19970116004341997011600434GL 1997 1 16 HEEA978817 219970107G723023039791 SPLINE ADAPTER 6890550 ALLSN 250C 250C20B 03013GL ENGINE BELOW SPEC E HEEAK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAC24241 CAE270204 RECEIVING INSPECTION REVEALED: EXTERNAL SPLINES BELOW MANUFACTURERS SPECS ON ADAPTER. INSTALLED A NEW ADAPTER. 3 U E4CE 19970130001411997013000141EA 1997 1 30 97ZZZX436 219970103G732295351610 O-RING BENDIX RSA5AD1 MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA FUEL SERVO CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 NE011980J724 724 241000 DURING ANNUAL INSPECTION, A PRESSURE TEST OF THE ENGINE FUEL SYSTEM REVEALED A LEAK AT THE MIXTURE CONTROL SHAFT WHICH DRIPPED ON THE MUFFLER BELOW . REPLACEMENT OF O - RINGS 953516-10 AND 951401 CURED THE LEAK. SUBMITTER SUGGESTED CLOSE INSPECTION AND PRESSURE TESTING SHOULD EASILY FIND THIS PROBLEM. 1L71 3O3 O 2A3 1E10 19970306004161997030600416GL 1997 3 6 HEEA979151 219970226G72606877171 HOUSING ALLSN 250C 250C20B 03013GL GR BOX BELOW SPECS E HEEAK NONE O OTHER ININSP/MAINT 1 SW03 GEAR BOX HOUSING RECEIVING INSPECTION REVEALED: MEASURED .0025 BELOW SPECS (3.8490 MIN) ON GEARBOX HOUSING COMPRESSOR MOUNT STUD AS MARKED. 3 U E4CE 19970306006981997030600698GL 1997 3 6 97ZZZX921 219970210G7323369A70023 ACTUATOR HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GOV DEFECTIVE B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R8265 1151D DURING RUN-UP IT WAS DISCOVERED THE GOV NEEDED CONSTANT ADJUSTMENT UP AND DOWN WITH THE TRIM MOTOR. IT WAS FOUND THAT THE TRIM MOTOR HAS SOME INTERNAL SLOP. REPLACED TRIM MOTOR. 1G71 3U3 U H3WE E4CE 19970306006991997030600699GL 1997 3 6 97ZZZX922 219970210G73106844169 LINE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE FCU CHAFED B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R 1151D CAE832750 DURING RE-ASSEMBLY OF THE ENGINE, IT WAS FOUND THAT THE FUEL LINE FROM FCU TO THE CHECK VALVE WAS CONTACTING ANOTHER LINE. NORMALLY, THIS INDICATES IT IS INSTALLED BACKWARDS, BUT IN THIS CASE, IT HIT BOTH WAYS. NO PART NUMBER WAS FOUND ON THE TUBE, AND A NEW TUBE RECTIFIED THE PROBLEM. SUSPECT IT HAD BEEN A 'FIELD FIX' SOME TIME PAST. 1G71 3U3 U H3WE E4CE 19970306008421997030600842GL 1997 3 6 97ZZZX954 219970129G7321252464429 FUEL CONTROL BENDIX BELL 206 206B3 1181506SW ALLSN 250C 250C20J 03013GL ENGINE STUCK B OG5RR AUTOROTATION R PARTIAL RPM/PWR LOSS LDLANDING 1 GL21188ND 16 319777 3992 CAE270376 DURING AUTOROTATION FLIGHT TRAINING, INSTRUCTER ROLLED THROTTLE TO IDLE. N1 WENT PAST 60 PERCENT N1 IDLE SPEED TO 52 PERCENT. FOUND PR/PG SHAFT NOT WORKING. SHAFT WOULD NOT FOLLOW CAM ON SHAFT TO ALLOW PR/PG VALVE TO OPEN OR PREVENT UNDERSHOOTING IDLE. RPM OF 60 PERCENT N1. SUSPECT RUSHING AROUND SHAFT CAME OUT OF POSITION AND ALLOWED CAM TO BEND SHAFT IN FUEL CONTROL. 1G71 3U3 U H2SW E4CE 19970306008451997030600845GL 1997 3 6 97ZZZX957 219970211G72506898735 TURBINE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE NOZZLE DAMAGE D A K NONE O OTHER ININSP/MAINT 1 SO0140AP 8066 1098 37363 825D 833309 GROUND PERSONNEL NOTICED NOISE COMING FROM ENGINE DURING START-UP AND SHUT DOWN BETWEEN 20 PERCENT AND 60 PERCENT N1 RPM. THE ENGINE RAN NORMAL AT GROUND IDLE. UPON DISASSEMBLY OF THE ENGINE, THE CAUSE OF THE NOISE WAS FOUND TO BE EXCESSIVE HEAT DAMAGE TO THE NR 1 TURBINE NOZZLE AND NR 1 TURBINE WHEEL ALONG WITH SUBSEQUENT DAMAGE TO THE REMAINING TURBINE. SUBMITTER SUGGESTED CAUSE WAS A DEFECTIVE FUEL NOZZLE SINCE NO REPORTS OF A HOT START WERE RECORDED. 1G71 3U3 U H3WE E4CE 19970306008481997030600848SO 1997 3 6 97ZZZX960 219970211G8520 CRANKCASE CONT O360 IO360C 17025SO NR 2 CYL BASE CRACKED D K NONE W INADEQUATE Q C ININSP/MAINT 1 CE01 060656R FACTORY REMANUFACTURED ENGINE: OPENED CRATE TO INSTALL ENGINE. FOUND CRACK IN CRANKCASE REAR NR 2 TOP CYLINDER BASE STUD. CRACK APPROXIMATELY .6250 INCH LONG. ZERO TIME ON ENGINE. 3 O E1CE 19970306008521997030600852EA 1997 3 6 97ZZZX964 219970129G8530ECLW12988CP CYLINDER ENSTRMF28 F28C 3300407GL LYC O360 HIO360E1AD 41514EA NR 2 FAILED HL GWHVA UNSCHED LANDING A FLAME/FIRE NRNOT REPORTED 1 SW0951774568 06 440 L1970051A ON A NIGHT TRAINING FLIGHT, NR 2 CYLINDER BLEW OUT ABOVE THE EXHAUST PORT. THE BLOW-OUT STEERED THE NR 4 CYLINDER OIL LINE AND STARTED A FIRE. AN EMERGENCY LANDING WAS ACCOMPLISHED WITHOUT INJURY TO THE INSTRUCTOR OR THE STUDENT, HOWEVER, THE AIRCRAFT WAS COMPLETELY DESTROYED BY FIRE. SUBMITTER STATES HAVE HAD TWO OTHER SIMILAR FAILURES OF THESE CERMICROME CYLINDERS ON THIS ENGINE IN THE LAST 127 HOURS. (TOTAL OF 3.) 1G71 3O3 O H1CE 1E10 19970306008551997030600855SO 1997 3 6 97ZZZX967 219970220G8530 CYLINDER BEECH 35 V35TC 1151540CE CONT O520 TSIO520DB 17040SO ENGINE WEAR B CS3RK NONE O OTHER ININSP/MAINT 1 WP17222TB361 D8242 505012 DURING 100-HOUR INSPECTION, COMPRESSION CHECK REVEALED ALL SIX CYLINDERS LOW. TOTAL TIME 360.5 HOURS SINCE RAM CONVERSION TO STC SE3631SW ON ALL CYLINDERS. SUSPECT OVERLEANING. 1L71 3O3 O 3A15 E8CE 19970306008561997030600856SO 1997 3 6 97ZZZX968 219970115G7310330996F80240 LINE BEECH 36 B36TC 1151609CE CONT O520 TSIO520UB 17040SO ENGINE FUEL LEAKING D O OTHER O OTHER APAPPROACH 1 GL03317C 218 EA574 527213 ENGINE WOULD NOT IDLE ON FINAL. PRESSURE CHECKED HOSE AND FOUND SEVERAL LEAKS. (NOT VISIBLE WITH FIRE SLEEVE ON). HOSE DATE 4TH QUARTER '94. A/C AIRWORTHINESS 2-95. 1L71 3O3 O 3A15 E8CE 19970306008631997030600863SO 1997 3 6 97ZZZX975 219970220G8530 VALVE CESSNA210 T210M 2073451CE CONT O520 TSIO520R 17040SO NR 1 CYL WORN B CS3RK NONE O OTHER ININSP/MAINT 1 WP176457B825 21032768 269711R DURING 100 HOUR INSPECTION, FOUND NR 1 CYLINDER READING 20/80 DURING COMPRESSION CHECK, ALSO, ALL OTHER CYLINDERS IN LOW SIXTIES. TOTAL TIME 824.8 HOURS SINCE TCM. ZERO TIME REBUILD. 1H71 3O3 O 3A21 E8CE 19970306008641997030600864SO 1997 3 6 97ZZZX976 219970205G8530649543A1 VALVE CESSNA150 150K 2071822CE CONT O200 O200A 17020SO EXH NR 2 FAILED D O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 EA216474G1270 15071974 285158R DURING FLIGHT, PILOT EXPERIENCED ROUGH RUNNING AND POWER LOSS UPON INSPECTION OF CYLINDERS. FOUND NO COMPRESSION NR 2 CYLINDER. REMOVED CYLINDER, FOUND PISTON HEAD DAMAGED AND EXHAUST VALVE HEAD MISSING. VALVE STEM SEIZED IN GUIDE. SUBMITTER STATED NEEDS BETTER OILING OF VALVE STEM FOR EXHAUST VALVE. 1H71 3O3 O 3A19 E252 19970306008651997030600865SO 1997 3 6 97ZZZX977 219970220G8530 CYLINDER CESSNA210 P210N 2073454CE CONT O520 TSIO520P 17040SO ENGINE WORN B CS3RK NONE O OTHER ININSP/MAINT 1 WP17677PC794 P21000677 278685R DURING 100 HOUR INSPECTION, COMPRESSION CHECK REVEALED ALL SIX CYLINDERS LOW AS FOLLOWS: 35/57/50/51/49/51. CUSTOMER REPORTED USING 1 QUART PER HOUR PRIOR TO INSPECTION. REGULAR SOAP AT 50-HOUR OIL CHANGE REVEALED NO MAJOR PROBLEMS. TOTAL TIME 793.8 HOURS SINCE TCM. ZERO TIME REBUILD. SUBMITTER SUSPECTS OVERLEANING. 1H71 3O3 O 3A21 E8CE 19970306008681997030600868EA 1997 3 6 97ZZZX980 219970124G8530STD148 UNION LW13561 BEECH 60 A60 1153604CE LYC O541 TIO541E1C4 41536EA CYLINDER DRAIN DETACHED D K NONE O OTHER ININSP/MAINT 1 NM03928PT 600 P174 L122259 CYLINDER DRAIN FITTING CAME OUT OF HEAD. DRAIN LINE WAS STILL ATTACHED. THIS CAUSED ERRONEOUS READINGS ON SENSE SYSTEM. 1L72 3O3 O A12CE E10EA 19970306008711997030600871WP 1997 3 6 97ZZZX983 219970212G725030720681 BLADE AMD FALC10FALCON10 2730101EU GARRTTTFE731TFE7312 01518WP NR 2 ENG NR 3 LPSEPARATED D A E ENGINE SHUTDOWN E VIBRATION/BUFFET CLCLIMB 1 GL0573B 79 P73298 THE NR 2 ENGINE WAS SHUT DOWN DURING CLIMB-OUT DUE TO EXCESSIVE VIBRATIONS. INITIAL FINDS DURING TEAR DOWN INDICATE THAT SEVERAL BLADES SEPARATED FROM THE NR 3 L.P.T. THIS CAUSED SEVERE VIBRATIONS THAT, IN TURN, CAUSED THE N2 SECTION TO RUB. 2L72 4F4 F A33EU E6WE 19970306008731997030600873WP 1997 3 6 97ZZZX985 219970212G7210 BELLVILLE WASHER AMD FALC10FALCON10 2730101EU GARRTTTFE731TFE7312 01518WP PLANETARY GEAR FAILED D A K NONE O OTHER ININSP/MAINT 1 GL05174B 142 P73279 600 HOUR SOAP SAMPLE INDICATED HIGH METAL CONTENT. SUSPECT FROM THE PLANET GEARS. INSPECTION INDICATED BELLVILLE WASHER WAS SPINNING. PLANET GEARSHAFT AND WASHER REPLACED. ENGINE WAS APPROXIMATELY 600 HOURS OUT OF MPI. 2L72 4F4 F A33EU E6WE 19970313001531997031300153NE 1997 3 13 97ZZZX1015 219970207G7200 ENGINE AMD FALC20FALCON20F5 2730105EU GE CF700 CF7002D2 30010NE NR 2 POWER LOSS B AYL1RA UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 SW11108BG 2730 403 E304495B PILOT NOTES: AFTER RE-FUEL, THE ACFT LOST PWR ON T/O APPROX 200 FEET AGL. NR 2 ENG EGT WENT RED LINE APPROX 780 DEGREES FAHRENHEIT AND RPM HAD ROLL BACK. A POP WAS HEARD IN THE CABIN BY PASSENGERS. (POSSIBLE COMPRESSOR STALL). PILOT WENT TO FLT IDLE WITH NR 2 THROTTLE. THE ENG CONTINUED TO TURN AND PARAMETERS FOR ENGINE READINGS RETURNED TO NORMAL FOR FLT IDLE. THE AIRCRAFT RETURNED TO AIRPORT FOR SAFE LDG. EXTERIOR VISUAL AND INTERIOR BORESCOPE ON THE ENG DID NOT SHOW ANY MAJOR DAMAGE THAT WOULD CAUSE LOSS OF PWR, ADDITIONAL GROUND RUNS, LOW PWR, HIGH PWR, AND RAPID ACC TEST WERE NORMAL. CAUSE FOR PWR LOSS UNK. FUEL FILTERS CK OK. PART TOTAL CYCLES, 6518. 2L72 4F4 FRTA7EU E7EA 19970313001621997031300162GL 1997 3 13 97ZZZX1024 219970217G72616871311 TUBE ALLSN 250C 250C20 03013GL BEARING OIL CRACKED B YKERK NONE O OTHER ININSP/MAINT 1 EA17 DURING OVERHAUL OF THE TURBINE, FOUND THE BEARING OIL TUBE TO HAVE A CRACK IN THE FLARE. 3 U E4CE 19970313001761997031300176NE 1997 3 13 97ZZZX1038 219970219G7230817401 HUB PWA JT8 JT8D9A 52048NE FRONT COMPRESSORDAMAGED B VF5RK NONE O OTHER ININSP/MAINT 1 NE03 10797 P243242 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 481672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS AREA. 4 F E2EA 19970313001771997031300177NE 1997 3 13 97ZZZX1039 219970219G7230817401 HUB PWA JT8 JT8D9A 52048NE FRONT COMPRESSORDAMAGED B VF5RK NONE O OTHER ININSP/MAINT 1 NE03 9991 R12135 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 481672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS AREA. 4 F E2EA 19970313001781997031300178NE 1997 3 13 97ZZZX1040 219970219G7230817401 HUB PWA JT8 JT8D9A 52048NE FRONT COMPRESSORDAMAGED B VF5RK NONE O OTHER ININSP/MAINT 1 NE03 17861 M07042 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 481672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS AREA. 4 F E2EA 19970313001791997031300179NE 1997 3 13 97ZZZX1041 219970219G7230817401 HUB PWA JT8 JT8D9A 52048NE FRONT COMPRESSORDAMAGED B VF5RK NONE O OTHER ININSP/MAINT 1 NE03 10878 P24455 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 481672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS AREA. 4 F E2EA 19970313001801997031300180NE 1997 3 13 97ZZZX1042 219970219G7230817401 HUB PWA JT8 JT8D9A 52048NE FRONT COMPRESSORDAMAGED B VF5RK NONE O OTHER ININSP/MAINT 1 NE03 6382 S13547 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 481672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS AREA. 4 F E2EA 19970313001811997031300181NE 1997 3 13 97ZZZX1043 219970219G7230817401 HUB PWA JT8 JT8D9A 52048NE FRONT COMPRESSORDAMAGED B VF5RK NONE O OTHER ININSP/MAINT 1 NE03 22446 M98582 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 481672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS AREA. 4 F E2EA 19970313002291997031300229SO 1997 3 13 97ZZZX1049 219970127G8540653583A STARTER DRIVE 646209TMD CESSNA421 421C 2076016CE CONT O520 GTSIO520* 17032SO RT ENGINE WORN D K NONE O OTHER ININSP/MAINT 1 WP07411MZ700 421C1002 277166R STARTER DRIVE GEAR WEAR UNACCEPTABLE IAW TELEDYNE CONTINENTAL CSB 94-4 EVEN THOUGH THE SERVICE KIT REQUIRED BY TCM CSB 94-4 HAD BEEN PREVIOUSLY INSTALLED AT ENGINE OVERHAUL. SUBMITTER SUGGESTED CSB 94-4 MAY NOT BE SUFFICIENT. RECOMMENDED FLEET DATA BE EXAMINATED TO DETERMINE NUMBER AND FREQUENCY OF OCCURRENCES. 1L72 3O3 O A7CE E7CE 19970313002331997031300233SO 1997 3 13 97ZZZX1053 219970219G8550CH48109 FILTER CHAMPION AMTR STRDSTSTARDUSTR300 GL CONT E225 E225* 17015SO ENGINE OIL BURST H K NONE K FLUID LOSS ININSP/MAINT 1 WP277989 476 2582D OIL FILTER BURST AT START-UP. GASKET FORCED FROM GROOVE. ENGINE LOST ALL OIL. FILTER 'DOMED OUT' AT BOTH ENDS. ALL OIL PASSAGEWAYS IN ENGINE AND OIL COOLER OK. PRESSURE RELIEF VALVE IN ENGINE OK. SUSPECT FILTER BYPASS. 1Q71 3O3 O EXPA1Q71E267 19970313002391997031300239NE 1997 3 13 97ZZZX1059 219970218G72301B4790 STATOR VANE BOEING757 757* NM PWA 2037 PW2040 NE HPC MODULE FAILED B WA2DK NONE O OTHER ININSP/MAINT 1 NE03 16952 P726634 ENGINE WAS IN-FLIGHT, SHUT DOWN. DISASSEMBLY INSPECTION REVEALED ONE LIBERATED 10TH STAGE STATOR VANE AT THE CONVEX END OF ONE QUADRANT AT 9:00. THREE ADDITIONAL VANES IN THE SAME CLUSTER OF FIVE ARE FRACTURED THROUGH AT THE OUTSIDE DIAMETER SHROUD VANE BRAZE FILLET. METALLURIGCAL ANALYSIS OF THE 10TH STATOR AND 11TH BLADES IS BEING CONDUCTED BY PRATT AND WHITNEY MERL TO VERIFY FAILURE. 2L72 4F4 FRTA2NM E17NE 19970313002401997031300240NE 1997 3 13 97ZZZX1060 219970213G7230AS3209011 O-RING PWA 2037 PW2037 NE HPC MODULE MISSING B WA2DK NONE W INADEQUATE Q C ININSP/MAINT 1 NE03 3992 3992 P727149 DISASSEMBLY INSPECTION OF HPC MODULE REVEALED O-RINGS, P/N AS3209-011, TO BE MISSING FROM THE 9TH STAGE VARI-VANE TRUNNIONS (ALL VANES). THIS CONDITION WAS AN ORIGINAL MANUFACTURING ERROR. MANUFACTURING ADVISED OF CONDITION. NOTE: THE ABOVE CONDITION HAD NO BEARING ON ENGINE REMOVAL CAUSE. 4 F E17NE 19970313002451997031300245EA 1997 3 13 97ZZZX1063 219970224G853005K21103 CYLINDER CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA EXHAUST VALVES DETERIORATED B RH6RK NONE O OTHER ININSP/MAINT 1 NE014635L50 15284201 INSTALLED 4 NEW CYLINDERS ON OVERHAULED ENGINE. COMPRESSION LOSS STARTED AT ABOUT 300 HOURS THROUGH RINGS AND EXHAUST VALVE SEAT. PULLED CYLINDERS, FOUND BADLY HEATED EXHAUST STEM AND EXHAUST SEAT. EXHAUST VALVES ERODED AND BADLY PITTED. INSTALLED ADDITIONAL 4 NEW CYLINDERS ON 1-20-97 APPRXOIMATELY ONE MONTH AND 50 HOURS AND SAME PROBLEM. OIL TEMP OK AND BAFFLES INSTALLED. SUBMITTER STATED EXHAUST VALVE FAILURE IMMINENT. 1H71 3O3 ONT3A19 E223 19970313002471997031300247EA 1997 3 13 97ZZZX1065 219970204G7414ES103827901 COIL CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE MAGNETO CRACKED DL K NONE O OTHER ININSP/MAINT 1 NM031401E489 17270986 L597976T BENDIX MAGNETO OVERHAULED BY ELECTRO SYSTEMS, REPAIR STATION UT2R22GL. MAGNETO WAS FURNISHED WITH LYCOMING FACTORY OVERHAULED ENGINE IN 1995. MAGNETO WAS REMOVED FOR 500-HOUR INSPECTION AND C/W AD 96-12-07 AT 489.3 SMOH FOR THE FIRST TIME. FOUND ONE EACH COIL P/N ES 10-382790-1 WITH MFG DATE 2/01/95 CRACKED IN 10 PLACES WITH CRACKS RADIATING OUTWARD FROM CENTER SUPPORTS AND BRUSH CONTACT TANG. 1H71 3O3 ONT3A12 E274 19970313002481997031300248EA 1997 3 13 97ZZZX1066 219970130G7414D4RN2021 MAGNETO CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA DISTRIBUTOR GEARTEETH MISSING DL K NONE O OTHER ININSP/MAINT 1 NM031401E 489 17270986 L597976T BENDIX/TCM DUAL MAGNETO REMOVEDF FROM LYCOMING. FACTORY OVERHAULED ENGINE AT SMOH 489.3 FOR 500-HOUR INSPECTION AND C/W AD 96-12-07. FOUND MAGENTO DISTRIBUTOR GEARS WITH THREE TEETH MISSING FROM ONE GEAR AND ONE-HALF TOOTH MISSING FROM OTHER GEAR. CONTINUED OPERATION WOULD HAVE CAUSED CATASTROPHIC FAILURE. THIS MAGNETO WAS OVERHAULED BY ELECTRO SYSTEMS IN 1995 AND HAD AN ELECTRO SYSTEMS DATA PLATE AFFIXED TO MAGNETO. THIS MAGNETO WAS INSTALLED AT LYCOMING OVERHAUL AND NEVER REMOVED UNTIL SMOH 489.3. RECOMMEND ALL MAGNETOS OVERHAULED BY ELECTRO SYSTEMS BE REMOVED AND INSPECTED IAW BENDIX OVERHAUL MANUAL. 1H71 3O3 ONT3A12 E274 19970313004281997031300428GL 1997 3 13 HEEA979158 219970307G72606877181 HOUSING ALLSN 250C 250C20 03013GL GR BOX BELOW SPECS E HEEAK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 RECEIVING INSPECTION REVEALED: MEASURED .005 LEFT/.006 RIGHT BELOW SPECS ON GEARBOX HOUSING. COMPRESSOR MOUNT PAD STUDS AS MARKED. 3 U E4CE 19970320002681997032000268GL 1997 3 20 97ZZZX1092 219970303G723023057142 CASE BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL COMPRESSOR LINER LOOSE H K NONE O OTHER ININSP/MAINT 1 SW0918FH 1612 13642 2599 CAE833451 COMPRESSOR CASE PLASTIC LINER CAME LOOSE IN THE BLEED VALVE AIR FLOW BAND OF COMPRESSOR CASE. ONE PIECE APPROXIMATELY 2 SQUARE INCHES IN SIZE LODGED IN BLEED VALVE. 1G71 3U3 U H2SW E4CE 19970320002771997032000277SO 1997 3 20 97ZZZX1101 219970122G855012509225 ADAPTER CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO OIL FILTER LEAK D K NONE JK WARNING INDICATION FLUID LOSS NRNOT REPORTED 1 EA234853N 18267420 PILOT REPORTED LOW OIL PRESSURE IN-FLIGHT. UPON INSPECTION, FOUND OIL LEAKING FROM OIL FILTER ADAPTER. REMOVED ADAPTER, INSTALLED NEW O-RING AND REINSTALLED. NO FURTHER LEAKS FOUND. 1H71 3O3 ONT3A13 E273 19970320002781997032000278SO 1997 3 20 97ZZZX1102 219970303G8530A50222 CYLINDER CESSNA150 150J 2071820CE CONT O200 O200A 17020SO NR 4 CYL ROCKER FAILED D K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 EA05150J 1694 305 15069500 2045149A ENGINE RAN ROUGH ON START. REMOVED COWLING. RESTARTED ENGINE. SHAKING VIOLENTLY. REMOVED ROCKER COVER. ENTIRE ROCKER ARMS, PINS, AND BOSSES FELL IN COVER. SUSPECT VALVE STUCK. 1H71 3O3 O 3A19 E252 19970320003871997032000387GL 1997 3 20 97ZZZX1118 219970307G72506898735 TURBINE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL EXH COLLECTOR SMOKING B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R7015 543 1151D CAE832750 19.4 HOURS AFTER A REPAIR TO THE TURBINE PT SUPPORT, THE TURBINE STARTED SMOKING HEAVILY ON SHUT DOWN. AFTER THE ENGINE COOLED, A VISUAL INSPECTION FOUND OIL PUDDLING IN THE TURBINE EXHAUST COLLECTOR. UNIT SENT BACK FOR REPAIR. 1G71 3U3 U H3WE E4CE 19970320006961997032000696WP 1997 3 20 97ZZZX1124 219970212G7200 ENGINE BEECH 18 C45H 1151018CE GARRTTTPE331TPE331101B 01514WP RT ENGINE FAILED D K NONE Y ENGINE STOPPAGE APAPPROACH 1 GL234209V7782 6310 AF884 P93010 RIGHT ENGINE QUIT RUNNING ON APPROACH TO YIP. UNEVENTFUL LANDING CARRIED OUT. ENGINE EXPERIENCED INTERNAL FAILURE, CAUSE AT THIS TIME UNKNOWN. ENGINE REPLACED WITH SERVICEABLE UNIT. AIRCRAFT RETURNED TO SERVICE. 1L72 3R3 T A765 E3WE 19970320007051997032000705EA 1997 3 20 97ZZZX1133 219970225G8530 CYLINDER HILLERUH12 UH12E 4360122WP LYC O540 VO540C2A 41532EA FLANGE NOT TO SPEC D K NONE O OTHER ININSP/MAINT 1 NM0936MV 5060 L254243 DURING ASSEMBLY OF ENGINE, MEASURED DRY TAPPET CLEARANCE FROM .107 INCH TO .187 INCH. LYC OHM REQUIRES .028 INCH TO .080 INCH. RETURNED 6 CYLINDERS TO EC/SW WHERE THEY CUT/REMOVED MATERIAL FROM THE CYL FLANGE. CYLINDERS WERE RE-INSTALLED. THESE CYLINDERS JUST MADE THE .080 INCH DTC USING THE LONGEST PUSH ROD AND NEW ROCKER ARMS. 1G71 3O3 O 4H11 E304 19970320007061997032000706GL 1997 3 20 97ZZZX1134 219970305G72606854857A GEARSHAFT ALLSN 250C 250C20B 03013GL TACH DRIVE WORN D K NONE O OTHER ININSP/MAINT 1 NM11 4889 UPI342 CAG37227 TACH DRIVE END WORN ABOUT .040 INCH. SUBMITTER STATED FOUND ABOUT 50 PERCENT OF ALL THE GEARS ARE FOUND WORN WHEN INSPECTED. 3 U E4CE 19970320007111997032000711GL 1997 3 20 97ZZZX1139 219970225G72106875776 NOZZLE 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GEARBOX GOUGED BS EOORK NONE O OTHER ININSP/MAINT 1 AL038639F6734 CAG36146 1280431D CAE832846 DURING DISASSEMBLY OF ENGINE GEARBOX, NR 4 BEARING WAS FOUND NOT TO BE SEATED ALL THE WAY ON THE JOURNAL ON THE HELICAL GEAR DUE TO IMPROPER INSTALLATION. SUBSEQUENT INSPECTION FOUND THE 6875776 OIL NOZZLE GOUGED ON THE BOTTOM FLANGE BY THE BEARING. REPLACED NOZZLE. 1G71 3U3 U H3WE E4CE 19970320007121997032000712GL 1997 3 20 97ZZZX1140 219970226G72106876925 OIL TUBE 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GEARBOX TOO SHORT B EOORK NONE W INADEQUATE Q C ININSP/MAINT 1 AL038639F6734 3420 CAG36146 1280431D CAE832846 INSPECTED OIL TUBE PER CEB1307 AND IS TOO SHORT PER REQUIREMENTS OF THE BULLETIN. PART WAS REPLACED. 1G71 3U3 U H3WE E4CE 19970327000641997032700064EA 1997 3 27 97ZZZX1146 219970210G8530SL14995 SPRING CESSNA172 172K 2072430CE LYC O320 O320E2D 41508EA ENG CYL BROKEN DL K NONE W INADEQUATE Q C ININSP/MAINT 1 WP25100PD 17257902 L7598927A RECEIVING INSPECTION OF A NEWLY OVERHAULED ENGINE FOUND PUSH ROD HOUSING COULD BE POPPED OUT OF SEAT. REMOVED ROCKER COVER AND FOUND HOLD-DOWN SPRING BROKEN. FURTHER INVESTIGATION FOUND 3 OF 4 PUSH ROD SPRINGS BROKEN. SUBMITTER SUSPECTS SPRINGS MISMANUFACTURED AND ARE BRITTLE. 1H71 3O3 ONT3A12 E274 19970327000681997032700068SO 1997 3 27 97ZZZX1150 219970207G7414 DISTRIBUTOR GEARBENDIX BEECH 58 58TC 1152746CE CONT O520 TSIO520L 17040SO MAG BROKE B BIORAE UNSCHED LANDING ENGINE SHUTDOWN J WARNING INDICATION NRNOT REPORTED 1 EA23117HS3695 A156805 TK21 508213 DISTRIBUTION GEAR BROKE AND CONTACT STUCK ON NR 2 CYL LEAD. MAG CONTINUED TO ROTATE CAUSING ONLY NR 2 CYL TO FIRE EACH TIME POINTS OPENED. THIS CAUSED SEVERE DETONATION IN NR 2 CYL BURNING A HOLE THROUGH PISTON. THIS RESULTED IN AN INFLIGHT SHUT DOWN. ENGINE INSP, AND FOUND TO BE CONTAMINATED WITH METAL. ENGINE REPLACED. SUBMITTER STATED IMPROPER MAINT AND OVERHAUL TIME OF MAG NOT C/W. 1L72 3O3 O A23CE E8CE 19970327000771997032700077SO 1997 3 27 97ZZZX1159 219970227G8530631475 PISTON BEECH 33 35C33A 1151410CE CONT O520 IO520BA 17032SO 1ST-2ND RING BROKEN B IQ4RK NONE O OTHER ININSP/MAINT 1 SO099480S CE6 1208025B INSTALL NEW TCM CYLINDER AND VALVE ASSY USED SA 631475 PISTON DUE TO WEIGHT DIFFERENCE (TO BALANCE PISTON SET). INSTALL TCM RING SET. FLEW 228.1 HOURS. REMOVE CYL DUE TO ENG MISSING. FOUND TOP OF PISTON AND 1ST RING GLAND BROKEN. TOP 2 RINGS BROKEN. REASON UNKNOWN. 1L71 3O3 O 3A15 E5CE 19970327002441997032700244EA 1997 3 27 97ZZZX1174 219970218G72613034393A FILTER BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA ENG OIL SCREEN FAILED B DX4RK NONE W INADEQUATE Q C ININSP/MAINT 1 SO03711MB665 BB437 80969 THE INNER CONE SHAPED SCREEN HAD SEPARATED ON OIL FILTER. SEPARATION APPEARED TO BE AT A SEAM ON THE SCREEN. 1L72 4T4 T A24CE E4EA 19970327002561997032700256GL 1997 3 27 97ZZZX1186 219970225G72106875035 BEARING 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GRBOX PITTED B EOORK NONE O OTHER ININSP/MAINT 1 AL038639F6734 3420 CAG36146 1280431D CAE832846 DURING INSPECTION OF ENGINE GEARBOX, BEARING WAS FOUND TO BE PITTED ON SEVE RAL ROLLERS. 1G71 3U3 U H3WE E4CE 19970327002571997032700257GL 1997 3 27 97ZZZX1187 219970225G72106851505 PICOLLO TUBE 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GRBOX BURRS B EOORK NONE O OTHER ININSP/MAINT 1 AL038639F6734 3420 CAG36146 1280431D CAE832846 INSPECTED PICOLLO TUBE PER CEB 1177 (S/N BN16959) AND FOUND BURRS - SCRAPPED PER CEB. 1G71 3U3 U H3WE E4CE 19970327002581997032700258CE 1997 3 27 97ZZZX1188 119970227G716011111 ELBOW CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO NR 2 INDUCTION TORN D A O OTHER R PARTIAL RPM/PWR LOSS CRCRUISE 1 WP136604C 414A0030 519399 PILOT REPORTED THAT THE RIGHT ENGINE WOULD NOT MAINTAIN POWER. MANIFOLD PRESSURE DECREASED DURING FLIGHT. TAKEOFF POWER OKAY ON BOTH ENGINES. DURING CLIMB, THE RIGHT ENGINE ONLY DEVELOPED 27 IN HG. IT WAS DISCOVERED THAT THE INBOARD INDUCTION ELBOW RAM P/N 1111-1, LOCATED BETWEEN THE INTERCOOLER ASSEMBLY P/N 635921 AND NR 2 INTAKE MANIFOLD ELBOW P/N 642590 HAD TORN. INDUCTION ELBOW REPLACED. ENGINE RUN UP OKAY. AIRCRAFT RETURNED TO SERVICE. SUBMITTER STATED IT IS NOT UNCOMMON FOR THE RAM P/N 1111-1 OR TCM P/N 646020 INDUCTION TO TEAR. 1L72 3O3 O A7CE E8CE 19970327002771997032700277CE 1997 3 27 97ZZZX1193 119970101G81204810B49001 WASTEGATE CESSNA421 421 2076010CE CONT O520 GTSIO520H 17032SO ENG TURBO CRACKED DP K NONE O OTHER ININSP/MAINT 1 SW99 1361 DURING AN OIL AND FILTER CHANGE, THE WASTEGATE CRACK DEFECT WAS FOUND. DEFECT NOT PRESENT AT 50 HOUR CHECK 50 HOURS PREVIOUS. 1L72 3O3 ORTA7CE E7CE 19970327002781997032700278EA 1997 3 27 97ZZZX1194 219970304G8550 LINE SOCATATB20 TB21 8680697EU LYC O540 TIO540AB1A 41533EA TURBO OIL FAILED DPA A UNSCHED LANDING K FLUID LOSS NRNOT REPORTED 1 WP2320NB 1738 557 INFLIGHT FAILURE OF THE TURBOCHARGER OIL RETURN LINE BETWEEN THE TURBOCHARGER HOUSING AND A SMALL RESERVOIR CAN LOCATED UNDER THE ENGINE. THE AIRCRAFT LOST 9 QUARTS OF OIL INFLIGHT AND WAS LANDED WITHOUT INCIDENT. THE OIL RETURN LINE WAS FOUND WITH A CRACK RUNNING AROUND 300 DEGREES OF THE TUBE'S CIRCUMFERENCE WHERE IT MADE A SWEEPING 90 DEGREE BEND BELOW THE MOUNTING FLANGE. MATERIAL FATIGUE FAILURE IN THE 90 DEGREE RADIUS BEND OF THE OIL RETURN LINE TUBE BETWEEN THE 2 BOLT MOUNTING FLANGE TO THE TURBOCHARGER HOUSING AND OIL RESERVOIR CAN. VISUAL INSPECTION INDICATES THAT THE OUTER RADIUS WALL THICKNESS WAS MUCH THINNER THAN THE INNER RADIUS WALL THICKNESS WHERE THE CRACK OCCURRED. 