N77204

Part: DNLOCK ACTUATOR — INOPERATIVE (NLG)

THE LANDING GEAR WAS EXTREMELY STIFF DURING RETRACTION FROM UP TO OFF WITH NO NOTICEABLE DETENT AT OFF. THE NOSE GEAR EXTENDED APPROXIMATELY 12 TO 15 SECONDS AFTER MAINS. MAINTENANCE REMOVED AND REPLACED THE NLG LOCK ACTUATOR IAW MM 32-33-21 PAGE 401. THE GEAR WAS SWUNG AND LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: LINE — CHAFED (NR 2 ENGINE)

LOST A-SYSTEM HYDRAULICS IN FLIGHT. REPLACED NUMBER 2 ENGINE HYDRAULIC SUPPLY LINE AT RIGHT WING ROOT.

Part: THERMO VALVE — INOPERATIVE (RIGHT)

THE RT PACKED TRIPPED AT 6,000 FEET LEAVING EWR AND SMOKE BEGAN TO ENTER THE CABIN. SHORTLY AFTERWARDS THE BLEED TRIPPED. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. THE 450 DEGREE THERMO VALVE WAS REMOVED AND REPLACED, AN ENGINE BLEED AIR COMPRESSION TEST WAS PERFORMED IAW MM 21-11-0. THE ENGINES WERE RUN FULL POWER WITN NO PACK OR BLEED TRIP OR SMOKE.

Part: STIFFENER — CRACKED (RT WING)

INSPECTION FOUND A 2 INCH CRACK IN RT WING VERTICAL STIFFENER AT STRINGER 13R. THE STIFFENER WAS REPAIRED IAW ECRA 5710-01773 AND IN REFERENCE TO BOEING DRAWING 65C34533.

Part: FLOORBEAM — CORRODED (BS 328)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 328, BL 0 TO RBL 55. A FLOORBEAM WAS FABRICATED AND INSTALLED IAW SRM 51-10-3.

Part: SPAR — TORN (LT HORIZ STAB)

INSPECTION FOUND A 3 BY .375 INCH TEAR IN LOWER FLANGE OF LT HORIZONTAL STABILIZER FORWARD LEADING EDGE SPAR. THE TEAR WAS LOCATED THREE FEET FROM OUTBOARD EDGE. A FILLER AND DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW SRM 55-10-5, FIGURE 1.

Part: SKIN — CRACKED (BS 745)

INSPECTION FOUND A 2.25 INCH CRACK IN RT FUSELAGE SKIN AT STA 745 BETWEEN STRINGERS 15R AND 16R. THE CRACKED AREA WAS REMOVED AND A DOUBLER WAS INSTALLED IAW SRM 51-30-2.

Part: SUPPORT — CORRODED (BS 312-328)

INSPECTION FOUND CENTER FLOORBEAM SUPPORT CORRODED UNDER PANEL NR 8 BETWEEN STA 312 AND 328. A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 53-10-2.

Part: SKIN — CORRODED (LT WING)

INSPECTION FOUND LT WING ROOT LOWER SKIN PANEL CORRODED. THE SKIN WAS REPAIRED IAW ECRA 5730-01471.

Part: HYD LINE — BROKEN (NR 4 SLAT ACT)

THE A-HYDRAULIC SYSTEM PRESSURE AND QUANTITY DROPPED TO ZERO WHEN GEAR WAS LOWERED ON FINAL APPROACH TO CLE. THE FLAPS WERE LOWERED TO 15 DEGREES ELECTRICALLY AND THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 4 SLAT ACTUATOR HYDRAULIC LINE BROKEN. THE LINE WAS REMOVED AND REPLACED. BOTH THE NR 1 & NR 2 ENGINE DRIVEN HYDRAULIC PUMPS WERE REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: FIRELOOP — MALFUNCTIONED (NR 1 ENGINE)

THE NR 1 ENGINE FIRE WARNING LIGHT AND BELL ACTIVATED DURING CLIMB OUT OF EWR. BOTH FIRE BOTTLES WERE DISCHARGED, THE NR 1 ENGINE WAS SHUTDOWN, AND AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 1 ENGINE BOTTOM FIRE DETECTOR LOOP AT FAULT. THE FIRE DETECTOR LOOP AND THREE CONNECTORS WERE REMOVED AND REPLACED. BOTH FIRE BOTTLES WERE REMOVED AND REPLACED. THE NR 1 ENGINE WAS RUN AT TAKEOFF POWER AND ALL INDICATIONS WERE NORMAL.

