19960119001701996011900170NE 1996 1 19 GMAL9501021 219960102G7323116085025 GOVERNOR KAMAN K1200 K1200 05625F6SW LYC T53 T5317A 41549NE ENG OVERSPEED DEFECTIVE H GMALO OTHER J WARNING INDICATION EXEXTERNAL LOAD 1 NM09132KA410 A940004 PILOT REPORTED GOVERNOR DECAY FROM 104 PERCENT NR DOWN TO 97 PERCENT NR DURING HOVER. PROBLEM INTERMITTENT EVERY 3 TO 4 TURNS DURING LOGGING OPERATIONS. (X) 1G71 4F4 UNTTR7BO E17EA 19960119002541996011900254GL 1996 1 19 HEEA966329 219960102G725023032345 COUPLING 23033185 BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL 3RD STAGE STEP WEAR E HEEAK NONE O OTHER ININSP/MAINT 1 SW035007Y453 CAT70022 45192 CAE860583 ENGINE REMOVED DUE TO TURBINE 3RD STAGE WHEEL REPLACEMENT. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIMITS ON N1 COUPLING I.D. SPLINES. INSTALLED NEW N1 COUPLING. 1G71 3U3 U H2SW E1GL 19960223006811996022300681EA 1996 2 23 96ZZZX775 219960201G85307380685 PUSHROD LYC O235 O235L2C 41505EA CYLINDER BALL SEPARATION D A K NONE E VIBRATION/BUFFET ININSP/MAINT 1 WP11 L1840015 370 HOURS AFTER OVERHAUL, ENGINE VIBRATION WAS DETERMINED TO BE CAUSED BY BALL END SEPARATION FROM PN 73806-85 PUSHROD. PUSHROD WAS REPLACED AND ENGINE VIBRATION WAS BACK TO NORMAL. AD'S 80-25-02R2 AND 95-03-10 DO NOT PERTAIN TO THESE PUSHRODS. 3 O E223 19960223006851996022300685EA 1996 2 23 96ZZZX779 219960123G732213662 FLOAT BRACKET MA45 CESSNA177 177 2073704CE LYC O360 O360A1F6 41514EA CARBURETOR BROKEN BS SL5RA UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 NE0334102 500 75020609 17701642 L1573636A ENGINE LOST POWER IN CRUISE FLIGHT. AFTER SAFE LANDING AT NEARBY AIRPORT, REMOVED CARBURETOR AND DISASSEMBLED. FOUND FLOAT BRACKET BROKEN IN BEND RADIUS ALLOWING EXCESS FUEL TO ENTER CARBURETOR WHEN FLOAT VALVE COULD NOT SEAT. BEND RADIUS OF FLOAT BRACKET APPEARED TO BE 90 DEGREES. SUBMITTER STATED LARGER BEND RADIUS MIGHT PREVENT UNUSUAL STRESSES IN THE METAL REDUCING THE POSSIBILITY OF BREAKAGE. 1H71 3O3 ONTA13CE E286 19960223006921996022300692EA 1996 2 23 96ZZZX786 219960201G853073806V PUSHROD LYC O235 O235L2C 41505EA CYLINDER WRONG PART D K NONE W INADEQUATE Q C ININSP/MAINT 1 WP11 L1610415 ENGINE WAS OVERHAULED BY FACTORY 2-20-95. DURING STC'D CONVERSION PRIOR TO INSTALLATION IN AIRCRAFT, ALL EIGHT PUSHRODS WERE FOUND TO BE P/N 73806 'V' PUSHRODS. SUBMITTER STATED AD 95-03-10 DOES NOT COVER THIS ENGINE (BUT SHOULD). FACTORY WAS NOTIFIED AND REPLACEMENT PUSHRODS INSTALLED. 3 O E223 19960223007041996022300704SO 1996 2 23 96ZZZX798 219960126G854063217H QUILL SHAFT CESSNA421 421A 2076012CE CONT O520 GTSIO520D 17032SO LT ENG DRV GEAR FAILED B EKIRA UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 WP07200CH1320 481 421A0102 219168R LEFT ENGINE QUIT ON CLIMB-OUT. PROP FEATHERED AIRCRAFT, MADE SAFE LANDING. FOUND HOLE IN CASE UNDER INTERCOOLER FROM FAILED CONNECTING ROD. PROP TURNS FREELY. ENGINE NOT TORN DOWN AT THIS DATE. SUBMITTER SUSPECTS QUILL SHAFT FAILED ALLOWING ENGINE TO OVERSPEED. WILL SUBMIT FOLLOW-UP M OR D WHEN ENGINE IS TORN DOWN. 1L72 3O3 O A7CE E7CE 19960223007191996022300719WP 1996 2 23 96ZZZX813 219960103G725031038393 ROTATING SEAL GARRTTTPE331TPE33112UAR 01514WP 1ST STAGE TURB FLANGE CRACKED B DSCRK NONE O OTHER ININSP/MAINT 1 GL25 7218 P70104 DURING INSPECTION FOR METAL CONTAMINATION, FOUND PART CRACKED AT SEALING FLANGE. THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIFE-LIMIT IS 20,000 CYCLES. SUBMITTER STATED THIS IS THE 24TH MALFUNCTION/DEFECT REPORT SUBMITTED ON THIS PART BY THIS REPAIR STATION. 4 T E4WE 19960301002201996030100220EU 1996 3 1 96ZZZX821 219960125G7230 BUSHING GULSTMG1159 G1159 3953505SO RROYCESPEY SPEY5118 54523EU HP COMPRESSOR SHIFTED BL GJQRO OTHER E VIBRATION/BUFFET DEDESCENT 1 NM0126WP 8630 1920 024 8576 ENGINE HAD INTERMTTENT HIGH VIBRATION READINGS. CREW REPORTED A BUZZ ON DESCENT AT 79 PERCENT HI PRESS ROTOR SPEED. IN-FLT VIB SURVEY SHOWED VIB PEAK OF 1.3 MILS CORRESPONDING TO HP ROTATIONAL FREQ AT THAT POWER SETTING. SECONDARY SMALLER PEAK CORRESPONDING TO LP ROTOR NOTED. ENG DISASSEMBLED. SEVERAL 1ST STG HI PRESS COMPR BLADES WERE BOUND UP. ROTOR DISASSEMBLED, MTNG BUSHINGS FND BACKED OUT OF PIN HOLES. BUSHINGS SHOWED EVIDENCE OF CONTACT WITH ROTOR HUB. LOW PRESS COMPR BLADE PINS CONTAMINATED WITH DIRT & RUST. 1ST STAGE HAD HEAVIEST ACCUMULATION. 2 BRACKETS HOLD OUTER DUCT TO ENG BROKEN. BRACKETS NEAR MNT LOC FOR AFT VIB PICK-UP. LOCALIZED THERMAL DISTRESS TO NOZZLE GUIDE VANES & COMB CANS. 2L72 4F4 FRTA12EA E2EU 19960301004701996030100470NE 1996 3 1 96ZZZX829 219960116G7250 BLADE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE ENGINE HPT FAILURE BL DJFRK NONE O OTHER ININSP/MAINT 1 EA23120JP 550468 71331 ENGINE SOUNDED STRANGE AFTER START. TROUBLESHOT TO ENGINE INTERNAL. SENT OUT FOR OVERHAUL. FOUND 3 HT BLADES FAILED. 1L72 4F4 F A22CE E1NE 19960301004831996030100483NE 1996 3 1 96ZZZX842 219960116G7230310463301 ANTIROTATE RING CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE ENGINE FAILED B DJFRK NONE O OTHER ININSP/MAINT 1 EA23511AB 550299 70350 AFTER ENGINE START, ENGINE SOUNDED STRANGE (LIKE VACUUM CLEANER). TROUBLESHOT AND SUSPECTED INTERNAL DAMAGE. ENGINE REMOVED AND SENT FOR OVERHAUL. FOUND THE ANTI-ROTATION RING HAD FAILED. 1L72 4F4 F A22CE E1NE 19960301004871996030100487NE 1996 3 1 96ZZZX846 219960206G72107895922 TAB WASHER HAMSTD 775800 SAAB SF340 SF340A 7850100EU GE CT7TP CT75A2 30030NE GC49 GEARBOX CRACKED BS SI3RK NONE O OTHER ININSP/MAINT 1 NE033903G11548 340A0227 GEE785278 GEARBOX RETURNED TO HAMILTON STANDARD FOR FAILED BORESCOPE REPAIR. AT DISASSEMBLY OF THE DRIVE (BULL) GEAR, HAMILTON STANDARD DISCOVERED THE TABBED WASHER WAS CRACKED. THE CRACK IS ADJACENT TO A TAB AND EXTENDS THROUGH TO THE INSIDE DIAMETER TAB. THE DRIVE GEAR RETENTION NUT REQUIRED 1,600 FEET/POUNDS OF TORQUE TO REMOVE. THIS PART SUPERSEDED P/N 775796-4. 2L72 4T4 TRTA52EU E8NE6 19960301004891996030100489WP 1996 3 1 96ZZZX848 219960117G72508683793 STATOR GULSTM690TP 690A 0141722SW GARRTTTPE331TPE3315 01514WP HOT SECTION DEFECTIVE BL DJFRK NONE W INADEQUATE Q C ININSP/MAINT 1 EA23690HF 11298 P06541C DURING C/W WITH AD 95-16-08, FOUND HOT SECTION 3RD STATOR WAS IMPROPER DUE TO NOT BEING STAMPED OR SIGNED AND SERIAL NUMBER OF PART NOT ENTERED. 1H72 3T4 T 2A4 E4WE 19960301004921996030100492SO 1996 3 1 96ZZZX851 219960117G8520 CRANKCASE CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO NR 3 CYLINDER CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 SO067560Q 421B0346 600641 UPON INSPECTION IAW AD 77-13-22 CRANKCASE CRACKS, CRACK FOUND AT NR 3 CYLINDER UPWARDS UNDER ENGINE DATA PLATE, LENGTH UNDETERMINED, BUT LEAKING OIL MAKES UNAIRWORTHY. ENGINE REMOVED FROM LEFT POSITION. ENT TT, 3,334.2 HOURS. ENG TSMOH, 916.3 HOURS. NOTE: RIGHT ENGINE HAS HEAVY CASE INSTALLED. 1L72 3O3 O A7CE E7CE 19960301004941996030100494EA 1996 3 1 96ZZZX853 219960210G741466M21195 CLAMP NUT SLICK 4370 CESSNA172 172N 2072434CE LYC O360 O360A4M 41514EA RT MAG ATTACH MISSING G K NONE O OTHER ININSP/MAINT 1 GL13734FH 95040291 17268817 L2821736A RIGHT MAGNETO TOP ATTACHMENT MISSING. CLAMP, 66M21195. WASHER, STD-475. WASHER, STD-1727. NUT, STD-1410. RIGHT MAGNETO INSTALLED 10-12-95. TOTAL TIME 168 HOURS. ACFT TT 4,328.5 HOURS. 1H71 3O3 ONT3A12 E286 19960301004971996030100497EA 1996 3 1 96ZZZX856 219960206G8520 CRANKSHAFT PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA ENGINE PITTED B LK1RK NONE O OTHER ININSP/MAINT 1 NE014333C1679 288416039 L1319839A DURING 100-HOUR ENGINE INSPECTION FOR AIRCRAFT ANNUAL INSPECTION, LYC SB 505A WAS C/W AND THE CRANKSHAFT FOUND PITTED IN THE AREA NOTED IN SB 505A. ENGINE WAS REMOVED AND REPLACED WITH A LYC FACTORY OVERHAULED. AFTER REMOVAL OF THE CRANKSHAFT PLUG, THE INTERIOR OF THE CRANKSHAFT WAS FOUND COMPLETELY PLUGGED WITH SLUDGE (1.25 POUNDS). GENERAL CONDITION AND RECORDS INDICATE A WELL MAINTAINED AIRCRAFT WITH MULTI-VISCOSITY OIL CHANGES AS REQUIRED. 1L71 3O3 O 2A13 E274 19960301005311996030100531NE 1996 3 1 96ZZZX890 219960115G7210310835601 SUN GEAR BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE POWER SECTION DEFECTIVE B MASRK NONE O OTHER ININSP/MAINT 1 SW015YV 6668 21C611 UE05 114046 ALTHOUGH ALL INDICATIONS POINT TO AN ELECTRICAL DISCHARGE, THE POSSIBILITY OF A SUN GEAR FAILURE IS NOT BEING RULED OUT. THE NR 6 BEARING AND THE SUN GEAR WILL BE SHIPPED FOR FURTEHR INVESTIGATION. 2L72 4T4 TRTA24CE E26NE 19960308005491996030800549SO 1996 3 8 96ZZZX938 219960130G7324 LINE PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360E 17025SO NR 6 NOZ B-NUT BROKE H O OTHER ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NRNOT REPORTED 1 SO01999CC 347570159 303156 FUEL LINE FROM FLOW DIVIDER TO NR 6 NOZZLE BROKE AT B-NUT NOZZLE AND SPRAYED RAW FUEL ON ENGINE. ENGINE ROUGH, BUT NOT SHUT DOWN AND LANDED OK WITH NO FIRE. VERY LUCKY! 1L72 3O3 O A7SO E9CE 19960308005521996030800552EA 1996 3 8 96ZZZX941 219960220G853073806 PUSHROD CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA NR 4 CYL EXH FAILED G A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 SW996110Q 15285135 L1545415 AIRCRAFT CRASHED AFTER TAKEOFF. POST-CRASH INSPECTION REVEALED NR 4 CYLINDER EXHAUST PUSHROD BROKEN AT VALVE END. NR 4 EXHAUST VALVE NOT IN OPERATION DUE TO BREAK OF PUSHROD. AD 80-25-02 AND AD 95-03-10 WERE ISSUED PERTAINING O-235 PUSHRODS. TWO OTHER PUSHROD INCIDENTS WERE NOTED FROM CESSNA OWNER'S ORGANIZATION MAGAZINE, MARCH '96 ISSUE. SUBJECT PUSHROD IAW OF AD 80-25-02 AND AD 95-03-10. 1H71 3O3 ONT3A19 E223 19960315000751996031500075GL 1996 3 15 96ZZZX1023 219960126G72306871534 CHIP PLUG HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL COMPRESSOR LEAKING B EOORK NONE K FLUID LOSS ININSP/MAINT 1 AL035074R 1151D CAE832750 DURING REMOVAL OF COMPRESSOR, CHIP PLUG FOUND LEAKING PAST THE INSULATOR. REPLACED CHIP PLUG. 1G71 3U3 U H3WE E4CE 19960315000761996031500076GL 1996 3 15 96ZZZX1024 219960220G72506890040 SHIELD 6898735 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL NR 1 TURB NOZZLEWARPED B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R 513 1151D CAE832750 DURING REPLACEMENT OF NR 1 TURBINE NOZZLE, THE NOZZLE SHIELD WAS FOUND WARPED OUT OF SHAPE. PART SENT IN FOR OVERHAUL. 1G71 3U3 U H3WE E4CE 19960315000971996031500097GL 1996 3 15 96ZZZX994 219960209G732323007505 GOVERNOR BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ENGINE FAIL B AC2RK NONE O OTHER ININSP/MAINT 1 SW035059C1499 86090389 S779 GOVERNOR SHAFT FAILED. REPLACED GOVERNOR. 1G72 3U3 U H3EU E4CE 19960315001671996031500167NE 1996 3 15 96ZZZX1029 219960201G7260430110701 BEARING BELL 222 222 1182122SW LYC LTS101LTS101650C3 41560NE ACCY GEARBOX DEFECTIVE D K NONE O OTHER ININSP/MAINT 1 EA2529KH 2554 79K027 47053 LE41123 ENGINE REMOVED FOR PT WHEEL REPLACEMENT. DURING DISASSEMBLY, SPUR GEAR PLAY FOUND EXCESSIVE. GEARBOX DISASSEMBLED AND SPUR GEAR ASSY REMOVED. THE NR 19 BEARING HAD BEEN SPINNING IN ITS BORE, WEARING AND ELONGATING BORE. SUBMITTER RECOMMENDS PINNING OR SECURING BEARING OUTER RACE IN CASE. 1G72 3U3 U H9SW E5NE 19960315001771996031500177GL 1996 3 15 96ZZZX1039 219960110G7323 SPLINE SHAFT HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL N2 GOVERNOR CAP DETACHED DP A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 WP138625F 1338 13605 470111D CAE830515 WHILE RETURNING TO BASE DURING FLIGHT, N2 RPM DROOPED. PILOT LANDED AIRCRAFT AND REPORTED MALFUNCTION TO THE MECHANIC. UPON INSPECTION OF GOVERNOR AND ATTACHING AIR LINES, THE DRIVE SPLINE RETAINING CAP WAS FOUND DETACHED AND SMALLER SHAFT FOUND PARTIALLY FAILED AND TWISTED. 1G71 3U3 U H3WE E4CE 19960315003661996031500366SO 1996 3 15 96ZZZX1048 219960227G8530642619F PISTON PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360KB 17025SO NR 2 CYLINDER RINGS BROKEN H EA ENGINE SHUTDOWN UNSCHED LANDING K FLUID LOSS NRNOT REPORTED 1 NM09838281540 348133089 315090 ENGINE LOST OIL PRESSURE DURING FLIGHT. PILOT SHUT DOWN ENGINE AND MADE UNEVENTFUL LANDING. LARGE AMOUNT OF OIL WAS FOUND UNDER THE ENGINE AND UNDER THE WING. COMPRESSION CHECK SHOWED ZERO COMPRESSION ON NR 2 CYLINDER. CYLINDER REMOVED AND DISCOVERED ALL RINGS BROKEN AND THE RING GLANDS SEVERELY BROKEN AND WORN. A SUBSTANTIAL AMOUNT OF ALUMINUM WAS FOUND IN THE FILTER AND SCREEN. 1L72 3O3 O A7SO E9CE 19960315003981996031500398GL 1996 3 15 96ZZZX1080 219960120G7323369A795155 ROD END HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GOV/THROTTLE STIFF B EOORK NONE O OTHER ININSP/MAINT 1 AL034571V 4904870 DURING ANNUAL INSPECTION, THE ROD ENDS FROM THE GOVERNOR THROTTLE SHAFT TO THE BELLCRANK WERE FOUND EXTREMELY STIFF WITH SOME TEFLON RESIDUE COMING FROM THE ROD ENDS. REPLACED PARTS. 1G71 3U3 U H3WE E4CE 19960315006321996031500632SO 1996 3 15 96ZZZX1083 219960217G8550 PUMP CESSNA210 T210H 2073438CE CONT O520 TSIO520R 17040SO ENGINE OIL MISOVERHAULED D E ENGINE SHUTDOWN JW WARNING INDICATION INADEQUATE Q C ININSP/MAINT 1 SW1365093 21061844 293717R ON THE 6TH RUN FOR GROUND ADJUSTMENTS, OIL PRESSURE DROPPED TO 30 THEN 10 PSI AND ENGINE SECURED. REPEATED ATTEMPTS TO PRIME OIL SYSTEM, COULD NOT GET OIL PRESSURE UP. PUMP WAS REMOVED AND INSPECTED WITH NO OBVIOUS DEFECTS. OIL PAN WAS REMOVED AND PICK-UP TUBE INSPECTED WITH NO DEFECTS. ONLY DEFECT NOTED WAS THAT OIL PUMP WAS PROBABLY INCORRECTLY SILK THREADED ALLOWING AIR TO BE SUCKED INTO SYSTEM AROUND ORIFICE. AFTER REINSTALLATION OF COMPONENTS, NO FURTHER PROBLEMS ENCOUNTERED AND ACFT FLOWN WITH NO PROBLEMS. 1H71 3O3 O 3A21 E8CE 19960315006481996031500648EA 1996 3 15 96ZZZX1099 219960128G7322MA3AU CARBURETOR CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA ENGINE DEFECTIVE G K NONE O OTHER ININSP/MAINT 1 SW11757UK4625 2552 CR0665 15280012 L1307415 INSPECTION FOUND CARBURETOR COMPOSITE FLOATS BLACK AND CARBONED. IN ADDITION, THROTTLE ARM WORN. TWO PIECE VENTURI WAS INSTALLED. 1H71 3O3 ONT3A19 E223 19960315006541996031500654SO 1996 3 15 96ZZZX1105 219960126G8520649134 CRNAKSHAFT CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO NR 2 MAIN FAILED D A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 SW034691E975 325 B089312N 18503842 175052R CRANKSHAFT BROKE AFT OF NR 2 MAIN JOURNAL AT OIL TRANSFER TUBE. PARTS SET TO TCM FOR DETERMINATION OF FAILURE. CAUSE WAS DETERMINED TO BE LOW THROUGH-BOLT TORQUE WHICH, IN TURN, CAUSED BEARING TO SHIFT AND CRANKSHAFT TO VIBRATE. AIRCRAFT HAD DEPARTED NORMALLY, WHEN LEVELLING AND SETTING CRUISE CONDITION VIBRATION WAS NOTICED. WHEN AIRCRAFT TURNED TO RETURN TO BASE, ENGINE FAILED. AIRCRAFT LANDED WITHOUT INCIDENT. (SEAPLANE). VAR TYPE CRANKSHAFT. CUT .010 INCH UNDER. 1H71 3O3 O 3A24 E5CE 19960315006621996031500662EA 1996 3 15 96ZZZX1113 219960119G74141068256011 MAGNETO BENDIX PIPER PA28 PA28236 7102815SO LYC O540 O540J3A5 41532EA MAG MOUNT FLANGE FAILED H A A UNSCHED LANDING Y ENGINE STOPPAGE NRNOT REPORTED 1 WP052476Y E109008GR 288511016 RL2277540A BOTH MOUNTING FLANGES OF THE SINGLE DRIVE DUAL MAGNETO WERE BROKEN. MAGNETO BACKED OUT OF ENGINE GEAR DRIVE CAUSING ENGINE TO STOP. AIRCRAFT LANDED IN OCEAN. 1L71 3O3 O 2A13 E295 19960315006651996031500665NE 1996 3 15 96ZZZX1116 219960207G7210310709001 BEARING PWA 118 PW118A NE RGB NR 19 SPALLED B RA1RK NONE O OTHER ININSP/MAINT 1 SW05 8360 73C029 115608 INSPECTION FOUND REMOTE GEARBOX NR 19 BEARING SPALLED. 4 T E20NE 19960315006661996031500666NE 1996 3 15 96ZZZX1117 219960215G7210310924401 BEARING PWA 118 PW118A NE RGB NR 15 SPALLED B RA1RK NONE O OTHER ININSP/MAINT 1 SW05 8486 RH475 121119 INSPECTION FOUND RGB NR 15 BEARING SPALLED. 4 T E20NE 19960315006671996031500667EU 1996 3 15 96ZZZX1118 219960215G72503053556220 BEARING CFMINTCFM56 CFM563B2 13802EU HPT ROTOR DAMAGED B RA1RK NONE O OTHER ININSP/MAINT 1 SW05 RR10056 721339 ENGINE WAS REMOVED FROM SERVICE DUE TO IN-FLIGHT SHUT DOWN. DISASSEMBLY OF THE ENGINE REVEALED THE NR 4 BEARING AREA WITHIN THE HPT ROTOR REAR SHAFT AND LPT NR 4 BEARING ROTATING SEALS HAD HEAVY DAMAGE. FURTHER INVESTIGATION IS IN PROCESS AT AVIALL. 4 F E21EU 19960315006711996031500671SO 1996 3 15 96ZZZX1122 219960221G7414S6LN25 MAGNETO BENDIX PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360EB 17025SO MAGNETO COIL CLAMP BROKEN B APCRK NONE O OTHER ININSP/MAINT 1 NM014490F 1489 B119325DR 747670339 COIL CLAMP FOUND BROKEN AT BEND RADIUS DURING MAGNETO 500-HOUR INSPECTION. NOTE: CLAMP HAD WHITE DYKEM MARK PER TCM MANUAL PAGE 7-6, PARAGRAPH 7.2.G(D). 1L72 3O3 O A7SO E9CE 19960315006721996031500672EA 1996 3 15 96ZZZX1123 219960223G7414D6LN2230 MAGNETO BENDIX PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA RETARD LEAD DEFECTIVE B APCRK NONE W INADEQUATE Q C ININSP/MAINT 1 NM0127343 317752163 RL727061A MAGNETO CAME INSTALLED ON FACTORY OVERHAULED ENGINE. WHEN CONNECTING IGNITION HARNESS, NOTED RETARD LEAD COULD BE PUSHED ALL THE WAY INTO THE MAG WITHOUT TOUCHING CONTACT FINGER SPRING. REAR COVER REMOVED TO ADJUST FINGER AND RIGHT POINT SET FOUND LOOSE, AND FIVE DEGREE SPLIT BETWEEN LEFT AND RIGHT POINTS. INSTALLER MADE NECESSARY ADJUSTMENTS AND SECURED POINT ATTACHING SCREWS. 1L72 3O3 O A20SO E14EA 19960322000021996032200002NE 1996 3 22 96ZZZX1129 219960222G7200 ENGINE CESSNA650 650 2076802CE GARRTTTFE731TFE7313B 01518NE FWD FAN GRBOX OIL LOSS B MUCREA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION NRNOT REPORTED 1 GL13275GC2316 6500162 87437 ENGINE EXHIBITED LOW OIL PRESSURE AND ENGINE WAS SHUT DOWN. AIRCRAFT MADE NORMAL LANDING ON SINGLE ENGINE. FOUND TWO QUARTS OF OIL IN ENGINE. NORMAL CAPAPCITY (6 QUARTS). COULD NOT DUPLICATE ANY MALFUNCTIONS DURING TROUBLESHOOTING, BUT SUSPECT OIL SYSTEM PRESSURIZED FORCING OIL OUT BREATHER AS THE RESULT OF EITHER BREATHER PRESSURIZING VALVE STICKING OR UNSEATED CARBON SEAL. REPLACED NR 1 AND NR 3 CARBON SEAL AND BREATHER PRESSURIZING VALVE. 2L72 4F4 F A9NM E6WE 19960322000081996032200008WP 1996 3 22 96ZZZX1135 219960207G726030702192 GEARSHAFT 30700934 BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE7315R 01518WP TRANSFER GRBOX FAILED D A UNSCHED LANDING JY WARNING INDICATION ENGINE STOPPAGE CRCRUISE 1 CE051910H5314 P4880 258023 P91118 AIRCRAFT WAS IN CRUISE FLIGHT AT 39,000 FEET WHEN MASTER WARNING FLASHER CAME ON AND WOULD NOT CANCEL. SEVERAL SECONDS LATER, RT N2 INDICATION DROPPED TO ZERO FOLLOWED BY SHUT DOWN OF RT ENGINE. AIRCRAFT LANDED SAFELY WITHOUT INCIDENT. CAUSE OF SHUT DOWN WAS FAILURE OF BEVEL GEAR ON VERTICAL GEARSHAFT, PN 3070219-2, INSIDE TRANSFER GEARBOX, PN 3070093-4. THERE IS NO REQUIREMENT TO DISASSEMBLE AND DETAIL INSPECT THE GEARBOX ON CIVILIAN AIRCRAFT. AN ANALYSIS OF THE FAILED GEAR IS BENG PERFORMED BY ALLIED SIGNAL. 2L72 4F4 FRTA3EU E6WE 19960322000151996032200015NE 1996 3 22 96ZZZX1142 219960220G8520 CAMSHAFT DOUG DC3 DC3C 3021457WP PWA R1830 R183092 52020NE RT ENGINE FAILED E E ENGINE SHUTDOWN ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 SW1159316 715 18986 BP462185 RIGHT ENGINE STARTED TO BACKFIRE AND RUN ROUGH. ENGINE WAS SHUT DOWN IN-FLIGHT AND PROP FEATHERED. UPON TROUBLESHOOTING, FOUND VALVES ON REAR CYLINDERS NOT ACTUATING. SUSPECT BROKEN CAM GEAR. ENGINE WAS REMOVED FOR REPAIR AND A SERVICEABLE ENGINE WAS INSTALLED. 2L72 4R4 R A669 5E4 19960322001281996032200128GL 1996 3 22 96ZZZX1167 219960101G724023056130 COMBUSTION LINER HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE BURNED B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R 1151D CAE832750 WHILE REMOVING TURBINE, THE COMBUSTION LINER WAS FOUND BURNED, WARPED, AND CRACKED. PART REPLACED. 1G71 3U3 U H3WE E4CE 19960322001301996032200130GL 1996 3 22 96ZZZX1169 219960202G72616853301 SUMP HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL NR 6-7 BEARING WARPED B EOORK NONE K FLUID LOSS ININSP/MAINT 1 AL035074R 1436 1151D CAE832750 DURING ANNUAL INSPECTION, NR 6 AND NR 7 BEARING SUMP ON THE TURBINE FOUND LEAKING AT THE MATING SURFACE. SUBSEQUENT INSPECTION REVEALED FLANGE WAS WARPED. 1G71 3U3 U H3WE E4CE 19960322001311996032200131GL 1996 3 22 96ZZZX1170 219960211G7323230574869 GOVERNOR HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE ERRATIC B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R 591 24657 1151D CAE832750 DURING RUN-UP, PILOT WAS ADJUSTING ENGINE 'BEEP' AND THE GOVERNOR HESITATED, BUT WHEN AN INCREASE WAS NOTED, IT JUMPED UP 3 PERCENT TO 4 PERCENT AND WAS NOT A SMOOTH TRANSITION. PART SENT IN FOR REPAIR. 1G71 3U3 U H3WE E4CE 19960322004441996032200444EA 1996 3 22 96ZZZX1254 219960227G853060828 PISTON PIN PLUG CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA CYLINDER FAILED H K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 GL199926325 17276424 L1141539A PISTON PIN PLUG, PN 60828, IS NOT CORRECT, BUT LOCATION IS CORRECT. ENGINE OVERHAULED 24.8 HRS AGO. COMPLAINT OF LOSS OF POWER. GROUND RUN SEEMED OK, NOTHING OBVIOUS. COMPRESSION TEST FOUND LOW COMPRESSION ON ONE CYLINDER. BORESCOPED AND COULD SEE METAL FLAKES. UPON DISASSEMBLY OF CYLINDER, FOUND SMALL ALUMINUM BALL IN CHEWED UP PISTON. AREA FROM NR 2 RING DOWN TO TOP OF PISTON PIN, HOLE WORN AWAY. SECTION OF BOTTOM RING BROKE OFF. CYLINDER WALL IN THIS AREA DAMAGED. 1H71 3O3 ONT3A12 E274 19960322004571996032200457SO 1996 3 22 96ZZZX1267 219960228G8550CH48109 OIL FILTER CHAMPION 641639 BEECH 58 58 1152740CE CONT O550 IO550C SO LT/RT ENGINES MISINSTALLED B ERY2K NONE O OTHER ININSP/MAINT 1 SO11123ZM22 TH1768 676924 DURING FIRST ROUTINE ENGINE OIL AND FILTER CHANGE, THE OIL FILTER WAS EXTREMELY DIFFICULT TO REMOVE FROM THE ADAPTER ASSY. SUBMITTER SUSPECTS CAUSE FOR PROBLEM: NO LUBRICATION AT INSTALLATION AS ENGINE WAS READIED FOR SERVICE. SUGGEST FOLLOW RECOMMENDED PROCEDURE PER MFG. SAME PROBLEM ENCOUNTERED WITH RIGHT ENGINE. (RIGHT ENGINE SN 676926, SAME TOTAL TIME). 1L72 3O3 O 3A16 E3SO 19960322004691996032200469SO 1996 3 22 96ZZZX1279 219960215G732230764 FLOAT 103965121 CESSNA182 182 2072702CE CONT O470 O470L 17026SO CARBURETOR DETACHED B KC2RO OTHER Y ENGINE STOPPAGE CRCRUISE 1 GL03 4000457 ENGINE QUIT IN-FLIGHT ONCE AND ON THE GROUND ONCE. FOUND ONE PONTOON OF FLOAT ASSEMBLY HAD BROKEN OFF. DATE CODE STAMPED IN FLOAT BRACKET IS 884. IT IS A FACTORY MANUFACTURED FLOAT; NOT A PMA. 1H71 3O3 ONT3A13 E273 19960329002261996032900226EA 1996 3 29 96ZZZX1341 219960227G74141051676 CAPACITOR BENDIX S6RN23 HILLERUH12 UH12B 4360110WP FRNKLN6AV3356V335B 27020EA RT MAG FAILED D K NONE O OTHER ININSP/MAINT 1 WP074785C7 430043 312 WHEN RT MAG SELECTED DURING ENGINE RUN-UP CHECK, ENGINE FAILED. OBSERVED EXCESSIVE SPARKING AND POINT WEAR (7 HRS SINCE NEW). ENGINE RAN NORMALLY AFTER REPLACEMENT OF CAPACITOR AND POINT ADJUSTMENT. SUSPECT MANUFACTURING DEFECT OF PMA CAPACITOR. 1G71 3O3 O 6H2 E244 19960329002441996032900244NE 1996 3 29 96ZZZX1359 219960209G7230 BLADE RKWELLNA265 NA26560 7630106CE PWA JT12 JT12A8 52042NE COMPRESSOR RUB B JV2RK NONE O OTHER ININSP/MAINT 1 CE03401MS 1210 30617 P673149NB DURING INSPECTION OF ENGINE, SN P673149NB, A CRACKED INLET GUIDE VANE PROMPTED REMOVAL OF INLET CASE FOR REPAIRS. WITH CASE REMOVED, A COMPRESSOR BLADE RUB, WHICH RESULTED IN DETERIORATION TO A STATOR, WAS NOTED AND REPORTED. AUTHORIZATION WAS RECEIVED FROM CUSTOMER TO DISASSEMBLE COMPRESSOR FOR FURTHER INVESTIGATION. UPON DISASSEMBLY OF COMPRESSOR, SEVERE CORROSION NOTED ON STEEL COMPONENTS. A CORROSION INSPECTION AND SUBSEQUENT COMPRESSOR OVERHAUL PER P&WA, SB 1508R16, WAS INITIATED. 2L72 4J4 JRTA2WE 1E9 19960329002451996032900245NE 1996 3 29 96ZZZX1360 219960209G7250566101 BLADE RKWELLNA265 NA26560 7630106CE PWA JT12 JT12A8 52042NE 1ST STG TURBINE OVERLAP BL JV2RK NONE O OTHER ININSP/MAINT 1 CE03401MS 1210 30617 P673152NB DUE TO CORROSION DMG DISCOVERED ON RT ENG, CUSTOMER ELECTED TO DISASSEMBLE LT ENG FOR CORROSION INSP, & SUBSEQUENT COMPR OVERHAUL PER P&WA. UPON DISASSEMBLY OF COMPR, SEVERE CORROSION NOTED ON STEEL COMPONENTS. CORRRODED STEEL DISK REJECTED. CUSTOMER ELECTED TO REPLACE LIFE LIMITED DISKS IN BOTH ENGS TO ALLOW ENGS TO CONTINUE IN SERV TO 3000 HRS TBO; THUS, PROMPTING TO ACCESS TURB AREA ON ENG, SN P673152NB, TO REPLACE LIFE LIMITED TURB DISKS. TURB BLADES REMOVED DUE TO REPLACMENT OF LIFE LIMITED TURB DISK. NOTED 76 1ST STG TURB BLADES SHOWED SIGNS OF SHROUD OVERLAP, DISPLACED METAL & METAL SEPARATION IN NOTCH SURFACE OF SHROUD. 14 TURB BLADES PREV INSTALLED IN NEW COND (TT: ZERO) & 2 WERE SERVICEABLE. 2L72 4J4 JRTA2WE 1E9 19960329003481996032900348NE 1996 3 29 96ZZZX1377 219960210G72613008127 GEARSHAFT 3024287 PWA PT6 PT6A42 52043NE OIL CAV PMP SHEARED D EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 GL1718260 2730 D618 PCE93133 PILOT REPORTED A LOW FUEL PRESSURE LIGHT FOLLOWED BY AN AUTOFEATHER ON LEFT ENGINE. PILOT SHUT DOWN ENGINE AND LANDED WITHOUT INCIDENCE. UPON INVESTIGATION, NOTED THE OIL LEVEL LOW, THERE WAS OIL IN THE EXHAUST CASE, AND METAL PARTICLES AND FLAKES PRESENT IN THE OIL FILTER. FURTHER INVESTIGATION SHOWED SCAVENGE PUMP SHAFT HAD SHEARED. ENGINE REMOVED FOR METAL IN OIL. 4 T E4EA 19960329003501996032900350EA 1996 3 29 96ZZZX1379 219960131G7250 SHROUD RING BEECH 200 B200 1152922CE PWA PT6 PT6A41 52043EA PT SECTION LUG MISSING B RX8RK NONE O OTHER ININSP/MAINT 1 SO15203BS BB476 PCE85365 BINDING, WHEN PROPELLER WAS ROTATED, FOUND DURING MORNING PRE-FLIGHT. THE POWER SECTION WAS REMOVED AND SENT TO DALLGO AIRMOTIVE. D.A. FOUND A MISSING LOCATING LUG FROM THE PT SHROUD RING THAT WAS BINDING UP THE ROTATION OF THE POWER SECTION. 