N543DA

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 60,295 hrs · 44,638 cycles

THE FWD FRAME OF THE C1 DOOR OPENING AT FS 560 WAS FOUND WITH TWO WEB CRACKS AT EXISTING FASTENER LOCATIONS BELOW THE UPPER DOOR SILL. THE CRACKS ARE TYPICAL OF BAC S/B 727-53-0219 AND AD 99-23-13. THE CRACKS WERE CUT OUT OF THE WEB AND REPAIRED WITH A TITANIUM DOUBLER INSTALLED PER ER/A 382085-14AD, REV C.

Part: SLAT — CRACKED (# 3) · airframe 60,181 hrs · 44,556 cycles

MULTIPLE RIBS CRACKED,REPAIRED PER AMM 57-54-000-8 FIG 814

Part: ANGLE — CRACKED (LEFT WING L/E) · airframe 59,609 hrs · 44,179 cycles

COVE SKIN ATTACH ANGLE CRACKED BELOW TAI DUCT #2 SLAT __REPAIRED PER MM 57-54-000-8

Part: ANGLE — CRACKED (RT WING SPAR) · airframe 59,609 hrs · 44,179 cycles

FOUND ON F1 LETTER CK NUMBER 8 SLAT ACTUATOR INBD ATTACH ANGLE CRACKED . REPAIRED PER MM 57-20-021-8.

Part: ANGLE — CRACKED (LEFT WING L/E) · airframe 59,609 hrs · 44,179 cycles

COVE SKIN ATTACH ANGLE CRACKED BELOW TAI DUCT #3 SLAT __REPAIRED PER MM 57-54-000-8

Part: BRACKET — CRACKED (LEFT WING L/E) · airframe 59,609 hrs · 44,179 cycles

3 INCH CRACK AT #1 SLAT ACT. ATTACH I/B AND O/B BRACKET __REPAIRED PER M/M 57-20-021-8

Part: STIFFENER — CRACKED (WING) · airframe 59,609 hrs · 44,179 cycles

FOUND ON F-1 CK 1 INCH CRACK L/E WING VERTICAL SPAR STIFFENER O/B SIDE OF NUMBER 6 SLAT O/B TRACK.

Part: INDICATOR — FAULTY (COCKPIT) · airframe 59,254 hrs · 43,936 cycles

AFTER TAKEOFF RETRACTING FLAPS TO 5 DEGS INBD FLAPS REMAINED AT 15 DEGS. INBOARD FLAPS REMAINED AT 15 DEGS AFTER POM PROCEDURES. PILOT DECLARED EMERGENCY. REPLACED INBD FLAP POSITION IND AND INBD FLAP ASSY LOCK OUTRELAY R-187.

Part: BATTERY — INOPERATIVE (CABIN) · airframe 58,428 hrs · 43,383 cycles

L2 OVERHEAD EMERGENCY LIGHT INOP. REPLACED BATTERIES, CHECKS GOOD.

Part: ENGINE — MISSING (NR 3) · airframe 58,377 hrs · 43,351 cycles

NR 3 OIL QTY DECREASE TO ZERO. DURING CRUISE FOLLOWED BY FLUCUATING OIL PRESS, SHUT DOWN NR 3 ENGINE PER POM. COMPLETED ENGINE FLAME OUT / LOSS OF THRUST SHUTDOWN FORM. ENGINE SHUTDOWN TIME 30 MIN / OIL PRESS WINDMILL 25 PSI / OIL QTY 0. FOUND 3 STUDS ON GEARBOX BAD. REPAIRED SAME PER JT8D MANUAL, LEAK CKS GOOD.

Part: FRAME — CRACKED (FUSELAGE) · airframe 56,475 hrs · 42,058 cycles

A .5 INCH CRACK WAS FOUND IN THE WEB OF THE C1 DOOR OPENING AFT FRAME (FS 620) JUST BELOW THE NR 6 DOOR STOP. THE CRACK WAS COMMON TO A FASTENER HOLE ATTACHING THE WEB TO THE OUTER FRAME CHORD. THE WEB WAS LOCALLY TRIMMED AWAY TO REMOVE THE CRACK AND REPAIRED WITH A TITANIUM DOUBLER PER ER/A 377272-14AD.

