N59630

Part: ENGINE — FAILED (NR 1) · airframe 43,848 hrs · 22,910 cycles

SUDDEN NR 1 ENG FAILURE AT FL 360. NR 1 ENG PARAMETERS DURING DESCENT: N1-18% N2-0 EGT DECREASING REPLACED NR 1 ENG PER W/C 03-7100-1-9400 AND PERFORMED ENG RUN TEST 9 W/C 03-7100-1-8902 OPS LEAKED CHECKED NORMAL ROTABLE PARTS CHANGE WAS INDICATED - TT # 0809921 S/N OFF 06918 ENGINE, BASIC, OFF 03-7200-9-0001 6918 ON 03-7200-9-0001 0239.

Part: LOCK — FAILED (GEAR HANDLE) · airframe 43,815 hrs · 22,892 cycles

ON TAKEOFF GEAR HANDLE STAYED IN THE LOCKED POS. COULD NOT RAISE GEAR, RAN CHECK LIST. RELEASED UP LOCK TRIGGER GEAR CAME UP APPERS THE LEVER LOCK FAILED. JACKED A/C PER AMM 07-11-11-582-020 AND OPS CHECKED LANDING GEAR PER AMM 32-32-00-715-001 AND AMM 32-33-00-735-005, OPS CHECK NORMAL.

Part: TRANSMITTER — INOPERATIVE (TE FLAP) · airframe 41,928 hrs · 21,845 cycles

WHILE EXTENDING FLAPS, FLAPS STOPPED EXTENDING BETWEEN 1+2DEG. ALTERNATE FLAP EXTENSION PROCEDURE USED FOR FLAP 15DEG LANDING. R & R LEFT WING FLAP POSITION TRANSMITTER IAW MM27-58-12 404/ 406. OPS CHECK GOOD. PERFORMED LAND VERIFY IAW 22-03-10 (TEST PASSED). A/C REMAINS CAT 2 AUTOLAND.

Part: UPLOCK SENSOR — MALFUNCTIONED (RT MLG) · airframe 38,874 hrs · 20,285 cycles

FOR TDR PURPOSES ONLY. FOR TDR PURPOSES ONLY, REF LP 8236020, R MLG DID NOT INDICATE UP AND LOCKED AFTER GEAR RETRACTION.

Part: WIRE HARNESS — DAMAGED (RT WING) · airframe 38,379 hrs · 20,000 cycles

RIGHT WING FUEL QUANTITY INDICATOR SYSTEM (FQIS) WIRING SHIELD BRAIDING BROKEN AT JET PUMP. REMOVED AND REPLACED FQIS HARNESS M1734 PER 28-41-45-404-025, OPS CHECKS GOOD.

Part: WIRE HARNESS — DAMAGED (LT WING) · airframe 38,379 hrs · 20,000 cycles

LEFT WING FUEL QUANTITY INDICATOR SYSTEM (FQIS) SHIELD BRAIDING BROKEN AT JET PUMP. REMOVED AND REPLACED FQIS HARNESS M1732 PER 28-41-45-404-025, OPS CHECKS GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 38,326 hrs · 19,968 cycles

FORWARD RIGHT ENTRY DOOR EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED BATTERY PACK FOR FORWARD RIGHT DOOR IAW 33-51-51.

Part: CABLE ASSY — MISINSTALLED (R2 DOOR) · airframe 38,276 hrs · 19,946 cycles

R-2 DOOR EMERGENCY ESCAPE SLIDE LATCH CABLE LOOP ENDS ARE INSTALLED ON THE INCORRECT SIDES OF THE LATCH HOLE REF AMM 737-3/5, TASK 25-61-35-402-007, FIGURE 205 CAUSING CABLE TO TWIST OR CROSS OVER BETWEEN THE GIRT BAR AND THE LATCH. REPOSITIONED CABLE END LOOPS ON LATCH/BOLT. NEW NUT AND CABLE TIE WRAPS, 737-3/5 MM 25-61-35-402-007 ARM AND STOW OK.

