N401DA

Part: VALVE — FAILED (RT PACK)

AFTER NR 3 ENG START AND RT PACK SELECTED ON, LOUD BANG WAS HEARD IN COCKPIT/CABIN. RT DUCT PRESS NEEDLE WENT TO ZERO AND AFT FLT ATTENDANTS REPORTED FUEL SMELL. INSPECTED DUCTS AT NR 3 ENG/PYLON/AFT AIRSTAIR FOR DAMAGE/LEAKAGE, CK GOOD. CHECKED DUCTS AT RT PACK BAY CK OK. RAN NR 3 ENG AND RAN RT PACK OPS CK NML. REPLACED RT AFT PACK VLV PRECAUTIONARY. SYSTEM CK NORMAL.

Part: ACTUATOR — FAILED (NR 3 LE FLAP)

NUMBER THREE LEADING EDGE FLAP INDICATION AND UNCOMMANDED ROLL. REPLACED NUMBER THREE LEADING EDGE FLAP ACTUATOR.

Part: LIGHT — DAMAGED (ROW 20 DEF)

ONE EMERGENCY LIGHT AT 20 DEF INOP. REPLACED SEAT ASSY AT ROW 20 DEF. OPS CHECK GOOD. MCO AND PLACARD REMOVED.

Part: SKIN — CRACKED (NR 7 LE SLAT)

NR 7 SLAT LWR COVE SKIN ATTACH ANGLE CRACKED AT I/B STOP PAD. REPAIRED PER M/M 57-54-0.

Part: BRACKET — CRACKED (NR 8 LE SLAT ACT)

NR 8 SLAT ACT I/B MOUNT BRACKET CRACKED AT WEB. REPAIRED PER M/M 57-20-21.

Part: STIFFENER — CRACKED (WING LE SPAR)

TPA - LTR CHK C-1 02/26/99, WING LE SPAR STIFFENER CRACKED AT I/B SIDE NR 2 SLAT I/B TRACK BOX. REPLACED STIFFENER PER MM 57-20-21.

Part: SKIN — CRACKED (BS 444)

LFEC INSPECTION OF THE STRINGER 4L SKIN LAP SPLICE BETWEEN FS 360 AND 460 INDICATED A SINGLE CRACK. INTERNAL HFEC INSPECTION CONFIRMED ONE CRACK ONLY AT FS 444. THE CRACK WAS ROUTED OUT OF THE SKIN LAP AND REPAIRED PER THE B727 SRM 53-30-3, FIG 5. TEN FASTENERS FWD AND AFT OF THE CRACK WERE ADDITIONALLY REMOVED TO ALLOW FOR HFEC SURFACE SCAN WITH NO RIVET TAIL INTERFERENCE. NO OTHER CRACKS WERE NOTED.

Part: SKIN — CRACKED (BS 681-740)

LFEC INSPECTION REVEALED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN AT THE STRINGER 4R LAP SPLICE BETWEEN FS 681 AND 740. INTERNAL HFEC INSPECTION VERIFIED 27 CRACKS ALONG THE PANEL LENGTH. THE SKIN LAP WAS CUT OUT ALONG THE ENTIRE PANEL LENGTH AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 366711-14, REV A.

Part: SKIN — CRACKED (BS 360-481)

LFEC INSPECTION REVEALED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN PANEL OF THE STRINGER 4R LAP SPLICE BETWEEN FS 360 AND 481. INTERNAL HFEC INSPECTION CONFIRMED 7 CRACKS ALONG THE PANEL LENGTH. THE LAP SPLICE WAS CUT OUT ALONG THE ENTIRE PANEL LENGTH AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 366710-14, REV A.

Part: SKIN — CRACKED (BS 480-681)

LFEC INSPECTION REVEALED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN OF THE STRINGER 26L LAP SPLICE BETWEEN FS 480 AND 681. INTERNAL HFEC INSPECTION CONFIRMED A TOTAL OF 6 CRACKS ALONG THE PANEL LENGTH. THE SKIN LAP SPLICE WAS CUT OUT ALONG THE ENTIRE LOWER PANEL LENGTH AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 366709-14, REV A.

