N245US

Part: CARRIAGE — CRACKED (SPINDLE) · airframe 53,816 hrs · 46,526 cycles

DURING ROUTINE ACCOMPLISHMENT OF ULTRASOUND INSPECTION OF THE SPINDLES ON THE OB FLAPS IAW AD 2003-24-08 FOUND THE RT IB SPINDLE TO SHOW A CRACK INDICATION. LAST ULTRASONIC INSPECTION PERFORMED 46 CYCLES AGO. REPLACED SPINDLE AND CARRIAGE ASSEMBLY WITH NEW P/N 65C80736-712.

Part: SKIN — MISREPAIRED (FUSELAGE) · airframe 53,755 hrs · 46,481 cycles

DURING OWNER REQUEST FOR REPLACEMENT OF FUSELAGE SKIN BS 907 - 1016, STR 20L - 25L (P/N 65C80736-834) TO ELIMINATE PREVIOUS PERMANENT AND TEMPORARY SKIN REPAIRS, DISCOVERED NON-STANDARD REPAIR AT BS992.80, STR 20L IDENTIFIED AS A CUTOUT IN THE ADJACENT UPPER SKIN. INSTALLED NEW REPAIR PER BOEING REPAIR INSTRUCTION 1-248459651-6, REFERENCE BOEING ISSUED FAA FORM 8100-9, DATED 30 NOV 2006.

Part: TORQUE TUBE — CORRODED (ZONE 600) · corrosion level 2 · airframe 54,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE CHECK WHILE PERFORMING 10 YEAR CPCP REQUIREMENTS TO THE TRAILING EDGE FLAP CARRIAGES FOUND NR 5 FLAP CARRIAGE OUTER TORQUE TUBE TO BE CORRODED. LEVEL 2. REPLACED WITH SERVICABLE UNIT V/S REPAIR FOR CUSTOMER CONVENIENCE.

Part: CARRIAGE — CORRODED (WING) · corrosion level 2 · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE INSPECTION WHILE PERFORMING 10 YEAR CPCP INSPECTION REQUIREMENTS TO THE TRAILING EDGE FLAP CARRIAGES FOUND THE NR 5 CARRIAGE OTBD CARRIAGE HALF TO BE CORRODED. LEVEL 2. REPLACED WITH SERVICABLE UNIT V/S REPAIR FOR CUSTOMER CONVENIENCE.

Part: TORQUE TUBE — CORRODED (WING FLAP) · corrosion level 2 · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE CHECK WHILE PERFORMING 10 YEAR CPCP INSPECTION REQUIREMENTS TO THE TRAILING EDGE FLAP CARRIAGES FOUND THE NR 5 CARRIAGE INNER TORQUE TUBE TO BE CORRODED. LEVEL 2. REPLACED WITH SERVICEABLE UNIT V/S REPAIR FOR CUSTOMER CONVENIENCE.

Part: CARRIAGE — CORRODED (TE FLAP) · corrosion level 2 · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE CHECK WHILE PERFORMING 10 YEAR CPCP REQUIREMENTS TO TRAILING EDGE FLAP CARRIAGES FOUND NR 5 CARRIAGE, INBD CARRIAGE HALF CORRODED. LEVEL 2. REMOVED AND REPLACED WITH SERVICEABLE UNIT V/S REPAIR FOR CUSTOMER CONVENIENCE.

Part: CASE — CRACKED (NR 2 ENGINE) · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE INSPECTION FOUND CRACKED OUT SECTION IN REAR EXHAUST CASE OF NR 2 ENGINE. REPLACED WITH OVERHAULED UNIT.

Part: SKIN — DENTED (FUSELAGE) · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY CHECK INSPECTION DISCOVERED 9 CREASE/DENTS ON EXTERIOR SKIN AT STA 305 - 372, STR 23R - STR 24R. REPAIRED EXTERIOR SKIN IAW B 737 SRM FIGURE 48, DETAIL XXIX AND XIX.

Part: BOLT — CRACKED (LT MLG) · airframe 53,581 hrs · 46,357 cycles

DURING INSPECTION REQUIREMENTS OF AD2005-20-39, SB737-32A1367 FOUND LT MLG TEE BOLT, P/N 65-46140-6SPL, S/N XZ865 CRACKED AT RADIUS OF LARGEST BEARING SURFACE CIRCUMFERENCE. UNIT HAD TOTAL HOURS OF 29571, TOTAL CYCLES 22830. LAST OVERHAULED 1998 WITH ACCUMULATION OF 9248 HOURS AND 5265 CYCLES SINCE OVERHAUL. CRACK WAS AROUND 80% OF CIRCUMFERENCE. REPLACED WITH SERVICABLE UNIT.

Part: SKIN — MISDRILLED (FUSELAGE) · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE INSPECTION FOUND SNOWMAN SHAPED HOLE WITH A SOLID AND CHERRY MAX IN IT AT STA 727A, STR 26L. REPAIR PATCH AND DOUBLER INSTALLED PER BOEING ENGINEERING 1-185416133. FAA FORM 8109-9.0

Part: SKIN — CRACKED (FUSELAGE) · airframe 53,381 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE INSPECTION FOUND SKIN CRACK UNDER RT WING TO BODY FAIRING AT STA 727B, STR 19R. REMOVED EXSISTING ADJACENT PATCH AT STA 727A, STR 18R. INSTALLED PATCH, INCORPORATING OLD REPAIR AND NEW DAMAGE IAW B737 SRM FIG. 48, 55-30-3 AND BOEING ENGINEERING 1-185385517-1.