1L71 3O3 ORTA51EU E14EA 19970327002791997032700279EA 1997 3 27 97ZZZX1195 219970217G8530S14995 SPRING CESSNA182 T182 2072736CE LYC O540 O540L3C5 41532EA CYL SHROUD TUBE BROKEN BLAWTXRK NONE K FLUID LOSS ININSP/MAINT 1 NM07201SP 18268313 L2385040A AFTER AN INITIAL TEST FLIGHT OF 1.1 HOURS, IT WAS NOTED THAT A LARGE AMOUNT OF OIL HAD COLLECTED ON THE RT SIDE OF THE ENG. FURTHER INSP REVEALED THAT THE PUSHROD HOUSING ON THE INTAKE SIDE OF THE NR 1 CYL RETAINING SPRING WAS FOUND TO BE BROKEN. WHEN THE REMAINING ROCKER COVERS WERE REMOVED, THE PUSHROD RETAINING SPRING FROM THE NR 5 CYLINDER WAS FOUND TO BE CRACKED. THESE PARTS WERE INSTALLED FROM A SUPERIOR AIR PARTS GASKET SET SL 13377 PURCHASED FROM SUPERIOR JAN. 1997. SUPERIOR SL 94-002 AND LYCOMING SB 519 ADDRESSED THE PROBLEM OF CERTAIN SHROUD TUBE RETAINING SPRINGS THAT WERE BREAKING IN SERVICE. HOWEVER, THOSE SPRINGS WERE MADE AND SOLD IN 1994. THESE SPRINGS WERE SOLD IN 1997. 1L71 3O3 O 3A13 E295 19970327002881997032700288 1997 3 27 97ZZZX1204 119970310G2434649093 HUB ASSY CONT O550 IO550* SO ALTERNATOR FAILED G K NONE O OTHER ININSP/MAINT 1 SW11 281690P ALTERNATOR KEY (633342-10) FAILED CAUSING HUB ASSY TO SPIN ON ALTERNATOR SHAFT. THE RESULTS WERE EXCESSIVE WEAR TO ALTERNATOR SHAFT AND HUB ASSEMBLY. THERE WAS ALSO WEAR ON THE TEETH OF THE ALTERNATOR FACE GEAR. 3 O E3SO 19970327002941997032700294SO 1997 3 27 97ZZZX1208 119970214G2822RR12040F PUMP LKHEED1329 1329 5263102SO GARRTTTFE731TFE7313 01518WP NR 2 FAILED D K NONE O OTHER ININSP/MAINT 1 AL03817BD 466 5083 FUEL PUMP WAS OVERHAULED BY CRS NR ZK3R027M ON 10-5-93. OVERHAUL REQUIREMENT IS 2000 HOURS. TIME SINCE OVERHAUL ON PART WAS 466 HOURS. PUMP WOULD NOT MAINTAIN PRESSURE WITH COLD FUEL. SUBMITTER STATED SEVERAL OPERATORS HAVE COMPLAINED ABOUT SIMILAR PROBLEMS WITH PUMPS FROM THE SAME CRS. 2L74 4J4 F 2A15 E6WE 19970403000081997040300008EA 1997 4 3 97ZZZX1224 219970318G8520 CRANKSHAFT SOCATATB9 TB9 8680694EU LYC O320 O320D2A 41508EA FLANGE CRACKED BPANI1RK NONE O OTHER ININSP/MAINT 1 CE03508PC 1477 L1754339A THIS AIRCRAFT IS USED EXCLUSIVELY FOR FLIGHT TRAINING. ON PRE-FLIGHT, STUDENT AND INSTRUCTOR FOUND OIL ON THE COWLING. UPON INSPECTION, TWO CRACKS WERE FOUND ON THE CRANKSHAFT COVERGING AT THE RADIUS OF THE CRANKSHAFT AND CRANKSHAFT FLANGE. THIS ENGINE AND PROPELLER HAVE NO HISTORY OF PROPELLER STRIKE OR SUDDEN STOPPAGE. IN SERVICE DATE FOR THIS ENGINE AND PROPELLER 4/92. TOTAL TIME SINCE NEW, ENGINE AND PROPELLER, 1,809 HOURS. 1L71 3O3 ONTAS1EU E274 19970403000121997040300012EA 1997 4 3 97ZZZX1228 219970311G74141038256013 DISTRIBUTOR GEARELECTROSYS PIPER PA32 PA32R300 7103213SO LYC O540 IO540K1A5 41532EA ENGINE MAGNETO TEETH BROKE D K NONE O OTHER ININSP/MAINT 1 AL011392H655 6021788R 32R7780156 L1642048A MAGNETO DISTRIBUTOR TEETH BROKE DURING RUN-UP. RECOMMEND BETTER QC DURING MANUFACTURE. 1L71 3O3 O A3SO 1E4 19970403000161997040300016SO 1997 4 3 97ZZZX1232 219970306G8530653446A5 CYLINDER CESSNA210 210R 2073458CE CONT O520 IO520L 17032SO NR 3 CRACKED D K NONE O OTHER ININSP/MAINT 1 GL23962CC1101 21064986 294563R NR 3 CYLINDER WAS REMOVED DUE TO LOW COMPRESSION. THE CYLINDER WAS SENT FOR INSPECTION. THE CYLINDER INSPECTION REVEALED A CRACK WHICH BEGAN AT THE SPARK PLUG HOLE AND TERMINATED AT THE INTAKE VALVE SEAT. 1H71 3O3 ORT3A21 E5CE 19970403000171997040300017SO 1997 4 3 97ZZZX1233 219970306G8530653446A5 CYLINDER CESSNA210 210R 2073458CE CONT O520 IO520L 17032SO NR 2 CRACKED D K NONE O OTHER ININSP/MAINT 1 GL23962CC1297 21064986 294563R WHILE PERFORMING TCM SB 96-12, CONTINUED AIRWORTHINESS INSTRUCTIONS FOR TCM CYLINDERS, BUBBLES WERE FOUND ACCUMULATING AROUND THE NR 2 CYLINDER UPPER SPARK PLUG HOLE. INSPECTION REVEALED A CRACK AT THE SPARK PLUG HOLE. THE CRACK ORIGINATED AT THE 3 O'CLOCK POSITION AND EXTENDED AFT TOWARD THE FUEL NOZZLE HOLE. 1H71 3O3 ORT3A21 E5CE 19970403000181997040300018SO 1997 4 3 97ZZZX1234 219970312G8520641931075 THROUGH BOLT BEECH 58 58 1152740CE CONT O520 IO520C 17032SO NR 2 CYLINDER FAILED D O OTHER O OTHER CRCRUISE 1 SW17977GF781 TH175 287057R UPON INSPECTION OF LT ENGINE, FOUND NR 2 CYLINDER SEPARATED FROM CASE BY 2-3 INCHES. UPPER THROUGH-BOLT APPEARS TO BE BROKEN INTERNALLY AS WELL AS LOWER THROUGH-BOLT, ALL UPPER AND LOWER CASE STUDS TO CYLINDER HOLD-DOWN APPEAR TO BE BROKEN AT THREAD AREA OR AFT OF THREAD AREA. PISTON STILL CONNECTED TO CONNECTING ROD TO CRANKSHAFT. EVIDENCE OF PISTON SKIRT AND RING MATERIAL IN CASE. AIRCRAFT IN NORMAL CRUISE SETTING WITH TEMPS AND PRESSURES NORMAL. 1L72 3O3 O 3A16 E5CE 19970403002941997040300294EA 1997 4 3 97ZZZX1237 219970307G8530LW12987C2 CYLINDER HUGHES269 269C 4470504WP LYC O360 HIO360D1A 41514EA NR 1 DEFECTIVE B FW7RK NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 EA072044F 162 S1722 L2674451A AFTER THIS CYLINDER WAS INSTALLED, THE ENGINE OIL CONSUMPTION INCREASED. EVEN AFTER A SUFFICIENT BREAK-IN PERIOD, THE CONSUMPTION DID NOT DROP. AFTER APPROXIMATELY 162 HOURS, THE ENGINE RAN EXTREMELY ROUGH EVEN WITHOUT THE MAIN ROTOR ENGAGED. THE SPARK PLUGS WERE REMOVED, AND THE LOWER NR 1 PLUG WAS FOUND COMPLETELY OIL FOULED. THE CYLINDER WAS REPLACED WITH A FACTORY NEW UNIT. 1G71 3O3 O 4H12 1E10 19970403002961997040300296GL 1997 4 3 97ZZZX1239 219970317G723023052270 COMPRESSOR BELL 206 206L1 1182107SW ALLSN 250C 250C30P 03013GL SCROLL CRACKED H K NONE O OTHER ININSP/MAINT 1 SW095748H8342 6506 CAC90373 45490 CAC890611 DURING DAILY INSPECTION OF ENGINE ASSY, A CRACK WAS DISCOVERED ON THE RIGHT UPPER SIDE OF THE SCROLL, 1.50 INCHES IN LENGTH. 1G71 3U3 U H2SW E1GL 19970403003011997040300301SO 1997 4 3 97ZZZX1244 219970311G73146462123A1 PUMP CESSNA310 310Q 2074242CE CONT O470 IO470V 17026SO RT ENG FUEL SHAFT SHEARED BL CSLRA UNSCHED LANDING Y ENGINE STOPPAGE NRNOT REPORTED 1 CE017872Q1230 1230 310Q0653 170980R RIGHT ENGINE FUEL PUMP FAILED DURING FLIGHT. BOOST PUMP WOULD NOT RUN AND ENGINE STOPPED, UNEVENTFUL LANDING WAS MADE. FOUND FUEL PUMP DRIVESHAFT SHEARED. FOUND BOOST PUMPS WOLD PRIME ENGINE AND ALLOW ENGINE TO RUN, BUT WOULD NOT RUN IN HIGH OR LOW BOOST PUMP POSITION. FOUND OIL PRESSURE SWITCHES IN NACELLE TO BE DIRTY AND NOT ALLOWING BOOST PUMP TO RUN. CLEAN AND ADJUST SWITCHES PER CESSNA 3100 MM, CHAPTER 11. NOTE: MEB 88-3 WAS C/W. 1L72 3O3 O 3A10 3E1 19970403003021997040300302CE 1997 4 3 97ZZZX1245 119970311G2822 SWITCH CESSNA310 310Q 2074242CE CONT O470 IO470V 17026SO BOOST PUMP DIRTY B CSLRK NONE O OTHER ININSP/MAINT 1 CE017872Q1230 310Q0653 170980R RIGHT ENGINE FUEL PUMP FAILED DURING FLIGHT. BOOST PUMP WOULD NOT RUN AND ENGINE STOPPED, UNEVENTFUL LANDING WAS MADE. FOUND FUEL PUMP DRIVESHAFT SHEARED. FOUND BOOST PUMPS WOLD PRIME ENGINE AND ALLOW ENGINE TO RUN, BUT WOULD NOT RUN IN HIGH OR LOW BOOST PUMP POSITION. FOUND OIL PRESSURE SWITCHES IN NACELLE TO BE DIRTY AND NOT ALLOWING BOOST PUMP TO RUN. CLEAN AND ADJUST SWITCHES PER CESSNA 3100 MM, CHAPTER 11. NOTE: MEB 88-3 WAS C/W. 1L72 3O3 O 3A10 3E1 19970403003051997040300305SO 1997 4 3 97ZZZX1248 219970320G8520 CRANKCASE BEECH 58 58 1152740CE CONT O520 IO520C 17032SO NR 6 CYL STUD CRACKED D K NONE O OTHER ININSP/MAINT 1 SW05999AN TH924 561912 DURING OIL CHANGE, FOUND 1 INCH CRACK EXTENDING FROM CYLINDER NR 6 UPPER REAR STUD. AD 77-13-22 PARA(A) ADDRESSES THIS SUBJECT, BUT IS NOT INCLUDED IN THE SERIAL NUMBER REQUIREMENT LIST. 1L72 3O3 O 3A16 E5CE 19970403003091997040300309NE 1997 4 3 97ZZZX1251 219970305G7313 NOZZLE LEAR 25 25B 5170511CE GE CJ610 CJ6106 30006NE STAGE 1 REQUIRED ADJ D K NONE X ENGINE FLAMEOUT NRNOT REPORTED 1 GL2350CK 103997232 157 241033 LEFT ENGINE FLAMED OUT. ADJUSTED STAGE 1 AIR NOZZLE. GROUND RUN AND PERFORMANCE CHECK GOOD. C/W ALTITUDE ACCELERATION TEST FLIGHT. OPS CHECK GOOD. 2L72 4J4 J A10CE 1E16 19970403003101997040300310NE 1997 4 3 97ZZZX1252 219970309G7200 ENGINE LEAR 25 25B 5170511CE GE CJ610 CJ6106 30006NE LEFT ENGINE FAIL CHECK E K NONE L NO TEST ININSP/MAINT 1 GL2350CK 104057233 157 241033 LEFT ENGINE FLAME OUT. RE-ADJUSTED STAGE 1 AIR NOZZLE. INSPECTED COMBUSTION LINER AND INSTALLED OVERHAULED FUEL CONTROL UNIT. GROUND RUN LEAK AND PERFORMANCE CHECK GOOD. LEFT ENGINE FAILED ACCELERATION CHECK AT FL 410. REPLACED ENGINE WITH S/N 251-095A. GROUND RUN AND LEAK CHECK GOOD. 2L72 4J4 J A10CE 1E16 19970403003111997040300311NE 1997 4 3 97ZZZX1253 219970312G7320C2995150202 CONTROL CABLE CESSNA208 208B 2073701CE PWA PT6 PT6A114 52043NE EMERGENCY POWER WORN D K NONE O OTHER ININSP/MAINT 1 WP17762FE2774 208B0255 19131 EMERGENCY POWER CABLE AND ATTACH BRACKETS WORN. THE BRACKETS WORN WITHIN .0625 INCH OF BEING COMPLETELY THROUGH MATERIAL. EMERGENCY POWER CABLE WORN THROUGH ATTACH POINT ON CABLE. SUGGEST WEAR IS NORMAL, CABLE AND ATTACH BRACKETS NEED TO BE OF HEAVIER MATERIAL. 1H71 3T3 T A37CE E4EA 19970403003121997040300312NE 1997 4 3 97ZZZX1254 219970312G732024510022 BRACKET CESSNA208 208B 2073701CE PWA PT6 PT6A114 52043NE EMERGENCY POWER WORN D K NONE O OTHER ININSP/MAINT 1 WP17762FE2774 208B0255 19131 EMERGENCY POWER CABLE AND ATTACH BRACKETS WORN. THE BRACKETS WORN WITHIN .0625 INCH OF BEING COMPLETELY THROUGH MATERIAL. EMERGENCY POWER CABLE WORN THROUGH ATTACH POINT ON CABLE. SUGGEST WEAR IS NORMAL, CABLE AND ATTACH BRACKETS NEED TO BE OF HEAVIER MATERIAL. 1H71 3T3 T A37CE E4EA 19970403003131997040300313NE 1997 4 3 97ZZZX1255 219970312G732024510021 BRACKET CESSNA208 208B 2073701CE PWA PT6 PT6A114 52043NE EMERGENCY POWER WORN D A K NONE O OTHER ININSP/MAINT 1 WP17762FE2774 208B0255 19131 EMERGENCY POWER CABLE AND ATTACH BRACKETS WORN. THE BRACKETS WORN WITHIN .0625 INCH OF BEING COMPLETELY THROUGH MATERIAL. EMERGENCY POWER CABLE WORN THROUGH ATTACH POINT ON CABLE. SUGGEST WEAR IS NORMAL, CABLE AND ATTACH BRACKETS NEED TO BE OF HEAVIER MATERIAL. 1H71 3T3 T A37CE E4EA 19970403003141997040300314GL 1997 4 3 97ZZZX1256 219970312G72606854857 GEARSHAFT ALLSN 250C 250C20B 03013GL TACH DRIVE WORN D K NONE O OTHER ININSP/MAINT 1 NM11 UPI314 TACHOMETER DRIVE END WORN ABOUT .040 INCH. 3 U E4CE 19970403006621997040300662GL 1997 4 3 97ZZZX1281 219970109G7320G851430 REAR SUPPORT G890550 BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ENGINE COMP CRACKED B ALGRK NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 SW034572V37119770 ER38066 S665 CAE836143 COMPRESSOR WAS REMOVED FOR LOW POWER AND UPON PRELIMINARY INSPECTION, FOUND CRACKING OF REAR SUPPORT. AT APPROXIMATELY 1-5 INCHES OUT FROM BEARING BORE, FOUND CRACKING FROM 220 DEGREES - 260 DEGREES AROUND ON REAR SUPPORT. 1G72 3U3 U H3EU E4CE 19970403008321997040300832SO 1997 4 3 97ZZZX1313 219970226G8550 ENGINE CONT O470 IO470C 17026SO ENGINE OIL LOW PRESSURE D K NONE O OTHER ININSP/MAINT 1 SO05 2842 7 711617C AT ANNUAL INSPECTION, ENGINE OIL PRESSURE WAS BELOW SPECIFIED LIMITS. CAUSE UNKNOWN. 3 O E273 19970403008381997040300838EA 1997 4 3 97ZZZX1319 219970307G8530SL14995 SPRING PIPER PA25 PA25235 7102504SO LYC O540 O540B2C5 41532EA SHROUD TUBE BROKE D A K NONE O OTHER ININSP/MAINT 1 GL218677L 255427 L1480540 DURING ASSEMBLY OF THIS ENGINE, 6 SHROUD TUBE SPRINGS WERE INSTALLED, 3 BROKE WHEN THE NUT WAS TIGHTENED. THESE SPRINGS WERE SUPPLIED AS PART OF A PACKET SET FROM SUPERIOR AIR PARTS. 1L71 3O3 O 2A10 E295 19970403008421997040300842GL 1997 4 3 97ZZZX1323 219970321G72106889700 PINION GEAR 6886442 ALLSN 250C 250C20B 03013GL GEARBOX WORN D K NONE O OTHER ININSP/MAINT 1 NM11 4889 2229076 INTERNAL SPLINES WORN OR AT LEAST BEYOND MAXIMUM LIMITS. NO WEAR STEP. BOTH BEARINGS JOURNALS .0002 INCH BELOW MINIMUM DIAMETER. 3 U E4CE 19970403008471997040300847EA 1997 4 3 97ZZZX1328 219970310G731402532330003 PUMP PESCO BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA LT ENGINE FUEL SEIZED D O OTHER X ENGINE FLAMEOUT CRCRUISE 1 GL23942CE6295 3459 BB494 PCE81782 LEFT ENGINE ROLLED BACK TO IDLE CUT-OFF IN FLIGHT. (FLAME OUT.) MAIN ENGINE FUEL PUMP SEIZED CAUSING ROUNDING OFF OF SPLINE ON PUMP AND DRIVE COUPLING. SUBMITTER SUGGESTED TO INCREASE FREQUENCY OF INSPECTION FOR THIS COMPONENT. 1L72 4T4 T A24CE E4EA 19970410000651997041000065WP 1997 4 10 97ZZZX1358 219970310G721031016051 TRANSFER TUBE STBROSSC7 SC7SERIES3 8100512EU GARRTTTPE331TPE3312201A WP GEARBOX OIL FRACTURED B ILIRE ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 WP07101UV467 SH1842 P90255 PILOT REPORTED A LOSS OF POWER AND GEARBOX NOISE AND SHUT THE ENGINE DOWN. AFTER DISASSEMBLY OF THE GEARBOX, DISCOVERED THE OIL TUBE 3101605-1 HAD FRACTURED AND A 3 INCH PIECE OF THE TUBE WAS FOUND IN THE GEARBOX NEXT TO THE OIL SCAVENGE PUMP PICK-UP TUBE. THIS TUBE FEEDS OIL PRESSURE TO THE HIGH SPEED PINION WHICH FAILED AFTER OIL PRESSURE WAS LOST. AD 76-16-01 COVERS THIS PROBLEM, BUT AFTER CHECKING THE AD AND ITS MANUFACTURER'S SB, IT WAS DETERMINED THAT TUBE 3101605-1 IS THE TUBE CALLED FOR DURING C/W THE AD AND SB. C/W THE AD WAS PERFORMED 19 YEARS PRIOR TO THE TUBE FAILURE. 1H72 3T4 TNTA15EU E3WE 19970410000791997041000079EU 1997 4 10 97ZZZX1372 219970331G7210837280 SHAFT SPLINES DIAMONDA20A1DA20A1 05626UXGL ROTAX 912 ROTAX912 55555EU PROP GEARBOX MISSING D A K NONE O OTHER ININSP/MAINT 1 WP23608F 1161 10033 4380627 FOUND METAL IN CHIP DETECTORS. PULLED GEARBOX FOUND MISSING SPLINES ON PROPELLER SHAFT, P/N 837-280. 1L71 3O3 INTTA4CH EXPE3I 19970410000801997041000080EU 1997 4 10 97ZZZX1373 219970331G7210837280 SHAFT SPLINE DIAMONDA20A1DA20A1 05626UXGL ROTAX 912 ROTAX912 55555EU PROP GEARBOX MISSING D A K NONE O OTHER ININSP/MAINT 1 WP23607F 1024 10027 4380622 FOUND METAL IN CHIP DETECTOR. PULLED GEARBOX, FOUND MISSING SPLINES. 1L71 3O3 INTTA4CH EXPE3I 19970410000851997041000085GL 1997 4 10 97ZZZX1378 219970217G72506875491 MATING RING ALLSN 250C 250C28B 03013GL TURBINE LEAKING B TI1RK NONE K FLUID LOSS ININSP/MAINT 1 SW05 24 QL61430 MATING RING LEAKING AFTER ONLY 23.5 HOURS. 3 U E1GL 19970410000911997041000091GL 1997 4 10 97ZZZX1384 219970217G72506898764 BELLOWS SEAL ALLSN 250C 250C20B 03013GL ENGINE LEAKING B TI1RK NONE K FLUID LOSS ININSP/MAINT 1 SW05 24 95859 CARBON BELLOWS SEAL LEAKING AFTER ONLY 23.5 HOURS. 3 U E4CE 19970410003171997041000317GL 1997 4 10 97ZZZX1409 219970317G72106899402 PTO GEAR SPLINE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GEARBOX WORN B EOORK NONE O OTHER ININSP/MAINT 1 AL038639F6734 3420 CG80352 1280431D CAE832846 DURING INSPECTION OF GEARBOX GEARS, FOUND THE PTO GEAR INTERNAL DRIVE SPLINES WORN BEYOND LIMITS. 1G71 3U3 U H3WE E4CE 19970410003181997041000318GL 1997 4 10 97ZZZX1410 219970317G72106896437 SPUR GEAR 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GEARBOX SPALLED B EOORK NONE O OTHER ININSP/MAINT 1 AL038639F6734 3420 60509 1280431D CAE832846 DURING INSPECTION OF GEARBOX GEARS, THE TEETH WERE FOUND SPALLED. 1G71 3U3 U H3WE E4CE 19970410003191997041000319GL 1997 4 10 97ZZZX1411 219970317G72106876529 SPUR GEAR 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GEARBOX SPALLED B EOORK NONE O OTHER ININSP/MAINT 1 AL038639F UP1341 1280431D CAE832846 INSPECTION FOUND GEAR TEETH SPALLED. 1G71 3U3 U H3WE E4CE 19970410003201997041000320GL 1997 4 10 97ZZZX1412 219970317G72606854857 GEARSHAFT 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL TACH DRIVE WORN B EOORK NONE O OTHER ININSP/MAINT 1 AL038639F 3420 UP1341 1280431D CAE832846 INSPECTION FOUND TACHOMETER DRIVE WORN BEYOND LIMITS. 1G71 3U3 U H3WE E4CE 19970410003211997041000321GL 1997 4 10 97ZZZX1413 219970317G7260689701 GEAR 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL TORQUE METER WORN B EOORK NONE O OTHER ININSP/MAINT 1 AL038639F6734 3420 NN60045 1280431D CAE832846 DURING INSPECTION OF GEARBOX GEARS, FOUND THE TORQUE METER GEAR DAMPER RING GROOVE WORN BEYOND LIMITS. 1G71 3U3 U H3WE E4CE 19970410003231997041000323GL 1997 4 10 97ZZZX1415 219970324G72616840532 FILTER ASSY ALLSN 250C 250C20B 03013GL GEARBOX CRACKED D K NONE O OTHER ININSP/MAINT 1 NM11 4889 UPI342 GEARBOX FILTER ASSY EPOXY IS CRACKED. 3 U E4CE 19970410004291997041000429SO 1997 4 10 97ZZZX1451 219970317G8510634503 BEARING CONT O520 GTSIO520* 17032SO PROP DRV GEAR MISPACKAGED B VA1RK NONE W INADEQUATE Q C ININSP/MAINT 1 SW19 P/N 630571 (BEARING FOR PROP DRIVER GEAR IN ENGINE CRANKCASE) MARKED ON PACKAGING AS P/N 630571. BEARING ITSELF MARKED AS P/N 634503. P/N 634503 IS CRANKSHAFT MAIN BEARING. PURCHASED NEW FROM TELEDYNE CONTINENTAL MOTORS. BEARINGS WILL FIT IN CRANKCASE SADDLES WHEN SWITCHED, BUT OIL HOLES DO NOT LINE UP AND BEARING OIL GROOVES ARE DIFFERENT WIDTHS. COULD CAUSE BEARING FAILURE/OIL STARVATION. 3 O E7CE 19970410004321997041000432NE 1997 4 10 970326 219970313G7230384347 AIR SEAL PWA JFTD12JFTD12A5A 52047NE 7TH STAGE REAR CRACKED B JYDRK NONE O OTHER ININSP/MAINT 1 NM09 1537 677775 ON MARCH 13, 1997, COMPRESSOR ASSY S/N 677775 WAS SCHEDULED FOR AN OVERHAUL, W.O. NR 25419. TEAR DOWN WAS COMPLETED ON MARCH 14, 1997, WITH NO PROBLEMS. THE AIR SEAL ON THE REAR OF THE 7TH STAGE DISK WAS NOTED TO HAVE A CRACK COMPLETELY THROUGH IT AND ANOTHER CRACK HALF-WAY THROUGH APPROXIMATELY 130 DEGREES FROM THE FIRST CRACK. SIGNS OF AIR SEAL RUBBING WERE NOTED OVER A 2 INCH LONG AREA ON THE ADJACENT PART. THE AIR SEAL EXHIBITED OVERHEAT DAMAGE FROM RUBBING 360 DEGREES AROUND ITS EDGE. (X) 4 U E15EA 19970410004501997041000450EU 1997 4 10 97ZZZX1471 219970401G7314996592 PUMP DIAMONDA20A1DA20A1 05626UXGL ROTAX 912 ROTAX912 55555EU OUTPUT TUBE CRACKED D A O OTHER K FLUID LOSS CRCRUISE 1 WP07671DA164 960157 10180 4412507 DURING FLIGHT, THE FUEL PUMP HOUSING CRACKED AT THE OUTPUT TUBE CAUSING THE AVAILABLE FUEL TO BE PUMPED INTO THE ENGINE COMPARTMENT. ONE-QUARTER TO ONE-HALF OF THE FUEL TANK WAS LOST IN APPROX 15 MINUTES. CAUSE OF THE FAILURE IS BELIEVED TO BE RELATIVE MOVEMENT OF THE RIDGED FUEL LINE OF ITS ATTACH POINT ON THE BALANCE TUBE. THE BALANCE TUBE WAS FOUND CHAFED. THIS IS THE SECOND OCCURRENCE OF THIS PROBLEM ON THIS AIRCRAFT. SUBMITTER RECOMMENDS AIRCRAFT INSPECTION AND RETURN TO AN EARLIER DESIGN USING SOFT LINES. 1L71 3O3 INTTA4CH EXPE3I 19970410004701997041000470GL 1997 4 10 HAIHEEA9214 219970318G725023055430 NOZZLE 23031899 ALLSN 250C 250C20B 03013GL NR 2 DEFECTIVE E HEEAK NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 SW03 CAT70200 ENGINE REMOVED DUE TO TURBINE OVERHAUL. TURBINE DISASSEMBLED DUE TO LOW POWER ON TEST CELL. DISASSEMBLY INSPECTION REVEALED: MATERIAL FLAKING AND MISSING ON #2 NOZZLE #2 TIP PATH. INSTALLED A DALLAS AIRMOTIVE OVERHAULED #2 NOZZLE. 3 U E4CE 19970410004761997041000476GL 1997 4 10 HAIHEEA9220 219970319G726023055466 GEARBOX COVER 6894171 ALLSN 250C 250C20B 03013GL ACCY GR BOX DEFECTIVE E HEEAK NONE WK INADEQUATE Q C FLUID LOSS ININSP/MAINT 1 SW03 CAG37111 CAE820964F GEARBOX DISASSEMBLED DUE TO AFT T/M LEAK ON TEST CELL. DISASSEMBLY INSPECTION REVEALED: AFT BUSHING HEIGHTH EXCEEDS PRINT DIMENSION ON GEARBOX COVER. INSTALLED A DALLAS AIRMOTIVE REPAIRED GEARBOX COVER. TIME SINCE REPAIR 0:00. 3 U E4CE 19970410004801997041000480GL 1997 4 10 HAIHEEA9225 219970321G725023008054 NOZZLE ALLSN 250C 250C28B 03013GL NR 1 BELOW SPEC E HEEAK NONE O OTHER ININSP/MAINT 1 SW03 RECEIVING INSPECTION REVEALED: MEASURED .044 BELOW MIN. SPECS (6.200) ON #1 NOZZLE AFT ROPE PACKING INNER RIM ID. 3 U E1GL 19970410005111997041000511NE 1997 4 10 HAIW6HR0072 219970211G7310430128602 FUEL MANIFOLD BELL 222 222U 1182140SW LYC LTS101LTS101750C1 41560NE ENGINE DEFECTIVE E W6HRE ENGINE SHUTDOWN A FLAME/FIRE ININSP/MAINT 1 WP21429MA 47523 LE47194 ENGINE SHOOTS OUT 2 FOOT FLAME PAST EXHAUST EJECTOR DURING START WITHOUT ANY MGT INDICATION UNTIL START PROGRESSES, THEN REMAINDER OF START IS NORMAL. SUSPECT EXCESS FUEL GETTING INTO ENGINE AT BEGINNING OF START ENGAGEMENT. SHIPPED CORE RETURN MANIFOLD TO RMH 02-11-97, SHIPPING MEMO# 97-0065. RDM 02/14/97. 1G72 3U3 U H9SW E5NE 19970417000551997041700055SO 1997 4 17 97ZZZX1582 219970310G8530637836 SPRING CONT O520 GTSIO520M 17032SO VALVE BROKEN BLAWTXRK NONE O OTHER ININSP/MAINT 1 NM07 1014 276111R ENGINE WAS RECEIVED AT FACILITY FOR INSPECTION DUE TO METAL CONTAMINATION. UPON DISASSEMBLY OF THE CYLINDERS, NOTED THERE WAS ONE BROKEN VALVE SPRING ON EACH CYLINDER IN THE INTAKE POSITION. CYLINDERS NR 1, NR 3, AND NR 4 HAD BROKEN INNER VALVE SPRINGS AND CYLINDERS NR 2, NR 5, AND NR 6 HAD BROKEN OUTER VALVE SPRINGS. THE SPRING ON NR 3 CYLINDER APPEARED TO HAVE BEEN BROKEN FOR SOME TIME AND WAS THE SOURCE OF THE METAL CONTAMINATION IN THE ENGINE. 3 O E7CE 19970417000561997041700056SO 1997 4 17 97ZZZX1583 219970310G8530637837 SPRING CONT O520 GTSIO520M 17032SO VALVE BROKEN BLAWTXRK NONE O OTHER ININSP/MAINT 1 NM07 1014 276111R ENGINE WAS RECEIVED AT FACILITY FOR INSPECTION DUE TO METAL CONTAMINATION. UPON DISASSEMBLY OF THE CYLINDERS, NOTED THERE WAS ONE BROKEN VALVE SPRING ON EACH CYLINDER IN THE INTAKE POSITION. CYLINDERS NR 1, NR 3, AND NR 4 HAD BROKEN INNER VALVE SPRINGS AND CYLINDERS NR 2, NR 5, AND NR 6 HAD BROKEN OUTER VALVE SPRINGS. THE SPRING ON NR 3 CYLINDER APPEARED TO HAVE BEEN BROKEN FOR SOME TIME AND WAS THE SOURCE OF THE METAL CONTAMINATION IN THE ENGINE. 3 O E7CE 19970417000621997041700062SO 1997 4 17 97ZZZX1589 219970321G8530TM641370 CYLINDER CONT O360 TSIO360F 17025SO NR 2 HEAD SEPARATED D K NONE O OTHER ININSP/MAINT 1 SW15 305385 DURING ANNUAL INSPECTION, FOUND NR 2 CYLINDER HEAD SEPARATING FROM BARREL. THE HEAD WAS TURNED COUNTERCLOCKWISE 4 DEGREES AND WAS .0625 INCH FARTHER FROM FIRST CYLINDER FIN THAN OTHER CYLINDERS. LEAK CHECK (PARAGRAPH C TCM SB 96-12) REVEALED LEAK. COMPRESSION WAS 69/80. 3 O E9CE 19970417002351997041700235SO 1997 4 17 97ZZZX1641 219970228G8530635448CN CYLINDER BEECH 36 36BEECH 1151602CE CONT O520 IO520B 17032SO NR 2 FAILED D O OTHER O OTHER NRNOT REPORTED 1 SW051194A 1400 E159 CYLINDER HEAD CAME OFF IN-FLIGHT 2-28-97. NO DAMAGE OR OIL LEAK OCCURRED. REPLACED CYLINDER. 1L71 3O3 O 3A15 E5CE 19970417002361997041700236EA 1997 4 17 97ZZZX1642 219970325G73203030523 SUPPORT BRACKET PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA P3 FILTER CRACKED DLA K NONE O OTHER ININSP/MAINT 1 GL09234074021 31T7920055 51979 INSPECTION FOUND P3 FILTER HOUSING SUPPORT BRACKET CRACKED. IF UNIT FAILED COULD AFFECT FCU. 1L72 3T4 T A8EA E4EA 19970417002391997041700239NE 1997 4 17 97ZZZX1645 219970228G72503029241 GAS GENERATOR CESSNA501 501 2076603CE PWA JT15 JT15D1 52060NE DIFFUSER TUBE CORROSION HOLE B EBVRK NONE O OTHER ININSP/MAINT 1 GL091AT 4730 1533 5010159 77405 WHILE TROUBLESHOOTING AN EXISTING PROBLEM WITH ONE ENGINE, THE DIFFUSER TUBES WERE FOUND TO HAVE HEAVY CORROSION WITH SEVERAL HOLES CORRODED THROUGH. SUBSEQUENT INSPECTION OF THE OTHER ENGINE RESULTED IN FINDING THE SAME PROBLEM. BOTH ENGINES WERE REMOVED AND SENT TO THE MANUFACTURER. 1L72 4F4 F A27CE E1NE 19970417002401997041700240NE 1997 4 17 97ZZZX1646 219970228G72503029241 GAS GENERATOR CESSNA501 501 2076603CE PWA JT15 JT15D1 52060NE DIFFUSER TUBE CORROSION HOLE B EBVRK NONE O OTHER ININSP/MAINT 1 GL091AT 4730 1533 5010159 77402 WHILE TROUBLESHOOTING AN EXISTING PROBLEM WITH ONE ENGINE, THE DIFFUSER TUBES WERE FOUND TO HAVE HEAVY CORROSION WITH SEVERAL HOLES CORRODED THROUGH. SUBSEQUENT INSPECTION OF THE OTHER ENGINE RESULTED IN FINDING THE SAME PROBLEM. BOTH ENGINES WERE REMOVED AND SENT TO THE MANUFACTURER. 1L72 4F4 F A27CE E1NE 19970417005491997041700549EA 1997 4 17 97ZZZX1666 219970331G8520 CRANKCASE ENSTRMF28 280F 3300550GL LYC O360 HIO360F1AD 41514EA CRANKCASE MISALIGNED DL K NONE W INADEQUATE Q C ININSP/MAINT 1 CE01199TV 1510 L2313251A A FACTORY OVERHAULED ENGINE WAS INSTALLED. ENGINE STARTED TO MAKE METAL. WHEN OIL WAS DRAINED, IT LOOKED LIKE ALUMINUM PAINT. AN OIL SAMPLE AND FILTER ELEMENT WERE SENT TO FACTORY. FACTORY REQUESTED THAT ENGINE BE REMOVED AND SENT IN FOR REPAIR. TIME ON ENGINE 63.5 HRS SMOH. SUSPECT CAUSE WAS MISALIGNED CRANKCASE. THIS CAUSED PISTON PINS TO SHIFT. 1G71 3O3 O H1CE 1E10 19970417005651997041700565GL 1997 4 17 97ZZZX1682 219970318G72106871064 DAMPER RING 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GEARBOX CRACKED D K NONE O OTHER ININSP/MAINT 1 AL038639F6734 3420 CAG36146 1280431D CAE832846 FOUND DAMPER RING CRACKED AND A SMALL CHIP MISSING ON THE OUTSIDE DIAMETER OF THE RING. THIS DEFECT BEING ON THE GEAR SIDE OF THE RING, FITS ALL THE WAY IN THE GROOVE, AND WAS ONLY FOUND AFTER REMOVAL. CRACK WAS 2 INCHES FROM THE END OF THE RING. 1G71 3U3 U H3WE E4CE 19970424000211997042400021SO 1997 4 24 97ZZZX1710 119970402G8120 RETAIN RING PIPER PA23 PA23250 7102308SO LYC O540 TIO540C1A 41532EA TURBO SCAV PUMP DISLODGED D O OTHER O OTHER NRNOT REPORTED 1 WP07548303440 277554128 EXTERNAL RETAINING RING THAT HOLDS THE TURBO SCAVENGE PUMP DRIVEN GEAR IN PLACE DISLODGED ALLOWING GEAR TO DISENGAGE WITH SUBSEQUENT PUMP FAILURE. WITH SCAVENGE PUMP INOPERABLE, OIL WAS FORCED BY TURBO SEAL AT A RAPID RATE AND BURNED IN THE EXHAUST UNNOTICED BY PILOT UNTIL TAXIING IN. MINUTES MORE IN FLIGHT COULD HAVE RESULTED IN IMMINENT ENGINE FAILURE. SUBMITTER SUSPECT CAUSE WAS FAILURE TO C/W LYC SI NR 1338 DATED 7-2-76, AT ENGINE OVERHAUL WHICH WOULD HAVE REPLACED RETAINING RING WITH A ROLL PIN. POTENTIAL CONSEQUENCES OF THIS MALFUNCTION SHOULD HAVE WARRANTED MORE ATTENTION THAN JUST A SERVICE INSTRUCTION. 