N2815W

Part: BATTERY — DISCHARGED (FLASHLIGHT) · airframe 77,634 hrs · 52,722 cycles

EMERGENCY FLASHLIGHT AT AFT F/A SEAT LIGHT NOT BLINKING. REPLACED BATTERY, OPS NORMAL.

Part: SKIN — CRACKED (FUSELAGE) · airframe 77,164 hrs · 52,402 cycles

WHILE ACCOMPLISHING LFEC INSP PER 4-74176-12AD ON S4L LAP JOINT, CRACK INDICATION WAS NOTED BETWEEN BS 440 AND 460. INTERNAL HFEC INSPECTION OF ENTIRE PANEL PER SI A SINGLE CRACK WAS VERIFIED BETWEEN BS 440 AND 460 (FASTENER NR 10). DAMAGE WAS REPAIRED PER ERA 377499-14AD.

Part: ACTUATOR — INOPERATIVE (RT MLG) · airframe 77,004 hrs · 52,298 cycles

RT MAIN GEAR FAILED TO EXTEND DURING NORMAL EXTENSION. CHECK LIST PROCEDURES WERE USED AND RT GEAR WAS EXTENDED AND LEFT IN THE EXTENDED POSITION FOR THE REMAINDER OF THE FLT. REPLACED RT GEAR SEQUENCE VLV PER MM 32-32-21, NO HELP. STILL NEEDS MANUAL EXTENSION CHECK. PERFORMED GEAR EXTENSION. REPLACED MAIN GEAR ACTUATOR, NO HELP. REPLACED MAIN GEAR DOOR ACT. CYCLED GEAR THROUGH SEVERAL TIMES. GEAR OPS CHECKS OK PER MM CHAPT 32.

Part: SKIN — CRACKED (BS 662)

THE UPPER FUSELAGE SKIN WAS FOUND WITH CRACK INDICATIONS AT THE UPPER ROW OF FASTENERS IN THE STRINGER 26R SKIN LAP SPLICE AT FS 662. ALL CRACK DAMAGE WAS REMOVED WITH A 4.25 X 2.75 CUTOUT. THE CUTOUT WAS REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER PER B727 SRM 53-30-3, FIG 14 AND ER/A 369202-14, REV A.

Part: SKIN — DENTED (TE FLAP)

INBOARD L/E DENTED AND WORN. REPAIRED ON SHOP ORDER 927514 PER M/M 57-52-0 FIG 803 {FLAP SHOP}.

Part: STIFFENER — CRACKED (SPAR)

TPA LTR CHK B-1, O/B SPAR STIFFENER CRACKED AT NR 3 SLAT I/B TRACK. REPLACED STIFFENER PER M/M 57-20-21 .

Part: FRAME — CRACKED (PAX DOORWAY)

FOUND AT B-1 LTR CK, AFT CABIN ENTRY DOOR FRAME CUTOUT CRACKED LT SIDE 10 INCHES FROM TOP OF CUTOUT. REPAIRED PER SRM 53-10-9.

Part: SKIN — CRACKED (BS 360-380)

FUSELAGE SKIN FS 360-380 STRINGER 4R SKIN LAP SPLICE, CRACK REPAIR. LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 AND 480 INDICATED A CRACK IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED A SINGLE CRACK BETWEEN FS 360 AND 380. THE CRACK WAS ROUTED OUT AND REPAIRED PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A 367260-14AD.

Part: SKIN — CRACKED (BS 481-681)

FUSELAGE SKIN FS 481-681, STRINGER 4R, SKIN LAP SPLICE, CRACK REPAIR. LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 481 AND 681 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED 20 CRACKS. THE ENTIRE SKIN LAP WAS CUT OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 367259-14AD.

Part: SKIN — CORRODED (BS 259.5-360)

ON HUSH-KIT MOD OPN 57118, LOWER SKIN LAP JOINT INSPECTION FOUND CORROSION ON FUSELAGE SKIN BETWEEN BONDED METAL SKIN LAYERS AT STATION 259.5R TO 360R. REPLACED SKIN SECTION WITH A/C SKIN SECTION FROM MANUFACTURER.

Part: SKIN — CORRODED (BS 300)

THE FUSELAGE SKIN PANEL BETWEEN FS 259.5 AND 360 AND BETWEEN STRINGER 19R AND 24R WAS FOUND WITH SEVERAL AREAS OF CORROSION. THE PANEL WAS REMOVED AND A NEW BOEING SKIN PANEL INSTALLED PER ER/A 366991-14.

Part: ANGLE — CORRODED (NR 2 ENGINE)

ON HUSH-KIT MOD FOUND RT NR 2 ENG AFT MOUNT CHORD ANGLE CORRODED BEYOND MFG LIMITS. REPLACED CHORD ANGLE WITH PART OF NEW MFG.

