N304DL

Part: ADC — CONTAMINATED (E/E BAY) · airframe 59,380 hrs · 45,017 cycles

AFTER DE-ICING AUTOTHROTTLES DISARMED DURING T/O, NO RE-ENGAGE AT ACCEL PDC CADC FAIL MSG, MACH TRIM FAIL LIGHT. DURING CLIMB CAPTS A/S AND ALTM OFF MSG AFTER LVL OFF. AT FL 290 APPROX 5 MIN CABIN ALT WARN HORN DIFF PRESS 6 PSI, CABIN ALT 10K. FOLLOWED QRH AND RTB CVG. FOUND CAPTS ALT OFF FLAG / PDC INPUT FAIL LIGHT ON, FOUND BOTTOM OF CADC NR 1 WET W/GYLCOL. INSPECTED MOISTURE TRAPS BOTH SYS DRY. DRIED AREA RPLCD NR 1 CADC PER M/M. PERFORMED CADC TEST PER MM, ALL IND OF SUSPECT GYLCOL ENTERED/ STAIRWAY DOOR.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHT) · airframe 59,259 hrs · 44,924 cycles

ON L/O CHECK, FOUND FWD CABIN EMERGENCY PATH LIGHTS INOP. REPLACED FWD CABIN EMERGENCY LIGHTS POWER SUPPLY. CHECKS GOOD.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 57,790 hrs · 43,803 cycles

INSPECTION OF THE AFT P-DOME WEB PER AD 99-08-23 REVEALED CRACKS IN THE WEB COMMON TO THE BULKHEAD Y-CHORD NEAR STRINGER 5R. THE CRACKED AREA OF WEB WAS REMOVED WITH A SINGLE CUTOUT AND REPAIRED WITH AN ALUMINUM REPAIR DOUBLER. THE REPAIR WAS ACCOMPLISHED PER ER/A 089561-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 57,789 hrs · 43,802 cycles

THE FUSELAGE SKIN WAS FOUND WITH A CRACK AT FS 727B+2 ALONG THE BONDED DOUBLER LINE JUST BELOW STRINGER 18L. THE CRACK IS TYPICAL OF BAC S/B 737-53-1065. THE CRACK WAS REMOVED WITH A CUTOUT IN THE SKIN AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER THE S/B AND PER ER/A 089524-14.

Part: SKIN — CRACKED (FUSELAGE) · airframe 57,789 hrs · 43,802 cycles

INSPECTION OF THE STRINGER 10R SKIN LAP JOINT FROM FS 360 TO 540 PER AD 2003-08-15, REVEALED A SINGLE CRACK AT FS 370. THE CRACK WAS REMOVED WITH A 1 X 4.25 INCH CUT OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER B737 SRM 53-30-3 AND PER ER/A 089539-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 57,789 hrs · 43,802 cycles

INSPECTION OF THE STRINGER 4L SKIN LAP JOINT BETWEEN FS 540 & 727 PER AD 2003-08-15, REVEALED 15 CRACK INDICATIONS. THE ENTIRE LAP JOINT WAS CUT OUT AND REPLACED WITH ALUMINUM REPAIR DOUBLERS PER BAC S/B 737-53A1177 AND ER/A 089523-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 57,789 hrs · 43,802 cycles

INSPECTION OF THE STRINGER 14L SKIN LAP JOINT PER AD 2003- 08-15, REVEALED A CRACKED FASTENER HOLE AT FS 500A+10 & ANOTHER AT FS 500B+15. THE CRACKS WERE REMOVED WITH SKIN CUTOUTS (1 X 4 & 1 X 7 INCH RESPECTIVELY). THE CUTOUTS WERE REPAIRED WITH ALUMINUM DOUBLERS PER BAC 737 SRM 53-30-3 FIG 42 AND DOCUMENTED PER ER/A 089542-14.

