20050420001082005042000108NM 2005 4 20 CA050125007 120050121G5330 SKIN BOEING737 737296 1384486NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AN OUTER FUSELAGE CRACK WAS FOUND DURING A PHASE EIGHT CHECK AT STRINGER 16L, STATION 727+14.5 APPROXIMATELY 1.5 INCHES IN LENGTH. FUSELAGE CRACK REPAIRED IAW REO-L00889 REV 1R TIMES - 59761:05 HOURS AND 54470 CYCLES 2L72 4F4 FRTA16WE E2EA 20050420001122005042000112SW 2005 4 20 CA050125017 120050125G6710212001181001 COLLECTIVE STICK BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA THROTTLE GRIPS BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 28648 (CAN) THE ENGINEER WAS ABOUT TO GREASE THE SWASHPLATE. TO GREASE SOME OF THE ZERK FITTINGS IT IS EASIER TO LIFT THE COLLECTIVE CONTROL STICK UP. THE ENGINEER WAS MOVING THE COLLECTIVE CONTROL STICK UP WHEN THE RIDGED TUBE BENT AND BROKE IN TWO. THE BREAKAGE OCCURED BETWEEN THE TWO THROTTLE GRIPS WHERE THERE IS A SLOT IN THE TUBE FOR THE THROTTLE CONTROL. 1G71 4U4 U H4SW E22EA 20050427000452005042700045SO 2005 4 27 2005FA0000354 220050224G74146320 MAGNETO CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO LEFT FAILED B AIHRK NONE O OTHER ININSP/MAINT 1 GL11468TW 414A0071 516571 LT MAGNETO, PN 6320, SN 02091734 FAILED AFTER 54 HOURS TT IN SERVICE. INVESTIGARTION FOUND BROKEN CONTACT ASSY. VISUAL INSPECTION OF BOTH LT AND RT CONTACT ASSY IF SN IS WITHIN 100 HOUR OF FAILED PART. NOTE; RT MAGNETO SAME ENGINE, PN 6320, SN 02091744 FAILED AT 58.0 HOURS TT IN SERVICE. FROM SAME PROBLEM. (GL11200508227) (K) 1L72 3O3 O A7CE E8CE 20050427000442005042700044SO 2005 4 27 2005FA0000352 120050307G3210 BOLT PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA RT TORQUE LINK MISSING G K NONE O OTHER ININSP/MAINT 1 SO133542K5664 2823617 EXAMINATION OF THE AC REVEALED THAT THE LOWER STRUT, BRAKE AND TIRE ASSY WERE MISSING FROM THE RT MAIN GEAR. UPPER MAIN GEAR TORQUE LINK WAS ATTACHED TO THE UPPER STRUT HOUSING. BRAKE LINE WAS BROKEN OFF AT THE BRAKE CYLINDER FITTING AND LOWER STRUT ASSY WAS MISSING. IT APPEARS THAT TORQUE LINK BOLT FAILED ALLOWING LOWER STRUT ASSY TO EXTEND OUT OF THE STRUT HOUSING AND FALL FREE OF THE AC. UNABLE TO CONFIRM BASED ON AVAILABLE MAINTENANCE RECORES, BUT AC APPEARS TO HAVE GREASE BOLT REPLACMENT KIT (PN 760-910) INSTALLED. REPETITIVE NDT INSPECTION BE PERFORMED ON LANDING GEAR TORQUE LINK BOLT. (SO13200503296) (K) 1L71 3O3 O 2A13 E274 20050503000012005050300001CE 2005 5 3 CA050317006 120050311G3240195183 SHUTTLE VALVE BFGOODRICH CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE RT BRAKE ASSY UNSERVICEABLE W O OTHER P NO WARNING INDICATION TXTAXI/GRND HDL 1 CA 2792 (CAN) UPON ROUTINE BRAKING DURING TAXI FROM RAMP TO RUNWAY, AC VEERED TO THE LT ON TAXIWAY. HARD PEDDLE(S) WHERE NOTED DURING THE ATTEMPT TO STOP. IN ORDER TO ENSURE DIRECTIONAL CONTROL AND BRING THE AC TO A COMPLETE STOP REVERSE THRUST WAS UTILIZED. THE AIRCRAFT WAS TOWED TO THE HANGAR FACILITY. INSPECTED BRAKE SYSTEM INCLUDING TRANSDUCERS AND BRAKE ASSEMBLIES. ATTEMPTED TO BLEED BRAKES AND FOUND EXTREMELY SMALL AMOUNTS OF FLUID COMING FROM RT BRAKE BLEED BLOCK (HARD RT PEDAL EVEN WHEN POWER BRAKE SYSTEM SHUT OFF). REMOVED RT BRAKE SHUTTLE VALVE ASSEMBLY P/N 195-183 AND INSTALLED SERVICEABLE UNIT. BRAKE SYSTEM BLED. GROUND AND TAXI CHECKED SERVICEABLE. 2L72 4F4 FRTA22CE E25EA 20050503000022005050300002GL 2005 5 3 CA050317005 320050309G6114 HUB CESSNA185 A185E 2072818CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C58 GL PROPELLER CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 770963 (CAN) PROPELLER DISMANTLED FOR 10 YEAR O/H. 1-S90AT-4 BLADE, 1 C58 HUB AND 2-A3054 FERRULES U/S DUE TO SEVERE CORROSION. PROPELLER HAS EXCEEDED THE MANUFACTURERS RECOMENDED CALENDAR TBO BY 4 YRS. 1H71 3O3 O 3A24 E5CE 5 CP3EA 20050503000042005050300004NM 2005 5 3 CA050317002 120050315G3230485023 RELEASE CABLE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU MLG CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A MLG AREA INSPECTION, EMERGENCY RELEASE CABLE P/N 48502-3 INSTALLED IN THE LT NACELLE WAS FOUND CHAFED. INSPECTION OF THE CABLE IN THE RT NACELLE WAS COMPLETED WITHOUT ANY FINDINGS. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050503000052005050300005CE 2005 5 3 CA050316006 120050315G3244178K235 TIRE GOODYEAR LEAR 35 35LEAR 5170600CE GARRTTTFE731TFE73122B 01518WP SIDEWALL CUT W K NONE O OTHER ININSP/MAINT 1 CA SEP871568 (CAN) LEAKS FOUND ON TIRE ON SIDEWALL. UNUSUAL CUT IN THE SHAPE OF AN (X). REMOVED AND REPLACED M/W ASSY. 2L72 4F4 F A10CE E6WE 20050503000112005050300011NE 2005 5 3 CA050315005 220050130G73100301007220 LINE SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE FUEL SYS CRACKED W K NONE KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) THE AIRCRAFT SHOWED SIGNS OF IRREGULAR STARTS. WHILE WATCHING A START, THE ENGINEER NOTICED WHISPS OF SMOKE COMING FROM THE RT SIDE OF THE ENGINE. TUBE WAS REMOVED AND INSPECTED AND FOUND CRACK ON FLARED END UNDER FERRULE. 1G71 3U3 UNCH9EU E19EU 20050503000132005050300013NE 2005 5 3 CA050315003 220050309G7250304574101 BLADE PWA PT6 PT6A114A 52043NE ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 CA PC0592 (CAN) AFTER ENGINE SPLIT, ENGINE SUFFERED A CT BLADE FAILURE. 1 CT BLADE HAD LOST APPROX HALF OF ITS AIRFOIL, & OTHER BLADES HAD MATERIAL MISSING MOSTLY IN THE AIRFOIL UPPER PORTION APPARENTLY AS A RESULT OF IMPACT DAMAGE. MATERIAL FROM CT BLADES ALSO DAMAGED HOT SECTION DOWNSTREAM OF CT VANE. GG CASE DIFFUSER DUCTS HAD UNUSUAL & UNIFORM CRACKING DAMAGE. FRACTURE OF BLADE AT MID SPAN IS SUGGESTIVE OF A FATIGUE FAILURE DUE TO BLADE VIBRATION. CT BLADES WERE INSPECTED AT THE LAST O/H IAW O/H MANUAL. 12 BLADES FOUND TO HAVE UNACCEPTABLE COATING LOSS & REPLACED NEW & BALANCE OF SET INSPECTED AS SERVICEABLE & WERE RE-INSTALLED. THE CT BLADE FAILURE INVESTIGATION. 3 T E4EA 20050503000142005050300014EU 2005 5 3 CA050315002 220050314G7310 FITTING BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU FUEL LINE BROKEN W C ABORTED TAKEOFF KJ FLUID LOSS WARNING INDICATION TOTAKEOFF 1 CA (CAN) AIRCRAFT PROCEEDED TO TAKEOFF WET POWER. WET TORQUE WAS NOT ACHIEVED ON RT ENGINE AND TAKEOFF WAS ABORTED. UPON INVESTIGATION, MAINTENANCE FOUND THE FLEXIBLE FUEL FEED LINE TO THE NR5 COMBUSTION CAN BROKEN AT THE ONE END (STEEL PORTION OF LINE) FUEL LINE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 3T4 T A24EU A196 6 CP899 20050503000152005050300015CE 2005 5 3 CA050314003 120050307G2820652635537 LINE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE FUEL BOOST WORN W K NONE O OTHER ININSP/MAINT 1 CA 11253 (CAN) DURING THE ACCOMPLISHMENT OF MFG SB 550-28-14 WING FUEL BOOST PUMP WIRING IMPROVEMENT, LINE ASSEMBLY P/N 6526355-37 FOUND DAMAGED, WHICH THE ELECTRIC FUEL PUMP HARNESS CUT THROUGH THE WALL OF TUBING. NO DAMAGED FOUND ON ELECTRICAL HARNESS. 1L72 4F4 F A22CE E1NE 20050503000162005050300016NM 2005 5 3 CA050314001 120050311G7170DSC1975 LINE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120 NE HAMSTD14SF 14SF7 NE ENGINE DRAIN BLOCKED W EF ENGINE SHUTDOWN ACTIVATE FIRE EXT. JA WARNING INDICATION FLAME/FIRE TXTAXI/GRND HDL 1 CA (CAN) DURING A MAINTENANCE GROUND RUN, THE RT ENGINE DEVELOPED A TAIL PIPE FIRE AFTER THE ENGINE START WAS INITIATED. THIS WAS CONFIRMED BOTH BY FIRE WARNING IN THE COCKPIT AND BY GROUND PERSONNEL. THE ENGINE WAS SHUT DOWN AND THE ENGINE FIRE BOTTLES WERE ACTIVATED. INVESTIGATION SHOWED THAT THE GAS GENERATOR CASE DRAIN FLEXIBLE FLUID LINE WAS PLUGGED WITH DEBRIS. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050503000172005050300017EA 2005 5 3 CA050312004 120050310G5610NP1393211 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA 20183 (CAN) LT WINDSHIELD CRACKED DURING LEVEL FLIGHT. DIVERTED FLIGHT. LT WINDSHIELD WAS REPLACED IAW AMM. 2L72 4F4 FRTA21EA E15NE 20050503000212005050300021EA 2005 5 3 CA050311002 220050123G8530 ENGINE BNORM BN2 BN2A26 1520226EU LYC O540 O540E4C5 41532EA HARTZLHCC2Y HCC2YK2 GL FAILED W O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION LDLANDING 1 CA L1152240 (CAN) ENG FOUND TO HAVE DROP IN OIL PRESS. INSP, PUNCTURE HOLE WAS FOUND IN TOP OF RT CRANKCASE HALF. METAL WAS FOUND IN OIL SCREEN. CYL 2, 4, AND 6 WERE REMOVED FOR INSP. 4 OF 12 LIFTER BODY CONTACT FACES WERE BROKEN. BROKEN MATERIAL FROM LIFTER BODIES INTRODUCED TO ENGINE, RESULTING, COMPLETE DESTRUCTION OF ENG INTERNAL. EXACT CAUSE OF LIFTER BODY CONTACT FACES BREAKING COULD NOT BE DETERMINED, SUSPECTED THAT EXCESS CORROSION ON LIFTER FACE COULD HAVE BEEN TO BLAME. DETERMINED BY RETRIEVAL OF BROKEN PIECES IN ENGINES OIL SUMP AND OIL SCREEN AND EXAMINING THEM. CORROSION WAS EVIDENT ON 2 OF LIFTER FACES. ENG DOES NOT REACH HIGH ENOUGH OPERATING TEMP TO BURN OFF MOISTURE CREATED BY ENG OPERATION. 1H72 3O3 O A17EU E295 5 CP920 20050503000232005050300023EA 2005 5 3 CA050310005 120050113G2824T99B38601 EJECTOR CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE FUEL SYSTEM STUCK W O OTHER J WARNING INDICATION CLCLIMB 1 CA (CAN) WHILE PARKED IN BREST, THE CREW NOTICED AND UNCOMMAND FUEL TRANSFERED INTO THE CENTER TANK DURING THE NIGHT. THE NEXT REVENUE FLIGHT WAS CANCELED FOR TROUBLESHOOTING. TROUBLESHOOTING (JAN. 13, 2005) REVEALED A LEAK ON THE LT TRANSFER EJECTOR PUMP. THE UNIT WAS REPLACED. IT WAS NOTED THAT THE TRANSFER EJECTOR CHECK VALVE WAS STUCK (OPEN) THE FUEL QUANTITY GAUGE COMPUTER (FQGC) WAS ASLO REPLACED BY PRECAUTIONARY MEASURES. 2L72 4F4 FRTA21EA EOOO63EN 20050503000252005050300025EU 2005 5 3 CA050310002 120050309G2750527521214 DRIVE ASSY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAPS BENT W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT IB FLAP DRIVE ARM BENT AND CRACKED LENGTHWISE. CAUSE OF FAULT IS FLAP INTERCONNECT CABLE FREEZING AND WHEN THE FLAPS ARE EXTENDED IT BENT AND CRACKED DRIVE ARM. NOTE FROM QA, SYSTEM WAS STILL FUNCTIONING PROPERLY AT THE TIME OF FINDING THE CRACKED ARM. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20050503000262005050300026EA 2005 5 3 CA050309012 120050306G7810311178001 DUCT DHAV DHC3 DHC3 2800202EA PWA PT6 PT6A34 52043EA HARTZLHCB3T HCB3TN3 GL EXHAUST PORT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA RB0138 (CAN) AT EXHAUST PORT, THE FLANGE THAT PROTRUDES OUT OF THE CASE TO PREVENT EXHAUST GASES FROM EXITING THROUGH THE FLANGE WHERE THE EXHAUST STACK BOLTS ON, WAS CRACKED ABOUT 320 DEGREES AROUND THE CIRCUMFERENCE. THE OPPOSITE PORT WAS DETERMINED TO BE CRACKED TO A LESSOR AMOUNT. THE EXHAUST FLANGE ON THE EXHAUST DUCT ITSELF WAS SERVICEABLE. 1H71 3R4 T A815 E4EA 6 CP15EA 20050503000272005050300027SW 2005 5 3 CA050309011 120050307G62402060763731 TACH GENERATOR BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL MAIN ROTOR WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE WORN SPLINES WERE FOUND. NOTE: THESE SPLINES DRIVE THE HYDRAULIC PUMP. TACH GENERATOR WAS REMOVED AND SENT FOR OVERHAUL. PART WAS RETURNED 2 MONTHS LATER WITH NEW PAINT AND THE SAME WORN OUT SPLINES. OLD GREASE WAS STILL IN THE WORN SPLINES. 1G71 3U3 U H2SW E1GL 20050503000282005050300028EA 2005 5 3 CA050309009 120050304G5610601R3303317 WINDSCREEN CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT BROKEN W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) A/C , WAS ENROUTE AT FL 360 WHEN THE CREW ADVISED ATC THAT THEIR WINDSCREEN SHATTERED AND REQUESTED DESCENT. A SHORT TIME LATER, THE CREW REQUESTED DIVERSION . THE FLIGHT LANDED SAFELY AT 2313Z. NO EMERGENCY WAS DECLARED BUT AFF RESPONDED. A/C WAS FERRIED TO HAVE WINDSCREEN REPLACED. 2L72 4F4 FRTA21EA E15NE 20050503000342005050300034SW 2005 5 3 CA050309002 120050228G6520406340105101 SEAL BELL BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL T/R GEARBOX LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA AFS2825 (CAN) T/R GEARBOX OUTPUT SEAL LEAKING, SENT FOR SEAL REPLACEMENT. THE SPRING INSIDE THE SEAL WAS AT THE SEAL LIP AND MARKED THE SLEEVE . 1G71 3U3 U H2SW E1GL 20050503000352005050300035EA 2005 5 3 CA050308020 120050304G5610NP1393226 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER APAPPROACH 1 CA (CAN) ON APPROACH THE CO-PILOT'S WINDOW CRACKED. WINDOW REPLACED IAW AMM AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20050503000372005050300037SW 2005 5 3 CA050308018 120050228G2910278100322040 LINE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP MCAULY4HFR344HFR34C652 NE HYD SYSTEM CHAFED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) LINE CHAFED WHERE LINE COMES THROGH THE COOLING TURBINE MODULATING VALVE. NEW LINE FABRICATED AND INSTALLED WITH ADDITIONAL CLAMPS TO PREVENT FUTURE CHAFING. W.S. 39.1 IPC FIG 29-10-50 FIG 2 ITEM 2 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20050503000392005050300039EU 2005 5 3 CA050308014 120050125G6520350A33020005 GEARBOX SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE TAIL ROTOR LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) UPON A PREFLIGHT IT WAS NOTED THAT ALL OIL HAD EXITED THE TAIL ROTOR GEARBOX. THE INPUT SEAL WAS THE AREA WHERE THE OIL EXITED. THE GEARBOX WAS REPLACED AS A PRECAUTION. 1G71 3U3 U H9EU E19EU 20050503000402005050300040EU 2005 5 3 CA050308012 120050224G57541372030B57 BRACKET BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP MCAULY4HFR344HFR34C652 NE FLP/SLT SUPPORT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 14051 (CAN) FLAP SLAT BRACKET FOUND CRACKED DURING MAINTENANCE, CHECK THE CRACKS IN THOSE 3 BRACKETS ARE 1 INCH LONG LOCATED IN THE FORWARD RADIUS OF THE BENDS. 2L72 4T4 TRTBA15CAA E4WE 6 C3PNE 20050503000412005050300041NE 2005 5 3 CA050308011 220050304G7200 ENGINE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE NR 1 FAILED W C ABORTED TAKEOFF RJ PARTIAL RPM/PWR LOSS WARNING INDICATION TOTAKEOFF 1 CA 718043 (CAN) DURING TAKE-OFF THE CREW HEARD A LOUD BANG FOLLOWED BY A DROP IN N1 FROM 80 PERCENT TO 19 PERCENT ON THE NR 1 ENGINE. AT 70 KNOTS FORWARD SPEED A REJECTED TAKE-OFF WAS INITIATED WITHOUT INCIDENT. ON RETURN TO THE GATE, OIL PRESSURE DROPPED TO ZERO. NR 1 ENGINE WAS REPLACED IAW TASK CARD 80UN-014 AND ENGINE RUN CARRIED OUT SERVICEABLE IAW TASK CARD 80EC-001AR1. AIRCRAFT WAS DISPATCHED AND NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. ENGINE WILL BE SHIPPED TO THE O/H FACILITY FOR TEARDOWN AND REPORT ISSUED. 2L72 4F4 FRTA6WE E9NE 20050503000422005050300042WP 2005 5 3 CA050308010 220050304G7310B99193 SHAFT SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCE4N HCE4N3 NE ENGINE LOOSE W EA ENGINE SHUTDOWN UNSCHED LANDING WE INADEQUATE Q C VIBRATION/BUFFET CLCLIMB 1 CA P54093 (CAN) UPON CLIMB OUT, RT ENGINE BEGAN TO SURGE WITH NO RESPONSE FROM PWR LEVER INPUTS. FLIGHT CREW ELECTED TO SHUTDOWN ENG AS A PRECAUTION AND CARRIED OUT AN UNEVENTFUL LANDING. UPON INSP OF ENG, IT WAS FOUND THAT ENG CNTRL CENTER SHAFT OR CHRISTMAS TREE DISCONNECTED FROM PROP GOV. IT WAS DETERMINED THAT SET SCREW WHICH SECURES ARM BETWEEN CENTER SHAFT AND PROP GOV WAS BACKED OUT WHICH ALLOWED ARM TO DISCONNECT FROM SHAFT. INSP OF SET SCREW REVEALED A FLAT SPOT ON IT WHERE SHAFT HAD BEEN WEARING INTO SCREW DUE TO FACT IT WAS LOOSE. LINKAGES WERE RE-INSTALLED AND ENG RUNUP CARRIED OUT, SERVICEABLE. FLIGHT TO BASE REVEALED A FUEL LIMITED CONDITION WITH ENG, FCU WAS REPLACED AS A PRECAUTION. 2L72 4T4 TRTA8SW E4WE 5 CP10NE 20050503000432005050300043NM 2005 5 3 CA050308008 120050305G1430BACC30BK5 COLLAR DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE RT WING FASTENERCRACKED W K NONE O OTHER ININSP/MAINT 1 CA 34826 (CAN) 8 COLLARS WERE FOUND CRACKED ON THE RT WING FORWARD SPAR AT EXTENSION SPLICE YW 490.00, ANOTHER 2 OF THE SAME COLLARS WERE ALSO CRACKED ON THE SAME LOCATION ON THE AFT SIDE. INSPECTION OF THE LT WING IN THE SAME YW 490.00 LOCATION REVEALED FURTHER TWO FASTERNERS WITH THE SAME P/N COLLARS CRACKED ON THE FRONT SPAR AND FOUR OTHER CRACKED ON THE AFT SIDE. ALL OF THE ABOVE DEFECTS WERE NOTED DURING A C-CHECK INSPECTION. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050425000492005042500049EA 2005 4 25 CA050110002 120050106G321017002110 LANDING GEAR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE RIGHT COLLAPSED W O OTHER D INFLIGHT SEPARATION LDLANDING 1 CA 12490 (CAN) FOLLOWING A REPOSITIONING FLIGHT (FERRY FLIGHT WITH NO PAX), THE RT MLG COLLAPSED ON LANDING. NOBODY WAS INJURED DURING THE INCIDENT. THE INVESTIGATION IS STILL IN PROGRESS 2L72 4F4 FRTA21EA E15NE 20050425000532005042500053EA 2005 4 25 CA050111005 220050109G7323210631 GOVERNOR BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL OVERSPEED FAILED W E ENGINE SHUTDOWN E VIBRATION/BUFFET APAPPROACH 1 CA (CAN) ON APPROACH, WHEN THE CREW TRIED TO THROTTLE BACK, THE LT ENGINE WOULD NOT GO BELOW 1000 LB. OF TORQUE. THE CREW MOVED THE THROTTLE FORE AND AFT SEVERAL TIMES BUT NO CHANGE. THE CREW DECLARED AN EMERGENCY AND SHUT DOWN THE LT ENGINE ON FINAL APPROACH. UPON INVESTIGATION BY MAINTENANCE IT WAS FOUND THAT THE OVERSPEED GOVERNOR HAD FAILED INTERNALLY. THE OVERSPEED GOVERNOR WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 5 CSTC 20050425000552005042500055CE 2005 4 25 CA050112002 120050110G56105042006936 WINDSHIELD BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL COCKPIT CRACKED W B EMER. DESCENT O OTHER CRCRUISE 1 CA (CAN) IN CRUISE PILOT HEARD LOUD BANG, NOTICED CO-PILOTS INNER PANE SHATTERED. STARTED DECENT TO 130000 ASL, BROUGHT CABIN PRESSURE DOWN TO 2 PSI. LANDED AT DESIGNATION. 1L72 3T4 T A14CE E4EA 5 CSTC 20050425000892005042500089NE 2005 4 25 CA050127003 220050117G7261310047001 ELBOW BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE ENG OIL LINE FRACTURED W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION DEDESCENT 1 CA 12780 PS0218 (CAN) IMMEDIATELY AFTER STARING DESCENT, CREW NOTED OIL PRESSURE DROPPING FOLLOWED BY WARNING ANNUCIATORS ON LT POSITION. ENGINE CONTINUED TO LOSE OIL PRESSURE AND ENGINE WAS SHUTDOWN AND FEATHERED. MAINT FOUND OIL BOSS (ELBOW) FOR REDUCTION GEAR CASE RETURN OIL LINE HAD FRACTURED THROUGH 1 OF 2 ATTACHING BOLT HOLES AND HEAD OF 1 BOLT WAS DETACHED FROM STUD PORTION. HEAD WAS RETAINED BY SAFETY WIRE. IT WAS UNCERTAIN AS TO WHY THE BOSS HAD FRACTURED SO ENGINE WAS REPLACED FOR PRECAUTIONARY REASONS. ENGINE HAS SINCE BEEN CHECKED AND IS IN NORMAL OPERATING CONDITION LEADING TO DETERMINATION THAT BOSS AND/OR ATTACHING BOLTS SIMPLY FAILED AND WAS NOT CAUSED BY OIL PRESSURE SPIKES OR. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20050425000932005042500093SO 2005 4 25 CA050130001 120050125G3220AN17413 BOLT PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE3Y HCE3YR2A GL NLG FAILED W O OTHER D INFLIGHT SEPARATION LDLANDING 1 CA (CAN) WHEN THE NOSE WAS LOWERED DURING LANDING, A SEVERE VIBRATION DEVELOPED WHEN THE NOSE TIRE TOUCHED THE RUNWAY. STEERING WAS NOT AVAILABLE BUT DIRECTIONAL CONTROL WAS MAINTAINED WITH RUDDER. AS THE AIRCRAFT SLOWED, THE VIBRATION EASED UP. TURNING TO EXIT THE RUNWAY WAS ACCOMPLISHED BY DIFFERENTIAL ENGINE POWER. WHEN THE AIRCRAFT WAS SHUTDOWN IT WAS DISCOVERED THE BOLT HOLDING THE UPPER AND LOWER NOSE SCISSOR LINKS TOGETHER WAS MISSING AND THE LINKS WERE OPEN. SINCE THE PARTS WERE NOT FOUND IT COULD NOT BE DETERMINED WHICH PART FAILED, THE BOLT, THE NUT OR THE LOCKING PIN. DAMAGE WAS LIMITED TO THE TIRE. NEW HARDWARE WAS INSTALLED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20050425001092005042500109EA 2005 4 25 CA050207001 120050205G2820C6PF10761 TUBE DHAV DHC6 DHC6100 2802610EA PWA PT6 PT6A20 52043EA HARTZLHCB3T HCB3TN3 GL FUEL SYSTEM CORRODED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) INVESTIGATION OF A (FUEL SMELL IN THE CABIN) AND A MINOR EXTERNAL FUEL LEAK REVEALED THAT WELDED FUEL TUBE ASSY BETWEEN FUEL TANK AND FLEX HOSE TO THE WING STRUT WAS LEAKING. REMOVAL OF ADEL CLAMP REVEALED CORROSION PITS UNDERNEATH WITH ASSOCIATED FUEL SEEPAGE. INVESTIGATION INTO OPPOSITE SIDE TUBE REVEALED SIMILAR CONDITION, BUT CORROSION WAS NOT ADVANCED ENOUGH TO CAUSE A LEAK. BOTH TUBE ASSYS WERE REPLACED AND AC RETURNED TO SERVICE. TIMES AND CYCLES ARE NOT MAINTAINED ON THESE ITEMS. AC HAS FLOWN 3 YEARS SINCE A COMPLETE CORROSION CHECK, AND OPERATES EXCLUSIVELY IN A CORROSIVE ENVIRONMENT. 1H72 3T3 TRTA9EA E4EA 6 CP15EA 20050425001172005042500117EA 2005 4 25 CA050209002 120050105G5310CC670341757 CROSSBEAM CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ONGOING C-CHECK OF A/C 5 CRACKS AND SLIGHT CORROSION WERE FOUND ON FS 280.0 CROSSBEAM P/N CC670-34175-7 AND ANGLE P/N CC670-33292-9 AT LBL 9.0 AND RBL 9.0. NOTE: REPAIR TO BE PERFORMED WITH ACOMBINATION OF GEN REOS 670-53-11-045, -046, -047, -052 AND IS MODSUM IS670531100026. 2L72 4F4 FRTA21EA EOOO63EN 20050425001202005042500120NE 2005 4 25 CA050209005 220050123G7250 TURBINE BLADES DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE NR 2 ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA AW0091 (CAN) CREW NOTED THAT THEY HAD NO NP INDICATION AFTER START OF THE NR 2 ENGINE, AND OBSERVED THAT THERE WAS NO PROPELLER ROTATION THE ENGINE WAS THEN SHUTDOWN. CREW REPORTED ALL OTHER ENGINE INDICATIONS WERE NORMAL DURING THE START. INITIAL INVESTIGATION NOTED THAT THE PROPELLER WAS UNABLE TO BE TURNED BY HAND AND THE AIRCRAFT WAS REMOVED FROM SERVICE FOR FURTHER INVESTIGATION. BOROSCOPE INSPECTION WAS CARRIED OUT THROUGH T6 PROBE AND THERE APPEARED TO BE NO TIP CLEARANCE ON THE 1ST STAGE POWER TURBINE WITH BLADE SHROUD DAMAGE EVIDENT. THERE WAS ALSO MINOR IMPACT DAMAGE NOTED TO THE 2ND STAGE NOZZLE AND POWER TURBINE. ENGINE WAS THEN REMOVED FROM THE AIRCRAFT. MFG INVESTIGATING ISSUE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050425001262005042500126EA 2005 4 25 CA050211003 220050113G7230 ENGINE PWA PT6 PT6A50 52043EA FAILED W K NONE O OTHER ININSP/MAINT 1 CA 86464 (CAN) DESTRUCTION OF COMPRESSOR OF ENGINE RESULT OF TIE ROD BOLT STRETCH. LACK OF TORQUE REMAINING ON HALF OF TIE RODS INDICATES THAT 3 LOOSE TIE RODS STRETCHED & CAUSED COMPRESSOR TO LOSE AXIS OF ROTATION & ALLOWED COMPRESSOR TO RUB HEAVILY & CAUSE MATERIAL TO BE LIBERATED. APPEARS CT BLADE DAMAGE IS SECONDARY DAMAGED CAUSED BY LIBERATED MATERIAL FROM COMPRESSOR. DAMAGE ON CT BLADES MAY ALSO BEEN INCREASED BY HEAVY TIP RUB OF THE CT DISK AFTER COMPRESSOR LOST AXIS & CAUSED SIGNIFICANT VIBRATION ON ROTATING ASSY. DAMAGE ON POWER SECTION A RESULT OF MATERIAL LOST FROM CT BLADES & COMPRESSOR. COMPLETE OVERHAUL OF ENGINE. ALL TIE RODS & NR 1 & 2 BEARINGS WILL BE SCRAPPED REGARDLESS OF THEIR CONDITION. 4 T E4EA 20050425001272005042500127NM 2005 4 25 CA050211004 120050126G2910DSC252B40124 HOSE DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE HYD SYSTEM RUPTURED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER TAKE-OFF AND ON GEAR UP SELECTION, THE NOSE GEAR FAILED TO RETRACT AND IT WAS OBSERVED BY THE CREW THAT THE NR 2 HYDRAULIC SYSTEM WAS ALMOST DEPLETED OF OIL. AIRCRAFT WAS MAINTAINED VISUALLY IN THE CIRCUIT WHILE ALL RELEVANT QRH PROCEDURES WERE COMPLETED. FOLLOWING COMPLETION OF DRILLS A NORMAL APPROACH AND LANDING WAS CARRIED OUT. ENGINEERING INVESTIGATION REVEALED A RUPTURE FAILURE OF A FLEXIBLE HOSE IN THE NLG RETRACTION HYDRAULIC SYSTEM. THE HOSE WAS REPLACED AND FOLLOWING SATISFACTORY COMPLETION OF MM REQUIREMENTS THE AIRCRAFT WAS RELEASED TO SERVICE WITHOUT FURTHER INCIDENT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050425001372005042500137EU 2005 4 25 CA050213008 120050208G731210839 FUEL HEATER FOKKERF27 F27FOKKER* 4990614EU PWA PWA120PW125B NE ENGINE LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA 10266 (CAN) FUEL WAS FOUND LEAKING FROM THE FUEL HEATER DURING MAINTENANCE OPERATIONS. THE LEAK WAS FOUND TO BE ASSOCIATED WITH CORROSION PITTING. 2H72 4T4 T A817 E20NE 20050425001392005042500139EA 2005 4 25 CA050214002 220050124G7200 ENGINE PWA PT6T PT6T3 52045EA INOPERATIVE W E ENGINE SHUTDOWN J WARNING INDICATION TXTAXI/GRND HDL 1 CA TH0196 (CAN) FOLLOWING FIRST START OF THE DAY THE ENGINE EXPERIENCED AN UNCOMMANDED N2 ACCELERATION. THE PILOT SHUT THE ENGINE DOWN. MFG WILL INVESTIGATE THE EVENT AND WILL SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE DETERMINED. 4 U E22EA 20050425001422005042500142NM 2005 4 25 CA050214006 120050214G2742PNB18834 BALLSCREW BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE STAB TRIM ACTUATCORRODED W K NONE O OTHER ININSP/MAINT 1 CA 0247 (CAN) FAULT: WHILE CARRYING OUT AN INSPECTION. FOUND RUSTY COLORED LUBRICANT AND REDDISH STAINING ON THE STAB. JACKSCREW GIMBAL. A PURGING OF THE LUBRICANT FROM THE GIMBAL ASSY WAS CARRIED OUT. THE RUST COLORING WAS CONFIRMED TO BE DUE TO IRON IN THE GREASE. FURTHER INSP ALSO REVEALED DAMAGE TO THE THREADS OF THE BALLSCREW. 2L72 4F4 FRTA1NM E3NE 20050425001562005042500156EU 2005 4 25 CA050216009 120050216G53021400200201 SKIN SNIAS 350 AS350BA 8680817EU LYC LTS101LTS101600A3 41560NE TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK FOUND ON VERTICAL UPPER FIN. 1G71 3U3 UNCH9EU E5NE 20050503000442005050300044CE 2005 5 3 CA050308007 120050113G2720105740X2F0250 BUSHING BEECH BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCD4N3HCD4N3A GL RUDDER PEDAL FAILED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) BOLT, P/N 130909B172, ATTACHING RUDDER PEDAL TO RUDDER PEDAL ARM WILL NOT FIT PROPERLY THROUGH BUSHING. THE RUDDER PEDAL MUST THEN TURN ON THE BOLT AND THE BUSHING MUST TURN WITHIN THE RUDDER PEDAL ARM CAUSING PREMATURE WEAR AND/OR POSSIBLE FAILURE. 1L72 3T4 TRT3A20 E4EA 5 CSTC 20050503000452005050300045CE 2005 5 3 CA050308004 120050110G5511043200146 RIB CESSNA CESSNA150 A152 2071836CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LEADING EDGE, LT IB RIB WAS FOUND CRACKED AT THE TOP REAR CORNER (RADIUS). 1H71 3O3 O 3A19 E223 5 NP50GL 20050503000462005050300046EU 2005 5 3 CA050308003 120050104G3260 SWITCH AMD FALCONFALCON20 2730103EU GE CF700 CF7002D2 30010NE MLG FAILED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AC DEPARTED IN HEAVY RAIN, LANDED IN FREEZING CONDITIONS. ON TAKEOFF LANDING GEAR WAS SELECTED UP, LANDING GEAR DOORS OPENED, LANDING GEAR RETRACTED, BUT DOORS WOULD NOT CLOSE. LANDING GEAR WAS SELECTED DOWN, LANDED SAFELY. MAINT FOUND MOISTURE IN LANDING GEAR CONNECTOR PLUGS. CONNECTOR PLUGS WERE CLEANED, GEAR SWING WAS COMPLETED TO VERIFY CORRECT OPS, AC WAS RELEASED FOR SERVICE, FLEW SAFELY FOR 2 NIGHTS, THEN SAME SCENARIO REPEATED ITSELF. INVEST REVEALED THAT RT DOOR ACTUATOR MICROSWITCH HAD HEAVY GREASE INSIDE SWITCH. SWITCH WAS CLEANED AND A GEAR SWING COMPLETED. AC RETURNED TO SERVICE. IMPLEMENTED AN INSP OF ALL 9 MICROSWITCHES AND CONNECTOR PLUGS (6 WEEK INTERVAL) TO PREVENT RECURRENCE. 2L72 4F4 FRTA7EU E7EA 20050503000472005050300047WP 2005 5 3 CA050308002 120050306G79207938314501 LINE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE OIL PRESSURE CRACKED W EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA P728034 (CAN) FLIGHT DIVERTED, DUE TO THE NR 1 ENGINE PROBLEM. THE NR 1 ENGINE LOST OIL QTY TO 0, ASSOCIATED WITH LOW PRESSURE LIGHT AND PRESSURE INDICATION AT 22 PSI. THE ENGINE WAS SHUT DOWN IN FLIGHT. ON GROUND, MAINTENANCE FOUND ONE OIL LINE LEAKING. 2L72 4F4 FRTA6WE E9NE 20050503000482005050300048EA 2005 5 3 CA050308001 120050303G5610NP1393226 WINDOW CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER APAPPROACH 1 CA (CAN) WE HAVE RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. RT SIDE WINDOW CRACKED DURING DESCENT AT ABOUT 4000 FEET. COPILOT'S SIDE WINDOW REPLACED IAW AMM AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20050503000492005050300049 2005 5 3 CA050307013 420050303G83008679225 PLANETARY GEAR SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCE4N HCE4N3 NE GEARBOX CRACKED W K NONE O OTHER ININSP/MAINT 1 CA P54202 (CAN) DURING ROUTINE MAINTENANCE, THE OIL PRESSURE TREND WAS NOTICED TO HAVE DROPPED ABOUT 12 PSI IN RECENT DAYS. THIS TOGETHER WITH A BAD OIL SAMPLE INDICATED A PLANETARY CARRIER PROBLEM AS EXPERIENCED IN THE PAST BY THIS OPERATOR. THE ENGINE GEARBOX WAS DISASSEMBLED AND THE PLANETARY GEAR CARRIER WAS FOUND CRACKED. THE CRACKS ORIGINATED FROM THE OIL GALLERY PASSAGES. THE ENGINE WAS REMOVED FOR REPAIR. 