N635DL

Part: SKIN — DAMAGED (LT WING) · airframe 90,927 hrs · 41,900 cycles

LEFT WING OTBD FIXED L/E COMPOSITE SKIN PANEL CRACKED AT CENTER OF NR 4 SLAT. REPAIRED LEFT WING OTBD FIXED L/E FIXED PANEL AT CENTER OF NR 4 SLAT IAW SRM AND AMM.

Part: GUIDE — OUT OF ADJUST (L4 DOOR) · airframe 89,953 hrs · 41,509 cycles

L4 DOOR BUSTLE IS RUBBING AGAINST DOOR FRAME. ADJUSTED L4 DOOR GUIDE ARM IAW AMM 52-11-04. REMOVED BUSTLE & PINNED SLIDE PACK, AND REMOVED GIRT BAR. CHECKED EMERGENCY POWER TRIGGER MECHANISM IAW AMM 52-11-32. RII INSPECTION COMPLIED WITH. VERIFIED EMERGENCY POWER TRIGGER MEASURMENT IAW AMM 52-11-32. INSTALLED DOOR ASSIST BOTTLE, DOOR GIRT BAR AND REMOVED SLIDE PACK PIN IAW AMM 52 -11-32. VERIFIED PIN REMOVAL ON SLIDE GIRT BAR ARM/PIN AND ASSIST BOTTLE INSTALLATION IAW AMM 52-11-30. REINSTALLED L4 DOOR BUSTLE.

Part: SWITCH — STIFF (EMERGENCY LIGHTS) · airframe 88,859 hrs · 41,039 cycles

ON FIRST FLIGHT, THE OVERHEAD PANEL EMERGENCY LIGHTS SWITCH WAS HARD TO OPERATE. REPLACED OVERHEAD PANEL IAW AMM 33-51. OPS CKS GOOD.

Part: WIRE HARNESS — INOPERATIVE (EMERGENCY LIGHT) · airframe 86,010 hrs · 39,843 cycles

SEAT 4CD EMERGENCY LIGHT INOPERATIVE. REPLACED EMERGENCY LIGHT SEAT WIRE HARNESS.

Part: SKIN — DAMAGED (BS 1422) · airframe 85,124 hrs · 39,492 cycles

FUSELAGE SKIN , AFT CARGO DOOR CUTOUT BS 1422, S27-29R DAMAGED. REAPAIRED IAW ERA 505017-14 REV A.

Part: FRAME — CRACKED (BS 1440) · airframe 85,116 hrs · 39,488 cycles

FRAME BS 1440, BETWEEN S23-24L CRACKED. REPAIRED IAW ER/A 505288-14AD, REV A.

Part: WIRE HARNESS — DAMAGED (EMERGENCY LIGHT) · airframe 85,049 hrs · 39,460 cycles

SEAT 41DE EMERGENCY LIGHT INOPERATIVE. REPLACED SEAT 41DEF EMERGENCY LIGHT HARNESS IAW AMM 33-51.

Part: WIRE — DAMAGED (EMERGENCY LIGHT) · airframe 83,748 hrs · 38,894 cycles

ROW 23 AND 34 EMERGENCY LIGHTS INOPERATIVE. REPLACED PIGTAIL ON ROW 34 AND SPLICED IN NEW SEAT WIRE IAW SWPM 20-30-12 ON ROW 23. BOTH LIGHTS OPS NORMAL.

Part: BOTTLE — INOPERATIVE (OVERWING SLIDE) · airframe 82,699 hrs · 38,447 cycles

EMERGENCY ESCAPE SLIDE RT ILLUMINATED ON P61 PANEL. REPLACED OVERWING EMERGENCY ESCAPE SLIDE INFLATOR.

Part: ELBOW — BROKEN (INFLATION LINE) · airframe 82,690 hrs · 38,445 cycles

FOUND LT OVERWING SLIDE INFLATION LINE ELBOW BROKEN. REPLACED SLIDE INFLATION LINE ELBOW IAW AMM 25-65.

