N505DA

Part: ANGLE — CRACKED (LT MLG WW) · airframe 73,700 hrs · 49,797 cycles

FOUND ON B1 LETTER CK, 1.5 INCH CRACK IN STA 870 WEB VERTICAL CHORD AT I/B END OF LT WHEEL WELL. REPAIRED PER B727 DRD 53-10-9D FIG 806.

Part: ACTUATOR — LEAKING (SPOILER)

LOST B HYDRAULIC SYSTEM PRESS AND FLUID IN FLIGHT. MADE UNSCHEDULED LANDING. FOUND NUMBER 3 SPOILER ACTUATOR LEAKING. REPLACED NR 3 SPOILER ACTUATOR.

Part: WEB — DENT (VERTICAL STAB)

THE NR 4 RIB OF THE VERTICAL STABILIZER HAS A DENT IN THE WEB THAT RESULTED IN A 1 INCH DIAMETER CUTOUT. THE DAMAGE WAS FOUND AT HMV AND REPAIRED PER ERA 333924-14.

Part: RIB — CRACK (LE FLAP)

AT HMV2, FOUND NR 4 SLAT RIB (MARKED) CRACKED. FABRICATED DOUBLER PER MM 57-54-0 FIG 804. DYE CHECKED END OF CRACK PER FIG 504. CHEM TESTED PER PS 900-2-4-1 NR 2. REPAIRED RIB PER MM 57-54-0.

Part: RIB — CRACKED (LE FLAP)

AT HMV2, FOUND NR 8 SLAT RIB'S CRACKED, NR 4, 14 (MARKED). REMOVED I/B SLTRK AND STOP DRILLED CRACK PER MM 57-40-0 FIG 809, FABRICATED REPAIR PARTS PER MM 57-54-00 FIG 809.

Part: RIB — CRACKED (LE FLAP)

AT HMV2 FOUND NR 3 SLAT RIBS CRACKED. REPAIR AT RIB MARKED NR 3, RIB MKD NR 10, RIB MKD NR 17. CORROSION - DYE CKD AS PER PS 900-6-3 AND NO CRACKS. FABRICATED DOUBLER PER MM 57-54-0 PG 807. INSTALLED DOUBLER PER SAME, DYE CHECKED RIB NR 17 PER PS 900-6-3 STOP DRILLED CRACK, FABD DOUBLER PER MM 57-54-00 PG 813, CHEM TREAT PER PS 900-2-4-1 NR 02, FABD SHIMS PER MM 57-54-00 PG 813A, PAIT/TREAT, AND INSTALLED PER MM 57-54-00.

Part: SKIN — TORN (ELEVATOR)

AT HMV2 ELEVATOR T/E CHIPPED/TORN LT ELEVATOR EXTREME O/B END. BUSHED AREA AND FOUND TO BE WITHIN LIMITS PER SRM 55-20-1 FIG 161, INSTALLED FASTENERS.

Part: SKIN — DELAMINATED (LT ELEVATOR)

AT HMV2, FOUND LT ELEVATOR T/E DELAMINATED I/B AND O/B OF TAB. REPAIRED PER MM 55-20-0 PG 801 NR 2.

Part: SKIN — DISBONDED (RT ELEVATOR)

AT HMV2, FOUND RT ELEV T/E DISBONDED BETWEEN UPPER AND LWR SKIN SEVERAL AREA'S FROM I/B TO O/B AREA. REPAIRED PER MM 55-20-0 PG 801 NR 2.

Part: SKIN — DISBONDED (RT ELEVATOR)

AT HMV2, FOUND RT ELEVATOR I/B TRAILING EDGE DISBONDED. REPAIRED PER MM 55-20-0 PG 801 NR 2.

Part: STRINGER — CRACKED (VERTICAL STAB)

AT HMV2, FOUND STRINGER 5R CRACKED AT RIB NR 9 VERT STAB INTERIOR. DYE CHECKED AND FOUND CRACK EXTENDS TO EDGE OF MATERIAL. CHEM TREATED PER PS 900-2-4-1 NR 2, FABRICATED REPAIR PER MM 55-30-0 PG 803, AND INSTALLED PER SAME.

