N69348

Part: INTERCOSTAL — CORRODED (BS 227) · airframe 62,249 hrs · 31,927 cycles

FUSELAGE FRAME, SKIN AND SURROUNDING STRUCTURE CORRODED STATION 227.8 FROM LBL-12 TO RBL-12 (BILGE). REMOVED CORROSION FROM HORIZONTAL CHORD, FOUND TO BE WITHIN LIMITS, AND FOUND INTERCOSTAL TO BE OUT OF LIMITS. CLEANED AREA AND INSTALLED NEW INTERCOSTAL PER B737 SRM 51-10-2 AND 51-4.

Part: SKIN — CRACKED (FUSELAGE) · airframe 62,249 hrs · 31,927 cycles

STRINGER 24L, STATION 727E - 718 OUTER SKIN HAS 1 INCH CRACK. REPAIRED CRACK IN OUTER SKIN STRINGER 24L STATION 727 - 718 PER B737 SRM 53-00-01 FIG 201. TOTAL WEIGHT OF REPAIR, 9.84LBS FOR WEIGHT AND BALANCE CALCULATION.

Part: SKIN — DELAMINATED (NR 5 SLAT) · airframe 62,249 hrs · 31,927 cycles

RIGHT WING NR 5 SLAT TRAILING EDGE WEDGE INBOARD AND OUTBOARD PROTECTIVE FINISH FOUND DELAMINATION ON OUTBOARD TRAILING EDGE. FABRICATED REPAIR DOUBLER AND REPLACED DAMAGED HONEYCOMB. BONDED REPAIR DOUBLER AND CORE, SEALED INBOARD AND OUTBOARD TRAILING EDGE WEDGE SEALANT IAW SRM 51-70-10. RESTORED PROTECTIVE FINISH TO NR 5 SLAT PER CAL SPEC 5100 S00128, REV Q.

Part: FLOORBEAM — CRACKED (BS 328) · airframe 62,249 hrs · 31,927 cycles

FLOORBEAM BS 328 LBL 12 UPPER TEE CAP CRACKED SL-7 69. REPAIRED CRACKED FLOORBEAM AT BS 328 LBL 12 UPPER TEE CAP PER SRM 53-10-51 FIG 201.

Part: SKIN — DELAMINATED (NR 3 SLAT) · airframe 62,249 hrs · 31,927 cycles

LEFT WING NR 3 SLAT INBOARD END SKIN IS DELAMINATED. REPAIRED LEFT WING NR 3 SLAT TRAILING EDGE WEDGE PER SRM 51-70-10.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 62,249 hrs · 31,927 cycles

FORWARD CARGO DOOR CUTOUT FORWARD FRAME CRACKED AT LOWER DOOR STOP FITTING AT STR 24R. REMOVED AND REPLACED FORWARD CARGO DOOR CUTOUT FORWARD FRAME PER SRM 51-10-2, PAGE 8, MAT ID 65-20722U70, PAC 59980.

Part: SKIN — CORRODED (BS 967 S27L) · airframe 61,387 hrs · 31,527 cycles

GENERATED DIP DUE TO HEAVY CORROSION AT STATION 967, STR 27LT TO STR 27RT, PERFORM A PERMANET REPAIR PER EC/RA 5331-01244 WITHIN 6,000 FLIGHT CYCLES OR 24 MONTHS, WHICHEVER OCCURS FIRST. DURING OPEN-UP FOUND MORE CORROSION, REMOVED EXISTING REPAIRS AND REPAIRED PER EC/RA 5330-03827.

Part: ACTUATOR — INOPERATIVE (LT MLG UPLOCK) · airframe 59,006 hrs · 30,408 cycles

THE LEFT MLG DID NOT INDICATE DOWN & LOCKED WHEN GEAR WAS EXTENDED ON APPROACH TO IAH. MANUAL EXTENSION WAS PERFORMED AND YAW WAS FELT WHEN LEFT MAIN EXTENDED. THE GEAR INDICATED 3 GREEN AND LANDING WAS NORMAL. THE GEAR WAS SWUNG SEVERAL TIMES WITH NO FAULTS NOTED. THE LEFT MAIN GEAR UPLOCK ACTUATOR WAS REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE IAW M/M 32-32-41. OPERATIONAL CHECKS WERE GOOD.