Part: CARRIAGE — CORRODED (WING) · corrosion level 2 · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE CHECK WHILE PERFORMING CPCP 10 YEAR REQUIREMENTS TO THE TRAILING EDGE FLAP CARRIAGES FOUND THE NR 3 TRAILING EDGE FLAP CARRIAGE IB CARRIAGE HALF TO HAVE LEVEL 2 CORROSION. REMOVED AND REPLACED WITH NEW UNIT V/S REPAIR FOR COMPANY CONVENIENCE.

Part: CARRIAGE — CORRODED (ZONE 500) · corrosion level 2 · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE CHECK WHILE PERFORMING A 10 YEAR CPCP INSPECTION REQUIREMENTS OF THE TRAILING EDGE FLAP CARRIAGES FOUND LEVEL 2 CORROSION ON NR 3 CARRIAGE OB CARRIAGE HALF. REPLACED WITH NEW HALF V/S REPAIR FOR COMPANY CONVENIENCE.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 1 · airframe 53,581 hrs · 46,357 cycles

DURING HEAVY MAINTENANCE INSPECTION FOUND CORROSION AT STR 28 LT, STA 1000 TO 1006. CORROSION FOUND TO BE BEYOND LIMITS. STRINGER REPLACED I.A.W. B737 SRM 53-10-2 AND 51-10-1 PG. 9 PARA 7. STRINGER REPLACED STA 986 - 1016 PLUS/MINUS 28". ORIGINAL SPLICE REUSED. SPLICE PIECE CLEANED AND PAINTED. LEVEL 1 CPCP ISOLATED TO LAV LEAK AND NOT EXPERIENCED ACROSS THE FLEET.

Part: SKIN — CRACKED (FUSELAGE) · airframe 53,253 hrs · 46,102 cycles

DURING ROUTINE MAINTENANCE FOUND A 3 INCH CRACK IN THE FUSELAGE SKIN AT BS 973, STR 21L. INSTALLED TEMPORARY REPAIR DOUBLER IAW 8110-3 APPROVED REPAIR, REFERENCE DWG 33-05565-1.

Part: SPINDLE — CRACKED (FLAP CARRIAGE) · airframe 53,253 hrs · 46,102 cycles

DURING ROUTINE NDT INSPECTION OF OB FLAP SPINDLE IAW AD 2003-24-08 AND SB 737-57A1277 FOUND A FLAP CARRIAGE SPINDLE CRACKED 40 PERCENT AT THE RADIUS OF THE YOKE TO THE FIRST BEARING LAND. FLAP CARRIAGE ASSEMBLY REPLACED WITH A NEW UNIT. RECORDS INDICATE 5221 CYCLES SINCE OVERHAUL.

Part: SKIN — GOUGED (BS1036,STR8L) · airframe 53,140 hrs · 46,015 cycles

DURING ROUTINE INSPECTION FOUND A GOUGE IN THE SKIN AT BS 1036.5, STR 8L. REPAIRED IAW MFG MESSAGE 1-115922448-4 AND SRM 53-30-3, FIG. 50. BLENDED, REMOVED DAMAGE, EDDY CURRENT INSPECTED FOR CRACKS AND INSTALLED AN EXTERNAL DOUBLER IAW MESSAGE AND SRM REFERENCED.

Part: MODULE — MALFUNCTIONED (FUEL SYSTEM) · airframe 52,656 hrs · 45,636 cycles

"NR 2 ENG FUEL FILTER ICING LIGHT ILLUMINATED INFLIGHT FL 320. FOLLOWED PROCEDURE LIGHT REMAINED ILLUMINATED. RETURNED TO ANC" THIS WAS A REPEAT WRITE-UP. CONTINUITY CHECK AND INSPECTION OF ALL ACCESSIBLE WIRING NORMAL. REPLACED FUEL MODULE , (AFTER TESTING BY VENDOR) REPLACED FUEL PRESSURE SWITCH P/N 42D185 WITH NEW UNIT AND REPLACED FUEL PRESSURE SWITCH CANNON PLUG WITH NEW. OPERATIONAL CHECK FLIGHT CONDUCTED WITH NO FAULTS OBSERVED. AIRCRAFT RETURNED TO SERVICE 12-10-04.

Part: FUEL FILTER — ICED (NR 2 ENGINE) · airframe 52,668 hrs · 45,657 cycles

DURING CRUISE NR 2 ENGINE FILTER ICING LIGHT CAME ON AND WOULD NOT CLEAR WITH FUEL HEAT. OTHER ENGINE PARAMETERS INDICATE FUEL HEAT WAS OPERATIVE WITH ENGINE OPERATION NORMAL. UNEVENTFUL RETURN TO DEPARTURE AIRPORT. REMOVED AND REPLACED NR 2 ENGINE MAIN FUEL FILTER IAW WITH , MM 73-11-01 WITH GOOD ENGINE RUN. NOTE: REMOVED FILTER VISUALLY HAD SLIGHT AMOUNT OF DEBRIS PRESENT.

Part: LIGHT — CORRODED (EXTERIOR) · airframe 52,490 hrs · 45,515 cycles

L2 DOOR EXTERIOR LIGHT INOP. REMOVED AND REPLACED L2 EXTERIOR EMERGENCY LIGHT IAW B737 M/M 33-51-61 - OPS CH'D GOOD.

