N736BP

Part: RIVET — PULLED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPLACED RIVETS PULLING THROUGH KEEL BEAM LOWER SKIN AT STA BS 715 TO BS 727, LBL 6.5 AND STA BS 720 TO BS 727, RBL 6.5 IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 53-30-3, FIGURE 40. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK 383, DATED JULY 20, 2009.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPAIRED CRACK ON FORWARD ENTRY DOOR S-10L AUX INTERCOSTAL P/N 65-17684-65 UPPER HINGE TO SKIN ANGLE AT STA BS 294.5 TO BS 303.9 JUST ABOVE STR S-10L IN ACCORDANCE WITH BOEING ENGINEERING DOA APPROVED FORM 8100-9, 200907130131-0002D1, REV IR, DATED AUGUST 7, 2009 BY FABRICATION AND INSTALLATION OF HINGE INTERCOSTALS REPAIR KIT 65C38823-1. THIS DEVIATION HAS BEEN APPROVED AS AN ALTERNATE METHOD OF COMPLIANCE (AMOC) TO PARAGRAPH (L) AND (M) OF AD 2005-20-03. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 100, DATED AUGUST 10, 2009.

Part: FITTING — CHAFED (TE FLAP) · airframe 40,284 hrs · 38,146 cycles

REPAIRED WORN FITTING P/N 65-50750-12 INSIDE RT INBOARD CANOE FAIRING RT WING IN ACCORDANCE WITH FAA DER APPROVED FORM 8110-3 ASI SOLUTIONS, INC 208-1226-09-683, DATED JULY 27, 2009. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE 325, DATED JULY 29, 2009.

Part: BEAR STRAP — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

CRACKS FOUND IN FASTENER HOLES AT STA BS 303.90 IN THE BEAR STRAP AT THE UPPER AND LOWER FORWARD ENTRY DOOR HINGE CUTOUTS REPAIRED IN ACCORDANCE WITH BOEING ENGINEERING DOA APPROVED FORM 8100-9, 200907270110-0002D1, REV IR, DATED AUGUST 12, 2009, ALTERNATE METHOD OF COMPLIANCE (AMOC) FOR AD 2008-11-04. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE 479, DATED AUGUST 13, 2009.

Part: SILL — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPAIRED CRACK ON LOWER FORWARD CARGO PIT DOOR SILL IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-40-3, FIGURE 1, PAGES 1-5. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 229, DATED 07/20/09.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPAIRED DAMAGED STRINGER TO BELT FRAME CLIP AT STA BS 986.5, STR S24L BY REPLACEMENT WITH NEW P/N 69-35364U2 IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-30-02, PARAGRAPH 7, PAGE 5, AND BOEING DRAWING 65-46548, REV DD, DATED JUNE 15, 1999. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK 247, DATED JULY 22, 2009.

Part: FITTING — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPLACED CRACKED ANGLE CLIP AT STA BS 294, STR S10.5R WITH NEW P/N 65-45807U30 IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-30-2 AND BOEING DRAWING 65-45807, REV K. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 191, DATED 07/23/09.

Part: FITTING — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPLACED CRACKED ANGLE CLIP AT STA BS 294, STR S9.5R WITH NEW P/N 65-45807-34 IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-30-2 AND BOEING DRAWING 65-45807, REV K. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 192, DATED 07/23/09.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPAIRED FUSELAGE SKIN BLEND OUT AND FRAME AT STRINGER S-22R, BETWEEN STA BS 312 AND BS 285.6 IN ACCORDANCE WITH BOEING ENGINEERING DOA APPROVED FORM 8100-9, 200907210070-0003D1, REV IR, DATED AUGUST 5, 2009 BY REMOVAL OF DAMAGE FROM SKIN P/N 65-45800-1128 AND STRAP P/N 65-45808-102 AND INSTALLATION OF FABRICATED REPAIR PARTS. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 52, DATED AUGUST 10, 2009.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPAIRED CORROSION ON LOWER KEEL BEAM AT STA BS 680 - BS 685 AND BS 700 - BS 727 LBL 6.5 BY REMOVING CORROSION IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-10-1 AND 53-10-1 AND REPAIRING KEEL BEAM IN ACCORDANCE WITH FAA DER APPROVED FORM 8110-3 ASI SOLUTIONS, INC 211-1226-09-685, DATED JULY 30, 2009. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK 224, DATED AUGUST 7, 2009.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPLACED DAMAGED STRINGER TO BELT FRAME CLIP AT STA BS 986.5, STR S25L WITH NEW P/N 69-35364U2 IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-30-2, PARAGRAPH 7, PAGE 5 AND BOEING DRAWING 65-46548, REV DD, DATED JUNE 15, 1999. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 175, DATED 07/22/09.

Part: FITTING — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPLACED CRACKED ANGLE CLIP AT STA BS 294, STR S12.5R WITH NEW P/N 65-45807U30 IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-30-2 AND BOEING DRAWING 65-45807, REV K. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 190, DATED 07/23/09.

Part: FITTING — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPLACED CRACKED ANGLE CLIP AT STA BS 294, STR S11.5R WITH NEW P/N 65-45807U31 IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-30-2 AND BOEING DRAWING 65-45807, REV K. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 189, DATED 07/23/09.

Part: SKIN — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPAIR SKIN CUTOUT AT AFT R1 GALLEY ENTRANCE DOOR HINGE. REPAIRED SKIN CUTOUT FOR AFT RT ENTRANCE DOOR HINGE (R1 GALLEY) STA BS 947 BETWEEN STR S14R AND S15R IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 53-30-3, FIGURE 35 (NDT-09-0681). REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 133, DATED 07/20/09.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 40,284 hrs · 38,146 cycles

REPAIR DAMAGED STRINGER TO BELTFRAME CLIP. REPLACED DAMAGED STRINGER TO BELTFRAME CLIP AT STA BS 747, STR S26L WITH NEW P/N 69-35350-1 IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL (SRM), CHAPTER 51-30-2, PARAGRAPH 7, PAGE 5 AND BOEING DRAWING 65-46548, REV DD, DATED JUNE 15, 1999. REFERENCE KELOWNA FLIGHTCRAFT NON-ROUTINE TASK CARD 173, DATED 07/22/09.

