20030507001562003050700156CE 2003 5 7 2003FA0000395 120000714G323012416307 BUMPER BLOCK CESSNA210 P210N 2073454CE CONT O520 TSIO520* 17040SO MLG DEBONDED B SMTRO OTHER O OTHER NRNOT REPORTED 1 EA175555S201 P21000417 LEFT AND RIGHT MAIN LANDING GEAR SHELL BUMPER DEBONDS, THE BUMPER EDGES CURL OVER PREVENTING MAIN GEAR STRUT FROM MAKING FULL DOWN TRAVEL. THIS CONDITION PREVENTS MAIN GEAR STRUT FROM CONTACTING DOWNLOCKS AND PROPER DOWNLOCK SWITCH ACTUATION, THEREFORE, AN UNSAFE CONDITION. IT APPEARS THAT MFG MAY HAFE CHANGED THE COMPOSITION OF THE SHELL BUMPER MATERIAL WHICH DOES NOT HAVE GOOD BONDING QUALITIES. RECOMMEND CHANGING COMPOSITION OF BUMPER MATERIAL. (PHOTO) 1H71 3O3 O 3A21 E8CE 20030718000912003071800091SO 2003 7 18 CA030709003 220000720G8520 STUD CESSNA180 180C 2072608CE CONT O470 O470K 17026SO MCAULY2A34C 2A34C203 GL ENGINE LEAKING W O OTHER K FLUID LOSS ININSP/MAINT 1 CA (CAN) ENGINE REMOVED TO INSTALL NEW CAM. WHEN THE ENGINE WAS REPAIRED, IT LEAKED OIL FROM THROUGH STUD. ENGINE WAS REMOVED. NEW TYPE STUDS INSTALLED. IT SOLVED THE PROBLEM. TTAC 4603 1H71 3O3 O 5A6 E273 5 CP3EA 20000317000022000031700002WP 2000 3 17 2000ZZZX582 220000103G725030723515 DISK GARRTTTFE731TFE7313R1H 29001WP LP TURBINE FAILED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 2419 2148 103229852 P80131C ENGINE RECEIVED WITH TURBINE DAMAGE. FIELD REPORT REVEALED THIS ENGINE EXPERIENCED AN IN-FLIGHT SHUT DOWN AT FL 350. DURING TEAR DOWN, THE LPT1 ROTOR ASSY HAD ALL BLADES BROKEN OFF JUST ABOVE THE FIR TREE AREA. ONE LPT1 BLADE COULD NOT BE FOUND. DISK GROWTH MEASURED 0.060 INCH. SUBMITTER SUSPECTED BLADE RELEASE. (X) 4 F E6WE 20000317000082000031700008WP 2000 3 17 2000ZZZX588 220000207G725030720695 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 990322903007 NEW PART RECEIVED FROM HONEYWELL WITH NICKS AND SCRATCHES IN POST FIR TREE AREA, TWO PLACES ON EACH SIDE. (X) 4 F E6WE 20000317000092000031700009WP 2000 3 17 2000ZZZX589 220000204G725030720695 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 990322903661 NEW PART RECEIVED FROM HONEYWELL WITH STEP IN WEB AROUND CURVIC AREA ON FORWARD SIDE OF DISK; ALSO, HAS NICKS IN FIR TREE AREA ON BOTH SIDES OF DISK. (X) 4 F E6WE 20000317000102000031700010WP 2000 3 17 2000ZZZX590 220000204G725030720695 DISK GARRTTTPE331TPE331* 01514WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 NEW PART RECEIVED FROM HONEYWELL WITH ROUGH SPOTS IN WEB AREA ROUND DISK ON FORWARD SIDE; ALSO, NICKS IN POST FIR TREE AREA ON AFT SIDE. (X) 3 T E2WE 20000317000112000031700011WP 2000 3 17 2000ZZZX591 220000208G725030720695 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 NEW PART RECEIVED FROM HONEYWELL WITH SCRATCHES IN WEB AREA THAT CAN BE FELT WITH AN .080 INCH STYLIST ON FORWARD SIDE; ALSO, ONE NICK IN POST FIR TREE AREA ON FORWARD SIDE. (X) 4 F E6WE 20000317000122000031700012WP 2000 3 17 2000ZZZX592 220000120G726131032173 SHAFT GARRTTTPE331TPE33112UA 01514WP OIL PUMP SHEARED B UO2RO OTHER YJ ENGINE STOPPAGE WARNING INDICATION NRNOT REPORTED 1 GL19 2568 9714075319 P66184 ENGINE EXPERIENCED AN IN-FLIGHT SHUT DOWN CAUSED BY OIL PUMP SHAFT SHEARED. (X) 4 T E4WE 20000317000132000031700013WP 2000 3 17 2000ZZZX593 220000125G725030723515 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 990322902774 NEW PART RECEIVED FROM HONEYWELL WITH DISK WEB DAMAGE. (X) 4 F E6WE 20000317000142000031700014WP 2000 3 17 2000ZZZX594 220000128G725030723163 DISK GARRTTTPE331TPE331* 01514WP HP TURBINE NICKED B UO2RK NONE W INADEQUATE Q C ININSP/MAINT 1 GL19 990322900255 NEW PART RECEIVED FROM HONEYWELL WITH CURVIC NICKS AT FIR TREE AREA. (X) 3 T E2WE 20000317000152000031700015WP 2000 3 17 2000ZZZX595 220000128G723030724434 PLENUM GARRTTTPE331TPE331* 01514WP COMPRESSOR MISMANUFACTURED B UO2RK NONE W INADEQUATE Q C ININSP/MAINT 1 GL19 5991 OP51825 REPAIRED PART FROM HONEYWELL. DIM. C OUT OF LIMITS. (X) 3 T E2WE 20000317000162000031700016WP 2000 3 17 2000ZZZX596 220000209G725030720695 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 990322903684 NEW PART RECEIVED FROM HONEYWELL WITH NICKS IN BORE REGION ON AFT SIDE. (X) 4 F E6WE 20000317000172000031700017WP 2000 3 17 2000ZZZX597 220000125G725030723515 DISK GARRTTTPE331TPE331* 01514WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 NEW PART RECEIVED FROM HONEYWELL WITH CURVIC TEETH DAMAGE, NICKS. (X) 3 T E2WE 20000317000182000031700018WP 2000 3 17 2000ZZZX598 220000125G725030723515 DISK GARRTTTPE331TPE331* 01514WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 990322902797 NEW PART RECEIVED FROM HONEYWELL WITH CURVIC TEETH DAMAGE, NICKS. (X) 3 T E2WE 20000317000192000031700019WP 2000 3 17 2000ZZZX599 220000125G725030723515 DISK GARRTTTPE331TPE331* 01514WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 990322902992 NEW PART RECEIVED FROM HONEYWELL WITH CURVIC TEETH DAMAGE, NICKS. (X) 3 T E2WE 20000317000202000031700020WP 2000 3 17 2000ZZZX600 220000125G725030723515 DISK GARRTTTPE331TPE331* 01514WP LP TURBINE NICKED B UO2RK NONE O OTHER ININSP/MAINT 1 GL19 990322902819 NEW PART RECEIVED FROM HONEYWELL WITH CURVIC TEETH DAMAGE, NICKS. (X) 3 T E2WE 20000317000232000031700023SO 2000 3 17 2000ZZZX603 220000217G74146320 MAGNETO SLICK PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360KB 17025SO ENGINE FAILED D O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 EA21198PS449 97110674 3449051 MAGNETO FAILED IN-FLIGHT. FOUND SEVERE DAMAGE TO DISTRIBUTOR FROM ARCING. ARCING APPEARED TO HAVE STARTED BEWEEN COIL AND REAR BEARING HOUSING. SUBMITTER STATED CAUSE UNKNOWN. (X) 1L72 3O3 O A7SO E9CE 20000317000782000031700078EA 2000 3 17 2000ZZZX616 220000204G8520LW10545S PISTON PIPER PA31 PA31310 7103103SO LYC O540 TIO540J2BD 41532EA ENGINE CORRODED H K NONE O OTHER ININSP/MAINT 1 NM082336V 31135 RL472661A ENGINE WAS 438 HOURS FROM FACTORY REMANUFACTURE. REMOVED LONER PLUG FROM NR 3 CYLINDER AND FOUND CYLINDER HAD EXCESSIVE OIL IN PLUG. REMOVED CYLINDER AND FOUND THE OIL CONTROL RING LAND AND PISTON PIN HOLE WERE EXCESSIVELY PITTED AND CORRODED. ENGINE WAS REPORTED AS NEEDING TO 'CLEAR ITS THROAT' BEFORE IT WOULD RUN SMOOTH. 1L71 3O3 ORTA20SO E14EA 20000317000812000031700081SO 2000 3 17 2000ZZZX619 220000210G8530 EXHAUST VALVE CESSNA150 150L 2071826CE CONT O200 O200A 17020SO ENGINE STUCK G O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SO1111567 738 15075527 2047329A AIRCRAFT LOST POWER WHEN PERFORMING 'TOUGH AND GOES'. AIRCRAFT LANDED APPROXIMATELY 150 FEET FROM THE END OF THE RUNWAY. AN INVESTIGATION HAS DETERMINED THE MOST POSSIBLE CAUSE OF THE ENGINE'S POWER LOSS WAS AN EXHAUST VALVE THAT WAS INTERMITTENTLY STUCK 'OPEN'. AIRCRAFT WAS SUBSTANTIALLY DAMAGED. 1H71 3O3 O 3A19 E252 20000317000872000031700087SO 2000 3 17 2000ZZZX625 220000314G8520633945 MANIFOLD CESSNA421 421 2076010CE CONT O520 GTSIO520D 17032SO ENGINE CRACKED BS MI3RK NONE O OTHER ININSP/MAINT 1 NM093121K 42100102 DURING ANNUAL INSPECTION, A CRACK EXTENDING ABOUT 2 INCHES EACH SIDE OF THE THREADED BOSS. THE BOSS HAD BEEN DRILLED AND TAPPED FOR A HELICOIL. THREADED BOSS IS FOR ATTACHING THE INTERCOOLER. 1L72 3O3 ORTA7CE E7CE 20000317000912000031700091EA 2000 3 17 2000ZZZX629 220000208G8530SL14995 RETAINER CUP SLC36100B PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA PUSH ROD HOUSINGBROKEN D K NONE O OTHER ININSP/MAINT 1 EA073659R346 285762 L1480036A ON ANNUAL INSPECTION, ROCKER COVERS REMOVED FOR GASKET LEAKS. FOUND PUSH ROD RETAINERS ON NR 1 AND NR 2 CYLINDERS BROKEN. THESE WERE SUPERIOR MILLENIUM CYLINDERS WITH 346 HRS SINCE NEW. SUBMITTER STATED PROBLEM IS BELIEVED TO BE INSUFFICIENT SURFACE AREA FOR THE RETAINER TO SEAT AGAINST. 1L71 3O3 O 2A13 E286 20000317001222000031700122EA 2000 3 17 2000ZZZX647 220000110G741410382681 CAPACITOR 66E21576 MAULE M7 M7235 5460170SO LYC O540 O540J1A5 41532EA MAGNETO FAILED C K NONE O OTHER ININSP/MAINT 1 SO21783SP1 G109900C 4101C L2076840A PROBLEM STARTED WITH INSTALLATION OF NEW TCM HARNESS IGNITION SYSTEM. RESULTED IN REPEATED FAILURES IN MAGNETO ON ONE SIDE OR OTHER (I.E., LEFT AND RIGHT). MAGNETOS WERE REMOVED AND CHECKED. POINTS AND CAPACITORS REPLACED. ENGINE AND AIRFRAME ELECTRICS CHECKED OK. CAPACITOR BATCH NR 9920 FOUND DEFECTIVE. REPLACED WITH NR 9948. OK TO-DATE, 1-24-00. (X) 1H71 3O3 ONC3A23 E295 20000323005722000032300572EA 2000 3 23 2000ZZZX713 220000217G7313 INJECTOR NOZZLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE FAILED H O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SW99498ER848 17280674 L2786151A PILOT EXPERIENCED A BRIEF ROUGHNESS IN CRUISE. THREE FUEL INJECTOR NOZZLES WERE CHANGED. 1H71 3O3 ONT3A12 1E10 20000323005742000032300574EA 2000 3 23 2000ZZZX715 220000118G8550LW15688 TUBE CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA OIL SUMP DISCONNECTED B O OTHER O OTHER NRNOT REPORTED 1 SO135246B 769 15283815 RL1871015 INDUCTION TUE ATTACHED TO OIL SUMP BECAME LOOSE CAUSING ROUGH RUNNING ENGINE. ENGINE OIL SUMP REPLACED TO CORRECT PROBLEM. SUBMITTER STATED THIS IS SECOND ENGINE FOUND WITH THIS CONDITION ON FACTORY OVERHAULED ENGINE. 1H71 3O3 ONT3A19 E223 20000323005862000032300586GL 2000 3 23 2000ZZZX727 220000115G732323065121 GOVERNOR BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL ENGINE MALFUNCTIONED BLAVBVRA UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW0935WH 1266 21482 2736 CAE836154 IN CRUISE FLIGHT, THE POWER TURBINE ROTOR DROOPED TO 90 PERCENT AND WOULD NOT RECOVER. THE PILOT LOWERED COLLECTIVE, RECOVERED ROTOR SPEED AND DID A POWER ON RECOVERY. 1G71 3U3 U H2SW E4CE 20000403000162000040300016NE 2000 4 3 20000330SH017 220000128G7230 BLADE BOEING747 747121 1384871NM PWA JT9 JT9D7A 52054NE NR 1 ENGINE BENT B K NONE O OTHER ININSP/MAINT 1 WP03480EV 20348 DURING WALKAROUND INSPECTION, SEVEN N1 FAN BLADES WERE FOUND BENT BEYOND LIMITS ON NR 1 ENGINE. AIRCRAFT WAS GROUNDED NAN. FAN BLADES WERE REPLACED AND TEST RUN CARRIED OUT BY EVERGREEN. (X) 2L74 4F4 F A20WE E20EA 20000404004582000040400458EA 2000 4 4 20000328SH001 220000321G8500 ENGINE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA NOSE MALFUNCTIONED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION DEDESCENT 1 SW999559D724 17280488 L2757151A ENGINE RAN ROUGH AND ALMOST SHUT DOWN DURING DESCENT. (X) 1H71 3O3 ONT3A12 1E10 20000404004632000040400463WP 2000 4 4 20000328SH012 220000120G720030755141 SEAL GARRTTTFE731TFE7315R 01518WP ENGINE LEAKING B U02RK NONE K FLUID LOSS ININSP/MAINT 1 GL19 1946 P91165 ENGINE EXPERIENCED IN-FLIGHT SHUT DOWN BY HIGH GEARBOX PRESSURE WHICH EXPANDED OIL TANK AND CREATED HOLE IN OIL TANK AT A SPOT WELD DUE TO HIGH GEARBOX PRESSURE. ENGINE LOST OIL PRESSURE AND WAS SHUT DOWN BY PILOT. (X) 4 F E6WE 20000404004652000040400465NE 2000 4 4 20000328SH014 220000201G720030756441 SEAL GARRTTTFE731TFE73121C NE ENGINE LEAKING B K NONE K FLUID LOSS ININSP/MAINT 1 GL19 P73466 ENGINE EXPERIENCED HIGH GEARBOX PRESSURE AT TEST CELL AFTER ENGINE CORE REPAIR WITH NEW NR 4 AND NR NR 5 SEALS AND RUNNERS. (X) 4 F E6WE 20000404004662000040400466NE 2000 4 4 20000328SH015 220000201G720030756392 SEAL GARRTTTFE731TFE73121C NE ENGINE LEAKING B UO2RK NONE K FLUID LOSS ININSP/MAINT 1 GL19 P73466 ENGINE EXPERIENCED HIGH GEARBOX PRESSURE AT TEST CELL AFTER ENGINE CORE REPAIR WITH NEW NR 4 AND AND NEW NR 5 SEALS AND RUNNERS. (X) 4 F E6WE 20000404004672000040400467NE 2000 4 4 20000328SH016 220000201G720030756332 SEAL GARRTTTFE731TFE73121C NE ENGINE LEAKING B UO2RK NONE K FLUID LOSS ININSP/MAINT 1 GL19 P73466 ENGINE EXPERIENCED HIGH GEARBOX PRESSURE AT TEST CELL AFTER ENGINE CORE REPAIR WITH NEW NR 4 AND NR 5 SEALS AND RUNNERS. (X) 4 F E6WE 20000404004682000040400468NE 2000 4 4 20000328SH017 220000201G720030756451 SEAL GARRTTTFE731TFE73121C NE ENGINE LEAKING B UO2RK NONE K FLUID LOSS ININSP/MAINT 1 GL19 P73466 ENGINE EXPERIENCED HIGH GEARBOX PRESSURE AT TEST CELL AFTER ENGINE CORE REPAIR WITH NEW NR 4 AND NEW NR 5 SEALS AND RUNNERS. (X) 4 F E6WE 20000404004702000040400470EA 2000 4 4 20000328SH020 220000208G853065007 RETAINER SEAL MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA NR 1 CYLINDER DAMAGED B K NONE O OTHER ININSP/MAINT 1 SO053935H 2006 240982 DURING ANNUAL INSPECTION, DISCOVERED NR 1 CYLINDER EXHAUST PUSH ROD TUBE SEAL AREA AT CASE HALF RETAINER PROTRUDING AT AN ANGLE. REMOVED NR 1 EXHAUST PUSH ROD, FOUND LIFTER BODY CRACKED, AND BROKEN. LIFTER WILL NOT COME OUT. SUBMITTER SUSPECTED CAUSE WAS STUCK EXHAUST VALVE AT SOME TIME. ENGINE IS AT TBO AND WILL BE REPLACED. (X) 1L71 3O3 O 2A3 1E10 20000404004732000040400473EA 2000 4 4 20000329SH004 220000214G732255018010 CARBURETOR CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA AIRBOX CONTAMINATED D A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 WP275259R3706 17263473 A ROUGH RUNNING ENGINE, AND A LOSS OF ENGINE POWER (MAXIMUM RPM 2200) CAUSED PILOT TO MAKE A PRECAUTIONARY LANDING. TECHNICIAN INSPECTED THE INDUCTION SYSTEM AND FOUND THE CARBURETOR HEAT AIR VALVE SEAL MATERIAL HAD SEPARATED AND WAS INGESTED BECOMING LODGED ACROSS THE CARBURETOR VENTURI. THIS DISRUPTION OF AIR FLOW THROUGH THE VENTURI CAUSED IMPROPER FUEL/AIR MIXTURE AND FUEL SCHEDULING RESULTING IN A LOSS OF POWER. THIS PART HAD NOT BEEN CHANGED SINCE MANUFACTURE OF AIRCRAFT 25 YEARS AGO. TOTAL TIME ON AIRCRAFT 3,706.0 HOURS. RECOMMENDATION: MORE FREQUENT INSPECTIONS OF CARBURETOR AIR BOX ASSEMBLY FOR WEAR AND DETERIORATION AND TOTAL TIME IN SERVICE. (X) 1H71 3O3 ONT3A12 E274 20000404004742000040400474EA 2000 4 4 20000329SH005 220000217G7421 SPARK PLUG CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE DIRTY H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 SW99477ER1062 17280622 L2803951A DURING FLIGHT, THE PILOT REPORTED ROUGH ENGINE OPERATION FOR SEVERAL SECONDS. THE SPARK PLUGS WERE SERVICED. (X) 1H71 3O3 ONT3A12 1E10 20000404004752000040400475EA 2000 4 4 20000329SH006 220000217G7421 SPARK PLUG CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE DIRTY H O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SW99417ER1903 17280305 L2727851A DURING FLIGHT, PILOT REPORTED ROUGH ENGINE OPERATION FOR A FEW SECONDS. THE INJECTOR NOZZLES WERE CLEANED, THE SPARK PLUGS WERE SERVICED, AND THE ELECTRIC BOOST PUMP WAS REPLACED. (X) 1H71 3O3 ONT3A12 1E10 20000404004762000040400476EA 2000 4 4 20000329SH007 220000217G7320 FLOW DIVIDER CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE MALFUNCTIONED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 SW99460ER 17280668 L2786851A DURING FLIGHT, THE PILOT REPORTED ROUGH ENGINE OPERATION FOR A FEW SECONDS. THE FUEL FLOW DIVIDER WAS REPLACED AND THE NR 1 NOZZLE WAS REPLACED. (X) 1H71 3O3 ONT3A12 1E10 20000404004832000040400483SO 2000 4 4 20000329SH038 220000214G74141051324 SPRING CONT O470 O470* 17026SO IMPULSE COUPLINGDAMAGED B QKKRK NONE W INADEQUATE Q C ININSP/MAINT 1 CE01 NEW PARTS HAVE FINGER PRINTS ON THEM. PARTS ARE NEW, NOT REMOVED FROM MANUFACTURER''''S BAG SINCE TIME OF BAGGING AT SUPPLY CENTER. SUBMITTER STATED PROBLEM IS SPRING STEEL WITH SWEAT FROM THE PERSONS WORKING ON THE PART. 3 O E273 20000404004882000040400488EA 2000 4 4 20000329SH044 220000302G853005K21123 CYLINDER CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA ENGINE DAMAGED B WIWRK NONE O OTHER ININSP/MAINT 1 WP0795512466 15285911 RL897015 WHILE PERFORMING ANNUAL INSP, ALUMINUM SHAVINGS WERE FOUND IN THE OIL FILTER. FILTER SENT TO LYC FOR ANALYSIS AND DETERMINED TO BE PISTON PIN PLUG MATERIAL. UPON REMOVAL OF ALL 4 CYLINDERS, SEVERE PITTING FOUND AT BOTTOM OF EACH CYL WALL AT THE POINT WHERE PISTON TOUCHES ITS LOWEST TRAVEL. ALL 4 CYL''S REJECTED AND FACTORY NEW INSTALLED. FACTORY STATES THIS IS RESULT OF ENG NOT REACHING PROPER OPERATING TEMP. ACFT IS OPERATED IN PHOENIZ, AZ, OIL TEMP GAUGE IS ACCURATE. 1H71 3O3 ONT3A19 E223 20000404004892000040400489EA 2000 4 4 20000329SH045 220000302G853005K21123 CYLINDER CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA ENGINE DAMAGED B WIWRK NONE O OTHER ININSP/MAINT 1 WP07757NZ681 15279885 L2507515 WHILE PERFORMING ANNUAL INSP, SMALL ALUMINUM PARTICLES WERE FOUND IN THE OIL FILTER. A BORESCOPE INSP REVEALED WEAR ON CYLINDER WALLS AND PITTING AT THE BASE OF EACH CYL (INSIDE) AT THE POINT OF THE PISTON''S FARTHEST TRAVEL DOWNWARDS. TWO OF THE CYL''S WERE FACTORY NEW WITH 681 HRS SINCE NEW. THE OTHER TWO WERE REPAIRED 1,176.7 HRS AGO AT FACTORY''S REQUEST BY A FACTORY APPROVED REPAIR FACILITY UNDER WARRANTY. THIS IS 3RD OCCURRENCE IN 1,859.5 HRS SMOH BY LYC. THE 1ST OCCURANCE RESULTED IN ALL OF THE ABOVE AND BELOW ACCEPTABLE COMPRESSIONS ON ALL 4 CYL''S. FACTORY STATES ENGINE IS RUNNING TOO COLD IN PHX, AZ. 1H71 3O3 ONT3A19 E223 20000404004922000040400492CE 2000 4 4 20000329SH048 120000316G28225100003 PUMP CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA FUEL BOOST INOPERATIVE H O OTHER O OTHER NRNOT REPORTED 1 SW99416ER443 17280281 L2732651A THE CREW REPORTED THE ELECTRIC BOOST PUMP INOPERABLE. THE PUMP WAS REPLACED. THIS PUMP ROUTINELY FAILS IN THIS FLEET OF 172R AIRCRAFT, AND IN MOST CASES, PRODUCES METAL THAT CONTAMINATED THE FUEL INJECTION COMPONENTS. (X) 1H71 3O3 ONT3A12 1E10 20000404005102000040400510EA 2000 4 4 20000330SH002 220000306G8500 CASE MOONEYM20 M20E 5870212SW LYC O360 IO360A1A 41514EA ENGINE CRACKED H K NONE K FLUID LOSS ININSP/MAINT 1 SW993419X3270 1250 1118 L230151A PILOT NOTED OIL LEAK. DURING INSPECTION FOR OIL LEAK, ENGINE CASE WAS FOUND CRACKED BELOW NR 1 CYLINDER BASE PAD. CRACK IS APPROXIMATELY 4.5 INCHES PARALLEL TO CYLINDER PAD. ALSO FOUND NR 1 INTAKE TUBE LOOSE. 1L71 3O3 O 2A3 1E10 20000404005132000040400513EA 2000 4 4 20000330SH006 220000322G8550LW14729 DIPSTICK PIPER PA32 PA32RT300T 7103216SO LYC O540 TIO540C1A 41532EA OIL CAP SEPARATED H O OTHER KJ FLUID LOSS WARNING INDICATION TXTAXI/GRND HDL 1 SW999452C 206 32R7887006 L527061A PILOT REPORTED TO REPAIR SHOP, THAT AFTER LANDING, HE HAD AN OIL LEAK IN THE ENGINE AREA. AFTER INSPECTION, FOUND THAT DIP ROD IN THE OIL CAP WAS NOT INSTALLED IN THE CAP AND HAD FALLEN DOWN INTO THE OIL FILL TUBE OF THE ENGINE. UNDER INSPECTION WITH A MAGNIFYING GLASS, NO SIGNS THE ROLL PIN THAT SHOULD HAVE BEEN INSTALLED TO HOLD THE ROD INTO THE CAP HAD EVER BEEN INSTALLED. THIS ENGINE HAD BEEN OVERHAULED BY THE LYCOMING FACTORY, AND WAS NOT AN AFTER MARKET OVERHAUL. 1L71 3O3 O A3SO E14EA 20000404005142000040400514NE 2000 4 4 20000330SH007 220000211G72502A227401 BEARING IAE V2528 V2528D5 NE NR 4 DAMAGED A WA2DK NONE O OTHER ININSP/MAINT 1 NE03 1320 V20006 ENGINE RECEIVED FOR THIRD LPT BLADE DAMAGE. DISASSEMBLY INSPECTION REVEALED FLOODED NR 4 BEARING AREA/POSSIBLE FIRE AND CONTACT BETWEEN T2 DISK AND 1-2 AIR SEAL. (X) 4 F E40NE 20000404005152000040400515NE 2000 4 4 20000330SH008 220000211G72502A227401 BEARING IAE V2528 V2528D5 NE NR 4 DAMAGED B WA2DK NONE O OTHER ININSP/MAINT 1 NE03 1320 V20006 ENGINE RECEIVED FOR 3RD LPT BLADE DAMAGE. DISASSEMBLY INSPECTION REVEALED FLOODED NR 4 BEARING AREA/POSSIBLE FIRE AND CONTACT BETWEEN T2 DISK AND 1-2 AIR SEAL. (X) 4 F E40NE 20000404005182000040400518SO 2000 4 4 20000330SH011 220000215G8520630826 BEARING CESSNA210 210L 2073448CE CONT O520 IO520* 17032SO CRANKSHAFT CRAZED H K NONE O OTHER ININSP/MAINT 1 SW994667Q 21059567 DURING ENGINE TEAR DOWN DUE TO SUDDEN STOPPAGE. INSPECTION OF THE BEARINGS FOUND 7 OUT OF 12 BEARING HALVES FOUND WITH EXCESSIVE CRAZING ON THE SURFACE. ENGINE WAS ASSEMBLED 12-28-99 AND PUT INTO SERVICE ON 1-29-00 AND WAS DISASSEMBLED 2-25-00. SUBMITTER STATED CAUSE AND PREVENTION UNKNOWN. (X) 1H71 3O3 O 3A21 E5CE 20000404005192000040400519SO 2000 4 4 20000330SH012 220000215G8520653547 BEARING CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO CRANKSHAFT DAMAGED H K NONE O OTHER ININSP/MAINT 1 SW994667Q45 21059567 295047R DURING ENGINE TEAR DOWN DUE TO SUDDEN STOPPAGE, INSPECTION OF THE BEARINGS FOUND 4 OUT OF 10 BEARING HALVES WERE FOUND WITH EXCESSIVE CRACKING ON THE SURFACE. ENGINE WAS ASSEMBLED 12-28-99, AND PUT INTO SERVICE ON 1-29-00, AND WAS DISASSEMBLED 2-25-00. CAUSE AND PREVENTION UNKNOWN. (X) 1H71 3O3 O 3A21 E5CE 20000404005222000040400522WP 2000 4 4 20000330SH015 220000117G723030756451 CARBON SEAL LEAR 35 36A 5170603CE GARRTTTFE731TFE73122B 01518WP ENGINE FAILED B IY2RO OTHER XJ ENGINE FLAMEOUT WARNING INDICATION NRNOT REPORTED 1 SW1532AJ 231 36A048 P89174 ENGINE EXPERIENCED IN-FLIGHT SHUTDOWN 230.5 HRS FOLLOWING CZI (COMPRESSOR ZONE INSP) AND INSTALL OF NEW STYLE CARBON SEALS PER SB 72-3596 REV 7. ENG TEARDOWN REVEALED FAILURE OF PLANETARY GEAR BEARINGS, PLANETARY GEARS, SUN GEAR, AND RING GEAR. FAILURE CAUSED BY OIL STARVATION TO PLANETARY ASSY DUE TO BLOCKAGES OF PLANETARY OIL MANIFOLDS OIL JET STRAINER, PN 894764-3. THE HAT SHAPED STRAINER WAS PACKED WITH CARBON WHICH REDUCED OIL FLOW TO PLANETARY GEAR AREA. ENG TOTALLY DISASSEMBLED TO ACCOMPLISH LUBRICATION CONTAMINATION INSP AND DETERMINE WHICH COMP GENERATED CARBON PARTICLES. PARTICLES TRACED TO NEW NR 5 CARBON SEAL PN 3075645-1, SN 9919366801122. (X) 2L72 4F4 F A10CE E6WE 20000404005242000040400524WP 2000 4 4 20000330SH018 220000229G731431080261 PUMP GARRTTTPE331TPE331* 01514WP DRIVE GEAR FROZEN B UO2RO OTHER O OTHER NRNOT REPORTED 1 GL19 13285 P66294 PUMP FROZE DURING FLIGHT STRIPING DRIVE GEAR. (X) 3 T E2WE 20000405000062000040500006WP 2000 4 5 20000403SH007 220000229G720030756842 RETAINER AMD FALC50FALCON900 2700160EU GARRTTTFE731TFE7315BR WP ENGINE BROKEN B UO2RK NONE O OTHER ININSP/MAINT 1 GL1975V 697 13 P95151 DISASSEMBLED ENGINE BECAUSE OF BAD S.O.A.P. SAMPLE. FOUND NR 3 SEAL RUNNER RETAINER BROKEN. (X) 2L73 4F4 FRTA46EU E6WE 20000405000312000040500031NE 2000 4 5 20000404SH015 220000119G7310 MANIFOLD BOEING777 777* UTILUSENM PWA 4090 PW4090 52119NE FUEL SYSTEM LEAKING H WA2DFC ACTIVATE FIRE EXT. ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 NE03EICRT968 P222110 FIRE WARNING ON TAKEOFF, BOTTLES DISCHARGED, AIR TURN BACK. DISASSEMBLY INSPECTION REVEALED MANIFOLD NUT BACKED OFF, NOT SAFETY WIRED. PRATT & WHITNEY ENG/MFG REVIEWING. SUSPECT ASSEMBLY ERROR. (X) 2L72 4F4 FRTT00001SEE46NE 20000406000612000040600061WP 2000 4 6 20000331SH002 220000301G725030720705 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE NICKED B K NONE O OTHER ININSP/MAINT 1 GL19 NEW PART RECEIVED FROM HONEYWELL WITH TWO SMALL NICKS IN WEB AREA FORWARD SIDE AND DAMAGE IN POST FIR TREE AREA ON BOTH SIDES. (X) 4 F E6WE 20000406000662000040600066WP 2000 4 6 20000331SH009 220000307G725030723515 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED B K NONE O OTHER ININSP/MAINT 1 GL19 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST-FIR TREE AREA. (X) 4 F E6WE 20000406000682000040600068CE 2000 4 6 20000331SH010 220000310G7414 PLATE SLICK MOONEYM20 M20K 5870220SW CONT O360 TSIO360MB 17025CE MAGNETO MOUNT MISMANUFACTURED D K NONE W INADEQUATE Q C ININSP/MAINT 1 NE03252BA631 95030022 251122 317134 WHEN LT AND RT MAGNETOS WERE BEING INSTALLED ON ENGINE AFTER INTERNAL INSPECTION OF MAGNETOS, NOTED MAGNETO HOLD-DOWN PLATES FROM ENGINE STUD TO MAGNETO MOUNTING FLANGE ONLY ENGAGED FLANGE BY APPROXIMATELY .0625 INCH IF MOUNTED EVEN, OR ONLY ONE CORNER OF PLATE IF COCKED TO ONE SIDE. SUBMITTER STATED MOUNTING PLATES ARE TYPE NORMALLY SENT WITH NEW MAGNETOS. ORDERED 4 EACH TCM, PN 630535, MOUNT PLATES AND INSTALLED, FIT GOOD. (X) 1L71 3O3 O 2A3 E9CE 20000406000692000040600069CE 2000 4 6 20000331SH011 220000310G7414 PLATE SLICK MOONEYM20 M20K 5870220SW CONT O360 TSIO360MB 17025CE MAGNETO MOUNT MISMANUFACTURED D K NONE W INADEQUATE Q C ININSP/MAINT 1 NE03252BA 97030194 251122 317134 WHEN LT AND RT MAGNETOS WERE BEING INSTALLED ON ENGINE AFTER INTERNAL INSPECTION OF MAGS, NOTED MAGNETO HOLD-DOWN PLATES FROM ENGINE STUD TO MAGNETO MOUNTING FLANGE ONLY ENGAGED FLANGE BY APROXIMATELY .0625 INCH IF MOUNTED EVEN, OR ONLY ONE CORNER OF PLATE IS COCKED TO ONE SIDE. SUBMITTER STATED MOUNTING PLATES ARE TYPE NORMALLY SENT WITH NEW MAGNETOS. ORDERED 4 EACH TCM PN 630535 MOUNT PLATES AND INSTALLED, FIT GOOD. (X) 1L71 3O3 O 2A3 E9CE 20000406000712000040600071CE 2000 4 6 20000331SH019 120000303G7120H30024 SHOCK MOUNT CESSNA336 336 2075602CE CONT O360 IO360A 17025SO FIREWALL FAILED H O OTHER O OTHER TXTAXI/GRND HDL 1 SW993856U1841 33610156 DIFFICULT TO INSPECT. PILOT HEARD AND NOTICED COWL RUBBING PROPELER SPINNER DURING SHUT DOWN AT FUEL PIT AT MADERA AIRPORT. (X) 1H72 3O3 O A2CE E1CE 20000406000732000040600073EA 2000 4 6 20000331SH021 220000312G8500 ENGINE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA NOSE ROUGH H O OTHER EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 SW99410ER 17280257 LW2722651A6 THE ENGINE WAS REPORTED ROUGH IN CRUISE. CORRECTIVE ACTION WAS TAKEN AND THE AIRCRAFT WAS RETURNED TO SERVICE. (X) 1H71 3O3 ONT3A12 1E10 20000406000742000040600074SO 2000 4 6 20000331SH023 220000120G8530 STUD BENDIX CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO ENGINE CYLINDER BROKEN H K NONE O OTHER ININSP/MAINT 1 GL0342RH 10 18266776 820036R NEW REBUILT ENGINE PURCHASED FROM CONTINENTAL. 10.6 HOURS AFTER INSTALLATION, NR 4 CYLINDER, NR 2 AND NR 3 CYLINDER MOUNTING STUDS BROKE. NR 5 AND NR 6 MISSING NUTS. (TORQUE WAS CHECKED ON ALL OTHER CYLINDERS AND FOUND OK). SAME ENGINE UPON INSTALLATION REQUIRED THE REPLACMENT OF THE RIGHT MAGNETO AT ZERO HOURS. (X) 1H71 3O3 ONT3A13 E273 20000406000762000040600076SO 2000 4 6 20000331SH025 220000306G8530 STUD CESSNA421 421 2076010CE CONT O520 GTSIO520N 17032SO NR 5 CYLINDER FAILED B K NONE O OTHER ININSP/MAINT 1 GL13421CH628 4210176 277018R DURING INSPECTION OF OIL LEAK, FOUND NR 5 CYLINDER BASE FRONT LOWER MOUNT STUD BROKEN. POSSIBLY, THE STUD WAS HARD AND BROKE UNDER STRESS. (X) 1L72 3O3 ORTA7CE E7CE 20000406000782000040600078SO 2000 4 6 20000403SH002 220000306G8530 STUD CESSNA421 421C 2076016CE CONT O520 GTSIO520N 17032SO ENGINE FAILED B AZORO OTHER K FLUID LOSS NRNOT REPORTED 1 GL13421LH128 421C1207 292129R DURING NORMAL ENGINE OPERATION, NOTICED OIL LEAK ON FRONT OF ENGINE. AFTER CLEANING AND INSPECTION, FOUND THE FRONT THROUGH-STUD BROKEN. POSSIBLE CAUSE COULD BE IMPROPER HARDENING OF THE BOLT. (X) 1L72 3O3 O A7CE E7CE 20000406000802000040600080SO 2000 4 6 20000403SH006 220000225G8500 ENGINE BEECH 58 58 1152740CE CONT O520 IO520C 17032SO RIGHT MAKING METAL B BSYRC ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 GL077383R TH502 ATL - RIGHT ENGINE PROPELLER WENT INTO FEATHER ON TAKEOFF. FOUND ALUMINUM PLUGGING PROPELLER SCREEN. REMOVED AND REPLACED ENGINE. SUBMITTER STATED CAUSE UNKNOWN AT THIS TIME. (X) 1L72 3O3 O 3A16 E5CE 20000406000832000040600083SO 2000 4 6 20000404SH001 220000308G8530652956 EXHAUST VALVE BLANCA17 1730A 1220433GL CONT O520 IO520K 17032SO NR 1 CYLINDER WORN B CRJRK NONE O OTHER ININSP/MAINT 1 CE019606E145 7630819 224130R EXCESSIVE WEAR FOUND DURING COMPRESSION TEST. EXHAUST VALVE WAS LEAKING. EX GUIDE MEASURED .4384 INCH AT THE TOP AND .4624 INCH AT THE BOTTOM. EX VALVE MEASURED .4337 INCH AT THE TOP OF THE STEM AND .4263 INCH AT APPROX 2 INCHES FROM THE BOTTOM OF THE VALVE. CLEARANCE BETWEEN VALVE AND GUIDE IS .0361 INCH. SERVICEABLE LIMIT IS .006 INCH. NO METAL WAS FOUND IN THE OIL SCREEN. ENGINE IS NOT EQUIPPED WITH A SPIN ON FILTER. ALL OTHER CYLINDERS'' COMPRESSIONS TESTED OK. ENGINE WAS INSTALLED AFTER FACTORY REMAN IN JAN 98. M OR D SUBMITTED BY HAP''S AIR SERVICE AMES, IA. (X) 1L71 3O3 O A18CE E5CE 20000406000842000040600084SO 2000 4 6 20000404SH002 220000308G8530643767 GUIDE BLANCA17 1730A 1220433GL CONT O520 IO520K 17032SO NR 1 CYLINDER WORN B CRJRK NONE O OTHER ININSP/MAINT 1 CE019606E145 7630819 224130R EXCESSIVE WEAR FOUND DURING COMPRESSION TEST. EXHAUST VALVE WAS LEAKING. EX GUIDE MEASURED .4384 INCH AT THE TOP AND .4624 INCH AT THE BOTTOM. EX VALVE MEASURED .4337 INCH AT THE TOP OF THE STEM AND .4263 INCH AT APPROX 2 INCHES FROM THE BOTTOM OF THE VALVE. CLEARANCE BETWEEN VALVE AND GUIDE IS .0361 INCH. SERVICEABLE LIMIT IS .006 INCH. NO METAL WAS FOUND IN THE OIL SCREEN. ENGINE IS NOT EQUIPPED WITH A SPIN ON FILTER. ALL OTHER CYLINDERS'' COMRPESSIONS TESTED OK. ENGINE WAS INSTALLED AFTER FACTORY REMAN IN JAN 98. M OR D SUBMITTED BY HAP''S AIR SERVICE, AMES, IA. (X) 1L71 3O3 O A18CE E5CE 20000406000852000040600085CE 2000 4 6 20000404SH003 220000227G7320RSA5AD SERVO PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE FUEL INJECTOR FAILED G O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION LDLANDING 1 WP079299E16 3449043 819256R ON BASE LEG TO GOODYEAR AIRPORT, THE LEFT ENGINE LAGGED POWER TO LANDING. A SAFE LANDING WAS MADE AND THE AIRCRAFT WAS TAKEN TO MAINTENANCE FOR INSP OF THE LEFT ENGINE. ON GROUND RUN-UP, FOUND THE LEFT ENGINE WAS RUNNING RICH AT LOW POWER SETTINGS. THE LEFT FUEL SERVO WAS REMOVED AND SENT TO TCM FOR WARRANTY. A NEW FUEL SERVO WAS INSTALLED FROM STOCK AND TRIM RUN COMPLETED, THE AIRCRAFT RETURNED TO SERVICE. (X) 1L72 3O3 O A7SO E9CE 20000406001132000040600113EA 2000 4 6 20000405SH009 220000215G7324 FLOW DIVIDER CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA FUEL SYSTEM MALFUNCTIONED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99403ER6011 140 17280245 L2786651A ENGINE HAD MOMENTARY ROUGHNESS WHILE IN CRUISE FLIGHT. REPLACED FUEL FLOW DIVIDER, FUEL SERVO, AND ELECTRIC BOOST PUMP. (X) 1H71 3O3 ONT3A12 1E10 20000406001142000040600114EA 2000 4 6 20000405SH010 220000215G7313 NOZZLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA FUEL SYSTEM DIRTY H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99403ER6014 144 17280245 L2786651A ENGINE HAD MOMENTARY ROUGHNESS WHILE IN CRUISE FLIGHT. CLEANED ALL FUEL NOZZLES. (X) 1H71 3O3 ONT3A12 1E10 20000406001152000040600115EA 2000 4 6 20000405SH011 220000215G7313 NOZZLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA NR 2 CYLINDER MALFUNCTIONED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99445ER1360 17280662 L2785651A ENGINE HAD MOMENTARY ROUGNESS WHILE IN CRUISE FLIGHT. REPLACED NR 2 CYLINDER INJECTOR NOZZLE. (X) 1H71 3O3 ONT3A12 1E10 20000406001162000040600116EA 2000 4 6 20000405SH012 220000215G7421 SPARK PLUG CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE MALFUNCTIONED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99445ER1406 17280662 L2785651A ENGINE HAD MOMENTARY ROUGHNESS DURING CRUISE. CHANGED ONE SPARK PLUG. (X) 1H71 3O3 ONT3A12 1E10 20000406001172000040600117EA 2000 4 6 20000405SH013 220000215G7421 SPARK PLUG CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE FAILED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99434ER1275 17280655 L2784651A ENGINE HAD MOMENTARY ROUGHNESS WHILE IN CRUISE FLIGHT. REPLACED ALL SPARK PLUGS. (X) 1H71 3O3 ONT3A12 1E10 20000406001182000040600118EA 2000 4 6 20000405SH014 220000215G7310 MANIFOLD CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA FUEL SYSTEM MALFUNCTIONED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99434ER1303 17280655 L2784651A ENGINE HAD MOMENTARY ROUGHNESS DURING CRUISE. REPLACED FUEL MANIFOLD. (X) 1H71 3O3 ONT3A12 1E10 20000406001192000040600119EA 2000 4 6 20000405SH015 220000215G7421 SPARK PLUG CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE FAILED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99443ER348 17280661 L2719151A DURING NORMAL CRUISE, ENGINE RAN ROUGH FOR SEVERAL SECONDS. THE SPARK PLUGS WERE SERVICED. (X) 1H71 3O3 ONT3A12 1E10 20000406001202000040600120EA 2000 4 6 20000405SH016 220000215G7313 NOZZLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA NR 3 CYLINDER FAILED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99460ER1290 17280668 L2786851A ENGINE HAD MOMENTARY ROUGHNESS WHILE IN CRUISE FLIGHT. REPLACED NR 3 CYLINDER NOZZLE. (X) 1H71 3O3 ONT3A12 1E10 20000406001212000040600121EA 2000 4 6 20000405SH017 220000215G7421 SPARK PLUG CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE FAILED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SW99478ER1179 17280623 L2779151A ENGINE HAD MOMENTARY ROUGHNESS DURING CRUISE. CHANGED ONE SPARK PLUG. INSTALLED NEW SPARK PLUGS. (X) 1H71 3O3 ONT3A12 1E10 20000406001302000040600130GL 2000 4 6 20000405SH028 220000203G72406870992 COMBUSTION LINERALLSN BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL TURBINE SECTION CRACKED D O OTHER J WARNING INDICATION HOHOVERING 1 EA21777CP 199 33573 3429 CAE830498 DURING HOVERING ON A TRAINING FLIGHT, THE PILOT NOTICED THAT TOT TEMPERATURE WAS HIGHER THAN NORMAL. AFTER TROUBLESHOOTING WHICH INCLUDED CHANGING BLEED VALVE AND CHECKING ANTI-ICE FOR PROPER CLOSING, THERE WAS NO CHANGE. POWER CHECK ON ENGINE INDICATED SUBSTANTIAL POWER LOSS. THIS WAS A RENTAL ENGINE SO THE AMOC WHICH OWNED THE ENGINE WAS NOTIFED. THEY CAME AND REMOVED THE ENGINE. UPON REMOVAL, A CRACK WAS NOTICED ON THE BACK OF THE COMBUSTION CASE NEXT TO THE FUEL NOZZLE ABOUT 3 INCHES LONG. ENGINE RETURNED TO AMOC FOR REPAIR. (X) 1G71 3U3 U H2SW E4CE 20000406001442000040600144EU 2000 4 6 20000406SH006 120000128G71700174078010 DRAIN VALVE AEROSPSA365 SA365N1 8680668EU TMECA ARRIELARRIEL1C 60030NE START DRAIN LEAKING B TI1RK NONE K FLUID LOSS ININSP/MAINT 1 EA0794MD 2008 6317 5069 VALVE LEAKING AROUND SPLIT LINE OF CASING. (X) 1G72 3U3 U H10EU E19EU 20000406001602000040600160NE 2000 4 6 20000406SH025 220000104G73214302022307 FUEL CONTROL BELL 222 222 1182122SW LYC LTS101LTS101650C 41560NE ENGINE FAILED B TI1RO OTHER O OTHER NRNOT REPORTED 1 SW05911MK 47515 FUEL CONTROL FAILED UPON INSTALLATION. REMOVED AND REPLACED. (X) 1G72 3U3 U H9SW E5NE 20000407000242000040700024CE 2000 4 7 20000405SH025 120000129G2810 FUEL TANK CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA LEFT CONTAMINATED D K NONE O OTHER ININSP/MAINT 1 SO13714VA7679 2107 15279456 L2000615 ENGINE FAILURE AFTER TAKEOFF. OUTSIDE AIR TEMPERATURE BELOW FREEZING FOR APPROX 2 WEEKS BEFORE FLIGHT. SNOW/SLEET IN AREA SEVERAL DAYS PRIOR TO FLIGHT. POSSIBLE CAUSE WAS WATER CONTAMINATED FUEL OR CARBURETOR ICING. DRAINED FUEL TANKS, WATER FOUND IN LT FUEL TANK. FLUSHED FUEL SYSTEM. CHANGED FUEL CAP TO HELP PREVENT RECURRENCE. (X) 1H71 3O3 ONT3A19 E223 20000411001362000041100136NE 2000 4 11 20000406SH057 220000209G7421CH34682 IGNITOR PWA 305 PW305 NE ENGINE FAILED B R14RK NONE O OTHER ININSP/MAINT 1 EA17 RECEIVED 3 EACH IGNITORS FROM SUPPLY. THE 4TH IGNITOR OPS CHECKED OK. BATCH NUMBER UNKNOWN. THE IGNITOR USED NORMALLY IS INSTALLED ON P&W 305 SERIES ENGINES. P/N 34682. (X) 4 F E35NE 20000411001402000041100140SO 2000 4 11 20000407SH001 220000221G8530654960A1 CYLINDER CESSNA182 182P 2075816CE CONT O470 O470U 17026SO NR 3 WORN D K NONE O OTHER ININSP/MAINT 1 GL23952CC765 18263638 470757 DURING A ROUTINE COMPRESSION CHECK, THE NR 3 CYLINDER WAS FOUND TO HAVE EXCESSIVE LEAKAGE 53/80 PAST THE PISTON RINGS. THE REMOVED CYLINDER WAS FOUND WORN OUT AT THE TOP OF THE CYLINDER. (X) 1H71 3O3 ONTTA13 E273 20000411001412000041100141SO 2000 4 11 20000407SH002 220000221G8520653877 LIFTER CESSNA182 182P 2075816CE CONT O470 O470U 17026SO NR 3 CYLINDER DAMAGED D K NONE O OTHER ININSP/MAINT 1 GL23952CC1230 18263638 470757 DURING THE REMOVAL OF THE NR 3 CYLINDER, THE EXHAUST VALVE LIFTER WAS INSPECTED AND FOUND TO HAVE CHIPS OF MATERIAL MISSING FROM THE CORNERS NEAR THE LOWER FACE. THE FACE OF THE LIFTER AND CAM LOBE WERE NOT FOUND TO HAVE ANY DEFECTS. (X) 1H71 3O3 ONTTA13 E273 20000411001432000041100143NM 2000 4 11 20000407SH011 120000219G2430 RCCB DOUG MD11 MD11 3023602NM GE CF6 CF680C2D1F 30025NE E/E BAY FAILED H K NONE O OTHER ININSP/MAINT 1 SW99150EV 48544 LAX/TPE - RIGHT EMER AC BUS'' OFF MESSAGE DURING FLIGHT. DIVERTED TO CTS WITH LIMITED INSTRUMENT. ''REAC SENS RELAY/INTFC'' CURRENT FAULT FOUND ON CFDS, BUT PERFORM EPU R-T-S TEST PASS AND CHECK ALL FUNCTIONAL NORMAL. FOR MAINTENANCE PREVENTION, REPLACED RCCB B1-138 IAW MM 24-25-0, AND PERFORM OPERATIONAL TEST, FUNCTION NORMAL. (X) 2L73 4F4 FRTA22WE E31N3 20000411001472000041100147CE 2000 4 11 20000407SH015 120000221G8120640321 SUPPORT BRACKET BEECH 58 58TC 1152746CE CONT O520 TSIO520L 17040SO RT ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 NM03227BR3304 TK31 2419489 DURING ANNUAL INSPECTION, FOUND RT ENGINE TURBO MOUNT BRACKET CRACKED UNDER AND NEAR END OF LOWER STIFFENER BEND. CRACK IS APPROXIMATELY ONE INCH LONG AND EXTENDING TOWARD BUT NOT TO LOWER LIGHTING HOLE. NO EVIDENCE OF CAUSE FOR CRACK. (X) 1L72 3O3 O A23CE E8CE 20000411001492000041100149 2000 4 11 20000407SH017 420000228G6122D20594 SHAFT MCAULY CESSNA404 404 2075901CE CONT O520 GTSIO520M 17032SO PROP GOVERNOR CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO176764D 801100 4040693C CRACK INDICATION. (X) 1L72 3O3 ORTA25CE E7CE 20000411001692000041100169EA 2000 4 11 20000407SH029 220000306G8500 ENGINE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA NOSE MALFUNCTIONED H O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION APAPPROACH 1 SW99445ER1503 17280662 L2785651A DURING FINAL APPROACH, THE ENGINE STUMBLED AND RAN ROUGH. (X) 1H71 3O3 ONT3A12 1E10 20000411001702000041100170EA 2000 4 11 20000407SH030 220000307G8500 ENGINE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA NOSE MALFUNCTIONED H A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 SW99476ER1402 17280638 L2778251A WHILE IN THE PATTERN ON A DUAL FLIGHT, THE ENGINE BEGAN TO RUN ROUGH ON THE CROSS-WIND LEG. IT CONTINUED DOING SO ON DOWN-WIND. AN EMERGENCY WAS DECLARED AND A SUCCESSFUL LANDING WAS MADE. (X) 1H71 3O3 ONT3A12 1E10 20000411001732000041100173SO 2000 4 11 20000407SH033 220000306G852011577L CRANKCASE CESSNA414 414 2075908CE CONT O520 TSIO520NB 17040SO ENGINE CRACKED E K NONE O OTHER ININSP/MAINT 1 CE09661CE 881 4140943 L514353 CRANKCASE CRACKED FROM BASE OF NR 4 CYLINDER ACROSS THE TOP OF THE BACKBONE TO THE BASE OF NR 3 CYLINDER. CAUSE UNKNOWN AT THIS TIME. (X) 1L72 3O3 ORTA7CE E8CE 20000413000152000041300015GL 2000 4 13 LS1R066572 220000320G7322 FCU BELL 206 206B3 1181506SW ALLSN 250C 250C20B 03013GL ENGINE DAMAGED E LS1RK NONE O OTHER ININSP/MAINT 1 EA139907K 2040 PART IS RUPTURED. HOLE IN SKID. 1G71 3U3 U H2SW E4CE 20000413003002000041300300GL 2000 4 13 2000ZZZX813 220000131G7261E23001832 NOZZLE ALLSN 250C 250C30 03013GL PT OIL MISDRILLED B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAT98100 HOLES IN UPPER PART OF NOZZLE DRILLED IMPROPERLY, DISCOVERED ON SHELF. PART WAS NEW AND SUBMITTER STATED THIS WAS DONE DURING MANUFACTURING. NOTE: SHOULD HAVE 4 HOLES. 3 U E1GL 20000413003022000041300302GL 2000 4 13 2000ZZZX815 220000131G7261E23001832 NOZZLE ALLSN 250C 250C30 03013GL PT OIL MISDRILLED B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAT95221 HOLES IN UPPER PART OF NOZZLE DRILLED IMPROPERLY, DISCOVERED ON SHELF. PART WAS NEW AND SUBMITTER STATED THIS WAS DONE DURING MANUFACTURING. NOTE: SHOULD HAVE 4 HOLES. 3 U E1GL 20000413003032000041300303GL 2000 4 13 2000ZZZX816 220000131G7261E23001832 NOZZLE ALLSN 250C 250C20 03013GL PT OIL MISDRILLED B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAT44377 HOLES IN UPPER PART OF NOZZLE DRILLED IMPROPERLY, DISCOVERED ON SHELF. PARTS WAS NEW AND SUBMITTER STATED THIS WAS DONE DURING MANUFACTURING. NOTE: SHOULD HAVE 4 HOLES. 3 U E4CE 20000413003042000041300304GL 2000 4 13 2000ZZZX817 220000131G7261E23001832 NOZZLE ALLSN 250C 250C30 03013GL PT OIL MISDRILLED B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAT44316 HOLES IN UPPER PART OF NOZZLE DRILLED IMPROPERLY, DISCOVERED ON SHELF. PART WAS NEW AND SUBMITTER STATED THIS WAS DONE DURING MANUFACTURING. NOTE: SHOULD HAVE 4 HOLES. 3 U E1GL 20000413003052000041300305GL 2000 4 13 2000ZZZX818 220000131G7261E23001832 NOZZLE ALLSN 250C 250C30 03013GL PT OIL MISDRILLED B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAT90149 HOLES IN UPPER PART OF NOZZLE DRILLED IMPROPERLY, DISCOVERED ON SHELF. PART WAS NEW AND SUBMITTER STATED THIS WAS DONE DURING MANUFACTURING. NOTE: SHOULD HAVE 4 HOLES. 3 U E1GL 20000413003062000041300306GL 2000 4 13 2000ZZZX819 220000131G7261E23001832 NOZZLE ALLSN 250C 250C30 03013GL PT OIL MISDRILLED B ALGRK NONE W INADEQUATE Q C ININSP/MAINT 1 SW03 CAT95422 HOLES IN UPPER PART OF NOZZLE DRILLED IMPROPERLY, DISCOVERED ON SHELF. PART WAS NEW AND SUBMITTER STATED THIS WAS DONE DURING MANUFACTURING. NOTE: SHOULD HAVE 4 HOLES. 3 U E1GL 20000413003122000041300312EA 2000 4 13 2000ZZZX827 220000308G741410382681H CAPACITOR BENDIX 66E21576 CESSNA182 R182 2072734CE LYC O540 O540L3C5 41532EA MAGNETO FAILED D K NONE O OTHER ININSP/MAINT 1 GL154689S35 F259910G R18200591 L2225140A NEW CAPACITOR INSTALLED TO SATISFY TCM CSB662A FAILED ON FIRST ENGINE RUN AFTER INSTALLATION. DATE CODE ON FAILED CAPACITOR IS 00-08. FAILURE WAS INTERMITTENT DURING 15 MINUTE ENGINE RUN-UP. 1H71 3O3 ORT3A13 E295 20000413003152000041300315SO 2000 4 13 2000ZZZX831 220000226G7414M3050 IMPULSE COUPLINGSLICK 6310 CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO MAGNETO FAILED H K NONE O OTHER ININSP/MAINT 1 SO15123TM 91120142 U20601768 247629R THE IMPULSE COUPLING ENGAGES ONLY 1 OUT OF 5 TIMES WHEN PROPELLER IS TURNED BY HAND. THE SPRING WHICH HOLDS THE PAWL OUT TO ENGAGE IMPULSE COUPLING HAS NOT BROKEN BUT HAS TOTALY LOST ITS SPRING EFFECT. 1H71 3O3 O A4CE E5CE 20000413003242000041300324CE 2000 4 13 2000ZZZX843 120000214G53200512128 BRACKET CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO BS 65.33 BROKEN H K NONE O OTHER ININSP/MAINT 1 NM114640E9884 18503824 293336R RIGHT FLAP RETRACTED AFTER PILOT SELECTED FIRST NOTCH OF FLAPS. FOUND INBOARD MOUNTING EARS BROKEN AWAY FROM PULLEY BRACKET LOCATED JUST AFT OF FLAP HANDLE. SUBMITTER STATED THIS IS THIRD BRACKET REPLACED IN FLEET OF THREE A185F'S. 1H71 3O3 O 3A24 E5CE 20000413004072000041300407GL 2000 4 13 20000412SH008 120000210G2421ALY8402 WIRE BLANCA17 1730A 1220433GL CONT O520 IO520K 17032SO ALTERNATOR ARCED G A UNSCHED LANDING O OTHER CRCRUISE 1 WP178843V 30367 209105K71 OPERATOR REPORTED DISCHARGE FROM ALTERNATOR IN CRUISE FLIGHT. MASTER SWITCH WAS TURNED OFF. