N495DA

Part: BATTERY PACK — DISCHARGED (CARGO BAY)

EMERGENCY LIGHTS ON AFT CARGO DID NOT ILLUMINATE DURING TEST. REPLACED BATTERY PACK.

Part: LIGHT — INOPERATIVE (CABIN)

AFT CARGO DOOR EMERG LIGHT INOP. REPLACED BATTERY AT RACK M957, CHECKS GOOD.

Part: LIGHT — FAILED (CABIN)

EMERGENCY EXIT SIGN TOO DIM TO SEE ON EMERGENCY PWR TEST. REPLACED LIGHT ASSY.

Part: RIB — CRACKED (LT LE FLAP)

OUTBOARD RIB CRACKED. REPAIRED PER M/M 57-54-0 FIG 814.

Part: RIB — CRACKED (LT LE FLAP)

NR 11 RIB CRACKED. REPAIRED RIB PER M/M 57-54-0.

Part: RIB — CRACKED (LT LE SLAT)

NR 8 RIB CRACKED IN CORNER OF RADIUS. REPAIRED RIB PER M/M 57-54-0, FIG 814.

Part: SKIN — CRACKED (LT LE FLAP)

SKIN CRACKED AT CORNER OF T DUCT HOLE. REPAIRED SKIN PER M/M 57-54-0, FIG 802A.

Part: STIFFENER — CRACKED (LT SPAR)

FOUND DURING D1 LETTER CHECK/SHUTTLE MOD NRC 69, NR 3 L/E SLAT SPAR STIFFENER CRACKED APPROX 1.5 INCH AT INBD TRACK OUTBD STIFFENER. REPLACED SPAR STIFFENER PER M/M 57-20-21 P 813.

Part: WEB — CRACKED (BS 1323)

A .25 INCH CRACK AT LIGHTENING HOLE IN TORQUE BOX OF 48 SEC, STA 1323 LEFT SIDE. ROUTED OUT DAMAGED AREA PER M/M 53-11-0, DYE CHECK OK.

Part: SWITCH — FAILED (TE FLAPS)

RUDDER LIMITER WITH FLAPS EXT. REPLACED FLAP UP LIMIT SWITCH.

Part: TRANSMITTER — FAILED (RT TE FLAP)

OUTBOARD FLAPS LOCKED OUT AT 2 DEGREES ON FLAP EXTENSION INBOUND TO ORF ON FLT 1220/17. DIVERTED TO RIC. MTC FOUND THE RT POSITION TRANSMITTER TO BE AT FAULT. REPLACED THE RT OUTBOARD POSITION TRANSMITTER, OPS CHECK NORM.

Part: FRAME — CRACKED (PAX DOORWAY)

FOUND AT C-2 LETTER CK, LEFT AFT ENTRY WAY DOOR FRAME HAS .375 IN VISIBLE CRACK AT UPPER CUTOUT. REPAIRED PER SRM 53-10-9.

Part: WEB — CRACKED (BS 1289)

FOUND ON C2 LETTER CK, RT VERTICAL TORQUE BOX WEB CRACKED .375 INCH AT STA 1289. REPAIRED PER MM 53-11-0.

Part: ACTUATOR — FAILED (NR 2 LE FLAP)

SLC- AFTER T/O, LOST -A- SYSTEM HYDRAULIC SYSTEM. FOUND NR 2 L/E FLAP ACTUATOR LEAKING AND ACTUATOR BRACKET BROKEN. REPLACED SAME.

Part: SKIN — CRACKED (BS 681-740)

DURING SPECIAL HFEC INSPECTION, THE STRINGER 4R SKIN LAP SPLICE WAS FOUND WITH 4 CRACK INDICATIONS IN THE LOWER ROW OF FASTENERS OF THE INNER SKIN PANEL. THE ENTIRE LAP SPLICE WAS CUT (UPPER AND LOWER SKIN) AND REMOVED FOR FURTHER EVALUATION. THE CUT SKIN LAP WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND STRUCTURAL FILLER PER ER/A 366490-14, REV A.