Part: HINGE FITTING — GOUGED (THRUST REVERSER) · airframe 80,569 hrs · 37,590 cycles

DURING ENGINE CHANGE FOUND GOUGE DAMAGE ON NR 1 THRUST REVERSER HINGE FITTING FWD WEB UPPER BIFURCATION. BLENDED GOUGE AREA IAW SRM 54-31-01, FIG 101 THICKNESS OF WEB .125" MINIMUM AFTER BLEND WAS MAINTAINED.

Part: SKIN — DENTED (FUSELAGE) · airframe 78,926 hrs · 36,892 cycles

DISCOVERED A DENT IN THE FUSELAGE FWD OF APU COMPARTMENT DOOR RIGHT SIDE. COMPLIED WITH ERA 505011-14 REV ORIGINAL PERMANENT REPAIR.

Part: FRAME — CORRODED (BS 1460) · airframe 78,922 hrs · 36,890 cycles

ON REMOVAL OF SHEAR TIE FOUND CORROSOIN ON FRAME AT BS 1460 BETWEEN STRINGERS 29 AND 30R. FOUND OUT OF LIMITS. COMPLIED WITH ERA 505296-14 REV ORIG.

Part: FRAME — CRACKED (BS 1440 S24L) · airframe 78,922 hrs · 36,890 cycles

ON REMOVAL OF FRAME SPLICE AT BS 1440 STRINGER 24L, FOUND FRAME IN AFT CARGO CRACKED. ACCOMPLISHED ERA 505288-14 REV ORIG.

Part: SEAT TRACK — CORRODED (BS 760-879) · airframe 78,922 hrs · 36,890 cycles

MAIN CABIN SEAT TRACK AT LBL 24 WORN ON LUGS, SMALL AREAS OF CORROSION AND BARE METAL FROM BS 760-879. FOUND TO BE OUT OF LIMITS, REPLACED SEAT TRACK IAW SRM 51-40-02.

Part: SEAT TRACK — CORRODED (BS 874) · airframe 78,922 hrs · 36,890 cycles

MAIN CABIN SEAT TRACK AT LBL 45 HAS CORROSION AND WEAR BS 760-879. FOUND TO BE OUT OF LIMTS AT BS 874. REPLACED SEAT TRACK BS 760-879 IAW SRM 51-40-02.

Part: SEAT TRACK — CORRODED (BS 760-879) · airframe 78,922 hrs · 36,890 cycles

MAIN CABIN SEAT TRACK AT RBL 24 BS 760-879 WORN ON LUGS, AND SMALL AREA OF CORROSION AND BARE METAL. FOUND TO BE OUT OF LIMITS. REPLACED SEAT TRACK IAW SRM 51-40-2 AND DWG 143N5470.

Part: KEELBEAM — CORRODED (BS 1400-1415) · airframe 78,922 hrs · 36,890 cycles

CORROSION ON AFT CARGO KEEL BEAM IN CENTER POCKET AND AROUND FASTENERS RT BS 1400-1415. COMPLIED WITH ERA 504618-14 REV ORIG.

Part: CREASE BEAM — CORRODED (BS 960-984) · airframe 78,922 hrs · 36,890 cycles

CREASEBEAM WEB EXFOLIATED AT STA 960-984 RBL71.5. DAMAGE BEYOND LIMITS. REPLACED CREASEBEAM WEB AT IAW SRM 51-40-2.

Part: SHEAR TIE — CORRODED (BS 1460) · airframe 78,922 hrs · 36,890 cycles

CORROSION ON AFT CARGO BAY FRAME AND FWD SIDE BETWEEN STR 29L AND 28R AND ON AFT SIDE BELOW FAI/SAFE BETWEEN STR 29L-30 AT BS 1460. CORROSION DAMAGE TO FRAME WAS FOUND IN LIMITS. FOUND CORROSION ON SHEAR TIE OUT OF LIMITS. FABRICATED AND INSTALLED NEW SHEAR TIE IAW B757 SRM 51-40-2 PG 7 PAR D AND PG 21 FIG 4 AT STA 1460 BETWEEN STR 29L-30.