Part: CONTROLLER — INOPERATIVE (CABIN PRESSURE) · airframe 58,764 hrs · 30,293 cycles

THE CREW RECEIVED A CABIN ALTITUDE WARNING CLIMBING THROUGH FL 270. THE QRH WAS FOLLOWED AND A RAPID DESCENT TO 13,000 FEET WAS ACCOMPLISHED. CABIN PRESSURE WAS RECOVERED VIA MANUAL DC. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT FURTHER PROBLEM. A CABIN PRESSURE CONTROLLER WAS REMOVED AND REPLACED IAW MM 21-31-21, PAGE 401. OPERATIONAL CHECKS WERE GOOD IAW MM 21-31-00, PAGE 201.

Part: BRACE — CORRODED (BS 1104-1112) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND HORIZONTAL STABILIZER CENTER BRACE RT LOWER I/B CHORD CORRODED BETWEEN STA 1104 AND 1112. THE AREA WAS REPAIRED IAW ECRA 5510-01840.

Part: FRAME — CORRODED (BS 1121-1129) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND HORIZONTAL STABILIZER CENTER BRACE LT LOWER I/B CHORD CORRODED BETWEEN STA 1121 AND 1129. THE AREA WAS REPAIRED IAW ECRA 5510-01841.

Part: SKIN — CORRODED (WS 70-140) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND CORROSION ON AFT INTERIOR SURFACE OF THE LT WING AFT FUEL BOOST PUMP SKIN CUTOUT AT WS 70.85-140. A REPAIR WAS INSTALLED IAW ECRA 5720-01990.

Part: SKIN — CORRODED (BS 967 S27R) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND FUSELAGE SKIN CORRODED AT STA 967, S27R. A SKIN REPAIR WAS INSTALLED IAW ECRA 5331-01244.

Part: FLOORBEAM — CRACKED (BS 328) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND A 1.25 INCH CRACK ON THE TOP EDGE OF FLOORBEAM WEB AT STA 328, BL 0. A REPAIR WAS INSTALLED IAW ECRA 5321-01373.

Part: STRINGER — CRACKED (BS 360 S15L) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND A 1 INCH CRACK AT FORWARD PASSENGER DOOR CUTOUT ON STRINGER 15L SPLICE CHANNEL, STA 360, LBL 50. THE STRINGER WAS REPAIRED IAW ECRA 5311-01259 AND A DIP WAS ISSUED TO REINSPECT THE REPAIR WITHIN 6,000 FLIGHT CYCLES.

Part: SKIN — CRACKED (CARG DOOR) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND A CRACK AT THREE EACH LIGHTENING HOLES ON THE INNER SKIN OF THE FORWARD CARGO DOOR. THE SKIN WAS REPAIRED IAW ECRA 5232-01076.

Part: SKIN — CRACKED (BS 765) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND A 1 INCH CRACK IN FUSELAGE SKIN AT STA 765 JUST ABOVE STRINGER 21R ON BONDED DOUBLER LINE. THE CRACKED SECTION OF SKIN WAS CUT OUT AND A DOUBLER REPAIR WAS INSTALLED IAW SRM 53-00-0, REPAIR 31, PROCEDURE V, DETAIL VII, FIGURE 201, PAGE 228.

Part: FLOORBEAM — CORRODED (BS 328) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND MAIN CABIN FLOORBEAM CORRODED AT STA 328, RBL 11-36. REPLACED T-CAP ON FLOORBEAM IAW SRM 53-10-5, REPAIR 5.

Part: BELTFRAME — CORRODED (FUSELAGE) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND FORWARD BAGGAGE BIN BELT FRAME CORRODED AT STA 500D, S27L, LBL11-13. A DOUBLER WAS INSTALLED IAW SRM 53-00-07 FIGURE 201 REPAIR 7.

Part: BELTFRAME — CORRODED (FUSELAGE) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND FORWARD BAGGAGE BIN BELT FRAME CORRODED AT STA 480, S27L, LBL 13-17. REPAIRED IAW SRM 53-00-07.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 55,495 hrs · 28,798 cycles

INSPECTION FOUND L-2 DOOR Z-ANGLE CORRODED AT STA 947-999, LBL 40. THE Z-ANGLE WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: FRAME — CRACKED (CARGO DOOR) · airframe 55,271 hrs · 28,688 cycles

INSPECTION FOUND A 1.5 INCH CRACK IN THE FORWARD CARGO DOOR LOWER CORNER FRAME JUST BELOW DOOR HOLD OPEN HOOK. THE DOOR FRAME WAS REPAIRED IAW SRM 51-40-02 AND EA 5230-01030.

