N496DA

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 72,692 hrs · 58,006 cycles

LT AFT BODY FAIRING EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK PER M/M. OPS CHK NML.

Part: SPAR — CRACKED (WING BOX) · airframe 72,687 hrs · 58,001 cycles

THE WING CENTER SECTION REAR SPAR WEB WAS FOUND WITH 2 SMALL .25 INCH CRACKS JUST BELOW THE UPPER SPAR CAP. THE CRACKS ARE TYPICAL OF BAC S/B 727-57A0182 AND AD 97-25-15 AND WERE LOCATED AT RBL 5 AND LBL 15. THE CRACKS WERE ROUTED OUT OF THE WEB AND REPAIRED WITH AN ALUMINUM DOUBLER AND STRUCTURAL FILLER PER ER/A 377559-14AD.

Part: BATTERY — INOPERATIVE (CABIN)

AISLE EMERGENCY LIGHT OUT AT OVERWING EXIT. REPLACED BATTERIES.

Part: ANGLE — CRACKED (NR 2 SPOILER)

FOUND ON C2 LETTER CK, CRACK AT LOWER BOLT HOLE OF NR 2 SPOILER O/B SPAR ATTACH ANGLE. REPAIRED PER MM 57-42-0.

Part: ANGLE — WORN (NR 2 ENGINE COWL)

COWL STRIKER ANGLE WORN LOWER FWD EDGE OF NR 2 ENGINE CUTOUT 5:30 POSITION. REPAIRED PER M/M 53-11-0 PAGE 801.

Part: SKIN — CRACKED (BS 420-440)

INTERNAL HFEC INSPECTION OF THE STRINGER 4L SKIN LAP SPLICE BETWEEN FS 360 AND 480 REVEALED A SINGLE CRACK IN THE LOWER FASTENER ROW OF THE LOWER SKIN BETWEEN FS 420 AND 440. THE CRACK WAS ROUTED OUT OF THE SKIN LAP AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER B727 SRM 53-30-3, FIG 5 AND ER/A 367400-14AD.

Part: SKIN — CRACKED (BS 360-380)

INTERNAL HFEC INSPECTION OF THE STRINGER 4L SKIN LAP SPLICE BETWEEN FS 360 AND 480 INDICATED A SINGLE CRACK IN THE LOWER FASTENER ROW OF THE LOWER SKIN BETWEEN FS 360 AND 380. THE CRACK WAS ROUTED OUT OF THE SKIN LAP AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER B727 SRM 53-30-3, FIG 5 AND ER/A 367401-14AD.

Part: FRAME — CRACKED (BS 620)

STA 620 FRAME UPPER FLANGE AT RBL 8 HAS CRACK IN RADIUS. CRACK TRIMMED OUT AND REPAIR DOUBLER INSTALLED PER ERA 332727-14. ACTION TAKEN, ERA 332727-14.

Part: SKIN — CRACKED (BS 481-681)

DURING INSP PER SI 4-74176-12 ON S4R, LAP JOINT CRACK INDICATIONS WERE NOTED FROM BS 481 TO BS 681 APPROX 19 CRACK INDICATIONS WERE NOTED BY HFEC INSP. LAP JOINT CUT OUT AND REPAIRED PER ERA 332726-14.

Part: RIB — CRACKED (BS 760)

MULTIPLE CRACKS FOUND IN THE WING RIB UPPER CHORD AT BS 760 AT R/LBL 70.85 DURING INSPECTIONS PER SI 4-58560-12AD. ALL CRACKS FOUND WERE TYPICAL OF PER SB727-57-0112, R5. ALSO, TOOLING DAMAGE WAS DONE DURING REPAIR INSTALLATION. REPAIRED PER ERA 332730-14AD.

