N305DL

Part: LINE — LEAKING (NR 2 ENGINE) · airframe 61,569 hrs · 46,098 cycles

LOSS OF A SYSTEM HYD, ALT GEAR EXTENSION. REPLACED LEAKING PRESSURE LINE IN RIGHT PYLON.

Part: SKIN — CRACKED (FUSELAGE) · airframe 59,957 hrs · 44,945 cycles

THE FUSELAGE SKIN WAS FOUND WITH A CRACK AT FS 764 RUNNING ALONG THE BONDED DOUBLER MILL LINE JUST ABOVE STRINGER 19L. THE CRACK IS TYPICAL OF AD 2004-18-06. THE CRACK WAS REMOVED WITH A CUT OUT IN THE SKIN AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER B737 SRM AND PER ER/A 096925-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 59,957 hrs · 44,945 cycles

A CRACK WAS FOUND IN THE FUSELAGE SKIN JUST BELOW STRINGER 18R RUNNING ALONG THE MILL LINE OF THE BONDED INTERNAL DOUBLER. THE CRACK IS TYPICAL OF AD 2004-18-06. THE CRACK WAS REMOVED WITH A CUTOUT TO THE SKIN AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER B737 SRM AND ER/A 096927-14AD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,275 hrs · 43,662 cycles

APPROX 3 INCH LONGITUDINAL CRACK IN FUSELAGE SKIN STA 944 ABOVE STR 24R. REPAIRED PER SRM.

Part: ROLLER — OUT OF POSITION (T/E FLAP) · airframe 58,232 hrs · 43,628 cycles

DURING ROTATION A STRONG RT WING UP FORCE WAS ENCOUNTERED AS THE AIRCRAFT BECAME AIRBORNE. SUBSTANTIAL RT AILERON WAS NECESSARY TO KEEPS WINGS LEVEL. FOUND LT OB FLAP IB TRACK WITH BELLCRANK ROLLER OUT OF CAMTRACK. REPLACED BELLCRANK.

Part: SKIN — DELAMINATED (T/E FLAP) · airframe 58,222 hrs · 43,621 cycles

NR 2 AFT FLAP AFT SKIN SEPARATED/DELAMINATED AT IB END. REPAIRED IAW SRM 51-40-20 FIG 10.

Part: SKIN — DELAMINATED (LT ELEVATOR) · airframe 58,222 hrs · 43,621 cycles

WHILE WORKING N/R 13 FOUND LT ELEVATOR UPPER SURFACE DELAMINATED UNDER CONDUCTIVE FRAME REPAIRED PER SRM 55-20-03 FIG 1 TABLE 1.

Part: SKIN — CRACKED (C2 DOOR CUTOUT) · airframe 58,222 hrs · 43,621 cycles

3/16 INCH CRACK IN FUSELAGE OUTER SKIN AT C2 DOOR CUTOUT UPPER AFT CORNER , FASTENER REPAIR PER SRM 53-30-3 FIG 6

Part: SKIN — CRACKED (RT SPOILER) · airframe 58,222 hrs · 43,621 cycles

DENT & CRACK ON LWR SIDE OF I/B GROUND SPOILER 1.5 INCH FWD OF T/E AFT OF INBOARD ACTUATOR.

Part: SKIN — CRACKED (FUSELAGE) · airframe 57,548 hrs · 43,111 cycles

THE FUSELAGE SKIN WAS FOUND WITH A 2.75 INCH CRACK RUNNING ALONG THE BONDED DOUBLER LINE JUST ABOVE STRINGER 19L BETWEEN FS 776 & 787. THE CRACK WAS REMOVED WITH A CUTOUT IN THE SKIN AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER BAC S/B 737-53-1065 AND ER/A 088294-14.

Part: GASPER FAN — FAILED (CARGO COMP) · airframe 56,740 hrs · 42,461 cycles

ON CLIMBOUT FLIGHT ATTENDANTS REPORTED SMOKE ODOR IN CABIN, STRONGER IN AFT PART OF CABIN, NO SMOKE VISIBLE. GASPER FAN WAS TURNED OFF AND ODOR DISSIPATED. FOUND GASPER FAN AT FAULT. REPLACED SAME.

