N921WA

Part: TRUNNION — CORRODED (NLG) · corrosion level 2 · airframe 62,910 hrs · 31,242 cycles

DURING NOSE GEAR CHANGE, INSPECTED REPORTED LT NOSE GEAR TRUNNION BOSS CORRODED. REPLACED NOSE GEAR TRUNNION BOSS.

Part: DUCT — BROKEN · airframe 59,709 hrs · 29,114 cycles

ENROUTE FROM SAN TO DEN, FLIGHT CREW REPORTED CABIN SIDEWALL AT ROW 7 EXTREMELY HOT TO THE TOUCH AND AN OVERHEAT ODOR. AN EMERGENCY WAS DECLARED AND AIRCRAFT DIVERTED TO YUMA, AZ WITHOUT INCIDENT. AIRCRAFT WAS FERRIED TO PHX FOR REPAIR. MAINTENANCE REPLACED BROKEN BOOT IN MAIN DISTRIBUTION BAY. REPLACED BROKEN DUCT ON RT. SIDE OF CHRISTMAS TREE IN MAIN DISTRIBUTION SYSTEM. INSTALLED NEW CLAMP ON RT. SIDE OF CONDENSER CAN, REPLACED WATER SEPARATOR BAG AND O-RINGS. REPLACED DAMAGED TUBING AT ROWS 7A AND 7F. RAN BOTH ENGINES AND PERFORMED PRESSURIZATION CHECK AND LEAK CHECK. SYSTEMS CHECKED OKAY.

Part: DOOR FRAME — CRACKED · airframe 59,676 hrs · 29,090 cycles

DURING C-3 CHECK, INSPECTION REPORTED CRACK IN LOWER AFT CORNER OF C1 DOOR. DOOR WAS REPAIRED AT VENDOR AND RETURNED IN SERVICEABLE CONDITION.

Part: DOOR FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 59,676 hrs · 29,090 cycles

DURING C-3 CHECK, INSPECTION REPORTED CORROSION ON LT SIDE OF E&E DOOR CUTOUT BETWEEN CHORD AND SKIN. REMOVED DOOR FITTINGS, CORRODED WEBS, SKIN AND CHORDS. INSTALLED NEW CHORDS, WEBS AND STIFFENERS, NEW SKIN, FASTENERS, DOOR FITTINGS AND ALL RELATED HARDWARE AND STRUCTURE PER BOEING DRAWINGS 65-45800 AND SRM 53-10-2, 51-40-2 AND 53-10-1.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 59,676 hrs · 29,090 cycles

DURING C-3 CHECK, INSPECTION REPORTED AFT CARGO COMPARTMENT DOOR FRAME CRACKED AT LOWER SET OF BACK FASTENERS. REPAIRED PER SRM 51-40-04.

Part: SKIN — CRACKED (FUSELAGE) · airframe 59,676 hrs · 29,090 cycles

DURING C-3 CHECK, INSPECTION REPORTED CRACK IN L-2 DOOR CUTOUT, LOWER FWD CORNER, BS 947.5, S-18L, APPROXIMATELY 3.5 INCHES LONG. REPAIRED CRACK PER SRM 53-30-3, FIGURE 24.

Part: OIL FILTER — DIRTY (NR 1 ENGINE) · airframe 58,719 hrs · 28,490 cycles

FLIGHT CREW REPORTED NR 1 ENGINE OIL FILTER BYPASS LIGHT ILLUMINATED AT CRUISE. NR 1 ENGINE WAS SHUT DOWN IN FLIGHT AND AN EMERGENCY WAS DECLARED. AIRCRAFT DIVERTED TO MCI FROM ITS PLANNED DESTINATION OF MDW AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED NR 1 ENGINE OIL FILTER PER MM 79-35-0, PERFORMED BREATHER PRESSURE TEST PER MM 79-21-0 AND OPS CHECKED OK.

Part: ATTACH FITTING — BROKEN (FOREFLAP) · airframe 42,939 hrs · 27,467 cycles

DURING A-CHECK, MAINTENANCE REPORTED LT WING OTBD FOREFLAP OTBD ATTACH LINK BROKEN. REPLACED LT WING OTBD FOREFLAP.

