N355US

Part: FRAME — CRACKED (FUSELAGE)

PIT - FOUND FRAME CRACKED .125 INCH, STATION 480, S8L-S9L. INSTALLED REPAIR ANGLES PER TYPICAL REPAIR 53-10-20A. (M)

Part: BEAM — CRACKED (VERTICAL STAB)

PIT - FOUND BEAM CRACKED 2 INCHES, 3 INCHES FROM LOWER END OF VERT STAB LT T/E BEAM. DEFECTIVE PART REPLACED WITH IDENT PART PER SRM 53-30-13 FIG 1. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

PIT - FOUND BEAM CORRODED THREE 1 INCH DIAMETER AREAS, BS 947 LBL 30 TO LBL 46. REMOVED CORROSION, TREATED AND PRIMED, PERFORMED TYP REPAIR 53-15-01B, SRM 51-10-02. CORROSION LEVEL 1, TASK NR C53-107-02. (M)

Part: STRINGER — CORRODED (FUSELAGE)

FOUND STRINGER CORRODED TWO AREAS, 1 INCH BY 6 INCHES AND 1 INCH BY 4 INCHES, FS 1016-1022 FORWARD SIDE OF AFT PRESSURE BULKHEAD. REPLACED STIFFENERS AND INSTALLED DOUBLERS AND SPLICES PER SRM 53-80-08 AND BOEING DWG PL 65C28106. (M)

Part: ARM — FRACTURED (LT MLG)

CLT - FLT 240 - UPON GEAR RETRACTION, CREW HEARD A LOUD THUMP. THE LEFT MAIN GEAR INDICATED RED. CREW DECLARED AN EMERGENCY. THE FLIGHT RETURNED TO CLT AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND BOTH LUGS OF THE LEFT MAIN GEAR ACTUATOR BEAM ARM ASSY HAD FRACTURED, ALLOWING THE RETRACT ACTUATOR BEAM, (WALKING BEAM) AND ACTUATOR TO MOVE OUTBOARD. AT THE OUTBOARD END OF THE ACTUATOR BEAM, THE SUPPORT LINK ASSEMBLY WAS ALSO FRACTURED. REMOVED AND REPLACED LEFT MAIN GEAR ACTUATOR BEAM ARM ASSEMBLY, SUPPORT LINK ASSEMBLY AND MAIN LANDING GEAR BEAM ASSEMBLY. REPAIRED IMPACT DAMAGE TO AFT FACE OF LEFT WING REAR SPAR WEB AND FRACTURE DAMAGE TO TWO NEARBY VERTICAL STIFFENERS OF THE REAR SPAR ASSEMBLY.

Part: ARM — CRACKED (LT MLG ACTUATOR) · airframe 59,000 hrs

UPON GEAR RETRACTION, CREW HEARD A LOUD THRUMP. THE LEFT MAIN GEAR INDICATED RED. CREW DECLARED AN EMERGENCY. THE FLIGHT RETURNED AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE ACTION PENDING. LT MAIN LANDING GEAR ACTUATOR BEAM ARM FOUND CRACKED. REAR MAIN LANDING GEAR SUPPORT BEAM DAMAGED. BEAM ARM HAD 59,000 LANDINGS. LAST ULTRASONIC INSPECTION WAS DEC, 2003. PARTS TO BE ANALLYZED.

Part: SKIN — CRACKED (FUSELAGE)

FOUND SKIN CRACKED 2 INCHES, 727D AND S23R. INSTALLED DOUBLER PER SRM 53-00-01. (M)

Part: SERVO — FAILED (AUTOPILOT SYS)

DURING FLIGHT, EN ROUTE, THE STABILIZER OUT OF TRIM LIGHT ILLUMINATED. THE AUTOPILOT WOULD NOT TRIM. FLIGHT DIVERTED AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE AUTOPILOT SERVO MOTOR. OPS CHECK AND BITE TEST NORMAL. (M)

Part: SUPPORT FITTING — WORN (VERTICAL STAB)

PIT - FOUND TERMINAL SUPPORT FITTING HAS TWO WORN BOLTS, VERTICAL STABILIZER AFT TERMINAL SUPPORT FITTING BOLT HOLES. REWORKED WORN HOLES PER EA 94263A, THIS IS AN INTERIM REPAIR. (M)

Part: STIFFENER — CRACKED (FUSELAGE)

