N45793

Part: FLOOR — CORRODED (BS 1177-1171)

INSPECTION FOUND CABIN FLOOR PAN CORRODED AT AFT ENTRY STA 1177 TO 1171, BL 0 TO LBL 18. THE FLOOR PAN WAS REMOVED AND A NEW FLOOR PAN WAS INSTALLED IAW SRM 53-10-2.

Part: FLOOR — CORRODED (BS 1111-1183)

INSPECTION FOUND CORROSION ON RT AFT LAV FLOOR PAN AT BS 1111 TO 1183. THE FLOOR PAN WAS REMOVED AND A NEW PAN WAS INSTALLED IAW SRM 51-30-2, 51-40-2 FIGURE 1, 51-10-2 AND MM 51-20-11.

Part: FUSE — BLOWN (CABIN)

INSPECTION FOUND LT AFT EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE REMOVED AND REPLACED A BLOWN FUSE AND OPERATION CHECKED GOOD IAW MM 33-51-00.

Part: SKIN — DELAMINATED (NR 8 SPOILER)

INSPECTION FOUND TOP SURFACE OF NR 8 SPOILER DELAMINATED. THE NR 8 SPOILER WAS REMOVED AND REPLACED IAW MM 27-62-81.

Part: SKIN — DELAMINATED (RT TE FLAP)

INSPECTION FOUND RT WING O/B TE AFT FLAP O/B END UPPER SURFACE DELAMINATED AT SPAR. THE AFT FLAP WAS REMOVED AND REPLACED IAW MM 27-51-11.

Part: STIFFENER — CORRODED (WS 244)

INSPECTION FOUND RT WING FRONT SPAR VERTICAL STIFFENER CORRODED AT STA 244. THE STIFFENER WAS REPLACED IAW SRM 51-10-1 PAGE 4 AND 6A, SRM 51-10-2 AND 51-30-2.

Part: ANGLE — CRACKED (CARGO DOOR)

INSPECTION FOUND A 1 INCH CRACK IN C-3 DOOR T-ANGLE AT LOWER AFT DOOR STOP AREA. THE ANGLE WAS REMOVED AND A NEW ANGLE WAS INSTALLED IAW SRM 51-10-101.

Part: CHORD — CRACKED (WS 135.2)

INSPECTION FOUND A 2 INCH CRACK IN LT WING AFT FALSE SPAR LOWER CHORD AT WBL 135.2. THE CRACKED AREA WAS CUT OUT AND SPLICE ANGLE AND STRAPS WERE INSTALLED IAW SRM 51-30-2, 51-10-2, ECRA 5740-01866.

Part: SKIN — PUNCTURED (RT ELEVATOR)

INSPECTION FOUND TWO .25 INCH DIAMETER HOLES IN RT ELEVATOR UPPER SKIN JUST AFT OF NR 3 ATTACH HINGE. A DOUBLER REPAIR WAS INSTALLED IAW SRM 55-20-3, PAGE 9.

Part: BRACKET — CRACKED (NR 1 FLAP ACT)

INSPECTION FOUND A .5 INCH CRACK IN INBOARD SUPPORT BRACKET AT LOWER END WHERE LT WING NR 1 L/E FLAP ACTUATOR IS MOUNTED. A NEW SUPPORT BRACKET WAS INSTALLED IAW SRM 51-30-2, PAGE 3.

Part: FRAME — CRACKED (BS 344)

INSPECTION FOUND A .5 INCH CRACK IN FLOOR LEVEL RIB AT RT SIDE OF STA 344. A STRAP WAS INSTALLED IAW SRM 51-10-2 AND 53-10-8 FIGURE 6.

Part: SPAR — CRACKED (LT ELEVATOR)

INSPECTION FOUND A .5 INCH CRACK IN LT ELEVATOR REAR SPAR. THE LT ELEVATOR WAS REMOVED AND REPLACED IAW MM 27-30-1, PAGE 401 AND 402. RIG AND OPERATIONAL CHECK WAS ACCOMPLISHED IAW MM 27-30-81 PAGE 507.

