N69735

Part: FRAME — DENTED (FUSELAGE)

NO FLIGHT: DURING INSPECTION THE FRAME AT STATION 600 WAS FOUND DENTED BETWEEN STRINGERS S6R AND S7R. REPAIRED FRAME WITH DOUBLER REPAIR SRM. AIRCRAFT RETURNED TO SERVICE. (K)

Part: FRAME — DENTED (BS 380 S6L)

NO FLIGHT: DURING INSPECTION THE FRAME AT STATION 380 WAS FOUND DENTED BETWEEN STRINGERS S5L AND S6L. REPAIRED FRAME WITH DOUBLER REPAIR IAW SRM. AIRCRAFT RETURNED TO SERVICE. (K)

Part: FRAME — DENTED (FUSELAGE)

NO FLIGHT: DURING INSPECTIO THE FRAME AT STATION 400 WAS FOUND DENTED BETWEEN STRINGERS S6L AND S7L. REPAIRED FRAME WITH DOUBLER REPAIR SRM. AIRCRAFT RETURNED TO SERVICE. (K)

Part: FRAME — DENTED (FUSELAGE)

NO FLIGHT: DURING INSPECTION THE FRAME AT STATION 560 WAS FOUND DENTED BETWEEN STRINGERS S5R AND S6R. REPAIRED FRAME WITH DOUBLER REPAIR IAW SRM. AIRCRAFT RETRUNED TO SERVICE. (K)

Part: TURBINE — FAILED (LT WING)

DURING TAKEOFF AFTER V- THE FLIGHT CREW FELT A DULL THUD ON AN ENGINE THE NR 1 ENGINE THEN FAILED. THE FLIGHT CREW DECLARED AN EMERGENCY AND RETURNED TO DEPARTURE. AN UNEVENTFUL LANDING WAS MADE. INSPECTION REVEALED TURBINE BLADE DAMAGE ON THE NR 1 ENGINE. REMOVED AND REPLACED NR 1 ENGINE ASSY. AIRCRAFT WAS RETURNED TO SERVICE. (K)

Part: FILTER — BYPASSING (NR 3 ENGINE)

DURING CLIMB, OIL FILTER BYPASS LIGHT ILLUMINATED. RETARDING THROTTLE DID NOT EXTINGUISH. PERFORMED PRECAUTIONARY ENGINE SHUTDOWN IAW ABNORMAL PORCEDURES. NOTE: THE ENGINE WAS WINDMILLING FOR ABOUT 15-20 MIN AND OIL PRESSURE WAS ABOUT 20-25 PSI. FLIGHT RETURNED TO MSP WHERE A LANDING WAS MADE WITHOUT INCIDENT. INSPECTED MAIN OIL FILTER ON NR 3 ENGINE, FOUND NO CONTAMINATION. INSTALLED NEW OIL FILTER. RAN ENGINE. RE-INSPECTED OIL FILTER NO CONTAMINATION NOTED. RE-INSTALLED NEW FILTER. RAN ENGINE. NO OIL FILTER BYPASS LIGHT NOTED. OK FOR CONTINUED SERVICE. RAN ENGINE NO LEAKS NOTED. RESERVICED OIL TANK. AIRCRAFT WAS RETURNED TO SERVICE. (K)

Part: OIL FILTER — BYPASSING (NR 3 ENG)

DURING CRUISE, DURING FLIGHT VIBRATION AND NOISE FOLLOWED BY OIL FILTER BYPASS LIGHT ON NR 3 ENGINE. NR 3 EINGINE SHUTDOWN AND ENGINE WINDMILLING PROCEDURE FOLLOWED (OIL FILTER BYPASS LIGHT WENT OUT BELOW 25 PERCENT, N2) NOTE: ENGINE WINDMILLED FOR 38 MIN AT 20 PSI. FLIGHT CONTINUED, WHERE LANDING WAS MADE WITHOUT INCIDENT. (K)

Part: SWITCH — OUT OF ADJUST (MAIN CARGO DOOR)

