20081222 CE 2008 12 22 CA080207001 120071214G2160IE502 ACTUATOR VALVE CESSNA560 560XL 2076702CE PWC 545 PW545B NE HEAT EXCHANGER STICKING W C ABORTED TAKEOFF MJ OVER TEMP WARNING INDICATION TOTAKEOFF 1 CA 88 88 (CAN) RT BLEED AIR OVERTEMP WARNING LITE CAME ON DURING T/O. TWICE IN 42 T/O. THE HEAT EXCHANGER VALVE WAS STICKING IN CLOSED POSITION - VALVE ACTUATOR PIN IE50-2 WAS REPLACED. 2L72 4F4 FRTA22CE E00059EN 20081222 CE 2008 12 22 CA080207002 120071214G783064ND782047 ACTUATOR CESSNA560 560XL 2076702CE PWC 545 PW545B NE THRUST REVERSER LEAKING W D RETURN TO BLOCK K FLUID LOSS TXTAXI/GRND HDL 1 CA 88 88 (CAN) LT THRUST REVERSER INBD ACTUATOR. WEEPING HYDRAULIC FLUID. NOTE: THIS ACTUATOR WEEPED FLUID FROM DAY ONE ON 560 S/N 0648 HAD 2 ACTUATORS I/B LT REPLACED FOR HYDRAULIC FLUID LEAKS OVER APPROX 1800 HRS. 2L72 4F4 FRTA22CE E00059EN 20070213001652007021300165EA 2007 2 13 2007FA0000095 220070109G8520AEL321031 CRANKSHAFT CESSNA172 172L 2072432CE LYC O320 O320E2D 41508EA ENGINE BROKEN B VA1RO OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION DEDESCENT 1 SW1915RA 410 17259568 L2207127A ENGINE BEGAN RUNNING ROUGH AND BECAME SMOOTH AGAIN DURING DESCENT. TROUBLESHOOTING FIRST FOUND BRASS METAL PARTICLES IN AIR FILTER AND OIL. CRANKSHAFT WAS APPARENTLY BROKEN OR CRACKED BUT STILL TOGETHER. AFTER NUMEROUS GROUND RUSN AND KNOCKING NOISES HEARD, THE CRANKSHAFT BROKEN AND ROD THROWN THROUGH CASE. THE BREAK WAS BETWEEN NR 3 AND NR 4 ROD JOURNALS. SENG BACK TO ENGINE COMPONENTS FOR WARRANTY AND ANALYSIS. (K) 1H71 3O3 ONT3A12 E274 20070124001832007012400183SO 2007 1 24 2007FA0000039 120070116G2497 WIRE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA UNKNOWN WORN C O OTHER O OTHER NRNOT REPORTED 1 SO17456M 318152081 THE WIRING THAT PASSES THROUGH THE NOSE RIB GROMMETS HAVE WORN TO THE EXTENT THAT THE INSULATION IS GONE AT PLACES CAUSING THE METAL CONDUCTOR TO SHOW THROUGH. IT APPEARS THAT THIS IS WORSE WITH THE GREATER AMOUNT OF CABLES IN THE BUNDLE. BUNDLES OF ONLY 2 WIRES DO NOT HAVE THIS PROBLEM. APPARENTLY THE BUNDLE IS (SLAPPED) UP AND DOWN WITH VIBRATION. THIS IS CAUSE FOR CONCERN DUE TO SPARKING NEAR THE FUEL TANK. 1L72 3O3 O A20SO E14EA 20070125001342007012500134SO 2007 1 25 2007FA0000056 120070110G5521510229615 ATTACH ANGLE AMRGENAG5B AG5B 3990100SO LYC O360 O360* 41514EA STABILIZER CRACKED D K NONE O OTHER ININSP/MAINT 1 SW17119661190 10121 DURING INSPECTION, ANGLE PN 5102296-15 AND PN 5102296-16, WERE FOUND CRACKED IN THE BEND RADIUS OF THE UPPER END OF THE ANGLE AS INSTALLED. CAUSE OF CRACKING IS BELIEVED TO BE DUE TO HIGH STRESS LOADS IN THIS AREA. (K) 1L71 3O3 ONT1L71 E286 20070129002222007012900222SO 2007 1 29 CA070109006 220070109G8530AEC648005PL PISTON RING CESSNA206 206CESSNA 2073302CE CONT O520 IO520F 17032SO ENGINE SEPARATED W O OTHER O OTHER NRNOT REPORTED 1 CA 1344 1344 (CAN) MATERIAL FROM THE FACE OF THE TOP COMPRESSION RING HAD FLAKED AWAY ON PISTONS NR1, NR2, NR4, AND NR6 (TC NR 20070109006). 1H71 3O3 O A4CE E5CE 20070129003102007012900310EA 2007 1 29 CA070118005 220070103G73203027791 SENSE LINE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL ENGINE BROKEN W O OTHER J WARNING INDICATION CLCLIMB 1 CA 5597 PCE85142 (CAN) P3 TUBE SUDDENLY BROKEN WHILE AIRCRAFT WAS IN CLIMB. ENGINE FAIL TO IDLE, ENGINE WAS SHUTDOWN BY THE CREW. AIRCRAFT RETURN TO DEPARTURE AIRPORT WITHOUT OTHER DIFFICULTY. (TC NR 20070118005) 1L72 4T4 T A24CE E4EA 6 CP15EA 20070129003472007012900347SO 2007 1 29 2007FA0000042 120070116G2497 WIRE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA ELECTRICAL SYS CHAFED C O OTHER O OTHER NRNOT REPORTED 1 SO17456M 318152081 THE WIRING THAT PASSES THROUGH THE NOSE RIB GROMMETS HAS WORN TO THE EXTENT THAT THE INSULATION IS GONE AT PLACES CAUSING THE METAL CONDUCTOR TO SHOW THROUGH. IT APPEARS THAT THIS IS WORSE WITH THE GREATER AMOUNT OF CABLES IN THE BUNDLE. BUNDLES OF ONLY 2 WIRES DO NOT HAVE THIS PROBLEM. APPARENTLY THE BUNDLE IS (SLAPPED) UP AND DOWN WITH VIBRATION. THIS IS CAUSE FOR CONCERN DUE TO SPARKING NEAR THE FUEL TANK. 1L72 3O3 O A20SO E14EA 20070125001572007012500157NM 2007 1 25 SROM200700001 120070105G212065544709 DUCT BOEING737 737201 1384454NM PWA JT8 JT8D15 52051NE A/C PACK RUPTURED I SROMH DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 AL03245US 22751 UPON TAKEOFF A POP WAS WAS HEARD FOLLOWED BY PERCEIVED SMOKE (DUST) IN THE CABIN. PACS WERE SELECTED TO OFF AND A IMMEDIATE LANDING MADE AT THE DEPARTURE AIRPORT. ALL COCKPIT INDICATIONS NORMAL. FOUND LT AIR CONDITIONING PAC MIXING CHAMBER AND HOT AIR SUPPLY DUCT SEPARATED/ DAMAGED ALLOWING HOT CONDITIONED AIR TO ENTER CABIN THROUGH RETURN GRILLS, THUS CREATING DUST. APPEARS TO HAVE EXPERIENCED INTERNAL DAMAGE RESULTING IN BACK PRESSURE WHICH CAUSED THE DUCT/FLANGE FAILURE. NO OTHER DAMAGE NOTED. REPLACED MIXING AND HOT AIR DUCTS. 2L72 4F4 F A16WE E2EA 20070125001972007012500197SO 2007 1 25 2007FA0000050 120070110G5521510229615 ATTACH ANGLE AMRGENAA5 AA5A 3960106SO LYC O320 O320* 41508EA STABILIZER CRACKED D K NONE O OTHER ININSP/MAINT 1 SW179962U3163 AA5A0362 DURING INSPECTION, ANGLE PN 5102296-15 AND PN 5102296-16, WERE FOUND CRACKED IN THE UPPER END OF THE ANGLE AS INSTALLED. CAUSE OF CRACKING IS BELIEVED TO BE DUE TO HIGHT STRESS LOADS IN THIS AREA. (K) 1L71 3O3 O A16EA E274 20070126002512007012600251SO 2007 1 26 2007FA0000041 120070116G3233400872 CLEVIS BOLT PIPER PA28 PA28R201 7102816SO LYC O360 IO360A1A 41514EA NLG SHEARED B OG5RA UNSCHED LANDING FDJFLT CONT AFFECTED INFLIGHT SEPARATION WARNING INDICATION CRCRUISE 1 GL21289ND4558 2844039 DURING CRUISE FLIGHT, CREW REPORTED LOUD BANG FOLLOWED BY A NOSE GEAR DOWN AND LOCKED INDICATION. AIRCRAFT LANDED WITHOUT INCIDENT. UPON INSPECTION BY MX PERSONNEL NOSE GEAR ACTUATOR ROD END CLEVIS BOLT (AN23-21A) MISSING WITH EVIDENCE OF BOLT FAILURE. 1L71 3O3 O 2A13 1E10 20070129002192007012900219NM 2007 1 29 CA070109002 120070108G3040 INSULATION SIERRACIN 80260007 DHAV DHC8 DHC8* NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU WINDSHIELD HEAT OUT OF POSITION W H DEACTIVATE SYST/CIRCUITS WB INADEQUATE Q C SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 30 729 (CAN) INVESTIGATING SMELL OF SMOKE IN COCKPIT AFTER CREW TURNED ON WINDSHIELD HEAT. FOUND THE LUG ON 3041-TB1 POSITION L2 HAD INSULATION BETWEEN THE SCREW HEAD AND THE LUG. REMOVED THE INSULATION FROM UNDER THE HEAD OF THE SCREW. (TC NR 20070109002) 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20070129002362007012900236EA 2007 1 29 CA070111013 220070108G7310 FUEL LINE BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA ENGINE CHAFED W K NONE K FLUID LOSS NRNOT REPORTED 1 CA (CAN) THE FLIGHT CREW REPORTED FUEL LEAKAGE FROM THE RT ENGINE AREA AFTER SHUTDOWN. THE ENGINE COWLING WAS REMOVED AND INVESTIGATION HAD SHOWN THAT THE ENGINE DRIVEN FUEL PUMP TO FCU LINE HAD CHAFED AN THE BACK EDGE OF THE FCU. THE LINE IS ON CONDITION AND NOT A TIMED UNIT. A FLEET CAMPAIGN AND TECHNICAL INFORMATION BULLETIN WAS RELEASED TO ENSURE CORRECT ROUTING OF THE LINE AND ADEQUATE PROTECTION. ANY SUSPECT LINES REPLACED. (TC NR 20070111013) 2L72 4T4 TRTA24CE E4EA 20070129002382007012900238NE 2007 1 29 CA070111015 220070111G73103035987 FUEL LINE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE ENGINE CHAFED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) FUEL LEAK AT ENGINE FIREWALL PRESSURE LINE. THE LINE WAS DAMAGED BY CHAFFING ON COLLAR (P/N 3043536-01A) AND RETAINING PLATE (P/N 3043535-01). POST SB21460. 2 OTHER LINES COVERED BY THE SAME SB (INCORPORATED IN DEC.2001) SHOWED SAME DAMAGE AND NEEDS REPLACEMENT. (TC NR 20070111015) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070129003082007012900308SO 2007 1 29 CA070118003 220070110G73146467582 PUMP PIPER PA28 PA28R201T 7102813SO CONT O360 TSIO360F 17025SO HARTZLHCC2Y BHCC2YF1 GL ENGINE FAULTY W O OTHER J WARNING INDICATION NRNOT REPORTED 1 CA 1056 (CAN) ENGINE DRIVEN FUEL PUMP OUTPUT IS LOW AT RATED RPM 2600. (TC NR 20070118003) 1L71 3O3 O 2A13 E9CE 5 CP920 20070131001682007013100168EU 2007 1 31 200700114 120070130G57202121151091 STIFFENER CASA C212 C212 2410200EU GARRTTTPE331TPE33110R 0517 WP ROTOL R334 R334482F13 GL LT WING CRACKED B KGBRK NONE O OTHER ININSP/MAINT 1 NM04515RL5409 405 WHILE PERFORMING CASA COM LETTER 212-224 AND CASA SB 212-57-57-30, A CRACK WAS NOTED FROM THE 4TH RIVET TO THE 5TH RIVET FROM THE BOTTOM, ON THE VERTICAL STIFFINER LOCATED ON THE LT WING AT STA 4700, AFT SPAR WEB. THREE STIFFINERS NEXT TO THE ORIGINAL ARE CRACKED EXACTLY THE SAME, CRACKS ARE LOCATED INT HE SAME POSITIONS, BETWEEN THE 4TH AND 5TH RIVIT FROM THE BOTTOM. THIS TOTALS 4EA CRACKED STIFFINERS. 2H72 4T4 T A43EU E4WE 6 CP61GL 20070131001712007013100171SO 2007 1 31 PAI52007S4448 220070130G8520 STUD CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO NR 4 CYLINDER BROKEN B PAI5K NONE O OTHER ININSP/MAINT 1 SO05414CJ 1403 414A0432 519053 DURING ANNUAL INSPECTION FOUND 5 BROKEN HOLD DOWN STUDS ON NR 4 CYLINDER. ENGINE WAS MODIFIED IAW RAM STC SE3630SW AND SE3631SW AT PREVIOUS OVERHAUL. 1L72 3O3 O A7CE E8CE 20070205000302007020500030CE 2007 2 5 2007FA0000105 120070202G571151220311 SPAR CAP CESSNA310 T310R 2074246CE CONT O520 TSIO520BB 17040SO MCAULY3AF32C3AF32C87 GL LT WING CORRODED D K NONE O OTHER ININSP/MAINT 1 EA17465DL1132 310R1622 LT TOP WING SPAR CAPS AND TOP SKINS SEVERELY CORRODED IN AREA OF FACTORY NACELLE FUEL BLADDERS. LT-PN 5122031-1. 1L72 3O3 O 3A10 E8CE 5 CP22EA 20070209000362007020900036CE 2007 2 9 2007FA0000112 120070108G71601116 AIR FILTER CESSNA172 R172K 2072431CE CONT IO360 IO360* 17025CE TWISTED G K NONE O OTHER ININSP/MAINT 1 SO15758EJ R1723034 DURING REMOVAL OF THE AIR FILTER THE CENTER WIRE MESH SCREEN WAS FOUND TWISTED AND BENT. SOME OF THE WELDS WERE BROKEN. SCREEN DEFORMATION CAN LEAD TO UNFILTERED AIR AND FOD ENTERING THE ENGINE. APPARENT CAUSE IS EITHER OVERTORQUEING WING NUT AND/OR INSUFFICIENT STRENGTH OF SCREEN. RECOMMEND UTILIZING A STRONGER MESH/PERFORATED SCREEN OR EVALUATING INSTALLATION INSTRUCTIONS/TORQUEING PROCEDURES. 1H71 3O3 O 3A17 E1CE 20070125002922007012500292SO 2007 1 25 2007FA0000064 120070109G32136531904 CYLINDER PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA LT MLG DAMAGED B A5ORK NONE O OTHER ININSP/MAINT 1 SO09157153501 287325144 DURING AN ANNUAL INSPECTION FO THE LT MLG CYLINDER ASSY PN 6531904, IT WAS FOUND TO BE LOOSE IN THE MAIN WING SPAR. THE LT MLG WAS REMOVED FOR FURTHER INSPECTION OF THE LT MAIN WING SPAR ASSY GEAR ATTACHING BOLT HOSES AND ATTACH POINTS. CLOSE INSPECTION FO THE WING SPAR SHOWED THAT THE LOWER (4) BOLTS HOLES HAD BEEN ELONGATED. THE HOLES IN THE LT LANDING GEAR CYLINDER WERE FOUND TO BE ELONGATED ALSO. IT APPEARED THAT ALL BOLTS WERE TIGHT AND THIS CONDITION HAD BEEN LOOSE FOR SOME TIME. AIRCRAFT WING SPAR WS REPAIRED AND THE LT MLG CYINDER WAS REPLACE WITH A LATER MODEL CYLINDER ASSY FROM MFG SINCE THE ORIGINAL PART WAS NO LONGER AVAILABLE. RECOMMEND CLOSE INSPECTION OF LANDING GEAR ATTACH POINTS DURING AL1L71 3O3 O 2A13 E274 20070126000062007012600006CE 2007 1 26 2007FA0000046 120070105G571305112821 STRINGER CESSNA170 170B 2072306CE CONT O300 O300* 17022SO WING CRACKED D K NONE O OTHER ININSP/MAINT 1 AL033436D4200 26979 CRACKED AT FORWARD END AND PROGRESSES AFT. PROP STRIKE, OUT OF BALANCE PROP. EXAMPLE FROM C-170B WITH THE ENGINE INSTALLED. (K) 1H71 3O3 O A799 E253 20070129002012007012900201GL 2007 1 29 CA070105004 220070105G72406899237 COMBUSTION CASE ALLSN 250C28B BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA CAE860657 CAE860657 (CAN) DURING A 200 HR INSPECTION A CRACK WAS FOUND IN THE ARM PIT AREA OF THE OUTER COMBUSTION CASE. CASE REPLACED. (TC NR 20070105004) 1G71 3U3 U H2SW E1GL 20070129002022007012900202CE 2007 1 29 CA070105007 120070103G243566082019 SHAFT LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP GENERATOR SHEARED W O OTHER J WARNING INDICATION CRCRUISE 1 CA 616 (CAN) LT GENERATOR CAME OFF LINE .5 HR BEFORE LANDING . THE INDICATOR SHOWED 0 AMPS, A RESET WAS ATTEMPED BUT DID NOT COME ONLINE. WHEN MAINTENANCE REMOVED THE GENERATOR FOR INSPECTION, THE GENERATOR SHAFT WAS FOUND SHEARED. THE GENERATOR WAS INSPECTED FURTHER AND ROTATED FREELY. CAUSE OF SHEARED SHAFT IS UNKNOWN. (TC NR 20070105007) 2L72 4F4 F A10CE E6WE 20070129002042007012900204EA 2007 1 29 CA070108003 120070108G2910TA3050052403 FAIRLEAD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE HYDRAULIC SYS WORN W K NONE O OTHER ININSP/MAINT 1 CA 1471714717 (CAN) DURING MAINTENANCE INSPECTION, FOUND FAIRLEAD (CLAMP) ON NR 1 HYDRAULIC SYSTEM LINES FAIRLEAD IN AFT FUSELAGE (APU COMPARTMENT) WORN. [IPC 29-11-00 FIG 15 (H) ITEM 395. BLOCK HAS 3 HOLES FOR CLAMPING HYDRAULIC LINES AND CENTER HOLE (PRESSURE LINE) MATERIAL WORN THROUGH TO CASE DRAIN LINE HOLE, ALLOWING PRESSURE LINE AND CASE DRAIN LINE TO START CHAFFING. SEVERAL SIMILAR CLAMPS IN THIS AREA ALSO EXHIBITING SIMILAR SIGNS OF WEAR. FAIRLEAD (CLAMP BLOCK) ASSEMBLY REPLACED. AIRCRAFT RETURNED TO SERVICE. (TC NR 20070108003) 2L72 4F4 FRTA21EA E15NE 20070129002322007012900232EA 2007 1 29 CA070111006 120070110G2750 FLAP CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE WING FROZEN W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 CA (CAN) FLAP FAIL AT 20. ON APPROACH, ON FLAP EXTENSION, THEY FROZE AT 20 DEGREES. OAT WAS ABOUT -25 DEGREES C AT THE TIME, ALTHOUGH THEY WERE ABOUT 1 HOUR AND 10 MINUTES IN FLIGHT AT ABOUT -50 DEGREES FOR MOST OF THE FLIGHT. AIRSPEED WAS 170 KNOTS AT THE TIME OF THE FAILURE. (TC NR 20070111006) 2L72 4F4 FRTA21EA E15NE 20070129002552007012900255EA 2007 1 29 CA070115003 120070113G2750 FLAP SYSTEM CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE WING JAMMED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) FLAPS FAILED UPON SELECTION TO 8 DEGREES, THEY DID NOT MOVE FROM 0 DEGREES, OAT -46 AT ALTITUDE, - 15 DEGREES ON APPROACH. AIRCRAFT LANDED FLAPS ZERO. (TC NR 20070115003) 2L72 4F4 FRTA21EA E15NE 20070129003042007012900304EA 2007 1 29 CA070115016 120070112G2731C6CF14053 CONTROL CABLE DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL ELEVATOR TRIM BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) TRIM CABLE WAS FOUND BROKEN AND WAS REPLACED. THE BROKEN CABLE IS BEING ANALYZED AT THEIR LOCAL AIRWORTHINESS AUTHORITY AND WE AWAIT THE RESULTS. (TC NR 20070115016) 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20070129003462007012900346SO 2007 1 29 2007FA0000040 120070116G3233400872 CLEVIS BOLT PIPER PA28 PA28R201 7102816SO LYC O360 IO360A1A 41514EA NLG SHEARED B A UNSCHED LANDING FJ FLT CONT AFFECTED WARNING INDICATION CRCRUISE 1 GL21289ND4558 2844039 DURING CRUISE FLIGHT, CREW REPORTED LOUD BANG FOLLOWED BY A NOSE GEAR DOWN AND LOCKED INDICATION. AIRCRAFT LANDED WITHOUT INCIDENT. UPON INSPECTION BY MX PERSONNEL NOSE GEAR ACTUATOR ROD END CLEVIS BOLT (AN23-21A) MISSING WITH EVIDENCE OF BOLT FAILURE. 1L71 3O3 O 2A13 1E10 20070131000332007013100033CE 2007 1 31 2007FA0000070 120070108G25205514551129 ATTACH FITTING CESSNA CESSNA500 500CESSNA 2076602CE PWA JT15 JT15D1 52060NE CABIN CRACKED B ESERO OTHER O OTHER NRNOT REPORTED 1 SO11117TW 5000059 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. CHAIR WAS REPAIRED IAW STC ST01042WI STRUCTURAL SEAT REPAIR. (K) 1L72 4F4 F A22CE E1NE 20070131000662007013100066SO 2007 1 31 2007FA0000074 120070123G5312624403 BULKHEAD PIPER PA28 PA28180 7102808SO LYC O360 O360A3A 41514EA SNSNCH76E 76EM8 EA FUSELAGE CORRODED D K NONE O OTHER ININSP/MAINT 1 GL097095W4309 28882 L148936C 15028K THE BULKHEAD, BRACKETS, AND DOUBLERS AT STA. 228.3 WERE SEVERELY CORRODED. THIS BULKHEAD IS THE FRONT SUPPORT FOR THE VERTICAL STABILIZER/RUDDER ASSEMBLY. THE CORROSION COVERED AN AREA APPROXIMATE THE SIZE OF THE FRONT RUDDER ATTACHMENT BRACKET THAT IS PART OF THIS BULKHEAD ASSEMBLY. THE CORROSION WAS FOUND DURING AN ANNUAL INSPECTION AND WAS ONLY VISIBLE, WITHOUT DISASSEMBLY, AS SLIGHT BUBBLING OF THE METAL ON THE BRACKETS FACING REARWARD THAT ARE ATTACHED TO THE AFORE MENTIONED BULKHEAD ASSEMBLY. 1L71 3O3 O 2A13 E286 5 NP4EA 20070131001852007013100185NE 2007 1 31 R021692 320070117G6111D7745 BEARING BEECH 1900 1900D 1154162CE PWA PT6 PT6* 52043EA HARTZLHCE4A HCE4A3A NE PROPELLER BLADE BROKEN B SJ3RO OTHER E VIBRATION/BUFFET ININSP/MAINT 1 GL05SJ3R 3115 HJ1819 ON 12/14/06 REPORTED AIRCRAFT VIBRATIONS FROM STBD ENGINE. INSPECTION OF PROPELLER ON GROUND REVEALED EXCESSIVE RADIAL PLAY OUT OF LIMIT OF NR 3 BLADE. PROPELLER REMOVED FROM AIRCRAFT FOR FURTHER INVESTIGATION. SERVICE CENTER NOTES: BLADE NR 3 CAM FOLLOWER BROKEN, PRELOAD PLATE GOUGED, BLADE SIDE D-7745 BEARING CRACKED RADIALLY AND PIECE MISSING. RETAINING WASHER ATTACHED TO PC KNOB. BLADE NR 3 FORK SLOT WORN 0.028, OTHER 3 SLOTS WORN 0.015-0.021, CIRCUMFERENTIAL WEAR IN FORK SEAT. BLADE NR 3 RETENTION SHOULDER HEIGHT MEASURED 0.914 - 0.974, UNABLE TO PERFORM OPTICAL COMPARATOR INSPECTION OF RADIUS DUE TO SHOULDER HEIGHT DIMENSION BELOW 0.972. SEE S/B 287. 2L72 4T3 TRTA24CE E2NE 5 CP10NE 20070201000152007020100015WP 2007 2 1 200600083 120070131G5711 SPAR CAP CVAC PB4Y2 PB4Y2 2421102WP WRIGHTR2600 R260035 67050EA HAMSTD23E 23E50 NE WING CRACKED B KGBRK NONE O OTHER ININSP/MAINT 1 NM042872G7162 66300 WHILE PERFORMING THE REQUIREMENTS IN AD 2003-18-01, CRACKS WERE NOTED THRU-OUT THE WING. THE MAJOR CRACK IS A 4-5 INCH CRACK IN THE FWD LT LOWER SPAR CAP AFT ANGLE AT THE WING ATTACH POINT TO THE BELT FRAME. THE CRACK IS IN THE ANGLE (SPAR CAP AFT LEG), DOUBLER AND SPAR WEB. THERE ARE ALSO CRACKS .1250-.2500 INCH EMANATING FROM 3 OF THE 4 BELT FRAME CUTOUTS ON THE LOWER WING. 2H74 4R4 RRT PAGE42 6 CP603 20070202000152007020200015SO 2007 2 2 CWQD200702 120070130G32511159LM305489 SCISSORS GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU MLG STEERING CRACKED B DXTAK NONE O OTHER ININSP/MAINT 1 GL05411QS9576 1311 DURING CHECKLIST FOUND UPPER TORQUE LINK CRACKED P/N 1159LM30548-9 AT CONNECTING LOWER TORQUE LINK P/N 1159LM30553-3. 2L72 4F4 FRTA12EA E25NE 20070213000552007021300055CE 2007 2 13 2007FA0000109 120070131G273050524401 BELLCRANK BEECH 90 65A901 1152901CE PWA PT6 PT6* 52043EA ELEVATOR FAILED C NBFGO OTHER O OTHER NRNOT REPORTED 1 EA2787V LM130 FOUND BROKEN FORK ON ELEVATOR BELLCRANK SUPPORT ARM AT FWD END OF ELEVATOR LT PUSHROD. FOUND THE PUSH ROD FWD ATTACH BOLT HAD BEEN OVER-TORQUED SO MUCH AS TO CREATE A 0.016 INCH -0.021 INCH DEPRESSION IN EACH (MAGNESIUM) FORK WHERE THEY PRESSED INTO THE ROD END BEARING. MFG SB2231R2 INCLUDES: INSPECTION FOR CRACKS IN THIS AREA OF ELEVATOR BELLCRANK. PROPER GAP BETWEEN ROD END AND SUPPORT ARM FORKS (0.00 INCH TO 0.01 INCH GAP) PROPER TORQUE OF PUSHROD ATTACH BOLT (70-108 INCH LBS) RECOMMEND FOLLOWING PROPER INSPECTION, INSTALLATION AND TORQUE WHEN INSTALLING THE BELLCRANK AND PUSHRODS. FOLLOW THE INSTRUCTIONS IN THE MM AND SB2231R2. (K) 1L72 3T3 T 3A20 E2NE 20070213000602007021300060NE 2007 2 13 2007FA0000108 220070101G7200CFM563B1 POWERPLANT BOEING737 737300 1384610NM GE CFM56 CFM563B1 13802NE OIL SYSTEM CONTAMINATED B UOXRA UNSCHED LANDING RYJPARTIAL RPM/PWR LOSS ENGINE STOPPAGE WARNING INDICATION NRNOT REPORTED 1 SO19XAMAA449273514 720721 ENGINE SUFFERED AN IFSD DUE TO POWER LOSS AND A COMMANDED ENGINE SHUTDOWN WAS CARRIED OUT. ENGINE RESTART WAS ATTEMPTED, UNSUCCESSFULLY. FURTHER INVESTIGATION REVEALED THAT NR 10 STRUT ON FAN FRAME (9 O`CLOCK STRUT AFT LOOKING FWD) WHICH RADIAL DRIVE SHAFT IS LOCATED WAS PUNCTURED, BOTH ON UPPER AND LOWER SURFACES OF STRUT. IT WAS AGREED TO CARRY OUT ENGINE REMOVAL AND RETURN ENGINE TO REPAIR FACILITY. HYDRAULIC FLUID WAS FOUND IN OIL SYSTEM, AIR STARTER AND CSD OIL SUMPS. ALL OIL WETTED ITEMS REQUIRE INSP. ENGINE HAD UNDERGONE TROUBLESHOOTING FOR HIGH OIL CONSUMPTION FOLLOWING REPORTS ON 2 FLIGHTS AND RETURN ON DEC 22, 2006. LEVELS OF 2.08 GALLON QUARTERS/HOUR WERE REPORTED AND AVERAGE OIL CON WAS 0.15 2L72 4F4 FRTA16WE E2GL 20070213000672007021300067CE 2007 2 13 2007FA0000120 120070129G3340CM358910 SWITCH CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA TAXI LIGHT ODOR B ODARA UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 EA21321ME 172S8566 PILOT REPORTED TO APPROACH THAT THERE WAS AN ELECTRICAL SMELL IN CABIN. AN EMERGENCY WAS DECLARED AND AIRCRAFT LANDED WITHOUT INCIDENT. UPON INSPECTION, FOUND THE TAXI LIGHT CIRCUIT BREAKER/SWITCH WAS SLIGHTLY DISCOLORED, SMELLED BURNED AND IT WAS INOPERATIVE. THERE WAS NO APPARENT OTHER DAMAGE TO CIRCUIT OR ANY OTHER PART. (K) 1H71 3O3 ONT3A12 1E10 20070213001892007021300189EA 2007 2 13 2007FA0000102 120070109G5755 BRACKET CNDAIRCL600 CL6002B16 1900305EA GE CF34 CF343B1 NE FLT SPOILER CRACKED B RO3RO OTHER O OTHER NRNOT REPORTED 1 CE03684TS 5384 WHILE PERFORMING A 96 MONTH AIRFRAME INSPECTION, DISCOVERED THE LT FLIGHT SPOILER TRANSMITTER BRACKET WAS CRACKED. UPON REMOVING BRACKET, DISCOVERED MATTING SURFACE WITH TRANSMITTER WAS CORRODED. DECIDED TO REMOVE TO INSPECT RT TRANSMITTER BRACKET AND FOUND THE RT SIDE CORRODED AS WELL. REMOVED AND REPLACED BOTH BRACKETS. RT AND LT HAVE THE SAME PN. (K) 2L72 4F4 FRTA21EA E15NE 20070130001762007013000176EU 2007 1 30 2007FA0000065 120070103G2742 ACTUATOR PARTENP68 P68C 6780105EU LYC O360 IO360A1A 41514EA PITCH TRIM SEIZED D O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 GL033832Q 274 (REF NR: PT202781) AIRCRAFT ARRIVED WITH PITCH TRIM ACTUATOR SEIZED IN FULL NOSE UP POSITION. ACTUATOR IS DRIVEN BY TRIM CABLE LOOPED OVER ACTUATOR PULLEY WITH NO MEANS OF PREVENTING CABLE FROM SLIPPING ON THE PULLEY. IT IS POSSIBLE TO RUN TRIM TO FULL TRAVEL ALLOWING ACTUATOR TO BIND. WHEN TRIM CONTROL IS REVERSED THE CABLE CAN SLIP OVER PULLEY WITH OUT MOVING ACTUATOR IF PROPER CABLE TENSION IS NO PRESENT. SUGGEST REVISION TO POH/AFM ADVISING CREW TO VISUALLY CHECK OPERATION OF PITCH TRIM SYSTEM PRIOR TO FLIGHT. (K) 1H72 3O3 O A31EU 1E10 20070131000672007013100067SO 2007 1 31 2007FA0000075 120070123G5312624403 BULKHEAD PIPER PA28 PA28180 7102808SO LYC O360 O360A3A 41514EA SNSNCH76E 76EM8 EA FUSELAGE CORRODED D K NONE O OTHER ININSP/MAINT 1 GL097095W4309 28882 L148936C 15028K THE BULKHEAD, BRACKETS, AND DOUBLERS AT STA. 228.3 WERE SEVERELY CORRODED. THIS BULKHEAD IS THE FRONT SUPPORT FOR THE VERTICAL STABILIZER/RUDDER ASSEMBLY. THE CORROSION COVERED AN AREA APPROXIMATE THE SIZE OF THE FRONT RUDDER ATTACHMENT BRACKET THAT IS PART OF THIS BULKHEAD ASSEMBLY. THE CORROSION WAS FOUND DURING AN ANNUAL INSPECTION AND WAS ONLY VISIBLE, WITHOUT DISASSEMBLY, AS SLIGHT BUBBLING OF THE METAL ON THE BRACKETS FACING REARWARD THAT ARE ATTACHED TO THE AFORE MENTIONED BULKHEAD ASSEMBLY. 1L71 3O3 O 2A13 E286 5 NP4EA 20070131001062007013100106SO 2007 1 31 2007FA0000085 120070117G2434635796 COUPLING CONT PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360KB 17025SO MCAULY3AF32C3AF32C509 GL ALTERNATOR FAILED C B EMER. DESCENT HG ELECT. POWER LOSS-50 PC MULTIPLE FAILURE CRCRUISE 1 GL09321AK4479 869 3447021 812128R 961321 ALTERNATOR DRIVE COUPLING FAILED ON LT AND RT ALTERNATOR, IN IMC SIMULTANEOUSLY. COUPLING FAILURE RESULTED IN TOTAL ELECTRICAL FAILURE, RT ENGINE. 1L72 3O3 O A7SO E9CE 5 CP22EA 20070201000012007020100001NE 2007 2 1 2007FA0000071 120070110G62207610208051105 TIE BOLT SKRSKYS76 S76B 8143007NE PWA PT6 PT6* 52043EA MAIN ROTOR BROKEN D O OTHER O OTHER NRNOT REPORTED 1 EA17411JW3392 760357 WHILE PERFORMING A ROUTINE INSPECTION OF THE MAIN ROTOR SPINDLES, A SPINDLE TIE BOLT WAS FOUND BROKEN AT THE THREADED END OF THE BOLT WHERE THE NUT ATTACHES. THE NUT WAS FOUND INSIDE THE SPINDLE CUFF WHERE THE ROTOR BLADE IS ATTACHED. A BROKEN SECTION OF THE BOLT WAS STILL THREADED INTO THE NUT. IT IS UNCLEAR WHY THE BOLT BROKE. THE BOLT AND SPINDLE HAVE BEEN REMOVED AND SENT TO MFG AIRCRAFT FOR FURTHER INVESTIGATION TO DETERMINE CAUSE OF FAILURE. (K) 1G72 4U3 T H1NE E2NE 20070213000572007021300057EA 2007 2 13 2007FA0000122 220070105G8530 NUT CESSNA172 172N 2072434CE LYC O320 O320* 41508EA ARM RETAINER LOOSE B ONFRO OTHER O OTHER NRNOT REPORTED 1 EA055123E1788 17271722 RL8312761 THE NR 3 CYLINDER EXHAUST ROCKER ARM RETAINING NUT BECAME LOOSE, REDUCING LIFT ON THE EXHAUST VALVE, NOT ALLOWING SUFFICIENT AIR TO EXIT THE CYLINDER. PRESSURE IN THE CYLINDER EXCEDED THE STRENGTH OF THE INTAKE VALVE SYSTEM TO OPEN, CAUSING THE INTAKE PUSHROD TO FALL (BEND). RECOMMEND A SIMPLE LOCKPLATE BE ADDED UNDER THE ROCKER ARM RETAINING NUT WITH A LOCK TAB TO ELIMINATE THIS POSSIBLE FAILURE. (K) 1H71 3O3 ONT3A12 E274 20070213001742007021300174GL 2007 2 13 2007FA0000106 120070111G7603 FRICTION LOCK AMTR LANCARLANCAIR 05616TSGL WALTERM601 M601E EU POWER LEVER INOPERATIVE G O OTHER O OTHER NRNOT REPORTED 1 SW11750TL154 LIV555 913008 AIRCRAFT EXPERIENCED LOSS OF POWER DURING TAKEOFF AND LANDED WITH LANDING GEAR RETRACTED DEPARTING RUNWAY FROM WHICH TAKEOFF WAS MADE. INVESTIGATION REVEALED FRICTION LOCK WAS NOT EFFECTIVE. (K) 1L71 3O3 TRTEXPA1L71EXPE3T 20070214000832007021400083SO 2007 2 14 2007FA0000096 120070103G3230455180 CONDUIT PIPER PA24 PA24250 7102404SO LYC O540 O540* 41532EA LT MLG PUSH PULLSEPARATED D O OTHER O OTHER NRNOT REPORTED 1 EA636632P3200 241755 THE LT MAIN LANDING GEAR PUSH PULL CONDUIT SEPARATED AT THE BALL END WHERE IT IS ATTACHED TO THE SUPPORT STRUCTURE IN THE WHEEL WELL. BELIEVE THIS FAILURE OCCURRED AT THE PREVIOUS LANDING GEAR RETRACTION. (K) 1L71 3O3 O 1A15 E295 20070215001692007021500169WP 2007 2 15 2007FA0000092 220070115G725031021069 TURBINE WHEEL GULSTM690TP 690B 7630516SW GARRTTTPE331TPE33110T WP HARTZLHCB3T HCB3TN5 GL ENGINE DAMAGED B IZ2RO OTHER O OTHER NRNOT REPORTED 1 SW15690LL2245 11544 P99112C BVA7239 INSPECTION OF ENGINE REVEALED DAMAGE TO 3RD STAGE TURBINE ROTOR VISIBLE THROUGH ENGINE TAILPIPE. ENGINE WAS REMOVED FROM AIRCRAFT AND THE TURBINE SECTION MODULE REMOVED TO INVESTIGATE FOR CAUSE OF DAMAGE. UPON INSPECTION 4 EA PINS WERE FOUND MISSING FROM 2ND STAGE TURBINE ROTOR ASSEMBLY CAUSING SIGNIFICANT DAMAGE TO VARIOUS TURBINE SECTION COMPONENTS, SEVERAL OTHER PINS WERE ALSO FOUND LOOSE AND DAMAGED. SB ADDRESSES REMOVAL OF 2ND STAGE TURBINE ROTORS PN 310210610 UTILIZING AN IMPROVED PIN DESIGN. FURTHERMORE MFG HAS INDEPENDENT SERVICE CENTER SPECIAL PROGRAM IN PLACE TO COVER PIN REPLACEMENT ON AFFECTED TURBINE ROTORS AT NO CHARGE, COVERING SECONDARY DAMAGE ON A PRORATED BASIS. (K) 1H72 3T4 T 2A4 E4WE 6 CP15EA 20070220000102007022000010CE 2007 2 20 2007FA0000115 120070111G7120 MOUNT BEECH 36 A36 1151604CE CONT O550 IO550B SO MCAULY3A32C D3A32C* GL ENGINE CORRODED D K NONE O OTHER ININSP/MAINT 1 SW131562F E2857 687034 940159 PERFORMED ANNUAL INSPECTION ON ENGINE, FOUND BLACK (FRETTING) CORROSION BELOW CENTER 2 (LT AFT) ENGINE MOUNT BOLTS. BOLTS WERE LOOSE IN MOUNT, BUT THE NUTS WERE TIGHT ON BOLTS. PROBLEM IS THAT THE BOLTS ARE A LITTLE TOO LONG AND THE NUTS WERE RUNNING OUT OF THREADS ON THE BOLTS. SOLUTION WAS TO ADD ANOTHER WASHER BELOW THE NUTS, THEN RETORQUE BACK TO SPECS. (K) 1L71 3O3 O 3A15 E3SO 5 CP21EA 20070214001432007021400143SO 2007 2 14 FCPR20070003 220070131G8520655516 GEAR BEECH 36 A36 1151604CE CONT O550 IO550B SO CAMSHAFT BROKEN B FCPRA UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 NM0918391200 E1113 685492 ENGINE FAILED IN FLIGHT. FOUND 13 TEETH MISSING FROM CAMSHAFT GEAR P/N 655516. 1L71 3O3 O 3A15 E3SO 20070226000302007022600030EU 2007 2 26 2007FA0000166 120070223G62301090110677 FITTING AGUSTAA109 A109A2 0260120EU ALLSN 250C 250C20 03013GL MAIN ROTOR WORN D K NONE O OTHER ININSP/MAINT 1 EA35745HA 32 7413 MAIN ROTOR DRIVELINK UPPER FITTING STEEL BUSHES (109-0110-70-1) AND UPPER SLEEVE (109-0110-69-1) SEVERELY WORN. SLEEVE STEPPED TO LESS THAN HALF MANUFACTURED DIAMETER AT BOTH ENDS. STEEL BUSHES WORN THROUGH COMPLETELY, WEAR EXTENDING INTO FITTING. HOLE IN BOTH ENDS OF FITTING FOR STEEL BUSHES ELONGATED. PHOTOGRAPHS AND DISCREPANT PARTS AVAILABLE IF REQUIRED. DEFECTIVE PARTS REPLACED. 1G72 3U3 U H7EU E4CE 20070226000762007022600076CE 2007 2 26 2007FA0000145 120070215G781002R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA LT ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 SO09 6162 731 PCE85441 WHILE PERFORMING SCHEDULED MAINTENANCE, REMOVED LT ENGINE EXHAUST STACKS TO FACILITATE INSPECTING THE EXHAUST DUCT. FOUND A 14 INCH CRACK FOLLOWING THE CIRCUMFERENCE OF THE SKI SLOPE WITH A 3 INCHES CRACK PROPAGATING LONGITUDELY AT THE 10 O'CLOCK POSITION FROM THE 14 INCHES CRACK. EXHAUST DUCT HAD PWA SB 3380 COMPLIED WITH 731 HOURS EARLIER. BECAUSE OF THE REMAINING ENGINE TIME, IT WILL BE PULLED FOR OVERHAUL. 1L72 4T4 T A24CE E4EA 20070226001652007022600165CE 2007 2 26 2007001HAGGAN 120070223G57402322330177 SUPPORT BRACKET GARKENYON 26044 LEAR 60 60LEAR 5170707CE PWA 305 PW305A 52128NE ZONE 500 FAILED B H51RO OTHER F FLT CONT AFFECTED APAPPROACH 1 NM03252FX5936 0295 196 DURING FLAP OPERATION, FLAP ACTUATOR SUPPORT BRACKETS FAILED CAUSING FLAP ACTUATOR TO DAMAGE LEFT WING RIB SEGMENT. 2L72 4F4 FRTA10CE E35NE 20070227000542007022700054CE 2007 2 27 HAG07001 120070223G57532322330177 SUPPORT BRACKET GARKENYON 26044 LEAR 60 60LEAR 5170707CE PWA 305 PW305 NE FLAP ACTUATOR FAILED B H51RO OTHER F FLT CONT AFFECTED APAPPROACH 1 NM03252FX5936 0295 196 DURING FLAP OPERATION, FLAP ACTUATOR SUPPORT BRACKETS FAILED CAUSING FLAP ACTUATOR TO DAMAGE LT WING RIB SEGMENT. 2L72 4F4 FRTA10CE E35NE 20070227000602007022700060EA 2007 2 27 2007FA0000183 220070211G854013S19646 GEAR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL CRANKSHAFT LOOSE D A UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 GL15242SP1855 172S8226 L2830651A SK039 DURING TAKEOFF AT 400 FT AGL ENGINE QUIT FORCING AN OFF AIRPORT EMERGENCY LANDING. INITIAL INSPECTION FOUND NO MOVEMENT OF ACCESSORIES AND VALVE MOVEMENT. REMOVED ACCESSORIES CASE AND FOUND DRIVE GEAR ON CRANKSHAFT MOUNT BOLT LOOSE AND PIN SHEARED. MARKS SHOW THAT BOLT AND GEAR WERE LOOSE FOR SOME TIME ALLOWING WEAR ON PIN UNTIL FAILURE. SUSPECT INCORRECT TORQUE OR INCORRECT SEATING OF GEAR TO FLANGE. ALSO WITH GEAR LOOSE BOLT COULD BE TURNED IN LOCKING TAB. HOLE IN LOCKING TAB TOO LOOSE ON BOLT. ENGINE NEW FROM MFG. WITH 1855.3 HOURS. 