N408DA

Part: SKIN — CRACKED (BS 360 - 480)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 & 740 REVEALED CRACK INDICATIONS IN THE LOWER SKIN OF THE LOWER FASTENER ROW. INTERNAL MFEC INSPECTION OF THE SKIN PANEL BETWEEN FS 360 & 480 CONFIRMED A TOTAL OF 4 CRACKS IN ALONG THE SKIN LENGTH. THE ENTIRE LAP JOINT WAS CUT OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 368979-14AD.

Part: SKIN — CRACKED (BS 680 - 740)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 & 740 REVEALED CRACK INDICATIONS. INTERNAL MFEC INSPECTION OF THE 4R LAP SPLICE BETWEEN FS 680 & 740 CONFIRMED 7 CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN ALONG THE LENGTH OF THE PANEL. THE SKIN LAP WAS CUT OUT OVER THE PANEL LENGTH AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 368980-14AD.

Part: SKIN — CRACKED (BS 480 - 680)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 & 740 REVEALED CRACK INDICATIONS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL MFEC INSPECTION OF THE SKIN PANEL BETWEEN FS 480 & 680 CONFIRMED CRACKS IN CONSECUTIVE FRAME BAYS. THE ENTIRE SKIN LAP WAS CUT OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 368977-14AD.

Part: POWER SUPPLY — INOP (CABIN)

FIRST CLASS EMERGENCY LIGHTS INOP. REPLACED BATTERY PWR SUPPLY, NOW CKS GOOD.

Part: SKIN — CRACKED (BS 940)

A CRACK WAS FOUND IN THE FUSELAGE SKIN, SIMILAR TO S/B 727-53-0172. STRINGER 18A LOWER FLANGE WAS FOUND WITH A CRACK. REPAIR PER ERA 332141-14.

Part: STRINGER TAB — CRACKED (WS 171.5)

STRINGER 18 TAB ON THE RT WING VENT BOX WAS FOUND CRACKED. REPAIR PER ER/A 332222-14.

Part: CLIP — CRACKED (BS 400)

FS 400 FRAME CLIP BETWEEN STR 17 AND 18 WAS FOUND CRACKED. REPAIRED PER ER/A 332224-14 REV A.

Part: STIFFENER — DAMAGED (WS 300)

WING UPPER SURFACE J STIFFENER REPAIR (STR 17 RT AT WS 300). REPAIR PER ER/A 332215-14 REV A.

Part: CHORD — GOUGED (BS 990)

THE C-2 DOOR STA 990 INBOARD CHORD WAS FOUND WITH A GOUGE AT STRINGER 26R. THE GOUGE WAS LOCATED ON THE OUTER CORNER OF THE INTERSECTION OF THE 2 LEGS OF THE L-SHAPED CHORD. REPAIRED PER ER/A 332209-14 REV A.

Part: BALL NUT — RUSTED (NLG)

AT HMV, LANDING GEAR CHECK OUT THE NOSE GEAR EMERGENCY EXTENSION FAILED TO OPERATE DUE TO THE BALL NUT AND SCREW ASSY BEING RUSTED AND FROZEN UP. REF IPC 32-31-00-06 ITEM 185 (P/N 10-60744-1). THE ASSY WAS REPLACED AND THE CHECK OUT COMPLETED SATISFACTORY.

Part: RIB — CRACKED (WS 171.5)

UPPER CHORD ANGLE OF THE LT WING RIB AT WS 171.5 WAS FOUND CRACKED. REPAIRED PER ERA 332223-14.

Part: DUCT — BENT (PYLON)

DOGHOUSE AFT LIP, ON AIRINTAKE DUCT 360 DEGREES AREA, BENT AND DISTORTED. HEAVY ACCUMULATION OF SEALER. REMOVED DAMAGE DOUBLER, BEGAN DRILLING NEW DOUBLER. COMPLETED FABRICATION OF NEW DOUBLER PER SRM 54-10-3 FIG 13 D. OK TO INSTALL DOUBLER. INSTALLED REPAIR PER SRM 54-10-3 FIG 13.

Part: ANGLE — CRACKED (LT TE MIDFLAP)

DURING SHOP INSPECTION, THE AFT LOWER WAS FOUND CRACKED IN 2 PLACES, 32 AND 37 FROM IB END. THE ANGLE WAS REPAIRED PER 727MM 57-52-0, FIG 802 BY INSTALLING A DOUBLER.