Part: TERMINAL — INOP (L1 DOOR)

INSPECTION FOUND L-1 OVERHEAD EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE REPAIRED TERMINAL AT LIGHT SOCKET ASSEMBLY AND OPERATIONAL CHECKS WERE GOOD AT MM 33-60-00, PAGE 201.

Part: WIRE — LOOSE (L2 DOOR)

INSPECTION FOUND THE L-2 OVERHEAD EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE FOUND A LOOSE WIRE IN HARNESS. THE WIRE WAS REPQIRED AND OPERATIONAL CHECKS WERE GOOD IAAW MM 33-60-01, PAGE 201.

Part: NUT — LEAKING (A-HYD SYST)

ON TAKEOFF DURING GEAR RETRACTION, A-SYSTEM HYDRAULICS FAILED. FOUND LEAK AT A-SYSTEM RETURN LINE T-FITTING AT FWD KEEL BEAM RT WHEEL WELL. TIGHTENED B-NUT AND SERVICED SYSTEM.

Part: HYD LINE — RUPTURED (LT MLG DOOR)

THE AIRCRAFT LOST A-SYSTEM HYDRAULIC QUANTITY DURING GEAR EXTENSION WHILE ON APPROACH TO IAH. ABNORMAL AND EMERGENCY PROCEDURES WERE FOLLOWED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LT GEAR DOOR HYDRAULIC LINE RUPTURED. THE HYDRAULIC LINE WAS REMOVED AND REPLACED. THE HYDRAULIC SYSTEM WAS SERVICED TO FULL AND LEAK CHECKS WERE GOOD.

Part: RELAY — INOPERATIVE (NR 1 ENGINE)

THE NR 1 ENGINE FIRE DETECTION FAULT LIGHT AT B POSITION ILLUMINATED INTERMITTENTLY WHILE IN FLIGHT. TROUBLESHOOTING THE NR 1 ENGINE FIRE DETECTION SYSTEM FOUND R147 TEAT RELAY FAULTY. THE R147 RELAY WAS REMOVED AND REPLACED. THE NR 1 ENGINE B FIRE DETECTION LOOP WAS REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

INSPECTION FOUND LEFT OVERWING EXIT AFT LIGHT INOPERATIVE. THE LEFT OVERWING EXIT LIGHT POWER SUPPLY WAS REMOVED AND REPLACED. OPERATION OF THE LIGHT CHECKED GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND OVERHEAD EMERGENCY LIGHTS AT ROW 17 INOPERATIVE. THE BATTERY PACK WAS REPLACED.

Part: STRINGER — CRACKED (WS 686.5)

INSPECTION FOUND A 1 INCH CRACK IN UPPER AREA OF RT WING STRINGER, SECOND FROM AFT AT STA 686.5. THE CRACK WAS STOP DRILLED, A REPAIR WAS FABRICATED AND INSTALLED IAW EA 5762-01050 AND SRM 51-30-2.

Part: RIB — CRACKED (WS 760)

INSPECTION FOUND A 2 INCH CRACK IN RT WING FUEL TANK RIB AT WS 760. THE CRACK WAS STOP DRILLED, A REPAIR WAS INSTALLED IAW SRM 57-10-5.

Part: FRAME — PUNCTURED (CARGO DOOR)

INSPECTION FOUND LOWER OUTBOARD EDGE OF FORWARD PIT DOOR FRAME PUNCTURED. THE LOWER FRAME WAS REMOVED AND A NEW FRAME WAS FABRICATED AND INSTALLED IAW SRM 51-40-3.

Part: STRINGER — CRACKED (WS 519)

INSPECTION FOUND A 1 INCH CRACK IN UPPER AREA OF STRINGER, THIRD FROM AFT AT RT WING RIB STA 519. THE CRACK WAS STOP DRILLED, A REPAIR WAS FABRICATED AND INSTALLED IAW EA 5762-01050 AND BOEING SERVICE BULLETIN 57A159.

