N533DA

Part: ACTUATOR — LEAKING (#4 LE INBD FLAP) · airframe 64,403 hrs · 47,629 cycles

ON APPROACH AFTER FLAPS 15 COMPLETE LOSS OF A SYSTEM QUANTITY AND PRESSURE. EMERGENCY PROCEDURES CHECKLIST FOLLOWED WITH MANUAL LANDING GEAR EXTENSION. A SYSTEM HYDRAULIC PUMPS WERE DEACTIVATED WITHIN 2 MINUTES CA_FOUND NBR 4 KREUGER FLAP ACTUATOR LEAKING. REPL SHUTTLE VVALVE PER MM. RMVD NBR 4 ACTUATOR FOUND ATTACH POINT O/B CRASUPPORT BRACKET AND REPL NBR 4 KREUGER FLAP ACTUATOR PER OPN7054.

Part: HANDLE — BROKEN (L2 DOOR) · airframe 64,265 hrs · 47,522 cycles

L2 DOOR UPPER CRANK BROKE WHILE CLOSING DOOR, ROD ALSO DAMAGED SHEET METAL ON DOOR. REPLACED DOOR.

Part: FRAME — CRACKED (FUSELAGE) · airframe 63,899 hrs · 47,238 cycles

THE INNER CHORD OF THE FS 1303 FRAME WAS FOUND CRACKED AT A HYDRAULIC LINE CLAMP ATTACHMENT LOCATION JUST ABOVE RT VENTRAL STAIRWAY TORQUE BOX STRUCTURE. THE CHORD WAS CUT ABOVE THE DAMAGE AND THE LOWER SECTION OF CHORD REMOVED. A NEW SECTION OF CHORD WAS INSTALLED AND SPLICED WITH A REPAIR ANGLE PER ER/A 383919-14, REV A.

Part: SPAR — DAMAGED (T/E FLAP) · airframe 63,466 hrs · 46,922 cycles

NR 2 MID FLAP REMOVED FROM AC 533 DURING HMV. AFT SPAR RAIL REPAIRED PER M/M 57-52-0 FIG 802.

Part: SKIN — CRACKED (VERTICAL STAB) · airframe 62,527 hrs · 46,316 cycles

A .9375 INCH CRACK WAS FOUND FROM FASTENER HOLE AT THE STRINGER 7L SKIN SPLICE TO THE EDGE OF THE SKIN. THE CRACK WAS VERIFIED TO BE CONTAINED IN THE FASTENER HOLE THROUGH HFEC INSPECTION. THE CRACKED AREA WAS REPAIRED WITH AN EXTERNAL TITANIUM DOUBLER.

Part: SPAR — CRACKED (NR 7 SLAT) · airframe 62,527 hrs · 46,316 cycles

FOUND ON A2 LETTER CHECK, NR 7 SLAT FWD SPAR AND RIB CRACKED AT ACTUATOR ROD END. REPAIRED PER MM 57-54-000-8.

Part: LIGHT — INOPERATIVE (L1 DOOR) · airframe 62,421 hrs · 46,253 cycles

EMERGENCY EXIT SIGN AT L1 DOOR INOP. REPLACED LIGHTS ASSY AND BATTERIES, CHECKS OK.

Part: LIGHT — INOPERATIVE (L1 DOOR) · airframe 61,942 hrs · 45,955 cycles

L1 DOOR EMERGENCY LIGHT INOP. REPLACED LIGHT ASSY.

Part: FRAME — CRACKED (FRAME) · airframe 61,262 hrs · 45,479 cycles

A 2" CRACK WAS FOUND AT THE FS 416 AFT FRAME OF THE R1 DOOR CUTOUT. THE CRACK WAS CUT OUT AND A REPAIR ANGLE INSTALLED.THE DAMAGE WAS FOUND AT HMV.

Part: FRAME — CRACKED (FUSELAGE) · airframe 61,259 hrs · 45,477 cycles

THE UPPER FAIL-SAFE CHORD OF THE FS 720B FRAME WAS FOUND CRACKED INBOARD OF STR 26L. THE DAMAGE WAS FOUND DURING INSP AT HMV.