Part: SPRING — BROKEN (RUDDER)

IN-FLT RUDDERS BECAME SUPER SENSITIVE, LITTLE OR NO PRESSURE ON RUDDER PEDALS. A/C WANTED TO ROLL LT WITH UPPER 'B' OFF. A/C RESPONSE WAS CLOSE TO NORMAL. FOUND LT SPRING ON RUDDER FEEL/CENTERING UNIT BROKEN.

Part: BRACKET — CRACKED (NR 1 LE SLAT)

FOUND ON C-1 LETTER CK, NR 1 SLAT I/B ACTUATOR ATTACH BRACKET CRACKED. REPAIRED PER MM 57-20-21.

Part: FRAME — CRACKED (PAX DOORWAY)

A .5 INCH VISIBLE CRACK AT AFT ENTRY DOOR CUTOUT LT FRAME FWD END APPROX 6 BELOW UPPER STOP CASTING. REPAIRED PER SRM 53-10-9 FIG 11.

Part: FIRE LOOP — FAILED (NR 2 ENGINE)

ENG NR 2 FIRE WARNING CAME ON DURING CLIMB-OUT SHORTLY AFTER T/O, LIGHT STAYED ON AFTER GOING OUT INITIALLY. FOLLOWING THROTTLE BEING REDUCED TO IDLE. SHUT DOWN ENG. BOTH BOTTLES DISCHARGED. REPLACED FIREWALL LOOP, CKS OK. NO FIRE.

Part: BATTERY PACK — DISCHARGED (CABIN)

AFT AIRSTAIR EMER LIGHT INOP. REPLACED BATT PACK AND LIGHT RACK, OPS OK.

Part: STIFFENER — CRACKED (NR 6 LE FLAP)

FOUND DURING B-1 LETTER CHECK, INBD VERTICAL STIFFENER CRACKED NR 6 SLAT O/B TRACK BOX. REPAIRED PER M/M 57-20-21.

Part: BRACKET — CRACKED (NR 8 LE SLAT ACT)

FOUND DURING B-1 LETTER CHECK, 2 IN VISIBLE CRACK NR 8 SLAT ACTUATOR ATTACH BRACKET. REPAIRED PER M/M 57-20-21.

Part: ANGLE — CRACKED (NR 8 LE SLAT)

FOUND DURING B-1 LETTER CHECK, .25 IN CRACK NR 8 SLAT COVE SKIN ATTACH ANGLE BELOW O/B STOP PAD. REPAIRED PER M/M 57-54-0.

Part: MEGAPHONE — INOPERATIVE (CABIN)

FIRST CLASS MEGAPHONE INOP. REPLACED MEGAPHONE.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

EMERG EXIT SIGN LIGHTS DON'T ILLUMINATE OVER LT WING EXITS IN TEST. REPLACED PWR SUPPLY RACK AND BATTERY PACK.

Part: BULKHEAD WEB — CRACKED (BS 1183)

THE B.S. 1183 BULKHEAD WEB WAS FOUND TO BE CRACKED AT RBL 24. THE CRACK WAS .25 INCH LONG EMANATING FROM A FASTENER HOLE AT WL 178. THE CRACK LOCATION IS OUTSIDE OF THE INSPECTION AREA SPECIFIED BY BACO S/B 727-53-171, REV. 2. A REPAIR DOUBLER WAS INSTALLED PER B727 SRM 51-10-01, NR 06.

Part: WINDOW POST — CRACKED (CABIN)

THE F-N WINDOW POST ON THE RT SIDE OF THE AIRCRAFT WAS FOUND CRACKED DURING A X-RAY INSPECTION PER SI 4-35207-12AD (OPN 8706). THE CRACK IS LOCATED JUST ABOVE THE FIRST ROW OF FASTENERS ABOVE THE LOWER SKIN SPLICE. REV A - UPON NDT INSPECTION, THE CRACK LOCATION WAS DETERMINED TO BE JUST ABOVE THE RADIUS OF THE WINDOW POST, GOING THROUGH THE DOUBLER ONLY.

