20100308 CE 2010 3 8 2010F00027 120100304G5320 TUBE CESSNA560 560XL 2076702CE PWC 545 PW545B NE ZONE 100 SHORT B K NONE O OTHER ININSP/MAINT 1 GL07587QS1184 5605805 THE RUDDER CONTROL CABLES PASS THROUGH A PLASTIC GUIDE TUBE BETWEEN WING AND FUSELAGE. THIS GUIDE TUBE IS NOT SUPPORTED AT AFT END. IT IS TOO SHORT TO PASS THROUGH THE SUPPLIED SUPPORT CLAMP. SB560XL-27-20 ADDRESSES THIS CONDITION BUT IS NOT APPLICABLE TO THIS SN ACFT. ON THIS ACFT, THE INTENT OF THE SB WAS INCORPORATED DURING PRODUCTION. REPLACEMENT OF THE GUIDE TUBE WITH A LONGER TUBE WOULD CORRECT THE PROBLEM BUT DUE TO ACCESS DIFFICULTY, REPLACEMENT IS NOT REALLY FEASIBLE. MFG ENGINEERING SUPPLIED DWGS TO CORRECT THE SITUATION ON THIS ACFT. 2L72 4F4 FRTA22CE E00059EN 20100309 SO 2010 3 9 2010FA0000092 220100115G8530653888 LIFTER BEECH 58 58 1152740CE CONT O550 IO550C SO NR 5 CYLINDER SPALLED B K NONE O OTHER ININSP/MAINT 1 SW05731P 1250 TH1997 685280 REMOVED NR 6 CYLINDER FOR REPAIR, WHILE INSPECTING ASSOC COMPONENTS FOUND SPALLING ON FACE OF NR 5 CYLINDER EXHAUST LIFTER AND NR 5 AND NR 6 CYLINDER INTAKE LIFTERS CAUSING DAMAGE TO CAMSHAFT LOBES. (K) 1L72 3O3 O 3A16 E3SO 20100120 EU 2010 1 20 5APR577Y23 120100105G3240244755 BRAKE DISC PILATSPC12 PC1247 7090552EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL BRAKE ASSY CRACKED B K NONE O OTHER ININSP/MAINT 1 EA65794AF2061 2061 0740 794 PR0677 KX442 DURING A 100 HOUR INSP THE RT BRAKE OTBD DISC WAS DISCOVERED TO BE CRACKED. REMOVED AND REPLACED BRAKE ASSEMBLY IAW MFG MX INSTRUCTIONS. 1L71 4T4 TRTA78EU E26NE 5 CP210NE 20100120 SO 2010 1 20 2010FA0000002 120100107G792153E19600 VERNATHERM LYC PIPER PA32 PA32RT300 7103215SO LYC 0540 IO540K1G5D 41532SO HARTZLHCC2Y HCC2YK1 GL OIL FILTER ADAPTDISTORTED D K NONE O OTHER ININSP/MAINT 1 WP1582EB 1320 1320 32R7985028 RL1873548A CH33807B AFTER REMOVING THE LT OIL COOLER SUPPLY HOSE AT THE CASE FOR ACCESS TO MAGNETO, IT WAS NOTICED THAT THE NUT OFF THE END OF THE VERNATHERM WAS STUCK IN THE FITTING STICKING OUT OF THE CASE. VERNATHERM WAS REMOVED AND REMAINING PARTS LOCATED. INSPECTED SEAT AREA AND FOUND NO UNUSUAL MARKS. REMOVED AND INSPECTED SUCTION SCREEN AND OIL FILTER ELEMENT. NO UNUSUAL CONTAMINANTS NOTED. THIS HOSE CONNECTION HAD BEEN REMOVED 13 HOURS PREVIOUS FOR OTHER MX AND NO NUT WAS VISIBLE AT THAT TIME. SB 518B APPLIES BY PN, BUT THIS VALVE IS A HIGHER SN THAN THAT SPECIFIED IN THE SB. THIS ENG IS A FACTORY REBUILT 8/27/1994. 1L71 3O3 O A3SO 1E4 5 CP920 20100127 CE 2010 1 27 2010FA0000001 120100107G32333582517213 ARM BEECH 58 58 1152740CE CONT O550 IO550* SO NLG ACTUATOR CRACKED C K NONE O OTHER ININSP/MAINT 1 EA05202P 1074 ALG9426 TH1875 NOSE GEAR ACTUATOR ARM FOUND CRACKED IN AREA OF WHERE THE ARM JOINS THE INPUT DRIVE BOSS. 2 OF THE 4 WEBS ATTACHING THE ARM TO THE BOSS WERE CRACKED. 1L72 3O3 O 3A16 E3SO 20100127 EU 2010 1 27 5APR577Y24 120100109G3240244755 BRAKE DISC PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG BROKEN B K NONE O OTHER ININSP/MAINT 1 EA65656AF1480 1480 656 PR0530 KX266 DURING A 100 HR INSP, DISCOVERED THE RT BRAKE OTBD DISC WAS BROKEN INTO 2 PIECES. REMOVED AND REPLACED BRAKE ASSY IAW MM INSTRUCTIONS. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20100127 EA 2010 1 27 2010FA0000015 220100110G8530AEL14995 SHROUD LYC FRCN040 AMTR VANS RV9A 05614C3GL LYC O320 O320D2J 41508EA NR 3 CYLINDER CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 GL15128CE185 185 362427 90989 L1428339A PN AEL 14995 (SPRING, SHROUD TUBE) WAS FOUND BROKEN ON NR3 CYLINDER. THE TUBE HAD BACKED PARTIALLY OUT LEAKING A SMALL AMOUNT OF OIL. 1L71 3O3 ONTEXPA1L71E274 20100127 EU 2010 1 27 5APR577Y25 120100109G32315322012289 DRAG LINK PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL NLG DOOR CRACKED B K NONE O OTHER ININSP/MAINT 1 EA65656AF3450 3450 656 PR0530 KX266 DURING NDT INSP OF NLG RT DRAG LINK PN 532.20.12.289 IAW AMM 12-A-32-20-06-00A-313A-A AND AD 09-14-13 A CRACK INDICATION WAS DETECTED IN THE PRESCRIBED NDT INSPECTION AREA. REMOVED RT DRAG LINK AND INSTALLED AN UPGRADED DRAG LINK PN 532.20.12.296 IAW SRM AND AD 09-14-13. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20100201 GL 2010 2 1 CA100111004 120100111G3220D4132232033B ROD DIAMONDA40 DA40 2990002GL LYC O360 IO360M1A NE DAMPER WORN W K NONE O OTHER ININSP/MAINT 1 CA 695 (CAN) THE DAMPER ASSEMBLY D41-3223-20-00G WAS DISASSEMBLED TO REPLACE WORN RUBBER ELEMENTS. IT WAS DISCOVERED THAT THE LOWER END OF THE DAMPER ROD THAT HOLDS THE ASSEMBLY TOGETHER HAD BEEN SEVERELY WORN AND WAS BEYOND LIMITS. IT APPEARS THAT THE LOWER DAMPER PLATE (DAMPER PLATE III AND DAMPER PLATE I) HAVE BEEN SLIDING AGAINST THE DAMPER ROD CAUSING THE DETERIORATION. (TC NR 20100111004) 1L71 3O3 ONTA47CE 1E10 20100201 EA 2010 2 1 CA100114003 120100113G5610601R3303312 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 30070NE COCKPIT CRACKED W O OTHER O OTHER DEDESCENT 1 CA 2181521815 (CAN) DURING DESCENT THE RT COCKPIT SIDE WINDOW INNER PLY CRACKED. THE A/C LANDED SAFELY AND THE WINDOW WAS REPLACED BEFORE FURTHER FLIGHT. WINDOW P/N 601R33033-12, S/N 99116H6100. WINDOW HOURS AND CYCLES, TSN 21815, CSN 16578. (TC NR 20100114003). 2L72 4F4 FRTA21EA E15NE 20100201 CE 2010 2 1 CA100114004 120100113G2434DOFF10300BR ALTERNATOR CESSNA206 TU206G 2073357CE CONT O550 IO550F 17042SO DC SYSTEM FAILED W A UNSCHED LANDING HJ ELECT. POWER LOSS-50 PC WARNING INDICATION CRCRUISE 1 CA (CAN) ALTERNATOR FAILED DURING FLIGHT. ELECTRICAL POWER LOSS INDICATED TO CREW. CREW RETURNED FOR LANDING AT CYTZ. (TC NR 20100114004) 1H71 3O3 O A4CE E3SO 20100202 CE 2010 2 2 2010FA0000035 120100108G27000510105360 CONTROL CABLE CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL FLT CONTROLS FRAYED B K NONE O OTHER ININSP/MAINT 1 WP07558ER 172S10562 L3350451E ABD23511A DURING FLAP & AILERON CABLE INSP FLAT SPOTS WERE NOTICED ON 3 AILERON CONTROL CABLES. ROLLED CABLES FOR BETTER VIEW OF CONTACT POINT WITH PULLEYS & WAS ABLE TO CATCH FRAYED WIRES WITH A RAG & COULD SEE A SUBSTANTIAL GROOVE IN CARRY-THRU CABLE. CABLE TENSIONS WITHIN SPECS & AREA CLEAN & FREE OF DIRT & DEBRIS. PLASTIC PULLEYS INSPECTED, CLEAN & FREE TO ROLL. PROBLEM SEEMS TO BE HAPPENING DURING NORMAL FLT TRAINING SCHOOL USE & HAS BEEN NOTICED TO BE HAPPENING WITH OUR OTHER ACFT WITH SAME TIMES. CAUSE IS PROBABLY FROM PULLEYS THEMSELVES. THEY ARE MADE FROM A HARD WHITE PLASTIC MATERIAL. THE BRAIDED STEEL CABLES ARE RUBBING AGAINST THE PULLEYS INSTEAD OF ROLLING ON THEM. THAT IS CAUSING THEM TO FLAT SPOT AT1H71 3O3 ONT3A12 1E10 5 NP857 20100202 EU 2010 2 2 5APR577Y27 120100115G3240244755 BRAKE DISC PILATSPC12 PC1247 7090552EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ZONE 700 CRACKED B K NONE O OTHER ININSP/MAINT 1 EA65 1397 1397 1018 874 PR0760 KX543 DURING A LINE CHECK THE LT BRAKE OTBD BRAKE DISC WAS FOUND TO BE CRACKED. R & R BRAKE ASSEMBLY IAW MM INSTRUCTIONS. 1L71 4T4 TRTA78EU E26NE 5 CP210NE 20100202 GL 2010 2 2 2010FA0000016 220100108G723023073567 CARBON SEAL ALLSN AE3007AE3007C 03047GL COMPRESSOR WORN B K NONE O OTHER ININSP/MAINT 1 SW99 330256 OIL FOUND AT 6:00 POS INSIDE FAN CASE. NR O CARBON SEAL WAS REPLACED. REPLACED IAW MM 72-25-25. 4 F TE6CH 20100202 CE 2010 2 2 2010F00014 120100112G2612 FIRE WARNING LEAR 35 36LEAR 5170601CE GARRTTTFE731TFE73122B 01518WP RT ENGINE FALSE ACTIVATIONC A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 EA2112FN 016 P74498 RT ENG FIRE WARNING LIGHT ILLUMINATED SHORTLY AFTER TAKEOFF. THROTTLE RETARDED AND FIRE WARNING LIGHT WENT OUT. THIS IS THE SECOND IN-FLIGHT FALSE FIRE WARNING LIGHT ILLUMINATION ON THIS RENTAL ENGINE. INVESTIGATION IN PROGRESS. 2L72 4F4 F A10CE E6WE 20100202 CE 2010 2 2 2010FA0000023 120100106G7160S1053K25T39 DUCT CESSNA206 206H 2073301CE LYC O540 IO540* 41532EA INDUCTION INTAKECOLLAPSED D K NONE O OTHER ININSP/MAINT 1 FS6010457 20608194 DURING ANNUAL INSP, FOUND DUCT JUST AFT OF INDUCTION FILTER TO BE PARTIALLY COLLAPSED. AFTER REMOVING DUCT, FOUND THE INTERNAL WIRE FORMERS TO BE DISCONNECTED AND UNRAVELED CAUSING THE DUCT TO COLLAPSE. 1H71 3O3 ORTA4CE 1E4 20100202 GL 2010 2 2 2010FA0000059 220100114G72506853279 TURBINE WHEEL ALLSN 250C 250C20B 03013GL ENGINE SEPARATED B E ENGINE SHUTDOWN T ENGINE CASE PENETRATION CRCRUISE 1 SW99 3881 389 CAT25587 DURING A TURBINE TEST (SLAVE ENGINE) THERE WAS AN UNCONTAINED FAILURE OF THE PT ROTOR ASSY (4TH STAGE WHEEL). THE WHEEL EXITED THE ENGINE AND CAUSED SUBSTANTIAL DAMAGE TO THE TEST FACILITY. 2 TEST MECHANICS RECEIVED MINOR INJURIES. 3 U E4CE 20100204 CE 2010 2 4 2010FA0000062 120100121G261337702810 CONTROL BOX LEAR 35 36LEAR 5170601CE GARRTTTFE731TFE73122B 01518WP OVERHEAT UNKNOWN E BHKAA UNSCHED LANDING N FALSE WARNING CLCLIMB 1 EA2112FN 1685313853 016 P74498 REPLACED THE OVERHEAT CONTROL BOX AND THE EXHAUST PIPE FIRE ELEMENT. NO FURTHER PROBLEMS NOTED. 2L72 4F4 F A10CE E6WE 20100204 CE 2010 2 4 2010FA0000065 120100121G2510SK210174A RELEASE CABLE CESSNA206 U206G 2073356CE CONT O520 IO520* 17032SO PILOT SEAT BROKEN B K NONE O OTHER ININSP/MAINT 1 AL019623R U20606906 PILOT REPORTED DIFFICULTY RELEASING THE PILOT SEAT ADJUSTMENT. SEAT WAS LOCKED IN FWD POSITION. THIS ACFT HAD PREVIOUSLY BEEN MODIFIED IAW SEB 07-5R1 BY THE INSTALLATION OF THE SERVICE KIT SK210-174A, WHICH CONSISTS OF AN INERTIA REEL SYS INSTALLED TO PREVENT SEAT FROM MOVING REARWARD IN THE EVENT OF A SEAT LATCHING MECHANISM FAILURE. RELEASE CABLE WAS BROKEN AT THE END THAT ATTACHES TO SEAT ADJUSTMENT HANDLE. THIS IS THIRD CABLE IN FLEET ACFT FOUND DAMAGED IN THAT AREA (SECOND ONE IN 2 DAYS). PROBLEM APPEARS TO COME FROM MISALIGNMENT OF CABLE CLAMP DURING INSTALLATION. THESE SERVICE KITS ARE BEING INSTALLED BY MFG SERVICE CTR ON ACFT WITH SEAT LATCHING MECHANISMS AFFECTED BY MFG SL SE83-6 AND (AD) 87-20-1H71 3O3 O A4CE E5CE 20100208 CE 2010 2 8 2010FA0000093 120100114G554140261T023 SPAR AYRES S2 S2R 7630202CE WRIGHTR1820 R182071 67020EA HAMSTD33D 33D50 GL RUDDER CRACKED D O OTHER O OTHER NRNOT REPORTED 1 NM138893Q 1565R SW041794 TOP RUDDER ATTACH BRACKET CRACKED OUT OF REAR SPAR ON THE VERTICAL FIN. NOTICED CRACK AT ANNUAL INSP. THE RUDDER BEARINGS ARE ALL FREE AND OK. POSSIBLY INSTALL A HEAVIER REAR SPAR. 1L71 3R4 RNCA4SW 5E10 6 CP749 20100201 NM 2010 2 1 CA100111005 120100111G2497 WIRE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE NR 2 EFIS SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA 25 (CAN) WHILE PERFORMING A VISUAL INSPECTION OF AIRCRAFT ZONE 200 INTERIOR, THE TECHNICIAN FOUND TWO SHIELDED WIRES FOR NR 2 EFIS SYSTEM SHORTED ON THE EDGE OF THE RETAINER AT LEFT FUSELAGE STA X302.400 BETWEEN STRINGERS 7 AND 8. THE RETAINER HAS MINOR DAMAGE FROM ELECTRICAL ARCING. PROBLEM APPEARS CAUSED BY INSUFFICIENT PROTECTION OF THE WIRING HARNESS AS THE BRAIDED WRAPPING DOES NOT EXTEND OVER THE DAMAGED WIRING. (TC NR 20100111005) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20100201 CE 2010 2 1 CA100111006 120100108G324616218000 WHEEL BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER STRIPPING, A VISUAL INSPECTION OF BOTH HALF WHEELS WAS PERFORMED BEFORE SENDING TO NDT. BOTH HALF WHEELS TIE BOLTS HOLES FOUND CORRODED BEYOND LIMIT AND MANY SHOWED SIGNS OF CRACKS. (TC NR 20100111006) 1L72 3T4 T A14CE E4EA 20100201 GL 2010 2 1 CA100114001 120100112G324660042RSDIN625 BEARING DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO WHEEL DAMAGED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 689 (CAN) ALL BALL BEARINGS MISSING FROM THE SEALED BEARING (TC NR 20100114001). 1L71 3O3 ONTTA4CH E7SO 20100202 EU 2010 2 2 5APR577Y26 120100119G3240244755 BRAKE DISC PILATSPC12 PC1247 7090552EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ZONE 700 BROKEN B K NONE O OTHER ININSP/MAINT 1 EA65721AF1186 1186 0392 721 PR0591 KX335 DURING A LINE CHECK DISCOVERED THE RT BRAKE OTBD BRAKE DISC WAS BROKEN INTO 2 PIECES. REMOVED AND REPLACED BRAKE ASSY IAW MM INSTRUCTIONS. 1L71 4T4 TRTA78EU E26NE 5 CP210NE 20100202 NE 2010 2 2 2010FA0000058 220100116G7200SU326 O-RING RROYCEBR700 BR700710A22054004NE NR 2 BEARING PINCHED B K NONE O OTHER ININSP/MAINT 1 SW99 12 12 12827 WHILE ACCOMPLISHING DISASSEMBLY FOR NR 2 BEARING HOUSING REPAIR (SB72-900500), A DEFECTIVE O-RING WAS FOUND ON THE FRONT PANEL ASSY. O-RING PN WAS AN SU-326. THE PACKING APPEARED PINCHED FROM ASSY OF THE NR1 BRG HSG ONTO THE FRONT PANEL ASSY. 4 F E00057EN 20100204 CE 2010 2 4 CA100106005 120100103G3250AIR45396 STEERING SYS RAYTHN900 HAWKER900XP 4220011CE GARRTTTFE731TFE7315R 01518WP NLG FAILED W O OTHER S AFFECT SYSTEMS LDLANDING 1 CA 1309 (CAN) NOSE WHEEL STEERING UNSERVICEABLE AFTER LANDING NOSE WHEEL STEERING SYS INSPECTED AND LUBRICATED AND FUNCTION TESTED IAW MM 32-50-00. SYS OPS CHECK OK. FAULT DID NOT DUPLICATE. 