N69741

Part: WEB — CORRODED (LAVATORY)

LEFT AFT LAVATORY SHEAR WEB BETWEEN STA 1130 AND STA 1176, LBL 17 TO LBL 62 HAS CORROSION THROUGHOUT. (X)

Part: STRINGER — CRACKED (FUSELAGE)

FOUND SKIN BULGING AT APPROXIMATELY STA 1052 AND STR 27R. CUT OUT SKIN, NO CORROSION ON SKIN. FOUND CORROSION AND CRACK ON LOWER SURFACE OF STR 27R BY RADIUS LOWER PORTION. (X)

Part: SKIN — CORRODED (FUSELAGE)

LEFT FUSELAGE SKIN AT APPROXIMATE STA 700 AND STR 29L, AREA HAD CORROSION. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND THE CENTER OVERHEAD EMERGENCY EXIT LIGHTS ALL DIM OR INOPERATIVE. THE BATTERY PACK WAS REMOVED, THE CONNECTORS WERE CLEANED AND THE BATTERY PACK WAS RECHARGED. THE BATTERY PACK WAS REINSTALLED AND OPERATION CHECKED GOOD IAW MM 33-51-01, PAGE 5.

Part: BATTERY PACK — DISCHARGED (EMER EXIT)

INSPECTION FOUND THE LT AND RT FORWARD EXIT DOOR OVERWING EXIT EMERGENCY LIGHT INOPERATIVE. THE BATTERY PACK WAS REMOVED, THE CONNECTOR WAS CLEANED, AND THE BATTERY PACK WAS RECHARGED. THE BATTERY PACK WAS REINSTALLED AND OPERATION CHECKED GOOD IAW M 33-51-01, PAGES 5 & 6.

Part: BATTERY PACK — DISCHARGED (GALLEY)

INSPECTION FOUND THE FORWARD GALLEY DOOR RT OUTSIDE EMERGENCY LIGHT INOPERATIVE. THE BATTERY PACK WAS RECHARGED AND OPERATION CHECKED GOOD IAW MM 33-50-0, PAGE 201.

Part: BATTERY PACK — DISCHARGED (EMER EXIT)

INSPECTION FOUND THE LT AND RT AFT EXIT DOOR OVERWING EXIT EMERGENCY LIGHTS INOPERATIVE. THE BATTERY PACK WAS REMOVED, THE CONNECTOR WAS CLEANED, AND THE BATTERY PACK WAS RECHARGED. THE BATTERY PACK WAS REINSTALLED AND OPERATION CHECKED GOOD IAW MM 33-51-01, PAGES 5 & 6.

Part: BATTERY PACK — DISCHARGED (ROW 17)

INSPECTION FOUND EMERGENCY EXIT LIGHTS AT FORWARD ENTRY DOOR AND OVERHEAD AT ROW 17 INOPERATIVE. THE BATTERY PACKS WERE REMOVED, RECHARGED, AND REINSTALLED. OPERATION CHECKED GOOD IAW MM 33-50-0, PAGE 201.

Part: SKIN — DELAMINATED (NR 8 SPOILER)

INSPECTION FOUND NR 8 SPOILER DELAMINATED. THE NR 8 SPOILER WAS REMOVED AND REPLACED IAW MM 27-62-1, PAGE 401 & 403.

Part: SKIN — GOUGED (RT TE FOREFLAP)

INSPECTION FOUND RIGHT I/B FOREFLAP O/B LEADING EDGE GOUGED. THE RIGHT I/B FOREFLAP WAS REMOVED AND REPLACED IAW MM 27-51-1, PAGE 404 AND 406.

Part: SWITCH — INOPERATIVE (NLG DOORS)

THE NOSE GEAR DOOR LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION DEPARTING IAH. GEAR RECYCLING DID NOT HELP. FUEL WAS DUMPED AND THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. BOTH NOSE GEAR DOOR SWITCHES WERE REMOVED AND REPLACED IAW MM 32-62-11. OPERATION AND INDICATION CHECKED GOOD.

Part: SKIN — DEBONDED (NR 2 SPOILER)

INSPECTION FOUND THE LT WING NR 2 SPOILER DEBONDED AT TRAILING EDGE. THE NR 2 SPOILER WAS REMOVED AND REPLACED IAW MM 27-61-81.

Part: SKIN — CORRODED (NR 10 SPOILER)

INSPECTION FOUND THE LT WING NR 10 SPOILER CORRODED WITH SCREWS PULLING THROUGH SKIN AT TOP CENTER HINGE. THE SPOILER WAS REMOVED AND REPLACED IAW MM 27-62-1.

Part: FITTING — CRACKED (NR 5 FLAP TRACK)

INSPECTION FOUND A .5 INCH CRACK IN NR 5 FLAP TRACK CARRIAGE LOWER FORWARD ROLLER I/B YOKE FITTING. THE FLAP CARRIAGE WAS REMOVED AND REPLACED IAW MM 27-51-3.

Part: SKIN — CORRODED (LT TE MIDFLAP)

INSPECTION FOUND LT O/B MIDFLAP UPPER TRAILING EDGE SKIN CORRODED AND SEPARATING I/B TO O/B END. INSTALLED NEW TRAILING EDGE IAW SRM 51-30-2.

Part: SKIN — DELAMINATED (LT TE AFT FLAP)

INSPECTION FOUND LT TRAILING EDGE O/B AFT FLAP UPPER SURFACE DELAMINATED. THE LT O/B AFT FLAP WAS REMOVED AND REPLACED IAW MM 27-51-12.

Part: SKIN — DELAMINATED (NR 13 SPOILER)

INSPECTION FOUND THE LT WING NR 13 SPOILER UPPER TRAILING EDGE DELAMINATED. THE SPOILER WAS REMOVED AND REPLACED IAW MM 27-61-00.

Part: SKIN — CORRODED (NR 6 LE SLAT)

INSPECTION FOUND LT WING NR 6 L/E SLAT O/B END UPPER AND LOWER SURFACES CORRODED AT SCREWS. THE SLAT WAS REMOVED AND REPLACED IAW MM 27-80-00.

Part: SKIN — CORRODED (RT TE FOREFLAP)

INSPECTION FOUND RT O/B FOREFLAP CORRODED ON LOWER AND UPPER SURFACE I/B TO O/B. THE FOREFLAP WAS REMOVED AND REPLACED IAW MM 27-51-11.

Part: SKIN — DELAMINATED (RT TE AFT FLAP)

INSPECTION FOUND RT TRAILING EDGE O/B AFT FLAP LOWER SURFACE DELAMINATED. THE AFT FLAP WAS REMOVED AND REPLACED IAW MM 27-50-02.

Part: ACOUSTIC PANEL — TORN (NR 2 ENG NACELLE)

INSPECTION FOUND NR 2 ENGINE INLET ACOUSTIC PANEL TORN. THE TORN AREA WAS CUT OUT AND A REPAIR WAS INSTALLED IAW SRM 54-10-3.

Part: SPAR CHORD — CORRODED (WS 355-367)

INSPECTION FOUND TOP SURFACE OF LT WING FRONT SPAR LOWER CHORD CORRODED AT FS 355 TO 367. THE FASTENERS AND RIB WERE REMOVED FOR ACCESS. THE CORROSION WAS REMOVED AND A REPAIR WAS INSTALLED IAW SRM 51-10-1, 51-20-2, AND ECRA 5710-01945.