Part: ENGINE — BIRD INGESTION (NR 1) · airframe 39,416 hrs · 37,457 cycles

INGESTED LARGE BIRD ON APPROACH TO AKU, SHUT-DOWN ENGINE AND COMPLETED MISSED APPROACH. DIVERTED TO SCC AND MADE UNEVENTFUL LANDING. REMOVED AND REPLACED NR 1 ENGINE.

Part: WIRE — BURNED (START SWITCH) · airframe 38,641 hrs · 36,872 cycles

DURING CLIMB SPARKS AND SMOKE EMITTED FROM THE AREA OF THE NR 1 START SWITCH. LOW IGNITION CB POPPED AT WHICH TIME THE SPARKS AND SMOKE CEASED. FLIGHT CREW RETURNED TO THE DEPARTURE AIRPORT FOR AN UNEVENTFUL LANDING. REPLACED SWITCH DUE TO ARCING ON CASE AND REPAIRED WIRING. INSPECTED OTHER AIRCRAFT IN FLEET NO OTHER CHAFED WIRES FOUND IN VICINITY OF THE START SWITCHES.

Part: SKIN — NICKED (ZONE 100) · airframe 38,551 hrs · 36,808 cycles

NICK STA 847 STR 21 LT. NICK AT STA 847 STR 21L FOUND TO BE BEYOND LIMITS. NICK REMOVED AND AREA AT STA 847 STR 21L REPAIRED IAW SRM 53-30-3, FIG 48.

Part: SKIN — NICKED (BS 907) · airframe 38,551 hrs · 36,808 cycles

NICK STA 907 STR 22 LT. NICK AT STA 907, STR 22L REPAIRED IAW SRM 53-30-3, FIG 48. NICK BEYOND LIMITS AND DAMAGE REMOVED. HFEC IAW NDT PART 6, 53-30-00, FIG 4 OF REPAIR AT FUSELAGE SKIN STA 907 STR 22L. NO CRACKS EVIDENT.

Part: SKIN — NICKED (ZONE 100) · airframe 38,551 hrs · 36,808 cycles

NICK STA 887 STR 24L-25L LT. DAMAGED AREA OF SKIN REMOVED AND REPAIR PLATES FABRICATED IAW SRM 53-30-3, FIG 48. INSTALLED REPAIR IAW 51-30-2.

Part: INTAKE DUCT — CORRODED (APU) · airframe 38,551 hrs · 36,808 cycles

NR481 - CORROSION AROUND AIR INLET DUCT FLANGE APU TORQUE BOX WEB BS 1064 RIGHT HAND SIDE. REPLACED AIR INLET DUCT FLANGE IN ACCORDANCE WITH BOEING SRM 51-10-1, PAGE 8, 51-30-2, FIGURES 11, 12, 13, AND 51-30-6, FIGURE 3.

Part: SKIN — CRACKED (FUSELAGE) · airframe 38,551 hrs · 36,808 cycles

NR393 - FUSELAGE SKIN CRACKED AT AIRSTAIR CONTROL HANDLE CUTOUT AT BS 378 BETWEEN STRINGERS 21-L AND 22-L. REPAIR DOUBLER FABRICATED AND INSTALLED IN ACCORDANCE WITH BOEING SB 737-53-1093.

Part: FLOORBEAM — CORRODED (ZONE 100) · airframe 38,551 hrs · 36,808 cycles

NR296-CORROSION ON FLOORBEAM UPPER FLANGE AT STA 294 AND RBL 43 TO 53. FLOORBEAM UPPER FLANGE FROM RBL 6 (EXISTING SPLICE) TO RBL 60, STA 294 REMOVED AND REPLACED IAW WITH MFG SRM 53-10-9, FIG 5, SHEET 1-5.

Part: SUPPORT BEAM — CRACKED (NLG) · airframe 38,551 hrs · 36,808 cycles

NR419 - CRACK ON NLG ACTUATOR SUPPORT BEAM AT BS 227-0 UPPER RIGHT SIDE. REPLACED NLG ACTUATOR UPPER RIGHT SIDE SUPPORT BEAM IN ACCORDANCE WITH BOEING 737 SRM 51-10-1, 53-10-2 AND 51-30-2.

Part: SKIN — GOUGED (HORIZONTAL STAB) · airframe 38,551 hrs · 36,808 cycles

NR378 - RT STABILIZER LOWER SURFACE FOUND WITH A GOUGE IN THE SKIN ON THE RIB ATTACH LOCATION AT 138.7 DEPT IS 0.037 WHICH IS OVER 50 PERCENT. DAMAGED SECTION OF SKIN ON RT STABILIZER LOWER SURFACE LOCATION 138.7 REMOVED. REPAIR DOUBLER FABRICATED AND INSTALLED IN ACCORDANCE WITH DER APPROVED DRAWING NR 73R55116228.

Part: FLOORBEAM — CORRODED (BS 328) · airframe 38,551 hrs · 36,808 cycles

NR392-CORROSION ON UPPER CHORD OF FLOORBEAM STA 328 RBL 52. FLOORBEAM REPAIRED IAW SRM 53-10-9, FIG 5, PAGE 21.

Part: SKIN — DENTED (BS 900 S17-18L) · airframe 38,551 hrs · 36,808 cycles

NR247- DENT FOUND STA 900 LT BETWEEN STRINGERS 17 AND 18. REPAIRED IAW MFG SRM 53-30-3, PAGES 253-320 AND 51-30-3, PAGE 7 AND 51-30-02.

Part: TRUNNION — WORN (LT MLG) · airframe 38,551 hrs · 36,808 cycles

WEAR DAMAGE, LT MLG FUSELAGE TO TRUNNION SUPPORT BEAM ATTACH FITTING. BLEND REPAIRED IAW MFG, FORM 8100-9, MESSAGE NR 1-515849678-6, DATED AUGUST 23, 2007.