Part: LIGHT — FAILED (PAX CABIN)

LGA - THE AFT SERVICE DOOR EMERGENCY EXIT SIGN WAS INOPERATIVE. MAINTENANCE REPLACED THE EMERGENCY LIGHT ASSEMBLY. (M)

Part: BATTERY PACK — DISCHARGED (FWD CABIN)

BDL - MAINTENANCE FOUND THE L1 AND R1 DOOR EMERGENCY EXIT IDENTIFIER LIGHTS DIM DURING TEST. MAINTENANCE REMOVED AND REPLACED THE BATTERY PACK. OPERATIONAL CHECK GOOD. (M)

Part: ACCESSORY UNIT — FAILED (E/E BAY)

BWI - FLT 2735 - UPON GEAR EXTENSION INTO BWI, CREW RECEIVED THREE GREEN AND THREE RED GEAR LIGHTS. CREW ENSURED GEAR HANDLE WAS IN DOWN DETENT. AFTER RECYCLING GEAR, CREW RECEIVED NORMAL THREE GREEN GEAR LIGHTS AND NO RED LIGHTS. FLIGHT LANDED AT BWI WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE LANDING GEAR LEVER SWITCH (P/N MS25383-1) AND THE LANDING GEAR ACCESSORY UNIT. PERFORMED GEAR SWING. OPERATIONAL CHECK GOOD. (M)

Part: FITTING — CORRODED (REAR SPAR)

CLT - FOUND REAR SPAR FITTING CORRODED 4 INCHES, RT HINGE ATTACH CLEVIS. CORROSION LEVEL 1 C53-701-02. SPOT FACED INBOARD/OUTBOARD CLEVIS PER EA 68752. (M)

Part: FITTING — CORRODED (REAR SPAR)

CLT - FOUND FITTINGS SPAR CORRODED 4 INCHES, REAR SPAR HINGE FITTING LT CLEVIS AND LUG. CORROSION LEVEL 1 C53-701-02. SPOT FACED LUG PER EA 68689. (M)

Part: FRAME — CRACKED (ENTRY DOOR)

CLT - FOUND FRAME CRACKED 3 INCHES, FORWARD ENTRY DOOR BOTTOM FRAME. REPLACED FRAME PER SRM 51-10-1. (M)

Part: STIFFENER — CORRODED (FUSELAGE)

CLT - FOUND STIFFENER CORRODED 7 INCHES BY 1 INCH, BS 235, RBL 10, WL 195 FORWARD UPPER ACCESS PANEL. INSTALLED ANGLE AND STIFFENER PER SRM 53-10-2 AND 53-30-0. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

TPA - MAINTENANCE FOUND THE EMERGENCY EXIT LIGHTS ON SEAT ROWS 1 THROUGH 8 INOPERATIVE. MAINTENANCE REPAIRED A BROKEN WIRE AT SEAT 8A AND REMOVED AND REPLACED THE BATTERY PACK AT SEAT 17A. OPERATIONAL CHECK GOOD. (M)

Part: STRINGER — CORRODED (FUSELAGE)

CLT - FOUND 2 INCHES OF CORROSION, BS 962, STRINGER 25R INSIDE STRINGER. CORROSION LEVEL 1 C 53-202-01. STRINGER STRAP REPLACED PER SRM 51-30-2. (M)

Part: STRINGER — CORRODED (FUSELAGE)

CLT - FOUND STRINGER CORRODED 3 INCHES, BS 990, STRINGER 25R INSIDE STRINGER. SPLICED REPAIR PER SRM 53-10-3. CORROSION LEVEL 1 C53-202-01. (M)

Part: WEB — CRACKED (FUSELAGE)

CLT - FOUND WEB FLANGE CRACKED 4 INCHES, STATION 727 AFT SIDE LBL 12, 26 INCHES ABOVE STRINGER 26L. REPLACED CRACKED INTERCOSTAL PER SRM 51-10-01. (M)

Part: STRINGER — CRACKED (FUSELAGE)

CLT - FOUND STRINGER CRACKED 1 INCH, STRINGER 27R PLUS 909. REMOVED AND REPLACED DAMAGED PART SPLICE AND FILLER PER EA 68674A. (M)

Part: STRUCTURE — CORRODED (FUSELAGE)

FOUND CORROSION ON T-CAP .250 INCH BY .250 INCH, BS 947, RBL 36 - RBL 52. INSTALLED FILLER AND DOUBLER PER EA 68715. (M)

Part: STIFFENER — CRACKED (BULKHEAD)

CLT - FOUND HORIZONTAL STIFFENER CRACKED 4 INCHES, 727 BULKHEAD, LBL 11 - LBL 12, UP FROM CARGO FLOOR. FABRICATED NEW PART AND INSTALLED PER SRM 51-10-01. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND FRAME CRACKED .5 INCH, BELLY AT STATION 767, BL 0. INSTALLED DOUBLER PER EA 68722. (M)

Part: STRINGER — CORRODED (FUSELAGE)

CLT - FOUND STRINGER CORRODED 3 INCHES, STATION 907, STRINGER 20R. CORROSION LEVEL 1 C53-107-02. INSTALLED STRINGER SPLICE PER SRM 51-10-02 AND 51-10-1. (M)

Part: SHEAR TIE — CORRODED (FUSELAGE)