Part: ANGLE — CORRODED (NR 2 ENGINE)

ON HUSH-KIT MOD FOUND LT NR 2 ENGINE AFT MOUNT CHORD ANGLE CORRODED BEYOND MFG LIMITS. REMOVED CHORD ANGLE AND REPLACED WITH NEW MFG PART.

Part: INSULATION — CRACKED (NR 3 ENGINE)

DURING HUSH-KIT MOD FOUND INSULATION CRACKED ON GEN FEEDER CABLES IN PYLON ON NR 3 ENGINE. SPLICED IN NEW CABLE (P/N 0122107330) FROM SPLICES IN 48 SECTION TO FIREWALL DISCONNECT.

Part: LIGHT — INOP (COCKPIT)

F/O MAP LIGHT SMOKED AND FUMED. REPLACED LIGHT ASSY.

Part: CLACKER — FAILED (COCKPIT)

ATB - ELECT SMELL FROM RT SIDE OF COCKPIT. REPLACED OVERSPEED CLACKER.

Part: BOLT — MISSING (NR 3 LE FLAP ACT)

ON APPROACH, LEADING EDGE FLAP NR 3 UNSAFE HAD AMBER LIGHT, ON GO-AROUND FLAPS WENT GREEN. SAFE INDICATION ON LANDING. AFTER LANDING FLAPS TO 25 DEGREES, FLAP INDICATION WENT TO AMBER. FOUND ACTUATOR DISCONNECTED FROM FLAP, BOLT MISSING. DAMAGE TO FLAP CONSISTS OF A 1.75 INCH CROSS SHAPED CRACK. FLAP (P/N 574703325), REPLACED FLAP AND REPLACED ACTUATOR AS PRECAUTIONARY.

Part: ANGLE — CRACKED (RT TE MIDFLAP)

DURING SHOP INSP, THE LOWER AFT CHORD ANGLE WAS FOUND CRACKED 33 AND 36.5 INCHES FROM I/B END OF FLAP. THE ANGLE WAS REPAIRED PER MM 57-52-0, FIG 802 BY INSTALLING A DOUBLER.

Part: SHIM — MIGRATED (LT TE FLAP)

THE I/B TRACK OF THE LT WING I/B FLAP WAS FOUND WITH THE LAMINATED SHIM MIGRATED .25 AS TYPICAL OF S/B 727-57-0178 AND AD 90-07-05. THE SHIM WAS REPLACED PER THE REQUIREMENTS OF THE S/B AND DOCUMENTED PER ER/A 365509-14AD.

Part: BATTERY — DISCHARGED (CABIN)

OVERWING EMERGENCY EXIT LIGHTS FLASHING. REPLACED RACK AND BATTERY, OPS CHECK GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

R-1 DOOR EMERG LIGHT INOP. REPLACED BATT PACK, OPS NOW OK.

Part: AUX SPAR — CHAFED (LT WING)

MLG AUX SPAR CHAFED AT INBD FWD END LT SIDE. REPAIRED PER MM 57-43-0 P 801.

Part: WEB — CRACKED (BS 1233)

FOUND ON A1 LETTER CK .25 IN CRACK AT LIGHTENING HOLE VERTICAL WEB STA 1233R IN 48 SECTION. ROUTED OUT DAMAGED AREA PER MM 53-11-0.

Part: STRAP — CRACKED (R1 DOORWAY)

THE R1 DOOR CUTOUT REINFORCING DOUBLER (BEAR STRAP) WAS FOUND WITH A TYPICAL CRACK IN UPPER HINGE CUTOUT. THE SKIN WAS CUT TO ACCESS THE CRACK AND THE BEAR STRAP WAS CUT TO REMOVE THE CRACK. THE CUTOUTS WERE REPAIRED WITH A DOUBLER AND TRIPLER PER THE GUIDLINES OF BOEING S/B 727-53-0136 AND ER/A 364227-14.

Part: FRAME — CRACKED (NR 2 CARGO DOOR)

NR 2 CARGO DOOR FWD FRAME HAS A 1.5 INCH CRACK AT LWR DOOR STOP FITTING. INSTALLED DOUBLER PER SRM 53-10-4.

Part: BATTERY — DISCHARGED (CABIN)

RT OVERWING EXTERIOR EMERG LIGHT INOP. REPLACED BATTERY, CKS NORMAL.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

ON L/O CK, FOUND RT OVERWING EXIT SIGNS WOULD NOT ILLUMINATE WITH EMER LTS ON. REPLACED POWER SUPPLY AND BATTERY, OPS CKS OK.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

ON L/O CK, FOUND RT OVERWING EXIT SIGNS WOULD NOT ILLUMINATE WITH EMERGENCY LIGHTS ON. REPLACED POWER SUPPLY AND BATT, OPN CKS OK.