1L72 4F4 FRTA3EU E6WE 20100201 NM 2010 2 1 CA100107005 120100107G2710NAS427K9 GUARD DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE PULLEY MISSING W O OTHER O OTHER NRNOT REPORTED 1 CA 35 (CAN) COCKPIT COMPONENTS REMOVED FOR ACCESS. ROLL DISCONNECT HANDLE REMOVED. UPPER MOST CABLE PULLEY FOR ROLL DISCONNECT WAS FOUND MISSING QUANTITY X2 PULLEY GUARD PINS. INSPECTION OF TWO OTHER DASH-8`S, S/N`S 668 AND 669 DID NOT FIND SAME CONDITION. REFERENCE IPC 27-16-00 FIGURE 5. (T NR 20100107005) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20100201 CE 2010 2 1 CA100108002 120100104G3230MS24171D1 RELAY BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE MLG FAILED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION APAPPROACH 1 CA (CAN) ON APPROACH WHEN CREW SELECTED DOWN GEAR THE CONTROL CB POPPED AND CREW HAD TO MANUALLY EXTEND THE GEAR. UPON ARRIVAL WHEN OUTSIDE THE AIRCRAFT WITH POWER ON THE CREW HEARD THE HYDRAULIC PUMP RUNNING SO THEY TURNED OFF POWER, CONTACTED MAINTENANCE AND WERE INSTRUCTED TO OPEN THE 60 AMP CB FOR POWER SOURCE TO THE MAIN RELAY FOR THE HYDRAULIC PUMP. AIRCRAFT FERRIED GEAR DOWN BACK TO MAINTENANCE WHERE THE MAIN RELAY FOR THE HYDRAULIC PUMP HAD FAILED CLOSED. THIS CAUSED THE CONTROL CB TO FAIL, YET REMAIN THE PUMP RUNNING IN BYPASS. MAINTENANCE REPLACED THE RELAY AND ALL FUNCTION TESTS CARRIED OUT SATISFACTORY. (TC NR 20100108002) 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20100201 CE 2010 2 1 CA100108005 120100107G2422SPS1307 INVERTER RAYTHNB300 B300RAYTHEON7150007CE PWA PT6 PT6A60A 52043NE AC SYSTEM FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA (CAN) THIS AIRCRAFT WAS PREVIOUSLY HAD SMOKE IN THE CABIN AND NO CONCRETE SOURCE OF THE SMOKE WAS FOUND. REFER TO CADOR 2009P1941. DURING AN OVERNIGHT INSPECTION ON 1/7/10, THE MEDICAL EQUIPMENT POWER WAS TURNED ON AND THE AFT LIFEPORT MEDICAL PLUS UNIT (BASE FOR THE STRETCHER) INVERTER WAS FOUND TO BE UNSERVICEABLE. THE COOLING FAN HAD FAILED AND THE UNIT WAS EMITTING A BURNING SMELL AND WAS VERY HOT. NO DEFECTS WERE REPORTED IN THE 7 DAY PERIOD BETWEEN THE OCCURRENCE AND THE DISCOVER OF THE INVERTER. IT’S POSSIBLE THAT THIS UNIT MAY NOT HAVE BEEN USED IN THE INTERVENING PERIOD AND MAY HAVE CONTRIBUTED TO THE SMOKE AND ELECTRICAL SMELL AS DISCOVERED IN FLIGHT. THE LIFEPORT IS INSTALLED BY STC SA00273WI NO2L72 4T4 TRTA24CE E4EA 20100201 GL 2010 2 1 CA100108007 120100105G5712C2W753 RIB DHAV DHC2 DHC2MKI 2801830GL PWA R985 R985AN14B 52008NE WING CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 15349 (CAN) DURING INSPECTION (CF 66-03) THE BOTTOM FLANGE OF WING RIB PN NR C2W753 WAS FOUND CRACKED FROM THE STRINGER CUT OUT TOWARDS THE REAR SPAR APPROX 2 INCHES SEE ATTACHED PHOTO (TC NR 20100108007) 1H71 3R3 RRCA806 5E1 20100201 GL 2010 2 1 CA100108008 120100105G5711C2FS5471A ATTACH FITTING DHAV DHC2 DHC2MKI 2801830GL PWA R985 R985AN14B 52008NE WING CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 15349 (CAN) LT WING REMOVED FOR REPAIR OF CRACKED RIB INTERNAL FLANGE OF REAR FORK ON THE LT REAR SPAR FUSELAGE ATTACH FITTING WAS FOUND CORRODED (SEE ATTACHED PICTURE). THIS DEFECT WAS NOT NOTICEABLE WITH THE WING INSTALLED ON THE FUSELAGE AND ONLY BECAME APPARENT WHEN THE WING WAS REMOVED FROM THE AIRCRAFT. CORROSION TO THE FITTING WILL DICTATE REPLACEMENT. NOTE: OPERATORS SHOULD PAY PARTICULAR ATTENTION TO THIS AREA DURING INSPECTION, DEPENDING ON THE AIRCRAFT FIT AND FINISH THIS AREA MAY NOT BE ABLE TO BE INSPECTED PROPERLY WITH THE WING INSTALLED, IN THIS CASE THE ONLY WAY THAT THIS AREA CAN BE ADEQUATELY INSPECTED IS TO REMOVE THE WING. (TC NR 20100108008) 1H71 3R3 RRCA806 5E1 20100201 CE 2010 2 1 CA100112001 120100106G3246 WHEEL MTSBSIMU2 MU2B60 5780460CE GARRTTTPE331TPE33110 29053NE MLG CRACKED W K NONE O OTHER TXTAXI/GRND HDL 1 CA 130 69 (CAN) AIRCRAFT LANDED WITH LOW TIRE PRESSURE WHEEL ASSY REPLACED AFTER WHEEL ASSY REPAIRED IT WAS FOUND THAT THE TUBE HAD 3 SMALL CRACKS ON THE SIDE WALL. NOTE OUTSIDE AIR TEMP WAS -30 DEGREES. TUBE AND TIRE REPLACED AND WHEEL ASSY RETURNED TO SERVICE (TC NR 20100112001) 1H72 3T4 TRTA10SW E4WE 20100201 NE 2010 2 1 CA100112003 220100107G72613059258 OIL FILTER CESSNA208 208 2073702CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL ENGINE FAILED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) INNER CONE (SCREEN) SEAMS ARE BECOMING UNGLUED. (TC NR 20100112003) 1H71 3T3 TNTA37CE E4EA 5 CP60GL 20100201 NE 2010 2 1 CA100112004 220100107G7261305925801 OIL FILTER CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL ENGINE FAILED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) INNER CONE (SCREEN) SEAMS ARE BECOMING UNGLUED. (TC NR 20100112004) 1H71 3T3 T A37CE E4EA 5 CP60GL 20100201 2010 2 1 CA100113001 420100112G341651922702031 ALTIMETER BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA COCKPIT INTERMITTENT W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 40 (CAN) AIRCRAFT DEPARTED CYXD. AFTER ROTATION THE CAPTAIN NOTED HIS ALTIMETER FLAGGED OFF. HE THEN RETURNED TO CYXD. UPON LANDING THE ALTIMETER BEGAN TO FUNCTION AGAIN. SHIPS WIRING CHECKED, NO FAULTS FOUND. ALTIMETER WAS REMOVED AND SENT TO A LOCAL AVIONICS SHOP. IT WAS CONFIRMED THAT THE ALTIMETER WAS INTERMITTENT, AND SOME PROBLEMS WERE FOUND WITH THE INTERNAL CIRCUIT BOARD. A DIFFERENT ALTIMETER IS CURRENTLY ON ORDER. (TC NR 20100113001) 1L72 3T4 T A14CE E4EA 20100204 EA 2010 2 4 CA100105002 220100105G7414M3100 IMPULSE COUPLING ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA MUHBR MTV MTV9* EU MAGNETO BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 549 (CAN) THE MECHANIC CONDUCTING A SCHEDULED 50 HOUR INSP NOTICED THAT THE IMPULSE COUPLING DID NOT HAVE THE USUAL "SNAP" WHILE ROTATING THE PROP. A PAWL SPRING WAS FOUND BROKEN AND THE REMAINING SPRING FELT VERY WEAK. 1L71 3O3 O0 A76EU 1E10 5 CP24NE 20100208 SO 2010 2 8 2010FA0000100 120100104G32455005 TUBE PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA MLG TIRE DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 EA612496X523 288516071 1119239E A57165 TIRE WENT FLAT WHEN THE ACFT WAS JACKED. TIRE APPEARS FINE. SMALL PINHOLE IN SIDEWALL OF THE TUBE. 1L71 3O3 O 2A13 E274 5 NP88614 20100224 SO 2010 2 24 2010FA0000072 120100126G2820PT30GA LINE PIPER PA23 PA23250 7102308SO LYC O540 TIO540C1A 41532EA HARTZLHCE2Y HCE2Y* GL LEFT ENGINE FUELLOOSE G O OTHER KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 GL2323WB 112 277405281 L299561 BP6734 ON APPROACH, TOWER NOTIFIED ACFT THAT SMOKE WAS COMING OUT OF THE LT ENGINE. ON LANDING, LT ENGINE WAS SHUTDOWN AND ACFT TAXIED OFF THE ACTIVE RUNWAY. ACFT WAS MET BY THE FIRE DEPARTMENT AND THE LT ENGINE FIRE WAS EXTINGUISHED. ACFT WAS TOWED AND NOT WORKED ON UNTIL INVESTIGATED BY THE FAA. FOLLOW UP INSP REVEALED THE B NUT ON THE PRESSURE FUEL LINE FROM THE MANIFOLD TO THE PRESSURE TRANSDUCER, LOOSE. THIS INSTALLATION WAS INSTALLED 02-25-1997 UNDER STC SA00068SE. LEAKING FUEL LINE IS POSITIONED JUST ABOVE THE TURBOCHARGER. THE ACFT WAS ANNUALED 02/27/2009. 1L72 3O3 O 1A10 E14EA 5 CP9EA 20100224 2010 2 24 5APR577Y28 420100119G3420066031252500 INDICATOR PILATSPC12 PC1247 7090552EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL COCKPIT ODIFEROUS B HA DEACTIVATE SYST/CIRCUITSUNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 EA65851AF1672 1672 851 PR0743 KX514 SHORTLY AFTER TAKEOFF FLIGHT, CREW REPORTED NR 1 EHSI (ELECTRONIC HORIZONTAL SITUATION INDICATOR) WENT BLACK, AND FLIGHT DIRECTOR AND AUTOPILOT DISENGAGED. FLIGHT CREW ALSO REPORTED AN ELECTRICAL BURNING ODOR. AFTER SEVERAL MINUTES, THE NR1 EHSI RETURNED TO NORMAL. FLIGHT WAS ABORTED AND THE ACFT RETURNED WITHOUT INCIDENT. R & R THE NR1 EHSI (WHICH DID HAVE AN ELECTRICAL BURNING ODOR) ALONG WITH THE NR 1 SYMBOL GENERATOR AND THE AUTO PILOT MODE CONTROLLER. ALL MX WAS PERFORMED IAW MFG INSTRUCTIONS AND A TEST FLIGHT WAS SUCCESSFUL. 1L71 4T4 TRTA78EU E26NE 5 CP210NE 20100224 CE 2010 2 24 2010F00024 120100202G2711118130022607 TAB BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE AILERON MISMANUFACTURED D K NONE O OTHER ININSP/MAINT 1 GL03221CJ UE221 RECEIVED NEW AILERON TRIM TAB FROM VENDOR. TAB WAS A NEW PART FROM THE MFG. INCOMING INSP NOTED THE RIVETS THAT SHOULD HAVE BEEN INSTALLED TO SECURE THE ACTUATOR HORN TO THE TAB WERE MISSING. THERE IS ALSO A ROW OF RIVETS, ALONG THE HINGE LINE, THAT WERE MISSING. THESE RIVETS ARE THE SUBJECT OF A SB. THIS IS THE SECOND TAB REJECTED FOR THIS PROBLEM. 2L72 4T4 TRTA24CE E26NE 20100224 WP 2010 2 24 2010FA0000075 120100127G2913C8187B MOTOR ROBSINR44 R44RAVENII 7640122WP LYC O540 IO540AE1A5 41530NE HYD PUMP BURNED OUT D D RETURN TO BLOCK J WARNING INDICATION TXTAXI/GRND HDL 1 WP13822F 850 10860 AUX PUMP LIGHT ILLUMINATED AFTER PICK UP. PUMP MOTOR DEFECTIVE, WILL NOT TURN WHEN POWER APPLIED. 1G71 3O3 O H11NM 1E4 20100224 SW 2010 2 24 2010FA0000076 120100127G3250 ROD MOONEYM20 M20K 5870220SW CONT O360 TSIO360* 17025SO NLG STEERING FAILED C O OTHER O OTHER LDLANDING 1 EA13252VV2450 251149 STEERING LINKAGE ROD BROKE AT THE NLG TRUSS ASSY. 1L71 3O3 O 2A3 E9CE 20100310 EU 2010 3 10 2010FA0000132 120100207G30409598110109 WINDSHIELD PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE ZONE 200 CRACKED E AAJAO OTHER O OTHER APAPPROACH 1 WP01932SP 222 WINDSHIELD CRACKED/SHATTERED IN DESCENT PORTION OF FLIGHT. ACFT DID NOT DEPRESSURIZE AND WINDSHIELD HEAT STILL FUNCTIONED. APPEARS UPON INSPECTION FOR FERRY PERMIT THAT SOMETHING OF UNKNOWN ORIGIN IMPACTED WINDSHIELD. COULD FIND EXACT POINT OF IMPACT AND WINDSHIELD SHOWED NO INDICATION OF INTERNAL FAILURE FROM CABIN OR FROM HEAT SYS. NO ARCHING AT ALL AND HEAT FUNCTION STILL WORKED WELL. THE CRACKED ONLY EFFECTED THE EXTERNAL PANE OF WINDOW, INTERIOR STILL IN TACT. 1L71 3T4 TRTA78EU E26NE 20100202 2010 2 2 2010FA0000021 420100104G6122ATF27A CONTROL UNIT PIPER PA28 PA28R201 7102816SO LYC O360 IO360C1C6 41514EA MCAULY2D34C B2D34C213 GL PROP GOVERNOR WORN B K NONE O OTHER ININSP/MAINT 1 GL194160F 2844028 L2760551E 060908 DURING ANNUAL INSP OF ENG, FOUND PROP GOVERNOR CONTROL UNIT CONTROL ARM HIGH RPM ADJUSTABLE STOP SCREW AND STOP PIN EXCESSIVELY WORN. CONTROL ARM STOP PIN HAS A GROOVE IN WHICH CONTROL ARM RETURN SPRING IS HOOKED IN. THE WEAR BETWEEN THE ADJUSTABLE HIGH RPM STOP SCREW AND CONTROL ARM PIN IS DIRECTED ON RETURN SPRING GROOVE. OVER TIME HIGH RPM STOP SCREW AND/OR STOP PIN WILL WEAR ENOUGH TO INCREASE ENGINE SPEED WHICH WILL EVENTUALLY CAUSE AN OVERSPEED CONDITION OR COMPROMISE INTEGRITY OF CONTROL ARM RETURN SPRING ATTACHMENT. IT IS RECOMMENDED TO DESIGN STOP PIN WITHOUT RETURN SPRING GROOVE TO COME IN CONTACT WITH ADJUSTABLE HIGH RPM STOP SCREW OR CHANGE STOP SCREW AND PIN CONTACT SURFACES TO A MORE WEAR RES1L71 3O3 O 2A13 1E10 5 CP7EA 20100202 CE 2010 2 2 2010FA0000034 120100108G27000510105364 CONTROL CABLE CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL FLT CONTROLS GROOVED B K NONE O OTHER ININSP/MAINT 1 WP07558ER 172S10562 L3350451E ABD23511A CABIN OVERHEAD CTR PANEL WAS REMOVED FOR PROGRESSIVE INSP. DURING FLAP & AILERON CABLE INSP FLAT SPOTS WERE NOTICED ON 3 AILERON CONTROL CABLES. ROLLED CABLES FOR BETTER VIEW OF CONTACT POINT WITH PULLEYS AND WAS ABLE TO CATCH FRAYED WIRES WITH A RAG AND COULD SEE A SUBSTANTIAL GROOVE IN THE CARRY-THRU CABLE. CABLE TENSIONS WERE WITHIN PROPER SPECS AND AREA WAS CLEAN & FREE OF ANY DIRT/DEBRIS. ALSO PLASTIC PULLEYS WERE INSPECTED, THEY WERE CLEAN AND FREE TO ROLL. THIS PROBLEM SEEMS TO BE HAPPENING DURING NORMAL FLIGHT TRAINING SCHOOL USE AND HAS BEEN NOTICED TO BE HAPPENING WITH OUR OTHER ACFT WITH THE SAME TIMES. CAUSE IS PROBABLY FROM PULLEYS THEMSELVES. THEY ARE MADE FROM A HARD WHITE PLASTIC MATERIAL.1H71 3O3 ONT3A12 1E10 5 NP857 20100202 CE 2010 2 2 2010FA0000020 120100105G73123013446 TUBE CESSNA208 208B 2073701CE PWA PT6 PT6A114 52043NE HARTZLH3B3M HCB3M GL OIL/FUEL HEATER CORRODED B O OTHER O OTHER NRNOT REPORTED 1 SW054655B 208B0160 PCE17256 BUA29128 THE RIGID STEEL TUBE THAT FEEDS INTO THE OIL/FUEL HEATER HAS DEVELOPED LITTLE PIN HOLES UNDERNEATH THE FIRE LOOP BRACKET THAT ATTACHES THERE. WHEN YOU TAKE THE LINE OFF, IT JUST LOOKS LIKE LITTLE DOTS OF CORROSION BUT WHEN YOU PRESSURIZE IT WITH AIR, IT LEAKS AT AN EXTREME RATE. POSSIBLE CAUSE COULD BE ADEL CLAMP CHAFING OR CORROSION. 1H71 3T3 T A37CE E4EA 5 CP9NE 20100202 GL 2010 2 2 E81RJW30228 220100113G73208063735 FUEL CONTROL RAYTHN390 390 7150030CE WILINTFJ44 FJ442A GL LEFT ENGINE MALFUNCTIONED B D RETURN TO BLOCK E VIBRATION/BUFFET TXTAXI/GRND HDL 1 GL03972PF 882 RB38 1083 INVESTIGATED REPORTED LT ENG SURGING AND "POPPING" AFTER START. REPLACED FUEL CONTROL ASSY. (HMU) WITH REPAIRED EXCHANGE UNIT, ENGINE OPERATIONS NORMAL. RECOMMEND ACCY MFG INVESTIGATE AT TEARDOWN FOR FAULTS TO DETERMINE IF ONE-TIME PROBLEM, OR FURTHER INVESTIGATION REQUIRED. 1L72 3F4 FRTA00010WIE3GL 20100202 CE 2010 2 2 2010FA0000045 120100115G323015130551 TRACK CESSNA337 337G 2075730CE CONT IO360 IO360* 17025CE MLG BROKEN D O OTHER O OTHER NRNOT REPORTED 1 NM021871M2747 1 33701471 PN 1513055-1 CAM TRACK ASSY BROKE UPON GEAR RETRACTION. NOSE GEAR THEN WOULD NOT RETRACT PROPERLY OR EXTEND AND LOCK PROPERLY. PUMP MOTOR C/B CONTINUED TO TRIP DURING THE FLIGHT. ACFT WAS LANDED WITHOUT INCIDENT. IT WAS NOTICED THAT THE NOSE GEAR WAS COCKED TO THE RIGHT AND COULD NOT BE TURNED PAST CENTER. 