N79748

Part: LIGHT — INOPERATIVE (L1 DOOR)

DURING ROUTINE MAINTENANCE AT FWA, IT WAS DISCOVERED THAT THE MAIN ENTRY EMERGENCY EXIT LIGHT DID NOT ILLUMINATE. REMOVED AND REPLACED THE EMERGENCY EXIT LIGHT. OPERATIONALLY CHECKED GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: INDICATOR — FALSE INDICATION (NR 2 ENG OIL)

FLT 879 - RNO-SJC - DURING CRUISE, THE FLIGHT CREW NOTICED THAT THE OIL QUANTITY ON NR 2 ENGINE WAS STEADILY DECREASING. THE CREW DECLARED AN EMERGENCY AND MADE A PRECAUTIONARY SHUT DOWN OF THE NR 2 ENGINE. DURING APPROACH THE OIL QUANTITY RETURNED TO NORMAL. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT AT SJC. THE NR 2 ENGINE OIL FILTER WAS INSPECTED AND NO DEFECTS WERE NOTED. THE ENGINE AND OIL QUANTITY INDICATION OPS CHECKED NORMAL. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: HINGE — CRACKED (CARGO DOOR)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FORWARD MAIN CARGO DOOR HINGE WAS CRACKED. INSTALLED NEW HINGE SECTION PER AEI SERVICES BULLETIN 01-01. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SKIN — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THERE WAS A DENT IN THE SKIN AT BS 1130, STRINGER 27L. REMOVED OLD REPAIR CUT OUT DAMAGED AREA INSTALLED FILLER, DOUBLER AND TRIPLER PER BOEING SRM 53-30-3, FIGURE 5. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SKIN — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THERE WAS A DENT IN THE SKIN AT BS 1090, STRINGER S15R. CUT OUT DAMAGED AREA FABRICATED DOUBLER IAW B727 SRM 53-30-3, FIGURE 1, SHEET 2, PATE 6. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: PLENUM — CORRODED (WING)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE LEFT AFT PLENUM LOWER SKIN HAS CORROSION IN TWO PLACES. FOUND CORROSION OUT OF LIMITS. INSTALLED DOUBLER AND TRIPLER IAW B727 SRM 57-30-3 FIGURE 8. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: DOOR FRAME — CORRODED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT AT THE E/E ACCESS, THE AFT DOOR LOCKING FRAME HAD CORROSION AT THE FRAME TO SKIN AT BS 460, STRINGER S29L TO S28L. REMOVED FRAME DAMAGE, AND REPAIRED PER BOEING SRM 51-10-2 FIGURE 3. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SKIN — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FORWARD LOWER CARGO DOOR CUTOUT FRAME AND SKIN WAS DENTED NEAR STRINGER S23R AT THE FORWARD PORTION OF THE DOOR CUTOUT FRAME (FUSELAGE SKIN). C/A: ACCOMPLISHED REPAIR IAW REPAIR ORDER. AIRCRAFT WAS RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE BS 360, FRAME INBOARD FLANGE WAS DENTED AND CRACKED IN THE AREA OF STRINGER 16 LEFT. CUT OUT DAMAGED AREA IAW B727 SRM 51-40-3, FIG 1 FABRICATED DOUBLER IAW B727 SRM 51-20-1 AND 51-40-3 FIG 1. THE AIRCAFT WAS RETURNED TO SERVICE. (M0

Part: FRAME — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FORWARD CARGO COMPARTMENT, THE FRAME AT BS 680 HAS THREE DENTS INTO THE RADIUS OF STRINGERS S25L TO S23L. COLD WORKED DENTS, NDT FOUND NO CRACKS, FABRICATED DOUBLER REPAIR IAW B727 SRNM 51-40-3, FIGURE 1. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: FRAME — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FUSELAGE FRAME WAS DENTED JUST ABOVE FLOOR LEVEL AT THE RIGHT SIDE MAIN CARGO COMPARTMENT BS 560. CUT OUT DAMAGED AREA OF FRAME IAW B727 SRM 51-40-3, FIGURE 1. FABRICATED DOUBLER IAW B727-SRM 51-40-3, FIGURE 1 AND 53-10-2 FIGURE 2. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SKIN — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FUSELAGE EXTERIOR NOSE SECTION AT BS 310 THROUGH 330 BETWEEN STRINGERS 21R TO STRINGER 22R SKIN WAS DENTED. CUT OUT DAMAGED AREA. FABRICATED DOUBLER AND FILLER TREATED AND PRIMED AREA IAW SRM 53-30-3 FIGURE 2. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: HINGE — CRACKED (CARGO DOOR)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE AFT MAIN CARGO DOOR HINGE WAS CRACKED. INSTALLED NEW HINGE SECTION AEI SERVICE BULLETIN 01-01. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: FRAME — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FUSELAGE FRAME WAS DENTED JUST ABOVE FLOOR LEVEL AT THE RIGHT MAIN CARGO COMPARTMENT BS 580. CUT OUT DAMAGED AREA OF FRAME IAW B727 SRM 51-40-3, FIGURE 1. FABRICATED DOUBLER IAW B727 SRM 51-40-3 AND 53-10-2. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: FRAME — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FUSELAGE FRAME DENTED JUST ABOVE FLOOR LEVEL RIGHT CABIN BS 540. CUT OUT DAMAGED AREA OF FRAME IAW B727 SRM 51-40-3 FIGURE 1. FABRICATED DOUBLER IAW B727 SRM 51-40-3, FIGURE 1 AND 53-10-2 FIGURE 2. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: FRAME — DENTED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FUSELAGE FRAME WAS DENTED JUST ABOVE FLOOR LEVEL RIGHT MAIN CARGO COMPARTMENT BS 600. CUT OUT DAMAGED AREA OF FRAME IAW B727 SRM 51-40-3 FIGURE 1, FABRICATED REPAIR DOUBLER IAW B727 SRM 51-40-3 AND 53-10-2. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: STRINGER — CRACKED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT IN THE MAIN CARGO COMPARTMENT INTERIOR AT BS 720B HAD A CRACK AT STRINGER S15L FORWARD OF WING LIGHT SUPPORT. CUT OUT DAMAGED AREA, FABRICATED NEW PART IAW B727 SRM 53-10-3, FIG 5. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: STRINGER — CRACKED (FUSELAGE)

