N69333

Part: SPRING — BROKEN (L-2 DOOR SLIDE) · airframe 56,110 hrs · 29,420 cycles

THE R-2 DOOR AND L-2 DOOR ESCAPE SLIDE AFT GIRT BAR FLOOR BRACKETS WERE FOUND WITH SPRINGS BROKEN. NEW GIRT BAR FLOOR BRACKETS WERE INSTALLED AT BOTH AFT DOORS AT AFT POSITIONS IAW MM 25-61-51.

Part: FRAME — CORRODED (BS 847) · airframe 55,760 hrs · 29,254 cycles

AFT BAG BIN FLOOR FRAME STA 847 CORRODED AT SHEAR CLIPS. REPLACE FRAME SECTION PER SRM 51-10-02.

Part: SKIN — CRACKED (CARGO DOOR) · airframe 55,760 hrs · 29,254 cycles

AFT BAG BIN CARGO DOOR SKIN CRACKED AROUND HANDLE. INSTALLED DOUBLER PER SRM 52-00-01, 51-40-02, 51-20-05, 51-20-01.

Part: WEB — CORRODED (RT LAVATORY) · airframe 55,760 hrs · 29,254 cycles

AFT RIGHT LAV PAN CORRODED. REPLACED LAV PAN PER SRM 51-40-01.

Part: KEELBEAM — CORRODED (BS 500D) · airframe 55,760 hrs · 29,254 cycles

LEFT KEELBEAM CORRODED FWD OF STA 500D. INSTALLED NEW SECTION OF KEEL BEAM PER SRM 53-60-12.

Part: BULKHEAD — CORRODED (BS 1016) · airframe 55,760 hrs · 29,254 cycles

CORROSION AT STA 1016, BL 0, FWD LWR PRESSURE BULKHEAD. REPAIRED PER DRAWING 65C28106.

Part: FLOORBEAM — CORRODED (BS 1016) · airframe 55,760 hrs · 29,254 cycles

INSPECTION FOUND THE RT SIDE OF UPPER CHORD OF FLOORBEAM CORRODED AT STA 1016, RBL 16 TO RBL 35. THE FLOORBEAM WAS REPAIRED BY SPLICING IN A NEW SECTION OF UPPER CHORD IAW ECRA 5321-01299.

Part: WEB — CORRODED (LT LAVATORY) · airframe 55,760 hrs · 29,254 cycles

AFT LEFT LAV PAN CORRODED. REPLACED LAV PAN PER SRM 51-40-01.

Part: SKIN — CRACKED (BS 767) · airframe 55,760 hrs · 29,254 cycles

INSPECTION FOUND A 1.5 INCH CRACK IN FUSELAGE SKIN ON BONDED DOUBLER LINE STA 767 BETWEEN S22R AND S23R. A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-00-01, FIGURE 201.

Part: SKIN — CRACKED (BS 767) · airframe 55,760 hrs · 29,254 cycles

INSPECTION FOUND A 1 INCH CRACK IN FUSELAGE SKIN BONDED DOUBLER LINE STA 767 BETWEEN S21R AND S22R. A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-00-01, FIGURE 201.

Part: BULKHEAD — DAMAGED (BS 1016) · airframe 55,760 hrs · 29,254 cycles

RIVET HOLE ELONGATED AT AFT PRESSURE BULKHEAD WEB, STA 1016, BL 0. INSTALLED SKIN PER DRAWING 65C28106.

Part: FLOORBEAM — CORRODED (STA 344) · airframe 55,760 hrs · 29,254 cycles

INSPECTION FOUND MAIN DECK FLOORBEAM CORRODED AT STA 344, LBL 16 TO RBL 9. THE SECTION OF FLOORBEAM WAS REPLACED IAW SRM 53-10-51.

Part: FLOORBEAM — CORRODED (STA 328) · airframe 55,760 hrs · 29,254 cycles

INSPECTION FOUND MAIN DECK FLOORBEAM CORRODED AT STA 328, RBL 42 TO LBL 35. THE FLOORBEAM SECTION WAS REMOVED AND REPLACED IAW SRM 51-10-02 AND 51-40-02.