Part: CHARGER — INOPERATIVE (ESCAPE SLIDE) · airframe 57,724 hrs · 27,838 cycles

L-1 DOOR SLIDE LIGHT INOPERATIVE. REPLACED L-1 DOOR SLIDE LIGHT ASSY, BATTERY AND CHARGER PER MM 33-51-71.

Part: STRINGER — CORRODED (CARGO BAY) · corrosion level 2 · airframe 23,039 hrs · 27,294 cycles

DURING C-2 CHECK, INSPECTION REPORTED CORROSION ON STR 21-R, STA 847 TO 867, AND CORROSION ON INTERCOSTAL BETWEEN STR 21-R AND 22-R, STA 847 TO 867. MAINTENANCE REMOVED DAMAGED STRINGER AND INTERCOSTAL, FABRICATED REPLACEMENT PARTS AND INSTALLED PER SRM 53-10-2 AND 53-10-3.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 23,039 hrs · 27,294 cycles

DURING C-2 CHECK, INSPECTION REPORTED CRACK IN R-1 DOOR CUTOUT UNDER SCUFF PLATE AT LOWER AFT CORNER. MAINTENANCE VERIFIED CRACK BY ACCOMPLISHING AN NDT INSPECTION PER SRM 53-30-3 AND FABRICATED AND INSTALLED REPLACEMENT PARTS PER SRM 53-30-3, FIG 26.

Part: STRINGER — CORRODED (CARGO BAY) · corrosion level 2 · airframe 23,039 hrs · 27,294 cycles

DURING C-2 CHECK, INSPECTION REPORTED CORROSION ON INSIDE SURFACE OF STRINGER 25L, STA 1006, AROUND FASTENER. MAINTENANCE BLENDED CORROSION AND FOUND TO BE OUT OF LIMITS PER SRM 51-00-4 AND 51-10-6. REMOVED DAMAGED STR 25L BETWEEN STA 1058 TO STA 1088 PER SRM 51-30-2. FABRICATED STRINGER REPLACEMENT AND STRINGER SPLICE AND INSTALLED PER SRM 53-10-3.

Part: SKIN — CHAFED (LT WING)

DEN - DURING C-2 CHECK INSPECTION, REPORTED CHAFING ON LEFT LEADING EDGE ABOVE NR 1 ENGINE PYLON. MAINTENANCE REPLACED WING LEADING EDGE SECTION ABOVE NR 1 ENGINE PYLON. REPLACED SKIN SECTION ON LEADING EDGE CAP OUTBOARD OF NR 1 PYLON AND REPAIRED SKIN INBOARD OF PYLON PER SRM 51-20-01, 51-30-02, 51-30-05, 51-30-02, 51-30-05 AND EA 57-737-063. (M)

Part: STRINGER — CORRODED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORT CORROSION ON STRINGER 23R FROM STATION 259 TO STATION 312. MAINTENANCE FABRICATED AND INSTALLED NEW STRINGER PER SRM 53-10-03, FIGURE 1. (M)

Part: STRUCTURE — CRACKED (FUSELAGE)

DEN - DURING C-2 CHECK, INSPECTION REPORTED CRACK IN FORWARD PRESSURE BULKHEAD FLOOR STRUCTURE NEXT TO INTERCOSTAL, WL 207, LBL 27. MAINTENANCE INSTALLED NEW WEB PER SRM 51-30-2. (M)

Part: STRUCTURE — CRACKED (FUSELAGE)

DURING C-2 CHECK, INSPECTION REPORTED CRACK IN FORWARD PRESSURE BULKHEAD FLOOR STRUCTURE NEXT TO INTERCOSTAL WL 207, RBL 27. MAINTENANCE INSTALLED NEW WEB PER SRM 51-30-2. (M)

Part: VALVE — CORRODED (LAVATORY DUMP)

DEN - DURING C-2 CHECK INSPECTION, FOUND MOUNT STRUCTURE FOR AFT LAVATORY DUMP VALVE CORRODED. MAINTENANCE FABRICATED REPLACEMENT PAN DOUBLER AND BRACKET PER SRM 53-30-02. CLEANED, PAINTED PAN AND INSTALLED REPAIR PARTS PER SRM 20-10-18 AND 51-30-02. INSTALLED SERVICING VALVE AND DUMP VALVE PER EO 38-30-737-001. (M)

