N541DA

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,282 hrs · 43,200 cycles

LFEC INSPECTIONS OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 480 & 680 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN PANEL. INTERNAL MFEC INSPECTION CONFIRMED 19 CRACKS ALONG THE LENGTH OF THE PANEL. THE ENTIRE SKIN LAP JOINT WAS CUT AND REMOVED. THE JOINT WAS RESTORED WITH AN EXTERNAL ALUMINUM DOUBLER INSTALLED PER ER/A 378506-14AD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 58,282 hrs · 43,200 cycles

OVERHEAD EMERGENCY LIGHT INOP AT R-1 DOOR. REPLACED RACK, CKS OK.

Part: BEAM — CRACKED (FUSELAGE) · airframe 58,198 hrs · 43,144 cycles

THE RT VENTRAL STAIR CUTOUT TORQUE BOX FWD, UPPER HORIZONTAL BEAM AT STA 1263 WAS FOUND WITH AN APPROX 2 INCH CRACK. ERA 378352-14AD REPLACED THE DAMAGED PART AS PER S/B 727-53-0129. THE DAMAGE WAS FOUND ON INSPECTION IN TPA.

Part: STRUCTURE — DAMAGED (NLG DOOR) · airframe 57,560 hrs · 42,709 cycles

UPON GEAR RETRACTION HEARD LOUD NOISE ACCOMPANIED WITH UNSAFE INDICATION. REPAIRED NOSE GEAR DOORS AND LINKAGE.

Part: SKIN — CORRODED (BS 950F - 970)

TWO CUTOUTS WERE MADE IN THE SKIN BETWEEN FS 950F AND 970 ALONG STR 28L DUE TO CORROSION. THE DAMAGE WAS FOUND AT MV AND REPAIRED PER ERA 334022-14.

Part: STRINGER — CRACKED (BS 946)

THERE WERE CRACKS FOUND IN STRINGER 18A AND THE FUSELAGE SKIN AT FS 946. THE DAMAGE WAS FOUND AT MV AND REPAIRED PER ERA 334023-14.

Part: FRAME — DENTED (BS 500 - 720)

THE FOLLOWING FRAMES WERE DENTED DUE TO SERVICE DAMAGE BETWEEN STR 23L AND 25L, FS 500, 520, 560, 620, 660 AND 720. THE DAMAGE WAS FOUND AT MV AND WERE REPAIRED PER ERA 334016-14.

Part: FRAME — CORRODED (BS 1166)

THE FUSELAGE FRAME 1166 HAD CORROSION AT THE SHEAR CLIP BETWEEN STR 29R AND STR 30. THE DAMAGE WAS FOUND AT MV AND REPAIRED PER ERA 334020-14.

Part: WINDOW POST — CRACKED (COCKPIT)

FUSELAGE COCKPIT WINDOW FRAME, E-F WINDOW POST, DENT/CRACK REPAIR. THE E-F COCKPIT WINDOW FRAME POST WAS DENTED AT THE LOWER SILL OF THE R3 COCKPIT WINDOW WHEN THE FRONT END OF THE AIRCRAFT WAS BLOWN INTO A FIXED STRUCTURE. INSPECTION OF THE POST REVEALED A CRACK AT THE DENTED LOCATION. THE DAMAGED POST WAS REMOVED AND A NEW POST INSTALLED PER ER/A 367851-14, REV A.

Part: SKIN — DENTED (BS 240)

FUSELAGE SKIN FS 230-245, R3 COCKPIT WINDOW SURROUND, DENT/TEAR REPAIR. THE FUSELAGE SKIN JUST BELOW THE R3 COCKPIT WINDOW BETWEEN FS 230 AND 245 WAS DENTED AND TORN WHEN THE FRONT END OF THE AIRCRAFT STRUCK A FIXED STRUCTURE DURING A WIND STORM. THE DAMAGED SECTION OF SKIN WAS CUTOUT AND AN ALUMINUM DOUBLER INSTALLED PER ER/A 367840-14, REV B.

Part: ANGLE — CRACKED (NR 2 LE SLAT)

FOUND ON D2 LETTER CK, LOWER COVE SKIN ATTACH ANGLE CRACKED AT NR 2 SLAT I/B STOP PAD. REPAIRED PER MM 57-54-0.

Part: SKIN — CRACKED (BS 513 & 632)

LFEC INSPECTION OF THE LOWER ROW OF FASTENERS IN THE STR 4R LAP SPLICE GAVE TWO CRACK INDICATIONS. INTERNAL HFEC INSPECTION CONFIRMED ONLY TWO CRACKS, ONE AT FS 513, AND ONE AT FS 632. FASTENERS WERE REMOVED FWD AND AFT OF EACH CRACK AND HFEC SURFACE INSPECTION AGAIN REVEALED NO FURTHER CRACKS. THE CRACKS WERE CUTOUT OF THE LAP AND REPAIRED PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A 366612-14.

Part: BATTERY CHARGER — FAILED (RT OVERWING EXIT)

ON LAYOVER CHECK, FOUND EMERGENCY EXIT LIGHTS INOP OVER THE RIGHT WING OVER WING EXITS. REPLACED BATTERY CHARGER OPERATION NORMAL DPN 334701744 S/N OFF 10007, ON DL52.

Part: WEB — CRACKED (BS 1240)

REF SHIP 541 TPA LTR CHK D1, FOUND 1 IN CRACK AT LIGHTNING HOLE STA 1240 RT VERTICAL WEB TORQUE BOX AREA. REPAIRED PER MM 53-11-10.

