N737D

Part: HOSE — DETERIORATED (CABIN DOOR)

EN ROUTE, AT APPROX 41000 FT AGL, THE CABIN DOOR SEAL ANNUNCIATOR LIGHT ILLUMINATED. FLIGHT CREW FOLLOWED ACFT FLIGHT MANUAL AND DESCENDED BELOW 41000 FT AT WHICH POINT THE ANNUNCIATOR EXTINGUISHED. A NORMAL DESCENT, APPROACH AND LANDING WAS MADE. WHILE EXAMINING DOOR SEAL AFTER THE FLIGHT, THE AIR SUPPLY HOSE FOR THE PRIMARY DOOR SEAL WAS NOTED TO BE WEATHER CHECKED AND DETERIORATED. IT WAS REMOVED AND TESTED AND FOUND TO HAVE SMALL LEAKS. A NEW HOSE WAS INSTALLED AND SEAL OPERATION RETURNED TO NORMAL.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 75,432 hrs · 21,887 cycles

PWR SUPPLY WILL NOT ILLUMINATE OVERHEAD SIGNS AT R2 DOOR. REPLACED POWER SUPPLY.

Part: CARBON SEAL — LEAKING (APU) · airframe 75,309 hrs · 21,790 cycles

ON PUSHBACK FROM GATE WHEN STARTING ENGINES, NOTICED HOT PLASTIC SMELL. NOTIFIED BY CABIN ATTENDANTS OF CABIN FILLING WITH SMOKE AND ALL SMOKE ALARMS GOING OFF. FOUND GARLOCK SEAL FOR APU GENERATOR LEAKING OIL. REPLACED CARBON SEAL.

Part: IDG — FAILED (NR 2 ENGINE) · airframe 74,769 hrs · 21,603 cycles

DURING CLIMB NR 2 IDG LOW PRESSURE LIGHT FLICKERING. GEN DISCONNECTED, POM C/W. FOUND METAL IN NR 2 IDG CASE DRAIN AND PRESS FILTERS NR 2 IDG AND COOLER REPLACEMENT.

Part: LIGHT — MISSING (CABIN) · airframe 74,342 hrs · 21,495 cycles

FOUND EMERGENCY TRACK LIGHT AT SEAT 1C MISSING. REPLACED LAMP LENS AND SOCKET PER M/M, OPS CHECKS GOOD.

Part: SEAL — TORN (CARGO DOOR) · airframe 72,761 hrs · 21,112 cycles

CARGO BIN 2 UPPER AFT CORNER SEAL BLOWN. REPLACED SEAL.

Part: BOLT — MISSING (NR 3 ENGINE) · airframe 71,841 hrs · 20,889 cycles

DURING CLIMBOUT, NR 3 A FIRE LOOP LIGHT CAME ON WITH FIRE DET LOOP LIGHT ON P.A.P. B- LOOP SELECTED AND SHORTLY -B- LOOP LIGHT CAME ON WITH FIRE HANDLE LIGHT ON AND FIRE BELL. SELECTED BOTH WITH SAME AND A AND B LIGHTS ON. FOUND NUMBER 16 FUEL NOZZLE FWD BOLT MISSING. REPLACED SAME.

Part: SKIN — CORRODED (BS 1715)

THE FUSELAGE SKIN WAS FOUND WITH AN AREA OF CORROSION BETWEEN FS 1710 & 1720 AT STRINGER 39. THE CORROSION WAS CENTERED AROUND THE EXISTING TITANIUM TEAR STRAP. THE CORROSION WAS CUT OUT OF THE SKIN WITH A 8 X 4 CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND TRIPLER PER ER/A 368769-14, REV A.

Part: PUMP — CRACKED (C HYD SYS)

HYDRAULIC SYS C QUANTITY GAUGE SLOWLY DECREASED BELOW ONE-HALF INDICATOR MARK. SHUTOFF C1 PUMP AND C2 ATM AS PER POM. QTY CONTINUED TO DECREASE TO .125 AND LOW QTY LIGHT CAME ON. FOUND C SYS A/C PUMP LEAKING FROM CASE. REPLACED WITH BORROWED TWA PART S/N 277295. INSPECTED CASE DRAIN PRESSURE AND RETURN FILTERS CKS GOOD. A/C PUMP OPS AND LEAK CKS GOOD. RESET C1 PUMP MOTORED ENG CKS GOOD.

Part: POWER SUPPLY — INOP (L4 DOOR)

L4 EMERGENCY EXIT SIGNS INOP. REPLACED POWER SUPPLY.

Part: POWER SUPPLY — INOP (L4 DOOR)

L-4 AFT CABIN EMERGENCY LIGHTS AND L-4 EXTERIOR EMERGENCY LIGHTS FLASHING. REPLACED L-4 EMERGENCY LIGHT POWER SUPPLY, SYSTEM OPS CHECKS NORMAL.