1L72 4T4 T A24CE E4EA 19960329003551996032900355NE 1996 3 29 96ZZZX1384 219960201G753234A39709 COVER A39710K PWA JT9 JT9* 52054NE PRBC IMPROPER WELD B SF3RK NONE W INADEQUATE Q C ININSP/MAINT 1 NE03 1151823 RECEIVED CECO P.R.B.C. FROM TOWER AIR INC., FOR ZERO TIME OVERHAUL 8-30-95. DISASSEMBLY AND INSPECTION OF COVER REVEALED UNAUTHORIZED REWORK HAD BEEN PERFORMED (WELD). 4 F E20EA 19960405004021996040500402EA 1996 4 5 96ZZZX1467 219960301G8520SL75060 ROD BOLT PIPER PA32 PA32300 7103212SO LYC O540 IO540K1A5 41532EA NR 4 FAILED G A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SO168951N 3240753 L762248 NR 4 TOP ROD BOLT FAILED IN-FLIGHT. SEE AD NOTE 95-7-1 TW SMITH SENT LETTER TO SATISFY AD, THAT BOLT WAS NOT INSTALLED AT ENGINE OVERHAUL. TIME SINCE O/H WAS ABOUT 120 HRS. 1L71 3O3 O A3SO 1E4 19960405004031996040500403SO 1996 4 5 96ZZZX1468 219960314G8530653446A6 CYLINDER BEECH 58 58 1152740CE CONT O520 IO520CB 17032SO NR 2 CRACKED D K NONE O OTHER ININSP/MAINT 1 SW056650D1531 TH1375 282375R FINDING STEEL CYLINDERS ARE CRACKING FROM THE FUEL INJECTOR BOSS ACROSS TO THE SPARK PLUG BOSS ON A REGULAR BASIS. SUBMITTER REPORTS SOME CYLINDERS WITH AS LITTLE AS 600.0 TT CRACKED. SUBMITTER BELIEVES THERE MUST BE SOME TYPE OF MANUFACTURING PROBLEM. 1L72 3O3 O 3A16 E5CE 19960405004111996040500411SO 1996 4 5 96ZZZX1476 219960225G732246512 VENTURI FACET MA35PA CESSNA150 150 2071802CE CONT O200 O200A 17020SO CARBURETOR CASTING FLAW D K NONE W INADEQUATE Q C ININSP/MAINT 1 GL0511831 DE2216306R 15075658 INSPECTION OF A NEW PMA CARBURETOR VENTURI FOUND CASTING FLAWS. SUBMITTER STATES HAS SEEN THIS DEFECT FREQUENTLY. 1H71 3O3 ONT3A19 E252 19960405006241996040500624SO 1996 4 5 96ZZZX1501 219960219G8500 ENGINE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO LT ROUGHNESS I K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 NE053249M760 402C0296 290143R FLIGHT CREW NOTICED ROUGHNESS IN LEFT ENGINE. INSPECTED MAGS, COMPRESSION TESTED CYLINDERS, CHECKED SPARK PLUGS. ENGINE WAS GROUND RUN. FLIGHT OK'D. NOTED NO PROBLEMS. RETURNED TO SERVICE. NOTED: MINUS 21 DEGREES FAHRENHEIT TEMPERATURE. 1L72 3O3 O A7CE E8CE 19960405006521996040500652SO 1996 4 5 96ZZZX1529 219960301G8530 CYLINDER CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO ENGINE HEAD SEPARATED D K NONE O OTHER NRNOT REPORTED 1 EA235009J 1428 310R0730 266054R CYLINDER HEAD SEPARATED FROM BARREL. 1L72 3O3 O 3A10 E5CE 19960405006571996040500657EA 1996 4 5 96ZZZX1534 219960322G732230766 FLOAT FACET MA3PA CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA CARBURETOR CRACKED D A UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 SW155366B864 DM0922 15283849 CARBURETOR FLOAT FILLED WITH FUEL AND SANK IN-FLIGHT RESULTING IN ENGINE STOPPAGE AND FORCED LANDING. FLOAT WAS IN C/W AD 93-19-04. FLOAT CRACKED AND FILLED WITH FUEL. RECOMMEND RE-ENGINEERED FLOAT NOT PRONE TO CRACKING. 1H71 3O3 ONT3A19 E223 19960405006611996040500661SO 1996 4 5 96ZZZX1538 219960124G8520 MOUNT STUD CESSNA340 340A 2076405CE CONT O520 TSIO520N 17040SO NR 4 CYLINDER BROKEN B EBVRK NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 GL0961JK 340A0333 509498 PILOT COMPLAINED RT ENGINE WAS ROUGH RUNNING. FOUND NR 1 CYLINDER HELD ON BY ONLY AFT TWO THROUGH-BOLTS. ALL OTHER MOUNT STUDS WERE BROKEN. REMOVED CYLINDER AND THROUGH-BOLTS. PENETRATE CHECK OF CASE MOUNTING AREA REVEALED TWO CRACKS (1 O'CLOCK AND 7 O'CLOCK) AT MOUNT STUD HOLES AND MAG PARTICLE OF THROUGH-BOLTS REVEALED ONE CRACKED. 1L72 3O3 O 3A25 E8CE 19960405006681996040500668SO 1996 4 5 96ZZZX1545 219960305G8550 OIL FILTER CESSNA180 180J 2072622CE CONT O470 O470S 17026SO CONNECTION WRONG PART B FE6RK NONE W INADEQUATE Q C ININSP/MAINT 1 NM117824K 18052758 464271 DURING AN ANNUAL INSPECTION, NOTED A CHAMPION CH 48103 (.8125 INCH BY 16 INCH FEMALE THREAD) OIL FILTER WAS INSTALLED. THE CORRECT OIL FILTER FOR THIS INSTALLATION SHOULD HAVE BEEN A CH-48110 (.75 INCH BY 16 INCH MALE THREAD). IT IS BELIEVED THAT THE THREADED ADAPTER CAME OUT OF AN OIL FILTER (BRAND UNKNOWN) IN TIMES PAST (RECORDS SHOW CH 48103 FILTER INSTALLED AT LEAST SINCE MARCH 1993) AND BECAME STUCK IN THE FEMALE THREADS OF THE OIL FILTER ADAPTER. PERSONNEL, AT THAT TIME, OBTAINED A FILTER THAT FIT, ALBEIT POORLY. MAINTENANCE PERSONNEL, AFTER THAT TIME, REINSTALLED THE SAME PART NUMBER THAT WAS REMOVED. 1H71 3O3 O 5A6 E273 19960405006691996040500669SO 1996 4 5 96ZZZX1546 219960305G8540635050A4 ADAPTER CESSNA182 182P 2075816CE CONT O470 O470S 17026SO STARTER FAILED B LX5RK NONE O OTHER ININSP/MAINT 1 GL19841LL 1397 18263908 463648 WHEN STARTER WAS ENGAGED, THE PROPELLER MADE APPROXIMATELY ONE-EIGHTH REVOLUTION AND STOPPED. FURTHER ATTEMPTS WITH STARTER WOULD NOT TURN PROPELLER. PROP WAS 'STIFF' TURNING IN DIRECTION OF NORMAL ROTATION. PROP COULD NOT BE TURNED AT ALL IN OPPOSITE DIRECTION. REMOVED STARTER ADAPTER FROM ENGINE AND PROP ROTATION FELT NORMAL IN BOTH DIRECTIONS. 1H71 3O3 ONTTA13 E273 19960405006821996040500682SO 1996 4 5 96ZZZX1559 219960301G8520115721 CRANKCASE CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO LT ENGINE CRACKED BL VA1RK NONE O OTHER ININSP/MAINT 1 SW19124552080 677 1A688P 414A1207 800530 ENGINE CRANKCASE 1157-21 DEFECTIVE DUE TO CRACKS AFT OF NR 2 CYLINDER. ALSO, NR 2 AND NR 3 BEARING SADDLES HAVE CRACKS. CRANKCASE PN 643202 MODIFIED TO 1157-21 PER STC SE 3630SW. 1L72 3O3 O A7CE E8CE 19960412000911996041200091NE 1996 4 12 96ZZZX1630 219960228G73217280774 SPIDER VALVE PWA JT8 JT8* 52044NE FUEL CONTROL SEIZED B RD43K NONE Y ENGINE STOPPAGE ININSP/MAINT 1 SW05 21J F9606 ENGINE SHUT DOWN IN TEST CELL DURING POST-RENTAL INSPECTION TEST. THE ENGINE WAS AT FULL POWER AT THE TIME OF SHUT DOWN. REMOVAL OF THE FUEL CONTROL SHOWED A SHEARED DRIVE SHAFT. REMOVAL OF THE HYDRAULIC HOUSING FROM THE LINKAGE HOUSING ON THE CONTROL SHOWED A SEIZED SPEED GOVERNOR PILOT VALVE IN THE SPIDER. THE CONTROL WAS RE-ASSEMBLED AND IS BEING ROUTED TO AAR FOR INVESTIGATION. 4 F E2EA 19960412000961996041200096NE 1996 4 12 96ZZZX1635 219960209G7250569551 VANE PWA JT12 JT12A8 52042NE 1ST STG TURB PLATING PEEL BL IV2RK NONE O OTHER ININSP/MAINT 1 SW15 P637109NB REPORTED CAUSE FOR REMOVAL OF ENGINE FROM AIRCRAFT WAS TURBINE BLADE FAILURE. INVESTIGATION FINDINGS: ENGINE DISASSEMBLED AS NECESSARY AND REPAIRED DUE TO TURBINE BLADE FAILURE. DISCREPANCY NOTED DURING INSPECTION WAS PLATING PEELING OFF 23 EACH, PN 569551, FIRST STAGE TURBINE VANES WITH A TOTAL TIME OF 396.6 HRS, AND 10 EACH REWORKED (OVERHAULED) PN 569551 VANES WITH 396.6 HRS TSO (REF P & WA PN 435108 OVERHAUL MANUAL, PAGES 6-92, PARA 6-229). SUBJECT VANES WERE REPLACED. 4 J 1E9 19960412004961996041200496WP 1996 4 12 96ZZZM638 219960128G72603588941 BEARING SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP LT GEARBOX FAILED A PNSAE ENGINE SHUTDOWN Y ENGINE STOPPAGE CRCRUISE 1 AL03640PA4729 AC759B P44691 DURING CRUISE FLIGHT, LEFT ENGINE FUEL CONTROL DRIVE GEARBOX BEARING FAILED. 2L72 4T4 TRTA8SW E4WE 19960412006981996041200698EA 1996 4 12 96ZZZX1705 219960315G8500 ENGINE MOONEYM20 M20E 5870212SW LYC O360 IO360A1A 41514EA PWR SECTION SEIZED H A UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 SW991940Y 247 L60951 AIRCRAFT WAS IN LEVEL FLIGHT AT 13,500 FEET, HAD COMPLETE ENGINE FAILURE AND SEIZED WITH NO PRIOR WARNING. DECLARED EMERGENCY. GLIDED 17.2 NM BACK TO AIRPORT, LANDED WITHOUT FURTHER INCIDENT. NO DAMAGE TO AIRCRAFT AND NO INJURIES. ENGINE SCHEDULED TO BE REPLACED 3-28-96. 1L71 3O3 O 2A3 1E10 19960412007021996041200702EA 1996 4 12 96ZZZX1709 219960303G8530 CYLINDER LYC O320 O320E2A 41508EA SKIRT AREA DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 NM01 100 DURING A TEAR DOWN OF AN ENGINE, FOUND CYLINDERS WERE VERY HARD TO MOVE. AFTER THEY WERE TAKEN OFF, NOTICED ENGRAVED ETCHING ON CYLINDER SKIRT WAS RAISED AND VERY MUCH HIGHER THAN THE SURROUNDING AREA. THE VIBRATING PENCIL WAS VERY SHARP AND SET TO CUT MAXIMUM. STONING THE EFFECTED AREA AND SMOOTHING THE CRANKCASE TO RELIEVE STRESS SOLVED THE PROBLEM. 3 O E274 19960412007031996041200703EA 1996 4 12 96ZZZX1710 219960214G741410382894 GEARTOOTH BENDIX DYRN2021 CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA LT MAGNETO BROKEN D K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 EA211465E 343 5023753R 17271012 L122176T REMOVED MAGNETO DUE TO ROUGH ENGINE. FOUND A TOOTH BROKEN OFF OF LEFT DISTRIBUTOR GEAR. MAGNETO WAS ON A LYCOMING FACTORY OVERHAUL. MAGNETO WAS OVERHAULED BY ELECTRO SYSTEMS, INC. 1H71 3O3 ONT3A12 E274 19960412007041996041200704SO 1996 4 12 96ZZZX1711 219960314G8530 VALVE PIPER PA28 PA28R200 7102811SO CONT O360 IO360C 17025SO NR 4 INT FAILED D A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CLCLIMB 1 EA27324811526 28R7535061 L2220251A ON TAKEOFF, ENGINE BEGAN TO VIBRATE (AT FULL POWER SETTINGS). RETURNED TO AIRPORT. UPON INSPECTION, FOUND NR 4 INTAKE VALVE BROKEN IN HALF ON FACE AREA. NR 4 PISTON SEVERELY DAMAGED, COULD NOT LOCATE PARTS OF MISSING VALVE. SUSPECT INJESTED INTO ENGINE THOUGH NO METAL WAS FOUND IN OIL FILTER OR SUMP SCREEN. TT 1,526.0 HOURS ON ENGINE. 1L71 3O3 O 2A13 E1CE 19960412007051996041200705EA 1996 4 12 96ZZZX1712 219960316G7414M3525 COIL SLICK 4270 PIPER PA28 PA28140 7102802SO LYC O320 O320E2A 41508EA RT MAGNETO OPEN D K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 NE05217LM4270 21689 2821972 L2406227AC DURING RUN-UP, PILOT EXPERIENCED RT MAGNETO EXCESSIVE DROP. ON REMOVAL BY MAINTENANCE, ENGINE WOULD NOT RUN ON RT MAGNETO. FOUND OPEN IN SECONDARY COIL WINDINGS. 1L71 3O3 O 2A13 E274 19960412007191996041200719WP 1996 4 12 96ZZZX1726 219960103G725031038393 SEAL 31033155 GARRTTTPE331TPE33112UHR WP TURB 1ST STAGE FLANGE CRACKED B DSCRK NONE O OTHER ININSP/MAINT 1 GL25 7217 1233151952 P70104 DURING INSPECTION FOR METAL CONTAMINATION, FOUND AIR SEAL CRACKED AT SEALING FLANGE. THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIFE-LIMIT IS 20,000 CYCLES. SUBMITTER STATES THIS IS THE 24TH MALFUNCTION/DEFECT REPORT SUBMITTED ON THIS PART BY THIS REPAIR STATION. PART TOTAL CYCLES, 7,541. 4 T E4WE 19960412007201996041200720WP 1996 4 12 96ZZZX1727 219960212G725031038393 SEAL 31033155 GARRTTTPE331TPE33112UHR WP TURB 1ST STAGE FLANGE CRACKED B DSCRK NONE O OTHER ININSP/MAINT 1 GL25 7318 1233151936 P70112 DURING SCHEDULED CAM INSPECTION, FOUND AIR SEAL CRACKED AT FLANGE. THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIFE-LIMIT IS 20,000 CYCLES. SUBMITTER SUGGESTS THIS IS THE 26TH MALFUNCTION/DEFECT REPORT ON THIS PART BY THIS FACILITY. PART TOTAL CYCLES, 7,435. 4 T E4WE 19960412007231996041200723WP 1996 4 12 96ZZZX1730 219960314G725031038393 SEAL 31033155 GARRTTTPE331TPE33112UHR WP TURB 1ST STAGE FLANGE CRACKED B DSCRK NONE O OTHER ININSP/MAINT 1 GL25 7144 1233151935 P70111C DURING SCHEDULED CAM INSPECTION, FOUND ROTATING AIR SEAL CRACKED AT FLANGE. THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIFE-LIMIT IS 20,000 CYCLES. SUBMITTER STATES THIS IS THE 29TH MALFUNCTION/DEFECT REPORT SUBMITTED BY THIS FACILITY ON THIS DISCREPANCY. PART TOTAL CYCLES, 7,125. 4 T E4WE 19960418001631996041800163EA 1996 4 18 96ZZZX1782 219960307G8520LW19332S CONNECTING ROD PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA NR 1 CYLINDER FAILED G O OTHER ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NRNOT REPORTED 1 CE0923NP 1903 318352007 L40668A CONNECTING ROD NR 1 CYLINDER FAILED AND CAME THROUGH THE CASE. THE ROD BEARING HAD NOT SPUN, THE ONLY ROD BOLT FOUND APPEARED TO HAVE FAILED AFTER THE FACT. 1L72 3O3 O A20SO E14EA 19960418001711996041800171EA 1996 4 18 96ZZZX1790 219960306G8530LW11800 SPRING CESSNA175 175 2072502CE LYC O360 O360A1A 41514EA NR 4 CYL EXH VLVBROKEN D K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 WP279462B 400 55262 L1471536A ROUGH ENGINE OPERATION ABOVE 2,500 RPM'S. FOUND NR 4 CYLINDER OUTER EXHAUST VALVE SPRING BROKEN. 1H71 3O3 ONT3A17 E286 19960418002591996041800259GL 1996 4 18 96ZZZX1824 219960302G721023039793 SCAVENGE BODY 23035179 SKRSKYS76 S76 8143010NE ALLSN 250C 250C30S 03013GL SCAVENGE TUBE WORN B ALGRK NONE O OTHER ININSP/MAINT 1 SW03701AL1833 760238 890772S UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY. VISUALLY INSPECTED, SHOWED WEAR AT SCAVENGE BODY SURFACE, AND IN THE TUBE BONE. SCAVENGE TUBE WORN IN SCAVENGE BODY. SUSPECT CAUSE IS DUE TO IMPROPER FIT OR ALIGNMENT BRACKETS. 1G72 3U3 U H1NE E1GL 19960418002671996041800267GL 1996 4 18 96ZZZX1832 219960320G732323057869 GOVERNOR HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE ERRATIC B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R 916 28419 1151D CAE832750 THIS IS THE SECOND TIME THIS UNIT HAS BEEN REMOVED FOR ERRATIC CONDITION. PILOT MUST MAKE CONSTANT ADJUSTMENTS TO THE GOVERNOR 'BEEP' WITH EVERY POWER CHANGE. 1G71 3U3 U H3WE E4CE 19960425003061996042500306EU 1996 4 25 96ZZZX1953 219960325G7310 REGULATOR GULSTMG1159 G1159 3953505SO RROYCESPEY SPEY5118 54523EU ENG FUEL FLOW MALFUNCTIONED B UA9RK NONE O OTHER ININSP/MAINT 1 EA17125JJ 906 B1669R 15 8674 ENGINE WAS INSPECTED FOR SUSPECTED OVERTEMPERATURE PER CREW REPORT. INSPECTION ACCOMPLISHED PER ROLLS ROYCE OVERHAUL MANUAL. RESULTS SHOWED NO OVERTEMPERATURE EFFECTS. PRIOR TO DISASSEMBLY, NOTED THE P2 TOWER ON THE FUEL FLOW REGULATOR WAS LOOSE. THREE MOUNTING BOLTS HAD PULLED OUT OF THE HOUSING. THE P2 PORT WAS EXPOSED TO ATMOSPHERE, LOSS OF P2 SIGNAL WOULD EFFECT THE ENGINE'S ABILITY TO CORRECTLY METER FUEL. 2L72 4F4 FRTA12EA E2EU 19960425003081996042500308SW 1996 4 25 96ZZZX1955 119960214G733299120332 SWITCH WIRE GULSTM560 560 0141402SW LYC O540 IGO540B1A 41532EA LT BOOST PRESS CHAFED B EBVRK NONE J WARNING INDICATION NRNOT REPORTED 1 GL0960GL 1152 0187 AIRCRAFT WAS EXPERIENCING PERIODIC UNCOMMANDED LT BOOST PUMP OPERATION WITH LT BOOST PUMP AND LT FUEL LOW PRESSURE ANNUNCIATOR LIGHTS COMING ON. PROBLEM FOUND TO BE CAUSED BY THE LT ENGINE FUEL PRESSURE SWITCH WIRES HAD CHAFED THROUGH AGAINST THE SHARP EDGE OF THE FUEL FLOW TRANSMITTER. SUBMITTER STATED WIRES SHOULD BE INSPECTED ON THESE AIRCRAFT FOR CHAFE DAMAGE, PROTECT AND REROUTE AS ABLE. 1H72 3O3 O 6A1 1E11 19960425003141996042500314EA 1996 4 25 96ZZZX1961 219960301G72503027301 BLADE 3028821 BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA CT WHEEL ERODED B CWBRK NONE O OTHER ININSP/MAINT 1 GL056739P 993 2F642 BB628 PCE81899 BORESCOPE INSPECTION FOUND EVIDENCE OF COATING LOSS FROM COMPRESSOR TURBINE BLADES. COATING WAS ERODED FROM LEADING EDGES OF SOME BLADES. ENGINE WAS SPLIT AT 'C' FLANGE, HOT SECTION INSPECTED FURTHER. CT WHEEL REMOVED AND SHIPPED TO PRATT AND WHITNEY FOR INSPECTION AND DETERMINATION OF CAUSE FOR COATING LOSS. CT BLADES WERE INSTALLED AT OVERHAUL IN SERVICEABLE CONDITION. THESE BLADES WILL NOT BE REINSTALLED IN THIS ENGINE. 1L72 4T4 T A24CE E4EA 19960425003981996042500398EA 1996 4 25 96ZZZX2020 219960401G7414M3056 DISTRIBUTOR GEARSLICK 6363 PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532EA MAGNETO DAMAGED B WC7RK NONE O OTHER ININSP/MAINT 1 GL25202SE 4622092 C908761A 'ENGINE WON'T START' - 766.8 HRS HOBBS. FOUND DISTRIBUTOR GEAR M3056 BURNED. FOUND THE MS20822 FITTING TO PRESSURIZE THE MAGNETO HAD BEEN SCREWED INTO THE OUTER CASE AND BOTTOMED OUT AGAINST THE DISTRIBUTOR HEAD M3820. SUBMITTER SURMISES THE LACK OF PRESSURIZING AIR CAUSED ARCING THAT, IN TURN, BURNED THE NYLON DISTRIBUTOR GEAR M3056. REPLACED MAGNETO, TRIMMED FITTING MS20822 SO IT WOULD NOT COME IN CONTACT WITH DISTRIBUTOR HEAD. REF: 40-2350. 1L71 3O3 ORTA25SO E14EA 19960425004061996042500406SO 1996 4 25 96ZZZX2028 219960326G8530 CYLINDER CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO ENGINE MISINSTALLED D K NONE W INADEQUATE Q C ININSP/MAINT 1 NM119438M 1117 U20604546 248770R WHEN TRYING TO REMOVE CYLINDERS FOR A TOP OVERHAUL, FOUND TORQUES VERY HIGH TO ALMOST FINGER TIGHT ON CYLINDER STUDS AND THROUGH-BOLTS. THIS ENGINE HAS TORQUE PASTE STILL IN PLACE - ONE-HALF INCH DRIVE AIR WRENCH DID NOTHING - HAD TO CHISEL TWO NUTS OFF SO FAR - TWO CYLINDERS TO GO. SUBMITTER SUGGESTS QUALITY CONTROL SEVERELY LACKING ON THIS FACTORY REMANUFACTURED ENGINE. ENGINE WAS INSTALLED JUNE '89. NO PRIOR PROBLEMS. BROKE CYLINDER WRENCH ON NR 2 CYLINDER. 1H71 3O3 O A4CE E8CE 19960425007151996042500715EA 1996 4 25 96ZZZX2063 219960327G7414ES10382585 CONTACT ASSY BENDIX S1227 PIPER PA28 PA28R200 7102811SO LYC O360 IO360C1C 41514EA MAGNETO LOOSE D K NONE O OTHER ININSP/MAINT 1 EA257693C 907002 28R7635113 L657751A DURING 100-HOUR INSPECTION AND C/W AD 78-9-7R3 (BENDIX IMPULSE COUPLING AND PIN INSP), THE MAIN CONTACT ASSY WAS FOUND LOOSE AND SURROUNDING AREA FROSTED. AGAIN, THE MOUNTING SCREWS WERE TIGHT, BUT THE MFG ASSY SCREW AND NUT WERE LOOSE CAUSING CONTACT HALVES TO DRIFT FROM ALIGNMENT. THE CONTACTS TOTAL TIME WAS UNKNOWN, BUT ESTIMATING BY THE LOOKS, THEY HAD NO MORE THAN 500 HOURS ON THEM. DATE FOUND WAS 3-22-96. 1L71 3O3 O 2A13 1E10 19960425007161996042500716EA 1996 4 25 96ZZZX2064 219960327G7414ES10382585 CONTACT ASSY BENDIX D2000 CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MAGNETO LOOSE D K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 EA25739NT413 8324738 17270680 RL460276T ENGINE FAILED TO MAKE FULL STATIC RPM ON GROUND. UPON FURTHER INSPECTION, IT WAS DETERMINED TO BE A MAGNETO PROBLEM. UPON OPENING MAG COVER, BOTH SETS OF CONTACTS WERE FOUND TO BE LOOSE. THE CONTACT ASSY SCREW (NOT MOUNTING SCREWS) WERE DETERMINED TO BE LOOSE. CONTACT HALVES WERE MISALIGNED WITH ONE ANOTHER CAUSING EXCESSIVE FROSTING AROUND ENTIRE CONTACT AREA AND ON DISTRIBUTOR CAP. 1H71 3O3 ONT3A12 E274 19960425007181996042500718SO 1996 4 25 96ZZZX2066 219960308G8520633620 CRANKSHAFT CESSNA340 340CESSNA 2076404CE CONT O520 TSIO520J 17040SO NR 3 MAIN BRG FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 EA2378S 6209 1140 10991 3400151 20818870J AFTER TAKEOFF WHILE IN LEVEL FLIGHT, THE PILOT EXPERIENCED A SUDDEN ENGINE SEIZURE ON THE RT ENGINE. AN UNEVENTFUL LANDING WAS MADE. THE CRANK WAS FOUND BROKEN AT THE NR 3 MAIN BEARING SADDLE BETWEEN THE NR 4 AND NR 5 ROD THROW. THERE WAS CATASTROPHIC DAMAGE INSIDE AND OUTSIDE THE ENGINE TO CASES, CYLINDERS, AND COMPONENTS. THE NR 5 ROD WAS TORN LOOSE FROM ITS THROW. LOGS SHOWED THE CRANK TO BE OF AIRMELT TYPE AND HAD BEEN GROUND .010 INCH UNDER AT LAST OVERHAUL 1,140 HRS AGO. CAUSE OF CRACK COULD NOT BE DETERMINED. ENGINE WAS A R.A.M. CONVERSION. 1L72 3O3 O 3A25 E8CE 19960425007201996042500720SO 1996 4 25 96ZZZX2068 219960325G8540SA539800M15 CLUTCH SPRING 641348A8 CONT O360 TSIO360EB 17025SO STARTER FAILED B QX2RK NONE O OTHER ININSP/MAINT 1 EA11 1 311356 CLUTCH SPRING WOUND ITSELF AROUND STARTER SHAFT GEAR AND WOULD NOT ALLOW ENGINE TO START. 3 O E9CE 19960502001071996050200107EA 1996 5 2 96ZZZX2074 219960228G8530LW13561 CYLINDER BEECH 60 B60 1153605CE LYC O541 TIO541E1C4 41536EA NR 4 EXH ROCKER FAILED B BKHRK NONE O OTHER ININSP/MAINT 1 WP01294D 829 P451 RL98559 DURING ENGINE RUN-UP FOR TAKEOFF, ENGINE QUIT. INVESTIGATION BY BORESCOPE FOUND NR 4 CYLINDER EXHAUST VALVE NOT WORKING. REMOVED ROCKER BOSS AND FOUND EXHAUST VALVE ROCKER SHAFT INBOARD ROCKER BOSS CASTING AND COVER TAB FAILED. OUTBOARD CASTING OK. ALL OTHER CYLINDERS ROCKER CASTINGS OK. SUSPECT ROCKER RETAIN CLIP FAILED INITIALLY. 1L72 3O3 O A12CE E10EA 19960502001151996050200115SO 1996 5 2 96ZZZX2082 219960403G8550640726 TUBE ASSY CESSNA421 421C 2076016CE CONT O520 GTSIO520* 17032SO FUEL MANIFOLD FAILED C A UNSCHED LANDING K FLUID LOSS CRCRUISE 1 SW996867L890 421C1087 R610188 DURING FLIGHT, OIL WAS NOTICED ON THE RIGHT NACELLE, THE AIRCRAFT LANDED SAFELY AND THE PROPELLER WAS FEATHERED. INVESTIGATION REVEALED TUBE ASSEMBLY FROM THE CRANKCASE TO THE FUEL MANIFOLD HAD BROKEN FROM THE SOLDER JOINT CLOSEST TO THE FUEL MANIFOLD. 1L72 3O3 O A7CE E7CE 19960502001261996050200126NE 1996 5 2 96ZZZX2093 219960409G75308008311001L7 CONTROL CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE BLEED VALVE MALFUNCTIONED E A UNSCHED LANDING RM PARTIAL RPM/PWR LOSS OVER TEMP CLCLIMB 1 GL07312QS740 5600312 500109 ON TAKEOFF, THE RIGHT ENGINE RPM ROLLED BACK 10 PERCENT AND THE I.T.T. INCREASED TO 700 DEGREES. AIRCRAFT RETURNED AND ENGINE WAS INSPECTED. NO PROBLEM WAS FOUND. AIRCRAFT WAS TEST FLOWN AND NR 2 ENGINE I.T.T. WAS 50 DEGREES HIGHER. FOUND BLEED VALVE OPERATING ON GROUND WHEN NOT CALLED FOR. BLEED VALVE CONTROL AND BLEED VALVE ACTUATOR WERE REPLACED AND PROBLEM CORRECTED. 2L72 4F4 FRTA22CE E25EA 19960502001271996050200127NE 1996 5 2 96ZZZX2094 219960409G7532F008881L1 ACTUATOR CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE BLEED VALVE MALFUNCTIONED E A UNSCHED LANDING RM PARTIAL RPM/PWR LOSS OVER TEMP CLCLIMB 1 GL07312QS740 F22028 5600312 500109 ON TAKEOFF, THE RIGHT ENGINE RPM ROLLED BACK 10 PERCENT AND THE I.T.T. INCREASED TO 700 DEGREES. AIRCRAFT RETURNED AND ENGINE WAS INSPECTED. NO PROBLEM WAS FOUND. AIRCRAFT WAS TEST FLOWN AND NR 2 ENGINE I.T.T. WAS 50 DEGREES HIGHER. FOUND BLEED VALVE OPERATING ON GROUND WHEN NOT CALLED FOR. BLEED VALVE CONTROL AND BLEED VALVE ACTUATOR WERE REPLACED AND PROBLEM CORRECTED. 2L72 4F4 FRTA22CE E25EA 19960502002721996050200272SO 1996 5 2 96ZZZX2150 219960320G8530652954A1 CYLINDER CESSNA206 U206A 2073316CE CONT O520 IO520A 17032SO CYLS 2,6,1,3,5 CRACKED D K NONE O OTHER ININSP/MAINT 1 AL034975U778 U20605179 284679R NR 2, NR 6, NR 1, NR 3, AND NR 5 CYLINDERS WERE FOUND CRACKED AT INTAKE SEAT. 1H71 3O3 O A4CE E5CE 19960502002731996050200273SO 1996 5 2 96ZZZX2151 219960301G8530652954A1 CYLINDER CESSNA206 U206 2073306CE CONT O520 IO520A 17032SO CYLS NR 4, 1 CRACKED D K NONE O OTHER ININSP/MAINT 1 AL034672U540 U20605046 284695R NR 4 AND NR 1 CYLINDERS WERE FOUND CRACKED AT INTAKE SEAT. 1H71 3O3 O A4CE E5CE 19960502002741996050200274SO 1996 5 2 96ZZZX2152 219960320G8530652954A1 CYLINDER CESSNA206 U206 2073306CE CONT O520 IO520A 17032SO CYLS NR 3, 2, 5 CRACKED D K NONE O OTHER ININSP/MAINT 1 AL03244PL760 4371 28468R NR 3, NR 2, AND NR 5 CYLINDERS WERE FOUND CRACKED AT INTAKE SEAT. 1H71 3O3 O A4CE E5CE 19960502002831996050200283SO 1996 5 2 96ZZZX2161 219960401G7414 CONTACT POINTS SLICK 6320 CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO LT ENG LT MAG CORRODED B CRJRK NONE O OTHER ININSP/MAINT 1 CE01135BG 92080002 414A0419 521195 JUST PRIOR TO AIRCRAFT BEING INDUCTED FOR 100-HOUR INSPECTION, PILOT INFORMED MAINTENANCE OF ROUGH RT MAG ON RT ENGINE. INVESTIGATION SHOWED SEVERE CORROSION ON POINTS, GEARS, CAPACITOR, AND BEARINGS. CHECK REMAINING 3 MAGNETOS AND FOUND IDENTICAL CONDITIONS OF SEVERE CORROSION. ALL FOUR MAGNETOS WERE CLEANED AND AFFECTED PARTS WERE REPLACED. PROBLEM BELIEVED TO BE CAUSED BY PRESSURIZED AIR FROM TURBOS. 1L72 3O3 O A7CE E8CE 19960502002841996050200284SO 1996 5 2 96ZZZX2162 219960401G7414 CONTACT POINTS SLICK 6320 CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO RT ENG LT MAG CORRODED B CRJRK NONE O OTHER ININSP/MAINT 1 CE01135BG 93020037 414A0419 521195 JUST PRIOR TO AIRCRAFT BEING INDUCTED FOR 100-HOUR INSPECTION, PILOT INFORMED MAINTENANCE OF ROUGH RT MAG ON RT ENGINE. INVESTIGATION SHOWED SEVERE CORROSION ON POINTS, GEARS, CAPACITOR, AND BEARINGS. CHECK REMAINING 3 MAGNETOS AND FOUND IDENTICAL CONDITIONS OF SEVERE CORROSION. ALL FOUR MAGNETOS WERE CLEANED AND AFFECTED PARTS WERE REPLACED. PROBLEM BELIEVED TO BE CAUSED BY PRESSURIZED AIR FROM TURBOS. 1L72 3O3 O A7CE E8CE 19960502002851996050200285SO 1996 5 2 96ZZZX2163 219960401G7414 CONTACT POINTS SLICK 6320 CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO LT ENG RT MAG CORRODED B CRJRK NONE O OTHER ININSP/MAINT 1 CE01135BG 92080010 414A0419 521195 JUST PRIOR TO AIRCRAFT BEING INDUCTED FOR 100-HOUR INSPECTION, PILOT INFORMED MAINTENANCE OF ROUGH RT MAG ON RT ENGINE. INVESTIGATION SHOWED SEVERE CORROSION ON POINTS, GEARS, CAPACITOR, AND BEARINGS. CHECK REMAINING 3 MAGNETOS AND FOUND IDENTICAL CONDITIONS OF SEVERE CORROSION. ALL FOUR MAGNETOS WERE CLEANED AND AFFECTED PARTS WERE REPLACED. PROBLEM BELIEVED TO BE CAUSED BY PRESSURIZED AIR FROM TURBOS. 1L72 3O3 O A7CE E8CE 19960502002861996050200286SO 1996 5 2 96ZZZX2164 219960401G7414 CONTACT POINTS SLICK 6320 CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO RT ENG RT MAG CORRODED B CRJRK NONE O OTHER ININSP/MAINT 1 CE01135BG 93020044 414A0419 521195 JUST PRIOR TO AIRCRAFT BEING INDUCTED FOR 100-HOUR INSPECTION, PILOT INFORMED MAINTENANCE OF ROUGH RT MAG ON RT ENGINE. INVESTIGATION SHOWED SEVERE CORROSION ON POINTS, GEARS, CAPACITOR, AND BEARINGS. CHECK REMAINING 3 MAGNETOS AND FOUND IDENTICAL CONDITIONS OF SEVERE CORROSION. ALL FOUR MAGNETOS WERE CLEANED AND AFFECTED PARTS WERE REPLACED. PROBLEM BELIEVED TO BE CAUSED BY PRESSURIZED AIR FROM TURBOS. 