Part: WEB — CORRODED (FUSELAGE) · airframe 61,259 hrs · 45,477 cycles

CORROSION WAS FOUND ON THE C2 DOOR SILL WEB AT FS 970. THE DAMAGE WAS FOUND DURING AN INSPECTION AT HMV.

Part: FLAP TRACK — CORRODED (T/E FLAP) · airframe 61,259 hrs · 45,477 cycles

INBOARD FLAP, NR 4 TRACK WAS FOUND WITH CORROSION AND WEAR AT THE MLG AND SPOILER BEAM ATTACH PADS, FWD ATTACH LUGS, MLG DOOR HINGE FITTING ATTACH HOLES, TOGGLE DETENT HOLE, AND CLIP ASSY AND SPACER BAR ATTACH HOLES.

Part: STRINGER — CRACKED (LT WING) · airframe 61,259 hrs · 45,477 cycles

AT HMV FOUND STRINGER CRACKED UPPER STRINGER 10 AT LT WS 629-00.

Part: FRAME — CRACKED (FUSELAGE) · airframe 61,259 hrs · 45,477 cycles

THE RT FS 784 FRAME HAS A SMALL CRACK EMANATING FROM THE FIRST HOLE ABOVE THE FLOOR LINE IN THE INNER CHORD.

Part: SKIN — CRACKED (SKIN) · airframe 61,259 hrs · 45,477 cycles

DURING HMV CRACKS WERE FOUND IN THE STRINGER 4L LAP JOINT BETWEEN FS 970 AND FS 990. THE CRACKS WERE REPAIRED PER B727 SRM 53-30-3, FIG 5.

Part: FRAME — CRACKED (CABIN) · airframe 61,259 hrs · 45,477 cycles

A CRACK WAS FOUND IN THE LOWER HOLE OF THE FS 783.95 FRAME TYPICAL TO THAT NOTED IN SB 727-53-0197. THE CRACK WAS CUT OUT AND REPAIRED WITH A 65C36280-24 KIT PER THE S/B. THE DAMAGE WAS FOUND DURING THE AD MANDATED INSPECTION.

Part: FLAP TRACK — CORRODED (T/E FLAP) · airframe 61,259 hrs · 45,477 cycles

INBOARD FLAP, NR 4 INBOARD TRACK FOUND WITH CORROSION AND WEAR AT MLG AND SPOILER BEAM ATTACH PADS, AND FWD LUG AND MLG DOOR HINGE FITTING HOLES. REPAIR PER ER/A 402041-14AD.

Part: DOUBLER — CRACKED (T/E FLAP) · airframe 61,259 hrs · 45,477 cycles

AFT CHORD ANGLE, LOWER SPAR RAIL, REPAIR DOUBLER CRACKED 37 INCHES FROM I/B END. REPAIRED ON SHOP ORDER A64256, N/R CARD 018778.

Part: SKIN — CRACKED (LAP JOINT) · airframe 61,259 hrs · 45,477 cycles

WHILE ACCOMPLISHING LFEC INSPECTIONS PER AD 99-04-22, A CRACK WAS FOUND IN THE STR 4L LAP JOINT AT BETWEEN FS 440 AND 460. THE CRACK WAS CUT OUT AND REPAIRED PER B727 SRM 53-30-3, FIGURE 5. THE DAMAGE WAS FOUND AT HMV.

Part: RIB — CRACKED (#6 SLAT TRACK) · airframe 61,259 hrs · 45,477 cycles

AT HMV FOUND RIB CRACKED #3 O/B RIB OF O/B SLAT TRACK(#6 SLAT) CORR: TRIMED OUT DAMAGE FABD REPAIR DOUBLER PER MM 57-54-000-8,REMOVED SLAT TRACK,OK INSTL REPAIR,INSTLD #3 OB RIBDOUBLER PER MM 57-54,INSTLD DOUBLER AND SLAT TRACK PER MM 57-51.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 60,448 hrs · 44,915 cycles

ON L/O FOUND FWD ESCAPE PATH FLOOR LIGHTS ROWS 20 TO 26 INOPERATIVE. SECURED CONNECTON AT SEAT 20D AND REPLACED BATTERY M9027 PACK- OPS NML NOW.

