N476DA

Part: OIL COOLER — WORN · airframe 300 hrs

THE OIL COOLER SUPPORT SHOE RUBBER COATING IS FAILING AND EATING INTO THE OIL COOLER .020 TO .040 OF AN INCH. IAW MM IT IS INSTALLED AT ENGINE ASSY AND ADJUSTED AFTER INITIAL TEST RUN. THERE IS NO PUBLISHED IN SERVICE INSTRUCTION FOR IT. IF THIS CONDITION IS NOT ADDRESSED BY REPLACEMENT OF SHOE AND OIL COOLER THE POSSIBILITY OF LOSS OF ENGINE OIL IS HIGH. THE 5 AIRCRAFT THAT WE HAVE FOUND, ON THOSE AC THE OIL COOLER HAD TO BE REPLACED. IN ADDITION TO THAT WE HAVE TO REPLACE 18 OIL COOLER SHOE'S PN 632983. THE FAILURE TIME FROM NEW TO HAVING WORN INTO THE ENGINE OIL COOLER IS LESS THEN 600HRS TTAF. THIS IS DUE TO THE RUBBER PORTION OF SHOE FAILING AND ALLOWING THE STEEL PART TO CUT INTO THE OIL COOLER.

Part: TRACK — CORRODED (T/E FLAP)

AN I/B FLAP TRACK WAS FOUND WITH CORROSION IN TWO BOLT HOLES WHICH ARE THE SUBJECT OF AD 90-07-05. THE CORROSION WAS CLEANED UP BY OVERSIZING THE HOLES WITHIN THE LIMITS OF B727, S/B 57-0178, REV 5 AND DOCUMENTED PER ER/A 367543-14AD.

Part: BATTERY — DISCHARGED (PASSENGER DOOR)

AFT ENTRY DOOR EMERGENCY EXIT LIGHT INOP.

Part: FRAME — CRACKED (R-1 DOOR)

FOUND AT A-1 LETTER CHECK, .5 INCH VISIBLE CRACK ON AFT FRAME OF R-1 DOOR AT FWD SIDE OF LWR STOP CASTING. REPAIRED PER MM 52-12-0.

Part: FRAME — CRACKED (PAX DOORWAY)

FOUND AT A-1 LETTER CHECK, .5 INCH VISIBLE CRACK ON AFT ENTRYWAY LT FRAME APPROX 6 INCHES BELOW UPPER STOP CASTING. REPAIRED PER SRM 53-10-9.

Part: SKIN — DAMAGED (BS 1140)

THE FUSELAGE SKIN AT STRINGER 22L BETWEEN FS 1110 AND 1166 WAS TORN AND GOUGED DUE TO CONTACT WITH GROUND EQUIPMENT. THE DAMAGE WAS REMOVED FROM THE SKIN WITH TWO CUTOUTS MEASURING 4 X 28.25 AND 3.25 X 16.5. THE CUTOUTS WERE REPAIRED WITH A SINGLE EXTERNAL ALUMINUM DOUBLER. INSTALLED PER ER/A 365850-14, REV A. A NEW SECTION OF STRINGER WAS SPLICED IN PER THE B727 SRM.

Part: SKIN — CRACKED (LT ELEVATOR)

LT ELEVATOR CRACKED ADJACENT PREVIOUS REPAIR LOWER SIDE AFT OF NR 3 BALANCE BOARD PANEL SRM 55-20-3.

Part: BATTERY PACK — DISCHARGED (CABIN)

AFT LT EXT EMERG LIGHT INOP. REPLACED BATTERY PACK M955, CHKS GOOD.

Part: DOUBLER — CRACKED (BS 373)

FUSELAGE, FWD GALLEY DOOR SURROUND DOUBLER, UPPER HINGE: REPAIR FOR CRACK AT HINGE CUTOUT. THE FWD GALLEY DOOR SURROUND DOUBLER WAS FOUND WITH A 1.8 CRACK AT THE UPPER HINGE CUTOUT. THE CRACK WAS STOP DRILLED AND A DOUBLER REPAIR INSTALLED PER BOEING S/B 727-53-0136 AND DOCUMENTED PER ER/A 363425-14.

