N403DA

Part: OVEN — CONTAMINATED (GALLEY)

FORWARD GALLEY WORK LIGHT C/B POPPED. F/A REPORTED LIGHT PLASTIC SMELL. NO SMOKE NOTED. BREAKER WAS NOT RESET. ON CHECK, FOUND GALLEY WORK LIGHT C/B POPPED AND COLLARED BY PREVIOUS ENG ORDER. CHKD OPS OF OVENS, COFFEEMAKER. ALL ELEC OPERATIONS NORMAL. FOUND MASKING TAPE ON OVEN INSERT/CARRIER. REMOVED CARRIER AND OPD OVEN AGAIN, NO ODOR NOTED. AGAIN ALL ELECTRIC OPERATION WAS NORMAL.

Part: BRACKET — CRACKED (NR 2 LE FLAP ACT)

A .125 INCH CRACK IN NR 2 L/E FLAP ACTUATOR SUPPORT BOX INBD LWR BRACKET. INSTALLED DOUBLER PER M/M 57-20-21.

Part: FRAME — CRACKED (R-1 DOORWAY)

FOUND ON C2 LETTER CHECK, 1.5 INCH CRACK ON R-1 DOOR FWD FRAME AT THE LOWER STOP CASTING. REPAIRED PER ERA AND MM 52-12-0.

Part: FRAME — CRACKED (PAX DOORWAY)

FOUND ON C1 LETTER CK, AFT RT ENTRY DOOR FRAME CRACKED. REPAIRED PER SRM 53-10-9.

Part: SKIN — CRACKED (BS 360-480)

LFEC INSPECTION OF THE STRINGER 4L SKIN LAP SPLICE BETWEEN FS 360 AND 480 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN PANEL. HFEC INTERNAL INSPECTION CONFIREMD SEVERAL CRACKS. THE SKIN LAP SPLICE WAS CUT OUT ALONG THE ENTIRE LENGTH OF THE PANEL AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 366854-14AD.

Part: SKIN — CRACKED (BS 660-681)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 481 AND 681 REVEALED A CRACK BETWEEN FS 660 AND 681 IN THE LOWER FASTENER ROW OF THE LOWER SKIN. HFEC INTERNAL INSPECTION OF THE ENTIRE PANEL CONFIRMED THE SINGLE CRACK. THE CRACK WAS ROUTED OUT OF THE SKIN LAP SPLICE AND REPAIRED PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A 366852-14AD, REV A.

Part: SKIN — CRACKED (BS 400-420)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 AND 480 REVEALED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. HFEC INTERNAL INSPECTION OF THE ENTIRE SKIN PANEL CONFIRMED ONE CRACK BETWEEN FS 400 AND 420. THE CRACK AREA WAS ROUTED OUT OF THE SKIN PANEL LAP SPLICE AND REPAIRED PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A 366853-14AD, REV A.

Part: LIGHT — INOP (R1 DOOR)

ON LAYOVER CK, FOUND R-1 DOOR OVERHEAD EMERGENCY LIGHT INOP. REPLACED LIGHT ASSY PER M/M, CKS OK.

Part: ACTUATOR — FAILED (NR 4 L/E SLAT)

A-SYS HYD FAILURE ON APPROACH. FOUND THE NR 4 L/E SLAT ACT FAILED. REPLACED SAME.

Part: BULKHEAD WEB — CRACKED (BS 1183)

TWO CRACKS OF .75 INCH LENGTH OR LESS WERE FOUND IN THE FS 1183 BULKHEAD WEB AT RBL 18 BETWEEN WL 166 AND 169 AND ONE .375 INCH CRACK WAS FOUND IN THE WEB AT LBL 25, WL 169. THE CRACKS WERE REPAIRED WITH A DOUBLER PER ER/A 365537-14 AND SET UP FOR REPETITIVE INSPECTIONS UNTIL ACCOMPLISHMENT OF PERMANENT S/B MODIFICATIONS PRIOR TO 60,000 TOTAL AIRCRAFT CYCLES.