Part: ANGLE — CRACKED (L/E SLAT) · airframe 60,163 hrs · 44,726 cycles

AT HMV FOUND ANGLE CRACKED UNDER I/B UP STOP NR 6 SLAT.

Part: BEAM — CRACKED (FUSELAGE) · airframe 59,852 hrs · 44,521 cycles

FUSELAGE / VENTRAL STAIRWAY OPENING / RT TORQUE BOX / FS 1263 : CRACKED BEAM AND GUSSET INSPECTIONS OF THE RT VENTRAL STAIRWAY TORQUE BOX STRUCTURE REVEALED A .5" CRACK IN THE UPPER HORIZONTAL BEAM AND A 1.5 INCH CRACK IN THE GUSSET CHANNEL AT FS 1263. THE CRACKS ARE TYPICAL OF BAC S/B 727-53-0129. THE DAMAGED STRUCTURE WAS REPLACED WITH NEW PARTS PER ER/A 379598-14AD.

Part: SKIN — CRACKED (VERTICAL STAB) · airframe 59,849 hrs · 44,519 cycles

FOUND ON F2 LETTER CK 1 INCH AND 3/8 IN CRACK IN VERTICAL STAB SKIN BELOW L/H SIDE OF ACCESS PANEL 9501. REPAIRED PER SRM 55-30-3.

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 59,059 hrs · 43,950 cycles

INBOUND ITEM RT WINDSHIELD DAMAGED. CREW REPORTED ENCOUNTERING HAIL. RADOME DAMAGED AS WELL. REPLACED AFFECTED PARTS.

Part: ANGLE — CRACKED (SPOILER)

NR 14 SPOILER ACT O/B MOUNT CASTING CRACKED {ATTACH ANGLE}. REPLACED ANGLE PER M/M 57-42-0..

Part: SKIN — CRACKED (BS 480-680)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 480 AND 680 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN PANEL. INTERNAL HFEC INSPECTION CONFIRMED 12 CRACKS ALONG THE PANEL LENGTH. THE ENTIRE SKIN LAP WAS CUT OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 367489-14AD.

Part: FRAME — CORRODED (BS 1142)

FUSELAGE C3 DOOR CUTOUT AFT FRAME FS 1142 STRINGER 28R:CORROSION REPAIR. THE SKIN ATTACH FLANGE OF THE AFT FRAME OF THE C3 DOOR CUTOUT WAS FOUND CORRODED AT STRINGER 28R. THE CORRODED FLANGE WAS TRIMMED AWAY AND REPAIRED WITH AN ALUMINUM REPAIR ANGLE PER ER/A 367222-14, REV A.

Part: SKIN — CORRODED (BS 560-580)

FUSELAGE SKIN FS 560-580, STRG 28L, SKIN CORROSION REPAIR. AN AREA OF CORROSION WAS FOUND IN THE FUSELAGE SKIN NEAR STRINGER 28L BETWEEN FS 559 AND 564. THE CORROSION WAS CUTOUT WITH A 7 BY 1.85 CUTOUT. THERE WAS AN EXISTING REPAIR DOUBLER ADJACENT TO THIS LOCATION FOR THE REPAIR OF TWO SMALLER SKIN CUTOUTS. THE EXISTING REPAIR DOUBLER WAS REMOVED AND A SINGLE EXTERNAL ALUMINUM DOUBLER INSTALLED TO REPAIR ALL CUTOUTS PER ER/A 367221-14, REV B.

