N921L

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 82,176 hrs · 88,182 cycles

THE EGRESS LIGHTS WERE INOPERATIVE IN FIRST CLASS AND PART OF COACH CABIN. REPLACED THE POWER SUPPLY. CHECK-C 8-2-00 MCI.

Part: STRAP — DAMAGED (RT PYLON) · airframe 80,617 hrs · 86,844 cycles

THE RT PYLON RT AFT UPPER CAP STRAP AND RELATED STRUCTURE HAD OVERSIZED HOLES IN EXCESS OF THE NUMBER AUTHORIZED. REPAIRED PER EMLR 71221. UPPER CAP STRAP AND STRUCTURE REWORKED. CHECK-C 8-2-00 MCI.

Part: FRAME — CRACKED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINTENANCE CHECK FOUND (P/N 9911505-7) FRAME ON RIGHT SIDE HAD A .875 INCH CRACK IN RADIUS AT X=-1, CENTER WINDSHIELD. REPLACED FRAME WITH NEW, INSTALLED.

Part: SKIN — DELAMINATED (SPOILER) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINTENANCE CHECK, THE LEFT WING OUTBOARD FLIGHT SPOILER HAD DELAMINATED AREA ON TOP OF SPOILER INBOARD END. INSTALLED SERVICEABLE PANEL AND RIGGED.

Part: ACCESS PANEL — DAMAGED (LT WING) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK FOUND LT WING BOTTOM FUEL TANK ACCESS PLATE NR 1365, HAD 2 MOUNT RING SCREW HOLES ELONGATED. REPAIRED PER ARA 16924A. REAMING PER SRM 51-30-10, AND COLD WORKING PER SRM 51-30-9. ---CLOSED---

Part: SKIN — DAMAGED (LT WING) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK FOUND TOP OF LT WING WITH A CRACK APPROX 1 INCH LONG AT INBD FUEL TANK ENTRY MOUNT FLANGE (PLATE LANDING) NUMBER 1307. ACOMP EDDY CURRENT INSP PER NDT 51-00-03 CRACK CONTAINED. INSTALLED REPAIR DOUBLER PER ARA 16921. ---CLOSED---

Part: DOOR FRAME — CRACKED (CARGO BAY) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, THE FWD CARGO COMPT DOOR JAM LOWER AFT CORNER HAD 1.5 IN LONG CRACK IN FUSELAGE SKIN, AND 2.625 IN LONG CRACK IN DOUBLER. FUSELAGE SKIN AND DOUBLER REPLACED PER ARA 16930.

Part: INTERCOSTAL — CRACKED (NR 2 PYLON) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, NUMBER 2 PYLON INTERCOSTAL WAS CRACKED OFF TOP 6 INCHES FROM FUSELAGE, BOTTOM AFT OF PYLON INTERIOR, AFT END. REMOVED CRACKED INTERCOSTAL. FABRICATED REPAIR PER SRM 53-01 PAGE 8. HEAT TREATED REPAIR DOUBLER 2024, 0.050 TO 2024-T3 PER 51-10-2A. MATERIAL SUBSTITUTION PER 51-60-0. SEALED PER SRM 51-20-00.

Part: INTERCOSTAL — CRACKED (RT PYLON) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK ON RT PYLON BOTTOM AFT INTERIOR, 11 INCHES FROM FUSELAGE, TOP FWD INTERCOSTAL WAS CRACKED APPROX 2 INCHES LONG. CUT OUT CRACKED AREA, INSTALLED DOUBLERS PER SRM 54-01, PAGE 7 EXAMPLE D.

Part: ANGLE — CRACKED (NR 2 PYLON) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK ON NUMBER 2 PYLON, TOP FWD CLIP ANGLE WAS CRACKED OFF ON INTERCOSTAL 3.5 INCHES FROM FUSELAGE AFT BOTTOM AREA. REMOVED BRACKET PER MO 72J95 AND PER REWORK DRAWING 5917717.

Part: MOUNT — CRACKED (RT ENGINE) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, STA 1036 RT PYLON FWD SIDE OF ENGINE MOUNT STRUCTURE, 6 INCHES FROM FUSELAGE HAD CRACK AT AFT I/B CORNER OF BOX. STOP DRILLED CRACK, FABRICATED AND DRILLED 2 TITANIUM DOUBLERS AND INSTALLED ON ACFT PER SRM 54-01 METAL TO METAL REPAIR. FASTENER SUBSTITUTION PER SRM 51-60-00.