Part: SKIN — CRACKED (BS 480-681)

DURING ACCOMPLISHMENT OF SPECIAL HFEC AND LFEC INSPECTIONS, 82 CRACK INDICATIONS WERE FOUND IN THE LOWER ROW OF THE LOWER SKIN OF STRINGER 4R LAP SPLICE BETWEEN FS 480 TO 681. THE SKIN LAP AREA WAS CUT AWAY AND REMOVED. THE SPLICE WAS RESTORED WITH AND EXTERNAL ALUMINUM DOUBLER AND STRUCTURAL FILLER PER ER/A 366485-14, REV A.

Part: SKIN — CRACKED (BS 480-681)

THE LT SIDE LWR FUSE SKIN AT S26L LAP SPLICE WAS FOUND WITH AN APPROX 19 INCH LONG CRACK BETWEEN BS 536 AND BS 564. THE CRACK IS LOCATED IN THE LWR OVERLAPPED SKIN, EXTENDING NEARLY HORIZ BETWEEN 20 FASTENERS IN THE LWR ROW OF THE TRIPLE ROW ATTACH PATTERN. REPAIRED PER ERA 366303-14.

Part: WEB — CRACKED (BS 1228)

REF A/C 495 TPA LTR CHECK C-1, VERTICAL WEB CRACKED .5 INCH LT SIDE LWR LIGHTENING HOLE STA 1228. REPAIRED PER MM 53-11-0.

Part: LIGHT — INOPERATIVE (CABIN)

LT OVERWING EMERGENCY EXIT SIGN LIGHTS ARE INOP. REPLACED LIGHT CARTRIDGE, CHECKS NORMAL.

Part: RACK — INOPERATIVE (CABIN)

LT OVERWING EMERGENCY EXIT SIGN LIGHTS INOP. REPLACED LIGHT RACK, CHECKS NORMAL.

Part: BATTERIES — DISCHARGED (CABIN)

FWD Y/C CENTER AISLE LIGHTS VERY DIM. REPLACED BATTERIES, CHECKS GOOD.

Part: LIGHTS — INOPERATIVE (CABIN)

OVERWING EMERGENCY EXIT SIGN LIGHTS INOP. REPLACED LIGHT CARTRIDGE, CHECKS NORMAL.

Part: DOOR — DAMAGED (RT MLG)

UPON LANDING, 2 MAIN TIRES BLEW CAUSING DAMAGE TO RT MAIN GEAR FLYING DOOR, RT I/B FLAP TRACK FAIRING, RT I/B TRAILING EDGE FLAP. REPLACED FLYING DOOR, REPLACED RT I/B TRAILING EDGE FLAP. REPAIRED RT I/B FLAP FAIRING.

Part: FRAME — CRACKED (BS 930)

A 3 INCH CRACK IN FS 930 FRAME AT STR 14R. TRIMMED UPPER FRAME PER SRM 53-10-4 FIG 25. DYE CHECKED PER SRM 53-10-4, NO CRACKS FOUND. FORMED REPAIR ANGLE FROM 071. 7075-0 SENT TO HEAT TREAT PER SRM 53-10-4. COMPLETED REPAIR PER SRM 53-10-4.

Part: STRINGER — CORRODED (BS 980)

STRINGER 28R WAS CUT AT STA 980 IN ORDER TO REMOVE CORROSION. THE AFT SECTION OF THE STRINGER, TO STA 1010 WAS REPLACED AND A NEW STRINGER SECTION WAS SPLICED IN. THE STRINGER WAS TOO THICK TO BE REPAIRED PER THE SRM. THE REPAIR WILL CONSIST OF SPLICING IN A NEW SECTION OF THE STRINGER WITH A NESTED HAT CHANNEL. THIS REPAIR WAS APPROVED BY FAA/ DER FORM 8110-3, DER DESIGNATION SO-889, DATED 6-20-97.

Part: FLAP — DAMAGED (LT TE MID FLAP)

NR 2 MID FLAP BN242 AFT SPAR CRACKED 32 FROM I/B END OF SPAR REPAIRED PER M/M 57-52-0 FIG 802.