Part: SKIN — CORRODED (BS 1050)

FUSELAGE SKIN FS 1010-1080 STRG 26L-26R, CORROSION REPAIR. THE FUSEALAGE SKIN WAS FOUND CORRODED BETWEEN FS 1046 AND 1055 BELOW STRINGER 27. THERE WERE SEVERAL OTHER SKIN PANEL. REPAIR DOUBLERS IN THE AREA. TO ELIMINATE THE DAMAGE AND EXISTING REPAIRS, THE SKIN WAS CUT AT FS 1080 BETWEEN STRINGER 16R AND 26L AND THE SECTION REMOVED TO FS 1010. A NEW SKIN SECTION WAS SPLICED IN PLACE PER ER/A 367217-14.

Part: SKIN — CORRODED (BS 960)

FUSELAGE SKIN FS 950F-970, STRINGER 28L, CORROSION CUTOUT REPAIR. THE FUSELAGE SKIN WAS FOUND CORRODED AT STRINGER 28L BETWEEN FS 950F AND FS 970. THE CORROSION WAS REMOVED WITH A 26 BY 3 CUTOUT IN THE SKIN. THE CUTOUT WAS REPAIRED WITHAN EXTERNAL ALUMINUM DOUBLER AND TRIPLER INSTALLED PER ER/A 367230-14.

Part: WIRE — FAILED (LT GENERATOR)

LT GENERATOR ON LANDING, LOUD SOUND OF GENERATOR FAILING. ELECTRICAL SMELL IN COCKPIT. DIFF FAULT LIGHT ON ANN PANEL. MTC FOUND BURNT WIRES GOING TO DISTRIBUTION 1 SECT X C/B C829. REPAIRED WIRING PER M/M.

Part: RIB — CRACKED (NR 5 LE SLAT)

FOUND ON E1 LETTER CK, NR 5 SLAT ACT I/B ATTACH RIB CRACKED. REPAIRED PER MM 57-54-0.

Part: WEB — CRACKED (BS 1303)

FOUND ON D1 LETTER CK, .25 INCH CRACK RT TORQUE BOX VERTICAL WEB LIGHTENING HOLE STA 1303. ROUTED OUT DAMAGED AREA PER MM 53-11-0.

Part: WEB — CRACKED (BS 1263)

FOUND ON D1 LETTER CK, .5 INCH CRACK AT LT TORQUE BOX VERICAL WEB LIGHTENING HOLE STA 1263. REPAIRED PER MM 53-11-0.

Part: SKIN — DEFORMED (BS 660-680)

THE SKIN WAS FOUND WITH AN OIL CANNED SKIN CONDITION OVER FIVE STRINGER BAYS BETWEEN STA 660 TO 680 AND STRINGERS 20R TO 25R. A NEW SECTION OF SKIN WAS SPLICED IN PER ER/A 363183-14.

Part: LIGHT — INOPERATIVE (CABIN)

OVHD EMERGENCY LIGHT INOP AT SEAT 14. REPLACED LIGHT ASSY EMERGENCY LIGHT, OPERATES NORMALLY PER MM.

Part: O-RING — FAILED (NR 2 ENGINE)

IN CRUISE, NR 2 ENG OIL QTY DECREASED TO ZERO, OIL PRESS FLUCT AT 40 PSI, ALL OTHER IND NORM. OIL PRESS LIGHT ILLUMINATED AT IDLE, SHUT ENG DOWN. REPLACED O-RING ON FUEL PUMP DRIVE SHAFT.

Part: BATTERY — DISCHARGED (CABIN)

EMERG LIGHT O/H ROW 13 DID NOT TEST. REPLACED BATTERY, CKS OK.

Part: TIRE — FAILED (RT MLG)

NR 4 BLEW ON T/O. REPLACED NR 3, 4 MAIN WHEEL ASSY. A/C FERRIED TO DFW ACCT OF DAMAGE TO RT INBD MID FLAP AND RT MAIN GEAR WING DOOR.

Part: LIGHT — INOPERATIVE (L2 DOOR)

L2 DOOR EXTERIOR EMERGENCY SLIDE ILLUMINATION LIGHT INOP. CLEANED LIGHT SOCKET CENTER CONTACT, REBULBED AND OPN NOW NORMAL.

