c5 c10 c12 c14 c15 c16 c17 c18 c20 c25 c35 c40 c90 c100 c110 c120 c130 c140 c150 c152 c160 c170 c180 c190 c192 c200 c210 c220 c230 c240 c250 c260 c270 c280 c290 c300 c310a c310b c310c c310d c314a c314b c314c c314d c320a c320b c320c c324a c324b c324c c330 c332 c340 c350 c360 c370 c380 c390 c400 c410 c420 c430 c440 c450 c460 c490 c510a c510b c510c c510d c510e c510f c602 c604 c606 c608 c610 c612 c614 c616 c620 c640 c652 c654 c660 eof 1995013000131 19950130 00131 EA 1995 1 30 95ZZZX409 2 19950104 G 7421 SR88 SPARK PLUG CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA CENTER ELECTRODE FAILED C K NONE O OTHER IN INSP/MAINT 1 GL 03 5227K 100 17274020 SUBMITTER STATES A VERY POOR SERVICE FROM AUBURN SPARK PLUGS. HAS NOTED CENTER ELECTRODE PORCELAIN FAILS. FAILED ELECT RODE PIECES THEN CAN CAUSE DAMAGE TO VALVES, SEATS, RINGS, AND PISTONS. SUBMITTER RECOMMENDS TO NOT USE THESE SPARK PLU GS IN AIRCRAFT ENGINES. 1 H 7 1 3O 3 O NT 3A12 E274 1995013000133 19950130 00133 EA 1995 1 30 95ZZZX411 2 19950107 G 8530 ECI12967CP RINGS PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA NR 1 CYLINDER DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 AL 01 59764 151 317652037 L148468A OIL BLOWING OUT BREATHER. FOUND NR 1 CYLINDER AT 10/80. PULLED CYLINDER AND FOUND COMP. RINGS BROKEN IN MANY PIECES AB OUT .25 INCH TO 2.5 INCH. THESE RINGS ARE OF WRONG COMPOSITION. (BRITTLE). 1 L 7 2 3O 3 O A20SO E14EA 1995030300155 19950303 00155 GL 1995 3 3 HEEA954392 2 19950221 G 7250 6886407 WHEEL 6898735 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL 1ST STAGE BLADES SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 91070 1195 CAT25067 S145 CAE831141 ENGINE REMOVED DUE TO HIGH TOT. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: SULFIDATION ON 1ST STAGE WHEEL B LADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 2 3U 3 U H3EU E4CE 1995030300160 19950303 00160 EU 1995 3 3 HEEA954397 2 19950221 G 7532 97914211 VALVE BOLKMS 117 BK117B2 5626013 EU LYC LTS101 LTS101650B1 41560 NE BLEED SOV PIN BROKEN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 132AE 860 7238 PIN BROKEN IN CONNECTOR. 1 G 7 2 3U 3 U NC H13EU E5NE 1995030300167 19950303 00167 GL 1995 3 3 HEEA954406 2 19950223 G 7250 23031426 NOZZLE 23035128 BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL 4TH STAGE DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6160Z CAT90585 51610 CAE895571 ENGINE REMOVED DUE TO N2 DRAG. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: LIFTING AND FLAKING PLASMA IN 4TH STAGE NOZZLE #4 TIP PATH. INSTALLED SERVICEABLE 4TH STAGE NOZZLE. 