IT - FOUND STIFFENER ANGLE CRACKED 1 INCH LONG, VERTICAL STIFFENER MLG W/W FORWARD BULKHEAD CENTER LINE STATION 663. FABRICATED AND INSTALLED 2 REPAIR STRAPS AND ATTACH ANGLE IAW EA 75025. (M)

Part: OUTFLOW VALVE — FAILED (CABIN PRESSURE)

PIT - FLT 1146 - EN ROUTE FROM PHL TO CMH, AT FL350, THE CABIN ALTITUDE WARNING HORN SOUNDED. CREW NOTICED CABIN ALTITUDE AT 11,000 FEET. CREW WAS UNABLE TO CONTROL CABIN ALTITUDE, DESCENDED TO 10,000 FEET PER QUICK REF HANDBOOK PROCEDURES. FLIGHT DIVERTED TO PIT AND LANDED WITHOUT FURTHER INCIDENT. NO EMERGENCY WAS DECLARED. MAINTENANCE FOUND THE AC MOTOR HAD FAILED ON THE AFT OUTFLOW VALVE. REMOVED AND REPLACED AFT OUTFLOW VALVE PER MM 21-31-11. OPS CHECK NORMAL. CHECKED FORWARD OUTFLOW VALVE PER MM 21-43-11. OPS CHECK NORMAL. (M)

Part: SKIN — CRACKED (FUSELAGE)

CLT - FOUND SKIN CRACKED, STATION 200, LBL 5. INSTALLED EXTERIOR DOUBLER PER EA 68798. (M)

Part: BULKHEAD — CRACKED (FUSELAGE)

CLT - FOUND WEB CRACKED 1 INCH, STATION 178, WL 198, LBL 4. INSTALLED DOUBLER PER EA 68679. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND FRAME CRACKED .5 INCH, STATION 727B STRINGER 14R. INSTALLED ANGLE PER SRM 53-00-07. (M)

Part: INTERCOSTAL — CRACKED (BULKHEAD)

CLT - FOUND INTERCOSTAL CRACKED .750 INCH BY 1 INCH, BS 178, WL 195, RBL 24. INSTALLED NEW INTERCOSTAL PER SRM 51-10-02 AND EO5300V157. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND CHORD CRACKED 1.5 INCH, BS 178, WL 207, RBL 29. REMOVED SECTION AND INSTALLED NEW SECTION PER EA 68680 AND EO 5300V157. (M)

Part: INTERCOSTAL — CRACKED (BULKHEAD)

CLT - FOUND INTERCOSTAL CRACKED 1 INCH BY 1 INCH, BS 178, WL 195, LBL 24. INSTALLED NEW INTERCOSTAL PER SRM 51-10-02. (M)

Part: FLOORBEAM — CRACKED (FUSELAGE)

CLT - FOUND FLOORBEAM CRACKED 1 INCH BY 1 INCH, STATION 344, LBL 9. CORROSION LEVEL 1. REMOVED T-CAP AND FABRICATED NEW T-CAP AND SPLICE PER SRM 53-10-51 AND 53-40-51. (M)

Part: DOUBLER — CRACKED (FUSELAGE)

CLT - FOUND ANTENNA DOUBLER CRACKED .5 INCH, STATION 727D-727E, BL 0. INSTALLED NEW DOUBLER PER SRM 51-10-02. (M)

Part: SHEAR TIE — CRACKED (FUSELAGE)

CLT - FOUND TIE ANGLE CRACKED .333 INCH, FRAME 360 BETWEEN STRINGER 14R AND STRINGER 15R. REMOVED DAMAGE AND INSTALLED DOUBLER PER SRM 53-00-07 FIG 207. (M)

Part: TIE CLIP — CRACKED (FUSELAGE)

CLT - FOUND TIE CLIP CRACKED 1 INCH, STATION 344, STRINGER 10R. FABRICATED NEW CLIP PER SRM 53-10-15 AND SRM 51-10-2. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

CLT - FOUND T-CAP CORRODED 1 INCH, STATION 328 FLOORBEAM AT RBL 14, 21, 35. CORROSION LEVEL 1 C53-107-01. INSTALLED NEW T-CAP AND FABRICATED SPLICE ANGLES PER SRM 53-10-51. (M)

Part: INTERCOSTAL — CRACKED (FUSELAGE)

CLT - FOUND INTERCOSTAL CRACKED .25 INCH, INTERCOSTAL AT FS 294.5, STRINGER 7L. REMOVED DAMAGE AND INSTALLED REPAIR DOUBLER PER SRM 51-70-11. (M)

Part: ATTACH ANGLE — CRACKED (FUSELAGE)

