N977AX

Part: BATTERY — DISCHARGED (EMERGENCY LIGHTS) · airframe 58,707 hrs · 55,502 cycles

DURING PRE-DEPARTURE CHECK, EMERGENCY LIGHTS FOUND INOPERATIVE. REPLACED EMERGENCY LIGHT POWER SUPPLY BATTERIES IAW DC9 MM 33-53-00-8.

Part: BATTERY — DISCHARGED (EMERGENCY LIGHT) · airframe 57,966 hrs · 54,793 cycles

EMERGENCY EXIT LIGHTS WOULD NOT COME ON. REPLACED EMERGENCY LIGHT POWER SUPPLY BATTERIES IAW DC9 MM 33-53-00-8-0001.

Part: PANEL — CORRODED (WINDOW BELT) · airframe 57,641 hrs · 54,443 cycles

WINDOW 22 RIGHT HAD CORROSION ON LOWER SIDE OF OUTER FRAME. REMOVED AND REPLACED CORRODED AREA OF WINDOW BELT IAW DC9 SRM.

Part: SPLICE — CORRODED (BS 1021-1041) · airframe 57,641 hrs · 54,443 cycles

AFT LOWER CARGO BETWEEN FS 1021 AND 1041, LONGERON 30 SPLICE HAD MINOR CORROSION. REMOVED AND REPLACED LONGERON SPLICE AT STA 1021 TO 1041, LONGERON 30 IAW DC9 SRM 53-02.

Part: FITTING — CRACKED (FWD CARGO) · airframe 57,641 hrs · 54,443 cycles

RIGHT CANTED KEEL WEB TO WING SPAR FITTING WAS CRACKED. REPLACED FITTING ON NON ROUTINE 0366 IAW DC9 SRM.

Part: WINDOW — CRAZED (CABIN) · airframe 57,641 hrs · 54,443 cycles

CABIN WINDOW LONGERON 17 CRAZED BEYOND LIMITS. REMOVED AND REPLACED WINDOW IAW DC9 MM ON JOB CARD 0159.

Part: CONTROL PANEL — DEFECTIVE (COCKPIT PEDESTAL) · airframe 56,862 hrs · 53,629 cycles

ON CLIMB-OUT FROM RIC, SMOKE OBSERVED COMING FROM CENTER CONSOLE. AIRCRAFT DIVERTED TO ROA. ISOLATED SMOKE TO PEDESTAL RED FILL LIGHT RHEOSTAT KNOB. DISCONNECTED PLUG TO PEDESTAL LIGHT CONTROL. REMOVED AND REPLACED PEDESTAL INSTRUMENT PANEL LIGHT CONTROL ASSEMBLY IAW DC-9 AMM 33-00-00.

Part: FRAME — CRACKED (FUSELAGE) · airframe 56,609 hrs · 53,350 cycles

RT FORWARD MAIN FRAME E CRACKED ON FORWARD FLANGE AT ZEE CLIP ATTACH FASTENERS, MIGRATES UNDER SPLICE PLATE RT (G) TO POINT (J) ON ES01144. REPAIRED MAIN FRAME IAW EA 53400120-001-2.

Part: FRAME — CRACKED (FUSELAGE) · airframe 56,609 hrs · 53,350 cycles

RT AFT MAIN FRAME, STA. 775, AFT UPPER FLANGE WAS CRACKED BETWEEN POINTS G AND J. REPAIRED MAIN FRAME IAW EA 53400320-001-2.

Part: SKIN — DENTED (PAX DOOR) · airframe 56,609 hrs · 53,350 cycles

FS 165 TO 200 PASSENGER DOOR LONGERON 16 LT SKIN DENTED. DAMAGE OUT OF LIMITS. REMOVED DAMAGED SKIN, FABRICATED DOUBLERS, REPAIRED IAW SRM 52-05.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 55,605 hrs · 52,295 cycles

F.S. 1072 FLOORBEAM UPPER ANGLE CRACKED, RBL 54. REPAIRED FS 1072 FLOORBEAM UPPER ANGLE AT RBL 54 IAW DC-9 SRM.