Part: BEAR STRAP — CRACKED (FUSELAGE) · airframe 56,730 hrs · 42,453 cycles

THE FUSELAGE SKIN AND BONDED DOUBLER WERE FOUND WITH A TYPICAL CRACK AT THE UPPER HINGE CUTOUT OF THE L1 DOOR OPENING. THE UNDERLYING BEAR STRAP WAS UNCRACKED. THE CRACK WAS REMOVED WITH A 1.7 INCH CUTOUT IN THE SKIN AND BONDED DOUBLER AND REPAIRED WITH AN EXTERNAL STEEL DOUBLER PER ER/A 087355-14, REV A.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 56,142 hrs · 41,973 cycles

WHILE ACCOMPLISHING INSPECTIONS OF THE AFT PRESSURE BULKHEAD IAW AD 99-08-23, 2 CRACKS WERE FOUND EMANATING FROM FASTENER HOLES IN THE BULKHEAD AT THE ATTACH AREA. THE CRACKED AREA OF WEB WAS CUTOUT AND REPAIRED WITH AN ALUMINUM DOUBLER IAW SRM AND ER/A 385086-14AD.

Part: SUPPORT FITTING — DAMAGED (ENGINE MOUNT) · airframe 55,780 hrs · 41,640 cycles

FWD ENGINE MOUNT SUPPORT FITTING ASSY WAS FOUND WITH O/S MOUNT HOLES. REPAIR PER ER/A 422119-14AD.

Part: DOOR FRAME — CRACKED (C2 DOOR) · airframe 55,476 hrs · 41,522 cycles

DOOR / C-2 CARGO DOOR / FWD FRAME / LAP SPLICE : CRACK REPAIR THE C-2 CARGO DOOR WAS FOUND WITH A 1" CRACK IN THE UPPER AND LOWER FRAME WEB AT THE LAP JOINT FOR THE TWO FRAMES. THE CRACK WAS STOP DRILLED IN BOTH MEMBERS AND REPAIRED WITH 2 TITANIUM REPAIR ANGLES PER ER/A 384452-14, REV A.

Part: SMOKE — DETECTED (CABIN) · airframe 55,299 hrs · 41,451 cycles

SMOKE/ODOR OF UNKNOWN ORIGIN MID TO FWD CABIN TO COCKPIT, SIMILAR TO FIRECRACKER FUSE. AFTER DEPLANING, COULD NOT LOCATE A SOURCE FOR THE ODOR OR SMOKE, SUSPECT A PIECE OF GROUND EQUIPMENT WAS THE SOURCE. A/C OK FOR SVC.

Part: TIRE — FLAT (NLG) · airframe 55,073 hrs · 41,358 cycles

IR/ UPON EXTENSION OF GEAR AND 3 GREEN INDICATIONS. SEVERAL SECONDS LATER HEARD A THUMP NOISE. INSPECTED GEAR THROUGH NOSE GEAR PORT AND CONFIRMED GEAR DOWN. EMERGENCY DECLARED MCO. FOUND LEFT NOSE TIRE FLAT. REPLACED BOTH NOSE WHEEL ASSYS PER MM.

Part: SKIN — CRACKED (FUSELAGE) · airframe 54,498 hrs · 41,117 cycles

THE FUSELAGE SKIN AT FS 525 AND STRINGER 16R WAS FOUND TO BE CRACKED ALONG THE UPPER CHEM-MIL EDGE OF THE INTERNAL BONDED DOUBLER. THE CRACK FOUND WAS APPROXIMATELY 3 INCHES IN LENGTH. THE CRACK WAS NOT FOUND BY DOING INSPECTIONS PER BOEING SB 737-53A1210. THE CRACK WAS REPAIRED PER 737-200 SRM 53-30-3, FIGURE 1.

Part: BATTERY — DISCHARGED (CABIN) · airframe 53,667 hrs · 40,776 cycles

RT OVERWING EMERGENCY EXIT SIGN INOP. REPLACED BATTERY, OPS NORMAL.

Part: ENGINE — FAILED (NR 1) · airframe 53,197 hrs · 40,579 cycles

PASSING THROUGH 10,000 FT ON DEPARTURE, HAD LOUD BANG FROM NR 1 ENGINE. ENGINE RPM DECREASED RAPIDLY AND TEMPERATURE WENT TO MAX INDICATED ON GAUGE. SHUT DOWN ENGINE AND RETURNED TO AIRPORT. REPLACED NR 1 ENGINE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 52,746 hrs · 40,398 cycles

OVERHEAD EMERGENCY FLOODLIGHT INOP AT SEAT 04C. RELAMPED.

