N37882

Part: STRUT — DISCHARGED (NLG) · airframe 49,403 hrs · 39,292 cycles

THE NLG WOULD NOT RETRACT AFTER TAKEOFF FROM DTW. THE NOSE GEAR INDICATED UNSAFE AND A LOUD MECHANICAL CLUNKING NOISE WAS HEARD. THE GEAR WAS CYCLED WITH NO CHANGE IN RESULTS. THE GROUND CONTROL ALSO REVERTED TO THE GROUND MODE. THE AIRCRAFT WAS DIVERTED TO CLE WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NOSE GEAR STRUT FLAT. THE NOSE GEAR SHRADER VALVE WAS REPLACED AND A FULL SERVICE WAS PERFORMED ON THE NOSE GEAR STRUT. THE GEAR WAS SWUNG AND OPERATION CHECKED GOOD IAW MM 32-21-02, 32-30-00, PAGES 201-206, AND 07-11-00, PAGES 201-220.

Part: O-RING — LEAKING (NLG STRUT) · airframe 48,863 hrs · 38,720 cycles

THE LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF FROM TPA. QRH PROCEDURES WERE COMPLIED WITH AND THE AIRCRAFT WAS DIVERTED TO MCO WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NLG SCHRADER VALVE O-RING LEAKING AND THE STRUT WAS FLAT. THE O-RING WAS REPLACED AND A FULL NOSE STRUT SERVICING WAS PERFORMED. THE GEAR WAS CYCLED AND ALL SYSTEMS CHECKED NORMAL.

Part: SUPPORT — CRACKED (BS 408)

INSPECTION FOUND A 6 INCH CRACK IN FORWARD CARGO BAY GILL LINER SUPPORT FRAME AT FS 408, LONGERON 25L. THE SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 51-30-2, 51-10-3, AND 51-10-4.

Part: SUPPORT — CORRODED (DOOR FRAME)

INSPECTION FOUND AFT CARGO LOWER AFT DOOR JAMB CORNER SUPPORT CORRODED AT LONGERON 27R. THE CORNER SUPPORT WAS REMOVED AND A NEW CORNER SUPPORT WAS INSTALLED IAW SRM 51-30-2, 51-10-4, AND 51-30-5.

Part: ANGLE — CRACKED (HORIZ STAB)

INSPECTION FOUND A 10 INCH CRACK IN HORIZONTAL STABILIZER RIGHT I/B LEADING EDGE I/B ANGLE AT XHR 9.652. THE ANGLE WAS REMOVED AND REPLACED IAW SRM 51-30-02, 51-30-05, 51-10-04, AND 51-30-01.

Part: ANGLE — CRACKED (PAX DOOR)

INSPECTION FOUND L-1 DOOR UPPER AND LOWER ATTACH ANGLES CRACKED. THE CRACKS WERE 0.75 LONG. THE ANGLES WERE REMOVED AND NEW ANGLES WERE INSTALLED IAW SRM 51-10-3, 51-10-4, 51-30-2, 51-30-5, AND 51-30-7.

Part: SKIN — GOUGED (VERTICAL STAB)

INSPECTION FOUND LEFT VERTICAL STABILIZER SKIN GOUGED ALONG HORIZONTAL STABILIZER RUN LINE. THE PANEL WAS REMOVED AND A NEW PANEL WAS INSTALLED IAW SRM 51-30-1, 51-30-2, 51-10-4, AND 51-30-5.

Part: FLOORBEAM — CRACKED (BS 503)

INSPECTION FOUND A 1.5 INCH CRACK IN FORWARD CARGO BAY GILL-LINER FLOOR SUPPORT FRAME AT STA 503, LONGERON 25L. A NEW FLOOR SUPPORT WAS INSTALLED IAW SRM 51-30-2.

Part: FRAME — CRACKED (BS 1309)

INSPECTION FOUND A 2 INCH CRACK IN AFT CARGO BAY GILL LINER SUPPORT FRAME AT STA 1309, LONGERON 23L. THE CRACK WAS STOP DRILLED IAW SRM 53-01-2. A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-01-2.

