N324DL

Part: SKIN — CRACKED (L2 DOOR CUTOUT) · airframe 55,618 hrs · 42,399 cycles

A 3 INCH CRACK WAS FOUND IN THE FUSELAGE SKIN AND BEAR STRAP AT THE L-2 DOOR CUTOUT, LOWER FORWARD CORNER. INSTALLED REPAIR DOUBLERS PER THE SRM AND AUTHORIZED LIMITED BLIND FASTENERS PER ER/A 451664-14.

Part: SKIN — CRACKED (FUSELAGE) · airframe 52,260 hrs · 39,939 cycles

FUSELAGE SKIN CRACKED AT STA 750 AND STR 18R ADJACENT TO AN EXISTING CHEM-MILL. AREA REPAIRED IAW ERA 092053-14.

Part: BOLT — DAMAGED (ELEVATOR) · airframe 52,053 hrs · 39,795 cycles

YOKE FAILED TO RETURN TO NEUTRAL AFTER DEFLECTION. REPLACED BOLT IN ELEVATOR FEEL AND CENTERING OUTPUT ROD.

Part: CSD — FAILED (RT GENERATOR) · airframe 51,429 hrs · 39,310 cycles

ON TAKEOFF RT GEN LOW OIL PRESS LIGHT ON WITH GEN DROPPING OFF LINE WITH APU POWERING LEFT BUS DUE TO MCO ON LEFT GEN. AFTER FIVE MINUTES LOW OIL PRESSURE LIGHT OUT AND RIGHT GEN BACK ON RIGHT BUS, FREQS LOW AT 390, RIGHT GEN FELL OFF BUS AGAIN FOR REMAINDER OF FLIGHT. REPLACED CSD AND COOLER.

Part: ATTACH FITTING — CORRODED (HORIZ STAB) · airframe 50,639 hrs · 38,711 cycles

DURING INSPECTIONS PER EO 03-069697-03 AND 03-053025-03AD THE HORIZ STAB ATTACH FITTINGS, SEVERAL LUG BORES WERE OVERSIZED TO REMOVE CORROSION. CORROSION DAMAGE WAS CLEANED UP AND REWORKED PER ERA 38580314AD.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 50,639 hrs · 35,711 cycles

DURING REPAIR OF STA 663 FRAME AT S3L AN EXISTING FASTENER LOCATION WAS NOTED TO HAVE SHORTED ALONG WITH STANDOFFS THAT INTERFERED WITH REPAIR ACCOMPLISHMENT. REPAIR INSTRUCTIONS WERE ISSUED VIA ERA 385749-14.

Part: SKIN — DENTED (FUSELAGE) · airframe 50,639 hrs · 38,711 cycles

A DENT WAS FOUND IN THE FUSELAGE SKIN AT BS 380 BETWEEN S17L AND S17A. DENT WAS REPAIRED PER ERA 385801-14.

Part: THRUST REVERSER — INOPERATIVE (NR 1 ENGINE) · airframe 50,569 hrs · 38,680 cycles

T/O ABORTED ON 13R AT 120 KNOTS FOLLOWING NR 1 T/R LIGHT FLICKERING AND THEN STEADY. T/O WT 103,00 LBS. LOCKED OUT NR 1 ENGINE REV PER MEL 78-00-01A. FWD TO MCO.

Part: ENGINE — FAILED (NR 1) · airframe 49,518 hrs · 38,230 cycles

NR 1 ENGINE FAILURE ON TAKEOFF. REPLACED ENGINE.

Part: DUCT — RUPTURED (LEFT A/C PACK) · airframe 48,123 hrs · 37,630 cycles

FLIGHT ATTENDANT HEARD POP IN OVERHEAD NEAR FRONT OF A/C JUST AFTER INITIATION OF T/O POWER. ANOTHER POP AT V1. AFTER T/O SMOKE FILLED CABIN. AFTER DISCOVERY OF SMOKE IN CABIN SHUT OFF PACKS. SMOKE STARTED TO DISSIPATE. FOUND LEFT PACK MIX CHAMBER DUCT BLOWN AND DIST DUCT DAMAGE. REPLACED BOTH DUCTS AND INSPECTED AND REPLACED BOTH COALESCER BAGS. ALL LEAK CK GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 47,157 hrs · 37,219 cycles

AT DEPARTURE FWD SECTION OF EMERGENCY LIGHTS WAS FOUND TO BE INOP. REPLACED DEFECTIVE POWER SUPPLY AND BATTERY.

Part: BEAM — CRACKED (FUSELAGE) · airframe 45,398 hrs · 36,449 cycles

THE WEB OF THE STR 18A SHEAR BEAM AT FS 727, RT WAS FOUND WITH A CRACK AT AN ATTACH FASTENER ON THE AFT END. THE CRACK IS TYPICAL OF CRACKS NOTED IN S/B 737-53-1066, THOUGH THE S/B IS NOT EFFECTIVE FOR THIS AIRCRAFT. THE CRACK TERMINATED IN AN ADJACENT FASTENER HOLE AND WAS REPAIRED WITH A STEEL ANGLE PER ER/A 369718-14, REV A.

Part: FAN — FAILED (COCKPIT)

AT DEPARTURE - WHEN FLT CREW SWITCHED ON GASPER FAN GOT ELECTRICAL SMELL IN COCKPIT AND CABIN. REMOVED BAGS FROM FWD B/B AND PULLED AFT WALL TO CONFIRM GASPER FAN AT FAULT. REPLACED GASPER FAN, OP CHECKS GOOD.