Part: SKIN — CORRODED (FUSELAGE) · airframe 56,475 hrs · 42,058 cycles

THE FUSELAGE SKIN WAS FOUND CORRODED AT FS 560 OVER STRINGER 28L. THE CORROSION WAS REMOVED WITH A 14 X 1.5 CUTOUT IN THE SKIN. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 377271-14.

Part: LINE — CHAFED (LT WING) · airframe 56,269 hrs · 41,917 cycles

A SYSTEM FAILURE. FOUND LINE TO NR 2 LEAKING. REPLACED WITH TEMP/APPROVED LINE. LEAK AND OPS CKS GOOD. HYD FLUID AT 3 GAL.

Part: BATTERY — DISCHARGED (CABIN) · airframe 56,121 hrs · 41,815 cycles

MID CABIN OVERHEAD EMERGENCY EXIT LIGHT INOP. REPLACED BATTERY, OPS NOW OK.

Part: BATTERY — DISCHARGED (CABIN) · airframe 56,121 hrs · 41,815 cycles

AFT CABIN DOOR OVERHEAD EMERGENCY LIGHT INOP. REPLACED BATTERIES, OPS NOW OK.

Part: DOOR — FAILED (RT PACK)

RIGHT PACK TRIP FOLLOWED BY SMOKE IN CABIN. FOUND RT COOLING DOOR NOT OPENING WHEN PACK SELECTED. REPLACED RT COOLING DOOR ACTUATOR RELAY.

Part: BATTERY — DISCHARGED (CABIN)

AFT AIRSTAIR EMERGENCY EXIT LIGHT INOP. REPLACED BATTERIES, OPS CK OK.

Part: WEB — CRACKED (TORQUE BOX)

FOUND ON D2 LETTER CK, .25 INCH CRACK LEFT VERTICAL TORQUE BOX WEB LIGHTENING HOLE STA 1323.. ALSO, RT VERTICAL TORQUE BOX WEB AT LIGHTENING HOLE AT STA 1233 CRACKED .25 INCH. REPAIRED PER MM 53-11-0.

Part: FLAP — BROKE (RT TE OTBD FLAP)

ON APPROACH, RIGHT O/B TRAILING EDGE FOREFLAP BROKE IN HALF. DID NOT LEAVE AIRCRAFT. DID GO-AROUND. A/C LANDED WITHOUT INCIDENT.

Part: WEB — CRACKED (BS 1283)

RT SIDE TORQUE BOX WEB HAS .125 INCH CRACK PROTRUDING PAST. ROUTE OUT REPAIR AT STA 1283 LOWER HOLE M/M 53-11-0 PG 832.

Part: GEARBOX — LEAKING (NR 2 ENGINE)

ON APPROACH INTO CVG PASSING THROUGH APPROX 9000 AGL, NR 2 LOW OIL PRESS LIGHT ILLUMINATED. OIL QTY WAS AND NOW OBSERVED TO DECREASE, OIL TEMP NORMAL, INCREASED ABOVE 105 DEG C. ENGINE SHUT DOWN PER POM PROCEDURES. FOUND NR 2 ENG GEARBOX LEAKING AT 6 O'CLOCK POSITION. CHANGED NR 2 ENG GEARBOX.

Part: BULKHEAD WEB — CRACKED (BS 1183)

THE FS 1183 BULKHEAD WEB WAS FOUND WITH A 1 INCH CRACK AT RBL 25 AND WL 169. THE CRACK WAS REPAIRED WITH A TITANIUM REPAIR DOUBLER ON A TEMPORARY BASIS WITH REPETITIVE INSPECTIONS. THE PERMANENT REPAIR WILL ACCOMPLISH A WEB MODIFICATION PER BAC S/B 727-53-0215. THE REPAIR WAS ACCOMPLISHED PER ER/A 365397-14.

Part: SKIN — CORRODED (BS 480)

A 24 X 17.5 AREA OF SKIN WAS TRIMMED AWAY BETWEEN FS 480 AND FS 500, AND BETWEEN STRINGERS 27L AND 27R. THE SKIN CUTOUT WAS REPAIRED WITH A DOUBLER AND TRIPLER INSTALLED PERER/A 364006-14, REV A.