Part: WIRE — SHORTED (EMERGENCY LIGHT) · airframe 53,624 hrs · 27,883 cycles

THE FIRST CLASS EMERGENCY ESCAPE AISLE PATH LIGHTING WAS FOUND INOPERATIVE. MAINTENANCE FOUND SHORTED WIRING TO TRANSFORMER. THE WIRING WAS REPAIRED AND OPERATIONAL CHECKS WERE GOOD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 51,400 hrs · 26,811 cycles

INSPECTION FOUND A 2 INCH CRACK IN FUSELAGE SKIN BELOW FASTENER ROW BETWEEN STA 727E AND 747, S24R. A REPAIR DOUBLER AND TRIPLER WERE INSTALLED IAW SRM 53-00-01, FIGURE 229.

Part: SKIN — CORRODED (FUSELAGE) · airframe 50,797 hrs · 26,487 cycles

INSPECTION FOUND FUSELAGE SKIN CORRODED AND CRACKED AT STA 259.5-360, S24L TO S29L. THE SKIN WAS REMOVED AND REPLACED IAW ECRA 5310-04421.

Part: SKIN — CRACKED (FUSELAGE) · airframe 50,577 hrs · 26,375 cycles

INSPECTION FOUND A 1.5 INCH CRACK IN FUSELAGE SKIN AT STA 747, STRINGER 23L. DOUBLERS WERE INSTALLED IAW SRM 53-00-01, FIGURE 229.

Part: SKIN — CRACKED (STA 727D) · airframe 47,449 hrs · 24,615 cycles

INSPECTION FOUND A 3" CRACK IN FUSELAGE SKIN AT STA 727A, S23L. REPAIRED IAW ECRA 5330-03090.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 45,998 hrs · 23,716 cycles

INSPECTION FOUND KEEL BEAM LT LOWER O/B CHORD CORRODED AT STA 727. REPAIRED IAW ECRA 5311-01127.

Part: SKIN — CRACKED (#6 SLAT) · airframe 45,998 hrs · 23,716 cycles

INSPECTION FOUND #6 SLAT SKIN CRACKED. REPAIRED IAW SRM 57-43-01.

Part: SEAT TRACK — CORRODED (BS 787 & 797) · airframe 45,998 hrs · 23,716 cycles

INSPECTION FOUND MAIN CABIN FLOOR R/H I/B SEAT TRACK HAD CORROSION AND WORN LOBES AT BS 787 AND 797, THE CORRODED AND WORN SECTION OF SEAT TRACK WAS REMOVED AND A NEW SEAT TRACK SECTION WAS SPLICED IN IAW SRM 53-00-52, FIGURE 204.

Part: SEAT TRACK — CORRODED (STA 907-940) · airframe 45,998 hrs · 23,716 cycles

INSPECTION FOUND L/H I/B SEAT TRACK CORRODED AT STA 907-940. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 53-00-52.

Part: SEAT TRACK — CORRODED (STA 907-935) · airframe 45,998 hrs · 23,716 cycles

INSPECTION FOUND R/H I/B SEAT TRACK CORRODED AT STA 907-935. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 53-60-52.

Part: STRAP — CORRODED (STA 1006-APB) · airframe 45,998 hrs · 23,716 cycles

INSPECTION FOUND R/H SIDE Y STRAP CORRODED FROM STA 1006 TO AFT PRESSURE BULKHEAD, RBL 6. THE STRAP WAS REMOVED AND REPLACED IAW SRM 51-40-02.

Part: SEAT TRACK — CORRODED (STA 270-294) · airframe 45,998 hrs · 23,716 cycles

INSPECTION FOUND SEAT TRACK CORRODED AT STA 270-294, RBL 43. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 51-10-02.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 45,998 hrs · 23,716 cycles

INSPECTION FOUND FLOOR SUPPORT UNDER R2 DOOR Z-ANGLE AT STA 969 CORRODED. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 51-10-02, 51-40-02, AND 51-30-01.

Part: HARNESS — BROKEN (ROW 6 AND 22) · airframe 40,274 hrs · 20,756 cycles

EMERGENCY AISLE PATH LIGHTING INOP AT ROW 6 AND 22. REPLACED WIRE HARNESS AT BOTH ROWS PER MAINTENANCE MANUAL 33-51-02 PG 501.

