N498DA

Part: BATTERY PACK — DISCHARGED (CABIN)

ON MTC LAYOVER, LT OUTSIDE EMERGENCY EGRESS LIGHTING INOP. REPLACED FWD LIGHT POWER SUPPLY. REPLACED BULBS FOR MID LIGHT AND REPLACED BATTERY PACK ON AFT LIGHT, OPER NOW NORMAL.

Part: POWER SUPPLY — FAILED (ROW 2)

CABIN OVERHEAD EMERGENCY LIGHTS INOP ROW 2. REPLACED POWER SUPPLY AND BATTERY PACK.

Part: SPAR WEB — CRACKED (CENTER WING)

WING CENTER SECTION, REAR SPAR WEB, RBL 13. CRACK REPAIR. THE CENTER WING REAR SPAR WEB WAS FOUND WITH A 1.5 INCH LONG TYPICAL CRACK AT RBL 13, JUST BELOW THE UPPER SPAR CAP. THE CRACK WAS ROUTED OUT OF THE SPAR WEB AND REPAIRED WITH AN ALUMINUM DOUBLER PER ER/A 367243-14AD.

Part: SKIN — CRACKED (BS 681-740)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 681 AND 740 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED 19 CRACK INDICATIONS ALONG THE PANEL LENGTH. THE SKIN LAP SPLICE WAS CUT OUT ALONG THE PANEL LENGTH AND REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER PER ER/A 366962-14AD, REV A.

Part: SKIN — CRACKED (BS 481-681)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 481 AND 681 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED 85 CRACKS INCLUDING A 15 INCH LONG CRACK LINK UP BETWEEN FS 640 AND 660. THE ENTIRE SKIN LAP SPLICE WAS CUT OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 366960-14AD, REV A.

Part: SKIN — CRACKED (BS 440-460)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 AND 480 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED 8 CRACKS BETWEEN FS 440 AND 460. THE CRACKED AREA OF SKIN LAP SPLICE WAS CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A 366965-14AD.

Part: SKIN — CRACKED (BS 460-480)

LFEC INSPECTION OF THE STRINGER 4L SKIN LAP SPLICE BETWEEN FS 360 AND 480 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN PANEL. INTERNAL HFEC INSPECTION CONFIRMED 2 CRACKS BETWEEN FS 460 AND 480. THE CRACKS WERE ROUTED OUT AND REPAIRED PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A 366964-14AD.

Part: SKIN — CRACKED (BS 590)

LFEC INSPECTION OF THE STRINGER 26L SKIN LAP SPLICE BETWEEN FS 481 AND 681 INDICATED A CRACK IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED ONE CRACK BETWEEN FS 580 AND 600. THE CRACK WAS ROUTED OUT AND REPAIRED PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A366963-14AD.

Part: FITTING — CRACKED (VERT STAB)

FOUND ON B2 LETTER CK, LT INBD VERTICAL STAB TIE BOLT FITTING CRACKED 1 INCH AT THE FIRST FASTENER HOLE AFT OF THE TIE BOLT. REPLACED FITTING PER BOEING DRAWING 65-17509.

Part: ACCESS PANEL — CRACKED (LT ELEVATOR)

FOUND ON B2 LETTER CK, 4 INCH CRACK ON BALANCE BOARD ACCESS PANEL 9114. REPAIRED PER SRM 55-20-3.

Part: VALVE — FAILED (RT MLG)

AFTER T/O LOST ALL 'A' HYD SYS QTY AND PRESSURE. REPLACED RT MLG LOCK OPERATED SEQUENCING VALVE.

Part: ANGLE — CRACKED (NR 8 LE SLAT)

ANGLE AT NR 8 SLAT O/B UPSTOP IS CRACKED. REPAIRED PER M/M 57-54-0 PG 816.

Part: RIB — CRACKED (7 LE SLAT)

NOSE RIB AT NR 7 SLAT IS CRACKED. REPAIRED PER M/M 57-54-0 PG 819. REPAIRED UPPER CRACK PER M/M 57-54-00 PG 809.

Part: SKIN — CRACKED (R1 DOORWAY)

UPON REMOVAL OF A TIME LIMITED REPAIR ON THE UPPER HINGE CUTOUT OF THE R1 DOOR THE CRACK WAS FOUND TO HAVE LENGTHENED TO 2.75 IN THE REINFORCING STRAP/ DOUBLER WHICH IS BEYOND M/M LIMITS. THIS CRACK WAS REPAIRED WITH A DOUBLER PER ERA 362243-14.

