N302DL

Part: MODULE — MALFUNCTIONED (NR 1 FIRE WARN) · airframe 56,261 hrs · 43,531 cycles

ON CLIMBOUT AT 14,000 FEET NR 1 ENG OVERHEAT LIGHT ILLUM. IAW CK LIST THRUST LEVER RETARDED. LIGHT WENT OUT. REPLACED ENG FIRE/OVERHEAT MODULE. RAN ENGS AT T/O AND CLIMB PWR, ALL TEST NORMAL.

Part: ACTUATOR — FAILED (NR 1 SPOILER) · airframe 55,965 hrs · 43,317 cycles

AFTER LANDING A-SYS HYD QTY DROPPED TO 0. REPLACED NR 1 SPOILER ACTUATOR FOR LEAKING.

Part: RMI — SMOKE (COCKPIT) · airframe 54,965 hrs · 42,566 cycles

NR 2 RMI STARTED TO SMOKE. REPLACED SAME

Part: SKIN — CRACKED (FUSELAGE) · airframe 54,695 hrs · 42,348 cycles

INSPECTION OF THE SKIN LAPS PER AD 2003-08-15 REVEALED A CRACKED FASTENER HOLE IN THE STRINGER 10R SKIN LAP SPLICE AT FS 432. A 1 X 6 INCH CUTOUT WAS MADE IN THE SKIN TO REMOVE THE CRACKED AREA. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER BAC B737 SRM AND PER ER/A 089002-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 54,695 hrs · 42,348 cycles

INSPECTION OF THE SKIN LAP JOINTS PER AD 2003-08-15 REVEALED A CRACKED FASTENER HOLE IN THE STRINGER 14R SKIN LAP JOINT. A 1 X 6 INCH CUTOUT WAS MADE IN THE SKIN TO REMOVE THE DAMAGED AREA AND AN ALUMINUM REPAIR DOUBLER INSTALLED PER B737 SRM AND DOCUMENTED PER ER/A 089003-14AD.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 54,695 hrs · 42,348 cycles

STRINGER 4L DAMAGED IN LWR RADIUS AT STA 797. REPAIRED PER SRM 53-10-3 FIG 4.

Part: CHARGER — INOPERATIVE (EMERGENCY LIGHT) · airframe 54,428 hrs · 42,143 cycles

MCO OVERHEAD EMERGENCY LIGHT BULLNOSE INOP 19D. FOUND BATTERY CHARGER RACK AT M1134 STA 629L INOP. REPLACED CHARGER RACK.

Part: DUCT — DAMAGED (NR 2 ENGINE) · airframe 53,787 hrs · 41,650 cycles

RT ENGINE OVERHEAT LIGHT CAME ON DURING CLIMB, WENT OUT WITH THROTTLE AT IDLE. FOUND DAMAGED STARTER DUCT. REPLACED SAME.

Part: BULKHEAD — CRACKED (FS 178) · airframe 52,311 hrs · 40,769 cycles

FUSELAGE / BULKHEAD / FS 178 / WEB AND SIDE CHORDS : CRACK REPAIR THE FS 178 BULKHEAD WEB AND SIDE CHORDS WERE FOUND WITH CRACKS TYPICAL OF BAC S/B 737-53-1173 AND AD 2000-05-29. THE WEB HAD SEVERAL EXISTING REPAIRS INSTALLED. THE WEB WAS REMOVED AND REPLACED, AND THE CRACKED SIDE CHORDS REPLACED PER THE PROCEDURES OF THE BAC S/B AND PER ER/A 384474-14AD.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 50,297 hrs · 39,908 cycles