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE DISCOVERED ONE BRUSH WIRE BROKEN AND THE RETAINER SPRING WELDED TO THE HOLDER. (X) 1L71 3O3 O A18CE E5CE 20000413004102000041300410WP 2000 4 13 20000412SH011 220000309G725030723515 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 GL19 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE ON FORWARD SIDE IN WEB AREA AND AFT SIDE IN POST FIR TREE AREA. REF: LOT NUMBER 00P040. (X) 4 F E6WE 20000413004112000041300411WP 2000 4 13 20000412SH012 220000309G723030723163 DISK GARRTTTFE731TFE731* 01518WP HP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE ON FORWARD SIDE IN POST FIR TREE AREA. REF: LOT NUMBER 99P243. (X) 4 F E6WE 20000413004122000041300412WP 2000 4 13 20000412SH013 220000316G725030747522 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST FIR TREE AREA ON BOTH FORWARD AND AFT SIDES. REF: LOT NUMBER 99P278 4 F E6WE 20000413004132000041300413WP 2000 4 13 20000412SH014 220000309G725030723515 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE ON FORWARD SIDE IN POST FIR TREE AREA. REF: LOT NUMBER 99P341. (X) 4 F E6WE 20000413004142000041300414WP 2000 4 13 20000412SH015 220000310G725030723515 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH GRIND MARKS THROUGHOUT FIR TREE AREA. REF: LOT NUMBER: 00P040. (X) 4 F E6WE 20000413004192000041300419GL 2000 4 13 20000412SH019 220000128G74206870855 IGNITION LEAD HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE CHAFED B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R 1151D CAE832750 DURING POST-FLIGHT, IGNITION LEAD WAS FOUND CHAFING ON THE LOWER B-NUT OF THE PC AIR REFERENCE LINE ON THE GOVERNOR. FURTHER INSPECTION REVEALED THE ADEL CLAMPS FOR THE LEAD AND LINE, AT THAT POINT, WERE MISSING. REPLACED MISSING CLAMPS. (X) 1G71 3U3 U H3WE E4CE 20000413004292000041300429GL 2000 4 13 20000412SH021 220000104G7310AN8378D FITTING HUGHES369 369D 4470706WP ALLSN 250C 250C* GL FUEL SYSTEM LOOSE B EOORK NONE O OTHER ININSP/MAINT 1 AL035074R 1151D DURING INSPECTION, DISCOVERED THE FIREWALL FUEL FITTING (BULKHEAD FITTING) WAS LOOSE IN THE FIREWALL. RE-TORQUED JAM NUT. (X) 1G71 3U3 U H3WE E4CE 20000413004872000041300487WP 2000 4 13 20000412SH028 120000307G7720 PROBE HUGHES369 369HS 4470728WP ALLSN 250C 250C20 03013GL ENGINE DAMAGED B H8ORO OTHER O OTHER NRNOT REPORTED 1 NM079094F1000 1110352S CEA82310 THE NYLON INSERT IN THE TEMPERATURE PROBE LET GO RESULTING IN FLUCTUATION AND DROPPING OIL PRESSURE AND A LOSS OF OIL. THE ENGINE HAD TO BE TORN DOWN FOR INSPECTION. MAIN DAMAGE SEEMS TO BE THE ENGINE''S NR 8 BEARING WHICH WAS DESTROYED. (X) 1G71 3U3 U H3WE E4CE 20000413004892000041300489NE 2000 4 13 20000412SH030 220000320G731030718321 MANIFOLD ISRAEL1124 1124 4500102EU GARRTTTFE731TFE73131G 29003NE FUEL SYSTEM LEAKING H K NONE K FLUID LOSS ININSP/MAINT 1 SW99727AT6382 284 P76205 DURING ROUTINE 300-HR ENG INSP, FUEL DISCOVERED PUDDLED INSIDE THE LEFT ENGINE LOWER COWLING. A LEAK CHECK CONFIRMED FUEL LEAKING FROM BOTTOM RIB DUCT WHERE THE PRIMARY AND SECONDARY FUEL MANIFOLD LINES ENTER THE 6 O''CLOCK STRUT. LEAK WAS PINPOINTED TO A CRACKED INNER FUEL MANIFOLD FITTING INSIDE STRUT. INNER MANIFOLD HAD CRACKED AT SECONDARY MANIFOLD FITTING WHERE IT IS BRAZED ONTO INNER MANIFOLD. (X) 2M72 4F4 F A2SW E6WE 20000417001282000041700128EA 2000 4 17 20000414SH001 220000209G8550NR5 BEARING PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532EA ENGINE MAKING METAL B AJVRK NONE O OTHER ININSP/MAINT 1 GL119299P336 4636123 L984961A DURING AN ANNUAL INSPECTION, FOUND METAL SHAVINGS IN OIL SCREEN. REMOVED ENGINE AND SENT TO LYCOMING FOR REPAIRS. (X) 1L71 3O3 ORTA25SO E14EA 20000417001542000041700154EA 2000 4 17 20000414SH007 220000315G8520STD847 BOLT PIPER PA28 PA28180 7102808SO LYC O320 O320* 41508EA CRANKSHAFT MISSING D K NONE O OTHER ININSP/MAINT 1 SW998804J 282754 L864836A FOUND CRANKSHAFT DRIVE GEAR ATTACHING BOLT MISSING AFTER REMOVAL OF REAR HOUSING FOR OIL PUMP GEAR REPLACEMENT. REPLACED GEAR, DOWEL PILOT, BOLT AND LOCKPLATE. (X) 1L71 3O3 O 2A13 E274 20000417001632000041700163EA 2000 4 17 20000412SH027 220000318G7322LW10540 CARBURETOR PIPER PA32 PA32260 7103206SO LYC O540 O540E4B5 41532EA ENGINE SEPARATED D O OTHER O OTHER NRNOT REPORTED 1 SO336YB 1800 321179 L669940 CARBURETOR SEPARATED AT PARTING SURFACE CAUSING BOTTOM HALF OF CARBURETOR TO ALMOST FALL OFF. LOCKING TABS WERE LOCKED, BOLTS WERE LOOSE. SUBMITTER STATED THIS IS THE 3RD CARBURETOR TO HAVE THIS TYPE FAULT. (X) 1L71 3O3 O A3SO E295 20000417001652000041700165SO 2000 4 17 20000412SH039 120000223G792253E19600 VERNATHERM PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA OIL TEMP REGULATDAMAGED B FGQRA UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 SO01137JH 318252025 L247468A PILOTS REPORTED ENGINE NOT MAKING FULL POWER AND OIL PRESSURE LOW. MAINTENANCE FOUND A PIECE OF CLIP UNDER THE OIL PRESSURE RELIEF VALVE. THE RETAINING CLIP FOR THE VERNATHERM VALVE FOUND TO BE THE SOURCE. FOUR NEW VERNOTHERM VALVES INSTALLED. (X) 1L72 3O3 O A20SO E14EA 20000417001662000041700166CE 2000 4 17 20000412SH040 120000222G78101099500001 EXHAUST PIPE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ENGINE CRACKED B BQVRK NONE O OTHER ININSP/MAINT 1 EA01600FL282 LJ1540 CRACKED EXHAUST STACK. 2.75 INCH CRACK WAS FOUND AROUND CIRCUMFERENCE AT WELD ATTACH POINT OF NACELLE INLET DE-ICE TUBE. SUBMITTER STATED THIS IS THE 5TH OCCURRENCE OF SAME PROBLEM ON SAME AIRCRAFT. A RAYTHEON REP HAS BEEN CONTACTED AND A FUTURE SERVICE BULLETIN IS PENDING RELEASE. (X) 1L72 3T4 TRT3A20 E4EA 20000417001672000041700167EA 2000 4 17 20000414SH002 220000209G8550NR5 BEARING PIPER PA46 PA46350P SO LYC O540 TIO540A2A 41532EA ENGINE MAKING METAL B K NONE O OTHER ININSP/MAINT 1 GL11229MA215 4636129 L985961A DURING AN ANNUAL INSPECTION, FOUND METAL SHAVINGS IN OIL SCREEN. REMOVED ENGINE AND SENT TO LYCOMING FOR REPAIRS. (X) 1L71 3O3 ORTA25SO E14EA 20000417001802000041700180NE 2000 4 17 20000413SH014 220000125G73130283317500 INJECTOR BOLKMSBK117 BK117C1 5626025EU TMECA ARRIELARRIEL1 60030NE ENGINE CLOGGED B TI1RK NONE O OTHER ININSP/MAINT 1 SW05317MC 7505 INJECTOR CLOGGED. REMOVED AND REPLACED. (X) 1G72 3U3 UNCH13EU E19EU 20000417001812000041700181NE 2000 4 17 20000413SH015 220000125G73130283317500 INJECTOR BOLKMSBK117 BK117C1 5626025EU TMECA ARRIELARRIEL1 60030NE ENGINE CLOGGED B TI1RK NONE O OTHER ININSP/MAINT 1 SW05317MC 7505 INJECTOR CLOGGED. REMOVED AND REPLACED. (X) 1G72 3U3 UNCH13EU E19EU 20000417002332000041700233SW 2000 4 17 20000413SH036 120000106G6300222044006109A SHAFT BELL 230 230 1182149SW ALLSN 250C 250C30 03013GL MAIN ROTOR WILL NOT BALANCEB TI1RK NONE O OTHER ININSP/MAINT 1 SW054UV 1246 23019 ENGINE SIDE OF SHAFT WILL NOT BALANCE. REMOVED AND REPLACED. (X) 1G72 3U3 UNCH9SW E1GL 20000419002632000041900263EA 2000 4 19 20000413SH045 220000102G8520 SHAFT PIPER PA18 PA18150 7101828SO LYC O320 O320A2B 41508EA IDLER GEAR DAMAGED H K NONE O OTHER ININSP/MAINT 1 NM055986Z1591 188242 L4842427A 1,590.6 HRS SINCE FACTORY NEW ENGINE INSTALLED. CRANKSHAFT APPEARED TO BE BINDING WITH SPARK PLUGS REMOVED. METAL (STEEL & ALUM) IN SCREENS. UPON REMOVAL OF MAGNETOS, OBSERVED LT IDLER GEAR COCKING BEFORE IT TURNED, WHILE MOVING CRANKSHAFT FLANGE BACK AND FORTH APPROX 30 DEGREES. UPON REMOVAL OF ACCESSORY CASE, FOUND LT IDLER SHAFT LOOSE AT CRANKCASE ATTACH. DAMAGE NOTED TO IDLER SHAFT AND CRANKCASE BOSS, RT IDLER SHAFT ATTACH BOLT, LOWER BOLT FND FINGER TIGHT, UPPER, BOLT FND PROPERLY TORQUED. BOTH STILL SAFETY WIRED. ENGINE DISMANTLED FOR COMPLETE O/H. (X) 1H71 3O3 O 1A2 E274 20000419002722000041900272EA 2000 4 19 20000413SH054 220000228G8530LW12416 CYLINDER CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA NR 4 DAMAGED H A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 SW999621V832 17264401 L3469527A PILOT REPORTED ROUGH RUNNING ENGINE AND LOW RPM. MAINTENANCE FOUND NR 4 CYLINDER HAD EXHAUST VALVE STUCK OPEN, NR 4 CYLINDER PUSH ROD AND HOUSING WERE BENT WITH NO OIL LEAKAGE. THE PISTON WAS NOT DAMAGED AND NO METAL FOUND IN THE ENGINE OIL FILTER. (X) 1H71 3O3 ONT3A12 E274 20000419002792000041900279GL 2000 4 19 20000413SH055 320000328G6114B4426 SNAP RING CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO MCAULY2A34C C2A34C204 GL HUB SEPARATED D O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 WP03735HK 18265435 813259R 767951 INSTALLED OVERHAULED PROPELLER. FLIGHT TEST PERFORMED, ABOUT 20 MINUTES LATER, FELT SLIGHT VIBRATION. LANDED FOR CAUSE AND FOUND SNAP RING AND SHIMS OUT OF HUB ON BLADE SHANK. PROPELLER TSO: .4 HOUR. (X) 1H71 3O3 ONT3A13 E273 5 CP3EA 20010222001242001022200124GL 2001 2 22 CA000215012 220000207G72406878426 NOZZLE ALLSN 6898734 ALLSN 250C 250C20 03013GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1401 CAT31116P (CAN) THE 2ND STAGE NGV,FIRST STAGE BLADE PATH WAS FOUND CRACKED 50% AROUND THE CIRCUMFERENCE. THE BLADE PATH HAD BEEN REPLACED AND WAS JOINED AT THE SECOND NOZZLE BY A BRAZED BUT JOINT. THIS IS /WAS A DAR APPROVED REPAIR. SUSPECT NGV ARE REQUESTED TO BE REMOVED FROM OPERATIONS AS REQUESTED BYALERT NOTICE FROM ORENDA AEROTECH ALERT SERVICE NOTICE DATED 02/23/00.CORRECTIVE ACTIO N ADRESSING FAA AND CANADIAN OPERATORS UNDER REVIEW. 3 U E4CE 20000420001122000042000112NE 2000 4 20 20000413SH056 320000404G6111C60661 BLADE DORNERDO32 DO328100 2996000NM PWA 119 PW119B NE HARTZLHDE6C HDE6C3B NE PROPELLER CRACKED H K NONE O OTHER ININSP/MAINT 1 SW99 HL274 DURING SEARCH INSPECTION, 4 EACH C-6066-1 PRELOAD PLATES WERE FOUND CRACKED. (X) 2H72 4T4 TRTA45NM E20NE 6 CP34NE 20000420001132000042000113NE 2000 4 20 20000413SH057 320000405G6114A4959 BUSHING DORNERDO32 DO328100 2996000NM PWA 119 PW119B NE HARTZLHDE6C HDE6C3B NE HUB BROKEN H K NONE O OTHER ININSP/MAINT 1 SW99 HL274 DURING SEARCH INSPECTION, FOUND THE A-4659 VESPEL BUSHING WAS MISSING FROM THE HUB PITCH CHANGE ROD BORE. FRAGMENTS OF THE BUSHING WERE FOUND IN THE HUB ASSEMBLY. (X) 2H72 4T4 TRTA45NM E20NE 6 CP34NE 20000420001142000042000114NE 2000 4 20 20000413SH058 320000404G6111C60661 PLATE DORNERDO32 DO328100 2996000NM PWA 119 PW119B NE HARTZLHDE6C HDE6C3B NE PROPELLER BLADE CRACKED H K NONE O OTHER ININSP/MAINT 1 SW99426JS 2161 3038 HL221 DURING SEARCH INSPECTION, 4 EACH C-6066-1 PRELOAD PLATES WERE FOUND CRACKED. ONE EACH PRELOAD PLATE WAS CRACKED IN SUCH A MANNER THAT IT BROKE DURING INSPECTION. TIME SINCE LAST INSPECTION: 2,160:30 HOURS. (X) 2H72 4T4 TRTA45NM E20NE 6 CP34NE 20000420001172000042000117EA 2000 4 20 20000413SH060 220000329G732230766 FLOAT FACET CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA CARBURETOR STUCK D O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SW15757NJ 75027003 15279870 L167571 ENGINE LOST POWER. POSSIBLE CAUSE WAS LACK OF FUEL CAUSED BY STICKING FLOAT. REMOVED CARBURETOR AND DISASSEMBLED. COULD FIND NO CAUSE FOR FLOAT TO STICK. SUBMITTER SUGGESTED TO PREVENT RECURRENCE, USE NEW STYLE FLOAT AT OVERHAUL. (X) 1H71 3O3 ONT3A19 E223 20000425000362000042500036EA 2000 4 25 20000414SH004 220000321G7322A44PA FUEL BOWL PIPER PA28 PA28151 7102805SO LYC O320 O320E3D 41508EA CARBURETOR LOOSE B K NONE O OTHER ININSP/MAINT 1 EA2144542 287415662 WHEN ENGINE WAS UNCOWLED, FOUND CARBURETOR BOWL LOOSE. THE BOLTS HAD LOCK WASHERS WITH THE TABS BENT UP. THE BOWL GASKET WAS IN PLACE. THE PRECISION MANUAL CALLS FOR A TORQUE OF 35-45 INCH/POUNDS ON THESE BOLTS. SUBMITTER STATED UNABLE TO VERIFY THIS. (X) 1L71 3O3 O 2A13 E274 20000425000842000042500084EA 2000 4 25 20000413SH064 220000209G8500NR5 BEARING PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532EA ENGINE MAKING METAL B AJVRK NONE O OTHER ININSP/MAINT 1 GL11997MA337 4636126 L984061A DURING AN ANNUAL INSPECTION, FOUND METAL IN OIL SCREEN. REMOVED ENGINE AND SENT TO LYCOMING FOR REPAIRS. (X) 1L71 3O3 ORTA25SO E14EA 20000425001232000042500123EA 2000 4 25 20000417SH011 220000316G7314LW15472 PUMP PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA FUEL SYSTEM UNSERVICEABLE B DINRO OTHER O OTHER NRNOT REPORTED 1 EA138269E93 288116039 L1334539A NOTED THE FUEL PRESSURE WOULD DROP OFF AS ALTITUDE INCREASE, FROM 5 PSI AT GROUND LEVEL, TO ABOUT 1-1/2 PSI AT 10,000 FEET. TURNING ON BOOST PUMP WOULD RESTORE 5 PSI. INSTALLED ANOTHER NEW PUMP AND IT CURED THE PROBLEM. FAILED PUMP, SN 154723199. GOOD PUMP, SN 154720200. (X) 1L71 3O3 O 2A13 E274 20000425001342000042500134NE 2000 4 25 20000417SH012 220000214G8530 PUSHROD AIRTRCAT300 AT301 0390103SW PWA R1340 R1340AN1 52016NE ENGINE MISINSTALLED G LSVGK NONE W INADEQUATE Q C ININSP/MAINT 1 WP0923043 3010352 19074 ENGINE VALVE PUSH RODS AND ROCKER ARMS WERE REVERSED DURING INSTALLATION ON THE NR 5 CYLINDER. SINCE THE INTAKE ROD IS LONGER AND ENGINE HAS SOLID TAPPETS, THE PUSH ROD ON THE EXHAUST SIDE BENT, AND THE ROCKER ARM BROKE RESULTING IN ENGINE FAILURE. ENGINE OPERATED NORMALLY FOR AT LEAST SEVERAL HOURS BEFORE FAILURE LEADING TO SPECULATION THAT IT DID NOT FAIL UNTIL THE ROCKER ARM BROKE PREVENTING THE EXHAUST VALVE FROM OPENING. (X) 1L71 3R3 R A9SW 5E2 20000425001462000042500146SO 2000 4 25 20000417SH017 220000229G8550LW13094 GASKET LYC PIPER PA32 PA32R300 7103213SO LYC 0540 IO540K1G5D 41532SO ENGINE OIL FAILED B EKIRO OTHER KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 WP016925J4377 653 32R7680388 L2012548A ENGINE LOST OIL ON START-UP DUE TO EXCESSIVE OIL PRESSURE WHICH BENT PLATE ON OIL FILLER KIT CAUSING GASKET TO BLOW OUT. (X) 1L71 3O3 O A3SO 1E4 20000425001562000042500156EU 2000 4 25 20000413SH049 220000211G7320CASE504 REGULATOR GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU RT ENGINE FAULTY B BTVRO OTHER J WARNING INDICATION DEDESCENT 1 GL237800 3445 1098 16135 ON DESCENT FROM HIGH ALTITUDE WITH AUTO-THROTTLES DISCONNECTED, THE RT ENGINE WOULD NOT DECREASE TO AN IDLE SETTING WITH THE THROTTLES PHYSICALLY IN THE HARD IDLE POSITION. ENGINE FINALLY RETARDED TO IDLE WHEN DESCENDING BELOW 10,000 FEET, SLOWING BELOW 260 KNOTS AND TURNING ON ENGINE AND WING ANTI-ICE. AIRCRAFT WAS BEING FLOWN ON A MAINTENANCE TEST FLIGHT DUE TO A DOUBLE ENGINE CHANGE. AIRCRAFT LANDED SAFELY. (X) 2L72 4F4 FRTA12EA E25NE 20000425002952000042500295CE 2000 4 25 20000424SH001 120000304G2820 FUEL LINE CESSNA185 185F 2072820CE CONT O550 IO550D 17042SO ENGINE FAILED D K NONE O OTHER ININSP/MAINT 1 SW07CGZTT2300 18503490 284122R RDM/RNO - EN ROUTE 55 MILES NORTH OF LMT, PILOT SENSED A STRONG FUEL ODOR. BRIEF TROUBLESHOOTING CONFIRMED A FUEL LINE FAILURE WITH SYMPTOMS. FUEL FLOW INDICATING ZERO. HIGHER THAN NORMAL EGT'S AND CHT'S (ACFT EQUIPPED WITH A 12-POINT ENG ANALYZER. STRONG AND DANGEROUS FUEL ODOR. PILOT CORRECTLY ASSESSED THE SITUATION AND LEFT POWER SETTING UNTOUCHED AND MIXTURE RICH. PILOT SET UP ON A HIGH APPROACH TO SOUTH RUNWAY AT LMT. ENGINE FAILED WHEN THROTTLE RETARDED. POST-FLIGHT INSPECTION REVEALED FUEL PRESSURE LINE FROM AFT OF ENGINE BAFFLE TO FIREWALL FAILED. LINE SEVERED ONE INCH AFT OF ENGINE BAFFLE. (X) 1H71 3O3 O 3A24 E3SO 20000425003022000042500302SW 2000 4 25 20000424SH019 120000308G62206887772D BEARING ALLSN BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL GEARBOX MAKING METAL D K NONE O OTHER ININSP/MAINT 1 NM1137488 38410 2188 823399 METAL FLAKES DETECTED ON MAGNETIC PICK-UP IN LOWER GEARBOX AND OIL PUMP MAGNETIC PICK-UP. DISASSEMBLED GEARBOX FOR INSPECTION. BEARING INNER AND OUTER RACES BOTH HAD AREAS THAT HAD FLAKED OFF METAL. (X) 1G71 3U3 U H2SW E4CE 20000505000762000050500076NE 2000 5 5 20000425SH031 220000201G73203026983 NUT CESSNA500 500CESSNA 2076602CE PWA JFTD12JFTD12A4A 52047NE FCU LOOSE H K NONE O OTHER ININSP/MAINT 1 CE0597DD 5000159 P76506 UPON BORESCOPE OF FUEL CONTROL SHUT OFF MECHANISM, NOTED CLEVIS LANYARD THROUGH-BOLT HAD BACKED OFF FROM CLEVIS ON END OF BOLT. (THROUGH-BOLT LOOSE). NUT HAD BACKED OFF. (X) 1L72 4F4 U A22CE E15EA 20000505000772000050500077NE 2000 5 5 20000425SH032 220000201G7320311707802 BOLT CESSNA500 500CESSNA 2076602CE PWA JT15 JT15D1 52060NE NR 4 BEARING LOOSE B K NONE O OTHER ININSP/MAINT 1 CE0597DD 5000159 P76506 UPON BORESCOPE OF FUEL CONTROL SHUT OFF MECHANISM, NOTED CLEVIS LANYARD THROUGH-BOLT HAD BACKED OFF FROM CLEVIS ON END OF BOLT. (THROUGH-BOLT LOOSE). NUT HAD BACKED OFF. (X) 1L72 4F4 F A22CE E1NE 20000505000782000050500078WP 2000 5 5 20000425SH033 220000322G725030723515 DISK GARRTTTFE731TFE731* 01518WP NR 1 LPT DAMAGED H K NONE O OTHER ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST FIR TREE AREA. (X) 4 F E6WE 20000505000792000050500079WP 2000 5 5 20000425SH034 220000322G7250300723515 DISK GARRTTTFE731TFE731* 01518WP NR 1 LPT DAMAGED H K NONE O OTHER ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST FIR TREE AREA. (X) 4 F E6WE 20000505000812000050500081CE 2000 5 5 20000425SH037 120000403G2820S14956 FUEL LINE CESSNA172 172N 2072434CE LYC O320 O320E2D 41508EA WING ROOT LEAKING H K NONE K FLUID LOSS ININSP/MAINT 1 SW995444J5430 17273798 RL96576T DURING REPLACEMENT OF CABIN INTERIOR, FOUND ONE EACH HOSE LEAKING. REPLACED ALL 6 HOSES IN FUEL VENT SYSTEM. CONDITION OF THESE HOSES THE SAME. AGE OF HOSES, 19 YEARS. (X) 1H71 3O3 ONT3A12 E274 20000505000832000050500083SO 2000 5 5 20000425SH039 220000403G8520629588 DRIVE GEAR PIPER PA28 PA28R201T 7102813SO CONT O360 TSIO360FB 17025SO CAMSHAFT BROKEN H A UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION NRNOT REPORTED 1 SW99474451618 28R7703379 237331R PILOT WAS IN-FLIGHT WHEN ENGINE FAILED. PILOT PERFORMED EMERGENCY PROCEDURES AND RETURNED TO AIRPORT. INSPECTION REVEALED THE GOVERNOR DRIVE GEAR HAD FAILED. GOVERNOR DRIVE GEAR ALSO DRIVES THE ENGINE DRIVEN FUEL PUMP WHICH, WHEN GEAR FAILED, TOOK THE ENGINE DRIVEN FUEL PUMP OFF-LINE. GOVERNOR DRIVE GEAR APPEARS TO HAVE BEEN CRACKED BEORE FAILURE. (X) 1L71 3O3 O 2A13 E9CE 20000505000932000050500093NE 2000 5 5 20000426SH005 220000330G7421CPW3039828 IGNITOR PWA JT15 JT15* 52060NE ENGINE DAMAGED B K NONE O OTHER ININSP/MAINT 1 GL03 DURING NORMAL MAINTENANCE, FOUND IGNITERS ON TWO SEPARATE AIRCRAFT (BOTH BATCH NR 1H99), CENTER ELECTRODES AND CERAMIC INSULATORS RECESSED APPROXIMATELY .75 INCH. UPON FURTHER INVESTIGATION, FOUND ELECTRODE ASSY WAS LOOSE AND FREE TO FLOAT WITHIN IGNITER. BOTH IGNITERS WERE INOPERABLE UPON REMOVAL. (X) 4 T E1NE 20000505000942000050500094NE 2000 5 5 20000426SH006 220000330G7421CPW3039828 IGNITOR PWA JT15 JT15* 52060NE ENGINE DAMAGED B K NONE O OTHER ININSP/MAINT 1 GL03 DURING NORMAL MAINTENANCE, FOUND IGNITERS ON TWO SEPARATE AIRCRAFT (BOTH BATCH NR 1H99), CENTER ELECTRODES AND CERAMIC INSULATORS RECESSED APPROXIMATELY .75 INCH. UPON FURTHER INVESTIGATION, FOUND ELECTRODE ASSY WAS LOOSE AND FREE TO FLOAT WITHIN IGNITER. BOTH IGNITERS WERE INOPERABLE UPON REMOVAL. (X) 4 T E1NE 20000508000662000050800066EA 2000 5 8 20000426SH025 220000328G741410382681 CAPACITOR BENDIX PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA MAGNETO FAILED D O OTHER O OTHER NRNOT REPORTED 1 EA0327329 317752150 NUMEROUS MAGNETO PROBLEMS. UNUSUAL DROP OFF, COMPLETELY DEAD MAG, AND NO HARD STARTING WERE ATTRIBUTED TO CAPACITORS IN THE DUAL MAG SYSTEM. AFTER THE FACT, TCM NOTIFIED AND STATED CAPACITORS CODED PRIOR TO 9946 WERE TO BE PULLED OUT OF SERVICE. REF TCM CSB NR 662A NEWER CODED CAPACITORS WERE INSTALLED AND MAG OPERATION HAS BEEN SATISFACTORY. (X) 1L72 3O3 O A20SO E14EA 20000508000712000050800071SO 2000 5 8 20000426SH032 220000324G73200850250189 CONDUIT CESSNA310 310C 2074210CE CONT O470 IO470D 17026SO ENGINE NACELLE FAILED D K NONE O OTHER ININSP/MAINT 1 NM113311H 35835 10512670R MIXTURE CONTROL CONDUIT IN ENGINE NACELLE BETWEEN MIXTURE CONTROL AND WING ROOT. CONDUIT THAT HOUSES CABLE FATIGUED AND BROKE CAUSING HOUSING TO MOVE AND MIXTURE TO REMAIN IN IDLE CUT-OFF WHICH CAUSED AIRCRAFT TO MAKE AN OFF-AIRPORT LANDING. THE ENGINE WAS NOT ABLE TO RE-START. (X) 1L72 3O3 O 3A10 3E1 20000508001072000050800107NE 2000 5 8 20000427SH032 220000313G72301703A38G02 SHAFT GE CF6 CF650* 30018NE ENGINE SPOOL DAMAGED B KRDYK NONE O OTHER ININSP/MAINT 1 EA31 530197 AFTER SHOP MAINTENANCE AND RETURN TO SERVICE, ENGINE SUSTAINED TRANSPORT DAMAGE TO FAN SECTION. THE ENGINE WAS RETURNED TO THE SHOP FOR REPAIR AND TEST RUN. DURING TEST RUN, OIL LEAKAGE OCCURRED FORCING A DISASSEMBLY OF THE ENGINE. AFTER DISASSEMBLY, NOTED THE 11/14 SPOOL SHAFT HAD A CRACK IN THE THREADED AREA WHERE THE AIR DUCT CONNECTS. THIS PART IS UNDER INVESTIGATION BY GE AND KLM. PART LIFE LIMIT: 10,000 HOURS. (X) 4 F E23EA 20000508001082000050800108SO 2000 5 8 20000427SH033 120000329G8011MHB4014 LEAD PRESTOLITE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA STARTER SEPARATED H K NONE O OTHER ININSP/MAINT 1 SW99274711071 317852018 L100268A RIGHT ENGINE FAILED TO START. INVESTIGATION REVEALED BOTH FIELD BRUSH LEADS WERE SEPARATED FROM THEIR RESPECTIVE BRUSHES. ONE BRUSH SHOWED NO INDICATION OF ARCING IN THE LEAD ATTACH HOLE IN THE BRUSH, WHILE THE OTHER DID. IT APPEARED ONE BRUSH LEAD SEPARATED AND PLACED THE ENTIRE START LOAD ON THE OTHER BRUSH CAUSING IT TO FAIL AT THE LEAD ATTACH POINT. THE STARTER''S OVERALL CONDITION WAS EXCELLENT. THE INSIDE WAS CLEAN AND BRIGHT. FAILURE APPARENTLY WAS DUE TO A POORLY CONSTRUCTED BRUSH/LEAD ASSY THAT LEAD TO PREMATURE FAILURE. WHEN THE OLD BRUSHES WERE COMPARED TO NEW BRUSHES, THE WEAR WAS NEGLIGIBLE. (X) 1L72 3O3 O A20SO E14EA 20000510001752000051000175WP 2000 5 10 20000503SH001 220000410G725030720705 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED H K NONE O OTHER ININSP/MAINT 1 GL19 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN CURVIC AREA AND POST FIR TREE AREA. LOT NR: 00P081. (X) 4 F E6WE 20000510001762000051000176WP 2000 5 10 20000503SH002 220000404G725030740962 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED H K NONE O OTHER ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST FIR TREE AREA. LOT NR: 99P350. (X) 4 F E6WE 20000510002282000051000228SO 2000 5 10 20000504SH005 120000331G8011MHB2399S ARMATURE ELECTROSYS PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA STARTER MISMANUFACTURED B UC2RK NONE W INADEQUATE Q C ININSP/MAINT 1 GL194149G839 8050831 2843191 L3632336A SUBMITTER STATED THEY HAVE FOUND 6 ARMATURES TO HAVE SEEMINGLY SOFT METAL ON THE DRIVE END SPLINES. THEY HAVE BEEN FOUND WITH THE SPLINES COMPLETELY GROUND OR STRIPPED AWAY LEAVING SHARDS OF STEEL IN THE GEAR CASING THAT CONTAMINATE THE ROLLER BEARINGS. THE BENDIX DRIVE GEAR IS NOT DAMAGED AND THE SHEAR PIN DOES NOT SHEAR. THE ARMATURE DRIVE END MAY NOT BE PROPERLY HEAT TREATED OR MAYBE THE SHEAR PIN IS TOO HARD. (X) 1L71 3O3 O 2A13 E286 20000510002422000051000242WP 2000 5 10 20000504SH019 220000309G732066001983 VALVE LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP FLOW CONTROL FAILED A BSYAO OTHER J WARNING INDICATION NRNOT REPORTED 1 GL0756JA 342 P74242C DEN - LOST PRESSURIZATION