N648DL

Part: WIRE — DISCONNECTED (EMERGENCY LIGHTS) · airframe 85,814 hrs · 37,170 cycles

EMERGENCY PATH LIGHTS FROM SEAT 39 TO SEAT 45 ARE INOPERATIVE. FOUND WIRE DISCONNECTED. RECONNECTED WIRE.

Part: SKIN — DAMAGED (BS 480) · airframe 84,414 hrs · 36,678 cycles

LIGHTNING STRIKE AT BS 480, STRINGER 9L. REMOVED DAMAGE FOUND TO BE OUT OF LIMITS IAW SRM 53-00-01. REPAIRED IAW ERA 524911-14, REV A PERM REPAIR.

Part: SKIN — DAMAGED (BS 480) · airframe 86,094 hrs · 37,271 cycles

SKIN DAMAGED. REPAIRED LIGHTNING STRIKE DAMAGE AT BS 480, S9L IAW ER/A 524911-14.

Part: LIGHT — INOPERATIVE (SEAT 39D) · airframe 84,307 hrs · 36,641 cycles

EMERGENCY LIGHT INOPERATIVE AT 39D. REPLACED LIGHT ASSY, CHECKED GOOD.

Part: TRUNNION — CORRODED (LT WING) · corrosion level 2 · airframe 83,804 hrs · 36,464 cycles

LT WING MLG FWD TRUNNION ATTACH FITTING, LOWER BORES ARE CORRODED.

Part: TRUNNION — CORRODED (MLG) · airframe 83,804 hrs · 36,464 cycles

TRUNNION ATTACH FITTING, LOWER BORES CORRODED. REPAIRED IAW ER/A 499930-14AD.

Part: LIGHT — INOPERATIVE (DOOR SLIDE) · airframe 84,032 hrs · 36,539 cycles

LT DOOR SLIDE EMERGENCY LIGHT INOPERATIVE. REPAIRED IAW ERA 522660-14, REV A. OPS CHECKED GOOD.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 83,238 hrs · 36,272 cycles

FOUND ON WALK AROUND, AFT LAVATORY SERVICE PANEL HAS CORROSION ON BELLY SKIN UNDER DOUBLER ON FWD INBD SIDE. REPAIRED IAW ERA 520885-14 REV 0.

Part: SKIN — CORRODED (BS 1682-1701) · corrosion level 2 · airframe 83,246 hrs · 36,274 cycles

CORROSION FOUND ON FUSELAGE SKIN UNDER THE AFT LAV SERVICE PAN, BETWEEN BS 1682-1701 S28-29R. DAMAGE REPAIRED IAW SECTION I OF ER/A 520885-14, REV ORIGINAL.

Part: SKIN — DAMAGED (FUSELAGE) · corrosion level 2 · airframe 83,238 hrs · 36,272 cycles

SKIN HAS CORROSION DAMAGE AT FWD LT CORNER. REMOVED AT LAV PAN ASSY AT STA 1682 AND STR 29R-26R TO ACCESS SKIN DAMAGE AND REF PRI 520885-14 AD REV ORIG INSTALLED LAV PAN ASSY IAW DWG 146N3650.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHT) · airframe 82,959 hrs · 36,165 cycles

DURING SERVICE CHECK, FOUND L1 AND R1 VERTICAL EMERGENCY LIGHTS INOPERATIVE. REPLACED POWER SUPPLY, OPS CHECKED GOOD.

Part: SKIN — CRACKED (BS 1814) · airframe 77,846 hrs · 34,357 cycles

DURING INSPECTION FOUND FUSELAGE SKIN CRACK AT STATION 1814 BETWEEN STRINGERS 25R AND 19R. MAINTENANCE TRIMMED OUT DAMAGE AND ACCOMPLISHED HFEC OF CUT OUT AREA. FABRICATED REPAIR DOUBLER PER SRM 53-00-01 REPAIR 3 AND INSTALLED.

