20081028 CE 2008 10 28 2008FA0000713 120041013G251005140778 SEAT FRAME CESSNA172 172M 2072418CE LYC O320 O320* 41508EA COCKPIT CRACKED D K NONE O OTHER ININSP/MAINT 1 SW99204545822 17261300 DURING A ROUTINE 100 HOUR INSPECTION IT WAS DISCOVERED THAT THE PILOTS FULLY ADJUSTABLE SEAT FRAME WAS CRACKED IN SEVERAL PLACES. SOME AREAS WERE COVERED UP BY THE UPHOLSTERY WHICH IS GLUED TO THE FRAME IN THAT AREA. OTHER AREAS OF CONCERN WERE INCOMPLETE WELDS DONE AT THE FACTORY. (3) OUT OF (4) SUPPORT LEGS WERE CRACKED AT THE WELD AND AT THE ATTACHMENT POINT TO THE BOTTOM SEAT ASSY. (K) 1H71 3O3 ONT3A12 E274 20050425000092005042500009EA 2005 4 25 CA041222016 220041222G7421REM38E SPARK PLUG CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE CRACKED W A UNSCHED LANDING ERJVIBRATION/BUFFET PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 CA L2751651A (CAN) NR 1 TOP SPARK PLUG INSULATOR FOUND BROKEN UNDER ELECTRODES. REPLACED NR 1 TOP SPARK PLUG, REMAINING PLUGS FOR LT MAGNETO CLEANED AND FUNCTION TESTED. GROUND RUN CARRIED OUT, LT MAGNETO OPERATION NORMAL. 1H71 3O3 ONT3A12 1E10 20040225000292004022500029WP 2004 2 25 54140A 220040119G7200310166811 PLENUM JETAIRJETSTMJETSTM4101 1500501EU GARRTTTPE331TPE33110UG 01514WP ENGINE CRACKED B DSCRK NONE O OTHER ININSP/MAINT 1 GL25 FOUND CRACKED AT DRAIN. 2L72 4T4 TRTA41NM E4WE 20040227000822004022700082SW 2004 2 27 2004FA0000142 120040123G5711 SPAR BBAVIA7 7AC 2110102SW CONT A75 A75* 17005SO WINGS CRACKED D K NONE O OTHER ININSP/MAINT 1 CE0783899 7AC2580 AD 200-25-02-R1, INSPECTION OF WING SPARS WAS SIGNED OFF AS COMPLIANCE WITH, ON 19 AUG O1 AS A NON-REOCCURRING INSP. DURING ANNUAL INSPECTION IN JAN 04, BOTH MAIN SPARS WERE FOUND TO BE CRACKED AT THE ROOT END. 1H71 3O3 O A759 E213 20040301000832004030100083CE 2004 3 1 2004FA0000190 120040211G551204121761 SKIN CESSNA150 150B 2071806CE CONT O200 O200A 17020SO MCAULY1A100 1A100* GL HORIZONTAL STAB CRACKED D K NONE O OTHER ININSP/MAINT 1 CE091163Y3548 15059563 30082A 36505 REMOVED HORIZONTAL STABILIZER FOR TAILCONE REPAIR. FOUND TWO 1.5 INCH CRACKS RADIATING FROM LOWER FORWARD CORNER OF TAIL CONE SKIN WHERE BOTTOM OF HORIZONTAL LEADING EDGE RESTS. CRACKS PROGRESSING TOWARDS FORWARD HORIZONTAL STABILIZER MOUNT BOLT HOLES. APPEARS INTERFERENCE FIT BETWEEN HORIZONTAL AND TAIL CONE WAS A CONTRIBUTING FACTOR. AREA HAD TO BE CLEANED TO FIND CRACK DUE TO THE ACCUMULATION OF DEBRIS AND WEAR MATERIAL. 1H71 3O3 O 3A19 E252 5 NP918 20040301000842004030100084CE 2004 3 1 2004FA0000191 120040211G551204121761 SKIN CESSNA150 150B 2071806CE CONT O200 O200A 17020SO MCAULY1A100 1A100* GL ZONE 300 CRACKED D K NONE O OTHER ININSP/MAINT 1 CE091163Y3548 15059563 30082A 36505 REMOVED HORIZONTAL STABILIZER FOR TAILCONE REPAIR. FOUND TWO 1.5 INCH CRACKS RADIATING FROM LOWER FORWARD CORNER OF TAIL CONE SKIN WHERE BOTTOM OF HORIZONTAL LEADING EDGE RESTS. CRACKS PROGRESSING TOWARDS FORWARD HORIZONTAL STABILIZER MOUNT BOLT HOLES. APPEARS INTERFERENCE FIT BETWEEN HORIZONTAL AND TAIL CONE WAS A CONTRIBUTING FACTOR. AREA HAD TO BE CLEANED TO FIND CRACK DUE TO THE ACCUMULATION OF DEBRIS AND WEAR MATERIAL. 1H71 3O3 O 3A19 E252 5 NP918 20040301001142004030100114CE 2004 3 1 6604 120040212G534307436062 FITTING CESSNA182 182P 2075816CE CONT O470 O470* 17026SO NLG BROKEN B C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 GL117371Q2737 18261011 ABORTED TAKEOFF AFTER LOUD NOISE HEARD ON TAKEOFF AND RUDDER KICKED FULL DEFLECTION. FOUND NOSE GEAR LOWER FITTING BROKEN IN TWO, INSPECT THIS FITTING CLOSELY AT ANNUAL. 1H71 3O3 ONTTA13 E273 20040301001212004030100121CE 2004 3 1 2004FA0000182 120040204G213340117 CHECK VALVE CESSNA650 650 2076802CE GARRTTTFE731TFE731* 01518WP CABIN PRESSURE CRACKED G K NONE O OTHER ININSP/MAINT 1 GL03600JD 6500236 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSEMBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECKED AND AN IDENTICAL CHECK VALVE CONDITION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2L72 4F4 F A9NM E6WE 20040301001272004030100127EA 2004 3 1 2004FA0000186 220040114G74144347 MAGNETO MOONEYM20 M20C 5870208SW LYC O360 IO360A1A 41514EA ENGINE FAILED D K NONE O OTHER ININSP/MAINT 1 CE056784V665 700083 L1506136A ROUGH ENGINE ON RUNUP. MAGNETO REMOVED AND DISASSEMBLED. BEARING CAP ASSEMBLY NOT HELD STATIONARY IN FRAME. RETAINING SCREWS AND TABS WERE FOUND TIGHT BUT NOT TIGHT ON BEARING CAP. BEARINGS FOUND TO BE OK. BELIEVE THAT CAP ON HOUSING WAS MACHINED INCORRECTLY AND WAS NEVER TIGHT FROM DAY ONE. 1L71 3O3 O 2A3 1E10 20040303000892004030300089CE 2004 3 3 2004FA0000199 120040202G8120K1250860M105 INLET CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO TURBO EXH SYS MISMANUFACTURED B CVDRK NONE O OTHER ININSP/MAINT 1 WP17111VF 21064005 2935795 UPON INSPECTION OF NEW PARTS DEFECTS WERE FOUND WITH THE TURBO INLET COMPONENT. DAMAGE WAS NOTED ON THE TURBOCHARGER MOUNTING FLANGE AND THE WELDING HAD VERY POOR PENETRATION. PART REJECTED AND SENT BACK TO O/H FACILITY. UPON RECEIVING PARTS, FACILITY WAS NOT ABLE TO IDENTIFY IF PART WERE NEW OR REPAIRED DUE TO INSUFFICIENT PAPER WORK. W/O AND INVOICE IS ONE AND SAME FOR NEW PARTS AND OVERHAULED PARTS. 1H71 3O3 O 3A21 E8CE 20040217001552004021700155SW 2004 2 17 2004FA0000148 120040109G7120204060031015 FITTING BELL 205 205A1 1181414SW LYC T53 T5313B 41549NE ENGINE DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 AL034750R 30009 LEO7587 UPON OPENING PACKED FOR FITTING ASSEMBLY FOUND THREADS ON LONG SIDE OF FITTING PULLED LOOSE. PART REJECTED BEFORE INSTALLATION. 1G71 4U4 U H1SW E17EA 20040303001022004030300102CE 2004 3 3 YK1R062001 120040227G4920GTCP36150W APU RAYTHNDH125 HAWKER800XP 7150012CE GARRTTTFE731TFE7313R1H 29001WP APU BAY FAILED B YK1RHE DEACTIVATE SYST/CIRCUITSENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 SW11653XP11 11 258653 DURING TAXI, SMOKE RAPIDLY FILLED THE COCKPIT AND THE CABIN. EMERGENCY SHUTDOWN OF ALL SYSTEMS WAS PERFORMED, GROUND EMERGENCY DECLARED AND AIRCRAFT EVACUATED. IT WAS FOUND DUE TO FAILURE IN THE APU, OIL ENTERED THE BLEED AIR DUCT WHICH CAUSED THE SMOKE. SYSTEM IS IN TROUBLESHOOTING/TEARDOWN PROCESS. 2L72 4F4 FRTA3EU E6WE 20040303001852004030300185NM 2004 3 3 SROM200400002 120040220G5310655495616 SHEAR TIE BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE FUSELAGE DAMAGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND ELONGATED HOLE IN SHEAR TIE AT STA 500 BETWEEN STR 16R AND 17R, FORWARD UPPER HOLE. REMOVED DAMAGED SHEAR TIE. FABRICATED AND INSTALLED REPLACEMENT SHEAR TIE IAW B737 SRM 53-10-4. 2L72 4F4 FRTA16WE E2EA 20040303001912004030300191SO 2004 3 3 2004FA0000208 220040211G8530AEC631397SN712B CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE UNSERVICEABLE D K NONE O OTHER ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER AS RECEIVED. FOUND EXHAUST VALVE GUIDE INSIDE DIAMETER TO BE BELOW MINIMUM SPECIFICATIONS, AND VALVE SEAT MACHINING NOT CONCENTRIC. 1H71 3O3 O 3A21 E8CE 20040303001922004030300192SO 2004 3 3 2004FA0000210 220040202G8530AEC631397SN712B CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE MISMANUFACTURED D K NONE O OTHER ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER ASSY AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE DID NOT MEET MINIMUM MFG. DIMENSIONS, AND VALVE SEAT MACHINING NOT CONCENTRIC. 1H71 3O3 O 3A21 E8CE 20040303001962004030300196SO 2004 3 3 2004FA0000209 220040202G8530AEC631397SN712 CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE MISMANUFACTURED D K NONE O OTHER ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHING NOT CONCENTRIC. 1H71 3O3 O 3A21 E8CE 20040303001972004030300197SO 2004 3 3 2004FA0000214 220040202G8530AEC631397SN712 CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE UNSERVICEABLE D K NONE O OTHER ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. 1H71 3O3 O 3A21 E8CE 20040303002032004030300203SW 2004 3 3 2004FA0000216 120040217G3210P1912506252M ROLL PIN MOONEY MOONEYM20 M20R 5870225SW CONT O550 IO550G 17042SO MCAULY3A32C 3A32C418G GL LT MLG TUBE SHEARED C A UNSCHED LANDING J WARNING INDICATION DEDESCENT 1 GL09909WM1923 182352 290152 679307 010286 SHEAR PINS ON LT MLG TUBE ASSEMBLY FAILED. AFT INSERT SEPARATED FROM TUBE ASSEMBLY. LT MAIN GEAR SUBSEQUENTLY REMAINED UNSAFE AND RETRACTED UPON CONTACT WITH RUNWAY. RT MLG AND NOSE GEAR WERE IN THE DOWN AND LOCKED AT TIME OF LT MLG FAILURE. 1L71 3O3 ORT2A3 E3SO 5 CP21EA 20040304000252004030400025WP 2004 3 4 2004FA0000219 120040113G61206873725012 O-RING AEROPRODTSXX CVAC 440 440 2422902WP ALLSN 501D 501D13 03004GL TRANSFER TUBE CUT B MV1RA UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 EA1749 33437603 R242 479 AT CRUISE FLIGHT NR 1 PROP EXPERIENCED RPM FLUCTUATIONS. AS A PRECAUTIONARY MEASURE, PROP WAS FEATHERED. PILOT LANDED UNEVENTFULLY. FOUND REGULATOR TO PROP, OIL TRANSFER TUBE, O-RING CUT. INSTALLED NEW O-RING. GROUND RUN FUNCTIONAL AND LEAK CHECKS GOOD. 2L72 4R4 T 6A6 E282 20040304000282004030400028NM 2004 3 4 SROM200400003 120040223G5310654652548 SHEAR TIE BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE FUSELAGE DAMAGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND SHEAR TIE AT STA 380 BETWEEN STR 20R AND 21R HAS HOLES THAT ARE LARGER THEN SRM LIMITS. REMOVED DAMAGED SHEAR TIE, FABRICATED AND INSTALLED REPLACEMENT SHEAR TIE IAW B737 SRM 51-40-3. 2L72 4F4 FRTA16WE E2EA 20040304000292004030400029NM 2004 3 4 SROM200400004 120040224G53406935352U14 STRINGER CLIP BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 639, STR 4L. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED NEW CLIP IAW B737 SRM 51-30-2 2L72 4F4 FRTA16WE E2EA 20040304000312004030400031NM 2004 3 4 SROM200400006 120040223G53406935352U14 STRINGER CLIP BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 616, STA 4L. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED NEW STRINGER CLIP IAW B737 SRM 51-30-2 2L72 4F4 FRTA16WE E2EA 20040304000412004030400041EA 2004 3 4 2004FA0000223 220040130G8520LW16812 LIFTER CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE WORN B FTURK NONE O OTHER ININSP/MAINT 1 NE05738271033 17267703 L23476T DURING A ROUTINE OIL CHANGE, WHILE COMPLYING WITH AD. MINUTE METAL PARTICLES WERE FOUND IN THE OIL FILTER WHEN IT WAS CUT OPEN FOR INSPECTION. HYDRAULIC LIFTERS WERE REMOVED FOR A MORE DETAILED INSP. THE ONE CAM LOBE FOR NR 3 AND NR 4 CYLINDERS HAD PLATING SEVERELY WORN OFF THE TOP OF THE LOBE AND THE BASE OF THOSE TWO LIFTERS HAD SEVERE DAMAGE. THIS ENGINE GETS FREQUENT OIL CHANGES. THIS ENGINE HAS THE 76T MOD INSTALLED INFORMATION WAS FORWARDED TO CERTIFICATION OFFICE. THIS ENGINE HAS BEEN REMOVED AND SENT FOR OVERHAUL. (NE05200404276) 1H71 3O3 ONT3A12 E274 20040304000502004030400050SO 2004 3 4 2004FA0000226 220040210G7310631526 DIAPHRAGM BEECH 35 M35 1151526CE CONT O470 IO470C 17026SO FUEL MANIFOLD CRACKED D ET9TO OTHER O OTHER NRNOT REPORTED 1 NM07762AA3600 D6168 718869C FUEL DIAPHRAGM ON THE FUEL MANIFOLD VALVE SHOWED DETERIORATION DUE TO AGEING. FUEL LEAKED OUT OF THE AIR BLEED HOLE ON THE FUEL MANIFOLD VALVE, CAUSING ENGINE FUEL FLOW PROBLEMS. ADDITIONAL INSPECTIONS AFTER PROLONGED STORAGE. 1L71 3O3 O 3A15 E273 20040304000722004030400072EU 2004 3 4 B30R20040226 120040219G5310 DOOR FRAME SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE FUSELAGE CRACKED B B3ORK NONE O OTHER ININSP/MAINT 1 SW035204Y1359 100 3101 9571 DURING 100 HOUR INSPECTION DISCOVERED CO-PILOT DOOR POST CRACKED 14 INCHES LONG STARTING 8 INCHES ABOVE CABIN FLOOR, EXCEEDING THE LIMITS IN REPAIR MANUAL. REPAIRED CRACK IAW MM. REQUESTED FROM MFG. 1G71 3U3 U H9EU E19EU 20040304000822004030400082GL 2004 3 4 2004FA0000236 120040206G1430 FASTENER AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA LT AILERONS CHAFED B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM28 201023 DEFLECTION OF LT AILERON UP CAUSES IT TO RUB AGAINST AN EXPOSED RIVET. DEFLECTION OF RT AILERON UP CAUSES IT TO RUB AGAINST TWO EXPOSED RIVETS POSSIBLY HINDERING TRAVEL. (GL13200405339) 1L71 3 O EXPA1L71E223 20040304000872004030400087GL 2004 3 4 2004FA0000239 120040206G3250 BUNGEE CYLINDER AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA NLG STEERING STIFF B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM 201023 NOSE WHEEL STEERING BUNGEES ARE EXTREMELY STIFF, CAUSES THE RUDDER TO REQUIRE EXTREMELY HIGH RUDDER INPUTS IN FLIGHT. PILOT CAN FEEL A BREAKOVER POINT. (GL13200405339) 1L71 3 O EXPA1L71E223 20040304000902004030400090 2004 3 4 2004FA0000240 420040206G3454 INDICATOR AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA VOR SYSTEM INACCURATE B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM28 201023 NEWLY INSTALLED VORS INDICATORS 6-10 DEGREES DIFFERENCE. NAV 1 G430 W G5, NAV 2 BK W G5 KX 155. (GL13200405339) 1L71 3 O EXPA1L71E223 20040304000922004030400092GL 2004 3 4 2004FA0000241 120040206G5260 STEP AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA PAX DOOR LOOSE B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM 201023 RT ENTRANCE STEP IS EXTREMELY LOOSE. (GL200305339) 1L71 3 O EXPA1L71E223 20040304000932004030400093SO 2004 3 4 2004FA0000248 120040227G323067502000 RETAINER PIPER PA34 PA34200 7103405SO LYC O360 IO360A1A 41514EA RT MLG LOOSE D EH ENGINE SHUTDOWN DEACTIVATE SYST/CIRCUITS W INADEQUATE Q C LDLANDING 1 SO0515412 347350060 ON LANDING ROLL-OUT, RIGHT MLG COLLAPSED AFT AND CAME TO REST AGAINST AFT PORTION OF WHEEL WELL.RETAINING PIN HAD SLIPPED OUT OF TRUNNION, ALLOWING GEAR TO COLLAPSE. THIS GEAR WAS PREVIOUSLY REMOVED FOR SPAR REPAIR. THE RETAINER BOLT WAS EITHER LEFT OUT OR WAS NOT INSTALLED CORRECTLY. OVER A PERIOD OF TIME, THE RETAINER SLID OUT OF THE TRUNNION. RECOMMEND POST MAINTENANCE INSPECTIONS BE MORE COMPLETE. THIS INCIDENT, IF IT HAD HAPPENED 20 SECONDS EARLIER, WOULD HAVE CAUSED MAJOR STRUCTURAL DAMAGE AND POSSIBLY PERSONAL INJURY. 1L72 3O3 O A7SO 1E10 20040304000952004030400095GL 2004 3 4 2004FA0000243 120040206G5320 BRACKET AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA CARB HEAT BROKEN B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM21 201023 CARB HEAT BRACKET BROKE LOOSE IN FLIGHT. 1L71 3 O EXPA1L71E223 20040304000962004030400096 2004 3 4 2004FA0000244 420040206G2300 AUDIO PANEL AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA COCKPIT INOPERATIVE B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM13 201023 STEREO INPUT INTO AIRCRAFT DOES NOT WORK. (GL13200405339) 1L71 3 O EXPA1L71E223 20040304000982004030400098CE 2004 3 4 8570000 120040227G2731S3280 GEAR BEECH 1900 1900D 1154162CE PWA PT6 PT6* 52043EA ELEVATOR TRIM SLIPPED A JJBAK NONE O OTHER ININSP/MAINT 1 EA01857CA5662 UE403 WHILE CHECKING ELEVATOR TRIM FOR FCD BE2703 DISCOVERED ELEVATOR TAB DIAL MECHANISM MOUNT ASSY HAD SLIPPED CAUSING THE TRIM INDEX MARK CALIBRATION TO CHANGE. UPON FURTHER INSPECTION IT WAS DISCOVERED THAT THE SLIPPAGE WAS CAUSED BY A PRESSED ON GEAR IN THE ELEVATOR TAB DIAL MECHANISM MOUNT ASSY THAT HAD SLIPPED ON ITS SHAFT. 2L72 4T3 TRTA24CE E2NE 20040304001052004030400105NM 2004 3 4 SROM200400008 120040225G5310654654851 SHEAR TIE BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE ZONE 100 CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND AT STA 747 SHEAR TIE CRACKED AT FASTNER HOLE BETWEEN STR 20L AND 21L. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR SHEAR TIE IAW SRM 53-10-4. 2L72 4F4 FRTA16WE E2EA 20040304001062004030400106NM 2004 3 4 SROM200400009 120040225G5513654577428 STRINGER BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE ZONE 100 ELONGATED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND AFT CARGO PIT STRINGER 20L HAS SEVERAL ELONGATED FASTNER HOLES AND MULTIPLE CRACK INDICATIONS AROUND HOLES STA 747 TO 887. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR STRINGER AND SPLICES IAW SRM 53-10-3. 2L72 4F4 FRTA16WE E2EA 20040304001072004030400107NM 2004 3 4 SROM200400010 120040226G534069353521 STRINGER CLIP BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE ZONE 100 CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND STRINGER TO FRAME CLIP CRACKED AT STA 495-500, STR 24R. REMOVED DAMAGED STRINGER CLIP, FABRICATED AND INSTALLED REPLACEMENT STRINGER CLIP IAW B737 SRM 51-20-1, 51-30-2. 2L72 4F4 FRTA16WE E2EA 20040315000012004031500001NM 2004 3 15 AUS20040043 120040117G5210723D1009 ACTUATOR BOEING747 747438 NM RROYCERB211 RB211524* NE PAX DOOR INTERMITTENT W O OTHER J WARNING INDICATION CRCRUISE 1 AUS 34991 (AUS) RT UPPER DECK DOOR FLIGHT LOCK ACTUATOR INTERMITTENT IN OPERATION. ACTUATOR INTERMITTENTLY UNLOCKS DOOR HANDLE. 2L74 4F4 FRTA20WE E12EU 20040315000022004031500002CE 2004 3 15 CA040211007 120040122G561010138402524 WINDSHIELD BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) RT WINDSHIELD INNER LAYER CRACKED IN FLIGHT AT FLIGHT LEVEL 240. REPORTED OAT -45C. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040315000032004031500003EU 2004 3 15 CA040123006 120040105G2497WIRE161 WIRE HARNESS BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE NR 1 GENERATOR CHAFED W O OTHER J WARNING INDICATION APAPPROACH 1 CA 3728737287 (CAN) DURING APPROACH WHEN ATTEMPTING TO START APU , LOST AC BUSS 1 AND ESSAC , NR 1 GENERATOR WOULD NOT RE-SET, AIRCRAFT LANDED NORMALLY. MAINTENANCE INSPECTION FOUND CHAFING OF THE 'B' PHASE (YELLOW STRIPE) NR 1 ENGINE GENERATOR WIRING CHAFED TO GROUND AT THE LT TOP FWD COWL (WIRING BUNDLE CONTAINING FEEDER CABLE AND GEN CONTROL WIRING), ALSO FOUND CHAFING OF THE NR 1 GENERATOR 'RED STRIPE' WIRING AT PYLON COVER. NOTE: PREVIOUS SIMILAR EVENT ON THIS AIRCRAFT HAD BEEN BLAMED ON CONTAMINATION OF THE CONNECTOR (1XB-7R), PROBLEMS WERE SEVERAL DAYS APART. 2H74 4F4 F A49EU E6NE 20040315000082004031500008 2004 3 15 AUS20040046 420040122G3418C809072 TRANSDUCER DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE STALL WARNING STICKING W O OTHER N FALSE WARNING TOTAKEOFF 1 AUS (AUS) RT STALL WARNING SYSTEM TRANSDUCER STICKING IN FORWARD POSITION. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315000092004031500009SW 2004 3 15 AUS20040047 120040130G53302722197002 DOUBLER SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCB3T HCB3TN5 GL FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE DOUBLER LOCATED AT RT EMERGENCY EXITS, BADLY CORRODED. 2L72 4T4 TRTA8SW E4WE 6 CP15EA 20040315000102004031500010NM 2004 3 15 AUS20040048 120040129G531065056131 DOOR FRAME BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AFT CARGO DOOR CUTOUT FRAME LOCATED AT BS 1090 RIB BL28 CRACKED. CRACK LENGTH 8.255MM (0.325IN). 2L73 4F4 FRTA3WE E2EA 20040315000122004031500012SW 2004 3 15 CA040211010 120040209G8012 REGULATOR SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP MCAULY4HFR344HFR34C652 NE ENGINE INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA 27214 (CAN) CREW WERE ON A TRAINING FLIGHT AND WENT THROUGH A SIMULATED ENGINE FAILURE. ENGINE WOULD NOT RESTART AFTER 3 ATTEMPTS. AIRCRAFT RETURNED TO BASE. MAINTENANCE FOUND THE START PRESSURE REGULATOR TO BE AT FAULT. PART WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE AFTER SUCCESSFUL ENGINE STARTS IAW MM. 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20040315000142004031500014CE 2004 3 15 CA040212001 120040204G5210051300735 POST CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL CREW DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 10532 (CAN) DURING 200 HR INSPECTION, CRACK NOTED AT LOWER DOOR HINGE IN LT FRONT DOORPOST. VISIBLE THROUGH ACCESS HOLE ON INSIDE OF POST. CRACK APPEARS TO HAVE INITIATED DUE TO FLEXING CAUSED BY HINGE PULLING ON POST WHEN DOOR CLOSES. 1H71 3O3 ONT3A12 E274 5 NP910 20040315000172004031500017CE 2004 3 15 CA040212005 120040206G521050430043619 CHANNEL BEECH BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL CABIN DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION OF THE DOOR HINGE FOR LOOSE RIVETS, A CRACK WAS DISCOVERED THAT PROPAGATED APPROXIMATELY .7500 THE LENGTH OF THE DOOR CHANNEL. THE DOOR WAS REMOVED AND SENT TO AN APPROVED REPAIR STATION. 1L72 4T4 T A24CE E4EA 5 CSTC 20040315000222004031500022CE 2004 3 15 CA040126002 120040122G71601019100209 HINGE BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCB3T HCB3TN3 GL INLET VANE WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) MAINTENANCE INSPECTION DISCOVERED LT ENGINE INLET VANE HINGE PIN WAS WORKING OUT OF THE HINGE AND CONTACTING THE INNER COWL STRUCTURE. MFG ADVISES THE HINGE ENDS ARE CRIMPED TO PREVENT PIN MOVEMENT, HOWEVER ON THIS ASSY THE PIN APPEARS TO HAVE WORN THROUGH THE CRIMP. HINGE ASSEMBLY REPLACED NEW. 1L72 4T4 T A24CE E4EA 6 CP15EA 20040315000352004031500035EU 2004 3 15 CA040127002 120040126G300023053191 LEVER BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ANTI ICE ACT CRACKED W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) PILOT REPORTED THAT THE INLET ANTI-ICE SYSTEM WAS UNSERVICEABLE. THE ANTI-ICE VALVE WOULD NOT TO CLOSE. THE CIRCUIT BREAKER FOR THE SYSTEM ALSO TRIPPED. UPON INSPECTION MAINTENANCE FOUND THAT THE ANTI-ICE LEVER WAS CRACKED AND ELONGATED WHERE IT ATTACHES TO THE ACTUATOR ALLOWING THE ANTI-ICE LEVER TO DISCONNECT FROM THE ACTUATOR. THE ACTUATOR WOULD RUN BUT NOT EXTEND OR RETRACT THE INLET ANTI-ICE VALVE. 1G72 3U3 U H3EU E4CE 20040315000442004031500044EA 2004 3 15 CA040213010 120040210G2731C2T41 JACKSCREW DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE ELEVATOR TRIM CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 12498 (CAN) MINOR CORROSION NOTED ON THE EXTERNAL SURFACE OF THE TRIM DRUM (CABLE GROOVES EXFOLIATING NEAR THE CABLE INDEX PIN) ON REMOVAL OF THE TRIM DRUM SCREW ASSEMBLY THE MIDDLE PORTION OF THE JACK SCREW PN NR C2T41 WAS FOUND TO BE SEVERELY CORRODED IN THE MID PORTION OF THE ACME THREAD. THIS PART OF THE JACKSCREW IS NOT VISIBLE DURING ROUTINE MAINTENANCE, AND REQUIRES THE JACK TO BE DISASSEMBLED TO VERIFY ITS CONDITION. 1H71 3R3 R A806 5E1 5 CP206 20040315000492004031500049EA 2004 3 15 CA040127006 120040127G215032156221 REGULATOR VALVE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE LT & RT PACK INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT AND RT PACK HI PRESS. MESSAGE ON T/O, CHECKLIST COMPLETED. LT PACK CAME BACK MOMENTARILY. BOTH PACKS U/S WITH HIGH PRESS. MSG. LT AND RT PRESSURE REGULATOR VALVES REPLACED, BOTH PACKS OPERATED AT T/O POWER, NO FAULT FOUND. CONS.SERV. 2L72 4F4 FRTA21EA E15NE 20040315000542004031500054NM 2004 3 15 CA040127011 120040127G3230273T41202 GEAR BOEING767 7673Y0 NM PWA 4060 PW4060 52119NE NLG LOCK INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHEN GEAR WAS LOWERED, NOSE DID NOT LOCK. CREW WAS ABLE TO EXTEND AND LOCK USING THE ALTERNATE METHOD, CONTINUING THE LANDING WITHOUT FURTHER INCIDENT. ACFT REMOVED FROM SERVICE FOR INVESTIGATION. 2L72 4F4 FRTA1NM E24NE 20040315000632004031500063CE 2004 3 15 CA040216006 120040213G251005142132 LOCK CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL COCKPIT SEAT SHEARED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) DURING THE PRE-FLT PHASE, THE PILOT ATTEMPTED TO ADJUST THE LT SEAT WHEN THE SEAT BACK DROPPED BACK BEYOND ITS NORMAL RANGE OF ADJUSTMENT. IT WAS DETERMINED THEN THAT THE SEAT WAS NOT IN A SAFE CONDITION TO USE AND THE CREW MADE AN ENTRY IN THE LOGBOOK THUS GROUNDING THE AIRCRAFT. CLOSER EXAMINATION OF THE SEAT ADJUSTING MECHANISM BY THE MAINTENANCE PERSONNEL REVEALED THAT THE AFT ROD ATTACHMENT FOR THE LOCK CYLINDER HAD SHEARED WHERE THE ROD IS SECURED INTO THE END CAP. THE CRIMP REMAINED INTACT WHERE AS THE SHEAR OCCURRED JUST FORWARD OF THE CRIMP. DIRECTLY CAUSING THE SEAT ADJUSTMENT MECHANISM TO FAIL. A NEW REPLACEMENT PART ORDERED FROM THE MFG. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20040315000652004031500065CE 2004 3 15 CA040217001 120040217G7120265102215 MOUNT CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE THE ENGINE MOUNT RING (HORSE COLLAR) WAS FOUND CRACKED AT TWO OF THE FOUR CORNERS, INSIDE JOINT. DUE TO THIS BEING A KNOWN PROBLEM, AN ADDITIONAL TASK CARD TO CHECK FOR THIS CONDITION, INITIATED IN 1999, WAS ADDED TO OUR MAINTENANCE SCHEDULE EVERY 100 HOURS. AS A RESULT, WE HAVE DISCOVERED THE CONDITION ON 9 SEPARATE COLLARS. THE COLLAR WAS REPLACED AND THE AIRCRAFT RELEASED. 1H71 3T3 T A37CE E4EA 5 CP60GL 20040315000672004031500067SO 2004 3 15 CA040127018 120040124G2820465299 LINE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL FUEL SYSTEM LEAKING W O OTHER KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA (CAN) DURING START UP, PILOT NOTICED FUEL ODOR IN CABIN SHORTLY AFTER ENGINE START UP. MAINTENANCE WAS NOTIFIED AND AFTER INSPECTION IT WAS NOTED A FINE MIST FROM RT FLEXIBLE FUEL PRESSURE LINE. HOSE WAS REPLACED WITH NO FURTHER PROBLEMS. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315000692004031500069SW 2004 3 15 CA040217002 120040211G521044P14 HOSE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCB3T HCB3TN5 GL DOOR SEAL CRACKED W B EMER. DESCENT W INADEQUATE Q C CRCRUISE 1 CA (CAN) THE HOSE THAT SUPPLIES THE CABIN DOOR SEAL CRACKED, ALLOWING THE SEAL TO DEFLATE WHICH IN TURN ALLOWED THE CABIN OF THIS FREIGHTER TO DEPRESSURIZE AT 17000 FT. THE CREW DESCENDED TO A SAFE ALTITUDE AND COMPLETED THE FLIGHT. 2L72 4T4 TRTA8SW E4WE 6 CP15EA 20040315000702004031500070CE 2004 3 15 CA040217003 120040217G3040KRP3DH24 RELAY CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL WINDSHIELD BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING TROUBLESHOOTING OF THE WINDSHIELD HEAT AUTO FUNCTION, THE AUTO RELAY WAS FOUND TO BE INTERNALLY SHORTED AND HAD MELTED THE CLEAR CASE. THE RELAY WAS REPLACED AND THE AIRCRAFT RELEASED. 1H71 3T3 T A37CE E4EA 5 CP60GL 20040315000742004031500074NM 2004 3 15 CA040217008 120040213G2750696670833 CONTROL CABLE BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE LT IB FLAP FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING SCHEDULED MAINTENANCE, IT WAS OBSERVED THAT THE LT IB FLAP ASSY WAS DROOPING. UPON FURTHER INVESTIGATION, THE CABLE ASSY WAS FOUND FRAYED AND BROKEN. A NEW CABLE ASSY WAS INSTALLED IAW MM 27-51-5 AND FUNCTIONED SERVICEABLE IAW MM 27-51-0. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2L73 4F4 F A3WE E2EA 20040315000782004031500078SW 2004 3 15 CA040217009 120040210G2497206075559005 CONNECTOR BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL LEAD GRD CONNECTBURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BURNED CABLE CONNECTORS AT FUSELAGE GROUND CONNECTION. LOOSE/CORRODED CONNECTION. CABLE ASSEMBLY REPLACED. THIS MAY HAVE CONTRIBUTED TO EARLIER PROBLEMS WITH RCR /VOLT.REG. (CABLE K5B8N AND K5D8N) 1G71 3U3 U H2SW E4CE 20040315000882004031500088EA 2004 3 15 CA040218003 220040212G8530LW12966 CYLINDER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE DAMAGED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) OVERHAUL ENGINE WAS INSTALLED AT 7117.6. IN THE PROCESS OF DOING A 100 HOUR, FOUND NR 1 CYLINDER VERY LOW ON COMPRESSION. REPLACED CYLINDER WITH OVERHAULED CYLINDER. CHECKED COMPRESSION AFTER INSTALLATION AND COMPRESSION WAS WHERE IT WAS SUPPOSED TO BE. GROUND RUN NO FAULTS FOUND. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315000892004031500089SW 2004 3 15 CA040128001 120040128G6510407340339107 BEARING RACE BELL 427 427 1182207SW PWC PW207 PW207D NE T/R DRIVE MISMANUFACTURED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) IT WAS BROUGHT TO OUR ATTENTION THAT A BEARING WAS DELIVERED TO A CUSTOMER AND FOUND WITHOUT THE REQUIRED 4 (.062 DIA.) LUBE HOLES. THE 4 LUBE HOLES TO BE LOCATED IN THE LUBRICATION GROOVES. 1G71 3U3 U R00001RCE42NE 20040315000922004031500092NM 2004 3 15 CA040128004 120040127G7711 LINE BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE PT7 NR 1 ENGINE CHAFED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) NR 1 ENGINE EPR INDICATION ERRATIC. FOUND PT7 LINE CHAFED ON LT WING LEADING EDGE AT WBL 114.0. ELBOW AT END OF LINE CONNECTION FOUND CRACKED. BOTH CHAFED LINE AND ELBOW REPLACED. 2L72 4F4 F A16WE E2EA 20040315000932004031500093EA 2004 3 15 CA040128005 220040109G7414 BEARING CONT 3200 PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL MAGNETO CONTAMINATED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA A0491056R (CAN) ON RETURN FLIGHT THE LT ENGINE STARTED TO RUN ROUGH. UPON LANDING THE PILOT DID A MAGNETO CHECK AND FOUND THAT THE MAGNETO DROP WAS EXCESSIVE. REMOVED MAGNETO WITH COVER OFF FOUND METAL IN BACK OF MAGNETO. INSTALLED OVERHAULED MAGNETO, GROUND RUN AIRCRAFT NO FAULTS FOUND. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315000952004031500095NM 2004 3 15 CA040128007 120040126G3242214664 BRAKE DISC DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG BRAKE UNIT DEFORMED W K NONE O OTHER ININSP/MAINT 1 CA 0092 (CAN) DURING REMOVAL OF THE BRAKE UNIT FROM THE AIRCRAFT, HALF OF THE BRAKE DISC DROPPED ONTO THE FLOOR. ONCE THE BRAKE UNIT WAS REMOVED FROM THE AIRCRAFT, THE REMAINING HALF OF THE DISC WAS RECOVERED FROM THE BRAKE UNIT. IT APPEARS TO BE SOME DEFORMITY OF THE DISC. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315000992004031500099EA 2004 3 15 CA040218004 220040212G8530LW12966 CYLINDER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE INOPERATIVE W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) OVERHAUL ENGINE WAS INSTALLED AT 7117.6. IN THE PROCESS OF DOING A 100 HOUR FOUND NR 6 CYLINDER VERY LOW ON COMPRESSION. REPLACED CYLINDER WITH OVERHAUL CYLINDER CHECKED COMPRESSION AFTER INSTALL, COMPRESSION WAS WHERE IT WAS SUPPOSED TO BE. GROUND RUN NO FAULTS FOUND. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315001002004031500100EU 2004 3 15 CA040218005 120040218G7830 THRUST REVERSER AIRBUSA340 A340313 EU CFMINTCFM56 CFM565C4 13802NE NR 1 ENGINE INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) SHORTLY AFTER T/O ROTATION ECAM ENG. NR 1 REV. UNLOCKED. NO BUFFET EXPERIENCED. JETTISONED FUEL AFTER ECAM AND RETURNED TO LAND, OVERWEIGHT 229,000, VERTICAL SPEED AT TOUCHDOWN ESTIMATED APPROX 300/FTM. THRUST REVERSER PLACED UNDER MEL 78-30-01. IAW REQUEST FROM MOC DFDR REMOVED FOR POSSIBLE INVESTIGATION. 2L74 4F4 FRTA197 E37NE 20040315001012004031500101CE 2004 3 15 CA040218007 120040128G56105042006937 WINDSHIELD BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) PILOTS FRONT WINDOW CRACKED ACROSS WINDOW ON OUTER PANE. 1L72 3T4 T A14CE E4EA 5 CSTC 20040315001022004031500102GL 2004 3 15 CA040219001 120040216G78102078000107 EXHAUST STACK DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912 55555EU HOFMANHOV352HOV352F NE CYLINDER HEAD BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE RT REAR EXHAUST STACK WAS FOUND TO BE COMPLETELY FRACTURED IN TWO AT THE BEND NEAR THE CYLINDER HEAD. THIS FAILURE IS THE SECOND COMPLETE FRACTURE NOTED IN THE PAST WEEK. A THIRD EXHAUST STACK WAS FOUND CRACKED IN THE SAME LOCATION DURING THE PREVIOUS WEEK. 1L71 3O3 INTTA4CH EXPE3I 5 CTP5BO 20040315001042004031500104NE 2004 3 15 CA040219003 220040218G7200JT8D15A ENGINE BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE NR 1 FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 CA 685598 (CAN) UPON THE TRANSITIONING FROM CLIMB TO CRUISE, A LOUD BANG WAS HEARD AND SUBSEQUENT VIBRATION FELT THROUGHOUT THE AIRFRAME. ALL NR 1 ENGINE PARAMETERS IMMEDIATELY BEGAN TO DETERIORATE RAPIDLY. AT FL280, ENGINE FAILURE DRILL INITIATED AND COMPLETED. ATC ADVISED OF ENGINE FAILURE. EMERGENCY DECLARED AND AIRCRAFT RETURNED. EMERGENCY CREW MET AIRCRAFT AND AFTER INSPECTION OF ENGINE, AIRCRAFT WAS THEN TAXIED BACK TO RAMP AND SHUT DOWN. MORE TO FOLLOW AFTER INVESTIGATION. 2L73 4F4 F A3WE E2EA 20040315001082004031500108EU 2004 3 15 CA040129006 120040119G6320350A38101891 BEAM SNIAS 350 AS350B1 8680811EU TMECA ARRIELARRIEL1D1 NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AIRCRAFT ON HELISKIING WHEN THIS OCCURRED. INSPECTED IAW AD96-156-071(B) R1 PART 1.1, EVERY 30 HOURS OR 150 CYCLES. THIS WAS BEING INSPECTED DUE TO THE CYCLES EVERY 2 OR 3 DAYS. THE CROSSBEAM WAS FOUND SMOKING IN THE REGION OF SUSPECTED CRACK. THE AREA WAS CLEANED, INSPECTED AND FOUND TO BE SERVICEABLE. AFTER A NEXT DAY FLYING IT WAS INSPECTED AGAIN AND FOUND TO BE SMOKING AGAIN REMOVED FROM SERVICE TO BE NDT. SENT TO A NDT AMO AND CRACK WAS CONFIRMED. THE AD IS WORKING. 1G71 3U3 U H9EU E19EU 20040315001132004031500113 2004 3 15 CA040102002 420040102G34179B810202 ADC BOEING737 737200 1384453NM PWA JT8 JT8D17 52049NE COCKPIT INTERMITTENT W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) PRIOR TO DEPARTURE THE FLIGHT CREW A MACH AIRSPEED WARNING CLACKER INOPERATIVE ASSOCIATED WITH A FLAG ON THE MACH AIRSPEED INDICATOR. RECTIFICATION THE MACH AIRSPEED INDICATOR WAS REPLACED. HOWEVER THE SNAG RETURNED ON DECEMBER 29. THE SYSTEM WAS PLACED ON MEL. THE MACH AIRSPEED INDICATOR WAS REPLACED AGAIN ON DECEMBER 31. HOWEVER THE FAULT RETURNED FOR A THIRD TIME ON JANUARY 2, 2004. 2L72 4F4 F A16WE E2EA 20040315001172004031500117NM 2004 3 15 CA040130002 120040106G2422054021 RESISTOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE INVERTER FAILED W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA 1882S8 (CAN) COMPONENT RESPONSIBLE FOR INVERTER FAILURE WAS THE RESISTOR (R324) P/N 054021 DESCRIPTION: ON APPROACH, PRIMARY INVERTER, SECONDARY INVERTER, AND AUX INVERTER, L26AC BUS, AND R26AC BUS CAUTION LIGHTS ILLUMINATED. AFTER AUX INVERTER SWITCHED OFF, PRIMARY, SECONDARY AND BOTH 26AC BUS LIGHTS WENT OUT. CREW BROKE OFF APPROACH AND AC RETURNED. COULD NOT FAULT ON GROUND. PRIMARY INVERTER VOLTAGE INDICATING 107V AND REPLACED. AUX INVERTER REPLACED FOR T/S. ALL RELATED CONNECTOR PLUGS AND CIRCUIT BREAKERS INSPECTED SVC. INVERTERS SENT OUT TO VENDOR AND RETURNED WITH S/N 1882-S8 S WO CONFIRMING FAULT, AND NAMING THE RESISTOR AS THE CULPRIT COMPONENT P/N 054021. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315001182004031500118NE 2004 3 15 CA040130003 220040126G72003020159 RETAINER CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL ENGINE COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE HOT SECTION WAS GIVEN A SCHEDULED HOT SECTION INSPECTION. FOUR CT SHROUD SEGMENTS HAD SHIFTED SLIGHTLY. THE RETAINING RING HAD COME OUT OF THE GROOVE. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. PWA HAS ISSUED P/N 3110741-02 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42, 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETAINING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 1H71 3T3 T A37CE E4EA 5 CP60GL 20040315001202004031500120EU 2004 3 15 CA040130006 120040125G623011741904 SWASHPLATE BOLKMS117 BK117B1 5626012EU LYC LTS101LTS101750B1 41560NE MAIN ROTOR WORN W O OTHER O OTHER CRCRUISE 1 CA (CAN) UPON RETURNING AFTER A TRIP THE PILOTS REPORTED A (HUMP) (VERTICAL VIBRATION) ON THE AIRCRAFT. A VISUAL INSPECTION WAS CARRIED OUT ON THE MAIN ROTOR HEAD, BLADES, PITCH LINKS, AND THE SWASHPLATE. CHECKING THE SWASHPLATE FOUND IT TO HAVE AN EXCESSIVE AMOUNT OF PLAY. 1G72 3U3 U H13EU E5NE10 20040315001222004031500122SO 2004 3 15 CA040103001 120040102G55404004009 TORQUE TUBE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL RUDDER CORRODED W K NONE F FLT CONT AFFECTED ININSP/MAINT 1 CA (CAN) WHILE COMPLYING WITH AD 2003-24-07, FOUND SURFACE CORROSION OF RUDDER TORQUE TUBE (VISUAL INSPECTION OF RUDDER INTERNAL STRUCTURE MFG SB NR 1105A. REMOVED TORQUE TUBE AND FOUND AREA TO BE INSPECTED IAW AD REPAIRABLE BUT FOUND THAT THE INTERNAL TORQUE TUBE CORROSION SEVERE AND METAL/OXIDE FALLING OFF TORQUE TUBE INTERNAL WALLS. (NOT MENTIONED BY AD). RUDDER ALUMINUM RIBS TO STEEL TORQUE TUBE CORROSION ALSO NOTED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315001262004031500126SO 2004 3 15 CA040219006 120040218G32134041304 AXLE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2A GL MLG BROKEN W CD ABORTED TAKEOFF RETURN TO BLOCK D INFLIGHT SEPARATION TXTAXI/GRND HDL 1 CA 16094 (CAN) PILOT WAS TAXIING OUT FOR TAKEOFF WHEN THE AXLE BROKE. VIBRATION AND NOISE WAS HEARD. TAXIED BACK AND DISCOVERED THE MAIN WHEEL HAD TILTED OVER AND WAS RUBBING ON THE FORK ASSEMBLY. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315001282004031500128 2004 3 15 CA040220002 420040211G341624929412 ALTIMETER BEECH 99 99 1154002CE PWA PT6 PT6A36 52043NE HARTZLHCB3T HCB3TN3 GL COCKPIT FAILED W A UNSCHED LANDING P NO WARNING INDICATION CRCRUISE 1 CA 1535 (CAN) CAPTAIN'S ALTIMETER ERROR OF APPROXIMATELY 1,000 FEET CHECKED OK PRIOR TO DEPARTURE. NOT SURE WHEN FAILURE OCCURRED, BUT NOTICED ERROR AT LEVEL CRUISE. MAINTENANCE CONFIRMED NO STATIC SYSTEM LEAKS. 1L72 3T4 T A14CE E4EA 6 CP15EA 20040223001082004022300108EU 2004 2 23 2004FA0000077 120040104G769730709341 WIRE HARNESS BRAERODH125 HS125700A 4230170EU GARRTTTFE731TFE7313R 01518WP RT ENGINE DETERIORATED D A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 CE03120JC6970 6970 NA0247 P80195C WHILE EN ROUTE, NOTED RT ENGINE COMPUTER AMBER WARNING LAMP BECAME ANNUNCIATED. ALSO NOTED, INDICATED LOSS OF POWER RT ENGINE. CONSULTED AND COMPLIED WITH EMERGENCY PROCEDURES WHICH INSTRUCTED TO SWITCH TO MANUAL CONTROL AND MONITOR ALL APPLICABLE ENGINE PARAMETERS. IMMEDIATE NOTIFICATION TO ATC REQUESTS TO DIVERT TO DAL FOR INSPECTION AND REPAIRS. FOLLOWING TROUBLESHOOTING AND INSPECTION TO DETERMINE SOURCE OF DEFECT, IT WAS NOTED THAT THE RT ENGINE PT2 HARNESS WAS DEFECTIVE. PARTS WERE REPLACED, ENGINE AND COMPUTER FUNCTIONS WERE TESTED, AND NO RECURRING DEFECTS WERE NOTED. 2L72 4F4 F A3EU E6WE 20040225000322004022500032NM 2004 2 25 2004FA0000080 120040119G5711 SPAR UNIVAR415 415C 0420302NM CONT C85 C8512F 17008SO MCAULY1A90 1A90CF GL CENTER WING CORRODED D K NONE O OTHER ININSP/MAINT 1 CE0593517 840 28872712 598 AD 2002-26-02 CORROSION INSPECTION: REMOVED BOTH WINGS AND BOTH FUEL TANKS. INSPECTED ENTIRE CENTER SECTION AND FOUND FOUR QUARTER SIZED AREAS OF LIGHT CORROSION ON FWD SIDE OF FRONT CENTER SECTION SPAR. CORROSION AREAS WERE SANDED WITH 240 GRIT SANDPAPER AND THE ENTIRE CENTER SECTION WAS CLEANED AND SPRAYED WITH CORROSION PREVENTIVE. CLEANED AND INSPECTED EXTERIOR OF BOTH GAS TANKS AND FOUND NO CORROSION. REPLACED ONE RIVET IN TOP EDGE OF RIGHT FRONT CENTER SECTION SPAR CAP WITH AN OVERSIZE RIVET. REINSTALLED BOTH WING PANELS AND BOTH FUEL TANKS. WORK PERFORMED IAW AC 43.13-1B, SB-31 REVISION 1, AC 43-4A AND PATIENCE. 1L71 3O3 O A718 E233 5 NP842 20040225000412004022500041NM 2004 2 25 2004FA0000088 120040112G2720ABC10800318 CONTROL CABLE AMBLP A150 A150 3850110NM LYC O360 IO360A1A 41514EA RUDDER FAILED D O OTHER O OTHER NRNOT REPORTED 1 SO15154ZP 104 NICOPRESS FITTING FAILED ON THIS PARTICULAR CABLE. 1B72 3O3 O0 SOOOO2SE1E10 20040223000772004022300077 2004 2 23 2004FA0000033 420040105G2562E01 ELT AVIAT A1 A1A 2210405GL LYC O360 O360A1D 41514EA CABIN CORRODED P K NONE O OTHER ININSP/MAINT 1 AL0340HU 1315 OPERATIONAL TEST OF ELT ON PRE-FLIGHT AT THE REMOTE SWITCH SHOWED THE ELT WAS NOT WORKING. MANUALLY TURNED THE ELT ON AT THE UNIT, STILL NOT WORKING. REMOVED ELT AND OPENED UP THE UNIT TO DISCOVER CONDENSATION AND ELECTROLYSIS CORROSION HAD COMPLETELY RENDERED THE UNIT USELESS. THE O-RINGS APPEARED TO BE IN GOOD SHAPE. THE ELT HAD BEEN INSPECTED AND NEW BATTERIES INSTALLED DURING THE 100 HR. INSPECTION ON 9/2003. TEMPERATURES OUTSIDE HAVE BEEN IN THE -30 DEG. F RANGE AND THE PLANE HAD BEEN PUT INTO THE HANGAR TO WARM UP. 1H71 3O3 ONCA22NM E286 20040223000922004022300092CE 2004 2 23 CM2R 120040108G7160963800295 SEPARATOR BEECH 55 95C55 1152708CE CONT O520 IO520C 17032SO ENG AIR INTAKE OBSTRUCTED C K NONE W INADEQUATE Q C ININSP/MAINT 1 SW153367 TE146 810839R OLD ENGINE SEPARATOR WAS CRACKED. ORDERED NEW PART. INSPECTED NEW PART AND COULD NOT BLOW THROUGH IT. THE AIR OUTLET TUBE WAS BLOCKED INTERNALLY. NEW OUT OF BOX FAILURE. IF THIS UNIT WAS INSTALLED ON THE ENGINE IT WOULD HAVE PRESSURIZED THE CASE AND LEAD TO POSSIBLE ENGINE FAILURE DUE TO ENGINE OIL LOSS. 1L72 3O3 O 3A16 E5CE 20040223001242004022300124SO 2004 2 23 2004FA0000055 220040109G8520AEC648029 PISTON CONT CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO NR 2 CYLINDER BROKEN C D RETURN TO BLOCK J WARNING INDICATION TXTAXI/GRND HDL 1 WP234810N260 273185R 18267384 273185R REBARRELED CYL, ECI PISTONS. LOSS OF OIL PRESSURE, 260 STOH, 1043 SMOH. CAUSE, BROKEN NR 2 PISTON, PARTS BLOCKING OIL PICKUP SCREEN. POSSIBLE CAUSES. DEFECTIVE PISTON CASTING, DROPPED PISTON OR IMPROPERLY MACHINED NR 4 RING GROOVE, SQUARE CUT BOTTOM OF GROOVE. 50 PERCENT OF BOTTOM SKIRT BROKE OFF PISTON. PISTON RING BROKE INTO ABOUT 20 PIECES. 1H71 3O3 ONT3A13 E273 20040223001262004022300126CE 2004 2 23 2004FA0000058 120040110G7921TCM639171 OIL COOLER CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO ENGINE LOOSE C K NONE P NO WARNING INDICATION ININSP/MAINT 1 WP234810N206 206 18267384 273185R 8/22/2002, OIL COOLER TCM 639171. TACH TIME NOT LOGGED. APPROX 830 SMOH. 12/1/2003 A MAJOR OIL LEAK DEVELOPED AROUND THE OIL COOLER AND THE NR 5 CYL PUSH ROD TUBES. ISOLATED LEAK TO OIL COOLER GASKETS. 1036 SMOH. DURING REMOVAL OF OIL COOLER BASE PLATE, IT WAS DETERMINED THAT THE ATTACHING BOLTS WERE IMPROPERLY TORQUED. NEW GASKETS WERE INSTALLED AND COOLER ATTACHING BOLTS PROPERLY TORQUED. PROBLEM CAUSED BY IMPROPERLY TORQUED ATTACHING BOLTS. 1H71 3O3 ONT3A13 E273 20040223001302004022300130EA 2004 2 23 2004FA0000059 220040112G73242524321 FLOW DIVIDER BENDIX PIPER PA28 PA28R180 7102809SO LYC O360 IO360B1E 41514EA HARTZLHCC2Y HCC2YK1 GL FUEL SYSTEM BYPASSING G O OTHER GRJMULTIPLE FAILURE PARTIAL RPM/PWR LOSS WARNING INDICATION TOTAKEOFF 1 SO074658J4947 28R30553 L481751A 7666A2 FUEL FLOW DIVIDER, TEARDOWN AND TEST OF DIVIDER SHOWED UNIT WAS BY-PASSING FUEL , WHICH INTERRUPTED FLOW OF FUEL TO ENG UNDER HIGH POWER SETTINGS, LEADING TO INTERRUPTION OF ENG POWER AND/OR TOTAL LOSS OF ENG POWER. FURTHER TEAR DOWN, REVEALED DIAPHRAGM WAS STIFF, AN INDICATION OF LONG TIME IN SERVICE. CONNECTING SCREW WHICH ATTACHES DIAPHRAGM TO SHAFT WAS LOSE, NOT TORQUED. ESTIMATED DIAPHRAM WAS MANUFACTURED IN 1967. AFTER TIGHTENING ATTACHMENT SCREW TO ITS PROPER TORQUE, DIVIDER WAS TESTED AGAIN. AT 2.5 POUNDS OF FUEL PRESSURE APPLIED, NO INDICATION OF FUEL DIVIDER FLOWING UNTIL 3.7500 POUNDS OF FUEL PRESS WAS APPLIED. 1 POUND OF PRESSURE DIFFERENCE FOR FUEL FLOW WAS DUE TO STIFFNESS OF DIAPHRAGM. 1L71 3O3 O 2A13 1E10 5 CP920 20040225000712004022500071EU 2004 2 25 2004FA0000097 120040109G32301090512431 SELECTOR VALVE AGUSTAA109 A109A2 0260120EU ALLSN 250C 250C20 03013GL MLG WORN D O OTHER O OTHER NRNOT REPORTED 1 NM011PJ 7262 LANDING GEAR WOULD NOT EXTEND. FINALLY FORCE LANDING GEAR HANDLE DOWN GEAR EXTENDED AND LOCKED BUT STILL HAD TRANSITION LIGHT. PART FAILED PRIMARILY DUE TO AGE AND USE (WEAR). 1G72 3U3 U H7EU E4CE 20040225000972004022500097 2004 2 25 2004FA0000132 420040116G3424303770 INDICATOR PIPER PA28 PA28RT201 7102818SO LYC O360 IO360C1C6 41514EA MCAULY2D34C 2D34C215 GL TURN COORDINATORFAILED G O OTHER S AFFECT SYSTEMS NRNOT REPORTED 1 WP178227V 236 28R8018085 62208651A 931655PC085 TURN COORDINATOR UNIT FAILED DURING IFR CONDITIONS. PROBLEM SEEMS TO BE INTERMITTENT BECAUSE AFTER LANDING, UNIT WORKED AND CONTINUED FOR DURATION OF FLIGHT (VFR) FROM FCH TO FYI (FAT). (WP17200402720) 1L71 3O3 O 2A13 1E10 5 CP7EA 20040301000492004030100049SO 2004 3 1 2004FA0000197 220040206G7414641742 GEAR CONT O550 IO550B SO MAGNETO DRIVE GALLED B K NONE O OTHER ININSP/MAINT 1 SO09 500 500 684070 DURING ENGINE DISASSEMBLY FOR CYLINDER REPLACEMENT FOUND RT MAGNETO DRIVE GEAR DISCOLORED AND THRUST SURFACE GALLED. MAGNETO/ACCESSORY DRIVE ADAPTER BUSHING GALLED AND HEAT DAMAGED. 3 O E3SO 20040301000712004030100071SO 2004 3 1 2004FA0000171 120040122G531045467016017 RIB PIPER PA31 PA31310 7103103SO LYC O540 TIO540* 41532EA MLG WW CORRODED B C85RO OTHER O OTHER NRNOT REPORTED 1 NE01131PJ5052 317912030 REPORTED OCCASIONAL GEAR CYCLING PROBLEM. INSPECTED LANDING GEAR AND FOUND RIBS (WHICH ARE IN THE LT AND RT MAIN GEAR WHEEL WELLS) TO BE SEVERELY CORRODED. MOUNTED ON THIS RIBS IS THE BRACKET FOR THE UPLOCK LATCH SWITCH. THERE WAS ENOUGH MOVEMENT IN THE RIBS THAT SWITCH CONTACT BECAME AN ISSUE. BOTH RIBS WERE REPLACED . SOME OF PROBLEMS MIGHT BE CORRECTED BY INSTALLING KIT, WHICH C/W AND CHANGED THE GEAR PUSH-PULL TUBES TO CABLES INSTEAD. THIS WAS ALSO DONE. REMOVED OLD PUSH-PULL TUBES, WHICH WERE CORRODED. (NE01200402913) 1L71 3O3 ORTA20SO E14EA 20040301000762004030100076CE 2004 3 1 2004FA0000173 120040122G3260 DOWNLOCK SWITCH CESSNA340 340A 2076405CE CONT O520 TSIO520* 17040SO MLG FAILED D O OTHER J WARNING INDICATION APAPPROACH 1 GL17356D 340A0745 LANDING GEAR WOULD NOT EXTEND, FOUND LANDING GEAR ACTUATOR DOWN LIMIT SWITCH STUCK IN GEAR DOWN POSITION. PERIODIC REPLACEMENT OF SWITCH WOULD BE THE ONLY WAY TO PREVENT REOCURRENCE. THE SWITCH IS A SEALED UNIT AND CANNOT BE INSPECTED INTERNALLY. (GL17200402312) 1L72 3O3 O 3A25 E8CE 20040301001162004030100116EA 2004 3 1 2004FA0000178 220040109G8550LW13792 SEAL AMRGENAA1 AA1B 0631206SO LYC O235 O235C2C 41505EA ENGINE WORN G O OTHER K FLUID LOSS NRNOT REPORTED 1 EA256291L1446 AA1B0091 L1121615 FOUND CRANKSHAFT SEAL PUSHED FREE FROM ITS MOUNTING AREA. SEAL APPEARED DRY ROTTED AND INSTALLED WITH INSUFFICIENT SEALANT. INSTALLED NEW SEAS IAW SRM. INSPECTED OIL SCREEN AND TOOK OIL SAMPLE. NO METAL FOUND SEAL SHOULD BE INSPECTED FOR PROPER MOUNTING EVERY 100 HOURS. 1L71 3O3 O A11EA E223 20040301001222004030100122CE 2004 3 1 2004FA0000184 120040204G213340117 CHECK VALVE CESSNA650 650 2076802CE GARRTTTFE731TFE731* 01518WP CABIN PRESSURE CRACKED G K NONE O OTHER ININSP/MAINT 1 GL03900JD4923 6500213 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSEMBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECKED AND AN IDENTICAL CHECK VALVE CONDITION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2L72 4F4 F A9NM E6WE 20040301001232004030100123CE 2004 3 1 2004FA0000185 120040204G213340117 CHECK VALVE CESSNA650 650 2076802CE GARRTTTFE731TFE731* 01518WP CABIN PRESSURE CRACKED G K NONE O OTHER ININSP/MAINT 1 GL03900JD4923 6500213 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSEMBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECK AND AN IDENTICAL CHECK VALVE CONDITION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2L72 4F4 F A9NM E6WE 20040301001302004030100130CE 2004 3 1 041332 120040212G2823CCA1550 DRAIN CESSNA CESSNA172 172 2072402CE CONT O300 O300* 17022SO FUEL VALVE CRACKED B W2ORK NONE O OTHER ININSP/MAINT 1 GL096341E 46441 PILOT REPORT OF FUEL LEAK FROM SELECTOR. FOUND LEAKAGE PAST SHAFT SEAL. REMOVED SELECTOR VALVE FOR REPAIR. CCA-1550 DRAIN VALVE WAS INSTALLED IN BOTTOM OF SELECTOR VALVE. WHEN DRAIN VALVE WAS REMOVED, ORING RETAINING WASHER AT END OF DRAIN VALVE WAS OBSERVED TO BE CRACKED IN NUMEROUS PLACES AND IN IMMINENT DANGER OF FAILURE. HAD THE WASHER BROKEN OFF, AN UNCONTROLLABLE LOSS OF FUEL THROUGH THE DRAIN VALVE WOULD HAVE OCCURRED. THE ONLY WAY TO PREVENT FUEL LEAKAGE WOULD HAVE BEEN TO SHUT OFF THE FUEL SELECTOR, WHICH RESULTS IN ENGINE STOPPAGE. 1H71 3O3 ONT3A12 E253 20040303000812004030300081CE 2004 3 3 2004FA0000198 120040204G7921654585 OIL COOLER CESSNA210 T210L 2073449CE CONT O520 TSIO520* 17040SO ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 SO15732HN465 367 21061527 821036R LOWER OB FLANGE OF ENGINE OIL COOLER IS CRACKED AND LEAKING. 1H71 3O3 O 3A21 E8CE 20040303000932004030300093SO 2004 3 3 2004FA0000215 220040218G8530655166 VALVE GUIDE CONT CONT O520 IO520D 17032SO CYLINDER LOOSE C K NONE O OTHER ININSP/MAINT 1 WP07 109 109 Q226 293450 MFG CYLINDER (109.9HRS) DISASSEMBLED FOR REASONS NOT RELATED TO THIS REPORT. INTAKE VALVE GUIDE FOUND TO BE ONLY FINGER TIGHT, NO INTERFERENCE FIT. P005 FOUND STAMPED NEXT TO GUIDE. 3 O E5CE 20040303001842004030300184NM 2004 3 3 SROM200400001 120040217G3397 WIRE BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE EMERGENCY LIGHT DAMAGED C SROMK NONE L NO TEST ININSP/MAINT 1 AL03736BP 6 23465 AFT LEFT EMERGENCY EXIT LIGHT UNDER FA JUMP SEAT INOPERATIVE. REPAIRED WIRE TO LIGHT ASSEMBLY. LIGHT OPS NORMAL WITH EMERGENCY LIGHTS TURNED ON. 2L72 4F4 FRTA16WE E2EA 20040303001882004030300188 2004 3 3 21200004 420040221G221055X AUTOPILOT SYS CESSNA210 T210L 2073449CE CONT O520 TSIO520* 17040SO COCKPIT DEFECTIVE C H DEACTIVATE SYST/CIRCUITS F FLT CONT AFFECTED CRCRUISE 1 NM102084S 700 21061050 AIRCRAFT PORPOISES WHILE IN ALTITUDE HOLD MODE. DISABLE ALTITUDE HOLD MODE. MAINTENANCE CONFIRMS DEFECTIVE UNIT BY MANUFACTURER. MANUFACTURER UNABLE TO SUPPLY REPLACEMENT PART. 1H71 3O3 O 3A21 E8CE 20040303001892004030300189SO 2004 3 3 2004FA0000205 220040210G8530AEC631397SN712B CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE MISMANUFACTURED D K NONE W INADEQUATE Q C ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE DID NOT MEET MINIMUM SIZE DIMENSIONS AND VALVE SEAT MACHINING NOT CONCENTRIC. 1H71 3O3 O 3A21 E8CE 20040303001902004030300190SO 2004 3 3 2004FA0000207 220040203G8530AEC631397SN712B CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE UNSERVICEABLE D K NONE O OTHER ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER ASSY TISN 71.2BCA AS RECEIVED. FOUND VALVE SEAT MACHINING NOT CONCENTRIC AND EXHAUST VALVE SEAT DIAMETER CUT TO APPX. 1.847 INCH WHEN IT SHOULD BE APPX. 1.781 INCH ACCORDING TO PRINT DIMENSIONS IN OVERHAUL MANUAL. 1H71 3O3 O 3A21 E8CE 20040303001942004030300194SO 2004 3 3 2004FA0000212 220040202G8530AEC631397SN712 CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE UNSERVICEABLE D K NONE O OTHER ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. PRE-SIZED GUIDES ARE USED ON THIS UNIT AND 5 OTHERS IN THIS BATCH INSPECTED. ALL UNAIRWORTHY. ALL BALL SIZED. ALL BELL MOUTHED. 1H71 3O3 O 3A21 E8CE 20040303001952004030300195SO 2004 3 3 2004FA0000213 220040202G8530AEC631397SN712 CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE UNSERVICEABLE D K NONE O OTHER ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MFG. MINIMUM SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. 1H71 3O3 O 3A21 E8CE 20040303002022004030300202SO 2004 3 3 BHA03RS 220040223G8500 ENGINE CESSNA340 340A 2076405CE CONT O520 TSIO520NB 17040SO MCAULY3AF32C3AF32C505 GL RIGHT DAMAGED E A UNSCHED LANDING FK FLT CONT AFFECTED FLUID LOSS CLCLIMB 1 NM04114BH3094 1494 340A1230 503082 020379 DURING FLIGHT, RT ENGINE OIL PRESSURE GAGE INDICATED A SIGNIFICANT INCREASE IN PRESSURE. RT ENGINE DAMAGE OCCURRED. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. 1L72 3O3 O 3A25 E8CE 5 CP22EA 20040304000212004030400021CE 2004 3 4 2004FA0000217 120040124G1430NAS679A4 NUT BEECH 58 58 1152740CE CONT O520 IO520* 17032SO HORIZONTAL STAB CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO034423A7200 TH28 NUTS ON SEVERAL HORIZONTAL STABILIZER REAR SPAR BOLTS WERE CRACKED OR BROKEN. NUT INSTALLED, NO NUTS HAD COME OFF AND BOLTS WERE NOT LOOSE IN SPAR. REPLACED NUTS AND NEW BOLTS WITH CURRENT HARDWARE. 1L72 3O3 O 3A16 E5CE 20040304000302004030400030NM 2004 3 4 SROM200400005 120040223G53406935352U14 STRINGER CLIP BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 639, STR 4R. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED NEW STRINGER CLIP IAW B737 SRM 51-30-2. 2L72 4F4 FRTA16WE E2EA 20040304000342004030400034GL 2004 3 4 2004FA0000221 220040128G7323252469211 GOVERNOR BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL ENGINE FAILED D O OTHER O OTHER NRNOT REPORTED 1 SW11124AE 645 51591 CAE890804 SUSPECT HIGH END GOVERNOR FAILURE. OVERSPEED OF N2. (SW11200403763) 1G71 3U3 U H2SW E1GL 20040304000472004030400047SO 2004 3 4 2004FA0000224 120040210G554263396802 SKIN PIPER PA28 PA28181 7102807SO LYC O360 O360* 41514EA RUDDER CRACKED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP074166H4759 4759 2843119 DURING PREFLIGHT, FLIGHT INSTRUCTOR FOUND THE RUDDER SKIN CRACKED. PROBABLE CAUSE AIR FLOW OVER THE SKIN. NO RECOMMENDATIONS AT THIS TIME. 1L71 3O3 O 2A13 E286 20040304000482004030400048CE 2004 3 4 2004002 120040220G8011MHB6016 STARTER CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA ENGINE DISENGAGED D K NONE O OTHER TXTAXI/GRND HDL 1 WP0797811 17276232 L1550339A STARTER WAS INSTALLED AFTER ORIGINAL STARTER FAILED ON 2/11/2004 (SDR FILED) FOR A SHATTERED BENDIX DRIVE GEAR. ENGINE WAS SUCCESSFULLY STARTED TWICE AND RETURNED TO SERVICE. ON FIRST FLIGHT ATTEMPT AFTER STARTER WAS INSTALLED THE BENDIX DRIVE GEAR WOULD NOT ENGAGE THE ENGINE STARTER RING GEAR, THE STARTER MOTOR WOULD SPIN BUT THE GEAR WOULD NOT COME FORWARD TO ENGAGE THE ENGINE GEAR. THIS UNIT HAD ZERO HOURS SINCE NEW. 1H71 3O3 ONT3A12 E274 20040304000552004030400055EU 2004 3 4 2004FA0000229 120040217G5330 DOPE FILM AVIAT S2B PITTSS2B 2210308EU LYC O540 AEIO540D4A5 41532EA SKIN FABRIC DELAMINATED C K NONE O OTHER ININSP/MAINT 1 EA1779D 560 5260 ALL OF THE DOPE FILM DELAMINATED FROM THE CECONITE 102 FABRIC. AFTER SEVERAL PHONE CALLS, IT WAS DETERMINED THAT IMPROPER APPLICATION METHOD WAS USED. THE RANDOLPH DOPE PROCESS REQUIRES THE USE OF RANDO PROOF PRIMER FOR THE FIRST TWO COATS ON CECONITE FABRIC AND THE FIBERS OF THE FABRIC MUST BE COMPLETELY ENCAPSULATED. AFTER ADDITIONAL CALLS, IT WAS DETERMINED THAT THE FACTORY OMMITED THE RANDO PROOF PRIMER STEP AND FAILED TO ENCAPSULATE THE FABRIC FIBERS RESULTING IN THE DELAMINATION OF THE DOPE FILM. (EA17200405558) 1Q71 3O3 ONCA8SO 1E4 20040304000712004030400071CE 2004 3 4 40188138 120040226G5520556555026 BRACKET CESSNA500 500CESSNA 2076602CE PWA JT15 JT15D1 52060NE BALANCE WEIGHT CRACKED B K NONE O OTHER ININSP/MAINT 1 GL0926NS 7280 5000340 BALANCE WEIGHT ARM FOR ELEVATOR CONTROL SYSTEM IS CRACKED. 