CLT - FOUND SHEAR TIE CORRODED .5 INCH BY 5 INCHES, BS 767 BETWEEN STRINGER 26R-27R. CORROSION LEVEL 1. INSTALLED DOUBLER PER SRM 53-10-4 9A. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND FRAME CRACKED .25 INCH, STATION 727 BETWEEN STRINGER 14L AND 15L. INSTALLED FILLER AND DOUBLER PER EA 68651. (M)

Part: WEB — CRACKED (FUSELAGE)

CLT - FOUND WEB SIDE CHORD CRACKED .875 INCH, BS 178, LBL 26, WL 207. NEW CHORD SPLICED IN PER EA 68631 AND EO 5300V157. (M)

Part: WEB — CRACKED (FUSELAGE)

CLT - FOUND WEB SIDE CHORD CRACKED .875 INCH, BS 178 RBL 26, WL 207. NEW CHORD SPLICED IN PER EA 68631 AND EO 5300V157. (M)

Part: SKIN — CRACKED (FUSELAGE)

CLT -FOUND FUSELAGE SKIN CRACKED 1.625 INCH, BS 767 PLUS 8 INCHES AND STRINGER 18L. CUTOUT DAMAGED AND INSTALLED EXTERNAL DOUBLER PER SRM 53-30-3. (M)

Part: STRUCTURE — CRACKED (FUSELAGE)

CLT - FOUND VERTICAL CHORD CRACKED .250 INCH, BS 178 AFT SIDE BULKHEAD. NEW CHORD AND DOUBLER INSTALLED PER SRM 53-10-11. (M)

Part: SKIN — CRACKED (FUSELAGE)

CLT - FOUND SKIN CRACKED .25 INCH, BS 326, WL 207 STRINGER 17R. REPAIRED PER SRM 53-30-3. (M)

Part: STRUCTURE — CRACKED (WING BOX)

CLT - FOUND T-CAP AND WEB CRACKED 6 INCHES, STATION 663, BL 0. INSTALLED DOUBLER PER TR 57-10-04. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND FRAME CRACKED .5 INCH, STATION 787, STRINGER 13L. INSTALLED DOUBLER PER SRM 51-40-3 AND TR 53-10-27. (M)

Part: WEB — CRACKED (FUSELAGE)

CLT - FOUND WEB CRACKED 4 PLACES 1 INCH EACH, BS 178, LBL 5.7 FROM WL 195 TO 215. REMOVED DAMAGE PER EA 68663. (M)

Part: WEB — CRACKED (FUSELAGE)

CLT - FOUND WEB CRACKED THREE PLACES .875 INCH, BS 178 WL 218, LBL 12 - LBL 14. NEW WEB AND DOUBLER INSTALLED PER EA 68663 AND SRM 53-10-11. (M)

Part: ANGLE — CRACKED (FUSELAGE)

CLT - FOUND CHORD ANGLE CRACKED .5 INCH, STATION 663, RBL 25, WL 203. SPLICED ANGLES PER EA 68620. (M)

Part: STRAP — CORRODED (FWD CARGO BAY)

CLT - FOUND INNER PLATE/STRAP CORRODED TWO AREAS .75 INCH, INSIDE FORWARD CARGO DOOR CUTOUT. REPLACED STRAP PER SRM 51-10-1. (M)

Part: STRINGER — CRACKED (FUSELAGE)

CLT - FOUND 5 CRACKS IN STRINGER .5 INCH TO .25 INCH, STRINGER 15L, BETWEEN BS 520 AND 540. REPAIRED PER SRM 53-10-3. (M)

Part: ANGLE — CRACKED (FUSELAGE)

CLT - FOUND CHORD ANGLE CRACKED .5 INCH, UPPER CHORD ANGLE STATION 663, LBL 25, WL 203. INSTALLED ANGLE PER EA 68620. (M)

Part: FLOORBEAM — CRACKED (FUSELAGE)

CLT - FOUND FLOORBEAM CRACKED 1 INCH, FLOORBEAM UPPER CHORD STATION 578, LBL 62. INSTALLED UPPER CHORD FLOORBEAM PER SRM 51-10-01. (M)

Part: ATTACH ANGLE — CRACKED (FUSELAGE)

CLT - FOUND FRAME ATTACH ANGLE CRACKED 2 INCHES, STATION 348, STRINGER 15L. REPAIRED PER SRM 51-40-02. (M)

Part: SKIN — CRACKED (FUSELAGE)

CLT - FOUND SKIN CRACKED 3.5 INCH, STATION 952 LOWER FORWARD CORNER AFT ENTRY DOOR. REPAIRED FILLER, DOUBLER, TRIPLER PER SRM 53-30-03. (M)

Part: SKIN — CRACKED (FUSELAGE)

CLT - FOUND SKIN PLATE CRACKED 2.25 INCH, FORWARD STATION 947 STRINGER 22L. REMOVED DAMAGED AND FABRICATED FILLER AND DOUBLER PER SRM 53-30-3. (M)

Part: WINDOW POST — CRACKED (FUSELAGE)

CRACK STA 231.8. CORRECTIVE ACTION: INSTALLED DOUBLER PER SRM 53-30-3

Part: GUSSET — CRACKED (NLG ACTUATOR)

CRACK NOSE GEAR ACTUATOR ATTACH GUSSET. CORRECTIVE ACTION: REPLACED PART PER SRM 51-30-3 & 51-10-1

Part: CREASE BEAM — CORRODED (FUSELAGE)

