N526DA

Part: SKIN — CORRODED (FS 490, S-28R) · airframe 63,050 hrs · 49,590 cycles

FUSELAGE / SKIN / FS 485-500 / STRG. 27R-28R : CORROSION CUTOUT REPAIR THE FUSELAGE SKIN WAS FOUND CORRODED BETWEEN FS 485 & 500 AND BETWEEN STRINGERS 27R & 28R. THE CORROSION WAS REMOVED WITH A 13.5" X 8.25" CUTOUT. THE CUTOUT WAS REPAIRED WITH TWO EXTERNAL ALUMINUM DOUBLERS INSTALLED PER ER/A 381459-14,REV A.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 63,050 hrs · 49,590 cycles

FUSELAGE C1 DOOR OPENING FWD FRAME AT FS 560 CRACKED. INSPECTION OF THE C1 DOOR CUTOUT SURROUND FRAME WEBS PER AD 99-23-13 REVEALED A TYPICAL CRACK IN THE FWD FRAME WEB BELOW THE LIGHT SWITCH WEB CUTOUT ALONG THE OUTER CHORD ATTACHMENT LOCATIONS.

Part: BEAM — CRACKED (FUSELAGE) · airframe 63,050 hrs · 49,590 cycles

FUSELAGE BULKHEAD AT FS 1183, RBL 8, WL 182 VERTICAL BEAM CRACKED. A 1 INCH TYPICAL CRACK WAS FOUND ON THE RBL 8 VERTICAL BEAM OF THE FS 1183 BULKHEAD EXTENDING FROM THE LOWER END OF THE BEAM AT WL 182. THE CRACK IS TYPICAL OF THOSE DOCUMENTED PER BAC S/B 727-53-0175. THE CRACK WAS REPAIRED WITH A REPAIR ANGLE PER THE SB AND PER ER/A 381430-14.

Part: ANGLE — CRACKED (#2 SLAT) · airframe 63,050 hrs · 49,590 cycles

FOUND ON MV4 1/4 CRACK IN #2 SLAT COVE SKIN ANGLE BELOW TAI DUCT. REPAIRED PER MM 57-54-000-8

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 63,050 hrs · 49,590 cycles

1/4 INCH CRACK ON 870 BULKHEAD AFT SIDE BELOW APU LOAD CONT BOX. REPAIRED PER SRM 53-10-9.

Part: ATTACH ANGLE — CRACKED (L/E SLAT) · airframe 63,050 hrs · 49,590 cycles

NR 7 SLAT COVE SKIN ATTACH ANGLE CRACKED INBD OF INDB UP STOP. REPAIRED PER M/M 57-54-000-8

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 62,865 hrs · 49,461 cycles

RT EMERGENCY EXTERIOR EXIT BETWEEN OVERWING EXIT INOP. RELAMPED, OPS CHECK NORMAL PER M/M.

Part: BATTERY PACK — INOPERATIVE (RT OVERWING) · airframe 61,793 hrs · 48,729 cycles

FWD RT OVERWING EMERGENCY LIGHT INOP. REPLACED BATTERY PACK, LIGHT OPN NORMAL.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 61,573 hrs · 48,583 cycles

L-2 DOOR EMERGENCY EXIT SIGN INOP. REPLACED ASSY.

Part: STIFFENER — CRACKED (LEADING EDGE) · airframe 60,424 hrs · 47,291 cycles

FOUND ON B1 LETTER CK, L/E SPAR STIFFENERS CRACKED L/E SPAR I/B AND O/B OF NR 7 SLAT ACTUATOR. REPAIRED PER MM 57-20-21.

Part: BALLEST — FAILED (CABIN)

BALLAST CAUSES BREAKER TO TRIP. REPLACED FWD LIGHT CONTROL BALLAST. OP CHECKS GOOD.

Part: SIGN — INOP (GALLEY)

FWD EMER EXIT SIGN DOES NOT ILLUMINATE DURING TEST.

Part: LIGHT — INOPERATIVE (L2 DOOR)

L2 EMER LIGHT INOP. REPLACED BATTERY PACK. NO HELP. REPLACED BASE. OPS OK NOW.

Part: BATTERY PACK — DISCHARGED (L-2 DOOR)

L-2 DOOR EXIT EMERGENCY LIGHT OUT. REPLACED BATTERY PACK, CKS GOOD.