1L72 4F4 F A22CE E1NE 20040304000852004030400085 2004 3 4 2004FA0000237 420040206G6113 SPINNER AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA PROPELLER CHAFED B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM 201023 PROP SPINNER RUBS AGAINST COWL, INCH LONG AND GOING THOUGH FIBERGLASS COWL. (GL13200405339) 1L71 3 O EXPA1L71E223 20040304000882004030400088SO 2004 3 4 2004FA0000249 120040227G281063901038 HOSE PIPER PA28 PA28R200 7102811SO LYC O360 IO360A1A 41514EA FUEL SYSTEM MISROUTED D K NONE W INADEQUATE Q C ININSP/MAINT 1 SO0515143 28R7335027 LANDING GEAR (IN-TRANSIT) LIGHT CAME ON INTERMITTENTLY. DURING TROUBLESHOOTING, FOUND FUEL FEED LINE FROM ELECTRIC PUMP TO ENGINE DRIVEN PUMP MISROUTED. HOSE WAS BEING JAMMED BETWEEN NLG TIRE AND ENGINE MOUNT WHEN GEAR IS RETRACTED. THIS CAUSED NLG TO INCOMPLETELY RETRACT, CAUSING UP-LIMIT SWITCH TO BE INTERMITTENT. REROUTED HOSE AND RIGGED GEAR PER MM. OPS CK OK.ENGINE MOUNT HAD BEEN REMOVED FOR REPAIR. WHEN IT WAS REINSTALLED, THE PART WAS PROBABLY NOT PUT BACK ON CORRECTLY AND NOT FOUND DURING POST MAINTENANCE INSPECTION. THERE IS NO WAY THE GEAR RIG CHECK WAS GOOD AFTER REINSTALLATION OF MOUNT. 1L71 3O3 O 2A13 1E10 20040304000942004030400094GL 2004 3 4 2004FA0000242 120040206G2810 FUEL TANK AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA LT WING LEAKING B KC5RO OTHER K FLUID LOSS NRNOT REPORTED 1 GL13622AM 201023 WITH FULL FUEL TANKS AND THE AIRCRAFT ON THE GROUND AN AMOUNT OF FUEL (.5 GALLON +) WILL DRAIN FROM THE VENT OF THE LT FUEL TANK AFTER A FORWARD OR AFT MOVEMENT OF THE AIRCRAFT. (GL13200305339) 1L71 3 O EXPA1L71E223 20040304000972004030400097GL 2004 3 4 2004FA0000245 120040206G1100 PLACARD AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA TRIM CNTRL WHEELMISSING B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM13 201023 DOES NOT INDICATE TAKEOFF POSITION, PLACARD MISSING. (GL13200405339) 1L71 3 O EXPA1L71E223 20040304001082004030400108NM 2004 3 4 SROM200400011 120040226G533065479576 SKIN BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE ZONE 100 CORRODED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND AFT PIT STA 807 LOWER FORWARD CARGO CUTOUT HAS NON-CPCP CORROSION. REMOVED DAMAGE FABRICATED AND INSTALLED REPAIR DOUBLER IAW 53-10-1, 51-40-3 AND 51-30-2. 2L72 4F4 FRTA16WE E2EA 20040315000042004031500004SO 2004 3 15 CA040123008 120040120G1430AN546 BOLT PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2A GL MLG CORRODED W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA (CAN) THE AIRCRAFT WAS ON APPROACH WHEN THE CREW COULD NOT GET A DOWN AND LOCKED (GREEN) INDICATION ON THE RT MAIN GEAR. THE AIRCRAFT FLEW LOCALLY AND AFTER SEVERAL ATTEMPTS FLEW TO ANOTHER AIRPORT FOR A TOWER FLYBY AND LANDING. UPON TOUCHDOWN, THE RT MAIN GEAR LIGHT ILLUMINATED. MAINTENANCE FOUND THE RT MAIN DOWN LOCK TO BE SLIGHTLY STIFF. SOME MOISTURE AND SLIGHT CORROSION WAS NOTED ON THE PIVOT BOLT FOR THE RT DOWNLOCK AND THE BOLT WAS REPLACED. BOTH MAIN DOWN LOCKS WERE REMOVED, CLEANED, INSPECTED, AND RE-LUBRICATED. SUBSEQUENT GEAR SWINGS WERE NORMAL AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315000052004031500005NE 2004 3 15 CA040123009 220040119G7412103815504C IGNITER BOX PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ENGINE IGNITION INOPERATIVE W O OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) THE PILOT MADE TWO ATTEMPTS TO START THE AIRCRAFT. THE ENGINE FAILED TO START AND THE PILOT NOTED THAT THE IGNITION LIGHT ON THE CAWS PANEL HAD NOT ILLUMINATED DURING EITHER ATTEMPT. THE CAWS PANEL LIGHTS WERE TESTED AND FOUND SERVICEABLE. AFTER APPROX. 5 MINUTES A THIRD STARTING SEQUENCE WAS INITIATED AND SUCCESSFUL. THE AIRCRAFT RETURNED TO BASE WITHOUT FURTHER INCIDENT. MAINTENANCE CARRIED STARTED THE AIRCRAFT WITH NO INDICATION OF ANY DEFECT. THE AIRCRAFT WAS SHUT DOWN, AND FURTHER INVESTIGATION REVEALED THAT THE IGNITION EXCITER BOX WAS NOT FIRING IAW THE ENGINE MFG REQUIREMENTS. A REPLACEMENT UNIT WAS INSTALLED, AND TESTED SERVICEABLE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040315000062004031500006CE 2004 3 15 AUS20040044 120040127G574035115050602 ATTACH FITTING BEECH 36 A36 1151604CE CONT O520 IO520B 17032SO MCAULY2A36C 2A36C23 GL RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING UPPER AFT ATTACHMENT FITTING CORRODED. MAXIMUM DEPTH OF CORROSION 1.27MM (0.050IN). FOUND DURING INSPECTION IAW AD. 1L71 3O3 O 3A15 E5CE 5 CP880 20040315000072004031500007NM 2004 3 15 AUS20040045 120040123G5210 PIN BOEING767 767338 1385151NM GE CF6 CF680C2* GL PAX DOOR OUT OF ADJUST W O OTHER J WARNING INDICATION CRCRUISE 1 AUS (AUS) L1 FORWARD ENTRY DOOR CRACKED OPEN IN FLIGHT WITH HANDLE MOVING APPROXIMATELY HALF WAY UP. INVESTIGATION FOUND THE DOOR LOCK SENSOR LATCH PIN TO BE 0.762MM (0.030IN) OUT OF LIMITS. 2L72 4F4 FRTA1NM E23EA 20040315000112004031500011CE 2004 3 15 CA040211008 120040122G561010138402523 WINDSHIELD BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING SERVICING THE LT WINDSHIELD WAS FOUND CRACKED IN THE OUTER PLY. REPORTED OAT FOR THE PREVIOUS FLIGHT WAS -45C. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040315000132004031500013EU 2004 3 15 CA040211011 120040114G6220350A31190703 STARFLEX SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE MAIN ROTOR HEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 CA M4517 (CAN) ON A ROUTINE AIRFRAME INSPECTION, A CRACK WAS NOTED ON THE TRAILING EDGE OF THE STAR ARM. AFTER COMPLETING THE REPAIR TO THE AREA IAW THE SRM, IT WAS FOUND TO STILL BE A MUCH DEEPER FLAW. THE STAR WAS SENT TO MFG FOR FURTHER INVESTIGATION. A NEW STARFLEX WAS INSTALLED. 1G71 3U3 U H9EU E19EU 20040315000182004031500018GL 2004 3 15 CA040213001 120040209G78102078000103 EXHAUST STACK BOMBDR DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912 55555EU HOFMANHOV352HOV352F NE CYLINDER HEAD FRACTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE LT REAR EXHAUST STACK WAS FOUND COMPLETELY BROKEN AND SEPARATED AT THE BEND NEAR THE CYLINDER. 1L71 3O3 INTTA4CH EXPE3I 5 CTP5BO 20040315000202004031500020SO 2004 3 15 CA040125001 120040122G29131213HBG310A PUMP PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL HYD SYSTEM FAILED W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) THE FAILURE OF PUMP WAS FOUND BY PILOT AFTER FLIGHT HYDRAULIC PUMP CHECK- PUMP FAILED THE TEST. TIME EXCEEDED 11 SECONDS. PUMP REMOVED, INSPECTED - NO DAMAGE FOUND FAILED INTERNALLY. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315000232004031500023NM 2004 3 15 CA040126003 120040114G2910AN81510D COUPLING DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE PRESS MANIFOLD CRACKED W O OTHER KJ FLUID LOSS WARNING INDICATION DEDESCENT 1 CA (CAN) APPROXIMATELY 90 DME FROM LANDING AT THE TOP OF DESCENT THE CREW NOTICED THE NR 2 HYD CONTENTS DROPPING. AT APPROX 12 DME THE NR 2 HYD CAUTION LIGHT ILLUMINATED. A PAN WAS CALLED AND QRH ACTIONS WERE CARRIED OUT. ENGINEERING INVESTIGATION REVEALED THAT THE NR 2 PRESSURE MANIFOLD INLET UNION HAD FRACTURED. THE UNION WAS REPLACED ALONG WITH THE HYD PUMP AND THE AIRCRAFT WAS RETURNED TO SERVICE. OPERATOR HAS BEEN INFORMED OF SYD 8-29-002, WHICH REPLACES THE ALUMINUM FITTINGS WITH STAINLESS STEEL FITTINGS FOR THIS AREA. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315000242004031500024EU 2004 3 15 CA040126004 120040126G3232D3221401700062 UPLOCK AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE NLG DOOR INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) NOSE LDG DOOR WOULD NOT CLOSE AFTER T/O. RECYCLED 3 TIMES (NO SUCCESS) DOOR CLOSED NORMALLY WITH GEAR DOWN. NLG DOOR UPLOCK REPLACED IAW AMM32-31-21-400-001, CONSIDERED SERVICEABLE. 2L72 4F4 FRTA28NM E29NE 20040315000292004031500029CE 2004 3 15 CA040126005 120040126G257110112011613 FLANGE BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL BATTERY COVER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) INSPECTION REVEALED THE BATTERY COVER SUPPORT FLANGE (FWD) CRACKED WHERE IT ATTACHES TO THE VERTICAL SUPPORT ANGLES. PART TO BE REPLACED NEW. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040315000302004031500030GL 2004 3 15 CA040213003 120040209G78102078000107 EXHAUST STACK BOMBDR DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912 55555EU HOFMANHOV352HOV352F NE CYLINDER HEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE RT REAR EXHAUST STACK WAS FOUND CRACKED APPROX .5000 WAY AROUND THE CIRCUMFERENCE AT THE BEND NEAR THE CYLINDER. THIS CRACK WAS IN A SIMILAR LOCATION AS THE ONE THAT LEAD TO THE COMPLETE FAILURE OF THE LT REAR EXHAUST STACK. 1L71 3O3 INTTA4CH EXPE3I 5 CTP5BO 20040315000322004031500032EU 2004 3 15 CA040126007 120040126G3250Z4242170001 SPRING MORAVN242 Z242L 5920207EU LYC O360 AEIO360A1B6 41514EA MUHBR MTV MTV3BC EU NLG STEERING BROKEN W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI A STUDENT PILOT NOTICED THAT THE AIRCRAFT WOULD NOT STEER PROPERLY. MAINTENANCE NOTICED THAT THE RT STEERING SPRING WAS BROKEN. THIS HAS BEEN AN ON GOING PROBLEM WITH STUDENTS WHEN THEY TRY TO STEER THE AIRCRAFT WITHOUT GETTING THE AIRCRAFT ROLLING FIRST ADDING STRESS TO THE SPRINGS. 1L71 3O3 ONTA76EU 1E10 5 CUSSR 20040315000332004031500033EA 2004 3 15 CA040126008 120040106G2720272613 SWITCH CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE RUDDER TRIM FAILED W A UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) 30 MINS OUT, FL260 RUDDER TRIM FAILED, INADVERTENT AND SUDDEN DISPLACEMENT TO HALFWAY TO FULL NOSE LT. DECLARED EMERGENCY, UNEVENTFUL LANDING. RUDDER TRIM FAILED. REMOVED AND REPLACED RUDDER TRIM SWITCH. OPS CHECKS REQUIRED WHEN PANEL REINSTALLED IAW27-12-10, REMOVED AILERON/RUDDER TRIM CONTROL PANEL, REINSTALLED TRIM CONTROL PANEL AND TESTED IAW AMM 27-12-00, CHECKS OK. 2L72 4F4 FRTA21EA E15NE 20040315000342004031500034NM 2004 3 15 CA040127001 120040121G2720682015 SWITCH BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU RUDDER TRIM INOPERATIVE W A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) AFTER TAKE OFF, THE FLIGHT CREW REPORTED RUDDER TRIM INOPERATIVE. QRH PERFORMED. RETURNED TO DEPARTURE AIRPORT FOR LANDING WITHOUT FURTHER INCIDENT. MECHANIC RESET THE RUDDER TRIM CB THEN TESTED TRIM, NO MOVEMENT. RUDDER TRIM PANEL REMOVED AND PANEL WAS (TAPPED) THEN RE-INSTALLED, THEN TRIM OPERATION WAS NORMAL. RUDDER TRIM SWITCH REPLACED AS PRECAUTION. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040315000382004031500038EA 2004 3 15 CA040213004 120040213G7830MPN1267587 POWER UNIT CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE THRUST REVERSER INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) LT THRUST UNLOCKED IN CLIMB. QHR PARTIALLY CARRIED OUT LANDED (WOULD NOT STOW) FELT LIKE IT WAS NEVER DEPLOYED. AIRCRAFT CAME BACK FOR TROUBLESHOOTING AND REPAIR. 2L72 4F4 FRTA21EA E15NE 20040315000402004031500040NE 2004 3 15 CA040213006 120040202G62106117020201067 SPAR SKRSKY SKRSKYS61 S61N 8142104NE GE CT58 CT581402 30011NE M/R BLADE CRACKED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA 61M3314311 (CAN) MAIN ROTOR BLADE LEAK CHECKED AT BASE AND SPAR FOUND TO BE CRACKED. 2G72 4U4 U 1H15 1E3 20040315000412004031500041EA 2004 3 15 CA040213007 120040210G2720C2CF209 TORQUE TUBE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE RUDDER PEDAL CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 12498 (CAN) RT RUDDER PEDAL TORQUE TUBE HAD AGGRESSIVE CORROSION BUILD UP ON THE EXTERIOR OF THE TORQUE TUBE IN THE VICINITY OF THE OIL COOLER. THIS IS A COMMON PROBLEM WITH FLOAT EQUIPPED AIRCRAFT OPERATING IN A SALT WATER ENVIRONMENT. 1H71 3R3 R A806 5E1 5 CP206 20040315000422004031500042EA 2004 3 15 CA040213008 120040210G5552C2T7A TORQUE TUBE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE ELEVATOR WORN W K NONE O OTHER ININSP/MAINT 1 CA 12498 (CAN) LOSS OF ELEVATOR CABLE TENSION REVEALED WORN ATTACH POINTS ON THE ELEVATOR TORQUE TUBE ASSEMBLY. 1H71 3R3 R A806 5E1 5 CP206 20040315000452004031500045 2004 3 15 CA040213011 420040210G2562110324 ANTENNA ARTEX DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE ELT BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ELT ANTENNA FOUND BROKEN AT THE BASE OF THE ANTENNA MOUNTING FLANGE (EXTERNAL). 1H71 3R3 R A806 5E1 5 CP206 20040315000472004031500047NM 2004 3 15 CA040216001 120040216G2120 ODOR BOEING767 76735H 1385208NM GE CF6 CF680C2B6F 30025NE COCKPIT DETECTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) THE FLIGHT EXPERIENCED AN ACRID ODOR IN THE COCKPIT. AC DECLARED AN EMERGENCY LANDING AND CARRIED OUT THE QRH. AC SENT TO HANGAR FOR INVESTIGATION. 2L72 4F4 FRTA1NM E13NE 20040315000482004031500048WP 2004 3 15 CA040216002 120040207G793356B17C SENSOR DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE OIL TEMP FAILED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) RT ENGINE OIL TEMP EXCEEDED 160 DEGREES DURING CRUISE. AIRCRAFT DIVERTED. OIL TEMP SENSOR REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. ON THE NEXT DAY FEB. 8, 2004, AIRCRAFT DEPARTED AND SAME PROBLEM CAME BACK DURING CLIMB. AIRCRAFT LANDED. THE OIL TEMP SENSOR WAS REPLACED WITH THE SYSTEM DISPLAY PANEL P/N 201EDP1-1 S/N AD660/072. AIRCRAFT DISPATCHED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040315000502004031500050EA 2004 3 15 CA040127007 120040127G3250 STEERING SYS CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE NLG FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LOST NOSEWHEEL STEERING ON LANDING CLT. TRIED NUMEROUS RESETS WITH NO SUCCESS. TUG ARRIVED AND TOWED TO GATE. OUT OF SERVICE FOR INVESTGATION. 2L72 4F4 FRTA21EA E15NE 20040315000592004031500059EA 2004 3 15 CA040127016 120040127G2613 OVERHEAT SENSOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE LT ENGINE INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT 14TH DUCT MESSAGE ON EICAS AT 500 AGL (84 PERCENT N1) SHORTLY AFTER T/O, DUCT SHOWED RED BETWEEN COWL A/I AND WING A/I VALVES ON ANTI-ICE STATUS PAGE. CREW RETURNED, LANDED 700 KGS OVERWEIGHT. 2L72 4F4 FRTA21EA E15NE 20040315000602004031500060CE 2004 3 15 CA040216003 120040114G273126616151 ACTUATOR CESSNA208 208B 2073701CE PWA PT6 PT6A114 52043NE MCAULY3AF34C3GFR34C703 GL ELEVATOR TRIM FAILED W O OTHER F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) DURING CRUISE FLIGHT WITH AUTOPILOT ENGAGED, PILOT NOTED THAT AIRCRAFT WAS NOT HOLDING ALTITUDE. PILOT DISENGAGED AUTOPILOT AND AIRCRAFT PITCHED NOSE UP. ELECTRIC ELEVATOR TRIM SELECTED BUT NO TRIM MOVEMENT. ATTEMPTED MANUAL TRIM BUT TRIM WHEEL WOULD NOT MOVE, SPRING BACK. PILOT MAINTAINED CONTROL OF AIRCRAFT WITH ELEVATOR AND LANDED WITHOUT INCIDENT. INITIAL INSPECTION UNABLE TO MOVE ELEVATOR TRIM. AIRCRAFT HANGARED FOR SHORT PERIOD AND TRIM OPERATION OKAY. ELEVATOR TRIM CABLE/CHAIN CIRCUIT INSPECTED, NO DEFECTS. LT AND RT TRIM ACTUATOR DISASSEMBLED AND FOUND MOISTURE. ACTUATORS INSPECTED AND LUBRICATED IAW MFG INSTRUCTIONS. 1H71 3T3 T A37CE E4EA 5 CP60GL 20040315000612004031500061NM 2004 3 15 CA040216004 120040121G2910APT7510004000SG TRANSDUCER DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE HYD SYSTEM LEAKING W L ABORTED APPROACH KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 CA (CAN) DURING APPROACH TO AIRPORT THE HYDRAULIC ISOLATION VALVE LIGHT ILLUMINATED. THE CREW BROKE OFF THE APPROACH TO CHECK LIGHT AND NOTED THE NR 1 HYDRAULIC CONTENTS LOW. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE PERSONNEL DISCOVERED A LEAK FROM THE NR 1 HYDRAULIC STANDBY PUMP PRESSURE TRANSDUCER. NEW TRANSDUCER INSTALLED, HYDRAULIC FLUID REPLENISHED AND LEAK CHECKED OKAY. CLOSE INSPECTION OF THE TRANSDUCER FOUND A CRACK IN THE BODY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315000642004031500064NE 2004 3 15 CA040216007 220040205G72203036723 RETAINER PWA 120 PW123D 52152NE ENG BREATHER MISSING W A UNSCHED LANDING KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) ENGINE TSN 13318, TSO291, CSN 13305,AFTER TAKEOFF CONTROL TOWER NOTED FLUID LOSS/SMOKE FROM ENGINE AND INFORMED PILOT. PILOT REDUCED POWER AND RETURNED TO DEPARTURE AIRPORT WHERE UNEVENTFUL LANDING WAS MADE. EXAMINATION OF THE ENGINE SHOWED BREATHER SHAFT PLUG AND RETAINING CIRCLIP TO BE MISSING. ENGINE REMOVED FOR TEARDOWN TO DETERMINE WHETHER CLIP FRACTURED AND ENTERED AGB. OPERATOR IS CHECKING FLEET TO CONFIRM PRESENCE OF CIRCLIP AND PLUG IS PRESENT ON ALL ENGINES. SHOP HAS IMPLEMENTED DOUBLE WITNESS CHECK OF PLUG & CIRCLIP INSTALLATION. 4 T E20NE 20040315000662004031500066SW 2004 3 15 CA040127017 120040105G6310269A54021 NUT HUGHES269 269C1 8059504SW LYC O360 HO360C1A 41514EA FREEWHEEL UNIT LOOSE W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) OIL LEAKING FROM FREEWHEEL WAS NOTED AT REFUELING STOP. NUT (WHICH IS ALSO SEAL RUNNER) WAS FOUND LOOSE. NUT WAS RETORQUED AND FLUSH OF FREEWHEEL PRODUCED NO DISCOLORATION OR PARTICLES. LEAK CHECK CARRIED OUT AND RETURNED TO SERVICE. NOTE: THAT OIL ONLY LEAKED OUT AFTER SHUTDOWN (NO OIL SPRAY). THEREFORE, IN THIS INSTANCE, THE OIL WAS DYNAMICALLY HELD IN, EVEN WITH THE LACK OF SEALING AT FRONT. 1G71 3O3 OO 4H12 E286 20040315000682004031500068CE 2004 3 15 CA040127020 120040112G3340055201913 RING CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL LANDING LIGHT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LANDING LIGHT ASSEMBLY MOUNTING RING (MADE OF ALUMINUM, RIVETED INTO COWLING NOSE BOWL) CRACKED THROUGH SEVERAL RIVET HOLES AND ANCHOR NUT HOLES. THESE RINGS ARE PRONE TO CRACKING, BUT THIS ONE HAS LASTED ONLY 20 MONTHS/1100 HOURS. MATERIAL MAY BE TOO BRITTLE. OTHER FACTORS: FREQUENT LANDING LIGHT CHANGES, VIBRATION, POSSIBLE HEAT FROM LIGHTS, POSSIBLE OVER TIGHTENING OF SCREWS. 1H71 3O3 ONT3A12 E274 5 NP910 20040315000862004031500086 2004 3 15 CA040218001 420040212G221640002928511 SERVO PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ELEVATOR TRIM INOPERATIVE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) ELEVATOR TRIM SERVO WAS VERY NOISY REMOVED FOR REPAIR. LOANER INSTALLED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315000872004031500087 2004 3 15 CA040218002 420040212G221640002928511 SERVO PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ELEVATOR TRIM JAMMED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHEN TRIM WAS TESTED BY THE PILOT, THE TRIM SERVO JAMMED AND COULD NOT BE RELEASED. THE FLIGHT WAS CANCELLED. INSTALLED LOANER NEXT DAY AIRCRAFT SERVICEABLE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315000902004031500090EU 2004 3 15 CA040128002 120040128G351089151114 OXYGEN BOTTLE AIRBUSA330 A330* EU RROYCERB211 RB211TRENT77 NE COCKPIT FAILED W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) RAMP CHECK CREW O2 WAS 1200 PSIG AFTER 3.5 HOURS WE HEARD A RUSHING AIR NOISE WAS F/O O2 MASK THIS NOISE WAS STOP BY PUSHING TEST BUTTON O2 WAS DOWN TO 72 PSIG (MUST HAVE BEEN SLOWLY LEAKING ALONG THEN FAILED. CREW O2 BOTTLE AND REG. REPLACED. F/O MASK TESTED AND RESET OK. 2L72 4F4 FRTA46NM E39NE 20040315001032004031500103NE 2004 3 15 CA040219002 220040219G7200 ENGINE AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE NR 1 STALLED W A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) NR 1 ENGINE STALL IN CRUISE. DUE TO HISTORY MTC ADVISED RETURN FOR INVESTIGATION AND FURTHER T/S. DFDR PULLED. 2L72 4F4 FRTA28NM E29NE 20040315001102004031500110SO 2004 3 15 CA040129008 120040122G3230 BRACKET PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL NLG BENT W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 14630 (CAN) ON TAKE OFF WHEN GEARS SELECTED UP PILOT FOUND GEARS INTERMITTED INDICATION. NOSE GEAR WON'T STAY UP LOCKED. TROUBLESHOT SNAG FOUND TUBE ASSEMBLY, NOSE LANDING GEAR IDLER LINK PN: 41770-00, UNSERVICEABLE. UPLOCK HOOK HOLDING BRACKET IS BENT AND WORN, AS RESULT UPLOCK HOOK MISALIGNED WITH UPLOCK ROLLER, PREVENTING NOSE GEAR FROM LOCKING UP. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315001142004031500114 2004 3 15 CA040130001 420040125G3417C17053AC03 ADC BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU COCKPIT INOPERATIVE W O OTHER J WARNING INDICATION LDLANDING 1 CA (CAN) DURING LANDING ROLL OUT IAS MISMATCH MESSAGE APPEARED, NR 1 IAS WAS 30 KTS HIGHER THAN NR 2 IAS. AFTER PARKING AT THE ARRIVAL GATE, NR 1 IAS INDICTED 38 KTS AND TAS WAS SCROLLING. NR 2 IAS STEADY AT 30 KTS (NORMAL). MAINTENANCE PURGED NR 1 PITOT/STATIC LINES THEN RECONNECTED. NR 1 IAS CONTINUED TO FLUCTUATE AT 38 KTS FOR SEVERAL MINUTES THEN DROPPED TO 30 KTS AND BECAME STEADY. NR 1 ADU REPLACED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040303001872004030300187 2004 3 3 2004FA0000204 420040220G2210ST566 AUTOPILOT SYS CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO HARTZLHCJ3Y PHCJ3YF1 GL COCKPIT MALFUNCTIONED C H DEACTIVATE SYST/CIRCUITS S AFFECT SYSTEMS CRCRUISE 1 WP03210MT201 21064165 291649R FP235A ONCE ESTABLISHED IN CRUISE FLIGHT WITH ALTITUDE HOLD ENGAGED, THE S-TEC SYSTEM 55X AUTOPILOT FREQUENTLY BEGINS TO GENTLY PORPOISE IN PITCH. THIS GETS PROGRESSIVELY WORSE UNTIL THE AUTOPILOT CAUSES SERIOUS PITCH EXCURSIONS OF SEVERAL HUNDRED FEET PER MINUTE UP AND DOWN. THE ONLY SOLUTION FOUND IS TO DISENGAGE THE ALTITUDE HOLD MODE AND SELECT VERTICAL SPEED EQUALS ZERO. THE OTHER MAJOR PROBLEM NOTICED WITH SYSTEM 55X IS THAT DURING THE APPROACH TO LANDING, THE AUTOPILOT WILL PITCH DOWN ABRUPTLY WHEN THE FLAPS AND/OR GEAR ARE DEPLOYED. THIS CAN BE ALARMING, ESPECIALLY DURING AN INSTRUMENT APPROACH IN INSTRUMENT METEOROLOGICAL CONDITIONS. 1H71 3O3 O 3A21 E8CE 5 CP36EA 20040303001932004030300193SO 2004 3 3 2004FA0000211 220040202G8530AEC631397SN712 CYLINDER CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE MISMANUFACTURED D K NONE O OTHER ININSP/MAINT 1 NE03 517404 INSPECTED NEW CYLINDER ASSY AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG SPECS., AND VALVE SEAT MACHINING NOT CONCENTRIC. 1H71 3O3 O 3A21 E8CE 20040304000462004030400046CE 2004 3 4 2004001 120040211G8000MHB6016 STARTER CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA ENGINE FAILED D K NONE O OTHER TXTAXI/GRND HDL 1 WP0797811163 136 17276232 L1550339A RECEIVED AN OVERHAULED ENGINE FROM MFG ON 5 DEC 2003 AND INSTALLED ON THE AIRCRAFT. STARTER BENDIX DRIVE GEAR SHATTERED AGAINST ENGINE RING GEAR ON A START ATTEMPT. 1H71 3O3 ONT3A12 E274 20040304000492004030400049SO 2004 3 4 2004FA0000225 120040206G2420 HOUSING PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ALTERNATOR BROKEN B VJ3RK NONE O OTHER ININSP/MAINT 1 WP074130W99 D071998 2843204 L2847836A DURING ROUTINE INSPECTION, LOWER FRONT ATTACHMENT EAR FOR ALTERNATOR WAS FOUND TO BE CRACKED THROUGH AND BROKEN. PROBABLE CAUSE IS VIBRATION, POOR MFG OR MATERIAL FAILURE. NO RECOMMENDATIONS AT THIS TIME. 1L71 3O3 O 2A13 E286 20040304000702004030400070GL 2004 3 4 2004FA0000230 120040220G55502055300099 SLEEVE DIAMONDA20 DA20C1 2990001GL CONT O240 IO240A SO RUDDER HINGE PINLOOSE D K NONE O OTHER ININSP/MAINT 1 NM03922AF C0179 THE SLEEVE ON THE RUDDER HINGE PIN CAME LOOSE FROM ITS LOCTITED POSITION ON THE PIN AND WORKED UP INTO THE CAVITY ABOVE THE BEARING ON THE FIN. RUDDER HAD CONSIDERABLE PLAY AT THE TOP. 1L71 3O3 ONTTA4CH E7SO 20040304000802004030400080GL 2004 3 4 2004FA0000234 320040206G6110C50462 PLATE CESSNA182 R182 2072734CE LYC O540 O540* 41532EA MCAULY2D34C B2D34C218 GL PROP BULKHEAD CRACKED D W59RK NONE O OTHER ININSP/MAINT 1 WP0735G 144 R18201785 776893 DURING AN INSPECTION, THE BULKHEAD MOUNTING PLATES WERE FOUND CRACKED AND BROKEN AROUND THE HOLES THROUGH WHICH THE PROPELLER MOUNTING STUDS PASS. THIS CONDITION IS FOUND VERY OFTEN AND THE PLATES REALLY NEED TO BE REDESIGNED TO NOT CRACK AS EASILY AS THEY DO NOW. SHOULD THE CRACKS GO UNDETECTED, FAILURE OF THE SPINNER ASSEMBLY AND DAMAGE TO THE PROPELLER AND COWLING WILL RESULT. (WP07200403102) 1H71 3O3 ORT3A13 E295 5 CP7EA 20040304000812004030400081GL 2004 3 4 2004FA0000235 120040206G2700 STRUCTURE AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA STABILATOR CHAFED B KC5RO OTHER O OTHER NRNOT REPORTED 1 GL13622AM28 201023 STABILATOR RUBS AGAINST FUSELAGE SCREW. .5 INCH GAP ON LT SIDE, .2500 INCH GAP ON RT SIDE. (GL13200405339) 1L71 3 O EXPA1L71E223 20040304000862004030400086GL 2004 3 4 2004FA0000238 120040206G5540 RUDDER AMTR AMD ALARUSCH2T 0033001GL LYC O235 O235* 41505EA VERTICAL STAB MISINSTALLED B KC5RO OTHER W INADEQUATE Q C NRNOT REPORTED 1 GL13622AM 201023 RUDDER CONTACTS FUSELAGE BEFORE REACHING STOPS. (GL13200405339) 1L71 3 O EXPA1L71E223 20040304000892004030400089SO 2004 3 4 2004FA0000246 120040227G3210400885 BOLT PIPER PA28 PA28R200 7102811SO LYC O360 IO360A1A 41514EA NLG DOWNLOCK MISSING D K NONE O OTHER ININSP/MAINT 1 SO0515143 28R7335027 LANDING GEAR (IN-TRANSIT) LIGHT CAME ON INTERMITTENTLY. DURING TROUBLESHOOTING, FOUND NLG DOWNLOCK BOLT MISSING (GOES IN METAL BLOCK ON RT LOWER ENG MOUNT STRUCTURE). THIS IS THE BOLT THE DOWNLOCK HOOK ENGAGES IF THE NLG COLLAPSES. ORDERED REPLACEMENT BOLT AND INSTALLED IAW MM. RETRACTION CHECK OK. ENGINE MOUNT HAD BEEN REMOVED FOR REPAIR. WHEN IT WAS REINSTALLED, THE PART WAS PROBABLY NOT PUT BACK ON (UP LIMIT STOP BOLT WAS ALSO MISSING). THERE IS NO WAY THE GEAR RIG CHECK WAS GOOD AFTER REINSTALLATION OF MOUNT. RECOMMEND MAINTENANCE ACTIONS ON MAJOR ACFT SYSTEMS BE STRICTLY BY THE BOOK. LUCKILY THERE WAS NOT A HARD NOSE LANDING ON THIS ACFT WHILE THE BOLT WAS MISSING. 1L71 3O3 O 2A13 1E10 20040304001112004030400111NM 2004 3 4 SROM200400015 120040226G5313654577835 STRINGER BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE ZONE 100 ELONGATED C SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA339637874 23466 DURING D CHECK INSPECTION FOUND AFT CARGO PIT STRINGER 21R HAC ELONGATED HOLE STA 927. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR FILLER CHANNEL SRM 53-10-3. 2L72 4F4 FRTA16WE E2EA 20040315000162004031500016EU 2004 3 15 CA040212004 120040203G6520350A020005 GEARBOX SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE TAIL ROTOR MAKING METAL W K NONE J WARNING INDICATION ININSP/MAINT 1 CA (CAN) T/R GEARBOX MAKING METAL. CHIPS DETECTED ON DETECTORS. REPLACED T/R GEARBOX. 