Part: ANGLE — CRACKED (RT TE MIDFLAP)

DURING SHOP INSPECTION, THE AFT LOWER CHORD ANGLE WAS FOUND CRACKED IN 21 PLACES AT I/B CUTOUT FOR I/B AFT FLAP DRIVE. THE ANGLE WAS REPAIRED BY STOP DRILLING THE CRACKS AND INSTALLING A DOUBLER PER 727 MM 57-52-0, PG 807.

Part: ACTUACTOR — LEAKING (NR 3 LE FLAP)

IN CRUISE FLIGHT LEVEL 310 A SYSTEM QTY RAPIDLY DECREASED TO ZERO FOLLOWED BY A SYSTEM PRESSURE DECREASING TO ZERO. WHILE RUNNING POM OUTBOARD FLAPS FAILED TO ALT EXTEND. REPLACED NR 3 LED FLAP ACUTATOR. REPLACED NR 1 AND NR 2 HYD CASE DRAIN FILTERS. LEAK CHECK OK. RAN ENGINE OPERATION OF PUMPS AND FLAPS NORMAL. CLEANED CANNON PLUG ON OUTBOARD ALT FLAP BYPASS VALVE. OPERATION OF ALT FLAPS OPERATION NORMAL.

Part: RIB — CRACKED (NR 6 LE SLAT)

NR 6 SLAT RIB CRACKED. REPAIRED PER M/M 57-54-0.

Part: FITTING — MISLOCATED (WS 656)

WHILE PERFORMING A REPAIR TO WING STR 9 PER MM 57-13-0, FIG 802 AT WS656.5 AN EXISTING HOLE ON THE TOP FLANGE OF THE RIB CHORD ASSY FALLS OUT IN THE RADIUS OF THE STRINGER TO RIB ATTACHMENT ANGLE. REWORKED PER ERA 331251-14AD.

Part: FRAME — CRACKED (BS 303.9)

THE 65C20303-13 REPLACEMENT WEB PREVIOUSLY INSTALLED AS PART OF THE 65C20303-25 FRAME REPAIR KIT WAS FOUND CRACKED. THE -25 KIT WAS INSTALLED BY ERA 111762-14, CIRCA 6/86. THE CRACK IS LOCATED AT APPROX WL216. REPAIRED PER ERA 331194-14AD.

Part: SKIN — DAMAGED (BS 1030)

FUSELAGE SKIN DAMAGE AT BS 1030 AND S3L OCCURRED. REPAIRED PER ERA 331249-14.

Part: STRINGER — CORRODED (BS 990)

STRINGER 30 WAS CORRODED NEAR FS 990. THE STRINGER WILL BE CUT AT FS 990 AND A REPLACEMENT SECTION SPLICED IN. REPAIR PER ERA331185-14.

Part: SKIN — CRACKED (LT TE MIDFLAP)

DURING SHOP INSPECTION, THE AFT LOWER SPAR ANGLE WAS FOUND CRACKED. THE ANGLE WAS REPAIRED PER 727 MM 57-52-0 BY INSTALLING A REPAIR ANGLE.

Part: ANGLE — DAMAGED (BS 1343)

TEMPORARY REPAIR STA 1343 BL 0 AFT AIRSTAIR OPENING AFT EDGE LWR SIDE. REMOVED REPAIR, CHORD ANGLE, NR 2 ENG FIREWALL PNL. BEGAN DRILLED NEW CHORD AND SKIN. COMPLETED DRILLING CHORD. OK TO INST CHORD. BEGAN INSTALLING CHORD. FINISHED INSTALLING CHORD. COMPLIED WITH ERA 363434-14 REV A.