DURING A ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE MAIN CARGO COMPARTMENT INTERIOR BS 720B HAD A CRACK AT STRINGER S15R END, FORWARD OF WING LIGHT SUPPORT. CUT OUT DAMAGED AREA, FABRICATED AND INSTALLED NEW PART IAW B727 SRM 53-10-3, FIGURE 5. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: FRAME — CHAFED (FUSELAGE)

FLT - 3850 - MSP-FWA - DURING CRUISE, THE FLIGHT CREW NOTICED THAT THE 'A' SYSTEM HYDRAULIC FLUID QUANTITY WAS DECREASING. AN EMERGENCY WAS DECLARED AND THE HYDRAULIC SYSTEM WAS ISOLATED THE AIRCRAFT CONTINUED TO FWA. THE AIRCRAFT MADE AN UNEVENTFUL LANDING. FURTHER INSPECTION REVEALED THAT A FUSELAGE FRAME AND A HYDRAULIC LINE WERE DAMAGED FROM CHAFING. INSPECTION REVEALED A HYDRAULIC LINE HAD CHAFED AGAINST THE FRAME AT FUSELAGE STATION 1303. THE LINE AND THE NR 1 AND NR 2 ENGINE DRIVEN HYDRAULIC PUMPS AND FILTER WERE REPLACED. THE FRAME WAS REPAIRED IAW FV1 DRAWING 53-01590-1. THE SYSTEM OPS CHECKED GOOD. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: HYDRAULIC LINE — CRACKED (HYDRAULIC SYS)

FLT 3850 - MSP-FWA - DURING CRUISE, THE FLIGHT CREW NOTICED THAT THE 'A' SYSTEM HYDRAULIC SYSTEM WAS ISOLATED THE AIRCRAFT CONTINUED TO FWA. THE AIRCRAFT MADE AN UNEVENTFUL LANDING. INSPECTION REVEALED A CRACKED HYDRAULIC LINE AT FUSELAGE STATION 1303. THE LINE AND THE NR 1 AND NR 2 ENGINE DRIVEN HYDRAULIC PUMPS AND FILTERS WERE REPLACED. THE SYSTEM OPS CHECKED GOOD. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: LIGHT — NOT SEATED (CABIN)

MAINTENANCE FOUND EMERGENCY EXIT LIGHTS INOPERATIVE. FOUND LIGHT ASSEMBLY NOT SEATED IN CONNECTOR. REINSTALLED AND OPERATIONALLY CHECKED SYSTEM. SYSTEM CHECKS GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: HYDRAULIC LINE — LEAKING (HYD SYSTEM)

FLT 1850 - PDX-SEA - UPON LANDING GEAR EXTENSION, LOST A SYSTEM HYDRAULICS QUANTITY WENT TO ZERO. AIRCRAFT MADE AN UNEVENTFUL LANDING IN SEA. INSPECTION OF AIRCRAFT FOUND LEAKING LEFT GEAR DOOR ACTUATOR RETURN HOSE. REMOVED AND LEFT ACTUATOR RETURN HOSE. REMOVED AND REPLACED NR 1 AND NR 2 ENGINE DRIVEN HYDRAULIC PUMPS IAW B727 MM 29-11-31. SERVICED A SYSTEM. SYSTEM CHECKS GOOD IAW B727 MM 29-11-0. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LINE — RUPTURED (HYS SYSTEM)

FLT 1805 - FWA-LAX - AT FL310, HYDRAULIC SYSTEM ''A'' PRESSURE AND QUANTITY WENT TO ZERO. AIRCRAFT MADE AN UNEVENTFUL LANDING IN DEN. TROUBLESHOOT AND FOUND RUPTURED HYDRAULIC LINE IN RIGHT SIDE OF AFT AIRSTAIR. REMOVED AND REPLACED THE HYDRAULIC LINE PER B727 MM 20-10-5. LEAKS CHECKS GOOD ON GROUND. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: LINE — LEAKING (NR 2 ENGINE)