Part: WIRE — LOOSE (L2 DOOR)

INSPECTION FOUND L-2 DOOR EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE FOUND A LOOSE WIRE AT POWER SUPPLY CONNECTOR. THE WIRING WAS SECURED AND OPERATIONAL CHECKS WERE GOOD IAW MM 33-50-22, PAGE 201.

Part: SKIN — DELAMINATED (LT TE FLAP)

INSPECTION FOUND LT WING I/B AFT FLAP DELAMINATED. THE AFT FLAP WAS REMOVED AND REPLACED IAW MM 27-50-2.

Part: WIRE — FAILED (LT EMER EXIT)

INSPECTION FOUND LT AFT OVERWING EXTERIOR EMERGENCY LIGHT INOPERATIVE. MAINTENANCE FOUND POWER WIRE AT BATTERY PACK AT FAULT. THE WIRING SPLICE WAS REPAIRED IAW MM 33-51-01.

Part: FITTING — BROKEN (RT AILERON TAB)

INSPECTION FOUND RT O/B AILERON TAB SUPPORT FITTING (SECOND FROM O/B END) BROKEN OFF INSIDE AILERON. THE TAB SUPPORT FITTING WAS REMOVED AND REPLACED IAW SRM 51-10-1, PAGE 4 AND 51-30-2.

Part: WIRE — FAILED (CABIN)

INSPECTION FOUND FORWARD AISLE EMERGENCY CEILING LIGHT INOPERATIVE. MAINTENANCE FOUND EMERGENCY AISLE LIGHT FORWARD SECTION WIRING SPLICE AT FAULT. THE WIRING SPLICE WAS REPLACED AND OPERATION CHECKED GOOD IAW MM 33-50-5, PAGE 501.

Part: SPOILER — DELAMINATED (NR 11 POSITION)

INSPECTION FOUND NR 11 SPOILER SPLIT AND DELAMINATED AT CENTER T/E TOP SURFACE AREA. THE SPOILER WAS REMOVED AND REPLACED IAW MM 27-61-1.

Part: MIDFLAP — BENT (LT TE FLAP)

INSPECTION FOUND LT WING IB MIDFLAP BENT AT AFT IB AREA. THE BENT AREA WAS CUT OUT AND A HOT BOND REPAIR WAS INSTALLED IAW SRM 57-50-2, PAGE 5.

Part: SKIN — DEBONDED (NR 4 SPOILER)

INSPECTION FOUND LT WING NR 4 SPOILER UPPER SURFACE OB T/E DEBONDED. THE SPOILER WAS REMOVED AND REPLACED IAW MM 27-61-1.

Part: BEAM — CRACKED (LT WING)

INSPECTION FOUND A .25 CRACK IN J BEAM ABOVE LT WING NR 7 SPOILER ACTUATOR. THE J BEAM WAS REMOVED IAW SRM 51-30-2. A NEW J BEAM WAS INSTALLED WITH NUT PLATE IAW SRM 51-30-2 AND 51-10-2.

Part: WIRE — SHORTED (ROW 5-15)

INSPECTION FOUND EMERGENCY PATH SEAT MOUNTED LIGHTS INOPERATIVE FROM ROW 5 TO 15. CAPPED SHORTED WIRES AND OPERATION CHECKED NORMAL IAW MM 33-51-00, PAGE 112.

Part: BEAM — CORRODED (LT MLG)

LEFT MLG SUPPORT BEAM LOWER ATTACH BORE FOR SWING LINK FORWARD AND AFT FACES CORRODED. REMOVED CORROSION, PEENED AREA, ALODINED AND PRIMED AREA, FABRICATED AND INSTALLED BUSHINGS PER EC/RA 5740-01841.

Part: PANEL — STAINED (BS 950-1183)

AFT CARGO COMPARTMENT FS 950 TO 1183, LBL 60 TO RBL 60 STAINED WITH BLUE WATER. FABRICATED AND INSTALLED NEW CEILING AND SIDE WALL PANELS PER EC/RA 2550-01040 AND EC/RA 2011-01000.

Part: TRUNNION — CORRODED (LT MLG)

LEFT MLG FWD TRUNNION I/B SIDE OF FITTING INNER SIDE CORRODED. REPAIRED PER EO 97-871 AND EC/RA 5740-01840.

Part: 0OWNLOCK — WORN (LT MLG)

LEFT MLG DOWNLOCK CRANK HOLES ARE OVERSIZED. FABRICATED AND INSTALLED TWO BUSH INGS PER OHM 32-01-02.

Part: SKIN — CORRODED (FUSELAGE)

COMPLY WITH FWD DRAIN HOLE EA 5330-01463. REMOVED BELLY SKIN AND VERIFIED DOUBLERS INSTALLED. CLEANED AND REINSTALLED EXISTING DOUBLERS PER EA 5330-01463.

Part: STRINGER — CORRODED (BS 950)

AFT CARGO PIT STR 29R STA 950 CORRODED. REMOVED AND REPLACED STRINGER PER DWGS 65C20489 AND 65C13913.

Part: SKIN — CORRODED (BS 950)

AFT CARGO PIT STR 29R STA950 CORRODED. REMOVED AND REPLACED NR 4 BELLY SKIN PER DWGS 65C20489 AND 65C13913.

Part: ANGLE — CRACKED (BS 950)

AFT FUSELAGE AT FS 950 RT ELEPHANT EAR FAIRING ATTACH ANGLE CRACKED (3). CUT OUT CRACKED PORTION OF FAIRING ATTACH ANGLE. FABRICATED AND INSTALLED REPAIR PER SRM 51-40-4.

Part: SWING LINK — CORRODED (LT MLG)

LEFT MLG SWING LINK ATTACH LUGS ARE CORRODED ON FACES AND BORE HOLES. COMPLIED WITH REWORK PER EO 98-0847 AND EC/RA 5740-01842.

Part: FITTING — CORRODED (LT MLG)

LEFT MLG FWD TRUNNION ATTACH ANGLE FITTING ON LEG CORRODED. REPAIRED PER EO 98-871 AND EC/RA 5740-01840.

Part: PANEL — CRACKED (LT WING)

LT UPPER INBOARD T/E PANEL HAS SURFACE CORROSION AND CRACK. REMOVED SURFACE CORROSION. STOP DRILLED CRACK AND INSTALLED DOUBLER PER SRM 51-10-1, 51-10-6, AND 51-40-2.

Part: PAN — CORRODED (AFT LAVATORY)

AFT LAV SERVICE PAN HAS CORROSION THROUGH OUT. REMOVED SERVICE PAN WEB FRAME. FABRICATED REPAIR ANGLE. INSTALLED NEW WEB FRAME. NEW SUPPORT HINGES PER SRM 51-30-2, 51-20-1, AND 51-10-2.

Part: BRACKET — CRACKED (LT MLG)

LT MLG WALKING BEAM PANEL HAS BROKEN ATTACH BRACKET (1/2 CRACK) I/B END OF PANEL. REMOVED DAMAGED AREA. FABRICATED AND INSTALLED REPAIR PER SRM 51-40-3 AND 51-30-2.

Part: GEARBOX — CRACKED (NR 2 ENGINE)

NUMBER 2 ENGINE GEARBOX DATA PLATE MOUNT BOLT HOLE (UPPER AFT) BROKEN OUT. REPAIRED GEARBOX DATD PLATE MOUNT BOLT HOLE PER EC/RA 7261-01251.