Part: BATTERY PACK — DISCHARGED (CABIN)

RIGHT AFT OVERWING EMERGENCY EXIT LIGHT INOP. REPLACED BATTERY PACK AND BATTERY RACK FOR RIGHT AFT OVERWING EMERGENCY EXIT LIGHT, LIGHT OPERATES NORMALLY.

Part: STIFFENER — CRACKED (NR 3 SLAT)

A 1.5 INCH CRACK WING FRONT SPAR VERTICAL STIFFENER AT NR 3 SLAT INBD TRACK CUTOUT. REPLACED SPAR STIFFENER PER M/M 57-20-21.

Part: WEB — CRACKED (BS 1223)

ONE CRACK 48 SECTION TORQUE BOX WEB AT UPPER EDGE STA 1223 LT. REPAIRED PER M/M 53-11-0.

Part: SWITCH — DEFECTIVE (NR 2 ENGINE)

WITH NR 1 AND NR 2 ENGINES RUNNING, STARTED NR 3 ENG AND THEN NR 2 FLAMED OUT. RESET FUEL SHUTOFF VALVE CIRCUIT BREAKER AND STARTED ENG, CONTRACT MTC CKD FUEL S/O VLV OPERATION. CKD ENG FOR FUEL LEAKS. CKD INTAKE/EXHAUST. ALL OK. STARTED ENG SEVERAL TIMES, ALL WAS NORMAL. SUBSEQUENT OCCURRENCE, MTC FOUND DEFECTIVE START LEVER SWITCH. REPLACED SWITCH OPERATION NORMAL.

Part: DNLOCK SWITCH — FAILED (NLG)

ON GEAR EXTENSION RECEIVED RED NOSE GEAR LIGHT, VISUALLY VERIFIED DOWN AND LOCKED. REPLACED NOSE GEAR DOWNLOCK SWITCH AND NOSE GEAR POSITION SWITCH. ALSO, AS PRECAUTION REPLACED LANDING GEAR ACCESORY UNIT AND OPERATION NORMAL.

Part: STRINGER — CRACKED (WS 656.5)

THE VENT STRINGER 13 ON THE LT WING WAS FOUND WITH A CRACK IN THE STRINGER TO RIB ATTACH TAB AT WING STATION 656.5. DUE TO THE EXTENT OF THE CRACK, THE STOP DRILL REPAIR CALLED OUT IN EO 4-60350-3AD COULD NOT BE ACCOMPLISHED. THE DAMAGED TAB WAS REMOVED AND A FILLER INSTALLED PER FAA/DER FORM 8110-3, 12-21-95 DL ERA 302915-14AD.

Part: SKIN — CRACKED (SERV DOOR CUTOUT)

THE FUSELAGE SKIN AT THE RT AFT SERVICE DOOR CUTOUT, LOWER AFT CORNER WAS CUT OUT TO REMOVE DAMAGE AROUND EXISTING NUTPLATE HOLE. THE RESULTANT CUT OUT IS APPROX 2.3 UP/DOWN AND 2.1 FWD/AFT. THE CUT OUT IS THROUGH THE SKIN AND BONDED DOUBLER ONLY. INSTALLED A REPAIR DOUBLER AND TRIPLER TO RESTORE THE INTEGRITY OF THE LOWER AFT CORNER OF THE RT AFT SERVICE DOOR CUTOUT. THIS WAS REPAIRED PER FAA/DER FORM 8110-3, 12-22-95 DL ERA 302894-14.

Part: FRAMES — CRACKED (FS 784)

THE LT FS 784 OVERWING EXIT FRAME WAS FOUND WITH A CRACK 1.1 INCH LONG. IT BEGAN AT A FASTENER HOLE ON THE INBD FLANGE AT WL 215 AND RAN HORIZONTALLY FWD AND THROUGH THE BEND RADIUS JUST INTO THE WEB. THIS CRACK IS OUTSIDE THE TYPICAL CRACK AREA AS DEFINED IN S/B 727-53-0197 REV 2. ALSO, A 1 INCH CRACK WAS FOUND ON THE LT FRAME OUTBD FLANGE RADIUS JUST ABOVE THE LOWER END OF THE PART. INSTALLED A MODIFIED REPAIR BASED ON THE 727-53-0197 REV 2 SERVICE BULLETIN PER FAA LETTER 95-120S-1456, DL ERA 302852-14AD.