Part: SKIN — CRACKED (FUSELAGE) · airframe 57,789 hrs · 43,802 cycles

INSPECTION OF THE STRINGER 10L LAP JOINT BETWEEN FS 360 & 540 REVEALED A CRACKED FASTENER HOLE AT FS 380. THE CRACKED HOLE WAS REMOVED WITH A 1 X 4 INCH CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER BAC 737 SRM 53-30-3, FIG 42. THE REPAIR WAS DOCUMENTED PER ER/A 089541-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 57,789 hrs · 43,802 cycles

INSPECTION OF THE STRINGER 4R SKIN LAP JOINT PER AD 2003-08-15, REVEALED A TOTAL OF 9 CRACKED FASTENER HOLES AT THREE LOCATIONS IN THE JOINT. THE CRACKS WERE REMOVED WITH CUTOUTS OF 15.5 X 1 INCH AND TWO CUTOUTS OF 7.25 X 1 INCH. THE CUTOUTS WERE REPAIRED WITH ALUMINUM DOUBLERS PER BAC 737 SRM 53-30-3, FIG 42 AND DOCUMENTED PER ER/A 089522-14AD.

Part: FRAME — CORRODED (FUSELAGE) · airframe 57,789 hrs · 43,802 cycles

CORROSION ON AFT SIDE OF FORMER STA 827 O/B OF STR 27R. INSTALLED PERMANENT REPAIR PER SRM 53-10-4 FIG 6. COMPLETED AND SENT SSI DATA RETRIEVAL.

Part: SKIN — DENTED (RT WING) · airframe 57,155 hrs · 43,325 cycles

DAMAGE FOUND ON LOWER SKIN PANEL OF RIGHT WING AT STA 525 NEAR OUTBOARD TIP. REPAIRED PER ERA 426849-14.

Part: SWITCH — BROKEN (FWD F/A PANEL) · airframe 56,639 hrs · 42,918 cycles

ELECTRICAL SMELL COMING FROM FWD FLIGHT ATTENDANT INTERPHONECOMM PANEL. FOUND CABIN SIDEWALL LIGHT SWITCH AT FWD F/A PANEL BROKEN AND SHORTING. REPLACED SWITCH, CHECKS OK.

Part: ENGINE — BIRD INGESTION (NR 1) · airframe 56,180 hrs · 42,554 cycles

IRREG: ON T/O DETECTED SMELL IN COCKPIT AND CABIN. RETURN TO CVG. FOUND EVIDENCE OF BIRD STRIKE NR 1 ENG. INSP ENG AND ENG BLEED DUCTS. PERFORMED DUCT BURNOUT AND REPLD. WATER SEPARATOR BAGS.

Part: VALVE — STUCK (E&E BAY) · airframe 55,868 hrs · 42,296 cycles

IR: 20KFT CABIN ALTITUDE HORN WENT OFF.CBN ALT AT 11 KFT. STARTED DESCENT SWITCHED TO STBY CBN WOULD NOT PRESS. MANUAL MODE ALSO INOP. REPLACED E & E COOLING EXHAUST VALVE. ALSO FOUND LEFT ENGINE 450 DEG THERMOSTAT SENSE LINE BACKED OFF. TIGHTENED SAME,RAN ENGINES ACFT PRESSURIZED TO 5 PSID.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 52,865 hrs · 40,883 cycles

CENTER WING / LONGITUDINAL OVERWING FLOORBEAM / BL 24.82 / FS 678 : CHORD AND WEB CRACK REPAIR INSPECTION OF THE LBL & RBL 24.82 LONGITUDINAL FLOORBEAMS PER AD 2001-17-18 REVEALED TYPICAL CRACKS IN THE BEAM WEB, WEB DOUBLER, AND UPPER CHORD AT FS 678 AT THE AILERON CONTROL QUADRANT CUTOUT. THE CRACKS ARE TYPICAL OF BAC S/B 737-57-1139. THE UPPER CHORDS AND WEB DOUBLERS WERE REPLACED. THE WEB CRACKS WERE ROUTED OUT AND REPAIRED WITH AN ALUMINUM DOUBLER. THE WORK WAS DONE PER ER/A 382700-14AD.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 52,865 hrs · 40,883 cycles

INSPECTION OF THE FS 178 BULKHEAD PER AD 2000-05-29 REVEALED A SMALL CRACK IN THE LEFT SIDE CHORD AT WL 207 AND ANOTHER AT WL 195. THE LT CHORD WAS CUT AT WL 212 AND A NEW LOWER SECTION INSTALLED PER THE REQUIREMENTS OF BAC S/B 737-53A1173. THE WORK WAS DOCUMENTED PER ER/A 382698-14AD.