1H72 3O3 O A6CE E1CE 20100204 GL 2010 2 4 JO0M2008102800001220100114G726123056413 TUBE EMB 135 EMB135LR 3260305SO ALLSN AE3007AE3007A 03030GL OIL PRESSURE FAILED I JO0MK NONE K FLUID LOSS TXTAXI/GRND HDL 1 GL23983JC2912 14500977 CAE312949 TUBE ASSY, PRESSURE OIL TO COOLER, PN 23056413 RUBBING STARTER AIR VALVE CLAMP BURST AT CHAFE RESULTING IN LOSS OF APPROX ONE QUART OF OIL. 2L72 4F4 FRTT00011ATTE6CH 20100208 WP 2010 2 8 2010FA0000097 220100114G72308681551 HOUSING GARRTTTPE331TPE3312UA 01514WP COMPRESSOR DELAMINATED D K NONE O OTHER ININSP/MAINT 1 WP07 P97001C ENGINE WAS ASSEMBLED AND TESTED. AFTER TEST METAL SPRAY WAS NOTED IN THE TAIL PIPE. ENGINE WAS DISASSEMBLED AND DELAMINATION OF THE METAL SPRAY ON THE COMPRESSOR HSG WAS NOTED. THERE IS NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME. 3 T E3WE 20100302 GL 2010 3 2 2010FA0000060 320100119G61143A36C434A HUB MCAULY BEECH 33 35C33 1151408CE CONT O470 IO470L 17026SO MCAULY3A36C 3A36C434 GL PROPELLER MISMANUFACTURED D K NONE O OTHER ININSP/MAINT 1 NM091310A2200 215 991694 991694 PROPELLER FACTORY NEW IN 12/10/99. PROPELLER HUB FOUND AT O/H TO BE UNAIRWORTHY DUE TO CYLINDER HOLES DEPTH DRILLED BY FACTORY TOO DEEP. 3 SMALL DIMPLES NOTED ON UNDERSIDE OF HUB ON INSPECTION. MFG HAS REJECTED HUB. FACTORY HAD TO HAVE IMPROPERLY DRILLED HUB AS THEY ARE THE ONLY ONE THAT HANDLES THE MACHINING IN THIS AREA. SUBSEQUENT CONVERSATIONS STATE REPAIR STATIONS HAVE ALSO SEEN THIS IN OTHER HUBS. IMPROPER DEPTH OF DRILLING AT MACHINING PROCESS OF NEW HUB IS THE ONLY WAY THIS HUB COULD HAVE BEEN DAMAGE. POSSIBLE NOT TO FIND IN INSP UNTIL WHICH TIME PROPELLER CYLINDER HAD BEEN OFF AND ON ENOUGH. FEEL THERE MAY BE MANY MORE THAT WERE DRILLED THE SAME DAY OUT IN THE FIELD THAT HAVE NOT BEEN FOUND. 1L71 3O3 O 3A15 3E1 5 CP47GL 20100301 SO 2010 3 1 2010FA0000155 220100119G8530AEC631397 CYLINDER CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO HARTZLHCC3Y PHCC3YF2 GL ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 NM03414FB 414A1203 ON BOTH ENGINES, FOUND FUEL STAINS ON SEVERAL INDUCTION TUBES AFTER FURTHER INSPECTION FOUND FUEL STAINS ON CYLINDER FINS BY INTAKE VALVES/ REMOVED AND REPLACED ALL CYLINDERS/ LOOKING AT PAST RECORDS FOUND THAT INDUCTION GASKETS HAD BEEN CHANGED SEVERAL TIMES AND LEAKING CONTINUED TO INCREASES OVER TIME. CRACKED CYLINDERS IS MOST LIKELY CAUSE SENT CYLINDERS BACK TO RAM ACFT INSP. 1L72 3O3 O A7CE E8CE 5 CP25EA 20100212 CE 2010 2 12 2010FA0000082 120100202G3230SM50D7 RELAY BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO HARTZLHCC3Y PHCC3YF1 GL MLG FAILED B O OTHER O OTHER NRNOT REPORTED 1 SW075581T410 CE1350 830246R EE6078B LANDING GEAR WILL NOT RETRACK OR EXTEND. DYNAMIC RELAY FAILED. 1L71 3O3 O 3A15 E5CE 5 CP25EA 20100311 NE 2010 3 11 2010FA0000181 220100218G720035C051001 ENGINE CESSNA510 510 2076617CE PWC PW615 PW615FA 52282NE RIGHT MAKING METAL B PAZREA ENGINE SHUTDOWN UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 CE03910SY1147 5100009 LB0016 CREW SHUTDOWN RT ENG AFTER HEARING A BANG AND NOTICING ITT RISE AT ALTITUDE 27,000 FT ON 18FEB2010. CREW LANDED. REMOVED THIS ENGINE AFTER FINDING METAL IN OIL & DEBRIS ON CHIP DETECTOR. COMPLETED A SOAP ANALYSIS WITH NORMAL RESULTS. REMOVED THE ENGINES FADEC PN 35C4035-03, SN 06-150 AND DOWNLOADED ENGINE DATA. SENT ENGINE TO MFG FOR ANALYSIS. CONTACTED THE LOCAL FAA FSDO AT SAINT ANN, MO, MFG AND ACFT MFG ON 18FEB2010. INSTALLED A RENTAL/SERVICEABLE ENGINE SN LB0015 AND COMPLETED A SUCCESSFUL GROUND RUN. 1L72 4F4 FRTA00014WIE00073EN 20100311 SO 2010 3 11 2010FA0000179 220100223G8530631397 CYLINDER CESSNA340 340A 2076405CE CONT O520 TSIO520NB 17040SO ENGINE CRACKED D O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 GL05711SD421 340A0958 21750271J (1) CYL HEAD SEPARATED AT 360 TTSN ON THE RT ENG. ALL CYL ON BOTH ENGINES HAD JUST PASSED COMPRESSION CHECK WITH VALUES IN THE MID TO UPPER 70'S BUT PILOT REPORTED VIBRATION IN CRUISE FLIGHT ON LT ENGINE - UPON FURTHER INSP USING SHOP AIR AND LIQUID LEAK DETECTOR, 4 ADDITIONAL CYL WERE FOUND TO HAVE CRACKS (3 CYL ON LT ENG AND 1 CYL ON RT ENG). ALL CRACKS WERE LOCATED ABOVE THE EXHAUST PORT AT THE 3RD OR 4TH FULL COOLING FIN BEHIND THE SPARK PLUG. ALL CYL ARE STAMPED "A" ON THE FLANGE OF THE ROCKER BOSS. 1L72 3O3 O 3A25 E8CE 20100311 CE 2010 3 11 2010FA0000183 120100224G7160716RA00013 INLET RAYTHN900 HAWKER900XP 4220011CE GARRTTTFE731TFE731* 01518WP ZONE 400 DAMAGED E X4RAK NONE O OTHER ININSP/MAINT 1 GL25900PE300 HA0057 ON POST FLIGHT INSP, DISCOVERED 2 RIVET HEADS MISSING FROM THE LT ENGINE INLET COWL. THE ENGINE WAS VISUALLY INSPECTED AND DAMAGE TO THE FAN BLADES WAS NOTED. A BOROSCOPE INSP WAS ACCOMPLISHED ON THE 1ST STAGE COMPRESSOR BLADES AND DAMAGE WAS NOTED. THE ENGINE WAS REMOVED FOR REPAIR. 1L72 4F4 FRTA3EU E6WE 20100301 CE 2010 3 1 2010FA0000185 120100202G5752118130022607 TAB BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE LT AILERON MISMANUFACTURED B E81RK NONE W INADEQUATE Q C ININSP/MAINT 1 GL03221CJ UE221 RECEIVED NEW AILERON TRIM TAB FROM VENDOR. TAB WAS A NEW PART FROM MFG. INCOMING INSP NOTED THE RIVETS THAT SHOULD HAVE BEEN INSTALLED TO SECURE THE ACTUATOR HORN TO THE TAB WERE MISSING. THERE IS ALSO A ROW OF RIVETS, ALONG THE HINGE LINE, THAT WERE MISSING. THESE RIVETS ARE THE SUBJECT OF A SB. THIS IS THE SECOND TAB REJECTED FOR THIS PROBLEM. 2L72 4T4 TRTA24CE E26NE 20100301 SW 2010 3 1 2010FA0000169 120100108G7603660226001 THROTTLE CABLE MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6D 41828NE FRAYED D O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 GL15576514920 241484 L2382451A THROTTLE CABLE LOCKED IN FLIGHT, EXAMINATION FOUND PARTIAL FAILURE OF INTERNAL CABLE APPROX I5 CM FROM SWAG AT CONTROL KNOB END OF ASSY. BELIEVE FAILURE TO BE CAUSED BY TURNING KNOB WHILE TIGHTENING THROTTLE LOCK OR BY ATTEPTING TO USE A VENIER CONTROL. 1L71 3O3 O 2A3 1E10 20100301 CE 2010 3 1 2010FA0000165 120100209G2700NAS56138 ROLL PIN CESSNA180 180J 2072622CE CONT O470 O470* 17026SO TRIM SPROCKET FAILED D O OTHER O OTHER NRNOT REPORTED 1 AL037551K2029 18052672 463979 THE ROLL PIN THAT SECURES THE CHAIN SPROCKET TO THE TRIM WHEEL SHAFT NEXT TO THE TRIM WHEEL, SHEARED OFF AND WAS TURNING FREELY ON THE SHAFT. RENDERING THE ENTIRE STABILIZER TRIM SYS, INOPERATIVE. 1H71 3O3 O 5A6 E273 20100212 CE 2010 2 12 2010FA0000147 120100210G7120NAS148 BOLT BOEING75 A75N1 1380134CE JACOBSR755 R7557 35003EA ENGINE MOUNT FAILED D K NONE O OTHER ININSP/MAINT 1 SW9976195100 751755 DURING INSPECTION OF THE ENGINE INSTALLATION OF THIS AIRCRAFT IT WAS DETERMINED THAT ONE OF THE FOUR HIGH STRENGTH NAS-148 BOLTS THAT HOLT THE ENGINE MOUNT TO THE FUSELAGE WAS FRACTURED COMPLETLY THROUGH UNDER THE HEAD OF THE BOLT. THIS BOLT HAS 100HRS TOTAL TIME IN SERVICE. AFTER INFORMING THE STC HOLDER OF THE FAILURE WE WERE INFORMED THAT WE SHOULD HAVE RE-TORQUED THESE BOLTS AFTER 25HRS OF OPERATION. THIS INFORMATION WAS NOT INCLUDED IN THE STC. ACCORDING TO THE STC HOLDER IT APPARENTLY WAS REFERANCED TO IN THE ORIGINAL AIRCRAFT MAINTENANCE MANUAL WHERE IT STATES THAT THE ORIGINAL ENGINE MOUNT "STUDS" SHOULD BE RETORQUED TO 450 TO 500 INCH POUNDS AFTER THE FIRST 25HRS. THESE ORIGINAL ENGINE MOUNT STUDS ARE1Q71 3R3 R A743 5E11 20100224 EU 2010 2 24 5APR577Y29 120100121G3240244755 BRAKE DISC PILATSPC12 PC1247 7090552EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG CRACKED B K NONE O OTHER ININSP/MAINT 1 EA65869AF1381 1381 0956 869 PR0756 KX535 DURING A LINE CHECK, DISCOVERED LT BRAKE OTBD BRAKE DISC CRACKED. R & R BRAKE ASSY IAW MFG MX INSTRUCTIONS. 1L71 4T4 TRTA78EU E26NE 5 CP210NE 20100302 SO 2010 3 2 V0XR201001120012 120100112G532014523171003 CHANNEL EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 RT SILL HAT SECTION BEAM UNDER GUSSET FROM FRM 5-62 IS CORRODED OUT OF LIMITS. R & R HAT SECTION BEAM. 2L72 4T4 FRTT00011ATTE6CH 20100302 SO 2010 3 2 V0XR201001120013 120100112G532014520609001 SILL EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 LT SILL FROM FRM 24-29 IS CORRODED OUT OF LIMITS. R & R SILL. 2L72 4T4 FRTT00011ATTE6CH 20100302 SO 2010 3 2 V0XR201001120014 120100112G532014525422001 SILL EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 LT SILL FROM FRM 60-65 IS CORRODED OUT OF LIMITS. R & R SILL. 2L72 4T4 FRTT00011ATTE6CH 20100224 CE 2010 2 24 2010FA0000079 120100128G7602 CONTROL ARM BEECH 33 F33C 1151434CE LYC O540 IO540AE1A5 41530NE MIXTURE CONTROL BINDING B D RETURN TO BLOCK YJ ENGINE STOPPAGE WARNING INDICATION TXTAXI/GRND HDL 1 SW07851K 8 CJ178 1001403 AFTER LANDING ACFT, WAS TAXIING BACK TO PARKING AND ENGINE QUIT. TECH TROUBLESHOT SYS AND FOUND FUEL CONTROL UNIT MIXTURE CONTROL ARM WAS BINDING INTERNALLY ON THE THROTTLE SIDE OF UNIT. 1L71 3O3 O 3A15 1E4 20100224 CE 2010 2 24 2010FA0000081 120100202G3230SM50D7 RELAY BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO HARTZLHCC3Y PHCC3YF1 GL MLG INTERMITTENT B D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 SW078101C303 CE1538 836912R EE4860B LANDING GEAR WILL NOT RETRACK . 1L71 3O3 O 3A15 E5CE 5 CP25EA 20100224 NE 2010 2 24 2010F00020 320100114G61106044T35P01 GEARBOX ROTOL SAAB SF340 340B 7860101EU GE CT7TP CT75A2 30030NE ROTOL R354 R3544123F13 NE PROPELLER FAILED D E ENGINE SHUTDOWN J WARNING INDICATION CRCRUISE 1 SO19157SD36468 DRG409488 340A157 367508DKU DRG409488 WHILE IN CRUISE AT FLT LVL 210, PIC NOTICED THAT RT PROPELLER GEARBOX OIL PRESSURE WAS LOW FOLLOWED IMMEDIATELY BY THE MASTER WARNING LIGHT. THE PILOT IMMEDIATELY SHUTDOWN AND SECURED ENGINE AND CONTINUED TO DESTINATION AND LANDED UNEVENTFULLY. UPON LANDING IT WAS DISCOVERED THAT THE RT PROPELLER GEARBOX HAD FAILED. 2L72 4T4 TRTA52EU E8NE6 6 CP61GL 20100216 NM 2010 2 16 ABXR201002010001 120100201G5730 SKIN BOEING727 727227 1384078NM LT WING TORN B K NONE O OTHER ININSP/MAINT 1 GL23308AS 22002 WHILE ACCOMPLISHING ROUTINE SCHEDULED MX, THE LT WING-TIP WAS FOUND TO HAVE A TEAR OUT IN THE AREA OF THE AFT LOWER MOUNTING FASTENER HOLE. CUT DAMAGED AREA OUT AND PERFORMED HFEC TO ENSURE DAMAGE WAS REMOVED IAW NDT MANUAL PART 6 51-00-00 FIG. 23. REPAIR INSTALLED IAW SRM 57-20-5 AUTHORIZED BY AMES REA B257-60111MR. ITEM RETURNED TO SERVICE. 2L73 4F A3WE 20100224 NM 2010 2 24 2010FA0000068 120100123G5730 SKIN BOEING727 727227 1384078NM LT WING CORRODED I R5KBK NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 CORROSION FOUND AROUND FASTENERS ON RT WING, L/E AT WING STA 320. 2L73 4F A3WE 20100301 SO 2010 3 1 V0XR201001120007 120100112G532014521725001 SILL EMB 145 EMB145LR 3260212SO ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 SILL FROM FRM 19-20, LY 790 IS CORRODED OUT OF LIMITS. R & R SILL. 2L72 4T RTT00011AT 20100212 SO 2010 2 12 V0XR20100190002 120100119G53151452915000 FLOORBEAM EMB 145 EMB145ER 3260211SO ZONE 100 CORRODED B K NONE O OTHER ININSP/MAINT 1 NM05807HK 119 ANGLE AT FRM 23 OVER TOP OF FLOORBEAMS FROM Y0.0 TO YR 780.00 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED ANGLE. 2L72 4F RTT00011AT 20100225 CE 2010 2 25 UVVR2010021500004120100212G533030631201622 SKIN RKWELLNA265 NA26565 7630107CE ZONE 200 CRACKED B K NONE O OTHER ININSP/MAINT 1 CE0347SE 8000 28 46534 FUSELAGE SKIN CRACKED AT LOWER FWD CORNER OF RT OVERWING ESCAPE HATCH OPENING. 2L72 4J A2WE 20100119 CE 2010 1 19 2010FA0000036 120100115G2497 TERMINAL BEECH 33 F33A 1151425CE CONTROL PANEL LOOSE D K NONE O OTHER ININSP/MAINT 1 SO0588AN CE1700 CONTACT TERMINALS ARE LOOSE AND CAN BE MOVED BY HAND. SWITCH THROW HANDLE IS ALSO LOOSE AND CAN BE MOVED FROM ANY POSITION. 1L71 3O 3A15 20100301 NM 2010 3 1 2010FA0000154 120100201G322065B054544 BOLT BOEING747 747* NM NLG COMPONENT CRACKED D K NONE O OTHER ININSP/MAINT 1 GL09 17808417 FREV19990140 BOLT IS CRACKED, VISIBLE IN THE INNER BORE PROGRESSING FROM A SMALL LUBE HOLE. BOLT WAS GOING THROUGH A NORMAL O/H PROCES. INITIAL FLUORESCENT MAGNETIC PENETRANT INSP (FMPI) DID NOT REVEAL CRACK. BOLT WAS SUBSEQUENTLY MACHINED TO REMOVE CORROSION FROM THE NSIDE FACE OF BOLT HEAD. BOLT WAS INITAL ETCH INSPECTED AND STRESSED RELIEVED FOR 4 HRS AT 375 DEGREES F =/-25 DEGREES F. BOLT WAS FMPI PRIOR TO SHOTPEEN WHEN CRACK WAS DISCOVERED. CRACK PROGRESSES IN BOTH DIRECTION FROM A LUBE HOLE LOCATED APPROX 2.275 INCHES FROM THE THREADED END OF THE BOLT. THE CRACK RUNS APPROX 1 INCH FROM THE LUBE HOLE TOWARD THE THEADED END OF THE BOLT AND APPROX .250 INCH, 180 DEGREES IN THE OPPOSITE DIRECTION. BOLT IS A LIFE L2L74 4F RTA20WE 20100202 NM 2010 2 2 2010FA0000048 120100116G5330 SKIN BOEING727 727227 1384078NM BS 720A-720B CORRODED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 CORROSION ON SKIN UNDER STRINGER 27R FROM 720A TO 720B+10". 2L73 4F A3WE 20100310 CE 2010 3 10 E81RJW302431 120100218G30205188001 SHUTOFF VALVE RAYTHN390 390 7150030CE RT ENG ANTI-ICE FAILED B E81RK NONE J WARNING INDICATION ININSP/MAINT 1 GL03713AZ23 RB111 INVESTIGATED REPORTED RT ENG ANTI-ICE FAIL ANNUNCIATOR INDICATION. REPLACED INOPERATIVE ENG INLET ANTI-ICE SHUTOFF VALVE WITH NEW SHUTOFF VALVE, ENGINE ANTI-ICE FUNCTIONAL CHECKS OK. HAVE REPLACED SEVERAL LOW TIME NEW AND O/H ANTI-ICE VALVES ON ACFT THIS FALL/WINTER SEASON. 