Part: ANGLE — CORRODED (BS 950)

FS 950 RT ELEPHANT EAR FAIRING ATTACH ANGLE HAS CORROSION ON UPPER AND LOWER FLANGES. CUT OUT SECTION OF ATTACH ANGLE FABRICTED FILLER AND ANGLE. TREATED, PRIMED AND INSTALLED ANGLES PER SRM 51-10-6, 53-10-6, 53-10-1, 51-40-4 51-30-2, AND 57-40-4.

Part: APRON — CRACKED (NR 1 ENGINE)

NUMBER 1 ENGINE FORWARD APRON CRACKED (2) ON UPPER SIDE. REMOVED DAMAGED, INSTALLED DOUBLER AND FILLER PER SRM 51-40-2 AND 51-30-2.

Part: APRON — CRACKED (NR 1 ENGINE)

NUMBER ONE ENGINE AFT APRON HAS DAMAGED SKIN CAUSED BY CHAFING ON FORWARD STIFFENER. FABRICATED, TREATED, PRIMED, AND INSTALLED REPAIR PER SRM 51-10-2, 54-10-3, 51-30-2, AND MM 51-20-11.

Part: RIB — CRACKED (NR 1 PYLON)

FIRST RIB AFT OF AFT ENG MOUNT IS CHAFED TWO SPOTS NUMBER ONE ENGINE PYLON. REMOVED DAMAGED AREA NR 1 ENGINE PYLON MOUNT RIB. FABRICATED NEW REPAIR, INSTALLED PER SRM 51-40-2 AND 51-30-2.

Part: TRUNNION — GOUGED (LT MLG)

LEFT MAIN LANDING GEAR FORWARD TRUNNION FITTING O/B SIDE OF FITTING BOTH UPPER AND LOWER BUSHING ARE GOUGED. REAMED HOLE AND FABRICATED 2 BUSHINGS PER BOHM 32-10-13 FIGURE 3.

Part: TRUNNION — CORRODED (LT MLG)

LEFT MLG FORWARD TRUNNION FITTING HAS CORROSION AROUND BOTH LOWER BUSHINGS INNER SIDES AND I/B SIDE OF FITTING UPPER BUSSING INNER SIDE. REAMED HOLES AND FABRICATED TWO BUSHINGS PER BOHM 32-10-13.

Part: ACCESS PANEL — DELAMINATED (LT HORIZ STAB)

HORIZ STAB ELEVATOR PCU ACCESS PANEL DELAMINATED 3 X 10. CUT OUT DAMAGED AREA. FABRICATED REPAIR DOUBLER AND BONDED TO PANEL PER SRM 55-20-3 AND 51-40-5.

Part: ACCESS PANEL — CORRODED (LT HORIZ STAB)

LT LOWER HORIZ STAB BAL BAY ACCESS PANEL CORRODED. CUT OUT CORRODED AND DELAMINATED AREA, FABRICATED DOUBLER AND BONDED TO CUT OUT AREA PER SRM 55-20-3 AND 51-40-5.

Part: SUPPORT — CORRODED (BS 535)

FLOOR SUPPORT AT STA 535 LBL 8 OUT OF LIMITS. FORMED ANGLE FROM 7075-0 PER SRM 51-40-3. HEAT TREAT PER BCA 5602. TRATED, PRIMED AND INSTALLED PER SRM 51-10-2, 51-40-3, AND MM 51-20-11.

Part: LIGHT — INOPERATIVE (CABIN)

AFT AIRSTAIRS EMERGENCY EXIT LIGHT INOP. REMOVED AND REPLACED AFT AIRSTAIR EMERGENCY EXIT LIGHT PER MM33-50-61.

Part: PANEL — CORRODED (BS 950-970)

TRANSITION PANEL AFT PIT STA 950 TO 970 LT SIDE CORRODED ON UNDER SIDE OF PANEL. REMOVED CORRODED AREAS, FABRICATED AND INSTALLED REPAIR DOUBLERS PER SRM 51-10-6, 53-10-1, 51-4-0-2, 51-10-2, 51-30-2, AND MM 51-20-11.

Part: PANEL — CORRODED (BS 580-620)

FORWARD PIT LT TRANSITION PANEL STA 620 TO 580 HAS CORROSION. FABRICATED, TREATED, PRIMED AND INSTALLED REPAIR PER SRM 51-40-2, 51-10-2, AND MM 51-20-11.

Part: FAIRING — CORRODED (BS 950)

LOWER SKIN FAIRING AT STA 950 IS CORRODED BEYOND LIMITS. FABRICATED, TREATED, PRIMED, AND INSTALLED NEW LOWER SKIN FAIRING PER SRM 51-40-2, 51-10-2 AND MM 51-20-11.

Part: STEP — CORRODED (AFT AIRSTAIRS)

AFT AIRSTAIRS NR 8 STEP PANEL CORRODED. REMOVED CORRODED AREA, FABRICATED, TREATED AND INSTALLED REPAIR SECTION PER SRM 51-40-2, 51-10-2 AND MM 51-20-11.

Part: TRUNNION — CORRODED (RT MLG)

RIGHT MLG FORWARD TRUNNION ATTACH FITTING AIRCRAFT SIDE HAS CORROSION ON INNER FACE OF BOTH I/B AND O/B ATTACH FITTINGS AROUND BUSHINGS BOTH UPPER AND LOWER HOLES. REMOVED CORROSION, REAMED HOLES, FABRICATED AND INSTALLED BUSHINGS PER BOHM 32-10-13 AND BSOP 20-10-3.

Part: APRON — CRACKED (NR 1 ENGINE)

NUMBER ONE ENGINE FORWARD APRON CRACKED AT RIVET HEAD IN LOWER AFT CORNER (.5). REMOVED CRACKED DOUBLER. FABRICATED, TREATED, PRIMED, AND INSTALLED DOUBLER AFTER REMOVING CRACKED AREA PER SRM 51-40-2, 51-10-2, AND MM 51-20-11.

Part: LIGHT — INOPERATIVE (R1 DOOR)

R1 DOOR EMERGENCY EXIT LIGHT INOP. REPLACED R1 EMERGENCY LIGHT ASSY PER MM 33-50-91.

Part: SUPPORT — CORROSION (BS 1166)

AFT PIT STA 1166 FLOOR SUPPORT IS OUT OF LIMITS AT RBL 5. CUT OUT AREA, FABRICATED REPAIR, TREATED, PRIMED AND INSTALLED PER SRM 53-105, 51-10-2, 51-30-2 AND 51-20-11.

Part: FITTING — CORRODED (BS 1183)

AFT PIT FS 1183 STR 30 AFT JACK PAD MOUNT CORRODED BEYOND LIMITS. DRILLED, DEBURRED, TREATED, AND PRIMED NEW MOUNT AND NEW INTERCOSTAL PER SRM 51-30-5, 51-10-2, AND MM 51-20-11. INSTALLED NEW MOUNT AND INTERCOSTAL PER SRM 51-30-2. INSTALLED E/Q BAFFLE PER SRM 51-30-2.

Part: ISOLATOR — SLIPPED (NR 2 ENGINE)

NUMBER 2 ENGINE FORWARD MOUNTS HAVE EVIDENCE OF SLIPPAGE AND DISBONDING. REPLACED NUMBER 2 ENGINE FORWARD ISOLATORS PER MM 71-21-1.

Part: SUPPORT — GOUGED (BS 1007)

AFT CARGO PIT FLOOR SUPPORT GOUGE AT STA 1007 LBL 15. REMOVED GOUGED AREA, FABRICATED NEW PART AND DOUBLERS AND INSTALLED PER SRM 51-40-4.