Part: RIB — CRACKED (RT WING)

ITEM: AT HMV2 FOUND R/W STA 656-5 UPPER STRINGER TO RIB ATTACH IS CRACKED LOC 2ND STRINGER FWD OF REAR SPAR. PLUGGED HOLE PER ERA 33125-14AD STOP DRILLED/REPAIR PART PER MM 57-13-0 FABD PART PER ERA.

Part: STRINGER — CRACKED (WS 629)

RT WING HFEC INSP SHOWS CRACK INDICATION AT NO 13 STRINGER-TO-RIB HOLE AT WS 629.0. DRILLED ACCESS HOLE PER M/M 57-13-0. DRILLED REPAIR PARTS PER M/M 57-13-0. OK TO INSTALL. INSTALLED REPAIR PER M/M 57-13-0.

Part: STRINGER — CRACKED (WS 546.5)

ITEM: LH WING HFEC INSP SHOWS CRACK INDICATION AT UPPER STRINGER-TO-RIB NO. 8 AT W.S. 546.5. CORRECTION: COMPLETED STEPS #1 THRU 4 PER MM 57-13-0 FIG 802. FINISHED DRILLING REPAIR ANGLES PER MM 57-13-0 FIG 802. OK TO INSTALL. BEGAN INSTALLING REPAIR PER MM 57-13-0. FINISHED INSTALLING REPAIR PER MM 57-13-0 FIG 802.

Part: SKIN — WORN (NR 4 TE MIDFLAP)

DURING SHOP VISIT INSPECTION, THE MIDFLAP LEADING EDGE WAS FOUND WORN BEYOND SRM LIMITS AT THE IB END OF FLAP. THE LEADING EDGE WAS REPAIRED PER 727 MM 57-52-0 BY REMOVING THE DAMAGE AND INSTALLING A DOUBLER.

Part: STRINGER — CRACKED (WS 656.6)

RIGHT WING STA 656.6 UPPER STRINGER TO RIB ATTACH IS CRACKED LOC AT FWD VENT BOX AFT LUG. PROVIDED CUTOUT IN VENT STRINGER FOR ACCESS AS PER DETAIL I M/M 57-13-0 PG 806. FORWARD ANGLE IN PLACE, NEED TO DRILL UP TO VENT BOX STRINGER. DRILLED UP FWD AND REPAIR PIECES PER MM 57-13-0. INSTALLED REPAIR PER M/M 57-13-0.

Part: STRINGER — CRACKED (WS 601.5)

LEFT WING STA 601.5 UPPER STRINGER TO RIB ATTACH IS CRACKED. FIRST STRINGER FWD OF REAR SPAR. REPAIRED PER MM 57-13-0.

Part: WEB — CRACKED (NR 6 LE FLAP)

NR 6 L/E SLAT INTERNAL WEB CRACKED ON O/B SIDE OF SLAT TRACK MT FITTING. REPAIRED PER MM 57-40-00.

Part: WEB — CRACKED (NR 1 SLAT)

WEB CRACKED NR 1 SLAT ACTUATOR ATTACH HOUSING WEBS BOTH CRACKED I/B AND O/B SIDE. FABRICATED AND DRILLED I/B REPAIR PER M/M 57-54-0 FIG 804. FABRICATED AND DRILLED UP O/B REPAIR AS PER M/M 57-40-0 FIG 804. OK TO INSTALL. INSTALLED REPAIRS PER M/M 57-54-0 FIG 804.

Part: SKIN — CRACKED (S-DUCT)

S-DUCT INTERIOR SKIN CRACKED AND BENT UPWARD FROM 10 O'CLOCK TO 1 O'CLOCK POSITION. REMOVED DAMAGED SECTION OF SKIN. FAB REPAIR DOUBLER AND FILLER PER ERA 331180-14. INSTALLED DOUBLER PER ERA 331180. INSTALLED TAPERED SHIM AND CLOSED OUTER SKIN PER ERA 331180-14.

