N546DA

Part: BEAM — CRACKED (FUSELAGE) · airframe 58,786 hrs · 42,948 cycles

INSPECTIONS OF THE VENTRAL STAIRWAY OPENING TORQUE BOX STRUCTURE REVEALED TYPICAL CRACKS IN THE UPPER BEAM CAPS OF THE FS 1263 AND 1273 BEAMS ON THE RT SIDE. THE CRACKS ARE TYPICAL OF BAC S/B 727-53-0129. THE CRACKED STRUCTURE WAS REMOVED AND NEW PARTS INSTALLED. THE WORK WAS ACCOMPLISHED PER ER/A 382272-14AD.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 58,252 hrs · 42,610 cycles

FWD EMER PATH/OVERHEAD LIGHTS INOP. CA REPLACED BATTERY PACK.

Part: SKIN — CRACKED (FUSELAGE) · airframe 57,444 hrs · 42,059 cycles

THE FUSELAGE SKIN WAS FOUND WITH A 1 INCH LONG CRACK AT FS 570 BETWEEN STRINGERS 6R & 7R. THE CRACK WAS REMOVED WITH A CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER. THE REPAIR WAS ACCOMPLISHED PER ER/A 380795-14.

Part: SKIN — CRACKED (VERTICAL STAB) · airframe 57,444 hrs · 42,059 cycles

THE LT SKIN OF THE VERTICAL STABILIZER WAS FOUND WITH A .75 INCH CRACK EMANATING FROM AN ATTACHMENT TO THE REAR SPAR. THE CRACK WAS LOCATED JUST ABOVE THE FUSELAGE SKIN INTERFACE. THE CRACK WAS STOP DRILLED AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER. THE REPAIR WAS ACCOMPLISHED PER ER/A 380797-14, REV B.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 56,638 hrs · 41,502 cycles

EMERGENCY LIGHT AT STA 360 FORWARD CENTER AISLE INOP. REPLACED BATTERY PACK AND RACK, OPS OK.

Part: BATTERY PACK — INOPERATIVE (CABIN) · airframe 56,589 hrs · 41,469 cycles

EMERGENCY EXIT LIGHTS ON FWD RAFT COMPARTMENT INOP. REPLACED BATTERY PACK, OPN NML.

Part: BATTERY PACK — INOPERATIVE (CABIN) · airframe 56,589 hrs · 41,469 cycles

EMERGENCY EXIT SIGN ON CEILING BETWEEN AFT LAV DOORS INOP. REPLACED BATTERY PACK.

Part: CSD — FAILED (NR 2 ENGINE) · airframe 55,133 hrs · 40,462 cycles

NR 2 GENERATOR CIRCUIT BREAKER TRIPPED IN FLIGHT, NR 2 CSD IN TEMP IN CAUTION RANGE, VOLTS AND FREQS NORMAL. NR 1 GENERATOR ALREADY ON MCO. REPLACED CSD, GENERATOR, AND CSD OIL COOLER. ALL OPERATION AND LEAK CHECKS NORMAL.

Part: STRAP — CORRODED (HORIZONTAL STAB) · airframe 54,981 hrs · 40,357 cycles

THE HORIZONTAL STABILIZER UPPER REAR SPAR FAIL SAFE STRAP WAS FOUND CORRODED AT LBL 13. THE BLEND DEPTH WAS FOUND TO BE .025 INCHES. ERA 334574-14 REPAIRS THIS DAMAGE. IT WAS FOUND AT MV.

Part: SKIN — CORRODED (FUSELAGE) · airframe 54,981 hrs · 40,357 cycles

CORROSION WAS FOUND IN THE FUSELAGE SKIN AT APPROXIMATELY FS 690 BETWEEN STR 27R AND STR 28R. THE DAMAGE WAS FOUND IN CLOSE PROXIMITY TO AN EXISTING DOUBLER. THE EXISTING REPAIR WAS REMOVED AND INCORPORATED INTO THE REPAIR FOR THE NEW DAMAGE. NEW DAMAGE CUTOUT EXTENDED FROM FS 680-700 AND FROM STR 27R TO STR 28R. AREA WAS REPAIRED PER B727 SRM 53-30-3, FIGURE 3A. THE DAMAGE WAS FOUND AT MV.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 54,981 hrs · 40,357 cycles