FLT 3712 - FWA-ELP - SYSTEM ''A'' HYDRAULIC PRESSURE AND QUANTITY DROPPED TO ZERO ON CLIMB-OUT. AIRCRAFT MADE AN UNEVENTFUL RETURN TO FWA. FOUND NR 2 ENGINE ''A'' SYSTEM RETURN LINE LEAKING. INSTALLED FLEX LINE AND PERFORMED ENGINE RUN. NO LEAKS NOTED AND HYDRAULICS FLUID FULL. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (L-1 DOOR)

NO FLIGHT. DURING ROUTINE MAINTENANCE, DISCOVERED THE L-1 DOOR EMERGENCY EXIT LIGHT INOPERATIVE. REMOVED AND REPLACED THE EMERGENCY LIGHT ASSEMBLY. OPERATIONALLY CHECKED GOOD. THE AIRCRAFT RETURNED TO SERVICE. (X)

Part: ROD END — SHEARED (NOSE GEAR)

DISCREPANCY: TAKE OFF ABORTED AT 70 KTS DUE TO VIOLENT NOSE WHEEL SHIMMY.CORRECTIVE ACTION: FOUND NOSE GEAR TORQUE LINKS TO BE DISCONNECTED CAUSING EXCESSIVE SHIMMY, RE-CONNECTED AS REQUIRED. UPON FURTHER INSPECTION FOUND NOSE WHEEL STEERING BYPASS LINKAGE ROD END TO BE SHEARED. REMOVED AND REPLACED AS REQUIRED. NO FURTHER DEFECTS NOTED. A/C RETURNED TO SERVICE.

Part: LIGHT — INOPERATIVE (COCKPIT)

FOUND DURING PREFLIGHT, FLIGHT DECK EMERGENCY EXIT LIGHT INOPERATIVE. REMOVED AND REPLACED EMEREGNCY EXIT LIGHT ASSEMBLY. OPERATIONALLY CHECKED SYSTEM GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

FLT 1849 - MSP-SEA - ENCOUNTERED DURING CRUISE, THE EMERGENCY EXIT LIGHTS REMAINED DIMLY ILLUMINATED. TURNED SWITCH ON AND LIGHTS ALL ILLUMINATED BRIGHTLY, BUT COULD NOT TURN OFF. THE FILGHT CONTINUED TO SEA AND LANDED SAFELY WITHOUT ANY FURTHER DIFFICULTIES. OPERATIONALLY CHECKED SYSTEM GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: LIGHT — UNSECURE (COCKPIT)

DURING ROUTINE MAINTENANCE AT TYS,THE COCKPIT EMERGENCY EXIT LIGHT ASSEMBLY WAS FOUND UNSECURED. REINSTALLED COCKPIT EMERGENCY LIGHT ASSEMBLY. OPERATIONALLY CHECKED NORMAL. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: BULB — FAILED (CABIN)

FOUND DURING ROUTINE MAINTENANCE AT MIA, THE LIGHT BULB INOPERATIVE FOR THE MAIN CABIN DOOR EMERGENCY EXIT LIGHT. REMOVED AND REPLACED BULB AT THE MAIN CABIN DOOR EMERGENCY EXIT LIGHT. OPERATIONALLY CHECKS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SKIN — DAMAGED (FUSELAGE)

FOUND DURING ZERO B, TRANSITION CHECK AT AVBORNE HEAVY MAINTENANCE FACILITY, DAMAGE WAS FOUND ALONG FUSELAGE SKIN FROM STATION 697 TO 708, BETWEEN STRINGER 28L AND STRINGER 28R. INSTALLED EXTERNAL DOUBLER REPAIR FROM STATION 697 TO STATION 708, BETWEEN STRINGER 28L AND STATION 28R. MATERIAL USED, 2024-T3, 0.090 INCH, 12 INCH BY 11 INCH. REPAIR ACCOMPLISHED IAW SRM 53-30-3 FIG 3. SEE NON-ROUTINE 3049 FOR DETAILS. (M)

Part: FLOORBEAM — DAMAGED (FUSELAGE)

FOUND DURING ZERO B, TRANSITION CHECK AT AVBORNE HEAVY MAINTENANCE FACILITY, DAMAGE WAS FOUND ON FLOORBEAM UPPER T CHORD AT STATION 344 FROM LBL 62.62 TO RBL 62.62. INSTALLED FLOORBEAM UPPER T CHORD REPAIR AT STATION 344 FROM LBL 62.62 TO RBL 62.62. MATERIAL USED, PART NR BAC1505-29222. ACCOMPLISHED IAW SRM 51-30-2 FIG SEE NON ROUTINE 5512 FOR DETAILS. (M)

Part: SKIN — DAMAGED (FUSELAGE)

FOUND DURING ZERO B, TRANSITION CHECK AT AVBORNE HEAVY MAINTENANCE FACILITY, DAMAGE WAS FOUND ON EXTERIOR SKIN FROM STATION 575 TO 588 STRINGER 26L TO 27L. INSTALLED EXTERIOR FUSELAGE SKIN REPAIR FROM STATION 575 TO 588, STRINGER 26L TO 27L. MATERIAL USED 2024-T3, 0.063 INCH, 9 INCH BY 13 INCH. REPAIR ACCOMPLISHED IAW SRM 53-30-3 FIG 3. SEE NON ROUTINE 3057 FOR DETAILS. (M)

Part: STRINGER — DAMAGED (FUSELAGE)