DURING CLIMB FROM 14,000 FEET THE (MAIN CARGO DOOR NOT CLOSED) LIGHT ILLUMINATED. THE FLIGHT CREW DECLARED AN EMERGENCY AND RETURNED TO DEPARTURE. ON DECENT THE LIGHT WENT OFF AT 12,000 FEET. AN UNEVENTFUL LANDING WAS MADE AT DEPARTURE. THE MAIN CARGO DOOR WAS VERIFIED TO BE CLOSED AND LOCKED AND THE MAIN CARGO DOOR INDICATING SYSTEM WAS DEFERRED. INSPECTION REVELED THAT THE MAIN CARGO DOOR LATCH LOCK SWITCH WAS OUT OF ADJUSTMENT. THE SWITCH WAS ADJUSTED AND THE AIRCRAFT WAS RETURNED TO SERVICE. (K)

Part: TUBE — BROKEN (NR 2 ENGINE)

FLT 6007 - SEA-KTN - DURING DEPARTURE, ENGINE NR 2 N2 AT 102 PERCENT AND EGT AT RED LINE ON CLIMB-OUT, EPR AT 1.89. AIRCRAFT RETURNED. LANDING WEIGHT 142000, NORMAL LANDING AND BRAKING. LANDING WAS MADE WITHOUT INCIDENT. INSPECTED NR 2 ENGINE AND FOND BROKEN PRBC LINE. REMOVED AND REPLACED PRESSURE LINE. RUN NR 2 PER KHA JET RUN HANDBOOK. OPS CHECK GOOD. ENGINE NR 2 TAKEOFF POWER AT 2.01 EPR, N1-95 PERCENT, EGT 560, N2 93 PERCENT. SYSTEM OPS CHECK GOOD. NO DEFECT NOTED. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: INDICATOR — MALFUNCTIONED (COCKPIT)

AFTER PUSH-BACK, FLIGHT CREW INDICATED SMOKE COMING FROM RADAR INDICATOR. INSPECTED RADAR SYSTEM, FOUND BAD RADAR INDICATOR, TRANSFERRED TO DMI NR 1855 IAW MEL 34-21, CAT (C) DUE.

Part: INDICATOR — SMOKE (RADAR)

BOS - AFTER PUSH-BACK, FLIGHT CREW INDICATED SMOKE COMING FROM RADAR INDICATOR. REMOVED AND REPLACED RADAR INDICATOR. OPS CHECK AND SELF TEST GOOD ON GROUND. THIS CLEARS DMI NR 1855. PLACARD REMOVED. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (NACELLE)

DURING B-CHECK INSPECTION MAINTENANCE, FOUND A 2.5 INCH CRACK TO THE NR 3 ENGINE NOSE COWL SKIN LOCATED AT NAC STATION 77.5. MAINTENANCE REMOVED AND REPLACED THE NR 3 ENGINE NOSE COWL. THE AIRCRAFT WAS THEN RETURNED TO SERVICE. (M)

Part: HYDRAULIC LINE — PUNCTURED (HYDRAULIC SYS)

FLT 1925 - FWA-BNA - DURING CLIMB-OUT, THE CREW NOTICED THAT SYSTEM 'A' WAS LOSING HYDRAULIC FLUID. THE CREW RETURNED TO FWA, AND DECLARED AN EMERGENCY. AN UNEVENTFUL LANDING WAS MADE AT FWA. THE AIRPLANE REQUIRED TOW BACK TO THE MAINTENANCE RAMP. MAINTENANCE FOUND A PUNCTURE IN THE NR 2 SYSTEM PRESSURE LINE LOCATED IN THE AFT STAIR WELL. MAINTENANCE REPLACED THE LINE IAW THE BOEING 727 AMM CHAPTER 29-10. THE AIRCRAFT WAS THEN RETURNED BACK TO SERVICE. (M)

Part: SWITCH — DIRTY (NLG)

FLT 2011 - PDX-MHR - DURING APPROACH, THE GEAR WAS SELECTED TO THE DOWN POSITION. ALL THREE GREEN LIGHTS ILLUMINATED AND THE NOSE GEAR LIGHT WENT OUT AND DID NOT COME BACK ON. THE FLIGHT CREW DECLARED EMERGENCY, VERIFIED NOSE GEAR POSITION THROUGH THE VIEWING PORT AND LANDED. THE AIRCRAFT LANDED AT MHR WITHOUT ANY FURTHER DIFFICULTIES. CLEANED THE NOSE GEAR DOWN AND LOCKED SWITCH. PERFORMED A RETRACTION AND EXTENSION. OPS CHECKED GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: WARNING SYSTEM — ACTIVATED (APU FIRE BELL)

