N61304

Part: SKIN — CRACKED (CARGO DOOR) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1 INCH CRACK IN FORWARD CARGO DOOR INNER SKIN AT THE CENTER INTERCOSTAL ON THE BOTTOM. A DOUBLER WAS INSTALLED IAW ECRA 5232-01081.

Part: INTERCOSTAL — CRACKED (BS 294-312) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1/2" CRACK IN L-1 DOOR FORWARD SIDE UPPER HINGE INTERCOSTAL LOWER WEB AT STA 294.5-312, S10L. THE INTERCOSTAL WEB WAS REPAIRED IAW ECRA 5311-01270 AND A DIP WAS INITIATED TO REINSPECT THE AREA.

Part: STRINGER SPLICE — CRACKED (BS 344-360) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1/2" CRACK IN L-1 DOOR AFT NR 15 INTERCOSTAL STRINGER SPLICE AT STA 344-360, S15L. A NEW STRINGER SPLICE CHANNEL WAS INSTALLED IAW ECRA 5311-01269 AND A DIP WAS INITIATED TO REINSPECT THE AREA.

Part: STRINGER SPLICE — CRACKED (BS 344-360) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1/2" CRACK IN THE L-1 DOOR AFT NR 14 INTERCOSTAL STRINGER SPLICE AT STA 344-360, S14L. THE STRINGER SPLICE WAS REPLACED IAW ECRA 5311-01271 AND A DIP WAS INITIATED TO REINSPECT THE AREA.

Part: FITTING — CRACKED (BS 639) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1/4" CRACK IN A FRAME FITTING ON RT SIDE OF FUSELAGE JUST AFT OF STA 639, S15L, FRAME IS JUST BELOW THE CREASE BEAM IN THE MAIN CABIN. REPAIRED IAW SRM 51-10-02.

Part: FRAME — CORRODED (BS 227) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND LOWER O/B CHORD OF BULKHEAD CORRODED AT STA 227.8, LBL 5 TO RBL 10, S29L TO 29R. A REPAIR WAS INSTALLED IAW ECRA 5311-01268.

Part: SLAT TRACK — CRACKED (NR 6 SLAT) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1 INCH CRACK AROUND RIVET HOLES IN RT WING NR 6 SLAT I/B AUX TRACK LOWER AREA. THE AREA WAS REPAIRED IAW SRM 57-43-01.

Part: FRAME — CORRODED (BS 727B S26-27L) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND UPPER SURFACE OF FRAME CORRODED AT STA 727B BETWEEN S26L AND S27L. THE CORRODED SECTION OF FRAME WAS TRIMMED OFF AND A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-00-07, FIGURE 201.

Part: FITTING — CORRODED (BS 1088) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND LEFT AFT FWD, RIGHT AFT FWD, AND RIGHT AFT O/B VERTICAL STABILIZER DRAG ANGLE FITTINGS CORRODED AT STA 1088, S2L AND S2R. THE FITTINGS WERE REMOVED AND REPLACED IAW SRM 51-40-02 AND BOEING DRAWING 65-73744.

Part: FITTING — CORRODED (FLAP TRACK) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND NR 1 FLAP TRACK AFT SPAR FITTING CORRODED AT MOUNT BOLT. THE SPAR FITTING WAS REMOVED AND REPLACED IAW SRM 51-40-02 AND BOEING DRAWING 65-46429.

Part: SHEAR TIE — CORRODED (STA 500) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND LOWER CENTER SHEAR CLIP ON FRAME IN FORWARD CARGO COMPARTMENT AT STA 500, S28L TO 28R CORRODED. THE CORRODED AREA WAS REMOVED AND FILLER AND DOUBLER WERE INSTALLED IAW SRM 53-00-07.

Part: STRINGER — CORRODED (BS 967 S25L) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND STRINGER 25L CORRODED AT STA 967. A NEW STRINGER SECTION WAS SPLICED IN IAW SRM 53-00-03.

Part: STRINGER — CORRODED (STA 344-360) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND STRINGER 25L CORRODED AT STA 344-360. THE CORRODED SECTION OF STRINGER WAS CUT OUT AND A STRINGER REPAIR WAS INSTALLED IAW SRM 53-00-03, REPAIR NR 1.

Part: INTERCOSTAL — CRACKED (BS 360) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1" CRACK IN L-1 DOOR AFT INTERCOSTAL INNER STRAP AT STA 360, S16L. THE INTERCOSTAL INNER STRAP WAS REPAIRED IAW SRM 53-10-04.

Part: STRINGER — CORRODED (BS 1016 S24L) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND STRINGER 24L CORRODED AT STA 1016, LBL 20. THE STRINGER WAS REPAIRED IAW SRM 53-00-03.

