N637DL

Part: LIGHT — INOPERATIVE (ROW 19) · airframe 72,376 hrs · 34,030 cycles

EMERGENCY EGRESS AISLE LIGHTING INOP AT ROW 19. REPLACED LIGHT ASSY AND LENS AT ROW 19. CHECKS OK.

Part: OUTFLOW VALVE — MALFUNCTIONED (CABIN PRESSURE) · airframe 71,987 hrs · 33,837 cycles

AT FL340 HAD CABIN ALT WARNING. CABIN WAS AT 11000 WITH 500FT MIN CLIMB. BOTH PACKS WERE ON AND NO ABNORMAL IND EXCEPT THE OUTFLOW VALVE SHOWED OPEN 3/4. PASS 02 MASKS DEPLOYED IAW "CABIN ALT" WARN PROCEDURE.

Part: SKIN — CORRODED (BS 1851-1854) · corrosion level 2

FOUND CORRODED SKIN AT BS 1845 BS 1850 LBL 24 (EMPENNAGE INTERNAL). REPAIRED BY TRIMMING OUT CORRODED AREA, HFEC INSPECTED NO CRACKING NOTED. FABRICATING AND INSTALLING PERMANENT REPAIR DOUBLER 9.5 BY 10.0 FROM 7075-T6 .063 AND FILLER FROM 7075-T6 .071 CLAD IAW DELTA ERA 460838-14 REV ORIGINAL DATED 4-26-07, B757 SRM 53-00-01 FIGURE 101, DETAIL II, 51-40-08, FAA FORM 8100-9.

Part: STRINGER — CORRODED (BS 1850) · corrosion level 2

FOUND CORRODED STRINGER 25L AT BS 1850 (EMPENNAGE INTERNAL). REPAIRED BY REMOVING SHEAR TIE AND SECTION OF STRINGER. FABRICATED AND INSTALLED STRINGER 25.0 FROM BAC 1498-132 AND SPLICE 10.0 FROM BAC1498-144 IAW B757 SRM 53-00-03 FIG 201, 51-20-01 AND 51-40-02.

Part: SKIN — CORRODED (BS 1851-1854) · airframe 63,682 hrs · 29,970 cycles

DURING CURRENT HMV, CORROSION WAS FOUND ON THE INTERIOR SKIN PANEL JUST BELOW THE S-25L LAP FROM BODY STATION 1851 TO 1854 LEFT. THE DAMAGE WAS OUTSIDE OF THE SRM LIMITS. THE DAMAGE WAS TRIMMED OUT AND A BOEING APPROVED REPAIR WAS INSTALLED PER 460838-14.

Part: SKIN — DAMAGED (BS 560-580) · airframe 63,682 hrs · 29,970 cycles

FOUND 2 LIGHTNING STRIKES BETWEEN BS 560 - BS 580 AND S-2R S-3R. REPAIRED BY CUTTING OUT LIGHTNING STRIKE AREA. HFEC CUT OUT IAW D6-34N301-6-51-00-19, NO RELEVANT INDICATIONS NOTED. FABRICATED AND INSTALLED REPAIR DOUBLER 10-3/8 BY 10-3/8 FROM 2024-T3 .063 IAW B757 SRM 53-00-01 FIG 201 PG 201 REPAIR (2).

Part: SKIN — GOUGED (BS 1390) · airframe 63,682 hrs · 29,970 cycles

FOUND AFT CARGO DOOR EXT SKIN BS 1390 S-26 - S-27R GOUGED. REPAIRED BY FABRICATING AND INSTALLING REPAIR DOUBLER 5-1/2" BY 16-7/8 FROM 2024-T3 .071 IAW B757 SRM 51-20-01, 51-41-00-352-013.