1L72 3O3 O A7CE E8CE 19960502002981996050200298EA 1996 5 2 96ZZZX2176 219960328G853065007 RETAINER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA INTAKE PUSHROD CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 WP178172Q 500 288090263 L2803436A PUSHROD TUBE ON NR 2 CYLINDER INTAKE HAS A PERSISTENT OIL LEAK NEAR THE CRANKCASE. WHEN CHANGING THE PUSHROD TUBE SEAL THIS TIME, THE PUSHROD TUBE RETAINER WHICH IS PRESSED INTO THE CRANKCASE WAS FOUND CRACKED ABOUT ONE-FOURTH OF THE WAY AROUND THE CIRCUMFERENCE. 1L71 3O3 O 2A13 E286 19960502003001996050200300EA 1996 5 2 96ZZZX2178 219960412G73223472 VALVE SEAT MA45 CESSNA182 182R 2072731CE LYC O540 O540L3C5 41532EA PUMP DISCHARGE WORN D K NONE O OTHER ININSP/MAINT 1 CE0158JK 656 75030510 18268286 ENGINE RUNNING EXTREMELY RICH. FOUND PUMP DISCHARGE CHECK VALVE SEAT WORN OFF. 1L71 3O3 ONT3A13 E295 19960502003111996050200311EA 1996 5 2 96ZZZX2189 219960322G852075060 CONNECT ROD PIPER PA32 PA32300 7103212SO LYC O540 IO540K1A5 41532EA NR 6, NR 1 ROD BOLT NOT MARKED D K NONE W INADEQUATE Q C ININSP/MAINT 1 SO154053R 339 3240355 L794448 ENGINE DISASSEMBLED AND FOUND 3 BOLTS WITH NO HEAD MARKING. ONE EACH LOCATED ON NR 6 ROD. TWO EACH LOCATED ON NR 1 ROD. 1L71 3O3 O A3SO 1E4 19960502005921996050200592GL 1996 5 2 96ZZZX2218 219960307G72106889326 BEARING SKRSKYS76 S76A 8143006NE ALLSN 250C 250C30S 03013GL GEARBOX GALLED B ALGRK NONE O OTHER ININSP/MAINT 1 SW03768AL MP02911 760031 890074S UPON DISASSEMBLY OF GEARBOX, CLEANED AND INSPECTED PARTS AS REQUIRED. FOUND EXCESSIVE GALLING ON PTO AFT, BEARING INNER RACE. EXCESSIVE GALLING, BEARING INNER RACE, POSSIBLY DUE TO BEARING CAGE OUT-OF-ROUND CAUSING TIGHT FIT BETWEEN INNER AND OUTER RACE AND BALLS. 1G72 3U3 U H1NE E1GL 19960509001031996050900103NE 1996 5 9 96ZZZX2228 219960403G72404059T02601 RETAINER CNDAIRCL600 CL6002B16 1900305EA GE CF34 CF343A 30015NE NR 5 BEARING FAILED ES A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 GL03826JP2656 5050 350353 PILOTS NOTICED ABNORMAL VIBRATION ON LT ENGINE OVER THE NORTH ATLANTIC. UNSCHEDULED LANDING. GE WAS CONTACTED AND ENGINE WAS REPLACED. ON TEAR-DOWN, NR 5 BEARING RETAINER LOCK PIN FOUND TO HAVE BROKEN OFF ALLOWING BEARING TO SPIN IN ITS SEAT, SUBSEQUENTLY, DAMAGING MOST OF THE ROTATING COMPONENTS ATTACHED. THE PTO SHAFT WAS FOUND LOOSE IN THE ENGINE, AND MAY HAVE BEEN A CONTRIBUTING FACTOR DUE TO VIBRATION. THIS PTO CONDITION WAS FOUND ON THE AIRCRAFT'S OTHER ENGINE AT 375 TTSN. 2L72 4F4 FRTA21EA E15NE 19960509001171996050900117NE 1996 5 9 96ZZZX2242 219960228G7321 EEC SMITHSIND LEAR 60 60LEAR 5170707CE PWA 305 PW305 NE LT ENGINE MALFUNCTION C O OTHER J WARNING INDICATION CRCRUISE 1 SW09799SC54 Y7545 067 PCE305250 AMBER AND WHITE COMPUTER LIGHTS CAME ON AND ITT INDICATION WAS LOST FOR THE LEFT ENGINE; OTHERWISE, OPERATION WAS NORMAL IN-FLIGHT. ENGINE WOULD NOT START ON GROUND. NO ITT INDICATION CAUSED THE FADER TO ABORT START ATTEMPTS. REPLACED E.E.C. OPERATION NORMAL. 2L72 4F4 FRTA10CE E35NE 19960509003241996050900324SO 1996 5 9 96ZZZX2292 219960329G741410349271 COIL BENDIX S6RN1225 BEECH 55 95B55 1152706CE CONT O470 IO470L 17026SO MAGNETO CRACKED D K NONE O OTHER ININSP/MAINT 1 SW092023Z A224421 TC2171 465369 DURING ANNUAL INSPECTION, FOUND MAGNETO COIL CRACKED IN NUMEROUS PLACES. AD 94-01-03 R2 REQUIRES REPLACEMENT OF THESE COILS, BUT THIS SERIAL NUMBER MAGENTO IS NOT COVERED BY THE AD (COIL IS AN OPAQUE AMBER COLOR AS REFERENCED IN TELEDYNE CONTINENTAL IGNITION SYSTEMS SB MSB644). THERE ARE NO MAINTENANCE RECORD ENTRIES OF THESE COILS HAVING BEEN PREVIOUSLY REPLACED. 1L72 3O3 O 3A16 3E1 19960509003251996050900325SO 1996 5 9 96ZZZX2293 219960411G7414104001664 IMPULSE CAM S6RN25 CESSNA182 182B 2072706CE CONT O470 O470L 17026SO LT MAGNETO WORN D K NONE O OTHER ININSP/MAINT 1 NM117244E596 K149104DR 52244 069744R UPON INSPECTION OF CAMS IN IMPULSE COUPLINGS FOR WEAR PER AD 78-09-07, FOUND ONE FLYWEIGHT AND RIVET WORN WELL BEYOND LIMITS. THIS IS NEW STYLE CAM WITH SNAP RING ASSEMBLY. FOR A TOTAL TIME OF ONLY 595 HOURS, FEEL THIS TO BE SIGNIFICANT WEAR AND WOULD ALSO QUESTION THE HARDNESS OF METAL. 1H71 3O3 ONT3A13 E273 19960509003261996050900326EA 1996 5 9 96ZZZX2294 219960317G8530 VALVE PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA NR 1 CYL INTAKE HEAD SEPARATED D O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 GL158347C1734 287690121 L2101336A ENGINE ROUGHNESS DURING FLIGHT FOUND BENT PUSHROD HOUSING AND PUSHROD. REMOVED CYLINDER AND FOUND VALVE HEAD SEPARATED FORM STEM INTAKE SIDE. 1L71 3O3 O 2A13 E286 19960509003321996050900332NE 1996 5 9 96ZZZX2300 219960304G72107757571 BEARING 5074T6LG10 SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE GC 49 GEARCASE CRACKED B SI3RK NONE O OTHER ININSP/MAINT 1 NE03202KD1073 9376 340B202 GEAR CASE WAS RETURNED FOR OIL CONTAMINATION. UNIT WAS DISASSEMBLED AND AN EXAMINATION OF INTERNAL HARDWARE REVEALED A CRACKED INNER RACE ON THE PROPELLER SHAFT FORWARD ROLLER BEARING RACE. LEFT - TSI 4,239.5 HRS. CSI, 4,048. 2L72 4T4 TRTA52EU E8NE 19960516000581996051600058GL 1996 5 16 96ZZZX2357 219960207G721023030994 SCAVENGE TUBE 23035178 BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL GEARBOX BRACKET BROKEN B ALGRK NONE O OTHER ININSP/MAINT 1 SW03366AL4181 51470 CAE895428 UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY, AND SCAVENGE TUBE. FOUND ALIGNMENT BRACKET ON SCAVENGE TUBE BROKEN. ALIGNMENT BRACKET AT LOWER END OF SCAVENGE TUBE WAS FOUND BROKEN AT WELD AREA. SUSPECT CAUSE IS DUE TO IMPROPER FIT ON ALIGNMENT BRACKETS. 1G71 3U3 U H2SW E1GL 19960516000631996051600063GL 1996 5 16 96ZZZX2362 219960207G726123039793 SCAVENGE BODY 23035179 SKRSKYS76 S76 8143010NE ALLSN 250C 250C30S 03013GL GEARBOX WORN B ALGRK NONE O OTHER ININSP/MAINT 1 SW03769AL2570 760048 CAE890253S UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY. VISUALLY INSPECTED, SHOWED WEAR AT SCAVENGE BODY AND SCAVENGE TUBE MATING SURFACE. SCAVENGE TUBE WORE INTO SCAVENGE BODY. SUSPECT CAUSE IS DUE TO IMPROPER FIT ON ALIGNMENT BRACKETS. 1G72 3U3 U H1NE E1GL 19960516002571996051600257SO 1996 5 16 96ZZZX2389 219960319G8550 ENGINE CONT O470 O470R 17026SO OIL SYSTEM FAILED D A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 EA03 987908RR ENGINE 235.3 SMOH, 7.6 HRS AFTER NR 4 CYLINDER REMOVED FOR REPAIR. PHILLIPS XC OIL BEING USED. AV BLEND PUT IN ENGINE AFTER CYLINDER WAS REPAIRED. IN-FLIGHT, OIL PRESSURE STARTED TO DECREASE. LANDING MADE OK. AT IDLE, OIL PRESSURE DROPPED TO ZERO PSI, TOTAL FLIGHT TIME, 7 MINUTES. OIL DRAINED, FOUND SLUDGE OF UNKNOWN SUBSTANCE, ABOUT 1-2 TABLESPOONS OF MATERIAL, BROWNISH COLOR, DRAINED OUT WITH OIL. OIL SCREEN WAS VERY CLEAN. NONE OF THIS MATERIAL IN SCREEN. 3 O E273 19960516002591996051600259GL 1996 5 16 96ZZZX2391 219960220G7261 ENGINE CESSNA206 U206G 2073356CE ALLSN 250C 250C20 03013GL OIL SYSTEM CHIP LIGHT B LX5RK NONE J WARNING INDICATION NRNOT REPORTED 1 GL19891LL829 U206G06937 CAE290031 RECEIVED OIL CHIP LIGHT INDICATION. PERFORMED REQUIRED MAINTENANCE PER ALLISON 250-C20S AND SOLOY/CESSNA MAINTENANCE AND OVERHAUL MANUALS. RECEIVED SECOND CHIP LIGHT INDICATION 3.9 HRS TIS LATER. ENGINE REMOVED AND SENT OUT FOR INSPECTION/REPAIR PER ALLISON 250-C20S MAINTENANCE AND OVERHAUL MANUALS. 1H71 3O3 U A4CE E4CE 19960516002671996051600267EA 1996 5 16 96ZZZX2399 219960225G855062817 FILTER SCREEN MOONEYM20 M20C 5870208SW LYC O360 O360A1D 41514EA ACCESSORY CASE SPLIT D K NONE O OTHER ININSP/MAINT 1 EA277821V 2805 RL1289236A DURING ANNUAL, OIL PRESSURE SCREEN WAS REMOVED AND CHECKED FOR METAL, ETC. AFTER SCREEN WAS CLEANED IN PARTS WASHER, IT WAS NOTED THE SOLDERED SEAM OF THE INNER FINE MESH SCREEN WAS SPLIT. ON CLOSER INSPECTION, THE OUTER SCREEN SHOWED APPROXIMATELY FOUR STRANDS SEPARATED FROM THE SOLDER. THE AREA OF SEPARATION IS MIDWAY AND THE SCREEN LOOKS AS IF IT WAS SWOLLEN. SUSPECT AGE, HEAT CHANGES, AND DIFFERENTIAL OF PRESSURES ON THE INNER AND OUTER SIDES OF SCREEN FROM DIRT, GRIT, AND COLD THICK OIL WERE CAUSES. SUBMITTER STATED MORE FREQUENT AND THOROUGH CLEANING OF SCREEN OR REPLACMENT AT INTERVALS (500 HOURS OR 5 YEARS). 1L71 3O3 O 2A3 E286 19960516002751996051600275SO 1996 5 16 96ZZZX2407 219960402G8530646303 PISTON CESSNA421 421C 2076016CE CONT O520 GTSIO520N 17032SO LT ENG NR 5 BURNED B ITWRK NONE R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 NM0767934 900 421C1026 610051 AIRCRAFT LOST POWER ON NR 1 ENGINE. REMOVAL OF NR 5 CYLINDER REVEALED PISTON DOME EDGE BURNED AWAY FROM 6:00 POSITION TO 12:00 POSITION. AT 9:00 POSITION, PISTON DOME BURNED COMPLETELY THROUGH, APPROXIMATELY 1 INCH OF PISTON MATERIAL MISSING FROM EDGE TOWARDS CENTER OF DOME. 1L72 3O3 O A7CE E7CE 19960516002761996051600276SO 1996 5 16 96ZZZX2408 219960320G8530 CYLINDER CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO ROCKER BOSS CRACKED D K NONE O OTHER ININSP/MAINT 1 SW99732DZ1669 21061446 567326 FIVE OF SIX CYLINDERS HAVE CRACKS IN ROCKER BOSS AREA UP TO THE ROCKER SHAFT RETAINING BOLTS. TWO OF THESE FIVE HAVE CRACKS ON INTAKE AND EXHAUST BOSSES. THIS ENGINE DOES NOT INCORPORATE LONG BOLTS AND SOLID SHAFTS. 1H71 3O3 O 3A21 E5CE 19960516002781996051600278SO 1996 5 16 96ZZZX2410 219960307G854099101371 SHAFT CESSNA421 421C 2076016CE CONT O520 GTSIO520H 17032SO RT ENG HYD SHEARED D K NONE O OTHER ININSP/MAINT 1 GL09215MP 421C1231 FOUND DRIVE SHAFT ON AIR CONDITIONING, HYDRAULIC PUMP SHEARED. UPON REMOVAL, SYSTEM HYDRAULIC PUMP SHAFT SPLINES WERE FOUND WORN OUT AND RUSTED. SUBMITTER SUGGESTS SPLINES BE LUBED AT 200-HOUR INTERVALS TO PREVENT THIS PROBLEM FROM RECURRING. 1L72 3O3 O A7CE E7CE 19960516002801996051600280SO 1996 5 16 96ZZZX2412 219960320G8530 ENGINE CESSNA210 T210M 2073451CE CONT O520 TSIO520R 17040SO CYLINDER DEFECTIVE B EBVRK NONE O OTHER ININSP/MAINT 1 GL09761TF1975 21062499 PRE-PURCHASE INSPECTION OF AIRCRAFT REVEALED ENGINE COMPRESSION WELL BELOW ACCEPTABLE LIMITS, SEAT RAILS WERE WORN BEYOND LIMITS. ESTABLISHED BY AIRWORTHINESS DIRECTIVE. ELEVATOR TRIM TAB WITH HOLES CORRODED THROUGH THE TAB SKIN. AIRCRAFT WAS ANNUALLED THE FIRST WEEK OF MARCH, 1996, AND LESS THAN 2 HOURS AGO. 1H71 3O3 O 3A21 E8CE 19960516003041996051600304EU 1996 5 16 96ZZZX2437 219960322G7314996590 PUMP DIAMONDA20A1DA20A1 05626UXGL ROTAX 912 ROTAX912 55555EU ENGINE OIL LEAK D K NONE K FLUID LOSS ININSP/MAINT 1 SW99526SS24 10085 FUEL PUMP STARTED LEAKING OIL AT SEAM WHERE DIAPHRAM WAS IN PUMP. 1L71 3O3 INTTA4CH EXPE3I 19960516005341996051600534GL 1996 5 16 96ZZZX2482 219960425G72506899373 WHEEL ALLSN 250C 250C20B 03013GL THIRD STAGE SHROUD CRACKED B YKERK NONE O OTHER ININSP/MAINT 1 EA17 HX58891 CAE820030 TURBINE WAS DISASSEMBLED AS PART OF ENGINE REPAIR FOR COMPRESSOR STALLS. FOUND THE SHROUD ON THE THIRD STAGE WHEEL CRACKED ALL THE WAY THROUGH. 3 U E4CE 19960516005561996051600556SO 1996 5 16 96ZZZX2505 219960425G8530653445A11 CYLINDER BEECH 58 58 1152740CE CONT O520 IO520CB 17032SO PLUG BOSS CRACKED I K NONE O OTHER ININSP/MAINT 1 SW073695V1216 TH1183 282447R THE CONTINENTAL CYLINDER CRACKED WITH ONLY 1,216.4 HOURS ON IT. THE CRACK ORIGINATED AT THE SPARK PLUG BOSS AND WAS TRAVELLING TO THE FUEL INJECTION NOZZLE. THE COMPRESSION WAS STILL IN THE UPPER 60'S. SUBMITTER STATED THEY HAVE BEEN EXPERIENCING ALOT OF THIS TYPE OF CRACKING AND BELIEVE IT TO BE A PROBLEM WITH THE MANUFACTURING PROCESS AT CONTINENTAL OR THEIR SUB-CONTRACTORS. 1L72 3O3 O 3A16 E5CE 19960516005571996051600557SO 1996 5 16 96ZZZX2506 219960410G8530 CYLINDER CESSNA150 150M 2071830CE CONT O200 O200A 17020SO NR 1 CYL EXH RKRBOSS CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 EA279264U 1438 15078214 254467 DURING POST 100 HOUR OPERATIONAL RUN AND LEAK CHECK, NOTED A NOISE SIMILAR TO A 'BAFFLE RATTLE' BEING MADE. AFTER SHUT DOWN, NO LOOSE BAFFLES WERE FOUND. THE ROCKER BOX COVERS WERE REMOVED TO REPLACE THE GASKETS FOUND LEAKING. WHEN NR 1 COVER REMOVED, A SMALL 'HALF-MOON' SHAPED PIECE OF CASTING WAS FOUND. THE OUTER EXHAUST ROCKER SHAFT BOSS HAD BROKEN OFF THROUGH ITS DIAMETER PARALLEL WITH THE ROCKER ARM. AD 94-05-05 ADDRESSES THIS PROBLEM AT OVERHAUL. 1H71 3O3 O 3A19 E252 19960516005611996051600561SO 1996 5 16 96ZZZX2510 219960423G8520 CRANKCASE PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360EB 17025SO RT NR 5 CYL CRACKED B APCRK NONE O OTHER ININSP/MAINT 1 NM018407C151331266 347670137 265901R SMALL CRACK FOUND IN RIGHT SIDE OF CRANKCASE NEXT TO THROUGH-BOLT JUST FORWARD OF CYLINDER NR 5. CONSIDERED NON-CRITICAL AREA PER SB M90-17. 1L72 3O3 O A7SO E9CE 19960516005621996051600562EA 1996 5 16 96ZZZX2511 219960423G7414M2637 POINTS SLICK 6393 LYC O540 IO540C4B5 41532EA LT MAG DEFORMED D K NONE O OTHER ININSP/MAINT 1 NE05 392 94020017 RL1924648A AIRCRAFT WAS BEING RUN BEFORE FLIGHT. WHEN SHUTTING RIGHT MAG OFF ON LEFT ENGINE, ENGINE QUIT. CHECKED P-LEADS FOR GROUNDING AND PROPER INSTALLATION. REMOVED MAG AND CHECKED COIL, POINT GAP AND REPLACED CONDENSER. UPON CHECKING E-GAP FOUND POINTS NOT CLOSING. REPLACED POINTS WHICH CORRECTED DISCREPANCY. SUSPECT CAUSE: INSPECTING POINTS WRONG. WHEN OPENING POINTS TO INSPECT, BE CAREFUL NOT TO OPEN TOO FAR. 3 O 1E4 19960516005631996051600563SO 1996 5 16 96ZZZX2512 219960426G8520653877 LIFTER CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO LIFTER FACE GALLED D K NONE O OTHER ININSP/MAINT 1 NE0561368433 18504159 282672R WHILE DOING TOP OVERHAUL, FOUND 3 HYDRAULIC LIFTERS PITTED AND GALLED. SUBMITTER RECOMMENDS CLOSER INSPECTION OF LIFTERS AT OVERHAUL. 1H71 3O3 O 3A24 E5CE 19960516005661996051600566EA 1996 5 16 96ZZZX2515 219960413G7414 MAGNETO BENDIX 2000 MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA ENGINE MISINSTALLED H A UNSCHED LANDING YW ENGINE STOPPAGE INADEQUATE Q C CLCLIMB 1 EA174244H 240679 ENGINE FAILURE OCCURRED UPON REACHING 4,500 FEET. EMERGENCY LANDING AT AIRPORT WAS MADE. INVESTIGATION DETERMINED MAGNETO HAD FALLEN OFF ENGINE. INSPECTION REVEALED MAGNETO HAD BEEN REMOVED 4 MONTHS EARLIER TO C/W AD 78-09-07RE. UPON REINSTALLATION OF MAGNETO, A FLANGED TYPE GASKET P/N 62224 HAD BEEN USED INSTEAD OF PROPER ROUND GASKET, P/N CW12681. THIS ALLOWED GASKET MATERIAL TO BE COMPRESSED BETWEEN MAGNETO HOLD-DOWN CLAMPS AND ACCESSORY HOUSING RESULTING IN IMPROPER TORQUING AND SUBSEQUENT FAILURE. 1L71 3O3 O 2A3 1E10 19960516005701996051600570SO 1996 5 16 96ZZZX2519 219960424G8520 CRANKSHAFT BBAVIA7 7BCM 2110106SW CONT C85 C858 17008SO PROPELLER ATTACHFAILED G K NONE O OTHER NRNOT REPORTED 1 GL0946AC 120 7AC3382 PROPELLER SEPARATED FROM ENGINE DUE TO CRANKSHAFT FAILURE. INDICATION OF PREVIOUS CRACK AT AREA OF FRACTURE. 1H71 3O3 O A759 E233 19960516005731996051600573GL 1996 5 16 96ZZZX2522 219960404G725023055438 2ND STG NOZZLE ALLSN 250C 250C30 03013GL GP SEC DIAPHRAGM LOOSE B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 X61606 UPON RECEIVING FROM ALLISON (NEW) 3-5-96, NOZZLE HAD A DIAPHRAGM MOVEMENT OF .005 INCH. ACCORDING TO CEB-72-3188, THE DIAPHRAGM SHOULD HAVE A RADIAL MOVEMENT OF .003 INCH MAXIMUM. THE NOZZLE WAS SENT BACK TO ADDISON FOR WARRANTY. TIGHTENED THE KEYS ON THE DIAPHRAGM INNER RING. 3 U E1GL 19960516005741996051600574GL 1996 5 16 96ZZZX2523 219960404G725023055438 2ND STG NOZZLE 23035128 ALLSN 250C 250C30 03013GL GP SEC DIAPHRAGM LOOSE B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 X61647 UPON RECEIVING FROM ALLISON (NEW) 3-5-96, NOZZLE HAD A DIAPHRAGM MOVEMENT OF .005 INCH. ACCORDING TO CEB-72-3188, THE DIAPHRAGM SHOULD HAVE A MAXIMUM MOVEMENT OF .003 INCH. THE NOZZLE WAS SENT BACK TO ALLISON FOR WARRANTY. TIGHTENED THE KEYS ON THE DIAPHRAGM INNER RING. 3 U E1GL 19960516005751996051600575GL 1996 5 16 96ZZZX2524 219960404G725023055438 2ND STG NOZZLE 2305128 ALLSN 250C 250C30 03013GL GP SEC DIAPHRAGM LOOSE B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 X61626 UPON RECEIVING FROM ALLISON (NEW) 3-8-96, NOZZLE HAD A DIAPHRAGM MOVEMENT OF .004 INCH. ACCORDING TO CEB-72-3188, THE DIAPHRAGM SHOULD HAVE A MAXIMUM MOVEMENT OF .003 INCH. THIS IS UNACCEPTABLE. THE NOZZLE WAS SENT BACK TO ALLISON FOR WARRANTY. TIGHTENED THE KEYS ON THE DIAPHRAGM INNER RING. 3 U E1GL 19960521000041996052100004GL 1996 5 21 96ZZZX2367 219960319G72606859435 BEARING AGUSTAA109 A109A2 0260120EU ALLSN 250C 250C20B 03013GL GEARBOX FAILED B KUVRO OTHER J WARNING INDICATION NRNOT REPORTED 1 SO198WH 266 7256 CAE832739 CHIP LIGHT ILLUMINATED IN-FLIGHT. SHORTLY THEREAFTER, ENGINE FAILED. MAINTENANCE FOUND THE BEARINGS ON EITHER END OF THE FUEL CONTROL AND OIL PUMP SPUR GEARSHAFT FELL APART STOPPING FUEL CONTROL OPERATION. EXACT CAUSE UNKNOWN AT THIS TIME. UNUSUAL BECAUSE SHAFT IS SUPPORTED ON BOTH ENDS. SUSPECT ONE BEARING FAILED ALLOWING SHAFT TO WOBBLE AND DESTROY SECOND BEARING. 1G72 3U3 U H7EU E4CE 19960521000081996052100008EA 1996 5 21 96ZZZX2371 219960415G8530 CYLINDER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA NR 3 FAILED D K NONE O OTHER ININSP/MAINT 1 GL15396092800 400 287890542 L2519936A NR 3 CYLINDER BARREL BROKEN. BARREL FAILED 75 PERCENT OF RADIUS ABOUT 2 INCHES DOWN FROM TOP OF CYLINDER BARREL. 1L71 3O3 O 2A13 E286 19960523002221996052300222SO 1996 5 23 96ZZZX2555 219960228G8530 VALVE GUIDE CESSNA182 182P 2075816CE CONT O470 O470R 17026SO NR 1 CYLINDER LOOSE D K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 SO1652727 390 18262801 462760 VALVE GUIDE LOOSENED IN CYLINDER HEAD ALLOWING CYLINDER TO MISFIRE. NOTE: DIFFICULT TO DIAGNOSE. COMPRESSION WAS 55/80 UNTIL SPRING ASSY WAS MOVED. SUBMITTER RECOMMENDS CHECKING SPRING ASSYS FOR SIDE PLAY WHEN VALVE COVERS REMOVED FOR ANY REASON. 1H71 3O3 ONTTA13 E273 19960523002261996052300226EA 1996 5 23 96ZZZX2559 219960124G8520SL72877 LIFTER BBAVIA7 7KCAB 21101P3CE LYC O320 IO320E2A 41508EA FACE DAMAGED D K NONE O OTHER ININSP/MAINT 1 WP098643 84 35473 L495755A ANNUAL INSPECTION - LARGE AMOUNT OF METAL FRAGMENTS IN OIL PRESSURE AND OIL SUCTION SCREENS. CYLINDERS REMOVED, 7 LIFTER BODIES NOT TURNING, ENGINE TEAR-DOWN REVEALED VERY LITTLE TAPER ON CAM LOBE TIPS EXCEPT NR 4 EXHAUST LUBE. IT HAD .001 INCH TAPER AND WAS TURNING. FURTHER INVESTIGATION REVEALED NR 3 CONNECTING ROD AND NR 3 ROD JOURNAL SCORED BADLY RENDERING CRANKSHAFT AND NR 3 ROD UNREPAIRABLE DUE TO LARGE FRAGMENT FROM NR 2 INTAKE LIFTER BODY PASSING THROUGH OIL SUCTION SCREEN AND BACK INTO OIL SYSTEM. 1H71 3O3 O A759 1E12 19960523003331996052300333EA 1996 5 23 96ZZZX2579 219960402G7414103493704 IMPULSE COUPLER PIPER PA32 PA32300 7103212SO LYC O540 IO540K1B5 41532EA MAGNETO WORN D K NONE O OTHER ININSP/MAINT 1 NE013044K 327940025 960402 MAGNETO SQAWKED AS DEAD. REMOVED AND DISASSEMBLED MAGNETO, FOUND COIL TAB BENT UPWARD TO MAKE UP FOR THE ERODED CONDITION OF TAB. TAB HAD COME IN CONTACT WITH METAL AREA OF ROTOR. WORN THROUGH, GROUNDING MAG. IMPULSE COUPLING WORN SO BADLY AS TO NARROWLY MISS CONTACT WITH STOP POSTS DURING ENGINE RUN MODE. IMPULSE COUPLING SPRING BROKEN. THIS MAGNETO HAS 250 HRS SINCE ENGINE OVERHAUL. WHILE SERVICING TIRES TO MOVE AIRCRAFT OUT OF HANGAR, NOTED MISSING SCREWS ON LEFT FUEL TANK. 1L71 3O3 O A3SO 1E4 19960523003341996052300334SO 1996 5 23 96ZZZX2580 219960426G8530 CYLINDER CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO ROCKER SHAFT BOLTS FAILED B FCPRE ENGINE SHUTDOWN O OTHER NRNOT REPORTED 1 NM09421CW 421C0137 292087R ENGINE WAS SHUT DOWN IN-FLIGHT BY PILOT. FOUND ROCKER SHAFT BOLTS BROKEN, AND BENT PUSH ROD. VALVES, GUIDES AND PISTON WERE INSPECTED. ALL PARTS FOUND IN GOOD CONDITION. REINSTALLED CYLINDER AND GROUND RUN. ALL FOUND GOOD. 1L72 3O3 O A7CE E7CE 19960523007141996052300714GL 1996 5 23 96ZZZX2586 219960426G73136898735 TURBINE BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL NR 1 NOZZLE FAILED H A A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 SW093187D6260 3284 1326 CAE833935 DURING CRUISE FLIGHT, TORQUE YAW WAS EXPERIENCED ALONG WITH TOT RISES TO 890 DEGREES CELSIUS. TORQUE WAS REDUCED TO 60 PERCENT AND TOT STABILIZED TO 800 DEGREES CELSIUS. PILOT RETURNED TO OIL PLATFORM WHERE HE SAFELY LANDED. INSPECTION OF ENGINE REVEALED NR 1 NOZZLE (ON CONDITION PART) HAD FAILED. 1G71 3U3 U H2SW E4CE 19960523007211996052300721NE 1996 5 23 96ZZZX2593 219960304G72500292507640 COVER SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE MODULE 3 CRACKED D A K NONE O OTHER ININSP/MAINT 1 SO14869AC518 1695 652 ENGINE NOISE DURING START-UP AND SHUT-DOWN. REMOVED AND DISASSEMBLED MO5, 4, AND 3. FOUND COVER AND DEFLECTOR BROKEN AND RUBBING ON MO4 TURBINE DISC. THIS IS 2ND TIME THIS ENGINE SERIAL NUMBER HAS HAD A COVER AND DEFLECTOR BROKEN. SUBMITTER SUGGESTS A DIFFERENT STYLE COVER AND DEFLECTOR ABLE TO WITHSTAND ENGINE HEAT AND NORMAL VIBRATION LEVELS. 1G71 3U3 U H9EU E19EU 19960523007231996052300723GL 1996 5 23 96ZZZX2595 219960424G7230A23034784 GEARSHAFT RACE 6890550 BOLKMS105 BO105C 5626005EU ALLSN 250C 250C20B 03013GL SPUR ADAPTER SPALLED H K NONE O OTHER ININSP/MAINT 1 CE03205LF489 010 S146 THE RACE OF THIS SPUR ADAPTER GEARSHAFT SUPPORTS THE TWO AND ONE-HALF BEARING. THE TWO AND ONE-HALF BEARING CAGE FAILED SPALLING THE RACE. THIS GEARSHAFT DRIVES THE TURBINE AND COMPRESSOR. THIS IS AN FAA PMA PART MFG BY SUPERIOR PARTS. 1G72 3U3 U H3EU E4CE 19960523007251996052300725GL 1996 5 23 96ZZZX2597 219960307G732323007506 GOVERNOR BENDIX BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL INPUT LEVER CRACKED D K NONE O OTHER ININSP/MAINT 1 WP01211WP 509 6740 3225 CAE833581 DURING A DAILY INSPECTION, MECHANIC FOUND GOVERNOR WITH .75 INCH CRACK AT AREA OF INPUT LEVER BUSHING. GOVERNOR WAS REMOVED AND REPLACED. THESE GOVERNORS HAVE A 2,000-HOUR OVERHAUL. ENGINE HAD BEEN OPERATING NORMALLY. 1G71 3U3 U H2SW E4CE 19960523007261996052300726GL 1996 5 23 96ZZZX2598 219960410G7261206075659001 TUBE ASSY BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL ENGINE OIL CHAFED B PN5RA UNSCHED LANDING K FLUID LOSS NRNOT REPORTED 1 NM03617DE6133 51138 895179 FREEWHEEL RETURN HOSE CHAFED THROUGH ENGINE OIL PRESSURE TUBE CAUSING OIL TO LEAK ONTO DECK. PRECAUTIONARY LANDING MADE, LINE REPLACED AND RETURNED AIRCRAFT TO SERVICE. 1G71 3U3 U H2SW E1GL 19960523007341996052300734GL 1996 5 23 96ZZZX2606 219960315G726123057790 SEAL BELL 206 206B 1181511SW ALLSN 250C 250C20J 03013GL OIL JET LEAK D O OTHER B SMOKE/FUMES/ODORS/SPARKS LDLANDING 1 SO09 381 CAC42587 UPON LANDING FOR STUDENT CHANGE, SMOKE WAS SEEN COMING FROM ENGINE COMPARTMENT. REPLACED NR 6 AND NR 7 ENGINE OIL JET SEAL. 1G71 3U3 U H2SW E4CE 19960523007351996052300735GL 1996 5 23 96ZZZX2607 219960424G7230A23034787 BEARING 6894171 BOLKMS105 BO105C 5626005EU ALLSN 250C 250C20 03013GL ENGINE GRBX FAILED D K NONE J WARNING INDICATION ININSP/MAINT 1 CE03205LF489 034 S146 831080 PART IS AN FAA PMA BEARING. BEARING CAGE CAME APART CAUSING 'CHIP' LIGHT. BEARING FAILURE ALSO CAUSED SPALLING OF THE INNER RACE ON SPUR ADAPTER GEARSHAFT. THIS GEARSHAFT COUPLES (DRIVES) TURBINE AND COMPRESSOR. 1G72 3U3 U H3EU E4CE 19960523007431996052300743NE 1996 5 23 96ZZZX2615 219960402G732132448512 FUEL CONTROL CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE NR 1 ENGINE DEFECTIVE HL O OTHER J WARNING INDICATION CRCRUISE 1 GL03502T 3281 B29352 5600153 108317 FOLLOWING POWER REDUCTION FOR DESCENT, WHEN THROTTLE ADVANCED, NO ENGINE RESPONSE. SELECTED ANTI-ICE OFF AND ENGINE RESPONSE INCREASED TO NORMAL OPERATION. SERVICE CENTER REPLACED BOTH ENGINE FUEL CONTROLS. TEST FLIGHT, ENGINE OPERATED, NORMAL AT ALL ALTITUDES. 2L72 4F4 FRTA22CE E25EA 19960523007441996052300744NE 1996 5 23 96ZZZX2616 219960402G732132448512 FUEL CONTROL CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE NR 2 ENGINE DEFECTIVE HL O OTHER J WARNING INDICATION CRCRUISE 1 GL03502T 3281 B29358 5600153 108316 FOLLOWING POWER REDUCTION FOR DESCENT, WHEN THROTTLE ADVANCED, NO ENGINE RESPONSE. SELECTED ANTI-ICE OFF AND ENGINE RESPONSE INCREASED TO NORMAL OPERATION. SERVICE CENTER REPLACED BOTH ENGINE FUEL CONTROLS. TEST FLIGHT, ENGINE OPERATED, NORMAL AT ALL ALTITUDES. 2L72 4F4 FRTA22CE E25EA 19960530000111996053000011SO 1996 5 30 96ZZZX2648 219960514G8530653445 CYLINDER BEECH 58 58 1152740CE CONT O520 IO520CB 17032SO PLUG BOSS CRACKED D K NONE O OTHER ININSP/MAINT 1 SW071847F1019 TH1291 298505R THE CONTINENTAL STEEL CYLINDER CRACKED FROM THE SPARK PLUG BOSS TO THE AREA BEHIND THE FUEL NOZZLE. THE CYLINDER HAD A TOTAL TIME OF ONLY 1,019.0 HRS. THE CYLINDER STILL HELD GOOD COMPRESSION, BUT WITH A SOAP CHECK, THE AIR LEAK WAS EVIDENT. SUBMITTER STATES HAVE BEEN HAVING A SERIOUS PROBLEM WITH CYLINDERS CRACKING IN THIS POSITION. BELIEVE THIS IS A SERIOUS PROBLEM AND SHOULD BE INVESTIGATED FURTHER. 