Part: INTERCOSTAL — CORRODED (FUSELAGE) · airframe 55,605 hrs · 52,295 cycles

LEVEL I CORROSION BETWEEN FS 218 - 200 AT FLOOR SUPPORT INTERCOSTAL, JUST INBOARD FROM 29 RT LONGERON. REPLACED INTERCOSTAL IAW DC-9 SRM.

Part: SKIN — CORRODED (NLG DOOR) · airframe 55,605 hrs · 52,295 cycles

RT FORWARD NOSE LANDING GEAR DOOR EXTERIOR SKIN WAS CORRODED AROUND AFT DOUBLER. REPLACED RT NOSE LANDING GEAR DOOR IAW DC-9 MM 32-22-01-2.

Part: SWITCH — DEFECTIVE · airframe 55,064 hrs · 51,730 cycles

WHEN THE LEFT LANDING LIGHT SWITCH WAS SELECTED TO EXTEND, COCKPIT FILLED WITH SMOKE. REPLACED THE LEFT LANDING LIGHT SWITCH. OPS CHECKED GOOD IAW DC-9 MM.

Part: WIRE — SHORTED (COCKPIT) · airframe 55,057 hrs · 51,724 cycles

WHILE ADJUSTING FIRST OFFICER'S OVERHEAD MAP LIGHT, SPARKING AND SMOKE CAME FROM BEHIND IT. MAP AND BRIEFCASE CIRCUIT BREAKER TRIPPED. FOUND WIRE L453A24 BEHIND THE FIRST OFFICER'S MAP LIGHT CHAFED THROUGH AND SHORTING TO GROUND. REPLACED A FIVE INCH SECTION OF WIRE L453A24 FROM TERMINAL END BACK IAW DC-9 AMM 20-50-01-2.

Part: ODOR — DETECTED (CABIN) · airframe 55,055 hrs · 51,721 cycles

THROUGH 10,000 FT, 10 - 15 SECONDS AFTER EXTENDING WING LANDING LIGHTS THERE WAS A VERY NOTICEABLE ELECTRICAL BURNING ODOR THAT LASTED 30 SECONDS TO 1 MIN, THEN DISSIPATED AND DID NOT RECUR. ALL ELECTRICAL INDICATIONS WERE NORMAL. EXTENDED THE LIGHT AGAIN IN CHOCKS AFTER LANDING WITH NO ODOR. PERFORMED OPERATIONAL CHECK OF LT AND RT WING LANDING LIGHTS. INSPECTED LT AND RT WING LANDING LIGHT SWITCHES. INSPECTED WIRES FROM LANDING LIGHT SWITCHES TO BEHIND THE INSTRUMENT PANEL AND ALL INTERIOR LIGHTING AND BALLASTS. CHECKED EMERGENCY INVERTER, LT & RT WING LANDING LIGHT ASSY. OPERATED WING LANDING LIGHTS AS WELL AS ALL OTHER EXTERIOR LIGHTS AND INTERIOR LIGHTS NUMEROUS TIMES. NO DEFECTS OR ODORS NOTED.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 54,399 hrs · 51,179 cycles

RIGHT FUSELAGE FRAME SHEAR TIE AT STATION 1021 HAD CRACK AT RIVET BETWEEN LONGERON 14 AND 15 RIGHT. REPAIRED SHEAR TIE AT STATION 1021 BETWEEN LONGERON 14 RIGHT - 15 RIGHT IAW DC-9 SRM 53-03, FIGURE 3.

Part: SKIN — CRACKED (FUSELAGE) · airframe 54,399 hrs · 51,179 cycles

FOUR CRACKS AT FORWARD LOWER CARGO DOOR CUTOUT AFT LOWER CORNER. INSPECTION EVALUATED AND ONLY FOUND ONE CRACK. REPAIRED AREA IAW DC-9 EA 53100113-001 AND REA D953-41279-MR.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 54,399 hrs · 51,179 cycles

SHEAR TIE APPROXIMATELY FS 432 LONGERON 16 RIGHT CRACKED. REPLACED SHEAR TIE FS 432 LONGERON 16 RIGHT IAW DC-9 SRM.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,399 hrs · 51,179 cycles

CANTED FRAME AT STATION 1180 WAS CRACKED AT LONGERON 16 RIGHT - 19 RIGHT. REPLACED FRAME IAW DC-9 SRM.

