N859AA

Part: WEB — CORRODED (AFT LAV)

TUL - FOUND 11 SPOTS OF CORROSION IN LEFT AFT LAVATORY FLOOR FROM LBL 30 INCHES TO LBL 50 INCHES. REMOVED CORROSION PER SRM 51-10-00. INSTALLED REPAIR DOUBLER OVER OUT OF LIMITS PORTION PER SRM 51-40-00. TREATED AND PRIMED AREA. (M)

Part: BEAM — CRACKED (FUSELAGE)

TUL - FOUND VERTICAL BEAM 36.83 AT STATION 1183 CRACKED OUTBOARD FLANGE. STOPPED DRILLED CRACK AND INSTALLED REPAIR ANGLES ON BEAM PER SERVICE BULLETIN 727-53-0192 REV 1 MAY 30, 91. (M)

Part: STRUCTURE — CRACKED (NR 1 PYLON)

TUL - HFEC INDICATES CRACK 1 INCH BY 1 INCH, ON UPPER CHORD ANGLE OUTBOARD AFT HOLE NR 1 ENGINE PYLON AT FORWARD ENGINE MOUNT FITTING. REPAIRED PER ESO 11697, DATED 11-22-2000. (M)

Part: SKIN — CRACKED (FUSELAGE)

TUL - FOUND CRACK IN SKIN AND GEAR STRAP AT FORWARD GALLEY DOOR AFT LOWER CORNER, FUSELAGE SKIN. STOP DRILLED CRACK AND INSTALLED DOUBLER PER SERVICE BULLETIN 727-53-0188. (M)

Part: BULKHEAD — CRACKED (TAIL)

TUL - FOUND CRACK IN PRESSURE BULKHEAD WEB INSIDE TAIL SKID CAVITY LBL 8 WL 202, STATION 1183. CUT OUT CRACKED AREA AND INSTALLED DOUBLER PER SERVICE BULLETIN 727-53-0175 REV 3. (M)

Part: LIGHT — DAMAGED (CABIN)

TUL - FOUND LIGHT ASSEMBLY DAMAGED DURING GALLEY REMOVAL FORWARD AISLE LIGHTING NR 1 GALLEY, STATION 360-400. REPLACED AND OPS CHECKED OK PER MM 33-60-098-4. (M)

Part: WEB — CRACKED (BS 294.5)

TUL - STA 294.5 WEB CRACK, RBL 23 INCHES FROM CENTER JUST ABOVE AND INBOARD OF RIGHT TUNNEL IN CHAMPAGNE LOUNGE. INSTALLED DOUBLER PER SRM 51-40-2. TST: 63,374 HOURS. CYCLES: 39,840. (X)

Part: STIFFENER — DAMAGED (BS 1183)

TUL - VERTICAL STIFFENER AT 1183 BULKHEAD FORWARD SIDE RBL 8 INCHES. REMOVED AND REPLACED VERTICAL STIFFENER, REF SRM 51-10-1, PG 4. TST: 63, 374 HOURS. CYCLES: 39,840. (X)

Part: LIGHT — INOPERATIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, FORWARD SECTION OF COACH CABIN OVERHEAD EMERGENCY EXIT LIGHT INOPERATIVE. REPLACED OVERHEAD EMERGENCY EXIT LIGHT ASSEMBLY. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — DEFECTIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT FLOOR PATH LIGHTS IN COACH CABIN INOPERATIVE. REPLACED EMERGENCY EXIT FLOOR PATH LIGHT JUMPER WIRE BETWEEN COACH AND FIRST CLASS CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: PACKING — DEFECTIVE (NR 3 ENGINE)

DFW - FLT 1614 - 10 MINS AFTER TAKEOFF DFW, WHILE ACCELERATING TO CLIMB POWER, THE NR 3 THROTTLE STARTED BINDING 2 KNOB WIDTHS SHORT OF CLIMB POWER. AT SAME TIME, NR 3 ENGINE OIL QTY STARTED TO DECREASE TO 0 AND THE NR 3 ENGINE OIL TEMPERATURE WENT TO 160 DEGREES CELSIUS. NR 3 OIL PRESSURE DECREASED TO 0 PSI. NR 3 LOW OIL PRESSURE LIGHT ILLUMINATED. NR 3 ENGINE WAS SHUT DOWN PER EMERGENCY PROCEDURES. ENGINE 1 AND 2 INDICATIONS WERE NORMAL. RETURNED AND LANDED DFW WITHOUT INCIDENT. REPLACED ENGINE. SYSTEM GROUND CHECKED NORMAL OPERATION. ENGINE TEAR DOWN REVEALED THAT THE NR 4 BEARING PRESSURE LINE PACKING WAS DETERIORATED. THE PACKING MATERIAL IN THE ID WAS TORN. (M)

Part: BLADE — FAILED (NR 2 ENGINE)