1L72 3O3 O 3A16 E5CE 19960530002311996053000231NE 1996 5 30 96ZZZX2698 219960507G72612380 OIL BEECH B300 B300 1159232CE PWA PT6 PT6A60A 52043NE ENGINE METAL FOD H A K NONE W INADEQUATE Q C ININSP/MAINT 1 NE01207R FL14 PCE95489 WHEN ADDING OIL TO ENGINE (EXXON 2380 LOT NR B652 11-29-95) NOTICED METAL CONTAMINATION IN STRAINER USED TO POUR OIL INTO ENGINE. INVESTIGATED OIL IN CAN, FOUND PARTICLES COULD BE PICKED UP BY A MAGNET. DRAINED AND FLUSHED ENGINE OIL SYSTEM. INFORMED EXXON AND FAA. OIL SAMPLE SUPPLIED TO EXXON. 2L72 4T4 TRTA24CE E4EA 19960530002331996053000233EA 1996 5 30 96ZZZX2700 219960430G73212528973 BEARING BENDIX DPF2 BEECH 90 B90 1152912CE PWA PT6 PT6A20 52043EA RT ENG FUEL CONTFAILED D O OTHER Y ENGINE STOPPAGE NRNOT REPORTED 1 WP23388MC 322 194208 LJ383 PCE22420 RIGHT ENGINE FLUCTUATIONS 2-3 SECONDS, 3 TIMES. AIRCRAFT YAW. FIFTEEN MINUTES LATER, FLUCTUATINS OCCURRED THEN FUEL FLOW WENT TO ZERO. ENGINE QUIT. RESTARTED ON GROUND, NO RESPONSE TO THROTTLE. DISASSEMBLED FUEL CONTROL, FOUND BUSHING ASSY BEARING FAILED. 1L72 3T3 T 3A20 E4EA 19960530002961996053000296SO 1996 5 30 96ZZZX2762 219960513G7414104001664 IMPULSE COUPLER BENDIX S6RN25 PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360EB 17025SO MAGNETO CAM SPLIT B APCRK NONE O OTHER ININSP/MAINT 1 NM015384F1751 V149214DR 347770013 MAGNETO IMPULSE COUPLER CAM SPLIT IN HALF DURING RE-INSTALLATION ON MAGNETO DURING MAGNETO 500-HOUR INSPECTION AND IMPULSE COUPLER AD 78-09-07R3. 1L72 3O3 O A7SO E9CE 19960530002991996053000299SO 1996 5 30 96ZZZX2765 219960504G8530 PISTON PIN CESSNA337 337C 2075712CE CONT O360 IO360C 17025SO NR 2 CYLINDER FAILED D O OTHER ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CRCRUISE 1 AL032615S312 3370915 501398C IT APPEARS THE PISTON PIN BROKE AND THE PISTON HIT THE CRANKSHAFT COUNTERWEIGHT WHICH BROKE A LARGE HOLE IN THE TOP OF THE CRANKCASE. THE AIRCRAFT WAS ON A CROSS-COUNTRY FLIGHT AT NORMAL CRUISE. WHEN THE VIBRATION STARTED, THE PILOT REDUCED POWER, BUT THE VIBRATION CONTINUED SO THE PROPELLER WAS FEATHERED AND FLIGHT CONTINUED WITH REAR ENGINE OPERATING. 1H72 3O3 O A6CE E1CE 19960530003001996053000300SO 1996 5 30 96ZZZX2766 219960507G8540539800 SPRING CLUTCH CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO RT START ADAPTERFAILED D K NONE O OTHER ININSP/MAINT 1 GL134677N26 414A0068 290873R TWENTY-SIX HOURS AFTER INSTALLING A TCM OVERHAULED ENGINE, STARTER ADAPTER FAILED. INSPECTION SHOWED THAT SPRING CLUTCH FAILED AND WAS UNCOILING INTO ENGINE ACC CASE. 1L72 3O3 O A7CE E8CE 19960530003051996053000305CE 1996 5 30 96ZZZX2771 119960401G8120641284 COUPLING BEECH 58 58P 1152744CE CONT O520 TSIO520L 17040SO TURBO EXHAUST CRACKED D K NONE O OTHER ININSP/MAINT 1 NE054269S TJ96 237270R CLAMP WAS FOUND CRACKED WHEN REMOVED FOR OTHER MAINTENANCE ON THE EXHAUST SYSTEM. SUBMITTER SUSPECTS CLAMP WAS OVERTORQUED AT PRIOR INSTALLATION. FAILURE OF THIS CLAMP COULD ALLOW HOT EXHAUST GASES TO BE RELEASED IN THE ENGINE COMPARTMENT. SUBMITTER RECOMMENDS CLOSE INSPECTION OF ALL V-BAND STYLE CLAMPS DURING SCHEDULED MAINTENANCE INSPECTION. DEFECT WOULD BE DETECTABLE WITHOUT REMOVAL. 1L72 3O3 O A23CE E8CE 19960606001321996060600132EA 1996 6 6 96ZZZX2786 219960423G741467542 BEARING PIPER PA31 PA31310 7103103SO LYC O540 TIO540A2B 41532EA MAG DRIVE MISINSTALLED DL A UNSCHED LANDING YW ENGINE STOPPAGE INADEQUATE Q C CRCRUISE 1 SO16107FC 31612 L807761 WHILE IN LEVEL FLIGHT, THE RIGHT ENGINE QUIT WITHOUT WARNING. UPON INVESTIGATION, DETERMINED THE DRIVE DOWEL PIN (STD-1065) HAD BEEN SHEARED, AND THE LEFT IDLER GEAR (71668) HAD LOST A TOOTH AND JAMMED THE MAGNETO DRIVE GEAR (GEAR RETAINER ASSY LW-19102 OR LW 19096). WHEN THE LEFT MAGNETO (S6LN-1208) WAS REMOVED, THE MAGNETO HAD A BURNED APPEARANCE. UPON DISASSEMBLY, FOUND THE ROTOR HAD CONTACTED THE POLE SHOES IN THE HOUSING. AFTER SENDING THE MAGNETO TO THE BENDIX FACTORY, DISCOVERED THE DRIVE GEAR HAD A SIDE LOAD PLACED ON IT CAUSING THIS TO OCCUR. 1L71 3O3 ORTA20SO E14EA 19960606001661996060600166NE 1996 6 6 96ZZZX2799 219960301G73109550147560 ELECTROVALVE AEROSPSA365 SA365N1 8680668EU TMECA ARRIELARRIEL1C 60030NE NR 2 ENG START FAILED B KY1RK NONE O OTHER ININSP/MAINT 1 EA0792MD 2906 3521 6311 5094 NR 2 ENGINE WOULD NOT HAVE T4 CLIMB UNTIL NG SHOWED 30 PERCENT, THEN RAPID RISE ONCE IGNITION OCCURRED. REPLACED START FUEL ELECTROVALVE. 1G72 3U3 U H10EU E19EU 19960606008741996060600874EA 1996 6 6 96ZZZX2868 219960513G8530 VALVE SEAT PIPER PA31 PA31325 7103105SO LYC O540 TIO540F2BD 41532EA LT ENG NR 2 CYL DISLODGED D O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 GL2562992 554 LW12967 317712013 L631961AC ON A SHORT FLIGHT, A ROUGHNESS DEVELOPED IN THE LEFT ENGINE. NO EMERGENCY ACTION WAS REQUIRED. AFTER PERFORMING A COMPRESSION CHECK, FOUND THE EXHAUST VALVE SEAT ON NR 2 CYLINDER HAD BECOME DISLODGED CAUSING THE EXHAUST VALVE TO REMAIN PARTIALLY OPEN. THE CYLINDER (HEAD) IN THE AREA OF THE EXHAUST SEAT WAS DAMAGED BEYOND REPAIR, AND THE VALVE OR SEAT CAUSED MINOR DAMAGE TO THE PISTON. NO CAUSE FOR THE SEAT BECOMING DISLODGED HAS BEEN DETERMINED. 1L72 3O3 O A20SO E14EA 19960606008851996060600885SO 1996 6 6 96ZZZX2879 219960508G8530 CYLINDER CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO NR 1 CYLINDER HEAD SEPARATED B ETEREA ENGINE SHUTDOWN UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CLCLIMB 1 SO1149TD 421C0025 241033R ON TAKEOFF, NR 1 CYLINDER SEPARATED AT THE HEAD CAUSING ENGINE POWER LOSS. PILOT SHUT DOWN LEFT ENGINE AND RETURNED TO AIRPORT. ENGINE AND CYLINDER HAD 757 HOURS SINCE OVERHAUL WITH .010 INCH OVERSIZED BARRELS. CYLINDER TOTAL TIME UNKNOWN. 1L72 3O3 O A7CE E7CE 19960606008921996060600892EA 1996 6 6 96ZZZX2886 219960410G73228618 LOCKWIRE FACET MA4SPA PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA CARB MIX CONTROLFAILED D K NONE O OTHER ININSP/MAINT 1 WP093567P2200 CK815279 288016202 L1271039A CARBURETOR MIXTURE CONTROL DID NOT FUNCTION PROPERLY. UPON INSPECTION, PN 86-18 LOCKWIRE, FOUND FATIGUED, CRACKED IN HALF, NOT ALLOWING FOR MIXTURE CONTROL SHAFT TO BE PROPERLY OPERATED. 1L71 3O3 O 2A13 E274 19960606008931996060600893EA 1996 6 6 96ZZZX2887 219960501G8500 ENGINE SLNSBYT67 T67M260 8323006EU LYC O540 AEIO540D4A5 41532EA POWER PLANT FAILED D O OTHER Y ENGINE STOPPAGE ABAEROBATIC 1 SW173193K100 2233 L2559748A ENGINE STOPPED IN-FLIGHT AFTER POWER REDUCTION IN SPIN DURING POWER ON OF THE SPIN DEMONSTRATION SORTIE. ENGINE RESTARTED WITH START BUTTON. 1L71 3O3 ONTA73EU 1E4 19960606008941996060600894EA 1996 6 6 96ZZZX2888 219960508G7414M3525 COIL SLICK 4271 PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA LT MAGNETO FAILED D K NONE O OTHER ININSP/MAINT 1 CE018089C220 89100029 28769002 RL3247136A AFTER FLIGHT, ENGINE WOULD NOT START. BOTH MAGNETOS FOUND TO BE INOPERATIVE, NO SPARK. IT HAS BEEN FOUND THAT ONE MAG GOES INOP. ENGINE STARTS ON THE GOOD ONE, UNTIL IT FAILS. AFTER THE ENGINE RPM MEETS OR EXCEEDS 600 RPM, THESE COILS WILL MAG CHECK OK. INSTALLED FACTORY NEW COILS, PN M3975. OPS SATISFACTORY. 1L71 3O3 O 2A13 E286 19960606009051996060600905GL 1996 6 6 96ZZZX2899 219960513G72506892828 NOZZLE SHIELD 23031925 ALLSN 250C 250C30 03013GL 1ST STAGE TURB CRACKED B YKERK NONE O OTHER ININSP/MAINT 1 EA17 CAT90284 CAE890278 DURING REPAIR OF THE TURBINE, NOTED THE DEFLECTOR ON THE FIRST STAGE NOZZLE SHIELD WAS BURNED. CLOSER EXAMINATION REVEALED 2 CRACKS IN THE DOME DETAIL. THE DOME WAS CHECKED FOR PROPER MATERIAL PER DEB A-72-3208 AND WAS FOUND TO CONFORM. SUSPECT THE CAUSE COULD BE A STREAKING FUEL NOZZLE. 3 U E1GL 19960606009101996060600910WP 1996 6 6 96ZZZX2904 219960315G72503587591 BEARING LEAR 35 35LEAR 5170600CE GARRTTTFE731TFE73122B 01518WP ENG NR 4 FAILED BL MJ1RE ENGINE SHUTDOWN EJ VIBRATION/BUFFET WARNING INDICATION DEDESCENT 1 EA11130F 2399 044 P74225 DURING DESCENT, FLT CREW OBSERVED FLUCTUATING FUEL FLOW ON RT ENG FOLLOWED BY VIBRATION AND NOISE. CREW REDUCED POWER SETTING TO IDLE AND CONTINUED FLT. DURING FINAL APROACH, OIL PRESSURE BEGAN TO FLUCTUATE AND LOW OIL PRESSURE CAUTION LIGHT ILLUMINATED. PILOT COMMANDED A SHUT-DOWN AND LANDED ACFT WITHOUT FURTHER INCIDENCE. UNABLE TO ROTATE EITHER THE LP OR HP SPOOLS. EXAMINATION OF INLET AREA SHOWED NO EVIDENCE OF FOREIGN OBJECT INGESTION. METAL CONTAMINATION FND IN OIL TANK, XSFER GEARBOX AND OIL FILTER, FILTER BYPASS BUTTON WAS NOT OUT. UNABLE TO DISASSEMBLE OIL PUMP DUE TO INTERNAL DAMAGE. ENG IN-FLT SHUTDOWN CAUSED BY FAILURE OF NR 4 BEARING AND SUBSEQUENT INTERNAL DOMESTIC OBJECT DAMAGE TO ENGINE.2L72 4F4 F A10CE E6WE 19960613002171996061300217GL 1996 6 13 96ZZZX2935 219960510G7230 ROTOR ASSY HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL COMPRESSOR DEFECTIVE D K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 WP07911FT3888 1257 811036D CAE836410 POWER CHECK RESULTS - LOW POWER. COMPRESSOR ASSY REPLACED, DISCREPANCY CLEARED. (ALLISON MODEL 250 REPORT NR A 134718). 1G71 3U3 U H3WE E4CE 19960613003771996061300377GL 1996 6 13 96ZZZX2943 219960507G7200 ENGINE AGUSTAA109 A109C 0260118EU ALLSN 250C 250C20 03013GL NR 2 MAKING METAL D A K NONE J WARNING INDICATION NRNOT REPORTED 1 GL0397CH 337 7657 CAE295546 NR 2 ENGINE REMOVED DUE TO EXCESSIVE CHIP LIGHTS. THIS IS THE 3RD OCCURRENCE WITH THIS ENGINE. ENGINE TT, 336.5 HRS SINCE NEW. 1G72 3U3 U H7EU E4CE 19960613003861996061300386EA 1996 6 13 96ZZZX2952 219960501G8520AL12186 NUT PIPER PA32 PA32301 7103207SO LYC O540 IO540K1G5 41532EA CON ROD BOLT MISMANUFACTURED HL K NONE W INADEQUATE Q C ININSP/MAINT 1 SW992586Y 328506007 L2254348A ASSEMBLING THIS ENGINE DURING NORMAL OVERHAUL, THE ROD BOLT NUT WAS TORQUED AND THE BOLT MEASURED FOR STRETCH LENGTH. THE MICROMETER DID NOT SMOOTHLY SNUG UP. THE BOLT'S OUTBOARD EDGE MEASURED 2.255 INCHES AND INBOARD EDGE MEASURED, 2.259 INCHES. BELIEVING THE BOLT TO BE DEFECTIVE, IT WAS REMOVED. WHEN SPUN, THE NUT HAD A WOBBLE. INSPECTION FOUND THE THREADS OF THE NUT WERE NOT SQUARE WITH THE FACE AND THIS CAUSED THE BOLT TO BE BENT WHEN TORQUED. THE BOLT WAS STRAIGHT WHEN UNTORQUED. REPLACED BOTH THE NUT AND BOLT WITH NEW PARTS. 1L71 3O3 O A3SO 1E4 19960613003941996061300394NE 1996 6 13 96ZZZX2960 219960514G8550 CYLINDER SCWZERG164 G164A 3952704EA PWA R1340 R1340AN1 52016NE NR 8 CRACKED HS MWRGA UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CLCLIMB 1 EA176620Q 1693 10419 PILOT EXPERIENCED POPPING, MISFIRING, AND POWER LOSS DURING TAKEOFF. AN UNSUCCESSFUL OFF AIRPORT LANDING MADE. AIRCRAFT FLIPPED OVER AND WAS SUBSTANTIALLY DAMAGED. INSPECTION REVEALED NR 8 CYLINDER CRACKED BETWEEN SPARK PLUG BOSSES AND DOWN TO BARREL ON BACK SIDE OF CYLINDER. AIRCRAFT HAD BEEN OPERATED SEVERAL TIMES DURING AG OPERATIONS ON THIS DAY. SMOH: 930.0 HRS. 1Q71 3R3 R 1A16 5E2 19960613004101996061300410EA 1996 6 13 96ZZZX2976 219960423G7322105135 CARBURETOR ARM FACET PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA THROTTLE DETACHED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW053457Q250 CK815086 287716157 L732439A CARBURETOR THROTTLE ARM CAME LOOSE FROM THROTTLE SHAFT DUE TO ATTACHMENT NUT LOOSENING OFF OF ARM. THE SUSPECT CAUSE OF THE NUT COMING LOOSE WAS IMPROPER INSTALLATION OF KOTTER KEY INTO NUT. 1L71 3O3 O 2A13 E274 19960613004111996061300411SO 1996 6 13 96ZZZX2977 219960514G74141051324 SPRING 10400307 CESSNA182 182C 2072708CE CONT O470 O470R 17026SO MAG IMPULSE COUPBROKEN D K NONE O OTHER ININSP/MAINT 1 NM018617T7 52517 988558RR TWO NEW SNAP-RING COUPLINGS INSTALLED AT ANNUAL INSPECTION. SEVEN HOURS LATER BOTH COUPLING SPRINGS FAILED ON CONSECUTIVE ENGINE STARTS. SPRING FAILURES APPEAR TO BE IDENTICAL. COUPLINGS WERE BOUGHT AND INSTALLED AS ASSEMBLIES PREVENTING INSPECTION OF SPRINGS PRIOR TO INSTALLATION. 1H71 3O3 ONT3A13 E273 19960613006911996061300691SO 1996 6 13 96ZZZX2995 219960426G8530625393 RETAINER PIPER PA46 PA46310P 7104605SO CONT O520 TSIO520BE 17040SO NR 6 CYL VALVE FRACTURED D K NONE O OTHER ININSP/MAINT 1 EA056908P1350 468508062 528156 ON REMOVAL OF NR 6 CYLINDER DUE TO METAL FOUND IN OIL FILTER, FOUND PIECES IN ROCKER AREA. THIS WAS VERIFIED AS CONTAMINANTS THROUGH T.C.M. NO SERVICE INFO ISSUED TO DATE ON AN ONGOING PROBLEM OF THIS PART. 1L71 3O3 O A25SO E8CE 19960613006921996061300692CE 1996 6 13 96ZZZX2996 119960601G7920 HOSE BEECH 95 B95A 1153406CE LYC O360 IO360B1A 41514EA OIL COOLER CHAFE H A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 SW99 10 GROUND PERSONNEL NOTED FUEL TYPE VAPORS TRAILING BEHIND TAXIING BEECH TRAVEL AIR. ACFT RETURNED TO AIRPORT. INVESTIGATION REVEALED VAPOR WAS, IN FACT, BURNING OIL FROM CHAFED THROUGH OIL LINES FROM COOLER. LINE WAS CHAFED AND BURNED THROUGH BY UNSHIELDED EXHAUST. REPLACED OIL LINE WITH LONGER HOSE AND ADDED AN ADEL CLAMP, ROUTING HOSE FURTHER DOWN IN COWL. A NEW OIL HOSE HAD BEEN INSTALLED ONLY 10 HOURS PREVIOUSLY. 1L72 3O3 O 3A16 1E10 19960613006931996061300693NE 1996 6 13 96ZZZX2997 219960517G8530 PISTON SCWZERG164 G164A 3952704EA PWA R1340 R1340AN1 52016NE NR 1 CYLINDER RING BROKE D A UNSCHED LANDING RK PARTIAL RPM/PWR LOSS FLUID LOSS NRNOT REPORTED 1 EA176565 1921 722 38065 FIRST OR SECOND COMPRESSION RING BROKE CAUSING RING LANDS TO WEAR BETWEEN FIRST AND SECOND RING LAND AND THROUGH PISTON HEAD. COMBUSTION HEAT BURNED HOLE LARGER DIRECTING PRESSURE TO ENGINE CASE. THIS PRESSURE BLEW THE ENGINE OIL OVERBOARD. THIS RESULTED IN AN EMERGENCY LANDING. 1Q71 3R3 R 1A16 5E2 19960613006941996061300694NE 1996 6 13 96ZZZX2998 219960528G732267019 MIXTURE CONTROL BENDIX P012H4 DOUG DC3 DC3A 3021433WP PWA R1830 R1830* 52020NE CARB AUTO MIX MALFUNCTION H O OTHER MEROVER TEMP VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 SW1732MS 844 5682114A 4978 CYLINDER HEAD TEMPERATURE RUNNING HIGHER THAN NORMAL AND ENGINE ERRATIC WHEN AUTO LEAN SELECTED AT CRUISE. AMC TIME IN SERVICE, 843.9 HRS. 2L72 4R4 R A669 5E4 19960613007041996061300704EA 1996 6 13 96ZZZX3008 219960525G731441270175 FUEL PUMP PIPER PA32 PA32260 7103206SO LYC O540 O540E4B5 41532EA ENGINE FAILED H A UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 SW9940933 327400025 L48648 PILOT REPORTED LOSS OF ENGINE POWER ON TAKEOFF AND ELECTED TO LAND ON GOLF COURSE. DURING INVESTIGATION, ENGINE WAS OPERATED AND ENGINE DRIVEN FUEL PUMP FOUND INOPERATIVE. 1L71 3O3 O A3SO E295 19960620004261996062000426WP 1996 6 20 96ZZZX3045 219960509G72608968042 GEARSHAFT 31017262 MTSBSIMU2 MU2B60 5780460CE GARRTTTPE331TPE33110 01514WP FUEL PUMP SHEARED B IZ2RO OTHER Y ENGINE STOPPAGE NRNOT REPORTED 1 SW15175CA4942 3P9426 736SA P36014 AIRCRAFT EXPERIENCED AN UNCOMMANDED ENGINE SHUT DOWN. ENGINE DISASSEMBLY REVEALED GEARSHAFT HAD SHEARED CAUSING FUEL PUMP TO STOP TURNING. REFERENCE: 1PC 72-01-16, SECTION 72-10-17, PAGE 2, ITEM 40. 1H72 3T4 TRTA10SW E4WE 19960620004381996062000438SO 1996 6 20 96ZZZX3057 219960513G8550643716 FILTER ADAPTER CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO WASTEGATE OIL WRONG CONN BL EVGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SO332FOR U20606295 EXPERIENCED INCONSISTENT MANIFOLD PRESS & FUEL FLOWS. LOOKED AT SOURCE OF OIL TO WASTEGATE FROM OIL PUMP HSNG P/N 643716, & FND PORT USED SUPPLIED UNFILTERED OIL. OIL PUMP HSNG IS NEW P/N WHICH USES FULL FLOW OIL FILTER. NEW HSNG HAS, BELOW FILTER BASE, A 2ND PORT THAT WILL PROVIDE FILTERED OIL. OLD P/N 632770 OIL PMP HSNG WHICH USES OTHER STYLE OF FILTER (CESSNA SUPPLIED OIL FILTER ADAPTER P/N 1250922-4) HAS 1 PORT FOR FILTERED OIL SUPPLY TO W/G. PORT IS IN SAME LOCALE AS UNFILTERED PORT ON NEW P/N HSNG. PROBLEM DEVELOPED WHEN REPLACING ENG WITH OLD HSNG WITH ENG HAVING NEW. ASSUMED FILTERED OIL WOULD COME OUT OF SAME LOCALE, PORT IS DIFFERENT INSIDE. PORT IS PLUGGED WITH ALLEN HEAD PLUG. 1H71 3O3 O A4CE E8CE 19960620007561996062000756SO 1996 6 20 96ZZZX3072 219960528G741410357281H COIL PIPER PA28 PA28RT201T 7102817SO CONT O360 TSIO360FB 17025SO ENGINE RT MAG WIRE BROKEN D K NONE W INADEQUATE Q C ININSP/MAINT 1 CE0542946 28R8331025 299532R INSTALLED NEW MAGNETO, WAS INOPERATIVE. TROUBLESHOOTING REVEALED THE COIL WIRE WAS BROKEN AT THE TERMINAL END. (INSULATION WAS STILL INTACT). SUBMITTER STATED CAUSE WAS DUE TO THE TERMINAL END BEING CRIMPED TOO HARD RESULTING IN BROKEN WIRE. RECOMMEND MANUFACTURER BE INFORMED. 1L71 3O3 O 2A13 E9CE 19960620007571996062000757SO 1996 6 20 96ZZZX3073 219960526G7414107902018R MAGNETO PIPER PA28 PA28RT201T 7102817SO CONT O360 TSIO360FB 17025SO ENG RT MAG FAILED D K NONE O OTHER NRNOT REPORTED 1 CE054294659 28R8331025 299532R MAGNETO FAILED. DID NOT TROUBLESHOOT MAG DUE TO IT BEING UNDER WARRANTY. 1L71 3O3 O 2A13 E9CE 19960620007581996062000758SO 1996 6 20 96ZZZX3074 219960528G7414 CONDENSER 107902018R PIPER PA28 PA28RT201T 7102817SO CONT O360 TSIO360FB 17025SO ENG LT MAG FAILED D K NONE O OTHER ININSP/MAINT 1 CE054294690 28R8331025 299532R INVESTIGATION FOR MAG PROBLEM FOUND CONDENSER HAD NO CONTINUITY. 1L71 3O3 O 2A13 E9CE 19960620007591996062000759SO 1996 6 20 96ZZZX3075 219960528G741410357281H CONDENSER 107902018R PIPER PA28 PA28RT201T 7102817SO CONT O360 TSIO360FB 17025SO ENG RT MAG WIRE BROKEN DL K NONE W INADEQUATE Q C ININSP/MAINT 1 CE054294659 28R8331025 299532R RT MAG INOPERATIVE. INSTALLED NEW MAG, SN 1069532DR. THIS NEW MAG WAS INOPERATIVE. TROUBLESHOOTING BOTH MAGS REVEALED ORIGINAL MAG HAD BAD CONSENSER AND THE NEW MAGNETO HAD A BAD COIL. BOTH NEW MAGNETOS HAD A BAD COIL. BOTH THE CONDENSER AND COIL PROBLEMS RESULTED FROM THE TERMINAL ENDS BEING CRIMPED TOO HARD CAUSING THE WIRE TO FAIL. SUBMITTER RECOMMENDS THE MANUFACTURER BE INFORMED ON THIS PROBLEM. 1L71 3O3 O 2A13 E9CE 19960620007651996062000765GL 1996 6 20 96ZZZX3081 219960515G7322 CARBURETOR AMTR SONERISONERAI GL AMTRVWVOLKS VW1700VOLKS 99999GL ENGINE BLOCKED VENT D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 CE05283SX55 283 DURING TAKEOFF ENGINE HAD POWER LOSS. FUEL STARVATION DUE TO BLOCKED VENT SUSPECTED. SPARK PLUGS CONFIRM EXCESSIVE LEAN MIXTURE CAUSED POWER LOSS. 1M71 3O3 O EXPA1M71EXP3O 19960620007691996062000769EA 1996 6 20 96ZZZX3085 219960521G8550STD1686 SCREEN PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA LT ENGINE DEFECTIVE B OG5RK NONE O OTHER ININSP/MAINT 1 GL2163ND 178 317852098 L697361A DURING SCHEDULED MAINTENANCE FOUND SCREW AND GASKET MATERIAL IN SUCTION SCREEN. REMOVED OIL SUMP/PAN, INSTALLED SCREW PER LYCOMING INSTRUCTIONS. 1L72 3O3 O A20SO E14EA 19960627006451996062700645EA 1996 6 27 96ZZZX3198 219960530G741410382896 GEAR ASSY PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA RT MAG TEETH MISSING D K NONE O OTHER ININSP/MAINT 1 AL0159829 1071 317652081 L521661A MAGNETO CHECK PRIOR TO TAKEOFF. ENGINE WOULD NOT RUN ON RT MAGNETO. INSPECTION OF MAGNETO FOUND 4 TEETH MISSING, RT SIDE DISTRIBUTOR GEAR ASSY. ALL TEETH ON RT AND LT GEAR ASSYS BADLY WORN AND CHIPPED. SUSPECT CAUSE, AGE, HEAT, AND LACK OF LUB ON DRIVE GEAR. CLOSER INSPECTION OF MAG GEARS ON INSPECTION. 1L72 3O3 O A20SO E14EA 19960627006461996062700646EA 1996 6 27 96ZZZX3199 219960522G8530 PISTON PIPER PA32 PA32300 7103212SO LYC O540 IO540K1A5 41532EA NR 3 CYLINDER RINGS WORN D K NONE O OTHER ININSP/MAINT 1 AL034170R4065 141 3240502 L465848A LOWER SPARK PLUG FOWLED WITH OIL. REMOVED CYLINDER ASSY AND FOUND UPPER FACE OF RINGS KNIFE EDGED. REMOVED AND REPLACED CYLINDER ASSY. 1L71 3O3 O A3SO 1E4 19960627006521996062700652SO 1996 6 27 96ZZZX3205 219960514G73223232 FLOAT SHAFT FACET MA35PA CESSNA150 150D 2071810CE CONT O200 O200A 17020SO CARBURETOR BROKEN D K NONE O OTHER ININSP/MAINT 1 SO136006T3978 1493 15060706 2048879A DURING CARBURETOR TEAR DOWN, FLOAT SHAFT WAS FOUND WITH ONE END BROKEN, PUMP PLUNGER, PN 194-593, WAS ALSO FOUND DETERIORATED, AS WELL AS THE BOWL BEING FULL OF TRASH. SUBMITTER STATED CARBURETORS, AS WELL AS ALL OTHER ACCESSORIES, SHOULD BE OVERHAULED OR HAVE A CLOSE INSPECTION EACH 500-800 HRS OF OPERATION. 1H71 3O3 O 3A19 E252 19960627006541996062700654SO 1996 6 27 96ZZZX3207 219960529G8550 FILL TUBE CONT O360 TSIO360FB 17025SO ENGINE OIL RUSTY D K NONE O OTHER ININSP/MAINT 1 NE03 2135 305857 THE INSIDE OF THE OIL FILLER TUBE AND OIL CAP WERE RUSTED TO THE POINT OF FLAKES OF RUST BEING KNOCKED OFF OF THE SURFACE AND FALLING INTO THE CRANKCASE. SUBMITTER STATED THESE ASSEMBLIES SHOULD PROBABLY BE MADE OF STAINLESS STEEL. THEY ARE CADMIUM PLATED WHEN NEW, AND THAT DOESN'T SEEM TO PREVENT THE CORROSION. 3 O E9CE 19960627006581996062700658EA 1996 6 27 96ZZZX3211 219960515G8530LW19281 CYLINDER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA NR 4 CYL EXH CRACKED B KD4RK NONE K FLUID LOSS NRNOT REPORTED 1 SO17350MP 342 318152116 L606961A PILOT REPORTED OIL LEAK ON THE LT ENGINE FOLLOWING A FLIGHT OF APPROXIMATELY 1 HOUR. MAINTENANCE UNCOWLED ENGINE AND DISCOVERED AN EXHAUST STUD FROM THE NR 4 CYLINDER HAD BACKED OUT OF EXHAUST FLANGE. STUD BOUNCED AGAINST THE PUSH ROD HOUSING WEARING A HOLE THROUGH IT APPROX THE SAME SIZE AS THE STUD DIAMETER CAUSING THE OIL LEAK. ENGINE WAS OPERATING NORMALLY WITH THE EXCEPTION OF THE REPORTED OIL LEAK. AN INVESTIGATION REVEALED A CRACK EXTENDING FROM THE EXHAUST PORT TO STUD RETENTION AREA. CRACK RELIEVED TENSION ON THE STUD CAUSING IT TO BECOME DISLODGED. FURTHER INVESTIGATION REVEALED 4 OF 6 CYLINDERS HAD CRACKS IN SAME GENERAL AREA. 1L72 3O3 O A20SO E14EA 19960703003901996070300390SO 1996 7 3 96ZZZX3319 219960618G8530653452A9 CYLINDER CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO NR 2 HEAD CRACKED BS APCRK NONE O OTHER ININSP/MAINT 1 NM0148SA 163 4040417 276408R FOUND NR 2 CYLINDER HEAD CRACKED AT LOWER SPARK PLUG HOLE. 1L72 3O3 O A25CE E7CE 19960703003921996070300392EA 1996 7 3 96ZZZX3321 219960503G8550 FITTING GULSTMAA5 AA5B 3960105SO LYC O360 O360A4K 41514EA ACCESSORY CASE FAILED D A K NONE K FLUID LOSS NRNOT REPORTED 1 SW1528462125 AA5B0626 L2208436A OIL PRESSURE FITTING AT ENGINE TO GAUGE HAD BRASS FITTING AND THEN 90 DEGREE RESTRICTIVE FITTING. APPEARS TO HAVE BEEN TOO CLOSE TO MOUNT. BRASS FITTING BROKE FLUSH AT ACCESSORY CASE AND OIL PUMPED OUT OF ENGINE. BRASS FITTING APPEARED TO BE INCORRECT PART NUMBER. 1L71 3O3 O A16EA E286 19960703003941996070300394EA 1996 7 3 96ZZZX3323 219960618G8530LW12993 CYLINDER MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA ROCKER BOX DRAINCRACKED DSA K NONE W INADEQUATE Q C ININSP/MAINT 1 GL05201RP A319521 240215 L1725451AC FOUR NEW LW-12993 CYLINDERS HAVE CRACKS AT THE ROCKER BOX DRAIN FITTING BOSS. THESE CRACKS OCCUR AT A CASTING FLAW. THIS MAY BE CAUSED BY THE TAPERED THREAD OF THE MS-20823-6D ELBOW FITTING. 1L71 3O3 O 2A3 1E10 19960703003951996070300395EA 1996 7 3 96ZZZX3324 219960618G8530LW12993 CYLINDER MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA ROCKER BOX DRAINCRACKED D K NONE W INADEQUATE Q C ININSP/MAINT 1 GL05201RP A300517 240215 L1725451AC FOUR NEW LW-12993 CYLINDERS HAVE CRACKS AT THE ROCKER BOX DRAIN FITTING BOSS. THESE CRACKS OCCUR AT A CASTING FLAW. THIS MAY BE CAUSED BY THE TAPERED THREAD OF THE MS-20823-6D ELBOW FITTING. 1L71 3O3 O 2A3 1E10 19960703003961996070300396EA 1996 7 3 96ZZZX3325 219960618G8530LW12993 CYLINDER MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA ROCKER BOX DRAINCRACKED D K NONE W INADEQUATE Q C ININSP/MAINT 1 GL05201RP A340519 240215 L1725451AC FOUR NEW LW-12993 CYLINDERS HAVE CRACKS AT THE ROCKER BOX DRAIN FITTING BOSS. THESE CRACKS OCCUR AT A CASTING FLAW. THIS MAY BE CAUSED BY THE TAPERED THREAD OF THE MS-20823-6D ELBOW FITTING. 1L71 3O3 O 2A3 1E10 19960703003971996070300397EA 1996 7 3 96ZZZX3326 219960618G8530LW12993 CYLINDER MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA ROCKER BOX DRAINCRACKED D K NONE W INADEQUATE Q C ININSP/MAINT 1 GL05201RP A167521 240215 L1725451AC FOUR NEW LW-12993 CYLINDERS HAVE CRACKS AT THE ROCKER BOX DRAIN FITTING BOSS. THESE CRACKS OCCUR AT A CASTING FLAW. THIS MAY BE CAUSED BY THE TAPERED THREAD OF THE MS-20823-6D ELBOW FITTING. 1L71 3O3 O 2A3 1E10 19960703004111996070300411EA 1996 7 3 96ZZZX3340 219960605G7414 P-LEAD PIPER PA24 PA24180 7102402CE LYC O360 O360A1A 41514EA LT MAGNETO DETERIORATED G K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 GL055984P2222 241077 L143836 ENGINE INTERMITTENT, ROUGHNESS, WAS BELIEVED CAUSED BY LEFT MAGNETO P-LEAD SHORTING OUT AGAINST OUTSIDE SHIELDING. BOTH LT AND RT P-LEADS INTERNAL INSULATION HAD DETERIORATED TO POWDER. THIS CONTRIBUTED TO ACCIDENT. P-LEADS APPEARED TO BE ORIGINAL EQUIPMENT ON AIRCRAFT. 1L71 3O3 ONT1A15 E286 19960703004131996070300413EA 1996 7 3 96ZZZX3342 219960424G8530 HELICOIL PIPER PA32 PA32300 7103212SO LYC O540 IO540K1A5 41532EA NR 6 CYL PLUG CAME LOOSE D K NONE O OTHER ININSP/MAINT 1 AL034170R3965 41 3240502 L465848A SPARK PLUG UPPER HELICOIL CAME LOOSE WITH SPARK PLUG. REMOVED CYLINDER ASSEMBLY AND REPLACED WITH OVERHAULED CYLINDER ASSY. 1L71 3O3 O A3SO 1E4 19960703004141996070300414EA 1996 7 3 96ZZZX3343 219960617G8530LW11633 CYLINDER CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA NR 3 CYL LOWER HELICOIL FAILED B CBCRA UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 NM0393069 1356 1285389 L1405315 LOWER SPARK PLUG HELICOIL BLEW OUT ON NR 3 CYLINDER RESULTING IN LOSS OF THAT CYLINDER COMRPESSION AND LOSS OF ENGINE POWER. AIRCRAFT LANDED ON HIGHWAY WITHOUT INCIDENT. SUSPECT CAUSE: OVERTORQUE OR UNDERTORQUE OF SPARK PLUG ALLOWING PLUG TO MOVE IF UNDERTORQUED, OR PULLED THREADS IF OVERTORQUED. THIS ENGINE HAS STC SE792NW AND SA1008NW - HIGHER COMPRESSION PISTONS AND WOULD AGGRAVATE THE SUGGESTED CAUSE. 