N59302

Part: SHEAR TIE — CORRODED (BS 747) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND SHEAR TIE CORRODED AT STA 747, LBL 4. THE CORRODED SECTION OF SHEAR TIE WAS CUT OUT AND A NEW SHEAR TIE WAS INSTALLED IAW SRM 53-00-07, REPAIR 3, FIGURE 201.

Part: KEELBEAM — CORRODED (BS 520 S28L) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND LT KEELBEAM CORRODED AT STA 520, S28L. THE KEELBEAM SECTION WAS REPLACED IAW SRM 53-60-12.

Part: FRAME — CRACKED (BS 847 S18-27R) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND A 1 INCH CRACK IN AFT CARGO CUTOUT AFT FRAME LOWER DOOR STOP AT STA 847, S18R TO S27R. THE FRAME WAS REPLACED IAW SRM 51-40-02.

Part: ATTACH ANGLE — CRACKED (BS 360 S14L) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND A 1 INCH CRACK IN ANGLE THAT ATTACHES STRINGER TO WEB AT STA 360, S14L. THE ANGLE WAS REPLACED IAW ECRA 5311-01277.

Part: FRAME — CORRODED (BS 227) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND LOWER FRAME CORRODED AT STA 227.8, RBL 3 TO LBL 3, S1L TO S1R. A REPAIR WAS INSTALLED IAW ECRA 5311-01275.

Part: KEELBEAM — CORRODED (BS 536) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND RT KEEL BEAM CORRODED ON INBOARD SIDE JUST AFT OF BULKHEAD AT STA 536. THE KEEL BEAM SECTION WAS REPLACED IAW SRM 53-60-12.

Part: STRINGER — CORRODED (BS 864) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND AFT CARGO COMPARTMENT STRINGER 26R CORRODED AT STA 864. THE STRINGER WAS REPLACED IAW SRM 53-00-03.

Part: SKIN — CORRODED (BS 727 S27L) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND FUSELAGE SKIN PANEL CORRODED AT STA 727 + 4.00 AND CENTERED OVER THE LT KEEL BEAM AT S27L. THE SKIN WAS REPAIRED IAW ECRA 5331-01274.

Part: SHEAR TIE — CRACKED (BS 360 S13L) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND A .5 INCH CRACK IN LOWER SHEAR TIE FOR FUSELAGE FRAME AT STA 360, S13L. THE SHEAR TIE WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: SEAT TRACK — CORRODED (BS 897-927) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND RT OB SEAT TRACK CORRODED AT STA 897-927, RBL 45.5. A NEW SEAT TRACK WAS INSTALLED IAW SRM 53-00-52.

Part: ATTACH FITTING — CRACKED (BS 616 S8L) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND A .5 INCH CRACK IN FUSELAGE TO BELTFRAME CLIP AT STA 616, S7L TO S8L. THE CLIP WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: ANGLE — CORRODED (BS 907-1006) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND L-2 DOOR Z-ANGLE CORRODED AT STA 907-1006, LBL 34 TO LBL 60. A NEW Z-ANGLE WAS INSTALLED IAW SRM 51-40-02.

Part: BELTFRAME — CRACKED (STA 616) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND A 2 INCH CRACK IN BELTFRAME AT STA 616, S7L. REPAIRED IAW SRM 53-00-07.

Part: SEAT TRACK — CORRODED (BS 907-938) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND RIGHT I/B SEAT TRACK CORRODED AT STA 907-938, BL 0. A NEW SEAT TRACK WAS INSTALLED IAW SRM 53-00-02, REPAIR 3.

Part: FLOORBEAM — CORRODED (BS 344) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 344, LBL 50 TO RBL 25. DOUBLERS AND A SECTION OF T-CHORD WERE INSTALLED IAW SRM 53-10-51.

Part: SEAT TRACK — CORRODED (BS 907-947) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND LT I/B SEAT TRACK CORRODED AT STA 907-947.5, LBL 24.75. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 53-00-52.

