N478AC

Part: FITTING — CRACKED (L-1 DOOR)

INSPECTION FOUND A 1 CRACK IN L-1 DOOR LOWER HINGE FITTING. A NEW FITTING WAS INSTALLED IAW SRM 51-10-4.

Part: SUPPORT — DAMAGED (BS 465)

INSPECTION FOUND ELONGATED BOLT HOLES IN FORWARD BAGGAGE BIN FLOORBOARD SUPPORT BEAM AT STA 465 FROM STRINGER 227R TO 27L. THE FLOORBOARD SUPPORT BEAM AND FASTENERS WERE REPLACED IAW ECRA 5320-01588.

Part: SKIN — DENTED (RT TE FLAP)

INSPECTION FOUND RT O/B FLAP PANEL O/B LOWER SURFACE DENTED WITH A BULGE ON O/B END. A DOUBLER REPAIR WAS INSTALLED IAW SRM 51-10-2 AND 51-10-3.

Part: SKIN — CRACKED (BS 200-207)

INSPECTION FOUND A 1.25 INCH CRACK IN SKIN AT FASTENER HOLE OF STA 200-207, LONGERON 15L. THE SKIN WAS REPAIRED IAW EA PD80-53-006.

Part: SKIN — CRACKED (FUSELAGE)

INSPECTION FOUND THE RT LOWER FUSELAGE SKIN AFT OF NOSE GEAR CRACKED COMPLETELY THROUGH. REMOVED AND INSTALLED LOWER FUSELAGE SKIN IAW SRM 53-05.

Part: TRACK — CORRODED (BS 1007-1155)

INSPECTION FOUND AFT CARGO TIE DOWN TRACK CORRODED AT STA 1007-1155. THE TIE DOWN TRACK WAS REPLACED IAW SRM 51-30-1.

Part: SKIN — DELAMINATED (RUDDER TAB)

INSPECTION FOUND RUDDER TRIM TAB DELAMINATED ON TRAILING EDGE AT AFT TOP CORNER AND BOTTOM CORNER. THE RUDDER TAB WAS REMOVED, REPAIRED, AND REINSTALLED IAW MM 27-20-2 AND SRM 51-90-2.

Part: SKIN — GOUGED (L1 DOORWAY)

INSPECTION FOUND A GOUGE IN FUSELAGE SKIN AT L-1 DOOR AFT CUTOUT. REPAIRED IAW SRM 53-05, FIGURE 26A.

Part: AIR SEAL — WORN (NR 1 ENG COMP)

THE NR 1 ENGINE FAILED ACCOMPANIED BY A LOUD BANG DURING CLIMB-OUT OF EWR AT 10,000 FEET. THE CREW SHUT THE ENGINE DOWN AND THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. THE NR 1 ENGINE WAS REMOVED AND REPLACED. THE ENGINE WAS RUN AND ALL PARAMETERS CHECKED GOOD. ENGINEERING CONCLUDED THAT THE PRIMARY CAUSE OF ENGINE FAILURE WAS DUE TO A WORN SECOND STAGE INNER AIR SEAL.

Part: B-NUT — LOOSE (BRAKE CON VLV)

WHEN HYDRAULICS WERE SWITCHED TO LOW DURING CLIMBOUT. THE LEFT HYDRAULIC SYSTEM PRESSURE AND QUANTITY WENT TO ZERO. THE LEFT SWITCHES WERE TURNED TO OFF AND THE LEFT HYDRAULIC QUANTITY SLOWLY INCREASED TO 16 QUARTS. THE FLIGHT WAS CONTINUED TO ATL WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND A LOOSE B-NUT ON LT DUAL BRAKE CONTROL VALVE. THE B-NUT WAS TIGHTENED. THE LT ENGINE DRIVEN HYDRAULIC PUMP WAS REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE. THE LT HYDRAULIC SYSTEM WAS SERVICED TO FULL. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: BLADE — FAILED (NR 1 ENGINE)

THE NR 1 ENGINE GAVE OFF A LOUD BANG AND QUIT DURING CLIMBOUT. AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. THE NR 1 ENGINE WAS REMOVED AND REPLACED. *S/D* SHOP FINDINGS REVEALED C-7 BLADE FAILURE.