FLT 3771 - FWA-MCI - DURING CRUISE, THE APU FIRE BELL AND LIGHT CAME ON. PERFORMED CHECKLIST, DECLARED AN EMERGENCY, AND DIVERTED TO MLI. THE AIRCRAFT LANDED AT MLI WITHOUT ANY FURTHER DIFFICULTIES. DEFERRED THE APU FIRE DETECTION SYSTEM PER KHA B727 MEL. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: LIGHT — WILL NOT TEST (COCKPIT)

FOUND DURING PREFLIGHT, EMERGENCY EXIT LIGHT DOES NOT TEST AT ENTRY WAY DOOR. MAINTENANCE REMOVED AND REPLACED THE EMERGENCY EXIT LIGHT ASSEMBLY. PERFORMED A SATISFACTORY OPERATIONAL CHECK PER B-727-224 AMM. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: FIRE DETECTOR — MALFUNCTIONED (APU BAY)

MHR/LAX - FLT 2031 - DURING CRUISE, THE APU FIRE WARNING LIGHT ILLUMINATED. THE CREW PERFORMED ABNORMAL CHECK LIST AND DECLARED AN EMERGENCY AND RETURNED TO MHR. THE AIRCRAFT LANDED SAFELY WITHOUT ANY INCIDENT. VISUALLY INSPECTED APU AND SHROUD FOR EVIDENCE OF FIRE. NONE NOTED. ITEM TRANSFERRED TO DEFERRED MAINTENANCE ITEM MINIMUM EQUIPMENT LIST. THE AIRCRAFT WAS RELEASED BACK TO SERVICE. (X)

Part: SENSE LINE — DISCONNECTED (NR 2 ENGINE)

FLT 2027 - DEN-MHR - DURING TAKEOFF, THE NR 2 ENGINE FAILED AFTER TAKEOFF. THE CREW PERFORMED ABNORMAL CHECKLIST AND RETURNED TO DEN DECLARING AN EMERGENCY LANDING. THE AIRCRAFT LANDED SAFELY WITHOUT ANY INCIDENT. MAINTENANCE FOUND THE SENSE LINE TO THE FUEL CONTROL DISCONNECTED. RECONNECTED SENSE LINE. RAN ENGINE ALL PARAMETERS NORMAL AT THIS TIME. THE AIRCRAFT WAS RELEASE TO SERVICE. (M)

Part: FITTING — CORRODED (NR 4 FLAP TRACK)

INSPECTION FOUND NR 4 FLAP TRACK ATTACH FITTING CORRODED. THE ATTACH FITTING WAS REMOVED AND REPLACED IAW ECRA 5740-01862 AND MM 32-11-51.

Part: FITTING — CORRODED (NLG)

NLG TRUNNION CORRODED AND PITTED IN BORES LT AND RT. REMOVED CORROSION AND PITTING, FABRICATED AND INSTALLED NEW BUSHINGS PER SRM 53-40-1.

Part: FITTING — WORN (RT WING)

RIGHT WING FORWARD SIDE OF MLG BEAM WING T/E PANEL TO BEAM ATTACH LINK FITTING HAS ELONGATED BOLT HOLES. REMOVED AND REPLACED FITTING PER SRM 51-30-1.

Part: FAIRING — CRACKED (NR 6 FLAP TRACK)

NR 6 FLAP TRACK MID FAIRING IS CRACKED .5 INCH LONG AT SKIN AFT EDGE. STOP DRILLED CRACK, HFEC INSP, FABRICATED TYPICAL REPAIR, DRILLED, DEBURRED, COUNTERSUNK, INSTALLED REPAIR. REMOVED AN INSTALLED TRACK GUIDE, TREATED, PRIMED PER SRM 51-10-1, 51-40-2, 51-30-2, 51-10-2, AND NDT MANUAL 51-00-00.