Part: FRAME — CRACKED (BS 930)

STA 930 FRAME AT STR 14 FRAME CRACK AND VERTICAL SKIN STRAP CRACK AT SAME LOCATION. REMOVED FASTENERS AND CUT OUT REPAIR AREA PER SRM 53-10-4 PG 7. ALSO, PERFORMED DYE PENETRANT CHECK PER PS 900-6-3 NR 1. DYE CHECK OK. BEGAN DRILLING REPAIR ANGLES, FINISHED FABRICATING REPAIR ANGLES PER SRM 53-10-4 FIG 25. OK TO INSTALL. INSTALLED REPAIR PER SRM 53-10-4.

Part: WEB — CRACKED (VERT STAB)

WEB CRACKED VERTICAL STAB INTERIOR, WEB CRACKED LT SIDE OF VERTICAL, APPROX STA 1303 ABOVE S-DUCT. REPAIRED PER SRM 53-10-4.

Part: WEB — CRACKED (VERT STAB)

WEB CRACKED VERTICAL STAB INTERIOR, WEB CRACKED RT SIDE OF VERTICAL APPROX STA 1303. REPAIRED PER SRM 53-10-4.

Part: FRAME — DENTED (BS 1050)

FRAME DENTED FS 1050 BETWEEN STR 25L AND 26L. REMOVED DAMAGE AND DYE-CHECKED PER SRM 53-10-4. NO CRACKS FOUND AROUND CUTOUT. DRILLED UP DOUBLER AS PER SRM 53-10-4 FIG 27. OK TO INSTALL, BEGAN INSTALLING REPAIR. INSTALLED PER SRM 53-10-4.

Part: STRINGER — CRACKED (BS 542)

STR 18L, INDICATIONS FOUND 3 EA ON TOP ROW, 2ND HOLE FROM FRONT. ON BOTTOM ROW 1ST AND 3RD HOLE FROM FRONT. REFERENCE SUPPLEMENTAL CARD - ATTACHMENT A OPN 250. CLEANED HOLES. REAMED HOLE IN STRINGER 2ND HOLE FROM FRONT ON BOTTOM TO 542. BEGAN DRILLING REPAIR ANGLES PER M/M 53-12-0 SECT IV. COMPLETED FABRICATION OF REPAIR PER M/M 53-12-0 S IV. INSTALLED REPAIR PER M/M 53-12-0 S IV.

Part: BRACKET — CRACKED (NR 3 LE FLAP)

BRACKET CRACKED, ACT ATTACH BRACKET NR 3 KRUEGER FLAP OUTBD SIDE. BEGAN MANUFACTURING ANGLE REPAIR DOUBLER AS PER M/M 57-20-21 FIGURE 807. FINISH MFG ANGLE REPAIR DOUBLER PER MM 57-20-21 FIG 807. OK TO INSTALL DOUBLER. INSTALLED DOUBLER PER M/M 57-20-21 FIG 807.

Part: SUPPORT — CRACKED (NR 6 LE FLAP ACT)

SUPPORTS CRACKED NR 6 L/E FLAP ACTUATOR SUPPORTS ARE CRACKED. VERIFIED CRACKS TO BE PRESENT PER PS 900-6-3. REMOVED CRACKED SUPPORTS FROM A/C. FABRICATED REPAIR PARTS PER M/M 57-20-32 FIG 807. OK TO TREAT AND PAINT TREATED AND PAINTED PER PS 900-3-6 ASSEMBLED REPAIR PARTS PER M/M 57-20-21 FIG 807.

Part: FRAME — DENTED (BS 1030)

FRAME DENTED FS 1030 AT STR 26L. REPAIRED PER SRM 53-10-4 FIG 27.

Part: LINER — CRACKED (NR 2 ENGINE)

NR 2 ENG INLET ASSY (DOGHOUSE) ACCOUSTICAL LINER 12 O'CLOCK POS AFT CRACKED AND SEPARATING. REMOVED DAMAGED AREA, FABRICATED DOUBLER AND FILLER AS PER SRM 54-10-3 FIG 13. BEGAN INSTALLATION OF REPAIR PER SRM 54-10-3 FIG 13. COMPLETE REPAIR PER SRM 54-10-3 FIG AND PER PS 900-5-1 NR 4.

