N72822

Part: CABLE — FRAYED (TAILCONE) · airframe 51,301 hrs · 24,466 cycles

THE TAILCONE FAILED TO SEPARATE FROM AIRCRAFT WHEN USING AFT ENTRANCE DOOR TO DEPLOY TAILCONE. FOUND L/H TAILCONE RELEASE CABLE FRAYED IN TWO PLACES WHERE IT PASSES OVER UPPER PULLEY. REPLACED CABLE AND PERFORMED ADJUSTMENT TEST OF TAILCONE SYSTEM IAW MM 53-53-00.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 51,301 hrs · 24,466 cycles

INSPECTION FOUND RT TIEDOWN RAIL CORRODED AT STA 522 - 636. A NEW TIEDOWN RAIL WAS INSTALLED IAW ECRA 5321-01134.

Part: FRAME — CRACKED (STA 1418) · airframe 51,301 hrs · 24,466 cycles

INSPECTION FOUND A 1" CRACK IN FUSELAGE FRAME AT STA 1418, LONGERON 1L. REPAIRED IAW SRM 53-03, PAGE 5.

Part: PAN — CRACKED (CARGO DOOR) · airframe 51,301 hrs · 24,466 cycles

INSPECTION FOUND A 1.5 INCH CRACK IN FORWARD BAGGAGE BIN BACK PAN AT AFT SIDE WALL JUST AT LOWER LATCH BETWEEN THE TWO LOWER STOP PADS. A DOUBLER WAS INSTALLED IAW SRM 52-05, FIGURE 26A.

Part: LONGERON — CRACKED (STA 1418) · airframe 51,301 hrs · 24,466 cycles

INSPECTION FOUND A 2" CRACK IN LONGERON 2R AFT OF STA 1418. A SPLICE REPAIR WAS INSTALLED IAW ECRA 5311-01132.

Part: LONGERON — CORRODED (STA 351) · airframe 49,661 hrs · 23,599 cycles

LONGERON 28R AT STATION 351 CORRODED. CUT OT DAMGED SECTION. SPLICED IN NEW SECTION PER SRM 53-02.

Part: SKIN — DAMAGED (RT SLAT) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND RT NR 3 SLAT LEADING EDGE SKIN CREASED. THE INNER SKIN WAS REMOVED IAW SRM 51-30-8. THE SLAT SKIN WAS REPAIRED IAW ECRA 5754-01039. REINSTALLED INNER SKIN IAW SRM 51-30-8. REINSTALLED ANTI-ICE DUCT IAW MM 30-10-00. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: BEAM — CORRODED (CARGO BAY) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND AFT CARGO PIT DOOR JAMB BEAM CORRODED. A NEW BEAM WAS INSTALLED IAW SRM 51-30-4 AND 51-30-5. TWO DOOR STOP BRACKETS AND 3 SCUFF PLATE STRAPS WERE INSTALLED IAW SRM 51-30-5 AND 51-30-2.

Part: WEB — CRACKED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND A 6 INCH CRACK IN MAIN CABIN DOOR TORQUE BOX WEB TANG AT FS 200, LBL 54. THE TORQUE BOX WEB TANG WAS REPAIRED IAW EA 9-5314-2-A0880 AND ECRA 5310-04121.

Part: FLOOR PANEL — CORRODED (CABIN) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND MAIN CABIN FLOOR PANEL CORRODED AT STA 256-313, LBL 22-44. THE PANEL WAS REMOVED AND A NEW PANEL WAS INSTALLED IAW ECRA 5320-01265 AND SRM 51-30-1.

Part: SKIN — DENTED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND EXTERNAL FUSELAGE SKIN DENTED AT FS 200-220 BETWEEN LONGERON 18 L AND 19L. THE DENTED AREA WAS CUT OUT IAW SRM 53-04, FIGURE 25. A REPAIR DOUBLER AND FILLER WERE INSTALLED IAW SRM 53-01, FIGURE 25, 51-10-3, AND 53-04, FIGURE 25. REINSTALLED ALL REMOVED PARTS IAW SRM 51-30-01 AND 51-30-02. SPLICED CUSP WEB IAW SRM 53-01.