2L72 4T4 TRTA8SW E4WE 5 CP10NE 20050503000502005050300050CE 2005 5 3 CA050307012 120050303G2750SM50D7 RELAY BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE TE FLAP CONTROL INTERMITTENT W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) CREW REPORTED FLAP MOVEMENT AS INTERMITTENT. MAINTENANCE REPLACED THE FLAP CONTROL RELAY AND THE AIRCRAFT WAS RELEASED. FURTHER INVESTIGATION INTO THE RELAYS IDENTIFIED A KNOWN MANUFACTURER PROBLEM WITH RELAYS PRIOR TO DATE CODE 0444. THE CODE IDENTIFIES YEAR 2004-WEEK 44. POST 0444 RELAYS HAVE BEEN MODIFIED TO CORRECT THE INTERMITTENT ISSUE WITH THE RELAYS THROUGH A MODIFICATION TO PREVENT STICKING AND INTERMITTENT ACTUATION. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20050503000512005050300051EU 2005 5 3 CA050307011 120050304G2497 WIRE PIAGIOP180 P180 6960204EU PWA PT6 PT6A66 52043NE HARTZLHCE5N HCE5N3 GL OVERHEATED W K NONE M OVER TEMP ININSP/MAINT 1 CA (CAN) OVERHEATED WIRES ON TB-10 WERE REPAIRED THIS WAS DUE TO LOOSE NUT ON MAIN POWER FEED. 1H72 3O4 TRTA59EU E26NE 5 CPZONE 20050503000532005050300053NE 2005 5 3 CA050307009 220050228G7320324485318 FCU DHAV DHC8 DHC8* NM PWA PW120 PW123 NE ENGINE FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB, THE ENGINE EXPERIENCED AN UNCOMMANDED REDUCTION IN POWER. THE CREW SHUT THE ENGINE DOWN IN FLIGHT AND DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INVESTIGATION REVEALED AN UNSERVICEABLE ENGINE MECHANICAL FUEL CONTROL UNIT(FCU). 2H72 4T4 TRTA13NM E20NE 20050503000542005050300054NM 2005 5 3 CA050307008 120050224G324058570 BRAKE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE EMERGENCY PARK FAILED W O OTHER O OTHER CRCRUISE 1 CA (CAN) WHILE ON ROUTE FROM THE HANGAR THE AIRCRAFT FELT LIKE IT HAD A FLAT TIRE. ADDITIONAL POWER WAS REQUIRED TO CLEAR RUNWAY AND MANOUVERING AREA. ONCE SAFELY CLEAR OF ABOVE MENTIONED AREAS THE AIRCRAFT WAS SHUTDOWN AND INSPECTED. IT WAS NOTE THAT ALL 4 BRAKE ASSEMBLIES WERE GLOWING. ALL 4 BRAKE ASSEMBLIES AND WHEELS WERE REPLACED ALONG WITH THE EMERGENCY PARK BRAKE ASSEMBLY. FUNCTIONAL CHECK CARRIED OUT AND NO FURTHER FAULTS FOUND. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050503000552005050300055NE 2005 5 3 CA050307006 220050221G7230 ENGINE FOKKERF27 F27MK50 EU PWA PW120 PW127 NE LEAKING W EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 CA AS0005 (CAN) DURING FLIGHT, THE ENGINE LOST OIL PRESSURE. THE PILOT SHUT THE ENGINE DOWN AND DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED A SEIZED HIGH PRESSURE ROTOR. MFG WILL MONITOR THE INVESTIGATION OF THIS EVENT AND WILL SUPPLEMENT THIS REPORT TO REFLECT ROOT CAUSE ONCE DETERMINED. 2H72 4T4 TRTA817 E20NE 20050503000562005050300056NM 2005 5 3 CA050307005 120050225G7312108790 FUEL HEATER BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU ENGINE CRACKED W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 CA (CAN) THE ENGINE EXPERIENCED A LOSS OF OIL PRESSURE IN FLIGHT. THE PILOT SHUT THE ENGINE DOWN IN FLIGHT AND DECLARED AN EMERGENCY. SUBSEQUENT INSPECTION REVEALED EXTERNAL OIL LEAKAGE FROM A CRACKED FUEL OIL HEAT EXCHANGER. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050503000572005050300057NE 2005 5 3 CA050307004 220050218G73218063162C FMU UROCOPEC135 EC135P1 8680990EU PWA PW206 PW206B 0 NE ENGINE UNSERVICEABLE W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CRUISE, THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION ACCOMPANIED BY A (FADEC FAILED) ANNUNCIATION. THE PILOT ASSUMED MANUAL CONTROL OF THE ENGINE, ABORTED THE FLIGHT AND DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INVESTIGATION REVEALED AN UNSERVICEABLE ENGINE FUEL MANAGEMENT MODULE. 1G72 3U3 UO H88EU E42NE 20050503000582005050300058NE 2005 5 3 CA050307003 220050210G7320324485824 HMU FOKKERF27 F27MK50 EU PWA PWA120PW125B NE ENGINE FAILED W E ENGINE SHUTDOWN J WARNING INDICATION APAPPROACH 1 CA (CAN) DURING APPROACH, (ENGINE OUT) INDICATION ANNUNCIATED. THE PILOT SHUT THE ENGINE DOWN IN FLIGHT AND COMPLETED A SINGLE-ENGINE LANDING AT POINT OF DESTINATION. SUBSEQUENT INVESTIGATION REVEALED AN UNSERVICEABLE ENGINE HYDRO MECHANICAL FUEL CONTROL UNIT. 2H72 4T4 TRTA817 E20NE 20050503000592005050300059EA 2005 5 3 CA050307002 220050203G732132447452 FCU BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ENGINE MALFUNCTIONED W EA ENGINE SHUTDOWN UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB, THE ENGINE EXPERIENCED AN UNCOMMANDED INCREASE IN TORQUE AND FAILED TO RESPOND TO THROTTLE INPUT. THE ENGINE WAS SHUTDOWN IN FLIGHT. SUBSEQUENT INVESTIGATION REVEALED A FRACTURED FUEL CONTROL COUPLING SHAFT. 1L72 3T4 TRT3A20 E4EA 20050503000602005050300060NE 2005 5 3 CA050307001 220050224G7200 ENGINE BELL 212 212 1181420SW PWA PT6T PT6T3B 52045NE BOTH UNRESPONSIVE W R AUTOROTATION R PARTIAL RPM/PWR LOSS APAPPROACH 1 CA TX0066 (CAN) ON APPROACH NEITHER ENGINE RESPONDED TO INCREASED COLLECTIVE. THE AIRCRAFT AUTOROTATED TO A HEAVY LANDING. MFG WILL MONITOR THE INVESTIGATION INTO THIS EVENT AND WILL SUPPLIMENT THIS REPORT TO REFLECT ROOT CAUSE, ONCE ESTABLISHED. 1G71 4U4 U H4SW E22EA 20050503000612005050300061WP 2005 5 3 CA050306001 120050225G6210369D21100523 BLADE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL MAIN ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) MAIN ROTOR BLADE SKIN CRACKED AT DOUBLER LIP ON BOTTOM SIDE OF BLADE CHORDWISE. CRACK LENGTH 2 INCHES. RUNS UNDERNEATH SEALANT THAT BOND DOUBLER TO THE BLADE. FOUND DURING 100 HR INSPECTION M/R TORQUE EVENT INSPECTION. 1G71 3U3 U H3WE E4CE 20050503000622005050300062CE 2005 5 3 CA050305003 120050304G531212134121318 BULKHEAD CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO HARTZLHCJ3Y PHCJ3YF1 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 10239 (CAN) STN 18.4 BULKHEADS FOUND CRACKED LT AND RT SIDE AT AFT FUELING STEP ATTACHPOINTS. BULKHEAD REPAIRED LT AND RT SIDE IAW MM SECTION 1 8 PAR 18-64 FIGURE 18-4. 1H71 3O3 O A4CE E5CE 5 CP36EA 20050503000642005050300064CE 2005 5 3 CA050304003 120050302G5310 DOOR FRAME CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 12700 (CAN) WHEN COMPLYING WITH MFG REPETIVE SEB 03-5, A 2 INCH CRACK WAS DISCOVERED IN THE AREA OF THE LT LOWER DOOR HINGE ATTACH POINT ON THE DOOR POST. INSTALLED SERVICE KIT SK172-154TO REPAIR THE CRACK. NO INDICATIONS OF CRACKS ON THE RT SIDE. 1H71 3O3 ONT3A12 E274 5 NP910 20050503000652005050300065 2005 5 3 CA050304001 420050214G6122469153 ROD END HARTZL PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL PROP GOVERNOR BROKEN W C ABORTED TAKEOFF RJ PARTIAL RPM/PWR LOSS WARNING INDICATION TOTAKEOFF 1 CA 02219TJ (CAN) ON TAKEOFF ROLL RT ENGINE UNDERSPED BY 300 RPM. TAKEOFF REJECTED AND RETURNED FOR MAINTENANCE. MAINTENANCE FOUND RT PROP GOVERNOR ROD END (JOINT) BROKEN. PART REPLACED AND GROUND RUN C/W SERVICEABLE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20050503000662005050300066SW 2005 5 3 CA050303014 120050303G622047120252011 GRIP BELL 47 47G4A 1181031SW LYC O540 VO540B1B3 41532EA MAIN ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ROTOR GRIP WAS SUBMITTED FOR NDT TESTING IAW AD 2001-17-17 AND WAS REJECTED DUE TO CRACKING IN THE ADAPTER NUT THREAD AREA. GRIP WAS NEW AND HAD ONLY ACCUMULATED 196.9 HOURS SINCE NEW. 1G71 3O3 O 2H3 E304 20050503000692005050300069EU 2005 5 3 CA050303012 120050303G56109599122104 NOZZLE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL WINDOW LOOSE W C ABORTED TAKEOFF D INFLIGHT SEPARATION TOTAKEOFF 1 CA (CAN) DURING TAKEOFF THE FLIGHT CREW HEARD A LOW PITCH HOWLING NOISE FROM THE COPILOTS SIDE THAT SEEM TO INTENSIFY WITH INCREASED POWER SETTINGS. MAINTENANCE CONDUCTED GROUND RUNS AND FOUND THE NOISE TO BE COMING FROM THE COPILOTS FRESH AIR VENT. WHEN THE VENT WAS OPEN THE NOISE DISAPPEARED, WHEN CLOSING THE VENT THE SOUND WOULD REAPPEAR AND INCREASE AS IT WAS CLOSED OFF. THE ECS SYSTEM WAS FUNCTIONING NORMAL IN ALL OTHER RESPECTS. THE VENT WAS TO BE LEFT OPEN A SMALL AMOUNT AND THE FLIGHT CREW TO REPORT FURTHER. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20050503000712005050300071NM 2005 5 3 CA050303010 120050302G3260841101 PROXIMITY SENSOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE NLG BROKEN W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER COMPLETION OF A NORMAL TAKEOFF THE WT ON WHEELS CAUTION LIGHT ILLUMINATED. THE AIRCRAFT LEVELED OUT AND THE DECISION WAS MADE TO RETURN BACK TO BASE. THE A/C LANDED SUCCESSFULLY WITH NO FURTHER INCIDENT. IT WAS NOTED THE THE WT ON WHEELS CAUTION LIGHT EXTINGUISHED AT THE MOMENT THE NOSE WHEEL CONTACTED THE GROUND. IT WAS FOUND THAT THE NOSE GEAR WOW PROXIMITY SENSORS WERE PHYSICALLY DAMAGED AND THE LT SENSOR WAS CAUSING THE CAUTION LIGHT. THE PROX SENSORS WERE REPLACED AND THE A/C WAS RETURNED TO SERVICE. THESE ARE THE OLD STYLE PROXIMITY SENSORS WHICH ARE MADE OF PLASTIC. THE NEW STYLE PROXIMITY SENSOR ( P/N 8-642-02) ARE MADE OF STEEL. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050503000732005050300073EU 2005 5 3 CA050303008 120050303G2913623977 PUMP AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE HYDRAULIC SYS LEAKING W O OTHER K FLUID LOSS CLCLIMB 1 CA 28654 (CAN) FAULT: TOTAL LOSS OF ALL GREEN HYD FLUID. LOST MOST OF THE FLUID ON DEPARTURE AND THE REST ON LANDING. NR1 EDP REPLACED IAW AMM 29-11-51. ENG RUN FUNCTIONAL CHECK CARRIED OUT SERVICEABLE. 2L72 4F4 FRTA28NM E29NE 20050503000772005050300077EA 2005 5 3 CA050303002 120050228G5610NP1393225 WINDOW CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT BROKEN W A UNSCHED LANDING O OTHER CLCLIMB 1 CA (CAN) CLIMBING THROUGH FL340, THE CAPT DV WINDOW SHATTERED. DIVERTED. REMOVED AND REPLACED WINDOW. 2L72 4F4 FRTA21EA EOOO63EN 20050503000822005050300082EU 2005 5 3 CA050302001 120050301G5610D205443205 WINDSHIELD FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) DURING ENROUTE, THE CAPTAIN OBSERVED HIS SIDE WINDSHIELD ASSY WAS CRACKED. THE AIRCRAFT WAS DIVERTED AND LANDED WITHOUT INCIDENT. THE CAPT'S SIDE WINDSHIELD ASSY WAS REPLACED IAW MM 56-11-00. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRT E25NE 20050503000882005050300088CE 2005 5 3 CA050301008 120050221G5210 BRACKET CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160CTM GL DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LOWER DOOR POST SUPPORT BRACKETS CRACKED BOTH SIDES. 1H71 3O3 ONT3A12 E274 5 NP910 20050503000922005050300092CE 2005 5 3 CA050301005 120050224G2133781904 OUTFLOW VALVE CESSNA425 425 2076018CE PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) OVERHAULED VALVE PURCHASED JANUARY 23, 2001, GATE VALVE WAS FOUND STUCK IN THE CLOSED POSITION. THE VALVE WOULD NOT OPEN WHEN THE PRESSURE SELECTOR WAS SWITCHED TO THE OPEN POSITION. 1L72 3T3 TRTA7CE E4EA 5 CP60GL 20050503000972005050300097GL 2005 5 3 CA050301002 120050301G8011852401 SPRAG CLUTCH DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912F3 EU HOFMANHOV352HOV352F NE CRANKSHAFT LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 3300 (CAN) ENG WAS FOUND TO HAVE SEVERAL OIL LEAKS AND HARD STARTING. DURING INSP IT WAS NOTED THAT CRANKCASE SEALANT WAS NOT IAW MFG REC. SEALANT HAD RUBBERY/SILICONE COMPOSITION AS OPPOSED TO APPEARANCE OF CORRECT SEALANT. DURING COLD STARTS, STARTING SPRAG CLUTCH WOULD SLIP. DURING TEARDOWN INSP, DISCOVERED THAT SPRAG CLUTCH HSG WAS ASSEMBLED USING INCORRECT RETAINING COMPOUND, ALLOWING HSG TO SLIPON CRANKSHAFT. SPRAG CLUTCH HSG WAS GALLED AND UNSERVICABLE, CRANKSHAFT SUSTAINED NO DAMAGE. INCORRECT CRANKCASE SEALANT ALLOWED MOVEMENT BETWEEN CRANKCASE HALVES CAUSING FRET DAMAGE, CASE DAMAGE. NOTE: INCORRECT SEALING COMPOUND AND THREAD LOCKING COMPOUND WAS FOUND TO HAVE BEEN USED THROUGHOUT ENGINE. 1L71 3O3 ONTTA4CH E00051EN5 CTP5BO 20050503001142005050300114EA 2005 5 3 CA050228013 220050224G7200 ENGINE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA UNKNOWN W R AUTOROTATION R PARTIAL RPM/PWR LOSS LDLANDING 1 CA (CAN) A/F 18258 HOURS. HELI SKIING OPERATION. PILOT WAS DESCENDING DOWN A HILL AND SETTING UP HIS APPROACH TO LAND HELICOPTER. THE PILOT PULLED IN POWER TO CONTROL HIS DESCENT RATE AND NOTICED THAT THE ENGINES REMAINED IN FLIGHT IDLE. HE CHECKED HIS THROTTLE GRIPS AND FOUND THAT BOTH THROTTLES WERE ON MAX STOP. HE SET UP HIS AUTOROTATION AND LANDED HARD IN POWDER SNOW. HELICOPTER DAMAGED. NTSB HAS BEEN NOTIFIED OF THIS INCIDENT AND WILL BE INVESTIGATING IN THE NEAR FUTURE. THE PILOT WAS THE ONLY ONE ON BOARD. 1G71 4U4 U H4SW E22EA 20050503001222005050300122CE 2005 5 3 CA050228007 120050227G3297MS24171D1 RELAY BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE MLG BURNED W O OTHER J WARNING INDICATION LDLANDING 1 CA (CAN) DURING APPROACH, CREW ATTEMPTED TO EXTEND THE GEAR BUT REQUIRED MANUAL EXTENSION. MAINTENANCE FOUND THE LANDING GEAR MOTOR RELAY TO BE BURNED IN THE CONTACT AREA. THE RELAY WAS REPLACED AND THE AIRCRAFT RELEASED. THIS OPERATOR HAS HARD TIMED THE RELAYS TO 3000 HOURS. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20050503001262005050300126EA 2005 5 3 CA050228001 220050225G7200 ENGINE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 2 FLUCTUATES W EB ENGINE SHUTDOWN EMER. DESCENT KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA FA0151 (CAN) IN-FLIGHT SHUTDOWN OF NR 2 ENGINE DUE TO OIL PRESSURE FLUCTUATION. AIRCRAFT WAS ENROUTE WHEN THE EVENT OCCURRED, AT WHICH AN EMERGENCY WAS DECLARED AND THE AIRCRAFT HAD TO COMPLETE AN UNSCHEDULED LANDING. AFTER LANDING INSPECTION, AIR CREW REPORTED AN EXCESSIVE AMOUNT OF OIL AROUND LOWER AFT NACELLE AREA, INDICATING A POSSIBLE OIL LEAK AROUND THE OIL COOLER AREA. BORESCOPE INSPECTION SHOWED DAMAGED HP IMPELLER . ENGINE MUST BE REPLACED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050503001312005050300131 2005 5 3 CA050226001 420050216G83006014T81G27 GEARBOX CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE NR 2 ENGINE MAKING METAL W EA ENGINE SHUTDOWN UNSCHED LANDING XJ ENGINE FLAMEOUT WARNING INDICATION CRCRUISE 1 CA (CAN) NR 2 ENGINE SELF SHUTDOWN AT 11,000 FEET. DECLARED AN EMERGENCY AND LANDED WITH ONE ENGINE. NO OTHER PROBLEMS NOTED. MAINTENANCE FOUND THE GEARBOX TO BE AT FAULT. REPLACED THE GEARBOX AND RETURNED THE AIRCRAFT TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20050503001392005050300139 2005 5 3 CA050225004 420050223G34256226190204 AHRS BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE7315R 01518WP NR 2 FAILED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA (CAN) AHRS NR 2 FAILED ON TAKEOFF, CAUSING THE AUTOPILOT AND YAW DAMPENER TO FAIL. AHRS WAS RECENTLY OVERHAULED. ATTITUDE AND HEADING REFERENCE SYSTEM (AHRS). 2L72 4F4 FRTA3EU E6WE 20050503001402005050300140CE 2005 5 3 CA050225003 120050221G551407321014 REINFORCEMENT CESSNA CESSNA185 A185E 2072818CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C58 GL STAB HINGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1851087 (CAN) BOTH STABILIZER HINGE REINFORCEMENT FOUND CRACKED WHILE PERFORMING ANNUAL INSPECTION. REPLACEMENT PARTS ORDERED FROM MFG. THIS IS NOT UNCOMMON TO FIND CRACKS IN THIS AREA. PROBABLE GROUND HANDLING LOADS OR MISFIT ON INSTALLATION. NOTE THAT STABILIZER HAS BEEN REBUILT IN 1996 AFTER AIRCRAFT GROUND LOOP. 1H71 3O3 O 3A24 E5CE 5 CP3EA 20050503001412005050300141GL 2005 5 3 CA050225002 220050221G72506870832G COUPLING BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL ENGINE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA CAE802228BA (CAN) PITTING ON CIRCUMFERENCE OF COUPLING. 1G71 3U3 U H2SW E4CE 20050503001432005050300143 2005 5 3 CA050224013 420050224G3420066031252500 DISPLAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL EHSI FAILED W O OTHER O OTHER CRCRUISE 1 CA (CAN) PILOT'S EHSI WENT INTERMITENTTLY FUZZY. INFORMATION STILL READABLE. DISPLAY UNIT REPLACED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20050503001452005050300145NE 2005 5 3 CA050224010 220050219G7200PW530A ENGINE CESSNA500 550 2076604CE PWA 530 PW530A NE FAILED W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION DEDESCENT 1 CA DA0423 (CAN) THE ENGINE EXPERIENCED AN UNCOMMANDED SHUTDOWN IN DESCENT. MFG WILL INVESTIGATE THE INCIDENT AND WILL SUPPLEMENT THIS REPORT TO REFLECT ROOT CAUSE ONCE ESTABLISHED. 1L72 4F4 F A22CE E00053EN 20050503001462005050300146NE 2005 5 3 CA050224009 220050218G7200 ENGINE PWA PT6 PT6A34AG 52053NE POWER LOSS W O OTHER O OTHER TOTAKEOFF 1 CA 56561 (CAN) THE ENGINE WAS REPORTED TO HAVE LOST POWER SHORTLY AFTER DEPARTING THE RUNWAY. THE AIRCRAFT SUBSEQUENTLY IMPACTED THE GROUND. MFG WILL MONITOR INVESTIGATION OF THE INCIDENT AND WILL SUPPLEMENT THIS REPORT TO REFLECT ROOT CAUSE, ONCE DETERMINED. 4 T E4EA 20050503001492005050300149CE 2005 5 3 CA050224006 120050222G55144555301480003 TORQUE LINK LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE7312 01518WP HORIZONTAL STAB MISINSTALLED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) DURING COMPLIANCE OF SB 45-27-13, REPLACEMENT OF HORIZONTAL STAB. UPPER AND LOWER TORQUE LINK ASSYS, THE LOWER TORQUE LINK WAS FOUND INSTALLED UPSIDE DOWN AND WAS MAKING CONTACT WITH THE UPPER TORQUE LINK WHEN HORIZONTAL STAB. TRAVELS TO FULL DOWN POSITION 10.4 DEG. (AIRCRAFT NOSE UP). NEW TORQUE LINKS WERE INSTALLED AND FOUND THEY MAKE NO DIFFERENCE IN TRAVELS. 2L72 4F4 FRTT00008WIE6WE 20050503001532005050300153NM 2005 5 3 CA050224003 120050224G3260S258 SENSOR BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE LT MLG BROKEN W O OTHER N FALSE WARNING LDLANDING 1 CA (CAN) ON TOUCHDOWN, MASTER WARNING CONFIG LIGHT GEAR NOT DOWN CAUTION, LT SIDE BRACE LIGHT AND LT GEAR GREEN LIGHT EXTINGUISHED. AIRCRAFT STOPPED, GEAR PINS INSTALLED AND TAXIED IN. FOUND TOP OF SENSOR S258 SHEARED OFF. REPLACED SENSOR. S258 AND S236 ADJUSTED IAW MM 32-61-02. CHECKS OK. 2L72 4F4 FRTA1NM E3NE 20050503001602005050300160CE 2005 5 3 CA050223012 120050220G5341501200742 FITTING BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL WING TO BODY CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 23322 (CAN) DURING AD-81-25 THIS FITTING WAS FOUND CRACKED AND IT WAS REPLACED IAW THE SIRM. 1L72 3T4 T A14CE E4EA 5 CSTC 20050503001922005050300192NM 2005 5 3 CA050218003 120050210G792081196501 TUBE BOEING727 727225 1384077NM PWA JT8 JT8D15 52051NE GEARBOX SEPARATED W EJA ENGINE SHUTDOWN DUMP FUEL UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA 44603 (CAN) DURING CLIMB THROUGH 18000 FT ENGINE NR 1 LOW OIL PRESSURE LIGHT ILLUMINATED ACCOMPANIED BY RAPIDLY DECREASING OIL QUANTITY AND PRESSURE INDICATIONS. CREW CARRIED OUT ENGINE SHUTDOWN CHECKLIST DECLARED AN EMERGENCY, DUMPED FUEL AND RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. DURING INVESTIGATION BY MAINTENANCE, IT WAS FOUND THAT THE GEARBOX TO OIL COOLER LINE HAD PULLED DIRECTLY OUT OF THE ENGINE GEARBOX HOUSING. THIS IS NOT REPAIRABLE ON-WING AND DUE TO THE LENGTH OF TIME ENGINE WINDMILLED WITHOUT OIL, RESULTS IN AN ENGINE CHANGE. AS A PRECAUTION WE ARE CARRYING OUT A FLEETWIDE INSPECTION FOR ANY SEPARATION BETWEEN THIS LINE AND THE GEARBOX ON ALL ENGINES. 2L73 4F4 F A3WE E2EA 20050503001932005050300193EA 2005 5 3 CA050218002 120050217G61207827402 RETAINER HAMSTD CNDAIRCL215 CL2156B11415 EA PWA PW120 PW123 NE HAMSTD14SF 14SF* NE ACTUATOR LOOSE W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA 940104 (CAN) RETAINER, UNIVERSAL WAS FOUND WITH RELATIVE MOTION BETWEEN RETAINER AND RING, IPL 5-270C. CRIMPS (DIMPLES) HAD WORN OFF OF ONE OF FOUR DIMPLES ALMOST COMPLETELY, HALF THE DIAMETER OF TWO OTHERS. REPAIR 9-1 DETAILS INSTRUCTIONS FOR REPLACEMENT OF THE RETAINER. THE INSPECTION FOR RELATIVE MOTION BETWEEN THE RETAINER AND RING IS LISTED AS A (DCC), DESIGN CRITICAL CHARACTERISTICS, WHICH THERE IS NO MOVEMENT ALLOWED IAW THE REPAIR. THE RETAINER IS PART OF THE PITCH LOCK VALVE ASSEMBLY OF THE ACTUATOR. IF THE RETAINER WERE TO COME OFF OF BLADE ANGLE. IT COULD ALSO ALLOW THE PIVOT PINS IPL 5-260C TO COME OUT THE RING, WHICH COULD CAUSE A TOTAL LOSS OF CONTROL OF PITCH CHANGE FOR THE PROPELLER. 2H72 4T4 TRTA14EA E20NE 6 CP7NE 20050503001952005050300195NM 2005 5 3 CA050217004 120050214G2421736664E IDG BOEING757 757200 1384950NM RROYCERB211 RB211535E43754555NE GENERATOR INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 30776 (CAN) DURING INITIAL CLIMB, DEPARTING OGG, R (GEN DRIVE) MESSAGE DISPLAYED, GEN DRIVE LIGHT ILLUMINATED. RT IDG DISCONNECTED. AIRCRAFT DIVERTED. RT IDG REPLACED WITH LOANER UNIT, A/C DEPARTED, NO FAULTS REPORTED. REPLACEMENT UNIT FITTED. IDG SENT TO OEM FOR TEARDOWN AND REPAIR. AWAITING STRIP REPORT. 2L72 4F4 FRTA2NM E12EU 20050503001972005050300197EA 2005 5 3 CA050216006 120050215G5740 ATTACH FITTING CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE RT WING SEPARATED W K NONE O OTHER ININSP/MAINT 1 CA 22812 (CAN) FORWARD RT WING ATTACH FITTING FORWARD SIDE FLANGED BUSHING HAS COMPLETE SEPARATION OF FLANGE FROM BUSHING SLEEVE. RECTIFICATION REQUESTED FROM MFG. 2L72 4F4 FRTA21EA E15NE 20050503002162005050300216SO 2005 5 3 2005FA0000585 120050404G32136531904 STRUT PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA SNSNCH76E 76EM8S5 EA MLG BROKEN D A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 WP09833649047 288390035 L3013736A 22486K FAILURE OF THE (CAST) MAIN LANDING GEAR STRUT CYLINDER. CRACK IN UPPER SCISSOR ATTACHMENT RESULTED IN LOSS OF GEAR AND STRUT ASSY DURING TAKE-OFF. 1L71 3O3 O 2A13 E286 5 NP4EA 20050503002482005050300248SO 2005 5 3 2005FA0000474 120050316G7120102403053 SHIELD PIPER PA46 PA46500TP 7104622SO PWA PT6 PT6* 52043EA RT ENG MOUNT CHAFED B FTURK NONE O OTHER ININSP/MAINT 1 NE055335R474 4697100 DURING NORMAL EVENT INSPECTION, IT WAS FOUND THAT THE AIR SHIELD WAS CHAFFING AGAINST THE UPPER RT ENGINE MOUNT LEG WHERE IT PASSES THROUGH THE BAFFLE SHIELD FOR THE PLENUM ASSY. RECOMMENDED THAT CLOSE INSPECTION BE GIVEN TO AREA WHERE BAFFLING COULD BE CUTTING INTO THE ENGINE MOUNT. BOTH TIMES THIS WAS FOUND, ENGINE MOUNTS HAD TO BE REPAIRED BY APPROVED WELDING METHODS BY AUTHORIZED REPAIRED FACILITIES. (K) 1L71 3O3 TRTA25SO E2NE 20050503002512005050300251SW 2005 5 3 2005FA0000475 120050306G6300269A54301 SPLINE HUGHES269 269C1 8059504SW LYC O360 HO360* 41514EA MAIN ROTOR BELT STRIPPED D AB UNSCHED LANDING EMER. DESCENT F FLT CONT AFFECTED CRCRUISE 1 SO1572LP 1138 0152 WHILE IN CRUISE FLIGHT, TAIL ROTOR FAILURE AT APPROX 700 FT, PILOT WENT TO FLAT PITCH, PUT HELICOPTER IN A DIVE TO AVOID ROTATION FROM TORQUE, PERFORMED FULL AUTOROTATION TO THE GROUND, NO DAMAGE TO HELICOPTER OR INJURIES TO OCCUPANTS. DRIVE GEAR ON TAIL ROTOR INPUT SHAFT STRIPPED AS WELL AS FWD GEAR ON TAIL ROTOR DRIVE SHAFT. SUSPECT POSSIBEL METAL PROBLEM. CURRENT INSPECTION IS 600 AND 1200 HOURS OR 24 MONTHS, POSSIBLY LOWERING INSPECTION INTERVALS TO SAY 300 HOURS. HELICOPTER WAS 30 HOURS FROM 1200 HR. (K) 1G71 3O3 OO 4H12 E286 20050503002612005050300261CE 2005 5 3 2005FA0000478 120050110G3233 ACTUATOR CESSNA500 550 2076604CE PWA JT15 JT15* 52060NE NOSE GEAR WORN B MDORK NONE O OTHER ININSP/MAINT 1 CE07228CC 5500133 INSTALLED NEWLY OVERHAULED NLG ACTUATOR AND FOUND TO HAVE EXCESSIVE IN LINE MOVEMENT OF TNE LOCKING MECHANISM. MOVEMENT IN EXCESS OF .1250, MAX ALLOWED .035. (K) 1L72 4F4 T A22CE E1NE 20050504000342005050400034EU 2005 5 4 HE89099847 120050317G2435150SG117Q STARTER GEN AEROSPAS355 AS355F1 8680810EU ALLSN 250C 250C20F 03013GL ENGINE UNSERVICEABLE Z O OTHER O OTHER TXTAXI/GRND HDL 1 SW03ZKHDG 5212 CAE840557 STARTER WOULDN'T START ENGINE 1G72 3U3 U H11EU E4CE 20050504000532005050400053NE 2005 5 4 2005FA0000599 220050401G720030729202 BEARING RACE ISRAEL1124 1124 4500102EU GARRTTTFE731TFE73131G 29003NE ENGINE FRACTURED B K NONE O OTHER ININSP/MAINT 1 WP07 1052 P77111C ENGINE RETURNED TO SERVICE CENTER FOLLOWING COMMANDED SHUTDOWN IN FLIGHT DUE TO LOW OIL PRESSURE. DURING INSPECTION A FRACTURED CAGE AND OUTER RACE WAS FOUND ON A FORWARD PLANETARY ROLLER BEARING. 2M72 4F4 F A2SW E6WE 20050504001142005050400114SO 2005 5 4 2005FA0000598 220050413G8530532200 O-RING CONT O520 IO520* 17032SO CYLINDER BASE IMPROPER PART G O OTHER W INADEQUATE Q C CRCRUISE 1 GL13 INCORRECT CYLINDER BASE O-RINGS INSTALLED AT TOP-OVERHAUL. THE O-RINGS INSTALLED APPEARED TO BE THE SIZE FOR THE ENGINE. THESE LARGER CROSS SECTION SEALS WERE PINCHED BETWEEN THE CYLINDER BASE AND THE CRANKCASE. THIS RESULTED IN A LOW THROUGH-BOLT TORQUE. NUMBERS 2 AND 3 MAIN BEARINGS SPUN, DISRUPTING OIL FLOW TO THE NUMBER 4 CONNECTING ROD. THE NUMBER 4 CONNECTING ROD FAILED AND PENETRATED THE CASE. 3 O E5CE 20050505000082005050500008EA 2005 5 5 A6WA200540124 120050325G5330 SKIN CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE FUSELAGE SCRATCHED A A6WAK NONE O OTHER ININSP/MAINT 1 GL31415AW 7593 2 SCRATCHES IN FUSELAGE AT CARGO DOOR CUT-OUT, (APPROX 1 INCH LONG AND .5 INCH LONG.) PERFORMED A MAJOR REPAIR AT FS 549, STR 14-16 IAW EO. (K) 2L72 4F4 FRTA21EA E15NE 20050505000902005050500090EA 2005 5 5 2005FA0000492 120050321G3244256K433 TIRE CNDAIRCL600 CL6002B16 1900305EA GE CF34 CF34* NE LT MLG BULGED B JGVRK NONE O OTHER ININSP/MAINT 1 CE09915BD89 5091 UPON INSPECTION, TECH FOUND BULGE IN SIDEWALL OF LT MLG OB TIRE; SERIAL NR 22000882, 89 TOTAL LANDINGS. (CE09200503308) (K) 2L72 4F4 FRTA21EA E15NE 20050505000942005050500094CE 2005 5 5 2005FA0000496 120050325G2810052600058 FUEL TANK CESSNA172 172P 2072436CE LYC O360 O360A4M 41514EA RIGHT MISMANUFACTURED D K NONE W INADEQUATE Q C ININSP/MAINT 1 GL119443L 17276558 DURING INSTALLATION OF NEW TANK, IT WAS DISCOVERED THAT THE BUNGS FOR INSTALLING THE FUEL STRAINER ASSEMBLIES HAVE BEEN BRAZED TO THE TANK INVERSELY. THE BUNG THAT SHOULD HAVE BEEN BRAZED AT THE AFT LOCATION WAS BRAZED IN THE FORWARD MOUNT WAS BRAZED IN THE AFT MOUNT. (K) 1H71 3O3 ONT3A12 E286 20050505000952005050500095 2005 5 5 2005FA0000497 420050223G6122D20880 FLYWEIGHT CESSNA182 182 2072702CE LYC O540 IO540V4A5 41532EA GOVERNOR CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO17195RB 990056 26005C FLYWEIGHT BASE CRACKED ALSO ASSOCIATED PART C20886 SPRING HEAD AND B20882-1. SPRING DRIVE ALSO CRACKED. (K) (22124) 1H71 3O3 ONT3A13 1E4 20050505000962005050500096NE 2005 5 5 2005FA0000498 320050223G6110D4951 FORK BEECH 1900 1900D 1154162CE PWA PT6 PT6* 52043EA HARTZLHCE4A HCE4A3A NE PROPELLER CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO17 HJ1597 NDT SHOWS CRACKED IN (2) PLACES ON FORK. (K) (12235) 2L72 4T3 TRTA24CE E2NE 5 CP10NE 20060209001202006020900120NE 2006 2 9 2005AP02002 220051226G7250 GUIDE VANE BOEING747 747100 1384825NM RROYCERB211 RB211* 54555NE NR 1 ENGINE CRACKED B K NONE O OTHER ININSP/MAINT 1 EA33 ENGINE NR 3 LP TURBINE STAGE 3, NOZZLE GUIDE VANE APPROX 6:10 O'CLOCK POSITION ROOT AREA WITH CRACK. 2L74 4F4 FRTA20WE A12EU 20050120000472005012000047CE 2005 1 20 2005FA0000009 120050104G24352307900001 STARTER GEN BEECH 100 B100 1152919CE GARRTTTPE331TPE3316252B 01514WP LEFT ENGINE FAILED E D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TXTAXI/GRND HDL 1 GL2588FA 790 BE74 LEFT ENGINE FAILED ROTATE DURING START SEQUENCE INITIATION. MAINTENANCE DETERMINED BRUSHES BURNT, APPROXIMATELY 50 PERCENT LENGTH/LIFE REMAINING. STARTER/GENERATOR WAS REPLACE, ALONG WITH DC VOLTAGE REGULATOR. NR 1 INVERTER HAD FAILED COUPLE DAYS PRIOR, NO INDICATION ONE FAILURE CONTRIBUTED TO OTHER. 1L72 4T4 T A14CE E2WE 20050201000222005020100022SW 2005 2 1 2005FA0000014 120050121G5711 SPAR BBAVIA7 7AC 2110102SW CONT A65 A65* 17003SO WING CRACKED B N3SSO OTHER O OTHER NRNOT REPORTED 1 NM052974E 7AC6560 DURING PRE-PURCHASE, COMPLIED WITH INSPECTION. BOTH SPARS IN BOTH WINGS WERE FOUND TO HAVE LOOSE AND MISSING NAILS THAT HOLD RIBS OT THE SPARS. SEVERAL LONGITUDINAL CRACKS WERE FOUND. RECOMMENDATION TO OWNER WAS TO REPLACE ALL WOOD SPARS, WITH STC METAL SPARS. 1H71 3O3 O A759 E205 20050201000232005020100023CE 2005 2 1 2005FA0000026 120050113G2700 CONTROL PANEL CESSNA172 172 2072402CE CONT O300 O300* 17022SO PITCH CONTROL WORN G K NONE O OTHER ININSP/MAINT 1 EA258803B3663 2 36503 AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING A LANDING ACCIDENT. PILOT WAS UNABLE TO FLARE AIRPLANE. DURING A POST ACCIDENT INSPECTION BY FAA INSPECTORS, IT WAS DISCOVERED THAT THE AIRPLANE'S CONTROL TEE PULLEYS FOR THE AILERON SYSTEM WOULD GET (HUNG UP) ON THE RADIO TRAY ASSEMBLY, WHEN THE CONTROL WHEEL TUBE WOULD REACH HALF TRAVEL. THE CONTROL TEE PIVOT AND THE LEFT INSTRUMENT PANEL CONTROL TUBE BALL SOCKET, EXHIBITED WEAR, AND THE CONTROL TEE COULD BE MOVED LATERALLY ALONG A PORTION OF THE CONTROL TEE PIVOT BOLT. ADDITIONALLY, THE RADIO-MOUNTING TRAY DID NOT INCLUDE THE INSTALLATION OF A VERTICAL SUPPORT TO HELP ASSURE PROPER CLEARANCE BETWEEN THE TRAY AND THE CONTROL TEE ASSEMBLY. 