N303DL

Part: PCU — MALFUNCTIONED (AILERON) · airframe 60,175 hrs · 45,262 cycles

AFTER MOVING FLAPS TO 5 DEGREES SYS-A HYD QTY DROPPED TO ZERO. REPLACED LOWER A-SYSTEM AILERON PCU FOR LEAKING.

Part: CHARGER — MALFUNCTIONED (EMERGENCY LIGHT) · airframe 58,902 hrs · 44,315 cycles

PRIOR TO TAXI OUT, F/A NOTIFIED FLT CREW THAT EMERGENCY LIGHTS SEAT MOUNTED FROM MIDDLE OF A/C TO BACK OF A/C WERE ILLUMINATED DIM. REPLACED M9013 BATTERY PACK, BASE TESTS GOOD.

Part: GASPER FAN — FAILED (AIR COND BAY) · airframe 58,745 hrs · 44,201 cycles

DURING CRUISE SMELLED BURNING ODOR THAT REMAINED THROUGH LANDING. FOUND GASPER FAN C/B TRIPPED. RAN PACKS TO CLEAR ODOR. REPLACED FAN.

Part: TRANSMITTER — FAILED (NR 1 ENGINE) · airframe 58,627 hrs · 44,109 cycles

NUMBER 1 OIL PRESSURE WENT TO 6 PSI AFTER LEVEL OFF. REPLACED NR 1 OIL PRESSURE TRANSMITTER.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,513 hrs · 44,017 cycles

INSPECTION OF THE SKIN LAP JOINTS PER AD 2003-08-15, REVEALED A CRACK IN THE STRINGER 4R SKIN LAP JOINT AT FS 695. THE CRACK WAS REMOVED WITH A 4.25 INCH LONG CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER B737 SRM AND DOCUMENTED PER ER/A 090771-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,513 hrs · 44,017 cycles

INSPECTION OF THE SKIN LAP JOINTS PER AD 2003-08-15, REVEALED A CRACK IN THE STRINGER 10R SKIN LAP JOINT AT FS 439. THE CRACK WAS REMOVED WITH A 4.25 INCH CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER B737 SRM AND DOCUMENTED PER ER/A 090887-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,513 hrs · 44,017 cycles

INSPECTION OF THE FUSELAGE SKIN LAP JOINTS PER AD 2003-08-15, REVEALED A CRACK IN THE STRINGER 4R SKIN LAP JOINT AT FS 847. THE CRACKED AREA WAS REMOVED WITH A 4.25 INCH CUTOUT IN THE SKIN. THE AREA WAS REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER THE B737 SRM AND DOCUMENTED PER ER/A 090881-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,513 hrs · 44,017 cycles

INSPECTION OF THE SKIN LAP JOINTS PER AD 2003-08-15, REVEALED A CRACK IN THE STRINGER 4R SKIN LAP JOINT AT FS 439. THE CRACK WAS REMOVED WITH A 4.25 INCH CUTOUT IN THE SKIN. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER B737 SRM AND DOCUMENTED PER ER/A 090880-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,513 hrs · 44,017 cycles

INSPECTION OF THE FUSELAGE SKIN LAP JOINTS PER AD 2003-08 -15 REVEALED CRACKS IN THE STRINGER 4L SKIN LAP JOINT BETWEEN FS 560 & 590. THE CRACKS WERE REMOVED WITH A 32.5 INCH LONG CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER THE B737 SRM AND DOCUMENTED PER ER/A 090759-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,513 hrs · 44,017 cycles

INSPECTION OF THE SKIN LAP JOINTS PER AD 2003-08-15, REVEALED CRACKS IN THE STRINGER 4L LAP JOINT BETWEEN FS 430 & 450. THE CRACKS WERE REMOVED WITH A 25 INCH CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER B737 SRM AND DOCUMENTED PER ER/A 090993-14AD.

Part: FRAME — CORRODED (FUSELAGE) · airframe 58,513 hrs · 44,017 cycles

CORROSION ON FWD AND AFT SIDE OF FRAME STA 827 BETWEEN STR 27 LT AND RT. REPAIRED PER SRM 53-10-04.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 58,513 hrs · 44,017 cycles

FLOORBEAM TEE CAP UPPER FLANGE CRACKED STA 328 AT LBL 12. INSTALLED REPAIR PER SRM 53-10-9D.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 57,606 hrs · 43,319 cycles

ON PREFLIGHT FOUND FWD ESCAPE PATH LIGHTING INOP. REPLACED BATTERY PACK AND RACK.