FOUND DURING ZERO B, TRANSITION CHECK AT AVBORNE HEAVY MAINTENANCE FACILITY, PRIOR TO THIS AIRCRAFT BEING ON THE KHA CERTIFICATE, DAMAGE WAS FOUND ON STRINGER 28R FROM BODY STATION 682 TO STATION 694. INSTALLED STRINGER REPAIR FROM STATION 682 TO STATION 694, STRINGER 28R. MATERIAL USED, PART NR BAC1498-141. REPAIR ACCOMPLISHED IAW SRM 53-10-3 FIG 1. AIRCRAFT RETURNED TO SERVICE. (M)

Part: STRINGER — DAMAGED (FUSELAGE)

FOUND DURING ZERO B, TRANSITION CHECK AT AVBORNE HEAVY MAINTENANCE FACILITY, DAMAGE WAS FOUND ALONG STRINGER AT STRINGER 27L FROM STATION 573 TO 588. INSTALLED STRINGER REPAIR AT STRINGER 27L FROM STATION 573 TO STATION 588. MATERIAL USED, PART NR BAC1498-141. REPAIR ACCOMPLISHED IAW SRM 53-10-3 FIG 1, SEE NON-ROUTINE 3057 FOR DETAILS. (M)

Part: PANEL — CRACKED (VERT STAB)

INSPECTION FOUND TWO 3 CRACKS IN VERTICAL STABILIZER SADDLE PANEL. THE SADDLE PANEL WAS REMOVED, REPAIRED IAW SRM 55-30-7, FIGURE3, AND REINSTALLED IAW MM 55-30-1, PAGE 201.

Part: SKIN — CRACKED (NR 7 SPOILER)

INSPECTION FOUND A 2 INCH CRACK IN LT WING NR 7 SPOILER PANEL SKIN WITH DENTS ON LOWER SURFACE. THE SPOILER PANEL WAS REMOVED, REPAIRED, AND REINSTALLED IAW SRM 57-30-00, PAGE 30 AND MM 27-62-1, PAGE 403.

Part: SKIN — CORRODED (NR 5 LE FLAP)

INSPECTION FOUND NR 5 L/E FLAP BULL NOSE CORRODED. THE FLAP BULL NOSE WAS REMOVED AND REPLACED IAW MM 27-81-1, PAGE 401.

Part: SKIN — DEBONDED (NR 2 SPOILER)

INSPECTION FOUND LT WING NR 2 SPOILER UPPER SKIN DEBONDED WITH SURFACE CORROSION AROUND SCREW HEADS. THE NR 2 SPOILER PANEL WAS REMOVED AND REPLACED IAW MM 27-61-1, PAGE 407.

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND CABIN EMERGENCY AISLE PATH LIGHTING INOPERATIVE. MAINTENANCE FOUND A BLOWN FUSE AND INOPERATIVE BATTERY. THE FUSE AND BATTERY PACK WERE REMOVED AND REPLACED IAW MM 33-50-1.

Part: FITTING — CRACKED (RT MLG)

INSPECTION FOUND A 1.5 CRACK IN RT MLG BEAM SUPPORT FITTING. THE SUPPORT FITTING AND BUSHING WERE REMOVED AND REPLACED IAW ECRA 5740-01102.

Part: FITTING — CORRODED (RT MLG)

INSPECTION FOUND RT MLG BEAM H FITTING ATTACH HOLE AND UPPER FORWARD LUG CORRODED. THE ATTACH HOLE WAS REPAIRED IAW ECRA 5740-01903, PAGE 2 AND THE FITTING WAS REPLACED.

Part: TRACK — CORRODED (RT TE FLAP)

INSPECTION FOUND RT WING NR 5 FLAP TRACK CORRODED. THE FLAP TRACK WAS REMOVED AND REPLACED IAW MM 27-51-31, PAGE 402-410.

Part: FITTING — CRACKED (RT WING)

INSPECTION FOUND A .75 INCH CRACK IN RT WING REAR SPAR O/B ATTACH FITTING FOR MLG. THE FITTING WAS REMOVED AND REPLACED IAW ECRA 5740-01901.

Part: CASTING — CRACKED (RT EMER EXIT)

INSPECTION FOUND A 1 INCH CRACK IN RT FORWARD OVERWING DOOR INNER UPPER CASTING. THE CASTING WAS REMOVED AND A NEW CASTING WAS INSTALLED IAW SRM 51-30-2, FIGURE 1.

Part: FITTING — CORRODED (LT TE FLAP)

INSPECTION FOUND FORWARD END OF LT WING NR 4 FLAP TRACK FITTING CORRODED. THE FITTING WAS REMOVED AND REPLACED. THE FLAP TRACK WAS REINSTALLED IAW MM 27-51-72, PAGE 401.

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND FORWARD OVERHEAD EMERGENCY LIGHT AT ROW NR 2 INOPERATIVE. MAINTENANCE FOUND THE BATTERY PACK AT FAULT. THE BATTERY PACK WAS RECHARGED AND REINSTALLED. OPERATION CHECKED GOOD IAW MM 33-50-81, PAGE 403.

Part: FLOORBEAM — CORRODED (BS 1130)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1130, RBL 0 TO WALL. THE CORRODED AREA WAS CUT OUT AND A REPAIR WAS INSTALLED IAW ECRA 5310-03893.