1H71 3O3 ONT3A12 E253 20050201000202005020100020CE 2005 2 1 2005FA0000025 120050110G21211013841763 BLOWER BEECH 200 B200 1152922CE PWA PT6 PT6* 52043EA COCKPIT ARCED D K NONE B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 NM07773TP1613 1613 BB1722 PILOT REPORTED AN ELECTRICAL SMELL DURING FLIGHT AND THEN THE FORWARD VENTILATION BLOWER WENT INOPERATIVE. FOUND THE BRUSHES WORN OUT AND ARCING ON THE ARMATURE. REPLACED WITH OVERHAULED UNIT AND FUNCTIONAL CHECK OK. 1L72 4T3 T A24CE E2NE 20050201000192005020100019CE 2005 2 1 2005FA0000024 120050117G1430 BOLT CESSNA210 T210M 2073451CE CONT O520 TSIO520R 17040SO WASTEGATE VALVE LOOSE D K NONE O OTHER ININSP/MAINT 1 SW05732YK 287 21061879 294273R 3 OF THE 4 BOLTS THAT ATTACH THE METAL PLATE THAT THE ACTUATOR IS MOUNTED ON TO THE WASTEGATE BODY WERE MISSING. FOURTH BOLT WAS BACKED OUT ABOUT HALF WAY. ALL THREE BOLTS FOUND LOOSE IN ENGINE COMPARTMENT. WASTEGATE ASSEMBLY ONLY 287 FROM OVERHAUL BY MAIN TURBO.THESE BOLTS ARE NOT EASILY OBSERVABLE AND REQUIRE A MIRROR TO SEE. RECOMMEND INSPECTION AT EACH OIL CHANGE AND TIGHTEN AS NEEDED. 1H71 3O3 O 3A21 E8CE 20050214001872005021400187NE 2005 2 14 CA050117011 220050113G7210 TURBINE BLADES AEROSPATR42 ATR42* 8680900EU PWA 120 PW120 NE ENGINE DAMAGED W E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) DURING CRUISE THE PILOT REPORTED A (PUFF) FROM THE ENGINE ACCOMPANIED BY A LOSS OF TORQUE. POWER LEVER ADVANCEMENT RESULTED IN ENGINE TEMPERATURE INCREASE AND AN OIL SMELL AND SMOKE IN THE CABIN. THE ENGINE WAS SHUT DOWN, AN EMERGENCY DECLARED AND THE FLIGHT DIVERTED. SUBSEQUENT INSPECTION REVEALED DAMAGED TURBINE BLADES. MFG WILL INVESTIGATE THE INCIDENT AND SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE ESTABLISHED. 2H72 4T4 TRTA53EU E20NE 20050214002042005021400204NM 2005 2 14 CA050119003 120050119G3260H1010153 SWITCH BOEING727 727233 138408ANM PWA JT8 JT8D15 52051NE NLG INTERMITTENT W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) ON APPROACH, LANDING GEAR CYCLED DOWN FOR LANDING. THE NOSE LANDING GEAR RED INDICATOR STAYED ILLUMINATED AND NO GREEN INDICATION WAS SEEN. GEAR WAS RE-CYCLED AND THE GEAR WAS EXTENDED WITH PROPER INDICATION. MAINTENANCE LUBED THE NOSE GEAR AND JACKED THE GEAR AND CYCLED THE GEAR NUMEROUS TIMES, NO FAULTS FOUND. THE AIRCRAFT WAS DISPATCHED, NO FAULT ON LANDING THERE. THIS IS THE SECOND OCCURENCE AND SECOND SDR FOR THE SAME AIRCRAFT AND SNAG. DUE TO ITS HISTORY, NOSE GEAR DOWN POSITION SWITCH S93 AND THE NOSE GEAR LOCKED SWITCH S96 ARETO BE REPLACED BEFORE THE AIRCRAFT WILL BEDISPATCHED.POSSIBLE INTERNAL INTERMITTENT FAILURE TO ONE OF THE SWITCHES AND AT THE SAME TIME ALL WIRING WILL BE INSPECTED. 2L73 4F4 FRTA3WE E2EA 20050214002052005021400205 2005 2 14 CA050119005 420050117G3425800610350 COMPUTER FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE FLT DIRECTOR FAILED W A UNSCHED LANDING HJ ELECT. POWER LOSS-50 PC WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB, IT WAS OBSERVED THAT THE MFDS FAILED. FLIGHT WARNING COMPUTER WAS SUSPECTED. AIRCRAFT RETURNED TO BASE AND LANDED WITHOUT INCIDENT. THE FLT WARNING COMPUTER WAS REPLACED AND CHECKED SERVICEABLE IAW MM 31-51-00. THERE WAS NO PROBLEM WITH THIS SYSTEM DURING THE SUBSEQUENT FLIGHT. 2L72 4F4 FRT E25NE 20050214002082005021400208 2005 2 14 CA050119008 420050103G3418 PROBE AEROSPATR42 ATR42300 8680920EU PWA 120 PW120 NE HAMSTD14SF 14SF5 NE ANGLE OF ATTACH STICKING W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AFTER DEPARTING, THE CREW OBSERVED A STICK SPURRIOUS SHAKER WARNING. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. THE ANGLE OF ATTACK PROBE WAS FOUND TO BE STICKING, MAINTENANCE LURICATED THE PROBE AND THE SYSTEM WAS CHECKED SERVICEABLE. THE AIRCRAFT WAS RETURNED TO SERVICE. 2H72 4T4 TRTA53EU E20NE 6 CP7NE 20050214002112005021400211EA 2005 2 14 CA050120003 120050120G2720215T2429080 FITTING CNDAIRCL215 CL2156B11415 EA PWA PW120 PW123 NE HAMSTD14SF 14SF* NE RUDDER BROKEN W K NONE F FLT CONT AFFECTED ININSP/MAINT 1 CA (CAN) THE RUDDER GEAR/TRIM TAB UPPER FITTING FOUND BROKEN ON A VISUAL INSPECTION. A/C 1655, HOURS 1054, CYCLES 7200 DROPS. 2H72 4T4 TRTA14EA E20NE 6 CP7NE 20050215000022005021500002EA 2005 2 15 CA050120010 120050116G3250DSC167 LIMIT SWITCH DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE NLG STEERING CORRODED W K NONE O OTHER TXTAXI/GRND HDL 1 CA (CAN) ON TAXI TO GATE NOSE WHEEL STEERING FAILED CAUSING OVER STEER CONDITION. MAINTENANCE FOUND STEERING ACTUATOR LINKAGES DAMAGED. DURING TROUBLESHOOTING / REPAIRS, LIMIT SWITCH WAS FOUND WITH CONNECTOR PINS CORRODED AND BROKEN OFF. STEERING ACTUATOR, TRANSFER TUBE, LIMIT SWITCH AND CONNECTOR REPLACED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050215000032005021500003NM 2005 2 15 CA050125000 120050123G29151849 PRESSURE VALVE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MANIFOLD FAULTY W A UNSCHED LANDING MJ OVER TEMP WARNING INDICATION CLCLIMB 1 CA O409A (CAN) THE CREW REPORTED , AFTER GEAR UP SELECTION , LOST NR 2 MAIN AND STANDBY PRESSURE (SPU ON). AFTER APPROXIMATELY 3 MINUTES THEY RECEIVED NR 2 STANDBY PUMP HOT LIGHT. ON SHORT FINAL NR 2 MAIN PRESSURE RETURNED BUT NR 2 STANDBY HOT LIGHT REMAINED ON EVEN THOUGH NR 2 STANDBY PUMP CIRCUIT BREAKER WAS PULLED . IT ONLY WENT OUT WHEN BOTH ENGINES FEATHERED AFTER APPROXIMATELY 2 MINUTES. THE MAINTENANCE CREW AFTER TROUBLESHOOTING DETERMINED THE PRESSURE RELIEF VALVE TO BE AT FAULT AND REPLACED . 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050214002062005021400206CE 2005 2 14 CA050118005 120050117G3211 LANDING GEAR CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO MCAULY3FF32 3FF32C501 GL RIGHT COLLAPSED W O OTHER O OTHER APAPPROACH 1 CA (CAN) RT LANDING GEAR COLLAPSED ON LANDING, THIS IS A PRELIMINARY REPORT MORE INFORMATION WILL FOLLOW. 1L72 3O3 O A7CE E7CE 5 CP45GL 20050215000042005021500004EU 2005 2 15 CA050111002 120050111G2760 SERVO AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE SPOILER INTERMITTENT W O OTHER F FLT CONT AFFECTED TOTAKEOFF 1 CA 3889814851 (CAN) FAULT: JUST PRIOR TAKE-OFF, FLIGHT RECEIVED A FLT CTL SPOILER 1 FAULT. CREW TAXIED ONTO A TAXIWAY AND PERFORMED A SUCCESSFUL RESET. HOWEVER, AT 3000 FT/210 KNOTS ON CLIMB, THE FAULT RETURNED AGAIN. FURTHER INTO THE FLIGHT IN CRUISE SLAT SYSTEM. ACTION: ACFT OUT OF SERVICE FOR INVESTIGATION. 2L72 4F4 FRTA28NM E29NE 20050214001862005021400186NM 2005 2 14 CA050114003 120050112G2910887087 MOTOR BOEING757 75728A 1384976NM RROYCERB211 RB211535E43754555NE HYD ACTUATOR LEAKING W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) A/C DEPARTED AND TURNED AROUND AFTER NOTICING SLOW STEADY DECLINE IN CENTER SYSTEM QUANTITY. MAINTENANCE FOUND FLUID LEAKING FROM FUSELAGE DRAIN HOLES IN THS COMPARTMENT. UPON INVESTIGATION MAINTENANCE FOUND CENTER SYSTEM HYD MOTOR ON THIS GEARBOX LEAKING FLUID OUT MOTOR DRAIN LINE BUT MOST WAS COMING OUT THS GEAR BOX VENT HOLE ON FWD SIDE OF GEARBOX POSSIBLY DUE TO A PARTIALLY BLOCKED MOTOR DRAIN LINE. MFG INDICATED THAT WE WILL HAVE TO REPLACE THE THS ACTUATOR DUE TO THE HYDRAULIC FLUID LEAKAGE CONTAMINATING THE ACTUATOR GEAR BOX. 2L72 4F4 FRTA2NM E12EU 20050215000082005021500008NM 2005 2 15 CA050113003 120050110G29136617302 PUMP BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU HYD SYSTEM CRACKED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) NR2 HYDRAULIC SYSTEM FAILED DURING CLIMBOUT FROM BASE. PILOTS COMPLETED CHECKLIST AND PERFORMED AIR TURNBACK WITH UNEVENTFUL LANDING . PUMP HOUSING CRACKED WITH SUBSEQUENT FLUID LOSS INTO NACELLE. ENGINE DRIVEN PUMP REPLACED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050215001292005021500129EA 2005 2 15 2005FA0000071 220050128G8500 CRANKCASE GULSTM500 500B 0141106SW LYC O540 IO540B1C5 41532EA ENGINE CRACKED B G6NRO OTHER O OTHER NRNOT REPORTED 1 CE09324RR 1386139 CRANKCASE, LARGE CRACK UNDER NR 2 CYLINDER, RESULTING IN MASIVE OIL LOSS. (K) 1H72 3O3 O 6A1 1E4 20050224000762005022400076SO 2005 2 24 2005FA0000108 220050130G8520SA631991 SHAFT PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360E 17025SO ENGINE OUT OF ROUND D O OTHER O OTHER NRNOT REPORTED 1 SW99123AP 347770015 303972 UPON INSTALLING A SHAFT INTO A ROCKER WITH INADEQUATE TOLERANCE LIMITS, NOTED BINDING IN THREE CLOCK POSITIONS. WITH PRUSSION BLUE, FOUND THAT THE SHAFT IS FORMED IN AN ELIPTICAL OR, MODIFIED TRI-ANGULAR SHAPE WITH REDUCED WEAR SURFACE AREA DUE TO INCONSISTANT DIAMETER OF THE SHAFT. ALL 24 NEW SHAFTS DISPLAYED THE SAME MACHINING RESULTS. THE HIGHEST PRESSURE POINT WAS AT THE NARROWEST CONTACT POINT. GALLING OF THESE SHAFTS APPEARS TO BE CONSISTANT WITH REDUCED WEAR SURFACE AND CROWNING OF THE SHAFT. WHILE OTHER FACTORS MAY BE ATTRIBUTED TO THE CAUSE OF THE PREMATURE SHAFT FAILURE, THE REDUCTION IN SURFACE AREA IS CONSISTANT WITH ACCELERATED DECOMPOSITION OF BEARING SURFACE. AIRWEST AIRCRAFT ENGINES SUPPLIE1L72 3O3 O A7SO E9CE 20050201001302005020100130GL 2005 2 1 2005FA0000029 120050107G3242 ROD AMTR COZY COZY 05613R8GL LYC O320 O320* 41508EA RT BRAKE CYL ACTBENT G O OTHER O OTHER TXTAXI/GRND HDL 1 SW01154MD 25 154MD RT BRAKE CYLINDER ACTUATING ROD, LOCATED BEHIND RT RUDDER PEDAL, WAS SLIGHTLY BENT AFT. THIS CONDITION CAUSED INSUFFICIENT BRAKE CYLINDER PISTON TRAVEL AND MAKING THE RT BRAKE INOPERATIVE. 1M71 3O3 ONTEXPA1M71E274 20050214001842005021400184NM 2005 2 14 CA050111001 120050105G3221654581945 GUSSET BOEING737 7372Q9 138448MNM PWA JT8 JT8D9A 52048NE NLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A ROUTINE PHASE 3 CHECK (137.5 HRS.), A 2.75 INCH CRACK WAS FOUND ON THE NOSE LANDING GEAR GUSSET WHILE CARRYING OUT SERVICE DIFFICULTY ALERT AL-2002-03.RETRACT ACTUATOR SUPPORT FITTING GUSSET REPLACED IAW SRM 51-30-2 FIG II. TIMES. 61981.7 CYCLES. 52905. 2L72 4F4 F A16WE E2EA 20050214001852005021400185NM 2005 2 14 CA050113002 120050109G29136617302 PUMP BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 1 HYD SYSTEM MAKING METAL W A UNSCHED LANDING J WARNING INDICATION APAPPROACH 1 CA (CAN) DURING APPROACH TO BASE, NR 1 HYD ISO VLV AND NR 1 ENG HYD PUMP CAUTION LIGHT ILLUMINATED. NR 1 SYSTEM PRESSURE 0 PSI. STBY PRESS NORMAL AFTER SPU SELECTED ON. EMERGENCY LANDING DECLARED. AIRCRAFT STOPPED ON RUNWAY AND WAS TOWED IN. NR1 PROP COULD NOT BE ROTATED BY HAND. METAL FOUND IN CASE DRAIN AND PRESSURE FILTERS. REPLACED NR 1 EDP. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050214002072005021400207EU 2005 2 14 CA050119007 120050105G3211 LANDING GEAR BRAERO748 HS7482B 1500248EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU UNKNOWN W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) ON TAKEOFF, THE LANDING GEAR WOULD NOT RETRACT AFTER BEING SELECTED. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE AND LANDED NORMALLY. THE AIRCRAFT WAS HANGARED AND A GEAR SWING CARRIED OUT, THE FAULT COULD NOT BE DUPLICATED. THE AIRCRAFT WAS RETURNED TO SERVICE. 2L72 3T4 T A24EU A196 6 CP899 20050214002102005021400210EU 2005 2 14 CA050119009 120050112G2140S200 HEATER BRAERO748 HS7482B 1500248EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU CABIN FAILED W A UNSCHED LANDING O OTHER CLCLIMB 1 CA (CAN) SHORTLY AFTER DEPARTING, THE CABIN HEATER FAILED. THE CREW RETURNED THE AIRCRAFT TO POINT OF DEPARTURE. THE HEATER UNIT WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 3T4 T A24EU A196 6 CP899 20050215000052005021500005NM 2005 2 15 CA050111003 120050111G25306253190003 OVEN BOEING767 767375 1385217NM GE CF6 CF680C2B6F 30025NE MID GALLEY FIRE W F ACTIVATE FIRE EXT. A FLAME/FIRE CRCRUISE 1 CA (CAN) FAULT: JUST PRIOR TO DESCENT, SOMETHING WAS BEING COOKED IN THE MID CABIN GALLEY. AS THE F/A WAS ABOUT TO REMOVE IT, A FIRE WAS FOUND AT THE BACK OF THE OVEN. 3 FIRE EXT. WERE USED TO DOUSE THE FIRE. NO EMERGENCY WAS DECLARED, NO ADVERSE PAX REACTION. AIRCRAFT REMOVED FROM SERVICE, WIRING INSPECTION U/WAY. 2L72 4F4 FRTA1NM E13NE 20050214002032005021400203EA 2005 2 14 CA050119002 120050118G53306003303913 ACCESS PANEL CNDAIRCL601 CL6012A12 1900303EA GE CF34 CF34* NE FUSELAGE DISTORTED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AC REMOVED FROM HEATED HANGAR (20 DEG C) TO RAMP (-27 DEG C) T/E OF UPPER ELEC BAY ACCESS PANEL DEFLECTED .345 FROM AIRFRAME. FURTHER INVESTIGATION SHOWED DISTORTION THROUGHOUT PANEL WITH GREATEST DISTORTION AT CORNERS RANGING FROM .100IN TO .345 IN. SIMILAR DISTORTION WAS FOUND ON LT DOOR. WHEN AC WAS RETURNED TO HEATED HANGAR DOORS RETURNED TO NORMAL AS THE AIRFRAME WARMED. AC 144615,144616 WERE TESTED UNDER SAME CONDITIONS, AGAIN SIMILAR RESULTS WERE NOTED. DISCUSSIONS WITH MFG THROUGH SRPSA WERE CONDUCTED WITH RECOMMENDATION THAT AC NOT BE FLOWN UNTIL DOORS IN QUESTION COULD BE REPLACED. COMPLETE LIST OF MEASURMENTS FOR 144614,144615,144616 ARE ON FILE WITH OPERATOR. 2L72 4F4 FRTA21AE E15NE 20050215000072005021500007NM 2005 2 15 CA050128009 120050127G3242 DISK DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE BRAKE ASSY SEIZED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 14693 0410 (CAN) AFTER STARTED AIRCRAFT, RELEASED PARK BRAKE AND TAXIED NORMALLY , BRAKING AS REQUIRED, DUE TO LONG LINE UP AWAITING TAKEOFF PARK BRAKE WAS APPLIED. WHEN PART BRAKE WAS RELEASED AIRCRAFT UNABLE TO TAXI. MAINTENANCE INSPECTION FOUND BRAKE PISTONS WERE RELEASING USING TOE BRAKES OR PARK BRAKE, BUT BRAKE DISKS ON THE NR3 AND NR4 BRAKES WERE SEIZED AND WOULD NOT ROTATE. BOTH NR3 AND NR4 BRAKE ASSEMBLIES REPLACED. NR3 BRAKE S/N 0410 HAD 88CY SINCE OVERHAUL (BUILD NR1) CARRIED OUT. NR4 BRAKE S/N 3120P HAD 208CY SINCE OVERHAUL (BUILD NR1) CARRIED OUT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050302000442005030200044SO 2005 3 2 2005FA0000161 120050301G27216666100 CONNECTOR PIPER PA28 PA28181 7102807SO LYC O360 O360* 41514EA RUDDER TRIM BROKEN D K NONE O OTHER ININSP/MAINT 1 NE017653F4809 287790205 RUDDER TRIM CONNECTOR FOUND BROKEN OFF DURING ANNUAL INSPECTION. 1L71 3O3 O 2A13 E286 20050401000452005040100045CE 2005 4 1 2005FA0000385 120050131G5753052323113 FLAP TRACK CESSNA172 172H 2072424CE CONT O300 O300D 17022SO LT WING WORN D O OTHER O OTHER NRNOT REPORTED 1 SO094989R 17256343 28598D4D WHILE FLAPS WERE BEING RETRACTED, THE LT IB FLAP ATTACH BRACKET CAUGHT ON THE WING COVE PANEL SUPPORT. THIS CAUSED SUBSTANTIAL DAMAGE TO THE COVE PANEL SUPPORT AS WELL AS THE ATTACH BRACKET. CAUSE WAS DETERMINED TO BE WORN FLAP TRACKS. THE FLAP TRACKS AND ROLLERS WERE REPLACED WITH NEW PARTS AND THE LT FLAP WAS REPLACED WITH A SERVICEABLE ASSY DUE TO LACK OF PARTS AT THE MFG FOR REPAIR. SINCE MFG DOES NOT HAVE LIMITATIONS ON THEIR FLAPS TRACKS, WOULD SUGGEST THAT THEY BE REMOVED AND REPLACED AT 5,000 HOUR INTERVALS. (K) 1H71 3O3 ONT3A12 E253 20050301000452005030100045CE 2005 3 1 2005FA0000079 120050127G552212346204 ELEVATOR CESSNA210 T210F 2073422CE CONT O520 IO520* 17032SO RT & LT MISREPAIRED D K NONE W INADEQUATE Q C ININSP/MAINT 1 WP076772R T2100172 DURING AN ANNUAL INSP, FOUND LT ELEVATOR TORQUE TUBE LOOSE, AFTER REPAIR WHILE CHECKING CONTROL SURFACE BALANCE, SURFACE WAS FOUND TO BE BADLY OUT OF BALANCE AT +21 IN LBS. REMOVED T/E AND FOUND IT TO HAVE BEEN REPLACED WITH A FIELD FABRICATED PART BY PERSONS UNKNOWN. FOUND THE MATERIALS USED TO BE .040 SHEET ALUMINUM, THE FACTORY T/E WAS MADE OUT OF .016 AND WAS FOAM FILLED, REPLACED THE T/E WITH FACTORY PARTS, REPLACED T/E AND TRIM TAB ON OTHER ELEVATOR DUE TO SAME CONDITION, REBALANCED CONTROL SURFACES AND FOUND TO BE WITHIN RANGE OF 0 TO +5.4 IN LBS. (WP07200509576) (K) 1H71 3O3 O 3A21 E5CE 20050308002762005030800276WP 2005 3 8 COOSDR05003 120050125G5310 DOOR FRAME DOUG DC9 DC915F 3022037WP PWA JT8 JT8D* NE FUSELAGE CRACKED B EE4YK NONE O OTHER ININSP/MAINT 1 SO23785TW 47015 FWD CARGO COMPARTMENT, DOOR JAMB, STUB BEAM, PN 5921718-1, SHORT FLANGES CRACKED. (K) 2L72 4F4 F A6WE E2EA 20050311000012005031100001SW 2005 3 11 2005FA0000134 120050216G6230407010104109 CONE BELL BELL 407 407 1182206SW ALLSN 250C 250C47B GL M/R MAST WORN D K NONE O OTHER ININSP/MAINT 1 EA0117SP 53444 53444 REPLACED MAIN ROTOR MAST CONE PN 407-010-104-109 FOR HUB SHIFT/MAST NUT TORQUE STABILIZATION PROBLEM. ORDERED NEW CONE P/N 407-010-104-109 FROM MFG. NEW PART WAS RECEIVED WITH A WEAR GROOVE IN CENTER OF CONE FACE (APPEARED USED). REORDERED ANOTHER NEW CONE AND INSTALLED. INSTALLED MAST NUT AND STABILIZED TORQUE. 1G71 3U3 UO H2SW E1GL 20050311000032005031100003WP 2005 3 11 LCQ54 120050120G5320 PANEL DOUG DC9 DC932 3022066WP PWA JT8 JT8D9A 52048NE CABIN ELONGATED C K NONE O OTHER ININSP/MAINT 1 SO15867AT 47170 MAIN CABIN PANEL E5-3 HAS ELONGATED HOLES ON THE END OF PANEL. S/O 152051, OPS 29566, ZONE 6C-143 2L72 4F4 F A6WE E2EA 20050311000102005031100010EU 2005 3 11 CA050113005 120050111G3220 LANDING GEAR SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE ROTOL R390 R3904123F27 NE NOSE FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) AFTER A NORMAL LANDING, THE AIRCRAFT TAXIED OFF THE RUNWAY AND STOPPED IN FRONT OF THE AIRPORT TERMINAL. THE ENGINES WERE SHUT DOWN AND THE CREW COMPLETED THEIR COCKPIT CHECKS. WHEN THE ELECTRICAL MASTER SWITCH WAS TURNED TO OFF THE NOSE UNDERCARRIAGE RETRACTED, DROPPING THE NOSE OF THE AIRCRAFT ONTO THE TARMAC. A SHORT WHILE LATER, AS THE GROUND CREW WERE POSITIONING A TEMPORARY TAIL SUPPORT, THE MAIN UNDERCARRIAGE STARTED TO RETRACT.THE AIRCRAFT WAS RECOVERED TO A MAINTENANCE HANGAR FOR INVESTIGATION. 2L72 4T4 TRTA52EU E8NE 6 CP31NE 20050311000122005031100012WP 2005 3 11 LCQ57 120050120G5320 CHANNEL DOUG DC9 DC932 3022066WP PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15867AT 47170 MAIN CABIN PANEL, NR A53 HAS CHANNELS CRACKED. S/O 152051, OPS 29572, ZONE 6C-149 2L72 4F4 F A6WE E2EA 20050311000162005031100016EA 2005 3 11 CA050115001 120050111G2420755469D IDG CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE GENERATOR INOPERATIVE W O OTHER H ELECT. POWER LOSS-50 PC APAPPROACH 1 CA 16558 (CAN) LOSS OF BOTH IDGS ON APPROACH FOLLOWED BY AN ADG DEPLOYMENT. NO PROBLEM WAS REPORTED WITH THE ADG. FLIGHT CREW DECIDED TO ABORT THE APPROACH. EMERGENCY WAS DECLARED. THE CREW DECIDED TO START DE APU TO POWER THE AIRCRAFT BUSES. THE AIRCRAFT LANDED. THE IDG 2 WAS INSPECTED. OIL LEVEL WAS LOW. ANS REPORTS 2 LITERS WERE ADDED. IDG 1 OIL LEVEL WAS OK. GROUND RUNS COULD NOT DUPLICATE THE SNAG. BOTH IDG'S AND BOTH GCUS WERE REPLACED. WIRING INSPECTION INCLUDING ENGINES AND PYLONS WITH NO ANOMALY FOUND. 2L72 4F4 FRTA21EA E15NE 20050311000172005031100017CE 2005 3 11 CA050117002 120050106G323391929 SWITCH CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE LT MLG ACTUATOR FAILED W O OTHER J WARNING INDICATION DEDESCENT 1 CA 3248 (CAN) WHILE CARRYING OUT NIGHT LANDINGS ON A LOCAL TRAINING FLIGHT, THE LT MAIN GEAR DOWNLOCK INDICATION FAILED TO ILLUMINATE ON THE NINTH LANDING APPROACH. THE CREW CARRIED OUT AN EMERGENCY EXTENSION PROCEDURE AND LANDED SAFELY. MAINTENANCE CREW SERVICED THE LANDING GEAR IAW THE MM AND REPLACED THE LT MAIN GEAR ACTUATOR P/N 9912053-21. THE GEAR DOWNLOCK SWITCH WHICH FAILED IS INTEGRAL TO THE ACTUATOR. A SUCCESSFUL LANDING GEAR EXTENSION AND RETRACTION TEST WAS CARRIED OUT AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 4F4 F A22CE E1NE 20050311000182005031100018NM 2005 3 11 CA050117003 120050117G71209604209 MOUNT BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 1 ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION OF THE NR1 ENGINE MOUNT PN 96042-09, A CRACK WAS FOUND ON THE CORE ASSY PN. 19-9495-01. MFG IS INVESTIGATING THE ISSUE. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050311000192005031100019NE 2005 3 11 CA050117008 220050111G73215001T39G39G29 FCU AMD FALCONFALCON20 2730103EU GE CF700 CF7002D2 30010NE ENGINE FAILED W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION CRCRUISE 1 CA 304415B (CAN) AC WAS DISPATCHED FOR A TEST FLIGHT DUE TO DUAL ENGINE CHANGE. AT FL370 MAX ACCELERATION CHECK COMPLETED, WITHOUT INCIDENT. ON RETURN, ENGINE FLAMED OUT, ENGINE RELIGHT AT FL180. ENGINE FCU RIGGING, BLEED VALVES RIGGING AND AIR SENSOR LINES WERE INSPECTED, NOTHING UNUSUAL FOUND. SECOND TEST FLIGHT WAS CONDUCTED ON 13 JAN 05. ENGINE WAS INTENTIONALLY SHUTDOWN AT FL250 AND A RELIGHT ATTEMPTED WITH PARTIAL SUCCESS. ENGINE WOULD NOT ACCELERATE PAST 40 PERCENT N2 UNTIL AC HAD DESCENDED TO FL180. AC RETURNED WITHOUT INCIDENT AND THE AC WAS GROUNDED PENDING THE REPLACEMENT OF THE FCU CHANGE, WHICH IS CURRENTLY IN PROCESS. 2L72 4F4 FRTA7EU E7EA 20050311000202005031100020EU 2005 3 11 CA050117009 120050116G7603 POWER LEVER AMD FALC50FALCON900 2700160EU GARRTTTFE731TFE7315BR WP ENGINE FROZEN W E ENGINE SHUTDOWN E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) DURING CRUISE FLIGHT, NOTICED BY CREW THAT THE NR1 ENGINE POWER LEVER WAS FROZEN IN POSITION. THE ENGINE WAS SHUTDOWN AND AN UNEVENTFUL LANDING WAS COMPLETED. WITH WARMER TEMPERATURES, POWER LEVER WAS ABLE TO MOVE FREELY THROUGH ITS FULL RANGE OF TRAVEL. FLIGHT WAS CONDUCTED WITH NO FAULTS NOTED. ON THE 3RD FLIGHT, WHILE IN CRUISE, IT WAS NOTED THAT POWER LEVER BECAME DIFFICULT TO MOVE. ENGINE POWER WAS REDUCED TO IDLE, SCHEDULED LANDING. REVEALED WATER LEAK FROM LAV SINK SUPPLY LINE MIGRATED BELOW FLOOR ONTO NR 1 ENGINE PWR LEVER BELLCRANK, ICE ACCUMULATION WAS EVIDENT IN AREA. LEAK WAS REPAIRED, CONTAMINATED AREAS WERE CLEANED, DRIED AND LUBRICATED. ENGINE PWR LEVER FUNCTION CHECKED SERVICEABLE. 2L73 4F4 FRTA46EU E6WE 20050311000342005031100034WP 2005 3 11 LCQ56 120050120G5320 CHANNEL DOUG DC9 DC932 3022066WP PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED C K NONE O OTHER ININSP/MAINT 1 SO15867AT 47170 MAIN CABIN PANEL NR 75 HAS CHANNELS CRACKED OUT AND SURFACE CORROSION. S/O 152051, OPS 29569, ZONE 6C-146 2L72 4F4 F A6WE E2EA 20050311000352005031100035WP 2005 3 11 LCQ61 120050120G5321 FLOOR PANEL DOUG DC9 DC932 3022066WP PWA JT8 JT8D9A 52048NE FUSELAGE BROKEN C K NONE O OTHER ININSP/MAINT 1 SO15867AT 47170 MAIN CABIN FLOOR PANEL NR 76 RT CENTER FS 680 - 760 IB HAS HOLES BROKEN OUT ON THE END. S/O 152051, OPS NR 29576, ZONE 6C-153 2L72 4F4 F A6WE E2EA 20050311000362005031100036WP 2005 3 11 LCQ62 120050120G5321 FLOOR PANEL DOUG DC9 DC932 3022066WP PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED C K NONE O OTHER ININSP/MAINT 1 SO15867AT 47170 MAIN CABIN FLOOR PANEL NR 81 HAS CRACKS AROUND RIVETS, 2 EACH PUNCTURES AND SURFACE CORROSION. S/O 152051, OPS NR 29583, ZONE 6C-156 2L72 4F4 F A6WE E2EA 20050311000402005031100040SW 2005 3 11 2005FA0000065 120050103G5610 WINDSHIELD SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP COCKPIT CRACKED B OZ5RB EMER. DESCENT J WARNING INDICATION CRCRUISE 1 NM053114G AC583 MRR-M05-01, NR 1 WINDSHIELD CRACKED IN FLIGHT JUST AS CREW STARTED DESCENT. CREW DEPRESSURIZED AC, DESCENDED TO AN APPROPRIATE ALTITUDE FOR NON-PRESSURIZED FLIGHT, AND DIVERTED TO AN AIRPORT WITH VMC CONDITIONS. CREW LANDED WITH NO FURTHER INCIDENT. OAT WAS APPROXIMATELY -40 AND WINDSHIELD HEAT WAS ON LOW. INNER GLASS PANE CRACKED, UNDER INVESTIGATION WITH THE OVERHAUL/REPAIR FACILITY. INNER PANE OF THE HEATED WINDSHIELD CRACKED EXTENSIVELY. REPLACED WINDSHIELD, OPS CHECK AND LEAK CHECK GOOD. (K) 2L72 4T4 TRTA8SW E4WE 20050311000612005031100061WP 2005 3 11 LCQ37 120050119G5310 DOOR FRAME DOUG DC9 DC932 3022066WP PWA JT8 JT8D9A 52048NE FUSELAGE CORRODED C K NONE O OTHER ININSP/MAINT 1 SO15867AT 47170 STA. 908.5, AFT CARGO DOOR FRAME WEB HAS CORROSION ON VERTICAL SUPPORT, FOUR CORNERS FWD SIDE. S/O 152051, OPS 29258, ZONE 1E-3 2L72 4F4 F A6WE E2EA 20050311000682005031100068EA 2005 3 11 2005FA0000247 120050208G6700269A731613 TRIM SYSTEM SCWZER269 269D 8059501EA LYC O360 HIO360* 41514EA CYCLIC STICK FAILED B NKVRK NONE O OTHER DEDESCENT 1 NM092096W152 S1865 DURING DESCENT TO LANDING THE CYCLIC STICK JAMMED SO AS TO NOT ALLOW ANY LATERAL MOVEMENT TO THE RT BEYOND NEUTRAL POSITION. THIS WAS CAUSED BY THE SPRING TUBE COMING OUT OF THE TRIM HOUSING AND LOCKING THE TRIM ARM AT A .7500 EXTENDED POSITION. THE SPRING TUBE CAME OUT OF THE TRIM HOUSING DUE TO A FAILURE OF THE EPOXY THAT HOLDS IT IN. THIS TRIM ACTUATOR HAS A DIFFERENT COLOR EPOXY THEN OLDER TRIM ACTUATORS. (WHITE-NEW/ GREEN-OLD) (K). 1G71 3U3 O0 4H12 1E10 20050314000312005031400031EU 2005 3 14 CA050105009 120050105G2435524321215 GENERATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL NR 2 DIRTY W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CRUISE FLIGHT, GEN 2 TRIPPED OFF LINE. PILOT TRIED TO RESET WITH NO SUCCESS, AND THEN RETURNED TO BASE. INVESTIGATION REVEALED THE ARMATURE TO BE VERY DIRTY. ARMATURE CLEANED, AIRCRAFT GROUND RUN AND FUNCTION TEST PREFORMED SATISFACTORY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20050615000082005061500008CE 2005 6 15 CA050517007 120050427G7603509440763 ARM BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL RT ENGINE WORN W O OTHER E VIBRATION/BUFFET LDLANDING 1 CA AFTER AN UNEVENTFUL FLT, CREW UNABLE TO GET THE RT ENGINE TO DROP BELOW 78 PERCENT NG AND IT HAD INSUFFICIENT REVERSE. MAINTENANCE INVESTIGATED AND FOUND THAT THE PIVOT ARM (50-944076-3) ON THE CAM CLUSTER HAD WORN ALLOWING IT TO SLIP ON THE CAM, CHANGING THE RELATIONSHIP BETWEEN THE POWER LEVER AND THE FUEL CONTROL UNIT. THIS CAUSED THE LOSS OF THE REVERSE CAPABILITY AND THE 78 PERCENT NG WITH THE POWER LEVER SET AT IDLE. THE BOLT SECURING THE PIVOT ARM WAS TIGHTEN TO STOP THE SLIPPING BUT THE SLOT IN THE PIVOT ARM BOTTOMED OUT BEFORE IT WAS TIGHT ENOUGH TO BE SECURE. THE PIVOT ARM WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. SEE ATTACHED PICTURES. 1L72 4T4 T A24CE E4EA 5 CSTC 20050311000762005031100076CE 2005 3 11 2005FA0000276 120050211G3246378941 HEAT SHIELD BFGOODRICH CESSNA560 560XL 2076702CE PWA 545 PW545A NE WHEEL CONTAMINATED C O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 SO11404BT 0708 5605038 AFTER LANDING, SMOKE AND SMALL FLAME OBSERVED FROM LT MAIN GEAR WHEEL. FIRE WAS EXTINGUISHED, NO DAMAGE TO LANDING GEAR OR AIRCRAFT. LT MAIN GEAR WHEEL ASSEMBLY WAS REPLACED AS A PRECAUTION. THE LT WHEEL HAD BEEN RECENTLY CLEANED WITH A WATER BASED SOLVENT IAW THE WHEEL CMM. SUSPECT THAT THE PARTS CLEANER USED TO CLEAN THE WHEEL MAY HAVE BEEN CONTAMINATED WITH A PETROLEUM BASED LIQUID. IAW MFG, THERE HAVE BEEN REPORTED CASES OF WHEEL FIRES DUE TO THE HEAT SHIELD ABSORBING A PETROLEUM SOLVENT. 2L72 4F4 FRTA22CE E00059EN 20050314000452005031400045NM 2005 3 14 CA050111004 120050105G2932106055410 TRANSMITTER BOEING727 727223 1384074NM PWA JT8 JT8D15A 52051NE HYD SYSTEM STICKING W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA 5665956659 (CAN) 'A' SYSTEM LOW LEVEL LIGHT ILLUMINATED, 'A' SYSTEM QUANTITY DOWN TO 2 GALLONS AFTER GEAR RETRACTION. CREW RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. MAINTENANCE ARRIVED AND INSPECTED AIRCRAFT AND FOUND 3 GALLONS INDICATING. FOUND SMALL LEAK ON B-NUT ON TAIL SKID ACTUATOR. ALSO FOUND HYDRAULIC QUANTITY TRANSMITTER STICKING ON 'A' SYSTEM RESERVOIR, INDICATION FLUCTUATED +/- 1.5 GALLONS BY TAPPING ON TRANSMITTER. TRANSMITTER REPLACED ENGINE RUNS CARRIED OUT WITH NO FURTHER LEAKS FOUND AND INDICATION WORKING CORRECTLY. 2L73 4F4 F A3WE E2EA 20050314000462005031400046NE 2005 3 14 CA050113006 320050111G6111 BLADE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP MCAULY4HFR344HFR34C652 NE PROPELLER TIP BROKEN W C ABORTED TAKEOFF D INFLIGHT SEPARATION TOTAKEOFF 1 CA 011390 (CAN) DURING TAKE OFF ROLL OUT, THE LT PROP STRUCK DEBRIS ON RUNWAY AND A 3 INCH PORTION OF THE TIP OF THE PROP BROKE OFF AND WENT THROUGH THE FUSELAGE JUST BEHIND AND BELOW THE AIRSTAIR DOOR. A 2 -3 INCH HOLE IN RT PROP SPINNER WAS ALSO DISCOVERED AT THE SAME TIME. 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20050314000482005031400048EA 2005 3 14 CA050118002 220050112G741410382971 BEARING CONT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL LT MAGNETO SEIZED W A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 CA C139805GR (CAN) AFTER TAKEOFF, IN CRUISE FLIGHT, THE PILOT NOTICED THE LT ENGINE TACHOMETER NEEDLE FLUCTUATING. SHORTLY AFTER, THE ENGINE STARTED SURGING AND A NOTICEABLE VIBRATION WAS FELT. THE AIRCRAFT RETURNED, AN INVESTIGATION REVEALED THE LT ENGINE MAGNETO, UPPER BEARING, P/N 10-382971, HAD SEIZED IN THE DISTRIBUTOR BLOCK P/N 10 -682058. THIS IS THE FIRST INCIDENT OF THIS NATURE AND WITH OVER 15,000 HOURS ON THIS ENGINE TYPE, FEEL NOTHING COULD HAVE PREVENTED THIS OCCURRENCE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20050314000492005031400049 2005 3 14 CA050119006 420050117G34256228047541 DISPLAY FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE COCKPIT FAILED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CLCLIMB 1 CA (CAN) DURING CLIMB, IT WAS OBSERVED THAT THE NR1 AND NR2 EMUX SINGLE CHANNELS FAILED. THE AIRCRAFT RETURNED TO BASE AND LANDED WITHOUT INCIDENT. THE NR1 AND NR2 MAIN FLIGHT DISPLAY UNITS WERE REPLACED AND CHECKED SERVICEABLE IAW MM 31-61-01. