N33502

Part: HANDSET — OVERHEATED (ZONE 200) · airframe 76,153 hrs · 40,304 cycles

DURING FLIGHT THE AFT FLIGHT ATTENDANT HANDSET AND CORD BECAME EXTREMELY HOT. EMERGENCY DECLARED. LANDING UNEVENTFUL. AIRCRAFT GROUNDED. MAINTENANCE REMOVED AND REPLACED HANDSET IAW AMM 23-40-04. OPS CHECKED NORMAL.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 75,666 hrs · 40,001 cycles

EMERGENCY LIGHT BETWEEN ROWS 23 & 27 ILLUMINATE WHEN POWER IS REMOVED FROM ACFT. R & R BATTERY ASSEMBLY IAW AMM 33-53-00. OPS CHECKED NORMAL.

Part: PORTABLE LIGHT — FAILED (CABIN) · airframe 75,105 hrs · 39,659 cycles

REFERENCE WC CARD 0801, L1 DOOR PORTABLE EMER LIGHT FAILS TEST. REPLACED L1 DOOR PORTABLE EMER LIGHT IAW AMM 33-53-00. TESTED OK. THE ACFT WAS NOT GNDED.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 75,105 hrs · 39,659 cycles

EMER LIGHTS ROW 22 - 27 FAILED TO TEST. REPLACED B5-106 EMER LIGHT BATTERY PACK IAW AMM 33-53-00. TESTED OK. THE ACFT WAS NOT GNDED.

Part: STOP — CRACKED (CARGO DOOR) · airframe 74,511 hrs · 39,331 cycles

MID CARGO DOOR, FORWARD TOP DOOR STOP CRACKED. INSTALLED NEW SERVICEABLE MID CARGO, FWD TOP DOOR STOP FITTING CDK2345-3 IAW AARD 51-00-05-1 & DWG 4920233. ACFT IN BASE MX.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 74,511 hrs · 39,331 cycles

MID CARGO DOOR, FWD CTR DOOR STOP CRACKED. INSTALLED NEW SERVICEABLE MID CARGO DOOR, FWD CTR DOOR STOP FITTING CDK2345-3 IAW AARD 51-00-05-1 & DWG 4920233. ACFT IN BASE MX.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 74,511 hrs · 39,331 cycles

FORWARD CARGO DOOR, FWD SECOND FROM TOP DOOR STOP CRACKED. INSTALLED NEW FWD CARGO DOOR, FWD SECOND FROM TOP DOOR, STOP FITTING CDK2345-3 IAW AARD 51-00-05-1 & DWG 4920223. ACFT IN BASE MX.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 74,511 hrs · 39,331 cycles

SHEAR TIE CRACKED AT STATION 1451, BETWEEN LONGERON 1R & 2R. R & R SHEAR TIE IAW SRM 51-30-05. ACFT IN BASE MX.

Part: PRESSURE SWITCH — DEFECTIVE (RT ENGINE) · airframe 73,449 hrs · 38,678 cycles

AIR INTERRUPT, DIVERTED, EMER DECLARED, LANDING UNEVENTFUL & ACFT WAS OVERWEIGHT. CREW REPORTED THE RT ENG OIL FILTER CLOG LIGHT ILLUMINATED. REPLACED THE RT ENG FILTER DIFFERENTIAL PRESS SWITCH IAW AMM 79-35-01.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 72,226 hrs · 37,954 cycles

OVERHEAD EMER LIGHTS AT SEAT ROW 9 DO NOT GO OUT WHEN POWER IS REMOVED. R & R EMER BATTERY PACK B5-101 IAW AMM 33-53-00. SYS CHECKED NORMAL.

Part: GENERATOR — MALFUNCTIONED (RT ENGINE) · airframe 71,879 hrs · 37,745 cycles

RIGHT ENG GEN OIL TEMP HIGH WITH APU ON PLACARD. FLIGHT DIVERTED & LANDED WITHOUT INCIDENT. ACFT REMOVED FROM SERVICE. REPLACED RT ENG GEN & CONSTANT SPEED DRIVE. SYS GND CHECKED NORMAL, OPERATION CLOSED.

Part: RIB — CRACKED (LT WING) · airframe 71,246 hrs · 37,343 cycles

CRACK ON LE RIB LT NR 4 SLAT TRACK. INSTALLED RIB DOUBLER & SPACER IAW EA MD80-57-035828.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 71,246 hrs · 37,343 cycles

THIRD FROM BOTTOM DOOR STOP MOUNT CRACKED FWD SIDE. REPLACED MOUNT IAW AARD 51-00-05-1.