Part: SUPPORT BEAM — CORRODED (LT MLG) · airframe 38,551 hrs · 36,808 cycles

NR279 - PITTING LEFT MAIN LANDING GEAR TRUNNION SUPPORT BEAM UPPER SURFACE (LIGHT). REPLACED LEFT MLG SUPPORT BEAM IN ACCORDANCE WITH BOEING 737 AMM 57-15-0.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 38,551 hrs · 36,808 cycles

NR291 - CORROSION ON FLOORBEAM UPPER FLANGE STA 344 LBL 48-60. REPAIRED IN ACCORDANCE WITH BOEING SRM 53-10-9, FIGURE 1.

Part: SUPPORT FITTING — DAMAGED (RT MLG) · airframe 38,551 hrs · 36,808 cycles

NR269 - WEAR DAMAGE RIGHT MAIN LANDING GEAR FUSE TO TRUNNION SUPPORT BEAM ATTACH FITTING. REPAIRED IN ACCORDANCE WITH BOEING APPROVED FAA FORM 8100-9 MESSAGE 1-515849678-6, DATED AUGUST 23, 2007.

Part: SUPPORT BEAM — CORRODED (RT MLG) · airframe 38,551 hrs · 36,808 cycles

NR270 - PITTING RIGHT MAIN LANDING GEAR TRUNNION SUPPORT BEAM UPPER SURFACE. REPLACED RIGHT MLG SUPPORT BEAM IN ACCORDANCE WITH BOEING 737 AMM 57-15-0.

Part: NUT PLATE — STRIPPED (ELEVATOR) · airframe 38,551 hrs · 36,808 cycles

NR122-LT ELEVATOR TRIM TAB IB HINGE FITTING MISSING BOLT. NEW ELEVATOR INSTALLED 12/06/06, 982 TT, 717 TC. (2) OUT OF (4) HINGE ATTACH FITTING NUTPLATES STRIPPED FROM THE FACTORY. REPLACED NUTPLATES IAW SRM 51-30-2, FIGURES 3 AND 7.

Part: FLOORBEAM — CRACKED (BS 660) · airframe 38,551 hrs · 36,808 cycles

NR228-CRACK IN FLOORBEAM AND WEB STA 660 BL0. CRACKED FLOORBEAM AND WEB AT STA 660 BL0 REPAIRED IAW MFG SB 737-57-1210, REV 1, DATED AUG 27/07.

Part: FRAME — CORRODED (BS 783 S25R) · airframe 38,551 hrs · 36,808 cycles

NR145-LIGHT CORROSION ON FRAME AT STA 783 STR 25R. REPAIRED FRAME IAW MFG MESSAGE NR 1-518342007-2, DATED AUG 1, 2007 AND PRODUCTION DRAWINGS FOR PN 65-47959-47 STRAP AND PN 65C31240-1 FRAME DOUBLER.

Part: FRAME — CRACKED (BS 616) · airframe 38,551 hrs · 36,808 cycles

NR63-CRACK ON BODY FRAME INNER CHORD BS616 RT SIDE AT STUB BEAM LOWER CHORD ATTACH (ABOVE WING BOX BL64R). DAMAGE OF BODY FRAME INNER CHORD STA 616 RT SIDE AT STUB BEAM LOWER CHORD ATTACH REMOVED IAW MFG SB 737-53-1182R1. REPAIR ANGLE INSTALLED IAW MFG SB 737-53-1182R1 AND MFG MSG NR: 1-508321689-2.

Part: VALVE — FLUTTER (FLOW CONTROL) · airframe 38,318 hrs · 36,635 cycles

AFTER TAKEOFF AT AROUND 1000 FEET VIBRATION STARTED IN FWD PART OF AIRCRAFT AND TRAVELED TO REAR OF AIRCRAFT. AFTER SHUTTING OFF ALL PACKS AND BLEEDS IT SLOWLY WENT AWAY. AIRCRAFT RETURNED TO DEPARTURE AIRPORT. AIRCRAFT INSPECTED WITH NO FAULTS FOUND AND RELEASED FOR FLIGHT TO MAINTENANCE BASE WITH SLIGHT VIBRATION NOTED IN FLOOR. FURTHER INSPECTION FOUND CRACKED E&E BAY COOLING DUCT AND CHATTERING E&E BAY FLOW CONTROL VALVE. REPLACED DUCTS AND VALVE. NO REPORTS OF VIBRATION ON SUBSEQUENT FLIGHT.

Part: BEARING — LOOSE (ROD END) · airframe 38,311 hrs · 36,632 cycles

AIRFRAME BUFFET NOTED AFTER GEAR UP ON TAKEOFF & BEFORE FLAP RETRACTION & POWER REDUCTION DURING CLIMB. THIS IS THE 2ND WRITE UP OF THIS CONDITION. PERFORMED AIRFRAME CONDITIONAL INSPECTION. REPLACED NLG GRAVEL SKI DEFLECTOR ACTUATOR DUE TO LOOSE ROD END AND REPLACED BEARING IN LEFT INBOARD GROUND SPOILER OUTBOARD ACTUATOR LINKAGE DUE TO LOOSENESS. AIRCRAFT RELEASED FOR OPERATION CHECK FLIGHT WITH NO REPORTS OF VIBRATION ON TWO TAKEOFFS DURING CHECK FLIGHT.

Part: DOOR — BINDING (NLG) · airframe 38,299 hrs · 36,620 cycles

LOUD VIBRATION AFTER TAKEOFF. VIBRATION INCREASED WITH SPEED AND DECREASED AT LOWER SPEEDS. RETURNED TO DEPARTURE AIRPORT. PERFORMED VIBRATION CONDITIONAL INSPECTION. FOUND NLG DOORS ON GRAVEL SKI EQUIPPED AIRCRAFT TO BE BINDING ON EACH OTHER. ADJUSTED PER AMM 32-22-12. AIRCRAFT RELEASED AN OPERATIONAL CHECK FLIGHT NORMAL. NO REPORT OF VIBRATION ON SUBSEQUENT FLIGHTS.

Part: SPAR — CRACKED (ELEVATOR) · airframe 37,568 hrs · 36,091 cycles

DURING INSPECTION FOUND LT ELEVATOR TAB OUTBOARD HINGE FITTING TO HAVE CONSIDERABLE FLEX. UPON FURTHER EXAMINATION FOUND ELEVATOR REAR SPAR CRACKED IN THE AREA WHERE TAB HINGE FITTING ATTACHES. AD 2006-14-07/SB 737-55A1078 HAD NOT BEEN ACCOMPLISHED PRIOR TO THIS FINDING. REPLACED ELEVATOR AND TAB WITH NEW.