1H71 3O3 ONT3A12 1E10 5 NP857 20070227000712007022700071SO 2007 2 27 SDR0701 120070123G53121159B2156227 ANGLE GULSTMG1159 GIV 3980115SO RROYCETAY TAY6108 NE BS 793 CRACKED W K NONE O OTHER ININSP/MAINT 1 EA29254GA11823 1032 DURING SCHEDULED 5000 LANDING FS793 BULKHEAD CAP ANGLE NDT INSPECTION, DETECTED A 1.25 INCH LONG CRACK IN RT BULKHEAD CAP ANGLE. MANUFACTURER HAS RECOMMENDED REPLACEMENT OF LT AND RT FS793 BULKHEAD CAP ANGLES. 2L72 4F4 FRTA12EA E25NE 20070227000872007022700087CE 2007 2 27 2007FA0000174 120070201G2432 HOSE BEECH 95 B95 1153404CE LYC O360 O360* 41514EA BATTERY DRAIN DISCONNECTED C K NONE K FLUID LOSS ININSP/MAINT 1 NM019631R TD314 BATTERY ELECTROLYTE RESIDUE FOUND ON LT NOSE GEAR DOOR AND LOWER FORWARD FUSELAGE. INSPECTION REVEALED BATTERY BOX DRAIN HOSE DISCONNECTED AND HANGING IN LOWER NOSE STRUCTURE AREA BELOW THE BAGGAGE FLOOR. ACCESS IS HINDERED BY NUMEROUS FASTENERS THAT ARE HARD TO REMOVE. AT SOME TIME IN THE PAST THE ADF ANTENNA MAST, WHICH DOUBLED AS THE BATTERY DRAIN MAST, HAD BEEN REMOVED AND THE BATTERY DRAIN HOSE WAS NOT RECONNECTED TO A SUITABLE DRAIN. THIS COULD CAUSE CORROSION DAMAGE TO NOSE AREA LOWER STRUCTURE ON TRAVEL AIR AND BARON AIRPLANES, WHICH HAVE SIMILAR DESIGN. PARTS AND SHOP MANUALS CARRY NO REFERENCES ABOUT THE BATTERY DRAIN SYSTEM. SUGGEST REVIEW OF ANY MFG SB DISCUSSING BATTERY BOX DRAIN COMPONENTS, 1L72 3O3 O 3A16 E286 20070301002362007030100236SO 2007 3 1 2007FA0000148 120070214G3234761213 LEVER PIPER PA23 PA23250 7102308SO LYC O540 TIO540* 41532EA COCKPIT BROKEN D F7HSO OTHER O OTHER CLCLIMB 1 WP1331PD 7657 277654016 LANDING GEAR LEVER BROKE AT THE RIVET DURING TAKEOFF, AFTER RAISING LANDING GEAR LEVER UP TO RETRACT LANDING GEAR. (K) 1L72 3O3 O 1A10 E14EA 20070302000342007030200034SO 2007 3 2 2007FA0000177 120070223G575186562025 AILERON PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA WING MISREPAIRED D O OTHER WF INADEQUATE Q C FLT CONT AFFECTED CRCRUISE 1 WP07570ER3583 4496146 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM). ONCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. 1L72 3O3 O A19S0 E286 20070308000562007030800056SO 2007 3 8 2007FA0000178 120070223G575186562025 AILERON PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA WING MISREPAIRED B O OTHER WF INADEQUATE Q C FLT CONT AFFECTED CRCRUISE 1 WP07571ER3801 4496147 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND PIPER FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. PIPER HAS A HISTORY OF AILERON SKIN CRACKING. (IT HAS BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM). ONCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. THIS LEAD1L72 3O3 O A19S0 E286 20070308000572007030800057SO 2007 3 8 2007FA0000179 120070223G575186562025 AILERON PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA WING MISREPAIRED A O OTHER WF INADEQUATE Q C FLT CONT AFFECTED CRCRUISE 1 WP07572ER3160 4496148 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM.) ONCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. 1L72 3O3 O A19S0 E286 20070308000592007030800059SO 2007 3 8 2007FA0000182 120070223G575186562025 AILERON PIPER PA44 PA44180 7104402SO LYC O320 O320* 41508EA WING MISREPAIRED B O OTHER WF INADEQUATE Q C FLT CONT AFFECTED CRCRUISE 1 WP07577ER3881 4496153 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM.) ONCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. 1L72 3O3 O A19S0 E274 20070226001852007022600185SO 2007 2 26 2007FA0000144 120070205G32306741102 SWITCH PIPER PA34 PA34200 7103405SO LYC O360 IO360C1E6 41514EA MLG FROZEN C O OTHER O OTHER NRNOT REPORTED 1 EA171533E 347350050 UPON LANDING, GEAR EXTENSION, DURING APPROACH TO LANDING, PILOT NOTED AN EXCEPTIONALLY LONG TIME BETWEEN GEAR SWITCH ACTUATION AND INDICATION OF ALL DOWN AND LOCKED. OUTSIDE TEMP +9 F. BELIEVE THAT SWITCH ARM FOR DOWNLOCK HAD FROZEN IN PLACE (UP) AND REQUIRED TIME TO ACTUATE. (K) 1L72 3O3 O A7SO 1E10 20070302000332007030200033CE 2007 3 2 2007FA0000175 120070216G1100070507109 PLACARD CESSNA206 206CESSNA 2073302CE LYC O540 TIO540AJ1A EA MCAULY3D36C B3D36C432 GL WING FADED D K NONE O OTHER ININSP/MAINT 1 EA27 150 T20608291 L1083261A 002324 P/N 0705071-9) FUEL QUANTITY AND TYPE PLACARDS HAVE BEEN REPLACED ABOUT ONCE A YEAR DUE TO FADING. THIS AIRCRAFT IS HANGARED. THIS FADING HAS BEEN NOTED WITH OTHER MFG AIRCRAFT. RETAIL COST LAST YEAR NR 50.00+. THIS HAS NOW DOUBLED. OWNERS DON'T PLACARD IMPORTANCE FOR AIRWORTHINESS. 1H71 3O3 O A4CE E14EA 5 CP58GL 20070308000582007030800058SO 2007 3 8 2007FA0000180 120070223G575186562025 AILERON PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA WING MISREPAIRED B O OTHER WF INADEQUATE Q C FLT CONT AFFECTED CRCRUISE 1 WP07573ER3969 4496149 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND PIPER FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM). ONCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION.1L72 3O3 O A19S0 E286 20070309000462007030900046SO 2007 3 9 2007FA0000157 220070212G8530AEC63139 CYLINDER CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 AL037711D10226 U20603170 CRACKED CYLINDER BETWEEN 2ND AND 3RD FIN IB OF UPPER SPARK PLUG ORIENTED DOWN SIDE OF CYL HEAD. LARGE NEAR SEPARATION. (K) 1H71 3O3 O A4CE E5CE 20070309000612007030900061CE 2007 3 9 2007H0002 120070305G2730556545092 ACTUATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE ELEVATOR MISOVERHAULED B R3R2K NONE W INADEQUATE Q C ININSP/MAINT 1 SW012663Y 550602 ACTUATOR RODS PROVIDED WITH UNIT WERE TOO SHORT TO MOVE ELEVATOR TABS THE REQUIRED AMOUNT. 1L72 4F4 F A22CE E1NE 20070309001192007030900119EU 2007 3 9 2007FA0000191 120070227G5730S25WS3001 SKIN BRAERODH125 HS125700A 4230170EU GARRTTTFE731TFE731* 01518WP RT WING CORRODED D O OTHER O OTHER NRNOT REPORTED 1 WP23224EA9121 257088 RT WING LEADING EDGE(S) HAD SEVERE CORROSION WHERE THE TKS PANELS ATTACH. AFTER COMPLETE DISASSEMBLY IT WAS DETERMINED TO BE BEYOND ECONOMICAL REPAIR. RT WING LEADING EDGE HAD BEEN INSPECTED AT MFG 2.5 YEAR PRIOR TO THIS DISCOVERY. (K) 2L72 4F4 F A3EU E6WE 20070309001272007030900127SO 2007 3 9 2007FA0000158 220070212G8530AEC631397 CYLINDER CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 AL037711D U20603170 CYLINDER HEAD CRACKED AT UPPER SPARK PLUG HOLE THRU BEND TO EXHAUST SEAT. (K) 1H71 3O3 O A4CE E5CE 20070309001332007030900133EU 2007 3 9 2007FA0000194 120070221G551225TP1001A SKIN BRAERODH125 HS125700A 4230170EU GARRTTTFE731TFE731* 01518WP HORIZ STAB CORRODED C O OTHER O OTHER NRNOT REPORTED 1 WP01224EA9121 257088 LT AND RT HORIXONTAL STABILIZER LEADING EDGES HAD SEVERE CORROSION WHERE THE TKS PANELS ATTACH. AFTER COMPLETE DISASSEMBLY, IT WAS DETERMINED TO BE BEYOND ECONOMICAL REPAIR. THIS AREA HAD BEEN INSPECTED AT MFG 2.5 YEARS PRIOR TO THIS DISCOVERY. (K) 2L72 4F4 F A3EU E6WE 20070309001402007030900140EU 2007 3 9 2007FA0000187 120070222G2910285683 COUPLING AMD FALC10FALCON10 2730101EU GARRTTTFE731TFE7312 01518WP HYDRAULIC SYS DEFECTIVE D O OTHER O OTHER NRNOT REPORTED 1 GL0343EC 9017 168 THIS COUPLING IS A QUICK-DISCONNECT TYPE FITTING THAT IS IN LINE OF THE ENGINE DRIVEN HYDRAULIC PUMP AND LOCATED IN THE ENGINE PYLON. THERE IS ONLY ONE ON EACH ENGINE AND ONLY ON THE SUCTION LINE. THESE FITTINGS HAVE NO TIME CHANGE REQUIREMENT. WHEN THIS PART WAS CHANGED (DUE TO EXTERNAL LEAKAGE) IT WAS EXTREMELY DIFFICULT TO SEPARATE. ONCE SEPARATED, THE LOCKING BALLS HAD DUG SO DEEPLY INTO THE LOCK RING THAT PARTIAL UNSEATING OF THE O-RING HAD OCCURRED. THERE QUICK DISCONNECT COUPLINGS (LT AND RT) SHOULD BE REQUIRED TO BE INSPECTED AT EACH ENGINE REMOVAL AND REPLACED IF WEAR IS DETECTED. (K) 2L72 4F4 F A33EU E6WE 20070309001522007030900152SW 2007 3 9 2007FA0000151 120070214G5712 FASTENER BBAVIA7 7ECA 21101NNSW LYC O235 O235* 41505EA WING OUT OF POSITION D O OTHER O OTHER NRNOT REPORTED 1 NE055505N 126678 RIB NAILS PULLING OUT IN ALMOST EVERY RIB. RT TIP RIB HAS ALL NAILS PULLED OUT AND A SPACE BETWEEN RIBS AND SPARS, BOTH FRONT AND REAR LOCATIONS. LT WING HAS ONE NAIL THAT IS ABOUT TO FALL OUT AS IT IS PULLED/WORKED OUT .4375 INCH. 80 PERCENT OF RIBS HAVE AT LEAST ONE NAIL OUT OVER .1250 INCH, AND ONLY APPROX 10 PERCENT OF TOTAL NAILS ARE NOT MOVING. HAVE NOT DISASSEMBLE YET FOR SPAR DAMAGE, BUT HAVE SEEN A FEW NAILS THAT ARE (SMOKING) WHERE THEY CONTACT THE ALUMINUM RIB. ALL FOUND DURING ROUTINE INSPECTION AT ANNUAL IAW AD AND APPLICABLE SB`S IAW THE AD. (K) 1H71 3O3 O A759 E223 20070309001572007030900157CE 2007 3 9 2007FA0000200 120070301G257107120591P SUPPORT CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA BATTERY BOX CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SW1565KC 18281015 FOUND BATTERY SUPPORT CRACKED. TOTAL AIRFRAME TIME 1716. THIS IS THE THIRD ONE THAT WE FOUND SUPPORTS NEED TO BE BEEFED UP, THEY ARE TOO LIGHT FOR THE APPLICATION. (K) 1H71 3O3 ONT3A13 1E4 20070309001612007030900161SO 2007 3 9 2007FA0000163 120070201G8120 FITTING PIPER PA32 PA32301T 7103209SO LYC O540 TIO540S1AD 41532EA HARTZLHCE3Y HCE3YR1 GL TURBOCHARGER CRACKED D O OTHER K FLUID LOSS NRNOT REPORTED 1 SW058185Y 522 328024018 L699564A FM1408B THIS PART IS BOLTED TO THE TURBOCHARGER ASSY BETWEEN THE HOT AND COLD SECTIONS. THE HIGH PRESSURE OIL LINE CONNECTS TO THIS PART VIA A FITTING IN THE TOP OF THE PART. AFTER AN ANNUAL INSP, THE ENG WAS RUN-UP AND SYSTEM CHECKED. AN OIL SEEP WAS NOTED IN THE TURBOCHARGER AREA. THE HIGH PRESSURE OIL LINE AND FITTING WAS REMOVED. PN LW 14465 WAS REMOVED AND CLEANED. THE CRACK WAS NOTED. THE PART WAS REPLACED WITH NEW. AFTER RESEARCHING THE AC RECORDS, IT WAS NOTED THAT EXHAUST SYS, INCLUDING TURBOCHARGER WASTE GATE AND CONTROL ROD END WAS NOT OVERHAULED WITH THE ENGINE CORE AS REQUIRED BY MFG. TURBOCHARGER WAS REPLACED WITH NEW UNIT AT TIME OF O/H. UNKNOWN IF PN LW-14465 WAS REPLACED AT THAT TIME. PART IS1L71 3O3 O A3SO E14EA 5 CP33EA 20070309003032007030900303CE 2007 3 9 2007FA0000162 120070206G5511233201015 SPAR CAP LEAR LEAR 35 35A 5170602CE GARRTTTFE731TFE731* 01518WP HORIZ STAB CORRODED C BHKRK NONE O OTHER ININSP/MAINT 1 EA2196FN 17284 1187 186 VISUAL CONDITION CHECK PERFORMED ON HORIZONTAL STABILIZER AFT SPAR CAP AND ELEVATOR HINGE BRACKETS FOR CORROSION, BROKEN FASTENERS, ETC. FOUND SEVERE CORROSION ON UPPER SPAR CAP ASSEMBLY ALONG ENTIRE LENGTH. THIS REQUIRED REMOVAL AND REPLACEMENT OF UPPER SPAR CAP. CORROSION CAUSED BY OPERATING CONDITIONS, LACK OF CONSISTENT WASHING PROGRAM AND POSSIBLE EXPOSED, UNPROTECTED METAL. RECOMMENDA CONSISTENT AIRCRAFT WASHING PROGRAM WHEN OPERATIONS ARE IN OR NEAR COSTAL REGIONS AND ENSURING ALL EXPOSED SURFACES ARE PROPERLY TREATED AND PAINTED. (K) 2L72 4F4 F A10CE E6WE 20070312000222007031200022CE 2007 3 12 J0UR200700001 120070218G2121EM6039 MOTOR BEECH 90 C90A 1152911CE PWA PT6 PT6* 52043EA BLOWER FAILED B J0URA UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 SO091103G LJ1475 AIR CONDITIONING / VENT BLOWER MOTOR ASSEMBLY FAILED CAUSING SMOKE IN COCKPIT. PILOT DECLARED EMERGENCY AND LANDED AT CLOSEST AIRPORT WITHOUT FURTHER INCIDENT. 1L72 3T3 TRT3A20 E2NE 20070312000582007031200058CE 2007 3 12 HAG2007001 120070223G57402322330177 SUPPORT BRACKET GARKENYON 26044 LEAR 60 60LEAR 5170707CE PWA 305 PW305A 52128NE ZONE 500 FAILED B H51RO OTHER FJ FLT CONT AFFECTED WARNING INDICATION APAPPROACH 1 NM03252FX5936 0295 196 DURING FLAP OPERATION, FLAP ACTUATOR SUPPORT BRACKETS FAILED CAUSING FLAP ACTUATOR TO DAMAGE LT WING RIB SEGMENT. 2L72 4F4 FRTA10CE E35NE 20070312002532007031200253EA 2007 3 12 2007FA0000202 220070223G8520V537925914 CRANKSHAFT CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE CORRODED B YYBRK NONE O OTHER ININSP/MAINT 1 GL03988BC4170 2211 17280472 L2494851A DURING SCHEDULED OVERHAUL, THIS CRANKSHAFT WAS FOUND PITTED IN THE INNER BORE. THIS ENGINE WAS A FACTORY OVERHAUL JULY 2002, AND DID HAVE THE PID COATING. THE COATING DOES NOT SEEM TO BLOCK THE CORROSION. (K) 1H71 3O3 ONT3A12 1E10 20070312002542007031200254EA 2007 3 12 2007FA0000201 220070221G8520V53793493 CRANKSHAFT CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE CORRODED B YYBRK NONE O OTHER ININSP/MAINT 1 GL03982BT4744 2196 17280307 L1466351A THIS CRANKSHAFT WAS LAST INSPECTED AND PID COATED AT THE FACTORY APRIL 23, 2002, YET 6 YEARS AND 2196 HOURS LATER, IT WAS PITTED, AND REQURIED FURTHER MACHINING. THE PID COATING DOES NOT SEEM TO HOLD UP, OR BLOCK THE CORROSION. (K) 1H71 3O3 ONT3A12 1E10 20070226000312007022600031SO 2007 2 26 M1144 220070208G8530 EXHAUST VALVE CESSNA421 421C 2076016CE CONT O520 GTSIO520* 17032SO NR 5 CYLINDER BROKEN B B EMER. DESCENT RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 CE03540CA1776 612 421C0144 PILOT REPORTED THAT RT ENGINE WAS RUNNING ROUGH IN FLIGHT. HE DID NOT SHUTDOWN ENGINE. FOUND NO COMPRESSION IN NR 5 CYLINDER ON RT ENGINE. REMOVED CYLINDER AND FOUND EXHAUST VALVE WAS BROKEN. INSTALLED OVERHAULED CYLINDER ASSEMBLY. 1L72 3O3 O A7CE E7CE 20070226001702007022600170SO 2007 2 26 2007FA0000169 120070223G575186562025 AILERON PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA RIGHT MISREPAIRED B O OTHER W INADEQUATE Q C NRNOT REPORTED 1 WP07576ER3598 4496152 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM.) ONCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE T/E TAKES ON A (FAT) CONDITION. THIS LEADS1L72 3O3 O A19S0 E286 20070227000482007022700048CE 2007 2 27 2007FA0000171 120070220G3230504501033 TORQUE TUBE CESSNA CESSNA340 340A 2076405CE CONT O550 IO550* SO MLG BINDING D K NONE W INADEQUATE Q C ININSP/MAINT 1 GL15467DB 340A0467 DURING REPLACEMENT OF ORIGINAL EQUIPMENT TORQUE TUBE (P/N 5045010-18/19) WITH MFG REPLACEMENT P/N 5045010-32/33 INTERFERENCE BETWEEN THE TORQUE TUBE AND AIRFRAME ATTACHMENT FITTING WAS DISCOVERED. RIGGING THE MLG TO ACHIEVE A .1250 DROP OFF WAS IMPOSSIBLE DUE TO THE INTERFERENCE BETWEEN THE TORQUE TUBE AND THE ATTACHMENT FITTING. DROP OFF IS ACHIEVED ONCE THE TORQUE TUBE ROTATES FAR ENOUGH OVER CENTER TO ALLOW THE GEAR TO DROP .1250 BACK DOWN FROM ITS MAXIMUM HEIGHT. MFG TECHNICAL SUPPORT INDICATED THAT THE ORIGINAL TORQUE TUBE (-18/19) HAD A FLAT SPOT BETWEEN THE AFT HINGE ARMS DESIGNED TO CLEAR THE AIRCRAFT STRUCTURE. THIS FLAT SPOT WAS ORIENTED AT A 33 DEGREE OFFSET. THE TORQUE TUBES WERE REDESIGNED IN 1971L72 3O3 O 3A25 E3SO 20070309000012007030900001CE 2007 3 9 HAG07002 120070222G55324555030001804 PANEL LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE7312B WP VERTICAL STAB CRACKED B H51RK NONE O OTHER ININSP/MAINT 1 NM03451WM5571 091 DURING INSPECTION, FOUND RT SIDE VERTICAL STABILIZER CENTER BULLET FAIRING PANEL CRACKED IN 5 LOCATIONS. 2L72 4F4 FRTT00008WIE6WE 20070308000832007030800083SO 2007 3 8 2007FA0000206 120070223G575186562025 AILERON PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA WING MISREPAIRED B BF8XO OTHER WF INADEQUATE Q C FLT CONT AFFECTED CRCRUISE 1 WP07575ER3448 4496151 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AC WOULD SUDDENLY BREAK LEFT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND MFG TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. THIS MAKE OF AIRCRAFT HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM). ONCE THE CRACK IS PAST A CERTAIN POINT , YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE, THE TRAILING EDGE TAKES ON A (FAT) CON1L72 3O3 O A19S0 E286 20070309000042007030900004CE 2007 3 9 2007FA0000207 120070301G2432G35 BATTERY CESSNA180 180 2072602CE CONT O470 O470* 17026SO LEAKING D O OTHER O OTHER NRNOT REPORTED 1 GL159198C34 31297 BATTERY ACID LEAKED OR TRANSFERRED TO AFT, LOWEST CELL (AIRCRAFT TAIL WHEEL) AND SPILLED OUT. CORRODED HOLE IN BATTERY BOX AND SPILLED INTO BELLY OF AIRCRAFT. 1H71 3O3 ONC5A6 E273 20070309000052007030900005CE 2007 3 9 2007FA0000208 120070301G2432G35 BATTERY CESSNA180 180 2072602CE CONT O470 O470* 17026SO LEAKING D O OTHER O OTHER NRNOT REPORTED 1 GL159198C34 31297 BATTERY ACID LEAKED OR TRANSFERRED TO AFT, LOWEST CELL (AIRCRAFT TAIL WHEEL) AND SPILLED OUT. CORRODED HOLE IN BATTERY BOX AND SPILLED INTO BELLY OF AIRCRAFT. 1H71 3O3 ONC5A6 E273 20070309000412007030900041SO 2007 3 9 2007FA0000210 220070220G8530639614639615 ROCKER CONT O300D CESSNA172 172H 2072424CE CONT O300 O300D 17022SO ENGINE INCORRECT D K NONE R PARTIAL RPM/PWR LOSS CRCRUISE 1 EA178848Z 110 64805D6D 17255498 64805D6D PILOT REPORTED LOSS OF POWER (600 RPM DROP) SIGNIFICANT ENGINE ROUGHNESS DURING CLIMB. ENGINE RECOVERED SHORTLY AFTERWARDS. PILOT ELECTED TO CONTINUE AND HAD SAME PROBLEM AGAIN DURING CRUISE FLIGHT. ENGINE RECOVERED ON ITS OWN ONCE AGAIN. PILOT SAID CARB HEAT DID NOT MAKE ANY IMPROVEMENT DURING BOTH OCCURRENCES. AIRCRAFT WAS TURNED OVER TO MAINTENANCE. THE ONLY ABNORMALITY DISCOVERED WAS THAT THE EXHAUST VALVES ON 4 OF THE 6 CYLINDERS HAD INCORRECT ROCKER INSTALLED (639614, INTAKE ROCKER). PARTS MANUAL CALLS FOR 639615 (EXHAUST ROCKER) TO BE INSTALLED ON EXHAUST POSITION. 1H71 3O3 ONT3A12 E253 20070309000732007030900073CE 2007 3 9 2007FA0000214 120070307G801185562020 STARTER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE SPINNING G O OTHER O OTHER NRNOT REPORTED 1 WP05767CL57 172S9987 STARTER SPINS AND WILL NOT ENGAGE. 1H71 3O3 ONT3A12 1E10 20070309001142007030900114SO 2007 3 9 2007FA0000155 220070212G8530 CYLINDER CESSNA206 U206B 2073322CE CONT O520 IO520F 17032SO ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 AL034988F U2060688 CRACKED CYLINDER HEAD BETWEEN 4TH AND 5TH FIN IB OF TOP SPARK PLUG. CRACKS HEADED TOWARD VALVE SEAT. (K) 1H71 3O3 O A4CE E5CE 20070309001162007030900116CE 2007 3 9 2007FA0000199 120070301G257107120591P SUPPORT CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA BATTERY BOX CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SW153539G 18281039 FOUND BATTERY SUPPORT CRACKED. TOTAL AIRFRAME TIME 1075. THIS IS THE 3RD ONE THAT WE FOUND. SUPPORTS NEED TO BE BEEFED UP, THEY ARE TOO LIGHT FOR THE APPLICATION. (K) 1H71 3O3 ONT3A13 1E4 20070309001722007030900172SO 2007 3 9 2007FA0000186 220070222G7414 BUSHING BENDIX CESSNA172 172D 2072410CE CONT O300 O300D 17022SO MAGNETO LOOSE D K NONE O OTHER NRNOT REPORTED 1 WP172948U194 17250548 BRONZE BUSHING, VERY LOOSE IN DISTRIBUTOR BLOCK AND DISTRIBUTOR ARM WAS CONTACTING PINS IN BLOCK. MAG WOULD NOT OPERATE CORRECTLY. (K) 1H71 3O3 ONT3A12 E253 20070312002622007031200262CE 2007 3 12 2007FA0000165 120070206G5511233201015 SPAR CAP LEAR 35 36LEAR 5170601CE GARRTTTFE731TFE731* 01518WP HORIZ STAB CORRODED C BHKRK NONE O OTHER ININSP/MAINT 1 EA2112FN 15719 016 VISUAL CONDITION CHECK PERFORMED ON HORIZONTAL STABILIZER AFT SPAR CAP AND ELEVATOR HINGE BRACKETS FOR CORROSION, BROKEN FASTENERS, ETC. FOUND MODERATE CORROSION ON UPPER SPAR CAP ASSY AT LT OB ELEVATOR HINGE AREA. THIS REQUIRED REMOVAL AND REPLACEMENT OF UPPER SPAR CAP. CORROSION CAUSED BY OPERATING CONDITIONS, LACK OF CONSISTENT WASHING PROGRAM AND POSSIBLE EXPOSED, UNPORTECTED METAL. RECOMMEND A CONSISTENT AC WASHING PROGRAM WHEN OPERATIONS ARE IN OR NEAR COASTAL REGIONS AND ENSURING ALL EXPOSED SURFACES ARE PROPERLY TREATED AND PAINTED. (K) 2L72 4F4 F A10CE E6WE 20070313001972007031300197CE 2007 3 13 2007FA0000227 120070119G801185A34117 STARTER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE STUCK G O OTHER O OTHER NRNOT REPORTED 1 WP05767CL527 172S9987 STARTER STUCK IN ENGAGED POSITION. 1H71 3O3 ONT3A12 1E10 20070322000812007032200081CE 2007 3 22 2007FA0000215 120070301G3230MS2764816 BEARING BEECH 90 F90 1152909CE PWA PT6 PT6A135 52043NE MLG SEIZED B K NONE O OTHER ININSP/MAINT 1 SO0719RK 9280 LA12 PERFORMING A ROUTINE 6 YEAR LANDING GEAR OVERHAUL, THE LT LANDING GEAR GEARBOX-ACTUATOR TORQUE TUBE HAD A SEIZED MAIN SUPPORT BEARING. THIS MADE THE TORQUE TUBE EXTREMELY HARD TO TURN. THE BEARING WAS FOUND TO BE RUSTED, AND SEIZED. BEARING WAS REPLACED WITH NEW. 1L72 4T4 T A31CE E4EA 20070322001402007032200140CE 2007 3 22 2007FA0000247 120070227G716011702 CLAMP BEECH 58 58P 1152744CE CONT O520 TSIO520L 17040SO LT ENGINE FAILED D K NONE O OTHER ININSP/MAINT 1 GL2525RL TJ232 0 LT ENGINE REPORTED TO BE ROUGH RUNNING. INDUCTION HOSE CLAMP(P/N-RAM 1170-2)FAILED; ALLOWING INDUCTION COUPLER(P/N-632323) TO SEPARATE FROM INDUCTION TUBE. THIS INDUCTION LEAK OCCURRED BETWEEN THE Y AND INTAKE TUBES TO CYLINDERS NR 2, NR 4 AND NR 6. 1L72 3O3 O A23CE E8CE 20070326000602007032600060CE 2007 3 26 2007FA0000261 120070322G521099120754 SEAL CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE CABIN DOOR SEAL MISMANUFACTURED B K NONE O OTHER ININSP/MAINT 1 SW13797CW8177 300 5500232 WHILE INSTALLING THIS FACTORY NEW SEAL IT WAS NOTED THAT THE SEAL WAS VERY TIGHT GOING AROUND THE DOOR. UPON CABIN PRESS TEST THE SEAL WILL NOT INFLATE DUE TO BEING TO TIGHT. (2) SEAL FROM STOCK WERE TRIED WITH THE SAME AFFECT. THE LAST SEAL WAS INSTALLED AND INFLATED AS SHOULD BE. THE FACTORY NEEDS TO CHECK THERE SEALS CLOSER UPON RECEIPT FROM THERE VENDORS. 1L72 4F4 F A22CE E1NE 20070312000322007031200032CE 2007 3 12 2007FA0000176 120070222G275255651904 ROLL PIN CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE SPROCKET BROKEN B K NONE O OTHER ININSP/MAINT 1 SW13797CW8177 1200 5500232 DURING A PHASE 5 INSPECTION THE FLAPS SEAMED TO BE SLOW AND BINDING. AT CLOSER INSPECTION IT WAS FOUND THAT THE ROLL PIN HAD BROKEN ALLOWING THE SPROCKET TO MOVE FWD. ON THE P/N 5565190-9 BRAZE ASSY-DRIVE THIS CAUSED BINDING AND ALLOWED THE SPROCKET TO EVEN DROP DOWN ON TO THE P/N 6565193-9 CHAIN GUARD-LOWER FWD. THIS IS A HARD AREA TO LOOK AT EVEN WITH A MIRROR. A FEW MORE ACTIONS WITH THE FLAP WOULD HAVE LED TO TOTAL FAILURE OF THIS SYSTEM. 1L72 4F4 F A22CE E1NE 20070322000482007032200048CE 2007 3 22 20582007TJ001 120070313G5344551123515 HINGE CESSNA CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE PAX DOOR CRACKED B K NONE O OTHER ININSP/MAINT 1 SW136763L6986 5500673 DURING A DAILY INSPECTION OF THE AIRCRAFT A CRACK WAS FOUND ON THE UPPER LUG OF THE DOOR HINGE. DURING REPLACEMENT OF THE HINGE THE LUG COMPLETELY BROKE IN (2) PEICES. 1L72 4F4 F A22CE E1NE 20070326000982007032600098CE 2007 3 26 PAI52007S4508 120070322G760010052417717 CONDITION LEVER BEECH B300 B300 1159232CE PWA PT6 PT6A6 52043EA COCKPIT LOOSE B PAI5K NONE O OTHER ININSP/MAINT 1 SO05507EB4957 FL81 PILOT NOTED RT ENGINE CONDITION LEVER CONTROL FELT LOOSE AND IDLE N1 SPEED LOW. UPON INSPECTION, MAINTENANCE FOUND ALL SCREWS ATTACHING CONDITION LEVER TO QUADRANT LOOSE TO THE POINT OF ALMOST FALLING OUT. 2L72 4T3 TRTA24CE E4EA 20070326001012007032600101CE 2007 3 26 2007FA0000189 120070226G2750051010593 CONTROL CABLE CESSNA172 172N 2072434CE LYC O320 O320* 41508EA TE FLAPS FRAYED B O OTHER O OTHER NRNOT REPORTED 1 GL0531SZ 1372913729 17267732 PILOT REPORTED EXCESSIVE MOVEMENT IN LT FLAP DURING PRE-FLIGHT WALK AROUND OF AIRCRAFT. INITIAL INVESTIGATION BY MAINTENANCE PERSONNEL CONFIRMED FINDINGS. MAINTENANCE PERSONNEL DISCOVERED THAT CABLE P/N 0510105-93 HAD MULTIPLE BROKEN STRANDS/FRAYING NEAR THE TURNBUCKLE END. SUSPECTED CAUSE OF DAMAGE TO CABLE IS DUE TO EXCESSIVE FLEXING BETWEEN TURNBUCKLE END AND FLAP POSITION INDICATOR CLAMP, P/N 0560037-1. AD 80-06-03 HAD BEEN COMPLIED WITH ON 10/11/1982 BY INSTALLATION OF KIT SK172-60A. 1H71 3O3 ONT3A12 E274 20070326001162007032600116CE 2007 3 26 2007FA0000256 120070314G7810655503011 DUCT CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE EXHAUST ASSY MISMANUFACTURED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SW13797CW 5500232 DURING INSPECTION MULTIPLE PATCHES WERE FOUND ON EXHAUST DUCT ASSY P/N 6555030-11. A REPLACEMENT WAS ORDERED AND FOUND TO HAVE 2 HOLES MISDRILLED BY 2 DEGREES. MFG WAS CONTACTED AS TO WHAT COULD BE DONE AND AFTER CONFIRMING THAT IN TRUTH 2 HOLES WERE NOT PROPERLY PLACED WE WERE TOLD THAT IN FACT 4 DUCTS WERE FOUND NOT BUILT CORRECTLY AND 1 HAD GOTTEN TO THE FIELD. MFG HAS AGREED TO ACCEPT THE DUCT BACK FOR REPAIR BUT WANTS TO BILL US FOR THE FIX ON A NEW PART. AFTER REPAIR, WE ARE TO SUBMIT FOR FINANCIAL REIMBURSEMENT FOR THERE ENGINEERING REPAIR. 1L72 4F4 F A22CE E1NE 20070326001272007032600127CE 2007 3 26 2007FA0000258 120070301G3210MS2764816 BEARING BEECH 90 F90 1152909CE PWA PT6 PT6A135 52043NE LT MLG SEIZED B O OTHER O OTHER NRNOT REPORTED 1 SO0719RK 9280 LA12 PERFORMING A ROUTINE 6 YEAR LANDING GEAR OVERHAUL, THE LT LANDING GEAR GEARBOX-ACTUATOR TORQUE TUBE HAD A SEIZED MAIN SUPPORT BEARING. THIS MADE THE TORQUE TUBE EXTREMELY HARD TO TURN. THE BEARING WAS FOUND TO BE RUSTED, AND SEIZED. BEARING WAS REPLACED WITH NEW. 1L72 4T4 T A31CE E4EA 20070329002732007032900273EA 2007 3 29 2007FA0000223 220070124G7261 OIL FILTER PIPER PA32 PA32R300 7103213SO LYC O540 IO540* 41532EA ENGINE COLLAPSED D K NONE K FLUID LOSS NRNOT REPORTED 1 SW99 OIL LEAK NOTED AFTER OIL CHANGE. REMOVED OIL FILTER AND DISCOVERED PARTIAL COLLAPSE OF THE OIL FILTER ELEMENT. IT WAS DETERMINED THAT THE ENGINE MOUNTED INTERNAL BY-PASS VALVES OPERATION. PREVIOUS TO THIS OCCURRENCE THE SB MENTION HAD NOT BEEN COMPLIED WITH. AFTER THIS OCCURRENCE, SB WERE COMPLIED WITH AND A NEW OIL FILTER OF THE SAME MAKE AND MODEL WAS INSTALLED AND THE SYSTEM FUNCTIONED PROPERLY. SUBMITTER SUGGESTS THAT DUE TO THE SIGNIFICANT NR OF OCCURRENCES OF THIS TYPE THAT SB SI-1442 AND 1453 BECOME MANDATORY THROUGH AD FOR ADDED SAFETY. (K) 1L71 3O3 O A3SO 1E4 20070329002802007032900280CE 2007 3 29 2007FA0000220 120070223G2510551900921 SEAT CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE COCKPIT CRACKED D O OTHER O OTHER NRNOT REPORTED 1 CE05630CC 5500130 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAIR WAS REPAIRED IAW ST01042WI STRUCTURAL SEAT REPAIR. (K) 1L72 4F4 F A22CE E1NE 20070329002842007032900284EU 2007 3 29 2007FA0000236 120070121G2434 TERMINAL SOCATATB20 TB20TRINIDAD8680695EU LYC O540 IO540C4D5 41532EA ALTERNATOR BROKEN D O OTHER O OTHER NRNOT REPORTED 1 WP05711RP 1081 L1813148A FIELD WIRE TERMINAL END BROKEN AT ALTERNATOR TERMINAL LUG CAUSED FAILURE OF ALTERNATOR TO CHARGE BATTERY. (K) 1L71 3O3 ORTA51EU 1E4 20070329002902007032900290EA 2007 3 29 2007FA0000233 220070312G7414M3081 SPRING SLICK CESSNA182 T182T 2072738CE LYC O540 TIO540AK1A EA RT MAGNETO BROKEN D K NONE O OTHER ININSP/MAINT 1 WP295198G658 66LC35SDNP T18208150 L1121761A NEW POINTS (PN M3081) WERE INSTALLED IN BOTH MAGNETOS AT THE ANNUAL INSPECTION ON 2/22/07, TT 649.2. ON 3/10/07, TT 658.2, PART TT - 9.0 HOURS, THE PILOT/OWNER PERFORMED MAG CHECK AND THE ENGINE QUIT. A MECHANIC REMOVED THE RT MAG AND FOUND THAT THE SPRING THAT HOLDS HALF THE POINTS HAD SNAPPED OFF. THE MECHANIC TOLD THE OWNER THAT HE HAD NEVER SEEN POINTS FAIL LIKE THIS IN HIS 30 YEARS OF AC MAINTENANCE. TOLD HIM THAT I HAD NEVER SEEN THIS TYPE OF MALFUNCTION IN MY 10 YEARS OF MAINTENANCE. IT APPEARS THAT THE METAL SPRING THAT MAKES UP THE POINT KIT FAILED JUST AFT OF THE AREA WHERE THE METAL IS BENT ON BOTH EDGES FOR STRENGTHING PURPOSE. THE BREAK IS IN A SEMICIRCLE FRO ONE SIDE TO THE OTHER. THE METAL1H71 3O3 ONT3A13 20070329002922007032900292CE 2007 3 29 2007FA0000205 120070222G36101H1069 MIXING VALVE LEAR 60 60LEAR 5170707CE PWA 305 PW305 NE BLEED AIR SYS INTERMITTENT C A UNSCHED LANDING JB WARNING INDICATION SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 GL11500 83 306 SHORTLY AFTER TAKEOFF, AIRCRAFT (L BLEED AIR) WARNING ILLUMINATED, AND (R BLEED AIR) WARNING ILLUMINATED APPROX 5 SEC LATER, SMELLED ODOR IN CABIN. REDUCED POWER AND WARNING WENT OUT. AIRCRAFT DIVERTED FOR MAINTENANCE. UNABLE TO DUPLICATE MALFUNCTION ON GROUND RUN, LT MIXING VALVE WAS SUSPECTED, SO REPLACED. PERFORMED GROUND RUN FUNCTIONAL TEST OF BLEED AIR SYSTEM, AND FLIGHT TEST. NO FURTHER BLEED AIR WARNINGS. (K) 2L72 4F4 FRTA10CE E35NE 20070329002932007032900293SO 2007 3 29 2007FA0000230 120070220G55214602003 RIB PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA LT ELEVATOR BROKEN B K NONE O OTHER ININSP/MAINT 1 SO09112ED 31T8020060 1 INCH CRACK NOTED ON LOWER SKIN THRU RIVET. DRILLED OPEN SKIN AND FOUND 5 INCH OF RIB FLANGE BROKE OFF 2 INCHS FROM TRAILING EDGE. SKIN AND RIB HAVE TO BE REPLACED. (K) 1L72 3T4 T A8EA E4EA 20070329002952007032900295EA 2007 3 29 2007FA0000185 220070222G7414ESIO357424 BUSHING BENDIX MOONEYM20 M20D 5870210SW LYC O360 O360A1D 41514EA MAGNETO LOOSE D O OTHER O OTHER NRNOT REPORTED 1 WP176914U31 1060379 246 BRONZE BUSHING VERY LOOSE IN DISTRIBUTOR BLOCK AND MAG WOULD NOT OPERATE CORRECTLY. AN EMERGENCY LANDING WAS MADE. (K) 1L71 3O3 O 2A3 E286 20070329002992007032900299CE 2007 3 29 2007FA0000195 120070129G3233 LIMIT SWITCH CESSNA310 310J 2074226CE CONT O470 IO470* 17026SO NLG ACTUATOR FAILED G O OTHER O OTHER NRNOT REPORTED 1 SO153091L 310J0091 UP LIMIT SWITCH FAILED ON LANDING GEAR ACTUATOR, CAUSING OVER EXTENSION OF NOSE GEAR SYSTEM. THIS CAUSED THE INTERMEDIATE TORQUE TUBE TO BEND. (K) 1L72 3O3 O 3A10 E1CE 20070322000252007032200025 2007 3 22 2007FA0000209 420070306G23509903334446 AUDIO CONTROL GULSTMG1159 G1159 3953505SO PWA 530 PW530A NE COCKPIT SHORTED C O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 EA21685SF 94 UNIT WAS MANUFACTURED IN AUGUST 06 AND WAS INSTALLED IN DECEMBER 06. THE UNIT POPPED THE CIRCUIT BREAKER ON THE FIRST TRIP. THE UNIT WAS SENT IN FOR REPAIR AND REINSTALLED IN FEBRUARY 07 AND FAILED AGAIN ON THE FIRST FLIGHT. 