Part: OXYGEN BOTTLE — LEAKING (COCKPIT)

COCKPIT OXYGEN BOTTLE PRESSURE READS ZERO PSI. REPLACED OXYGEN BOTTLE. LEAK CHECKED AT BOTTLE CONNECTIONS AND AT MASK, ALL OK.

Part: WINDSHIELD — DAMAGED (RT COCKPIT)

STRONG BURNING ODOR IN COCKPIT FROM F/O WINDSHIELD. REPLACED WINDSHIELD AND CONTROLLER (S/N 3506LR) CONTR (S/N 5080012).

Part: SPAR — CRACKED (BS 1163)

FS 1163 UPPER SPAR CAP WAS FOUND CRACKED AT THE RADIUS OF THE VERTICAL LEG OF THE TEE ON THE RT SIDE OF THE AIRCRAFT. THE CRACK WAS IN THE UPPER PORTION OF THE TEE AND EXTENDED THROUGH THE VERT LEG. TOTAL CRACK LENGTH WAS ABOUT 1.6. REPAIRED PER ERA 330950-14.

Part: FRAME — CORRODED (BS 1043)

FS 1043 LWR CAP FOUND TO HAVE CORROSION ON UPPER SURFACE OF FWD FLANGE FROM LBL 81.6 TO RBL 94.5. REPAIRED PER ERA 331045-14.

Part: FRAME — CRACKED (BS 1223)

CRACK FOUND RUNNING FROM ONE FASTENER HOLE TO THE ADJACENT HOLE AT WL 250 IN THE OUTER CAP OF THE LT FRAME AT STA 1223. REPAIRED PER ERA 331024-14AD.

Part: BULKHEAD WEB — CORRODED (BS 328)

CORROSION FOUND ON THE RT LWR OUTB'D CORNER OF THE 328 BLKHD WEB. REPAIRED PER ERA 331000-14AD.

Part: SKIN — CRACKED (WS 562)

CRACK FOUND ON LT WING AT WS 562, STR 10. REPAIRED PER AMOC ERA 330977-14AD.

Part: BULKHEAD WEB — CRACKED (BS1363)

CRACKS FOUND IN BULKHEAD WEB AND LWR CAP AT FS 1363 BULKHEAD. REPAIRED PER AMOC ERA 331016-14AD.

Part: SKIN — CRACKED (RT HORIZ STAB)

LT AND RT HORIZ STAB UPPER SKINS WERE BOTH CRACKED IN IDENTICAL LOCATIONS, PANEL NR 4 AT HSS78.4 AT THE END OF BLADE 31 RUN OUT. REPAIRED PER ERA 330988-14.

Part: RIB — CRACKED (WS 503/555)

THE LT WING IWS503 RIB UPPER CAP AND IWS555 RIB UPPER CAP WERE FOUND CRACKED NEAR WING STRINGERS 18, 21 AND 24. REPAIRED PER ERA330921-14.

Part: COUNTERBALANCE — FAILED (L 1 DOOR)

L-1 COUNTERBALANCE FAILED SI INSPECTION 72565-12. REPLACED COUNTERBALANCE.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

FUSELAGE EMER LIGHT AT 3L INOP. REPLACED POWER SUPPLY.

Part: DECODER — MALFUNCTIONED (CABIN)

DURING TAXI OUT, PASSENGERS REPORTED ELECTRICAL ODOR IN THE VICINITY OF SEATS 28HJ. AIRCRAFT RETURNED TO GATE. AFTER BRIEF TROUBLE SHOOTING FOUND PASSENGER SVC SYS DECODER AT 27HJ TO BE EXCESSIVELY WARM AND SMELLING OF THE SAME ELECTRICAL ODOR. REMOVED THE DECODER FROM ITS MOUNT AND AFTER COOLING, PLACED IT IN THE COCKPIT PER THE CAPTAIN'S REQUEST. REPLACEMENT PART WAS NOT AVAILABLE AT THIS STATION DEFERRED PASS SVC SYS ITEMS (READING LIGHTS, CALL LIGHT AND AIR VENT) PER MEL 25-99-06. AIR VENT AT 27H REPLACED JUST PRIOR TO FLT 1680 DEPARTURE. REF CMI 071370011.

Part: SKIN — CRACKED (WS 562)

WHILE CHASING FUEL LEAKS, MTC VISUALLY DISCOVERED A CRACK IN THE RT WING LOWER AFT SKIN PANEL AT APPROX IWS 562. THE CRACK IS APPROX 2 INCHES LONG AND EXTENDS FROM THE AFT, O/B END OF THE EXTERNAL SPLICE PLATE AT STR 10 IN THE AFT DIRECTION. STOP DRILL, COLD WORK HOLE, FINAL REAM AND EDDY CURRENT INSPECT; REPAIR DOUBLER FROM 0.125 7075-T6; REPAIR TRIPLER FROM 0.190 7075-T6; CHEM-FILM TREAT.