1G71 3U3 UNCH9EU E19EU 20040315000212004031500021EA 2004 3 15 CA040126001 120040126G3234750006000 SELECTOR VALVE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE MLG DOOR INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) GEAR DISAGREE ON UP SELECTION AFTER T/O. NOISE IN FLT DECK CONFORMING NOSE GEAR NOT RETRACTED (INDICATED RED HATCHING ON EICAS CHECK- LIST CARRIED OUT GEAR INDICATED 3 GREEN AIRCRAFT RETURNED TO AIRPORT. DOOR SELECTOR VALVE REPLACED IAW AMM 32-22-15-400-801. A/C SERVICEABLE. 2L72 4F4 FRTA21EA E15NE 20040315000282004031500028 2004 3 15 CA040123004 420040114G3197 INSULATION PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ELECTRICAL WIRE CHAFED W O OTHER H ELECT. POWER LOSS-50 PC APAPPROACH 1 CA (CAN) DURING APPROACH FLIGHT ON MULTIPLE OCCASIONS THE PILOTS EHSI FAILED ON APPROACH , POWERED DOWN AND RE POWERED UNCOMMANDED. ON EACH OCCASION THE SYSTEM TESTED NORMAL AFTER LANDING AND DID NOT REOCCUR FOR DAYS. EACH COMPONENT IN THIS SYSTEM WAS REPLACED WITH A SERVICEABLE UNIT WITH NO CHANGE. DURING INSP OF THE A/C WIRING CHAFED WIRING WAS DISCOVERED UNDER THE COPILOTS SEAT IN THE OUTFLOW VALVE COMPARTMENT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040315000312004031500031EA 2004 3 15 CA040126006 120040126G27409960023 SWITCH CNDAIRCL600 CL6002D24 1390016EA GE CF34 CF343A1 30015NE STAB TRIM DIRTY W A UNSCHED LANDING FH FLT CONT AFFECTED ELECT. POWER LOSS-50 PC CLCLIMB 1 CA (CAN) WENT TO DISCONNECT STAB CHANNEL 1, LOST BOTH STAB TRIM CHANNELS AND MACH TRIM. TRIED TO ENGAGE EITHER STAB CHANNEL WITHOUT SUCCESS. ACTIONED QUICK RESPONSE PROCEDURE AND RETURNED TO AIRPORT USING FLAPS 20 IAW QRH. GREATER THAN NORMAL FORCE ELEVATOR FORCE WAS REQUIRED DURING APPROACH. LANDED WITHOUT FURTHER INCIDENT. THE STAB TRIM DISCONNECT SWITCH WAS CLEANED AND SYSTEM RETESTED SERVICEABLE IAW FUNCTIONAL TEST PROCEDURE P601R4500 PARA 5.6.20, THEN A/C WAS RETURNED TO FLIGHT WITHOUT ANY FURTHER OCCURENCES. 2L72 4F4 FRTA21EA E15NE 20040315000392004031500039EU 2004 3 15 CA040213005 120040213G7830 THRUST REVERSER AIRBUSA319 A319112 3930323EU CFMINTCFM565CFM565B6 13802NE ENGINE SMOKE W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) AFTER LANDING AND EXITING THE RUNWAY, THE FLIGHT CREW WERE ADVISED BY THE FLIGHT ATTENDANT THAT THE CABIN HAD FILLED WITH SMOKE. ATC CONTACTED AND EMERGENCY VEHICLE RESPONDED. THE SMOKE IN THE CABIN QUICKLY DISSIPATED AND ATC ADVISED. AFTER DISCUSSION WITH FLIGHT CREW SMOKE WAS INFACT INGESTED SMOKE FROM REVERSERS. THE CREW LEFT THE REVERSER WELL BELOW 60KTS LIMIT. (NO FURTHER ACTION REQUIRED). 2L72 4F4 FRTA28NM E37NE 20040315000432004031500043EA 2004 3 15 CA040213009 120040210G5552C2TP11 HOUSING DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 12498 (CAN) LOSS OF ELEVATOR CABLE TENSION REVEALED WORN BEARINGS IN THE C2TP15A HOUSINGS (2), ON REMOVAL OF THE LT HOUSING FOR BEARING REPLACEMENT A CORROSION ASSISTED CRACK WAS NOTED. FAILURE OF THE BEARING HOUSING WAS NOT EASILY DETECTABLE UNTIL THE HOUSING ASSEMBLY WAS REMOVED FOR BEARING REPLACEMENT. 1H71 3R3 R A806 5E1 5 CP206 20040315000462004031500046EA 2004 3 15 CA040215001 120040208G5610NP13932110 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA (CAN) TAKE OFF ABORTED AT APPROXIMATIVELY 80 KNOTS BECAUSE RT WINDSHIELD CRACKED. RT WINDSHIELD REPLACED. 2L72 4F4 FRTA21EA E15NE 20040315000512004031500051EA 2004 3 15 CA040127008 120040127G2120 ODOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE CABIN DETECTED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FLIGHT CREW NOTICED AN ACRID ODOR IN THE COCKPIT. AFTER NOTING THE ACRID ODOR THE FLIGHT CREW OBSERVED A CIRCUIT BREAKER THAT HAD POPPED. THE ODOR SEEMED TO CLEAR AND THEN REOCURRED ASSOCIATED WITH A SOUND. THE FLT CREW ELECTED TO DEC. MAINTENANCE INVESTIGATION UNDER WAY. 2L72 4F4 FRTA21EA E15NE 20040315000532004031500053CE 2004 3 15 CA040127010 120040121G561010138402521 WINDSHIELD BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL COCKPIT CRACKED W B EMER. DESCENT H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) IN CRUISE 28,000 FT, OAT-32, WINDSHIELD HEAT ON. HEARD A BANG - PILOT'S WINDSHIELD CRACKED. DESCENDED TO 12,500 FT, REDUCED AIRSPEED AND CABIN PRESSURE DIFFERENTIAL TO 4.0, RETURNED TO BASE. LANDED AIRCRAFT FROM RT SEAT. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040315000582004031500058EA 2004 3 15 CA040127015 120040127G5270 WARNING LIGHT CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE PAX DOOR FALSE ACTIVATIONW A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AFTER DEPARTURE, CREW HAD DOOR WARNING INDICATION. CREW ELECTED TO RETURN, LANDED WITHOUT INCIDENT. OFF LINE FOR INVESTIGATION. 2L72 4F4 FRTA21EA E15NE 20040315000622004031500062EA 2004 3 15 CA040216005 220040110G852078030 CONNECTING ROD CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1A175 1A175ATM GL ENGINE WORN W K NONE O OTHER ININSP/MAINT 1 CA L4427827A (CAN) ENGINE WAS CONTAMINATED. ABNORMAL WEAR WAS DETECTED ON FOUR CONNECTING RODS CAUSING METAL CONTAMINATION. DEMARCATION WAS ALSO NOTED ON CRANKSHAFT. AFTER COMPLETING A THOROUGH INSP (MEASUREMENT OF INTERNAL BUSHINGS, A TORSION, PARALLELISM, INSPECTION OF CONNECTING RODS, SIDE PLAY INSP OF CONNECTING RODS AND CRANKSHAFT), CONCLUDED THAT ALL MFG INSP REQUIREMENTS WERE CARRIED OUT IN CONFORMITY WHEN IT WAS OVERHAULED. AC WAS IN OPERATION WITH 100 MINERAL OIL (SUMMER OIL) BECAUSE 80 MINERAL OIL (WINTER OIL) WAS NOT AVAILABLE. WE CONCLUDED THAT USE OF 100 MINERAL OIL IN VERY COLD STARTING CONDITION CAUSED A LACK OF LUBRICATION IN THIS SPECIFIC AREA. 1H71 3O3 ONT3A12 E274 5 NP857 20040728002022004072800202EA 2004 7 28 AUS20040383 220040503G8530LW19339 SCREW CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL ENGINE CRACKED W O OTHER E VIBRATION/BUFFET CLCLIMB 1 AUS 591 (AUS) EXHAUST VALVE ROCKER ADJUSTMENT SCREW CRACKED ALLOWING LOCKNUT TO LOOSEN AND ADJUST VALVE CLEARANCE. 1H71 3O3 ONT3A19 E223 5 NP50GL 20040315000712004031500071EA 2004 3 15 CA040217005 220040210G8520LW13521 BEARING ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA CONNECT ROD FAILED W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA L2549440A (CAN) NR 5 CONNECTING ROD BEARING FAILED. BEARING FACE MATERIAL WAS BREAKING AWAY FROM BEARING. METAL CONTAMINATION WAS NOTED DURING PREFLIGHT CHECK. CONNECTING ROD BEARING HAD LOST APPROXIMATELY 15 PERCENT OF TOTAL SURFACE AREA. BOTH THE CRANKSHAFT AND IDLER GEAR HAD RECEIVED SIGNIFICANT DAMAGE TO THEIR TEETH. BOTH GEARS HAD TO BE REMOVED FROM SERVICE. 1G71 3O3 O H11NM E295 20040315000842004031500084EU 2004 3 15 CA040217012 120040216G243523085024 STARTER GEN PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ENGINE INOPERATIVE W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA (CAN) DURING AN ENGINE START THE PILOT NOTED THERE WAS AN ABNORMAL NOISE GENERATING FROM THE ENGINE. THE NOISE WAS NOTICEABLE AROUND 10 PERCENT GG SPEED AND DISAPPEARED AFTER STABLE RPM WAS REACHED AT 17 PERCENT GG SPEED. THE STARTER GENERATOR WAS REPLACED AND THE NOISE HAS NOT REOCCURRED. NO FURTHER ACTION REQUIRED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040315000852004031500085WP 2004 3 15 CA040217013 220040211G724031016687 COMBUSTION LINER BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP MCAULY4HFR344HFR34C652 NE LT ENGINE CRACKED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA (CAN) THE LT ENGINE WOULD NOT PRODUCE RATED POWER, IN FACT IT ONLY WENT TO 80 PERCENT. THE CREW ABORTED THE TAKEOFF ROLL AND RETURNED TO THE HANGAR. ON INVESTIGATION, A CRACK WAS FOUND ON THE LOWER CENTER OF THE COMBUSTION CASE. THE CRACK GOES AROUND AN UNUSED PORT ON THE CASE. THIS APPEARS AT FIRST GLANCE TO BE VERY SIMILAR TO A PREVIOUS PROBLEM HAD WITH ANOTHER ENGINE OF THE SAME TYPE. ON THAT ONE IT TURNED OUT TO BE A FAILED SECOND STAGE COMPRESSOR IMPELLER THAT WAS CAUSING DAMAGING VIBRATIONS. 2L72 4T4 TRTBA15CAA E4WE 6 C3PNE 20040315000912004031500091NM 2004 3 15 CA040128003 120040123G30204100S02801 HEATER BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU AIR INTAKE BURNED W F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA (CAN) AFTER OUR AIRCRAFT ARRIVED ON THE PARKING POSITION OUR TECHNICIAN REPORTED SMOKE AND FLAMES COMING OUT OF THE LT ENGINE COWLINGS AND AIR INTAKE SECTION. THE FIRE WAS EXTINGUISHED AND THE CAUSE WAS FOUND TO BE THAT THE AIR INTAKE HEATER CAUGHT FIRE. THE AIR INTAKE WHICH WAS THE CAUSE, WAS A PRE MOD UNIT PN 4100S028-01. RELATED REFERENCE, SYD 84-30-02, APPLIES ADDITIONAL SEALANT TO PREVENT FLUID INGRESS TO HEATER CORE. PN 4100S028-03, POST MODSUM 4-113435 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040315000982004031500098EU 2004 3 15 CA040129001 120040129G2120 ODOR AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE COCKPIT DETECTED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) STRONG ELECTRICAL ODOR FOR 2 MIN DURING DESCENT. WENT AWAY AFTER SHUTTING THE VTRS OFF. CIRCUIT BREAKER WAS PULLED FOR THE REMAINING OF THE FLIGHT, DUE UNABLE TO REACH ANYBODY TO INVESTIGATE IN FLIGHT. 2L72 4F4 FRTA28NM E29NE 20040315001062004031500106EA 2004 3 15 CA040129002 120040129G7110 ACCOUSTIC LINER CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE LT & RT ENGINE DAMAGED W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 CA (CAN) ON TAKEOFF, THRU 100KIAS N1 VIB. BOTH ENGINES 4.0 (RED),VIB. REDUCED AFTER APROX 5 MIN. FOUND ACCOUSTIC LINER DAMAGED. A/C REMOVED FROM SERVICE AND SENT TO HGR FOR REPAIR. (MORE INFO WILL FOLLOW). 2L72 4F4 FRTA21EA E15NE 20040315001162004031500116EA 2004 3 15 CA040219005 120040129G2701C3CF3915 CONTROL COLUMN DHAV DHC3 DHC3 2800202EA PWA PT6 PT6A34 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 14020 (CAN) CONTROL COLUMN FOUND CRACKED IN THREE LOCATIONS WHEN SB 3/39 CW. 1H71 3R4 T A815 E4EA 6 CP15EA 20040315001192004031500119NM 2004 3 15 CA040130005 120040116G561017180003 WINDOW DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE COCKPIT CRACKED W B EMER. DESCENT D INFLIGHT SEPARATION CRCRUISE 1 CA 14921 (CAN) SHORT WHILE AFTER TAKEOFF AT 13:54 AT 23000 FEET PILOT NOTICED COCKPIT PORT SIDE WINDOW SHOWING SIGNS OF DISCOLORATION. WHEN PILOT NOTICED DISCOLORATION SIDE WINDOW HEAT WAS SELECTED ON. SHORTLY AFTER HEAT WAS SELECTED ON, OUTER PANE CRACKED FOLLOWED NOT LONG AFTER BY A PARTIAL SEPARATION OF OUTER PANE. SEPARATION PORTION OF WINDOW PANE STRUCK THE LT IB WING LEADING EDGE AND LT HORIZONTAL STABILIZER CAUSING SOME MINOR DAMAGE TO DEICER BOOTS. FOLLOWING THIS, AC RETURNED TO DORVAL. MAINTENANCE REPLACED THE PORT COCKPIT SIDE WINDOW AND AC WAS RETURNED BACK TO SERVICE. RECORDS INDICATE THIS TO BE THE ORIGINAL WINDOW. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315001272004031500127EA 2004 3 15 CA040220001 220040219G8520 PISTON RING PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA HARTZLHCC2Y HCC2YR2 GL ENGINE CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) CYLINDER NR 4 REMOVED DURING 100 HR INSPECTION DUE TO OIL CONTAMINATED SPARK PLUG. TOP COMPRESSION RING FOUND IN SEVERAL PIECES EMBEDDED INTO PISTON. ALL CYLINDERS REMOVED FROM BOTH ENGINES, 8 TOTAL AND 3 OTHER PISTONS FOUND WITH CRACKED TOP COMPRESSION RINGS. NOTE THAT ALL OTHER CHECKS WHERE NORMAL, COMPRESSION TEST RESULTS ABOVE 70PSI. AFFECTED CYLINDERS SENT TO OVERHAUL FACILITY FOR REPAIR/REPLACEMENT. 1L72 3O3 O A19S0 E286 5 CP920 20040315001292004031500129CE 2004 3 15 CA040220003 120040211G3234404EN16 SWITCH BEECH 99 99 1154002CE PWA PT6 PT6A36 52043NE HARTZLHCB3T HCB3TN3 GL MLG SELECTOR CONTAMINATED W A UNSCHED LANDING O OTHER APAPPROACH 1 CA (CAN) LANDING GEAR FAILED TO EXTEND WHEN SELECTED. APPROXIMATELY 1-5 MINUTES GEAR EXTENDING WITH NO ADDITIONAL CREW ACTIONS. AIRCRAFT RETURNED TO MAINTENANCE BASE. AIRCRAFT EXPOSED TO -30 DEGREES COLD SOAK FOR APPROXIMATELY 3 HOURS. AIRCRAFT PREVIOUS OPERATED IN WARM CLIMATES FOR 20 YEARS. MAINTENANCE FOUND VERY DIRTY AND (GUMMED) SWITCHES IN LANDING GEAR CONTROL HANDLE. FIRST EXPOSURE TO COLD CONDITIONS SINCE IMPORT. 1L72 3T4 T A14CE E4EA 6 CP15EA 20040315001312004031500131WP 2004 3 15 CA040220005 120040211G7711LC80E1 TRANSMITTER DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE EPR FAILED W C ABORTED TAKEOFF N FALSE WARNING TOTAKEOFF 1 CA (CAN) TAKEOFF REJECTED DUE TO RT ENGINE EPR INDICATION INOPERATIVE. AIRCRAFT WAS DISPATCHED IAW MEL 77-1 FOR THE DAY. EPR TRANSMITTER REPLACED ON THE FOLLOWING DAY AND AIRCRAFT DISPATCHED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040315001322004031500132EA 2004 3 15 CA040104001 220040102G7320252444076 FUEL CONTROL BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL LT ENGINE FAILED W O OTHER YJ ENGINE STOPPAGE WARNING INDICATION DEDESCENT 1 CA PCE52113 (CAN) LT ENGINE HAD TO BE SHUT DOWN IN FLIGHT AS FCU THROTTLE ARM WOULD NOT RETURN TO IDLE. DUE TO WEEKEND AND PARTS ON ORDER WE WILL BE REMOVING FCU NEXT WEEK. 1L72 3T4 T A14CE E4EA 5 CSTC 20040315001332004031500133CE 2004 3 15 CA040130007 120040106G2434C6FF10555A HOUSING CESSNA337 337G 2075730CE CONT O360 IO360G 17025SO MCAULY2AF34CD2AF34C306 GL ALTERNATOR CRACKED W K NONE P NO WARNING INDICATION ININSP/MAINT 1 CA 9041135 (CAN) ON INSPECTION OF ALTERNATOR HOUSING 2 RIBS WERE FOUND CRACKED COMPLETELY THROUGH. THERE HAVE BEEN TWO OTHER SIMILAR ALTERNATORS FOUND WITH CRACKED RIBS. 1H72 3O3 O A6CE E1CE 5 CP5EA 20040315001362004031500136SW 2004 3 15 CA040130009 120040130G5412 CAP BELL BELL 212 212 1181420SW PWA PT6T PT6T3B 52045NE MAIN BEAM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) NOT UNUSUAL FOR THE OLDER STYLE BEAM CAP TO CRACK. THIS IS A REGION THAT IS PART OF OUR INSPECTION PROGRAM. THERE IS A MORE EXTENSIVE INSPECTION AFTER 10,000 HOURS. 1G71 4U4 U H4SW E22EA 20040315001372004031500137EU 2004 3 15 CA040131001 120040130G2913704A33690004 DRIVE BELT SNIAS 350 AS350BA 8680817EU LYC LTS101LTS101600A3 41560NE HYDRAULIC PUMP BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) THE BELT BROKE 2 MINUTES AFTER TAKE-OFF. OAT WAS -15C. THE AIRCRAFT MADE A NORMAL HYDRAULIC-OFF LANDING. NO UNCOMMANDED CONTROL MOVEMENT OCCURRED AT THE TIME OF THE INCIDENT. 1G71 3U3 UNCH9EU E5NE 20040315001382004031500138GL 2004 3 15 CA040202001 320040211G6110LW13792 SEAL PIPER PA30 PA30 7103002SO LYC O320 IO320B1A 41508EA HARTZLHCE2Y HCE2YL2 GL PROPELLER BLOWN W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA L175755A (CAN) PILOT NOTICED ENGINE SEEPING FROM LT ENGINE COWL, THEY WERE NEAR THE AIRPORT AND DECIDED TO SHUTDOWN LT ENGINE TO PREVENT ENGINE DAMAGE. IT WAS DETERMINED ON THE GROUND BY MAINTENANCE THAT THE LT PROP SEAL HAD BLOWN DUE TO A FROZEN BREATHER. IT WAS DETERMINED THAT PROBLEM RESULTED FROM AN EXTREME DROP IN TEMPERATURE CAUSING ANY MOISTURE IN THE BREATHER FROM PREHEAT TO FREEZE. PROP SEAL WAS REPLACED AND TEST FLIGHT SUCCESSFUL. 1L72 3O3 O A1EA 1E12 5 CP9EA 20040315001412004031500141NM 2004 3 15 CA040105001 120040101G243551539008D GCU LUCAS DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE STARTER GEN FAILED W E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA 3125131251 1163 (CAN) DURING NR 1 ENGINE START AFTER PUSHBACK SMOKE WAS NOTED COMING OUT OF THE GEN EXHAUST DUCT ON THE NR 1 NACELLE. THE PILOT IMMEDIATELY SHUT ENGINE DOWN AND DECLARED AN EMERGENCY, REQUESTED ERS RESPONCE. PASSENGERS WERE DEPLANED AND PILOT NOTED THAT GENERATOR WAS STILL SPOOLING AFTER EVERYTHING WAS SHUT DOWN, MAINTENANCE WAS SUMMONED TO AC AND MAIN BATTERY WAS DISCONNECTED AND GENERATOR STOPPED. AC WAS BROUGHT BACK TO HANGAR AND STARTER GEN, GCU AND MAIN BATTERY WERE REPLACED AND AIRCRAFT RETURNED TO SERVICE AFTER ALL FUNCTION CHECKS WERE CARRIED OUT. COMPONENTS WILL BE SENT OUT FOR REPAIR AND INVESTIGATION AS TO WHY THE GEN DIDN'T DISENGAGE AFTER START UP WHICH CAUSED THE INCIDENT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315001492004031500149EA 2004 3 15 CA040220008 220040218G7510909100999 HOSE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL ANTI ICE SYSTEM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT COWL ANTI ICE FLEX HOSE FOUND CRACKED DURING OPS 1 INSPECTION. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040315001502004031500150EA 2004 3 15 CA040220009 220040202G7220109910029121 DUCT BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LOWER FORWARD COWL AIR INLET DUCT CRACKED. REPAIR TO BE ACCOMPLISHED IAW MFG FIELD REPAIR PROCEDURE. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040315001522004031500152EU 2004 3 15 CA040223001 120040221G2597RDAV400111 WIRE AIRBUS320 A320232 3930326EU IAE V2527 V2527A5 NE VIDEO SYSTEM BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) WHILE TROUBLE SHOOTING THE NON-DEPLOYMENT OF A VIDEO MONITOR IT WAS FOUND THAT THE JUNCTION BOX FOR THIS MONITOR HAD FAILED. THE UNIT SMELLED OF BURNED ELECTRICAL MATTER. THERE WHERE SIGNS OF ARCING SHOWING ON THE OUTSIDE CASE. THE ASSOCIATED MONITOR DID NOT WORK AND DID NOT WORK WITH ANOTHER JUNCTION BOX. BOTH THE MONITOR AND JUNCTION BOX WERE REPLACED AND FUNCTIONED SERVICEABLE. THE JUNCTION BOX WILL BE INVESTIGATED. 2L72 4F4 FRTA28NM E40NE 20040315001582004031500158WP 2004 3 15 CA040202004 120040105G213339271411 OUTFLOW VALVE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE CABIN PRESSURE FAULTY W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) UNABLE TO PRESSURIZE THE AIRCRAFT. AIRCRAFT LANDED. MAINTENANCE FOUND RT PRSO VALVE P/N 392714-1-1 S/N 2653 IN FAULT. VALVE REPLACED. 2L72 4F4 FRTA6WE E9NE 20040315001592004031500159WP 2004 3 15 CA040202005 120040109G213339245431 REGULATOR VALVE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE CABIN PRESSURE FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) COULD NOT PRESSURIZE THE AIRCRAFT. AIRCRAFT LANDED BACK, FOLLOWING INVESTIGATION, MAINTENANCE FOUND IN FAULT THE LT PILOT PRESSURE REGULATING VALVE P/N 392454-3-1 S/N 6549 AND LT PRESSURE REGULATOR VALVE P/N 392714-1-1 S/N 4522. BOTH VALVES REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040315001602004031500160WP 2004 3 15 CA040202006 120040115G2910 B-NUT DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE HYD LINE LOOSE W O OTHER KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA (CAN) UPON ARRIVAL AT GATE WHEN APU AIR SELECTED 'ON', CABIN AND COCKPIT FILLED WITH BLUE SMOKE. CAUSED BY THE INGESTION OF HYDRAULIC OIL IN THE APU AIR INTAKE. SOURCE OF FLUID CAME FROM RT WHEEL WELL. MAINTENANCE FOUND 2 (B) NUTS LOOSE ON ONE HYDRAULIC LINE NEAR RT HYDRAULIC RESERVOIR. NUTS TIGHTENED AND SYSTEM CHECKED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040315001632004031500163CE 2004 3 15 CA040224001 120040218G7830282D0007505 PRESSURE SWITCH EATON LEAR 60 60LEAR 5170707CE PWA 305 PW305A 52128NE HCU FALSE INDICATIONW O OTHER LJ NO TEST WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) WHILE TAXIING AIRCRAFT, FLIGHT CREW INCREASE ENGINE POWER. ONE THRUST REVERSER LIGHT STAYS ON. AFTER TROUBLESHOOTING, MAINTENANCE REPLACED HYDRAULIC CONTROL UNIT. THE PRESSURE SWITCH INSIDE THE HCU GIVES A FALSE INDICATION. AIRCRAFT RETURN TO SERVICE. 2L72 4F4 FRTA10CE E35NE 20040315001692004031500169CE 2004 3 15 CA040202012 120040113G54105012000886 SPAR RAYTHN BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCD4N3HCD4N3A GL NACELLE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA LJ1305 (CAN) NACELLE OB WEB TO SPAR ATTACHMENT CHANNEL CRACKED IN BEND RADIUS ON LOWER END OF CHANNEL. THIS CONDITION EXISTED IN THE SAME AREA ON BOTH NACELLES. CRACKS ARE COMMON IN THESE AREAS ON HIGH CYCLE AIRPLANES. LATER SN AIRCRAFT COME FROM THE FACTORY WITH DOUBLERS ALREADY INSTALLED IN THESE AREAS. 1L72 3T4 TRT3A20 E4EA 5 CSTC 20040315001732004031500173NM 2004 3 15 CA040202017 120040106G2422116250 CONNECTOR DH103024600CDHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE LOAD EQUALIZER FAILED W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA 1814S8 (CAN) COMPONENT RESPONSIBLE FOR INVERTER FAILURE IS SOLDER CONNECTION ON LOAD EQUALIZER SUBASSEMBLY P/N 116250. ON APPROACH, PRIMARY INVERTER, SECONDARY INVERTER, AND AUX INVERTER, L26AC BUS, AND R26AC BUS CAUTION LIGHTS ILLUMINATED. AFTER AUX INVERTER SWITCHED OFF, PRIMARY, SECONDARY AND BOTH 26AC BUS LIGHTS WENT OUT. CREW BROKE OFF APPROACH AND AC RETURNED. COULD NOT FAULT ON GROUND. PRIMARY INVERTER VOLTAGE INDICATING 107V AND REPLACED. AUX INVERTER REPLACED FOR T/S. ALL RELATED CONNECTOR PLUGS AND CIRCUIT BREAKERS INSPECTED SVC. INVERTERS SENT TO VENDOR AND RETURNED WITH S/N 1814-S8 CONFIRMING FAULT, AND NAMING SOLDER CONNECTION ON LOAD EQUALIZER SUBASSEMBLY AS CULPRIT COMPONENT P/N 116250. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315001742004031500174CE 2004 3 15 CA040203001 120040130G32601EN18 DOWNLOCK SWITCH LEAR 35 35LEAR 5170600CE GARRTTTFE731TFE73122B 01518WP RT MLG FALSE INDICATIONW O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) ON GEAR SELECT DOWN, INDICATED RT MAIN GEAR NOT DOWN AND LOCKED WITH 2 MAIN GEAR DOOR UNSAFE RED. LIGHT BULB TEST INDICATED THAT BULBS WERE OK. RECYCLED GEARS SELECTOR 3 TIMES WITH NO SUCCESS. HYDRAULIC PRESSURE WAS NORMAL. CONDUCTED EMERGENCY GEAR EXTENSION PROCEDURE BUT DID NOT OBTAIN NORMAL (DOWN AND LOCK) GREEN LIGHTS. TOWER CONFIRMED THAT THERE WAS NO LANDING LIGHT ON RT SIDE. EMERGENCY WAS DECLARED, LANDING WAS PERFORMED WITH NO FURTHER PROBLEMS, BESIDE (DOWN AND LOCK) LIGHTS. RT DOWN AND LOCK SWITCH WAS REPLACED, GEAR SWINGS WERE C/O, AND THE SYSTEM WAS FOUND SERVICEABLE AND AIRCRAFT RELEASED TO SERVICE. 2L72 4F4 F A10CE E6WE 20040315001752004031500175EA 2004 3 15 CA040225002 120040218G33402LA00691307 LIGHT CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT INOPERATIVE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) FLOODLIGHT CAUSED SMOKE IN THE FLT DECK. CB POPPED AND WHEN FLOOD LIGHT WAS TURNED OFF IT QUIT SMOKING. FLOOD LIGHT ASSEMBLY WAS REPLACED. 2L72 4F4 FRTA21EA EOOO63EN 20040315001772004031500177CE 2004 3 15 CA040225005 120040121G2710051010513 CONTROL CABLE CESSNA180 180C 2072608CE CONT O470 O470K 17026SO MCAULY2A34C 2A34C203 GL AILERON FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CABLE FRAYED AT PULLEY AREA. WING ROOT PULLEY WAS NOT SEIZED. 1H71 3O3 O 5A6 E273 5 CP3EA 20040315001832004031500183EA 2004 3 15 CA040106008 120040106G2497 WIRE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE E/E COMP. FAILED W K NONE BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION ININSP/MAINT 1 CA (CAN) AFTER LANDING, CAUTION MSG ESS TRU 1 ON EICAS A PUFF OF ELECTRICAL ODOR WAS DETECTED AT GATE FOUND A1 CB POPPED WOULD NOT RESET. DUE TO THIS SITUATION THREE WIRES WERE CHANGED ALSO TR1 REPLACED AND J12 CONNECTOR REPLACED. 2L72 4F4 FRTA21EA E15NE 20040319000132004031900013NM 2004 3 19 18069 120040303G5710 STRUCTURE LKHEEDP2V P2V7 5260112NM WRIGHTR3350 R3350* 67040EA LT WING CRACKED F K NONE O OTHER ININSP/MAINT 1 NM04139HP9034 145906 THE CRACK/CORROSION IS LOCATED ON THE AFT VERTICAL SIDE OF STRINGER (HAT SECTION) NR 18. IT IS LOCATED IN THE LEFT HAND OUTER WING AT WING STATION 284. THE CRACK/CORROSION IS 1.25 INCH LONG AND RUNS SPAN WISE. THE CORROSION WAS REMOVED COMPLETELY AT .024 OF GRIND OUT. THE CRACK IS STILL EVIDENT AND APPEARS TO GO ALL THE WAY THRU THE MATERIAL. THE MATERIAL THICKNESS OF THE HAT SECTION IS .120. 2M72 4R4 RRTA1RM E272 20040325000282004032500028CE 2004 3 25 CA040203004 120040130G3230MS24171D1 RELAY BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL MLG MOTOR FAILED W O OTHER O OTHER APAPPROACH 1 CA (CAN) LANDING GEAR FAILED TO EXTEND ON APPROACH. EMERGENCY EXTENSION WAS CARRIED OUT AND AIRCRAFT LANDED SAFELY. MAINTENANCE FOUND THAT THE LANDING GEAR MOTOR WAS NO LONGER RUNNING. THE LANDING GEAR RELAY WAS FOUND INTERNALLY DAMAGED WITH THE CONTACTS STUCK IN THE CLOSED POSITION THUS PROVIDING CONTINUOUS POWER TO THE LANDING GEAR MOTOR. THIS CAUSED THE MOTOR TO FAIL. P/N OF RELAY MS24171D1 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040325000362004032500036CE 2004 3 25 CA040225011 120040224G275014601008 CONTROL CABLE CESSNA337 337A 2075704CE CONT O360 IO360C 17025SO MCAULY2AF34CD2AF34C59 GL TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FLAP CABLES REMOVED FOR INSPECTION DUE TO SERVICE DIFFICULTY ALERT AL-2003-05. LT AND RT OUTBOARD FLAP CABLES FOUND TO BE FREYED AT THE INBOARD BELLCRANK, APPROXIMATELY 1 INCH FROM THE SWAGGED TERMINAL. BOTH CABLES ARE ORIGINAL CESSNA FLAP CABLES AND WERE REPLACED WITH NEW CESSNA FLAP CABLES. ALSO, THE RT, INBOARD FLAP CABLE WAS FREYED AT THE INBOARD BELLCRANK, APPROXIMATELY 1 INCH FROM THE SWAGGED TERMINAL. 1H72 3O3 O A6CE E1CE 5 CP5EA 20040325000392004032500039EA 2004 3 25 CA040226003 120040224G2421721428 IDG CNDAIRCL600 CL600* EA LYC ALF502ALF502* 41580EA LT ENGINE LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) OIL NOTED LEAKING FROM LT ENGINE DRAIN MAST. INTEGRATED DRIVE GENERATOR REMOVED AND ACCESSORY DRIVE GARLOCK SEAL AND IDG SHAFT O-RING REPLACED. LEAK RETURNED AT DRAIN MAST TWO DAYS LATER. IDG WAS REMOVED AND INSPECTED. THE LEAK WAS DETERMINED TO ORIGINATE FROM THE INTEGRATED DRIVE GENERATOR CARBON SEAL. THIS IS AN ABNORMAL OCCURRENCE. IDG REPLACED WITH SERVICEABLE UNIT. 2L72 4F4 FRTA21EA E6NE 20040325000432004032500043EA 2004 3 25 CA040108003 120040107G2497BMS1360T01C03G0 WIRE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE ELECTRICAL INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE RE-INSTALLING CIRCUIT BREAKER PANEL THAT WAS ROBBED TO SERVICE AN OTHER AIRCRAFT THE MECHANIC NOTICE THREE POWER CABLES WERE SHAVING ALONG THE STRUCTURE OF THE PANEL. (STRAINS WERE SHOWING) THOSE THREE WIRES WERE REPLACED, FOLLOWING THIS FINDING, A CAMPAIN WILL BE LAUNCHED DUE TO FIRE POTENTIAL. 2L72 4F4 FRTA21EA E15NE 20040325000462004032500046CE 2004 3 25 CA040108007 120040107G2820 VALVE CESSNA560 560XL 2076702CE PWA 545 PW545A NE FUEL CROSSFEED INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING REFUELING, FBO LINE CREW FAILED TO CARRY OUT SINGLE POINT REFUELING PRE-CHECK. DURING FUELLING, ONLY LT TANK WAS FILLED (RT REFUELING VALVE APPARENTLY FAILED IN THE CLOSED POSITION). BY THE TIME THE FLIGHT CREW NOTICED THE DIFFICULTY A SIGNIFICANT FUEL IMBALANCE HAD BEEN CREATED, REQUIRING CROSSFEED FROM LT TO RT TANK. 2L72 4F4 FRTA22CE E00059EN 20040325000502004032500050NM 2004 3 25 CA040109004 120040109G2612 FIRE DETECTOR BOEING727 72722C 138400FNM PWA JT8 JT8D7B 52053NE ENGINE BAY MALFUNCTIONED W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) ON APPROACH, THE ENGINE FIRE WARNING BELL SOUNDED CONTINUOUSLY, THERE WERE NO ENGINE WARNING LIGHTS ON. ON THE GROUND MAINTENANCE INSPECTED ALL ENGINES NO FAULTS WERE FOUND. MAINTENANCE WAS UNABLE TO DUPLICATE PROBLEM AGAIN ON THE GROUND. THE FIRE DETECTION DETECTOR UNIT P/N 65-24920-3 WAS REPLACED . REMOVED AND INSPECTED AND CLEANED PIN/SOCKETS AN ALL THREE ENGINE FIRE DETECTION POWER OPERATING UNITS P/N 1011B-1. THE SYSTEM WAS TESTED WITH NO FAULTS. THE AIRCRAFT WAS RETURNED TO SERVICE AND OPERATED WITHOUT ANY FURTHER PROBLEMS. 