Part: SUPPORT — CORRODED (BS 1166)

AFT PIT STA 1166 FLOOR SUPPORT IS OUT OF LIMITS AT RBL 5. CUT OUT AREA. FABRICATED REPAIR, TREATED, PRIMED AND INSTALLED PER SRM 53-10-5, 51-10-2, 51-30-2 AND MM 51-20-11.

Part: CHORD — CORRODED (BS 950)

INSPECTION FOUND LOWER RT T-CHORD CORRODED AT FS 950. THE CHORD WAS REMOVED. A NEW CHORD WAS FABRICATED AND INSTALLED IAW SRM 51-10-4, PAGE 4, PARAGRAPH 4 AND SRM 51-30-2.

Part: STRINGER — CORRODED (BS 950)

INSPECTION FOUND STRINGER 28L AND STRINGER TIE CORRODED AT FS 950. THE STRINGER TIE AND CORRODED END OF STRINGER WERE REMOVED. REPAIR WAS INSTALLED IAW SRM 51-10-2, 53-10-3, AND MM 51-20-11.

Part: SUPPORT — CRACKED (BS 485)

INSPECTION FOUND A 6.5 CRACK IN FLOOR SUPPORT AT STA 485, LBL 12. THE CRACKED SECTION WAS CUT OUT. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-40-3, 51-10-2, 51-30-2, AND MM 51-20-11.

Part: CLIP — CORRODED (BS 950)

INSPECTION FOUND STRINGER TIE CLIP CORRODED AT FS 950E. THE CLIP WAS REMOVED AND A NEW CLIP WAS FABRICATED AND INSTALLED IAW SRM 51-10-2, 51-30-2, AND MM 51-20-11.

Part: SUPPORT — CORRODED (BS 535)

INSPECTION FOUND FLOOR SUPPORTS AT RBL 2 AND LBL 2, STA 535 CORRODED. THE CORRODED AREAS WERE CUT OUT. REPAIR ANGLES WERE FABRICATED AND INSTALLED IAW SRM 51-40-36, 51-10-2, 51-30-2, 51-40-3, FIGURE 1, AND MM 51-20-11.

Part: SUPPORT — CORRODED (BS 1166)

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT LBL 12 AND LBL 4, STA 1166. THE CORRODED SECTIONS OF FLOOR SUPPORT WERE CUT OUT. REPAIRS WERE FABRICATED AND INSTALLED IAW SRM 53-10-5, 51-30-5, 51-10-2, 51-30-2, AND MM 51-20-11.

Part: SUPPORT — CORRODED (BS 1166)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 1166, RBL 16. THE CORRODED AREA WAS CUT OUT. A CHANNEL AND ANGLES WERE FABRICATED AND INSTALLED IAW SRM 53-10-5, 51-10-2, AND MM 51-20-11.

Part: INTERCOSTAL — CRACKED (BS 950)

INSPECTION FOUND A 5 CRACK WITH CORROSION IN INTERCOSTAL FOOT BETWEEN STRINGERS 29R AND 28R AT STA 950E. THE CRACKED AND CORRODED AREA WAS CUT OFF IAW SRM 53-10-4. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-4, 51-10-2, 51-30-2, AND MM 51-20-11.

Part: SUPPORT — CORRODED (BS 535)

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT RBL 8 AND LBL 13, STA 535. THE CORRODED AREAS WERE CUT OUT. REPAIR ANGLES WERE FABRICATED AND INSTALLED IAW SRM 51-40-3, 51-10-2, AND MM 51-20-11.

Part: FLOOR SUPPORT — CRACKED (STA 680)

INSPECTION FOUND A 10.75 CRACK IN FLOOR SUPPORT AT STA 680, RBL 24. THE CRACKED AREA WAS CUT OUT. A REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-40-4, FIGURE 1, 51-10-2, AND MM 51-20-11.

Part: SWITCH — INOPERATIVE (LT MLG DOOR)

GUM - FLT 0949 - L/P 7950069 - AIR RETURN DUE TO LEFT LANDING GEAR DOOR LIGHT ILLUMINATED AFTER GEAR RETRACTION. MAINTENANCE REQUESTED FOR FLY-BY TO CONFIRM GEAR DOOR CLOSED. MAINTENANCE TROUBLESHOT SYSTEM, FOUND LEFT LANDING GEAR DOOR SWITCH BAD. PLACARDED DOOR LIGHT INOP AND FLT DISPATCHED WITHOUT FURTHER INCIDENT. SAIPAN STATION REMOVED AND REPLACED LEFT GEAR DOOR WARNING SWITCH PER MM 32-62-11. OPS CHECKS GOOD AND RELEASED AIRCRAFT FOR SERVICE. (X)

Part: BEAM — CRACKED (WING)

KUL - NRC: 813821 - SPOILER SUPPORT BEAM, LOWER CHORD, FOUND CRACKED. FABRICATED DOUBLER IAW SRM 51-40-4, FIG 1, ALODINED AND PRIMED PER SRM 51-10-2. CARRIED OUT REPAIR IAW SRM 51-40-4. INSTALLED FASTENERS IAW SRM 51-30-2, AND PL, REF DRAWING NR 65-24966. (X)

Part: FRAME — CORRODED (BS 970)

KUL - CORROSION FOUND ON AFT CARGO FRAME 970 AT BASE OF FORWARD FACE BETWEEN STR 29R TO STR 30. CORRODED AREA REMOVED AND DOUBLER FABRICATED AND INSTALLED IAW SRM 53-10-4. (X)

Part: SEAT TRACK — CORRODED (BS 1130)

KUL - HNRC: 813843 - Q-CHECK FOUND LIGHT SURFACE CORROSION ON END OF FLOOR SEAT TRACK AT STA 1130 RBL 20 NEAR THE RT LAVATORY. CORROSION REMOVED AND FOUND OUT OF LIMIT DEPTH 0.035 INCH AREA 1 INCH BY 4 INCHES IAW SRM 53-10-1. REPLACED FABRICATED SEAT TRACK IAW 53-10-5. (X)

Part: SEAT TRACK — CORRODED (BS 1130)

KUL - HNRC: 813847 - Q-CHECK FOUND LIGHT SURFACE CORROSION ON FLOOR SEAT TRACK AT STA 1130 NEAR RT LAVATORY RBL 45. CORROSION REMOVED AND FOUND OUT OF LIMIT DEPTH 0.041 INCH AREA 2 INCHES BY 16 INCHES IAW 53-10-1. FABRICATED AND REPLACED SEAT TRACK IAW SRM 53-10-5. (X)

Part: SEAT TRACK — CORRODED (BS 1130)

KUL - HNRC: 813856 - Q-CHECK FOUND FLOOD TRACK AT STA 1130, RBL 45.5, CORRODED BEYOND LIMITS. REPLACED FABRICATED SEAT TRACK IAW SRM 53-10-5. (X)

Part: SEAT TRACK — CORRODED (BS 1130)

KUL - HNRC: 813855 - Q-CHK FOUND FLOOR TRACK AT STA 1130 RBL 27.75 CORRODED BEYOND LIMITS. REPLACED FABRICATED SEAT TRACK IAW SRM 53-10-5. (X)

Part: SEAT TRACK — CORRODED (BS 1130)