1L72 3F RTA00010WI 20100202 CE 2010 2 2 DYCR020099 120100120G3411 PITOT LINE CESSNA182 182T 2072703CE ZONE 500 MELTED B A UNSCHED LANDING M OVER TEMP CLCLIMB 1 GL07542EC406 18281691 PILOT REPORTED LOW AIRSPEED INDICATION DURING TAKEOFF, CONTINUED FLIGHT TO ALTITUDE AND NOTICED THAT A/S INDICATION WAS SLOWLY DROPPING. KNOWING THAT THE PROBLEM WAS INDICATION ONLY, THE PILOT LANDED WITHOUT INCIDENT. MX INVESTIGATED THE CAUSE OF THE PROBLEM AND DISCOVERED THAT THE PLASTIC PITOT LINE NEAR THE PITOT TUBE HAD MELTED AND RESTRICTED AIRFLOW. 1H71 3O NT3A13 20100212 CE 2010 2 12 UVVR2010021100001120100210G5311265312254031 FRAME RKWELLNA265 NA26565 7630107CE ZONE 100 CRACKED B K NONE O OTHER ININSP/MAINT 1 CE0347SE 8000 601 46534 3 INCH CRACK IN LEFT FUSELAGE SIDE FRAME AT FUSELAGE STATION 257.65 APPROXIMATELY 2 INCHES ABOVE CABIN FLOOR. 2L72 4J A2WE 20100208 SO 2010 2 8 2010FA0000117 120100112G532014525422403 SILL EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 RT SILL FRM FR 60.5 - 65 IS CORRODED OUT OF LIMITS. RT SILL R & R IAW SRM. 2L72 4T RTT00011AT 20100204 SO 2010 2 4 V0XR20100125001 120100125G532014522226003 GUSSET EMB 145 EMB145EP 3260221SO FUSELAGE CORRODED B RAIAK NONE O OTHER ININSP/MAINT 1 NM05807HK 145119 GUSSET AT LT Y-439 FROM FRAME 59-61 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED GUSSET. 2L72 4F RTT00011AT 20100204 2010 2 4 2010FA0000064 420100121G310035380132101 SWITCH BEECH 33 F33A 1151425CE NAVIGATION LIGHTSHORTED B K NONE L NO TEST ININSP/MAINT 1 WP078173C7 CE1541 DURING THE USE OF THE NAVIGATION LIGHTS, THE NAVIGATION LIGHT CIRCUIT BREAKER SWITCH WOULD POP AND NOT RESET. TROUBLESHOT SYS AND FOUND FAULT TO BE WITH CIRCUIT BREAKER SWITCH. REMOVED AND REPLACED SWITCH WITH SAME PN 35-380132-101. THESE SWITCHES ARE SUPPOSE TO BE NEW AND IMPROVED WHICH WAS INSTALLED UNDER AD 2008-13-17 DATED 6 AUG 2008 TO PREVENT FAILURE OF THE CIRCUIT BREAKER TOGGLE SWITCH. THESE CIRCUIT BREAKER SWITCHES ARE STILL CONTINUING TO FAIL INTERNALLY. RECOMMEND THAT MFG INVESTIGATE QUALITY PROCESS AND IMPROVE OR TO SEPARATE THE SWITCH FOR AN INDEPENDENT TOGGLE SWITCH WITH A SEPARATE CIRCUIT BREAKER FOR PROTECTION. 1L71 3O 3A15 20100208 SO 2010 2 8 2010FA0000110 120100114G532014530633003 GUSSET EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK23264 145256 CORROSION FOUND ON FLOOR GUSSET UNDER CTR SEAT RAIL FR 25-28 BEYOND LIMITS, R & R CORRODED FLOOR GUSSET IAW SRM. 2L72 4T RTT00011AT 20100208 SO 2010 2 8 2010FA0000121 120100113G532014522465007 ANGLE EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 CORROSION AND FRETTING ON ANGLE FROM FR 19, RY 400-Y0.0 OUT OF LIMITS. R & R ANGLE IAW SRM. 2L72 4T RTT00011AT 20100202 CE 2010 2 2 E81RJW302211 120100113G30205188001 ANTI-ICE VALVE RAYTHN390 390 7150030CE RT ENGINE MALFUNCTIONED B K NONE E VIBRATION/BUFFET ININSP/MAINT 1 GL03713AZ 5 RB111 INVESTIGATED REPORT OF VIBRATION FELT THROUGH ACFT AFTER REPLACEMENT OF RT ENGINE NACELLE INLET ANTI-ICE SHUT-OFF VALVE ASSY. WITH AN O/H VALVE ASSY. SUSPECT VIBRATION CAUSED BY RAPID MODULATION OF ANTI-ICE SHUTOFF VALVE. VALVE O/H 12/21/2009 ON WO R82102. RECOMMEND INVESTIGATE IF A VALVE O/H PROCEDURES QA ISSUE OR IF COMPONENT OVERHAUL LIMITS NEED TO BE REVISED. 1L72 3F RTA00010WI 20100309 CE 2010 3 9 2010FA0000210 120100222G2840 TRANSMITTER BBAVIA8 8KCAB 2110612CE FUEL SYSTEM LEAKING B O OTHER K FLUID LOSS NRNOT REPORTED 1 GL13829LT65 10782008 FUEL LEAKING FROM SENDING UNIT, SCREW TOO LONG. WE ADDED NR 10 LOCK -O-SEAL TO EACH SCREW. 1H71 3O A21CE 20100208 SO 2010 2 8 2010FA0000101 120100114G32455005 TUBE PIPER PA28 PA28161 7102803SO TIRE CUT D O OTHER O OTHER TXTAXI/GRND HDL 1 EA613152K98 2842272 TIRE WENT FLAT ON THE RAMP. ACFT WAS PARKED. SMALL CUT (PINHOLE) IN OUTER SIDEWALL. TIRE APPEARS TO BE FINE. 1L71 3O 2A13 20100212 CE 2010 2 12 2010FA0000149 120100211G532007120591 SUPPORT BRACKET CESSNA182 182S 2072701CE BATTERY SHELF CRACKED D K NONE O OTHER ININSP/MAINT 1 SW99403ES424 18280050 DURING ANNUAL INSPECTION BOTH AIRCRAFT BATTERY SHELF/TRAY LEFT & RIGHT SUPPORT BRACKETS P/N 0712059-1 FOUND CRACKED IN FWD & AFT ENDS (TOTAL OF 4 CRACKS). EACH CRACK STARTED AT ENDS OF SUPPORTS IN 90 DEGREE BEND RADIUS AND PROPAGATED TOWARD THE CENTER OF EACH SUPPORT. CRACKS .25 TO .75 INCHS LONG. THIS IS THE FOURTH 182S/T MODEL WE HAVE FOUND TO BE CRACKED IN THIS MANNER AND HAD TO INSTALL REPLACEMENT SUPPORTS. ONE AIRCRAFT PREVIOUSLY REPAIRED HAS ALREADY CRACKED THE REPLACEMENT PARTS AND REQUIRED YET ANOTHER SET TO BE INSTALLED. THESE SUPPORT BRACKETS ARE NOT OF A THICK ENOUGH GAUGE SHEETMETAL TO WITHSTAND BOTH THE WEIGHT OF THE 24V BATTERY IT SUPPORTS AND NORMAL AIRFRAME VIBRATION. RECOMMEND CLOSE INSPECTI1H71 3O NT3A13 20100208 CE 2010 2 8 2010FA0000099 120100107G5343264101214 TRUNNION CESSNA208 208B 2073701CE RT MLG CHAFED D K NONE O OTHER ININSP/MAINT 1 AL011314X1913 208B1314 RT MLG TRUNNION WAS FOUND CHAFED AND WORN BEYOND LIMIT BY CONTACT WITH MLG FAIRING PN 2641018-28. WEAR LIMIT IS ESTABLISHED IN CAB05-17 WHICH ADDRESSES THIS CONDITION IN EARLIER SN AIRPLANES BUT DOES NOT COVER THIS AIRPLANE MFG 6/5/08. CONDITION WAS NOT DETECTED UNTIL MLG WAS REMOVED FOR SCHEDULED CORROSION INSP ALTHOUGH THE AREA IS EASILY INSPECTED WITH THE FAIRING REMOVED. AIRPLANE CAME FROM FACTORY WITH NO RUB STRIP ON THE TRUNNION OR RUBBER MOLDING ON THE LOWER EDGE OF THE FAIRING AS CALLED FOR IN CAB05-17. THIS AREA SHOULD BE INSPECTED ANY TIME THE FAIRING IS REMOVED ON EITHER SIDE. 1H71 3T A37CE 20100224 CE 2010 2 24 2010FA0000066 120100118G334035380132103 SWITCH BEECH 33 F33A 1151425CE TAXI LIGHT SHORTED B O OTHER O OTHER TXTAXI/GRND HDL 1 WP075582X888 CE1353 PILOT REPORTED TAXI LIGHT INOPERATIVE, INVESTIGATION BY TECH, FOUND TAXI LIGHT CIRCUIT BREAKER SWITCH WAS AT FAULT. REPLACED CIRCUIT BREAKER SWITCH SYS OPS CHECKED NORMAL. THIS CIRCUIT BREAKER SWITCH WAS REPLACED 888 HOURS FLIGHT TIME PRIOR TO FAILURE IAW AD 2008-13-17. RECOMMEND MFG INVESTIGATE QUALITY PROCESS AND IMPROVE TO PREVENT PREMATURE FAILURES OF CIRCUIT BREAKERS. PREVIOUS CIRCUIT BREAKER SWITCHES WERE MORE RELIABLE SWITCHES. 1L71 3O 3A15 20100120 CE 2010 1 20 2010FA0000018 120100113G3397S20641 CONNECTOR CESSNA172 172P 2072436CE LANDING LIGHTS BURNED D K NONE L NO TEST ININSP/MAINT 1 SW9997LP 17274398 LANDING & TAXI LIGHTS INOP ON PRE-FLIGHT. FOUND COWLING CONNECTOR ASSY, COMPRISING PN S1637-3 & -4, PLUS POWER WIRE AND CONNECTOR PINS BURNED AND CONNECTOR MELTED. REPLACED CONNECTOR AND REMOVED BURNED POWER WIRE. OPS CHECK SAT. THIS CONDITION IS CAUSED BY LEAVING LANDING AND TAXI LIGHTS ON IN FLIGHT FOR EXTENDED TIMES AS THE SYS IS NOT CAPABLE OF THIS ELECTRICAL LOAD FOR EXTENDED OPERATION WITH OUT OVERHEATING WIRES, CONNECTORS AND SWITCHES. SEB09-6A ADDRESSED THIS PROBLEM WITH THE LANDING/TAXI LIGHT SWITCHES REQUIRING INITIAL SWITCH REPLACEMENT AND REOCCURRING REPLACEMENT AT 4 YEARS. SWITCH WAS REPLACED PREVIOUSLY DUE TO OVERHEATING. THIS PROBLEM EXISTS WITH THIS MODEL ACFT, 12 AND 24 VOLT SYS, WITH CO1H71 3O NT3A12 20100208 SO 2010 2 8 2010FA0000112 120100112G532014520609007 SILL EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK23254 145256 RT SILL FRM FR 29-36 IS CORRODED OUT OF LIMITS. RT SILL R & R IAW SRM 51-40-02. 2L72 4T RTT00011AT 20100208 SO 2010 2 8 2010FA0000123 120100114G532014522460013 GUSSET EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK23254 145256 CORROSION FOUND ON GUSSET FR 20-23, ACFT CENTERLINE BEYOND LIMITS. R & R CORRODED GUSSET IAW SRM. 2L72 4T RTT00011AT 20100308 CE 2010 3 8 2010FA0000212 120100217G2840FXT231 TRANSDUCER CESSNA182 182C 2072708CE FUEL SYSTEM LEAKING C K NONE K FLUID LOSS ININSP/MAINT 1 SW07511W 97 52495 DURING INSPECTION, FOUND EVIDENCE OF FUEL LEAKING FROM WITHIN THE FUEL TRANSDUCER. FUEL STAINS WERE FOUND ON EXTERIOR OF THE TRANSDUCER AND ON THE FIRE SHIELD SURROUNDING IT. THERE WAS NO APPARENT LEAKING OUTSIDE OF THE FIRE SHIELD ITSELF. THE UNIT WAS RETURNED FOR EVALUATION AND REPLACEMENT. 1H71 3O NT3A13 20100202 NM 2010 2 2 2010FA0000055 120100116G5730 SKIN BOEING727 727227 1384078NM CENTER WING CORRODED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 CTR WING SKIN CORRODED AT STRINGER 3C, LBL 17 INSIDE LT RAM AIR DUCT. 2L73 4F A3WE 20100308 CE 2010 3 8 2010FA0000203 120100217G5711 SPAR BBAVIA8 8KCAB 2110612CE LT WING CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO118693V 18575 FOUND CRACK IN LT MAIN WOOD SPAR APPROX 16 " INBD OF LIFT STRUT. 1H71 3O A21CE 20100305 CE 2010 3 5 2010FA0000204 120100204G3230505530401 CABLE ASSY CESSNA210 210N 2073453CE MLG BROKEN D K NONE O OTHER ININSP/MAINT 1 SO155229A 21063320 MFG SERVICE KIT PN SK210-174 CABLE ASSY STRAINS OF CABLE BROKEN AT THREADED END. 1H71 3O 3A21 20100208 SO 2010 2 8 2010FA0000125 120100114G532014821725015 SILL EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 SILL AFT OF SERVICE DOOR FROM FRAME 22-23 RY 730 CORRODED BEYOND LIMITS. R & R SILL IAW SRM. 2L72 4T RTT00011AT 20100202 NM 2010 2 2 2010FA0000056 120100116G5330 SKIN BOEING727 727227 1384078NM BS 660-680 CANNING B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 FUSELAGE SKIN OIL CANNING STA 660-680 BETWEEN STRINGER 21R AND 22R. 2L73 4F A3WE 20100309 CE 2010 3 9 2010FA0000094 120100108G2897KTKSAD10280X3 CONNECTOR CESSNA206 206H 2073301CE FUEL PUMP LOOSE B A UNSCHED LANDING F FLT CONT AFFECTED NRNOT REPORTED 1 EA17236KS1650 20608236 PILOT REPORTED THAT FLAPS WOULD NOT EXTEND. CONNECTED EXTERNAL POWER AND FOUND THAT FLAPS WORKED PROPERLY. ON POST INSPECTION RUN UP FOUND THAT FUEL BOOST PUMP WOULD NOT OPERATE AND BEACON WOULD NOT FLASH. FOUND THAT THE ABOVE COMPONENTS WERE ON THE SAME ELECTRICAL BUS. CHECK CONNECTIONS AT JUNCTION BOX AND FOUND GOOD CONTINUITY ON ALL CONNECTIONS INSIDE THE JUNCTION BOX. THE 3 WIRE CONNECTOR THAT ALSO INCLUDES THE WIRE FOR THE BUS OF THE INOPERATIVE COMPONENTS, WAS FOUND LOOSE. WHEN CONNECTOR WAS OPENED THE PINS THAT FED THE AVIONICS WAS BURNED AND ARCHED (NR1 BUS). REPLACED THE CONNECTOR ALONG WITH THE CONNECTOR PINS. ALSO APPLIED TYWRAPS TO THE CONNECTOR AND TIED IT SECURELY TO A NEARBY WIRE BUNDLE. 1H71 3O RTA4CE 20100204 SO 2010 2 4 V0XR20100123002 120100123G532014522461011 DOUBLER EMB 145 EMB145EP 3260221SO FUSELAGE CORRODED B RAIAK NONE O OTHER ININSP/MAINT 1 NM05807HK 145119 BOTH DOUBLERS ON RT BEAM Y-479.0 AT FRAME 20-22 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED DOUBLERS. 2L72 4F RTT00011AT 20100225 CE 2010 2 25 2010FA0000085 120100203G3245G156006 TUBE CESSNA172 172S 2072439CE TIRE FLAT D O OTHER O OTHER LDLANDING 1 SW9952519269 172S10903 DURING TOUCH-AND-GO LANDINGS, PILOTS REPORTED TO HEAR A STRANGE NOISE IN THE LANDING GEAR AT ROTATION AFTER SECOND LANDING. REMAINDER OF FLIGHT WAS NONEVENTFUL. AFTER NORMAL LANDING TOUCHDOWN AND ACFT DECELERATION, ACFT STARTED VEERING TO THE LT OF CTR. LT MAIN TIRE WAS OBSERVED TO BE FLAT. ACFT WAS TAXIED TO FIRST AVAILABLE TURNOFF AND ENGINE WAS STOPPED AFTER ACFT WAS CLEAR OF ACTIVE RUNWAY. WHEEL AND TIRE ASSY WAS REPLACED WITH SPARE AND ACFT OPERATION CONTINUED. DEFECTIVE WHEEL DISASSEMBLED AND INNER TUBE SHOWED SIGNS OF CHAFING AGAINST THE INNER WALL OF THE TIRE TO A POINT THAT THE TUBE BECAME SO THIN THAT A RESULTING BOLE IN THE TUBER ALLOWED DEPRESSURIZATION OF THE TIRE. INSTALLED TUBE SEEMED TO B1H71 3O NT3A12 20100225 EU 2010 2 25 2010FA0000180 120100224G27505275212153 DRIVE ASSY PILATSPC12 PC1247 7090552EU TE FLAPS CRACKED B O OTHER O OTHER TXTAXI/GRND HDL 1 SO13939HE330 1005 FLAP CAS CAUTION ON ROLLOUT AFTER LANDING - FLAPS STOPPED AROUND 13 DEGREES WHILE RETRACTING. CHECKED FLAP ERROR CODES, FOUND SEVERAL E211 CODES. INSPECTED LT INNER RESOLVER INSTALLATION. FOUND RESOLVER DRIVE PIN PULLED FROM SOCKET. FURTHER INSPECTION FOUND INBD LT FLAP DRIVE ARM ASSY, PN 527.52.12.153, CRACKED IN SEVERAL PLACES. PROBABLE CAUSE: UNKNOWN - NO RECORDED OVERSPEED ON ACFT'S CAS SYSTEM, NO SIGNS OF IMPACT DAMAGE OR SIDE LOADS, RIGGING OF FLAPS CHECKED OK, NO OTHER DAMAGE FOUND. 1L71 4T RTA78EU 20100309 CE 2010 3 9 2010FA0000215 120100218G271010652404419 CONTROL CABLE BEECH 36 A36 1151604CE AILERONS FRAYED B K NONE O OTHER ININSP/MAINT 1 SW05315W 2266 E3515 DURING A PRE-PURCHASE INSPECTION, FOUND CONTROL YOKE BINDING WHEN TURNED TO THE LT AT APPROX 45 DEGREES. INSPECTED AILERON CNTRL SYS AND FOUND SCREW LODGED IN PULLEY GROOVE AND DAMAGED CABLE. ACFT HAD FLOWN 2.0 HRS SINCE LAST ANNUAL INSPECTION. THE SCREW APPEARED TO BE A FLOOR PANEL SCREW. 1L71 3O 3A15 20100224 NM 2010 2 24 2010FA0000067 120100123G5311 SKIN BOEING727 727227 1384078NM BS 1148 S24-27R BULGED I R5KBK NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 FUSELAGE SKIN, EXTERNAL, HAS A BULGE AND PULLING FASTENERS AT STA 1148, BETWEEN STRINGER 24R AND 27R. 2L73 4F A3WE 20100301 SO 2010 3 1 V0XR1001120007A 120100112G532014521718007 PROFILE EMB 145 EMB145LR 3260212SO ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 256 PROFILE FWD OF FRM 20, LY 455 IS CORRODED OUT OF LIMITS. R & R PROFILE. 