Part: WEB — CRACKED (BS 1227)

FOUND DURING A-2 LETTER CHECK, .75 INCH CRACK LT LWR TORQUE BOX WEB STA 1227 UPPER EDGE OF VERT WEB. REPAIRED PER M/M 53-11-0.

Part: SKIN — CRACKED (RT ELEVATOR)

FOUND DURING A-2 LETTER CHECK, 1.75 INCH CRACK IN RT ELEVATOR UPPER SKIN AT DOUBLER BETWEEN O/B 2 ELEVATOR HINGES. REPAIRED PER ERA 363435-14.

Part: FRAME — WORN (BS 1352)

FOUND DURING A-2 LETTER CHECK, ANGLE WORN THROUGH 11 INCHES, 6 O'CLOCK POSITION FS 1352 FRAME. REPAIRED PER ERA 363434.

Part: ACTUATOR — FAILED (NR 3 LE SLAT)

SYS-A HYDRAULIC QTY DECREASED TO ZERO IN FLT. FOUND NR 3L SLAT ACTUATOR FAILED IN RETRACT POSITION. SEALS BLOWN AT ACTUATOR ROD.

Part: TACH GEN HOUSING — LEAKING (NR 3 ENGINE)

OIL TEMP NR 3 STEADILY INCREASED REACHING A MAX OF RED RADIAL. NR 3 OIL QTY STEADILY DECREASED TO APPROX 2 GALLONS. NR 3 OIL PRESSURE DROPPED TO 20 PSI SHUT DOWN ENGINE IAW CHECK LIST. FOUND OIL PUDDLED IN INTAKE. REPLACED N1 TACH GEN HOUSING AND O-RING. RAN ENGINE PER PFHB LK CK GOOD ALSO, LEAK CHECKED GEARBOX, NO LEAKS FOUND. OIL PRESSURE AND TEMP GOOD THROUGH ALL PHASES OF ENGINE RUN.

Part: BATTERY — DISCHARGED (CABIN)

AFT DOOR SLIDE LIGHTS INOP. REPLACED BATT PACK, ALL EMERG LIGHTS NOW OP NORMAL.

Part: ACCESSORY UNIT — FAILED (E/E COMPT)

BOTH PACKS OVERHEATED AND SMOKED CABIN. PACK FAN CONTROL C/B POPPED AND WOULD NOT RESET. REPLACED LANDING GEAR ACCY UNIT.

Part: SPAR — CRACKED (NR 2 TE MID FLAP)

NR 2 MID FLAP AFT LOWER SPAR RAIL WAS FOUND CRACKED DURING INSPECTION. REPAIRED PER MM 57-52-0, PAGE 807.

Part: SPAR — CRACKED (NR 2 TE MID FLAP)

DURING INSPECTION, FOUND NR 2 MID FLAP AFT SPAR RAIL CRACKED. THE RAIL WAS REPAIRED PER MM 57-52-0, PG 807.

Part: SKIN — CRACKED (BS 1099)

TWO CRACKS IN LT SIDE OF DOG HOUSE NR 2 ENG S-DUCT, 1 FT ABOVE FUSELAGE SKIN STA 1099. DYE CHECKED FOR CRACKS PER PS 900-6-3, 2 CRACKS FOUND. REPAIRED ONE CRACK PER MM 54-30-0 PG 802. REMOVED DAMAGED SECTION OF FWD LOWER AREA AND DRILLED REPAIR DOUBLER PER MM 53-30-0 FIG 802. INSTALLED REPAIR PER MM 54-30-0 PG 802.

Part: LIGHT — INOPERATIVE (CABIN)

ROW 35 EMERGENCY FLOOR PATH LGHT INOP. REPLACED LIGHT, OPS CHECK GOOD.