Part: SKIN — DENTED (CARGO DOOR) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND FORWARD CARGO DOOR DENTED ON OUTER SKIN. THE CARGO DOOR WAS REMOVED IAW MM 52-31-00. THE DOOR WAS REPAIRED IAW SRM 53-04, FIGURE 38 AND 51-10-3. THE DOOR WAS REINSTALLED IAW MM 52-31-00.

Part: SKIN — GOUGED (T/E FLAP) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND RIGHT T/E INBOARD FLAP LOWER SKIN AFT OF MLG PITTED AND GOUGED. THE INBOARD T/E FLAP WAS REMOVED IAW MM 27-50-00. THE INBOARD T/E FLAP WEDGE WAS RESKINNED IAW SRM 51-10-4, 51-30-2, AND 57-50-9. THE INBOARD T/E FLAP WEDGE WAS REINSTALLED IAW MM 27-50-00 AND SRM 51-30-1. A REPAIR DOUBLER WAS INSTALLED ON OUTBOARD T/E IAW SRM 57-01, FIGURE 3, 51-10-4, AND 51-30-8.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND A CRACK IN AFT FUSELAGE TO VERTICAL STABILIZER ANGLE AT AFT END RT SIDE. THE CRACKED AREA WAS REMOVED IAW SRM 53-05, FIGURE 23. DOUBLER AND FILLER WERE INSTALLED IAW SRM 51-10-3, 53-05, FIGURE 23, AND 51-20-0.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND A CRACK IN AFT FUSELAGE TO VERTICAL STABILIZER ANGLE AT AFT END LT SIDE. THE CRACKED AREA WAS REMOVED IAW SRM 53-05, FIGURE 23. DOUBLER AND FILLER WERE INSTALLED IAW SRM 53-05, FIGURE 23, 51-10-3, 51-20-0, AND 51-30-5.

Part: FRAME — CRACKED (RT W/W) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND A 1 INCH CRACK IN RIGHT W/W FORWARD FRAME AT I/B LEADING EDGE NEXT TO KEEL BEAM. REPAIR DOUBLERS WERE INSTALLED IAW SRM 53-01, FIGURE 2, 51-10-4, 51-10-3, AND 51-30-2.

Part: BEAM — CORRODED (CARGO BAY) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND MID CARGO DOOR JAMB BEAM CORRODED. THE CORROSION WAS REMOVED. A DOUBLER WAS INSTALLED IAW ECRA 5310-03027.

Part: FRAME — CRACKED (LT W/W) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND A 1 INCH CRACK IN LEFT W/W LOWER FORWARD FRAME I/B NEXT TO KEEL BEAM. REPAIR DOUBLERS WERE INSTALLED IAW 53-01, FIGURE 2, 51-10-4, 51-10-3, AND 51-30-2.

Part: WEB — CORRODED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND E&E BAY OVERHEAD FLOOR WEB PANEL HAD CORROSION BLEEDING OUT FROM THE FLOORBEAM AND LOWER SURFACE OF WEB PANEL AT STA 200, RBL 10. THE FLOOR PANEL WAS REMOVED FOR ACCESS AND THE CORROSION WAS REMOVED IAW SRM 51-10-3. THE CORROSION WAS FOUND OUT OF LIMITS IAW SRM 51-10-3. THE FLOOR SUPPORT WAS REMOVED FOR ACCESS IAW SRM 51-30-2. A DOUBLER WAS INSTALLED IAW SRM 53-01, FIGURE 4, SHEET 3 AND 51-30-2. THE SUPPORT AND FLOOR PANEL WERE INSTALLED IAW ECRA 5100-01844.

Part: SKIN — DENTED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND EXTERNAL FUSELAGE SKIN DENTED AT FS 200 - 220 BETWEEN LONGERON 17L AND 18L. THE SKIN WAS REPAIRED IAW ECRA 5330-02471.