Part: FLOORBEAM — CORROSION (BS 1030)

CORROSION ON FLOORBEAM STA 1030 AT BOLT HOLES AT BL 0, LBL 9 AND RBL 10.5. CORROSION WITHIN LIMITS AT BL 0 AND RBL 10.5. CORROSION OUT OF LIMIT AT STA LB 9 PER SRM 53-10-1. INSTALLED REPAIR PER M/M 53-20-11.

Part: FLOORBEAM — CRACKED (BS 344)

.75 INCH CRACK ON FLOORBEAM STA 344 AT LBL 30 AT FLOOR PANEL FASTENER HOLE. DRILLED UP REPLACEMENT SECTION PER SRM 53-10-8.

Part: BULB — FAILED (CABIN)

ONE WHITE EMERGENCY PATH LIGHT INOP. REPLACED BULB.

Part: PACK FAN — INOPERATIVE (RIGHT)

REJECTED TAKEOFF AT DFW 18L DUE TO RT PACK TRIPPING OFF AND FILLING THE CABIN WITH SMOKE. REPLACED RIGHT PACK FAN. OPS CHECK NORMAL.

Part: SKIN — CRACKED (FWD OF L1 DOOR)

FOUND ON A2 LETTER CHECK, L1 DOOR UPPER AND LOWER HINGE CUTOUTS CRACKED, UPPER .5 INCH LOWER .875 INCH. REPAIRED PER MM 53-30-0.

Part: SKIN — CRACKED (NR 7 LE SLAT)

FOUND ON A2 LETTER CHECK, 1 INCH VISIBLE CRACK ON NR 7 SLAT COVE SKIN SUPPORT ANGLE. REPAIRED PER MM 57-54-0.

Part: AIR DISTR — ODOR (AFT GALLEY)

DURING FINAL APPROACH, FLT ATTN NOTICED BURNING SMELL LIKE FIREWORKS, AROUND LT AFT LAV AREA. MTC POWERED A/C, TURNED ON ALL GALLEY AND LAV EQUIPMENT AND WAS UNABLE TO REPRODUCE ANY NOTICEABLE SMELL.

Part: HPRSOV — MALFUNCTIONED (NR 2 PACK)

ON DECENT AT ABOUT 9K, STRONG DUSTY ELEC SMELL IN AFT ENTRY AREA. THE WING AND ENGINE HEAT OFF. DEACTIVATED GALLEY POWER AND LAV FLUSH MOTORS AS PRECAUTION. INSPECTED AND OPERATED SYSTEMS, UNABLE TO DUPLICATE. SUBSEQUENT OCCURENCE ISOLATED PROBLEM TO HIGH BLEED PRESSURE TO NR 2 PACK. REPLACED HPRSOV, LEAK AND OPERATION CHECK NORMAL. NO ODOR NOTED.

Part: BAFFLE — CRACKED (NR 2 LE SLAT)

DURING ROUTINE SHOP INSPECTION, A CRACK WAS FOUND IN THE ANTI-ICE BAFFLE BETWEEN THE 11TH AND 12TH RIB FROM THE I/B END. BAFFLE WAS REPAIRED AS PER MM 57-57-0 FIG 8103A FOR NR 2 L/E SLAT.

Part: ANGLE — CRACKED (NR 2 SLAT)

FOUND ON A-1 LETTER CHECK, .25 INCH CRACK NR 2 L/E SLAT COVE SKIN ATTACH ANGLE. REPAIRED PER MM 57-54-0.

Part: NOSE COWL — CRACKED (NR 3 ENGINE)

OUTER FRAME AND BULKHEAD DAMAGED UNDER TEMP. REPAIR AT 3 O'CLOCK POSITION. DAMAGE WAS REPAIRED PER B-727 SRM 54-10-3 FIG 3 FOR NR 3 ENGINE NOSE COWL, DURING SHOP INSPECTION.

Part: SKIN — DENTED (NR 1 TE FLAP)

DURING SHOP VISIT, FOUND THE NR 1 MIDFLAP LEADING EDGE SKIN DENTED I/B OF F/F TRACK CUTOUT 98 INCHES FROM I/B END. CUT OUT DAMAGE AND INSTALLED DOUBLER PER MM 57-50-0 FIG 803 PG 808.