Part: GATE — CORRODED (L4 DOOR) · airframe 78,922 hrs · 36,890 cycles

L4 DOOR UPPER GATE LEVELING COMPOUND CRACKED AND DISBONDING, AFTER REMOVING COMPOUND FOUND CORROSION IN ALL POCKETS COROSION FOUND TO BE OUT OF LIMTS. REPLACED UPPER GATE IAW AMM 52-11-38.

Part: GATE — CORRODED (R4 DOOR) · airframe 78,922 hrs · 36,890 cycles

R4 DOOR UPPER GATE HAS CORROSION AND DISBONDED LEVELING COMPOUND THROUGH OUT. REMOVED CORROSION AND FOUND OUT OF LIMITS. REPLACED GATE IAW SRM 51-40-05.

Part: STRINGER — GOUGED (BS 740-760) · airframe 78,922 hrs · 36,890 cycles

FWD CARGO COMPARTMENT STRINGER 21R HAS GOUGE BS 740-760. CW ERA 505287-14 REV ORIGINAL.

Part: FLOORBEAM — CORRODED (BS 1640) · airframe 78,922 hrs · 36,890 cycles

CORROSION ON MAIN CABIN FLOORBEAM BS 1640 LBL 5. FOUND CORROSION OUT OF LIMITS ON UPPER TEE FROM BS 1640 BETWEEN LBL 10-34. FABRICATED AND INSTALLED REPAIR PER SRM 53-08-51 REPAIR 3.

Part: FLOORBEAM — CORRODED (BS 365) · airframe 78,922 hrs · 36,890 cycles

CORROSION ON MAIN CABIN FLOORBEAM UPPER SURFACE AND BOTTOM AROUND FASTENER HOLES. REMOVED CORROSION FOUND TO BE OUT OF LIMITS. FABRICATED AND INSTALLED NEW FLOORBEAM IAW SRM 53-00-51 REPAIR 3.

Part: FLOORBEAM — CORRODED (BS 377) · airframe 78,922 hrs · 36,890 cycles

CORROSION ON MAIN CABIN FLOORBEAM BS 377 LBL 2-22 UPPER SURFACE AND BELOW SEVERAL FASTENER HOLES. COMPLIED WITH ERA 481634-14 MA REV ORIG.

Part: GATE — CORRODED (L1 DOOR) · airframe 78,922 hrs · 36,890 cycles

L1 DOOR LOWER GATE HAS PITTING CORROSION ALONG BOTH LOWER EDGES AND A LONG GOUGE ON THE GREY PAINTED BAND. FOUND DAMAGE TO BE OUT OF LIMITS. REPLACED L1 DOOR LOWER GATE IAW AMM 52-11-38.

Part: SKIN — DENTED (BS 1872) · airframe 78,922 hrs · 36,890 cycles

DENT AT APPROX BS 1872 ON FUSELAGE FWD OF APU COMPARTMENT DOOR RIGHT SIDE, REPAIRED IAW SRM 53-00-01 PG103 ITEM 1.

Part: SKIN — GOUGED (C2 DOOR SKIN) · airframe 78,922 hrs · 36,890 cycles

AFT CARGO COMPT DOOR EXTERIOR SKIN GOUGED. COMPLIED WITH ERA 505293 REV ORIG.

Part: SKIN — GOUGED (C1 DOOR) · airframe 78,922 hrs · 36,890 cycles

FWD CARGO COMPARTMENT DOOR AFT LOWER CORNER GOUGED ON BOTTOM EDGE ON EXTERIOR OF DOOR. COMPLIED WITH ERA 505297-14 REV ORIG.