Part: SKIN — CORROSION (BS 681-720)

CORROSION WAS FOUND ON THE FUSELAGE LOWER SKIN BETWEEN AT 681 AND 720 JUST I/B OF STR 26R IN THE VICINITY OF AN EXISTING REPAIR. THE EXISTING DOUBLER WAS REMOVED AND A SINGLE REPAIR COVERED BOTH AREAS. THIS REPAIR IS APPROVED BY FAA/DER FORM 8110-3, DER DESIGNATIOIN SO-831.

Part: SKIN — GOUGED (FUSELAGE)

DURING THE INSTALLATION OF THE UPPER HINGE REPAIR/MODIFICATION PER 727-53-0198, A GOUGE WAS FOUND IN THE LOWER FUSELAGE SKIN JUST AFT OF THE REPAIR AREA. DAMAGE REMOVAL RESULTED IN A 1 INCH BY 2 INCH CUT-OUT IN THE SKIN. DUE TO THE CLOSE PROXIMITY OF THIS DAMAGE TO THE EXISTING REPAIR/MODIFICATION, THE TWO REPAIRS WERE INCORPORATED INTO ONE. THE SERVICE BULLETIN REPAIR WAS EXTENDED TO COVER THE ADDITIONAL DAMAGE.

Part: SKIN — CRACKED (FUSELAGE)

AT MIDVISIT, THE SKIN AT GROUND PNEUMATIC DUCT ACCESS DOOR WAS FOUND CRACKED AT THE AFT I/B CUTOUT CORNER. A DOUBLER WAS FABRICATED AND DRILLED AND INSTALLED PER MM 53-30-0 FIG 802.

Part: SKIN — CRACKED (L1 DOORWAY)

TWO CRACKS IN THE SKIN AND DOOR SURROUND STRUCTURE WERE FOUND IN THE LOWER AFT CORNER OF THE L1 DOOR CUTOUT. THE FIRST CRACK MEASURES APPROXIMATELY 2.25 INCHES AND PENETRATES THE EXTERNAL SKIN AND BONDED DOUBLER. THE SECOND CRACK MEASURES APPROXIMATELY 2.25 INCHES AND PENETRATES THE BEAR STRAP. THIS DAMAGE WAS TRIMMED OUT AND REPAIRED WITH REPAIR DOUBLERS WHICH WERE APPROVED BY FAA/DER FORM 8110-3, DER DESIGNATION SO-889.

Part: BULKHEAD — CRACKED (BS 1303)

AT MIDVISIT THE BULKHEAD WEB WAS FOUND CRACKED AT BOTH LOWER O/B CORNERS AT FS 1303. THIS WAS REPAIRED PER SRM 53-10-4.

Part: DOOR FRAME — CRACKED (R2 DOOR)

FOUND R-2 DOOR FRAME CRACKED AT UPPER HINGE CUTOUT. FABRICATED DOUBLER PER SRM 52-40-2 FIG 4. ROUTED OUT DAMAGE PER SRM 52-40-2 FIG 4, INSTALLED DOUBLER PER SRM 52-40-2 FIG 4.

Part: ANGLE — CORROSION (BS 820-920)

CORROSION ON MOUNT ANGLES AROUND PERIPHERY OF LOWER FUSELAGE FAIRING OPENING AFT OF LOWER ROTATING BEACON. BEGAN REMOVING T-ANGLES FROM STA 820-920. FABRICATED NEW REPLACEMENT PARTS FOR RT BEAM PER SRM 53-30-1. COMPLETED INST OF RT ANGLE. FABRICATED LT BEAM AND BEGAN DRILLING PER SRM 51-00. FINISHED DRILLING, TREATED AND PAINTED LT ANGLE PER 51-00. INSTALLED LT BEAM PER 51-00.

Part: STIFFENER — CRACKED (NR 3 SLAT TRACK)

L/E VERTICAL SPAR STIFFENER CRACKED AT NR 3 SLAT O/B TRACK I/B STIFFENER. REPLACED STIFFENER PER MM 57-20-21.

Part: TR UNIT — BURNT (E/E COMPT)

VISIBLE SMOKE EXHAUSTING FROM E/E COMP WITH ESS TR C/B POPPED, SMELLS ELECTRICAL. FOUND AND REMOVED ESS T/R AND REPLACED NR 3 TR, OPS OK.

