N59338

Part: STRINGER SPLICE — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

STRINGER SPLICE CHANNEL AT STRINGER 14L BETWEEN STA 350 AND 360 CRACKED. REMOVED AND REPLACED SPLICE CHANNEL PER ECRA 5311-01400.

Part: SILL — CRACKED (FUSELAGE) · airframe 33,465 hrs · 10,744 cycles

SILL ASSEMBLY AT STA 303.9 FORWARD LATERAL FRAME CRACKED. REMOVED AND REPLACED SILL AT STA 303.9 PER SRM 51-40-02.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

ATTACHING CLIP AT STRINGER 8L BETWEEN BS 350 AND 360 CRACKED. REMOVED AND INSTALLED NEW CLIP PER ECRA 5311-01400.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

THE 7L INTERCOSTAL FORWARD OF STA 294.5 CRACKED. REMOVED AND REPLACED INTERCOSTAL PER ECRA 5311-01400.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

ATTACHING CLIP AT STRINGER 11L BETWEEN BS 350 AND 360 CRACKED. REMOVED AND INSTALLED NEW CLIP PER ECRA 5311-01400.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

STRINGER 16L U-CHANNEL CRACKED AT STA 360. REMOVED AND REPLACED U-CHANNEL PER ECRA 5311-01400.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

CLIP ON FORWARD END BOTTOM SIDE OF INTERCOSTAL AT STA 15L THAT ATTACHES INTERCOSTAL TO 348.2 FRAME HAS .875 INCH CRACK IN RADIUS AT I/B END. REMOVED AND REPLACED CLIP PER ECRA 5311-01400.

Part: BELTFRAME — CORRODED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

AFT CARGO BILGE AREA - CORROSION AT BELT FRAME, STA 807, APPROX LBL 24. REMOVED CORROSION AND INSTALLED REPAIR AT STA 807 APPROX LBL 24 REF SRM 53-00-07.

Part: FRAME — CORRODED (FUSELAGE) · airframe 68,218 hrs · 29,606 cycles

AFT CARGO BILGE AREA - CORROSION ON FRAME AT STA 727E APPROX LBL 24. FABRICATED REPAIR PARTS, TREATED, PRIMED AND INSTALLED REF SRM 53-00-07 REPAIR 5.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

STRINGER CLIP AT STRINGER 4L STA 380 CRACKED. REMOVED AND REPLACED STRINGER CLIP REF SRM 51-40-02.

Part: SKIN — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

R-1 DOOR CUTOUT LWR AFT CORNER CRACKED APPROX 1.5 INCHES LONG. INSTALLED REPAIR REF SRM 53-10-01 REPAIR 2.

Part: SKIN — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

R-1 DOOR CUTOUT LWR AFT CORNER CRACKED APPROX 1.5 INCH LONG. INSTALLED REPAIR REF SRM 53-10-01 REPAIR 2.

Part: STRINGER — DAMAGED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

STRINGER 4-L DAMAGED AT STA 380. REMOVED DAMAGED SECTION OF STRINGER FROM A/C AND SPLICED IN NEW. REF SRM 53-00-03 REPAIR 3.

Part: SKIN — DENTED (AFT CARGO DOOR) · airframe 65,218 hrs · 29,606 cycles

C2 AFT CARGO DOOR, DENT FOUND ON OUTER SKIN, CUT OUT DAMAGE APPROX 2 INCH SQ AT 22 INCH FROM TOP, 31 INCH FROM FWD. INCORPORATED PREVIOUS REPAIR TO FORM ON DOUBLER PER SRM 52-00-01 FIG 201 REPAIR 3. DIP ISSUED TO INSPECT REPAIR PER SRM 52-00-01 REPAIR 3 WITHIN EVERY 4000 FLIGHT CYCLES.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 65,218 hrs · 29,606 cycles

AFT FRAME WEB IS CRACKED ABOVE UPPER I/B BOLT OF LOWER STOP PAD, FWD CARGO DOOR, AFT FRAME WEB. REPLACED C-1 AFT FRAME PER SRM 51-40-02.