1L72 3O3 O 1A10 E14EA 19970424000231997042400023SO 1997 4 24 97ZZZX1712 219970404G8540635050A1 ADAPTER GEAR CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO STARTER FAILED B UG1RK NONE O OTHER ININSP/MAINT 1 SW03999VE1067 421C0629 272357R ENGINE FAILED TO START. INSPECTION REVEALED FAILED STARTER ADAPTER. REMOVED ADAPTER AND FOUND DRIVE GEAR AND CRANKSHAFT GEAR DEFECTIVE. INSPECTION OF OIL FILTER REVEALED METAL CONTAMINATION OF ENGINE OIL SYSTEM. ENGINE TSOH: 1,067 HOURS. SUBMITTER RECOMMENDS C/W MANUFACTURER'S SB CSB94-4. 1L72 3O3 O A7CE E7CE 19970424000281997042400028NE 1997 4 24 97ZZZX1716 219970327G7230745704 C4 DISK PWA JT8 JT8D1 52044NE WINDAGE TAB CORRODED B VF5RK NONE O OTHER ININSP/MAINT 1 NE03 25321 K52635 C4 DISK WAS RETURNED DUE TO CORROSION. DISK WAS RECEIVED WITH 3 BROKEN AND 6 BENT WINDAGE TABS. PER ENGINE MANUAL 481672 SECTION 72-33-35, INSP 01. THIS PART IS SCRAP. PART WAS TAGGED SCRAP AND RETURNED. 4 F E2EA 19970424002821997042400282WP 1997 4 24 97ZZZX1739 219970328G7210 ENGINE GULSTM690TP 695 7630518SW GARRTTTPE331TPE33110 01514WP GEARBOX FAILED D E ENGINE SHUTDOWN J WARNING INDICATION CRCRUISE 1 WP233U 3451 17 95041 P38096 LEFT ENGINE SHUT DOWN IN-FLIGHT DUE TORQUE PRESSURE DROP (40 PSI). SPEED INCREASE TO 103+ . ON INSPECTION, NO OUTWARD SIGN OF DAMAGE, BUT COULD NOT ROTATE PROPELLER. ENGINE OIL FILTER REMOVED, METAL IN FILTER. METAL ON CHIP DETECTOR (NO LIGHT). OIL BLACK AND MILKEY. S.O.A.P. OBTAINED. SUSPECT GEARBOX PROBLEM. ENGINE REMOVED AND SHIPPED TO REPAIR AGENT FOR INVESTIGATION. 1H72 3T4 T 2A4 E4WE 19970424002881997042400288EA 1997 4 24 97ZZZX1745 219970408G731402532330003 PUMP PESCO BEECH 200 B200 1152922CE PWA PT6 PT6A41 52043EA LT ENG FUEL SHAFT FAILED D O OTHER X ENGINE FLAMEOUT CRCRUISE 1 GL23942CE 7476 BB494 PCE817782 ENGINE WENT TO IDLE CUT OFF IN-FLIGHT. (FLAME OUT.) MAIN ENGINE PUMP SEIZED. ENGINE SHAFT BECAME WORN AND ROUNDED OFF SPLINES. 1L72 4T4 T A24CE E4EA 19970424003031997042400303NE 1997 4 24 97ZZZX1760 219970219G7240 LINER CESSNA501 501 2076603CE PWA JT15 JT15D1 52060NE ENGINE COMB BURNED D O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 WP25501AF6024 2522 500139 79128 PILOT REPORTED TEMP SPLIT BETWEEN ENGINES. MECHANIC PERFORMED GROUND PERFORMANCE RUN AND NOTED THE RIGHT ENGINE'S OUTPUT LOW. A BORESCOPE INSPECTION OF ENGINE HOT SECTION THROUGH THE INBD IGNITER HOLE WAS MADE AND FOUND THE COMBUSTION LINER BURNED AT THE OTBD IGNITER HOLE BY THE IGNITER. THE ENGINE HOT SECTION WAS REMOVED AND ALL COMPONENTS SENT TO P&WC FOR INSPECTION AND REPAIR. 1L72 4F4 F A27CE E1NE 19970424003291997042400329GL 1997 4 24 97ZZZX1786 219970318G72606889094 GEAR 6894171 HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GEARBOX TEETH PITTED B EOORK NONE O OTHER ININSP/MAINT 1 AL038639F UPI341 1280431D CAE832846 FOUND PTTING AND NICKS ON TEETH OF AIR OIL SEPARATOR GEAR. 1G71 3U3 U H3WE E4CE 19970424008701997042400870SO 1997 4 24 97ZZZX1821 219970404G8550653491 FILTER ADAPTER BEECH 36 A36 1151604CE CONT O550 IO550B SO ENGINE OIL PLUG LOOSE D A K NONE O OTHER ININSP/MAINT 1 WP278294M239 E2761 296844R WHEN THE OIL FILTER WAS REMOVED DURING AN ENGINE INSPECTION, DISCOVERED A PLUG THAT WAS PRESSED INTO AN UNUSED OIL PASSAGE IN THE OIL FILTER ADAPTER HAD COME LOOSE. THIS ALLOWED THE OIL FILTER TO BE BYPASSED AND FOR UNFILTERED OIL TO BE PUMPED IN THE OIL SYSTEM. THIS WAS A FACTORY REBUILT ENGINE WITH 239 HRS SINCE INSTALL. IT IS RECOMMENDED THE OIL FILTER ADAPTERS THAT HAVE THIS FEATURE BE INSPECTED TO CONFIRM THE SECURITY OF THE BLOCK-OFF PLUG INSTALLATION. 1L71 3O3 O 3A15 E3SO 19970424008741997042400874EA 1997 4 24 97ZZZX1825 219970407G8530AEL12949 VALVE 75137CN HILLERUH12 UH12E 4360122WP LYC O540 VO540C2A 41532EA NR 2 CYLINDER FAILED DL K NONE O OTHER ININSP/MAINT 1 NM0936MV 167 06 5060 L256043 THE HELICOPTER WAS RUNNING ROUGH SO A COMPRESSION CHECK WAS RUN. THE NR 2 CYLINDER HELD NO COMPRESSION AND WAS REMOVED FOR INSPECTION. NOTED A .1250 INCH BY .25 INCH SECTION OF THE VALVE FACE WAS MISSING. THE MISSING SECTION WAS IRREGULAR IN SHAPE AND APPEARED TO HAVE MANUFACTURING VOIDS WITHIN THE BASE METAL. SMALL CRATER LIKE HOLES WERE FOUND ALONG THE EDGE OF THE BROKEN SECTION. THE VALVE STEM SHOWED HIGH WEAR ADJACENT TO THE VALVE KEEPERS UNDER THE HAT SECTION AT THE TOP OF THE VALVE. IT APPEARED AS THOUGH THE VALVE WAS MANUFACTURED WITH SOFT MATERIAL. 1G71 3O3 O 4H11 E304 19970424008751997042400875SO 1997 4 24 97ZZZX1826 219970206G8540631871 CRANK GEAR CESSNA421 421 2076010CE CONT O520 GTSIO520H 17032SO CRANKSHAFT SCREWS LOOSE BL CY4RK NONE W INADEQUATE Q C ININSP/MAINT 1 AL034584L 4210784 21015370H UPON ENGINE DISASSEMBLY FOUND ALL 6 CRANK GEAR RETAINING SCREWS 'GANG WIRED'. IN ADDITION TO NOT BEING LOCK WIRED CORRECTLY, THE CRANK GEAR SCREWS WERE ALL LOOSE. SEE TELEDYNE CONTINENTAL MOTORS SIL 93-15 FOR CORRECT USE OF SAFETY WIRE, KEYS, AND LOCK TABS. FURTHER INSP REVEALED THE STARTER SHAFT NEEDLE BEARING, P/N 537721 (SEE GTSIO-520 PARTS BOOK NR X30046A, FIG 1, ITEM NR 3), WAS MISSING AND APPEARED THAT IT WAS NEVER RE-INSTALLED AT OVERHAUL, DATED 7-20-95. ALSO, LOG ENTRIES OF 2-16-96, TSO NOT NOTED, REVEALED CONTINUAL REPORTS OF STARTER/STARTER DRIVE SEAL LEAKS AND REPAIR WHICH IN 'HINDSIGHT' ARE UNDERSTANDABLE KNOWING STARTER DRIVE WAS NOT PROPERLY SUPPORTED ON THE LOWER OF 'CRANKCASE END' OF THE SH1L72 3O3 ORTA7CE E7CE 19970424008841997042400884EA 1997 4 24 97ZZZX1834 219970401G7414M3548 ROTOR SHAFT SLICK 4370 CESSNA172 172P 2072436CE LYC O360 O360A4M 41514EA MAGNETO BROKEN B EBVRK NONE O OTHER ININSP/MAINT 1 GL095361K 260 94100187 74080 L3350536A MAGNETO ROTOR SHAFT SHEARED .25 INCH BELOW CAM. SUBMITTER RECOMMENDS VISUAL INSPECTION OF SHAFT AT DISASSEMBLY. 1H71 3O3 ONT3A12 E286 19970424008881997042400888SO 1997 4 24 97ZZZX1838 219970301G8530 CYLINDER BEECH 36 A36 1151604CE CONT O550 IO550B SO ALL CYLS EXCESS WORN H K NONE O OTHER ININSP/MAINT 1 GL1172291850 E2247 REMOVED ALL CYLINDERS FROM AN 850-HOUR FACTORY REMANUFACTURED (ZERO TIME) ENGINE DUE TO LOW COMPRESSION. FOUND ALL CYLINDERS WORN .009 INCH - .011 INCH OVER NEW SPECS. OPERATOR KEEPS OIL SAMPLES WITH NO INDICATIONS. NORMAL OIL CHANGES AND GOOD PILOT OPERATION. 1L71 3O3 O 3A15 E3SO 19970424008911997042400891SO 1997 4 24 97ZZZX1841 219970408G8550 OIL PAN CESSNA172 172A 2072404CE CONT O300 O300A 17022SO PLUG BOSS CORRODED D K NONE O OTHER ININSP/MAINT 1 EA218591B 36291 16036 CORROSION FOUND INSIDE OF THE BOTTOM OF THE OIL PAN AROUND THE PLUG BOSS. THIS WAS DUE TO MOISTURE CONDENSING AND COLLECTING AT THE BOTTOM OF PAN. IF THE AIRCRAFT IS GOING TO SIT FOR WEEKS ON END;SUBMITTER SUGGESTS ONE-QUARTER OF THE OIL BE DRAINED AS THIS WILL FACILITATE REMOVAL OF THE COLLECTED MOISTURE. 1H71 3O3 O 3A12 E253 19970424008981997042400898NE 1997 4 24 970401 219970414G7230536210 TAB LOCK PWA JFTD12JFTD12A4A 52047NE COMP BLADE MISSING B JYDRK NONE O OTHER ININSP/MAINT 1 NM092FOR 2998 672538 TAB LOCK FOUND MISSING WHEN ENGINE DISASSEMBLED. NO CONTACT NOTED BETWEEN BLADE AND 3RD STAGE STATOR. BROKEN PIECES OF THE TAB LOCK CONTACTED BLADES AND STATORS AFT OF THE 3RD STAGE CAUSING IMPACT DAMAGE. ENGINE WAS LAST OVERHAULED BY PRATT AND WHITNEY. (X) 4 U E15EA 19970428000971997042800097NM 1997 4 28 CA970109001 119970103G21003033716X2 SEALS DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE AIR COND SYS LEAKING W D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA 120854 (CAN) HAZE IN CABIN AND LAV. SMOKE DETECTOR SOUNDED. #1 AND #2 ENGINE COMPRESSOR DRAINS CHECKED FOR OIL. NONE FOUND. P2.5 AND P3 SWITCHING VALVE PISTON RINGS REPLACED. 2H72 4T4 TRTA13NM E20NE 19970428000981997042800098NE 1997 4 28 CA970109002 319970103G6112SFA13M1ROA BLADE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE DEICE BOOT BURNED BOOT W K NONE O OTHER ININSP/MAINT 1 CA 8380 8380 120226 881010 (CAN) #2 PROPELLER BLADE DE-ICE BOOT SHORTED BURNED RUBBER OFF THE BLADE. BLADE REPAIRED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 19970501001221997050100122EA 1997 5 1 97ZZZX1867 219970225G8500 ENGINE PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA ENGINE REAR FIRE B KG4RK NONE A FLAME/FIRE NRNOT REPORTED 1 SO19437334154 667 288416122 L1131939A ENGINE COMPARTMENT ON FIRE AT REAR OF ENGINE. INSPECTION OF ENGINE REVEALS NO APPARENT CAUSE FOR START-UP OF FIRE. CARBURETOR SENT TO SOUTHEAST FUEL SYSTEM, CRS TW4R559M FOR INSPECTION. REFER TO CEU INV NR 27646/2878 FOR DETAILS. 1L71 3O3 O 2A13 E274 19970501001231997050100123EA 1997 5 1 97ZZZX1868 219970404G7414M3975 COIL SLICK 4371 CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA MAG SHORTED B EEARK NONE O OTHER ININSP/MAINT 1 WP2165875218 17275910 RL1835339A RIGHT MAGNETO ON ENGINE INOPERATIVE. NO ELECTRICAL OUTPUT. FOUND COIL AND SECONDARY COIL OHMS READING TO BE OUT OF TOLERANCE. REMOVED COIL FOUND BURNED OUT SPOT ON BOTTOM OF COIL SHORTED OUT TO CASE. INSTALL NEW COIL. 1H71 3O3 ONT3A12 E274 19970501001271997050100127SO 1997 5 1 97ZZZX1872 219970401G855012509221 ADAPTER CESSNA206 U206G 2073356CE CONT O520 IO520L 17032SO OIL FILTER DAMAGED D K NONE O OTHER ININSP/MAINT 1 NM09756HK4271 U20604102 567375 DURING ENGINE CHANGE, THE OIL FILTER ADAPTER WAS REMOVED AND THE THREADS WERE FOUND DAMAGED AS DEPICTED IN AD 96-12-22. THERE WERE NO SIGNS OF LEAKAGE, BUT THE BREAKAWAY TORQUE APPEARED TO BE LOW. SUBMITTER STATED THIS IS THE THIRD ADAPTER OF THIS TYPE FOUND WITH THREAD DAMAGE. DIFFICULTY IN TORQUING WHILE MAINTAINING PROPER ALIGNMENT MAY BE A POSSIBLE CAUSE. 1H71 3O3 O A4CE E5CE 19970501001341997050100134EA 1997 5 1 97ZZZX1879 219970403G8520SL13521 ROD BEARING BEECH 23 C23 1151242CE LYC O360 O360A4K 41514EA NR 3 FAILED B UC2RK NONE O OTHER ININSP/MAINT 1 GL1913FC 661 M2017 L2620936A METAL WAS FOUND IN THE SCREEN AND OIL FILTER AT THE 100-HOUR INSPECTION. THE CYLINDERS WERE REMOVED AND NO EVIDENCE OF METAL WEAR COULD BE FOUND. THE AIRCRAFT WAS PUT BACK INTO SERVICE AND FLOWN FOR APPROXIMATELY 50 HOURS. THE SCREENS AND FILTERS WERE AGAIN CHECKED FOR METAL. MORE METAL WAS FOUND AND THE ENGINE WAS REMOVED AND DISASSEMBLED FOR FURTHER INSPECTION. THE NR 3 ROD BEARING WAS FOUND TO HAVE THE TOP LAYER OF MATERIAL (BABBIT) STARTING TO SEPARATE AND FLAKE OFF. 1L71 3O3 O A1CE E286 19970501001381997050100138SO 1997 5 1 97ZZZX1883 219970317G8540536421 CRANK GEAR CESSNA180 180 2072602CE CONT O470 O470J 17026SO ASSY CASE TEETH BROKEN OFFD K NONE O OTHER ININSP/MAINT 1 NM093129D 1656 31927 469748JR NOISE HEARD AT IDLE POWER AFTER LANDING THAT SOUNDED LIKE A ROD KNOCK (OR A WELL RUNNING RADIAL ENG). DECIDED TO DISASSEMBLE ENGINE FOR OVERHAUL. FOUND TWO TEETH MISSING FROM CRANK GEAR P/N 536421 AND ONE TOOTH MISSING AND ANOTHER TOOTH CRACKED ON CAM GEAR P/N 535660. TEETH WERE FOUND IN OIL PAN. SUSPECT GEARS WERE STRESSED FROM SUDDEN STOPPAGE IN 1972. ENG TT SINCE CONT REMAN: 2,615 HRS. 1H71 3O3 ONC5A6 E273 19970501001391997050100139SO 1997 5 1 97ZZZX1884 219970317G8540535660 CAM GEAR CESSNA180 180 2072602CE CONT O470 O470J 17026SO ASSY CASE TEETH BROKEN OFFD K NONE O OTHER ININSP/MAINT 1 NM093129D 1656 31927 469748JR NOISE HEARD AT IDLE POWER AFTER LANDING THAT SOUNDED LIKE A ROD KNOCK (OR A WELL RUNNING RADIAL ENG). DECIDED TO DISASSEMBLE ENGINE FOR OVERHAUL. FOUND TWO TEETH MISSING FROM CRANK GEAR P/N 536421 AND ONE TOOTH MISSING AND ANOTHER TOOTH CRACKED ON CAM GEAR P/N 535660. TEETH WERE FOUND IN OIL PAN. SUSPECT GEARS WERE STRESSED FROM SUDDEN STOPPAGE IN 1972. ENG TT SINCE CONT REMAN: 2,615 HRS. 1H71 3O3 ONC5A6 E273 19970501001441997050100144NE 1997 5 1 97ZZZX1889 219970109G72603013883H IDLER GEAR BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE ACCESSORY CASE FAILED GPA K NONE O OTHER ININSP/MAINT 1 SW036606R2368 BB1122 PILOT REPORTED AIR COND INOP. MAINT SUSPECTED 'QUILL SHAFT' HAD SHEARED. REMOVED AND FOUND SHAFT IN SERVICEABLE CONDITION. REMOVAL OF ACCESSORY CASE FOUND IDLER GEAR HAD FAILED RESULTING IN LOSS OF DRIVE FOR AIR/COND COMP. NO REASON FOR FAILURE HAS BEEN DETERMINED AT THIS TIME. PART HAS BEEN SENT TO PRATT AND WHITNEY FOR EVAL. 1L72 4T4 T A24CE E4EA 19970501003441997050100344EA 1997 5 1 97ZZZX1901 219970325G74141068291018 MAGNETO ELECTROSYS D6RN3200 PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA BASE FLANGE LOOSE B V0ARK NONE W INADEQUATE Q C ININSP/MAINT 1 SO012QC 400 4052388 317752124 INSPECTION FOUND MAG COULD BE MOVED DUE TO BASE METAL FROM FLANGE MISSING TOP AND BOTTOM ABOUT .0625 INCH. MAG P/N 10-68291018, TYPE D6RN3200. SUBMITTER STATED THIS IS 2ND MAG 2000/3000 SERIES FOUND LOOSE WITH FLANGE METAL MISSING. 1L72 3O3 O A20SO E14EA 19970501003461997050100346NE 1997 5 1 97ZZZX1903 219970301G73231412654 BEARING WOODWARD 8210 PWA PT6 PT6A25 52043NE GOVERNOR MISASSEMBLY H K NONE W INADEQUATE Q C ININSP/MAINT 1 NM03 NEW WOODWARD BEARING P/N 1412-654. RECEIVING IN INSPECTION REVEALED THAT INNER BEARING RACE, ROLLER BALLS, AND BALL CAGE WERE NOT SEATED CORRECTLY INTO THE OUTER RACE. BEARING WOULD SPIN, HOWEVER, THE OUTER RACE WOULD 'WOBBLE' WHEN ROTATED. 3 T E4EA 19970501003671997050100367WP 1997 5 1 CA970110002 219970115G732130708165 PT SENSOR LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP #2 ENGINE FAULTY W AH UNSCHED LANDING DEACTIVATE SYST/CIRCUITS R PARTIAL RPM/PWR LOSS CLCLIMB 1 CA 9657 P74369 (CAN) DURING TAKEOFF THE #2 ENGINE RPM BEGAN TO OSCILLATE. THE ENGINE COMPUTER WAS SELECTED TO THE OFF POSITION. THE ENGINE RPM STABILIZED BUT WOULD NOT MAKE POWER, APPROXIMATELY 80 PERCENT N1. THE AIRCRAFT RETURNED TO BASE AND LANDED WITHOUT INCIDENT. TROUBLESHOOTING FOUND THE PT2 SENSOR PROBE TO BE THE FAULT, ALTHOUGH NO DAMAGE TO THE PROBE WAS EVIDENT. THE PROBE WAS REPLACED AND THE ENGINE GROUND RUN WITH THE COMPUTERS ON AND OFF CARRIED OUT. ALL PARAMETERS NORMAL AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 F A10CE E6WE 19970501003681997050100368NM 1997 5 1 CA970110003 119970101G24351243106 STARTER DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE #1 ENG FAILED W OF OTHER ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA 575A 120549 (CAN) CREW ABORTED START DUE TO SMOKE FROM #1 ENGINE NACELLE. ON PREVIOUS FLIGHT GENERAL CAUTION LIGHT HAD FAILED WITH EXCITER BREAKER POP. STARTER/GENERATOR REPLACED. 2H72 4T4 TRTA13NM E20NE 19970501003721997050100372EA 1997 5 1 CA970114001 219970105G8550CH48103 OIL FILTER CHAMPION PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA ENG OIL COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA L613961A (CAN) DURING OIL FILTER REPLACEMENT, THE OIL FILTER WAS FOUND COLLAPSED. COLD WEATHER OPERATION IS THE SUSPECTED CAUSE. LYCOMING SERVICE BULLETIN #1442 COMPLIED WITH TO PREVENT REOCCURRENCE. 1L72 3O3 O A20SO E14EA 19970501003821997050100382EA 1997 5 1 CA970114019 219970107G8550CCB3700 VALVE DRAIN CURTIS PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA BOTTOM #1 ENGINELEAKING W O OTHER K FLUID LOSS CRCRUISE 1 CA 1925 L159368A (CAN) OIL LEAK ON #2 ENGINE FOLLOWING FLIGHT. INSPECTION FOUND THE OIL DRAIN COCK LEAKING. OIL SEAL APPEARED AGED AND HARDENED. OIL SEAL REPLACED AND DRAIN COCK CLEANED AND REPLACED. 1L72 3O3 O A20SO E14EA 19970501003871997050100387WP 1997 5 1 CA970114026 119970101G215021700091 AIR CYCLING MACH DOUG DC9 DC932 3022066WP PWA JT8 JT8D7A 52053NE LH AIR CONDITIONFAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA P656990D (CAN) LEFT HAND AIR CONDITIONING PACK CAUSED OIL SMELL IN CABIN. LEFT AIR CONDITIONING AIR CYCLING MACHINE CHANGED. OPERATION AND LEAK CHECKED CARRIED OUT. SYSTEM CHECKED SERVICEABLE. 2L72 4F4 F A6WE E2EA 19970501003891997050100389WP 1997 5 1 CA970114028 119970104G213121011403 CONTROLLER DOUG DC9 DC932 3022066WP PWA JT8 JT8D7A 52053NE NR 1 PRESSURE FAILED W BG EMER. DESCENT O2 MASK DEPLOYED O OTHER CRCRUISE 1 CA P657224D (CAN) LOSS OF PRESSURIZATION AT 12,600 FT. CABIN OVER 10,000 FT. OXYGEN MASKS DEPLOYED. BITE CHECK CARRIED OUT AND SHOWED #1 CONTROLLER AT FAULT. BOTH AUTO PRESSURIZATION CONTROLLERS CHANGED AND OPERATIONALLY CHECKED SERVICEABLE. 2L72 4F4 F A6WE E2EA 19970501003901997050100390EA 1997 5 1 CA970114029 119970101G326016215103 BRACKET CNDAIRCL600 CL6002B19 EA GE CF34 CF343A 30015NE NLG PROX SWITCH DAMAGED W O OTHER J WARNING INDICATION CLCLIMB 1 CA 5312 807157 (CAN) AFTER NOSE GEAR RETRACTION, NOSE GEAR REMAINED DOWN. GEAR DISAGREE AND NOSE DOOR OPEN MESSAGES APPEARED. FOUND NOSE LANDING GEAR CENTERING PROXIMITY SWITCH BRACKET DAMAGED. BRACKET REPLACED AND SWITCH ADJUSTED. 2L72 4F4 FRTA21EA E15NE 19970501003921997050100392SW 1997 5 1 CA970115002 119970107G6322204060448001 BLOWER BELL 204 204B 1181404SW LYC T53 T5313B 41549NE OIL COOLER ROUGH BEARING W K NONE O OTHER ININSP/MAINT 1 CA LE18135A (CAN) BEARINGS IN OIL COOLER BLOWER SOUND ROUGH AND DRY WHEN FAN IS TURNED BY HAND. BLOWER REMOVED AND BEARINGS REPLACED. 1G71 4U4 U H1SW E17EA 19970501003931997050100393EA 1997 5 1 CA970115006 119970108G2421755469C IDG SUNDSTRANDEM CNDAIRCL600 CL6002B19 EA GE CF34 CF343A 30015NE #2 ENGINE FAILED W CD ABORTED TAKEOFF RETURN TO BLOCK O OTHER TOTAKEOFF 1 CA 2253 H807335 (CAN) AIRCRAFT REJECTED TAKEOFF DUE TO #2 GENERATOR TRIPPING OFF LINE. INTEGRATED DRIVE GENERATOR REPLACED. 2L72 4F4 FRTA21EA E15NE 19970501003951997050100395SW 1997 5 1 CA970115008 119970103G7603MS20392211 CLEVIS PIN SWRNGN 2761002009 SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP POWER LEVER FRETTING W K NONE O OTHER ININSP/MAINT 1 CA P54024 (CAN) IN REFERENCE TO SERVICE DIFFICULTY ADVISORY AV-96-06, INSPECTION CARRIED OUT ON THE CLEVIS PIN IN THE POWER LEVER SYSTEM. THE PINS IN THE LEFT AND RIGHT ENGINES WERE NOTICEABLY WORN, AND THE COTTER PIN HOLES ELONGATED. BOTH CLEVIS AND COTTER PINS WERE REPLACED. 2L72 4T4 TRTA8SW E4WE 19970501003961997050100396CE 1997 5 1 CA970117001 119970104G27301156100181 SUPPORT BEECH 115610010325BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA ELEV TORQ TUBE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 9005 PCE50045 (CAN) CRACK FOUND ON THE INBOARD TAPER PIN HOLE ON THE TORQUE TUBE SUPPORT BRACKET WHERE IT ATTACHES TO THE ELEVATOR. 1L72 3T4 T A14CE E4EA 19970501003971997050100397GL 1997 5 1 CA970117002 319970109G6111900CA2 PROP BLADE CESSNA180 180F 2072614CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C203 GL LEADING EDGE STONE NICKED W K NONE O OTHER ININSP/MAINT 1 CA 134 842373R4 750677 (CAN) DURING CORROSION INSP PROPELLER BLADES WERE FOUND "STONE" NICKED. NICKS WERE TRIMMED OUT. 1H71 3O3 O 5A6 E273 5 CP3EA 19970501003981997050100398EU 1997 5 1 CA970117006 119970109G3230 LANDING GEAR AEROSPATR42 ATR42300 8680920EU PWA 120 PW120 NE HAMSTD14SF 14SF5 NE NOSE ICED UP W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 120905 880501 (CAN) AFTER TAKEOFF THE NOSE LANDING GEAR DID NOT RETRACT. MAINTENANCE FOUND THE NOSE GEAR BAY CONTAMINATED WITH A LOT OF SNOW AND ICE. 2H72 4T4 TRTA53EU E20NE 6 CP7NE 19970501004001997050100400EA 1997 5 1 CA970121006 119970109G301015323 DEICE VALVE BENDIX DHAV DHC6 DHC6100 EA PWA PT6 PT6A20 52043EA WING DE ICE FAILED W O OTHER O OTHER APAPPROACH 1 CA 120 42952U PCE21305 (CAN) ON APPROACH AIRCRAFT ENCOUNTERED HEAVY ICING CONDITIONS. AFTER LANDING THE INBOARD HALF OF WING FOUND COVERED WITH ICE. WING DEICE DISTRIBUTOR VALVE WAS CYCLED BUT DID NOT WORK. VALVE REPLACED. A MOD WILL BE INTRODUCED TO INSTALL HEATER AROUND THE VALVES AS THE PREVIOUS VALVE HAD MOISTURE IN IT. 1H72 3T3 T A9EA E4EA 19970501004071997050100407EA 1997 5 1 97ZZZX1917 219970417G8520LW18639 LOCKPLATE CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA CRANKSHAFT GEAR FAILED D K NONE O OTHER ININSP/MAINT 1 CE074863H1551 15283989 L2045515 SEE LYCOMING O-235 SERIES PARTS CATALOG PC-302, FIGURE 3, INDEX 9. WHILE TROUBLESHOOTING EXCESSIVE MAGNETO DROP AND INSUFFICIENT STATIC RPM, DISCOVERED SCREW (STD 2213) HAD BACKED OUT OF CRANKSHAFT. THE LOCKPLATE EARS WERE FOUND IN THE OIL SUMP; THE CRANKSHAFT GEAR (13S19646) AND DOWEL (STD 1065) WERE WORN BEYOND LIMITS. THE ENGINE HAD BEEN OVERHAULED SEVEN YEARS PRIOR TO THIS EVENT; THE LOGBOOK ENTRY STATES, 'ASSEMBLED CRANKSHAFT GEAR ON CRANKSHAFT IAW LYCOMING SB NR 475. USED A NEW BOLT AND LOCKPLATE, FINAL TORQUES TO 204 INCH/POUND.....'. 1H71 3O3 ONT3A19 E223 19970501004091997050100409SO 1997 5 1 97ZZZX1919 219970422G8520653580 GEAR CESSNA421 421C 2076016CE CONT O520 GTSIO520N 17032SO CRANKSHAFT FAILED B VA1RK NONE O OTHER ININSP/MAINT 1 SW196867L400 421C1087 608068 NEW CRANKSHAFT GEAR P/N 653580 INSTALLED AT TIME OF ENGINE OVERHAUL IN CONJUNCTION WITH TCM SB CSB 94-4 IN KIT EQ6642. ENGINE FAILED APROXIMATELY 400.0 HOURS LATER. ENGINE DISASSEMBLY REVEALED THE POSSIBILITY THE GEAR BROKE FIRST CAUSING DAMAGE TO VALVE TRAIN, STARTER ADAPTER GEAR, AND IDLER GEAR. 1L72 3O3 O A7CE E7CE 19970501004101997050100410SO 1997 5 1 97ZZZX1920 219970415G8520 CRANKCASE BEECH 35 S35 1151532CE CONT O520 IO520B 17032SO NR 2 CYL BASE CRACKED D K NONE O OTHER ININSP/MAINT 1 SO138604Q2078 940 D7635 1219368B DURING ANNUAL INSPECTION, CRANKCASE AT NR 2 CYLINDER BASE STUD FOUND CRACKED FOUR INCHES LONG. THIS IS A LIGHT CASE ENGINE. 1L71 3O3 O 3A15 E5CE 19970506000061997050600006EU 1997 5 6 CA970121005 219970101G7320196 FUELFLOW REG FOKKERF28 F28MK1000 4990808EU RROYCESPEY SPEY55515 54521EU #1 ENGINE FAULTY W CD ABORTED TAKEOFF RETURN TO BLOCK J WARNING INDICATION TOTAKEOFF 1 CA 2944 L820 9635 (CAN) ON TAKEOFF ROLL THE #1 ENGINE WOULD NOT SPOOL UP TO FULL POWER. AIRCRAFT RETURNED TO GATE. MAINTENANCE FOUND THE FUEL FLOW REGULATOR TO BE FAULTY. THE FUEL FLOW REGULATOR WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA20EU E2EU 19970508000121997050800012EA 1997 5 8 97ZZZX1934 219970401G853075838 VALVE GUIDE ENSTRMF28 F28C 3300407GL LYC O360 HIO360E1BD 41514EA NR 4 CYLINDER FAILED D O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 EA175691Y566 4792 L1981551A EXHAUST VALVE GUIDE BROKE UP LETTING THE EXHAUST VALVE LOOSEN IN THE CYLINDER. EXHAUST VALVE DID NOT FAIL. PIECES FROM THE GUIDE JAMMED THE TURBOCHARGER TURBINE WHEEL DESTROYING THE TURBOCHARGER AND CAUSING LOSS OF POWER. 1G71 3O3 O H1CE 1E10 19970508004021997050800402NE 1997 5 8 97ZZZX1938 219970416G7250657803 T3 DISK BELL 206 206B 1181511SW PWA JT3D JT3D3B 52039NE TIE ROD HOLES CRACKED D K NONE O OTHER ININSP/MAINT 1 SO1930VA 12935 3229 P645748 DURING ROUTINE DISASSEMBLY AND ENGINE BUILD-UP, AD 82-14-02 WAS C/W ON T-3 DISK. DURING EDDY CURRENT INSPECTION, FOUND 2 TIE ROD HOLES HAD CRACKS RADIATING FROM HOLES INTO DISK. DISK WAS REMOVED FROM SERVICE AND SCRAPPED. CYCLES, 6,623. 1G71 3U4 F H2SW 1E8 19970508004101997050800410EA 1997 5 8 97ZZZX1946 219970402G7314RG17980J PUMP ROMEC PIPER PA23 PA23250 7102308SO LYC O540 TIO540C1A 41532EA ENGINE FUEL LEAK D A O OTHER KA FLUID LOSS FLAME/FIRE TOTAKEOFF 1 SO0327FM 1100 1100 B8608 277654087 L416961A PUMP LEAKAGE AT SEAM CASE TO PUMP. PUMP LEAKAGE OCCURRED AT TAKEOFF. SPRAYED FUEL DIRECTLY ON HOT TURBOCHARGER CAUSING FIRE IN ENGINE COMPARTMENT. APPEARED TO LEAK AT GASKET FLANGE. 1L72 3O3 O 1A10 E14EA 19970508004131997050800413EA 1997 5 8 97ZZZX1949 219970324G8530 CYLINDER PIPER PA34 PA34200 7103405SO LYC O360 LIO360C1E6 41515EA NR 2 CYLINDER CRACKED D K NONE O OTHER ININSP/MAINT 1 SO13557773993 1762 347350244 L71467A NR 2 CYLINDER FOUND CRACKED AT THE MOLD LINE THROUGH THE SPARKPLUG HOLE OUT ONTO THE TOP OF THE CYLINDER, THE INTAKE SIDE, RIGHT ENGINE. 1L72 3O3 O A7SO 1E10 19970508004141997050800414EA 1997 5 8 97ZZZX1950 219970414G8520SL13212M03 BEARING BEECH B80 B80 1153010CE LYC O540 IGSO540A1D 41532EA CONNECT ROD DETERIORATED D K NONE O OTHER ININSP/MAINT 1 GL1965RW 775 LD404 L240950 SECTIONS FROM THE CENTER OF THE BEARING APPEARED TO DETERIORATE OR DISSOLVE WITH NO APPARENT REASON. QUALITY OF BEARING IS IN QUESTION. 