THE AFT LT LAVATORY FLOOR SUPPORT WAS FOUND TO BE CORRODED. ERA 334556-14 FABRICATES AND INSTALLS A NEW FLOOR SUPPORT. DAMAGE WAS FOUND AT MV.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 54,981 hrs · 40,357 cycles

THE RT FRAME OF THE AFT ENTRY DOOR AT FS 1183 HAD A FASTENER HOLE IN THE WEB THAT INDICATED A CRACK DURING INSPECTION PER SERVICE BULLETIN INSPECTION. THE HOLE WAS OVERSIZED TO .688 AND THE PERVENTITIVE MOD WAS INSTALLED PER S/B 727-53-0210 IN ACCORDANCE WITH AD 99-18-05. THE DAMAGE WAS FOUND AT MV.

Part: FRAME — WORN (FUSELAGE) · airframe 54,962 hrs · 40,343 cycles

AT MV4, FOUND FLANGE WORN STA 1342 LOWER FLANGE IS WORN AT 6 O''CLOCK POSITION. FLANGE THICKNESS IS WITHIN ALLOWABLE LIMITS PER MM 53-11-0 PG 801. REPAIRED AREA PER MM 53-11-0 PG 801.

Part: SKIN — DELAMINATED (LH ELEVATOR) · airframe 54,962 hrs · 40,343 cycles

AT MID VISIT, THE AFT EDGE OF THE LT ELEVATOR WAS FOUND DELAMINATED I/B OF TAB. REPAIRED PER M/M 55-20-0 PG 801 ITEM 2.

Part: ACTUATOR — LOOSE (NR 2 SPOILER) · airframe 54,962 hrs · 40,343 cycles

AT HMV, THE NR 2 SPOILER ACTUATOR WAS FOUND LOOSE AT LWR FWD AND SUPPORT FIXTURE LOOSE AT LWR ATTACH POINTS. SPOILER ACTUATOR REPLACED ON ROUTINE OP 7053 RC 494. RESECURED LWR ATTACH POINTS OF SUPPORT FIXTURE.

Part: WEB — CRACKED (FUSELAGE) · airframe 54,962 hrs · 40,343 cycles

AT MV4, FOUND WEB 1303 CRACKED AT PREVIOUS REPAIR LOWER LEFT CORNER. REMOVED BRACE TO ACCESS AREA, REMOVED PREVIOUS REPAIR, DYE CHECKED AND NO CRACK FOUND. REMOVED ANTI-ICE DUCT, RE-INSTALLED DOUBLER, BRACKET ANTI-ICE DUCT REINSTALLED ON N/R 570.

Part: SKIN — CRACKED (LE SLAT NR 6) · airframe 54,555 hrs · 40,063 cycles

LOWER EXT SKIN CRACKED AT RIB ATTACH FASTENER HOLES 8.5 INCHES FROM I/B END. REPAIRED PER MM 57-54-0 FIG 801.

Part: AIR DIST — SMOKE (CABIN)

SMOKE HAZE IN CABIN, LT PACK UNCONTROLLABLE OVERHEAT. CHECKED LT PACK SYS AND CONTROLLER, ACM CKS OK. RAN PACK CK OK. UNABLE TO DUPLICATE HAZE.

Part: BATTERY — DISCHARGED (R1 DOOR)

R1 DOOR EMERGENCY EXIT LIGHTS LOW. REPLACED BATTERY.

Part: BATTERY — DISCHARGED (ROW 13)

ROW 13 OVERHEAD EMERGENCY EXIT LIGHT DIM. REPLACED BATTERY.

Part: FUEL PUMP — FAILED (NR 3 ENGINE)

AT FL 330, AFTER DEPARTURE SAT, NR 3 ENG FLAMEOUT. ALL IND NORMAL. FOUND FUEL PUMP SHAFT SHEARED. REMOVED AND REPLACED FUEL PUMP AND FUEL CONTROL RAN ENG PER PFHB TEST.

Part: FRAME — CRACKED (PAX DOORWAY)

FOUND AT C-1 LETTER CK, .375 INCH VISIBLE CRACK ON LT AFT ENTRYWAY FRAME APPROX 6 INCHES BELOW UPPER STOP PAD. REPAIRED PER SRM 53-10-9.

Part: BULB — FAILED (CABIN)

ON L/O, FOUND L1 DOOR EMERGENCY LIGHT OUT. RE-LAMPED, OPS CK-OK.

