N538DA

Part: WINDOW — LEAKING (COCKPIT) · airframe 59,021 hrs · 43,741 cycles

LOUD SQUUEAL FROM R2 WINDOW AT 1000 FEET AGL. REPLACED R2 WINDOW AND CHECKED TORQUE ON R3 WINDOW, PRESSURIZIED A/C CHECKS NORMAL

Part: ACTUATOR — MALFUNCTIONED (STABILIZER) · airframe 58,522 hrs · 43,417 cycles

STABILIZER JAMMED IN THE 3 DEGREE NOSE UP POSITION. OCCURRED DURING FLIGHT. A/C OFF LANDED IN CVG. MTC CHANGED ACTUATOR (P/N 274001078) (S/N 104-00AA) AND ACTUATOR (P/N 2774003971) (S/N 1278-00AA. ) A/C FERRY FLIGHT TO ATL FLT 9930 ON 9/14/00. MTC REPLACING STAB SCREWJACK ASSY (P/N 274001001) (S/N 1241). ALSO, FOUND STAB TRIM CABLE. CABLE STA FRAYED REPLACING SAME.

Part: BEAM — DAMAGED (FUSELAGE) · airframe 57,895 hrs · 42,988 cycles

WHILE ACCOMPLISHING MANDATED INSPECTIONS OF THE FS 1183, BULKHEAD VERTICAL BEAM AT LBL 17.8 PER AD 99-18-05, A HOLE COMMON TO THE BEAM AND THE WL 273.25 INTERCOSTAL WAS FOUND ELONGATED. THE HOLE WAS REAMED TO A ROUND CONDITION AND AN OVERSIZE FASTENER INSTALLED PER ER/A 377670-14AD.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 57,510 hrs · 42,719 cycles

ONE INCH VISIBLE CRACK R-1 DOOR AFT FRAME AT LOWER STOP PAD. REPAIRED PER M/M 52-12-0.

Part: DOOR — UNSECURE (SERVICE) · airframe 57,446 hrs · 42,677 cycles

LEFT AFT SERVICE DOOR NOT CLOSED PROPERLY. RETURNED TO PHX. CLOSED DOOR, PRESSURIZED AIRCRAFT. ALL CKD NORMAL.

Part: DOOR FRAME — CRACKED (FUSELAGE)

FOUND DURING WALKAROUND CARGO STRAP STICKING OUT OF FWD LWR CORNER OF C-3 DOOR. UPON CLOSER INSPECTION A 10 INCH CRACK WAS FOUND ON INNER DOOR FRAME WHERE IT ATTACHES TO DOOR SKIN. REPLACED DOOR.

Part: LINE — LEAKING (HYDRAULIC SYS)

DURING CLIMBOUT OF STL, A SYS QTY DROPPED TO 1.2 GAL AFTER GEAR RETRACTION. ONCE AT CRUISE ATL, A SYS QTY SLOWLY DROPPED TO .2 GAL. A SYS LOSS PROCEDURES WERE FOLLOWED. LANDING GEAR WAS LOWERED NORMALLY AND FLAPS WERE LOWERED BY ALT METHOD. LOW PRESS LIGHTS DID NOT ILLUMINATE. REPLACED A SYS HYD PRESS LINE FROM NR 2 ENG IN 48 SECTION.

Part: FRAME — CRACK (BS 560)

THE WEB OF THE FS 560 C1 DOOR JAMB FRAME WAS FOUND WITH 2 SMALL CRACKS AT EXISTING FASTENER HOLES BELOW THE UPPER SILL. THE CRACKS WERE ROUTED OUT OF THE WEB AND A TITANIUM DOUBLER INSTALLED TO REPAIR THE DAMAGE AND ENABLE INSTALLATION UNDER THE EXISTING UPPER FRAME SPLICES. THE REPAIR WAS ACCOMPLISHED PER ER/A 368792-14AD.

Part: WEB — CRACKED (BS 1223)

A .375 INCH CRACK LT VERTICAL TORQUE BOX WEB AT UPPER END STA 1223 (MARKED). REPAIRED PER MM 53-11-0 PAGE 832.

Part: WEB — CRACKED (BS 1213)

A .125 INCH CRACK LT VERTICAL TORQUE BOX WEB AT UPPER END STA 1213L (MARKED). MANUFACTURED AND INSTALLED FILLER PER MM 53-11-0 PG 832.

Part: PANEL — WORN (HORIZONTAL STAB)

FOUND DURING MV2 CORROSION VISIT NRC 165, A .75 INCH HOLE IN NR 4 BALANCE BOARD CLOSURE PANEL. REPAIRED PER SRM 55-20-3.

Part: WIRE — CHAFED (CABIN)

EMERGENCY EXIT CONTROL RT CIRCUIT BREAKER POPPED AND WILL NOT RESET. REPLACED WIRE W338-176-18 FROM ABOVE PACK FLOW CONTROL VLV TO ASSY L622 AND REPLACED C/B C267, OPS CK NORMAL.

Part: LIGHT — INOPERATIVE (AFT STAIRWAY)

EMERGENCY EXIT CONTROL C/B POPPED, WILL NOT RESET. FOUND AFT STAIR LIGHT INOP. REPLACED LIGHT ASSY AND BATTERY. ALSO, FOUND LOSE TERMINAL IN 48 SEC. REPAIRED SAME, OPS CK NORMAL.

Part: ANGLE — CORRODED (DOOR 3448R)

FOUND ON D2 LETTER CK, CORROSION ON ATTACH ANGLE FOR A/C DOOR 3448R. REPAIRED PER MM 53-30-1.