Part: SKIN — CORROSION (BS 540)

MTC REPORTS CORROSION ON THE FUSELAGE SKIN AT STA 540 AT STR 27R. CUT-OUT RESULTED IN 5.5 INCHES FWD/AFT BY 3.3 INCHES CIRCUM. AN EXISTING REPAIR INBD OF NEW DAMAGE REPAIRS A CUTOUT MEASURING .15 INCH FWD/AFT BY 2.5 INCHES CIRCUM. SKIN IS MACHINED FROM .125 INCH 2024-T3. LOCAL THICKNESS IS .110 INCH. REPAIR WILL INCORPORATE BOTH LOCATIONS INTO ONE REPAIR.

Part: FRAME — CRACKED (L2 DOOR)

L-2 DOOR FRAME UPPER HINGE CUTOUT CRACKED. REPAIRED PER SRM 52-40-2.

Part: DOUBLER — CRACKED (RT ELEVATOR)

REPAIR DOUBLER CRACKED RT ELEV 3RD FROM O/B HINGE RIB. REPAIRED PER M/M 55-10-31.

Part: SKIN — CRACKED (VERT STAB)

TWO, .75 INCH CRACKS IN VERTICAL STAB SKIN FWD OF SADDLE PANEL RT SIDE ABOVE PANEL 9516. REPAIRED PER M/M 54-30-0.

Part: LIGHT — INOPERATIVE (COCKPIT)

ON T/S INSP, FOUND COCKPIT OVER DOOR EMERGENCY EXIT/FLASHLIGHT DID NOT OPERATE IN THE ON POSITION DURING TEST. REPLACED ASSEMBLY 334701743.

Part: BULB — FAILED (NR 1 ENGINE)

ENGINE FIRE TEST CAUSES NR 1 ENG A/B FIRE DETECTION CIRCUIT BREAKER TO TRIP. REPLACED ENG FIRE TEST PANEL. REPLACED FIRE DET MOD. NO HELP. REPLACED FAULT BULB IN FIRE HANDLE. SYSTEM NOW CKS NORMAL.

Part: SKIN — CRACKED (NR 6 LE FLAP)

DURING SHOP INSPECTION, NR 6 L/E SLAT WAS FOUND WITH FLOATING SKIN CRACKED AT FASTENERS BETWEEN RIBS NR 8 AND 9, 13 AND 14. REPAIRED PER MM 57-54-0.

Part: RIB — CRACKED (NR 1 SLAT)

DURING ROUTINE SHOP INSPECTION, RIB NR 13 FROM THE O/B END WAS FOUND TO BE CRACKED. THE RIB WAS REPAIRED PER THE B-727 MM 57-54-0 PG 806 AND 807, FOR NR 1 L/E SLAT.

Part: SKIN — CRACKED (NR 5 LE SLAT)

UPON INITIAL INSPECTION, CRACK FOUND IN NR 5 SLAT SKIN UNDER AIR FENCE. REPAIRED PER M/M 57-54-0.

Part: RIB — CRACKED (NR 1 LE SLAT)

NR 1 SLAT RIB MARKED 15 CRACKED. REPAIRED PER MM 57-54-0 PG 819.

Part: RIB — CRACKED (NR 6 LE FLAP)

DURING SHOP INSPECTION, NR 6 L/E SLAT WAS FOUND WITH RIB NR 13 CRACKED. REPAIRED PER MM 57-54-0.

Part: ANGLE — CRACKED (NR 2 SLAT)

NR 2 SLAT, ANGLE CRACKED UNDER I/B STOP PAD. FOUND AT D-2 LETTER CHECK. REPAIRED PER MM 57-54-0 PG 12.

Part: ANGLE — CRACKED (NR 2 SPOILER)

NR 2 SPOILER I/B CASTING MOUNT LUG BROKEN. FOUND AT D-2 LETTER CHECK, REPLACED ATTACH ANGLE PER MM 57-42-0.

Part: WEB — CRACKED (FS 1213)

ONE-HALF INCH CRACK FOUND AT UPPER END OF VERT. WEB AT TORQUE BOX, RIGHT SIDE OF FS 1213. FOUND AT D-2 LETTER CHECK. REPAIRED PER MM 53-11-0 PG 832-833.

Part: BULKHEAD WEB — CRACKED (BS 1183)

BS 1183 BULKHEAD WEB CRACKED IN 4 PLACES AT RBL18. 1.0 INCH CRACK AT WL173, 0.5 INCH CRACK AT WL175, 1.25 INCH CRACK AT WL177, AND 1.0 INCH CRACK AT WL 179. CRACKS STOP DRILLED AND REPAIR DOUBLER INSTALLED. DAMAGE FOUND DURING LETTER CHECK, REPAIRED PER EAR 259480-14RVC.