N242WA

Part: SKIN — CRACKED (BS 727B-750 S18R) · airframe 52,589 hrs · 38,249 cycles

CRACKS WERE FOUND IN THE FUSELAGE SKIN AT BS 727B-750, STR 18R AT THE CHEM MILL. CRACKS WERE REMOVED AND A DOUBLER INSTALLED PER ER/A 451748-14AD AND THE SRM. REF AD 2004-18-06, 2005-13-30.

Part: SKIN — CRACKED (FUSELAGE) · airframe 50,040 hrs · 36,392 cycles

INSPECTION OF THE FUSELAGE SKIN PER AD 2004-18-06 REVELED A 4 INCH LONG CRACK RUNNING ALONG THE BONDED DOUBLER EDGE AT STRINGER 18L AND FS 727B. THE CRACK WAS REMOVED WITH A CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER ER/A 094729-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 50,040 hrs · 36,392 cycles

INSPECTION OF THE SKIN PER AD 2004-18-06 REVEALED A 4.7 INCH CRACK ALONG THE BONDED DOUBLER LINE JUST ABOVE STRINGER 24L BETWEEN FS 937 & 947. THE CRACK WAS ADJACENT TO AN EXISTING REPAIR DOUBLER FOR ANOTHER SKIN CRACK CUTOUT. THE CRACK WAS REMOVED WITH A CUTOUT AND THE EXISTING REPAIR WAS REMOVED. THE NEW AND PREVIOUS CUTOUT WERE REPAIRED WITH 2 EXTERNAL ALUMINUM DOUBLERS PER ER/A 094732-14AD.

Part: TRANSCEIVER — FAILED (WX RADAR) · airframe 48,845 hrs · 35,512 cycles

WX RADAR FAILED ON T/O. REPLACED R/T UNIT.

Part: PROXIMITY SENSOR — FAILED (NR 6 SLAT) · airframe 48,531 hrs · 35,270 cycles

DISCONTINUED T/O AT 30 KTS FOR NR 6 SLAT IND. REPLACED NR 6 SLAT PROX SENSOR.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

SCRIBE MARKS WERE NOTED IN THE LOWER SKIN AT THE S10L LAP SPLICE BETWEEN BS 259 AND 291. DAMAGE WAS REMOVED AND REPAIRED PER ERA 386027-14.

Part: FITTING — CORRODED (VERTICAL STAB) · airframe 48,208 hrs · 35,020 cycles

DURING ACCOMPLISHMENT OF 03-085220-03 CORROSION WAS NOTED ON THE TWO VERT STAB FIN LUGS. ADDITIONALLY, TWO FUSELAGE CLEVIS LUGS WERE NOTED AS HAVING LUG THICKNESSES BELOW THAT ALLOWED BY 03-085220-03. CORROSION REMOVED AND LUGS/CLEVISES REWORKED PER ERA 386006-14.

Part: SKIN — CORRODED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

CORROSION WAS NOTED IN THE FUSELAGE SKIN AT S27L BETWEEN BS 947.50 TO 967. CORROSION WAS REMOVED AND AREA REPAIRED PER ERA 386110-14.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

SCRIBE MARKS WERE NOTED IN THE LWR SKIN AT LAP SPLICE LOCATED AT S14L BETWEEN BS 345 TO BS 360. SCRIBE MARKS REMOVED AND AREA REPAIRED PER ERA 088065-14.

Part: BEAM — CRACKED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

A CRACK INDICATION WAS NOTED IN THE BS 616 STUB BEAM WEB. CRACK INDICATION WAS REMOVED THE REWORKED/REPAIRED PER ERA 386098-14.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

THE LOWER SKIN OF THE STRINGER 10R LAP JOINT WAS FOUND SCRIBED ALONG THE LENGTH OF THE PANEL FROM FS 330-360. THE SCRIBED SECTION OF SKIN WAS CUT AND REMOVED. THE AREA WAS REPAIRED WITH 2 EXTERNAL ALUMINUM REPAIR DOUBLERS PER ER/A 386026-14.