1H71 3O3 ONT3A19 E223 19960703004291996070300429EA 1996 7 3 96ZZZX3358 219960426G732246A226 VENTURI MA45 CESSNA172 172N 2072434CE LYC O360 O360A4M 41514EA CARBURETOR FRACTURED BS ZM3RK NONE O OTHER ININSP/MAINT 1 WP07260ER3991 1985 75034605 17270223 L3261636A DURING INSPECTION FOR OVERHAUL, VENTURI WAS FOUND BROKEN AT 3 SUPPORT LEGS AT CENTER OF THE VENTURI. 1H71 3O3 ONT3A12 E286 19960710000131996071000013SO 1996 7 10 96ZZZX3371 219960426G8550 ENGINE BEECH 36 A36 1151604CE CONT O520 IO520BB 17032SO OIL SYSTEM EXCESS SLUDGE B ZM3RK NONE O OTHER ININSP/MAINT 1 WP073869A1760 E1853 2745064 ENGINE WAS DISASSEMBLED FOR MAJOR OVERHAUL. FOUND EXCESSIVE SLUDGE BUILD-UP IN CRANKSHAFT AND OIL SUMP. SLUDGE BUILD-UP IN OIL SUMP HAD IMPACTED ALL P/U TUBE SCREENS TO THE POINT OF 80 PERCENT RESTRICTION. THE OIL DRAIN IS FORWARD OF THE OIL P/U TUBE, SO WHEN NOSE OF AIRCRAFT IS UP WHEN DRAINING OIL, IT DOES NOT ALLOW PROPER DRAINAGE OF CONTAMINATION. SUGGEST LOWERING NOSE OF AIRCRAFT AND ALLOWING OIL TO DRAIN OVERNIGHT. 1L71 3O3 O 3A15 E5CE 19960710000151996071000015SO 1996 7 10 96ZZZX3373 219960610G7414ES10349276 CONDENSER ELECTROSYS BEECH 55 95B55 1152706CE CONT O470 IO470L 17026SO ENGINE MAGNETO DEFECTIVE D K NONE W INADEQUATE Q C ININSP/MAINT 1 SW0399DC TC1490 CS20158672L MAGNETOS OVERHAULED WITH NEW ELECTROSYSTEM CONDENSER, PN E510-349276, CODE NR 03108 AND NR 9544. MAGNETOS CHECKED ON TEST STAND, OPERATED NORMALLY. MAGS INSTALLED AND TIMED TO ENGINE. DURING GROUND RUN, 3 MAGS CHECKED NORMAL. FOURTH MAG DEVELOPED A 1,000 RPM DROP. CHECKED MAG, FOUND BAD CONDENSER. REPLACED CONDENSER WITH NEW CONDENSER. GROUND RUN, SAME PROBLEM DEVELOPED. REPLACED CONDENSER WITH A USED BENDIX CONDENSER. ENGINE RAN NORMAL. 1L72 3O3 O 3A16 3E1 19960710000211996071000021EA 1996 7 10 96ZZZX3379 219960411G8530 CYLINDER PIPER PA32 PA32300 7103212SO LYC O540 IO540K1A5 41532EA NR 2-6 CYLINDERSWORN D K NONE O OTHER ININSP/MAINT 1 AL039000N148 3240883 L1338348A INSPECTION FOUND CYLINDER ASSEMBLIES WERE STEPPED AT TOP OF BORE. RINGS HAD KNIFE EDGE AT TOP FACE OF RING. 1L71 3O3 O A3SO 1E4 19960710000361996071000036WP 1996 7 10 96ZZZX3394 219960604G7421CH31815 IGNITER CHAMPION AMD FALC50FALCON900 2700160EU GARRTTTFE731TFE7315BR WP ENGINE IGNITER FAILED D K NONE O OTHER ININSP/MAINT 1 GL09523AC852 139 DURING ROUTINE MAINTENANCE, THE IGNITER FIRING TIP OF THE CENTER ELECTRODE WAS FOUND LOOSE. THE IGNITER IS AN EXTENDED LIFE IRIDIUM IGNITER. THIS WAS A NON-SERIALIZED IGNITER, BUT THE 'TST' INDICATES PREVIOUS SPECIAL TESTING FOR LOOSE CENTER ELECTRODE WAS COMPLIED WITH BY CHAMPION, THE MANUFACTURER. 2L73 4F4 FRTA46EU E6WE 19960710002881996071000288NE 1996 7 10 96ZZZX3411 219960503G72309136M89G19 ROTOR SPOOL GE CF6 CF650* 30018NE HP COMP CRACKED GS K NONE O OTHER ININSP/MAINT 1 EU01 517842 DURING NDT INSPECTION, A CRACK WAS FOUND IN THE 3-9 HPC SPOOL. THE CRACK IS NOT IN THE AREA DESCRIBED IN THE AD ON SPOOLS. 4 F E23EA 19960710002941996071000294GL 1996 7 10 96ZZZX3417 219960424G7323252466713 GOVERNOR BOLKMS105 BO105CBS 5626008EU ALLSN 250C 250C20B 03013GL ENGINE DEFECTIVE B EOPRO OTHER R PARTIAL RPM/PWR LOSS APAPPROACH 1 AL01493HL 26236 S809 GOVERNOR REQUIRED TO BE RETRIMMED FREQUENTLY, THEN ENGINE FELL TO IDLE ON DESCENT FOR FINAL. GOVERNOR WAS CLOSE TO OVERHAUL, 56.0 HOURS LEFT. REPLACED GOVERNOR. 1G72 3U3 UNCH3EU E4CE 19960718000141996071800014EA 1996 7 18 96ZZZX3426 219960601G8520SL13792 SEAL CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA CRANKSHAFT LOOSE H K NONE O OTHER ININSP/MAINT 1 SO1667658 15285305 1656615 OUTER CIRCUMFERENCE OF SEAL IS NOT A TIGHT FIT TO THE CRANKCASE. AFTER SEAL IS INSTALLED, SEAL IS ABLE TO ROTATE. NO SEALANT IS RECOMMENDED IN THE OVERHAUL OR SERVICE MANUALS, PN 13792 AND SL 13792 SEALS. 1H71 3O3 ONT3A19 E223 19960718000291996071800029SO 1996 7 18 96ZZZX3441 219960624G8530648005CP RING CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO PISTON BROKEN E O OTHER R PARTIAL RPM/PWR LOSS CRCRUISE 1 EA2533247 U20602692 553910 TEMPORARY POWER LOSS DURING CRUISE. SUSPECT CAUSE: BROKEN PISTON RING WHICH BECAME WEDGED BETWEEN PISTON AND CYLINDER WALL. REPLACED COMPLETE CYLINDER ASSY. 1H71 3O3 O A4CE E5CE 19960718000301996071800030SO 1996 7 18 96ZZZX3442 219960212G8520 CRANKCASE BEECH 58 58 1152740CE CONT O520 IO520C 17032SO NR 1-2 CYLINDERSFAILED E A O OTHER O OTHER APAPPROACH 1 GL254520S1086 TH660 287021R DIPSTICK DEPARTED AIRCRAFT ON FINAL. MAINTENANCE UNCOWLED ENGINE TO PERFORM COMPRESSION TEST. ENGINE CRANKCASE HAD ERUPTED BETWEEN NR 1 AND NR 2 CYLINDER. BOTH MAGNETOS TORN FROM MOUNTING PADS NR 1 AND NR 2 CYLINDER ROD CAPS AND ROD BOLTS SHEARED FROM RODS AND 1 COUNTERWEIGHT DETACHED FROM CRANKSHAFT. SUSPECT CAUSE: COUNTERWEIGHT PIN FAILURE. ENGINE MANUFACTURER NOTIFED AND REP TO EXAMINE ENGINE TEAR DOWN INSPECTION REQUESTED BY OWNER, OPERATOR, AND MAINTENANCE. 1L72 3O3 O 3A16 E5CE 19960718000321996071800032SO 1996 7 18 96ZZZX3444 219960530G8520643202 CRANKCASE CESSNA340 340CESSNA 2076404CE CONT O520 TSIO520J 17040SO LT HALF CRACKED BS CTURK NONE O OTHER ININSP/MAINT 1 GL21123KK 809 3400251 509176 ENGINE CRANKCASE WAS FOUND CRACKED FROM THE CRANKCASE THROUGH-BOLT AT CYLINDER NR 2. THE CASE WAS REPLACED 4-9-95. THE ENGINE CURRENTLY HAS 1,257 HOURS TSO. 1L72 3O3 O 3A25 E8CE 19960718000361996071800036SO 1996 7 18 96ZZZX3448 219960620G7322182022111 SUPPORT CESSNA182 182Q 2072732CE CONT O520 IO520D 17032SO THROTTLE BODY CRACKED D K NONE O OTHER ININSP/MAINT 1 NM11182PG58 18266379 293230R THIS AIRCRAFT IS MODIFIED PER STC SA00152W1 AND THE ITEM IS PART OF THE MODIFICATION. THIS SUPPORT WAS CRACKED TWO-THIRDS THE WAY THROUGH; AND, IF HAD BROKEN OFF, WOULD HAVE LET THE FUEL CONTROL UNIT SLIP DOWN AND CAUSE A VERY LEAN MIXTURE AND A POSSIBLE ENGINE CUT-OFF. THE SUPPORT COULD BE REMOVED COMPLETELY OR MADE OF STEEL. 1H71 3O3 ONT3A13 E5CE 19960718001081996071800108GL 1996 7 18 96ZZZX3486 219960531G73232523240 BEARING 23007505 BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20 03013GL FLYWEIGHTS FROZEN B AALGRK NONE O OTHER ININSP/MAINT 1 SW03107AL1447 S772 DURING TEAR DOWN INVESTIGATION OF UNIT, FOUND 2523240 BEARINGS FROZEN CAUSING FLYWEIGHTS TO STICK. 1G72 3U3 U H3EU E4CE 19960718002161996071800216NE 1996 7 18 96ZZZX3523 219960611G7230 COMPRESSOR RKWELLNA265 NA26540 6402608CE PWA JT12 JT12A8 52042NE ENGINE BINDING D K NONE O OTHER ININSP/MAINT 1 SO09317NT10605322 282100 P637622NB COMPRESSOR VERY DIFFICULT TO ROTATE AND SPOOL DOWN VERY SHORT. INTERNAL BINDING COULD BE FELT WHEN ROTATING BY HAND. THIS IS A MULTI-STAGE UNIT, SO VISUAL INSPECTION/DETECTION OF A PARTICULAR PARTS FAILURE IS VERY DIFFICULT. NO FOD NOTED AND NO DAMAGE OR DEFECTS NOTED IN TURBINE HOT SECTION. ALL IN-FLIGHT AND GROUND TEST PARAMETERS NORMAL. 2L72 4J4 J A2WE 1E9 19960718002211996071800221EA 1996 7 18 96ZZZX3528 219960628G7414M3525 COIL SLICK 4270 CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA RT MAG FAILED H O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 EA0192595200 89020072 17261591 ENGINE SUDDENLY BECAME ROUGH. MAG CHECK INDICATED TROUBLE WITH RIGHT MAG, FLIGHT CONTINUED ON SINGLE MAG. OPERATION - AT TERMINATION OF FLIGHT, MAGS RE-CHECKED. RT MAG DEAD; OPENING UP MAG REVEALED 'BEARING' GREASE IN MAG HOUSINGS. COIL APPEARED INTACT, BUT DID NOT CHECK OUT. FRONT BEARING HAD 'ROUGH SPOTS'. TOTAL TIME SINCE NEW, 200 HOURS. 1H71 3O3 ONT3A12 E274 19960718002221996071800222EA 1996 7 18 96ZZZX3529 219960619G8520 CRANKCASE PIPER PA28 PA28R200 7102811SO LYC O360 IO360C1C 41514EA NR 2 CYLINDER CRACKED DS K NONE O OTHER ININSP/MAINT 1 EA2175340 1000 28R7635292 RL1019351A DURING 100-HOUR INSPECTION, THE CRANKCASE WAS FOUND CRACKED (2 INCHES). THIS WAS THE SAME CRACK THAT WAS FOUND 2 YEARS AGO WHEN THE ENGINE HAD 1,500 HOURS TSMO. THE CASE HALVES WERE REPLACED AND NOW 1,000 HOURS LATER, THE SIMILAR CRACK HAS RE-APPEARED. SUSPECT VIBRATION PROBLEM. 1L71 3O3 O 2A13 1E10 19960718002281996071800228SW 1996 7 18 96ZZZX3535 119960702G812060051004 HOUSING ROTOMASTER 3AT6EE10J2 MOONEYM20 M20K 5870220SW CONT O360 TSIO360GB 17025SO TURBO CRACKED B AWTXRK NONE O OTHER ININSP/MAINT 1 NM07123VW 222449 250447 309450 SUBMITTER RECOMMENDS THAT ROTO-MASTER TURBINE HOUSING P/N 600510-04 (TCM P/N 643931) BE ADDED TO ROTO-MASTER AD 82-27-03. AD 82-27-03 STATES THIS INSPECTION MAY BE DISCONTINUED WITH THE INSTALLATION OF P/N 600510-04, BUT SUBMITTER HAS FOUND THIS TURBINE HOUSING TO BE CRACKING IN THE SAME AREAS SHOWN IN FIGURE 2 OF AD 82-27-03. 1L71 3O3 O 2A3 E9CE 19960718002291996071800229EA 1996 7 18 96ZZZX3536 219960702G8530 VALVE GULSTMAA5 AA5A 3960106SO LYC O320 O320E2G 41508EA NR 4 CYL INT BLOCKED OPEN D K NONE W INADEQUATE Q C ININSP/MAINT 1 SW03263901961 AA5A0557 L4583127A ON INITIAL RUN-UP AFTER INSTALLING ENGINE AFTER MAJOR OVERHAUL, ENGINE WAS RUN AROUND 5 MINUTES AT 1,000-1,200 RPM'S. ENGINE RPM WAS INCREASED TO 1,700 FOR MAG CHECK. THE ENGINE STARTED TO RUN EXTREMELY ROUGH. ENGINE WAS SHUT DOWN. COMPRESSION CHECK SHOWED ZERO COMPRESSION ON NR 4 CYLINDER. FURTHER INSPECTION WAS CONDUCTED AND AN OBJECT WAS FOUND LODGED BETWEEN THE VALVE GUIDE BOSS AND THE VALVE WHICH HELD IT OPEN. IT APPEARED TO BE A ROUND SAND CAST ROD OF ALUMINUM. 1L71 3O3 O A16EA E274 19960718004281996071800428NE 1996 7 18 96ZZZX3561 219960506G8530 CYLINDER SCWZERG164 G164A 3952704EA PWA R1340 R1340* 52016NE NR 1 CRACKED D K NONE O OTHER ININSP/MAINT 1 EA2348395 261 1628 21888 INSPECTION FOUND NR 1 CYLINDER CRACKED HORIZONTALLY THROUGH SPARK PLUG BUSHING ON FORWARD FACE. 1Q71 3R3 R 1A16 5E2 19960718004331996071800433EA 1996 7 18 96ZZZX3566 219960313G7414 IMPULSE COUPLER SLICK 4371 CESSNA172 172K 2072430CE LYC O320 O320E2D 41508EA MAGNETO EXCESS WEAR D K NONE O OTHER ININSP/MAINT 1 GL0979301115 95090178 17258030 L2497227A DURING ROUTINE MAINTENANCE (COMPRESSION CHECK) ENGINE 'LOCKED UP.' UPON INVESTIGATION/EXAMINATION, IMPULSE COUPLER PAWL AND PAWL AXIS FOUND EXTREMELY WORN ALLOWING IMPULSE COUPLING TO JAM INTERMITTENTLY WITH NO WARNING. 1H71 3O3 ONT3A12 E274 19960718007451996071800745EU 1996 7 18 96ZZZX3632 219960507G72503013300650 SHAFT CFMINTCFM56 CFM563B2 13802EU LPT ROTOR CRACKED B RD43K NONE O OTHER ININSP/MAINT 1 SW05 28425 FN01136 721108 THE LPT SHAFT HAS 2 EACH CRACKS, ONE IS 5 AND ONE IS 7 INCHES LONG, ONE INCH APART STARTING APPROXIMATELY .50 INCH FROM THE AFT END OF THE SPLINES. INVESTIGATION IS IN PROGRESS BY CFMI. 4 F E21EU 19960718007461996071800746NE 1996 7 18 96ZZZX3633 219960607G7210447245 BEARING PWA JT8 JT8D217A 52053NE N2 GEARBOX FAILED B RD43K NONE J WARNING INDICATION NRNOT REPORTED 1 SW05 717374 ENGINE EXPERIENCED LOUD BANG AND EPR AND RPM WENT TO ZERO. ENGINE WAS REMOVED WITH INTERNAL AND EXTERNAL DAMAGE TO THE N2 GEARBOX. DISASSEMBLY OF THE GEARBOX REVEALED A FAILED BEARING. INVESTIGATION IS STILL UNDER WAY AT AVIALL. 4 F E9NE 19960722000021996072200002SO 1996 7 22 96ZZZX3551 219960628G7421 SPARK PLUG CHAMPION CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO ENGINE ELECTRODE LOOSE D K NONE W INADEQUATE Q C ININSP/MAINT 1 WP2511174 18504435 282968R NEW SPARK PLUG HAS DEFECT, SIDE ELECTRODE LOOSE. 1H71 3O3 O 3A24 E5CE 19960725003831996072500383SO 1996 7 25 96ZZZX3678 219960710G8530530341 PISTON CESSNA172 172E 2072412CE CONT O300 O300D 17022SO NR 1 CYLINDER CRACKED D K NONE O OTHER ININSP/MAINT 1 NE053793S 925 17250993 28332D3D DURING SCHEDULED OIL CHANGE, OWNER REQUESTED A COMPRESSION CHECK BE DONE. NR 1 CYLINDER WAS LOW AT 28/80. FURTHER INVESTIGATION REVEALED THE FOLLOWING: PISTON CRACKED FROM SKIRT TO FACE AT 6:00 O'CLOCK POSITION. TOP COMPRESSION RING BROKEN AND CYLINDER WALL SCORED. THIS ENGINE ONLY HAD 30 HOURS SINCE PREVIOUS COMPRESSION CHECK WHICH WAS WELL WITHIN TCM CRITERIA. SUBMITTER RECOMMENDS COMPRESSION CHECKS BE DONE ON THESE OLDER ENGINES ESPECIALLY IF TOTAL TIME IS UNKNOWN AND TSMOH IS MID-POINT OR BEYOND. 1H71 3O3 ONT3A12 E253 19960725003881996072500388EA 1996 7 25 96ZZZX3683 219960601G8550 TUBE CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA OIL RUNBACK HOLE CHAFED D K NONE K FLUID LOSS ININSP/MAINT 1 SO1669082 15282477 INSPECTION FOUND WIRING FOR ALTERNATOR MISROUTED, WORE HOLE IN OIL RUNBACK TUBE CAUSING OIL LEAK. 1H71 3O3 ONT3A19 E223 19960725003981996072500398EA 1996 7 25 96ZZZX3694 219960708G8520 CASE CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA NR 2 CYL LT SIDECRACKED B DPODK NONE O OTHER ININSP/MAINT 1 NM07739PJ 1431 17270694 L607576T LEFT CASE CRACKED BELOW NR 2 CYLINDER BASE. CRACK WAS ABOUT 2.5 INCHES LONG. 1H71 3O3 ONT3A12 E274 19960725004011996072500401EA 1996 7 25 96ZZZX3697 219960702G8530434011 CYLINDER NAMER NA260 T28* GL WRIGHTR1820 R1820* 67020EA FLANGE CRACKED D O OTHER BK SMOKE/FUMES/ODORS/SPARKS FLUID LOSS NRNOT REPORTED 1 SW9928YF 400 137799W ENGINE SHOWED EVIDENCE OF OIL LEAK. MECHANIC MUST HAVE THOUGHT HE HAD CURED PROBLEM. AIRCRAFT CLEARED FOR FLIGHT. NR 1 CYLINDER DEPARTED ENGINE SOME TIME AFTER PILOT NOTICED SMOKE IN COCKPIT. INSTRUMENTS SHOWED NORMAL READINGS. CYLINDER HAD EVIDENCE OF OLD CRACK IN AREA OBSCURED BY COOLING FINS AND PROPELLER GOVERNOR. FOLLOWING MILITARY MAINTENANCE PROGRAM, COULD (MIGHT) HAVE HELPED, BUT CYLINDER CRACKS OCCURRED IN MILITARY USE ALSO. 1L71 4R4 R 1A18 5E10 19960725004041996072500404EA 1996 7 25 96ZZZX3700 219960625G7414M3065 ROTOR SLICK 4347 BEECH 95 D95A 1153408CE LYC O360 IO360B1B 41514EA MAGNETO SHAFT FAILED DS K NONE O OTHER ININSP/MAINT 1 WP13199Q 205 94120022 TD581 L655351A ENGINE NO START. TROUBLESHOOTING ISOLATED TO MAGNETO. OPENED MAGNETO HOUSING TO INSPECT. REMOVED DISTRIBUTOR BLOCK AND GEAR ASSEMBLY. NOTICED ROTOR GEAR APPEARED DETACHED. REMOVED GEAR AND FOUND SHAFT HAD BROKEN AT AREA BELOW POINT CAM SLOT. SLOTTED PORTION OF SHAFT REMAINED IN ROTOR GEAR. BREAK AREA APPEARED TO HAVE HAD MATERIAL DEFECT/CORROSION FROM DISCOLORED DARK AREA. SUBMITTER STATED DUE TO LOW TIME, SUSPECT DEFECTIVE MATERIAL. 1L72 3O3 O 3A16 1E10 19960725004061996072500406SO 1996 7 25 96ZZZX3702 219960703G8550CH48108 FILTER CHAMPION BEECH 58 58P 1152744CE CONT O520 TSIO520WB 17040SO ENGINE OIL DEFECTIVE D K NONE W INADEQUATE Q C ININSP/MAINT 1 NE056648K TJ204 248173R OIL FILTER CUT OPEN AT OIL CHANGE. NOTICED INSIDE GASKET WAS CUT AND SLIGHTLY MISALIGNED. CLOSER LOOK REVEALED METAL PORTION WAS CUT APPROXIMATELY ONE INCH AND ONE INCH SLIVER ABOUT .0625 INCH THICK WAS STICKING INTO OIL OUTLET PATH. HAD THIS SLIVER COME LOOSE, IT WOULD HAVE GONE INTO THE ENGINE, POSSIBLY CAUSING A CATASTROPHIC FAILURE. RECOMMEND STICKING FINGER INTO NEW FILTERS PRIOR TO INSTALLING TO CHECK FOR DEFECTS. 1L72 3O3 O A23CE E8CE 19960725005741996072500574GL 1996 7 25 96ZZZX3728 219960607G7200 ENGINE DOUG DC10 DC1030 3023501WP GE CF6 CF66D 30020GL NR 3 FIRE B ZUFYK NONE A FLAME/FIRE ININSP/MAINT 1 EA35833LA 46937 DURING ENGINE START ON PUSH-BACK, NR 3 ENGINE SUFFERED A JET-PIPE FIRE AT MANCHESTER. FIRE EXTINGUISHED BY AIRPORT FIRE SERVICE. NO DAMAGE. AIRCRAFT HISTORY OF FUEL FLOW PROBLEMS. FIRE OCCURRED ON SECOND ATTEMPT TO START. NR 3 ENGINE, NR 2 FIRE BOTTLE USED, NO EFFECT. NR 1 FIRED. OK. FULL REPORT TO FOLLOW. 2L73 4F4 F A22WE E23EA 19960725005771996072500577GL 1996 7 25 96ZZZX3731 219960110G7323A1AA1 GOVERNOR HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL N2 GOVERNOR SHAFT SEPARATED DP K NONE O OTHER NRNOT REPORTED 1 WP138625F1338 327 13605 470111D CAE830515 ENGINE RPM DROOPED. REMOVED N2 GOVERNOR AND FOUND DRIVE SPLINE, SPRING AND WASHERS HAD FALLEN OFF. 1G71 3U3 U H3WE E4CE 19960802001961996080200196SO 1996 8 2 96ZZZX3750 219960701G855015000793 NIPPLE CESSNA337 T337C 2075714CE CONT O360 TSIO360A 17025SO ACCESSORY CASE FAILED B ADJ3RAE UNSCHED LANDING ENGINE SHUTDOWN K FLUID LOSS NRNOT REPORTED 1 WP172522S 3370822 197111R THE RIGID PIPE NIPPLE THAT IS THREADED INTO ACCESSORY CASE BETWEEN MAGNETOS FAILED AT THE BOTTOM OF THE THREAD GROOVE FLUSH WITH THE ACCESSORY CASE. THIS ALLOWED RETURN OIL FROM THE WASTEGATE CONTROLLERS TO GO OVERBOARD. THE PILOT SAW THE OIL PRESSURE DROPPING. SHUT DOWN ENGINE AND MADE A SAFE LANDING. THE PART INSTALLED IN FACTORY REBUILT ENGINE. ENGINE TIME AT FAILURE 172 HOURS. FAILURE WAS CAUSED BY METAL FATIGUE AND CONCENTRATED STRESS OF A RIGID ARM PROTRUDING 8 INCHES SUPPORTING A T-FITTING AND TWO HOSES. THIS IS A CESSNA PART ALTHOUGH IT CAME FROM CONTINENTAL ON THE ENGINE. 1H72 3O3 O A6CE E9CE 19960802002031996080200203EA 1996 8 2 96ZZZX3757 219960318G74141016301010 MAGNETO S6L200 PIPER PA23 PA23250 7102308SO LYC O540 TIO540C1A 41532EA DRIVE FAILED D K NONE O OTHER ININSP/MAINT 1 SW99123CF550 J229127EX 278054017 MAGNETO WAS FOUND WITH DRIVE NUT HAVING NO THREADS AND NO THREADS ON DRIVE. 1L72 3O3 O 1A10 E14EA 19960802002091996080200209EA 1996 8 2 96ZZZX3763 219960705G8520 CRANKCASE CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA RT CASE NR 1 CYLCRACKED B DPODK NONE O OTHER ININSP/MAINT 1 NM07181SP 299 17268171 RL101576 RIGHT CRANKCASE CRACKED BELOW NR 1 CYLINDER BASE. CRACK WAS APPROXIMATELY 6 INCHES LONG. CASE WAS NOT REPAIRABLE. 1H71 3O3 ONT3A12 E274 19960802004621996080200462SO 1996 8 2 96ZZZX3766 219960713G8530627335D13B NOZZLE CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO FUEL INJ THREADS STRIPPEDD K NONE O OTHER ININSP/MAINT 1 SO152013S 21060981 294685R WHEN REMOVING FUEL INJECTOR NOZZLE FOR CLEANING AT FIRST 91-HOUR TSMOH, FACTORY REMANUFACTURE, NOZZLE CAME OUT OF CYLINDER HEAD WITH ALUMINUM, STRIPPED THREADS IN CLYINDER HEAD. 1H71 3O3 O 3A21 E5CE 19960802004701996080200470SO 1996 8 2 96ZZZX3774 219960711G8530635448CP CYLINDER CESSNA207 T207A 2073614CE CONT O520 TSIO520H 17040SO NR 3 SEPARATED D K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 WP076308H 1018 20700476 506728 PILOT REPORTED ROUGH ENGINE AND LARGE RPM DROP ON MAG CHECK. INSPECTION FOUND NR 3 CYLINDER CRACKED. WHEN CYLINDER REMOVED, IT WAS DISCOVERED THE HEAD WAS COMPLETELY SEPARATED. BOTTOM SPARK PLUG WAS FOULED. 1H71 3O3 O A16CE E8CE 19960806000011996080600001EU 1996 8 6 CA960103002 119960102G3320S2806102 SOCKET BAG BAE146BAE146200A 1500266EU LYC ALF502ALF502R5 41580NE SIDEWALL LIGHT BURNT W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA LF05465A (CAN)SMOKE COMING FROM SIDEWALL LIGHTING ROW 16 DEF. SOCKET FOR LIGHT BAR FOUND BURNED FROM ELECTRICAL ARCING. LAMP HOLDER REPLACED. 2H74 4F4 FRTA49EU E6NE 19960808000461996080800046SO 1996 8 8 96ZZZX3795 219960712G8530653445 CYLINDER BEECH 58 58 1152740CE CONT O520 IO520CB 17032SO ENGINE CRACKED B LNCRK NONE O OTHER ININSP/MAINT 1 SW053695V1315 TH1183 282448R ON INSPECTION, THE CYLINDER WAS FOUND TO HAVE A CRACK FROM THE SPARK PLUG BOSS TO THE FUEL NOZZLE. THE CRACK TRAVELS ALONG THE CASTING MARK ON THE CYLINDER. THE CYLINDER WAS STILL HOLDING 78/80. SUBMITTER BELIEVES THAT THIS IS A MANUFACTURING PROBLEM. 1L72 3O3 O 3A16 E5CE 19960808000481996080800048NE 1996 8 8 96ZZZX3797 219960719G7322PD12FS CARBURETOR BENDIX DOUG DC3 DC3 3021401WP PWA R1830 R183090D 52020NE ENGINE MALFUNCTION D K NONE O OTHER ININSP/MAINT 1 SW1732MS 740817A 4978 CP350411 ENGINE WILL NOT IDLE, DIES/RESTARTS OK. WILL NOT TAKE THROTTLE. WANTS TO BACKFIRE THROUGH CARBURETOR. REMOVED CARBURETOR. REPLACED WITH OVERHAULED UNIT. 2L72 4R4 R A669 5E4 19960808000591996080800059EA 1996 8 8 96ZZZX3808 219960510G8500 ENGINE SLNSBYT67 T67M260 8323006EU LYC O540 AEIO540D4A5 41532EA POWER SECTION STOPPAGE C O OTHER Y ENGINE STOPPAGE ABAEROBATIC 1 SW173037C 2134 L2524848 ENGINE STOPPED DURING AEROBATIC MANEUVER. SUCCESSFUL RESTART AND RETURN TO BASE WITHOUT FURTHER INCIDENT. ALL INDICATIONS NORMAL. PRELIMINARY ASSESSMENT IS THAT AIRCRAFT WAS PUT IN CONDITION KNOWN TO INDUCE ENGINE STOPPAGE. 1L71 3O3 ONTA73EU 1E4 19960808000601996080800060EU 1996 8 8 96ZZZX3809 119960425G7931 SENDER SLNSBYT67 T67M260 8323006EU LYC O540 AEIO540D4A5 41532EA ENG OIL PRESS FAILED C A UNSCHED LANDING J WARNING INDICATION NRNOT REPORTED 1 SW173037X 2137 L2557048A PILOT MADE AN EMERGENCY LANDING AT A SMALL AIRSTRIP. THE PILOT REPORTED LOW OIL PRESSURE AND RAISING OIL TEMPERATURE. A DOSS MAINTENANCE TEAM WAS SENT TO THE AIRSTRIP TO RECOVER THE AIRCRAFT. THE MAINTENANCE PERSONNEL REMOVED AND REPLACED THE OIL PRESSURE SENDING UNIT. GROUND RUN WAS ACCOMPLISHED, OPERATION CHECK GOOD. THE AIRCRAFT WAS FLOWN BACK TO HONDO AT APPROXIMATELY 1,500 HOURS, 25 APRIL 1996, WITH NO RETURN FLIGHT PROBLEMS. 1L71 3O3 ONTA73EU 1E4 19960808000611996080800061EA 1996 8 8 96ZZZX3810 219960625G8500 ENGINE SLNSBYT67 T67M260 8323006EU LYC O540 AEIO540D4A5 41532EA POWERPLANT STOPPAGE C O OTHER Y ENGINE STOPPAGE ABAEROBATIC 1 SW173192E 2227 L2257048A ENGINE STOPPED. DURING TRAFFIC PATTERN STALL MANEUVERS WITH THE ENGINE AT APPROXIMATELY IDLE. STARTER WAS ENGAGED FOR A SUCCESSFUL RESTART. DURING LANDING THE ENGINE STALLED AGAIN, NO RESTART WAS ATTEMPTED. AIRCRAFT LANDED WITHOUT INCIDENT. ALL OTHER INDICATIONS WERE NORMAL. NO KNOWN REASON AT THIS TIME. AIRCRAFT IMPOUND, PUT INTO DEPOT STATUS. DOSS AVIATION IS PERFORMING AN ENGINE STOPPAGE CHECK LIST. NO DISCREPANCIES FOUND AT THIS TIME. ENGINE AND AIRFRAME TIME IS 72.0 HOURS. 1L71 3O3 ONTA73EU 1E4 19960808000641996080800064NE 1996 8 8 96ZZZX3813 219960610G8530 CYLINDER SCWZERG164 G164A 3952704EA PWA R985 R985AN1 52008NE NR 4 HEAD LEAKAGE D K NONE O OTHER ININSP/MAINT 1 SO015296 580 24011 OVER LAST 200 HOURS, CYLINDER HEAD SEPARATED ON 3 CYLINDERS IN FLIGHT OR ON TAKEOFF. THE 4TH CYLINDER HAD STAINS AND LEAKAGE AND REMOVED BEFORE FAILURES, BUT WAS NOT BETWEEN NR 2 AND NR 3 FIN PER AD 78-08-07. IT WAS LEAKING BETWEEN TOP STEEL FIN AND NR 1 ALUMINUM FIN. NONE OF FAILED CYLINDERS SHOWED LEAKAGE PRIOR TO FAILURE. 1Q71 3R3 R 1A16 5E1 19960808000741996080800074NE 1996 8 8 96ZZZX3823 219960408G7250566004 TURBINE RKWELLNA265 NA26540 6402608CE PWA JT12 JT12A8 52042NE 2ND STAGE FAILED D EFA ENGINE SHUTDOWN ACTIVATE FIRE EXT. UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 SO09307NT1196 282072 P637801NB CLIMBING THROUGH 5,000 FEET, THE CREW HEARD AND FELT A LOUD REPORT FOLLOWED IMMEDIATELY BY THE LT ENGINE FIRE WARNING LIGHT. THE LT ENGINE SPEED ROLLED BACK TO APPROXIMATELY 12 PERCENT. PILOT SHUT ENGINE DOWN, DISCHARGED THE FIRE BOTTLE AND MADE A SINGLE ENGINE LANDING. INSPECTION REVEALED NUMEROUS 1ST AND 2ND STAGE TURBINE BLADES MISSING AND EXTENSIVE DAMAGE TO 2ND STAGE DISK. 2L72 4J4 J A2WE 1E9 19960808007341996080800734SO 1996 8 8 96ZZZX3869 219960717G8520 CRANKCASE PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360EB 17025SO LT ENG NR 5 CYL CRACKED BS APCRK NONE O OTHER ININSP/MAINT 1 NM0136319 347870318 265936R THE INSPECTION FOUND CRANKCASE HAS A SMALL .3750 INCH CRACK NEXT TO THE UPPER BOLT JUST FORWARD OF CYLINDER NR 5. THIS IS CONSIDERED A NON-CRITICAL AREA PER SB M90-17. 1L72 3O3 O A7SO E9CE 19960808007401996080800740EA 1996 8 8 96ZZZX3875 219960723G852011F20022D3 CRANKCASE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA NR 6 CYL STUDS FAILED B WC7RO OTHER R PARTIAL RPM/PWR LOSS CRCRUISE 1 GL25585DT493 318052117 L172868A PILOT REPORTED HEARING A 'BOOM' AND A DECREASE IN MANIFOLD PRESSURE DURING FLIGHT. UPON INSPECTION, NR 6 CYLINDER OF RIGHT ENGINE WAS FOUND TO BE AWAY FROM CRANKCASE PAD. FIVE OUT OF EIGHT CYLINDER HOLD-DOWN STUDS HAD BROKEN OFF. TWO THROUGH STUDS, AND ONE SHORT STUD REMAINED TO HOLD CYLINDER ON. SUSPECT CAUSE, NOT TORQUED PROPERLY. 1,454.3 HOBBS. 1L72 3O3 O A20SO E14EA 19960808007411996080800741EA 1996 8 8 96ZZZX3876 219960701G8530EC75971 CYLINDER BEECH 23 C23 1151242CE LYC O360 O360A4K 41514EA NR 4 CRACKED D K NONE O OTHER ININSP/MAINT 1 GL0563TW 1209 M1762 L2069136A INSPECTION FOUND NR 4 CYLINDER CRACKED FROM OUTSIDE RADIUS OF INTAKE VALVE TO OUTSIDE RADIUS OF EXHAUST VALVE. CYLINDER HEAD SPLIT OPEN BLOWING BOTTOM SPARK PLUG FROM CYLINDER. 1L71 3O3 O A1CE E286 19960808007421996080800742EA 1996 8 8 96ZZZX3877 219960715G8530SL13790A ROCKER SHAFT LYC O320 O320* 41508EA ENGINE BENT B CYKRK NONE W INADEQUATE Q C ININSP/MAINT 1 GL07 ROUTINE CHECK OF O320 SERIES ENGINE ROCKER SHAFTS FROM STOCK, FOUND P/N SL13790A, LOT NR 510924 DATED 4-30-96, 9 OUT OF 20 WERE FOUND BENT. 3 O E274 19960815000771996081500077NE 1996 8 15 96ZZZX3897 219960621G7310991202426 HOSE CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE MOTIVE FLOW FUELCHAFED B ACNQRK NONE O OTHER ININSP/MAINT 1 CE07323QS785 5600323 FOUND THE LEFT ENGINE THRUST REVERSER CONTROL LINKAGE HAD CUT INTO THE OUTER PROTECTIVE COVER OF THE MOTIVE FLOW FUEL HOSE. THE FUEL HOSE ASSY WAS REPLACED AND THE T/R CONTROL LINKAGE SAFETY WIRE REPOSITIONED TO PREVENT IT FROM CHAFING THE HOSE. 2L72 4F4 FRTA22CE E25EA 19960815000861996081500086NE 1996 8 15 96ZZZX3906 219960710G7230 COMPRESSOR RKWELLNA265 NA26540 6402608CE PWA JT12 JT12A8 52042NE ENGINE BINDING D K NONE O OTHER ININSP/MAINT 1 SO09309NT119701398 28261 P638364NB COMPRESSOR VERY DIFFICULT TO ROTATE AND SPOOL DOWN VERY SHORT. INTERNAL BINDING COULD BE FELT WHEN ROTATING BY HAND. THIS IS A MULTI-STAGE UNIT, SO VISUAL INSPECTION/DETECTION OF A PARTICULAR PART FAILURE IS VERY DIFFICULT. NO FOD NOTED AND NO DAMAGE OR DEFECTS NOTED IN TURBINE HOT SECTION. ALL IN-FLIGHT AND GROUND TEST PARAMETERS NORMAL. 