2L72 4T RTT00011AT 20100309 CE 2010 3 9 2010FA0000173 120100129G273166600031 CONTROL CABLE CESSNA560 560XL 2076702CE ELEVATOR TRIM BROKEN B A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CE07511CS 5605324 AFTER T/O, THE ELEVATOR TRIM WHEEL STARTED TO FREE PLAY DURING MOVEMENT. A POST FLIGHT INSP FOUND THE RT ELEVATOR TRIM ACTUATOR FROZEN IN PLACE AND THE ELEVATOR TRIM CABLE BROKEN. IT IS BELIEVED AT THIS TIME THAT THE ISSUES ARE RELATED. MFG ENGINEERING HAS BEEN NOTIFIED. THE ELEVATOR TRIM SYS WAS GIVEN A FULL INSP WITH NO FURTHER RELATED DEFECTS FOUND. A FULL SYS RIG CK AND OPS CK WAS PERFORMED AND THE ACFT WAS APPROVE FOR RETURN TO SERVICE. 2L72 4F RTA22CE 20100208 SO 2010 2 8 2010FA0000127 120100112G5320 PROFILE EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 PROFILE AND BEAM AT FR 17, YL 610 & 690 IS CORRODED OUT OF LIMITS. PROFILE AND BEAM R & R IAW SRM. 2L72 4T RTT00011AT 20100208 CE 2010 2 8 2010FA0000096 120100111G272012604568 TORQUE TUBE CESSNA210 210M 2073450CE RUDDER CRACKED D O OTHER O OTHER TXTAXI/GRND HDL 1 SO15732LW 21061606 UPON LANDING, PILOT LT RUDDER TORQUE TUBE CRACKED AT PEDDLE ATTACH POINT BELOW WELD. NO EVIDENCE OF FATIGUE OR STRESS CRACKS. NOTED CLEAN FRESH BREAK. 1H71 3O 3A21 20100115 WP 2010 1 15 2010FA0000040 120100115G29101489951 VALVE DOUG DC10 DC1010 3022110WP NR 2 HYD SYS SEPARATED D O OTHER O OTHER NRNOT REPORTED 1 WP01910SF 46524 THIS IS TO REPORT A LOSS OF NR 2 HYD SYS "PRESSURE AND QUANTITY" PRIOR TO TAKE-OFF, ACFT RETURNED TO GATE. INVESTIGATION FOUND VALVE ASY (M1-164) FOR THE 2-1 NON-REVERSIBLE MOTOR PUMP TO BE AT FAULT. REF IPC 29-12-59, FIG 1, PG 9, ITEM 340, PN 148995-1, SN 331. THE VALVE SEPARATED AT THE UNION POINT OF THE MOTOR AND VALVE RESULTING IN COMPLETE LOSS OF FLUID IN NR 2 HYD SYS. THE DISCREPANT VALVE HAS BEEN SENT FOR FAILURE ANALYSIS. 2L73 4F A22WE 20100208 SO 2010 2 8 2010FA0000118 120100114G532014522469003 SUPPORT EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 CORROSION FOUND ON SUPPORT FWD OF FRM 20 BEYOND LIMITS. R & R CORRODED SUPPORT IAW SRM. 2L72 4T RTT00011AT 20100202 NM 2010 2 2 2010FA0000051 120100116G5313 STRINGER BOEING727 727227 1384078NM BS 430 S24L DAMAGED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 STRINGER 24L DAMAGED AT STA 430. 2L73 4F A3WE 20100208 SO 2010 2 8 2010FA0000120 120100112G532014521718007 PROFILE EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 PROFILE FWD OF FR 20, LY 455 IS CORRODED OUT OF LIMITS. PROFILE R & R SRM, 2L72 4T RTT00011AT 20100208 SO 2010 2 8 2010FA0000107 120100112G532014524994003 PROFILE EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK23284 145256 FROFILE AT FR 51 RT SIDE CORRODED OUT OF LIMITS. R & R IAW SRM. 2L72 4T RTT00011AT 20100303 SO 2010 3 3 2010FA0000087 120100204G5711 SPAR PIPER J3 J3C65 7100510SO RT WING CORRODED D K NONE O OTHER ININSP/MAINT 1 EA61343WS 18086 SEVERE CORROSION ON LT AND RT AILERON MAIN SPARS BETWEEN SPAR AND BRACKETS. SPAR BULGES AROUND RIVETS ATTACHING THE BRACKETS TO THE SPAR. THIS CONDITION WAS FOUND WHEN INSPECTING AILERONS PRIOR TO RECOVERING. SUSPECT THEY MAY HAVE BEEN ON SEA PLANE OPERATED ON SALT WATER. 1H71 3O A691 20100303 WP 2010 3 3 2010FA0000071 120100125G6230521103 FORK HILLERUH12 UH12E 4360122WP MAIN ROTOR DAMAGED D K NONE O OTHER ININSP/MAINT 1 SW99 FOUND DURING AN INCOMING INSPECTION THE FOLLOWING DEFECTS ON 4EA NEW FAA PMA PARTS SN 11566P/11567P/ 11568P & 11569P AS FOLLOWS; EDGE RADIUS OF ALL FORK BLADE PIN BORES DO NOT HAVE A SUFFICIENT RADIUS TO LET BLADE ATTACHMENT PIN TO SEAT AGAINST THE TOP SURFACE OF THE UPPER FORK TANG, WITH PIN INSERTED, MEASURED BETWEEN .008" TO .011" GAP UNDER HEAD OF PIN. TO INSERT BLADE PIN THROUGH EACH FORK, THE FORK HAD TO BE SPREAD APART RANGING FROM .004" TO .012". BEFORE SPREADING THE FORK, FOUND ALL FORK TANGS TO BE PARALLEL. 1G71 3O 4H11 20100208 SO 2010 2 8 2010FA0000129 120100114G532014522450015 GUSSET EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 GUSSET FROM FR17-18 Y0.0-YL830 IS CORRODED. R & R CORRODED GUSSET IAW SRM. 2L72 4T RTT00011AT 20100202 EU 2010 2 2 2010F00012 120100120G5320 FLOOR SKIN BOLKMS117 BK117B1 5626012EU ZONE 400 CRACKED B K NONE O OTHER ININSP/MAINT 1 CE09156AM10996 7173 AFTER REMOVAL OF NR 1 ENGINE, FOUND THE FIRE EXTINGUISHER TUBE HAD CHAFED THROUGH THE ENGINE DECK SKIN 130MM LONG 5MM WIDE AND A 34MM CRACK IN THE MIDDLE. 1G72 3U H13EU 20100208 SO 2010 2 8 2010FA0000116 120100109G532014525437001 GUSSET EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 RT GUSSET FROM FRAME 59-61 HAS CORROSION. R & R GUSSET IAW SRM. 2L72 4T RTT00011AT 20100202 NM 2010 2 2 2010FA0000053 120100116G5340 STRINGER CLIP BOEING727 727227 1384078NM BS 950A CORRODED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 STRINGER CLIP CORRODED AT STRINGER 30, BS 950A. 2L73 4F A3WE 20100208 SO 2010 2 8 2010FA0000109 120100112G532014523171003 BEAM EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 RT HAT SECTION BEAM UNDER GUSSET FR 58 - 62 IS CORRODED OUT OF LIMITS. RT HAT SECTION BEAM R & R IAW SRM. 2L72 4T RTT00011AT 20100202 2010 2 2 E81RJW3022512 420100116G34178221109016 ADC RAYTHN390 390 7150030CE NR 2 MALFUNCTIONED B K NONE J WARNING INDICATION ININSP/MAINT 1 GL03390JV1258 RB129 INVESTIGATED REPORT OF RT (COPILOT'S) SIDE PITCH TRIM FAIL INDICATION. ALSO SHOWING RED "X" INDICATIONS FOR AIRSPEED, ALTITUDE, AND VERTICAL SPEED. ALTITUDE PRESELECT TURNS RED, THEN BLUE. REPLACED NR 2 AIR DATA COMPUTER WITH AN O/H UNIT, DISPLAY INDICATIONS NORMAL. RECOMMEND MFG SERVICE FACILITY INVESTIGATE AT TEAR-DOWN TO DETERMINE IF INTERNAL COMPONENT FAILURE OR WATER CONTAMINATION. SB 34-3972, MODIFICATION OF NR 2 AIR DATA COMPUTER PLUMBING, WAS PREVIOUSLY COMPLIED WITH. 1L72 3F RTA00010WI 20100208 SO 2010 2 8 2010FA0000114 120100107G532014522225003 GUSSET EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 LT GUSSET FROM FR 59-61 IS CORRODED BEYOND LIMITS. R & R GUSSET IAW SRM. 2L72 4T RTT00011AT 20100310 CE 2010 3 10 2010FA0000160 120100209G3231 DOOR RAYTHN850 HAWKER850XP 7150016CE MLG FROZEN C L ABORTED APPROACH O OTHER APAPPROACH 1 GL11853CC 258803 ACFT WAS ON APPROACH. WHEN THE GEAR WAS EXTENDED THE NOSE GEAR DID NOT COME DOWN. THE CREW DIVERTED TO AND AFTER SOME HIGH "G" MANEUVERS GOT THE NOSE GEAR TO EXTEND. THE ACFT MADE A NORMAL LANDING. THE ACFT WAS JACKED AND A GEAR SWING AND INSP WAS PERFORMED. NO PROBLEMS FOUND. THE ACFT WAS REPOSITIONED TO THE SERVICE CENTER FOR A MORE IN DEPTH INSP WITH NO PROBLEMS FOUND. AFTER TALKING WITH THE TECH REP THIS IS A KNOWN PROBLEM WITH THE ACFT AFTER DEPARTING IN MOISTURE AND GOING TO ALTITUDE. IT IS SURMISED THAT MOISTURE GETS IN BETWEEN THE GEAR DOORS AND FUSELAGE AND FREEZES KEEPING THE NOSE GEAR FROM EXTENDING. SOME TESTING WAS PERFORMED AT MFG AND IT WAS DETERMINED THAT A SIX INCH PIECE OF TAPE ACROSS THE NOS1L72 4F RTA3EU 20100119 CE 2010 1 19 2010FA0000037 120100115G2497 TERMINAL BEECH 33 F33A 1151425CE SWITCH LOOSE D K NONE O OTHER ININSP/MAINT 1 SO0588AN CE1700 CONTACT TERMINALS ARE LOOSE AND CAN BE MOVED BY HAND. SWITCH THROW HANDLE IS ALSO LOOSE AND CAN BE MOVED FROM ANY POSITION. 1L71 3O 3A15 20100208 SO 2010 2 8 2010FA0000113 120100112G532014529495003 SILL EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 LT SILL FROM FR 59-61 IS CORRODED OUT OF LIMITS. LT SILL REMOVED AND REPLACED IAW SRM. 2L72 4T RTT00011AT 20100305 SO 2010 3 5 2010FA0000199 120100204G24978000904 BATTERY CABLE PIPER PA31 PA31350 7103110SO MASTER BATTERY LOOSE D O OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 NM136GR 317752130 LOOSE BATTERY CABLES LED TO A COMPLETE LOSS OF ELECTRICAL POWER WHILE IN FLIGHT AT IFR FLIGHT LEVEL 13000. LOOSE CABLES CAUSE A LOSS OF ACFT BATTERY. WHEN THE ALTERNATORS WERE UNABLE TO CARRY THE LOAD, IT RESULTED IN TOTAL ELECTRICAL LOSS. 1L72 3O A20SO 20100224 NM 2010 2 24 2010FA0000078 120100127G5711 SPAR BOEING727 727212 138407GNM RT WING CORRODED B I5PAK NONE O OTHER ININSP/MAINT 1 WP35319NE 21349 THE ACFT INPUT FOR 6C CHK ON DEC 10, 2009. DURING VISUAL INSP BY INSPECTOR, THE LEVEL 2 CORROSION WAS FOUND ON RT WING FRONT SPAR LOWER CHORD AT WS 727.5. THE CHORD THICKNESS OF ORIGINAL IS 0.103". THE CHORD THICKNESS OF CORROSION REMOVED IS 0.040". PHOTO WILL BE SENT BY E-MAIL. AFTER (OWNER) VERIFY AS A MAJOR REPAIR ON JAN 29, 2010, THE SPAR LOWER CHORD HAS BEEN REPAIRED IAW FAA DER APPROVED DATA AND FORM 337 WILL BE SUBMITTED TO FAA FOR FINAL RESULT OF CORRECTIVE ACTION DETAIL. 2L73 4F A3WE 20100301 2010 3 1 2010FA0000166 420100213G341879513 SWITCH RAYTHNC90 C90GT 7150062CE STALL WARNING ERRATIC D O OTHER J WARNING INDICATION NRNOT REPORTED 1 WP11991GT540 LJ1805 THE STALL WARNING SYS ACTIVATES ERRATICALLY. INCIDENTS SURROUNDING THE STALL WARNING SYS ANOMALIES: SITTING MOTIONLESS ON THE GROUND, ENGINES NOT RUNNING. SITTING MOTIONLESS ON THE ENGINE RUNNING. DURING CLIMB, IN CLEAR AIR, BETWEEN 108 AND 140 KIAS. AT CRUISE, FL 270, 165 KIAS, SMOOTH AIR. MFGS ARE AWARE OF THE PROBLEM. WING TRANSDUCER PN 795-13 HAS BEEN REPLACED, NO AFFECT. COMMON PROBLEM AMONG THESE ACFT OPERATORS. UNABLE TO GET RESOLUTION FROM MFGS. 1L72 3T RT3A20 20100301 SO 2010 3 1 V0XR201001120006 120100112G531014524199001 BEAM EMB 145 EMB145LR 3260212SO ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 PROFILE AND BEAM AT FRM 17, YL 610 & 690 IS CORRODED OUT OF LIMITS. R & R PROFILE AND BEAM. 2L72 4T RTT00011AT 20100225 CE 2010 2 25 UVVR2010021500005120100212G533030631201621 SKIN RKWELLNA265 NA26565 7630107CE ZONE 200 CRACKED B K NONE O OTHER ININSP/MAINT 1 CE0347SE 8000 28 46534 FUSELAGE SKIN CRACKED AT LOWER AFT CORNER OF LEFT OVERWING ESCAPE HATCH OPENING. 2L72 4J A2WE 20100204 SO 2010 2 4 V0XR20100126003 120100126G534714530659011 SEAT TRACK EMB 145 EMB145EP 3260221SO FUSELAGE CORRODED B RAIAK NONE O OTHER ININSP/MAINT 1 NM05807HK 145119 FORWARD SEAT TRACK ON LT YL 479.0 BEAM CORRODED BEYOND LIMITS. REMOVED AND REPLACED FWD SEAT TRACK. 2L72 4F RTT00011AT 20100224 2010 2 24 E81RJW3022513 420100116G34608220883701 FMC RAYTHN390 390 7150030CE MALFUNCTIONED B O OTHER O OTHER NRNOT REPORTED 1 GL03390JV1258 RB129 INVESTIGATED REPORT OF FLIGHT MANAGEMENT SYS LOSING LAST SAVED POSITION, THEN GOING TO NORTH ZERO DEGREES AND EAST ZERO DEGREES. REPLACED NR 1 FMC-3000 FLIGHT MANAGEMENT COMPUTER CARD WITH AN O/H REPLACEMENT CARD AND RELOADED DATABASE. FMS OPS NORMAL. RECOMMEND MFG SERVICE FACILITY INVESTIGATE AT TEAR-DOWN TO DETERMINE IF CAUSED BY FAILED INTERNAL COMPONENT OR IF CAUSED BY WATER CONTAMINATION. 1L72 3F RTA00010WI 20100303 NM 2010 3 3 2010FA0000069 120100123G5710 STRUCTURE BOEING727 727227 1384078NM RWS 277 CORRODED D K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 CORROSION FOUND AROUND FASTENERS ON RT WING L/E WING STATION 277. 2L73 4F A3WE 20100208 SO 2010 2 8 2010FA0000128 120100114G532014521721009 FLOOR SUPPORT EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 DIGITAL PLATE FROM FR 15, YL 70 IS CORRODED AROUND NUTPLATE. R & R CORRODED CTR SECTION OF DIGITAL IAW SRM. 2L72 4T RTT00011AT 20100225 SO 2010 2 25 V0XR20100119 120100119G53201452226003 GUSSET EMB 145 EMB145ER 3260211SO ZONE 100 CORRODED B K NONE O OTHER ININSP/MAINT 1 NM05807HK 119 GUSSET AT Y.0 FRM 59 - 61 CORRODED BEYOND LIMITS. R & R GUSSET. 2L72 4F RTT00011AT 20100202 NM 2010 2 2 2010FA0000049 120100116G5330 SKIN BOEING727 727227 1384078NM BS 720C S27R CORRODED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 CORROSION ON SKIN OTBD OF STRINGER 27R FWD OF BS 720C. 2L73 4F A3WE 20100219 CE 2010 2 19 DGCA10501 120100128G2913PF24390615BCES62PUMP RKWELLNA265 NA26565 7630107CE HYD SYS FAILED B A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CE03570R 500 465075 HYDRAULIC PUMP FAILURE. 2L72 4J A2WE 20100310 WP 2010 3 10 2010FA0000074 120100113G6210MS21042L4 NUT ROBSINR22 R22 7640102WP M/R BLADE CRACKED C K NONE O OTHER ININSP/MAINT 1 SW99 100 50 2 NUTS FITTED TO MAIN ROTOR BLADE PITCH CHANGE HORNS ON ACFT R227/09 FOUND CRACKED IN SERVICE. FURTHER ENQUIRIES FOUND OTHER NUTS FROM SAME LOT NR 16838 SUPPLIED 7/09 FITTED TO H369 M/R DRAG DAMPER 7 OUT OF 12 NUTS ALSO CRACKED. INVESTIGATION LABS DISCOVERED HYDROGEN EMBRITTLEMENT OF NUTS. SUPPLIER TRACED MFG . MOST OF APPROX 400 NUTS SUPPLIED FROM THIS LOT NR 16838 TRACED AND AIRWORTHINESS ACTION PENDING. REMAINING 600 NUTS QUARANTINED. THIS IS A SIGNIFICANT ISSUE AS THESE STANDARD PARTS ARE FITTED TO NUMEROUS ACFT COMPONENTS. 1G71 3O H10WE 20100208 CE 2010 2 8 2010FA0000098 120100128G5530 NUT CESSNA182 182P 2075816CE VERTICAL STAB BROKEN D K NONE O OTHER ININSP/MAINT 1 NE0121462 18261646 ONE OF THE 4 BOLTS HOLDING THE REAR ATTACHMENT BRACKET ON VERTICAL STABILIZER, HAD A BROKEN/ SPLIT NUT. PROBABLE CAUSE COULD HAVE BEEN FROM CORROSION FOUND BETWEEN THE NUT AND WASHER CAUSING STRUCTURAL LOSS OF THE NUT. INSPECTED NUTS FOR CORROSION AND REPALCED AS NECESSARY WITH A SOLID TYPE SELF-LOCKING NUT. 1H71 3O NTTA13 20100224 CE 2010 2 24 E81RJW3022016 120100108G52303903850150002 LATCH BEECH 76 76 1153005CE CARGO DOOR FAILED B K NONE O OTHER ININSP/MAINT 1 GL03112CM604 RB123 INVESTIGATED PILOT REPORT OF AFT LT BAGGAGE COMPARTMENT DOOR LATCH OPENING IN FLIGHT. FOUND LOWER FWD ROTARY-TYPE LATCH (POST SB 52-3864) WORN. REPLACED LATCH WITH NEW LATCH ASSY, OPS CHECKS OK. RECOMMEND MFG TRACK TO SEE IF A FLEET PROBLEM WITH NEW STYLE LATCHES OR IF AN ISOLATED INCIDENT. 