CLT - FOUND ATTACH ANGLE CRACKED .5 INCH, FORWARD OF FS 303.9 ABOVE STRINGER 10L. INSTALLED NEW ATTACH ANGLE PER SRM 51-10-02. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

CLT - FOUND FLOORBEAM CORRODED .5 INCH, STATION 312 BL 0. CORROSION LEVEL 2 C53-107-02. REPLACED T-CAP PER SRM 53-00-51. (M)

Part: ATTACH ANGLE — CRACKED (FUSELAGE)

CLT - FOUND FRAME ATTACH ANGLE CRACKED .25 INCH, FRAME ATTACH ANGLE AT FS 348.2 STRINGER 11L. FABRICATED NEW ATTACH ANGLE PER SRM 51-10-2. (M)

Part: SHEAR TIE — CRACKED (FUSELAGE)

CLT - FOUND FRAME SHEAR TIE CRACKED .5 INCH, STATION 967, BETWEEN STRINGER 6L AND 7L. REMOVED AND INSTALLED DOUBLER PER EA 68751. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

CLT - FOUND SPLICE ANGLE T-CAP CORRODED, STATION 344, RBL 9, LBL 37. REPLACED T-CAP PER SRM 53-10-51. (M)

Part: ANGLE — CRACKED (DOOR FRAME)

CLT - FOUND CORNER ANGLE CRACKED .75 INCH, DOOR CUTOUT LOWER AFT CORNER ANGLE. INSTALLED NEW CORNER ANGLE. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND FRAME CRACKED .25 INCH, FRAME STATION 887 STRINGER 9R. REPAIRED DOUBLER PER TR 53-10-14. (M)

Part: STRINGER CLIP — CRACKED (FUSELAGE)

CLT - FOUND STRINGER CLIP CRACKED .5 INCH, STATION 639, STRINGER 2L CLIP. REPLACED PART PER SRM 51-10-2 AND 51-40-2. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND FRAME CRACKED .25 INCH, FS 847, STRINGER 9R. INSTALLED DOUBLER PER TR 53-10-14. (M)

Part: STRINGER CLIP — CRACKED (FUSELAGE)

CLT - FOUND STRINGER CLIP CRACKED 1 INCH, STATION 807, STRINGER 4L. REPLACED CLIP PER SRM 51-10-02. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND FRAME CRACKED .25 INCH, FRAME 400 ABOVE STRINGER 9R. REPAIRED DOUBLER PER TR 53-10-14. (M)

Part: FRAME — CRACKED (FUSELAGE)

CLT - FOUND FUSELAGE FRAME CRACKED .5 INCH, STATION 827 ABOVE STRINGER 9L. INSTALLED DOUBLER PER TR 53-10-14. (M)

Part: TIE CLIP — CRACKED (FUSELAGE)

CLT - FOUND TIE CLIP CRACKED .125 INCH, STATION 727E, STRINGER 7R. REPAIRED PER SRM 51-10-02. (M)

Part: TIE CLIP — CRACKED (FUSELAGE)

CLT - FOUND TIE CLIP CRACKED .50 INCH, STATION 616 STRINGER 2R. INSTALLED TIE CLIP PER SRM 51-10-02 AND SRM 51-40-03. (M)

Part: CREASE BEAM — CRACKED (FUSELAGE)

CLT - FOUND CREASE BEAM CRACKED 1 INCH, BS 639 BETWEEN STATION 619-639 STRINGER 17L REPAIRED PER SRM 51-10-2. (M)

Part: WEB — CRACKED (FUSELAGE)

CLT - FOUND WEB PLATE CRACKED 2 INCHES, STATION 639 STRINGER 17R. REPAIRED PER SRM 51-10-2. (M)

Part: ACTUATOR — FAILED (STAB TRIM)

PHL - FLT 1063 - EN ROUTE FROM RIC TO BOS, THE STABILIZER ELECTRIC TRIM HAD FAILED. FLIGHT DIVERTED TO PHL AND LANDED WITHOUT FURTEHR INCDIENT. NO EMEGENCY WAS DECLARED. MAINTENANCE PERFORMED FUNCTIONAL CHECK ON STABILIZER TRIM SYSTEM AND FOUND ALL FUNCTIONS NORMAL. REMOVED AND REPLACED THE STABILIZER TRIM ACTUATOR ASSY AS PRECAUTIONARY AND PERFORMED OPERATIONAL CHECK PER MM 27-41-71. ALSO, REMOVED AND REPLACED STABILIZER TRIM SAFETY RELAY R66 AND STABILIZER CONTROL RELAY R64 (P/N 9123-8071) AS PRECAUTIONARY. SYSTEM CHECKS NORMAL. VISUALLY INSPECTED STABILIZER JACKSCREW AND GIMBAL AND MOUNTING OF CUTOFF SWITCHES. NO DEFECTS NOTED. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