Part: BRACKET — CRACKED (NR 8 SPOILER ACT)

FOUND DURING F-1 LETTER CHECK, 2 INCH CRACK NR 8 SPOILER ACTUATOR MOUNT CASTING LWR ATTACH BRACKET. REPAIRED PER M/M 57-20-22.

Part: FRAME — CRACKED (R 1 DOORWAY)

A 1.5 INCH CRACK IN UPPER AFT RADIUS OF R-1 DOOR AFT FRAME. REPAIRED PER ERA 363204-14 AND M/M 52-12-0.

Part: FITTING — WORN (LT MLG DOOR)

LT MLG DOOR FWD ATTACH FITTING WORN. REPAIRED PER SRM 57-43-0 PG 806 AND 807 IPC LOC 32-10-00-10 ITEM 345.

Part: FITTING — WORN (RT MLG DOOR)

RT MLG DOOR FWD ATTACH FITTING WORN. REPAIRED PER SRM 57-43-0 PG 806 AND 807, IPC REF 65-26763-10 ITEM 350.

Part: LIGHT — INOPERATIVE (AIRSTAIR)

AFT AIRSTAIR EMERGENCY EXIT LIGHTS INOP. REPLACED AFT AIRSTAIR EMERGENCY EXIT LIGHT ASSY AND BATTERY.

Part: SKIN — CRACKED (NR 2 LE SLAT)

A .25 INCH VISIBLE CRACK AT NR 2 SLAT COVE SKIN ANGLE AT I/B UPSTOP PAD. REPAIRED PER MM 57-54-0.

Part: WEB — CRACKED (BS 1273)

LT VERT TORQUE BOX WEB CRACKED AT LIGHTENING HOLE STA 1230. REPAIRED PER MM 53-11-0.

Part: STOP PAD — CRACKED (NR 7 SLAT)

DOUBLER CRACKED AT LWR COVER SKIN ANGLE AT NR 7 SLAT I/B STOP PAD. REPAIRED PER DELTA ER/A 362251-14.

Part: VERT WEB — CRACKED (BS 1303)

VERT WEB ABOVE S-DUCT AT STA 1303 HAS 2 EA CRACKS ONE AT LWR RT CORNER AND ONE AT LWR LT CORNER. INSTALLED REPAIR PER SRM 53-10-4.

Part: TORQUE BOX — CRACKED (BS 1215)

A .75 INCH CRACK IN UPPER LT TORQUE BOX WEB STA 1215 CRACKED AT CHORD ATTACH POINT, MARKED. STOP DRILLED CRACKS, DRILLED REPAIR DOUBLER PER M/M 53-11-0, INSTALLED REPAIR.

Part: TORQUE BOX — CRACKED (BS 1273)

TORQUE BOX CHORD CRACKED STA 1273R. CRACK HORIZ TORQUE BOX ANGLE STA 1273. REPAIRED PER SRM 53-10-10.

Part: FLOORBEAM — CORRODED (BS 344)

CORROSION FOUND ON FLOORBEAM STA 344 AND RBL 2. INSTALLED REPAIR PER SRM 53-10-8 FIG 11.

Part: SKIN — CRACKED (VERT STAB)

FOUND 3 CRACKS EXTENDING FROM RIVET HOLE AT BASE OF VERTICAL STABILIZER LT SIDE APPROX 10 FT AFT OF L/E. REPAIR PER MM 54-30-0.

Part: WEB — CRACKED (BS 1235)

A .375 AND .3125 INCH CRACK RT TORQUE BOX VERT WEB LIGHTENING HOLE AT STA 1235. REPAIRED PER MM 53-11-0.

Part: SKIN — CRACKED (FUSELAGE)

FOUND 1 INCH CRACK FUSELAGE SKIN COMING FROM R-5 COCKPIT WINDOW CUTOUT UPPER AFT CORNER. REPAIRED PER SRM 53-30-3.

Part: SKIN — CRACKED (VERT STAB)

A 1 INCH CRACK ACROSS RIVET HOLE AT RT SIDE OF VERT STAB BELOW ACCESS PANEL APPROX 10 FT AFT OF L/E. REPAIRED PER SRM 54-30-0.

Part: AIR DISTRIBUTION — SMOKE (MID CABIN)

IN CRUISE, FLT ATT REPORTED SMOKE IN MID CABIN AREA WITH ELECTRICAL SMELL. UNABLE TO DUPLICATE PROBLEM OR FIND ANY DESCREPENCIES THAT MAY HAVE CAUSED PROBLEM.