THE LONGITUDINAL FLOOR BEAM AT RBL 24 WAS FOUND WITH A TYPICAL CRACK IN THE BEAM WEB AND WEB DOUBLER AT FS 678. THE BEAM UPPER CHORD WAS FOUND CRACKED AT FS 674. THE UPPER CHORD WAS REMOVED AND REPLACED. THE WEB DOUBLER WAS REPLACED PER BAC S/B 737-57-1139 AND AN ALUMINUM DOUBLER INSTALLED TO REPAIR THE WEB. THE BEAM WAS THEN MODIFIED PER THE S/B. THEREPAIR WAS ACCOMPLISHED PER ER/A 380644-14.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 50,244 hrs · 39,883 cycles

RT AFT AISLE EMERGENCY LIGHT INOP. REPLACED BATTERY POWER SUPPLY CKS NORMAL

Part: MOUNT — WORN (ENGINE) · airframe 50,025 hrs · 39,795 cycles

FWD ENGINE MOUNT FOUND WITH MIGRATING BEARING RESULTING IN OVERSIZED MOUNT HOLES. REPAIR PER ER/A 401250-14AD.

Part: PCU — MALFUNCTIONED (RUDDER) · airframe 48,584 hrs · 39,188 cycles

ON T/O ROLL 125 KNOTS FELT A UNCOMMANDED YAW TO THE RIGHT, FELT LIKE SOMEONE KICKED THE RUDDER PEDAL. REPLACED RUDDER PCU PER M/M.

Part: COFFEEMAKER — BURNED (GALLEY) · airframe 47,422 hrs · 38,679 cycles

ON T/O, STRONG SMELL OF SMOKE/ELECTRICAL/SULFUR. RETURN TO LAND MCO OVERWEIGHT LANDING AT 200 FPM, LANDING WEIGHT 112.8. REPLACED BOTH COALESCER BAGS. BOTH CLEAN, NO ODOR. PULLED FLIGHT INSTRUMENTS, NO SMELL. OPENED C/B PANELS, NO SMELLS. FOUND BURNT COFFEE IN FWD COFFEEMAKER, STILL ON. REPLACED FORWARD COFFE MAKER AND CLEANED AREA. OPERATED ALL COCKPIT LIGHTING, UNABLE TO DUPLICATE SMELL.

Part: SMOKE DETECTOR — WILL NOT TEST (AFT LAV) · airframe 47,292 hrs · 38,621 cycles

AFT LAV SMOKE DETECTOR WOULD NOT TEST. REPLACED SMOKE DETECTOR.

Part: UNKNOWN — ODOR (COCKPIT) · airframe 46,636 hrs · 38,325 cycles

FLT 2452 MCO-EWR, HAD ELECTRICAL ODOR AROUND THE FWD F/A JUMPSEAT. CREW DIVERTED TO RIC. TROUBLESHOOTING WITH CONTRACT MTC AND NOTHING FOUND. SENT MECH FROM CVG DUE TO ATL FLT DELAYED DUE TO MECHANICAL. DAL MECH ALSO FOUND NOTHING WRONG WITH ACFT.

Part: DOUBLER — WORN (FUSELAGE) · airframe 46,566 hrs · 38,293 cycles

AN EXISTING DOUBLER WAS WORN ALONG IT'S AFT EDGE LOCATED AT THE FORWARD EDGE OF THE C1 DOOR. THE DOUBLER WAS REMOVED AND REPLACED PER ERA 334214-14. THE DAMAGE WAS FOUND AT HMV.

Part: SPAR — CORRODED (HORIZONAL STAB) · airframe 46,544 hrs · 38,283 cycles

CORROSION WAS FOUND ON THE FRONT AND REAR SPAR OF THE HORIZONTAL STABILIZER CENTER SECTION ATTACH FITTING. CORROSION WAS FOUND ON THE FORWARD AND AFT FACES AND IN THE BORE. THE DAMAGE WAS REMOVED, TREATED AND PAINTED PER ERA 334168-14 AT HMV.

Part: FITTING — CORRODED (HORIZONTAL STAB) · airframe 46,544 hrs · 38,283 cycles

CORROSION WAS FOUND ON THE REAR SPAR ATTACH LUGS OF THE HORIZONTAL STABILIZER. THE CORROSION WAS TO THE FORWARD AND AFT FACES OF THE FITTING AND INSIDE THE LOWER BORE. THE CORROSION WAS REMOVED, TREATED AND PAINTED PER ERA 334170-14AT HMV.