Part: CHORD — CRACKED (NR 2 TE MIDFLAP)

THE NR 2 MIDFLAP BN242 WAS FOUND WITH A CRACK IN THE AFT CHORD 41 FROM OB END OF FLAP DURING SHOP INSPECTION. THIS CONDITION WAS REPAIRED BY STOP DRILLING CRACK AND INSTALLING A DOUBLER PER 727 MM 57-52-0.

Part: SKIN — SEPARATED (RT ELEVATOR)

AT HMV, THE T/E OF RT ELEV WAS FOUND TO BE SEPARATED IN THREE DIFFERENT AREAS. THIS WAS REPAIRED PER MM 55-20-0 PG 801.

Part: SKIN — CRACKED (NR 3 LE SLAT)

AT HMV, A CRACK WAS FOUND AT NR 3 SLAT AT RIB 4. THIS WAS REPAIRED PER MM 57-54-0 PG 801.

Part: SPAR WEB — CRACKED (TE MIDFLAP)

THE CENTER SPAR WEB WAS FOUND CRACKED IN TWO PLACES. THE FIRST LOCATION IS APPROX .75 INCH LONG LOCATED APPROX 25 INCHES FROM I/B END AT THE FOREFLAP CUTOUT NEAR THE UPPER I/B CORNER. THE OTHER CRACK WAS 51 INCHES FROM THE I/B END AT THE I/B CARRIAGE SUPPORT FITTING AND WAS 4 INCHES IN LENGTH. THE UPPER SKIN WAS CRACKED 1.5 INCHES ABOVE THE SPAR CHORD 52 INCHES FROM THE I/B END THROUGH TWO HOLES COMMON TO A MODIFICATION PER S/B 727-57-0160. A NEW SECTION OF SPAR WEB WAS SPLICED IN. THE SKIN WAS REPAIRED WITH AN INTERNAL DOUBLER PER DALA ER/A 357935-14AD.

Part: BATTERIES — DISCHARGED (CABIN)

ON PREFLIGHT, FOUND 1 EMERGENCY FLASHLIGHT AT 1L DOOR LED NOT FLASHING. REPLACED BATTERY AND BULB, NOW OPN NORM.

Part: ANGLE — CORRODED (AFT CARGO DOOR)

LOWER AFT T-ANGLE CORRODED BEYOND NEGLIGABLE DAMAGE LIMITS. REPLACED ANGLE PER CMM 65-56927-1.

Part: FRAME — CORRODED (AFT CARGO DOOR)

LOWER FWD FRAME SECTION CORRODED BEYOND ALLOWABLE LIMITS. REPLACED FRAME SECTION PER CMM 65-56927-1.

Part: P/D VALVE — LEAKING (NR 2 ENGINE)

DESCENDING INTO ROC, NR 2 ENG FAILED/FLAME-OUT. ATTEMPTED RESTART NOT SUCCESSFUL. PRIOR TO DESCENT NR 2 FUEL FLOW 1,000 LBS HIGHER THAN OTHERS AND IT USED 1,000 LBS MORE DURING FLT. FOUND FUEL LEAK AT P AND D VLV. REPLACED PACKING, RAN ENGINE AND LEAK CHECK GOOD.

Part: SKIN — CRACKED (FUSELAGE)

A .375 INCH CRACK AT F/O EYEBROW WINDOW LOWER FWD CORNER CUTOUT. FOUND DURING F-2 LTR CHECK TPAMM. REPAIRED PER SRM 53-30-3.

Part: DECK — CRACKED (BS 940-950)

DURING MIDVISIT, TWO 1 INCH CRACKS WERE FOUND IN THE LT MAIN LANDING GEAR WHEEL WELL PRESSURE DECK BETWEEN STATIONS 940 AND 950, BETWEEN LBL 50 AND 60. MODIFICATION INSTALLED IN ACCORDANCE WITH BOEING SERVICE BULLETIN 727-53-0149, REVISION 4.

Part: HINGES — CORRODED (ACCESS DOOR)

FROM MV2 ATL ITEM, CORROSION BEHIND HINGES ON ACCESS DOOR 3448R, LOC RT A/C COMP. REMOVED ACCESS DOOR 3448R, DAMAGE SECTION OFF ANGLE AND INSTALLED REPAIR PER MM 53-30-1 PG 807.

