N369DL

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 61,729 hrs · 41,958 cycles

ROUTINE INSPECTIONS OF THE FWD GALLEY DOOR (R1) SURROUND STRUCTURE PER AD 98-22-10, REVEALED A CRACK IN THE LOWER INTERCOSTAL OF THE AFT DOOR FRAME. THE CRACK IS TYPICAL OF BAC S/B 737-53A1108. THE CRACKED INTERCOSTAL WAS REMOVED AND AN IMPROVED VERSION INSTALLED PER THE BAC S/B AND ER/A 378881-14AD, REV A.

Part: TRANSMISSION — SEIZED (TE FLAPS) · airframe 61,182 hrs · 41,511 cycles

FLAPS LOCKED OUT ON APPROACH TO CAE. CREW DID GO-AROUND. FOUND FLAP TRANSMISSION SEIZED. REPLACED FLAP TRANSMISSION AND JACK SCREW ASSY, CHECKS GOOD.

Part: ENGINE — FOD (NR 2) · airframe 60,866 hrs · 41,254 cycles

ON TAKEOFF, HEARD LOUD BANG. SUSPECT BIRD STRIKES. FOUND NR 2 ENG 1ST STAGE FAN BLADE FOD. REPLACING FAN.

Part: SKIN — CRACKED (FUSELAGE) · airframe 60,680 hrs · 41,116 cycles

A 2 INCH CRACK WAS FOUND EMANATING FROM UNDER A WING TO BODY FAIRING AT FS 727A+3 AND STRINGER 17L. AN EXISTING REPAIR WAS NEAR THE CRACK. THE PREVIOUS REPAIR WAS REMOVED AND THE NEW CRACK AND EXISTING REPAIR CUTOUT WERE COMBINED INTO A 20 X 11 INCH CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 377172-14, REV A.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 60,680 hrs · 41,116 cycles

THE RBL 45.5 FLOOR LONGITUDINAL FLOORBEAM OVER THE MLG WHEEL WELL WAS FOUND WITH A 12 INCH CRACK IN THE BEAM WEB BETWEEN FS 633 & 645. THE CRACKED SECTION OF WEB WAS CUT AND REMOVED. A NEW SECTION OF WEB WAS SPLICED IN WITH TWO ALUMINUM SPLICE DOUBLERS PER ER/A 377146-14, REV B.

Part: DAMAGED (NO.8 POS)

RT WING OUTBOARD FLAP JACKSCREW DAMAGED. REPLACED NR 8 JACKSCREW TRANSMISSION ASSY.

Part: RADAR TR UNIT — INOP (E/E COMPT)

WX RADAR ANT FLASHING ON SCREEN. NO RADAR AVAILABLE. REPLACED WX RARAR TRANSCEIVER.

Part: GENERATOR — FAILED (NR 1)

NR 1 ENG GEN FAILED SHORTLY AFTER T/O. THERE WAS NO INDICATION ON THE OVERHEAD ELECT PANEL THAT THE GENERATOR HAD FAILED. REPLACED GCU.

Part: BATTERY PACK — DISCHARGED (CABIN)

ONE SECTION OF EMERGENCY LIGHTS REMAINED ON DURING FLT. REPLACED EMERG BATTERY PACK, OPS CK OK.

Part: SKIN — CRACKED (R2 DOORWAY)

THE FUSELAGE SKIN, DOUBLER AND BEAR STRAP WERE FOUND WITH A 1 INCH TYPICAL CRACK IN THE LOWER FWD CORNER OF THE R2 DOOR CUTOUT. THE CRACK WAS REPAIRED PER B737 SRM 53-30-3, FIG 24 EXCEPT BLIND FASTENERS WERE AUTHORIZED ON A TIME-LIMITED BASIS. THE REPAIR WAS DOCUMENTED PER ER/A 366018-14, REV B.

Part: CIRCUIT BREAKER — TRIPPED (COCKPIT)

AIR TURNBACK DUE TO LANDING GEAR LEVER WOULDN'T MOVE TO UP POS ON T/O. ABNORMAL PROCEDURES RUN TO RAISE LANDING GEAR. LAND GEAR EXT NORMAL ON RETURN. RESET LEVER LATCH C/B. CYCLED LAND GEAR LEVER, ALL IND NORMAL. REPLACED LEVER LATCH C/B. CYCLED L/G LEVER SEVERAL TIMES, SYS OPS NORMAL.

Part: SKIN — PUNCTURED (BS 460)

A 1.5 X 1.5 PUNCTURE WAS FOUND IN THE FUSELAGE SKIN JUST AFT OF STA 460 BELOW THE STRINGER 25R SKIN LAP SPLICE. THE PUNCTURE WAS TRIMMED TO A SMOOTH CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND AN ADDITIONAL DOUBLER TO OVERLAP THE SKIN LAP SPLICE. THE REPAIR WAS ACCOMPLISHED PER ER/A 364666-14, REV A.