Part: SKIN — CRACKED (FUSELAGE) · airframe 54,399 hrs · 51,179 cycles

THREE EACH CRACK INDICATIONS ON FORWARD LOWER CARGO UPPER FORWARD CORNER. INSPECTION EVALUATED AND ONLY FOUND TWO CRACKS. REPAIRED FORWARD LOWER CARGO CORNER IAW DC-9 EA 53100110-001.

Part: WINDOW — OUT OF ADJ (COCKPIT) · airframe 53,658 hrs · 50,537 cycles

FIRST OFFICER''S CLEARVIEW WINDOW WOULD NOT OPEN. ADJUSTED FIRST OFFICER''S CLEARVIEW WINDOW FORWARD UPPER LOCK BAR AND ENGAGEMENT PIN.

Part: WIRE — BURNED (LT WING) · airframe 53,602 hrs · 50,483 cycles

ON PRE-DEPARTURE CHECK FOUND FUEL LEAKING FROM LEFT WING, INBOARD FORWARD SPAR AREA. REPLACED FUEL CONDUIT TO LEFT FORWARD BOOST PUMP. FOUND WIRING LOOSE AND BURNED AT TERMINAL STRIP NR S3-1 AND TERMINAL NR 4. SPLICED WIRES 1Q11C20A AND 1Q11E20A IAW ABX REA D928-38013.

Part: FITTING — OUT OF ADJUST (COCKPIT)

FIRST OFFICER'S CLEARVIEW WINDOW WOULD NOT OPEN. ADJUSTED FIRST OFFICER'S LOWER TRACK ROLLER IAW DC9 MM.

Part: SKIN — CRACKED (BS 1208)

DURING C-CHECK, FOUND FUSELAGE SKIN CRACKED, LEFT SIDE APPROXIMATELY 12 INCHES ABOVE VENTRAL STAIRWAY AT STATION 1208. REPAIRED IAW DC9 SRM 53-01-00.

Part: FITTING — CRACKED (BS 642)

DURING C-CHECK, FOUND RIGHT WING TO FUSELAGE ATTACH FITTING CRACKED AT STATION 642. REPAIRED FITTING IAW ABX REA D957-33523MR.

Part: BLKHD STIFFENER — CRACKED (BS 549)

DURING C-CHECK, FOUND VERTICAL STIFFENER NR 7 CRACKED AT STATION 549 BULKHEAD LOWER END. REPAIRED IAW DC9 SRM DWG K05159.

Part: SHEAR TIE — CRACKED (BS 1021)

DURING C-CHECK, FOUND SHEAR-TIE CRACKED AT STATION 1021 BETWEEN LONGERON 15 AND 16 LEFT. REPLACED SHEAR-TIE IAW DC9 SRM 51-30-2 AND 51-30-5.

Part: ANGLE — CRACKED (BS 237)

DURING C-CHECK, FOUND ANGLE CRACKED AT STATION 237 BETWEEN LONGERON 27 AND 28 LEFT. REPLACED ANGLE IAW DC9 SRM 51-30-05.

Part: SWITCH — DEFECTIVE (NLG)

NOSE GEAR UNSAFE LIGHT FAILED TO ILLUMINATE WITH THROTTLES AT IDLE AND GEAR IN THE UP POSITION. REPLACED NOSE LANDING GEAR UP AND DOWN LIMIT SWITCHES.

Part: ANGLE — CRACKED (LT PYLON)

DURING C-CHECK, FOUND THE LEFT UPPER PYLON ATTACH ANGLE CRACKED BETWEEN STATION 1054 AND 1064. REPAIRED ANGLE IAW DC9 SRM 54-04.

Part: BULKHEAD TEE — CRACKED (AFT PRESS BLKHD)

DURING C-CHECK, FOUND THE AFT PRESSURE BULKHEAD NR 6 TEE CRACKED. REPLACED TEE IAW ABX EA 53-12-3.

