N37615

Part: DUCT — CONTAMINATED (AC SYSTEM) · airframe 37,131 hrs · 19,726 cycles

AFTER TAKEOFF SMOKE ENTERED FLIGHT DECK AND CABIN AT APPROX 1000FT MSL. RETURNED TO FIELD. CABIN AND FLT DECK BEGAN TO CLEAR ON FINAL. FOUND DE-ICING FLUID CONTAMINATION IN AC SYSTEM AFTER DE-ICING. SMOKE BURN OUT OF PNEUMATIC SYSTEM AND REPLACEMENT OF COALESCER BAGS. RAN ENGINES AT VARIOUS POWER SETTING, NO SMOKE.

Part: OVEN — INOPERATIVE (FWD GALLEY) · airframe 31,800 hrs · 16,893 cycles

SMOKE AND A BURNING METALLIC ODOR CAME FROM THE FORWARD GALLEY 205 OVEN. THE GALLEY POWER WAS TURNED OFF AND THE SMOKE CEASED. THE FLIGHT ATTENDANT REPORTED THAT THE OVEN WAS EMPTY AT THE TIME OF THE OCCURRENCE. THE FORWARD GALLEY OVEN WAS REMOVED AND REPLACED AND OPERATIONAL CHECKS WERE GOOD.

Part: SKIN — CRACKED (L-1 DOOR) · airframe 30,277 hrs · 16,130 cycles

INSPECTION FOUND A .5 INCH CRACK FROM RIVET IN L-1 DOOR AT TOP AFT CORNER. A REPAIR WAS INSTALLED IAW ECRA 5210-01822.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 30,277 hrs · 16,130 cycles

INSPECTION FOUND MAIN CABIN FLOOR LT O/B SEAT TRACK CORRODED AT STA 887-927, LBL 48. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 53-00-52.

Part: SKIN — DENTED (ELEVATOR) · airframe 25,914 hrs · 13,848 cycles

THE AIRCRAFT SUFFERED HAIL DAMAGE TO THE LT ELEVATOR UPPER SKIN PANEL AT APPROXIMATELY ELEVATOR STATION 110.49. THE HAIL IMPACT CAUSED A SMALL DENT APPROXIMATELY 4.5 INCHES FORWARD OF THE ELEVATOR TRAILING EDGE. THE DAMAGE CLEAN UP REQUIRED REMOVAL OF ALL PLIES. THE SKIN WAS REPAIRED IAW ECRA 5520-01329.

Part: SKIN — DENTED (ELEVATOR) · airframe 25,914 hrs · 13,848 cycles

AIRCRAFT SUFFERED HAIL DAMAGE TO THE RT ELEVATOR UPPER SKIN PANEL. THE HAIL IMPACT CAUSED A SMALL DENT AT APPROXIMATELY ELEVATOR STATION 88.9 AND 10.25 INCHES FORWARD OF THE ELEVATOR TRAILING EDGE. THE DAMAGE CLEAN UP REQUIRED REMOVAL OF ALL PLIES AND THE CORE. THE SKIN WAS REPAIRED IAW ECRA 5520-01332.

Part: SKIN — PUNCTURED (ELEVATOR) · airframe 25,914 hrs · 13,848 cycles

AIRCRAFT SUFFERED HAIL DAMAGE TO THE RT ELEVATOR UPPER SKIN PANEL. THE HAIL IMPACT CAUSED A SMALL PUNCTURE AT APPROXIMATELY ELEVATOR STATION 129.4 AND 9.25 INCHES FORWARD OF THE ELEVATOR TRAILING EDGE. THE DAMAGE WAS THROUGH ALL PLIES AND TO THE CORE. THE SKIN WAS REPAIRED IAW ECRA 5520-01331.

Part: SKIN — PUNCTURED (ELEVATOR) · airframe 25,914 hrs · 13,848 cycles

THE AIRCRAFT SUFFERED HAIL DAMAGE IN THE FORM OF A SMALL PUNCTURE TO THE LT ELEVATOR UPPER SKIN PANEL AT APPROXIMATELY ELEVATOR STATION 128.79. THE HOLE WAS APPROXIMATELY 17.5 INCHES FORWARD OF THE ELEVATOR TRAILING EDGE. THE DAMAGE CLEAN UP REQUIRED REMOVAL OF ALL PLIES AND CORE. THE SKIN WAS REPAIRED IAW ECRA 5520-01328.