Part: STRAP — CORRODED (STA 847 FRAME) · airframe 58,665 hrs · 26,679 cycles

INSPECTION FOUND AFT CARGO STRAP ON FRAME CORRODED AT STA 847 ABOVE S25R. THE STRAP ON FRAME WAS REPAIRED IAW ECRA 5311-01244.

Part: STRUCTURE — CORRODED (BS 227.8) · airframe 58,665 hrs · 26,679 cycles

INSPECTION FOUND LOWER O/B CHORD CORRODED AT STA 227.8 FROM LBL 6 TO RBL 8. REPAIRED IAW ECRA 5311-01245.

Part: GATE — CORRODED (R1 DOOR) · airframe 58,665 hrs · 26,679 cycles

INSPECTION FOUND THE R-1 DOOR LOWER GATE CORRODED AT STOP PINS AND LOWER EDGE, STA 312-328, S18R. A NEW LOWER GATE WAS INSTALLED IAW MM 52-41-61. ADJUSTMENT AND CHECK PERFORMED PER WORK CARD 03-5230-1-8651.

Part: STRINGER — CORRODED (STA 344-360) · airframe 58,665 hrs · 26,679 cycles

INSPECTION FOUND STRINGER 25L CORRODED BETWEEN STA 344 AND 360 AT FORWARD O/B SUPPORT FOR E-2 AVIONICS RACK. THE STRINGER WAS REMOVED AND REPLACED IAW SRM 53-00-03.

Part: SKIN — CRACKED (CARGO DOOR) · airframe 58,665 hrs · 26,679 cycles

INSPECTION FOUND A 1/2" CRACK IN AFT CARGO DOOR INNER SKIN AT LIGHTENING HOLE ABOVE DOOR HANDLE, STA 807-847. A REPAIR DOUBLER WAS INSTALLED IAW ECRA 5232-01068.

Part: SKIN — CRACKED (CARGO DOOR) · airframe 58,665 hrs · 26,679 cycles

INSPECTION FOUND A 1/2" CRACK AT HOLE CUTOUT IN C-1 INNER DOOR SKIN, STA 440-480, S19R TO S24R. REPAIRED IAW ECRA 5232-01067.

Part: FRAME — CRACKED (STA 294.5) · airframe 58,665 hrs · 26,679 cycles

INSPECTION FOUND A .5 INCH CRACK JUST BELOW UPPER HINGE, LOWER GUIDE PLATE AREA IN R-1 DOOR FUSELAGE CUTOUT FRAME, STA 294.5, S11 R TO S14R. THE DOOR FUSELAGE CUTOUT FRAME WAS REMOVED AND REPLACED IAW SRM 51-10-02 AND 51-40-02.

Part: SKIN — GOUGED (NR 6 SLAT) · airframe 54,322 hrs · 24,708 cycles

INSPECTION FOUND RT UPPER WING L/E SKIN GOUGED BETWEEN NR 5 AND NR 6 SLAT, AT WS 250. REPAIRED IAW SRM 51-70-17.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 54,322 hrs · 24,708 cycles

INSPECTION FOUND STRINGER 27L CORRODED IN FORWARD CARGO AREA AT STA 480-500B. THE CORRODED SECTION OF STRINGER WAS REMOVED AND A REPAIR WAS INSTALLED IAW SRM 53-00-03, FIGURE 201.

Part: CARGO TRACK — DAMAGED (FUSELAGE) · airframe 54,322 hrs · 24,708 cycles

INSPECTION FOUND LT TIE DOWN RAIL LOWER FLANGE DAMAGED BY A SCREW BETWEEN STA 747-767 ABOVE STRINGER 29L. A NEW TIE DOWN RAIL WAS INSTALLED IAW SRM 53-00-53.

Part: CARGO TRACK — DAMAGED (FUSELAGE) · airframe 54,322 hrs · 24,708 cycles

INSPECTION FOUND LT TIE DOWN RAIL LOWER FLANGE DAMAGED BY A SCREW JUST AFT OF STA 867 AND ABOVE STRINGER 27L. A NEW TIE DOWN RAIL WAS INSTALLED IAW SRM 53-00-53.