Part: FRAME — CRACKED (BS 616 S18R) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND A 1/2" CRACK IN MAIN FRAME AT STA 616 JUST BELOW FLOOR, S18R. REPAIRED IAW ECRA 5311-01158.

Part: FRAME — CRACKED (BS 616 S17L) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND A 0.6" CRACK IN MAIN FRAME AT STA 616 JUST BELOW FLOOR, S17L. REPAIRED IAW ECRA 5311-01158.

Part: STRINGER — CORRODED (BS 1006-1016) · airframe 62,991 hrs · 32,474 cycles

INSPECTION FOUND STRINGER 26R IN AFT CARGO COMPARTMENT CORRODED FROM STA 1006-1016. THE STRINGER WAS REMOVED AND REPLACED IAW SRM 53-80-03 AND BOEING DRAWING 65-45776.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 62,991 hrs · 32,474 cycles

CORRODED AFT ENTRY FLOORBEAM AT STA 986.5. REPAIRED IAW ECRA 5310-03851.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 62,991 hrs · 32,474 cycles

CORRODED FLOORBEAM 312 RBL 35. REPAIRED IAW SRM 53-10-51, REPAIR 5, FIG 201.

Part: FRAME — CORRODED (FUSELAGE) · airframe 62,463 hrs · 32,235 cycles

INSPECTION FOUND AFT PIT FORWARD FLOOR FRAME UNDER CAMPLATE CORRODED THROUGH FRAME AT STA 787-807, S2R TO S17R. THE CORRODED SECTION OF FRAME WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: DOOR FRAME — CRACKED (AFT CARGO BAY) · airframe 62,463 hrs · 32,235 cycles

INSPECTION FOUND A 1" CRACK IN AFT CARGO DOOR AT PULLEY ATTACHMENT. THE AFT CARGO DOOR FORWARD UPPER AND LOWER CORNER ASSEMBLY (FRAME) WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: PLENUM — RUPTURED (APU)

TURBINE PLENUM OF APU RUPTURED AT A PREVIOUSLY REPAIRED WELD SEAM.

Part: SKIN — CORRODED (FUSELAGE) · airframe 59,111 hrs · 30,604 cycles

FUSELAGE SKIN CORRODED AT NR 3 VHF ANTENNA SUPPORT. INSTALLED CHANNEL PER ECRA 5331-01179.

Part: SKIN — CORRODED (STA) · airframe 58,980 hrs · 30,537 cycles

INSPECTION FOUND THE FUSELAGE SKIN UNDER NR 3 VHF ANTENNA CORRODED, STA 727D, S29L TO S29R. INSTALLED REPAIR IAW ECRA 5331-01179.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 58,980 hrs · 30,537 cycles

INSPECTION FOUND SKIN BULGING AT STA 360 MINUS 6 INCHES TO 360 WITH CORROSION ON STRINGER 25L. REPAIRED STRINGER IAW ECRA 5311-01219.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,622 hrs · 30,353 cycles

INSPECTION FOUND A .5 INCH CRACK IN FUSELAGE SKIN EIGHT INCHES FORWARD OF STA 727E AND BELOW STRINGER 22L. AN INTERIM REPAIR WAS PERFORMED IAW ECRA 5330-03410. A DIP WAS ISSUED TO INSPECT PER PART 2 WITHIN 60,000 FLIGHT CYCLES FROM REPAIR INSTALLATION AND THEN REINSPECT EVERY 25,000 CYCLES.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,622 hrs · 30,353 cycles

INSPECTION FOUND A .5 INCH CRACK IN SKIN AFT OF RT WING TO BODY FAIRING, 10 INCHES AFT OF EMERGENCY LIGHT (JUST 2 INCHES FORWARD OF BS 727E AT S23R). INSTALLED SKIN REPAIR IAW ECRA 5330-03409. A DIP WAS ISSUED TO INSPECT THE REPAIR WITHIN 60,000 FLIGHT CYCLES PER PART 2A AND REINSPECT EVERY 25,000 FLIGHT CYCLES PER PART 2B.