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND A SECTION OF CABIN EMERGENCY LIGHTS INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED AND OPERATION CHECKED GOOD IAW MM 33-50-01.

Part: WIRE — BROKEN (R1 DOOR)

INSPECTION FOUND THE R-1 DOOR EXIT LIGHT INOPERATIVE. REPAIRED BROKEN WIRE TO CHARGER AND R-1 DOOR EXIT IDENTIFIER, AND RELAMPED. OPERATION CHECKED GOOD IAW SRM 33-51-0.

Part: WIRE — BROKEN (L1 DOOR)

INSPECTION FOUND THE L-1 DOOR EXIT LIGHT INOPERATIVE. REPAIRED BROKEN WIRE AT THE L-1 DOOR EXIT IDENTIFIER. OPERATION CHECKED GOOD IAW MM 33-51-0.

Part: WEB — CRACKED (BS 1110-1130)

INSPECTION FOUND A 1.5 INCH CRACK AND A BEND IN INTERCOSTAL WEB BETWEEN BS 1110-1130, BL 0. THE INTERCOSTAL WEB WAS REMOVED AND REPLACED IAW SRM 51-10-1, PAGE 2 AND 4.

Part: STRUCTURE — GOUGED (CARGO DOOR)

INSPECTION FOUND FORWARD CARGO COMPARTMENT DOOR LOWER FORWARD AND AFT CORNERS GOUGED. THE FORWARD AND AFT CORNERS OF DOOR WERE REMOVED IAW SRM 51-10-1, PAGE 4. REPAIRED IAW SRM 51-10-2, PAGE 4, 51-10-1, PAGE 4, AND OVERHAUL MANUAL 52-30-23, PAGE 403.

Part: FLOORBEAM — CORRODED (BS 320)

INSPECTION FOUND CABIN FLOORBEAM CORRODED AT STA 320, BL 0 TO LBL 42. THE CORRODED AREA WAS CUT OUT AND A REPAIR WAS INSTALLED IAW SRM 53-10-8, PAGE 51-52.

Part: ANGLE — CRACKED (RT WING)

INSPECTION FOUND FOUR CRACKS IN RT WING FIXED LEADING EDGE RIB TO SKIN INBOARD SIDE CURVED ATTACH ANGLE AT WBL 92, ACCESS CUTOUT 6401. THE CRACKS MEASURED FROM .5 TO FIVE INCHES IN LENGTH. THE CRACKS WERE STOP DRILLED, A REPAIR DOUBLER, ANGLE AND STIFFENER WERE INSTALLED IAW SRM 57-30-4, 51-40-3, 51-10-2, 51-40-3, AND 51-30-4.

Part: ANGLE — CRACKED (RT WING)

INSPECTION FOUND TWO .5 INCH CRACKS THROUGH BOLT HOLES AT O/B LOWER ANGLE INSIDE RT WING FIXED LEADING EDGE RIB, WBL 92.0 (AFT OF NR 4 L/E FLAP I/B END). THE ANGLE WAS REMOVED AND A NEW ANGLE WAS INSTALLED IAW SRM 51-30-2, PAGE 2, 51-40-3, PAGE 1, AND 51-20-2, PAGE 1.

Part: FLOORBEAM — CORRODED (BS 312)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 312, LBL 44. THE CORRODED AREA WAS CUT OUT. A REPAIR DOUBLER AND FILLER WAS INSTALLED IAW SRM 53-10-8, 51-30-2, AND 51-10-6.

Part: SHEAR WEB — CORRODED (BS 1183)

INSPECTION FOUND AFT CABIN SHEAR WEB CORRODED JUST FORWARD OF BS 1183, LBL 17 TO RBL 17. THE WEB WAS REMOVED AND A NEW WEB WAS INSTALLED IAW SRM 51-10-1, PAGE 4 AND 51-10-7, PAGE 4.

Part: WEB — CORRODED (BS 1183)

INSPECTION FOUND TOP OF WEB CORRODED AT STA 1183, LBL 14. THE CORRODED AREA WAS CUT OUT AND A NEW WEB WAS INSTALLED IAW SRM 51-40-2, PAGE 6, FIGURE 1.

Part: SUPPORT — CORRODED (BS 1138)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT STA 1138, RBL 18. THE FLOOR SUPPORT WAS REMOVED AND A NEW SUPPORT WAS INSTALLED IAW SRM 51-10-1, PAGE 4 AND 51-30-2, PAGE 2.

Part: ANGLE — CRACKED (RT WING)

INSPECTION FOUND A 4.5INCH CRACK IN UPPER T-ANGLE ABOVE WHERE RT O/B AILERON I/B HINGE BRACKET ATTACHES AT RT WING T/E RIB. THE ANGLE WAS REMOVED AND A NEW ANGLE WAS INSTALLED IAW SRM 51-10-01, PAGE 401 AND 51-30-2.

Part: ANGLE — CRACKED (RT NR 7 LE SLAT)

INSPECTION FOUND A .25 INCH CRACK IN RT WING NR 7 SLAT LOWER CHORD. THE LOWER CHORD ANGLE WAS REMOVED AND A NEW CHORD WAS INSTALLED IAW SRM 51-40-4, 51-30-2, 51-10-2.