Part: SOCKET — FAILED (SEAT 10)

PILOT REPORT, FIRST CLASS SECTION EMERGENCY TRACK LIGHTING INOP. FOUND BAD SOCKET AT 10DEF REPLACED FUSE AT FWD POWER SUPPLY PACK. SYSTEM OPS NORMAL DEFERED SOCKET AT 10DEF PER MEL 33-00-17B SOCKET DISCONECTED AND WIRE HARNESS SECURED. REPLACED SEAT MOUNTED LIGHT ASSY.

Part: FRAME — CRACKED (CARGO DOORWAY)

FUSELAGE C1 DOOR SURROUND FRAME, FS 560, WEB CRACK REPAIR. A INCH 2 CRACK WAS FOUND IN THE WEB OF THE FORWARD JAMB FRAME OF THE C1 DOOR OPENING. THE CRACK WAS LOCATED AT THE 2ND FROM THE TOP DOOR STOP. THE CRACK WAS ROUTED OUT AND REPAIRED WITH A DOUBLER PER ER/A 368008-14.

Part: WEB — CRACKED (BS 1223)

1 INCH CRACK AT RIGHT TORQUE BOX VERTICAL WEB AT UPPER RIVET ROW STA 1223 (48 SEC). REPAIR PER MM 53-11-0.

Part: ACCESSORY UNIT — INOPERATIVE (RT MLG)

GEAR EXTENSION BUF UNSAFE GEAR WARNING WITH RT MAIN GEAR RED INDICATOR LIGHT ON WITHOUT THE GREEN DOWN AND SAFE LIGHT ON. REPLACED LANDING GEAR ACCESSORY UNIT.

Part: SKIN — CRACKED (BS 680-740)

INTERNAL HFEC INSPECTION OF THE LOWER FASTENER ROW OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 680 AND 740 INDICATED 8 CRACKS ALONG THE PANEL LENGTH. THE SKIN LAP WAS CUT OUT ALONG THE PANEL LENGTH AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 367500-14AD.

Part: SKIN — CRACKED (BS 440-460)

INTERNAL HFEC INSPECTION OF THE LOWER FASTENER ROW OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 AND 480 INDICATED 2 CRACKS BETWEEN FS 440 AND 460. THE CRACKS WERE CUT OUT OF THE SKIN LAP AND REPAIRED WITH AN ALUMINUM DOUBLER PER B727 SRM 53-30-3, FIG 5 AND ER/A 367499-14AD.

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 47 CRACKS ALONG THE PANEL LENGTH. THE ENTIRE SKIN LAP WAS CUT OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 367496-14AD.

Part: BATTERY — DISCHARGED (CABIN)

RT OVERWING EMERGENCY LIGHT INOP. REPLACED BATTERY AT M957, OPS CHECKS GOOD.

Part: FRAME — DAMAGED (BS 783.95)

FUSELAGE RT OVERWING EXIT CUTOUT FRAME FS 783.95, REPAIR FOR DAMAGED HOLES. UPON INSPECTION FOR TYPICAL CRACKS IN THE INNER CHORD OF THEFS 783.95 OVERWING EXIT CUTOUT FRAME, SEVERAL HOLES WERE FOUND MISDRILLED. THE PREVENTATIVE MODIFICATION PER BAC S/B 727-53-0197 WAS INSTALLED WITH CHANGES TO ACCOUNT FOR DISCREPANT CONDITIONS. THE REPAIR WAS DOCUMENTED PER ER/A 366645-14AD.

Part: FRAME — CRACKED (BS 761)

FUSELAGE RT OVERWING EXIT FRAME, FS 761, FRAME CHORD REPAIR. THE FS 761 FRAME FOR THE RT OVERWING EXIT CUTOUT WAS FOUND WITH A TYPICAL CRACK IN THE INNER CHORD. THE FRAME WAS REPAIRED/MODIFIED PER BAC S/B 727-53-0197 WITH MODIFICATIONS REQUIRED DUE TO EXISTING AUX. FUEL TANK MODIFICATION PARTS AND OTHER DISCREPANCIES. THE REPAIR WAS DOCUMENTED PER ER/A 366652-14AD.