KUL - NRC: 813682 - FOUND CORROSION ON SEAT TRACK FORWARD OF LEFT AFT LAVATORY STA 1130 LBL 55 AS MARKED. CORROSION REMOVED AND AREA CLEANED FOUND OUT OF LIMIT DIMENSION 1 INCH BY 6 INCH DEPTH 35 PERCENT. REMOVED IAW 51010-1. REPLACED FABRICATED SEAT TRACK IAW SRM 53-10-5. (X)

Part: FLOOR BEAM — CORRODED (BS 1130)

KUL - NRC: 813733 - AFT LEFT LAVATORY FLOOR SUPPORT BEAM AT LBL 20 STA 1130, FOUND PITTING CORROSION. CORROSION REMOVED FOUND OUT OF LIMIT DEPTH 0.04 INCH DIMENSION 2 INCHES BY 5 INCHES IAW 53-10-1. FABRICATED NEW SUPPORT BEAM PER DRAWING 65-31774. RE-INSTALLED SUPPORT BEAM PER SRM 51-30-2. (X)

Part: SEAT TRACK — CORRODED (BS 1110-1130)

KUL - HNRC: 813684 - Q-CHK FOUND CORRODED SEAT TRACK FORWARD OF LT AFT LAVATORY BETWEEN STA 1130 AND STA 1110, LBL 27.75 AS MARKED. REMOVED CORROSION IAW 51-10-6 AND FOUND OUT OF LIMIT DEPTH 0.040 INCH AREA 2 INCHES BY 20 INCHES IAW 53-10-1. REPLACED FABRICATED SEAT TRACK IAW SRM 53-10-5. (X)

Part: STRINGER — CORRODED (BS 684)

KUL - NRCA: 813752 - FORWARD CARGO BILGE AREA, LEVELING COMPOUND FOUND DAMAGED IN THE CHANNEL OF STR 27R AT BS 684. LEVELING COMPOUND REMOVED. REMOVED STRINGER FOUND CORRODED. CORROSION REMOVAL CARRIED OUT, MATERIAL REMOVED FOUND BEYOND STRUCTURAL REPAIR MANUAL ALLOWABLE LIMITS. REPAIR CARRIED OUT PER SRM 53-10-4. (X)

Part: SUPPORT — CORRODED (BS 1176)

KUL - HNRC: 813679 - Q-CHECK FOUND CORROSION ON RT AFT LAVATORY PARTITION LOWER AFT CORNER INBOARD AND OUTBOARD METAL PLATE AT RBL 24.75 STA 1176 AS MARKED. CORROSION REMOVED AND FOUND OUT OF LIMITS 4 INCHES BY 2 INCHES BY 0.030 INCH. FABRICATED NEW SUPPORT BEAM IAW DRAWING 65-31774 AND REINSTALLED SUPPORT BEAM PER SRM 51-30-2. (X)

Part: SUPPORT — CORRODED (BS 340)

KUL - NRC: 813657 - HEAVY EXFOLIATION CORROSION FOUND AT FLOOR CHANNEL T-ANGLE OF FORWARD LAVATORY AT BS 340 BETWEEN RBL 30 AND RBL 40. CORROSION FOUND IS BEYOND LIMITS LESS 50 PERCENT FLANGE THICKNESS REMAINING. REPLACED FLOOR SUPPORT OF FORWARD LAVATORY IAW SRM 51-10-2. AREA IS 10 INCHES BY 2 INCHES.

Part: SKIN — DELAMINATED (NR 3 SPOILER)

KUL - NRC: 813667 - NR 3 SPOILER T/E DELAMINATED ALL ALONG THE LENGTH. REPAIR CARRIED OUT PER SRM 727 51-40-6. DOUBLER FABRICATED IAW SRM 727 57-50-2. PAINTED IAW 51-20-0. RE-INSTALLED SPOILER IAW 727 MM 27-61-1. (X)

Part: SEAT TRACK — CORRODED (BS 1110-1130)

KUL - NRC: 844739 - SEAT TRACK LBL 24.75 STA 1130 - STA 1110, SEAT TRACK FLANGE CORROSION. REMOVED CORROSION AT FLANGE AREA IAW 51-10-6 AND FOUND OUT OF LIMITS 1 INCH BY 8 INCH DEPTH 37 PERCENT REMOVED. REPLACED FABRICATED SEAT TRACK IAW SRM 53-10-5. (X)

Part: ANGLE — CORRODED (BS 300)

KUL - HNRC: 813656 - Q-CHECK FOUND LIGHT SURFACE CORROSION AT FLOOR CHANNEL T-ANGLE OF FORWARD LAVATORY AT BS 300 BETWEEN RBL 20 AND RBL 30. CORROSION FOUND OUT OF LIMITS IAW SRM 53-10-1, DEPTH 0.043 INCH AREA 5 INCHES BY 3 INCHES. FABRICATED AND RE-INSTALLED T-ANGLE OF FLOOR CHANNEL PER DRAWING 65-16312. (X)

Part: SEAT TRACK — CORRODED (BS 1030-1070)

KUL - HNRC: 844756 - Q-CHK FOUND SEAT TRACK RBL 45.5 STA 1030 - STA 1070 FLANGE CORRODED. REMOVED CORROSION ON FLANGE OF SEAT TRACK AND FOUND OUT OF LIMIT DEPTH 0.037 INCH AREA 2 INCHES BY 3 INCHES. FABRICATED AND REPLACED SEAT TRACK IAW 53-10-2. (X)

Part: FLOOR BEAM — CORRODED (BS 1130)

KUL - HNRC: 844633 - Q-CHECK FOUND TRANSVERSE FLOOR BEAM STA 1130 RT LAVATORY RBL 20 UPPER CHANNEL CORRODED. REMOVED CORROSION IAW SRM 51-10-6. FOUND BEYOND LIMITS IAW SRM 51-10-6. DIMENSION 2 INCHES BY 4.5 INCHES BY 0.046 INCH. REPLACED FLOOR BEAM CHORD IAW DRAWING 65-19606-19. (X)

Part: SEAT TRACK — CORRODED (BS 380-400)

KUL - HNRC: 844677 - FLOOR TRACK BETWEEN GALLEY NR 1 AND GALLEY NR 2 STA 380 - STA 400, FOUND WITH SURFACE AND PITTING CORROSION. CORROSION REMOVED AND FOUND OUT OF LIMIT DEPTH 0.042 INCH AREA 2 INCHES BY 14 INCHES IAW 53-10-1. FABRICATED AND REPLACED SEAT TRACK IAW SRM 53-10-5. (X)

Part: SKIN — MISREPAIRED (BS 1074)

KUL - HNRC: 844702 - Q-CHECK FOUND PREVIOUS BLEND-OUT OF DAMAGE AT STA 1074 AT STR 17L (CREASE BEAM) EXTERIOR FUSELAGE SKIN TO BE EXCESSIVE. CHECKED DEPTH AND DAMAGE LIMIT. BLEND-OUT RE-ASSESSED. AREA 1.5 INCHES BY 1.5 INCHES BY 0.013 INCH DEPTH BEYOND SRM LIMITS IAW SRM 53-30-1. EXTERNAL DOUBLER MANUFACTURED AND FITTIED IAW ECRA 5330-02601. (X)

Part: SEAT TRACK — CORRODED (BS 1130)