Part: COFFEEMAKER — MALFUNCTIONED (GALLEY) · airframe 52,130 hrs · 40,132 cycles

AFT COFFEEMAKER HAD SMALL AMOUNT OF SMOKE REPORTED BY FLT ATTENDANT. COFFEEMAKER TURNED OFF, SMOKE STOPPED. REQUESTED INSPECTION OF COFFEMAKER. INSPECTED WIRING AT COFFEEMAKERES 1 AND 2, ALL OK. COULD NOT DETERMINE 1 OF 2 INOP. PULLED AND COLLARED 1 AND 2 COFFEEMAKER C/B'S. FWD TO MCO, PLAC PER MEL 25-00-10. AFT COFFEEMAKERS INOP.

Part: SKIN — CRACKED (FUSELAGE) · airframe 48,953 hrs · 38,817 cycles

FUSELAGE / SKIN / AFT ENTRY DOOR OPENING / LWR HINGE CUTOUT:CRACK REPAIR THE LOWER HINGE CUTOUT OF THE AFT ENTRY DOOR OPENING SURROUND SKIN WAS FOUND WITH A TYPICAL CRACK IN THE SKIN AND BONDED DOUBLER. THE BEAR STRAP WAS NOT CRACKED. THE CRACK WAS REMOVED WITH A .5" CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND STELL TRIPLERPER B737 SRM 53-30-3, FIG. 34 AND ER/A 379396-14, REV A.

Part: UNKNOWN — ODOR (COCKPIT) · airframe 48,487 hrs · 38,617 cycles

PILOTS DETECTED A MELTING PLASTIC SMELL AT CRUISE (FL 330.7M) SMELL WAS INTERMITTENT AND FLT CREW WAS UNABLE TO DETERMINE THE SOURCE. EXECUTED PRECAUTIONARY, DIVERT TO ATL. FUMES/SMELL DID NOT REOCCUR AFTER INITIAL DESCENT INTO ATL. INSP PACK INLETS, INSP BEHIND C/B PANELS IN C/P. INSPECTED FORWARD AND MAIN E & E, NOTHING FOUND. REPLACED WATER SEPARATOR BAGS. RAN BOTH ENGINES TO POWER FOR 5 MIN PER PFHB, NO ODOR. FOUND OK FOR FLIGHT.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

THE LT AFT KEEL CHORD (STR 27L) WAS FOUND CORRODED BETWEEN FS 907 AND FS 927. AS A RESULT STRINGER 27L WAS REMOVED FROM FS 907 TO FS 1016 AND A NEW SECTION SPLICED IN PER ERA 334591-14 AT HMV.

Part: FRAME — CRACKED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

A CRACK WAS FOUND IN THE LOWER FASTENER OF THE INBOARD CHORD OF THE FS 616 JUST BELOW THE CABIN FLOOR. THE CRACK IS SIMILIAR TO THAT OF S/B 737-53-1182. ADDITIONALLY, A PILOT HOLE FROM THE FACTORY WAS FOUND AT THE LOWER EDGE OF THE SIXTH FASTENER FROM THE BOTTOM. ERA 334541-14 INSTALLS A REPAIR SIMILIAR TO THAT OF THE S/B. THE DAMAGE WAS FOUND AT HMV.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

THE LOWER STUB FRAME FOR THE FORWARD SIDE OF THE AFT GALLEY DOOR CUTOUT WAS FOUND DAMAGE AND REPLACED ON ERA 334610-14 AT HMV.

Part: ATTACH FITTING — CORRODED (HORIZONTAL STAB) · airframe 47,556 hrs · 38,207 cycles

CORROSION WAS FOUND ON THE RHS AFT SPAR LUGS OF THE HORIZ STABILIZER. CORROSION WAS REMOVED BY OVERSIZING THE BORES AND SPOTFACING THE FORWARD AND AFT FACES OF THE LUG. THE DAMAGE WAS FOUND AT HMV AND REPAIRED PER ERA 334542-14.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

THE FUSELAGE WING CENTER SECTION FLOOR BEAM AT RBL 12 WAS CRACKED IN THE WEB AND UPPER CAP. THE UPPER CAP WAS CUT AND SPLICED TO REMOVE THE DAMAGE AND THE WEB WAS REPAIRED PER ERA 334535-14. THE DAMAGE WAS FOUND AT HMV.

