N504DA

Part: TRANSMITTER — FAILED (YAW DAMPER) · airframe 77,763 hrs · 51,939 cycles

AFTER T/O RUDDER OSCILLATIONS FOLLOWED POM PROCEDURE. FOUND POSITION TRANSMITTER COIL OPEN REMOVED AND REPLACED POS XMTR PER MM ADJ/TEST OF YAW DAMP CHKS GOOD PER MM.

Part: COUPLER — INTERMITTENT (YAW DAMPER) · airframe 77,763 hrs · 51,939 cycles

ON TAKEOFF SLIGHT RUDDER OSCILLATIONS WITH HIGH WIND. AFTER TAKEOFF EXCESSIVE RUDDER MOVEMENT. FOLLOWED YAW DAMP INOP POM PROC. NO HELP. REMOVED AND REPLACED UPPER AND LOWER YAW DAMP COUPLERS PER M/M. SYSTEM TEST NORMAL.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 76,874 hrs · 51,349 cycles

STRINGER 29L WAS FOUND BADLY CORRODED BETWEEN FS 950E AND FS 980.

Part: FITTING — CORRODED (FUSELAGE) · airframe 76,874 hrs · 51,349 cycles

FOUND DURING MV4 CORROSION VISIT NRC 54 CORROSION ON STR 27R END FITTING AT STA 740, OUTBD SIDE OF STR BEHIND RAM AIR DUCT.

Part: BEAM — CRACKED (FUSELAGE) · airframe 76,570 hrs · 51,138 cycles

INSPECTION OF THE RT TORQUE BOX STRUCTURE OF VENTRAL STAIRWAY OPENING REVEALED A 3 INCH CRACK IN THE UPPER HORIZONTAL BEAM AT FS 1263. THE CRACKED PART WAS REMOVED AND A NEW PART INSTALLED PER ER/A 380894-14AD. THE CRACK IS TYPICAL OF BAC S/B 727-53-0129.

Part: STIFFENER — CRACKED (WING) · airframe 76,563 hrs · 51,135 cycles

A 2 INCH CRACK AT WING L/E FRONT SPAR STIFFENER AT NR 6 SLAT O/B TRACK-O/B STIFFENER. REPAIR PER M/M 57-20-021-8.

Part: SHAFT — SHEARED (NR 3 ENG PUMP) · airframe 75,812 hrs · 50,636 cycles

NR 3 ENG FAILED ON T/O ROLL. ABORTED AT 130 KIAS. REPLACED NR 3 ENG FUEL PUMP PER M/M. OPS CK AND LEAK CK ON IDLE RUN. ALSO TRIM ENG PER PFHB 4077 TEST Y. CK NML. RETORQUED FUEL PUMP QUAD RING PER M/M.

Part: LENS — CRACKED (SEAT 21D) · airframe 75,178 hrs · 50,267 cycles

PASS. ST 21D EMERGENCY TRACK LIGHTING FLOOR LIGHT DAMAGED CA- RPLD LENS

Part: RIB — CRACKED (NR 5 SLAT) · airframe 74,886 hrs · 50,077 cycles

FOUND ON C2 LETTER CK, NR 5 SLAT INBOARD ROD END ATTACH RIB AFT LEG CRACKED. REPAIRED PER MM 57-54-0.

Part: FRAME — CRACKED (NR 2 NACELLE) · airframe 74,886 hrs · 50,077 cycles

CHANNEL WORN/DAMAGED ALONG LWR FLANGE 5 O CLOCK TO 6 O CLOCK POSITION AT NR 2 ENG FWD COWL CUTOUT. REPAIRED PER MM 53-11-0 PG 801.

Part: RIB — CRACKED (NR 5 SLAT) · airframe 74,886 hrs · 50,077 cycles

FOUND ON C2 LETTER CK, NR 5 SLAT O/B ROD END ATTACH RIB AFT LEG CRACKED. REPAIRED PER MM 57-54-0.

Part: LIGHT — INOPERATIVE (SEATS 16 & 17) · airframe 74,491 hrs · 49,837 cycles

SEAT MOUNTED PROXIMITY LIGHTS INOP AT SEATS 16D AND 17D. RELAMPED AND REPLACED LENS AT 17D OPERATION NORMAL. FWD LIGHT AT 16D TO MCO AND PLACARD PER MEL.