1 G 7 1 3U 3 U H2SW E1GL 1995030300172 19950303 00172 GL 1995 3 3 HEEA954411 2 19950224 G 7532 23005368 BODY 23005366 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30 03013 GL BLEED VALVE MIS MFG E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 5427S FF50119 760168 RECEIVING INSPECTION OF NEW, NEVER INSTALLED BLEED VALVE BODY INDICATED PORT HOLE FOR ORIFICE P/N 23003102-01 IS IMPROPE RLY MACHINED WITHOUT THREADS. INSTALLED NEW BLEED VALVE BODY. 1 G 7 2 3U 3 U H1NE E1GL 1995030300394 19950303 00394 EA 1995 3 3 95ZZZX927 2 19950126 G 8530 VALVE DOUG DC3 DC3C 3021457 WP WRIGHT R1820 R1820* 67020 EA NR 7 CYL EXH BROKE E A E A ENGINE SHUTDOWN UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 WP 13 99131 912 18949 SW022927 APPROXIMATELY 10 MINUTES AFTER TAKEOFF A SLIGHT INTERRUPTION OF POWER WAS NOTED WHICH RETURNED IMMEDIATELY TO NORMAL. P RESSURES AND TEMPS INDICATED AN INCREASE IN OIL TEMP AND A DECREASE IN OIL PRESSURE. ENGINE WAS FEATHERED AND RETURNED A/C TO HNL. EXAMINATION OF ENGINE INDICATED NR 7 CYLINDER EXHAUST VALVE HEAD BROKE. SCREENS INDICATED A SMALL AMOUNT O F ALUMINUM. 2 L 7 2 4R 4 R A669 5E10 1995030300419 19950303 00419 SO 1995 3 3 95ZZZX952 2 19950120 G 8530 24044 RETAINER 641917 UNIVAC GC1 GC1B 9230104 NM CONT O300 O300A 17022 SO NR 2 CYL EXH VLV MISSING D K NONE O OTHER IN INSP/MAINT 1 NM 01 2420B 40 3720 16110DR DISASSEMBLY OF THE CYLINDER DISCLOSED A MISSING RETAINER FOR THE EXHAUST VALVE SPRING. WEAR INTO THE ALUMINUM HEAD WAS NOTED. 'NR 2 CYLINDER'. 1 L 7 1 3O 3 O A766 E253 1995030300421 19950303 00421 SO 1995 3 3 95ZZZX954 2 19950127 G 8520 6419311075 BOLT BEECH 33 G33 1151435 CE CONT O520 IO520BB 17032 SO NR 2 CYLINDER BROKEN D K NONE K FLUID LOSS IN INSP/MAINT 1 WP 09 1740W 129 CD1302 285662R DURING ROUTINE MAINTENANCE, AN OIL LEAK WAS NOTED BETWEEN THE NR 2 CYLINDER AND THE OIL COOLER. FURTHER INSPECTION REVE ALED LOWER AFT THROUGH-BOLT BROKEN APPROXIMATELY ONE-THIRD ITS LENGTH. REPLACEMENT BOLT WAS A SLIGHTLY DIFFERENT DESIGN . ENGINE TIME SINCE FACTORY REBUILD, 128.64. 1 L 7 1 3O 3 O 3A15 E5CE 1995030300423 19950303 00423 SO 1995 3 3 95ZZZX956 2 19950120 G 7414 1057441 IMPULSE COUPLING BENDIX S6LN21 BEECH 35 F35 1151514 CE CONT E225 E2258 17015 SO BORE CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 25 3376C 800 8410 D4043 DURING INSPECTION OF IMPULSE COUPLING, I.E., AD 78-09-07R3, NUT WAS LOOSE DUE TO CRACK IN BORE OF IMPULSE COUPLING. TCM BENDIX SB 639 REFERS TO INSTALLATION OF COUPLINGS. AD 78-09-07R3 DOES NOT REQUIRE REMOVAL OF COUPLING FOR INSPECTION. MAYBE IT SHOULD TO DETECT CRACKS IN BORE OF COUPLING. BOTH MAGS AND IMPULSES REPLACED WITH REBUILT TCM UNITS. 1 L 7 1 3O 3 O A777 E267 1995030300429 19950303 00429 EA 1995 3 3 95ZZZX962 2 19950127 G 7322 HA6IC5 CARBURETOR CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA ACCELERATOR PUMP BINDING H K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 5482T 23 75036815 R18201877 L2162940A CARBURETOR ACCELERATOR PUMP STICKING OR BINDING CAUSING EXTREMELY DIFFICULT THROTTLE OPERATION. THIS WAS A FACTORY REMA NUFACTURED ENGINE WITH A NEW CARBURETOR. TIME IN SERVICE IS 23.0 HOURS. THIS HAS OCCURRED ONCE BEFORE ON THE SAME MODE L CARBURETOR, ON A DIFFERENT ENGINE AND AIRCRAFT. SUBMITTER RECOMMENDS INSPECTING ACCELERATOR PUMP AND THROTTLE SHAFT F OR FREEDOM OF MOVEMENT AND PROPER TRAVEL BEFORE INSTALLATION. 