N8890Z

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 54,146 hrs · 35,491 cycles

2 EMERGENCY EXIT LIGHTS MID CABIN OVERHEAD EXIT SIGNS INOP. REPLACED POWER SUPPLY AND BATTERY PACK, CKS OK.

Part: BATTERY — DISCHARGED (CABIN) · airframe 53,607 hrs · 35,079 cycles

EMERGENCY LIGHT OVER 1L DOOR WILL NOT LIGHT. REPLACED BATTERIES, OP CHECKS NORMAL.

Part: SPAR — CRACKED (L/E SLAT) · airframe 53,316 hrs · 34,872 cycles

FOUND ON B2 LETTER CK 1 IN CRACK NR 7 SLAT SPAR AT TAI DUCT CUTOUT UPPER INBD CORNER. REPAIRED PER MM 57-54-000-8 AND ERA.

Part: CHARGER — INOPERATIVE (CABIN) · airframe 52,915 hrs · 34,606 cycles

FOUND AFT OVERHEAD EXIT LIGHT INOP. REMOVED AND REPLACED BATTERY PACK AND CHARGING RACK. CHECKS GOOD.

Part: SKIN — DEBONDED (T/E FLAP) · airframe 52,690 hrs · 34,472 cycles

RIGHT OUTBOARD MIDFLAP TRAILING EDGE BONDED. ASSEMBLY WAS FOUND WITH TYPICAL LOWER SKIN TO CORE DEBONDING.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 52,355 hrs · 34,278 cycles

AFT SEAT ROWS EMERGENCY LIGHTS INOP. REPLACED EMERGENCY POWER SUPPLY M9027.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 52,320 hrs · 34,256 cycles

DURING S/C FOUND FWD LEFT DOOR OVERHEAD EMERGENCY LIGHTS INOP. REMOVED AND REPLACED LIGHT ASSEMBLY AND BATTERY PACK. CHECKS GOOD.

Part: TRANSCEIVER — FAULTY (WX RADAR) · airframe 52,090 hrs · 34,109 cycles

RADAR INOP. REPLACED TRANSCEIVER AND NR 2 VG CHECKS GOOD.

Part: SKIN — CORRODED (FS 500, S-26L/R) · airframe 52,071 hrs · 34,098 cycles

FUSELAGE / SKIN / FS 481-520 / STRG. 26L-26R : CORROSION REPAIR THE FUSELAGE SKIN WAS CORRODED IN SEVERAL AREAS BETWEEN FS 481 & 520 AND BETWEEN STRINGERS 26L & 26R. THE SKIN WAS CUT AT FS 520 BETWEEN THE LAP JOINT STRINGERS 26L & 26R. THE CORRODED SECTION OF SKIN WAS REMOVED AND REPLACED WITH A NEW SKIN. THE SKIN WAS SPLICED AT FS 520 WITH TWO EXTERNAL ALUMINUM DOUBLERS PER ER/A 382204-14AD, REV A.

Part: RIB — CRACKED (RT WING) · airframe 52,071 hrs · 34,098 cycles

INSPECTIONS OF THE UPPER RIB CHORD ON THE RT WING AT RBL 70.5 PER BAC S/B 727-57-0112 AND AD 94-07-08 REVEALED A CRACK IN A FASTENER HOLE AT FS 760.95. THE HOLE WAS OVERSIZED TO REMOVE THE CRACK AND THEN COLD WORKED. THE HOLE WAS BUSHED AND THE CHORD REINFORCED WITH AN ALUMINUM ANGLE PER THE BAC S/B AND PER ER/A 382192-14AD, REV A.