Part: FITTING — CRACKED (LE SLAT TRACK) · airframe 71,246 hrs · 37,343 cycles

CRACK ON NR 4 RT SLAT TRACK FITTING. INSTALLED RIB DOUBLER & SPACER IAW EA MD80-57-035828.

Part: SKIN — CRACKED (FUSELAGE) · airframe 71,246 hrs · 37,343 cycles

CRACK IN FUSELAGE SKIN AT STATION 1380 FROM LONGERON 13 TO 14 LT. INSTALLED DOUBLER IAW SRM 53-01-00.

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 71,246 hrs · 37,343 cycles

RIVET HEAD AT STATION 1309 BETWEEN LONGERON 6 & 7 RT CRACKED. INSTALLED FILLER & REPAIR DOUBLER IAW AARD 53-04-00 FIGURE 32 & EA MD80-53-035822.

Part: GOVERNOR — MALFUNCTIONED (RT ENGINE) · airframe 69,989 hrs · 36,608 cycles

DFW CREW REPORTED DURING CLIMB OUT RT ENG HAD UNCOMMANDED SHUTDOWN WITH NO WARNINGS PRIOR TO SHUT DOWN. EMERGENCY DECLARED FLIGHT RETURNED DFW LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED FUEL FLOW GOVERNOR & FUEL PUMP. SYSTEM GND CHECKED NORMAL OPERATION CLOSED.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 69,617 hrs · 36,404 cycles

AFT TAIL COMPARTMENT EMERGENCY LIGHTS INOPERATIVE. R & R BATTERY PACK FOR AFT TAIL COMPARTMENT EMERGENCY LIGHTS. OPERATIONS CHECKED NORMAL

Part: SHEAR TIE — DAMAGED (FUSELAGE) · airframe 67,340 hrs · 35,101 cycles

TWO DOUBLE DRILLED HOLES IN SHEAR TIE, STATION 886, JUST ABOVE LONGERON 9 LEFT. INSTALLED FORMER REPAIR AND SPLICE DOUBLER PER SRM 53-03-00.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,340 hrs · 35,101 cycles

CORROSION ON LEFT CUSP, OUTBOARD OF SEAT TRACK NUMBER 1, APPROXIMATE STATION 565. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,340 hrs · 35,101 cycles

CORROSION ON CUSP UNDER FIBERGLASS HAT CHANNEL AT STATION 187, INBOARD OF FORWARD SERVICE DOOR. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — DAMAGED (FUSELAGE) · airframe 67,340 hrs · 35,101 cycles

RIGHT CUSP IS DAMAGED AT THE OUTBOARD EDGE BEHIND THE WIRE BUNDLE ATTACH CLIP AT STATION 574. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 67,340 hrs · 35,101 cycles

LONGERON CRACKED AT ATTACHMENTS TO FRAME, STATION 160 AND LONGERON 4 LEFT. INSTALLED SPLICE REPAIR PER SRM 53-02-00 FIGURE 18.

Part: FRAME — CRACKED (FUSELAGE) · airframe 67,340 hrs · 35,101 cycles

RIGHT STATION 886 FRAME HAS CRACK IN RADIUS AT 0 WATERLINE INBOARD SIDE OF FRAME. INSTALLED NEW BELLFRAME AT STATION 886 PER MCM CARD 5974, FAA-AD 2008-13-29 AND BOEING DRAWING SR09530282.

Part: LONGERON — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,340 hrs · 35,101 cycles

LONGERON 23 RIGHT AT STATION 1295 CORRODED ON OUTBOARD SIDE INSIDE CHANNEL. REMOVED AND REPLACED CORRODED SECTION OF LONGERON 23 RIGHT PER SRM 53-02-00 FIGURE 18.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 67,340 hrs · 35,101 cycles

LEFT CUSP AT STATION 756 CORRODED. REMOVED DAMAGED AREA AND INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: SUPPORT FITTING — CRACKED (SPOILER) · airframe 67,340 hrs · 35,101 cycles

RIGHT WING GROUND SPOILER DRIVE SUPPORT FITTING CRACKED, AT OUTBOARD SIDE OF ACTUATOR FORWARD ATTACH POINT. REMOVED AND REPLACED FITTING PER SRM 51-30-05 AND 51-30-02.