1 H 7 1 3O 3 O RT 3A13 E295 1995030300430 19950303 00430 EA 1995 3 3 95ZZZX963 2 19950201 G 7414 S6LN MAGNETO PIPER PA31 PA31310 7103103 SO LYC O540 TIO540J2BD 41532 EA LT MAG SEPARATED D A UNSCHED LANDING K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 SW 99 27337 14 8220066 3186 L160061 PILOT RETURNED TO BASE AFTER NOTICING SMOKE FROM LEFT ENGINE SOON AFTER TAKEOFF. MAINTENANCE DISCOVERED LT MAGNETO HAD SEPARATED FROM ENGINE CAUSING OIL LEAK AND SMOKE. REASON FOR MAGNETO SEPARATION IS UNKNOWN. NEW NUTS AND LOCKWASHERS H AD BEEN USED DURING INSTALLATION, AND STUDS ARE IN A GOOD CONDITION. 1 L 7 1 3O 3 O RT A20SO E14EA 1995030300432 19950303 00432 SO 1995 3 3 95ZZZX965 2 19950207 G 7414 10357281 CAPACITOR 101630601 CESSNA 310 T310R 2074246 CE CONT O520 TSIO520B 17040 SO RT ENG, RT MAG FAILED B AHTR K NONE O OTHER IN INSP/MAINT 1 GL 11 5094C 466 9324 310R1417 RT176631R DURING ENGINE RUN-UP FOR A ROUTINE 50-HOUR INSPECTION, THE MECHANIC NOTED THE RIGHT ENGINE, RIGHT MAGNETO DID NOT RESPON D TO THE IGNITION SWITCH. FURTHER INVESTIGATION REVEALED THE MAGNETO CAPACITOR TO BE FAULTY. AFTER REPLACING THE CAPAC ITOR, THE MAGNETO OPERATION CHECKED NORMAL. NOTE: THIS IS THE SAME CONDITION THAT AD 94-06-09 PERTAINED TO, EXCEPT THE AD DOES NOT APPLY TO THIS CAPACITOR PART NUMBER OR DATE CODE. SUBMITTER STATED THIS CONDITION COULD CAUSE INJURY OR DE ATH. 1 L 7 2 3O 3 O 3A10 E8CE 1995030300441 19950303 00441 NE 1995 3 3 95ZZZX974 2 19950123 G 7230 778487 MODULE DOUG DC9 DC981 3022081 WP PWA JT8 JT8D217A 52053 NE 6TH-7TH STAGES BLADE DAMAGE B A ASTY A UNSCHED LANDING O OTHER CR CRUISE 1 SO 23 10022 5383 48024 P696930D FLT 410 - DURING FLIGHT, PILOT REPORTED A BANG ON NR 2 ENGINE. PILOT REDUCED POWER AND MADE A QRF. LANDING PERFORMED W ITHOUT INCIDENTS. AT THE BASE, ENGINE WAS BORESCOPED BEFORE ANY ATTEMPT TO RESTART. DAMAGE FOUND ON 6TH, 7TH, AND 13TH STAGES COMPRESSOR GROUPS BLADES. DEBRIS IMPACTED ON TURBINE STAGES AND MIXER WITHOUT MAJOR DAMAGE. ENGINE WAS REPLACE D, GROUND TEST PERFORMED SUCCESSFULLY. ACFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F A6WE E9NE 1995030300592 19950303 00592 NE 1995 3 3 95ZZZX981 2 19950206 G 7210 7757571 BEARING HAMSTD 77580010 SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE GC 49 GEARCASE CRACKED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 174AE 7018 9138 340B174 THE GEARCASE WAS RETURNED FOR 'MAKING METAL'. THE UNIT WAS DISASSEMBLED. EXAMINATION OF INTERNAL HARDWARE REVEALED A C RACKED INNER BEARING RACE ON THE PROPELLER SHAFT FORWARD ROLLER BEARING. REF. CMM 72-11-02. 2 L 7 2 4T 4 T RT A52EU E8NE 1995030300593 19950303 00593 NE 1995 3 3 95ZZZX982 2 19950119 G 7530 6927221 COTTER PIN HAMSTD EVC32 BOEING 747 747* NM PWA JT9 JT9* 52054 NE ENG VANE CONTROL MISSING B S A SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 75363 677 UPON DISASSEMBLY FOR OVERHAUL IT WAS OBSERVED THAT COTTER PIN, REF. CMM 75-31-01, FIGURE 2, ITEM 49, AND SHIM, FIGURE 2, ITEM 50, WERE NOT INSTALLED. NOTE: HEADED STRAIGHT PIN, FIGURE 2, ITEM 51, REMAINED IN INSTALLED POSITION. NOTE 2: L AST REPAIR PERFORMED BY ANOTHER AGENCY. 