N735D

Part: WIRE — MELTED (COCKPIT) · airframe 58,217 hrs · 26,433 cycles

WIRE BUNDLE ARCED AND BURNED OVER R-2 WINDOW IN COCKPIT - REPAIRED WIRING

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 56,969 hrs · 26,053 cycles

FOUND DURING L/O CK, ALL EXIT IDENTIFIER AT 2R INOP. REPLACED POWER SUPPLY, CHECK NORMAL.

Part: SKIN — CORRODED (FUSELAGE) · airframe 56,338 hrs · 25,851 cycles

THE FUSLEAGE SKIN WAS FOUND CORRODED BETWEEN FS 970 & 983 AND BETWEEN STRINGERS 33 & 34. THE CORROSION WAS CUT OUT, RESULTING IN A 14 X 14 CUTOUT IN THE SKIN. THE CUTOUT WAS REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER AND TRIPLER INSTALLED PER ER/A 377339-14, REV A.

Part: ENGINE — DAMAGED (NR 2) · airframe 56,303 hrs · 25,838 cycles

ENGINE VIB ON NR 2 ENGINE 2.6 ON CLIMBOUT. SHUT ENG DOWN, ENG WINDMILLED APPROX 20 - 25 MIN. REPLACED DIFF PRESS SWITCH SCAVANGE OIL FILTER, BORO IPC AND HPC, CKS NORMAL. BORO 1ST STAGE FOUND DAMAGED. ENG CHANGE IN PROGRESS.

Part: BATTERY PACK — DISCHARGED (2L DOOR)

EMERGENCY BATTERY PACK ABOVE 2L DOOR FLIGHT ATTENDANT SEAT SMOKED. REPLACED BATTERY PACK, CHECKS GOOD.

Part: FAN — FAILED (COCKPIT)

IRREG HEARD STRANGE FAN LIKE NOISE BEHIND SS/O PANEL FOLLOWED BY SMOKE/FUMES IN COCKPIT. FOUND INSTRUMENT COOLING FAN AT FAULT (CB3 A21 TRIPPED) FAN SIEZED UP FWD TO MCO AND PLAC 21-25-21B C/P TIED BACK.

Part: OIL PUMP — FAILED (NR 3 ENGINE)

NR 3 ENG LOSING OIL IN CRUISE. BROUGHT NR 3 ENG BACK TO IDLE. DIVERTED TO SLC. INSPECTED SCAVENGE AND MAIN OIL FILTERS, NO METAL FOUND. CKD ALL CHIP DETECTORS, NO METAL FOUND. SERVICED AND RAN ENG TO TAKEOFF PWR. NO LEAKS NOTED, OIL PRESS AND QTY STABLE. REPLACED ENGINE OIL PUMP.

Part: SKIN — CRACKED (HORIZ STAB)

THE UPPER SKIN OF THE LT HORIZONTAL STABILIZER WAS FOUND WITH A .75 INCH LONG CRACK AT FS 80 AT THE RUNOUT OF STRINGER 31. THE CRACK WAS ROUTED OUT OF THE SKIN WITH A 1.5 INCH DIA HOLE AND REPAIRED WITH AN ALUMINUM DOUBLER AND TRIPLER PER ER/A 367701-14 AND L1011 SRM 55-15-00, FIG 802.

Part: CONTROL CABLE — OUT OF ADJ (RUDDER PEDALS)

DURING CONTROL CHECK, THE RIGHT RUDDER DISPLACEMENT WAS SIGNIFICANTLY RESTRICTED WHEN FULL PHYSICAL EFFORT WAS PLACED ON THE RIGHT RUDDER IT BROKE FREE WITH A LOAD NOISE FROM UNDER THE F/O'S PANEL. RETURNED TO GATE. MTC INSPECTED RUDDER PEDALS CONTROL AND PEDAL ADJUSTMNT SYS. FOUND COPILOTS PEDAL ADJUSTMENT TELEFLEX CABLE MAY HAVE RUBBED. REPOSITIONED TELEFLEX ALL RUDDER PEDAL, OPRN CHECKS NORMAL.

Part: SIGN — INOPERATIVE (R3 DOOR)

ALL EMERGENCY EXIT SIGNS BY R3 DOOR INOP. REPLACED POWER SUPPLY, CHECK NORMAL.

Part: SIGN — INOPERATIVE (L3 DOOR)

EMERGENCY EXIT SIGNS BY L3 DOOR INOP. REPLACED POWER SUPPLY, CHECK NORMAL.

Part: ENGINE — FAILED (NR 3)

NR 3 ENG SHUT DOWN, LOW OIL PRESS. FOUND METAL ON CHIP DETECTORS. REPLACED ENGINE.