2L72 4J4 J A2WE 1E9 19960815000901996081500090EA 1996 8 15 96ZZZX3910 219960613G8530LW16475 SPRING SEAT PIPER PA44 PA44180T 7104404SO LYC O360 LTO360E1A6 41515EA VALVE FAILED B PAIRO OTHER Y ENGINE STOPPAGE CRCRUISE 1 SO058269T 229 448107022 RL00026674T THE OPERATOR INCURRED AN IN-FLIGHT FAILURE. INSPECTION REVEALED VALVE SEAT FAILED. SUBMITTER STATED THIS UNIT WAS NOT REPLACED DURING LAST OVERHAUL BECAUSE LYCOMING SB 447A FAILED TO LIST LTO-360-E1A6D AS AN EFFECTED ENGINE. SUBMITTER STATED AD 80-14-07 NEGLECTED TO ADDRESS THIS ENGINE MODEL POSSIBLY IN ERROR. 1L72 3O3 O A19SO E26EA 19960815000911996081500091EA 1996 8 15 96ZZZX3911 219960717G741410357592 OIL SEAL S4LN200 HUGHES269 TH55A 4471004WP LYC O360 HIO360B1A 41514EA MAG DRIVE END FAILED D O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 WP07331SD 450 00349 291105 L333351A DURING TRAINING FLIGHT, ENGINE ROUGHNESS 'FELT' IN-FLIGHT; FOUND MAGNETO POINTS SATURATED WITH OIL. REPLACED MAGNETO WITH REBUILT UNIT. 1G71 3R3 O 1E10 19960815001081996081500108EA 1996 8 15 96ZZZX3928 219960722G7421REM37BY SPARK PLUG PIPER PA38 PA38112 7103812SO LYC O235 O235L2C 41505EA NR 4 CYLINDER FOULED D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 SW092416B50 3879A0052 L1758615 WHILE FLYING, PILOT EXPERIENCED PARTIAL LOSS OF ENGINE RPM AND MADE A PRECAUTIONARY LANDING IN A FIELD. UPON INVESTIGATION, FOUND THE BOTTOM SPARK PLUG IN NR 4 CYLINDER WAS NOT GAPPED PROPERLY. A PIECE OF CARBON GOT STUCK BETWEEN THE ELECTRODES OF THE SPARK PLUG ALLOWING IT TO BECOME OIL FOULED. THERE WAS NO DAMAGE TO AIRCRAFT OR PERSONS. 1L71 3O3 O A18SO E223 19960815001091996081500109EA 1996 8 15 96ZZZX3929 219960701G7322105267 CARBURETOR CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA FINGER SCREEN BLOCKAGE D K NONE R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 GL053281R 15284363 L2106415 PARTIAL POWER LOSS. FINGER SCREEN WAS FOUND PARTIALLY FILLED WITH A LINT-LIKE SUBSTANCE TO THE POINT THAT FUEL FLOW WAS RESTRICTED. THE FUEL SYSTEM WAS CHECKED BY DRAINING FUEL FROM SUMPS, GASCOLATOR, FUEL LINE, CARBURETOR FLOAT BOWL. NO FURTHER CONTAMINATION WAS FOUND. GASCOLATOR WAS DISASSEBLED, AND SCREEN WAS FOUND TO BE CLEAN. THE GASOLATOR HAD FAILED TO TRAP CONTAMINATION. SYSTEM REASSEMBLED, AIRCRAFT GROUND RUN AND TEST FLOWN. OPERATION NORMAL, RETURNED TO SERVICE. 1H71 3O3 ONT3A19 E223 19960815001121996081500112NE 1996 8 15 96ZZZX3932 219960722G8530399354 CYLINDER SCWZERG164 G164A 3952704EA PWA R985 R985AN14B 52008NE NR 1 CYLINDER CRACKED D K NONE O OTHER ININSP/MAINT 1 SW118605H5000 1157 1432 13782 ENGINE INSPECTION FOUND NR 1 CYLINDER HEAD HAD CRACKED FROM FORWARD SPARK PLUG BOSS UP OVER CENTER OF CYLINDER HEAD AROUND BELOW EXHAUST PORT, FORWARD AT CYLINDER HEAD/BARREL ATTACH AREA, BACK TO LOWER SIDE OF FORWARD SPARK PLUG BOSS. 1Q71 3R3 R 1A16 5E1 19960815002391996081500239GL 1996 8 15 96ZZZX3944 219960729G72306898607 BEARING 6896028 BELL 206 206L 1181522SW ALLSN 250C 250C28B 03013GL NR 1 FAILED B KUVRO OTHER J WARNING INDICATION NRNOT REPORTED 1 SO19165BH2509 R1747 45249 CAE860728 AIRCRAFT EXPERIENCED 3 CHIP LIGHTS WITHIN 50 HOURS. AIRCRAFT GROUNDED PER ALLISON MM. UPON INVESTIGATION FOUND NR 1 BEARING CAGE BROKEN INTO PIECES AND BEARING FELL APART. SIMPLE MECHANICAL FAILURE THAT COULD HAVE CAUSED ENGINE FLAME-OUT. 1G71 3U3 U H2SW E1GL 19960815002401996081500240EA 1996 8 15 96ZZZX3945 219960718G7260330170501 HOUSING 330160203 SKRSKYS76 S76B 8143007NE PWA PT6 PT6B36 52043EA NR 1 ENG AGB DAMAGED B EGRRK NONE O OTHER ININSP/MAINT 1 EA1722CP 999 760425 36207 AIRCRAFT TT: 999.1 HOURS. NR 1 ENGINE TT, 999.1 HOURS. DURING REPLACEMENT OF NR 1 HMU, FOUND CORROSION DAMAGE IN THE BORE ON THE HOUSING WHERE HMU IS INSTALLED. CORROSION DAMAGE WAS AT THE 6 O'CLOCK POSITION, AND RANGED FROM MINOR TO SOME DEEP PITS UP TO .140 INCH DEEP. ENGINE IS BEING REMOVED AND SENT FOR EVALUATION AND REPAIR. 1G72 4U4 U H1NE E4EA 19960815007421996081500742EA 1996 8 15 96ZZZX4007 219960719G852075154 STUD PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA NR 4 BEARING CORRODED B OG5RK NONE O OTHER ININSP/MAINT 1 GL21145ND3197 796 2841226 RL1708539A DURING ENGINE TEAR DOWN FOLLOWING ACCIDENT, CRANKCASE HALF NUT ON NR 4 BEARING STUDS SEIZED RESULTING IN STUD BACKING OUT OF CRANKCASE. UPON REMOVAL, FOUND BOTH NR 4 BEARING CRANKCASE STUDS HEAVILY CORRODED/RUSTED. ALSO, HAD GLASS BEADS IN STUD RECEPTACLES. ENGINE WAS FACTORY OVERHAULED 11-18-94, INSTALLED 1-95. 1L71 3O3 O 2A13 E274 19960815007481996081500748 1996 8 15 96ZZZX4013 119960801G781062749 GASKET CONT A65 A658 17003SO NR 2/3 CYL EXH MISMANUFACTURED DP K NONE W INADEQUATE Q C ININSP/MAINT 1 SW15 NEW EXHAUST GASKET IS MISMANUFACTURED .032 INCH LARGER THAN ORIGINAL. IT WILL FIT OK ON CYLINDERS 1 AND 4, BUT DUE TO CLEARANCE REQUIRED FOR FIT, IT IS TOO LARGE FOR CYLINDERS 2 AND 3. 3 O E205 19960815007501996081500750NE 1996 8 15 96ZZZX4015 219960730G726131B360801 PUMP LEAR 60 60LEAR 5170707CE PWA 305 PW305 NE LT ENG OIL HOUSING CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 SW0565BL 371 17A861 054 305218 EXCESSIVE OIL LEAK ON LEFT ENGINE. FOUND OIL PUMP HOUSING CRACKED AT UPPER LEFT BOLT HOLE AREA. SUBMITTER STATED THIS IS TURNING INTO A FLEET-WIDE CONCERN AS THIS CAN CAUSE AN ENGINE SHUTDOWN IN FLIGHT. OTHER OPERATORS HAVE EXPERIENCED THIS SAME CRACK. AD RECOMMENDED. 2L72 4F4 FRTA10CE E35NE 19960822000801996082200080NE 1996 8 22 96ZZZX4037 219960725G7250805172 VANE PWA JT8 JT8D217A 52053NE N1 TURBINE FAILED D E ENGINE SHUTDOWN O OTHER NRNOT REPORTED 1 SW05 709893 ENGINE WAS REMOVED FROM SERVICE DUE TO A LOUD BANG AND ENGINE EXPERIENCED AN IN-FLIGHT SHUT DOWN. DISASSEMBLY OF THE ENGINE REVEALED A SECOND STAGE VANE CLUSTER WAS MISSING AND THE REMAINDER OF THE N1 TURBINE HAD MASSIVE DAMAGE. THE CAUSE FOR THE FAILURE IS STILL UNDER INVESTIGATION. 4 F E9NE 19960822004041996082200404NE 1996 8 22 96ZZZM1243 219960717G7320 P3 LINE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE RT ENGINE LOOSE A AMWAA UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 CE07182YV UE182 FLT 5627 - AFTER TAKEOFF RIGHT ENGINE ROLLED BACK TORQUE AND THEN STABILIZED AT ABOUT 1000 FT/LBS OF TORQUE, AIRCRAFT. RETURNED TO FIELD AT MCI. MAINTENANCE TIGHTENED P3 LINE C/W FLIGHT TEST RETURNED AIRCRAFT TO SERVICE. (M) 2L72 4T4 TRTA24CE E26NE 19960829001621996082900162EA 1996 8 29 96ZZZX4059 219960716G852072877 CAM FOLLOWER LYC O540 O540B2C5 41532EA CYLS 1,3,5 BROKEN DP K NONE O OTHER ININSP/MAINT 1 NM07 1481540 CAM FOLLOWERS BROKEN ON NR 1 CYLINDER EXHAUST NR 3, EXHAUST AND INTAKE, NR 5 CYLINDER-INTAKE. REST OF CAM FOLLOWERS PITTED OR SPALLED. NR 2 CYLINDER DROPPED THE EXHAUST VALVE. OIL SUMP REMOVED FOR INSPECTION AND CLEANING. FOUND PIECES OF CAM FOLLOWERS IN SUMP. ENGINE DISASSEMBLED FOR OVERHAUL. ALL SIX ROD CAPS DAMAGED. ALL PIECES RETAINED AND ARE AVAILABLE FOR SCRUTINY. 3 O E295 19960829001751996082900175EA 1996 8 29 96ZZZX4072 219960517G8520 CRANKCASE PIPER PA28 PA28R200 7102811SO LYC O360 IO360C1C 41514EA LT NR 2 CYL FWD CRACKED B DPODK NONE O OTHER ININSP/MAINT 1 NM072141T 1058 28R7135144 L619151A LEFT CRANKCASE CRACKED BELOW NR 2 CYLINDER, FORWARD LOWER BASE STUD. CRACK WAS APPROXIMATELY 2 INCHES LONG. CASE WAS REPAIRED. 1L71 3O3 O 2A13 1E10 19960829001771996082900177CE 1996 8 29 96ZZZX4074 119960722G8120 CLAMP CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO TURBO FAILED G EA ENGINE SHUTDOWN UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 GL0928SA 4040072 276238R CLAMP CAME LOOSE AND DUCT BETWEEN TURBO AND INTAKE THROAT LEAKED CAUSING ENGINE TO RUN ROUGH. PILOT CHOSE TO SHUT DOWN ENGINE IN-FLIGHT AND MADE SAFE SINGLE ENGINE LANDING. NEW CLAMP WAS INSTALLED AND TORQUED TO SPECS. 1L72 3O3 O A25CE E7CE 19960829001791996082900179EA 1996 8 29 96ZZZX4076 219960701G741410682016 GEAR PIPER PA32 PA32RT300T 7103216SO LYC O540 TIO540S1AD 41532EA MAGNETO FAILED D K NONE O OTHER ININSP/MAINT 1 NE0336201529 32R7887027 L697961A MAGNETO DISTRIBUTOR GEAR FAILED. 1L71 3O3 O A3SO E14EA 19960829001841996082900184EA 1996 8 29 96ZZZX4081 219960730G741410682016 GEARTOOTH D6LN3000 CESSNA182 TR182 2072735CE LYC O540 O540L3C5 41532EA MAGNETO FAILED D K NONE O OTHER ININSP/MAINT 1 EA016339T E029002GR R18201986 RL2385940A DURING C/W AD 96-12-07, DISCOVERED DISTRIBUTOR GEAR MISSING A TOOTH, DID NOT AFFECT ENGINE OPS. REPLACED BOTH DISTRIBUTOR GEARS WITH NEW. REASON FOR FAILURE UNKNOWN, NO OTHER DEFECTS NOTED. 1H71 3O3 O 3A13 E295 19960829003271996082900327GL 1996 8 29 HEEA967686 219960822G723023033439 DAMPER SEGMENT 23038126 ALLSN 250C 250C20B 03013GL ENG COMP BELOW SPECS E HEEAK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAC15233 CAE830070 RECEIVING INSPECTION REVEALED DAMPER SEGMENT LENGTH .0335 BELOW BLUE PRINT SPECS OF .542 - .544. REPLACED DISCREPANT PART WITH NO CHARGE REPLACEMENT RECEIVED FROM ALLISON. 3 U E4CE 19960829003351996082900335EA 1996 8 29 96ZZZX4142 219960418G8530LW14115 CYLINDER PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA NR 1 CYL SLEEVE CRACKED H K NONE K FLUID LOSS ININSP/MAINT 1 GL2517PS 321 31P7630008 RL62362 HOBBS - 3,213.6 HOURS. OIL APPEARED AROUND NR 1 CYLINDER PUSH ROD TUBES. SEALS REPLACED, GROUND CHECK OPS GOOD. AFTER FLIGHT, OIL APPEARED AGAIN. REMOVED NR 1 CYLINDER, FOUND CYLINDER SLEEVE CRACKED APPROXIMATELY THREE-FOURTHS OF CIRCUMFERENCE. LOG REVEALED THIS TO BE THE 3RD CYLINDER ON NR 1 IN 4 YEARS. PISTON P/N LW 10545 SHOWED SIGNS OF BEING HOT. SUSPECT OIL NOZZLE FOR PISTON COOLING INOPERATIVE. REPLACED NOZZLE, P/N 73772. REPLACED CYLINDER KIT, P/N 05K21116-3, AND ASSOCIATED SEALS AND GASKETS. PISTON SKIRT WAS OIL COKED AND DISCOLORED. 1L72 3O3 O A8EA E19EA 19960829003391996082900339EA 1996 8 29 96ZZZX4146 219960410G7420 P-LEAD PIPER PA32 PA32RT300 7103215SO LYC O540 IO540K1G5 41532EA FIREWALL SHORTING H K NONE O OTHER ININSP/MAINT 1 GL25376AA 32R7885094 L1803048A TROUBLESHOOTING FOR INTERMITTENT INOPERATIVE CONDITION ON RT MAGNETO FOUND P-LEAD SHORTING WHERE IT EXITS THROUGH FIREWALL. REPLACED P-LEADS AND INSTALLED PLASTIC SLEEVING. 1L71 3O3 O A3SO 1E4 19960829003441996082900344SO 1996 8 29 96ZZZX4151 219960807G73106410321147 VALVE PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360EB 17025SO FUEL MANIFOLD LEAKING B APCRK NONE K FLUID LOSS ININSP/MAINT 1 NM01666HL54 ED89606CK 347770235 809072R FUEL MANIFOLD VALVE HAS FUEL LEAKING FROM TOP OF UNIT. INCREASE TORQUE VALUE FOR SCREWS. 1L72 3O3 O A7SO E9CE 19960829003491996082900349EA 1996 8 29 96ZZZX4156 219960728G7414M3081 CONTACT POINTS SLICK 4373 CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA MAGNETO SPRING DEFECT D K NONE O OTHER ININSP/MAINT 1 SO1373785239 94090132 17267677 AIRCRAFT LANDED AFTER CROSS-COUNTRY. WHEN THE PILOT ATTEMPTED TO DEPART, ENGINE WOULD NOT START. TROUBLESHOOTING DETERMINED THE POINTS IN THE LEFT MAGNETO WOULD NOT CLOSE COMPLETELY. GAP WAS WITHIN TOLERANCE. RETURN SPRING APPEARED TO BE BOWED, NOT SUPPLYING ENOUGH TENSION. INSTALLED NEW CONTACT KIT. 1H71 3O3 ONT3A12 E274 19960829003501996082900350SO 1996 8 29 96ZZZX4157 119960806G81203AT6EE10J2 TURBOCHARGER GARRTT PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360EB 17025SO RT ENGINE LOCKED UP E K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW1198HD 1258 347870461 PILOT APPLIED POWER TO RIGHT ENGINE FOR PRE-FLIGHT CHECK. ENGINE WOULD ONLY TURN UP TO 26 INCHES MAN/PRESSURE. FOUND TURBO HAD LOCKED UP. INSTALLED OVERHAULED TURBO, ENGINE GROUND RAN, CHECKED NORMAL. AIRCRAFT TEST FLOWN, ALL CONDITIONS NORMAL. 1L72 3O3 O A7SO E9CE 19960905001401996090500140EA 1996 9 5 96ZZZX4232 219960821G8520LW17060 CRANKSHAFT PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA FLANGE CRACKED DS A UNSCHED LANDING K FLUID LOSS NRNOT REPORTED 1 NE03846526047 288216062 L947639A THE AIRCRAFT COMPLETED AN UNSCHEUDLED ON AIRPORT EMERGENCY LANDING DUE TO OIL SPRAYING ON THE WINDSHIELD. THE CRANKSHAFT WAS FOUND CRACKED AT THE RADIUS BY THE PROPELLER FLANGE. (APPROXIMATELY 1.75 INCH VISIBLE.) 1L71 3O3 O 2A13 E274 19960905006751996090500675EA 1996 9 5 96ZZZX4287 219960814G8530LW11634 VALVE LW11633 PIPER PA38 PA38112 7103812SO LYC O235 O235L2C 41505EA NR 1 CYL EXH FAILED G K NONE O OTHER ININSP/MAINT 1 CE0533BA 200 511561 3879A0021 L1598715 EXHAUST VALVE FAILURE, 200 HOURS AFTER CYLINDER OVERHAUL. YELLOW TAG INDICATES CYLINDER WAS REBUILT USING SERVICEABLE PARTS. REBUILDER WAS CONTACTED, BUT COULD NOT DETERMINE TOTAL NUMBER OF HOURS ON VALVE WHEN INSTALLED. LYC SB NR 301B STATES EXHAUST VALVES SHOULD NOT BE RE-USED UNLESS THEY HAVE BEEN RECENTLY INSTALLED AND MEET INSPECTION CRITERIA. 1L71 3O3 O A18SO E223 19960905006801996090500680SO 1996 9 5 96ZZZX4292 219960201G8530646100A1 CYLINDER CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO SPARK PLUG HOLE CRACKED BS APCRK NONE O OTHER ININSP/MAINT 1 NM0141SA 1449 4040023 276274R DURING A ROUTINE ENGINE COMPRESSION TEST, CYLINDER NR 1 SHOWED 10/80. A VISUAL INSPECTION CONFIRMED A CRACK EMANATING FROM THE LOWER SPARK PLUG HOLE TO THE COOLING FINS, APPROXIMATELY 1.50 INCHES LONG. THIS IS A RECURRING ITEM, OPERATOR KNOWS OF AT LEAST 12 OCCURRENCES OVER THE LAST 2 YEARS. 1L72 3O3 O A25CE E7CE 19960905007011996090500701EA 1996 9 5 96ZZZX4313 219960812G8550CH48111 FILTER CHAMPION CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA ENGINE OIL LEAKING DS K NONE K FLUID LOSS ININSP/MAINT 1 GL159960463 F11F181 172766477 WHEN OIL FILTER WAS REMOVED, MECHANIC NOTICED THE CAN AREA OF THE FILTER TURNED, BUT THE ATTACH MOUNTING (CRIMPED FLANGE END BRACKET) STAYED STATIONARY. 1H71 3O3 ONT3A12 E274 19960912000481996091200048SO 1996 9 12 96ZZZX4316 219960731G731060100040234 HOSE CESSNA206 U206F 2073333CE CONT O520 TSIO520C 17040SO FUEL SYSTEM LEAKING G K NONE K FLUID LOSS ININSP/MAINT 1 EA072316U U20602360 HOSE ASSY FAILED AFTER 2 YEARS AND LESS THAN 200 HOURS OF OPERATION. HOSE TSO: C531, MFG DATE A1094, LOT NR 06827. 1H71 3O3 O A4CE E8CE 19960912000491996091200049SO 1996 9 12 96ZZZX4317 219960731G731060100040286 HOSE ASSY AEROQUIP CESSNA206 U206F 2073333CE CONT O520 TSIO520C 17040SO FUEL SYSTEM LEAKING DL K NONE K FLUID LOSS ININSP/MAINT 1 EA072316U U20602360 HOSE ASSY FAILED AFTER 2 YEARS AND LESS THAN 200 HOURS OF OPERATION. HOSE IS TSO C53A, MFG DATE A1094, LOT NR 06827. 1H71 3O3 O A4CE E8CE 19960912000551996091200055NE 1996 9 12 96ZZZX4323 219960701G7230536210 LOCK PWA JT12 JT12A8 52042NE 3RD STAGE DISK MISSING B JV2RK NONE O OTHER ININSP/MAINT 1 CE03 322 P637622NB INTERNAL BLADE RUBBING, BINDING, AND LOCKING UP. AN INDUCTION TEST RUN WAS PEFORMED ON 6-20-96. DURING THE TEST, VIBRATION OF 3.8 MIL AT 75 PERCENT WAS NOTED. (3.2 MIL IS MAXIMUM ALLOWABLE). ENGINE WAS DISASSEMBLED AS NECESSARY TO ACCESS COMPRESSOR ASSY. COMPRESSOR WAS DISASSEMBLED TO ELEVATE RUBBING CONDITION. P/N 536203, 3RD STAGE COMPRESSOR BLADE WAS FOUND LOOSE IN THE BLADE SLOT OF 3RD STAGE DISK. BLADE HAD MOVED AFT MAKING CONTACT WITH COMPRESSOR STATOR, P/N 385503, DAMAGING EVERY VANE. BLADE LOCK COULD NOT BE FOUND AND SUSPECT IT MAY HAVE FAILED AND EXITED ENGINE ALLOWING BLADE TO WORK LOOSE. NO OBVIOUS DAMAGE FROM LOCK WAS NOTED. CAUSE OF LOCK FAILURE IS UNKNOWN AT THIS TIME. ONE EACH P/N 536 4 J 1E9 19960912000631996091200063NE 1996 9 12 96ZZZX4331 219960808G7230 COMPRESSOR RKWELLNA265 NA26540 6402608CE PWA JT12 JT12A8 52042NE ENGINE BINDING D K NONE O OTHER ININSP/MAINT 1 SO09302NT5836 420 28281 P672953NB COMPRESSOR VERY DIFFICULT TO ROTATE, IINTERNAL BINDING COULD BE FELT WHEN ROTATING BY HAND WITH SHORT SPOOL DOWN TIME. NO FOD NOTED, NO DAMAGE OR VISUAL DEFECTS NOTED IN TURBINE HOT SECTION. ALL IN-FLIGHT AND GROUND TEST PARAMETERS NORMAL. ENGINE WAS REMOVED FROM SERVICE AND RETURNED TO SABERLINER FOR TEAR DOWN INSPECTION. 2L72 4J4 J A2WE 1E9 19960912000681996091200068NE 1996 9 12 96ZZZX4336 219960719G72303021436 BYPASS DUCT MTSBSIMU300 MU300 5780602CE PWA JT15 JT15D4 52112NE LT ENGINE FAILED D A K NONE O OTHER ININSP/MAINT 1 SO0383BG 452 A018SA PCE70623 A CRACK DEVELOPED AT THE FORWARD FLANGE OF THE AFT INNER BYPASS DUCT AT THE 6 O'CLOCK POSITION ALLOWING IT TO COME OUT OF THE MATING FLANGE AND ENTER THE AIR FLOW, THEREBY CAUSING A 3 INCH (APPROX) SECTION TO PEEL BACK AND CAUSE A 2 INCH (APPROX) TEAR ALONG THE RADIUS OF THE BEND. THE PILOT NOTICED THE PIECE HANGING DOWN DURING PRE-FLIGHT INSPECTION AND ASSY WAS REPLACED BEFORE FURTHER FLIGHT. 2H72 4F4 FRTA14SW E1NE 19960912000741996091200074NE 1996 9 12 96ZZZX4342 219960711G7230536211 LOCK PWA JT12 JT12A8 52042NE 4TH STAGE DISK MISSING BL JV2RK NONE O OTHER ININSP/MAINT 1 CE03 1300 P672928NB METAL-TO-METAL CONTACT, BIND, BLADE RUB. INVESTIGATION FINDINGS: AN INDUCTION TEST RUN COULD NOT BE ACCOMPLISHED DUE TO RUBBING CONDITION. THE ENGINE AND COMRPESSOR ASSEMBLY WERE DISASSEMBLED TO IDENTIFY CAUSE OF DISCREPANCY. INVESTIGATION REVELAED THAT P/N 536204, FOURTH STAGE COMPRESSOR BLADE, WAS FOUND LOOSE IN THE BLADE SLOT OF THE FOURTH STAGE DISK. THE BLADE HAD MOVED AFT MAKING CONTACT WITH THE INNER SEAL AREA OF THE FOURTH STAGE COMPRESSOR STATOR, P/N 542274. P/N 536211, BLADE LOCK, COULD NOT BE FOUND AND SUSPECT IT MAY HAVE FAILED AND LEFT THE ENGINE ALLOWING THE BLADE TO WORK LOOSE. NO OBVIOUS DAMAGE FROM THE LOCK WAS NOTED. 4 J 1E9 19960912005301996091200530SO 1996 9 12 96ZZZX4373 219960813G8530635448CP CYLINDER CESSNA188 A188B 2073005CE CONT O520 IO520D 17032SO NR 4 FAILED D A UNSCHED LANDING ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CRCRUISE 1 SW179370R 450 5538AA620 18802262T 563670 NR 4 CYLINDER HEAD SEPARATED FROM BARREL CAUSING ENGINE FAILURE IN-FLIGHT RESULTING IN FORCED LANDING (I-35 SOUTH, SAN ANTONIO). R2 CYLINDER ASSY OPS CHECK OK. 1L71 3O3 O A9CE E5CE 19960912005311996091200531CE 1996 9 12 96ZZZX4374 119960822G37103P194FA PUMP PESCO CESSNA182 182J 2072722CE CONT O470 O470N 17026SO VACUUM SYSTEM DRIVE SHEARED D K NONE O OTHER NRNOT REPORTED 1 CE072714F PE09124FDG 18256814 1319985R VACUUM PUMP DRIVESHAFT SHEARED AND SPLINES EXTREMELY WORN. IT STILL MADE VACUUM PRESSURE. SUBMITTER RECOMMENDS MORE FREQUENT INSPECTIONS OF DRIVE SPLINE ASSY (NOTE: WET DRIVE VACUUM PUMP). 1H71 3O3 ONT3A13 E273 19960912005371996091200537NE 1996 9 12 96ZZZX4380 219960814G7313231009801 NOZZLE 216362036 BAG BAE146BAE146100A 1500260EU LYC ALF502ALF502R 41580NE FUEL MANIFOLD CRACKED BSAPGLRK NONE O OTHER ININSP/MAINT 1 SO13 82F001 OVERTORQUED CONDITION RESULTING IN CRACKED FLANGE AREA. RECOMMEND USE OF PROPER TORQUE DURING INSTALLATION OF NOZZLE INTO MANIFOLD ASSY. 2H74 4F4 FRTA49EU E6NE 19960912005391996091200539EA 1996 9 12 96ZZZX4382 219960820G8530 CYLINDER CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA NR 2 CRACKED D C ABORTED TAKEOFF ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TOTAKEOFF 1 NM0146758 15283101 L1612315 TAKEOFF ABORTED FOR LOSS OF POWER/ROUGH RUNNING ENGINE. POST-FLIGHT MAINTENANCE INSPECTION REVEALED 3 INCH HAIR LINE CRACK RUNNING CIRCUMFERENTIALLY, BETWEEN NR 14 AND NR 15 FIN (COUNTING DOWN FROM TOP) OF NR 2 CYLINDER. SMALL BURN AREA OBSERVED ON NR 4 CYLINDER INTAKE PUSH ROD TUBE. REPLACED ENGINE. 1H71 3O3 ONT3A19 E223 19960912005401996091200540SO 1996 9 12 96ZZZX4383 219960801G85206436511 STUD PIPER PA28 PA28RT201T 7102817SO CONT O360 TSIO360FB 17025SO CYLINDER BASE STRETCH BPAYYBRK NONE W INADEQUATE Q C ININSP/MAINT 1 GL032847J 28R7931221 24809612 ENGINE WAS BEING REPAIRED FOR SEVERAL BROKEN CYLINDERS, BASE STUDS, AND LOOSE NUTS. MECHANIC RECEIVED 36 BRAND NEW STUDS FROM THREE DIFFERENT VENDORS IN TCM PACKAGING. UPON TORQUING TO THE REQUIRED MINIMUM TORQUE VALVE, A TOTAL OF 12 STRETCHED. THEY WERE ALL REMOVED. TWO WERE SUBMITTED TO TCM FOR ANALYSIS. 1L71 3O3 O 2A13 E9CE 19960912005551996091200555EA 1996 9 12 96ZZZX4398 219960722G7414103493576 IMPULSE CAM 1038255511 CESSNA177 177RG 2073709CE LYC O360 IO360A1B 41514EA MAGNETO WORN B K NONE O OTHER ININSP/MAINT 1 SW9952073426 177RG1161 L1696551A INSPECTED MAGNETO RIVETED CAM ASSY AND FOUND WORN BEYOND 'X' PLUS .014 INCH. SUBMITTER STATES THESE EARLY RIVETED UNITS SHOULD BE CHANGED OUT TO THE SNAP RING STYLE AT 500 HOURS. NEW STYLE FOR THIS APPLICATION IS 10-400167-9. 1H71 3O3 O A20CE 1E10 19960912005561996091200556SO 1996 9 12 96ZZZX4399 219960725G8530625393 SPRING RETAINER BEECH 58 58P 1152744CE CONT O520 TSIO520U 17040SO EXH VALVE NR 3 FAILED B QL5RK NONE O OTHER ININSP/MAINT 1 NM05112Z 1336 TJ371 274153R WHILE CHANGING VALVE COVER GASKET ON NR 3 CYLINDER, MECHANIC FOUND TWO SMALL PIECES OF METAL IN VALVE COVER. INVESTIGATED AND DETERMINED PIECES CAME FROM THE EXHAUST VALVE INNER VALVE SPRING RETAINER TCM. PERFORMED HIDDEN DAMAGE INSPECTION. INSPECTED AND CHECKED OK. INSTALLED NEW SPRING RETAINER. ENGINE IS A TCM FACTORY REMANUFACTURED WITH 1,336 HOURS TSMOH. 1L72 3O3 O A23CE E8CE 19960912005571996091200557EU 1996 9 12 96ZZZX4400 219960627G8530 PISTON AMTR 500 MINI500 13015HWGL ROTAX 582 ROTAX582 55555EU SKIRT UNDERSIZE FLA K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 CE05500ZZ 0000 4655214 THE ENGINE BACKFIRED AND MOMENTARILY HAD A LOSS OF POWER. THE PISTONS WERE FOUND UNDERSIZED AT THE SKIRT END. THIS COULD HAVE POSSIBLY BEEN CAUSED BY IMPROPER BREAK IN PROCEDURES. 1G71 3I3 INCEXPA1G71EXPE3I 19960912005581996091200558EA 1996 9 12 96ZZZX4401 219960807G74141038255514 MAGNETO BEECH 76 76 1153005CE LYC O360 IO360A1G6 41514EA RT ENGINE SEPARATED D O OTHER Y ENGINE STOPPAGE TOTAKEOFF 1 WP2766291 ME224 MAGNETO SEPARATED FROM ENGINE ON TAKEOFF CAUSING ENGINE TO STOP. THIS IS A DUAL MAGNETO ON A SINGLE DRIVE. IT WAS DETERMINED THE NUTS HAD LOOSENED AND ALLOWED MAG TO COME OFF. THERE IS NO TORQUE LISTED FOR THIS MAGNETO EXCEPT STANDARD TORQUE. RECOMMEND THAT MAGNETO ATTACHMENTS BE CHECKED AT 50-HOUR INTERVALS. ALSO, MAG NEEDS TO BE CHECKED FOR NEW STYLE HOLD-DOWN BRACKETS. TIME SINCE LAST CHECK OF HOLD-DOWN NUTS WAS APPROXIMATELY 80 HOURS. 1L72 3O3 O A29CE 1E10 19960912005591996091200559EA 1996 9 12 96ZZZX4402 219960729G8520 CRANKSHAFT BOEING75 A75N1 1380134CE WRIGHTR975 R975* 67012EA HUB SOCKET SCREWS FAILED D A UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 WP2768251 700 757976 78224 AFTER TAKEOFF, ENGINE STOPPED. AIRCRAFT CRASH LANDED IN A FIELD. AIRCRAFT DESTROYED BY POST-FIRE. INVESTIGATION FOUND CRANKSHAFT GEAR ASSEMBLY HUB SOCKET SCREWS SHEARED. P/N 401337. TSO: 700 HOURS. TT: UNKNOWN. 1Q71 3R3 R A743 ATC21 19960912005641996091200564CE 1996 9 12 96ZZZX4407 119960805G2752C3010020103 MOTOR CESSNA150 150L 2071826CE CONT O200 O200A 17020SO FLAP SHORTED D K NONE O OTHER NRNOT REPORTED 1 EA077513G4089 15074679 242709R FLAPS EXCEEDED THE LIMIT SWITCH, STOPS, AND BROKE THE DOWN-LIMIT SWITCH AND FUSE BLEW. PROBLEM WAS CAUSED BY FLAP MOTOR DEVELOPED AN INTERNAL SHORT WHICH PROVIDED THE GROUND NORMALLY WHICH IS PROVIDED THROUGH THE LIMIT SWITCH CIRCUIT. THIS MOTOR IS A REVERSING 12V DC MOTOR WHICH CHANGES POWER AND GROUND CIRCUIT THROUGH THE SWITCH AND LIMIT SWITCHES NORMALLY. NO LOG ENTRY SHOWS MOTOR CHANGED PREVIOUSLY. 1H71 3O3 O 3A19 E252 19960912005651996091200565SO 1996 9 12 96ZZZX4408 219960625G8550CH48109 FILTER CHAMPION PIPER PA46 PA46310P 7104605SO CONT O520 TSIO520BE 17040SO ENGINE OIL BROKEN B JAVRK NONE W INADEQUATE Q C ININSP/MAINT 1 NE0194MA 23 F11E111 468608056 273793R AFTER CUTTING OIL FILTER OPEN, THE MANUFACTURER'S ANTI-DRAIN BACK VALVE ROLLED EDGE WAS FOUND CRACKED APPROXIMATELY ONE-HALF WAY AROUND AND A PIECE, APPROXIMATELY 1 INCH LONG, HAD BROKEN OFF. BROKEN PIECES WERE FOUND AFTER OIL COOLER WAS REMOVED AND BACK-FLUSHED. 1L71 3O3 O A25SO E8CE 19960912005821996091200582SO 1996 9 12 96ZZZX4425 219960801G741410400309 IMPULSE COUPLER BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO ENGINE MAG CRACKED D K NONE O OTHER ININSP/MAINT 1 SW99255EM TC1552 WHILE C/W AD 78-09-07R3, AN IMPULSE COUPLER WAS FOUND TO NEED REPLACEMENT. A NEW PART WAS INSTALLED ON MAG. WHILE TIGHTENING NUT ON COUPLER TO 240 INCH/POUNDS, THE COUPLER CRACKED WHERE IT SLIDES ON THE TAPERED SHAFT. SUBMITTER FOUND THAT IMPULSE COUPLERS THAT ARE CHECKED ARE ONLY LASTING FOR ONE CYCLE (500 HOURS) OF AD INSPECTION, WHERE IN THE PAST, AN IMPULSE COUPLER WOULD OFTEN LAST FOR 1,000 HOURS OR MORE. SUBMITTER SUSPECTS THE MATERIAL USED FOR NEW UNITS IS NOT AS GOOD A MATERIAL AS WAS USED IN THE PAST. 1L72 3O3 ORT3A16 3E1 19960912008501996091200850EU 1996 9 12 CA960123027 219960102G7200 ENGINE RROYCESPEY SPEY55515P 54521EU TAIL PIPE MAKING METAL W E ENGINE SHUTDOWN E VIBRATION/BUFFET CRCRUISE 1 CA 9796 (CAN)VIBRATIONS FELT AT FL250. POWER REDUCED FROM 94 PERCENT TO 91 PERCENT & VIBRATIONS INCREASED. ENGINE WAS SHUTDOWN & FLIGHT DIVERTED. POST FLIGHT INSPECTION FOUND METAL IN TAILPIPE & DAMAGE TO BOTH THE LP & HP SYSTEMS. FURTHER DETAILS WILL FOLLOW ENGINE TEARDOWN. 