Part: WIRE HARNESS — BURNED (RH AFT W/W) · airframe 55,760 hrs · 29,254 cycles

FUEL SHUT-OFF VALVE WIRES & O/B LANDING LIGHT WIRES FOUND BURNED IN JUNCTION BOX NEAR D5164J (LANDING LIGHT DISCONNECT) AT RT SIDE AFT WHEEL WELL. SMOKE & COKING RESIDUE ON INSIDE SURFACE OF JUNCTION BOX COVER PLATE. ALL 3 LANDING LIGHT WIRES APPEARED TO HAVE INSULATION BURNED AS DID 2 FUEL SHUT-OFF VALVE WIRES. THIS WIRING IS I/B OF SPLICE THAT IS SPLICED TO W804 WIRE BUNDLE & NOT IN W804 WIRE BUNDLE. WIRES WERE REMOVED & REPLACED WITH NEW WIRING IAW WDM 28-21-08 AND 33-42-01. IN ADDITION, NR 2 ENGINE FUEL SHUT-OFF VALVE AND P5-2 PANEL WERE FOUND FAULTY. THE VALVE AND PANEL WERE REMOVED AND REPLACED IAW MM 28-22-11 AND 28-22-43. OPERATIONAL CHECKS OF THE VALVE, PANEL, AND LANDING LIGHT WERE GOOD.

Part: SKIN — DENTED (AFT CARGO DOOR) · airframe 52,035 hrs · 27,317 cycles

INSPECTION FOUND A DENT IN AFT CARGO DOOR OUTER SKIN. THE DENTED AREA WAS CUT OUT. A REPAIR DOUBLER WAS INSTALLED IAW SRM 52-00-01, FIGURE 203.

Part: STRAP — CORRODED (FUSELAGE) · airframe 52,036 hrs · 27,317 cycles

INSPECTION FOUND FLOOR STRAP CORRODED ALONG FASTENER HOLES AT BS 727D. THE STRAP WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: ANGLE — CRACKED (FUSLEAGE) · airframe 52,036 hrs · 27,317 cycles

INSPECTION FOUND A 2 INCH CRACK IN MAIN CABIN FLOOR SHEAR WEB ANGLE AT STA 384, BL 0. THE SHEAR WEB ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 52,036 hrs · 27,317 cycles

INSPECTION FOUND A 2 INCH CRACK IN INTERCOSTAL AT STA 344, BL 0. THE INTERCOSTAL WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: FLAP — DELAMINATED (LT WING) · airframe 52,036 hrs · 27,317 cycles

INSPECTION FOUND LEFT WING NR 1 AFT FLAP INBOARD T/E DELAMINATED. REPAIRED IAW SRM 51-70-10.

Part: GEARBOX — FAILED (NR 2 ENGINE) · airframe 51,230 hrs · 26,880 cycles

THE NR 2 ENGINE SUDDENLY AUTO SHUTDOWN WHILE CLIMBING THROUGH 19K AFTER TAKEOFF FROM EWR. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE TRANSFER GEARBOX AT FAULT. THE NR 2 ENGINE TRANSFER GEARBOX WAS REMOVED AND REPLACED IAW MM 72-62-01. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: PRESSURE PANEL — CRACKED (FUSELAGE) · airframe 49,674 hrs · 26,032 cycles

INSPECTION FOUND A CRACK IN THE PRESSURE DECK WEB AT STA 663, LBL 32. THE CRACK WAS ESTIMATED AT BEING .5 - .75 INCH LONG. A REPAIR WAS PERFORMED IAW SRM 53-60-51, FIGURE 203 AND ECRA 5310-04315.

Part: PUMP — FAILED (NR 2 ENGINE) · airframe 48,800 hrs · 25,570 cycles

THE NR 2 ENGINE FLAMED OUT WHILE ON DESCENT AT 10,000 FEET. AN ENGINE RESTART WAS ATTEMPTED, BUT WAS UNSUCCESSFUL. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE FUEL PUMP AND MEC. LEAK AND OPERATIONAL CHECKS WERE GOOD. IN ADDITION, THE SPAR VALVE WAS REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE.