Part: STRINGER — CRACKED (WS 656.5)

INSPECTION FOUND A ,25 INCH CRACK AT LEFT WING TANK UPPER STRINGER, FIRST FORWARD FROM REAR SPAR, WS 656.5 AT TANK CUT OUT. A REPAIR WAS INSTALLED IAW ECRA 5762-01050.

Part: FLOORBEAM — CORRODED (BS 400)

INSPECTION FOUND CABIN FLOORBEAM CORRODED AT FS 400 BL 0 TO RBL 24. THE CORRODED AREA WAS CUT OUT AND A REPAIR WAS ACCOMPLISHED IAW SRM 53-10-8, PAGE 47.

Part: PRESS PANEL — CRACKED (RT EMER EXIT)

INSPECTION FOUND A .5 INCH CRACK IN FORWARD RT OVERWING EXIT LOWER PRESSURE PANEL. THE CRACKED AREA WAS CUT OUT IAW SRM 51-10-1, PAGE 5. A DOUBLER WAS INSTALLED IAW SRM 51-40-3, PAGE 1, 51-10-2, PAGE 1, AND 51-30-2, PAGE 1.

Part: SKIN — CHAFED (LT TE FOREFLAP)

INSPECTION FOUND THE LEFT O/B FOREFLAP CHAFED IN TWO AREAS AT INBOARD END. THE CHAFED AREAS WERE CUT OUT IAW SRM 57-50-4, PAGE 17. REPAIR PARTS WERE INSTALLED IAW SRM 57-50-4, PAGE 17 AND 51-30-2.

Part: STIFFENER — CRACKED (RT WING)

INSPECTION FOUND A 1 INCH CRACK IN STIFFENER ON I/B SIDE OF FIXED L/E RIB O/B OF RT WING FORWARD BOTTLE PIN (AFT OF ANTI-ICE DUCT, ACCESS CUTOUT 6402). THE CRACK WAS STOP DRILLED IAW SRM 51-10-1, PAGE 2. A FORMER ANGLE WAS INSTALLED IAW SRM 51-40-3, FIGURE 1 AND 51-10-2, PAGE 2.

Part: WEB — CRACKED (CARGO DOOR)

INSPECTION FOUND TWO CRACKED WEBS AT FORWARD CARGO COMPARTMENT DOOR AFT EDGE. THE CRACKS WERE .5 INCH LONG. NEW WEBS WERE INSTALLED IAW SRM 52-30-1 AND 51-30-2.

Part: SKIN — CRACKED (BS 680)

INSPECTION FOUND A 2 INCH CRACK IN RT LOWER FUSELAGE SKIN AT STA 680, STRINGER 28R. THE CRACKED AREA AND FASTENERS WERE REMOVED IAW SRM 51-30-2, PAGE 2 AND 53-30-3, PAGE 14E. DOUBLER AND FILLER WERE INSTALLED IAW SRM 53-30-3, PAGE 14E.

Part: BATTERY PACK — DISCHARGED (RT EMER EXIT)

INSPECTION FOUND THE RT AFT OVERWING EXIT LIGHT INOPERATIVE. THE BATTERY PACK WAS REPLACED IAW MM 33-50-01.

Part: ANGLE — CRACKED (LT WING)

INSPECTION FOUND A .625 INCH CRACK IN LT WING AFT FALSE SPAR LOWER CHORD ANGLE AT BOLT HOLE (FWD OF NR 7 SPOILER ACTUATOR CASTING, WBL 135). THE ANGLE WAS CUT OUT AND A NEW ANGLE, SPLICE AND STRAPS WERE INSTALLED IAW SRM 51-30-2.

Part: SKIN — DELAMINATED (RT ELEVATOR TAB)

INSPECTION FOUND RT ELEVATOR CONTROL TAB TRAILING EDGE DELAMINATED. THE CONTROL TAB WAS REMOVED AND REPLACED IAW MM 27-30-11.

Part: SKIN — BENT (LT AILERON)

INSPECTION FOUND LT OUTBOARD AILERON INBOARD END UPPER AND LOWER SKIN BENT. THE AILERON WAS REMOVED AND REPLACED IAW MM 27-20-13.

Part: BRACKET — WORN (LT ELEVATOR TAB)

INSPECTION FOUND LOOSE BOLTS AND WORN BOLT HOLES IN LT ELEVATOR TAB NR 1,3, AND 4 SUPPORT BRACKETS. THE TAB SUPPORT BRACKETS WERE REMOVED AND REPLACED IAW MM 27-30-11.

Part: TAB — BENT (RT AILERON)

INSPECTION FOUND RT WING OUTBOARD AILERON TAB BENT AT INBOARD TRAILING EDGE. THE AILERON TAB WAS REMOVED AND REPLACED IAW MM 27-10-41.

Part: SEAT TRACK — CORRODED (BS 380-400)

INSPECTION FOUND RT SEAT TRACK CORRODED AT FS 380-400. THE SEAT TRACK WAS REMOVED AND A NEW TRACK WAS INSTALLED IAW SRM 51-30-2,51-10-1, AND 51-10-2.

Part: SERVICE PANEL — CORRODED (RT LAVATORY)

INSPECTION FOUND RT FORWARD LAV SERVICE PANEL CORRODED AND DRAIN HANDLE WAS BROKEN. THE PANEL WAS REMOVED AND A NEW PANEL WAS INSTALLED IAW SRM 51-10-1 AND 51-10-2.