Part: FLOORBEAM — CORRODED (BS 1016) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1016, RBL 4 TO RBL 36. THE FLOORBEAM UPPER CHORD WAS REMOVED AND REPLACED IAW ECRA 5310-03851.

Part: CREASE BEAM — CRACKED (BS 616) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1.5 INCH CRACK IN RIGHT SIDE CREASE BEAM WEB JUST AFT OF STA 616, RBL 45. THE WEB WAS REMOVED AND A NEW WEB WAS INSTALLED IAW SRM 51-40-02.

Part: FLOORBEAM — CORRODED (BS 1016) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1016, RBL 4 TO RBL 36. THE FLOORBEAM UPPER CHORD WAS REMOVED AND REPLACED IAW ECRA 5310-03851.

Part: PRESSURE PANEL — CRACKED (BS 663.75) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1.5 INCH CRACK IN MAIN CABIN LOWER PRESSURE DECK AT STA 663.75, LBL 30. A REPAIR WAS INSTALLED IAW SRM 53-60-51, FIGURE 201.

Part: FRAME — CORRODED (FUSELAGE) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND HEAVY INTERGRANULAR CORROSION ON FORWARD SIDE OF FRAME AT STA 219.8, S27R, RBL 17, O/B LOWER CHORD. A NEW CHORD WAS INSTALLED IAW SRM 51-2-02 AND 51-40-02.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND RT OB SEAT TRACK CORRODED AT STA 540-727, RBL 24. THE SEAT TRACK WAS REPLACED IAW SRM 53-00-52, REPAIR 2, FIGURE 201.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A .5 INCH CRACK IN STRINGER 16L BETWEEN STA 500C AND 500D. THE STRINGER WAS REMOVED AND REPLACED IAW SRM 53-30-03.

Part: FITTING — CORRODED (RT HORIZ STAB) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND RT HORIZONTAL STABILIZER FORWARD AIRFRAME MOUNT LUG AT LOWER AFT AND FORWARD POSITIONS AND AT UPPER FORWARD AND AFT POSITIONS CORRODED. THE AREA WAS REPAIRED AND NEW BUSHINGS WERE INSTALLED IAW SRM 55-10-10.

Part: FITTING — CORRODED (RT HORIZ STAB) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND RT HORIZONTAL STABILIZER AFT AIRFRAME MOUNT LUG AT LOWER AND UPPER FORWARD POSITIONS CORRODED. THE AREA WAS REPAIRED AND NEW BUSHINGS WERE INSTALLED IAW SRM 55-10-10.

Part: FRAME — CRACKED (FUSELAGE) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND A 1 INCH CRACK IN LT MAIN FRAME AT STA 616 JUST BELOW FLOOR, S17L. A REPAIR ANGLE AND FILLER WERE INSTALLED IAW ECRA 5311-01158.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND SEAT TRACK CORRODED AT STA 270-294.5, RBL 42. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND RIGHT O/B SEAT TRACK CORRODED AT STA 328. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 61,624 hrs · 31,931 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 328, RBL 32-50. THE CORRODED AREA WAS BLENDED OUT AND A STRAP DOUBLER WAS INSTALLED IAW SRM 53-00-51 FIGURE 201.

Part: BEAM — CRACKED (WS 538 AILERON) · airframe 60,113 hrs · 31,218 cycles

THE LT AILERON BEAM WAS FOUND CRACKED AT WS 538, THE CRACK WAS STOP DRILLED PER ECRA 5752-01230. A DIP WAS ISSUED TO REINSPECT THE AREA AT 50 FLIGHT HOUR INTERVALS UNTIL A PERMANENT REPAIR IS PERFORMED PER ECRA 5752-01230.

Part: PANEL — CRACKED (NR 2 PYLON) · airframe 57,324 hrs · 29,797 cycles

INSPECTION FOUND TWO 1 INCH CRACKS IN NR 2 PYLON PANEL CUTOUT 5824R. THE CRACKS WERE LOCATED AT UPPER FORWARD CORNER OF PANEL. ONE CRACK ORIGINATED FROM RIVET HOLE FOR RUB STRIP AND THE OTHER WAS ON FAYING SURFACE FOR ACCESS PANEL.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 57,324 hrs · 29,797 cycles

INSPECTION FOUND LT SIDE KEELBEAM CORRODED BETWEEN STA 520 AND 540, LBL 10. A KEEL BEAM SPLICE REPAIR WAS INSTALLED IAW SRM 53-60-12, FIGURE 203.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 55,976 hrs · 25,318 cycles

INSPECTION FOUND STRINGER 26L CORRODED BETWEEN STA 440 AND 500D. THE STRINGER WAS REPAIRED USING A SPLICE IAW ECRA 5311-01215.