Part: FITTING — CORRODED (FUSELAGE) · airframe 46,542 hrs · 38,282 cycles

CORROSION WAS FOUND ON ALL EIGHT OF THE AFT SPAR ATTACH LUGS ON THE BODY ATTACHMENT POINT FOR THE VERTICAL STABILIZER AT APPROXIMATELY FS 1080. CORROSION WAS REMOVED AND THE AREA TREATED AND PAINTED PER ERA 334185-14 AT HMV.

Part: FITTING — CORRODED (VERTICAL STAB) · airframe 46,542 hrs · 38,282 cycles

CORROSION WAS FOUND ON THE FORWARD AND AFT FACE OF BOTH THE INNER LUGS OF THE VERTICAL STABILIZER ATTACH FITTING. THE CORROSION WAS REMOVED AND THE AREA WAS TREATED AND PAINTER PER ERA 334169-14. THE DAMAGE WAS FOUND AT HMV.

Part: DOUBLER — WORN (FUSELAGE) · airframe 46,542 hrs · 38,282 cycles

WEAR WAS FOUND ON THE LAP JOINT LOWER INTERNAL BONDED DOUBLER AT APPROXIMATELY FS 310 AND STR 10L JUST BELOW THE L1 DOOR UPPER HINGE CUTOUT. THE WEAR WAS .25 IN DIAMETER AND A MAXIMUM OF .011 DEEP. THE AREA WAS BLENDED AND TREATED PER ERA 334203-14. THE DAMAGE WAS FOUND AT HMV.

Part: SEAL — SEPARATED (NR 1 ENGINE)

NR 1 ENG HAD MULTIPLE COMPRESSOR STALLS AT FL310 AS THROTTLES RETARDED FROM CLIMB EPR TO CRUISE EPR OF 1.96. COMPRESSOR STALLS STOPPED AS THROTTLES WERE PULLED TO IDLE THE ENG WAS NOT SHUTDOWN AND OPERATED NORMALLY AT IDLE. REPLACED C2 FAN FOR SEAL LIBERATION.

Part: LIGHT — INOPERATIVE (ROWS 1 - 3)

EMERGENCY EXIT LIGHTING INOP ROWS 1 THRU 3. REPLACED PWR SUPPLY AND FOUND WIRES SHORTED AT ROW 4 D, E, F. REPAIRED SAME, OPS CKS NORMAL.

Part: LIGHT — INOPERATIVE (CABIN)

ON MTC INSPECTION, FOUND FWD CABIN EMERGENCY LIGHTS WOULD NOT EXTINGUISH AFTER TEST. REPLACED POWER SUPPLY AND TEST GOOD.

Part: FITTING — CORRODED (BS 685)

THE LT AND RT FS 685 MLG SIDE STRUT SUPPORT FITTINGS WERE FOUND WITH CORROSION IN THE STRUT ATTACH LUG BORES. THE LUGS WERE OVERSIZED TO CLEAN UP THE CORROSION, INSPECTED, AND REPAIRED WITH STELL BUSHINGS PER ER/A 367450-14, REV A.

Part: SKIN — CRACKED (BS 520)

FUSELAGE SKIN, FS 520, S-16L SKIN CRACK REPAIR. THE FUSELAGE SKIN WAS FOUND WITH A CRACK ABOVE STRINGER 16L AT FS 520. THE CRACK WAS CUTOUT AND REPAIRED WITH AN EXTERNAL DOUBLER PER B737 SRM 53-30-3, FIG 1. THE REPAIR WAS DOCUMENTED PER ER/A 365917-14. THE REPAIR EXTENDS UNDER A FAIRING WHICH IS CONSIDERED AN SSI AREA SO THE REPAIR WILL BE HAVE A DAMAGE TOLERANCE ANALYSIS PERFORMED WITHIN 12 MONTHS PER THE REQUIREMENTS OF AD 98-11-03.