Part: FUSE — INOPERATIVE (EMERGENCY LIGHT) · airframe 56,386 hrs · 42,340 cycles

EMERGENCY SEAT LIGHTS INOPERATIVE, FROM CLOSET 1R THROUGH ROW 10. RPLCD FUSE AT D1133. CLOSET LIGHTS STILL INOPERATIVE. REPAIRED BROKEN WIRES AT CLOSET BULKHEAD. NOW OPS NORMAL. 1L EMERGENCY SLIDE LIGHT, INOPERATIVE, RELAMPED, CKS GOOD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 56,176 hrs · 42,160 cycles

THE FUSELAGE SKIN WAS FOUND WITH A 2 INCH CRACK RUNNING ALONG THE MILL/BONDED DOUBLER LINE OF STRINGER 23R AT FS 867. THE CRACK IS TYPICAL OF BAC S/B 737-53A1210. THE CRACK WAS CUTOUT OF THE SKIN AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER THE B737 SRM AND PER ER/A 384995-14, REV A.

Part: SKIN — CRACKED (FUSELAGE) · airframe 56,159 hrs · 42,146 cycles

THE FUSELAGE SKIN WAS FOUNE WITH A 2 INCH CRACK RUNNING ALONG THE BONDED WAFFLE DOUBLER EDGE AT STRINGER 17L AND FS 790. THE CRACK WAS REMOVED WITH A CUTOUT IN THE SKIN AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER ER/A 384984-14.

Part: SKIN — CRACKED (FUSELAGE) · airframe 56,159 hrs · 42,146 cycles

MAJOR REPAIR TO FUSELAGE SKIN WHERE CRACKS WERE FOUND DUE TO INSPECTION EO 5-75366-12AD. A/C WILL BE REPAIRED PER ERA 384984-14.

Part: BULKHEAD — CRACKED (FS1016,LBL2,) · airframe 54,990 hrs · 41,587 cycles

A .625 INCH CRACK WAS FOUND EMANATING FROM A FASTENER HOLE IN THE GORE/WEB OF THE AFT PRESSURE DOME AT FS 1016 AT LBL 2 & WL 244. THE CRACK TIPS WERE STOP DRILLED AND REPAIRED WITH A DOUBLER PER ER/A 384128-14, REV A.

Part: BULB — BURNED OUT (CABIN) · airframe 50,199 hrs · 39,567 cycles

R2 DOOR EXTERIOR EMERGENCY LIGHT INOPERATIVE. RELAMPED.

Part: LINE — RUPTURED (NR 2 ENGINE) · airframe 48,610 hrs · 38,891 cycles

SYSTEM A PRESSURE WENT TO ZERO AND BOTH PUMP LIGHTS ON, WHEN GEAR SELECTED DOWN. GEAR WAS MANUALLY EXTENDED. FOUND RUPTURED HYD LINE ON NR 2 ENG PYLON TO FIREWALL.

Part: RECEIVER — INOPERATIVE (NR 1 VOR) · airframe 47,241 hrs · 38,300 cycles

IN CLIMB LVL OFF AT 330, .74M AP-A ENGDG HEARD AND FELT MUFFLED BANG ASSOC W/ROLLING A/P DISENGAGED BANKED SEVERAL TIMES BEFORE STABILIZED BANK NEARED 30 DEGREES. NO OBSERVED ABNML ENG OR SYS INDICATIONS AFTER STABILIZING ACFT, NO OTHER ABNORMALTIES OCCURED DID NOT FEEL LIKE WAKE TURB. NR 1 VOR ILS XCVR CAUSES A A/P TO DISCONNECT. SWAPPED BOXES, PROBLEM DISAPPEARS. SWAPPED BACK REPLACED NR 1 VOR XCVR VOR ILS TESTS NORM PER M/M. PERFORMED YAW DAMP TEST NTF. PERF FLT CONT CK NTF. PERF BORESCOPE BOTH ENG''S NTF.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 47,063 hrs · 38,222 cycles

