N77827

Part: CHANNEL — CRACKED (R FWD MLG DR) · airframe 46,415 hrs · 22,188 cycles

INSPECTION FOUND A 2.5" CRACK IN R/H W/W FORWARD DOOR JAMB CHANNEL, O/B OF CENTER SPLICE. THE DOOR JAMB CHANNEL WAS REMOVED AND A NEW CHANNEL WAS INSTALLED IAW SRM 51-30-0.

Part: FRAME — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND T-CHORD FRAME CORRODED JUST AFT OF THE LT WHEEL WELL AT STA 1003, LBL 10. THE T-CHORD FRAME WAS REMOVED AND A NEW T-CHORD FRAME WAS INSTALLED IAW SRM 51-30-2, 51-30-5, 53-54-0, AND 51-30-1.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND CABIN FLOOR SUPPORT CORRODED AT STA 148 - 198, LBL 7. THE FLOOR SUPPORT WAS REMOVED AND A NEW FLOOR SUPPORT WAS INSTALLED IAW SRM 51-30-1 AND 53-24-0, FIGURE 3.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND LEFT I/B SEAT TRACK CORRODED FROM STA 1116 - 1186, LBL 24. THE SEAT TRACK WAS REMOVED AND A NEW SEAT TRACK WAS INSTALLED IAW SRM 51-30-1 AND 53-24-0, FIGURE 6.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND LEFT O/B CABIN SEAT TRACK CORRODED AT STA 845 - 1028. THE CORROSION WAS REMOVED IAW SRM 53-05, FIGURE 4B. THE SECTION OF TRACK FROM STA 856 - 860, LBL 54 WAS OUT OF LIMITS. THE SEAT TRACK SECTION FROM STA 856 - 860 WAS REMOVED AND A NEW TRACK WAS INSTALLED USING STRAPS AND SPLICES IAW SRM 51-30-2, 51-10-1, 51-30-5, AND 53-05, FIGURE 4F.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 200, LBL 18. THE FLOOR SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 53-24-0, FIGURE 3, 51-30-2, AND 51-30-1.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND CORROSION ON THE UPPER SURFACE OF THE AFT CARGO PIT TIE DOWN TRACK AT FS 1111 - 1174, RBL 16. THE TIE DOWN TRACK WAS REMOVED AND A NEW TRACK WAS INSTALLED IAW SRM 53-05, FIGURE 4G.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND RT CABIN I/B SEAT TRACK CORRODED AROUND NUT PLATES FROM STA 200 - 260. A REPLACEMENT TRACK WAS INSTALLED IAW SRM 51-10-3, 53-05, FIGURES 4F & 5, 51-30-2, AND 53-04, FIGURE 4.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND RT SEAT TRACK CORRODED FROM STA 200 - 275, RBL 45. THE SEAT TRACK WAS REMOVED AND A NEW TRACK WAS INSTALLED IAW SRM 53-05, FIGURE 4, 51-30-1, 51-30-5, AND ECRA 5310-01675.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND CABIN FLOOR SUPPORTS CORRODED AT STA 195, LBL 52 AND AT STA 160 - 194, LBL 56. THE FLOOR SUPPORTS WERE REMOVED AND NEW SUPPORTS WERE INSTALLED IAW SRM 53-14-1, FIGURE 11, 51-30-5, AND 51-30-2.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 148, RBL 4 TO LBL 4. THE FLOOR SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 53-14-1, FIGURE 11 AND 51-30-2.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND SEAT TRACK CORRODED AT STA 1199 - 1227, LBL 44. THE SEAT TRACK WAS REMOVED AND A NEW TRACK WAS INSTALLED IAW SRM 53-05, FIGURE 4F AND 51-30-5.

Part: DOUBLER — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND SPLICE DOUBLER CORRODED IN AFT CARGO AREA AT LT CARGO TRACK BETWEEN STA 1212 AND 1231. THE CORRODED SPLICE WAS REMOVED AND A NEW SPLICE WAS INSTALLED IAW SRM 51-30-5, 53-05, FIGURE 4G, AND 51-10-3.

Part: DOOR FRAME — CORRODED (CARGO DOOR) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND MID CARGO DOOR JAMB CORRODED. THE REPAIR SPACER AND DOUBLER WERE REMOVED AND REPLACED IAW SRM 53-05, FIGURE 63.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 169 - 181, LBL 45. A REPAIR WAS PERFORMED IAW SRM 53-14-1, FIGURE 11.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND A 1 INCH CRACK IN AFT CARGO DOOR OUTER FRAME AT AFT LATCH. THE CRACKED AREA WAS REMOVED AND A REPAIR DOUBLER WAS INSTALLED IAW SRM 52-05, FIGURE 29.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT STA 200 - 258, LBL 16 AND AT STA 237, LBL 10. THE FLOOR SUPPORTS WERE REMOVED AND NEW SUPPORTS WERE INSTALLED IAW SRM 51-30-2, 51-14-3, FIGURE 12, 51-10-3, 51-30-5, 51-30-4, AND 53-14-2, FIGURE 2.