Part: SKIN — CRACKED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

THE FUSELAGE SKIN WAS FOUND CRACKED JUST BELOW STR 18L AT FS 727B. THE 3 INCH CRACK WAS CUTOUT AND AN EXTERNAL REPAIR WAS ACCOMPLISHED PER B737-200 SRM 53-30-3, FIGURE 6. THE DAMAGE WAS FOUND AT HMV.

Part: ATTACH FITTING — CORRODED (VERTICAL STAB) · airframe 47,556 hrs · 38,207 cycles

CORROSION WAS FOUND ON THE FUSELAGE SIDE OF THE VERTICAL FIN ATTACH LUGS. LUG BORES WERE OVERSIZED THE THE LUG FACES WERE SPOTFACED TO REMOVE THE CORROSION. THE DAMAGE WAS FOUND AT HMV AND REPAIRED PER ERA 334526-14.

Part: SKIN — CRACKED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

THE FUSELAGE SKIN WAS FOUND CRACKED JUST ABOVE STR 19R AT FS 767. THE 2.5 INCH CRACK WAS CUTOUT AND A REPAIR WAS INSTALLED PER B737-200 SRM 53-30-3, FIGURE 6. THE DAMAGE WAS FOUND AT HMV.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

THE BL .07 FLOORBEAM WAS FOUND CRACKED IN THE WEB BETWEEN FS 700 AND FS 717. ERA 334520-14 REPAIRED THE DAMAGE SIMILIARLY TO S/B 737-57-1210 AT HMV.

Part: ATTACH FITTING — CORRODED (HORIZONTAL STAB) · airframe 47,556 hrs · 38,207 cycles

CORROSION WAS FOUND ON THE LEFT AND RIGHT FORWARD AND AFT CLEVIS LUGS. THE DAMAGE WAS REMOVED BY INCREASING THE DIA OF THE BORES AND SPOTFACING SOME OF THE FACE OF THE NR 3 LUG. THE DAMAGE WAS FOUND AT HMV AND REPAIRED BY ERA 334525-14.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

THE UPPER CAP AND WEB OF THE LBL 24 FLOOR BEAM WAS FOUND CRACKED BETWEEN STATIONS 670 AND 678. THE UPPER CAP WAS SPLICED AND THE WEB WAS REPAIRED PER ERA 334555-14 AT HMV.

Part: FRAME — MISDRILLED (FUSELAGE) · airframe 47,556 hrs · 38,207 cycles

A DOUBLE DRILLED HOLE WAS FOUND ON THE ORIGINAL INSTALLATION OF THE FS 663 FRAME BETWEEN STRINGERS 9L AND 10L. THE HOLE WAS CLEANED UP AND REPAIRED PER ERA 334565-14 AT HMV.

Part: FITTING — CORRODED (VERTICAL STAB) · airframe 47,550 hrs · 38,203 cycles

DURING HMV CORROSION WAS FOUND ON THE AFT FACES OF THE LEFT AND RIGHT VERTICAL STABILIZER PRIMARY REAR SPAR TERMINAL FITTING. THE AREA WAS BLENDED AND TREATED PER ERA 334527-14AT HMV.

Part: ATTACH FITTING — CORRODED (HORIZONTAL STAB) · airframe 47,550 hrs · 38,203 cycles

CORROSION WAS FOUND ON THE HORIZONTAL STABILIZER FRONT AND REAR SPAR ATTACH FITTING LUGS. THE LUGS WERE SPOT FACED AND THE BORES OVERSIZED PER ERA 334517-14 AT HMV.

Part: TRANSFORMER — FAILED (NR 2 OIL QTY IND) · airframe 47,421 hrs · 38,145 cycles

C/B POPPED, CREW REPORTED SMOKE AND BURNING SMELL BEFORE C/B POPPED. FOUND SHORTED TRANSFORMER IN OIL QTY INDICATOR. REPLACED SAME.

Part: SKIN — CRACKED (FUSELAGE)

THE LOWER FORWARD CORNER OF THE AFT ENTRY DOOR (L2) CUTOUT WAS FOUND WITH A TYPICAL CRACK IN THE SKIN, BONDED DOUBLER, AND BEAR STRAP. THE CRACK WAS REMOVED WITH A 1.3 X 2.4 CUTOUT AND REPAIRED WITH 3 EXTERNAL DOUBLER PER B737 SRM 53-30-3, FIG 24 AND ER/A 369361-14, REV A.