Part: NOSE COWL — DAMAGED (ENGINE)

DURING SHOP INSPECTION, FOUND AFT BULKHEAD TORN AND BENT AT STATION 99.25, OF NOSE COWL. REPAIRED DAMAGE PER SRM 54-10-3 FIG NR 3.

Part: TE PANEL — DELAMINATED (RT SPOILER)

DURING SHOP INSPECTION, FOUND RIGHT WING SPOILER PANEL TRAILING EDGE DELAMINATED. REPAIRED PER SRM 57-50-6.

Part: PANEL — DELAMINATED (NR 12 SPOILER)

DURING HMV, FOUND NR 12 SPOILER PANEL DELAMINATED AT THE TRAILING EDGE, REPAIRED PER B-727 SRM 51-40-6.

Part: BRACKET — CRACKED (RT WING)

AT HMV, NR 6 LEADING EDGE FLAP ACTUATOR SUPPORT BRACKETS WERE FOUND CRACKED. REPAIRED THE BRACKETS PER MAINTENANCE MANUAL 57-20-21.

Part: SUPPORT BRACKET — CRACKED (NR 5 LE FLAP)

AT HMV, FOUND NR 5 KRGR FLAP ACT SUPPORT BRACKET CRACKED AT LWR OB LEG. FABRICATED AND INSTALLED NEW DOUBLER PER M/M 57-20-21.

Part: ANGLE — CRACKED (NR 3 TE MID FLAP)

AT SHOP INSPECTION, NR 3 MID FLAP WAS FOUND WITH CHORD ANGLE CRACKED AT I/B AFT FLAP TRACK CUTOUT. REPLACED CHORD PER SRM 57-52-0.

Part: SPAR — CRACKED (NR 3 TE MID FLAP)

BOTTOM REAR SPAR CHORD CRACKED 54 INCHES FROM I/B END OF NR 3 MID FLAP. REPLACED CHORD PER MM 57-52-0. FOUND DURING SHOP INSPECTION.

Part: SKIN — DELAMINATED (NR 14 SPOILER)

AT HMV, FOUND NR 14 SPOILER DELAMINATED. REPAIRED PER SRM 57-50-6.

Part: REAR SPAR — CRACKED (NR 3 TE MID FLAP)

AT SHOP INSP, NR 3 MID FLAP WAS FOUND WITH BOTTOM REAR SPAR CRACKED AT 40 INCHES FROM I/B END. REPAIRED PER MM 57-52-0 PG 807.

Part: FLAP TRACK — CORROSION (INBD TE FLAP)

THE LEFT SIDE INBOARD TRACK FOR THE INBOARD FLAP WAS FOUND WITH CORROSION IN THE RADIUS BLOCK FASTENER HOLE, FORWARD OF THE AFT TRACK TO MAIN LANDING GEAR BEAM ATTACH HOLE, ON BOTH THE INBOARD AND OUTBOARD SIDES OF THE TRACK. THE HOLES WERE BOTH OVERSIZED TO .560 DIAMETER TO REMOVE CORROSION AND ALLOW FOR REPAIR BUSHING INSTALLATION. A STEEL REPAIR BUSHING WILL BE INSTALLED, PER DL ERA 301187-14AD.

Part: ANGLE — CRACKED (NR 3 TE MID FLAP)

CHORD ANGLE REPAIR CRACKED AT I/B PUSH ROD CUTOUT NR 3 MID FLAP. REPLACED CHORD PER MM 57-52-0.

Part: FITTING — WORN (NR 3 MID FLAP)

AT SHOP INSPECTION, NR 3 MID FLAP CARRIAGE SUPPORT FITTING INBOARD THRUST BEARING RETAINER BOLT HOLES ARE CORRODED. REAMED HOLE TO .312 TO REMOVE CORROSION HFEC, TREATED AND BUSH PER SRM 57-50-4.

Part: RIB — CRACKED (NR 3 SLAT)

AT HMV, FOUND NR 3 SLAT CLOSE OUT ATTACH RIBS NR 5 AND NR 17 CRACKED IN RADIUS. FABRICATED REPAIR PER MM 57-54-0.