Part: FLOORBEAM — CORRODED (BS 1110)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1110 FROM BL 0 TO RT WALL. THE CORRODED AREA WAS CUT OUT, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8.

Part: STRINGER — CORRODED (BS 740)

INSPECTION FOUND STRINGER 27L CORRODED AT STA 740. THE CORRODED SECTION OF STRINGER WAS CUT OUT, A NEW STRINGER SECTION AND FILLER WERE FABRICATED AND INSTALLED IAW SRM 53-10-3 AND 51-30-2.

Part: BULKHEAD WEB — CRACKED (VERT STAB)

INSPECTION FOUND A 3 INCH CRACK IN BULKHEAD WEB PLATE AT STRINGER 7 AND RIB 8 OF LT SIDE OF VERTICAL STABILIZER INTERIOR. THE CRACKED PLATE WAS REMOVED, A REPLACEMENT PLATE WAS FABRICATED AND INSTALLED IAW SRM 51-40-2.

Part: PANEL — CRACKED (BS 286)

INSPECTION FOUND THREE CRACKS AT FASTENER HOLES IN TOP CENTER PANEL AT STA 286, NLG WHEEL WELL. THE CRACKS MEASURED .25 TO .375 INCH LENGTH. THE CRACKED AREA WAS CUT OUT, A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW BOEING SERVICE BULLETIN 727-53-0145.

Part: FLOORBEAM — CORRODED (BS 480)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 480, RBL 25. THE CORRODED AREA WAS CUT OUT, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8.

Part: SKIN — CORRODED (LT TE FOREFLAP)

INSPECTION FOUND LT WING OUTBOARD FOREFLAP LOWER TRAILING EDGE SKIN CORRODED AND FIBERGLASS WAS DEBONDED. THE CORRODED SKIN AND CORE WERE CUT OUT, REPAIR PARTS WERE FABRICATED AND A HOT BOND REPAIR WAS ACCOMPLISHED IAW SRM 51-40-6.

Part: HINGE FITTING — CRACKED (AILERON)

INSPECTION FOUND A .25 INCH CRACK IN HINGE FITTING FORWARD OF OUTBOARD AILERON, SECOND HINGE FROM OUTBOARD END. THE HINGE FITTING WAS REMOVED AND REPLACED IAW SRM 51-10-1 AND 51-30-2.

Part: SKIN — CRACKED (LT WING)

INSPECTION FOUND LT WING LOWER LEADING EDGE SKIN BENT WITH A .25 INCH CRACK AT CUTOUT DIRECTLY OVER NR 2 SLAT ACTUATOR PISTON. THE CRACKED OUTER SKIN WAS CUT OUT, THE CRACKED INNER SKIN WAS STOP DRILLED, FILLER AND DOUBLER WERE FABRICATED AND INSTALLED IAW SRM 51-10-1, 51-10-6, AND 51-30-2.

Part: SKIN — CRACKED (LT WING)

INSPECTION FOUND A .75 INCH CRACK IN LT WING UPPER LEADING EDGE SKIN AT CUTOUT WHERE NR 4 SLAT OUTBOARD HOOK INSERTS. A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW SRM 57-30-4.

Part: FLOORBEAM — CORRODED (BS 380)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 380, RBL 25 TO 45. THE CORRODED AREA WAS CUT OUT, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8.

Part: SKIN — CRACKED (E/E COMPT DOOR)

INSPECTION FOUND A 2.5 INCH CRACK IN E AND E COMPARTMENT ACCESS DOOR SKIN ALONG RIGHT EDGE. THE CRACKED AREA WAS CUT OUT, FILLER AND DOUBLER WERE FABRICATED AND INSTALLED IAW SRM 52-00-3.