DFW - FLT 392 - ON TAKEOFF FROM DFW, EN ROUTE DFW-IAD, EXPERIENCED SEVERE VIBRATION FROM NR 2 ENGINE. VIBRATION WAS NOTICED IN THE CABIN AND COCKPIT. N2 ROLLED BACK TO ZERO. ACCOMPLISHED PRECAUTIONARY SHUTDOWN CHECKLIST. DECLARED AN EMERGENCY AND RETURNED DFW AND LANDED WITHOUT INCIDENT. REPLACED NR 2 ENGINE. SYSTEM GROUND CHECKED NORMAL OPERATION. DISASSEMBLY REVEALED DAMAGE TO THE 1ST STAGE HIGH PRESSURE TURBINE BLADES. VISUAL INSPECTION REVEALED MINIMAL SIGNS OF SULFIDATION IN ONE EACH THE LIGHTENING HOLES. FAILURE INDICATES THAT THE BLADE MATERIAL UNDERWENT CREEP AND STRESS RUPTURE. ONE EACH BLADE WAS EVALUATED FOR OVERTEMP SHOWING A METAL TEMP OF LESS THAN 2000 DEG F (LIMIT = 2000 DEG F, AT THE B

Part: LIGHT — DEFECTIVE (CABIN)

RDU - DURING OVERNIGHT MAINTENANCE, AFT EMERGENCY LIGHT IN AIRSTAIR INOPERATIVE. REPLACED EMERGENCY LIGHT ASSEMBLY IN AIRSTAIR. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: FRAME — CRACKED (BS 930)

TUL - FOUND CRACK ON FRAME AT STATION 930 AT STRINGER 14R. INSTALLED DOUBLER PER FIG 3 OF SB 727-53-0162. REWORK PRING 65C25313. (M)

Part: SKIN — GOUGED (TE MID FLAP)

TUL - FOUND APPROX 3 INCHES GOUGE IN TOP SKIN AT INBOARD END. INSTALLED DOUBLER REPAIR OVER DAMAGED AREA PER SRM 57-50-4 PAGE 21A. (M)

Part: STRINGER — CORRODED (BS 1182-1169)

TUL - FOUND STRINGER 29R BULGING 9 INCH SECTION, STATION 1176. REPLACED CORRODED STRINGER AND SPLICED PER SRM 53-10-3 FIG 1. (M)

Part: SKIN — CORRODED (BS 698-720)

TUL - FOUND CORROSION ON SKIN LAP JOINT STRINGER 26L FROM STATION 698-720. REMOVED DAMAGE AND FAB AND INSTALLED FILLER AND DOUBLER PER SRM 53-30-3, PAGE 76. (M)

Part: WEB — CORRODED (BS 1130-1178)

TUL - RIGHT SIDE OF WEB BETWEEN THE AFT LAVS CORRODED. MANUFACTURED NEW WEB. INSTALLED PER SRM 51-10-1. (M)

Part: GEAR BEAM — CORRODED (RT WING)

TUL - FOUND NR 5 FLAP TRACK INBOARD HOLE IN GEAR BEAM IS MISSING TOP SECTION OF BUSHING. RIGHT GEAR BEAM INBOARD HOLE HAS LIGHT CORROSION. REPAIRED AS PER ESO 11697. (M)

Part: ANGLE — CRACKED (BS 870)

TUL - FOUND CRACK AT LEFT CHORD ANGLE AT STATION 870. REPAIRED PER ESO 11697 AND SB 727-53-0208. (M)

Part: STRINGER — CORRODED (BS 950-952)

TUL - FOUND STRINGER 29R CORRODED STATION 950E TO 952E. INSTALLED DOUBLER STRAP PER ESO NR 11697. (M)

Part: SKIN — CORRODED (BS 1166)

TUL - FOUND CORROSION ON FUSELAGE SKIN STATION 1166, STRINGER 30. REMOVED CORROSION AND INSTALLED DOUBLER PER SRM 53-30-3 PAGE 8. (M)

Part: SKIN — CORRODED (BS 970)

TUL - FOUND FUSELAGE SKIN CORRODED BELOW BELL FRAME, STATION 970, RBL 8-RBL 11. CUT OUT CORROSION SECTION, ALODINED, PRIMED REINSTALLED NEW SECTION AND DOUBLER, FASTENERS PER SRM 53-10-4. (M)

Part: WEB — CORRODED (BS 1173-1178)

TUL - LEFT REAR CORNER OF CENTER WEB BETWEEN THE AFT LAV IS CORRODED. MANUFACTURED NEW WEB. INSTALLED PER SRM 51-10-1. (M)

Part: STRINGER — CORRODED (BS 1183)

TUL - FOUND AFT END OF STRINGER 29L BULGING. SPLICED IN NEW SECTION OF STRINGER PER SRM 53-10-3 DETAIL NR 1 PAGE 4B. (M)

Part: EEL TERMINAL — DEFECTIVE (AFT STAIRS)

MIA - DURING OVERNIGHT CHECK, FOUND AFT STAIRS EMERGENCY LIGHT INOPERATIVE. REPLACED GROUND TERMINAL END. SYSTEM GROUND CHECKED NORMAL OPERATION. (X)