Part: RIB — CRACKED (NR 2 LE SLAT)

AT HMV, FOUND NR 2 SLAT RIB MKD NR 2 CRACKED AT LWR T/E RADIUS. FABRICATED AND INSTALLED NEW REPAIR PER M/M 57-54-0 PG 819.

Part: STRINGER — CRACKED (15R)

FOUND AT HMV RT WING L/E LT BOX FWD SIDE HAS CRACK IN STR 15R. FABRICATED REPAIR PER SRM 53-10-3 FIG 2.

Part: STRINGER — CRACKED (LT BOX)

AT HMV, FOUND L/WING L/E LT BOX CRACK IN STR 15L FWD AND AFT OF BOX. DRILLED AND INSTALLED NEW REPAIR PER SRM 53-10-3 FIG 1.

Part: WEB — CRACKED (FS 357)

AT HMV FOUND SUPPORT WEB CRACKED AT STA 357 STR 16 L AIR DUCT CUTOUT. FABRICATED DOUBLER PER ERA 301217-4. INSTALLED PER SRM 53-10-4.

Part: LT BOX — CORROSION (RT WING LE)

AT HMV, FOUND CORROSION UNDER SEALANT AT RW L/E LT BOX AT STR 15R CABIN. FABRICATED REPAIR PER SRM 53-30-3.

Part: FORMER — DAMAGED (FS 540)

AT HMV FOUND HOLE IN FORMER STA 540 STR 24L. FABRICATED AND INSTALLED NEW DOUBLER PER SRM 53-10-4 FIG 26.

Part: SKIN — DELAMINATED (NR 11 SPOILER)

AT HMV, FOUND NR 11 SPOILER PANEL DELAMINATED AT T/E. REPAIRED AS PER SRM 57-50-06.

Part: STRINGER — DAMAGED (FS 580)

AT HMV FOUND HOLE IN STR 25L AT STA 580. FABRICATED AND INSTALLED REPAIR PER SRM 53-10-3.

Part: SKIN — DELAMINATED (NR 12 SPOILER)

AT HMV, FOUND NR 12 SPOILER DELAMINATED. MADE BONDED NOTE PER SRM 51-50-6.

Part: BRACKET — CRACKED (NR 2 LE FLAP)

AT HMV, FOUND NR 2 L/E FLAP ACT. BRACKET L/E CRACKED IB AND OB. FABRICATED AND INSTALLED NEW DOUBLER PER M/M 57-20-21.

Part: SUPPORT — CRACKED (HORIZ STAB)

AT HMV FOUND SUPPORT STRIP CRACKED ON T/E OF STAB BELOW O/B ELEV ATTCH HNGE POINT. INSTALLED NEW T/E BEAM.

Part: SKIN — DELAMINATED (NR 9 SPOILER)

AT HMV, FOUND NR 9 SPOILER DELAMINATED. BONDED REPAIR PER SRM 57-60-6.

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

FOUND AT HMV IB/OB AT NR 1 L/E FLAP ACTUATOR ATTACH BRACKET CRACKED. REPAIRED BRACKETS PER M/M 57-20-21 FIG 807.

Part: PANEL — DAMAGED (NR 7 SPOILER)

AT HMV, FOUND NR 7 SPOILER PANEL HAS BOTTOM SURFACE TEMPORARY. REPAIRED PER B727 SRM 51-40-6 FIG 35.

Part: SKIN — DELAMINATED (RT TE FOREFLAP)

DURING SHOP INSPECTION, BOTTOM SKIN DELAMINATED 15 INCHES FROM I/B END OF NR 4 FOREFLAP. REPAIRED PER SRM 57-50-4, WITH REF TO SRM 51-40-6.

Part: SKIN — DELAMINATED (RT TE FOREFLAP)

DURING SHOP INSPECTION, BOTTOM SKIN FOUND DELAMINATED 19 INCHES FROM I/B END OF NR 4 FOREFLAP. REPAIRED PER SRM 57-50-4, WITH REF TO SRM 51-40-6.