2L72 4F4 FRTA12EA E00053EN 20070322000372007032200037CE 2007 3 22 2007FA0000238 120070316G3242RA66109 BRAKE PADS CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL MLG FRACTURED D K NONE O OTHER ININSP/MAINT 1 EA076440V49 172RG0701 L2783136A 951039 DURING A 50 HR OIL CHANGE AND INSPECTION, FOUND BOTH LT AND RT BRAKE PADS FALLING APART, SEVERELY CRACKED WITH LARGE PIECES MISSING. BOTH SIDES WERE CHANGED AT THE PREVIOUS 100 HOUR INSPECTION. THIS HAS BEEN A FREQUENT PROBLEM WITH THESE BRAKE PADS ON ALL OF OUR AIRCRAFT (2 C152, 1 C172, 1 C172RG), NEW PADS FAILING WITHIN 200 HOURS OR LESS SINCE WE STARTED USING THEM. PREVIOUSLY, WE USED OTHER MFG PADS WITH VERY FEW PROBLEMS. 1H71 3O3 O 3A17 E286 5 CP7EA 20070326001252007032600125EA 2007 3 26 2007FA0000257 220070224G8530 ROCKER SHAFT UNIVAR108 1081 9230404NM FRNKLN6A41506A4150* 27024EA NR 3 CYLINDER BROKEN G B EMER. DESCENT R PARTIAL RPM/PWR LOSS CRCRUISE 1 WP119088K 1082088 THE NR 3 CYLINDER ROCKER ARM SHAFT FAILED (BROKE) AT THE CENTER SUPPORT POSITION. ADDITIONALLY, (2) OF THE (3) ROCKER ARM BOSS SECURING BOLTS FAILED AND THE THIRD BOLT PULL OUT OF THE HEAD. 1H71 3O3 O A767 E238 20070326001442007032600144EU 2007 3 26 2007FA0000192 120070227G5754S25WS3002 SKIN BRAERODH125 HS125700A 4230170EU GARRTTTFE731TFE731* 01518WP RT WING LE CORRODED D O OTHER O OTHER NRNOT REPORTED 1 WP23224EA9121 257088 RT WING LEADING EDGE(S) HAD SEVERE CORROSION WHERE THE TKS PANELS ATTACH. AFTER COMPLETE DISASSEMBLY, IT WAS DETERMNED TO BE BEYOND ECONOMICAL REPAIR. RT WING LEADING EDGE HAD BEEN INSPECTED AT MFG 2.5 YEARS PRIOR TO THIS DISCOVERY. (K) 2L72 4F4 F A3EU E6WE 20070329002692007032900269EA 2007 3 29 2007FA0000219 220070302G7310 B-NUT CESSNA182 182T 2072703CE LYC O540 IO540AB1A5 EA FUEL SYSTEM LOOSE D K NONE O OTHER ININSP/MAINT 1 SO1138AL 18281450 L2980148A IN THIS CASE, FOUND THAT THE B-NUT CONNECTING TO THE FUEL CONTROL FROM THE SPIDER WAS LOOSE. IT WAS NOT LEAKING, BUT REQUIRED A THIRD OF A TURN TO TORQUE DOWN TO PROPER TORQUE. NO OTHER WORK HAS BEEN DONE TO THE SPIDER OR FUEL CONTROL BECAUSE I HAVE DONE THE WORK SINCE NEW ON THIS AIRCRAFT. TT 228.8. REMEMBER FINDING A LOOSE FIREWALL FITTING ON THE FIRST INSPECTION. THIS IS THE SECOND INSPECTION DONE ON THIS AIRCRAFT. IT WAS CERTIFIED 11/11/2004. (K) 1H71 3O3 ONT3A13 1E4 20070329002962007032900296SO 2007 3 29 2007FA0000156 220070212G8530 CYLINDER CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 AL037711D U20603170 CRACKED CYLINDER LEAD BETWEEN 4TH AND 5TH FIN IB AT UPPER SPARK PLUG. CRACK NOT VISIBLE INSIDE CYLINDER. (K) 1H71 3O3 O A4CE E5CE 20070402001292007040200129CE 2007 4 2 2007FA0000269 120070321G6100 NONE BEECH 90 C90 1152913CE PWA PT6 PT6A21 52043EA HARTZLHCD4N3HCD4N3A GL PROPELLER UNKNOWN B O OTHER O OTHER NRNOT REPORTED 1 SO13427DM LJ804 AIRCRAFT HAS RAISEBECK STC SA3593NM INSTALLED WHICH STATES THE PROPS ARE NOT TO BE OPERATED BELOW THE SET MINIMUM RPM. PRE PHASE INSPECTION RUNS REVEALED THIS CONDITION. IAW MFG SERVICE LETTER 61-254 THIS CAN CAUSE NO REACTION MODE VIBRATORY RESONANCE AND MAY RESULT IN HIGH STRESS IN THE BLADES. IT WAS RECOMMENDED THAT THE PROPELLERS BE REMOVED AND BE SENT TO A PROPELLER SHOP FOR INSPECTION. CUSTOMER DECLINED RECOMMENDATION. NO FURTHER ACTION WAS TAKEN AT THIS INSPECTION. BOTH THE LT AND RT PROPELLERS HAVE A TSO OF 957.9 AND A TT OF 2615.2 1L72 3T4 T 3A20 E4EA 5 CSTC 20070402001352007040200135CE 2007 4 2 M40675 120070320G274045AS610023139 ACTUATOR BEECH MU300 400A 1155402CE PWA JT15 JT15D5 52112NE PITCH TRIM INOPERATIVE C R71AO OTHER F FLT CONT AFFECTED DEDESCENT 1 WP05790SS1550 RK363 DIFFICULTY OCCURRED UPON DESCENT. PILOT RECEIVED A WARNING PITCH TRIM WAS NOT SYNCHRONIZED WITH AUTOPILOT SYSTEM AND TO PREPARE FOR RESISTANCE WHEN AUTOPILOT IS DISCONNECTED. PITCH TRIM ACTUATOR WAS FOUND INOPERATIVE IN THE EMERGENCY MODE/AUTOPILOT MODE. REPLACED PITCH TRIM UNIT AND RETURNED AIRCRAFT TO SERVICE. THIS AIRCRAFT WAS LAST INSPECTED ON 11-9-06 AT 1408.6 TT. 2H72 4F4 FRTA16SW E25EA 20070402001512007040200151CE 2007 4 2 40675 120070320G274145AS610023139 ACTUATOR BEECH MU300 400A 1155402CE PWA JT15 JT15D5 52112NE PITCH TRIM INOPERATIVE C R71AO OTHER F FLT CONT AFFECTED DEDESCENT 1 WP05790SS1550 RK363 DIFFICULTY OCCURED UPON DESCENT. PILOT RECIEVED A WARNING PITCH TRIM WAS NOT SYNCRONIZED WITH AUTOPILOT SYSTEM AND TO PREPARE FOR RESISTANCE WHEN AUTOPILOT IS DISCONNECTED. PITCH TRIM ACTUATOR WAS FOUND INOPERATIVE IN THE EMERGENCY MODE/AUTOPILOT MODE. REPLACED PITCH TRIM UNIT AND RETURNED AIRCRAFT TO SERVICE. THIS AIRCRAFT WAS LAST INSPECTED ON 11-9-06 AT 1408.6 TT. 2H72 4F4 FRTA16SW E25EA 20070402001572007040200157SO 2007 4 2 2007FA0000264 120070306G53501159B541014 FAIRING GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700715A130 NE FUSELAGE DEPARTED G A UNSCHED LANDING D INFLIGHT SEPARATION NRNOT REPORTED 1 CE07401HF1300 5039 ON MARCH 6, 2007, DURING A FLIGHT, THE SUBJECT AIRCRAFT EXPERIENCED AN IAPPARENT IN-FLIGHT STRUCTURAL FAILURE OF THE RIGHT WING-TO FUSELAGE FORWARD FAIRING. THE INCIDENT OCCURRED AT FLIGHT LEVEL 400 AT 90 DME ON THE (LNK) VOR 220 RADIAL AT .85 MACH. AFTER ONE HOUR AND 45 MINUTES INTO THE FLIGHT (APPROX 2115Z), THE CREW NOTED AN AUDIBLE (THUMP) FOLLOWED BY A (CHANGE IN WIND NOISE). AS THE AIRCRAFT IS EQUIPPED WITH PROXIMITY CAMERAS, THE FIGHT CREW WAS ABLE TO SEE A (HOLE OF SIGNIFICANT SIZE) IN THE AREA OF THE SINGLE POINT REFUELING ACCESS DOOR USING THE LOWER AFT-FACING FUSELAGE CAMERA. THE FLIGHT CREW NOTIFIED AND REQUESTED EMERGENCY LANDING, WHERE THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE FSDO WA2L72 4F4 FRTA12EA E00061EN 20070402001662007040200166SW 2007 4 2 2007FA0000287 120070322G7110 RIVET MOONEYM20 M20J 5870219SW LYC O360 IO360A1A 41514EA COWLING CORRODED D K NONE O OTHER ININSP/MAINT 1 SO119156X 243253 OWNER BROUGHT COWLINGS IN FOR REPAIR BECAUSE THE THROUGH SKIN RIVETS WERE CORRODING AND SHEARING OFF AT THE MFG HEAD AS EXHIBITED BY BLISTERING PAINT AT THE RIVET LOCATIONS. INSPECTION REVEALED MOST OF THE AD TYPE RIVETS WERE SEVERELY CORRODED BECAUSE THE COWLINGS WERE CONSTRUCTED WITH A HYBRID COMPOSITE LAMINATE OF E-GLASS AND CARBON GRAPHITE PLIES. IT IS STANDARD INDUSTRY PRACTICE TO USE CORROSION RESISTANT FASTENERS SUCH AS RIVETS THROUGH CARBON GRAPHITE STRUCTURE AND IT IS UNKNOWN WHY ALUMINUM RIVETS ARE USED IN THIS CASE. AFFECTED AREAS: UPPER COWL/ OIL DOOR CUTOUT DOUBLER RIVETS COOLING AIR INLET AFT EDGE RIVETS. LOWER COWL/ BOTH UPPER CAMLOCK RECEPTACLE GANG STRIPS (SEVERELY CORRODED AND CONCEALED BY1L71 3O3 O 2A3 1E10 20070402001682007040200168WP 2007 4 2 2007FA0000196 220070220G72618961051 COVER BEECH 100 B100 1152919CE GARRTTTPE331TPE3316 01514WP LT ENGINE BROKEN D O OTHER O OTHER NRNOT REPORTED 1 WP09241CW BE54 P27188 PILOT REPORTED HIGH OIL CONSUMPTION, INSPECTED LT ENGINE SCAVENGE PUMP AND FOUND THE PUMP COVER BROKEN AND MISSING PIECES. ALSO FOUND THE SCAVENGE PUMP OIL TUBE COVER BROKEN AND CHAFING A HOLE THROUGH THE OIL TUBE. RECOMMEND REMOVING EXHAUST PIPE AT INSPECTIONS TO INSPECT PUMP COVER AND TUBE ASSY FOR DEFECTS. (K) 1L72 4T4 T A14CE E4WE 20070402002222007040200222EU 2007 4 2 2007FA0000267 120070228G81204066109031 BEARING SOCATATB20 TB21 8680697EU LYC O540 TIO540AB1A 41533EA TURBOCHARGER FAILED B BNGRO OTHER O OTHER NRNOT REPORTED 1 GL19189GT685 2022 21052261A IN FLIGHT, DROP IN MANIFOLD PRESSURE, TROUBLESHOT, FOUND TURBOCHARGER BEARING FAILURE. FOUND METAL IN OIL FILTER. ENGINE REMOVED FOR REPAIR. (K) 1L71 3O3 ORTA51EU E14EA 20070402002372007040200237EA 2007 4 2 2007FA0000221 220070222G8520 CRANKSHAFT CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE CORRODED B YYBRK NONE O OTHER ININSP/MAINT 1 GL03 2199 L130951A DURING NORMAL OVERHAUL, CRANKSHAFT FOUND PITTED IN THE INTERNAL BORE. THIS ENGINE WAS LAST OVERHAULED BY THE FACTORY, JULY 2002.. THE PID COATING DOES NOT SEEM TO PREVENT PITTING OR CORROSION. (K) 1H71 3O3 ONT3A12 1E10 20070403000342007040300034SO 2007 4 3 2007FA0000290 120070402G532137829007 FLOOR PANEL PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE ZONE 100 DEBONDED D IBIRK NONE O OTHER ININSP/MAINT 1 EA27682JK968 3449154 322291 FLOOR PANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING BRACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. HAVE CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEARD ANYTHING AS YET. 1L72 3O3 O A7SO E9CE 20070403000352007040300035SO 2007 4 3 2007FA0000291 120070402G532137829007 FLOOR PANEL PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE ZONE 100 DEBONDED D IBIRK NONE O OTHER ININSP/MAINT 1 EA27682JK968 3449154 322291 FLOOR PANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING BRACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. HAVE CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEARD ANYTHING AS YET. 1L72 3O3 O A7SO E9CE 20070403000492007040300049CE 2007 4 3 2007FA0000270 120070326G271035524314 CONTROL CABLE BEECH 35 N35 1151528CE CONT O470 IO470* 17026SO AILERONS WORN C O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 WP231363Z7541 D6787 (REF MODEL 35 SERIES IPC FIG. 27) LT AILERON CABLE FOUND RIDING ON PROP CONTROL CABLE SHEATH, ABOUT 2 INCHES AFT OF FIREWALL. AILERON CABLE WAS WORN ABOUT HALF THROUGH, AND THE PROP CABLE WAS WORN THROUGH THE SHEATH TO THE INNER STEEL CABLE. (VERY DIFFICULT TO ACCESS THIS AREA FOR VISUAL INSPECTION.) NO INDICATION OF RUBBING OR DRAGGING DURING GROUND CONTROL SYSTEM CHECKS, OR IN FLIGHT. IT IS RELATIVELY EASY TO HAVE THE PROP CONTROL CABLE DISPLACED INTO CONTACT WITH THE AILERON CABLE WHEN WORKING IN THIS AREA DURING, FOR EXAMPLE, PANEL MODIFICATIONS OR AVIONICS UPGRADES. RECOMMEND VISUAL AND TACTILE INSPECTION IN THIS AREA TO CONFIRM CLEARANCE. UPON REMOVAL OF CABLE ASSEMBLY FOR REPLACEMENT, FOUND ADDITIO1L71 3O3 O 3A15 E1CE 20070322000912007032200091GL 2007 3 22 R022366 320070316G6110A20742 SEAL RING CIRRUSSR SR22 2130001GL CONT O550 IO550F 17042SO HARTZLHCJ3Y PHCJ3YF1 GL PROPELLER BLADE DEBONDED B SJ3RK NONE E VIBRATION/BUFFET ININSP/MAINT 1 GL05 81 FP5296B TEFLON (BLADE SEAL) DEBONDED FROM THE SHANK OF BLADE SN A0336 CAUSING GREASE LEAK. 1L71 3O3 ONTA00009CHE3SO 5 CP36EA 20070322000922007032200092CE 2007 3 22 2007FA0000243 120070226G5310VP10 ANTENNA BEECH 33 35B33 1151406CE CONT O470 IO470* 17026SO VHF SYSTEM MISINSTALLED B A UNSCHED LANDING WD INADEQUATE Q C INFLIGHT SEPARATION CRCRUISE 1 CE031768G94 94 CD509 THE DOUBLER FOR THE VHF ANTENNA APPEARS TO HAVE BEEN TOO SMALL(SLIGHLY LARGER THAN THE BASE OF THE ANTENNA)AND WAS NOT RIVITED TO THE FUSELAGE,ALLOWING THE ANTENNA TO FLUTTER WHILE AIRBORNE.ON POST FLIGHT INSPECTION THE PILOT DISCOVERED TEARING ON THREE SIDES ON TOP OF THE FUSELAGE AROUND THE BASE OF THE ANTENNA.NOTE THE TACH ONLY READS 94.5 1L71 3O3 O 3A15 E1CE 20070322000932007032200093CE 2007 3 22 2007FA0000244 120070301G5551071204221 BRACKET CESSNA185 A185F 2072821CE CONT O520 IO520* 17032SO HORIZONTAL STAB CRACKED D K NONE O OTHER ININSP/MAINT 1 NM074640E 18503824 DURING A DETAILED INSPECTION OF THE EMPENAGE, THE RT HORIZONTAL STABILIZER HINGE BRACKET P/N 0712042-2 WAS FOUND CRACKED AND HAD (2) SHEARED RIVETS. UPON DISASSEMBLY THE LT BRACKET P/N 0712042-1 WAS FOUND TO HAVE (2) SHEARED RIVETS. THESE PARTS ARE IN THE MFG 180/185 IPC FIG 32 INDEX NR 36 AND NR 37.THERE IS NOTHING IN THE RECORDS THAT SHOW THESE PARTS CHANGED, HOWEVER THE RT BRACKET DID HAVE (2) NR 5 RIVETS WHERE ALL OF THE REST ON BOTH BRACKETS WERE NR 4S. LEADING US TO BELIEVE THAT IT MAY HAVE BEEN REPLACED BEFORE. 1H71 3O3 O 3A24 E5CE 20070322000982007032200098CE 2007 3 22 2007FA0000246 120070313G2820050011849 LINE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA FUEL SYSTEM CHAFED D K NONE K FLUID LOSS ININSP/MAINT 1 SW0530LU 847 17281257 DURING PREFLIGHT INSP. PILOT FOUND FUEL ON RAMP UNDER CENTER FUSELAGE MECHANIC INVESTIGATED INSIDE COCKPIT FLOOR AND FOUND ALUMINUM FUEL LINE CHAFING AGAINST RT STEERING TUBE, CAUSING THE FUEL LEAK. MECHANIC INSPECTED 6 OTHER 2005/2006 172R AIRCRAFT IN OUR FLEET AND FOUND CHAFING IN (3) OTHER AIRCRAFT, WITH ANOTHER LEAK IMMINENT. ALL AC UNDER 900 HRS AFTT. OUR AIRCRAFT CAME FROM THE FACTORY WITH THIS FUEL LINE/STEERING TUBE CONFIGURATION. SUBMITTER SUGGESTS IMMEDIATE INSPECTION FOR THIS CONDITION. NOTE: FUEL WAS NOT SMELLED IN COCKPIT. 1H71 3O3 ONT3A12 1E10 20070323000012007032300001SW 2007 3 23 2007FA0703221 120070322G32345059 HANDLE MOONEYM20 M20A 5870204SW LYC O360 O360* 41514EA MLG BROKEN G O OTHER O OTHER APAPPROACH 1 SW171068B 1295 GEAR HANDLE (MECHANICAL RETRACTION HANDLE) BROKE OFF IN THE PILOT'S HAND DURING GEAR EXTENSION ON LANDING APPROACH. THE LANDING GEAR DISENGAGED BUT IT DID NOT EXTEND FULLY. THE BREAK WAS JUST BELOW THE WELD. 1L71 3O3 O 2A3 E286 20070326001282007032600128SO 2007 3 26 2007FA0000259 120070301G8000PM1201 STARTER PIPER PA28 PA28236 7102815SO LYC O540 O540J3A5 41532EA HARTZLHCF3Y HCF3YK1 GL ENGINE WORN G K NONE O OTHER ININSP/MAINT 1 SO052177Z28 28 287911154 L2117640A CM288 THIS AIRCRAFT HAS HAD (5) PM1201 STARTERS INSTALLED SINCE 03-08-2004. THE STARTERS HAD TO BE REPLACED AT THE FOLLOWING INTERVAL: 58 HOURS TIME IN SERVICE, 18 HOURS TIME IN SERVICE, 11 HOURS TIME IN SERVICE, 5 HOURS TIME IN SERVICE, 28 HOURS TIME IN SERVICE. ALL STARTERS SUFFER THE SAME PROBLEM. AFTER THE ENGINE IS STARTED AND THE AIRCRAFT HAS FLOWN FOR A SHORT PERIOD OF TIME, (LESS THAN ONE HOUR) THE BENDIX GEAR WILL BEGIN TO CREEP OUT AND TRY TO ENGAGE/RUB THE RING GEAR. IN FEW FLIGHT HOURS THE BENDIX GEAR WILL START SHOWING WEAR ON BOTH THE BENDIX GEAR AS WELL AS THE RING GEAR ON THE FLYWHEEL. ALL THE STARTERS WERE REPORTED TO HAVE HAD THE SAME PROBLEM. THE OWNER DECIDED TO REMOVE THE STARTER FROM HIS AIR1L71 3O3 O 2A13 E295 5 CP31EA 20070326001452007032600145CE 2007 3 26 2007FA0313001 120070313G521055123515 HINGE CESSNA CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE PAX DOOR CRACKED B O OTHER O OTHER TXTAXI/GRND HDL 1 SW136763L6986 5500673 DESCRIPTION AMENDED TO SAY THAT THE LOWER LUG WAS CRACKED INSTEAD OF THE UPPER LUG. 1L72 4F4 F A22CE E1NE 20070329002652007032900265EA 2007 3 29 2007FA0000164 220070206G8500 ENGINE CESSNA206 T206H 2073303CE LYC O540 TIO540A1A 41532EA MAKING METAL D K NONE O OTHER ININSP/MAINT 1 GL213543B T20608330 L1123761A UNDER NORMAL CONDITIONS AND UNDER OIL SAMPLE PROGRAM, ENGINE HAS HAD (6) HIGH BAD SAMPLES, HIGH IRON, COPPER AND ALUMINUM. AC IS A PUBLIC USE AIRCRAFT WITH CUSTOMS AND BORDER PROTECTION, BUT AM REPLACING ENGINE WITH NEW/ OVERHAUL. CONTACTED MFG ABOUT PROBLEM BUT WAS TOLD TO KEEP CHANGING OIL AND FILTERS. RECOMMEND THA THIS TYPE ENGINE BE INVESTIGATED CLOSER. THIS ENGINE WAS CHANGED IN 2005 DUE TO SIMILAR PROBLEM. (K) 1H71 3O3 ORTA4CE E14EA 20070329002912007032900291SW 2007 3 29 2007FA0000268 120070308G291020144 B-NUT GULSTM500 500S 0141107SW LYC O540 TIO540A1A 41532EA LT MLG LOOSE D O OTHER O OTHER NRNOT REPORTED 1 GL19280MB 3255 PILOT NOTICED A FLUCTUATION AND LOSS OF HYDRAULIC PRESSURE IN FLIGHT, AFTER INSPECTION THE FORWARD HYDRAULIC HOSE B-NUT ON THE LT GEAR ACTUATOR WAS FOUND TO BE LOOSE. THE B-NUT WAS TIGHTENED AND TORQUE SEAL WAS PUT ON THE B-NUT. SERVICED HYDRAULIC RESERVOIR WITH H-5606. AC WAS TEST FLOWN AND LEAK CHECK GOOD. (K) 1H72 3O3 O 6A1 E14EA 20070329002942007032900294CE 2007 3 29 2007FA0000188 120070215G2510551900922 SEAT CESSNA CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE COCKPIT CRACKED D O OTHER O OTHER NRNOT REPORTED 1 CE05404BS 5500403 UPPER CHAIR BASE ASSY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAIR WAS REPAIRED IAW STC 01042WI STRUCTURAL SEAT REPAIR. (K) 1L72 4F4 F A22CE E1NE 20070329002982007032900298SO 2007 3 29 2007FA0000231 120070215G2910 HYDRAULIC LINE PIPER PA23 PA23250 7102308SO LYC O540 IO540* 41532EA HYDRAULIC SYS CHAFED G O OTHER K FLUID LOSS NRNOT REPORTED 1 SO19144CN5200 278054036 AIRCRAFT HYDRAULIC SYSTEM RT GEAR DOWN ALUMINUM LINE LOCATED UNDER COCKPIT FLOOR WAS CHAFING AGAINST CONTROL CABLE AND WAS PENETRATED CAUSING LEAK AND DEPLETION OF HYDRO FLUID WHICH RESULTED IN AIRCRAFT LANDING WITH UNSAFE NOSE GEAR AND DAMAGE TO AIRCRAFT NOSE SECTION. THIS AREA SHOULD BE INSPECTED AT LEAST DURING ANNUAL INSPECTIONS. (K) 1L72 3O3 O 1A10 1E4 20070402001692007040200169EA 2007 4 2 2007FA0000218 220070202G855056G23399 BAFFLE PIPER PA32 PA32301 7103207SO LYC O540 TIO540AH1A 42003EA OIL SUMP CRACKED D K NONE O OTHER ININSP/MAINT 1 NM07447KC85 3255047 L1239361A DURING ENGINE OIL CHANGE FOUND RIVET HEAD IN OIL SUMP SCREEN. REMOVED ENGINE AND OIL SUMP ASSY. FOUND OIL SUMP BAFFLE ASY RIVETS SHEARED OFF AND ATTACH HOLES BROKEN OUT AND BAFFLE ASSY CRACKED. RETRIEVED RIVET STEMS AND HEADS. REMOVED AND REPLACED OIL SUMP BAFFLE ASSY WITH NEW PART. REASSEMBLED ENGINE AND REINSTALLED. (K) 1L71 3O3 O A3SO E14EA 20070402002142007040200214CE 2007 4 2 2007FA0000237 120070301G561010138402524 WINDSHIELD BEECH 300 300BEECH 1152930CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL COCKPIT CRACKED B AHTRA UNSCHED LANDING O OTHER CRCRUISE 1 GL11200VC728 FL316 AT AN ALTITUDE OF 17,000 FT OAT -6 DEGREES C, THE RT WINDSHIELD CRACKED FROM THE CENTER OB FROM THE TOP TO THE BOTTOM ABOUT 2 INCHES OB ON THE OUTER PANE. RETURNED TO THE DEPARTING AIRPORT WITHOUT ANY PROBLEMS. WINDSHIELD WAS REPLACED AND NO KNOWN CAUSE FOR THE WINDSHIELD TO CRACK. (K) 2L72 4T4 T A24CE E4EA 6 CP56GL 20070406001602007040600160CE 2007 4 6 2007FA0000295 120070320G8120 BEARING CESSNA414 414A 2075907CE CONT O520 TSIO520* 17040SO TURBOCHARGER WORN D O OTHER O OTHER NRNOT REPORTED 1 GL133247M1031 FKL00044 414A0828 FAILURE OF RT TURBOCHARGER SEAL AND CENTER BEARING CAUSED SMOKE OUT OF EXHAUST AND SQUEALING NOISE RESULTING IN THE FLIGHT CREW TO FEATHER PROPELLER AND SHUTDOWN THE ENGINE. CAUSE OF FAILURE DO TO WEAR. (K) 1L72 3O3 O A7CE E8CE 20070406001632007040600163CE 2007 4 6 2007FA0000301 120070406G1400 NUT CESSNA172 172S 2072439CE LYC O360 IO360A1A 41514EA MISMANUFACTURED B O OTHER O OTHER NRNOT REPORTED 1 EA07949SP 172S8145 WHILE INSTALLING KIT MK172-25-10C TO COMPLY WITH SB 04-25-01 R4 AND AD 2007-05-10, ONE OF THE PARTS IN THE KIT WAS MACHINED IMPROPERLY. THE HEIGHT ADJUSTING NUT HAD THE THRU HOLE FOR THE ULTRALOC WITH MIS FORMED THREADS. THE MINOR DIAMETER OF THE THREAD WAS GREATER THAN THE MAJOR DIAMETER OF THE THREADS ON THE ULTRALOC. THE CROSS HOLE FOR MOUNTING WAS INCORRECTLY LOCATED WITH INSUFFICIENT EDGE DISTANCE, AND THE PILOT HOLE WAS OFFSET GIVING AN EGG SHAPED HOLE. 1H71 3O3 ONT3A12 1E10 20070409000282007040900028CE 2007 4 9 2007FA0000315 120070402G36101H1068 MIXING VALVE LEAR 60 60LEAR 5170707CE PWA 305 PW305 NE LT BLEED AIR SYSOUT OF TOLERANCEB C ABORTED TAKEOFF B SMOKE/FUMES/ODORS/SPARKS TOTAKEOFF 1 GL09706CR 168 DURING TAKEOFF ROLL CREW EXPERIENCED A RUSH OF WARM OILY SMELLING AIR IN THE COCKPIT. CREW ABORTED TAKEOFF AND RETURNED TO BASE. MAINTENANCE CREW RAN AIRCRAFT AND DUPLICATED PROBLEM FINDING THE DUCT OVRHT LIGHT AND LT BLEED LIGHT ON AT FULL POWER. FURTHER TROUBLESHOOTING FOUND THAT THE LT BLEED AIR MIXING VALVE WAS ALLOWING MORE THAN 200PSI OUT PUT OF AIR. LT BLEED AIR MIXING VALVE WAS REPLACED WITH A SERVICEABLE INSPECTED VALVE AND OPS CHECKED GOOD. 2L72 4F4 FRTA10CE E35NE 20070409000322007040900032CE 2007 4 9 2007FA0000310 120070406G140007900072 NUT CESSNA172 172S 2072439CE LYC O360 IO360A1A 41514EA KIT MISMANUFACTURED B O OTHER W INADEQUATE Q C NRNOT REPORTED 1 EA07949SP 172S8145 WHILE INSTALLING KIT MK172-25-10C TO COMPLY WITH SB 04-25-01 R4 AND AD 2007-05-10, ONE OF THE PARTS IN THE KIT WAS MACHINED IMPROPERLY. THE HEIGHT ADJUSTING NUT HAD THE THRU HOLE FOR THE ULTRALOC WITH MALFORMED THREADS. THE MINOR DIAMETER OF THE THREAD WAS GREATER THAN THE MAJOR DIAMETER OF THE THREADS ON THE ULTRALOC. THE CROSS HOLE FOR MOUNTING WAS INCORRECTLY LOCATED WITH INSUFFICIENT EDGE DISTANCE, AND THE PILOT HOLE WAS OFFSET GIVING AN EGG SHAPED HOLE. 1H71 3O3 ONT3A12 1E10 20070409000372007040900037CE 2007 4 9 2007FA0000303 120070403G273165651412 ACTUATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE ZONE 200 BINDING B K NONE O OTHER ININSP/MAINT 1 SW135314J5592 300 5500663 AFTER A PHASE 1-4 INSPECTION THE ELEVATOR TRIM WAS FOUND TO BE BINDING. INSPECTION OF THIS SYSTEM FOUND THAT THE WILKIE BUTTON IN THE BACK OF THE ACTUATOR TRIM JACK SCREWS HAD COME OUT AND WAS BINDING THE TRIM CHAIN AND SPROCKETS. WHEN THE ACTUATORS ARE LUBED THE WILKIE BUTTONS HAVE A TENDENCY TO POP OUT OF THERE PLACE IF YOU DONT LOOK CLOSELY AFTER LUBING THESE ACTUATORS THE GREASE PUSHES THESE PLUGS OUT AND THEY STICK TO THE INTERCONNECT CHAIN CAUSING A BINDING CONDITION. THIS COULD ALSO HAPPEN IN FLIGHT CAUSING A LIKE CONDITION WITH MORE DIRE PROBLEMS. I THINK MFG SHOULD REMOVE THIS PLUG OR MORE SECURELY FIX THIS PLUG IN PLACE. 1L72 4F4 F A22CE E1NE 20070409000812007040900081WP 2007 4 9 2007FA0000313 220070330G721031030351 BEARING GARRTTTPE331TPE33110U 01514WP IDLER GEAR MISINSTALLED B K NONE W INADEQUATE Q C ININSP/MAINT 1 WP07 723 P44218C SUBASSEMBLY BEARINGS TO 2ND IDLER GEAR ASSEMBLED BACKWARDS, CAGE FAILED. 4 T E4WE 20070409001252007040900125NM 2007 4 9 QXEANM09417 120070314G4920164161100 DRAIN VALVE BOMBDRDHC8 DHC8402 1390042NM PWC 150 PW150A EA APU PLUGGED G QXEAO OTHER O OTHER NRNOT REPORTED 1 NM09417QX 4086 BALL ON WRONG SIDE OF SPRING ALLOWING IMPROPER DRAINAGE. 2H72 4T4 TRTA13NM E00062EN 20070326001072007032600107CE 2007 3 26 2007FA0000253 120070307G272065651412 ACTUATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE ELEVATOR BINDING C K NONE O OTHER ININSP/MAINT 1 SW13797CW8177 300 0232 WHILE REPLACING TRIM ACTUATOR P/N 6565141-2 WITH WHAT MFG SAID WAS AN APPROVED SUB PART P/N 5565450-92. IT WAS FOUND THAT THE LOLLIPOPS (JACK SCREWS) WERE 5.5 INCHES LONG AND THE ORIGINAL LOLLIPOPS ARE 5.75 INCHES LONG. IF YOU LOOK AT THE COMPONENT MANUAL FOR THIS ACTUATOR 6565141-2 IT SHOWS 4 DIFF. DASH NUMBERS. -4 AT 5.5 INCHES, -7 AT 5.5 INCHES, -15 AT 4.85 INCHES, AND -21 AT 5.75 INCHES ALL WHICH IS TO THE SAME LOLLIPOP P/N. THE -92 ACTUATORS FITS UNITS 692 TO 924, WHILE OUR UNIT IS 232. MFG NEEDS TO FIX THESE P/NS AND CLEAR THE WAY THESE MANUALS ARE WRITTEN FOR CLARITY. TO MANY ACTUATORS ARE TO ANOTHER P/N WITH INCORRECT JACKSCREW LENGTHS. 1L72 4F4 F A22CE E1NE 20070402001582007040200158SO 2007 4 2 2007FA0000226 220070220G8500 ENGINE CESSNA404 404 2075901CE CONT O520 GTSIO520M 17032SO FAILED D O OTHER O OTHER NRNOT REPORTED 1 CE03442EH 4040202 604103 THIS ENGINE FAILED TO THE TERMINOLOGY OF CATASTROPHIC AT THE NR 1 AND NR 2 CYLINDER CONNECTING ROD LOCATIONS DURING A MAINTENANCE TEST FLIGHT WITHIN TEN MINUTES INTO THAT FLIGHT WITH A MECHANIC ON BOARD MONITORING THE ENGINE INSTRUMENTS. THE OIL PRESSURE SUDDENLY DROPPED TO ZERO, THE PROPELLER STARTED TO FEATHER AND DURING SHUTDOWN AND SECURING, THE ENGINE LOCKED UP. PRIOR TO THIS, THE OIL FILTER WAS REMOVED, CUT OPEN AND INSPECTED WITH NO DEFECTS NOTED. AN OIL SOAP SAMPLE WAS TAKEN. THE OIL PUMP AND AIRCRAFT OIL PRESSURE GAUGE WAS CHECKED FOR A POSITIVE OIL PRIME AND INDICATION. AN EXTENDED ENGINE GROUND RUN WAS DONE AT LOW AND HIGH POWER SETTINGS WITH NO OIL PRESSURE DISCREPANCIES NOTED. THESE CHECKS WE1L72 3O3 ORTA25CE E7CE 20070402001602007040200160GL 2007 4 2 2007FA0000276 120070306G5551 BOLT DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA HORIZ STAB BROKEN D O OTHER O OTHER NRNOT REPORTED 1 NM03921DA C0395 650218 AG5429 AC, RETURN FROM FLIGHT WITH BOTH BOLTS BROKEN; ATTACHING THE FORWARD HORIZONTAL STABILIZER MOUNT BRACKETS. ATT 1) GIVES FLIGHT INFO. ATT 2 AND 3) SHOW THE IPB BRAKE DOWN OF THE BOLTS AND LOCATION FROM MFG PARTS BOOK. ATT 4) PICTURES OF BOLTS AND AIRCRAFT. ATT 5) THE NTSB PAPERWORK. ATT 6) IS SOME EMAIL TRAFFIC. WE REMOVED THE RUDDER AND HORIZONTAL STABILIZER TO INSPECT ENTIRE AREA. WE REPLACE THE AFT MOUNT PLATE AND FORWARD MOUNT BRACKET ALONG WITH ALL NEW BOLTS, WASHERS AND NUTS. WE ALSO INSPECTED OUR OTHER 9 AC AND REPLACED BOTH BOTH ON ALL 9 AC. NO OTHER ISSUES WERE FOUND ON OUR OTHER AC. MFG HAS BEEN BRIEFED AND IS WORKING WITH THE NTSB. (K) 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20070403000322007040300032SO 2007 4 3 2007FA0000288 120070402G532137829007 FLOOR PANEL PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE FUSELAGE DEBONDED D IBIRK NONE O OTHER ININSP/MAINT 1 EA27682JK968 3449154 322291 FLOOR PANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING BRACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEARD ANYTHING AS YET. 1L72 3O3 O A7SO E9CE 20070411000012007041100001SO 2007 4 11 2007FA041101 120070407G7160 AIR BOX PIPER PA18 PA18105SPEC 7101808SO LYC O360 O360* 41514EA CARBURETOR FAILED P O OTHER O OTHER NRNOT REPORTED 1 SO118326 96 7 182341 CARBURATOR AIR BOX AIR FILTER RETAINING SHAFT SHEARED ADJACENT TO FISH MOUNTH WELD AT FORWARD EDGE OF HORIZONTAL PLATE (APPROXIMATELY 1/3 SHAFT LENGTH FROM BASE). AIR FILTER DOME, SHAFT AND RETAINING NUT APPEARANTLY DEPARTED AIRPLANE IN FLIGHT. AIR FILTER WAS FOUND LOOSE IN COWL AIR SCOOP AFTER LANDING. NO OPERATIONAL INDICATIONS AND NO DAMAGE TO PROPELLER, COWL, FUSELAGE OR LANDING GEAR. AIRPLANE COMPLETELY REBUILT 2004. NEW K & N AIR FILTER INSTALLED AT ANNUAL INSPECTION NOVEMBER 2006. PHOTOS AVAILABLE. 1H71 3O3 O 1A2 E286 20070412000062007041200006CE 2007 4 12 FMOR20070001 120070409G323057412025 UPLOCK HOOK CESSNA414 414A 2075907CE CONT O520 TSIO520* 17040SO ZONE 700 CRACKED B O OTHER S AFFECT SYSTEMS CRCRUISE 1 SO156161Z7024 414A0019 PILOT REPORTED THAT THE LANDING GEAR CAME UNHOOKED FROM THE UP POSITION IN FLIGHT. THE GEAR WAS EXTENDED AND THE AIRCRAFT LANDED. THE AIRCRAFT WAS JACKED AND THE GEAR CYCLED TO THE UP POSITION. WHEN ALL (3) UPLOCK SWITCHES WERE MADE THE RT MAIN GEAR FELL FROM THE WHEEL WELL. A DISTORTED AND CRACKED UPLOCK HOOK WAS FOUND. THE CRACK WAS FROM THE CENTER OF THE HOOK TO THE HOLE FOR THE UPLOCK SWITCH. 1L72 3O3 O A7CE E8CE 20070413001112007041300111CE 2007 4 13 FMOR20070002 120070410G2731NAS302665170 CONTROL CABLE BEECH 90 C90A 1152911CE PWA PT6 PT6* 52043EA FS 216 FRAYED B O OTHER S AFFECT SYSTEMS CRCRUISE 1 SO15120TT5072 LJ1073 THE ELEVATOR TRIM CABLE BEGAN UNRAVELING JUST FORWARD OF THE CABIN DOOR. FROM THERE THE CABLE BEGAN BINDING IN A PULLEY UNDERNEATH THE PILOT'S SIDE FORWARD FACING PASSENGER CHAIR CAUSING STIFFNESS OF OPERATION BY HAND AND THE MALFUNCTION OF THE ELECTRIC TRIM SYSTEM LEADING TO THE EVENTUAL INOPERATION OF THE ELEVATOR TRIM. THE ISSUE MOST LIKELY AROSE DUE TO AGE. WHILE UNDER THE SCHEDULED INSPECTION PROGRAM OUTLINED BY MFG THE INSPECTION OF THESE AREAS OCCURS ONCE EVERY (2) YEARS OR 800 HOURS. 1L72 3T3 TRT3A20 E2NE 20070402001272007040200127CE 2007 4 2 2007FA0000224 120070215G282199120154 FUEL FILTER PUROLATOR CESSNA500 500CESSNA 2076602CE PWA JD15 JT15D1A NE RT WING SEPARATED B J7BRO OTHER O OTHER NRNOT REPORTED 1 SW01409S 10045 5000238 76509 THE RT FUEL FILTER ASSY SEPARATED FROM THE STANDPIPE DUE TO THE SNAP-RING BECOMING DISLODGED AND RESULTED IN A SUBSTANTIAL FUEL LEAK. 1L72 4F4 F A22CE E25EA 20070403000332007040300033SO 2007 4 3 2007FA0000289 120070402G532137829007 FLOOR PANEL PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE ZONE 100 DEBONDED D IBIRK NONE O OTHER ININSP/MAINT 1 EA27682JK968 3449154 322291 FLOOR PANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING BRACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEARD ANYTHING AS YET. 1L72 3O3 O A7SO E9CE 20070403000362007040300036SO 2007 4 3 2007FA0000292 120070402G532137829007 FLOOR PANEL PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE ZONE 100 DEBONDED D IBIRK NONE O OTHER ININSP/MAINT 1 EA21682JK968 3449154 322291 FLOORPANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING BRACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. HAVE CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEARD ANYTHING AS YET. 1L72 3O3 O A7SO E9CE 20070403000372007040300037EU 2007 4 3 2007FA0000263 120070321G7600L810BQ54 SOLENOID SNIAS 350 AS350B3 8680954EU TMECA ARRIELARRIEL2B NE AUTO THROTTLE UNSERVICEABLE B N37RK NONE O OTHER ININSP/MAINT 1 SW15186AE189 3872 22484 (REF NR: 186AE-2007-I-0032) WHILE PERFORMING A CHECK OF THE TWIST GRIP SOLENOID, ENGAGED THE SOLENOID BY PLACING THE AUTO/MAN SWITCH TO MAN MODE FOR A TOTAL OF 10 MINUTES. AFTER THE 10 MINUTE PERIOD HAD ELAPSED, RETURNED THE AUTO/MAN SWITCH TO AUTO. AFTER 15 MINUTES MOVED AUTO/MAN SWITCH BACK TO MAN, THE PISTON FROM THE SOLENOID FAILED TO MOVE. THE PISTON SHOULD HAVE RETRACED IMMEDIATELY. PROBABLE CAUSE: SOLENOID OVERHEATING AND MALFUNCTIONING. RECOMMENDATION TO PREVENT RECURRENCE: REPLACING CURRENT PN OF SOLENOID WITH ONE THAT CAN EITHER RUN COOLER OR WITHSTAND THE HEAT. (K) 1G71 3U3 U H9EU E00054EN 20070409000082007040900008SW 2007 4 9 2007FA0000297 120070305G6410HAC473 BLADE BELL 47 47G5 1181032SW LYC O435 VO435* 41516EA TAIL ROTOR DAMAGED B ECGRO OTHER O OTHER NRNOT REPORTED 1 EA131202W 7857 THE STAINLESS STEEL ABRASION STRIP ON THE LEADING EDGE OF THE COMPOSITE TAIL ROTOR BLADE SEPARATED FROM BLADE IN FLIGHT. PILOT NOTED A VIBRATION IN A SPRAY TURN AND ELECTED TO LAND; AND LANDED SAFELY (NO INJURIES). 1G71 3O3 O 2H3 E279 20070409000222007040900022NE 2007 4 9 2007FA0000311 220070305G7314 REGULATOR NAMER T6 AT6D 6400416GL PWA R1340 R1340AN1 52016NE HAMSTD12D 12D40 NE FUEL PUMP STUCK P O OTHER YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 NM038541B THE PRESSURE REGULATOR (IN THE WOBBLE PUMP) STUCK IN THE (BYPASS) POSITION CAUSING LOSS OF FUEL PRESSURE AND POWER LOSS DUE TO LACK OF FUEL. 1L71 3R3 R A2575 5E2 5 CP257 20070416000522007041600052NE 2007 4 16 UE5R1 220070402G72303023401 BLADE PWC BEECH 100 100BEECH 1152916CE PWC PT6 PT6A67AG 52211NE COMPRESSOR DISC CRACKED B UE5RK NONE O OTHER ININSP/MAINT 1 EA61 7P070 COMPRESSOR TURBINE DISC BLADE FAILURE. SINGLE BLADE IN COMPRESSOR TURBINE DISC CRACKED IN FUR TREE AREA OF BLADE. CAUSED MISALIGNMENT OF CT BLADE AND SUBSEQUENT RUB ON SHROUD SEGMENTS. THE CRACK IN FIR TREE WAS NOT VISIBLE WITH ENGINE SPLIT IF PERFORMING A ROUTINE INSPECTION, HOWEVER BLADE MISALIGNMENT AND RUB WERE VISIBLE. THE BLADE CRACK BECAME VISIBLE WHEN CT DISC ASSY WAS REMOVED FROM ENGINE. 