2L73 4F4 F A3WE E2EA 20040325000542004032500054CE 2004 3 25 CA040203009 120040116G32205042013497A FORK CESSNA CESSNA340 340A 2076405CE CONT O520 TSIO520N 17040SO MCAULY3AF32C3AF32C93 GL NLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK FOUND IN FORK CASTING ON LT SIDE OF TUBE BORE. DISASSEMBLY REVEALED FORK CRACKED COMPLETELY THROUGH LT SIDE OF BORE. 1L72 3O3 O 3A25 E8CE 5 CP22EA 20040325000572004032500057GL 2004 3 25 CA040203013 120040123G7820973670 MUFFLER DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912S3 EU HOFMANHOV352HOV352F NE ENGINE EXHAUST BROKEN W A UNSCHED LANDING O OTHER CLCLIMB 1 CA (CAN) TAILPIPE NEARLY SNAPPED OFF FROM MUFFLER, INTERNAL BAFFLES LOOSE AND OBSTRUCTING EXHAUST OUTLET PART, CAUSING THE BACK PRESSURE TO RISE AND FAILURE OF TAILPIPE HAS OCCURRED. ENGINE POWER WAS ROBBED AND FORCED THE BUILD-UP OF BACK PRESSURE TO EXIT THE HOLE IT HAS CREATED. CORRECTION ACTION IS TO SEND MUFFLER TO AN AMO WHOM MAY REPAIR MUFFLER AND COMPLETE TAP TESTS TO MUFFLER TO VERIFY THE STATUS OF INTERNAL BAFFLES, AT EVERY INSPECTION. 1L71 3O3 ONTTA4CH E00051EN5 CTP5BO 20040325000582004032500058SW 2004 3 25 CA040203014 120040128G6320206040030101 BEARING RACE BELL BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL M/R GEARBOX SPALLED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA BKW1417 (CAN) BEARING SPALLED AND CAUSED A CAUTION LIGHT TO COME ON. 1G71 3U3 U H2SW E4CE 20040325000622004032500062EU 2004 3 25 CA040109006 120040107G2913716988 PUMP BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE HYDRAULIC SYS LEAKING W EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA 2368223682 LF05559AC (CAN) IN FLIGHT SHUT DOWN OF NR 2 ENGINE DUE TO LOSS OF OIL PRESSURE AND QUANTITY. MAINTENANCE FOUND EVIDENCE OF HYD FLUID MIGRATION INTERNALLY FROM HYDRAULIC PUMP TO THE PUMP SHAFT. SUSPECT THAT HYD FLUID CAUSED DETERIORATION OF THE PUMP SHAFT SEAL (O-RING) TO THE POINT THAT IT CAUSED THE ENGINE OIL TO BE LOST. PUMP REPLACED. NR 2 ENGINE ALSO BEING REPLACED. 2H74 4F4 F A49EU E6NE 20040315001302004031500130WP 2004 3 15 CA040220004 120040216G2410902241 WHEEL PRESTOLITE ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA ALTERNATOR BROKEN W K NONE O OTHER ININSP/MAINT 1 CA F219612E (CAN) BROKEN ALTERNATOR FAN WHEEL. REPLACED WHEEL. 1G71 3O3 O H11NM E295 20040315001342004031500134CE 2004 3 15 CA040220006 120040213G282005001183 LINE CESSNA172 172K 2072430CE LYC O320 O320E2D 41508EA MCAULY1C172 1C172MTM GL FUEL SYSTEM CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUEL LINE WAS FOUND CHAFED DURING 200 HR INSPECTION. 1H71 3O3 ONT3A12 E274 5 NP910 20040315001352004031500135SO 2004 3 15 CA040130008 120040127G322067054003 TRUNNION PIPER PA28 PA28R200 7102811SO LYC O360 IO360C1C 41514EA HARTZLHCC2Y HCC2YK1 GL NLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK EMANATING FROM TOP OF WEB JUST RT OF CENTER STRUT HOUSING. NO REPORT OF HARD LANDING OR ABUSE. 1L71 3O3 O 2A13 1E10 5 CP920 20040315001402004031500140 2004 3 15 CA040104002 420040101G8300 FLANGE BOEING727 727231 1384079NM PWA JT8 JT8D15A 52051NE ACCESSORY GEARBOCRACKED W K NONE O OTHER ININSP/MAINT 1 CA 6674486K (CAN) SCHEDULED MAINTENANCE WAS CARRIED OUT TO REPLACE THE FCU/FUEL PUMP QUAD RING. THE RUN OUT TORQUE INSPECTION WAS CARRIED OUT AND THE CLEARANCE FAILED. DISASSEMBLY OF THE AREA DETERMINED THAT THE QUAD RING NUT ATTACHMENT FLANGE WAS CRACKED. THE UNSERVICEABLE GEARBOX WAS REMOVED AND A SERVICEABLE UNIT WAS INSTALLED. NO FURTHER PROBLEM WAS FOUND. 2L73 4F4 F A3WE E2EA 20040315001482004031500148CE 2004 3 15 CA040220007 120040218G213347061 VALVE CESSNA441 441 2076020CE GARRTTTPE331TPE3318 01514WP HARTZLHCB3T HCB3TN5 GL ENERGENCY PRESS FAILED W BG EMER. DESCENT O2 MASK DEPLOYED DJ INFLIGHT SEPARATION WARNING INDICATION CLCLIMB 1 CA (CAN) DURING THE CLIMB THE AIRCRAFT EMERGENCY PRESSURIZATION VALVE OPENED WITH OUT BEING SELECTED. THE CREW DEPRESSURIZED THE AIRCRAFT AND RETURNED TO BASE. THE EMERGENCY PRESSURIZATION VALVE WAS REPLACED AND THE AIRCRAFT SYSTEMS FUNCTION CHECKED SERVICABLE 1L72 3T4 TRTA28CE E4WE 6 CP15EA 20040315001512004031500151CE 2004 3 15 CA040220010 120040202G561010138402523 WINDSCREEN BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AIR CREW REPORTED THAT THE PILOTS WINDSCREEN WAS DISCOLOURED AT THE OB EDGES AND HAD A MILKY APPEARANCE. THE WINDSCREEN HAD PREVIOUSLY BEEN REPAIRED BY THE MFG. THE WINDSCREEN WAS REPLACED WITH A NEW UNIT AND THE DAMAGED UNIT WAS RETURNED TO THE MFG FOR EVALUATION. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040315001532004031500153NM 2004 3 15 CA040223002 120040217G561056100165 WINDOW BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE COCKPIT CRACKED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) UPON ARRIVAL AT GATE THE CREW NOTICED F/O NR 4 EYEBROW WINDOW CRACKED. SUSPECT INTERNAL O/HEAT WINDSHIELD SYSTEM CHECKED SERVICEABLE NR 4 EYEBROW WINDOW REPLACED AIRCRAFT RETURNED TO SERVICE 2L72 4F4 F A16WE E2EA 20040315001562004031500156EU 2004 3 15 CA040105008 120040103G3260A23802105 SQUAT SWITCH AMD FALC20FALCON20F5 2730105EU GE CF700 CF7002D2 30010NE NLG FROZEN W O OTHER N FALSE WARNING LDLANDING 1 CA (CAN) ON LANDING THE PIC COULD NOT ACTIVATE THE NORMAL BRAKES AND THE NOSE WHEEL STEERING. PIC USED NR 2 BRAKE SYSTEM AND DIFFERENTIAL POWER TO CONTROL THE AC. SQUAT SWITCH WAS REMOVED, CLEANED AND RE-INSTALLED. NORMAL BRAKES AND NOSE WHEEL STEERING FUNCTION TESTED SERVICEABLE. AC RETURNED TO SERVICE. OPERATOR PLANS TO IMPLEMENT MONTHLY INSPECTION AND CLEANING OF ALL LANDING GEAR SWITCHES OF MOISTURE. 2L72 4F4 FRTA7EU E7EA 20040315001572004031500157NE 2004 3 15 CA040202003 220040102G7320 BELLCRANK DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE FUEL LEVER LACK OF LUBE W K NONE WE INADEQUATE Q C VIBRATION/BUFFET ININSP/MAINT 1 CA (CAN) COULD NOT SHUT DOWN LT ENGINE WITH FUEL LEVER. HAD TO PULL FIRE HANDLE. ALSO RT ENGINE VERY DIFFICULT TO SHUT OFF. CABLE MECHANISM FOUND STIFF DUE TO VERY COLD WEATHER. FUSELAGE TO PYLON BELLCRANK LUBRICATED AND BOTH SYSTEMS SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040315001612004031500161NM 2004 3 15 CA040202010 120040202G7830 THRUST REVERSER BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE ENGINE INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER T/O CREW RECEIVED A FLAP WARNING AND T/O WARNING HORN. SIMILAR INCIDENT. THE FLIGHT RETURNED AND UPON LANDING, THE RT ENGINE QUIT. A/C REMOVED FROM SERVICE FOR INVESTIGATION. FLIGHT DATA RECORDER REMOVED FOR READOUT. CAPT CONTACTED REGARDING ENGINE QUIT STATEMENT, THE ENGINE DID NOT QUIT, IT ROLLED BACK BELOW 60 KTS AFTER THRUST REVERSER STOWED NIL EGT, INCREASE NOTICED BY CREW. INCIDENT UNDER INVESTIGATION. 2L72 4F4 FRTA1NM E3NE 20040315001622004031500162CE 2004 3 15 CA040202011 120040109G526010151417617 HANDLE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE AIRSTAIR DOOR FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 17475 (CAN) DURING TAKEOFF ROLL THE AIRSTAIR DOOR EXTERIOR HANDLE SEPARATED FROM THE DOOR. FURTHER INSPECTION FOUND IMPACT DAMAGE TO LT PROPELLER AND LT IB FLAP. APPROXIMATELY ONE INCH MISSING FROM TIP OF ONE PROPELLER BLADE AND DENT IN LOWER SKIN OF IB FLAP. HANDLE RECOVERED AND INSPECTED FOR CONDITION. RETAINER RING P/N MS16624-1075 MISSING ALLOWING HANDLE TO SEPARATE FROM DOOR. LSO FOUND PIN P/N MS9048-072 SHEARED. THIS PIN HOLDS SHAFT IN HANDLE. HANDLE ASSEMBLY REPLACED WITH NEW. PROPELLER ASSEMBLY REPLACED. SKIN REPAIR CARRIED OUT TO IB FLAP. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040315001642004031500164CE 2004 3 15 CA040224003 120040216G3240 RIVET CLEVELAND BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA MCAULY4HFR344HFR34C652 NE BRAKE PAD RIVETSSHEARED W K NONE O OTHER ININSP/MAINT 1 CA 1544 (CAN) BRAKE ASSEMBLY S/N 1544 WAS FOUND WITH THE BRAKE PAD RIVETS SHEARED ALLOWING THE PADS TO BECOME DISLODGED, THIS IS THE SECOND TIME WE HAVE HAD WEAR PADS BEING DISLODGED FROM THE PRESSURE PLATE ASSEMBLY. THIS BRAKE ASSEMBLY WAS IN SERVICE FOR ONE YEAR SINCE NEW. NO TIMES AVAILABLE. 1L72 4T4 T A24CE E4EA 6 C3PNE 20040315001652004031500165NE 2004 3 15 CA040106002 220040102G7200 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE NR 2 MAKING METAL W A UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA 872684 (CAN) CREW REPORTED APPROXIMATELY 30 MINUTES FROM DESTINATION, THAT NR 2 ENGINE OIL PRESSURE HAD DROPPED BELOW MINIMUM. CREW ELECTED TO PERFORM IN FLIGHT SHUT DOWN. CREW REQUESTED CFR AND LANDED WITHOUT INCIDENT. INSPECTION REVEALED NR 2 ENGINE 2 QTS LOW WITH NO SOURCE OF OIL LEAKS. AGB CHIP DETECTOR REVEALED SOME METAL DEBRIS. CHIP DETECTOR TROUBLESHOOTING KIT WAS INSTALLED AND SECOND INSPECTION OF THE CHIP DETECTOR REVEALED A SIGNIFICANT AMOUNT OF METAL. A BOROSCOPE INSPECTION REVEALED THAT THE AXIS P GEAR WAS MISSING TEETH AND THAT THE AXIS B-B GEAR WAS HEAVILY WORN. LAB ANALYSIS OF THE REMOVED DEBRIS CONFIRMED TO BE M50 MATERIAL. ENGINE WAS REPLACED. 2L72 4F4 FRTA21EA E15NE 20040315001702004031500170 2004 3 15 CA040225001 420040213G3497MS2536175 CIRCUIT BREAKER CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE EDU INOPERATIVE W O OTHER O OTHER TOTAKEOFF 1 CA (CAN) DURING TAKE OFF ROLL (LESS THAN 20 KTS), THE CAPT'S PFD, MFD, NR 2 EDU AND NR 1 RTU WENT BLANK THAN CAME BACK ON. REPLACED 75 AMP. DC ESS FEED, CIRCUIT BREAKER IN LT DCPC. 2L72 4F4 FRTA21EA EOOO63EN 20040315001712004031500171EU 2004 3 15 CA040202015 120040130G6320332A32323300 TIE ROD UROCOP SNIAS AS332 AS332L 8680809EU TMECA MAKILAMAKILA1A 60040EU M/R GEARBOX SHEARED W K NONE O OTHER ININSP/MAINT 1 CA M279 (CAN) ONE OF THE THREE BOLTS ATTACHING THE ENGINE TO THE MAIN GEARBOX WAS DISCOVERED SHEARED DURING A TURN AROUND CHECK. THE BOLT WAS SHEARED ABOUT MIDWAY IN THE THREADED PORTION OF THE BOLT. THE ENGINE WAS REMOVED AND AREA INSPECTED IAW WRITTEN PROCEDURES. NO REASON FOR BOLT DAMAGE WAS DETERMINED. 2G72 4U4 U H4EU E12NE 20040315001722004031500172EU 2004 3 15 CA040202016 120040202G3230D172890 CONTROL CABLE BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE7315R 01518WP MLG BINDING W K NONE P NO WARNING INDICATION ININSP/MAINT 1 CA (CAN) UPON FUNCTIONAL TEST OF LANDING GEAR RETRACTION, THE SECONDARY MECHANICAL NOSE GEAR INDICATOR WAS NOT INDICATING PROPER EXTENSION (PROTRUSION OF CABLE END). PROBLEM TRACED TO BINDING CABLE. EXAMINATION OF DEFECTIVE PART (REMOVAL OF CABLE FROM METAL JACKET BY CUTTING) REVEALED BULGE AT SWAGED END CAUSING CABLE TO BIND WITHIN ITS JACKET. THIS ASSY IS TO BE LUBRICATED (HAND PACKED) EVERY 48 MONTHS IAW MFG RECOMMENDATIONS. HOWEVER THE LIMITED TRAVEL OF THE CABLE WOULD PRE-EMPT ANY LUBRICANT FROM REACHING THE SWAGED WIRE PORTION ON THE E-CABLE. ONLY THE METAL ROD END WOULD RECEIVE THE LUBRICANT. 2L72 4F4 FRTA3EU E6WE 20040315001862004031500186EA 2004 3 15 CA040106011 120040104G2710 CONTROL CABLE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE AILERON CONTAMINATED W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA (CAN) WHILE TAXING DURING FLT CONTROL CHECK FOUND AILERONS NOT RETURNING TO NEUTRAL. AFTER INVESTIGATION FOUND WHEEL WELL CONTAMINATED WITH DIRT AND MOISTURE. AREA CLEANED AND LUBRICATED. 2L72 4F4 FRTA21EA E15NE 20040325000262004032500026EA 2004 3 25 CA040224002 220040216G7261 OIL SYSTEM PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL RT ENGINE CONTAMINATED W O OTHER O OTHER LDLANDING 1 CA PCE51909 (CAN) PILOT REDUCED ENG POWER FOR LANDING AFTER FIRST FLIGHT OF DAY, RT ENGINE PRESSURE DECREASE WAS OBSERVED. TECH DISCOVERED LARGE QUANTITY OF CARBON IN ENGINE OIL FILTER. ENGINE WAS REMOVED AND SENT TO MFG FOR INVESTIGATION. ENGINE WAS DISSEMBLED AT THE (C FLANGE) FOR AN ITT PROBLEM. AFTER REASSEMBLY, ALL GROUND TESTS WERE PERFORMED AND AC WAS RETURNED TO SERVICE AND ENGINE OIL WAS ADDED. AN INTERNAL INVESTIGATION DETERMINED THAT CARBON DISCOVERED IN FILTER WAS MADE OF LITTLE BLACK STONES. FUNNEL THAT WAS USED TO ADD ENGINE OIL WAS LOCATED, INSPECTED AND CLEANED AND SAME LITTLE BLACK STONES WERE DISCOVERED IN THE FUNNEL. WE WERE NOT ABLE TO DETERMINE THE ORIGIN OF THE LITTLE BLACK STONES. 1L72 3T4 T A8EA E4EA 6 CP15EA 20040325000272004032500027SW 2004 3 25 CA040203003 120040202G27102771026001 CONTROL CHAIN SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCE4N HCE4N3 NE AILERON WORN W O OTHER F FLT CONT AFFECTED DEDESCENT 1 CA (CAN) DURING DECENT THE FLIGHT CREW NOTICED THE AILERONS BINDING AND VERY DIFFICULT TO MOVE. UPON SLOWING DOWN THE AIRCRAFT THE AILERON CONTROL RETURNED TO NORMAL. INVESTIGATION BY MAINTENANCE REVEALED THAT THE 27-71026-001 CONTROL CHAIN WAS SEIZED AND ALMOST WORN THROUGH ON A COUPLE OF CHAIN LINK SEGMENTS. IT APPEARS AS THOUGH DURING HIGH SPEED FLIGHT THE AIR LOAD ON THE AILERONS CAUSED HIGHER TENSION LOADS ON THE CONTROL CABLES PUTTING MORE FORCE ON THE CHAIN WHICH THEN BECAME VERY DIFFICULT TO MOVE. THE CHAINS (27-71026-001) AND SPROCKETS (26-71010-3) ON BOTH CONTROL COLUMN WHEELS WERE REPLACED AND THE AIRCRAFT RELEASED FOR FLIGHT. 2L72 4T4 TRTA8SW E4WE 5 CP10NE 20040325000292004032500029CE 2004 3 25 CA040203006 120040108G561010138402518 WINDSHIELD BEECH 200 B200C 1152924CE PWA PT6 PT6A42 52043NE HARTZLHCD4N3HCD4N3A GL COCKPIT BROKEN W B EMER. DESCENT H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) IN CRUISE RT WINDSHIELD HEAT ON, WINDOW SHATTERED, DESCENDED TO 12,000 FT, REDUCED AIR SPEED AND CABIN PRESSURE AND RETURNED TO BASE. 1L72 4T4 T A24CE E4EA 5 CSTC 20040325000352004032500035GL 2004 3 25 CA040107008 120040107G7921654585 OIL COOLER CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO HARTZLHCJ3Y PHCJ3YF1 GL ENGINE CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) OIL COOLER FOUND CRACKED ON OB FORWARD LOWER CORNER FLANGE WHERE THE BAFFLE IS ATTACHED. CRACK IS ABOUT 1 INCH LONG. THIS IS THE THIRD COOLER FOUND CRACKED ON THE TYPE OF INSTALLATION. 1L71 3O3 ONTA00009CHE3SO 5 CP36EA 20040325000372004032500037CE 2004 3 25 CA040225014 120040224G275014601007 CONTROL CABLE CESSNA337 337A 2075704CE CONT O360 IO360C 17025SO MCAULY2AF34CD2AF34C59 GL TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FLAP CABLES REMOVED FOR INSPECTION, REFERENCE SD ALERT AL-2003-05 IB FLAP CABLE, RT SIDE, PART NR 1460100-7 FRAYED APPROX 50 PERCENT AT IB BELLCRANK. 1 INCH FROM SWAGGED TERMINAL. ALSO BOTH OB CABLES PN 1460100-8 FRAYED AT IB BELLCRANK, APPROX. 1 INCH FROM SWAGGED TERMINAL. ALL CABLES ARE ORIGINAL FLAP CABLES AND HAVE BEEN REPLACED WITH NEW FLAP CABLES SUPPLIED BY MFG. 1H72 3O3 O A6CE E1CE 5 CP5EA 20040325000382004032500038EU 2004 3 25 CA040226002 120040217G641010531980 BLADE UROCOP BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20 03013GL TAIL ROTOR PEELING W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) TAIL ROTOR BLADES RECEIVED FROM MFG WITH THE PAINT REFINISHED AFTER REPAIR OR INSPECTION ARE PEELING OR SHREDDING TO THE BLADE BODY SURFACE BELOW. THIS IS OCCURRING USUALLY WITHIN THE FIRST 100 HOURS OF OPERATION. THE NEW REFINISHED PAINT SURFACE IS THICK ENOUGH TO PROTRUDE CONSIDERABLY ABOVE THE LEADING EDGE ABRASION STRIP CAUSING THE PAINT TO PEEL BACK ON THE SURFACE OF THE BLADE, CAUSING IMBALANCE, AND BLADE SURFACE TO BE SUSCEPTIBLE TO MOISTURE. THE PAINT REFINISHING PROCESS APPEARS TO BE TOO THICK WITH NO TRANSITION POINT TO THE LEADING EDGE ABRASION STRIP. THIS IS AN ON GOING PROBLEM INVOLVING NUMEROUS TAIL ROTOR BLADE SETS FOR THE PAST 18 MONTHS. 1G72 3U3 U H3EU E4CE 20040325000402004032500040EA 2004 3 25 CA040226004 220040224G7322G20102 FLOAT VALVE CNDAIRCL600 CL600* EA LYC ALF502ALF502* 41580EA CARBURETOR CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING GROUND RUN MAINTENANCE NOTED A RUMBLE FROM THE RT ENGINE AT HI IDLE AND BELOW. THE ECOLOGY TANK FLOAT VALVE WAS REMOVED AND THE FLOAT WAS FOUND TO BE CORRODED AND DETERIORATED PREVENTING PROPER VALVE OPERATION. THE VALVE WAS HELD OPEN ALLOWING AIR TO BE DRAWN INTO THE INLET SIDE OF THE ENGINE DRIVEN FUEL PUMP CAUSING THE PUMP TO CAVITATE. ABOVE HIGH IDLE THE EJECTOR VALVE CLOSES THE SUCTION LINE PREVENTING FURTHER CAVITATION AND STOPPING THE RUMBLE. A NEW FLOAT VALVE WAS INSTALLED AND A SUBSEQUENT GROUND RUN CONFIRMED THE REPAIR. 2L72 4F4 FRTA21EA E6NE 20040325000422004032500042EA 2004 3 25 CA040203007 120040122G24352007583 GROUND WIRE DHAV DHC3 DHC3 2800202EA PWA PT6 PT6A34 52043EA HARTZLHCB3T HCB3TN3 GL STARTER GEN FAILED W F ACTIVATE FIRE EXT. BA SMOKE/FUMES/ODORS/SPARKS FLAME/FIRE TXTAXI/GRND HDL 1 CA (CAN) ON STARTING THE ENGINE THERE WAS ARCING AND SPARKS COMING FROM THE STARTER GROUND ATTACHMENT LOCATED UNDERNEATH THE COCKPIT. THE SPARKS CAME FROM THE GROUNDING ATTACHMENT BOLT ANCHOR NUT RIVET. RECOMMEND A BETTER GROUNDING LOCATION AND ATTACHMENT. 1H71 3R4 T A815 E4EA 6 CP15EA 20040325000492004032500049EA 2004 3 25 CA040109003 120040108G5270600314703 ROLLER CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE STRIKER GUIDE MISALIGNED W K NONE N FALSE WARNING ININSP/MAINT 1 CA (CAN) AFTER TAKE OFF, DOOR LATCH CAUTION. 30 SEC LATER, PASSENGER DOOR. PRESSURE OK AND DOOR INDICATION PIN INSIDE WERE IN THE GREEN. REPLACED FORWARD STRIKER GUIDE ROLLER IAW FMR. SEAL LUB AND VENT HOLE ALIGN. ALL LATCH PINS & HANDLE LUB. 2L72 4F4 FRTA21EA E15NE 20040325000552004032500055CE 2004 3 25 CA040203010 120040126G56109031002P WINDSHIELD BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB4T HCB4TN3 GL COCKPIT CRACKED W B EMER. DESCENT O OTHER CRCRUISE 1 CA (CAN) DURING CRUISE, PILOT HEARD SMALL CRACK SOUND THOUGHT HE DROPPED SOMETHING, WHILE LOOKING AROUND, NOTICED RT WINDSHIELD CRACK DESCENDED AND CARRIED ON. LANDED WITHOUT INCIDENT. 1L72 3T4 T A14CE E4EA 6 CP40EA 20040325000562004032500056NE 2004 3 25 CA040203011 220040127G732291620 SHAFT BELL 204 204B 1181404SW LYC T53 T5313B 41549NE FUEL CONTROL WORN W O OTHER P NO WARNING INDICATION NRNOT REPORTED 1 CA 2ADS1203 (CAN) UPON SUSPECTING A PROBLEM WITH FUEL CONTROL UNIT. REMOVED FCU FROM THE ENGINE TO INSPECT THE SPLINES IAW MFG SBT5313-107. FOUND THE INTERNAL SPLINES KNIFE EDGED AND VERY CLOSE TO TOTAL FAILURE OF THE FCU. THIS WOULD HAVE LEAD TO THE FAILURE AND SHUTDOWN OF THE ENGINE. THESE PARTS HAD 434 HOURS SINCE THEY WERE REPLACED WITH SERVICEABLE UNITS. SHAFTS P/N 9162076081. 1G71 4U4 U H1SW E17EA 20040325000692004032500069NM 2004 3 25 CA040112001 120040109G561080260008 WINDSHIELD BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) DURING A FLIGHT THE RT COCKPIT WINDSHIELD CRACKED, ZERO VISIBILITY AND AN EMERGENCY LANDING WAS CARRIED OUT. MAINTENANCE TECH'S CHANGED WINDOW AND A/C RETURNED TO SERVICE. A/C JUST CAME OUT OF 'C' CHECK, IS MODSUM 4Q5300002 COMPLETED, WHICH REMOVES BOTH WINDSHIELDS FOR RE-SEALING. BELIEVE THAT THE WINDOW WAS DAMAGED DURING THE REMOVAL PROCESS. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040325000712004032500071NM 2004 3 25 CA040112003 120040109G3242 BRAKE PADS BOEING727 727260 NM PWA JT8 JT8D17 52049NE MLG DAMAGED W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI, CREW REPORTED THAT THERE WAS SOME DRAGGING FELT WHEN THE BRAKES WERE APPLIED. THE AIRCRAFT RETURNED TO THE BLOCKS. A DETAILED INSPECTION WAS CARRIED OUT AND NR 4 BRAKE WAS FOUND UNSERVICEABLE. THE BRAKE PADS WERE DAMAGED AND BROKEN. A SERVICEABLE BRAKE WAS INSTALLED IAW MM 32-41-31 AND CHECKED SERVICEABLE. THERE WAS NO PROBLEM DURING SUBSEQUENT FLIGHT. 2L73 4F4 FRTA3WE E2EA 20040325000862004032500086CE 2004 3 25 CA040204005 120040121G2710051010516 CONTROL CABLE CESSNA180 180C 2072608CE CONT O470 O470K 17026SO MCAULY2A34C 2A34C203 GL AILERON FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AILERON DIRECT CABLE LT AND RT FRAYED EACH IN 3 DIFFERENT PLACES AT PULLEYS, PULLEYS WERE NOT SEIZED, ROTATES FREELY, ALSO FRAYED AILERON CARRY THROUGH CABLE P/N 0510105-113 AT PULLEY AREA. 1H71 3O3 O 5A6 E273 5 CP3EA 20040325000882004032500088EU 2004 3 25 CA040204009 120040128G52105521012219 PIN PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL PAX DOOR HANDLE MISSING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PAX/CREW DOOR HANDLE LOCKING MECHANISM HARD TO OPERATE EXCEPT UPON ARRIVAL AT MAIN BASE. INSPECTING DOOR, FOUND PIN LOCK AND ITS SPRING FROM SAFETY LOCKING MECH TO BE MISSING. LOCKING MECH STOPS ACCIDENTAL OPERATION OF DOOR HANDLE INSIDE AC. RELEASE LEVER IS INSTALLED ON INSIDE OF DOOR BELOW INNER HANDLE. CABLE CONNECTS IT TO A LOCKING PIN WHICH ENGAGES IN OUTER HANDLE IF PIN LOCK BREAKS OR IS FORCED OUT OF CRANK, COMPRESSION SPRING EJECTS ITSELF AND PIN LOCK AWAY FROM AC AND THE DOOR CAN BE OPENED JUST BY ACTIVATING HANDLE. SUSPECT FORMATION OF ICE BETWEEN THE LOCKING PIN AND THE DOOR STRUCTURE TO RESTRAIN MOVEMENT OF PIN AND CAUSE A FAILURE OF LOCKING MECHANISM. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040325000902004032500090NE 2004 3 25 CA040112004 220040112G8500 ENGINE DOUG DC3 DC3C 3021457WP PWA R1830 R183092 52020NE HAMSTD23E 23E50 NE RIGHT FAILED W E ENGINE SHUTDOWN J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB THE PILOT NOTICED THE RT ENGINE OIL TEMPERATURE WAS INCREASING SIGNIFICANTLY. THE ENGINE WAS SHUT DOWN AND FLIGHT CARRIED OUT WITHOUT INCIDENT. 2L72 4R4 R A669 5E4 6 CP603 20040325000912004032500091SO 2004 3 25 CA040112005 120040111G32304204200 ARM PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL MLG BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER TAKE-OFF, CREW SELECTED LANDING GEAR UP. RT MAIN LANDING GEAR STILL INDICATED DOWN AND LOCKED AFTER RETRACTION. CREWS SELECTED GEAR DOWN AND ALL GEAR INDICATED DOWN AND LOCKED. AIRCRAFT RETURNED TO BASE WITH NO FURTHER FAULTS NOTED BY CREW. VISUAL INSPECTION OF LANDING GEAR SYSTEM CARRIED OUT. FOUND RT MAIN LANDING GEAR RETRACTION ARM P/N 42042-00 BROKEN. THIS PART ORIGINAL CRACK LOCATION NOT POSSIBLE TO BE INSPECTED OR FOUND WITH OUT COMPLETE DISMANTLE OF RETRACTION SYSTEM. RETRACTION ACTUATOR ROD END P/N 762-554 ALSO DAMAGED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040325000932004032500093EU 2004 3 25 CA040113001 120040113G3234210TS07Y01 SELECTOR AIRBUSA340 A340313 EU CFMINTCFM56 CFM565C4 13802NE MLG MALFUNCTIONED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SELECTED GEAR DOWN AND NOTHING HAPPENED FOR AT LEAST A MINUTE, THEN WIGGLED HANDLE THEN THE GEAR CAME DOWN. NOTE: AC SENT TO HANGAR FOR TROUBLE/SHOOTING. 2L74 4F4 FRTA197 E37NE 20040325000962004032500096NM 2004 3 25 CA040113004 120040113G5610141T480150 WINDSHIELD BOEING767 767333 1385301NM PWA 4060 PW4060 52119NE COCKPIT FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA 36170 (CAN) WHILE IN FLT ENROUTE FROM YYZ TO TLV, R1 WINDSHIELD OUTER PANE SHATTERED. FLT CONTINUED WITHOUT FURTHER INCIDENT. MTCE POOLED A WINDOW AND CHANGED. 2L72 4F4 FRTA1NM E24NE 20040325000982004032500098SW 2004 3 25 CA040113006 120040107G6710AN17415 BOLT BELL BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA DAMPER ARM SHEARED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) HELISKI OPERATION. PILOT REPORTED BAD VIBRATION IN TURNS AND CONTROLLABILITY CONCERNS, ALSO IN TURNS. RETURNED TO BASE IMMEDIATELY. SHEARED BOLT FOUND WHERE MAIN ROTOR HYDRAULIC DAMPER CONTROL ARM ATTACHES TO STABILIZER BAR CONTROL TUBE ROD END. BOLT WAS CORRODED WITH EVIDENCE OF BEING LOOSE. ALSO BLACK ON NUT AND WASHER. NO OTHER DAMAGE FOUND. ATTACHMENT HARDWARE REPLACED WITH NEW AND AIRCRAFT RETURNED TO SERVICE. 1G71 4U4 U H4SW E22EA 20040325001022004032500102CE 2004 3 25 CA040204012 120040114G32601CH25 DOWNLOCK SWITCH BEECH 100 B100 1152919CE GARRTTTPE331TPE3316252B 01514WP HARTZLHCB4T HCB4TN5 GL NLG FROZEN W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) ON APPROACH THE PILOT SELECTED GEAR DOWN. THERE WAS NO NOSE GEAR INDICATION. AFTER CONFIRMING WITH THE TOWER THAT THE GEAR WAS DOWN, THE AIRCRAFT LANDED WITHOUT INCIDENT. THE DOWNLOCK SWITCH WAS FOUND DEFECTIVE AND SUBSEQUENTLY REPLACED. OAT WAS -25 TO -30 DEGREES CELSIUS. 1L72 4T4 T A14CE E2WE 6 CP40EA 20040325001062004032500106EA 2004 3 25 CA040205003 120040126G5610601R330333 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA 14843 (CAN) DURING CRUISE, FLIGHTDECK LT SIDE WINDOW CRACKED. FLIGHT WAS DIVERTED WHERE THE WINDOW WAS REPLACED. THE CRACKED WINDOW HAD BEEN FITTED SINCE THE A/C WAS NEW. THERE IS NO PRE OR POST SB FOR SIDE WINDOWS. 2L72 4F4 FRTA21EA E15NE 20040325001202004032500120NM 2004 3 25 CA040113007 120040111G575565982962 HINGE BOEING727 72725C 138400HNM PWA JT8 JT8D7B 52053NE SPOILER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 61773 (CAN) DURING SERVICE CHECK, FOUR CRACKS WERE FOUND ON THE NR 7 GROUND SPOILER SUPPORT HINGE. HINGE REPLACED WITH NEW PART. ALL HINGES INSPECTED FOR CRACKS, NO FAULTS FOUND. 2L73 4F4 F A3WE E2EA 20040325001252004032500125SW 2004 3 25 CA040206002 120040128G2810206288017 SIGHT GLASS BELL 206 206L 1181522SW ALLSN 25OC 250C20R GL RANGE EXTENDER CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) SIGHT GLASS ON FORWARD SIDE OF RANGE EXTENDER WAS FOUND TO BE THE CAUSE OF A SLOW FUEL LEAK. WHEN THE AIRCRAFT WAS FULL OF FUEL AND KEPT IN THE HANGAR OVER NIGHT A SMALL POOL OF FUEL WAS NOTICED ON THE FLOOR. A CRACK RUNNING ACROSS FROM TWO SCREWS WAS FOUND. A NEW SIGHT GLASS HAS BEEN ORDERED AND WILL BE INSTALLED WHEN RECEIVED. UPON FURTHER INSPECTION OF AIRCRAFT, ANOTHER WITH THE SAME RANGE EXTENDER WAS FOUND TO HAVE THE SAME CRACK IN THE SAME LOCATION. 1G71 3U3 U H2SW E4CE 20040325001272004032500127NM 2004 3 25 CA040113009 120040107G291082970009121 LINE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE HYDRAULIC SYS LEAKING W O OTHER KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 CA (CAN) ON APPROACH, CREW REPORTED NR 2 HYDRAULIC SYSTEM WENT LOW. NR 2 ISO VALVE LIGHT AND OB ROLL SPOILER CAUTION LIGHTS CAME ON, WHEN MAIN LANDING GEAR SELECTED DOWN. AFTER LANDING DOWN DOORS STAYED OPEN AND FLUID LEAKING FROM LT WHEEL WELL. MAINTENANCE FOUND HYDRAULIC LINE FOR NR 2 SYSTEM MLG UP PRESSURE TO BE LEAKING FROM PIN HOLES. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040325001372004032500137GL 2004 3 25 CA040114002 120040111G2752 SEAL DIAMON DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA FLAP ACTUATOR LOOSE W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) PILOT REPORTED FLAP STUCK IN LANDING POSITION, UPON INSPECTION IT WAS FOUND THAT THE SPLINED RUBBER SEAL PUSHED OUT OF POSITION ON FLAP ACTUATOR ROD ASSY. SPLINED RUBBER SEAL INTERFERED WITH FLAP POSITION MICRO SWITCHES. RE-INSTALLED SPLINED RUBBER SEAL WITH EPOXY AND ALLOWED TO CURE. FLAP SYSTEM FUNCTION TESTED, FLAP POSITION LIGHTS AND FLAPS SERVICEABLE. IT APPEARED THAT THE SPLINES WERE USED TO KEEP THE SEAL IN PLACED BUT AS THERE IS LITTLE LUBRICATION REQUIRED ON THE FLAP ACTUATOR SHAFT, FRICTION OF THE SHAFT ON THE SEAL, PULLS THE SEAL OUT OF POSITION AND DRAGS IT ALONG WITH IT INTO THE SWITCHES. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20040325001382004032500138CE 2004 3 25 CA040114004 120040107G77223031566 BUSS BAR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL ENGINE UNSERVICEABLE W O OTHER P NO WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) PILOTS WERE CARRYING OUT AN ENGINE START ON THE RT ENGINE AND NOTICED THAT THERE WAS NO ITT INDICATION SO THE ENGINE WAS SHUT DOWN. MAINTENANCE TROUBLESHOOTING DETERMINED THE ITT HARNESS WAS SERVICEABLE BUT THAT THE ENGINE INTERNAL BUSSBAR HAD FAILED. THE ENGINE WAS SPLIT AT THE C FLANGE AND THE BUSS BAR WAS FOUND SEPARATED FROM THE TOP OF THE JUNCTION BLOCK. THE BUSS BAR P/N 3031566 WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 4T4 T A24CE E4EA 6 CP15EA 20040325001392004032500139 2004 3 25 CA040114005 420040112G2297BACC47DJ1DJ2 PIN ROSEMOUNT BOEING757 757* NM RROYCERB211 RB211535E43754555NE RELAY MISMANUFACTURED W A UNSCHED LANDING W INADEQUATE Q C CLCLIMB 1 CA A44369 (CAN) UPON ROTATION, TAT PROBE EICAS MESSAGE FOLLOWED BY AUTO THROTTLE DISCONNECT, AND ASSOCIATED WARNINGS. AIR TURN BACK. TAT PROBE REPLACED. GROUND TEST GOOD. DEFECT RECURRED ON NEXT TAKEOFF.K143 AND K203 AIR/GND RELAYS REPLACED. TESTED GOOD IAW MM 30-33-00-501. NO FAULTS ON RETURN FLIGHT TO YVR. REVIEW OF THE RECORDS SHOWED 4 REPORTS SINCE 4TH DECEMBER 2003. DUE TO THE INTERMITTENT NATURE OF THIS DEFECT, AS A PRECAUTIONARY MEASURE WIRING CHECKS WERE PERFORMED ON RETURN TO YVR. A POOR CRIMP AT THE BASE OF RELAY K203 PIN B2 WAS FOUND. PIN REPLACED. 2L72 4F4 FRTA2NM E12EU 20040329000732004032900073CE 2004 3 29 CA040209001 120040205G2121903840311 BLOWER BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL AIR CONDITIONINGSEIZED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) JUST AFTER LEVELING OUT PILOT NOTICED SMOKE IN THE COCKPIT/CABIN AREA. AIRCRAFT WENT TO 10000 FT, DEPRESSURIZED AND ELECTRICAL POWER WAS REMOVED. POWER WAS RESTORED AND AIRCRAFT RETURNED TO BASE WITHOUT FURTHER INCIDENT. UPON INVESTIGATION IT WAS DETERMINED THAT THE VENTILATION BLOWER BEARING SEIZED AND CAUSED THE SMOKE. VENT BLOWER WAS REPLACED AND SYSTEM TESTED SERVICEABLE. 1L72 3T4 T A14CE E4EA 5 CSTC 20040329000962004032900096NM 2004 3 29 CA040209003 120040205G3260189915 TARGET BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE MLG MISINSTALLED W D RETURN TO BLOCK N FALSE WARNING TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI, THE RT MLG UNSAFE LIGHT ILLUMINATED AND GREEN SAFETY LIGHT WAS OUT. MAINTENANCE INSTALLED LANDING GEAR PINS AND THE AIRCRAFT TAXIED BACK TO THE RAMP. DURING INSPECTION OF THE PROXIMITY LANDING GEAR SWITCHES, IT WAS OBSERVED THE TARGETS WERE INSTALLED IMPROPERLY. THE TARGETS WERE RE-INSTALLED CORRECTLY IAW MM 32-41-91 AND 32-04-121. FUNCTION CHECKED SERVICEABLE IAW MM 32-61-91. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2L73 4F4 F A3WE E2EA 20040325000632004032500063NM 2004 3 25 CA040109007 120040109G5610NP1579029 WINDOW DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE COCKPIT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON PREFLIGHT INSPECTION , FLT ENGINEER DISCOVERED OUTER PLY OF PILOT SIDE WINDOW WITH MULTIPLE CRACKS EXTENDING AROUND THE CIRCUMFERENCE OF WINDOW ORIGINATING FROM LOWER FWD CORNER. NO OBVIOUS IMPACT DAMAGE FOUND ON INSPECTION. NO M.E.L. RELIEF. MANUFACTURER ADVISED TO CHANGE WINDOW BEFORE FURTHER FLIGHT. OVERNIGHT TEMP: -13C 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040325000682004032500068EU 2004 3 25 CA040110001 120040109G29979740926112 RELAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER TAKE OFF THE CREW SELECTED GEAR UP. THE HYDRAULIC CAWS LIGHT CAME ON AND THE GEAR WOULD NOT FULLY RETRACT. THE GEAR WAS EXTENDED FULLY WITH THE HAND PUMP AND AN UNEVENTFUL LANDING CARRIED OUT. UPON INSPECTION BY MAINTENANCE, THE HYDRAULIC RELAY K601 WAS FOUND TO BE AT FAULT. THE RELAY WAS REPLACED, GEAR SWINGS CARRIED OUT AND THE AIRCRAFT RETURNED TO SERVICE. THERE ARE SEVERAL OTHER INSTANCES INVOLVING FAILURE OF THESE RELAYS, WITH SIMILAR SNAG CIRCUMSTANCES. A SUGGESTION TO PLACE THESE COMPONENTS ON A HARD TIME INTERVAL IN LIEU OF, ON-CONDITION FOR OTHER OPERATORS WOULD BE BENEFICIAL. WE ARE CURRENTLY RESEARCHING THE TIME BETWEEN FAILURE, AS THESE ARE NOT NORMALLY TIME TRACKED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040325000892004032500089EU 2004 3 25 CA040204010 120040130G243523085024 BEARING LUCAS PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL STARTER GEN FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA Y0253 (CAN) GEN NR 1 FAILED IN FLIGHT. UPON ARRIVAL, MAINTENANCE FOUND THE REAR BEARING OF THE STATER GENERATOR FAILED CAUSING THE COOLING FAN TO RUB ON THE CASE.CREATING VIBRATION. STARTER GENERATOR REPLACED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040325000922004032500092GL 2004 3 25 CA040112006 120040107G2752 SEAL DIAMON DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA FLAP ACTUATOR LOOSE W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) PILOT REPORTED FLAP STUCK IN LANDING POSITION, OVERSPED FLAPS 100 KTS FOR 5 MIN,FLAP INDICATOR U/S. UPON INSPECTION IT WAS FOUND THAT SPLINED RUBBER SEAL PUSHED OUT OF POSITION ON FLAP ACTUATOR ROD ASSY. SPLINED RUBBER SEAL INTERFERED WITH FLAP POSITION SWITCHES. RE-INSTALLED SPLINED RUBBER SEAL WITH EPOXY AND ALLOWED TO CURE. FLAP SYSTEM FUNCTION TESTED, FLAP POSITION LIGHTS AND FLAPS SERVICEABLE. FLAPS INSPECTED FOR OVER SPEED DAMAGE NONE FOUND. AC RELEASED. IT APPEARED THAT THE SPLINES WERE USED TO KEEP THE SEAL IN PLACED BUT AS THERE IS LITTLE LUBRICATION REQUIRED ON THE FLAP ACTUATOR SHAFT, FRICTION OF THE SHAFT ON THE SEAL, PULLS THE SEAL OUT OF POSITION AND DRAGS IT ALONG INTO THE SWITCHES. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20040325000942004032500094NM 2004 3 25 CA040113002 120040113G2824MA20A10011 ACTUATOR BOEING767 767209 1385127NM PWA JT9 JT9D7R4D 52054NE CROSSFEED VALVE FAILED W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) ON PRE-DESCENT CHECK WHEN FUEL CROSSFEED WAS CHECKED ON AND OFF, EICAS MESSAGE FUEL CROSSFEED AND VALVE LIGHT ON CROSSFEED SWITCH REMAINED ILLUMINATED. ON GROUND RECYCLED CIRCUIT BREAKER NIL FIX. TAKEN OFF LINE FOR INVESTIGATION FLT CANCLED PART: ELECTRIC ACTUATOR REPLACED IAW AMM 28-22-12. 2L72 4F4 FRTA1NM E3NE 20040325000972004032500097EU 2004 3 25 CA040113005 120040113G3230D31AAB4431 SAFETY VALVE AIRBUSA340 A340313 EU CFMINTCFM56 CFM565C4 13802NE MLG INOPERATIVE W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) ON APPROACH, GEAR DID NOT EXTEND NORMALLY ON FIRST ATTEMPT, SECOND ATTEMPT HAD SAME RESULT. CREW ELECTED TO CARRY OUT GO AROUND. LANDING GEAR CONTROL LEVER REPLACED AND TESTED IAW MM 32-31-11-400, MLG ISOLATION SAFETY VALVE (85GA) REPLACED IAW MM 32-31-17. MLG. EXTENDED AND RETRACTED SEVERAL TIMES IAW MM 32-31-00-710-801, CHKD. SERV. REMOVE UNI 32-30-0482C1024AC 001 FISOS: NINSTALLUNI 32-30-0482 FTN 1341Q9 AC 001REMOVE UNI 32-30-0513 FTN 5Y25Z5 AC FI SOS: N INSTALL UNI 32-30-0513FTN 55656R AC. 2L74 4F4 FRTA197 E37NE 20040325001012004032500101NE 2004 3 25 CA040204011 220040111G7200 ENGINE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE LEFT FAILED W A UNSCHED LANDING C F.O.D. CRCRUISE 1 CA (CAN) DURING CRUISE AT 31,000 FT, ENGINE SURGE FELT ON LT ENGINE (EPR REDUCED TO 1.67) WITH AN IMMEDIATE ODOR. SAME SURGE/ODOR WAS FELT A SECOND TIME APPROXIMATELY 45 MINUTES LATER. AIRCRAFT DIVERTED TO POP. MAINTENANCE FOUND FORWARD LAVATORY LEAKING. LT ENGINE INSPECTED IAW MM 72-0-04 P.115 AND ENGINE RUN C/OUT TO 2-0 EPR AND NO FAULT FOUND. AIRCRAFT DISPATCHED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040325001042004032500104EA 2004 3 25 CA040205001 120040129G3310 LIGHT CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) SMOKE AND SPARKS WERE COMING FROM THE FIRST OFFICER FLOOD LIGHT. MAINTENANCE ACTION WAS TO REPLACED THE FLOOD LIGHT ASSEMBLY AND TO RETORQUE THE SIDE WINDOW. 2L72 4F4 FRTA21EA EOOO63EN 20040325001212004032500121CE 2004 3 25 CA040205005 120040202G8011PM2401H DRIVE ASSY LAMAR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL STARTER JAMMED W E ENGINE SHUTDOWN O OTHER TXTAXI/GRND HDL 1 CA 85017317 (CAN) STARTER DRIVE ONCE ENGAGED DID NOT RETRACT JAMMED OUTWARD. 1H71 3O3 ONT3A12 1E10 5 NP857 20040325001222004032500122EU 2004 3 25 CA040205006 120040203G7714 DISPLAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL EIS FAILED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) DURING CRUISE FLIGHT, THE UPPER PORTION OF THE ENGINE INDICATION SCREEN FAILED TQ, NG, & ITT. THE ALTERNATE SCREEN WAS SELECTED AND PERFORMED PROPERLY. THE EIS COMPUTER WAS REPLACED WITH A SERVICEABLE UNIT AND FUNCTION TREATED SERVICEABLE. IT WAS NOTED A NORMAL ENGINE START COULD NOT BE ACCOMPLISHED AS THERE WAS NO ENGINE NG INFORMATION AVAILABLE TO THE START COMPUTER TO SIGNAL IGNITION AND BOOST PUMPS. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040325001232004032500123NE 2004 3 25 CA040205007 220040122G7321 FUEL CONTROL CESSNA560 560XL 2076702CE PWA 545 PW545A NE LT ENGINE INOPERATIVE W D RETURN TO BLOCK XJ ENGINE FLAMEOUT WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) WHILE TAXIING, LT ENG POWER LEVER WAS ADVANCED TO FACILITATE TURN. THRUST LEVER WAS ADVANCED, LT ENG SUFFERED A ROLL BACK AND FLAME-OUT. AC WAS TAXIED CLEAR OF RUNWAY, FAULT ANALYSIS RELIGHT ATTEMPTED WITH NO SUCCESS. RELIGHT WAS SUCCESSFUL. AC WAS THEN SHUT DOWN AND SURRENDERED TO MAINT FOR ACTION. EVENT FOLLOWED ACTION AND INSTALLATION OF SB 30253. FUEL LINE, ATTENUATOR ASSY AND FCU WERE REMOVED AND SENT TO MFG FOR ANALYSIS. DURING REMOVAL, A BLACK SUBSTANCE WAS DETECTED. SUBSTANCE WAS SENT OFF FOR CHEMICAL ANALYSIS BY MFG. NR C 10420020 REGARDING SUBSTANCE. FUEL LINE, ATTENUATOR ASSY AND FCU WERE REPLACED, IAW SB 30253. AC WAS GROUND RUN AND TEST FLOWN SATISFACTORILY, RETURNED TO SERVICE. 2L72 4F4 FRTA22CE E00059EN 20040325001242004032500124NE 2004 3 25 CA040205008 220040122G7200 ENGINE CESSNA560 560XL 2076702CE PWA 545 PW545A NE LEFT FLAMED OUT W D RETURN TO BLOCK XJ ENGINE FLAMEOUT WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) WHILE TAXIING AND TURNING ONTO THE RUNWAY, THE LT ENGINE POWER LEVER WAS ADVANCED TO FACILITATE THE TURN. AS THE THRUST LEVER WAS ADVANCED, THE LT ENGINE SUFFERED A ROLL BACK AND FLAME-OUT. THE AIRCRAFT WAS TAXIED CLEAR OF THE RUNWAY AND A FAULT ANALYSIS RELIGHT ATTEMPTED WITH NO SUCCESS. THE AIRCRAFT WAS THEN TAXIED TO THE RAMP WHERE A FURTHER RELIGHT WAS ATTEMPTED. THE RELIGHT WAS SUCCESSFUL. THE AIRCRAFT WAS THEN SHUT DOWN AND SURRENDERED TO MAINTENANCE FOR ACTION. THE EVENT FOLLOWED ACTION AND INSTALLATION OF SERVICE BULLETIN 30253. 2L72 4F4 FRTA22CE E00059EN 20040325001262004032500126EU 2004 3 25 CA040113008 120040108G33102527 LAMP PIAGIOP180 P180 6960204EU PWA PT6 PT6A66 52043NE HARTZLHCE5N HCE5N3 GL MAP LIGHT INOPERATIVE W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) DURING CRUISE, COCKPIT ROOF MOUNTED MAP LIGHT FAILED, C/B ACTIVATED, CREW NOTICED A SLIGHT ODOR. DURING TROUBLESHOOTING THE ROOF PANEL WAS REMOVED AND IT WAS DISCOVERED THAT THE LAMP TERMINAL HAD BEEN IN CONTACT WITH AIRFRAME STRUCTURE CAUSING THE RUBBER PROTECTIVE BOOT ON THE TERMINALS TO WEAR THROUGH AND GROUND ELECTRICAL SUPPLY. IT WAS ESTABLISHED THAT DURING COMPLETION AT A THIRD PARTY COMPLETION CENTER SPACER RINGS UNDER THE LAMP COLLAR HAD BEEN OMITTED. FLEET REVIEW FOUND THAT SISTER AIRCRAFT WAS IN SAME CONDITION, BUT AN OTHER HAD SPACERS INSTALLED. SPACERS OBTAINED AND INSTALLED ON AFFECTED AIRCRAFT. 1H72 3O4 TRTA59EU E26NE 5 CPZONE 20040325001402004032500140SO 2004 3 25 CA040206003 120040204G2140 BLADE JANITROL B4050 PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL FAN CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) ONE OF FOUR BLADES SEPARATED FROM FAN AND MADE A SIGNIFICANT AMOUNT OF NOISE AND VIBRATION IN THE HEATER SUCH THAT THE PILOT SHUT THE HEATER DOWN IN FLT. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040325001412004032500141EU 2004 3 25 CA040206004 120040205G31109728132012 DISPLAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL CAWS FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) DURING CRUISE THE CREW NOTICED SOME OF THE CAWS LIGHTS OUT. THE TEST BUTTON WAS USED TO DETERMINE IF THE BULBS WERE AT FAULT. ONCE PRESSED THE CAWS PANEL AND MASTER CAUTION/WARNING ILLUMINATED FOLLOWED A SERIES OF FLICKERING LIGHTS AND A ODOR OF BURNED WIRES, THE PANEL THEN GOING BLACK. THE BREAKERS WERE PULLED, THE ODOR DISAPPEARED AND AIRCRAFT CONTINUED FLIGHT TO ITS MAIN MAINTENANCE BASE. NO PASSENGERS WERE ON BOARD THE AIRCRAFT. THE CAWS DISPLAY AND CAWS COMPUTER WERE BOTH REPLACED AND THE AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER FAULTS. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040325001422004032500142EU 2004 3 25 CA040206005 120040202G2197 WIRE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL HEATING SYSTEM BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ONE POWER WIRE FOR THE FOOT HEATER HEAT CONTROL HAD FALLEN ON TO THE BRAKE LINE THAT RUNS ALONG THE FIREWALL JUST AHEAD OF THE RUDDER PEDALS. AS A RESULT ARCING OCCURED AND BURNED A HOLE IN THE LINE. THE .2500 INCH ALUMINUM BRAKE LINE WAS REPLACED, SYSTEM BLED AND THE WIRE WAS REPLACED AND SECURED BETTER TO THE BUNDLE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040325001542004032500154NE 2004 3 25 CA040205004 220040131G7200 ENGINE CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE NR 2 FAILED W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER TAKE OFF, 2000 ASL, NR 2 LOUD BANG FOLLOWED BY ENGINE STOPPAGE, MAYDAY DECLARED, ENGINE SECURED AND QRH DRILLS ACTIONED. RADAR VECTORED SINGLE ENGINE APPROACH AND LANDING. FIRE SERVICE ESCORTED ON LANDING, PAX OFFLOADED ON STAND. THE ENGINE WAS REPLACED. 2L72 4F4 FRTA21EA EOOO63EN 20040329000512004032900051NE 2004 3 29 CA040208002 220040126G7320 FUEL CONTROL CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE RT ENGINE FAILED W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION LDLANDING 1 CA (CAN) JUST AFTER TOUCHDOWN THE RT FADEC CAUTION MESSAGE CAME ON FOLLOWED BY THE RT ENG FLAMEOUT CAUTION MESSAGE. MAINTENANCE STARTED AND OPERATED THE ENGINE THROUGH SEVERAL CYCLES WITHOUT DUPLICATION OF THE FLAMEOUT CONDITION. MAINTENANCE REPLACED THE RT FADEC AND FUEL MANAGEMENT UNIT, THEN OPERATED THE ENGINE THROUGH SEVERAL MORE CYCLES INCLUDING HIGH POWER AND REVERSE WITH NO FLAMEOUT OCCURANCE. 2L72 4F4 FRTA21EA EOOO63EN 20040329000522004032900052EA 2004 3 29 CA040208003 120040125G493038004883 APU CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE APU BAY LEAKING W K NONE KJ FLUID LOSS WARNING INDICATION ININSP/MAINT 1 CA (CAN) FOR THE OVERNIGHT, THE FLIGHT CREW WERE ASKED TO LEAVE THE APU RUNNING TO PERMIT AIRCRAFT GROOMING. APPROXIMATELY ONE HOUR AFTER ARRIVAL, THE APU FIRE DETECTION SYSTEM PERFORMED AN AUTO SHUTDOWN AND APU FIRE BOTTLE WAS DEPLETED. GROUND/AIRCRAFT PERSONNEL CONTACTED THE FIRE DEPARTMENT. THE APU WAS INSPECTED, AND EVIDENCE OF FUEL WAS OBSERVED, HOWEVER THE SOURCE OF THE APU FUEL LEAK COULD NOT BE ABSOLUTELY PIN-POINTED AND RESULTED IN THE APU'S REPLACEMENT. THE AIRCRAFT RETURNED TO SERVICE FOLLOWING THE APU REPLACEMENT. 2L72 4F4 FRTA21EA E15NE 20040329000592004032900059NM 2004 3 29 CA040115001 120040110G323054C546349 SOLENOID VALVE DHAV DHC8 DHC8103 1386005NM PWA PW121 PW121 52124NE HAMSTD14SF 14SF7 NE MLG FAILED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) DURING TAKEOFF AND THE GEAR UP SELECTION THE AIRCRAFT EXPERIENCED A COMPLETE LOSS OF ALL FLUID FROM THE NR2 HYDRAULIC SYSTEM. ALTERNATE LANDING GEAR EXTENSION PREFORMED AND AIRCRAFT RETURNED SAFELY TO BASE. FINDINGS, LT MLG SOLENOID SEQUENCE VALVE FAILED. SOLENOID SEPARATED FROM VALVE. TWO BOLTS OF FOUR, WHICH CONNECT SOLENOID HOUSING, HAD BROKEN. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329000602004032900060NM 2004 3 29 CA040115003 120040112G492038007021 APU BOEING737 73776N 13844CHNM CFMINTCFM567CFM567B22 13802NE APU BAY SMOKE W O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA (CAN) ON ARRIVAL TO THE GATE, GROUND POWER WAS PLUGGED IN, SMOKE IN THE FLIGHT DECK AND CABIN WHEN APU BLEED AIR AND PNEUMATICS SELECTED 'ON'. CAPTAIN THEN SELECTED APU ELECTRICAL 'ON' AND F/O CONTACTED GROUND CONTROL TO REQUEST CFR. SMOKE CLEARED AND MAINTENANCE WAS CALLED TO AIRCRAFT. SUSPECT DE-ICE FLUID IN THE APU INLET AS A RESULT OF DE-ICING OUT OF YOW. APU MEL'D AND GROUND CHECKED SERVICEABLE. ON NEXT RUN, APU MEL CLEARED FOLLOWING FLIGHT MONITORING AND MAINTENANCE PERFORMANCE RUNS. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2L72 4F4 FRTA16WE E00055EN 20040329000722004032900072 2004 3 29 CA040115005 420040101G2562 G SWITCH DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE ELT FAILED W K NONE L NO TEST ININSP/MAINT 1 CA 55130 (CAN) ELT HAS HAD A PREVIOUS HISTORY OF SELF ACTIVATIONS (1 PREVIOUS, ELT ACTIVATED WHILE THE AIRCRAFT WAS INACTIVE). ELT WAS RECERTIFIED AND ON INSTALLATION THE UNIT SELF ACTIVATED. REPAIR SHOP NOTED THAT THE G SWITCH ON THIS MODEL WAS VERY SUSCEPTIBLE TO MOISTURE RELATED FAILURES. DUE TO AGE THERE ARE NO PARTS AVAILABLE FOR REPAIR, THE UNIT WILL BE SCRAPPED. 1H71 3R3 R A806 5E1 5 CP206 20040329000952004032900095NM 2004 3 29 CA040209002 120040205G561057176249 WINDOW BOEING727 727260 NM PWA JT8 JT8D17 52049NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CLCLIMB 1 CA (CAN) DURING CLIMB, THE F/O OBSERVED THE R2 SLIDING WINDOW WAS CRACKED. THE DECISION WAS MADE TO RETURN TO BASE. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE R2 WINDOW ASSY WAS REPLACED IAW MM 56-12-11 AND CHECKED SERVICEABLE. THE R2 WINDOW HEAT CONTROLLER AND TEMP SWITCH WERE CHANGED AS A PRECAUTION. FUNCTIONAL CHECK WAS CARRIED OUT SERVICEABLE IAW MM 30-41-02. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2L73 4F4 FRTA3WE E2EA 20040329000992004032900099NM 2004 3 29 CA040209007 120040206G490023088002B STARTER GEN DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE APU BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) APU FAILED TO START, TECHNICIANS FOUND STARTER / GENERATOR BURNED, THE ATTACHED WIRES AND CONNECTORS WERE ALSO FOUND DAMAGED. OPERATOR ADVISED BY THEIR SPARES THAT THE STARTER GENERATOR, P/N 23088-002B SN Y0084 WAS REPAIRED BY THE VENDOR ONCE ALREADY. THE GENERATOR WAS REPLACED YESTERDAY AND FAILED AFTER 2 FLIGHTS. THE APU WAS STARTED WITH BATTERY POWER. DUTY CYCLE WAS OBSERVED. TIME SINCE REPAIR: 1.37 CYCLE SINCE REPAIR: 2. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329001022004032900102EU 2004 3 29 CA040116001 120040116G5270 WARNING SYSTEM AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE CARGO DOOR INOPERATIVE W O OTHER N FALSE WARNING CLCLIMB 1 CA (CAN) IN CLIMB OUT OF 17T ECAM MSG DOOR AFT CARGO. PRESSURISATION NORMAL. MSG DISAPPEARED IN CRUISE 10 MIN. LATER. (SEE COMMENTS FOR TROUBLESHOOTING. FOR TROUBLESHOOTING, CARRY OUT TSM FAULT ISOLATION TASK NR 32-31-00-810-831 AND 32-31-00-810-833. SENSOR 34WV GAP WITHIN TOLERANCE. SENSOR 32WV RESISTANCE ONLY 11 OHMS BETWEEN PINS A AND B. (SHOULD BE 13) SENSOR 32WV REPLACED IAW AMM 52-71-12. CHECKED SERVICEABLE. 2L72 4F4 FRTA28NM E29NE 20040329001032004032900103EA 2004 3 29 CA040116003 120040116G2760270007 PCU CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE SPOILERS INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) REPEAT OF L1411710 UPON RT ENG START WITH HYD PUMPS IN AUTO RT FLT SPOILER HAS UNCOMMANDED DEPLOYMENT TO 50 DEG SLOWLY AND THEN RETRACTS TO ZERO . SPOILERS DO NOT OPERATE DURING THIS OCCURANCE REGARDLESS OF FLT SPOILER LEVER POSN. UNTIL RT SPOILER REACHES 0 DEG SECU'S INTERROGATED AND BOTH, NR 1 AND NR 2 FAULT LOG SHOWS CODE 82 (THROTTLE SWITCH). THROTTLE QUADRANT REPLACED IAW MM., TASK 76-10-00-720-801, CUTOUT, NO FAULTS. ACFT. SERVICEABLE. TH. QUADRANT REMOVED: FTN NR X21X8B INSTALLED: FTN NR JW4J0A. 2L72 4F4 FRTA21EA E15NE 20040330001192004033000119NE 2004 3 30 CA040116004 220040113G7230 COMPRESSOR WHEEL LEAR 60 60LEAR 5170707CE PWA 305 PW305A 52128NE ENGINE FRACTURED W E ENGINE SHUTDOWN E VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA (CAN) FOLLOWING UNEVENTFUL LANDING AND ROLL-OUT, CREW NOTED VIBRATION AND RISING ITT. ENGINE WAS SECURED. POST FLIGHT EXAMINATION SHOWED THAT ROTOR 1 OF THE HPC HAD .3333 OF ONE AIRFOIL MISSING. 2L72 4F4 FRTA10CE E35NE 20040330001262004033000126CE 2004 3 30 CA040116006 120040116G3242 PIN CESSNA180 180J 2072622CE CONT O470 O470S 17026SO MCAULY2A34C 2A34C203 GL BRAKE LINKAGE WORN W K NONE O OTHER ININSP/MAINT 1 CA 13232 (CAN) DURING GROUND HANDLING THE RT RUDDER PEDAL BRAKE ASSY SEEMED SLOPPY COMPARED TO THE LT UNIT. INVESTIGATION REVEALED THAT THE PIN THAT CONNECTS THE BRAKE PEDAL TO THE MASTER CYLINDER WAS ALMOST COMPLETELY WORN THROUGH, THIS IS A HOLLOW SHAFT PIN ASSY. WORN PARTS WERE REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1H71 3O3 O 5A6 E273 5 CP3EA 20040330001272004033000127NE 2004 3 30 CA040117001 120040115G6320 WARNING LIGHT SKRSKYS61 S61N 8142104NE GE CT58 CT581402 30011NE GEARBOX OIL ILLUMINATED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA 24309 (CAN) AT 5500 FT VFR ENROUTE TO THE PLATFORM, JUST NEARING THE COASTLINE, THE MASTER CAUTION AND INTERMEDIATE GEARBOX CHIP LIGHT ILLUMINATED. 2G72 4U4 U 1H15 1E3 20040330001302004033000130CE 2004 3 30 CA040119001 120040115G3260404EN16 SWITCH LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP MLG FAULTY W A UNSCHED LANDING P NO WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER TAKE-OFF PILOT SELECTED THE GEAR HANDLE TO THE UP POSITION. THE GEAR WOULD NOT RETRACT. AIRCRAFT RETURN TO MAINTENANCE BASE. MAINTENANCE TECH FOUND RT TRUNNION SWITCH AT FAULT. SWITCH REPLACED AND LANDING GEAR SYSTEM SWUNG. AIRCRAFT RETURN TO SERVICE. 2L72 4F4 F A10CE E6WE 20040330001312004033000131CE 2004 3 30 CA040119002 120040116G212111438002811 BLOWER BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE AFT VENT BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) DURING CLIMB, CREW NOTED AN ELECTRICAL ODOR AND TRACE OF SMOKE IN CABIN. AIRCRAFT RETURNED TO AIRPORT WITHOUT FURTHER INCIDENT. MAINT FOUND THE AFT VENT BLOWER HAD OVERHEATED DUE TO ONE OF THE BEARING RESISTING ROTATION. THE NORMAL TEMPERATURE FUSE THAT IS SUPPOSED TO BLOW, DISCONTINUING POWER TO THE UNIT DID NOT APPEAR TO OPEN PRIOR TO BOTH SPEED RESISTORS BECOMING BADLY HEATED AND DISTORTED. THE RESISTORS AND TEMP FUSE ARE CONTAINED INSIDE A METAL CONTAINER MOUNTED ON THE SIDE OF THE BLOWER. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040330001452004033000145NM 2004 3 30 CA040119003 120040117G381024E507009G03 WATER HEATER AIRBUSA319 A319114 3930350NM CFMINTCFM56 CFM565A1 NE LAVATORY FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) BURNING ELECTRICAL ODOR NOTICED IN LAVATORY D. WHEN ODOR BECAME STRONGER, FLIGHT DIVERTED, DECLARING AN EMERGENCY, FOUND TO BE THE WATER HEATER AT FAULT HEATER DE-ACTIVATED, UNDER MEL. 2L72 4F4 FRTA28NM E29NE 20040330001462004033000146WP 2004 3 30 CA040209010 120040203G2540 WASTE TANK DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE LAVATORY LEAKING W O OTHER K FLUID LOSS DEDESCENT 1 CA (CAN) ON DESCENT, RT THROTTLE STUCK AT APPROXIMATELY 2 CM ABOVE IDLE POSITION. (UNABLE TO CONTROL POWER ON ENGINE) REGAINED CONTROL OF THROTTLE AT 1000 FEET ABOVE GROUND. FUNCTIONED NORMAL FOR LANDING AND TAXI. MAINTENANCE FOUND ICE BUILD UPON RT ENGINE THROTTLE CABLE SYSTEM QUADRANT TO CROSS SHAFT. SYSTEM CLEANED AND CHECKED FREE FOR MOVEMENT. THE ICE BUILD UP CAME FROM WATER LEAK FROM RT REAR LAVATORY. THE LAVATORY FAUCET WAS STUCK OPEN DURING FLIGHT AND OVERFILLED THE WASTE TANK. WATER OVERBOARD THE TANK ON THE TOILET FLOOR AND DRIPPED OVER THE ENGINE CONTROL. 2L72 4F4 FRTA6WE E9NE 20040330001472004033000147EU 2004 3 30 CA040209011 120040209G3297G21A24 WIRE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG INDICATOR BROKEN W O OTHER N FALSE WARNING TXTAXI/GRND HDL 1 CA (CAN) LT MLG GREEN INDICATION WAS INTERMITENTLY LOST. FAULT COULD BE DUPLICATED BY WIGGLING THE WIRES AT THE ACTUATOR PLUG. WIRE G21A24 FOUND BROKEN AT P055 CONNECTOR, REPAIRED, GROUND TESTS SATISFACTORY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040330001482004033000148NE 2004 3 30 CA040209012 220040127G732185634 SHAFT BELL 204 204B 1181404SW LYC T53 T5313B 41549NE FUEL CONTROL WORN W K NONE O OTHER ININSP/MAINT 1 CA 2ADS1203 (CAN) FUEL CONTROL RECEIVED FROM CUSTOMER FOR INSPECTION FOLLOWING PREVIOUS RECORDS ABOUT PUMP FAILURE (WSDR 20040128006). FUEL CONTROL HAS TSO- 3195.3 AND WAS OPERATING ON EXTENSION TIME DUE TO A GOOD PERFORMANCES. IT WAS REMOVED FROM A/C FOR INSPECTION IAW SB. T5317A-1-107 (CECO SB.73-39). INSPECTION FOUND WORN EXCESSIVELY, WORN MAIN DRIVE INTERNAL SPLINES, SECONDARY LARGE SPLINE AND PRIMARY PUMP GEAR EXTERNAL SPLINE. THIS IS THIRD CASE OF PUMP-MAIN DRIVE SHAFT FAILURE INVESTIGATED. WE HAVE REPORTED THIS CASE TO MANUFACTURER AND WE ARE WAITING FOR FUTHER GUIDANCE. 1G71 4U4 U H1SW E17EA 20040330001502004033000150CE 2004 3 30 CA040210003 120040208G7120265102215 RING CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL ENGINE MOUNT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE THE ENGINE MOUNT RING (HORSE COLLAR) WAS FOUND CRACKED AT TWO OF THE FOUR CORNERS, INSIDE JOINT. DUE TO THIS BEING A KNOWN PROBLEM, AN ADDITIONAL TASK CARD TO CHECK FOR THIS CONDITION, INITIATED IN 1999, WAS ADDED TO OUR MAINTENANCE SCHEDULE EVERY 100 HOURS. AS A RESULT, WE HAVE DISCOVERED THE CONDITION ON 8 SEPARATE COLLARS. THE COLLAR WAS REPLACED AND THE AIRCRAFT RELEASED. 