Part: SKIN — DENTED (BS 1422 S27R) · airframe 78,922 hrs · 36,890 cycles

TWO DENTS ON LOWER FUSELAGE SKIN AT BS 1422 BETWEEN STR 27R- 29R. FOUND DENTS TO BE OUT OF LIMITS. COMPLIED WITH ERA 505017-14 REV ORIG.

Part: SPLICE PLATE — CORRODED (BS 900) · airframe 78,922 hrs · 36,890 cycles

CORROSION INSIDE OF BUTT JOINT AT BS 900 AND BULGING SEALANT OBSERVED BETWEEN STRINGERS 16-17R. FOUND SPLICE PLATE CORRODED. REPLACED SPLICE PLATE IAW SRM 51-40-02.

Part: SKIN — DENTED (BS 1680 S16-17R) · airframe 78,922 hrs · 36,890 cycles

DENT ON EXTERNAL FUSELAGE AT BS 1680 BETWEEN STRINGER 16R-17R. FOUND TO BE OUT OF LIMITS. COMPLIED WITH ERA 505010-14 REV ORIG.

Part: SKIN — DAMAGED (FS470-500) · airframe 78,914 hrs · 36,885 cycles

MAINTENANCE DISCOVERED LIGHTNING STRIKE DAMAGE FS 470 BETWEEN STR 1 AND STR 2L AND AT FS 500 BETWEEN STR 1 AND 2L. INSPECTED AREA AND FOUND OUT OF LIMITS. PERFORMED REPAIR AND INSPECTED PER B757 SRM 53-00.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 73,928 hrs · 34,722 cycles

DURING LAYOVER CHECK, MAINTENANCE FOUND THE EMERGENCY PATH LIGHTS AT THE FWD GALLEY, SEAT 4C AND THE AFT RIGHT LAVATORY INOPERATIVE. MAINTENANCE REPAIRED A WIRE AT THE BASEBOARD. OPERATIONAL CHECK WAS GOOD. (2010-D1265)(DL757102881)

Part: CONNECTOR — DAMAGED (EMERGENCY LIGHT) · airframe 71,922 hrs · 33,849 cycles

DURING LAYOVER CHECK, MAINTENANCE DISCOVERED SEAT EMERGENCY LIGHTS INOPERATIVE AT ROW 4DC, 22DEF, AND 28-37DEF. MAINTENANCE REPAIRED CONNECTOR AT ROW 28, REPLACED LIGHT ASSY. AT 4DC, AND RELAMPED 22DEF. ALL LIGHTS OPERATED NORMAL.

Part: GEAR — UNKNOWN (TE FLAP) · airframe 69,297 hrs · 32,458 cycles

TRAILING EDGE FLAP TRANSMISSION GEAR - REPLACEMENT IAW 06-097281-03 REV A ME04.

Part: WINDOW — CRACKED (COCKPIT) · airframe 65,418 hrs · 30,731 cycles

1L WINDOW CRACKED AT FL370 M .78. REPLACED 1L WINDOW AND CONTROLLER. RETORQUE OF WINDOW AND TERMINAL CONTACTS FWD TO MCO PER M/M.

Part: ENGINE — SHUTDOWN (NR 2) · airframe 65,079 hrs · 30,568 cycles

RIGHT ENGINE ROLLED BACK AND SHUTDOWN DURING TAXI. MAINTENANCE IN PROGRESS DNTC. RAN ENG AT IDLE AND TAKEOFF AND MONITORED ALL ENGINE, PARAMETERS. NO PROBLEMS NOTED.

Part: ATTACH FITTING — MISALIGNED (NR 2 PYLON) · airframe 64,546 hrs · 30,338 cycles

INSTALLATION OF NEW NR 1 AND NR 2 PYLON WING ATTACH TENSION CLIPS WOULD HAVE REQUIRED SPOTFACE GREATER THAN THE 0.005" ALLOWABLE PER EO 6-070332-03 WHICH PERTAINED TO S/B 757-54-0034 REV 1 FOR THE SIP MODIFICATION. TAPERED RADIUS FILLERS WERE FABRICATED AND INSTALLED FOR EACH HOLE.