Part: SKIN — CRACKED (LT WING)

INSPECTION FOUND THE LT WING UPPER TRAILING EDGE SKIN AT CUTOUT FOR NR 4 SPOILER SECOND FROM O/B HINGE AND SECOND FROM I/B HINGE CRACKED. BOTH CRACKS WERE 5/16 LONG. THE FASTENERS WERE REMOVED IAW SRM 51-30-2. THE CRACKS WERE STOP DRILLED AND DOUBLER REPAIRS WERE INSTALLED IAW SRM 57-30-4, FIGURE 10.

Part: BATTERY — DISCHARGED (CABIN)

FORWARD GALLEY AISLE EMERGENCY LIGHT INOPERATIVE. CHARGED BATTERIES AND REINSTALLED LIGHT ASSEMBLY IN ACCORDANCE WITH MM 33-50-0.

Part: CONNECTOR — BROKEN (CABIN)

LEFT OVER WING EMERGENCY LIGHT INOPERATIVE. REPAIRED CONNECTOR.

Part: SOCKET — DIRTY (CABIN)

L1 EXTERIOR SLIDE LIGHT INOPERATIVE. CLEANED AND REPAIRED LIGHT SOCKET PER MM 33-50-0.

Part: STRINGER — CRACKED (VERT STAB)

VERTICAL STABILIZER INNER COMPARTMENT NR 6 RIB AND STRINGER 10 (LEFT) CRACKED 1. CUT OUT DAMAGED SECTION. FABRICATED AND INSTALLED REPAIR IN ACCORDANCE WITH SRM 55-30-4.

Part: SKIN — HOLE (RT TE FOREFLAP)

HOLE IN UPPER INBOARD SURFACE OF RIGHT INBOARD FOREFLAP. REMOVED AND REPLACED RIGHT INBOARD FLAP ASSEMBLY IN ACCORDANCE WITH MM-27-51-01.

Part: SKIN — DELAMINATED (RT TE MIDFLAP)

INSPECTION FOUND TRAILING EDGE OUTBOARD END OF RT OUTBOARD MID FLAP DELAMINATED. A COLD BOND REPAIR WAS PERFORMED IAW SRM 51-40-6.

Part: SKIN — DELAMINATED (RT TE FLAP)

INBOARD T/E OF RIGHT OUTBOARD T/E FLAP HAS SLIGHT DELAMINATION. REMOVED AND REPAIRED TRAILING EDGE FLAP IN ACCORDANCE WITH SRM 27-51-2.

Part: SKIN — CRACKED (RT TE FLAP)

RIGHT INBOARD AFT FLAP INBOARD AFT CORNER DELAMINATED. REPLACED FLAP IN ACCORDANCE WIH MM 27-51-01.

Part: STRAP — CORRODED (BS 1130)

CABIN FLOORBEAM STIFFENER STRAP CORRODED. POSSIBLE BEAM LOWER CHORD WITH CORROSION BS 1130, RBL 54. CUT OUT DAMAGE. FABRICATED NEW STRAP, TREAT PRIME AND INSTALLED NEW STRAP. REMOVED CORROSION AT BEAM LOWER CHORD PER SRM 53-10-1 FIG 3 AND FCD 5316-63307.

Part: ANGLE — CRACKED (BS 1273)

INSPECTION FOUND A 2 INCH CRACK IN RIGHT TORQUE BOX CHANNEL ANGLE, AT BS 1273 BELOW AFT STAIR ACTUATOR FITTING ATTACHMENT. THE ANGLE WAS REMOVED AND REPLACED IAW SRM 51-10-1.

Part: SKIN — CRACKED (WS 456)

RIGHT WING UPPER LEADING EDGE SKIN IS CRACKED AT STA 456 CRACK 3. REMOVED DAMAGED AREA. FABRICATED REPAIR, TREATED, PRIMED, AND INSTALLED IN ACCORDANCE WITH SRM 57-30-4.

Part: FIRE WARNING — ACTIVATED (APU)

THE APU FIRE WARNING LIGHT ILLUMINATED WHILE EN ROUTE. THE APU FIRE BOTTLE WAS DISCHARGED AND THE LIGHT EXTINGUISHED, BUT CAME BACK ON. THE AIRCRAFT WAS DIVERTED TO PIT. THE LIGHT EXTINGUISHED AGAIN AFTER 10 MINUTES AND THE AIRCRAFT LANDED AT PIT WITHOUT FURTHER PROBLEM. MAINTENANCE INSPECTED THE WHEEL WELL AREA, APU AND APU EXHAUST AND FOUND NO EVIDENCE OF FIRE OR OVERHEAT CONDITIONS. THE APU FIRE BOTTLE WAS REMOVED AND REPLACED. THE APU WAS RUN AND A FIRE TEST WAS PERFORMED WITH NO FIRE WARNING INDICATIONS NOTED. MAINTENANCE WAS UNABLE TO DUPLICATE THE PROBLEM.

Part: SKIN — DELAMINATED (RT ELEV TAB)

INSPECTION FOUND RT ELEVATOR TRIM TAB TRAILING EDGE DELAMINATED. A COLD BOND REPAIR WAS ACCOMPLISHED IAW SRM 51-40-6. WEIGHT AND BALANCE CHECKED WITHIN LIMITS IAW SRM 51-80-9.