Part: HOUSING — CORRODED (LT MLG)

LEFT SIDE AFT TRUNNION BEARING HOUSING IS PITTED. REMOVED AND REPLACED LT AFT BEARING HOUSING PER MM 32-11-0.

Part: FAIRING — CRACKED (NR 4 FLAP TRACK)

NR 4 FLAP TRACK FAIRING AFT INBOARD ANGLE IS CRACKED .5 LONG. STOP DRILLED CRACK ON NR 4 FLAP TRACK FAIRING. FABRICATED REPAIR FROM 7075 T6 .050. LOCATED, DRILLED, DEBURRED, ALODINED, PRIMED PER SRM 51-40-3, 51-10-2, MM 51-20-12 AND INSTALLED PER SRM 51-30-2.

Part: PANEL — CRACKED (RT WING)

RT WING 35 FLAP TRACK AFT INBD PANEL LEADING EDGE OF PANEL IS BENT AND TORN. BLEND OUT TORN AREA PER SRM 53-10 FIG 1 MAT LOSS .001.

Part: ANGLE — CRACKED (NR 5 FLAP TRACK)

RT WING NR 5 FLAP FWD INBOARD FAIRING BRACKET CRACKED IN RADIUS .25 INCH LONG. FABRICATED ANGLE FROM 7075 T6 .063. LOCATED, DRILLED, DEBURRED, TREATED, PRIMED, AND INSTALLED PER SRM 51-40-3.

Part: FAIRING — CRACKED (WS 124)

INSPECTION FOUND A .25 INCH CRACK IN LT WING NR 4 FLAP TRACK FAIRING AT WS 124. A DOUBLER WAS INSTALLED IAW SRM 51-40-2, 51-10-2, MM 51-20-11.

Part: FAIRING — CRACKED (NR 5 FLAP TRACK)

INSPECTION FOUND A .25 INCH CRACK AT BOLT HOLE OF NR 5 FLAP TRACK CENTER FAIRING. A REPAIR WAS INSTALLED IAW SRM 51-40-2, 51-10-2, 51-40-2, 51-30-2, AND MM 51-20-11.

Part: ANTI-ICE DUCT — BLOWN (NR 3 ENGINE)

THE FIRE WARNING BELL SOUNDED FOLLOWED BY ILLUMINATION OF THE NR 3 ENGINE FIRE WARNING LIGHT ON CLIMB-OUT OF IAH AT ABOUT 900 FEET. THE NR 3 ENGINE POWER WAS REDUCED AND THE FIRE WARNINGS CEASED. A VALID FIRE TEST WAS RUN. THE LIGHT AND BELL CAME ON AGAIN WHEN ENGINE WAS RETURNED TO CLIMB POWER. FUEL WAS DUMPED AND THE AIRCRAFT WAS RETURNED TO IAH FOR A NORMAL LANDING WITH NR 3 ENGINE AT REDUCED POWER. MAINTENANCE FOUND THE NR 3 ENGINE ANTI-ICE DUCT BLOWN. THE DUCT WAS REMOVED AND REPLACED. THE NR 3 ENGINE WAS RUN WITH NO LEAKS NOTED AND OPERATION CHECKED GOOD.

Part: SKIN — CRACKED (PAX DOORWAY)

INSPECTION FOUND A .5 INCH CRACK AT LEFT SIDE OF FUSELAGE AT CUTOUT FOR L-1 DOOR UPPER HINGE ARM. THE CRACKED AREA WAS CUT OUT. A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW ECRA 5330-02675, SRM 51-10-2 AND SRM 51-30-2, AND SERVICE BULLETIN 727-53-0198.

Part: SKIN — CRACKED (L1 DOORWAY)

INSPECTION FOUND A 2.75 INCH CRACK IN FUSELAGE SKIN AT L-1 DOOR LOWER HINGE CUTOUT. THE CRACKED AREA WAS CUT OUT, A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-10-2 AND 51-20-4.

Part: ANGLE — CRACKED (VERT STAB)

INSPECTION FOUND A .5 INCH CRACK IN FRAME ATTACH ANGLE INSIDE LT SIDE OF VERTICAL STABILIZER AT STRINGER 5L. THE CRACK WAS STOP DRILLED IAW SRM 51-10-1. A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-40-4.