Part: FLOORBOARD — CRACKED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP16 FOUND A CRACK IN THE FLOOR MEMBRANE AT FS 614 RBL 56. REMOVED MEMBRANE FROM STATION 598 - 658 REF INTER-SHOP WORK TICKET 858855 FOR NEW MEMBRANE FABRICATION, INSTALLED MEMBRANE ON THE AIRCRAFT PER MD SRM 51-30-02 RIVET INSTALLATION AND 51-30-0 BOLTS, NUTS, WASHER INSTALLATION. OP16 05-19-00 MCI.

Part: RIB — CRACKED (LT WING) · airframe 80,344 hrs · 86,616 cycles

LEFT WING AFT END OF REPAIR ON LEADING EDGE RIB HAS A CRACK APPROX 1 INCH LONG XRS 350 AFT OF NUMBER 4 LEADING EDGE SLAT. STOP DRILLED AND CHECKED PER EDDY CURRENT PART 6 51-00-03 FIG 5 SHT 1. OP16 05-17-00 MCI.

Part: FRAME — CRACKED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP16, FOUND RT FRAME FS 658 HAS FIELD REPAIR ON EDGE STR 19R. ACCOMPLISHED A HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AREA PER TWA NDT 51-00-03 PART 6. CRACK CONTAINED. INSTALLED DOUBLER PER SRM 53-03 FIG 16 & 51- 60-0 PG 11. OP16 05-16-00 MCI.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP16, FOUND FS 1038 REAR ENGINE MOUNT WEB, TOP FWD END OF INTERCOSTAL IS CRACKED IN THE WEB RADIUS 13 INCHES FROM THE FUSELAGE. INSTALLED DOUBLER TOP FORWARD END OF THE INTERCOSTAL PER SRM 54-01 FIG 2 PG 7. OP16 05-15-00 MCI.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, FOUND STA 598, RBL 54 IN, HAD FLOOR MEMBRANE CRACKED. INSTALLED DOUBLER ON WEB PER SRM 53-01-9, FIG 2.

Part: INTERCOSTAL — CRACKED (NR 2 PYLON) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK ON NUMBER 2 PYLON, FOUND INTERCOSTAL CRACKED 3.5 INCHES FROM FUSELAGE AND 7 INCHES FROM FRONT, BOTTOM AFT AREA OF PYLON. REPAIRED CRACK PER SRM 54-01 PAGE 97 EX D. INSTALLED FASTENERS PER 51-30 AND 51-10-4. SEALED PER 51-70-2.

Part: RIB — CRACKED (HORIZONTAL STAB) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK ON LT HORIZ STAB LEADING EDGE ASSEMBLY, NUMBER 1 LEADING EDGE RIB, I/B END WAS CRACKED ON BOTTOM TRAILING EDGE, NUMBER 1 FROM I/B END. ACCOMP HIGH FREQ EDDY CURRENT ON END OF CRACK FOR CONTAINMENT PER 51-00-03 PART 6 OF NDT MANUAL. STOP DRILLED CRACK AND INSTALLED REPAIR CLIP -9 PER SRM 55-02 FIG 18.

Part: SKIN — DENTED (LT WING LE) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK ON LT WING, FOUND DENTS IN LEADING EDGE OF NUMBER 3 LEADING EDGE SLAT, DENT LOCATED 13 INCHES I/B FROM O/B END OF SLAT WAS 1 INCH WIDE BY 1 INCH LONG AND 0.050 INCH DEEP, DENT LOCATED 18 INCHES I/B FROM O/B END OF SLAT WAS .75 INCH LONG, 1 INCH WIDE AND 0.040 DEEP, AND DENT LOCATED 26 INCHES O/B FROM I/B END OF SLAT WAS 1 INCH LONG BY 1 INCH WIDE AND 0.040 IN DEEP. ON ALL 3 DENTS, ACCOM HIGH FREQ EDDY CURRENT PER NDT 51-00-03 PART 6 AND NO CRACKS FOUND. REPAIRED DENTS PER SRM 57-03 FIG 14A.

Part: SKIN — CRACKED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, FOUND FUSELAGE SKIN CRACKED AT LOWER AFT CORNER OF FWD RT SERVICE DOOR ENTRYWAY. INSTALLED DOUBLERS PER TWA DRAWING SRO 9530172.