Part: SKIN — CRACKED (BS 481-680)

LFEC INSPECTION REVEALED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN OF THE STRINGER 4R LAP SPLICE BETWEEN FS 481 AND 680. INTERNAL HFEC INSPECTION CONFIRMED 31 CRACKS ALONG THE PANEL LENGTH. THE LAP SPLICE WAS CUTOUT ALONG THE PANEL LENGTH AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 366712-14, REV A.

Part: POWER SUPPLY — INOP (CABIN)

FUSE BLOWN, EMERGENCY LIGHTS INOP. REPLACED POWER SUPPLY.

Part: BATTERY — DISCHARGED (ENTRY DOOR)

RT FWD ENTRY DOOR OVERHEAD EMEGENCY LIGHT WILL NOT TEST. REPLACED BATTERIES AND RACK NOW CKS NORMAL.

Part: TRACK — CORROSION (TE FLAP)

INBD FLAP INBD TRACK TYP CORROSION AT MLG BEAM ATTACH HOLES AND FWD LUG: AD 90-07-05: TYPICAL CORROSION WAS FOUND TO THE MLG BEAM ATTACH HOLES (WITHIN THE AD AREA) AND AT THE FWD ATTACH LUG. OVERSIZED CORRODED HOLES AND MACHINED LUG FACES.

Part: TRACK — CORRODED (TE FLAP)

BUSH FWD ATTACH LUG AND REPAIR MLG BEAM ATTACH HOLES PER SB 727-57-0178, EXCEPT INCREASE HOLE DIA TO .847.

Part: TRACK — CORRODED (TE FLAP)

TYPICAL CORROSION FOUND IN MLG BEAM ATTACH HOLES. REPAIRED SIMILAR TO SB 727-57-0178 EXCEPT TO OS HOLES, .838 MAX DIAMETER TO REMOVE ALL CORROSION.

Part: SWITCH — FAILED (NR 1 LE SLAT)

AMBER LEADING EDGE FLAP LIGHT WOULD NOT EXTINGUISH WHEN FLAPS WERE MOVED FROM 5 TO 2 DEGREES. REPLACED RETRACT SWITCH ON NR 1 SLAT ACTUATOR.

Part: SKIN — CRACKED (BS 211.8)

FOUND AT B-2 LETTER CK, .5 INCH CRACK, FUSELAGE SKIN AT L-4 WINDOW SCREW LOWER INBD CORNER. REPAIRED PER SRM 53-30-3.

Part: BATTERY PACK — DISCHARGED (CABIN)

LT OVERWING EMERGENCY EXIT LIGHT INOP. RELAMPED LIGHT ASSY AND CHANGED BATTERY PACK PER M/M. OP CHECK GOOD BATTERY PACK REMOVED 7997. BATTERY PACK INSTALLED, C6495 P/N 334102486.

Part: RACK — INOPERATIVE (CABIN)

RT SIDE EMER LIGHT OVERWING EXIT LIGHTS INOP. REPLACED LIGHT RACK.

Part: RACK — INOPERATIVE (CABIN)

OVERWING EXIT EMERG LIGHTS FAILED TO ILLUMINATE. REPLACED RACK.

Part: BATTERY PACK — DISCHARGED (CABIN)

AFT GALLEY OVERHEAD EXIT SIGN INOP. REPLACED POWER PACK.

Part: BATTERY PACK — DISCHARGED (CABIN)

AFT EXIT AISLE OVERHEAD EMERGENCY LIGHT INOP. REPLACED BATTERY PACK, SYSTEM OPERATIONAL CHECK NORMAL.

Part: SKIN — CRACKED (S-DUCT)

SKIN, CRACKED THE FWD SECTION OF S DUCT FWD SKIN LIP AT THE 12:00 O'CLOCK POSITION. REMOVED DAMAGED SECTION OF SKIN PER SRM. FABRICATED REPAIR PARTS PER SRM 54-10-3 FIG 13. TREATED AND PAINTED PER SRM 54-10-3. OK TO INSTALL REPAIR PER SRM 54-10-3. INSTALLED REPAIR PER SRM 54-10-3 FIG 13. OK TO INSTALL CLOSEOUT PANEL. INSTALLED CLOSEOUT PANEL.