Part: PANEL — CRACKED (NLG WW)

INSPECTION FOUND CRACKS IN THE NLG WHEEL WELL TOP LEFT AND TOP RIGHT SKIN PANELS. THE CRACKS WERE .75 TO 1 INCH LONG. THE SKIN WAS REMOVED IAW SRM 51-10-1. WEB SKIN WAS FABRICATED AND INSTALLED IAW SRM 53-10-2, 51-10-2, AND 51-30-2.

Part: STRINGER — CRACKED (WS 171.5)

INSPECTION FOUND A 1.375 INCH CRACK IN RT WING VENT BOX STRINGER 19 AT WS 171.5, NR 2 TANK. THE CRACKED AREA WAS CUT OUT, A REPAIR DOUBLER, FILLER, AND ANGLE WERE FABRICATED AND INSTALLED IAW SRM 57-10-4, 51-10-2, 51-30-2, 51-10-6, AND 51-20-4.

Part: SKIN — CRACKED (BS 1215)

INSPECTION FOUND A .75 INCH CRACK THROUGH FASTENER HOLE OF SKIN AT LT SIDE OF VERTICAL STABILIZER AROUND ACCESS PANEL 9523 ABOVE BS 1215. THE CRACK WAS STOP DRILLED, A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-10-0, 55-30-3, 51-10-2, 51-30-2, AND 51-00-00.

Part: SKIN — CRACKED (R-1 DOORWAY)

INSPECTION FOUND A 2.75 INCH CRACK IN LOWER AFT FUSELAGE SKIN CUTOUT AT R-1 DOOR. THE CRACK WAS STOP DRILLED, A DOUBLER AND TRIPLER WERE FABRICATED AND INSTALLED IAW ECRA 5307-01141.

Part: HOUSING — CRACKED (R-2 DOOR HINGE)

INSPECTION FOUND A 1.5 INCH CRACK IN R-2 DOOR CUTOUT UPPER HINGE HOUSING. THE HINGE HOUSING WAS REMOVED IAW SRM 51-10-1. A NEW HOUSING WAS FABRICATED AND INSTALLED IAW SRM 51-10-1.

Part: STRINGER — CRACKED (BS 720)

INSPECTION FOUND A 1.25 INCH CRACK IN STRINGER 15R AND A 2 INCH CRACK IN STRINGER 15L AT STA 720B. REPAIRS WERE FABRICATED AND INSTALLED IAW SRM 53-10-00, 53-10-3, AND 51-10-2.

Part: FLOORBEAM — CORRODED (BS 303-344)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 303 TO 344, LBL 28. THE CORROSION WAS REMOVED IAW SRM 51-10-8. ANGLES WERE FABRICATED AND INSTALLED IAW SRM 51-40-8.

Part: DOOR — CRACKED (CARGO DOOR)

INSPECTION FOUND A 1.5 INCH CRACK IN AFT CARGO C-2 DOOR BOTTOM AFT CORNER. THE CORNER OF C-2 DOOR WAS REMOVED AND REPLACED IAW SRM 51-10-2.

Part: WEB — CRACKED (BS 700)

INSPECTION FOUND STA 700 SUPPORT WEBS CRACKED AT S22L, S23L, S23R, AND S25R. THE CRACKS WERE 1 TO 1.5 INCH LONG. THE CRACKED AREAS WERE CUT OUT. REPAIR ANGLES WERE FABRICATED AND INSTALLED IAW SRM 51-40-3.

Part: FRAME — CRACKED (BS 680)

INSPECTION FOUND A .5 INCH CRACK IN FORWARD CARGO COMPARTMENT FRAME AT BS 680 BETWEEN STRINGER 23L AND 24L. THE CRACK WAS STOP DRILLED, A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 53-10-4 AND 51-10-2.

Part: FLOORBEAM — CORRODED (BS 344)

INSPECTION FOUND FORWARD LAV FLOORBEAM AT STA 344, RBL 24 CORRODED. THE CORRODED AREA OF FLOORBEAM WAS REMOVED, A NEW FLOORBEAM SECTION WAS FABRICATED AND INSTALLED IAW SRM 51-10-1, 51-10-2, AND 51-30-2.