Part: SKIN — CORRODED (FS 580, S-26L) · airframe 52,071 hrs · 34,098 cycles

FUSELAGE / SKIN / FS 549-604 / STRG. 25L-28L : CORROSION CUTOUT REPAIR THE FUSELAGE SKIN WAS FOUND CORRODED NEXT TO AN EXISTING REPAIR. THE EXISTING REPAIR WAS REMOVED AND ALL DAMAGES REMOVED WITH A 50" X 16" CUTOUT BETWEEN STRINGERS 25L & 28L AND BETWEEN FS 549 & 604. THE CUTOUT WAS REPAIRED WITH TWO EXTERNAL ALUMINUM DOUBLERS PER ER/A 382201-14, REV B.

Part: SKIN — CRACKED (FUSELAGE) · airframe 52,071 hrs · 34,098 cycles

THE LOWER HINGE CUTOUT OF THE L1 DOOR OPENING WAS FOUND WITH A 3/8 INCH CRACK IN THE SKIN AND UNDERLYNG BEARSTRAP. THE CRACK WAS ROUTED OUT OF THE SKIN AND BEARSTRAP STACK-UP TO REMOVE THE DAMAGE. THE ROUTE OUT WAS REPAIRED PER ER/A 382170-14, REV A.

Part: STIFFENER — CRACKED (FUSELAGE) · airframe 52,071 hrs · 34,098 cycles

A 1 INCH CRACK WAS FOUND AT THE LOWER END OF THE LBL 8 VERTICAL BEAM AT WL 182 ON THE FS 1183 BULKHEAD. THE CRACK IS TYPICAL OF BAC S/B 727-53-0175. THE CRACK WAS REPAIRED PER THE S/B AND PER ER/A 382193- 14.

Part: FRAME — DAMAGED (STA 580 STR 28L) · airframe 52,071 hrs · 34,098 cycles

REPAIRED STA 580 SHEAR TIE JUST OUTBD OF STR 28L PER SRM 53-10-4 FIG 15. SSI DATA RETRIEVAL FORM COMPLETED AND SENT

Part: FRAME — CRACKED (STA 500 STR 28L) · airframe 52,071 hrs · 34,098 cycles

MADE 2 EA REPAIRS TO STA 520 SHEAR TIES ON INBD AND OUTBD SIDES OF STR 28L PER SRM 53-10-4 FIG 15. SSI DATA RETRIEVAL FORM COMPLETED AND SENT.

Part: ATTACH FITTING — CRACKED (FLAP ACTUATOR) · airframe 52,071 hrs · 34,098 cycles

1/4 INCH CRACK NR 5 L/E FLAP ACTUATOR ATTACH BOX O/B RIB. REPAIRED PER MM 57-20-021-8

Part: SLAT — CRACKED (#2 POSITION) · airframe 52,071 hrs · 34,098 cycles

REPAIRED #2 SLAT LOWER COVE SKIN ATTACH ANGLE PER 727 M/M 57-54-000-8 FIG 807A AND ERA 382247-14 REV ORG

Part: BATTERY — DISCHARGED (AIRSTAIRS) · airframe 51,844 hrs · 33,953 cycles

AIRSTAIRS EMERGENCY LIGHT INOP. REPLACED BATTERIES, OPS NORMAL NOW.

Part: COALESCER BAG — DIRTY (A/C BAY) · airframe 51,094 hrs · 33,444 cycles

AT FL 310 FLIGHT CREW SMELLED STRONG ODOR OF RAW CAR GAS, F/A IN AFT OF A/C SMELLED SAME. DIVERTED TO CVG, RAN FUME CHECKLIST IN ENTIRETY. INSPECTED E/E COMPARTMENT BAG BINS AND LAV AREAS NO GASOLINE SMELLS. RAN ENGINES PRESS A/C NO SMELLS NOTED. REPLACED WATER SEPARATOR BAGS, INSPECTED ACMS. NO PROBLEMS NOTED. A/C OK FOR SVC.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 50,974 hrs · 33,375 cycles

DURING SVC CHECK FOUND LT AFT OVERWING EMERGENCY LIGHT OUT. RELAMPED, NO HELP. NO POWER AT SOCKETS. REPLACED BATTERY PACK, OPS CHECK GOOD.