Part: RIB — CRACKED (NR 4 TE MIDFLAP)

DURING SHOP VISIT, THE IB AFT CLOSEOUT RIB WAS FOUND CRACKED. THE RIB WAS REPAIRED PER 727 MM 57-52-0 BY STOP DRILLING THE CRACK AND INSTALLING A DOUBLER.

Part: STRAP — CRACKED (BS761)

THE REINFORCEMENT STRAP OF THE FS 761 LT FRAME HAD PILOT HOLES DOUBLE DRILLED WITH EXISTING FASTENER HOLES AT THE 3RD AND 4TH FASTENER LOCATION BELOW THE FLOOR LINE. ADDITIONALLY, THE FRAME ITSELF HAS A CRACK MEASURING APPROX 2.5 LONG. AREA WAS REPAIRED PER ERA 330865-14AD.

Part: STRAP — DOUBLE DRILL (BS 761)

THE REINFORCEMENT STRAP OF THE FS 761 LT FRAME HAD PILOT HOLES DOUBLE DRILLED WITH EXISTING FASTENER HOLES AT THE THIRD AND FOURTH FASTENER LOCATION BELOW THE FLOOR LINE. ADDITIONALLY, THE FRAME ITSELF HAD A CRACK MEASURING APPROXIMATELY 2.5 LONG AT THE FLOOR LINE. REPAIRED PER ERA 330865-14.

Part: SKIN — DAMAGED (LT ELEVATOR)

ELEVATOR BONDED BEADED SKIN DAMAGED LT ELEVATOR STA 15 LWR SKIN 3RD AND 4TH BEAD. MFG AND SEALED REPAIR DOUBLERS, INSTALLED DOUBLERS REPAIRED PER SRM 55-20-3 PG 4 FIG 3.

Part: RIB — CRACKED (NR 3 LE FLAP)

NUMBERS 5, 8 AND 12 RIB CRACKED ON NR 3 SLAT. REPAIRED PER MM57-54-0.

Part: RIB — CRACKED (NR 3 LE SLAT)

RIB CRACKED NR 17 ON L/E NR 3 SLAT. REPAIRED PER MM 57-54-0.

Part: RIB — CRACKED (NR 4 LE SLAT)

RIB CRACKED, THE NR 4 L/E SLAT ACTUATOR SUPPORT RIB IS CRACKED AND MARKED WITH TEMPORARY REPAIR. REMOVED TEMP REPAIR AND BEGAN FABRICATION OF PERMANENT REPAIR PER M/M 57-54-0 FIG 804. INSTALLED REPAIR.

Part: RIB — CRACKED (LE FLAP)

NUMBER 3 AND 7 RIB CRACKED. REPAIRED PER SRM 57-54-0.

Part: SKIN — CRACKED (RT TE FLAP)

COVE SKIN CRACKED 32 INCHES FROM I/B END OF FLAP. REPAIRED PER MM 57-52-0 PAGE 819.

Part: RIB — CRACKED (NR 4 LE SLAT)

NR 4 L/E SLAT ATTACH RIBS ARE CRACKED I/B AND O/B SIDE OF ACTUATOR ATTACH POINT. REMOVED TEMP REPAIR ON OTBD RIB OF ACTUATOR ATTACH POINT AND BEGAN FABRICATION OF RIB DOUBLERS PER M/M 57-54-0 FIG 804. OK TO INSTALL INBD REPAIR. OK TO INSTALL OUTBD REPAIR. REPAIR PER M/M 57-54-0 FIG 804. COMPLETED INSTALLATION OF REPAIRS IAW M/M 57-54-0 FIG 804.

Part: RIB — CRACKED (NR 1 TE MIDFLAP)

THE OB MIDFLAP IB AFT CLOSEOUT RIB WAS FOUND CRACKED AT THE AFT LOWER CORNER DURING SHOP INSPECTION. THE RIB WAS REPAIRED BY STOP DRILLING THE CRACK AND INSTALLING A DOUBLER PER MM 57-52-0.

Part: RIB — CRACKED (NR 6 LE SLAT)

RIB CRACKED NR 6 SLAT, RIB NR 12 IS CRACKED. FABRICATED REPAIR DOUBLER PER M/M 57-54-0 FIG 814. OK TO INSTALL. REPAIRED PER M/M 57-54-0 FIG 814.