Part: SKIN — CORRODED (BS 720)

INSPECTION FOUND FUSELAGE BELLY SKIN CORRODED AT BS 720 TO 720A, BL 0. A DOUBLER AND SHEAR TIE WERE FABRICATED AND INSTALLED IAW SRM 53-30-3, 53-30-4, AND 53-10-4.

Part: SIDEWALL — CRACKED (NLG WW)

THE NLG WHEEL WELL RIGHT SIDEWALL AND TOP CENTER PANEL HAD CRACKS MEASURING .5 TO 1 INCH LONG. THE CRACKED AREAS WERE CUT OUT, DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 53-10-2, 51-10-2, AND 51-30-2.

Part: SUPPORT — CRACKED (BS 400/760)

INSPECTION FOUND A 1 CRACK IN FLOORBEAM SUPPORT AT STA 400-420, BL 0. A 2 CRACK WAS FOUND IN FLOORBEAM SUPPORT AT STA 760, BL 0. THE FLOOR SUPPORT AT STA 400-420 WAS REMOVED IAW SRM 51-30-2. A NEW FLOOR SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-10-2, 51-10-1, 51-40-5, AND 51-30-2. THE CRACKED AREA OF FLOOR SUPPORT AT STA 760 WAS CUT OUT. AN ANGLE REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-40-3 AND 51-10-6.

Part: FLOORBEAM — CORRODED (BS 380)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 380 BETWEEN RBL 32 AND RBL 42. THE CORRODED AREA OF FLOORBEAM WAS CUT OUT IAW SRM 53-10-8. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8, 51-10-2, AND 51-40-4.

Part: SEAT TRACK — CORRODED (BS 400-420)

INSPECTION FOUND SEAT TRACK CORRODED BETWEEN STA 400 AND 420, RBL 48. THE CORRODED SECTION OF SEAT TRACK WAS REMOVED IAW SRM 51-30-2. A NEW SEAT TRACK WAS FABRICATED AND INSTALLED IAW SRM 53-10-5, 51-30-2, AND 51-10-2.

Part: FLOORBEAM — CORRODED (BS 328-380)

INSPECTION FOUND FLOORBEAM CORROSION AT STA 328, LBL 30 AND 45, STA 344, STA 380, RBL 32 TO 42. THE CORRODED AREAS OF FLOORBEAM WERE CUT OUT. REPAIRS WERE FABRICATED AND INSTALLED IAW SRM 53-10-8, 51-10-2, AND 51-40-4.

Part: SUPPORT — CORRODED (BS 380-400/1150)

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT STA 380 TO 400, RBL 16 AND STA 1150, RBL 18. THE FLOOR SUPPORTS WERE REMOVED, NEW FLOOR SUPPORTS WERE FABRICATED AND INSTALLED IAW SRM 51-10-2, 51-30-2, AND 51-10-1.

Part: RIB — CRACKED (WS 171.5)

INSPECTION FOUND A .375 INCH CRACK IN UPPER OUTBOARD FLANGE OF RT WING RIB AT WS 171.5, STRINGER 16. AN ANGLE REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-40-3 AND 51-10-6.

Part: FLOORBEAM — CORRODED (BS 380)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 380, RBL 18. THE CORRODED AREA WAS CUT OUT IAW SRM 53-10-8. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-8, 51-10-2, AND 51-40-4.

Part: ANGLE — CRACKED (RT TE MIDFLAP)

INSPECTION FOUND A CRACK IN AFT END OF LOWER ANGLE AT RT OUTBOARD MID-FLAP INBOARD END RIB. THE CRACK WAS STOP DRILLED AND A DOUBLER WAS FABRICATED AND INTALLED IAW SRM 51-40-2.

Part: SEAT TRACK — CORRODED (BS 360)

INSPECTION FOUND SEAT TRACK CORRODED AT STA 360, RBL 48. THE CORRODED SECTION OF SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 51-10-1 AND 53-10-5.

Part: SKIN — TORN (RUDDER)

INSPECTION FOUND A 1 TEAR IN UPPER RUDDER RT SIDE TRAILING EDGE SKIN. THE TORN AREA WAS CUT OUT. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-40-2.