Part: SKIN — WORN (NR 4 FOREFLAP)

THE L/E WAS WORN 52.5 INCHES FROM THE O/B END OF NR 4 FOREFLAP. THE AREA WAS CLEANED UP AND AN EXTERNAL DOUBLER INSTALLED PER SRM 57 50 4 FIG 1.

Part: SKIN — WORN (NR 4 FOREFLAP)

THE LT SKIN WAS WORN AT APPROX 7.5 INCHES AND 10.5 INCHES FROM THE I/B END OF NR 4 FOREFLAP. REPAIRED PER SRM 57-50-4 FIG 1.

Part: SKIN — DELAMINATED (RT TE FOREFLAP)

DURING SHOP INSPECTION, TOP SKIN FOUND DELAMINATED 46 TO 59 INCHES FROM O/B END OF NR 4 FOREFLAP. REPAIRED PER SRM 57-50-4, WITH REF TO SRM 51-40-6.

Part: SKIN — DELAMINATED (RT TE FOREFLAP)

DURING SHOP INSPECTION, TOP SKIN FOUND DELAMINATED 46 INCHES FROM I/B END OF NR 4 FOREFLAP. REPAIRED PER SMR 57-50-4, WITH REF TO SRM 51-40-6.

Part: SKIN — DELAMINATED (RT TE FOREFLAP)

DURING SHOP INSPECTION, TOP SKIN FOUND DELAMINATED 21.5 INCHES FROM O/B END OF NR 4 FOREFLAP. REPAIRED PER SRM 57-50-4, WITH REF TO SRM 51-40-6.

Part: SKIN — DENTED (RT TE FOREFLAP)

DURING SHOP INSPECTION, FOUND TOP SKIN DENTED 89 INCHES FROM O/B END OF NR 4 FOREFLAP. REPAIRED PER SRM 57-50-4, WITH REF TO SRM 51-40-6.

Part: SKIN — DENTED (LT AILERON)

AT HMV, FOUND LEFT INBOARD AILERON WITH A DENT ON THE UPPER SKIN. THE DENT WAS REPAIRED BY INSTALLING A FLUSH REPAIR PER SRM 57-50-5 FIG 1.

Part: SKIN — DELAMINATED (RT TE FOREFLAP)

DURING SHOP INSPECTION, TOP SKIN FOUND DELAMINATED 19 INCHES FROM I/B END, RT WING NR 4 FOREFLAP. REPAIRED PER SRM 57-40-4, WITH REF TO SRM 51-40-6.

Part: SKIN — WORN (NR 4 FOREFLAP)

A TEMP REPAIR WAS FOUND 47 INCHES FROM THE OB END. AN AREA WAS WORN THROUGH BOTH THE REPAIR AND THE LE SKIN OF NR 4 FOREFLAP. CLEANED UP DAMAGE AND INSTALLED DOUBLER PER SRM 57-50-4 FIG 1.

Part: SKIN — WORN (NR 4 FOREFLAP)

A TEMP REPAIR WAS FOUND 74 INCHES FROM THE O/B END ON L/E SKIN OF NR 4 FOREFLAP. REMOVED REPAIR AND INSTALLED PERMANENT REPAIR PER SRM 57 50 4 FIG 1.

Part: FLAP — CORROSION (LT I/B MID FLAP)

NR 2 MID FLAP DURING HMV WAS FOUND TO HAVE CORROSION IN ALL FOUR I/B THRUST BEARING RETAINER BOLT HOLES. THE HOLES WERE REPAIRED PER SRM 57-50-4 PAGE 34.

Part: FLAP — CORROSION (LT I/B MID FLAP)

NR 2 MID FLAP DURING HMV WAS FOUND TO HAVE CORROSION IN ALL FOUR O/B THRUST BEARING RETAINER BOLT HOLES. THE HOLES WERE REPAIRED PER SRM 57-50-4 PAGE 34.

Part: FLAP — CRACKED (LT I/B MID)

NR 2 FLAP DURING HMV SHOP INSP WAS FOUND TO HAVE A CRACK IN DOULBER ON AFT SPAR 36 INCHES FROM I/B END. DOUBLER WAS REPLACED PER SMR 57-52-0 PAGE 807.