1H71 3T3 T A37CE E4EA 5 CP60GL 20040330001512004033000151NE 2004 3 30 CA040119004 220040112G7200 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE NR 2 FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 CA 807608 (CAN) AIRCRAFT HAS RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. WHILE IN CRUISE, THE FLIGHT CREW FELT VIBRATION AND NR 2 ENGINE VIBRATION WAS FLUCTUATING BUT WAS WITHIN LIMITS. AFTER A FEW SECONDS, OIL PRESSURE DROPED TO ZERO. THE CREW FOLLOWED THE QRH, AN EMERGENCY WAS DECLARED, NR 2 ENGINE WAS SHUT DOWN, AIRCRAFT DIVERTED AND LANDED WITHOUT FURTHER INCIDENT. ENGINE REMOVED AND REPLACED. AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20040330001532004033000153WP 2004 3 30 CA040120002 120040119G6322C1861 HUB ROBSIN ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA CONING FLANGE GALLED W K NONE O OTHER ININSP/MAINT 1 CA LOT102A (CAN) OTHER PART AFFECTED LOWER BEARING C181-3 S/N 1328 UPON REMOVING FAN ASSY FOR ACCESS TO A DEFECTIVE ACTUATOR C051-1, DAMAGE (FRETTING AND GALLING) WAS DISCOVERED ON BOTH MATING FLANGE OF FAN HUB C186-1 (PART OF D174-2 ASSY) AND LOWER BEARING C181-3. NO PREVIOUS SIGN OF MOVEMENT WERE NOTED PRIOR TO DISMANTLING FAN ASSY. FAN WAS NEVER REMOVED AFTER IT LEFT FACTORY. FAN HAD BEEN BALANCED ONCE SINCE NEW. FAN HAS BEEN SPLIT APART FOR INVESTIGATION AND A LARGE AMOUNT OF METAL PARTICLES WERE DISCOVERED BETWEEN BACK PLATE AND FAN AND ALSO SOME EXTENSIVE CORROSION BETWEEN SHIM C178-2 FLANGES, HUB MATING SURFACE AND FAN ITSELF. PART REMOVED AND RETURNED FOR REPAIR AND FURTHER INVESTIGATION. 1G71 3O3 O H11NM E295 20040330001552004033000155NE 2004 3 30 CA040120005 220040120G7200 ENGINE BOEING767 76735H 1385208NM GE CF6 CF680C2B6F 30025NE LEFT FLAMED OUT W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) ON TAXI OUT LT ENGINE FLAMED OUT, WITH OIL ODOR IN THE CABIN. RETURNED TO GATE, AIRCRAFT CHANGED, ENGINE REPLACED IAW 71-00-02 CONF. 2L72 4F4 FRTA1NM E13NE 20040330001632004033000163EU 2004 3 30 AUS20040001 120040103G32315322112082 ROD PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG DOOR SHEARED W O OTHER J WARNING INDICATION CLCLIMB 1 AUS (AUS) LT NOSE LANDING GEAR DOOR OPERATING ROD BROKEN IN AREA LOCATEDADJACENT TO LOWER WITNESS HOLES. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040330001642004033000164GL 2004 3 30 AUS20040002 320040104G6111 CLIP MCAULY CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL PROPELLER BLADE SEPARATED W K NONE O OTHER ININSP/MAINT 1 AUS 1280 (AUS) PROPELLER BLADE ROOT CIRCLIP AND ASSOCIATED SHIMS SEPARATED. 1H71 3O3 O A4CE E5CE 5 CP47GL 20040330001652004033000165NE 2004 3 30 AUS20040003 320040106G61104HFR34C652 PROPELLER SWRNGN SWRNGNSA227 SA227* SW GARRTTTPE331TPE3312U 01514WP MCAULY4HFR344HFR34C652 NE PROPELLER LIGHTNING STRIKEW O OTHER C F.O.D. CRCRUISE 1 AUS 944 DC873B (AUS) LIGHTNING STRIKE ON RT PROPELLER AND RT FUSELAGE ADJACENT TO SAS VANE. SAS CIRCUIT BREAKER POPPED. DAMAGE TO RT PROPELLER AND RT FUSELAGE CONSISTENT WITH LIGHTNING STRIKE. 2L72 4T3 TRTA5SW E3WE 6 C3PNE 20040330001672004033000167EA 2004 3 30 AUS20040005 220040104G7322 NEEDLE PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA CARBURETOR STICKING W O OTHER EYBVIBRATION/BUFFET ENGINE STOPPAGE SMOKE/FUMES/ODORS/SPARKS LDLANDING 1 AUS (AUS) FIRE IN ENGINE COWLS. SUSPECT CAUSED BY STICKING CARBURETOR NEEDLE AND SEAT CAUSING FLOODING OF ENGINE. EXCESS FUEL LEAKED INTO COWLS AND IGNITED. 1L71 3O3 O 2A13 E274 5 NP88614 20040330001682004033000168NM 2004 3 30 CA040120009 120040120G55106524189 BLOCK BOEING727 727171C 1384057NM PWA JT8 JT8D7A 52053NE HORIZONTAL STAB WORN W K NONE O OTHER ININSP/MAINT 1 CA 46421 (CAN) DURING C CHECK, ONE RUB BLOCK (P/N 69-31604-4) WAS FOUND LOOSE ON THE LOWER BEAM. AFTER REMOVAL OF THE BLOCK, IT WAS FOUND THAT THE LOWER BEAM WAS WORN OUT OF LIMIT AT THE PLACE WHERE THE RUB BLOCK WAS INSTALLED. THE LOWER BEAM HAS TO BE REPLACED. 2L73 4F4 F A3WE E2EA 20040330001702004033000170EA 2004 3 30 AUS20040007 220040108G7414103827991 ROTOR BENDIX BEECH 76 76 1153005CE LYC O360 LO360A1G6 41514EA HARTZLHCM2Y HCM2YR GL MAGNETO FAULTY W O OTHER O OTHER NRNOT REPORTED 1 AUS 274 9032476 (AUS) RT ENGINE MAGNETO ROTATING MAGNETIC SLIPPED ON SHAFT BY APPROXIMATELY 25 DEGREES. 1L72 3O3 O A29CE 1E10 5 CP43GL 20040330001712004033000171NE 2004 3 30 AUS20040008 120040108G32302071235 BEARING RACE SKRSKYS76 S76C 8143008NE TMECA ARRIELARRIEL1S 60030NE MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LANDING GEAR INTERCONNECT ROD SPHERICAL BEARING INNER RACE CRACKED. FOUND DURING INSPECTION IAW AD/S-76/66 PT4. 1G72 3U3 UNCH1NE E19EU 20040330001732004033000173NE 2004 3 30 AUS20040010 120040108G62107615009043050 CAP SKRSKYS76 S76C 8143008NE TMECA ARRIELARRIEL1S 60030NE MAIN ROTOR BLADECRACKED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) MAIN ROTOR BLADE TIP CAP TOP SKIN CRACKED IN AREA ADJACENT TO THE ATTACHMENT DOUBLER. CRACK LENGTH 270MM (10.62IN). TIP CAP HAD DISBONDED INTERNALLY FROM THE METAL DOUBLER ASSEMBLY AND THE KEVLAR SKIN HAD CRACKED AND DELAMINATED. 1G72 3U3 UNCH1NE E19EU 20040330001742004033000174EU 2004 3 30 AUS20040011 120040110G5740SD3230488XA ATTACH FITTING STBROSSD3 SD360 8100606EU PWA PT6 PT6A67R 52043NE HARTZLHCA6A HCA6A3 NE LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING STRUT FORWARD LOWER STRUT TO STUB WING ATTACHMENT LUG CORRODED ON AFT FACE. DEPTH OF CORROSION 3.327MM (0.131IN) WHICH IS APPROXIMATELY 13 PERCENT OF THE FITTING THICKNESS. FOUND DURING INSPECTION IAW AD/SD3-60/48 AMDT2. 2H72 4T4 T A41EU E26NE 6 CP14NE 20040330001752004033000175NM 2004 3 30 AUS20040012 120040101G27424012373817 ACTUATOR DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE STABILIZER FAULTY W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) YAW DAMPER LINEAR ACTUATOR FAULTY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040330001762004033000176EU 2004 3 30 AUS20040013 220040105G7200CFM563C1 ENGINE BOEING737 737376 NM CFMINTCFM56 CFM563C 13802EU OVERHEATED W O OTHER M OVER TEMP NRNOT REPORTED 1 AUS 724786 (AUS) ENGINE EXCEEDED EGT LIMITS. EGT REACHED 938 DEGREES C. 2L72 4F4 FRTA16WE E21EU 20040329000972004032900097SO 2004 3 29 CA040209004 120040205G61202489410 CONTROL CABLE PIPER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL PROP GOVERNOR BROKEN W O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA (CAN) AT ENGINE WARMING UP PILOT FOUND ( WHEN TRYING CHECK OF PROP GOVERNOR WORK) LT PROP CONTROL LEVER WENT LOOSE, PROP DID NOT FOLLOW SETTING ANY MORE. INSPECTION REVEALED LT PROP GOVERNOR CABLE PN:24894-10 BROKEN AND SEPARATED CABLE END FITTING AT GOVERNOR SIDE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040329000982004032900098WP 2004 3 29 CA040209005 120040208G6320369D25100505 NOZZLE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL M/R GEARBOX MISSING W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) UNIT INSTALLED IN A/C AFTER REPLACEMENT OF CRACKED CASE BY CUSTOMER US REPAIR FACILITY. AFTER INITIAL TEST RUNS IT WAS REPORTED TO HAVE VERY LOW OIL PRESSURE, AFTER NUMEROUS HOURS OF TROUBLESHOOTING (PRESSURE PUMP, SWITCH, GAUGE REPLACEMENT AND WIRING CHECKS), THE UNIT WAS REMOVED FROM A/C FOR FURTHER INSPECTION. THE T/R O/P PINION WAS REMOVED TO EXPOSE A LARGE PART OF THE PRESSURE PROBLEM AS THE I/P OIL NOZZLES WERE MISSING. WE HAVE DOCUMENTED THIS ON DIGITALLY WITH PICTURES.WE AWAIT FURTHER INSTRUCTION. 1G71 3U3 U H3WE E4CE 20040330001282004033000128EA 2004 3 30 CA040118001 120040107G33972LA006913 WIRE CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE FLOOD LIGHT BURNED W O OTHER A FLAME/FIRE APAPPROACH 1 CA (CAN) THE COPILOT REPORTED FWD FLOOD LIGHT WIRES CAUGHT FIRE. CAPTAIN REPORTED THAT FO PINCHED WIRE WITH FINGERS TO EXTINGUISH FLAMES. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE FI FWD FLOOD LIGHT ASSEMBLY WAS REPLACED. 2L72 4F4 FRTA21EA EOOO63EN 20040330001522004033000152NM 2004 3 30 CA040120001 120040120G5610141T480150 WINDSHIELD BOEING767 767333 1385301NM PWA 4060 PW4060 52119NE COCKPIT BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE IN FLIGHT, R1 WINDSHIELD OUTER PANE SHATTERED. (FL370) R1 WINDOW REPLACED IAW AMM 56-11-01 REMOVED: UNI 56-10-0174 MPN: 141T4801-50 INSTALLED: UNI 56-10-0174 MPN: 141T4801-50 2L72 4F4 FRTA1NM E24NE 20040330001542004033000154NE 2004 3 30 CA040120004 320040120G611452590 THRUST WASHER CNDAIRCL215 CL2151A10 1900320EA PWA R1340 AWASP 52016NE HAMSTD43E 43E60 NE PROPELLER GALLED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PROPELLER REMOVED FOR AD 81-13-06R2, CF 83-16 CORROSION INSPECTION. EVIDENCE OF CORROSION WAS NOT FOUND BUT EXTENSIVE PITTING / GALLING WAS DISCOVERED ON A BEVELED THRUST WASHER P/N 52590 AND FLAT WASHER P/N 57525 AS IDENTIFIED IN HAMILTON STANDARD BLADE OVERHAUL MANUAL NO. 130B, PAGE 424. PROPELLER TO BE SENT FOR REPAIR AND OVERHAUL ASSESSMENT. 2H72 4R3 RRTA14EA ATC14 6 CP871 20040330001582004033000158NM 2004 3 30 CA040120008 120040120G551165174392 RIB BOEING727 727171C 1384057NM PWA JT8 JT8D7A 52053NE HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 46421 (CAN) DURING C CHECK,THE INSPECTION OF THE HORIZONTAL STABILIZER, REVEALED A CRACK ON THE ELEVATOR HINGE SUPPORT RIB ON THE RT SIDE AT STATION 136.5. 2L73 4F4 F A3WE E2EA 20040330001662004033000166 2004 3 30 AUS20040004 420040104G22104051601937 CONTROL PANEL BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU AUTOPILOT SYSTEMFAILED W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS 90101410 (AUS) AUTOPILOT MODE CONTROL PANEL FAILED. 2L72 4F4 FRTA16WE E21EU 20040330001692004033000169CE 2004 3 30 AUS20040006 120040107G5341BB148 WASHER BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL LT & RT WING WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) LT AND RT WING LOWER ATTACHMENT BOLT WASHERS INCORRECTLY FITTED. DAMAGE TO BATHTUB FITTING. PERSONNEL/MAINTENANCE ERROR. 1L72 4T4 T A24CE E4EA 6 CP15EA 20040330001792004033000179NM 2004 3 30 CA040121001 120040119G771110607371 TRANSMITTER BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE ENGINE EPR FAILED W D RETURN TO BLOCK N FALSE WARNING TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI, IT WAS OBSERVED THAT THE NR 1 ENGINE EPR HAD NO INDICATION. THE AIRCRAFT WAS RETURNED TO THE RAMP. AFTER SOME TROUBLESHOOTING, MEL 77-01-01 WAS RAISED. THIS IS A 3 FLIGHT DAY, A CAT, MEL. THE AIRCRAFT WAS DISPATCHED.ON RETURN TO HOME BASE, THE EPR TRANSMITTER WAS REPLACED AND CHECKED SERVICEABLE AND NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2L73 4F4 F A3WE E2EA 20040330001812004033000181CE 2004 3 30 CA040121004 120040104G56101013840252 WINDSHIELD BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL COCKPIT BROKEN W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) WINDOW SHATTERED IN CRUISE, INSIDE AND OUT SIDE PANE. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040330001822004033000182EU 2004 3 30 CA040121005 120040121G324632200022 BEARING AIRBUSA321 A321211 3930370EU IAE V2530 V2530A5 NE NLG WHEEL FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT NOSE WHEEL SEPARATED FROM THE NLG SHOCK ABSORBER DURING TAXING IN, IT IS BELIEVED THAT THIS HAPPENED ON THE LAST TURN TO THE GATE. THE AC HAS ACCUMULATED 4,747FH AND 1,813CY. A FAILURE OF THE NOSE LANDING GEAR WHEEL BEARING (TFU 32.41.12.006) IS SUSPECTED. 2L72 4F4 FRTA28NM E40NE 20040330001832004033000183GL 2004 3 30 CA040122001 320040121G6114D1657 CYLINDER PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL PROPELLER HUB DEFECTIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PROPELLER CYLINDER FOUND DEFECTIVE. MANUFACTURE DEFECT IN THE C AREA MISSING MATERIAL. THIS HAS BEEN SEEN IN SEVERAL OTHER CYLINDERS, MFG WAS CONTACTED ON ALL OF THE DEFECTIVE ASSEMBLIES. MFG INSPECTED AND ANALYZED THEM ALL AND HAS NOT PROVIDED ANY LIMITS FOR DAMAGES IN THE C AREA. ALL CYLINDERS HAVE BEEN WARRANTEED FOR REPLACEMENT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040330001842004033000184CE 2004 3 30 CA040122002 120040121G275014601008 CONTROL CABLE CESSNA337 T337G 2075726CE CONT O360 TSIO360CB 17025SO MCAULY2AF34CD2AF34C303 GL TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION IT WAS DICOVERED THAT THESE CABLES (2EA. 1 LT AND 1 RT) WERE FRAYED WHERE THE CABLE BENDS AROUND THE FLAP CABLE QUADRANT LOCATED IN THE WING TRAILING EDGE. 1H72 3O3 O A6CE E9CE 5 CP5EA 20040330001852004033000185CE 2004 3 30 CA040122003 120040121G275014601007 CONTROL CABLE CESSNA337 T337G 2075726CE CONT O360 TSIO360CB 17025SO MCAULY2AF34CD2AF34C303 GL TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION IT WAS DISCOVERED THAT THESE CABLES (2EA. 1 LEFT AND 1 RIGHT) WERE FRAYED WHERE THE CABLE BENDS AROUND THE FLAP CABLE QUADRANT LOCATED IN THE WING TRAILING EDGE. 1H72 3O3 O A6CE E9CE 5 CP5EA 20040330001862004033000186NM 2004 3 30 AUS20040016 120040113G3230161A661143 SPRING BOEING737 7377Q8 1384418NM GE CFM56 CFM567B24 NE MLG UPLOCK MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT MAIN LANDING GEAR AFT UPLOCK SPRING MISSING. 2L72 4F4 FRTA16WE E00055EN 20040401001602004040100160 2004 4 1 2004FA0000255 420040105G3418 STALL WARNING DIAMONDA20 DA20C1 2990001GL CONT O240 IO240A SO FROZEN B FE4RO OTHER O OTHER NRNOT REPORTED 1 AL03102U 319 C0205 WE HAVE FOUND THAT THE STALL WARNING SYSTEM ON THIS TYPE OF AIRCRAFT IS PRONE TO FREEZE UP. MOISTURE IS INTRODUCED TO THE SYSTEM THROUGH THE SENSORY HOLE IN THE LEFT WING. MOISTURE TRAVELS TO THE LOW POINT IN THE SYSTEM LOCATED IN THE AIRCRAFT BELLY AD FREEZES UP CAUSING THE STALL WARNING SYSTEM TO NOT FUNCTION. 1L71 3O3 ONTTA4CH E7SO 20040401001642004040100164EA 2004 4 1 2004FA0000257 220040101G8550LW13388 GASKET PIPER PA32 PA32R300 7103213SO LYC O540 TIO540* 41532EA OIL FILTER FAILED G O OTHER K FLUID LOSS NRNOT REPORTED 1 WP21589Q 32R7780492 OIL FILTER CONVERTER PLATE GASKET (PN LW13388) PROTRUDED OUT OF THE PLATE CAUSING LOSS OF OIL AND SUBSEQUENT ENGINE SEIZURE. RECOMMENDATION: CURRENT AD ALONG WIGH LYC SI CAN LEAD INTO MECHANIC TRAP. IF THE OIL FLITER CONVERTER PLATE KIT (PN LW-13904, THIS PROBLEM WOULD BE RESOLVED. (WP21200402668) 1L71 3O3 O A3SO E14EA 20040401001692004040100169CE 2004 4 1 2004FA0000261 120040201G3243988200104 MASTER CYLINDER CESSNA172 172S 2072439CE LYC O360 IO360A1A 41514EA LT BRAKE INOPERATIVE B EHHRO OTHER O OTHER NRNOT REPORTED 1 EA17641SP679 172S8049 PILOT REPORTED NO RESPONSE FROM LT BRAKE PEDAL, FOUND THAT BOTTOM LT BRAKE MASTER CYLINDER ATTACHMENT CLEVIS PIN MISSING. LOCATED CLEVIS PIN ON UPPERSIDE OF BELLY SKIN AND COTTER PIN. FOUND THAT COTTER PIN WAS BARELY BENT AND APPEARENTLY FELL OUT O F CLEVIS PIN HOLE THUS ALLOWING CLEVIS PIN TO FALL OUT OF BRAKE MASTER CYLINDER ATTACHMENT. 1H71 3O3 ONT3A12 1E10 20040401001702004040100170SW 2004 4 1 2004FA0000262 120040213G5753190151 HINGE BBAVIA8 8GCBC 1220803SW LYC O360 O360C1E 41514EA HARTZLHCC2Y HCC2YR1 GL TE FLAP CRACKED D K NONE O OTHER ININSP/MAINT 1 AL015060M 32679 L2722636A CH24256 CONDUCTED ANNUAL INSPECTION ON AIRCRAFT. FOUND BOTH LEFT AND RIGHT WING FLAP CONTROL ROD ATTACH POINTS TO CONTROL SURFACES TO BE CRACKED. SPECULATE DAMAGE MAY HAVE BEEN INDUCED BY WIND ACTION AND LACK OF USE OF CONTROL SURFACE LOCK. 1H71 3O3 O A21CE E286 5 CP920 20040401001712004040100171EA 2004 4 1 2004FA0000263 220040213G7414 IMPULSE COUPLING CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MAGNETO CRACKED B NF1RO OTHER O OTHER NRNOT REPORTED 1 CE079210H1936 95120132 17266017 L4305327A ONE OF THE MAGNETO IMPULSE COUPLING PAWLS OR PAWL ATTACH RIVETS FAILED DURING TOUCH AND GO OPERATION. THE PAWL BROKE THE MAGNETO MOUNTING CASTING AND DEPARTED THE AIRCRAFT. MAGNETO WAS HANGING FROM THE ACCESSORY HOUSING WITH THE HELP OF THE IGNITION HARNESS. PILOT REPORTED ONLY A SLIGHT BACKFIRE DURING CLIMB OUT WITH A LITTLE LOSS OF POWER. MAGNETO HAD RECEIVED A 500 HOUR INSPECTION 260 HOURS PRIOR TO FAILURE. IF FAILURE HAD OCCURRED DURING A LONG CROSS COUNTRY FLIGHT, TOTAL LOSS OF OIL MAY HAVE OCCURRED. (PILOT WOULD HAVE PROBABLY ADVANCED THROTTLE SLIGHTLY TO MAKE UP FOR ONE MAGNETO FAILING AND DROPPING RPM SLIGHTLY). 1H71 3O3 ONT3A12 E274 20040401001722004040100172CE 2004 4 1 2004FA0000264 120040213G3244 TIRE CESSNA172 172M 2072418CE LYC O320 O320* 41508EA NLG OUT OF BALANCE D O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 SW1364107 17265023 PILOT REPORTED NOSE WHEEL SHIMMY AFTER TOUCH DOWN AND HIGH SPEED TAXI. INSPECTED NOSE GEAR AND NOTED SHIMMY DAMPENER AND STEERING COLLAR BEARING A LITTLE MORE THAN NORMAL AXIAL MOVEMENT, TIRE STILL HAD 65 PERCENT TREAD AND SAW NO OBVIOUS TIRE DEFECTS. REMOVED NOSE STRUT TO INSPECT AND RESHIM STEERING COLLAR AND SERVICE/SHIM SHIMMY DAMPENER. WHEN THE NOSE STRUT LOWER FRONT HALF CLAMP WAS REMOVED, THE NOSE STRUT TUBE SPRUNG FORWARD .120 OUT OF ALIGNMENT WITH THE TOP STRUT MOUNT. FOUND NO DAMAGE TO AIRFRAME OR NO NOSE GEAR HISTORY. POSSIBLE LEAVING FACTORY LIKE THIS. INSPECTED AND RESHIMED NOSE GEAR ASSEMBLY AND LOWER STRUT CLAMP UP TO RELIEVE STRESS. MOUNTED NEW TIRE, DIFFERENT BRAND. NO SHIMMY DETECTED.1H71 3O3 ONT3A12 E274 20040401001742004040100174EA 2004 4 1 2004FA0000265 220040129G732230768 FLOAT PIPER PA44 PA44180 7104402SO LYC O360 O360E1A6 41514EA CARBURETOR SATURATED B WIWRO OTHER K FLUID LOSS NRNOT REPORTED 1 WP07923RS 75132505 447995196 RL70177T PILOTS REPORTED THAT UPON LANDING THE LEFT ENGINE DIED AND THAT FUEL WAS DRIPPING FROM THE COWLING. MAINTENANCE INSPECTED LEFT ENGINE AND COULD NOT FIND FUEL LEAKAGE. AIRCRAFT WAS GROUND RUN AND OPERATIVE NORMALLY EXCEPT AT IDLE. AT IDLE AIRCRAFT RAN SMOOTHLY FOR ABOUT 15 TO 20 SECONDS AND THEN WOULD BEGIN TO DIE AS IF THE ENGINE WAS EXCESSIVELY RICH. MIXTURE WAS LEANED TO ICO AND ENGINE CONTINUED TO RUN AND THERE WAS FUEL DRIPPING FROM THE AIRBOX. CARBURETOR WAS REMOVED FROM THE AIRCRAFT AND THE TOP OPENED. THE FLOAT INSIDE THE CARBURETOR WAS FOUND TO BE HALF FILLED WITH FUEL. MFG TO MONITOR PRODUCTION OF FLOATS. (WP07200410619) 1L72 3O3 O A19S0 E286 20040401001752004040100175CE 2004 4 1 2004FA0000266 120040218G326012700344 SAFETY SWITCH CESSNA337 337H 2075732CE CONT O360 IO360GB 17025SO MCAULY2AF34CD2AF34C* GL NLG DAMAGED B LX5RA UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 GL191244S5920 33701892 236691R 780550 AFTER TAKE OFF PILOT WAS UNABLE TO RETRACT THE LANDING GEAR, THE GEAR DID SHOW DOWN AND LOCKED. THE PLANE LANDED WITHOUT INCIDENT. FOUND NOSE GEAR SAFETY SWITCH BAD INTERNALLY NOT ALLOWING NOSE GEAR TO RETRACT, (SENSING STILL ON GROUND). IT IS SUSPECTED THAT THIS WAS NORMAL WEAR OF SWITCH. THERE WAS NO EVIDENCE OF EXTERNAL DAMAGE. 1H72 3O3 O A6CE E1CE 5 CP5EA 20040401001762004040100176CE 2004 4 1 2004FA0000267 120040212G3297SM50D7 RELAY BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO MLG INTERMITTENT B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP071565A CE1331 825800R PILOT REPORTED THAT LANDING GEAR WOULD NOT EXTEND. AFTER GEAR HANDLE CYCLED SIX TIMES GEAR CAME DOWN. UPON TROUBLESHOOTING OF THE LANDING GEAR SYSTEM FOUND LANDING GEAR DYNAMIC RELAY INTERMITTENT. NO RECOMMENDATIONS AT THIS TIME. 1L71 3O3 O 3A15 E5CE 20040402000012004040200001EU 2004 4 2 CA040210006 120040206G73348346 PRESSURE SWITCH SAAB SF340 SF340A 7850100EU GE CT7TP CT75A2 30030NE ROTOL R389 R3894123F25 NE FUEL SYSTEM LEAKING W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA 367302 (CAN) DUE TO INTERNAL LEAKAGE OF DIFFERENTIAL PRESSURE SWITCH, A LOST OF FUEL WAS HAPPENING THRU THE OVERBOARD DRAIN WHICH WAS CREATING A PRESSURE DROP IN FUEL PUMP SYSTEM, THE AUX PUMP WOULD THEN COME ON AND OFF THUS CREATING A SMALL FLUCTUATIONIN THE ENGINE PARAMETERS. AFTER INVESTIGATION AN IMPROVE SWITCH WAS MADE AVAILABLE THRU SB73-011 DUE TO IMPROVED RELIABILITY. THE OLD PN 8346 CAN BE NOW IMPROVE BY USING PN 8346-001. 2L72 4T4 TRTA52EU E8NE6 6 CP30NE 20040402000022004040200002EA 2004 4 2 CA040211006 120040205G7921853877 OIL COOLER DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA ENGINE CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) AIRCRAFT RETURNED FROM FLIGHT WITH AN EXCESSIVE OIL LEAK ON THE LT ENGINE COWLS. INVESTIGATION DISCOVERED A CRACK IN THE OIL COOLER VERNATHERM INLET/OUTLET HOUSING. THE OIL COOLER WAS REPLACED WITH AZERO TIME UNIT AND CHECKED SERVICEABLE.THE OIL COOLER HAD BEEN INSTALLED 77.2 HOURS EARLIER AS PART OF A 3000 HOUR BENCH TEST REQUIREMENT. 1H72 3T4 TRTA9EA E4EA 20040402000032004040200003CE 2004 4 2 CA040122004 120040108G52101295140791 BRACKET BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE PAX DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 12505 (CAN) DURING GROUND HANDLING, CREW ATTEMPTED TO OPEN DOOR FROM INSIDE AND THE MAIN HANDLE UPON APPLYING PRESSURE, RELEASED WITHOUT ACTUATING DOOR CAMS. MAINTENANCE FOUND THAT THE MAIN DOOR ACTUATION BRACKETHAD BROKEN INTO TWO PIECES. THE BRACKET WAS REPLACED AND THE AIRCRAFT CONTINUED OPERATIONS. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040405000012004040500001EA 2004 4 5 CA040308009 120040304G331082510189S103 RHEOSTAT DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE COCKPIT LIGHT FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA 2849728497 (CAN) DURING MAINT WHEEL REPLACEMENT ON RAMP , FLIGHT CREW (ONLY PERSONNEL ONBOARD) NOTICED SMOKE IN THE COCKPIT (NO FIRE) . MAINTENANCE INSPECTION FOUND OVERHEAD READING LIGHT RHEOSTAT WAS SOURCE OF SMOKE. COCKPIT OVERHEAD PANEL ASSEMBLY WITH RHEOSTAT REPLACED. AIRCRAFT RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040405000042004040500004EA 2004 4 5 CA040309002 120040304G632061352095012 COVER SKRSKY CARSONS61 S61LSKRSKY EA GE CT58 CT581401 30011NE M/R GEARBOX CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 26356 A14994 (CAN) CRACK ON LOWER LT LEG OF MAIN GEARBOX REAR COVER DISCOVERED ON DAILY INSPECTION. 2G72 4U4 U H8EA 1E3 20040405000052004040500005NE 2004 4 5 CA040309003 120040307G6320 FILTER SKRSKY 613520600046SKRSKYS61 S61N 8142104NE GE CT58 CT581401 30011NE M/R GEARBOX INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION HOHOVERING 1 CA 18054 A141027 (CAN) MAIN GEAR BOX OIL PRESSURE DROPPED IN FLIGHT. AIRCRAFT RETURNED TO LANDING AREA AND SHUT DOWN. EXAMINATION OF MGB COARSE SCREEN FILTER REVEALED RESIN COATING FROM INSIDE OF MGB HAD FLAKED OFF. MGB REPLACED. 2G72 4U4 U 1H15 1E3 20040405000062004040500006NM 2004 4 5 CA040309004 120040225G27426355B000103 MOTOR BOEING737 73776N 13844CHNM CFMINTCFM567CFM567B22 13802NE STAB TRIM JAMMED W H DEACTIVATE SYST/CIRCUITS FJ FLT CONT AFFECTED WARNING INDICATION CRCRUISE 1 CA (CAN) 2 HRS INTO FLT (STAB OUT OF TRIM) LIGHT ILLUMIN. NON-NORMAL CKLIST WAS COMPLETED, ELEC TRIM REMAINED INOP,TRIM CHANGES ACCOMPLISHED MANUALLY. MAINT CTRL WAS CONSULTED AND CB 6B AND 610 WERE PULLED AND RESET. (STAB OUT OF TRIM) LIGHT CONTINUED INTERMITTENT, PILOTS CONTINUED MANUALLY INPUT REQUIRED TRIM CHANGES. STAB BECAME COMPLETELY JAMMED NON-NORMAL CKLIST WAS COMPLETED. STAB REMAINED JAMMED FOLLOWING COMPLETION OF CKLIST, MAINT CTRL REQUESTED THAT CB 6B AND 610 BE PULLED AND LT OUT. MAN CTRL OF STAB WAS RESTORED AND A NON-NORMAL LANDING WAS COMPLETED, WITHOUT FURTHER INCIDENT. UPDATE: MAR.09/04 - MFG HAS REQUESTED FLIGHT DATA RECORDED READOUT FROM SUBJECT FLIGHT AND RELATED TROUBLESHOOTING RESULTS. 2L72 4F4 FRTA16WE E00055EN 20040405000072004040500007NM 2004 4 5 CA040310001 120040306G4997 CONNECTOR GARRTT GTCP8511 BOEING737 7372H4 138448CNM PWA JT8 JT8D9A 52048NE APU BURNED W AE UNSCHED LANDING ENGINE SHUTDOWN J WARNING INDICATION CRCRUISE 1 CA P34583 (CAN) INDICATION OF APU FIRE AT 35,000 FT. AFTER DISCHARGING BOTTLE AND SHUTTING DOWN APU, RED WARNING LIGHT EXTINGUISHED. CREW DIVERTED AND AC LANDED W/O INCIDENT. MAINT INSP FOR FIRE DAMAGE IAW SRM 51-4-10. FIRE CONTAINED BETWEEN BLKHD STA.1156 AND APU EXHAUST BAFFLE. NO EVIDENCE OF BURNED PRIMER OR DISCOLORED METAL. APU EGT AND TAIL PIPE FIRE DETECTION WIRING HARNESS FOUND BURNED, TAIL PIPE FIRE. APU TUB REMOVED AND INSP, NO LEAKS AND NO INDICATION OF FIRE DAMAGE. MAINT SUSPECT CAUSED OFFIRE AT EGT CONNECTORS TO WIRE HARNESS, FOUND BURNED. POSSIBLE SHORT OCCURRED, DAMAGED WIRING HARNESSES REPLACED AND APU FIRE DETECTION SYSTEM TESTED SERVICEABLE. APU FIRE BOTTLE REPLACED. AC RETURNED TO SERVICE. 2L72 4F4 F A16WE E2EA 20040405000082004040500008EU 2004 4 5 CA040310002 120040308G2510EQMFG200002901 SEAT BELT SNIAS 350 AS350B3 8680954EU TMECA ARRIELARRIEL2B NE COCKPIT INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SHOULDER HARNESS INERTIA REEL ON COPILOT'S SEAT WOULD NOT RETRACT AFTER FULL EXTENSION. THE PN SPECIFIED IN 9B APPLIES TO THE 4 POINT HARNESS ON ENERGY ABSORBING STYLE OF SEAT. 1G71 3U3 U H9EU E00054EN 20040405000102004040500010SW 2004 4 5 CA040310004 120040225G5313206031314123 LONGERON BELL 206 206L1 1182107SW ALLSN 250C 250C30P 03013GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING SCHEDULED MAINTENANCE THE ENGINEER DETECTED THE ENGINE MOUNT TO BE LOOSE. FURTHER INVESTIGATION INDICATED A CRACKED LONGERON WITH THE ENGINE MOUNT IS ATTACHED. 1G71 3U3 U H2SW E1GL 20040405000212004040500021EU 2004 4 5 CA040311007 120040311G33400320713406 LIGHT PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL EXTERIOR FAILED W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) NAVIGATION LIGHT ASSEMBLY (TAIL) APPEARS TO HAVE PROBLEMS WITH THE TOP BULB BURNING OUT. THERE HAS BEEN 8 BULBS P/N 972.87.87.184 REPLACED WITHIN 7 DAYS. THE COMPLETE ASSEMBLY HAS BEEN REPLACED ALONG WITH A ELECTRONIC SWITCH UNIT. THE SAME RESULTS. THE BULBS THEMSELVES ARE EXTREMELY HOT WITHIN A SORT TIME OF OPERATION.(SECONDS) THIS NAV LIGHT ASSEMBLY IS PART OF A KIT P/N 500.50.12.276 DUAL NAV LIGHT SYSTEM. MFG S/B 33-009 WAS USED FOR THE INSTALLATION OF THIS PRODUCT. IN SHORT, THE LIGHT IS UNRELIABLE. ON GOING TRIALS ARE CONTINUING TO FIND A SOLUTION. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040405000252004040500025CE 2004 4 5 CA040311011 120040227G521050430043619 CHANNEL BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION A CRACK WAS DISCOVERED ALONG THE TRAILING EDGE OF THE CABIN DOOR CHANNEL P/N 50430043619. THE CRACK PROPAGATED APPROXIMATELY 6 IN, JUST ABOVE THE DOOR HINGE. THE DOOR WAS REMOVED AND SENT TO AN APPROVED OVERHAUL SHOP, REPAIRED AND REINSTALLED. AIRCRAFT RETURNED TO SERVICE. 1L72 4T4 T A24CE E4EA 5 CSTC 20040405000292004040500029GL 2004 4 5 CA040315001 220040309G72106850209 GEARBOX LKHEED382 382G 526414USO ALLSN 501D 501D22A 03006GL HAMSTD54H 54H60117 NE NR 2 REDUCTION CONTAMINATED W E ENGINE SHUTDOWN J WARNING INDICATION CLCLIMB 1 CA (CAN) AT TOP OF CLIMB ENROUTE, NR 2 RGB CHIP LIGHT OBSERVED. THE INDICATION WOULD NOT CLEAR, NR 2 ENGINE WAS SHUT DOWN. MAINTENANCE FOUND BOTH RGB CHIP PLUGS BRIDGED. NR 2 ENGINE WAS REPLACED FOR CONVENIENCE AND THE AIRCRAFT RETURNED TO SERVICE. 