Part: BRACKET — CRACKED (NR 5 LE FLAP)

INSPECTION FOUND A .75 INCH CRACK IN NR 5 LEADING EDGE FLAP INBOARD MOUNT BRACKET. THE BRACKET WAS REMOVED AND A NEW BRACKET WAS FABRICATED AND INSTALLED IAW SRM 51-30-2, 51-40-3, AND 51-10-2.

Part: HYD LINE — LEAKING (B-HYD SYST)

DURING CLIMB, B-SYSTEM HYDRAULIC QUANTITY WENT TO ZERO. FOUND LEAKING HYDRAULIC LINE. REPLACED LINE.

Part: SPLICE PLATE — CRACKED (WS 224.5)

INSPECTION FOUND A 2 INCH CRACK AT SPLICE PLATE INSIDE LEFT WING UPPER LEADING EDGE ABOVE NR 2 LEADING EDGE FLAP ACTUATOR/ANTI-ICE DUCT AREA, WS 224.5. THE SPLICE PLATE WAS REMOVED AND A STRAP WAS FABRICATED AND INSTALLED IAW SRM 57-50-2 AND 51-30-2.

Part: SKIN — CRACKED (LT WINGTIP)

INSPECTION FOUND A .625 INCH CRACK AND TWO SHEARED FASTENERS IN LEFT WINGTIP LOWER TRAILING EDGE SKIN. THE FASTENERS WERE REMOVED AND THE CRACK WAS STOP DRILLED. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 51-40-02.

Part: WIRE — BROKEN (CABIN)

INSPECTION FOUND THE LEFT AND RIGHT FORWARD OVERWING EMERGENCY EXIT LIGHTS INOPERATIVE. MAINTENANCE FOUND A BROKEN WIRE AT CANNON PLUG. THE WIRE WAS REPAIRED AND THE BATTERIES WERE CHARGED.

Part: RIB — CRACKED (RT WINGTIP)

INSPECTION FOUND A 1.5 CRACK IN WINGTIP MOUNT RIB AT WINGTIP AREA AFT OF NAV STROBE LIGHT. AN ANGLE DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-40-3.

Part: DOUBLER — CRACKED (RT WINGTIP)

INSPECTION FOUND A 2 INCH CRACK IN DOUBLER OF RT WINGTIP TRAILING EDGE AT WBL 626. THE WINGTIP WAS REMOVED AND A NEW DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-40-2. THE WINGTIP WAS REINSTALLED IAW SRM 51-30-2 AND MM 33-40-0.

Part: RIB — CRACKED (NR 2 LE SLAT)

INSPECTION FOUND A 2 CRACK IN NR 2 LEADING EDGE SLAT RIB OUTBOARD OF ANTI-ICE DUCT. A REPAIR ANGLE WAS FABRICATED AND INSTALLED IAW SRM 57-50-3.

Part: LIGHT — INOPERATIVE (CABIN)

INSPECTION FOUND THE RT AFT GALLEY DOOR EMERGENCY EXIT LIGHT TOO DIM. THE LIGHT ASSEMBLY WAS REPLACED IAW MM 33-50-101.

Part: FRAME — CORRODED (CARGO DOORWAY)

INSPECTION FOUND C-3 DOOR FRAME CORRODED AT CUTOUT AT FORWARD LOWER END WHERE IT MEETS THRESHOLD AT BS 1090. THE CORRODED AREA WAS CUT OUT. A DOUBLER AND FILLER REPAIR WAS INSTALLED IAW SRM 51-40-3.

Part: CASTING — CRACKED (LT TE FOREFLAP)

INSPECTION FOUND A 1 INCH CRACK IN LT OUTBOARD FOREFLAP OUTBOARD END CASTING LOWER ATTACH LUG. THE LT OUTBOARD FOREFLAP VANE WAS REMOVED AND REPLACED IAW MM 27-50-00.

Part: SKIN — DEBONDED (LT TE FOREFLAP)

INSPECTION FOUND LT INBOARD FOREFLAP INBOARD TRAILING EDGE SKIN DEBONDED WITH CHAFE MARKS ALONG UPPER SURFACE. THE FOREFLAP WAS REMOVED, REPAIRED AND REPLACED.