Part: SKIN — PUNCTURED (BS 920)

THE FUSELAGE SKIN WAS PUNCTURED DUE TO GROUND EQUIPMENT IMPACT AT FS 920 AND STRINGERS 21L-22L. ALSO, STRINGER 22L WAS DAMAGED. THE SKIN WAS REPAIRED WITH AN EXTERNAL ALUM DOUBLER PER SRM 53-30-3 WITH MINOR FASTENER CHANGES AND THE STRINGER WAS REPAIRED PER SRM 53-10-3 WITH MINOR FASTENER CHANGES. THE REPAIRS WERE DOCUMENTED PER ER/A 364707-14.

Part: FUEL CONTROL — FAILED (NR 1 ENGINE)

PUSHED PWR UP FOR T/O AND ENGAGED, ATS NOTICED NR 2 ENG INST ROLLING BACK AS IF FLAMING OUT. PERFORMED ABORT PROCEDURES AND REALIZED NR 1 ENG WAS STILL OPER AT T/O PWR WITH BOTH THROTTLES AT IDLE. SHUT DOWN NR 1 ENG AFTER EXITING RUNWAY. REPLACED NR 1 ENGINE FCU. ALSO, REPLACED NR 1 ENG FUEL PUMP PRECAUTIONARY. ENG RUN PER PFHB CK GOOD.

Part: BULKHEAD WEB — CRACKED (BS 178)

THREE CRACKS FOUND ON THE FWD FACE OF THE STA 178 BLKHD WEB. THE FIRST CRACK WAS LOCATED NEAR LBL 5.7 VERTICAL STRAP AT APPROX WL 195, THE SECOND CRACK WAS LOCATED NEAR RBL 5.7 VERTICAL STRAP AT APPROX WL 200 AND THE THIRD CRACK WAS LOCATED NEAR BL 0 AT APPROX WL 190. THE WEB WAS REPAIRED WITH A DOUBLER IN ACCORDANCE WITH FAA/DER FORM 3110-3 BY SO-831, DTD 06-11-96.

Part: FLOOR BEAM — CRACKED (BS 660)

THE BL .07 FLOOR BEAM OF THE WING CENTER SECTION IS CRACKED AT FS 660. NO CRACKS WERE FOUND IN THE WEB. THE CRACK IS TYPICAL PER BACO SB 737-57-1210. THIS ERA WILL INSTALL THE SERVICE BULLETIN REPAIR FOR THIS CONDITION.

Part: TRACK LIGHT — CRACKED (CABIN)

ON LAYOVER, FOUND FLOOR TRACK TOP COVER CRACKED BETWEEN ROWS 15 AND 18. REPLACED TOP TRACK BETWEEN ROWS 15 AND 18.

Part: ACTUATOR FITTING — FAILED (RT SPOILER)

ONE OF THE ACTUATOR FITTINGS HAS FAILED ON THE RT INBOARD GROUND SPOILER. THE FITTING IS THE SUBJECT OF S/B 737-57-1207. ACCOMPLISHED REPAIRS PER DL ERA 357237-14.

Part: SKIN — DENTED (FS 847)

FOUND ON LAY OVER-DENT AFT OF AFT B/B DOOR APPROX. .25 INCH IN DIAMETER. REPAIRED PER SRM 53-30-3 FIG. 23.

Part: SKIN — DAMAGED (BS 360)

DURING LAYOVER IN ATLANTA, THE FUSELAGE SKIN WAS DAMAGED JUST AFT OF STATION 360 AND JUST ABOVE STRINGER 19R WHEN STRUCK BY A BAGGAGE CONTAINER. DAMAGE WAS CUT OUT AND REPAIRED WITH AN EXTERNAL DOUBLER IN ACCORDANCE WITH B737-200 SRM 53-30-3 FIG 1 PER ER/A 300978-14.