CLT - MAINTENANCE FOUND THE EMERGENCY EVACUATION LIGHTING INOPERATIVE AT ROW 12 ABC THROUGH ROW 16 ABC AND AT ROW 21 AND 22 ABC. ALSO, FOUND THE RIGHT AFT SERVICE DOOR OVERHEAD EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE BATTERY PACKS. OPERATIONAL CHECK GOOD. (M)

Part: CONTROLLER — FAILED (E/E BAY)

PIT - FLT 723 - ON CLIMB-OUT FROM PIT, THE AUTO FAIL PRESSURIZATION LIGHT ILLUMINATED. CREW ACCOMPLISHED QUICK REF HANDBOOK PROCEDURES BUT WAS UNABLE TO PRESSURIZE AIRCRAFT. FLIGHT RETURNED TO FIELD AT PIT AND LANDED WITHOUT FURTHER INCIDENT. NO EMERGENCY WAS DECLARED. MAINTENANCE PRESSURIZED AIRCRAFT ON GROUND. CHECKS NORMAL PER MM 21-31-00. REMOVED AND REPLACED CABIN PRESSURE CONTROLLER AS PRECAUTIONARY. OPERATIONAL CHECK GOOD. AIRCRAFT OK FOR SERVICE. (M)

Part: UNKNOWN — ODOR (CABIN)

MCO - FLT 2152 - 20 MINUTES AFTER T/O FROM RSW, UNIDENTIFIED FUMES WERE RECOGNIZED IN THE AFT GALLEY. CREW TURNED OFF GALLEY POWER SWITCH AND PULLED ALL CIRCUIT BREAKERS IN THE GALLEY. NO SMOKE WAS PRESENT BUT FUMES BECAME STRONGER. CREW DECLARED EMERGENCY AND THE FLIGHT DIVERTED TO MCO. FLT LANDED WITHOUT INCIDENT. MX FOUND THE FOUL ODOR IN THE FORWARD CARGO COMPT TO BE COMING FROM A CARDBOARD BOX CONTAINING CHINCHILLAS. CONTENTS WERE REMOVED AND THE ODOR DISSIPATED. INSPECTED OTHER AIRCRAFT COMPARTMENTS. RAN APU, ENGINES AND AIR CONDITIONING PACKS AT VARIOUS POWER SETTINGS. RESET CIRCUIT BREAKERS AND OPERATIONALLY CHECKED ALL COFFEE MAKERS. NO FUMES OR ODORS DETECTED. (M)

Part: ENGINE — VIBRATION (NR 1)

CLT - FLT 8052 - ON CLIMB-OUT FROM CLT, THE NR1 ENGINE VIBRATION MONITOR INDICATED 2 UNITS ACCELERATING THROUGH 210 KNOTS. FLIGHT RETURNED TO FIELD AT CLT AND LANDED WITHOUT FURTHER INCIDENT. NO EMERGENCYWAS DECLARED. MAINTENACNE ACCOMPLISHED TROUBLESHOOTING PROCEDURE PER MM 71-00-00 PAGE 24Y AND PERFORMED JOB CARD J377-30-1 AVM SIGNAL CONDITIONER CHECK. ALL P ARAMETERS ARE WITHIN THE NO ACTION REQUIRED RANGE. AIRCRAFT OK FOR SERVICE. CL T - FLT 1531, LATER THAT DAY, FLT RETURNED TO FIELD A SECOND TIME AT CLT FOR SAM E ENGINE VIBRATION. AIRCRAFT WAS AT FL260 WHEN THE CAPTAIN DECIDED TO RETURN TOFIELD. FLIGHT LANDED WITHOUT INCIDENT. NO EMEREGNCY WAS DECLARED. (M)

Part: COFFEEMAKER — MALFUNCTIONED (GALLEY)