Part: SKIN — DENTED (BS 510 S28-29R) · airframe 63,682 hrs · 29,970 cycles

FOUND FUSELAGE SKIN DENTED AT BS 510 S-28R - S-29R GOUGED. DENT RATIO A/Y = .020 TOO CLOSE TO FRAME. CUT OUT DENT IAW B757 SRM 53-00-01 FIG 201. HFEC CUT OUT IAW B757 NDT PT. 6, 51-00-19, NO RELEVANT INDICATIONS NOTED. FABRICATED AND INSTALLED DOUBLER 6.8" BY 8.6" FROM 2024-T3 .050" IAW B757 SRM 51-20-01 AND 53-00-01 FIG 201.

Part: SKIN — DAMAGED (BS 660-680) · airframe 63,682 hrs · 29,970 cycles

FOUND 2 LIGHTNING STRIKES BETWEEN BS 660 - BS 680 AND S-4R – S-6R. REPAIRED BY CUTTING OUT .750" CIRCLE AT LIGHTNING STRIKE AREA. HFEC CUT OUT IAW D6-34N301-6-51-00-19, NO RELEVANT INDICATIONS NOTED. FABRICATED AND INSTALLED REPAIR DOUBLER 5.5" BY 5.5 FROM 2024-T3 .090 AND SHEAR TIE FROM 7075-T6 .050" IAW B757 SRM 51-40-05, 51-40-06, 51-40-08, 51-40-02 AND 53-00-01 FIG 201 REPAIR (7).

Part: CREASE BEAM — CORRODED (BS 1180-1200) · corrosion level 2

FOUND CORRODED CREASE BEAM ANGLE AT BS 1180 TO BS 1200 LT. REPAIRED BY REMOVING CREASE BEAM, FABRICATED, HEAT TREATED AND INSTALLED REPAIR BEAM 2 BY 2 BY 22 FROM 60-11925 EXTRUSION P/N T827537-1 BOEING DWG.146N5600 IAW B737 SRM 51-40-02, 51-40-05 AND 51-20-01.

Part: TRUNNION — CORRODED (BS 1180) · corrosion level 2

FOUND CORRODED RT MLG AFT TRUNNION BEARING AND HOUSING. REPAIRED BY REMOVING AND REPLACING TRUNNION BEARING AND HOUSING WITH P/N NR S113N103-05 S/N K05639 IAW B757 MM 57-54-07.

Part: SKIN — DAMAGED (BS 440-460) · airframe 63,682 hrs · 29,970 cycles

FOUND LIGHTNING STRIKE BETWEEN BS 440 AND BS 460 S-1R. REPAIRED BY CUTTING OUT STRIKE AREA. FABRICATED AND INSTALLED REPAIR DOUBLER 14.40 BY 7.40 FROM 2024-T3 .063 IAW B757 SRM 53-00-01 FIG 201.

Part: BULKHEAD — TOOL DAMAGE (NR 1 PYLON) · airframe 63,682 hrs · 29,970 cycles

DURING ACCOMPLISHMENT OF EA 06-070332-03AD (SIP MOD), A HOLE WAS DAMAGED BY A BROKEN DRILL BIT ON THE NR 1 PYLON AFT BULKHEAD. THE DAMAGE REQUIRED THE HOLE TO BE OVERSIZED TO 0.640 AND OVERSIZED FASTENER INSTALLED PER BOEING APPROVAL, AS DETAILED IN ERA 460837-14AD.

Part: FRAME — CHAFED (BS 1600)

FOUND BENT AND CHAFED FRAME IN AFT PIT BS 1600 S-25R - S-26R. REPAIRED BY BLENDING, CUTTING OUT DENTED AREA. FABRICATED AND INSTALLED DOUBLER REPAIR 14-1/2 BY 2 FROM 2024-T3 .063 B757 SRM 53-00-07 FIG 201.