Part: LIGHT — INOPERATIVE (CABIN)

ESCAPE PATH LIGHTING LENS CRACKED AND LIGHT INOP. REPLACED LENS AND LIGHT, OPS CHECK NORMAL.

Part: LIGHT — INOPERATIVE (CABIN)

LT AFT SERVICE DOOR OVERHEAD EMERGNECY LIGHT INOPERATIVE. REPLACED LIGHT ASSY AND BATTERIES, CHECKS NORMAL.

Part: WHEEL BEARING — FAILED (LT MAIN GEAR)

ON TAXI IN TO GATE, NR 1 MAIN WHEEL ASSY LOCKED UP. FOUND NR 1 WHEEL ASSY DAMAGED. INBOARD WHEEL BEARING DESTROYED, AXLE CRACKED AND BROKEN AT INBOARD BEARING RACE. FOUND BRAKE ATTACH BOLT FROM ELEVEN O`CLOCK POSTION LAYING BETWEEN AXLE AND WHEEL ASSY. REPAIR WILL REQUIRE THE REPLACEMENT OF LT MAIN GEAR STRUT INTER-CYLINDER ASSY.

Part: SKIN — CRACKED (FUSELAGE)

THE FUSELAGE SKIN AND UNDERLYING DOUBLER WAS FOUND TO HAVE A .25 INCH CRACK IN THE UPPER FORWARD CORNER OF THE L-1 DOOR CUTOUT. A TIME LIMITED REPAIR HAS BEEN INSTALLED AND A PERMANENT REPAIR WILL BE INSTALLED PER SB 727-53-0186, REV 1.

Part: WEB — CRACKED (BS 284.5-285.5)

THE LT SIDEWALL WEB OF THE NOSE WHEEL WELL HAS A 2.5 INCH CRACK BETWEEN STA 294.5 AND 285.5 APPROXIMATELY AT WL 170. THE WEB AT THIS LOCATION IS 0.040 CLAD 2024-T3. THE DAMAGED PORTION OF THE WEB WILL BE TRIMMED OUT AND A REPAIR DOUBLER AND TWO STRAPS WILL BE INSTALLED. THE REPAIR IS ACCOMPLISHED PER S/B 727-53-0145. THIS REPAIR DOES NOT PROVIDE TERMINATING ACTION FOR EO 4-59270-3AD.

Part: WEB — CRACKED (TORQUE BOX)

TWO LIGHTENING HOLES IN RT VERT WEB OF AFT AIR STAIR TORQUE BOX WERE FOUND WITH CRACKS ROUTED PAST LIMITS. FOUND AT D-2 LTR CHECK AND REPAIRED PER MM 53-11-0.

Part: BATTERY — DISCHARGED (CABIN)

L-2 PORTABLE EMERGENCY LIGHT INOP, REPLACED BATTERIES, OPERATION NORMAL.

Part: LIGHT BALLAST — FAILED (CABIN)

AFTER STOPPING AT GATE AND DEPLANING, SMOKE STARTED COMING OUT OF OVERHEAD PANEL ABOVE 21A. PULLED ALL CABIN LIGHTING C/BS. FOUND CEILING LIGHT BALLAST BETWEEN 21 AND 22 ABC BURNT UP. DISCONNECTED SAME FWD TOMCO AND PLACED PER MEL 33-00-02. BALLAST WAS SUBSEQUENTLY REPLACED, OPERATION NORMAL.

Part: CLIP — CORROSION (FS 950)

FOUND DURING CV-2 CHECK, CORROSION FWD OF FORMER 950F WHERE IT ATTACHES TO SKIN BETWEEN STR 30 AND 28L. REPAIRED PER MM 53-11-0 FIG 825.

Part: CLIP — CORROSION (FS 970)

FOUND DURING CV-2 CHECK, CORROSION WHERE FORMER 970 ATTACHES TO SKIN BETWEEN STR 30 AND 28L. REPAIRED PER MM 53-11-0 PG 825.

Part: STRINGER — CORROSION (FS 950)

FOUND DURING CV-2 CHECK, CORROSION AROUND RIVETS IN STRINGER 25L BETWEEN STA 950D AND 950E. REPAIRED PER MM 53-11-0.

