N332DL

Part: FRAME — CRACKED (C2 DOOR) · airframe 48,890 hrs · 39,035 cycles

A 1 INCH CRACK WAS FOUND IN THE WEB OF THE UPPER FRAME EMANATING FROM A FASTENER HOLE COMMON TO THE UPPER AND LOWER FRAME LAP JOINT. THE CRACK WAS STOP DRILLED AND THE FRAME REPAIRED WITH 2 TITANIUM REPAIR ANGLES PER ER/A 095286-14.

Part: SKIN — CRACKED (FUSELAGE) · airframe 47,278 hrs · 37,804 cycles

THE STRINGER 4L & 4R SKIN LAP JOINTS WERE FOUND WITH SEVERAL CRACKS BETWEEN FS 540 & 727 WHEN INSPECTED PER AD 2003-08-15. THE CRACKED LAP JOINTS WERE CUTOUT IN THEIR ENTIRETY AND REPAIRED WITH EXTERNAL ALUMINUM DOUBLERS PER BAC S/B 737-53A1177 AND PER ER/A 386137-14AD.

Part: CONTROLLER — FAILED (CABIN PRESSURE) · airframe 46,724 hrs · 37,559 cycles

UNABLE TO PRESSURIZE AIRCRAFT WITH LEFT PACK. REPLACED PRESSURIZATION CONTROLLER, GROUND OPS OK. CLEANED RT PACK COMPRESSOR DISCHARGE SW S2. RT PACK OPS OK.

Part: SKIN — CRACKED (FUSELAGE) · airframe 45,927 hrs · 37,218 cycles

A .5 INCH CRACK WAS FOUND IN THE BONDED SKIN OF THE UPPER HINGE CUTOUT OF THE AFT ENTRY DOOR CUTOUT. THE CRACK WAS REMOVED WITH A SMALL CUTOUT. THE AREA WAS REPAIRED WITH AN EXTERNAL CRES STEEL DOUBLER PER ER/A 380735-14, REV A.

Part: SKIN — CRACKED (FUSELAGE) · airframe 45,927 hrs · 37,218 cycles

A TYPICAL CRACK WAS FOUND IN THE BONDED SKIN AND UNDERLYING BEAR STRAP IN THE LOWER FWD CORNER OF THE AFT GALLEY DOOR CUTOUT. THE CRACK WAS REMOVED WITH A 1.2 X 1.3 INCH CUTOUT IN ALL LAYERS. THE AREA WAS REPAIRED WITH THREE EXTERNAL ALUMINUM DOUBLERS PER ER/A 380739-14, REV A.

Part: SWITCH — FAILED (NR 2 SLAT) · airframe 44,292 hrs · 36,529 cycles

AFTER T/O CREW HAD SLAT INTRANSIT LIGHTS ON NR 2 AND NR 6 SLAT AFTER RETRACTION. REPLACED NR 2 SLAT ROD END SWITCH AND SLAT INDICATION BOX, ALL INDICATIONS NOW NORMAL.

Part: CIRCUIT BREAKER — DAMAGED (COCKPIT) · airframe 43,502 hrs · 36,185 cycles

SVC CK FAILS STEP 13 BATT VOLTAGE CK. REPLACED BATTERY, CHARGER, AND C/B C167 BATTERY TRANSFER CONTROL. REPLACED BATTERY BUS CIRCUIT BREAKER C20. RAN TEST OPS NORMAL.

Part: SKIN — DENTED (FUSELAGE) · airframe 42,212 hrs · 35,624 cycles

THE AFT EDGE OF THE CARGO DOOR CUTOUT WAS STRUCK BY GROUND EQUIPMENT BETWEEN STRINGERS 20R & 21R. THE DAMAGE WAS REMOVED WITH A 1 WIDE X 9 TALL CUTOUT IN THE SKIN ASSY AND BEARSTRAP. THE DAMAGE CUTOUT WAS REPAIRED WITH TWO EXTERNAL ALUMINUM DOUBLERS INSTALLED PER ER/A 369761-14, REV A.

Part: FITTING — CORRODED (BS 685)

THE STRUT ATTACH LUG OF THE RT MAIN LANDING GEAR SIDE STRUT SUPPORT FITTING AT FS 685 WAS FOUND WITH CORROSION IN THE LUG BORE AND ON THE LUG FACES. THE BORE WAS OVERSIZED AND THE LUG FACES MACHINED TO REMOVE THE CORROSION. A REPAIR BUSHING WAS INSTALLED AND THE INSTALLATION RE-ASSEMBLED PER ER/A 368888-14, REV A.

Part: FRAME — DAMAGED (BS 420 - 787)

DURING MODIFICATION OF THE FUSELAGE FRAMES SEVERAL WERE DAMAGED. THE DAMAGE REQUIRED TRIMMING OFF/OUT THE TOOLING DAMAGE. REPAIRED PER ERA 332294-14.

Part: SKIN — DAMAGED (CARGO DOORWAY)

C2 DOOR CUTOUT WAS WITH AN EXISTING REPAIR ALONG THE FWD EDGE. UPON REMOVAL OF THE REPAIR ADDITIONAL DAMAGE WAS FOUND. REPAIRED PER ERA 332286-14.