Part: CONTACT — BROKEN (LIGHT ASSEMBLY) · airframe 76,656 hrs · 33,912 cycles

LINE MAINTENANCE FOUND AFT SLIDE ILLUMINATION LIGHT INOPERATIVE. INSPECTION REVEALED CONTACT BROKEN IN LIGHT ASSEMBLY. LIGHT ASSEMBLY REPLACED AND OPERATION NORMAL.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 65,838 hrs · 30,192 cycles

UPON DAMAGE REMOVAL OF MAIN CABIN DECK PLATE, FOUND STA 1680 FLOORBEAM CORRODED IN NUMEROUS LOCATION. BLENDED CORROSION IAW 757 SRM 51-10-02. CORROSION FOUND OUT OF LIMITS. REPLACEMENT FLOORBEAM CAP INSTALLED IAW SRM 51-40-02 AND ERA 470312-14.

Part: FLAP — GOUGED (WING) · airframe 65,838 hrs · 30,192 cycles

RIGHT OUTBOARD MAIN FLAP L/E GOUGED ON I/B END. BLENDED OUT GOUGE IAW 757 SRM 51-10-02; OUT OF LIMITS. INSTALLED REPAIR DOUBLER, FILLER, AND CAP END IAW 757 SRMS 51-46-02 AND 57-53-01.

Part: RIB — DAMAGED (RT WING) · airframe 65,838 hrs · 30,192 cycles

RT WING RIB STA 18 HAS 1 EA ELONGATED HOLE AT STR 9.5 FWD OUTBOARD HOLE ON FWD LEG OF STR CHANNEL. REWORKED DAMAGED HOLE TO A FINAL SIZE OF .250, EDGE MARGIN OF .450 IAW 757 SRM 51-40-05 FIG 2. INSTALLED 1 EA FASTENER ON STRINGER CLIP U9.5 RT WING RIB 18 PER BAC5004-2 AND ERA 470542-14.

Part: SKIN — GOUGED (L/E SLAT) · airframe 65,838 hrs · 30,192 cycles

SMALL GOUGE ON T/E OF SLAT NR 3. REMOVED DAMAGED LOWER SKIN ON NR 3 SLAT AND PREPARED AREA FOR INSTALL OF FLUSH REPAIR IAW B757 SRM 51-70-10 REPAIR 4 FIG 202. BONDED REPAIR DOUBLER IAW SRM 51-70-10.

Part: FITTING — DAMAGED (NR 1 PYLON) · airframe 65,838 hrs · 30,192 cycles

NR 1 PYLON SHEAR TIE DRAG FITTING ASSY HAS ELONGATED HOLE. REPAIR C/W PER ERA 470311-14 REV 1 AND SRM 51-20-07.

Part: SKIN — CORRODED (FUSELAGE) · airframe 65,838 hrs · 30,192 cycles

FUSELAGE SKIN STA 610 (AT RADIO ALT) HAS CORROSION. REPAIR C/W PER ERA 470545-14.

Part: SKIN — DENTED (FUSELAGE) · airframe 65,836 hrs · 30,191 cycles

DURING HMV AT SAA, A DENT WAS FOUND IN A FUSELAGE SKIN SECTION WHICH HAD BEEN PREVIOUSLY SPLICED IN DURING AN EARLIER SKIN REPAIR. THE DENT WAS REMOVED AND REPAIRED PER B757 SRM GUIDELINES. THE ER/A IS CLASSIFIED AS MAJOR AND AD RELATED BECAUSE OF THE PREVIOUS REPAIR CLASSIFICATION.

Part: SPAR — GOUGED (LT WING) · airframe 65,836 hrs · 30,191 cycles

DURING WINGLET MOD, THE LT WING REAR SPAR LOWER CHORD WAS DAMAGED BY TOOLING. A GOUGE WAS BLENDED SMOOTH AND TREATED FOR CORROSION PROTECTION. THE BLEND AND TREATMENT WAS APPROVED BY BOEING.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 65,836 hrs · 30,191 cycles

DURING HMV AT SAA, ADDITIONAL DAMAGE WAS FOUND IN A PREVIOUSLY INSTALLED SKIN SPLICE REPAIR BETWEEN STA 610 AND 660, STRINGERS S-15L TO S-19L. A DENT AND CREASE WAS FOUND IN THE SPLICED IN SKIN SECTION AT STA 620 BETWEEN S-16L AND S-17L. THE EXISTING SKIN SPLICE DOUBLER WAS REPLACED WITH A NEW DOUBLER WHICH INCORPORATED A REPAIR FOR THE DENT.