Part: SUPPORT — CRACKED (BS 541)

INSPECTION FOUND MID CARGO BAY BULKHEAD VERTICAL SUPPORT CRACKED AT STA 541. THE VERTICAL SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 51-30-2 AND 51-30-5.

Part: DOOR PAN — PUNCTURED (SERVICE DOOR)

INSPECTION FOUND A PUNCTURE IN R-1 DOOR AT LOWER AFT INTERNAL PAN. A PLUG REPAIR WAS INSTALLED IAW SRM 52-01, FIGURE 1.

Part: SKIN — CRACKED (SERVICE DOOR)

INSPECTION FOUND A CRACK IN FORWARD LAV SERVICE DOOR LOWER AFT CORNER. THE DOOR WAS REMOVED AND A NEW DOOR WAS INSTALLED IAW SRM 51-30-2.

Part: ANGLE — CRACKED (APU DOOR)

INSPECTION FOUND A 3.5 INCH CRACK IN RT APU DOOR Z-ANGLE AT FS 1320, LONGERON 27R. THE Z-ANGLE WAS REMOVED AND REPLACED IAW SRM 51-30-02, 51-10-04, AND 51-10-3.

Part: SKIN — CRACKED (APU DOOR)

INSPECTION FOUND A 2.5 INCH CRACK IN LEFT APU DOOR SKIN AT I/B EDGE, FS 1320, LONGERON 30. THE CRACK WAS STOP DRILLED AND A DOUBLER REPAIR WAS INSTALLED IAW SRM 52-01, FIGURE 2 AND 51-30-2..

Part: ANGLE — CRACKED (BS 1250 - 1271)

INSPECTION FOUND A 4.2 INCH CRACK IN ANGLE IN AFT PIT AT FS 1250-1271, LONGERON 25L. THE ANGLE WAS REMOVED AND REPLACED IAW SRM 53-01, 51-30-1, AND 53-14-3.

Part: ANGLE — CRACKED (NR 2 ENGINE COWL)

INSPECTION FOUND ANGLE CRACKED THROUGH LOWER ACCESS PANEL NR 7406 OF NR 2 ENGINE NOSE COWL. THE ANGLE WAS REMOVED AND A NEW ANGLE WAS INSTALLED IAW SRM 51-10-4, 51-10-3, 51-30-5, AND 51-30-2.

Part: FRAME — CRACKED (BS 1485)

INSPECTION FOUND LT SIDE OF CANTED FRAME CRACKED JUST O/B OF LIGHT ASSEMBLY IN TAIL COMPARTMENT AT FS 1485. REPAIR DOUBLERS WERE INSTALLED IAW SRM 53-01, FIGURE 2, SHEETS 3 AND 4, 51-30-2, AND 51-30-5, PAGE 4.

Part: FITTING — CRACKED (BS 1220)

INSPECTION FOUND LONGERON 25R END FITTING CRACKED IN AFT CARGO BAY AT STA 1220. THE FITTING WAS REMOVED AND NEW FITTING WAS INSTALLED IAW SRM 51-30-5, 51-10-4, AND 51-10-3.

Part: FLOORBEAM — CRACKED (BS 1271)

INSPECTION FOUND FLOOR SUPPORT CRACKED IN AFT CARGO BAY AT STA 1271, L28L. THE FLOOR SUPPORT WAS REMOVED IAW SRM 51-30-2 AND 51-10-4. REMOVED GUSSETS AND FASTENERS FROM INTERCOSTAL TO GAIN ACCESS TO TRAPPED FASTENER AND REINSTALLED IAW SRM 51-30-2 AND 51-10-4. INSTALLED NEW FLOOR SUPPORT IAW SRM 51-30-2, 51-10-4, AND 51-30-5.

Part: SKIN — CRACKED (RT WING)

INSPECTION FOUND RT WING LEADING EDGE SKIN CRACKED AT I/B END OF REFUELING DOOR. THE CRACK WAS STOP DRILLED AND A DOUBLER WAS INSTALLED IAW SRM 57-06B, FIGURE 3 AND 51-30-1.