Part: FRAME — CRACKED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, FRAME STA 945 LT WAS CRACKED AT LONGERON 12L. REPLACED FRAME SECTION (P/N 9957739-127) PER SPM 6-70-1, PARA 4 PAGE 2 AND 3 AND REF DOUGLAS DRAWING 995739. WORKED IN CONJUNCTION WITH MO 72J14 PHASE G, REF DWG JO60119.

Part: ANGLE — CRACKED (WINDOW FRAME) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, IN CABIN THE UPPER FWD WINDOW FRAME TIE ANGLE WAS CRACKED AT STA 680, RT SIDE. REPAIRED PER SSRM 53-10-114 PAGE 201. INSTALLED REPAIR PART WET WITH SEALER, WITH FASTENERS PER 51-30-2.

Part: PANEL — CRACKED (RT WING) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, FOUND CRACK INDICATION FROM THIRD BOLT HOLE, RT UPPER TRAP PANEL FLANGE OF WING CENTER SECTION. ACCOMP NDT PER PART 6-51-00-03. CUT OFF FLANGE PER SRM 57-09 FIG 6, TO FOURTH BOLT HOLE. ALODINE AND PRIME PER SRM 57-09 FIG 6 NOTE F.

Part: SKIN — CRACKED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, FUSELAGE SKIN WAS CRACKED APPROX .5 INCH AT TOP AFT ADJUSTMENT HOLE FOR FWD ENTRY DOOR, STA 200 AND STRINGER 9L. REPAIRED PER MO 72M82, PRINT SRO9530252-2001, AND EMLR 70777.

Part: FRAME — MISREPAIRED (FUSELAGE) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, THE LT 980 FRAME HAD A TEMPORARY REPAIR BETWEEN LONGERON 18 AND 16. REMOVED DAMAGED FRAME SECTION AND INSTALLED NEW SECTION PER SRM 53-03 FIG 32. REPAIR WORKED IN CONJUCTION WITH MO72J14 PHASE G CARD 0003 OF 7.

Part: SPAR — CRACKED (RT WING) · airframe 80,344 hrs · 86,616 cycles

DURING OP 16 MAINT CHECK, ON THE RT WING, HAD CRACK INDICATION ON WING SPAR CAP AT I/B FLAP HINGE FITTING, STA XRS164, LOWER I/B BOLT HOLE EXTENDED INTO LOWER RADIUS. REPLACED LOWER REAR SPAR CAP PER DOUGLAS DRAWING JO60165 AND MCD-AD-35.

Part: PAN — CORRODED (FUSELAGE)

DURING OP 16 MAINT CHECK, FOUND CORROSION ON THE FORWARD SERVICE DOOR ENTRY WAY LOWER PAN AREA. REPLACED THE LOWER PORTION OF THE DOOR PAN PER SRM 53-05, FIG 55 SHEET 1 THROUGH 7, DRAWING JO 60288.

Part: STRUCTURE — DAMAGED (BS 200)

DURING OP 16 MAINT CHECK, THE RT CABIN SERVICE DOOR ENTRY WAY PAN WAS DAMAGED AT STA 200, STRINGER 15R. INSTALLED DOUBLER PER SRM 53-05, FIG 42 SHEET 1 THROUGH 9.

Part: ANGLE — CORRODED (FUSELAGE)

DURING OP 16 MAINT CHECK, FOUND CORROSION ON FORWARD RT CABIN SERVICE DOOR ENTRYWAY, LOWER FWD CORNER UPPER CUSP ANGLE. REMOVED CORROSION SECTION OF CUSP ANGLE. INSTALLED NEW SECTION PER SRM 53-05 FIG 55.

Part: SKIN — CORRODED (FUSELAGE)

DURING OP 16 MAINT CHECK, FOUND CORROSION BETWEEN SKIN DOUBLERS AT FORWARD RT CABIN SERVICE DOOR ENTRYWAY, LOWER FWD CORNER. REMOVED CORROSION AND TREATED PER SRM 51-10-9. SPLICED IN NEW CUSP ANGLE PER SRM 53-05, FIG 55.

Part: ANGLE — DAMAGED (BS 165)

DURING OP 16 MAINT CHECK, THE RT FORWARD SERVICE DOOR ENTRYWAY LOWER FWD CORNER AT STA 165, HAD STRINGER 18R CUSP ANGLE CUT. REPAIRED LOWER CUSP ANGLE PER SRM 53-05 FIG 55 AND ARA 16238A.

Part: STRINGER — CRACKED (BS 200)

DURING OP 16 MAINT CHECK, STRINGER 4L WAS CRACKED AT STA 200. REPLACED STRINGER 4L AT STA 155 TO 229 PER SRM 51-01, PAGE 1. FASTENERS PER SRM 51-30-02 AND 51-30-5.