Part: DRAG ANGLE — DAMAGED (NR 1 PYLON) · airframe 65,836 hrs · 30,191 cycles

DURING HMV AT SAA, THE NR 1 PYLON SHEAR TIE DRAG FITTING HAD AN ELONGATED HOLE. THE HOLE WAS OVERSIZED TO REMOVE THE ELONGATION AND A FREEZE PLUG BUSHING WAS INSTALLED ACCEPT A NOMINAL SIZE FASTENER PER BOEING REPAIR INSTRUCTIONS.

Part: BULKHEAD — CORRODED (FUSELAGE) · airframe 65,836 hrs · 30,191 cycles

DURING HMV AT SAA, CORROSION WAS FOUND IN THE RADIUS OF THE AFT LOWER CHORD OF THE AFT PRESSURE BULKHEAD AT STA 1862. THE CORROSION WAS REMOVED BY BLENDING TO A DEPTH OF 0.030 INCH. THE AREA WAS TREATED FOR CORROSION PREVENTION AND APPROVED AS IS BY BOEING ENGINEERING. A DAMAGE TOLERANCE ANALYSIS IS REQUIRED WITHIN 12 MONTHS.

Part: SKIN — CORRODED (FUSELAGE) · airframe 65,836 hrs · 30,191 cycles

DURING HMV AT SAA, CORROSION WAS FOUND ON THE BELLY SKIN UNDER THE RADIO ALTIMETER ANTENNA. THE CORROSION WAS REMOVED AND A REPAIR WAS INSTALLED PER BOEING INSTRUCTIONS.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 65,836 hrs · 30,191 cycles

DURING CURRENT HMV, CORROSION WAS FOUND ON THE 1681 FLOORBEAM, ON THE UPPER CHORD (UPPER AND LOWER SURFACE). DUE TO THIS, THE UPPER CAP WAS CUT OUT AND REMOVED PER BOEING INSTRUCTIONS, AND A REPLACEMENT UPPER CAP INSTALLED AS DOCUMENTED IN ER/A 470312-14 (CATEGORY A REPAIR).

Part: RIB — DAMAGED (LT WING) · airframe 65,836 hrs · 30,191 cycles

LT WING RIB 25 LOWER SKIN PANEL RIB CHORD HAS SHORT EDGE MARGIN ON UPPER ROW OF FAST HOLES. REPAIR C/W PER ERA 470544-14 REV O AND APB DWG 757-3250 REV B.

Part: FRAME — CORRODED (FUSELAGE) · airframe 65,836 hrs · 30,191 cycles

FRAME CHORD HAS PITTING CORROSION STA 1862 AT ACCESS DOOR 313AL. C/W REPAIR PER ERA 470550-14.

Part: SPAR — DAMAGED (NR 1 PYLON) · airframe 65,836 hrs · 30,191 cycles

DURING CURRENT HMV, AN OVERSIZED HOLE WAS FOUND ON THE SPAR CHORD, NR 1 PYLON, DURING ACCOMPLISHMENT OF PYLON MOD. SUBJECT HOLE IS COMMON TO SIDE STRUT SKIN. BOEING WAS CONTACTED CONCERNING OVERSIZING SUBJECT HOLE, INSPECTING, AND INSTALLATION OF OVERSIZED FASTENER. DOCUMENTED IN ERA 469688-14.

Part: SPAR — DAMAGED (LT WING) · airframe 65,836 hrs · 30,191 cycles

LT WING REAR SPAR LWR T-CAP HAS TOOLING MARK AT RIB STA 23. COMPLETED REPAIR PER ERA 470321-14 REV O.

Part: SKIN — DAMAGED (NR 1 PYLON) · airframe 65,836 hrs · 30,191 cycles

ONE EACH HOLE IS OVERSIZED TO .437 ON NR 1 PYLON I/B SIDE. REPAIR C/W PER ERA 469688-14 DATED 9/10/08.

Part: STRUCTURE — DAMAGED (NR 1 PYLON) · airframe 65,836 hrs · 30,191 cycles

1 HOLE IS OVERIZED TO .437 (NEXT NOMINAL STANDARD) ON NR 1 ENG PYLON I/B SIDE. INSTALLED 1 FASTENER AND COLLAR IAW SRM 51-40-02. COMPLIED WITH ERA 469688.