Part: BEAM — CORRODED (CARGO BAY)

INSPECTION FOUND AFT CARGO DOOR JAMB BEAM CORRODED. THE DOOR JAMB BEAM WAS REPAIRED IAW ECRA 5310-03027, SRM 51-30-2, AND 51-30-5.

Part: FRAME — CRACKED (BS 1060 - 1297)

INSPECTION FOUND GILL-LINER SUPPORT FRAMES CRACKED IN AFT CARGO BAY AT STA 1060-1297, L24R TO L27R. THE SUPPORTS WERE REMOVED AND REPLACED IAW SRM 51-10-4 AND 51-30-2.

Part: FRAME — CRACKED (BS 1250 & 1117)

INSPECTION FOUND FLOOR SUPPORT FRAMES CRACKED IN AFT CARGO BAY AT STA 1250, L29L AND AT STA 1117, L27L. THE SUPPORTS WERE REMOVED AND NEW SUPPORTS WERE INSTALLED IAW SRM 51-10-4, 51-30-2, AND 51-30-5.

Part: SKIN — DENTED (RT WING)

INSPECTION FOUND RT WING L/E SKIN DENTED JUST FORWARD OF REFUELING DOOR. A REPAIR DOUBLER AND FILLER WERE INSTALLED IAW SRM 57-06B, FIGURE 5, 51-10-4, 51-10-3, 51-20-00, 51-30-2, AND 51-30-5.

Part: ACTUATOR — LEAKING (LT MLG)

WITH APU AIR ON AND PACKS ON, CABIN FILLS WITH SMOKE AND STRONG BURNING SMELL. FOUND LEFT GEAR RETRACT ACTUATOR IN TRANSIT LEAK. REMOVED AND REPLACED ACTUATOR PER MM 32-32-02. PERFORMED BURN OUT OF PNEUMATIC DUCT PER MM 21-20-02.

Part: SUPPORT — CORRODED (BS 148-200)

FLOOR SUPPORT HAT SECTION CORRODED STA 148 - 200. FABRICATED AND INSTALLED NEW HAT SECTION PER SRM 51-30-01.

Part: RECEPTICLE — WORN (TAIL CONE)

TAIL CONE TOP FIVE ALIGNMENT PIN RECEPTICLES WORN. REPLACED TOP FIVE ALIGNMENT PIN RECEPTICLES.

Part: LONGERON — CRACKED (BS 1338)

INSPECTION FOUND A .4375 INCH CRACK T CAP AT STA 1338, LONGERON 14R. REPAIRED IAW EA 5310-01272.

Part: SKIN — CHAFED (BAGGAGE DOOR)

INSPECTION FOUND FORWARD BAGGAGE BIN LOWER DOOR SKIN CHAFED IN SEVERAL PLACES BELOW LOCK HANDLE. A REPAIR WAS FABRICATED AND INSTALLED IAW ECRA 5230-01397.

Part: PAN — CRACKED (AFT ENTRY DOOR)

INSPECTION FOUND A 1.5 CRACK IN AFT ENTRY DOOR PAN AND A 1.5 CRACK IN INNER PAN ANGLE AT CENTER RT DOOR STOP PAD. REPAIRS WERE INSTALLED IAW ECRA 5220-01034.

Part: FRAME — GOUGED (BS 1380)

INSPECTION FOUND THAT THE LEFT HEAT VALVE HAD GOUGED THE FRAME INNER CAP AT STA 1380. A REPAIR STRAP WAS INSTALLED IAW ECRA 5311-01042.

Part: SKIN — OVERSIZE HOLES (DORSAL FIN)

INSPECTION FOUND OVERSIZED HOLES IN FUSELAGE SKIN AT OUTER DORSAL FIN ATTACH ANGLE ON LEFT AND RIGHT SIDES. REPAIRED IAW ECRA 5340-01312.

Part: CUSP BEAM — CORRODED (BS 229)

INSPECTION FOUND CUSP BEAM CORRODED AT STA 229, LONGERON 18L. REPAIRED IAW ECRA 5310-03678.