Part: BUSHING — MIGRATED (NR 2 PYLON) · airframe 64,546 hrs · 30,338 cycles

THE DIAGONAL BRACE WING END FITTINGS OF BOTH THE NR 1 AND NR 2 PYLONS WERE FOUND WITH MIGRATED BUSHINGS DURING ACCOMPLISHMENT OF 6-75079-3. NEW BUSHINGS WERE INSTALLED AS AN AMOC TO AD 2003-18-05.

Part: ATTACH FITTING — MISALIGNED (NR 2 PYLON) · airframe 64,546 hrs · 30,338 cycles

NUMBER 2 PYLON SIDE LINK ATTACH FITTING HOLE NR 3 WAS FOUND MISALIGNED WHILE ACCOMPLISHING DELTAS EO 6-70332-3 COVERING SB 757-54-0034. A TAPERED RADIUS FILLER WAS INSTALLED PER ANAMOC TO AD 2003-18-05.

Part: SPAR — DAMAGED (RT WING) · airframe 64,527 hrs · 30,329 cycles

DURING REMOVAL OF A RT WING LOWER PANEL, A FASTENER HOLE WAS MISDRILLED AND OVERSIZED THROUGH THE PANEL EXTERIOR SKIN AND THE FRONT SPAR LOWER CHORD. PERMANENT REPAIR WAS ACCOMPLISHED BY ACTS IN VANCOUVER.

Part: LINE — LEAKING (RT DOWNLOCK ACT) · airframe 64,358 hrs · 30,256 cycles

JUST PRIOR TO LANDING, LOST LEFT HYDRAULIC FLUID. FOUND PRESS HYD LINE FOR RT GEAR DOWN LOCK ACTUATOR LEAKING. REPLACED LINE AND SERVICED HYD QTY .

Part: WARNING SYSTEM — UNKNOWN · airframe 60,957 hrs · 28,967 cycles

ON APPROACH AT 1900 FT CENTER AUTOPILOT DISCONNECTED. RE-ENGAGED AUTOPILOT IN APPROACH MODE AFTER THREE SECONDS. A/P WARNINGS AND AFT AND FWD CARGO FIRE WARNINGS CAME ON FOR ABOUT TWO SECONDS. PERFORMED TEST 30 FLIGHT FAULT REVIEW, NO FAULTS LOGGED. PERFORMED TEST 40 PASSED ALL 3 FCCS PASSED NO HISTORY, OPS CHECKS GOOD.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 60,957 hrs · 28,967 cycles

ON APPROACH AUTO PILOTS DISCONNECTED WITH A/P WARNING AND BOTH CARGO COMPARTMENTS HAD FIRE DETECTION EICAS MESSAGES NO FIRE WARNINGS ON FIRE DETECTION/CONTROL PANEL OR WARNING BELLS, PERFORMED TEST 30, NO CURRENT FAULT REVIEW NO FAULTS. LOGGED PERFORMED TEST 40, ALL 3 FCCS PASSED. NO HISTORY, FIRE TEST GOOD ON CONTROL PANEL WITH NO ABNORMALITIES OR MESSAGES.

Part: FITTING — MISDRILLED (NR 2) · airframe 60,727 hrs · 28,883 cycles

THE ATTACH HOLE IN THE SIDE LINK FITTING IS BEYOND ANGULAR TOLERANCE. A TAPERED RADIUS FILLER WAS INSTALLED TO PROPERLY ALIGN THE HOLE.

Part: FITTING — MISALIGNED (NR 1 & NR 2) · airframe 60,727 hrs · 28,883 cycles

INSTALLATION OF MODIFICATION TENSION CLIPS WOULD REQUIRE MORE THAN THE ALLOWED 0.005 INCH SPOT FACE. A TAPERED FILLER WILL BE USED TO INSTALL THE TENSION CLIPS.