Part: ACCESSORY UNIT — FAULTY (RT MLG) · airframe 37,474 hrs · 36,024 cycles

DURING DEPARTURE, UPON LANDING GEAR RETRACTION RT MLG INDICATION REMAINED RED. MOVED LANDING GEAR HANDLE TO OFF AND THEN BACK TO UP, RED INDICATOR LIGHT REMAINED ON. SELECTED GEAR DOWN AND GOT 3 GREEN AND NO RED. RETURNED TO ANC WITH NORMAL LANDING. WITH AIRCRAFT ON JACKS FOUND LANDING GEAR ACCESSORY UNIT TO BE FAULTY. REPLACED LANDING GEAR ACCESSORY UNIT AND ALL OPERATIONS CHECK NORMAL. AIRCRAFT RELEASED WITH NORMAL OPERATIONS ON SUBSEQUENT FLIGHTS.

Part: CAP — INOPERATIVE (CHECK VALVE)

AFTER COMPLETING 2 FLIGHTS, (A) HYDRAULIC SYSTEM BECAME INOPERATIVE. A LARGE AMOUNT OF FLUID WAS NOTED ON THE GROUND UNDER THE LT WHEEL. UPON FURTHER INVESTIGATION IT WAS NOTED THAT THE RT (A) SYSTEM MODULE CHECK VALVE INSTALLATION CAP HAD SHEARED IN THE MODULE CHECK VALVE INSTALLATION CAP HAD SHEARED IN THE MODULE PACKAGE, ALLOWING A LARGE QUANTITY OF HYDRAULIC FLUID TO BE LOST. DO NOT HAVE A PROBABLE CAUSE OR ANY RECOMMENDATIONS. (K)

Part: SKIN — CRACKED (ZONE 600) · airframe 36,560 hrs · 35,364 cycles

RT WING LEADING EDGE CRACKED AT NR 5 SLAT UPSTOP CUTOUT JUST OB OF THE ACTUATOR. REPAIRED BY INSTALLING INTERNAL STAINLESS DOUBLER IAW DER APPROVED 8110, REPORT NR SCS-5740-001SR.

Part: ACTUATOR — BYPASSING (LT MLG UPLOCK) · airframe 35,823 hrs · 34,769 cycles

AFTER TAKE-OFF FROM ANC, GEAR WAS SELECTED UP, LT MAIN WOULD NOT INDICATE UP AND LOCKED. AIRCRAFT RETURNED FOR AN UNEVENTFUL LANDING. DETERMINED LT UPLOCK ACTUATOR WAS BYPASSING FLUID. REPLACED UPLOCK ACTUATOR. SUBSEQUENT GEAR SWING AND FLIGHT CHECK WERE SATISFACTORY.

Part: SENSOR — OUT OF ADJUST (MLG) · airframe 35,682 hrs · 34,654 cycles

AFTER TAKEOFF THE LANDING GEAR LEVER WOULD NOT MOVE TO THE GEAR UP POSITION. GEAR WAS LEFT DOWN AND AIRCRAFT RETURNED TO DEPARTURE AIRPORT AND MADE A UNEVENTFUL OVERWEIGHT LANDING. TROUBLE SHOOTING FOUND NO FAULTS WITH THE WIRING HARNESS ASSOCIATED WITH THE LANDING GEAR CONTROL SYSTEM. FOUND GROUND SAFETY SENSOR ACTUATOR GAP OUT OF ADJUSTMENT. ADJUSTED GAP, GROUND SPOILER INTERLOCK. OPS CHECKED SAFETY SENSOR, GROUND SPOILER AND LANDING GEAR EXTENSION & RETRACTION SYSTEMS IAW B737 AMM.

Part: FLOOR SUPPORT — DAMAGED (STA797,STR 8R) · airframe 35,678 hrs · 34,650 cycles

DURING 24 MONTH INSPECTION FOUND DAMAGE TO CARGO FLOOR SUPPORT STRUCTURE AT STA 797 STR 8R. ALLOWABLE DAMAGE .090 IAW SRM 63-10-1 FIG 5, DAMAGE - .340. REPAIRED DAMAGE IAW SRM 53-10-5, FIG 6.

Part: SKIN — GOUGED (STA910,STR16) · airframe 35,678 hrs · 34,650 cycles

DURING 24 MONTH INSPECTION FOUND GOUGE IN SKIN AT STA 910, STR 16 TO BE OUT OF LIMITS DUE TO SKIN THICKNESS AFTER BLENDING. REPAIRED GOUGE IN SKIN AT STA 910, STR 16 IAW B737 SRM 53-30-3 FIG. 18.

Part: LIGHT — INOPERATIVE (EMERGENCY LIGHTS) · airframe 35,653 hrs · 34,631 cycles

EMERGENCY TRACK LIGHTING AT ROW 17 AFT AND L2 GROUND LEVEL EXIT LIGHT INOP. REMOVED AND REPLACED ILLUMINATION AISLE STRIP AT ROW 19 IAW 33-51-191. OPERATIONAL CHECK GOOD.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 34,450 hrs · 33,620 cycles

L2 DOOR EMERGENCY LIGHT INOP. CHANGED OUT BATTERY PACK. OPS CHECKED GOOD.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHT) · airframe 34,275 hrs · 33,473 cycles

DURING PREFLIGHT INSPECTION EMERGENCY LIGHTS AT ROWS 10, 11, 15, 16 AND 18 INOPERATIVE. REPLACED BATTERY PACKS AT STATIONS 753 LT AND 629 RT. OPS CHECK NORMAL.

Part: WIRE — DAMAGED (EMERGENCY LIGHT) · airframe 33,778 hrs · 33,068 cycles

AFT LEFT EMERGENCY EXIT LIGHT UNDER FA JUMP SEAT INOPERATIVE. REPAIRED WIRE TO LIGHT ASSEMBLY. LIGHT OPS NORMAL WITH EMERGENCY LIGHTS TURNED ON.

