACCOMPLISHED PER ER/A'S 230787-14 AND 230789-14. IN ADDITION, AN EXISTING DENT HAS BEEN CUT OUT FWD OF FS 380, ABOVE STR 19R, 2.8 BY 5. THIS ER/A SUPERSEDES PREVIOUS SUBJECT ER/A'S. THE SKIN IS MANUFACTURED FROM 0.036 2024-T3 CLAD SHEET WITH A BONDED 0.036 2024-T3 CLAD WAFFLE DOUBLER. INSTALLED NEW REPAIR PER DL ERA 302905-14.

Part: FRAME — CRACKED (FWD CARGO DOOR)

DURING SHOP INSPECTION, A 0.70 INCH CRACK WAS FOUND IN THE INNER RADIUS OF THE FORWARD CARGO DOOR FRAME. THE CRACK IS LOCATED ON THE FORWARD EDGE OF THE DOOR BETWEEN DOOR STOP NR 4 & NR 5. REPAIRED PER ERA 270046-14AD.