2H74 4T4 T A1SO E282 6 CP906 20040413000112004041300011CE 2004 4 13 CA040315008 120040302G28231013890253 SHUTOFF VALVE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL FUEL SYSTEM FAILED W O OTHER L NO TEST TXTAXI/GRND HDL 1 CA (CAN) DURING PRESTART CHECKS FLIGHT CREW COULD NOT EXTINGUISH (LOW FUEL PRESSURE) WARNING LIGHT. FLIGHT CANCELLED. INSPECTION FOUND RT FUEL SHUT OFF VALVE HAD FAILED IN THE CLOSED POSITION. VALVE HAD BEEN RECENTLY OVERHAULED. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040413000122004041300012EU 2004 4 13 CA040315009 120040306G5330 SKIN BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 36314 (CAN) A PILOT IN THE PROCESS OF DOING HIS DAILY INSPECTION OF THE AIRCRAFT NOTICED A CRACK (2.5 INCHES) IN THE LT FORWARD FUSELAGE SKIN JUST BELOW A LAP JOINT BETWEEN FRAMES 10 AND 11 NEAR THE WATER LINE. THE AIRCRAFT WAS REMOVED FOR SERVICE, A SECTION OF SKIN IN THE AFFECTED AREA WAS REMOVED AND SENT FOR ANALYSIS, THE BREAK OCCURRED ON AN INSIDE RADIUS OF THE SKIN THAT WAS CHEMICALLY MILLED. OUR SHEET METAL PEOPLE EXAMINED THE SPECIMEN THAT WAS REMOVED AND THEY FELT THAT THE RADIUS OF THE CONTOUR WAS A BIT SHARP WHERE THE CRACK OCCURRED. THE AIRCRAFT WAS TEMPORARILY REPAIRED IAW BARA/AVR/6681/04-DC INSTRUCTIONS FROM THE MANUFACTURER WITH A PERMANENT REPAIR DUE AT THE NEXT C-CHECK. 2H74 4F4 F A49EU E6NE 20040413000132004041300013NM 2004 4 13 CA040315010 120040308G325065727628 COLLAR BOEING727 727233 138408ANM PWA JT8 JT8D15 52051NE NLG STEERING WORN W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA 12000 (CAN) THE TAKE-OFF WAS REJECTED AT 70KTS DUE TO NLG SHIMMEY. BOTH NLG WHEELS REPLACED AND STEERING COLLAR ADJUSTMENT CHECKED. AIRCRAFT WAS RETURNED TO SERVICE. 2L73 4F4 FRTA3WE E2EA 20040413000142004041300014CE 2004 4 13 CA040315011 120040308G77123012347 VALVE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3A NE TORQUEMETER ERODED W O OTHER O OTHER DEDESCENT 1 CA PS0164 (CAN) FLIGHT CREW REPORTED OCCASIONAL PROBLEMS WITH TORQUE INDICATION DURING POWER REDUCTIONS. TORQUE INDICATION WOULD HANG UP AT VARIOUS HIGH SETTINGS DESPITE POWER REDUCTIONS TO IDLE. FROM A PREVIOUS CASE OF THIS ON ANOTHER AIRCRAFT, THE POWER REDUCTION CASE WAS SPLIT WITH AN EXPECTATION THAT THE TORQUEMETER VALVE WAS PREMATURELY WORN, AND IT WAS. A PREVIOUS SUBMISSION UNDER AGL-0120 REFLECTS EXACTLY THE SAME PROBLEM, PRESENTATION AND FIX. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040413000152004041300015EU 2004 4 13 CA040315012 120040314G6730AC67246 SERVO VALVE SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE COLLECTIVE UNSERVICEABLE W C ABORTED TAKEOFF F FLT CONT AFFECTED TOTAKEOFF 1 CA (CAN) PILOT REPORTED THAT WHEN HE TRIED TO PULL THE COLLECTIVE UP, IT FELT VERY HEAVY. IT WAS NOTED DURING TROUBLESHOOTING THAT THE SPOOL VALVE WAS VERY DIFFICULT TO MOVE AND THEN IT WOULD ONLY MOVE A SMALL AMOUNT. A SERVICEABLE SERVO WAS INSTALLED AND CONTROLS CHECKED OUT NORMAL. 1G71 3U3 U H9EU E19EU 20040413000192004041300019NM 2004 4 13 CA040316008 120040305G301085720014005 BOOT DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE LT LE DEICE DELAMINATED W C ABORTED TAKEOFF N FALSE WARNING TOTAKEOFF 1 CA 3687436874 (CAN) CREW REJECTED TAKE-OFF AT ROTATION DUE TO STICK PUSHER SHAKE. AIRCRAFT WAS AT MORE THAN 80 KNOTS AT TIME OF REJECTION. FLIGHT RETURNED TO GATE. BOTH STALL SYSTEMS CHECKED SERVICEABLE ON THE GROUND. FOUND THAT THE LT LE DEICE BOOT DELAMINATING CAUSING THE STALL/STICK SHAKER TO ACTIVATE. THE LEADING EDGE WAS REPLACED AND THE AIRCRAFT BROUGHT BACK TO SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040413000242004041300024NM 2004 4 13 CA040203012 120040203G2910272T3100351 LINE BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE HYDRAULIC SYS RUPTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT HYDRAULIC QTY LOST ON T/O ROLL NO HYD FLUID REMAINING ASSOCIATED SYSTEM AFFECTED. FOUND LT HYDRAULIC RETURN LINE RUPTURED. LINE REPLACED, PRESS/CASE FILTERS REPLACED. LEAK AND FUNCTION CHECK SERVICEABLE. 2L72 4F4 FRTA1NM E3NE 20040413000252004041300025SW 2004 4 13 CA040318004 120040311G6420AN5161A GREASE FITTING BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL TAIL ROTOR CLOGGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING 50 HOUR LUBRICATION INTERVAL. FITTINGS WOULD NOT PASS GREASE. FITTING REPLACED. 1G71 3U3 U H2SW E4CE 20040413000282004041300028CE 2004 4 13 CA040319002 120040309G30201099100491 ANTI-ICE SYSTEM BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL RT ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AIR INTAKE ANTI-ICE LIP WAS FOUND CRACKED AT THE WELDED ATTACH JOINTS AT BASE OF EXHAUST INLET/OUTLET TUBES. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040413000292004041300029GL 2004 4 13 CA040216008 120040213G2510 VISOR BOMBDRBD700 BD7001A10 1390006GL RROYCEBR700 BR700710A22009500NE COCKPIT SEPARATED W O OTHER YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA (CAN) PILOT WAS MOVING HIS VISOR BACK FROM EXTREME RT SIDE OF VISOR RAIL TO LT, WHEN VISOR FELL OFF RAIL ONTO THROTTLE QUADRANT. LT ENGINE RUN SWITCH ON QUADRANT WAS INADVERTENTLY MOVED TO OFF POSITION BY VISOR IMPACT AND ENGINE STARTED TO SHUT DOWN. PILOT DESCENDED TO FL410 TO KEEP SPEED UP, SELECTED ENGINE RUN SWITCH BACK TO RUN POSITION. SUCCESSFUL RELIGHT OF ENGINE OCCURRED AND A/C WAS BROUGHT BACK TO FL450 AND TRIP CONTINUED WITHOUT FURTHER INCIDENT. MAINT CREW RAN ENGINES ON GROUND TO VERIFY THROTTLE QUADRANT AND ENGINE RUN SWITCHES FUNCTIONALITY OF ENGINE RUN SWITCH CONFIRMED. ENGINE GROUND RUNS PERFORMED BEFORE AIRCRAFT RETURNED TO SERVICE. NO FURTHER CONCERNS WERE IDENTIFIED. 2L72 4F4 FRTT00003NYE00061EN 20040413000302004041300030NM 2004 4 13 CA040319006 120040317G2421700842A CSD BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE AC GENERATOR FAILED W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC TOTAKEOFF 1 CA (CAN) DURING TAKEOFF, IT WAS OBSERVED THAT ELECTRICAL POWER WAS LOST WITH NR 3 GENERATOR. A REJECTED TAKE-OFF WAS CARRIED OUT AND AIRCRAFT RETURNED TO THE GATE WITHOUT INCIDENT. NR 3 ENGINE CONSTANT SPEED DRIVE WAS DISCONNECTED AND SYSTEM WAS DEFERRED IAW MEL 24-01. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L73 4F4 F A3WE E2EA 20040416000332004041600033SO 2004 4 16 CA040322007 220040311G8530631397 CYLINDER HEAD CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO HARTZLHCJ3Y PHCJ3YF1 GL ENGINE SEPARATED W O OTHER EDBVIBRATION/BUFFET INFLIGHT SEPARATION SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 195786R (CAN) IN FLIGHT SEPARATION OF CYL NR 3 HEAD. 1H71 3O3 O A4CE E5CE 5 CP36EA 20040416000342004041600034NM 2004 4 16 CA040322008 120040322G252025606801 SEAT BACK BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE CABIN BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE IN THE AIR, SEATBACK 17K BROKE AT HINGE CAUSING PAX WHO WAS SITTING IN SEAT TO HURT THEIR BACK. YYZ MTCE TO REPAIR DURING O/NIGHT.STUD PIVOT PIN REPLACED. 2L72 4F4 FRTA1NM E3NE 20040416000352004041600035WP 2004 4 16 CA040323001 120040318G4900 CSD DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE APU OVERSERVICED W A UNSCHED LANDING WMJINADEQUATE Q C OVER TEMP WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CRUISE FROM FLL, LT CSD OIL TEMP WENT HIGH. GENERATOR SWITCHED OFF. AIRCRAFT LANDED BACK TO FLL DUE TO APU NOT START. MAINTENANCE FOUND LT CSD OIL OVERFILLED. CSD RESERVICED IAW MM AND AIRCRAFT DISPATCHED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040330001252004033000125NM 2004 3 30 CA040116005 120040104G2910DSC3461 LINE DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE HYDRAULIC SYS RUPTURED W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) AFTER ENGINE START NR 2 HYD CAUTION LIGHT ILLUMINATED, NR 2 QUANTITY NOTED TO BE DECREASING. A/C SHUT DOWN. LARGE HYDRAULIC LEAK FROM NR 2 ENGINE NOTED. FOUND PRESSURE LINE P/N DSC346-1 RUPTURED IN THE FLEXIBLE SECTION. LINE REPLACED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040330001432004033000143GL 2004 3 30 CA040209009 220040209G7397JG7039C2C33 WIRE HARNESS CVAC 340 340CVAC 242270AWP ALLSN 501D 501D13H 03004GL FUEL QTY CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING WINTER MAINTENANCE INSPECTION, WIRES WERE FOUND RUBBING AGAINST EACH OTHER AT A FUEL QUANTITY TRANSMITTER PROBE IN THE LT WING AT APPRX WS 253.0. ONE WIRE HAD CHAFED ENOUGH TO EXPOSED THE BARE WIRE. ALL OTHER AREAS IN BOTH WINGS WERE INSPECTED AT THE FUEL QUANTITY PROBES WITH NO OTHER DAMAGE NOTED. 2L72 4R4 T 6A6 E282 20040330001492004033000149EA 2004 3 30 CA040210001 120040209G33102LA00691307 LIGHT CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT INOPERATIVE W O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA (CAN) THE FLIGHT CREW REPORTED, ON POWER UP, SMOKE COMING FROM THE RT SIDE OF COCKPIT. ADDITIONAL INFORMATION IS THAT THE SMOKE WAS COMING FROM AROUND THE FO WINDSHIELD/WINDOW POST. MAINTENANCE DEFERED THE FLIGHT DECK FLOOD LIGHTS IAW MEL 33-11-01, AND RETURNED THE AIRCRAFT TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20040330001562004033000156EU 2004 3 30 CA040120006 120040120G5610NP1752321 WINDSHIELD AIRBUSA330 A330* EU RROYCERB211 RB211TRENT77 NE COCKPIT BROKEN W A UNSCHED LANDING O OTHER CLCLIMB 1 CA 14463 (CAN) AFTER TAKE OFF, CLIMBING THROUGH 10000 FT, THE CAPTS SLIDING WINDOW SHATERED. CREW ELECTED TO RETURN TO CDG AND LANDED APPROX 35000 KG OVER MLW. CAPTS SIDE WINDOW CHANGED IAW 56-12-11. PARTS: SLIDE WINDOW MPN NR NP175232-1 INSTALLED. OUTER STRUCTURAL PANE WAS SHATERED ON CAPTS SLIDING WINDOW (NO) DAMAGED REPORTED ON STRUCTURE. 2L72 4F4 FRTA46NM E39NE 20040330001572004033000157CE 2004 3 30 CA040120007 120040118G2435M230881320 BRUSHES LUCAS BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE STARTER GEN WORN W K NONE O OTHER ININSP/MAINT 1 CA 98048 (CAN) DURING FLEET WIDE INSPECTION OF PREMATURE BRUSH WEAR. THIS UNIT FOUND TO HAVE EXCESSIVE WEAR. 149.4 SINCE TBO.618 HRS OF BRUSH WEAR REMAINING. TBO 1500 HRS. VENDOR IN CONTACT WITH BRUSH MANUFACTURER. OTHER OPERATORS FINDING SIMILAR SDR ALERT WOULD SPEED RECTIFICATION PROCESS. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040330001722004033000172CE 2004 3 30 AUS20040009 120040105G712026011895 SUPPORT CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE HARTZLH3B3M HCB3M GL ENGINE MOUNT FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE SUPPORT HOUSING FOR AIR CONDITIONER DRIVE LEAKING OIL. INVESTIGATION FOUND THE SUPPORT HOUSING ALIGNMENT SPIGOT TO BE TOO LONG TO FIT INTO THE RECESS IN THE ENGINE MOUNT PAD. THESPIGOT BOTTOMS OUT ON THE SEAL CARRIER CAUSING A 0.33MM (0.013IN) GAP ON THE GASKET FLANGE. THE SPIGOT BOTTOMING ON THE PAD CAUSES EXCESSIVE WEAR ON THE DRIVE SHAFT SPLINES PN 2601267-2 AND THE INTERNAL SPLINES ON THE DRIVE GEAR PNO 3100450-01. 1H71 3T3 T A37CE E4EA 5 CP9NE 20040330001772004033000177NM 2004 3 30 AUS20040014 120040105G2781189929 PROXIMITY SWITCH BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU SLATS FAULTY W O OTHER N FALSE WARNING CRCRUISE 1 AUS 196670 (AUS) NR 3 LEADING EDGE SLAT PROXIMITY SWITCH FAULTY. 2L72 4F4 FRTA16WE E21EU 20040330001782004033000178 2004 3 30 AUS20040015 420040114G611305502636 SUPPORT MCAULY CESSNA172 172H 2072424CE CONT O300 O300C 17022SO MCAULY1C172 1C172EM GL SPINNER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 30 (AUS) PROPELLER SPINNER FORWARD SUPPORT CRACKED AROUND PROPELLER BOLT ATTACHMENT HOLES. SUPPORT HAD BEEN FITTED 30 HOURS AGO DUE TO THE SAME PROBLEM WITH THE PREVIOUS SUPPORT. 1H71 3O3 ONT3A12 E253 5 NP910 20040401001632004040100163SO 2004 4 1 2004FA0000256 120040116G572062371008 HINGE PIPER PA28 PA28R200 7102811SO LYC O360 IO360A1A 41514EA IB RT AILERON WORN D O OTHER W INADEQUATE Q C NRNOT REPORTED 1 EA0156264 28R7535212 RECEIVED 2 NEW HINGES FROM API WITH EXCESSIVE PLAY BETWEEN PIN AND HINGE HALFES. DATE CODES: 12/23/03 AND 01/16/04. HINGES ARE MADE BY AC MFG. 1L71 3O3 O 2A13 1E10 20040401001662004040100166SO 2004 4 1 2004FA0000259 220040207G8530SA10200A1 CYLINDER CESSNA150 150F 2071814CE CONT O200 O200A 17020SO NR 4 BROKEN G O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 EA158745S 841 15062045 AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING A FORCED LANDING AFTER TOTAL LOSS OF ENGINE POWER. INVESTIGATION SHOWED THE CYLINDER HAD COMPLETELY SEPARATED IN THE MIDDLE WHILE IN FLIGHT, CAUSING THE TOTAL LOSS OF POWER. 1H71 3O3 O 3A19 E252 20040405000032004040500003CE 2004 4 5 CA040309001 120040303G76031143890503 CONTROL CABLE BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL POWER LEVER SEVERED W ED ENGINE SHUTDOWN RETURN TO BLOCK WE INADEQUATE Q C VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA (CAN) AFTER LANDING AND SUBSEQUENT TAXI THE RT ENGINE SPOOLED UP AND DID NOT RESPOND TO POWER LEVER MOVEMENT. THE ENGINE WAS SHUT DOWN AND THE AIRCRAFT COMPLETED TAXI TO THE TERMINAL ON THE LT ENGINE. MAINTENANCE INVESTIGATED AND DISCOVERED THAT THE POWER LEVER CABLE HAD BEEN SEVERED BY THE PULLEY OF THE VAPOR CYCLE AIR CONDITIONING SYSTEM. THE CABLE HAD BEEN ROUTED TOO CLOSE TO THE PULLEY DURING AN ENGINE REMOVAL AND REINSTALLATION 64 HOURS PRIOR TO THE INCIDENT. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040405000142004040500014SO 2004 4 5 CA040310009 120040310G3230WTC345 POWERPACK PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE3Y HCE3YR2A GL HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) WHEN THE PILOT SELECTED GEAR UP, ONE OF THE GEARS WAS NOT RETRACTING AND THE TRANSITION LIGHT REMAINED ILLUMINATED. AFTER SEVERAL ATTEMPTS THE GEAR RETRACTED AND EVERYTHING WAS NORMAL. THE POWER PACK WAS REPLACED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040405000152004040500015NM 2004 4 5 CA040310010 120040309G5610NP15790213 WINDOW DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE COCKPIT BROKEN W O OTHER O OTHER CLCLIMB 1 CA (CAN) AFTER TAKEOFF THROUGH 6000 FT. THE OUTER PANE OF THE CAPTAIN'S SIDE WINDOW SHATTERED. THERE WAS NO NOTICEABLE CHANGE IN PRESSURIZATION. THE CAPTAIN DEPRESSURIZED THE AIRCRAFT AND THE FLIGHT RETURNED WITHOUT FURTHER INCIDENT. DETERMINED TO BE OUTER PLY (NON-STRUCTURAL).WINDOW SPEED TAPED AND DETERMINED TO BE SAFE FOR FERRY. A/C FERRIED FOR REPAIRS. LOG PAGE 343040 AND 343041 EXPLAIN THE DEFECT AS DESCRIBED ABOVE, AND DESCRIBE THE RECTIFICATION DETAILS TO BE AS FOLLOWS: LT SIDE WINDOW REPLACED, AND TEMP CONTROLLER REPLACED. LT SIDE WINDOW P/N NP157902-13, S/N 00213H4459 TEMP CONTROLLER P/N SYLZ50970, S/N 724C REASON FOR FAILURE NOT YET DETERMINED. TEAR DOWN REPORTS TO FOLLOW. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040405000172004040500017NM 2004 4 5 CA040311002 120040208G6120697073002 PITCH CONTROL BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 1 PROP INOPERATIVE W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 CA (CAN) AIRCRAFT EXPERIENCED NR 1 PROPELLER TO FEATHER PITCH JUST AFTER TAKEOFF POWER WAS SET ON. PIREP RATING POWER SET, NR 1 ENG TORQUE INDICATION IN TURNED RED AND PROPELLER RPM DECREASED TO 200RPM. CONDITION LEVER MOVED TO START/FEATHER THEN BACK TO MAX BUT NO HELP. TAKE OFF REJECTED. NR 1 PROP REMAINED FEATHERED DURING TAXI TO GATE. PP FAULTS CHECKED, NO FAULTS. EMU DOWNLOAD, NO PP EXCEEDENCE RECORDED. ENGINE RUN-UP CHECKS, COULD NOT DUPLICATE. CLEANED FADEC, PEC AND PCU CONNECTORS. REPLACED NR 1 PCU FOR TROUBLESHOOTING. AIRCRAFT RTS. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040405000192004040500019EU 2004 4 5 CA040311005 120040310G28229868411404 PUMP PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL FUEL BOOST INOPERATIVE W K NONE J WARNING INDICATION CRCRUISE 1 CA (CAN) WHILE IN CRUISE FLIGHT THE PILOT NOTED A 2 LED DIFFERENCE BETWEEN LT AND RT FUEL INDICATORS. A FEW MINUTES LATER THE RT BOOST PUMP LT INDICATOR CAME ON. THE LT REMAIN ON FOR THE DURATION OF THE FLIGHT AND THE FUEL IMBALANCE REMAINED. ON THE GROUND THE FUEL BOOST PUMPS WERE TESTED MANUALLY. THE RT BOOST PUMP INDICATED NORMALLY BUT NO SOUND OF THE PUMP RUNNING WAS NOTED. THE FUEL PUMP WAS REPLACED AND THE SYSTEM TESTED SERVICEABLE. NO FURTHER ACTION WAS REQUIRED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040405000222004040500022NE 2004 4 5 CA040311008 220040308G72303040933 DISK PWA PT6 PT6A67B 52043NE COMPRESSOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ENGINE WAS STRIPPED AS PART OF ROUTINE SCHEDULED OVERHAUL. VISUAL EXAMINATION OF HPC DISK 3 SHOWS CRACK IN RIM OF DISK. FURTHER INVESTIGATION IS UNDERWAY. 4 T E26NE 20040405000232004040500023WP 2004 4 5 CA040311009 120040310G3220 STRUT DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE NLG DEFLATED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB OUT, L/G SELECTED UP, NOSE GEAR UNSAFE LIGHT ON WITH ASSOCIATED BUFFERING & NOISE. AIRCRAFT LANDED. MAINTENANCE FOUND NOSE OLEO DEFLATED. NOSE STRUT SERVICED, GEAR RETRACTION CARRIED OUT AND AIRCRAFT DISPATCHED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040405000272004040500027SO 2004 4 5 CA040312003 220040312G8530C8512F CYLINDER HEAD CESSNA120 120 2071402CE CONT C85 C8512F 17008SO MCAULY1B90 1B90CM GL ENGINE MISALIGNED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) ENGINE WAS SENT TO ENGINE SHOP FOR PROP STRIKE INSPECTION. UPON REINSTALLATION OF NR 1 CYLINDER, IT WAS DISCOVERED THAT THE BARREL AND HEAD WERE MISALIGNED BY APPROX. 5 DEGREES (UNIT WAS REPLACED). ENGINE SHOP ADVISES THIS IS A DEFECT OCCURING DURING ORIGINAL ASSEMBLY AT THE FACTORY AND FURTHER ADVISE THAT THIS IS THE SECOND ONE THEY HAVE FOUND. 1H71 3O3 O A768 E233 5 NP842 20040405000282004040500028NM 2004 4 5 CA040312004 120040311G3230 ACCESSORY UNIT BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE MLG FAULTY W L ABORTED APPROACH N FALSE WARNING LDLANDING 1 CA (CAN) DURING APPROACH AND LANDING GEAR HANDLE EXTENDED, IT WAS OBSERVED THAT THERE WAS AN UNSAFE LT LANDING GEAR LIGHT. IT WAS DECIDED THAT A MISSED APPROACH WOULD BE CARRIED OUT AND GO AROUND. EMERGENCY PROCEDURES WERE CARRIED OUT. TOWER WAS NOTIFIED OF THE PROBLEM AND EMERGENCY EQUIPMENT WAS MADE READY. IT WAS CONFIRMED THE GEAR WAS DOWN AND LOCKED AND THE LANDING WAS PERFORMED WITHOUT INCIDENT. MTCE INSPECTED THE AIRCRAFT AND THE LANDING GEAR ACCESSORY UNIT WAS SWAPPED WITH ANOTHER AIRCRAFT FOR TROUBLESHOOTING. IT WAS CONFIRMED THAT THE L/G ACCESSORY UNIT WAS AT FAULT AND A SERVICEABLE UNIT WAS INSTALLED, ADJUSTED AND FUNCTIONED SERVICEABLE IAW MM 32-09-121. NO FAULT DURING SUBSEQUENT FLIGHT. 2L73 4F4 F A3WE E2EA 20040406000022004040600002SO 2004 4 6 CA040315003 120040310G3245650X10600X6 TUBE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL NLG FLAT W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) A/C DEPARTED WITH 10KT WINDS AND BLOWING SNOW. A/C MADE ROUTINE TAKE OFF AND FLIGHT. AFTER LANDING, DURING TAXI ON RUNWAY, PILOT NOTICED A/C WAS PULLING TO ONE SIDE. PILOT TAXIED OFF RUNWAY AND PARKED. HE THEN VISUALLY INSPECTED LT MAIN TIRE AND SAW IT WAS FLAT. MAINT WAS DISPATCHED. MAINT REPLACED MAIN WHEEL AND INSTALLED NEW TUBE IN NOSE WHEEL. UPON INSP MAIN ASSY HAD A SHEARED VALVE STEM AND NOSE TUBE HAD A PIN HOLE IN IT. CAUSE OF SHEARED VALVE STEM IS BELIEVED TO HAVE BEEN FROZEN BRAKES. CAUSE OF PIN HOLE IN THE NOSE TUBE IS BELIEVED TO HAVE BEEN THE CHANGE IN TEMPERATURE BETWEEN AREA OF DEPARTURE AND AREA OF ARRIVAL CAUSING WHEEL PRESSURE TO HAVE GONE DOWN AND TUBE GETTING PINCHED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040406000032004040600003CE 2004 4 6 CA040315004 120040311G251005130391 LIGHTER CESSNA172 172N 2072434CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160CTM GL COCKPIT SHORTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) SMOKE/ FUMES DETECTED IN COCKPIT DURING CRUISE FLT. CREW SURVEYED ELECTRICAL SYSTEM CONTROLS AND FOUND CIGAR LIGHTER TO BE HOT. REMOVED LIGHTER FROM DASH AND RETURNED TO BASE WITH NO FURTHER COMPLICATIONS. INSPECTION REVEALED COILS OF LIGHTER SHORTED CAUSING FUMES. MAINTENANCE DISCONNECTED POWER WIRE TO LIGHTER ASSEMBLY IAW AD 78-08-03. NOTE: THIS AD DOES NOT APPLY TO THIS A/C SN BUT CERTAINLY WAS AFFECTED IN THIS INSTANCE, SHIPS AFFECTED BY THIS SN SHOULD BE REVISITED BY THE AD ISSUER. 1H71 3O3 ONT3A12 E274 5 NP910 20040413000162004041300016SO 2004 4 13 CA040315014 220040312G8530538684 BUSHING CIRRUSSR SR20 05628AJGL CONT O360 IO360ES SO HARTZLHCJ2Y BHCJ2YF1 GL ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 357431 (CAN) DURING OIL CHANGE, NOTED A .5000 LONG X .1250 INCH WIDE ROUND PIECE OF WHAT APPEARS TO BE BUSHING MATERIAL STUCK ON THE OIL DRAIN PLUG S MAGNET. FOUND THE NR 5 CYLINDER CONNECTING ROD S PISTON PIN BUSHING HAD A MISSING PIECE WHICH MATCHES THE PIECE FOUND ON THE OIL SUMP DRAIN PLUG. 1L71 3O3 ONTA00009CHE1CE 5 CP37EA 20040413000172004041300017EU 2004 4 13 CA040316004 120040218G243503600923 BEARING LUCAS PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL STARTER GEN WORN W O OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 CA 98103 (CAN) OPERATOR HEARD GRINDING NOISE DURING ENGINE START. NOISE WAS LOUDEST AT 10 PERCENT NG. ABORTED START AND INVESTIGATED. FOUND RADIAL PLAY AT FAN END OF ARMATURE. REPLACED STARTER GEN. SENT FAILED UNIT FOR REPAIRS. FOUND THE ADE BEARING HAD RADIAL PLAY, MEASURED .0045 INCH. INSPECTED FOR CORRECT ASSY AT PREV OVERHAUL, FOUND OK(BRG PART NR TOWARD ARMATURE). REMOVED BEARING. IT RATTLES, IS LOOSE, HAS CONSIDERABLE PLAY BOTH RADIALLY AND AXIALLY. IF LEFT IN SERVICE, THIS WOULD HAVE FAILED AND DESTROYED THE STARTER-GEN WITHIN AFEW HOURS. BEARINGS WERE REPLACED AND UNIT OVERHAULED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040413000182004041300018NM 2004 4 13 CA040316006 120040305G2897W5200100718 WIRE BOEING757 75728A 1384976NM RROYCERB211 RB211535E43754555NE PYLON CHAFED W O OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) RT SPAR FUEL SHUTOFF VALVE CB C1062 ACTIVATED DURING SHUTDOWN AFTER FLIGHT. CB WOULD NOT RESET, AND SPAR VALVE DISAGREEMENT LIGHT ALSO ILLUMINATED. TROUBLESHOOTING REVEALED WIRE HAD CHAFING DAMAGE AT BULKHEAD LOCATED AT STATION PP STN 208.40 VISIBLE BEHIND PANEL 313N5018. WIRE WAS REPAIRED IAW SWPM20-30-12. GIVEN THE PROBLEM IS IN THE FLAMMABLE AREA OF THE NACELLES, IT IS SUGGESTED THAT THE COMPLETE WIRE BUNDLE CONTAINING WIRE W5200-1007-18 BE INSPECTED REPAIRED AN D PROTECTED AS REQUIRED BETWEEN CONNECTION POINTS AT D92292J AT BRACKET AN2285 TO THE VALVE CONNECTOR D2022 AT STN PP STN 265.60AFTSN 7524:36 AFCSN 2509 2L72 4F4 FRTA2NM E12EU 20040413000212004041300021CE 2004 4 13 CA040317004 120040311G5520115610010125 SPLINE BEECH 100 B100 1152919CE GARRTTTPE331TPE3316252B 01514WP HARTZLHCB4T HCB4TN5 GL ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON INSPECTION FOUND THREE VISUAL CRACKS IN OB SECTION OF THE ELEVATOR TRAILING EDGE SPLINE, AS DESCRIBED IN OTHER SDR'S /SERVICE DIFFICULTY ADVISORY. 1L72 4T4 T A14CE E2WE 6 CP40EA 20040413000222004041300022EA 2004 4 13 CA040318001 220040309G72503032151 RING BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA ENGINE VANE BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE HOT END BORESCOPE INSPECTION, HOT END DISTRESS WAS NOTED. POWER SECTION REMOVED FROM AIRCRAFT, HOT END REMOVED. COMBUSTION CHAMBER CRACKED (MANY) ON NR 2 LOUVERED COOLING RING. SMALL DUCT BURNED/WARPED IN TWO AREAS (VANES). VANE RING ASSEMBLY, SEVERE BURNING ON 1 VANE AT TRAILING EDGE APPROXIMATELY .5 SQUARE INCH MISSING. ADJACENT VANE TRAILING EDGE CRACKED. VANE RIM BURNED AND CRACKED (3032151). HOUSING ASSEMBLY, CT SHROUD, ONE SEGMENT 3018503 WARPED INWARD CAUSING CT BLADE CONTACT. BLADE LEADING EDGE AT TIP ROUNDED. DISK/BLADE ASSEMBLY, CONTACT WITH WARPED BLADE SHROUD SEGMENT. 1G71 4U4 U H4SW E22EA 20040413000262004041300026WP 2004 4 13 CA040318005 120040315G56105887275505 WINDSHIELD DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) CENTER WINDSHIELD CRACKED IN FLIGHT AND SPARK, CREW DECIDED TO TURNBACK. THE CENTER WINDSHIELD WAS REPLACED IAW THE MM 56-10-01. THE WINDSHIELD ANTI-ICE AND ANTI-FOG SYSTEM WAS CHECKED SERVICEABLE IAW THE AMM. 2L72 4F4 FRTA6WE E9NE 20040413000272004041300027EU 2004 4 13 CA040319001 120040312G2731Z4244120000 CONTROL CABLE MORAVN242 Z242L 5920207EU LYC O360 AEIO360A1B6 41514EA MUHBR MTV MTV9* EU ELEVATOR TRIM FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A 100 HOUR INSPECTION, IT WAS NOTICED THAT THE AFT TRIM CABLE HAD A BROKEN STRAND FORWARD OF THE RT PULLEY NEAR THE TRIM DRUM. THROUGH EXPERIENCE IT WAS FOUND THAT CONDITION WOULD LEAD TO A TOTAL FAILURE OF THE CABLE IN THE NEAR FUTURE. THE CABLE WOULD FRAY SO MUCH THAT IT WOULD BIND UP IN THE DRUM ASSEMBLY RENDERING THE ELEVATOR TRIM SYSTEM INOPERABLE. THIS SYSTEM IS CLOSELY INSPECTED EVERY 100 HOUR INSPECTION DUE TO SIMILAR FAILURES OF THIS CABLE. 1L71 3O3 ONTA76EU 1E10 5 CP24NE 20040421000192004042100019GL 2004 4 21 CA040326001 320040323G6114 PROPELLER PIPER J3 J3L65 7100546SO CONT A65 A658F 17003SO MCAULY1B90 1B90CM GL CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CUSTOMER REQUESTED REPITCH ONLY. ADVISED CUSTOMER TO OVERHAUL DUE TO VISUAL CORROSION ON PROP CORROSION REMOVED IAW MANUAL 730720. 1H71 3O3 O A698 E205 5 NP842 20040422001242004042200124NE 2004 4 22 2004FA0000309 220040401G7250557501 TURBINE WHEEL PWA JT8 JT8D7B 52053NE ENGINE WORN B ZAVRO OTHER O OTHER NRNOT REPORTED 1 WP07 7381 4723 649049 T-1 DISC RUB ON INNER TURBINE NOZZLE CASE SEAL. SEAL COMPLETELY RUBBED OFF. 4 F E2EA 20040422001252004042200125CE 2004 4 22 2004FA0000296 120040325G55231695240761 ROD BEECH 23 C23 1151242CE LYC O360 O360* 41514EA TRIM TAB CORRODED D O OTHER O OTHER NRNOT REPORTED 1 GL0924652 M1430 DURING ANNUAL INSPECTION THE TRIM TAB ROD WAS FOUND TO HAVE RUST ON IT. WHILE CLEANING THE PART, A HOLE WAS FOUND AT THE MID POINT OF THE ROD AND MOISTURE(WATER) WAS FOUND INSIDE. IT APPEARS THIS ROD IS RUSTING FORM THE INSIDE OUT. THIS UNIT SHOULD BE TAKEN APART, INSPECTED, CLEANED, PAINTED INSIDE AND OUT AND REASSEMBLED TO ASURE THE AIRCRAFT HAS A SERVICEABLE PART. (GL092004040017) 1L71 3O3 O A1CE E286 20040330001802004033000180CE 2004 3 30 CA040121003 120040119G275266000863 ACTUATOR LEAR 35 35LEAR 5170600CE GARRTTTFE731TFE73122B 01518WP TE FLAP CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) DURING PRE-FLIGHT INSPECTION FLUID LOSS WAS NOTED. F