Part: BATTERY — DISCHARGED (CABIN) · airframe 50,828 hrs · 33,280 cycles

RT OVERWING LIGHT INOP. REPLACED BATTERY.

Part: SKIN — CRACKED (FUSELAGE) · airframe 50,673 hrs · 33,167 cycles

FUSELAGE SKIN, R1 DOOR CUTOUT LOWER AFT CORNER. A CRACK WAS FOUND IN THE SKIN AND UNDERLYING BEARSTRAP OF THE LOWER AFT CORNER OF THE FWD GALLEY (R1) DOOR CUTOUT. THE CRACK WAS REMOVED WITH A 3 IN X 3 IN CUTOUT. THE CRACK WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND TRIPLER INSTALLED PER ER/A 380623-14, REV A.

Part: PANEL — MISSING (LT WING) · airframe 50,161 hrs · 32,826 cycles

ON WALK-AROUND FOUND PANEL AFT OF LT WING FENCE MISSING. REPLACED PANEL.

Part: FRAME — TOOL DAMAGE (FUSELAGE) · airframe 50,154 hrs · 32,821 cycles

MISDRILLED HOLE REPAIR WHILE ACCOMPLISHING INSPECTIONS AND MTC. TO THE FWD FRAME OF THE C1 DOOR OPENING, THREE HOLES COMMON TO THE OUTER FRAME CHORD AND FRAME SPLICE NEAR S-18R WERE BADLY MISDRILLED. THE DAMAGED SECTION OF CHORD WAS REMOVED AND A NEW SECTION SPLICED IN WITH A STEEL SPLICE ANGLE. THE WEB WAS CUT AND A NEW SECTION SPLICED IN WITH AN ALUMINUM DOUBLER. THE REPAIR WAS ACCOMPLISHED PER ER/A 379930-14AD, REV A.

Part: BATTERY — DISCHARGED (LEFT OVERWING) · airframe 49,819 hrs · 32,584 cycles

LEFT EXTERIOR OVERWING LIGHT FOUND TO BE WEAK. REPLACED BATTERY PACK

Part: LINE — LOOSE (NR 3 ENGINE) · airframe 49,333 hrs · 32,245 cycles

NR 3 ENGINE OIL LEAK IN-FLIGHT. SERVICED OIL. RAN ENGINE AND FOUND B-NUT AT NR 4 BEARING SCAVENGE LINE LOOSE. TIGHTENED SAME.

Part: POWER SUPPLY — MALFUNCTIONED (FUEL FLOW IND) · airframe 49,258 hrs · 32,189 cycles

REJECTED T/O AT 80 KTS, 181,000 LBS. ALL FUEL FLOWS WENT TO ZERO ON T/O ROLL AFTER HITTING A BUMP AT 80 KTS. DURING ABORT ALL FF''S BEGAN WORKING AGAIN. REPLACED FF PWR SUPPLY AND BOTH FF C/B''S. GROUND RUN, CHECK NORMAL.

Part: MOUNT — CRACKED (NR 1 & 3 PYLONS) · airframe 48,153 hrs · 31,412 cycles

BHEC INSPECTION OF THE NR 1 & 3 ENGINE PYLON FWD ENGINE MOUNTS INDICATED A CRACKED FASTENER HOLE IN THE NR 3 MOUNT AND 2 CRACKED HOLES IN THE NR 1 MOUNT. THE CRACKS ARE TYPICAL OF BAC S/B 727-54A0010 AND AD 97-05-08. THE CRACKS WERE REMOVED WITH A .0156 INCH O/S OF EACH HOLE. AN ADDITIONAL .0312 INCH INSURANCE CUT WAS MADE ON EACH HOLE AND NEW FASTENERS INSTALLED PER ER/A 377118-14AD, REV A.