Part: BULKHEAD — CORRODED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

CORROSION WAS NOTED ON THE BS 1016 PRESSURE BULKHEAD, AT BL 0 AND AFFECTED BOTH THE WEB AND CHANNEL STIFFENERS. CORROSION WAS REMOVED AND DAMAGE REPAIRED PER ERA 385929-14.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

SCRIBE MARKS FOUND ON THE LOWER SKIN OF THE LAP SPLICE AT S10L, BETWEEN BS 908 TO 1016. A NEW SKIN PANEL IS TO BE INSTALLED. HOWEVER, THE NEW PANEL WAS NOTED TO HAVE DISCREPANCIES. THE SUBJECT SKIN PANEL WAS REWORKED AT BS 908, S-14L PER ERA 386020-14, IN ORDER TO INSTALL THE SUBJECT PANEL.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

SCRIBE MARKS WERE FOUND AT THE LAP JOINT LOCATED AT S10R, BETWEEN BS 259 TO BS 290. DAMAGE WAS REMOVED AND REPAIRED PER ERA 386028-14.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

SCRIBE MARKS FOUND IN THE LOWER SKIN OF THE LAP SPLICE AT S10L BETWEEN BS 908 AND 1016. THE SKIN PANEL WAS BEING REPLACED. THE NEW PANEL WAS NOTED AS HAVING SEVERAL DISCREPANCIES FROM THE MANUFACTURER. DISCREPANCIES WERE NOTED ALONG THE S20L LAP AND WERE REWORKED IAW ERA 386019-14.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

THE LOWER SKIN OF THE STRINGER 14L LAP JOINT WAS FOUND WITH A SCRIBE LINE ALONG THE PANEL LENGTH FROM FS 360-540. THE LAP JOINT AND SCRIBE WERE COMPLETELY CUT OUT TO REMOVE ALL DAMAGE. THE AREA WAS RESTORED WITH 2 EXTERNAL ALUMINUM REPAIR DOUBLERS PER BAC S/B 737-53-1177 AND ER/A 087863-14.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

THE LOWER FUSELAGE SKIN OF THE STRINGER 14L SKIN LAP JOINT WAS FOUND SCRIBED ALONG THE LENGTH OF THE PANEL FROM FS 727 TO FS 908. THE LAP JOINT AND SCRIBE LINE WERE REMOVED WITH A CUTOUT. THE AREA WAS REPAIRED WITH TWO EXTERNAL ALUMINUM REPAIR DOUBLERS PER BAC S/B 737-53-1177 AND ER/A 087865-14.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

THE LOWER SKIN OF THE STRINGER 14R SKIN LAP JOINT WAS FOUND WITH A SCRIBE ALONG THE LENGTH OF THE PANEL FROM FS 727 TO FS 908. THE LAP JOINT AND SCRIBE WERE CUT OUT AND REPAIRED WITH 2 EXTERNAL ALUMINUM DOUBLERS PER BAC S/B 737-53-1177 AND ER/A 087866-14.

Part: SKIN — DAMAGED (FUSLEAGE) · airframe 48,208 hrs · 35,020 cycles

THE LOWER SKIN PANEL AT THE STRINGER 10L SKIN LAP JOINT WAS FOUND WITH A SCRIBE LINE ALONG THE PANEL LENGTH FROM FS 345 TO FS 360. THE LOWER SKIN WAS CUT BELOW THE SCRIBE AND THE DAMAGED SECTION REMOVED. THE CUT AND LAP JOINT WERE REPAIRED WITH 2 EXTERNAL ALUMINUM REPAIR DOUBLERS PER ER/A 386029-14, REV A.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

THE LOWER SKIN OF THE STRINGER 10R SKIN LAP JOINT WAS FOUND WITH A SCRIBE LINE ALONG THE PANEL LENGTH FROM FS 360 TO FS 540. THE SKIN LAP JOINT WAS CUT OUT TO REMOVE THE LAP AND THE SCRIBE MARK. THE AREA WAS THEN REPAIRED WITH TWO EXTERNAL ALUMINUM DOUBLERS PER BAC S/B 737-53-1177 AND ER/A 087862-14.

Part: SKIN — SCRATCHED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

THE LOWER SKIN OF THE STRINGER 10R SKIN LAP JOINT WAS FOUND WITH A LIGHT SCRIBE MARK ALONG THE LENGTH OF THE PANEL FROM FS 540-727. THE LAP JOINT WAS UNFASTENED, SEPARATED, ALL DAMAGE REMOVED THROUGH MACHINING, AND THOROUGHLY INSPECTED TO ENSURE NO CRACKS OR FURTHER DAMAGE. THE JOINT WAS THEN REASSEMBLED. THE REPAIR WAS ACCOMPLISHED PER ER/A 087869-14.

Part: LAP JOINT — SCRATCHED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

THE LOWER SKIN OF THE STRINGER 10L SKIN LAP JOINT WAS FOUND WITH A LIGHT SCRIBE MARK ALONG THE PANEL LENGTH FROM FS 540 - FS 727. THE LAP JOINT WAS DISASSEMBLED, INSPECTED, ALL DAMAGE MACHINED AWAY, RE-INSPECTED AND RE-ASSEMBLED. THE REPAIR WAS ACCOMPLISHED PER ER/A 087868-14.

