N327DL

Part: POWER SUPPLY — FAILED (EMERGENCY LIGHTS) · airframe 55,814 hrs · 42,149 cycles

EMERGENCY LIGHTS INOP ROW 11 THRU 15. REPLACED PWR SUPPLY FUSE. REPAIRED CHAFED WIRE.

Part: BLADE — BROKEN (NR 2 ENGINE) · airframe 54,853 hrs · 41,398 cycles

AT TOP OF DESCENT UPON THROTTLE RETARD NR 2 ENGINE VIBRATION. ALL ENGINE PARAMETERS NORMAL. AT 75 PERCENT VIBRATION DISCONTINUED. LEFT ENGINE AT 75 PERCENT. FOUND TURBINE BLADE DAMAGE. REPLACED ENGINE.

Part: MEGAPHONE — INOPERATIVE (CABIN) · airframe 53,627 hrs · 40,504 cycles

ON PREFLIGHT FWD MEGAPHONE INOP. REPLACED MEGAPHONE.

Part: BULKHEAD — CORRODED (FUSELAGE) · airframe 48,818 hrs · 38,492 cycles

CORROSION WAS FOUND ON THE WEB, Y-CHORD AND STIFFENER OF THE FS 1016 BULKHEAD. THE CORRODED AREAS WERE CUT OUT AND REPAIRS INSTALLED. THE DAMAGE WAS FOUND AT HMV.

Part: SKIN — DENTED (SKIN) · airframe 48,798 hrs · 38,481 cycles

A CRACK AND DENT WERE FOUND AT THE LOWER HINGE CUTOUT OF THEAFT GALLEY DOOR. THE DAMAGES WERE CUTOUT AND A DOUBLER, TRIPLER, AND QUADRUPLER WERE INSTALLED. THE DAMAGE WAS FOUND AT HMV.

Part: FRAME — CRACKED (CABIN) · airframe 48,798 hrs · 38,481 cycles

THE FS 663.75 FRAME WAS FOUND CRACKED AT STR 1 AND STR 3L. THE CRACKS WERE CUT OUT, THE AREA NDT INSPECTED AND A REPAIRPER SRM 53-10-4, FIGURE 14 INSTALLED. THE DAMAGE WAS FOUND AT HMV.

Part: FRAME — CRACKED (CABIN) · airframe 48,798 hrs · 38,481 cycles

THE FRAMES AT FS 727B-RH, 747-LH, 787-RH, 787-RH, 827-LH, 847-LH AND 907-RH WERE ALL FOUND CRACKED AT STR 9. THE DAMAGED FLANGES WERE CUT OUT AND REPAIRED PER SRM 51-40-3, FIG 1. THE DAMAGE WAS FOUND AT HMV.

Part: KEELBEAM — CRACKED (FUSELAGE) · airframe 46,236 hrs · 37,398 cycles

FUSELAGE / STRG. 18A SHEAR BEAM / FS 727 / LT & RT SIDES : CRACK REPAIRS THE WEB SECTION OF THE STRINGER 18A SHEAR BEAMS WERE FOUND CRACKED AT FS 727. THE RH BEAM CRACK IS 3 INCH LONG AND THE LT BEAM CRACK IS 1.5 INCH. THE CRACKS ARE SIMILAR TO THOSE SHOWN IN BAC S/B 737-53-1066, HOWEVER THE S/B IS NOT EFFECTIVE FOR THIS AIRCRAFT. THE CRACKS WERE STOP DRILLED AND REPAIRED WITH STEEL REPAIR ANGLES PER ER/A 379531-14, REV A.

Part: SKIN — PUNCTURED (FUSELAGE) · airframe 45,771 hrs · 37,193 cycles

THE FUSELAGE SKIN WAS STRUCK BY GROUND EQUIPMENT RESULTING IN TEARING AND GOUGING OF THE SKIN. THE DAMAGE WAS REMOVED WITH AN APPROX 20 X 7 INCH CUTOUT BETWEEN FS 896 AND 925 BETWEEN STRINGERS 19R AND 20R. THE SKIN BUTT SPLICE STRAP AT FS 907 WAS ALSO DAMAGED AND HAD A SECTION TRIMMED OUT. THE SKIN WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND THE BUTT SPLICE WITH A STRAP PER ER/A 379043-14, REV A.