Part: WEB — CRACKED (BS 1288)

FOUND ON F2 LETTER CK, TWO .25 INCH CRACKS ON RT VERTICAL TORQUE BOX WEB AT UPPER LIGHTENING HOLE STA 1288. REPAIRED PER MM 53-11-0.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY EXIT LIGHT ABOVE R2 PASSINGER DOOR INOP. REPLACED BULBS AND BATTERY PACK.

Part: PUMP — FAILED (B HYD SYS)

HYD SYSTEM B NR 2 PUMP LIGHT CAME ON INTERMITTANTLY THEN STEADY B HYD PRESSURE FLUCTUATED THEN WENT TO ZERO AND LOST SYSTEM B NR 1 HYD PUMP AT THE SAME TIME. A HYD SYSTEM GOOD WITH GOOD PRESSURE.

Part: SKIN — BIRD STRIKE (NR 3 LE SLAT)

NR 3 L/E SLAT/UPPER SKIN / OSS 170 - 190 DENT REPAIR. AT SHOP VISIT, THE UPPER SKIN WAS FOUND WITH A LARGE DENT. UPPER SKIN CUTOUT RESULTED IN APPROX 20 X 20 CUTOUT. INCLUDING THE UPPER SKIN AFT OF THE NOSE BEAM AND THE L/E SKIN FWD OF THE NOSE BEAM. EXTENERAL REPAIR INSTALLED USING SOLID FASTENERS AFT OF NOSE BEAM AND BLIND FASTENERS. INSTALLED FWD OF NOSE BEAM IN INACCESSIBLE AREAS.

Part: ANGLE — CRACKED (LT WING)

ANGLE CRACKED APPROX 3 INCHES AND FASTENERS SHEARED AT FWD SIDE OF NR 7 SPOILER ACTUATOR CASTING. REPAIRED ANGLE PER M/M 57-20-22 PG 809 PER ERA 367745-14 REF NR 64.

Part: FLOORBEAM — CORRODED (BS 344)

DURING MV1 CORROSION VISIT, NRC 54 CORROSION ON TOP SURFACE OF FLOORBEAM STA 344 FROM LBL 24 TO RBL 12. REPAIRED PER SRM 53-10-8 FIG 11.

Part: TR LIGHT — ILLUMINATED (NR 3 ENGINE)

ON RUNWAY, NR 3 T/R OPERATING LIGHT CAME ON. CYCLED HANDLE LIGHT EXTINGUISHED. TAKEOFF TERMINATED. CHECKED NR 3 T/R. ALL CKS OK RAN NR 3 ENG, OPERATED NR 3 T/R. ALL CKS OK, ALL IND NORMAL.

Part: ANGLE — CORRODED (NR 2 ENGINE)

WHILE WORKING HUSH-KIT, FOUND NR 2 ENG RT AFT MOUNT CHORD ANGLE CORRODED BEYOND MFG SPECS. REPLACED PART WITH ONE OF NEW MFG.

Part: WEB — CRACKED (BS 1233)

REF SHIP 438 TPA LTR CHK E-2 12-02-98, .5 CRACK RT TORQUE BOX VERT WEB AT UPPER END STA 1233. REPAIRED PER MM 53-11-0 PG832.

Part: STRINGER — CRACKED (VERT STAB)

REF SHIP 538 TPA LTR CHK E-2 12-02-98, VERT FIN STRINGER 10L CRACKED STA 180.6. REPAIRED PER MM 55-30-0.

Part: WEB — CRACKED (BS 1236 & 1228)

REF SHIP 438 TPA LTR CHK E-2 12-02-98, TWO CRACKS AT LIGHTNING HOLES RT SIDE TORQUE BOX STA 1236 AND 1228. REPAIRED PER MM 53-11-0 PG 828.

Part: PWR SUPPLY — INOP (ROW 1-11)

FOUND ON L/O, EMERGENCY ESCAPE PATH LIGHTS INOP ROW 1 THROUGH 11. REPLACED POWER SUPPLY AND BATTERY.