Part: STRUCTURE — DENTED (EMERGENCY EXIT) · airframe 65,836 hrs · 30,191 cycles

LT FWD OVERWING EMERGENCY ESCAPE HATCH DOOR LWR RT SIDE EDGE DENTED. REFORMED AREA AT LT FWD OVERWING ESCAPE HATCH DOOR LWR RT SIDE IAW SRM 51-30-01.

Part: SKIN — GOUGED (NR 3 SLAT) · airframe 65,836 hrs · 30,191 cycles

SMALL GOUGE ON T/E OF SLAT NR 3. BONDED SKIN FILLER AND INTERNAL DOUBLER AND CORE PLUG IAW SRM 51-70-10.

Part: SEAT TRACK — CORRODED (BS 686-710) · airframe 65,836 hrs · 30,191 cycles

SEAT TRACK HAS EXFOLIATED CORROSION AT STA 686-710 LBL 45.5. REMOVED SEAT TRACK FROM STA 669 TO STA 788 LBL 45.5 IAW SRM 53-00-51. INSTALLED REPLACEMENT SEAT TRACK IAW SRM 51-20-01.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 65,836 hrs · 30,191 cycles

SEAT TRACK HAS CORROSION STA 686-710 LBL 24.5. REMOVED AND REPLACED SEAT TRACK PER SRM 51-00-02.

Part: SKIN — DENTED (BS 1620 S27-28R) · airframe 65,836 hrs · 30,191 cycles

FUSELAGE STA 1620 BETWEEN S27R AND S28R LWR SIDE HAS DENT. INSTALLED DOUBLER AND 2 FILLERS IAW SRM 53-00-01.

Part: TERMINAL — BROKEN (L2 DOOR TEST SWH) · airframe 65,836 hrs · 30,191 cycles

EMERGENCY LIGHT TEST SWITCH AT L2 DOOR HAS A BROKEN COVER AND TERMINAL. (OFF A/C PART). PROCURED EMERGENCY LIGHT TEST SWITCH FOR L2 DOOR. REPLACED SWITCH ON DELTA OPN 1818 AND TESTED ON DELTA OPN 6813.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 65,836 hrs · 30,191 cycles

ACCOMPLISH PERM REPAIR PER SRM 53-00-01, FIG 201, SHT 6 ACTL LINE 3103; HOLE/CRACK AT STA 646 LEFT HAND SIDE BELOW S17L. REMOVED EXTERNAL SPLICE AND 5 INTERNAL DOUBLERS IAW ERA470314-14 AND B757 SRM 51-40-02. INSTALLED REPAIR DOUBLER, FILLER IAW SRM 53-00-01, FIG 201, ITEM 6 OF ERA 470314-14.

Part: COLLAR — CRACKED (R4 DOOR) · airframe 59,619 hrs · 28,261 cycles

REPORTED TO MTC 4R DOOR WILL NOT STAY OPEN. FOUND 4R DOOR GUST LOCK COLLAR BROKEN/CRACKED. REPLACED GUST LOCK COLLAR PER AMM 52-11-08.

Part: TRANSMITTER — INTERMITTENT (TE FLAP SYS) · airframe 51,667 hrs · 25,423 cycles

DURING DESCENT INTO EWR FLAPS LOCKED OUT AT LESS THAN 1 UNIT WITH STATUS MSG T/E FLAP DISAGREE AND T/E FLAP ASYMMETRY. FLAP UP LANDING AT EWR. REPLACED LT FLAP TRANSDUCER.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHT) · airframe 48,754 hrs · 24,304 cycles

DOOR 4R OVERHEAD EXIT SIGN EMERGENCY LIGHT WILL NOT ILLUMINATE. FOUND BAD BATTERY ASSY. REPLACED SAME.

Part: TIRE — CUT (NLG) · airframe 47,794 hrs · 23,930 cycles

LT. NOSE TIRE HAS FOD DAMAGE - REPLACED SAME

Part: LIGHT — INOPERATIVE (CABIN) · airframe 45,800 hrs · 23,000 cycles

EMERGENCY EXIT LIGHT OVER 2R DOOR INOP.