Part: RIB — CRACKED (NR 6 LE SLAT)

RIB CRACKED NR 6 SLAT, RIB NR 18 IS CRACKED. FABRICATED REPAIR DOUBLER PER M/M 57-54-0 FIG 814. OK TO INSTALL. REPAIRED PER M/M 57-54-0 FIG 814.

Part: DOUBLER — CRACKED (RT TE FLAP)

DOUBLER ON AFT SPAR RAIL CRACKED FROM I/B END OF FLAP. REPLACED FLAP.

Part: RIB — BROKEN (VERT STAB)

RIBS BROKEN LT SIDE NR 4 AND 5 RIBS BROKEN FROM REAR SPAR 3RD CANTED BLKHEAD AFT OF ACCESS INTERIOR VERTICAL STAB. REMOVED ATTACH BOLTS AND BROKEN PIECES FOR FURTHER EVALUATION. FABRICATED ANGLE DOUBLER FOR STRINGER NR 4. FABRICATED STRINGER CLIP FOR NR 4 AND ANGLE DOUBLER FOR STR NR 5. OK TO INSTALL ON NR 5 LOCATION. INSTALLED NR 5. SHIM NEED TO BE INSTALLED. COMPLETED INSTALLATION OF NR 4 AND NR 5 STRINGER REPAIRS PER M/M 55-30-0 FIGURE 803.

Part: RIB — CRACKED (VERT STAB)

RIB CRACKED 5TH FROM BOTTOM SPAR, LT SIDE, 2ND CANTED BLKHD INTERIOR VERT STAB. FABRICATED REPAIR DOUBLER AND INSTALLED PER M/M 55-30-0 FIG 802.

Part: BRACKET — CRACKED (NR 6 LE FLAP ACT)

BRACKET CRACKED AT UPPER AND LWR CORNERS OF NR 6 L/E FLAP ACTUATOR ATTACH ANGLES. REMOVED BRACKET, STOP DRILLED CRACKS, TREATED AND PAINTED EXISTING PARTS. REPAIRED BRACKET IAW M/M 57-20-21 FIG 807.

Part: REAR SPAR — CRACKED (RT ELEVATOR)

THE RT ELEVATOR REAR SPAR HAS A CRACK EMANATING .25 INCH FROM THE LOWER INBOARD CORNER OF THE SHEAR PLATE UNDER THE SECOND TAB HINGE FITTING O/B FROM THE I/B END. THIS DAMAGE WAS REPAIRED IN ACCORDANCE WITH AD 96-06-05 AND S/B 727-55-0089.

Part: BATTERY PACK — DISCHARGED (CABIN)

LOWER LEFT SLIDE EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK, CHECKS NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

AFT SERVICE DOOR LOWER LEFT SLIDE EMERGENCY LIGHT INOPERATIVE. FOUND ON LAYOVER. REPLACED BATTERY PACK FOR AFT LOWER LEFT AND RIGHT EMERGENCY LIGHT. CHECKS OK.

Part: SKIN — CORROSION (BS 480-500)

THE SKIN BETWEEN STA 480 TO 500 AND STR 27R TO 28R WAS FOUND CORRODED. THE DAMAGED SECTION WAS TRIMMED OUT LEAVING A CUTOUT DIMENSION OF 19.5 INCH BY 8.5 INCH. ER/A WILL INSTALL AN EXTERNAL DOUBLER AND TRIPLER FOR THE DAMAGE. REV A DETAILS ADDITIONAL CORROSION FOUND. THE NEW DAMAGE IS LOCATED AT STA 500 AND 520. THE ER/A WILL INSTALL AN INTERNAL DOUBLER AT BOTH NEW DAMAGE LOCATIONS ON A TIME-LIMITED BASIS REF DL ERA 303302-14.

Part: RIB — CRACKED (LT/RT WING)

MTC DISCOVERED CRACKS IN THE LT AND RT WING RIB CHORD DURING MV-2 IN ATL. THE CRACK WAS REMOVED BY OVERSIZING THE HOLES TO .628 INCH IN THE LT RIB CHORD. IN THE RT RIB CHORD THE CRACK WAS REMOVED BY OVERSIZING THE UPPER HOLE TO .6435 INCH AND THE LOWER HOLE TO .629 INCH, .25 INCH MATERIAL REMAINS BETWEEN THE TWO HOLES. ACCOMPLISHED REPAIRS PER DL ERA 303299-14.