Part: BATTERY — DISCHARGED (ROW 1-11)

FOUND ON L/O, EMERGENCY ESCAPE PATH LIGHTS INOP ROWS 1-11. REPLACED PWR SUPPLY AND BATTERY.

Part: FUSE — FAILED (CABIN)

FWD EMER FLOOR LIGHTS INOP. REPLACED FUSES NR 1 PWR SUPPLY, OPS CKS NORMAL.

Part: RETRACT MECH — FAILED (RT MLG)

UPON CLIMBOUT, RT MAIN GEAR REMAINED DOWN WITH GEAR HANDLE RAISED. CYCLED GEAR PER POM PROCEDURES. GEAR REMAINED DOWN. FLT RETURNED TO CVG. REPLACED UPLOCK ACTUATOR AND SEQUENCE VLV. DID RETRACTION AND EXTENT CHECK. ALSO, MANUAL EXTENT CHECK PER M/M CHAP 32, OPS NORMAL.

Part: BATTERY — DISCHARGED (CABIN)

F/C EMERGENCY TRACK LIGHTS INOP. REPLACED BATTERY.

Part: BRACKET — CRACKED (NR 1 LE SLAT ACT)

WING NR 1 SLAT ACTUATOR SUPPORT BRACKET, REPAIR FOR CRACKED WEB AND DOUBLER. THE NR 1 SLAT OUTBD ACTUATOR SUPPORT BRACKET WAS FOUND WITH THE WEB AND DOUBLER CRACKED. BOTH THE INBD AND OUTBD BRACKETS WERE MODIFIED PER BAC S/B 727-57-0130. THE REPAIR WAS DOCUMENTED PER ER/A 365812-14AD.

Part: DOOR — CRACKED (LT/RT MLG)

A .300 LONG CRACK AT THE RT AND LT MLG DOOR CLOSE OUTS. TIME LIMITED REPAIR MADE PER ERA 364849-14.

Part: WIRE — SHORTED (CABIN)

EMERGENCY TRACK LIGHTS INOP AT ROW 10 TO 17. REPAIRED SHORTED WIRES IN TRACK AT 13 DEF.

Part: WEB — CRACKED (BS 1283)

A .3750 INCH CRACK AT LIGHTENING HOLE RT TORQUE BOX VERTICAL WEB STA 1283. ROUTED PER M/M 53-11-0 NR 15.

Part: SKIN — DAMAGED (BS 219.8)

THE FUSELAGE SKIN WAS DAMAGED DUE TO CONTACT WITH GROUND SUPPORT EQUIPMENT. THE DAMAGE LIES FWD OF THE STA 227.8 CIRC BUTT JOINT, AND BELOW THE S-24R LAP SPLICE. THERE IS NO REPORTED DAMAGE TO THE INTERNAL STRUCTURE. IN ADDITION, THE SKIN AFT OF THE STA 227.8 CIRC BUTT JOINT HAS A 6 LONG BY .12 MAX DEEP SCRATCH RUNNING AFTWARD FROM THE PANEL FWD EDGE. THE SCRATCH RUNS THROUGH ONE OF THE FORMER ATTACH FASTENERS LOCATED IMMEDIATELY AFT OF THE SKIN PANEL FWD EDGE, BACR15CE6D. REPAIRED PER ERA 362748-14 REV A.

Part: SKIN — CORROSION (BS 830-840)

FOUND CORROSION ON THE LOWER SKIN BETWEEN S-4C AND S-3C AND BETWEEN BS 830 AND BS 840. REPAIRED IN ACCORDANCE WITH DAL ER/A 304410-14AD, REV B.

Part: SKIN — CRACKED (RUDDER)

FOUND A 2 INCH CRACK IN THE LOWER RUDDER SKIN, MIDWAY CENTER. REPAIRED PER SRM 55-20-3.

Part: FLOORBEAM — CORRODED (BS 360)

FLOOR BEAM STA 360 CORRODED. REPAIRED PER M/M 53-20-11 FIG. 804A.