AFTER TAKEOFF OUT OF DENVER. FOUND FLOW CONTROL VALVE STUCK CLOSED. REMOVED AND REPLACED FLOW CONTROL VALVE. OPS CHECKED GOOD. (X) 2L72 4F4 F A10CE E6WE 20000510002832000051000283SO 2000 5 10 20000505SH005 220000405G8530538304P030 PUSHROD BEECH 55 95A55 1152704CE CONT O520 IO520CB 17032SO NR 6 CYLINDER BENT B K NONE O OTHER ININSP/MAINT 1 GL03 5115 190 244255R NR 6 EXHAUST PUSHROD BENT, BROKEN AND WORN HALFWAY THRU FROM RUBBING ON INSIDE OF THE PUSHROD HOUSING. NR 6 INTAKE PUSHROD BROKEN IN TWO. CYL HAS 190 HRS SINCE NEW AND BOTH VALVES MOVED FREELY IN GUIDES. NR 6 CONNECTING ROD FOUND VISIBLY BENT. INTAKE MANIFOLD DRAINS DID NOT DRAIN WHEN TESTED. POSSIBLE CAUSE, HYD LOCK, TCM SB96-11. NR 6 CYL ON THIS INSTALL (RT ENG OF BEECH BARON) IS FRONT INBD CYL. CANT OF ENG WOULD MAKE THIS A LOW SPOT IN INTAKE WHERE FUEL WOULD ACCUMULATE. WITH FUEL DRAIN INOP, IT WOULD NOT DRAIN OUT. RECOMMENDATION IS TO INCLUDE A TEST OF MANIFOLD DRAINS AT 100-HR ANNUAL INSPECTION. (X) 1L72 3O3 O 3A16 E5CE 20000510002852000051000285NE 2000 5 10 20000505SH007 220000404G7250304418301 BLADE PWA PT6 PT6A67D NE POWER TURBINE DAMAGED B MASRK NONE O OTHER ININSP/MAINT 1 SW07 PART WAS REMOVED FROM STOCK NEW. BLADE PLATFORM ON ONE BLADE WAS FOUND TO BE TAPERED AND VERY THIN. P&WC WAS NOTIFIED AND WERE ADVISED TO REMOVE BLADE FROM STOCK AND SHIP BAD BLADE BACK TO P&WC. PART WAS NEVER PUT INTO SERVICE. (X) 4 T E26NE 20000510002862000051000286WP 2000 5 10 20000505SH011 220000414G725030723163 DISK GARRTTTFE731TFE731* 01518WP HP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST FIR TREE AREA. LOT NR 00P054. (X) 4 F E6WE 20000510002872000051000287WP 2000 5 10 20000505SH012 220000412G725030723163 DISK GARRTTTFE731TFE731* 01518WP HP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH 3 DENTS IN POST FIR TREE AREA AFT SIDE. LOT NR 00P054. (X) 4 F E6WE 20000510002882000051000288WP 2000 5 10 20000505SH013 220000414G725030723163 DISK GARRTTTFE731TFE731* 01518WP HP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 NEW PART RECEIVED FRON HONEYWELL WITH DAMAGE IN POST FIR TREE AREA. LOT NR 00P054. (X) 4 F E6WE 20000516000352000051600035SO 2000 5 16 20000515SH021 120000310G325063300008 HORN PIPER PA28 PA28140 7102802SO LYC O320 O320E3D 41508EA NLG STEERING BROKEN C O OTHER O OTHER LDLANDING 1 SW997615F5644 287725090 L4656327A WHILE LANDING, EXPERIENCED EXTREME SHIMMY IN NOSE GEAR. NOSE GEAR STEERING HORN, PN 63300-008, FOUND BROKEN AT WELD. PART TT: 5,633.43 HRS. (X) 1L71 3O3 O 2A13 E274 20000516001302000051600130EA 2000 5 16 20000515SH007 220000515G732230800 FLOAT PRECISION HA6 LYC O360 O360F1A6 41514EA CARBURETOR DAMAGED B K NONE O OTHER ININSP/MAINT 1 SO09 75062805 100CC FUEL LEAKED INTO THE CHAMBER CLOSEST TO THE FULCRUM OF THE FLOAT ASSEMBLY DUE TO THE COMPROMISED INTEGRITY OF THE PLASTIC WELDED SEAM. (X) 3 O E286 20000516001312000051600131EA 2000 5 16 20000515SH008 220000425G8530LW14995 SPRING LYC O540 O540* 41532EA PUSH ROD BROKEN H K NONE O OTHER ININSP/MAINT 1 WP23 280 PUSH ROD RETAINER SPRING, PN LW-14995, BROKEN. PART INSTALLED FROM KIT MFG AFTER DATES LISTED IN LYC SB 519. (X) 3 O E295 20000516001422000051600142CE 2000 5 16 20000515SH013 120000407G5320085112132 BEAM CESSNA340 340A 2076405CE CONT O520 TSIO520NB 17040SO ENGINE CORRODED B BXSRK NONE O OTHER ININSP/MAINT 1 EA09269PC3679 340A0785 ENGINE BEAM FOUND EXFOLIATED/CRACKED ON THE TOP OUTBOARD ANGLE, JUST FORWARD AND INBOARD OF THE TAILPIPE. AD 2000-01-16 PAR(D) HAD BEEN C/W 64 HOURS AND 10 WEEKS PREVIOUSLY. (X) 1L72 3O3 O 3A25 E8CE 20000516001482000051600148EA 2000 5 16 20000515SH020 220000320G7322A105219 FLOAT HA6 AMRGENAA5 AA5B 3960105SO LYC O360 O360A4K 41514EA CARBURETOR DAMAGED B HO1RO OTHER O OTHER NRNOT REPORTED 1 EA214553C 225 AA5B1202 12504236A ENGINE WOULD NOT RUN UNLESS MIXTURE WAS LEANED ALMOST TO IDLE CUT OFF. IT WAS VERY RICH AND WOULD NOT RUN ABOVE 1,500 RPM. FOUND PLASTIC FLOAT TO BE FILLED WITH AVGAS TWO OF THREE CHAMBERS. FLOAT, P/N 30-800, CARBURETOR ASSY DATE, 9-97. (X) 1L71 3O3 O A16EA E286 20000518000082000051800008SO 2000 5 18 20000417SH018 220000317G8530639614 ROCKER BBAVIA7 7AC 2110102SW CONT A65 A658 17003SO NR 4 CYLINDER BROKEN D O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 SO1384729 500 7AC3445 PILOT REPORTED A REDUCTION IN POWER. AFTER INVESTIGATING, THE ROCKER ARM HAD BROKEN AT THE CENTER. THIS IS THE OLD TYPE WHICH DOES NOT HAVE AS MUCH MATERIAL AS THE NEW TYPE. (X) 1H71 3O3 O A759 E205 20000518000482000051800048CE 2000 5 18 20000424SH014 120000403G2820AN816620 FUEL LINE CESSNA421 421B 2076014CE CONT O520 GTSIO520* 17032SO RT FUEL CELL CORRODED D K NONE O OTHER ININSP/MAINT 1 NM05421SE 421B0393 DURING ANNUAL INSP, RT WING AUXILIARY TRANSFER PUMP PRESS SWITCH THAT OPERATES RT AUX PUMP ANNUNCIATOR LIGHT, WAS FOUND TO HAVE LIGHT FUEL STAINING AROUND BASE OF MICROSWITCH. AFTER REMOVING PRESS SWITCH ASSY (DUE TO CONDITION OF LEFT ONE), FOUND PIPE THREAD PORTION OF AN 816-6-20 VISIBLE, EXPOSING SEVERE CORROSION TO THE POINT OF ALMOST HALF DIAMETER BEING ERODED AWAY. (X) 1L72 3O3 O A7CE E7CE 20000518000532000051800053WP 2000 5 18 20000425SH035 220000322G725030725422 DISK GARRTTTFE731TFE731* 01518WP NR 2 LPT DAMAGED B K NONE O OTHER ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST FIR TREE AREA. (X) 4 F E6WE 20000518000602000051800060SO 2000 5 18 20000504SH025 220000309G8520520 CRANKSHAFT CESSNA340 340CESSNA 2076404CE CONT O520 TSIO520NB 17040SO ENGINE FAILED B VAIRO OTHER YJ ENGINE STOPPAGE WARNING INDICATION NRNOT REPORTED 1 SW1969520485 3400353 514988 ENGINE IN-FLIGHT FAILURE DUE TO BROKEN CRANKSHAFT. THIS CRANKSHAFT INSTALLED AS NEW ON MAY 4, 1999 TO REPLACE PREVIOUS NEW CRANKSHAFT AFFECTED BY AD 99-19-01. THIS S/N CRANCKSHAFT, SN B129901N, IS NOT IN AD. CRNAKSHAFT S/N''S IN AD GO THROUGH 12-1998. (X) 1L72 3O3 O 3A25 E8CE 20000523000052000052300005WP 2000 5 23 20000505SH014 220000410G723030720705 DISK GARRTTTFE731TFE731* 01518WP LP TURBINE DAMAGED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST FIR TREE AREA. LOT NR 99P189. (X) 4 F E6WE 20000613002912000061300291GL 2000 6 13 EY2R811K 320000428G6111S78FBM15 BLADE BEECH 23 A2324 1151226CE LYC O360 IO360A2B 41514EA MCAULY2D34C 2D34C9 GL THRD/SHNK AREA CRACKED B EY2RO OTHER O OTHER UKUNKNOWN 1 GL03 900526 BLADE CRACKED IN SHANK AND THREAD AREA. 1L71 3O3 O A1CE 1E10 5 CP7EA 20000613002922000061300292EA 2000 6 13 BJ3RE000001 220000427G8550AN470 RIVET PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532EA BAFFLE BROKEN G BJ3RK NONE O OTHER ININSP/MAINT 1 WP15117NJ118 4636168 LW13383 DURING AN OIL CHANGE, TWO RIVET HEADS (AN470) WERE FOUND IN THE OIL SUCTION SCREEN. THE ENGINE WAS REMOVED AND THE OIL SUMP PULLED OFF. TWO RIVET HEADS WERE MISSING FROM THE OIL SUMP BAFFLE. THESE ARE MS20470AD4-4 RIVETS. THE HOLES ON THE DRIVEN SIDE APPEARED TO BE COUNTERSUNK OR EXCESSIVELY DEBURRED, WHICH GAVE LITTLE BEARING SURFACE FOR THE RIVET HEAD. LYCOMING SB489B REFERS TO THESE RIVETS AND THEIR REPLACEMENT. 1L71 3O3 ORTA25SO E14EA 20000613002932000061300293EA 2000 6 13 BJ3RE000002 220000427G855061298 GEAR PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532EA TEETH WORN G BJ3RK NONE O OTHER ININSP/MAINT 1 WP15117NJ118 4636138 RL1041561A UPON REMOVAL OF THE OIL PUMP, TO CHECK FOR POSSIBLE DAMAGE DUE TO TWO RIVET HEADS FOUND IN THE OIL SUCTION SCREEN, IT WAS NOTED THAT THE ALUMINUM OIL PUMP GEAR HAD EXCESSIVE WEAR ON THE DRIVEN SIDE OF EACH TOOTH, AND CHIPS MISSING ON THE OUTER EDGE OF SEVERAL TEETH. IT ALMOST APPEARS THAT THE HARDNESS OF THE ALUMINUM GEAR WAS NOT CORRECT. THE STEEL DRIVING GEAR 61297 WAS ALSO DAMAGED, POSSIBLY DUE TO THE ALUMINUM GEAR. 1L71 3O3 ORTA25SO E14EA 20000613003522000061300352CE 2000 6 13 20000505SH018 120000329G7820075016128 MUFFLER CESSNA182 182G 2072716CE CONT O470 O470R 17026SO EXHAUST SEPARATED D O OTHER O OTHER NRNOT REPORTED 1 NE052354R 18255454 1301794R DURING ANNUAL INSPECTION, THE LT INTERNAL BAFFLE WAS FOUND TO HAVE SEPARATED AND WAS PARTIALLY BLOCKING THE EXHAUST PORT IN THE MUFFLER. UPON REMOVAL, THE RT EXHAUST STACK WAS FOUND BADLY DETERIORATED WITH SEVERAL PIECES MISSING. ONLY MINOR EXHAUST LEAK WAS NOTED FROM UNDER CLAMP. TIME IN SERVICE OF THESE PARTS IS NOT KNOWN. (X) 1H71 3O3 ONT3A13 E273 20000613004592000061300459SO 2000 6 13 20000609SH011 120000514G282037756003 SWITCH ALCO PIPER PA44 PA44180T 7104404SO LYC O360 TO360E1A6 41514EA INTERNAL OF SW SHORTED D K NONE O OTHER CRCRUISE 1 NE032913U1350 448107057 617173 LEFT ENGINE IN-FLIGHT ROUGH AND SMOKE. FOUND ELECTRICAL FUEL PRIMER SOLENOID ACTIVATED AND TIME MASTER SWITCH ON. PUSH TO PRIME SWITCH AT COCKPIT INSTRUMENT PANEL SHORTED TO A CONTINUOUS CLOSED CIRCUIT. REPLACED DEFECTIVE SWITCH WITH SAME PART NUMBER. PROBLEM REPAIRED. (X) 1L72 3O3 O A19SO E26EA 20000613004612000061300461NE 2000 6 13 20000609SH013 220000504G8530 CYLINDER HEAD DHAV DHC3 DHC3 2800202EA PWA R1340 R134059 52016NE NUMBER 7 CRACKED D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 NM01357AS 694 357 P5844 UPON CLIMB-OUT AFTER TAKEOFF, PILOT REPORTED ROUGH RUNNING ENGINE AND A LOSS OF POWER. PILOT STARTED TURNING BACK FOR AIRPORT AND DECIDED NOT ENOUGH POWER AND LANDED SAFELY IN A FARMER''S FIELD. DISCOVERED, NR 7 CYLINDER HEAD CRACKED FROM ONE SPARK PLUG HOLE ALL THE WAY TO THE OTHER. MAINTENANCE SUGGESTED ALONG WITH A VISUAL INSPECTION OF CYLINDER AND WHILE DOING A COMPRESSION CHECK, ALSO DO A SOAP AND WATER CHECK FOR CRACKS WHEN AIR IS PUT TO THE CYLINDER. (X) 1H71 3R3 R A815 5E2 20000614001192000061400119CE 2000 6 14 20000505SH019 120000329G7820075016131 MUFFLER CESSNA182 182G 2072716CE CONT O470 O470R 17026SO INTERNAL CONNECTDETERIORATED D K NONE O OTHER ININSP/MAINT 1 NE052354R 18255454 1301794R DURING ANNUAL INSPECTION, THE LT INTERNAL BAFFLE WAS FOUND TO HAVE SEPARATED AND WAS PARTIALLY BLOCKING THE EXHAUST PORT IN THE MUFFLER. UPON REMOVAL, THE RT EXHAUST STACK WAS FOUND BADLY DETERIORATED WITH SEVERAL PIECES MISSING. ONLY MINOR EXHAUST LEAK WASNOTED FROM UNDER CLAMP. TIME IN SERVICE OF THESE PARTS IS NOT KNOWN. (X) 1H71 3O3 ONT3A13 E273 20000614001202000061400120EA 2000 6 14 20000505SH025 220000407G8530AEL6510241 CYLINDER PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA HEAD CRACKED B MW2RK NONE O OTHER ININSP/MAINT 1 GL174381L878 288516016 L1341139A FOUND ZERO COMPRESSION ON ROUGH RUNNING ENGINE. FOUND CRACK FROM TOP SPARK PLUG AROUND OUTSIDE OF EXHAUST SEAT TO BOTTOM SPARK PLUG. (X) 1L71 3O3 O 2A13 E274 20000614001212000061400121EA 2000 6 14 20000505SH026 220000407G8530AEL6510241 CYLINDER PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA CYLINDER CRACKED B MW2RK NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 GL174381L878 288516016 L1341139A FOUND ZERO COMPRESSION ON ROUGH RUNNING ENGINE. FOUND CRACK FROM TOP SPARK PLUG AROUND OUTSIDE OF EXHAUST SEAT TO BOTTOM SPARK PLUG. (X) 1L71 3O3 O 2A13 E274 20000614001312000061400131EA 2000 6 14 20000505SH031 220000505G74144150 MAGNETO BBAVIA8 8KCAB 2110612CE LYC O320 AEIO320E1B 41508EA CONTAMINATED D K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 EA2350395 A9379 L567955A OWNER COMPLAINED OF ROUGH RUNNING/MISSING WHEN ENGINE HOT WHILE AT LOW POWER SETTINGS. RT MAG (4150) REMOVED. EXCESS PLAY IN DIST END BEARING (APPROX PLAY, .030 INCH) SN 9010274. LT MAG REMOVED (4151) SN 9010270. FOUND ENTIRE INTERIOR OF MAG CONTAMINATED BY GREASE FROM DRIVE END BEARING. THESE MAGS (4100 SERIES) ARE NOT REBUILDABLE AND SLICK SB RECOMMENDS REPLACEMENT AND TIS TO BE NOT IN EXCESS OF 800 HRS. ENGINE TT: 494 HRS SINCE NEW. 1H71 3O3 O A21CE 1E12 20000614001322000061400132EA 2000 6 14 20000505SH032 220000505G74144151 MAGNETO BBAVIA8 8KCAB 2110612CE LYC O320 AEIO320E1B 41508EA CONTAMINATED B K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 EA2350395 A9379 L567955A OWNER COMPLAINED OF ROUGH RUNNING/MISSING WHEN ENGINE HOT WHILE AT LOW POWER SETTINGS. RT MAG (4150) REMOVED. EXCESS PLAY IN DIST END BEARING (APPROX PLAY, .030 INCH) SN 9010274. LT MAG REMOVED (4151) SN 9010270. FOUND ENTIRE INTERIOR OF MAG CONTAMINATED BY GREASE FROM DRIVE END BEARING. THESE MAGS (4100 SERIES) ARE NOT REBUILDABLE AND SLICK SB RECOMMENDS REPLACEMENT AND TIS TO BE NOT IN EXCESS OF 800 HRS. ENGINE TT: 494 HRS SINCE NEW. (X) 1H71 3O3 O A21CE 1E12 20000614002022000061400202EA 2000 6 14 20000508SH005 220000324G8530LW15318 ROCKER BOSS LYC CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA FAILED D K NONE O OTHER ININSP/MAINT 1 SW1575958 85 17268069 RL81676 VALVE ROCKER RETAINING STUD, PN 31-16, SHEARED FLUSH WITH THE CYL HEAD SURFACE. THIS CAUSED PARTS TO MOVE AROUND AT RANDOM IN THE HEAD. IT IS SUSPECTED THESE LOOSE PARTS INTERFERRED WITH OPER OF INTAKE VALVE MECHANISM CAUSING THE INTAKE PUSH ROD TO BEND, CREATING AN OIL LEAK AT THE PUSH ROD HOUSING. SAME PROBLEM OCCURRED 65.7 HRS EARLIER WITH NR 1 CYL, 19.2 HRS SINCE O/H. INSP OF ENG REVEALED EXH ROTATOR CAP DISLODGED, LAYING IN BOTTOM OF VALVE COVER ON NR 2 CYL. SUSPECTED EXH VALVES MAY BE STICKING IN OPEN POSITION ALLOWING ROTATOR CAP TO FALL OUT OF POSITION. THE EXCESSIVE CLEARANCE THEN CREATED BETWEEN ROCKER ARM AND EXH VALVE STEM COULD POSSIBLY CAUSE ABNORMAL STRESS TO ROCKER ARM RETAINING STUD. 1H71 3O3 ONT3A12 E274 20000614002062000061400206EA 2000 6 14 20000508SH019 220000414G8540 GEAR BNORM BN2 BN2A26 1520226EU LYC O540 O540E4C5 41532EA CRANKSHAFT BROKEN D A UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 SO21678TA6418 2106 77 L1395540 ON CRUISE FLIGHT, LEFT ENGINE QUIT. PILOT LANDED, INVESTIGATION REVEALED BROKEN CRANKSHAFT GEAR. ENGINE RETIRED FROM SERVICE AND AND OVERHAULED ENGINE INSTALLED ON AIRCRAFT. (X) 1H72 3O3 O A17EU E295 20000614002072000061400207SO 2000 6 14 20000508SH020 220000310G7421 SPARK PLUG CONT CESSNA207 207A 2073604CE CONT O520 IO520* 17032SO NR 2 CYLINDER FAILED A FMAAA UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 AL0175703 20700639 814764R PISTON TOP BEGAN TO DISINTEGRATE CAUSING SEVERAL SPARK PLUG FAILURES AND ENOUGH POWER LOSS TO CAUSE A FORCED LANDING. (X) 1H71 3O3 O A16CE E5CE 20000614003002000061400300GL 2000 6 14 20000607SH004 220000324G7322 FUEL CONTROL AMTR KR2 KR2 GL AMTRVWVW VW2200 99999GL FAILED G A UNSCHED LANDING O OTHER CRCRUISE 1 WP0773BP 3634 FAILURE OF MAIN MIXTURE ADJUSTMENT NEEDLE LOCKING DEVICE DURING FLIGHT CAUSING MIXTURE TO GO RICH DRAMATICALLY INCREASING FUEL CONSUMPTION WHICH LED TO FUEL STARVATION AND A FORCED LANDING. (X) 1L71 3O3 O EXPA1L71EXP3O 20000614003022000061400302 2000 6 14 20000613SH008 420000525G6122B41832 FLYWEIGHT PIPER PA32 PA32300 7103212SO LYC O540 IO540K1G5 41532EA CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO172947E E103U 327940222 RELEVANT INDICATION OF CRACK IN FLYWEIGHT ASSY. 1L71 3O3 O A3SO 1E4 20000614003062000061400306WP 2000 6 14 20000613SH021 220000601G725030747522 DISK GARRTTTFE731TFE731* 01518WP POST FIR TREE OUT OF TOLERANCEH K NONE O OTHER ININSP/MAINT 1 SW99 NEW PART RECEIVED FROM HONEYWELL WITH DAMAGE IN POST FIR TREE AREA. NICK MORE THAN .001 INCH IN DEPTH ON FORWARD SIDE. LOT NUMBER 00P0130. (X) 4 F E6WE 20000614003072000061400307 2000 6 14 20000613SH023 420000525G6122B41832 FLYWEIGHT HARTZL PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO17 A3858T RELEVANT CRACK INDICATION AT BASE OF FLYWEIGHT. (X) 1L72 3O3 O 1A10 1E4 20000614003082000061400308SO 2000 6 14 20000613SH024 120000509G241075536 BUSHING LYC PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA FAILED B PAIRK NONE K FLUID LOSS CRCRUISE 1 SO0561CG 31P30 L47262 PILOT EXPERIENCED ALTERNATOR FAILURE ON LT ENGINE IN-FLIGHT. UPON INSPECTION AFTER LANDING, FOUND LT SIDE OF AIRCRAFT COVER IN OIL AND LT ALTERNATOR LYING INSIDE OF COWLING. SUSPECT FAILURE OF GOVERNOR ADAPTER ASSY. BUSHING, PN 75539, CAUSED MIS-ALIGNMENT OF ALT DRIVESHAFT WHICH CAUSED COUPLING, PN LW-14464, TO FAIL IN SUCH A MANNER THAT CAUSED ALTERNATOR ADAPTER ASSY, PN LW-10259, TO FAIL. (X) 1L72 3O3 O A8EA E19EA 20000614003092000061400309CE 2000 6 14 20000613SH025 120000525G7810NH10010910 COUPLING CESSNA414 414 2075908CE CONT O520 TSIO520NB 17040SO CRACKED D K NONE O OTHER ININSP/MAINT 1 SW014243C100 4140539 ***TONY, LAST SENTENCE?????***WASTEGATE ELBOW COUPLING INSTALLED ON RAM SERIES VII C-340 AND 414, IAW STC SA4331SW. FOUND CRACKED AND REPLACED EACH 50 - 100 HOURS FOR 150 HOURS. (X) 1L72 3O3 ORTA7CE E8CE 20000616003272000061600327EA 2000 6 16 20000505SH027 220000407G8530AEL6510212 CYLINDER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA EXHAUST VALVE BROKEN B MW2RK NONE O OTHER APAPPROACH 1 GL174350G586 288490058 L2749236A EXHAUST VALVE BROKE ON FINAL APPROACH. (X) 1L71 3O3 O 2A13 E286 20000616003362000061600336GL 2000 6 16 EY2R54036 320000503G611157D04952 FORK HARTZL BEECH 200 200BEECH 1152920CE PWA PT6 PT6* 52043EA HARTZLHCD4N3HCD4N3A GL FORWARDEARS CRACKED B EY2RK NONE O OTHER ININSP/MAINT 1 GL03 FY561 FY561 FORWARD EARS OF PITCH CHANGE FOR CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 EACH CRACKS. 1L72 4T3 T A24CE E2NE 5 CSTC 20000616004082000061600408CE 2000 6 16 20000613SH001 120000511G782070120 MUFFLER BEECH 35 V35B 1151548CE CONT O550 IO550B SO LEFT BULGED B MOGRK NONE O OTHER ININSP/MAINT 1 GL2524161 D10103 297079R DURING A BASIC VISUAL INSPECTION OF THE ENGINE, THE LEFT MUFFLER WAS NOTED AS HAVING SEVERAL BULGES. UPON REMOVAL OF THE MUFFLER AND HEAT SHIELD, THE MUFFLER HAD SEVERAL LARGE HOLES THAT WERE NOT VISIBLE UNTIL THE HEAT SHIELD WAS REMOVED. CAUSE UNKNOWN. SUBMITTER SUGGESTED HEAT SHIELD BE REMOVED FOR CLOSER INSPECTION OF MUFFLER DURING 100 HOUR/ANNUAL INSPECTIONS. (X) 1L71 3O3 O 3A15 E3SO 20000616004142000061600414GL 2000 6 16 EY2R56491 320000605G6114C4716C58 HUB MCAULY D2A34C58 CESSNA185 185 2072802CE CONT O520 IO520* 17032SO MCAULY2A34C D2A34C58 GL NR 2 BLADE SOCKECRACKED B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 788328 788328 CRACK FOUND IN NR 2 BLADE SOCKET BETWEEN 6-7 O''''CLOCK, ENGINE SIDE. (X) 1H71 3O3 ONC3A24 E5CE 5 CP3EA 20000616004152000061600415GL 2000 6 16 EY2R56491A 320000605G6111S90AT4 BLADE MCAULY D2A34C58O CESSNA185 185 2072802CE CONT O520 IO520* 17032SO MCAULY2A34C D2A34C58 GL THREAD AREA CRACKED B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 788328 788328 TWO EACH BLADES CRACKED IN THREAD AREA. (X) 1H71 3O3 ONC3A24 E5CE 5 CP3EA 20000616004162000061600416GL 2000 6 16 EY2R56491B 320000605G6111C4902 NUT MCAULY D2A34C58O CESSNA185 185 2072802CE CONT O520 IO520* 17032SO MCAULY2A34C D2A34C58 GL THREAD AREA CRACKED B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 788328 788328 BLADE NUT CRACKED IN THREAD AREA. (X) 1H71 3O3 ONC3A24 E5CE 5 CP3EA 20000616004172000061600417GL 2000 6 16 EY2R56492 320000605G6111C4902 NUT MCAULY D2A34C58O CESSNA185 185 2072802CE CONT O520 IO520* 17032SO MCAULY2A34C D2A34C58 GL THREAD AREA CRACKED B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 7910189 7910189 BLADE NUT CRACKED IN THREAD AREA. (X) 1H71 3O3 ONC3A24 E5CE 5 CP3EA 20000616004182000061600418GL 2000 6 16 EY2R56492A 320000605G6114C4716C58 HUB MCAULY D2A34C58O CESSNA185 185 2072802CE CONT O520 IO520* 17032SO MCAULY2A34C D2A34C58 GL MOUNTING SURFACECORRODED B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 7910189 7910189 HUB CORRODED ON MOUNTING SURFACE BEYOND LIMITS. (X) 1H71 3O3 ONC3A24 E5CE 5 CP3EA 20000616004192000061600419CE 2000 6 16 EY2R56492B 120000605G6100C3054 FERRULE MCAULY D2A34C58O CESSNA185 185 2072802CE CONT O520 IO520* 17032SO MCAULY2A34C D2A34C58 GL THREADED AREA CORRODED B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 7910189 7910189 FERRULE CORRODED IN THREADED AREA. 1H71 3O3 ONC3A24 E5CE 5 CP3EA 20000616004422000061600442CE 2000 6 16 EY2R56492C 120000605G6100C5262 CYLINDER MCAULY D2A34C58O CESSNA185 185 2072802CE CONT O520 IO520* 17032SO MCAULY2A34C D2A34C58 GL INNER SURFACE CORRODED B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 7910189 7910189 CYLINDER CORRODED ON INNER SURFACE BEYOND LIMITS. 