Part: SKIN — CRACKED (R/W FIXED L/E) · airframe 533,466 hrs · 27,558 cycles

INSPECTION FOUND AN 8" CRACK IN R/H WING FIXED L/E SKIN PANEL ABOVE #4 SLAT ACTUATOR. THE SKIN PANEL WAS REMOVED AND REPLACED IAW ECRA 5720-01894.

Part: STRINGER — CORRODED (STA 375) · airframe 53,466 hrs · 27,558 cycles

INSPECTION FOUND STRINGER 23L CORRODED AT STA 375 IN FORWARD CARGO PIT. THE CORRODED SECTION OF STRINGER WAS CUT OUT AND A NEW SECTION OF STRINGER WAS SPLICED IN IAW SRM 53-00-03.

Part: FLOORBEAM — CRACKED (STA 328) · airframe 53,466 hrs · 27,558 cycles

INSPECTION FOUND FLOORBEAM CRACKED ON UPPER ANGLE AT STA 328, LBL 12. THE CRACKED SECTION OF FLOORBEAM WAS REMOVED AND REPLACED IAW SRM 53-10-51.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 53,466 hrs · 27,558 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 990 FROM LBL 14 TO LBL 45. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 51-10-2.

Part: SEAT TRACK — CORRODED (STA 270-294.5) · airframe 53,466 hrs · 27,558 cycles

INSPECTION FOUND SEAT TRACK CORRODED BETWEEN STA 270 AND 294.5, RBL 43 UNDER G-1 GALLEY. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 53-00-52 AND 51-10-02.

Part: OVEN — MALFUNCTIONED (GALLEY) · airframe 52,045 hrs · 26,799 cycles

A STRONG TOXIC ODOR WAS OBSERVED IN THE CABIN WHILE EN ROUTE FROM MSY TO EWR. THE CABIN CREW AND PASSENGERS COMPLAINED OF THE ODOR. THE FLIGHT WAS DIVERTED TO ATL WHERE IT LANDED WITHOUT FURTHER EVENT. MAINTENANCE FOUND THAT A RELAY WITHIN THE AFT GALLEY NR 1 OVEN HAD MELTED WHICH RESULTED IN THE TOXIC ODOR. THE OVEN WAS REMOVED AND REPLACED. THE OVEN AND CONTROLLER WILL BE SHIPPED TO ENGINEERING FOR ANALYSIS.

Part: AILERON — CRUSHED (L/H WING) · airframe 50,485 hrs · 25,990 cycles

INSPECTION FOUND LEADING EDGE I/B CORNER OF L/H AILERON CRUSHED. THE AILERON WAS REPAIRED IAW ECRA 5761-01026.

Part: SKIN — DENTED (E&E DOOR) · airframe 50,485 hrs · 25,990 cycles

INSPECTION FOUND EXTERNAL SKIN OF E&E DOOR DENTED. THE E&E DOOR OUTER SKIN WAS REMOVED AND REPLACED IAW SRM 51-10-2.

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 50,485 hrs · 25,990 cycles

THE AFT RIGHT SERVICE DOOR EXTERNAL EMERGENCY LIGHT WAS FOUND INOPERATIVE. THE LIGHT ASSEMBLY WAS REMOVED AND REPLACED IAW MM 33-51-11 AND OPERATION CHECKED GOOD.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 50,485 hrs · 25,990 cycles

INSPECTION FOUND A .5 INCH CRACK IN AFT BAGGAGE BIN FLOOR SUPPORT AT STA 767, RBL 14. A REPAIR WAS INSTALLED IAW SRM 53-00-53.

Part: FRAME — CRACKED (L-1 WINDOW) · airframe 50,485 hrs · 25,990 cycles

INSPECTION FOUND A 1" CRACK IN L-1 WINDOW FRAME AT UPPER O/B CORNER. THE WINDOW FRAME WAS REPAIRED IAW SRM 53-10-01.