Part: SKIN — DENTED (ELEVATOR) · airframe 25,914 hrs · 13,848 cycles

THE AIRCRAFT SUFFERED HAIL DAMAGE TO THE UPPER SKIN PANEL OF THE LT ELEVATOR. THE HAIL IMPACT CAUSED A SMALL DENT AT APPROXIMATELY ELEVATOR STATION 86.8. THE DAMAGE CLEAN UP REQUIRED REMOVAL OF ALL PLIES. THE DENT WAS APPROXIMATELY 15.5 INCHES FORWARD OF THE ELEVATOR TRAILING EDGE. THE SKIN PANEL WAS REPAIRED IAW ECRA 5520-01330.

Part: SKIN PANEL — GOUGED (RUDDER L/E) · airframe 25,495 hrs · 13,630 cycles

INSPECTION FOUND THE LOWER L/H SIDE OF RUDDER LEADING EDGE SKIN PANEL GOUGED. A PERMANENT REPAIR WAS INSTALLED IAW ECRA 5540-01162.

Part: SKIN — CORRODED (STA 450) · airframe 25,496 hrs · 13,631 cycles

INSPECTION FOUND FORWARD CARGO DOOR CUTOUT SKIN CORRODED ON INNER SIDE JUST BELOW LOWER AFT DOOR STOP, STA 450, STRINGER 22R.. THE CORRODED SECTION WAS REMOVED AND A DOUBLER AND TRIPLER WERE INSTALLED IAW ECRA 5331-01121.

Part: BEAR STRAP — CORRODED (C DOOR CUTOUT) · airframe 25,496 hrs · 13,630 cycles

INSPECTION FOUND CORROSION AT THE INSIDE SURFACE OF THE BEAR STRAP AT THE LOWER AFT CORNER OF THE FORWARD CARGO DOOR CUTOUT. THE CORROSION WAS REMOVED AND REPAIR WAS PERFORMED IAW ECRA 5331-01121.

Part: SEAL — LEAKING (NR 2 ENGINE) · airframe 23,002 hrs · 12,259 cycles

SMOKE ENTERED THE COCKPIT AND CABIN ON TAKEOFF FROM EWR. THE APU WAS RUNNING AND BOTH ENGINE BLEEDS WERE ON WITH BOTH PACKS OPERATING. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. BOTH ENGINES WERE BORESCOPED. MAINTENANCE FOUND THE AIR/OIL SEAL LEAKING AND OIL HAD ENTERED THE NR 2 ENGINE COMPRESSOR. THE NR 2 ENGINE WAS REMOVED AND REPLACED. A DUCT BURNOUT WAS PERFORMED AND BOTH PACK COALESCER BAGS WERE REMOVED AND REPLACED. A HIGH POWER ENGINE RUN WAS PERFORMED AND OPERATIONAL CHECKS WERE GOOD.

Part: RETRACT MECH — DAMAGED (LT TE FLAP)

THE FLAPS STUCK AT EIGHT DEGREES ON APPROACH TO EWR. THE FLAPS COULD NOT BE CYCLED HYDRAULICALLY OR ELECTRICALLY. A GO-AROUND WAS PERFORMED AND AN EMERGENCY LANDING WAS DECLARED. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LT FLAP TORQUE SHAFT CLEARANCE DOOR DAMAGED. THE TRACK FAIRING AND SHAFT CLEARANCE DOOR WERE REMOVED. CONFIGURATION DEVIATION LIST 57-53-01 WAS ISSUED PENDING DOOR REPLACEMENT AND THE TRACK FAIRING WAS REINSTALLED. THE FLAPS OPERATED NORMALLY THROUGHOUT ENTIRE TRAVEL.

Part: SEAL — LOOSE (AFT CARGO DOOR)

CABIN PRESSURIZATION WAS LOST WHILE AT CRUISE. INITIAL ATTEMPTS TO CONTROL CABIN WITH STANDBY OR MANUAL WERE UNSUCCESSFUL. THE OXYGEN MASKS WERE DEPLOYED AND CABIN CONTROL WAS REGAINED USING MANUAL DC. THE ACFT LANDED WITHOUT FURTHER PROBLEM. MAINTENANCE PRESSURIZED THE ACFT TO 5 PSI TWICE, ONCE IN AC MANUAL AND ONCE IN DC MANUAL. PRESSURIZATION WAS SUCCESSFUL. THE AFT CARGO DOOR SEAL WAS FOUND COMING LOOSE AT THE FORWARD LOWER CORNER. THE AFT CARGO DOOR SEAL WAS REMOVED AND REPLACED. THE ACFT WAS PRESSURIZED AGAIN AND LEAK CHECK WAS GOOD. IT WAS OBSERVED THAT ALL OXYGEN MASKS HAD DEPLOYED. THE OXYGEN GENERATORS WERE REMOVED AND REPLACED IAW MM 35-22-11.