STR 27L WAS FOUND CORRODED FROM FS 907 TO FS 947. THE STR WAS CUT AND REMOVED FROM FS 907 TO FS 1016 AND SPLICED IN PER ERA 3-53-11.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 47,063 hrs · 38,222 cycles

TWO CRACKS WERE FOUND THE THE FS 178 BULKHEAD WEB AT APPROX WL 233.5. ONE WAS AT LBL 12 AND THE OTHER AT RBL 12. THE CRACKS WERE ROUTED OUT AND DOUBLERS WERE INSTALLED ON THE FORWARD SIDE OF THE WEB PER ERA 334418-14AD AT HMV.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 47,063 hrs · 38,222 cycles

A 2.2 INCH CRACK WAS FOUND AT RBL 24.75 IN THE VERTICAL WEB OF THE FS 520 FLOORBEAM. ADDITIONALLY, A CHANNEL ON THE AFT SIDE OF THE BEAM AT LBL 24.75 WAS FOUND TO HAVE A .5 INCH CRACK. THE CHANNEL WAS REPLACED AND THE BEAM WAS REPAIRED SIMILIAR TO THAT OF SB 737-53-1120 PER ERA 334436-14 AT HMV.

Part: SKIN — CRACKED (BS 951)

A TYPICAL CRACK WAS FOUND IN THE SKIN AND BONDED DOUBLER OF THE LOWER HINGE CUTOUT OF THE AFT ENTRY DOOR (L2) CUTOUT. THE UNDERLYING BEARSTRAP WAS INSPECTED AND FOUND TO BE CRACK FREE. THE CRACK WAS ROUTED OUT OF THE SKIN ASSY WITH A .75 INCH CUTOUT AND REPAIRED WITH AN EXTERNAL DOUBLER AND TRIPLER PER B737 SRM 53-30-3, FIG 34 AND ER/A 369234-14, REV A.

Part: FITTING — CORRODED (BS 685)

FUSELAGE / LT MLG SIDE STRUT SUPPORT FITTING / FS 685 : LUG BORE CORROSION. THE LUG BORE OF THE LT MLG SIDE STRUT SUPPORT FITTING WAS FOUND WITH CORROSION. THE BORE WAS OVERSIZED TO REMOVE THE CORROSION AND AN OVERSIZE BUSHING INSTALLED. THE REPAIR WAS ACCOMPLISHED PER ER/A 367806-14, REV A.

Part: MASK — LEAKING (COCKPIT)

IN CRUISE, O2 GAUGE INDICATED ZERO. SUPPLY AT MASK NIL. ACCOMPLISHED POM PROCEDURE. REPLACED BOTTLE AND FOUND OBS MASK LEAKING. REPLACED MASK, SYS LEAK CHECKS OK.

Part: SKIN — CRACKED (BS 747)

THE FUSELAGE SKIN WAS FOUND WITH A 2 INCH CRACK AT FS 747 JUST BELOW S-18R. THE CRACK WAS ROUTED OUT OF THE EXISTING SKIN AND AN EXISTING, ADJACENT SKIN REPAIR WAS REMOVED AND THE UNDERLYING EXISTING SKIN CUTOUT INSPECTED. BOTH AREAS WERE INCORPORATED INTO A SINGLE EXTERNAL ALUMINUM DOUBLER REPAIR ACCOMPLISHED PER THE GUIDELINES OF B737 SRM 53-30-3. THE REPAIR AND FOLLOW-UP DTA REQUIREMENT WERE DOCUMENTED PER ERA.

Part: SKIN — CRACKED (R2 DOORWAY)

THE R-2 DOORWAY HAS A CRACK AT THE LOWER FORWARD CORNER EXTENDING 2. THE CRACK REMAINS WITHIN THE DAMAGE LIMITATIONS OF THE B737-200 SRM 53-30-3, FIGURE 24. THE CRACK EXTENDS THROUGH THE ENTIRE BONDED ASSEMBLY OF SKIN, DOUBLER, AND BEAR STRAP. THE SKIN AND DOUBLER ARE BOTH MADE OUT OF CLAD 2024-T3 WITH A THICKNESS OF .036. THE BEAR STRAP IS .090 CLAD 2024-T3. REPAIRED PER ERA 362753-14.

Part: SKIN — CRACKED (R-2 DOORWAY)

APPROX 2 IN CRACK IN FUSELAGE SKIN AT R-2 DOORWAY AT LWR FWD CORNER. REPAIR PER ERA 362753-14 REF SRM 53-30-3.