Part: SKIN — CRACKED (#6 SLAT) · airframe 46,838 hrs · 24,547 cycles

INSPECTION FOUND CRACKS COMING FROM THREE RIVETS ON LOWER SIDE OF #6 SLAT SKIN BELOW I/B AUX TRACK. REPAIRED SLAT IAW SRM 57-43-01.

Part: SKIN — CRACKED (#1 SLAT) · airframe 46,838 hrs · 24,547 cycles

INSPECTION FOUND #1 SLAT SKIN CRACKED AT AFT ROW OF RIVETS APPROXIMATELY 1/8" ON EITHER SIDE OF RIVET, 43" O/B OF I/B END. A REPAIR WAS INSTALLED IAW SRM 57-43-01, FIGURE 206.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 46,838 hrs · 24,547 cycles

INSPECTION FOUND TIE DOWN RAIL CORRODED AROUND FASTENER HOLES AT STA 727-945.5, RBL 26. THE CORRODED SECTIONS OF TIE DOWN RAIL WERE REMOVED AND REPLACED IAW SRM 53-00-53, FIGURE 202.

Part: BRACKET — CRACKED (LEFT ELEVATOR) · airframe 46,838 hrs · 24,547 cycles

LEFT ELEVATOR #4 HINGE UPPER ACCESS COVER OUTBOARD ATTACH BRACKET CRACKED. FABRICATED AND INSTALLED NEW BRACKET ON ELEVATOR PER SRM 51-40-01.

Part: FRAME — DENTED (BS727 AT S-21L) · airframe 46,838 hrs · 24,547 cycles

FRAME 727B UPPER CAP DENTED AT S-21LT. FABRICATED AND INSTALLED REPAIR PER SRM 51-70-11.

Part: SKIN — DENTED (HORIZ STAB) · airframe 46,838 hrs · 24,547 cycles

DENT IN LEADING EDGE OF RIGHT HORIZONTAL STABILIZER AT STATION 263. PERFORMED INTERIM REPAIR PER SRM 55-10-01. PERMANENT REPAIR REQUIRED IN 18 MONTHS.

Part: ANGLE — WORN (RT TE ATTACH) · airframe 46,838 hrs · 24,547 cycles

T ANGLE ON FUSELAGE FORWARD END AT FILLET FAIRING SUPPORT ANGLE THAT ATTACHES TO UPPER WING TRAILING EDGE WORN. REMOVED AND REPLACED ANGLE PER SRM 51-10-2 AND 51-40-00.

Part: KEEL — WORN (FUSELAGE) · airframe 46,838 hrs · 24,547 cycles

STRUCTURE AROUND HOLES FOR ATTACHMENT OF WHEEL WELL FAIRING WORN IN LEFT MLG. REPAIRED AREA ON KEEL REQUIRED BY EC/RA 5310-03740.

Part: SKIN — CRACKED (L2 DOOR) · airframe 46,838 hrs · 24,547 cycles

L2 DOOR SKIN CRACKED AT UPPER HINGE CUT OUT (5/16"). REPAIRED PER SRM 52-00-01.

Part: SEAT TRACK — CORRODED (STA 727-767) · airframe 46,838 hrs · 24,547 cycles

CABIN RIGHT SIDE INBOARD SEAT TRACK CORRODED FROM STATION 727E TO STATION 767. REMOVED AND REPLACED SEAT TRACK PER SRM 53-00-52, SOPM 20-41-04 AND AMM 51-21-00.

Part: PANEL — CORRODED (STA420-440 RT) · airframe 46,838 hrs · 24,547 cycles

TRANSITION PANEL CORRODED AT BS 420 - 440 RIGHT. FABRICATED AND INSTALLED TRANSITION PANEL PER SRM 51-40-02.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 46,838 hrs · 24,547 cycles

FLOORBEAM STATION 986.5 HAS SEVERAL CORRODED HOLES AT UPPER FLANGE (TOP AND BOTTOM). REPAIRED FLOORBEAM PER EC/RA 5310-03851.

Part: WEB — CRACKED (FUSELAGE) · airframe 46,838 hrs · 24,547 cycles

AFT LEFT AREA STATION 996 FLOOR WEB CRACKED (1 INCH) UNDER L2 Z-ANGLE. INSTALLED SERVICEABLE WEB WITH FASTENERS PER SRM 51-10-02.