Part: FRAME — OVERSIZED HOLES (FS 761)

DURING ACCOMPLISHMENT OF EO4-61904-3AD, SEVERAL HOLES IN THE INB'D FRAME FLANGE AT FS 760.95 LT AND RT WERE OVERSIZED BEYOND LIMITS. THE OVERSIZED HOLES WERE REWORKED AND OVERSIZED FASTENERS WERE INSTALLED PER BACO TWX DAL-ATL-95-1340RR DTD 11 DEC 95, DL ERA 302845-14AD.

Part: STRINGER — CRACKED (WS 686.50)

FROM ATL HMV: REF OPN 8602AD HFEC INSP. RT WING OUTER UPPER STRINGER TO RIB INSP. CRACK IND. W.S. 686.50 AFT VENT BOX FWD TAB. CORRECTION: STOP DRILLED CRACK AND INSTALLED REPAIR PER MM 57-13-0, FIG 804.

Part: TE SKIN — SEPARATING (ELEVATOR)

AT HMV, TRAILING EDGE OF LEFT ELEVATOR SEPARATED IN SEVERAL PLACES. REPAIRED PER MM 55-20-0 PG 801.

Part: SKIN — CORRODED (FS 680-720)

DURING INSPECTION, CORROSION WAS FOUND IN SCATTERED LOCATIONS FROM STA 680 TO 720, BETWEEN S-26L AND 26R. ALSO, THERE WERE THREE EXISTING REPAIR DOUBLERS ON THE LOWER SKIN IN THE SAME AREA. IN ACCORDANCE WITH BAC/O S/B 727-53A203, RV 2, THE EXISTING EXTERNAL REPAIR DOUBLER AND THE DAMAGED SECTIONS OF SKIN WERE REPAIRED WITH A SKIN SPLICE, PER DL ERA 302834-14.

Part: FLOORBEAM — CORRODED (FS 344)

AT HMV, CORROSION ON FS 344 FLOORBEAM UPPER CAP LBL 35R BL 25 C53-224-01.05. REPAIRED PER SRM 53-10-8 FIG 10.

Part: BRACKET — CRACKED (NR 1 LE FLAP)

BRACKET CRACKED: NR 1 LE FLAP ACTUATOR INBOARD BRACKET ON FRONT SPAR IS CRACKED IN LOWER FORWARD RADIUS. REMOVED BRACKET. STOP DRILLED CRACK AND INSTALLED DOUBLER REPAIR PER MM 57-20-21, PG 811.

Part: STRINGER — DAMAGED (BS 1000)

FROM ATL/HMV - STR 29L HAS TOOLING DAMAGE AT STA 1000. CORRECTION: FORMED REPAIR DOUBLER AND BEGAN DRILLING DOUBLER. ROUTED OUT DAMAGE, FABRICATED FILLER PER M/M 53-12-0, FIG. 806. OK TO INSTALL REPAIR. INSTALLED DOUBLER PER M/M 53-12-0.

Part: INLET SKIN — DAMAGED (NR 2 ENGINE)

NR 2 ENGINE INLET EXT SKIN RIGHT SIDE TEMPORARY REPAIR DOUBLER AT LWR AFT CUTOUT FOR PANEL 9516. MANUFACTURED NEW DOUBLER PER M/M 54-30-0. INSTALLED REPAIR PER M/M 54-30-0.