Part: FLOORBEAM — CORRODED (BS 337 S17L) · corrosion level 2

FOUND CORROSION ON FLOORBEAM UPPER TEE CAP AT BS 377 AND LBL 19. REPAIRED BY CUTTING OUT CORRODED AREA, FABRICATED AND INSTALLED REPAIR TEE CAP 13 BY 2 BY 2 BY 2-1/2 FROM BAC1505-100617, REPAIR L-ANGLE 11 BY ½ BY 2 FROM BAC 1490-6199 7075-T6 .063 AND 13 BY 2 BY ½ FROM 7075-T6 .050 AND REPAIR STRAP 11 BY ½ FROM 7075-T6 .090 AND 13 BY ½ BY FROM 7075-T6 .063 IAW B757 SRM 51-20-01 AND 53-00-51D.

Part: SELECTOR VALVE — BYPASSING (LT HYD SYSTEM) · airframe 62,633 hrs · 29,596 cycles

MULTIPLE LEFT HYDRAULIC SYSTEM MALFUNCTIONS. NOSE GEAR NOT EXTENDING IN NORMAL MODE. ALT OK. LEFT HYDRAULIC SYSTEM OVERHEAT INDICATION ALSO. FOUND LANDING GEAR SELECTOR VLV BYPASSING. ALSO, ACMP AND EDPCASE RETURN FILTERS WITH DEBRIS. REPLACED ACMP, EDP AND ALL ASSOCIATED FILTERS.

Part: GIRT BAR — UNSECURE (3L CABIN DOOR) · airframe 51,872 hrs · 25,751 cycles

ACFT PARKED AT GATE AND JUST PRIOR TO DEPARTURE FLT ATT CLOSED 3L CABIN DOOR AND NOTICED THAT THE GIRT BAR APPEARED ABNORMAL. MTC SECURED GIRT BAR ATTACH BRACKETS TO SLIDE ASSY AS PER MM.

Part: ANTENNA — MALFUNCTIONED (WX RADAR SYS) · airframe 50,994 hrs · 25,342 cycles

RADAR INDICATOR PAINTS AND TESTS ONLY 30 DEG LEFT OF CENTER /C TRY INDICATOR AND T/R NO HELP. REPLACED ANTENNA, OPS CHECKS GOOD.

Part: RELAY — FAILED (LANDING GEAR) · airframe 48,508 hrs · 24,198 cycles

WHILE PERFORMING 757 ACJIC 6017 GEAR DOORS FAILED TO OPERATE AS REQUIRED. TROUBLESHOOTING REVEALED POWERPACK MOTOR HAD BAD INTERNAL WINDING DUE TO CONSTANT VOLTAGE APPLICATION. RELAY K10369 AND POWERPACK ASSY WERE CHANGED AND TESTED PER 757ACJIC OP 6017 WITH NO FURTHER PROBLEMS. AC WAS RETURNED TO SERVICE AFTER COMPLETING SCHEDULED MTC. FAILURE OF RELAY K10369 IN CLOSED POSITION CAUSED FAILURE OF POWERPACK ASSY.

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 47,052 hrs · 23,500 cycles

FOUND ON WALK AROUND, LEFT FWD AND AFT OVERWING EXTERIOR EMERGENCY EXIT LIGHTS INOP.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 44,903 hrs · 22,498 cycles

WHILE ACCOMPLISHING A DOUBLER MODIFICATION TO THE SKIN CUTOUT FOR THE LOWER AFT VHF ANTENNA AT FS 1473 & RBL 3.2, AN EXISTING REPAIR DOUBLER WAS FOUND. THE EXISTING REPAIR WAS REMOVED AN THE ANTENNA CUTOUT INCREASED TO REMOVE THE PREVIOUS REPAIR FASTENER LOCATIONS. AN EXTERNAL ALUMINUM DOUBLER AND TRIPLER WERE INSTALLED PER ER/A 380557-14, REV BTO REPAIR THE AREA.

Part: SKIN — GOUGED (FUSELAGE) · airframe 44,903 hrs · 22,498 cycles

THE FUSELAGE SKIN WAS FOUND WITH A DEEP GOUGE AT THE SKIN BUTT JOINT AT FS 780 NEAR STRINGER 18L. THE GOUGE WAS REMOVED WITH A 3.5 X 1 INCH CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 380515-14, REV A.