Part: SKIN — CRACKED (R2 DOORWAY)

DURING RTN VISUAL INSPECTIONS, A CRACK WAS FOUND IN THE LWR BONDED SKIN PANEL AT THE LWR HINGE CUTOUT OF THE AFT GALLEY DOOR (R2) SURROUND. TRIMMING OUT THE DAMAGE IN THE LWR BONDED SKIN REVEALED A CRACK IN THE BEAR STRAP. TRIM OUT IN BEAR STRAP IS APPROX 1 INCH AND THE SKIN TRIM OUT IS APPROX 2 INCHES. REPAIRED PER ERA 366386-14.

Part: ELECTRICAL SYST — LOST (NR 1 & 2)

ON BASE LEG, SELECTED GEAR DOWN AND FLAPS 15, LOST ALL ELECTRICAL POWER, INCLUDING STBY PWR, HAD NO COMM/NAV. FLEW WITH STBY INST ON LANDING BLEW NR 1 TIRE DUE TO NO ROTATION. REPLACED NR 1 GCU P/N 948F458-2 S/N NF4063, NR 2 GCU S/N 3934, BATT P/N 23168 S/N 13163, BATT CHARGER P/N 2-301-3 S/N 1776. NR 1 BUS TIE BKR P/N 9410335-4 S/N NF6911, NR 2 BTB S/N ZH9271. NR 1 GEN BKR P/N 9410335-4 S/N 6811, NR 2 GEN BKR S/N YE6831, APU BKR S/N ZH9252, BATT CHRGR RELAY R-39, APU START INTERLOCK RELAY R-89, AND TRANSFER RELAYS R-3 AND R-4. ALL CHECKS OK ON TEST FLT PER TOPPS.

Part: SKIN — CRACKED (C1 DOORWAY)

THE FUSELAGE SKIN WAS FOUND TO HAVE 2 CRACKS ON THE FWD EDGE OF THE FWD CARGO DOOR BETWEEN STA 455 AND STA 440. THE UPPER CRACK IS JUST ABOVE STRINGER 23R AND WAS FOUND IN THE BONDED SKIN ASSEMBLY (.036 + .036 CLAD 2024-T3). IT MEASURED .22 FWD AND 1.25 VERTICALLY. THE LOWER CRACK LOCATION IS BELOW STRINGER 24R AND WAS FOUND IN THE OUTER SKIN (.036 CLAD 2024-T3) AND INTERNAL BEAR STRAP (.112 2024-T3), BUT NOT THE BONDED DOUBLER. IT MEASURED .7 FWD AND 1.0 VERTICALLY. REPAIRED PER INSTRUCTIONS OF ER/A330765-14 REV A.

Part: FLOOR BEAM — FATIGUE (BS 520)

THE STATION 520 FLOORBEAM WAS FOUND CRACKED AT THE FOLLOWING LOCATIONS: RBL 45, RBL 25, LBL 25 AND LBL 45. THE CRACKS ARE TYPICAL OF THOSE FOUND IN BACO S/B 737-53-1120 REV 1. THE FLOOR BEAM IS FABRICATED FROM 7075-T6511 EXTRUSION TO BAC 1518-338. NOTE: THIS A/C IS A GRP 3 A/C PER S/B 737-53-1120 REV 1. AT THREE LOCATIONS (LBL 45, LBL 25, RBL 25) THE REQUIREMENTS OF THE S/B COULD NOT BE MET IN RESPECT TO DISTANCE OF THE STOP DRILL TO THE EXISTING FASTENER HOLES. AT THOSE LOCATIONS, THE DAMAGE WILL BE TRIMMED OUT AND A DOUBLER INSTALLED.