Part: SWIVEL — CRACKED (RT MLG)

RIGHT MLG GREEN LIGHT DID NOT ILLUMINATE ON APPROACH, GEAR INDICATOR ON RIGHT WING VERIFIED POPPED UP. FOUND UPPER DRAG BRACE SWIVEL CRACKED. PART AOG'G FROM ATL (327002516).

Part: SPAR CAP — CRACKED (BS 1043/1163)

THE RT ENDS OF THE FS 1043 AND FS 1163 INTERMEDIATE SPAR UPPER SPAR CAPS WERE FOUND CRACKED BEYOND SRM OR LAC S/B LIMITS. THE CRACKED ENDS OF THE CAPS WERE CUT AND REMOVED AND NEW SECTIONS SPLICED IN WITH STEEL REPAIR ANGLES AND STRAPS. THE REPAIRS WERE ACCOMPLISHED PER ER/A 365153-14, REV A.

Part: BULB — FAILED (CABIN)

R3 OUTSIDE EMERGENCY LIGHT INOP. RELAMPED, OPN NML.

Part: BULB — FAILED (CABIN)

LT SIDE EMERGENCY LIGHT AT WING RT INOP. RELAMPED, CKS GOOD.

Part: TIRES — FLAT (NLG)

BOTH NOSE TIRES WENT FLAT ON TAXI./REPLACED LT. AND RT. NOSEWHEELS.

Part: TIRES — FLAT (NLG)

BOTH NOSE TIRES WENT FLAT ON TAXI./REPLACED LT. AND RT. NOSEWHEELS.

Part: MEGAPHONE — INTERMITTENT (CABIN)

F/C MEGAPHONE TEST INTERMITTENT. REPLACED MEGAPHONE.

Part: PRESSURE DECK — CRACKED (BS 380)

THE FUSELAGE HORIZONTAL PRESSURE DECK PANEL WAS FOUND WITH AND APPROX 1.0 LONG CRACK. THE CRACK IS LOCATED AT RBL 102 JUST AFT OF FS 378, AND EXTENDS DIAGONALLY INBOARD AND AFT FROM THE FORWARD EDGE OF THE PANEL AT THE EXISTING FRAME CUTOUT. THE CRACK EXTENDS OVER A LOWER INTEGRAL PANEL STIFFENERS. REMOVAL OF THE CRACK RESULTED IN A CUTOUT 1.0 BY 1.25 WIDE. THE REPAIR WAS APPROVED BY FAA/DER FORM 8110-3, DER DESIGNATION SO-831, DTD 7-11-97.

Part: SKIN — CORROSION (BS 649-669)

CORROSION WAS FOUND IN THE FUSELAGE SKIN BETWEEN FRAME STA 649 AND 669 AND UNDER STR 34. REMOVAL OF THE DAMAGED SKIN RESULTED IN A CUTOUT 4.25 X 4.25. CURROSION WAS ALSO FOUND ON THE CENTERLINE INTERNAL STRAP. REPAIRS TO THE CENTER LINE STRAP AND TEAR STRAP WERE ACCOMPLISHED PER DAL SRM 53-31-00, FIG 825. THE OTHER DAMAGE WAS REPAIRED PER DAL SRM 53-31-00, FIG 812, 815.

Part: RIB — CRACKED (LT TE FLAP)

THE LT NR 1 FLAP INBOARD END CAP AT STA ITS 27.4 HAS A CRACKED LOWER CAP ANGLE AND IS LOCATED APPROX 4 FROM THE FORWARD END. TWO STRAPS WERE USED TO REPAIR THIS PART. THE REPAIR WAS APPROVED BY FAA/DER FORM 8110-3, DER DESIGNATION SO-831.

Part: SKIN — CORRODED (BS 911)

THE FUSELAGE SKIN AT STA 911 BETWEEN STR 34 AND STR 35 WAS FOUND TO BE BULGED. CORROSION WAS THE CAUSE OF THIS BULGE. THIS WAS REPAIRED BY TRIMMING OUT THE CORROSION AND REPAIRING IT WITH A DOUBLER APPROVED BY FAA/DER FORM 8110-3, DER DESIGNATION SO-831, DATED 3-7-97.

Part: BATTERY — DISCHARGED (CABIN)

FLASHLIGHT AT 4R INOP. REPLACED BATTERY, BULB AND PLACARD.

Part: FIRE LOOP — MALFUNCTIONED (NR 1 ENGINE)

NR 1 ENGINE FIRE LIGHT AND BELLS, WENT THROUGH PROCEDURES AND SHUTDOWN, FIRED FIRE BOTTLES. INSPECTION REVEALED THAT NO FIRE HAD OCCURED. REPLACED ALL FIRE DET LOOPS, CHECKS GOOD ON ENGINE RUN FOR TWO HOURS AT DIFFERENT SETTINGS.