KUL - NRC: 844635 - TRANSVERSE FLOOR BEAM STA 1130 LEFT LAVATORY LBL 20 - LBL 30 UPPER CHANNEL FOUND CORRODED. CORROSION REMOVED IAW 51-10-6 AND FOUND OUT OF LIMIT AREA 1 INCH BY 5 INCH DEPTH 0.04 INCH. REPLACED FLOOR EXTRUSION IAW DRAWING 65-19606-19. (X)

Part: GALLEY TRACK — CORRODED (BS 340-380)

KUL - NRC: 844755 - S-CHECK FOUND GALLEY TRACK STA 380 - STA 340 RBL 45.5, CORRODED. REMOVED CORROSION IAW SRM 51-10-6. FOUND DIMENSION 3 INCHES BY 4 NCHES BY 0.035 INCH BEYOND LIMIATIONS OF SRM 51-10-6. REPLACED TRACK IAW SRM 53-10-2. (X)

Part: GALLEY TRACK — CORRODED (BS 340-380)

KUL - NRC: 844755 - S-CHECK FOUND GALLEY TRACK STA 380 - STA 340 RBL 45.5 CORRODED. REMOVED CORROSION IAW SRM 51-10-6. FOUND DIMENSION 3 INCHES BY 4 INCHES BY 0.035 INCH BEYOND LIMITATION OF SRM 51-10-6. REPLACED TRACK IAW SRM 53-10-2. (X)

Part: FITTING — WORN (LOWER RUDDER)

KUL - NRC: 844297 - Q-CHECK - VERTICAL STABLIZER LOWER RUDDER TAB SUPPORT FITTING HAS WORN TAB ROD BOLT HOLES. WORN HOLES REAMED TO 0.620 INCH AND BUSHINGS FABRICATED AND INSTALLED IAW ECRA 5530-01195. TAB RODS RE-INSTALLED AND TAB RIGGING/FUNCTIONS CHECK C/OUT. (X)

Part: INTERCOSTAL — CORROSION (BS 1070)

KUL - HNRC: 844757 - FLOOR BEAM, STA 1070, RBL 50 INTERCOSTAL FOUND CORRODED. CORROSION REMOVED AND FOUND OUT OF LIMIT DEPTH 0.045 INCH AREA 2 INCHES BY 8 INCHES IAW SRM 53-10-1. REPLACED NEW INTERCOSTAL IAW SRM 53-10-2. (X)

Part: SEAT TRACK — CORRODED (BS 1030)

KUL - HNRC: 844328 - SURFACE CORROSION FOUND ALONG FLOOR TRACK AT STA 1030 NEAR R2 DOOR, BOTH INBOARD AND OUTBOARD TRACK. CORROSION REMOVED, FOUND OUT OF LIMIT DEPTH 0.045 INCH AREA 2 INCHES BY 5 INCHES. FABRICATED AND REPLACED SEAT TRACK IAW SRM 53-10-2. (X)

Part: DOUBLER — CORRODED (BS 900)

KUL - NRC: 844351 - LEFT WHEELWELL PRESSURE DECK STRAP DOUBLER AT BS 900 AND LBL 30, 36, 39, 43, AND 51 IS CORRODED. STRAP DOUBLER REPLACED. (X)

Part: BEAM — CORRODED (LT HORIZ STAB)

KUL - HNRC: 844304 - Q-CHECK FOUND LEFT HORIZONTAL STABILIZER UPPER AFT AUXILIARY (HINGE SUPPORT) BEAM EXFOLIATED AT (ELEVATOR) STA 106 - STA 109 AND STA 128 - STA 132 ON LOWER FORWARD (FREE) FLANGE. CORROSION REMOVED TO A DEPTH OF 0.070 INCH OUT OF SRM 55-10-1 LIMITS. HOWEVER, ECRA 5510-01385 ADVISED BLEND-OUT IS STRUCTURALLY SATISFACTORY. HFEC CHECK CONFIRMED NO CRACKS. AREA FLAP PEENED IAW SOPM 20-10-3. AREA RE-PROTECTED. (X)

Part: WINDOW — CRACKED (LT COCKPIT)

FLT 976 - GUM - CAPTAINS L-1 WINDOW CRACKED IN FLIGHT. REMOVED AND REPLACED CAPTAINS S-1 WINDOW AS PER MM 56-11-11. (M)

Part: HYDRAULIC PUMP — FAILED (NR 1/NR 2 ENGINE)

GUM - FLT 0957 - L/P 41880812/7943851 - AFTER TAKEOFF FROM PNI WITH GEAR HANDLE IN UP POSITION, LOST ALL A-SYSTEM FLUID. UPON LANDING IN GUM, MAINTENANCE FOUND NR 1 ENGINE HYDRAULIC PUMP FAILED INTERNALLY 'LEAKING OUT OF SUMP'. ALSO, FOUND LOTS OF METAL IN THE CASE DRAIN FILTERS AND BURNED HYDRAULIC FLUID. ON L/P 7943851, MAINTENANCE REMOVED AND REPLACED NR 1 AND NR 2 ENGINE DRIVEN HYDRAULIC PUMPS PER MM 29-11-31, AND REPLACED CASE DRAIN FILTERS PER MM 29-11-41. SYSTEM FLUSHED OF CONTAMINATES AND BLED A-SYSTEM. RAN ENGINE NR 1 AND NR 2, FOUND NO LEAKS ON THE HYDRAULIC PUMPS AND OPS CHECK GOOD. AIRCRAFT RELEASED FOR SERVICE. (X)

Part: FITTING — LEAKING (NR 2 OIL PRESS)

FLT 863 - GUM - LOSS OF NR 2 OIL QUANTITY. SHUTDOWN ENGINE AT 2115 OIL PRESS 45 PSI. TROUBLESHOOTING FOUND FITTING FOR OIL DIFF PRESSURE X-MITTER SUPPLY LINE LEAKING. REPLACED FITTING, LK AND OPS CHECK GOOD ON ENGINE RUN PER MM 79-20-0. OIL QTY SERVICED TO FULL, COWLINGS SECURED. (M)

Part: WEB — CORRODED (TAIL SKIN COMP)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, SEVERE CORROSION WAS FOUND ON TAIL SKIN COMPARTMENT RT SIDE OF WEB AT AFT LOWER POSITION. THE CORRODED WEB WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-2 FIGURE 1. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 840802 (SEQ NR 01150). (M)

Part: ANGLE — CORRODED (TAIL SKID)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, BULGE WAS FOUND ON TAIL SKID COMPARTMENT CUTOUT AT REAR POSITION. THE CORRODED ANGLE WAS REMOVED REPAIRED PER B727 SRM 51-40-3 FIG 1. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 840803 9SEQ NR 01151). (M)

Part: SIGN COVER — BROKEN (CABIN)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, BROKEN 'EXIT' SIGN COVER WAS FOUND ON LEFT AFT EMERGENCY EXIT DOOR. THE DAMAGED 'EXIT' SIGN ASSEMBLY WAS REMOVED AND REPLACED WITH P/N BR9279-105 PER B727 MM 33-50-11 AND OPERATIONAL CHECK FOUND SATISFACTORY. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 814756 (SEQ NR 02242) (M)

Part: SIGN COVER — BROKEN (CABIN)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, BROKEN 'EXIT' SIGN COVERS WERE FOUND ON PASSENGER CABIN COMPARTMENT AT THE FOLLOWING POSITIONS; SIDE OF R1 GALLEY DOOR, SIDE OF R2 GALLEY DOOR, SIDE OF RT FORWARD EMERGENCY EXIT DOOR. THE DAMAGED 'EXIT' SIGN ASSEMBLIES WERE REMOVED AND REPLACED WITH P/N BR9279-16 PER B727 MM 3350-11 AND OPERATIONAL CHECK FOUND SATISFACTORY. REF, HANGAR NON ROUTINE REPAIR ITEM CARDS NR 814753, 814754 AND 814755 (SEQ NR 02239, 02240 AND 02241). (M)