Part: FRAME — CORRODED (BS 1130)

INSPECTION FOUND FRAME CORRODED BETWEEN STRINGER 27L AND 28L AT STA 1130. A SHEAR TIE REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-10-4.

Part: STRINGER — CORRODED (BS 1148-1166)

INSPECTION FOUND STRINGER 30 CORRODED BETWEEN STA 1166 AND 1148. A STRINGER REPAIR WAS FABRICATED AND INSTALLED IAW SRM 53-3-10, FIGURE 1, SHEET 1 TO 4.

Part: FLANGE — CRACKED (LT MLG WW)

INSPECTION FOUND COLLAR CRACKED THROUGH LOCKING BOLT HOLE AT PIN BETWEEN INBOARD END OF GEAR BEAM AND H-LINK IN LT WHEELWELL AREA. THE PIN RETAINER FLANGE WAS REMOVED AND REPLACED IAW SRM 57-40-0.

Part: SKIN — CRACKED (LT WING LE)

INSPECTION FOUND THE LT WING LEADING EDGE SKIN BENT AND WITH SEVERAL 1 INCH CRACKS AT NR 3 SLAT ACTUATOR CUTOUT. REPAIR DOUBLERS AND FILLER WERE FABRICATED AND INSTALLED IAW ECRA 5720-01540.

Part: SKIN — DENTED (BS 720)

INSPECTION FOUND RT FUSELAGE SKIN DENTED AT STA 720C. THE DENT WAS REWORKED IAW SRM 53-30-1. AN HFEC INSPECTION WAS ACCOMPLISHED WITH NO CRACKS NOTED.

Part: BATTERY — INOPERATIVE (CABIN)

THE RT OVERWING EMERGENCY EXIT LIGHT WAS FOUND INOPERATIVE DURING EMERGENCY LIGHT OPERATIONAL CHECK. THE BATTERY CARTRIDGE WAS REMOVED AND REPLACED AND OPERATION OF THE EXIT LIGHT CHECKED GOOD IAW MM 33-50-0.

Part: SKIN — CHAFED (RT TE FLAP)

INSPECTION FOUND THE RT INBOARD TRAILING EDGE AFT FLAP CHAFED AT TOP SURFACE, INBOARD END. THE CHAFED AREA WAS CUT OUT AND A HOT BOND REPAIR WAS ACCOMPLISHED IAW SRM 51-40-6.

Part: SKIN — DELAMINATED (NR 4 TE FOREFLAP)

INSPECTION FOUND LT INBOARD FORE FLAP LOWER SURFACE DELAMINATED BOTH SIDES OF NR 4 FLAP TRACK. A FIBERGLASS OVERLAY REPAIR WAS ACCOMPLISHED IAW SRM 51-40-6.

Part: SKIN — DELAMINATED (LT TE AFT FLAP)

INSPECTION FOUND A DENT WITH DELAMINATION 33 INCHES FROM INBOARD END LOWER SURFACE OF LT OUTBOARD AFT FLAP. THE DAMAGED AREA WAS CUT OUT AND A HOT BOND REPAIR WAS ACCOMPLISHED IAW SRM 51-40-6.

Part: BEARING — RUSTED (TE FLAP)

FLT NR 0267 - EWR - THE TRAILING EDGE FLAPS WOULD NOT RETRACT BEYOND 3.5 DEGREES AFTER TAKEOFF FROM EWR. FUEL WAS DUMPED AND THE AIRCRAFT WAS RETURNED TO EWR. MAINTENANCE FOUND THE FLAP HANDLE BINDING. THE INPUT CRANK IN RIGHT WHEEL WELL WAS DISCONNECTED AND THE FLAP HANDLE OPERATED FREELY. THE PULLEY WAS LUBRICATED AND CABLE RUNS AND CONTROL VALVES WERE INSPECTED. THE LOWER BEARING ON CONTROL DRUM WAS FOUND RUSTED. THE BEARING WAS REPLACED AND THE FLAPS WERE CYCLED SEVERAL TIMES WITH NO BINDING. (M)

Part: SHEAR TIE — CRACKED (VERT STAB)

GSO - INSPECTION FOUND A .5 INCH CRACK IN SHEAR TIE AT VERTICAL STABILIZER STATION 157, STRINGER 9R. THE SHEAR TIE WAS REMOVED. A NEW SHEAR TIE WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND BAC DRAWING 65-16812. (M)

Part: SHEAR TIE — CRACKED (VERT STAB)

GSO - INSPECTION FOUND A .5 INCH CRACK IN SHEAR TIE AT VERTICAL STABILIZER STATION 25, STRINGER 7R. THE SHEAR TIE WAS REMOVED. A NEW SHEAR TIE WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND BAC DRAWING 65-16811. (M)

Part: SHEAR TIE — CRACKED (VERT STAB)

GSO - INSPECTION FOUND A .75 INCH CRACK IN SHEAR TIE AT VERTICAL STABILIZER STATION 25, STRINGER 10R. THE SHEAR TIE WAS REMOVED. A NEW SHEAR TIE WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND BAC DRAWING 65-16881. (M)