Part: FRAME — DAMAGED (BS 784)

FUSELAGE LT OVERWING EXIT CUTOUT FRAME FS 784, REPAIR FOR DISCREPANT FASTENER HOLES. WHILE ACCOMPLISHING INSPECTIONS OF THE LT OVERWING EXIT CUTOUT FRAME AT FS 784, SEVERAL FASTENER HOLES WERE FOUND OVERSIZED DAMAGED. THE MODIFICATION PER BAC S/B 727-53-0197 WAS INSTALLED WITH FASTENER DEVIATIONS TO CLEAR UP THE DAMAGE. THE REPAIR WAS DOCUMENTED PER ER/A 366646-14AD, REV A.

Part: SUPPORT — CORRODED (LT WING)

WING MLG SUPPORT BEAM, LT AFT ATTACH LUG, REPAIR FOR CORRODED LUG. THE AFT ATTACH LUG OF THE LT MLG SUPPORT BEAM WAS FOUND CORRODED. THE CORROSION WAS REMOVED BY OVERSIZING THE LUG HOLE BORE AND SPOTFACING THE SURFACE OF THE LUG. THE LUG WAS REPAIRED BY INSTALLING AN OVERSIZE FLANGED BUSHING. THE REPAIR WAS ACCOMPLISHED PER ER/A 366623-14.

Part: SKIN — GOUGED (BS 500)

A GOUGE WAS FOUND IN THE SKIN PANEL AT FS 500 BELOW THE STRINGER 26L LAP SPLICE. THE DAMAGE WAS TRIMMED OUT OF THE SKIN WITHOUT DAMAGING THE EXISTING LAP. THE CUTOUT WAS REPAIRED PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A 366548-14.

Part: SKIN — CRACKED (NR 7 LE SLAT)

NR 7 SLAT LOWER COVE SKIN ATTACH ANGLE CRACKED AT I/B STOP PAD. REPAIRED PER MM 57-54-0.

Part: LINE — CRACKED (HYD SVC BAY)

CREW LOST B HYDRAULICS PRESSURE AND QUANTITY ON ARRIVAL TO PHL. FOUND BROKEN HYDRAULIC LINE IN HYD SERVICE BAY REF IPC-29- 14-00-06 ITEM 160. MPN-65-17849-61M. DPN-294201161. INSTALLED TEMP HYDRAULIC LINE, SERVICED HYD SYS TO FULL AND LEAK CHKS NORMAL. FWD TEMP LINE INSTALLATION TO MCO.

Part: STOP — LOOSE (NR 7 LE SLAT)

WING NR 7 SLAT, DOWNSTOP FITTING, REPAIR FOR LOOSE BOLT. THE NR 7 SLAT DOWNSTOP FITTINGS WERE FOUND WITH LOOSE BOLTS. DURING INSPECTIONS PER S/B 727-57-171. THE STOP FITTINGS FOR THE SLAT WERE MODIFIED PER THE REQUIREMENTS OF THE S/B. THE MODIFICATION OF THE NR 7 SLAT STOPS WAS DOCUMENTED PER ER/A 366172-14AD.

Part: BATTERY PACK — DISCHARGED (CARGO DOOR)

RIGHT AFT EMERGECY OVERWING LIGHTS ON AFT CARGO DOOR INOP. REPLACED BATTERY PACK.

Part: WEB — CRACKED (BS 1228)

.1875 IN CRACK ON VERTICAL WEB LIGHTNING HOLE STA 1228 LT SIDE. ROUTE CRACK PER M/M 53-11-0.

Part: MOUNT — CRACKED (NR 1 LE FLAP ACT)

NR 1 LE FLAP ACTUATOR MOUNT CRACKED UPPER O/B CORNER. REPAIR PER M/M 57-20-21.