Part: SPAR — CRACKED (LT TE FLAP)

CRACK AFT SPAR RAIL 19 FROM I/B END OF FLAP. REPAIRED ON SHOP ORDER 553647 PER MM 57-52-0 FIG 802.

Part: SKIN — CRACKED (LT TE FLAP)

.5 INCH LONG CRACK IN COVE SKIN -31 FROM I/B END OF FLAP, REPAIRED ON SHOP ORDER 553647 PER MM5 7-52-0 FIG 809.

Part: STRINGER — CRACKED (VERT STAB)

STRINGER CRACKED. VERTICAL STAB INTERIOR, STRINGER CRACKED AT FIN STA 157.2 STR 8L. CRACK RAN FROM CTR OF HOLE TO EDGE OF STRINGER. FABRICATED REPAIR ANGLE PER MM 55-30-0 FIG 803 OK TO INSTALL REPAIR. INSTALLED REPAIR PER M/M 55-30-0 FIG 803.

Part: COWL — WORN (NR 2 PYLON)

FOUND AT HMV, STA 1352 FWD COWLING RING WORN THROUGH AT 6 O'CLOCK POSITION. ROUTED OUT DAMAGE MANFCT BDLER PER MM 53-11-0 PG 801 AND INSTALLED PER SRM 53-11-0 PG 801.

Part: STRINGER — CRACKED (VERT STAB)

STRINGER CRACKED VERTICAL STAB INTERIOR, STRINGER CRACKED AT FIN STA 180.6 STA 9L. CRACK RUNS FROM HOLE TO EDGE OF PART. NO STOP DRILL REQUIRED. FABRICATED REPAIR PER M/M 55-30-0 FIG 803. IK INSTALL. BEGAN INSTALL OF REPAIR PER M/M 55-30-0 FIG 803. FINISHED INSTALL OF REPAIR PER M/M 55-30-0 FIG 803.

Part: BATTERIES — DISCHARGED (CABIN)

ON L/O, FOUND 2L DOOR EMERGENCY LIGHT INOP. REPLACED BATTERIES.

Part: STRINGER — CRACKED (VERT STAB)

FOUND AT A2 LETTER CHECK, VERTICAL STAB STRINGER 6L CRACKED AT BOLT HOLE FIN STA 157.2. REPAIRED PER M/M 55-30-0.

Part: FLAP — CRACKED (NR 4 LE FLAP)

A .75 INCH CRACK IN NR 4 L/E FLAP AT OUTBOARD LIP HINGE CUTOUT. REPAIRED PER ERA NR 362925-14 AND M/M 57-53-0.

Part: RIB — CRACKED (LT LE FLAP)

FOUND ON A1 LETTER CK, 2 IN VISIBLE CRACK NR 1 SLAT ACTUATOR INBD ATTACH RIB. REPAIRED PER MM 57-20-21.

Part: FITTING — CRACKED (NR 8 LE SLAT)

FOUND DURING A1 LETTER CHECK, 1 INCH CRACK NR 8 SLAT ACT INBD ATTACH FITTING OUTBD SIDE. REPAIRED PER M/M 57-20-21.

Part: FRAME — CRACKED (R1 DOOR)

FOUND ON A1 LETTER CK, .5 IN CRACK FWD FRAME AT LOWER STOP CASTING R-1 DOOR. REPAIRED PER MM 52-12-0 AND ERA.

Part: ACTUATOR — FAILED (NR 4 LE SLAT)

SYS-A HYD QTY WENT TO 0 AND BOTH LOW PRESS LIGHTS CAME ON WITH EXTENSION OF FLAPS ON TAXI OUT. FOUND NUMBER 4 SLAT ACTUATOR LEAKING. REPLACED ACTUATOR.

Part: SKIN — CRACKED (L1 DOOR CUTOUT)

FOUND A GOUGE IN THE LOWER FUSELAGE SKIN JUST AFT OF THE L-1 DOOR. REPAIRED PER DAL EO 4-60829-3 AND ER/A 30446-14, REV A.

Part: SUPPORT — CRACKED (NR 1 LE SLAT ACT)

FOUND CRACK ON THE NR 1 SLAT ACTUATOR SUPPORT STRUCTURE. REPLACED CRACKED WEB IAW DAL ER/A 304444-14AD.