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRT E25NE 20050314000622005031400062CE 2005 3 14 2005FA0000190 120050223G6100D4951 FORK HARTZL BEECH 1900 1900D 1154162CE PWA PT6 PT6* 52043EA HARTZLHCE4A HCE4A3A NE PROPELLER CRACKED B LU4RK NONE O OTHER ININSP/MAINT 1 SO17 HJ1597 HJ1597 NDT SHOWS CRACKED IN 2 PLACES ON FORK. (K) (REF: 12235) 2L72 4T3 TRTA24CE E2NE 5 CP10NE 20050314000742005031400074SW 2005 3 14 2005FA0000224 120050215G6700NAS66039D BOLT BELL 407 407 1182206SW ALLSN 250C 250C47B GL DUAL CONTROL MISINSTALLED D K NONE O OTHER ININSP/MAINT 1 SW0745RX 1064 53412 CAE847447 FOUND THAT MAX POS OF THROT (POWER LEVER ANGLE) COULD NOT BE OBTAINED USING NML ADJ PROC. FOUND COPILOT THROTTLE LINKAGE WAS FOULING ON COLLECT ELBOW (PN 206-001-203-101). LINKAGE IS ATTACHED TO COL THROTTLE LEVER WITH (NAS6603-9D) BOLT INSTALLED W/HEAD FACING FWD. DUE TO INSTALL OF AIR COMM BLEED AIR HTR KIT (PN 407H-200M12 STC:SR00221DE) BOLT HAD BEEN TURNED AROUND W/HEAD FACING AFT. INSTR CALLS TO REPLACE FACTORY BOLT (NAS6603-9D) W/SHORTER BOLT (NAS6603-8D), NOT INSTALLED ON THIS AC. FOUND THAT BOLT (NAS6603-8D) ALSO FOULS IF WASHER/COTTER PIN ARE INSTALLED INCORRECTLY. ONLY FLIGHT FADEC FAILURE WOULD PILOT MOVE THROT PAST (FLIGHT) DETENT POS, USING MAX THROT RANGE. AC TO BE CHECKED FOR COMPLIANCE. 1G71 3U3 UO H2SW E1GL 20050314000852005031400085SW 2005 3 14 2005FA0000278 120050209G6230430310461101 BEARING BELL BELL 430 430 1182150SW ALLSN 250C 250C40B 03032NE SWASHPLATE WORN C K NONE O OTHER ININSP/MAINT 1 EA019SP 992 49086 49086 SWASHPLATE DUPLEX BEARING P/N 430-310-461-101 S/N ZV10085 FOUND WORN ON LOWER RACE. 1G72 3U3 URTH9SW E1GL 20050315001092005031500109SO 2005 3 15 2005FA0000255 220050121G7310628437 FITTING PIPER PA34 PA34200T 7103406SO CONT O360 LTSIO360EB 17025SO RT ENGINE SHEARED B FFKREA ENGINE SHUTDOWN UNSCHED LANDING K FLUID LOSS CRCRUISE 1 SO052140791 91 347870435 807968R AIRCRAFT WAS IN CRUISE FLIGHT WHEN IT EXPERIENCED AN IMMEDIATE ENGINE FAILURE ON THE RIGHT ENGINE, PILOT COULD NOT RESTART ENGINE. AFTER LANDING MAINTENANCE REPORTED A FITTING ON THE FUEL PUMP FOR THE VAPOR RETURN LINE HAD SHEARED. 1L72 3O3 O A7SO E9CE 20050315002232005031500223SW 2005 3 15 2005F00043 120050217G801123032027 STARTER BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL ENGINE INOPERATIVE G O OTHER O OTHER NRNOT REPORTED 1 SW0370Q 3160 CAE840517 SHUT DOWN THE HELICOPTER AT ICY, WHEN ATTEMPTING TO RESTART THE IGNITER WAS FIRING BUT THE COMPRESSOR WAS NOT TURNING. WENT BACK THROUGH THE CHECKLIST, ON THE SECOND ATTEMPT THE SAME THING HAPPENED, WITH MAINTENANCE PRESENT ON THE THIRD ATTEMPT THE COMPERSSOR WAS TURNING AND THE FUEL LIT OFF BUT PRIOR TO REACHING FLIGHT IDEL 30-40 PERCENT THE FLAME WENT OUT. MAINTENANCE REMOVED AND REPLACED THE STARTER GENERATOR, INSPECTED THE COMPRESSOR FOR FOD, INSPECTED FUEL NOZZLE, AIR LINES AND THE FUEL. GROUND RUN CHECK COMPLIED WITH AND STARTED THREE TIMES WITH THE PILOT RESTARTING THE LAST START. NO OTHER DEFECTS FOUND AND STARTING TIME IS 25-35 SECONDS. (M) 1G71 3U3 U H2SW E4CE 20050315002762005031500276NE 2005 3 15 2005F00045 220050211G7200 ENGINE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE RIGHT MALFUNCTIONED G O OTHER J WARNING INDICATION CRCRUISE 1 SW9987550 UE205 114436 FLT - FLL/EYW - DURING FLIGHT, DETECTED SMOKE IN THE COCKPIT AND CABIN. RIGHT ENGINE LOW PRESSURE ANNUNCIATOR ILLUMINATED. REMOVED AND REPLACED RIGHT ENGINE. OPERATIONAL CHECK NORMAL. (M) 2L72 4T4 TRTA24CE E26NE 20050308002812005030800281NE 2005 3 8 2005FA0000192 220050207G8520375202 CRANKSHAFT SCWZERG164 G164A 3952704EA PWA R1340 R1340* 52016NE ENGINE FRACTURED B CP2RK NONE O OTHER ININSP/MAINT 1 SW15 ZP102313 THE CRANKSHAFT REAR HALF FRACTURED IN TWO, JUST AFT OF THE MASTER ROD BEARING JOURNAL. (K) 1Q71 3R3 R 1A16 5E2 20050311000022005031100002EA 2005 3 11 2005FA0000252 220050131G8550LW18110 IMPELLER CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA OIL PUMP DESTROYED D A UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 SO35100M 1657 17265590 FLYING AT 1700 FT WITH PWR SETTING OF 2400 RPM, VIBRATION OCCURED. SCANNED GAGES, ALL NORMAL. PULLED CARB HEAT AND VIBRATION DISAPPEARED. SCANNED GAGES AGAIN, NOTICED OIL PRESS WAS ZERO. PWR STARTED TO BLEED OFF, RPM`S DROPPED TO 2200, DID NOT RESPOND TO THROTTLE ADVANCE. DESCENDED TO LAND, ENGINE SEIZED. LANDED AC IN A FIELD W/O DAMAGE TO AC, PERSONNEL INJURY. INSP REVEALED OIL SUPPLY AT 7 QTS. NO METAL IN OIL AND PROP WAS FREE TO ROTATE. PILOT INDICATED OIL TEMP WAS NORMAL DURING INCIDENT. UPON DISASSEMBLY OF ENG, FOUND A LARGE AMOUNT OF NON-FERROUS PARTICLES. OIL SCREEN FOUND TO BE CLEAN. DISSASSEMBLED OIL PUMP, FOUND IMPELLER PARTIALLY DESTROYED AND CRACK STARTING AT CENTER BORE. (SO35200508187)1H71 3O3 ONT3A12 E274 20050311000052005031100005NE 2005 3 11 2005FA0000188 220050203G73149234A8 PUMP GE LEAR 24 24D 5170311CE GE CJ610 CJ6108 30006NE RT ENG FUEL FLAKING B K NONE O OTHER ININSP/MAINT 1 EA23101VS GAT6864 218 211035A THE INTERNAL COATING IN THE GEAR SECTION OF THE FUEL PUMP STARTED FLAKING OFF AND GOT INTO THE HIGH PRESSURE FUEL LINE THAT GOES TO THE JET PUMPS IN THE RT WING. THE MATERIAL CLOGGED UP THE ORIFICES IN THE JET PUMPS, NOT ALLOWING FUEL TO BE TRANSFERRED FROM THE TIP TANK TO THE WING. NOTE: THE FUEL PUMP HAD ABOUT 4400 HOURS SINCE O/H. THE DATE WAS 1994 AT O/H IAW SUBMITTER. (EA23200505548) (K) 2L72 4J4 J A10CE 1E16 20050311000092005031100009NM 2005 3 11 CA050113004 120050112G2910AN81510D UNION DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE NR 1 HYD SYS FRACTURED W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CRUISE, THE NR 1 HYDRAULIC SYSTEM SUFFERED A TOTAL HYDRAULIC SYSTEM FLUID LOSS. A FULL EMERGENCY LANDING WAS DECLARED INTO BASE, WHICH WAS CARRIED OUT WITHOUT FURTHER INCIDENT. UPON INSPECTION BY ENGINEERING IT WAS DISCOVERED THAT THE NR 1 HYDRAULIC PRESSURE MANIFOLD HAD SUFFERED A FAILURE OF THE AN815-10D UNION. THE AIRCRAFT MFG HAS PREVIOUSLY IDENTIFIED THIS DEFECT, AND A SYD 8-29-002 WAS ISSUED THAT PERMITS THE REPLACEMENT OF THE ALLOY UNION WITH A CORROSION RESISTANT STEEL UNION. AS A RESULT OF THIS INCIDENT, ALL DASH 8 / 315 SERIES AIRCRAFT OPERATED THIS AIRLINE HAVE HAD SYD 8-29-002 INCORPORATED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050311000372005031100037WP 2005 3 11 LCQ30 120050119G5330 SKIN DOUG DC9 DC932 3022066WP PWA JT8 JT8D9A 52048NE FUSELAGE LIGHTNING STRIKEC K NONE O OTHER ININSP/MAINT 1 SO15867AT 47170 AIRCRAFT NOSE RT STA 69, APPROX. 15 INCHES ABOVE FLOOR REFERENCE PLANE HAS A LIGHTNING STRIKE. S/O 152051, OPS 29036, ZONE 1A-18 2L72 4F4 F A6WE E2EA 20050311000652005031100065GL 2005 3 11 2005FA0000277 220050120G73236871461 TUBE SCWZER269 269D 8059501EA ALLSN 250C 250C20 03013GL ENGINE WORN C R AUTOROTATION J WARNING INDICATION CRCRUISE 1 SW098375F1967 47 0031A CAE845077 THE PILOT WAS FLYING AT APPROX. 600 FEET INDICATED, WHEN HE EXPERIENCED A VIOLENT YAW TO THE RIGHT AND A HIGH PITCH ENG. SOUND. AN EMERGENCY LANDING WAS MADE WITH PARTIAL POWER UNTIL THE LAST 50 FT. AND THEN THE PILOT HAD TO ENTER AUTOROTATION WITH NO POWER DUE TO EXCESSIVE SURGING AND YAWING THAT RESULTED. IT HAD BEEN INSTALLED AND WORKING 47.1 HOURS BEFORE THE OCCURANCE. THE PROBLEM WAS A B-NUT ON THE PR LINE (REGULATED AIR PRESSURE) HAD SOMEHOW BACKED OFF FROM THE POWER TURBINE GOVERNOR. THIS CAUSED GOVERNOR FAILURE, CAUSING EXTREME ERRATIC OPERATION OF THE BENDIX FUEL SYS. COMPONENTS. 1G71 3U3 U0 4H12 E4CE 20050314000082005031400008EU 2005 3 14 TXER099315 120050120G240051455Y2 RELAY UROCOPEC155 EC155B 8681000EU TMECA ARRIELARRIEL2B NE UNKNOWN FAILED B TXERO OTHER O OTHER NRNOT REPORTED 1 SW09155EW 6660 RELAY FAILED. 1G72 3U3 U H10EU E00054EN 20050314000472005031400047WP 2005 3 14 CA050117004 120050116G324495502675 TIRE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE NLG OVERSERVICED W C ABORTED TAKEOFF WD INADEQUATE Q C INFLIGHT SEPARATION TOTAKEOFF 1 CA (CAN) DURING TAKE-OFF ROLL, A NOSE WHEEL SHIMMY WAS FELT AND REJECTED TAKE-OFF WAS CARRIED OUT. THE AIRCRAFT RETURNED TO THE GATE WITHOUT INCIDENT. UPON INVESTIGATION, IT WAS OBSERVED THAT THE NR2 NOSE WHEEL TIRE WAS OVER-SERVICED. THE NOSE WHEEL TIRE WAS SERVICED CORRECTLY IAW MM 12-00-00. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRTA6WE E9NE 20050314000532005031400053NE 2005 3 14 CA050105005 120050104G7810 EXHAUST DUCT SKRSKYS76 S76A 8143006NE ALLSN 250C 250C30S 03013GL NR 2 EGINE CRACKED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA CAE890793S (CAN) PILOT REPORTED, NO N2 INDICATION FOR NR 2 ENGINE. UPON INSPECTION, WHEN N2 PICKUP WAS REMOVED FROM THE ACCY GEARBOX, IT WAS OBSERVED THAT THE NR 5 BEARING NUT HAD BACKED OFF ON THE PT OUTER SHAFT TRAVELING AWAY FROM THE N2 PICKUP, HENCE 'NO N2 INDICATION'. IT WAS OBSERVED THAT THE 12 O'CLOCK MOUNTING STRUT ON THE EXHAUST COLLECTOR HAS DEVELOPED SEVERAL CRACKS. THE LOCK WASHER APPEARED TO HAVE BEEN DEFORMED IN TWO PLACES AT SOME POINT AND TIME, HOWEVER, THE DEFORMATIONS WERE EITHER WERE NOT SUFFICIENT TO PREVENT THE NR 5 NUT FROM BACKING OFF, OR THE NUT HAS NOT BEEN TORQUED CORRECTLY TO BEGIN WITH. TURBINE HAS BEEN REPLACED AND TEARDOWN REPORT REQUESTED FROM THE AUTHORIZED MAINTENANCE CENTER. 1G72 3U3 U H1NE E1GL 20050324000372005032400037SW 2005 3 24 CA050105015 120050104G79208941172 ADAPTER SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP OIL FILTER CRACKED W E ENGINE SHUTDOWN KJYFLUID LOSS WARNING INDICATION ENGINE STOPPAGE CRCRUISE 1 CA P54108 DURING CRUISE, RT ENG OIL PRESS WARNING LIGHT ILLUM ON ANNUNCIATOR. UPON LOOKING AT RT OIL PRESS IND FLT CREW NOTICED OIL PRESS DECREASING THROUGH 40 PSI. CREW ELECTED TO SHUTDOWN RT ENG AS A PRECAUTION. A/C CONTINUED IT'S FLIGHT TO YWG WHERE IS LANDED W/O FURTHER INCIDENT WITH EMERGENCY SERVICES STANDING BY. UPON INSPECTION BY MX OF RT ENG, OIL FILTER HOUSING ADAPTER FOUND CRACKED AT MOUNTING FLANGE WHICH PROPAGATED TO ADAPTERS O-RING GROOVE, WHICH CAUSED LOSS OF OIL. 3 OF 8 US QUARTS OF ENGINE OIL SYS LOST DUE TO LEAKING ADAPTER. ENG OIL PRESS ONLY DROPPED TO 40 PSI BEFORE ENG SHUTDOWN. OIL FILTER ADAPTER CHANGED & LEAK CHECKS PERFORMED. 2L72 4T4 TRTA8SW E4WE 20050324000512005032400051CE 2005 3 24 CA050120011 120050118G33971303640448 WIRE HARNESS BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL LIGHTS BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA ACFT POWERED UP FOR DAILY INSPECT IN HANGER. CABIN INDIRECT LIGHTING TURNED ON, SOON AFTER, SMOKE NOTED COMING FROM AFT HEADLINER ASSY, OUT OF CABIN DOOR. HEADLINER REMOVED & CONNECTER W2J4 WAS BURNED, & WIRING DAMAGED. IT SHOULD BE NOTED THAT WIRING IN CLOSE PROXIMITY TO OXYGEN LINES. SYS DISABLED UNTIL FURTHER INVESTIGATION COMPLETED. FOLLOWING DAY AFT PORTION OF LIGHTING DISCONNECTED & DEFERRED FOR PARTS AVAILABILITY, FRONT PORTION REMAINS OPERATIONAL. CONSULTED WITH RAYTHEON WHO ADVISED THAT SYS HAD 3000 VOLTS, & THAT CONNECTOR DAMAGE COMMON WHEN CONNECTERS ARE MISHANDLED DURING ASSY. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20050311000322005031100032WP 2005 3 11 LCQ49 120050120G5321 FLOOR PANEL DOUG DC9 DC932 3022066WP PWA JT8 JT8D9A 52048NE MAIN CABIN CORRODED C K NONE O OTHER ININSP/MAINT 1 SO15867AT 47170 MAIN CABIN FLOOR PANEL NR 83 HAS SURFACE CORROSION AND A PUNCTURE. S/O 152051, OPS 29530, ZONE 6C-125 2L72 4F4 F A6WE E2EA 20050324000342005032400034NE 2005 3 24 CA050112005 220050109G7250 ENGINE AGUSTAA109 A109 0260109EU PWC PW206CPW206C NE MALFUNCTIONED W E ENGINE SHUTDOWN RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 CA BC0368 THE ENGINE EXPERIENCED A RAPID, UNCOMMANDED DECREASE IN TORQUE IN FLIGHT, ACCOMPANIED BY AN INCREASE IN OTHER ENGINE PARAMETERS. THE ENGINE WAS SHUT DOWN AND THE AIRCRAFT RETURNED TO BASE. SUBSEQUENT INSPECTION REVEALED POWER TURBINE BLADE DAMAGE. PWC WILL INVESTIGATE THE INCIDEMT AND SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE DETERMINED. 1G72 3U3 U H7EU E42NE 20050328000322005032800032 2005 3 28 2005FA0000398 420050224G3416 ENCODER PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA ALTIMETER LEAKING B ZV8RK NONE O OTHER ININSP/MAINT 1 EA1395369 2825901 UNIT HAS INTERNAL LEAK. LEAK PROBABLE CAUSE DUE TO AGE. DISCREPENCY FOUND DURING MODE C AND ALTIMETER CORRELATION CHECK IAW AC43.6B. (K) 1L71 3O3 O 2A13 E274 20050328000432005032800043CE 2005 3 28 2005FA0000141 120050218G361099144022 PRECOOLER CESSNA525 525 2076601CE WILINTFJ44 FJ44 66000GL LT PYLON BLOWN D K NONE GM MULTIPLE FAILURE OVER TEMP ININSP/MAINT 1 SO2570KW 2200 5250050 DURING A PREFLIGHT INSPECTION IT WAS NOTED THE PAINT ON THE LOWER SKIN OF THE LEFT PYLON WAS DISCOLORED AND BUBBLED UP. VISUAL INVESTIGATION REVEALED THE PRECOOLER ASSEMBLY HAD FAILED, ALLOWING BLEED AIR INTO THE 6312209-1, DUCT ASSEMBLY, WHICH CAUSED THE 6312209-1 DUCT ASSEMBLY TO FAIL, ALLOWING BLEED AIR INTO THE PYLON. A CONDUCTIVITY CHECK OF THE COMPONENTS WHICH MAKE UP THE PYLON, PYLON SKINS AND FUSELAGE SKINS IN THE AREA OF THE PYLON SHOWED MANY OF THE COMPONENTS TEMPERATURE TO HAVE CHANGED. THE FUSELAGE SKIN IN THE PYLON AND THE AREAS SURROUNDING THE PYLON WERE NOT AFFECTED BY THE HEAT. 1L72 4F4 FRTA1WI E3GL 20050328000442005032800044SO 2005 3 28 2005FA0000350 220050309G8530 EXHAUST VALVE CESSNA150 150F 2071814CE CONT O200 O200* 17020SO NR 3 CYLINDER STUCK D K NONE O OTHER ININSP/MAINT 1 GL176627F174 15063227 629926A NR 3 CYLINDER HAS A STUCK EXHAUST VALVE. UPON CYLINDER REMOVAL IT WAS FOUND THAT THE VALVE HEAD WAS MUSHROOMED AND THE ROCKER ARM WAS ALSO DAMAGED. THIS CAUSED CONCERN DUE TO THE FACT THAT THE CYLINDER ONLY HAD 174.1 TOTAL HOURS SINCE IT WAS PURCHASED NEW. CYLINDER WAS SENT FOR REPAIRS AND THEN INSTALLED BACK ON THE ENGINE. (K) 1H71 3O3 O 3A19 E252 20050328000462005032800046SO 2005 3 28 TCMMAQ1 220050125G7414103493504 MAGNETO CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C402 GL ENGINE DEFORMED D K NONE W INADEQUATE Q C ININSP/MAINT 1 WP21PKMAB509 U20606806 532226 COIL WEDGES OVERDRIVEN TO THE POINT OF CONTACT WITH COIL, CRACKING THE INSULATION. 1H71 3O3 O A4CE E8CE 5 CP47GL 20050328000472005032800047SO 2005 3 28 TCMMAQ2 220050125G7414103493505 MAGNETO CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C402 GL ENGINE DEFORMED D K NONE W INADEQUATE Q C ININSP/MAINT 1 WP21PKMAB509 U20606806 532226 COIL WEDGES OVERDRIVEN TO THE POINT OF CONTACT WITH COIL, CRACKING THE INSULATION. 1H71 3O3 O A4CE E8CE 5 CP47GL 20050328000482005032800048CE 2005 3 28 2005FA0000142 120050205G321120410141 SUPPORT CESSNA177 177RG 2073709CE LYC O360 IO360A1B6 41514EA MLG ACTUATOR CRACKED D K NONE O OTHER ININSP/MAINT 1 EA172773V 70 177RG0694 AFTER GEAR EXTENSION PILOT DID NOT GET DOWN AND LOCKED GREEN LIGHT. EMERGENCY PROCEDURES WERE COMPLETED WITH SAME RESULTS. GEAR APPEARED DOWN AND LOCKED BY OBSERVERS ON THE GROUND, DURING LOW APPROACH. UPON TOUCH DOWN THE PILOT REPORTED A SAFE GEAR INDICATION. MAINTENANCE INSPECTION REVEALED MAIN GEAR ACTUATOR SUPPORT BRACKETS (LT AND RT) WERE CRACKED. ALSO FOUND ACTUATOR THROUGH PIN TO BE FRACTURED ON RT SIDE. SPECIFIC CAUSE OF FAILURE UNKNOWN. GEAR SYSTEM OPERATIONALLY CHECKED SATISFACTORY AFTER REPLACEMENT OF DAMAGED PARTS. AIRCRAFT HAD RECEIVED 100 HOUR INSPECTION 70 HOURS PRIOR WITH NO ABNORMALITIES NOTED IN MAIN GEAR ACTUATOR SYSTEM. 1H71 3O3 O A20CE 1E10 20050328000502005032800050SO 2005 3 28 2005FA0000143 120050126G3252400910 BOLT PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360* 17025SO NLG CENTERING MISINSTALLED G K NONE O OTHER ININSP/MAINT 1 GL25249PM3964 80 347770422 DURING RAMP INSPECTION, INSPECTOR NOTICED BOLT ATTACHING NOSE GEAR CENTERING DEVICE WAS INSTALLED INCORRECTLY, HEAD OF BOLT AT TOP OF HARDWARE STACK. AD 92-13-05 AND SB 893 REQUIRE BOLT TO BE INSTALLED WITH HEAD DOWN AND A CAUTIONARY PLACARD TO BE AFFIXED. PLACARD WAS ABSENT TOO. MAINTENANCE RECORD CONTAIN DESCRIPTION OF AD BEING ACCOMPLISHED IN 1993. SUBSEQUENT RECORD ENTRY IN 2003 DESCRIBES REPLACEMENT OF CENTERING DEVICE ROD END AND BOLT. SUSPECT PLACARD WAS ABSENT THEN, TECHNICIAN NOT AWARE OF AD REQUIREMENTS AND INSTALLED BOLT IAW STANDARD PRACTICES, RATHER THAN AD. 1L72 3O3 O A7SO E9CE 20050328000512005032800051SO 2005 3 28 2005FA0000215 120050104G534051023306 PLATE AMRGENAG5B AG5B 3990100SO LYC O360 O360A1D 41514EA SEATBELTS MISINSTALLED B IG8RK NONE O OTHER ININSP/MAINT 1 EA07123VU5944 10059 WHILE REPLACING REAR PX SEATBELTS, IT WAS DISCOVERED THAT REINFORCEMENT PLATE HAD BEEN INSTALLED ON FWD SIDE OF AFT SEAT BLKHD UNDER SEATBELT ATTACH BRACKET. (-6) PLATE SHOULD HAVE BEEN INSTALLED ON AFT SIDE OF BLKHD IAW AGAG DWG 5102299. MS203641032 (THIN SHEER NUT) WAS USED TO SECURE AN3-5A RETAINING BOLTS. NUTS SHOULD HAVE BEEN INSTALLED IAW DWG. RESULTS IN REDUCED SEATBELT ATTACHMENT STRENGTH COMPARED WITH DESIGN CONFIGURATION. AC APPEARED TO HAVE ORIGINAL SEATBELTS INSTALLED, THIS IMPROPER INSTALLATION WAS ACCOMPLISHED DURING ASSY. REAR SEAT SEATBELT OB ATTACH BRACKETS INSP FOR PROPER INSTALLATION OF PLATE AND PROPER ATTACH HARDWARE PRIOR TO CARRYING REAR SEAT PASSENGERS. (EA07200502731)(K) 1L71 3O3 ONT1L71 E286 20050328000532005032800053SO 2005 3 28 2005FA0000343 120050303G2140CD21701 SOLENOID VALVE PIPER PA31T PA31T 7103124SO PWA PT6 PT6A60A 52043NE HEATER FAILED D J8SRK NONE O OTHER ININSP/MAINT 1 GL11220FS 31T7620052 INSTALLED A NEW C&D AIRCRAFT HEATER AS A REPLACEMENT TO THE OLD HEATER UNIT. THE NEW HEATER WOULD RUN APPROX 5 MINUTES AND THEN PRODUCE NO HEAT. TROUBLESHOOTING SHOWED THAT FUEL WAS REACHING TO THE NOZZLE SOLENOID VALVE, BUT NOT PAST. VOLTAGE WAS PRESENT, AS WELL AS A CLICK FROM THE SOLENOID. REPLACED THE SOLENOID VALVE WITH THE SAME PN, AND HAD THE SAME ISSUE. FURTHER TROUBLESHOOTING, USING SHOP AIR ON THE VALVE AND A BENCH POWER SUPPLY, SHOWED THAT AFTER VALVE WOULD HEAT UP FROM THE ELECTRICAL CURRENT RUNNING THRU IT (APPROX 5 MINUTES) THE UNIT WOULD NOT ALLOW AIR TO PASS. THE MFG WAS ADVISED OF THESE FINDINGS, AND TESTED A REPLACEMENT VALVE OF THE SAME PN, BUT OF A DIFFERENT BATCH NR AND FOUND IT TO 1L72 3T4 T A8EA E4EA 20050328000582005032800058SO 2005 3 28 2005FA0000428 120050322G571278475009 RIB PIPER PA28 PA28R201 7102816SO LYC O360 IO360C1C6 41514EA RT WING CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15706ER2592 2844060 L715451A DURING A VISUAL INSPECTION, A SMALL CRACK WAS FOUND IN THE RT NOSE RIB P/N-62021-005 AND -004. A MORE THOROUGH INSPECTION REVEALED THAT AN ADDITIONAL CRACK, MUCH LARGER (ABOUT4 INCHES LONG), WAS FOUND ON THE RIB P/N-78475-009 AND -008. THESE RIBS ARE INCLUDED IN THE MOUNTING ASSEMBLY FOR THE P/N-95643-007 AND -006 AND BRACKET(MAIN GEAR TRUSS). THE OPERATOR OF THIS AIRCRAFT OPERATES A FLEET OF 6 OF THESE AIRCRAFT, AND ALL THE OTHER AIRCRAFT HAD SIMILAR CRACKS, ON BOTH LT AND RT WINGS. THE FLEET IS GROUNDED AND THE AFFECTED PARTS ARE BEING REPLACED. 1L71 3O3 O 2A13 1E10 20050328000632005032800063CE 2005 3 28 2005FA0000361 120050205G5311504200285758 FRAME BEECH 90 F90 1152909CE PWA PT6 PT6* 52043EA FUSELAGE FRACTURED D K NONE O OTHER ININSP/MAINT 1 GL05325WR LA10 DURING 6000 CYCLE AIRFRAME INSPECTION, FOUND LT AND RT CABIN FORMERS FRACTURED INTO 2 PIECES AT STA 177.00 AT WL 90-91 (APPROXIMATE) CAUSE OF FAILURE UNKNOWN (SUSPECT HARD LANDING). OBTAINED DER FOR REPAIR- CONSULTED MFG TECH SUPPORT ON FINDINGS. REMOVED AND REPLACED LT AND RT FORMERS. (K) 1L72 4T3 T A31CE E2NE 20050328000662005032800066CE 2005 3 28 2005FA0000257 120050217G561010138402519 WINDSHIELD BEECH 200 B200 1152922CE PWA PT6 PT6A60A 52043NE COCKPIT BROKEN B R1JRBA EMER. DESCENT UNSCHED LANDING O OTHER CRCRUISE 1 SO15345WK2025 BB1580 PILOT REPORTS THAT AT CRUISE ALTITUDE 24,000 FT, EVERYTHING NORMAL THE PILOTS WINDSHIELD OUTER GLASS SHATTERED. TO PREVENT RECURRENCE, REPLACED WITH KIT-STRESS FREE WINDOW INSTALLATION IAW INSTRUCTIONS PROVIDED. (K) 1L72 4T4 T A24CE E4EA 20050328000702005032800070CE 2005 3 28 2005FA0000302 120050205G3246D306001 WHEEL CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160CTM GL ZONE 700 FAILED D O OTHER O OTHER TXTAXI/GRND HDL 1 NE01132633920 17262622 L3598627A 723093 FOUND RT MAIN TIRE WAS LOCKED UP. PUT WHEEL ON DOLLY AND PULLED PLANE TO HANGER. CLOSER LOOK IN HANGER FOUND THAT RIM HAD BLOWN APART. DEFLATED TIRE AND LOOKED INSIDE RIM. FOUND PIECE BROKEN OUT OF CENTER SECTION OF RIM. CRACKS WERE FOUND AROUND BOLT HOLES OF RIM HALVES. EXAMINED BROKEN PIECE AND FOUND PORTION OF CRACK WAS OLD, REST BEING NEW. WITH AIR PRESSURE IN TIRE, IT WAS TRYING TO BLOW IT APART. HAVE SEEN THIS PROBLEM ALOT WITH MFG WHEELS HAVING CRACKS AROUND BOLT HOLES, BUT NEVER SEEN ONE COME APART. CAN ONLY SEE CRACKS WHEN CHANGING TIRE FROM INSIDE. THINK IT IS FROM OVER TIGHTENING THE BOLTS UPON ASSY WHEN CHANGING TIRES. ALSO, POOR DESIGN HAVING STEEL BOLTS THREADING INTO ALUMINUM HOUSING. 1H71 3O3 ONT3A12 E274 5 NP910 20050328000732005032800073CE 2005 3 28 2005FA0000430 120050318G3230504501025 TORQUE TUBE CESSNA414 414 2075908CE CONT O520 TSIO520* 17040SO MLG CRACKED C K NONE O OTHER ININSP/MAINT 1 WP05414RD4723 4140502 LANDING GEAR TORQUE TUBES ARE CRACKED. 1L72 3O3 ORTA7CE E8CE 20050328000902005032800090 2005 3 28 2005FA0000303 420050307G3418 TERMINAL CESSNA182 T182T 2072738CE LYC O540 TIO540* 41532EA STALL WARNING LOOSE D O OTHER O OTHER CRCRUISE 1 WP0766139 T18208367 STALL WARNING INOP, FOUND STALL WARNING SWITCH TERMINAL SCREW LAYING INSIDE WING, SCREW BACKED OUT IN FLIGHT. 1H71 3O3 ONT3A13 E14EA 20050328001002005032800100SO 2005 3 28 2005FA0000258 120050219G55146358500 TAB PIPER PA28 PA28R200 7102811SO LYC O360 IO360A1A 41514EA STABILIZER CRACKED C R5NSO OTHER J WARNING INDICATION CRCRUISE 1 EA05413434853 28R7435171 PILOT NOTED IN FLIGHT WITH MAX NOSE DOWN TRIM AND AIRCRAFT STILL WANTED TO CLIMB. INSP REALIZED THAT STABILATOR TAB HORN BEGAN TO TEAR AWAY FROM TAB SKINS. THIS DECREASED OVERALL TAB EFFECTIVENESS. STAB TRIM TAB SKIN AND RIBS WERE CRACKED AT THE IB JACK SCREW CONTROL HORN ATTACH POINT. TAB SKINS (PN 63586-00, 63586-01, NEW STYLE REPLACEMENT (PN 635866-800). TAB IB RIB (PN 63587-00, 63587-01, NEW STYLE REPLACEMENT (PN 63587-002, 63587-003). NOTE: KNOTS 2U STAB/TAB GAP SEAL KIT IS INSTALLED ON THIS AIRCRAFT. THIS KIT MAY HAVE CAUSED EXCESSIVE PRESSURE ON THE TAB`S AND CAUSED CRACK TO FORM AT EACH ATTACH POINT. (K) 1L71 3O3 O 2A13 1E10 20050328001112005032800111CE 2005 3 28 2005FA0000174 120050214G5540NAS682A3 NUT PLATE CESSNA CESSNA150 150D 2071810CE CONT O200 O200* 17020SO RUDDER PIVOT WORN G A UNSCHED LANDING O OTHER CRCRUISE 1 NM07901SW 15060734 UPPER RUDDER PIVOT BOLT BACKED OUT OF SELF-LOCKING NUTPLATE AT UPPER RUDDER PIVOT ATTACH AND PIVOT POINT WHILE IN FLIGHT, RUDDER WAS RIPPED FROM THE LOWER BELLCRANK CONTROL AND DEPARTED AIRCRAFT. AIRCRAFT LANDED WITHOUT INCIDENT. RUDDER WAS RECOVERED AND THE UPPER PIVOT BOLT WAS RETAINED IN THE UPPER RUDDER CAP. THE BOLT COULD BE INSERTED IN THE NUTPLATE WITH LIGHT FINGER PRESSURE ONLY, AND REMOVED SAME WAY. NUTPLATE WAS WORN AND LOST ITS LOCKING ABILITY. AT INSTALLATION OF A NEW FACTORY RUDDER ASSEMBLY, A DRILLED AN BOLT WAS USED TO INCLUDE A COTTER KEY BELOW THE NUTPLATE. (NM07200503694)(K) 1H71 3O3 O 3A19 E252 20050328001172005032800117GL 2005 3 28 2005FA0000305 320050203G6110C4451 FERRULE MCAULY CESSNA210 210J 2073439CE CONT O520 IO520* 17032SO MCAULY3A32C D3A32C88 GL BEARING FLANGE CRACKED B W59RK NONE O OTHER ININSP/MAINT 1 WP073301S 746891 21059101 746891 DURING DISASSEMBLY FOR OVERHAUL, BLADE RETENTION FERRULE C4451 FOUND CRACKED IN BEARING FLANGE ON NR 2 BLADE. THE CRACK APPEARS TO HAVE STARTED AT AN OLD ACTUATING PIN HOLE AND IS OVER THREE INCHES LONG. S/B 196B HAD NOT BEEN ACCOMPLISHED ON THIS PROPELLER. 1H71 3O3 O 3A21 E5CE 5 CP21EA 20050328001182005032800118SW 2005 3 28 2005FA0000413 120050111G6410212010750105 BLADE BELL 412 412EP 1182205SW PWA PT6T PT6T3 52045EA TAIL ROTOR VIBRATION B VE3RO OTHER O OTHER NRNOT REPORTED 1 WP01304FD936 36229 ON FIRST GROUND RUN, AFTER APPROX 24 HOURS OF HARD RAIN, THE HELICOPTER DEVELOPED A SEVERE VIBRATION. THE VIBRATION WAS TRACED TO A TAIL ROTOR BLADE. SUSPECT BLADE COLLECTED THE RAIN WATER. THE BLADE WAS SCRAPPED IAW THE MM. (K) 1G72 4U4 U H4SW E22EA 20050330000072005033000007CE 2005 3 30 2005FA0000408 120050302G3030 RELAY CESSNA500 560CESSNA 2076750CE PWA 545 PW545A NE SENSOR HEAT FAILED D K NONE O OTHER ININSP/MAINT 1 EA091094L 5605094 DURING POST FLIGHT WALK AROUND, PILOT NOTICED THAT THE ROSEMONT SENSOR HAD ICE ON IT. UPON OPERATIONAL CHECK, FOUND THAT THE SENSOR WAS NOT HEATING. TROUBLESHOOTING THE SYSTEM, FOUND THAT THERE WAS NO POWER TO THE HEATING ELEMENT OF THE PROBE. UPON FURTHER INVESTIGATION, FOUND THAT THE RELAY KC311 PINS- X1 AND X2 WERE PINNED IN REVERSE ORDER. REPINNED THE RELAY AND OPS CHECKED THE SYSTEM, GOOD. (EA09200500318) (K) 2L72 4F4 FRTA22CE E00059EN 20050330000142005033000014CE 2005 3 30 2005FA0000407 120050308G32132342100022 STRUT LEAR 60 60LEAR 5170707CE PWA 305 PW305 NE NLG DAMAGED B WVERK NONE O OTHER ININSP/MAINT 1 EA09247FX 187 DURING 300 HOUR INSPECTION (GEAR SERVICE) THE INNER STRUT CHROME WAS FOUND DAMAGED APPROXIMATELY .001 INCH DEEP. PROBABLE CAUSE: WEAR OF SEALS CAUSING THE UPPER CAM TO CONTACT THE INNER CYLINDER. INSPECTION REPACK OF THE NOSE LANDING GEAR ASSY AT 3,000 LANDING INSPECTION. (EA09200504488) (K) 2L72 4F4 FRTA10CE E35NE 20050330000152005033000015CE 2005 3 30 2005FA0000397 120050225G5712082340063 BULKHEAD CESSNA CESSNA421 421B 2076014CE CONT O520 GTSIO520C 17032SO LT TIP TANK CRACKED B E81RK NONE O OTHER ININSP/MAINT 1 GL03421CT6881 421B0510 DURING AN ANNUAL INSPECTION, FOUND AFT BULKHEAD OF THE LT WING TIP TANK ASSY. CRACKED THROUGH FROM APPROXIMATE CENTER OF THE IB LIGHTENING HOLE HORIZONTALLY TO THE BULKHEAD IB EDGE. CRACKED AREA IS ADJACENT TO AFT ATTACH POINT FOR THE TIP TANK ASSY. AIRCRAFT HISTORY THIS AREA UNKNOWN; MAY HAVE POSSIBLY BEEN CAUSED BY PREVIOUS GROUND MISHANDLING OR (HANGAR RASH) TYPE INCIDENT. (K) 1L72 3O3 O A7CE E7CE 20050330000162005033000016CE 2005 3 30 2005FA0000399 120050303G1430 SCREW HONEYWELL KS271C CESSNA172 172S 2072439CE LYC O360 IO360A1A 41514EA ROLL SERVO BACKED OUT D K NONE O OTHER ININSP/MAINT 1 SW11434SP 3679 172S8302 ROLL SERVO HAD SCREW COME LOOSE AND MADE CONTACT WITH CIRCUIT BOARD CAUSING SHORT AND BURNING UP COMPONENTS ON BOARD. RECOMMEND TO USE LOCTITE ON SCREWS TO PREVENT SCREWS FROM BACKING OUT OF HOLES. (K) 1H71 3O3 ONT3A12 1E10 20050330000172005033000017CE 2005 3 30 2005FA0000396 120050225G5712502205053 RIB CESSNA421 421B 2076014CE CONT O520 GTSIO520C 17032SO WINGS CRACKED B E81RK NONE O OTHER ININSP/MAINT 1 GL03421CT6881 421B0510 DURING AN ANNUAL INSP, NOTED CRACKS IN LT AND RT WING T/E RIBS AT FORWARD END AFT SPAR ATTACHMENT POINT AREAS. AFFECTED RIBS ARE FIRST RIBS IB OF SPOILER SYSTEM ACTUATOR ATTACH POINTS. ALSO FOUND CRACKED AREA IN WING OB T/E SKIN PANEL AT ATTACHMENT POINT TO WS 118.24 T/E RIB, ALSO ADJACENT TO THE RT SPOILER AREA. AIRCRAFT HAD A MFG ELECTRIC/HYDRAULIC SPOILER SYSTEM INSTALLED PREVIOUSLY IAW STC SA4755NM. SUSPECT IN-FLIGHT STRESSES FROM NORMAL OR HIGH-SPEED OPERATIONS CAN BE CAUSING ACCELERATED FATIGUE IN THESE AREAS. RECOMMEND ROUTINE CLOSE VISUAL INSPECTION OF THESE AREAS. (K) 1L72 3O3 O A7CE E7CE 20050330000212005033000021CE 2005 3 30 2005FA0000259 120050222G7820045033862 MUFFLER CESSNA150 150E 2071812CE CONT O200 O200A 17020SO ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 NM113596J 15061296 607525A CRACKING AROUND FRONT RISER. PART HAS BEEN INSPECTED IAW AD 67-03-01. PRESSURE CHECK AS REQUIRED AT 100 DEGREE INTERVELS. AIRCRAFT NOT FLOWN SINCE LAST ANNUAL. 