4 F E2EU 19960919000011996091900001EA 1996 9 19 96ZZZX4371 219960824G8530 CYLINDER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA SPARK PLUG HOLE CRACKED D A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SO1630230 287990088 L2558336A CYLINDER CRACKED FROM TOP SPARK PLUG HOLE AROUND SIDE TO BOTTOM SPARK PLUG HOLE. AIRCRAFT LANDED SAFELY WITHOUT FURTHER PROBLEMS (LOSS OF RPM). ENGINE TT, 2,601.4 HOURS. TSMOH: 607.7 HOURS. SUBMITTER STATED THIS IS THE THIRD CRACKED CYLINDER ON THIS AIRCRAFT SINCE OVERHAUL. 1L71 3O3 O 2A13 E286 19960919000061996091900006EA 1996 9 19 AU960002 219960102G852074309 BEARING LYC O540 TIO540J2BD 41532EA NR 4 CON ROD FAILED W K NONE O OTHER ININSP/MAINT 1 AUS L462561A (AUS) ENGINE NO4 CONNECTING ROD BEARING FAILED IN AREA OF RELIEF FOR CONNECTING ROD BOLT SHANK 3 O E14EA 19960919000071996091900007EU 1996 9 19 AU960003 119960103G7160352002034 HOSE BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA ENG AIR INT COLLAPSED W O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TOTAKEOFF 1 AUS L2549448A (AUS) LH ENGINE INDUCTION HOSE BETWEEN ALTERNATE AIR BOX AND FUEL CONTROL COLLAPSED - SUSPECT CAUSED BY FAULTY BATCH OF SCAT HOSES 1H72 3O3 O A17EU 1E4 19960919000141996091900014EU 1996 9 19 AU960010 119960103G71107271110505 COWLING SAAB SF340 SF340A 7850100EU GE CT7TP CT75A2 30030NE ENGINE COWL SYS DAMAGED W K NONE ED VIBRATION/BUFFET INFLIGHT SEPARATION CLCLIMB 1 AUS 367303K (AUS) LH ENGINE INBOARD COWL UNLATCHED - PROPELLER SLIPSTREAM HAD DISTORTED THE COWL CRACKING SEVERAL INTERNAL STIFFENER FRAMES -SUSPECT LATCHES LEFT UNLOCKED FOLLOWING ENGINE SERVICING - PERSONNEL/MAINTENANCE ERROR 2L72 4T4 TRTA52EU E8NE6 19960919000241996091900024EA 1996 9 19 AU960021 219960109G8550 NOZZLE PIPER PA36 PA36285 7103610SO LYC O720 IO720A1B 41546EA ENGINE OIL SYS FAILED W K NONE O OTHER CRCRUISE 1 AUS L12775AA (AUS) ENGINE OIL SYSTEM CONTAMINATED BY METAL - NO3 CYLINDER OIL SQUIRT NOZZLE MISSING - THE NOZZLE BALL WAS FOUND IN THE CRANKCASE ANDTHE REMAINDER OF THE NOZZLE WAS FOUND IN THE SUMP FOLLOWING REMOVAL - INVESTIGATION FOUND THAT THE NOZZLE HAD BEEN CRUSHED BETWEEN THE CONNECTING ROD CAP AND THE CRANKCASE AND DESTROYED - SUSPECT THE NOZZLE WAS UNDERTORQUED DURING ASSEMBLY 1L71 3O3 O A10SO 1E15 19960919000311996091900031EU 1996 9 19 AU960028 119960112G7160352002034 HOSE BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA ENG AIR INT RT FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RH ENGINE INDUCTION HOSE COLLAPSED IN MID SECTION - INNER WIRE SEPARATED FROM OUTER WALL 1H72 3O3 O A17EU 1E4 19960919000321996091900032EU 1996 9 19 AU960029 119960112G7160352002034 HOSE BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA ENG AIR INT LT FAILED W K NONE OEROTHER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 AUS (AUS) LH ENGINE INDUCTION HOSE COLLAPSED 1H72 3O3 O A17EU 1E4 19960919000331996091900033EU 1996 9 19 AU960030 119960112G7160352002034 HOSE BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA ENG AIR INT RT FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RH ENGINE INDUCTION HOSE BETWEEN AIR FILTER AND FUEL SERVO UNIT INTERNAL WIRE DISPLACED 1H72 3O3 O A17EU 1E4 19960919000381996091900038EA 1996 9 19 AU960035 219960111G7414M3485 BEARING SLICK 4371 LYC O360 O360A4K 41514EA ENG MAG LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS 92020112 L2674136A (AUS) MAGNETO DISTRIBUTOR END BEARING LOOSE AND SPINNING IN HOUSING - MAGNETO FILLED WITH BLACK DUST 3 O E286 19960919000391996091900039EU 1996 9 19 AU960036 219960101G7200MAKILA1A ENGINE TMECA MAKILA1A SNIAS AS332 AS332L 8680809EU TMECA MAKILAMAKILA1A 60040EU ENGINE (TURBINE OVER TEMP W KE NONE ENGINE SHUTDOWN M OVER TEMP NRNOT REPORTED 1 AUS 877 241 241 (AUS) ENGINE OVERTEMPED ON START - EGT WAS BELOW 900 DEGREES C FOR 38 SECONDS - EGT LIMITS ON START 810 DEGREES C TO 900 DEGREES C FOR 2 SECONDS - SUSPECT START FOLLOWED ABORTED START WHICH LEFT A SUBSTANTIAL AMOUNT OF FUEL IN THE ENGINE 2G72 4U4 U H4EU E12NE 19960919000401996091900040EU 1996 9 19 AU960037 119960116G7160352002034 HOSE BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA ENG AIR INT RT FAILED W K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TOTAKEOFF 1 AUS (AUS) LH ENGINE INDUCTION AIR HOSE BETWEEN AIR BOX AND FUEL CONTROL COLLAPSED - RH ENGINE INDUCTION HOSE INSPECTED AND WAS FOUND TOBE ALSO CLOSE TO FAILURE - NUMEROUS OTHER FAILURES RECORDED IN FLEET 1H72 3O3 O A17EU 1E4 19960919000411996091900041CE 1996 9 19 AU960038 119960112G2434 BRUSH ALTERNATOR CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA GENERATOR-ALT WORN W K NONE O OTHER ININSP/MAINT 1 AUS 1850 L330176 (AUS) ALTERNATOR BRUSHES WORN EXCESSIVELY - PIGTAIL JUNCTION WORN INTO SLIP RING 1H71 3O3 ONT3A12 E274 19960919000421996091900042CE 1996 9 19 AU960039 119960112G5320 DOOR POST CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA FS 65.3 CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1850 (AUS) AFT DOOR POST ASSEMBLY CRACKED IN AREA OF INNER RELIEF AT FS 65.3 TOWARDS OUTBOARD LANDING GEAR HOUSING FASTENERS 1H71 3O3 ONT3A12 E274 19960919000491996091900049EA 1996 9 19 AU960047 219960111G7230 BLADE PWA PT6 PT6A34 52043EA T ENG CMPRSR/FANFOD W K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CLCLIMB 1 AUS 40582 (AUS) ENGINE GAS GENERATOR 1ST STAGE COMPRESSOR BLADES (15OFF) CONTAIND FOD TO THE LEADING EDGES - INVESTIGATION FOUND THAT THE 1ST STAGECOMPRESSOR SPACER RUBBED ON THE STATOR AND CRACKED CIRCUMFERENTIALLY LIBERATING A PIECE OF MATERIAL APPROXIMATELY 12.7MM (0.5IN) WIDE AND 76.2MM (3IN) LONG WHICH WAS INGESTED THROUGH THE COMPRESSOR - DAMAGE TO THE TRAILING EDGES OF THE 1ST STAGE STATOR BLADES - EVIDENCE OF FURTHER DAMAGE DOWNSTREAM - ONE COMPRESSOR BLADE HAD FORE AND AFT MOVEMENT OF APPROXIMATELY5.08MM TO 7.62MM (0.2IN TO 0.3IN) 4 T E4EA 19960919000521996091900052CE 1996 9 19 AU960050 119960112G7603 CABLE BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO THROTTLE BROKEN W K NONE O OTHER DEDESCENT 1 AUS 272978R (AUS) THROTTLE INNER CABLE BROKE APPROXIMATELY 25MM (1IN) FROM SLIDING SLEEVE INSIDE FLEXIBLE PART OF CABLE ON THE ENGINE SIDE - CABLE HAD A VERY MINOR KINK NEAR THE ATTACHMENT BRACKET - SUSPECT INCORRECT INSTALLATION - PERSONNEL/MAINTENANCE ERROR 1L72 3O3 ORT3A16 3E1 19960919000551996091900055EU 1996 9 19 AU960120 119960205G3220115C5201 FORK GROB G115 G115C 1660303EU LYC O360 O360A1F6 41514EA NOSE GEAR SYS DELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR FORK DELAMINATED - AIRCRAFT NLG HAD BEEN BOGGED IN SAND - SEE MDR 96/0093 AND MDR 96/0121 FOR FURTHER INFORMATION 1L71 3O3 ONTA57EU E286 19960919000561996091900056EU 1996 9 19 AU960121 119960202G3220115C5201 FORK GROB G115 G115C 1660303EU LYC O360 O360A1F6 41514EA NOSE GEAR SYS CRACKED W K NONE O OTHER LDLANDING 1 AUS 82032C2 (AUS) NOSE LANDING GEAR FORK CRACKED AND DELAMINATED - FOUND DURING INSPECTION FOLLOWING REPORTED HEAVY LANDING - SEE MDR 96/0093 ANDMDR 96/0120 FOR FURTHER INFORMATION 1L71 3O3 ONTA57EU E286 19960919000691996091900069EU 1996 9 19 AU960662 119960521G2842 TRANSMITTER GROB G115 G115C 1660303EU LYC O360 O360F1A6 41514EA FUEL INDICATION FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LH AND RH FUEL TRANSMITTER FLOATS DETERIORATED 1L71 3O3 ONTA57EU E286 19960919000731996091900073EA 1996 9 19 AU960670 219960523G7310 HOSE LYC O360 O360A1F6 41514EA ENG FUEL DIST SYFAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE PRIMER HOSE FAULTY - END FITTINGS CAN BE PULLED AWAY FROM HOSE 3 O E286 19960919000791996091900079SO 1996 9 19 AU960679 219960520G852063026143 BEARING CONT COUNTERWGHT CONT O360 IO360HB 17025SO RT ENG CTRWT WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 353395 (AUS) CRANKSHAFT COUNTERWEIGHT ROLLER BEARING PNO 630261-43 INCORRECT PART - CORRECT PART NUMBER FITTED SHOULD HAVE BEEN PNO 630261-44 - COUNTERWEIGHT RETAINING WASHER WORN INTO COUNTERWEIGHT - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 3 O E1CE 19960919002521996091900252SO 1996 9 19 96ZZZX4623 219960801G732239077 NEEDLE VALVE BENDIX NAS3A1 CESSNA140 140 2071602CE CONT C90 C9012F 17009SO FLOAT CHAMBER SWELLED UP G CD ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TOTAKEOFF 1 NM06 CARBURETOR FLOAT CHAMBER NEEDLE VALVE TIP SWELLED UP, PROBABLY DUE TO 100 LL OR AUTOGAS. ENGINE FALTERED AT HIGH POWER SETTINGS. TAKEOFF ABORTED. 1H71 3O3 ONCA768 E252 19960919003031996091900303GL 1996 9 19 HEEA967779 219960904G725023008054 NOZZLE ALLSN 250C 250C28 03013GL NR 1 OUT OF SPECS E HEEAK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 RECEIVING INSPECTION REVEALED: MEASUREMENT ON #1 NOZZLE DIMENSION (A) .019 BELOW CEB72-2103R-6 SPECS, (B) .005 BELOW BLUEPRINT SPECS, (C) .012 BELOW BLUEPRINT SPECS. 3 U E1GL 19960919003081996091900308GL 1996 9 19 HEEA967786 219960906G723023056634 GEAR 23033193 ALLSN 250C 250C30P 03013GL SPUR ADAPTER DEFECTIVE E HEEAK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAC91370 CAE895336 RECEIVING INSPECTION REVEALED: SERIAL NUMBER ON SPUR GEAR DOES NOT MATCH NUMBER ON BOX. REPLACED DISCREPANT PART. 3 U E1GL 19960919005511996091900551CE 1996 9 19 CA960126034 119960112G273005130631 BRACKET CESSNA 05130631 CESSNA172 172F 2072414CE CONT O300 O300D 17022SO ELEV BELLCRANK CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 5948 29320D4D (CAN)AT THE ANNUAL INSPECTION OF THIS AIRCRAFT THE FORWARD ELEVATOR BELLCRANK SUPPORT BRACKET WAS FOUND CRACKED. THE LOCATION IS AT THE LEFT FORWARD ATTACHMENT ANGLE UNDER THE CABIN FLOOR AFT OF THE FUEL S ELECTOR. THE TOP BAR SUPPORTING THE BELLCRANK CENTRE BOLT WAS ALSO FOUND BROKEN. THE PART WAS NOT REPAIRABLE AND THEREFORE WAS REPLACED WITH NEW P/N 0513063-1. SUBMITTER NOTES THAT THE REPLACEMENT PART WAS FOUND TO BE MORE ROBUST THAN THE ORIGINAL. 1H71 3O3 ONT3A12 E253 19960919005921996091900592GL 1996 9 19 96ZZZX4704 219960322G721023035178 GEARBOX BELL 206 206L3 1182108SW ALLSN 250C 250C30 03013GL MOUNT PAD CORRODED D K NONE O OTHER ININSP/MAINT 1 EU01722H 3546 CAG95568 51452 PITTED CORROSION ON RT GEARBOX BOSS OCCURRED DURING NORMAL OPERATION. FOUND DURING ROUTINE INSPECTION. RECOMMENDED SUPPLIER CHECK MATERIALS FOR DEFECTS. SIMILAR PROBLEM FOUND ON THREE GEARBOXES. 1G71 3U3 U H2SW E1GL 19960919006041996091900604WP 1996 9 19 96ZZZX4717 219960821G725030733543 AIR SEAL 30727262 GARRTTTFE731TFE73122B 01518WP TRANSITION DUCT DEFECTIVE BL IY2RK NONE O OTHER ININSP/MAINT 1 SW15 4225 463 1013453990 P74146 DURING AN UNSCHEDULED MAINTENANCE EVENT, FOUND AN P/N 3073354-3, AIR SEAL WAS INSTALLED IN THE TRANSITION DUCT, P/N 3072726-2, S/N 1-01345-3990. SB TFE731-72-3577, REV ZERO, ADDRESSES THIS SUBJECT. 4 F E6WE 19960919006161996091900616SO 1996 9 19 96ZZZX4729 219960819G7310 HOSE CESSNA210 210E 2073416CE CONT O520 IO520A 17032SO ENGINE FUEL DETERIORATED G K NONE O OTHER ININSP/MAINT 1 WP234931U 21058631 1108644A FUEL HOSES NON-OPERATONAL FOR 3 YEARS ALLOWING NON-PRESSURE SIDE OF FUEL HOSES TO DRY OUT AND INSIDE OF HOSE TO DETERIORATE. SMALL PIECES OF RUBBER HOSE BROKE OFF AND CLOGGED FUEL LINES IN FUEL INJECTION SYSTEM. 1H71 3O3 O 3A21 E5CE 19960919009271996091900927SO 1996 9 19 96ZZZX4742 219960806G8530 ROCKER BOSS CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO NR 3 CYL EXH FAILED D K NONE ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NRNOT REPORTED 1 AL01105AK 40400833 243227R ROCKER BOSS FAILED (CRACKED) ON EXHAUST SIDE ON CYLINDER NR 3. ROCKER SHAFT PUNCHED THROUGH VALVE COVER. INSPECTED MAGNETO DRIVE COUPLING PER SB M90-11, FOUND OK. 1L72 3O3 O A25CE E7CE 19960919009361996091900936EA 1996 9 19 96ZZZX4751 219960821G8520AS16507A01 CAMSHAFT PIPER PA44 PA44180 7104402SO LYC O360 O360E1A6 41514EA LT ENGINE BROKE D K NONE O OTHER ININSP/MAINT 1 SO152110F 1897 WB1122M182 447995152 L45377T ENGINE WAS REMOVED FOR CAM FAILURE AT 299.20 TSMOH. A RE-GROUND CAM WAS INSTALLED BY CRS. AT 2,195.50 TSMOH, ENGINE WAS REMOVED FOR OVERHAUL AND DISASSEMBLY REVEALED CAM HAD BROKEN IN 2 PIECES WHERE THE PROP GOVERNOR GEAR P/N LW-15274 IS INSTALLED AND CRACKED WHERE THE WOODRUFF KEY P/N STD-96 IS INSTALLED TO SECURE THE PROP GOVERNOR DRIVE GEAR. THE ORIGINAL PART NUMBER FOR THIS CAM BEFORE IT WAS RE-GROUND AND INSTALLED BY THE CRS WAS AS16508. NOTE: THIS ENGINE NEVER GAVE AN INDICATION OF FAILURE/METAL IN OIL. 1L72 3O3 O A19S0 E286 19960926001221996092600122EA 1996 9 26 96ZZZX4785 219960705G74141051324 SPRING CESSNA172 172 2072402CE LYC O320 O320H2AD 41508EA IMPULSE COUPLINGBROKEN DL K NONE O OTHER ININSP/MAINT 1 EA2175814578 17267971 CHECKED IGNITION TIMING. FOUND APROXIMATELY 90 DEGREES OFF. REMOVED MAGNETO, FOUND IMPULSE COUPLING SPRING BROKEN. CHECKED I-C PER AD 78-09-07R3/AD 96-12-0-7 AND FOUND SATISFACTORY. REVIEWED MAG O/H DATE FAXED BY INS. ADJ. FOUND I-C SPRING, INSP AND REUSED, CONTRARY TO MANUFACTURER'S DATA TO "REPLACE AT EACH DIS ASSEMBLY WITH NEW PARTS." 1H71 3O3 ONT3A12 E274 19960926001401996092600140SO 1996 9 26 96ZZZX4803 219960910G74141015828Y MAGNET BENDIX SFS4RNR CONT A75 A75* 17005SO ENGINE MAG SHAFT FAILED H A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 EA07 80998 MAGNETO FAILED IN-FLIGHT. MAGNET, P/N 10-15828Y, SHAFT FAILED. BROKE IN TWO PIECES AT THE INNER WOODRUFF KEY SLOT AT THE OUTER EDGE OF THE SLOT. THIS FAILURE WAS INSIDE THE MAGNETO SO THE GEAR AND OUTWARD END OF THE SHAFT CONTINUED TO ROTATE. THE ENGINE CONTINUED RUNNING UNTIL A SUCCESSFUL LANDING WAS MADE. THE MAGNETO DRIVE GEAR TILTED PARTIALLY GRINDING ALUMINUM FROM THE ACCESSORY CASE CONTAMINATING THE OIL AND RESULTING IN SUBSEQUENT ENGINE OVERHAUL. THERE IS NO EVIDENCE OF A LOCK-UP OF THE MAGNETO CAUSING THE SHAFT TO SHEAR THE WAY IT DID. THE BEARINGS WERE VERY ROUGH, BUT INTACT. MAGNETO MAINTENANCE HISTORY IS UNKNOWN AND TOTAL TIME IS UNKNOWN. THE MAGNETO WAS USED ON A HOMEBUILT. ENGINE, CONTINE 3 O E213 19960926001451996092600145EA 1996 9 26 96ZZZX4808 219960528G853005K21120 CYLINDER PIPER PA28 PA28RT201 7102818SO LYC O360 IO360C1C6 41514EA NRS 1/2-3/4 WORN D K NONE O OTHER ININSP/MAINT 1 NM09377LC4544 689 28R7918120 L277151A COMPRESSION CHECK INDICATES ALL 4 CYLINDERS NOT SERVICEABLE DUE TO LOW COMPRESSION. TSO: 689 HOURS. TT: 4,544 HOURS. 1L71 3O3 O 2A13 1E10 19960926001501996092600150SO 1996 9 26 96ZZZX4813 219960514G732230764 FLOAT ASSY FACET MA45 CESSNA182 182A 2072704CE CONT O470 O470L 17026SO CARBURETOR DETACHED B YECRK NONE O OTHER ININSP/MAINT 1 NM0988MA 850 3997983 34691 CARBURETOR WAS REMOVED AT ANNUAL INSPECTION FOR EXCESSIVE WEAR ON THROTTLE SHAFT. UPON DISASSEMBLY, ONE OF THE FLOATS WAS FOUND BROKEN FROM THE ACTUATING ARM. IT WAS NOT RUPTURED OR WORN THROUGH. FLOAT WAS DATE CODED 4-84. SUSPECT A ROUGH RUNNING ENGINE AND/OR A BAD SOLDER POINT ON THE FLOAT TO BRACKET. NOTE: THE ENGINE WAS 'OVERHAULED' 77 HOURS AGO. THE CARBURETOR WAS NOT. 1H71 3O3 ONT3A13 E273 19960926001521996092600152EA 1996 9 26 96ZZZX4815 219960720G72303108301 CT BLADE BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA GAS GEN FAILED A AMASRE ENGINE SHUTDOWN O OTHER CRCRUISE 1 SW07156YV3059 UC156 32460GG AN IN-FLIGHT SHUT DOWN OF THE RIGHT ENGINE DUE TO THE FAILURE OF THE HOT SECTION CT BLADE. AT THE ENGINE TEAR DOWN, NOTED ONE CT BLADE HAD LIBERATED AT THE ROOT AND ALL THE OTHER CT BLADES WERE SEVERELY DAMAGED DUE TO THE CONTACT WITH THE LIBERATED BLADE. THE CT BLADE REMAINING ROOT SECTION WAS SENT TO PRATT AND WHITNEY FOR FURTHER INVESTIGATION 2L72 4T4 TRTA24CE E4EA 19960926001531996092600153EA 1996 9 26 96ZZZX4816 219960507G7210310076701 SUN GEAR BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA POWER SECTION FAILED A AMASRE ENGINE SHUTDOWN O OTHER NRNOT REPORTED 1 SW01157YV1355013550 55C036 UC157 32512PS AN IN-FLIGHT SHUT DOWN OF THE LT ENGINE DUE TO THE FAILURE OF THE POWER SECTION. AT THE ENGINE TEAR DOWN, THE INVESTIGATION REVEALED THE 1ST STAGE SUN GEAR HAD FAILED AND IS BEING CONSIDERED THE CAUSE OF THE SHUT DOWN. 2L72 4T4 TRTA24CE E4EA 19960926001561996092600156EA 1996 9 26 96ZZZX4819 219960801G8530 VALVE PIPER PA28 PA28161 7102803SO LYC O320 O320E3D 41508EA ENGINE EXHAUST FAILED B BXPRA UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 EA09324901709 287515169 L3989027A ENGINE LOST POWER ON TAKEOFF. PILOT ABLE TO MAINTAIN ALTITUDE AND RETURN TO AIRPORT. VALVE APPEARS TO BE P/N 75068 WHICH IS PRONE TO BREAKAGE WHEN USING FUEL HIGHER THAN 80/87 (REF: LYCOMING SB 404). ANY VALVES STILL IN SERVICE SHOULD BE REPLACED. 1L71 3O3 O 2A13 E274 19960926001621996092600162EA 1996 9 26 96ZZZX4825 219960504G74141068255511 MAGNETO D4KB3999 MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA DIST BLOCK DEFECTIVE D K NONE O OTHER ININSP/MAINT 1 SO1191307 K20882G 243201 L2556651A INSPECTED MAG IAW 500-HOUR INSPECTION AT 1,057 HRS TTSN AND FOUND DISTRIBUTOR BLOCK DRIVEN GEAR BEARING BROKEN LOOSE FROM BLOCK (BROWN BLOCK). REPLACED WITH 10-682054 BLOCK. ENGINE STILL HAD ACCEPTABLE MAG DROP. APPROXIMATELY 500 HRS SINCE LAST 500-HOUR COMPLYING INSPECTION. NO 500-HOUR INSPECTION LISTED FOR MAGNETO IN LOG BOOKS. 1L71 3O3 O 2A3 1E10 19960926001661996092600166GL 1996 9 26 96ZZZX4829 219960202G72506877736 LABYRINTH SEAL 6898735 ALLSN 250C 250C20B 03013GL GP TURBINE FRACTURED B YKERK NONE O OTHER ININSP/MAINT 1 EA17 TURBINE WAS REMOVED DUE TO RUB. UPON DISASSEMBLY, FOUND THE GP STATOR SEAL HAD FRACTURED AT THE FORWARD END OF THE BEARING BORE. THIS TURBINE HAD THE NEW NR 8 BEARING AND RETAINING PLATE INCORPORATED PER CEB 1326. CAUSE OF FAILURE UNKNOWN. 3 U E4CE 19960926002161996092600216GL 1996 9 26 96ZZZX4838 219960729G74126899093 EXCITER BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ENGINE IGNITION FAILED B JSNRK NONE O OTHER ININSP/MAINT 1 NM09204PC648 S895 836679 START CIRCUIT BREAKER OPENED 1-2 SECONDS AFTER START INITIATED. TROUBLESHOT AND FOUND HIGH TENSION SIDE OF IGNITION EXCITER SHORTED OUT. REPLACED EXCITER. THIS AIRCRAFT HAS CONTINUOUS IGNITION SYSTEM WHICH MUST BE OPERATED WHEN FLYING IN FALLING SNOW. THIS SYSTEM OPERATES APPROXIMATELY 25 OF LAST 30 FLIGHT HOURS. PERHAPS TOO MUCH FOR EXCITER UNIT. AIRCRAFT SHOULD INCORPORATE AUTO-RELIGHT INSTEAD. 1G72 3U3 U H3EU E4CE 19960926002191996092600219GL 1996 9 26 96ZZZX4841 219960725G72306871259 TIE BOLT 6890550 BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL COMP ROTOR UNDERSIZE B ALGRK NONE O OTHER ININSP/MAINT 1 SW03107AL 59038 S772 821484 DISCOVERED DEFECT DURING TOLERANCE INSPECTION. THE TIE BOLT SHOULDER UNDER SIZE BY .002 INCH, .440 INCH, BPS .4420 INCH TO .4425 INCH. 1G72 3U3 U H3EU E4CE 19960926002271996092600227GL 1996 9 26 96ZZZX4849 219960719G726123030994 SCAVENGE TUBE 23035179 SKRSKYS76 S76 8143010NE ALLSN 250C 250C30S 03013GL GEARBOX BRACKET BROKEN B ALGRK NONE O OTHER ININSP/MAINT 1 SW03702AL4117 760243 CAE890588S UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY AND SCAVENGE TUBE. FOUND ALIGNMENT BRACKET ON SCAVENGE BROKEN. 1G72 3U3 U H1NE E1GL 19960926002531996092600253GL 1996 9 26 96ZZZX4868 219960910G732323057869 GOVERNOR BELL 206 206B 1181511SW ALLSN 250C 250C20J 03013GL ENGINE MALFUNCTION D O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 NE05221GP863 BR40733 4309 CAE270674 ENGINE RPM BLEEDS OFF. UNABLE TO ADJUST, DROOPS IN-FLIGHT. REPLACED GOVERNOR. 1G71 3U3 U H2SW E4CE 19960926002611996092600261EA 1996 9 26 96ZZZX4876 219960904G7230 ENGINE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA RT ENG COMP FAILED H O OTHER Y ENGINE STOPPAGE CRCRUISE 1 WP07200FV BB299 80637 WHILE IN-FLIGHT, THE RIGHT PROPELLER STOPPED TURNING SUDDENLY. INITIAL INSPECTION REVEALED A FAILURE OF THE COMPRESSOR SECTION OF THE RIGHT ENGINE CAUSING COMPLETE STOPPAGE. ENGINE WAS REMOVED AND SENT TO PRATT AND WHITNEY, CANADA, FOR EVALUATION. 1L72 4T4 T A24CE E4EA 19961003004191996100300419EA 1996 10 3 96ZZZX4930 219960909G8530LW11775 PIN PLUG PIPER PA28 PA28* SO LYC O360 IO360C1C 41514EA ENGINE CYLINDERSFAILED B PB2RK NONE O OTHER ININSP/MAINT 1 GL23 450 CYLINDER REMOVED FROM ENGINE DUE TO ALUMINUM IN OIL SCREEN. FOUND PIN PLUG SHAVED COMPLETELY OFF ON NR 3 CYLINDER ALLOWING PIN TO RUB AGAINST CYLINDER WALL. THESE TYPES OF PIN PLUGS ARE A LOOSE FIT UNLIKE SUPERIOR AIR PARTS, INC., STYLE AND WERE INSTALLED WITH CORRECT LYCOMING PART NUMBER AND FIT. REMAINING PIN PLUGS SHAVED ALSO. 1L71 3O3 O 2A13 1E10 19961003004211996100300421NE 1996 10 3 96ZZZX4932 219960911G8520AT90114 CRANKSHAFT PWA R1340 R1340AN1 52016NE AFT CNTRWEIGHT CRACKED B AEJ4RK NONE O OTHER ININSP/MAINT 1 SW11 1800 900 RE56 18171 ENGINE RECEIVED FOR OVERHAUL DUE TO CRACK IN REAR COUNTERWEIGHT. UPON INSPECTION, FOUND THE REAR COUNTERWEIGHT CRACKED IN THE 4-1/2 ORDER FLYWEIGHT LINER AREA OF CRANKSHAFT. THIS SAME CRANKSHAFT WAS FOUND CRACKED IN THE SAME AREA AT THE PREVIOUS OVERHAUL, 900 HOURS. AT THAT TIME, CRANKSHAFT WAS RETURNED TO AIR TRACTOR TO HAVE SNOW ENGINEERING CO. SL NR 134 C/W. AD NOTE 96-15-02 DID NOT APPLY TO THIS CRANKSHAFT AS IT ALREADY HAD THE LATE PART NUMBERED COUNTERWEIGHTS INSTALLED (AT 90133-1 AND AT 90134-1). 3 R 5E2 19961003004221996100300422EA 1996 10 3 96ZZZX4933 219960224G8520LW17676 CRANKSHAFT BNORM BN2 BN2 1520202EU LYC O540 O540E4C5 41532EA FRONT MAIN CORROSION PITS BP YECRK NONE O OTHER ININSP/MAINT 1 NM09XCDUT L2223640A ENGINE DISASSEMBLED AT O/H, CRANKSHAFT INSPECTED. FRONT MAIN ID FND WITH NUMEROUS CORROSION PITS, APPROX 2.0 INCHES AFT OF FRONT EDGE OF FLANGE PILOT. CRANK ASSY LW 17676, SN V721 (CRANK AND BUSHING SUBASSY LW17622) HAS ALWAYS OPERATED WITH CONSTANT-SPEED PROP AND IS NOT INCLUDED BY MDL OR DESIGN IN INSP REQUIREMENTS OF LYC SB 505A. THIS REPAIR STATION INSPECTS ALL CRANKS FOR INTERNAL CORROSION REGARDLESS OF MDLS AND THIS IS 2ND CONSTANT-SPEED PROP CRANK SUBMITTER HAS SEEN IN PAST MONTH WITH SERIOUS INTERNAL CORROSION. CRANKSHAFT SUGGESTS ENVIRONMENT AND OPERATION ARE KEY FACTORS IN AFFECTING CORROSION AS WELL AS CONSTANT-SPEED/FIXED PITCH APPLICATION. SUBJECT ACFT OPERATED IN MEXICO AND HAWAII. 1H72 3O3 O A17EU E295 19961003004381996100300438EA 1996 10 3 96ZZZX4949 219960806G853075413 PISTON CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA CYLINDERS WRONG PART B PB2RK NONE W INADEQUATE Q C ININSP/MAINT 1 GL2352219250 17274443 L1227539A CUSTOMER COMPLAINED OF LOW STATIC RPM AND SLUGGISH PERFORMANACE OF AIRCRAFT. THIS CORRESPONDED WITH APPROXIMATE TIME OF A TOP OVERHAUL. PROPELLER AND TACHOMETER WERE CHECKED AND WITHIN SPECIFICATIONS. LOG BOOK ENTRIES STATING WORK DONE WAS VERY VAGUE AND NO PARTS LIST PROVIDED. ONE CYLINDER WAS REMOVED TO EXAMINE INTERNAL ENGINE CONDITION AND PARTS INSTALLED. LOW COMPRESSION (150 HP) PISTON P/N LW75413 WERE INSTALLED INSTEAD OF HIGH COMPRESSION (160 HP) PISTON PN 75089. 1H71 3O3 ONT3A12 E274 19961003004471996100300447SO 1996 10 3 96ZZZX4958 219960705G8520631716 CRANKSHAFT CESSNA210 T210M 2073451CE CONT O520 TSIO520H 17040SO PROPELLER FLANGE FAILED B MW2RK NONE O OTHER NRNOT REPORTED 1 GL177398M 21062018 506302 PROPELLER AND CRANKSHAFT PROPELLER FLANGE SEPARATED FROM ENGINE. 1H71 3O3 O 3A21 E8CE 19961003006981996100300698EA 1996 10 3 96ZZZX4988 219960911G7414ES1068291012 MAGNETO D6LN3200 PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA MOUNT FLANGE CHAFED DS K NONE O OTHER ININSP/MAINT 1 NE053587P 112 5032447 318052120 RL263261A LEFT ENGINE WITH LESS THAN 100 HOURS SINCE OVERHAUL HAD NAGGING SMALL LEAK AT MAGNETO, WAS THOUGHT TO BE IMPROPER INSTALLATION, MAG GASKET GETTING DAMAGED. UPON FURTHER INVESTIGATION, FOUND MOUNTING FLANGE WORN AT SPOT WHERE CLAMP GOES. ORDERED NEW BENDIX SHELL PN 10-682001-1, AND FOUND FLANGE TO BE MUCH THICKER. ALSO, BEFORE MAG WAS REMOVED, IT SHOWED SIGNS OF BEING LOOSE. ALSO, FOUND ONE OTHER MAG OF SAME TYPE STARTING TO WEAR AT SAME SPOT PN ES10-382910-12. 1L72 3O3 O A20SO E14EA 19961003006991996100300699EA 1996 10 3 96ZZZX4989 219960911G7414ES10398291012 MAGNETO D6LN3200 PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA MOUNT FLANGE CHAFED D K NONE O OTHER ININSP/MAINT 1 NE053587P 112 R011355010 318052120 RL263261A LEFT ENGINE WITH LESS THAN 100 HOURS SINCE OVERHAUL HAD NAGGING SMALL LEAK AT MAGNETO, WAS THOUGHT TO BE IMPROPER INSTALLATION, MAG GASKET GETTING DAMAGED. UPON FURTHER INVESTIGATION, FOUND MOUNTING FLANGE WORN AT SPOT WHERE CLAMP GOES. ORDERED NEW BENDIX SHELL PN 10-682001-1, AND FOUND FLANGE TO BE MUCH THICKER. ALSO, BEFORE MAG WAS REMOVED, IT SHOWED SIGNS OF BEING LOOSE. ALSO, FOUND ONE OTHER MAG OF SAME TYPE STARTING TO WEAR AT SAME SPOT PN ES10-382910-12. 