1L72 3T4 T A14CE E26NE 20070417000302007041700030GL 2007 4 17 ODAR3 120070411G2421BC4101 ALTERNATOR CIRRUSSR SR22 2130001GL CONT O550 IO550* SO NR 2 DESTROYED B ODARK NONE J WARNING INDICATION ININSP/MAINT 1 EA2115DR 0394 OWNER REPORTED NR 2 ALTERNATOR LIGHT ILLUMINATED. REMOVED TOP COWLING TO INSPECT NR 2 ALTERNATOR. FOUND NR 2 ALTERNATOR BROKEN OFF AT MOUNTING PLATE BY (3) STUDS. ONE STUD STILL ATTACHED WITH NUT, BUT LOOSE. REMOVED P/N BC410-1, S/N 0921403. PICTURES AVAILABLE AT THIS FACILITY. 1L71 3O3 ONTA00009CHE3SO 20070409000332007040900033SO 2007 4 9 AMCR200700001 120070329G2822B12520 PRESSURE SWITCH GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU BOOST PUMP FAILED B AMCRO OTHER J WARNING INDICATION DEDESCENT 1 GL09706VA1267 1528 DURING DESCENT, THE RT MAIN FUEL PUMP FAILED. MAINTENANCE FOUND THAT THE FUEL PRESSURE SWITCH ON THE RT MAIN FUEL PUMP HAD FAILED. THIS IS THE SECOND FAILURE OF A PUMP PRESSURE SWITCH WE KNOW OF WITHIN THE LAST 4 MONTHS. 2L72 4F4 FRTA12EA E25NE 20070409000362007040900036CE 2007 4 9 2007FA0000302 120070403G273165651412 ACTUATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE ELEVATOR TRIM BINDING B K NONE O OTHER ININSP/MAINT 1 SW135314J5592 300 5500663 AFTER A PHASE 1-4 INSPECTION THE ELEVATOR TRIM WAS FOUND TO BE BINDING. INSPECTION OF THIS SYSTEM FOUND THAT THE WILKIE BUTTON IN THE BACK OF THE ACTUATOR TRIM JACK SCREWS HAD COME OUT AND WAS BINDING THE TRIM CHAIN AND SPROCKETS. WHEN THE ACTUATORS ARE LUBED THE WILKIE BUTTONS HAVE A TENDENCY TO POP OUT OF THERE PLACE IF YOU DONT LOOK CLOSELY AFTER LUBING THESE ACTUATORS THE GREASE PUSHES THESE PLUGS OUT AND THEY STICK TO THE INTERCONNECT CHAIN CAUSING A BINDING CONDITION. THIS COULD ALSO HAPPEN IN FLIGHT CAUSING A LIKE CONDITION WITH MORE DIRE PROBLEMS. I THINK MFG SHOULD REMOVE THIS PLUG OR MORE SECURELY FIX THIS PLUG IN PLACE. 1L72 4F4 F A22CE E1NE 20070409001532007040900153NE 2007 4 9 200701 220070328G7210311300001 GEARBOX ACQCORF22 F22 8850908EA PWA JT15 JT15D4 52112NE ACCESSORY G/B MISDRILLED B LM1RK NONE O OTHER ININSP/MAINT 1 EA09 ENGINE WAS ROUTED TO OUR FACILITY FOR OVERHAUL AND DURING A FLUSHING PROCESS WE DISCOVERED A WALL IN AN ACCESSORY GEARBOX WITH A MISDRILLED OIL PASSAGE. THE OIL PASSAGE DID SUPPLY OIL TO THE REQUIRED AREA BUT IT BROKE THROUGH THE WALL DURING THE MANUFACTURING PROCESS RESTRICTING THE OIL SUPPLY. THE ENGINE HAS BEEN OPERATING WITH THIS CONDITION WITH NO APPARENT EFFECT. THE AGB COMPONENTS WAS INSPECTED AND NO DAMAGE WAS FOUND AS A RESULT OF THIS CONDITION. 1H71 3O4 FNC1A9 E1NE 20070424000832007042400083GL 2007 4 24 2007FA0000340 120070419G2720 ARM CIRRUSSR SR20 05628AJGL CONT O550 IO550N 17042SO RUDDER MISRIGGED B LC1RD RETURN TO BLOCK F FLT CONT AFFECTED TXTAXI/GRND HDL 1 EA07636ST 1720 PILOT WAS TURNING ONTO RUNWAY IN CROSSWIND WITH FULL OPPOSITE AILERON AND RUDDER CONTROLS. CONTROLS LOCKED IN CROSSED POSITION AND WOULD NOT RETURN TO NEUTRAL. PILOT RETURNED TO RAMP. INSPECTION FOUND RUDDER/AILERON INTERCONNECT MISRIGGED RESULTING IN THE BOLT CONNECTING THE BUNGEE TO THE RUDDER/AILERON INTERCONNECT ARM LOCKING OVER THE BOLT GOING THROUGH THE FORWARD CABLE CLAMP. IN THE NEUTRAL POSITION, THE DISTANCE FROM THE C/L OF THE ARM IS SUPPOSED TO BE 4.5 INCHES. ON THIS AIRPLANE IT WAS JUST OVER 3 INCHES. THERE WAS NO EVIDENCE OF ANYONE MOVING THE CLAMP OR THE CLAMP SLIDING. RECORDS SHOW THAT THERE WAS NO FLIGHT CONTROL RIGGING DONE SINCE THE AIRCRAFT LEFT THE FACTORY. 1L71 3O3 ONTA00009CHE3SO 20070424000852007042400085GL 2007 4 24 2007FA0000339 120070419G2720 ARM CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO RUDDER MISRIGGED B LC1RK NONE W INADEQUATE Q C ININSP/MAINT 1 EA07927SE 2238 EACH AC THAT CAME INTO THE SHOP WAS INSPECTED FOR THE SAME CONDITION WITH THE AILERON/RUDDER INTERFERENCE. INSPECTION FOUND RUDDER/AILERON INTERCONNECT MISRIGGED RESULTING IN THE BOLT CONNECTING THE BUNGEE TO THE RUDDER/AILERON INTERCONNECT ARM HITTING THE FORWARD CABLE CLAMP AND DEFLECTING THE RT AILERON CABLE. THE CONTROLS DID NOT LOCK BUT THERE WAS DEFINITE INTERFERENCE. IN THE NEUTRAL POSITION, THE DISTANCE FROM THE C/L OF THE ARM IS SUPPOSED TO BE 4.5 INCHES. ON THIS AIRPLANE IT ABOUT 3.75 INCHES. THERE WAS NO EVIDENCE OF ANYONE MOVING THE CLAMP OR THE CLAMP SLIDING. RECORDS SHOW THAT THERE WAS NO FLIGHT CONTROL RIGGING DONE SINCE THE AIRCRAFT LT THE FACTORY. 1L71 3O3 ONTA00009CHE3SO 20070425002472007042500247GL 2007 4 25 2007FA0000337 120070418G2710 CONTROL SYSTEM CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO AILERON SYS OUT OF RIG B K NONE O OTHER ININSP/MAINT 1 EA07636ST 2153 DURING INSPECTION, FOUND AILERON RUDDER INTECONNECT OUT OF RIG AND CAUSING INTERFERENCE BETWEEN RUDDER AND AILERON. THIS IS THE FOURTH AIRCRAFT WE'VE FOUND WITH THIS PROBLEM AND ONE ACTUALLY HAD THE RUDDER AND AILERON LOCK IN FULL OPPOSITE DEFLECTIONS JUST PRIOR TO TAKEOFF. 1L71 3O3 ONTA00009CHE3SO 20070425002582007042500258CE 2007 4 25 2007FA0000334 120070402G531207126161 BULKHEAD CESSNA182 182L 2072726CE CONT O470 O470* 17026SO FUSELAGE CRACKED D K NONE O OTHER ININSP/MAINT 1 WP09420534571 18258832 SMALL CRACK AT RUDDER CABLE CUTOUT IB, APPROX .2500 INCH, NO CAUSE. 1H71 3O3 ONT3A13 E273 20070425002602007042500260CE 2007 4 25 FMOR477K 120070409G323057412025 UPLOCK HOOK CESSNA414 414A 2075907CE CONT O520 TSIO520* 17040SO MLG DISTORTED B O OTHER O OTHER CRCRUISE 1 SO156161Z7024 414A0019 PILOT REPORTED THAT THE LANDING GEAR CAME UNHOOKED FROM THE UP POSITION IN FLIGHT. THE GEAR WAS EXTENDED AND THE AIRCRAFT LANDED. THE AIRCRAFT WAS JACKED AND THE GEAR CYCLED TO THE UP POSITION. WHEN ALL (3) UPLOCK SWITCHES WERE MADE THE RT MAIN GEAR FELL FROM THE WHEEL WELL. A DISTORTED AND CRACKED UPLOCK HOOK WAS FOUND. THE CRACK WAS FROM THE CENTER OF THE HOOK TO THE HOLE FOR THE UPLOCK SWITCH. 1L72 3O3 O A7CE E8CE 20070425002632007042500263CE 2007 4 25 2007FA0000325 120070325G7810 EXHAUST PIPE CESSNA182 182A 2072704CE CONT O470 O470* 17026SO MCAULY2A34C 2A34C203 GL RT EXHAUST BROKEN D O OTHER O OTHER NRNOT REPORTED 1 CE035848B 33848 668686L 891146 RT EXHAUST BROKE AT ELBOW, PART HAD BEEN REPAIRED 544 HRS AGO. DID NOT SHOW ANY CRACK 50 HRS EARLIER. DO NOT REPAIR EXHAUST PARTS THAT HAVE 1000 HRS ON THEM. (K) 1H71 3O3 ONT3A13 E273 5 CP3EA 20070425002732007042500273 2007 4 25 2007FA0000336 420070416G23120464105430 RADIO BOLKMS117 BK117A1 5626010EU LYC LTS101LTS101650B1 41560NE NR 2 COMM SHORTED E BAQRK NONE B SMOKE/FUMES/ODORS/SPARKS AAAIR AMBULANCE 1 EA03952CJ S7052 WHILE SHUTTING DOWN AIRCRAFT THE CREW NOTED A WHIFF OF SMOKE AND ELECTRICAL SMELL IN THE COCKPIT. FOUND THE NR (2) COMM RADIO INTERNALLY SHORTED. 1G72 3U3 U H13EU E5NE 20070410000682007041000068NM 2007 4 10 QXEANM09402 120070315G4920164161100 DRAIN VALVE SUNDSTRANDEM BOMBDRDHC8 DHC8402 1390042NM PWC 150 PW150A EA APU MISINSTALLED G K NONE O OTHER ININSP/MAINT 1 NM09402QX 4032 BALL ON WRONG SIDE OF SPRING, WHICH ALLOWS IT TO REST IN CLOSED POSITION, NOT ALLOWING PROPER DRAINAGE. 2H72 4T4 TRTA13NM E00062EN 20070412000272007041200027EU 2007 4 12 2007FA0000229 120070308G2820653014 VALVE ISRAEL1124 1124A 4500103EU GARRTTTFE731TFE731* 01518WP RT LWR FUEL CELLCRACKED B JGVRO OTHER O OTHER NRNOT REPORTED 1 CE09328PC8597 328 CRACK IN INTERCONNECT VALVE MOTOR HOUSING. FOUND DURING BAG REMOVAL AND REINSTALLATION. CAUSE OF CRACK, UNKNOWN. (K) 2M72 4F4 F A2SW E6WE 20070425002592007042500259SO 2007 4 25 2007FA0000342 220070421G8520655910 CONNECTING ROD CONT TSIO520E CESSNA402 402B 207590PCE CONT O520 TSIO520E 17040SO MCAULY3AF34C3AF34C* GL RT ENGINE FAILED E E ENGINE SHUTDOWN E VIBRATION/BUFFET CLCLIMB 1 NM058FB 176257 402B1372 176257 DURING CLIMB AFTER THE POWER HAD BEEN REDUCED FROM THE TAKEOFF SETTING, THE RT ENGINE STARTED TO VIBRATE. THE PILOT COULD SEE OIL SPLASHING FROM AROUND THE OIL ACCESS DOOR AND RUNNING BACK ON THE TOP COWLING. THE PILOT SHUTDOWN THE ENGINE AND FEATHERED THE RT PROPELLER. THE PILOT RETURNED TO THE DEPARTURE AIRPORT AND LANDED WITHOUT FURTHER INCIDENT. UPON INITIAL INVESTIGATION, A LARGE HOLE WAS FOUND IN THE CRANKCASE ABOVE THE NR 4 ROD JOURNAL. THE NR 4 CONNECTING ROD WAS SEPARATED FROM THE CRANKSHAFT AND PROTRUDING FROM THE HOLE IN THE CASE. THE NR 4 CONNECTING ROD CAP WAS ALSO SEPARATED FROM THE CONNECTING ROD AND WAS STICKING UP OUT OF THE HOLE. 1L72 3O3 O A7CE E8CE 5 CP22EA 20070426002672007042600267 2007 4 26 2007FA0000346 420070122G3417702490031304 ADC LEAR 35 35A 5170602CE GARRTTTFE731TFE731* 01518WP MALFUNCTIONED B O OTHER O OTHER NRNOT REPORTED 1 GL07813AS 167 DURING PRE-FLIGHT, THE CREW NOTED THAT THE PILOTS ALTIMETER AND ALTITUDE ALERTER WERE FLAGGED. ATTEMPTS TO RECYCLE THE SYSTEM WERE NOT SUCCESSFUL. THE CREW GROUNDED THE AIRCRAFT. AN AVIONICS TECH WAS DISPATCHED TO THE AIRCRAFTS LOCATION AND DETERMINED THAT THE ADC HAD FAILED. THE ADC WAS REPLACED. THE SYSTEM WAS TESTED AND INSPECTED AND FOUND TO COMPLY WITH FAR 91.411, PART 43 AND TO REMAIN RVSM COMPLIANT. (K) 2L72 4F4 F A10CE E6WE 20070501000852007050100085CE 2007 5 1 OMKR20071 120070331G323008420003 DRAG LINK CESSNA310 310C 2074210CE CONT O470 IO470* 17026SO NLG BROKEN B OMKRO OTHER O OTHER LDLANDING 1 NM034411 39024 UPON LANDING, THE NOSE LANDING GEAR DRAG LINK ASSEMBLY P/N 0842000-3 BROKE AT THE STRUT ATTACH POINT, ALLOWING THE NOSE GEAR TO COLLAPSE REARWARD, CAUSING THE AIRCRAFT TO SLIDE ON ITS NOSE UNTIL IT STOPPED. THE DRAG LINK ASSEMBLY APPEARS TO HAVE BROKEN THROUGH THE FORWARD ATTACH HOLE. TOTAL TIME OF THE PART AND TOTAL TIME OF THE AIRCRAFT ARE UNKNOWN AT THIS TIME DUE TO ABSENCE OF LOG BOOKS. CURRENT HOBBS TIME IS 118.4. 1L72 3O3 O 3A10 E1CE 20070503000022007050300002CE 2007 5 3 CA070329005 120070329G2560110195203 BUCKLE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE SEATBELT INTERFERENCE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CONTROL YOKE INTERFERENCE WITH ROTORY SEAT BUCKLES INSPECTED IAW INTERNAL CAMPAIGN NOTICE 010-25-10-011. OPERATION OF EITHER PILOTS AND CO-PILOTS YOKES WITH SEATS FULL FORWARD CONFIRMS THAT INTERFERENCE CAN CAUSE UNLATCHING OF THE SEATBELT ROTARY BUCKLES. (TC NR 20070329005) 1L72 4F4 F A22CE E1NE 20070503000032007050300003SO 2007 5 3 CA070329006 220070313G8530 CYLINDER CESSNA150 150L 2071826CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL NR 4 DETACHED W A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 CA 1587 (CAN) ENGINE VIBRATION AND POWER LOSS IN FLIGHT, ENGINE CAME TO TOTAL STOP ON TAXIWAY. CYLINDER NR 4 FOUND DETACHED. ENGINE (2587.4 HOURS). ENGINE REMOVED FOR OVERHAULED. (TC NR 20070329006) 1H71 3O3 O 3A19 E252 5 NP918 20070503000042007050300004CE 2007 5 3 CA070329009 120070329G2897 WIRE BEECH B300 B300 1159232CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL SHUTOFF VALVE CHAFED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CRCRUISE 1 CA 434 (CAN) 5 AMP ANNUNCIATOR INDICATION (CB4) POPPED IN FLIGHT AND THE CREW LOST THE GREEN AND WHITE ANNUNCIATOR LIGHTS. THE CREW ATTEMPTED TO RESET THE 5 AMP CIRCUIT BREAKER, BUT COULD NOT BE RESET. PROBLEM WAS IN FOUND ON WIRE PIN D WIRE NR Q62A20 ON THE RT FUEL SHUTOFF VALVE HAD CHAFED TO GROUND ON ONE OF THE SCREWS THAT HOLDS ON THE INSPECTION PANEL ON. DID A REPAIR ON WIRE NR Q62A20 AND THE SYSTEM WAS FUNCTION TESTED NORMAL. (TC NR 20070329009) 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20070503000052007050300005NE 2007 5 3 CA070330005 220070326G7261 ENGINE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE RIGHT MAKING METAL W D RETURN TO BLOCK J WARNING INDICATION TXTAXI/GRND HDL 1 CA 144916131 PS0149 (CAN) PILOTS LOADED PAX DEPARTED THE GATE. AFTER RECEIVING TAXI CLEARANCE THE PILOT NOTICED THE RIGHT LOW OIL PRESSURE WARNING LIGHT,THE AIRCRAFT WAS TURNED AROUND AND THE ENGINE SHUTDOWN. THE AIRCRAFT RETURNED TO THE GATE AND THE PASSENGERS UNLOADED. THE AIRCRAFT WAS TOWED BACK TO THE MAINTENANCE HANGER AND INSPECTED. WHEN THE OIL FILTER WAS REMOVED THERE WAS A LARGE AMOUNT OF SILVER COLORED MAGNETIC PARTICLES IN THE FILTER. THE ENGINE HAS BEEN REMOVED AND WILL BE SENT BACK TO MFG FOR INSPECTION/OVERHAUL, (TC NR 20070330005) 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20070503000082007050300008NM 2007 5 3 CA070402001 120070329G6120666000459 CONTROL UNIT BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 2 PROPELLER MALFUNCTIONED W EA ENGINE SHUTDOWN UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) DURING LEVEL FLIGHT FL. 250, ENGINE NR 2 PROPELLER SPEED WENT TO 1051 RPM, FOLLOWED BY POWERPLANT ON ED. THIS CASE WAS TREATED AS AN OVERSPEED AND QRH CONSULTED, ENDING UP WITH ENGINE SHUTDOWN, ON NR 2 ENGINE. EMERGENCY DECLEARED AND A NORMAL DESCENT TOWARDS BASE WAS INITIATED. LANDING PERFORMED AND TAXI TO REMOTE GATE WAS DONE. MAINTENANCE ARRIVED AND FOUND FAULT CODE 160 CH A AND B. FIM TASK 61-20-04-810-813 PERFORMED. NO CONTACT WITH MPU AND BUSS BARS. REMOVE AND REPLACED MPU. (TC NR 20070402001) 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20070503000192007050300019EU 2007 5 3 CA070402003 120070322G2917973811430 PRESSURE SWITCH PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL HYD SYSTEM LEAKING W K NONE O OTHER ININSP/MAINT 1 CA 165 (CAN) DURING INSPECTION IT WAS NOTED THAT THIS HYDRAULIC PRESSURE SWITCH WAS LEAKING FLUID AT THE SWAGED SEEM OF THE SWITCH. THE SWITCH WAS REPLACED WITH NEW. (TC NR 20070402003) 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20070503000232007050300023EU 2007 5 3 CA070402004 120070330G7700304544902 CHIP DETECTOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 6574 (CAN) WHEN THE CONNECTOR WAS REMOVED FROM THE CHIP DETECTOR AT INSPECTION, IT WAS NOTED THAT ONE OF THE PINS OF THE CHIP DETECTOR HAD BROKE, AND STAYED IN THE CONNECTOR. THE CHIP DETECTOR WAS REPLACED. (TC NR 20070402004) 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20070417001342007041700134CE 2007 4 17 CWQR200702 120070416G541065526022 FLANGE CESSNA500 560CESSNA 2076750CE PWA 530 PW535A NE NACELLE CRACKED B DXTAK NONE O OTHER ININSP/MAINT 1 GL05820QS2627 5600650 DURING A PHASE 1-4 INSPECTION A 2.5 INCH CRACK WAS FOUND ON THE ENGINE INLET FLANGE, THIS CRACK PASSES THROUGH (2) FASTENERS THAT ATTACH THE INLET TO THE FLANGE. AND ARE AT THE 3 O'CLOCK POSITION ON BOTH THE LT AND RT ENGINES. 2L72 4F4 FRTA22CE E00053EN 20070503000332007050300033 2007 5 3 CA070403003 420070321G61223020094 DRIVE GEAR WOODWARD GARRTTTPE331TPE331* 01514WP PROPELLER GOV MAKING METAL W K NONE O OTHER ININSP/MAINT 1 CA 1754695 (CAN) CONSTANT SPEED, SINGLE ACTING PROPELLER GOVERNOR P/N 895490-10 WAS RECEIVED AT MFG WITH REPORTED PROBLEM CUSTOMER RETURNED ON IN TRANSIT B69894 AND IRR NR 5170 STATING PROP GOVERNOR HAS NO RESET PRESSURE AND SHAFT STICKS AND WILL NOT RETURN TO MINIMUM STOP. THE FAULT WAS NOT CONFIRMED BY AN EXTERNAL VISUAL INSPECTION. A (RUN AS RECEIVED) WAS PERFORMED AND THE FOLLOWING WAS NOTED: ( PUMP CAPACITY WAS 7.8 QPM, SHOULD HAVE BEEN 9.0 QPM ) RELIEF VALVE PRESSURE WAS 440 PSI, SHOULD HAVE BEEN 465 +/- 20 PSI MAGNETIC PICKUP WAS 3.2 VOLTS AT 3700 RPM, SHOULD HAVE BEE 4.5 +/- 0.2 VOLTS THE UNIT WAS SYSTEMATICALLY DISASSEMBLED IAW COMPONENT MM (CMM 33091C, 1986), AND SIGNIFICANT DAMAGE WAS FOUND TO SEVERAL INTERNAL 3 T E2WE 20070503000342007050300034SO 2007 5 3 CA070403004 120070331G3250AN3H7A ATTACH BOLT PIPER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL STEERING ARM SHEARED W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 CA (CAN) DURING T/O ROLL DEPARTING CREW ABORTED T/O DUE A VIBRATION AND PULLING TO THE RIGHT. A/C TAXIED OFF RUNWAY, SHUTDOWN AND CREW VISUALLY INSPECTED A/C, NO DEFECTS NOTED. TAXIED BACK TO HANGER, MTCE WAS NOTIFIED. MAINTENANCE INSPECTION REVEALED (2) STEERING ARM ATTACH BOLTS SHEARED. NLG INSPECTED FOR OVER STEERAGE FROM GROUND HANDLING, NO OBSERVED DEFECTS NOTED. STEERING BOLTS REPLACED WITH NEW AND SYSTEM/TRAVEL/LANDING GEAR FUNCTION TESTS C/W . (TC NR 20070403004) 1L72 3O3 O A20SO E14EA 5 CP33EA 20070503000372007050300037GL 2007 5 3 CA070404002 120070402G5511C2TP39ND RIB DHAV DHAV DHC2 DHC2MKI 2801830GL PWA R985 R985AN14B 52008NE HARTZLHCB3R HCB3R304 GL HORIZONTAL STAB CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 112 (CAN) DURING MAIN SPAR REPLACEMENT AFTER COMPLETION OF SB 2/47, A SINGLE NOSE RIB WAS FOUND TO BE HEAVILY CORRODED. AIRCRAFT TT 22235.0. THE AIRCRAFT OPERATES ON FLOATS IN A CORROSIVE ENVIRONMENT. PREVIOUS CORROSION TREATMENT WAS NOT IN EVIDENCE (TC NR 20070404002) 1H71 3R3 RRCA806 5E1 5 CP28EA 20070503000382007050300038EA 2007 5 3 CA070404003 120070403G2797UK WIRE HARNESS CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE RUDDER POSITION DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA 30222 (CAN) DURING AN INSPECTION, THE RUDDER POSITION TRANSMITTER HARNESS WAS FOUND TO BE DAMAGED. THE CAUSE OF THE DAMAGE WAS FOUND TO BE IMPROPER ROUTING BY COMPARING WITH ANOTHER A/C S/N 7163. THE ACTUAL ROUTING DRAWING WHERE REQUESTED FROM BOMBARDIER AND THE HARNESS WILL BE REPAIRED AND REROUTED PROPERLY. (TC NR 20070404003) 2L72 4F4 FRTA21EA E15NE 20070504001182007050400118EA 2007 5 4 CA070404011 120070330G490038004883 APU CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE FAILED W F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA 4510 (CAN) TECHNICIAN WAS TROUBLESHOOTING THE APU FOR APU AUTO SHUTDOWN, LOSS OF APU DOOR POSITION ON STATUS PAGE. ECU CODE: 109,224,91 MAINTENANCE FOUND THE ELECTRICAL CONNECTOR FOR OIL TEMP SENSOR PARTIALLY INSTALLED ( CODE 91). RESECURED THE CONNECTOR AND PROCEEDED TO START THE APU. AT THAT TIME NO FUEL LEAK / OIL LEAK WERE NOTED IN THE APU ENCLOSURE. START THE APU WITH NO PROBLEM AND WITH BOTH A/C PACKS RUNNING, A STRONG SMELL OF FUEL IN THE COCKPIT AND GALLEY AREA WAS NOTED. SOME FUEL ON THE GROUND AT THE DRAIN AREA WAS NOTED. SHUTDOWN THE APU, CLIMBED IN THE AFT EQUIPMENT BAY, START TO OPEN THE OIL SERVICING PANEL ONCE A FEW FASTENERS WERE LOOSE THEN A FIRE FLARED UP. ASKED THE CREW TO DISCHARGE THE ONBOAR2L72 4F4 FRTA21EA E15NE 20070504001202007050400120EA 2007 5 4 CA070405005 120070405G2120C6VF11531 FLAPPER VALVE DHAV DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA RAM AIR DUCT OBSTRUCTED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA 14 (CAN) THE RAM AIR FLAPPER VALVE, P/N C6VF1153-1, BECAME JAMMED IN IT`S DUCT. ATTEMPTS BY THE PILOT TO RECTIFY THE PROBLEM BY MOVING THE CONTROL LEVER BACK AND FORTH RESULTED IN THE CONTROL CABLE, P/N 130-032A22.75B29.0, BECOMING KINKED AND UNSERVICEABLE. DIS-ASSEMBLY OF THE SYSTEM REVEALED THAT THE RUBBER-LIKE MATERIAL USED TO SEAL THE PERIMETER OF THE FLAPPER VALVE HAD BECOME DISTORTED AND ENLARGED, POSSIBLY DUE TO EXPOSURE TO HEAT. THIS CAUSED THE SEAL TO CONTACT THE INNER WALLS OF THE DUCT BEFORE THE FLAPPER WAS AT A 90-DEGREE ANGLE TO THE DUCT, IE: BEFORE THE FLAPPER WAS IN THE CLOSED POSITION. REMOVAL AND REPLACEMENT OF THE DAMAGED CABLE AND FLAPPER VALVE REQUIRED REMOVAL AND REPLACEMENT OF MUCH OF THE A1H72 3T4 TRTA9EA E4EA 20070504001232007050400123EA 2007 5 4 CA070405008 120070405G3220713381 TORQUE LINK DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL NLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LOWER TORQUE LINK CRACKED AT ATTACHMENT LUG TO UPPER TORQUE LINK. CRACK FOUND ON ROUTINE MAINTENANCE INSPECTION (TC NR 20070405008) 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20070504001252007050400125NM 2007 5 4 CA070407001 120070404G5280 DOOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE NLG DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA 4480344803 (CAN) MAINTENANCE CARRIED OUT A LIGHTENING STRIKE INSPECTION IAW AMM 05-50-31 AND DAMAGE WAS NOTED ON THE RT FWD NOSE GEAR DOOR, BURN AND PITTING MARKS ON BELLY FUSELAGE AND LT ELEVATOR STATIC WICK WAS BURNED OFF. NDT WAS CARRIED OUT AND THE BELLY SKIN WAS REPAIRED IAW MFG RD8-53-9556 ISSUE 1, TEMP REPAIR FOR 1000 HRS. THE ELEVATOR TIP FAIRING FASTENERS WERE REPLACED IAW SRM AND THE STATIC WICK WAS REPLACED AND BONDING CHECKS WERE CARRIED OUT. RT NOSE GEAR DOOR A SCREW WAS REPLACED. ALL SYSTEMS AND FLIGHT CONTROLS FUNCTION CHECKED SERVICEABLE AND THE A/C WAS RETURNED TO SERVICE. (TC NR 20070407001) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070504001332007050400133 2007 5 4 2007FA0000370 420070427G2562MN1300 BATTERY ACK PIPER PA28 PA28236 7102815SO LYC O540 O540J3A5 41532EA HARTZLHCF2Y HCF2YR1 GL ELT LEAKING D K NONE K FLUID LOSS ININSP/MAINT 1 EA01 12 020150 28791146 L2113440A CM285 BATTERIES LEAKED ACID/ALKALII, CORRODING CONTACTS SERVERLY AND RENDERING ELT INOPERABLE. BATTERIES WERE INSTALLED IN 2006. SHELF DATE ON BATTERIES WERE MAR 2011. ELT WAS NOT FOUND ACTIVATED. THIS IS THE THIRD CASE OF THIS I HAVE SEEN IN 2006/2007 AND THERE HAVE BEEN SEVERAL OTHERS IN THE PAST 5 YEARS. IN ALL CASES THE BATTERIES RENDERED THE ELT INOP PRIOR TO THE REPLACEMENT DATE (HALF OF SHELF LIFE IAW FAR 91.207 (C)). ALL PROBLEMS WERE DETECTED DURING ANNUAL INSPECTIONS OF ELT IAW FAR 91.207 D. 1L71 3O3 O 2A13 E295 5 CP27EA 20070504001342007050400134 2007 5 4 2007FA0000371 420070427G2562MN1300 BATTERY ACK PIPER PA28 PA28236 7102815SO LYC O540 O540J3A5 41532EA HARTZLHCF2Y HCF2YR1 GL ELT LEAKING D K NONE K FLUID LOSS ININSP/MAINT 1 EA01 12 020150 28791146 L2113440A CM285 BATTERIES LEAKED ACID/ALKALII, CORRODING CONTACTS SERVERLY AND RENDERING ELT INOPERABLE.BATTERIES WERE INSTALLED IN 2006. SHELF DATE ON BATTERIES WERE MAR 2011. ELT WAS NOT FOUND ACTIVATED. THIS IS THE THIRD CASE OF THIS I HAVE SEEN IN 2006/2007 AND THERE HAVE BEEN SEVERAL OTHERS IN THE PAST 5 YEARS. IN ALL CASES THE BATTERIES RENDERED THE ELT INOP PRIOR TO THE REPLACEMENT DATE (HALF OF SHELF LIFE I/A/W FAR 91.207 (C)). ALL PROBLEMS WERE DETECTED DURING ANNUAL INSPECTIONS OF ELT I/A/W FAR 91.207 D. 1L71 3O3 O 2A13 E295 5 CP27EA 20070504001382007050400138NM 2007 5 4 2007FA0000228 120070306G3260 SENSOR BOEING747 747230B 1384889NM GE CF6 CF650* 30018NE MLG MALFUNCTIONED B GJPYO OTHER O OTHER NRNOT REPORTED 1 WP33760SA 21221 DURING TAKEOFF, THE LANDING GEAR HANDLE WILL NOT GO TO UP OR RETRACT POSITION. AIRCRAFT RETURNED TO BASE. PERFORMED TROUBLESHOOTING ON THE LANDING GEAR SYSTEM AND FOUND THAT LT WING GEAR TRUCK ROTATION SENSOR AT FAULT. ADJUSTED THE LT WING GEAR TRUCK ROTATION SENSOR IAW AMM 32-61-04. PERFORMED LANDING GEAR SYSTEM EXTENSION AND RETRACTION SEVERAL TIMES IAW AMM 32-32-00/501, TEST NORMAL. (K) 2L74 4F4 F A20WE E23EA 20070504001402007050400140GL 2007 5 4 2007FA0000324 120070317G3240 PLATE TCRAFTBC BC12D 8850316GL CONT O200 O200A 17020SO MCAULY1A100 1A100* GL LT BRAKE LOOSE D O OTHER O OTHER NRNOT REPORTED 1 GL15433361669 6995 666377A G1885 WHEN BRAKES WERE APPLIED AFTER LANDING. IT APPEARS THAT THE PINS HOLD THE BACK PLATE ALLOW IT TO SHIFT ENOUGH TO HAVE POSSIBLY MADE CONTACT WITH THE BRAKE ACCUATOR ARM AND NOT ALLOW IT TO RELEASE. (K) 1H71 3O3 O A696 E252 5 NP918 20070504001412007050400141CE 2007 5 4 2007FA0000294 120070222G36101H1069 MIXING VALVE LEAR 60 60LEAR 5170707CE PWA 305 PW305 NE LT ENGINE INTERMITTENT C O OTHER O OTHER NRNOT REPORTED 1 GL11500 83 306 SHORTLY AFTER TAKEOFF, AIRCRAFT (LT BLEED AIR) WARNING ILLUMINATED, AND (RT BLEED AIR) WARNING ILLUMINATED APPROX 5 SEC LATER, SMELLED ODOR IN MAINTENANCE. UNABLE TO DUPLICATE MALFUNCTION ON GROUND RUN; LT MIXING VALVE WAS SUSPECTED, SO REPLACED. PERFORMED GROUND RUN FUNCTIONAL TEST OF BLEED AIR SYSTEM, AND FLIGHT TEST. NO FURTHER BLEED AIR WARNINGS. (K) 2L72 4F4 FRTA10CE E35NE 20070504001452007050400145SO 2007 5 4 2007FA0000298 120070320G2400100201021346 INVERTER GULSTMGVSP GVSPG550 3980203SO GE CF34 CF343A 30066NE SHORTED D O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 GL055PG 1383 5046 WHEN TURNING MAIN BATTERY SWITCHES ON, MECHANIC HEARD A LOUD POPPING SOUND, FOLLOWED BY THE AROMA OF SMOKE IN THE ENTRANCE AREA OF THE AIRCRAFT. THE FLOORBOARD WAS REMOVED AND FOUND THAT WATER FROM THE FORWARD LAVATORY AREA HAD BEEN RUNNING ONTO THE TOP OF THE EMERGENCY INVERTER CAUSING H2O AND AC VOLTAGE TO MEET (H2O WON). THE LAV AREA ON BOTH OF OUR AC WERE INSPECTED FOR LEAKS AND FOUND AREAS WHERE WATER HAD BEEN SITTING, EVEN THROUGH THERE WERE NO LEAKS. IT IS POSSIBLE THAT WHEN STOWING THE SINK (HINGED AND FOLDS UP INTO A CLOSEOUT) RESIDULE WATER IS DUMPING INTO THE CLOSEOUT. THE INVERTER WAS REPLACED AND WE SHUT THE WATER SUPPLY OFF FOR THE FORWARD LAY SINK ON BOTH. THERE IS NO PREFLIGHT OR SCHEDULED 2L72 4F4 FRTA12EA E15NE 20070504001532007050400153 2007 5 4 2007FA0000372 420070502G2562MN1300 BATTERY AMERIKING CESSNA182 R182 2072734CE LYC O540 O540J3C5 41532EA ELT LEAKING D K NONE K FLUID LOSS ININSP/MAINT 1 EA01 12 12 353328 01165 BATTERIES LEAKED INSIDE ELT UNIT PREVENTING ELT OPERATION AND DESTROYING CONTACTS INSIDE UNIT. THIS IS ONE OF SEVERAL TIMES THIS PROBLEM HAS BEEN SEEN IN THE NEWER OR MORE RECENTLY MANUFACTURED BATTERIES THIS PARTICULAR SET HAD AN EXPIRATION OF 2012 AND HAD ONLY BEEN INSTALLED IN THE UNIT FOR ONE YEAR. RECOMMEND BAT REPLACEMENT EVERY 6 MONTHS UNTIL THIS PROBLEM IS ADDRESSED BY ELT MANUFACTURES OR THE BATTERY COMPANY NOTE OLDER BATTERIES DID NOT EXHIBIT THIS PROBLEM. 1H71 3O3 ORT3A13 E295 20070504001542007050400154CE 2007 5 4 2007FA0000359 120070403G551012320131 FITTING CESSNA207 T207A 2073614CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C401 GL STABILIZER CRACKED D O OTHER O OTHER NRNOT REPORTED 1 WP07803AN11657 20700570 248811R 765815 FWD RT STABILIZER FITTING CRACKED. FOUND CRACKED FITTING UPON ANNUAL INSPECTION OF EMPENNAGE. (K) 1H71 3O3 O A16CE E8CE 5 CP47GL 20070504001652007050400165CE 2007 5 4 2007FA0000222 120070215G282199120154 FUEL FILTER CESSNA500 500CESSNA 2076602CE PWA JD15 JT15D1A NE RT WING SEPARATED D J7BRO OTHER O OTHER NRNOT REPORTED 1 SW01409S 10045 5000238 THE RT FUEL FILTER ASSY SEPARATED FROM THE STANDPIPE DUE TO THE SNAP-RING BECOMING DISLOGED AND RESULTED IN A SUBSTANTIAL FUEL LEAK. (K) 1L72 4F4 F A22CE E25EA 20070504001682007050400168EU 2007 5 4 2007FA0000329 120070406G5510T700A5530072102 FITTING SOCATATBM TBM700 8682000EU PWA PT6 PT6A64 EA HARTZLHCE4N HCE4N3 NE STABILIZER CORRODED D O OTHER O OTHER NRNOT REPORTED 1 EA05704QD5980 188 PCEPM0073 HH463 DURING A 6000HR/10 YEAR CORROSION INSPECTION AD2007-06-11 WAS BEING COMPLIED IAW AD AND MANDATORY SB70-104, AMENDMENT 2. AFTER COMPLETING THE PENETRANT INSPECTION, NO CRACKS WERE DETECTED IN THE SPECIFIED AREAS HOWEVER THE FITTINGS LISTED IN BLOCK 5 WERE REMOVED FROM SERVICE FOR LIGHT PITTING CORROSION. RECENTLY IN OUR FACILITY, THERE WAS A LEVEL 3 NDT RECURRENT COURSE BEING GIVEN AND THE REMOVED FITTINGS WERE CRACK CHECKED USING A ROTARY TOOL FOR BOLT HOLE EDDY CURRENT SET UP ON /030 CORNER EDM NOTCH AS A REFERENCE STANDARD. AT THIS TIME THERE WERE CORROSION PITTING CRACKS DETECTED IN BOTH FITTINGS. THE INSPECTION CRITERIA STATED IN AD AND SB ARE INSUFFICIENT FOR CRACK DETECTION IN THIS AREA. POSSIBLY THE1L71 3T4 TRTA60EU E4EA 5 CP10NE 20070504001862007050400186CE 2007 5 4 2007FA0000348 120070330G3240 LINE CESSNA170 170B 2072306CE CONT C145 C145* 17012SO BRAKE CHAFED D O OTHER O OTHER NRNOT REPORTED 1 WP094696C2611 25640 DURING AN ANNUAL INSPECTION, THE RT BRAKE SUPPLY LINE WAS FOUND CHAFED BY THE ELEVATOR CONTROL CABLE. THE CHAFING OCCURRED WHEN THE ELEVATOR IS OPERATED NEAR THE (UP) LIMIT OF TRAVEL. THE LOCATION OF CHAFE IS VIEWED DIRECTLY BELOW THE ELEVATOR TRIM WHEEL, LOOKING SLIGHTLY FORWARD. THE BRAKE TUBE WAS NOT SUPPORTED BY ANY CLAMPING MEANS TO SECURE THE TUBE. A REPLACEMENT TUBE WAS FABRICATED AND INSTALLED WITH ADEQUATE CLAMPING TO INSURE NO FURTHER CHAFING ACTION. THE BRAKE WAS SERVICED AND A SATISFACTORY LEAK CHECK WAS ACCOMPLISHED. THE ELEVATOR CONTROL CABLE WAS CHECKED FOR DAMAGE AND IS ACCEPTABLE FOR SERVICE. PHOTOS DETAILING THE CHAFED AREA AND MFG IPC FOR INSTALLATION DETAIL. (K) 1H71 3O3 O A799 E253 20070504001902007050400190SO 2007 5 4 2007FA0000331 220070404G7200629340 ROD BOLT CESSNA310 310R 2074245CE CONT O520 IO520MB 17032SO LT ENGINE BROKEN D O OTHER O OTHER NRNOT REPORTED 1 GL232641D740 310R1678 829015R PRELIMINARY INSPECTION FINDINGS: IN FLIGHT, LT ENGINE FAILURE ON CLIMB OUT. LT ENGINE HAD 737.1 HOURS AND PUT IN SERVICE 05/2003. LARGE HOLE IN CASE AROUND NR 5 AND 6 CYLINDER. NR 5 ROD SEPARATED FROM CRANK AND BROKEN IN TWO PIECES A FEW INCHES FROM PISTON PIN. SUBSEQUENT FINDINGS FROM ENGINE TEARDOWN REPORT PERFORMED BY MFG. THE SIGNATURES PRESENT ON THE NR 5 CYLINDER BORE AND THE DAMAGE TO THE NR 5 CONNECTING ROD ARE CONSISTENT WITH A HYDROSTATIC LOCK EVENT. PRELIMINARY INFORMATION WAS BASED ON A SB CE-00-07, AND SDR REPORTS ISSUED BETWEEN 1995 AND PRESENT, ON SAME MODEL ENGINE WITH SIMILAR BOLT FAILURES. (K) 1L72 3O3 O 3A10 E5CE 20070504001982007050400198SO 2007 5 4 2007FA0000332 220070401G8500 SNAP RING CESSNA180 180A 2072604CE CONT O470 IO470* 17026SO ENGINE MISMANUFACTURED D O OTHER O OTHER NRNOT REPORTED 1 AL034145 32840 CS76646PF SNAP RING USED TO RETAIN PLATE PN 643629 AND COUNTERWEIGHT PIN 643626-101 WAS BEING INSTALLED IN COUNTERWEIGHT. UPON INSTALLING, THE LAST SNAP RING, IT WAS NOTICED THAT THE SNAP RING DID NOT HAVE ANY RETAINING PROPERTIES. IT LACKED TEMPER TO SPRING BACK AND COULD BE FORMED INTO ANY POSITION WHICH COULD HAVE ALLOWED THE PLATE AND PIN TO FALL OUT OF THE COUNTERWEIGHT CAUSING ENGINE FAILURE.. THE SNAP RING WAS PURCHASED ON 12 MARCH, 2007. THE BATCH NR LISTED FOR THE SNAP RING WAS 0000070137 UNDER API`S PO NR 4500018586. (K) 1H71 3O3 O 5A6 E1CE 20070504002042007050400204 2007 5 4 2007FA0000345 420070117G3417702490031304 ADC LEAR 35 35A 5170602CE GARRTTTFE731TFE731* 01518WP LT AVIONICS BAY MALFUNCTIONED B O OTHER N FALSE WARNING NRNOT REPORTED 