Part: SPAR — CRACKED (RT ELEV REAR)

HORIZ STABILIZER RT ELEVATOR REAR SPAR, REPAIR FOR TYPICAL CRACKS. THE RT ELEVATOR REAR SPAR WAS FOUND WITH TWO TYPICAL CRACKS .25 OR SMALLER EXTENDING FROM UNDERNEATH THE 2ND HINGE FITTING FROM THE OUTBD END OF THE SPAR. THE CRACKS WERE STOP DRILLED PER BAC S/B 727-55-0089 AND SET-UP FOR REPEAT INSPECTION AND PERMANENT MODIFICATION PER ER/A 364338-14AD.

Part: FLOORBEAM — CORRODED (BS 344)

CORROSION FOUND ON FLOORBEAM STA 344 FROM LBL3 TO LBL27. REPAIRED PER SRM53-10-8 FIG 11.

Part: FLOORBEAM — CORRODED (BS 344)

CORROSION ON FLOORBEAM STA 344 FROM LBL 47 TO LBL 62. REPAIRED PER SRM 53-10-8 FIG 11.

Part: FLOORBEAM — CORRODED (BS 344)

CORROSION FOUND ON FLOORBEAM STA 344 FROM LBL 30 TO LBL 45. REPAIRED PER SRM 53010-8 FIG 19.

Part: WIRE — NOT GROUNDED (CABIN)

FLOOR EMERGENCY EXIT LIGHTS INOP FROM ROW 28 BACK. REPAIRED BAD GRD WIRE, LIGHTS WORKED NORMAL.

Part: TRANSVERSE BEAM — CRACKED (STA 1263 /1273)

THE AFT CHANNEL (P/N 65-17517-37) AND THE UPPER FORWARD ANGLE (P/N 65-17517-38) OF THE TRANSVERSE BEAM AT STA 1263 WERE FOUND CRACKED. SIMILAR DAMAGE WAS FOUND AT STA 1273 WHERE THE AFT GUSSET ANGLE (P/N 17518-6) AND THE UPPER FORWARD ANGLE (P/N 69-67881-1) OF THE TRANSVERSE BEAM WERE CRACKED. THESE PARTS ARE THE SUBJECT OF A.D. 94-07-08 WHICH REQUIRES INSPECTION PER S/B 727-53-0129. THE PARTS WERE REPLACED IN ACCORDANCE WITH THE S/B.

Part: TORQUE BOX WEB — CRACKED (BS 1240)

RT VERT TORQUE BOX WEB LIGHTENING HOLE AT STA 1240 HAS .25 INCH CRACK AT LOWER HOLE. REPAIRED PER M/M 53-11-0.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

AFT CABIN EMERGENCY TRACK LIGHTS INOP. REPLACED POWER SUPPLY M9027 AND INSTALLED NEW BATTERIES, OPS CK NORMAL.

Part: PWR CONTL UNIT — MALFUNCTIONED (ELEVATOR)

A/C PORPOISED AND VIBRATES ON CLIMB/CRUISE WITH A/P OFF. FEELS LIKE THERE IS PLAY IN CONTROL COLUMN IN PITCH. CONTROL COLUMN KICKS BACK OCCASIONALLY. REPLACED ELEVATOR POWER CONTROL UNIT, PERFORMED AUTO-PILOT AUTH CHECK, ALL INDICATIONS NORMAL.

Part: PBE — DEFECTIVE (CABIN)

PBE, LOCATED IN FIRST CLASS COAT CLOSET, HAS UNSERVICEABLE INDICATOR PROTRUDING PAST CONTAINER. REPLACED PBE.

Part: APU — SMOKING (CABIN)

DEPARTURE TIME WITH APU, EITHER PACK PUTS SMOKE IN CABIN. FOUND APU PUTTING SMOKE IN CABIN DEACTIVATED APU PER MEL.

Part: WEB — CRACKED (BS 1223)

FOUND ON A2 LETTER CK, TORQUE BOX WEB CRACKED .5 INCH AT FASTENER UPPER ROW OF RIVETS LT SIDE STA 1223. REPAIRED PER MM 53-11-0.

Part: ANGLE — CRACKED (NR 5 SLAT)

FOUND ON A2 LETTER CK, .5 INCH VISIBLE CRACK ON COVE SKIN ATTACH ANGLE BELOW THE OUTBOARD STOP PAD NUMBER 5 SLAT. REPAIRED PER MM 57-54-0.

Part: COMPRESSOR BLADE — FRACTURED (NR 1 ENGINE)

DURING CRUISE, FL 370, NR 1 ENGINE STALLED AND FLAMED OUT. THERE WAS SOME SMOKE ODOR IN CABIN FOLLOWING FLAME-OUT. LANDED SLC. FOUND METAL IN TAILPIPE AND BLEED AIR MANIFOLD. ENGINE WAS REPLACED AND ROUTED TO SHOP. SUPPLEMENT: FRACTURED 7TH STAGE COMPRESSOR BLADE FOUND AT ENGINE SHOP DISASSEMBLY. VERY LIGHT FOD NOTED AT FRACTURE INITIATION SITE ON BLADE L/E. DAMAGE THROUGHOUT DOWNSTREAM STAGES OF THE HPC.

Part: ANGLE — CRACKED (FS 1273)

THE RT TORQUE BOX FORWARD TRANSVERSE BEAM GUSSET ANGLE AT FS 1273 WAS FOUND CRACKED. THE AFT TRANSVERSE BEAM WAS ALSO FOUND CRACKED. THIS DAMAGED AREA OF THE TORQUE BOX IS THE SUBJECT OF S/B 53-0129. REPAIRS WILL REPLACE THE DAMAGED GUSSET ANGLE AND THE UPPER TRANSVERSE BEAM IN ACCORDANCE WITH THE S/B.