Part: CUSP BEAM — CORRODED (BS 200)

INSPECTION FOUND CUSP BEAM CORRODED AT STA 200, LONGERON 18L. REPAIRED IAW ECRA 5310-03678.

Part: SKIN — DENTED (BS 218-256)

INSPECTION FOUND FUSELAGE SKIN DENTED AT FLOOR LEVEL AFT OF L-1 DOOR, STA 218 TO 256, LONGERON 18L. THE SKIN WAS REPAIRED IAW ECRA 5330-01204.

Part: BELTFRAME — CORRODED (BS 1322)

INSPECTION FOUND BELTFRAME CORRODED ACROSS BOTTOM ON FRONT CENTER AND LOWER CHANNEL AT STA 1322 FROM LONGERON 28L TO 28R. A REPAIR WAS INSTALLED IAW SRM 53-03.

Part: BEAM — CRACKED (PAX DOOR)

INSPECTION FOUND A 1.25 INCH CRACK AT AFT END OF MAIN CABIN DOOR NR 7 BEAM AND A 1 INCH CRACK WAS LOCATED AT FORWARD END OF NR 7 BEAM. A 1 INCH CRACK WAS FOUND AT FORWARD END OF MAIN CABIN DOOR NR 8 BEAM. A .75 INCH CRACK WAS FOUND AT FORWARD END OF MAIN CABIN DOOR NR 2 BEAM. THE BEAMS WERE REPAIRED IAW SRM 52-05, FIGURE 31 AND ECRA 5211-01022.

Part: ANGLE — CRACKED (PAX DOOR)

INSPECTION FOUND A .125 INCH CRACK IN MAIN CABIN DOOR ANGLE AT BAYONET CUTOUT. REPAIRED IAW SRM 52-05, FIGURE 33.

Part: LONGERON — CORRODED (BS 1322)

INSPECTION FOUND LONGERON 29R CORRODED UNDER FLANGE AT STA 1322. THE CORRODED SECTION OF LONGERON WAS REMOVED AND A NEW SECTION WAS SPLICED IN IAW SRM 53-02, FIGURE 2.

Part: PIVOT PLATES — CORRODED (HORIZ STAB)

INSPECTION FOUND INBOARD AND OUTBOARD SET OF HINGE PIVOT PLATES CORRODED ON RT HORIZONTAL STABILIZER. THE OUTBOARD SET OF HINGE PIVOT PLATES WERE FOUND CORRODED ON LT HORIZONTAL STABILIZER. THE PIVOT PLATES WERE REMOVED AND REPLACED IAW SRM 51-30-5.

Part: BEAM — CORRODED (CARGO DOORWAY)

INSPECTION FOUND MID BAGGAGE BIN DOOR JAMB BEAM CORRODED. THE AREA WAS REPAIRED IAW SRM 53-05, FIGURE 63.

Part: SUPPORT — CORRODED (BS 148-160)

INSPECTION FOUND FLOOR SUPPORT CORRODED BETWEEN PANEL D AND E AT STA 148 TO 160, FORWARD ENTRY AREA. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 53-01, 51-10-3, AND 51-30-2.

Part: ACTUATOR — LEAKING (LT T/E FLAP)

THE RT HYDRAULIC SYSTEM QUANTITY INDICATED ZERO ACCOMPANIED BY THE RT HYDRAULIC PRESSURE LOW LIGHT ILLUMINATING WHILE EN ROUTE. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LT INBOARD FLAP ACTUATOR LEAKING. THE FLAP ACTUATOR WAS REPLACED IAW MM 27-52-02, LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: ACTUATOR — LEAKING (LT TE FLAP)

THE RT HYDRAULIC QUANTITY WAS LOST WHILE ON APPROACH. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND SEAL LEAKING AT LEFT INBOARD FLAP ACTUATOR. THE LT INBOARD FLAP ACTUATOR CYLINDER WAS REPLACED IAW MM 27-52-02. THE FLAPS AND ALL OTHER FLIGHT CONTROLS WERE OPERATED SEVERAL TIMES WITH NO DEFECTS OR LEAKS NOTED. THE HYDRAULIC SYSTEMS WERE SERVICED.