Part: BALLAST — FAILED (CABIN)

SMOKE AND ORANGE GLOW OBSERVED COMING FROM PANEL ABOVE RIGHT PASSENGER AISLE IN C-ZONE. HALON BOTTLE FROM 2L FIRED, SMOKE EXTINGUISHED. FOUND SHORTED BALLAST AT 25FG. DISCONNECTED BALLAST. LUMINAIRE INOP AT 25FG. FWD TO MCO. COLLARED C/B. REPLACED HALON FIRE EXTINGUISHER AT 2L.

Part: OVEN — MALFUNCTIONED (GALLEY)

F/C OVENS OVERHEATS CAUSED SMOKE ALARM IN LAV TO GO OFF. REPLACED OVEN ASSY, CHECKS GOOD.

Part: BATTERY PACK — DISCHARGED (L2 DOOR)

SECTION OF LIGHT TRACK LT SIDE FROM L2 DOOR AFT ILLUMINATES FOR ONLY A SHORT PERIOD DURING TEST. REPLACED RACK AND BATT PACK, CHKS GOOD.

Part: POWER SUPPLY — INOPERATIVE (L2 DOOR)

EMERGENCY LIGHT AT EXTERIOR OF L2 DOOR INOP. REPLACED POWER SUPPLY, CHKS GOOD.

Part: SIG CONDITIONER — MALFUNCTIONED (NR 1 ENGINE)

WHILE AT CRUISE JUST PRIOR TO DESCENT, NR 1 ENGINE FLAMED OUT, GRAVITY FEED FAILED TO KEEP UP WITH ENGINE NEEDS (TANK TO ENG). BOTH TANK PUMP LOW LIGHTS ILLUMINATED JUST BEFORE FLAMEOUT. RESTART AND SUBSEQUENT OPERATION WAS NORMAL. TANK 1A TRANSFER VALVE ON MCO AND PLAC 28-27-02A. REPLACED SIGNAL CONDITIONER. OPS CHECK GOOD.

Part: SKIN — DENTED (C1 DOOR CUTOUT)

DENT IN THE FUSELAGE SKIN WAS FOUND APPROX 15 AFT OF THE AFT EDGE OF THE C-1 DOOR OPENING BETWEEN STR 24, 25. THE DAMAGE WAS CUT OUT, FILLED AND REINFORCED.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

FOUND ON LAYOVER CHECK. R2 EMERGENCY EXIT SIGN AND F2 EMERGENCY EXTERIOR ILLUMINATION LIGHT INOPERATIVE. REPLACED POWER SUPPLY. SYSTEM CHECKS NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY LIGHTS BATTERY PACK FOUND INOPERABLE ON L/O. REPLACED SAME, CKS OK.

Part: EEL WIRES — CHAFED (CABIN)

EMERGENCY PATH LIGHT WIRES CHAFED AT 21HJ REF R/C 476. C/A REPAIRED WIRES.

Part: SENSOR — MALFUNCTIONED (NR 1 TANK)

ON CLIMBOUT AND CRUISE WITH FULL FUEL LOADS, AIRCRAFT EXPERIECNED SEVERAL INSTANCES OF EXCESSIVE FUEL VENTING OVERBOARD, RESULTING IN AIR TURNBACK. EXTENSIVE TROUBLESHOOTING DETERMINED PROBLEM WAS WITH FUEL TRANSFER SYSTEM. A FAULTY THERMISTOR AND SIGNAL CONDITIONER RESULTED IN SIGNALS THAT TRANSFERRED FUEL TO A FULL TANK, THUS CAUSING IT TO VENT THE FUEL OVERBOARD. REPLACED WAS THE HIGH LEVEL FLOAT SWITCH (PN 739400107), FOUND CONTAMINATED, THERMISTOR(FOUND INTERMITTENT)AND SIGNAL CONDITIONER, FOUND TRANSFER CIRCUIT FAULTY.

Part: GEARBOX — FAILED (NR 1 ENGINE)

DURING CRUISE NR 1 ENGINE FLAMED OUT WITHOUT ANY WARNING, HAD NO OIL PRESSURE INDICATION AFTER FLAME OUT. FOUND ACCESSORY GEARBOX FAILED. REPLACED GEARBOX OPERATION NORMAL.

Part: TRANSDUCER — FAILED (LEFT WING)

ON APPROACH AT FLAP EXTENSION. GOT A FLAP/SLAT LOCK LIGHT. HAD FULL SLATS AND LESS THAT 4 DEGREES OF FLAPS. FOUND LEFT FLAP TRANSDUCER FAULTY. REPLACED TRANSDUCER OPERATION NORMAL.

Part: ADC — MALFUNCTIONED (E/E COMPARTMENT)

DURING CRUISE, F/O INSTRUMENT WARNING FLAGS APPEARED INTERMITENTLY, ADC INSTRUMENTS FLUCTUATE. DIVERTED TO LAX. REPLACED AIR DATA COMPUTER. LEAK CHECK OK, RETURNED TO SERVICE.