2 L 7 4 4F 4 F RT A20WE E20EA 1995030300594 19950303 00594 NE 1995 3 3 95ZZZX983 2 19950206 G 7210 7757535 IDLER GEAR HAMSTD 77580010 SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE GC 49 GEARCASE FAILURE B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 201AE 8129 1C6412310 340B201 THE UNIT WAS REMOVED FROM THE AIRCRAFT DUE TO A LT IDLER GEAR FAILURE. THE FAILED GEAR BROKE THROUGH THE GEAR CASE HOUS ING. DISASSEMBLY OF THE UNIT REVEALED THE IDLER GEAR WEB HAD FAILED. ALSO, OBSERVED WAS BROKEN DAMPER RINGS, BROKEN RE TAINING RINGS AND A BROKEN SLIDER BLOCK HOUSING. REF. CMM 72-11-02. 2 L 7 2 4T 4 T RT A52EU E8NE 1995031000047 19950310 00047 EA 1995 3 10 95ZZZX1007 2 19950208 G 8530 LW16343 INTAKE PIPE AMTR GHAWK GOSHAWK GL LYC O540 IO540P1A5 41532 EA NR 3 CYL FLANGE BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 09 345RM 304 001 L800048 DURING ROUTINE MAINTENANCE, MAINTENANCE PERSONNEL NOTED THAT NR 3 CYLINDER INTAKE PIPE WAS LOOSE AT CYLINDER. FOUND INT AKE PIPE BROKEN ABOUT 45 DEGREES AT THE FLANGE. REPLACED PART WITH A NEW INTAKE PIPE. OLD INTAKE PIPE HAD BEEN CHROMEP LATED BY UNKNOWN SHOP. SUSPECT HYDROGEN EMBRITTLEMENT. RECOMMEND THAT INTAKE PIPES NOT BE CHROMEPLATED. 1 H 7 1 3O 3 O EXPA1H71 1E4 1995031000049 19950310 00049 SO 1995 3 10 95ZZZX1009 2 19950127 G 7322 6462124 PUMP FITTING GULSTM 500 500A 0141104 SW CONT O470 IO470M 17026 SO ENGINE FUEL FAILED B UPNR O OTHER O OTHER NR NOT REPORTED 1 WP 25 57EB 1C109407BR 500A124571 FOUND FUEL PUMP HAS 90 DEGREE MALE TO FEMALE BRASS FITTING DEFECTIVE. FITTINGS ARE OVERTORQUED AND ONE FITTING FAILED I N-FLIGHT. OTHER PUMP, UPON REMOVAL, HAD FITTING FAIL WITH ABOUT 25 INCH/POUNDS OF TORQUE. 1 H 7 2 3O 3 O 6A1 3E1 1995031000055 19950310 00055 NE 1995 3 10 95ZZZX1015 2 19950209 G 7250 3054289010 MANIFOLD DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C1 13802 NE INLET PORT RT CRACKED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 28348 45978 693209 ENGINE NR 1, LOW PRESSURE TURBINE COOLING MANIFOLD DISTRIBUTOR INLET PORT CRACKED AT RIGHT SIDE. 2 L 7 4 4F 4 F RT 4A25 E2GL 1995031000056 19950310 00056 NE 1995 3 10 95ZZZX1016 2 19950209 G 7250 3054289010 MANIFOLD DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C1 13802 NE NR 3 ENGINE CRACKED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 27785 45978 693303 ENGINE NR 3 LOW PRESSURE TURBINE COOLING MANIFOLD DISTRIBUTOR, CRACKED AT 10 O'CLOCK POSITION. 2 L 7 4 4F 4 F RT 4A25 E2GL 1995031000233 19950310 00233 SW 1995 3 10 HEEA954468 1 19950301 G 6320 206040190005 PUMP BELL 206 206L1 1182107 SW ALLSN 250C 250C30P 03013 GL XMSN OIL LEAKING E HEEA K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 2125M 45649 LEAKING. REPLACED WITH SERVICEABLE OIL PUMP. 1 G 7 1 3U 3 U H2SW E1GL 1995031000256 19950310 00256 GL 1995 3 10 HEEA954491 2 19950303 G 7230 23008090 GEAR SHAFT 23005200 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL SPUR ADAPTER STEP WEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3178K 915 CAC70148 45765 CAE860046 ENGINE REMOVED DUE TO OIL OVERTEMP INSPECTION. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP WEAR BEYO ND LIMITS ON SPUR ADAPTER GEARSHAFT FORWARD AND AFT SPLINES. INSTALLED NEW SPUR ADAPTER GEARSHAFT. 1 G 7 1 3U 3 U H2SW E1GL 1995031000433 19950310 00433 NE 1995 3 10 95ZZZX1049 2 19950209 G 7261 ENGINE SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A3 41560 NE OIL SYSTEM CHIP WARNING D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 WP 13 5771N 1344 DURING FLIGHT, ENGINE CHIP LIGHT WARNING MADE PRECAUTIONARY LANDING. MECHANIC INSPECTED ENGINE LUBE SYSTEM, CHIP PLUGS AND WIRING, FOUND NO DEFECTS. ACFT RETURNED TO SERVICE. 1 G 7 1 3U 3 U H9EU E5NE 1995031000586 19950310 00586 SO 1995 3 10 95ZZZX1095 2 19950201 G 8540 GEAR TCRAFT 19 F19 9230703 GL CONT O200 O200A 17020 SO CRANKSHAFT FAILED D A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SO 04 20001 F126 255880 ACFT ON LOCAL FLIGHT WHEN ENGINE QUIT AT 1,000 FEET AGL. EMERGENCY LANDING MADE WITH ACFT DAMAGE. INVESTIGATION FOUND RT MAG BROKEN AT BASE. BOLTS HOLDING GEAR TO CRANKSHAFT FAILED. STARTER AND CLUTCH FROZEN. 1 H 7 1 3O 3 O 1A9 E252 1995031000592 19950310 00592 EA 1995 3 10 95ZZZX1101 2 19950201 G 7414 10682016 DISTRIBUTOR GEAR BENDIX D6LN3000 CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MAG TEETH STRIPPED D K NONE O OTHER IN INSP/MAINT 1 SW 07 4949S 157 3070356 R18201488 L2110340A ACFT WAS FLOWN ON THE PREVIOUS EVENING. NO PROBLEMS NOTED. NEXT MORNING, ACFT WOULD NOT START. AFTER TROUBLESHOOTING ACFT, FOUND MAGNETO PROBLEMS UPON DISASSEMBLY OF MAG. BOTH DISTRIBUTOR GEARS WERE SEVERELY DAMAGED (TEETH WERE STRIPPED FROM BOTH GEARS). A NEW MAG WAS INSTALLED AND NO OTHER PROBLEMS WERE ENCOUNTERED. ACFT WAS RELEASED FOR SERVICE. 1 H 7 1 3O 3 O RT 3A13 E295 1995031000595 19950310 00595 SO 1995 3 10 95ZZZX1104 2 19950131 G 8540 646209 DAMPENER CESSNA 421 421C 2076016 CE CONT O520 GTSIO520N 17032 SO ACCESSORY CASE SEPARATED B ETER K NONE O OTHER IN INSP/MAINT 1 SO 11 6794D 730 421C1030 FOUND METAL IN OIL. FOUND REAR ACCESSORY CASE JOURNAL HOLDING STARTER ADAPTER SHAFT SEVERELY WORN AND WALLOWED OUT. VI SCOUS DAMPENER SEPARATED FROM HUB. 1 L 7 2 3O 3 O A7CE E7CE 1995031000605 19950310 00605 SO 1995 3 10 95ZZZX1114 2 19950218 G 8530 ROCKER BOSS CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO ENGINE CYLINDER FAILED D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 17 3XZ 336 15074013 72IABKA48 CYLINDER EXHAUST AND INTAKE VALVE ROCKER BOSSES SEPARATED DURING FLIGHT RESULTING IN PRECAUTIONARY LANDING DUE TO LOSS O F ENGINE POWER. CYLINDER REPLACED AND AIRCRAFT RETURNED TO SERVICE. REF. AD 94-05-05. 