Part: SKIN — CRACKED (BS 200)

DURING OP 16 MAINT CHECK AT STA 200, THE FIRST FASTENER ABOVE STRINGER 4L HAD CRACK IN FUSELAGE SKIN 0.250 IN LONG. CRACK STOP DRILLED AND CONTAINMENT CONFIRMED BY NDT PER PART 6-51-00-03. SKIN WAS REPAIRED PER SRM 53-04 FIG 38.

Part: STRINGER — CRACKED (BS 200)

DURING OP 16 MAINT CHECK STRINGER 2L WAS CRACKED AT STA 200. INSTALLED NEW STRINGER FROM STA 149 TO 229, WITH RIVETS PER SRM 51-30-2 AND 51-30-5.

Part: SUPPORT — CRACKED (BS 69)

DURING OP 16 MAINT CHECK, THE VERTICAL SUPPORT WAS CRACKED AT STA 69, RBL 12 AT 1 O'CLOCK POSITION. INSTALLED NEW VERTICAL SUPPORT PN 9951860-6 PER DOUGLAS DRAWING 9957860 AND SPM 6-70-01, PAGE 3 PART 4B.

Part: LONGERON — CRACKED (BS 718)

FOUND A .1875 INCH CRACK AT LONGERON 6L STA 718. REPAIRED PER SRM 53-02, FIG 18. CHECK-C 7-14-98 STL.

Part: LONGERON — CRACKED (BS 658)

FOUND A .25 INCH CRACK IN LONGERON 6L AT STA 658. REPAIRED PER SRM 53-02, FIG 18. CHECK-C 7-14-98 STL.

Part: ACTUATOR — LEAKING (RT ENGINE)

YYZ - FLT 605 - AFTER TAKEOFF, RT HYDRAULIC SYSTEM INDICATED A FLUID LOSS. REPLACED LEFT MLG RETRACT CYLINDER AND RT ENGINE HYDRAULIC PUMP. (M)

Part: PUMP — LEAKING (RT ENGINE)

YYZ - FLT 605 - AFTER TAKEOFF, RT HYDRAULIC SYSTEM INDICATED A FLUID LOSS. REPLACED LEFT MLG RETRACT CYLINDER AND RT ENGINE HYDRAULIC PUMP. (M)

Part: FUEL TANKS — OVERFILLED (LT WING)

MCI - FLT 425 - DURING CRUISE, FUEL STARTED LEAKING OUT OF THE AFT LEFT WING. FOUND BOTH MAIN TANKS OVER FUELED, 9800 LBS IN BOTH TANKS. TRANSFERRED FUEL TO CENTER TANK. (M)

Part: HYD LINE — CHAFED (RT AFT BLKHD)

STL - FLT 358 - DURING DESCENT, RIGHT HYDRAULIC QUANTITY WENT TO ZERO. FOLLOWED QUICK REFERENCE HANDBOOK PROCEDURES. REPLACED HYDRAULIC LINE P/N 7912697-504 AND LEAK CHECKED. (M)

Part: OIL LINE — CRACKED (NR 1 ENGINE)

CMH - FLT 425 - DURING CRUISE, SHUT DOWN NR 1 ENGINE, SN 2146, DUE TO LOSS OF OIL QUANTITY. FOUND CRACKED OIL LINE, MFG PN 814776-01. REPLACED OIL LINE, SERVICED ENGINE OIL. ENGINE OPERATION CHECKED NORMAL. ENGINE TOTAL TIME: 58,369 HOURS; 68,640 CYCLES. CHECK C- 11-13-95 - STL.

Part: LONGERON — CRACKED (BS 756)

STL - DURING SPECIAL CHECK, FOUND A CRACK IN LONGERON 1L, STATION 756. REPAIRED PER SRM 53-02, FIGURE 4, PAGE 5. (M)

Part: WIRE HARNESS — OUT OF POSITION (COCKPIT)

FLT NR 471 - STL - DURING CLIMB, MAIN LANDING GEAR HANDLE WOULD NOT TRAVEL BEYOND ONE-THIRD OF TRAVEL. SPOILERS WOULD NOT ARM FOR LANDING. FOUND WIRE BUNDLE BLOCKING GEAR CONTROL LEVER. REPOSITIONED TO CLEAR AND SECURED WIRE BUNDLE. GEAR SWING OPERATIONS NORMAL.