Part: SKIN — DENTED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND EXTERNAL FUSELAGE SKIN DENTED AT FS 463 BETWEEN LONGERON 16R AND 17R. A DOUBLER WAS INSTALLED IAW SRM 53-04, FIGURE 38, VIEW E, 51-10-3, AND 51-30-2.

Part: SKIN — DENTED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND LT AFT FUSELAGE LOWER SKIN DENTED BELOW OUTFLOW VALVE. THE AREA WAS REFORMED IAW SRM 53-04, FIGURE 38. A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-04, FIGURE 38, 51-10-4, 51-10-3, AND 51-30-2.

Part: SKIN — DENTED (FUSELAGE) · airframe 46,688 hrs · 22,015 cycles

INSPECTION FOUND EXTERNAL FUSELAGE SKIN DENTED AT FS 200 - 220 BETWEEN LONGERON 16R AND 18R. A REPAIR DOUBLER WAS INSTALLED.

Part: PROXIMITY SWITCH — OUT OF RIG (NLG) · airframe 44,531 hrs · 20,871 cycles

THE RED NOSE GEAR LIGHT REMAINED ILLUMINATED WHEN GEAR WAS RETRACTED AFTER TAKEOFF. THE GEAR WAS CYCLED, BUT THE LIGHT REMAINED ILLUMINATED. THE AIRCRAFT WAS RETURNED TO DEN WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NOSE GEAR UPLOCK PROXIMITY SWITCH OUT OF RIG. THE PROXIMITY SWITCH WAS ADJUSTED IAW MM 32-60-05. IN ADDITION, THE NOSE STRUT WAS SERVICED WITH NITROGEN. A NOSE GEAR SWING WAS PERFORMED WITH OPERATION AND INDICATIONS CHECKING NORMAL.

Part: HANDLE — OUT OF ADJUST (TAIL CONE)

THE TAIL CONE EXTERIOR RELEASE HANDLE FAILED PULL TEST. THE HANDLE FAILED LOW AT 18 POUNDS. THE TAIL CONE EXTERIOR RELEASE HANDLE WAS RIGGED AND FELL WITHIN TEST LIMITS IAW MM 53-53-00.

Part: SKIN — DENTED (BS 260)

INSPECTION FOUND FUSELAGE SKIN DENTED AT STA 260, LONGERON 19R. REPAIRED IAW SRM 53-04, FIGURE 38.

Part: BEAM — CRACKED (SERVICE DOOR)

FORWARD SERVICE DOOR NUMBER 4 BEAM CRACKED AT AFT SIDE RADIUS 3/4. INSTALLED NEW BEAM PER SRM 51-30.

Part: SKIN — DENTED (BS 294)

DENT AT STA 294 LEFT BETWEEN LONG 22 AND 23. COLD FORMED DENT BACK TO CONTOUR. FABRICATED AND INSTALLED REPAIR DOUBLER PER SRM 53-04.

Part: SKIN — LIGHTNING STRIKE (BS 180 - 313)

SEVERAL SMALL LIGHTNING STRIKES, LONG 24 TO 26 LT STA 218 TO 313. BLENDED OUT LIGHTNING STRIKE DAMAGE OR PLUGGED AS NECESSARY PER SRM 53-04 FIG 38.

Part: SKIN — DENTED (BS 237)

FUSELAGE SKIN AT STA 237 HAS A DEEP DENT. INSTALLED NEW SECTION OF SKIN PER EC/RA 5330-02445.

Part: SKIN — DAMAGED (FUSELAGE)

SMALL CUTOUT FOR MAIN CABIN DOOR HOLD OPEN HOOK FUSELAGE SKIN PULLED AWAY, 2 X 1 X .125. INSTALLED DOUBLERS PER SRM 53-04.

Part: SEAT TRACK — CORRODED (BS 1136 - 1231)

CORROSION ON FLOOR BOARD SUPPORT FLANGE LEFT CENTER SEAT TRACK, SEVERAL AREAS STA 1136 TO 1231. REMOVED AND REPLACED SEAT TRACK PER SRM 51-30-0 FROM STA 1032 TO 1245.