Part: CHORD — CORRODED (NLG)

AT MID VISIT, THE NLG LT LWR CHORD WAS FOUND TO BE CORRODED. CORROSION WAS REMOVED AND REPAIR ACCOMPLISHED PER SRM 53-10-4.

Part: BULKHEAD SUPPORT — WORN (C1 BIN)

AT MID VISIT, THE VERT SUPPORT BEAMS FOR AFT C1 BIN BULKHEAD WERE FOUND TO BE WORN. THEY WERE REPAIRED PER SRM 53-10-9.

Part: MEGAPHONE — INOPERATIVE (CABIN)

FWD MEGAPHONE BATTERY LOW. REPLACED MEGAPHONE, TESTS GOOD.

Part: SKIN — CRACKED (NR 5 LE SLAT)

SKIN CRACKED AT FAIRING NUMBER 5 SLAT.

Part: BELL CRANK — WORN (RT AILERON TAB)

PILOT REPORTS, AT 230 KTS A LOUD VIBRATION WAS HEARD FROM THE F/O WINDOW AREA DURING CLIMBOUT AND AT 220 KTS DURING DECEL THE VIBRATION STOPPED. REPLACED THE RIGHT HAND OUTBOARD AILERON TRIM TAB BELL CRANK, WHICH WAS FOUND TO HAVE OBLONGED MOUNT HOLES. RIG CHECK OK.

Part: RIB — CRACKED (NR 5 LE FLAP)

RIB WAS FOUND TO BE CRACKED ON INSPECTION. RIB WAS REPAIRED PER M/M 57-54-00. FOUND DURING SHOP INSPECTION OF NR 5 L/E SLAT.

Part: SKIN — CRACKED (NR 5 LE SLAT)

LOWER L/E SKIN CRACKED AND WORN AT FENCE ATTACH HOLE. SKIN WAS REPAIRED PER M/M 57-54-0. FOUND DURING SHOP INSPECTION OF NR 5 LE SLAT.

Part: SKIN — CRACKED (NR 5 LE SLAT)

OUTER SKIN CRACKED AT FENCE ATTACH HOLE AND GROOVED AT REMAINING ATTACH HOLES. SKIN WAS REPAIRED PER M/M 57-54-0. FOUND DURING SHOP INSPECTION OF NR 5 L/E SLAT.

Part: LIGHT — INOPERATIVE (LT OVERWING)

ON INSPECTION, LEFT OVERWING EMERGENCY LIGHT INOP. REPLACED LIGHT ASSY, OPN CKS NORMAL.

Part: TRANSVERSE BEAM — CRACKED (BS 1273)

THERE IS A .5 INCH CRACK IN THE ANGLE OF BOTH THE FWD AND AFT TRANSVERSE BEAMS OF THE RT TORQUE BOX AT FS 1273. THESE AREAS OF THE TORQUE BOX ARE THE SUBJECT OF AIRWORTHINESS DIRECTIVE 94-07-08, WHICH REQUIRES INSPECTION PER S/B 53-0129.

Part: BLKHD WEB — CRACKED (BS 870)

FOUND ON E2 LETTER CHECK, STA 870 BULKHEAD WEB CRACKED 3 INCHES AT APU LOAD CONTROL VALVE CUTOUT, LWR END IN RT W/W. REPAIR PER SRM 53-10-9, TIME LIMITED INST.

Part: ANGLE — CRACKED (NR 4 LE SLAT)

FOUND DURING E-2 LETTER CHECK, .375 INCH CRACK NR 4 L/E SLAT COVE SKIN LWR ATTACH ANGLE AT O/B END. REPAIRED PER M/M 57-54-0 PAR 5A.

Part: ANGLE — CRACKED (RT WW)

FOUND ON E2 LETTER CHECK, KEEL BEAM VERT STIFFENER CRACKED .5 INCH FWD INBD RT W/W. TIME LIMITED REPAIR PER SRM 53-10-9.

Part: SKIN — DENTED (AILERON)

DURING SHOP INSPECTION, AILERON PANEL UPPER SKIN WAS FOUND DENTED. SPLICED UPPER SKIN PER SRM 57-53-5 FIG 3.