1L72 3O A29CE 20100225 CE 2010 2 25 UVVR2010021200003120100211G5720259W002372 STRIP RAYTHNDH125 HAWKER800XP 7150012CE ZONE 600 CHAFED B K NONE O OTHER ININSP/MAINT 1 CE03300CQ2482 2482 258555 RT WING L/E ASSY INBD RIB (1A) IS CHAFING AGAINST THE FWD WING/FUSELAGE FAIRING SUPPORT STRIP. THE SUPPORT STRIP IS FLUSH RIVETED TO THE OTBD WEB OF THE WING/FUSELAGE FAIRING AND SANDWICHES A SEAL. THE SUPPORT STRIP AND SEAL WERE INSTALLED OVER THE TOP OF MS20470AD UNIVERSAL HEAD RIVETS CREATING A BULGE IN THE SUPPORT STRIP WHICH IS CAUSING THE SUPPORT STRIP TO CONTACT THE LEADING EDGE RIB. REPLACEMENT OF THE ABOVE MENTIONED MS20470AD RIVETS WITH FLUSH RIVETS WOULD ALLEVIATE THIS PROBLEM. 2L72 4F RTA3EU 20100208 SO 2010 2 8 2010FA0000111 120100112G532014520809001 SILL EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 LT SILL FROM FR 24-29 IS CORRODED OUT OF LIMITS. LT SILL R & R IAW SRM 51-40-02. 2L72 4T RTT00011AT 20100208 SO 2010 2 8 2010FA0000122 120100114G531014521713005 BEAM EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK23254 145256 BEAM CORRODED BEYOND LIMITS. R & R BEAM IAW SRM. 2L72 4T RTT00011AT 20100224 CE 2010 2 24 2010F00019 120100120G2797 TERMINAL BEECH 200 B200 1152922CE TE FLAPS LOOSE D O OTHER F FLT CONT AFFECTED TXTAXI/GRND HDL 1 SW09727B BB1734 CREW LANDED; UPON TAXING TO RAMP, DISCOVERED THAT THE FLAPS WOULD NOT MOVE OUT OF TAKEOFF/APPROACH. CREW CHECKED ALL CIRCUIT BREAKERS, NO DEFECTS NOTED. AFTER PARKING, PERFORMED WALK AROUND AND INSPECTED FLAP SYS, AGAIN NO DEFECTS NOTED. NOTIFIED MX. MX WAS UNABLE TO DUPLICATE DISCREPANCY, FLAP SYS OPERATED NORMAL. DURING TROUBLESHOOTING, FOUND NR 3 BUSS HAD 2 LOOSE TERMINALS; TIGHTENED AS REQUIRED. PERFORMED OPS CHECK OF FLAP SYS, NO DEFECTS NOTED. 1L72 4T A24CE 20100202 NM 2010 2 2 2010FA0000054 120100116G5730 SKIN BOEING727 727227 1384078NM CENTER WING CORRODED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 LOWER CTR WING SKIN CORRODED AT STRINGER 6C, LBL 30 INSIDE LT RAM AIR DUCT. 2L73 4F A3WE 20100308 CE 2010 3 8 2010FA0000202 120100217G5751 SPAR BBAVIA8 8KCAB 2110612CE AILERON CRACKED D K NONE O OTHER ININSP/MAINT 1 SO118693V 18575 FOUND CRACK IN THE INBD AILRON BAY AREA. 1H71 3O A21CE 20100310 CE 2010 3 10 2010FA0000133 120100207G5100 PIVOT CESSNA182 R182 2072734CE UNKNOWN CRACKED D K NONE O OTHER ININSP/MAINT 1 SW99 PIVOT CRACKED AT INBD END OF SHAFT. 1H71 3O RT3A13 20100202 CE 2010 2 2 E81RJW302212 120100113G7400M8353610028L RELAY RAYTHN390 390 7150030CE IGNITION CLOSED B O OTHER O OTHER NRNOT REPORTED 1 GL03713AZ RB111 INVESTIGATED REPORT OF LT ENG IGNITION SYS NOT SHUTTING OFF AFTER ENG START SEQUENCE. FOUND LT IGNITION SYS STANDBY POWER RELAY 80K7 NOT FUNCTIONING. REPLACED 80K7 RELAY WITH NEW RELAY, IGNITION SYS OPS NORMAL. HAVE REPLACED NUMEROUS PN M83536/10-028L IGNITION POWER AND STANDBY POWER RELAYS ON 390 SERIES ACFT FOR IGNITION SYS FAULTS. RECOMMEND ACFT MFG INVESTIGATE WHETHER A RELAY VENDOR QUALITY CONTROL ISSUE OR IF SYS DESIGN IS CAUSING PREMATURE FAILURES. ONCE FAILURE MODE DETERMINED, RECOMMEND A KIT OR RECOMMENDED SB BE ISSUED. IGNITION SYS RELAY FAILURES HAVE CAUSED NUMEROUS ACFT DISPATCH DELAYS AND TRIP CANCELLATIONS FOR ENGINE IGNITION SYS FAILURES OVER PAST SEVERAL YEARS. 1L72 3F RTA00010WI 20100310 2010 3 10 2010F00043 420100217G23303070571102 ANTENNA BOEING737 737* NM ENTERTAINMENT SYWRONG PART D K NONE W INADEQUATE Q C ININSP/MAINT 1 SW99 CUSTOMER (LIVETV) REPORTED IN-FLIGHT ENTERTAINMENT RECEIVE ANTENNA PN 3070571-102, SN 369 CAUSED VHF NR 1 RECEPTION PROBLEM ON ACFT. ACFT WORK REQUEST STATES, "COMPLETE ENG RUN AND MONITORED VHF WHILE SELECTING SYS ON AND OFF. FOUND THAT LTV SYS CAUSED A 6-10DBM DROP IN SENSITIVITY ON NR 1 VHF SYS, NO EFFECT ON NR 2 VHF SYS USING IFR 4000 TEST BOX. NO OTHER SYS CAUSED ANY SENSITIVITY PROBLEMS ON VHF. DBM DROP GREATER AT HIGHER FREQS." EMS ANTENNA TROUBLESHOOTING CONFIRMED ANTENNA EMI EMISSIONS OUT OF SPEC IN VHF RANGE. INSPECTION INDICATED INTERMITTENT CONNECTION ON POWER CABLE SHIELD TO GROUND AND MISSING EMI FILTER IN 9-PIN CONNECTOR ON SUBASSEMBLY 190525-1. FAILURE ANALYSIS, PART INSPECTIONS AND CA ARE 2L72 4F RTA16WE 20100225 CE 2010 2 25 2010FA0000077 120100127G339735380132103 CIRCUIT BREAKER BEECH 33 F33A 1151425CE LANDING LIGHT FAILED B O OTHER O OTHER LDLANDING 1 SW075587K748 CE1392 WHEN PILOT SELECTED LANDING LIGHT, LIGHT DID NOT WORK. TECH TROUBLESHOT AND FOUND FAULT TO BE WITH LANDING LIGHT CIRCUIT BREAKER, INTERNAL FAILURE OF CIRCUIT BREAKER. 1L71 3O 3A15 20100202 CE 2010 2 2 E81RJW30230 120100114G276012SX1T SWITCH RAYTHN390 390 7150030CE SPOILER OUT OF ADJUST B O OTHER F FLT CONT AFFECTED DEDESCENT 1 GL03115WZ RB197 INVESTIGATED, VERIFIED REPORTED INOPERATIVE IN FLIGHT OPERATION OF SPEED BRAKE SYS. FOUND LT POWER LEVER 80 PERCENT SPOILER SYS SWITCH S1 OUT OF ADJUSTMENT. ADJUSTED S1 SWITCH AS REQUIRED, SPOILER/SPEED BRAKE SYS OPS NORMAL. TRANSIENT ACFT, MX HISTORY NOT AVAILABLE. 1L72 3F RTA00010WI 20100204 SO 2010 2 4 V0XR20100123003 120100123G532014525991004 DOUBLER EMB 145 EMB145EP 3260221SO FUSELAGE CORRODED B RAIAK NONE O OTHER ININSP/MAINT 1 NM05807HK 145119 RT LOWER DOUBLER AT FRAME 61 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED DOUBLER. 2L72 4F RTT00011AT 20100225 NM 2010 2 25 2010FA0000084 120100202G5710 BOLT COLUMBLC41 LC41550FG4005150011NM RT WING MISINSTALLED D K NONE W INADEQUATE Q C ININSP/MAINT 1 SW17542BP 41674 PROBLEM WITH ELECTRICAL CONDUCTIVITY OF RT TOP WING SKIN WAS TRACED TO IMPROPERLY TORQUED WING TO FUSELAGE JUNCTION. 20 OUT OF 28 WING ASSY BOLTS WERE UNDER OR IMPROPERLY TORQUED; OF THESE 12 OUT OF 14 WERE ON THE RT SIDE CAUSING THE CONDUCTIVITY PROBLEM. 8 OF THE NUTS WERE FOUND TO BE BOTTOMED OUT ON THE THREADS OF THE BOLTS AND NOT BEARING ON THE PARTS. 1L71 3O NTA00003SE 20100202 SO 2010 2 2 2010FA0000046 120100113G7603554528 THROTTLE CABLE PIPER PA44 PA44180 7104402SO RT ENGINE FROZEN B EA ENGINE SHUTDOWN UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 GL21595ND94 4496271 ON CLIMBOUT, PILOT TRIED TO BRING THROTTLES BACK BUT FOUND THE RT THROTTLE STUCK AT FULL POWER. ENG WAS SHUTDOWN AND ACFT LANDED WITH OUT INCIDENT. UPON INSP BY MX RT THROTTLE CABLE WAS FOUND TO BE CORRODED ON SHAFT WHERE IT EXITS THE PROTECTIVE OUTER HSG AT THE ENG END. THIS IS THE 2ND OCCURRENCE ON THIS ACFT IN LESS THAN 100 HRS OF OPERATION. 1L72 3O A19S0 20100224 NM 2010 2 24 2010FA0000070 120100123G5330 SKIN BOEING727 727227 1384078NM BS 540 S27R CORRODED I R5KBK NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 CORROSION ON FUSELAGE SKIN AFT OF BS 540, INBD OF STRINGER 27R 2L73 4F A3WE 20100208 SO 2010 2 8 2010FA0000126 120100114G5320 SILL EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 CORROSION FOUND ON SILL FWD OF SERVICE DOOR FRM 18-20 RY 730 BEYOND LIMITS. R & R CORRODED SILL IAW SRM. 2L72 4T RTT00011AT 20100310 2010 3 10 E81RJT227504 420100208G31608221084014 DISPLAY RAYTHN390 390 7150030CE COCKPIT INOPERATIVE B E81RO OTHER P NO WARNING INDICATION NRNOT REPORTED 1 GL03322BJ 567 RB93 PILOT REPORTED COPILOT'S PRIMARY FLIGHT DISPLAY SCREEN WENT BLANK FOR APPROX 1 SECOND IN FLIGHT. UNABLE TO DUPLICATE DURING ON-GROUND CHECKS. REPLACED FLIGHT DISPLAY WITH AN O/H EXCHANGE UNIT, NO FAULTS OBSERVED. REMOVED UNIT O/H 8/26/2005. 1L72 3F RTA00010WI 20100225 CE 2010 2 25 UVVR2010021200002120100211G5720259W002371 STRIP RAYTHNDH125 HAWKER800XP 7150012CE ZONE 500 CHAFED B K NONE O OTHER ININSP/MAINT 1 CE03300CQ2482 2482 258555 LT WING L/E ASSY INBD RIB (1A) IS CHAFING AGAINST THE FWD WING/FUSELAGE FAIRING SUPPORT STRIP. THE SUPPORT STRIP IS FLUSH RIVETED TO THE OTBD WEB OF THE WING/FUSELAGE FAIRING AND SANDWICHES A SEAL. THE SUPPORT STRIP AND SEAL WERE INSTALLED OVER THE TOP OF MS20470AD UNIVERSAL HEAD RIVETS CREATING A BULGE IN THE SUPPORT STRIP WHICH IS CAUSING THE SUPPORT STRIP TO CONTACT THE L/E RIB. REPLACEMENT OF THE ABOVE MENTIONED MS20470AD RIVETS WITH FLUSH RIVETS WOULD ALLEVIATE THIS PROBLEM. 2L72 4F RTA3EU 20100208 SO 2010 2 8 2010FA0000119 120100112G532014521725001 SILL EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 SILL FROM FR 19-20 IS CORRODED OUT OF LIMITS. SILL R & R IAW SRM 51-40-02. 2L72 4T RTT00011AT 20100204 SO 2010 2 4 V0XR20100123001 120100123G532014525991003 DOUBLER EMB 145 EMB145EP 3260221SO FUSELAGE CORRODED B RAIAK NONE O OTHER ININSP/MAINT 1 NM05807HK 145119 LT LOWER DOUBLER AT FRAME 61 IS CORRODED BEYOND LIMITS. REMOVED AND REPLACED DOUBLER. 2L72 4F RTT00011AT 20100202 NM 2010 2 2 2010FA0000050 120100116G5311 FRAME BOEING727 727227 1384078NM BS 1090 S27R CRACKED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 FUSELAGE FRAME CRACKED 1.5", BEYOND REPAIR, CUTOUT ABOVE STRINGER 27R AT BS1090. 2L73 4F A3WE 20100208 SO 2010 2 8 2010FA0000106 120100112G530014525931004 DOUBLER EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK23254 145256 RT LOWER DOUBLER FWD PARTITION AT FR 61 CORRODED OUT OF LIMITS. DOUBLER R & R IAW SRM. 2L72 4T RTT00011AT 20100202 NM 2010 2 2 2010FA0000057 120100116G5210 STRUCTURE BOEING727 727227 1384078NM R1 DOOR DAMAGED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 R1 DOOR CREASED BS 385-410 BETWEEN STR 14R AND 16R. 2L73 4F A3WE 20100127 CE 2010 1 27 E81RJW302236 120100111G30205188001 SHUTOFF VALVE RAYTHN390 390 7150030CE RT ANTI-ICE FAILED B O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 GL03115WZ RB197 REPLACED FAILED RT ENG INLET ANTI-ICE SHUTOFF VALVE ASSY WITH "0 TSOH" VALVE. NEWLY O/H VALVE CAUSED VIBRATION FELT THROUGH AIRFRAME, BELIEVED TO BE CAUSED BY RAPID VALVE MODULATION. VALVE O/H WO NR R79693 DATED 10/27/2009. THIS IS THE SECOND RECENTLY O/H VALVE INSTALLED IN LAST MONTH FROM SAME FACILITY THAT HAVE HAD SIMILAR FAILURES UPON INSTALLATION OR SHORTLY THEREAFTER. RECOMMEND MFG O/H FACILITY REVIEW RECORDS TO DETERMINE IF A QUALITY CONTROL/POST-MX TESTING ISSUE, OR IF O/H STANDARDS NEED TO BE REVISED. 1L72 3F RTA00010WI 20100208 SO 2010 2 8 2010FA0000108 120100112G532014528422001 SILL EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK23254 145256 LT SILL FROM FR 60-66 IS CORRODED OUT OF LIMITS. LT SILL R & R IAW SRM. 2L72 4T RTT00011AT 20100202 NM 2010 2 2 2010FA0000052 120100116G5313 STRINGER SPLICE BOEING727 727227 1384078NM BS 660-680 CORRODED B K NONE O OTHER ININSP/MAINT 1 EA68422BN 20735 STRINGER 25R SPLICE CORRODED BETWEEN BS 660 AND 680. 2L73 4F A3WE 20100311 EU 2010 3 11 2010FA0000139 120100208G5520A730258N HINGE BRACKET LET L23 L23SUPERBLAN1360308EU ELEVATOR CRACKED B K NONE O OTHER ININSP/MAINT 1 NM03420BA 029007 RT UPPER FWD, DURING A 100 HOUR INSP, IT WAS DISCOVERED THAT THE INBD ELEVATOR HINGE BRACKET EXHIBITED SEVERAL CRACKS. ADDITIONAL CRACKS WERE FOUND ON THE NOTED ACFT AFTER A FLEET WIDE ONE TIME INSP WAS COMPLETED. 1K00 G60EU 20100310 2010 3 10 2010FA0000150 120100211G3245 TUBE TIRE EXPLODED C O OTHER O OTHER NRNOT REPORTED 1 SW99 LIQUID PENETRANT MAY CAUSE A TUBE-TYPE TIRE TO EXPLODE IF USED INDISCRIMINATELY. THIS WAS DISCOVERED AS PENETRANT WAS APPLIED TO LOOSEN FROZEN BICYCLE SPOKE NUTS. WHEN THE PENETRANT WORKED ITS WAY INTO THE WHEEL INTERIOR VIA THE SPOKE NUT, IT CONTACTED THE INNER TUBE WHICH INSTANTLY RUPTURED AND BLEW THE TIRE OFF THE RIM WITH A REPORT THAT SOUNDED LIKE A SHOTGUN BLAST. A SIMILAR REACTION INVOLVING A TUBE-TYPE ACFT OR GSE TIRE COULD BE DEADLY. THE MFG OF PENETRANT DID NOT RESPOND TO A CAUTIONARY EMAIL SUBMITTED VIA THEIR WEBSITE. 20100201 EA 2010 2 1 CA100113004 120100108G7500C6VE10233 DUCT DHAV DHC6 DHC6 2802606EA BLEED AIR MISMANUFACTURED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) DISCOVERED THAT 32 OF THESE DUCTS WERE MANUFACTURED WITH INCORRECT OUTER INSULATING COVER INSTALLED. THE BATCHES INVOLVED ARE: WO-58717/1, WO-59849/1, WO-65452/1, WO-65452/1.1, WO-66588/1, WO-67938/1, WO-74046/1, WO-77354/1. VIKING HAS PULLED EXISTING STOCK ON HAND TO BE REWORKED TO THE CORRECT CONFIGURATION. WORKING ON A SB TO HAVE THE INCORRECT ITEMS REMOVED FROM SERVICE ONCE REPLACEMENTS BECOME AVAILABLE. (TC NR 20100113004) 1H72 3T RTA9EA 20100224 NM 2010 2 24 2010F00022 120100120G3241NAS42DD452FC SPACER BOEING767 767332 1382001NM ZONE 100 CHAFED B K NONE O OTHER ININSP/MAINT 1 WP03597HA 23277 OCCURRENCE REPORT O248-10. CABLE (ABOVE), WRONG SIDE OF KEEPER/GUIDE, CABLE LGB 4A, BODY STATION 456R, FWD CARGO CEILING, SECOND FROM OTBD. CABLE FOUND IN THIS POSITION DURING INSP, NO RECORDED MAINT CARRIED OUT IN THIS AREA PREVIOUSLY. 2L72 4F RTA1NM 20100202 EU 2010 2 2 2010F00011 120100120G62304639205016 MAST BOLKMS117 BK117B1 5626012EU MAIN ROTOR CORRODED B K NONE O OTHER ININSP/MAINT 1 CE09156AM3566 2886 KA0459 7173 AFTER MAIN ROTOR HEAD WAS REMOVED FOR OTHER MX, THE MAST WAS FOUND TO HAVE CORROSION ON THE MATING SURFACE AND AROUND MOUNTING BORES. 