1H71 3O3 ONC3A24 E5CE 5 CP3EA 20000616004482000061600448SW 2000 6 16 20000510SH015 120000415G5320407030801105 BEARING BELL BELL 407 407 SW ALLSN 250C 250C47B GL TAIL ROTOR G/B FRETTED C K NONE O OTHER ININSP/MAINT 1 SO11407DD634 AFS979 53328 CAE847380 WHILE PERFORMING SCHEDULED LUBRICATION OF TAIL ROTOR HANGER BEARINGS, MECHANIC NOTICED METALLIC FRETTING DUST AROUND TAIL ROTOR GEARBOX MOUNTING AREA. FURTHER INVESTIGATION REVEALED MOVEMENT BETWEEN TAIL ROTOR GEARBOX AND TAILBOOM. THIS MALFUNCTION IS UNDER INVESTIGATION BY MANUFACTURER AND SUBMITTER IS AWAITING RESULTS OF THIS INVESTIGATION. (X) 1G71 3U3 UO H2SW E1GL 20000619002772000061900277EA 2000 6 19 20000615SH010 220000412G73203027974 TUBE BEECH 90 C90 1152913CE PWA PT6 PT6A21 52043EA FCU BROKEN E AOBAO OTHER O OTHER TOTAKEOFF 1 EA11369GA7845 5 LJ934 PCE24685 WHILE APPLYING POWER FOR TAKEOFF, THE LEFT ENGINE WOULD NOT RESPOND. INSPECTED AND FOUND THE PY LINE CRACKED AT THE FUEL CONTROL UNIT. (X) 1L72 3T4 T 3A20 E4EA 20000620000102000062000010 2000 6 20 20000508SH023 420000404G6122B41832 FLYWEIGHT HARTZL PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO17100RN D2691T 318152080 RELEVENT CRACK INDICATION ON FLYWEIGHT BASE. (X) 1L72 3O3 O A20SO E14EA 20000620000112000062000011 2000 6 20 20000508SH024 420000405G6122B20908 FLYWEIGHT MCAULY CESSNA402 402C 207590RCE CONT O520 IO520* 17032SO CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO17 860296 RELEVANT CRACK INDICATION ON BASE OF FLYWEIGHT DISC. (X) 1L72 3O3 O A7CE E5CE 20000620001252000062000125SO 2000 6 20 20000531SH022 220000504G8530536727 CYLINDER BEECH 35 E35 1151512CE CONT E225 E2258 17015SO BARREL SEPARATED B K2YRK NONE O OTHER ININSP/MAINT 1 EA217382B1548 752 D3845 35681D98R AT ANNUAL INSPECTION, FOUND SIGNS OF SEEPAGE AT BARREL (INDICATIONS OF BARREL SEPARATING FROM HEAD) IN NR 4, NR 5, NR 6 CYLINDERS. POSSIBLE CAUSE IS AGE ON CYLINDERS AND TIME IN SERVICE. (X) 1L71 3O3 O A777 E267 20000620001262000062000126GL 2000 6 20 20000531SH023 320000509G6110C5270 BEARING MCAULY CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL GROOVED B LU4RK NONE O OTHER ININSP/MAINT 1 SO17CTEXT 369 931446 RELEVANT INDICATION IN BEARING GROOVE. (X) 1L72 3O3 O A7CE E8CE 5 CP22EA 20000620001352000062000135SO 2000 6 20 20000601SH006 120000509G241075536 BUSHING LYC PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA FAILED B PAIRO OTHER O OTHER CRCRUISE 1 SO0561CG 31P30 L47262 PILOT EXPERIENCED ALTERNATOR FAILURE ON LT ENGINE IN-FLIGHT. UPON INSPECTION AFTER LANDING, FOUND LT SIDE OF AIRCRAFT COVERED IN OIL AND LT ALTERNATOR LYING INSIDE OF COWLING. SUBMITTER SUSPECTED FAILURE OF GENERATOR ADAPTER ASSY BUSHING PN 75539 CAUSED MISALIGNMENT OF ALT DRIVESHAFT WHICH CAUSED COUPLING PN LW-14464 TO FAIL IN SUCH A MANNER THAT CAUSED ALTERNATOR ADAPTER ASSY PN LW-10259 TO FAIL. (X) 1L72 3O3 O A8EA E19EA 20000620001392000062000139GL 2000 6 20 20000601SH017 220000503G7250FABT8851 TURBINE GE CF6 CF6* 30020GL STACKING BOLTS MISINSTALLED B SK33K NONE O OTHER ININSP/MAINT 1 GL03 3124 327 CF6-6 ENGINE 451-327 WAS PULLED FOR OVERHAUL AT GE. FOUND TO BE MISSING THE LOCKWIRES FROM THE STACKING BOLTS TO THE TURBINE IN EACH OF 8 POSITIONS. SUBMITTER STATED FURTHER INVESTIGATION FOUND STACKING CALCULATION ERROR ON THIS AND 26 OTHER CF6-6 TMF ASSEMBLIES. (X) 4 F E23EA 20000620001402000062000140CE 2000 6 20 20000601SH018 120000425G2810993800007 FUEL CELL BEECH 99 99A 1154003CE PWA PT6 PT6A27 52043EA RT NACELLE PUNCTURED A TIMAK NONE K FLUID LOSS ININSP/MAINT 1 NM0799GH 33344 U112 RIGHT NACELLE FUEL CELL FOUND LEAKING FUEL. INSPECTION REVEALED A PUNCTURE IN THE SIDE OF THE CELL CAUSED BY A TANK HANGER THAT HAD BECOME DISLODGED FROM ITS ORIGINAL LOCATION. THE HANGER PROTRUDING CLIP HAD REPOSITIONED TOWARD THE TANK LINER CAUSING THE TANK TO BE PUNCTURED AS THE FUEL LEVEL INCREASED. DURING INITIAL INSTALL OF FUEL CELL, SUBMITTER STATED CARE SHOULD BE TAKEN TO VERIFY PROPER SEATING OF THE CELL HANGERS TO PREVENT THIS FROM RECURRING. (CELL DATED 1979 AND OTHERWISE APPEARED IN GOOD CONDITION). (X) 1L72 3T4 T A14CE E4EA 20000620001412000062000141EA 2000 6 20 20000601SH019 220000518G7414M3333 IMPULSE COUPLINGSLICK PIPER PA32 PA32300 7103212SO LYC O540 IO540K1G5 41532EA PAWL-PLATE RIVETDESTROYED B JM2RO OTHER O OTHER ININSP/MAINT 1 EA13323CA309 96051744 327740026 L1741148A PAWL-PLATE RIVETS BROKE. IMPULSE HOUSING PAWL STEPS BROKEN OFF. IMPULSE COUPLING FAILED AT START-UP. CAUSE UNKNOWN. (X) 1L71 3O3 O A3SO 1E4 20000620001562000062000156SO 2000 6 20 20000602SH005 220000508G8520649134 CRANKSHAFT CESSNA180 180 2072602CE CONT O470 O470K 17026SO ENGINE DAMAGED B CY4RK NONE O OTHER ININSP/MAINT 1 AL039028C1 31076 049406R PER TCM MSB 00-5, CRANKSHAFT WAS REJECTED BY TELEDYNE CONTINENTAL MOTORS. (X) 1H71 3O3 ONC5A6 E273 20000620002282000062000228EA 2000 6 20 20000615SH008 220000605G8530LW12892 PLUG PIPER PA23 PA23250 7102308SO LYC O540 O540C4B5 41532EA ROCKER SHAFT DETERIORATED D K NONE O OTHER ININSP/MAINT 1 GL1317WE 277854118 L1811048A FOUND IN BOTH ENGINES DURING ANNUAL WHILE PERFORMING LYC 400-HOUR ROCKER ARM INSP, SEVERAL OF THE ROCKER SHAFT THRUST BUTTONS WERE FOUND DETERIORATING. A COUPLE OF THEM WERE FOUND BROKEN OFF AND OUT OF THE ROCKER SHAFT. THE OIL SCREEN WAS FOUND TO CONTAIN SOME BITS OF PLASTIC. ALL THE THRUST BUTTONS WERE REMOVED AND SEVERAL OF THEM CRUMBLED WHEN SQUEEZED. ENGINES HAD JUST OVER 1,600 HRS SMOH IN 1982. A FEW HRS AFTER INSPECTION, ONE OF THE ENGINES DEVELOPED HIGH OIL PRESSURE PROBLEMS, POSSIBLY DUE TO PLUGGED OIL PASSAGES. ALL OF THE THRUST BUTTONS REPLACED AT INSP, BUT THERE STILL COULD BE PLASTIC BITS IN THE ENGINE WHICH COULD PLUG PASSAGES. (X) 1L72 3O3 O 1A10 E295 20000620002292000062000229EA 2000 6 20 20000615SH009 220000605G8530LW12892 PLUG PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA ROCKER SHAFT DETERIORATED D K NONE O OTHER ININSP/MAINT 1 GL1317WE 277854118 L1815148A FOUND IN BOTH ENGINES DURING ANNUAL WHILE PERFORMING LYC 400-HOUR ROCKER ARM INSP, SEVERAL OF THE ROCKER SHAFT THRUST BUTTONS WERE FOUND DETERIORATING. A COUPLE OF THEM WERE FOUND BROKEN OFF AND OUT OF THE ROCKER SHAFT. THE OIL SCREEN WAS FOUND TO CONTAIN SOME BITS OF PLASTIC. ALL THE THRUST BUTTONS WERE REMOVED AND SEVERAL OF THEM CRUMBLED WHEN SQUEEZED. ENGINES HAD JUST OVER 1,600 HRS SMOH IN 1982. A FEW HRS AFTER INSPECTION, ONE OF THE ENGINES DEVELOPED HIGH OIL PRESSURE PROBLEMS, POSSIBLY DUE TO PLUGGED OIL PASSAGES. ALL OF THE THRUST BUTTONS REPLACED AT INSP, BUT THERE STILL COULD BE PLASTIC BITS IN THE ENGINE WHICH COULD PLUG PASSAGES. (X) 1L72 3O3 O 1A10 1E4 20000620002342000062000234EA 2000 6 20 20000619SH029 220000525G7300 ENGINE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA POWER LOSS A BSYAO OTHER R PARTIAL RPM/PWR LOSS TOTAKEOFF 1 GL0735453 318052006 L167861A GRR - RIGHT ENGINE WOULD NOT COME ABOVE 2,000 RPM''S ON TAKEOFF. MAINTENANCE TROUBLESHOT, NO PROBLEM FOUND. GROUND RUN CHECKED GOOD. (X) 1L72 3O3 O A20SO E14EA 20000620002372000062000237SO 2000 6 20 20000620SH003 220000525G7300 ENGINE CESSNA310 310R 2074245CE CONT O520 IO520MB 17032SO SURGES A BSYAO OTHER R PARTIAL RPM/PWR LOSS APAPPROACH 1 GL075215C 310R1515 277772R CMH - RIGHT ENGINE ON APPROACH STARTED SURGING BETWEEN 2,200 RPM AND 2,600 RPM. CHECKED ENGINE OUT COMPLETELY, COULD NOT DUPLICATE. OPS CHECKED GOOD. (X) 1L72 3O3 O 3A10 E5CE 20000620002392000062000239EA 2000 6 20 20000620SH005 220000505G73145006050 COUPLER PESCO BEECH 90 65A901 CE PWA PT6 PT6A20 52043EA CASE TO PUMP SHEARED D O OTHER Y ENGINE STOPPAGE CRCRUISE 1 SW997089Q 516 5489 LM77 21043 EXPERIENCED AN ENGINE FAILURE DURING CRUISE AT 4,500 FEET. AFTER SOME TROUBLESHOOTING ON THE GROUND, FOUND IT TO BE THE HIGH PRESSURE FUEL PUMP, PARTICULARLY THE DRIVE COUPLING. THE SPLINES WERE DAMAGED (SHEARED) ENOUGH THAT IT ALLOWED TOO MUCH PLAY AND THE PUMP QUIT PUMPING. THE POSSIBLE CAUSE COULD HAVE BEEN INSUFFICIENT LUBRICATION TO THE DRIVE COUPLING. THE PUMP ITSELF HAS NOT YET BEEN TORN ALL THE WAY DOWN TO SEE IF THERE WERE INTERNAL PROBLEMS THAT MAY HAVE CONTRIBUTED. (X) 1L72 3T3 T 3A20 E4EA 20000621000032000062100003SW 2000 6 21 20000508SH031 120000328G781040821089 EXHAUST PIPE LYC MOONEYM20 M20M 5870222SW LYC 0540 TIO540AF1B 41532EA CONNECTS CYL 2 CRACKED B FE6RO OTHER O OTHER CRCRUISE 1 NM11139WT45 270283 L1036461A PILOT REPORTED NEW CO2 INDICATOR TURNS BLACK EACH FLIGHT. FLT WITH DIGITAL CO2 INDICATING INSTRUMENT INDICATES 200 RPM. MAINT LOCATED 1.75 INCH CRACK AT BASE OF NR 2 CYL RISER, FLG MATING TO CYL NR 1 - 5. (LYC PN''S 40B19822 AND 40B19825) FOUND WARPED APPROX .020 INCH. EXH PIPE COUPLING FLG FOR CYL NR 4 (LYC PN 40B19824) FND DISTORTED WITH GASKET (PN 78084) JOINING IT TO CYL NR 6 BADLY DAMAGED, OUT OF PLACE. ALL CRACKED AND DISTORTED COMPONENTS REPLACED WITH FACTORY NEW. FLG MATING TO CYL 1- 5 ARE DRESSED ON A SURFACE PLATE. (X) 1L71 3O3 ORT2A3 E14EA 20000621000042000062100004SO 2000 6 21 PNSA000403 120000420G7330565583 FUEL LINE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA FUEL INDICATOR LEAKING E PNSAA UNSCHED LANDING K FLUID LOSS CRCRUISE 1 AL0315PR 318052011 DURING CRUISE, PILOT SMELLED FUEL. AFTER LOOKING AROUND THE COCKPIT, PILOT NOTICED A SMALL FUEL STAIN IN THE COPILOT''S CARPET. THE AIRCRAFT IMMEDIATELY RETURNED TO THE AIRPORT. REPLACED FUEL LINE TO FUEL FLOW INDICATOR. 1L72 3O3 O A20SO E14EA 20000621000082000062100008EA 2000 6 21 20000510SH003 220000407G7310MS21044N3 NUT CESSNA206 206H 2073301CE LYC O540 O540* 41532EA FUEL INJECTION DEFECTIVE E K NONE O OTHER ININSP/MAINT 1 AL057273Q191 20608045 DURING A 100-HOUR INSPECTION, THE FUEL INJECTION LINE CLAMPS WERE FOUND SECURED WITH FIBER LOCK NUTS, OF WHICH THE FIBER LOCK WAS MELTED FROM THE HEAT OF THE ENGINE DURING OPERATION. ALL NUTS WERE REPLACED WITH ALL-STEEL LOCK NUTS, P/N MS21045. (X) 1H71 3O3 ORTA4CE E295 20000621000102000062100010GL 2000 6 21 EY2R56679 320000510G611182PA6 BLADE MCAULY B2D34C208 CESSNA172 172 2072402CE LYC O360 O360A1A 41514EA MCAULY2D34C B2D34C208 GL TIP BROKEN B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 287 745149 745149 TIP OF NR 2 BLADE SNAPPED OFF 3.50 INCHES. 1H71 3O3 ONT3A12 E286 5 CP7EA 20000621000122000062100012CE 2000 6 21 20000510SH008 120000310G71209691001061 ENGINE BEECH 58 58 1152740CE CONT O520 IO520CB 17032SO UPPER CROSS-OVERCRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 EA2337SF 105252344 TH627 244230 DURING A SCHEDULED INSPECTION, A CRACK WAS DISCOVERED IN THE LEFT ENGINE MOUNT AT THE UPPER CROSSOVER TUBE NEAR THE WELD AT THE UPPER INBOARD ENGINE ATTACH POINT (CUSHION MOUNT). AD 91-15-20 A3 AND C HAD BEEN PREVIOUSLY C/W 2,344.4 HOURS AGO. THE MOUNT WAS REMOVED AND REPAIRED BY REPLACING THE DAMAGED TUBE. A RECORD CHECK SHOWS SUDDEN ENGINE STOPPAGE 1,160.8 HOURS PRIOR TO THIS DISCOVERY, AT WHICH TIME THE ENGINE WAS OVERHAULED AND THE MOUNT WAS INSPECTED FOR DAMAGE. IT IS BELIEVED THAT IN LIGHT OF THE PAST HISTORY, THE SUDDEN STOPPAGE FATIGUED THE MOUNT AT THIS POINT AND NORMAL ENGINE VIBRATION ALLOWED THE CRACK TO DEVELOP. (X) 1L72 3O3 O 3A16 E5CE 20000621000142000062100014EU 2000 6 21 20000510SH021 120000428G79300235237790 CHIP DETECTOR SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D NE ENGINE DEFECTIVE H O OTHER J WARNING INDICATION CRCRUISE 1 WP13451H 352 3231 9643 WHILE PILOT FLYING ON TOUR FLIGHT, NOTICED AN ENGINECHIP LIGHT ILLUMINATED. PILOT IMMEDIATELY MADE PRECAUTIONARY LANDING. INSPECTED AIRCRAFT AND FOUND THAT ENGINE CHIP PLUG HAD A DEFECT. CLEANED CHIP PLUGS AND C/W OPERATIONAL CHECK AND FUNCTIONALLY CHECKED GOOD. AIRCRAFT RETURNED TO SERVICE. (X) 1G71 3U3 U H9EU E19EU 20000621001622000062100162EA 2000 6 21 20000620SH015 220000530G72503013102 BLADE BEECH 99 B99 1154004CE PWA PT6 PT6A27 52043EA PT DISK MISSING B TIMAO OTHER E VIBRATION/BUFFET TOTAKEOFF 1 NM1199TH U155 PCE40840100 ON TAKEOFF, PILOT FELT AIRCRAFT SHUDDER, RETURNED TO FIELD WITHOUT ANY DAMAGE TO AIRCRAFT. UPON INVESTIGATION ON ENGINE, FOUND 2 INCH SQUARE AREA MISSING FROM EXHAUST. UPON FURTHER INVESTIGATION, FOUND PORTION OF POWER TURBINE BLADE MISSING. THIS ENGINE HAD 339.1 HOURS SINCE POWER SECTION WAS DISASSEMBLED FOR POWER TURBINE BLADE INSPECTION. (X) 1L72 3T4 T A14CE E4EA 20000621001632000062100163EA 2000 6 21 20000620SH016 220000317G7310125099016 LINE CESSNA206 206H 2073301CE LYC O540 IO540AC1A5 EA FUEL PRESS CHAFED D K NONE O OTHER ININSP/MAINT 1 CE07950HP 20608002 L2667948A **ISAAC, NADA, PART NAME, ETC.***FOUND FUEL PRESSURE LINE, PN 1250990-16, AND OIL PRESSURE LINE, PN 1250990-15, RUBBING IN ENGINE COMPARTMENT. THESE LINES RUN FROM FUEL DISTRIBUTOR MANIFOLD TO RT REAR BAFFLE AND RT FRONT OIL PASSAGE TO RT REAR BAFFLE. OIL PRESSURE LINE IS CLAMPED TO PUSH ROD TUBES TWO PLACES. BOTH LINES WERE WORN THROUGH TO THE POINT OF LEAKING AT ANY TIME. THIS IS A NEW AIRCRAFT WITH 450 TOTAL HOURS. LINES NEED TO BE BENT SLIGHTLY AND REPOSITIONED TO PREVENT THIS PROBLEM. NOTE: THIS COULD HAVE CAUSED A FIRE IN THE ENGINE COMPARTMENT AS SOON AS THE NEXT FLIGHT. (X) 1H71 3O3 ORTA4CE 1E4 20000622000872000062200087NE 2000 6 22 20000509SH001 220000421G855030506353 ROTOR CFE CFE73811B NE OIL PUMP MISALIGNED H K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 IT WAS FOUND THAT THE SEAL ROTOR, PN 3120524-2, WAS INSTALLED BACKWARDS. (X) 4 F E44NE 20000622001052000062200105NE 2000 6 22 20000509SH007 220000418G72302A0003 BEARING IAE IAE V2500 V2500A1 NE NR 4 OUTER RACE SCORED B RA1RO OTHER O OTHER ININSP/MAINT 1 SW05 2299 P421091 V10491 ENGINE WAS REMOVED FOR ''NR 4 BEARING INSPECTION/REPAIR''. THE NR 4 BEARING EXHIBITED AXIAL SCORING OF THE ROLLERS AND OUTER RACE. . (X) 4 F E311NE 20000626000012000062600001NE 2000 6 26 20000510SH005 220000405G7261MS9388019 O-RING CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE ENGINE OIL CUT E K NONE K FLUID LOSS ININSP/MAINT 1 AL051275N161 208B0756 PCEPO0686 DURING A POST-FLIGHT INSPECTION, THE PILOT NOTED EXCESSIVE OIL ON THE LOWER COWL AND DOWN THE LEFT SIDE OF THE AIRCRAFT. UPON FURTHER INSPECTION, DETERMINED A NR 2 BEARING OIL SCAVENGETUBE COUPLING O-RING LOCATED AT C-FLANGE WAS LEAKING. UPON REMOVAL OF THE O-RING, IT WAS FOUND TO BE 75 PERCENT CUT IN HALF. THE O-RING WAS REPLACED. (X) 1H71 3T3 T A37CE E4EA 20000626000242000062600024EA 2000 6 26 20000511SH015 220000501G8550LW13383 BAFFLE PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532EA OIL SUMP MISALIGNED B BJ3RK NONE O OTHER ININSP/MAINT 1 WP15117NJ118 4636138 RL1041561A TWO EACH AN470AD RIVET HEADS FOUND IN OIL SUCTION SCREEN. REMOVED SUMP, FOUND BAFFLE HAD 2 RIVETS WITH HEADS MISSING. FURTHER EXAMINATION SHOWED RIVET HOLES COUNTERSUNK ON THE HEAD SIDE. THIS BAFFLE WAS THE NEW STYLE WITH 5 EACH AN470-4-4 AD RIVETS ON EACH BAFFLE PIECE, NOT THE OLDER 3 RIVETS AS PICTURED IN LYC SB 489A. (X) 1L71 3O3 ORTA25SO E14EA 20000626000252000062600025EA 2000 6 26 20000511SH016 220000501G855061298 GEAR PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532EA TEETH WORN B BJ3RK NONE W INADEQUATE Q C ININSP/MAINT 1 WP15117NJ119 4636138 RL10415612A ON REMOVAL OF OIL PUMP, WEAR WAS NOTED ON ALUMINUM GEAR TEETH FACES. IT LOOKED LIKE IMPROPER HARDENING. WEAR ALSO ON TEETH EDGES. DATE CODE: 36/99. (X) 1L71 3O3 ORTA25SO E14EA 20000626000262000062600026GL 2000 6 26 EY2R56628 320000511G611457C4503 FORK HARTZL PIPER PA31 PA31310 7103103SO LYC O540 TIO540* 41532EA HARTZLHCC4Y HCC4YR2 GL FORWARD EAR CRACKED B EY2RO OTHER O OTHER ININSP/MAINT 1 GL03 FH685 FH685 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 1 EACH CRACK. 1L71 3O3 ORTA20SO E14EA 5 CP52GL 20000626000512000062600051CE 2000 6 26 EY2R56608 120000512G6100C4503 FORK HARTZL HCC4YF2 BEECH 58 58 1152740CE CONT O550 IO550* SO HARTZLHCC4Y HCC4YF2 GL FORWARD EAR CRACKED B EY2RO OTHER Z SIGNIFICANT FAILURE REPORT ININSP/MAINT 1 GL03 GL61 GL61 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 1 EACH CRACK. 1L72 3O3 O 3A16 E3SO 5 CP52GL 20000627001442000062700144EA 2000 6 27 20000622SH036 220000404G7322MA4SPA CARBURETOR CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA SEPARATED D O OTHER WR INADEQUATE Q C PARTIAL RPM/PWR LOSS CRCRUISE 1 EA076212G764 17273579 RL515876T AIRCRAFT ENGINE RAN ROUGH DURING FLIGHT. WAS UNABLE TO SHUT ENGINE DOWN USING MIXTURE CONTROL. FOUND CARBURETOR BOWL SEPARATING FROM CARBURETOR BODY. ALL SCREWS WERE SECURED BY SAFETY TABS AND FACTORY TORQUE SEAL, BUT SCREWS WERE LOOSE. SUBMITTER SUSPECTED IMPROPER TORQUE OF SCREWS DURING OVERHAUL. CARBURETOR REPLACED W ITH OVERHAULED UNIT. FUNCTIONS NORMAL. (X) 1H71 3O3 ONT3A12 E274 20000627001452000062700145CE 2000 6 27 20000622SH040 120000531G8100LW15550 ROTOR LYC CESSNA182 TR182 2072735CE LYC O540 O540L3C5 41532EA OIL PUMP BROKEN G A UNSCHED LANDING O OTHER CRCRUISE 1 NM07738FN 287 R18200921 ENGINE TURBO SCAVENGING PUMP FAILED. THIS ALLOWED THE ENGINE TO PUMP ALL THE ENGINE OIL OVERBOARD THROUGH THE TURBO. EMERGENCY OFF AIRPORT LANDING CAUSED SUBSTANTIAL DAMAGE TO AIRCRAFT. (X) 1H71 3O3 O 3A13 E295 20000627001522000062700152WP 2000 6 27 20000623SH013 220000609G723030752272 DISK GARRTTTFE731TFE731* 01518WP CURVIC INADEQUATE H K NONE O OTHER ININSP/MAINT 1 GL19 NEW PART RECEIVED WITHOUT HIGH SPOT ON CURVIC BEING MARKED ON EITHER SIDE. LOT NR: 00P159. (X) 4 F E6WE 20000627001532000062700153SW 2000 6 27 20000623SH015 120000520G792031014284 FITTING MTSBSIMU2 MU2B30 5780410SW GARRTTTPE331TPE3316 01514WP COOLER DETERIORATED C DKBAE ENGINE SHUTDOWN K FLUID LOSS CRCRUISE 1 SO0913RR 8000 4000 682 P20478 OIL SUPPLY LINE FOR OIL COOLER, FITTING THREADS IN CASE DETERIORATED ALLOWING FITTING TO BLOW OUT. THIS ALLOWED ENGINE OIL TO PUMP OUT. PILOT SHUT ENGINE DOWN WITHOUT DAMAGE TO ENGINE. (X) 1H72 3T4 T A2PC E4WE 20000627001552000062700155 2000 6 27 20000623SH017 420000607G6122A20066 GEAR MCAULY MOONEYM20 M20K 5870220SW CONT O360 TSIO360LB 17025SO CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO17231MS462 794319 250313 RELEVANT CRACK INDICATION. (X) 1L71 3O3 O 2A3 E9CE 20000628001922000062800192CE 2000 6 28 20000622SH027 220000518G7322RSA5AD2 SERVO PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE FUEL INJECTOR FAILED B VJ3RO OTHER Y ENGINE STOPPAGE TXTAXI/GRND HDL 1 WP074142N923 450 3449128 322265LN LEFT ENGINE DIED ON ROLL-OUT AFTER LANDING. THIS SERVO HAS 923 HOURS TT SINCE NEW AND 450 HOURS FROM REPAIR OF MIXTURE PLATE. ENGINE RAN ROUGH AT IDLE AND AT LOW POWER SETTINGS. THE MIXTURE WAS ON THE RICH SIDE AND UNABLE TO ADJUST MIXTURE. SERVO REMOVED AND A NEW ONE INSTALLED IAW TCM AND PIPER MM. (X) 1L72 3O3 O A7SO E9CE 20000628001932000062800193EA 2000 6 28 20000622SH028 220000506G8530 SEAT AMRGENAA5 AA5 0631410SO LYC O320 O320D3G 41508EA NR 1 CYLINDER MISALIGNED H K NONE W INADEQUATE Q C ININSP/MAINT 1 WP115437L92 AA50337 L133339A ANNUAL INSPECTION FOUND NO COMPRESSION ON NR 1 CYLINDER. REMOVED CYLINDER, SENT FOR REPAIR. FOUND INTAKE VALVE SEAT INSTALLED WRONG (AT ANGLE) HAD BENT INTAKE VALVE. ALSO, ENGINE HAD NOT BEEN DE-SLUDGED AT OVERHAUL CAUSING PITS. FOUND AT AD INSPECTION AFTER 20 HOURS. (X) 1L71 3O3 O A16EA E274 20010309000712001030900071CE 2001 3 9 CA000511012 120000428G554050600016 BELLCRANK BEECH 100 B100 1152919CE GARRTTTPE331TPE3316252B 01514WP RUDDER LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 6848 P27206 (CAN) PILOT COMPLAINED OF WING ROCKING PROBLEM. INVESTIGATION FOUND 1/4 PLAY AT RUDDER TRAILING EDGE WHILE PEDALS BEING HELD AT FULL DEFLECTION. PLAY FOUND TO ORIGINATE FROM BELLCRANK FITTING (P/N 50-600016) AND LOWER SUPPORT TUBE ATTACHMENT POINT (RIVETS). DISASSEMBLY FOUND THE RIVETS WORN, THE 3 BOLTS (P/N AN173-12A) CONNECTING THE RUDDER BELLCRANK AND BELLCRANK FITTING SLIGHTLY BENT AND THE HOLES DISTORTED NEW BELLCRANK, BELLCRANK FITTING AND BOLTS INSTALLED. SUBMITTER SUSPECTS DAMAGE CAUSED FROM WIND GUSTS AND TOWING WITH GUST LOCK ON. 1L72 4T4 T A14CE E2WE 20000628001972000062800197GL 2000 6 28 CA000511016 220000504G723023009609 BEARING BELL 206 206L 1181522SW ALLSN 250C 250C20R2 GL COMPRESSOR MAKING METAL W K NONE O OTHER ININSP/MAINT 1 CA 32230 CAE295288 (CAN) NR 1 COMPRESSOR ROLLER BEARING MAKING METAL. 1G71 3U3 U H2SW E4CE 20000628001982000062800198CE 2000 6 28 CA000511018 120000510G3297V31001 WIRE BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA MLG SWITCH LOOSE W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA PCE50717 (CAN) AIRCRAFT RETURNED WITH GEAR IN-TRANSIT LIGHT. AFTER NUMEROUS GEAR SWINGS IT WAS DISCOVERED THAT THE WIRE WAS LOOSE WHERE IT IS ATTACHED TO THE EMERGENCY GEAR EXTENTION MICRO-SWITCH.THIS SWITCH CUTS POWER SO THAT WHEN THE EMERGENCY SYSTEM IS USED THERE IS NO POWER. THE INTERMITTANT POWER CAUSED THE GEAR NOT TO FULLY RETRACT AND CAUSE THE IN-TRANSIT LIGHT TO STAY ON. WIRE WAS SECURED. 1L72 3T4 T A14CE E4EA 20000628001992000062800199CE 2000 6 28 CA000511030 120000502G5720082260030 FITTING CESSNA 082260068 CESSNA402 402B 207590PCE CONT O520 TSIO520E 17040SO TIP TANKS LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 11500 502131A (CAN) DURING SCHEDULED INSPECTION, MOVEMENT WAS NOTICED AT THE AFT TIP TANK FITTING AS MAINTENANCE PERSONNEL APPLIED UP AND DOWN FORCES TO THE TIP TANK TRAILING EDGE. THE TWO MOST OUTBOARD RIVETS WHICH ATTACH THE FITTING TO THE OUTBOARD RIB (THROUGH THE REAR SPAR) WERE FOUND SHEARED. THE SUBMITTER STATES THAT THIS IS THE SECOND AIRCRAFT HE HAS FOUND IN THIS CONDITION. 1L72 3O3 O A7CE E8CE 20000628002002000062800200CE 2000 6 28 CA000511038 120000504G5753052323113 FLAP TRACK CESSNA CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA TE FLAP CRACKED W O OTHER O OTHER CLCLIMB 1 CA L3234327A (CAN) FOLLOWING A SIMULATED FORCED APPROACH, THE INSTRUCTOR AND STUDENT HEARD A LOUD BANG AS THE FLAPS WERE RETRACTING. THE FLAPS CONTINUED TO RETRACT TO THE FULL UP POSITION AND THE FLIGHT CONTINUED BACK TO BASE AND LANDED UNEVENTFULLY.MAINTENANCE PERSONNEL FOUND THAT THE LEFT INBOARD FLAP TRACK (RIB ASSY) HAS CRACKED. 1H71 3O3 ONT3A12 E274 20000628002012000062800201 2000 6 28 CA000511042 420000417G2562E01 SWITCH CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ELT CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 CA L3197827A 726767 (CAN) ELT FALSE ALARM - EVIDENCE OF MOISTURE ON REMOTE SWITCH PLUG END. 1H71 3O3 ONT3A12 E274 5 NP910 20000628002022000062800202SO 2000 6 28 CA000511043 120000418G7603554546 CABLE PIPER PA44 PA44180 7104402SO LYC O360 LO360E1A6 41514EA PEDESTAL SEPARATED W O OTHER E VIBRATION/BUFFET TOTAKEOFF 1 CA L43472 (CAN) DURING TAKEOFF, THE LEFT ENGINE REMAINED AT MAXIMUM RPM WHEN CLIMB POWER WAS SELECTED FOR BOTH ENGINES. MAINTENANCE FOUND THE LEFT THROTTLE CABLE BROKEN WITHIN THE PEDESTAL AREA AT THE POINT WHERE THE CABLE ENTERS THE HOUSING. CABLE REPLACED. 1L72 3O3 O A19S0 E286 20000628002032000062800203EA 2000 6 28 CA000511044 220000418G85303116 STUD LYC LW15322 PIPER PA44 PA44180 7104402SO LYC O360 LO360E1A6 41514EA NR 3 CYLINDER BROKEN W C ABORTED TAKEOFF ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TOTAKEOFF 1 CA 9400020940 L32872T (CAN) INTAKE ROCKER STUD FOUND BROKEN ON #3 CYLINDER. CYLINDER SENT FOR EVALUATION WHERE IT WAS DETERMINED THAT STRESS TO THE THREADED PORTION OF THE STUD WAS THE CAUSE OF ITS FAILURE. 