Part: BUS GEN CONT — INOPERATIVE (EQUIP INSTL)

BOTH GENERATOR OFF-LIGHTS ILLUMINATED AND ALL GENERATOR POWER WAS LOST DURING CLIMB AT 9,000 FEET. THE AC CROSSTIE LOCKOUT LIGHT ALSO CAME ON. THE GENERATORS WERE RESET AND OPERATION WAS NORMAL, BUT THE AC CROSSTIE LOCKOUT LIGHT REMAINED ILLUMINATED. THE FLIGHT WAS CONTINUED WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND THE BUS GENERATOR CONTROL UNIT AT FAULT. THE BUS GENERATOR CONTROL UNIT WAS REMOVED AND REPLACED. THE ENGINES WERE RUN AND OPERATIONAL CHECKS WERE GOOD. PART TOTAL CYCLES 6,407.

Part: CKT BREAKER — FAILED (COCKPIT)

THE RT AC BUS 50 AMP CIRCUIT BREAKER, AFT CENTER AND LEFT FUEL BOOST PUMP CIRCUIT BREAKERS POPPED WHILE EN ROUTE. CREW ATTEMPTED TO RESET CIRCUIT BREAKERS WITHOUT SUCCESS. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE RT AC BUS 50 AMP CIRCUIT BREAKER B1-276 AT FAULT. THE CIRCUIT BREAKER WAS REMOVED AND REPLACED. THE OTHER POPPED CIRCUIT BREAKERS WERE RESET. BOTH ENGINES WERE RUN WITH FULL ELECTRICAL LOAD AND ALL OPERATION CHECKED GOOD WITH NO CIRCUIT BREAKERS POPPING.

Part: STRUT — FLAT (NLG)

FLT NR 303 - EWR - THE N/G WOULD NOT RETRACT AFTER T/O FROM EWR. THE GEAR HANDLE WAS CYCLED SEVERAL TIMES, BUT WOULD NOT RAISE BEYOND HALFWAY POINT. THE AUTO SPOILER 'DO NOT' USE LIGHT WAS ON AND THE A/C WOULD NOT PRESSURIZE. THE A/C WAS RETURNED TO EWR WHERE IT LANDED W/O INCIDENT. MX SERVICED THE NLG STRUT TO PROPER X-DIMENSION. THE N/G WAS JACKED AND ALL FUNCTIONS CHECKED GOOD DURING N/G RETRACTION TEST. THE N/G FAILED TO RETRACT ON A SUBSEQUENT FLT, BUT CYCLING THE GEAR REMEDIED THE PROBLEM. THE N/G STRUT WAS SERVICED WITH NITROGEN AGAIN AND THE GEAR WAS LUBRICATED. A DIP WAS ISSUED FOR FULL SERVICE OF THE NOSE STRUT. FULL SERVICE OF THE NOSE STRUT ACCOMP PER GMM 09-31-01 AND DIP WAS CLOSED. (M)

Part: HANDLE — LACK OF LUBE (FLAP SYSTEM)

FLT NR 1490 - CLE - THE FLAP/SLAT HANDLE WOULD NOT LOCK INTO THE SLAT RETRACT POSITION. WHEN HOLDING FLAP/SLAT HANDLE TO SLAT RETRACT POSITION THE SLAT DISAGREE LIGHT CAME ON AND BOTH LEFT AND RIGHT HYDRAULIC GAUGES DROPPED. THE DIAL-A-FLAP WAS MOVED SEVERAL TIMES. A SNAP WAS HEARD, AND THEN SLATS WERE RAISED. THE AIRCRAFT WAS RETURNED TO CLE WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE DIAL-A-FLAP STOP MECHANISM AND FLAP/SLAT HANDLE DIRTY AND GUMMED UP. THE STOP MECHANISM AND HANDLE WERE CLEANED AND LUBRICATED. OPERATION WAS SMOOTH AND NO DEFECTS WERE NOTED. (M)