Part: FRAME — CRACKED (CARGO DOOR) · airframe 52,865 hrs · 40,883 cycles

FORWARD CARGO DOOR WAS FOUND WITH CRACKED LOWER FOWARD AND AFT CORNER FRAMES, FORWARD AND AFT LOWER STOP BEAMS. REPAIRED.

Part: FLASHLIGHT — INOPERATIVE (CABIN) · airframe 51,346 hrs · 40,244 cycles

DURING L/O FOUND EMERGENCY FLASHLIGHT AT AFT-LOWER STATION INOP.

Part: SKIN — CRACKED (FS 960, S-17L) · airframe 51,089 hrs · 40,134 cycles

FUSELAGE / SKIN ASSY / AFT ENTRY DOOR (L2) / LWR FWD CORNER:CRACK REPAIR THE LOWER FORWARD CORNER OF THE AFT ENTRY DOOR CUTOUT WAS FOUND WITH A TYPICAL CRACK THROUGH THE SKIN AND UNDERLYING BEAR STRAP. THE CRACK WAS REMOVED WITH A 1.25" X 2.2" CUTOUT. THE CUTOUT WAS REPAIRED WITH A STACK-UP OF THREE EXTERNAL ALUMINUM REPAIR DOUBLERS INSTALLED PER ER/A 381368-14, REV A.

Part: SKIN — CRACKED (FUSELAGE) · airframe 51,089 hrs · 40,134 cycles

FOUND FUSELAGE SKIN AT LOWER FORWARD CORNER OF L-2 DOOR CUTOUT WITH 0.75 INCH CRACK. ALSO FOUND BEARSTRAP AT THAT LOCATION WITH 1.5 INCH CRACK. REPAIRED PER SRM 53-30-3.

Part: CONTROLLER — FAILED (WINDOW HEAT) · airframe 49,845 hrs · 39,608 cycles

ELECTRIAL CONNECTOR TO RIGHT FWD WINDOW BEGAN SMOKING, TURNED OFF WINDOW HEAT SMOKE STOPPED. / REPLACED R1 WINDOW AND WINDOW HEAT CONTROLLER PER M/M. OPNL TEST OF WINDOW HEAT GOOD

Part: LINE — DAMAGED (NR 2 ENGINE) · airframe 48,368 hrs · 38,986 cycles

ENGINE HYD PUMP NR 2 PRESSURE LIGHT ON SYSTEM. REPLACED NR 2 ENGINE HYD PUMP AND HYD PRESS LINE. REPLACED FILTERS AND INSP A SYSTEM RETURN MODULE, ALL NORMAL. FLUSHED LINES, NO CONTAMINATION FOUND. RAN ENGINES, CHECKS NORMAL.

Part: SKIN — CRACKED (FUSELAGE) · airframe 48,301 hrs · 38,954 cycles

THE FUSELAGE SKIN AND BONDED DOUBLER WAS FOUND WITH A TYPICAL CRACK IN THE LOWER HINGE CUTOUT OF THE AFT GALLEY DOOR CUTOUT. THE CRACK WAS REMOVED WITH A 1 X 1.5 INCH CUTOUT. THE CUTOUT WAS LOCALLY REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND STEEL TRIPLER PER BAC 737 SRM 53-30-3, FIG 33 AND ER/A 378706-14, REV A.

Part: SKIN — CRACKED (FUSELAGE) · airframe 48,301 hrs · 38,954 cycles

A 4 INCH CRACK WAS FOUND IN THE FUSELAGE SKIN NEAR FS 520 AND STRINGER 16L. THE SKIN WAS CUT OUT TO REMOVE THE CRACK. THE CUT OUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER. THE REPAIR WAS INSTALLED PER ER/A 378705-14.