Part: KEELBEAM — WORN (FUSELAGE) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND THE RT W/W AFT FAIRING ATTACH HARDWARE HAD WORN INTO RT KEEL BEAM LOWER O/B CHORD AT STA 678-727. REPAIRED IAW ECRA 5310-04218.

Part: STIFFENER — CRACKED (FUSELAGE) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND A .125 INCH CRACK IN RT WHEEL WELL AFT PANEL T-CHORD AT BS 727. A NEW T-CHORD WAS INSTALLED IAW SRM 51-10-2.

Part: DOUBLER — CRACKED (CARGO DOOR) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND A THREE INCH CRACK RUNNING PAST STOP DRILL IN C-1 DOOR INTERIOR SKIN DOUBLER. A REPAIR DOUBLER WAS INSTALLED IAW ECRA 5230-01637.

Part: FITTING — CORRODED (VERT STAB) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND VERTICAL STABILIZER ATTACH FITTING IN FUSELAGE CORRODED AT R/H AFT O/B FORWARD LUG AND AT L/H AFT O/B FORWARD LUG. THE CORROSION WAS REMOVED AND AN OVERSIZE BUSHING WAS INSTALLED AT EACH LOCATION IAW ECRA 5340-01356.

Part: BELTFRAME — CORRODED (FUSELAGE) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND BELTFRAME CORRODED IN AFT BAGGAGE BIN AT STA 927, BL 0. THE BELTFRAME WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: SKIN — DENTED (STA 807) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND FUSELAGE SKIN DENTED AND INTERNAL INTERCOSTALS BROKEN AT STA 807 FROM LBL 10 TO RBL 10. REPAIRED IAW SRM 51-10-02.

Part: WEB — CRACKED (STA 492) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND A 1/4" CRACK IN FORWARD BAGGAGE BIN WEB AT DOOR JAMB, STA 492, S25R. REPAIRED WEB IAW SRM 51-70-13.

Part: SKIN — CRACKED (#3 SLAT) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND A 1/4" CRACK AT 2 EACH RIVETS IN L/H WING #3 SLAT SKIN. REPAIRED SKIN IAW SRM 57-43-01, FIGURE 206.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 950, RBL 9-17. A NEW FLOOR SUPPORT WAS INSTALLED IAW SRM 51-10-02.

Part: STIFFENER — CORRODED (STA 1016) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND AFT PRESSURE BULKHEAD FORWARD STIFFENER LOWER CORNER CORRODED ON R/H SIDE JUST AFT OF STA 1016, BL 0. A TYPICAL FORMED SECTION REPAIR WAS INSTALLED IAW SRM 51-70-11.

Part: FLOORBEAM — CORRODED (STA 947) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND CABIN FLOORBEAM CORRODED AT STA 947, BL 0 TO LBL 6. A REPAIR WAS INSTALLED IAW SRM 53-60-51.

Part: SEAT TRACK — CORRODED (STA 917-923) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND CABIN L/H I/B SEAT TRACK CORRODED AT STA 917-923, LBL 15. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 53-00-52.

Part: FLOORBEAM — CORRODED (STA 294.5) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND FLOORBEAM UPPER CHORD CORRODED AROUND SEVERAL FASTENERS AT STA 294.5, LBL 35-51. A NEW CHORD SECTION WAS INSTALLED IAW SRM 53-10-51, FIGURE 205, SHEETS 1-4.

Part: ATTACH ANGLE — CRACKED (BS 305) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND A 1" CRACK IN STRINGER 4L ATTACH ANGLE AT BS 305. THE ATTACH ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: WEB — CRACKED (STA 637) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND A 3" CRACK IN WEB AT FLOOR LINE BELOW R/H EXIT OPENING AT STA 637, S17R. THE WEB WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: SEAT TRACK — CORRODED (STA 370) · airframe 48,440 hrs · 21,977 cycles

INSPECTION FOUND L/H O/B SEAT TRACK CORRODED AT STA 370. A REPAIR WAS INSTALLED IAW SRM 53-00-52, FIGURE 202.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 48,439 hrs · 21,977 cycles

CABIN LAVATORY WALL FLOOR SUPPORT ANGLE CORRODED AT STATION 995 LBL 13 - 42. REMOVED AND REPLACED L-ANGLE PER SRM 51-10-02.