Part: ANGLE — DAMAGED (NR 2 ENGINE)

UPON HMV, FOUND NR 2 ENG PYLON CIRCUMFERENTIAL ANGLE FOR MOUNTING SURFACE OF FWD COWL HAS TEMPORARY REPAIR INSTALLED. FABRICATED AND INSTALLED NEW ANGLE PER MM 53-11-0.

Part: INLET SKIN — DAMAGED (NR 2 ENGINE)

TIME LIMITED REPAIR INSTALLED AT NR 2 ENGINE INLET DUCT HOUSING RT SKIN AT LOWER AFT CORNER OF ACCESS PLATE 9516 CUTOUT REF NR 86 PER M/M 54-30-0 PG 802. REPAIRED PER M/M 54-30-0 REF NR 861.

Part: DOOR — CRACKED (R 1 DOOR)

A FIVE INCH CRACK WAS FOUND IN THE R-1 DOOR. THE CRACK EXTENDED FROM THE UPPER AFT CORNER DOWN THE AFT FRAME. REPAIR INCLUDED DOOR REPLACEMENT.

Part: SKIN — CRACKED (R 1 DOOR.)

UPON SHOP INSPECTION, FOUND OUTER SKIN AND FRAME CRACKED AT UPPER FORWARD CORNER. REPAIRED SKIN PER SRM 52-00-3, FIG 4 AND REPAIRED FRAME PER MM 52-12-0, FIG 805, FOR R-1 SERVICE DOOR.

Part: ANGLE — CRACKED (NR 7 LE SLAT)

NR 7 SLAT COVE SKIN ANGLE DOUBLER CRACKED AT I/B STOP PAD. FOUND DURING F-1 LTR CK TPAMM. REPAIRED PER MM 57-54-0.

Part: ANGLE — CRACKED (NR 7 LE SLAT)

NR 7 SLAT COVE SKIN ANGLE CRACKED UNDER TAI DUCT. FOUND DURING F-1 LTR CK TPAMM. REPAIRED PER MM 57-54-0.

Part: FAN — SHORTED (AC COMP)

DURING CRUISE, HAD ELECTRICAL BURNING ODOR IN CABIN AND FLIGHT DECK. ODOR STOPPED AFTER SECURING GASPER FAN. GASPER FAN WAS FOUND SHORTED. REPLACED FAN, OPERATION NORMAL.

Part: SKIN — WORN (LT AILERON)

DURING SHOP INSPECTION, LEFT WING AILERON WAS FOUND WITH DAMAGE TO UPPER SKIN. SPLICED IN NEW SECTION OF SKIN PER SRM 57-50-1.

Part: SKIN — WORN (LT AILERON)

DURING INSPECTION, LEFT WING AILERON WAS FOUND WITH WEAR DAMAGE TO THE LOWER SKIN. REPAIRED PER SRM 57-51-0.

Part: FITTING — CORRODED (NR 3 MID FLAP)

NR 3 MID FLAP I/B CARRIAGE FITTING UPPER THRUST BEARING RETAINER BOLT AND HOLES HAVE CORROSION. FOUND AT SHOP INSPECTION. REAM HOLES TO .312 AND INSTALLED BUSHING.

Part: BEARING MOUNT — CORRODED (L/H MLG)

LT MLG FWD TRUNNION BEARING MOUNT CORRODED ON INBD FACES AND ALL FOUR BORES.

Part: SKIN — DAMAGED (NR 1 FORE FLAP)

DURING SHOP INSPECTION THE LEFT WING NR 1 FORE FLAP WAS FOUND WITH THE LEADING EDGE SKIN DAMAGED AT 7 INCHES TO 12 INCHES FROM THE INBOARD END OF FLAP. REPAIRED PER SRM 57-50-4.

Part: FOREFLAP — DAMAGED (NR 1 TE FLAP)

DURING SHOP INSP NR 1 FORE FLAP WAS FOUND WITH WEAR DAMAGE AT 108 INCHES FROM THE INBOARD END OF FLAP. REPAIRED PER SRM 57-50-4.