Part: FITTING — BROKEN (SLAT TRACK)

INSPECTION FOUND THE RT WING LEADING EDGE NR 3 SLAT OUTBOARD TRACK ATTACH FITTING BROKEN. A NEW FITTING WAS INSTALLED IAW SRM 51-00.

Part: LONGERON — CORRODED (BS 1287)

INSPECTION FOUND LONGERON 22L CORRODED JUST AFT OF FUSELAGE STA 1287 BELOW AFT NOZZLE VALVE. A REPAIR WAS INSTALLED IAW SRM 53-02.

Part: SKIN — DENTED (BS 320)

INSPECTION FOUND LT FUSELAGE SKIN DENTED AT STA 320, LONGERON 21. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 53-04, PAGE 39.

Part: SKIN — DENTED (BS 218/237)

INSPECTION FOUND LT FUSELAGE SKIN DENTED IN TWO AREAS JUST AFT OF MAIN CABIN DOOR AT STA 218 AND 237. A DOUBLER WAS FABRICATED AND INSTALLED IAW ECRA 5330-01535.

Part: RIB — CRACKED (LT WING LE)

INSPECTION FOUND A .75 INCH CRACK IN LT WING FIXED LEADING EDGE NOSE RIB TWENTY INCHES OUTBOARD OF NR 2 SLAT TRACK (XRS 30) AND A .75 INCH CRACK WAS FOUND FOURTEEN INCHES OUTBOARD OF NR 2 SLAT TRACK (XRS 25). DOUBLER REPAIRS WERE FABRICATED AND INSTALLED IAW SRM 57-00-01.

Part: WIRE — FAILED (ELEC EQ COMP)

THE CIRCUIT BREAKER FOR CENTER FUEL TANK AFT BOOST PUMP POPPED AND ALL FUEL QUANTITY GAUGES WENT BLANK AT TAKEOFF. BOTH A AND B CHANNELS WERE BLANK. THE CIRCUIT BREAKER WAS RESET, BUT IT POPPED AGAIN. THE CIRCUIT BREAKER FOR FUEL QUANTITY POWER TRANSFER WAS PULLED AND RESET. THE AIRCRAFT WAS RETURNED TO EWR. MAINTENANCE FOUND THE RT MAIN AC BUS CIRCUIT BREAKER (B1-739) BAD AND A BURNT BUSING CABLE B7-5. THE CABLE AND CIRCUIT BREAKER WERE REMOVED AND REPLACED.

Part: APU — LEAKING OIL (AFT FUSELAGE)

SMOKE WAS REPORTED IN THE AFT AND FORWARD SECTION OF CABIN DURING INITIAL CLIMB OUT OF IAH. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE APU INLET AND BLEED OIL SOAKED. THE APU WAS REMOVED AND REPLACED. THE APU INLET BOX WAS ALSO DISASSEMBLED AND CLEANED. THE APU INLET DOOR ACTUATOR WAS ALSO REPLACED. A BURN OUT PROCEDURE WAS PERFORMED IAW MM 21-20-02. BOTH WATER SEPARATOR SOCKS WERE REPLACED. BOTH ENGINES AND THE APU WERE RUN WITH LEFT AND RIGHT PACKS OPERATING AND NO SMOKE WAS PRODUCED. PART TOTAL CYCLES, 10,443.

Part: APU — OVERSERVICED (A/C TAIL)

SMOKE AND ODOR ENTERED THE CABIN SHORTLY AFTER TAKEOFF. BOTH THE SMOKE AND ODOR DISAPPEARED AFTER PULLING THE RECIRCULATING FAN CIRCUIT BREAKER. MAINTENANCE FOUND NO PROBLEMS WITH THE RECIRCULATING FAN. THE APU WAS CLEANED AND RUN WITH NO LEAKS NOTED. MAINTENANCE REMOVED THE APU BURNER CAN AND FOUND OIL IN TORUS AREA. THE BURNER CAN WAS REINSTALLED, THE COALESCER BAGS WERE CHANGED. THE APU WAS OPERATED WITH PACKS RUNNING TO LEAK CHECK AND CLEAR OUT SMELL FROM APU BEING OVERSERVICED. OPERATION CHECKED GOOD WITH NO LEAKS NOTED.