Part: SPAR — MISDRILLED (NR 3 TE MIDFLAP)

DURING SHOP VISIT AND ACCOMPLISHMENT OF EO 4-58705-3AD, MTC UNABLE TO INSTALL REQUIRED COLLAR FOR ONE OF THE UPPER SPAR-TO-UPPER SKIN ATTACH FASTENERS DUE TO PROXIMITY TO SPAR RADIUS. AUTHORIZED USE OF RADIUS BLOCK AND MINI NUT.

Part: BATTERY PACK — DISCHARGED (L2 DOORWAY)

OVERHEAD EMERGENCY EXIT SIGN WOULD NOT ILLUM WHEN TESTED. REPLACED BATTERY PACK, CKS NORMAL.

Part: SKIN — WORN (BS 1096)

WEAR IN FUSELAGE SKIN AT STA 1096 AT STR-1. REPAIRED PER ERA 332760-14AD.

Part: RIB — CORRODED (VERT STAB)

CORROSION FOUND ON THE INBD FACE OF THE INBD LUG ON THE LT FIN CLOSURE RIB CLEVIS. DAMAGE REMOVED WITH A 1.6 DIA SPOTFACE W/DEPTH OF 0.062. REWORKED PER ERA 332753-14.

Part: SPAR — CORRODED (HORIZ STAB)

WEAR WAS FOUND ON THE I/B AND O/B PIVOT LUG FACES OF THE REAR SPAR CENTER FORGIN OF THE HORIZ STAB. ADDITIONALLY CORROSION WAS FOUND IN THE BORES OF EACH OF THE TWO LUGS. REWORKED PER ERA 332761-14.

Part: SKIN — CRACKED (BS 720-730)

WHILE ACCOMPLISHING LFEC INSPECTION PER SI 4-74176-12, REV B ON THE S4R LAP JOINT, CRACK INDICATIONS WERE FOUND BETWEEN BS 640 AND BS 740. AFTER GAINING INTERNAL ACCESS AND ACCOMPLISHING THE REQUIRED HFEC INSPECTIONS; ONE CRACK WAS CONFIRMED AT A FASTENER LOCATED AT BS 720+10 ON THE LWR ROW OF THE LWR SKIN PANEL. REPAIRED PER ERA 332735-14.

Part: SKIN — DAMAGED (BS 1170)

DURING ACCOMPLISHMENT OF EO 4-69078-3AD, THE BONDED INTERNAL DOUBLER WAS DAMAGED (TOOLING DAMAGE). REPAIRED PER ERA 332737-14.

Part: SKIN — CRACKED (VERT STAB)

A SKIN PANEL REPAIR WAS FOUND ON THE RHS VERT STAB WHICH WAS INSTALLED W/ BLIND RIVETS PER SRM. REPAIRED PER ERA 332755-14.

Part: SPAR — DAMAGED (CENTER WING)

FOUR FASTENER HOLES WERE MISDRILLED DURING ACCOMPLISHMENT OF EO 4-72440-3AD. HOLES WERE OVERSIZED TO 0.312 DIA. REPAIRED PER ERA 332757-14AD.

Part: BLKHD STIFFENER — CRACKED (BS 1183)

CRACK FOUND IN VERT STIFFENER AT RBL 36.83 ON THE FWD SIDE OF BS 1183 BLKHD, CRACK IS LOCATED AT APPROX WL 238 AND IS NO LONGER THAN 2. REPAIRED PER ERA 332741-14.

Part: BLKHD STIFFENER — CRACKED (BS 1183)

CRACK FOUND IN THE LBL 36.83 VERT STIFFENER ON THE FWD SIDE OF BS 1183. CRACK LOCATED AT APPROX WL 238 AND WAS APPROX 2 INCHES LENGTH. REPAIRED PER ERA 332750-14.

Part: SKIN — WORN (BS 1096)

GOUGE/WORN AREA WAS FOUND IN THE FUSELAGE SKIN CAUSED BY THE ENGINE INLET SKATE ANGLE. REPAIRED PER ERA 332760-14AD.

Part: TRACK — CORRODED (TE FLAP)

INB'D FLAP / INB'D TRACK / MLG BEAM ATTACH PAD: CORROSION AD 90-07-05 AND 90-06-09. CORROSION TO (1) MLG BEAM ATTACH HOLES AND (2) MLG DOOR AFT ATTACH FITTING BOLT HOLES. BOTH HOLES ARE WITHIN AD AREA. MLG BEAM ATTACH HOLES OVERSIZED AND LEFT AS IS. MLG DOOR FITTING HOLE OVERSIZED AND OVERSIZED FASTENER INSTALLED.