Part: BATTERY PACK — INOPERATIVE (OVERWING LIGHT) · airframe 74,185 hrs · 49,637 cycles

RIGHT WING CENTER OVERWING LIGHT INOP. REMOVED AND REPLACED RIGHT WING OVERWING BATTERY CHARGER.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY LIGHT INOP AT CENTER AISLE NEAR AFT GALLEY. REMOVED AND REPLACED BATTERY PACK.

Part: LIGHT — BROKEN (R1 DOOR)

EXIT LIGHT FORWARD OF R-1 DOOR IS UNSECURED/LOOSE. REPLACED SAME.

Part: BATTERY PACK — DISCHARGED (CABIN)

F/C SEAT MOUNTED EMERGENCY LIGHTS WON'T TEST. REPLACED RACK AND BATTERY PACK, CHECKS NORMAL.

Part: START VALVE — FAILED (NR 1 ENGINE)

NR 1 START VALVE LIGHT ILLUMINATED IN FLIGHT. ENG SHUT DOWN PER PILOTS CK LIST. REPLACED START VALVE.

Part: SKIN — CRACKED (BS 481-681)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 481 & 681 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED 13 CRACKS ALONG THE PANEL LENGTH. THE SKIN LAP SPLICE WAS CUT OUT FOR THE ENTIRE PANEL AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 367051-14AD, REV B.

Part: SKIN — CRACKED (LT TE FLAP)

I/B DRIVE ROD CUTOUT IN COVE SKIN IS CRACKED AT O/B AFT CORNER. REPAIRED PER M/M 57-52-0 FIG 809, ON SHOP ORDER 643487.

Part: FRAME — CORRODED (BS 1166)

CORROSION WAS FOUND ON THE BS 1166 FRAME AT THE SKIN CLIP BETWEEN S29R AND S30. DAMAGE RESULTED IN CUTOUT IN THE LWR 2.5 OF THE FRAME AS WELL AS THE BONDED FAIL SAFE STRAP. REPAIRED PER ERA 332608-14.

Part: STRINGER — CRACKED (WS 171.5)

UPPER CHORD ON THE RT WING RIB AT WS 171.5 WAS FOUND CRACKED. THE CRACK WAS LOCATED FROM A FAST HOLE ON THE HORIZ FLANGE OF THE CHORD ANGLE UNDER STR 17. REPAIRED PER ERA 332571-14.

Part: STRINGER — CRACKED (WS 171.5)

THE UPPER CHORD ANGLE OF THE LT WING RIB AT WS 171.5 WAS FOUND CRACKED. THE CRACK WAS LOCATED PROPAGATING FROM A FAST. HOLE ON THE HORIZ FLANGE OF THE CHORD ANGLE UNDER STR 16. REPAIRED PER ERA 332570-14.

Part: TRACK — CORRODED (TE FLAP)

INB'D FLAP INB'D TRACK, CORROSION AT MLG BEAM ATTACH PAD AND HOLES: AD 90-07-05 AND 90-06-09. THE SPOT-FACE DEPTH FOR THE MLG BEAM ATTACH HOLE HAS BEEN INCREASED TO REMOVE CORROSION. AUTHORIZED INCREASE DAMAGE REMOVAL WITHOUT ANY RE-INFORCING REPAIR.

Part: FRAME — CRACKED (BS 380)

DURING INSPECTION A CRACK WAS FOUND IN THE FRAME AT BS 380 WL 280; JUST ABOVE THE R1 DOOR CUTOUT. THE CRACK IS LOCATED ON THE INBD FLANGE OF THE PART AT A FASTENER HOLE. REPAIRED PER ERA 332549-14.

Part: SPAR — CRACKED (LT TE FLAP)

AFT SPAR RAIL LWR CHORD ANGLE CRACKED 2 PLACES 19 AND 23 FROM I/B END. REPAIRED PER M/M 57-52-0 FIG 802, ON SHOP ORDER 634487.

Part: SPAR — CRACKED (LT TE FLAP)

AFT SPAR RAIL LWR CHORD ANGLE CRACKED 2 PLACES 32 AND 37 FROM I/B END. REPAIRED PER M/M 57-52-0 FIG 802, ON SHOP ORDER 634487.

Part: SPAR — CRACKED (LT TE FLAP)

AFT SPAR RAIL LWR CHORD ANGLE CRACKED 61 FROM I/B END. REPAIRED PER M/M 57-52-0 FIG 802, ON SHOP ORDER 634487.