8.9 HOURS SINCE LAST REQUIRED INSPECTION IAW AD. RECOMMEND INSPECTION ANNUALLY IAW AD. (K) 1H71 3O3 O 3A19 E252 20050330000242005033000024NM 2005 3 30 2005FA0000410 120050307G7603 THROTTLE BOEING757 757200 1384950NM RROYCERB211 RB211535* NE NR 1 ENGINE MISINSTALLED B LLMYO OTHER W INADEQUATE Q C NRNOT REPORTED 1 EA35512TZ 26635 30763 REF: (ATC0515) NR 1 ENGINE THROTTLE TELEFLEX CABLE OUTER SLEEVE RETAINING NUT FOUND TO HAVE COME ADRIFT, ALLOWING THE OUTER PORTION OF TELEFLEX CABLE TO MOVE. THE RETAINING NUT, ALTHOUGH DRILLED FOR WIRE LOCKING, THERE IS NO EVIDENCE OF WIRE LOCKING BEING CARRIED OUT. AC ENTER THE HANGAR WITH TECH LOG DEFECT OF THROTTLE STAGGER, PLA FAULT AND FLUCTUATING EPR. BELIEVE THAT HTIS IS RELATED TO THE ABOVE DEFECT. IN ADDITION, 4 FAN CASE BOLTS AND NUTS WERE FOUND MISSING FROM THE FAN CASE FLANGE BETWEEN 3 OCLOCK AND 10 OCLOCK POSITIONS. ALL DEFECT RECERTIFICATION HAS BEEN CARRIED OUT AND DOCUMENTED AT REPAIR STATION UNDER W/O: 5200/2005. (K) 2L72 4F4 FRTA2NM E12EU 20050330000252005033000025CE 2005 3 30 2005FA0000187 120050215G3260622EN186 SQUAT SWITCH CESSNA525 525 2076601CE WILINTFJ44 FJ44 66000GL LT MLG DEFECTIVE B K NONE O OTHER ININSP/MAINT 1 WP07901CJ1252 5250278 SQUAT SWITCH FOUND WITH ROLLER MISSING. DURING TROUBLESHOOTING FOR THRUST REVERSER (T) DEPLOYMENT SHORTLY AFTER TAKEOFF. AIRCRAFT RETURNED TO FIELD AND MADE AN UNEVENTFUL LANDING. REPLACED SQUAT SWITCH WITH NEW OF SAME PN. NO OTHER DEFECTS NOTED ON SWITCH. RECOMMEND THAT PRE-FLIGHT PROCEDURES INCLUDE CHECK FOR PRESENCE AND CONDITION OF SQUAT SWITCH ROLLERS. (K) 1L72 4F4 FRTA1WI E3GL 20050330000282005033000028CE 2005 3 30 2005FA0000415 120050311G3240SM50D7 RELAY BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO BRAKES FAILED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP078240T3 CE1542 825916R DURING GEAR RETRACTION, GEAR WAS VERY SLOW TO EXTEND. TROUBLESHOOTING SYSTEM FOUND DYNAMIC RELAY WAS LOOSING 12 VOLTS ACROSS DOWN RELAY SIDE. PROBABLE CAUSE AT THIS TIME IS UNKNOWN RETURNED TO MFG FOR ANALYSIS. NO RECOMMENDATION AT THIS TIME. (K) 1L71 3O3 O 3A15 E5CE 20050330000342005033000034WP 2005 3 30 2005FA0000418 120050107G6510269A5498005 SHAFT HUGHES269 269C 4470504WP LYC O360 HIO360* 41514EA DRIVE SPLINES WORN D K NONE O OTHER ININSP/MAINT 1 SO15269TJ414 S1807 DURING ANNUAL INSPECTION GREASE IN LOWER PULLEY SHAFT HAD A RUSTY (BROWN) COLOR (NOTE: ANDEROL GREASE IS BLACK). UPON INSPECTION PART HAS 414.2 HOURS SINCE NEW, THE SPLINES WERE WORN BEYOND LIMITS. SPECULATION OF MFG AND OUR FACILITY IS THAT THE GREASE WAS CONTAMINATED. (K) 1G71 3O3 O 4H12 1E10 20050330000392005033000039CE 2005 3 30 2005FA0000387 120050201G5711052340051 SPAR CESSNA172 172H 2072424CE CONT O300 O300D 17022SO MCAULY1C172 1C172EM GL RT WING CRACKED D K NONE O OTHER ININSP/MAINT 1 SO094974R13293 17256328 29834 XK44008 DURING A BORESCOPE INSPECTION OF THE REAR WING SPAR, A CRACK WAS FOUND AT THE IB FLAP TRACK ATTACH POINT. PROBABLE CAUSE IS FATIGUE. THIS IS A VERY HIGH TIME AC WITH OVER 13,000 HOURS TT. IT HAS ALSO BEEN USED AS A FLIGHT TRAINER FOR ITS ENTIRE LIFE. (K) 1H71 3O3 ONT3A12 E253 5 NP910 20050330000442005033000044SO 2005 3 30 2005FA0000195 220050207G731464621238AZR PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO FUEL SYSTEM INOPERATIVE B VJ3RO OTHER RYJPARTIAL RPM/PWR LOSS ENGINE STOPPAGE WARNING INDICATION NRNOT REPORTED 1 WP071556A178 CE1318 830106R ENGINE KEPT DYING AT IDLE. MAINTENANCE TECH TROUBLESHOT SYSTEM AND FOUND THAT THE ENGINE DRIVEN FUEL PUMP PRESSURE WILL NOT STABILIZE. VARIES BETWEEN 7.5 TO 10 PSI. REMOVED AND REPLACED ENGINE DRIVEN FUEL PUMP OPS CHECK NORMAL. PROBABLE CAUSE INTERNAL FAILURE IN FUEL PUMP. (K) 1L71 3O3 O 3A15 E5CE 20050330000812005033000081SW 2005 3 30 2005FA0000067 120050106G5270 WARNING SYSTEM SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP PAX DOOR MALFUNCTIONED B OZ5RA UNSCHED LANDING N FALSE WARNING CRCRUISE 1 NM0560NE AC760B MRR-M05-3, CREW OBSERVED THE CABIN DOOR LIGHT CAME ON DURING CRUISE. CREW VERIFIED HANDLE WAS IN THE FULL CLOSED POSITION. THE LIGHT WENT OUT WHEN CABIN DIFFERENTIAL PRESSURE WAS LOWERED. THE LIGHT STAYED OUT FOR THE REMAINDER OF DESCENT AND LANDING. CREW ALSO NOTED THE DOOR SEAL LEAKS. ONE OF THE FOLLOWING: DOOR CLOSING PROCEDURES, DOOR HARD TO CLOSE, DOOR CLICKCLACK RIGGING/ LUBRICATION, OR INDICATOR SWITCH RIGGING. NO FAULT FOUND, COULD NOT GET SYSTEM TO FAIL. COULD NOT DUPLICATE MALFUNCTION, INITALLY DEFERRED IAW MEL. (K) 2L72 4T4 TRTA8SW E4WE 20050314000892005031400089CE 2005 3 14 2005FA0000196 120050210G3211MS203922C45 CLEVIS PIN BEECH 90 E90 1152914CE PWA PT6 PT6A60A 52043NE RT MAIN GEAR BROKEN B AIHRO OTHER E VIBRATION/BUFFET LDLANDING 1 GL116571S LW171 PILOT REPORTED SOUND (LIKE A TIRE BLOWING OUT) UPON LANDING. THERE WAS SEVERE VIBRATION ON ROLLOUT. THERE WAS NO VIBRATION ON TAXI BACK TO HANGAR. UPON EXITING AIRCRAFT, PILOT NOTICED RT MAIN GEAR MISALIGNED. FURTHER INSP BY MAINTENANCE, FOUND RETAINING CLEVIS PIN FOR UPPER TORQUE LINK SHEARED, CAUSING PIN TO DRIFT OB, CAUSING THE UPPER TORQUE LINK TO BREAK AND SEPARATE FROM THE TRUNNION. RECOMMEND REPLACING CLEVIS PINS WITH NEW EVERY TIEM AD 2002-01-10 IS PERFORMED. (GL11200507567) (K) 1L72 3T4 T 3A20 E4EA 20050324001502005032400150SO 2005 3 24 MN3525 220050224G8500IO520F ENGINE CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL MAKING METAL B K NONE O OTHER ININSP/MAINT 1 CE039938Z2508 872 U20606757 112700R 010968 DURING AIRCRAFT 50 HOUR INSPECTION, FOUND METAL IN THE OIL FILTER. TOOK OIL SAMPLE DURING ENGINE OIL CHANGE. RECOMMENDED TO OWNER TO CHANGE ENGINE. REPLACED ENGINE AFTER OWNER APPROVAL. 1H71 3O3 O A4CE E5CE 5 CP47GL 20050328000412005032800041GL 2005 3 28 2005FA0000395 220050316G7310P49389 CHECK VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL FUEL SYSTEM MISINSTALLED C K NONE W INADEQUATE Q C ININSP/MAINT 1 EA0118SP 796 53533 COMPONENT INSTALLED ON THE SIDE OF ENGINE. WHEN IT WAS INSPECTED FOUND NUT DISLODGED FROM STUD COVER OF CHECK VALVE. 1G71 3U3 UO H2SW E1GL 20050328000642005032800064CE 2005 3 28 2005FA0000298 120050205G3246D306001 WHEEL CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160CTM GL MLG FAILED D D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 NE01132633920 17262622 L3598627A 723093 FOUND RT MAIN TIRE WAS LOCKED UP. PUT WHEEL ON DOLLY AND PULLED PLANE TO HANGER. CLOSER LOOK IN HANGER FOUND THAT RIM HAD BLOWN APART. DEFLATED TIRE AND LOOKED INSIDE RIM. FOUND PIECE BROKEN OUT OF CENTER SECTION OF RIM. CRACKS WERE FOUND AROUND BOLT HOLES OF RIM HALVES. EXAMINED BROKEN PIECE, FOUND THAT PORTION OF CRACK WAS OLD, REST BEING NEW. WITH AIR PRESSURE IN TIRE, IT WAS TRYING TO BLOW IT APART. HAVE SEEN THIS PROBLEM ALOT WITH MFG WHEELS HAVING CRACKS AROUND BOLT HOLES, BUT HAVEN`T SEEN ONE COME APART. YOU CAN ONLY SEE CRACKS WHEN CHANGING TIRE FROM THE INSIDE. I THINK IT IS FROM OVER-TIGHTENING BOLTS UPON ASSY WHEN CHANGING TIRES. ALSO, HAVING STEEL BOLTS THREADING INTO ALUMINUM HOUSING. 1H71 3O3 ONT3A12 E274 5 NP910 20050328000692005032800069CE 2005 3 28 2005FA0000301 120050205G3246D306001 WHEEL CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160CTM GL ZONE 700 FAILED D O OTHER O OTHER TXTAXI/GRND HDL 1 NE01132633920 17262622 L3598627A 723093 FOUND RT MAIN TIRE WAS LOCKED UP. PUT WHEEL ON DOLLY AND PULLED PLANE TO HANGER. CLOSER LOOK IN HANGER FOUND THAT RIM HAD BLOWN APART. DEFLATED TIRE AND LOOKED INSIDE RIM. FOUND PIECE BROKEN OUT OF CENTER SECTION OF RIM. CRACKS WERE FOUND AROUND BOLT HOLES OF RIM HALVES. EXAMINED BROKEN PIECE AND FOUND THAT PORTION OF CRACK WAS OLD, REST BEING NEW. WITH AIR PRESSURE IN THE TIRE, IT WAS TRYING TO BLOW IT APART. HAVE SEEN THIS PROBLEM ALOT WITH MFG WHEELS HAVING CRACKS AROUND BOLT HOLES. BUT NEVER SEEN ONE COME APART. YOU CAN ONLY SEE CRACKS WHEN CHANGING TIRE FROM INSIDE. THINK IT IS FROM OVER TIGHTENING THE BOLTS UPON ASSEMBLY WHEN CHANGING TIRES. ALSO, HAVING STEEL BOLTS THREADING INTO ALUMINUM HOUSING. 1H71 3O3 ONT3A12 E274 5 NP910 20050328001052005032800105EA 2005 3 28 2005FA0000304 220050207G8530LW12425 CYLINDER HEAD PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA ENGINE CRACKED D E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS DEDESCENT 1 EA1762BA 2588 738 274859 L947248 DESCENDING IN FLIGHT NR 3 CYL ON RT ENG FAILED. ENG WAS SHUTDOWN AND FEATHERED. AC LANDED WITHOUT FURTHER INCIDENT. THERE WAS NO FIRE. POST INCIDENT INSP OF AREA FOUND, CYLINDER HAD CRACKED AND DISLOCATED AT INTERFACE AREA OF STEEL BARREL AND CYLINDER HEAD. INTAKE PUSHROD HAD SEPARATED AND WAS LYING ON THE CYLINDER HEAD, WITH CONSIDERABLE OIL LOSS. FURTHER INSP FOUND ENGINE BAFFLING INTACT AND CORRECTLY POSITIONED. CYLINDER PRESENTED NO OBVIOUS FLAWS AT THE MOST RECENT INSP, WITH OIL CONSUMPTION AND COMPRESSION WITHIN NORMAL LIMITS. IT IS SUSPECTED THAT A DEFECT IN CYLINDER REPAIR PROCESS (I.E., GRINDING) ALLOWED AN ABNORMAL STRESS CONCENTRATION TO CAUSE A FAILURE. CYL WAS REGROUND AND HONED TO P.010. (K) 1L72 3O3 O 1A10 1E4 20050330000092005033000009EU 2005 3 30 2005FA0000403 120050311G5420L713M2055102 BRACKET UROCOPEC135 EC135T1 5620026EU TMECA ARRIELARRIEL1 60030NE NACELLE CRACKED B A7RRK NONE O OTHER ININSP/MAINT 1 SW19135TG262 0298 EJECTOR COWLING ALIGNMENT BRACKET CRACKED DUE TO VIBRATION. (K) 1G72 3U3 U H88EU E19EU 20050330000182005033000018CE 2005 3 30 2005FA0000402 120050209G56105042006930 WINDSHIELD BEECH 100 B100 1152919CE GARRTTTPE331TPE331* 01514WP COCKPIT BROKEN D O OTHER J WARNING INDICATION CRCRUISE 1 CE01564CA3905 BE58 INSIDE LAYER OF CO-PILOT WINDSHIELD CRACKED WHILE IN-FLIGHT AT 25,000 FT. AIRCRAFT RETURNED. NO PROBABLE CAUSE OR RECOMMENDATION CAN BE MADE TO PREVENT REOCCURRENCE. WINDSHIELD CRACKED FOR NO APPARENT REASON. (K) 1L72 4T3 T A14CE E2WE 20050330000472005033000047CE 2005 3 30 2005FA0000416 120050310G7430A5109 IGNITION SWITCH CESSNA172 172R 2072401CE LYC O360 IO360A1A 41514EA COCKPIT WORN D K NONE O OTHER ININSP/MAINT 1 WP27106AF3488 17281055 DURNG ENGINE RUNUP MAGNETO CHECK, IGNITION SWITCH WILL NOT CAUSE RPM TO DROP WHEN KEY IS TURNED TO LT POSITION. WHEN KEY IS IN LT POSITION, SLIGHT SIDE TO SIDE MOVEMENT OF KEY WILL CAUSE RPM DROP. UPON OPENING SWITCH, FOUND WORN AND ARCHING CONTACTS. THE ABOVE MALFUNCTION SEEMS TO OCCUR DUE TO WORN CONTACTS ON SWITCH INTERIOR. DURING RUNUP, FOLLOW MFG CHECKLIST FOR MAGNETO CHECK. IF ABOVE DEFECT IS FOUND, RECOMMENDATION WOULD BE TO TROUBLESHOOT SYSTEM, VERYIFYING THAT THE SIDE TO SIDE MOVEMENT OF KEY ALLOWS NORMAL SWITCH OPERATION, UPON DETERMINATION REPLACE OR OVERHAUL IGNITION SWITCH. (K) 1H71 3O3 ONT3A12 1E10 20050330001512005033000151SO 2005 3 30 2005FA0000117 220050111G8530AEC631397ST2 CYLINDER HEAD BEECH 36 A36 1151604CE CONT O550 IO550B SO ENGINE SEPARATED B MW2RK NONE O OTHER ININSP/MAINT 1 GL17362SB409 E1848 ECI CYLINDER HEAD AND BARRLE SEPERATION. (K) 1L71 3O3 O 3A15 E3SO 20050330001562005033000156CE 2005 3 30 2005FA0000120 120050110G321305412024 BUSHING CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL MLG STRUT WORN B OF1RK NONE O OTHER ININSP/MAINT 1 EA179453Z495 17280193 L2722351A RD071 DURING NORMAL ANNUAL INSPECTION RT MAIN GEAR WAS JACKED AND CHECKED FOR ATTACHMENT FREEPLAY. EXCESSIVE FREEPLAY WAS NOTED AND UPON FURTHER VISUAL INSPECTION, IT WAS DETERMINED THAT RUBBER EXTRUDING OUT FROM THE GAP BETWEEN THE RT MAIN GEAR LEG AND PN 05912024, GEAR LEG BUSHING WAS RESPONSIBLE FOR THE INCREASED FREEPLAY. REPLACEMENT OF THE PIN - 05412024 RT MAIN GEAR LEG BUSHING WITH NEW ELIMINATED ALL RT GEAR LEG FREEPLAY. (K) 1H71 3O3 ONT3A12 1E10 5 NP12EA 20050330001642005033000164WP 2005 3 30 2005FA0000124 220050124G72103101320 HOUSING MTSBSIMU2 MU2B60 5780460CE GARRTTTFE731TFE731* 01518WP SCAV PUMP FAILED B W6NRO OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 GL25772DA 772SA IN FLIGHT, PILOT NOTICED FLUCTUATING OIL PRESSURE AND TORQUE. PRECAUTIONARY LANDING MADE, FOLLOWING TROUBLESHOOTING ENGINE WAS DISASSEMBLIED GEARBOX SCAVENGE OIL PUMP WAS CRACKED. APPROXIMATELY 7 HOURS PRIOR, THE NR 8 STAINLESS OIL SCAV. LINE CRACKED. APPROXIMATELY 7 HOURS PRIOR THE NR 8 STAINLESS OIL SCAV LINE CRACKED. IT IS BELIEVED OIL PRESSURE CYCLING FROM LINE FAILURE FRACTURED SCAV PUMP HSG REPLACED PUMP. (K) 1H72 3T4 FRTA10SW E6WE 20050401000062005040100006EA 2005 4 1 2005FA0000459 220050321G7414BL68256013 MAGNETO PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540* 41532EA ENGINE INOPERATIVE D O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 EA0332SJ 32R8429016 AIRCRAFT ARRIVED AT HANGAR WITH ROUGH RUNNING ENGINE. FOUND DUEL MAG DEAD AND ON SIDE. REMOVED MAG FROM ENGINE. FOUND TEETH MISSING ON MAG GEAR. WAS TOLD BY OWNER THAT MAG WAS NOT THAT OLD. 1L71 3O3 O A3SO E14EA 20050401000082005040100008EA 2005 4 1 2005FA0000461 220050318G732262F1 STOP PIN PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA THROTTLE BODY WORN B UC2RK NONE O OTHER ININSP/MAINT 1 GL194146T 224 G508088 2843168 L3625536A STUDENT PILOT REPORTED THROTTLE WOULD NOT ADVANCE BEYOND IDLE. FOUND CARBURETOR BINDKING INTERNALLY. DISASSEMBLED CARBURETOR AND FOUND AIR METERING PIN STOP PIN WORN WHICH ALLOWED AIR METERING PIN TO EXTEND BEYOND NORMAL RANGE AND JAM BETWEEN STOP PIN AND ACTUATING ARM ON PUMP LEVER ASSEMBLY. (K) 1L71 3O3 O 2A13 E286 20050401000132005040100013SO 2005 4 1 2005FA0000357 120050321G71206843949 SUPPORT LKHEED382 382G 526414USO ALLSN 501D 501D22A 03006GL NR 2 ENGINE INCORRECT G NO1YK NONE O OTHER ININSP/MAINT 1 EA35401LC 4606 8CLMG DURING NR 2 ENGINE REPLACEMENT AND INSTALLATION OF THERMOCOUPLES THE FOLLOWING OBSERVATIONS WERE MADE: 2 COMBUSTION LINER SUPPORTS HAD BEEN GROUND TO FIT INTO LINER. LOOSE LOCKWIRE ON REAR SCAVANGE PUMP RETAINING NUTS. INLET/ OUTLET OIL TRANSFER TUBE RETAINING SCREWS LOOSE NOT SAFETY WIRED. (K) 2H74 4T4 T A1SO E282 20050401000172005040100017SO 2005 4 1 2005FA0000342 120050209G2910HYC5005 POWERPACK PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360* 17025SO HYD SYSTEM FAILED B FFKRA UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 SO054358X1826 347670027 AC DEPARTED, DIVERTED, PILOT THOUGHT THAT HIS LANDING GEAR WAS NOT FULLY IN THE UP AND LOCK POSITION (UNKNOWN IF GEAR UNSAFE LIGHT WAS ON). PILOT SELECTED GEAR DOWN, NOTHING HAPPENED, PULLED EMERGENCY GEAR EXTENSION AND LANDED WITH NO FURTHER INCIDENT. MAINTENANCE INSPECTED SYSTEM AND FOUND THE HYDRAULIC POWER PACK TO HAVE FAILED. REPLACED POWER PACK. (SO05200506731) 1L72 3O3 O A7SO E9CE 20050401000212005040100021EA 2005 4 1 2005FA0000358 220050307G8520AEL18840 CAMSHAFT PIPER PA30 PA30 7103002SO LYC O320 IO320C1A 41508EA ENGINE BROKEN C BA EMER. DESCENT UNSCHED LANDING E VIBRATION/BUFFET CLCLIMB 1 SO138833Y 100 301991 L00587655A WHILE CLIMBING OUT OF 4,000 FT, RT ENGINE (2-23-05) SHUTTERED AND BEGAN VIBRATING EXCESSIVELY. RETURNED TO AIRPORT. INSPECTION REVEALED THE CAMSHAFT HAD BROKEN COMPLETELY INTO 2 PIECES, ENGINE REMOVED AND SENT TO REPAIR FACILITY FOR FURTHER EVALUATION. ENGINE TT SINCE O/H 100 HOURS. AUTHORISED RELEASE FORM SHOWED NEW PART RELEASED ON APRIL 25, 2002. (K) 1L72 3O3 O A1EA 1E12 20050401000402005040100040 2005 4 1 2005FA0000346 320050221G61103026652 SEAL PIAGIOP180 P180 6960204EU PWA PT6 PT6A66 52043NE PROP SHAFT LEAKING D K NONE O OTHER ININSP/MAINT 1 EA25106SL1060 1070 RK0087 PROPELLER SHAFT SEAL WAS LEAKING, CAUSING HIGH OIL CONSUMPTION. (K) 1H72 3O4 TRTA59EU E26NE 20050401000552005040100055CE 2005 4 1 2005FA0000388 120050131G5711052340050 SPAR CESSNA172 172H 2072424CE CONT O300 O300D 17022SO MCAULY1C172 1C172* GL LT WING CRACKED D K NONE O OTHER ININSP/MAINT 1 SO094989R12536 17256343 28598D4D UF022 WHILE CHANGING THE FLAP TRACKS ON THE LT WING 2 SMALL CRACKS, .2500 INCH LONG, EACH WERE NOTICED ON THE IB AFT WING SPAR AT THE IB FLAP TRACK ATTACH POINT. PROBABLE CAUSE IS FATIGUE. THIS IS A VERY HIGH TIME AIRCRAFT WITH OVER 12,000 HOURS TT. IT HAS ALSO BEEN USED AS A FLIGHT TRAINER FOR ITS ENTIRE LIFE. (K) 1H71 3O3 ONT3A12 E253 5 NP910 20050401000672005040100067EU 2005 4 1 2005FA0000345 120050222G2731Z00N6071017251 ACTUATOR SOCATATBM TBM700 8682000EU PWA PT6 PT6A64 EA HARTZLHCE4N HCE4N3 NE ELEVATOR TRIM FROZEN D O OTHER J WARNING INDICATION CRCRUISE 1 WP23883CA 294 PCEPM174 HH1868 AFTER THE AIRCRAFT HAD BEEN LEFT OUT IN THE RAIN, THE PREVIOUS DAY, THE AC WAS FLOWN. UPON HAND FLYING THE AIRCRAFT TO ALTITUDE, THE PILOT REPORTED THA THE TRIM WHEEL BECAME INCREASINGLY MORE DIFFICULT TO MOVE AS HE ENTERED FREEZING LEVELS. AT OAT -8 THE TRIM WHEEL HAD BECOME COMPLETELY FROZEN. AFTER THE AC HAD TO BE FORCED NOSE OVER, AT OAT +2, THE TRIM WHEEL UNFROZE AND WAS ABLE TO BE TRIMED NORMALLY. (K) 1L71 3T4 TRTA60EU E4EA 5 CP10NE 20050324000322005032400032EU 2005 3 24 CA050107002 120050104G32115321012077 BOLT PILATS PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG BROKEN W K NONE O OTHER ININSP/MAINT 1 CA VLG018 LOWER LANDING GEAR ACTUATOR BOLT ON LEFT GEAR LEG MISSING BOLT HEAD. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20050328000342005032800034CE 2005 3 28 2005FA0000409 120050211G2910 LINE CESSNA177 177RG 2073709CE LYC O360 IO360A1B6 41514EA HYDRAULIC SYS CHAFED C O OTHER KJ FLUID LOSS WARNING INDICATION LDLANDING 1 SO0552668 177RG1241 WHILE INVESTIGATING A GEAR UP LANDING, IT WAS NOTED THAT THE HYDRAULIC LINE FROM THE LANDING GEAR PUMP WAS CHAFING AGAINST THE FLIGHT CONTROL CABLES ROUTED IN THE BATTERY COMPARTMENT AREA. SUGGEST INSPECTING THIS AREA FOR CHAFING AND RE-ROUTE HYDRAULIC LINE TO PREVENT CHAFING. WAS REPLACING INTERIOR PANEL AND MAY HAVE BENT THE LINE INTO THE CABLES. (K) 1H71 3O3 O A20CE 1E10 20050328000352005032800035SW 2005 3 28 2005FA0000377 120050106G2810206064633105 FUEL CELL BELL 206 206L4 1182110SW ALLSN 250C 250C30P 03013GL AFT DAMAGED C UOHRK NONE O OTHER ININSP/MAINT 1 GL13206GH3333 52112 DURING A SCHEDUALED 12 MONTH FUEL SYSTEM INSPECTION IAW MM, THE DEFECT WAS NOTED ON A CUSTOMERS AIRCRAFT. THE BOTTOM INSIDE OF THE AFT FUEL CELL WAS BLISTERED WITH .2500 INCH BLISTER IN DIAMETER, SPACED FROM .5000 INCH TO .2500 INCH APART. THE BLISTERS CONTINUED UP THE SIDE OF THE CELL 6 INCHES WITH THE SPACING BECOMING LARGER BETWEEN BLISTERS. THE FORWARD 2 FUEL CELLS SHOWED NO DEFETS, ALL FILTERS WERE NORMAL, THE 2 INLINE SCREENS AND INJECTOR PUMP WERE CLEAN ALSO. THE AIRCRAFT MFG WAS NOTIFIED AND THE CELL WAS DETERMINED TO BE UNAIRWORTHY AND WILL BE RETURNED TO THE AIRCRAFT MFG. PROBABLE CAUSE IS UNKNOWN, RECOMMENDATIONS ARE TO RETURNE THE CELL TO MFG TO EVALUATE DEFECTS.(K) 1G71 3U3 UNCH2SW E1GL 20050328000602005032800060CE 2005 3 28 2005FA0000348 120050318G55000411930 BRACKET CESSNA150 150C 2071808CE CONT O200 O200* 17020SO EMPENAGE INOPERATIVE D K NONE O OTHER ININSP/MAINT 1 NM091918Z 15059718 (1) RIVET SHEARED AND BRACKET ROTATED, PARTIALLY. THIS WAS CAUSED BY FLAP CABLES BEING RIGGED TOO TIGHT. THIS CAUSED A TWIST IN THE CABLES ALLOWING (1) CABLE TO RIDE UP AND OVER THE OTHER CAUSING IT TO COME OFF AN210-2A PULLEY. THE PILOT REPORTED GREAT DIFFICULTY IN EXTENDING FLAPS. FOLLOW MFG INSTRUCTIONS. (K) 1H71 3O3 O 3A19 E252 20050328000892005032800089CE 2005 3 28 2005FA0000351 120050302G534024130351 ANGLE CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL FUSELAGE CORRODED B DDERO OTHER O OTHER NRNOT REPORTED 1 WP016543V 172RG0766 L2664936A 806017 THIS ANGLE IS WHAT TIES TOGETHER THE WING STRUT, ATTACHES ON THE LT AND RT SIDES OF THE FUSELAGE. IF THIS CORROSION WHERE TO PROGRESS MUCH FURTHER, IT COULD CAUSE THE STRUTS TO FAIL. (K) 1H71 3O3 O 3A17 E286 5 CP7EA 20050330000082005033000008WP 2005 3 30 2005FA0000400 220050303G72108962321 PLANETARY GEAR MTSBSIMU2 MU2B60 5780460CE GARRTTTPE331TPE33110 01514WP HARTZLHCB4T HCB4TN5 GL REDUCTION G/B FAILED B IZ2REA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 SW15644EM 2905 1534SA P36337C CDA3481MI ON 2/26-2005 AN UNCOMMANDED, INFLIGHT CONTAINED SHUTDOWN OCCURED ON THE LT ENGINE DUE TO A GEARBOX FAILURE. THE AIRCRAFT WAS NOT DAMAGED AND MADE A NORMAL LANDING. INVESTIGATION IN THE ENGINE GEARBOX REVEALED THAT THE RING GEAR SUPPORT AND PLANETARY SPUR GEAR WERE BROKEN. (K) 1H72 3T4 TRTA10SW E4WE 6 CP40EA 20050330000382005033000038NM 2005 3 30 2005FA0000417 120050309G3340300909201 LIGHT BOEING737 737* NM GE CFM56 CFM56* 13802NE TAILCONE MISINSTALLED D K NONE W INADEQUATE Q C ININSP/MAINT 1 WP2390R 893 32775 WHILE CLEANING LENS, IT APPEARED TO BE LOOSE IN THE HOUSING. A VERY GENTLE PULL RELEASED THE LENS FROM ITS HOUSING. THE LENS IS THICK GLASS THAT COULD BE A RUNWAY HAZARD IF IT FELL FROM THE AC AND BROKE. PROBABLE CAUSE IS SKYDROL WHICH LEAKED FROM RUDDER PCU AND COMPROMISED THE ADHESIVE FEATURES OF THE SEALANT ATTACHING THE LENS TO THE HOUSING ASSEMBLY. RECOMMEND INSPECTION OF AC THAT HAVE HAD RUDDER PCU SKYDROL LEAKAGE PROBLEMS. SOME TYPE OF MECHANICAL ATTACHMENT OF LENS TO THE HOUSING SHOULD BE CONSIDERED. (K) 2L72 4F4 FRTA16WE E2GL 20050330000482005033000048CE 2005 3 30 2005FA0000194 120050211G2510551900922 SEAT BACK CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE SEAT CRACKED B K NONE O OTHER ININSP/MAINT 1 CE051250V 5500439 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. ALSO, PREVIOUS INAPPROPRIATE REPAIR. CHAIR WAS REPORTED IAW STC ST01042WI, STRUCTURAL SEAT REPAIR. (CE05200503843) (K) 1L72 4F4 F A22CE E1NE 20050330000802005033000080SW 2005 3 30 2005FA0000066 120050105G5270 WARNING SYSTEM SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP PAX DOOR MALFUNCTIONED B OZ5RB EMER. DESCENT J WARNING INDICATION CRCRUISE 1 NM0560NE AC760B CREW OBSERVED THE CABIN DOOR LIGHT CAME ON DURING CRUISE. CREW VERIFIED HANDLE WAS IN THE FULL CLOSED POSITION. THE LIGHT WENT OUT DURING DESCENT, AND WAS ON FOR APPROXIMATELY 10 MINUTES. THE LIGHT STAYED OUT FOR THE REMAINDER OF DESCENT AND LANDING. ONE OF THE FOLLOWING: DOOR CLOSING PROCEDURES, DOOR HARD TO CLOSE, DOOR CLICKCLACK RIGGING/ LUBRICATION, OR INDICATORS SWITCH RIGGING. NO FAULT FOUND, COULD NOT GET SYSTEM TO FAIL. COULD NOT DUPLICATE MALFUNCTION, CLEANED ALL CABIN DOOR SWITCHES AND OPS CHECKED DOOR SYSTEM. OPS CHECKED GOOD. (K) 2L72 4T4 TRTA8SW E4WE 20050330001442005033000144EU 2005 3 30 2005FA0000112 120050118G7430103572101 IGNITION SWITCH GROB 120 G120A 1660208EU LYC O540 AEIO540* EA COCKPIT INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07865AF 85005 PILOT REPORTED STARTER WOULD NOT ENGAGE, AFTER FURTHER INVESTIGATION FOUND IGNITION SWITCH WAS BAD. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME. (K) 1L71 3O3 ORTA49CE 1E4 20050401000642005040100064CE 2005 4 1 2005FA0000465 120050225G3610AA3216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO DRY AIR DAMAGED B VJ3RO OTHER J WARNING INDICATION CRCRUISE 1 WP075544A CE1343 DURING FLIGHT, FLIGHT CREW NOTICED THAT AIR PRESSURE WAS READING ZERO. LANDED AIRCRAFT AND MAINTENANCE INSPECTED AND FOUND THE ENGINE DRIVEN DRY AIR PUMP SHAFT WAS SHEARED. PROBABLE CAUSE IS UNKNOWN. (K) 1L71 3O3 O 3A15 E5CE 20050401000792005040100079SO 2005 4 1 2005FA0000177 220050204G74144001 MAGNETO CESSNA150 150M 2071830CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL ENGINE BROKEN D K NONE O OTHER ININSP/MAINT 1 WP21704YL394 15078978 255492A48 K19171 FLANGE BROKEN ON RT SIDE FOR SUPPORT OF MAG. FOUND ON ANNUAL INSP. 4001 MAG TT 394. (K) 1H71 3O3 O 3A19 E252 5 NP918 20050401000802005040100080SO 2005 4 1 2005FA0000178 120050131G2140 COMBUSTION LINER PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360* 17025SO HEATER CRACKED B CTURK NONE O OTHER ININSP/MAINT 1 GL2113AG A980311 347770115 WHILE PERFORMING AD 04-21-05, THE HEATER FAILED THE PRESSURE DECAY TEST. REMOVED UNIT AND FOUND CRACKS IN END OF COMBUSTION LINER. UNIT WAS REMOVED AND REPLACED WITH OVERHAULED UNIT. UNIT INSTALLED MAY 1998, AND CONTAINED NEW STYLE CERAMIC LINER. 1L72 3O3 O A7SO E9CE 20050401000852005040100085EU 2005 4 1 2005FA0000180 120050210G35009571222212 VALVE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE OXYGEN OUTLET LEAKING B K5SRK NONE O OTHER ININSP/MAINT 1 NM07956PC 323 PCEPR0186 PIOTS OXYGEN OUTLET VALVE LEAKS WHEN MASK PLUGGED IN. SUSPECT INTERNAL SEAL FAILURE. (K) 1L71 3T4 TRTA78EU E26NE 20050401000872005040100087CE 2005 4 1 2005FA0000213 120050121G533097430000604 SKIN BEECH 200 200BEECH 1152920CE PWA PT6 PT6A60A 52043NE FUSELAGE MISMANUFACTURED B P6URK NONE W INADEQUATE Q C ININSP/MAINT 1 NE05905GP6043 BB789 UPON REMOVAL OF AC TOP SKIN, FOUND 4 RIVETS ON STRINGER NR 4R JUST FWD OF THE EMERGENCY EXIT HATCH TO HAVE NO EDGE DISTANCE. ABOVE THIS AREA AT FS165.25 AND STRINGER NR 2R THERE WAS FOUND ONE FASTENER HOLE WITH SHORT EDGE DISTANCE. FWD OF THIS AREA AT FS 148.90 AND STRINGER NR 3R, FOUND A DOUBLE DRILLED HOLE WITH NO EDGE DISTANCE BETWEEN THEM. PROB CAUSE: DEFECT IN MANUFACTURING. RESOLUTION: MFG ISSUED ENGINEERING REPAIR FOR THE AFFECTED DISCREPANCY. DOCUMENT NR FR-KA-01494, REV 2 DATED 01-13-05. 