Part: SUPPORT — CORRODED (BS 190)

FLOOR SUPPORT CORRODED STA 190 APPROX BETWEEN PANEL K AND J FORWARD ENTRY, LIGHT CORROSION. FABRICATED FLOOR SUPPORT, PRIMED AND INSTALLED PER SRM 51-3-2.

Part: BULKHEAD DOUBLER — CORRODED (AFT PRESS BLKHD)

APB HAS CORROSION, BOTTOM AFT OF LONG 30. REMOVED AND REPLACED JACKPOST DOUBLER PER SRM 51-30-1 AND 51-30-2.

Part: SEAT TRACK — CRACKED (BS 218 - 229)

CORROSION AND EXPOSED SEAT TRACK MATERIAL RT CENTER SEAT TRACK BETWEEN STA 218 - 229. REMOVED AND REPLACED SEAT TRACK AT STA 218 THROUGH STA 229 RT CENTER PER SRM 53-05.

Part: DUCT — RUPTURED (NR 2 ENGINE)

THE RT FIRE DETECTOR LOOP LIGHT ILLUMINATED, FOLLOWED BY THE RT FIRE WARNING LIGHT AND BELL WHILE EN ROUTE FROM IAH TO CLE. THE RIGHT ENGINE POWER WAS REDUCED AND THE FIRE WARNINGS CEASED. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE ANTI-ICE DUCT ON TOP OF NR 2 ENGINE RUPTURED. THE ANTI-ICE DUCT WAS REMOVED AND REPLACED. IN ADDITION, THE NR 2 ENGINE UPPER COWLING WAS REMOVED AND REPLACED DUE TO HEAT DAMAGE CAUSED BY RUPTURE OF THE ANTI-ICE DUCT. LEAK CHECKS WERE GOOD AND A FIRE DETECTION TEST WAS NORMAL.

Part: C-7 BLADE — BROKEN (NR 1 ENGINE)

THE TOWER REPORTED THAT THE NR 1 ENGINE HAD SPARKS COMING FROM EXHAUST AREA AFTER TAKEOFF. THE CREW REPORTED THAT THERE WERE NO UNUSUAL NR 1 ENGINE INSTRUMENT INDICATIONS AND OPERATION APPEARED NORMAL. THE ENGINE WAS NOT SHUTDOWN. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. THE NR 1 ENGINE WAS REMOVED AND REPLACED. *S/D* ENGINEERING CONCLUDED THAT THE PRIMARY CAUSE OF ENGINE FAILURE WAS DUE TO A BROKEN C-7 BLADE.

Part: FMA — BURNED (LT COCKPIT)

A PUFF OF SMOKE WAS SEEN COMING FROM BEHIND CAPTAIN'S FMA UPON LANDING AT IAH. THE FMA WENT BLANK AND THE SMOKE STOPPED. THE AIRCRAFT ARRIVED AT GATE WITHOUT INCIDENT. MAINTENANCE VERIFIED THAT THE FMA WAS BURNED. THE ASSOCIATED WIRING BEHIND CAPTAIN'S PANEL WAS CHECKED AND FOUND GOOD. THE CAPTAIN'S FMA WAS REMOVED AND REPLACED. A BITE CHECK WAS GOOD. RTS WAS PERFORMED ON SYSTEM NR 1 AND NR 2 WITH BOTH GO.

Part: ACTUATOR — INOPERATIVE (YAW DAMPER)

AUTOTHROTTLES DISENGAGED AND SPEED FLAGS CAME INTO VIEW ON BOTH F/D'S DURING T/O ROLL. A/C BEGAN TO OSCILLATE IN YAW DURING INITIAL CLIMB. THE YAW DAMP WAS TURNED OFF AND YAWING STOPPED. AUTOTHROTTLE AND AUTOPILOT WOULD NOT ENGAGE. THE C/B LABELLED DFGS SWITCH B(C-18) POPPED AND WOULD NOT RESET. MX WIRES FROM TERMINAL STRIP TO RUDDER POSITION SENSOR SHORTED. NEW WIRES INSTALLED AND C/B'S RESET. WHEN RTS WAS PERFORMED BOTH SYS FAILED. THE YAW DAMP SYS PLACARDED INOP. THE YAW DAMP ACT WAS R/R'D AND PLACARD REMOVED. HONEYWELL TEARDOWN REVEALED SEVERAL ROUGH AND DRY BEARINGS, WORN GASKETS, AND LOCKED UP STOP SPRING.