Part: BULB — FAILED (CABIN)

EMER TRACK LIGHTING FWD RED BULB BURNED OUT. RELAMPED, CKS OK.

Part: BULKHEAD WEB — CRACKED (BS 178)

DURING MID-VISIT, 178 BULKHEAD WAS FOUND TO BE CRACKED IN WEB. DAMAGE WAS REPAIRED WITH AN ALUMINUM DOUBLER IN ACCORDANCE WITH FAA/DER FORM 8110-3, DER DESIGNATION SO-867.

Part: SKIN — CRACKED (BS 373)

THE SKIN AT THE COOLING DUCT CUTOUT, BS 373 LBL 3, FOUND CRACKED AT THE AFT EDGE OF THE CUTOUT. THE CRACK IS APPROX 2 INCH LENGHTH AND IS TYPICAL OF CRACKS DESCRIBED IN BACO S/B 737-53-1117 R1. THE CRACK WILL BE STOP DRILLED AND A PERMANENT REPAIR WILL BE INSTALLED PER BACO.

Part: SPOILER ACTUATOR — RUPTURED (LT WING)

TOTAL LOSS OF A-SYSTEM HYDRAULICS SYSTEM IN FLIGHT.

Part: LIGHT COVER — MISSING (CABIN)

ON INSPECTION, FOUND OVERWING EMERGENCY EXIT SIGN AT ROW 15A MISSING. REPLACED LENS AND REBULBED, OPERATION NORMAL.

Part: UPLOCK ACT — FAILED (LT MLG)

LT MLG UNSAFE LIGHT ON IN FLT WITH LT GEAR VIB ALONG WITH UNSAFE INDICATION. JACKED A/C, RAN GEAR AND FOUND UNLOCK ACTUATOR BYPASSING FLUID. REPLACED SAME, GEAR CKS OK.

Part: HEAT EXCHANGER — DIRTY (RT PACK)

IN FLT STRONG SMOKE SMELL IN CABIN, BOTH LAV SMOKE ALARMS WENT OFF RETURNED ATL. REMOVED DEBRIS FROM RIGHT PACK HEAT EXCHANGER, RAN ENGINES AND PACKS ALL NORMAL.

Part: FLOORBEAM — CRACKED (FS 662)

DURING CORROSION VISIT, FOUND THE BL 0 FLOORBEAM OF THE WING CENTER SECTION CRACKED AT FS 662. THE UPPER CAP OF THE BEAM IS COMPLETELY CRACKED THROUGH, INCLUDING TWO FASTENER HOLES. ACCOMPLISHED REPAIRS PER SB 737-57-1210.

Part: SKIN — DELAMINATED (AILERON TAB)

ON INITIAL SHOP INSPECTION, 2 AREAS OF DELAMINATION WERE FOUND. THE FIRST AREA OF DAMAGE IS ON BOTTOM SKIN, APPROX 12 INCHES FROM I/B END. THE DAMAGED AREA IS DELAMINATED APPROX 8 INCH BY 2 INCH. THIS DAMAGE WAS REPAIRED IN ACCORDANCE WITH SRM 57-50-6 WITH REF TO SRM 51-40-12. THE SECOND DELAMINATED AREA IS DAMAGED 22 INCHES FROM I/B ON TOP SKIN. THIS DAMAGE WAS REPAIRED IN ACCORDANCE WITH SRM 57-50-6 WITH REF TO SRM 51-40-12, FOR AILERON TAB PANEL.

Part: ENGINE — FAILED (NR 1)

AFTER TAKOFF, RDU NR 1 ENGINE FLAMED-OUT AT TOP OF CLIMB. OFF LANDED GSO. FOUND METAL ON CHIP DETECTOR AND OIL SCREEN, N1 FAN BINDING AND UNABLE TO TURN N2. REPLACED ENGINE AND ROUTED TO SHOP FOR REPAIRS (SUPPLEMENT 5-18-95). UPON DISASSEMBLY IN SHOP, FOUND NR 3 BEARING STACK FAILURE. NR 3 BEARING STACK HAS SPUN, FUSING SEVERAL PARTS TOGETHER DL EO 42-61043, WHICH PREVENTS THIS FAILURE, HAD NOT YET BEEN INCORPORATED.