1 GL07700SJ 082 WHILE ENROUTE, THE PILOTS ALTIMETER (FROZE UP) AT ABOUT 8000 FT AND THE OVERSPEED HORN WENT OFF. THE PILOT RECYCLED THE ADC AND ITS OPERATION WAS RESTORED. THE ADC WAS TESTED AND NO DEFECTS WERE FOUND. THERE WAS NO EVIDENCE OF WATER OR MOISTURE IN OR AROUND THE ADC. THE ADC WAS REPLACED AND TESTED. THERE HAS BEEN NO PREVIOUS REPORTED FAILURES OF THIS SYSTEM IN THIS AIRCRAFT. (K) 2L72 4F4 F A10CE E6WE 20070504002052007050400205GL 2007 5 4 2007FA0000285 220070319G732323065121 GOVERNOR HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE FROZEN B EOORK NONE O OTHER ININSP/MAINT 1 AL03CGPHC 293 180257D DURING AN INSPECTION IT WAS NOTED THAT THE BEAING RETAINING WASHER FOR THE ROD END WAS INCORRECT. AFTER THE BOLT WAS REMOVED IT WAS THEN DISCOVERED THAT THE THROTTLE ARM WAS SEIZED UP ON THE GOVERNOR, REPLACED GOVERNOR. (K) 1G71 3U3 U H3WE E4CE 20070504002132007050400213CE 2007 5 4 2007FA0000366 120070412G7921652065 GASKET CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO OIL COOLER BROKEN D O OTHER O OTHER NRNOT REPORTED 1 CE0142776322 421B0394 607077 AIRCRAFT DEPARTED ON A CHARTER , PILOT WAS OVER LAKE WHEN HE NOTICED ENGINE OIL COMING OUT OF TOP ENGINE COWLING COOLING LOUVERS. PILOT NOTIFIED CONTROL HE WAS LOSING OIL. FEATHERED THE RT ENGINE AND DIVERTED . PILOT MADE UNEVENTFUL SINGLE ENGINE LANDING AND TAXIED TO MAINTENANCE HANGAR. DISCOVERED THE ENGINE WAS SEIZED AND THE COWLING AND NACESSE BOTTOM COVERED WITH OIL. STARTED DISASSEMBLY AND FOUND THE OIL COOLER GASKET, PN 652065, HAD .1250 INCH SECTION MISSING FROM THE UPPER FORWARD AREA OF THE GASKET. (K) 1L72 3O3 O A7CE E7CE 20070507000232007050700023SO 2007 5 7 2007FA0000277 220070322G8520A049405N CRANKSHAFT CONT O360 TSIO360EB 17025SO ENGINE FAILED B LU4RO OTHER O OTHER NRNOT REPORTED 1 SO19 A049405U CRANKSHAFT FAILED NDI SB MSB96-10. (K) 3 O E9CE 20070507000512007050700051NE 2007 5 7 2007FA0000351 220070424G8560230319303 THRUST BEARING LYC LF507 LF5071F NE SUPERCHARGER FAILED B O OTHER O OTHER NRNOT REPORTED 1 WP07 LF07712 NR 8 THRUST BEARING FAILURE RESULTED IN FAN AND SUPERCHARGER ROTORS TO SHIFT FORWARD CAUSING DAMAGE TO SUPERCHARGER 2ND DISK TO CONTACT THE STATORS MACHINING THROUGH THE 2ND SUPERCHARGER DISK WEB, RESULTING IN IN-FLIGHT SHUTDOWN OF NR 1 ENGINE. OPERATIONAL DESCRIPTION OF EVENT DID NOT INDICATE LOW OIL PRESSURE PRIOR TO THE FAILURE. WARNING SEQUENCE WAS DESCRIBED AS (1) SMELL IN THE CABIN, HIGH VIBRATIONS WARNING AND VISUAL SPARKES COMING FROM ENGINE, THEN SHUT-DOWN. BEARING APPEARS TO BE STARVED OF OIL UPON DISASSEMBLY, ALONG WITH VERY LOW OIL CONTENT IN ADJACENT NR 9 BEARING AND PLANETARY REDUCTION GEAR CARRIER. CURRENTLY INVESTIGATING CAUSE OF OIL STARVATION. LUBE PUMP IS FROZEN, BUT ENGINE NR 2 AND NR 4 F E6NE 20070507000762007050700076EA 2007 5 7 CA070404009 120070401G2740706010 CONTROL UNIT CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE HORIZONTAL STAB MALFUNCTIONED W BA EMER. DESCENT UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) SHORTLY AFTER TAKEOFF, FLIGHT EXPERIENCED A HSTA RUNAWAY. ACFT HAD JUST DEPARTED RUNWAY AND FLAPS WERE RETRACTED TO 0 DEGREES. AUTOPILOT DISENGAGED. TRIM SELECTION INPUT MADE. STABILIZER TRIM CONTINUED TO RUN & ASSOCIATED AURAL ALERT SOUNDED. IMMEDIATE ACTION CHECKLIST WAS COMPLETED, AS WAS QRH PROCEDURE. MODERATE CONTROL PULL FORCES WERE REQUIRED TO FLY ACFT AT 10,000 & 250 KNOTS. CREW USED ACARS SYSTEM TO CALCULATE A WEIGHT & BALANCE, & REDISTRIBUTED CABIN LOAD TO ALLEVIATE CONTROL FORCES. ICE ENCOUNTERED AT 10,000 FT & REQUIRED DESCENT TO 8,000 FT. EMERGENCY DECLARED. ACFT RETURNED. FLAPS SELECTED TO 20 DEGREES WHILE BETWEEN 8000 & 6000 FT. CONTROL FORCES WERE SIGNIFICANTLY LIGHTER ONCE FL2L72 4F4 FRTA21EA E15NE 20070507000772007050700077WP 2007 5 7 CA070409007 220070228G7314 GEAR GARRTTTPE331TPE33110UG 01514WP ROTOL R333 R333482F12 GL FUEL PUMP UNKNOWN W A UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA P63259 (CAN) GEARS DRIVING THE FUEL PUMP FAILED CAUSING THE ENGINE TO SHUTDOWN IN FLIGHT. (TC NR 20070409007) 4 T E4WE 6 CP61GL 20070507000792007050700079EU 2007 5 7 CA070410002 120070408G27501700637 DRIVE SHAFT EMB ERJ170ERJ170100 EU GE CF34 CF348E5A1 30015NE FLAP DRIVE DAMAGED W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) DURING APPROACH, THERE WAS A FLAP FAIL MSG. ACFT LANDED WITH FLAPS LOCKED OUT. TROUBLESHOOTING REVEALED THAT GEARBOX SPLINED SHAFT AND DRIVE SHAFT WERE NOT LOCKED INTO PLACE BY LOCK SCREW. SIMILAR SCENARIO OCCURRED ON RHS, WHERE THE IB MOST FLAP ACTUATOR DISCONNECTED WITH THE SPLINE IN THE SAME WAY. THE LOCKBOLT WAS IN PLACE AND SAFETIED, BUT WAS NOT INSTALLED THROUGH THE HOLE IN THE SPLINED SHAFT. ANGLED GEARBOX PN IS AS ABOVE, BUT FLAP ACTUATOR PN IS C154814-2. (TC NR 20070410002) 2L72 4F4 FRTA56NM E00063EN 20070507000812007050700081EA 2007 5 7 CA070411005 120070410G5310C3FS249 STRUT DHAV DHC3 DHC3 2800202EA PWA R1340 R1340* 52016NE HAMSTD23D 23D40 NE WINDSCREEN CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING REPLACEMENT OF THE LT WINDSCREEN, CORROSION WAS FOUND ON THE STRUT PN C3FS2-49. AFTER REMOVAL OF SEALANT IT WAS NOTED THE STRUT WAS CORRODED COMPLETELY THROUGH ONE OF THE WALLS OF THE STRUT. RT STRUT INSPECTED AND NO FAULT FOUND (TC NR 20070411005) 1H71 3R3 R A815 5E2 6 CP719 20070507000972007050700097EA 2007 5 7 CA070413001 120070407G7830 COWLING CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE THRUST REVERSER DEPARTED W BA EMER. DESCENT UNSCHED LANDING DE INFLIGHT SEPARATION VIBRATION/BUFFET CRCRUISE 1 CA (CAN) A/C EXPERIENCED A THRUST REVERSER UNLOCK IN FLIGHT AT A CRUISE FLIGHT LEVEL OF 16000 FEET WITH AN APPROXIMATE SPEED OF 280 KNOTS. A SMALL VIBRATION IN THE AIRFRAME WAS FELT BY THE CREW PRIOR TO RECEIVING THE (REVERSER UNLOCK) MSG, FOLLOWED BY A LOUD BANG, WITH THE AIRCRAFT PITCHING UP AND ROLLING LT.  THE CREW STOWED THE REVERSER AND VIBRATIONS SUBSEQUENTLY STOPPED. UPON LANDING INTO ORD UNDER A DECLARED EMERGENCY, IT WAS NOTE THAT T/R TRANSLATING COWLS WERE MISSING, ALONG WITH THE STRUCTURAL DAMAGE TO THE VERTICAL AND HORIZONTAL STAB. LIST OF AFFECTED COMPONENT TO FOLLOW. (TC NR 20070413001) 2L72 4F4 FRTA21EA E15NE 20070507001012007050700101CE 2007 5 7 CA070416002 120070413G77203034389 PROBE BEECH 99 99 1154002CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL ENGINE T5 CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) 7 OUT OF 8 T5 INDICATION PROBES WERE FOUND WITH LOOSE OR BROKEN TERMINALS AND MISSING CERAMIC INSULATION. THE PROBES APPEAR TO QUITE FRAGILE IN COMPARISON TO THE OEM PART. THE PARTS IN QUESTION ARE PMA PARTS, THEIR PN 26584. PROBES REPLACED AND AIRCRAFT RETURNED TO SERVICE (TC NR 20070416002) 1L72 3T4 T A14CE E4EA 6 CP15EA 20070507001252007050700125GL 2007 5 7 CA070418001 120070416G38104E32612 POTABLE WATER BOMBDRBD700 BD7001A10 1390006GL RROYCEBR700 BR700710A22009500NE GALLEY LEAKING W D RETURN TO BLOCK KJ FLUID LOSS WARNING INDICATION TXTAXI/GRND HDL 1 CA 422 (CAN) FOLLOWING THE ADVISORY WIRE FROM MFG, THE WATER SYSTEM VENT VALVES (6) WHERE REPLACED IN MFG. ON THE NEXT CUSTOMER FLIGHT, ONE VENT VALVE FROM THE GALLEY HAS STARTED TO LEAK. END RESULT, AVIONICS BAY FLOODED, BLACK BOXES FULL OF WATER. INVESTIGATION SHOWED THAT THE 2 VALVES ARE ACTING REVERSE. AS A TEMPORARY MEASURE, MFG DRAWING NR BAS67038670 INCORPORATED. (REMOVED VENT VALVES AND INSTALLED PLUGS) (TC NR 20070418001) 2L72 4F4 FRTT00003NYE00061EN 20070507001302007050700130NE 2007 5 7 CA070418006 220070322G8530CH90ER CYLINDER HEAD PWA R985 R985AN14B 52008NE ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 586 (CAN) ON 100 HR INSPECTION DURING A DIFFERENTIAL CHECK CYLINDER WAS READING LOW. USING A SOAP SOLUTION IT WAS DETERMINED THAT THERE WAS A LEAK ACROSS THE HEAD DUE TO A CRACK BETWEEN THE COOLING FINS. (TC NR 20070418006) 3 R 5E1 20070507001402007050700140NE 2007 5 7 CA070420001 220070419G8530153084 CYLINDER DOUG DC4 DC4 3021502WP PWA R2000 R20007M2 52023NE NR 4 ENGINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) REPLACED NR 14 CYLINDER ON NR 4 ENGINE, DUE TO CRACK. AIRCRAFT RETURNED TO SERVICE. (TC NR 20070420001) 2L74 4R4 R A762 5E5 20070507001432007050700143EA 2007 5 7 CA070420003 120070418G5220 DOOR DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE EMERGENCY EXIT STIFF W K NONE O OTHER ININSP/MAINT 1 CA 3470434704 (CAN) ON GROUND, WHEN FLIGHT ATTENDANTS UNDERGOING RECURRENT TRAINING ATTEMPTED TO OPEN FWD RT EMERG EXIT DOOR, WERE UNABLE TO GET DOOR OPEN. MAINTENANCE CALLED TO ASSIST AND REQUIRED TWO ENGINEERS (ONE ON INSIDE HANDLE AND ONE ON OUTSIDE HANDLE) TO GET DOOR OPEN . MAINTENANCE INSPECTED AND LUBRICATED INTERNAL DOOR MECHANISM, DOOR RE-INSTALLED AND FUNCTIONED WITH NORMAL OPENING FORCE. (TC NR 20070420003) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070507001822007050700182CE 2007 5 7 2007FA0000364 120070420G3230 LANDING GEAR CESSNA500 S550 2076607CE PWA JT15 JT15D4 52112NE MALFUNCTIONED B EBVRO OTHER O OTHER NRNOT REPORTED 1 GL0932TX S5500026 EMERGENCY LANDING GEAR DEPLOYMENT SYSTEM INSPECTED DURING ROUTINE PHASE INSPECTION. EMERGENCY GEAR CABLES CHECKED FOR CORRECT RIGGING, AND EMERGENCY GEAR SYSTEM FUNCTION TESTED WITH AIRCRAFT ON JACKS. SYSTEM FUNCTION TESTED PROPERLY. PILOT ELECTED TO PERFORM IN FLIGHT CHECK OF SAME SYSTEM AND FOUND THAT MAIN GEAR WOULD NOT DEPLOY. PILOT EXTENDED GEAR USING NORMAL HYDRAULIC SYSTEM OPERATION AND LANDED WITHOUT INCIDENT. AC WAS FLOWN TO SERVICE CENTER FOR EVALUATION. (K) 1L72 4F4 FRTA22CE E1NE 20070507001852007050700185SO 2007 5 7 2007FA0000356 220070418G8530FRCN68OACA01 CYLINDER HEAD CESSNA182 182A 2072704CE CONT O470 O470L 17026SO NR 1 SEPARATED D FO7RK NONE O OTHER ININSP/MAINT 1 SO135162D145 51262 PERFORMED CYLINDER COMPRESSION TEST AND FOUND NR 1 CYLINDER READING 0 PSI AND FOUND LEAKING AROUND CYLINDER HEAD AND BARREL FINS. UPON REMOVAL THE HEAD IS COCKED SIDEWAYS ON THE BARREL. THE HEAD WAS SEPARATING FROM BARREL. THE CYLINDER PN FRCN68. OACA/01 CL68 CERMINIL FREEDOM. CYLINDER ONLY HAD 145.6 HRS TIME IN SERVICE OVERHAUL IN DEC 2003. (K) 1H71 3O3 ONT3A13 E273 20070507001932007050700193EU 2007 5 7 CA070423001 120070420G6220601741 BEARING BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL MAIN ROTOR FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING PERFORMANCE OF A 100/300 HOUR INSPECTION OF THE AIRCRAFT AND IN PARTICULAR THE MAIN ROTOR BLADES. THE ENGINEER FOUND THAT THE PENDULUM ABSORBER OF THE RED MAIN ROTOR BLADE WAS EXTREMELY ROUGH. UPON DISASSEMBLY OF THE PENDULUM ABSORBER IT WAS FOUND THAT THE BEARINGS WERE DRY, WITH NO TRACE OF OIL PRESENT. ONE BEARING CAGE HAD FAILED, AND THE BALL BEARINGS HAD WORN TO WELL BEYOND ANY CIRCULAR SHAPE. JUST A NOTE TO SAY THAT THERE HAD BEEN NO TRACE OF OIL ON THE HEAD IN PREVIOUS INSPECTIONS TO INDICATE A LEAK. ONE BEARING AND SEAL WERE REPLACE, THE ASSEMBLY REASSEMBLED AND INSTALLED ONTO THE ROTOR BLADE. AIRCRAFT RETURNED TO SERVICE UPON COMPLETION OF THE INSPECTION. (TC NR 20070423001) 1G72 3U3 U H3EU E4CE 20070507001942007050700194EA 2007 5 7 CA070423002 220070423G8530LW12427 CYLINDER BEECH 23 C23 1151242CE LYC O360 O360A4K 41514EA SNSNCH76E 76EM8S5 EA ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1397 (CAN) CRACK FOUND IN CYLINDER. (TC NR 20070423002) 1L71 3O3 O A1CE E286 5 NP4EA 20070509000622007050900062EA 2007 5 9 CA070424005 220070424G7230 COMPRESSOR WHEEL PWA PT6 PT6A27 52043EA ENGINE MAKING METAL W K NONE O OTHER ININSP/MAINT 1 CA (CAN) OPERATOR REPORTED THAT WHEN THE ENGINE WAS STARTED, THE PROPELLER DID NOT ROTATE. AFTER SHUTDOWN, THE ENGINE AND PROP COULD BE ROTATED BY HAND. HOWEVER, SEVERAL SMALL PIECES OF METALLIC DEBRIS WAS REMOVED FROM THE EXHAUST AREA. DISASSEMBLY OF THE ENGINE REVEALED SEVERE IMPACT DAMAGE ON THE FWD FACE OF THE CT DISC ASSY AND 4 MISSING CT VANE RETAINING BOLTS. FURTHER INVESTIGATION REVEALED IMPACT DAMAGE ON THE CT VANE LOCK PLATE, CT VANE, CT BLADES AND PT BLADES. (TC NR 20070424005) 4 T E4EA 20070509000642007050900064CE 2007 5 9 CA070111018 120070109G32335082021811 SHAFT BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL NLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE NOSE GEAR ACTUATOR WAS REMOVED TO PERFORM AN END PLAY CHECK. THE NOSE GEAR RETRACT DRIVE SPROCKET AND SHAFT (PN 50-820218-11) ASSEMBLY WAS REMOVED FOR CLEANING. INSPECTION OF THE DRIVE SPROCKET AND SHAFT FOUND THAT A CRACK HAD FORMED ON THE END DIAMETER (.745) THAT ENGAGES THE SUPPORT BEARING. THE CRACK STARTS AT THE END OF THE SHAFT, EXTENDS AXIALLY FOR .350 AND THEN EXTENDS RADIALLY FOR ANOTHER .400. THE CRACK HAS THE APPEARANCE OF STRESS CORROSION. THE TOTAL TIME AND TOTAL CYCLES OF THIS PART IS UNKNOWN. (TC NR 20070111018) 1L72 4T4 T A24CE E4EA 6 CP15EA 20070509000672007050900067 2007 5 9 CA070114003 420070104G3442066311400 INDICATOR BEECH 200 B200 1152922CE PWA PT6 PT642A NE HARTZLHCB3T HCB3TN3 GL WEATHER RADAR MALFUNCTIONED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA BB1343 (CAN) CREW REPORTS THAT IN CRUISE NOTED THE WEATHER RADAR FAILED AND IMMEDIATELY BOTH MAIN GENERATOR BUSES FAILED. CREWS RESET GENERATORS AND MONITORED BUS VOLTAGES AND LOADS, NORMAL. CREW THEN NOTED THE 28VDC CIRCUIT BREAKER POPPED ON THE AVIONICS BUS FOR THE WEATHER RADAR. BREAKER RESET BUT INDICATOR UNSERVICEABLE. AFTER AIRCRAFT RETURNED TO MTC BASE, MAINTENANCE CREW INSPECTED ELECTRICAL SYSTEM WITH NO FAULTS FOUND. RADAR INDICTOR REPLACED AND F/C NORMAL. UNSERVICEABLE WEATHER RADAR SENT TO REPAIR FACILITY WITH DETAILS OF INCIDENT AND REQUEST FOR WORK / STRIP REPORT. (TC 20070114003) 1L72 4T4 T A24CE E4EA 6 CP15EA 20070509000692007050900069SO 2007 5 9 CA070115002 120070109G2140D405065D793 HEATER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL CABIN FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 649 (CAN) PILOT REPORTED EXHAUST ODOR WHEN FRONT COMBUSTION HEATER WAS OPERATING. SOOT COLLECTED ON THE PILOT AND CO-PILOT WINDSHIELDS ABOVE THE DEFROST VENTS. COMPLETED A HEATER DECAY TEST WHICH CONFIRMED THE BURNER CAN WAS DEFECTIVE. REMOVED THE HEATER FROM THE AIRCRAFT AND DISCOVERED 2 HOLES IN THE BURNER CAN APPROXIMATELY .5 INCH WIDE AND OPEN ABOUT .2500 INCH. HEATER WAS REPLACED WITH OVERHAULED UNIT AND AIRCRAFT RETURNED TO SERVICES. (TC NR 20070115002) 1L72 3O3 O A20SO E14EA 5 CP33EA 20070509000762007050900076SW 2007 5 9 CA070115014 120070102G5730204382 SKIN AIRTRCAT802 AT802 0390305SW PWA PT6 PT6A67A 52043NE HARTZLHCB5M HCB5MA3 GL WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 452 (CAN) DURING ANNUAL INSPECTION SEVERAL CRACKS WERE DETECTED AT THE RIVET HOLES WHERE THE FLAP BAY SKIN (PN 20438-2) ATTACH TO THE RIB FLANGES. CRACKS WERE STOP DRILLED AND PLATE INSTALLED OVER THE RIB FLANGE AREA IAW AIR TRACTOR INSTRUCTIONS (ATTACHED). THIS PROBLEM HAS BEEN FOUND ON EARLY SN AIRCRAFT (802-001 - 802A-0014), SUBSEQUENT S/N HAD EXTRA RIVETS INSTALLED BY MFG. THIS AIRCRAFT S/N IS 802-0121. (TC NR 20070115014) 1L71 3T4 TNCA19SW E26NE 6 CP44GL 20070509000772007050900077SW 2007 5 9 CA070117003 120070115G56102719442004 WINDSHIELD SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCE4N HCE4N3 NE COCKPIT DELAMINATED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA 2751 (CAN) DURING FLIGHT THE FLIGHT CREW HEARD A LOUD CRACK FROM THE RT HEATED WINDSHIELD. THEY IMMEDIATELY NOTICED THE WINDOW PANES BEGIN TO DELAMINATE. NO OBJECT WAS WITNESSED HITTING THE AIRCRAFT OR WINDSHIELD. THE AIRCRAFT LANDED SAFELY AND THEN RETURNED TO BASE ON A FLIGHT PERMIT FOR REPAIRS. NO CRACKING IN THE WINDOW WAS EVIDENT. THE WINDOW WAS REPLACED BY MAINTENANCE. (TC NR 20070117003) 2L72 4T4 TRTA8SW E4WE 5 CP10NE 20070425002462007042500246GL 2007 4 25 2007FA0000341 120070416G2750 RELAY CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO T/E FLAP FAILED P A UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 SW01105SR 1866 DURING A TRAINING FLIGHT, THE FLAPS BECAME STUCK IN THE DOWN POSITION. THE AIRCRAFT RETURNED TO THE AIRPORT WITHOUT INCIDENT AND THE AIRCRAFT WAS SENT TO MAINTENANCE FOR TROUBLESHOOTING. MAINTENANCE DISCOVERED THE FLAPS DOWN RELAY FAILED. 1L71 3O3 ONTA00009CHE3SO 20070425002552007042500255EU 2007 4 25 2007FA0000328 120070406G5554T700A5340023100 FITTING SOCATATBM TBM700 8682000EU PWA PT6 PT6A64 EA HARTZLHCE4N HCE4N3 NE RUDDER CRACKED D K NONE O OTHER ININSP/MAINT 1 EA05704QD 188 PCEPM0073 HH463 DURING A 6000HR/10 YEAR CORROSION INSPECTION AD2007-06-11 WAS BEING COMPLIED IAW AD AND MANDATORY SB70-=104, AMENDMENT 2. AFTER COMPLETING THE PENETRANT INSPECTION NO CRACKS WERE DETECTED IN THE SPECIFIED AREAS HOWEVER THE FITTINGS LISTED IN BLOCK 5 WERE REMOVED FROM SERVICE FOR LIGHT PITTING CORROSION. RECENTLY IN OUR FACILITY, THERE WAS A LEVEL 3 NDT RECURRENT COURSE BEING GIVEN AND THE REMOVED FITTINGS WERE CRACK CHECKED USING A ROTARY TOOL FOR BOLT HOLE EDDY CURRENT SET UP ON .030 CORNER EDM NOTCH AS A REFERENCE STANDARD. AT THIS TIME THERE WERE CORROSION PITTING CRACKS DETECTED IN BOTH FITTINGS. THE INSPECTION CRITERIA STATED IN AD AND SB ARE INSUFFICIENT FOR CRACK DETECTION IN THIS AREA. POSSIBLY THE1L71 3T4 TRTA60EU E4EA 5 CP10NE 20070425002572007042500257EA 2007 4 25 2007FA0000335 220070417G7414 SPRING SLICK PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA IMPULSE COUPLINGBROKEN D O OTHER R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 NE05 1603 38 PILOT STARTED AIRCRAFT NORMALLY AND DID RUN UP WITH A BAD MAGNETO CHECK. PILOT DID NOT FLY AIRCRAFT AND RETURNED TO HANGER. AIRCRAFT WOULD NOT RESTART. IMPULSE COUPLE DID NOT MAKE ANY NOISE, TIMING WAS WAY OFF. FOUND IMPULSE COUPLE SPRING BROKEN A TURN AND A HALF FROM OUTER END. 1L71 3O3 O 2A13 E286 20070501001172007050100117CE 2007 5 1 PAZR200700001 120070416G5551663110215 ATTACH FITTING CESSNA560 560XL 2076702CE PWA 545 PW545A NE ZONE 300 CRACKED B PAZRK NONE O OTHER ININSP/MAINT 1 CE03186XL2179 5605186 DURING A SCHEDULED INSPECTION, A 1.5 INCH CRACK WAS FOUND IN THE LOWER RADIUS OF THE HORIZONTAL STABILIZER AFT ATTACH FITTING. 2L72 4F4 FRTA22CE E00059EN 20070503000362007050300036CE 2007 5 3 CA070404001 120070325G561010138402521 WINDSHIELD BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) DURING CRUISE FLIGHT THE L/H OUTER WINDSHIELD PANE CRACKED IN SEVERAL PLACES. THE CREW CARRIED OUT THE APPLICABLE PROCEDURES AND LANDED AT THE NEAREST AIRPORT. THE WINDSHIELD WAS INSPECTED BY MAINTENANCE AND THE AIRCRAFT WAS FERRIED TO A MAINTENANCE FACILITY WHERE THE WINDSHIELD WAS REPLACED. THE AIRCRAFT WAS THEN RETURNED TO SERVICE. (TC NR 20070404001) 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20070504000832007050400083CE 2007 5 4 CA070329008 120070327G32501018100327 TORQUE KNEE BEECH 200 B200 1152922CE PWA PT6 PT642A NE HARTZLHCD4N3HCD4N3A GL MLG WORN W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA 7020 7020 (CAN) WHILE TAXING BACK TO THE RAMP, THE PILOT NOTICED THAT THE STEERING WAS MORE DIFFICULT AND INEFFECTIVE. HE SHUTDOWN BOTH ENGINES AND ON INVESTIGATION FOUND THE LT LANDING GEAR TORQUE KNEE BOLT DISCONNECTED. THE CAUSE OF THE DISCONNECTION WAS A WORN OUT RETAINING WASHER. MAINTENANCE REPLACED THE WASHER AND RETURNED THE AIRCRAFT TO SERVICE. THIS AREA WAS RECENTLY INSPECTED. THE MM DOES NOT SPECIFY DISASSEMBLING THIS AREA TO INSPECT. THE ONLY WAY THIS COULD HAVE BEEN DETECTED WAS BY DISASSEMBLY. OUR MAINTENANCE PROGRAM TRACKING SHEETS HAVE BEEN AMENDED TO INCLUDE DISASSEMBLY OF THE TORQUE KNEES EACH 800 HOURS. (TC NR 20070329008) 1L72 4T4 T A24CE E4EA 5 CSTC 20070504000942007050400094NM 2007 5 4 CA070330004 120070329G3230 LANDING GEAR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MALFUNCTIONED W O OTHER J WARNING INDICATION CRCRUISE 1 CA 4800748007 (CAN) DURING CRUISE CREW RECEIVED INTERMITTENT LANDING GEAR INOP CAUTION LIGHT. CREW ELECTED TO RETURN TO ORIGINATING AIRPORT. ALTERNATE GEAR EXTENSION USED TO LOWER LANDING GEAR. NORMAL LANDING. MAINTENANCE INSPECTION FOUND NO FAULTS. AIRCRAFT WILL BE RETURNED TO SERVICE SUBJECT TO A SATISFACTORY TEST FLIGHT. (TC NR 20070330004) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070504001242007050400124SO 2007 5 4 CA070405010 120070405G3220203601042 AXLE CURTIS CURTISC46 C46DAIRLIFT SO PWA R2800 R280051 52026NE HAMSTD23E 23E50 NE TAIL GEAR FRACTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING TAXI TO RUNWAY POSITION, TAIL WHEEL AXEL FRACTURED RESULTING IN TAIL WHEEL DEPARTING TAIL GEAR ASSEMBLY. TAXI WAS AT SLOW SPEED BUT TAIL FORK DAMAGED DURING AXEL FAILURE. TAIL WHEEL FORK AND AXEL ASSEMBLY, WERE REPLACED AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20070405010) 2L72 4R4 R 3A2 5E8 6 CP603 20070504001352007050400135CE 2007 5 4 2007FA0000293 120070322G7830 LINK CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE THRUST REVERSER CORRODED D O OTHER O OTHER NRNOT REPORTED 1 GL15413LC6894 5600003 PCE108003 ALL DRIVE LINK PIVOT BOLTS AND OVER CENTER LINKS SEVERELY CORRODED AND WORN. PROBABLE CAUSE IS INADEQUATE LUBE. MANUAL STATES TR`S MUST BE TORN DOWN AND LUBED UPON ASSEMBLY AT SPECIFIC INTERVALS. ENGINEERING STATES THAT TEARDOWN IS NOT NECESSARY AND ON WING LUBRICATION IS ADEQUATE. THESE FINDINGS INDICATE OTHERWISE. (K) 2L72 4F4 FRTA22CE E25EA 20070504001372007050400137EA 2007 5 4 2007FA0000333 220070406G8530LW15014 ROCKER CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE CYLINDER BROKEN B YYBRO OTHER O OTHER NRNOT REPORTED 1 GL032994E 17271398 L717976T THE STAMPED EXHAUST STEEL ROCKER ARM WAS FOUND BROKEN THROUGH AT PUSH ROD, AND THE INTAKE ROCKER ARM WAS CRACKED, AND THE PUSH ROD WAS BENT BADLY. THE ENGINE HAD 120 HR TSO AND NEW FACTORY CYLIDERS WERE INSTALLED. (K) 1H71 3O3 ONT3A12 E274 20070504001442007050400144CE 2007 5 4 2007FA0000300 120070327G324016011800 HOUSING CLEVELAND CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL BRAKE CALIPER DEFECTIVE D O OTHER O OTHER NRNOT REPORTED 1 WP21PKMPS 017 208B0656 PCEPC0548 001276 THE MAIN CASTING, WHICH HOUSES THE BRAKE CALIPER PISTONS LEAKS FLUID UNDER NORMAL BRAKING PRESSURE. THE LEAKS ARE FROM EXCESSIVE POROSITY IN THE CASTING. CASTING THIS IS THE SECOND OCCURRENCE IN OUR OPERATIONS. THE FIRST WAS NOT REPORTED. (K) 1H71 3T3 T A37CE E4EA 5 CP60GL 20070504001992007050400199CE 2007 5 4 2007FA0000354 120070402G2697MS24266R12B12SN CONNECTOR BEECH 200 B200 1152922CE PWA PT6 PT6* 52043EA FIRE DETECTION CORRODED D GONRA UNSCHED LANDING N FALSE WARNING NRNOT REPORTED 1 SW01200VU3534 BB1393 THE AIRCRAFT WAS FLYING THROUGH IMC, WITH ALOT OF RAIN ON THEIR WAY TO DESTINATION. AS THE CREW WAS LETTING DOWN TO LAND THE LT ENGINE FIRE LIGHT LIT UP. THE CREW SCANNED ALL THE GAGES, AND DETERMINED THAT THIS WAS A FALSE LIGHT. THE AC LANDED WITHOUT COMPLICATION. UPON INSPECTION OF THE LT ENGINE FIRE DETECT SYSTEM, THE TECH FOUND SOME VERY LIGHT CORROSION AND MOISTURE ON THE J102 CONNECTOR PLUG, LOCATED ON THE LT ENGINE FIRE WALL. THE MOISTURE AND CORROSION WAS REMOVED AND THE FIRE DETECT SYSTEM TESTED PROPERLY, THE AC WAS RETURNED TO SERVICE. APPLING A THIN COATING OF DC-4 GREASE IN THE CONNECTOR PLUG WOULD PREVENT MOISTURE FROM ENTERING THE PLUG AND THEREFORE KEEP THE CORROSION OUT. (K) 1L72 4T3 T A24CE E2NE 20070504002152007050400215SO 2007 5 4 2007FA0000383 120070430G55202039700 HORN PIPER PA24 PA24250 7102404SO LYC O540 O540* 41532EA STABILIZER CRACKED D O OTHER O OTHER NRNOT REPORTED 1 WP075977P6000 241070 FOUND STABILATOR HORN P/N 20397-00 SEVERELY CRACKED FROM THE INSIDE WHERE THE ATTACH BOLTS CONNECT THE BALANCE WEIGHT TUBE P/N 20398-02 AND STABILATOR TORQUE TUBE ASSEMBLY P/N 20203-03. 1L71 3O3 O 1A15 E295 20070507000782007050700078NE 2007 5 7 CA070410001 220070408G7260 CASE DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE ACC GEARBOX CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA 3019810612 PW123150 (CAN) ON MARCH 28TH/07 IT WAS REPORTED AN OIL LEAK ON NR 2 ENGINE. THE OIL LEVEL WHEN DOWN 2L IN 5.55 HOURS OF FLIGHT TIME. THE PROPELLER ASSY AND THE LT SIDE OF THE ENGINE WAS REPORTED TO HAVE BEING WASHED WITH OIL AND BOTH THEY WERE INSPECTED FOR LEAKAGE. NO SIGNS OF DETERIORATION FOUND AT THE TIME AND IT WAS DECIDED TO DO A POWER RUN CHECK. AGAIN NO SIGNS OF LEAKAGE FOUND. ON MARCH 29TH/07 WAS REPORTED ANOTHER OIL LEAKAGE FROM NR 2 ENGINE. PERSONNEL INVESTIGATED THE PROPELLER AND THE ENGINE AND IT WAS FOUND AN APPROXIMATE 2. (TC NR 20070410001) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070507000802007050700080EU 2007 5 7 CA070411002 120070405G3230A2757040500200 SWITCH AIRBUS310 A310304 3930339EU GE CF6 CF680C2A5 NE MLG STICKING W A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) DURING CLIMB THE AIRCRAFT HAD A (KRUGER) FAULT ECAM WARNING.QAH CARRIED OUT BUT WARNING REMAINED ON. AIRCRAFT RETURNED TO THE STATION. DURING TROUBLESHOOTING THE BITE TEST ON THE SFCC 1 AND 2 FAULTED THE RT RETRACT SWITCH. THE SWITCH WAS FOUND DIRTY AND STICKING AND TARGET WAS FOUND WORN. SWITCH WAS CLEANED AND TARGET ADJUSTED IAW MM. SYSTEM WAS TESTED SERVICEABLE. (TC NR 20070411002) 2L72 4F4 FRTA35EU E13NE 20070507000842007050700084NE 2007 5 7 CA070412004 220070330G7323116085023 GOVERNOR BELL 205 205A1 1181414SW LYC T53 T5317A 41549NE ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA 2920 1160 LE07576 (CAN) DURING THE DAILY INSPECTION PERFORMED BY THE ENGINEER, THE SCREW HOLDING THE GOV SERVO LEVER PLATE IN PLACE WAS ENTIRELY BACKED OUT OF THE HOLE. THIS PART HAD BEEN REPLACED, TESTED AND ADJUSTED AT TSN 2346.3 FOR LOOSE SCREWS. THE SCREWS ARE STAKED IN PLACE AND YET WERE STILL ABLE TO BACK OUT. THE GOVENOR WAS SENT FOR REPAIR. THE SCREW MAY POISE A RISK IN JAMMING THE SERVO LEVER. (TC NR 20070412004) 1G71 4U4 U H1SW E17EA 20070507000982007050700098NM 2007 5 7 CA070413002 120070409G323069141061 CYLINDER BOEING727 727233 138408ANM PWA JT8 JT8D15 52051NE NLG FAILED W O OTHER KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 CA (CAN) THE CREW OBSERVED AN A SYSTEM DEPLETION CONDITION AFTER EXTENDING THE LANDING GEAR. THE AIRCRAFT LANDED WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND THE NOSE LANDING GEAR SYSTEM TRANSFER CYLINDER HAD FAILED. THE CYLINDER HAD FAILED AT THE LAST END CAP THREAD. THE UNIT WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. (TC NR 20070413002) 2L73 4F4 FRTA3WE E2EA 20070507001022007050700102NM 2007 5 7 CA070416003 120070415G3297471515 WIRE HARNESS BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NLG DAMAGED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER T/O LANDING GEAR WOULD NOT RETRACT WHEN SELECTED. A/C RETURNED TO BASE FOR MAINTENANCE INSPECTION. HARNESS WOW NR 2 REPLACED IAW AMM. A/C RTS (TC NR 20070416003) 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20070507001072007050700107NM 2007 5 7 CA070416006 120070315G2750C1486742003 CONTROL UNIT BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU TE FLAPS MALFUNCTIONED W A UNSCHED LANDING FJ FLT CONT AFFECTED WARNING INDICATION CRCRUISE 1 CA 1613 (CAN) ENROUTE BASE, THE FLAP POWER CAUTION LIGHT ILLUMINATED. RESET WAS CARRIED OUT IAW QRH 10.11 HOWEVER ONE MINUTE LATER THE CAUTION LIGHT RE-ILLUMINATED. IAW THE QRH FLAPS RENDERED UNAVAILABLE FOR LANDING. FLAPLESS LANDING WAS CARRIED OUT WITHOUT INCIDENT. ENGINEERING INVESTIGATION REVEALED FAILURE OF THE FLAP CONTROL UNIT. UNIT REPLACED AND TESTED IAW MAINTENANCE MANUAL REQUIREMENTS. AIRCRAFT RETURNED TO SERVICE WITHOUT FURTHER INCIDENT. AS DEFECT CONFIRMED WITH REPLACEMENT OF THE FCU. (TC NR 20070416006) 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20070507001382007050700138SW 2007 5 7 CA070419004 120070419G6520476206297 BEARING BELL 47 47G2 1181008SW LYC O435 VO435A1D 41516EA TAIL ROTOR GB MAKING METAL W K NONE O OTHER ININSP/MAINT 1 CA 3111 685 (CAN) DURING ROUTINE 100 HR INSPECTION THE OIL WAS FOUND TO BE DARKER IN COLOR THAN NORMAL, AFTER CLOSER INSPECTION AND CHECKING FOR STEEL WITH A MAGNET THE DARKNESS IN COLOR WAS ATTRIBUTED TO METAL CONTAMINATION IN THE OIL SO FINE THAT IT LOOKED LIKE METALLIC PAINT. THE GEARBOX IS IN FOR TEARDOWN AND WILL ADVISE THE FINDINGS AFTER INSPECTION. (TC NR 20070419004) 1G71 3O3 O H1 E279 20070507001762007050700176EA 2007 5 7 CA070409002 120070404G2913R1309P216 PLUG CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE RT EDP MISSING W B EMER. DESCENT KJYFLUID LOSS WARNING INDICATION ENGINE STOPPAGE CRCRUISE 1 CA 8717 (CAN) AFTER TAKEOFF FROM SOUTH BEND (SBN), THE AIRCRAFT CLIMBED TO FL 290. SHORTLY AFTER REACHING CRUISE ALTITUDE, THE RT ENGINE OIL PRESS WARNING ILLUMINATED FOLLOWED BY A DROP IN THE OIL PRESSURE ON THE RT OIL PRESSURE GAUGE. THE FLIGHT CREW PERFORMED THE QRH PROCEDURES AND REDUCED POWER ON THE RT ENGINE. SEEING THAT THE OIL PRESSURE CONTINUED TO DROP, THE CAPTAIN ELECTED TO SHUTDOWN THE ENGINE. AN EMERGENCY WAS DECLARED AND AN UNEVENTFUL APPROACH AND LANDING WAS MADE AT MSP. UPON LANDING, MAINTENANCE FOUND THAT THE AIRCRAFT HAD A MEL OPENED FOR NR 2 ENGINE DRIVEN HYDRAULIC PUMP. FURTHER INVESTIGATION REVEALED THE RT EDP HAD NOT BEEN PROPERLY MEL`D AND THAT THE OIL LOSS WAS THE RESULT OF A MISSING SPLINE PL2L72 4F4 FRTA21EA E15NE 20070507002412007050700241CE 2007 5 7 CA070105006 120070104G561010138402523 WINDSHIELD BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT CRACKED W O OTHER O OTHER DEDESCENT 1 CA (CAN) DURING PRESSURIZED FLIGHT THE LT WINDSHIELD CRACKED IN SEVERAL PLACES ALL ALONG THE IB SECTION OF THE WINDOW. THE WINDOW WAS ORIGINALLY A REPAIRED WINDOW AND WAS INSTALLED FOR 1512.9HRS/1450CYCLES BEFORE FAILING. (TC NR 20070105006) 1L72 4T4 T A24CE E4EA 6 CP15EA 20070509001862007050900186EA 2007 5 9 CA070117007 120070115G5610601R3303311 WINDOW CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA 9980 (CAN) PILOT SIDE WINDOW INNER LAYER CRACKED. SIDE WINDOW ACC AMM 56-12-01 REPLACED. OPERATIONAL TEST