Part: CHANNEL — CORRODED (FUSELAGE) · airframe 48,439 hrs · 21,977 cycles

CORROSION ON SUPPORT CHANNEL STATION 995 LBL 13 - 42. REMOVED AND REPLACED HAT SECTION PER SRM 51-10-02.

Part: WEB — CRACKED (STA616 17LT) · airframe 48,439 hrs · 21,977 cycles

WEB CRACKED AT STATION 616 AND STR 17 LEFT BELOW LEFT EXIT OPENING. REMOVED AND REPLACED CRACKED WEB PER SRM 51-10-02.

Part: SEAT TRACK — CORRODED (BS290 RBL35) · airframe 48,439 hrs · 21,977 cycles

SEAT TRACK CORRODED BS290 RBL 35. REPLACED SEAT TRACK PER SRM 53-00-52.

Part: MOUNT — CORRODED (FUSELAGE) · airframe 48,439 hrs · 21,977 cycles

L1 DOOR AFT GIRT LATCH MOUNT CORRODED. REMOVED AND REPLACED GIRT MOUNT PER SRM 51-10-02.

Part: MOUNT — CORRODED (FUSELAGE) · airframe 48,439 hrs · 21,977 cycles

L1 DOOR FORWARD GIRT LATCH MOUNT CORRODED. REMOVED AND REPLACED LATCH MOUNT BRACKET PER SRM 51-10-02.

Part: WIRE — BROKEN (ROW 11)

INSPECTION FOUND SEAT MOUNTED RED EMERGENCY EXIT LIGHT AT ROW 11 INOPERATIVE. MAINTENANCE FOUND A WIRE IN THE SEAT HARNESS BROKEN. THE HARNESS WAS REMOVED AND REPLACED AND OPERATION OF THE LIGHT CHECKED GOOD.

Part: WINDOW POST — CRACKED (L-1 WINDOW)

INSPECTION FOUND A 0.37 INCH CRACK IN CAPTAIN'S L-1 WINDOW POST AT AFT UPPER CORNER. THE CRACKED AREA WAS REMOVED AND A REPAIR DOUBLER WAS INSTALLED IAW ECRA 5330-02833.

Part: FLOORBEAM — CORRODED (BS 312&344)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 312, RBL 0 TO RBL 10 AND AT STA 344, RBL 0 TO RBL 2. THE CORRODED SECTIONS OF FLOORBEAM WERE REMOVED AND REPAIRS WERE INSTALLED IAW SRM 53-10-51, FIGURE 205 AND 53-00-51.

Part: CONNECTOR — FAILED (NR 2 GENERATOR)

THE NR 2 AND NR 3 TRANSFORMER RECTIFIER CIRCUIT BREAKERS POPPED ACCOMPANIED BY AN ELECTRICAL SMELL IN THE CABIN DURING CRUISE AT FL 310. THE AIRCRAFT LANDED AT CLE WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 2 GENERATOR D410 FIREWALL CANNON PLUG BURNT. THE D410 PLUG AND A PIN SOCKET AND THE FIREWALL GENERATOR RECEPTACLE D3026 AND A PIN WERE REPLACED IN REFERENCE TO WIRING DIAGRAM 24-21-21 AND STANDARD WIRE PRACTICES MANUAL 20-62-26. OPERATION OF THE NR 2 GENERATOR CHECKED GOOD.

Part: SKIN — CRACKED (RT PYLON)

INSPECTION FOUND A .375 INCH CRACK IN UPPER RT PYLON SKIN AT CUTOUT FOR ACCESS NR 5827. THE SKIN WAS REPAIRED IAW ECRA 5430-01230.

Part: FLAP — DELAMINATED (LT TE MIDFLAP)

INSPECTION FOUND UPPER MOST OUTBOARD END OF LT OUTBOARD MIDFLAP DELAMINATED. THE FLAP WAS REPAIRED IAW SRM 51-70-10, FIGURE 12.