Part: LAP JOINT — SCRATCHED (FUSELAGE) · airframe 48,208 hrs · 35,020 cycles

INSPECTION OF THE LOWER SKIN OF THE STRINGER 10R SKIN LAP JOINT BETWEEN FS 727 & 908 REVEALED A SCRIBE LINE ALONG THE LENGTH OF THE PANEL. THE ENTIRE LAP JOINT ALONG THE PANEL LENGTH WAS CUT AND REMOVED AND REPAIRED WITH EXTERNAL ALUMINUM DOUBLERS. THE REPAIR WAS ACCOMPLISHED PER BAC S/B 737-53A1177 AND ER/A 087849-14.

Part: DRAIN — FAILED (FUSELAGE) · airframe 45,625 hrs · 33,821 cycles

ON CLIMBOUT NOTICED EXCESSIVE CABIN CLIMB RATE. LEVELED OFF AT 10000 FT. CABIN CONTINUED TO CLIMB TO 10000 FT. OUTFLOW VALVE SHOWED FULL CLOSED. FORWARD OUTFLOW VALVE SHOWS FULL CLOSED. COULD NOT CONTROL CABIN ALTITUDE AT ALL IN DESCENT. REPLACED SEVERAL FUSELAGE DRAINS.

Part: SKIN — CRACKED (FUSELAGE) · airframe 45,549 hrs · 33,788 cycles

THE SKIN AT THE UPPER HINGE CUTOUT OF THE AFT GALLEY DOOR (R2) CUTOUT WAS FOUND WITH A .375 INCH TYPICAL CRACK. THE CRACK WAS CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL DOUBLER PER ER/A 383941-14, REV A.

Part: TIRE — SEPARATED (RT MLG) · airframe 45,547 hrs · 33,787 cycles

NR 4 TIRE TREAD SEPARATION ON T/O FROM FLL. OUTBOARD GEAR DOOR MISSING WITH DAMAGE TO NR 2 ENGINE NACELLE AND RIGHT FLAP ASSEMBLY ONLY MINOR BUMP FELT ON T/O ROLL PRIOR TO ROTATION. REPLACED BOTH RIGHT MAIN WHEEL ASSY, REPLACED DOOR, RPD NACELLE.

Part: WIRE — CHAFED (CABIN) · airframe 44,704 hrs · 33,444 cycles

ON ARRIVAL FOUND RIGHT OVERWING EMERGENCY EXIT SIGN INOP. REPLACED EXIT SIGN OVERHEAD BATTERY AND BATTERY POWER SUPPLY, REPAIRED CANNON PLUG WIRING AT POWER SUPPLY DUE TO CHAFED WIRING. ALL CHECK NORMAL.

Part: COALESCER BAG — DIRTY (A/C BAY) · airframe 43,479 hrs · 32,938 cycles

WITH POWER APPLIED THERE WAS A SMELL LIKE BURNING RUBBER. SMELL DISSIPATED WITH POWER BACK, NO INDICATIONS. RAN BOTH ENGS TO T/O POWER WITH PACKS ON, ANTI-ICE ON. CHECKED AIR MIX DISTRIBUTION PLENUM IN FWD B/B, NO CRACKS. REPLACED BOTH WATER SEPARATOR BAGS, LEAK CHECKS OK.

Part: ODOR — DETECTED (CABIN) · airframe 43,479 hrs · 32,938 cycles

WITH POWER APPLIED HAD A SMELL LIKE BURNING RUBBER. DISSIPATED WITH POWER BACK, NO INDICATIONS. RAN BOTH ENGINES TO T/O POWER WITH PACKS ON, NO SMELL. CHECKED AIR MIX DISTRIBUTION PLENUM IN FWD BAG BIN, NO CRACKS OR LEAKS. REPLACED RIGHT AND LEFT WATER SEPARATOR BAGS. LEAK CHECK OK.

Part: DOUBLER — CRACKED (WING BOX) · airframe 42,011 hrs · 32,306 cycles

INSPECTION OF THE LONGITUDINAL FLOORBEAM AT RBL 24 ABOVE THE CENTER WING BOX REVEALED A CRACK IN THE REINFORCING DOUBLER OF THE BEAM WEB AT FS 678 ADJACENT TO A CABLE CUTOUT.