Part: HYD LINE — CHAFED (RT REAR SPAR)

THE A-SYSTEM HYDRAULIC QUANTITY DROPPED TO ZERO WHILE EN ROUTE. THE HYDRAULIC LOSS CHECKLIST WAS COMPLIED WITH AND THE AIRCRAFT WAS DIVERTED TO GSO WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE A-SYSTEM HYDRAULIC SUPPLY LINE IN THE RT REAR SPAR AREA WITH A HOLE CHAFED THROUGH IT. THE SUPPLY LINE WAS REMOVED AND REPLACED. IN ADDITION, THE HYDRAULIC LINE IT RUBBED AGAINST WAS REPLACED AS A PRECAUTIONARY MEASURE. LEAK CHECKS WERE GOOD.

Part: ACTUATOR — INOPERATIVE (NR 4 SLAT)

FLT NR 1598 - GSO - THE NR 4 SLAT WOULD NOT RETRACT DURING CLIMB-OUT OF GSO, THE AIRCRAFT WAS RETURNED TO GSO. MAINTENANCE FOUND THE NR 4 LEADING EDGE SLAT ACTUATOR AT FAULT. THE ACTUATOR WAS REMOVED AND REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD. (M)

Part: TRACK — CRACKED (LT TE FLAP)

EWR - INSPECTION FOUND A .25 INCH CRACK IN LT OUTBOARD TRAILING EDGE FLAP TRACK. THE CRACKED AREA WAS REPAIRED IAW ECRA 5750-02364. (X)

Part: STRINGER — CORRODED (BS 446)

GSO - INSPECTION FOUND CORROSION ON STR 27R AT STA 446. REPAIR ANGLES WERE FABRICATED AND INSTALLED IAW SRM 53-10-3 AND SRM 51-30-2. (X)

Part: INTERCOSTAL — CRACKED (BS 984)

GSO - INSPECTION FOUND A .50 INCH CRACK IN INTERCOSTAL UPPER FLANGE AT BS 984, LBL 37. THE INTERCOSTAL WAS REMOVED AND REPAIR PARTS WERE FABRICATED AND INSTALLED IAW SRM 53-10-2 AND SRM 51-30-0. (X)

Part: ANGLE — CORRODED (BS 440)

GSO - INSPECTION FOUND CORROSION INSIDE WEB OF DOOR SILL ANGLE AND NUT PLATES AT STA 440, STR 25R. A NEW ANGLE WAS INSTALLED IAW SRM 51-10-2 AND SRM 51-1-21A. (X)

Part: ANGLE — CRACKED (FS 333)

GSO - INSPECTION FOUND A .50 INCH CRACK IN FRAME TO STRINGER ATTACH ANGLE AT STR 26R, STA 333. THE CRACKED ANGLE WAS REMOVED AND A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-10-2, SRM 51-30-2, AND SRM 53-10-3. (X)

Part: STRINGER — CRACKED (FS 420-440)

GSO - INSPECTION FOUND A 1 INCH CRACK IN STR 28R, LOCATED IN THE FORWARD PIT AT STA 420 - STA 440. THE DAMAGED AREA WAS CUT OUT AND CHANNEL FILLER AND SHIMS WERE INSTALLED IAW SRM 53-10-3, SRM 51-10-2, AND SRM 51-30-2. (X)

Part: WEB — CORRODED (NLG WW)

GSO - NOSE WHEELWELL, LEFT UPPER PANEL WEB, WAS FOUND BULGED AT FORWARD EDGE AND THERE WAS CORROSION ON UPPER SURFACE AND INSIDE FASTENER HOLES. AN INTECOSTAL WAS FABRICATED AND INSTALLED IAW SRM 54-10-3 AND SRM 51-30-2. (X)

Part: WEB — CORRODED (NLG WW)

GSO - THE NOSE WHEELWELL, RT UPPER PANEL WEB, WAS FOUND BULGED AT FORWARD EDGE AND THERE WAS CORROSION INSIDE FASTENER HOLE. AN INTERCOSTAL WAS FABRICATED AND INSTALLED IAW SRM 54-10-3 AND SRM 51-30-2. (X)

Part: SKIN — CRACKED (BS 188-253)

GSO - INSPECTION FOUND CRACK INDICATIONS IN SKIN AT LEFT FS BS 188-253, WL 208.1 TO WL 234.35. THE CRACKS WERE APPROXIMATELY .50 INCH LONG. THE CRACKED AREAS OF SKIN WERE CUT OUT AND DOUBLERS AND FILLERS WERE INSTALLED IAW EA 5310-01188. (X)