1G72 3U H13EU 20100309 CE 2010 3 9 2010FA0000172 120100129G2731666016112 ACTUATOR CESSNA560 560XL 2076702CE ELEVATOR TRIM FROZEN B A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CE07511CS 5605324 AFTER T/O, THE ELEVATOR TRIM WHEEL STARTED TO FREE PLAY DURING MOVEMENT. A POST FLIGHT INSP FOUND THE RT ELEVATOR TRIM ACTUATOR FROZEN IN PLACE AND THE ELEVATOR TRIM CABLE BROKEN. IT IS BELIEVED AT THIS TIME THAT THE ISSUES ARE RELATED. MFG ENGINEERING HAS BEEN NOTIFIED. THE ELEVATOR TRIM SYS WAS GIVEN A FULL INSP WITH NO FURTHER RELATED DEFECTS FOUND. A FULL SYS RIG CK AND OPS CK WAS PERFORMED AND THE ACFT WAS APPROVE FOR RETURN TO SERVICE. 2L72 4F RTA22CE 20100208 SO 2010 2 8 2010FA0000115 120100112G532014522226003 GUSSET EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 CTR GUSSET FROM FR 59-61 IS CORRODED OUT OF LIMITS. CTR GUSSET R & R IAW SRM. 2L72 4T RTT00011AT 20100302 SO 2010 3 2 V0XR201001120011 120100112G532014520609007 SILL EMB 145 EMB145LR 3260212SO ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 RT SILL FROM FRM 29-35 IS CORRODED OUT OF LIMITS. R & R SILL. 2L72 4T RTT00011AT 20100208 SO 2010 2 8 2010FA0000124 120100109G530014522461011 DOUBLER EMB 145 EMB145LR 3260212SO FUSELAGE CORRODED B TNSAK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 DOUBLER AT FRAME 20, RY 479 HAS CORROSION. R & R DOUBLER IAW SRM. 2L72 4T RTT00011AT 20100312 CE 2010 3 12 2010FA0000186 120100225G5320SK8160 ACOUSTIC LINER LEAR 35 35A 5170602CE ZONE 200 INADEQUATE B K NONE O OTHER ININSP/MAINT 1 SO19 35A296 AFTER INSTALLATION OF ACOUSTIC OVERFRAME BLANKET, PN BK-8160 LOT NR 123009-BL60, MECHANICS NOTICED THAT ALL THEIR TOOLS USED TO CUT AND FIT THE BLANKETS RUSTED OVERNIGHT. FURTHER INVESTIGATION BY WAY OF A TEST, USING 2 NEW RAZORS, ONE USED TO CUT A PIECE OF BLANKET, WHERE PLACED SIDE BY SIDE AND THE RAZOR THAT WAS USED TO CUT THE BLANKET RUSTED IN LESS THAN 12 HRS. CALLED MFG AND INFORMED OF PROBLEM AND AFTER SOME INTERNAL TEST THEY REQUESTED TO HAVE ALL THE BLANKETS REMOVED FROM ACFT DUE TO LOW PH. BLANKETS WHERE REMOVED IMMEDIATELY. FURTHER INVESTIGATION AND INSP TO THE ACFT IS REQUIRED FOR THE DETECTION OF RUST AND/OR CORROSION ON ACFT INSTALLED HARDWARE AND STRUCTURES THAT HAS COME IN CONTACT WITH BLANKET2L72 4F A10CE 20100309 CE 2010 3 9 2010FA0000095 120100122G243523081023 STARTER GEN CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE ENGINE UNSERVICEABLE B O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION NRNOT REPORTED 1 SW059766B39 39 208B0112 PILOT REPORTED HIS GENERATOR FAILED. MX FOUND THAT THE INPUT SHAFT HAS EITHER SHEERED INTERNAL OF THE UNIT OR BECAME DISCONNECTED. UNIT HAS NOT BEEN OPENED UP FOR INSP AT THIS TIME. A VIDEO SHOWING THIS CONDITION IS ACCOMPANYING THIS REPORT. UNIT WILL BE SENT FOR REPAIR AND A TEAR DOWN REPORT WILL BE REQUESTED. (K) 1H71 3T3 T A37CE E4EA 20100309 SO 2010 3 9 2010FA0000168 120100128G27308351502 CONTROL CABLE PIPER PA46 PA46350P 7104602SO LYC O540 TIO540* 41532EA ELEVATOR ASSY FRAYED B K NONE O OTHER ININSP/MAINT 1 GL199214H2995 4622114 WHILE INSP INOPERATIVE ELEVATOR TRIM, WHICH WAS CAUSED BY FRAYED CABLE JAMMING TRIM DRUM, FOUND LOOSE ELEVATOR ACTUATOR ARM PN 8351502. THE END OF THE ARM COULD BE MOVED 1 INCH IN ALL DIRECTIONS. ALL ACTUATOR ARM TO ELEVATOR RIVETS EXCEPT 1 WERE SHEARED OR LOOSE. SINCE BOTH UP AND DOWN STOPS ARE ON THIS ARM, WE BELIEVE A JET BLAST OR SEVERE WIND, FROM THE REAR CAUSED THE ELEVATOR TO HIT STOPS. 1L71 3O3 ORTA25SO E14EA 20100309 SO 2010 3 9 2010FA0000177 120100205G812007A19870 BRACKET PIPER PA46 PA46350P 7104602SO LYC O540 TIO540AE2A 41532EA TURBOCHARGER BROKEN B K NONE O OTHER ININSP/MAINT 1 GL11928351683 4636097 L981261A DURING AN ANNUAL INSP, THE LT TURBO MOUNTING BRACKET (PN 07A19870) WAS FOUND BROKEN IN 2 PLACES. THE CAUSE WAS PROBABLY A COMBINATION OF HEAT AND VIBRATION. 1L71 3O3 ORTA25SO E14EA 20100309 SW 2010 3 9 1E9R201001 120100219G6410222016001131 BLADE BELL 430 430 1182150SW ALLSN 250C 250C40B 03032NE TAIL ROTOR CRACKED B K NONE O OTHER ININSP/MAINT 1 SO19430TX 49005 CAE844009 ACFT WAS FLOWN TO FACILITY, REPORTED DEBONDING OF TAIL ROTOR BLADE L/E AT TIP OF BLADE. UPON FURTHER INVESTIGATION OF BLADE, IT WAS DISCOVERED THAT THE ROOT END OF THE BLADE HAD CRACKED AND THE SKIN WAS SEPARATED FROM THE BLADE END. INFO SUBMITTED TO MFG PRODUCT SUPPORT ENGINEERING. PROBABLE CAUSE UNKNOWN AT THIS TIME. 1G72 3U3 URTH9SW E1GL 20100309 EA 2010 3 9 2010FA0000200 120100204G531160034014102 FRAME CNDAIRCL600 CL6002A12 1900304EA GE CF34 CF34* 30015NE FS 235 CRACKED B K NONE O OTHER ININSP/MAINT 1 NE03500PG 3039 FWD FUSELAGE FRAME AT FS 235 ABOVE FLOOR, PILOTS AND COPILOTS SIDE, FOUND CRACKED DURING 240 MONTH INSP. 2L72 4F4 FRTA21EA 20100309 EA 2010 3 9 2010FA0000201 120100205G531160034014107 FRAME CNDAIRCL600 CL6002A12 1900304EA GE CF34 CF343A 30066NE FS 235 CRACKED B K NONE O OTHER ININSP/MAINT 1 NE03500PG9885 3039 350183 FWD FUSELAGE FRAME AT FS235 ABOVE FLOOR, PILOTS AND COPILOTS SIDE, FOUND CRACKED. DURING 240 MONTH INSP. 2L72 4F4 FRTA21EA E15NE 20100309 EU 2010 3 9 2010FA0000209 120100222G6320350A32030004 GEARBOX SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 60053NE MAIN ROTOR MAKING METAL B A UNSCHED LANDING J WARNING INDICATION NRNOT REPORTED 1 WP13972BH 2804 9954 DURING A TOUR FLIGHT THAT DEPARTED AIRPORT, THE MGB CHIP LIGHT ILLUMINATD 3 MINUTES INTO THE FLIGHT. THE PILOT RETURNED TO DEPARTURE WITHOUT INCIDENT. THE MECHANIC INSPECTED THE CHIP PLUGS AND FOUND METAL ON LOWER PLUG. THE OIL WAS CHANGED AND THE CHIP PLUG LIGHT ILLUMINATED AGAIN. THE MAIN GEAR BOX AND OIL COOLER WAS CHANGED. 1G71 3U3 U H9EU E19EU 20100310 GL 2010 3 10 2010FA0000134 220100125G7261206061505115 TANK BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE OIL LEAKING D EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 SO19311DJ2167 53440 CAE848121 DURING MX TEST FLIGHT AFTER ENGINE INSTALLATION AN EXCEEDANCE OF 150 PSI ENGINE OIL PRESSURE OCCURS FOLLOWED BY A LOSS OF OIL PRESSURE. AN EMERGENCY LANDING PERFORMED FOLLOWED BY ENGINE SHUTDOWN. 1G71 3U3 UO H2SW E1GL 20100310 CE 2010 3 10 2010F00039 120100208G2697 WIRE CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE CONNECTOR LOOSE D EFA ENGINE SHUTDOWN ACTIVATE FIRE EXT. UNSCHED LANDING N FALSE WARNING CRCRUISE 1 SO15539VP 5600339 RT ENG FIRE WARNING ANNUNCIATOR ILLUMINATED IN FLIGHT. CREW DISCHARGED BOTH FIRE EXTINGUISHER BOTTLES TO THE RT ENG. THE LIGHT REMAINED ON. THE CREW SHUTDOWN THE RT ENG AND LANDED. TECHS AT THE SERVICE CENTER INSPECTED THE ACFT. THEY DETERMINED THERE WAS NO FIRE OR BLEED AIR LEAK. THE CAUSE OF THE FALSE FIRE WARNING LIGHT WAS DETERMINED TO BE A LOOSE WIRE IN WIRE CONNECTOR P122. P122 WAS REPLACED. BOTH FIRE EXTINGUISHER BOTTLES WERE REPLACED. A FUNCTIONAL CHECK OF THE FIRE WARNING SYS WAS SATISFACTORY. ACFT APPROVED FOR RETURN TO SERVICE. 2L72 4F4 FRTA22CE E25EA 20100311 EA 2010 3 11 CA100114005 220100107G72613030359 CHIP DETECTOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA ENGINE SHEARED W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) LT ENGINE CHIP DETECTOR SHEARED IN HALF IN FLIGHT CAUSING PROP TO SLOW DOWN AND OIL PRESSURE TO DROP OFF. (TC NR 20100114005) 1L72 4T4 T A24CE E4EA 20100301 EA 2010 3 1 2010FA0000153 220100131G85303731630 CYLINDER PIPER PA12 PA12 7101202SO LYC O235 O235* 41505EA ENGINE CRACKED C K NONE O OTHER ININSP/MAINT 1 SW093222M 121887 CYLINDER SN 37316-30 WAS PRESSURE TEST INSPECTED IAW AD 2009-26-12 AND WAS FOUND TO BE CRACKED WHERE CYLINDER HEAD CONNECTS TO CYLINDER BARREL. THE DEFECTIVE CYLINDER IN THE NR 3 POSITION, WAS INSTALLED ON ENGINE ON 5/19/2006 AND HAD 397 HOURS IN SERVICE. CYLINDER NR 1 (SN 37316-26) ON THE SAME ENGINE WAS ALSO AFFECTED BY THE REF AD. NO LEAKS OR DEFECTS WERE DISCOVERED ON THIS CYLINDER, WHICH HAD THE SAME NR OF HOURS IN SERVICE AS THE DEFECTIVE CYLINDER DESCRIBED ABOVE. (K) 1H71 3O3 O A780 E223 20100301 SO 2010 3 1 2010FA0000175 220100112G741410357586 DISTRIBUTOR GEAR CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO MISSING TEETH BROKEN D K NONE O OTHER ININSP/MAINT 1 GL23359CD D041A305 1184 917417 MAGNETO WAS REMOVED FROM ACFT FOR ROUTINE 500 HR MAGNETO INSP. DURING INSP, DISTRIBUTOR GEAR WAS FOUND TO BE MISSNG A FEW TEETH. THE ELECTRODE WAS LOOSE IN THE DISTRIBUTOR GEAR AND HAD WORN THE DISTRIBUTOR BLOCK ELECTRODE POSTS. BOTH PARTS WERE REPLACED. THERE IS NO INDICATION WHAT CAUSED THE TEETH TO BE BROKEN OFF OR THE ELECTRODE TO BECOME LOOSE. THERE WAS NO INDICATION DURING PRE-INSPECTION RUN-UP THAT THERE WAS A PROBLEM WITH THE MAGNETO INTERNAL COMPONENTS. 1L71 3O3 ONTA00009CHE3SO 20100302 SO 2010 3 2 V0XR201001120016 120100112G532014525991004 DOUBLER EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 RT LOWER DOUBLER FWD PARTITION AT FRM 61 IS CORRODED OUT OF LIMITS. R & R DOUBLER. 2L72 4T4 FRTT00011ATTE6CH 20100302 SO 2010 3 2 V0XR201001120009 120100112G532014522226003 GUSSET EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 CTR GUSSET FROM FRM 59-61 IS CORRODED OUT OF LIMITS. R & R GUSSET. 2L72 4T4 FRTT00011ATTE6CH 20100302 SO 2010 3 2 V0XR201001120010 120100112G532014529495003 SILL EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 LT SILL FROM FRM 59-61 IS CORRODED OUT OF LIMITS. R & R SILL. 2L72 4T4 FRTT00011ATTE6CH 20100303 NE 2010 3 3 2010FA0000073 220100126G7200701000121 VALVE GARRTTTPE331TPE33111U 29073NE ENGINE OUTPUT STUCK D K NONE L NO TEST ININSP/MAINT 1 SW99 P44720C DURING TESTING OF ENGINE P-44720 AFTER REPAIR DUE TO BIRD INGESTION, IT WAS NOTED THAT THE NTS SYSTEM WOULD NOT SET IAW MM 72-00-25 REV 13, DATED FEB. 13 2003. AFTER TROUBLESHOOTING, HAD FOUND THAT THE NTS VALVE WOULD NOT SET (STUCK CLOSED) CAUSING THE NTS SYS TO FAIL. REPLACED THE VALVE WITH A NEW VALVE PN 70100012-1, SN 08P23169, NTS SYS TESTED GOOD. 4 T E4WE 20100212 CE 2010 2 12 E81RJT227501 120100208G30205188001 SHUTOFF VALVE RAYTHN390 390 7150030CE WILINTFJ44 FJ442A GL ANTI-ICE SYS MALFUNCTIONED B O OTHER S AFFECT SYSTEMS TXTAXI/GRND HDL 1 GL03322BJ210 8 RB93 105094 TROUBLESHOT INOPERATIVE RT ENG NACELLE INLET HEAT INDICATION AT IDLE. FOUND RT NACELLE INLET HEAT PRESSURE REGULATING/SHUTOFF VALVE FAILED. VALVE WAS INSTALLED 1/19/2010, AFTER O/H, REPLACED VALVE ASSY WITH ANOTHER O/H VALVE ASSY AND FUNCTIONAL CHECKS ON ENG GROUND RUN OPERATIONS WERE NORMAL. HAVE REPLACED NUMEROUS "0" TIME SINCE O/H PN 5188-00-1 ENGINE ANTI-ICE VALVES THIS FALL/WINTER SEASON FROM SAME FACILITY THAT HAVE FAILED AT INSTALLATION OR SHORTLY THEREAFTER. RECOMMEND MFG SERVICE FACILITY INVESTIGATE WHETHER THIS IS A QUALITY CONTROL ISSUE OR IF COMPONENT O/H SPECS NEED TO BE REVISED. 1L72 3F4 FRTA00010WIE3GL 20100224 CE 2010 2 24 2010FA0000063 120100121G323096380022 MOTOR BEECH 60 A60 1153604CE LYC O541 TIO541E1C4 41536EA HARTZLHCF3Y HCF3YR2 GL MLG SEIZED D O OTHER O OTHER LDLANDING 1 SO15111XL2212 2212 P197 L78459 DA535 LANDING GEAR FAILED TO EXTEND. ACFT LANDED GEAR UP. FOUND ELECTRIC MOTOR SEIZED. COULD NOT EXTEND LANDING GEAR MANUALLY. 1L72 3O3 O A12CE E10EA 5 CP31EA 20100308 EA 2010 3 8 2010FA0000211 220100222G8550 OIL FILTER CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA ENGINE INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 NM01835CP 18281304 WHILETRYING TO TIGHTEN A NEW OIL FILTER ONTO ENGINE, THE FILTER WOULD GET PARTIALLY TIGHT THEN POP LOOSE. REMOVED OIL FILTER TO FIND CENTER MOUNTING STUD HAD BROKEN LOOSE. REMOVED OIL FILTER TO FIND CENTER MOUNTING STUD HAD BROKEN LOOSE AND STRIPPED THREADS WHERE IT IS SCREWED INTO THE OIL FILTER. 1H71 3O3 ONT3A13 1E4 20100308 CE 2010 3 8 2010FA0000213 120100221G272070603103 PUSHROD CESSNA510 510 2076617CE PWC PW610 PW610FA 52267NE RUDDER PEDAL DISTORTED C NO1YK NONE O OTHER ININSP/MAINT 1 EA35GOAMB 5100050 DURING MX INSP IN THE AREA OF THE PILOT`S RUDDER PEDALS, IT WAS NOTICED THAT THE RT BRAKE PEDAL PUSH ROD HAD AT SOME POINT MADE CONTACT WITH AN ADJACENT FLOOR SUPPORT ANGLE CAUSING MINOR DISTORTION TO THE ANGLE VERTICLE FLANGE. THIS CONDITION COULD HAVE RESULTED IN THE BRAKE PEDAL REMAINING IN A PARTIALLY DEPRESSED STATE. CLEARANCE FROM STRUCTURE IN THIS LOCATION IS VERY LIMITED. THIS CONDITION WAS COMPOUNDED BY THE FACT THAT THE BOLT HAS LATERAL PLAY DUE TO INSUFFICIENT WASHERS BEING INSTALLED UNDER THE NUT, THE INSTALLATION HOWEVER WAS IAW THE IPC. MFG ADVISED. 1L72 4F4 FRTA00014WIE00074EN 20100308 CE 2010 3 8 2010FA0000205 120100101G3210504100111 BOLT CESSNA340 340A 2076405CE CONT O520 TSIO520* 17040SO MLG BROKEN D K NONE O OTHER ININSP/MAINT 1 CE07500CT4999 340A1236 AT TOUCHDOWN THE LT MAIN GEAR DID NOT LOCK OVER CTR RESULTING IN THE LT GEAR RETRACTING, PROP STRIKE AND DAMAGE TO LT TIP FUEL TANK. APPEARS BOLT (NAS464P4-26) AND SPACER (S133-4P32) THAT ATTACHES BELLCRANK (5041001-11) TO LT GEAR ASSY UPPER TRUNNION BROKE RESULTING IN BELLCRANK BREAKING AND GEAR NOT LOCKING OVER CENTER. RECOMMEND INSP AND REPLACEMENT OF ATTACH HARDWARE. 1L72 3O3 O 3A25 E8CE 20100308 SO 2010 3 8 2010FA0000207 220100216G741410391586 DISTRIBUTOR BLK BEECH 58 58P 1152744CE CONT O520 TSIO520WB 17040SO RT MAGNETO LOOSE D O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 SW13491WM F04AA402R TJ491 248247H CUSTOMER HAD INTERMITTENT ROUGH ENGINE THAT FINALLY HAD FAILED MAGNETO. DISASSEMBLED & FOUND DISTRIBUTOR GEAR AXEL WAS LOOSE IN BLOCK AND TOWER CONTACTS WERE GROUND OFF. REPLACED DISTRIBUTOR BLOCK AND LARGE GEAR. MAGNETO WAS O/H 250 PRIOR ON 11-1-2004. 