Part: LIGHT — INOP (DOOR 1R)

DOOR 1R EMERGENCY LIGHT FLASHES.

Part: SKIN — CRACKED (BS 951)

THE FUSELAGE SKIN ASSY AND BEAR STRAP WERE FOUND WITH AN APPROX 1 INCH LONG CRACK AT THE LOWER HINGE CUTOUT OF THE AFT GALLEY DOOR CUTOUT. THE CRACK WAS ROUTED OUT OF THE SKIN AND BEAR STRAP AND REPAIRED WITH THREE EXTERNAL ALUMINUM DOUBLERS. THE REPAIR WAS ACCOMPLISHED PER ER/A 366265-14, REV A.

Part: SIGN — INOPERATIVE (CABIN)

2L EMERGENCY DOOR LIGHT INOP. REPLACED ASSEMBLY.

Part: PRESS PACK — MALFUNCTIONED (LT MLG WW)

LOST PRESSURE ON BOTH A-SYS HYD PUMPS, HYD QTY NML. MTC HAS FOUND NO FLUID LOSS. MOTORED ENG'S AT GATE HAD PRESSURE. CKD CASE DRAIN AND PRESS FILTERS, NO CONTAMINATION FOUND. REPLACED A-SYS HYD PRESS PACKAGE AND CASE DRAIN FILTERS, RAN BOTH ENG'S AND EXERCISED ALL FLIGHT CONTROLS. ALL PRESSURES WERE NORMAL.

Part: FLOOR BEAM — CORRODED (BS 967)

DURING INSPECTION, BS 967 FLOOR BEAM HAD CORROSION BLENDED AWAY AT 2 NUTPLATE LOCATIONS. IN ACCORDANCE WITH BACOTWX DAL-ATL-96-124RR, DATED 14 AUG 1996, THE BEAM REPAIRED USING A REPAIR STRAP.

Part: GATE HINGE — CRACKED (R1 DOOR LOWER)

THE R-1 DOOR LOWER GATE HINGE WAS FOUND CRACKED. THE CRACK WAS TYPICAL TO THOSE DISCUSSED IN AND REPAIRED BY BACO S/B 737-52A1124. THE SUBJECT HINGE WAS REMOVED AND REPLACED WITH A SERVICEABLE PART.

Part: FLOOR BEAM — CRACKED (BS 663)

DURING INSPECTION, THE BL 0.07 FLOOR BEAM UPPER CAP OF WING CENTER SECTION IS CRACKED THROUGH AT FS 663. NO CRACKS FOUND IN WEB. THE DAMAGE WAS REPAIRED PER B737S/B 57-1210.

Part: BATTERY — DISCHARGED (CABIN)

RIGHT LOWER WING EMERGENCY LIGHT INOP. REPLACED BATTERY PACK, ALL OPS NORMAL.

Part: BATTERY — DISCHARGED (MEGAPHONE)

ON PREFLIGHT, FOUND AFT MEGAPHONE INOP. REPLACED BATTERIES, OPS CKS GOOD.

Part: DOOR CUTOUT — CRACKED (CABIN)

DURING INSPECTION, BOTH THE L1 AND R1 DOOR CUTOUTS HAD CRACKS RUNNING FROM THE LOWER AFT CORNER EDGES AND TERMINATING IN FASTENER HOLES. BOTH CRACKS EXTEND THROUGH THE SKIN, BONDED DOUBLER AND UNDERLYING BEAR STRAP. THE R1 DOOR CUTOUT WAS REPAIRED IN ACCORDANCE WITH B737-200 SRM 53-30-3, FIG 26. THE L1 DOOR WAS IN ACCORDANCE WITH BAC S/B 737-53-1083.

Part: EEL PIGTAIL — MISSING (CABIN)

PIGTAIL FOR A WHITE EMERGENCY FLOOR TRACK LIGHT WAS TORN OUT. REPLACED PIGTAIL ASSY LIGHT BULB AND LENS ASSY AT SEAT 1-C. LIGHT OPS CHECK OK.

Part: SKIN — DENTED (NR 4 LE FLAP)

DURING SHOP INSPECTION, NR 4 LEADING EDGE SLAT WAS FOUND WITH DENT TO LEADING EDGE SKIN AT 10 FROM THE OUTBOARD END, REPAIRED PER SRM 57-50-3, FIG 1.