Part: SKIN — DENTED (BS 1140)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DENT WAS FOUND ON FUSELAGE SKIN AT BS 1140 BETWEEN STRINGER 20L AND STRINGER 21L AND THE DENT DEPTH BEYOND THE SPECIFIED LIMIT. THE DAMAGED SKIN WAS REPAIRED PER B727 SRM 53-30-3 FIGURE 1. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810625 (SEQ NR 02201). (M)

Part: WEB — OIL CANNING (BS 1225-1303)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, OIL CANNING WAS FOUND ON LOWER VENTRAL STAIRWALL TORQUE BOX AT THE FOLLOWING AREAS, RT SIDE BETWEEN BS 1283 AND BS 1303, LEFT SIDE BETWEEN BS 1243 AND BS 1283, LT SIDE AT BS 1225. THE DAMAGED WEB WERE REPAIRED PER B727 SRM 51-40-2 FIGURE 1. REF, HANGAR NON ROUTINE REPAIR ITEM CARDS NR 810539, 810540 AND 810541 (SEQ NR 02151, 02152 AND 02153). (M)

Part: SKIN — TORN (OUTBOARD AILERON)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, RT WING OUTBOARD AILERON T/E HONEYCOMB LOWER SKIN WAS FOUND TO BE TORN AT AFT EDGE. THE DAMAGED SKIN .375 INCH BY 1 INCH IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810413 (SEQ NR 06043). (M)

Part: BULKHEAD WEB — CRACKED (BS 950)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, 4.5 INCH LONG CRACK WAS FOUND ON BS 950 PLUS 5.13 PRESSURE BULKHEAD WEB TO RT BULKHEAD FITTING SPLICE ANGLE (69-16269-2) AT WL 174.80. THE DAMAGED SPLICE ANGLE, P/N 69-16269-2 WAS REMOVED AND REPLACED PER B727 SRM 51-30-2. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810600 (SEQ NR 01033)(M)

Part: SHEAR TIE — CORRODED (BS 1166)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, SEVERE CORROSION WAS FOUND ON AFT CARGO COMPARTMEN BS 1166 FRAME SHEAR TIE BETWEEN STRINGER 28L AND STRINGER 29L. THE CORRODED SHEAR TIE WAS REMOVED AND REPLACED WITH NEW SHEAR TIE PER B727 SRM 53-10-4. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810591 (SEQ NR 01074). (M)

Part: STRINGER — CORRODED (BS 720)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, SEVERE CORROSION WAS FOUND ON FORWARD CARGO COMPARTMENT, STRINGER 27R BETWEEN BS 720F PLUS 15 AND BS 740. THE CORRODED STRINGER FROM BS 720F PLUS 12 TO BS 740 WAS TRIMMED OUT AND REPAIRED PER B727 SRM 53-10-3 FIGURE 1. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 839915 (SEQ NR 01100). (M)

Part: ANGLE — CORRODED (BS 740)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, INTERGRANNULAR CORROSION WAS FOUND ON FORWARD CARGO COMPARTMENT STRINGER 27R END TIE ANGLE AT BS 740. THE DAMAGED TIE ANGLE WAS REMOVED AND REPLACED WITH NEW TIE ANGLE PER B727 SRM 51-30-2. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 839916 9SEQ NR 01101). (M)

Part: SHEAR TIE — CORRODED (BS 1166)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, SEVERE CORROSION WAS FOUND ON AFT CARGO COMPARTMENT BS 1166 FRAME SHEAR TIE AT RT SIDE OF STRINGER 29R. THE CORRODED SHEAR TIE FROM STRINGER 28R AND STRINGER 29R WAS REMOVED AND REPLACED WITH NEW SHEAR TIE PER B727 SRM 53-10-4. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810593 9SEQ NR 01076). (M)

Part: SKIN — DELAMINATED (NR 4 FORE FLAP)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DELAMINATION WAS FOUND ON RT WING OUTBOARD T/E FORE FLAP L/E UPPER SKIN AT WBL 417. THE DAMAGED SKIN 2.2 INCH BY 3.2 INCH IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810414 (SEQ NR 06044). (M)

Part: SKIN — DELAMINATED (LT AFT TE FLAP)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, DELAMINATION WAS FOUND ON LT WING INBOARD T/E AFT FLAP T/E UPPER SKIN AT WBL 77. THE DAMAGED SKIN 2.2 INBY BY 7.8 INCH SIZE WAS TRIMED OUT AND REPAIRED PER B727 SRM 51-40-6. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810397 9SEQ NR 05047). (M)

Part: SHEAR TIE — CORRODED (BS 1166)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, SEVERE CORROSION WAS FOUND ON AFT CARGO COMPARTMENT BS 1166 FRAME SHEAR TIE BETWEEN STRINGER 29L AND STRINGER 30. THE CORRODED SHEAR TIE WAS REMOVED AND REPLACED WITH NEW SHEAR TIE PER B 727 SRM 53-10-4. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810592 (SEQ NR 01075) (M)

Part: WEB — CRACKED (BS 1220)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, .5 INCH LONG CRACK WAS FOUND ON LEFT SIDE LOWER VENTRAL STAIRWALL TORQUE BOX WEB AT BS 1220 LIGHTENING HOLE CUTOUT. THE CRACK WAS STOP DRILLED AND REPAIRED PER B727 SRM 51-40-2 FIGURE 1. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810533 (SEQ NR 02145). (M)

Part: WEB — CRACKED (BS 1213)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, ONE INCH LONG CRACK WAS FOUND ON LT SIDE LOWER VENTRAL STAIRWALL TORQUE BOX WEB AT BS 1213 LIGHTENING HOLE CUTOUT. THE CRACK WAS STOP DRILLED AND REPAIRED PER B727 SRM 51-40-2 FIGURE 1. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810531 (SEQ NR 02143). (M)

Part: SKIN — DELAMINATED (LT TE AFT FLAP)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, DELAMINATION WAS FOUND ON LT WING INBOARD T/E AFT FLAP T/E UPPER SKIN AT WBL 100. THE DAMAGED SKIN 1.75 INCH BY 8.5 INCH IN SIZE WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810396 (SEQ NR 05046). (M)

Part: WEB — CRACKED (BS 1225)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, .5 INCH LONG CRACK WAS FOUND ON LT SIDE LOWER VENTRAL STAIRWALL TORQUE BOX WEB AT BS 1225 LIGHTENING HOLE CUTOUT. THE CRACK WAS STOP DRILLED AND REPAIRED PER B727 SRM 51-40-2 FIGURE 1. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810532 (SEQ NR 02144). (M)

Part: SKIN — DELAMINATED (NR 4 SPOILER)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, DELAMINATION WERE FOUND ON LT WING NR 4 SPOILER T/E UPPER SKIN AT OUTBOARD AND INBOARD CORNERS. THE DAMAGED SKIN 2.5 INCH BY 6.4 INCH IN SIZE (ON OUTBOARD CORNER) AND 2.5 INCH BY 12.5 INCH IN SIZE (ON INBOARD CORNER) WERE TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. REF, HANGAR NON ROUTINE REPAIR ITEM CARD 810308 (SEQ NR 05008). (M)