Part: WIRE HARNESS — BURNED (NR 1 ENGINE)

A/C LOST N-1 INDICATION, FUEL HEAT LIGHT AND START VALVE LIGHT 'ON'. F/F STUCK ON 4800 PPH, ENGINE SHUTDOWN. FOUND WIRE HARNESS MELTED IN FWD PYLON SPLICED IN NEW ENG WIRING AT PLUGS D374J, D356J, D350J, D386P AND D362J, PERFORMED CK OUT PER PFHB AND CKS GOOD.

Part: TUBE — WORN (B HYD SYS)

PIREP LOSS OF ALL HYD B-QUANTITY IN-FLIGHT. FOUND HYD LINE IN LEFT BODY FAIRING AREA LEAKING. REF IPC 29-14-0-6, ITEM 155, AND ITEM 160. HOLE IN LINE DUE TO CHAFING.

Part: SKIN — CRACKED (NR 6 SLAT)

DURING SHOP INSPECTION, NR 6 L/E SLAT WAS FOUND WITH L/E SKIN CRACKED AT OUTBOARD END. REPAIRED PER SRM 57-30.

Part: RIB — CRACKED (NR 6 LE SLAT)

DURING SHOP INSPECTION, NR 6 L/E RIB WAS FOUND WITH L/E SUPPORT RIBS NRS 3, 4, 7, 8, 10 AND 12 CRACKED. REPAIRED PER MM 57-54-0.

Part: RIB — CRACKED (NR 6 LE SLAT)

DURING ROUTINE SHOP INSPECTION A CRACK WAS FOUND IN THE 16TH RIB AND A DOUBLER WAS INSTALLED USING MM 57-54-0 FOR NR 6 L/E SLAT.

Part: EEL PWR SUPPLY — FAILED (CABIN)

DURING POWER TRANSFER FWD CABIN EMERGENCY FLOOR TRACK LIGHTS FAILED TO LIGHT. REPLACED POWER SUPPLY, OPERATION NORMAL.

Part: SKIN — CORROSION (BS 870)

THE FUSELAGE SKIN WAS FOUND CORRODED AND CRACKED AT STA 870 STRINGER 10R. ONE CRACK WAS .25 INCH LENGTH AND THE OTHER 1.50 INCH LENGTH. DAMAGE WAS LOCATED IN OVERLAPPED SKIN PANELS FORWARD AND AFT OF THE BUTT SPLICE AND DAMAGE REMOVAL RESULTED IN TWO 2.75 BY 4.75 CUTOUTS. THE SKIN IS MILLED FROM 2024-T351 CLAD PLATE. MAINTENANCE REPORTS THAT THE MAXIMUM THICKNESS AT EITHER CUTOUT LOCATION IS .225. ACCOMPLISHED REPAIRS PER DL ERA 302753-14.

Part: SEAT TRACK — CRACKED (BS 1110)

THE INBOARD LT SEAT TRACK IS CRACKED AT FLANGE STA 1110, JUST FWD OF FLOORBEAM. REPAIRED TRACK BY SPLICING IN NEW SECTION OF SEAT TRACK PER 727 M/M 53-20-11 FIG 802.

Part: RIB — CRACKED (NR 5 LE SLAT)

NR 5 RIB CRACKED ON FORWARD FLANGE. REPAIRED PER M/M 57-54-0 FIGURE 809. FOUND DURING SHOP INSPECTION OF NR 5 L/E SLAT.

Part: BATTERY PACK — DISCHARGED (CABIN)

LT FWD OVERWING EMERGENCY LIGHT INOP IN TEST. REPLACED BATTERY PACK, CHECKS GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

MID CABIN OVERHEAD AISLE EMERGENCY LT INOP. REPLACED BATTERY PACK, OPERATION NORMAL.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY LIGHTS INOP AT REAR ENTRY EXIT SIGN. REPLACED BATTERIES, OPERATION NORMAL.

Part: ANGLE — CRACKED (NR 3 LE SLAT)

FOUND DURING E-1 LETTER CHECK, COVE SKIN ATTACH ANGLE CRACKED UNDER ANTI-ICE DUCT AT NR 3 SLAT. REPAIRED PER M/M 57-54-0 PG 807A.

Part: SKIN — CRACKED (NR 2 LE FLAP)

COVE SKIN ATTACH ANGLE CRACKED UNDER ANTI-ICE DUCT NR 2 SLAT, FOUND DURING E-1 LETTER CHECK. REPAIRED PER M/M 57-54-0 PG 80.