Part: RIB — CRACKED (LT TE MIDFLAP)

THE I/B AFT CLOSEOUT RIB WAS FOUND CRACKED DURING SHOP VISIT. THE RIB WAS REPAIRED BY INSTALLING A DOUBLER PER 727 M/M 57-52-0.

Part: BEAM — CRACKED (RT WING)

RT WING SPOILER SUPPORT BEAM CRACKED IN O/B BOLT HOLE FOR NR 5 FLAP TRACK. REMOVED DAMAGED SECTION OF SPOILER BEAM PER M/M 57-55-0 FIG 805. REMOVED SUPPORT BETWEEN SPOILERS 7 AND 8. FABRICATED EXTRUDED CHORD IAW M/M 57-55-0 PG 810. DRILLED CHORD, DOUBLER TRIPLER AND FILLER. COMPLETED REPAIR INST PER M/M 57-55-0 FIG 805.

Part: STRINGER — CRACKED (WS 686.5)

STRINGER CRACKED WS 686.5 STRINGER NR 10 IS CRACKED AT FASTENER HOLE. REPAIRED PER MM 57-13-0.

Part: FITTING — CORROSION (RT WING)

RT FT WING ATTACH FITTING HAS CORROSION AT SEVERAL LOCATIONS INSIDE BORE. REMOVED CORROSION IAW SRM 53-40-1 PG 18. TREATED AND PAINTED PER PS 900-3-6.

Part: SKIN — PUNCTURED (NR 2 TE MIDFLAP)

THE COVE SKIN WAS FOUND WITH A HOLE 26 FROM IB END DURING SHOP VISIT. THE DAMAGE WAS REMOVED AND A DOUBLER INSTALLED PER 727 MM 57-52-00.

Part: RIB — CRACKED (NR 6 LE SLAT)

NR 6 SLAT RIB CRACKED ON INBD END. MADE DOUBLER IAW MM. DRILLED UP AND TREATED AND PAINTED. INSTALLED DOUBLER PER M/M 57-54-0 FIG 814. INSTALLED SEAL.

Part: RIB — CRACKED (NR 7 LE SLAT)

NR 7 SLAT RIB CRACKED JUST OUTBD OF ACTUATOR ROD END AREA. FABRICATED REPAIR PER MM 57-54-0 FIG 814. INSTALLED REPAIR PER MM 57-54-0 FIG 814.

Part: ANGLE — CRACKED (NR 2TE MIDFLAP)

THE AFT LOWER CHORD ANGLE WAS FOUND CRACKED DURING SHOP VISIT. THE CHORD WAS REPAIRED PER 727 MM 57-52-00 BY REMOVING DAMAGE AND REPLACING AND INSTALLING A DOUBLER.

Part: FITTING — CORROSION (LT WING SPAR)

CORROSION ON LEFT AFT SPAR WING TO BODY FITTING (AFT END). REMOVED CORROSION IAW SRM 53-40-1 PG 18. TREATED AND PAINTED PER PS 900-3-6.

Part: STRINGER — CRACKED (WS 629)

LT WING STR TO RIB HFEC INSPECTION SHOWS STRINGER TO RIB ATTCH FLANGE MARKED 'C' AT WS 629.0 HAS CRACK INDICATIONS -MARKED- THAT EXTENDS FROM HOLE TO EDGE OF FLANGE. CUTOUT ACCESS HOLE ON VENT BOX PER MM 57-13-10. DRILLED REPAIR PARTS PER MM 57-13-10 FIG 804. INSTALLED REPAIR PER M/M 57-13-10 FIG I4. FINISHED INSTALLING HI-LOK ON REPAIR PER M/M 57-13-0 FIG 804. REPAIRED, INSTALLED COVER.