Part: SIDEWALL — CRACKED (FS 294.5-285.5)

THE RT SIDEWALL WEB OF THE NOSE WHEEL WELL HAS A 1 INCH CRACK BET STA 294.5 AND 285.5 APPROX AT WL 170. THE WEB AT THIS LOCATION IS 0.040 INCH THK 2024-T3 CLAD. THE DAMAGED PORTION OF THE WEB WILL BE TRIMMED OUT AND A REPAIR DOUBLER AND STRAP WILL BE INSTALLED. REPAIRED PER DL ERA 301493-14AD.

Part: SKIN — CORRODED (BS 480-500)

FOUND ON CV2 CHECK, CORROSION ON SKIN BETWEEN STA 480 AND 500 AT BL 0. REPAIRED PER SRM 53-30-3 FIG 1.

Part: WEB — CRACKED (BS 1263)

FOUND ON CV2 CHECK .25 INCH CRACK LIGHTNING HOLE TORQUE BOX SIDE WEBB STA 1263 LT SIDE. REPAIR: ROUTE OUT DAMAGED AREA PER M/M 53-11-0.

Part: CLIP — CRACKED (BS 990)

FOUND ON CV2 CHECK, ONE INCH CRACK IN SKIN CLIP BETWEEN STR 28L AND 29L FWD SIDE STA 990. REPAIR: REPAIRED PER M/M 53-11-0.

Part: STRINGER — CORRODED (BS 1030-1050)

FOUND ON CV2 CHECK, CORROSION AROUND RIVETS STR 27L STA 1030 TO STA 1050. REPAIRED PER ERA 301506-14 CODE 4-53-14.

Part: STRINGER — CORRODED (BS 950)

FOUND ON CV2 CHECK, CORROSION AROUND RIVETS STRINGER 25L FROM 950A TO 950B. REPAIRED PER SRM 53-10-3 AND PER PS 900-5-1.

Part: SEAT TRACK — CORRODED (BS 1070-1115)

FOUND ON CV2 CHECK, CORROSION AT O/B GALLEY ATTACH TRACK LBL 56 BETWEEN STA 1070 AND STA 1115. REPLACED SEAT TRACK FROM STA 1070 TO STA 1110 PER SRM 53-10-5 FIG 7.

Part: SEAT TRACK — CORRODED (BS 344-480)

FOUND ON CV2 CHECK, CORROSION ON RT CENTER SEAT TRACK STA 344 TO 480. CLEANED TREATED AND PAINTED FROM STA 460 TO 480 PER SRM 53-10-1, FROM STA 344 TO 460 REPLACED SEAT TRACK SECTION PER SRM 53-10-5 FIG 7.

Part: SKIN — CRACKED (RT SERVICE DOOR)

FOUND ON CV2 CHECK RT FWD SERVICE DOOR UPPER HINGE CUTOUT CRACKED .50 INCH. REPAIR: REPAIRED PER M/M 52-11-0 PG 808.

Part: SEAT TRACK — CORRODED (BS 380-480)

FOUND ON CV2 CHECK, CORROSION ON RT INBD SEAT TRACK STA 380 TO 480. REPLACED SEAT TRACK SECTION PER SRM 53-10-5 FIG 7.

Part: ANGLE — CRACKED (NR 8 SLAT)

FOUND ON CV2 NR 8 SLAT ANGLE CRACKED UNDER TELESCOPING TAI DUCT. REPAIRED PER MM 57-54-0 PAR 5A.

Part: ANGLE — CRACKED (NR 7 SPOILER)

FOUND ON CV2 CHECK, ONE INCH CRACK IN ATTACH ANGLE LOWER END OF NR 7 SPOILER ACTUATOR ATTACH FITTING. REPAIR: REPAIRED PER M/M 57-20-22 PAR 10.

Part: WEB — CORROSION (LT NLG WW)

CORROSION WAS FOUND ON THE SKIN CLIP AND WEB JUST O/B OF THE LT NOSE CHORD AT STA 303.9. THE DAMAGE WAS REPAIRED PER MM 53-30-0 FIG 806. DAMAGE FOUND DURING SPECIAL INSPECTION.