Part: BRACKET — MISINSTALLED (NR 2/7 SLAT)

DURING MID-VISIT, THE NR 2 AND NR 7 SLAT ACTUATOR MOUNT BRACKETS WERE FOUND WITH GAPS EXCEEDING THE 0.01 INCH LIMIT SET BY S.I. 4-59271-12. GAPS ARE SUBJECT OF S/B 727-57-1030. SHIMS WERE INSTALLED IN ACCORDANCE WITH THE SERVICE BULLETIN. BRACKETS WERE NOT FOUND TO BE CRACKED.

Part: FRAME — CRACKED (FS 950)

DURING A MID-VISIT, THE FRAME AT STATION 950F WAS FOUND WITH A DENT LOCATED NEAR STRINGER 25L AND A .25 INCH CRACK EMANATING FROM A TOOLING HOLE OUTBOARD OF STRINGER 27L. FRAME WAS SPLICED FROM THE FACTORY SPLICE AT STRINGER 25L TO JUST OUTBOARD OF STRINGER 27L. PER DL ERA 303258-14AD.

Part: SKIN — CRACKED (NR 4 LE SLAT)

HMV/ATL - NR 4 SLAT TOP SKIN - CRACK AT OUTBOARD SIDE OF STALL FENCE MID-AREA SCREW ATTACH POINT. CORRECTION: REMOVED FENCE. INSTALLED DOUBLER REPAIR PER MM 57-40-0.

Part: SKIN — WORN (NR 5 LE SLAT)

DURING A ROUTINE HANGAR INSPECTION, NR 637 WAS WRITTEN DUE TO A GROOVE WORN IN INNER SKIN OF NR 5 SLAT. THE DAMAGE WAS REPAIRED PER MM 57-54-0.

Part: LE RIB — CRACKED (NR 6 SLAT)

DURING LETTER CK F1, NR 6 L/E SLAT NR 2 L/E RIB CRACKED AT AFT FLANGE. REPAIRED PER MM 57-54-0 PG 819.

Part: SKIN — CRACKED (LT ELEV)

LT ELEVATOR SKIN CRACKED LOWER I/B END. FOUND AT F-1 LTR CK AND REPAIRED PER SRM 55-20-3.

Part: LE RIB — CRACKED (NR 4 SLAT)

A .5 INCH CRACK ON SLAT NOSE RIB RADIUS JUST O/B OF ACTUATOR BOLT. FOUND AT F-1 LTR CK AND REPAIRED PER MM 57-54-0.

Part: SKIN — CRACKED (NR 6/7 SLATS)

NR 6 SLAT PANEL CRACKED BELOW ANTI-ICE DUCT. NR 7 SLAT PANEL CRACKED BELOW ANTI-ICE DUCT. FOUND DURING F-1 LTR CK AND REPAIRED PER MM 57-50-3.

Part: PCU — FAILED (RUDDER)

DURING CLIMB THROUGH 18,000 FEET BOTH 'A' SYSTEM HYDRAULIC PUMPS FAILED, LANDED LAX. FOUND LOWER RUDDER PCU FAILED, CAUSING A SYSTEM FAILURE. REPLACED PCU AND BOTH 'A' SYSTEM PUMPS AND FILTERS.

Part: SKIN — CRACKED (FWD ENTRY DOOR)

DURING E-2 LETTER CHECK, FOUND MAIN ENTRY DOOR OUTER SKIN CRACKED .5 INCH AT LOWER HINGE CUTOUT LOWER AFT CORNER. REPAIRED PER B727MM 52-11-01 PG808.

Part: SKIN — CRACKED (LT ELEVATOR)

DURING E-2 L/C, FOUND ONE .25 INCH CRACK IN LWR SKIN OF LEFT ELEVATOR, 7 INCHES FROM I/B EDGE. REPAIRED PER SRM 55-20-3 FIG 4.

Part: SKIN — DAMAGED (RT ELEVATOR)

DURING LETTER CHECK, THE RIGHT ELEVATOR UPPER SKIN WAS FOUND WITH A SMALL HOLE JUST FWD OF TAB, DAMAGE WAS DUE TO LIGHTNING STRIKE. REPAIRED ELEVATOR SKIN PER SRM 52-20-3.