1L72 4T4 T A24CE E4EA 20050401000882005040100088CE 2005 4 1 2005FA0000217 120050113G2710 CONTROL CABLE LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE731* 01518WP AILERONS FAILED B JGVRK NONE O OTHER ININSP/MAINT 1 CE09146XL1780 187 PRIMARY FLIGHT CONTROL CABLES ARE FAILING INSP, DUE TO WEAR ON CONTROL CABLE FAIRLEADS IN FUSELAGE AND EMPANNAGE. DETAILED INSP IS PERFORMED AT 4800 HRS. FOLLOWING CABLES FAILE AT 1780.3 HRS. FUSELAGE AILERON CABLES, RUDDER CABLES, ELEVATOR CABLES. CAUSE IS DUE TO CABLE FAIRLEADS BEING MADE FROM TOO HARD OF MATERIAL CAUSING CONTROL CABLES TO WEAR INSTEAD OF FAIRLEADS. RECOMM: TO PERFORM SB, (FUSELAGE REPLACEMENT OF THE CABIN FLIGHT CONTROL FAIRLEADS) THIS SB INSTALLS DIFFERENT PN FAIRLEAD IN THE AC, WHICH IS MADE OF A SOFTER MATERIAL. (CE09200502297) (K) 2L72 4F4 FRTT00008WIE6WE 20050401000902005040100090CE 2005 4 1 2005FA0000181 120050206G2435 BEARING LUCAS BEECH B300 B300 1159232CE PWA PT6 PT6A11 52043NE STARTER GEN FAILED B AKGRK NONE O OTHER ININSP/MAINT 1 CE05893MC 98141 FL216 SHAFT BEARING AT THE COOLING FAN END OF THE S/G CAME APART. THIS CAUSE THIS END OF THE COMMUTATOR TO MOVE SIDE TO SIDE AND THE COOLING FUN RUBBED INTO THE HOUSING. (K) 2L72 4T3 TRTA24CE E4EA 20050401000932005040100093SO 2005 4 1 2005FA0000216 220050209G8520 CONNECTING ROD CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO ENGINE FAILED D K NONE O OTHER ININSP/MAINT 1 GL115130A 21063280 522211 NR 2 CONNECTING ROD FAILED BREAKING CRANKCASE, KNOCKING LT MAG FROM MOUNT. ROD SHOWED FRICTION WELDING TO CRANK PRIOR TO FAIURE. COUNTERWEIGHT DAMAGED BY IMPACT WITH ROD. APPEARS ENG CONTINUED TO OPERATE BRIEFLY FOLLOWING ROD SEIZURE. PILOT ACCOMPLISHED SUCCESSFUL LANDING IN FIELD, NO APPARENT DAMAGE TO AIRFRAME. ENG HAS HISTORY OF CYL BEING REMOVED FOR TOP O/H WITH 4 BEING CHANGED TWICE. HAD BEEN EXPERIENCING PERSISTENT OVERBOOSTING, PROBLEM HAD BEEN ADDRESSED AT DIFFERENT TIMES. TURBO CONTROLLER HAD BEEN REPLACED AND WASTEGATE HAD BEEN REMOVED, SERVICED AND REINSTALLED. AFTER COMPLETION, APPEARED OVERBOOST PROBLEM MITIGATED. ENGINE FAILED. (GL11200507447) 1H71 3O3 O 3A21 E8CE 20050401000972005040100097SW 2005 4 1 2005FA0000376 120050121G3210ED124061 SHAFT GULSTM690TP 690D 3970405SW GARRTTTPE331TPE331* 01514WP RT MLG BROKEN D K NONE O OTHER ININSP/MAINT 1 GL25909HH 15035 SHAFT SECURING TORQUE LINK TO RT MLG STRUT FOUND BROKEN DURING INSPECTION. THIS TORQUE LINK IS AT TOP OF STRUT AND ROTATES LOWER STRUT 90 DEGREES DURING RETRACT/ EXTEND CYCLE. INSTALLED NEW SHAFT. (K) 1H72 3T3 T 2A4 E2WE 20050401001062005040100106WP 2005 4 1 2005FA0000421 220050125G7200TFE73122B ENGINE LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP RIGHT FAILED B BHKRE ENGINE SHUTDOWN BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 EA2196FN 11671759 186 P74780 WHILE AT FL300, EXPERIENCED AN INFLIGHT FAILURE OF THE RT ENGINE AS FOLLOWS, RT ENGINE INSTRUMENTS, ITT, N1, N2 AND FUEL FLOW ALL BEGAN INCREASING. RT FUEL COMPUTER WAS TURNED OFF, POWER WAS REDUCED TO IDLE. THE ENGINE INSTRUMENTS CONTINUED TO INCREASE AND JUST PRIOR TO ENGINE SHUTDOWN, A LOUD BANG WAS HEARD FROM THE RT SIDE, FOLLOWED BY A BRIGHT FLASH AND SMELL OF SMOKE IN THE COCKPIT. AC LANDED SAFELY WITHOUT FURTHER INCIDENT. ENGINE WAS REMOVED FROM AIRCRAFT AND SENT TO AN OVERHAUL FACILITY DETAILS OF THE ENGINE DISASSEMBLY FINDINGS ARE CONTAINED IN REPORT NR GR2-703 ATTACHED. IT WAS RECOMMENDED THAT HP TURBINE BE FWD FOR FURTHER INSPECTION TO DETERMINE MODE FAILURE. (K) 2L72 4F4 F A10CE E6WE 20050401001122005040100112 2005 4 1 2005FA0000202 420050127G612254696 SPOOL HARTZL PIPER PA28 PA28R200 7102811SO LYC O360 IO360C1C 41514EA HARTZLHCC2Y HCC2YK1 GL GOVERNOR MISINSTALLED B W59RK NONE O OTHER ININSP/MAINT 1 WP0755696 3797 28R7335274 GOVERNOR SENT FOR REPAIR DUE TO RPM CONTROL ISSUES AND A HISTORY OF LEAKING. DURING DISASSEMBLY, THE PILOT SPOOL SHAFT THREADS WERE FOUND DAMAGED. IT WAS DISCOVERED THAT AT THE PREVIOUS ASSY OF THIS PART, A FINE THREADED B3808-4 NUT WAS USED IN PLACE OF THE REQUIRED B3808 (COARSE THREAD) NUT. THE B3808-4 WAS FORCED ONTO THE PILOT SPOOL DISTORTING AND CROSSTHREADED IT. UNIT WAS REPORTED TO HAVE BEEN OVERHAULED 3/1/94 AND HAD APPROX 200 HOURS TSO. 1L71 3O3 O 2A13 1E10 5 CP920 20050404000092005040400009CE 2005 4 4 2005FA0000184 120050214G280010810001259 ADAPTER BEECH 77 77 1153007CE LYC O235 O235* 41505EA FUEL TANK LEAKING D K NONE O OTHER ININSP/MAINT 1 SW091805V WA270 DOUBLER INSTALLEN IN FUEL TANK HAS NO ACCESS AND MFG CAN NOT TELL US HOW TO STOP FUEL LEAK. 1L71 3O3 O A30CE E223 20050404000132005040400013 2005 4 4 2005FA0000445 420050307G2562ELT10 RACK PIPER PA32 PA32301 7103207SO LYC O540 IO540K1G5 41532EA HARTZLHCC3Y HCC3YR GL ELT DISLODGED H K NONE O OTHER ININSP/MAINT 1 EA218310H149 328306009 L2276448A DY1697 DURING ANNUAL INSPECTION, FOUND ELT LAYING ON THE CONTROL CABLES IN AFT FUSELAGE. LATCH AHD FAILED ON ELT RACK. (EA21200505230) (K) 1L71 3O3 O A3SO 1E4 5 CP25EA 20050404000142005040400014CE 2005 4 4 2005FA0000452 120050317G2822A10055B PUMP CESSNA206 T206H 2073303CE LYC O540 TIO540* 41532EA FUEL BOOST LEAKING D O OTHER K FLUID LOSS NRNOT REPORTED 1 NE026555653 T20608496 BOOST PUMP WAS LEAKING AT SEAM BETWEEN ELECTRIC MOTOR AND VANE PUMP. FUEL HAD A CHANCE TO LEAK INTO ELECTRIC MOTOR BRUSHES. BELIEVE THIS TO A MAJOR FIRE HAZZARD. BOTH PUMP AND AIRCRAFT WERE NEW. THIS COULD HAVE BEEN PREVENTED BY BETTER QUALITY CONTROL AT THE FACTORY. (K) 1H71 3O3 ORTA4CE E14EA 20050404000232005040400023CE 2005 4 4 2005FA0000454 120050215G534324130023 FITTING CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA ACTUATOR CRACKED D K NONE O OTHER ININSP/MAINT 1 WP036400V 172RG0662 RL1993936A DURING EMERGENCY LANDING GEAR OPERATIONAL CHECK, THE MECHANIC FOUND THE CRACK ON BOTH SIDE CORNER OF THE FITTING NOSE GEAR ACTUATOR ATTACHING PART. IT MAY BE SUSPECTED THAT MATERIAL FATIGUE OR AN UNREPORTED LANDING. (K) 1H71 3O3 O 3A17 E286 20050404000242005040400024NE 2005 4 4 2005FA0000456 220050310G725030600501 TURBINE AMD FALC50FALCON50MYST2730106EU GARRTTTFE731TFE73140 29001NE NR 3 ENGINE FAILED C EA ENGINE SHUTDOWN UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 NM0126WP 1754 312 ENGINE SHUT DOWN AT FL360, ON DEPARTURE. FLIGHT CREW AND PASSENGERS HEARD LOUD BANG AND FELT VIBRATION. FLIGHT CREW OBSERVED NR 3 ENGINE N1 SPOOLDOWN AND 25 DEGREE HIGHER THAN NORMAL ITT, ENGINE OIL PRESSURE WAS NORMAL. ENGINE WAS SHUT DOWN AND FLIGHT RETURNED TO DEPARTURE. POSTFLIGHT INSP OF NR3 ENGINE REVEALED DEBRIS IN EXHAUST DUCT. NO VISIBLE DAMAGE TO THE LOW PRESSURE TURBINE. AFT OF FAN OR COMPRESSOR AREA, FWD. SUSPECT COMPONENT FAILURE FWD OF LOW PRESSURE TURBINE. ENGINE REMOVED FOR REPAIR, SHIPPED TO MFG. PENDING INSP TEARDOWN REPORT FROM MFG. NOT CERTAIN WHAT COMPOENT IN ENGINE FAILED. (K) 2L73 4F4 F A46EU E1NM 20050404000292005040400029EA 2005 4 4 2005FA0000182 120050222G5210600380091 TRACK BOMBDR CNDAIRCL600 CL6002B16 1900305EA GE CF34 CF343B1 NE PAX DOOR LOOSE B K NONE O OTHER ININSP/MAINT 1 GL1343R 2750 5334 872121 TRACK/CHANNELS, 600-380091, ARE U CHANNELS THAT FACE EACH OTHER ALLOWING STRUT, 600-38008-17 AND CAMS, TO MOVE UP AND DOWN INSIDE OF THESE TRACKS. THE TRACKS ARE MANUFACTURED WITH SMALLER SIDES AND POOR ENGAGEMENT/ LOOSE FIT OF THE STRUT/CAMS ALLOW THE CAMS TO LIFT OUT OF THE CHANNELS AND JAMMING THE STRUT. THE END RESULT IS ROD, 600-38003-3 BREAKING RESULTING IN THE PASSENGER DOOR GROUND SUPPORT PAD NOT EXTENDING AND THE DOOR TOUCHING THE GROUND. HAVE BROUGHT THIS TO THE ATTENTION OF MFG 8 YEARS AGO WHEN I HAD THE SAME PROBLEM WITH OUT CL-601, SN 5134. THEY FAILED TO CORRECT THE PROBLEM AND IT IS NOW AN ISSUE ON OUR CL-604. 2L72 4F4 FRTA21EA E15NE 20050404000452005040400045CE 2005 4 4 2005FA0000222 120050110G2720 CONTROL CABLE LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE731* 01518WP RUDDER WORN B JGVRK NONE O OTHER ININSP/MAINT 1 CE09886CA1183 154 AILERON, ELEVATOR, AND RUDDER SYSTEMS PRIMARY CONTROL CABLES ARE DUE INSPECTION AT 600 HOURS IAW MM, AS A PORTION OF PHASE B REQUIREMENTS. ALIERON, ELEVATOR AND RUDDER SYSTEMS PRIMARY CONTROL CABLES ARE DUE REMOVAL AND DETAILED INSPECTION AT 4,800 HOURS IAW MM. PRIMARY FLIGHT CONTROL CABLES ARE NOT LISTED MM (REPLACEMENT SCHEDULE). INSTALLED NEW RUDDER CONTROL CABLES, (PN7627202004-001, 7627202003-001). WORK PERFORMED AFTER INSPECTION IAW PHASE B REQUIREMENTS. (K) (CE09200502303) 2L72 4F4 FRTT00008WIE6WE 20050404000472005040400047CE 2005 4 4 2005FA0000386 120050131G5753052323113 FLAP TRACK CESSNA172 172H 2072424CE CONT O300 O300D 17022SO MCAULY1C172 1C172EM GL LT WING WORN D K NONE O OTHER ININSP/MAINT 1 SO094992R 17256346 29876D9DR 75113 DURING PREFLIGHT, THE LT OB FLAP TRACK WAS NOTICED TO HAVE DAMAGE. AIRCRAFT WAS IMMEDIATELY GROUNDED AND THE FLAP TRACKS AND ROLLERS WERE REPLACED WITH NEW PARTS. NO FURTHER DAMAGE HAD OCCURRED TO THE FLAP ASSY. SINCE MFG DOES NOT HAVE LIMITATIONS ON THEIR FALP TRACKS, WOULD SUGGEST THAT THEY BE REMOVED AND REPLACED AT 5,000 HOUR INTERVALS. (K) 1H71 3O3 ONT3A12 E253 5 NP910 20050404000512005040400051CE 2005 4 4 2005FA0000356 120050215G25974520133L WIRE ARTEX BEECH MU300 400A 1155402CE PWA JT15 JT15* 52060NE BATTERY BROKEN B E81RO OTHER O OTHER NRNOT REPORTED 1 GL0375RL 1195 00831 RK312 REMOVED BATTERY FROM ELT 110-406 FOR VISUAL INSPECTION IAW WITH MFG MM. UPON INITIAL INSPECTION FOUND ONE WIRING TERMINAL BROKEN OFF OF ONE BATTERY CELL. BATTERY EXPIRATION DATE 6/2006. (K) 2H72 4F4 TRTA16SW E1NE 20050404000622005040400062EU 2005 4 4 2005FA0000226 120050214G3320189411 POWER SUPPLY AMD FALC50FALCON50MYST2730106EU GARRTTTFE731TFE731* 01518WP CABIN LIGHT FAILED B G46RK NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 WP13253SJ 107 CREW HAD POWER ON AIRCRAFT AND NOTICED AN ELECTRICAL BURNING SMELL COMING FROM THE CABIN. AFTER INVESTIGATING THEY FOUND THE CABIN INDIRECT LIGHTING CIRCUIT BREAKER POPPED. THE MAINTENANCE FACILITY TROUBLESHOT THE PROBLEM TO A POWER SUPPLY THAT HAD BURNED UP. RECOMMEND INVESTIGATION INTO THIS PN POWER SUPPLIES TO SEE IF THEY SHOULD BE TOTALLY REMOVED FROM SERVICE. MFG RECOMMENDED SB F50-335 FOR REPLACING POWER SUPPLIES WITH IMPROVED POWER SUPPLY THAT INCORPORATES A PROTECTION CIRCUIT. THESE LIGHTING SYS WERE INSTALLED UNDER MFG MODIFICATION F50 M2065+M2674. THIS AIRCRAFT WILL HAVE SB -335 INSTALLED AS SOON AS PART CAN BE PROCURED. 2L73 4F4 F A46EU E6WE 20050404000802005040400080NE 2005 4 4 2005FA0000339 120050131G3213642550120101 AXLE SKRSKYS64 S64E 8142604NE PWA JFTD12JFTD12A4A 52047NE MLG CRACKED B JYDRK NONE O OTHER ININSP/MAINT 1 NM09154AC EAC14465 64037 (MDR05-073) FOUND CRACKED DURING NDT INSPECTION. CRACK IS APPROXIMATELY 1 INCH IN LENGTH AND IS IN THE KEY GROOVE. THIS IS FIRST KNOW DEFECT OF THIS TYPE FOR THIS PART. CAUSE IS UNKNOWN AND NO RECOMMENDATIONS TO PREVENT RECURRENCE AT THIS TIME. (K) 2G72 4U4 U H4EA E15EA 20050404000842005040400084CE 2005 4 4 2005FA0000197 120050211G76037184510 THROTTLE CABLE LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE731* 01518WP RT FWD DAMAGED D A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 GL11858MK1337 141 AFTER TAKEOFF, THROTTLE WOULD NOT COME BACK. THROTTLE HAD TO BE FORCEABLY PULLED BACK OUT OF TAKEOFF SETTING. CABLE WAS FOUND BAD. (GL11200507568) (K) 2L72 4F4 FRTT00008WIE6WE 20050404000862005040400086SO 2005 4 4 2005FA0000359 120050303G2140 GASKET JANITROL PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA REGULATOR LEAKING H LM8SO OTHER KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 NM07978WC 4496041 PILOT REPORTED SMELLING FUEL WHEN THE COMBUSTION HEATER WAS RUNNING. MAINTENANCE FOUND FUEL SPRAYING FROM A GASKET JOINT ON THE REGULATOR SIDE OF THE HEATER FUEL SHUTOFF AND REGULATOR VALVE. THIS VALVE WAS REPLACED FOR LEAKING IAW AD. THIS VALVE WAS INSPECTED FOR LEAKS DURING THE OPS CHECK OF THE HEATER AS PART OF THE ANNUAL INSPECTION ON 11-9-2004, 93.7 AIRCRAFT HOURS PRIOR TO THIS FAILURE. (K) 1L72 3O3 O A19S0 E286 20050404000992005040400099CE 2005 4 4 2005FA0000369 120050120G5397DPA13 CABLE CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO FUSELAGE BURNED D K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 GL13735WR 18265747 DEFECT WAS FOUND AT ENGINE REMOVAL AND FIREWALL CLEANING. THE ELECTRICAL CABLE BETWEEN AUX POWER RELAY AND STARTER RELAY WAS FOUND TO HAVE BURN MARKS AND OBVIOUS DAMAGE TO INSULATION. ADJACENT TO THE DAMAGED PORTION OF THE CABLE WAS A SHEET METAL SCREW IN THE FIREWALL (INSTALLED WITH THE HEAD OF THE SCREW ON AFT SIDE OF FIREWALL). THE POINTED END OF THE SCREW HAD PIERCED THE INSULATION AND CAUSED SOME ARCING. NEW CABLE INSTALLED ON AIRCRAFT, SCREW REMOVED AND REINSTALLED IN REVERSE POSITION (HEAD OF SCREW ON FORWARD SIDE OF FIREWALL). THE SCREW THAT CAUSED THE DAMAGE IS USED TO ATTACH A PLASTIC SHIELD THAT PROTECTS THE INTERIOR FROM BEING CAUGHT IN THE ELEVATOR CABLE PULLEY THAT IS LOCATED ON AFT SIDE OF F1H71 3O3 ONT3A13 E273 20050404001042005040400104CE 2005 4 4 2005FA0000132 120050128G2720071362856 SUPPORT CESSNA182 R182 2072734CE LYC O540 O540* 41532EA RUDDER PEDAL DAMAGED B PHKRK NONE O OTHER ININSP/MAINT 1 CE017579T R18200042 WHILE COMPLETING GROUND RUN, PRIOR TO 100 HOUR INSPECTION, NOTICED RUDDER PEDALS DID NOT FEEL RIGHT. FURTHER INVESTIGATION REVEALED THAT THE NUT-PLATES HAD RIPPED THROUGH THE RUDDER PEDAL SUPPORT PIECES. (K) 1H71 3O3 ORT3A13 E295 20050328000362005032800036SO 2005 3 28 2005FA0000427 220050318G8530AEC631397 CYLINDER HEAD CESSNA310 T310R 2074246CE CONT O520 TSIO520NB 17040SO ENGINE SEPARATED G C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 GL2796HC 475 475 45285 DURING TAKEOFF PILOT NOTICED A SHUDDER OR VIBRATION. UPON LANDING ENGINE BEGAN TO RUN ROUGH. MAINTENANCE FOUND LT ENGINE NR 6 CYLINDER HEAD HAD SEPARATED. ENGINE WAS OVERHAULED ON 4-23-2004 AND PUT IN SERVICE ON 5-18-2004. THE ENGINE HAD 475 HOURS SINCE OVERHAUL. THE CYLINDER WAS A NEW, INSTALLED AT OVERHAUL. 1L72 3O3 O 3A10 E8CE 20050328000492005032800049SW 2005 3 28 2005FA0000420 120050107G6320269A5498005 SHAFT HUGHES269 269C1 8059504SW LYC O360 HIO360* 41514EA DRIVE SPLINES WORN D K NONE O OTHER ININSP/MAINT 1 SO1572LP 600 0152 DURING 600 HOUR INSPECTION GREASE IN LOWER PULLEY SHAFT HAD A RUSTY (BROWN) COLOR (NOTE: ANDEROL GREASE IS BLACK). UPON INSPECTION PART HAS 600.0 HOURS SINCE NEW, THE SPLINES SHOWED IRREGULAR WEAR. SPECULATION OF MFG AND OUR FACILITY IS THAT THE GREASE WAS CONTAMINATED. FIRST 600 HOUR INSPECTION ON THIS AC, SAME GREASE SINCE DELIVERY FROM MFG. (K) 1G71 3O3 OO 4H12 1E10 20050328000652005032800065CE 2005 3 28 2005FA0000299 120050205G3246D306001 WHEEL CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160CTM GL ZONE 700 FAILED D O OTHER O OTHER TXTAXI/GRND HDL 1 NE01132633920 17262622 L3598627A 723093 FOUND RT MAIN TIRE WAS LOCKED UP. PUT WHEEL ON DOLLY AND PULLED PLANE TO HANGER. CLOSER LOOK IN HANGER FOUND THAT RIM HAD BLOWN APART. DEFLATED TIRE AND LOOKED INSIDE RIM. FOUND PIECE BROKEN OUT OF CENTER SECTION OF RIM. CRACKS WERE FOUND AROUND BOLT HOLES OF RIM HALVES. EXAMINED BROKEN PIECE AND FOUND THAT PORTION OF THE CRACK WAS OLD, REST BEING NEW. WITH AIR PRESSURE IN TIRE, IT WAS TRYING TO BLOW IT APART. HAVE SEEN THIS PROBLEM ALOT WITH MFG OF WHEELS HAVING CRACKS AROUND BOLT HOLES. BUT NEVER SEEN ONE COME APART. YOU CAN ONLY SEE THE CRACKS WHEN CHANGING TIRE FROM THE INSIDE. MAYBE FROM OVER-TIGHTENING THE BOLTS UPON ASSY WHEN CHANGING TIRES. ALSO, HAVING STEEL BOLTS THREADING INTO ALUMINUM HOUSING. 1H71 3O3 ONT3A12 E274 5 NP910 20050328000712005032800071CE 2005 3 28 2005FA0000429 120050318G3230504501024 TORQUE TUBE CESSNA414 414 2075908CE CONT O520 TSIO520* 17040SO MLG CRACKED D K NONE O OTHER ININSP/MAINT 1 WP05414RD4723 4140502 RT TORQUE TUBES CRACKED DURING GEAR RETRACTION. 1L72 3O3 ORTA7CE E8CE 20050328000792005032800079CE 2005 3 28 2005FA0000264 120050309G8011S24432 CONTACTOR CESSNA206 U206G 2073356CE CONT O550 IO550* SO STARTER FAILED D RDDRO OTHER J WARNING INDICATION TOTAKEOFF 1 WP21PKMPT U20606987 STARTER CONTACTOR DID NOT DISENGAGE AFTER ENGINE START. THIS RESULTED IN FAILURE OF THE STARTER AS WELL. THE SITUATION DID NOT BECOME APPARENT UNTIL AFTER TAKEOFF. THIS AIRCRAFT HAS A (STARTER ENGAGED) WARNING LIGHT INSTALLED BUT IT DID NOT INDICATE CLEARLY UNTIL AFTER TAKEOFF. PERHAPS BECAUSE AT HIGH POWER SETTINGS THE ALTERNATOR PRODUCED MAXIMUM POWER AND AT HIGH SPEED THE STARTER MOTOR WOULD DRAW FEWER AMPS THAN AT LOW SPEED, ALLOWING THE BUS VOLTAGE TO RISE AND ILLUMINATE THE LAMP BRIGHTER. FIRST LIGHTWEIGHT STARTER INSTALLED ON THIS AC, INDICATION THAT LIGHTWEIGHT STARTERS HAVE HIGHER CURRENT DRAW THAN LARGER STARTER THAT WAS USED. SUSPECT MFG CONTACTOR CANNOT HANDLE LOAD.(K) 1H71 3O3 O A4CE E3SO 20050328000862005032800086EA 2005 3 28 2005FA0000093 220050216G7314461740 PUMP PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA FUEL SYSTEM INCORRECT B OG5RK NONE K FLUID LOSS ININSP/MAINT 1 GL21357ND1564 2842185 L1977239A A59575 NOTICED A STICKY SUBSTANCE (OTHER THAN FUEL) LEAKING OUT OF MACHINED HOLE ON SIDE OF FUEL PUMP. THIS MACHINED HOLE COMES WITH THE HOLE SEALED FROM THE MFG. (K) 1L71 3O3 O 2A13 E274 5 NP88614 20050328001092005032800109CE 2005 3 28 2005FA0000198 120050131G5753052340051 SPAR CESSNA172 172H 2072424CE CONT O300 O300D 17022SO RT WING FLAP TRACRACKED D K NONE O OTHER ININSP/MAINT 1 SO094992R12474 17256346 29876D9DR WHILE REPLACING THE FLAP TRACK ASSY, A CRACK APPROX 2 INCHES IN LENGTH AND RUNNING THROUGH THE LOWER RIVET HOLES WAS FOUND UNDER THE IB FLAP TRACK. PROBABLE CAUSE IS FATIGUE. RECOMMEND THESE AC WITH MORE THAT 8,000 HOURS TT BE INSPECTED BY BORESCOPE OR OTHER ACCEPTABLE MEANS, AT THE REAR WING SPAR AROUND THE FLAP TRACK ATTACH AREA. (K) 1H71 3O3 ONT3A12 E253 20050330000102005033000010WP 2005 3 30 2005FA0000401 220050303G72108967451 RING GEAR MTSBSIMU2 MU2B60 5780460CE GARRTTTPE331TPE33110 01514WP HARTZLHCB4T HCB4TN5 GL REDUCTION G/B BROKEN B IZ2REA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 SW15644EM 2905 P36337C 1534 P36337C CDA3481MI ON 2/26/2005, AN UNCOMMANDED, INFLIGHT CONTAINED SHUTDOWN OCCURED ON THE LT ENGINE DUE TO A GEARBOX FAILURE. THE AIRCRAFT WAS NOT DAMAGED AND MADE A NORMAL LANDING. INVESTIGATION IN THE ENGINE GEARBOX REVEALED THAT THE RING GEAR SUPPORT AND PLANETARY SPUR GEAR WERE BROKEN. (K) 1H72 3T4 TRTA10SW E4WE 6 CP40EA 20050330000222005033000022SW 2005 3 30 2005FA0000419 120050107G6510269A5559003 DRIVE SHAFT HUGHES269 269C1 8059504SW LYC O360 HIO360* 41514EA TAIL ROTOR CORRODED D K NONE O OTHER ININSP/MAINT 1 SO1572LP 600 0152 DURING 600 HOUR INSPECTION GREASE IN DRIVE SHAFT HAD A RUSTY (BROWN) COLOR (NOTE: ANDEROL GREASE IS BLACK). UPON INSPECTION PART HAS 600.0 HOURS SINCE NEW. LIFE LIMIT OF 6000 HRS, THE SPLINES WERE WORN TO THE THICKNESS OF A PIECE OF PAPER (APPROX .090 NEW). SPECULATION OF MFG AND OUR FACILITY IS THAT THE GREASE WAS CONTAMINATED. FIRST 600 HOUR INSPECTION ON THIS AC, SAME GREASE SINCE DELIVERY. (K) 1G71 3O3 OO 4H12 1E10 20050330001502005033000150NM 2005 3 30 2005FA0000116 120050112G5330 SKIN BOEING727 727225 1384077NM PWA JT8 JT8D15 52051NE FUSELAGE MISDRILLED B FDERK NONE O OTHER ININSP/MAINT 1 WP23465FE 21289 DRILL START NOTED AT L-BAND NR 1 ANTENNA FWD RT MOUNT HOLE. BS410, RBL 1. (IN SKIN) FOUND WHILE PERFORMING INSPECTION OF ANTENNA IAW WORKCARD NR 34X4505. (K) 2L73 4F4 F A3WE E2EA 20050330001622005033000162GL 2005 3 30 2005FA0000122 220050131G7200 ENGINE BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL MAKING METAL B GS1RO OTHER J WARNING INDICATION LDLANDING 1 EA0341PH 1544 PILOT REPORTED HEARING A GRINDING NOISE FROM THE ENGINE WHICH WAS FOLLOWED BY AN ENGINE CHIP LIGHT INDICATION. A POWER ON PRECAUTIONARY LANDING WAS MADE. THE ENGINE WAS REMOVED AND REPLACD WITH A LOANER ENGINE. THE DISCREPANT ENGINE AS AN ASSEMBLY WAS SENT TO REPAIR STA. FOR FURTHER EVALUATION. (K) 1G71 3U3 U H2SW E4CE 20050401000612005040100061CE 2005 4 1 2005FA0000364 120050121G7810STC8645SW CLAMP CESSNA170 170B 2072306CE CONT C145 C145* 17012SO TAILPIPE OVERSIZED C K NONE O OTHER ININSP/MAINT 1 GL133167A 25811 7909D32 BOTH TAILPIPE/MUFFLER CONNECTIONS WERE FOUND TO BE OVERSIZED. THE EXHAUST PIPE CLAMPS WERE NOT OF SUFFICIENT STRENGTH TO SQUEEZE THE OVERSIZED PIPE DOWN ON THE MUFFLER EXHAUST TUBE. THE RESULTING LOOSE FIT WAS ALLOWING EXHAUST FUMES TO SHOOT INTO THE CABIN HEAT AND THE CARBURETOR HEAT SECTIONS OF THE MUFFLERS. ONE THING THAT AGGRAVATED THE CONDITION WAS THE FACT THAT THE TAILPIPES WERE CRAMMED TOO FAR UP ON THE MUFFLER PIPE. THIS MADE IT INEVITABLE THAT ANY LEAKAGE WOULD ENTER THE MUFFLER/HEAT SHROUD SECTION. SUGGEST GIVING THIS AREA CLOSE SCRUTINY. 1H71 3O3 O A799 E253 20050401001072005040100107NE 2005 4 1 2005FA0000341 120050131G6210151520604000 SPAR SKRSKYS64 S64E 8142604NE PWA JFTD12JFTD12A4A 52047NE M/R BLADE CRACKED B JYDRK NONE O OTHER ININSP/MAINT 1 NM09194AC5538 64M54385630 64017 (MDR05-074) THE SPAR IS CRACKED ON THE BOTTOM SIDE OF THE BLADE BETWEEN POCKET LOCATIONS NR 5 AND NR 6. CRACK IS APPROXIMATELY .300 INCH IN LENGTH .650 INCH FROM THE BACKWALL RUNNING CHORDWISE TO .950 INCH FROM THE BACKWALL. BLADE HAD A BIM INDICATION AND WAS REMOVED FROM AIRCRAFT. CAUSE IS UNKNOWN AND NO RECOMMENDATIONS TO PREVENT RECURRENCE AT THIS TIME.(K) 2G72 4U4 U H4EA E15EA 20050404000462005040400046CE 2005 4 4 2005FA0000382 120050120G3250204301410 SHIMMY DAMPENER CESSNA177 177RG 2073709CE LYC O360 IO360A1B6 41514EA NLG MISINSTALLED D O OTHER O OTHER NRNOT REPORTED 1 NM09534DW 177RG1004 DURING PRE-INSPECTION RUN UP/ TASK, STEERING WAS RESTRICTED TO RT. FOUND THAT WHOEVER HAD THE SHIMMY DAMPNER OFF LAST, REVERSED THE GIMBAL THAT ATTACHES IT TO THE ENGINE MOUNT. THERE SHOULD BE A WARNING PLACARD OR MODIFICATION THAT MAKES REVERSAL IMPOSSIBLE. (K) 1H71 3O3 O A20CE 1E10 20050404000712005040400071NE 2005 4 4 2005FA0000340 120050110G62206595211522102 BEARING RACE SKRSKY SKRSKYS64 S64F 8142610NE PWA JFTD12JFTD12A5A 52047NE M/R HEAD CRACKED B JYDRK NONE O OTHER ININSP/MAINT 1 NM09158AC654 64081 (MDR05-072) THE MRH SLEEVE AND SPINDLE ASSY DEVELOPED AN OIL LEAK WHILE ON AIRCRAFT AND WAS NOTED DURING ROUTE INSPECTION. UPON REMOVAL AND REPLACEMENT WITH A SERVICEABLE ASSY, A CRAK WAS FOUND ON THE INNER RACE. VISUAL INSPECTION SHOWS WEAR AND CORROSION TYPICAL FOR THIS PART THAT HAS BEEN IN SERVICE. NO OTHER ABNOMALITIES WITH THE EXCEPTION OF THE CRACK. CRACK IS APPROXIMATELY 3 INCHES IN LENGTH AND RUNS IN AXIAL DIRECTION. THIS IS A FIRST TIME OCCURANCE. CAUSE IS UNKNOWN AND NO RECOMMENDATIONS TO PREVENT RECURRENCE AT THIS TIME. (K) 2G72 4U4 U H6EA E15EA 20050330001522005033000152WP 2005 3 30 2005FA0000118 220050121G7210035A470105 LINE MTSBSIMU2 MU2B60 5780460CE GARRTTTPE331TPE33110 01514WP GEARBOX CRACKED B W6NREA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 GL25772DA 772SA NR 8 SCAVENGE OIL LINE FROM ENGINE GEARBOX TO VERNATHERM CRACKED INSIDE THE B-NUT SLEEVE AT GEARBOX. THIS LED TO SIGNIFICANT LOSS OF OIL AND A PRECAUTIONARY SHUTDOWN IN FLIGHT. AC RETURNED DEPARTURE, UNEVENTFUL LANDING, REPLACED OIL LINE. (K) 1H72 3T4 TRTA10SW E4WE 20050330001542005033000154EA 2005 3 30 2005FA0000119 220050110G741467542 BEARING PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA MAGNETO DRIVE FAILED B YYBRK NONE E VIBRATION/BUFFET ININSP/MAINT 1 GL0322PG 617 277305203 L1767848A CUSTOMER COMPLAINED OF A VIBRATION ON RT ENGINE. INSPECTION REVEALED CAGE FAILURE OF THE RT MAGNETO DRIVE GEAR BEARING (PN 67542). CAUSE OF CAGE FAILURE NOT KNOWN. CANNOT RECOMMEND ACTION TO PREVENT REOCCURRENCE. (K) 1L72 3O3 O 1A10 1E4 20050401000562005040100056WP 2005 4 1 2005FA0000344 120050222G56103403110307 WINDOW CVAC 340 340CVAC 242270AWP ALLSN 501D 501D22 03005GL HAMSTD54H 54H60 NE COCKPIT BLEW OUT D BA EMER. DESCENT UNSCHED LANDING O OTHER CRCRUISE 1 GL23391FL 278 DURING CRUISE FLIGHT AT FL230, THE FO SIDE WINDOW BLEW OUT; AT WHICH TIME, AN EMERGENCY DESCENT WAS EXECUTED TO AN UNEVENT LANDING. (K) 2L72 4R4 T 6A6 E282 6 CP906 20050401000652005040100065EU 2005 4 1 2005FA0000462 120050316G3246GYS18525 BOLT AMD FALC10FALCON10 2730101EU GARRTTTFE731TFE731* 01518WP MLG WHEEL BROKEN B UO2RK NONE O OTHER ININSP/MAINT 1 GL19655PE AR75349 199 A BROKEN BOLT WAS NOTICED DURING A TIRE PRESSURE CHECK. THE WHEEL COVER WAS REMOVED TO INVESTIGATE. ALL TEN BOLTS WERE NDT`D BY PAG PARTICLE INSP AND 3 OTHER BOLTS WERE FOUND CRACKED. PART CYCLES (LANDINGS) SINCE O/H IS 176 CSO. (K) 2L72 4F4 F A33EU E6WE 20050401000662005040100066CE 2005 4 1 2005FA0000464 120050317G8011643259 ADAPTER CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO STARTER DEFECTIVE B YYBRK NONE O OTHER ININSP/MAINT 1 GL03722SJ U20603361 830285R STARTER ADAPTER WAS REMOVED DUE TO DAMAGE CAUSED DURING A (KICK-BACK). INSPECTION FOUND BEARING RETAINING HOLES THAT HAD BEEN KNURLED AT THE FACTORY, MISALIGNED, AND COATED WITH A GREENISH BEARING RETAINING COMPOUND. THE STARTER ADAPTER WORM DRIVE SHAFT SHOWED SIGNS OF A HEAVY SIDE LOAD. THIS CAUSED THE STARTER ADAPTER TO BIND AND NOT RELEASE. THIS HOUSING HAS AN INSPECTION STAMP OF (TA33) AND A DATE STAMP OF (SEPT 15 2003). (K) 1H71 3O3 O A4CE E5CE 20050404000402005040400040SO 2005 4 4 2005FA0000355 120050304G272196319802 TORQUE TUBE PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360* 17025SO RUDDER ELONGATED B CTURK NONE O OTHER ININSP/MAINT 1 GL21396556496 347870403 DURING INSPECTION, TECH DISCOVERED PLAY IN RUDDER TORQUE TUBE FITTING. TECH INSTALLED SERVICE KIT 764-100V. AD AND SB ADDRESSES INSP AN REPLACEMENT OF THE STEEL TORQUE TUBE FITTING WITH A STEEL REPLACEMENT PART. THIS AC HAD THE STEEL TORQUE TUBE FITTING INSTALLED PREVIOUSLY. WITH THE STEEL TORQUE TUBE FITTINGS, SEEING THE HOLES ELONGATED. IT IS DIFFICULT TO NOTICE HOLES ARE ELONGATED DURING INSP SINCE THE RUDDER IS NOT REMOVED FROM THE TORQUE TUBE FITTING DURING TYPICAL SCOPE OF INSP. IF TECH MOVES RUDDER TO THE FULL STOP IN ONE DIRECTION AND THEN SLOWLY MOVES TO OPPOSITE STOP AND GENTLY PUSHES ON THE RUDDER YOU CAN NOTICE SLIP OF TORQUE TUBE WITHIN FITTING. 1L72 3O3 O A7SO E9CE 20050412000022005041200002NM 2005 4 12 CA050329003 120050327G5330 SKIN BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 63228 (CAN) DURING ROUTINE MAINTENANCE A CRACK WAS FOUND IN THE FUSELAGE AT STATION 759.5 BELOW STRINGER 18L. HFEC WAS CARRIED OUT TO VERIFY THE CRACK AND DETERMINE THE EXTENT. IT WAS DETERMINED THAT THE CRACK WAS APPROX 1.4 INCHES LONG. THE CRACK WAS REPAIRED IAW SRM 53-30-3 PAGE 284 FIG. 48 SHEET 32 DETAIL X. 2L72 4F4 F A16WE E2EA 20050412000032005041200003SO 2005 4 12 CA050324006 220050315G8520639196 COUNTERWEIGHT CONT CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C402 GL CRANKSHAFT FAILED W A UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 CA H25921N (CAN) ROLLER RETAINER AND SNAP RING CAME OUT OF CLUT, RELEASING ROLLER IN 5TH ORDER CWT. (NO DAMAGE TO PARTS, POSSIBILITY WAS NOT INSTALLED CORRECTLY.) ROLLER MIGRATED TO REAR OF ENGINE AND JAMMED BETWEEN 6TH ORDER CWT AND ENGINE CASE STOPPING ENGINE. CRANKSHAFT NRPLE AT NR2 ,AOM KPIRMA, FRP, SUDDEN STOPPAGE. 1H71 3O3 O A4CE E8CE 5 CP47GL 20050412000062005041200006WP 2005 4 12 CA050321006 220050304G72408939735 PLENUM BEECH 100 B100 1152919CE GARRTTTPE331TPE3316252B 01514WP HARTZLHCB4T HCB4TN5 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA P27081 (CAN) WHILE CONDUCTING AN ENGINE INSPECTION, A 2 INCH CRACK WAS DISCOVERED ON THE PLENUM NEAR THE BLEED AIR OUTLET. THE ENGINE WAS REMOVED AND THE CRACKED PART REPLACED. A FLEET WIDE ENGINE INSPECTION OF THE SAME DEFECT WAS CARRIED OUT. NO OTHER DEFECTS FOUND. 1L72 4T4 T A14CE E2WE 6 CP40EA 20050412000072005041200007GL 2005 4 12 CA050316004 320050314G6111S90AT2 BLADE MCAULY CESSNA180 180H 2072618CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C66 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 668 743155 743155 (CAN) PROPELLER, W/O T 64571, RECEIVED FOR 10 YEAR OVERHAUL. LAST OVERHAUL MAY 1996. NOW 667.9 HOUR SINCE OVERHAUL. FOUND BLADE S-90AT-2, SN B34101YS, CRACKED IN BLADE THREADS, FOUND WITH EDDY CURRENT. 1H71 3O3 O 5A6 E273 5 CP3EA 20050412000082005041200008NM 2005 4 12 CA050121007 120050107G2710 BEARING BOMBDR DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE LT AIL PULLEY WORN W K NONE O OTHER ININSP/MAINT 1 CA 3519935199 (CAN) DURING MAINTENANCE INSPECTION, LT AILERON CABLE PULLEY BEARING FOUND WORN AT WINGSPAR CENTER SECTION. PULLEYS REPLACED , CABLES RE-RIGGED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050412000092005041200009GL 2005 4 12 CA050314004 220050309G7250 TURBINE BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL ENGINE STIFF W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) AFTER A SCHEDULED INSP, WERE GOING TO DO A COMPRESSOR WASH, SINCE THE BLEED VALVE AREA WAS DIRTY. WHEN THE COMPRESSOR WAS NOTED AS BEING STIFF TO TURN, FURTHER INVESTIGATION WAS NEEDED. AFTER REMOVAL OF THE TURBINE ASSY, THE COMPRESSOR AND GEARBOX MOVED FREELY. THE 6 AND 7 BEARING AREA WAS CLEANED AND A HEAVY CARBON DEPOSIT NOTED. THE OIL FLOW AFTER CLEANING WAS GOOD AND SAW NO INDICATION OF MECHANICAL PROBLEM. THE TURBINE WAS INSTALLED AND TEST FLOWN SATISFACTORY. AFTER DISSCUSSION WITH A ENGINE REPAIR FACILITY THE OLD COOL DOWN PROCEDURE WAS NOTED AS BEING THE CULPRIT. 1G71 3U3 U H2SW E4CE 20050412000102005041200010EA 2005 4 12 CA050309013 120050306G6120210574AB CSU DHAV DHC6 DHC6200 2802620EA PWA PT6 PT6A20 52043EA HARTZLHCB3T HCB3TN3 GL PROPELLER FAILED W K NONE E VIBRATION/BUFFET ININSP/MAINT 1 CA (CAN) ON RUNUP AFTER INSTALLATION, IT WAS FOUND THAT THE OVERHAULED PROPELLER CONTROL UNIT WOULD NOT FUNCTION PROPERLY. THE PROPELLER REMAINED IN THE BETA MODE AND THERE WAS NO CONTROL OTHER THAN FEATHER/UNFEATHER. ANY ADDITION OF POWER RESULTED IN THE PROPELLER MOVING INTO THE REVERSE RANGE. THE UNIT WAS AN EXCHANGE. 1H72 3T3 TRTA9EA E4EA 6 CP15EA 20050412000122005041200012GL 2005 4 12 CA050308009 220050228G7230230397911 ADAPTER ALLSN 250C20B BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL COMPRESSOR CORRODED W K NONE O OTHER ININSP/MAINT 1 CA CAC36542 (CAN) COMPONENT DID NOT MAKE IT THROUGH ITS LIFE EXPECTANCY. FRETTING WEAR FOUND OVER PILOT OUTSIDE DIAMETER. 1G71 3U3 U H2SW E4CE 20050412000132005041200013NE 2005 4 12 CA050307007 220050225G7200 ENGINE AEROSPATR72 ATR72212A 8680902EU PWA PW120 PW127 NE FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 CA AM0057 (CAN) DURING CLIMB, THE ENGINE EXPERIENCED AN INCREASE IN TURBINE TEMPERATURE ACCOMPANIED BY VIBRATION AND NOISE. THE CREW SHUT THE ENGINE DOWN IN FLIGHT AND DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED DEBRIS ON THE TURBO MACHINERY AND REDUCTION GEARBOX CHIP DETECTORS. MFG WILL INVESTIGATE THE EVENT AND WILL SUPPLIMENT THIS REPORT TO REFLECT ROOT CAUSE ONCE DETERMINED. 2H72 4T4 TRTA53EU E20NE 20050412000142005041200014SW 2005 4 12 CA050303015 120050303G622047120252011 GRIP BELL 47 47G4A 1181031SW LYC O540 VO540B1B3 41532EA MAIN ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) MAIN ROTOR GRIP WAS REMOVED TO COMPLY WITH AD 2001-17-17 AND WAS REJECTED DUE TO CRACKING INDICATIONS IN THE THREADS OF THE ADAPTER NUT AREA. 1G71 3O3 O 2H3 E304 20050412000162005041200016NE 2005 4 12 CA050301004 220050221G723001R3028332 GAS GENERATOR BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCE4N HCE4N3 NE ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA PCEPJ0109 (CAN) DURING ENGINE INSPECTION USING A VIDEO BORESCOPE, THE HIGH PRESSURE BLEED VALVE TUBE FROM P3 WAS FOUND CRACKED OFF AND A HORIZONTAL CRACK APPROXIMATELY 3 INCHES LONG BELOW BLEED VALVE ATTACH FLANGE WAS NOTED. SOME STAINING INDICATED CRACK WAS PROBABLY NOT RECENT AND THIS AREA IS NOT READILY VISIBLE WITH THE BLEED VALVE SHROUDS INSTALLED. ALL ENGINE PERFORMANCE RUNS AND TREND MONITORING DATA WERE WITHIN ALLOWABLE PARAMETERS. GAS GENERATOR WAS REMOVED AND SHIPPED FOR REPAIR. 1L72 4T4 T A24CE E4EA 5 CP10NE 20050412000192005041200019NE 2005 4 12 CA050224012 220050217G7200 ENGINE AEROSPATR72 ATR72 EU PWA PW120 PW127 NE FAILED W C ABORTED TAKEOFF MJ OVER TEMP WARNING INDICATION TOTAKEOFF 1 CA 127102 (CAN) ON TAKEOFF ROLL THE AIRCRAFT EXPERIENCED A YAW ACCOMPANIED BY AN UNCOMMANDED REDUCTION IN ENGINE TORQUE AND TUBINE OVER TEMPERATURE AND LOW OIL PRESSURE WARNING ANNUNCIATIONS. TAKEOFF WAS ABORTED. MFG WILL INVESTIGATE THE INCIDENT AND WILL SUPPLIMENT THIS REPORT TO REFLECT ROOT CAUSE AS AND WHEN ESTABLISHED. 