Part: BUSHING — LOOSE (NR 1 & 2 PYLONS) · airframe 60,727 hrs · 28,883 cycles

THE NR 1 AND NR 2 PYLON WING DRAG FITTINGS HAVE BUSHING MIGRATION. THE BUSHINGS WERE REMOVED, THE HOLES INSPECTED; AND REPLACEMENT BUSHINGS INSTALLED.

Part: CONNECTOR — LOOSE (NR 2 ENGINE) · airframe 59,080 hrs · 28,292 cycles

DURING MAIN ENGINE START AFTER PUSHBACK NUMBER 2 ENGINE SPAR VALVE LIGHT REMAINED ILLUMINATED AND ENGINE FLAMED OUT. RESEATED CONNECTOR ON SPAR VALVE, ENGINE STARTS NORMALLY.

Part: MODULE — UNSERVICEABLE (COCKPIT) · airframe 55,377 hrs · 26,958 cycles

LANDING GEAR DISAGREE MSG. REPLACED LANGING GEAR HANDLE MODULE.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 47,498 hrs · 23,678 cycles

FUSELAGE / SKIN / FS 1680-1710 / STRG. 18L-21L : SKIN CUTOUT REPAIR. AN EXISTING SKIN REPAIR WAS REMOVED TO ALLOW FOR INSTALLATION OF A BETTER FATIGUE DESIGN REPAIR. THE PREVIOUS REPAIR CUTOUT WAS ENLARGED TO REMOVE THE PREVIOUS REPAIR FASTENER HOLES. THE CUTOUT MEASURED 22 INCHES X 25 INCHES AND WAS REPAIRED WITH TWO EXTERNAL ALUMINUM DOUBLERS PER ER/A 382661-14, REV A.

Part: BUSHING — CORRODED (NR 1 PYLON)

NR 1 PYLON UPPER LINK (P/N 311N3710-901) FOUND CORROSION IN LOWER BUSHING. AFTER REMOVAL OF DAMAGE, BUSHING WAS WORN BEYOND LIMITS. NEW BUSHING INSTALLED (P/N 310N3026-15). NO DAMAGE FOUND IN BORE OR UPPER LINK. DAMAGE WAS ISOLATED TO BUSHING ONLY.

Part: SKIN — CRACKED (NR 2 NACELLE)

NR 2 NACELLE STRUT SKINS, IB AND OB WERE FOUND CRACKED BEYOND PREV STOP DRILLS, ON REPETITIVE INSP BOTH WERE REPAIRED ON SRM 54-51-01-2-203 MIF ERA 259383-14. LOCATION IS NAC STA 107.7 REPAIR IS CLASSIFIED MAJOR.

Part: LAMP — FAILED (AFT CARGO DOOR)

EXTERIOR EMERGENCY LIGHT ON THE AFT CARGO DOOR INOP. RELAMPED, OP CK GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

L2 DOOR EMERGENCY LIGHTS INOP. REPLACED BATTERY PACK SYSTEM, CHECKS GOOD.

Part: SKIN — PUNCTURED (NR 4 LE FLAP)

A .25 INCH HOLE WAS FOUND ON THE LOWER SKIN AND PARTIALLY INTO THE CORE ON THE NR 4 LEADING EDGE SLAT. THE HOLE IS LOCATED 3 FT OUTBOARD OF THE INBOARD EDGE OF THE SLAT. THE TRAILING EDGE WEDGE IS AN ALUMINUM/HONEYCOMB PANEL WITH THE ALUMINUM SKIN MADE FROM 0.016 2024-T81 SHEET.

Part: SKIN — DELAMINATED (NR 9 LE SLAT)

NR 9 LE SLAT, TRAILING EDGE WAS FOUND TO BE DELAMINATED WEDGE WAS REPLACED DURING SHOP 38O VISIT PER SRM 57-43-02 AND AD 90-23-06.