Part: FRAME — CRACKED (BS 440)

STA 440 FRAME WEB FOUND CRACKED AT A TOOLING HOLE BETWEEN S13R - 14R. REPAIRED PER ERA 332298-14.

Part: FITTING — DAMAGED (BS 685)

THE LT MLG SIDE STRUT SUPPORT FITTING AT BS 685 WAS DAMAGED BY TOOL MARKS. REPAIRED PER ERA 332329-14.

Part: FRAME — CRACKED (BS 907)

CRACK FOUND IN THE FAIL/SAFE CHORD OF THE STA 907 FRAME AT APPROX S13R. REPAIRED PER ERA 332297-14.

Part: HEAT VALVE — INOPERATIVE (NR 1 ENGINE)

DURING FLIGHT, NR 1 ENGINE OIL TEMP WAS INDICATING IN AMBER RANGE. PERFORMED POM PROCEDURES, AFTER 15 MINUTES ELAPSED SHUT NR 1 ENGINE DOWN. REPLACED LT ENGINE FUEL HEAT VALVE. RAN ENGINE, CHECKS OK.

Part: SKIN — DENTED (BS 935)

THE FUSELAGE SKIN AT STRINGER 21L AND BETWEEN FS 927 AND 947.8 WAS DAMAGED BY GROUND EQUIPMENT. THE DAMAGED SKIN WAS CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 364605-14. THE UNDERLYING STRINGER WAS REPAIRED PER B737 SRM 53-10-3.

Part: ENGINE — FOD (NR 2)

AFTER TAKEOFF, HAD BURNING SMELL IN CABIN LIKE OVENS, BUT OVENS WERE NOT ON, FELT A SIDEWAY KICK AND A LOUD BANG. DECLARED EMERGENCY. RETURNED TO CVG. NO ABNORMAL ENG INDICATIONS. ON RETURN, PASSENGER REPORTED SEEING A BAG SUCKED INTO AN ENG ON TAXI OUT. CHECKED INLET AND EXHAUST. REMOVED PLASTIC FROM FAN OF RT ENG. RAN ENG TO TAKEOFF POWER PER PFHB. ALL INDS NORMAL. REPLACED WATER SEPARATER BAGS DUE TO CABIN SMELL. ENGINE TOTAL CYCLES, 20,907.

Part: ATTACH FITTING — CRACKED (RT MLG BEAM)

RIGHT WING OB AFT SUPPORT FITTING FOR THE MAIN LANDING GEAR BEAM WAS FOUND CRACKED. CRACKING TYPICAL TO THAT DESCRIBED IN BOEING SERVICE BULLETIN 737-57-1216. A/C 332 IDENTIFIED AS A GROUP 5 BY THE SERVICE BULLETIN. THE CRACKED FITTING WILL REMAIN IN SERVICE ON A TIME LIMITED BASIS AND WILL BE REPAIRED ACCORDING TO SERVICE BULLETIN REQUIREMENTS.

Part: LIGHT — INOP (LT AFT DOOR)

LEFT AFT DOOR EXTERIOR EMERGENCY LIGHT INOP. RELAMPED. CHECKS NORMAL.

Part: FLAP SKIN — DAMAGED (NR 4 TE FLAP)

DURING SHOP INSP, RT WING NR 4 AFT FLAP WAS FOUND WITH A TIME LIMITED REPAIR 10 INCHES FROM THE IN/B END ON THE L/E OF FLAP. INSTALLED PERMANENT REPAIR PER SRM 57-50-4 FIG 5.

Part: TE WEDGE — DELAMINATED (NR 4 AFT FLAP)

DURING SHOP INSPECTION, NR 4 AFT FLAP T/E WEDGE WAS FOUND DELAMINATED 10 FROM THE INBD END OF FLAP. REPAIRED PER SRM 51-70-10.

Part: TE WEDGE — DAMAGED (NR 4 AFT FLAP)

DURING SHOP INSPECTION, NR 4 AFT FLAP WAS FOUND WITH T/E WEDGE WITH DAMAGE TO O/B AFT CORNER. REPAIRED PER SRM 57-53-01.

Part: LE SKIN — DAMAGED (NR 4 AFT FLAP)

DURING SHOP INSPECTION, NR 4 AFT FLAP WAS FOUND WITH TIME LIMITED REPAIR ON L/E AT 16 FROM THE I/B END OF FLAP. REPAIRED PER SRM 57-50-4 FIG 5.

Part: COMPUTER — FAILED (E/E COMPT)

ON CLIMBOUT HAD ELEV, FEEL DIFF. PRESSURE LITE ON. RETURNED DFW, REPLACED FEEL COMPUTER, FOR RETURN TO SERVICE.

Part: WINDSHIELD — FAILED (FLIGHT DECK R-1)

DURING CRUISE, HEARD BURNING NOISE AND HAS ACRID SMELL IN FLT DECK, THEN HAD SMOKE AT R-1 WINDOW TERMINAL BLOCK, LANDED BNA, FOUND R-1 WINDOW TERMINAL BURNED. RELACED R-1 WINDOW, CONTROLLER AND CIRCUIT BREAKER. OPERATION NORMAL.