Part: BATTERY PACK — NOT SECURED (ROW 18DEF)

ON L/O, FOUND EMERGENCY OVERHEAD SEAT LIGHT AT 18DEF INOP. RELAMPED, NO HELP. FOUND BATTERY PACK NOT SECURED. REINSTALLED AND SECURED, OPN NOW CKS NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

ON TEST, EMERGENCY LIGHT PACK M1137 NOT ILLUMINATING RESPECTIVE LIGHTS. REPLACE BATTERY PACK.

Part: SKIN — CRACKED (BS 951)

THE FUSELAGE SKIN WAS FOUND CRACKED AT THE LOWER FWD CORNER OF THE L2 DOOR SURROUND LOWER HINGE CUTOUT. THE CRACK WAS .25 INCH LONG IN THE SKIN ONLY. THE CRACK WAS ROUTED OUT, THE UNDERLYING BEAR STRAP INSPECTED, AND AN EXTERNAL REPAIR DOUBLER INSTALLED PER ER/A 366680-14, REV A.

Part: BULB HOLDER — FAILED (CABIN)

SMELLS LIKE ELECTRICAL SMOKE COMING FROM OVERHEAD VENT NEAR ROW 17. FOUND FLOUR BULB CONTACTS BURNED AT ROW 18 RIGHT SIDE. REPLACED BALLAST AT ROW 17 FOR LAMPS 17-18 RIGHT SIDE. REPLACED FWD LAMP HOLDER DUE TO SAME BEING BURNED. NEW BULB AND SHIELD INSTALLED. OPS CKS GOOD, (BELIEVE HOLDER WAS SOURCE OF SMOKE, BALLAST CHANGED AS PRECAUTION.)

Part: BULB — FAILED (RT OVERWING)

RT OVERWING EVACUATION HATCH OUTSIDE EMERG LIGHT INOP, REPLACE LAMP.

Part: ACTUATOR — CRACKED (NR 8 SPOILER)

AFTER LANDING, DURING TAXI, LOST NOSE WHEEL STEERING WITH NR 1 ENG RUNNING AND NR 2 ENG SHUTDOWN. A SYSTEM PRESS AND QTY BOTH READ ZERO. REPLACED NR 8 GROUND SPOILER ACTATOR DUE TO CRACK.

Part: POWER SUPPLY — FAILED (CABIN)

RT WING EXTERIOR EMERGENCY LIGHT INOP. REPLACED EMERGENCY LIGHT PWR SUPPLY.

Part: RADOME — BIRD STRIKE (FWD FUSELAGE)

BIRD STRIKE ON LEFT SIDE OF A/C. NO ABNOMAL FLIGHT CHARACTERISTICS OR ENGINE INDICATIONS. AIR TURNBACK, PERFORMED BIRD STRIKE INSP AND NO DAMAGE FOUND. CONFIRMED NO INGESTION INTO ENGINES, ALL LE DEVICES CK NORMAL.

Part: LIGHT — INOPERATIVE (CABIN)

FOUND ON LAYOVER, 2 CHECK FWD RT EMERGENCY LIGHT EXTERIOR LIGHT INOP. RELAMPED SAME, OPN CHECKS GOOD.

Part: BULKHEAD WEB — CRACKED (BS 178)

THE FS 178 BULKHEAD WEB WAS FOUND CRACKED IN SEVERAL LOCATIONS. ADDITIONALLY, THE VERTICAL STIFFENER AT LBL 5.7 AND WL 187 WAS FOUND TO HAVE A 1 INCH CRACK. THE RESULTING CUTOUT REMOVES THE FLANGE COMMON TO THE BULKHEAD WEB. THE DAMAGE WILL BE REPAIRED PER ER/A 361238-14.

Part: PCU — MALFUNCTIONED (RUDDER)

UNCOMMANDED LEFT RUDDER INPUT YAW DAMP INDICATOR SHOWED LEFT DISPLACEMENT. THIS HAPPEDED DURING CLIMB JUST AFTER TAKEOFF, WINGS LEVEL 2500 AGL 210 KTS PWR STEADY AT CLIMB EPR. REPLACED RUDDER PCU, YAW DAMP COUPLER AND TEST OK.

Part: FRAME — CRACKED (BS 794.3)

THE C-2 DOOR CUTOUT FORWARD FRAME WAS FOUND WITH A 1 INCH CRACK AT THE NR 5 STOP FITTING. REPAIRED PER ERA 304090-14AD.

Part: HYD LINE — RUPTURED (LT MLG)

A/C 324 FLT 1500, JUST PRIOR TO TOUCHDOWN MASTER CAUTION LIGHT CAME ON FOR A-SYS HYD LEAK. WHILE TURNING OFF RUNWAY A-SYS HYD QUANTITY WENT TO ZERO, FLAP LEVER WAS LEFT AT 30 DEGREES TO AGREE WITH FLAPS. FOUND HYD PRESSURE LINE LEAKING ON LEFT LANDING GEAR ACTUATOR. REPLACED LINE.

Part: GEARBOX — STUDS STRIPPED (NR 1 ENGINE)

AFTER START, OIL QTY WENT TO ZERO, PRESS WENT TO ZERO, THEN SHUTDOWN ENGINE.

Part: DUCT — CRACKED (NR 1 ENGINE)

DURING CLIMB-OUT, HAD NR 1 ENGINE OVERHEAT LIGHT. RETURNED SLC, AND FOUND CRACKED BLEED DUCT. REPLACED DUCT, OPERATION NORMAL.

Part: PSU — FAULTY (CABIN)

AFTER TAKEOFF FLIGHT ATTENDANTS REPORTED STRONG BURING ODOR IN MID CABIN AND AFT. NO SMOKE OR FIRE NOTED. RETURNED HSV. TRACED SOURCE OF ODOR TO PSU AT ROW 17ABC. REPLACED PSU OPERATION NORMAL.