1L72 3O3 O A19S0 E286 20000628002042000062800204 2000 6 28 CA000516002 420000505G25620010009 BATTERY NARCO ELT10 CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ELT DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA 71322 3877627A 82493 (CAN) LOOSE BATTERY CELLS IDENTIFIED. 1H71 3O3 ONT3A12 E274 5 NP910 20000628002052000062800205EA 2000 6 28 CA000516003 220000509G855062817 SCREEN CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL OIL SYSTEM DETERIORATED W K NONE O OTHER ININSP/MAINT 1 CA L4429127A 732270 (CAN) DURING INSPECTION, THE OIL SCREEN WAS FOUND TO BE DETERIORATING AND BEGINNING TO FRAY IN ONE AREA. THE SUBMITTER SUGGESTS THAT THE SCREEN WAS DETERIORATING DUE TO OLD AGE AND REPEATED CLEANINGS. 1H71 3O3 ONT3A12 E274 5 NP910 20000628002062000062800206CE 2000 6 28 CA000516005 120000504G712005510171 MOUNT CESSNA172 172L 2072432CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA L4429127A E18147 (CAN) DURING SCHEDULED MAINTENANCE, THE ENGINE MOUNT LOWER HORIZONTAL BRACE WAS FOUND CRACKED AT BOTH ENDS. 1H71 3O3 ONT3A12 E274 5 NP910 20000628002072000062800207CE 2000 6 28 CA000516006 120000403G55101156100181 SUPPORT FITTING BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA TORQUE TUBE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 82080 50078 (CAN) ON 1000 HOUR INSPECTION, NDT FOUND CRACK IN TAPER PIN ATTACH HOLE. SUSPECT OVERTORQUING OF PIN. NEW TORQUE ASSY. REPLACED. 1L72 3T4 T A14CE E4EA 20000628002112000062800211SW 2000 6 28 CA000518007 120000216G6320212040001059 PLANETARY GEAR BELL 212040001059BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TRANSMISSION CHIPPED W O OTHER J WARNING INDICATION TOTAKEOFF 1 CA 56030 ABW40017 CPPS61014 (CAN) METAL FOUND ON THE PLANETARY CHIP DETECTOR (.040 INCH - .060 INCH). TRANSMISSION WAS REMOVED SHORT OFF AND SENT FOR REPAIR. 1G71 4U4 U H4SW E22EA 20000628002132000062800213NE 2000 6 28 CA000518009 220000301G75300177555170 TACHOMETER TMECA 0177555170 SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE INTERNAL UNSERVICEABLE W O OTHER O OTHER CLCLIMB 1 CA 1338B 290 (CAN) ENGINE BLEED VALVE WHICH IS CONTROLLED BY THE TACHOMETER BOX INADVERTENTLY OPENED TWICE AT 98 PERCENT NG. OPERATOR WAS NOT ABLE TO DUPLICATE. POSSIBLE CAUSE WAS A SHORT IN THE TACHOMETER BOX. 1G71 3U3 U H9EU E19EU 20000628002142000062800214EU 2000 6 28 CA000518011 120000229G7921RH2125 COOLER RH2125 SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE ENG OIL COOLER LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA 457 290 (CAN) EXTERNAL SEAM ON THE OIL COOLER LEAKING PROGRESSIVELY WORSE, UNIT REPLACED. 1G71 3U3 U H9EU E19EU 20000628002152000062800215EU 2000 6 28 CA000518012 120000302G2140350A72100509 HEATER 350A72100509SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE UNION FITTING CORRODED W O OTHER O OTHER ININSP/MAINT 1 CA 834 (CAN) LINE FOUND TO BE CORRODED AND CRACKED BY THE UNION. 1G71 3U3 U H9EU E19EU 20000628002162000062800216SW 2000 6 28 AU000124 120000410G6230412010407105 RING BELL BELL 412 412 1182202SW PWA PT6T PT6T3B 52045NE MAIN ROTOR MAST CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1706 RE0160 (AUS) SWASHPLATE OUTER RING CRACKED. 1G72 4U4 U H4SW E22EA 20000628002182000062800218EU 2000 6 28 AU000135 120000404G77140177555170 CONTROL BOX TMECA SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1A 60030NE ENGINE RPM INDICFAILED W K NONE E VIBRATION/BUFFET DEDESCENT 1 AUS 903B 4223 (AUS) ENGINE TACHOMETRIC BOX FAILED. SUSPECT CAUSED BY INTERNAL COMPONENT FAILURE. 1G71 3U3 U H9EU E19EU 20000628002192000062800219NM 2000 6 28 AU000136 120000310G7160 INTAKE DUCT LYC ROBSINR22 R22BETA NM LYC O320 O320B2C 41508EA ENGINE AIR INTAKCONTAMINATED W K NONE Y ENGINE STOPPAGE NRNOT REPORTED 1 AUS L1813339A (AUS) AIR INTAKE HOUSING BLOCKED BY WATER FOLLOWING LANDING IN FLOOD WATER. ENGINE FAILURE CAUSED A HARD LANDING WHICH RESULTED IN DAMAGE TO THE LANDING GEAR, ENGINE FRAMES AND BELLY SKIN. 1G71 3O3 O H10WE E274 20000628002202000062800220SW 2000 6 28 AU000165 120000328G531347322241173 LONGERON BELL 47G BELL 47 47G5A 1181034SW LYC O435 VO435B1A 41516EA FUSELAGE MAIN LOCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE LOWER LONGERON CRACKED. FOUND DURING X-RAY INSPECTION IAW AD/BELL47/62 AMDT2. 1G71 3O3 O 2H3 E279 20000628002212000062800221WP 2000 6 28 AU000331 120000412G6210269D21100513M BLADE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL MAIN ROTOR BLADECRACKED W K NONE F FLT CONT AFFECTED CRCRUISE 1 AUS (AUS) MAIN ROTOR BLADE CRACKED. BUSHING LOOSE. 1G71 3U3 U H3WE E4CE 20000628002222000062800222CE 2000 6 28 AU000335 120000408G32438000016 SEAL CESSNA 50440004 CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO MCAULY3FF32 3FF32C501 GL MASTER CYL/BRAKEWORN W K NONE O OTHER TXTAXI/GRND HDL 1 AUS (AUS) BRAKE MASTER CYLINDER LOC O SEAL'' FAILED. 1L72 3O3 O A7CE E7CE 5 CP45GL 20000629000372000062900037NE 2000 6 29 20000517SH003 220000428G72302A0003 BEARING IAE IAE V2500 V2500A1 NE NR 4 OUTER RACE SPALLED B RA1RK NONE O OTHER ININSP/MAINT 1 SW05 2703 V0106 ENGINE REMOVED FOR ''''PERFORMANCE DETERIORATION''''. THE NR 4 BEARING EXHIBITED AXIAL SCORING OF THE ROLLERS AND OUTER RACE. MINOR FATIGUE SPALLING WAS PRESENT AT THE DAMAGE SITES ON BOTH THE RACE AND ROLLERS. INVESTIGATION IS IN PROGRESS AT GE ENGINE SERVICES - DALLAS. (X) 4 F E311NE 20000629000382000062900038NE 2000 6 29 20000517SH004 220000428G72302A0003 BEARING IAE IAE V2500 V2500A1 NE NR 4 OUTER RACE MAKING METAL B K NONE O OTHER ININSP/MAINT 1 SW05 4369 V0340 ENGINE WAS REMOVED FOR ''''''''METAL IN NR 4 MCD''''''''. THE NR 4 BEARING EXHIBITED A REGION OF FATIGUE BREAK-UP ON THE OUTER RACE. INVESTIGATION IS IN PROGRESS AT GE ENGINE SERVICES - DALLAS. (X) 4 F E311NE 20000629000422000062900042EA 2000 6 29 20000517SH017 220000425G7414 BUSHING SLICK BNORM BN2 BN2A26 1520226EU LYC O540 O540E4C5 41532EA DISTRIBUTOR BOX WORN D FYOAK NONE O OTHER ININSP/MAINT 1 AL05999SA45 97121325 897 L1966540A PILOT REPORTED LEFT ENGINE WAS HARD TO START. REMOVED LEFT MAGNETO INSPECTION AND NOTED ''POINT'' MARKS USED FOR FACTORY SEALING STILL IN PLACE INDICATING MAGNETO INTERNAL INSPECTION REVEALED OILITE BUSHING IN DISTRIBUTOR BLOCK EXCESSIVELY WORN PRODUCING A METALLIC DUST COVERING INTERNAL COMPONENTS OF MAGNETO. BUSHING WAS .023 INCH LARGER THAN SHAFT OF ROTOR GEAR AND APPEARED TO HAVE NOT BEEN PROPERLY OILED AT FACTORY. (X) 1H72 3O3 O A17EU E295 20000629000432000062900043 2000 6 29 20000517SH018 420000424G6122B3124 SHAFT HARTZL PIPER PA24 PA24260 7102406SO LYC O540 IO540A1A5 41532EA FAILED B LU4RK NONE O OTHER ININSP/MAINT 1 SO179051P 1532 665U 244516 RELEVANT INDICATION ON CONTROL SHAFT AT THE SPEED ADJUSTMENT SHAFT. (X) 1L71 3O3 O 1A15 1E4 20000629000492000062900049CE 2000 6 29 20000517SH025 120000502G7920MILH60003Q98 HOSE CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA OIL BREATHER LINBLOCKED D A UNSCHED LANDING KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 GL1764448 17265235 L4200827A DURING ANNUAL INSP, ORIG OIL BREATHER LINE FOUND WEATHER CHECKED AND DETERMINED UNAIRWORTHY. NEW LINE WAS CUT OFF OF BULK LENGTH STOCK AND REPLACED ORIG LINE IAW STD PRACTICES, AFTER LINE REPLACED, ACFT TEST RUN, ENG RUN-UP ON GROUND AT TAKEOFF POWER, CRUISE POWER, AND POST-MAINT CHK IAW CESSNA MM, CESSNA 172M. PILOTS OPER HANDBOOK WITH NO DISCREPANCIES OR OIL LEAKS NOTED, ACFT RELEASED FROM MAINT. FIVE MINUTES AFTER TAKEOFF, PILOT NOTED OIL SMOKE ENTERING COCKPIT, DECLARED EMERG, RETURNED TO AIRPORT. DURING RETURN, FRONT CRANKSHAFT SEAL BLEW OUT CAUSING LOSS OF OIL PRESS, DUMPING OIL OUT OF FRONT SEAL. ACFT LANDED SAFELY. INSP FND NEW BREATHER LINE BLOCKED. PLASTIC CAP SHOVED 4 INCHES UP INSIDE HOSE.1H71 3O3 ONT3A12 E274 20000629000942000062900094NE 2000 6 29 20000607SH010 220000509G73149A2045 PUMP UROCOPEC135 EC135P1 8680990EU PWA PW206 PW206B 0 NE A/C FUEL SYSTEM INTERMITTENT A R7MAK NONE O OTHER ININSP/MAINT 1 NM07135SJ761 EC1350054 UNIT OPERATES INTERMITTENTLY. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. (X) 1G72 3U3 UO H88EU E42NE 20000629001242000062900124SW 2000 6 29 20000620SH030 120000602G6200MS3116FB4S CONNECTOR BELL 407 407 SW ALLSN 250C 250C47B GL M/R TRANSMISSIONREADS HIGH B CYXRO OTHER O OTHER NRNOT REPORTED 1 CE01407LG635 53143 CAE847161 *****MICKEY****,PART LOCATION: TRANSMISSION OIL PRESSURE MANIFOLD*****PILOT REPORTED A HIGH OIL PRESSURE INDICATION (110 PSI) ON THE TRANSMISSION OIL PRESSURE INDICATOR. THIS READING WAS CAUSED BY DIRT/CORROSION INSIDE OF AN ELECTRICAL CONNECTOR ON THE SYSTEMS PRESSURE TRANSDUCER. CONNECTOR WAS CLEANED AND SYSTEM WAS CHECKED GOOD WITH AN EXTERNAL CALIBRATED GAUGE. OPERATOR: ST LUKES HOSPITAL, CEDAR RAPIDS, IOWA. 1G71 3U3 UO H2SW E1GL 20000629001252000062900125NE 2000 6 29 20000621SH002 220000223G7313430167601 MANIFOLD BOLKMS117 BK117B1 5626012EU LYC LTS101LTS101750B1 41560NE FUEL NOZZLE DEFECTIVE A R7MAO OTHER O OTHER ININSP/MAINT 1 NM07911VU 7141 LE45583EFA IMPROPER NOZZLE SPRAY PATTERN. REQUIRED 6000-HOUR INSPECTION. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. (X) 1G72 3U3 U H13EU E5NE10 20000629001732000062900173SW 2000 6 29 AU000375 120000213G6720222012724103 SPACER BELL BELL 222 222U 1182140SW LYC LTS101LTS101750C1 41560NE TAIL ROTOR CONTRCORRODED W K NONE O OTHER TOTAKEOFF 1 AUS (AUS) TAIL ROTOR PITCH CHANGE MECHANISM SPACER SEVERELY CORRODED. A PIECE OF THE SPACER HAD FLAKED OFF AND JAMMED THE SPLINE PLATE PN 222-012-725-001 ON THE OUTPUT SHAFT SPLINES. 1G72 3U3 U H9SW E5NE 20000629001742000062900174EU 2000 6 29 AU000397 120000427G6510593404 BEARING AEROSP 350A34011004AEROSPAS355 AS355F 8680806EU ALLSN 250C 250C20F 03013GL TAIL ROTOR DRIVEFAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAIL ROTOR DRIVESHAFT BEARING SPINNING ON THE DRIVESHAFT WEARING A GROOVE INTO THE SHAFT. 1G72 3U3 U H11EU E4CE 20000703006212000070300621GL 2000 7 3 EY2R56802 320000613G6111A1851T BEARING HARTZL HCB3TN3 PWA PT6 PT6* 52043EA HARTZLHCB3T HCB3TN3 GL SURFACE CORRODED B EY2RO OTHER Z SIGNIFICANT FAILURE REPORT ININSP/MAINT 1 GL03 BU11072 BU11072 BLADE BEARING SURFACE CORRODED. 3 T E2NE 6 CP15EA 20000703007632000070300763CE 2000 7 3 AU000297 120000201G2800 FUEL TANK CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO MCAULY3A32C D3A32C88 GL FUEL SYSTEM CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS 577217 739868 (AUS) AIRCRAFT FUEL SYSTEM CONTAMINATED WITH ETHYLENE DIAMINE (EDA). 1H71 3O3 O 3A21 E5CE 5 CP21EA 20000703007642000070300764CE 2000 7 3 AU000298 120000127G2800 FUEL TANK CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA SNSNCH72C 72CK EA AIRCRAFT FUEL SYCONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS L1543715 K5410 (AUS) AIRCRAFT FUEL SYSTEM CONTAMINATED WITH ETHYLENE DIAMINE (EDA) 1H71 3O3 ONT3A19 E223 5 NP9045 20000703007652000070300765SO 2000 7 3 AU000300 120000412G3230451359 BUNGEE CYLINDER PIPER PA30 PA30 7103002SO LYC O320 IO320B1A 41508EA HARTZLHCE2Y HCE2YL2 GL LANDING GEAR RETFAULTY W K NONE OJ OTHER WARNING INDICATION NRNOT REPORTED 1 AUS (AUS) LANDING GEAR BUNGEE FAULTY. 1L72 3O3 O A1EA 1E12 5 CP9EA 20000703007672000070300767NE 2000 7 3 CA000412004 220000314G72610301037180 VENT LINE TMECA ARRIEL1D SNIAS 350 AS350B1 8680811EU TMECA ARRIELARRIEL1D NE REAR BRG VENTL BROKEN W K NONE O OTHER CRCRUISE 1 CA 3084 7026 7026 (CAN) ENGINE REAR BEARING VENT LINE SNAPPED OFF DURING FLIGHT AND WAS LATER DISCOVERED THAT THE VENT LINE WENT INTO THE TAIL ROTOR. THE PREVIOUS DAY THE VENT LINE CLAMP HAD BROKE AND IT WAS THEN NOTED THAT THE VENT LINE HAD CHAFE WEAR MARKS CAUSED BY THIS CLAMP. 1G71 3U3 U H9EU E19EU 20000706001352000070600135EA 2000 7 6 20000517SH024 220000320G732230800 FLOAT PRECISION AMRGENAA5 AA5B 3960105SO LYC O360 O360A4K 41514EA DAMAGED B HO1RO OTHER R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 EA214553C 225 DL41123 AA5B1202 12504236A ENGINE WOULD NOT RUN UNLESS MIXTURE WAS LEANED ALMOST TO IDLE CUT-OFF, IT WAS VERY RICH AND WOULD NOT RUN ABOVE 1,500 RPM. FOUND PLASTIC FLOAT FILLED 100 II AVGAS TWO OF THREE CHAMBERS, FLOAT PN 30-800 CARBURETOR ASSY, DATE 9-97. (X) 1L71 3O3 O A16EA E286 20000706002312000070600231NM 2000 7 6 AU000391 120000224G5511A0441 SPAR ROBSIN ROBSINR22 R22BETA NM LYC O320 O320B2C 41508EA HORIZ STABILIZERCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 2072 (AUS) HORIZONTAL STABILIZER SPAR CRACKED THROUGH ATTACHMENT BOLT HOLES (4 OFF). FOUND FOLLOWING TAIL ROTOR STRIKE INSPECTION ALTHOUGH IT IS SUSPECTED THAT THE CRACKS WERE ALREADY PRESENT. 1G71 3O3 O H10WE E274 20000706002322000070600232EU 2000 7 6 AU000392 120000512G62101178016602 BRACKET 11780166 BOLKMS117 BK117B1 5626012EU LYC LTS101LTS101750B1 41560NE MAIN ROTOR BLADECRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN ROTOR BLADE VIBRATION ABSORBER LOWER BRACKET CRACKED. 1G72 3U3 U H13EU E5NE10 20000706002332000070600233GL 2000 7 6 AU000393 220000420G725023062750 HEAT SHIELD BELL 206 206B3 1181506SW ALLSN 250C 250C20B 03013GL TURBINE SECTION CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS CAT36613 CAE832257 (AUS) FIRST STAGE TURBINE NOZZLE HEAT SHIELD CRACKED. FOUND DURING INSPECTION IAW ROLLS ROYCE CEBA-1370. 1G71 3U3 U H2SW E4CE 20000706002342000070600234GL 2000 7 6 AU000195 220000305G7260 BEARING BELL 206 206L1 1182107SW ALLSN 250C 250C30 03013GL TURBINE ENGINE WORN W K NONE O OTHER NRNOT REPORTED 1 AUS 89007 (AUS) ENGINE ACCESSORY GEARBOX 2.5 BEARING WORN. METAL CONTAMINATION OF OIL SYSTEM. 1G71 3U3 U H2SW E1GL 20010312004042001031200404NE 2001 3 12 CA000511007 220000408G72604050T12P01 BEARING BOEING107 1072 9420604EA GE CT58 CT581401 30011NE ACCESSORY DRIVE FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 CA 96 280209A (CAN) ENGINE CHIP PLUG INDICATED CHIPS & THEN PLUG CLEANED & INSPECTED, SHOWING NO SLIVERS, ONLY PASTE. NEXT DAY AFTER 50 MINS OF FLT, FLUXS OCCURRED ON FUEL & OIL PRESSURES&NG&THEN ENGINE FLAMED-OUT. SUBSEQUENTLY, SINGLE ENGINE LANDING CARRIED OUT AT LOGGING WORK SITE. INITIAL INDICATION IS THAT BEARING FAILED AT FRONT FRAME ACCESSORY DRIVE. POST TEARDOWN RPT STATES THAT FFAD BEARING FAILED WHICH CAUSED BEVEL&PINION GEARS TO WEAR&LOSE CONTACT CAUSING ENGINE FLAMEOUT. METAL THEN CLOGGED OIL FILTER WHICH WENT INTO BYPASS&THEN CONTAMINATED ALL BEARINGS WHICH FAILED INSP. COMPRESSOR SPOOL&CASES WERE RED-TAGGED BECAUSE OF HOT SPOTS FROM RUBBING WHICH WERE CAUSED BY HIGH VIBRATIONS. 2G72 4U4 U 1H16 1E3 20000711002932000071100293SW 2000 7 11 AU000384 120000515G6220206011147007 STRAP BELL 206011100145BELL 206 206B3 1181506SW ALLSN 250C 250C20B 03013GL MAIN ROTOR HEAD DETERIORATED W K NONE O OTHER ININSP/MAINT 1 AUS AAB51059 CAE832194 (AUS) TENSION-TORSION (TT) STRAPS DETERIORATED. THE STRAPS WERE DISTORTED AND THE URETHANE COATING ADJACENT TO THE LATCH BOLT BUSHINGS WAS SPLIT REVEALING THE INTERNAL WINDINGS. (X) 1G71 3U3 U H2SW E4CE 20000711002942000071100294NE 2000 7 11 CA000410036 220000305G73100301007710 LINE TMECA SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE BELOW FLARE CRACKED W O OTHER K FLUID LOSS ININSP/MAINT 1 CA 866 (CAN) ENGINE FAILED TO START, MAINTENANCE FOUND SPRAY OF FUEL BETWEEN THE LEFT HAND FITTING TO THE START INJECTOR. THE LINE WAS REMOVED AND FOUND CRACKED AT BASE OF THE FLARE. 1G71 3U3 UNCH9EU E19EU 20010309000512001030900051NE 2001 3 9 CA000505006 220000412G73217257256 FUEL CONTROL BOEING107 1072 9420604EA GE CT58 CT581401 30011NE ENGINE MISRIGGED W O OTHER R PARTIAL RPM/PWR LOSS APAPPROACH 1 CA 280319A ENGINE FAILED TO RESPOND TO COLLECTIVE INPUT. A/C COMPLETED TEST FLIGHT TO ISOLATE PROBLEM WITH NO POSITIVE RESULTS. ENGINE CHANGED OUT. REPORT REQUESTED .05, 15, 2000. ENGINE RIGGING SPECIFIED TO BE THE MOST LIKELY CAUSE. 2G72 4U4 U 1H16 1E3 20010309000682001030900068NE 2001 3 9 CA000511008 220000420G73108945682 LINE FRCHLDSA227 SA227CC SW GARRTTTPE331TPE33114 01514NE FCU CRACKED W EA ENGINE SHUTDOWN UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 CA 17743 (CAN) FUEL LINE ITEM NR 105 ON IPC 73-10-01 FOUND CRACKED DUE TO VIBRATION AND LACK OF CLAMP AS REQUIRED WITHIN IPC ITEM NR 110 73-10-01 FIG. 2PAGE 2B. 2L72 4T4 TRTA18SW E18NE 20000712001122000071200112SW 2000 7 12 AU000253 120000404G3230ES10106 DRAG BRACE GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCA3V HCA3VK2 GL LANDING GEAR RETFRACTURED W O OTHER C F.O.D. TOTAKEOFF 1 AUS (AUS) NOSE LANDING GEAR DRAG BRACE FAILED AFTER THE AIRCRAFT STRUCK A KANGAROO ON TAKEOFF. THE NLG COLLAPSED DURING LANDING. 1H72 3O3 O 6A1 1E4 5 CP6EA 20000712001742000071200174CE 2000 7 12 AU000295 120000204G2810 FUEL TANK CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL FUEL SYSYTEM CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS L821276T Q6004 (AUS) AIRCRAFT FUEL SYSTEM CONTAMINATED WITH ETHYLENE DIAMINE (EDA). 1H71 3O3 ONT3A12 E274 5 NP910 20000712001942000071200194SO 2000 7 12 AU000312 120000313G2710 CONTROL CABLE EMB 110 EMB110P1 3260122SO PWA PT6 PT6A34 52043EA HARTZLHCB3T HCB3TN3 GL AILERON CONTROL WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RIGHT WING FORWARD INBOARD AILERON CABLE AND LEFT WING AFT INBOARD AILERON CABLE SEVERELY ERODED IN THE AREA WHERE THEY EXIT THE FUSELAGE. 1L72 4T4 T A21SO E4EA 6 CP15EA 20000718000072000071800007EA 2000 7 18 20000717SH010 220000610G8520 CRANKSHAFT UNIVAR108 1082 9230406NM FRNKLN6A41656A4165B3 27025EA FAILED G O OTHER Y ENGINE STOPPAGE NRNOT REPORTED 1 EA219830K 1082830 ENGINE BEGAN RUNNING ROUGH AND THEN THE PROPELLER LOCKED IN THE VERTICAL POSITION. POST-INCIDENT INSPECTION OF THE ENGINE REVEALED THE CRANKSHAFT HAD FAILED. (X) 1H71 3O3 O A767 E238 20000718000122000071800012CE 2000 7 18 20000622SH018 220000425G7322654353 SERVO PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE TOP ENGINE (AFT)GOUGED H K NONE O OTHER ININSP/MAINT 1 SW994161D 70196810 3449141 322031 FUEL SERVO GOUGED AT BASE BY SHOCK MOUNT ATTACHED TO ENGINE. SUBMITTED STATED SHOCK MOUNT DOES NOT COVER COMPLETE BASE OF SERVO. (X) 1L72 3O3 O A7SO E9CE 20000718000162000071800016NM 2000 7 18 AU000416 120000521G6310A1681 RETAINER ROBSIN ROBSINR22 R22BETA NM LYC O320 O320B2C 41508EA ENGINE/TRANSMISSCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 409 4430 (AUS) CLUTCH SEAL PLATE CRACKED. 1G71 3O3 O H10WE E274 20000718000172000071800017NM 2000 7 18 AU000417 120000510G7820A1696 MUFFLER LYC ROBSINR22 R22BETA NM LYC O320 O320B2C 41508EA ENGINE NOISE SUPFAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) EXHAUST MUFFLER SPLIT. MUFFLER WAS A NEW ITEM. 1G71 3O3 O H10WE E274 20000718001302000071800130EA 2000 7 18 20000714SH029 220000714G8530 VALVE SEAT CESSNA206 T206H CE LYC O540 TIO540AF1A 41532EA EXHAUST LOOSE B O OTHER R PARTIAL RPM/PWR LOSS CRCRUISE 1 SW992638U T20608061 L1018861A AIRCRAFT HAD ENGINE FAILURE AT 79 FLIGHT HOURS. THE NR 1 CYLINDER EXHAUST VALVE SEAT CAME LOOSE FROM THE CYLINDER AND CAUSED SIGNIFICANT DAMAGE TO THE ENGINE. THE OUTSIDE DIAMETER OF THE EXHAUST VALVE SEAT WAS FOUND UNDERSIZED. (X) 1H71 3O3 O A4CE E14EA 20000718001312000071800131NE 2000 7 18 20000714SH030 220000627G7412CH346593 IGNITER CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE CENTER ELECTRODEFAILED D K NONE O OTHER ININSP/MAINT 1 SW0137WP 148 5600259 PCE108497 DURING PHASE 2 INSPECTION, LEFT ENGINE INBOARD IGNITER PLUG WAS FOUND TO HAVE APPROXIMATELY .6250 INCH OF THE CENTER ELECTRODE MISSING ON THE FIRING END. IT APPEARS THE ELECTRODE DEPARTED SHORTLY AFTER IGNITER PLUG INSTALLATION DUE TO VERY SLIGHT WEAR ON THE FIRING END OF PLUG. THE HP TURBINE BLADES BORESCOPED BY PRATT & WHITNEY REP WITH NO DISCREPANCIES NOTED. (X) 2L72 4F4 FRTA22CE E25EA 20000718001332000071800133CE 2000 7 18 20000714SH032 120000625G2820RSA5AD1 SERVO CESSNA172 172S 2072439CE LYC O360 O360* 41514EA FUEL ENG VAPOR LOCK D O OTHER Y ENGINE STOPPAGE TOTAKEOFF 1 NM03567JW590 172S8187 ACFT WAS ON NIGHT FLIGHT AND COMPLETED 5 LANDINGS. FULL STOP ON RUNWAY, THEN TAKING OFF. ON THE 6TH LANDING WHEN THROTTLE WAS RETARDED OVER THE RUNWAY THRESHOLD, ALTERNATOR LIGHT ILLUMINATED AND ON ROLL-OUT, ENGINE QUIT. ATTEMPTS WERE MADE TO RESTART, BUT WOULD NOT RESTART. ACFT TOWED TO PARKING. MAINTENANCE INSPECTED AND STARTED ENG WITH NO DIFFICULTIES. ALL OPERATING PERIMETERS NORMAL, IDLE SPEED, AND MIXTURE STRENGTH NORMAL. UPON RETURN HOME, ACFT DIVERTED FOR 1 HR DUE TO THUNDERSTORMS, THEN TOOK OFF, RETURNED HOME. UPON ARRIVAL, ENG IDLE WAS ROUGH, IDLE SPEED ERRATIC. ENG SHUT DOWN, RESTART ATTEMPTED, VAPOR LOCKED. RESTARTED END, NO DIFFICULTIES. FUEL SERVO SENT TO CESSNA FOR EXAMINATION. (X)1H71 3O3 ONT3A12 E286 20000718001352000071800135GL 2000 7 18 CA000516012 220000410G72506878426 NOZZLE ALLSN BELL 206 206BELL 1181502SW ALLSN 250C 250C20 03013GL 1 BLADE PATH CIRCRACKED W K NONE O OTHER ININSP/MAINT 1 CA CAT31780D CAT31780P (CAN) A GROUP OF 2ND STAGE NOZZLES ARE IN THE PROCESS OF RECALL. IT WAS FOUND THAT REPAIRS MADE TO SOME NOZZLES; WHICH WAS AN APPROVED REPAIR , HAVE FAILED TO REACH O/H AND ARE CRACKING WHERE THE FIRST STAGE BLADE PATH WAS JOINED TO THE 2ND STAGE NOZZLE. TRANSPORT CAW CORRECTIVE ACTION GROUP IS ADRESSSING THIS ISSUE. 1G71 3U3 U H2SW E4CE 20000718001562000071800156WP 2000 7 18 AU000258 120000412G63104474 CLUTCH ROBSINR22 R22 7640102WP LYC O320 O320B2C 41508EA ENGINE/TRANSMISSCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 570 (AUS) CLUTCH ASSEMBLY FREE WHEEL UNIT REAR FACE PLATE CRACKED. 1G71 3O3 O H10WE E274 20000718001682000071800168EA 2000 7 18 CA000404002 220000324G7314301600 PUMP PWA BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TURB PWR SECTIONFAILED W A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 CA 114412916 CPPS60876 (CAN) FUEL PUMP SHAFT WAS ROUGH TO TURN. SENT FOR EVALUATION. 