Part: SAFETY SWITCH — FAULTY (MLG) · airframe 41,880 hrs · 32,249 cycles

A/C DEPRESSURIZED, HAD TO DESCEND TO CONTROL CABIN. CABIN ALTITUDE REACHED 13,000 FEET WITH A/C DESCENDING BACK DOWN THROUGH 13,000 FEET AND THEN DESCENDED WITH AIRCRAFT TO TOUCHDOWN. REPLACED LDG SAFETY SWITCHES. OPS CHECKS GOOD.

Part: OUTFLOW VALVE — FAILED (CABIN PRESSURE) · airframe 41,792 hrs · 32,208 cycles

AT 23,000 FEET STARTED TO FEEL CABIN RISING AND GOT THE ALT HORN. CABIN WAS AT 11,000 FEET AND CLIMBING 1000 FPM. STARTED DESCENT AUTO SYS FAILED TO STBY BUT CABIN KEPT CLIMBING UNTIL A/C PASSED THROUGH ACTUAL ALTITUDE. REPLACED PRESSURE CONTROLLER AND AFT OUTFLOW VALVE PER MM.

Part: SKIN — CRACKED (FUSELAGE) · airframe 40,647 hrs · 31,711 cycles

A CRACK WAS FOUND IN THE SKIN AND UNDERLYING BEARSTRAP AT THE LOWER FWD CORNER OF THE L2 DOOR CUTOUT. THE CRACK WAS REMOVED WITH A 1.25 INCH DEEP CUTOUT. THE CUTOUT WAS REPAIRED WITH THREE EXTERNAL ALUMINUM DOUBLERS PER ER/A 380029-14.

Part: SKIN — GOUGED (FUSELAGE) · airframe 39,337 hrs · 31,160 cycles

THE LOWER FWD CORNER OF THE AFT GALLEY DOOR CUTOUT WAS FOUND WITH A DEEP GOUGE. THE GOUGE WAS LOCATED 2 INCHES ABOVE THE TYPICAL CRACK LOCATION FOR THIS CORNER. THE GOUGE WAS TRIMMED OUT OF THE SKIN AND BONDED DOUBLER. THE CUTOUT WAS REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER AND TRIPLER. INSTALLED PER ER/A 378758-14, REV B. THE REPAIR IS SIMILAR TO B737 SRM 53-30-3, FIG 24.

Part: GUIDE — DAMAGED (NR 2 SLAT) · airframe 38,857 hrs · 30,950 cycles

NR 2 SLAT INBOARD GUIDE BROKE ON TAKEOFF. PUNCTURED SLAT AND CAUSED SHEET METAL DAMAGE ON A/C AND SLAT ITSELF. REPLACED SLAT AND REPAIRED DAMAGE.

Part: PANEL — MISSING (NR 1 PYLON) · airframe 38,550 hrs · 30,814 cycles

UPON ARRIVAL FOUND 01 O/B PYLON PANEL 5126L MISSING. REPLACED SAME.

Part: ANGLE — CORRODED (FUSELAGE)

THE INNER CHORD ANGLE OF THE R1 DOOR SILL WAS FOUND CORRODED. A 1.5 X 1.0 CUTOUT WAS USED TO REMOVE THE DAMAGE. THIS WAS FOUND AT MV AND REPAIRED PER ERA 333863-14.

Part: STRINGER — CRACKED (FUSELAGE)

THE LT STR 18A HAD A CRACK RUNNING FWD AND AFT SIMILIAR TO THOSE NOTED IN S/B 737-53-1170 AND 737-53-1066. THE DAMAGE WAS FOUND AT MV AND REPAIRED PER ERA 333890-14.

Part: SKIN — GOUGED (BS 492)

THE FUSELAGE SKIN WAS GOUGED AT THE C-1 DOOR, FS 492 AND STR 23R. THE DAMAGE WAS FOUND AT HMV AND REPAIRED PER ERA 333902-14.

Part: BULKHEAD — CRACKED (BS 178)

TWO CRACKS WERE FOUND IN THE FS 178 BULKHEAD WEB. THE DAMAGE WAS FOUND AT MV IN ATL AND REPAIRED PER ERA 333854-14.

Part: SKIN — DENTED (BS 425)

THE FUSELAGE SKIN WAS FOUND DENTED AT FS 425 BETWEEN STR 14L AND 15L. THE DAMAGE WAS FOUND AT MV IN ATL AND REPAIRED PER ERA 333892-14.