Part: SKIN — DAMAGED (VERTICAL STAB) · airframe 67,166 hrs · 35,006 cycles

LOWER DORSAL LEADING EDGE REQUIRES DOUBLER AT STATION ZFS 52.267 DUE TO 9 HOLES BEING TO DEEP FOR REPAIR BUSHINGS. INSTALLED REPAIR DOUBLER PER SRM 55-03-00 PARAGRAPH 28.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 66,371 hrs · 34,537 cycles

LEFT AND RIGHT CEILING EMERGENCY LIGHTS BETWEEN AFT LAVATORIES INOPERATIVE. REPLACED BATTERY PACK AT RIGHT AFT LAVATORY. OPS CHECK NORMAL.

Part: BATTERY — DIRTY (CABIN) · airframe 66,371 hrs · 34,537 cycles

CEILING EMERGENCY LIGHTS INOP FROM ROW 28 TO ROW 30. CLEANED AND RESEATED EMERGENCY BATTERIES AT ROW 29DEF. OPS CHECK NORMAL.

Part: SUPPORT BRACKET — CRACKED (FUSELAGE) · airframe 64,105 hrs · 33,268 cycles

SUPPORT BRACKET FOR TIE DOWN AT STATION 1152 CRACKED. INSTALLED NEW SUPPORT BRACKET PER AARD 51-10-00-5.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 63,353 hrs · 32,854 cycles

EMERGENCY LIGHT AT LEFT NUMBER 1 DOOR INOPERATIVE. REPLACED LIGHT ASSEMBLY FOR EMERGENCY LIGHT AT LEFT NUMBER 1 DOOR. OPS CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 61,225 hrs · 31,656 cycles

EMERGENCY CEILING LIGHTS AT ROWS 3 TO 6 INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY CEILING LIGHT AT ROWS 3 TO 6. OPS CHECKED NORMAL.

Part: FITTING — CORRODED (LT WING) · corrosion level 2 · airframe 60,043 hrs · 30,995 cycles

LEFT TRAPEZOID ANGLE FITTING CORRODED. REMOVED AND REPLACED ANGLE FITTING PER SRM 51-31-01.

Part: FITTING — CORRODED (RT WING) · corrosion level 2 · airframe 60,043 hrs · 30,995 cycles

RIGHT TRAPEZOID ANGLE FITTING IS CORRODED. REMOVED AND REPLACED ANGLE FITTING PER SRM 51-30-01.

Part: REGULATOR VALVE — INOPERATIVE (CABIN PRESSURE) · airframe 60,018 hrs · 30,977 cycles

IAH - CREW REPORTED BURNING SMELL IN CABIN AFTER TAKEOFF. EMERGENCY DECLARED FLIGHT RETURNED IAH LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. ACCOMPLISHED CARDS 21-96-01 CABIN ODOR TROUBLESHOOTING AND NO ODOR NOTED. FLIGHT WAS FERRIED TO DFW FOR FURTHER MAINTENANCE. AT DFW REPLACED RIGHT AND LEFT PRESSURE REGULATOR VALVES AND ACCOMPLISHED PACK BURN. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: DUCT — BLOWN (CABIN AIR) · airframe 58,994 hrs · 30,422 cycles

CREW REPORTED TAIL COMPARTMENT HIGH TEMPERATURE LIGHT ILLUMINATED DURING CLIMB AT FLIGHT LEVEL 270. LANDED DFW WITHOUT INCIDENT. FOUND RIGHT AIR CONDITIONING SUPPLY DUCT BLOWN. REPLACED THE DUCT ASSEMBLY.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 58,704 hrs · 30,252 cycles

CEILING EMERGENCY LIGHTS AT SEAT ROWS 28 TO 32 ARE INOPERATIVE. REPLACED BATTERY PACK KB5-107. OPS CHECKED NORMAL.

Part: STRAP — MISSING (FLASHLIGHT) · airframe 58,271 hrs · 29,997 cycles

LGA - FORWARD LOWER FLASHLIGHT SAFETY STRAP MISSING. REPLACED SAFETY STRAP FOR FORWARD LOWER FLASHLIGHT.

Part: VALVE — INOPERATIVE (MLG DOORS) · airframe 55,941 hrs · 28,751 cycles

INFLIGHT T9610/29 SEP FCF. AFTER TEST OF ALTERNATE GEAR EXTENSION, GEAR DOOR INDICATION DID NOT GO OUT ON GEAR EXTENSION. LANDED TUL WITHOUT INCIDENT WITH RT MLG DOORS OPEN. REPLACED THE LG CONTROL VALVE ASSEMBLY. SYSTEM GROUND CHECKED NORMAL OPS.