Part: BEAM — CORRODED (LT MLG)

L MLG SUPPORT BEAM HOLES CORRODED. REAMED HOLES. NDT-BHEC BEAM HOLES. TURNED BUSHINGS. TREATED BORES, INSTALLED BUSHINGS. ROTO PEEN HOLES SURFACES AS PER ERA 332561-14. TREATED AND PAINTED AREAS PER ERA 332561-14. SEALED EDGES OF BUSHINGS PER ERA 332561-14.

Part: STRINGER — CRACKED (WS 656.5)

ITEM: OUTER WING UPPER STRINGER TO RIB WS 656.5 HAS A CRACK AT STRINGER 10 COMING FROM THE FASTENER HOLE. CRACK IS IN STRINGER. REPAIR INTO REFERENCED ON 8502AD ITEM 5. CRACK ORIGINATES IN FASTENER HOLE AND PROPAGATES TO EDGE OF STRINGER. DRILLED REPAIR DOUBLERS AND RADIUS BLOCKS AND STRINGER 10 AT WS 656.5 PER MM 57-13-0 PG 801-805. OK TO INSTALL. INSTALLED REPAIR PER MM 57-13-0 PG 801-805.

Part: BEAM — CORRODED (LT MLG)

LT MLG SUPPORT BEAM HOLES CORRODED. REAMED HOLES. BHEC INSP HOLES. TURNED AND TREATED BUSHINGS PER SRM 57-40. TREATED BORES. INSTALLED BUSHINGS. ROTO PEEN AREAS PER ERA 332561-14. TREATED AND PAINTED PER ERA 332561-14. SEALED ENDS OF BUSHINGS PER ERA 332561-14.

Part: BATTERY PACK — DISCHARGED (CABIN)

OVERWING EXIT EMERGENCY LIGHTS FAILED TO TEST DURING NR 3 SERVICE CHECK. REPLACED BATTERY PACK AND BASE, NOW CHECKS NML.

Part: BATTERY PACK — DISCHARGED (CABIN)

ON L/O CK, LIGHTED EXIT SIGNS OVER LT O/W EXIT DID NOT ILLUMINATE. REPLACED BATTERY PACK.

Part: BATTERY — DISCHARGED (CABIN)

ON L/O CK, AISLE EMERG LIGHT OVERHEAD ROW 13 DID NOT TEST. REPLACED BATTERY.

Part: BATTERY PACK — DISCHARGED (CABIN)

LEFT OVERWING EMERGENCY LIGHT INOP. REPLACED BATTERY PACK CHECKS GOOD.

Part: SKIN — CRACKED (BS 380)

A .5 INCH LONG CRACK WAS FOUND IN THE UPPER FWD CORNER OF THE R1 DOOR SKIN CUTOUT. THE CRACK WAS ROUTED OUT AND AN EXTERNAL ALUMINUM DOULBER INSTALLED PER ER/A 364704-14, REV A.

Part: WEB — CRACKED (BS 1235)

FOUND ON A2 LETTER CK, 1.25 IN CRACK LT LOWER TORQUE BOX WEB AT THE UPPER ROW OF RIVETS STA 1235. REPAIRED PER MM 53-11-0.

Part: FRAME — CUT OUT (BS 1130)

IN ORDER TO FACILITATE A REPAIR ON STRINGER S-28R, FRAME 1130 ALONG WITH ITS FAIL SAFE ANGLE WAS CUT AT APPROXIMATELY RBL 12. THE ENTIRE OUTBOARD SECTION OF THE FRAME WAS THEN REMOVED AND RETAINED FOR A LATER RE-INSTALLATION. THE DAMAGE WILL BE REPAIRED PER ER/A 304913-14 REVISION 'B'.

Part: SKIN — CORROSION (BS 950-970)

CORROSION WAS FOUND ON THE SKIN BELOW THE C2 DOOR BETWEEN STA 950F - 970 AT STR-28R. THE CORROSION WAS TRIMMED OUT LEAVING TWO CUT-OUTS MEASURING 3.6 INCHES BY 3 INCHES AND 4 INCES BY 2.6 INCHES. THE CUT-OUTS ARE 9 INCHES APART. REPAIRED PER DELTA ER/A 304894-14, REV.B.

Part: ANGLE — CRACKED (NR 3 TE MID FLAP)

FOUND THE NR 3 MID FLAP ATTACH ANGLE FOR AFT SEAL, CRACKED IN 2 PLACES, APPROX 24 IN AND 36 IN FROM THE I/B END. REPAIRED PER MM 57-52-0, PG 807, FIG 802.