Part: RIB — CRACKED (NR 6 LE SLAT)

NR 6 SLAT RIB CRACKED LOWER SURFACE. REMOVED RIVETS FORM RIB, BEGAN FABRICATION OF REPAIR DOUBLERS PER M/M 57-40-0 FIG 814. DRILLED AFT DOUBLER, STOP DRILLED PER SRM 57-54-0. ROUTED OUT DAMAGE PER SRM. INSTALLED REPAIR PER SRM.

Part: STOP — WORN (NR 4 SLAT)

NR 4 SLAT INBD STOP WORN, 2ND WEB FROM INBD END CRACKED OUT UNDER N/P. FABRICATED REPAIR PER MM 57-54-0 FIG 814. OK TO TREAT AND PAINT. TREATED AND PAINTED PER PS 900-2 NR 5. INSTALLED REPAIR PER MM 57-54-0 FIG 814. WEAR WITHIN LIMITS PER MM 27-87-0 FIG 504.

Part: ANGLE — CRACKED (NR 2 TE MIDFLAP)

THE LOWER AFT CHORD ANGLE WAS FOUND CRACKED 18 FROM IB END DURING A SHOP VISIT. THE CHORD WAS REPAIRED PER 727 MM 57-52-00 BY REMOVING DAMAGE AND INSTALLING A DOUBLER.

Part: FITTING — CORROSION (RT WING SPAR)

CORROSION ON RT FRONT SPAR WING TO BODY FWD FITTING. REMOVED CORROSION AT PER SRM 51-10-6. TREATED AND PAINTED PER PS 900-3-6.

Part: STRINGER — CORRODED (BS 720)

LIGHT BOX CORRODED STRINGER 152, BETWEEN STA 720B AND 720C. REMOVED LIGHT BOX FOR ACCESS, REMOVED CORROSION PER 51-10-6 NOT WITHIN ALLOWABLE LIMITS PER SRM 53-30-1 FIG 7. COMPLETED FABRICATING REPAIR DOUBLER PER SRM 53-30-3 FIG 22 T AND P PER PS 900-2 NR 5. INSTALLED DOUBLER PER SRM 53-30-3. INSTALLED LIGHT BOX.

Part: RIB — CRACKED (WS 629)

CRACK - STRINGER TO RIB WS 629, S-13 AFT HOLE, RT WING. REPAIRED PER MM 57-13-00.

Part: RIB — CRACKED (WS 629)

CRACK - STRINGER TO RIB WS 629, S-9 AFT HOLE, RT WING. REPAIRED PER MM 57-13-00.

Part: SKIN — CRACKED (PYLON)

SKIN CRACKED AT INSPECTION PANEL 9524. ROUTED OUT CRACK AND MANUFACTURED DOUBLER PER M/M 54-30-0. INSTALLED DOUBLER PER SRM 54-30-0, FIG 803.

Part: STRINGER — CRACKED (WS 656.5)

HFEC INSP SHOWED CRACK INDICATION AT WS 656.5 FWD VENT HOLE. CUT ACCESS HOLE IN VENT BOX PER M/M 57-13-00. REPAIRED CRACK PER MM 57-13-0 FIG 80.

Part: RIB — CRACKED (WS 629)

RT WING WS 629 S-AA CRACKED AT STR TO RIB CONNECTION REF OP8602 RC 882. REPAIRED PER MM 57-13-00.

Part: LIGHT BOX — CORRODED (BS 720)

LIGHT BOX CORRODED AROUND EDGES STA 720B AND 720C BETWEEN STRINGERS 16R TO 14R. REMOVED LIGHT BOX. REMOVED CORROSION PER SRM 51-10-6 NOT WITHIN ALLOWABLE LIMITS PER SRM 53-30-1 FIG 7. COMPLETED DRILLING DOUBLER PER SRM 53-30-3 FIG 22. INSTALLED DOUBLER PER SRM 53-30-3 FIG 22. LIGHT BOX PER SRM 53-30-3.

Part: SKIN — CRACKED (LT TE FLAP)

COVE SKIN CRACKED AT O/B SIDE OF I/B DRIVE ROD CUT OUT. REPAIRED PER M/M 57-52-0.