Part: SEAT TRACK — CRACKED (STA 328-380) · airframe 46,838 hrs · 24,547 cycles

SEAT TRACK RBL 44 BS 328 - 380 CORRODED. CRACK (1/2") AT BS 380. REPAIRED PER SRM 53-00-02 AND 51-30-02.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 46,838 hrs · 24,547 cycles

CORROSION ON Z1 ANGLE AND ON L ANGLES BENEATH THE Z (BS 312-328 AND 328-344). REMOVED AND REPLACED ZEE ANGLES AND L-ANGLES PER SRM 51-10-02.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 46,838 hrs · 24,547 cycles

FLOOR SUPPORT CRACKED AT SCREW HOLES BETWEEN STATIONS 927 AND 947.5 AT BL 0.0. FABRICATED AND INSTALLED SUPPORT ASSEMBLY PER SRM 51-10-2.

Part: ANGLE — CRACKED (BS 294 R1 FWD) · airframe 46,838 hrs · 24,547 cycles

BS 294 BOX ANGLE CRACKED AT R1 DOOR CUT OUT JUST ABOVE FLOOR BEAM. TRIMMED CRACKED FLANGE. APPLIED ALODINE ADN PRIMER AND INSTALLED .050 FILLER PER EC/RA 5310-03895.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 46,838 hrs · 24,547 cycles

FLOORBEAM BS 360, RBL 0-60, CORROSION UNDER G-2 GALLEY. REPAIRED FLOORBEAM IN REF TO SRM 53-00-51.

Part: SKIN — CRACKED (L-1 WINDOW) · airframe 46,838 hrs · 24,547 cycles

INSPECTION FOUND A 1/2" CRACK IN L-1 WINDOW POST SKIN. THE CRACKED AREA OF SKIN WAS REMOVED AND FILLER AND DOUBLER WERE INSTALLED IAW SRM 53-10-01.

Part: CIRCUIT BREAKER — POPPED (LEVER LATCH)

THE GEAR HANDLE WOULD NOT MOVE PAST OFF POSITION AFTER TAKEOFF. THE AIRCRAFT WAS RETURNED TO ORD WHERE IT LANDED WITHOUT INCIDENT. TROUBLESHOOTING BY MAINTENANCE IAW MM 32-31-21, DUPLICATED CONTROL LEVER LOCK ON GROUND. THE LEVER LATCH CIRCUIT BREAKER WAS FOUND POPPED. THE CIRCUIT BREAKER WAS RESET. GEAR OPERATION WAS SIMULATED AND THE LEVER LOCK OPERATED NORMALLY WITH THE LEVER LATCH CIRCUIT BREAKER REMAINING IN.

Part: CIRCUIT BREAKER — TRIPPED (LANDING GEAR)

THE GEAR LEVER WOULD NOT MOVE FROM THE OFF TO THE UP POSITION UPON GEAR RETRACTION AFTER TAKEOFF FROM IAH. CHECKLIST PROCEDURES WERE ACCOMPLISHED AND THE LOCK OVERRIDE TRIGGER WAS USED TO RETRACT THE GEAR. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LEVER LATCH CIRCUIT BREAKER ON P6 PANEL POPPED. THE CIRCUIT BREAKER WAS RESET AND MM 32-31-21 PROCEDURES WERE COMPLIED WITH. GROUND AND AIR MODES WERE SIMULATED AND OPERATION OF THE LANDING GEAR HANDLE WAS GOOD.

Part: WIRE — BROKEN (CABIN)

THE EMERGENCY TRACK LIGHTS AT LAST FIVE ROWS OF AIRCRAFT WERE FOUND INOPERATIVE DURING A PREFLIGHT CHECK. MAINTENANCE FOUND A WIRE BROKEN AT SEAT 21. THE WIRE WAS REPAIRED AND OPERATION OF THE LIGHTS WAS RESTORED.

Part: CHORD — CRACKED (NR 5 LE SLAT)

INSPECTION FOUND A 3 CRACK IN LOWER T-CHORD AT NR 5 SLAT. THE T-CHORD WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: FLOORBEAM — CORRODED (BS 294)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 294, RBL 10. THE FLOORBEAM WAS REPAIRED IAW SRM 53-10-51.