Part: BATTERY PACK — LOOSE (CABIN)

RIGHT OVERWING ESCAPE PATH AFT EMERGENCY LIGHT INOPERATIVE. RESEATED BATTERY PACK IN POWER SUPPLY M956.

Part: BATTERY PACK — DISCHARGED (CABIN)

LEFT OVERWING ESCAPE PATH AFT EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK IN POWER SUPPLY M654.

Part: BRACKET — CRACKED (LT WING)

FOUND DURING F-1 LETTER CHECK, CRACK EXTENDING FROM NR 2 SLAT ACTUATOR MOUNT BRACKET UPPER I/B BOLT HOLE. REPAIRED PER M/M 57-42-0.

Part: BRACKET — CRACKED (LT WING)

FOUND DURING F-1 LETTER CHECK, 1 INCH CRACK AT NR 2 L/E FLAP ACTUATOR MOUNT BRACKET. REPAIRED PER MM 57-54-21.

Part: FITTING — CORROSION (LEFT WING)

AT GEAR CHANGE THE NR 2 FLAP INBD TRACK SUPPORT FITTING WAS FOUND CORRODED ON THE OUTER FACE. THIS FITTING WAS REPAIRED PER M/M 57-42-0 FIG 805, DAMAGE WAS WITHIN LIMITS FOR THIS REPAIR.

Part: FITTING — CORROSION (LT WING)

AT GEAR CHANGE CORROSION WAS FOUND ON THE LEFT MAIN GEAR FWD TRUNNION ATTACH FITTING O/B LOWER HOLE, O/B UPPER HOLE AND INBD LOWER HOLE. ALL CORROSION WAS REMOVED AND FOUND IN LIMITS. THE AREA WAS REPAIRED PER M/M 57-43-0.

Part: BATTERY — DISCHARGED (CABIN)

RIGHT OVERWING CENTER EMERGENCY SLIDE LIGHT INOP. REPLACED BATTERY PACK AND CHECKS OK.

Part: BATTERY — DISCHARGED (CABIN)

RIGHT OVERWING EMERGENCY LIGHT EXIT SIGNS INOP. REPLACED BATTERY PACK AND CHECKS OK.

Part: WEB — FATIGUE (REAR SPAR)

MTC REPORTS, DAMAGE TO THE REAR SPAR WEB OF THE CENTER SECTION FUEL TANK. THE DAMAGE IS LOCATED APPROXIMATELY BETWEEN LBL 17.2 AND LBL 25.5. DAMAGE REMOVAL RESULTED IN A 3 I/B - O/B BY 1 UP/DOWN CUTOUT. THE WEB IS MANUFACTURED FROM 0.375 2024-T351 MACHINED LOCALLY TO A MINIMUM THICKNESS OF 0.040. REPAIRED PER DL ERA 302906-14.

Part: GIRT BAR HOOK — BROKEN (FWD ENTRY DOOR)

ON DEPARTURE, FWD ENTRY DOOR SLIDE GIRT BAR HOOK BROKEN, REPLACED HOOK, OPERATION NORMAL.

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

RIGHT CENTER OVERWING EXTERIOR EMERGENCY LIGHTS INOP. REPLACED BATTERY PACK, OPERATION NORMAL.

Part: ANGLE — CRACKED (BS 1183)

FOUND DURING E-2 LETTER CHECK, .25 INCH VISIBLE CRACK LT SIDE 1183 BL 8 ANGLE OUTBD SIDE. REPAIRED PER M/M 53-11-0 PAR 9.

Part: UPLOCK FRAME — CRACKED (RT MLG WW)

DURING E-1 LETTER CHECK, FOUND RT MLG UPLOCK FRAME CRACKED AT FS 913.5, ABOVE RADIUS BLOCK. REPAIRED PER MM 53-11-0 PG 834-837.