Part: ACTUATOR — FAILED (RT MLG) · airframe 37,868 hrs · 19,741 cycles

RIGHT MAN GEAR UNSAFE WARNING AFTER TAKEOFF, PERFORMED MANUAL GEAR EXTENSION, ALL GEAR INDICATED DOWN AND LOCKED. PERFORMED NORMAL LANDING. REMOVED AND REPLACED MAIN GEAR UPLOCK ACTUATOR PER AMM 32-32-41, OPS CHECKS GOOD. PERFORMED GEAR SWING, ALL INDICATIONS NORMAL AT THIS TIME, OK TO CONTINUE. ROTABLE PARTS CHANGE WAS INDICATED - T/T 1313833, S/N OFF 00630 ACTUATOR, MLG, OFF 03-3296-9-0001 0630 ON 03-3296-9-0001 3555.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

LEFT FUSELAGE FRAME IS CRACKED AT PSU RAIL SUPPORT BRACKET MOUNT RIVET LOCATED BETWEEN STRINGERS 8 AND 9 AND STATION 360. REMOVED SUPPORT RAIL AND ACCOMPLISHED REPAIR PER ECRA 5311-01428.

Part: SKIN — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

AIR CONDITONING ACCESS CUTOUT DAMAGED ON FUSELAGE, 1 INCH CRACK ON LEFT SIDE AND COMING LOOSE AT PREVIOUS DOUBLER ON AFT SIDE. INSTALLED INTERIM REPAIR TO FUSELAGE SKIN AT STATION 540 S-28R PER ECRA 5331-01427 AND INITIATED A DIP WHICH READS BEFORE THE ACCUMULATION OF 79,053 TOTAL AIRCRAFT FLIGHT CYCLES, PERFORM AN INSPECTION PER PART 2 OF ECRA 5331-01427. 53-DIP, CNTL 90817.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

STATION 178 BULKHEAD INSPECTION: REMOVED RT, LT SIDE WEBS AND CENTER WEB FOR INSPECTION REF EA 5310-03040 WHERE CRACKS WERE FOUND. INTERIM REPAIR COMPLETED AT BODY STATION 178 BULKHEAD PER ECRA 5310-04858 AND INITIATED A DIP WHICH READS ACCOMPLISH A PERMANENT REPAIR WITHIN 24 MONTHS FROM 21-OCT-08. PLANNING TO CONTACT ENGINEERING AFTER 21-AUG-10 BUT BEFORE 21-SEP-10 FOR PERMANENT REPAIR.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

RIGHT FUSELAGE FRAME IS CRACKED AT PSU RAIL SUPPORT BRACKET MOUNT RIVET LOCATED BETWEEN STRINGERS 8 AND 9 AT STATION 440. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED REPAIR ANGLES. SEALED AND PRESERVED REPAIR REF EA 5310-04498 OP 2.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

LEFT FUSELAGE FRAME IS CRACKED AT PSU RAIL SUPPORT BRACKET MOUNT RIVET LOCATED BETWEEN STRINGERS 8 AND 9. CUT OUT DAMAGED WEB OF FRAME STATION 867 BETWEEN S8L AND S9L AND INSTALLED REPAIR ANGLES REF EA 5310-04498 OP 2.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

LEFT FUSELAGE FRAME IS CRACKED AT PSU RAIL SUPPORT BRACKET MOUNT RIVET LOCATED BETWEEN STRINGER 8 AND 9 AT STATION 440. INSTALLED REPAIR DOUBLER PER EA 5310-04498 OP 2.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

CABIN STATION 867 BETWEEN S8R AND S9R PSU SUPPORT BRACKET TO FRAME CRACKED. REMOVED DAMAGED FRAME WEB AND INSTALLED REPAIR ANGLES REF EA 5310-04498 OP 2.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

FUSELAGE STATION 787 BETWEEN S8R AND S9R PSU SUPPORT BRACKET TO FRAME CRACKED. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR ANGLES PER EA 5310-04498.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