2H72 4T4 TRT E20NE 20050412000202005041200020EA 2005 4 12 CA050223011 220050222G8520LW16512LW16812 LIFTER CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL CAMSHAFT SPALLED W K NONE O OTHER ININSP/MAINT 1 CA RL208976T (CAN) DURING PROGRESSIVE CARE OPERATION NR2 ON INSPECTION OF OIL SUMP SCREEN FOUND LARGE METALLIC FERROUS PARTICLES. ENGINE ON FURTHER INVESTIGATION, IT WAS FOUND THAT ALL LIFTERS (INTAKE AND EXHAUST) WERE BADLY SPALLED, ALONG WITH SPALLED AND WORN CAM LOBES. MFG SPECIFY THAT THE EXHAUST VALVE CLEARANCES BE CHECKED, ALONG WITH AN INSPECTION OF THE EXHAUST LIFTERS, FOR THE 76T MODEL ENGINES AT 1000 HRS. THERE WAS NO INDICATION IN ENGINE PERFORMANCE TO INDICATE PROBLEMS. 20W50XC OIL, ALONG WITH LW16702 OIL ADDITIVE IS USED AND CHANGED EVERY 50 HRS. ENGINE-REMANUFACTURED, PURCHASED FROM LYCOMING. LYCOMING HAS BEEN CONTACTED ON THIS SITUATION. 1H71 3O3 ONT3A12 E274 5 NP910 20050412000222005041200022CE 2005 4 12 CA050126008 120050122G3297MS3126F1210P CONNECTOR BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE MLG CORRODED W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) DURING APPROACH CREW SELECTED GEAR DOWN HOWEVER, THE GEAR CONTROL C/B OPENED AND WOULD NOT RESET. MANUAL EXTENSION COMPLETED. MAINTENANCE FOUND THE CONNECTOR BEWTEEN THE NOSE GEAR ACTUATOR AND THE FRAME INTERNALLY CORRODED. THE CONNECTOR WAS REPLACED, GEAR SWUNG AND THE AIRCRAFT RELEASED. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20050412000232005041200023CE 2005 4 12 CA050127007 120050125G29101015800241 LINE BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCB3T HCB3TN3 GL LT WING UNSERVICEABLE W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) HYDRAULIC FLUID LEAKING OUT OF THE LT IB L/E. L/E REMOVED AND FOUND RIGID HYDRAULIC BRAKE LINE CHAFFED THROUGH BY ENGINE CONTROL CABLES ABOVE HEAT EXCHANGER. REPLACED LINE. ALL COMPANY AIRCRAFT USING THIS HYDRAULIC LINE VISUALLY INSPECTED AND FOUND DAMAGE ON ALL RANGING FROM MINOR TO MAJOR. BOTH LT P/N 101-580024-1 AND RT P/N 101-580025-1 LINES EFFECTED. 1L72 4T4 T A24CE E4EA 6 CP15EA 20050412000242005041200024EU 2005 4 12 CA050222006 120050222G3260 SENSOR AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE NLG DOOR OPEN W O OTHER N FALSE WARNING DEDESCENT 1 CA (CAN) LOWERED THE GEAR HANDLE AND GEAR SHOWED IN TRANSIT, THEN E-CAM FOR GEAR NOT DOWN AND LOCKED. RECYCLED THE HANDLE AND GEAR CAME DOWN, LANDED WITHOUT INCIDENT. POST FLT REPORT FLAGS RT NLG DOOR OPEN SENSOR 38GA. INTERCHANGED WITH C1 CARGO PROX SWITCH. LGCIU TESTED ON SYSTEM 1 AND 2 WITH NO FAULTS. SERV. 2L72 4F4 FRTA28NM E29NE 20050401000812005040100081SO 2005 4 1 2005FA0000179 120050210G2140EM608 BLOWER PIPER PA46 PA46350P 7104602SO LYC O540 TIO540* 41532EA DEFOGGER SEIZED B K5SRK NONE O OTHER ININSP/MAINT 1 NM0792884249 4636107 VENT DEFOG BLOWER TRIPPING VENT DEFOG BLOWER CIRCUIT BREAKER. BLOWER ASSY SEIZED. REMOVED AND REPLACED BLOWER ASSY. (K) 1L71 3O3 ORTA25SO E14EA 20050401000892005040100089CE 2005 4 1 2005FA0000463 120050211G8120 GARRTT BEECH 60 B60 1153605CE LYC O541 TIO541E1C4 41536EA HARTZLHCF3Y HCF3YR2 GL B CGHRK NONE O OTHER ININSP/MAINT 1 GL0330MM YH023923 P507 L156259 DA1311 WHILE INVESTIGATING OIL LEAK FROM TURBO, FOUND IMPELLER/TURBINE SHAFT HOLD DOWN NUT LOOSE ALLOWING SHAFT TO MOVE LATERALLY. THIS CAUSED SHAFT TO BECOME UNSEATED AT BEARING SEALS. DISCREPANCY WAS DISCOVERED EARLY ENOUGH TO KEEP IMPELLER AND TURBINE WHEELS FROM BEING DAMAGED. NOTE: TURBO WAS REPAIRED 1.9 HRS EARLIER. TURBO WAS REPAIRED AND INSTALLED. (K) 1L72 3O3 O A12CE E10EA 5 CP31EA 20050401001022005040100102SO 2005 4 1 2005FA0000353 220050224G74146320 MAGNETO CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO ENGINE FAILED D AIHRK NONE O OTHER ININSP/MAINT 1 GL11468TW58 414A0071 RT MAGNETO, PN 6320, SN 02091774 FAILED AFTER 58.0 HOURS TOTAL TIME IN SERVICE. INVESTIAGATION FOUND BROKEN CONTACT ASSY. VISUAL INSPECTION OF BOTH RT AND LT CONTACT ASSY IF SN IS WITHIN 100 OF FAILED PART. NOTE: LT MAGNETO SAME ENGINE PN 6320, SN 02091734 FAILED AT 54.0 HRS TT IN SERVICE. SAME PROBLEM. (GL11200508228) 1L72 3O3 O A7CE E8CE 20050404000192005040400019CE 2005 4 4 2005FA0000414 120050308G3297SM50D7 RELAY BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO DYNAMIC BRAKE FAILED B VJ3RO OTHER J WARNING INDICATION LDLANDING 1 WP071570A CE1333 830089R PILOT SELECTED GEAR DOWN AND NOTHING HAPPENED. LANDING GEAR WOULD NOT EXTEND. FLIGHT CREW EXTENDED LANDING GEAR MANUALLY AND LANDED WITHOUT INCIDENT. MAINTENANCE TECH TROUBLESHOT GEAR SYSTEM AND FOUND THAT THE DYNAMIC BRAKE RELAY WAS INTERMITTENT. PROBABLE CAUSE WAS DUE TO INTERNAL FAILURE WITH RELAY. TO PREVENT RECURRENCE IS INSTALL A NEWER MFG DATE RELAY WHICH IS AN IMPROVED UNIT IAW MFG. (K) 1L71 3O3 O 3A15 E5CE 20050404000272005040400027SW 2005 4 4 2005FA0000176 120050201G7921654585 OIL COOLER MOONEYM20 M20R 5870225SW CONT O550 IO550G 17042SO ENGINE CRACKED B DY1RK NONE O OTHER ININSP/MAINT 1 EA132138Z602 290158 679237 DURING ROUTINE OIL CHANGE, AN EXAMINATION OF THE OIL COOLER FLANGE AREA WHERE IT BOLTS ONTO THE ENGINE STUDS WAS FOUND TO BE CRACKED. THE CRACK WAS LOCATED BETWEEN THE STUDS MOUNTING AREA IN THE OIL COLLER SURFACE WELD. THIS IS THE FOURTH INSTANCE OF AN OIL COOLER CRACK FOUND AT THE OIL COOLER BY THIS STA WITHIN THE LAST YEAR. ALL PREVIOUS CRACKED COOLER HAD AT LEAST 500 HOURS TIME IN SERVICE. CLOSE EXAMINATION OF THIS AREA IS RECOMMENDED AT EACH OIL CHANGE OR COWLING REMOVAL. 1L71 3O3 ORT2A3 E3SO 20050404000392005040400039SO 2005 4 4 2005FA0000199 120050118G271062701099 CONTROL CABLE PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA AILERON FRAYED B ZKGRK NONE O OTHER ININSP/MAINT 1 NE052114J6218 287916224 FOUND BOTH FORWARD AILERON CONTROL CABLES FRAYED. (K) 1L71 3O3 O 2A13 E274 20050404000432005040400043CE 2005 4 4 2005FA0000446 120050304G5343460337 BRACKET BEECH MU300 400A 1155402CE PWA JT15 JT15* 52060NE ACTUATOR BROKEN B E81RO OTHER O OTHER NRNOT REPORTED 1 GL03484CW RK334 FLIGHT CREW REPORTED LANDING GEAR UNSAFE LIGHT REMAINED ILLUMINATED AFTER LANDING GEAR RETRACTION FOLLOWING DEPARTURE. CREW ELECTED TO RETURN TO AIRPORT. OBTAINED DOWN AND LOCKED INDICATION ON ALL 3 LANDING GEAR AND LANDED UNEVENTFULLY. UPON JACKING AC FOR INVESTIGATION NOTED LT MAIN GEAR ACTUATOR ATTACH BRACKET BROKEN AND DISTORTED AT LT MAIN GEAR ACTUATOR ATTACH POINT. ACTUATOR ATTACH HARDWARE STILL SECURE AND SAFTIED IN BROKEN PORTION. THIS SN AC WAS NOTED AS BEING AFFECTED BY MFG. CUSTOMER SL BJ-CSL-1004R1 ISSUED 11/01/2002. BJ-CSL-1004R1 REQUIRED REPLACEMENT OF ALL PN 46033-7, LT MAIN GEAR ACTUATOR BRACKETS ON AFFECTED AC DUE TO INCORRECT HEAT TREATMENT AND CHAMFERING. 2H72 4F4 TRTA16SW E1NE 20050404000882005040400088WP 2005 4 4 ASAA0580104 120050215G532198391951 FLOOR PANEL DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE CABIN DAMAGED A ASAAK NONE O OTHER ININSP/MAINT 1 NM02943AS 53018 OKC C-CHECK- PAX CABIN FLOOR PANEL PEELED. FIBERGLASS BOND REPAIRED. (K) 2L72 4F4 FRTA6WE E9NE 20050412000182005041200018WP 2005 4 12 CA050228004 120050226G3241406256 TRANSDUCER DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE WHEEL SPEED INOPERATIVE W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA (CAN) DURING TAKE-OFF, WHEEL NOT TURNING LIGHT ILLUMINATED AT 80 KNOTS. REJECTED TAKE-OFF CARRIED OUT WITHOUT INCIDENT. WHEEL NOT TURNING LIGHT EXTINGUISHED. SUSPECTED DE-ICING FLUID AND WET RUNWAY WAS THE CAUSE. CREW REQUESTED SECOND TAKE-OFF ATTEMPTED. UNABLE TO TAKE-OFF DUE TO SAME SNAG. REJECTED TAKE-OFF CARRIED OUT SERVICEABLE. MAINTENANCE REPLACED THE WHEEL SPEED TRANSDUCER IAW MM 32-40-00 AND CHECKED SERVICEABLE. NO FURTHER FAULT DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRTA6WE E9NE 20050412000272005041200027EA 2005 4 12 CA050207006 220050205G7321252444076 FUEL CONTROL BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL RT ENGINE INOPERATIVE W C ABORTED TAKEOFF RJ PARTIAL RPM/PWR LOSS WARNING INDICATION TOTAKEOFF 1 CA (CAN) PILOTS STARTED THE ENGINES AND TAXIED OUT FOR TAKEOFF. WHEN APPLIED POWER, THE RT ENGINE REMAINED AT IDLE. THEN RETURNED TO THE RAMP AND SHUT DOWN. ENGINEER CHANGED THE FCU. 1L72 3T4 T A14CE E4EA 5 CSTC 20050412000282005041200028EU 2005 4 12 CA050201006 120050130G5610D20543406 WINDSHIELD FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE COCKPIT CRACKED W K NONE O OTHER CRCRUISE 1 CA (CAN) DURING FLIGHT IT WAS OBSERVED THE RT WINDSHIELD OUTER PANE WAS CRACKED. CREW INITIATED QRH PROCEDURES AND FLIGHT WAS CONTINUED. AIRCRAFT LANDED WITHOUT INCIDENT. RT WINDSHIELD WAS REPLACED IAW MM 56-11-00. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRT E25NE 20050412000302005041200030NM 2005 4 12 CA050212001 120050206G61207901803 ACTUATOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE PROPELLER FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA 18089 (CAN) IN FLIGHT, CREW NOTICED NR1 OIL PRESSURE DROPPING, VISUALLY NOTICED OIL LEAK ON NR1 FORWARD COWLING, OIL PRESSURE DROPPED TO 45 PSI. CREW SHUT NR 1 ENGINE DOWN AS PRECAUTIONARY MEASURE, LANDED AIRCRAFT AT UNSCHEDULED AIRPORT. MAINTENANCE REPLACED NR1 PROPELLER ACTUATOR. GROUND RUNS AND LEAK CHECKS CARRIED OUT AND CHECKED SERVICEABLE. AIRCRAFT DISPATCHED THE FOLLOWING MORNING. NO REPORT FROM OVERHAUL FACILITY AS OF YET. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050412000332005041200033SO 2005 4 12 CA050221005 120050205G322040336000 LINK PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL NLG CRACKED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) IN DOING MFG SL NR1088, FOUND THE LINK ASSEMBLY CRACKED. ON DOING THE INSPECTION ON THE REST OF OUR FLEET, FOUND FOUR MORE CRACKED. WE WILL CONTINUE TO DO THE INSPECTION EVERY 500 HOURS IAW COMPLIANCE TIME OF SERVICE LETTER. DOING THE INSPECTION, ALSO NOTICED IN THE AREA OF THE CRACK THE ATTACHMENT LUGS HAD BEEN MADE WITH SHARP CORNERS AND NOT A SMOOTH FINISH. 1L72 3O3 O A20SO E14EA 5 CP33EA 20050412000362005041200036EU 2005 4 12 CA050112003 120050106G5630SPSEC130811 WINDOW UROCOP UROCOPEC130 EC130B4 8680989EU TMECA ARRIELARRIEL2B NE SLIDING DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 3759 (CAN) THE HELICOPTER PARKED OVERNIGHT OUTSIDE, WAS BEING PREPARED FOR FLIGHT, COVERS REMOVED AND DI COMPLETED. ALL WINDOWS WERE INSPECTED FOR CRACKS BECAUSE THE DAY BEFORE THE CO PILOTS WINDOW HAD CRACKED. PASSENGERS WERE LOADED AND HELICOPTER WAS STARTED. AFTER START, PASSENGER NOTICED A 16CM LONG CRACK IN THE UPPER LT CORNER OF THE SLIDING DOOR WINDOW. AC WAS SHUT DOWN AND MFG WAS CONTACTED. THIS CRACK WAS BEYOND THE ALLOWABLE LIMIT FOR OPERATION SO THE CRACK WAS STOP DRILLED, TAPED AND THE HELICOPTER WAS RETURNED TO BASE. DOOR HAS BEEN SENT TO MFG FOR WINDOW REPLACEMENT. TEMPERATURE WAS -22C AT TIME OF THE CRACK.(THE DAY BEFORE WHEN THE CO PILOTS WINDSCREEN CRACKED THE TEMP WAS -30C.) 1G72 3U3 U H9EU E00054EN 20050412000382005041200038EU 2005 4 12 CA050113008 120050112G5610SP350110 WINDOW SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE COCKPIT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING THE BLF THE MAIN WINDOW WAS FOUND TO BE CRACKED. THE OAT WAS -34 DEGREES. IT APPEARS TO HAVE BEEN INSTALLED WITH IMPROPER TORQUE AS THE CRACK ORIGINATED FROM THE TOP SCREW OF THE SLIP INDICATOR. 1G71 3U3 U H9EU E19EU 20050412000432005041200043NE 2005 4 12 CA050321007 220050314G7200 ENGINE ISRAEL1125 ASTRASPX 4500205EU GARRTTTFE731TFE73140 29001NE NR 2 MAKING METAL W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 113106 (CAN) AFTER TAKEOFF, CREW NOTICED NR2 ENG CHIP DETECTOR WARNING LITE ON, FOLLOWED SHORTLY BY NR 2 ENGINE OIL FILTER LITE (WARNING). PILOT REDUCED THRUST ON NR2 ENGINE AND RETURNED TO AIRPORT. MAINTENANCE INSPECTION DISCOVERED METAL ON CHIP DETECTOR AND IN FILTER. ENGINE REPLACED. DAMAGED ENGINE SENT FOR REPAIR. STRIP REPORT TO FOLLOW . 2L72 4F4 FRTA16NM E1NM 20050412000472005041200047EA 2005 4 12 CA050222001 120050211G554285540063101 SKIN DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE RUDDER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 18364 (CAN) DURING AN INSPECTION OF THE EMPENNAGE OF DASH 8-311 THE RUDDERS WERE MANUALLY MOVED FROM SIDE TO SIDE. WHEN IT WAS PUSHED FULL RT, TRAVEL A LARGE CRACK APPROXIMATELY TWO INCHES LONG WAS EXPOSED. THIS CRACK BEGAN AT THE LOWER EDGE OF THE L/E SKIN AND CONTINUED FOR APPROXIMATELY TWO INCHES IN AND UPWARD DIRECTION. UPON A CLOSER INSPECTION THE ROW OF RIVETS SECURING THE LOWER EDGE OF THIS L/E SKINS TO THE BOTTOM FRAME HAD BEEN SHEARED ON BOTH LT AND RT FORWARD SKINS. 2H72 4T4 TRTA13NM E20NE 20050412000482005041200048CE 2005 4 12 CA050222002 120050218G3297MS24171D1 RELAY BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE MLG BURNED W O OTHER O OTHER LDLANDING 1 CA (CAN) LANDING GEAR WAS SELECTED DOWN BUT THERE WAS NO LANDING GEAR EXTENSION. CREW NOTICED THAT THE TWO AMP LANDING GEAR RELAY CIRCUIT BREAKER, ADJACENT TO THE LANDING GEAR SELECTOR, WAS TRIPPED. LANDING GEAR WAS SELECTED DOWN AND THE MANUAL HANDPUMP USED TO GET LANDING GEAR DOWN AND LOCKED. MAINTENANCE CHECKS WERE CARRIED OUT AND THE 60 AMP LANDING GEAR POWER CIRCUIT BREAKER IN THE LT ELECTRICAL EQUIPMENT PANEL WAS TRIPPED. THE LANDING GEAR MOTOR RELAY WAS REPLACED, ALL CIRCUIT BREAKERS RESET AND LANDING GEAR RETRACTIONS/EXTENSIONS CARRIED OUT NORMALLY. ON INSPECTION OF THE MOTOR RELAY THE MAIN CONTACTS (200AMP RATING) WERE BADLY BURNED AND PITTED. SUSPECT THE RELAY WAS ORIGINAL FROM MANUFACTUR IN 1998. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20050412000502005041200050EU 2005 4 12 CA050215009 120050113G2910NE15FBATFI1T SWITCH SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE HYD SYSTEM DEFECTIVE W O OTHER O OTHER CRCRUISE 1 CA (CAN) PILOT COULD NOT TURN HYD OFF DURING FLIGHT BY PRESSING BUTTON ON COLLECTIVE STICK. TROUBLESHOOTING DETERMINE THE SWITCH WAS DEFECTIVE AND NOT SUPPLYING VOLTAGE TO SOLENOIDS. NEW SWITCH INSTALLED. 1G71 3U3 U H9EU E19EU 20050412000512005041200051EU 2005 4 12 CA050215010 120050211G2150BAS16346416 SLEEVE BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE7315R 01518WP A/C PACK DISCONNECTED W BG EMER. DESCENT O2 MASK DEPLOYED W INADEQUATE Q C CRCRUISE 1 CA (CAN) UPON REACHING CRUISING ALTITUDE, THE AIRCRAFT STARTED LOSING PRESSURIZATION. THE CREW DONNED THEIR OXYGEN MASKS, AT WHICH TIME THERE WAS A TOTAL LOSS OF PRESSURIZATION. UPON RETURNING TO MAINTENANCE, FOUND THAT THE SLEEVE CONNECTING THE DUCT TO THE WATER SEPARATOR HAD BECOME DISCONNECTED EVEN THOUGH THE CLAMPS WERE TIGHT. SLEEVE SECURED. 2L72 4F4 FRTA3EU E6WE 20050412000532005041200053SO 2005 4 12 CA050216005 220050131G8520654724 PISTON PIN CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO MCAULY3AF34C3AF34C92 GL ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PISTON (NR1) BROKE AT PIN BOSS RESULTING IN LARGE CHUNKS OF ALUMINUM FALLING INTO THE ENGINE, ENDING UP AT THE BOTTOM OF THE SUMP. SMALLER PIECES OF THE METAL WERE SUCKED UP THROUGH THE OIL PICK-UP AND RAN THROUGH THE OIL PUMP. 1L72 3O3 O A7CE E7CE 5 CP22EA 20050412000542005041200054EU 2005 4 12 CA050216007 120050207G1430C551S1101052 RIVET UROCOP UROCOPEC120 EC120B 8680987EU TMECA ARRIUSARRIU2F NE HORIZONTAL STAB LOOSE W K NONE O OTHER ININSP/MAINT 1 CA DVDB1 (CAN) DURING AME DAILY INSPECTION LT HORIZONTAL STABILIZER FOUND TO HAVE APPROXIMATE 1 INCH VERTICAL DISPLACEMENT AT TIP. RIVETS THAT SECURE THE OUTER SHIM HAD SHEARED ALLOWING BUSHING MOVEMENT. SB 55-001 TO BE INCORPORATED , NOT PREVIOUSLY COMPLIED WITH. TO BE CARRIED OUT. 1G72 3U3 UNCR0001RD E34NE 20050412000562005041200056EU 2005 4 12 CA050210003 120050210G3231MRH530014D BYPASS VALVE AIRBUSA330 A330* EU RROYCERB211 RB211TRENT77 NE MLG DOOR LEAKING W O OTHER K FLUID LOSS TXTAXI/GRND HDL 1 CA (CAN) FAULT: HYD GREEN FLUID UNDERFILLED. PRESSURE AT 3000 PSI, BRAKES FAILED AT 100 FEET FROM BRIDGE, REVERSE AND PARKING BRAKE USED TO STOP AIRCRAFT. ALTERNATE BRAKING NOT AVAILABLE. FOUND RT MLG DOOR BYPASS VALVE (5229GA), LEAKING AND SEAL PROTRUDING. CHANGED VALVE IAW AMM32-31-13-400-802 HYDRAULIC SYS TOPPED UP AND LEAK AND OPERATION CHECKED. S/V BRAKE SYSTEM TEST ALSO PERFORMED, OK. 2L72 4F4 FRTA46NM E39NE 20050412000572005041200057WP 2005 4 12 CA050210004 120050209G2913AS664116S666 PUMP DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE LT HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB, THE CREW OBSERVED LT HYDRAULIC PRESSURE LOW WITH LIGHT ILLUMINATING. HYDRAULIC PRESSURE INDICATED ZERO. QRH PROCEDURES INITIATED AND AIRCRAFT RETURNED TO BASE WITHOUT INCIDENT. MAINTENANCE REPLACED THE LT EDP. OPERATIONAL CHECK CARRIED OUT IAW MM 29-10-05. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRTA6WE E9NE 20050412000582005041200058NE 2005 4 12 CA050213001 220050126G7200 ENGINE AEROSPATR72 ATR72 EU PWA PW120 PW127 NE FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 CA 127051 (CAN) DURING CLIMB THE ENGINE LOST POWER ACCOMPANIED BY A LOUD NOISE AND VIBRATIONS. THE ENGINE WAS SHUT DOWN IN FLIGHT AND THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED DAMAGE TO THE TURBOMACHINE MODULE. MFG WILL MONITOR THE INVESTIGATION OF THIS EVENT AND WILL SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE ONCE ESTABLISHED. 2H72 4T4 TRT E20NE 20050412000592005041200059NE 2005 4 12 CA050213002 220050131G7200 ENGINE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE FAILED W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA PS0051 (CAN) DURING CRUISE THE ENGINE LOW OIL PRESSURE INDICATOR ANNUNCIATED. THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT INSPECTION EVIDENSED NOISE FROM THE REDUCTION G EAG THE PROP. MFG WILL INVESTIGATE THE EVENT AND WILL SUPPLIMENT THIS REPORT TO PROVIDE ROOT CAUSE AS AND WHEN ESTABLISHED. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20050412000602005041200060EU 2005 4 12 CA050218009 120050216G7920 VENT LINE AEROSPATR42 ATR42300 8680920EU PWA 120 PW120 NE HAMSTD14SF 14SF5 NE ENGINE BREATHER BLOCKED W D RETURN TO BLOCK BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI FROM COMPANY RAMP THE LAVATORY SMOKE DETECTOR INDICATOR ILLUMINATED, VISIBLE SMOKE WAS OBSERVED IN THE CABIN. THE AIRCRAFT WAS RETURNED TO THE COMPANY RAMP AND SHUTDOWN. MAINTENANCE FOUND OIL DRIPPING FROM THE NR 2 ENGINE TAIL PIPE. IT WAS DETERMINED THAT A COUPLING HOSE IN THE ENGINE VENT LINE HAD FOULED DURING REASSEMBLY. THE INNER LINING OF THE COUPLING HAD CAUGHT ON THE TUBE FOLDING INWARD CAUSING A BLOCKAGE IN THE VENT LINE. THE COUPLING WAS REPLACED AND THE AIRCRAFT GROUND RUN AND TEST FLOWN BEFORE RETURNING TO SERVICE. 2H72 4T4 TRTA53EU E20NE 6 CP7NE 20050412000612005041200061WP 2005 4 12 CA050218008 120050216G532099118755 INTERCOSTAL DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE AFT FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 24108 (CAN) WHILE PERFORMING TROUBLESHOOTING ON A POSSIBLE RUDDER PCU HYDRAULIC LEAK, FOUND RUDDER SUPPORT BRACKET, ALL FASTENERS LOOSE (SIX OFF) AND INTERCOSTAL BETWEEN TWO FRAMES SUPPORTING PCU BRACKET, CRACKED. 2L72 4F4 FRTA6WE E9NE 20050412000632005041200063NM 2005 4 12 CA050203005 120050202G322069141062 CYLINDER BOEING BOEING727 727233 138408ANM PWA JT8 JT8D15 52051NE NLG INTERMITTENT W O OTHER O OTHER APAPPROACH 1 CA 5Q1173 (CAN) NLG FAILED TO EXTEND ON APPROACH, THEN RE-CYCLED AND EXTENDED NORMALLY. NOSE GEAR JACKED, NOSE GEAR TRUNION GREASED AND GEAR RETRACTED AND EXTENDED 4 TIMES WITH NO FAULTS. AC WAS DISPATCHED WITH NO FURTHER FAULTS. QA GROUNDED THE AC DUE TO 2 OTHER EVENTS OF THE SAME NATURE. REF. SDR'S 20041123004 AND 20050119003. MAINTENANCE IN OTHER LOCATION, COMPANY MAINTENANCE OPERATIONS CONTROL, AND MAINTENANCE OPERATIONS CONTROL CENTER ALL CONTACTED TO TROUBLESHOOT THE DISCREPANCY. AFTER CONSULTATION, ALL CONCURRED THAT THE NOSE GEAR TRANSFER CYLINDER WAS AT FAULT. REPLACED THE TRANSFER CYLINDER AND GEAR WAS SWUNG NUMEROUS TIMES, NO FAULTS FOUND. AIRCRAFT WAS RETURNED TO SERVICE. T/C PMI CONTACTED WITH DETAILS. 2L73 4F4 FRTA3WE E2EA 20050412000642005041200064 2005 4 12 CA050330003 420050320G34607003974730 COMPUTER DHAV DHC8 DHC8102 2809003NM PWA 120 PW120 NE HAMSTD14SF 14SF7 NE FLT MANAGE FAILED W K NONE O OTHER ININSP/MAINT 1 CA 40034 (CAN) FLIGHT GUIDANCE COMPUTER FAILED DUE TO HARDWARE INTERNAL FAILURE. WHEN AIRCRAFT POWER WAS ATTACHED AND SELECTED ON: TO TROUBLE SHOOT YAW/DAMPER FAIL SNAG, MECHANICS NOTICED RED GLOW FROM INSIDE BOX AND FAINT SMOKE/MICARTA SMELL INDICATING OVERHEAT CONDITION - FLIGHT GUIDANCE COMPUTER REPLACED WITH NO FURTHER INCIDENT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050412000652005041200065NM 2005 4 12 CA050329002 120050328G561058935733 WINDOW BOEING737 737522 138449FNM GE CFM56 CFM56* 13802NE COCKPIT BROKEN W O OTHER D INFLIGHT SEPARATION APAPPROACH 1 CA (CAN) ON APPROACH, THE PILOTS NR 4 WINDSHIELD (EYEBROW) APPEARED TO SHATTER. THERE WAS NO LOSS OF PRESSURIZATION. THE LANDING WAS CONTINUED WITHOUT PROBLEM. ON INVESTIGATION, THE GLASS LAYER SEEMS TO HAVE FAILED. THE OUTER LAYERS WERE INTACT BUT THE INNER LAYER APPEARS TO HAVE SHATTERED. THE PILOTS DID NOT SEE ANY IMPACT NOR WAS THERE EVIDENCE OF A BIRD STRIKE. THE WINDOW WAS REPLACED WITH A SERVICEABLE UNIT. 2L72 4F4 FRTA16WE E2GL 20050414001042005041400104NE 2005 4 14 2005FA0000030 220050119G7210704A33652036 BEARING SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE REDUCTION G/B BROKEN C K NONE O OTHER ININSP/MAINT 1 NM031883H2367 2367 1883 BEVEL REDUCTION MODULE (PN 350A32-0300-05, SN M1899) WAS REMOVED AT TSO: 2367.5 FOR METAL CONTAMINATION. UPON TEARDOWN ANALYSIS IT WAS DISCOVERED THAT THE BEARING CAGE FOR BEARING (P/N 704A33-652-036) TSN: 2367.5, WAS BROKEN. SUBSEQUENT DETERIORATION OF BEARING WAS CAUSE FOR METAL CONTAMINATION. 1G71 3U3 U H9EU E19EU 20050412000372005041200037CE 2005 4 12 CA050112004 120050103G28201009200423 TUBE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL FUEL SYSTEM CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON INSPECTION OF THE FUEL TRANSFER PRESSURE SWITCH, IT WAS NOTICED THAT ONE OF THE ENGINE CONTROLS WAS RUBBING AGAINST THE MAIN FEED LINE TO THE RT NAC TANK. REPLACED TUBE ASSY AND TIED BACK TELEFLEX CABLES TO PREVENT FURTHER RUBBING. 1L72 4T4 T A24CE E4EA 6 CP15EA 20050412000402005041200040SW 2005 4 12 CA050110003 120050105G6310212040687001 COUPLING BELL BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA INPUT DRIVE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA A2000991 (CAN) DURING SCHEDULED INSPECTION PITTING CORROSION IN EXCESS OF .005 INCH HAS BEEN DISCOVERED. THE PATTERN AND LOCATION OF CORROSION PITTING CONFORMS TO PROCESS STAMP IMPRESSION (186). IT IS LIKELY THAT IMPROPER INK HAS BEEN USED DURING SHAFT OVERHAUL. OVERHAUL SHOP(S) HAVE BEEN ADVISED. THE ORIGIN OF THE STAMP IMPRESSION IS YET TO BE ESTABLISHED. 1G71 4U4 U H4SW E22EA 20050412000462005041200046NM 2005 4 12 CA050221007 120050202G243523088008 STARTER GEN DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE LT ENGINE OPEN W BA EMER. DESCENT UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CRUISE AT 16,000 FT, AC DEPRESSURIZED W/ILLUMINATION OF MSTR WARN LIGHT, MSTR CAUTION LIGHT, GPWS WARN LIGHT. SYS THAT REPORTED TO STOP WORKING: FMS, NAV, TRANSPONDER SYS. NR2 ADF WAS REPORTED TO BE WORKING, WAS USED TO LAND. ON APPROACH, LG WAS SELECTED DOWN, FLAPS EXTENDED, CAUTION LIGHT WAS REPORTED TO EXTINGUISH: AUX INV, RUD FULL, NR2 RYD HYD. WHEN AC WAS ON GROUND, BUS TIE SWITCH WAS SELECTED, AC STARTED TO PRESSURIZE. LT STARTER/GEN FAILED TO GENERATE PWR AND TO START ENGINE. NEXT START, NR1 GCU AND STARTER/GEN REPLACED, GROUND CHECKED IAW 24-31-03, 24-31-01 NO DEFECTS EVIDENT. START/GEN WAS CONFIRMED THAT UNIT HAD FAILED DUE TO NO GENERATION, SHUNT FIELD OF STATOR WAS OPEN CIRCUIT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050412000492005041200049EA 2005 4 12 CA050215008 120050209G5210NAS620754D BOLT CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE PAX DOOR SEIZED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) ON CLIMB OUT, CREW RECEIVED A (PAX DOOR LATCH) MESSAGE, AND THEN A (PASSENGER DOOR WARNING MESSAGE). CREW FOLLOWED QRH PROCEDURES AND COMPLETED AN UNEVENTFUL OVERWEIGHT LANDING. TROUBLESHOOTING FOUND BOLT P/N NAS6207-54D SEIZED IN BUSHING P/N NAS74A7E302P AS PART OF PASSENGER DOOR MID PIVOT ASSY. ALSO FOUND UPPER PIVOT ASSY 601R38383-1 VERY STIFF. IPC 52-11-02 FIG 2. BOTH FITTINGS AND ASSOCIATED HARDWARE REPLACED. DOOR RIGGED, FUNCTION TESTED AND RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20050412000522005041200052EA 2005 4 12 CA050214005 220050210G7230 STRUT BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU COMPRESSOR CRACKED W O OTHER BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION DEDESCENT 1 CA FA0190FA0191 (CAN) ON DESCENT, THE AIRCRAFT CABIN AIR WAS CONTAMINATED WITH SMOKE. A SIMILAR PROBLEM HAD BEEN ENCOUNTERED THE PREVIOUS DAY DURING GROUND HANDLING. SUBSEQUENT INSPECTION REVEALED DAMAGE TO THE COMPRESSOR INNER SUPPORT OF ENGINE FA0190 AND CRACKING OF TWO INTER-COMPRESSOR CASE STRUTS ON ENGINE FA0191. MFG WILL INVESTIGATE TO ESTABLISH ROOT CAUSE. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050412000622005041200062EU 2005 4 12 CA050218007 120050216G7540D48366403 SWITCH FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE SHROUD OVERHT INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CLIMB, NR1 ENGINE BLEED FAULT ILLUMINATED. AT CRUISE, THE BLEED WAS RESET RESULTING IN THE SAME BLEED DUCT LEAK ALERT. THE AIRCRAFT RETURNED TO BASE WITHOUT INCIDENT. MAINTENANCE REPLACED THE LT SHROUD OVERHEAT SWITCH IAW MM 36-11-11 AND TESTED SERVICEABLE IAW MM 36-11-11-720-855. THE AIRCRAFT WAS DISPATCHED WITH NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRT E25NE 20050415000732005041500073EA 2005 4 15 20050209 220050209G850070384 SHAFT PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA IDLER GEAR BROKEN B EVGRK NONE P NO WARNING INDICATION ININSP/MAINT 1 SO33 1985 1985 L251648 AT ENGINE DISASSEMBLY FOR OVERHAUL AFTER RUNNING FULL LIFE (1985.4 HRS) GOVERNOR IDLER GEAR SHAFT WAS FOUND BROKEN INSIDE THE GEAR. ENGINE RAN NORMALLY, NO OTHER DAMAGE NOTED. 1L72 3O3 O 1A10 1E4 20050627001032005062700103WP 2005 6 27 2005FA0000824 120050606G623023600 MAST HILLERUH12 UH12E 4360122WP ALLSN 250C 250C20B 03013GL MAIN ROTOR CRACKED D JYBGO OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 NM0976431 229 992 HELICOPTER EXPERIENCED A PROGRESSIVE LATRIAL VIBRATION. SUBSEQUENT INSPECTION FOUND 2 CRACKS FROM THE PITCH PIN SLOT AREA OF THE MAST. ONE CRACK FROM THE TOP OF ONE SLOT AND ANOTHER CRACK FROM THE BOTTOM OF THE SAME SLOT PROGRESSING THE OPPOSITE DIRECTION. THE TOP CRACK IS APPROX 1.6 INCHES AROUND THE DIAMETER OF THE MAST AND THE BOTTOM CRACK IS APPROX 1.3 INCHES. 1G71 3O3 U 4H11 E4CE 20050412000112005041200011SW 2005 4 12 CA050309001 120050301G2910214001023101 TUBE BELL BELL 214 214ST 1182106SW GE CT7TS CT72A 30030NE HYD SYSTEM CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE, THE SUBJECT TUBE WAS FOUND WITH A (0.375 INCH X 0.187 INCH) HOLE THAT ORIGINATED FROM CHAFING WITH A HYDRAULIC OIL LINE. THE HOLE WAS LOCATED APPROXIMATELY IN THE CENTER OF THE TUBE. THE TOTAL CHAFING DAMAGE IN THIS AREA, COVERED APPROXIMATELY TWENTY PERCENT OF THE TUBE CIRCUMFERENCE. IN ADDITION, THERE WERE TWO OTHER AREAS DISPLAYING SIGNIFICANT CHAFING DAMAGE NEAR THE TOP END OF THE TUBE, ORIGINATING FROM CONTACT WITH ANOTHER OIL LINE. IT WAS EVIDENT THAT INCORRECT ROUTING OF THE OIL LINES WAS THE CAUSE OF THE DISCREPANCY. THERE WAS NO DAMAGE TO THE OIL LINES AS THEY WERE COVERED WITH PLASTIC SPIRAL WRAP. 2G72 4U4 U H10SW E8NE 20050412000152005041200015CE 2005 4 12 CA050302004 120050321G555112120031 DOUBLER CESSNA 12124026 CESSNA210 T210K 2073447CE CONT O520 TSIO520H 17040SO MCAULY3A32C D3A32C88 GL BULKHEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE BULKHEAD DOUBLER REINFORCES THE HOLE WHERE THE HORIZONTAL STAB ATTCHES. DOUBLER SPLIT IN TWO THROUGH THE ANCHOR NUT RIVIT HOLE. THIS DOUBLER IS ONLY FOUND ON EARLY MODELS. 