Part: SKIN — CRACKED (NR 3 TE MIDFLAP)

COVE SKIN CRACKED 31 FROM I/B END OF FLAP, REPAIRED PER MM 57-52-0 FIG 809.

Part: FLAP — CRACKED (NR 2 TE MIDFLAP)

DOUBLER CRACKED AFT SPAR 19 AND 37S FROM I/B END. REPAIRED PER M/M 57-52-0 PG 802.

Part: STRINGER — CRACKED (WS 629)

OUTER WING UPPER STRINGER TO RIB ATTACHMENT CRACKED AT LT WING STA 629 STR 13. REMOVED FASTENERS, FILLERS, AND WASHERS, CUT ACCESS HOLE PER FIG 803. DRILLED UP REPAIR ANGLE AND RADIUS BLOCKS. REMOVED FASTENERS AT STRINGER 13, 14, 15, DRILLED UP REPAIR AT STR 13 PER M/M 57-13-0 FIG 804. INSTALLED REPAIR ANGLE AT STR 13 PER M/M 57-13-0 FIG 804. INSTALLED REPAIR AT STR NR 14.

Part: RIB — CRACKED (NR 5 SLAT)

RIB CRACKED INBD END NR 5 L/E SLAT. REPAIRED PER M/M 57-54-0 FIG 814.

Part: RIB — CRACKED (NR 6 LE SLAT)

TWO RIBS CRACKED IN NR 6 L/E SLAT. REPAIRED PER M/M 57-54-0 PG 807.

Part: FRAME — CRACKED (BS 910)

FRAME AT STA 910 LT CRACKED INSIDE LT W/W. REPAIRED PER M/M 53-11-0 PG 814.

Part: BRACKET — CRACKED (NR 5 LE FLAP ACT)

BRACKETS CRACKED THE NR 5 L/E FLAP I/B ACTUATOR BRACKET HAS PREVIOUS REPAIR STOP DRILL CRACKED BEYOND STOP DRILL. THE O/B NR 5 ACTUATOR BRACKET IS ALSO CRACKED AT LOWER RADIUS. REMOVED ACTUATOR REMOVED O/B BRACKET. STOP DRILLED CRACK. CRACK LENGTH AND REPAIR ARE WITHIN LIMITS PER MM 57-20-21 FIG 807. REPAIRED PER MM 57/20-21 FIG 807. INSTALLED ACTUATOR, LEAK CHECK GOOD.

Part: SKIN — CRACKED (R 1 DOORWAY)

R-1 DOOR UPPER HINGE CUTOUT CRACKED. REPAIRED PER ERA362243-14 REV. A.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

AFT SECTION OF TRACK LIGHTING SYS INOP. REPLACED BATTERY PACK AND RACK, CKS OK.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING TEST, CENTER EMERGENCY LIGHTS FLICKER. REPLACED POWER SUPPY, OPS CHECK NORMAL.

Part: WEB — FATIGUE (BS 1263)

THE AFT VENTRAL STAIRWAY TORQUE BOX RT VERTICAL WEB AT STA 1263 HAD A .75 INCH CRACK AT THE NR 2 ENGINE FUEL LINE CUTOUT. MADE SPLICE REPAIR PER ER/A 303593-14.

Part: SKIN — CRACKED (NR 2 INLET)

A 2 INCH CRACK IN NR 2 ENG INLET OUTER SKIN 3 FT FROM INLET LIP, 2 FT UP FROM FUSELAGE SKIN LT SIDE. REPAIRED PER M/M 54-30-0 FIG 801.

Part: RIB — CRACKED (LE SLAT)

RIB NR 18 WAS CRACKED. REPAIRED RIB PER MM 57-54-0 FIG 805.

Part: RIB — CRACKED (LE SLAT)

RIB NR 12 WAS CRACKED. REPAIRED RIB PER MM 57-54-0 FIG 805.

Part: RIB — CRACKED (LE SLAT)

RIB NR 8 WAS CRACKED. REPAIRED RIB PER MM 57-54-0 FIG 805.

Part: RIB — CRACKED (LE SLAT)

RIB NR 12 WAS CRACKED. INSTALLED REPAIR PER MM 57-54-0 FIG 805.