RIGHT FUSELAGE FRAME IS CRACKED AT PSU RAIL SUPPORT BRACKET MOUNT RIVET LOCATED BETWEEN STRINGERS 8 AND 9 AT STATION 380. REPAIRED FRAME STATION 380 RIGHT SIDE REF EA5310-04498.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

LEFT FUSELAGE FRAME IS CRACKED AT PSU RAIL SUPPORT BRACKET MOUNT RIVET LOCATED BETWEEN STRINGERS 8 AND 9 AT STATION 827. REMOVED DAMAGE AREA AND INSTALLED REPAIR ANGLES A AND B REF ECRA 5311-01427.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

LEFT FUSELAGE FRAME IS CRACKED AT PSU RAIL SUPPORT BRACKET MOUNT RIVET LOCATED BETWEEN STRINGERS 8 AND 9 AT STATION 400. REPAIRED LEFT FUSELAGE, FRAME STATION 400 BETWEEN S8L AND S9L PER EA 5310-04498.

Part: FRAME — CRACKED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

CABIN STATION 907 BETWEEN S8R AND S9R PSU SUPPORT BRACKET TO FRAME CRACKED, APPROXIMATELY 1 INCH. REPAIRED FRAME PER EA 5310-04498 OPT 2.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 36,527 hrs · 19,053 cycles

AFT ENTRY STATION 947 - 967 FLOOR SUPPORT AT LBL 25 CORRODED. REMOVED AND REPLACED FLOOR SUPPORT PER SRM 51-40-02.

Part: SKIN — WORN (FUSELAGE) · airframe 35,662 hrs · 18,588 cycles

UPPER FUSELAGE SKIN IS WORN AT STATION 875 - 880 CAUSED FROM DORSAL FIN SEAL CHAFING. INSTALLED PERMANENT REPAIR PER ECRA 5331-01408 REV B.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 30,858 hrs · 16,087 cycles

INSPECTION FOUND R-2 DOOR Z-ANGLE CORRODED IN SEVERAL AREAS ALONG ENTIRE LENGTH, STA 927-1006, S17R. THE Z-ANGLE WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 30,858 hrs · 16,087 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 947.5, LBL 5. THE CORROSION WAS REMOVED AND A REPAIR STRAP WAS INSTALLED IAW SRM 53-00-51, FIGURE 201.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 30,858 hrs · 16,087 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 986.5, LBL 4, LBL 30, LBL 43, AND RBL 38. THE CORROSION WAS REMOVED AND A REPAIR WAS INSTALLED AT EACH LOCATION IAW SRM 53-00-51, FIGURE 201.

Part: SPAR — GOUGED (FUSELAGE) · airframe 24,917 hrs · 13,065 cycles

INSPECTION FOUND A GOUGE IN RT HORIZONTAL STABILIZER L/E SPAR CAP BETWEEN STA 239.9 AND 249.1 AT I/B SIDE. REPAIRED IAW ECRA 5510-01704.

Part: SKIN — DENTED (HORIZONTAL STAB) · airframe 24,917 hrs · 13,065 cycles

THE RT HORIZONTAL STABILIZER LOWER SKIN SURFACE WAS FOUND DENTED APPROXIMATELY 1 INCH FROM FORWARD LOWER SPAR AND APPROXIMATELY 5 FT I/B OF TIP. REPAIRED IAW ECRA 5510-01704.

Part: SLIDE — UNSERVICEABLE (L1 DOOR) · airframe 21,896 hrs · 11,441 cycles

THE L1 DOOR EMERGENCY ESCAPE SLIDE PRESSURE WAS OUT OF GREEN BAND. THE SLIDE WAS REMOVED AND REPLACED IAW MM 25-61-35.

Part: PIN — CRACKED (LT MLG) · airframe 21,348 hrs · 11,126 cycles

THE LT MLG ACTUATOR BEAM ARM FAILED ULTRASONIC INSPECTION. THE AFT LUG (ANTI-ROTATION PIN LUG) HAD A 3 INCH CRACK. THE LT MLG ASSEMBLY WAS REMOVED AND REPLACED IAW MM 32-11-00.