Part: STRINGER — CRACKED (FUSELAGE)

THE RIGHT STR 18A HAD A CRACK IN THE SHEAR WEB SIMILAR TO THAT OF S/B 737-53-1170. DAMAGE WAS FOUND AT AMV IN ATL. DAMAGE WAS REPAIRED PER ERA 333859-14.

Part: SKIN — DAMAGED (BS 440)

FUSELAGE SKIN JUST FWD OF C-1 DOOR CUTOUT AT BS 440 WAS FOUND CRACKED IN TWO PLACES BETWEEN S-22R AND 24R. REPAIR ENLARGED TO ENCOMPASS STATIC PORT, ER/A 333852-14 REV A.

Part: RETRACT MECH — MALFUNCTIONED (NR 2 LE SLAT)

DURING FLIGHT, NR 2 SLAT WOULD NOT RETRACT FULLY. COCKPIT INDICATIONS SHOWED NR 2 RETRACTED. DURING EXTENSION FROM 1-5 DEGRESS IT DID NOT EXTEND, BUT FROM 5-10 DEGREES IT SLAMMED TO FULL EXTEND AND THEN RETRACTED TO EXT WITH ASSOCIATED L/E INTRANSIT LIGHT AND OVERHEAD AMBER IND. ALL OTHER FLAPS/SLATS OPERATED NORMALLY. FOUND I/B PROGRAM TRACK ATTACH POINT ON SLAT BROKEN. REPLACED SLAT, ACTUATOR, CLOSEOUT DOOR, 2 HYDRAULIC LINES AND MADE SHEET METAL REPAIR TO INBOARD SLAT TRACK CUTOUT PER M/M.

Part: SKIN — CRACKED (BS 332)

FUSELAGE / SKIN ASSY / R1 DOOR CUTOUT / LOWER AFT CORNER / FS 332 : CRACK REPAIR. THE R1 DOOR CUTOUT WAS FOUND WITH A .375 INCH LONG TYPICAL CRACK IN THE LOWER AFT CORNER (FS 332). THE CRACK WAS THROUGH THE SKIN ASSY AND BEAR STRAP. THE CRACK WAS ROUTED OUT AND REPAIRED WITH THREE EXTERNAL ALUMINUM DOUBLERS PER ER/A 367813-14, REV A.

Part: SKIN — CRACKED (BS 951)

THE FUSELAGE SKIN AND BONDED DOUBLER AT THE AFT GALLEY DOOR (R2) CUTOUT WAS FOUND WITH A .25 INCH LONG TYPICAL CRACK IN THE LOWER HINGE CUTOUT. THE UNDERLYING BEAR STRAP WAS NOT CRACKED. THE CRACK WAS ROUTED OUT OF THE SKIN ASSY AND REPAIRED WITH AN EXTERNAL DOUBLER PER B737 SRM 53-30-3, FIG 35. ER/A 366744-14, REV A WAS ISSUED TO ACCOMPLISH THE REPAIR WITH FASTENER DEVIATIONS.

Part: BEARING — FAILED (COCKPIT)

STAB TRIM JAMMED IN FLT AT 2 DEGS NOSE DOWN TRIM. FOUND CROSSOVER SHAFT AND BEARINGS SEVERLY DAMAGED. REPLACED SHAFT, BEARINGS AND STAB TRIM SPROCKET PER M/M, CKS NML.

Part: FAN — FAILED (COCKPIT)

SMOKE IN THE COCKPIT AFTER LDG IN ICT, ABOUT THE SAME TIME THE CONTROL CABIN AUG FAN C/B POPPED. CONTRACT MTC INSPECTED FAN AND TESTED A/C SYS, PLACED THE AUG FAN ON MCO. FAN WAS LATER REPLACED.

Part: FLOOR PANEL — CORRODED (BS 500-520)

AT HMV INSPECTION, FOUND THE FORWARD B/B LT FIXED FLOOR PANEL CORRODED AT STA 500-520. CORRECTION: REMOVED FIXED FLOOR. REPLACED FIXED FLOOR. INSTALLED FIXED FLOOR PANEL.

Part: EEL WIRE — DAMAGED (CABIN)

FOUND EMERGENCY FLOOR TRACK LIGHT MISSING AT ROW 10, AND TRACK WIRING IN POOR CONDITION. REPLACED LIGHT AND REPAIRED WIRING AS NECESSARY, OPERATION NORMAL.

Part: SPOILER — DAMAGED (RT WING)

FOUND DURING LETTER CHECK, INBD LOWER SIDE OF GROUND SPOILER DAMAGED. REPAIRED PER SRM 57-50-5 PAINTED AREA.