Part: FITTING — DELAMINATED (BS 895 S17L) · airframe 55,941 hrs · 28,751 cycles

TUL FITTINGS AT STRINGER 17 STATION 895 LT SIDE DELAMINATED WITH FUEL LEAKING BELOW FITTINGS. REPLACED BOTH FITTINGS AT KEELBEAM STATION 895 LT SIDE IN ACCORDANCE WITH SRM DRAWING 5930569.

Part: BATTERY PACK — LOOSE (EMERGENCY LIGHT) · airframe 55,941 hrs · 28,751 cycles

EMERGENCY LIGHT AT FORWARD OVERWING EXIT STAY ON. ADJUSTED BATTERY PACK FOR EMERGENCY LIGHT AT FORWARD OVERWING EXIT. SYSTEM GROUND CHECKED NORMAL OPS.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

LGA - EMERGENCY LIGHT AT OVERHEAD SEAT ROW 20DEF INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHT AT SEAT ROW 20DEF. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

LGA - EMERGENCY LIGHTS AT OVERHEAD FIRST CLASS INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS AT OVERHEAD FIRST CLASS. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

LGA - EMERGENCY LIGHTS AT OVERHEAD TAIL COMPARTMENT INOPERATIVE. REPLACED BATTERY PACK AT STATION 1338 FOR EMERGENCY LIGHTS AT OVERHEAD TAIL COMPARTMENT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

LGA - OVERHEAD EMERGENCY LIGHTS AT ROWS 20 TO 24 INOPERATIVE. REPLACED BATTERY PACK FOR INOPERATIVE OVERHEAD EMERGENCY LIGHTS AT ROWS 20 TO 24. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SENSOR — DIRTY (NLG)

SLC - LANDING GEAR WOULD NOT RETRACT. RETURNED SLC AND LANDED WITHOUT INCIDENT. CHECKED NOSE GEAR PER MM 32-52-07-2 AND CLEANED SENSORS AND COMPLETED SWING TEST. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

SAT OVERHEAD EMERGENCY LIGHTS AT ROW 20 AND BACK INOPERATIVE. REPLACED BATTERY PACK AND BATTERIES FOR OVERHEAD EMERGENCY LIGHTS AT ROW 20 AND BACK. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

SEA - OVERHEAD EMERGENCY EXIT LIGHTS AT AFT ENTRY AISLE INOPERATIVE. REPLACED BATTERY PACK B527 AT RIGHT HAND AFT LAVATORY FOR OVERHEAD EMERGENCY EXIT LIGHTS AT AFT ENTRY AISLE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: LIGHT — INOPERATIVE (CABIN)

DURING OVERNIGHT MAINTENANCE, SEAT MOUNTED EMERGENCY EXIT LIGHT AT SEAT 14D INOPERATIVE. REPLACED SEAT MOUNTED EMEGENCY EXIT LIGHT ASSEMBLY AT SEAT 14D. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: LIGHT — INOPERATIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, PORTABLE EMERGENCY EXIT LIGHT AT FLIGHT ATTENDANT SEAT INOPERATIVE. REPLACED PORTABLE EMERGENCY EXIT LIGHT AT FLIGHT ATTENDANT SEAT. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — DAMAGED (CABIN)

ORD - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHTS IN AFT STAIRWAY INOPERATIVE. REPAIRED WIRE ON EMERGENCY EXIT LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: SIGN — BROKEN (CABIN)

DURING OVERNIGHT MAINTENANCE AFT EMERGENCY EXIT SIGN LEFT OF GALLEY BROKEN. REPLACED EMERGENCY EXIT LIGHT ASSEMBLY. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: CONNECTOR — LOOSE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT LIGHT AT ROW 28 DIM. RE-SECURED EMERGENCY EXIT LIGHT CONNECTOR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — DAMAGED (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, LEFT SIDE EMERGENCY EXIT FLOOR PATH LIGHT INOPERATIVE. REPAIRED WIRE TO EMERGENCY EXIT FLOOR PATH LIGHT SYSTEM. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: GEAR SWITCH — DEFECTIVE (INSTR PANEL)

MIA - FLT NR 041 - DURING APPROACH TO MIA WHEN LANDING GEAR HANDLE LOWERED, ALL LANDING GEAR LIGHTS ILLUMINATED AND REMAINTED RED. RECYCLED LANDING GEAR AND LANDING GEAR EXTENDED WITH NO ABNORMAL INDICATIONS. AIRCRAFT LANDED MIA WITHOUT INCIDENT. REPLACED LANDING GEAR HANDLE SWITCH AND LUBRICATED ALL LANDING GEARS. SYSTEM GROUND CHECKED NORMAL OPERATION. (W)