Part: SKIN — CRACKED (NR 2 ENG)

A 1 INCH CRACK IN NR 2 ENG INLET OUTER SKIN LT SIDE 8 O'CLOCK POSITION APPROX 36 INCHES AFT OF L/E. INSTALLED DOUBLER PER SRM 55-30-0.

Part: WEB — CRACKED (BS 1228)

LOWER LT TORQUE BOX VERTICAL WEB CRACKED BEYOND ROUTED OUT REPAIR, UPPER LIGHTENING HOLE STA 1228. REPAIRED PER M/M 53-11-0 PG 828.

Part: STRINGER — CRACKED (VERT STAB)

A .75 INCH CRACK IN VERT STAB STR 7 AT 3RD BULKHEAD ABOVE OPENING TO CRAWLWAY. REPAIRED PER M/M 55-30-0.

Part: WEB — CRACKED (BS 1213)

A .375 INCH CRACK IN LT LOWER TORQUE BOX VERTICAL WEB UPPER FWD END STA 1213. REPAIRED PER M/M 53-11-0.

Part: BALLAST — FAILED (BS 910)

LOG ITEM 2, ELECTRICAL SMELL IN MID CABIN POPPED LT AFT CABIN CEILNG LIGHT C/B. FOUND BALLAST AT STA 910 INTERNALLY SHORTED CAUSING BURNT ELECTRICAL SMELL IN CABIN. REPLACED BALLAST, OPERATION NORMAL.

Part: DUCT — CRACKED (WATER SEPERATOR)

UNABLE TO MAINTAIN PRESSURIZATION DURING CRUISE. FOUND LEFT WATER SEPARATOR FWD CLAMP SEPARATED AND WATER SEPARATOR TO MIZ VALVE DUCT CRACKED IN SEVERAL PLACES. REPLACED DUCT AND SEPARATOR, OPERATION NORMAL.

Part: SKIN — WORN (LT AILERON)

DURING SHOP INSPECTION, L/W AILERON WAS FOUND WITH AREAS OF WEAR DAMAGE TO SKIN. ACCOMPLISHED REPAIRS PER SRM 51-50-5 AND SRM 51-40-3.

Part: SKIN — DAMAGED (NR 2 TE FLAP)

NR 2 AFT FLAP REPLACED TEMP. REPAIR 50 FROM INBD END LOWER SKIN PER SRM 57-50-4, FIG. 10 AND ERA 27109-14. FOUND DURING SHOP INSPECTION.

Part: SKIN — CRACKED (FWD ENT CUTOUT)

1.1250 INCH CRACK ON LWR HINGE CUT-OUT FWD ENTRY DOOR AT FUSELAGE SKIN. DAMAGE FOUND AT LETTER CHECK. REPAIRED PER PER M/M 53-30-0.

Part: RIBS — DAMAGED (NR 5 LE FLAP)

AT SHOP INSPECTION RT WING NR 5 SLAT WEB, FORWARD OF ACTUATOR RIBS WAS FOUND WITH ENLARGED HOLES AT RIB ATTACH POINT. REPAIRED PER SRM 57-50-3 FIG 4.

Part: RIB — CRACKED (NR 5 TE FLAP)

AT SHOP INSPECTION FOUND RT WING NR 5 SLAT WITH CRACKED RIB AT INBOARD TRACK ATTACH FITTING. REPAIRED PER MM 57-54-0.

Part: BEAM — CRACKED (FS 1183)

DURING LETTER CHECK, FOUND CRACK IN VERTICAL BEAM AT FS 1183 AT RBL 8. REPAIRED PER MM 53-11-0 FIG 809.

Part: WEB — CRACKED (FS 1218)

.25 INCH CRACK IN VERT. WEB RT SIDE OF STAIRWAY STA 1218 PROTRUDING FROM 1ST RIVET IN UPPER ROW. DAMAGE FOUND AT LETTER CHECK, REPAIRED PER MM 53-11-00 PG 832-833.