Part: OIL PRESURE TUBE — CRACKED (NR 1 ENGINE)

CREW NOTICE NR 1 ENGINE OIL PRESSURE DECREASING SHUTDOWN NR 1 ENGINE. INSPECTION FOUND CRACK TUBE TO OIL PRESSURE SWITCH. REPLACED TUBE (P/N 793814-501) LEAKED CHECK AND RETURNED TO SERVICE.

Part: SLIDE — LEAKING (GALLEY)

THE LT AFT GALLEY SLIDE PACK BEGAN TO DEPRESSURIZE DURING ARMING OF SLIDE. THE SLIDE WAS REMOVED AND REPLACED IAW MM 25-60-0.

Part: INTERCOSTAL — CRACKED (BS 769-788)

INSPECTION FOUND A .75 AND .625 CRACK IN MID BAGGAGE BIN CEILING INTERCOSTAL AT STA 769-788. THE AREA WAS REPAIRED BY INSTALLING A DOUBLER IAW SRM 51-30-5.

Part: SUPPORT — CORRODED (BS 1155)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 1155. A NEW FLOOR SUPPORT WAS INSTALLED IAW SRM 51-30-5.

Part: ANGLE — CRACKED (VERTICAL FIN)

INSPECTION FOUND A 1.3 CRACK IN LT SIDE VERTICAL FIN INNER ATTACH ANGLE. THE RT SIDE VERTICAL FIN INNER ATTACH ANGLE WAS FOUND BROKEN IN HALF. THE ATTACH ANGLES WERE REPLACED IAW SRM 51-30-5 AND 51-30-2.

Part: BRACKET — CRACKED (WS 164)

INSPECTION FOUND A 3 INCH CRACK IN LT WING LEADING EDGE RIB LOWER ATTACH BRACKET AND DOUBLER AT STA XRS 164, BETWEEN NR 5 AND NR 6 SLAT TRACKS. A REPAIR ANGLE AND DOUBLER WERE FABRICATED AND INSTALLED IAW ECRA 5710-01645.

Part: BRACKET — CRACKED (WS 289)

INSPECTION FOUND A .375 INCH CRACK IN LT WING LEADING EDGE RIB LOWER ATTACH BRACKET AT STA XRS 289, TWO RIBS INBOARD OF NR 9 SLAT TRACK. THE ATTACH BRACKET WAS REPLACED IAW SRM 51-30-2.

Part: CABLES — OUT OF ADJUST (TAILCONE)

THE TAILCONE RELEASE USING EXTERIOR HANDLE WAS LOW AT 20 POUNDS. THE TAILCONE RELEASE SYSTEM CABLES WERE ADJUSTED IAW MM 53-53-00.

Part: LINK — BROKEN (LT MLG)

THE CREW FOUND FORWARD UPPER SUPPORT LINK ON LT MLG BROKEN DURING A PREFLIGHT CHECK. THE FORWARD UPPER SUPPORT LINK ON LT MLG WAS REMOVED AND REPLACED IAW MM 32-11-04, PAGE 205-206A.

Part: ACM — OIL LEAK (RIGHT)

FLT NR 1529 - IAH - THE AIRCRAFT WAS RETURNED TO IAH FOR SMOKE IN CABIN AFTER TAKEOFF. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE RT AIR CYCLE MACHINE LEAKING OIL. THE RIGHT AIR CYCLE MACHINE WAS REMOVED AND REPLACED. AN OPERATIONAL CHECK OF THE RT AIR CYCLE MACHINE WAS NORMAL WITH NO LEAKS NOTED. (W)