Part: FUEL PUMP — SHEARED SHAFT (NR 1 ENGINE)

NR 1 ENG FAILED ON T/O, ALL INDICATIONS NORMAL. FOUND FUEL PUMP SHAFT SHEARED. REPLACED PUMP, CHECKS NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

AFT RT CABIN EMERGENCY LIGHT WILL NOT ILLUMINATE. REPLACED BATTERY PACK.

Part: ACTUATOR — FAILED (NR 8 SLAT)

AFTER TAKEOFF, AMBER LE FLAP LIGHT REMAINED ON AND NR 8 SLAT AMBER LIGHT ON S/O PNL. ON RETURN TO LAX LE FLAPS LIGHT STAYED ON, BUT ALL SLATS/FLAPS POS TEST SHOWS RETRACTED. RAN TEST USING TEST BOX 10M2425 PER M/M AND NR 8 SLAT ACTUATOR FAILED TEST. REPLACED NR 8 SLAT ACTUATOR AND OPS CK NORMAL PER M/M.

Part: PRBC — FAILED (NR 2 ENGINE)

ON TAKEOFF, GOT COMPRESSOR STALL NR 2 ENGINE. INSPECTED INLET AND EXHAUST, ALL OK. RAN ENGINE TO TAKEOFF POWER, ALL CKS NORMAL, BUT ON DECEL GOT COMPRESSOR STALL AT 80 TO 85 N2. REPLACED PRBC, RAN ENGINE PER PFHB TEST-E AND ALL CKS GOOD.

Part: RIBS — CRACKED (NR 6 LE FLAP)

DURING INSPECTION, NR 6 L/E SLAT WAS FOUND WITH RIBS NR 12, 13, 14 AND 15 CRACKED. ACCOMPLISHED REPAIRS PER MM 57-54-0.

Part: ANGLE — CRACKED (NR 6 LE FLAP)

LOWER FWD ANGLE CRACKED AT NR 13 RIB. REPAIRED PER MM 57-54-0 PG 807A. ALSO, WIND EROSION FWD OUTER SKIN. REPAIRED L/E WIND EROSION PER SRM 57-50-3 FIG 8 FOR L/E SLAT NR 6.

Part: RIB — CRACKED (LE FLAP)

REPAIRED CRACKED RIB AS PER SRM 57-54-0 FIG 814.

Part: SKIN — CORROSION (BS 480-520)

THE SKIN AND STRINGER AT FS 480 TO 520 AND STR 26R WERE FOUND CORRODED. THE SKIN CORROSION REQUIRED A 3.25 BY 2.75 CUTOUT IN THE UPPER AND LOWER SKINS OF THE STR 26R LAP JOINT. THE STRINGER CORROSION REQUIRED A CUTOUT IN THE STRINGER FROM THE EXISTING FACTORY SPLICE AT FS 480 RUNNING AFT TO FS 500 TO 520. MAINTENANCE REPORTS THE STRINGER TO BE 0.050 THICK. THE SKIN DAMAGE WILL BE REPAIRED PER THE SRM WITH A MINOR DEVIATION TO EXTEND THE FILLER TO THE STA 480 BUTT JOINT.

Part: WEB — CRACKED (RT TORQUE BOX)

FOUND ON E2 LETTER CK, .2187 INCH CRACK IN 48 SECT TORQUE BOX WEB LIGHTENING HOLE RT FWD SIDE. REPAIRED PER MM 53-11-0.

Part: WINDOW — ARCING (LT COCKPIT)

TOP LEFT CORNER OF L1 WINDOW AROUND SCREWS THERE WAS SPARKS AND SMOKE. WITH L1 WINDOW HEAT TURNED OFF THERE WAS NO SMOKE OR SPARKS. REPLACED WINDOW AND CONTROLLER.

Part: RIBS — CRACKED (NR 3 LE SLAT)

DURING SHOP INSPECTION, NR 3 L/E SLAT WAS FOUND WITH L/E SUPPORT RIBS NR 7 AND NR 10 CRACKED AT THE LOWER END AND LOWER ATTACH ANGLE CRACKED 38 INCHES FROM I/B END. REPAIRED PER MM 57-54-0.

Part: SKIN — CRACKED (MAIN ENTRY DOOR)

MAIN ENTRY DOOR OUTER SKIN IS CRACKED .125 AT RIVET, AFT UPPER CORNER. FOUND AT E-1 LTR CK. REPAIRED PER MM 52-11-01 PG 806.