Part: RIB — DAMAGED (LE SLAT)

RIB NR 11 WAS CRACKED. INSTALLED RIB REPAIR PER MM 57-54-0 FIG 805.

Part: SKIN — DAMAGED (HORIZ STAB)

AT MID-VISIT, THE HORIZ STAB PANEL NR 9215 WAS FOUND TO HAVE A HOLE IN THE TOP SURFACE. THE HOLE WAS REPAIRED PER SRM 55-10-2.

Part: BLKHD STIFFENER — CRACKED (BS 1183)

A CRACK WAS FOUND EMANATING FROM THE BOTTOM OF THE LT FLANGE ON THE VERTICAL STIFFENER FS 1183 AT RBL 8. THE CRACK WAS APPROXIMATELY 0.25 INCH IN LENGTH. S/B 727-53-0175, REV 2, WHICH IS REQUIRED BY A.D. 90-06-09, CONTAINS INSPECTION, MODIFICATION, AND REPAIR INSTRUCTIONS FOR THIS AREA. THE REMAINDER OF THE MOD WILL BE ACCOMPLISHED PER E.O. 4-59275-3AD AT THE NEXT OVERHAUL.

Part: SKIN — CRACKED (R2 DOOR)

AT MID-VISIT, THE R2 DOOR UPPER HINGE ARM CUTOUT WAS FOUND TO BE CRACKED. THE DAMAGE WAS ROUTED OUT AND A DOUBLER PREPARED AND INSTALLED PER SRM 52-40-2.

Part: FRAME — CRACKED (R2 DOOR)

AT MID-VISIT, THE R2 DOOR FRAME WAS FOUND CRACKED JUST BELOW UPPER HINGE CUTOUT. THE DAMAGE WAS ROUTED OUT AND DOUBLER PREPARED AND INSTALLED PER SRM 52-40-2.

Part: DOUBLER — DAMAGED (L1 DOOR)

AT MID-VISIT, A TEMP REPAIR WAS FOUND TO BE INSTALLED ON THE TOP AFT CORNER OF THE L1 DOOR OUTER SKIN. THE DOUBLER WAS REMOVED AND REPAIR INSTALLED PER MM 52-11-01 FIG 804.

Part: ANGLE — CRACKED (RT WHEEL WELL)

FOUND DURING F-1 LETTER CHECK, .25 INCH CRACK IN RADIUS FROM UNDER BLOCK STA 910 RT MLG UPLOCK H-BRACKET FWD SUPPORT ANGLE. REPAIRED PER M/M 53-11-0 PG 834 AND 835.

Part: FRAMES — MISDRILLED (EMER EXIT)

DURING ACCOMPLISHMENT OF SI 4-61904-12AD, MAINTENANCE DISCOVERED THAT THE FRAMES AT STA 760.95 LT AND RT AND STA 783.95 LT AND RT HAVE OPEN PILOT HOLES IN THE WEB ABOVE STR 17. THE HOLES WHICH ARE ATTACH POINTS FOR INSULATION BLANKETS, HAVE BEEN INSPECTED AND FOUND CRACK FREE. THE HOLES WILL BE INSPECTED UNTIL THE MODIFICATION PER EO 4-61904-3AD IS ACCOMPLISHED ON EACH FRAME.

Part: RIB — CRACKED (NR 5 SLAT)

DURING SHOP, INSPECTION RT WING NR 5 L/E SLAT WAS FOUNED WITH RIB NR 12 CRACKED. REPAIRED PER MM 57-54-00.

Part: RIB — CRACKED (NR 5 LE FLAP)

RIB NR 18 CRACKED NEXT TO NUTPLATE. INSTALLED DOUBLER PER MM 57-54-0 FIGURE 805. DURING SHOP INSPECTION OF RT WING NR 5 L/E SLAT.

Part: WEB — CRACKED (BS 1273)

VERT WEB CRACKED .625 INCH AT UPPER FASTENER ROW STA 1273, 48 SEC TORQUE BOX. FOUND AT E-2 LTR CK.

Part: SKIN — CRACKED (VERT STAB)

A 1.25 INCH CRACK IN VERT STAB SKIN RT SIDE AT CUTOUT FOR PANEL 9501 SADDLE PLATE. FOUND DURING E-2 LR CK. REPAIRED PER SRM 55-30-3 PAMM.