Part: CREASE BEAM — CRACKED (FUSELAGE) · airframe 18,772 hrs · 9,699 cycles

INSPECTION FOUND A 1 INCH CRACK IN LT CREASE BEAM AT STA 360 - 390. THE CREASE BEAM WAS REMOVED AND REPLACED IAW SRM 51-40-00.

Part: SKIN — DENTED (L1 DOOR) · airframe 18,772 hrs · 9,699 cycles

INSPECTION FOUND THE L-1 DOOR SKIN DENTED BELOW UPPER HINGE. A DOUBLER WAS INSTALLED IAW SRM 52-00-01.

Part: SKIN — CRACKED (T/E FLAP) · airframe 18,772 hrs · 9,699 cycles

INSPECTION FOUND L/E SKIN WORN WITH A .25 INCH CRACK AT LT WING O/B MIDFLAP O/B HALF. A FILLER AND DOUBLER WERE INSTALLED IAW SRM 57-53-01, FIGURE 208.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 18,772 hrs · 9,699 cycles

INSPECTION FOUND R-2 DOOR Z-ANGLE CORRODED AT STA 991. THE Z-ANGLE WAS REPLACED AND THE DRAIN PAN WAS REINSTALLED IAW SRM 51-10-02 AND 51-40-00.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 18,772 hrs · 9,699 cycles

Z-FLOOR SUPPORT STATION 992.5 RBL 37 CORRODED. REMOVED AND REPLACED FLOOR SUPPORT PER SRM 51-10-02 AND 53-60-51.

Part: SEAT TRACK — WORN (COCKPIT) · airframe 18,772 hrs · 9,699 cycles

SEAT TRACK AFT INBOARD FIRST OFFICER SEAT WORN. REMOVED AND REPLACED SEAT TRACK PER MM 25-11-11.

Part: COUPLER — INOPERATIVE (AP SYSTEM)

THE AIRCRAFT EXPERIENCED AN UNCOMMANDED ROLL OF 30 DEGREES LEFT AT 7,000 FEET AND 210 KNOTS. THE AUTOPILOT WAS DISCONNECTED AND LEVEL FLIGHT WAS REGAINED. WHEN THE AUTOPILOT WAS RECONNECTED THE AIRCRAFT FLEW NORMALLY. THE FLIGHT WAS CONTINUED WITHOUT FURTHER PROBLEMS. MAINTENANCE TESTED THE AUTOPILOT AND DFC SYSTEMS AND PERFORMED A LAND VERIFY WITH ALL SYSTEMS PASSING TEST. THE YAW DAMP COUPLER WAS REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE AND TESTED IAW MM 22-12-31. THE SDR WILL REMAIN OPEN PENDING SHOP FINDINGS ON YAW DAMP COUPLER. THE YAW DAMP COUPLER VENDOR TEAR-DOWN REPORT STATED THAT REJECTION OF THE COMPONENT WAS NOT CONFIRMED. PART TOTAL CYCLES, 2,077.

Part: STARTER — FAILED (NR 2 ENGINE)

SNA - FLT 1516 - THE NR 2 ENGINE WOULD NOT ROTATE ON START AND THE CREW REPORTED A MINOR EXPLOSION. INSPECTION OF THE NR 2 ENGINE REVEALED AN UNCONTAINED STARTER FAILURE WITH RESULTANT DAMAGE TO THE LT FAN COWL, NOSE COWL, AND CSD. THE NR 2 ENGINE STARTER WAS REPLACED IAW MM 80-11-01. THE DAMAGED CSD, LT FAN COWL, AND NOSE COWL WERE REMOVED AND REPLACED. IN ADDITION, THE CSD OIL COOLER AND STARTER SHUT-OFF VALVE WERE REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE. THE NR 2 ENGINE WAS RUN AND OPERATION CHECKED GOOD. (X)