OF WINDOW TEMP CONTR. DO A LEAK TEST OF LT SIDE WINDOW AFTER REPLACEMENT ACC AMM 56-12-400-801 A01 PERFORMED SATISFIED (TC NR 20070117007) 2L72 4F4 FRTA21EA EOOO63EN 20070509001872007050900187EA 2007 5 9 CA070117008 120070115G32137339FT160T SEAL BFGOODRICH CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE NLG STRUT LEAKING W O OTHER O OTHER APAPPROACH 1 CA SPP510096 (CAN) FLIGHT 5663 DEPARTED WITH 65 PASSENGERS ON BOARD WITH NO ISSUES NOTED. ON APPROACH, AFTER GEAR DOWN SELECTION CREW NOTED A NWS INOP CAUTION MESSAGE. TO GIVE THEMSELVES TIME TO GO THROUGH THE NWS INOP MESSAGE, THEY CARRIED OUT A GO AROUND. AS THEY FLEW BY THE RUNWAY, THE TOWER INFORMED THEM THAT THE NOSEWHEELS APPEARED TO BE TURNED 90 DEGREES. AN AC FLYING NEARBY OFFERED TO FLY BY THE AIRCRAFT AND INSPECT THE NOSE GEAR. THE PILOT REPORTED THAT THE NOSE GEAR WHEELS WERE OFF CENTER BY 20 DEGREES. AT THE GATE MAINTENANCE INSPECTED THE NOSE GEAR AND FOUND THAT THE STRUT WAS FLAT. MAINTENANCE SERVICED THE STRUT AND NOTED THAT THE STRUT WAS LEAKING. STL MAINTENANCE IS DISPATCHING MAINTENANCE AND SEALS TO2L72 4F4 FRTA21EA EOOO63EN 20070509001882007050900188CE 2007 5 9 CA070118001 120070115G554204330106 SKIN CESSNA CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL RUDDER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE DOING 100 HR INSPECTION ON AIRCRAFT, MECHANIC NOTICED THAT THERE WAS A CRACK BY THE LIGHTING HOLE BELOW THE TOP HINGE ATTACH BRACKET. NEW SKIN ORDERED AND WHEN RECEIVED NOTICED THAT MFG HAS REMOVED THIS LIGHTING HOLE. REST OF AIRCRAFT OF THIS TYPE IN FLEET WILL BE INSPECTED FOR THIS SAME DAMAGE. (TC NR 20070118001) 1H71 3O3 ONT3A19 E223 5 NP50GL 20070509001892007050900189EA 2007 5 9 CA070118002 120070117G2750 FLAP SYSTEM CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE TE FLAPS MALFUNCTIONED W O OTHER O OTHER APAPPROACH 1 CA (CAN) THE CREW REPORTED A FLAP FAIL MESSAGE ON APPROACH. THE CREW SELECTED FLAP 8 AND FLAP FAIL MESSAGE CAME ON IMMEDIATELY AND THE FLAPS FROZE AT 0 DEGREES INDICATED. ON THE GROUND A CB RESET WAS CARRIED OUT AND THE CODES WERE OBTAINED . THE AIRCRAFT WAS FERRIED WHERE AN INVESTIGATION IS STILL ONGOING BY LINE MAINTENANCE (TC NR 20070118002) 2L72 4F4 FRTA21EA E15NE 20070511000012007051100001EA 2007 5 11 CA070329002 120070323G5340CN6272017203 BRACKET CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE HYD LINE BROKEN W EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA 5723 (CAN) AC EXPERIENCED A COMMANDED IFSD DUE TO OIL PRESSURE LOSS DURING CRUISE. DURING FLIGHT, PILOT NOTICED OIL PRESSURE DECREASING STEADILY DURING CRUISE. AT 36 PSI OIL PRESSURE, PILOT INITIATED A COMMANDED SHUTDOWN OF THE NR 2 ENGINE AND DIVERTED INTO BILLINGS FOR AN UNEVENTFUL SINGLE ENGINE LANDING. UPON INSPECTION OF ENGINE, MECHANICS NOTICED A STATIC OIL LEAK FROM THE BOTTOM OF GEARBOX. AFTER FURTHER INSPECTION, IT WAS NOTICED THAT THE BRACKET HOLDING THE HYD LINE TO GEARBOX AT 6:30 ON THE AFT AGB FLANGE HAD BROKEN OFF, AND CONTACTED THE BOTTOM OF THE GEARBOX JUST ABOVE THE BRACKET LOCATION, HAD WORN A HOLE IN THE AGB HOUSING, RESULTING IN THE OIL LOSS. ENGINE IS BEING REMOVED AND REPLACED, ANOTHER ENGINE 2L72 4F4 FRTA21EA EOOO63EN 20070511000022007051100002EA 2007 5 11 CA070405009 120070403G2450VS643 RELAY CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE JUNCTION BOX NR6BURNED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) DURING CRUISE IB, FLIGHT CREW NOTICED AN AC ESSENTIAL BUS MESSAGE FOLLOWED BY A POPPING SOUND AND A BURNED ODOR ON THE FLT DECK. LOOKED AT AC ELECTRICAL SYNOPTIC PAGE AND EVERYTHINGS WAS NORMAL BUT THE F/A NOTICED THAT THE EMERGENCY LIGHTS WERE ON. FLIGHT CREW APPLIED QRH AND CARRIED ON FLIGHT. ON ARRIVAL AT THE GATE, BURNED ODOR WAS STRONGER AND THEY SHUTDOWN EVERYTHING INCLUDING THE APU. AFTER INVESTIGATION, MAINTENANCE FOUND AC ESSENTIAL RELAY K1XD BURNED IN JB6 AND CARBON TRACES WERE FOUND ON THE RELAY SOCKET AND JB6 BRACKET/CASING. REF LOG NR 565535 AC ESSENTIAL SENSE RELAY K1XD P/N VS 643 AND RELAY SOCKET PN S0-1021-7127 WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. (TC NR 20070405009) 2L72 4F4 FRTA21EA E15NE 20070511000052007051100005EA 2007 5 11 CA070118008 120070117G2752852D10019 ACTUATOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE TE FLAPS CONTAMINATED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA 6959 6959 (CAN) ON APPROACH CREW REPORTED A FLAPS FAIL MESSAGE AFTER SELECTION TO 8 DEGREES. FLIGHT COMPLETED A FLAPLESS LANDING WITHOUT INCIDENT. AIRCRAFT THEN COMPLETED A FERRY FLIGHT. TROUBLESHOOTING OF FAULT CODES AND REPAIRS CURRENTLY ONGOING BY MAINTENANCE. THE RT IB FLAP ACTUATOR WAS REPLACED DUE TO NOT ACCEPTING GREASE. SUSPECT MOISTURE INGRESS HAD FROZEN INSIDE ACTUATOR. AS PART OF REPAIRS MOD IS601R227530052 REV B: FLAP DRIVE SYSTEM-ALTERNATE METALLIC SEAL FOR FLEXIBLE DRIVE SHAFT WAS INCORPORATED. (TC NR 20070118008) 2L72 4F4 FRTA21EA E15NE 20070511000072007051100007EU 2007 5 11 CA070118010 120070118G5302350A13111620 BOLT SNIAS 350 AS350B1 8680811EU TMECA ARRIELARRIEL1D NE TAILBOOM DAMAGED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THIS IS (1) OF (2) BOLTS USED TO RETAIN THE HORIZONTAL STAB. TO THE TAIL BOOM OF THE HELICOPTER. THE THREADED SECTION OF THE BOLT AND THE NUT WERE FOUND MISSING. IT APPEARS THAT THE THREADED SECTION OF THE BOLT HAD BEEN CRACKED FOR SOME TIME BEFORE DEPARTING. (TC NR 20070118010) 1G71 3U3 U H9EU E19EU 20070511000092007051100009EA 2007 5 11 CA070119001 120070117G5610NP1393229 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 6269 (CAN) SEVERAL CRACKS IN LT SIDEWINDOW INNER AND CENTER. A/C AOG LT SIDEWINDOW CHANGED ACC AMM. ALL TESTS SATISFIED (TC NR 20070119001) 2L72 4F4 FRTA21EA E15NE 20070511000162007051100016CE 2007 5 11 CA070119009 120070116G5711122210614 SPAR CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C402 GL RT WING FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) EDGE DISTANCE OF RIVETS ON LOWER FLANGE LESS THAN MINIMUM ALLOWED. REPLACEMENT OF PART REQUIRED TO REPAIR PROBLEM. (TC NR 20070119009) 1H71 3O3 O A4CE E8CE 5 CP47GL 20070511000182007051100018NM 2007 5 11 CA070119011 120070116G534369634801 BOLT BOEING727 727227 1384078NM PWA JT8 JT8D9A 52048NE TRUNION SHEARED W O OTHER O OTHER NRNOT REPORTED 1 CA 63218 (CAN) DURING A ROUTINE (C) CHECK INSPECTION, IT WAS NOTICED THAT THE LT MAIN LANDING GEAR TRUNION BOLT P/N 69-63480-1 APPEARED TO BE SHEARED. UPON REMOVAL OF THE GEAR, IT WAS CONFIRME4D THAT THE BOLT WAS SHEARED AND ALSO THE BEARING P/N 10-61849-10 WAS CRACKED. THE ABOVE PN ARE WITH REFERENCE TO MFG IPC 32-10-00-01 P.4 ITEM 317. (TC NR 20070119011) 2L73 4F4 F A3WE E2EA 20070511000212007051100021SO 2007 5 11 CA070120001 120070118G8120 BEARING PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL TURBOCHARGER FAILED W K NONE K FLUID LOSS ININSP/MAINT 1 CA 13433121 L206368A (CAN) RT ENGINE OIL CONSUMPTION HAD INCREASED, OIL RESIDUE FOUND ON EXHAUST STACK. INSPECTION FOUND THAT THE EXHAUST SIDE OF THE RT TURBOCHARGER WAS COVER IN OIL. FOUND THAT THE INNNER SUPPORT BEARING AND SEAL HAD FAILED ALLOWING OIL TO BE INTRODUCED TO THE HOT SIDE OF THE TURBO. REPLACED TURBOCHARGER, CHANGED ENGINE OIL, INSPECTED RT ENGINE OIL FILTER FOR METAL, NO FAULT FOUND. (TC NR 20070120001) 1L72 3O3 O A20SO E14EA 5 CP33EA 20070511000252007051100025WP 2007 5 11 CA070122002 120070122G7800D3171 HEAT SHIELD ROBSINR44 R44RAVENII 7640122WP LYC O540 IO540AE1A5 41530NE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 152 (CAN) DURING A ROUTINE 100 HR ENGINE/AIRFRAME INSPECTION, IT WAS NOTED THAT THE SUBJECT HEAT SHIELD, THAT IS INSTALLED ON THE ENGINE EXHAUST TAILPIPE, WAS FOUND CRACKED. THE CRACK ORIGINATED IN THE DOUBLER AREA WHERE THE FORWARD CLAMP IS ATTACHED. THE CRACK LOOKS LIKE IT HAS ORIGINATED FROM A RIVET THAT ATTACHES THE DOUBLER AND BRACKET, WHICH PROVIDES A MEANS TO ATTACH THE CLAMP TO THE EXHAUST TAILPIPE. THE PART IN QUESTION HAS 151.3 HOURS SINCE NEW ON IT. THE AIRCRAFT IN QUESTION HAS 495.0 HOURS SINCE NEW. THE PART WILL BE SUBMITTED TO MFG FOR WARRANTY. THIS IS THE 3RD HEAT SHIELD TO BE REPLACED ON THIS AIRCRAFT SINCE IT WAS NEW. THE PRIOR HEAT SHIELDS WHERE REPLACED AT 343.5 AIRCRAFT HOURS, AND 203.2 AIRCRAFT1G71 3O3 O H11NM 1E4 20070511000282007051100028WP 2007 5 11 CA070122004 120070122G5311C2617C2618 RIB ROBSINR44 R44RAVENII 7640122WP LYC O540 IO540AE1A5 41530NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 495 (CAN) DURING A ROUTINE 100 HOUR ENGINE/AIRFRAME INSPECTION, IT WAS NOTED THAT THE SUBJECT PARTS WHERE CRACKED. THE CRACKS WHERE FOUND AT THE FORWARD ANCHOR NUT LOCTIONS. THE RIBS ARE PART OF THE STRUCTURE THAT ENCLOSES THAT MAST AREA. THE RIBS WHERE REPLACED WITH NEW ASSEMBLIES. THE AIRCRAFT IN QUESTION HAS 495.0 HRS SINCE NEW. (TC NR 20070122004) 1G71 3O3 O H11NM 1E4 20070511000472007051100047CE 2007 5 11 CA070123001 120070119G76039938000521 CONTROL CABLE BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB4T HCB4TN3 GL LT ENGINE SEPARATED W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 CA (CAN) THE LT ENGINE COULD NOT BE SHUTDOWN ON THE GROUND USING THE CONDITION LEVER, THE PILOT HAD TO USE THE FIREWALL SHUT-OFF IN ORDER TO SHUT THE ENGINE DOWN. INVESTIGATION BY MAINTENANCE FOUND THAT THE LT IDLE CONTROL CABLE ASSY FAILED AT THE MALE TERMINAL END AT THE ENGINE. THE MALE THREADED END PORTION SLIPPED OFF THE CABLE SLIDE AT THE POINT WHERE IT IS SWAGED/PRESSED ON. (TC NR 20070123001) 1L72 3T4 T A14CE E4EA 6 CP40EA 20070511000492007051100049EA 2007 5 11 CA070123002 120070122G2750 FLAP SYSTEM CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE TE FLAPS JAMMED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) AIRCRAFT HAD A FLAPLESS LANDING, AFTER FLAP SELECTION 8, LT FLAP INDICATED ZERO, RT UNKNOWN, CREW THEN SELECTED TO 20 AND FLAPS TRAVELED TO APROX 5 DEGREES INDICATION WAS GREEN TRAVELED TO 5 DEGREES AND THEN TURNED WHITE. CREW THEN RETRACTED FLAPS BACK TO FLAP ZERO AND LANDED FLAPLESS, FLAP FAIL CAUTION WAS NOT ILLUMINATED. FERRY FLIGHT FOR TROUBLESHOOTING. T/S C/O AND ALL DCU`S ARE DISPLAYING THE SAME INFO, APPEARS TO BE POTENTIOMETER FAIL. WAITING FOR PART TO BE INSTALLED. (TC NR 20070123002) 2L72 4F4 FRTA21EA E15NE 20070511000502007051100050EA 2007 5 11 CA070123005 120070118G2752852D10019 ACTUATOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE TE FLAPS WORN W L ABORTED APPROACH F FLT CONT AFFECTED APAPPROACH 1 CA 5457 5321 (CAN) ON FINAL APPROACH CREW SELECTED FLAPS 20 DEGREES. FLAPS STUCK AT 8 DEGREES AND CREW RECEIVED A FLAP FAIL MESSAGE. CREW BROKE OFF APPROACH AND CONTACTED DISPATCH. AIRCRAFT SUBSEQUENTLY LANDED WITHOUT INCIDENT WITH FLAPS AT 8 DEGREES. MAINTENANCE TROUBLESHOOTING FOUND EXCESSIVE LINEAR PLAY IN THE LT AND RT IB FLAP ACTUATORS. ACTUATORS REPLACED (RT IB ACTUATOR PN CL600-2B19, S/N 5051. TSN 5321:44 HOURS, TSO 5321:44, CYCLES 4332) MOD SUM IS601R27530052 REV B: FLAP DRIVE SYSTEM, ALTERNATE METALLIC SEAL FOR FLEXIBLE DRIVE SHAFT COMPLETED. SYSTEM RE-GREASED. FLAP SYSTEM RIGGED IAW AMM 27-51-10. SUCCESSFUL TEST FLIGHT COMPLETED AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20070123005) 2L72 4F4 FRTA21EA E15NE 20070511000582007051100058EA 2007 5 11 CA070123015 120070118G5610NP13932113 WINDSHIELD CNDAIRCL600 CL6002D24 1390016EA GE CF34 CF348C1 NE COCKPIT CRACKED W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA 564 (CAN) LT WINDSHIELD CRACKED. LT WINDSHIELD REPLACED IAW AMM 56-11-01-000-801 (TC NR 20070123015) 2L72 4F4 FRTA21EA EOOO63EN 20070511000592007051100059EA 2007 5 11 CA070125001 120070125G32336008500185 ACTUATOR CNDAIRCL601 CL6012A12 1900303EA GE CF34 CF343A 30015NE MLG INOPERATIVE W O OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 CA 251896776 (CAN) RT MAIN LANDING GEAR UNLOCK INDICATION APPROX. 15 - 20 MIN. AFTER ARRIVAL, NO PUMP, NO GEAR COMMAND, LOCK PARTIALLY MOVED TO UNLOCK POSITION. RETRACTING ACTUATOR REPLACED AND AC RETURNED TO SERVICE. 2L72 4F4 FRTA21AE E15NE 20070511000612007051100061GL 2007 5 11 CA070126001 220070121G7200 ENGINE EMB 135 EMB135LR 3260305SO ALLSN AE300 AE3007A GL MALFUNCTIONED W EBA ENGINE SHUTDOWN EMER. DESCENT UNSCHED LANDING BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CLCLIMB 1 CA 9808 CAE312136 (CAN) DURING CLIMB (280 KNOTS) AT FL350 , CREW HEARD A LOUD POP FOLLOWED BY MULTIPLE UNSPECIFIED EICAS MESSAGES AND ITT WAS IN THE AMBER RANGE. ENGINE SHUTDOWN UNCOMMANDED. F/A REPORTED WHITE SMOKE IN THE CABIN. CREW CONSIDERED ATTEMPTING A RE-START BUT OIL QUANTITY WAS ONLY 3 QUARTS. CREW DIVERTED AND A CMC DOWNLOAD REVEALED THAT AN OIL DEBRIS MESSAGE HAD BEEN SET ON JANUARY 19. ENGINE ENROUTE TO MFG FOR INVESTIGATION, FURTHER REPORT WILL BE SUBMITTED ON ENGINE TEARDOWN. (TC NR 20070126001) 2L72 4F4 FRTT00011ATTE6CH 20070511000652007051100065CE 2007 5 11 CA070122008 120070120G3230508103385 DRAG LINK BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL RT MLG FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER SCHEDULED MAINTENANCE THE AIRCRAFT WAS REMOVED FROM THE HANGER AND WAS TOWED TO THE FUEL PUMPS TO BE LEAK CHECKED. AFTER TOWING THE AIRCRAFT ABOUT 500 FEET THE RT MLG COLLAPSED CAUSING DAMAGE TO THE RT MAIN LANDING GEAR AND DOORS, WING TIP, CARGO POD AND ONE BLADE OF THE RT PROP. THE AIRCRAFT WAS THEN LIFTED AND JACKED TO ALLOW INSPECTION OF THE LANDING GEAR AREA AND ALLOWED FOR A TEMPORARY DOWNLOCK TO BE MADE AND THE AIRCRAFT WAS RETURNED TO THE HANGER. THE AIRCRAFT IS STILL BEING INSPECTED FOR OTHER UNSEEN DAMAGE. THE PRELIMINARY FINDINGS SHOW THAT THE PRIMARY FAILURE WAS OF THE DRAG LINK LOCK. THIS IS ONLY A PRELIMINARY REPORT A MORE CONCLUSIVE REPORT WILL BE ADDED TO THIS SDR WHEN THE FINDINGS A1L72 4T4 T A24CE E4EA 5 CSTC 20070511000682007051100068NE 2007 5 11 CA070123010 220070123G7261311145101 SEAL BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE NR 2 ENGINE LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA 158524083 (CAN) CREW LANDED AND REPORTED ENGINE NR 2 LEAKING OIL. MAINTENANCE INSPECTED AND FOUND THE OIL LEVEL DOWN CONSIDERABLY, THEY INSPECTED THE FWD CHIP DETECTOR, OIL FILTER, FUEL OIL HEATER AND FOUND NO DEFECTS. THE ENGINE WAS GROUND RUN WITH A LITTLE OIL LEAKAGE FOUND. THE OIL BREATHER LINE WAS REMOVED AND THE A/C SENT ON A TEST FLIGHT. WHEN IT RETURNED THE BAG WAS FULL (.5 LTR) WITH SOME SPILLAGE FROM THE BAG .THE A/C WAS GROUNDED AND WITH THE AID OF A MFG ENGINEER, THE REDUCTION GEAR BOX ASSY WAS REMOVED FROM THE ENGINE. CLOSE INSPECTION FOUND THE INTERNAL CARBON SEAL ASSY WITH SLIGHT DAMAGE AND STUCK IN THE OPEN POSITION. AS SOON AS THE SEAL WAS TOUCHED THE SPRING IN THE ASSY CLOSED THE OPENING IN THE SEAL ASS2L72 4T4 TRTA24CE E26NE 20070511000692007051100069CE 2007 5 11 CA070124003 120070119G575399160011 ROLLER BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL TE FLAPS WORN W A UNSCHED LANDING F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) PILOT REPORTED INTERFERENCE WITH AILERON CONTROL UPON APPROACH WHEN FLAPS WERE APPROXIMATELY 30 PERCENT. AIRCRAFT LANDED WITHOUT INCIDENT. INVESTIGATION REVEALED RT OB FLAP IB HINGE ATTACH BRACKET, PN 35-165050-31, FAILED AT THE AFT ROLLER ASSY ATTACH AREA. THIS IN TURN CAUSED THE OPPOSITE ATTACH BRACKET TO FAIL. THIS CAUSED THE IB AFT AREA OF THE FLAP TO MOVE FREELY AND CHANGE THE NORMAL ATTITUDE OF THE FLAP CAUSING INTERFERENCE WITH THE IB RT AILERON SKIN. THE HINGE ATTACH BRACKET FAILED FROM THE AFT ROLLER ASSY, P/N 99-160011, WEARING INTO THE HINGE ATTACH BRACKET. INSPECTED ALL OTHER HINGE ATTACH AREAS AND FOUND SIMILAR WEAR IN OTHER AFT ROLLER ATTACH LOCATIONS. THE ROLLER ASSEMBLY, PN 99-160011L72 3T4 T A14CE E4EA 5 CSTC 20070511000712007051100071EA 2007 5 11 CA070125005 220070125G7250312111101 BLADE PWA PT6 PT6A65B 52043EA TURBINE SECTION FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ENGINE PT6A-65B S/N: PCE-32399 WAS RECEIVED FOR OVERHAUL. DURING THE ENGINE DISASSEMBLING IT WAS FOUND THAT THE COMPRESSOR TURBINE BLADES WERE SEVERELY RUBBED AND ONE BLADE FAILED AT FIRTREE. ALSO THE INSPECTION REVEALED THAT THE COMPRESSOR TURBINE VANE TRAILING EDGE, SHROUD SEGMENTS AND SHROUD HOUSING ARE DAMAGED. THE POWER TURBINE COMPONENTS: 1ST AND 2ND STAGES BLADES AND VANES FOUND IMPACT DAMAGED. THE BLADE WHICH FAILED AT THE FIRTREE SHOWED EVIDENCE OF FATIGUE WITH AN ANOMALY AT THE ORIGIN. NOTE: CODES DETERMINED FROM PILOT REPORT. (TC NR 20070125005) 4 T E4EA 20070511000752007051100075SW 2007 5 11 CA070126006 120070121G5302206020113207 TAIL BOOM BELL 206 206L4 1182110SW ALLSN 250C 250C30P 03013GL VERTICAL FIN DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA 3368 52054 (CAN) UPON CHANGING FORMER P/N 206-020-113-093 ON VERTICAL FIN, DAMAGE/GOUGING DETECTED ON THE IB FIN SKIN WITHIN CLOSE PROXIMITY TO VERTICAL FIN MOUNTING HOLE. IT IS SUSPECTED THAT WHEN ORIGINALLY FITTING THE COWLS THAT THE FORMER WAS TRIMMED AND THAT AT THIS TIME THE DAMAGE OCCURRED. MFG WAS CONTACTED AND AN APPROVED REPAIR WAS PROVIDED AND CARRIED OUT. (TC NR 20070126006) 1G71 3U3 UNCH2SW E1GL 20070511001262007051100126EA 2007 5 11 CA070124001 120070122G284073664310 COMPUTER CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE FUEL QUANTITY MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA 1022010220 (CAN) JUST PRIOR TO TOP OF CLIMB, LEFT FUEL QUANTITY AND TOTAL FUEL QUANTITY STARTED TO REDUCE, FOLLOWED BY FUEL IMBALANCE MESSAGE. CREW ELECTED TO RETURN TO DEPARTURE AIRPORT. ON FINAL APPROACH FUEL INDICATIONS RETURNED TO NORMAL. FUEL SYSTEM INSPECTED, WITH NO LEAKAGE FOUND. AIRCRAFT DISPATCHED UNDER MEL. ON NEXT MAINTENANCE VISIT FUEL COMPUTER REPLACED. (TC# 20070124001) 2L72 4F4 FRTA21EA E15NE 20070511001272007051100127NM 2007 5 11 CA070125003 120070123G26123023143 SMOKE DETECTOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE CARGO BAY FALSE INDICATIONW A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA 2853028530 (CAN) ON DEPARTURE THROUGH 4000 FT, FLT CREW RECEIVED A MASTER WARNING BAGGAGE SMOKE INDICATION. FLIGHT CREW DECLARED AN EMERGENCY AND ELECTED TO RETURN TO DEPARTURE AIRPORT. THERE WAS A COMPANY LINE CHECK CAPTAIN ON BOARD WHO WITH THE FLIGHT ATTENDANT WENT TO CHECK THE CARGO HOLD. THERE WAS NO INDICATION OF SMOKE. FLIGHT LANDED SAFELY WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE NR 1 BAGGAGE SMOKE DETECTOR , THE LAMPS IN THE NR 2 DETECTOR (P/N 376), CLEANED THE CONNECTORS OF BOTH DETECTORS AND GROUND TESTED THEM SERVICEABLE. ENGINE RUNS WERE CARRIED OUT WITH NO DUPLICATION OF THE ORIGINAL DEFECT. TIME SINCE LAST REPAIR OF THE NR 1 DETECTOR WAS 1883:46 HOURS. (TC 20070125003) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070511001512007051100151SW 2007 5 11 31038042507 120070425G56103G5630F00111A2 WINDOW AGUSTAAB139 AB139 0260110SW PWA PT6 PT6* 52043EA CREW DOOR DEPARTED B O OTHER D INFLIGHT SEPARATION CRCRUISE 1 EA17139BK 31038 DURING CRUISE FLIGHT AT AN ALTITUDE OF 2000FT, IAS 152KTS,THE CO-PILOT DOOR WINDOW SEPARATED FROM AIRCRAFT. 2G72 6U3 T R00002RDE2NE 20070511001752007051100175CE 2007 5 11 CA070126010 120070123G2110206SZZC BEARING BEECH 115555024 BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL COMPRESSOR DISINTEGRATED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BEARING WITHIN RT ENGINE AIR CONDITIONING COMPRESSOR DRIVE PULLEY DISINTEGRATED WHICH GREATLY CAUSED FURTHER HARM TO ITS ASSOCIATED PARTS. THE QUILL SHAFT, COMPRESSOR DRIVE PULLEY, COMPRESSOR MOUNT ASSEMBLY, DRIVE SUPPORT, BEARING SHIMS AND SPACER, AND DUAL BELT (COMPRESSOR DRIVE BELT) HAVE HAD IRREVOCABLE DAMAGE. QUILL SHAFT DID NOT SHEAR. (TC NR 20070126010) 1L72 4T4 T A24CE E4EA 6 CP15EA 20070511001782007051100178 2007 5 11 CA070126012 420070124G2300 FEEDER CABLE BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33112UHR WP ROTOL R333 R333482F12 GL RADIO LOOSE W O OTHER H ELECT. POWER LOSS-50 PC APAPPROACH 1 CA (CAN) TOTAL LOSS OF CAPT`S RADIO COMMUNICATIONS. TROUBLESHOOTING FOUND MAIN POWER FEED CONNECTION NOT TIGHTEN ON TERMINAL BLOCK T5GA CAUSING CONNECTOR TERMINAL RING TO FLOAT AND REMOVE POWER SUPPLY TO CAPT`S AUDIO STATION BOX (TC NR 20070126012) 2L72 4T4 TRTBA15CAA E4WE 6 CP61GL 20070511001792007051100179NE 2007 5 11 CA070126013 220070126G7220 FAN CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE ENGINE DISLODGED W BA EMER. DESCENT UNSCHED LANDING DTYINFLIGHT SEPARATION ENGINE CASE PENETRATION ENGINE STOPPAGE CLCLIMB 1 CA (CAN) THE NR 1 ENGINE FAN DISLODGED ITSELF FROM THE ENGINE AND TORE OFF THE INLET AND FAN CASING. IT ALSO DID EXTENSIVE DAMAGE TO THE PYLON AND THE FUSELAGE. NTSB IS ON SITE FOR THE INVESTIGATION. MORE INFORMATIOON TO FOLLOW ONCE AVAILABLE. (TC NR 20070126013) 2L72 4F4 FRTA21EA E15NE 20070511001832007051100183EA 2007 5 11 CA070128002 120070126G4900 APU CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE CONTAMINATED W O OTHER BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CLCLIMB 1 CA (CAN) SHORTLY AFTER DEPARTURE, THE CREW NOTICED A LAV SMOKE WARNING AND SMOKE WAS VISIBLE IN THE CABIN FOR 3-4 MINUTES THEN IT DISSIPATED. SMOKE WAS BLUISH IN COLOR AND OILY SMELLING. (2) MAINTENANCE PERSONNEL WERE ON BOARD, INITIALLY THEY THOUGHT SINCE THE AIRCRAFT HAD JUST BEEN DE-ICED WITH ENGINES AND APU RUNNING THAT DE-ICE FLUID WAS THE CAUSE SO A DECISION WAS MADE TO CONTINUE. THE COALESER BAGS WERE INSPECTED AND REPLACED. AFTER ENGINE RUNS AND FURTHER TROUBLESHOOTING IT WAS NOTICED THAT NR 2 PRSOV IS RUNNING AT 38 TO 41 PSI AND MAY HAVE CAUSED DAMAGE TO NR 2 ACM. FURTHER TROUBLESHOOTING ON GOING. (TC NR 20070128002) 2L72 4F4 FRTA21EA E15NE 20070511001862007051100186EA 2007 5 11 CA070129004 120070115G256011011200 BUCKLE DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL CREW SEATBELT DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SPECIAL INSPECTION OF CREW SEAT BELT ROTORY LATCH SYSTEM PERFORMED. BOTH LT AND RT CREW SEATBELT BUCKLE ASSEMBLIES WERE CAPABLE OF BEING UNLATCHED WHEN CONTACTED BY THE CONTROL YOKE WHEN ROTATED LT OR RT WITH THE YOKE FULL AFT AND THE SEAT IN THE MOST FORWARD POSITION. THIS SPECIAL INSPECTION WAS MANDATED BY A COMPANY CAMPAIGN NOTICE TO INSPECT AIRCRAFT IAW FAA SPECIAL AIRWORTHINESS INFORMATION BULLETIN (NM-06-39)TO DATE, NO RECTIFICATION FOR THIS PROBLEM HAS BEEN PUBLISHED. (TC NR20070129004) 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20070511001882007051100188NM 2007 5 11 CA070129005 120070128G323083221002003 LOCK DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE NLG DAMAGED W O OTHER J WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER TAKEOFF THE NOSE LANDING GEAR FAILED TO RETRACT. FLIGHT CONTINUED AND LANDED TO THE DESTINATION AIRPORT WITHOUT FURTHER INCIDENT. MAINTENANCE INSPECTED THE AIRCRAFT AFTER ARRIVAL AND FOUND THE NOSE GEAR GROUND LOCK OUT, AND IN LOCK POSITION. (TC NR 20070129005) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070511001952007051100195CE 2007 5 11 CA070130003 120070129G76005052456849 CONDITION LEVER BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL CONTROL PEDESTALCRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PILOTS REPORTED LT FUEL CONDITION LEVER CRACKED HALF WAY DOWN LEVER. AIRCRAFT REMOVED FROM SERVICE. RT CONDITION LEVER INSPECTED AND SHOWED SIGNS OF WEAR. LT AND RT CONDITION LEVERS ON ORDER. (TC NR 20070130003) 1L72 3T4 T A14CE E4EA 5 CSTC 20070511001962007051100196NM 2007 5 11 CA070130004 120070126G2820 O-RING BOEING767 767306 1385148NM GE CF6 CF680C2B6F 30025NE FUEL SYSTEM LEAKING W O OTHER KJ FLUID LOSS WARNING INDICATION LDLANDING 1 CA (CAN) AC LANDED WITH LOW HYD FLUID IN CENTER SYS FOUND ACMP NR 2 CENTER FILTER MODULE PRESSURE DELTA P POP-UP LEAKING DUE TO A FAILED O-RING. O-RING REPLACED AND HYD SYSTEM SERVICED (37 QTS). (TC NR 20070130004) 2L72 4F4 FRTA1NM E13NE 20070511001982007051100198EA 2007 5 11 CA070131001 220070129G7397 CONNECTOR BENDIX DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL NR 1 TRANSMITTERSEPARATED W O OTHER N FALSE WARNING NRNOT REPORTED 1 CA 4801 812141 (CAN) AIRCREW REPORTED THAT THE NR 1 FUEL FLOW WAS FLUCTUATING WITH NO OTHER ENGINE PARAMETERS BEING AFFECTED. MAINTENANCE TROUBLESHOT THE SYSTEM, SWAPPED GAUGES FROM SIDE TO SIDE, PERFORMED ENGINE RUNS AND COULD NOT FAULT THE SYSTEM. AIRCRAFT WAS RELEASED FOR FLIGHT. WHEN AIRCRAFT RETURNED TO BASE THE AIRCREW REPORTED THAT THE SNAG WAS STILL PRESENT. MAINTENANCE BEGAN INVESTIGATING DEEPER INTO SYSTEM. WHEN THE NR 1 FUEL FLOW TRANSMITTER WAS LOOKED AT, IT WAS FOUND THAT THE CONNECTOR PLUG BOSS HAD SEPARATED FROM THE MAIN BODY, THIS ALLOWED THE WIRES TO STRIKE THE HOUSING SIDES DURING FLIGHT DUE TO NORMAL VIBRATIONS, SHORTING OUT THE TRANSMITTER. THIS COMPONENT HAS BEEN INSTALLED ON THE AIRCRAFT SINCE WE TOOK P1H72 3T4 TRTA9EA E4EA 6 CP15EA 20070511002002007051100200EA 2007 5 11 CA070131003 120070130G2750 FLAP SYSTEM CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE TE FLAPS FAILED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) THE CREW REPORTED THAT UPON APPROACH FLAPS 8 DEGREES WERE SELECTED OKAY. UPON FLAP 20 DEGREE SELECTION, THE FLAPS DID NOT MOVE AND THE FLAP FAIL CAUTION LIGHT ILLUMINATED. THE FLAPS LOCKED AT 8 DEGREES. THE AIRCRAFT IS CURRENTLY IN LINE, MAINTENANCE IS TROUBLESHOOTING.(TC NR 20070131003) 2L72 4F4 FRTA21EA E15NE 20070511002022007051100202SW 2007 5 11 CA070131004 120070122G6210206010200133 BLADES BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL MAIN ROTOR OUT OF BALANCE W K NONE E VIBRATION/BUFFET ININSP/MAINT 1 CA (CAN) COULD NOT ACHEIVE DYNAMIC BALANCE OF A/C. (TC NR 20070131004) 1G71 3U3 U H2SW E4CE 20070427000042007042700004CE 2007 4 27 2007FA0000357 120070425G3220 LANDING GEAR CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL NOSE BROKEN D O OTHER O OTHER LDLANDING 1 WP09757CM10768 15279633 RL2072615 770307 NOSE LANDING GEAR BROKE AT HARD NOSE LANDING, NO EVIDENCE OF PREVIOUS CRACKS. 1H71 3O3 ONT3A19 E223 5 NP50GL 20070501001162007050100116SO 2007 5 1 2007FA0000352 220070424G73223801552 CARBURETOR CONT A65 A65* 17003SO ENGINE MALFUNCTIONED B O OTHER O OTHER NRNOT REPORTED 1 EA07 CARBURETOR WAS SENT IN FOR AN OVERHAUL BECAUSE IT WOULD NOT ACCEPT THROTTLE. THERE WAS VERY LITTLE TIME ON THE CARBURETOR SINCE IT'S LAST OVERHAUL. UPON DISASSEMBLY, IT WAS FOUND THAT THE CARBURETOR HAD THE WRONG VENTURI INSTALLED AND THERE WAS OLD CORROSION IN THE FLOAT CHAMBER THAT WAS NOT REMOVED DURING THE PREVIOUS OVERHAUL. IT HAD THE WRONG SEAT INSTALLED FOR THE TYPE NEEDLE THAT WAS BEING USED. IT WAS OBVIOUS THAT SOMEONE WHO THOUGHT THEY KNEW CARBURETORS HAD ATTEMPTED TO OVERHAUL THE UNIT UNSUCCESSFULLY. 