Part: STIFFENER — CRACKED (NR 1 ENG PYLON)

DURING C-CHECK, FOUND NR 1 ENGINE PYLON STIFFENER CRACKED, (6 ABOVE FUEL SHROUD). REPLACED STIFFENER IAW DC9 SRM 51-30-2 AND 51-30-5.

Part: LOCKING TANG — CRACKED (RT HORIZ STAB)

DURING C-CHECK, FOUND FORWARD LOCKING TANGS CRACKED AND LOCKING PLATE SHIFTED ON THE HORIZONTAL STABILIZER MAIN ATTACH BOLT, RIGHT SIDE WHERE STABILIZER ATTACHES TO CENTER SECTION. REPLACED BOLT, SLEEVE, AND RETAINER IAW DC9 MM 55-10-0.

Part: SHEAR TIE — CRACKED (BS 1021)

DURING C-CHECK, FOUND SHEAR TIE CRACKED AT STATION 1021 BETWEEN LONGERON 14R AND 16R. REPLACED SHEAR TIE IAW DC9 SRM 51-30-2.

Part: BRACKET — CRACKED (LT MLG WW)

DURING C-CHECK, FOUND ATTACH BRACKET CRACKED AT TOP EDGE OF TRAPEZOIDAL PANEL IN LEFT WHEEL WELL. REPLACED ANGLE IAW DC9 SRM 51-30-5.

Part: ANGLE — CORRODED (LT MLG WW)

DURING C-CHECK, FOUND EXFOLIATION CORROSION ON L-ANGLE AT OUTBOARD, FORWARD CORNER OF WHEEL WELL AT SLANT PANEL. REPLACED ANGLE IAW DC9 SRM 51-30-1 AND 51-30-5.

Part: SEAT TRACK — DIRTY (RT)

FIRST OFFICERS SEAT WON'T LOCK IN THE FULL FORWARD POSITION. CLEANED DEBRIS OUT OF THE FORWARD INBOARD SEAT TRACK. THE FIRST OFFICERS SEAT OPS CHECK GOOD.

Part: TERMINAL ENDS — OUT OF POSITION (NLG LIGHT)

UNSATISFACTORY GEAR UPLATCH CHECK, CYCLED GEAR, NO GREEN GEAR LIGHTS. CHECKED P-27 CIRCUIT BREAKER, FOUND IT POPPED. RESET P-27. WHEN NOSE GEAR UNSAFE LIGHT PUSHED TO TEST, HEARD P-27 POP AGAIN. REPOSITIONED TERMINAL END ON LEFT GEAR UNSAFE LIGHT SOCKET, RESET P-27, ALL LIGHTS CHECK GOOD IAW DC-9 MM 32-60-0.

Part: FLOORBEAM — DAMAGED (BS 160)

DURING ACCEPTANCE INSPECTION, THE FLOORBEAM AT STATION 160 WAS FOUND TO HAVE SEVERAL DOUBLE DRILLED AND CLOSELY SPACED HOLES. THE FLOORBEAM WAS REPAIRED IAW REA D953-15436-MR.

Part: FLOORBEAM — DAMAGED (BS 237)

DURING ACCEPTANCE INSPECTION, THE FLOORBEAM AT STATION 237 WAS FOUND TO HAVE TWO GOUGES IN THE UPPER FOWARD FLANGE AT LBL 6. THE FLOORBEAM WAS REPAIRED IAW REA D953-15500-MR.

Part: FLOORBEAM — DAMAGED (BS 200)

DURING ACCEPTANCE INSPECTION, THE FLOORBEAM AT STATION 200 WAS FOUND TO HAVE SEVERAL DOUBLE DRILLED AND CLOSELY SPACED HOLES. THE FLOORBEAM WAS REPAIRED IAW REA D953-15436-MR.

Part: JAMB — CRACKED (BS 1012)

DURING ACCEPTANCE INSPECTION, WHILE ACCOMPLISHING AD 92-22-08, THE AFT LOWER CARGO DOOR JAMB WAS FOUND CRACKED AT STATION 1012 BETWEEN LONGERONS 26 AND 27 RIGHT. THE DOOR JAMB WAS REPAIRED IAW DC-9 SRM 53-05 FIG 44.