Part: STRUT — LOW PRESSURE (NLG)

FLT NR 0289 - CLE - THE NOSE GEAR RED UNSAFE LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION LEAVING CLE. CYCLING THE GEAR DID NOT HELP. THE AIRCRAFT WAS RETURNED TO CLE. MAINTENANCE FOUND THE NOSE STRUT PRESSURE LOW. THE NOSE STRUT WAS SERVICED TO PROPER LIMITS. A GEAR SWING WAS PEFORMED WITH OPERATION AND INDICATIONS CHECKING GOOD. IN ADDITION, THE NOSE GEAR AND DOORS WERE LUBRICATED AS A PRECAUTIONARY MEASURE. (M)

Part: LIMIT SWITCH — LOOSE (LT/RT THROTTLE)

FLT NR 0392 - PBI - ALL THREE RED GEAR UNSAFE LIGHTS REMAINED ILLUMINATED AFTER LANDING GEAR RETRACTION. THE GEAR WAS CYCLED WITH NO CHANGE, BUT THE RED GEAR LIGHTS EXTINGUISHED WITH THROTTLE MOVEMENT. MAINTENANCE TIGHTENED BOTH THE LEFT AND RIGHT AUTO THROTTLE LIMIT SWITCH SCREWS. THE SYSTEM CHECKED NORMAL PER MM 32-60-01, PAGE 203. (M)

Part: SWITCH — INOPERATIVE (LANDING GEAR)

FLT NR 0603 - CLE - ALL LANDING GEAR RED LIGHTS REMAINED ILLUMINATED AFTER TAKEOFF WITH THE GEAR HANDLE UP. WHEN THE GEAR WAS EXTENDED FOR RETURN TO CLE, ALL INDICATIONS WERE NORMAL. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LANDING GEAR LEVER SWITCH AT FAULT. THE SWITCH WAS REMOVED AND REPLACED IAW MM 32-60-00, PAGE 201. OPERATION AND INDICATIONS CHECKED GOOD DURING GEAR SWING. (M)

Part: O-RING — LEAKING (RT HYD SYST)

FLT NR 0436 - IAH - THE RT THRUST REVERSER ACCUMULATOR LIGHT ILLUMINATED WHILE AT CRUISE EN ROUTE FROM LAX TO SAT. THE LIGHT EXTINGUISHED AFTER PULLING CIRCUIT BREAKER AND TURNING OFF RIGHT SYSTEM, BUT REAPPEARED ABOUT TWO MINUTES LATER. SEVERAL MINUTES LATER THE RT HYDRAULIC SYSTEM QUANTITY WAS OBSERVED TO BE DROPPING. THE RT HYDRAULIC SYSTEM WAS TURNED OFF AND CREW ELECTED TO OVERFLY SAT FOR A LANDING AT IAH. THE AIRCRAFT LANDED SAFELY AT IAH. MAINTENANCE FOUND THE RT 'ACCUM LOW' PRESSURE SWITCH UNION O-RING LEAKING. THE O-RING WAS REPLACED. THE HYDRAULIC SYSTEM WAS SERVICED TO FULL AND LEAK CHECKS WERE NORMAL. (M)

Part: ANGLE — CRACKED (FS 1474)

INSPECTION FOUND A 1.5 INCH CRACK IN THE RADIUS OF THE VERTICAL STABILIZER TO FUSELAGE ATTACH ANGLE AT FS 1474. THE CRACK WAS STOP DRILLED. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-05. (M)

Part: BATTERY PACK — INOPERATIVE (EEL LT ROW 26)

FLT 182 - IAH - INSPECTION FOUND THE OVERHEAD EMERGENCY LIGHTS AFT OF ROW 26 INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED. (W)