Part: FLOORBEAM — CORRODED (STA 200) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND FORWARD GALLEY FLOORBEAM CORRODED AT STA 200, RBL 0 AND RBL 18. THE FLOOR SUPPORTS WERE REMOVED AND NEW SUPPORTS WERE INSTALLED IAW SRM 51-30-2, 53-14-1, FIGURE 11, 51-10-3, AND 51-30-5.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 160 - 200, RBL 44. THE SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 51-30-2, 51-30-3, AND 53-14-1, FIGURE 11.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND FLOOR SUPPORTS CORRODED AT STA 176, RBL 26 AND STA 180, BETWEEN RBL 10 AND RBL 42. THE FLOOR SUPPORTS WERE REMOVED AND NEW SUPPORTS WERE INSTALLED IAW SRM 53-14-1, 51-30-2, AND 51-30-5.

Part: WEB — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND ON UPPER AND LOWER SURFACES OF LT CUSP AT FS 984 - 1003. THE CORRODED AREA WAS CUT OUT IAW SRM 53-01, FIGURE 4. A DOUBLER AND FILLER WERE INSTALLED IAW SRM 53-01, FIGURE 4, 51-10-3, AND 51-30-2.

Part: ANGLE — CORRODED (TE FLAP) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND LT WING MID FLAP HINGE FAIRING BRACKET ANGLE CORRODED. THE ANGLE WAS REMOVED AND A NEW ANGLE WAS INSTALLED IAW SRM 51-30-1 AND 57-50-14, FIGURE 14.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1156, LBL 24 - LBL 42. THE FLOORBEAM WAS REMOVED AND A NEW BEAM WAS INSTALLED IAW SRM 51-10-5, 53-14-3, FIGURE 12, 51-10-3, 51-30-2.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND CABIN SUBFLOOR WEB CORRODED AT STA 200, LBL 58. THE CORRODED AREA WAS CUT OUT IAW SRM 53-01, FIGURE 4. THREE FLOOR SUPPORT ANGLES WERE REMOVED FOR ACCESS IAW SRM 51-30-2. A REPAIR WAS INSTALLED IAW SRM 53-10, FIGURE 4 AND 51-30-2. THE FLOOR SUPPORT ANGLES WERE REINSTALLED IAW SRM 51-30-2.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND CABIN FLOOR SUPPORT CORRODED AT STA 169 - 181, LBL 45. A REPAIRED WAS INSTALLED IAW SRM 53-14-1, FIGURE 11.

Part: FRAME — CRACKED (CARGO DOOR) · airframe 42,229 hrs · 19,947 cycles

INSPECTION FOUND A 1 INCH CRACK IN AFT CARGO DOOR OUTER FRAME AT FORWARD LATCH. THE CRACKED AREA WAS REMOVED AND A REPAIR DOUBLER WAS INSTALLED IAW SRM 52-05, FIGURE 26.

Part: POWER SUPPLY — INOP (EMER EXIT)

THE RIGHT AND LEFT AFT OVERWING EMERGENCY EXIT SIGNS WOULD NOT ILLUMINATE DURING TEST. THE BATTERY POWER SUPPLY WAS REMOVED AND REPLACED IAW MM 33-53-00.

Part: WIRE — BROKEN (ROW 26)

INSPECTION FOUND EMERGENCY SEAT MOUNTED LIGHTS INOPERATIVE AT ROW 14 TO 27. A BROKEN WIRE UNDER SEAT ROW 26 WAS REPAIRED.

Part: LONGERON — CRACKED (BS 1418)

INSPECTION FOUND A 1 INCH CRACK IN LONGERON 2R AND 2L AT STA 1418. THE AREAS WERE REPAIRED IAW SRM 53-02-18.

Part: JAMB — CORRODED (BAGGAGE DOOR)

INSPECTION FOUND AFT BAG BIN LOWER DOOR JAMB CORRODED. REPLACED WITH A NEW Z-ANGLE BEAM IAW SRM 51-30-2 AND 51-30-3.

Part: BELTFRAME — CORRODED (BS 1231)

INSPECTION FOUND AFT CARGO COMPARTMENT BELTFRAME CORRODED AT STA 1231, LONGERON 29L - 29R. THE CORRODED AREA WAS REMOVED AND A REPAIR WAS INSTALLED IAW SRM 53-03, FIGURE 24.

Part: SKIN — CRACKED (BS 470-480)

INSPECTION FOUND LOWER FUSELAGE SKIN CRACKED FROM STA 470 TO 480 BETWEEN LONGERON 30 AND 29L. THE SKIN WAS REPAIRED IAW ECRA 5330-02655.

Part: BELTFRAME — CRACKED (BS 1418)

INSPECTION FOUND TWO 1 INCH CRACKS IN BELTFRAME AT STA 1418, LONGERON 2L AND 2R. AN UPPER FRAME SPLICE REPAIR WAS INSTALLED IAW SRM 53-03, FIGURE 32.