Part: SKIN — FATIGUE (BS 379)

THE SKIN AT THE COOLING DUCT CUTOUT, BS 379 APPROXIMATELY BL0, WAS FOUND CRACKED AT THE AFT EDGE OF THE CUTOUT. THE CRACK IS APPROXIMATELY 1.0 IN LENGTH AND IS TYPICAL OF CRACKS DESCRIBED IN BACO S/B 737-53-1117, REV 1. REPAIRED PER ERA 330762-14.

Part: DUCT — CRACKED (NR 1 ENGINE)

AFTER T/O NR 1 ENG OVERHEAT LIGHT CAME ON. EXTINGUISHED WHEN THROTTLE RETARDED TO IDLE. MX IN PROGRESS, FOUND BROKEN DUCT FROM HP VALVE TO HORSE COLLAR, REPLACING DUCT.

Part: DUCT — LOOSE (NR 1 ENGINE)

AT CRUISE, POWER NR 1 ENG OVERHEAT LIGHT CAME ON, RETARD THROTTLE AND LIGHT WENT OUT. PUSH POWER UP AND LIGHT REMAINED OFF, TESTED THE FAULT LOOPS AND NR 1 ENG DID NOT TEST AND ENGINE FIRE BELL AND LIGHT ILLUMINATED ON NR 1. IDLE TEST NORMAL. FOUND AIR LEAKING FROM NR 1 ENG PNEU HOOK UP, REPOSITION NIPPLE STOP LEAK WITH MANIFOLD PRESS ON SYS. RAN ENG AT T/O POWER PER PFHB ALL CKS NORMAL.

Part: BULB — FAILED (R 1 DOOR)

FOUND ON LAYOVER CHECK - R1 EXTERIOR EMERGENCY LIGHT INOP. CORRECTIVE: RELAMPED - OPERATIOAL CHECKS NORMAL.

Part: UPLOCK SENSOR — FAILED (RT MLG)

DURING CRUISE, RT MLG UNSAFE LIGHT ILLUMINATED WITH GEAR UP, ALL INDICATIONS NORMAL WITH GEAR DOWN. FERRIED TO SLC, REPLACED RT MLG UPLOCK SENSOR, SWUNG GEAR AND OPERATION NORMAL.

Part: DG — INOPERATIVE (NR 1)

AIR TURNBACK, NR 1 COMPASS SYSTEM INTERMITTENTLY INOP, HGD FLAG IN CAPT HSI AND F/O RMI. REPLACED NR 1 DG AND OPS CKS OK.

Part: FLOOR BEAM — CRACKED (BS 661)

THE LB 0.07 FLOOR BEAM OF THE WING CENTER SECTION IS CRACKED AT STA 661. THE UPPER CAP OF THE BEAM IS COMPLETELY CRACKED, AND THE WEB AND WEB DOUBLER ARE CRACKED APPROXIMATELY 2.0 INCHES AT THE SAME LOCATION. THE CRACKS ARE TYPICAL PER BOEING SERVICE BULLETIN 737-57-1210. THE 65C34537-11 REINFORCING ANGLE CANNOT BE INSTALLED PER THE SERVICE BULLETIN BECAUSE THE FWD FIVE FASTENERS FALL INTO THE RADIUS OF THE ANGLE. ELIMINATING THESE FIVE FASTENER ROWS MAKE THE 65C34537-11 EQUIVALENT TO THE ORIGINAL 65-45410-104 REINFORCEMENT ANGLE. THUS, THE ORIGINAL ANGLE WILL BE REINSTALLED.

Part: CONTROL PANEL — SHORTED (FWD CABIN)

ON TAXI OUT, HAD SMOKE AND SPARKS COMING FROM CABIN LIGHT CONTROL PANEL AT FWD ENTRY DOOR. REPAIRED SHORTED WIRES, RETURNED TO SERVICE.

Part: SKIN — DAMAGED (ELEV TAB)

DURING SHOP INSPECTION, FOUND LEFT ELEVATOR TAB WITH DAMAGE TO COMPOSITE SKIN AT TAB HINGE CUTOUTS. REPAIRED PER SRM 55-20-1.