3 O E205 20070503000012007050300001EU 2007 5 3 CA070329001 120070326G6310350A35105901 COUPLING SNIAS SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE M/R DRIVESHAFT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK IN DISC LAMINATE FOUND DURING POST FLIGHT (DAILY) INSPECTION. (TC NR 20070329001) 1G71 3U3 U H9EU E19EU 20070503000102007050300010EU 2007 5 3 CA070402002 120070402G29107229160003 LINE SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE ROTOL R390 R3904123F27 NE HYD SYSTEM CHAFED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) HYDRAULIC FLUID WAS NOTICED ROUND ACCESS PANEL 151CB RT. INVESTIGATION REVEALED A WEAR MARK AND PIN HOLE IN A HYDRAULIC LINE UNDER THE PANEL. FURTHER INVESTIGATION INDICATED THAT AN AJACENT PANEL BONDING STRAP HAD LOOPED WHEN THE PANEL WAS CLOSED AND HAD BEEN RUBBING ON THE HYDRAULIC LINE. THAT THE STRAP WOULD CHAFE ON THE HYDRAULIC LINE WAS NOT OBVIOUS WHEN THE PANEL WAS CLOSED. (TC NR 20070402002) 2L72 4T4 TRTA52EU E8NE 6 CP31NE 20070503000302007050300030CE 2007 5 3 CA070403001 120070328G5740SPS8178510 BOLT BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL WING ATTACH CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 7540 (CAN) DURING A SCHEDULED NDT INSPECTION OF THE WING ATTACHMENT BOLTS THE FWD UPPER BOLT ON THE RT SIDE WAS REJECTED AFTER THE LIQUID PENETRANT INSPECTION REVEALED A CRACK AT THE HEAD OF THE BOLT. THE BOLT HAD 7540.5 TSN. THIS INSPECTION IS DUE EVERY 1000 HRS. (TC NR 20070403001) 1L72 3T4 T A14CE E4EA 5 CSTC 20070503000312007050300031SW 2007 5 3 CA070403002 120070401G56102719442004 WINDSHIELD SWRNGNSA226 SA226AT 8780405SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCB3T HCB3TN5 GL COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA 5049 (CAN) THE FLIGHT CREW OBSERVED THE LT HEATED WINDSHEILD DELAMINATE AND CRACK DURING FLIGHT. THEY CARRIED OUT THEIR EMERGENCY PROCEDURES AND LANDED AT THEIR POINT OF DESTINATION. MAINTENANCE REPLACED THE WINDSHEILD. NO REASON FOR THE FAILURE (IE IMPACT) COULD BE DETERMINED. THIS IS ONE OF MANY FAILURES OF THIS WINDSHEILD PN INCURRED BY THIS OPERATOR. MULTIPLE ATTEMPTS TO CONTACT THE MFG HAS RESULTED IN NO RESPONSE. (TC NR 20070403002) 2L72 4T4 TRTA5SW E4WE 6 CP15EA 20070503000352007050300035EA 2007 5 3 CA070403005 120070331G3820060150C1 WATER HEATER CNDAIRCL601 CL6013A 8070802EA GE CF34 CF343A 30015NE LAVATORY ODOR W BA EMER. DESCENT UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 5057 (CAN) WHILE EN ROUTE, A BURNING ODOR WAS NOTICED BY THE CREW AND PASSENGERS. NO SMOKE WAS APPARENT IN THE CABIN OR COCKPIT. THEN SEARCHED THE LAVATORY AND BAGGAGE COMPARTMENT. A TRACE OF SMOKE WAS FOUND IN THE BAGGAGE COMPARTMENT. A QUICK VISUAL INSPECTION OF THE LUGGAGE WAS CARRIED OUT TO SEE IF THIS WAS THE SOURCE OF THE SMOKE. IT WAS NOT. UPON EXITING THE LUGGAGE COMPARTMENT THE SMOKE WAS SEEN SLOWLY ADVANCING TO THE PASSENGER CABIN. CLOSED THE DOOR TO THE BAGGAGE AREA AS WELL AS TO THE LAVATORY. BRIEFED THE PASSENGERS TO NOT OPEN THE DOORS AND MOVED THEM TO THE MOST FORWARD SEATING POSITIONS. DECLARED AN EMERGENCY AND REQUESTED TO LAND. A RAPID DESCENT WAS INITIATED AND THE QRH PROCEDURE FOR SMOKE2L72 4F4 FRTA21EA E15NE 20070504000862007050400086NE 2007 5 4 CA070330002 320070216G611458462 BARREL HAMSTD DHAV DHC2 DHC2MKI 2801830GL PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 855 112779 (CAN) PROPELLER HISTORY - AUG 28 06 TTSOH 712.8 PROPELLER REPAIRED. - JAN 19 07 TTSOH 839.6 PROPELLER FLY WEIGHT ROLLER STIFF, ROLLER LUBRICATED AND RETURNED TO SERVICE. - FEB 16 07 TTSOH 854.9 PROPELLER REMOVED FROM SERVICE AND RETURNED TO O/H SHOP FOR REPAIR, SLOW TO CHANGE PITCH. - MAR 13 07 TTSOH 854.9 PROPELLER REPAIRED BY O/H SHOP, NEW CYLINDER AND COUNTER WEIGHT ROLLER KITS INSTALLED. - MAR 15 07 TTSOH 854.9 PROPELLER INSPECTED BEFORE INSTALLATION ON AIRCRAFT AND THE REAR PORTION OF THE PROPELLER BARREL (HUB) WAS FOUND TO BE CRACKED FROM THE BOLT BOSS 90` TO THE REAR OF THE BARREL ALONG THE OUTSIDE RADIUS. CONTINUED OPERATION OF THE UNIT IN THIS CONDITION WOULD HAVE LED TO A CATASTROPHIC FAILURE. THIS1H71 3R3 RRCA806 5E1 5 CP206 20070504000922007050400092WP 2007 5 4 CA070330003 120070329G2780N547E RELAY CVAC 340 340CVAC 242270AWP ALLSN 501D 501D13D 03004GL ALLSN A6441 A6441FN606 GL TE FLAP FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION, THE FLAPS WERE SELECTED DOWN. THEY STOPPED MOVING APPROXIMATELY HALF WAY DOWN. THE FLAP SOLENOID CIRCUIT BREAKER WAS OBSERVED TO BE OPEN. UPON INVESTIGATION THE FLAP RELAY LOCATED IN THE GENERAL RELAY PANEL WAS FOUND TO HAVE FAILED. THE RELAY WILL BE REPLACED WITH A SERVICEABLE UNIT. (TC NR 20070330003) 2L72 4R4 T 6A6 E282 6 CP898 20070504001092007050400109SW 2007 5 4 CA070404007 120070404G28102060636321 FUEL CELL BELL 206 206L1 1182107SW ALLSN 250C 250C28 03013GL LEFT LEAKING W O OTHER KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) RETURNING FROM A FLIGHT IT WAS NOTED THERE WAS A FUEL ODOR IN THE REAR CABIN. INVESTIGATING DETERMED THE LT FWD FUEL CELL HAD A SMALL LEAK. FUEL CELL WAS CHANGED OUT. (TC NR 20070404007) 1G71 3U3 U H2SW E1GL 20070504001142007050400114EA 2007 5 4 CA070404010 120070328G5610NP13932113 WINDSHIELD CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT FAILED W B EMER. DESCENT O OTHER CLCLIMB 1 CA (CAN) ON CLIMB OUT THROUGH 11000` PILOTS WINDSHIELD SHATTERED. REMARKS FROM PILOT (TOOK OFF CLIMBING THROUGH 11000 OR 12000) THE LT FRONT PILOT WINDSHIELD SPIDERWEBBED AND SHATTERED. IT SPIDERWEBBED ALL AT ONCE VERY QUICKLY. WE DECLARED AN EMERGENCY, DESCENDED TO 8000 FT AND SLOWED THE AIRCRAFT DOWN TO 190 KNOTS. COMPLETED THE QRH FOR LT WINDSHIELD HEAT. TRANSFERRED THE CONTROLS TO THE FIRST OFFICER AND PREPARED FOR AN EMERGENCY LANDING. BRIEFED THE FLIGHT ATTENDANTS AND SENT A MESSAGE TO DISPATCH VIA ACARS. NEXT WE ADVISED OPS WE WERE RETURNING AND WERE ASSIGNED GATE. FIRST OFFICER AND BRIEFED AN OVERWEIGHT LANDING AND COMPLETED IN RANGE AND BEFORE LANDING CHECKLIST. CONDITIONS WERE GUSTY WINDS GUSTIN2L72 4F4 FRTA21EA EOOO63EN 20070504001262007050400126CE 2007 5 4 CA070409003 120070404G291025800 SELECTOR VALVE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL HYD SYSTEM LEAKING W O OTHER K FLUID LOSS DEDESCENT 1 CA 2 (CAN) VALVE WAS OVERHAULED BY VENDOR. AFTER OVERHAUL IT WAS INSTALLED IN THE AIRCRAFT. AFTER 2 HOURS OF OPERATION A LEAK DEVELOPED. THE VALVE WAS REMOVED AND DISTRIBUTION MANIFOLD DISASSEMBLED. WHEN CHECKING THE IPC IT WAS NOTED THAT AT OVERHAUL, THE OVERHAUL FACILITY FAILED TO INSTALL 2 O-RINGS. THE O-RINGS WERE INSTALLED AND RE-ASSEMBLED, THE AIRCRAFT GEAR SWING CARRIED OUT SATISFACTORY (TC NR 20070409003) 1L72 4T4 T A24CE E4EA 5 CSTC 20070504001462007050400146WP 2007 5 4 2007FA0000343 220070411G726131080261 SCAVENGE PUMP CESSNA441 441 2076020CE GARRTTTPE331TPE33110 01514WP LT ENGINE FLUCTUATES B E ENGINE SHUTDOWN J WARNING INDICATION NRNOT REPORTED 1 GL25835MA 4410343 P77725 COMMANDED IN-FLIGHT SHUTDOWN OF LT ENGINE DUE TO FLUCTUATING OIL PRESSURE. UNEVENTFUL SINGLE ENGINE LANDING. ENGINE LOST OIL. OIL EXITED ENGINE FROM TURBINE AIR/OIL SEAL AS A RESULT OF TURBINE SCAVENGE PUMP FAILURE. RECOMMEND COMPLIANCE WITH SB 72-2074R1. (K) 1L72 3T4 TRTA28CE E4WE 20070504001482007050400148CE 2007 5 4 2007FA0000299 120070326G2820050011849 LINE CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA FUEL SYSTEM CHAFED D O OTHER O OTHER NRNOT REPORTED 1 EA232470N400 172S10070 FOUND FUEL LINE PN 05001( 8-49, FUEL RETURN LINE TO RESERVOIR WORN BY RUBBING ON NOSE STEERING ROD JUST BEHIND FIREWALL. INSTALLED NEW LINE SO AS NOT TO RUB ON STEERING. INSTALLED SPIRAL WRAP ON AREA WHERE RUBBING HAD OCCURRED. NOTE: FUEL LINE WAS WORN TO POINT OF LEAKING. RECOMMEND INSPECTING NEW AC FOR PROPER LINE INSTALLATION. (K) 1H71 3O3 ONT3A12 1E10 20070504001522007050400152SO 2007 5 4 2007FA0000322 120070330G5730427 SKIN GULSTMG1159 G1159A 3970109SO RROYCESPEY SPEY511* 54523EU RT WING CORRODED D K NONE O OTHER ININSP/MAINT 1 SW05300WY 427 DURING A WING NDT INSPECTION OF THE UPPER RT WING PLANK AT FS 452 AND BL 33, CORROSION WAS NOTED IN THIS AREA. ENGINEERING HAS DETERMINED THIS CORROSION IS EXCESSIVE ENOUGH TO REQUIRE ACCOMPLISHMENT OF ASC 229, WHICH REMOVES THE CORROSION ON THE PLANK AND INSTALLS A DOUBLER PLATE AND A NEW STYLE WING ATTACH PIN AS A CORRECTIVE ACTION. (K) 2L72 4F4 F A12EA E2EU 20070504001712007050400171GL 2007 5 4 2007FA0000330 220070403G724023031260 COMBUSTION CASE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE CRACKED B EOORO OTHER O OTHER NRNOT REPORTED 1 AL03CGPHC 180257D CAE831562 PILOT NOTICED CRACK IN COMBUSTION CAN ON PREFLIGHT CHECK REPLACED UNIT. (K) 1G71 3U3 U H3WE E4CE 20070504001722007050400172SO 2007 5 4 2007FA0000349 120070401G57533087B SPAR MAULE M4 M4210C 5460112SO CONT IO360 IO360* 17025CE RT FLAP LOOSE D O OTHER O OTHER NRNOT REPORTED 1 WP099810M5341 1020C DURING AN ANNUAL INSPECTION, THE RT FLAP IB HINGE/CONTROL BRACKET WAS FOUND TO BE LOOSE. FURTHER INSPECTION REVEALED THAT THE FLAP SPAR WAS CRACKED AT THE UPPER RIVET ATTACH POINTS. THE CRACK IS 3.5 INCH LONG AND EXTENDS PAST THE RIVET HOLES IN BOTH DIRECTIONS. ADDITIONALLY, BOTH CLOSURE RIBS, AT THEIR ATTACH ANGLES TO THE SPAR. THE SPAR PN IS 3078B, RIB PNS 3046-2 AND 3046-1, RIVET PNS SS/SS 34D AND SS/SS 32D (MFG SUPPLIED). THE FLAP SPAR AND RIBS WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. (K) 1H71 3O3 O 3A23 E1CE 20070504002062007050400206CE 2007 5 4 2007FA0000381 120070404G781002R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA RT ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 SO09 13510514 PCE81382 WHILE PREFORMING SCHEDULED MAINTENANCE, REMOVED LT ENGINE EXHAUST STACK TO FACILITATE INSPECTING THE EXHAUST DUCT. FOUND CRACK FOLLOWING THE CIRCUMFERENCE OF THE SKI SLOPE. THE EXHAUST DUCT HAD SB 3380 COMPLIED WITH 514 HOURS EARLIER.POWER SECTION WAS REMOVED AND SENT FOR REPAIR. 1L72 4T4 T A24CE E4EA 20070504002232007050400223CE 2007 5 4 2007FA0000369 120070404G3210084100097 LANDING GEAR CESSNA310 310D 2074212CE CONT O470 IO470* 17026SO LT MLG MALFUNCTIONED D O OTHER O OTHER NRNOT REPORTED 1 NM036981T 39281 THE PILOT NOTED THAT SOMETHING WAS HANGING DOWN UNDER THE AC IN CRUISE FLIGHT AND THAT THE AC WAS NOT GOING AS FAST AS IT NORMALLY DID. ANOTHER AC NOTED THAT THE GEAR WAS UP, BUT THAT THE LEFT IB GEAR DOOR WAS HANGING DOWN PART WAY. THE TOWER CONFIRMED THAT THE GEAR APPEARED TO BE DOWN AND LOCKED, BUT THAT THE LT IB GEAR DOOR WAS PART WAY DOWN. ALL INDICATIONS OF THE GEAR IN THE AC WERE NORMAL AND THE GREEN LIGHT WAS ON WHEN THE AC LANDED. THE AIRCRAFT LANDED NORMALLY AND ROLLED ABOUT 800 FT DOWN THE RUNWAY WHEN THE LEFT MAIN GEAR BROKE OUT OF THE WHEEL WELL. IT WENT STRAIGHT BACK BEHIND THE WING AND THE AC WENT AROUND TO THE LEFT AND OFF THE RUNWAY. THE LT IB DOOR WILL MOVE SOME BY HAND AND SEEMED TO OPE1L72 3O3 O 3A10 E1CE 20070504002252007050400225CE 2007 5 4 2007FA0000362 120070419G291098811281 POWERPACK CESSNA172 172RG 2072438CE LYC O360 O360* 41514EA HYD SYSTEM MISREPAIRED D O OTHER O OTHER NRNOT REPORTED 1 SW03413EB 172RG0113 INSTALLED A NEWLY OVERHAULED COMPLETE HYDRAULIC POWER PACK UNIT AS RECEIVED. AFTER INSTALLING THE UNIT IN THE AIRCRAFT AND PERFORMING A RETRACT TEST THE NEW OVERHAULED GEAR MOTOR WAS JERKY AND ACTING LIKE IT WAS SHORTING OUT. REMOVED MOTOR AND INSTALLED ANOTHER NEW OVERHAULED MOTOR AND SYSTEM WORKED FINE. (K) 1H71 3O3 O 3A17 E286 20070504002292007050400229CE 2007 5 4 2007FA0000361 120070419G2420 COUPLING CESSNA150 150M 2071830CE CONT O200 O200A 17020SO ALTERNATOR WORN B YYBRO OTHER O OTHER NRNOT REPORTED 1 GL0363332 15077241 250316 ALTERNATOR DRIVE COUPLING WAS WORN AND SEVERELY LOOSE WITH EXCESSIVE PLAY DUE TO SOFT, UNDERCUT BUSHINGS PN 632050. IN ADDITION, THE DRIVE HUB KEY WAY WAS SEVERELY WORN CAUSING EXCESSIVE PLAY OF THE HUB ON THE SHAFT. CONTINUED OPERATION WOULD RESULT IN DRIVE COUPLING RETAINER PN 352030 FAILING AND POTENTIALLY CAUSING CATASTROPHIC ENGINE FAILURE. THE CURRENT RUBBER BUSHINGS ARE SOFT AND ALLOW THE DRIVE GEAR TO CRUSH AND DEFORM THEM WHICH REDUCES SHOCK ABSORPTION AND LEADS TO DRIVE COUPLING FAILURE WHEN DRIVE GEAR BEGINS TO CONTACT THE RETAINER CUP DIRECTLY. THIS IS A RECURRING PROBLEM AS FOUND ON OTHER ALTERNATORS USING THIS TYPE OF DRIVE COUPLING AS LISTED IN SB 95-3B. (K) 1H71 3O3 O 3A19 E252 20070504002332007050400233CE 2007 5 4 2007FA0000363 120070411G321005412024 BUSHING CESSNA172 172S 2072439CE LYC O360 IO360A1A 41514EA RMLG UNSERVICEABLE B NU7RO OTHER O OTHER NRNOT REPORTED 1 GL13106RA3586 172S8241 BUSHING LINER SEPARATED FROM METAL SHELL, SLID OUT OF SHELL CAUSING AC TO LEAN RT WING TIP LOW. BETTER BONDING ADHESIVE FOR LINER TO SHELL. NEED TO GO TO A TIME SCHEDULE FOR INSPECTION. (K) 1H71 3O3 ONT3A12 1E10 20070507000032007050700003CE 2007 5 7 2007FA0000266 120070315G5510 HINGE BRACKET BEECH 23 A23 1151204CE CONT O346 IO346A 17033SO SNSNCH74DC M74DC EA STABILATOR CRACKED B MS2RO OTHER O OTHER NRNOT REPORTED 1 CE093573R3596 M756 1002075A 8623 UPON REMOVAL OF THE HORIZONTAL STABILATOR FOR BEARING REPLACEMENT, A CRACK WAS NOTED COMING OUT FROM UNDER THE LEFT HINGE BRACKET THAT IS RIVETED TO THE SPAR OF THE HORIZONTAL STABILATOR. (K) 1L71 3O3 O A1CE E3CE 5 NP88614 20070507000052007050700005CE 2007 5 7 2007FA0000355 120070417G7810265401416 EXHAUST DUCT CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 AL014365U 208B0253 CRACKING OCCURRED IN A SHORT TIME SPAN, DURING NORMAL OPERATION. CRACKS WERE OVER AN AREA APPROX 7 INCHES X 7 INCHES. ONE PIECE APPROX 3 INCHES X 3 INCHES SEPARATED FROM THE PART. AFTER CRACKING, DEFORMATION OF LOWER TRAILING EDGE OCCURRED BECAUSE IT WAS NO LONGER RIGID. IF THIS PROBLEM HAD GONE UNNOTICED, HEAT DAMAGE WOULD PROBABLY HAVE OCCURRED TO ADJACENT PARTS. MATERIAL OR MFG PROCESS COULD BE SUSPECT. RECENT MFG BULLETIN CAB 07-2 AFFECTS SOME PRIMARY EXHAUST DUCTS DUE TO IMPROPER MFG, BUT IT DOES NOT APPLY TO THIS ONE. (MFG HAS BEEN MADE AWARE OF THIS PROBLEM, PART WAS RETURNED TO THEM ON REQUEST FOR EVALUATION). (K) 1H71 3T3 T A37CE E4EA 20070507000062007050700006SO 2007 5 7 2007FA0000323 120070301G322095829000 DRAG LINK PIPER PA34 PA34200 7103405SO LYC O360 IO360A1A 41514EA NLG JAMMED G R2LSO OTHER O OTHER NRNOT REPORTED 1 SO1515338 347350051 THE NOSE GEAR LINK ASSEMBLY JAMS INTERMITTENTLY, KEEPING THE FWD AND AFT NOSE GEAR DRAG LINKS FROM LOCKING COMPLETELY. REFER TO SB NR 1123B. (K) 1L72 3O3 O A7SO 1E10 20070507001052007050700105NM 2007 5 7 CA070416004 120070413G6120699018002 CONTROL UNIT BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 2 PROP FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING FJ FLT CONT AFFECTED WARNING INDICATION CLCLIMB 1 CA (CAN) CREW COMPLETED A NR 2 ENGINE SHUTDOWN MANUALLY (IFSD) DUE POWERPLANT MESSAGE AND PEC CAUTION. MAINT ARRIVED AND FC 161 CH A AND B. FIM TASK PERFORMED. NO CONTACT WITH MPU AND BUSS BARS. REMOVED & REPLACED PEC. (TC NR 20070416004) 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20070507001082007050700108SO 2007 5 7 CA070416007 120070416G2910OAS229307 POWERPACK PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL HYD SYSTEM FAILED W K NONE O OTHER ININSP/MAINT 1 CA 1091 317552010 (CAN) DURING A MAINTENANCE RUN AFTER WORK ON AN ENGINE THE MECHANICS DID A HYDRAULIC PUMP CHECK BY SELECTING HANDLE TO GEAR DOWN POSITION. THE HANDLE WOULD NOT RETURN TO THE NEUTRAL POSITION AS IS NORMAL. WHEN GEAR SWINGS WERE CARRIED OUT IN THE HANGAR THE OB GEAR DOORS WOULD ONLY PROCEED HALFWAY AND THEN SIT AND SHUDDER. A LOUD BANG WAS HEARD FROM THE POWERPAK AND THEN THE DOORS WOULD CLOSE OR OPEN AS SELECTED. THERE WAS NO PRIOR INDICATION OF PROBLEMS WITH THE POWERPACK. (TC NR 20070416007) 1L72 3O3 O A20SO E14EA 5 CP33EA 20070507001292007050700129 2007 5 7 CA070418005 420070416G3497M227591622 WIRE DOUG DC3 DC3C 3021457WP PWA PT6 PT6A67R 52043NE HAMSTD23E 23E50 NE AIRSPEED WARNINGARCED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) THE AIRSPEED AURAL WARNING CIRCUIT BREAKER WAS FOUND TO BE (POPPED). WHEN THE UPPER PANEL WAS LOWERED EVIDENCE OF ARCING WAS FOUND ON AIRFRAME STRUCTURE. THE WIRE WAS REPAIRED THROUGH PARTIAL REPLACEMENT, CHAFE PROTECTOR WAS ADDED TO THE AIRFRAME STRUCTURE AND THE WIRE BUNDLE AND THE WIRE BUNDLE WAS RE-POSITIONED. (TC NR 20070418005) 2L72 4R4 T A669 E26NE 6 CP603 20070507001422007050700142EA 2007 5 7 CA070420002 220070417G8520SL12596 BOLT LYC O540 LTIO540J2BD 41533EA CONNECTING ROD FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 CA 671 (CAN) BOLT FAILED CAUSING CONNECTING ROD TO BECAME DETACHED FROM CRANKSHAFT CAUSING MAJOR DAMAGE TO LOWER END OF ENGINE. (TC NR 20070420002) 3 O E14EA 20070507001862007050700186SO 2007 5 7 2007FA0000232 120070305G2432RG380E44 BATTERY LKHEED1329 1329* SO GARRTTTFE731TFE7313 01518WP MASTER FAILED B VXWRO OTHER O OTHER NRNOT REPORTED 1 EA2158TS 5079 75238 THESE 2 EA PN RG-380E/44 MAIN SHIP BATTERIES WERE INSTALLED ON 10/30/2006. THESE BATTERIES WERE REPLACEMENTS FOR 2 EA BATTERIES THAT HAD BEEN IN SATISFACTORY SERVICE IN THIS AC FOR APPROX 48 MONTHS BUT FAILED A CAPACITY CHECK DURING A REGULAR SCHEDULED INSPECTION. LESS THAN 2 MONTHS AFTER INSTALLATION THE PILOTS WERE UNABLE TO START THE MAIN ENGINES USING THESE BATTERIES. AT THIS TIME THE BATTERIES HAD A TOTAL FLIGHT TIME OF 16 HOURS AND HAD PERFORMED 26 MAIN ENGINE STARTS AND 8 APU STARTS. THE MAIN ENGINES WERE STARTED USING A GROUND POWER UNIT. ALL CHARGING AND ELECTRICAL OPERATIONS APPEARED NORMAL. THE BATTERIES WERE REMOVED AND GIVEN TO REPAIR STATION FOR TESTING. BOTH BATTERIES WERE TESTED IAW (INST2L74 4J4 F 2A15 E6WE 20070508001902007050800190CE 2007 5 8 CA070108001 120070103G3220 LANDING GEAR BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL NOSE INOPERATIVE W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA (CAN) AIRCRAFT EXPERIENCED NO NOSE GEAR. (TC NR 20070108001) 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20070508001912007050800191CE 2007 5 8 CA070108002 120070103G3260404EN16 DOWNLOCK SWITCH BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL MLG MALFUNCTIONED W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA CVBCBNM7CXZZ (CAN) THE AIRCRAFT ORIGINALLY EXPERIENCED A GEAR WARNING SYSTEM FAILURE ON APPROACH. SUBSEQUENTLY, THE DOWNLOCK SWITCHES WERE CLEANED AND LUBRICATED AND THE SYSTEM TESTED SERVICEABLE. THE NEXT FLIGHT HAD A LT MAIN GEAR INDICATION FAILURE, EMERGENCY PROCEDURES WERE FOLLOWED AND THE LT GEAR INDICATION WORKED PRIOR TO TOUCH DOWN. THE AIRCRAFT WAS RETURNED TO MAINTENANCE AND THE LANDING GEAR SYSTEM WAS TROUBLESHOT EXTENSIVELY AND TEST FLOWN EACH TIME WORK WAS CARRIED OUT UNSUCCESSFULLY. THE SNAG ONLY OCCURRED AT HIGHER ALTITUDES OR COLDER TEMPERATURES. THE LT MAIN GEAR SWITCH WAS REPLACED DUE TO SUSPECT WATER PROPAGATION AND FREEZING. THE AIRCRAFT WAS TEST FLOWN AT THE SAME ALTITUDES AND WAS SUCCESSFUL. THE AIRC2L72 4T4 TRTA24CE E4EA 6 CP56GL 20070508001972007050800197EA 2007 5 8 CA070423005 220070419G8530LW12966 CYLINDER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1702 RL145668A (CAN) OIL WAS NOTICED LEAKING FROM THE PUSHROD AREA. THE PUSHROD WAS REMOVED TO REPLACE THE SEALS. THE CRACK IN THE CYLINDER HEAD WAS FOUND THEN. THE CRACK RAN FROM THE BOTTOM OF THE CYLINDER HEAD SEAM TO ABOUT 4-5 INCHES ALONG THE HOLLOW WHERE THE PUSHROD TUBE RESIDES. THE CYLINDERS WERE MANUFACTURED NEW STEEL AT OVERHAUL. (TC NR 20070423005) 1L72 3O3 O A20SO E14EA 5 CP33EA 20070508001992007050800199CE 2007 5 8 CA070423007 120070418G2430290143 PROBE BEECH 99 99 1154002CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL TEMP MONITOR INTERMITTENT W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) BATTERY TEMP MONITOR WAS INDICATING HIGHER THAN NORMAL ON APPROACH. AIRCRAFT LANDED WITHOUT INCIDENT. BATTERY WAS LUKEWARM TO THE TOUCH. MONITOR WAS UNRESPONSIVE. BATTERY AND PROBE WERE REPLACED ALONG WITH WIRING INSPECTED AND AIRCRAFT RETURNED TO SERVICE. NO FAULTS WERE FOUND DURING DEEP CYCLE OF BATTERY AT BATTERY SHOP. PROBE REPLACED DUE TO POSSIBLE INTERMITTENT OPERATION. (TC NR 20070423007) 1L72 3T4 T A14CE E4EA 6 CP15EA 20070508002012007050800201CE 2007 5 8 CA070423009 120070422G53229743000015 CROSS TIE BEECH B300 B300 1159232CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 7390 (CAN) THE INTERIOR WAS REMOVED FOR REFURBISHMENT. MAINTENANCE DISCOVERED A CRACK IN THE CROSS TIE, A STRUCTURAL MEMBER AROUND THE EMERGENCY EXIT ON THE LT SIDE OF THE AIRCRAFT. CONTACTED MFG FOR A REPAIR. (TC NR 20070423009) 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20070508002032007050800203SW 2007 5 8 CA070424011 120070418G7712 IDLER GEAR SWRNGNSA226 SA226* SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCE4N HCE4N3 NE TORQUE SENSOR LOOSE W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA 3115 3115 P8640C (CAN) FOUND ON TAKEOFF ROLL, THE RT CHIP LIGHT CAME ON THROUGH 70 KTS. THE TAKEOFF WAS ABORTED AND THE AC TAXIED BACK TO THE RAMP WITHOUT ANY FURTHER INCIDENT. AT THIS TIME MAINT HAD DONE A SOAP SAMPLE AND FOUND METAL IN THE OIL FILTER. WHEN THE ENGINE WAS TAKEN APART THE TORQUE SENSOR IDLER GEAR WAS NOTICED TO BE LOOSE DUE TO THE BEARING HAD FAILED ON THE IDLER GEAR THAT IS ATTACHED TO THE TORQUE SENSOR. (TC NR 20070424011) 2L72 4T4 TRTA56W E4WE 5 CP10NE 20070508002042007050800204NE 2007 5 8 CA070426002 220070424G73146078T39P04 PUMP CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE FUEL SYSTEM LEAKING W ED ENGINE SHUTDOWN RETURN TO BLOCK KJ FLUID LOSS WARNING INDICATION TXTAXI/GRND HDL 1 CA 24818683 872485 (CAN) DURING ENGINE START UP, GROUND CREW OBSERVED A LEAK COMING FROM BELOW THE ENGINE NR 2. LINE MAINTENACE FOUND A FUEL LEAK FROM A MICROSCOPIC PIN HOLE CLOSE TO A PLUGGED FITTING ADAPTOR ON ENGINE NR 2 FUEL PUMP AFT CASING. THE EXACT PIN HOLE LOCATION WAS NOT FOUND DUE TO THE HIGH FUEL PRESSURE MIST. FUEL PUMP SN CGWT0202. (TC NR 20070426002) 2L72 4F4 FRTA21EA E15NE 20070508002122007050800212EA 2007 5 8 CA070426003 220070426G853072242 ROCKER COVER RKWELL700 700 7630520SW LYC O540 TIO540R2AD 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE SEPARATED W A UNSCHED LANDING RE PARTIAL RPM/PWR LOSS VIBRATION/BUFFET CRCRUISE 1 CA 24 L633761A (CAN) SHORTLY AFTER TAKEOFF, THE PILOTS EXPERIENCED A POWER LOSS IN THE LT ENGINE, HOWEVER THE ENGINE REMAINED RUNNING. THEY RETURNED TO THE NEARBY AIRPORT WITHOUT INCIDENT. MAINTENANCE INSPECTED THE ENGINE AND FOUND THAT NR 6 CYLINDER ROCKER COVER HAD BEEN DAMAGED. THE COVER WAS REMOVED AND FOUND THAT THE RETAINING CLIP THAT HOLDS THE ROCKER SHAFTS IN PLACE FOR THE INTAKE AND EXHAUST VALVES HAD FALLEN OFF. THE ROCKER SHAFT FOR THE INTAKE VALVE HAD FALLEN OUT ALLOWING THE ROCKER TO BECOME DISLODGED THEREBY DISABLING THAT CYLINDER. THE VALVE ASSEMBLY WAS INSPECTED AND REINSTALLED WITH A REPLACEMENT VALVE COVER AND GASKET. GROUND RUNS COMPLETED AND ALL CHECKS FOUND SERVICEABLE. AS NOTED ABOVE, THE ENGINE 1L72 3O3 O A12SW E14EA 5 CP33EA 20070509000632007050900063CE 2007 5 9 CA070108010 120070105G5700817861018 BOLT BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1437 (CAN) SCHEDULED WING BOLT INSPECTION, NOTED RT UPPER AFT WING BOLT CRACKED ON BOLT HEAD TO SHANK RADIUS. BOLT REPLACED WITH NEW. (TC NR 20070108010) 1L72 3T4 T A14CE E4EA 5 CSTC 20070509000662007050900066EU 2007 5 9 CA070112002 120070106G55409408328506 BEARING PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL RUDDER WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION OF TAIL TOP ATTACH BOLT FOUND TO HAVE EXCESSIVE WEAR. RUDDER REMOVED AND NEW BOLT P/N 932.35.71.166 AND BEARING REPLACED. MFG AIRCRAFT NOTIFIED OF DEFECT. (TC NR 20070112002) 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20070509000702007050900070NE 2007 5 9 CA070115004 220070115G7200 ENGINE AIRBUS320 A320214 3930316EU CFMINTCFM56 CFM565B4P NE NR 1 FAILED W C ABORTED TAKEOFF YJ ENGINE STOPPAGE WARNING INDICATION TOTAKEOFF 1 CA 757267 (CAN) AFTER POWER SET FOR TAKEOFF, AND TAKEOFF ROLL COMMENCED, ENG NR 1 FAILED. AIRCRAFT TAXIED BACK TO THE GATE. (TC NR 20070115004) 2L72 4F4 FRTA28NM E38NE 20070509000782007050900078WP 2007 5 9 CA070117006 120070117G6310C1883 SPRAG CLUTCH ROBSINR44 R44RAVENII 7640122WP LYC O540 IO540AE1A5 41530NE MAIN ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 933 (CAN) DURING AN AES 1000HR INSPECTION, A CRACK WAS FOUND ON THE CAGE IN THE MIDDLE OF (1) CROSSBAR. (TC NR 20070117006) 1G71 3O3 O H11NM 1E4 20070503000262007050300026SW 2007 5 3 CA070402006 120070315G561036004314SS WINDSHIELD GULSTM690TP 690D 3970405SW GARRTTTPE331TPE3315 01514WP ROTOL R306 R306382F7 GL COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA 6350 (CAN) DURING A ROUTINE MEDIVAC FLIGHT AT AN ALTITUDE OF 12,000 FEET, THE FLIGHT CREW VISUALLY NOTED THAT THE RT WINDSHIELD WAS CRACKED ACROSS THE UPPER OB CORNER. AIRCRAFT RETURNED TO BASE. INSPECTION OF THE WINDSHIELD FOUND THE OUTER WINDOW PANE CRACKED APPROXIMATELY 2.5 INCHES LENGTH ACROSS THE CORNER. NEW WINDSHIELD INSTALLED AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20070402006) 1H72 3T4 T 2A4 E4WE 6 CP8EU 20070503000402007050300040EU 2007 5 3 CA070404004 120070404G2910AE2463774G0164 HOSE AIRBUS310 A310304 3930339EU GE CF6 CF680C2A5 NE HYD SYSTEM PUNCTURED W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) GREEN HYDRAULIC ECAM MESSAGE LOW LEVER WARNING CAME ON AFTER TAKE OFF. ON ARRIVAL, MAINTENANCE FOUND THE RT MAIN LANDING GEAR DOWN LOCK ACTUATOR FLEX LINE HOSE LEAKING. FOUND HOLE IN FLEX LINE. FLEX LINE WAS REPLACED WITH BOTH HYDRAULIC PUMPS, CASE DRAIN FILTERS AND GREEN SERVO CONTROL MANIFOLD FILTERS. (TC NR 20070404004) 2L72 4F4 FRTA35EU E13NE 20070504001072007050400107NM 2007 5 4 CA070404006 120070329G2781H1010262 SWITCH BOEING727 727243 138408DNM PWA JT8 JT8D9A 52048NE NR 3 KRUGER MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) ON FLAP RETRACTION THE CREW NOTICED THE NR 3 KRUGER FLAP INDICATED (IN TRANSIT). CREW RETURNED TO BASE. NR 3 KRUGER FLAP RETRACT SWITCH WAS REPLACED AND A/C RETURNED TO SERVICE. (TC NR 20070404006) 2L73 4F4 FRTA3WE E2EA 20070504001122007050400112CE 2007 5 4 CA070404008 120070329G571097430000150 CROSS TIE BEECH 300 300BEECH 1152930CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL BS 187 CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 10546 (CAN) THE STRUCTURAL PIECE CALLED A CROSSTIE P/N 97-430000-150 WAS FOUND CRACKED DURING INSPECTION. IPC / REF: 53-10-20 FIG. 20 ITEM NR 26. THE CRACK IS LOCATED LT SIDE OF AIRCRAFT AT FS 187.383 AND WL 119 ( LOWER LONGERON ). REPLACED WITH NEW. (TC NR 20070404008) 2L72 4T4 T A24CE E4EA 6 CP56GL 20070504001222007050400122EA 2007 5 4 CA070405006 120070405G32507116111 COLLAR DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL STEERING SYS CRACKED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) STEERING COLLAR CRACKED AT RADIUSED AREA OF ATTACH STUD TO STEERING ACTUATOR. FOUND AT ROUTINE MAINTENANCE INSPECTION (TC NR 20070405006) 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20070504001312007050400131CE 2007 5 4 CM2R747K 120070501G273053608014 BELLCRANK CESSNA340 340A 2076405CE ALLSN 250C 250C28B 03013GL ELEVATOR BROKEN B CM2RO OTHER F FLT CONT AFFECTED TXTAXI/GRND HDL 1 SW15397R 6383 127 0009 BEARING AND BOLT FAILED IN THE ELEVATOR BELLCRANK P/N 5360801-4. CENTER BEARING THAT SUPPORTS THIS BELLCRANK FAILED. BEARING IS P/N MS27640-4. BOLT P/N AN4-14 WAS SEVERELY WORN AND BROKEN IN TWO. IF EITHER END OF THE BOLT SLIPPED OUT OF THIS BELLCRANK, THE A/C WOULD HAVE LOST PRIMARY ELEVATOR CONTROL. THE ELEVATOR TRIM SYSTEM WOULD STILL FUNCTION. 1L72 3O3 U 3A25 E1GL 20070504001492007050400149NE 2007 5 4 2007FA0000350 220070401G72501767M75G03 SHAFT GE BOEING777 777224 1385225NM GE GE90 GE9090B NE LPT FAN UNSERVICEABLE B QEMYO OTHER O OTHER NRNOT REPORTED 1 EA357801736785 T900253 31679 900238 AIRCRAFT TAKEOFF WAS ABORTED, A 147 KNOTS AFTER ENGINE LOST POWER. AC WAS STOPPED SAFELY AND ALL PASSENGERS AND CREW DEPLANED SAFELY. UPON INSPECTION OF THE ENGINE, THE FAN ROTATED FREELY, BUT THE LPT DID NOT ROTATE. BS1 OF THE ENGINE SHOWED THAT THE HPT WAS CLEAN, BUT THE LPT WAS HEAVILY DAMAGED. THE ENGINE WAS SHIPPED TO MFG. INITIAL INSPECTIONS SHOWED THAT THE FAN MID SHAFT WAS SEPARATED IN THE AXIAL PLANE OF THE HPC S3 DISC. THE CENTER VENT TUBE WAS SEPARATED IN 3 PLACES ALL AFT OF FMS SEPARATION. AND INVESTIGATION IS ON GOING. (K) 2L72 4F4 FRTT00001SEE00049EN 20070504001552007050400155GL 2007 5 4 2007FA0000321 220070401G74126870885 EXCITER HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE INOPERATIVE B EOORO OTHER O OTHER NRNOT REPORTED 1 AL03CGBUY 6109580 CAE833577 PILOT WENT TO START THE AIRCRAFT AND THERE WAS NO IGNITION. FOUND IGNITION EXCITER INOPERATIVE, REPLACED. (K) 1G71 3U3 U H3WE E4CE 20070504001612007050400161GL 2007 5 4 2007FA0000375 120070427G2720 CONTROL CABLE CIRRUSSR SR22 2130001GL CONT O550 IO550* SO AILERONS INTERFERENCE B K NONE O OTHER ININSP/MAINT 1 EA07220SR 0391 DURING INSPECTION FOUND INTERFERENCE BETWEEN RUDDER/AILERON INTERCONNECT SYSTEM AND RT AILERON CABLE. CHECKED RIGGING AND FOUND CABLE CLAMP ON RT AILERON CABLE OUT OF POSITION. VISUAL INSPECTION INDICATES NO MOVEMENT BETWEEN CABLE AND CLAMP AND RECORDS REVIEW INDICATE THAT NO RIGGING HAS TAKEN PLACE SINCE THE AIRPLANE LEFT THE FACTORY. 1L71 3O3 ONTA00009CHE3SO 20070504001622007050400162CE 2007 5 4 2007FA0000284 120070317G5740NAS1738B ATTACH FITTING BEECH 300 300BEECH 1152930CE PWA PT6 PT6A60A 52043NE WING LOOSE B KX5RK NONE O OTHER ININSP/MAINT 1 GL151525C5500 FL88 MANY OF THE BLIND RIVETS, PN NAS1738B6, ATTACHING THE WING SKIN TO THE LOWER FORWARD WING ATTACHMENT FITTING WERE FOUND TO BE LOOSE. CONDITION EXISTED ON BOTH WINGS. CONDITION ALSO FOUND ON AC SN FL59 (8100 HRS). (K) 2L72 4T4 T A24CE E4EA 20070504001632007050400163GL 2007 5 4 050207 120070502G5210649 ROD END CIRRUS CIRRUSSR SR22 2130001GL CONT O550 IO550* SO CABIN DOOR BROKEN G B EMER. DESCENT D INFLIGHT SEPARATION CRCRUISE 1 SO13299JW300 1034 CABIN DOOR DEPARTED AIRCRAFT IN FLIGHT DUE TO THE ROD END HINGE FAILURE. IT APEARS THE ROD END FAILED DUE TO FATIGUE. THE ROD END SHOULD BE MADE OF A STRONGER MATERIAL. 1L71 3O3 ONTA00009CHE3SO 20070504001702007050400170CE 2007 5 4 2007FA0000377 120070426G3232 ROD GARKENYON LEAR 60 60LEAR 5170707CE WRIGHTR3350 R3350* 67040EA ACTUATOR FAILED D O OTHER J WARNING INDICATION LDLANDING 1 SO09718A 0290 065 WHEN LANDING GEAR WAS CYCLED DOWN, THE RT RED IB GEAR DOOR OPEN LIGHT WOULD NOT EXTINGUISH. GEAR DOWN LOCK LIGHTS WERE GREEN. NORMAL LANDING. INSPECTION REVEALED THAT THE ACTUATOR SHAFT HAD UNSCREWED FROM THE PISTON NOT ALLOWING THE DOOR TO CLOSE. FURTHER EXAMINATION REVEALED THAT THE ROLL PIN SECURING THE SHAFT TO THE PISTON WAS SHEARED. THE LT ACTUATOR WAS INSPECTED AND THE ACTUATOR ROD WAS FOUND TO BE 2.5 TURNS FROM DISENGAGING FROM THE PISTON. 6-7 TURNS BOTTOMS THE ROD IN THE PISTON. REPLACED BOTH DOOR ACTUATORS. 2L72 4F4 RRTA10CE E272 20070504001732007050400173EA 2007 5 4 2007FA0000344 220070323G732025765362 SERVO CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL ENGINE FUEL WORN B HUNRO OTHER O OTHER NRNOT REPORTED 1 NM019522S1938 17280432 RL30493351A SF010 PILOT REPORTS THAT ENGINE DIED ON FINAL APPROACH. ADJUSTED IDLE STOP SLIGHTLY AND MIXTURE SLIGHTLY. RAN ENGINE AND FOUND THAT SLIGHT ADJUSTMENTS MADE TO FUEL SERVO CREATED LARGE CHANGES IN THE ENGINE OPERATION. UNABLE TO ADJUST THE FUEL SERVO TO MEET PERFORMANCE REQUIREMENTS STATED IN AD2001-06-17, (D)(2). THIS IS THE SECOND ATTEMPT TO ADJUST THE FUEL SERVO. THE FUEL SERVO WAS REMOVED FROM THE AIRCRAFT AND FORWARDED FOR REPAIR UNDER THEIR W/O NR 07-00900. ORIGINAL FUEL SERVO, PN 25765362, SN 70148401, REINSTALLED ON AC UPON COMPLETION OF REPAIR, WITH REFERENCE TO MM, CHAP 73. IDLE AND MIXTURE ADJUSTMENT COMPLETED WITH REFERENCE TO MM, CHAP 73. OPERATIONAL/LEAK CHECK GOOD AT THIS TIME. (K) 1H71 3O3 ONT3A12 1E10 5 NP857 20070504001882007050400188CE 2007 5 4 2007FA0000378 120070426G323266000858 ACTUATOR LEAR 60 60LEAR 5170707CE WRIGHTR3350 R3350* 67040EA MLG FAILED D O OTHER J WARNING INDICATION LDLANDING 1 SO09718A 4200 065 WHEN LANDING GEAR WAS CYCLED DOWN, THE RT RED IB GEAR DOOR OPEN LIGHT WOULD NOT EXTINGUISH. GEAR DOWN LOCK LIGHTS WERE GREEN. NORMAL LANDING. INSPECTION REVEALED THAT THE ACTUATOR SHAFT HAD UNSCREWED FROM THE PISTON NOT ALLOWING THE DOOR TO CLOSE. FURTHER EXAMINATION REVEALED THAT THE ROLL PIN SECURING THE SHAFT TO THE PISTON WAS SHEARED. THE LT ACTUATOR WAS INSPECTED AND THE ACTUATOR ROD WAS FOUND TO BE 2.5 TURNS FROM DISENGAGING FROM THE PISTON. 6-7 TURNS BOTTOMS THE ROD IN THE PISTON. REPLACED BOTH DOOR ACTUATORS. 