Part: FITTING — CORRODED (FUSELAGE) · airframe 46,953 hrs · 38,352 cycles

CORROSION WAS FOUND ON THE LHS MLG SIDE STRUT SUPPORT FITTING. THE BORE WAS OVERSIZED AND A BUSHING INSTALLED PER ERA 334372-14 AT HMV.

Part: SKIN — CRACKED (FUSELAGE) · airframe 46,953 hrs · 38,352 cycles

THE FUSELAGE SKIN WAS FOUND WITH A .375 INCH CRACK AT THE R2 DOOR UPPER HINGE CUTOUT. THE DAMAGE WAS LIMITED TO THE SKIN ONLY. THE DAMAGE WAS REPAIRED PER ERA 259665-14 AT HMV.

Part: FRAME — MISINSTALLED (FUSELAGE) · airframe 46,953 hrs · 38,352 cycles

THE FS 440 FRAME INSTALLATION DID NOT MATCH THE CONFIGURATION FOUND IN S/B 737-53-1125. THE S/B REQUIRES INSTALLATION OF .2187 INCH FASTENERS AND THE FACTORY INSTALLATION INSTALLS .25 INCH FASTENERS. ERA 334319-14 ADDRESSES THIS CONDITION AND INSTALLS MS20470D8 FASTENERS. THIS WAS DISCOVERED AT HMV.

Part: ATTACH FITTING — CORRODED (HORIZONTAL STAB) · airframe 46,953 hrs · 38,352 cycles

THE HORIZONTAL STABILIZER REAR SPAR ATTACH LUGS WERE FOUND CORRODED. THE DAMAGE WAS REMOVED AND OVERSIZED BUSHINGS WERE INSTALLED PER ERA 334311-14 AT HMV.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 46,953 hrs · 38,352 cycles

CRACKS WERE DISCOVERED ON THE WEB OF STR 18AL AT FS 727. ERA 334331-14 REPAIRS THE DAMAGE SIMILIARLY TO THAT OF S/B 737-53-1170. THE DAMAGE WAS FOUND AT HMV.

Part: ATTACH FITTING — CORRODED (FUSELAGE) · airframe 46,953 hrs · 38,352 cycles

SEVERAL OF THE FIN ATTACHMENT LUGS WERE FOUND CORRODED AT THE AFT SPAR. THE CORROSION WAS REMOVED AND THE BUSHINGS WERE RE-MANUFACTURED PER ERA 334313-14 AT HMV.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 46,953 hrs · 38,352 cycles

A 4 INCH CRACK WAS FOUND IN THE OUTBOARD SKIN FLANGE OF THE S27R KEEL CHORD AT FS 727A. THE EXISTING FACTORY SPLICE ANGLES WERE MODIFIED TO REPAIR THE DAMAGE PER ERA 334332-14 AT HMV.

Part: SKIN — CORRODED (FUSELAGE) · airframe 46,953 hrs · 38,352 cycles

CORROSION WAS FOUND ON THE FUSELAGE SKIN AT FS 967 BETWEEN STR 27L AND 27R. THE FRAME SHEAR TIE AND STR 27R WAS ALSO CORRODED AT THIS LOCATION. THE STRINGER WAS REPAIRED PER B737-200 SRM 53-10-3, FIGURE 1, THE FRAME SHEAR TIE REPLACED AND THE SKIN WAS REPAIRED PER ERA 334341-14. THE DAMAGE WAS FOUND AT HMV.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 46,953 hrs · 38,352 cycles

THE WEB OF THE FS 178 BULKHEAD WAS FOUND CRACKED AT RBL 1 AND WL 190. THE CRACK WAS REMOVED BY A 1.0 X 2.0 CUTOUT AND A DOUBLER WAS INSTALLED PER ERA 334328-14.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 46,906 hrs · 38,328 cycles

CRACKING FOUND IN BL 0 LONGITUDINAL FLOORBEAM WEB AFT OF STA 717. RESULTED IN TRIMOUT OF BEAM WEB BETWEEN STA 700 AND 721. CORRECTIVE ACTION: ER/A 334337-14.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 46,907 hrs · 38,328 cycles

THE LOWER SKIN OF THE KEEL BEAM WAS FOUND CORRODED BETWEEN FS 661 AND FS 727. THE SKIN PANEL WAS REMOVED AND REPLACED PER ERA 334318-14 AT HMV.