IAD - FLT 488 - EN ROUTE FROM PIT-BWI, F/A REPORTED SMELL OF BURNING WIRES AND FUMES IN THE AFT CABIN. NO VISIBLE SMOKE WAS NOTED. AN EMERGENCY WAS DECLARED AND FLT DIVERTED TO NEAREST AIRPORT AT IAD. FLT LANDED W/O FURTHER INCIDENT. MX RAN BOTH ENGINES TO 70 PERCENT N1 FOR 20 MINUTES WITH BOTH AIR CONDITIONING PACKS ON. TURNED ALL COFFEE MAKERS ON. LOWERERED CEILING PANELS AND CHECKED ALL LIGHTS. CHECKED BOTH AFT LAVATORIES, INCLUDING WATER HEATERS, TRASH CANS FOR SIGNS OF FIRE AN FLUSHED TOILETS. CHECKED FIRE EXTINGUISHERS. ALSO, RAN APU.. NO SMELL OR FUMES NOTED. REMOVED AND REPLACED UPPER AFT GALLEY COFFEEMAKER AS PRECAUTIONARY. OPS CHECK GOOD. (M)

Part: INDICATOR — FAILED (COCKPIT)

RDU - FL 1494 - ON APPROACH TO RDU, CREW EXTENDED FLAPS FROM 25 TO 30 DEGREES AND RECEIVED A FLAP ASSYMETRY. CREW PLACED FLAPS BACK TO 25 DEGREES, ADVISED THE TOWER THEY HAD A PROBLEM AND DECLARED AN EMERGENCY. CREW ACCOMPLISHED A GO-AROUND AND PERFORMED EMERGENCY CHECK LIST IN REFERENCE TO TRAILING EDGE FLAP PROBLEM. CREW EXECUTED A LONG FINAL AND BROUGHT THE AIRCRAFT IN ON A SHALLOW APPROACH. FLIGHT LANDED WITHOUT FURTHER INCIDENT AND TAXIED TO THE GATE UNDER ITS OWN POWER. MAINTENANCE REMOVED AND REPLACED THE TRAILING EDGE FLAP POSITION INDICATOR. RAN FLAPS SEVERAL TIMES. OPERATIONAL CHECK GOOD PER MM. (X)

Part: WIRE — LOOSE (CABIN)

BWI - MAINTENANCE REPORTED THE LEFT AFT EXTERIOR EMERGENCY ESCAPE LIGHT WAS INOP. MAINTENANCE INSTALLED NEW WIRE FROM M1197 BATTERY PACK D3122 PIN 9 TO L732 ESCAPE SLIDE LIGHT. OPERATIONAL CHECK GOOD. (M)

Part: WIRE — BROKEN (CABIN)

BDL - AFT GALLEY OVERHEAD EMERGENCY EXIT SIGN INOPERATIVE. REPLACED WIRE BETWEEN POWER SUPPLY AND LIGHT ASSEMBLY CONNECTORS D3122 AND D3170. (M)

Part: WIRE — SHORTED (CABIN)

TPA - MAINTENANCE FOUND THE INTERIOR OVERWING EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE REPLACED A SHORTED WIRE IN THE FLOOR. OPERATIONAL CHECK GOOD. (X)

Part: FLOOR BEAM — CORROSION (BS 312)

CLT - INSPECTION VISUALLY FOUND LEVEL 2 CORROSION MEASURING 56 INCHES LOCATED AT FLOOR BEAM STATION 312. CORROSION TASK NR C53-107-03, CORROSION LEVEL 2. INSTALLED REPAIR ANGLES AS PER TYPICAL REPAIR 53-10-03. (M)

Part: ENGINE — BIRD STRIKE (RIGHT)

EWR - FLT 1293 - AFTER ROTATION FROM LGA AT APPROXIMATELY 100 FEET, CREW SAW 5 TO 9 SEAGULLS AHEAD OF THE AIRCRAFT. THE RIGHT ENGINE INGESTED ONE LARGE SEAGULL. CREW ELECTED TO MAKE A PRECAUTIONARY LANDING AT EWR ALTHOUGH ENGINE PARAMETERS WERE NORMAL. NO EMERGENCY WAS DECLARED AND THE FLIGHT LANDED IN EWR WITH NO FURTHER INCIDENT. MAINTENANCE FOUND AND REPLACED THE FOLLOWING ITEMS ON THE RT ENGINE DUE TO BIRD INGESTION: NR 6, NR 7, AND NR 8 FAN BLADES (DAMAGED), CSD OIL COOLER (CLOGGED) AND THE T-2 AND T-12 SENSORS (DAMAGED). NOTE: FAN BLADES NR 25, NR 26, AND NR 27 WERE REPLACED DUE TO REPLACEMENT OF FAN BLADES, NR 6, NR 7, AND NR 8. (X)