Part: SKIN — CRACKED (NR 4 LE SLAT)

DURING INSP, THE FOLLOWING DAMAGE WAS FOUND REQUIRING MRR'S N/R 0058 CRACKS FOUND IN NR 9 AND NR 18 RIB. REPAIRED PER M/M 57-54-0 FIG 805. N/R 0059 CRACKS FOUND IN REPAIR DOUBLERS ON NR 11 AND 12 RIBS. REPAIRED PER M/M 57-54-00. N/R 0062 CRACK FOUND IN UPPER SKIN AT FENCE MOUNTING HOLE. REPAIRED PER M/M 57-54-0 FIG 813 FOR NR 4 L/E SLAT.

Part: FRAME — CRACKED (BS 1110)

AT MID VISIT 2, FOUND FRAME CRACKED AT STA 1110 ABOVE STR 27L. REMOVED LT FIXED FLOOR PNL FROM 1070 TO 1130 FOR ACCESS. CUT OUT DAMAGE PER SRM 53-10-4 FIG 27 AND INSTALLED REPAIR PER SRM 53-10-4 FIG 27.

Part: ANGLE — CRACKED (NR 4 LE SLAT)

CRACK FOUND IN LWR AFT ATTACH ANGLE. REPAIRED PER M/M 57-54-00 FOR NR 4 L/E SLAT.

Part: MOUNT BOLTS — LOOSE (NR 2 SPOILER)

NR 2 SPOILER POWER PACK BOTTOM MOUNT BOLTS ARE LOOSE. REMOVED SPOILER ACTUATOR ATTACH FITTING. REMOVED AND REPLACED ANGLE PER MM 57-42-0 PG 804. INSTALLED POWER PACK, ACTUATOR AND MOUNT FITTING.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

RT AFT OVER DOOR EMERGENCY LIGHT OUT. REPLACED M1093 RACK AND OPERATIONAL CHECKS GOOD.

Part: RIBS — CRACKED (NR 7 LE FLAP)

DURING SHOP INSPECTION, NR 7 L/E SLAT WAS FOUND WITH NR 2 L/E RIB CRACKED IN LOWER AFT CORNER. REPAIRED PER MM 57-54-0 FIG 814.

Part: FRAME — CRACKED (FS 950)

FORWARD FRAME OF C-2 CARGO OPENING FOUND CRACKED. REPAIRED PER DL ERA 302087-14AD.

Part: SLAT — CRACKED (NR 8 LE SLAT)

FOUND DURING F-1 LETTER CHECK - .75 INCH CRACK BELOW NB 8 SLAT O/B STOP PAD. REPAIRED PER MM 75-54-0.

Part: SKIN — CRACKED (BS 1223)

FOUND DURING F-1 LETTER CHECK - LWR LT TORQUE BOX SKIN CRACKED .1250 INCH AT LWR FWD LIGHTNING HOLE STA 1223, LWR RT TORQUE BOX SKIN CRACKED .3750 INCH AT LWR FWD LIGHTNING HOLE STA 1223. REPAIRED PER MM 53-11-0.

Part: STIFFENER — CRACKED (RT WING)

FOUND DURING F-1 LETTER CHECK - L/E WING SPAR STIFFENER CRACKED AT NR 3 SLAT O/B TRACK O/B LEG. REPLACED WING SPAR STIFFENER PER M/M 57-20-21.

Part: STIFFENER — CRACKED (RT WING)

FOUND DURING F-1 LETTER CHECK - I/B L/E SPAR STIFFENER CRACKED AT NR 5 SLAT TRACK. REPLACED WING SPAR STIFFENER PER M/M 57-20-21, PG 813.

Part: SKIN — CRACKED (NR 5 LE FLAP)

ON WALK-AROUND FOUND CRACKS IN NR 5 KRUGER FLAP. CRACKS WERE REPAIRED PER SRM 57-50-3.

Part: FUEL PUMP — FAILED (NR 1 ENGINE)

ON TAKOFF NR 1 ENGINE FLAMED OUT. RETURNED PHX LANDED WITHOUT INCIDENT. REPLACED FUEL CONTROL AND PUMP. SHOP INSPECTION FOUND FUEL PUMP DRIVE SHAFT SHEARED.