Part: WEB — CRACKED (FUSELAGE)

DURING C-2 CHECK, INSPECTIN REPORTED 1 INCH CRACK IN WEB AT STATION 184 WL 235 LBL 15. MAINTENANCE REPAIRED WEB PER SRM 51-40-2. (M)

Part: FLOORBEAM — CORRODED (CABIN)

DEN - FOUND DURING C-2 CHECK, CORROSION ON TOP OF FLOORBEAM CENTER AT STATION 292.5, LBL 5. MAINTENANCE REPLACED FLOORBEAM UPPER CHORD PER SRM''S 51-10-02, 51-30-02, 53-10-01 AND 53-10-09. (M)

Part: BULKHEAD — CRACKED (FUSELAGE)

DEN - FOUND DURING C-2 CHECK, INSPECTION REPORTED STATION 178 BULKHEAD HORIZONTAL WEB CRACKED, WL 195, RBL 27. MAINTENANCE REMOVED DAMAGED AREA. FABRICATED REPLACEMENT INTERCOSTAL AND INSTALLED PER SRM 53-10-11 FIG 7. (M)

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

DEN - FOUND DURING C-2 CHECK INSPECTION, AFT FLOOR SUPPORT CORRODED STATION 986.5 TO 1006 BL0. MAINTENANCE REMOVED DAMAGED AREA, FABRICATED REPLACEMENT INTERCOSTAL AND INSTALLED PER EA 53-737-082. (M)

Part: STRINGER CLIP — CRACKED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED STRINGER TIE CLIP CRACKED AT STATION 639, STRINGER 8L. MAINTENANCE FABRICATED AND DRILLED REPLACEMENT CLIP AND INSTALLED CLIP PER SRM 51-20-01 AND 51-30-02. (M)

Part: PAN — CORRODED (LAVATORY FLOOR)

DEN - DURING C-2 CHECK INSPECTION, FORWARD LAVATORY OUTBOARD FLOOR PAN ATTACH ANGLE CORRODED IN 2 PLACES. MAINTENANCE FABRICATED, DRILLED AND INSTALLED NEW FLOOR PAN ATTACH ANGLE. (M)

Part: GATE — BROKEN (PAX DOOR)

DEN - FOUND DURING C-2 CHECK INSPECTION, REPORTED L1 DOOR LOWER GATE BROKEN AT PUSH-PULL ATTACH CENTER, EAR BROKEN OFF. MAINTENANCE REMOVED L1 DOOR LOWER GATE ASSEMBLY AND INSTALLED SERVICEABLE LOWER GATE ASSEMBLY PER SRM 51-30-02 AND 51-30-05. (M)

Part: FLOOR SUPPORT — CRACKED (CABIN)

DEN - DURING C-2 CHECK INSPECTION, REPORTED FLOOR ATTACH ANGLE BRACKET CRACKED AT STATION 312, LBL 10. MAINTENANCE REMOVED CRACKED ANGLE BRACKET PER SRM 51-30-02. FABRICATED NEW BRACKET PER SRM 51-30-06 AND INSTALLED PER SRM 51-10-02. (M)

Part: FLOOR SUPPORT — CRACKED (CABIN)

DEN - DURING C-2 CHECK INSPECTION, REPORTED FLOOR ATTACH ANGLE BRACKET CRACKED AT STATION 329, LBL 40. MAINTENANCE REMOVED CRACKED ANGLE BRACKET, FABRICATED NEW ANGLE PER SRM 51-30-06 AND 51-10-02 AND INSTALLED PER SRM 51-10-02. (M)

Part: STRINGER — CORRODED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED CORROSION BEYOND SRM LIMITS ON STRINGER 25L AT STATION 1006. MAINTENANCE REMOVED DAMAGED AREA AND FABRICATED AND INSTALLED NEW STRINGER SPLICE AND STRINGER PER SRM 51-00-04, 51-10-06, 51-30-02 AND 53-10-03. (M)

Part: FLOOR PANEL — CORRODED (CABIN)