Part: PRESSURE PANEL — CRACKED (BS 280)

INSPECTION FOUND A .25 AND .375 INCH CRACK IN NLG WHEEL WELL TOP LEFT PANEL AT STA 280. THE CRACKED AREA WAS CUT OUT, A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW BOEING SERVICE BULLETIN 727-53-0145.

Part: BULKHEAD — CRACKED (BS 286)

INSPECTION FOUND A .25 AND .375 INCH CRACK AT FASTENER HOLES IN NLG WHEEL WELL RIGHT SIDEWALL BULKHEAD STA 286. THE CRACKS WERE STOP DRILLED, A DOUBLER AND STRAP REPAIR WERE FABRICATED AND INSTALLED IAW BOEING SERVICE BULLETIN 727-53-0145.

Part: SKIN — CRACKED (LT ELEVATOR)

INSPECTION FOUND A 2 INCH CRACK IN LT ELEVATOR LOWER SKIN JUST AFT OF PANEL NR 9313. THE CRACK WAS STOP DRILLED, A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW SRM 55-20-3.

Part: ANGLE — CRACKED (LT WING)

INSPECTION FOUND A 2.25 INCH CRACK IN ANGLE INSIDE LT WING FIXED LEADING EDGE AT NOSE RIB, SLAT STA 0. THE ANGLE WAS REMOVED AND A REPLACEMENT ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-20-1 AND 51-30-2.

Part: SKIN — CRACKED (LT ELEVATOR)

INSPECTION FOUND A .25 INCH CRACK AT RIVET HOLE OF LT ELEVATOR LOWER SKIN JUST AFT OF PANEL NR 9310. THE CRACK WAS STOP DRILLED, A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 55-20-3.

Part: SKIN — CORRODED (BS 470-478)

EXTERNAL SKIN HAS CORROSION AT BOTTOM OF FUSELAGE STATION 470 TO STATION 478. REMOVED SKIN PANEL, CLEANED UP AREA, INSTALLED NEW SKIN PANEL PER EA 5330-01320.

Part: SKIN — CRACKED (BS 612)

ONE INCH CORROSION/CRACK ON FUSELAGE SKIN AT STATION 612 STRINGER 26L. CUT OUT DAMAGED AREA, FABRICATED AND INSTALLED REPAIR PER SRM 53-30-2 FIG 5.

Part: FITTING — CRACKED (L1 DOOR)

L 1 DOOR TOP AFT DOOR STOP FITTING CRACKED. REMOVED AND REPLACED STOP FITTING PER SRM 51-10-1.

Part: WEB — GOUGED (LT AILERON)

LEFT HAND OUTBOARD AILERON INBOARD HINGE AT WING TRAILING EDGE HAS WEB BADLY GOUGED AT OUTBOARD SIDE OF HINGE FITTING. GOUGE OUT OF LIMITS. FABRICATED AND INSTALLED REPAIR DOUBLER PER SRM 57-10-4.

Part: WEB — CRACKED (FWD ENT DOOR)

AT FORWARD ENTRY DOOR AFT END OF UPPER FRAME WEB HAS 4 INCH CRACK RUNNING FROM UPPER STOP FITTING. CUT OUT CRACKED AREA, FABRICATED AND INSTALLED REPAIR PER S/B 727-52-115.

Part: WEB — CRACKED (LT AILERON)

LEFT HAND OUTBOARD AILERON NR 3 AILERON HINGE FITTING AT WING TRAILING EDGE HAS OUTBOARD WEB CRACKED. FABRICATED AND INSTALLED DOUBLER PER SRM 51-40-2.

Part: SKIN — DENTED (FUSELAGE)

RIGHT HAND FUSELAGE SKIN JUST BELOW FORWARD SERVICE DOOR AREA HAS DENT. REWORKED DENT TO BRING WITHIN LIMITS. ACCOMPLISHED HFEC, NO CRACKS NOTED PER SRM 53-10-1 AND 51-40-1.