Part: SKIN — GOUGED (ZONE 100) · airframe 33,329 hrs · 32,698 cycles

DURING AN A-3 CHECK FOUND A GOUGE IN BOTTOM OF FUSELAGE SKIN .375 INCH LONG BY .25 INCH. INSPECTED AREA FOR CRACKS USING HFEC. NONE DETECTED. REPAIRED GOUGE AREA WITH FLUSH PATCH PER B737 SRM 53-30-3.

Part: SKIN — DENTED · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK, AFTER SKIN REPLACEMENT, FOUND DENT WITH GOUGE ON INNER SKIN AT BS 933.5 BETWEEN STR 22R AND 23R. REPAIRED DENT IAW B737 SRM 53-30-3, 53-30-1, 51-30-2 AND 51-10-2.

Part: SKIN — DENTED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND NUMEROUS DENTS IN FUSELAGE SKIN BETWEEN STR 18R & 20R STA 850 TO 890 THAT WERE OUT OF LIMITS IAW B737 SRM 53-30-1. REMOVED AND REPLACED SKIN PANEL AT STA 727 TO 907 STR 14R TO STR 20R IAW B737 SRM 51-30-2, 51-10-2.

Part: SKIN — DAMAGED (FUSELAGE)

DURING D CHECK INSPECTION CUSTOMER REQUEST TO REMOVE AND REPLACE SKIN ASSY P/N 65C36745-100 LOCATED AT BS 727 TO 907 STR 20R TO 25R DUE TO PREVIOUS REPAIRS. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2.

Part: SKIN — DENTED (CARGO DOOR) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION CUSTOMER REQUEST TO REMOVED AND REPLACED AFT CARGO DOOR SKIN DUE TO DENTS AND DINGS. REMOVED AND REPLACED IAW B737 SRM 51-30-2, 51-30-5, MM 57-31-0.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION CUSTOMER REQUEST TO REMOVE AND REPLACE SKIN ASSY P/N 65C35843-18 LOCATED AT BS 360 TO 540 STR 19R TO 26R DUE TO PREVIOUS REPAIRS. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2.

Part: BEAM — DENTED (VERTICAL STAB) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND DENT IN RT TRAILING EDGE BEAM OF VERTICAL STABILIZER AT APPROX STA 17.25. REFORMED RT TRAILING EDGE BEAM IAW EA 5530-01100 AND EA 10007.

Part: STRINGER — GOUGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND STRINGER 20R AT BS 500 GOUGED BEYOND ALLOWABLE LIMITS. REMOVED DAMAGED AREA OF STINGER, FABRICATED AND INSTALLED REPAIR IAW B737 SRM 53-10-2, 51-10-3, 51-10-2, 51-10-3 AND MM 51-21-171.

Part: SEAT TRACK — GOUGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND SEAT TRACK AT STA 540 TO 727, RBL 45 GOUGED ALONG CENTER AND TOP FLANGES IN NUMEROUS PLACES. REMOVED AND REPLACED SEAT TRACK IAW B737 SRM 51-30-2, 51-30-5 AND 51-10-2.

Part: BEAM — GOUGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND LONGITUDINAL BEAM AT STA 707, LBL 24, GOUGED AT FASTNER HOLE INBOARD FLANGE, WL 205. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR STRAPS IAW SRM 53-10-1, 53-10-2, EA 53-10-02240 AND AAR EA 05-53-EA239.

Part: SKIN — GOUGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND SKIN AT STA 846 BETWEEN STRINGER 24L AND 25L TO HAVE A SMALL DENT AND GOUGE. REMOVED DAMAGED AREA AND REPAIRED IAW B737 SRM 53-30-3, 53-30-2 AND 51-10-2.

Part: STRINGER CLIP — DAMAGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND DRILL BIT DAMAGE FROM A PREVIOUS REPAIR TO STRINGER CLIP AT STA 380 AND STRINGER 2 R. REMOVED AND REPLACED STRINGER CLIP IAW SRM 51-30-2 AND 51-10-1.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND CORROSION ON FLOORBEAM UPPER CAP AT STA 344 FROM LBL 30 TO RBL 30. REMOVED AND REPLACED DAMMAGED CAP IAW SRM 51-30-2, 51-10-6, 51-10-2 AND 53-10-1.CORROSION LEVEL 1

Part: SEAT TRACK — GOUGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND NUMEROUS GOUGES IN CENTER AND TOP OF SEAT TRACK BETWEEN BS 540 - 727, LBL 24. REMOVED AND REPLACED SEAT TRACK BETWEEN BS 540 TO 727 IAW SRM 51-30-2, 51-10-2 AND MM 51-21-0.

Part: SEAT TRACK — GOUGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND BARE METAL AND GOUGES ON SEAT TRACK BETWEEN STAS 727 AND 947, RBL 45.5. REMOVED AND REPLACED SEAT TRACK IAW SRM 51-10-1, 51-30-2, 51-10-2 AND MM 51-21-171.

Part: SKIN — SCRATCHED (HORIZONTAL STAB) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND FOUND SEVERAL SCRATCHES IN LOWER AND UPPER SURFACES OF THE RT IB HORIZONTAL STABLIZER LEADING EDGE. REMOVED AND REPLACED RT IB HORIZONTAL LEADING EDGE IAW SRM 51-30-2.

Part: SEAT TRACK — GOUGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND GAUGES IN SEAT TRACK ALONG CENTER AND TOP FLANGES BETWEEN STA 540 AND 727. REMOVED DAMAGED SEAT RACK AND REPLACED IAW SRM 53-10-1, 51-30-2 AND 51-10-2.

Part: STINGER — MISREPAIRED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION ELECTED TO REPLACE STINGER 24R FROM STA 500 TO 540 BECAUSE OF A PERVIOUS APPROVED REPAIR. REPLACED STRINGER IAW B737 SRM 51-10-2 AND MM 51-21-171.

Part: STRINGER — MISREPAIRED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION ELECTED TO REPLACE STRINGER 23R BETWEEN STA 500 AND 540 DUE ELIMINATE A PREVIOUS REPAIR. REMOVED AND REPLACED STRINGER IAW WITH B737 SRM 51-30-2, 51-10-2 AND MM 51-21-171.