Part: OIL PUMP PACKING — FAILED (NR 2 ENGINE)

FLT ATTENDENTS REPORTED SMOKE AND HAZE IN CABIN ON APPROACH. AFT LAV SMOKE DET WENT OFF. REPLACED OIL PUMP PACKING, CKS GOOD.

Part: PACK — ODOR (NR 2 PACK)

ON DESCENT, ALL AFT LAV SMOKE DETECTORS SOUNDED. ALCOHOL LIKE SMELL REPORTED BY F/A. MAINT RESET AND CHECKED LAV SMOKE DETECTORS. SUSPECT NR 2 PACK AS CAUSE WHEN POWER REDUCED.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

F/C EMERGENCY TRACK LIGHTS INOP. REPLACED POWER SUPPLY ASSBLY. FOUND DURING ROUTINE CHECK ON NR 2 SERVICE CHECK.

Part: GIRT BAR — OUT OF ADJUST (R1 DOOR)

R-1 DOOR GIRT BAR WOULD NOT ENGAGE. ADJUSTED SLIDE IN DOOR MOUNTS AND GIRT BAR ENGAGES NORMALLY NOW.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

WHILE WORKING OPN NR 78100 ITEM 2 STEP 9, PACKS FAIL TO ILLUMINATE EMERGENCY LIGHTS FOR TEN MINUTES. REPLACED POWER SUPPLY, OPERATION NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

CABIN EMERGENCY LIGHTS WOULDN'T STAY ON REQUIRED TIME. REPLACED BATT PACK, OPN CKS NORMAL.

Part: PDU — FAILED (RT TE FLAP)

ON TAKEOFF AT FLAP RETRACTION FROM 10 DEGREES TO 4 DEGREES, RT FLAP INDICATION STAYED AT 10 DEGREES WHILE LEFT WING INDICATION WENT TO 4 DEGREES. REPLACING FLAP PDU AS PRECAUTIONARY. REPLACED RT TRAINING EDGE FLAP POSITION TRANSMITTER.

Part: TIRE — FAILED (LT MLG)

ON TAKEOFF, NR 2 TIRE RECAP CAME OFF AND WAS INGESTED INTO NR 1 ENGINE. REJECTED TAKEOFF AT 130 KNOTS, HAD REPORT OF SPARKS FROM NR 1 ENGINE. AT GATE FOUND FOD DAMAGE TO ENGINE. REPLACED ENGINE AND ROUTED TO SHOP. REPLACED NR 1 AND NR 2 WHEEL ASSEMBLIES.

Part: BULKHEAD — OVERSIZED HOLE (BS 1363)

DURING ACCOMPLISHMENT OF THE FS 1363 BULKHEAD REPAIR PER SI 7-69959-12, TWO FASTENER HOLES WERE OVERSIZED DUE TO FASTENER REMOVAL. THE SUBJECT FASTENERS ARE LOCATED 2 ROWS BELOW S-23. THE FWD HOLE IS .328 MAX DIAMETER AND THE AFT HOLE IS .4364 MAX DIAMETER. REPAIR APPROVAL PER DL ERA 272198-14AD.

Part: PIN — CRACKED (LT MLG)

DURING PRE-FLIGHT INSPECTION, FOUND LEFT MLG ACTUATOR LOWER LINK ATTACH FITTING PIN ASSEMBLY CRACKED. REPLACED SAME OPERATION NORMAL.

Part: WHEEL BEARING — FAILED (LT MLG)

ON ROLL INTO LETTER CHECK INSPECTION, FOUND METAL BETWEEN NR 2F WHEEL AND BRAKE ASSY. UPON FURTHER INVESTIGATION FOUND INNER AND OUTER WHEEL BEARING DISINTEGRATED AND INNER BEARING RACE SEIZED ON AXLE. AXLE WAS FOUND DAMAGED AND WAS REPLACED PER MM.

Part: ATTACH FITTING — CRACKED (FS 1103)

CABIN FLOOR FRAME 1103 IS CRACKED AT VERTICAL LEG OF ATTACH FITTING RT SIDE ABOVE FAIL SAFE ANGLE. REPAIRED PER SRM 53-12-00 PG 813-815.

Part: HYD SYS — OVER SERVICED (TAIL)

AFTER TAKOFF, HAD STRONG ODOR THROUGHOUT CABIN, ACCOMPANIED BY SMOKE ALARMS IN AFT LAVATORIES. FOUND D-SYSTEM HYDRAULIC SYSTEM OVER SERVICED CAUSING APU INTAKE AIR CONTAMIMATION. RESERVICED D-SYSTEM RETURNED TO SERVICE.