Part: SKIN — DELAMINATED (RT ELEVATOR)

5 IN LENGTH DELAMINATION ON RT ELEVATOR TRAILING EDGE I/B END. REPAIR PER M/M 55-20-0.

Part: CASTING — CRACKED (NR 4 SPOILER)

0/B ACTUATOR ATTACH CASTING BROKEN AT LOWER MOUNT BOLT NR 4 SPOILER. REPLACED CASTING PER M/M 57-42-0.

Part: AIR DISTRIBUTION — SMOKE (CABIN)

AIR RETURN SMOKE IN AFT CABIN DURNING T/O CREW DUMPED FUEL TO 163,500 NORMAL LANDING AND STOP. RAN PACKS WITH APU AIR ALL PACKS OPERATED NORMAL. FLT CREW TAXI AND AND RAN ENGINES AT RUNUP AREA WITH MECHANIC, CHECKING PACKS WITH ENGINE AIR AT IDLE AND POWER. ALL PACKS OPERATED NORMAL, NO SMOKE IN CABIN. PERFORMED OVERWEIGHT LANDING CHECK PHASE 1, NO DAMAGE FOUND RETUNED A/C BACK TO SERVICE.

Part: LIGHT — INOPERATIVE (CABIN)

L-2 DOOR OVERHEAD EMERGENCY LIGHT INOP. REPLACED LIGHT ASSY, CKS GOOD.

Part: SPAR — CRACKED (RT ELEVATOR)

THE REAR SPAR OF THE RT ELEVATOR IS CRACKED ON THE LOWER I/B SIDE OF THE SECOND FROM THE I/B HINGE FITTING. THE CRACK IS APPROXIMATELY .25 LONG. THIS CRACK LENGTH IS WITHIN THE .250 STOP DRILL LIMITS OF BAC S/B 727-55-0089. THE CRACK WILL BE STOP-DRILLED UNTIL REPAIR/MODIFICATION PER DAL EO 4-70183-12AD.

Part: BATTERY PACK — DISCHARGED (CABIN)

AFT FLOOR EMERGENCY LIGHTS INOP. REPLACED BATTERY RACK M9027, ALL OPS NORMAL.

Part: REAR SPAR — CRACKED (LT ELEVATOR)

THE REAR SPAR OF THE RT ELEVATOR IS CRACKED ON THE LOWER INBD SIDE OF THE SECOND FROM INBD HINGE FITTING. THE CRACK IS APPROX .25 INCH LONG. THIS CRACK LENGTH IS WITHIN THE 0.250 STOP DRILL LIMITS OF BAC S/B 727-55-0089. THE CRACK WILL BE STOP-DRILLED (TEMPORARY) UNTIL REPAIR MODIFICATION PER DAL E.O. 4-70183-12AD. SUBMITTER STATES, THIS IS THE FIRST INSPECTION OF THE SPAR PER S.I. 4-70183-12AD. THIS DOES NOT TERMINATE INSPECTIONS.

Part: LIGHT — FRAYED WIRES (CABIN)

EMERGENCY LIGHTS OUT FROM ROWS 12 TO 19. FOUND FRAYED WIRES RUBBING AT ROW 17. REPLACED BULB SOCKET, FUSES IN M9026 AND M9027 POWER SUPPLIES, OP CKS NORMAL.

Part: LIGHT — INOPERATIVE (FWD ENTRY DOOR)

FWD ENTRY OVERHEAD EMERGENCY LIGHT INOP. REPLACED LIGHT ASSY, CKS GOOD.

Part: SLIDE — TORN WEBBING (R 2 DOOR)

ON PREFLIGHT, FOUND RT AFT SERVICE DOOR EMERGENCY SLIDE WEBBING AT GIRT BAR TORN. REPLACED SLIDE.