Part: ANGLE — CORRODED (SERVICE DOOR)

INSPECTION FOUND ATTACH ANGLE AT TOP OF SLIDE ON FORWARD SERVICE DOOR CORRODED. THE ANGLE WAS REPLACED IAW SRM 51-10-2.

Part: JAMB — CORRODED (BAGGAGE DOOR)

INSPECTION FOUND MID BAG BIN LOWER DOOR JAMB CORRODED. REPAIRED IAW SRM 53-05, FIGURE 63.

Part: HYD LINE — BROKEN (TR CONTL VALVE)

THE RT HYDRAULIC SYSTEM PRESSURE LOW LIGHT ILLUMINATED AND PRESSURE DROPPED TO ZERO WHILE EN ROUTE. ALTERNATE GEAR EXTENSION WAS USED. WHEN THE AIRCRAFT LANDED AT RSW THE RT MAIN GEAR DOOR SKID PLATE WAS DAMAGED. MAINTENANCE FOUND HYDRAULIC LINE BROKEN AT RIGHT THRUST REVERSER CONTROL VALVE. A FLEX LINE WAS INSTALLED AND A DIP WAS ISSUED TO REPLACE THE LINE WITHIN 500 FLIGHTS OR 1200 FLIGHT HOURS. THE RT MLG DOOR SKID AND SPACER WERE REMOVED IAW ECRA 5280-91175 AND A DIP WAS ISSUED TO REPAIR WITHIN TWO CYCLES. THE SKID AND SPACER WERE INSTALLED WHILE AIRCRAFT WAS OUT OF SERVICE IN EWR AND THE DIP WAS CLOSED.

Part: HYD LINE — BROKEN (RT HYD SYST)

THE RT HYDRAULIC SYSTEM PRESSURE AND QUANTITY WERE LOST ON APPROACH. APPROPRIATE CHECKLISTS WERE COMPLIED WITH AND THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE HYDRAULIC PRESSURE LINE TO RUDDER CONTROL VALVE BROKEN. THE HYDRAULIC LINE WAS REMOVED AND REPLACED PER MM 29-10-5. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: ACTUATOR — FAILED (NLG)

THE NOSE GEAR WOULD NOT RETRACT AFTER TAKEOFF. WHEN CYCLING THE GEAR, THE GEAR CAME DOWN, BUT THE GEAR HANDLE WOULD NOT RAISE. BOTH THE STALL INDICATION FAIL LIGHT AND AUTO SPOILER DO NOT USE LIGHT ILLUMINATED. THE AIRCRAFT WAS RETURNED TO SFO WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND METERING PIN BASE LOOSE IN LOWER CYLINDER; UPON REMOVAL PRESSED IN SLEEVE CAME OUT WITH BASE. THE LOWER PISTON AND AXLE ASSEMBLY WERE REPLACED IAW MM 32-21-02. THE NLG RETRACT CYLINDER AND BUNGEE CYLINDER WERE BOTH REPLACED AS A PRECAUTIONARY MEASURE. THE NOSE GEAR WAS SWUNG AND OPERATION CHECKED GOOD.

Part: STRUT — REQD SERVICE (NLG)

THE NLG WOULD NOT RETRACT AFTER TAKEOFF FROM IAH. THE NOSE GEAR UNSAFE LIGHT WAS ILLUMINATED AND THE AIRCRAFT WAS STILL IN GROUND MODE. THE AIRCRAFT WAS RETURNED TO IAH. MAINTENANCE FOUND THE NOSE GEAR STRUT FLAT. THE NOSE GEAR STRUT WAS REPACKED IAW MM 32-21-02. IN ADDITION, THE SCHRADER VALVE WAS REPLACED. A NOSE GEAR RETRACTION AND EXTENSION CHECK WAS PERFORMED WITH OPERATION AND INDICATIONS CHECKING GOOD.

Part: WIRE HARNESS — CHAFED (WS 70)

THE AFT LEFT FUEL TANK BOOST PUMP AND FORWARD LEFT FUEL TANK BOOST PUMP CIRCUIT BREAKERS TRIPPED ON FINAL APPROACH TO MIA. THE AFT LEFT FUEL BOOST PUMP CIRCUIT BREAKER COULD NOT BE RESET. THE FORWARD LEFT FUEL TANK BOOST PUMP CIRCUIT BREAKER WAS RESET, BUT THE LOW FUEL PRESSURE ANNUNCIATOR WAS STILL ILLUMINATED. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND WIRE BUNDLE CHAFED AGAINST SLAT ACCESS PANEL NUTPLATE CHANNEL AT LEFT WING STA 70 BETWEEN SLATS ZERO AND ONE. THE WIRING WAS REPAIRED USING RAYCHEM SPLICES IAW STANDARD PRACTICES 20-10-3. ALL ASSOCIATED SYSTEMS CHECKED GOOD.