Part: STRINGER — DAMAGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND SEVERAL ELONGATED HOLES IN STRINGER 23R BETWEEN STA 360 AND 440. REMOVED AND REPLACED STRINGER BETWEEN STA 360 AND 440 IAW SRM 51-30-2, 51-10-2 AND MM 51-21-171.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND STRINGER CLIP AT STA 360, STINGER 4 L CRACKED .25 INCH. REPLACED CLIP IAW SRM 51-10-1 AND 51-30-2.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND STINGER CLIP AT STA 360 5L WITH A .25 INCH CRACK. REPLACED CLIP IAW B737 SRM 51-10-1 AND 53-30-2.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND STRINGER CLIP AT STA 597 STINGER 8R CRACKED .3 INCH. REMOVED AND REPLACED IAW B737 SRM 51-10-1 AND 51-30-2.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND STINGER CLIP AT STA 616 AND STRINGER 8L WITH 1 FT CRACK. REMOVED AND REPLACED IAW MFG SRM 51-10-1 AND 51-30-2.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION FOUND STRINGER CLIP AT STA 616, STRINGER 8R WITH 1.5 INCH CRACK. REMOVED AND REPLACED CLIP IAW WITH MFG SRM 51-10-1 AND 51-30-2.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

SHEAR TIE AT STATION 616 BETWEEN STINGERS 7 AND 8L HAS .2500 INCH CRACK. REMOVED AND REPLACED SHEAR TIE IAW MFG SRM 51-10-1 AND 51-30-2.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 32,963 hrs · 32,402 cycles

DURING D CHECK INSPECTION CUSTOMER REQUESTED TO REMOVE AND REPLACE SKIN ASSY P/N 65C36745-116 LOCATED AT BS 908 TO 1016STG 20R TO 25R DUE TO PREVIOUS REPAIRS. REMOVED AND REPLACED IAW B737 SRM 51-30-2

Part: CHANNEL — CHAFED (ZONE 100) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND LT MLG WHEEL WELL CHANNEL AT 698 CHAFFED. REMOVED AND REPLACED LT WHEEL WELL CHANNEL PER SRM 51-30-2 STEP 9A-D. MINOR REPAIR.

Part: SKIN — GOUGED (NR 1 NACELLE) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK FOUND NR 1 ENGINE OUTBOARD COWL INNER SKIN GOUGED 24 INCHES FROM FWD END. REMOVED DAMAGE, FABRICATED REPAIR PARTS AND INSTALLED REPAIR PARTS PER SRM 54-30-1 & 53-30-3 MINOR REPAIR

Part: GUSSET — CRACKED (FUSELAGE) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND FRAME GUSSET AT STA 520, STR 19L FWD SIDE CRACKED IN FRAME RADIUS. REMOVED FRAME GUSSET AND CRACKED ANGLE, FABRICATED REPLACEMENT ANGLE AND REINSTALLED ANGLE GUSSET PER 51-30-2 & 51-10-2. MAJOR REPAIR.

Part: FRAME — DENTED (ZONE 100) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND STA 727B FRAME DENTED STR 22R - 23R. REMOVED DAMAGE, FABRICATED REPAIR DOUBLER AND INSTALLED PARTS PER SRM 51-40-3, PG 1, 2, 3 & 5. MAJOR REPAIR.

Part: FRAME — MISINSTALLED (ZONE 100) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND A FRAME SEGMENT IN AFT LT MLG WHEELWELL STA 726 LBL 36 FOR CLOSEOUT PANEL THAT HAS A DOUBLE DRILLED HOLE. REMOVED AND REPLACED FRAME SEGMENT PER SRM 51-30-2 STEP 9A-D. MINOR REPAIR.

Part: FRAME — DENTED (ZONE 100) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND AT STA 727A FRAME DENTED ON IB FLANGE STR 24L. REMOVED DAMAGE, FABRICATED REPAIR DOUBLER AND REINSTALLED REPAIR PARTS PER SRM 51-40-1, FIG. 1. MAJOR REPAIR.

Part: FRAME — DENTED (ZONE 100) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTIONS FOUND AT STA 767 FRAME DENTED AT STR 22R. REMOVED DAMAGE, FABRICATED REPAIR DOUBLER AND INSTALLED REPAIR PARTS PER SRM 51-40-3 FIG 1. MAJOR REPAIR

Part: GUSSET — GOUGED (WING) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND NUMBER TWO FIXED FAIRING NR 3 RIB GUSSET GOUGED. REMOVED, FABRICATED AND INSTALLED # 3 RI GUSSET PER SRM 54-30-1 & 51-30-2. MINOR REPAIR.

Part: BRACKET — CRACKED (FUSELAGE) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND THRESHOLD BRACKET CRACKED BS 807, RBL 22 IN AFT CARGO. REMOVED DAMAGED BRACKET AND INSTALLED NEW PER SRM 51-30-2. MAJOR REPAIR.

Part: ANGLE — BROKEN (NR 1 NACELLE) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND NR 1 I/B FIXED FAIRING'S NR 12 RIB ANGLE BROKE. REMOVED, FABRICATED AND INSTALLED ANGLE ON NR 12 RIB PER SRM 54-10 & 51-30-2. MINOR REPAIR.

Part: GUSSET — GOUGED (WING) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND NUMBER ONE O/B FIXED FAIRING UPPER AFT GUSSET GOUGED. REMOVED, FABRICATED AND INSTALLED GUSSET PER SRM 54-10-2 & 51-30-2. MINOR REPAIR.

Part: ANGLE — BROKEN (FAIRING) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND NR 2 ENGINE INBOARD FIXED FAIRING'S 12TH RIB UPPER ANGLE BROKE. REMOVED, FABRICATED AND INSTALLED ANGLE AND GUSSET ON NR 2 I/B FIXED FAIRING PER SRM 51-30-2. MINOR REPAIR.

Part: SKIN — WORN (PAX DOOR) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK REPLACED SMALL OUTER SKIN PANEL FWD OF L-1 DOOR BETWEEN HINGES THAT HAD A PREVIOUS REPAIR OF A HOLE IN THE SKIN WITH A EXTERNAL DOUBLER. REMOVED AND REPLACED PER SRM 51-30-2, 51-20-1. MAJOR REPAIR.