CORROSION LEVEL 1 1 CREASE BEAM S935 TO S990 WL 208CORRECTIVE ACTION: REPLACED CREASE BEAM PER SRM 51-10-1

Part: FLOORBEAM — CRACKED (FUSELAGE)

CRACK LBL 25 FLOORBEAM AT LWR FAST.S707-712, W1202.5. CORRECTIVE ACTION: FABRICATED DOUBLER PER EA 68629

Part: FRAME — CRACKED (FUSELAGE)

CRACK STA 767 STR 13R FUSE. FRAME SPLICE RIVET. CORRECTIVE ACTION: FABRICATED REPAIR ANGLE & FILLER INSTALLED PER SRM 53-10-7 & 51-40-3

Part: ANGLE — CORRODED (FUSELAGE)

CORROSION LEVEL 1 BS 298-BS360, RBL 64. CORRECTIVE ACTION: REMOVED SURFACE CORROSION PER SRM 51-10-02

Part: FLOORBEAM — CORRODED (FUSELAGE)

CORROSION LEVEL 1 LOWER SURFACE UPPER FLOORBEAM BS 324, LBL 12CORRECTIVE ACTION: REPLACED FLOORBEAM SUPPORT PER SRM 51-10-2

Part: STIFFENER — CRACKED (FUSELAGE)

CRACKED LBL 15 LONGITUDINAL STIFFENER STA 726 WL 202. CORRECTIVE ACTION: REPLACED ANGLE PER SRM 51-30-3

Part: FRAME — CRACKED (FUSELAGE)

FRAME CRACKED BS767, STR 13 & 14L. CORRECTIVE ACTION: FILLER & DOUBLER INSTALLED PER TR 53-10-27

Part: TIE CLIP — CRACKED (STA 747 STR 3R)

TIE CLIP CRACKED STA 747 STR 3R. CORRECTIVE ACTION: REPLACED TIE CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED BS 616 STR3. CORRECTIVE ACTION: REPLACED TIE CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

CRACK STA 663 STR 10LCORRECTIVE ACTION: INSTALLED NEW CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED BS 578 STR 3. CORRECTIVE ACTION: REPLACED TIE CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (BS520STR10L)

TIE CLIP CRACKED BS520 STR 10L. CORRECTIVE ACTION: INSTALLED NEW CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (BS639STR3)

TIE CLIP CRACKED BS 639 STR 3. CORRECTIVE ACTION: INSTALLED NEW CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED STA 747 STR 11R. CORRECTIVE ACTION: REPLACED TIE CLIP PER EO5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED STA 767 STR 11. CORRECTIVE ACTION: REPLACED TIE CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED BS520 STR 10R. CORRECTIVE ACTION: INSTALLED NEW CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED STA 787 STR 10L. CORRECTIVE ACTION: INSTALLED NEW CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED BS 639 STR 5. CORRECTIVE ACTION: INSTALLED NEW CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED BS 559 STR 3. CORRECTIVE ACTION: REPLACED TIE CLIP PER EO 5393G227

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED BS400 STR 4R. CORRECTIVE ACTION: REPLACED TIE CLIP PER SRM 51-10-1

Part: TIE CLIP — CRACKED (FUSELAGE)

TIE CLIP CRACKED STA 685 STR 4L. CORRECTIVE ACTION: REPLACED TIE CLIP PER EO5393G227

Part: PUMP — FAILED (HYD SYSTEM)

BOS - FLT 2822 - EN ROUTE FROM MCO-BOS, THE CAPT SENT ACARS MESSAGE THAT THE STANDBY HYDRAULIC LOW QTY LIGHT WAS ILLUMINATED. NO OTHER LIGHTS WERE ON AT THIS TIME AND A DECISION WAS MADE TO PROCEED ON. ON INITIAL APPROACH INTO BOS, THE A-HYDRAULIC SYSTEM DROPPED TO ONE GALLON AND THE CAPTAIN DECLARED AN EMERGENCY. ON SHORT FINAL, THE QTY HAD DROPPED TO A HALF GALLON. FLIGHT LANDED WITHOUT FURTHER INCIDENT AND THE AIRCRAFT TAXIED TO THE GATE. MAINTENANCE REMOVED AND REPALCED THE STANDBY HYDRAULIC PUMP. SERVICED HYDRAULIC SYSTEM. OPS CHECK AND LEAK CHECK GOOD PER MM 29-21-31. (M)

Part: O-RING — FAILED (NR 6 SPOILER)

BWI - FLT 2635 - DURING CRUISE, EN ROUTE FROM BOS TO FLL, FLIGHT LOST SYSTEM A HYDRAULICS. CREW ACCOMPLISHED QUICK REFERENCE HANDBOOK PROCEDURES AND DECLARED AN EMERGENCY. FLIGHT DIVERTED TO BWI AND LANDED WITHOUT INCIDENT. AIRCRAFT WAS TOWED TO THE GATE. MAINTENANCE FOUND A BROKEN O-RING FOR THE NR 6 SPOILER. REPLACED O-RING. ALSO, REMOVED AND REPLACED CASE DRAIN FILTERS FOR SYSTEM A HYDRAULICS. SERVICED HYDRAULIC SYSTEM. OPERATIONAL CHECK AND LEAK CHECK GOOD. (M)

Part: COUPLER — FAILED (E/E BAY)