Part: SKIN — GOUGED (FUSELAGE)

DURING ACCEPTANCE INSPECTION, THE FUSELAGE SKIN WAS FOUND GOUGED FOWARD OF THE MAIN ENTRY DOOR AT LONGERON 16 LEFT. THE SKIN WAS REPAIRED IAW REA D953-15392-MR.

Part: BULKHEAD TEE — DAMAGED (AFT PRESS BLKHD)

DURING ACCEPTANCE INSPECTION, THE AFT PRESSURE BULKHEAD LOWER TEE WAS FOUND TO BE GOUGED AND HAVE A HOLE DRILLED THROUGH THE TEE AT LONGERON 30. THE TEE SECTION WAS REPLACED AND TRIMMED FOR EASE OF INSTALLATION IAW REA D953-15368-MR, DC-9 SRM 51-30-5 AND 51-30-2.

Part: SKIN — DAMAGED (FUSELAGE)

DURING ACCEPTANCE INSPECTION, THE WATER SUPPLY PANEL WAS DEACTIVATED PER ABX EA FS-38-AA04. THE EXISTING SERVICE PANEL DOOR WAS DAMAGED BEYOND REPAIR AND REQUIRES AN ALTERNATIVE METHOD FOR PLUGGING THE PANEL ASSY OPENING. THE SKIN WAS REPAIRED IAW REA D938-15221-MR.

Part: ROD ASSY — WORN (LT MLG DOOR)

DURING ACCEPTANCE INSPECTION, WHILE ACCOMPLISHING AD 91-22-07, THE LEFT MAIN LANDING GEAR FLYING DOOR LINKAGE WAS FOUND WORN AT THE LOWER ATTACH POINT. THE LINKAGE WAS REPAIRED IAW DC 9 OHM 32-10-6.

Part: SEAT TRACK — CORRODED (CARGO COMPT)

DURING ACCEPTANCE INSPECTION WHILE ACCOMPLISHING AD 92-22-08, LEVEL TWO CORROSION WAS FOUND ON A SEAT TRACK AT STATION 370 LONGERON 28 RIGHT. THE TRACK WAS REPLACED IAW DC-9 SRM 51-30-5 AND 51-30-2.

Part: FRAME — DAMAGED (FUSELAGE)

DURING ACCEPTANCE INSPECTION, DOUBLE DRILLED HOLES WERE FOUND ON FRAMES AT FUSELAGE STATIONS 655, 617 AND 718 AT LONGERONS 4 LEFT AND RIGHT AND 737 AT LONGERON 5 LEFT. THE FRAMES WERE REPAIRED IAW REA D953-15501-MR.

Part: LONGERON — CRACKED (BS 200)

DURING ACCEPTANCE INSPECTION, WHILE ACCOMPLISHING AD 92-22-08, A LONGERON WAS FOUND CRACKED AT 4 LEFT STATION 200. THE LONGERON WAS REPLACED IAW DC-9 STM 51-30-5 AND 51-30-2.

Part: FITTING — CRACKED (BS 645)

DURING ACCEPTANCE INSPECTION, WHILE ACCOMPLISHING AD 92-22-08, A LONGERON END FITTING WAS FOUND CRACKED AT STATION 645 LONGERON 29 RIGHT. THE LONGERON WAS REPLACED BETWEEN STATIONS 420 AND 454 IAW THE DC-9 SRM 53-30-5.

Part: BULKHEAD CLIPS — CRACKED (AFT PRESS BLKHD)

DURING ACCEPTANCE INSPECTION, WHILE ACCOMPLISHING AD 92-22-08, SEVERAL RADIUS CLIPS WERE FOUND CRACKED ON THE FORWARD FACE OF THE AFT PRESURE BULKHEAD. THESE CLIPS ARE COMMON DEFECTS FOUND IN SERVICE BULLETIN 53-166. THE CLIPS WERE REPAIRED IAW DC-9 SRM 51-30-5 AND DRAWING K05159.

Part: TRUNNION — CORRODED (LT MLG)

DURING ACCEPTANCE INSPECTION, THE LEFT MAIN LANDING GEAR TRUNNION WAS FOUND GOUGED AND CORRODED. THE TRUNNION WAS REPAIRED IAW REA D957-15353-MR AND DC-9 DRAWING K05177.