DEN - DURING C-2 CHECK INSPECTION, REPORTED CORROSION ON TOP OF LONGITUDINAL FLOOR PANEL INTERCOSTAL FROM STATION 292.5 TO STATION 312, LBL 10. MAINTENANCE FABRICATED NEW FLOOR SUPPORT AND COVER CAP PER 51-30-02 AND INSTALLED PER SRM 51-10-02 AND 51-30-02. (M)

Part: FLOOR SUPPORT — CRACKED (CABIN)

DEN - DURING C-2 CHECK INSPECTION, REPORTED FLOOR ATTACH ANGLE BRACKET CRACKED AT STATION 329, RBL 35. MAINTENANCE REMOVED CRACKED ANGLE BRACKET PER SRM 51-30-02. FABRICATED NEW BRACKET PER SRM 51-30-06 AND 51-10-02 AND INSTALLED IT PER SRM 51-10-02. (M)

Part: DOUBLER — DAMAGED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED RIVETS ON EXISTING SCAB PATCH BETWEEN STATION 867 AND STATION 887, STRINGER 24R TO 25R, FAULTY. MAINTENANCE REMOVED EXISTING PATCH AND INSTALLED FLUSH PATCH PER SRM 53-30-03, FIGURE 7. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED CORROSION ON TOP OF FLOORBEAM AT STATION 329, LBL 30. MAINTENANCE REMOVED CORROSION BUT FOUND IT TO BE OUT OF LIMITS PER SRM 53-10-01. REMOVED DAMAGED SECTION, FABRICATED AND INSTALLED NEW REPAIR ANGLES PER SRM 51-40-04. (M)

Part: STRAP — DAMAGED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED SMALL HOLE IN RADIUS OF TEAR STRAP, STATION 277, STRINGER 21R. MAINTENANCE INSTALLED DOUBLER ON TEAR STRAP PER SRM 53-30-02. (M)

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED CORROSION ON TOP OF LONGITUDINAL FLOOR PANEL SUPPORT INTERCOSTAL AT STATION 295 RBL 10. MAINTENANCE REPLACED DAMAGED PART PER FRONTIER AIRLINES ENGINEERING AUTHORIZATION 53-737-082 AND SRM 51-30-02. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED CORROSION ON TOP OF FLOORBEAM AT STATION 295.0, RBL 10. MAINTENANCE REPLACED FLOORBEAM PER FRONTIER ENGINEERING AUTHORIZATION 53-737-082 AND SRM 51-30-02. (M)

Part: DOUBLER — DAMAGED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED RIVETS ON EXISTING SHEET METAL PATCH BETWEEN STATION 867 AND STATION 887, STRINGER 21R TO 22R, FAULTY. MAINTENANCE REMOVED EXISTING PATCH AND INSTALLED FLUSH PATCH PER SRM 53-30-03, FIGURE 7. (M)

Part: FRAME — CRACKED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED BELT FRAME CRACKED AT STATINO 380 AND AT TRANSITION PANEL ABOVE STRINGER 26R. MAINTENANCE REMOVED DAMAGED FLANGE, FABRICATED AND INSTALLED REPAIR DOUBLER PER SRM 51-40-03, FIGURE 1. (M)

Part: FLOOR SUPPORT — CORRODED (CABIN)

DURING C-2 CHECK, INSPECTION REPORTED CORROSION ON AFT FLOOR DIAGONAL SUPPORT, STATION 996 TO STATION 1012, LBL 4 TO 20. MAINTENANCE REPLACED EXISTING STRAP OVER FLOOR SUPPORT WITH NEW STRAP PER SRM 51-30-02. (M)

Part: DOOR FRAME — CORRODED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED CORROSION ALONG RIGHT AFT DOOR CHORD, STRINGER 17R FROM STATION 927 TO STATION 1006. MAINTENANCE REMOVED CORROSION, TREATED, PRIMED AND PAINTED PER SRM 51-10-6 AND 53-10-2. (M)

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, FOUND FLOOR SUPPORT AT STATION 927 TO 947.5, LBL 44 CORRODED IN SEVERAL PLACES. MAINTENANCE FABRICATED, HEAT TREATED, PRIMED AND INSTALLED NEW SUPPORT PER EO 51-00-737-001, SRM 51-10-01, SRM 51-20-01, SRM 51-30-02 AND 53-10-02. (M)