Part: WIRE — SHORTED (CABIN)

INSPECTION FOUND EMERGENCY EXIT FLOOR TRACK LIGHTING INOPERATIVE FROM ROWS 1 TO 7. A BLOWN FUSE WAS FOUND IN FORWARD BATTERY CHARGER. THE FUSE WAS REMOVED AND REPLACED. SHORTED WIRING WAS ALSO FOUND AT ROW 5. THE WIRING WAS REPAIRED AND OPERATION OF THE EMERGENCY LIGHTS WAS RESTORED.

Part: FUEL CONTROL — INOPERATIVE (NR 1 ENGINE)

THE NR 1 ENGINE FLAMED OUT ON APPROACH TO IAH. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE NR 1 ENGINE FUEL CONTROL UNIT. THE FUEL PUMP WAS ALSO REPLACED. THE ENGINE WAS TRIMMED PER MM 71-00-01 AND ALL PARAMETERS WERE NORMAL WITH NO LEAKS NOTED.

Part: CIRCUIT BREAKER — TRIPPED (NLG STEERING)

PHL - FLT 1755 - TAKEOFF WAS REJECTED AT 50 KNOTS DUE TO LIMITED NOSE WHEEL STEERING. MAINTENANCE FOUND THE NOSE WHEEL STEERING CIRCUIT BREAKER TRIPPED. THE CIRCUIT BREAKER WAS RESET AND STEERING OPERATION WAS NORMAL. (X)

Part: ANGLE — CORRODED (BS 947.5)

HOU - INSPECTION FOUND CORROSION ON AFT BAGGAGE BIN AFT BULKHEAD LOWER ATTACH ANGLE AT VERTICAL SUPPORTS, STATION 947.5, LBL 12 AND RBL 12. THE ANGLE WAS REMOVED AND A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 53-60-53 AND SRM 51-10-2. (M)

Part: FLOOR BEAM — CRACKED (BS 520)

HOU - INSPECTION FOUND A 2 INCH CRACK IN FLOOR BEAM UPPER FLANGE AT STATION 520, RBL 24.75. THE FLOOR BEAM UPPER FLANGE WAS REPAIRED IAW SRM 5320-01208. (M)

Part: GASKET — LEAKING (APU BURNER CAN)

FLT NR 0220 - CLE - THE APU WAS STARTED ON SHORT FINAL INTO CLE, THEN ON LANDING ROLL OUT THE APU FIRE WARNING ACTIVATED. THE APU WAS SHUT DOWN AND THE FIRE BOTTLE WAS DISCHARGED. THE FIRE WARNING CEASED. THE FIRE DEPARTMENT WAS ALERTED AND OBSERVED NO FIRE OR SMOKE. MAINTENANCE INSPECTED THE APU EXHAUST, ELEVATOR, AND RUDDER WITH NO EVIDENCE OF FIRE NOTED. MAINTENANCE FOUND A LEAK AT THE APU BURNER CAN GASKET. A NEW GASKET WAS INSTALLED ON THE BURNER CAN. THE APU WAS RUN SEVERAL TIMES WITH PACKS OPERATING AND NO PROBLEMS WERE NOTED. THE APU FIRE BOTTLE WAS REMOVED AND REPLACED. (M)

Part: SWITCH — INOPERATIVE (RT WHEEL WELL)

FLT NR 0608 - BOS - THE LANDING GEAR DID NOT RETRACT AFTER TAKEOFF AND WAS ACCOMPANIED BY AN INTERMITTENT WARNING HORN. OVERRIDE WAS EMPLOYED AND THE GEAR RETRACTED. THE AIRCRAFT RETURNED TO BASE THE DAY BEFORE FOR THE LANDING GEAR NOT RETRACTING, BUT TROUBLESHOOTING FOUND NO DEFECTS. MAINTENANCE FOUND THE S106 AIR SAFETY SWITCH AT FAULT. THE SWITCH WAS REPLACED. A LANDING GEAR HANDLE SOLENOID TEST WAS PERFORMED PER MM 32-31-31 AND OPERATION CHECKED GOOD. (M)