1L72 3O3 ORT3A20 1E7 19970508004171997050800417EA 1997 5 8 97ZZZX1953 219970304G8520LW15949 GEAR TOOTH CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA CRANKSHAFT FAILED D A UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 NM01734JD3050 350 17268882 RL323376T ENGINE STARTED TO MAKE A KNOCKING NOISE WHILE IN-FLIGHT. AS THE ENGINE WAS THROTTLED, BACK NOISE BECAME MORE PRONOUNCED. AIRCRAFT WAS LANDED AT NEAREST AIRPORT. INVESTIGATION OF KNOCKING NOISE REVEALED THAT ONE TOOTH WAS MISSING FROM THE CRANKSHAFT GEAR. ENGINE TIME SINCE FACTORY REMANUFACTURE APPROXIMATELY 3,050 HOURS. TIME SINCE MAJOR OVERHAUL, APPROXIMATELY 350 HOURS. CRANKSHAFT GEAR WAS MAGNAFLUXED AT MAJOR OVERHAUL. 1H71 3O3 ONT3A12 E274 19970508004181997050800418EA 1997 5 8 97ZZZX1954 219970401G7322MA3 CARBURETOR FACET CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA POWER JET FOD PLUG D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SW9968148 15282150 L1511415 AIRCRAFT LOST POWER DURING LOCAL FLIGHT. STUDENT PILOT COULD ONLY GET 1200/1400 RPM'S, BUT MADE IT BACK TO AIRPORT. AFTER CHECKING FUEL STRAINERS, PROBLEM APPEARED TO BE IN CARBURETOR. DISASSEMBLY REVEALED A SMALL INSECT IN THE NOZZLE POWER JET ASSEMBLY. THE INSECT THE SIZE OF A PENCIL POINT COULD NOT HAVE PASSED THROUGH THE FUEL STRAINERS. SUSPECT IT ENTERED WHILE ACFT WAS PARKED , THROUGH AIR BOX, AND INTO NOZZLE. TOTAL TIME ON CARBURETOR SINCE OVERHAUL, 836.0 HOURS. 1H71 3O3 ONT3A19 E223 19970508004261997050800426EU 1997 5 8 97ZZZX1962 219970215G7230EU58621A BLADE GULSTMG1159 G1159 3953505SO RROYCESPEY SPEY5118 54523EU 5TH STG COMP BROKEN E K NONE E VIBRATION/BUFFET ININSP/MAINT 1 SW9917ND 3041 63 8552 CREW REPORTED HIGH ENGINE VIBRATION ON THE RIGHT ENGINE. A BORESCOPE INSPECTION OF THE L.P. COMPRESSOR REVEALED A FIFTH STAGE L.P. COMPRESSOR BLADE DAMAGED (APPROXIMATELY THREE INCHES OF THE BLADE WAS BROKEN OFF). 2L72 4F4 FRTA12EA E2EU 19970508004281997050800428WP 1997 5 8 97ZZZX1964 219970401G72508965841 SUPPORT ASSY GARRTTTPE331TPE3316252B 01514WP STG 1 TURBINE MISOVERHAULED DL K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 AFTER INSTALLATION OF SUPPORT ASSY, ENGINE MADE CHATTERING NOISE WHEN ROTATED. DISASSEMBLY SHOWED IMPROPER MACHINING OF SUPPORT ALLOWING SEGMENTS TO CONTACT TURBINE WHEEL BLADES. CAUSE: IMPROPER REPAIR. SUBMITTER SUGGESTS BETTER QUALITY CONTROL DURING REPAIR. 4 T E2WE 19970508007211997050800721CE 1997 5 8 CA970121009 119970113G326010038100601 SWITCH 10038100601 BEECH 100 A100 1152915CE PWA PT6 PT6A34 52043EA MLG DOWNLOCK INTERMITTENT W A UNSCHED LANDING P NO WARNING INDICATION APAPPROACH 1 CA PCE56069 (CAN) DURING APPROACH, PILOTS UNABLE TO GET GEAR DOWN INDICATION. RETURNED TO BASE AND FLYBY CONFIRMED GEAR DOWN. MAINTENANCE FOUND THE DOWNLOCK SWITCH TO BE INTERMITTENT. 1L72 3T4 T A14CE E4EA 19970508007221997050800722SW 1997 5 8 CA970121011 119970113G324613600L BEARING BFGOODRICH 313571 SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL NR 2 MLG WHEEL ROLLERS MISSING W A K NONE O OTHER TXTAXI/GRND HDL 1 CA 5024 P447414 106175 (CAN) OUTSIDE BEARING ON #2 MAIN WHEEL ASSEMBLY FAILED AND RESULTED IN WHEEL DEPARTING THE AIRCRAFT. THE BEARING ROLLERS LEFT THE BEARING CAGE ALLOWING THE WHEEL TO EXIT THE AXLE OVER THE SPACER, WASHER AND NUT. INNER BEARING WAS EXCESSIVELY WORN, THERE WAS STILL GREASE IN BEARING. NO SPACER FOUND BETWEEN WHEEL HALVES. AXLE ON DAMAGE ON OPPOSITE WHEEL. INSPECTION PROGRAM BEING IMPLEMENTED FOR INITIAL INSPECTION OF WHEEL BEARINGS, CUPS AND AXLES ON ALL SA226/227 AIRCRAFT. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 19970508007231997050800723EA 1997 5 8 CA970122001 119970109G2920MX499336 HYDRAULIC LINE SPERRYVICRS 731840 DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE STDBY POWER LEAKING W CD ABORTED TAKEOFF RETURN TO BLOCK JK WARNING INDICATION FLUID LOSS TXTAXI/GRND HDL 1 CA MX499336 123192 (CAN) DURING TAXI CREW NOTICED HYDRAULIC LEAK AND LOSS OF FLUID FROM THE #1 HYDRAULIC SYSTEM. HYDRAULIC LINE AT THE STANDBY POWER UNIT FOUND LOOSE AND LEAKING 2H72 4T4 TRTA13NM E20NE 19970508007241997050800724NE 1997 5 8 CA970122004 219970114G7250310900301 PT BLADE PWA 118 PW118 NE ENGINE FRACTURED W K NONE O OTHER ININSP/MAINT 1 CA 1912910153 115070 (CAN) THE OPERATOR OBSERVED POWER TURBINE DAMAGE AND THE ENGINE WAS SENT FOR INVESTIGATION. DISASSEMBLY REVEALED THE ENGINE SUFFERED A PRIMARY FAILURE OF ONE POWER TURBINE BLADE. THE FRACTURE WAS THROUGH THE CORED POCKET APPROXIMATELY 1/4" ABOVE THE INNER PLATFORM. IT WAS CONCLUDED THE FAILURE OCCURRED DUE TO HIGH TIME ON THE BLADE. 4 T E20NE 19970508007261997050800726CE 1997 5 8 CA970128001 119970115G521005170392 DOOR HANDLE CESSNA 0711023105 CESSNA180 180J 2072622CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C203 GL STEEL INSERT BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 153 462647 950479 (CAN) A NEW STYLE OF HANDLE WAS INSTALLED WITH A STEEL BUSHING IN AN ALUMINUM HANDLE. THE TWO PART ASSEMBLY SEPARATED AT THE UNION. THE PART WAS SENT BACK FOR WARRANTY. 1H71 3O3 O 5A6 E273 5 CP3EA 19970508007291997050800729EA 1997 5 8 CA970128005 219970122G855075288 SHAFT GULSTM112 112 0144701SW LYC O360 IO360C1D6 41514EA HARTZLHCE2Y HCE2YR1BF GL OIL PUMP WORN KEYWAY W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA 985 L955051A DK330 (CAN) DURING COMPLIANCE WITH AD 96-09-10 IT WAS DISCOVERED THE DRIVE GEAR AND DRIVE SHAFT CONTAINED A KEYWAY. THE KEYWAY AND DRIVE GEAR WERE WORN APPROXIMATELY 0.060". THIS KEYWAY SHOULD HAVE BEEN REMOVED BY AD 75-08-09, BUT THIS ENGINE, BY SERIAL NUMBER, IS NOT APPLICABLE TO AD 75-08-09. A REPLACEMENT DRIVE SHAFT WAS INSTALLED. 1L71 3O3 O A12SO 1E10 5 CP9EA 19970508007301997050800730CE 1997 5 8 CA970128007 119970120G7931100381173 INDICATOR AEROMECH BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA #2 ENG OIL PRESSFAULTY W AE UNSCHED LANDING ENGINE SHUTDOWN JN WARNING INDICATION FALSE WARNING CRCRUISE 1 CA 27C18 PCE50253 (CAN) AIRCRAFT WAS IN CRUISE WHEN THE RIGHT HAND OIL PRESSURE INDICATOR WAS FLICKERING, ALL OTHER PARAMETERS WERE NORMAL. SEVERAL MINUTES LATER THE OIL PRESSURE WENT TO "0". THE #2 ENGINE WAS SHUTDOWN. POST FLIGHT INSPECTION FOUND THE OIL PRESSURE/TEMPERATURE GAUGE TO BE FAULTY. THE GAUGE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 19970508007311997050800731CE 1997 5 8 CA970128011 119970122G521050430043163 CHANNEL BEECH 50430043622 BEECH 80 65B80 1152812CE LYC O540 IGSO540A1D 41532EA CABIN DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 7437 RL370750 (CAN) CABIN DOOR HINGE HAD EXCESSIVE PLAY. WHILE REPLACING THE RIVETS A CRACK WAS FOUND IN THE STRUCTURE. 1L72 3O3 O 3A20 1E7 19970508007321997050800732WP 1997 5 8 CA970129001 119970113G3222MS288891 AIR VALVE DOUG DC9 DC932 3022066WP PWA JT8 JT8D7A 52053NE NLG OLEO LEAKING W O OTHER J WARNING INDICATION CLCLIMB 1 CA P657766D (CAN) ON TAKEOFF, UNABLE TO RAISE NOSE GEAR AND NOSE GEAR LIGHT CAME ON. QUICK REFERENCE HANDBOOK CHECK LIST CARRIED OUT. ON ARRIVAL FOUND NOSE GEAR OLEO FLAT. NOSE GEAR SERVICED AND SCHRADER VALVE REPLACED. 2L72 4F4 F A6WE E2EA 19970508007331997050800733WP 1997 5 8 CA970129002 119970114G2841DC26F16265 FUEL INDICATOR DOUG DC9 DC932 3022066WP PWA JT8 JT8D7A 52053NE RH FUEL QUANTITYINOPERATIVE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA P656873D (CAN) ELECTRICAL SMELL DETECTED AND RH FUEL QUANTITY INDICATOR FAILED. TROUBLESHOOTING OF SNAG REVEALED RH INDICATOR CIRCUIT BREAKER HAD POPPED. DEFECTIVE INDICATOR REPLACED AND SYSTEM CHECKED SERVICEABLE. 2L72 4F4 F A6WE E2EA 19970508007341997050800734EA 1997 5 8 CA970129003 119970112G3230 BRACKET CNDAIRCL600 CL6002B19 EA GE CF34 CF343A 30015NE NOSE GEAR OUT OF ADJUST W A UNSCHED LANDING O OTHER CLCLIMB 1 CA 3517 807267 (CAN) AFTER TAKEOFF UNABLE TO RETRACT NOSE GEAR. TARGET BRACKET REMOVED AND REPAIRED. 2L72 4F4 FRTA21EA E15NE 19970508007351997050800735EA 1997 5 8 CA970129004 119970115G274070607 HSTU CNDAIRCL600 CL6002B19 EA GE CF34 CF343A1 30015NE H STAB TRIM FAILED W O OTHER J WARNING INDICATION CLCLIMB 1 CA 3204 807281 (CAN) AFTER TAKEOFF FLIGHT REPORTED STABILIZER TRIM MESSAGE ON ECAM. HORIZONTAL STABILIZER TRIM UNT (HSTU) REPLACED. 2L72 4F4 FRTA21EA E15NE 19970508007361997050800736WP 1997 5 8 CA970129005 119970115G2530CA167072 RECEPTACLE DOUG DC9 DC932 3022066WP PWA JT8 JT8D7A 52053NE GALLEY SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA P654065D (CAN) ELECTRICAL SMELL DETECTED IN FLIGHT DECK. MAINTENANCE TROUBLESHOOTING FOUND #4 OVEN RECEPTACLE BURNT. OVEN RECEPTACLE REPLACED AND CHECKED SERVICEABLE. 2L72 4F4 F A6WE E2EA 19970508007451997050800745NE 1997 5 8 CA970129017 219970101G7220 FAN BLADES PWA 4056 PW4056 NE #2 ENGINE SHINGLED/DAMAGEDW O OTHER E VIBRATION/BUFFET TOTAKEOFF 1 CA P724426 (CAN) HIGH VIBRATION ON #2 ENGINE WITH FAN BLADE SHINGLING. INSPECTION FOUND ALL FAN BLADES SHINGLED, MOST OF THE BLADES HAD EXTENSIVE DAMAGE IN THE SHROUD AREA. THE ENGINE PICKED UP HEAVY SNOW DURING TAKEOFF. ALL FAN BLADES REMOVED. STAGE 2 FAN EXIT VANES AND EXHAUST CHECKED SERVICEABLE. FAN BLADE SET REPLACED. GROUND RUN AND VIBRATION SURVEY CARRIED OUT SERVICEABLE. 4 F E24NE 19970508007461997050800746EA 1997 5 8 CA970129018 219970123G7261 O-RING DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043EA TRANSFER TUBE LEAKING W EA ENGINE SHUTDOWN UNSCHED LANDING OK OTHER FLUID LOSS CRCRUISE 1 CA PCE40147 (CAN) OIL PRESSURE AND TORQUE FLUCTUATION IN FLIGHT NECESSITIATED ENGINE SHUTDOWN OF #1 ENGINE. POST FLIGHT INSPECTION FOUND AN "O" RING ON THE OIL TRANSFER TUBE AT THE "C" FLANGE WAS WORN FLAT AND LEAKING, CAUSING OIL TO LEAK ON THE EXHAUST CAN. 1H72 3T4 T A9EA E4EA 19970508007491997050800749NM 1997 5 8 CA970130008 119970109G2150 AIRCYCLE MACHINE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE AIR COND SEIZED W OH OTHER DEACTIVATE SYST/CIRCUITS BO SMOKE/FUMES/ODORS/SPARKS OTHER CRCRUISE 1 CA 120275 (CAN) PILOT REPORTED AIRCRAFT OPERATING WITH BATTERY ONLY AS AN ELECTRICAL BURNING SMELL WAS NOTED IN THE COCKPIT. MAINTENANCE FOUND THE AIR CYCLE MACHINE SEIZED. PILOT PROCEDURE IS TO SHUT DOWN BLEED SYSTEMS AND THEN GENERATORS UNTIL SMOKE CLEARS. 2H72 4T4 TRTA13NM E20NE 19970508007511997050800751EA 1997 5 8 CA970130013 219970119G74141038255514 MAGNETO BENDIX O4RN2000 CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL DIST GEAR BROKEN TEETH W A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 CA 700 L830076T 731179 (CAN) SHORTLY AFTER TAKEOFF THE ENGINE BEGAN TO RUN ROUGH AND LOSE POWER. AIRCRAFT RETURNED TO BASE. RUN UP THE FOLLOWING DAY REVEALED THE LEFT MAGNETO WAS DEAD. DISASSEMBLY OF THE MAGNETO REVEALED BROKEN TEETH ON THE DISTRIBUTOR GEARS. 1H71 3O3 ONT3A12 E274 5 NP910 19970508007531997050800753EA 1997 5 8 CA970130017 119970124G2730C3CF1957 CONTROL CABLE DHAV DHC3 DHC3 2800202EA PWA R1340 R134059 52016NE STA.308 FRAYED W K NONE O OTHER ININSP/MAINT 1 CA 9594 (CAN) AS A RESULT OF THE ELEV CABLE RUBBING ON THE PULLEY SOME CABLE STRANDS WERE BROKEN. 1H71 3R3 R A815 5E2 19970508007541997050800754EA 1997 5 8 CA970130018 119970124G2720C3CF1975 CONTROL CABLE DHAV DHC3 DHC3 2800202EA PWA R1340 R134059 52016NE STA.60 FRAYED W K NONE O OTHER ININSP/MAINT 1 CA 9594 (CAN) RUDDER CABLE FRAYED AT TWO PLACES, ON THE RUDDER QUADRANT AND ON A PULLEY TWO FEET AFT. 1H71 3R3 R A815 5E2 19970508007551997050800755NE 1997 5 8 CA970130020 219970121G7250311260201 TURBINE BLADES PWA PW121 PW121 52124NE AIRFOIL FRACTURED W K NONE O OTHER ININSP/MAINT 1 CA 1752313037 120518 (CAN) THE ENGINE HAD SUFFERED FRACTURE OF TWO LP TURBINE BLADES. 4 T E20NE 19970508007561997050800756CE 1997 5 8 CA970130022 119970122G56101143840202 WINDSHIELD BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA COCKPIT RT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA PCE32052 (CAN) PLANE WAS AT 24,000 FEET CRUISING ALTITUDE WHEN R/H WINDSHIELD CRACKED IN PIECES. AIRCRAFT MADE AN UNSCHEDULED, SAFE, LANDING FOR REPAIR. 2L72 4T4 TRTA24CE E4EA 19970508007581997050800758EA 1997 5 8 CA970131004 119970123G3230 SWITCH CNDAIRCL600 CL6002B19 EA GE CF34 CF343A 30015NE NOSE GEAR BENT W O OTHER O OTHER CLCLIMB 1 CA 5480 807157 (CAN) GEAR DISAGREEMENT ON TAKEOFF. GEAR CYCLED TWICE, SAME INDICATION. NOSE GEAR SHOWED DOWN DOOR OPEN. GEAR EXTENDED, 3 GREEN LIGHTS. FOUND NOSE GEAR EXTEND PROXIMITY SWITCH BENT AWAY FROM TARGET. 2L72 4F4 FRTA21EA E15NE 19970508007601997050800760NM 1997 5 8 CA970203001 119970108G7500 CABIN DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE BLEED AIR SMOKE W O OTHER B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA 19190 120854 (CAN) REPEAT OF PREVIOUS SMOKE IN CABIN PROBLEM. AFTER BLEEDS SELECTED ON #1 ENGINE THE CABIN FILLED WITH SMOKE. THIS TIME OIL WAS FOUND IN THE ENGINE BLEED AIR SYSTEM. 2H72 4T4 TRTA13NM E20NE 19970508007621997050800762EA 1997 5 8 CA970203006 119970116G2910AN62074 CHECK VALVE PARKER DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043EA FLAPS LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA 331 PCE42076 (CAN) DURING PREFLIGHT THE HYDRAULIC SYSTEM FOUND TO CYCLE DUE TO LOW PRESSURE. FLAP CHECK VALVE FOUND LEAKING. 1H72 3T4 T A9EA E4EA 19970508007641997050800764CE 1997 5 8 CA970203010 119970124G52101014301071 CHANNEL BEECH 1014301071 BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA CABIN DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 12865 PCE80204 (CAN) WITH CABIN DOOR OPEN, A CRACK WAS FOUND IN THE UPPER FRAME MEMBER. THE CRACK WAS APPROXIMATELY 6 INCHES LONG, ALONG THE DOOR HINGE RIVET LINE, RUNNING FROM THE AFT EDGE FORWARD. 1L72 4T4 T A24CE E4EA 19970508007651997050800765EA 1997 5 8 CA970203012 119970124G30207SC0058012 DE-ICER BOOT BFGOODRICH DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL #4 NACELLE SEPARATED W K NONE O OTHER ININSP/MAINT 1 CA PCE86302 237483 (CAN) AFTER LANDING AND DURING WALKAROUND BEFORE TURN AROUND, PILOT NOTICED OUTBOARD OF #4 NACELLE BOOT MISSING. BOOT FOUND ON BUTTON OF RUNWAY. 2H74 4T4 T A20EA E4EA 6 CP1NE 19970513000211997051300021EU 1997 5 13 CA970121010 119970108G7160350A54112220 INLET DUCT SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D NE START/GEN AIR LOST IN FLIGHT W K NONE D INFLIGHT SEPARATION ININSP/MAINT 1 CA 9322 (CAN) STARTER GENERATOR AIR INLET DUCT WAS LOST IN FLIGHT. SUSPECT CAUSE OF SEPARATION IS LOOSENING OF SECURING CLAMP. 1G71 3U3 U H9EU E19EU 19970515000051997051500005EA 1997 5 15 97ZZZX1974 219970417G7414LW68504611085 MAGNETO ELECTROSYS D6RN320 PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA RT ENGINE GEAR FAILED E K NONE O OTHER NRNOT REPORTED 1 AL033536B 660 6080503 317952205 RL191768A INTERNAL DRIVE GEARS FAILED ON BOTH THE LEFT AND RIGHT SIDES OF THIS 'DUAL STYLE' MAGNETO ASSEMBLY, MODEL NR D6RN-3200. AIR CREW WAS TAXIING AIRCRAFT WHEN RIGHT POWERPLANT STOPPED RUNNING. 1L72 3O3 O A20SO E14EA 19970515000101997051500010EA 1997 5 15 97ZZZX1979 219970227G7322105135 CARBURETOR SCREW CESSNA172 172L 2072432CE LYC O320 O320E2A 41508EA ENGINE LOOSE D O OTHER JR WARNING INDICATION PARTIAL RPM/PWR LOSS CRCRUISE 1 SW057729G199 CK13350 17259429 L1753927A IDLE ADJUSTMENT SCREW BACKED OUT OF CARBURETOR IN-FLIGHT. ENGINE FAILED TO RUN WITH POWER SETTING BELOW 2300 RPM'S. INSTALLED NEW SPRING AND SCREW. CARBURETOR THREADS APPEAR TO BE LOOSE. 1H71 3O3 ONT3A12 E274 19970515000141997051500014EA 1997 5 15 97ZZZX1983 219970415G732230628 FLOAT PRECISION MA3A CESSNA120 120 2071402CE LYC O235 O235C1 41505EA CARBURETOR FAILED DSA K NONE O OTHER ININSP/MAINT 1 SW01763811100 Y7FG2092 10802 L868215 AFTER OPENING UP CARBURETOR TO REPLACE TWO-PIECE VENTURI, NOTICED FLOAT WAS BRO KEN, ONE-HALF OF IT LAYING IN BOWL. REPLACED WITH NEW METAL TYPE. 1H71 3O3 O A768 E223 19970515000191997051500019EA 1997 5 15 97ZZZX1988 219970401G853073806P PUSH ROD CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 SW9995693 15285959 L2454815 PUSH ROD CRACKED BOTH ENDS. CRACKS APPROXIMATELY .50 INCH LONG. AD'S 80-25-02K2 AND 95-03-10 DO NOT APPLY. ENGINE FACTORY REMANUFACTURED APPROXIMATELY 3300 HOURS AGO. FIELD OVERHAUL APPROXIMATELY 900 HOURS AGO. RECORDS WOULD INDICATE 3300 HOURS ON PUSH ROD! 1H71 3O3 ONT3A19 E223 19970515000331997051500033NE 1997 5 15 97ZZZX2001 219970421G8530 CYLINDER AIRTRCAT300 AT301 0390103SW PWA R1340 R1340AN1 52016NE NR 9 HEAD SEPARATED DL A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 NM084397S 3010057 51132 AIRCRAFT EXPERIENCED A SUDDEN LOSS OF POWER. EMERGENCY LANDING MADE AT MOUNTAIN HOME AIR FORCE BASE. NR 9 CYLINDER HEAD HAD SEPARATED JUST ABOVE THE TOP OF PISTON TRAVEL. FATIGUE FRACTURE APPEARS TO ORIGINATE AT THE EXHAUST VALVE SEAT. 675 SMOH. 1L71 3R3 R A9SW 5E2 19970515000361997051500036WP 1997 5 15 97ZZZX2003 219970409G73148974001 PUMP STBROSSC7 SC73 8100512EU GARRTTTPE331TPE3312201A WP DRIVESHAFT LEAKAGE BLAILIRK NONE O OTHER ININSP/MAINT 1 WP071846 4060 SH1846 P90094 INVESIGATION FOR EXCESS OIL USAGE, FOUND THE OIL WAS ENTERING THE FUEL SYS VIA THE OIL WET SPLINE MOD TO THE DRIVESHAFT THAT DRIVES THE FUEL PUMP ON THE ENG GEARBOX. ALLIED SIGNAL SB TPE 331-72-0104 IS THE WET SPLINE MOD. 1H72 3T4 T A15EU E3WE 19970515000391997051500039EA 1997 5 15 97ZZZX2005 219970425G7250PCE84114 GAS GENERATOR STBROSSD3 SD330 8100602EU PWA PT6 PT6A45 52043EA RT ENGINE SEAL FAILED D EAH ENGINE SHUTDOWN UNSCHED LANDING DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 GL13936MA SH3036 84114 PILOTS REPORTED SMOKE IN COCKPIT AND CLOSED PRSOV VALVE STOPPING THE SMOKE. SEVERAL MINUTES LATER, THE PILOTS NOTICED TORQUE AND OIL PRESSURE FLUCTUATING. FEATHERED AND SHUT DOWN ENGINE AND LANDED WITHOUT INCIDENCE. ENGINE WAS LEAKING OIL FROM THE COMPRESSOR SEAL. 2H72 4T4 T A41EU E4EA 19970515002771997051500277EU 1997 5 15 CA970203013 119970124G29136506606 HYD PUMP AIRBUS310 A310324 3930206EU PWA 4152 PW4152 NE #1 SYSTEM SHEARED SPLINE W H DEACTIVATE SYST/CIRCUITS K FLUID LOSS CRCRUISE 1 CA 717722 (CAN) GREEN HYDRAULIC SYSTEM DEPLETED IN FLIGHT. GROUND INSPECTION FOUND THE #1 GREEN SYSTEM ENGINE DRIVEN PUMP (EDP) DRIVE SHAFT HAD SHEARED INTERNALLY. PUMP CASE LEAKED, CAUSING LOSS OF GREEN SYSTEM HYDRAULIC FLUID. 2L72 4F RTA35EU E24NE 19970515002781997051500278NE 1997 5 15 CA970203015 219970119G7200 ENGINE BOEING727 727277 138408SNM PWA JT8 JT8D17A 52049NE #3 ENGINE FAILED W D RETURN TO BLOCK KO FLUID LOSS OTHER NRNOT REPORTED 1 CA 109553794 P709477 (CAN) ON #3 ENGINE START N2 IMMEDIATELY ROSE TO 35 PERCENT THEN DROPPED TO 30 PERCENT AND FLUCTUATED. NO N1 ROTATION. OIL QUANTITY DROPPED TO ONE GALLON. ENGINE REPLACED. 2L73 4F4 FRTA3WE E2EA 19970515002801997051500280WP 1997 5 15 CA970204002 119970122G3260902624917 ANNUNCIATR PANEL CVAC 440 440 2422902WP ALLSN 501D 501D13 03004GL LT MLG INDICATIOLOOSE WIRE W O OTHER P NO WARNING INDICATION LDLANDING 1 CA 501795 (CAN) LEFT HAND MAIN LANDING GEAR DID NOT INDICATE DOWN AND LOCKED. MAINTENANCE TROUBLESHOOTING REVEALED A LOOSE WIRE ON THE REAR OF THE LH LANDING GEAR DOWN (GREEN) LIGHT SOCKET. WIRE REPAIRED. 2L72 4R4 T 6A6 E282 19970515002811997051500281EA 1997 5 15 CA970204004 119970126G3260 SENSOR CNDAIRCL600 CL6002B19 EA GE CF34 CF343A 30015NE NOSE LANDNG GEAROUT OF ADJUST W K NONE O OTHER CLCLIMB 1 CA 2364 807337 (CAN) NOSE LANDING GEAR FAILED TO RETRACT ON TAKEOFF. NOSE GEAR PROXIMITY SENSOR ADJUSTED. 2L72 4F4 FRTA21EA E15NE 19970515002821997051500282NE 1997 5 15 CA970204005 219970123G7250MS969611 BOLT PWA 118 PW118 NE INTERSTAGE CASE FRACTURED W K NONE O OTHER ININSP/MAINT 1 CA 11982 115571 (CAN) THE ENGINE WAS SENT FOR A SCHEDULED OVERHAUL. UPON DISASSEMBLY IT WAS DISCOVERED THE ENGINE HAD POWER TURBINE DAMAGE RESULTING FROM AN INTERSTAGE CASE BOLT FAILURE. THE ENGINE WAS PRE MOD 21175 AND THE LIBERATED BOLT HEAD INFLICTED IMPACT DAMAGE TO ALL THE 1ST STAGE PT ROTOR BLADES AND TO THE 2ND STAGE PT STATOR LOCKING LUGS. SECONDARY DAMAGE FROM PIECES OF DAMAGED PT1 BLADES WAS ALSO SUSTAINED BY THE PT STATOR AIRFOILS AND THE PT2 BLADE LEADING EDGES. IT IS THOUGHT THAT CORROSION OF THE BOLT BELOW THE HEAD COUPLED WITH SOME FLANGE CORROSION LEAD TO THE FRACTURE OF THE BOLT. 4 T E20NE 19970515002831997051500283CE 1997 5 15 CA970206001 119970124G7810 EXHAUST DUCT BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA AT #3 BEARING BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 3950 PCE50550 (CAN) DURING TROUBLESHOOTING OF HIGH OIL PRESSURE PROBLEM, NOTED OIL STAIN AND SMELL. FURTHER INSPECTION FOUND EXHAUST DUCT BROKEN AWAY AT #3 BEARING COVER. POWER SECTION SENT FOR REPAIR. 1L72 3T4 T A14CE E4EA 19970515002841997051500284EU 1997 5 15 CA970206002 119970127G7700M2217BB THRUST METER FOKKERF28 F28MK1000 4990808EU RROYCESPEY SPEY55515 54521EU NR 1 ENG STUCK W CD ABORTED TAKEOFF RETURN TO BLOCK O OTHER TOTAKEOFF 1 CA 7853 140 9111 (CAN) CREW REJECTED TAKEOFF DUE TO #1 ENGINE THRUST INDEX ON LEFT HAND THRUST METER BEING STUCK AT 85 PERCENT AND UNABLE TO ADJUST. AIRCRAFT RETURNED TO BASE AND THE THRUST INDICATOR WAS REPLACED. 2L72 4F4 FRTA20EU E2EU 19970515002851997051500285EU 1997 5 15 CA970206003 219970120G7320CASC211 REGULATOR FOKKERF28 F28MK1000 4990808EU RROYCESPEY SPEY55515 54521EU #2 ENG FUEL FLOWFAULTY W CD ABORTED TAKEOFF RETURN TO BLOCK EJ VIBRATION/BUFFET WARNING INDICATION TOTAKEOFF 1 CA 4227 2584 9279 (CAN) ON TAKEOFF ROLL THE #2 ENGINE DID NOT PRODUCE TAKEOFF RATED THRUST. THE TAKEOFF WAS REJECTED. MAINTENANCE FOUND THE PROBLEM TO BE AN AIR LEAK. CORR UJOINT AND 3 GASKETS WERE REPLACED ON THE #2 ENGINE FUEL FLOW REGULATOR AT THE P3 CONNECTION. ENGINE WAS GROUND RUN SERVICEABLE AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA20EU E2EU 19970515002861997051500286EA 1997 5 15 CA970206004 119970122G3010MS33205 CIRCUIT BREAKER DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE ELEV HORN HEAT FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 123192 (CAN) PILOT NOTED THAT THE LEFT ELEVATOR HORN HEAT CAUTION LIGHT CAME ON. HORN CIRCUIT BREAKER WAS FOUND UNSERVICEABLE. 2H72 4T4 TRTA13NM E20NE 19970515002871997051500287GL 1997 5 15 CA970206005 319970127G6110 PROPELLER CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL BALANCE HIGH VIBRATION W K NONE E VIBRATION/BUFFET CRCRUISE 1 CA 13 291253R 529A (CAN) HARTZELL PROPELLER INSTALLED AS PER STC #SA685AL. TROUBLESHOT VIBRATION SINCE INSTALLATION. INSTALLED SECOND PROP AND DID DYNAMIC BALANCE, THIS CHANGED THE POSITION OF VIBRATION. REMOVED PROP AND INSTALLED ZERO TIME MCCAULEY PROP. VIBRATION GONE. 1H71 3O3 O A4CE E5CE 5 CP47GL 19970515002901997051500290CE 1997 5 15 CA970206013 119970109G801164150020 STARTER CESSNA150 150M 2071830CE CONT O200 O200A 17020SO DRIVE STRIPPED W K NONE O OTHER ININSP/MAINT 1 CA 387 254684H (CAN) STARTER WOULD NOT ENGAGE. FAULTY STARTER CLUTCH DAMAGED STARTER DRIVE. 1H71 3O3 O 3A19 E252 19970515002911997051500291EA 1997 5 15 CA970206014 219970123G7261 O-RING DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043EA C FLANGE WORN W EA ENGINE SHUTDOWN UNSCHED LANDING O OTHER CRCRUISE 1 CA PCE40147 (CAN) "O" RING ON THE OIL PRESSURE TRANSFER TUBE AT THE "C" FLANGE WAS FOUND WORN FLAT IN ONE AREA, CAUSING OIL TO LEAK OUT ON TO THE EXHAUST CAN. THIS CAUSED A FLUCTUATION IN OIL PRESSURE AND TORQUE PROMOTED THE PILOT TO DO A PRECAUTIONARY SHUTDOWN AND RETURN TO BASE. 1H72 3T4 T A9EA E4EA 19970515002921997051500292NE 1997 5 15 CA970206019 219970126G7220 FAN LKHEED1011 1011385114 WP RROYCERB211 RB21122B02 54555NE #3 ENGINE SEIZED W K NONE O OTHER ININSP/MAINT 1 CA 382923239 10321 (CAN) NO N1 ROTATION DURING START OF #3 ENGINE. LP FAN FOUND SEIZED. ENGINE REPLACED. 2L73 4F4 F A23WE E12EU 19970515002931997051500293EA 1997 5 15 CA970206020 219970131G731427720007 FUEL PUMP SUNDSTRAND BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA DRAIN PIPE LEAKING W K NONE K FLUID LOSS LDLANDING 1 CA 4505 PE1416 CPPS61075 (CAN) AFTER TEST FLIGHT FOLLOWING 600 HOUR INSPECTION FUEL WAS SEEN COMING FROM THE DRAIN AT THE BOTTOM OF THE ENGINE. INSPECTION FOUND THE FUEL WAS COMING FROM THE PIPE THAT DRAINS THE AUTOMATIC FUEL CONTROL SEAL. CLOSER INVESTIGATION FOUND THE ENGINE DRIVEN FEUL PUMP WAS LEAKING AND THE DRAIN FOR THE FUEL SEAL WAS BLOCKED CAUSING FUE TO EVACUATE FROM THE AFCU SEAL. BOTH THE FUEL CONTROL AND THE FUEL PUMP WERE REPLACED. 1G71 4U4 U H4SW E22EA 19970515002941997051500294EU 1997 5 15 CA970206021 219970131G7250 BLADE FOKKERF28 F28MK1000 4990808EU RROYCESPEY SPEY55515 54521EU #2 ENG LP TURB MISSING W A E ENGINE SHUTDOWN E VIBRATION/BUFFET CLCLIMB 1 CA 2960027348 9299 (CAN) DURING CLIMB THROUGH FL270 THE CREW HEARD A "BANG" AND FELT A VIBRATION FROM #2 ENGINE, WHILE THE ENGINE WAS STILL MAKING POWER. AIRCRAFT RETURNED TO THE POINT OF DEPARTURE. INITIAL INSPECTION REVEALED A LOW PRESSURE TURBINE BLADE MISSING. THIS ENGINE SUFFERED A SIMILAR FAILURE ON 5 JANUARY 1990. THERE IS NO RECORD OF AN SDR AT THAT OCCURRENCE. 