Part: BOLT — LOOSE (NR 3 TE FLAP)

DURING AD MANDATED INSPECTION, THE OUTBD BOLT ON THE NR 3 FLAP OUTBD TRACK AFT ATTACH FITTING WAS FOUND LOOSE. THE CONDITION WAS CORRECTED BY INSTALLING THE TRACK MODIFICATION PER BAC S/B 737-57A1130. THE MODIFICATION WAS DOCUMENTED PER ER/A 364643-14AD.

Part: ANTI-ICE — ODOR (ENGINE)

AT 25,000, AN ELECTRICAL SMELL WAS NOTED IN ENTIRE AIRCRAFT WHEN ENGINE ANTI-ICE WAS TURNED ON. SMELL WENT AWAY WHEN ENGINE ANTI-ICE TURNED OFF. RAN ENGINES AND PACKS, INSPECTED FOR SOURCE, NO TROUBLE FOUND.

Part: FRAME — CRACKED (BS 727)

WHILE ACCOMP INSPECTIONS REQUIRED BY AD 95-12-17, A TYPICAL CRACK WAS FOUND IN THE BS 727 FRAME, OUTBOARD CHORD AT STR 18A, LHS. THE CHORD WILL BE REPLACED PER S/B 737-53-1088 AND A PREVENTATIVE MODIFICATION WILL BE ACCOMP PER S/B 737-53A1166. THE S/B REQUIRES CHORD REPLACEMENT PER BAC DWG 65C33722. CURING THE INSTALLATION OF THE EXTERNAL STRAP 69-78770-1. MX WAS UNABLE TO PICK UP THE FASTENER PATTERN SHOWN ON SHEET 1 OF 65C37277 IN THE LWR FWD PORTION OF THE STRAP. THE ER/A ADDRESSES THE DISCREPANCIES IN THE INSTALLATION OF THE EXTERNAL STRAP.

Part: SKIN — CUT (BS 727)

WHILE ACCOMPLISHING THE REPLACEMENT OF STA 727 FRAME CHORD PER E.O. 3-68646-3AD, THE FUSELAGE SKIN BETWEEN ST 727 BULKHEAD AND STA 727+10 WAS CUT IN ORDER TO PROVIDE ACCESS FOR THE CHORD REPLACEMENT. WHEN CUTTING THE SKIN, MX ALSO CUT THE INTERNAL BONDED WAFFLE DOUBLER. THE SKIN PANEL WAS REPLACED.

Part: FRAME — CRACKED (BS 727)

THE FS 727 BULKHEAD O/B CHORD AT STR 18A WAS FOUND CRACKED AND IS BEING REPLACED PER BACO DWG 65C33722, AS REQUIRED BY DAL EO 3-68646-3AD, WHICH ACCOMPLISHES S/B 737-53-1088. BETWEEN STR S-24 AND S-27, BACB30FP* FASTENERS, SAME SIZE AS REQUIRED BY BP, WERE INSTALLED INSTEAD OF BACR15CE*D AND BACR15BB*D FASTENERS CALLED OUT FOR THIS AREA. THIS ER/A WAS APROVED BY FAA/DER FORM 8110-3 DER DESGINATION NM-2222 DATED 8-22-97.

Part: LIGHT — INOP (CABIN)

ON L/O, FOUND EMERGENCY EXIT LIGHT ABOVE 2L DOOR INOP. REPLACED LIGHT ASSEMBLY.

Part: BOLT — WORN THREADS (NR 2 TE FLAP)

WHILE ACCOMPLISHING TORQUE CHECK OF CENTER ATTACH BOLT OF NR 2 FLAP O/B TRACK ATTACH FITTING, THE CENTER BOLT WAS FOUND TO HAVE DAMAGED THREADS. IN ACCORDANCE WITH SB 737-57A1130, THE PREVENTATIVE MOD WILL BE INSTALLED. ADDITIONALLY, THE FLAP TRACK BUSHING WAS FOUND TO HAVE MINOR FRETTING ON THE INNER BORE. IN ACCORDANCE WITH FIGURE 4 OF SB 737-57A1130, THE BUSHING HOLE CAN BE ENLARGED TO 0.5015 MAX DIAMETER.

Part: LIGHT — MALFUNCTIONED (CABIN)

FORWARD ENTRY DOOR EMERGENCY LIGHT COMES ON WHEN SWITCH NOT ARMED AND AIRCRAFT POWER OFF. REPLACED LIGHT ASSEMBLY (P/N 10-0067-7).

Part: BATTERY — DISCHARGED (CABIN)

ON PREFLIGHT, EMERGENCY EXIT LIGHT AT FWD SERVICE DOOR INOP. REPLACED BATTERIES, BULBS AND SECURED WIRE TERMINAL, OPERATION NORMAL.

Part: FLOORBEAM — CRACKED (BS 675)

DURING INSPECTION, THE LONGITUDINAL FLOORBEAM AT APPROXIMATELY STA 675 AND RBL 45 WAS FOUND WITH A 2.5 INCH CRACK IN THE LOWER CHORD. DAMAGE REMOVAL RESULTED IN TRIMMING OUT THE LOWER HORIZONTAL FLANGE OF THE CHORD IN ACCORDANCE WITH FORM 8110-3, DATED 2-2-96.