Part: MULTIPLIER — INOPERATIVE (RIGHT)

FL_330 LOSS PRESSURE,DESCEND TO 10,000 _REPLACED FLOW MULTIPLIER

Part: DRIVE MOTOR — FAILED (RT MLG)

AT FL 310, LOSS QUANTITY AND PRESSURE ON HYD SYS-A. FOUND FLAP HYD POWER UNIT LEAKING FLUID. REPLACED RT OTBD FLAP DRIVE MOTOR.

Part: LIGHT — INOPERATIVE (CABIN)

ROW 26 OVERHEAD EMER LIGHT INOP. REPLACED LIGHT, OPS NML.

Part: SKIN — CRACKED (S-DUCT)

A .5 INCH CRACK EMPENNAGE SKIN LT SIDE FWD OF SADDLE PLATE 9501. REPAIRED PER M/M 54-30-0 FIG 801, TIME LIMITED REPAIR.

Part: STIFFENER — CRACKED (RT WING)

O/B LEADING EDGE SPAR STIFFENER CRACKED AT NR 6 SLAT I/B TRACK. REPLACED STIFFENER PER M/M 57-20-21.

Part: START DUCT — FAILED (NR 1 ENGINE)

NUMBER ONE ENGINE FIRE INDICATION AT CRUISE, WHEN THROTTLE WAS MOVED TO IDLE, INDICATION EXTINGUISHED. ENGINE WAS SHUT DOWN PRECAUTIONARY. ENGINE WINDMILLED FOR APPROX 20 MINUTES N-2 RPM WAS APPROX 15 PERCENT, OIL PRESSURE WAS APPROX 20 PSI, ON APPROACH. FOUND START DUCT AND STARTER FLANGE FAILED. REPLACING STARTER GARLOCK SEAL PRECAUTIONARY. STARTER DUCT, (P/N 804101151) REF IPC 80-10-0 FIG 2 ITEM 135, ARRIVING FROM CONTENTIAL AIRLINES. STARTER (P/N 804001312) IN STOCK. NO DAMAGE NOTED TO GEARBOX/STARTER DRIVE PAD.

Part: STRINGER — CRACKED (BS 942)

THE RT STRINGER 18A CRACKED AT STA 942. REPAIRED PER MM 53-12-0, PAGE 819.

Part: FRAME — CRACKED (R2 DOOR)

AT MID-VISIT, THE R2 DOOR FORWARD SIDE FRAME WAS FOUND CRACKED OUT OF UPPER HINGE CUTOUT LOWER RADIUS; ALSO, CORROSION FOUND AROUND AREA. AREA WAS REPAIRED PER SRM 52-40-2, FIG 4.

Part: SWITCH — FAILED (COCKPIT)

ON INSPECTION, FOUND LT SIDE OF AIRCRAFT EMERGENCY EXIT SIGN ILLUMINATION LIGHTS INOP. REPLACED NO SMOKING SW ON PILOTS O/H PNL.

Part: WIRE — BROKEN (CABIN)

ON PREFLIGHT, EMERGENCY TRACK LIGHTING ON RT SIDE AT SEAT ROW 12 TO FIRST CLASS DIVIDER INOP. REPAIRED BROKEN WIRE AT SEAT ROW 12.

Part: WIRE — BROKEN (CABIN)

ON PREDEPARTURE, EMERGENCY TRACK LIGHTS IN FWD CABIN INOP. REPAIRED BROKEN WIRE AT ROW 14 AND OPERATION NORMAL.

Part: SKIN — DENTED (NR 8 LE SLAT)

DURING ROUTINE SHOP INSPECTION, AN AREA ON THE OUTER SKIN 11 INCHES FROM THE I/B END WAS FOUND TO BE DENTED AND OIL CANNED. THE DAMAGED AREA WAS CUT OUT AND REPAIRED PER SRM 57-50-3 FIG 1 FOR NR 8 L/E SLAT PANEL.

Part: ANGLE — CRACKED (NR 7 LE SLAT)

DURING F-1 LETTER CHECK, FOUND .375 INCH CRACK AND 1 INCH CRACK, NR 7 L/E SLAT COVE SKIN ATTACH ANGLE. REPAIRED PER M/M 57-54-0.