Part: INTERCOSTAL — GOUGED (NR 2 NACELLE) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND NR 2 ENGINE I/B FIXED FAIRING GOUGED ON INNER UPPER SURFACE 16 INCHES FROM FWD END. REMOVED AND REPLACED DAMAGED ANGLE PER SRM 51-30-2. MINOR REPAIR.

Part: SKIN — CHAFED (RT TE FLAPS) · airframe 32,285 hrs · 31,855 cycles

RT OUTBOARD FORE FLAP CHAFED INBOARD END 4 INCHES FROM INBOARD END ON LEADING EDGE. REPLACED CHAFFED SKIN PER SRM 57-50-1 & 51-30-2. MINOR REPAIR.

Part: BRACKET — CRACKED (NR 1 NACELLE) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND NR 1 ENGINE INLET COWL AFT FACE BRACKET CRACKED AT 5 O'CLOCK POSITION. REMOVED, FABRICATED AND INSTALLED BRACKET ON #1 ENGINE INLET COWL PER SRM 51-20-01 & 51-30-2. MINOR REPAIR.

Part: STANCHION — CRACKED (FUSELAGE) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND FWD CARGO BAY STANCHON CRACKED. REPLACED STANCHON PER SRM 51-30-2. 51-10-3, MINOR REPAIR.

Part: SLIDE — TORN (L2 DOOR) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION WHILE PERFORMING L2 ESCAPE SLIDE TEST PER TASK CARD SLIDE DEPLOYED, INFLATED THEN DEFLATED BECAUSE OF TORN SEAM.

Part: BRACKET — CRACKED (FUSELAGE) · airframe 32,285 hrs · 31,855 cycles

DURING C CHECK INSPECTION FOUND CRACKED BRACKET IN FWD CARGO COMPARTMENT BAY. REPLACED BRACKET PER SRM 51-30-2, 51-10-3. MINOR REPAIR.

Part: MOTOR — INOPERATIVE (GASPER FAN) · airframe 32,143 hrs · 31,745 cycles

FLIGHT CREW NOTICED A ELECTRICAL ODOR IN THE CABIN AFTER FLIGHT ATTENDENT ADJUSTED SIDE WALL LIGHTING INTENSITY. CABIN LIGHTING AND GALLEY POWER WERE SWITCHED OFF AND ODOR DIMINISHED. UPON LANDING TECHNICIANS FUNCTIONED CHECKED ALL LIGHTS, GALLEY EQUIPMENT AND PACS, WITH NO ABNORMAL INDICATIONS. GASPER FAN C/B WAS FOUND POPPED. BREAKER WOULD NOT RESET. REPLACED GASPER FAN AND OPS CHECKED NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 31,744 hrs · 31,416 cycles

"R1 EMERGENCY DOOR (OVERHEAD) STAYS LIT FOR ONLY 20 SEC." REPLACED BATTTERY PACK. CHECKED GOOD REF MM 33-51-01.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,030 hrs · 30,825 cycles

CORROSION ON FLOORBEAM BS 294.5, LBL12, WL208 CUT OUT AND REPLACED CORRODED SECTION OF FLOORBEAM PER SRM 53-10-2 & 53-10-9.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,030 hrs · 30,825 cycles

CORROSION ON FLOOR BEAM B.S.312 LBL 12 TP RBL 12 WL 208. REMOVED CORROSION, FOUND OUT OF LIMITS PER SRM 53-10-1 FIG. 1. FABRICATED REPAIR PARTS, COMPLETED REPAIR TO B.S. 312 FLOOR BEAM PER SRM 53-10-9 FIG. 5.

Part: SKIN — GOUGED (FUSELAGE) · airframe 31,030 hrs · 30,825 cycles

GOUGE ON FUSELAGE SKIN AT B.S. 791. 6 INCHES BELOW STR. 23 RIGHT. BLENDED GAUGE .028 REMAINING OUT OF LIMITS. REPAIRED IAW SRM 53-30-3 FIG. 46.

Part: COVER — BROKEN (PAX DOOR) · airframe 30,579 hrs · 30,453 cycles

"EXTREMELY LOUD AIR LEAK FROM L1 DOOR. RETURNED TO PANC." INSP FOUND L-1 DOOR LOWER HINGE TOP TRIM PIECE HAD BROKEN LOOSE AND JAMMED IN DOOR HINGE. REPLACED HINGE FLAP ASSY. PRESS A/C NO LEAKS.

Part: LINE — CHAFED (HYD SYSTEM) · airframe 30,386 hrs · 30,295 cycles

DURING NORMAL CRUISE FLIGHT LEFT "A" SYSTEM HYDRAULIC LOW PRESSURE LIGHT ILLUMINATED, LEFT "A" SYSTEM PUMP TURNED OFF AND NOTICED QUNTITY WAS LOW, THEN "A" SYSTEM RIGHT SIDE STARTED TO FLUCUATE AND SHUT DOWN WITH RETURN TO ANC. INSPECTION FOUND PRESSURE LINE CHAFFED THRU AT GENERATOR BLAST TUBE SUPPORT JUST AFT OF PUMP. REPLACE LINE. AND ADDED CLAMP STAND OFF. REPLACED CASE DRAIN FILTER WHICH WAS FOUND CLEAN. OPS AND LEAK CHECKED GOOD. REFILLED HYD SYSTEM. REF. 29-11-41.

Part: DISPLAY — FAILED (COCKPIT) · airframe 30,016 hrs · 29,982 cycles

CAPTAINS 5 ATI EHSI FAILED IN CRUISE FLIGHT. INSTUMENT DISPLAY WAS STILL PRESENTED, BUT WAS NON-FUNCTIONAL WITH A "DU FAILURE" ANNUNCIATOR LIT. REPLACEMENT UNIT CORRECTED THE PROBLEM.

Part: INDICATOR — FAILED (COCKPIT) · airframe 29,725 hrs · 29,756 cycles

DURING NORMAL CRUISE FLIGHT, 45 MINUTES INTO THE FLIGHT, THE FIRST OFFICIERS 5ATI EHSI WENT BLACK, FLICKERED BACK ON MOMENTARILY A FEW TIMES AND THEN STAYED BLACK. THIS WAS A NEW DISPLAY ON ITS FIRST FLIGHT.