Part: COMPRESSOR — STALLED (NR 2 ENGINE)

APPLYING TAKEOFF POWER HAD EXPERIENCED COMPRESSOR STALLS ON NR 2 ENG, WIND WAS APPROX 320 AT 17 TO 20 KTS, DEPARTED 35L DFW. AFTER TAKEOFF COMPRESSOR STALLS RETURNED ON CLIMBOUT AT 190 KTS. REPLACED PRBC AND P AND D VLV, NO HELP. ACTVATED 6TH STAGE BLEED PER M/M, RAN ENGINE AND OPN NORMAL. ALSO, BORESCOPED ENG 6, 7 AND 13TH STG HP COMPRESSOR AND NO TROUBLE FOUND.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING EMERGENCY LIGHTING CHECK, MAINT FOUND TRACK LIGHTING BETWEEN ROWS 12 AND 19 INOP. REPLACED POWER SUPPLY, OPERATION NORMAL.

Part: CASTING — CRACKED (NR 2 SLAT ACT)

FOUND ON D1 LETTER CK, NR 2 SLAT ACTUATOR MOUNT CASTING/ANGLE CRACKED O/B UPPER EAR. REPAIRED PER MM 57-42-0.

Part: ANGLE — CRACKED (NR 7 SLAT)

FOUND ON D1 LETTER CK, NR 7 SLAT LOWER ANGLE CRACKED AT THE ANTI-ICE DUCT CUTOUT. REPAIRED PER MM 57-54-0.

Part: ANGLE — CRACKED (NR 6 FLAP ACT)

FOUND ON D1 LETTER CK, NR 6 L/E FLAP ACTUATOR SUPPORT BOX CRACKED INBD END. REPAIRED PER MM 57-20-21.

Part: EEL CHARGER — MALFUNCTIONED (CABIN)

ON PREFLIGHT, EMERGENCY EXIT LIGHTING BATTERY CHARGER POPS CIRCUIT BREAKER. T/S SYS REPLACED BATT CHARGER C/B AND SPLICE SM17 WDM 33-51-02 PG 5, OPERATION NORMAL.

Part: PUMP — LEAKING (B-HYD SYS)

THE B-SYS HYDRAULIC IND SHOWED ZERO IN FLT, SYS-A SHOWS 2.1 GAL AND IS STEADY. LOSS OF INDICATION IN B-SYS WENT FROM FULL TO ZERO IN ABOUT 1 HOUR. FOUND NR 2 B-PUMP LEAKING, REPLACED AND LEAK CHECK OK. REPLACED BOTH B-SYS CASE DRAIN AND PRESS FILTER, RAN ALL SYS AND ENG PUMPS AND ALL LEAK CHECKS OK.

Part: WINDOW — BROKEN (LT EMER EXIT)

PREFLIGHT CHECK, FOUND LEFT FORWARD OVERWING EMERGENCY EXIT HATCH WINDOW OUTER PANE BROKEN. REPLACED WITH SERVICEABLE DOOR FOR RETURN TO SERVICE. SDR UNDER INVESTIGATION.

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

DURING LAYOVER C-2, CARGO EMERGENCY LIGHT INOP. REPLACED BATTERY PACK, OPERATION NORMAL.

Part: EEL ASSY — INOP (CABIN)

OVERHEAD EMERGENCY LIGHT IN FWD CABIN INOP. REPLACED LIGHT ASSEMBLY, OPERATION NORMAL.

Part: SKIN — CORRODED (FS 1010)

DURING CV-2 INSPECTION, TWO CUTOUTS WERE MADE IN THE BELLY SKIN AFT OG THE SKIN SPLICE AT STA 1010. THE RT CUTOUT IS O/B OF STR 28R AND MEASURES 3.5 BY 4.5. THE LT CUTOUT EXTENDS FROM STR 30 TO SEVERAL INCHES O/B OF STR 29L AND MEASURES 4.75 BY 8 AND WILL REQUIRE DTA. IN ACCORDANCE WITH B727 SRM 53-30-3, FIG 3A, THE CORROSION WAS CUTOUT FOR COMPLETE DAMAGE REMOVAL. REPAIRS ACCOMPLISHED IAW DL ERA 302267-14.

Part: FLOORBEAM — CORRODED (FS 344)

FOUND ON CV2 CORROSION AT FLOORBEAM STA 344 BL 0 THROUGH LBL 60. REPAIRED PER SRM 53-10-8 FIG 10, ID AS PERMANENT REPAIR PER PS 902-5-1 NR 4.