Part: SKIN — OVERSIZED HOLE (LT AILERON)

UPON INSPECTION, AN OVERSIZED HOLE WAS FOUND IN SKIN OF LEFT O/B AILERON. REPAIRED PER SRM 57-51-0 PG 801.

Part: RIB — CRACKED (NR 2 LE FLAP)

DURING SHOP INSPECTION, FOUND NR 2 L/E SLAT WITH RIB NR 20 CRACKED. REPAIRED PER MM 57-54-0 FIG 14.

Part: RIB — CRACKED (NR 2 LE SLAT)

DURING SHOP INSPECTION, FOUND RIB NR 9 AND NR 14 CRACKED. REPAIRED PER MM 57-54-0 FIG 814, NR 2 L/E SLAT.

Part: PANEL — DAMAGED (NR 2 SLAT)

DURING SHOP INSPECTION, FOUND LEADING EDGE SLAT DAMAGED ON OUTBOARD END. REPAI RED DAMAGE PER THE 727 SRM 57-50-3 FIG 1, FOR NR 2 L/E SLAT PANEL.

Part: RIB — CRACKED (NR 2 LE SLAT)

DURING A ROUTING SHOP INSPECTION, NR 8598 WAS WRITTEN FOR A CRACK IN THE 17TH RIB FROM I/B EDGE OF THE NR 2 SLAT. THE CRACK WAS REPAIRED PER M/M 57-54-0 FIG 819.

Part: RIB — CRACKED (NR 2 LE SLAT)

DURING A ROUTINE SHOP INSPECTION, NR 8596 WAS WRITTEN FOR A CRACK IN THE 3RD RIB FROM I/B EDGE OF THE NR 2 SLAT. THE CRACK WAS REPAIRED PER M/M 57-54-0 FIG 819.

Part: RIB — CRACKED (NR 2 LE SLAT)

DURING A ROUTINE SHOP INSPECTION, NR CARD 8598 WAS WRITTEN FOR A CRACK IN THE 15TH RIB FROM I/B EDGE OF THE NR 2 SLAT. THE CRACK WAS REPAIRED PER M/M 57-54-0 FIG 805.

Part: WINDOW — SMOKING (FLIGHT DECK)

CLIMBING THROUGH FL 320, HAD VISIBLE SMOKE AND FUMES COMING FROM CONDUIT BETWEEN R-2 AND R-3 COCKPIT WINDOWS ON F/O SIDE. SMOKE CLEARED WHEN WINDOW HEAT TURNED OFF. REPLACED R-2 WINDOW AND CONTROLLER.

Part: WEB — CRACKED (FS 1220)

CRACK, .25 INCH, IN WEB AT STA 1220 IN LT TORQUE BOX. TWO EA .25 INCH CRACKS IN RT TORQUE BOX WEB AT STA 1220, .1875 INCH CRACK AT LIGHTING HOLE AT STA 1220, RT TORQUE BOX. ALL CRACKS LOCATED IN 48 SECTION. FOUND AT E-2 LTR CHECK, REPAIRED PER MM 53-11-0.

Part: ANGLE — CRACKED (NR 3 SLAT)

NR 3 SLAT LWR CHORD ANGLE CRACKED .50 INCH BELOW TAI DUCT. FOUND DURING E-2 LTR CK TPA MM. REPAIRED PER MM 57-54-0 PG 807A.

Part: BRACKET — CRACKED (NR 2 LE FLAP)

NR 2 L/E FLAP I/B ACT ATTACH BRKT CRACKED UPPER AND LWR ENDS. FOUND DURING E-2 LTR CK. TPA MM. REPAIRED PER MM 57-20-21 PG 811.

Part: FAIRING — CRACKED (FS 720)

DURING INSPECTION, FOUND FUSELAGE TO WING BODY FAIRING RIGHT SIDE WITH A 7 INCH CRACK FS 720E PLUS 12 INCHES. REPAIRED PER SRM 53-30-3.