BWI - FLT 2674 - EN ROUTE FROM TPA TO BOS, AT FL230, A/C ENCOUNTERED SOME LIGHT CHOP AND STARTED TO OSCILLATE. YAW DAMPER APPEARED NORMAL WITH NO LIGHT INDICATIONS. AIRCRAFT CONTINUED TO OSCILLATE. CAPT LEVELED FLT AT FL310 AND TURNED YAW DAMPER OFF. NO CHANGE. TURNED BACK ON AND STILL NO CHANGE. FLEW WITH YAW DAMPER SWITCH OFF.. ENCOUNTERED LIGHT CHOP AGAIN. BASED ON FORECAST FOR TURBULENCE AND WEATHER, CAPT DECIDED TO DIVERT TO BWI. FLT LANDED WITHOUT FURTHER INCIDENT. NO EMERGENCY WAS DECLARED. MX FOUND THE YAW DAMP COUPER HARD FAILED. REMOVED AND REPLACED YAW DAMP COUPLER. FUNCTIONAL CHECK FOUND SATISFACTORY. (M)

Part: BATTERY PACK — DISC HARGED (CABIN)

MCO - MAINTENANCE FOUND THE LOW LEVEL EMERGENCY LIGHTS ATSEAT ROWS 8 THROUGH 16, LEFT SIDE, FAILED TO TEST. MAINTENANCE REMOVED AND REPLACED THE BATTERY PACK. OPERATIONAL CHECK GOOD. (M)

Part: O-RING — FAILED (NR 2 ENGINE)

MCO - FLT 2763 - ON TAKEOFF ROLL, OIL QTY ON THE NR 2 ENGINE WENT FROM 3.6 GALLONS TO 1 GALLONS. THE TOWER ALSO REPORTED SMOKEON TAKEOFF ROLL FROM THE SAME ENGINE. CAPTAIN ELECTED TO RETURN TO FIELD AT MCO. FLIGHT LANDED WITHOUT FURTHER INCIDENT. NO EMERGENCY WAS DECLARED. MAINTENA NCE FOUND THE NR 2 ENGINE MAIN OIL FILTER LEAKING. REPLACED OIL FILTER(P/N ACC 336F1665) AND O-RINGS (P/N RD3018). RAN ENGINE. NO LEAKS NOTED. (M)

Part: ADC — FAILED (E/E BAY)

PIT - FLT 2659 - EN ROUTE FROM CLE TO BWI, CRUISING AT FL 290, THE AIRCRAFT TOOK AN UNCOMMANDED ROLL TO THE RIGHT. ROLL WAS A FULL DEFLECTION, STOPPING AT 35 TO 45 DEGREES. CAPTAIN TOOK CONTROL AND RETURNED AIRCRAFT TO LEVEL FLIGHT. THE AUTOPILOT WAS DISCONNECTED AND THE PROBLEM CEASED. FLIGHT DIVERTED TO PIT AND LANDED WITHOUT FURTHER INCIDENT. NO EMERGENCY WAS DECLARED. MAINTENANCE REMOVED AND REPLACED THE NR 1 AIR DATA COMPUTER. FUNCTIONAL TEST GOOD. ACCOMPLISHED SATISFACTORY TEST FLIGHT. AUTOPILOT CHECKS NORMAL. (M)

Part: SKIN — CRACKED (BS 938)

TPA - DURING CX-4 CHECK VISUAL INSPECTION VERIFIED WITH EDDY CURRENT, FOUND A 3 INCH CRACK IN SKIN STATION 938, STRINGER 24L. INSTALLED DOUBLER PER SRM 53-30-3 FIG 6. (M)

Part: ADC — FAILED (E/E COMPT)

BWI - FLT 2612 - DURING TAKEOFF AND CLIMB-OUT FROM BWI, CAPTAIN REPORTED HE LOST NR 1 AIR DATA COMPUTER AND WINDSHEAR WARNING WAS GOING OFF. PRESSURIZATION WAS LOST IN AUTOMODE AND REGAINED BY SWITCHING OVER TO STANDBY MODE. CAPTAIN PLACED FLIGHT IN HOLDING PATTERN AT 8,000 FEET AND LET FIRST OFFICER FLY ACFT WHILE TRYING TO DETERMINE PROBLEM. CAPT DECLARED AN EMERGENCY AND ELECTED TO RETURN TO BWI. FLIGHT LANDED WITHOUT FURTHER INCIDENT. MAINT REMOVED AND REPLACED THE NR 1 AIR DATA COMPUTER. OPER CHECK NORMAL. RAN ENGINE AND CHECKED ELECTRICAL BUSSES. NO FAULTS NOTED. REPLACED POWER MANAGEMENT SYS COMPUTER (P/N 4050730-921) FOR FAILING TEST. BITE CHECK NORMAL. NO FURTHER DISCREPANCIES REPORTED. (X)

Part: ADC — FAILED (E/E COMPT)

TPA - FLT 2636 - AT ROTATION ON TAKEOFF FROM TPA, CREW RECEIVED THE FOLLWING INDICATIONS, FIRST OFFICER ALTIMETER INDICATED STANDBY AND COULD NOT BE RESET, FIRST OFFICER MACH INOPERATIVE, FIRST OFFICER VSI FLAG, ACARS INOPERATIVE, MACH TRIM FAIL AND ALTITUDE ALERT INOPERATIVE. FLIGHT RETURNED TO FIELD AT TPA AND LANDED WITHOUT FURTHER INCIDENT. NO EMERGENCY WAS DECLARED. REINSTALLED DISCONNECTED PITOT AND STATIC LINES TO AIR DATA COMPUTER. CHECKED BOTH BUSSES FOR PROPER OPERATION. OPS CHECK GOOD. (M)