Part: SKIN — DISBONDED (NR 3 SPOILER)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, DISBONDED WERE FOND ON LEFT WING NR 3 SPOILER T/E UPPER SKIN EXISTING REPAIR DOUBLER AT OUTBOARD AND INBOARD CORNERS. THE EXISTING REPAIR DOUBLERS (2.5 INCH BY 6 INCH ON OUTBOARD CORNER, 6.2 INCH BY 8 INCH ON INBOARD CORNER) WERE REMOVED AND REPAIRED PER B727 SRM 51-40-6. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810307 (SEQ NR 05007) (M)

Part: SKIN — DELAMINATED (NR 14 SPOILER)

TNN - DURING S-CHECK INSPECTION ON A/C AT AIR ASIA, DELAMINATION WAS FOUND RT WING NR 14 SPOILER T/E UPPER SKIN AT OUTBOARD AFT CORNER. THE DAMAGED SKIN 2.75 INCH BY 10.5 INCH WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810342 (SEQ NR 06012) (M)

Part: SKIN — DELAMINATED (NR 8 SPOILER)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, DELAMINATION DISBONDED WAS FOUND ON RT WING NR 8 SPOILER UPPER SKIN AND SKIN EXISTING REPAIR DOUBLER. THE DAMAGED SKIN AND EXISTING REPAIR DOUBLER 4 INCH BY 27 INCH WAS TRIMMED OUT AND REPAIRED PER B727 SRM 51-40-6. REF, HANGAR NON ROUTINE REPAIR ITEM CARD NR 810343 (SEQ NR 06013). (M)

Part: TURBINE — FAILURE (NR 3 ENGINE)

AT GEAR RETRACTION, PASSING ABOUT 300 FEET, NR 3 ENGINE FAILED (TURBINE SECTION) CLIMBED TO 1000 FEET, CLEANED UP, DID ENGINE FAIL CHECK LIST AND RETURNED TO PONAPE FOR NORMAL TWO ENGINE LANDING. REMOVED AND REPLACED NR 3 ENGINE PER JOB CARD 07-7100-1-8001 AND PER JT8D POWER ASSURANCE RUN NR JE07-7100-94-072-001. ENGINE RUN CHECKS NORMAL. (M)

Part: RADAR ANTENNA — FAILED (FWD FUSELAGE)

GUM - FLT NR 868 - AFTER DEPARTURE FROM GUAM, WEATHER RADAR WILL NOT PAINT ON GROUND CLUTTER. SCREEN BLANKS OUT BETWEEN 30 DEGREES AND 60 DEGREES. AIRCRAFT DIVERTED BACK TO GUAM. MAINTENANCE FOUND WEATHER RADAR ANTENNA NO GOOD, REMOVED AND REPLACED WEATHER RADAR ANTENNA, AS PRECAUTIONARY, ALSO REMOVED AND REPLACED WEATHER RADAR TRANSCEIVER UNIT. WEATHER RADAR SYSTEM TEST GOOD AND AIRCRAFT DISPATCHED. (M)

Part: COVER — BROKEN (DOOR EXIT SIGN)

TNN - DURING 1/2 D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, BROKEN COVER WAS FOUND ON RIGHT FORWARD EMERGENCY EXIT DOOR 'EXIT' SIGN COVER. THE DAMAGED EXIT SIGN ASSEMBLY WAS REMOVED AND REPLACED WITH P/N BR9279-10 ASSY PER B727 MM 33-50-11 AND OPERATIONAL CHECK FOUND SATISFACTORY. HANGAR NON ROUTINE REPAIR ITEM CARD NR 832332 (SEQ NR 02142). (M)

Part: WIRE — BROKEN (EMER EXIT DOOR)

TNN - DURING 1/2 D-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, EXCESSIVE BROKEN WIRE WERE FOUND ON RIGHT FORWARD OVERWING EMERGENCY ESCAPE HATCH STEP FORWARD CABLE. THE DAMAGED CABLE ASSY WAS REMOVED AND REPLACED PER B727 MM 52-21-0. HANGAR NON ROUTINE REPAIR ITEM CARD NR 832312 (SEQ NR 02092). (M)

Part: APU — FAILED (CABIN)

FLT NR 93827 - CTS - DURING BOARDING, MAIN CABIN FILLED WITH SMOKE, OFF LOADED PASSENGERS. TRACED SMOKE TO FAILED APU. PLACARDED APU INOPERATIVE PER MEL 49-01. RAN ENGINES AND CLEARED CABIN AND PACKS OF RESIDUE. (W)

Part: LOCK ACTUATOR — DIRTY (NOSE GEAR)

FLT NR 932 - GUM - ON FINAL, GEAR HANDLE DOWN, NOSE GEAR DID NOT EXTEND. NOSE GEAR DOORS DID NOT OPEN. UNSAFE GEAR LIGHT NOSE, DID NOT HAVE ANNUNCIATOR NOSE GEAR LIGHT. RECYCLE GEAR, OPERATED NORMALLY. MAINTENANCE FOUND LEFT AND RT NOSE GEAR DOOR FORWARD FAIRING DOOR SEALS COATED WITH TAR, WHICH CAUSING DOOR TO STICK. ALSO, FOUND SEVERAL GREASE FITTINGS DRY. CLEANED DOOR AREA AND LUBED NOSE LANDING GEAR AND DOOR PER MM 12-21. PRECAUTION REPLACED NOSE GEAR LOCK ACTUATOR.

Part: GASKET — FAILED (NR 1 ENGINE)

GUM - FLT 917 - APPROXIMATELY 25 MINUTES OUT OF SAIPAN, FLT 917, ACFT 741, CREW REPORTED STRUT OVERHEAT LIGHT CAME ON WHEN CLIMBING THROUGH APPROXIMATELY 10,000 FEET. THROTTLE WAS BROUGHT TO IDLE AND LIGHT WENT OUT. ABNORMAL CHECKLIST WAS RUN (ENGINE BLEEDS OFF AND POWER WAS RESTORED TO NR 1 ENGINE). ACFT WAS AIR DIVERTED TO GUAM. MAINTENANCE, IN TROUBLESHOOTING, FOUND HEAT EXCHANGE MANIFOLD WITH A BAD GASKET. INSTALLED NEW GASKETS, RAN ENGINE AT HIGH POWER, NO LEAKS FOUND. NR 1 STRUT OVERHEAT LIGHT DID NOT ILLUMINATE. ACFT CHECK FOR SERVICE. (X)

Part: ROLLER — DAMAGED (RT MLG DOOR)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, FROZEN WATER FOUND ON RT MLG DOOR GROUND RELEASE CRANK ROLLER. THE DAMAGED ROLLER WAS REMOVED AND REPLACED PER B727 MM 32-34-21 AND OPERATIONAL CHECK FOUND SATISFACTORY. HANGAR NON-ROUTINE REPAIR, ITEM CARD NR 0729691 (SEQ NR 01027). (X)

Part: SKIN — CORRODED (CENTER WING)

TNN - DURING S-CHECK INSPECTION ON AIRCRAFT AT AIR ASIA, CORROSION FOUND ON CENTER WING LOWER SKIN AT STIFFENER S-5, LBL 27. THE CORRODED SKIN WAS CLEANED UP AND REPAIRED PER EC/RA 5710-01663. HANGAR NON-ROUTINE REPAIR, ITEM CARD NR 0729690 (SEQ NR 01038). (X)