2L72 4F4 FRTA20EU E2EU 19970515002951997051500295NE 1997 5 15 CA970206022 219970129G7230311161801 BEARING PWA 120 PW120A NE HP ROTOR FAILED W E ENGINE SHUTDOWN O OTHER CRCRUISE 1 CA 16992 120767 (CAN) ENGINE WAS SENT FOR REPAIR AFTER A LOSS OF OIL PRESSURE AND AN INFLIGHT SHUTDOWN. METAL WAS FOUND IN THE REDUCTION GEARBOX, OIL FILTERS, CHIP DETECTORS. DISASSEMBLY OF THE ENGINE REVEALED TWO FAILURES, THE #4 BEARING AND THE AC GENERATOR. IT IS THE OPINION OF THE R&O SHOP THAT THE FAILURE OF THE #4 BEARING WAS THE CAUSE OF THE AC GENERATOR FAILURE. 4 T E20NE 19970515002991997051500299SO 1997 5 15 CA970211002 119970202G81204067870010 TURBINE SHAFT AIRESEARCH 4091709001R PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA ENG TURBO SHEARED W E ENGINE SHUTDOWN JK WARNING INDICATION FLUID LOSS CRCRUISE 1 CA 3 ZGO29356 L216068A (CAN) TURBOCHARGER WAS INSTALLED AS PART OF AN OVERHAULED ENGINE. TURBOCHARGER WAS PREOILED AND GROUND RUNS WERE SATISFACTORY. TWO TRAINING FLIGHTS WERE CARRIED OUT PRIOR TO THE FAILURE. PILOT REPORTED FLUCTUATING OIL PRESSURE AND SHUT THE ENGINE DOWN. POST FLIGHT INVESTIGATION FOUND THE TURBINE SHAFT HAD SHEARED ALLOWING THE COMPRESSOR TO DESTROY ITSELF. 1L72 3O3 O A20SO E14EA 19970515003001997051500300NE 1997 5 15 CA970211004 219970204G732232447593 FUEL CONTROL CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE #1 ENGINE FAULTY W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 CA 71718 (CAN) DURING CRUISE FLIGHT THE #1 ENGINE ROLLED BACK FROM CRUISE POWER TO APPROXIMATELY 80 PERCENT N2 AT FL390. AFTER LANDING THE "O" RINGS IN THE P3 PLUMBING WAS REPLACED AND THE ENGINE GROUND RUN SERVICEABLE. FOLLOWING DAY THE SAME PROBLEM RECURRED AND THE FUEL CONTROL UNIT WAS REPLACED. THE ENGINE RUN AND TEST FLIGHT WERE CARRIED OUT SERVICEABLE AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 4F4 F A22CE E1NE 19970515003011997051500301NM 1997 5 15 CA970211005 119970202G3220 NOSE GEAR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HYD SYS SLOW TO EXTEND W K NONE O OTHER DEDESCENT 1 CA 120542 (CAN) ON DESCENT NOSE GEAR SLOW TO EXTEND, BUT FINALLY INDICATED DOWN AND LOCKED. EXCESSIVE AMOUNT OF AIR FOUND IN HYDRAULIC SYSTEM FROM MAINTENANCE ON PREVIOUS DAY (NOSE GEAR HAD BEEN REPLACED THE DAY BEFORE). 2H72 4T4 TRTA13NM E20NE 19970515003021997051500302EU 1997 5 15 CA970211006 219970201G7260 DRIVE BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU ACCESSORY GEARBXFAILED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA 5919 7344 (CAN) AIRCRAFT WAS IN CRUISE FLIGHT WHEN THE PILOT REPORTED LOSS OF ACCESSORY GEARBOX ON #1 ENGINE. POST FLIGHT INSPECTION FOUND THE #1 ENGINE INTERNAL DRIVE FOR THE ACCESSORY GEARBOX FAILED, RESULTING IN METAL CONTAMINATION OF THE LUBRICATION SYSTEM. THE CONTAMINATION WAS WIDESPREAD AFFECTING ALL MAIN LINE BEARINGS, REDUCTION GEAR LAYSHAFTS AND PROPSHAFT, AS WELL AS OIL PUMPS AND LOWER BEVEL DRIVES. 2L72 3T4 T A24EU A196 19970515003031997051500303SO 1997 5 15 CA970212003 119970204G32209582900 LINK ASSY PIPER PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360EB 17025SO MCAULY NLG BROKEN W K NONE O OTHER LDLANDING 1 CA 5737 307973H (CAN) AIRCRAFT WAS ON A PILOT TRAINING FLIGHT. PILOT SELECTED GEAR DOWN AND THE SYSTEM INDICATED DOWN AND LOCKED. 3 GREEN AND VISUAL IDENT THROUGH THE SIDE MIRROR. UPON TOUCHDOWN THE NOSE GEAR COLLAPSED. AWAITING FURTHER INFORMATION. 1L72 3O3 O A7SO E9CE 19970515003041997051500304CE 1997 5 15 CA970212004 119970127G3411 STATIC TUBE CESSNA414 414 2075908CE CONT O520 TSIO520N 17040SO MCAULY TAIL STATIC PORTSPLIT W K NONE O OTHER ININSP/MAINT 1 CA 503283 (CAN) SUSPECT WATER IN THE LINE, BETWEEN THE STATIC PORT AND THE SUMP, FROZE AND SPLIT THE PIPE. 1L72 3O3 ORTA7CE E8CE 19970515003051997051500305EA 1997 5 15 CA970212008 219970130G7322 CARBURETOR CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE ICING W ABE UNSCHED LANDING EMER. DESCENT ENGINE SHUTDOWN E VIBRATION/BUFFET CRCRUISE 1 CA L243976 (CAN) THE AIRCRAFT WAS FLYING IN -30 DEGREES CELCIUS TEMPERATURE. AFTER 30 MINUTES OF FLIGHT THE ENGINE QUIT. THE PILOT MANUALLY PRIMED THE ENGINE AND IT RAN AFTER EACH SHOT. POST FLIGHT INSPECTION OF THE CARBURETOR AND FILTER FOUND MANY WATER DROPLETS. IT IS CONCLUDED WATER IN THE FUEL, PERHAPS THROUGH CONDENSATION, CAUSED CARBURETOR ICING. 1H71 3O3 ONT3A12 E274 19970515003061997051500306EA 1997 5 15 CA970213008 219970207G7532310082903 BLEED VALVE DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043EA COMPRESSOR ORIFICE DIRTY W K NONE O OTHER ININSP/MAINT 1 CA 1174 9E551 PCE42076 (CAN) DURING START THE #2 ENGINE TEMPERATURE WAS HOTTER THAN #1 ENGINE. THE COMPRESSOR BLEED VALVE WAS CHANGED AND DURING SUBSEQUENT STARTS THE TEMPERATURE WAS COOLER. TREND MONITORING CONFIRMED THE COOLER OPERATION. 1H72 3T4 T A9EA E4EA 19970515003071997051500307 1997 5 15 CA970213009 419970207G34442300303000 DRIVE MOTOR COLLINS 6221204002 DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043EA RADIO ALT INTERMITTENT W H DEACTIVATE SYST/CIRCUITS O OTHER CLCLIMB 1 CA 691 PCE42076 (CAN) DURING TAKEOFF ROTATION THE RADIO ALTIMETER WOULD FLAG AND NOT REACTIVATE UNTIL 25 TO 30 MINUTES LATER. SYSTEM DEACTIVATED. DRIVE MOTOR ASSEMBLY IN THE INDICATOR WAS FAULTY. 1H72 3T4 T A9EA E4EA 19970515003081997051500308EA 1997 5 15 CA970213012 219970211G72613020958 RELIEF VALVE 3026887 BEECH 99 B99 1154004CE PWA PT6 PT6A27 52043EA OIL SYSTEM SCORED W CE ABORTED TAKEOFF ENGINE SHUTDOWN O OTHER TOTAKEOFF 1 CA 40919 (CAN) ON TAKEOFF THE AIRCRAFT EXPERIENCED A MAJOR YAW TO THE LEFT. THE YAW WAS OF A SURGING NATURE AND THE LEFT HAND ENGINE WAS SHUTDOWN. THE AIRCRAFT RETURNED TO ITS DEPARTURE POINT. POST FLIGHT INSPECTION FOUND THE PRESSURE REGULATOR HAD EXCESSIVE SCORING ON THE SEAT FACE.THE SEAT WAS REPLACED AND THEAIRCRAFT WAS GROUND RUN SERVICEABLE AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 19970515003091997051500309NE 1997 5 15 CA970213013 219970205G7250310750201 BLADE PWA PW120 PW123 NE LP TURBINE FRACTURED W O OTHER O OTHER NRNOT REPORTED 1 CA 6094 123189 (CAN) THE ENGINE WAS SENT FOR REPAIR AFTER THE OPERATOR REPORTED AN LP TURBINE BLADE FAILURE. DISASSEMBLY OF THE ENGINE FOUND THE LP TURBINE BLADE FAILURE WAS CAUSED BY CORROSION IN THE CORE POCKETS OF 3 LP TURBINE BLADES. SECONDARY DAMAGE FROM THE FAILURE CAUSED DAMAGE TO THE 1ST AND 2ND STAGE PT BLADES; THE 1ST AND 2ND STAGE PT STATORS; THE REMAINING LP TURBINE BLADES; THE LP SHROUD SEGMENTS AND THE LP STATOR. THE #3 AND #6 BEARINGS WERE SCRAPPED AS A PRECAUTION. 4 T E20NE 19970515003101997051500310NE 1997 5 15 CA970217001 219970207G7210310119101 BEARING PWA 120 PW120A NE RED GRBX NR 10 SPALLED W K NONE O OTHER ININSP/MAINT 1 CA 10334 120225 (CAN) THE REDUCTION GEARBOX WAS SENT FOR INVESTIGATION OF METAL CONTAMINATION AND OVERHAUL. DISASSEMBLY OF THE RED GB REVEALED THE SOURCE OF THE METAL CONTAMINATION WAS A SPALLED #10 BEARING. THIS BEARING IS A LIFED ITEM AND IT IS THE OPINION OF THE REPAIR SHOP THAT THIS BEARING FAILED AT REACHING THE END OF ITS LIFE. 4 T E20NE 19970515003131997051500313WP 1997 5 15 CA970218001 119970131G2750 BOLT DOUG DC9 DC932 3022066WP PWA JT8 JT8D7 52053NE FLAP CONTROL LOOSE W A O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA P654059D (CAN) UNABLE TO RETRACT FLAPS TO LESS THAN 15 DEGREES DUE TO FLAP LEVER JAMMING. TROUBLESHOOTING REVEALED FLAP CONTROL LEVER INTERFERENCE CAUSED BY LOOSE BOLT. BOLT TIGHTENED AND LEVER MECHANISM OPERATED NORMALLY CHECKED SERVICEABLE. 2L72 4F4 F A6WE E2EA 19970515003141997051500314EA 1997 5 15 CA970218002 119970130G3260 BRACKET CNDAIRCL600 CL6002B19 EA GE CF34 CF343A1 30015NE NLG PROX SWITCH WORN W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 3984 807194 (CAN) ON DEPARTURE CREW GOT AN AURAL MESSAGE AND AN EICAS MESSAGE. GEAR DISAGREE, NOSE DOOR OPEN. CENTERING TARGET LOOKED WORN. PROXIMITY SWITCH S23 BRACKET REPLACED. 2L72 4F4 FRTA21EA E15NE 19970515003151997051500315NE 1997 5 15 CA970218003 219970210G725050062201 TIEBOLT PWA JT9 JT9D7R4D 52054NE LP TURBINE FRACTURED W K NONE O OTHER ININSP/MAINT 1 CA 15602 107J (CAN) THE ENGINE WAS SENT FOR REPAIR AFTER OIL WAS FOUND IN THE EXHAUST. DURING DISASSEMBLY IT WAS FOUND THAT THE 3RD STAGE TURBINE TIE BOLT HAD FRACTURED. SECONDARY DAMAGE CAUSED BY THE TIE BOLT FAILURE WAS THE HP TURBINE FRONT HUB; LP TURNBINE STAGES 3,4,5 WERE SCRAPPED. THE #3 AIRSEAL WAS REPAIRED. 4 F E3NE 19970515003161997051500316SW 1997 5 15 CA970219003 119970115G2820206061667001 TUBE ASSEMBLY BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL FUEL SYS CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 90 CAE821536 (CAN) ALUMINUM MAIN FUEL SYSTEM SUPPLY TUBE HAS A STEEL SLEEVE BETWEEN THE "B" NUT AND THE TUBE (FLARE), THIS SLEEVE WAS FOUND BADLY CORRODED. THE TUBE FLARE AND ADJOINING FITTING WERE ALSO CORRODED ALMOST TO THE POINT OF FAILING. 1G71 3U3 U H2SW E4CE 19970515003181997051500318SW 1997 5 15 CA970219006 119970205G27102770018011 CONTROL CABLE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL AILERON FRAYED W A K NONE F FLT CONT AFFECTED ININSP/MAINT 1 CA 1447 44131C 108152 (CAN) WHILE COMPLYING WITH FAIRCHILD 'B' INSPECTION, LEFT AILERON CONTROL CABLE WAS FOUND WITH THREE BROKEN STRANDS WHERE THE CABLE RUNS THROUGH THE PHENOLIC GUIDE BLOCK ATTACHED TO THE FUSELAGE BULKHEAD AT STATION 227-271. FAA AD 87-02-02 CALLS FOR CHECKS EVERY 400 HOURS AND REPLACEMENT AT 10,000 HOURS. THIS CABLE HAS BEEN INSPECTED AT EACH 'B' CHECK, THAT IS EVERY 200 HOURS AND SHOWED NO PROBLEMS UNTIL NOW. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 19970515003201997051500320EU 1997 5 15 CA970219011 219970129G7250 TURBINE BLADE FOKKERF28 F28MK1000 4990808EU RROYCESPEY SPEY55515 54521EU AFT TURBINEWHEELMISSING W A AE UNSCHED LANDING ENGINE SHUTDOWN E VIBRATION/BUFFET CLCLIMB 1 CA 29603 9299 (CAN) #2 ENGINE EXPERIENCED SUDDEN VIBRATIONS THROUGH FL270. ALL ENGINE PARAMETERS WERE FINE BUT VIBRATIONS COULD BE FELT THROUGH THE AIRCRAFT AND POWER LEVERS. ENGINE WAS SHUTDOWN AND THE AIRCRAFT RETURNED TO ITS POINT OF DEPARTURE. POST FLIGHT INSPECTION FOUND A BLADE MISSING FROM THE AFT TURBINE WHEEL. THE ENGINE WAS REPLACED, THE AIRCRAFT GROUND RUN SERVICEABLE AND THE AIRCRAFT RETURNED TO SERVICE. THE FAILED ENGINE WAS SENT TO ROLLS ROYCE FOR INVESTIGATION, FURTHER REPORT TO FOLLOW. 2L72 4F4 FRTA20EU E2EU 19970515003211997051500321EA 1997 5 15 CA970219013 119970213G2421731579 GENERATOR CNDAIRCL600 CL6002A12 1900304EA GE CF34 CF341A NE IDG CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 CA 350143 (CAN) INTEGRATED DRIVE GENERATOR OIL LEVEL FOUND LOW ON DAILY INSPECTION. CHIP DETECTOR PULLED AND FOUND METAL CONTAMINATED. 2L72 4F4 FRTA21EA E15NE 19970515003221997051500322SO 1997 5 15 CA970219014 119970209G3710 GASKET PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA VACUUM PUMP LEAKING W EA ENGINE SHUTDOWN UNSCHED LANDING KR FLUID LOSS PARTIAL RPM/PWR LOSS CRCRUISE 1 CA L286061A (CAN) AFTER TAKEOFF THE PILOT NOTICED A DROP IN MANIFOLD AND OIL PRESSURES ON #2 ENGINE. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT RETURNED TO BASE. POST FLIGHT INSPECITON FOUND THE #2 ENGINE COWLING SATURATED WITH ENGINE OIL. FURTHER INVESTIGATION FOUND THE VACUUM PUMP GASKET WAS LEAKING. THE PUMP WAS NEWLY INSTALLED AND THE FAULTY GASKET CAME WITH THE PUMP. A NEW LYCOMING VACUUM PUMP GASKET P/N 8313 WAS INSTALLED AND THE ENGINE GROUND RUN SERVICEABLE. 1L72 3O3 O A20SO E14EA 19970515003231997051500323GL 1997 5 15 CA970219016 119970203G652028135255R GEARBOX ENSTRMF28 280 3300502GL LYC O360 HIO360C1A 41514EA T/R MAKING METAL W K NONE O OTHER ININSP/MAINT 1 CA 719 RL672751A (CAN) CHIPS FOUND ON DETECTOR DURING 100 HOUR INSPECTION. 1G71 3O3 O H1CE 1E10 19970515003241997051500324NE 1997 5 15 CA970219017 219970210G7260M06118 GEARBOX LKHEED1011 1011385114 WP RROYCERB211 RB21122B02 54555NE ACCESSORY GRBOX MAKING METAL W K NONE O OTHER ININSP/MAINT 1 CA 1930 10145 ACESSORY GEAR BOX MAKING METAL 2L73 4F4 F A23WE E12EU 19970515003251997051500325NE 1997 5 15 CA970219018 219970206G7210310924401 BEARING PWA PW121 PW121 52124NE RED GEARBX NR 15SPALLED W K NONE O OTHER ININSP/MAINT 1 CA 9773 121239 (CAN) THE REDUCTION GEARBOX WAS SENT FOR REPAIR AND INVESTIGATION AFTER THE OPERATOR REPORTED THE ENGINE WAS MAKING METAL. DISASSEMBLY OF THE REDUCTION GEARBOX FOUND THE CAUSE OF THE ENGINE CONTAMINATION WAS A SPALLED ROLLER OF THE #15 BEARING. THE #15 BEARING ROLLERS AND OUTER RACE HAD EXTENSIVE ELECTRICAL PITTING. IT IS THE OPINION OF THE REPAIR FACILITY THAT THE LIKELY CAUSE OF THE FAILURE WAS A LIGHTNING STRIKE. 4 T E20NE 19970515003921997051500392SO 1997 5 15 97ZZZX2020 219970401G7414 CAM ASSY BEECH 35 K35 1151524CE CONT O470 IO470C 17026SO SNAP RING RIVET FAILED H K NONE O OTHER ININSP/MAINT 1 WP155008 D5865 DURING ACCOMPLISHING SB MSB645, NR 639, AND AD 96-12-07, FOUND MAG SNAP RING CAM ASSY HAD RIVET FAILURE. 1L71 3O3 O 3A15 E273 19970515003931997051500393SO 1997 5 15 97ZZZX2021 219970428G7414M3006 BEARING SLICK 6310 BEECH 58 58 1152740CE CONT O550 IO550C SO MAG DRIVE FAILED H K NONE O OTHER ININSP/MAINT 1 WP23877CA1385 94020912 TH1727 676761 PILOT REPORTED LEFT ENGINE LEFT MAGNETO WAS 'DEAD' ON RUN-UP. REMOVED MAGNETO AND OPENED UP FOR INSPECTION. FOUND INTERNAL DAMAGE - MATERIAL BEING WORN AWAY BY ROTATING MAGNET. FURTHER DISASSEMBLY REVEALED DRIVE END BEARING P/N M3006 BALL RETAINER CAGE AND GREASE SEAL GONE - BEARING WAS DRY WHICH MAY HAVE LEAD TO FAILURE. NEW MAGNETO INSTALLED ON AIRCRAFT AND RETURNED TO SERVICE. 1L72 3O3 O 3A16 E3SO 19970515003981997051500398EA 1997 5 15 97ZZZX2026 219970501G7322105217 CARBURETOR MA4SPA PIPER PA28 PA28180 7102808SO LYC O320 O320D3G 41508EA BOWL DRAIN LEAKING D K NONE K FLUID LOSS ININSP/MAINT 1 EA0715050 287225569 L2262227A TWO BOWL SCREWS LEAKING. FUEL BOWL DRAIN LEAKING. BOTTOM OF CARBURETOR SMALL HOUSING OF ACCELERATOR PUMP LEAKING. VERY POOR QUALITY ASSURANCE. SUBMITTER STATED ALSO SAME PROBLEM ON AN OVERHAULED MODEL - SAME P/N, 10-5217. 1L71 3O3 O 2A13 E274 19970515004021997051500402SO 1997 5 15 97ZZZX2030 219970401G8540643110 SPRING 643259A28 CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO START ADAPTER BROKEN D K NONE O OTHER ININSP/MAINT 1 WP03234CN 342 421C0404 292152R RIGHT ENGINE WOULD NOT TURN OVER TO START. FOUND CLUTCH SPRING INSIDE THE STARTER ADAPTER BROKEN. REPLACED STARTER ADAPTER. NOTE: THIS ENGINE AND STARTER ADAPTER IS NOT REQUIRED TO BE INSPECTED BY TCM BULLETIN CSB94-4A. 1L72 3O3 O A7CE E7CE 19970515004041997051500404EA 1997 5 15 97ZZZX2032 219970416G7322MA3A CARBURETOR FACET PIPER PA38 PA38112 7103812SO LYC O235 O235L2C 41505EA CARBURETOR MAIN JET BLOCKED D O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SO152585B3195 CR15849 3879A0132 L1768215 AIRCRAFT ENGINE LOST POWER FROM PARTIAL OBSTRUCTION OF MAIN JET WHICH FEEDS DISCHARGE NOZZLE. MATERIAL APPEARS TO HAVE BUILD-UP OF SEDIMENT SCALE. RECOMMEND INTERNAL BOWL INSPECTION OF CONDITION AT EACH 2,000-HOUR OPERATION. 1L71 3O3 O A18SO E223 19970515004071997051500407NE 1997 5 15 97ZZZX2035 219970409G7230204322017 VANE ASSY LYC LF507 LF5071F NE 3RD STAGE COMP FOD DAMAGE B SW5RK NONE O OTHER ININSP/MAINT 1 NE03 LF07338 SEVERE FOD DAMAGE TO 1ST, 2ND, AND EXIT VANE ROWS. TRAMP MATERIAL LODGED BETWEEN VANES. OUTER SHROUD DAMAGED FROM FOD IMPACTS. 4 F E6NE 19970515004081997051500408NM 1997 5 15 97ZZZX2036 219970429G7261 ENGINE GULSTM690TP 690C 7630517SW GARRTTTPE331TPE3315251K NM LT ENGINE LOW OIL PRESS D EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 NM043XY 1970 11638 P40341 UPON REACHING FL 26,000 FEET, PILOT OBSERVED OIL PRESSURE DECREASING SLOWLY. THE OIL PRESSURE HAD REACHED A LOW END RED LINE. THE PILOT ELECTED TO SHUT DOWN NR 1 ENGINE AND RETURN TO THE AIRPORT. AFTER LANDING, INVESTIGATION WAS MADE INTO OIL PRESSURE. PRESSURES WERE ALL GOOD ON THE GROUND. SOAP SAMPLES PROVED GOOD. PREVIOUS ENGINE WORK SUGGESTS SOME POSSIBLE NICKED O-RINGS ON OIL TRANSFER TUBES INTERNALLY IN ENGINE. THE ENGINE WAS REMOVED AND SENT BACK TO ALLIED SIGNAL FOR INSPECTION. 1H72 3T4 T 2A4 E2WE 19970515004091997051500409EA 1997 5 15 97ZZZX2037 219970424G8530LW14077 PISTON PIN HILLERUH12 UH12E 4360122WP LYC O540 VO540C2A 41532EA ENGINE DEFECTIVE H K NONE O OTHER ININSP/MAINT 1 WP1762392161 1591 L150943 AD 97-01-03 AND LYC SB 527B DO NOT REFERENCE VO540 ENGINES IN MODELS AFFECTED, BUT 4 OF 6 PISTON PINS IN ENGINE HAD TO BE REPLACED IN C/W THE SB REQUIRED ACTION. NOTE: 6-CYLINDER HELICOPTER ENGINES ARE LISTED IN WARRANTY LABOR ALLOWANCE AND A VO540 ENGINE IS LISTED IN MODEL AND S/N ATTACHMENT TO THE SB. 1G71 3O3 O 4H11 E304 19970515004131997051500413SO 1997 5 15 97ZZZX2041 219970401G8530625393 RETAINER CONT O520 GTSIO520H 17032SO NR 5 CYL INT VLVCRACKED D K NONE O OTHER ININSP/MAINT 1 NE03 267116R NR 5 CYLINDER VALVE RETAINER DEFECT. CHECKED TWO CYLINDERS ON THIS RUN-OUT CORE. ONE GOOD AND NR 5 WAS NOT DUE TO INTAKE VALVE SPRING RETAINER CRACKED. 3 O E7CE 19970515004141997051500414EA 1997 5 15 97ZZZX2042 219970401G8530SL798606 PUSHROD CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA CYLINDER LOOSE END D K NONE O OTHER ININSP/MAINT 1 NE03 2400 L1453615 RUN-OUT CORE ENGINE THAT WAS DISASSEMBLED FOR PUSHRODS FOR C/W AD 95-3-10. THIS ENGINE HAD ONE SUPERIOR AIR PARTS PUSHROD WITH LOOSE END. 1H71 3O3 ONT3A19 E223 19970515004151997051500415SO 1997 5 15 97ZZZX2043 219970401G8530625393 RETAINER CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO NR 3/4 EXH VLV CRACKED D K NONE O OTHER ININSP/MAINT 1 NE031562G673 421B0801 267147R NR 3 AND NR 4 CYLINDER EXHAUST VALVE RETAINER CRACKED. 1 EACH CYLINDER. INSPECTED ALL OTHER CYLINDERS. NONE FOUND DEFECTIVE. 1L72 3O3 O A7CE E7CE 19970515004161997051500416SO 1997 5 15 97ZZZX2044 219970422G8530542343CN CYLINDER CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO LT NR 5 SEPARATED D A UNSCHED LANDING ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CRCRUISE 1 SW11421FC 618 421C0442 604119 ACFT LOST NR 5 CYLINDER IN CRUISE FLIGHT TO JBR. CYLINDER SEPARATED ABOUT 1 INCH INBOARD OF THREADED AREA IN STEEL SLEEVE. AREA CRACKED IS 360 DEGREES AND EXPOSED TOP RINGS ON PISTON CAUSING METAL CONTAMINATION IN ENGINE. OIL PRESSURE WAS LOST 4 MINUTES BEFORE LANDING AT BVX. THE NR 5 CYLINDER THAT FAILED IS LOCATED ON THE LEFT ENGINE. CAUSE FOR THE CYLINDER FALURE HAS NOT BEEN DETERMINED. THE STEEL PORTION OF THIS CYLINDER HAD NO SIGN OF CRACKING OR LEAKING AT THE LAST INSPECTION WHICH WAS 15.9 HOURS AGO AT SCHEDULED OIL CHANGE ON 2-6-97. 1L72 3O3 O A7CE E7CE 19970515004171997051500417SO 1997 5 15 97ZZZX2045 219970326G8520530196A1 CRANKSHAFT PIPER PA17 PA17 7101702SO CONT A65 A658 17003SO NR 2 THROW FRACTURED G K NONE Y ENGINE STOPPAGE NRNOT REPORTED 1 SW114820H109 4F98 17118 T024483 CRANKSHAFT FRACTURED IN AFT CHEEK OF NR 2 THROW CAUSING ENGINE TO STOP. THE CRANKSHAFT WAS IN THE 0.010 INCH UNDER CONDITION. THE ORIGIN OF THE FRACTURE MAY HAVE BEEN THE AFT RADIUS OF THE NR 2 CRANK PIN. THE CRANKSHAFT WAS MAGNAFLUXED AT OVERHAUL. SUBMITTER RECOMMENDS MAKING ULTRASONIC INSPECTION AN OVERHAUL REQUIREMENT ON AGING ENGINES. 1H71 3O3 O A805 E205 19970515004191997051500419SO 1997 5 15 97ZZZX2047 219970401G8550625393 RETAINER CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO NR 4 CYL INT VLVFAILED D K NONE O OTHER NRNOT REPORTED 1 NE035451J280 421B0909 267346R NR 4 CYLINDER INTAKE VALVE RETAINER FAILED. INSPECTED ALL OTHER CYLINDERS, FOUND NO OTHER DEFECTS. 1L72 3O3 O A7CE E7CE 19970515004211997051500421SO 1997 5 15 97ZZZX2049 219970421G8530648045 PISTON 646657C CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE WRONG PART D K NONE W INADEQUATE Q C ININSP/MAINT 1 NM076480N 21063054 245650R UPON DISASSEMBLY OF ENGINE, FOUND WRONG PISTONS INSTALLED. RECORDS INDICATE PISTONS SOLD AS PART OF A TOP OVERHAUL KIT WITH CHROME CYLINDERS (4/1994). CYLINDERS REMOVED FOR GLAZING AND 3 PISTONS WERE SCORED ENOUGH TO REQUIRE REPLACEMENT. REPLACED ALL 6 WITH CORRECT SET OF BALANCED PISTONS. 1H71 3O3 O 3A21 E8CE 19970515004221997051500422EA 1997 5 15 97ZZZX2050 219970422G8530LW13561 CYLINDER PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA INTAKE PORT CRACKED D K NONE O OTHER ININSP/MAINT 1 CE0182606 81 31P7730011 L55762 DURING MAINTENANCE WITH INTAKE PIPE REMOVED, INTAKE GUIDE WAS FOUND MOVING WITH THE VALVE. CYLINDER REPLACED, TEAR DOWN REPORT REQUESTED FROM ENGINE OVERHAULER. REPORT STATED A CRACK HAD CAUSED THE PROBLEM. OUT OF 4 ENGINES OF THIS TYPE MAINTAINED BY THIS FACILITY, THIS WAS THE 6TH CYLINDER WITH CRACKS IN INTAKE PORT AREA. ALL CYLINDERS WERE OVERHAULED AND CHROMED. TIMES VARIED 81 AND 900 HOURS. 1L72 3O3 O A8EA E19EA 19970515004231997051500423EA 1997 5 15 97ZZZX2051 219970422G8530LW13561 CYLINDER PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA NR 1 CRACKED D K NONE O OTHER ININSP/MAINT 1 CE0182606 81 31P7730011 RL36662 DURING ROUTINE MAINTENANCE, NR 1 AND NR 3 CYLINDERS WERE FOUND CRACKED IN THE INTAKE PORT AREA. CRACKS WERE BETWEEN FIRST AND SECOND COOLING FINS FROM THE TOP AND PROGRESSED TO THE THINNER AREA OF THE PORT. CRACKS NOTED BY A GREENISH TO BLACK STAIN LOOKING FROM THE BOTTOM OF THE ENGINE. OF FOUR ENGINES OF THIS TYPE MAINTAINED BY THIS FACILITY, THESE ARE THE 4TH AND 5TH WITH SIMILAR CRACKS. ALL CYLINDERS WERE OVERHAULED AND CHROMED. TIMES WERE 80 HRS AND APPROX 900 HRS SINCE OVERHAUL. 1L72 3O3 O A8EA E19EA 19970515004241997051500424EA 1997 5 15 97ZZZX2052 219970422G8530LW13561 CYLINDER PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA NR 3 CRACKED D K NONE O OTHER ININSP/MAINT 1 CE0182606 81 31P7730011 RL36662 DURING ROUTINE MAINTENANCE, NR 1 AND NR 3 CYLINDERS WERE FOUND CRACKED IN THE INTAKE PORT AREA. CRACKS WERE BETWEEN FIRST AND SECOND COOLING FINS FROM THE TOP AND PROGRESSED TO THE THINNER AREA OF THE PORT. CRACKS NOTED BY A GREENISH TO BLACK STAIN LOOKING FROM THE BOTTOM OF THE ENGINE. OF FOUR ENGINES OF THIS TYPE MAINTAINED BY THIS FACILITY, THESE ARE THE 4TH AND 5TH WITH SIMILAR CRACKS. ALL CYLINDERS WERE OVERHAULED AND CHROMED. TIMES WERE 80 HRS AND APPROX 900 HRS SINCE OVERHAUL. 1L72 3O3 O A8EA E19EA 19970515004251997051500425SO 1997 5 15 97ZZZX2053 219970428G74141051324 SPRING BLANCA1419 14193 1220406GL CONT O470 IO470F 17026SO LT MAG BROKEN B QKKRK NONE O OTHER ININSP/MAINT 1 CE018838R26 446018 4192 BOTH MAGNETOS OVERHAULED APRIL 1995. NEW SPRINGS INSTALLED. BOTH SPRINGS FOUND BROKEN INTO 3 PARTS. CAUSE APPEARED TO BE FROM CORROSION PITS LEADING TO STRESS POINTS. THE REPORT WAS THAT MOST HOURS WERE FLOWN SHORTLY AFTER OVERHAUL AND THEN AIRCRAFT SAT. THE SPRINGS WERE PURCHASED BY THIS CRS DURING JANUARY 10 TO MARCH 21, 1995 RECORDS. 1L71 3O3 O 1A3 3E1 19970515004261997051500426SO 1997 5 15 97ZZZX2054 219970428G74141051324 SPRING BLANCA1419 14193 1220406GL CONT O470 IO470F 17026SO RT MAG BROKEN B QKKRK NONE O OTHER ININSP/MAINT 1 CE018838R26 441258 4192 BOTH MAGNETOS OVERHAULED APRIL 1995. NEW SPRINGS INSTALLED. BOTH SPRINGS FOUND BROKEN INTO 3 PARTS. CAUSE APPEARED TO BE FROM CORROSION PITS LEADING TO STRESS POINTS. THE REPORT WAS THAT MOST HOURS WERE FLOWN SHORTLY AFTER OVERHAUL AND THEN AIRCRAFT SAT. THE SPRINGS WERE PURCHASED BY THIS CRS DURING JANUARY 10 TO MARCH 21, 1995 RECORDS. 1L71 3O3 O 1A3 3E1 19970515009111997051500911EA 1997 5 15 HAIHEEA9582 219970424G7200 ENGINE PWA PT6 PT6A41 52043EA POWER PLANT NOISY E HEEAK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 PCE80435 ENGINE MAKING NOISE. TIME SINCE REPAIR 0:00. 4 T E4EA 19970519000011997051900001NE 1997 5 19 CA970203011 219970124G7240RK47289 COMB CHAMBER BRAERO748 HS7482B 1500248EU RROYCEDART DART5352 54509NE NOSE CONE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 19460 1860 (CAN) DURING INSPECTION THE NOSE CONE OF ONE OF THE COMBUSTION CHAMBERS WAS FOUND BROKEN AWAY FROM THE COMBUSTION CHAMBER BODY. 2L72 3T4 T A24EU E297 19970519000031997051900003EA 1997 5 19 CA970219007 219970209G8550LW14728 DIPSTICK PIPER PA31 PA31 7103102SO LYC O540 TIO540J2BD 41532EA HARTZLHCC4Y HCC4YR2 GL ENG OIL SYS BROKEN W K NONE K FLUID LOSS ININSP/MAINT 1 CA 84 L491261A FH780 (CAN) ON POST FLIGHT INSPECTION AN OIL LEAK WAS FOUND. INVESTIGATION FOUND THE OIL LEAK WAS A RESULT OF A BROKEN OIL DIP STICK. THE ROD HAD FALLEN OUT OF THE HANDLE DUE TO A MISSING PIN. 1L72 3O3 O A20SO E14EA 5 CP52GL 19970522000571997052200057NE 1997 5 22 97ZZZX2060 219970415G8500 ENGINE BEECH 18 H18 1151012CE PWA R985 R985AN14B 52008NE MAIN BEARING SEIZED G EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 SW11117ME 420 BA638 16729 WHILE IN CRUSE FLIGHT, PILOT NOTICED OIL PRESSURE STARTING TO DECREASE AND OIL TEMP STARTING TO RISE. ENGINE WAS SECURED, PROP WAS FEATHERED, AND A PRECAUTIONARY LANDING MADE. UPON LANDING, PILOT FOUND HE COULD NOT TURN PROP BY HAND. SUSPECT THAT THE MAIN BEARING FAILED. ENGINE HAD APPROXIMATELY 420 HOURS SINCE OVERHAUL. 