Part: SKIN — CRACKED (BS 757)

TPA - DURING CX-3 CHECK VISUAL INSPECTION, FOUND A .5 INCH CRACK IN SKIN RIGHT SIDE FUSELAGE STATION 757 AND STRINGER 18R. INSTALLED DOUBLER PER SRM 53-30-3 FIG 6. (M)

Part: SKIN — CRACKED (BS 727)

TPA - DURING CX-3 CEHCK VISUAL INSPECTION, FOUND A 1.5 INCH CRACK IN EXTERNAL SKIN RIGHT SIDE OF FUSELAGE AT STATION 727A PLUS 8 INCHES AND STRINGER 18R. INSTALLED DOUBLER PER SRM 53-30-3 FIG 6. (M)

Part: SKIN — CRACKED (SERVICE DOOR)

TPA - DURING CX-3 CHECK VISUAL, VERIFIED BY EDDY CURRENT INSPECTION, FOUND A .25 INCH CRACK IN FWD SERVICE DOOR EXTERIOR SKIN LOWER HINGE CUTOUT AFT UPPER CORNER. INSTALLED DOUBLER PER TR 52-40-03 A. (M)

Part: SKIN — CRACKED (BS 927)

TPA - DURING CX-6 CHECK VISUAL INSPECTION, FOUND A 3.5 INCH CRACK IN FUSELAGE SKIN RIGHT AFT FUSELAGE STATION 927 AND STRINGER 22R. INSTALLED DOUBLER PER SRM 53-30-3 FIG 6. (M)

Part: LIGHT — INOPERATIVE (FWD ENTRY)

DCA - PILOT REPORTED THAT UPON SHUTDOWN OF ALL POWER, EXCEPT GROUND SERVICE, LEAVES TWO EMERGENCY EXIT LIGHTS ON WHEN BATTERY SWITCH IS TURNED OFF. MAINTENANCE REMOVED AND REPLACED THE FORWARD ENTRY DOOR EMERGNCY EXIT LIGHT ASSEMBLY. ALL CABIN EMERGENCY LIGHTS OPS CHECK NORMAL. (M)

Part: LIGHT — INOPERATIVE (CABIN)

EWR - MAINTENANCE FOUND THE FORWARD MAIN ENTRY DOOR EMERGENCY EXIT INOP. MAINTENANCE REMOVED AND REPLACED THE MAIN ENTRY DOOR EXIT LIGHT ASSEMBLY. OPS CHECK GOOD. (M)

Part: BYPASS SWITCH — FAILED (NR 2 ENGINE)

CLT - FLT 765 - THE NR 2 ENGINE OIL FILTER BYPASS LIGHT ILLUMINATED IN FLIGHT ENROUTE TO CLT. CREW SHUT DOWN THE NR 2 ENGINE, ACCOMPLISHED PROCEDURES IN HANDBOOK AND DECLARED AN EMERGENCY. FLIGHT LANDED AT CLT WITHOUT FURTHER INCIDENT. TOTAL SINGLE ENGINE TIME WAS 18 MINUTES. MAINTENANCE INSPECTED THE NR 2 ENGINE MAIN OIL FILTER FOR CONTAMINATION. NONE FOUND. INSTALLED NEW OIL FILTER. ALSO, REMOVED AND REPLACED THE NR 2 ENGINE OIL FILTER BYPASS SWITCH. LEAK CHECK AND OPERATIONAL CHECK GOOD. ALL ENGINE PARAMETERS NORMAL. (M)

Part: SKIN — CRACKED (BS 845)

ROA - DURING CX-CHECK VISUAL INSPECTION, FOUND 2 INCH CRACK BS 845 STRINGER 19 LEFT FUSELAGE. INSTALLED DOUBLER, REPAIRED PER SRM 53-30-3 FIG 6. (M)

Part: SKIN — CRACKED (BS 950)

ROA - DURING CX-CHECK VISUAL INSPECTION, FOUND 3 INCH CRACK BS 950 STRINGER 24 LEFT FUSELAGE SKIN. INSTALLED DOUBLER, REPAIRED PER SRM 53-30-3 FIG 3. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

MCO - FOUND EMERGENCY EXIT LIGHT INOPERATIVE AT AFT RIGHT SERVICE DOOR (R2). MAINTENANCE REMOVED AND REPLACED BATTERY PACK. OPERATIONAL CHECK GOOD. (X)

Part: BULKHEAD — CRACKED (BS 178)

INT - DURING Q-6 CHECK EDDY CURRENT INSPECTION, FOUND 1.5 INCH CRACKED PRESSURE BULKHEAD STATION 178 WL 202, RBL 7 INCH. INSTALLED REPAIR DOUBLER, REPAIRED PER TR 53-10-11. (M)

Part: SKIN — CRACKED (FUSELAGE)

INT - DURING Q-6 CHECK EDDY CURRENT INSPECTION, FOUND .1875 INCH CRACK AFT SERVICE DOOR UPPER HINGE CUTOUT IN FLANGE SKIN. INSTALLED DOUBLER, REPAIRED PER SRM 53-30-3 FIG 21 A. (M)

Part: BULKHEAD FITTING — CORRODED (BS 663.75)