Part: SKIN — DENTED (BS 1352)

RIGHT HAND FUSELAGE SKIN DENTED AT APPROX STATION 1352. CUT OUT DENTED AREA, FABRICATED AND INSTALLED DOUBLER PER SRM 54-30-3 FIG 7.

Part: SKIN — CRACKED (NR 2 LE SLAT)

LEFT NR 2 SLAT HAS 1.5 INCH CRACK AT OUTBOARD ACCESS FOR ACTUATOR ATTACMENT. FABRICATED AND INSTALLED DOUBLER PER SRM 57-50-3.

Part: FLOOR BEAM — CORRODED (BS 1130)

AFT CARGO COMPARTMENT STATION 1130 BLU TO RBL 60 FLOORBEAM LOWER CAP HAS HEAVY CORROSION. REMOVED LOWER CAP, FABRICATED REPAIR TREATED, PRIMED, THEN INSTALLED IAW DWG 25770-5065 AND EC/RA 5310-03334.

Part: BRACKET — CRACKED (RT WING LE)

RIGHT WING BRACKET HAS CORROSION INSIDE FIXED L/E AT OUTBOARD SIDE OF NR 5 L/E FLAP OUTBOARD HINGE. REMOVED FABRICATED AND INSTALLED REPLACEMENT BRACKET PER SRM 51-10-1 AND 51-10-2.

Part: PANEL — DELAMINATED (NR 6 SPOILER)

NUMBER 6 SPOILER UPPER SURFACE DELAMINATED. REPAIRED SPOILER PANEL PER SRM 51-40-6.

Part: TAB — DELAMINATED (LT AILERON)

LEFT OUTBOARD AILERON TAB UPPER SURFACE HAS A SMALL AREA OF DELAMINATION AND SEVERAL DENTS. PERFORMED HOT BOND REPAIR PER SRM 51-40-6.

Part: SKIN — GOUGED (LT TE FORE FLAP)

LEFT INBOARD FORE FLAP LEADING EDGE GOUGED INBOARD AND OUTBOARD OF NR 4 CARRIAGE. REMOVED DOUBLER, FABRICATED AND INSTALLED REPLACEMENT DOUBLER PER SRM 57-40-04.

Part: PANEL — CRACKED (RT WING TE)

RIGHT WING TRAILING EDGE PANEL ATTACHED TO INBOARD END OF GEAR BEAM HAS AREA WORN THROUGH AND CRACKED INBOARD OF NR 8 SPOILER AREA. REMOVED PANEL, ACCOMPLISHED HOT BOND REPAIR AND REINSTALLED PER SRM 51-40-6.

Part: PANEL — DELAMINATED (RT SPOILER)

SPOILER PANEL FOUND DELAMINATED. REPAIRED PANEL PER SRM 51-40-6.

Part: HYD LINE — CHAFED (B-HYD SYST)

THE AIRCRAFT LOST B-SYSTEM HYDRAULICS WHILE EN ROUTE. THE AIRCRAFT WAS RETURNED TO BDA WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE HYDRAULIC PRESSURE LINE FROM NR 2 B-PUMP CHAFED AT CLAMP. THE HYDRAULIC LINE WAS REPLACED. THE HYDRAULIC SYSTEM WAS SERVICED TO FULL AND LEAK CHECKS WERE GOOD.

Part: SWITCH — INOPERATIVE (RT MLG DOOR)

THE RT GEAR DOOR LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTON DEPARTING EWR. THE RED DOORS LIGHT WAS ALSO ON. A RETURN TO EWR WAS BEGUN AND BOTH LIGHTS REMAINED ILLUMINATED WHEN GEAR WAS EXTENDED FOR LANDING. THE AIRCRAFT LANDED AT EWR WITHOUT INCIDENT. MAINTENANCE VERIFIED THE RIGHT GEAR DOOR WAS UP AND LOCKED WITH LIGHTS ON. THE LANDING GEAR DOOR WARNING SWITCH WAS FOUND AT FAULT. THE SWITCH WAS REMOVED AND REPLACED. OPERATION AND INDICATIONS CHECKED GOOD IAW MM 32-62-11, PAGE 501.