Part: SKIN — CRACKED (AFT CARGO DR) · airframe 50,485 hrs · 25,990 cycles

A PERMANENT REPAIR WAS INSTALLED WHERE AN INTERIM REPAIR HAD PREVIOUSLY BEEN DONE FOR 4 EACH CRACKS AT LIGHTENING HOLES IN AFT CARGO DOOR INNER SKIN. THE INTERIM REPAIR HAD BEEN PERFORMED IAW ECRA 5230-01488 AND A DIP WAS ISSUED. THE PERMANENT REPAIR WAS INSTALLED IAW ECRA 5230-01509.

Part: SKIN — CRACKED (FUSELAGE) · airframe 50,195 hrs · 25,862 cycles

INSPECTION FOUND A .5 INCH CRACK IN SKIN OF AFT CUTOUT FOR THE E&E COMPARTMENT COOLING EXHAUST AT STA 373. AN INTERNAL DOUBLER WAS INSTALLED IAW ECRA 5330-02894.

Part: SKIN — CRACKED (CARGO DOORWAY)

INSPECTION FOUND APPROXIMATELY A 2 INCH CRACK IN FUSELAGE SKIN AT FORWARD LOWER CORNER OF C-2 AFT CARGO DOOR CUTOUT. REPAIRED IAW ECRA 5330-02763.

Part: BATTERY PACK — DISCHARGED (BS 629)

THE BATTERY CHARGER ASSEMBLY AND BATTERY FAILED SYSTEM FUNCTIONAL CHECK, PACK M1135, STA 629R (28 VDC PRESENT AT PIN 2 OF PLUG POWER SUPPLY). REMOVED AND REPLACED TWO BATTERY PACKS.

Part: KEEL BEAM — CORRODED (BS 727)

INSPECTION FOUND KEEL BEAM CORRODED AT STA 727, STRINGER 27L. A REPAIR WAS INSTALLED IAW ECRA 5310-03814.

Part: FLOORBEAM — CORRODED (BS 986.5)

FLOOR SUPPORT BEAM HAS SURFACE CORROSION AROUND FASTENER HOLES STA 986.5. INSTALLED NEW FLOORBEAM PER EC/RA 5310-03450.

Part: FLOORBEAM — CORRODED (BS 328)

FORWARD GALLEY CORROSION IN HOLES UPPER AND LOWER SURFACE ON FLOORBEAM STA 328 BL 0 TO R1 Z ANGLE. CUT OUT DAMAGED SECTION OF CHORD, FABRICATED AND INSTALLED NEW CHORD PER SRM 53-10-51.

Part: FLOORBEAM — CORRODED (BS 312)

INSPECTION FOUND FLOORBEAM CORRODED AT NUTPLATES LOCATED IN E/E COMPARTMENT AT STA 312, RBL 3.5 TO 17. THE FLOORBEAM WAS REMOVED AND REPLACED IAW SRM 51-70-12, FIGURE 1.

Part: WEB — CRACKED (BS 807)

INSPECTION FOUND A 2 INCH CRACK IN AFT END OF AFT PIT CARGO DOOR UPLOCK BRACKET WEB AT STA 807. THE WEB WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: STRINGER — CORRODED (BS 5000)

INSPECTION FOUND STRINGER 27R CORRODED AT B.S. 5000. A NEW STRINGER WAS INSTALLED IAW SRM 53-30-03.

Part: FLOORBEAM — CORRODED (BS 328)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 328, 49 INCHES RIGHT OF CENTERLINE. AN L-ANGLE REPAIR WAS INSTALLED IAW SRM 51-70-11.

Part: ANGLE — CRACKED (BS 344)

INSPECTION FOUND A .50 INCH CRACK IN FLOORBEAM L-ANGLE AT STA 344, LT SIDE OF FUSELAGE. A DOUBLER WAS INSTALLED IAW SRM 51-40-2.