Part: ANGLE — CRACKED (LT TE MIDFLAP)

DURING SHOP INSPECTION, THE AFT LOWER CHORD ANGLE WAS FOUND CRACKED 36 INCHES FROM I/B END OF FLAP. THE ANGLE WAS REPAIRED BY STOP DRILLING THE CRACK AND INSTALLING A DOUBLER PER MM 57-52-0 FIG 802.

Part: SKIN — CRACKED (RT TE MIDFLAP)

THE COVE SKIN WAS FOUND CRACKED 37 FROM IB END OF FLAP. THE CRACK WAS REMOVED AND A DOUBLER INSTALLED PER MM 57-52-0, FIG 809.

Part: ANGLE — DAMAGED (RT TE MIDFLAP)

THE AFT LOWER CHORD ANGLE WAS FOUND DAMAGED 33 FROM OB END OF FLAP. THE ANGLE WAS REPAIRED PER MM 57-52-0 BY INSTALLING A DOUBLER.

Part: ANGLE — CRACKED (RT TE MIDFLAP)

THE AFT LOWER CHORD ANGLE WAS FOUND CRACKED 34 FROM IB END OF FLAP. THE ANGLE WAS REPAIRED BY INSTALLING A DOUBLER PER MM 57-52-0.

Part: ANGLE — CRACKED (RT TE MIDFLAP)

THE AFT LOWER CHORD ANGLE WAS FOUND CRACKED DURING SHOP INSPECTION 20 FROM IB END OF FLAP. THE ANGLE WAS REPAIRED PER MM 57-52-0 BY INSTALLING A DOUBLER AND NEW SECTION OF ANGLE.

Part: ANGLE — CRACKED (NR 1 TE MIDFLAP)

DURING SHOP INSPECTION, THE AFT LOWER SPAR ANGLE WAS FOUND CRACKED 21 INCHES FROM O/B END OF FLAP. THE ANGLE WAS REPAIRED PER MM 57-52-0 BY INSTALLING A REPLACEMENT SECTION OF ANGLE AND A SPLICE DOUBLER.

Part: PIN — CORRODED (RT WING)

AT HMV, FOUND BOTTLE PIN CORRODED. PITTED ON AFT FACE, RUSTY ON CAFER, AND BORE IS CORRODED. MACHINED BORE TO 40501 PER SRM 53-40-1. REMOVED ALL PER SAME AND INSTALLED.

Part: SKIN — CORRODED (BS 1050-1030)

AT HMV, FOUND SKIN CORRODED THROUGH AND ENTRAPPING WATER BETWEEN STA 1050 TO 1030 STRINGER 29L TO 28L. REMOVED FXD FLOOR RT STA 1030 TO 1060, REMOVED SKIN, REPAIRED PER MM 53-30-0 FIG 809 AND ERA 332746-14. FLOOR PANELS INSTALLED ON NR1162.

Part: SKIN — CORRODED (BS 1030-1050)

AT HMV, FOUND SKIN BULGED, EXT SKIN STA 1030 TO 1050 STRINGER 28L-27L. REPLACED SKIN ON N/R 297.

Part: ACTUATOR — BROKEN (NLG)

NOSE GEAR WOULD NOT GO DOWN AND LOCKED WHEN GEAR EXTENDED. FOLLOWED LANDING GEAR EXTENSION MALFUNCTIONS PER POM. GEAR CAME DOWN AND LOCKED WITH MANUAL EXTENSION NOSE GEAR. FOUND UPLOCK CYLINDER ROD END PULLED OUT. REPLACED UPLOCK CYLINDER AND PERFORMED NOSE GEAR RETRACT AND LEAK CK. ALL CKS OK.

Part: TORQUE BOX — CRACKED (BS 1273)

WHILE ACCOMPLISHING THE TORQUE BOX INSPECTIONS PER B727 S/B 53-0129 AS MANDATED BY AD 94-07-08, THE FS 1273 BEAM AND GUSSET WERE FOUND CRACKED. THE DAMAGE PARTS WERE REPLACED PER THE S/B AND DOCUMENTED PER ER/A 363483-14AD.

Part: RIB — CRACKED (NR 3 LE SLAT)

FOUND F2 LETTER CHECK, 1 IN CRACK NR 3 SLAT NOSE RIB AT SLAT ACT ROD END ATTACH I/B END. REPAIRED PER M/M 57-54-0 FIG 804.

Part: ANGLE — CRACKED (LT TE MID FLAP)

CHORD ANGLE CRACKED 19, 35, 37 AND 62 FROM I/B END. REPAIRED PER MM 57-20-0 FIG 802.