Part: FLOORBEAM — CORRODED (BS 294)

INSPECTION FOUND FLOORBEAM CORRODED AT BS 294 ON RT SIDE. THE CORRODED SECTION OF FLOORBEAM WAS REMOVED. A NEW SECTION AND DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 53-10-51.

Part: FLOORBEAM — CORRODED (BS 328)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 328, RBL 15. A SPLICE REPAIR WAS INSTALLED IAW SRM 53-10-51, FIGURE 205.

Part: DOOR — CREASED (CARGO DOOR)

C-1 DOOR UPPER HALF DEEP CREASE JUST FWD OF DOOR CENTER LINE. INSTALLED DOUBLER IN ACCORDANCE WITH SRM 52-00-01.

Part: FLAP — DELAMINATED (LT TE FLAP)

INSPECTION FOUND LT OUTBOARD AFT FLAP DELAMINATED. THE FLAP WAS REMOVED AND REPLACED.

Part: DOOR — DENTED (CARGO DOOR)

C-1 DOOR 2 DENTS UPPER HALF AND JUST AFT OF DOOR CENTER LINE. INSTALLED DOUBLER IN ACCORDANCE WITH SRM 52-00-01.

Part: SKIN — DENTED (CARGO DOOR)

FORWARD CARGO DOOR HAS DENT 2 BY 3. INSTALLED DOUBLER IN ACCORDANCE WITH SRM 52-00-01.

Part: FOREFLAP — DELAMINATED (LT TE FOREFLAP)

INSPECTION FOUND LEFT OUTBOARD TRAILING EDGE FOREFLAP DELAMINATED ON UPPER SURFACE. THE FOREFLAP WAS REMOVED AND REPLACED.

Part: GCU — INOPERATIVE (NR 1 POSITION)

THE NR 1 GENERATOR FAILED WHILE EN ROUTE FROM EWR TO ORD. THREE ATTEMPTS TO RESET WERE UNSUCCESSFUL. THE AIRCRAFT WAS DIVERTED TO BUF WHEN ELECTRICAL FUMES AND SMOKE DEVELOPED. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE NR 1 GCU AND THE BATTERY CHARGER WERE REMOVED AND REPLACED. THE NR 1 ENGINE WAS RUN AND THE GENERATOR REMAINED ON LINE. THE BATTERY CHARGER CHECKED GOOD ON THE DC AMMETER.

Part: SKIN — CRACKED (NR 1 SLAT)

HOU - INSPECTION FOUND CRACKS COMING FROM A LINE OF SIX RIVETS ON NR 1 SLAT LOWER SKIN JUST OUTBOARD OF ACTUATOR ATTACH FITTING. TOTAL LENGTH OF CRACKS WAS 5.5 INCHES. A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW BOEING DRAWING NR 65C30133 AND ECRA 5750-01159. (X)

Part: SKIN — CRACKED (NR 6 SLAT)

HOU - INSPECTION FOUND CRACKS COMING FROM A LINE OF THREE RIVETS ON NR 6 SLAT LOWER SKIN AT INBOARD AUXILIARY TRACK. TOTAL LENGTH OF CRACKS WAS 2.5 INCHES. A DOUBLER WAS FABRICATED AND INSTALLED IAW ECRA 5750-01159. (X)

Part: SKIN — CRACKED (NR 6 SLAT)

HOU - INSPECTION FOUND CRACKS COMING FROM A LINE OF TWO RIVETS ON NR 6 SLAT LOWER SKIN BETWEEN TAIL DUCT AND ACTUATOR. TOTAL LENGTH OF CRACKS WAS 1.125 INCHES. A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW ECRA 5750-01159. (X)

Part: SKIN — GOUGED (RUDDER)

HOU - INSPECTION FOUND A 0.2 INCH WIDE BY 6 INCH LONG GOUGE IN RUDDER RIGHT SKIN PANEL. THE AREA WAS REPAIRED IAW ECRA 5540-01061 AND SRM 51-70-17, FIGURE 19. (X)