Part: SKIN — CRACKED (FUSELAGE) · airframe 56,682 hrs · 29,459 cycles

INSPECTION FOUND A 1 INCH CRACK IN EXTERNAL SKIN BETWEEN STA 947.5 AND 967, S10L TO S11L (L-2 DOOR UPPER HINGE CUTOUT FORWARD CORNER RADIUS JUST BELOW THE RAIN GUTTER). A REPAIR WAS INSTALLED IAW SRM 53-60-01, FIGURE 205. A DIP WAS ISSUED TO REINSPECT THE AREA WHEN AIRFRAME HAS ACCUMULATED A TOTAL OF 60,000 CYCLES. THEN ACCOMPLISH REPETITIVE INSPECTIONS EVERY 4,000 CYCLES THEREAFTER AND WITHIN EVERY 15,000 CYCLES AFTER INITIAL, ACCOMPLISH MFEC INSPECTION OF BEARSTRAP INTERNALLY.

Part: SKIN — CRACKED (FUSELAGE) · airframe 54,936 hrs · 28,541 cycles

INSPECTION FOUND A 5 INCH CRACK IN FUSELAGE BELLY SKIN AFT OF E&E COOLING DUCT AT BS 380, S28L. THE CRACK WAS STOP DRILLED AND A DOUBLER WAS INSTALLED IAW ECRA 5330-02894.

Part: DOUBLER — CRACKED (R/W I/B T/E) · airframe 52,276 hrs · 27,079 cycles

INSPECTION FOUND A 2" CRACK IN R/H WING UPPER I/B T/E PANEL DOUBLER, WBL 80. THE DOUBLER WAS REMOVED AND REPLACED IAW SRM 51-70-11.

Part: ANGLE — CRACKED (L/W O/B AFT) · airframe 52,276 hrs · 27,079 cycles

INSPECTION FOUND A 3" CRACK IN L/H WING LOWER/AFT O/B SUPPORT ANGLE. THE SUPPORT ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-2.

Part: STIFFENER — CORRODED (BS 1016-1022) · airframe 52,276 hrs · 27,079 cycles

INSPECTION FOUND CENTER STIFFENER ON AFT PRESSURE BULKHEAD FORWARD FACE CORRODED ON R/H SIDE, IN BILGE, BS 1016-1022. REPAIRED STIFFENER IAW SRM 51-70-11 AND 53-80-08.

Part: STIFFENER — CRACKED (FUSELAGE) · airframe 52,276 hrs · 27,079 cycles

INSPECTION FOUND A .5 INCH CRACK IN STIFFENER ACROSS BOTTOM OF FLOORBEAMS AT STA 328, RBL 45, WL 201. A DOUBLER WAS INSTALLED IAW SRM 53-10-51.

Part: STIFFENER — CRACKED (FUSELAGE) · airframe 52,276 hrs · 27,079 cycles

INSPECTION FOUND A .5 INCH CRACK IN STIFFENER ACROSS BOTTOM OF FLOORBEAMS AT STA 312, RBL 36, WL 201. THE CRACK WAS STOP DRILLED AND A DOUBLER WAS INSTALLED IAW SRM 53-10-51.

Part: WEB — CRACKED (FUSELAGE) · airframe 52,276 hrs · 27,079 cycles

INSPECTION FOUND A .5 INCH CRACK IN CABIN FLOOR VERTICAL WEB AT STA 1016, LBL 26 BELOW STRAP. A REPAIR WAS INSTALLED IAW SRM 51-40-00.

Part: FLOORBEAM — CORRODED (STA 328) · airframe 52,276 hrs · 27,079 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 328, LBL 34. THE CORRODED AREA OF FLOORBEAM WAS CUT OUT. A CHORD AND SPLICE ANGLE REPAIR WAS INSTALLED IAW SRM 53-10-51, FIGURE 205.

Part: GROUND WIRE — UNSECURE (CABIN) · airframe 51,102 hrs · 26,449 cycles

THE RIGHT WING EMERGENCY EXIT SIGN WOULD NOT TEST. MAINTENANCE FOUND LIGHT ASSEMBLY GROUND WIRE NOT SECURED TO GROUND STUD. TIGHTENED LOCKING NUT AND OPERATION OF THE LIGHT CHECKED GOOD.

Part: ACCESS PANEL — CRACKED (LT PYLON) · airframe 49,005 hrs · 25,372 cycles

LEFT ENGINE PYLON UPPER OUTBOARD ACCESS PANEL CRACKED AT CUTOUT (.75 INCH). STOP DRILLED CRACK AND INSTALLED A REPAIR DOUBLER PER EC/RA 5430C01230.