Part: STRINGER — CRACKED (VERT STAB)

STRINGER FLANGE CRACKED INSIDE VERTICAL STRINGER 6L AT 2ND FROM TOP FRAME. FABRICATED REPAIR ANGLE PER M/M 55-30-0 PG 803. INSTALLED DOUBLER (REPAIR ANGLE) PER M/M 55-30-0, PG 803.

Part: SKIN — CRACKED (FUSELAGE)

AFT FUSELAGE SKIN, CRACK AT IB AFT CORNER RT ACCESS PANEL 3903. ROUTED OUT CRACK AND INSTALLED DOUBLER PER MM 53-30-0 PG 801-803.

Part: AILERON — GOUGED (LT WING)

SPAR GOUGED AT I/B SIDE OF T/E WEDGE. SPLICED IN SPAR SECTION PER SRM 51-40-3.

Part: RIB — GOUGED (RT LE SLAT)

RIGHT WING SLAT OUTBOARD TRACK BOLT HOLE DAMAGED. REPAIRED RIB PER M/M 57-54-00, FIG. 809.

Part: SKIN — CRACKED (RT LE SLAT)

LOWER INBOARD END OF RIGHT WING SLAT WAS CRACKED. REPAIRED PER M/M 57-54-0, FIG. 801.

Part: RIB — CRACKED (RT LE SLAT)

RIB ON RT WING SLAT ACTUATOR WAS FOUND CRACKED. REPAIRED RIB PER M/M 57-54-00, FIG 809.

Part: SKIN — CORRODED (FUSELAGE)

FOUND DURING E-2 LETTER CHECK, CORROSION UNDER AFT HINGE OF FUSELAGE ACCESS PANEL 3448R, CORROSION ON I/B AND O/B SIDES OF ATTACH ANGLE. REPAIRED PER B727 MM 53-30-1 PG 807 TO 808.

Part: ANGLE — CRACKED (NR 7 SLAT)

FOUND DURING E-1 LETTER CHECK, NR 7 SLAT ANGLE CRACKED AT ANTI-ICE DUCT CUTOUT. REPAIRED PER MM 57-54-0.

Part: ANGLE — CRACKED (NR 1 LE SLAT)

FOUND DURING E-1 LETTER CHECK, .1875 INCH CRACK IN COVE ANGLE NR 1 SLAT BELOW TAI DUCT. REPAIRED PER MM 57-54-0 PG 5A.

Part: EEL POWER PACK — INOPERATIVE (CABIN)

EMERGENCY LIGHT TRACKS BETWEEN SECTION 12A AND 19A. REPLACED EMERGENCY PACK POWER SUPPLY AND BATTERY PACK CHECKS OK.

Part: ANGLE — CRACKED (NR 3 LE SLAT)

CRACK UNDER NR 3 SLAT I/B PAD. FOUND AT D-2 LTR CHECK, REPAIRED PER MM 57-54-0.

Part: ANGLE — CRACKED (NR 8 LE SLAT)

NR 8 SLAT O/B STOP PAD ATTACH ANGLE IS CRACKED PAST PREVIOUS STOP DRILL. FOUND AT D-2 LTR CHECK, REPAIRED PER MM 57-54-0.

Part: CONTROL MODULAR — CRACKED (AILERON)

ON TAXIOUT, HAD SMOKE IN CABIN. AIRCRAFT WAS EVACUATED. FOUND AILERON CONTROL MODULE WITH BLOWN SEAL AND CRACKED HOUSING, CAUSING HYDRAULIC LEAK AND CONTAMINATING APU INLET, WHICH CAUSED SMOKE IN CABIN. REPLACED MODULE, OPERATION NORMAL.

Part: SLAT — CRACKED (NR 5 LE SLAT)

DURING INSPECTION OF NR 5 L/E SLAT, N/R CARD WAS WRITTEN TO COMPLY WITH EO NR 4-55122-3AD. THIS EO WAS COMPLIED WITH AND N/R CARD SIGNED OFF.

Part: RIB — CRACKED (NR 5 SLAT LE)

ON NR 5 L/E SLAT DURING INSPECTION A CRACK WAS FOUND ON A RIB. A REPAIR DOUBLER WAS INSTALLED PER M/M 57-54-00 FIG 809.

Part: SKIN — WORN (NR 5 LE SLAT)

DURING INSPECTION ON A B727 NR 5 L/E SLAT, A HOLE WAS FOUND TO BE ELONGATED UNDER WHERE THE FENCE IS MOUNTED. IN ADDITION, THE OUTER SKIN WAS FOUND TO BE WORN AT THE SAME LOCATION. AN EXTERNAL DOUBLER WAS INSTALLED PER THE M/M 57-54-00 PG 817.