Part: SKIN — CRACKED (NR 3 SLAT)

FOUND ON CV2 CHECK, .5 CRACK AT NR 3 SLAT INNER SKIN BELOW THERMAL ANTI-ICE TUBE. REPAIRED PER M/M 57-54-0 PG 807A.

Part: RIB — CRACKED (VERT STAB)

FOUND ON CV2 CHECK, CRACK FOUND INSIDE VERTICAL STABILIZER, 5 BULKHEADS UP FROM ACCESS HOLE 4TH RIB UP. CRACKED AT RIB BULKHEAD ATTACH POINT LT SIDE. REPAIRED PER M/M 55-30-0 FIG 803.

Part: RIB — CRACKED (VERT STAB)

FOUND ON CV2 CHECK, CRACK FOUND INSIDE VERTICAL STABILIZER, 2 BULKHEADS UP FROM ACCESS HOLE ON RT SIDE 2ND RIB UP. CRACKED AT RIB TO BULKHEAD ATTACH POINT. REPAIRED PER M/M 55-30-0 FIG 803.

Part: RIB — CRACKED (VERT STAB)

FOUND ON CV2 CHECK, CRACK FOUND INSIDE VERTICAL STABILIZER, 4 BULKHEADS UP FROM ACCESS HOLE ON LT SIDE 5TH RIB UP. CRACKED AT RIB TO BULKHEAD ATTACH POINT. REPAIRED PER M/M 55-30-0 FIG 803.

Part: TQ BOX — CRACKED (FS 1235)

FOUND ON CV2 CHECK, LIGHTENING HOLE CRACKED AT 48 SEC, TORQUE BOX STA 1235 LT SIDE. REPAIRED PER M/M 53-11-0 NR 16 PG 828.

Part: RIB — CRACKED (VERT STAB)

FOUND ON CV2 CHECK, CRACK FOUND INSIDE VERTICAL STABILIZER, 2 BULKHEADS UP FROM ACCESS HOLE AT LT SIDE 2ND RIB UP. CRACKED AT BOLT ATTACHED TO BULKHEAD. REPAIRED PER M/M 55-30-0 PG 803.

Part: RIB — CRACKED (VERT STAB)

FOUND ON CV2 CHECK, CRACK FOUND INSIDE VERTICAL STABILIZER, 2 BULKHEADS UP FROM ACCESS HOLE AT LT SIDE 3RD RIB UP. CRACKED AT RIB TO BULKHEAD ATTACH POINT. REPAIRED PER M/M 55-30-0 FIG 803.

Part: BALANCE BOARD — DAMAGED (LT ELEVATOR)

FOUND ON CV2 CHECK, LT ELEVATOR OUTBOARD MOST BALANCE BOARD BAY UPPER BONDED RIB HAS HOLE IN DOUBLER AT O/B END. REPAIRED PER SRM 55-20-3 FIG 3.

Part: RIB — CRACKED (VERT STAB)

FOUND ON CV2 CRACK, FOUND INSIDE VERTICAL STABILIZER, 5 BULKHEADS UP FROM ACCESS HOLE 4TH RIB UP. CRACKED AT RIB TO BULKHEAD ATTACH POINT RT SIDE. REPAIRED PER M/M 55-30-O.

Part: WINDOW — MISSING (EMERGENCY EXIT)

MOMENTARY SHUDDER AT FL 350 IN CRZ. SUSPECT NR 1 ENG COMPRESSOR STALL. CHECKED INLET AND EXHAUST. BORESCOPED NR 1 ENG PER MM. RAN ALL 3 ENGS PER PFHB, OPERATION NORMAL. POST-INSPECTION FOUND THE LEFT SIDE OVERWING AFT EMERGENCY EXIT DOOR WITH THE OUTER PANE OF DOOR WINDOW MISSING. EVIDENCE IS INCONCLUSIVE IF ANY PART OF WINDOW PANE WAS INGESTED. A NEW WINDOW WAS INSTALLED FOR RETURN TO SERVICE.