Part: SKIN — CRACKED (FUSELAGE) · airframe 48,925 hrs · 25,327 cycles

PILOTS OUTBOARD WINDOW POST CRACKED AT TOP OUTBOARD CORNER (.75 INCH). INSTALLED REPAIR DOUBLER ON PST PER SRM 53-10-01 FIG 210.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 48,360 hrs · 25,069 cycles

INSPECTION FOUND TWO 1 INCH CRACKS IN BULKHEAD WITH A STIFFENER BROKEN IN HALF AT STA 178. THE BULKHEAD WAS REMOVED AND REPLACED IAW EA 5310-03040.

Part: SKIN — CORRODED (FUSELAGE) · airframe 46,926 hrs · 24,298 cycles

INSPECTION FOUND SKIN CORRODED AND RIVET HEADS PULLED THROUGH SKIN AT STA 530-538, RBL 6.25. THE SKIN, KEEL BEAM LOWER CHORD, AND WING CENTER SECTION FRONT SPAR WERE REPAIRED IAW ECRA 5310-04024.

Part: FRAME/BEAM — CRACKED (FWD CARGO DR)

INSPECTION FOUND A 1 INCH CRACK IN LOWER AFT FRAME AND A 2 INCH CRACK IN T-BEAM OF FORWARD CARGO DOOR LOWER FORWARD CORNER. THE FRAME WAS REPLACED IAW SRM 51-10-02 AND 51-40-02. THE BEAM WAS REPAIRED IAW ECRA 5230-01491.

Part: FLOORBEAM — CORRODED (BS 1006)

INSPECTION FOUND LT AFT LAV FLOORBEAM CORRODED AT STA 1006, LBL 16 TO LBL 28. REPAIRED IAW SRM 53-00-51.

Part: FLOORBEAM — CORRODED (BS 1016)

INSPECTION FOUND LT AFT LAV FLOORBEAM CORRODED AT FASTENER HOLE, STA 1016, WL 208, LBL 5 TO LBL 38. THE FLOORBEAM WAS REPAIRED IAW ECRA 5310-03450.

Part: FLOORBEAM — CORRODED (BS 986.5)

INSPECTION FOUND FLOORBEAM T CAP CORRODED AT STA 986.5, WL 208, BBL 0 TO RBL 15. THE T CAP WAS REPLACED IAW SRM 53-00-51.

Part: LOGIC CARD — FAILED (NLG)

THE NOSE GEAR RED UNSAFE LIGHT ILLUMINATED WHILE EN ROUTE. THE LANDING GEAR LEVER WAS PLACED TO UP THEN OFF AGAIN, BUT THE LIGHT REMAINED ILLUMINATED. THE LIGHT EXTINGUISHED DURING DESCENT WITHOUT FURTHER ACTION. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE M983 LANDING GEAR LOGIC CARD AT FAULT. THE M983 LOGIC CARD WAS REPLACED. IN ADDITION, THE NOSE GEAR LOCK TARGET GAP WAS RESHIMMED, OPERATION AND INDICATIONS CHECKED NORMAL.

Part: SENSOR — INOPERATIVE (NLG)

THE NOSE GEAR RED LIGHT REMAINED ON WHEN GEAR WAS EXTENDED FOR LANDING ON APPROACH TO IAH. THE GEAR WAS MANUALLY EXTENDED AND THREE GREEN LIGHTS WERE INDICATED. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NLG SAFETY SENSOR AT FAULT. THE NLG SAFETY SENSOR WAS REMOVED AND REPLACED IAW MM 32-09-02, PAGE 401. THE NOSE GEAR WAS RETRACTED SEVERAL TIMES WITH OPERATION AND INDICATIONS CHECKING GOOD.

Part: BEARING — FAILED (RT MLG)

RDU - FLT 0238 - THE RT MLG BRAKE APPEARED TO BE DRAGGING AFTER LANDING AT RDU. MAINTENANCE FOUND THE NR 4 WHEEL BEARING ON THE RT MLG FAILED WITH RESULTANT DAMAGE TO THE AXLE. THE LOWER STRUT ASSY WAS REPLACED. BOTH THE NR 3 AND NR 4 BRAKE, TIRE AND WHEEL ASSYS ON THE RT GEAR WERE REMOVED AND REPLACED. THE SDR WILL REMAIN OPEN PENDING INVESTIGATION OF THE BEARING FAILURE. SUPPLEMENT - ENGINEERING CONFIRMED NR 4 BEARING FAILURE AS CAUSE. (X)

Part: FLOORBEAM — CORRODED (BS 328)

BFM - INSPECTION FOUND MAIN CABIN FLOORBEAM CORRODED AT BS 328, RBL 42. THE FLOORBEAM WAS REPAIRED IAW EC 5363-01007. (X)

Part: FLOORBEAM — CORRODED (FS 986.5)

BFM - INSPECTION FOUND FLOORBEAM CORRODED ON TOP CAP AND LOWER SURFACE AT STA 986.5. THE FLOORBEAM WAS REPAIRED IAW EC 5310-01102. (X)