1L72 3O3 O A20SO E14EA 19961003008151996100300815NE 1996 10 3 AU960055 219960121G7260 GEAR BAG BAE146BAE146100A 1500260EU LYC ALF502ALF502R3A 41580NE T ENG AUX DRIVE SEPARATED W KE NONE ENGINE SHUTDOWN E VIBRATION/BUFFET CRCRUISE 1 AUS LF050235 (AUS) NO3 ENGINE ACCESSORY GEARBOX INPUT BEVEL GEAR SEPARATED FROM THE MOUNTING FLANGE IN THE CASE - THE SLIMSERTS AND BOLTS WERE STILL ATTACHED TO THE GEAR AND BEARING HOUSING - METAL CONTAMINATION OFENGINE OIL SYSTEM 2H74 4F4 FRTA49EU E6NE 19961003008161996100300816NE 1996 10 3 AU960056 219960120G7200 ENGINE BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE ENGINE SYS BIRD STRIKE W K NONE EC VIBRATION/BUFFET F.O.D. TOTAKEOFF 1 AUS (AUS) DURING TAKEOFF THE AIRCRAFT HIT A FLOCK OF GALAHS - ALL ENGINE PARAMETERS REMAINED NORMAL FOLLOWING INGESTION - NO1 ENGINE REQUIRED MAINTENANCE AND NO3 ENGINE WAS REMOVED FOR RECTIFICATION DUE TO MINOR DAMAGE - SEE MDR 96/0176 FOR ADDITIONAL INFORMATION 2H74 4F4 F A49EU E6NE 19961010000991996101000099SO 1996 10 10 96ZZZX4999 219960911G8530646678 SEAL PIPER PA34 PA34220T 7103420SO CONT O360 LTSIO360KB 17025SO INT VALVE STEM FAILED D K NONE O OTHER ININSP/MAINT 1 SW1764TP 129 3447003 320270 DURING AN ANNUAL INSPECTION, THE ENGINE OIL SUCTION SCREEN WAS FOUND TO CONTAIN A SPRING AND FRAGMENTS OF A RUBBER COMPOUND. TELEDYNE CONTINENTAL SB CSB 95-4 PERTAINS TO THIS SUBJECT, BUT IS NOT SUBJECT TO MODELS AFFECTED BY SERIAL NUMBER. THE SB WAS C/W ON BOTH ENGINES, AND EACH SEAL WAS FOUND DEFECTIVE IN EACH ENGINE. SUGGEST REVISING SERIAL NUMBER APPLICABILITY OF SB. 1L72 3O3 O A7SO E9CE 19961010001061996101000106SO 1996 10 10 96ZZZX5007 219960918G7322643085 BRACKET CESSNA210 210M 2073450CE CONT O520 IO520L 17032SO THROTTLE BODY SEPARATED DS K NONE O OTHER ININSP/MAINT 1 SW999489M157 21062081 294714R THROTTLE BODY SUPPORT BRACKET FOUND SEPARATED AT ANNUAL INSPECTION. TIS: 156.5 HOURS, SEPARATED AT SPOT WELDS. 1H71 3O3 O 3A21 E5CE 19961010001221996101000122EA 1996 10 10 96ZZZX5023 219960820G8530 PISTON PIPER PA14 PA14 7101402SO LYC O290 O290D 41506EA NR 3 CYLINDER FAILED DP A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 NM115196H2286 14493 188521 DURING FLIGHT, THE PILOT REPORTED HEARING A SLIGHT KNOCKING IN THE ENGINE AND NOTED A 20 PSI DROP IN OIL PRESSURE. A PRECAUTIONARY LANDING WAS MADE WITHOUT INCIDENT. COMPRESSION CHECK REVEALED NR 3 CYLINDER LOW AT 50/80. CYLINDER REMOVAL REVEALED NR 3 PISTON SKIRT BROKE WITH 2 INCH BY 3 INCH PIECE LOCATED IN OIL SUMP OF ENGINE. 1H71 3O3 O A797 E229 19961010001891996101000189EA 1996 10 10 96ZZZX5038 219960618G854076327 DRIVE GEAR BELL 47 47G5 1181032SW LYC O435 VO435B1A 41516EA ACCY DRIVE BOLTS SHEARED H K NONE O OTHER ININSP/MAINT 1 GL271449W 530 7931 2345331 GEAR AND SHAFT ASSEMBLY IS A TWO-PART GEAR HELD TOGETHER BY SIX .25 INCH BOLTS AND THREE .25 INCH PILOT PINS. IT APPEARS THE SIX .25 INCH BOLTS WERE NOT PROPERLY TORQUED AT OVERHAUL AND THEY SHEARED OFF AT 529.6 HOURS SMOH. 1G71 3O3 O 2H3 E279 19961010001941996101000194NE 1996 10 10 96ZZZX5043 219960912G7250834401 BLADE PWA JT8 JT8D9A 52048NE N2 TURBO T1 FAILURE B SQ5RK NONE E VIBRATION/BUFFET ININSP/MAINT 1 NE03 P674220 ENGINE EXHIBITED HIGH VIBRATION IN SERVICE. DISASSEMBLY INSPECTION REVEALED T-2 BLADE FAILURE AND CONSEQUENTIAL DAMAGE TO THE 2ND, 3RD, AND 4TH AIRFOILS. THE CAUSE OF FAILURE IS UNDER INVESTIGATION. 4 F E2EA 19961010001951996101000195NE 1996 10 10 96ZZZX5044 219960912G7240628748001 T-DUCT PWA JT8 JT8D9A 52048NE COMB CHAMBER FAILURE B SQ5RK NONE O OTHER ININSP/MAINT 1 NE03 P674220 DISASSEMBLY INSPECTION OF ENGINE AFTER HPT BLADE FAILURE REVEALED FAILURE OF THE COMBUSTION CHAMBER SUPPORT/INNER C.C. CASE ATTACHMENT FINGERS. SUSPECT CAUSE OF FAILURE WAS RELATED TO SHORT TERM OPERATION OF MALFUNCTIONING ENGINE AFTER HPT BLADE FAILURE. 4 F E2EA 19961010001971996101000197NE 1996 10 10 96ZZZX5046 219960902G72503115154 NOZZLE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE PT HOUSING OIL PLUGGED A AMASRK NONE O OTHER ININSP/MAINT 1 SW0135YV 9267 1156 UE35 114031 AT DISASSEMBLY, THE NR 3 BEARING WAS FOUND COMPLETELY DESTROYED. IT APPEARS TO BE OIL STARVATION DUE TO THE NR 3 AND NR 4 BEARING OIL NOZZLE BEING PLUGGED. WHEN THE NOZZLE WAS FLOW CHECKED, IT REVEALED 3 OF THE 4 OIL PORTS WERE PLUGGED. THE BLOCKAGE APPEARS TO BE CARBON BUILD-UP INSIDE THE NOZZLE. THE OIL NOZZLE WAS SENT TO PRATT AND WHITNEY FOR INVESTIGATION ALONG WITH THE FAILED NR 3 BEARING REMAINS. 2L72 4T4 TRTA24CE E26NE 19961010002001996101000200NE 1996 10 10 96ZZZX5049 219960913G8530 CYLINDER DOUG DC3 DC3C 3021457WP PWA R1830 R183092 52020NE RT ENG NR 2 CRACKED E EA ENGINE SHUTDOWN UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 SW1159316 950 18986 359283 RIGHT ENGINE STARTED TO RUN ROUGH AND BACKFIRE IN-FLIGHT. ENGINE SHUT DOWN AND AN UNEVENTFUL LANDING WAS MADE. INVESTIGATION FOUND NR 2 CYLINDER CRACKED. CYLINDER WAS REMOVED AND REPLACED WITH A YELLOW TAGGED UNIT. ENGINE GROUND RAN, CHECKED SATISFACTORY. AIRCRAFT RETURNED TO SERVICE. SUSPECT FATIGUE AS CAUSE OF CRACK. 2L72 4R4 R A669 5E4 19961010002031996101000203NE 1996 10 10 96ZZZX5052 219960820G7250 ENGINE PWA JT8 JT8D219 52053NE TURBINE FAILURE B RH2RE ENGINE SHUTDOWN O OTHER NRNOT REPORTED 1 SO19 11588 725447 IN-FLIGHT SHUTDOWN AND ENGINE WAS REMOVED FROM AIRCRAFT DUE TO TURBINE FAILURE. 1ST, 2ND, 3RD, AND 4TH TURBINE BLADES AND 2ND, 3RD, AND 4TH NOZZLE GUIDE VANES SUSTAINED EXTENSIVE DAMAGE. EXACT CAUSE HAS NOT BEEN DETERMINED AT THIS TIME. IT IS SUSPECTED THE 2ND NGV'S MADE CONTACT WITH THE T-2 BLADES CAUSING FAILURE. SB'S 5830, 5840, AND 5891 HAD BEEN PREVIOUSLY C/W AND ASB 5782 WAS CURRENT. 4 F E9NE 19961010003181996101000318CE 1996 10 10 AU960063 119960122G7820075016189 MUFFLER CESSNA185 185B 2072806CE CONT O470 IO470F 17026SO ENG NOISE SUPPRSCRACKED W K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CLCLIMB 1 AUS 76735 (AUS) ENGINE MUFFLER TO OVERBOARD PIPE WELDED JOINT CRACKED - SCORCHINGOF LOWER COWL IN AREA OF CRACK - A NEW EXHAUST MUFFLER HAD BEENFITTED AT THE LAST PERIODIC INSPECTION 8 HOURS PREVIOUS - SUSPECT PIPE CONTACTED COWL IN AREA OF CUTOUT - PERSONNEL/MAINTENANCEERROR 1H71 3O3 O 3A24 3E1 19961010003261996101000326EA 1996 10 10 AU960072 219960122G8530SL134441 PIN BEECH 76 76 1153005CE LYC O360 O360A1G 41514EA ENG NR 1 CYL FRACTURED W K NONE O OTHER ININSP/MAINT 1 AUS 372 L54171A (AUS) ENGINE NO1 PISTON PIN FRACTURED IN CENTRE CAUSING PISTON PIN BOSSTO BREAK EVENLY ON BOTH SIDES OF PISTON - DURING THE 100 HOURLYINSPECTION THE OIL PRESSURE FILTER WAS FOUND TO CONTAIN LARGE AMOUNTS OF STEEL AND ALLOY AND THE ENGINE WAS STRIPPED - DAMAGETO TAPPET BODIES, CAMSHAFT, CONNECTING RODS, CRANKCASE AND CYLINDER SKIRTS - MEF INVESTIGATION FOUND THAT FAILURE WAS CAUSEDBY FATIGUE ORIGINATING FROM CORROSION PITTING ON THE SURFACE OF THE PISTON PIN 1L72 3O3 O A29CE E286 19961010003281996101000328NE 1996 10 10 AU960074 219960116G7230 SEAL BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE NR 2 BEARING LEAKING W K NONE B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 AUS LF05896A (AUS) NO3 ENGINE NO2 BEARING PACK SEAL FLATTENED AND LEAKING 2H74 4F4 F A49EU E6NE 19961010003291996101000329CE 1996 10 10 AU960075 119960119G2730040010730 CONTROL CABLE 040010728 CESSNA150 A150L 2071828CE CONT O200 O200A 17020SO ELEVATOR CONTROLCORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 0 (AUS) ELEVATOR REAR TRIM CABLES PN 0400107-28 AND PN 0400107-30 SEVERELY RUSTED AND FRAYED - 75% OF STRANDS BROKEN - PROBLEM SHOULD HAVE BEEN FOUND DURING PERIODIC INSPECTIONS - PERSONEL/MAINTENANCE ERROR 1H71 3O3 O 3A19 E252 19961010003421996101000342SO 1996 10 10 AU960089 219960112G8540537721 BEARING CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY R ENGINE REAR SEDISINTEGRATED W K NONE O OTHER ININSP/MAINT 1 AUS 276338R (AUS) CRANKCASE STARTER ADAPTER GEAR SHAFT NEEDLE BEARING DISINTEGRATED- CRANKCASE DAMAGED - OTHER COMPONENTS DAMAGED WERE OIL PUMP HOUSING, IMPELLERS, ENGINE BEARINGS, STARTER ADAPTER KIT SHAFT PNO EQ6642 AND CRANKSHAFT GEAR - METAL CONTAMINATION OF OILSYSTEM - ENGINE HAD BEEN MODIFIED AND COMPLIED WITH AD/CON/71 1L72 3O3 O A25CE E7CE 19961010003431996101000343CE 1996 10 10 AU960090 119960122G7921635996 OIL COOLER CONT IO520M CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MCAULY AC,ENG OIL DIST LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 AUS 786 565768 LH565768 (AUS) ENGINE OIL COOLER CORE LEAKING - LOSS OF 5 QUARTS OF OIL 1L72 3O3 O 3A10 E5CE 19961010003441996101000344NE 1996 10 10 AU960092 219960123G7260 BEARING DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE T ENG AUX DRIVE FAILED W K NONE O OTHER ININSP/MAINT 1 AUS PCE120282 (AUS) LH ENGINE ACCESSORY DRIVE SHAFT UPPER BEARING FAILED 2H72 4T4 TRTA13NM E20NE 19961010003461996101000346GL 1996 10 10 AU960094 319960123G6111FC84756 BLADE HARTZL BHCC2YF2 BEECH 55 E55 1152732CE CONT O520 IO520C 17032SO HARTZLHCC2Y BHCC2YF2 GL PROPELLER ASSY SDISTORTED W K NONE O OTHER ININSP/MAINT 1 AUS 80 AN694 AN694 (AUS) BOTH PROPELLER BLADES BENT AND TWISTED - NO IMPACT DAMAGE VISIBLE- SUSPECT DAMAGE CAUSED BY MISUSE OF BLADE BATS 1L72 3O3 O 3A16 E5CE 5 CP920 19961010003491996101000349WP 1996 10 10 AU960097 219960109G7261300143619AA1150CFILTER GULSTM690TP 690A 0141722SW GARRTTTPE331TPE3315 01514WP T ENGINE OIL SYSDISINTEGRATED W K NONE O OTHER ININSP/MAINT 1 AUS P0684M (AUS) LH ENGINE OIL FILTER ELEMENT DISINTEGRATING - METAL FROM FILTER ELEMENT CASING CONTAMINATED ENGINE OIL SYSTEM 1H72 3T4 T 2A4 E4WE 19961010003531996101000353EU 1996 10 10 AU960101 219960128G73218063210 FCU CFMINTCFM56 CFM563C 13802EU ENG,FUEL CONTROLFAULTY W K NONE R PARTIAL RPM/PWR LOSS TOTAKEOFF 1 AUS WYG76817 856531 (AUS) NO1 ENGINE FUEL CONTROL UNIT FAULTY - INVESTIGATION FOUND WEAR INTHE CDP PILOT BUSHING, NEEDLE BEARINGS AND BUSHING AND CDP LEVER ASSEMBLY 4 F E21EU 19961010003541996101000354EA 1996 10 10 AU960102 219960119G732260260 BUSHING FACET MA45PA CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA MCAULY ENG,FUEL CONTROLWORN W K NONE O OTHER ININSP/MAINT 1 AUS CK817203 (AUS) CARBURETTOR THROTTLE SHAFT PNO 13-1521 AND BUSHINGS PNO 60-260 HAD EXCESSIVE CLEARANCE DUE TO WEAR IN THE BUSHINGS WHICH WERE WORN THROUGH CAUSING WEAR IN THE BODY OF THE CARBURETTOR AS WELL - ACCELERATOR PUMP LEVER PNO 155-226 AND CONNECTING ROD PNO17-372 WERE ALSO EXCESSIVELY WORN - PERSONNEL/MAINTENANCE ERROR 1H71 3O3 ONT3A12 E274 19961010003561996101000356EU 1996 10 10 AU960105 119960129G2821 GASCOLATOR BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA HARTZL ENG,FUEL DIST SYLEAKING W K NONE K FLUID LOSS TOTAKEOFF 1 AUS (AUS) RH ENGINE GASCOLATOR LOOSE DUE TO RETAINER ARM MOVING AND ALLOWING BOWL TO MOVE SIDEWAYS - FUEL LEAKING FROM GASCOLATOR -SUSPECT CAUSED BY OVERTORQUEING OF THE RETAINER ARM CAUSING DISTORTION OF THE ARM 1H72 3O3 O A17EU 1E4 19961010003581996101000358NE 1996 10 10 AU960108 219960120G7321F4305ANSSN06 FCU LYC ALF502ALF502R5 41580NE ENG,FUEL CONTROLFAULTY W K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 AUS F4305ANSS LF05589A (AUS) NO1 ENGINE FUEL CONTROL UNIT FAULTY 4 F E6NE 19961010003601996101000360NE 1996 10 10 AU960110 219960120G7261AL366 PUMP BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE TURBINE ENGINE OFAILED W K NONE K FLUID LOSS DEDESCENT 1 AUS AL366 LF05582A (AUS) NO3 ENGINE DRIVEN OIL PUMP FAILED DUE TO GEAR WEAR AND EROSION OFTHE HOUSING GEAR POCKETS - ALUMINIUM METAL CONTAMINATION OF OILFILTER 2H74 4F4 F A49EU E6NE 19961010003751996101000375WP 1996 10 10 96ZZZX5067 219960901G7310300297719 MANIFOLD AMD FALC20FALCON200 2730150EU GARRTTATF3 ATF36A4 29002WP LT ENGINE CRACKED B GQRRK NONE O OTHER ININSP/MAINT 1 SW05200WY P426C P21122 509 FUEL MANIFOLD SHROUD WAS FOUND CRACKED. REPLACED WITH SERVICEABLE UNIT. UNKNOWN IF FUEL WAS LEAKING FROM MANIFOLD. AFTT: 3,358 HOURS. LE TT: 3,653 HOURS. TC LE: 2,655. 2L72 4F4 FRTA7EU E7WE 19961010003761996101000376WP 1996 10 10 96ZZZX5068 219960901G7240300174517 LINER AMD FALC20FALCON200 2730150EU GARRTTATF3 ATF36A4 29002WP COMB LINER CRACKED B GQRRK NONE O OTHER ININSP/MAINT 1 SW05200WY 509 P21122 DURING ROUTINE 600 HOUR INSPECTION, DISCOVERED SEVERAL COMBUSTION LINER CRACKS OUTSIDE OF MM LIMITATIONS. REMOVED AND REPLACED LINER. AFTT: 3,358 HOURS. LE TT: 3,653 HOURS. TC: 2,655. 2L72 4F4 FRTA7EU E7WE 19961010003771996101000377WP 1996 10 10 96ZZZX5069 219960901G725030031522 MID FRAME AMD FALC20FALCON200 2730150EU GARRTTATF3 ATF36A4 29002WP LT ENGINE CERAMIC FLAKING B GQRRK NONE O OTHER ININSP/MAINT 1 SW05200WY 5P3930 509 P21122 BLADE TIP SEALING CERAMIC FLAKED OFF 30 TO 40 PERCENT OF AREA. NO DETECTABLE RESULTING DISCREPANCY. DISCOVERED DURING SCHEDULED 600 HOUR INSPECTION BORESCOPE INSPECTION. NEW INNER MID-FRAME ASSY INSTALLED TO CORRECT PROBLEM. AFTT: 3,358 HOURS. LE TT: 3,653 HOURS. TC: 2,655. 2L72 4F4 FRTA7EU E7WE 19961010003871996101000387NE 1996 10 10 96ZZZX5079 219960827G72107757582 BEARING HAMSTD 7757582 SAAB SF340 SF340A 7850100EU GE CT7TP CT79B 30030NE GC 49 GEARCASE SPALLED BSA K NONE O OTHER ININSP/MAINT 1 SW99 11502 8137 GEE785540 DISASSEMBLY OF GEARCASE REVEALED THE AFT ROLLER BEARING ASSEMBLY SHOWED HEAVY SPALLING OF ALL BEARING COMPONENTS (775758-2) (ITEM 10, FIG 7, AND ITEM 110, FIG 8 IPL). 2L72 4T4 TRTA52EU E8NE 19961010003881996101000388NE 1996 10 10 96ZZZX5080 219960916G72107757651 ROLLER BEARING HAMSTD 7758001 SAAB SF340 SF340A 7850100EU GE CT7TP CT79B 30030NE GC 49 GEARCASE CAGE BROKEN A ASI3RK NONE O OTHER ININSP/MAINT 1 NE03 13095 5237 GEE367358 DISASSEMBLY OF GEARCASE REVEALED THE FORWARD INPUT ROLLER BEARING CAGE WAS BROKEN (775765-1, FIG 5, ITEM 180 OF 72-11-02 PARTS LIST). ALSO,THE INPUT PINION GEAR HAS STARTED TO HAVE SEVERE TOOTH BREAK DOWN (775755-3, FIG 3, ITEM 1558). BOTH IDLER GEARS ALSO HAD TOOTH WEAR. LT IDLER SN 1C6411358A (775753-5, FIG 8-40B). RT IDLER SN 1C64411268A (775754-5, FIG 8-75B).` 2L72 4T4 TRTA52EU E8NE 19961010004161996101000416SW 1996 10 10 CA960131014 119960123G65102060403389 HANGER ASSEMBLY BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL LUG AREA WORN W K NONE O OTHER ININSP/MAINT 1 CA CAE802381 (CAN)WHEN CARRYING OUT ASB 206-95-86 REV.B, INSPECTION OF TAIL ROTOR DRIVESHAFT HANGER ASSEMBLY AND SPRING. A VISIBLE WEAR STEP IN THE FILLET RADIUS OF THE HANGER LUG WAS FOUND. 1G71 3U3 U H2SW E4CE 19961010004221996101000422NM 1996 10 10 CA960202007 119960126G243503600923 BEARING LUCAS 23088002A DHAV DHC8 DHC8* NM PWA 120 PW120 NE GEN DRIVE END FAILED W K NONE O OTHER ININSP/MAINT 1 CA 1021 1284 120896 (CAN)DRIVE END BEARING FAILED ON STARTER GENERATOR. 2H72 4T4 TRTA13NM E20NE 19961010004231996101000423EU 1996 10 10 CA960202008 119960122G82002220FG TANK UNIT BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU MENTHENOL INTERMITTENT W K NONE O OTHER ININSP/MAINT 1 CA 14902 (CAN)WATER MENTHENOL TANK DOES NOT INDICATE CONTENTS OF TANK IN THE 20-27 RANGE. 2L72 3T4 T A24EU A196 19961010004331996101000433 1996 10 10 CA960202019 419960119G2360211SC1 STATIC WICK CHELTON EMB 120 EMB120RT SO PWA 118 PW118 NE HAMSTD14RF 14RF9 NE WINGS & ELEV CORRODED W K NONE O OTHER DEDESCENT 1 CA PCE115667 880130 (CAN)ON DESCENT IN LIGHT RAIN, AIRCRAFT HAD RADIO RECEPTION FAILURE, BUT COMMUNICATION TRANSMISSION WAS NORMAL. 8 STATIC WICKS HAD TO BE REPLACED. 2 ON EACH WING AND 2 ON EACH ELEVATOR. RESISTANCE CHECKS T O BE INCREASED TO 1200 HOURS FROM 4000. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 19961010004691996101000469EA 1996 10 10 96ZZZX5112 219960920G8520 LIFTER PIPER PA28 PA28151 7102805SO LYC O320 O320E3D 41508EA CYL NR 4 LOBE FAILED B CB1RK NONE O OTHER ININSP/MAINT 1 GL05431252243 287415430 L3796827A LIFTER FAILED AT NR 4 CYLINDER CAM LOBE. LOBE DAMAGED AND PEENED ON CAMSHAFT. CRANKSHAFT PILOT END, BENT OVER LIMITS. FLANGE ON CRANKSHAFT OUT OF LIMITS ON RUN-OUT. FINDINGS RESULT OF ENGINE, TIME EXPIRED INSPECTION. 1L71 3O3 O 2A13 E274 19961010004721996101000472EA 1996 10 10 96ZZZX5115 219960903G7310S1236C30420 HOSE CESSNA177 177RG 2073709CE LYC O360 IO360A1B6 41514EA FLOW DIVIDER DEFECTIVE D A A UNSCHED LANDING JK WARNING INDICATION FLUID LOSS CLCLIMB 1 EA07520 299 177RG1164 PILOT REPORTED A TOTAL DROP IN FUEL PRESSURE DURING CLIMB-OUT LANDING WITHOUT INCIDENT. UPON INSPECTION, FOUND FUEL PRESSURE HOSE FROM FIREWALL TO FLOW DIVIDER LEAKING PROFUSELY WHERE THE RE-USABLE SOCKET THREADS TO HOSE. THIS HOSE WAS PURCHASED FROM CESSNA ON 8-93 AND INSTALLED. THE METAL IDENTIFICATION BAND HAD AN ASSEMBLY DATE OF 4-85. RECOMMEND CESSNA REVIEW THEIR POLICY ON SHELF LIFE OF HOSES WHICH AT PRESENT IS CONTRARY TO THE HOSE MANUFACTURER. SUBMITTER STATED THIS SITUATION COULD HAVE BEEN CATASTROPHIC. 1H71 3O3 O A20CE 1E10 19961010008501996101000850EA 1996 10 10 96ZZZX5130 219960828G7310LW120980100 LINE PIPER PA32 PA32RT300T 7103216SO LYC O540 TIO540S1AD 41532EA NR 3 FUEL INJ FAILED DL K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 GL21396031767 32R7887119 1554961A AIRCRAFT OPERATOR REPORTED ROUGH RUNNING ENGINE. OWNER REMOVED TOP COWL AND FOUND NR 3 FUEL INJECTION LINE COMPLETELY BROKEN OFF AT AND JUST BEHIND WHERE NUT AND FITTING ARE WELDED TO LINE. FURTHER INSPECTION REVEALED NR 4 CYLINDER OIL RETURN TUBE CHAFED THROUGH BY FUEL INJECTION LINE AT THIS AREA (VIBRATING). OIL RETURN LINE AND FUEL INJECTION LINE BOTH REPLACED WITH NEW PARTS. FUEL INJECTION T-FITTING ON 2ND, 4TH, AND 6TH BANK OF CYLINDERS WAS FOUND LOOSE AT THIS TIME AND RESECURED. 1L71 3O3 O A3SO E14EA 19961010008611996101000861NE 1996 10 10 96ZZZX5141 219960923G724097861798P02 SCREW GE CFM56 CFM563B1 13802NE COMBUSTION SECT FAILED BL LY2RCD ABORTED TAKEOFF RETURN TO BLOCK J WARNING INDICATION TOTAKEOFF 1 CE07 10390 724982 ABORTED TAKEOFF DUE TO HIGH EGT. INVESIGATION FOUND DAMAGE TO HPTR BLADES. FOUND COMBUSTION SECTION SCREWS HAD BEEN REUSED AND FAILED. MANUAL CALLS FOR CENTER PUNCHING SCREW LEAKS TO AID IN REMOVAL OF THE SCREW. MANUAL CALLS FOR SCREWS TO BE DISCARDED AFTER REMOVAL. IN THIS CASE TWO SCREWS WERE REINSTALLED. 4 F E2GL 19961010008811996101000881NE 1996 10 10 96ZZZX5161 219960925G7320 CONTROL CABLE SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE ANTICIPATOR BINDING D O OTHER O OTHER APAPPROACH 1 SO1754EW 1936 949 ON FINAL APPROACH, COLLECTIVE WAS LOWERED TO START A DESCENT, ROTOR RPM OBSERVED HIGHER THAN NORMAL. THE COLLECTIVE WAS RAISED TO RESTORE ROTOR RPM TO NORMAL, BUT NO CHANGE WAS OBSERVED. PER THE MANUFACTURER'S FLIGHT MANUAL, THE FUEL FLOW CONTROL LEVER WAS USED TO SLOW RPM. THIS RESULTED IN AN OPPOSITE PROBLEM IN SLOWING THE RPM TOO MUCH. UPON LANDING, AIRCRAFT WAS GROUNDED UNTIL MAINTENANCE COULD LOOK AT THE AIRCRAFT, THEY DISCOVERED THE CABLE THAT ATTACHES TO THE FFC WAS BINDING, AND REPLACED THE CABLE. 1G71 3U3 U H9EU E19EU 19961017001571996101700157CE 1996 10 17 AU960117 119960129G792275944 NUT LYC VERNATHERM CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA AC ENG OIL DIST LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS 471 (AUS) ENGINE THERMOSTATIC OIL COOLER BYPASS VALVE (VERNATHERM) NUT LOOSE - FOUND DURING INSPECTION IAW AD/LYC/78 1H71 3O3 ONT3A19 E223 19961017001621996101700162CE 1996 10 17 AU960127 119960103G5330221300011 SKIN CESSNA 22130005 CESSNA182 R182 2072734CE LYC O540 O540J3C5 41532EA EXT PLATES/SKIN CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AIRCRAFT SKIN CORRODED UNDER SOUND INSULATION COMPOUND - LOWER LHFORWARD BELLY SKIN ALSO CORRODED - SKIN PNO 2213000-11, PNO2213000-5 AND PNO 2213000-6 - FOUND DURING INSPECTION IAW AD/C180/75 1H71 3O3 ORT3A13 E295 19961017001631996101700163WP 1996 10 17 AU960128 219960126G723031011607 SEAL GARRTTTPE331TPE33110U 01514WP T ENG CMPRSR/FANLEAKING W K NONE OJ OTHER WARNING INDICATION CRCRUISE 1 AUS 1816 (AUS) RH ENGINE COMPRESSOR SEAL LEAKING 4 T E4WE 19961017001671996101700167EU 1996 10 17 AU960139 119960201G7110365A24100503 COWLING 36010A AEROSPSA365 SA365C 8680667EU TMECA ARRIELARRIEL1A 60030NE NAC PYLON FAIRNGDAMAGED W K NONE D INFLIGHT SEPARATION CRCRUISE 1 AUS (AUS) TRANSMISSION RH COWLING FORWARD LATCH ASSEMBLY PNO 360-10A LOCKING PIN SHEARED ALLOWING FORWARD EDGE OF COWL TO LIFT ANDEVENTUALLY SEPARATE FROM AIRCRAFT 1G72 3U3 U H10EU E19EU 19961017001681996101700168EU 1996 10 17 AU960140 219960111G8520 BEARING RROYCEGIPSY GIPSY30* 20005EU R ENGINE POWER SFAILED W K NONE O OTHER CLCLIMB 1 AUS 1289 66850 (AUS) LH ENGINE OIL FILTER METAL CONTAMINATION - SUSPECT FAILED MAIN BEARING 3 I E294 19961017001691996101700169EA 1996 10 17 AU960145 219960209G852075060 BOLT LYC CONROD PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA R ENGINE POWER SUNAPPROVED PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS L1080840 (AUS) NO2 CYLINDER CONNECTING ROD PNO 74502 BOLT INCORRECT PART - BOLT PNO 75060/1 FITTED - CORRECT PNO 74644 - INCORRECT BOLT IS LONGERTHAN THE CORRECT ONE - IPC IS UNCLEAR ON CORRECT PART NUMBER BOLTTO BE FITTED - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 1L72 3O3 O 1A10 1E4 19961017001701996101700170SO 1996 10 17 AU960146 119960131G321078717O2 STUD PIPER ARROW PIPER PA28 PA28RT201 7102818SO LYC O360 IO360C1C6 41514EA MAIN GEAR SYS CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 3840 (AUS) RH MAIN LANDING GEAR SIDE BRACE STUD CRACKED IN AREA UNDER SHOULDER - FOUND DURING INSPECTION IAW AD/PA28/91 1L71 3O3 O 2A13 1E10 19961017001711996101700171EA 1996 10 17 AU960147 219960126G7310D2310 GASKET ROMEC FUELPUMP GULSTM680 680FLP 0141610SW LYC O720 IO720B1B 41546EA ENG,FUEL DIST SYLEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 AUS D2310 L75754 (AUS) ENGINE DRIVEN FUEL PUMP RELIEF VALVE GASKET LEAKING 1H72 3O3 O 2A4 1E15 19961017001761996101700176GL 1996 10 17 AU960152 219960202G72306871443 BLADE ALLSN 250C18B BELL 47 47G3B1 1181028SW ALLSN 250C 250C18 03011GL T ENG CMPRSR/FANFAILED W O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TOTAKEOFF 1 AUS 1030 CAC22003B 800621B (AUS) COMPRESSOR NO2/3 ROTOR ASSEMBLY BLADE FAILED - BLADES EXITED THROUGH BOTH COMPRESSOR CASE HALVES - FURTHER DAMAGE TO TURBINESECTION DUE TO FOD AND OVERTEMPERATURE - AIRCRAFT IS A SOLOY TURBINE ENGINE MODIFICATION ALLISON 250C18B POWERED BELL 47G3B1 1G71 3O3 U 2H3 E4CE 19961017001771996101700177GL 1996 10 17 AU960153 319960207G6111787699 BLADE MCAULY 3AF32C87N CESSNA310 310R 2074245CE CONT O520 TSIO520M 17040SO MCAULY3AF32C3AF32C87 GL PROPELLER ASSY SLOOSE W K NONE E VIBRATION/BUFFET TOTAKEOFF 1 AUS 271 787699 787699 (AUS) PROPELLER BLADE LOOSE - BLADE COULD BE ROTATED ABOUT 50.8MM (2IN)FROM FINE PITCH TO FEATHER - INVESTIGATION FOUND BLADE ACTUATING PIN FAILURE IN AREA ABOVE THREAD - MENTION WAS ALSO MADE OF FINDING FLAKES OF CHROME PLATING AND EVIDENCE OF SCUFFING 1L72 3O3 O 3A10 E8CE 5 CP22EA 19961017001801996101700180SO 1996 10 17 AU960157 219960131G8520 CRANKCASE BEECH 58 58 1152740CE CONT O520 IO520C 17032SO MCAULY3AF34C3AF34C502 GL R ENGINE POWER SCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1665 565559 (AUS) CRANKCASE CRACKED IN AREA OF NO4 CYLINDER - CRACK RADIATES FORWARD FROM THE FORWARD OIL FILTER STUD - CRACK LENGTH 135MM(5.314IN) - AIRCRAFT IS USED FOR TRAINING PURPOSES 1L72 3O3 O 3A16 E5CE 5 CP22EA 19961017001811996101700181SO 1996 10 17 AU960158 119960205G7170 PIPE PIPER PA28 PA28RT201 7102818SO LYC O360 IO360C1C6 41514EA ENG FLUID DRAIN/INCORRECT FIT W K NONE WK INADEQUATE Q C FLUID LOSS ININSP/MAINT 1 AUS L2006651A (AUS) ENGINE INTAKE FUEL DRAIN LINE INCORRECTLY FITTED - LINE WAS DOUBLED UP INTO A KINK PREVENTING FUEL FROM DRAINING - FUELLEAKED INSIDE COWLING - PERSONNEL/MAINTENANCE ERROR 1L71 3O3 O 2A13 1E10 19961017001851996101700185EA 1996 10 17 AU960164 219960205G7421RME38E SPARK PLUG CHAMPION REM38E PIPER PA28 PA28RT201 7102818SO LYC O360 IO360C1C6 41514EA ENG,IGNITN DISTRFAULTY W K NONE O OTHER ININSP/MAINT 1 AUS IO360CIC6 (AUS) SPARK PLUGS (6OFF) FAULTY - CENTRE ELECTRODE WAS BEYOND LIMITS FOR RECONDITIONING - NO1 CYLINDER TOP SPARK PLUG HAD TWO COPPERWASHERS FITTED - NO1 CYLINDER LOWER SPARK PLUG HAD CORE LEAKAGE -ENGINE HAD COMPLETED ONLY 38 HOURS SINCE OVERHAUL -PERSONNEL/MAINTENANCE ERROR 1L71 3O3 O 2A13 1E10 19961017001881996101700188GL 1996 10 17 AU960167 319960123G6111FC84756 BLADE HARTZL HCC2YF2CHUF BEECH 55 E55 1152732CE CONT O520 IO520C 17032SO HARTZLHCC2Y HCC2YF2 GL PROPELLER ASSY SDAMAGED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 80 AN694 AN694 (AUS) PROPELLER BLADE CONTAINED TOOLING MARK DAMAGE IN BALANCE CAVITY -SUSPECT CAUSED DURING REMOVAL OF BALANCE LEAD - BLADE SNO C49080 1L72 3O3 O 3A16 E5CE 5 CP920 19961017001901996101700190NE 1996 10 17 AU960170 219960202G7230701509 DISC BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE T ENG CMPRSR/FANCORRODED W K NONE O OTHER ININSP/MAINT 1 AUS P76768 687560 (AUS) ENGINE 9TH STAGE HIGH PRESSURE COMPRESSOR DISC CONTAINED CORROSION PITTING IN THE BLADE SLOT PRESSURE FACES AND BLADE SLOTSIDES IN EXCESS OF LIMITS - FOUND DURING INSPECTION IAW PWA SB 6038 AND AD/JT8D/29 - ENGINE HAD BEEN FITTED TO A LOW UTILISATIONAIRCRAFT 2L73 4F4 FRTA3WE E2EA 19961017001931996101700193SO 1996 10 17 AU960174 119960127G7922 NUT LYC VERNATHERM PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA AC,ENG OIL DIST LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS L566061A (AUS) ENGINE THERMOSTATIC OIL COOLER BYPASS VALVE (VERNA