2L72 4F4 RRTA10CE E272 20070504002212007050400221SO 2007 5 4 CA070409005 120070406G2823 SELECTOR PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA HARTZLHCE2Y HCE2YR2 GL FUEL FAILED W D RETURN TO BLOCK Y ENGINE STOPPAGE TXTAXI/GRND HDL 1 CA (CAN) DURING FUNCTIONAL TEST PRIOR TO TAKEOFF, WHEN MOVING FUEL SELECTOR FROM OB TO IB TANKS THE ROLL PIN CONNECTING THE FUEL SELECTOR HANDLE TO THE LINKAGE FAILED. THIS FAILURE LEFT THE RT ENGINE FUEL SELECTOR IN THE OFF POSITION, STARVING THE ENGINE FOR FUEL. THE AIRCRAFT RETURNED TO THE RAMP FOR REPAIRS. (TC NR 20070409005) 1L72 3O3 O 1A10 1E4 5 CP9EA 20070507000822007050700082 2007 5 7 CA070411006 420070411G230052611 CONTROL PANEL DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE AUDIO CONTROL BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 325134328 (CAN) ENROUTE CREW NOTICED SMOKE COMING FROM AUDIO CNTRL PANEL, PULLED CIRCUIT BREAKER, SMOKE STOPPED. CREW DONNED O2 MASKS AND ELECTED TO RETURN TO ORIGINATING AIRPORT FOR NORMAL LANDING. MAINTENANCE REPLACED LT AUDIO CNTRL PANEL AND AIRCRAFT RETURNED TO SERVICE (TC NR 20070411006) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070507000832007050700083SW 2007 5 7 CA070412001 120070320G7120206062102001 MOUNT BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON A ROUTINE ENGINE REPLACEMENT, IT WAS FOUND THAT THE LT LOWER ENGINE MOUNT WAS CRACKED AT THE ATTACH POINT. AFTER CLOSER INSPECTION THE MOUNT WAS COMPLETELY SEPARATED FROM THE AIRFRAME. THERE WAS NO INITIAL INDICATION OF A PROBLEM. IT WAS FOUND THAT THERE WAS EXCESSIVE TORQUE ON THE ATTACH BOLT TO THE AIRFRAME. THE ATTACH POINT WAS ALSO CUPPED TO INDICATE THAT THE PROPER PROCEDURE WAS NOT USED TO REMOVE THE ENGINE IE; LOOSENING THE ENGINE MOUNTS FIRST. (TC NR 20070412001) 1G71 3U3 U H2SW E4CE 20070507000852007050700085NM 2007 5 7 CA070412005 120070407G3110B030302104C94 HOSE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU INSTRUMENT PANELCUT W O OTHER J WARNING INDICATION CRCRUISE 1 CA 908 (CAN) CREW REPORTED THAT THE INTEGRATED STANDBY ELECTRONIC INSTRUMENT WAS NOT READING THE SAME AS THE PRIMARY FLYING DISPLAYS. INVESTIGATION REVEALED THAT THE LINES TO THE INSTRUMENT HAVE TO BE REMOVED TO PERFORM AD CF2005-15 PART B. ON REASSEMBLY IF THE LINES ARE NOT ORIENTED PROPERLY THAT WILL CHAFE ON STRUCTURE. (TC NR 20070412005) 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20070507000992007050700099EA 2007 5 7 CA070413004 120070410G6120C6NF1117 CONTROL BOX DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL BETA SYSTEM FAILED W C ABORTED TAKEOFF FJ FLT CONT AFFECTED WARNING INDICATION TOTAKEOFF 1 CA (CAN) THE AIRCRAFT WAS BEING USED FOR CREW TRAINING WHEN, ON TAKEOFF, THE RT PROPELLER RPM DROPPED TO 30 PERCENT. THE PILOTS ABORTED THE TAKEOFF AND RETURNED TO THE RAMP. THE PILOTS NOTED THAT NP WAS STILL AT 30 PERCENT WITH THE POWER LEVER AT IDLE. THE PROPELLER WAS FEATHERED WITH THE PROP LEVER AND IT DID SO. WHEN THE PROP LEVER WAS SELECTED FULLY FWD THE PROPELLER WOULD NOT UNFEATHER. TROUBLESHOOTING REVEALED THAT THERE WAS POWER TO THE BETA BACKUP SOLENOID VALVE. FURTHER TROUBLESHOOTING LED BACK TO THE BETA BACKUP CONTROL BOX P/N C6NF1117. THIS WAS REPLACED AND THE AIRCRAFT CHECKED SERVICEABLE. IT IS SUSPECTED THAT RELAY K4 MAY HAVE MALFUNCTIONED. THE CONTROL BOX IS BEING RETURNED TO THE OEM FOR EXAMINATIO1H72 3T4 TRTA9EA E4EA 6 CP15EA 20070507001062007050700106EA 2007 5 7 CA070416005 120070413G3297 CONNECTOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE SELECTOR VALVE CONTAMINATED W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA 149778924 1999 (CAN) ON APPROACH NOSE LANDING GEAR DID NOT EXTEND. CREW CARRIED OUT A GO-AROUND AND COMPLETED A MANUAL EXTENSION. THE GEAR LOWERED AND LOCKED-CREW RECEIVED 3 GREENS IN THE COCKPIT. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE WAS DISPATCHED TO TROUBLESHOOT. PSEU CODES READ AND FORWARDED TO TECH OPS. AFTER CONSULTATION WITH TECH OPS, SUSPECT THE NLG SELECTOR VALVE AT FAULT. AFTER FURTHER INSPECTION IT WAS NOTED THAT THE NLG SELECTOR VALVE HAD A SLIGHT LEAK NR THE SOLENOID CONNECTOR PLUG WAS CONTAMINATED WITH HYD FLUID. THE SELECTOR VALVE WAS REPLACED AND GEAR SWINGS WERE CARRIED OUT WITH NFF AND A/C WAS RETURNED TO SERVICE WITHOUT ANY FURTHER INCIDENTS. (TC NR 20070416005) 2L72 4F4 FRTA21EA E15NE 20070507001092007050700109 2007 5 7 CA070416008 420070324G3460101741111 COMPUTER DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE FMS MALFUNCTIONED W A UNSCHED LANDING BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 CA 534 (CAN) CREW REPORTED FMS FAILED THEN FLIGHT DECK EXPERIENCED SMOKE AND FUMES. CREW ELECTED TO RETURN THE AIRCRAFT TO BASE WHERE A LANDING WAS CARRIED OUT WITHOUT INCIDENT. ENGINEERING REPLACED THE FMS UNIT. INITIAL INVESTIGATION OF THE REMOVED UNIT INDICATES AN ELECTRICAL FAILURE OF AN INTERNAL CIRCUIT BOARD. UNIT HAS BEEN RETURNED TO THE MFG FOR REPAIR AND WITH A REQUEST TO PROVIDE A STRIP REPORT. (TC NR 20070416008) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070507001102007050700110NM 2007 5 7 CA070416009 120070327G242131708001A GENERATOR DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE NR 2 AC SYSTEM MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) ON INITIAL CLIMB AFTER TAKEOFF THE AC GENERATOR `HOT` CAUTION LIGHT ILLUMINATED. CREW ELECTED TO RETURN THE AIRCRAFT TO BASE WHERE AN APPROACH AND LANDING WAS CARRIED OUT WITHOUT INCIDENT. ENGINEERING REPLACED THE AC GENERATOR AND RETURNED THE AIRCRAFT TO SERVICE. (TC NR 20070416009) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070507001332007050700133GL 2007 5 7 CA070418007 120070417G5341VALTB12091 FITTING DHAV DHC1 DHC1 2801702GL PWA R985 R985AN14B 52008NE HARTZLHCB3R HCB3R304 GL WING TO BODY CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA 6052 (CAN) A CURSORY INSPECTION REVEALED CORROSION ON THE LT PORK CHOP FITTING. BOTH LT AND RT FITTINGS WERE REPLACED WITH NEW UNITS. DEPTH OF CORROSION WAS APPROX 25 PERCENT OF PART OVERALL THICKNESS. THE MANUFACTURE WAS CONTACTED. THE PART IN QUESTION IS APPROX 11 YEARS OLD. (TC NR 20070418007) 1L71 3O3 R EXPA1L715E1 5 CP28EA 20070507001362007050700136EA 2007 5 7 CA070419002 220070413G7230 BLADES PWC BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCD4N3HCD4N3A GL COMPRESSOR DEPARTED W E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 CA 4538 PCE51225 (CAN) LT ENGINE EXPERIENCED A SUDDEN POWER LOSS ON CLIMB OUT. THE ENGINE WAS SHUTDOWN AND THE A/C RETURNED TO BASE WITHOUT ANY FURTHER INCIDENT. THE POWER SECTION WAS REMOVED FOR INVESTIGATION. THE INVESTIGATION REVEALED THAT PIECES WERE MISSING FROM SEVERAL CT IGV`S, MULITPLE CT BLADES BEING DAMAGED (IE. MISSING PIECES) AS WELL AS DAMAGE TO SEVERAL PT BLADES AND GUIDE VANES. THE ENGINE HAS 4538.3 HRS AND 4622 CYCLES SINCE O/H AND IS ON CONDITION FOR HOT SECTION INSPECTIONS. THE LAST HSI WAS COMPLETED 2068.6 HRS AND 2695 CYCLES AGO WHEN 0.0 TSO CT BLADES P/N 3039901 WERE RE-INSTALLED. THE ENGINE HAS BEEN SENT FOR O/H AND FURTHER INFO WILL BE AVAILABLE AFTER WHEN A TEARDOWN REPORT BECOMES AVAILABLE (TC# 200701L72 3T4 T A14CE E4EA 5 CSTC 20070507001372007050700137CE 2007 5 7 CA070419003 120070418G55401145240253 TORQUE SHAFT BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE RUDDER CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 15917 (CAN) DURING A PHASE INSPECTION IT WAS DISCOVERED THAT THE RUDDER TORQUE SHAFT WAS CORRODED. IT IS BELIEVED THAT THE CORROSION OCCURRED DUE TO WATER MIGRATION FROM THE VERTICAL STABILIZER. THE TORQUE SHAFT WAS REPLACED. (TC NR 20070419003) 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20070507001782007050700178EU 2007 5 7 CA070410004 120070406G5753 BELLCRANK PZLWARWILGA PZL104W35A 7360104EU LYC O540 IO540K1B5 41532EA HARTZLHCE3Y HCE3YR1 GL TE FLAPS CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 276 (CAN) LOWER LT FLAP ACTUATOR BELLCRANK SUPPORT BRACKET CRACKED AT UPPER END. WHEN FLAP IS SUBJECTED TO A SIMULATED AIR LOAD, THE SUPPORT BRACKET FLEXES AND THE CRACK VISIBLY OPENS. THIS BRACKET HAS EVIDENCE OF PREVIOUS REPAIR (A DOUBLER IS PRESENT AT THE LOWER END). NONE OF THE OTHER (3) SUPPORT BRACKETS HAVE ANY DOUBLERS OR SHOW ANY EVIDENCE OF CRACKS. (TC NR 20070410004) 1H71 3R3 ONCEXPA1H711E4 5 CP33EA 20070507002402007050700240SW 2007 5 7 CA070105005 120070105G7921206061432031 IMPELLER BELL BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL OIL COOLER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA VN7184 (CAN) 300 HR NDT FOUND CRACKS IN THE WEB AREA. PART REPLACED. (TC NR 20070105005) 1G71 3U3 U H2SW E1GL 20070509001902007050900190WP 2007 5 9 CA070118006 120070117G6210369D21100516A BLADE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL MAIN ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 2813 (CAN) THE UPPER BLADE SURFACE IS CRACKED CHORDWISE FROM LEADING EDGE TO TRAILING EDGE BETWEEN BLADE STATION 120 AND 124. THE LOWER BLADE SURFACE IS ALSO CRACKED IN THE MID CORD AREA BETWEEN STATION 120 AND 124 BUT DOES NOT EXTENT TO THE LEADING EDGE OR TRAILING EDGE. (TC NR 20070118006) 1G71 3U3 U H3WE E4CE 20070511000032007051100003EA 2007 5 11 CA070417002 120070417G57512151500080680 RIB CNDAIRCL215 CL2151A10 1900320EA PWA R1340 CWASP 52016NE HAMSTD43E 43E60 NE AILERON DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DAMAGE FOUND TO BOTH AILERONS ON THE (2) FIRST CENTER HINGE RIBS ASSEMBLY, ADJACENT TO THE FIXED STOPS. A/C HOURS; 4658.7, CYCLES; 2973 (TC NR 20070417002) 2H72 4R3 RRTA14EA ATC14 6 CP871 20070511000062007051100006EA 2007 5 11 CA070118009 120070116G2910AE7090072 LINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE NR 2 EDP LOOSE W O OTHER EKJVIBRATION/BUFFET FLUID LOSS WARNING INDICATION CRCRUISE 1 CA MX598642 (CAN) ENROUTE CREW ADVISED THAT THEY HAD LOST NR 2 HYDRAULIC SYSTEM AND WERE DIVERTING. CREW DECLARED AN EMERGENCY AND ADVISED PASSENGERS OF REASON. WHEN THE INCIDENT HAPPENED THE CREW HAD A HYD 2 LOW PRESSURE MESSAGE, WHEN THEY TURNED ON NR 2 PUMP (HYD PUMP 2A) MESSAGE WAS CONTINUOUSLY ON. A FEW MINUTES LATER ALL NR 2 HYD QUANTITY WAS LOST. MAINTENANCE INSPECTION REVEALED THAT THE QUICK DISCONNECT FITTING ON THE CASE DRAIN LINE TO THE NR 2 PUMP WAS LEAKING AROUND THE BASE OF THE COUPLER. ONCE ALL THE FLUID LEAKED OUT IT STARVED THE PUMP CAUSING IT TO MAKE METAL CAUSING ENGINE VIBRATION AND EVENTUALLY SEIZE. THE CASE DRAIN LINE, NR2 EDP, PRESS AND CASE DRAIN FILTERS WERE REPLACED AND AIRCRAFT WAS FUNCTION2L72 4F4 FRTA21EA E15NE 20070511000082007051100008EU 2007 5 11 CA070118011 120070104G6730AC67244 SERVO SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE ROTOR UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 CA 1263 (CAN) DURING HYDRAULIC PRE-FLIGHT CHECK CAUSED CYCLIC TO MOVE 4-5 INCHES TOWARDS 8 O’CLOCK POSITION. SERVO REMOVED SERVICEABLE UNIT INSTALLED. SERVO SENT OUT FOR REPAIR AWAITING TEARDOWN REPORT. (TC NR 20070118011) 1G71 3U3 U H9EU E19EU 20070511000112007051100011EU 2007 5 11 CA070119005 120070118G30972840A SWITCH BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ANTI ICE SHORTED W H DEACTIVATE SYST/CIRCUITS H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA 851 (CAN) AIRCRAFT IS IN CRUISE FLIGHT WHEN PILOT SELECTED NR 1 AND NR 2 ANTI-ICE (ON) DUE TO THE OAT AND VISIBLE MOISTURE. ON SHORT FINAL TO THE BASE THE PILOT SELECTED BOTH ANTI-ICE SWITCHES TO THE (OFF) POSITION. IMMEDIATELY UPON ACTIVATING NR 1 SWITCH TO (OFF) THE PILOT HEARD AN AUDIBLE (CLICK). LOOKING DOWN HE NOTICED THAT THE NR1 ANTI-ICE 3AMP BREAKER HAD POPPED. ONE UNSUCCESSFUL ATTEMPT WAS MADE TO RESET THE BREAKER. AFTER THE AIRCRAFT HAD SHUTDOWN THE MAINTENANCE STAFF TROUBLESHOT THE SYSTEM AND FOUND THAT THERE WAS A (DEAD SHORT) IN THE ANTI ICE SWITCH P/N 2840A. THE SWITCH WAS REPLACED AND AIRCRAFT WAS RETURNED TO SERVICE. (TC NR 20070119005) 1G72 3U3 U H3EU E4CE 20070511000192007051100019SO 2007 5 11 CA070119012 120070113G81204091709001 TURBOCHARGER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ENGINE LEAKING W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 CA 1362 L430261A (CAN) EXCESSIVE SMOKE FROM THE LT ENGINE WAS REPORTED BY PASSENGER AND GROUND CONTROL DURING APPROACH TO AIRPORT. FLIGHT CREW DECLARED AN EMERGENCY AND AIRCRAFT LANDED AND PASSENGERS IMMEDIATELY DISEMBARKED. AIRPORT EMERGENCY RESPONSE VEHICLES ATTENDED. NO VISIBLE FLAMES OR FIRE WAS EVIDENT PRIOR TO OR AFTER LANDING. AIRCRAFT WAS TOWED FROM THE RUNWAY TO MAINTENANCE FACILITY. MAINTENANCE INVESTIGATION REVEALED EXCESSIVE OIL IN THE TURBOCHARGER EXHAUST. TURBOCHARGER REPLACED WITH O`HAULED UNIT AND AIRCRAFT/ENGINE OPERATION CHECKED NORMAL. (TC NR 20070119012) 1L72 3O3 O A20SO E14EA 5 CP33EA 20070511000262007051100026WP 2007 5 11 CA070122003 120070122G5310D3807 SHROUD ROBSINR44 R44RAVENII 7640122WP LYC O540 IO540AE1A5 41530NE ENGINE BAY CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 202 (CAN) DURING A ROUTINE 100 HR ENGINE/AIRFRAME INSP, IT WAS NOTED THAT THE SUBJECT SHROUD WAS CRACKED JUST AFT OF THE UPPER/AFT MOUNTING SCREW LOCATION. THE SHROUD IS PART OF A SERIES OF SHROUD COVERS THAT SURROUND THE ENGINE FOR COOLING PURPOSES. THE SHROUD HAS 201.8 HOURS SINCE NEW ON IT. THE AIRCRAFT HAS ACCUMULATED 495.0 HOURS SINCE NEW. THIS IS THE SECOND TIME THAT THIS PARTICULAR SHROUD HAS BEEN REPLACED. THE ORIGINAL SHROUD THAT CAME NEW WITH THE AIRCRAFT WAS FOUND CRACKED IN THE SAME LOCATION, AND REPLACED AT 293.2 AIRCRAFT HOURS. THIS SEEMS TO BE A WEAK AREA THAT IS SUBJECTED TO ENGINE VIBRATION. HAVE TAKEN NOTE OF THIS WEAK AREA AND HAVE STEPPED UP OUR VISUAL INSPECTIONS TO SPOT CRACKS IN THEIR EARLY D1G71 3O3 O H11NM 1E4 20070511000292007051100029EA 2007 5 11 CA070122005 120070119G5551600210713 BUSHING CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE HORIZONTAL STAB LACK OF LUBE W K NONE O OTHER ININSP/MAINT 1 CA 5433 (CAN) CREAKING NOISE HEARD WHEN HORIZONTAL STABLIZER WAS CYCLED THROUGH FULL RANGE. HORIZONTAL STAB HINGE BUSHINGS.THEY WERE FOUND DRY. IPC REF:27-43-01-01, ITEM NR 60. PARTS HAND LUBED AND RE-ASSEMBLED IAW MM TASK NR 000-13-320-121. CURRENT INTERVAL FOR THIS TASK IS 10,000 FLT.HRS (TC NR 20070122005) 2L72 4F4 FRTA21EA E15NE 20070511000422007051100042EA 2007 5 11 CA070122006 120070121G5551600210713 BUSHING CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE HORZONTAL STAB LACK OF LUBE W K NONE O OTHER ININSP/MAINT 1 CA 5406 (CAN) CREAKING NOISE HEARD WHEN THE HORIZONTAL STABILIZER WAS CYCLED THROUGH FULL RANGE. AFT FITTING ON THE HORIZONTAL STABILIZER DISASSEMBLED. BUSHING WAS FOUND DRY ( NO LUBRICATION ). PARTS CLEANED, INSPECTED, HAND LUBED AND RE-ASSEMBLED IAW MM TASK NR 000-12-320-121. CURRENT INTERVAL FOR THIS TASK IN THE MANUAL IS 10,000 FLIGHT HOURS. (TC NR 20070122006) 2L72 4F4 FRTA21EA E15NE 20070511000432007051100043NM 2007 5 11 CA070122007 120070105G291082970009235 LINE DHAV DHC8 DHC8101 2809002NM PWA PW121 PW121 52124NE HAMSTD14SF 14SF7 NE RT MLG RUPTURED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA 27198 (CAN) DURING TAKEOFF, AFTER SELECTING LANDING GEAR UP, NR 2 ENGINE HYD PUMP FAILED AND AFTER SEVERAL MIN, A/C LOST ALL OF THE NR 2 HYD QUANTITY. SYSTEM NR 2 PRESSURE LOW AND QUANTITY DEPLETED, ALTERNATE LANDING GEAR EXTENSION. AFTER INVESTIGATION HYD TUBE, P/N 82970009-235 AT RT HYD SYSTEM (L/G BAY), WAS FOUND RUPTURED (IN THE FLARED AREA). TUBE WAS REPLACED; BLEEDING AND LEAK CHECK C/OUT OF RT HYD SYSTEM AND NO LEAKS OBSERVED. (TC NR 20070122007) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070511000442007051100044SO 2007 5 11 CA070122009 220070117G8530EC649358CN CYLINDER CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO HARTZLHCC3Y HCC3YF1 GL NR 4 FAILED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA 755 (CAN) NR 4 CYILINDER FAILED, BURNING VARIOUS ENGINE COMPARTMENT WIRING AND DUCTING. (TC NR 20070122009) 1H71 3O3 O A4CE E5CE 5 CP25EA 20070511000452007051100045CE 2007 5 11 CA070122010 120070106G24971003641621 CONTROL PANEL BEECH 200 B200 1152922CE PWA PT6 PT642A NE HARTZLHCD4N3HCD4N3A GL COCKPIT LIGHTS SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) CREW REPORTED COCKPIT OVERHEAD PANEL LIGHTS CIRCUIT BREAKER POPPED AND ABOUT THE SAME TIME REPORTED SMELLING SMOKE. PCB PANEL REMOVED AND FOUND TO OF SHORTED OUT CAUSING SMALL BURN HOLE THROUGH PANEL SCORCHING METAL BEHIND PANEL. CAUSE OF SHORT BELIVED TO BE MOISTURE FROM EXCESSIVE CONDENSATION. (TC NR 20070122010) 1L72 4T4 T A24CE E4EA 5 CSTC 20070511000462007051100046SW 2007 5 11 CA070122011 120070122G67102040011841 COLLECTIVE STICK BELL 204 204B 1181404SW LYC T53 T5311B 41549NE MAIN ROTOR RATCHETING W A UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) PILOT COMPLAINED OF RATCHETING FEEL TO COLLECTIVE CONTROL STICK. AIRCRAFT RETURNED TO BASE. INSPECTION REVEALED THAT THE COLLECTIVE FRICTION SURFACE ROLL PIN WAS WORKING INTERNALLY AND CAUSING THE RATCHETING FEEL. ELBOW WAS REPLACED. (TC NR 20070122011) 1G71 4U4 U H1SW E1EA 20070511000512007051100051EA 2007 5 11 CA070123006 120070122G3230574205A VALVE DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE MLG MALFUNCTIONED W O OTHER J WARNING INDICATION APAPPROACH 1 CA 366499188 (CAN) DURING APPROACH WHEN LANDING GEAR SELECTED DOWN, NO GEAR MOVEMENT. CIRCUIT BREAKERS, HYDRAULIC PX AND QUANTITY AND DOORS ALL NORMAL. AFTER APPROXIMATELY 10 MINUETS, LANDING GEAR DEPLOYED NORMALLY TO EXTENDED POSITION. AIRCRAFT FERRIED GEAR DOWN TO MAINTENANCE BASE. LANDING GEAR SELECTOR VALVE REPLACED, GEAR SWINGS CARRIED OUT. SERVICEABLE. AIRCRAFT RETURNED TO SERVICE. (TC NR 20070123006) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070511000522007051100052EA 2007 5 11 CA070123008 120070123G5415TA305002403 FAIRLEAD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE HYD LINE WORN W K NONE O OTHER ININSP/MAINT 1 CA 102208646 (CAN) DURING MAINTENANCE INSPECTION , FOUND AFT FUSELAGE EQUIPMENT BAY HYDRAULIC LINE CLAMPS (FAIRLEAD), WITH CENTER (PRESSURE LINE) HOLES WORN THROUGH RUBBER/SILICON COMPOUND AND ALLOWING TUBING TO CHAFE ON METAL PORTION OF BLOCK. BLOCK PN TA3050024-03 CONSISTS OF (2) HALVES (INK STAMP P/N B0305103-002 OR 601R75126-3). CLAMP HALVES REPLACED. (TC NR 20070123008) 2L72 4F4 FRTA21EA E15NE 20070511000552007051100055EA 2007 5 11 CA070123013 120070117G2910AE2460260G0074 HOSE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE HYD SYSTEM LEAKING W O OTHER KJ FLUID LOSS WARNING INDICATION LDLANDING 1 CA (CAN) ON FINAL APPROACH WITH GEAR DOWN AND AT 2000FT THE MESSAGE HYD NR3 LOW PRESS CAME ON EICAS WITH THE HYDRAULIC NR3 RESERVOIR LEVEL AT 0 PERCENT. CREW COMPLIED WITH QRH. THE AIRCRAFT LANDED NORMALLY AND DEPLOYED THE THRUST REVERSER , THE GROUND SPOILERS DEPLOYED AND OPERATED BRAKES . THE AIRCRAFT AT A SPEED AROUND 70 KTS SUDDENLY DIVERTED ON THE RT END SIDE . THE AIRCRAFT LEFT THE SIDE OF THE RUNWAY BY 13 METER AND ENDED UP ON THE GRASS AFTER THE A/C COVERED 50/55 METERS (TC NR 20070123013) 2L72 4F4 FRTA21EA E15NE 20070511000562007051100056EA 2007 5 11 CA070123014 120070121G5610NP13932114 WINDSHIELD CNDAIRCL600 CL6002D24 1390016EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA 565 (CAN) RT WINDSHIELD CRACKED, FL240.IAS250 DIFF PRESS 7.4 RT WINDSHIELD REPLACED ACC AMM 56-11-01-400. CURE TIME OF SEALANT TIL 21-01-2007, 20:00 LOC TIME. PLS PERFORM ADJUSTMENT OF WIPER ARM TENSION ACC AMM 30-42-09-400-801-A01 AND OPS TEST OF WIPER AND PERFORM A LEAK TEST OF WINDSHIELD ACC AMM 56-11-01-400-801-A01 (E). CONDITION OF SEALANT CHECKED OK. ADJUSTMENT OF WIPER ARM IAW.AMM. CHECKED OK. OPS TEST OF WIPER OK. CABIN PRESSURE TEST UP TO DELTA P 6.0 PERFORMED FOUND SATISFIED. (TC NR 20070123014) 2L72 4F4 FRTA21EA EOOO63EN 20070511000602007051100060NE 2007 5 11 CA070125006 220070123G7261 ENGINE BOEING727 727243 138408DNM PWA JT8 JT8D9A 52048NE NR 3 LEAKING W EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA 674678505 666071 (CAN) ENROUTE, NR 3 ENGINE OIL LOSS, AIRCRAFT DIVERTED. INSPECTED AND FERRIED AIRCRAFT. ENGINE REPLACED (TC NR 20070125006) 2L73 4F4 FRTA3WE E2EA 20070511000702007051100070EU 2007 5 11 CA070125004 120070123G6220601741 BEARING BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL PENDULUM ABSORB FRACTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON LANDING AT THE MAINTENANCE BASE AND FOLLOWING HELICOPTER BEING SHUTDOWN, THE PILOT WAS EXITING AND LEAVING THE AIRCRAFT HE NOTICED THAT THE M/R PENDULUM ABSORBER ON THE YELLOW MAIN ROTOR BLADE WAS IN THE HORIZONTAL POSITION. CLOSER INSPECTION REVEALED THAT WHEN AN ATTEMPT TO ROTATE THE PENDULUM ABSORBER IT WAS EXTREMELY ROUGH AND DIFFICULT TO ROTATE. PENDULUM ABSORBER WAS REMOVED AND DISASSEMBLED, WHERE IT WAS FOUND THAT ONE OF THE BEARINGS HAD A FRACTURED OUTER CASE. THE BEARING APPEARED TO BE DRY, AS NO EVIDENCE OF LUBRICATION WAS FOUND. NEW BEARINGS, SEALS, AND O-RINGS WERE INSTALLED. PENDULUM ABSORBER WAS RE-INSTALLED AND AIRCRAFT NOW RETURNED TO SERVICE. (TC NR 20070125004) 1G72 3U3 U H3EU E4CE 20070511001012007051100101NE 2007 5 11 CA070409001 220070330G7200 ENGINE CNDAIRCL600 CL6002D24 1390016EA GE CF34 CF348E5 30015NE NR 1 MALFUNCTIONED W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA 194243 (CAN) ON TAKEOFF ROLL, 1ST OFFICER NOTICE A MOMENTARY FLUCTUATION OF ABOUT 2% ON NR 1 N1 GAGE JUST AFTER THE 80 KNOTS CALL. N1 THEN STABILIZED UNTIL REACHING JUST OVER 100 KNOTS, FLUCTUATED AGAIN. DID NOT HEAR OR FEEL ANY CHANGES IN ENGINE. THERE WERE NO EICAS MSG AND ALL OTHER ENGINE READOUTS WERE STABLE AND NORMAL. THIS WAS POSSIBLY A ERRONEOUS N1 READOUT, ELECTED TO CONTINUE TAKEOFF. EVERYTHING NORMAL ON CLIMB UNTIL SHORTLY AFTER ACCELERATION ALTITUDE WHEN NR 1 N1 BEGAN TO FLUCTUATE MORE SIGNIFICANTLY. COULD NOW HEAR AND FEEL NR 1 ENGINE SURGING. WITHIN SECONDS, ENGINE WENT INTO AN OVERSPEED CONDITION ACCOMPANIED BY A FADEC FAULT 1 STATUS MSG. BROUGHT THRUST LEVER TO IDLE, NO EFFECT. DECLARED AN EMER2L72 4F4 FRTA21EA E00063EN 20070516001362007051600136NM 2007 5 16 CA070205004 120070121G323183232013003 BELLCRANK DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE NLG DOOR BROKEN W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 3000 (CAN) AN OPERATOR MADE AIR TURN BACK DUE TO NOSE GEAR DOOR MALFUNCTION. THE NLG DOORS WON’T CLOSE WHEN SELECTED. THE AMBER NOSE GEAR DOOR LIGHT SHOWED ON LANDING GEAR CONTROL PANEL. MAINTENANCE FOUND THE NOSE GEAR BELLCRANK BROKEN AT ONE OF THE LUGS. (TC NR 20070205004) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20070516001382007051600138EU 2007 5 16 CA070212001 120070201G2711978731813 ACTUATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL AILERON TRIM TABINTERMITTENT W O OTHER F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) AILERON TRIM INTERMITTENT. TRIM TAB ACTUATOR REPLACED AND AIRCRAFT RETURNED TO SERVICE (TC NR 20070212001) 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20070511001742007051100174SO 2007 5 11 CA070126009 120070118G3246402377 BOLT PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2A GL LT MLG BROKEN W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) WHILE TAXIING, THE UPPER TORQUE LINK BOLT BROKE WHICH ALLOWED THE LT MAIN WHEEL TO TURN SIDEWAYS. (TC NR 20070126009) 1L72 3O3 O A20SO E14EA 5 CP33EA 20070511001802007051100180SO 2007 5 11 CA070127002 120070123G6120454254 CONTROL CABLE PIPER PA31 PA31325 7103105SO LYC O540 TIO540F2BD 41532EA HARTZLHCE3Y HCE3YR2A GL PROPELLER FAILED W K NONE O OTHER ININSP/MAINT 1 CA 317512033 (CAN) LT PROPELLER CONTROL CABLE FAILURE. THE PILOT NOTED THAT THE LT PROPELLER CONTROL WAS STIFF ON APPROACH. THE LT ENGINE AND PROPELLER CONTROLS WERE INSPECTED, MAINTENANCE DETERMINED THE LT PROPELLER CONTROL CABLE IN THE CABIN PEDESTAL HAD FAILED. THE PROPELLER CONTROL CABLE WIRES HAD TWISTED AND SEVERED APPROXIMATELY .2500 FROM THE SWAGED PORTION OF THE ROD END. THE LT PROPELLER CONTROL CABLE PN: 454-254 (ALT P/N: 24894-08) WAS REPLACED. THE AIRCRAFT RETURNED TO SERVICE. (TC NR 20070127002) 1L72 3O3 O A20SO E14EA 5 CP33EA 20070511001942007051100194EA 2007 5 11 CA070130001 120070129G2820 LINE DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL FUEL VACUUM LEAKING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FLIGHT CREWS REPORTED THAT FUEL FLOW FLUCTUATES WHEN BOOST PUMPS ARE SELECTED OFF. SEVERAL VACUUM LEAKS WHERE FOUND IN THE FUEL LINES IN THE NACELLE AREA. SYSTEM SEALED AS REQUIRED, ENGINE GROUND RUNS CARRIED OUT AND NO FLUCTUATIONS NOTED AT TAKEOFF POWER WITH BOOST PUMPS OFF. (TC NR 20070130001) 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20070511002032007051100203EU 2007 5 11 CA070131007 120070128G56101379628C401 WINDSHIELD BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP MCAULY4HFR344HFR34C652 NE COCKPIT DELAMINATED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING MAINTENANCE INSPECTION, WINDOW WAS FOUND TO BE DELAMINATING AT THE CENTER OF THE BOTTOM EDGE. WINDOW WAS REPLACED. (TC NR 20070131007) 2L72 4T4 TRTBA15CAA E4WE 6 C3PNE 20070511002042007051100204EU 2007 5 11 CA070131008 120070131G2910373Q2277 LINE BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU HYDRAULIC SYS LEAKING W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) IN CRUISE FLIGHT (30 MINUTES AFTER DEPARTURE THE FLIGHT CREW OBSERVED NR 1 AND NR 2 LOW HYDRAULIC PRESSURE LIGHTS ILLUMINATED. THE FLIGHT CREW RETURNED TO DEPARTURE, USED ALTERNATE MEANS FOR EXTENDING THE LANDING GEAR AND LANDED UNEVENTFUL. MAINTENANCE FOUND INSUFFICENT FLUID IN THE HYDRAULIC SYSTEM. A LEAK IN HYDRAULIC LINE P/N 373Q2277, CAUSED BY CHAFING WAS FOUND IN THE LT MAIN LANDING GEAR WHEEL WELL. THE LINE WAS REPLACED, SYSTEM BLEED AND FUNCTION CHECKED OK. (TC NR 20070131008) 2L72 3T4 T A24EU A196 6 CP899 20070514000042007051400004NM 2007 5 14 CA070201003 120070201G324631573 WHEEL BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 3 FAILED W O OTHER O OTHER LDLANDING 1 CA (CAN) AN AIRCRAFT EXPERIENCED NR 3 WHEEL AND TIRE SEPARATION UPON LANDING DUE TO WHEEL BEARING FAILURE. DETERIORATION OF THE MAIN LANDING GEAR WHEEL BEARINGS, RESULTING IN DAMAGE TO THE WHEEL, AXLE, AND BRAKE UNITS. (TC NR 20070201003) 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20070514000052007051400005EA 2007 5 14 CA070201004 120070201G2797 WIRE CNDAIR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE FLAP SYSTEM BROKEN W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION APAPPROACH 1 CA (CAN) APPROX 1 MILE OUTSIDE THE OUTER MARKER AT 3000 AGL, THE AMBER FLAP CAUTION LIGHT ILLUMINATED. THE CREW SELECTED FLAP 20 AND THE FLAPS WENT TO 20. WHEN THE LIGHT ILLUMINATED THE CREW WENT THROUGH THEIR EMERGENCY CHECKLIST AND CARRIED OUT AN UNEVENTFUL LANDING. THE AIRCRAFT WAS THEN FERRIED FOR MAINTENANCE. ALL FLAP ACTUATORS WERE PURGED AND SERVICED WITH FRESH GREASE IAW MM TASK 12-20-29-640-805. BOTH BPSU’S WERE REPLACED IAW MM TASK 27-51-10-000-80. FLAP OPERATIONAL TESTS AND A TEST FLIGHT WERE CARRIED OUT WITH NO FAULTS FOUND. JANUARY 29/2007 IN HOUSE TASK RJ2-275002 FLAP MOISTURE PREVENTION PROGRAM WAS CARRIED OUT. JANUARY 30/2007 THE AIRCRAFT FLEW FOUR LEGS AND ON THE FORTH LEG, THE FLAPS FAILED 2L72 4F4 FRTA21EA E15NE 20070514000062007051400006EU 2007 5 14 CA070201005 120070130G2710S27010022120100 WASHER AEROSPATR42 ATR42300 8680920EU PWA 120 PW120 NE HAMSTD14SF 14SF5 NE AILERON SPLIT W A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) THE CREW OBSERVED BINDING IN THE AILERON SYSTEM WHILE EXECUTING A RT TURN DURING DEPARTURE. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE WITHOUT FURTHER PROBLEM. POST FLIGHT INSPECTION DETECTED A LOCATION IN THE SYSTEM WHICH EXHIBITED AN INCREASED RESISTANCE TO TRAVEL WHEN CYCLING THE SYSTEM BUT THERE WAS NO RESTRICTION TO FULL MOVEMENT. MAINTENANCE FOUND A SPLIT TEFLON WASHER FOULING THE BEARING AT THE SWING LINK BETWEEN RIBS 8 AND 9. THE WASHER WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE WITHOUT FURTHER PROBLEM. (TC NR 20070201005) 2H72 4T4 TRTA53EU E20NE 6 CP7NE 20070514000072007051400007GL 2007 5 14 CA070201008 220070127G732123034702 FCU HUGHES369 369HS 4470728WP ALLSN 250C 250C20 03013GL THROTTLE LEVER FAILED W E ENGINE SHUTDOWN K FLUID LOSS NRNOT REPORTED 1 CA 2719 CAE820727 (CAN) AFTER THE AIRCRAFT WAS STARTED, THE PILOT DECIDED TO DO A WALK AROUND THE AIRCRAFT. FUEL WAS NOTICED FLOWING FROM THE ENGINE BAY TO THE GROUND. FURTHER INVESTIGATION REVEALED A MASSIVE FUEL LEAK AT THE FUEL CONTROL THROTTLE LEVER SHAFT SEAL. FUEL WAS FLOWING FROM THE FUEL CONTROL AND SATURATING THE STARTER GENERATOR WITH FUEL. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT EVACUATED. FCU REPLACED WITH SERVICABLE UNIT, STARTER VISUALLY INSPECTED AIRCRAFT GROUND RUN, LEAK CHECKED AND TEST FLOWN. AIRCRAFT RELEASED. THIS COULD HAVE BEEN A DIFFERENT STORY. NORMALLY THE PILOT WOULD HAVE JUST TAKEN OFF AFTER STARTING THE AIRCRAFT. HIS DECISION TO PERFORM A WALK AROUND MAY HAVE SAVED LIVES AS THE AMOUNT OF FUEL LEAKIN1G71 3U3 U H3WE E4CE 20070514000132007051400013EA 2007 5 14 CA070202002 120070126G493038834491 LINE HONEYWELL 38004883 CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE APU FUEL CHAFED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA P160 (CAN) JANUARY 296/2007 DEFECT 591259, THERE WAS A FUEL SMELL COMING FROM THE APU BLEED. THE APU WAS DEFERRED AND INHIBITED IAW MEL 49-10-01-1. JANUARY 29/2007 MAINTENANCE REPLACED THE ECU FOR TROUBLESHOOTING, BUT THERE WAS NO FIX. FEBRUARY 01/2007 FURTHER TROUBLESHOOTING CARRIED OUT BY MAINTENANCE AND APU FUEL LINE FOUND TO BE LEAKING ABOVE THE EXCITER BOX. THE ADEL CLAMP HAD CHAFED THROUGH THE LINE. FUEL LINE PN 3883449-1 WAS REPLACED, NEW CLAMPS INSTALLED AND APU LEAK AND FUNCTION CHECKED SERVICEABLE. APU HOUR SINCE OVERHAUL ARE 3254 AND CYCLES 2660. (TC NR 20070202002) 2L72 4F4 FRTA21EA E15NE 20070514000152007051400015NM 2007 5 14 CA070202003 120070116G5210 SEAL BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE FAILED W G O2 MASK DEPLOYED O OTHER CRCRUISE 1 CA (CAN) DURING CRUISE AT FL320, CABIN RATE STARTED TO CLIMB