Part: TRIGGER — OUT OF POSITION (PASSENGER DOOR)

FORWARD ENTRY DOOR WILL NOT OPEN. FOUND RELEASE LATCH MECHANISM DISSASSEMBLED AND TRIGGER OUT OF POSITION. REASSEMBLED AND TESTED PER MM 52-11-00 PAGE 501.

Part: STRINGER — CORRODED (BS 1006-1016)

INSPECTION FOUND STRINGER CORRODED JUST BELOW RT AFT LAV DUMP CHUTE FROM STA 1006 TO 1016. THE CORRODED SECTION OF STRINGER WAS REMOVED AND A NEW SECTION OF STRINGER AND SHIM WERE FABRICATED AND INSTALLED IAW ECRA 5360-01018.

Part: FLOORBEAM — CORRODED (BS 344)

INSPECTION FOUND FORWARD GALLEY FLOORBEAM CORRODED AT STA 344, LBL 30 TO 20. THE FLOORBEAM WAS REMOVED AND REPLACED IAW SRM 53-10-51.

Part: FLOORBEAM — CORRODED (BS 312)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 312, RBL 15 AND LBL 20. REPAIR DOUBLERS WERE INSTALLED IAW SRM 53-10-51.

Part: OVEN — DIRTY (AFT GALLEY)

THE CREW REPORTED SMOKE COMING FROM NR 1 AND NR 2 AFT GALLEY OVENS IN FLIGHT. THE SMOKE WAS MOMENTARY. THE FLIGHT WAS CONTINUED TO DEN WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND NO EVIDENCE OF FIRE. FOOD RESIDUE WAS FOUND ON THE HEATING ELEMENTS OF BOTH OVENS. THE ELEMENTS WERE CLEANED AND BOTH OVENS WERE OPERATED WITH NO SMOKE DETECTED.

Part: LOGIC CARD — INOPERATIVE (LANDING GEAR)

THE RT MLG INDICATION WAS SHOWING RED AND GREEN AFTER GEAR RETRACTION. THE GEAR WAS CYCLED AND THE RED LIGHT EXTINGUISHED. THE RED LIGHT ILLUMINATED INTERMITTENTLY DURING FLIGHT. MAINTENANCE FOUND THE M986 LOGIC CARD AT FAULT. THE M986 LOGIC CARD WAS REMOVED AND REPLACED AND OPERATIONAL CHECKS WERE GOOD IAW MM 32-09-20.

Part: TIRE — FAILED (LT MLG)

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

Part: WINDSHIELD — FAILED (RT COCKPIT)

A STRONG ODOR ACCOMPANIED BY SMOKE WAS OBSERVED IN THE COCKPIT DURING CLIMB-OUT OF DTW ENROUTE TO EWR. THE AIRCRAFT WAS DIVERTED TO CLE WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE FIRST OFFICER'S NR 5 WINDOW OVERHEATING AND CAUSING THE ODOR AND SMOKE. THE WINDOW AND WINDOW THERMAL SENSOR WERE REMOVED AND REPLACED IAW MM 56-11-31. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: ANGLE — CRACKED (BS 540)

INSPECTION FOUND A 1 INCH CRACK IN ANGLE AT STA 540, STRINGER 22R. THE CRACKED AREA WAS CUT OUT AND A REPAIR WAS INSTALLED IAW SRM 51-70-11.

Part: ROLLERS/TRACKS — LACK OF LUBE (NR 5 LE SLAT)

FLT NR 1708 - EWR - WHEN FLAPS WERE SELECTED BEYOND 5 DEGREES CREW RECEIVED T/E FLAP ASYMMETRY. THE SAFETY WIRES WERE BROKEN ON GPWS AND ALTERNATE FLAP MASTER SWITCH. THE LEFT INDICATOR WENT TO 10 DEGREES AND THE RIGHT STAYED AT 5 DEGREES. THE AIRCRAFT WAS DIVERTED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 5 SLAT ROLLERS AND TRACKS DRY. THE NR 5 SLAT ROLLERS AND TRACKS WERE LUBRICATED. AN ADJUSTMENT AND TEST OF THE SLAT LEADING EDGE SYSTEM WAS PERFORMED IAW MM 27-81-00. THE FLAPS/SLATS WERE OPERATED SEVERAL TIMES WITH NO ASYMMETRY PROBLEMS NOTED. (M)