Part: SKIN — CORRODED (FUSELAGE)

LT WING ICE LIGHT MATING FLANGE CORRODED. REPAIRED PER SRM53-30-3.

Part: RIB — CRACKED (VERT STAB)

VERTICAL RIB INSIDE PLATE 9504 CRACKED LEFT AND RIGHT SIDE JUST ABOVE S-DUCT. REPAIRED PER SRM 53-10-4.

Part: SPAR — DAMAGED (NR 4 TE FLAP)

NR 4 MID FLAP DAMAGED AT AFT SPAR I/B AFT CORNER, LOWER SIDE. REPAIRED DAMAGE PER MM 57-52-00, FIG. 808.

Part: BATTERY EMPTY (CABIN)

FOUND LT OVERWING EMERGENCY LIGHT OUT. REPLACED BATTERY PACK. OPS CHECK OK.

Part: WEB — CRACKED (BS 1213)

FOUND DURING C CHECK - .1250 INCH CRACK TORQUE BOX WEB ABOVE STAIRWAY CLOSEOUT PANEL, STA 1213. REPAIRED PER M/M 53-11-0.

Part: WEB — CRACKED (BS 1243)

FOUND DURING C-CHECK, .6250 INCH CRACK AT TORQUE BOX WEB LIGHTNING HOLE STA 1243R. REPAIRED PER M/M 53-11-0.

Part: ANGLE — CRACKED (NR 6 LE FLAP)

FOUND DURING C-CHECK - FOUND NR 7 SLAT ANGLE CRACKED AT ANTI-ICE DUCT CUTOUT. REPAIRED PER M/M 57-54-0. NR 6 SLAT OUTBOARD TRACK WING CUTOUT CRACKED .25 INCH. REPAIRED PER M/M 57-20-21.

Part: RIB — CRACKED (NR 6 LE SLAT)

FOUND DURING C-CHECK - NR 6 SLAT ACTUATOR ROD END ATTACH RIB CRACKED PAST PREVIOUS STOP DRILL INBOARD SIDE AND CRACKED .3750 INCH ON OUTBOARD SIDE. REPAIRED INBOARD RIB PER M/M 57-54-0, FIG 804 AND REPAIRED OUTBOARD RIB PER M/M 57-54-0, PG 803.

Part: ACT MOUNT BRKT — CRACKED (RT LE FLAPS)

FOUND DURING C-CHECK - CRACK NR 8 SLAT ACTUATOR MOUNT BRACKETS, INBOARD AND OUTBOARD SIDES. REPAIRED PER M/M 57-20-21.

Part: PACKING — LEAKING (NR 1 ENGINE)

NR 1 ENGINE SHUTDOWN IN FLIGHT DUE TO LOSS OF OIL PRESSURE AND QUANTITY. QUANTITY WENT TO ZERO AFTER SHUTDOWN. FOUND PACKING LEAKING ON N1 ACCESSORY HOUSING REF PW JT8D,IPC 72-21-00 FIG 3A ITEM 110 (P/N 528174). CHECKED MOS, FOUND CLEAN. REPLACED PACKING, PERFORMED HIGH POWER RUNUP AND LEAK CHECK OK.

Part: SKIN — CORROSION (LOWER WING)

DURING INSPECTION OF THE LOWER SKIN PER EO 4-37113-3, CORROSION WAS DISCOVERED ON THE AFT SKIN BETWEEN S-4C AND S-3C AT APPROX RBL 30. MTC REPORTS A MIN REMAINING THICKNESS OF .063 AT THE DAMAGE AREA. ERA WILL PROVIDE TEMP AND PERM REPAIR INSTRUCTIONS. TEMP INSTR WILL REMOVE ALL EVIDENCE OF CORROSION AND TREAT THE SURFACE. PERM INSTR WILL INSTALL A DOUBLER AND TRIPLER AND FILLER IN DAMAGE AREA, PER DL ERA 302731-14AD.