N259US

Part: BULKHEAD — BEAM CRACKED (BS 1183 LBL 37)

THE CRACK WAS FOUND IN THE AFT BULKHEAD VERTICAL BEAM LBL 36.83 (LT/RT). THE SUSPECT CAUSE WAS THE RESULT OF FATIGUE THAT WAS CAUSED BY PRESSURIZED FLIGHTS. SUBMITTER RECOMMENDATION: THERE SHOULD BE A LIMITED TIME TO INSTALL THE PREVENTIVE MODIFICATION PER SB B727-53-0192.

Part: BULKHEAD — CRACKED (BS 1183 LBL 26)

THE CRACK WAS FOUND IN THE AFT BULKHEAD VERTICAL BEAM LBL 26.83 WL 257.0. THE CRACK IS ATTRIBUTED TO PRESSURIZATION CYCLES. RECOMMENDATION: THE SB 53-0182 RECOMMENDED TO INSTALL THE PREVENTIVE MODIFICATION AT OR BEFORE 60,000 CYCLES. SUBMITTER RECOMMENDED THE PREVENTIVE MODIFICATION MUST BE INSTALLED AT OR BEFORE 45,000 CYCLES.

Part: BULKHEAD — BEAM CRACKED (BS 1183 RBL 37)

THE CRACK WAS FOUND IN THE AFT BULKHEAD VERTICAL BEAM LBL 36.83 (LT/RT). THE SUSPECT CAUSE WAS THE RESULT OF FATIGUE THAT WAS CAUSED BY PRESSURIZED FLIGHTS. SUBMITTER RECOMMENDATION: THERE SHOULD BE A LIMITED TIME TO INSTALL THE PREVENTIVE MODIFICATION PER SB B727-53-0192.

Part: TUBE — CRACKED (NR 3 ENGINE)

ENGINE NR 3 SHUT DOWN DUE TO FIRE WARNING. FOUND NR 3 ENGINE BLEED AIR MANIFOLD TUBE SEPARATED AT FLANGE WHERE ATTACHED TO FUEL HEAT VALVE. REPAIRED FLANGE TO PIPE IAW PWA ENGINE MANUAL 72-09-71. OPS CHECKED FUEL HEAT VALVE. NO LEAK NOTED. (M)

Part: LAP SEAM — CORRODED (BS 1170 S20L)

DURING VISUAL INSPECTION OF SB 727-53-0072 R5, LAP SEAM 520L AT STA 1170 WAS FOUND BULGING WITH POPPED RIVET HEADS IN THE LAP. LEVEL 2 CORROSION WAS NOTED BEHIND THE LAP SEAM WHEN OPENED UP FOR REPAIR.

Part: CONTROLLER — INOPERATIVE (CABIN)

FLT 9 - EWR-MCO - AT CRUISE, EXPERIENCED RAPID DECOMPRESSION AT 31,000 FEET, DECLARED EMERGENCY AND FOLLOWED RAPID DECOMPRESSION AND EMERGENCY DESCENT PROCEDURES. MADE NORMAL APPROACH AND LANDING AT MCO. VISUALLY INSPECTED EXTERIOR DOOR SEALS AND OUTFLOW VALVES. REPLACED MANUAL PRESSURE CONTROLLER AND OPS CHECK OK AS PER 21-30-00, PAGE 501. (M)

Part: BATTERY PACK — DIRTY (CABIN)

FORWARD EMERGENCY CEILING LIGHT OUT. REMOVED BATTERY AND CLEANED CONTACTS INSTALLED BATTERY PACK, OPS CHECK OK AS PER MM 33-50-01. (M)

Part: FLOW CONTL VALVE — INTERMITTENT (RIGHT VLV)

AFTER TAKEOFF AT ATL, FLT 73, ATL TO MCO, AIR TURN BACK DUE TO UNABLE TO PRESSURIZE ON DEPARTURE IN AUTO OR MANUAL. TROUBLESHOT PRESSURIZATION TO INTERMITTENT FLOW CONTROL VALVE. REMOVED AND REPLACED FLOW CONTROL VALVE PER MM 36-12-11. PRESSURIZED A/C PER MM 21-30-00. OPS CHECK OK. (M)

Part: POWER PACK — INOPERATIVE (CABIN)

EWR - FLT 81 - POST-FLIGHT, AFT OVERHEAD EMERGENCY LIGHT INOPERATIVE. REMOVED AND RPELACED POWER PACK. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

EWR - POST-FLIGHT - OVERHEAD EMERGENCY EXIT LIGHT ROW 11, INOPERATIVE. REMOVED AND REPLACED BATTERIES.

Part: TORQUE TUBE — LOOSE (TE FLAPS)

ATL/MDW - FLT 59 - INBOARD FLAPS WOULD NOT RETRACT ABOVE 15 DEGREES. AIR TURN BACK TO ATL. ON SYSTEM OPS AND INSPECTION, FOUND FLAPS IN BYPASS MODE. RESET ASSYMETRY. FOUND LOOSE TORQUE TUBE COUPLING AT OUTBOARD FLAP POWER CONTROL UNIT. SECURED LOOSE TORQUE TUBE COUPLING, RETORQUED SCREWS. OPS CHECK OK PER 27-51-01. (X)

Part: STRINGER — CORRODED (FS 359 STR 26)

DURING BOEING C.P.C.P. INSPECTION, FOUND SKIN BULGE AT STR 26R, STA 359. CUT OUT DAMAGED STRINGER SECTION. SKIN NOT DAMAGED. FABRICATED REPAIR FILLER AND DOUBLER FROM 7075-T6. TREATED PARTS AND PRIMED, AND INSTALLED IAW SRM 51-40-4, SRM 51-20-2, SRM 51-20-4, AND SRM 51-30-2.

Part: STRINGER — CORRODED (FS 675 STR 19L)

DURING INSPECTION OF AD 91-06-06, FOUND STR 19L AT BS 675 EXFOLIATED ON INBOARD LOWER FLANGE. REMOVED DAMAGED AREA OF STRINGER. FABRICATED STRINGER SPLICE FROM BAC 1498-125, 7075-T6 STRINGER MATERIAL AND NEW STRINGER TIE FROM .040 INCH, 7075-T6. TREATED MATERIALS, PRIMED, AND INSTALLED IAW SRM 51-20-1, SRM 53-10-3, SRM 51-10-2, AND SRM 51-30-2.