Part: SKIN — CRACKED (FUSELAGE)

DURING C CHECK INSPECTION, FOUND A SKIN CRACK AT AFT ENTRY DOOR (L2) CUTOUT (LOWER).

Part: SKIN — CRACKED (FUSELAGE) · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK INSPECTION FOUND SKIN DAMAGE/CRACK AT APU DOOR AFT HINGE CUTOUT.

Part: SKIN — CRACKED (FUSELAGE) · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK INSPECTION, FOUND SKIN DAMAGE/CRACK AT THE FORWARD APU DOOR HINGE CUTOUT.

Part: SKIN — CRACKED (FUSELAGE) · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK INSPECTION, FOUND A CRACK IN SKIN AT UPPER HINGE CUTOUT ON THE FORWARD GALLEY DOOR.

Part: SKIN — CRACKED (FUSELAGE) · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK INSPECTION, FOUND A CRACK IN THE FORWARD GALLEY DOOR (R1) EXTERIOR SKIN AT LOWER HINGE CUTOUT CRACKED AT UPPER CORNER.

Part: BEAM — CORRODED (LT MLG) · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK INSPECTION, FOUND THE LEFT MLG BEAM HAS SEVERAL AREA OF LEVEL 1 CORROSION ON LOWER SURFACE AT PANEL MOUNTING HOLES.

Part: ANGLE — CORRODED (FUSELAGE) · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK INSPECTION, FOUND LEVEL 1 CORROSION ON ANGLE.

Part: SHEAR TIE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK, FOUND CORROSION ON SHEAR TIE.

Part: FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK INSPECTION, FOUND CORROSION ON FRAME.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 29,717 hrs · 29,749 cycles

DURING C CHECK INSPECTION, FOUND CORROSION ON STRINGER.

Part: LENS — BROKEN (CABIN) · airframe 29,659 hrs · 29,706 cycles

OVERHEAD ENERGENCY LIGHT ROW 2 IS BROKEN NOTE: LENS ONLY BROKEN. REPLACED UNIT P/N 10-1042-5. EMER LT OPS CK GOOD.

Part: GUIDE — OUT OF ADJ (R2 DOOR) · airframe 29,375 hrs · 29,493 cycles

R2 DOOR HANDLE HARD TO OPERATE, HANDLE LOOSE. ADJUSTED GUIDE ARM ADJUSTMENT FITTING OF UPPER HINGE ASSEMBLY. DOOR TESTED OKAY. REF. AMM 52-41-0. (X)

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 28,739 hrs · 28,961 cycles

DURING TESTING, FOUND THE EXIT SIGN LIGHTING INOPERATIVE ABOVE AFT RIGHT SERVICE DOOR AND RIGHT OVERWING EXIT. REPLACED BATTERY PACK FOR BOTH LIGHTS AND OPERATIONAL CHECKED GOOD. (X)

Part: STRUT — DISCHARGED (NLG) · airframe 28,456 hrs · 28,718 cycles

AFTER TAKEOFF AND GEAR RETRACTION, NOSE GEAR FAILED TO INDICATE UP AND LOCKED. AIR NOISE CONFIRMED GEAR NOT UP AND LOCKED. AIRCRAFT RETURNED TO DEPARTURE AIRPORT. INSPECTION CONFIRMED NOSE GEAR WAS FLAT, WITH NO SIGNS OF FLUID LEAKAGE. NITROGEN SERVICING SCHRADER VALVE WITH ORING WAS REPLACED. RESERVICED STRUT WITH FLUID AND NITROGEN. NOSE GEAR WAS OPERATIONALLY RETRACTION TEST GOOD. AIRCRAFT RELEASED FOR FLIGHT WITH NO REOCCURANCE OF PROBLEM. NOTE: THIS AIRCRAFT IS EQUIPPED WITH A NOSE GEAR GRAVEL DEFLECTION SKI.

Part: WIRE — CHAFED (APU BAY) · airframe 28,422 hrs · 28,689 cycles

LEFT HAND WING/BODY OVERHEAT INDICATION. FOUND CHAFED SHORTED WIRE AT D-866 IN APU COMPARTMENT. REPLACED SAME AND OPS CHECKED PER MAINTENANCE MANUAL 26-18-0.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 28,351 hrs · 28,626 cycles

ON CABIN PREFLIGHT, FOUND TRACK LIGHT INOP AT FIRST FOUR ROWS. CLEANED MOISTURE FROM LIGHT TRACK AND REPLACEMENT OF POWER SUPPLY. OPERATIONAL CHECK OK. SUSPECT MOISTURE TO BE THE ROOT CAUSE.

Part: BATTERY PACK — INOPERATIVE (OVERWING EXIT)

DURING CABIN PREFLIGHT, EMERGENCY EXIT LIGHTS INOPERATIVE AT OVERWING EXIT AREA. REPLACED BATTERY PACK ADJACENT TO LEFT OVERWING EXIT DOOR. (M)

Part: OXYGEN HOSE — BROKEN (CABIN)

DURING A FLEET CAMPAIGN, MECHANICS FOUND 2 EACH OXYGEN HOSE ASSYS, P/N 417N3138-1 AND DASH 2 TORN OR BROKEN. THE DAMAGED AREA OF THE HOSE WAS JUST DOWNSTREAM OF THE OXYGEN GENERATOR IN THE OVERHEAD PASSENGER SERVICE UNITS. THE BOEING CO WAS INFORMED. THEY REFERRED TO SL 737-SL-35-009-A.

Part: OXYGEN HOSE — BROKEN (CABIN)

DURING A FLEET CAMPAIGN, MECHANICS FOUND 2 EACH OXYGEN HOSE ASSYS, P/N 417N3138-1 AND DASH 2 TORN OR BROKEN. THE DAMAGED AREA OF THE HOSE WAS JUST DOWNSTREAM OF THE OXYGEN GENERATOR IN THE OVERHEAD PASSENGER SERVICE UNITS. THE BOEING CO WAS INFORMED. THEY REFERRED TO SL 737-SL-35-009-A.