1G71 4U4 U H4SW E22EA 20000718001792000071800179NE 2000 7 18 CA000404015 220000404G75300177556170 TACHOMETER SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE INTERNAL FAILED W O OTHER O OTHER LDLANDING 1 CA 255 2194B 840 (CAN) TACHOMETER BOX FAILED TO SEND SIGNAL TO BLEED VALVE, CAUSING VALVE NOT TO CLOSE. 1G71 3U3 U H9EU E19EU 20000718001832000071800183EA 2000 7 18 CA000404031 220000309G7322HA61030 CARBURETOR HUGHES269 269C1 8059504SW LYC O360 HO360C1A 41514EA ENGINE FAILED W E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 CA 45 75048907 L3486936A (CAN) ENGINE QUIT DURING IDLE , AFTER RESTART, ENGINE WOULD NOT ACCELERATE FROM IDLE TO WARM UP RPM. CARBURETOR REPLACED. 1G71 3O3 OO 4H12 E286 20000718002002000071800200GL 2000 7 18 CA000606009 220000521G72606890914 BEARING ALLSN 6894171 BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL SUPP ADAPTR GEARWORN W A UNSCHED LANDING DP INFLIGHT SEPARATION NO WARNING INDICATION CRCRUISE 1 CA 49420 CAG34043 CAE801640BA (CAN) WHILE IN-FLIGHT, THE PILOT COULD HEAR A LOUD METALLIC SCREAMING GRINDING NOISE FROM THE ENGINE. HE LANDED AT A CLEARING AND SHUT DOWN ENGINE. THE ENGINE GEARBOX HAD QUICK DISCONNECT CHIP PLUGS, PULLED THE CHIP DETECTORS AND FOUND FERROUS METAL ON THE OUTER PERIMETER, BUT NO CHIPS CROSSING ONTO THE CENTER PROBE TO GIVE THE PILOT A CHIP LIGHT ON THE INSTRUMENT PANEL. THE SYSTEM WAS INSPECTED FOR LIGHT INDICATION AND FOUND SERVICEABLE. GEARBOX TSN 11,413.5 HOURS. TIME SINCE LAST MAJOR INSPECTION 4941.9 HOURS. 1G71 3U3 U H2SW E4CE 20000718002402000071800240 2000 7 18 CA000614018 420000605G25624000 ELT BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL ELT FAILED W O OTHER O OTHER ININSP/MAINT 1 CA 406329 CAE834205 (CAN) DURING ANNUAL RECERTIFICATION, THE ELT WAS FOUND TO HAVE NO TRANSMIT POWER OUTPUT. THE UNIT WAS SENT BACK TO FOR REPAIR STATION. 1G71 3U3 U H2SW E4CE 20000719001722000071900172EU 2000 7 19 AU000422 120000526G6230704A3364021 BUSHING AEROSP SCISSORLINK SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE MAIN ROTOR MAST BROKEN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN ROTOR SWASHPLATE TOP SCISSOR LINK BUSHING BROKEN. THE BROKEN BUSHING WORE INTO THE SCISSOR LINK. 1G71 3U3 U H9EU E19EU 20000719001732000071900173WP 2000 7 19 AU000429 120000508G6420B1151 BEARING ROBSINR22 R22ALPHA 7640104WP LYC O320 O320B2C 41508EA TAIL ROTOR HEAD WORN W K NONE O OTHER ININSP/MAINT 1 AUS DN (AUS) TAIL ROTOR TEETER BEARINGS WEARING PREMATURELY. 1G71 3O3 O H10WE E274 20000719001742000071900174SW 2000 7 19 AU000482 120000601G6220206011113103 TRUNNION BELL BELL 206 206B3 1181506SW ALLSN 250C 250C20B 03013GL MAIN ROTOR HEAD DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS 304 (AUS) MAIN ROTOR TRUNNION FAULTY. MAST AND SPLIT CONES ALSO REPLACED. 1G71 3U3 U H2SW E4CE 20000719001752000071900175EU 2000 7 19 AU000483 120000526G2435150SG10095 BRUSH BLOCK 150SG1RZQ SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE STARTER/GEN BROKEN W K NONE O OTHER ININSP/MAINT 1 AUS 5461 (AUS) STARTER/GENERATOR BRUSHES BROKEN. 1G71 3U3 U H9EU E19EU 20000719001762000071900176WP 2000 7 19 AU000500 120000621G622036124 CUFF HILLER HILLERUH12 UH12E 4360122WP ALLSN 250C 250C20 03013GL MAIN ROTOR HEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 527 10580 (AUS) MAIN ROTOR CUFF CRACKED FROM BOLT HOLE. CRACK LENGTH 10MM (0.393IN). FOUND DURING DYE PENETRANT INSPECTION IAW AD/HIL12/17(SB 36-1). 1G71 3O3 U 4H11 E4CE 20000719001772000071900177SW 2000 7 19 AU000501 120000624G3397 WIRE BELL 412 412 1182202SW PWA PT6T PT6T3B 52045NE PASSENGER COMPT BROKEN W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) CABIN DOME LIGHT DIMMER POTENTIOMETER WIRE BROKEN AND SHORT CIRCUITING. 1G72 4U4 U H4SW E22EA 20000719001782000071900178NE 2000 7 19 CA000419005 220000410G7210103019204 SUN GEAR LYC BELL 205 205A1 1181414SW LYC T53 T5313B 41549NE REDUCTION GEARBXBROKEN W O OTHER P NO WARNING INDICATION ININSP/MAINT 1 CA 72500 LE07187X (CAN) UPON FURTHER INVESTIGATION INTO WHY ENGINE WAS MAKING METAL, IT WAS FOUND THAT TWO TEETH HAD FRAGMENTED OFF THE GEAR. THE TEETH FRAGMENTS WERE .6250 INCH LONG AND WERE FOUND TRAPPED IN THE INTERNAL OIL SCREEN. THE CAUSE FOR THE GEAR FAILURE WAS NOT EVIDENT. AS SPECIFIED BY THE SUBMITTER AND IAW THE ENGINE MANUAL, THIS ENGINE COULD HAVE REMAINED IN SERVICE. 1G71 4U4 U H1SW E17EA 20000720000072000072000007NE 2000 7 20 20000619SH019 220000609G7250811935 SUPPORT BRACKET PWA JT8 JT8* 52044NE NR 5 BEARING CRACKED B WNFRK NONE O OTHER ININSP/MAINT 1 NE03 PART FAILED FMPI CRACK TEST IN SERVERAL LOCATIONS. (X) 4 F E2EA 20000720000082000072000008NE 2000 7 20 20000619SH020 220000609G7250811935 SUPPORT BRACKET PWA JT8 JT8* 52044NE NR 5 BEARING CRACKED B O OTHER O OTHER NRNOT REPORTED 1 NE03 PART FAILED FMPI CRACK TEST IN SEVERAL LOCATIONS. (X) 4 F E2EA 20000720000162000072000016SW 2000 7 20 AU000425 120000601G6220 MAIN ROTOR BELL TRUNNION BELL 206 206B3 1181506SW ALLSN 250C 250C20B 03013GL SPLIT CONE HALF DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS 304 (AUS) MAIN ROTOR SPLIT CONE HALF INSTALLED UPSIDE DOWN. MAIN ROTOR TRUNNION CHAMFER DAMAGED BY SHARP EDGE OF CONE. MAST SPLIT CONE SEAT FRETTING. 1G71 3U3 U H2SW E4CE 20000720000302000072000030EU 2000 7 20 AU000468 120000428G6220350A31190703 STARFLEX AEROSPAS355 AS355F1 8680810EU ALLSN 250C 250C20F 03013GL MAIN ROTOR HEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS M3308 CAE840630627 (AUS) MAIN ROTOR STARFLEX HEAD ASSEMBLY CRACKED. 1G72 3U3 U H11EU E4CE 20000720000542000072000054WP 2000 7 20 CA000412001 120000303G6510369D25518 DRIVE SHAFT HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL DAMPER BRACKET DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA 9502 CAE831949 (CAN) UPON REMOVAL OF TAIL ROTOR GEARBOX AND DRIVESHAFT, EXTENSIVE DAMAGE WAS FOUND ON TAIL ROTOR DRIVESHAFT. INVESTIGATION REVEALED THAT THE DAMPER BRACKET WAS BROKEN OFF WHICH ALLOWED THE TAIL ROTOR DRIVESHAFT TO WHIP AND RESULT IN THIS DAMAGE. 1G71 3U3 U H3WE E4CE 20000720000622000072000062SW 2000 7 20 CA000414009 120000411G2435230321380 BRUSH BLOCK LEARSIEGLER 23032018 BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL STARTER GENERATOBROKEN W K NONE O OTHER ININSP/MAINT 1 CA 436 4900 CAE832736 (CAN) POST-FLIGHT INSPECTION REVEALED THAT ONE OF THE BRUSHES WAS WORN DOWN TWICE AS MUCH AS THE OTHER VISIBLE BRUSH. UPON REMOVAL, IT WAS THEN NOTED THAT ONE OTHER BRUSH WAS BROKEN AND/OR BURNT OFF. HOWEVER, THE STARTER/GENERATOR WAS STILL FUNCTIONING AS IT GAVE NO FAILURE WARNING INDICATION. 1G71 3U3 U H2SW E4CE 20000720001382000072000138SO 2000 7 20 20000620SH018 120000508G79218535311 COOLER PIPER PA31 PA31310 7103103SO LYC O540 TIO540J2BD 41532EA RT ENG OIL SYS FAILED D C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CE077436L4600 120 317400994 L1028561A AS AIRCRAFT ROTATED DURING TAKEOFF, MANIFOLD PRESSURE DROPPED, PILOT FOUND LOW OIL RPESSURE, AND RETURNED TO AIRPORT AND SECURED ENGINE AFTER LANDING. ON INSPECTION, FOUND OIL COOLER BOWED OUTWARD AND INNER COILS BULGED WITH 2.5 INCH SPLIT. OIL COOLER WAS OVERHAULED APPROXIMATELY 120 HRS. NO APPARENT DAMAGE OTHER THAN LISTED FOUND ON COOLER. FOUND NO REASON FOR COOLER RUPTURE. ON ENGINE GROUND TEST, ALL ENGINE PRESSURES NORMAL. (X) 1L71 3O3 ORTA20SO E14EA 20000720002082000072000208SW 2000 7 20 CA000427004 120000411G5302212030447001 BEAM BELL 212030100103BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA LEFT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 11193 ADW04155 CPPS61242 (CAN) DURING PRE-FLIGHT, THE LEFT HAND BEAM CAP ON THE TAILBOOM PYLON WAS FOUND CRACKED (.080 INCH). NOTE: THIS CRACK WAS FOUND IN THE SAME PLACE AS DESCRIBED IN FAA AD 99-18-02 APPLICABLE TO BELL 205 SERIES. 1G71 4U4 U H4SW E22EA 20000720002352000072000235NE 2000 7 20 CA000614064 220000614G7250M031070 TURBINE SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE FUEL INJECT FAILED W O OTHER O OTHER TOTAKEOFF 1 CA 59300 7984810 786 (CAN) DURING START PROCEDURE STARTER WAS UNABLE TO MOTOR ENGINE. AFTER INSPECTING ENGINE FOR F.O.D. AND REMOVING COMPONENTS ON THE ACCESSORY GEARBOX,, ENGINE WAS DISMANTLED TO ISOLATE THE LOCK UP. LOCK UP WAS FOUND TO BE IN THE GAS PRODUCER ASSEMBLY (M024M03). ASSEMBLY WAS SENT TO REPAIR CENTER WHERE IT WAS FOUND TO BE FUEL COKING ON THE LABYRINTH SEALS OF THE CENTRIFUGAL INJECTION WHEEL. 1G71 3U3 U H9EU E19EU 20000720003082000072000308SW 2000 7 20 CA000427003 120000329G6710212076151007 TUBE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA CYCLIC LOOSE W K NONE O OTHER ININSP/MAINT 1 CA CPPS61242 (CAN) DURING INSPECTION, THE RIGHT CYCLIC SERVO INPUT LEVER WAS FOUND IN AN AFT OF CENTER ORIENTATION. SUBSEQUENT OBSERVATION REVEALED BOTH CYCLIC BOOST TUBES HAD LOOSE CLEVIS ASSEMBLIES AT LOWER END. THIS CAUSED THE SERVO TO ROTATE IN ANY POSITION AND INTERFERE WITH THE PARENT STRUCTURE. NORMALLY, THE CLEVISES MUST BE TIGHT AND LOCKED IN POSITION TO PREVENT THE SERVO FROM TURNING. THE USE OF SILICONE SEAL WAS USED TO BOND THE THREADED CLEVIS TO TUBE AS PER BELL MAINTENANCE MANUAL. BELL WAS INFORMED AND STATED THAT THEY ARE MAKING THE CORRECTION TO THE MAINTENANCE MANUAL. 1G71 4U4 U H4SW E22EA 20010309000542001030900054GL 2001 3 9 CA000505011 220000424G72406890040 SHIELD BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL NOZZLE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 771 CAT38320F (CAN) WHEN COMPLETING CEB A-1370, 1ST STAGE NOZZLE SHIELD INSPECTION, FOUND AREA OF INSPECTION CRACKED. 1G71 3U3 U H2SW E4CE 20010309000662001030900066EU 2001 3 9 CA000511004 120000501G64201053172904 BUSHING BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL TAIL ROTOR LOOSE W EC ENGINE SHUTDOWN ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA CAE835542 (CAN) PILOT STARTED AIRCRAFT AND FOUND PEDAL FORCES EXCESSIVE. AIRCRAFT WAS SHUT DOWN. T/R WAS DISASSEMBLED AND IT WAS FOUND THAT ONE OF THE OUTBOARD BUSHING HAD SLID APPROXIMATELY .25 INCH OFF THE INNER SLEEVE AND WAS RUBBING THE OUTBOARD SPACER, LOCATED INSIDE THE BLADE GRIP. 1G72 3U3 U H3EU E4CE 20010309000672001030900067EA 2001 3 9 CA000511005 120000416G64106117030201041 BLADE CARSONS61 S61LSKRSKY EA GE CT58 CT581401 30011NE TAIL ROTOR TORN W K NONE O OTHER ININSP/MAINT 1 CA 891 295082 (CAN) POST FLIGHT INSPECTION REVEALED TWO TEARS IN TAIL ROTOR BLADE POCKET (19 & 16 INCH FROM TIP). IT APPEARS THAT LEADING EDGE TAPE CAME LOOSE AND FLAPPED AGAINST BLADE CAUSING THE TWO TEARS. 2G72 4U4 U H8EA 1E3 20010309000702001030900070EU 2001 3 9 CA000511010 120000330G25105000B2 LATCH SNIAS 350 AS350D 8680803EU LYC LTS101LTS101600A2 41560NE SEAT BELT MALFUNCTIONED W K NONE O OTHER ININSP/MAINT 1 CA 10000 LE43488E (CAN) IT WAS NOTICED THAT 2 OF THE FOUR SEAT BELT LATHCHES DO NO ALWAYS ENGAGE PROPERLY. WHEN THE BUCKLE IS INSERTED ALL THE WAY INTO THE LATCH, IT SOUNDS AN D LOOKS LIKE IT IS LATCHED BUT IF WE PULL THE BELT TO TIGHTEN IT, THE BUCKLE PULLS OUT OF THE LATCH WITH NO RESTRICTION. IT TAKES 4 TO 5 ATTEMPTS BEFORE BUCKLE LATCHES POSITIVELY. PROBLEM HAS NOW BEEN IDENTIFIED AND REPLACEMENT PARTS ARE ON ORDER. 1G71 3U3 U H9EU E5NE 20010309000722001030900072GL 2001 3 9 CA000511020 220000315G723023056109 COMPRESSOR BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 860787 (CAN) 1.5 INCH CRACK FOUND ON COMPRESSOR SCROLL STARTING ALONG AFT RADIUS OF SCROLL PROGRESSING TOWARD DISCHARGE ELBOW AND TURNING TO MIDDLE OF OUTSIDE FACE. 1G71 3U3 U H2SW E1GL 20000724002592000072400259SW 2000 7 24 CA000511026 120000217G5347 HOOK BELL BELL 206 206L 1181522SW ALLSN 250C 250C20R2 GL ON THE LANYARD WRONG PART W O OTHER O OTHER CRCRUISE 1 CA 45146 CAE831288 (CAN) ROTORCRAFT WAS CARRYING A SKIDOO ON THE CARGO HOOK WHEN THE PILOT FELT IT RELEASE. RETURNED TO BASE WHERE THE HOOK AND MECHANICAL AND ELECTRICAL RELEASES WERE CHECKED. AS A PRECAUTIONARY MEASURE, THE HOOK WAS REPLACED. THE REMOVED ASSY WAS TESTED AS PER BREEZE EASTERN RECOMMENDATIONS (TWICE) AND NO DEFECTS WERE FOUND. IT IS SUSPECTED THAT THE WRONG SIZE RING WAS USED ON THE LANYARD. 1G71 3U3 U H2SW E4CE 20000724002612000072400261 2000 7 24 CA000516001 420000510G2562BS2166 BATTERY NARCO ELT10 BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL ELT BATTERY LEAKING W K NONE O OTHER ININSP/MAINT 1 CA C10317 CAE830913 (CAN) ELT WAS REMOVED FOR ANNUAL INSPECTION AND IT WAS NOTED THAT WHITE POWDER WAS ON OUTSIDE OF BATTERY AND ELT CASE. UPON INSPECTION AFTER BATTERY REMOVAL, A LEAK WAS DETECTED. BATTERY STILL HAD 5 MONTHS LEFT ON ITS LIFE. EXPIRATION, SEPT 2000. BATTERY WAS REPLACED AND ELT WAS TESTED SERVICEABLE. NO INTERNAL DAMAGE OCCURRED. OWNER DID NOT NOTICE LEAKAGE UNTIL ELT WAS REMOVED FROM BRACKET. ELT BATTERY LOT NR 1S 44181. MANUFACTURE DATE IS AUGUST 1998. 1G71 3U3 U H2SW E4CE 20000724002632000072400263NM 2000 7 24 CA000516035 120000313G6322A1874 CONE ROBSIN B1741 ROBSINR22 R22BETA NM LYC O320 O320B2C 41508EA CIRC OF CONE CHAFED W O OTHER O OTHER ININSP/MAINT 1 CA L1581339A (CAN) THE LENGTH OF THE SCREW THAT ATTACHES INSPECTION PLATE P/N D229-4 TO SCROLL SET P/N R7156 WAS EXTENDED THROUGH SCROLL SET TO A DEPTH THAT IT CONTACTED CONE P/N A187-4 CAUSING IT TO CHAFE AS THE FAN WHEEL ROTATED. UNABLE TO DETERMINE AT THIS TIME THE P/N OF THE SCREW THAT WAS INSTALLED. THE CORRECT P/N FROM ROBINSON R2 ILLUSTRATED PARTS CATALOG IS MS35206-227. IT IS SUSPECTED THAT AN OVERLY LONG SCREW WAS INSTALLED DURING THE ROTORCRAFT''S OVERHAUL. 1G71 3O3 O H10WE E274 20000726000622000072600062CE 2000 7 26 CA000516017 120000505G323399810057652 ACTUATOR BEECH 99 99 1154002CE PWA PT6 PT6A20 52043EA RT MLG INTERNAL SEIZED W O OTHER J WARNING INDICATION LDLANDING 1 CA 24134 (CAN) THE CREW ON A TRAINING FLIGHT NOTICED, AFTER A NUMBER OF TIMES CYCLING THE GEAR, THE GEAR HANDLE RED LIGHT REMAINING ON. AS THE AIRCRAFT LANDED, THE RIGHT LANDING GEAR COLLAPSED .MAINTENANCE FOUND THE RIGHT LANDING GEAR ACTUATOR SEIZED IN THE PARTIALLY RETRACTED POSITION. THE ACTUATOR IS BEING SENT OUT FOR EVALUATION. 1L72 3T3 T A14CE E4EA 20000726000632000072600063EA 2000 7 26 CA000516021 220000508G85207380685 PUSHROD CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA AT 1 BALL END DAMAGED W C ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TOTAKEOFF 1 CA 21960 RL1627815 (CAN) STEEL ENDS OF PUSH RODS DAMAGING ALUMINUM TUBES. LYCOMING SB 453 ADDRESSES ISSUE. LYCOMING HAS SINCE SWITCHED TO ALL STEEL PUSH RODS. 1H71 3O3 ONT3A19 E223 20000726000642000072600064CE 2000 7 26 CA000516022 120000508G3222AN5 BOLT CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL NLG AXLE BOLT MISSING W O OTHER O OTHER LDLANDING 1 CA 36000 L2827936A 815095 (CAN) AFTER LANDING, THE PILOT EXPERIENCED DIFFICULTY STEERING THE AIRCRAFT. THE AIRCRAFT WAS STOPPED ON THE RUNWAY AND IT WAS NOTICED THAT THE NOSEWHEEL WAS SITTING CROOKED ON THE NOSE GEAR FORK. FURTHER INSPECTION REVEALED THAT THE NOSE WHEEL AXLE BOLTAND ONE AXLE FERRULE WERE MISSING FROM THE NOSE GEAR. THE SUBMITTER SUSPECTS THAT THE NUT MAY HAVE COME OFF THE BOLT OR THE BOLT MAY HAVE BROKEN. 1H71 3O3 O 3A17 E286 5 CP7EA 20000726000702000072600070SO 2000 7 26 CA000516023 120000508G21208124402 TUBE PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA FWD PRT OF TUBE DISCONNECTED W GB O2 MASK DEPLOYED EMER. DESCENT W INADEQUATE Q C CRCRUISE 1 CA 85000 PCE51623 (CAN) AIRCRAFT MADE AN IN-FLIGHT RAPID DECOMPRESSION. THE FORWARD PART OF THE FRESH AIR DISTRIBUTION TUBE WAS FOUND TO BE DISCONNECTED. THE CLAMPS WERE REMOVED, INSPECTED, REINSTALLED, AND LOC WIRED TO PREVENT SLIPPAGE. THE SUBMITTER STATES THAT ALTHOUGH LOCKWIRING THE CLAMPS IS NOT IN THE MAINTENANCE MANUAL, LOCKWIRING GIVES BETTER SECURITY. 1L72 3T4 T A8EA E4EA 20000726000712000072600071SO 2000 7 26 CA000516024 120000508G3243492152 VALVE PIPER PA42 PA42 7104202SO PWA PT6 PT6A41 52043EA PARKING BRAKE FAILED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA 48090 PCE80156 (CAN) PILOTS CHECKED FOR BRAKE PRESSURE DURING CRUISE FLIGHT AT 33,000 FEET. BRAKES WERE VERY SOFT. PARKING BRAKE VALVE FOUND TO HAVE LEAKING O-RINGS. SEALS REPLACED. 1L72 4T4 T A23SO E4EA 20000726000772000072600077WP 2000 7 26 20000621SH009 220000309G725030720705 DISK GARRTTTFE731TFE731* 01518WP POST FIR TREE DAMAGED H K NONE O OTHER ININSP/MAINT 1 SW99 NEW PART RECEIVED WITH DAMAGE ON AFT SIDE IN POST FIR TREE AREA. LOT NUMBER: 99P348. (X) 4 F E6WE 20000726000792000072600079SO 2000 7 26 AU000214 220000307G8530 EXHAUST VALVE CONT O200A CESSNA150 150M 2071830CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL ENGINE SEIZED W K NONE O OTHER ININSP/MAINT 1 AUS 1340 252651A48 (AUS) NR 4 CYLINDER EXHAUST VALVE SEIZED. 1H71 3O3 O 3A19 E252 5 NP918 20000726000872000072600087SW 2000 7 26 AU000216 120000322G28105630061502 FUEL CELL GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA FUEL STORAGE DETERIORATED W K NONE OK OTHER FLUID LOSS ININSP/MAINT 1 AUS (AUS) RIGHT FORWARD AND AFT AND LEFT FORWARD INBOARD FUEL CELLS DETERIORATED AND LEAKING. 1H72 3O3 O 6A1 1E4 20000726000882000072600088SW 2000 7 26 AU000217 120000322G28105630080502 FUEL CELL GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA FUEL STORAGE DETERIORATED W K NONE OK OTHER FLUID LOSS ININSP/MAINT 1 AUS (AUS) RIGHT FORWARD AND AFT AND LT FORWARD INBOARD FUEL CELLS DETERIORATED AND LEAKING. 1H72 3O3 O 6A1 1E4 20000726000962000072600096EA 2000 7 26 AU000226 220000327G853074541 EXHAUST VALVE PIPER PA28 PA28180 7102808SO LYC O360 O360A3A 41514EA SNSNCH76E M76EMM EA ENGINE BROKEN W K NONE EREVIBRATION/BUFFET PARTIAL RPM/PWR LOSS VIBRATION/BUFFET CRCRUISE 1 AUS L840136A (AUS) NR 2 CYLINDER EXHAUST VALVE FAILED. NR 2 CYLINDER AND SPARK PLUGS DAMAGED. A FRAGMENT OF THE FAILED EXHAUST VALVE WAS INGESTED BY NR 3 CYLINDER CAUSING INTERNAL DAMAGE. 1L71 3O3 O 2A13 E286 5 NP4EA4 20000726000972000072600097NM 2000 7 26 AU000227 120000101G2820200072001 PIPE PIPER PA60 PA60602P 7106015NM LYC O540 IO540AA1A 41532NE ACFT FUEL DISTRICORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LEFT WING FUEL PIPE CORRODED. 1M72 3O3 ORTA17WE 1EA 20000726001002000072600100CE 2000 7 26 AU000236 120000311G2750 FLAP BEECH 200 200CBEECH 1152926CE PWA PT6 PT6A42 52043NE TE FLAP CONTROL FAULTY W K NONE F FLT CONT AFFECTED DEDESCENT 1 AUS (AUS) FLAPS WOULD NOT EXTEND. INVESTIGATION COULD FIND NO FAULT AND THE FLAPS HAVE OPERATED CORRECTLY SINCE. 1L72 4T4 T A24CE E4EA 20000726001012000072600101SO 2000 7 26 AU000241 120000308G2842550696 TRANSMITTER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL FUEL QUANTITY SECORRODED W K NONE O OTHER CRCRUISE 1 AUS (AUS) RIGHT FUEL TANK SENDERS OPEN CIRCUITED AND CORRODED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20000726001022000072600102SO 2000 7 26 AU000242 220000423G7421RHB32E SPARK PLUG CONT IO520F CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL SPARK PLUG/IGNITFAULTY W K NONE E VIBRATION/BUFFET CRCRUISE 1 AUS 286164R (AUS) NR 3 CYLINDER SPARK PLUGS (2 OFF) BRIDGED ACROSS ELECTRODES. 1H71 3O3 O A4CE E5CE 5 CP21EA 20000726001032000072600103SO 2000 7 26 AU000252 120000209G2434762489 STATOR CHRYSLER 4111810 PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA DC GENERATOR-ALTLOOSE W K NONE H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS 271 9021856 (AUS) ALTERNATOR STATOR LOOSE. STATOR WINDINGS SHORT CIRCUITED. 1L71 3O3 O 2A13 E274 5 NP88614 20000726001042000072600104SW 2000 7 26 AU000254 120000404G3230ES10107 DRAG BRACE GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCA3V HCA3VK2 GL LANDING GEAR RETFRACTURED W A UNSCHED LANDING C F.O.D. TOTAKEOFF 1 AUS (AUS) NOSE LANDING GEAR DRAG BRACE FAILED WHEN THE AIRCRAFT STRUCK A KANGAROO ON TAKEOFF. NLG COLLAPSED DURING LANDING. 1H72 3O3 O 6A1 1E4 5 CP6EA 20000726001202000072600120EA 2000 7 26 AU000250 220000406G731025243271 VALVE BENDIX RSA5 PIPER PA30 PA30 7103002SO LYC O320 IO320B1A 41508EA HARTZLHCE2Y HCE2YL2 GL ENGINE FUEL DISTCONTAMINATED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS L441755A (AUS) RIGHT ENGINE FUEL DISTRIBUTOR VALVE VENT HOLE BLOCKED BY A GREASE TYPE SUBSTANCE APPLIED TO THE DIAPHRAGM SPRING. 1L72 3O3 O A1EA 1E12 5 CP9EA 20000726001212000072600121SO 2000 7 26 AU000259 220000407G8530 PISTON CONT CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL ENGINE FAILED W O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CLCLIMB 1 AUS (AUS) NR 2 CYLINDER PISTON HOLED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20000726001612000072600161EU 2000 7 26 CA000518013 120000411G67201053178201 PITCH LINK BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL T/R GEAR BOX UNSERVICEABLE W O OTHER O OTHER ININSP/MAINT 1 CA 512519 CAE836046 (CAN) DURING A TAILROTOR (T/R) GEARBOX CHANGE,THE T/R PITCH CHANGE BELLCRANK WAS FOUND DAMAGED. THE DAMAGE WAS CAUSED FROM THE SAFETY WIRE CHAFING NEAR THE PIVOT BEARING. SAFETY WIRE IS FASTENED TO PIVOT BEARING STUD FROM THE T/R GEARBOX. 1G72 3U3 U H3EU E4CE 20000726001682000072600168WP 2000 7 26 20000621SH008 220000313G725030747522 DISK GARRTTTFE731TFE731* 01518WP POST FIR TREE DAMAGED B K NONE O OTHER ININSP/MAINT 1 GL19 NEW PART RECEIVED WITH DAMAGE IN POST FIR TREE AREA ON BOTH FORWARD AND AFT SIDE. RE: LOT NUMBER: OOPO14. (X) 4 F E6WE 20000726002452000072600245EU 2000 7 26 CA000518010 120000301G77129580113720 TRANSMITTER SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE TORQUE INDECATORINCORRECT W O OTHER O OTHER CLCLIMB 1 CA 30000 1451 451 (CAN) TORQUE TRANSMITTER WAS INSTALLED THE DAY BEFORE AND SET TO PROPER PRESSURE. CHECKED LATER AND FOUND TO BE OFF BY 3% PERCENT. UNIT RE-ADJUSTED. 