Part: O RING — LEAKING (NR 2 ENGINE)

ENGINE NR 2 LOW OIL PRESS LIGHT ON, QYT GAUGE TO ZERO AND OIL PRESS EVENTUALLY TO ZERO. SHUT DOWN NR 2 ENG PER POM. REPAIRED OIL LEAK AT BANJO FITTING.

Part: SKIN — DENTED (BS 1067)

THE FUSELAGE SKIN AT FS 1067 WAS FOUND DENTED JUST O/B OF STRINGER 29R. THE DAMAGE WAS ADJACENT TO AND EXISTING DOUBLER REPAIR FOR ANOTHER SKIN CUTOUT. THE DENT WAS CUT OUT OF THE SKIN, THE EXISTING DOUBLER REMOVED, AND A NEW EXTERNAL ALUMINUM DOUBLER WAS INSTALLED TO REPAIR BOTH CUTOUTS. THE REPAIR WAS ACCOMPLISHED PER ER/A 365529-14, REV A.

Part: BRACKET — CRACKED (LE FLAP ACT)

NR 1 L/E FLAP ACTUATOR ATTACH BRACKET CRACKED O/B LOWER END. FOUND ON D1 LETTER CK. REPAIRED PER MM 57-20-21.

Part: FUEL OIL COOLER — MALFUNCTIONED (NR 3 ENGINE)

PRECAUTIONARY NR 3 ENG SHUTDOWN AT TOP OF CLIMB. NR 3 OIL TEMPSETTLED IN YELLOW BAND, ALL OTHER ENG IND NORM, 60 DEG HOTTER THAN 1 AND 2 ENG. COULD NOT GET TEMP OUT OF YELLOW AFTER 15 MINS. REPLACED FUEL/OIL COOLER. IN FLIGHT SHUT DOWN.

Part: POWER PACK — INOPERATIVE (CABIN)

ON L/O, FOUND F/C OVERHEAD EMERGENCY EXIT LIGHT INOP. REPLACED BATTERY POWER PACK AND POWER PACK RACK. CKS NML AS PER M/M.

Part: BATTERIES — DISCHARGED (CABIN)

EMERGENCY LIGHTS ABOVE AIRSTAIRS INOP. REPLACED BATTERIES. CKS GOOD.

Part: SKIN — CRACKED (RUDDER)

FOUND ON C2 LETTER CK, TWO .75 INCH CRACKS OUT OF TWO ADJACENT RIVETS LT SIDE OF LOWER RUDDER. REPAIRED PER SRM 55-20-3 REF SRM 55-40-2 FIG 1 FOR INFO.

Part: FLOORBEAM — CORROSION (BS 344)

CORROSION FOUND AT NUTPLATE HOLE ON FLOORBEAM STA 344 AND LBL 45. REPAIRED PER SRM 53-10-8, FIG. 11.

Part: BULB — MISSING (CABIN)

EMERGENCY PATH LIGHTS MISSING LENSES IN AFT CABIN AND ONE LIGHT HAS WIRE DAMAGED. REPLACED MISSING LENSES AND REPLACED ONE BULB AND SOCKET ASSY, OPS CKS OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

BOTH AFT DOOR SLIDE LIGHTS INOP. REPLACED BATTERY PACK, CKS GOOD.

Part: HINGE FTG — CRACKED (LT ELEVATOR)

THE REAR SPAR OF THE LT ELEVATOR WAS FOUND CRACKED ON THE I/B SIDE OF THE THIRD FROM O/B HINGE FITTING. MODIFIED PER B727 S/B 727-55-0087, REV 1.

Part: ACTUATOR BRACKET — CRACKED (NR 8 LE SLAT)

NR 8 SLAT ACTUATOR MOUNT BRACKETS CRACKED OUTBOARD AND INBOARD SIDES. REPAIRED PER M/M 57-20-21.

Part: REAR SPAR — CRACKED (LT ELEV)

THE REAR SPAR OF THE LT ELEVATOR IS CRACKED ON THE INBOARD SIDE OF THE THIRD FROM OUTBOARD HINGE FITTING. THE CRACK IS APPROXIMATELY .1250 INCH LONG. THE CRACK LENGTH IS WITHIN THE .250 INCH STOP DRILL LIMITS OF THE BAC S/B 727-55-0087. THE CRACK WILL BE STOP-DRILLED UNTIL REPAIR/MODIFICATION PER DAL E.O. 4-57713-3AD.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY LIGHT OVER L1 DOOR INOP. REPLACED BATTERY PACK MFR NR 3106 DAL 334101877, BATTERY WEAK.

Part: ANGLE — CRACKED (NR 7 LE FLAP)

FOUND ON A2 LETTER CHECK, NUMBER 7 SLAT COVE SKIN ANGLE CRACKED .25 INCH IN UNDER ANTI-ICE DUCT. REPAIRED PER MM 57-54-0.

Part: ANGLE — CRACKED (NR 1 LE FLAP)

FOUND ON A2 LETTER CHECK, NR 1 SLAT COVE SKIN ANGLE CRACKED AT THE OUTBOARD STOP PAD. REPAIRED PER MM 57-54-0.

Part: SKIN — CRACKED (FUSELAGE SEC 48)

FOUND DURING A-1 LETTER CHECK - 48 SEC TORQUE BOX SKIN CRACKED .3750 INCH AT A LIGHTNING HOLE RT SIDE STA 1323. INSTALLED DOUBLER PER M/M 53-11-0.

Part: STIFFENER — CRACKED (NR 6 SLAT)

FOUND DURING A-1 LETTER CHECK - .50 INCH CRACK AT NR 6 SLAT STIFFENER AT COVE PANEL BELOW ANTI-ICE T-DUCT. REPAIRED PER M/M 57-54-0 PG 807A.