1L72 3R3 R A765 5E1 19970522000581997052200058EA 1997 5 22 97ZZZX2061 219970320G7314154739506 FUEL PUMP BEECH 23 B19 1151215CE LYC O320 O320E3D 41508EA PART NUMBER MISIDENTIFIED D A K NONE W INADEQUATE Q C ININSP/MAINT 1 NM022048A MB904 L4828827A NEW FUEL PUMP INSTALLED ON OVERHAULED ENGINE. DURING INITIAL RUN-UP, FUEL STREAMED OUT OF CARBURETOR. CARB RPLD WITH RE-MFG'D ONE AND PERFORMED IN LIKE MANNER. WHILE T/S, FOUND FUEL PUMP ONE OF A WRONG P/N, AND CAME FROM 'A' SUPPLIER IN ORIG TEXTRON LYC CONTAINER MARKED FUEL PUMP P/N LW-15472 WHICH IS NUMBER ENGINE REQUIRES (4-6 PSI). ACTUAL PART INSTALLED SHOWED P/N 154739506 (25-35 PSI). FOUND FLOAT CRUSHED ON BOTH REMFG'D CARBS INSTALLED. CHECKING STOCK REVEALED ONE P/N 154739506 INSTALLED IN ORIG SEALED CONTAINER MARKED LW15472. SUBMITTER SUSPECTED HIGHER PRESSURE FUEL PUMPS CAUSED FLOAT TO BE CRUSHED. RECOMMEND WHEN RECEIVING PARTS FOR STOCK, ENSURE EXTERIOR MARKED P/N IS SAME AS INTERIOR PART. 1L71 3O3 O A1CE E274 19970522003761997052200376NE 1997 5 22 PCAA9700363 219970409G7261 OIL SYSTEM DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE NR 1 ENGINE MALFUNCTION E PCAAA UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 EA13818EX 235 120448 OIL SYSTEM MALFUNCTION 2H72 4T4 TRTA13NM E20NE 19970522004791997052200479NE 1997 5 22 97ZZZX2093 219970429G7314GB3173CE FUEL PUMP FOKKERF27 F27MK500 4990629EU RROYCEDART DART5327R 54509NE LEFT ENGINE SHAFT SHEARED C A A UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 SO33709FE 4839 10375 14206 ON CLIMB-OUT OF LCK, THE LEFT ENGINE AUTOFEATHERED. THE CREW DECLARED AN EMERGENCY AND RETURNED TO LCK WITH NO FURTHER PROBLEMS. THE MECHANIC FOUND A SHEARED SHAFT ON THE FUEL PUMP. THE ENGINE CHECKED GOOD IAW THE FOKKER MM AFTER THE FUEL PUMP WAS REPLACED. 2H72 4T4 T A817 E297 19970522004801997052200480NE 1997 5 22 97ZZZX2094 219970206G7250 ENGINE FOKKERF27 F27MK500 4990629EU RROYCEDART DART5327R 54509NE LT ENG TURB DAMAGED C A EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 SO33721FE184303054 10460 14727 EWR/YMX - EN ROUTE, THE LEFT ENGINE STARTED TO AUTOFEATHER. THE LEFT ENGINE TEMP STARTED TO RISE, THE FLIGHT CREW THEN MANUALLY FEATHERED THE PROP. THE CREW DECLARED AN EMERGENCY AND WAS CLEARED TO LAND IN ALB. THE PILOT TRIED TO RESTART THE ENGINE, BUT IT WOULD NOT START. THE AIRCRAFT LANDED WITHOUT ANY OTHER PROBLEMS. A MAINTENANCE CREW WAS DISPATCHED TO ALB FOR THE ENGINE CHANGE. 2H72 4T4 T A817 E297 19970522004831997052200483EA 1997 5 22 97ZZZX2097 219970502G8530SL139973 RETAINER KEY LYC O360 O360* 41514EA CYLINDER KIT MISMANUFACTURED D K NONE W INADEQUATE Q C ININSP/MAINT 1 SO15 KEY NOT CUT ON ONE SIDE. PART IS IN A COMPLETE POWER SECTION. NEW CYLINDER KIT S/N 97-2806. 3 O E286 19970522004851997052200485SO 1997 5 22 97ZZZX2098 219970401G732263255424 LEVER 649052A2 BEECH 58 58 1152740CE CONT O520 IO520C 17032SO FUEL CONTROL MISINSTALLED D A K NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 DURING ROUTINE MAINTENANCE, FUEL INJECTION ASSY FOUND LOOSE. OF THE 3 BOLTS THAT ATTACH THIS TO THE THROTTLE CONTROL ASSY, 2 BOLTS MISSING, 1 LOOSE. ASSY ABOUT TO BREAK LOOSE. ALSO, SHROUD P/N 646673 BROKEN AND LOOSE, AND CHAFING ON FUEL LINE FITTINGS. FITTINGS WERE CHAFED OVER 50 PERCENT THROUGH SIDE WALL THICKNESS. APPEARS TO BE CAUSED BY THROTTLE LEVER BEING INSTALLED INCORRECTLY AND HITTING ASSY AND SHROUD CAUSING PRESSURE AND SHEARING OF THE BOLTS. ALSO, FULL TRAVEL OF THE THROTTLE WAS IMPAIRED. 1L72 3O3 O 3A16 E5CE 19970522004971997052200497EA 1997 5 22 97ZZZX2110 219970428G8520 CONNECTING ROD CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA NR 3 CYLINDER DETACHED D A UNSCHED LANDING ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CRCRUISE 1 SW07757CH700 15279629 L1736815 PILOT EXPERIENCED RPM DROP, LOSS OF OIL PRESSURE, AND ROUGHNESS. LANDED ON CITY STREET. NO AIRCRAFT DAMAGE. FOUND OIL APPARENTLY EXHAUSTED THROUGH CRANKCASE BREATHER. NR 4 CYLINDER PISTON BURNED THROUGH AFT SIDE UNDER RINGS .3750 INCH HOLE. NR 3 CYLINDER CONNECTING ROD BROKEN LOOSE AT END CAP. PUNCTURED BOTTOM OF CRANKCASE. NOTE: APPROX 8 FLIGHT HOURS PREVIOUSLY, CYLINDER COMPRESSION CHECKS WERE ALL IN THE MID 70'S, OVER 80. 1H71 3O3 ONT3A19 E223 19970522004981997052200498EA 1997 5 22 97ZZZX2111 219970428G8530 PISTON CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA NR 4 CYLINDER BURNED D A UNSCHED LANDING ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CRCRUISE 1 SW07757CH700 15279629 L1736815 PILOT EXPERIENCED RPM DROP, LOSS OF OIL PRESSURE, AND ROUGHNESS. LANDED ON CITY STREET. NO AIRCRAFT DAMAGE. FOUND OIL APPARENTLY EXHAUSTED THROUGH CRANKCASE BREATHER. NR 4 CYLINDER PISTON BURNED THROUGH AFT SIDE UNDER RINGS .3750 INCH HOLE. NR 3 CYLINDER CONNECTING ROD BROKEN LOOSE AT END CAP. PUNCTURED BOTTOM OF CRANKCASE. NOTE: APPROX 8 FLIGHT HOURS PREVIOUSLY, CYLINDER COMPRESSION CHECKS WERE ALL IN THE MID 70'S, OVER 80. 1H71 3O3 ONT3A19 E223 19970522005071997052200507SO 1997 5 22 97ZZZX2120 219970423G7414M917 SPRING SLICK 662 CESSNA210 T210L 2073449CE CONT O520 TSIO520H 17040SO IMPULSE COUPLINGBROKEN D K NONE O OTHER ININSP/MAINT 1 NM0193377 7110441 21060381 TROUBLESHOOTING OF 400 RPM MAG DROP FOUND LEFT MAGNETO TIMING AT 7 DEGREES BTC. REMOVED MAG AND FOUND IMPULSE COUPLING SPRING BROKEN TWO INCHES FROM OUTER END. 1H71 3O3 O 3A21 E8CE 19970522005271997052200527GL 1997 5 22 97ZZZX2123 219970401G723023005250 COMPRESSOR BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL SCROLL CRACKED D K NONE O OTHER ININSP/MAINT 1 SW09255EV 6506 51488 89550 DURING ROUTINE VISUAL INSPECTION FOUND COMPRESSOR SCROLL CRACKED AT 7:00 O'CLOCK POSITION LOOKING FORWARD. 1G71 3U3 U H2SW E1GL 19970529002331997052900233NE 1997 5 29 CA970220003 219970210G7210310703301 BEARING PWA 120 PW120A NE RED GRBOX NR 15 SPALLED W K NONE O OTHER ININSP/MAINT 1 CA 12306 121098 (CAN) REDUCTION GEARBOX WAS SENT FOR INVESTIGATION AFTER METAL CONTAMINATION WAS FOUND IN THE ENGINE. DISASSEMBLY OF THE GEARBOX FOUND THE #15 BEARING SEVERELY SPALLED ON THE OUTER RACE WITH SUBSTANTIAL MATERIAL LOSS. THE #15 AND #18 BEARINGS BOTH HAD ELECTRICAL EROSION TYPE CHAIN PITTING TYPICAL OF LOW ENERGY ELECTRICAL DISCHARGE AND ALSO SOME DEEPER, ARCING TYPE PITTING, TYPICAL OF HIGH ELECTRICAL DISCHARGE. THE MAGNETISM IN THE RGB IS RELATIVELY MINOR AND CERTAINLY NOT TYPICAL OF THE MAGNETIC PROFILE THAT TYPICALLY ARISES FOLLOWING A LIGHTNING STRIKE. IT IS THE OPINION OF R&O THAT THE RGB WAS SUFFERING FROM LOW LEVEL ELECTRICAL EROSION PITTING WHICH EITHER LED TO THIS FAILURE OR WOULD HAVE CAUSED FAILURE IN 4 T E20NE 19970529002351997052900235EA 1997 5 29 CA970221005 219970211G7322105135 CARBURETOR SCREWFACET MA4SPA CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE LOOSE W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 950 CK714171 RL125876TA (CAN) THE ENGINE DID NOT STOP AFTER THE MIXTURE CONTROL WAS CLOSED. THE ENGINE WAS STOPPED BY SHUTTING OFF THE MAGS. INSEPCTION FOUND THAT FOUR SCREWS THAT HOLD THE CARBURETOR HALVES TOGETHER WERE LOOSE AND ONE OF THE SCREWS WAS BROKEN. THE BROKEN SCREW WAS REMOVED AND REPLACED AND THE CARBURETOR WAS REASSEMBLED AND INSTALLED. THE ENGINE GROUND RUN SERVICEABLE AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1H71 3O3 ONT3A12 E274 19970529002371997052900237 1997 5 29 CA970226003 419970212G6113CA4393308 BACKPLATE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2A GL SPINNER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 25 RL139461C DJ11451A (CAN) THE SPINNER BACKPLATE WAS FOUND CRACKED ON INSPECTION. THE REPORT STATES THAT THIS IS THE THIRD BACKPLATE (IDENTICAL PART NUMBERS) THAT HAS CRACKED ON THIS ENGINE SINCE OCTOBER 9, 1996. 1L72 3O3 O A20SO E14EA 5 CP33EA 19970529002391997052900239EA 1997 5 29 CA970226005 219970220G853075362 CYLINDER BNORM BN2 BN2A 1520204EU LYC O540 O540E4C5 41532EA #1 POSITION CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1444 L1281340 (CAN) COMPRESSION CHECK AT INSPECTION REVEALED A CRACKED #1 CYLINDER. THE CRACK WAS AT THE LOWER SPARK PLUG HOLE. 1H72 3O3 O A17EU E295 19970529002411997052900241 1997 5 29 CA970226057 419970214G611357A24041 LOW PITCH STOP BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO HARTZLHCC2Y BHCC2YF2 GL LH SPINNER STRIPPED THREADSW K NONE O OTHER ININSP/MAINT 1 CA 1029 CS922825L AN6527 (CAN) DURING A DAILY INSPECTION THE L/H PROPELLER SPINNER WAS FOUND LOOSE. FURTHER INSPECTION REVEALED THE LOCK WIRE SECURING THE PROP SPINNER TO THE LOW PITCH STOP ASSEMBLY WAS BROKEN AND THE THREADS ON THE LOW PITCH STOP WERE STRIPPED. THE LOW PITCH STOP WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 3O3 ORT3A16 3E1 5 CP920 19970529002421997052900242EA 1997 5 29 CA970226058 219970217G72613026887 REGULATOR BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA #1 ENG OIL PRESSNOT ENGAGED W DE RETURN TO BLOCK ENGINE SHUTDOWN E VIBRATION/BUFFET CLCLIMB 1 CA PCE51808 (CAN) SHORTLY AFTER TAKEOFF THE #1 ENGINE LOST OIL PRESSURE AND HAD TO BE SHUTDOWN. INSPECTION OF THE OIL PRESSURE REGULATOR FOUND THE CLIP ON THE OIL PRESSURE HOUSING WAS NOT FULLY ENGAGED. THE REGULATOR WAS DISASSEMBLED AND INSPECTED, NO FAULT WAS FOUND. THE REGULATOR WAS REASSEMBLED AND INSTALLED. THE ENGINE RUN-UP SERVICEABLE AND THE AIRCRAFT RETURNED TO SERVICE. IT WAS CONCLUDED THAT THE OIL PRESSURE REGULATOR WAS NOT PROPERLY ENGAGED AND IT CAME LOOSE AND LOST OIL AND TORQUE. 1L72 3T4 T A14CE E4EA 19970529002431997052900243EA 1997 5 29 CA970226064 119970129G3260864806 PSEU CNDAIRCL600 CL6002B19 EA GE CF34 CF343A1 30015NE MLG FAILED W K NONE J WARNING INDICATION DEDESCENT 1 CA 2379 807343 (CAN) ON DESCENT THE PROXIMITY SYSTEM FAULT LIGHT CAME ON ALONG WITH GEAR DOWN RED LIGHTS. WHEN LANDING GEAR LEVER SELECTED DOWN NOTHING HAPPENED. LANDING GEAR MANUAL EXTENSION CARRIED OUT. PROXIMITY SENSOR ELECTRONIC UNIT REPLACED. 2L72 4F4 FRTA21EA E15NE 19970529002441997052900244WP 1997 5 29 CA970226065 119970211G3230 BRAKE HOSE DOUG DC9 DC932 3022066WP PWA JT8 JT8D7A 52053NE LT MLG MISALIGNED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA P653990D (CAN) UNABLE TO RAISE L/H MAIN LANDING GEAR. ALSO GEAR DOOR LIGHT REMAINED ON. QRH CARRIED OUT, NIL SUCCESS. MAINTNENANCE INVESTIGATION REVEALED UPPER FORWARD BRAKE HOSE SUPPORT HAD COME IN CONTACT WITH UPLATCH GUARD BAR. ALSO FOUND LH CEILING STOP DAMAGED. REPAIRS CARRIED OUT, OLEO SERVICED, GEAR SWING CHECKED SERVICEABLE. 2L72 4F4 F A6WE E2EA 19970529002451997052900245WP 1997 5 29 CA970226067 119970213G3222 LANDING GEAR DOUG DC9 DC932 3022066WP PWA JT8 JT8D7A 52053NE NLG OLEO FLAT W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA P657363D (CAN) AFTER TAKEOFF GEAR LEVER SELECTED UP, RED NOSE GEAR UNSAFE LIGHT REMAINED ON. NOSE GEAR APPEARED TO RETRACT PARTIALLY. QRH CARRIED OUT, SAME CONDITION REMAINED. GEAR SELECTED DOWN AND AIRCRAFT SAFELY LANDED. MAINTENANCE TROUBLESHOOTING FOUND NOSE OLEO FLAT WITH PISTON CHROME DAMAGE. NOSE LANDING GEAR OLEO PISTON ASSEMBLY CHANGED. GEAR SERVICED AND OPERATIONALLY CHECKED SERVICEABLE. 2L72 4F4 F A6WE E2EA 19970529002461997052900246NM 1997 5 29 CA970226071 119970218G3260864202 SENSOR DOWTY 8200105 DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE DRAG STRUT FAILED W HL DEACTIVATE SYST/CIRCUITSABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA DCL190 120699 (CAN) DURING CLIMB, CRUISE AND DESCENT THE MAIN GEAR DOOR LIGHTS AND NOSE GEAR UNSAFE LIGHT PLUS GEAR INTRANSIT LIGHT WERE ON PERIODICALLY. ON APPROACH, NOSE GEAR WOULD INDICATE UNSAFE AND THEN SAFE. ALTERNATE EXTENSION CARRIED OUT. NOSE LANDING GEAR DOWN LOCK SENSORS AND DRAG STRUT SENSOR WERE UNSERVICEABLE. BOTH SENSORS REPLACED. 2H72 4T4 TRTA13NM E20NE 19970529002471997052900247CE 1997 5 29 CA970227001 119970216G79223024999 RETAINING PLATE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA BYPASS VALVE BROKEN W AE UNSCHED LANDING ENGINE SHUTDOWN K FLUID LOSS CRCRUISE 1 CA 6643 PCE81135 (CAN) OIL LEAK LED TO INFLIGHT SHUTDOWN. POST FLIGHT INSPECTION FOUND THERMOSTATIC OIL BYPASS VALVE RETAINING PLATE BROKEN. THIS ALLOWED OIL PRESSURE TO FORCE OUT THE PLUG WHICH LED TO AN OIL LEAK CAUSING THE INFLIGHT SHUTDOWN. 1L72 4T4 T A24CE E4EA 19970529002481997052900248EA 1997 5 29 CA970228005 219970221G8530LW11775 PLUG PISTON PIN PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA #5 CYLINDER BROKEN W EA ENGINE SHUTDOWN UNSCHED LANDING BKMSMOKE/FUMES/ODORS/SPARKS FLUID LOSS OVER TEMP CRCRUISE 1 CA 1730 L217368A (CAN) PILOT NOTICED RISE IN OIL TEMPERATURE AND SMOKE FROM #2 ENGINE. ENGINE WAS SHUTDOWN AND PRECAUTIONARY LANDING WAS CARRIED OUT. POST FLIGHT INSPECTION FOUND THE #2 ENGINE, #5 CYLINDER PISTON PIN PLUG BROKEN AND THE DEBRIS HAD SEIZED THE RINGS CAUSING THE CRANKCASE TO PRESSURIZE AND DISCHARGE OIL OUT OF THE OIL BREATHER PIPE. 1L72 3O3 O A20SO E14EA 19970529002731997052900273NE 1997 5 29 97ZZZX2357 219970520G7260R1309P140 O RING 2CM82JIB GE CF700 CF7002D 30010NE START/GEN DRIVE LEAK G A UNSCHED LANDING K FLUID LOSS NRNOT REPORTED 1 GL05 304220B THE PILOT RETURNED AFTER 30 MINUTES DUE TO OIL PRESSURE AND OIL QUANTITY LOSS ON NR 2 ENGINE. AN INVESTIGATION REVEALED THE O-RING SEAL (ACCESS 'C') ON THE DRIVE END OF THE STARTER/GENERATOR HAD APPARENTLY BECOME DAMAGED DURING INSTALLATION 3 HOURS PREVIOUSLY. SPECIAL CARE SHOULD BE TAKEN DURING INSTALLATION OF THE SEAL AND A THOROUGH LEAK CHECK (ENGINE RUN) AFTER INSTALLATION OF THE STARTER/GENERATOR. 4 F E7EA 19970529002961997052900296SO 1997 5 29 97ZZZX2333 219970429G7322104894 CARBURETOR CESSNA150 150L 2071826CE CONT O200 O200A 17020SO MIX NEEDLE DEFECTIVE D K NONE W INADEQUATE Q C ININSP/MAINT 1 EA031413Q 4021425 15072713 INSTALLED OVERHAULED CARBURETOR. WOULD NOT MEET MINIMUM STATIC RPM OF 2,500 RPM. ANOTHER NEW CARBURETOR MET RPM. OLD UNIT OBSERVED IDLE MIXTURE NEEDLE AS TOO SHORT. VENTURI NUT CENTERED. SAFETY WIRE SLOPPY. 1H71 3O3 O 3A19 E252 19970529002971997052900297SO 1997 5 29 97ZZZX2334 219970510G8520 CRANKSHAFT BEECH 33 F33A 1151425CE CONT O520 IO520BA 17032SO JOURNAL 3-4 BROKE D A UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 SW051890W4500 1421 CE447 122913R CRANKSHAFT FAILED IN FLIGHT. BROKE THROUGH SHORT CHECK AREA BETWEEN ROD JOURNALS 3 AND 4. ENGINE FROZE IN FLIGHT. 1L71 3O3 O 3A15 E5CE 19970529003001997052900300EA 1997 5 29 97ZZZX2337 219970429G731076292 DIAPHRAGM VALVE LW13889 PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA FUEL PRESS LOOSE B AEKIRK NONE Y ENGINE STOPPAGE NRNOT REPORTED 1 WP07252MA3433 297 31P33 RL48862 SCREW THAT SECURES NEEDLE VALVE TO DIAPHRAGM IN FUEL PRESSURIZATION VALVE CAME LOOSE ALLOWING NEEDLE VALVE TO COME LOOSE WHICH SHUT ENGINE DOWN. SCREW STILL HAD EVIDENCE OF LOC-TITE ON THREADS. SUSPECT THAT FUEL MAY HAVE SOFTENED LOC-TITE WHICH ALLOWED SCREW TO BACK OUT. 1L72 3O3 O A8EA E19EA 19970529003021997052900302EA 1997 5 29 97ZZZX2339 219970429G7322MA4SPA CARBURETOR FACET PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA THROTTLE SHAFT FROZE G K NONE O OTHER ININSP/MAINT 1 SW9947717 287816126 L3589927A THROTTLE SHAFT FROZE IN BUSHINGS. POSSIBLE RESULT OF PREVIOUS INSTALLATION OF THROTTLE SHAFT KIT. UNABLE TO DETERMINE EXACT CAUSE. 1L71 3O3 O 2A13 E274 19970529003041997052900304EA 1997 5 29 97ZZZX2341 219970501G8520LW13885 BEARING PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA FRONT MAIN DETERIORATED B PAWRK NONE O OTHER ININSP/MAINT 1 EA17521WA86 317752103 L227268A AT INSPECTION, AN OIL CHANGE WAS BEING STARTED AND FOUND METAL SHAVINGS IN SUMP SCREEN AND FILTER. ENGINE WAS REMOVED AND SENT TO OVERHAUL FACILITY FOR TEAR DOWN AND INSPECTION. PRELIMINARY INSPECTION REPORT REVEALED FRONT MAIN CRANKSHAFT BEARING FAILURE. 1L72 3O3 O A20SO E14EA 19970529003061997052900306SO 1997 5 29 97ZZZX2343 219970511G8530639222 CYLINDER CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO NR 1 CYLINDER HEAD SEPARATED D A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 GL05727NE 511 U20605152 570521 CYLINDER HEAD SEPARATED FROM BARREL IN FLIGHT. PILOT NOTICED ROUGH ENGINE AND MADE PRECAUTIONARY LANDING. FAILED CYLINDER WAS 'LIGHT' CASTING WHILE OTHER FIVE WERE 'HEAVY' CASTING. HEAD SEPARATION ALSO CAUSED FUEL LINE SEPARATION AND EXHAUST Y-PIPE DAMAGE. ENGINE HAD 511 HOURS SINCE OVERHAUL BY SHOP IN CANADA. POSSIBLE CAUSE OF FAILURE, INTERNAL CORROSION BETWEEN BARREL AND HEAD THREADS. 1H71 3O3 O A4CE E5CE 19970603000021997060300002 1997 6 3 CA970226069 119970216G7120NAS6606D62 BOLT BARRYCTRLS 9505402 GARRTTTPE331TPE33111U 01514WP REAR ENG MOUNT SHEARED W K NONE O OTHER ININSP/MAINT 1 CA 4305 P75077 (CAN) DURING LEFT ENGINE MAINTENANCE THE BOLT FOR REAR ENGINE MOUNT WAS FOUND SHEARED OFF WITH WEAR TO ELASTOMER MOUNT SHANK. DELAMINATION OF ELASTOMER MOUNT ALSO FOUND. 4 T E4WE 19970605003041997060500304NE 1997 6 5 97ZZZX2485 219970501G7310F2MA521501100AZ LINE AMD FALC50FALCON2000 2730170NM CFE CFE73811B NE FUEL DIST CRACKED B CW1RK NONE K FLUID LOSS ININSP/MAINT 1 EA25790M 766 019 MAINTENANCE PERSONNEL NOTICED FUEL ON BOTTOM OF ENGINE COWL. FURTHER INVESTIGATION REVEALED A CRACKED WELD IN THE MAIN FUEL SUPPLY LINE WHERE THE FUEL PRESSURE SENDER IS LOCATED. LOCATION OF THE SENDER MAY IMPOSE UNDUE STRESS ON THE WELD. 2K73 4F4 FRTA50NM E44NE 19970605004821997060500482SO 1997 6 5 97ZZZX2578 219970501G8520 CRANKCASE UNIVACGC1 GC1B 9230104NM CONT O360 IO360C 17025SO OVER NR 2 CYL CRACKED D K NONE O OTHER ININSP/MAINT 1 EA092403B 3703 R55320SD THIRTY HOURS AFTER REPAIR AND OVERHAUL OF ENGINE, CRANKCASE WAS FOUND TO HAVE A CRACK ON UPPER AREA ABOVE NR 2 CYLINDER (NOT A STUD HOLE CRACK) EXTENDING 1 INCH FORE AND AFT APPROX 1 INCH INBOARD OF CYLINDER MOUNT AREA. CYLINDERS ALSO FOUND NOT TO HAVE BEEN OVERHAULED. ENGINE DISASSEMBLED AND FOUND NUMEROUS OTHER DISCREPANCIES. ( NO COTTER PIN, ETC.). SB 96-13 NOT SIGNED OFF. AD 92-04-09 NOT C/W. 1L71 3O3 O A766 E1CE 19970605004871997060500487EA 1997 6 5 97ZZZX2583 219970422G7414 ROTOR BENDIX S4LN203 PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA RT MAG SHAFT SHEARED D K NONE O OTHER ININSP/MAINT 1 GL095224T1857 A39663 287205248 L1661236A ROTOR SHAFT SHEARED OFF JUST AFT OF SEAL RUNNER BUSHING. THE BREAK IN THE SHAFT APPEARS TO HAVE BEEN CRACKED FOR SOME TIME. THIS ENGINE HAD MAJOR OVERHAUL 441 HOURS AGO FOR PROP STRIKE. THE RIGHT MAGNETO IS DIRECT DRIVE (NO IMPULSE), AND SUSPECT THE SHAFT FAILURE WAS DUE TO SUDDEN STOP OR TORSIONAL SHOCK TO MAGNETO ROTORSHAFT. THE ENGINE HAD SUDDEN STOPPAGE PREVIOUSLY, AND PROP WAS SEVERELY CURLED THE FIRST STRIKE. LOGS SHOW LEFT MAG TO BE ORIGINAL EQUIPMENT. 1L71 3O3 O 2A13 E286 19970605004971997060500497SO 1997 6 5 97ZZZX2593 219970520G7414S6RN1225 MAGNETO BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO IMPULSE COUPLINGCRACKED DP K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 SW052038X860 H21595 CE819 569620 WHEN CHECKING MAGNETOS DURING ENGINE RUN-UP PRIOR TO TAKEOFF, RIGHT MAGNETO GAVE A 350 FOOT RPM DROP ACCOMPANIED BY A VERY ROUGH RUNNING ENGINE. AFTER RIGHT MAGNETO WAS REMOVED FOR TROUBLESHOOTING, CRACKS WERE DISCOVERED ON THE TOP AND BOTTOM OF THE HOUSING EXTENDING FORWARD APPROXIMATELY 1.50 INCHES FROM THE FLANGE OF THE IMPULSE COUPLING. 1L71 3O3 O 3A15 E5CE 19970605005001997060500500EA 1997 6 5 97ZZZX2595 219970522G853073806 PUSHROD CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA NR 2 EXH VLV MUSHROOMED D K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 NE0169232 1897 15282575 L1709915 PILOT REPORTED ENGINE RUNS ROUGH. CHECKED VALVE CLEARANCE AND FOUND NR 2 EXHAUST TO BE .083 INCH. REMOVED NR 2 EXHAUST PUSHROD. PUSHROD FOUND MUSHROOMED AND BALL END WAS LOOSE. SUBMITTER SUGGESTS INSPECTING PUSHRODS FOR LOOSE BALL ENDS ANYTIME THE 100-HOUR VALVE TAPPET CLEARANCE INSPECTION DISCLOSES A LARGER THAN ACCEPTABLE VALUE OR WHEN LOW POWER IS NOTED. REFERENCE LYCOMING SI 1388C AND SI 1068A. 1H71 3O3 ONT3A19 E223 19970605005031997060500503SO 1997 6 5 97ZZZX2598 219970519G8530535666 SCREW 654761A1 BEECH 35 E35 1151512CE CONT E225 E2258 17015SO ROCKER SHAFT STRIPPED D K NONE O OTHER ININSP/MAINT 1 WP173251C D3916 30350D48 DURING CYLINDER INSTALLATION ATTEMPTING TO TORQUE ROCKER SHAFT HOLD-DOWN SCREWS RESULTED IN 2 SCREWS STRIPPING BEFORE THE MINIMUM TORQUE OF 180 INCH/POUND WAS REACHED. THIS IS THE 2ND OCCURRENCE ON THIS ENGINE. BOTH TIMES THE CORRECTIVE ACTION WAS REPLACING SCREWS AND CLEANING THREADS IN ROCKER SHAFT. COULD NOT DETERMINE IF THREADS IN SHAFT ARE STRIPPING OR IF SCREWS ARE DEFECTIVE. 1L71 3O3 O A777 E267 19970605007251997060500725SO 1997 6 5 97ZZZX2607 219970514G8530SA10200A20P CYLINDER CESSNA150 150M 2071830CE CONT O200 O200A 17020SO BARREL FAILED D A UNSCHED LANDING EYBVIBRATION/BUFFET ENGINE STOPPAGE SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 SW17148EL1024 15077412 253635A48 ON A TRAINING FLIGHT, THE ENGINE STARTED RUNNING ROUGH. INSTRUCTOR REQUESTED DIRECT RETURN. WHITE SMOKE CAME FROM ENGINE, A LOUD BANG, FOLLOWED BY VERY ROUGH ENGINE AND PARTIAL POWER LOSS. ENGINE STOPPED, SAFE LANDING, CYLINDER HEAD AND TOP ONE-THIRD OF BARREL SEPARATED FROM LOWER ONE-THIRD OF CYLINDER. PISTON DESTROYED, PUSH ROD BENT, SUBMITTER STATED CAUSE WAS DEFECTIVE CYLINDER BARREL, PREVENT BY USING NEW CONTINENTAL CYLINDERS. 1H71 3O3 O 3A19 E252 19970605007381997060500738SO 1997 6 5 97ZZZX2620 219970501G8530 CYLINDER CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO NR 4 STUDS FAIL D A UNSCHED LANDING O OTHER CRCRUISE 1 AL055246E779 18503943 281256R PILOT HEARD AND FELT ABRUPT CHANGE IN ENGINE 10 MINUTES INTO FLIGHT. UNEVENTFUL RETURN TO BASE WITH ENGINE INSTRUMENTS NORMAL. NR 4 CYLINDER HAD SHEARED ALL 8 STUDS AND HAD SEPARATED .50 INCH FROM CASE. ENGINE HAD HISTORY OF PROP STRIKE TEAR-DOWN 460 HRS PRIOR TO FAILURE. 1H71 3O3 O 3A24 E5CE 19970605007411997060500741CE 1997 6 5 97ZZZX2623 119970517G7160BA5110A AIR FILTER CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA AIR INDUCT WRONG PART D K NONE W INADEQUATE Q C ININSP/MAINT 1 SW17641547 17265049 L4166627A DURING ANNUAL INSPECTION, BRACKETT AIR FILTER ASSY WAS FOUND LOOSE ON THE AIRBOX. UPON REMOVAL, IT WAS FOUND TO BE THE INCORRECT ASSEMBLY FOR THE AIRCRAFT MODEL. THE MODEL 172M USES ASSEMBLY NR BA 5110, A BA 5710A WAS INSTALLED. THE CAMLOCK STUDS ON THE BA 5110A ARE TOO LONG. THE BASE GASKET WOULD NOT CONTACT THE AIRBOX LEAVING IT LOOSE AND FLOPPING. 1H71 3O3 ONT3A12 E274 19970605007421997060500742EA 1997 6 5 97ZZZX2624 219970521G7310 HOSE AEROQUIP PIPER PA24 PA24250 7102404SO LYC O540 O540A1A5 41532EA ENGINE COMPT DETERIORATED D K NONE O OTHER ININSP/MAINT 1 GL078174P2884 243430 FUEL HOSES IN ENGINE COMPARTMENT. ORIGNAL HOSES DATED 1962. HOSES WERE VERY STIFF, BUT NOT LEAKING. SHOULD HAVE BEEN CHANGED BEFORE THEY LOSE FLEXABILITY. 1L71 3O3 O 1A15 E295 19970605007461997060500746WP 1997 6 5 97ZZZX2628 219970227G7320 APR SYSTEM LEAR 55 55LEAR 5170702CE GARRTTTFE731TFE7313A 01518WP ENGINE MALFUNCTION D K NONE O OTHER NRNOT REPORTED 1 SW99646G 763 108291 016 AUXILIARY PERFORMANCE RESERVE (APR). WHEN SYSTEM IS 'ARMED' SYSTEM GOES STRAIGHT TO 'ON' WHEN N2'S ARE MATCHED. 2L72 4F4 F A10CE E6WE 19970605007491997060500749WP 1997 6 5 97ZZZX2631 219970513G726131081381 GASKET SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP TURB SCAV PUMP FAILED B ATZRK NONE E VIBRATION/BUFFET NRNOT REPORTED 1 CE0919WP 3154 TC390 P54286 SCAVENGE PUMP GASKET WENT BAD CAUSING SLOW LOSS OF ENGINE OIL. ALSO, THIS CAUSED VIBRATION TO BREAK OIL JET AT PUMP ASSY. NEW STYLE GASKET NOW INSTALLED. 2L72 4T4 TRTA8SW E4WE 19970605007501997060500750WP 1997 6 5 97ZZZX2632 219970407G72508682721 ROTOR SWRNGNSA226 SA226T 8780122SW GARRTTTPE331TPE3313U 01514WP 2ND STAGE TURB CRACKED B S2WRK NONE O OTHER ININSP/MAINT 1 WP07264B 2842 80134510069 T221 P03074C SECOND STAGE TURBINE ROTOR EXHIBITS RIVET HOLE CRACKS 0.020 INCH TO 0.050 INCH DEEP. DEFECT DISCOVERED 200 HOURS AFTER HOT SECTION INSPECTION AT UNSCHEDULED ENGINE REMOVAL. 2L72 4T4 TRTA5SW E4WE 19970605007561997060500756NE 1997 6 5 CA970228007 219970219G7532310092205 HP BLEED VALVE BEECH 200 B200C 1152924CE PWA PT6 PT6A42 52043NE #1 ENGINE FAULTY W O OTHER O OTHER DEDESCENT 1 CA 303 PCE93184 (CAN) ON DESCENT THERE WERE TWO LOUD BANGS FROM #1 ENGINE AND A FLASH OF FLAME FROM THE ENGINE EXHAUST DUCT. AFTER FIVE SECONDS THIS EVENT REPEATED ITSELF. AN EMERGENCY WAS DECLARED AND AN UNEVENTFUL LANDING WAS CARRIED OUT. POST FLIGHT INVESTIGATION FOUND THE #1 ENGINE HIGH PRESSURE BLEED VALVE HAD FAILED. THE VALVE WAS REPLACED. 