1L72 3O3 O A23CE E8CE 20100308 CE 2010 3 8 2010FA0000208 120100208G571250022001 RIB WTHRLY620 620B 9630605CE PWA R985 R985AN1 52008NE HARTZLHCB3R HCB3R304 GL LT WING CRACKED D O OTHER O OTHER NRNOT REPORTED 1 NM139024F2340 1629 P225078 EM67 MOST L/E RIBS CRACKED AT UPPER AND LOWER AFT CORNERS WHERE ATTACHED TO FWD HINGED HALF. 50 PERCENT TO LT WING RIBS WERE CRACKED AS WERE 90 PERCENT OF RT WING RIBS. THESE RIBS REQUIRED REPAIR AND REINFORCEMENT. OTHER ACFT MAY REQUIRE SIMILAR ACTION. 1L71 3R3 RNCA26WE 5E1 5 CP28EA 20100308 SO 2010 3 8 2010FA0000214 220100123G8530655465 CYLINDER LANCARLC42 LC42550FG 5150002NM CONT O550 IO550N 17042SO NR 3 CRACKED B BIERK NONE O OTHER ININSP/MAINT 1 EA2141LY 42018 687607 DURING ANNUAL INSP, FOUND FUEL STAIN TRAILING FROM FUEL INJECTOR NOZZLE PORT TOWARD SPARK PLUG HOLE ON NR 3 CYLINDER. CYLINDER HAS 980.9 TSN. ENGINE WAS MFG IN JULY 2003 AND INSTALLED IN ACFT (SN 42018). 1L71 3O3 ONTA00003SEE3SO 20100308 SO 2010 3 8 2010FA0000206 120100212G51006345100 SUPPORT PIPER PA28 PA28235 7102810SO LYC O235 O235B 41505EA HARTZLHCC2Y HCC2YK1 GL UNKNOWN MISINSTALLED D O OTHER O OTHER NRNOT REPORTED 1 WP2866LB 287310110 L1163340 10919 SHOULD HAVE AN960 WASHERS UNDER THE (4) AN3-4L BOLTS TO SPREAD THE LOAD ON THE ASSY. THERE ARE NO WASHERS SHOWN IN PARTS LIST. 1L71 3O3 O 2A13 E223 5 CP920 20100310 WP 2010 3 10 2010F00029 220100208G7300 WARNING LIGHT CESSNA650 650 2076802CE GARRTTTFE731TFE731* 01518WP ILLUMINATED D D RETURN TO BLOCK J WARNING INDICATION TXTAXI/GRND HDL 1 SW0940FC 6500143 AS THE FLIGHT CREW TAXIED TOWARDS THE RUNWAY, THEY NOTICED RT ENGINE "FUEL COMPUTER MANUAL" LIGHT ILLUMINATED. CREW RETURNED TO THE HANGER AND NOTIFIED MX. MX PERSONNEL DOWNLOADED AND CLEARED DEECS' AND FOUND CODES 2,237, AND 242. CHECKED N1 RESISTANCE AND INSULATION RESISTANCE CHECKS, NO DEFECTS NOTED. SWAPPED DEECS'. PERFORMED ENGINE GROUND RUN AND OPS CHECK OF DEECS', NO DEFECTS NOTED. ACFT RETURNED TO SERVICE. 2L72 4F4 F A9NM E6WE 20100310 WP 2010 3 10 2010FA0000167 120100219G2810369H810135 FUEL TANK HUGHES369 369E 4470707WP ALLSN 250C 250C20 03013GL ZONE 100 DETERIORATED D C ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TOTAKEOFF 1 SO21127PD 501E DURING TAKEOFF, A COMPRESSOR STALL FOLLOWED BY ENGINE SEARCH WAS EXPERIENCED. THE ENGINE HAS BEEN INSPECTED AND MX PROCEDURE PERFORMED FOUNDED ALL NORMAL. HELICOPTER FUEL TANK INSPECTED AND FOUNDED DEBRIS FROM AN UNKNOWN SOURCE LIKE RUBBER. HELICOPTER LATER RELEASED FOR FLIGHT AND THE SAME CONDITION REAPPEARS FURTHER INSP TO THE FUEL TANK REVEALS THAT THE RT SIDE WAS STARTING TO DECOMPOSE ON RUBBER MATERIAL FUEL TANK WAS REMOVED FROM THE ROTORCRAFT. MAIN FUEL TANKS HAVE BEEN REPLACED ON 1999. 1G71 3U3 U H3WE E4CE 20100312 NM 2010 3 12 2010FA0000187 120100226G3350900835A BATTERY PACK BOEING727 727212 138407GNM PWA JT8 JT8D17 52049NE EMERGENCY LIGHTSINOPERATIVE I R5KBK NONE L NO TEST ININSP/MAINT 1 EA68727NK 21945 CENTER CABIN EMERGENCY EXIT LIGHT INOP. REPLACED BATTERY PACK. 2L73 4F4 F A3WE E2EA 20100301 SW 2010 3 1 2010FA0000171 120100210G712023051106 SUPPORT BELL 407 407 1182206SW ALLSN 250C 250C47B GL COMPRESSOR DAMAGED D K NONE O OTHER ININSP/MAINT 1 WP2540RX 534 53872 CAE848154 ON 1/17/2010, THE PILOT, FLIGHT CREW, AND BASE MECHANIC REPORTED AN UNUSUAL NOISE COMING FROM THE ACFT/ENG. AFTER FLIGHT CKS, GROUND RUNS, AND TROUBLESHOOTIING OF THE ENG AND COMPONENTS, A DECISION WAS MADE TO REMOVE THE ENG FOR INSP AND REPAIR. ON 1/2/2010, THE ENGINE REPAIR VENDOR NOTIFIED US THAT THE SUSPECT ENG SUFFERED METAL TO METAL RUBBING CONTACT AND FAILED NR 1 COMPRESSOR BRG DUE TO IMPROPER INITIAL BUILD UP BY THE MFG. THIS NEW ENG (534 HRS TIS) WAS INSTALLED AS A NEW COMPONENT, AND HAD VERY LOW TIME ACCUMULATED. AS A PRECAUTION, WE REMOVED ANOTHER ENGINE FROM SERVICE ( 2 SERIAL NRS AWAY FROM THE DAMAGED ENGINE) UNTIL A VISUAL INSP BY REP WAS PERFORMED TO VERIFY THE INITIAL BUILDUP INSTALLATION, W1G71 3U3 UO H2SW E1GL 20100302 GL 2010 3 2 2010FA0000184 120100208G7160D4171662030 HOUSING DIAMONDA40 DA40 2990002GL LYC O360 IO360M1A NE HARTZLHCC2Y HCC2YR1 GL ALT AIR VALVE DAMAGED B U43RK NONE O OTHER ININSP/MAINT 1 NM03342AF147 401040 L3456251E CH44126B AFTER 150 HOURS ON ACFT DURING SCHEDULED MAINTENANCE THE FIRST ONE OF THE TYPE OF PROBLEM WAS FOUND. MECHANICS ARE FINDING THE ALTERNATE AIR VALVE BODY CONTROL CABLE (PN NR DAI-9076-00-04) LOOSE OR COMPLETELY DISCONNECTED AND HANGING NEXT TO THE PRIMARY/ALTERNATE AIR VALVE BODY (PN D41-7166-20-30). THEN WHEN THEY TRY TO REINSTALL THE CABLE THEY ARE FINDING THAT THE THREADS ARE STRIPPED OUT ON THE ALTERNATE AIR VALVE BODY. THIS PROBLEM HAS NOW OCCURRED ON 14 DIFFERENT ACFT IN OUR FLEET ALL BETWEEN 150 TO 350 HOURS TTSN. MY CONCERN IS THAT THE OPERATOR OF THE ACFT (IF THE CABLE HAS BECOME DISCONNECTED) MAY NOT KNOW IF THE ENGINE IS GETTING FILTERED OR UNFILTERED AIR. THE FIX MIGHT BE THAT THE MANUFACTURE MAK1L71 3O3 ONTA47CE 1E10 5 CP920 20100303 CE 2010 3 3 2010FA0000088 120100205G3010 WARNING LIGHT CESSNA750 750 2076810CE ALLSN AE3007AE3007C 03047GL SLAT ANTI ICE ILLUMINATED E DXTAO OTHER J WARNING INDICATION CRCRUISE 1 GL07971QS 7500071 SLAT ANTI ICE RT EICAS MESSAGE ON IN CRUISE POWER AT FL310. 2L72 4J4 FRTT00007WITE6CH 20100303 NM 2010 3 3 2010FA0000086 120100204G5220438513L WINDOW LKHEEDP2V P2V7 5260112NM WRIGHTR3350 R3350* 67040EA COCKPIT SEPARATED D A UNSCHED LANDING D INFLIGHT SEPARATION CLCLIMB 1 NM05445NA10933 140443 PILOTS OVERHEAD HATCH WINDOW SEPARATED FROM THE FRAME SHORTLY AFTER TAKEOFF. THE PLEXIGLASS WINDOW IS MOUNTED BY USE OF A FIBERGLASS LAMINATE. THE FIBERGLASS LAMINATE IS WHAT FAILED CAUSING THE SEPARATION. THE WINDOW RIPPED OFF THE COMM 1 ANTENNAE AND DENTED THE VERTICAL STABILIZER L/E. THE LT HORIZONTAL STABILIZER L/E WAS DENTED AS WELL. 2M72 4R4 RRTA1RM E272 20100310 EU 2010 3 10 5APR577Y30 120100210G3242244755 BRAKE DISC PILATSPC12 PC1247 7090552EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL RT MLG CRACKED B K NONE O OTHER ININSP/MAINT 1 EA65755HF841 841 0673 755 PR0633 KX394 DURING A 100 HR INSP THE RT BRAKE OTBD DISC WAS DISCOVERED CRACKED. R & R BRAKE ASSY IAW MM. 1L71 4T4 TRTA78EU E26NE 5 CP210NE 20100310 GL 2010 3 10 2010FA0000157 120100126G249770475K36 SUPPRESSOR DIAMONDA40 DA40 2990002GL LYC O360 IO360M1A NE VOLTAGE BLISTERED D A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 WP13778DS781 40678 SMELL OF SMOKE IN COCKPIT. REPLACED TRANSIENT VOLTAGE SUPPRESSOR. 1L71 3O3 ONTA47CE 1E10 20100224 NM 2010 2 24 CA100104001 120100101G249710962242 CONTACTOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ELECTRICAL RELAYDAMAGED W O OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 CA 7491 (CAN) AIRCRAFT POWER WOULD NOT TURN OFF WITH BATTERY MASTER SWITCH SELECTED OFF. A/C POWER DOWN BY DISCONNCTING THE STANDBY BATTERY. FOUND FAULT CODE 21 IN EPCU. REPLACED CONTACTOR K24 IAW AMM 24-31-41 (TC NR 20100104001) 2H72 4T4 TRTA13NM E00062EN 20100310 NM 2010 3 10 2010FA0000159 120100216G3220 LANDING GEAR GULSTM200 200 4500308NM PWC PW306 PW306A 52165NE NOSE MALFUNCTIONED C CWQAO OTHER P NO WARNING INDICATION APAPPROACH 1 GL05957P 062 NOSE GEAR DOES NOT INDICATE DOWN AND LOCKED AFTER PULLING EMERGENCY GEAR HANDLE. 2L72 4F4 FRTA53NM E35NE 20100310 SW 2010 3 10 2010FA0000164 120100218G6410212010750105 BLADE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TAIL ROTOR DETACHED B CUFAK NONE E VIBRATION/BUFFET ININSP/MAINT 1 WP17213SJ2573 30589 DURING GROUND RUN FOLLOWING COMPLETION OF ANNUAL INSP AND CHECK OF GENERATOR BEING INOPERATIVE. A VIB. WAS NOTED WITH THE ENGINE SHUTDOWN. INSP OF THE ACFT SHOWED A HOLE IN THE AFT COWLING TO THE RT SIDE OF THE OIL COOLER. THE DAMAGE CONTINUED THROUGH 2 BULKHEADS AND OFF THE ENGINE RPM COMP AND REFERENCE FLEX LINE DAMAGING THESE COMPONENTS. ADDITIONAL INSP SHOWED A MISSING STATIC WEIGHT ON ONE OF THE TAIL ROTOR BLADES. 1G71 4U4 U H4SW E22EA 20100301 GL 2010 3 1 2010FA0000174 220100206G7230 BLADES DOUG MD500 MD500E 3027372NM ALLSN 250C 250C20B 03013GL COMPRESSOR DAMAGED C A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 WP13742LA 00200E CAE821565F PILOT EXPERIENCED COMPRESSOR STALL DURING FLIGHT WITH LOUD NOISE AND YAW OF ACFT. PILOT EXPERIENCED LOSS OF ENGINE POWER AND PROCEEDED TO LAND ACFT. UPON INSP MX FOUND 1 EA 1ST STAGE COMPRESSOR BLADE BROKEN OFF AT ROOT AND LAYING IN PLENUM CHAMBER IN FRONT OF THE COMPRESSOR INLET AND SEVERE DAMAGE TO REMAINING BLADES AND STATORS. 1G72 3U3 UNC E4CE 20100301 EA 2010 3 1 2010FA0000156 220100202G7320 DIAPHRAGM PIPER PA32 PA32300 7103212SO LYC O540 IO540K1A5 41532EA FLOW DIVIDER LEAKING D K NONE O OTHER ININSP/MAINT 1 SW134133R2635 497J 3240450 1550548 CUSTOMER REPORTED ROUGH RUNNING ENGINE. FOUND FUEL FLOW DIVIDER ON ENGINE WAS LEAKING FUEL FROM DIAPHRAGM. HAD UNIT O/H AND FOUND PART TO ORIGINAL JAN 1967 PART. PART HAD NOT BEEN O/H IN 43 YEARS. 1L71 3O3 O A3SO 1E4 20100301 SO 2010 3 1 2010FA0000170 120100207G32455005 TUBE PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA MLG TIRE LEAKING D O OTHER O OTHER TXTAXI/GRND HDL 1 EA613152K29 2842272 L2014739E A61029 TIRE WENT FLAT IN THE RUNUP AREA. SMALL PIN HOLE IN THE TUBE ON THE OUTER SIDEWALL. TIRE APPEARS TO BE FINE. 1L71 3O3 O 2A13 E274 5 NP88614 20100311 EU 2010 3 11 2010FA0000182 120100224G7921727029 REGULATOR VALVE AGUSTA AGUSTAA109 A119 0261102EU PWA PT6 PT6* 52043EA OIL COOLER WORN L PO7LA UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 WP07196FB1180 1180 14056 PU0060 ENGINE OIL TEMPERATURE ROSE HIGHER THAN USUAL. FOUND TEMPERATURE REGULATOR VALVE (THERMAL VALVE)TO BE THE PROBLEM. 1G71 3U3 T H7EU E2NE 20100301 SO 2010 3 1 V0XR201001120015 120100112G532014525994003 PROFILE EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 149256 RT PROFILE AT FRM 61 IS CORRODED OUT OF LIMITS. R & R PROFILE. 2L72 4T4 FRTT00011ATTE6CH 20100301 SO 2010 3 1 V0XR201001120005 120100112G532014525140023 PROFILE EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 PROFILE AND BEAM AT FRM 17, YL 610 & 690 IS CORRODED OUT OF LIMITS. R & R PROFILE AND BEAM. 2L72 4T4 FRTT00011ATTE6CH 20100301 SO 2010 3 1 V0XR201001120008 120100112G532014525422003 SILL EMB 145 EMB145LR 3260212SO ALLSN AE3007AE3007A 03030GL ZONE 100 CORRODED B V0XRK NONE O OTHER ININSP/MAINT 1 NM05811HK 145256 RT SILL FROM FRM 60.5-65 IS CORRODED OUT OF LIMITS. R & R SILL. 2L72 4T4 FRTT00011ATTE6CH 20100310 CE 2010 3 10 2010FA0000135 120100208G282011492000041 LINE BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL FUEL SYSTEM CHAFED D K NONE O OTHER ININSP/MAINT 1 GL03CFKA UB67 PCE32185 FWA3145 MAIN FUEL LINE WAS REMOVED TO FACILITATE REPLACEMENT OF THE LT WING INBD WHEEL WELL KEEL. THE LINE WAS CHAFED APPROX HALF WAY THRU WHERE IT PASSES THRU THE KEEL. THIS AREA IS VERY DIFFICULT TO INSPECT AS IT IS ABOVE AND BEHIND THE MLG. THE RT WING MAIN FUEL LINE WAS INSPECTED AND FOUND TO BE CHAFED ALSO. BOTH LINES WERE REPLACED. SUGGEST CLOSE INSPECTION OF THESE LINES AT WING / WHEEL WELL INSPECTIONS. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20100119 CE 2010 1 19 2010FA0000022 120100104G553140261T023 SPAR AYRES S2 S2R 7630202CE WRIGHTR1820 R182071 67020EA HAMSTD33D 33D50 GL VERTICAL STAB CRACKED D K NONE O OTHER ININSP/MAINT 1 NM134999X 2136R SWO37946 TOP RUDDER ATTACH BRACKET CRACKED OUT OF REAR SPAR ON THE VERTICAL FIN. NOTICED CRACK AT ANNUAL INSPECTION. POSSIBLY INSTALL A HEAVIER REAR SPAR OR BEEF UPS IN THAT AREA. 1L71 3R4 RNCA4SW 5E10 6 CP749 20100115 CE 2010 1 15 2010FA0000033 120100108G27100510105365 CONTROL CABLE CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA AILERONS DAMAGED B K NONE O OTHER ININSP/MAINT 1 WP07558ER2096 172S10562 CABIN OVERHEAD CTR PANEL WAS REMOVED FOR PROGRESSIVE INSP. DURING FLAP & AILERON CABLE INSP FLAT SPOTS WERE NOTICED ON 3 AILERON CONTROL CABLES. ROLLED CABLES FOR BETTER VIEW OF CONTACT POINT WITH PULLEYS AND WAS ABLE TO CATCH FRAYED WIRES WITH A RAG AND COULD SEE A SUBSTANTIAL GROOVE IN THE CARRY-THRU CABLE. CABLE TENSIONS WERE WITHIN PROPER SPECS AND AREA WAS CLEAN & FREE OF ANY DIRT/DEBRIS. ALSO PLASTIC PULLEYS WERE INSPECTED, THEY WERE CLEAN AND FREE TO ROLL. THIS PROBLEM SEEMS TO BE HAPPENING DURING NORMAL FLIGHT TRAINING SCHOOL USE AND HAS BEEN NOTICED TO BE HAPPENING WITH OUR OTHER ACFT WITH THE SAME TIMES. CAUSE IS PROBABLY FROM PULLEYS THEMSELVES. THEY ARE MADE FROM A HARD WHITE PLASTIC MATERIAL.1H71 3O3 ONT3A12 1E10 20100120 GL 2010 1 20 2010FA0000061 320100107G6111 BLADE CONT O470 IO470* 17026SO MCAULY2A34C 2A34C66 GL PROPELLER CORRODED B K NONE O OTHER ININSP/MAINT 1 NM09 871502 PROPELLER RECENTLY OVERHAULED 10/29/2009 PROPELLER CAME IN FOR REPITCH WITH NO TIME ON SINCE OVERHAULED. 1 BLADE PAINT WAS REMOVED AND LOTS OF CORROSSION LEFT UNDER PAINT NOT REMOVED AS SHOULD BE WITH OVERHAUL. PROPELLER WILL HAVE TO BE REOVERHAULED TO DETERMINE THAT SPECIFICATIONS OF WIDTH AND THICKNESS WILL STILL BE AMPLE AFTER REPAIRS. 3 O E1CE 5 CP3EA