1H71 3O3 O 3A21 E8CE 5 CP21EA 20050412000172005041200017 2005 4 12 CA050124008 420050118G342240001728513 HSI PIPER PA31 PA31325 7103105SO LYC O540 TIO540F2BD 41532EA HARTZLHCE3Y HCE3YR2A GL COCKPIT STUCK W O OTHER I FLT. ATTITUDE INST. APAPPROACH 1 CA (CAN) NR1 HSI NEEDLE STUCK ON NORTHERN HEADING. NR1 ENGINE STARTED TO SURGE. ENGINE DROPPED TO 20 INCHES OF MANIFOLD PRESSURE. AIRCRAFT RETURNED TO BASE SAFELY. 1L72 3O3 O A20SO E14EA 5 CP33EA 20050414001112005041400111CE 2005 4 14 2005FA0000306 120050117G79218406E OIL COOLER BEECH 23 C23 1151242CE LYC O360 O360A4J 41514EA SNSNCH76E 76EM8S5 EA ENGINE CRACKED G EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 SO059JY 442 M2133 IN-FLIGHT ENGINE FAILURE DUE TO OIL STARVATION RESULTING IN AN EMERGENCY LANDING IN TREES. POST ACCIDENT INVESTIGATION REVEALED A CRACKED OIL COOLER, WHICH ALLOWED ENGINE OIL SUPPLY TO BE PUMPED OVERBOARD. REFERENCE ACCIDENT (NR ATL05CA047). 1L71 3O3 O A1CE E286 5 NP4EA 20050415001692005041500169GL 2005 4 15 2005FA0000314 320050224G6114D4885C61 HUB MCAULY D2AF34C61 CESSNA336 336 2075602CE CONT O360 IO360A 17025SO MCAULY2AF34CD2AF34C61 GL BLADE SOCKET CRACKED B K NONE K FLUID LOSS ININSP/MAINT 1 WP073860U 781897 3360160 781897 PROPELLER SENT FOR REPAIR OF RED DYE OIL LEAK. AT DISASSEMBLY HUB WAS FOUND CRACKED IN BLADE RETENTION SOCKET THREADS. 1H72 3O3 O A2CE E1CE 5 CP5EA 20050420000602005042000060CE 2005 4 20 MAFALT1 120050404G2430DOFF10300BR ALTERNATOR CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO ENGINE OPEN D A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 WP21 575 OPEN FIELD WINDING. 1H71 3O3 O A4CE E8CE 20050420000612005042000061CE 2005 4 20 MAFALT2 120050404G2430DOFF10300BR ALTERNATOR CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO ENGINE OPEN D A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 WP21 279 OPEN FIELD WINDING AT SLIP RING (WIRE BROKEN AT SOLDER JOINT). 1H71 3O3 O A4CE E8CE 20050420000622005042000062CE 2005 4 20 MAFALT3 120050404G2497 WIRE CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO ENGINE OPEN D A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 WP21 327 ES4145 OPEN FIELD WINDING AT SLIP RING (WIRE BROKEN AT SOLDER JOINT). 1H71 3O3 O A4CE E8CE 20050420000652005042000065SO 2005 4 20 DUKESPUMPPKMP 220050405G731441400015RX PUMP CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO FUEL SYSTEM LEAKING D K NONE O OTHER ININSP/MAINT 1 WP21PKMPG 321 U20606585 PUMP IS LEAKING AT THE SEAL AT THE BASE OF THE PUMP-NEAR/AT DRAIN PIPE. 1H71 3O3 O A4CE E8CE 20050420000662005042000066SO 2005 4 20 DUKESPUMPMPG 220050405G731441400015RX PUMP CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO FUEL SYSTEM LEAKING D O OTHER K FLUID LOSS NRNOT REPORTED 1 WP21PKMPG 321 U20606585 PUMP IS LEAKING AT THE SEAL AT THE BASE OF THE PUMP, NEAR DRAIN PIPE. 1H71 3O3 O A4CE E8CE 20050420000862005042000086EA 2005 4 20 CA050114004 220050106G7320A23D047 REGULATOR PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL FUEL SYSTEM LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA 317405143 (CAN) DURING AN INSPECTION NECESSARY BY AD 2004-25-16 THE FUEL REGULATOR WAS FOUND TO BE LEAKING AROUND THE SEAM. IT WAS NOT LEAKING ENOUGH TO RUN OUT THE DRAIN FOR THE PROTECTIVE COVER. 1L72 3O3 O A20SO E14EA 5 CP33EA 20050420000872005042000087EU 2005 4 20 CA050114005 120050114G5310350A38101891 CROSSBEAM SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AN ENGINEER WAS DOING A 30 HOUR INSPECTION IAW AWD 96-156-071(B) R1 PART 1.1.THE ENGINEER DISCOVERED A BLACK LINE IN THE REGION THAT IS TO BE INSPECTED, A CLOSER LOOK, IT WAS DETERMINED THAT IT WAS CRACKED. THE TSO IS ACTUALLY TSI SINCE THE LAST (NDT LIQUID DYE PENETRENT) INSPECTION IAW AWD. 1G71 3U3 U H9EU E19EU 20050420000882005042000088CE 2005 4 20 CA050117001 120050113G5411 FRAME BEECH 200 B200C 1152924CE PWA PT6 PT6A42 52043NE HARTZLHCD4N3HCD4N3A GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 20570 (CAN) DURING A ROUTINE INSPECTION A CRACK WAS FOUND PROPAGATING FROM THE OVAL HOLE IN THE RT FRAME AT STATION 207.125 (HALF WAY BETWEEN THE FLOOR AND THE WINDOW). THE CRACK WAS APPROXIMATELY 1 = INCH LONG AND EXTENDED FROM THE 11 O`CLOCK POSITION OF THE LIGHTNING HOLE TO A RIVET ON THE REINFORCEMENT PLATE. 1L72 4T4 T A24CE E4EA 5 CSTC 20050420000912005042000091CE 2005 4 20 CA050120006 120050109G2910661705213 LINE CESSNA560 560XL 2076702CE PWA 545 PW545A NE LT HYD SYS CRACKED W A UNSCHED LANDING K FLUID LOSS CLCLIMB 1 CA (CAN) AIRCRAFT DEPARTED. AS THE AIRCRAFT ACCELERATED THE CREW BECAME CONCERNED DUE TO A VIBRATION. THE AIRCRAFT WAS DIVERTED TO INTERNATIONAL AIRPORT. INVESTIGATION FOUND A CRACK IN THE HYDRAULIC LINE FROM THE LT ENGINE DRIVEN HYDRAULIC PUMP WHERE IT CONNECTS TO THE INPUT PORT OF THE LT PRESSURE FILTER. A NEW LINE WAS INSTALLED. THE HYDRAULIC SYSTEM WAS SERVICED AND GROUND FUNCTION TESTS WERE COMPLETED. THE AIRCRAFT WAS RELEASED TO SERVICE. 2L72 4F4 FRTA22CE E00059EN 20050420000932005042000093CE 2005 4 20 CA050120012 120050118G2752C1450046 ACTUATOR CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL TE FLAP WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FLAP ACTUATOR MAKING NOISE DURING FLAP OPERATION. PRIMARY FLAP MOTOR LOADING THROUGH PARTIAL TRAVEL OF FLAPS. SECONARDY FLAP SYSTEM WOULD NOT EXTEND OR RETRACED FLAPS BUT MOTOR STILL RUNNING. FLAP ACTUATOR/MOTOR ASSEMBLY REMOVED AND UPON INSPECTION FOUND DRIVE GEARS WORN AND SECONARDARY MOTOR DRIVE SHEARED. SUPECT WORN GEARS BINDING AND LOAD STRESS ON FLAP MOTORS. NEW FLAP MOTOR ASSEMBLY INSTALLED, TESTED SERVICABLE AND AIRCRAFT RETURNED TO SERVICE. 1H71 3T3 T A37CE E4EA 5 CP60GL 20050420000942005042000094EU 2005 4 20 CA050120013 120050112G6230350A37118101 SWASHPLATE SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE MAIN ROTOR WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A DAILY INSPECTION, WITH THE COLLECTIVE CONTROL RAISED, AME NOTICED THAT PROTECTIVE TEFLON TAPE WAS MISSING ON THE SWASHPLATE GUIDE (SEVERAL SQUARE INCHES IN AREA, FROM 7:30 O'CLOCK TO 2:00 O'CLOCK). CORRESPONDING WEAR STEP OF APPROXIMATELY .040 INCH HAS BEEN FOUND ON GUIDE'S SURFACE. THE WEAR HAS BEEN CAUSED BY THE BALL RING (UNIBALL) RUBBING ON BEAR SURFACE OF THE GUIDE. THE SWASHPLATE GUIDE HAS BEEN REPLACED AND A/C RETURNED TO SERVICE. 1G71 3U3 UNCH9EU E19EU 20050420000952005042000095CE 2005 4 20 CA050121001 120050120G3397 CONNECTOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE LANDING LIGHT BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT LND LIGHT WOULD NOT EXTING. (RELAY STUCK (ON)). RELAY WAS REPLACED, FAULT STILL PERSISTED, (SHORT) DISCOVERED TO X2. (COIL GROUND) TERM OF RELAY. BETWEEN RT GEAR WHEELWELL CNTR P/J 64 PIN W, RELAY TERM X2. WHEN P/J 62 WAS DISCONTD PIN SMALL (E) AND WIRE L590C16 SHOWED SIGNS OF OVERHEAT. PIN WAS HEAT TO PREVENT EXTRACT FROM CONN, WIRE WAS DISCOLORED ABOUT 8 IN FROM CONN. RELAY CONTACTS REMAINED CLOSED (RELAY ENERGISED)TO PERMIT FLOW OF DC PWR TO LIGHT IS STILL ON-GOING. PIN WAS OVERHEAT COULD BE RELATED TO EXT ILLUMN OF LDNG LIGHT. NOT AN INTERNAL (SHORT) IN CONN. COIL (GROUND SEEKING) WIRE USES PIN H OF THIS CONN , SMALL (E) PWR PIN. RELAY AND LAND LIGHT ON/OFF SWITCH (S2) HAVE BEEN REPLACED. 1L72 4F4 F A22CE E1NE 20050412000252005041200025EU 2005 4 12 CA050131004 120050115G243523079009 STARTER GEN BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP MCAULY4HFR344HFR34C652 NE ENGINE FAILED W O OTHER HB ELECT. POWER LOSS-50 PC SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) GENERATOR WENT OFF LINE, SMOKE AND OIL VISUAL ON COWLING. 2L72 4T4 TRTBA15CAA E4WE 6 C3PNE 20050412000262005041200026EA 2005 4 12 CA050218010 220050217G8520 CRANKCASE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT ENGINE LEAK, ENGINE RUN TO CONFIRM LEAK, HARD TO FIND, ENGINE PRESSURIZED, FOUND CRACK OF 1.5 INCH LONG FORWARD OF CYLINDER NR2 IN THE CASE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20050412000292005041200029WP 2005 4 12 CA050210002 120050209G3230H141016 SWITCH DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE NLG INTERMITTENT W O OTHER N FALSE WARNING CRCRUISE 1 CA (CAN) DURING FLIGHT, THE CREW OBSERVED THE NLG UNSAFE LIGHT ILLUMINATE BRIEFLY. THE FLIGHT CONTINUED AND LANDED WITHOUT INCIDENT. THE NLG LT GROUND INTERLOCK SWITCH WAS SUSPECTED AND REPLACED IAW MM 32-60-05. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRTA6WE E9NE 20050412000312005041200031NM 2005 4 12 CA050215007 120050211G33505521981 CELL GRIMES DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE EMERGENCY LIGHT BURNED W K NONE O OTHER ININSP/MAINT 1 CA 12160 1990 (CAN) EMERGENCY LIGHT BATTERY PACK WAS REMOVED FROM AIRCRAFT FOR A SCHEDULED MAINTENANCE RESTORATION TASK 3350/05 AND SENT TO AVIONICS SHOP. DURING INSPECTION OF THE CELLS, BURN MARKS ON STRAPS BETWEEN CELLS WERE NOTED. DURING DEEP CYCLE PROCESS, UNIT DISCHARGED AND DURING DISCHARGE UNDER A 4 AMP LOAD, CELLS BECAME EXCESSIVELY HOT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050412000392005041200039SW 2005 4 12 CA050107004 120050105G6320168459 HOUSING BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL OIL FILTER LEAKING W B EMER. DESCENT J WARNING INDICATION CLCLIMB 1 CA B12177 (CAN) DURING A TEST FLIGHT FOLLOWING AN OPS NR4 INSPECTION, THE TRANSMISSION OIL PRESSURE LIGHT ILLUMINATED AND THE OIL PRESSURE DROPPED SLIGHTLY BELOW THE RED LINE. AN IMMEDIATE DECENT WAS CONDUCTED AND UPON LANDING A MAJOR OIL LEAK WAS DISCOVERED. THE SOURCE OF THE LEAK WAS THE MAIN TRANSMISSION FILTER HOUSING. THE FILTER WAS REMOVED AND THE O-RING WAS FOUND NICKED APPROXIMATELY .1250 INCH WIDE. THE AIRCRAFT HAD COMPLETED A 30-MINUTE POST INSPECTION GROUND RUN TWO WEEKS EARLIER WITH NO LEAKS DETECTED. 1G71 3U3 U H2SW E4CE 20050412000422005041200042NE 2005 4 12 CA050321008 220050311G7320252444993 FUEL CONTROL BEECH 90 F90 1152909CE PWA PT6 PT6A135 52043NE HARTZLHCB4T HCB4TN3 GL ENGINE FAILED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA PCE92604 (CAN) ENGINE POWER REDUCED TO IDLE ON TAKEOFF. MAINTENANCE INSPECTION REVEALED FUEL CONTROL UNIT FAILURE. REPLACED ENGINE DRIVEN PUMP TO FUEL CONTROL COUPLING AND FUEL CONTROL UNIT. GROUND RUN SERVICEABLE. AIRCRAFT RETURNED TO SERVICE. 1L72 4T4 T A31CE E4EA 6 CP40EA 20050412000552005041200055SW 2005 4 12 CA050216008 120050208G7120206031302189 CHANNEL BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL RT ENG MOUNT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK FOUND IN CHANNEL AT RT FORWARD ENGINE MOUNT ATTACH AREA. CRACK APPROXIMATE 1.55 INCH. 1G71 3U3 U H2SW E4CE 20050414001122005041400112EA 2005 4 14 1622304 220050128G8520AELSTD2213 BOLT LYC LYC O360 IO360A3B6 41514EA CRANKGEAR FAILED B K NONE O OTHER ININSP/MAINT 1 EA23 V53790363 L2754551A DURING ENGINE OVERHAUL, THE PMA CRANKGEAR BOLT P/N: AELSTD2213 MANUFACTURED BY ENGINE COMPONENTS INC FAILED BEFORE REACHING RECOMMENDED TORQUE VALUE. THE AREA JUST BELOW THE GRIP AREA STRETCHED. 3 O 1E10 20050414001132005041400113SO 2005 4 14 2005FA0000484 220050130G8520SA631991REVC SHAFT PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360E 17025SO ENGINE OUT OF ROUND D O OTHER O OTHER NRNOT REPORTED 1 WP17123AP 347770015 303972 UPON INSTALLING A SHAFT INTO A ROCKER WITH INADEQUATE TOLERANCE LIMITS, NOTED BINDING IN 3 O`CLOCK POSITIONS. WITH PRUSSION BLUE FOUND SHAFT IS FORMED IN ELIPTICAL OR, MODIFIED TRIANGULAR SHAPE WITH REDUCED WEAR SURFACE AREA DUE TO INCONSISTANT DIA OF SHAFT. ALL 24 NEW SHAFTS DISPLAYED SAME MACHINING RESULTS. HIGHEST PRESSURE POINT WAS NARROWEST CONTACT POINT. GALLING OF THESE SHAFTS APPEARS TO BE CONSISTANT WITH REDUCED WEAR SURFACE & CROWNING OF SHAFT. WHILE OTHER FACTORS MAY BE ATTRIBUTED TO CAUSE OF PREMATURE SHAFT FAILURE, REDUCTUION IN SURFACE AREA IS CONSISTANT WITH ACCELERATED DECOMPOSITION OF BEARING SURFACE. AIRWEST AIRCRAFT ENGINES SUPPLIED PARTS. RETURNED PARTS. 1L72 3O3 O A7SO E9CE 20050415000852005041500085EA 2005 4 15 2005FA0000310 220050204G8500 ENGINE PIPER PA31 PA31325 7103105SO LYC O540 TIO540F2BD 41532EA HARTZLHCE2Y HCE2YR2 GL RIGHT FAILED C E ENGINE SHUTDOWN E VIBRATION/BUFFET TXTAXI/GRND HDL 1 SO1727447 317812022 L125968A THE PILOT ATTEMPTED TO START THE RT ENGINE, WHILE DOING SO, HE HEARD A LOUD BANG THE ENGINE STARTED, AFTERWARDS, SHUTDOWN THE ENGINE AND EXITED THE AIRCRAFT. UPON INVESTIGATION, OBSERVED SKIN DAMAGE BETWEEN THE INSIDE NACELLE AND FUSELAGE, THE WING LOCKER SUFFERED SKIN DAMAGE ALONG WITH THE WHEEL WELL WHERE OBSERVED DAMAGE TO THE INSPECTION PANEL. THE FLAP ALSO SUSTAINED DAMAGE. 1L72 3O3 O A20SO E14EA 5 CP9EA 20050415002282005041500228SO 2005 4 15 2005FA0000308 120050301G149739570002 RELAY PIPER PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA SHORTED B NX4TK NONE S AFFECT SYSTEMS ININSP/MAINT 1 SO15934ER13 13 4496191 CREW NOTED VARIOUS ROCKER SWITCHES, LOCATED ON INSTR PANEL, FAILED TO ILLUMINATE. IT WAS DISCOVERED THAT FUEL PUMP SWITCHES, LOCATED ON LWR PILOT'S PNL, JUST TO LT OF EMER GEAR EXT, WERE CONTACTING GEAR MUTE RELAY (SMALL METAL BOX) LOCATED DIRECTLY BEHIND THEM. CONTACT WAS MADE THROUGH LWR TRMNLS ON EACH SWITCH, WHICH WAS NOT INSULATED AS WERE SOME OF OTHER TRMNLS ON SAME SWITCH. TERMINALS ARE WHERE LIGHTING WIRES FOR INTERNAL SWITCH LIGHTS ARE CONNECTED TO SWITCH. THIS CAUSED ALL OF LIGHTS IN ALL OF PNL MOUNTED ROCKER SWITCHES TO NOT ILLUMINATE. EVIDENCE OF ABNORMAL HEAT BEING GENERATED BY LIGHT DIMMER ASSEMBLIES (P/N 39570-002), SO THAT ASSY WAS REPLACED WITH SERVICEABLE ASSY, RELAY WAS ALSO REPOSITIONED.1L72 3O3 O A19S0 E286 20050420000922005042000092CE 2005 4 20 CA050120007 120050117G561010138402523 WINDSHIELD BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT BROKEN W B EMER. DESCENT D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) ENROUTE IN CRUISE FLIGHT AT 16000 MSL, OAT -38C THE LT WINDSHEILD SHATTERED. THE WINDSHIELD HEAT WAS OFF AND HAD NOT BEEN USED DURING THE FLIGHT. THE DEFOG AIR WAS ALSO OFF. THE CREW DECLARED AN EMERGENCY AND REQUESTED CLEARENCE AND IMMEDIATE DECENT TO 8000 MSL. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE WINDSHIELD INNER PLY WAS FOUND SHATTERED. THE WINDSHIELD WILL BE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20050420000972005042000097SO 2005 4 20 CA050121008 120050120G2421ALU8421R ALTERNATOR PIPER PA31 PA31 7103102SO LYC O540 IO540M1A5 41532EA HARTZLHCE2Y HCE2YR2 GL ENGINE SHORTED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) AN INTERNAL SHORT IN THE ALTERNATOR CAUSED THE VOLTAGE REGULATER CIRCUIT BREAKER TO POP. DUE TO THE DESIGN OF THE SYSTEM, THE FAILURE WAS NOT ISOLATED TO THE FAILED SIDE. THE PILOT TURNED OFF ALL ELECTRIC DEVICES AND LANDED AT THE NEAREST AIRPORT. THE AIRCRAFT WAS FERRIED TO ANOTHER AIRPORT WERE THE ALTERNATOR WAS REPLACED. 1L72 3O3 O A20SO 1E4 5 CP9EA 20050420000982005042000098NE 2005 4 20 CA050121009 220050116G73207898426009 ECU DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ENGINE CORRODED W D RETURN TO BLOCK J WARNING INDICATION NRNOT REPORTED 1 CA 4201442014 (CAN) NR1 ENGINE, ENGINE CONTROL UNIT WOULD NOT INDICATE (ON). MAINTENANCE FOUND CORROSION INSIDE AND OUTSIDE CONNECTOR J1. ECU REPLACED. (NOTE: TIMES ARE AIRCRAFT TOTAL TIME NOT ACTUAL PART TIME) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050420000992005042000099EA 2005 4 20 CA050121010 120050117G3297324612CC225 WIRE HARNESS DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE MLG SHORTED W O OTHER J WARNING INDICATION APAPPROACH 1 CA 3067130671 (CAN) DURING APPROACH, WHEN GEAR SELECTED DOWN, OB ANTISKID CAUTION LIGHT ILLUMINATED. MAINTENANCE FOUND WIRE 32-46-12CC22-5 SHORTED TO SHIELD BETWEEEN 9811-P59 AND 9811-1J177 (PIN K). WIRING REPAIRED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050420001002005042000100CE 2005 4 20 CA050124001 120050117G323323271004 ACTUATOR LEAR 35 35LEAR 5170600CE GARRTTTFE731TFE73122B 01518WP MLG INOPERATIVE W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) DURING APPROACH CREW SELECTED GEAR DOWN. THE LT MLG WOULD NOT EXTENDED. LT MLG RED GEAR UNSAFE LIGHT CAME ON. GEAR EMERGENCY AIR SYSTEM ACTIVATED, RED LIGHT STAYS ON. ALTERNATE MEANS USED TO CONFIRM GEAR WERE DOWN AND LOCK. AIRCRAFT LANDED AND MAINTENANCE REPLACED THE LT MLG ACTUATOR. 2L72 4F4 F A10CE E6WE 20050420001012005042000101WP 2005 4 20 CA050124009 120050122G3260 WARNING LIGHT DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE NLG ILLUMINATED W O OTHER N FALSE WARNING CRCRUISE 1 CA (CAN) CREW OBSERVED NOSE GEAR LIGHT ILLUMINATED WITH THE GEAR HANDLE IN THE UP POSITION. HEARD A GRINDING NOISE WITH VIBRATION FELT. THE AIRCRAFT CONTINUED AND LANDING WITHOUT INCIDENT. NUMEROUS NOSE WHEEL RETRACTIONS/EXTENSIONS WERE CARRIED SUCCESSFULLY. THE NOSE GEAR TRUNNION WAS LUBRICATED AND THE NOSE GEAR WAS FOUND SERVICEABLE IAW MM 32-30-00. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRTA6WE E9NE 20050420001032005042000103EA 2005 4 20 CA050124011 220050109G7323 GOVERNOR BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL OVERSPEED DEFECTIVE W EA ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET DEDESCENT 1 CA 50153 (CAN) DURING DESCENT, ENGINE POWER COULD NOT BE REDUCED BELOW 1000 LBS TORQUE. THE AIRCRAFT DIVERTED TO BASE AND THE PILOT SHUT THE ENGINE DOWN IN FLIGHT AND ACCOMPLISHED A SINGLE ENGINE LANDING. SUBSEQUENT INSPECTION DETERMINED A DEFECTIVE OVERSPEED GOVERNOR AS THE SOURCE OF THE PROBLEM. 1L72 3T4 T A14CE E4EA 5 CSTC 20050420001042005042000104SW 2005 4 20 CA050124013 120050117G3244 TIRE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP MCAULY4HFR344HFR34C652 NE MLG DISINTEGRATED W C ABORTED TAKEOFF D INFLIGHT SEPARATION TOTAKEOFF 1 CA (CAN) UPON ROTATION IN APPROXIMATELY -35 DEGREE CELSIUS THE RT GEAR TIRES BLEW UP CAUSING VIBRATION AND A PULL OF THE RT. PILOT ABORTED TAKE OFF AND AIRCRAFT WAS TOWED OFF RUNWAY. THE CAUSE IS LEANING TO THE BELIEF THAT THE MFG (RETREAD) TIRES HAVE A STIFFER SIDEWALL AND THAT AIR PRESSURES WERE NOT MAINTAINED FOR THE ENVIRONMENT THAT THEY WERE FLYING TO INSTEAD OF THE ENVIRONMENT THAT THEY WERE LEAVING FROM. 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20050420001052005042000105EU 2005 4 20 CA050125004 120050123G3810 LINE FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE GALLEY BURST W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA (CAN) IT WAS OBSERVED BY THE FLIGHT ATTENDANTS THAT A WATER LEAK WAS FOUND COMING FROM THE FWD GALLEY AREA. THE MANUAL SHUT-OFF VALVE WAS CLOSED BUT THE LEAK WAS STILL OBSERVED. THE AIRCRAFT RETURNED TO THE GATE AND A WATER LINE UNDER THE FWD GALLEY HAD BURST. THE LINE WAS REPLACED AND NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L72 4F4 FRT E25NE 20050420001072005042000107CE 2005 4 20 CA050125006 120050114G321357411405 LINK CESSNA441 441 2076020CE GARRTTTPE331TPE33110 01514WP LT MLG WRONG PART W K NONE O OTHER ININSP/MAINT 1 CA (CAN) MLG WAS REMOVED FOR MODIFICATION IAW STC. NR SA00487SE. ON RE-INSTALLATION THE MLG TRAILING LINK P/N 5741140-5 - LT WAS INSTALLED ON THE RT MLG, AND P/N 5741140-6 RT WAS INSTALLED ON THE LT MLG. THIS ERROR WAS NOT OBVIOUS DURING LANDING GEAR FUNCTIONAL RETRACTION AND EXTENSION TESTING. THE GEAR RETRACTED AND LOCKED UP NORMALLY, EXTENDED AND LOCKED DOWN NORMALLY. THE AIRCRAFT FLEW WITH NO LOSS OF AIRSPEED OR ANY INDICATION OF AIRFRAME BUFFET DUE TO THE TRAILING LINKS HANGING BELOW THE WHEEL WELLS. THIS CONFIGURATION WAS REVERSED AND THE AIRCRAFT RETURNED TO SERVICE. IT IS VERY EASY TO MAKE THIS ASSEMBLY ERROR, WHICH RESULTS IN A LANDING GEAR CONFIGURATION MOST TECHNICIANS WOULD THINK (COULD NOT HAPPEN). 1L72 3T4 TRTA28CE E4WE 20050420001092005042000109EA 2005 4 20 CA050125008 120050119G52426003303913 ACCESS DOOR CNDAIRCL601 CL6012A12 1900303EA GE CF34 CF341A NE E/E BAY DISTORTED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THIS AIRCRAFT WAS INSPECTED AND TESTED AND FOUND TO EXHIBIT UNACCEPTABLE NOSE AVIONICS ACCESS DOOR DEFORMATION IN EXTREME COLD CONDITIONS. THE DEGREE OF DOOR CORNER CURLING EXCEEDS THE MANUFACTURERS LIMITS FOR SKIN WAVINESS FOR RVSM CERTIFICATION. (THIS CONDITION WAS PREVIOUSLY IDENTIFIED SDR 20050119002) 2L72 4F4 FRTA21AE E15NE 20050420001112005042000111EA 2005 4 20 CA050125016 120050122G57308711802005 PANEL DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE WING LOOSE W K NONE P NO WARNING INDICATION ININSP/MAINT 1 CA 31794 (CAN) DURING ROUTINE MAINTENANCE INSPECTION VISUALLY NOTICED SCREW HEADS PROTRUDING ABOVE WING SURFACE ON WING STRESS PANEL (DRYBAY ACCESS). APPROXIMATELY 50 PERCENT OF THE ATTACH SCREWS (CSP318-5) WERE FOUND LOOSE ON ACESS PANEL NR 522AT, ALSO SOME LOOSE SCREWS FOUND ON DRYBAY/WING CENTER BOX ACESS PANELS 521AT AND 622AT. AIRCRAFT HAS APPROX. 1980-2372 CYCLES SINCE PREVIOUS RE-TORQUE OF THESE SCREWS AFTER MAINTENANCE ACCESS. ALL SCREWS ON THESE PANELS RE-TORQUED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20050420001132005042000113NE 2005 4 20 CA050126001 220050112G7200 ENGINE AIRTRCAT400 AT402A 0390206SW PWA PT6 PT6A11AG 52043NE FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A SPRAYING RUN, THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION. THE AIRCRAFT CLIPPED TREES AND IMPACTED THE GROUND. MFG WILL PARTICIPATE IN THE INVESTIGATION OF THE INCIDENT AND WILL SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE ESTABLISHED. 1L71 3T3 TNCA17SW E4EA 20050420001152005042000115SO 2005 4 20 CA050126003 220050125G8530654004 EXHAUST VALVE CESSNA150 150L 2071826CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL ENGINE CORRODED W A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 CA 635636A (CAN) POOR ACCELERATION AND SLUGGISH PERFORMANCE DURING POWER UP AND DIFFERENT POWER SETTINGS. WHEN APPLYING POWER, ENGINE STUMBLED. INITIALLY SUSPECTED CARB ICING BUT GROUND CHECK RESULTED IN SAME FAILURE TO PRODUCE POWER. PRELIMINARY D/P CHECK SHOWED LOW POWER ON 3 OF 4 CYLINDERS (42-52 PSI) CYLINDERS DISMANTLED AND FOUND EXHAUST VALVES CORRODED AND DETERIORATED REF: SB M90-13. THIS SB SUGGESTS THAT VALVE STEMS, AT TIME OF OVERHAUL, SHOULD REQUIRE 100% REPLACEMENT. THIS IS THE SECOND FIELD EXPERIENCE OF SEVERE CORROSION 400+ HOURS PRIOR TO OVERHAUL. 1H71 3O3 O 3A19 E252 5 NP918 20050420001192005042000119CE 2005 4 20 CA050126011 120050120G323311238002223 ACTUATOR BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL NLG LEAKING W O OTHER J WARNING INDICATION LDLANDING 1 CA (CAN) NOSE LANDING GEAR WOULD NOT EXTEND UPON DESCENT INTO AIRPORT. EMERGENCY GEAR EXTENSION PROCEDURE COMPLETED AND THE AIRCRAFT LANDED SAFELY. NOSE LANDING GEAR ACTUATOR WAS REPLACED, FOLLOWED BY SEVERALGEAR SWINGS IN NORMAL AND EMERGENCY MODES. GEAR GROUND CHECKED SERVICEABLE AND AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20050420001202005042000120EU 2005 4 20 CA050127001 120050127G2150 ODOR AIRBUSA340 A340* EU RROYCERB211 RB211* 54555NE AIR CONDITIONINGDETECTED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) IN CRUISE LOUD GRINDING NOISE HEARD MID GALLEY, AFT J CLASS. AIRCRAFT FILLED WITH ACRID SMELL. AFT AND MID CABINS FILLED WITH SMOKE. SMELL AND SMOKE LASTED ONE TO TWO MINUTES. ALL SYSTEMS INDICATED NORMAL. PACK FLOW SET TO HIGH FOR 15 MINS. SMELL FOUND COMING FROM MID GALLEY AIR COOLER. CHILLER DE-ACT AND AIRCRAFT DISPATCHED UNDER MEL. NOTE: FURTHER INFO WILL FOLLOW AS AVAILABLE. 2L74 4F4 FRTA197 A12EU 20050420001252005042000125NM 2005 4 20 CA050128005 120050128G2121731376 COOLING FAN BOEING757 757236 1384971NM RROYCERB211 RB211535E43754555NE E/E BAY BINDING W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS DEDESCENT 1 CA (CAN) CREW NOTICED A BURNING SMELL THROUGHOUT AIRCRAFT AND THEN HAD AN EICAS MESSAGE (EQUIPMENT OVERHEAT) . MAINTENANCE CONFIRMED FWD EQUIPMENT COOLING FAN BINDING AND A BURNT SMELL COMING FROM UNIT. 2L72 4F4 FRTA2NM E12EU 20050420001272005042000127SW 2005 4 20 CA050128008 120050125G261217343450F FIRE DETECTOR SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP MCAULY4HFR344HFR34C652 NE LT NACELLE INTERMITTENT W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) PILOT CALLED AND NOTIFIED MAINTENANCE THAT ON APPROACH THE LT FIRE WARNING LIGHT CAME ON. LIGHT WENT OUT WHEN INLET HEAT WAS TURNED OFF. MAINTENACE INSPECTED AIRCRAFT AND FOUND NO SIGNS OF HEAT DISTRESS. TOP FIRE DETECTOR WAS REPLACED AND GROUND CHECKED SERVICIBLE. NO OTHER REPORTED INCIDENTS SINCE THEN. 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20050420001302005042000130EU 2005 4 20 CA050131007 120050111G7900 ENGINE BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP MCAULY4HFR344HFR34C652 NE FAILED W O OTHER O OTHER ININSP/MAINT 1 CA P63243 (CAN) SOAP SAMPLE INDICATED MAJOR ALUMINIUM IN THE OIL SYSTEM, 2ND SOAP SAMPLE TAKEN AND FOUND MAGNESIUM AND CARBON STEEL PARTICLES IN THE SAMPLE. ENGINE REMOVED AND SENT FOR EVALUATION, AMO 50-04. 2L72 4T4 TRTBA15CAA E4WE 6 C3PNE 20050420001312005042000131EU 2005 4 20 CA050131008 120050131G3246FN22A524 NUT BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE7315R 01518WP MLG WHEEL MISSING W K NONE O OTHER ININSP/MAINT 1 CA KR083 (CAN) AFTER ARRIVAL TO BASE OF OPERATIONS DURING A POST FLIGHT INSPECTION NR 2 MAIN WHEEL ASSY. A WHEEL TIE BOLT NUT WAS FOUND MISSING AND ANOTHER 180 DEGREES APART WAS FOUND SPLIT. WHEEL WAS CHANGED. THESE NUTS WERE INSTALLED NEW AS THAT IS OUR POLICY. MFG HAS BEEN NOTIFIED AS THE NUTS WERE PURCHASED FROM THEM. 2L72 4F4 FRTA3EU E6WE 20050420001342005042000134NE 2005 4 20 CA050202002 220050201G75320301007860 SCREEN SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE BLEED VALVE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 895 (CAN) WIRE BROKEN ON SCREEN THAT IS ATTACHED TO BLEED VALVE. 1G71 3U3 UNCH9EU E19EU 20050420001352005042000135CE 2005 4 20 CA050202003 120050201G3297MS24171D1 RELAY BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE MLG BURNED W O OTHER O OTHER APAPPROACH 1 CA (CAN) DURING APPROACH, FLIGHT CREW SELECTED GEAR DOWN BUT THE CONTROL CB OPENED AND WOULD NOT RESET. THE LANDING GEAR WAS MANUALLY EXDENDED WITH 3 GREENS. MAINTENANCE FOUND THE LANDING GEAR RELAY WAS BURNED AT THE CONTACTS AREA AND THE RELAY WAS REPLACED. THIS OPERATOR HAS HARDTIME, THE RELAY AT 5000 HOURS PREVIOUSLY TO PREVENT THESE TYPES OF OCCURENCES. TO DATE, THIS NUMBER HAS BEEN SUCCESSFUL BUT THIS FAILURE OCCURRED APPROX 3600 HOURS SINCE INSTALLATION. AS A RESULT, THE COMPANY HARDTIME ON THIS RELAY HAS BEEN LOWERED TO 3000 HOURS. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20050420001362005042000136CE 2005 4 20 CA050202004 120050125G5511053200198 SPAR CESSNA172 172N 2072434CE LYC O360 O360A4A 41514EA SNSNCH76E 76EM8 EA HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 12402 (CAN) DURING THE 200 HOUR INSPECTION CRACKS WERE FOUND STARTING FROM THE CENTRAL LIGHTENING HOLE IN THE FORWARD HORIZONTAL STABILIZER SPAR. THE CRACKS WERE STOP DRILLED AND REINFORCEMENT P/N 0531037-1 AND SKIN P/N 0523001-25 WERE INSTALLED IAW SEB94-8. 1H71 3O3 ONT3A12 E286 5 NP4EA 20050420001372005042000137CE 2005 4 20 CA050202005 120050201G243503601018 BEARING LUCAS CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE COMMUTATOR DESTROYED W O OTHER DEHINFLIGHT SEPARATION VIBRATION/BUFFET ELECT. POWER LOSS-50 PC CRCRUISE 1 CA 7128 (CAN) WHILE IN CRUISE BACK TO BASE, CREW ENCOUNTERED AIRFRAME VIBRATION FROM THE AFT CABIN, FOLLOWED BY THE RT GENERATOR FAIL LIGHT 10 MINUTES LATER. CREW CONFIRMED LOSS OF RT GENERATOR, AND DECLARED AN EMERGENCY DUE TO THE INTENSITY OF VIBRATION. A/C LANDED WITHOUT INCIDENT. ON DISASSEMBLY OF UNIT, DISCOVERED CUMMUTATOR BEARING DESTROYED. CAUSE OF FAILURE IS UNDER INVESTIGATION. THERE WAS ONLY 406 HRS ON THE BEARING SINCE REPLACEMENT. 1L72 4F4 F A22CE E1NE 20050420001382005042000138GL 2005 4 20 CA050202006 120050131G273010146005 CONTROL UNIT CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO HARTZLHCJ3Y PHCJ3YF1 GL ELEVATOR RESTRICTED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) PILOT NOTICED ELEVATOR CONTROL WAS STIFFER THAN USUAL ON APPROACH. UPON LANDING, FOUND THE LT ELEVATOR BALANCE WEIGHT HORN IS RUBBING AGAINST THE HORZIONTAL STABILIZER. FOUND THE ELEVATOR WILL NOT RUB ONCE THE AIRCRAFT IS WARMED UP. THE ELEVATOR TIP FAIRING MOUNTING SCREWS WERE LOOSENED AND THE ELEVATOR HORN WAS REPOSITIONED TO PROVIDE THE NECESSARY CLEARANCE. 1L71 3O3 ONTA00009CHE3SO 5 CP36EA 20050420001392005042000139CE 2005 4 20 CA050204001 120050128G55211156100181 SUPPORT BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ONE SCREW HOLE HAS 2 QUARTER INCH CRACKS RADIATING