Part: SKIN — DAMAGED (BS 440-495)

DURING ACCEPTANCE INSPECTION, THE FUSELAGE SKIN AND FUSELAGE FRAME SPLICE HAD AN EXISTING REPAIR WHICH DID NOT CONFORM TO THE DC-9 SRM, STATION 440 TO 495 AT LONGERON 15 TO 18 RIGHT. THE SKIN WAS REPAIRED IAW REA D953-15228-MR.

Part: FRAME — DAMAGED (BS 946)

DURING ACCEPTANCE INSPECTION, THE FUSELAGE FRAME AT STATION 946 AT LONGERON 5 RT HAD MISSING FASTENERS AND DOUBLE DRILLED HOLES. THE FRAME WAS REPAIRED IAW REA D953-15220-MR.

Part: FRAME — DAMAGED (BS 1005)

DURING ACCEPTANCE INSPECTION, THE FUSELAGE FRAME AT STATION 1005 AT LONGERON 5 RT HAD MISSING FASTENERS AND DOUBLE DRILLED HOLES. THE FRAME WAS REPAIRED IAW REA D953-15220-MR.

Part: FRAME — DAMAGED (BS 889)

DURING ACCEPTANCE INSPECTION, THE FUSELAGE AT STATION 889 AT LONGERON 5 RT HAD MISSING FASTENERS AND DOUBLE DRILLED HOLES. THE FRAME WAS REPAIRED IAW REA D953-15220-MR.

Part: FRAME — DAMAGED (BS 1012)

DURING ACCEPTANCE INSPECTION, THE FUSELAGE FRAME AT STATION 1012 AT LONGERON 5 RT HAD MISSING FASTENERS AND DOUBLE DRILLED HOLES. THE FRAME WAS REPAIRED IAW REA D953-15220-MR.

Part: FRAME — DAMAGED (BS 870)

DURING D-CHECK, THE FUSELAGE FRAME AT STATION 870 AT LONGERON 5 RT HAD MISSING FASTENERS AND DOUBLE DRILLED HOLES. THE FRAME WAS REPAIRED IAW REA D953-15220-MR.

Part: SEAL — CRACKED (LT MLG DOOR)

DURING ACCEPTANCE INSPECTION WHILE ACCOMPLISHING AD 92-22-08, THE METAL SEAL ON THE LEFT MAIN LANDING GEAR OUTBOARD DOOR WAS FOUND CRACKED ON THE TRAILING EDGE BY THE HINGE POINT. THE SEAL WAS REPLACED IAW DC-9 SRM 51-30-2.

Part: FITTING — CORRODED (BS 636)

DURING ACCEPTANCE INSPECTION, WHILE ACCOMPLISHING AD 92-22-08, THE RIGHT PORK CHOP FITTING FOR THE CENTER TANK AT STATION 636 WAS FOUND CORRODED. THE FITTING WAS REPLACED IAW DC-9 SRM 51-30-5 AND 51-30-2.

Part: FITTING — WORN (LT WING)

DURING ACCEPTANCE INSPECTION, THE LEFT WING OUTBOARD FLAP HINGE FITTING PIVOT POINT BUSHINGS WERE FOUND WORN AND GOUGED. THE HINGE FITTING WAS REPAIRED IAW REA D927-15041-MR.

Part: LONGERON — CRACKED (BS 446)

DURING ACCEPTANCE INSPECTION, WHILE ACCOMPLISHING AD 92-22-08, A LONGERON AT 5 LEFT WAS FOUND CRACKED AT STATION 446. THE LONGERON WAS REPLACED BETWEEN STATIONS 420 AND 454 IAW THE DC-9 SRM 53-02 FIG 2.

Part: BULKHEAD — CRACKED (AFT PRESS BLKHD)

DURING ACCEPTANCE INSPECTION, CRACKS WERE FOUND IN THE AFT PRESSURE BULKHEAD DOOR JAMB AT THE UPPER FOWARD RIGHT CORNER. THE FRAME WAS REPLACED AND THE SKIN WAS REPAIRED IAW THE DC-9 SRM 53-05 FIG 76.