Part: BATTERY — DISCHARGED (ROW 18)

EMERGENCY LIGHT AT 18D AND 2R DOOR ON. REPLACED CHARGER RACK AND BATTERY.

Part: STRINGER — CORRODED (BS 988)

STR 27 LT AT FS 988 CORRODED. REPAIRED PER SRM 53-10-3.

Part: STRINGER — CORRODED (BS 948)

STR 27 LT AT FS 948 CORRODED. REPAIRED PER SRM 53-10-3.

Part: STRINGER — CORRODED (BS 978)

STR 26R AT FS 978 CORRODED. REPAIRED PER SRM 53-10-3.

Part: STRINGER — CORRODED (BS 1006)

STRINGER 27L FS 1006 HAD CORROSION. REPAIRED PER SRM 53-10-3 FIG 1.

Part: WIRE — SHORTED (PAX DOOR)

LEFT AND RIGHT FWD DOORS EMERGENCY LIGHT EXIT IDENTIFIERS DO NOT ILLUMINATE WHEN TESTED. POWER SUPPLY FUSE BLOWN DUE TO LEFT LIGHT ASSY WIRE SHORTED. REPLACED FUSE IN POWER SUPPLY AND REPLACED LEFT LIGHT ASSY.

Part: BULB — FAILED (CABIN)

R2 SLIDE LIGHT INOP. RELAMPED.

Part: COALESCER BAG — DIRTY (NR 2 ENGINE)

UPON LIFTOFF NOTICED ACRID SMOKE SMELL AND CABIN FUMES, VERIFIED BY F/A'S. RETURNED FOR IMMEDIATE LANDING, OVERWEIGHT 110, BRAKE APPLICATION 90 KTS. INSPECTED AC FOR SOURCE OF SMELL, NO DEFECTS NOTED. PERFORMED T/O PWR RUN AND NOTICED LIGHT SMELL FROM RT ENG PNEUMATICS. SUSPECT BIRD RESIDUE FROM LAST LEG BIRDSTRIKE. REPLACED BOTH A/C WATER BAGS AS A PRECAUTION.

Part: CONTROLS — STIFF (AILERONS)

AILERONS STIFF, NO BINDING FELT BUT RESISTANCE TO CONTROL WHEEL MOVEMENT GREATER THAN NORMAL. REPLACED 'A' AND 'B' SYSTEMS RETURN FILTERS, CHECKED ROLL FORCE TRANSMITTER AND VISUALLY INSPECTED PULLEYS AND CABLES.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMER EXIT LIGHTS ABOVE 1B AND 2C REMAINED ILLUM WITH SWITCH IN ARMED POSITION. REPLACED OVHD BATT PACK AND PWR SUPPLY CKS OK.

Part: BLKHD WEB — CRACKED (FS 178)

REF. E.O. 03-069482-12 ME-04 OPN. 0445.1, 2 INCH CRACK AND 1 INCH CRACK IN BS 178 BULKHEAD WEB AT RT BL 5.7 INBOARD OF VERTICAL STIFFENER. .50 INCH CRACK IN 178 BULKHEAD WEB AT RT BL 5.7 OUTBOARD OF VERTICAL STIFFENER. TWO .25 INCH CRACKS AND 1 INCH CRACK IN 178 BULKHEAD WEB AT LT BL 5.7 INBOARD OF VERTICAL STIFFENER. ACCOMPLISHED REPAIRS PER SRM 53-10-11, REF S/B 737-53-1173.

Part: FLOOR BEAM — CRACKED (WING CTR SECT)

THE BL0.07 FLOOR BEAM OF THE WING CENTER SECTION IS COMPLETELY CRACKED. THE WEB AND WEB DOUBLER ARE CRACKED APPROXIMATELY 2.0 INCHES IN LENGTH IN THE SAME LOCATION. THE ORIGINAL 65-45410-104 ANGLE IS REINSTALLED TO REPAIR DAMAGE. REPAIRS ACCOMPLISHED PER DLA ERA 302296-14.