Part: SKIN — CRACKED (NR 4 LE SLAT)

INSPECTION FOUND SEVERAL .375 INCH CRACKS FROM FASTENER HOLE AT NR 4 SLAT UPPER SKIN WHERE INBOARD HOOK MOUNTS. TWO .375 INCH CRACKS WERE FOUND AT NR 4 SLAT UPPER SKIN WHERE OUTBOARD HOOK MOUNTS. DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 57-50-3.

Part: ANGLE — CRACKED (NR 2 LE SLAT)

INSPECTION FOUND A 3 INCH CRACK IN LT WING NR 2 SLAT CHORD ANGLE BELOW WHERE INBOARD STOP PAD MOUNTS. A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-10-01.

Part: SKIN — CRACKED (NR 4 SPOILER)

INSPECTION FOUND A 1.375 CRACK IN LT WING NR 4 SPOILER AT LOWER SKIN JUST INBOARD OF SECOND FROM INBOARD HINGE. THE NR 4 SPOILER WAS REMOVED AND REPLACED.

Part: CHANNEL — CORRODED (BS 540)

INSPECTION FOUND FORWARD CARGO BAY SIDEWALL FLOOR SUPPORT CHANNEL CORRODED AT BS 540, STRINGER 27R. A FLOOR SUPPORT CHANNEL WAS FABRICATED AND INSTALLED IAW SRM 51-30-1 AND 53-10-8.

Part: SUPPORT — CORRODED (BS 640)

INSPECTION FOUND FORWARD CARGO BAY FLOOR SUPPORT TRACK CORRODED AT BS 640, STRINGER 28L. A FLOOR SUPPORT TRACK WAS FABRICATED AND INSTALLED IAW SRM 53-10-2, FIGURE 8, SRM 51-10-6, AND 51-30-2.

Part: STRINGER — CORRODED (BS 520)

INSPECTION FOUND STRINGER 28L CORRODED AT BS 520. A STRINGER AND SPLICE REPAIR WAS INSTALLED IAW SRM 53-10-3, FIGURE 1.

Part: FLOOR — CORRODED (NR 2 GALLEY)

INSPECTION FOUND NR 2 GALLEY UPPER COMPARTMENT FLOOR CORRODED. THE CORROSION WAS REMOVED, TWO DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 51-40-2 AND 51-10-1.

Part: PACK — SMOKING (CABIN)

WHILE OPERATING RT PACK IN MANUAL WITH MIX VALVE AT HALF POSITION, THE RIGHT PACK TEMP WENT TO 150 DEGREES AND WAS ACCOMPANIED BY CABIN SMOKE DURING DESCENT INTO EWR. THE SMOKE CLEARED WHEN COOLING DOOR WAS OPENED AND MIX VALVE WAS ADJUSTED. THE AIRCRAFT LANDED AT EWR WITHOUT FURTHER PROBLEM. MAINTENANCE CHECKED THE OPERATION OF BOTH PACKS ON THE GROUND WITH ENGINES RUNNING AND WERE UNABLE TO DUPLICATE THE PROBLEM. THE ENGINE BLEED AIR DISTRIBUTION WAS ALSO CHECKED IAW MM 36-10-0 AND ALL OPERATION CHECKED GOOD.

Part: TRANSMISSION — INOPERATIVE (RT TE FLAP)

IAH - FLT 0414 - THE OUTBOARD FLAPS HAD A HISTORY OF NOT EXTENDING BOTH ON THE GROUND AND IN-FLIGHT. MAINTENANCE FOUND EXCESSIVE SHAFT PLAY IN THE NR 8 FLAP TRANSMISSION. THE NR 8 FLAP TRANSMISSION WAS REMOVED AND REPLACED. THE FLAPS WERE OPERATED ELECTRICALLY AND HYDRAULICALLY AND ALL CHECKED NORMAL. THE AIRCRAFT HAS COMPLETED AT LEAST FOUR FLIGHTS SINCE THIS CORRECTIVE ACTION WAS IMPLEMENTED, AND THERE HAVE BEEN NO REPEATS OF FLAP BINDING PROBLEMS. (X)