Part: SWITCH — FAILED (MLG)

INBOUND PILOT REPORT, GEAR FAILED TO RETRACT NORMALLY AFTER T/O. GEAR HANDLE LOCKED IN THE OFF POSITION. LOCK OVERRIDE USED TO RAISE GEAR. REPLACED RT AND LT MLG TILT PRESSURE SWITCH. REPLACED THE SHUTTLE VLV. ALSO, REPLACED THE LT TILT ACT. ALL CHECKED NORMAL DURING LANDING GEAR SWING.

Part: VALVE — FAILED (LT MLG)

LANDING GEAR WOULD NOT COME UP AFTER TAKEOFF. HANDLE WENT TO OFF, BUT WOULD NOT GO TO UP. GREEN GEAR LIGHTS STAYED ON. REPLACED LT MAIN GEAR TRUCK POSITIONING SHUTTLE VALVE.

Part: BATTERY CHARGER — INOPERATIVE (BS 985)

DURING L/O CHECK, FOUND LT EMERGENCY OVERWING EXIT LIGHTS OUT. ALSO, FOUND FWD EXTERIOR LIGHT FOR OFF-WING OUT. REPLACED LT CHARGER FOR BATTERY PACK M10567 LOCATED ON PSU SPACER PANEL STA 985 LBL 49.

Part: SKIN — CRACKED (BS 1681)

FUSELAGE/SKIN, SECTION 46, FS 1681, AFT LWR CORNER OF R1 DOOR CUTOUT, REPAIR FOR CRACK. HFEC INSPECTION OF A PREVIOUSLY REWORKED SKIN GOUGE, NEAR THE LOWER AFT CORNER OF THE R1 DOOR CUTOUT REVEALED A SMALL CRACK IN THE SKIN EMANATING FROM A FASTENER HOLE. THECRACK WAS CUTOUT WITH A 1.0 DIA HOLE AND A DOUBLER AND TRIPLER WERE INSTALLED PER ER/A 237547-14, REV C.

Part: BATTERY — DISCHARGED (CABIN)

F/C F/A INBD FLASHLIGHT LED INOP. REPLACED FLASHLIGHT BATTERY, OPS CK NORMAL.

Part: SKIN — DENTED (NR 3 LE SLAT)

A SPARE NR 3 SLAT WAS DAMAGED UPON REMOVAL FROM A SHIPPING CRATE AND PRIOR TO INSTALLATION ON A/C 637. THE INB'D AFT CORNER OF THE TE WEDGE WAS DENTED. THE SLAT WAS REPAIRED PER B757 SRM 51-70-10.

Part: TUBE — CRACKED (RT PYLON)

EN ROUTE, RECEIVED EICAS RT HYD SYS PRESS AND EICAS ADVISORY RT HYD QTY. RT HYD QTY READ .65 AND RF WAS DISPLAYED. BOTH RT SIDE PUMPS TURNED OFF IAW POM (2003Z). FOUND RT ENG HYD PRESSURE LINE (312N3100-24) IN PYLON CRACKED. REPLACED TUBE, OPERATION NORMAL.

Part: SLAT — DELAMINATION (NR 4 LE FLAP)

DURING INSPECTION OF THE NR 4 SLAT, THE TRAILING EDGE WAS FOUND DAMAGED WITH A DENT AND DELAMINATION OF THE UPPER TRAILING EDGE WEDGE SKIN, DAMAGE MEASURED 6 INCHES FORE/AFT AND 3 INCHES WIDE. ACCOMPLISHED REPAIRS PER DL ERA 302840-14 AD.

Part: SKIN — DAMAGED (NR 1 ENG COWL)

FOUND DURING LETTER CHECK, NOSE COWL L/E DAMAGED AT 5 O'CLOCK POS. ALSO, SMALL HOLES IN NOSE COWL 3 O'CLOCK POS. REPAIRED PER SRM 54-11-01.