INT - DURING Q-6 VISUAL INSPECTION, FOUND 3.9 INCH BY .5 INCH BONDED DOUBLER/BULKHEAD FITTING CORRODED AT BS 663.75 AT STRINGER 17R. REMOVED CORROSION AND INSTALLED REPAIR PER EA 41979. (M)

Part: BULKHEAD — CRACKED (BS 178)

INT - DURING Q-6 CHECK EDDY CURRENT, FOUND 2 INCH LONG CRACK PRESSURE BULKHEAD STATION 178, WL 198 RBL 7. INSTALLED REPAIR DOUBLER, REPAIRED PER TR 53-10-11. (M)

Part: SKIN — CRACKED (BS 376)

INT - DURING Q-6 CHECK VISUAL INSPECTION, FOUND 1.25 INCH LONG CRACK IN FUSELAGE SKIN AT EDGE OF EQUIPMENT COOLING EXHAUST OUTLET STATION 376, LBL 2 INCH. STOP DRILLED CRACK, INSTALLED EXTERIOR DOUBLER, REPLACED INTERIOR DOUBLER. REPAIRED PR 51-10-1 SRM, AND 53-30-2 SRM, AND BAC DRAWING NR 65C33930. (M)

Part: STRINGER — CORROSION (BS 939-995)

INT - DURING Q-6 CHECK VISUAL INSPECTION, FOUND 2 INCH BY 56 INCH CORRODED AREA AT STRINGER 27L, BS 939 - BS 995. SPLICED IN NEW SECTION OF STRINGER, REPAIRED PER EA 41963. CORROSION TASK NR C53-202-01, CORROSION LEVEL 2. (M)

Part: STRINGER — CORROSION (BS 902-914)

INT - DURING Q-6 CHECK VISUAL INSPECTION, FOUND CORROSION 1 INCH BY 12 INCH STATION 902 TO STATION 914, STRINGER 26L. INSTALLED REPAIR SPLICE, REPAIRED PER SRM 53-10-3. CORROSION TASK NR C 53-107-02, CORROSION LEVEL 2. (M)

Part: GEAR LIGHT — NO TEST (NLG)

CLT - FLT 2002 - AT FL270 CLIMBING OUT FROM IAD, A LOUD BANG WAS HEARD UNDER THE LT SIDE OF FWD ENTRY DOOR. ENG PARAMETERS AND HYD NORMAL. NOSE WHEEL GREEN LIGHT WOULD NOT TEST. CHECKED LIGHT BULBS, C/B AND SOCKETS. CAPTAIN MADE PRECAUTIONARY DIVERSION TO CLT. CHECKED GEAR SIGHT VIEWER BEFORE FINAL APPROACH. NO EMERGENCY WAS DECLARED AND THE FLIGHT LANDED WITHOUT INCIDENT. ALL GEAR INDICATIONS NORMAL ON LANDING, THREE GREEN AND NO RED. MX INSPECTED LEFT SIDE OF FUSELAGE FOR POSSIBLE BIRD STRIKE DAMAGE. NONE FOUND. PRESSURIZED A/C TO 3 PSI. NO BANGS HEARD. SWUNG GEAR. ALL GEAR INDICATIONS NORMAL. LIGHT PRESS TO TEST CHECK GOOD. (M)

Part: SKIN — CRACKED (BS 970)

INT - DURING DROP IN CHECK VISUAL INSPECTION, FOUND 4 INCH CRACK SKIN BS 970 STRINGER 21L. DOUBLER INSTALLED PER SRM 53-30-3, REPAIRED PER SRM 53-30-3. (M)

Part: SKIN — DENTED (BS 480)

CLT - INSPECTION VISUALLY FOUND A DENT 8 INCHES BY 4 INCHES IMPACT DAMAGE LOCATED AT BS 480 BETWEEN STRINGER 25R AND STRINGER 26R OF FUSELAGE SKIN. INSTALLED DOUBLER PER USA EA NR 40585. (M)

Part: SEAL — FAILED (FWD ENTRY DOOR)

BWI - FLT 2476 - ON CLIMB-OUT OF BWI, LOUD WHISTLING NOISE HEARD COMING FROM FORWARD ENTRY DOOR, FOLLOWED BY A LOUD BOOM. FLIGHT RETURNED TO BWI WHERE LANDING WAS WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED UPPER HINGE SEAL AND SEAL BRACKET. REFERENCE 95ZZZW459.

Part: SEAL BRACKET — FAILED (FWD ENTRY DOOR)

BWI - FLT 2476 - ON CLIMB-OUT OF BWI, LOUD WHISTLING NOISE HEARD COMING FROM FORWARD ENTRY DOOR, FOLLOWED BY A LOUD BOOM. FLIGHT RETURNED TO BWI WHERE LANDING WAS WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED UPPER HINGE SEAL AND SEAL BRACKET. REFERENCE USAA950240.

Part: SOLENOID — FAILED (LDG GEAR LEVER)

ROC - FLT 1670 - UNABLE TO RAISE GEAR HANDLE ON TAKEOFF. CREW PERFORMED CHECKLIST, DETERMINED THAT LANDING GEAR LEVER LATCH SOLENOID FAILED. OVER RIDE LEVER PULLED AND GEAR RETRACTED NORMALLY PER CHECK LIST. FLIGHT PROCEEDED ON TO PHL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED LOCK SOLENOID. (Z)