Part: LIGHT — MALFUNCTIONED (COCKPIT) · airframe 42,762 hrs · 21,517 cycles

ON APPROACH, PLACED GEAR HANDLE DOWN, DID NOT GET LEFT GEAR SAFE LIGHT. LIGHT TESTED GOOD. RAN GEAR LIGHT DISAGREEMENT CHECKLIST. IT FELT AS IF THE LEFT MAIN GEAR CAME DOWN AT THAT TIME, BUT NO GREEN LIGHT AND WOULD NOT TEST. COULD NOT RELAMP EASILY. REPLACED GREEN DOWN LIGHT ASSEMBLY. LUBED LT AND RT MAIN GEARS. PERFORMED GEAR SWING PER MM. OPS CHECK NORMAL.

Part: HYDRAULIC LINE — RUPTURED (RT MLG) · airframe 41,692 hrs · 21,031 cycles

LEFT HYD QTY LOSS IN FLIGHT. UNABLE TO STOP LOSS WITH POM PROCEDURES. FOUND RIGHT GEAR TRUCK TILT PRESSURE LINE RUPTURED. REPLACED LINE.

Part: PANEL — ARCED (COCKPIT) · airframe 38,053 hrs · 19,344 cycles

WHILE ENGAGING CAPTAINS AUTO/MAN VOR/DME SWITCH ON MCP A SMALL AMOUNT OF SMOKE CAME OUT FROM UNDER THE GLARESHIELD. SWITCH WAS PULLED OUT AND SMOKE STOPPED. FOUND VOR/DME CONTROL PANEL BULBS ARCING. REPLACED PANEL PER M/M. OPS CHECK GOOD.

Part: SKIN — DENTED (BS 1689)

FUSELAGE SKIN FS 1689, STRINGER 15L-16L, DENT CUTOUT REPAIR. THE FUSELAGE SKIN AT FS 1689 BETWEEN STRINGERS 15L AND 16L WAS FOUND DENTED. THE DAMAGED AREA OF SKIN WAS CUTOUT SPANNING THE STRINGERS OVER A 9.8 BY 2 AREA. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND TRIPLER PER ER/A 368048-14, REV A.

Part: VALVE — FAILED (TE FLAPS)

DURING APPROACH WITH FLAPS AT 1 DEG, THE /LE SLAT ASYM/EICAS MSG AND WARNING LIGHT ABOVE FLAP GAUGE CAME ON. ACCOMPLISHED CHECKLIST IN ATTEMPT TO ELECTRICALLY DRIVE FLAPS TO 20 DEG, BUT NOTHING CHANGED FROM THE 1 DEG POSITION. FLT DIVERTED TO JFK. REPLACED TRAILING EDGE BYPASS VALVE.

Part: SIGN — DAMAGED (R1 DOOR)

FOUND ON L/O, EMERG DOOR EXIT IDENTIFIER DAMAGED AT R1 DOOR. REPLACED EXIT IDENTIFIER AT R1 DOOR, CKS GOOD.

Part: SKIN — PUNCTURE (BS 840)

A SMALL PUNCTURE WAS FOUND IN THE FUSELAGE SKIN AT STA 840 AND STRINGER 16L JUST FWD OF A LIGHT CUTOUT. THE PUNCTURE WAS TRIMMED OUT TO A SMOOTH HOLE AND AN EXTERNAL DOUBLER AND TRIPLER WERE INSTALLED PER ER/A 364662-14.

Part: FUEL CONTROL — FAILED (NR 1 ENGINE)

ON ENGINE START LEFT ENGINE FIRE WAS NOTED. FIRE HANDLE PULLED AND AGENT NOT DISCHARGED. REPLACED LEFT ENGINE FUEL CONTROL UNIT, LEAK CKS GOOD AND PERFORMED PFHB TEST 15. LEFT ENGINE FUEL CONTROL CKS NORMAL. ALL LT ENG PARAMETERS NORMAL.

Part: SKIN — DELAMINATED (NR 4 LE SLAT)

DURING SHOP INSPECTION, NR 4 SLAT WAS FOUND WITH THE TRAILING EDGE WEDGE DELAMINATED. REPAIRED PER SRM 57-43-02.