1L72 4T4 T A24CE E4EA 19970605007571997060500757EU 1997 6 5 CA970228008 119970222G3230C24589000 UPLOCK BOX AEROSPATR42 ATR42300 8680920EU PWA 120 PW120 NE HAMSTD14SF 14SF5 NE NOSE FROZEN W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 16640 N446 120940 900533 (CAN) AIRCRAFT RETURNED TO BLOCKS AFTER LANDING BECAUSE NOSE LANDING GEAR WOULD NOT LOCK IN UP POSITION. UPLOCK BOX FROZEN. HEAT APPLIED TO FREE. 2H72 4T4 TRTA53EU E20NE 6 CP7NE 19970605007581997060500758NE 1997 6 5 CA970304005 219970301G7200 ENGINE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE HP TURB MAKING METAL W AEO UNSCHED LANDING ENGINE SHUTDOWN OTHER XBOENGINE FLAMEOUT SMOKE/FUMES/ODORS/SPARKS OTHER CLCLIMB 1 CA 1960 71748 (CAN) DURING CLIMB AFTER TAKEOFF A LOUD BANG WAS HEARD FOLLOWED BY A FLAME OUT. THE ENGINE WAS SHUTDOWN AS PER PROCEDURES AND THE AIRCRAFT RETURNED TO BASE. POST FLIGHT INSPECTION FOUND FERROUS METAL LAYING IN THE TAILCONE. BOROSCOPE OF THE H.P. TURBINE REVEALED TIP CONTACT WITH SHROUD SEGMENTS WITH A LARGE QUANTITY OF ABRADED MATERIAL STILL REMAINING IN THE H.P./L.P. TURBINE AREA. THE MAIN OIL FILTER WAS CHECKED AND IT AND THE OIL WERE RETAINED FOR SOAP ANALYSIS.A LARGE QUANTITY OF METAL (FERROUS AND NON-FERROUS) CAN BE SEEN IN THE OIL ALONG WITH DISTINCT DISCOLORATION. NO IMPACT DAMAGE APPARENT TO THE ENGINE. 1L72 4F4 F A22CE E1NE 19970605007601997060500760EU 1997 6 5 CA970305003 119970220G2720NB452153 PEDAL BEAMS BNORM BNORM BN2 BN2A 1520204EU LYC O540 O540E4C5 41532EA RUD PEDAL CRACKED W K NONE O OTHER ININSP/MAINT 1 CA L1281340 (CAN) DURING INSPECTION PER PBN SB 56 AND 111, FOUND PILOTS LEFT AND RIGHT RUDDER PEDAL BEAM CRACKED. ALSO FOUND JO-BOLTS LOOSE ON THE STEERING LEVER. NOTE: NB/M/948 AND 428 HAD BOTH BEEN INSTALLED 2500 CYCLES PREVIOUSLY. 1H72 3O3 O A17EU E295 19970605007621997060500762EU 1997 6 5 CA970305005 219970224G7322CCU5151106A5 FUEL CONTRL UNIT BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU #1 ENGINE FAULTY W A A UNSCHED LANDING O OTHER CRCRUISE 1 CA 459 7344 (CAN) SHORTLY AFTER REACHING CRUISE ALTITUDE THE RPM ON #1 ENGINE REACHED 14,500 RPM. THE PROP SYNC. WAS TURNED OFF AND THE RPM RETURNED TO NORMAL CRUISE RPM. A SHORT WHILE LATER WITH PROP SYNC. ON THE RPM AGAIN INCREASED, A PRECAUTIONARY LANDING WAS CARRIED OUT. POST FLIGHT INSPECTION FOUND THE FCU FAULTY AND THE FCU WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 3T4 T A24EU A196 19970605007631997060500763NE 1997 6 5 CA970305007 219970223G7200 ENGINE BOEING720 720B 1383804NM PWA JT3D JT3D1 52039NE #3 ENGINE MAKING METAL W O OTHER J WARNING INDICATION CLCLIMB 1 CA 4855815384 633053 (CAN) DURING CLIMB THE #3 ENGINE OIL PRESSURE AND TEMPERATURE INCREASED SLIGHTLY ABOVE MAXIMUM. PREVIOUS POWER SETTING WERE RESTORED AND THE ENGINE PARAMETERS RETURNED TO NEAR NORMAL. POST FLIGHT INSPECTION FOUND METAL IN THE N2 GEARBOX OIL STRAINER AND ENGINE MAIN OIL FILTER. THE ENGINE WAS REPLACED. 2L74 4J4 F 4A28 1E8 19970605007651997060500765NE 1997 6 5 CA970306013 219970227G7260 PACKING PWA 120 PW120A NE #5 BEARING AREA BROKEN W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA 7234 121319 (CAN) THE ENGINE WAS REMOVED FROM SERVICE AFTER REPORTS OF SMOKE IN THE CABIN, ONE TIME SO SEVERE IT SET OFF THE SMOKE ALARM. DISASSEMBLY OF THE ENGINE FOUND THE #5 BEARING AREA PACKING HAD DETERIORATED AND BROKEN. THERE WAS A CONSIDERABLE AMOUNT OF OIL IN AREAS WHERE OIL IS NOT SUPPOSED TO EXIST. IT IS CONCLUDED THE PROBLEM HAS ARISEN FROM A COMBINATION OF SEAL CLEARANCE DETERIORATIONS UPSETTING THE BALANCE OF THE SECONDARY AIR SYSTEM AND THE BROKEN PACKINGS. 4 T E20NE 19970605007661997060500766EA 1997 6 5 CA970310001 219970225G7200 ENGINE PWA PT6 PT6A50 52043EA #4 POSITION FAILED W E ENGINE SHUTDOWN X ENGINE FLAMEOUT APAPPROACH 1 CA (CAN) ON DESCENT THE POWER LEVERS WERE CLOSED TO INCREASE DESCENT AND THE FIRST OFFICER NOTICED THE #4 ENGINE FUEL PRESSURE CAUTION LIGHT CAME ON. THE AUXILIARY FUEL PUMP WAS SELECTED ON. DURING FINAL TURN AT 1,500 FEET THE #4 ENGINE TORQUE WAS VERY LOW AND THE ENGINE FAILED. THE AIRCRAFT COMPLETED A SUCCESSFUL 3 ENGINE LANDING. THERE IS NO FURTHER REPORT. 4 T E4EA 19970605007671997060500767GL 1997 6 5 CA970310004 319970307G6111C34112 BEARING CESSNA180 180H 2072618CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C201 GL PROP BLADE WARPED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA 3229 824 275613R 716093 (CAN) THE C3411-2 BEARING RACE WAS INSTALLED DURING THE ASSEMBLY STAGE OF THE OVERHAUL AND DURING THE BEARING SEATING INSPECTION IT WAS FOUND THAT THE BEARING SEATING AREA WAS NOT CONTACTING THE PROPELLER HUB. THE BEARING WAS REMOVED AND CHECKED FOR FLATNESS ON A PRECISION GRANITE STONE AND AN AREA 2" LONG DID NOT CONTACT THE STONE. THE BEARING WAS REMOVED FROM SERVICE. 1H71 3O3 O 5A6 E273 5 CP3EA 19970605007681997060500768NE 1997 6 5 CA970310008 219970212G7260 BEVEL DRIVE GEAR PWA 120 PW120A NE ACCESSORY GEARBXFRACTURED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 CA 11567 120583 (CAN) #2 ENGINE HAD A UNCOMMANDED SHUTDOWN IN CRUISE. POST FLIGHT INSPECTION FOUND THE CAUSE OF THE FAILURE WAS A FRACTURE OF THE ANGLE BEVEL DRIVE GEAR. 4 T E20NE 19970605007691997060500769NE 1997 6 5 CA970310009 219970221G7260 STARTER DIRVE PWA PW121 PW121 52124NE ACCESSORY GEARBXBROKEN W E ENGINE SHUTDOWN RB PARTIAL RPM/PWR LOSS SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 124688 (CAN) DURING CRUISE THE #2 ENGINE WAS REPORTED TO HAVE A LOSS OF TORQUE. SUBSEQUENT ATTEMPTS TO REGAIN POWER RESULTED IN ENGINE GRINDING NOISE WITH SMOKE IN THE CABIN AND A LOSS OF OIL PRESSURE. THE ENGINE WAS SHUTDOWN. POST FLIGHT INSPECTION FOUND A BROKEN STARTER DRIVE GEAR. 4 T E20NE 19970605007701997060500770NE 1997 6 5 CA970310010 219970226G7313 FUEL NOZZLES PWA PW120 PW124B NE #1 ENGINE LEAKING W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 CA 9874 7832 124367 (CAN) ON AIRCRAFT ROTATION THE #1 ENGINE TORQUE FELL TO ZERO. THE PILOT SATISFACTORILY COMPLETED A SINGLE ENGINE GO AROUND. GROUND INSPECTION REVEALED A HEAVY FUEL LEAK FROM THE FUEL MANIFOLD DRAIN. THIS WAS THE FIRST FLIGHT AFTER A FUEL NOZZLE CHANGE. IT WAS REPORTED THAT A FUEL LEAK CHECK HAD BEEN CARRIED OUT AFTER THE FUEL NOZZLE CHANGE. 4 T E2ONE 19970605007721997060500772NE 1997 6 5 CA970312008 219970304G8530ST90P10ER CYLINDER DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE #5 CYLINDER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1263 204816 (CAN) DURING INSPECTION THE #5 CYLINDER WAS FOUND CRACKED FROM THE FRONT SPARK PLUG HOLE TO THE REAR SPARK PLUG HOLE, ACROSS THE TOP OF THE CYLINDER BETWEEN THE COOLING FINS. THE CYLINDER WAS REPLACED. 1H71 3R3 R A806 5E1 19970605007731997060500773NE 1997 6 5 CA970314003 219970308G73223028325 AIR LINE BELL 212 212 1181420SW PWA PT6T PT6T3B 52045NE P3 FILTER BROKEN W K NONE O OTHER ININSP/MAINT 1 CA PS62080 (CAN) #2 ENGINE WOULD NOT START IN AUTO MODE. P3 AIR LINE WAS FOUND BROKEN FROM THE P3 AIR FILTER HOUSING. NEW PART INSTALLED. 1G71 4U4 U H4SW E22EA 19970605007751997060500775NE 1997 6 5 CA970318005 219970303G7322 FUEL CONTRL UNITBENDIX PIPER PA42 PA42 7104202SO PWA PT6 PT6A42 52043NE ENGINE FAULTY W EA ENGINE SHUTDOWN UNSCHED LANDING YO ENGINE STOPPAGE OTHER CLCLIMB 1 CA 5871 2870 80882 (CAN) ENGINE TORQUE AND TEMPERATURE CONTINUED TO INCREASE AS THROTTLE WAS RETARDED. PILOT SELECTED THROTTLE TO OFF POSITION, TEMPERATURE STILL INCREASED. ENGINE WAS SHUTDOWN. POST FLIGHT INSPECTION FOUND FUEL CONTROL UNIT FAULTY. FCU WAS REPLACED. 1L72 4T4 T A23SO E4EA 19970605007761997060500776NE 1997 6 5 CA970319001 219970310G7320511749 TUBE ASSY BOEING737 7372A3 138448ANM PWA JT8 JT8D9A 52048NE PT 7 MANIFOLD BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 665233 (CAN) #2 ENGINE E.P.R. GAUGE WAS READING LOW. MAINTENANCE FOUND THE PT7 MANIFOLD LINE BROKEN. THE LINE WAS REPLACED AND THE ENGINE GROUND RUN SERVICEABLE. THE AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4F4 F A16WE E2EA 19970605007771997060500777NE 1997 6 5 CA970319003 219970303G72503040911D CT DISK BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3A NE DISK PLATFORM WORN W K NONE O OTHER ININSP/MAINT 1 CA 1835 PCE114295 HJ332 (CAN) DURING HSI THE CT DISK ASSEMBLY WAS FOUND RUBBING ON THE CT AIR SEAL. FURTHER INSPECTION FOUND THAT EIGHT BLADE ROOTS ON THE OPPOSITE SIDE OF THE DISK ALONG WITH THE DISK PLATFORM WERE GROOVED. THE DEPTHS OF THE GROOVES WERE TO AN UNACCEPTABLE LIMIT. THE CT DISK ASSEMBLY AND THE AIR SEAL WERE REPLACED. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 19970605007781997060500778SO 1997 6 5 CA970325001 219970304G8530653446A11 CYLINDER ASSY CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO MCAULY3AF32C3AF32C505 GL INTAKE PORT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1173 519163H 820491 (CAN) DURING INSPECTION FUEL STAINS WERE FOUND AT THE COOLING FIN AREA ON ONE OF THE CYLINDERS. THE CYLINDER WAS REMOVED. FURTHER INVESTIGATION REVEALED A CRACK STARTING ABOVE THE VALVE SEAT UP AND TOWARD THE INTAKE PORT. THE CYLINDER WAS REPLACED. 1L72 3O3 O A7CE E8CE 5 CP22EA 19970605007791997060500779SO 1997 6 5 CA970325002 219970313G8530653446A11 CYLINDER ASSY CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL INTAKE PORT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1200 290342R 950419 (CAN) DURING INSPECTION FUEL STAINS WERE FOUND ON ONE CYLINDER OF THE LH ENGINE AND ONE CYLINDER OF THE RH ENGINE IN THE AREA OF THE COOLING FINS. FURTHER INSPECTION FOUND THE CYLINDERS WERE CRACKED. MAINTENANCE HAVE CONCLUDED THE CYLINDERS ARE CRACKING AS A ARESULT OF SHOCK COOLING. IT WAS REPORTED THAT THE AIRCRAFT WAS OPERATED AT VERY LOW AMBIENT TEMPERATURES. THE CYLINDERS WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 3O3 O A7CE E8CE 5 CP22EA 19970605007801997060500780EA 1997 6 5 CA970325005 219970307G8520SL72877 TAPPET BODY LYC O540 LTIO540J2BD 41533EA CAM LOBES WORN W K NONE O OTHER ININSP/MAINT 1 CA 49 RL13968A (CAN) DURING INSPECTION FERROUS AND NON-FERROUS METAL WAS FOUND IN THE OIL FILTER. CAMSHAFT LOBES #2 EXHAUST AND #5 AND #6 INTAKE AND CORRESPONDING TAPPET BODIES STARTING TO FAIL FROM SPALLING. REAR SECTION OF FRONT MAIN BEARING OVERHEATED WITH SURFACE MATERIAL MELTED, ROLLING AND FLAKING OFF THE BACKING. THESE FAILURES ARE NORMALLY ASSOCIATED WITH LACK OF LUBRICATION. AVCO LYCOMING RECOMMENDS AN OIL ADDITIVE BE ADDED. 3 O E14EA 19970605007811997060500781EA 1997 6 5 CA970325006 219970217G8520SL13885 FRONT BEARING SUPAIRPART LYC O540 TIO540A2C 41532EA CRANKSHAFT OVERHEATED W K NONE O OTHER ININSP/MAINT 1 CA 49 L744561A (CAN) PROP HARD TO CONTROL IN FLIGHT. INSPECTION FOUND NON FERROUS METAL IN THE MAIN OIL FILTER AND THE FINGER SCREENS. THE REAR SECTION OF THE FRONT MAIN BEARING INSIDE DIAMETER OVERHEATED WITH SURFACE MATERIAL MELTING, ROLLING AND FLAKING OFF THE BEARING BACK. PROP GOVERNOR OIL PRESSURE IS TAKEN FROM THE FRONT MAIN OIL GALLEY, DIRECTING OIL THROUGH THE CENTRE SECTION OF THE FRONT MAIN BEARING THROUGH THE CRANKSHAFT AND TO THE PROPELLER. FULL FEATHERING CHECK OF THE PROP IS NOT RECOMMENDED ON THE GROUND ON A NEWLY OVERHAULED ENGINE, CONTINUING TO DO SO CAN CAUSE LOSS OF OIL TO THE REAR HALF FRONT MAIN BEARING. THIS TYPE OF FAILURE IS CONSISTANT WITH LACK OF LUBRICATION DURING COLD WEATHER & EXERCISING THE PROP 3 O E14EA 19970605007821997060500782EA 1997 6 5 CA970325007 219970220G8520SL72877 TAPPET BODY SUPAIRPART SL19340 LYC O540 TIO540J2BD 41532EA CAM EXH LOBE WORN W O OTHER O OTHER NRNOT REPORTED 1 CA 930 HO15 L664861A (CAN) PILOT REPORTED HIGH EGT ON DESCENT AFTER MAKING A POWER REDUCTION. INSPECTION FOUND THE CAMSHAFT #1 EXHAUST LOBE AND #1 TAPPET BODY HAD 1/3 OF THE FACE MATERIAL WORN OFF AND RESTRICTING THE EXHAUST VALVE FROM FULL MOVEMENT. THE MAIN OIL FILTER HAD METAL CONTAMINATION. THE ENGINE MANUFACTURER CLAIMS THE CAMSHAFT LOBE PITTED AND WORN DUE TO CONTACT BETWEEN THE LOBE AND A SPALLED OR CHIPPED LIFTER BODY. LOBE DISTRESS IS SECONDARY AND BEGINS AFTER LIFTERS BECOME SPALLED BECAUSE OF INSUFFICIENT LUBRICATION FROM EITHER COLD STARTS AND RUN UPS DURING COLD WEATHER OR FROM OVER DILUTION. AVCO LYCOMING RECOMMENDS THE USE OF AN OIL ADDITIVE P/N 16702 ANTI-SCUFFING AGENT TO REDUCE WEAR. S.I. 1409 REFERS. 3 O E14EA 19970612001401997061200140EA 1997 6 12 97ZZZX2652 219970520G8500 ENGINE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA POWER SECTION FAILED D O OTHER J WARNING INDICATION DEDESCENT 1 AL013582P7799 1391 318052103 L655361A DURING DESCENT TO LANDING, PILOT NOTICED MANIFOLD PRESSURE STARTING TO DECREASE, FUEL FLOW INCREASE AND CYLINDER HEAD TEMP DECREASE AND THE EXHAUST GAS TEMP DECREASE. AFTER LANDING AND ON THE GROUND, THE ENGINE WOULD ONLY PRODUCE 2,200 RPM AND 28 INCHES OF MANIFOLD PRESSURE. THE OIL SCREENS WERE CHECKED WITH AN EXCESIVE AMOUNT OF STEEL AND ALUMINUM SHAVINGS FOUND. THE ENGINE WAS REMOVED FROM SERVICE FOR A TEAR DOWN INSPECTION. 1L72 3O3 O A20SO E14EA 19970612001441997061200144SO 1997 6 12 97ZZZX2656 219970404G8530J92KBW CYLINDER CESSNA150 150M 2071830CE CONT O200 O200A 17020SO SLEEVE CRACKED B BUPRK NONE O OTHER ININSP/MAINT 1 EA2345511 653426 15076955 1994529A WHILE CHANGING PUSHROD SEALS, A CRACK WAS FOUND IN THE CYLINDER SLEEVE, THE CRACK IS ABOUT 1.5 INCHES LONG AND TRAVELED RADIALLY. THE CRACK IS ABOUT 2 INCHES UP FROM THE BASE FLANGE. 1H71 3O3 O 3A19 E252 19970612001471997061200147EA 1997 6 12 97ZZZX2659 219970514G8530SL15345 PUSHROD CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE CYLINDER FAILED B QX2RK NONE O OTHER ININSP/MAINT 1 EA11738QZ312 17270167 L577876T BALL END OF PUSHROD BROKEN OFF. SUBITTER STATED A POSSIBLE MANUFACTURE MACHINING DEFECT. 1H71 3O3 ONT3A12 E274 19970612001481997061200148SO 1997 6 12 97ZZZX2660 219970505G8530641916 CYLINDER CESSNA172 172B 2072406CE CONT O300 O300D 17022SO HEAD CRACKED H K NONE O OTHER ININSP/MAINT 1 EA138220X3518 705 17248720 24677010 DURING AN INSPECTION, CYLINDER WAS FOUND WITH LOW COMPRESSION/EXHAUST VALVE LEAKAGE. CYLINDER WAS REMOVED FOR REPAIR AND SENT TO ENGINE SHOP. AFTER CLEANING, NOTED THE HEAD WAS CRACKED FROM THE ROCKER COVER FLANGE THROUGH THE EXHAUST PORT AND ACROSS TO THE UPPER SPARKPLUG HOLE. CYLINDER WAS REPLACED WITH A NEW ASSEMBLY. 1H71 3O3 ONT3A12 E253 19970612001491997061200149SO 1997 6 12 97ZZZX2661 219970331G8530SA10200A20P CYLINDER CESSNA150 150M 2071830CE CONT O200 O200A 17020SO NR 3 FAILED B BUPRA UNSCHED LANDING R PARTIAL RPM/PWR LOSS DEDESCENT 1 EA238898U 145 15078019 264405A48 WHILE PERFORMING A POWER OFF STALL TO FULL POWER RECOVERY, PILOT FELT ENGINE BEGIN TO RUN ROUGH. WHILE RETURNING TO AIRPORT, IT STARTED TO GET WORSE. PILOT SUCCESSFULLY LANDED AIRCRAFT. UPON INSPECTION, FOUND NR 3 CYLINDER SPLIT IN HALF ABOUT 2 INCHES UP FROM BASE FLANGE. VISUAL INSPECTION OF BREAK SHOWED 90 PERCENT SMOOTH AND 10 PERCENT JAGGED EDGE. PISTON AND CONNECTING ROD WERE BOTH DESTROYED. 1H71 3O3 O 3A19 E252 19970612001501997061200150EA 1997 6 12 97ZZZX2662 219970526G7322RSA5AD1 SERVO PIPER PA24 PA24260 7102406SO LYC O540 IO540D4A5 41532EA FUEL INJ SEAL LEAK D O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SO16991K 6543 244055 L138248 ENGINE ROUGHNESS DUE TO EXCESS RIGH MIXTURE. FOUND RECENT OVERHAULED SERVO TO BE AT FAULT DUE TO SEAL LEAKING FUEL INTO AIR CHAMBER. SERVO TSO SERVICE 30 HOURS. SEAL, S/N 2539561. 1L71 3O3 O 1A15 1E4 19970612001701997061200170NE 1997 6 12 97ZZZX2681 219970520G7220F2MA581100801 INLET AMD FALC50FALCON2000 2730170NM CFE CFE73811B NE ENGINE BOLTS LOOSE B ACW1RK NONE O OTHER ININSP/MAINT 1 EA25790M 798 FA037LN40 P105134 P105134 AFTER ENGINE FAILURE, MORE THAN HALF THE BOLTS SECURING THE ENGINE INLET HA D UNSCREWED THEMSELVES. THE REMAINING WERE LOOSE. SUBMITTER SUSPECTS UNUSUAL ENGINE VIBRATION CAUSED THE BOLTS TO BACK OUT. THE INLET COULD POSSIBLY FALL OFF THE AIRCRAFT IN-FLIGHT. 2K73 4F4 FRTA50NM E44NE 19970612001711997061200171NE 1997 6 12 97ZZZX2682 219970520G7250 ENGINE AMD FALC50FALCON2000 2730170NM CFE CFE73811B NE TURBINE FAILED B ACW1RA UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 EA25790M 19 P105134 RIGHT ENGINE COMPLETELY FAILED AFTER TAKEOFF AT APPROXIMATELY 200 FEET AGL. AFTER A SUCCESSFUL LANDING, ENGINE WAS EXAMINED AND FOUND THE FAN SEIZED; THE TURBINE BADLY DAMAGED. NO EVIDENCE OF FOD WAS FOUND. AWAITING EVALUATION FROM THE MANUFACTURER TO DETERMINE CAUSE. 2K73 4F4 FRTA50NM E44NE 19970612007801997061200780EA 1997 6 12 97ZZZX2708 219970514G8530SL134441 PISTON PIN CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE CYLINDER FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 WP11739ZL 700 17270936 L473076 CATASTROPHIC FAILURE AFTER TAKEOFF FROM CLEAR LAKE, CA ON 5-14-97. PILOT TURNED BACK AND MADE UNPOWERED LANDING AT AIRPORT. FOUND CYLINDER BROKEN OFF ENGINE. PISTON BROKEN, CRANKSHAFT BROKEN. PISTON PIN BROKEN IN HALF. 1H71 3O3 ONT3A12 E274 19970612007811997061200781CE 1997 6 12 97ZZZX2709 119970522G324020701900 HOSE PARKERHANFIN199101 MTSBSIMU2 MU2B36A 5780413CE GARRTTTPE331TPE3315 01514WP BRAKE KIT WRONG PART B RG4RK NONE W INADEQUATE Q C ININSP/MAINT 1 SO03105WM109 709SA FOUND, CLEVELAND BRAKE KIT 199-101 STC SA648GL BRAKE HOSES U/A HOSE LISTED SAE DOAS SAE DOT 3000 PSI AIR BRAKE HOSE, FITTING CONNECTORS WERE 45 DEGREE ANGLE AND HOSE FITTINGS WERE 45 DEGREES. CONICAL SEAL WAS FOUND IN ONE HOSE FOR SEALINGS. 1H72 3T4 T A10SW E4WE 19970612007821997061200782CE 1997 6 12 97ZZZX2710 119970522G324020701900 HOSE PARKERHANFIN19901 MTSBSIMU2 MU2B60 5780460CE GARRTTTPE331TPE33110 01514WP BRAKE KIT WRONG PART B RG4RK NONE W INADEQUATE Q C ININSP/MAINT 1 SO03223JS770 1544SA FOUND CLEVELAND BRAKE KIT 199-101 STC 648GL BRAKE HOSES WERE SAE DOT 3000 PSI AIR BRAKE HOSES. FITTINGS WERE 45 DEGREES. 1H72 3T4 TRTA10SW E4WE 19970612007951997061200795NE 1997 6 12 97ZZZX2723 219970527G7230 COMPRESSOR SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1D NE ENGINE DAMAGE D O OTHER EC VIBRATION/BUFFET F.O.D. HOHOVERING 1 WP0791GT 3497 500 1289 4078 PICKED UP HIGH FREQUENCY VIBRATION WHILE HOVERING TO MAINTENANCE HANGAR. UPON INSPECTION, FOUND FOD DAMAGE TO COMPRESSOR. SUSPECTED CAUSE IS ROTOR WASH KICKED UP FOD. 1G71 3U3 UNCH9EU E19EU 19970612008271997061200827GL 1997 6 12 97ZZZX2753 219970506G732323057869 GOVERNOR BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ENGINE DEFECTIVE B AC2RK NONE O OTHER ININSP/MAINT 1 SW0350588 194 86220668 S780 NR 1 ENGINE WOULD NOT BEEP PAST 95 PERCENT N2. REPLACED GOVERNOR, CURED PROBLEM. 1G72 3U3 U H3EU E4CE 19970612008281997061200828GL 1997 6 12 97ZZZX2754 219970502G732323057869 GOVERNOR BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ENGINE DEFECTIVE B AC2RK NONE O OTHER ININSP/MAINT 1 SW035352Y 814 85590222 S781 18 PERCENT TORQUE SPLIT. REPLACED GOVERNOR CURED PROBLEM. 1G72 3U3 U H3EU E4CE 19970612008301997061200830GL 1997 6 12 97ZZZX2756 219970507G732323004836 GOVERNOR SKRSKYS76 S76 8143010NE ALLSN 250C 250C30 03013GL ENGINE MALFUNCTION B AC2RK NONE O OTHER ININSP/MAINT 1 SW035402T 1331 25705 760140 UNRESPONSIVE AT HIGH TORQUE RANGES. SHAFT RATCHETY AND STIFF. REPLACED GOVERNOR. 1G72 3U3 U H1NE E1GL 19970612008311997061200831NE 1997 6 12 97ZZZX2757 219970312G73202525013 AFCU 324473513 BELL 412 412 1182202SW PWA PT6T PT6T3B 52045NE DIAPHRAGM TORN B ALGRK NONE O OTHER ININSP/MAINT 1 SW032071S833 33046 DURING REPAIR OF AFCU, FOUND DIAPHRAGM TORN AND ABOUT TO RUPTURE. 1G72 4U4 U H4SW E22EA 19970612008481997061200848GL 1997 6 12 CA970325011 319970401G611190DCA2 BLADE CESSNA180 180J 2072622CE CONT O470 O470S 17026SO MCAULY2A34C 2A34C203 GL LEADING EDGE EROSION W K NONE O OTHER ININSP/MAINT 1 CA 952 462382 750693 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADE FOUND ERODED ON THE LEADING EDGE. 1H71 3O3 O 5A6 E273 5 CP3EA 19970612008631997061200863NE 1997 6 12 CA970407001 219970325G7250414129001 PT ROTOR SNIAS 350 AS350D 8680803EU LYC LTS101LTS101600A3 41560NE ROTOR WHEEL BLADES DISPLACEDW K NONE O OTHER ININSP/MAINT 1 CA 676 203 43085CE (CAN) DURING INSPECTION THE POWER TURBINE ROTOR WAS FOUND TO HAVE SOME OF THE TURBINE BLADES DISPLACED AXIALLY BEYOND LIMITS. ALL BLADES BEYOND LIMITS HAD MOVED AFT. THE ENGINE WAS REMOVED FROM SERVICE AND A ZERO TIME TSO ENGINE INSTALLED. 1G71 3U3 U H9EU E5NE 19970612008641997061200864EA 1997 6 12 CA970407004 219970326G852076097 CAMSHAFT LYC O320 O320E2D 41508EA LOBES SPALLED W K NONE O OTHER ININSP/MAINT 1 CA 1754 L1993027A (CAN) INSPECTION FOUND CAMSHAFT LOBES SPALLED AND TAPPET BODIES WERE PITTED. THE SPALLING ON THE LOBES WAS A RESULT OF CORROSION ON THE LOBES AND ON THE TAPPET BODIES. THE CORROSION WAS A RESULT OF LONG PERIODS OF ENGINE INACTIVITY AND NO EVIDENCE OF INHIBITING BEING CARRIED OUT. THIS ENGINE HAS BEEN IN SERVICE SINCE 1968 AND HAS ACCUMULATED 1745 HOURS. 3 O E274 19970612008651997061200865GL 1997 6 12 CA970407006 319970326G6111FL7666A2 BLADE CONAERLA4 LA4 5110302NE LYC O360 IO360A1B 41514EA HARTZLHCC2Y HCC2YK1 GL LEADING EDGE ERODED W K NONE O OTHER ININSP/MAINT 1 CA 495 281 L716951A CH14770 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADE LEADING EDGE ERODED/CORRODED. FILING AND DRESSING OUT REQUIRED. 1H71 3O3 O 1A13 1E10 5 CP920 19970612008661997061200866GL 1997 6 12 CA970407007 319970326G6114B24573 FORK CONAERLA4 LA4 5110302NE LYC O360 IO360A1B 41514EA HARTZLHCC2Y HCC2YK1 GL PROPELLER WORN OUT W K NONE O OTHER ININSP/MAINT 1 CA 495 281 L716951A CH14770 (CAN) INSPECTION FOUND PROPELLER FORK WORN. 1H71 3O3 O 1A13 1E10 5 CP920 19970612008671997061200867GL 1997 6 12 CA970407008 319970327G61143921 HUB PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360KB 17025SO MCAULY3AF32C3AF32C508 GL PROP THREADS FLATENEDW K NONE O OTHER ININSP/MAINT 1 CA 1009 315475 814635 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION AND HUB THREADS WERE FOUND FLATTENED, DUE TO REMOVING AND INSTALLING THE PROPELLER. 1L72 3O3 O A7SO E9CE 5 CP22EA 19970612008681997061200868GL 1997 6 12 CA970407009 319970327G611182NFA6 BLADE PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360KB 17025SO MCAULY3AF32C3AF32C508 GL LEADING EDGE ERODED W K NONE O OTHER ININSP/MAINT 1 CA 1009 315475 814635 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION AND THE BLADES WERE FOUND ERODED AND REQUIRED FILING. THE TIP ANGLES WERE OUT OF SPECIFICATIONS AND REQUIRED TWISTING. 1L72 3O3 O A7SO E9CE 5 CP22EA 19970612008761997061200876EA 1997 6 12 97ZZZX2775 219970303G73202525013 DIAPHRAGM BENDIX 32447218 BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA AFCU RUPTURED B ALGRK NONE O OTHER ININSP/MAINT 1 SW032FOR A20325 30932 61073 DURING DISASSEMBLY OF AFCU, FOUND DIAPHRAGM RUPTURED, P/N 2525013. 1G71 4U4 U H4SW E22EA 19970617000051997061700005GL 1997 6 17 CA970310005 319970306G6111 BLADE CESSNA150 150G 2071816CE CONT O200 O200A 17020SO MCAULY1A100 1A100MCM GL TIP STATION CORRODED W O OTHER OW OTHER INADEQUATE Q C ININSP/MAINT 1 CA 5319 2846 657636A E4829 (CAN) PROPELLER WAS SENT FOR 5 YEAR INSPECTION. CORROSION WAS FOUND PAINTED OVER. PROP HAD NOT BEEN INSPECTED SINCE 1970. 1H71 3O3 O 3A19 E252 5 NP918 19970619002031997061900203EA 1997 6 19 97ZZZX2781 219970522G7322MA4SPA CARBURETOR PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA THROTTLE BODY LOOSE D K NONE O OTHER ININSP/MAINT 1 EA03 900 THROTTLE BODY LOOSE AT PARTING SURFACE TO FUEL BOWL DUE TO LOOSENING OF LOCKING TABS ' NOT THE RETAINING BOLTS'. SUBMITTER RECOMMENDS SAFETY WIRE IN PLACE OF TABS. THIRD INCIDENT NOTED WITH LOCKING TABS. 1L71 3O3 O 2A13 E274 19970619002111997061900211SO 1997 6 19 97ZZZX2789 219970516G855012504221 ADAPTER CONT O520 IO520A 17032SO OIL FILTER THREADS BROKEN DS K NONE O OTHER ININSP/MAINT 1 SW01 775 1116706A CESSNA OIL FILTER TOWER INSPECTED IAW AD 96-12-22. FOUND ONE THREAD BROKEN AWAY .6250 INCH LONG. NO DAMAGE TO INTERNAL THREADS OF OIL PUMP HOUSING. 3 O E5CE 19970619002131997061900213EA 1997 6 19 97ZZZX2791 219970527G8530LW15322 CYLINDER PIPER PA44 PA44180 7104402SO LYC O360 O360E1A6 41514EA ROCKER ARM LOOSE STUD B R2JRO OTHER R PARTIAL RPM/PWR LOSS CRCRUISE 1 EA21142CK1269 447995252 RL20677T ENGINE LOST POWER DURING FLIGHT. SAFE LANDING C/W. MAINT FOUND NR 2 CYLINDER PUSH ROD BENT. FURTHER INSPECTION REVEALED ROCKER ARMS ON THAT CYLINDER VERY LOOSE, ALMOST FELL OFF WHEN ROCKER COVER REMOVED. ROCKER SHAFT STUDS FOUND BACKED OUT. THERE ARE NO SAFTIES TO PREVENT THIS FROM HAPPENING. DAMAGED CYLINDER HAD TO BE CHANGED. SUBMITTER SUGGESTS C/W FACTORY RECOMMENDED 400-HOUR VALVE TRAIN INSPECTION PROCEDURES. ALSO, SUGGESTS MANUFACTURER RE-DESIGN ROCKER ARM ATTACHMENT OR INSTALL SAFETY ON STUDS. 