Part: TOGGLE — LOOSE (TE FLAPS)

DEN - DURNG C-2 CHECK INSPECTION, REPORTED EXCESSIVE OF OUTBOARD TOGGLE ASSY ON RT INBOARD FORE FLAP. RETORQUED AND SAFETIED RT INBOARD FORE FLAP OUTBOARD TOGGLE BRACKETS PER MM 27-50-01. (M)

Part: STRINGER — CORRODED (FUSELAGE)

DEN - DURING C-2 CHECK INSPECTION, REPORTED STRINGER 23L CORRODED BETWEEN STATION 500 AND 500A ON TOP AND BOTTOM AS WELL AS AROUND CENTER NUTPLATE. MAINTENANCE REMOVED DAMAGED SECTION. FABRICATED STRINGER REPAIR PER SRM 53-10-03 AND INSTALLED PER SRM 51-30-02. (M)

Part: LIGHT — INOPERATIVE (PAX DOORWAY)

DEN - DURING SERVICE CHECK, MAINTENANCE REPORTED FORWARD ENTRY DOOR EMERGENCY LIGHT INOPERATIVE. MAINTENANCE REPLACED FORWARD ENTRY DOOR EMERGENCY LIGHT ASSEMBLY. (M)

Part: SKIN — DAMAGED (FUSELAGE)

SMF - AFTER BLOCK-IN, A BELT LOADER IMPACTED THE AIRCRAFT BENEATH THE FOWARD BAGGAGE DOOR. GROUND PERSONNEL DID NOT CHOCK THE BELT LOADER AFTER PULLING UP NEXT TO THE AIRCRAFT. WHILE OFF-LOADING BAGGAGE, PARKING BRAKE SLIPPED OFF AND THE LOADER MOVED FORWARD HITTING THE FUSELAGE BENEATH THE FORWARD CARGO DOOR CAUSING TWO DENTS. ONE ABOUT 12 INCHES LONG, AND THE OTHER APPROXIMATELY 18 INCHES LONG. AIRCRAFT FERRIED TO TUCSON AND REPAIRED BY HAMILTON AVIATION PER BOEING SRM'S 53-30-3 AND 51-30-2. AIRCRAFT RETURNED TO SERVICE. (X)

Part: FIRE LOOP — CRUSHED (APU)

LGB - FLT 717 - ON CLIMB-OUT, CREW TURNED THE APU OFF AND THE FIRE WARNING SYSTEM ACTIVATED. CREW PULLED THE APU FIRE HANDLE, DISCHARGED THE BOTTLE, AND WENT TO THE OFF POSITION ON THE START SWITCH. AIRCRAFT RETURNED TO LGB AND LANDED WITHOUT INCIDENT. FOUND FIRE LOOP CRUSHED IN THE APU SHROUD. NO INDICATION OF FIRE OR OVERHEAT CONDITIONS. REPLACED THE APU FIRE BOTTLE AND THE FIRE ELEMENT. SYSTEM CHECK GOOD, AND AIRCRAFT RETURNED TO SERVICE. PART TC: 22. (X)

Part: FIRE LOOP — FAILED (NR 2 ENGINE)

LAS - FLT 518 - NR 2 ENGINE OVERHEAT LIGHT ILLUMINATED. ACCOMPLISHED ENGINE OVERHEAT CHECKLIST. ACCOMPLISHED ENGINE FIRE SEVERE DAMAGE OR SEPARATION CHECKLIST. USED BOTH FIRE EXTINGUISHERS. REMOVED AND REPLACED BOTH ENGINE FIRE BOTTLES IAW MM 26-21-11. INSPECTED ENGINE FOR FIRE SCORCHING, OVERHEATING, AND HOT DUCT PROBLEMS. NO INDICATIONS OF OVERHEAT CONDITIONS. INSPECTED FIRE LOOP AND FOUND ELEMENT GROUNDED TO SHIELD. REMOVED CENTER CONDUCTOR AWAY FROM SHIELD. CHECKED GOOD PER MM 26-11-0. AIRCRAFT RETURNED TO SERVICE. (X)