Part: FLOORBEAM — CRACKED (BS 520)

INSPECTION FOUND A .75 INCH CRACK IN UPPER RADIUS OF FLOORBEAM AT B.S. 520, LEFT INBOARD SEAT TRACK, OUTBOARD SIDE. REPAIRED IAW ECRA 5320-01406.

Part: STRAP — CRACKED (BS 328)

INSPECTION FOUND FLOORBEAM STRAP CRACKED IN HALF AT STA 328 CENTERLINE. A DOUBLER WAS INSTALLED IAW SRM 53-10-51, FIGURE 204.

Part: ANGLE — CRACKED (BS 328)

INSPECTION FOUND A 1 INCH CRACK IN FLOORBEAM L-ANGLE AT STA 328, 24 INCHES LEFT OF CENTERLINE. A .50 INCH CRACK WAS ALSO FOUND IN FLOORBEAM L-ANGLE AT STA 328, 32 INCHES RIGHT OF CENTERLINE. THE ANGLES WERE REMOVED AND REPLACED IAW SRM 51-10-02.

Part: YAW DAMPER — FAILED (E/E RACK)

EWR - FLT 0485 - THE AIRCRAFT TAIL BEGAN TO KICK BACK AND FORTH IN-FLIGHT TO EWR. THERE WAS NO NOTICEABLE RUDDER PEDAL MOVEMENT. THE KICKING OCCURRED IN BOTH AUTOPILOT A AND B MODES. WHEN THE YAW DAMPER WAS TURNED OFF THE CONDITION WORSENED. THE AUTOPILOT WAS RE-ENGAGED AND THEN TURNED OFF, BUT THE KICKING MOTION CONTINUED. THE AIRCRAFT LANDED WITHOUT INCIDENT. YAW DAMPER COUPLER FAILED BITE TEST. YAW DAMPER COUPLER REMOVED AND REPLACED. AUTOPILOT ACCESSORY UNIT WAS ALSO REPLACED DUE TO BITE TEST FAILURE. SDR WILL REMAIN OPEN PENDING COMPONENT TEAR-DOWN FINDINGS. SUPPLEMENT: TEAR-DOWN FND YAW DAMPER COUPLER RATE GYRO AT FAULT. NO TROUBLE FND WITH A/P ACCY UNIT WHICH PASSED ALL BENCH TESTS. (X)

Part: SAFETY SENSOR — LOOSE (RIGHT)

FLT NR 0320 - EWR - THE GEAR HANDLE WOULD NOT MOVE TO UP POSITION WHEN RAISING GEAR AFTER TAKEOFF. THE LANDING GEAR LATCH AND PRESS WARNING CIRCUIT BREAKER WAS RESET IN ACCORDANCE WITH QRH AND THE GEAR RAISED NORMALLY. MAINTENANCE FOUND THE RIGHT SAFETY SENSOR LOOSE IN ITS MOUNTING BRACKET AND CLEARANCE WAS EXCESSIVE. THE SAFETY SENSOR WAS ADJUSTED AD TIGHTENED PER MM 32-09-01, PAGES 501-507. OPERATION OF THE GEAR LEVER LATCH SYSTEM CHECKED GOOD. (M)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

BFM - INSPECTION FOUND THE EMERGENCY LIGHT ABOVE ROW 2D INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED. (W)

Part: EEL BATT PACK — DISCHARGED (CABIN)

BFM - INSPECTION FOUND THE EMERGENCY LIGHT ABOVE ROW 22 INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED. (W)

Part: EEL BATT PACK — DISCHARGED (CABIN)

BFM - INSPECTION FOUND EMERGENCY LIGHT ABOVE ROW 23 INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED. (W)

Part: EEL BATT PACK — DISCHARGED (CABIN)

BFM - INSPECTION FOUND THE EMERGENCY LIGHT ABOVE ROW 14 INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED. (W)

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

BFM - INSPECTION FOUND THE EMERGENCY LIGHT ABOVE ROW 16 INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED. (W)