1L72 3O3 O A19S0 E286 19970619002191997061900219EA 1997 6 19 97ZZZX2798 219970530G74141051659 BUSHING S4LN1227 CESSNA177 177A 2073706CE LYC O360 O360A2F 41514EA ENG LT MAG WRONG PART DL K NONE O OTHER ININSP/MAINT 1 GL0730567 85020127 17701332 ROUGH ENGINE, LEFT MAG DEAD ON RUN-UP. REMOVED LEFT MAG AND FOUND SHOULDERED MAGNETO DRIVESHAFT BUSHING WITH SHOULDER MISSING. UPON EXAMINATION OF BUSHING, DETERMINED IT WAS THE OLD STYLE, SINTERED IRON PN 10-51659. IT SHOULD HAVE HAD A MACHINED STEEL BUSHING PN 10-163049 INSTALLED. REF: TCM SB 556C OR AD 74-26-09. 1H71 3O3 O A13CE E286 19970619002241997061900224EA 1997 6 19 97ZZZX2803 219970508G8530LW12427 CYLINDER PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA EXH PORT CRACKED D K NONE O OTHER ININSP/MAINT 1 CE014749L 298 284077 L1118436A DURING AN ANNUAL INSPECTION OF ENGINE, CRACKS WERE FOUND IN THE TWO REAR CYLINDERS IN EXHAUST PORTS. ONE HAD CRACKS IN THE INNER (TOWARD CENTER OF HEAD) AND AFT. OTHER IN INNER ONLY. BOTH WERE INSTALLED DEC, '91 AND HAD ACCUMULATED APPROXIMATELY 300 HOURS. 1L71 3O3 O 2A13 E286 19970619002251997061900225EA 1997 6 19 97ZZZX2804 219970507G7322 CARBURETOR PRECISION PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA BOWL CRACKED D K NONE WK INADEQUATE Q C FLUID LOSS ININSP/MAINT 1 CE014749L K105073 284077 L1118436A DURING ANNUAL INSPECTION, FUEL FOUND SEEPING FROM LOWER AREA OF CARBURETOR. FURTHER INVESTIGATION FOUND A BOLT USED TO MOUNT THE AIRBOX TO THE CARBURETOR WAS TOO LONG AND HAD BROKEN THE CARBURETOR BOWL. SUBMITTER STATED MAINTENANCE PERSONNEL SHOULD BE REMINDED TO CHECK, IN THIS CASE, BOLTS TO ASSURE THEY ARE THE CORRECT LENGTH/PART NUMBER. 1L71 3O3 O 2A13 E286 19970619002261997061900226SO 1997 6 19 97ZZZX2805 219970519G8540643259A ADAPTER CESSNA310 310N 2074234CE CONT O520 IO520E 17032SO STARTER BINDING D K NONE O OTHER ININSP/MAINT 1 EA05488SP 90 310N0029 215853R WHILE PERFORMING COMPRESSION TEST, DISCOVERED ENGINE WOULD LOCK-UP WHEN ROTATED BACKWARDS. TROUBLESHOOTING REVEALED STARTER ADAPTER WAS CAUSE OF PROBLEM. FURTHER INSPECTION OF ADAPTER SHOWED ACCUMULATION OF RUST AT STARTER MOUNTING PAD. THIS WAS SECOND NEWLY OVERHAULED ENGINE FOUND WITH THIS PROBLEM. ADAPTER WAS REPLACED WITH NO FURTHER PROBLEMS. 1L72 3O3 O 3A10 E5CE 19970619002291997061900229CE 1997 6 19 97ZZZX2808 119970602G7160 INLET TUBE CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA CARB HEAT BOX DETACHED D A K NONE O OTHER ININSP/MAINT 1 WP035550L 15284352 L2275715 FOUND THAT WARM AIR INLET TUBE ROLLER FLANGE ON LT SIDE OF CARBURETOR AIRBOX BECOMES WORN AND DISCONNECTED. THIS RENDERS CARBURETOR HEAT AIR SUPPLY INEFFECTIVE. SUBMITTER SUGGESTS ATTACHING TUBE WITH SPOT WELDS. 1H71 3O3 ONT3A19 E223 19970619002311997061900231EA 1997 6 19 97ZZZX2810 219970505G8500 ENGINE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA OIL SYSTEM MAKING METAL E K NONE O OTHER ININSP/MAINT 1 WP07600EE 715 317952158 L21468A DURING SCHEDULED INSPECTION, ENGINE OIL FILTER WAS CUT OPEN AND INSPECTED. FILTER WAS FOUND CONTAMINATED WITH METAL PARTICLES. INSPECTION OF PROPELLER AND ALL OTHER ENGINE ACCESSORIES WAS SATISFACTORY. ENGINE WAS REMOVED FROM SERVICE. 1L72 3O3 O A20SO E14EA 19970619002321997061900232EA 1997 6 19 97ZZZX2811 219970607G8500 ENGINE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA POWER SECTION FAILED E K NONE Y ENGINE STOPPAGE ININSP/MAINT 1 WP07600EE 317952158 L150268A DURING COMPLIANCE OF LYCOMING SI 1427B, 'GROUND TEST PROCEDURES', ENGINE STOPPED RUNNING DURING 3 TO 5 SECONDS OF 'FULL STATIC POWER CHECK'. ALL ENGINE OPERATING PARAMETERS WERE NORMAL BEFORE FAILURE. PROPELLER COULD NOT BE MOVED BY HAND AFTER FAILURE. PROPELLER AND ALL ACCESSORIES WERE REMOVED AND INSPECTED. NO DEFECTS IN ACCESSORIES OR PROP WERE FOUND. 1L72 3O3 O A20SO E14EA 19970619002371997061900237SO 1997 6 19 97ZZZX2816 219970517G8530646612 EXHAUST VALVE 653426A13 CESSNA140 140 2071602CE CONT C85 C8512 17008SO ENGINE LEAK D K NONE O OTHER ININSP/MAINT 1 CE017274240 9921 22960612 FORTY HOURS AFTER CYLINDER ASSY REPLACED, ALLL EXHAUST VALVES WERE LEAKING ON COMPRESSION CHECK ON ALL 4 CYLINDERS. 1H71 3O3 ONCA768 E233 19970619002411997061900241SO 1997 6 19 97ZZZX2820 219970524G8530639614 ROCKER ARM UNIVAR415 415G 0420310NM CONT O200 O200A 17020SO NR 2 CYL EXHAUSTFAILED GS K NONE W INADEQUATE Q C ININSP/MAINT 1 GL19944153600 1225 5050 2045979A NR 2 CYLINDER HAD INTAKE AND EXHAUST ROCKER ARM ASSEMBLIES SWITCHED. NR 2 EXHAUST VALVE MIGHT HAVE STUCK DUE TO NO LUBRICATION OR COOLING FROM THE DRILLED PASSAGEWAY BECAUSE THE EXHAUST ROCKER ARM WAS IN THE INTAKE VALVE POSITION. INTAKE ROCKER FAILED. 1L71 3O3 O A787 E252 19970619003811997061900381GL 1997 6 19 97ZZZX2824 219970429G732323057870 GOVERNOR BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ENGINE FAILED B AAC2RK NONE O OTHER ININSP/MAINT 1 SW035059C1031 BR32500 S779 GOVERNOR FAILED TO MAINTAIN N2 ROTOR SPEED. HAVING ALOT OF PROBLEMS WITH THESE GOVERNORS FAILING AT ABOUT THIS TIME. THE COUPLINGS ON THESE GOVERNORS DO NOT HOLD UP. REPLACED GOVERNOR WITH SERVICEABLE ITEM. 1G72 3U3 U H3EU E4CE 19970619004601997061900460SO 1997 6 19 97031300233 219970219G8550CH48109 FILTER CHAMPION AMTR STRDSTSTARDUSTR300 GL CONT E225 E225* 17015SO ENGINE OIL BURST H K NONE OK OTHER FLUID LOSS ININSP/MAINT 1 WP277989 476 2582D OIL FILTER BURST AT START-UP. GASKET FORCED FROM GROOVE. ENGINE LOST ALL OIL. FILTER 'DOMED OUT' AT BOTH ENDS. ALL OIL PASSAGEWAYS IN ENGINE AND OIL COOLER OK. PRESSURE RELIEF VALVE IN ENGINE OK. SUSPECT FILTER BYPASS. 1Q71 3O3 O EXPA1Q71E267 19970619004651997061900465GL 1997 6 19 97ZZZX2837 219970508G73206893073 AIR LINE SKRSKYS76 S76A 8143006NE ALLSN 250C 250C30S 03013GL GOV PC TO FCU BROKEN B AZV1REA ENGINE SHUTDOWN UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 SW03202SR 760236 CAE890251S IN CRUISE FLIGHT, NR 2 ENGINE SPOOLED DOWN TO 30 PERCENT AND THEN DOWN TO 10 PERCENT. ENGINE WAS SECURED AND AIRCRAFT WAS FLOWN TO AIRPORT FOR LANDING. FOUND PC AIR LINE, PN 6893073, BROKEN AT FERRULE ON FUEL CONTROL. THIS LINE COMES FROM GOVERNOR TO FUEL CONTROL. REPLACED LINE. OPS CHECK AND FLIGHT OK. RAN VIB CHECK ON ENGINE. FOUND 1.25 IPS. REPLACED ENGINE ASSY DUE TO HIGH VIB LEVEL. RECOMMEND VIB CHECK AT LEAST EVERY 300 HOURS. 1G72 3U3 U H1NE E1GL 19970619004661997061900466EA 1997 6 19 97ZZZX2838 219970407G8530AEL12949 INTAKE VALVE HILLERUH12 UH12E 4360122WP LYC O540 VO540C2A 41532EA STEM AND FACE WORN D K NONE O OTHER ININSP/MAINT 1 NM0936MV 160 75137CN 5060 L256043 THE VALVE STEM UNDER THE KEEPER'S WAS HEAVILY WORN. THIS CONDITION WAS ALSO FOUND ON 4 OTHER VALVES (INTAKE) ALL HAVING THE SAME TOTAL TIME AND PART NUMBER. THE 6TH VALVE WAS A LYCOMING WITH THE SAME TIME AND INSTALLATION DATE. NO PROBLEM FOUND. 1G71 3O3 O 4H11 E304 19970619004731997061900473NE 1997 6 19 97ZZZX2845 219970602G8500 ENGINE BEECH 18 H18 1151012CE PWA R985 R985AN14B 52008NE LT ENGINE MAKING METAL G E ENGINE SHUTDOWN K FLUID LOSS CRCRUISE 1 SW11117ME 1266 BA638 P225009 WHILE IN CRUISE FLIGHT, PILOT NOTICED OIL LEAK ON LEFT ENGINE. ENGINE WAS SECURED, PROPELLER FEATHERED, AND AN UNEVENTFUL LANDING MADE. MAINTENANCE FOUND PROPELLER TO BE LEAKING, BUT THE ENGINE OIL SCREEN WAS FULL OF METAL. SUSPECT INTERNAL FAILURE. ENGINE TO BE REMOVED AND REPLACED. 1L72 3R3 R A765 5E1 19970619004781997061900478CE 1997 6 19 97ZZZX2850 119970528G81204066109005 TURBOCHARGER GARRTT CESSNA210 T210G 2073432CE CONT O520 TSIO520C 17040SO EXH HOUSING CRACKED D K NONE O OTHER ININSP/MAINT 1 NM016843R FDR0152 T2100243 1408179C TURBOCHARGER EXHAUST HOUSING CRACKED AROUND AUXILIARY MOUNTING LUG. 1H71 3O3 O 3A21 E8CE 19970619004821997061900482EA 1997 6 19 97ZZZX2854 219970412G853075068 VALVE GULSTMAA5 AA5B 3960105SO LYC O360 O360A4K 41514EA NR 1 CYL EXHAUSTFAILED GS O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TOTAKEOFF 1 NM0338X 2011 AA5B0889 L2699236A VALVE MALFUNCTION OCCURRED DURING TAKEOFF AT APPROXIMATELY 2,450 RPM. (AIRPORT AT 5,100 FEET). OAT 20 DEGREES FAHRENHEIT. 1L71 3O3 O A16EA E286 19970619005001997061900500 1997 6 19 CA970122002 419970117G25620025004 BATTERY DAYTON EB2BCD BOEING75 B75N1 1380144CE LYC R680 R680B4E 41540EA ELT CASE LEAKING W K NONE O OTHER ININSP/MAINT 1 CA 39254 13378 (CAN) AFTER TWO YEARS ARTEX BATTERY LEAKED AND CORRODED CHASSIS AND INSIDE OF CASE. 1Q71 3R3 R A743 TC108 19970619005101997061900510 1997 6 19 CA970203007 419970123G3416265411 COUNTER BOEING727 727171C 1384057NM PWA JT8 JT8D7A 52053NE ALTIMETER STICKING W K NONE O OTHER ININSP/MAINT 1 CA P653620B (CAN) DURING BI-ANNUAL CALIBRATION IT WAS IDENTIFIED THAT THE COUNTER IN THE ALTIMETER WAS CAUSING THE INSTRUMENT TO STICK AT VARIOUS ALTITUDES. REPLACED. 2L73 4F4 F A3WE E2EA 19970624000011997062400001EA 1997 6 24 97ZZZX2797 219970528G8520 CRANKCASE PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ALT MT LUG BROKEN D A O OTHER K FLUID LOSS CRCRUISE 1 CE072885D1969 287990520 L2678036A RIGHT CRANKCASE LOWER FRONT ALTLERNATOR SUPPORT MOUNT LUG BROKE OUT OF CRANKCASE AND LEFT A HOLE 1.50 INCHES IN DIAMETER. CAUSE UNKNOWN. CREATED OIL LEAK WITH OIL ON WINDSHIELD DURING FLIGHT. REMOVED ENGINE AND INSTALLED LYCOMING REBUILT. 1L71 3O3 O 2A13 E286 19970626000081997062600008CE 1997 6 26 CA970221004 119970218G2913542088030008 PRESSURE SWITCH CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO GEAR MOTOR INTERMITTENT W L ABORTED APPROACH GP MULTIPLE FAILURE NO WARNING INDICATION LDLANDING 1 CA 291550R (CAN) PILOT UNABLE TO GET INDICATION OF GEAR DOWN AND LOCKED. FLEW BY TOWER AND THEN LANDED SAFELY. GEAR MOTOR FOUND UNSERVICEABLE BUT WORKED IN THE SHOP AFTER REMOVAL. REPLACED THE PRESSURE SWITCH AND INSTALLED A DIODE AS PER SERVICE LETTER, IN ORDER TO EXTEND THE SWITCH LIFE. 1H71 3O3 O A4CE E8CE 19970626002751997062600275SO 1997 6 26 97ZZZX2871 219970528G74141052948 BEARING S6RSC25 CONT O360 LTSIO360EB 17025SO DRIVE END LOOSE H K NONE K FLUID LOSS ININSP/MAINT 1 GL21 361 D099634DR 807336R DRIVE END BEARING INNER RACE BECAME LOOSE ON SHAFT CAUSING OIL TO LEAK THOUGH SEAL. MAG HAD AN EXTREME AMOUNT OF OIL INTERNALLY AND STILL RAN NORMALLY. 3 O E9CE 19970626002791997062600279EA 1997 6 26 97ZZZX2874 219970605G7314RG9080J4A FUEL PUMP ROMEC PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA VALVE BODY LEAKING D K NONE K FLUID LOSS ININSP/MAINT 1 AL01300ED 510 317852008 RL267268A UPON PULLING AIRCRAFT IN HANGAR FOR A SCHEDULED INSPECTION, FOUND THE ENGINE DRIVEN FUEL PUMP LEAKING FUEL FROM THE VALVE BODY PARTING FLANGES. PUMP WAS REMOVED FROM SERVICE. SUSPECT CAUSE, THE PARTING HALF FLANGE SCREWS FOR THE VALVE BODY MAY BE IMPROPERLY TORQUED. GASKET MAY BE PINCHED. THIS HAS BEEN A PROBLEM WITH OTHER PUMPS IN THE PAST. 1L72 3O3 O A20SO E14EA 19970626002821997062600282SO 1997 6 26 97ZZZX2877 219970602G7322P16160 FULCRUM PIN BENDIX NAS3A1 CESSNA140 140 2071602CE CONT C85 C8512 17008SO CARBURETOR FLOATSPALLED D A UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 CE0576122 10519 24177612 ENGINE QUIT ON TAKEOFF JUST AFTER ROTATION RESULTING IN DAMAGE TO THE AIRCRAFT. ENGINE WAS CHECKED FOR FUEL, COMPRESSION, AND IGNITION. ENGINE WAS STARTED AND RUN-UP. OPERATION APPEARED TO BE NORMAL. DISASSEMBLED CARBURETOR AND BENCH CHECKED. FLOAT LEVEL WAS WITHIN SPECS. ALL PASSAGES CLEAN AND OPEN. DID FIND THE FLOAT FULCRUM PIN SPALLED. EXPERIENCE HAS SHOWN ANY WEAR ON THIS PIN CAN CAUSE THIS TYPE OF PROBLEM. BECAUSE OF THE VERY LIMITED MOVEMENT OF THE FLOAT LEVEL, IT IS HARD TO SAY WHAT THE FIX SHOULD BE. PERHAPS IT NEEDS SOME ENGINEERING STUDY. NTSB ACCIDENT NR CHI-97LA143. 1H71 3O3 ONCA768 E233 19970626002901997062600290EA 1997 6 26 97ZZZX2885 219970613G8550LW13901 SUMP SLNSBYT67 T67M260 8323006EU LYC O540 AEIO540D4A5 41532EA ENGINE OIL CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 SW173188R538 2205 L2551348A AFTER A PHASE INSPECTION AND AFTER ENGINE RUN-UP, THE ENGINE WAS CHECKED FOR OIL LEAKS BEFORE COWLING INSTALLED. A LEAK WAS NOTED BEHIND THE RIGHT REAR ENGINE MOUNT BRACKET. A CLOSER LOOK WAS MADE AND A CRACK WAS FOUND (ABOUT 2.50 INCHES LONG). OIL SUMP WAS REMOVED AND REPLACED WITH A SERVICEABLE PART. CAUSE UNKNOWN. 1L71 3O3 ONTA73EU 1E4 19970626002911997062600291EA 1997 6 26 97ZZZX2886 219970529G8520LW13831 CRANKCASE PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA LT CASE HALF CRACKED D K NONE O OTHER ININSP/MAINT 1 GL2746SD 1656 278054040 RL1583748A FOUND A CRACK IN THE LEFT CASE HALF BETWEEN NR 4 AND NR 6 CYLINDERS. 1L72 3O3 O 1A10 1E4 19970626002931997062600293EA 1997 6 26 97ZZZX2888 219970606G7310 HOSE PIPER PA24 PA24250 7102404SO LYC O540 O540A1A5 41532EA ENGINE FUEL DETERIORATED D K NONE O OTHER ININSP/MAINT 1 EA036159P5170 24412 HOSES HAVE NO IDENTIFICATION MARKINGS BECAUSE THEY ARE SO OLD. SEVERELY CHAFED, HARDENED WITH FOSSILIZED EMBRITTLEMENT. OUTER COVERING ON ONE HOSE HAS DISSENTEGRATED TO THE INNER CORE. SUBMITTER RECOMMENDED THAT ALL GENERAL AVIATION FLEXIBLE HOSES LOCATED IN THE ENGINE COMPARMENT HAVE A MANDATORY LIFE LIMIT ESTABLISHED BY AN AIRWORTHINESS DIRECTIVE. 1L71 3O3 O 1A15 E295 19970626002941997062600294EA 1997 6 26 97ZZZX2889 219970605G853074925 CYLINDER PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA NR 2 FAILED D O OTHER ERKVIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NRNOT REPORTED 1 GL156881Y 274230 L99348 PILOT NOTICED LEFT ENGINE COWLING BECOMING COVERED WITH OIL. ENGINE WAS UNCOWLED FOR INVESTIGATION AND FOUND NR 2 CYLINDER HEAD CRACKED COMPLETELY OFF THE CYLINDER BARREL. THE ONLY THING HOLDING THE CYLINDER HEAD IN PLACE WAS THE EXHAUST, INDUCTION TUBE, AND ENGINE BAFFLING. TOTAL TIME ON CYLINDER UNKNOWN. TIME ON CYLINDER SMOH, 1,905 HOURS. CAUSE UNKNOWN. 1L72 3O3 O 1A10 1E4 19970626003601997062600360EU 1997 6 26 97ZZZX2893 219970509G73211310526 SOLENOID WOODWARD 8063215 CFMINTCFM56 CFM563C 13802EU FUEL CONTROL MALFUNCTION BL UU2RK NONE O OTHER ININSP/MAINT 1 GL03 94318 WOODWARD RECENTLY BECAME AWARE OF A POTENTIAL NON-CONFORMANCE OF THE CFM56-3 IDLE RESET SOLENOID. THE NON-CONFORMANCE IS DIRECTLY RELATED TO A SPECIFICATION CHANGE FOR THE SOLENOID. SPECIFICALLY, THE SPEC WAS ALTERED TO REQUIRE DROP-OUT AT EXTREME RATHER THAN NORMAL PRESSURIZATION CONDITIONS. THE PRESSURIZATION CHARACTERISTICS AFFECT BOTH PULL-IN AND DROP-OUT OF THE SOLENOID, SO THE SUPPLIER ALTERED THE CALIBRATION OF THE UNIT ACCORDINGLY. AS A RESULT OF THE ALTERED CALIBRATION, IT HAS BEEN DETERMINED THAT IN SOME CASES THE SOLENOID WILL NOT DROP OUT WITH NORMAL PRESSURIZATION. 4 F E21EU 19970626003671997062600367EA 1997 6 26 97ZZZX2899 219970517G8530 SEAL PIPER PA31 PA31310 7103103SO LYC O540 TIO540A2C 41532EA NR 3 CYL PUSHRODLEAK D A UNSCHED LANDING K FLUID LOSS CLCLIMB 1 GL13666AW 317312061 L415661A AFTER TAKEOFF DURING CLIMB-OUT, PILOT NOTICED FINE SPRAY OF OIL MIST FROM RT ENGINE OUTBOARD SIDE AND TRACE OF OIL LEAK BEGIN TO FORM. PILOT MADE AN UNEVENTFUL LANDING AND ENGINEERING INVESTIGATION WAS CARRIED OUT. NR 3 CYLINDER EXHAUST PUSHROD LOCKING CLIP HAD UNLOCKED ALLOWING SEAL TO LEAK OIL DUE TO A LOOSE SHROUD TUBE. SUBMITTER RECOMMENDATION: TO WIRE LOCK WITH SAFETY WIRE IN PAIRS THE LOCKING CLIPS OF THE INDIVIDUAL SHROUD TUBES FOR EVERY CYLINDER. 1L71 3O3 ORTA20SO E14EA 19970626003681997062600368EA 1997 6 26 97ZZZX2900 219970425G732214190 THROTTLE VALVE MA4SPA CESSNA172 172K 2072430CE LYC O320 O320E2D 41508EA CARBURETOR OUT OF ADJUST DL K NONE W INADEQUATE Q C ININSP/MAINT 1 NM0378512 CK815294 17257646 L4478727A OVERHAULED CARBURETOR FURNISHED WITH LYCOMING OVERHAULED ENGINE WOULD NOT IDLE BELOW 1,000 RPM AFTER BUILD-UP AND INSTALLATION. CARUBURETOR WAS NEWLY OVERHAULED. REMOVAL AND INSPECTION REVEALED THE THROTTLE PLATE WAS NOT ALIGNED CORRECTLY AND WAS BINDING ON THROAT OF CARBURETOR WHEN CLOSED AND WOULD NOT HIT IDLE STOP WITH SCREW FULLY BACKED OUT. 1H71 3O3 ONT3A12 E274 19970626003721997062600372GL 1997 6 26 97ZZZX2904 219970602G72106894171 GEARBOX BELL 206 206B3 1181506SW ALLSN 250C 250C20B 03013GL ENGINE CRACKED H K NONE O OTHER ININSP/MAINT 1 GL03169177850 834952 2303 834952 FOUND ENGINE GEARBOX CRACKED AT TOP MOUNTING LOCATION FOR COMPRESSOR. NO ABNORMAL VIBRATIONS OR CIRCUMSTANCES LED TO FINDING CRACK. 1G71 3U3 U H2SW E4CE 19970626003731997062600373SO 1997 6 26 97ZZZX2905 119970608G73333006614 CLAMP PIPER PA42 PA42 7104202SO PWA PT6 PT6A41 52043EA FUEL FLOW XMIT MISSING H K NONE K FLUID LOSS ININSP/MAINT 1 GL25242RA 428001003 PCE80883 FUEL FLOW TRANSMITTER IS MOUNTED TO ENGINE WITH 2 STAINLESS LINES PN 3032010 AND PN 3026779 B1; AND, IF SUPPORT CLAMP PN 30006614 IS NOT INSTALLED, LINES WILL CRACK AT WELDS CREATING A HEAVY FUEL LEAKING ENGINE COMPARTMENT AND ONTO WING. 1L72 4T4 T A23SO E4EA 19970626007241997062600724EA 1997 6 26 97ZZZX2917 219970616G732212856 LEVER MA45 PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA THROTTLE SEPARATED G A UNSCHED LANDING R PARTIAL RPM/PWR LOSS APAPPROACH 1 GL255955V53 G519232 287790516 L2727336A WHILE ON APPROACH TO CAK, PILOT LOST THROTTLE CONTROL, AND , SUBSEQUENTLY, LANDED IN AN OPEN FARM FIELD. INVESTIGATION REVEALED THAT THE THROTTLE CONTROL LEVER WAS LOOSE EVEN THOUGH THE CASTLE NUT AND COTTER PIN WERE FAIRLY TIGHT AND INTACT. SUSPECT IMPROPER INSTALLATION PROCEDURE AND IMPROPER TORQUE OF NUT SECURING ARM. 1L71 3O3 O 2A13 E286 19970626007281997062600728EA 1997 6 26 97ZZZX2921 219970524G8530LYC16T19468 VALVE SEAT 05K21108CKP PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA RT ENG EXHAUST LOOSE E D RETURN TO BLOCK ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 AL03493SC1585 317652048 L184368A DURING TAXI FOR TAKEOFF, PILOT REPORTED ENGINE RUNNING ROUGH. RIGHT ENGINE MANIFOLD PRESSURE HIGHER THAN NORMAL. COMPRESSION CHECK FOUND NR 1 CYLINDER LOW, 10/80. DISASSEMBLY OF CYLINDER FOUND LOOSE EXHAUST VALVE SEAT. 1L72 3O3 O A20SO E14EA 19970626007331997062600733SW 1997 6 26 97ZZZX2926 119970520G2434ALU8421 ALTERNATOR MOONEYM20 M20J 5870219SW CONT O360 IO360A 17025SO HOUSING CRACKED D A K NONE O OTHER ININSP/MAINT 1 SO15658FT 190 5081285 243270 L1170451A FOUND ALTERNATOR HOUSING CRACKED AT THE FRONT MOUNTING ARM. AFTER INSPECTING LIKE AIRCRAFT, FOUND A SECOND ALTERNATOR CRACKED IN THE SAME LOCATION. THE SUSPECT CAUSE FOR THE CRACK IS INCORRECT SHIMMING OF THE ALTERNATOR TO THE MOUNT. SUBMITTER STATED CLOSE ATTENTION NEEDS TO BE GIVEN TO THE CORRECT SHIMMING OF THE ALTERNATOR WHEN IT IS INSTALLED. 1L71 3O3 O 2A3 E1CE 19970626007371997062600737SO 1997 6 26 97ZZZX2930 219970608G8530 CYLINDER CESSNA188 A188B 2073005CE CONT O520 IO520D 17032SO NR 5 AND NR 2 DEFECTIVE DL K NONE O OTHER ININSP/MAINT 1 SW174915R 1250 18802432T FOLLOWING TOP OVERHAUL, NOTED A KNOCK FROM CYLINDERS 5 AND 2. FOUND NEW PISTONS WERE HITTING ON THE CYLINDER HEADS. FOUND THE CYLINDER HEAD TO BARREL DISTANCE IS SMALLER THAN OTHER CYLINDERS. 1L71 3O3 O A9CE E5CE 19970703001381997070300138EA 1997 7 3 97ZZZX2941 219970428G8530 VALVE MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA NR2 CYL EXH DEFORMED B BJFRK NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 EA234182H 240656 L1938951A AT 308 HRS SMOH, ANNUAL INSPECTION REVEALED NR 2 CYLINDER HAD NO COMPRESSION. CYLINDERS WERE ECI CERMINIL CYLINDERS. UPON REMOVAL, FOUND EXHAUST VALVE AND SEAT DEFORMED. NEW CYLINDER INSTALLED ALL OPS CHECK GOOD. 314 HRS SMOH, PILOT REPORTS AIRCRAFT SEEMS TO BE LOSING POWER. COMPRESSION TEST REVEALED NR 3 CYLINDER COMPRESSON FAILING. REMOVED NR 3 CYLINDER AND FOUND DAMAGE SIMILAR TO NR 2. REMOVED NR 4 CYLINDER AND FOUND IRREGULAR WEAR MARKS. LOG BOOK RESEARCH REVEALED NR 1 CYLINDER REMOVED AT 208 HRS DUE TO EXHAUST VALVE FAILURE. 1L71 3O3 O 2A3 1E10 19970703001401997070300140EU 1997 7 3 97ZZZX2943 219970601G8520 ENGINE AMTR KITFOXKITFOX 05613LZGL ROTAX 582 ROTAX582 55555EU REAR CYLINDER SEIZED G A UNSCHED LANDING Y ENGINE STOPPAGE NRNOT REPORTED 1 NM03950AW 950 3971294 ENGINE SEIZED AFTER 2 HOURS OF FLIGHT OPERATION ON INITIAL FLIGHT. ENGINE WAS STORED FOR 4 YEARS AND UNCRATED FOR 2 YEARS. ENIGNE SHOWED SIGNS OF CORROSION ON OUTPUT SHAFT OF GEARBOX. MANUFACTURER OF THE KIT SUPPLIED NO INFORMATION FOR LONG TERM STORAGE OF THE ENGINE. THE REAR CYLINDER ROD LOST LUBRICATION, MADE METAL, AND SEIZED THE ENGINE. LOWER ROD BEARING COMPLETELY GONE AND ROD WAS HEAT DISCOLORED. SUBMITTER SUGGESTED KIT MANUFACTURER BE REQUIRED TO SUPPLY ENGINE STORAGE AND PREPARATION INFORMATION. 1H71 3I3 INCEXPA1H71EXPE3I 19970703002731997070300273 1997 7 3 CA970325017 419970307G2562006062 BATTERY PACK DORNEMARGLN DMELT61 PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA ELT LEAKING W K NONE O OTHER ININSP/MAINT 1 CA 53639 L758039A (CAN) ELT BEING CHECKED FOR RECERTIFICATION. BATTERY PACK WAS 2 YEARS OVERDUE AND WAS VERY BADLY LEAKING. BOTTOM OF BATTERY CASE WAS COMPLETELY CORRODED, THE SIDEWALL HAD A HOLE ABOUT 1 INCH IN DIAMETER. 1L71 3O3 O 2A13 E274 19970703002901997070300290NM 1997 7 3 CA970402004 119970324G7603 STOP MECHANISM DHAV 87610018003 DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE LT PWR LEVER MISALIGNED W E ENGINE SHUTDOWN O OTHER TXTAXI/GRND HDL 1 CA 21897 0 (CAN) DURING ENGINE RUN ON GROUND, THE PILOT BRISKLY BROUGHT BACK THE LEFT POWER LEVER. THE LEVER PASSED THROUGH FLIGHT IDLE GATE STOP AND CONTINUED INTO THE BETA RANGE. AIRCRAFT MANUFACTURER INVESTIGATE AND FOUND THE MISALIGNMENT WITH POWER LEVER STOP WHICH WAS THERE SINCE MANUFACTURE. A NEW UNIT INSTALLED P/N 87610018-007. 2H72 4T4 TRTA13NM E20NE 19970703002921997070300292GL 1997 7 3 CA970407013 319970327G6111L82NFA6 BLADE PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360KB 17025SO MCAULY3AF32C3AF32C509 GL LEADING EDGE ERODED W K NONE O OTHER ININSP/MAINT 1 CA 1009 315475 814786 (CAN) INSPECTION FOUND PROPELLER LEADING EDGE ERODED/CORRODED, WHICH REQUIRED FILING. THE BLADE TIP ANGLES WERE OUT OF SPECIFICATIONS AND REQUIRED TWISTING. 1L72 3O3 O A7SO E9CE 5 CP22EA 19970703003011997070300301EA 1997 7 3 CA970408008 119970331G523075230413001 FITTING ASSEMBLYDHAV DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA FWD PIN MECH CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 26190 0 (CAN) CRACKED BAGGAGE DOOR FITTING AT LOWER FORWARD PIN. FOUR AIRCRAFT FOUND WITH SAME PROBLEM. 2H74 4T4 T A20EA E4EA 19970703003031997070300303EA 1997 7 3 CA970421065 119970331G523075230413001 FITTING ASSEMBLYDHAV DHAV DHC7 DHC7* EA PWA PT6 PT6A50 52043EA FWD PIN MECH CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 26115 0 (CAN) CRACKED BAGGAGE DOOR FITTING AT LOWER FORWARD PIN. FOUR AIRCRAFT FOUND WITH SAME PROBLEM. 2H74 4T4 TRTA20EA E4EA 19970703003041997070300304EA 1997 7 3 CA970421066 119970331G523075230413001 FITTING ASSEMBLYDHAV DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA FWD PIN MECH CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 33157 0 (CAN) CRACKED BAGGAGE DOOR FITTING AT LOWER FORWARD PIN. FOUR AIRCRAFT FOUND WITH SAME PROBLEM. 2H74 4T4 T A20EA E4EA 19970710002521997071000252SO 1997 7 10 97ZZZX3017 219970624G74141051324 SPRING CESSNA337 337G 2075730CE CONT O360 IO360G 17025SO MAG IMPULSE BROKEN D K NONE O OTHER ININSP/MAINT 1 SW07 CUSTOMER COMPLAINED THAT UPON PERFORMING REAR ENGINE MAGNETO CHECK, ONE MAGNETO PRODUCED NO DROP, THE OTHER MAGNETO WOULD CAUSE ENGINE DECELERATE TO THE POINT OF STOPPING. MAGNETO'S WERE REMOVED AND INSPECTED. FOUND IMPULSE COUPLING SPRING BROKEN. THIS IS THE THIRD SUCH SPRING FOUND BROKEN IN ONE MONTH. 1H72 3O3 O A6CE E1CE 19970710002561997071000256EA 1997 7 10 97ZZZX3022 219970624G732230800 FLOAT HA6 CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA CARBURETOR DEFECTIVE D A K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ININSP/MAINT 1 WP076303V19 DL0198 172RG0615 PILOTS REPORT EXCESS MAGNETO DROPS OF GREATER THAN 300 RPM'S AND SEVERE ENGINE ROUGHNESS. THE FLOAT IN THE CARBURETOR WAS REMOVED AND FOUND THAT THE REAR-MOST CHAMBER WAS FILLED WITH FUEL. FLOAT IS A PLASTIC DESIGN WITH 3 VISABLE CHAMBERS. THE CHAMBER THAT WAS FULL OF FUEL WAS THE ONE CLOSEST TO THE NEEDLE VALVE. UPON INSTALLING A SERVICEABLE FLOAT, ENGINE OPERATED NORMALLY. 1H71 3O3 O 3A17 E286 19970710002591997071000259SO 1997 7 10 97ZZZX3025 219970407G8520 CRANKSHAFT PIPER PA34 PA34220T 7103420SO CONT O360 LTSIO360KB 17025SO NR 1 ROD CHEEK BROKE B MW2RK NONE O OTHER NRNOT REPORTED 1 GL1783878 348133097 233941H CRANKSHAFT BROKE AT NR 1 ROD CHEEK RESULTING IN ENGINE FAILU