Part: CONTROL CABLE — BENT (RT MLG)

FLT NR 1170 - EWR - THE RIGHT MLG UNSAFE LIGHT AND GEAR DOOR OPEN LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION. 'ABNORMAL' PROCEDURES WERE COMPLIED WITH, BUT THE LIGHTS STAYED ON FOR REMAINDER OF FLIGHT. THE AIRCRAFT LANDED AT EWR WITH GEAR DOORS OPEN. MAINTENANCE RESET THE DOORS AND THE AIRCRAFT TAXIIED TO GATE. MAINTENANCE FOUND THE RIGHT MLG MECHANICAL CONTROL CABLE BENT AND BINDING. THE CONTROL CABLE WAS REMOVED AND REPLACED IAW MM 32-31-00. THE CABLE WAS ADJUSTED AND TESTED IAW MM 32-31-00, PAGE 501-509. THE GEAR WAS SWUNG SEVERAL TIMES WITH OPERATION AND INDICATIONS CHECKING GOOD. (M)

Part: SKIN — CRACKED (LT MLG DOOR)

HOU - INSPECTION FOUND SEVERAL CRACKS IN THE EXTERIOR SKIN OF LT INBOARD MLG DOOR. THE CRACKS WERE LOCATED UNDER GROUND SKID ATTACH POINTS. THE LONGEST CRACK WAS 2 INCHES. NEW SKIN WAS INSTALLED IAW SRM 51-30-2. (X)

Part: RIB — CRACKED (LT HORIZ STAB)

HOU - INSPECTION FOUND LT HORIZONTAL STABILIZER LEADING EDGE RIB CRACKED. THE CRACK WAS LOCATED IN AREA WHERE SIDE ROLLER BRACKET ATTACHES AND MEASURED 1 INCH LONG. THE AREA REPAIRED IAW SRM 55-01. (X)

Part: ANGLE — CORRODED (DOOR CUTOUT)

HOU - INSPECTION FOUND ANGLE FITTING AT LOWER AFT CORNER OF AFT BAGGAGE BIN DOOR JAMB CUT-OUT CORRODED. THE CORRODED ANGLE FITTING WAS REMOVED AND A NEW ONE WAS INSTALLED IAW SRM 51-30-1. (X)

Part: PANEL — BROKEN (LT SPOILER)

HOU - INSPECTION FOUND THE LT WING INBOARD FLIGHT SPOILER PANEL NEARLY BROKEN IN HALF. THE SPOILER PANEL WAS REMOVED AND REPLACED IAW MM 27-61-01. (X)

Part: CABLES — OUT OF RIG (TAILCONES)

HOU - TAILCONE FAILED DROP TEST FROM INTERIOR HANDLE. A FORCE OVER 35 POUNDS WAS REQUIRED. THE TAILCONE CABLE SYSTEM WAS RIGGED AND TESTED IAW MM 53-53-00. (X)

Part: PROX SENSOR — INOPERATIVE (RT MLG)

FLT NR 0327 - EWR - THE RIGHT MLG RED LIGHT REMAINED ILLUMINATED WHEN GEAR WAS EXTENDED FOR LANDING ON APPROACH TO EWR. THE GEAR EMERGENCY EXTENSION LEVER WAS PULLED, BUT THE LIGHT REMAINED RED. A TOWER FLYBY WAS PERFORMED AND THE GEAR WAS VISUALLY CONFIRMED DOWN AND LOCKED. ALL CAWS UNSAFE WARNINGS ASSOCIATED WITH GEAR UP WERE RECEIVED. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE RT GEAR DOWN AND LOCK PROXIMITY SENSOR PER MM 32-60-05. GEAR OPERATION AND INDICATION CHECKED GOOD. (M)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

FLT NR 0301 - EWR - ROW 15 AND 32 HAD OVERHEAD EMERGENCY LIGHT INOP. RELAMPED OVERHEAD LIGHTS, OPS CHECK GOOD. FLIGHT DEPARTED WITH NO FURTHER OCCURRANCE. (W)