Part: SELECT VALVE — INOPERATIVE (LANDING GEAR)

THE TAIL SKID LIGHT REMAINED ILLUMINATED AFTER TAKEOFF. THE GEAR WAS CYCLED, BUT THE LIGHT WOULD NOT EXTINGUISH. THE LEFT AND RIGHT MLG RED AND GREEN LIGHTS REMAINED ILLUMINATED WITH GEAR HANDLE IN THE OFF POSITION. ALL THREE GEAR DOOR LIGHTS ALSO REMAINED ILLUMINATED. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE MLG SELECT VALVE AT FAULT. THE MLG SELECT VALVE WAS REMOVED AND REPLACED IAW MM 32-31-31, PAGE 401, LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: SOCKET — SHORTED (GLARESHIELD)

A SMALL AMOUNT OF SMOKE WAS OBSERVED COMING FROM UNDER GLARESHIELD, ACCOMPANIED BY ILLUMINATION OF SEVERAL WARNING LIGHTS AFTER GEAR WAS RAISED. FUEL WAS DUMPED AND THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 2 THRUST REVERSER OPERATING LIGHT SOCKET AT FAULT. THE LIGHT SOCKET WAS REPLACED AND OPERATIONAL CHECK WAS GOOD.

Part: BRAKE — BEARING DAMAGED (MLG WHEEL NR 3)

EWR - FLT 0700 - THE NR 3 MAIN WHEEL BRAKE CHATTERED ON LANDING ROLL-OUT WHILE TAXIING TO GATE IN EWR. MAINTENANCE REMOVED NR 3 TIRE AND FOUND INNER BEARING DAMAGED. THE NR 3 TIRE AND BRAKE WERE REMOVED AND REPLACED AND OPERATION CHECKED GOOD. (X)

Part: WIRE — BROKEN (EMERGENCY EXIT)

EWR - FLT 0242 - INSPECTION FOUND THE AFT EMERGENCY EXIT LIGHT BETWEEN SERVICE DOORS INOPERATIVE. MAINTENANCE FOUND A BROKEN WIRE AT WIRE BUNDLE CONNECTION. THE WIRE WAS REPINNED AND OPERATION OF THE EXIT LIGHT WAS RESTORED. (X)

Part: LIGHT — INOPERATIVE (AFT AIRSTAIR)

FLT NR 700 - EWR - INSPECTION FOUND THE EMERGENCY EXIT OVERHEAD LIGHTS IN AFT AIRSTAIR INOPERATIVE. THE LIGHT ASSEMBLY WAS REMOVED AND REPLACED AND OPERATION CHECKED GOOD. (M)

Part: BATTERY — INOPERATIVE (CABIN)

FLT NR 293 - EWR - THE OVERHEAD EMEGENCY EXIT LIGHT AT AFT GALLEY WOULD NOT ILLUMINATE. THE EMERGENCY EXIT LIGHT BATTERY WAS REPLACED AND OPERATION OF THE LIGHT WAS RESTORED. (M)

Part: FLOORBEAM — CORRODED (BS 410)

STATION 31J - CORROSION WAS FOUND ON THE MAIN CABIN FLOORBEAM AT BS 410. THE FLOORBEAM WAS REMOVED AND REPLACED IAW SRM 53-10-8 AND 51-10-1. (M)

Part: SKIN — CRACKED (BS 445)

STATION 31J - INSPECTION FOUND A 3 INCH CRACK IN FUSELAGE SKIN AT BS 445, S19L AND THERE WAS CORROSION AT THE FASTENERS. THE CRACKED AND CORRODED AREA WAS REMOVED AND A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-30-3. (M)