1G71 3U3 U H9EU E19EU 20000726002462000072600246NE 2000 7 26 CA000518014 220000329G75329550158260 BLEED VALVE SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE STUCK W O OTHER J WARNING INDICATION LDLANDING 1 CA 13780 347 (CAN) UNIT STICKS CLOSED INTERMITTENTLY. 1G71 3U3 U H9EU E19EU 20000726002472000072600247EU 2000 7 26 CA000519006 120000502G75001462502034 LINE SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE BLEED AIR BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 69280 841 (CAN) WHEN STARTING, PILOT NOTICED HE HAD TO MOVE POWER LEVER TO ALMOST HALF THROTTLE TO GET ENGINE STARTED. IN-FLIGHT, LACK OF POWER WAS NOT EVIDENT. UPON LANDING, IT WAS DISCOVERED THE BLEED AIR LINE HAD BROKEN COMPLETELY OFF NEAR THE 90 DEGREE FITTING WHERE THE LINE WENT INTO THE COMPRESSOR SECTION OF ENGINE. 1G71 3U3 U H9EU E19EU 20000726002492000072600249SW 2000 7 26 AU000218 120000322G28105630060501 FUEL CELL GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA FUEL STORAGE DETERIORATED W K NONE OK OTHER FLUID LOSS ININSP/MAINT 1 AUS (AUS) RIGHT FORWARD AND AFT AND LEFT FORWARD INBOARD FUEL CELLS DETERIORATED AND LEAKING. 1H72 3O3 O 6A1 1E4 20000726002522000072600252CE 2000 7 26 AU000228 120000405G32301454 BUSHING CESSNA 991015403 CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO LANDING GEAR RETCONTAMINATED W K NONE O OTHER LDLANDING 1 AUS (AUS) EMERGENCY LANDING GEAR BLOW DOWN BOTTLE HANDLE WOULD NOT OPERATE. INVESTIGATION FOUND THE TEFLON BUSHING LOCATED BETWEEN THE FIRING PLUNGER AND THE OUTLET LINE BLOCK WAS SWOLLEN AND JAMMED PREVENTING THE BOTTLE FROM FIRING. OIL CONTAMINATION WAS FOUND IN THE BOTTLE HEAD. 1L72 3O3 O A7CE E8CE 20000726002532000072600253NE 2000 7 26 20000615SH002 220000605G7230UL27681 COMPRESSOR WHEEL RROYCERB211 RB211535E4 54555NE COOLING HOLES CRACKED B XE5RK NONE O OTHER ININSP/MAINT 1 SW21 16222 31374 CRACK INDICATIONS FOUND DURING ACCOMPLISHMENT OF ROLLS-ROYCE SB RB211-72-C817. (X) 4 F E12EU 20000726002542000072600254CE 2000 7 26 AU000229 120000426G3233115380025 MOTOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL LANDING GEAR ACTFAULTY W O OTHER O OTHER LDLANDING 1 AUS (AUS) LANDING GEAR MOTOR FAILED TO OPERATE. 1L72 4T4 T A24CE E4EA 6 CP15EA 20000726002552000072600255SO 2000 7 26 AU000237 120000402G28402405105 PIPE PIPER PA30 PA30 7103002SO LYC O320 IO320* 41508EA HARTZLHCE2Y HCE2YR2 GL ACFT FUEL INDICALEAKING W K NONE K FLUID LOSS CLCLIMB 1 AUS (AUS) RIGHT FUEL FLOW LINE LOCATED AT BACK OF INSTRUMENT INADEQUATELY FLARED. FUEL LEAKING. 1L72 3O3 O A1EA 1E12 5 CP9EA 20000726002562000072600256SO 2000 7 26 AU000240 120000308G2842550695 TRANSMITTER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL FUEL QUANTITY SECORRODED W K NONE O OTHER CRCRUISE 1 AUS (AUS) RIGHT FUEL TANK SENDERS OPEN CIRCUITED AND CORRODED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20000726002572000072600257SO 2000 7 26 AU000245 220000412G74141050765 CLAMP BENDIX S6LN25T CESSNA337 337 2075702CE CONT O360 IO360D 17025SO MCAULY2AF34CD2AF34C306 GL MAGNETO/DISTRIBUBROKEN W K NONE O OTHER ININSP/MAINT 1 AUS 338 898959 57083 (AUS) FRONT ENGINE RIGHT MAGNETO COIL ATTACHMENT CLAMPS BROKEN. FOUND DURING INSPECTION IAW AD/ELECT/68. 1H72 3O3 O A6CE E1CE 5 CP5EA 20000727000452000072700045EA 2000 7 27 AU000262 220000303G8520 CRANKCASE LYC CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL ENGINE CRACKED W K NONE OK OTHER FLUID LOSS ININSP/MAINT 1 AUS L2161415 (AUS) CRANKCASE CRACKED IN THE AREA BETWEEN NR 2 AND NR 4 CYLINDERS. 1H71 3O3 ONT3A19 E223 5 NP50GL 20000727001712000072700171CE 2000 7 27 CA000720008 120000720G7100105217 CARBURETOR LYC O320H2AD CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL MIXTURE CNTRL FAILED W O OTHER O OTHER ININSP/MAINT 1 CA 85000 L81876T L81876T 79744 (CAN) THE RECENTLY OVERHAULED ENGINE WOULD START (ON PRIMING FUEL) AND THEN QUIT (AS IF THE MIXTURE CONTROL WAS IN IDLE CUTOFF), CARBURETOR REMOVED AND ANOTHER CARB PUT ON ENGINE - RAN NORMAL CARB MIXTURE, CONTROL SEEMS TO BE STUCK ON IDLE CUT-OFF INTERNALLY, ALTHOUGH EXTERNAL CONTROL ARM MOVES FROM LEAN TO RICH - SENT TO OVERHAUL FACILITY FOR REPAIR. 1H71 3O3 ONT3A12 E274 5 NP910 20000727001722000072700172CE 2000 7 27 CA000720009 120000620G7100 O-RING CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA CASE/STUD WRONG PART W O OTHER K FLUID LOSS ININSP/MAINT 1 CA 77500 L623815 (CAN) DURING TROUBLESHOOTING FOR AN ENGINE OIL LEAK, IT WAS DETERMINED THAT OIL WAS SEEPING OUT THE CENTER THROUGH-BOLT STUDS; ENGINE AND CRANKCASE WAS DISASSEMBLED FOR ACCESS TO THE THROUGH-STUD O-RINGS. IT WAS THEN DISCOVERED THAT THE WRONG O-RINGS WERE INSTALLED ON THE 6 THROUGH-STUDS. THE O-RINGS WERE THICKER THAN THE RECESS WAS GROOVED OUT FOR AND AS A RESULT THE 6 O-RINGS WERE SQUASHED AND STUCK IN THE MATING SURFACES OF THE CRANKCASE HALVES, WHICH RESULTED IN A LOSS OF TORQUE AND FRETTING OF THE CRANKCASE MATING SURFACES. THE CRANKCASE HALVES NEEDED TO BE MILLED AND LINE BORED. 1H71 3O3 ONT3A19 E223 20000727001732000072700173SO 2000 7 27 CA000720010 120000628G3260487862 SWITCH PIPER PA31T PA31T2 7103127SO PWA PT6 PT6A135 52043NE NLG OUT OF ADJ W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA PCE92653 (CAN) - PILOT DID NOT RECEIVE NOSE GEAR DOWN LIGHT INDICATION AFTER CYCLING GEAR DOWN FOR LANDING. MAINTENANCE ADVISED PILOT TO USE RUDDER PEDALS TO ACTIVATE NOSE GEAR DOWN MICROSWITCH. THIS ACTION GAVE NOSE GEAR DOWN INDICATION TO PILOT. THE AIRCRAFT WAS LANDED WITHOUT ANY INCIDENT. MAINTENANCE JACKED THE AIRCRAFT, CYCLED GEARS AND ADJUSTED THE NOSE GEAR DOWN MICROSWITCH. 1L72 3T4 TRTA8EA E4EA 20000727002392000072700239SW 2000 7 27 CA000530010 120000116G28102120606003E FUEL LINE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA FUEL CELL DELAMINATED W K NONE O OTHER ININSP/MAINT 1 CA 608 CPPS61552 (CAN) WHEN REPLACING FLEXIBLE LINES INSIDE THE FUEL CELL, IT WAS NOTED THAT THE BOTTOM OF THE FUEL CELL WAS SPONGY. IT WAS THEN DESCOVERED THAT LAYERS OF RUBBER WERE BREAKING DOWN AND SEPARATING. 1G71 4U4 U H4SW E22EA 20000727002402000072700240EU 2000 7 27 CA000530011 120000515G6720704A33651003 BEARING 350A332004 SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE TAIL ROTOR ROUGH W K NONE O OTHER ININSP/MAINT 1 CA 10040 M1652 382 (CAN)WHILE PERFORMING AN INSPECTION OF THE TAIL ROTOR PITCH CHANGE SPIDER BEARINGS FOR ROUGHNESS, DRAG AND TORQUE, (AWD 1999-085-076(A)R2). IT WAS DISCOVERED THAT BEARING WAS VERY ROUGH AND RATCHETY. THE AWD IS A REPETITIVE AWD FOR EVERY 50 HOURS. MANUFACTURES P/N 60102RS1HT33CA. 1G71 3U3 UNCH9EU E19EU 20010312004242001031200424EU 2001 3 12 CA000519007 120000404G5302 ATTACH FITTING SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE FUSE TO TAILBOOMCRACKED W K NONE O OTHER ININSP/MAINT 1 CA 9601 303 (CAN) CRACK FOUND ON THE FUSELAGE TO TAILBOOM ATTACHMENT FLANGE. CRACK LOCATED (LOOKING FORWARD) AT 2:30 POSITION ON RIGHT SIDE. CRACK LENGTH WAS APROXIMATELY 3.5 CM LONG AND ABOUT 2 MM FROM EDGE. THE TORQUE ON FUS/TAILBOOM ATTACH BOLTS WERE UNKNOWN AT THE TIME OF TAILBOOM REMOVAL (RE: CF-93-12R1). 1G71 3U3 U H9EU E19EU 20000728000352000072800035NE 2000 7 28 CA000530015 220000521G7314P94B12208 PUMP ZENITH SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE READS LOW W O OTHER O OTHER ININSP/MAINT 1 CA 32000 23455 4510 (CAN) PRIOR TO STARTING AIRCRAFT ENGINE, THE FUEL PRESSURE GAUGE WAS OBSERVED TO BE INDICATING ZERO PRESSURE WITH PUMP SWITCHED ON. WHEN LISTENED TO, THE PUMP SEEMED TO BE WORKING, BUT OBVIOUSLY THE ELECTRIC MOTOR WAS NOT ROTATING THE IMPELLER, AS PROVEN BY DISCONNECTING AN INLINE FUEL LINE AND OBTAINING NO FUEL FLOW. TSO ON THE PUMP HAS ONLY 32.1 HOURS, THUS EITHER A POOR OVERHAUL OR A FAULTY INTERNAL PART IS SUSPECT. THE PUMP WAS REPLACED WITH A NEWLY OVERHAULED UNIT AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1G71 3U3 UNCH9EU E19EU 20000728000362000072800036NE 2000 7 28 CA000530016 220000510G7314O94B12209 PUMP ZENITH SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE READS LOW W K NONE J WARNING INDICATION CRCRUISE 1 CA 89600 20617 4510 (CAN) DURING FLIGHT, THE PILOT NOTICED THE FUEL PRESSURE INDICATING ZERO. BEING CLOSE TO THE DESTINATION, THE SHORT FLIGHT WAS COMPLETED WITHOUT INCIDENT. WITH THE ENGINE SHUT DOWN, NOTICED THE PUMP OPERATION SOUNDED CORRECT WITH THE POWER APPLIED, BUT WAS FOUND TO BE PRODUCING NO PRESSURE AND WAS REMOVED. THE IMPELLER TO MOTOR DRIVE CONNECTION SEEMS TO HAVE FAILED. A REPLACEMENT PUMP WAS INSTALLED AND THE ROTORCRAFT RETURNED TO SERVICE. 1G71 3U3 UNCH9EU E19EU 20000728000372000072800037EU 2000 7 28 CA000606031 120000526G2612B232M FIRE DETECTOR BOLKMS105 BO105C 5626005EU ALLSN 250C 250C20B 03013GL ENGINE LOOSE W O OTHER N FALSE WARNING CRCRUISE 1 CA CAE835650 (CAN) #1 FIRE WARNING LIGHT CAME ON IN CRUISE FLIGHT. PILOT RETARDED THROTTLE TO IDLE & RETURNED TO BASE. AIRCRAFT INSPECTED LOOSE WIRE ON DETECTOR FOUND, WIRE (MEET) TORQUED SYSTEM CHECKED & FOUND SERVICEABLE, AIRCRAFT RETURNED TO SERVICE. 1G72 3U3 U H3EU E4CE 20000728000382000072800038SW 2000 7 28 CA000614008 120000520G6420206016201131 BEARING BELL 206011810125BELL 206 206L1 1182107SW ALLSN 250C 250C30 03013GL TAIL ROTOR FAILED W O OTHER O OTHER ININSP/MAINT 1 CA 58600 A805 CAE895116 (CAN) AIRCRAFT WAS GROUND RUN TO GROUND IDLE. TAIL ROTOR PEDDLES STARTED TO STIFFEN UP. AS THE AIRCRAFT RPM WAS INCREASED TO 100 PERCENT NR, TAIL ROTOR PEDDLES STIFFENED TO BEYOND LIMITS APPROXIMATELY 35 POUNDS. FORCE REQUIRED TO MOVE THE PEDDLES. AT THIS RPM, THE TAIL ROTOR SYSTEM WAS THOROUGHLY INSPECTED AND NO PROBLEMS FOUND. THE TAIL ROTOR BLADES WERE REMOVED AND THE AIRCRAFT RUN UP TO 100 PERCENT WITH ONLY THE T/R HUB INSTALLED. THE PEDDLES MOVED FREELY WITH NO STIFFNESS. SPHERICAL BEARINGS REPLACED ON BOTH BLADES. AIRCRAFT RUN UP AND PEDDLES MOVED FREELY WITH NO STIFFNESS. BEARINGS ARE AVAILABLE FOR INSPECTION. 1G71 3U3 U H2SW E1GL 20000728000392000072800039EU 2000 7 28 CA000614009 120000522G2932NE15BAT11TFGNOIRSWITCH 350A27055300SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE COLLECTIVE CRACKED W O OTHER O OTHER ININSP/MAINT 1 CA 21150 341 (CAN) PILOT REPORTED THAT THE SWITCH WAS INTERMITTENT (HYDRAULIC CUT-OFF SWITCH ON COLLECTIVE STICK). 1G71 3U3 U H9EU E19EU 20000728000402000072800040SW 2000 7 28 CA000614011 120000427G6720206001020045 PITCH LINK 206B BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL TAIL ROTOR UNSAFETIED W O OTHER W INADEQUATE Q C ININSP/MAINT 1 CA 11200 3055 CAE270029 (CAN) DURING MAINTENANCE, PERFORMED BELOW THE ENGINE PAN, A TAIL ROTOR FLIGHT CONTROL BOLT WAS FOUND UNFASTENED. T/R ANTI-TORQUE CONTROL TUBE (ITEM NR 21, 206 IPC FIG.67-2) REAR ATTACHMENT BOLT FOUND WITH NUT BACKED OFF, NO COTTER PIN INSTALLED. AIRCRAFT GROUNDED AND ALL FLIGHT CONTROLS WERE INSPECTED FOR SAFETY. ONE MORE BOLT THAT ATTACHES THE T/R PITCH CONTROL ROD TO THE PITCH CONTROL LEVER WAS ALSO FOUND UN-SAFETIED WITHOUT A COTTER PIN SAFETING THE NUT/BOLT. A QUALITY CONTROL PROBLEM DURING RECENT A/C REBUILD IS SUSPECTED TO BE A FACTOR IN THE FINDINGS. THE OVERHAUL SHOP HAS BEEN MADE AWARE OF THE FINDINGS. 1G71 3U3 U H2SW E4CE 20000731000012000073100001NE 2000 7 31 20000509SH002 220000417G726130506353 PUMP CFE CFE73811B NE SEAL ROTOR MISINSTALLED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 IT WAS FOUND THAT THE SEAL ROTOR, PN 3120524-2,WAS INSTALLED BACKWARDS. (X) 4 F E44NE 20000731000152000073100015GL 2000 7 31 AU000248 120000307G8010 RELAY LYC PAC CT4 CT4A 05623UCGL CONT O360 IO360HB 17025SO HARTZLHCC2Y BHCC2YF1 GL ENGINE CRANKING STUCK W K NONE E VIBRATION/BUFFET CLCLIMB 1 AUS (AUS) ENGINE STARTER SOLENOID RELAY JAMMED IN THE ON POSITION. STARTER MOTOR WOULD NOT DISENGAGE. (X) 1Q71 3I3 ORTA9PC E1CE 5 CP920 20000731000162000073100016SO 2000 7 31 AU000263 120000217G531031420 STRUCTURE PIPER PIPER PA31 PA31310 7103103SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2 GL FUSELAGE MAIN STDAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE SKIN CRACKED IN AREA OF LEFT WING FORWARD ATTACHMENT FITTING. INTERNAL STRUCTURE ALSO DAMAGED IN THE SAME AREA. CENTER SECTION LOWER FUSELAGE FRAMES BUCKLED AND LOWER SKIN DAMAGED. 1L71 3O3 ORTA20SO E14EA 5 CP33EA 20000731000172000073100017SO 2000 7 31 AU000267 120000216G573062061002 SKIN PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA SNSNCH76E 76EM8 EA WING PLATES/SKINCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING SKIN CRACKED. 1L71 3O3 O 2A13 E286 5 NP4EA 20000731000182000073100018EA 2000 7 31 CA000331010 220000325G73103011857 LINE PWA EMB 110 EMB110P1 3260122SO PWA PT6 PT6A34 52043EA FCU CRACKED W K NONE BK SMOKE/FUMES/ODORS/SPARKS FLUID LOSS LDLANDING 1 CA 6675 PCE56782 (CAN) FUEL LINE CRACK AT B-NUT FOUND TO BE THE CAUSE OF FUEL ODOR, AT FCU. FEEDBACK. 1L72 4T4 T A21SO E4EA 20000731000192000073100019NE 2000 7 31 CA000404001 220000321G7314 SHAFT PWA DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN1 52008NE FUEL PUMP BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 320 4221504 (CAN) ENGINE WOULD NOT RUN WITHOUT WOBBLE PUMP OPERATING. ENGINE DRIVEN PUMP REMOVED AND QUILL SHAFT FOUND BROKEN. 1H71 3R3 R A806 5E1 20010308001282001030800128GL 2001 3 8 CA000404022 320000317G6111S90AT4 BLADE MCAULY D2A34C58 CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C58 GL THREADED AREA CRACKED W O OTHER O OTHER ININSP/MAINT 1 CA 477 734108 816532R 734108 (CAN) BLADE THREADS CRACKED S/N K67168YS 1H71 3O3 O 3A24 E5CE 5 CP3EA 20000731000202000073100020SO 2000 7 31 CA000404025 120000323G6120B30012 COLLAR HARTZL AYRES S2 S2RT34NORMAL0970106SO PWA PT6 PT6A34AG 52053NE HARTZLHCB3T HCB3TN3 GL INNER SURFACE DAMAGED W O OTHER O OTHER ININSP/MAINT 1 CA 159 PCE56682 BU10976 (CAN) DAMAGE TO INNER SURFACE OF LOW STOP COLLAR DUE TO IMPROPERLY SECURED LOCK WIRE. 1L71 3T4 T A3SW E4EA 6 CP15EA 20000731000212000073100021SO 2000 7 31 CA000410010 120000331G8120 LINE CONT PIPER PA31 PA31 7103102SO LYC O540 TIO540F2BD 41532EA TURBOCHARGER BROKEN W AE UNSCHED LANDING ENGINE SHUTDOWN E VIBRATION/BUFFET APAPPROACH 1 CA L473961A L473961A (CAN) OIL LINE FAILURE AT FITTING FEEDING TURBOCHARGER SECONDARY DAMAGE TO CONNECTING ROD BEARING CAUSING ROD FAILURE. 1L72 3O3 O A20SO E14EA 20000731000232000073100023CE 2000 7 31 CA000414007 120000329G3397 WIRE CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL CABIN CHAFED W HA DEACTIVATE SYST/CIRCUITSUNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA RL462776T 728612 (CAN) DURING CLIMB, THE PILOT NOTICED A BURNING SMELL. THE PILOT TURNED OFF ALL ELECTRICS AND RETURNED FOR LANDING. MAINTENANCE PERSONNEL FOUND THE WIRES TO THE LIGHT DIMMING CIRCUIT WERE SHORTING TO GROUND WHERE THEY HAD CHAFED ON THE CONSOLE STRUCTURE. THE SHORT WAS INTERMITTANT AND DID NOT USE ENOUGH CURRENT TO CAUSE THE CIRCUIT BREAKER TO TRIP. THE WIRE WAS REPAIRED AND A CHAFE STRIP WAS ADDED TO THE STRUCTURE IN THE AREA OF THE WIRE DAMAGE. 1H71 3O3 ONT3A12 E274 5 NP910 20000731000242000073100024EA 2000 7 31 AU000068 220000130G8540 GEARBOX LYC PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA FAILED W K NONE E VIBRATION/BUFFET CLCLIMB 1 AUS L44162 (AUS) ENGINE GEARBOX SUSPECT FAILURE. 1L72 3O3 O A8EA E19EA 20000731000252000073100025EA 2000 7 31 AU000070 220000127G8500 ENGINE LYC PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL LEFT MAKING METAL W K NONE O OTHER ININSP/MAINT 1 AUS L17061A (AUS) LEFT ENGINE OIL FILTER NON-FERROUS METAL CONTAMINATION. 1L72 3O3 O A20SO E14EA 5 CP33EA 20000731000262000073100026EA 2000 7 31 AU000074 220000205G8530 VALVE SEAT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL NUMBER 5 LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS 897 L496861A (AUS) LEFT ENGINE NR 5 CYLINDER EXHAUST VALVE SEAT SEPARATED FROM CYLINDER HEAD. 1L72 3O3 O A20SO E14EA 5 CP33EA 20000731000272000073100027SO 2000 7 31 AU000081 120000207G32304204200 ARM PIPER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL LANDING GEAR RETBROKEN W O OTHER O OTHER TOTAKEOFF 1 AUS (AUS) LEFT MAIN LANDING GEAR RETRACTION ARM BROKEN. 1L72 3O3 O A20SO E14EA 5 CP33EA 20000731000282000073100028CE 2000 7 31 AU000084 120000208G2800 FUEL TANK CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO MCAULY2A34C E2A34C73 GL AIRCRAFT FUEL SYFAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AIRCRAFT FUEL SYSTEM INSPECTED IAW AD/GEN/79, AD/GEN/80 AND AD/GEN/81. 1H71 3O3 O 3A21 E5CE 5 CP3EA9 20000731000292000073100029CE 2000 7 31 AU000086 120000112G750025001 VALVE PARKER 25001 CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE ENGINE BLEED AIRCORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) BLEED AIR SOLENOID VALVE OPEN CIRCUITED. MOVING PARTS CORRODED. SUSPECT WATER INGRESS. 1H71 3T3 T A37CE E4EA 20000731000302000073100030EU 2000 7 31 AU000087 120000128G5730136 RIVET PARTEN PARTENP68 P68B EU LYC O360 IO360A1B6 41514EA HARTZLHCC2Y HCC2YK2 GL WING PLATES/SKINMISALIGNED W K NONE O OTHER ININSP/MAINT 1 AUS 136 (AUS) LEFT AND RIGHT WING INBOARD ENGINE COWL RIVETS MISALIGNED. THE RIVETS DID NOT IMPINGE ON THE SPAR. FOUND DURING INSPECTION IAWAD/P68/46. 1H72 3O3 O A31EU 1E10 5 CP920 20000731000312000073100031EA 2000 7 31 AU000090 220000120G8520LWI3885MO6 BEARING PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2 GL ENGINE FAILED W K NONE E VIBRATION/BUFFET NRNOT REPORTED 1 AUS RL11668A (AUS) RIGHT ENGINE FRONT BEARING PICKED UP ON CRANKSHAFT. ENGINE SEIZED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20000731000322000073100032SO 2000 7 31 AU000091 120000201G281007560106 PLUNGER MAULE M4 M4210 5460108SO CONT O360 IO360A 17025SO MCAULY2A34C D2A34C67 GL FUEL STORAGE DETERIORATED W K NONE O OTHER ININSP/MAINT 1 AUS 1042444 (AUS) FIREWALL MOUNTED FUEL STRAINER PLUNGER RUBBER NOT COMPATIBLE WITH FUEL PREVENTING FUEL FROM BEING DRAINED FROM STRAINER. PLUNGER WAS PURCHASED AND FITTED IN SEPTEMBER 1999. 1H71 3O3 O 3A23 E1CE 5 CP3EA 20000731000332000073100033SO 2000 7 31 AU000092 120000205G3260MS272402 SWITCH EMB 110 EMB110P1 3260122SO PWA PT6 PT6A34 52043EA HARTZLHCB3T HCB3TN3 GL LANDING GEAR POSINTERMITTENT W K NONE ON OTHER FALSE WARNING LDLANDING 1 AUS (AUS) RIGHT MAIN LANDING GEAR DOWNLOCK MICROSWITCH INTERMITTENT IN OPERATION. 1L72 4T4 T A21SO E4EA 6 CP15EA 20000731000342000073100034EA 2000 7 31 AU000093 220000219G8530LW12427 CYLINDER CESSNA172 172P 2072436CE LYC O360 O360A4M 41514EA MCAULY1A170 1A170CFA GL NR 4 SPARK PLUG CRACKED W K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 AUS 1239 L3256136A (AUS) NR 4 CYLINDER CRACKED FROM LOWER SPARK PLUG HOLE TO EXHAUST PORT. 1H71 3O3 ONT3A12 E286 5 NP857 20000731000352000073100035EA 2000 7 31 AU000094 220000202G7324254088 DIAPHRAGM BENDIX 25241783 GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA FUEL DIVIDER WORN W K NONE E VIBRATION/BUFFET CLCLIMB 1 AUS AGA631 (AUS) LEFT ENGINE FUEL FLOW DIVIDER DIAPHRAGM FAILED DUE TO CHAFING ON THE VALVE PLATE. 1H72 3O3 O 6A1 1E4 20000731000362000073100036SO 2000 7 31 AU000095 220000121G8540534728 STUD CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL IDLER GEAR SHEARED W K NONE ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 AUS 1170 276417R 960416 (AUS) IDLER GEAR SUPPORT PIN SECURING STUD SHEARED. 1L72 3O3 O A25CE E7CE 5 CP45GL 20000731000372000073100037CE 2000 7 31 AU000101 120000214G2800 FUEL TANK CESSNA150 A152 2071836CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL AIRCRAFT FUEL SYCONTAMINATED W K NONE EY VIBRATION/BUFFET ENGINE STOPPAGE CRCRUISE 1 AUS (AUS) AIRCRAFT FUEL SYSTEM CONTAMINATED WITH WATER. THE FUEL SYSTEM HAD BEEN FLUSHED WITH WATER IAW AD/GEN/80A1 FOLLOWED BY APPROVED PURGING OF THE WATER FROM THE SYSTEM. COMPLETE ENGINE FAILURE OCCURRED IN-FLIGHT. WHEN THE GASCOLATOR WAS DRAINED AFTER LANDING, APPROXIMATELY 100 ML OF WATER WAS RECOVERED FROM THE DRAIN. 1H71 3O3 O 3A19 E223 5 NP50GL 20000731000382000073100038CE 2000 7 31 AU000105 120000111G750025001 VALVE CESSNA208 208 2073702CE PWA PT6 PT6A114A 52043NE ENGINE BLEED AIRFAILED W K NONE O OTHER ININSP/MAINT 1 AUS 19391 (AUS) BLEED AIR SOLENOID VALVE OPEN CIRCUITED. MOVING PARTS CORRODED. SUSPECT MOISTURE INGRESS. 1H71 3T3 TNTA37CE E4EA 20000731000392000073100039SO 2000 7 31 AU000106 120000211G2822421135 PUMP WELDON 421135 PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL FUEL BOOST PUMP FAILED W K NONE J WARNING INDICATION LDLANDING 1 AUS 15 10082 (AUS) RIGHT FUEL BOOST PUMP BLADE RETAINING RING BROKEN. PUMP HAD ONLY JUST BEEN FITTED FOLLOWING OVERHAUL AND HAD ONLY OPERATED FOR APPROXIMATELY FIFTEEN MINUTES. 1L72 3O3 O A20SO E14EA 5 CP33EA 20000731000412000073100041EU 2000 7 31 AU000111 120000125G712068120251 MOUNT PARTEN P68B PARTENP68 P68B EU LYC O360 IO360A1B6 41514EA HARTZLHCC2Y HCC2YK2 GL ENGINE MOUNT SECCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 136 (AUS) LEFT AND RIGHT ENGINE MOUNTS CRACKED AND CORRODED. 1H72 3O3 O A31EU 1E10 5 CP920 20000731000422000073100042SO 2000 7 31 AU000115 120000405G3211AN717A BOLT PIPER PA38 PA38112 7103812SO LYC O235 O235L2C 41505EA SNSNCH72C 72CK EA MAIN LANDING GEACRACKED W O OTHER O OTHER LDLANDING 1 AUS (AUS) LEFT LANDING GEAR INBOARD ATTACHMENT BOLT FAILED. LEFT LANDING GEAR COLLAPSED. 1L71 3O3 O A18SO E223 5 NP9045 20000731000432000073100043NE 2000 7 31 AU000117 220000411G73133017957 NOZZLE PWA BEECH 200 200BEECH 1152920CE PWA PT6 PT6A42 52043NE MCAULY4HFR344HFR34C754 NE FUEL INJECTOR NOIMPROPER PART W K NONE O OTHER ININSP/MAINT 1 AUS AIJ234 (AUS) NR 13 FUEL NOZZLE TIP INCORRECT PART. PART FITTED