1 H 7 1 3O 3 O 3A19 E252 1995031000608 19950310 00608 SO 1995 3 10 95ZZZX1117 2 19950118 G 7324 63432610A9 FLOW DIVIDER CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO ENGINE FUEL DEFECTIVE C K NONE O OTHER IN INSP/MAINT 1 SW 07 535A 175 402B0591 20650271E PILOT REPORTED LT ENGINE WOULD NOT MAKE A CLEAN SHUT DOWN. INVESTIGATION REVEALED FLOW DIVIDER CHECK VALVE WAS PASSING FUEL BELOW PRESET PRESSURE. FOUND RUBER DIAPHRAGM DRIED OUT DUE TO LACK OF USE. 1 L 7 2 3O 3 O A7CE E8CE 1995031000609 19950310 00609 SO 1995 3 10 95ZZZX1118 2 19950119 G 7322 6462122 FUEL PUMP BEECH 33 F33A 1151425 CE CONT O520 IO520BA 17032 SO ENGINE FAILED C A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SW 07 1096W 65 CE436 569112 ENGINE LOST POWER WHEN REDUCED FOR DESCENT. EFFORTS TO RESTART ENGINE FAILED. AIRCRAFT MADE AN UNEVENTFUL OFF AIRPORT LANDING. AFTER AIRCRAFT SAT, ENGINE WAS ABLE TO BE RESTARTED. PUMP WAS REMOVED AND SENT OUT FOR CHECK. MULTIPLE DISCR EPANCIES WERE FOUND IN VALVE SEAT ALIGNMENT CAUSING ENGINE TO RUN RICH ON POWER REDUCTION. UNIT OVERHAULED LESS THAN 10 0 HOURS PRIOR BY CRS RV3R829L. 1 L 7 1 3O 3 O 3A15 E5CE 1995031000620 19950310 00620 SO 1995 3 10 95ZZZX1129 2 19950206 G 7322 ENGINE CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO CARB RAN ROUGH D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 13 501PA 1772 15077482 275920R AD 93-18-03 AND PRECISION AIRMOTIVE SB NR MSA-2 R1, WAS DONE ON THIS CARB. AT 1521 HRS SMOH WHICH IS THE SINGLE PIECE VE NTURI. IT WAS DONE BY A REPAIR STATION. AT 1771 HRS SMOH, ENGINE BEGAN TO RUN EXTREMELY ROUGH. OAT WAS ABOUT 27 DEGRE ES FAHRENHEIT. INVESTIGATION FOUND OUT THAT IF SINGLE PIECE VENTURI WAS INSTALLED AND ENGINE RAN ROUGH, IT NEEDED A DIF FERENT METERING NOZZLE, KIT PN 666-942. THIS WAS DONE AND IT RAN FINE. SUBMITTER SUGGESTS IF SINGLE PIECE VENTURI IS I NSTALLED, THAT CHANGING THE FUEL NOZZLE IS A MUST. IT IS COVERED IN SB MSA-2. 1 H 7 1 3O 3 O 3A19 E252 1995032000051 19950320 00051 GL 1995 3 20 95ZZZX1133 2 19950223 G 7250 6890040 SHIELD 6898735 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL NR 1 NOZZLE CRACKED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 3115Y 961 479130R 500716D CAE832750 DURING REPLACEMENT OF NR 1 NOZZLE, NOZZLE SHIELD WAS FOUND CRACKED. PART REPLACED AND SENT IN FOR OVERHAUL. 1 G 7 1 3U 3 U H3WE E4CE 1995032000056 19950320 00056 GL 1995 3 20 95ZZZX1138 2 19950221 G 7230 23007217 MOUNT ASSY ALLSN 250C 250C30P 03013 GL COMPRESSOR MISMANUFACTURED B UP9R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 07 1177 821 CAE895130 MOUNT FACE TO MOUNT BOSS HEIGHT LIMITS ARE 1.715 INCHES TO 1.707 INCHES IN THE O/H MANUAL. THIS MOUNT MEASURED 1.770 IN CHES TO 1.730 INCHES. THE MISALIGNMENT DAMAGED THE SPUR ADAPTER, GEAR SHAFT, COUPLING ADAPTER, AND IMPELLER BORE. 3 U E1GL 1995032000057 19950320 00057 WP 1995 3 20 95ZZZX1139 2 19950222 G 7250 3101512 BLADE 31016031 MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP 1ST STAGE FAILED B DQIR C D ABORTED TAKEOFF RETURN TO BLOCK J WARNING INDICATION TO TAKEOFF 1 NM 07 132BK 6530 90350120012 1529A P36236 DURING TAKEOFF POWER APPLICATION, LT ENGINE DEVELOPED HIGHER THAN NORMAL ITT. THE ENGINE WAS VISUALLY INSPECTED AND WAS FOUND TO HAVE EJECTED INTERNAL PARTS FROM THE TAILPIPE. TEAR DOWN INSPECTION REVEALED CAUSE TO HAVE BEEN GENERATED FRO M ONE FIRST STAGE TURBINE BLADE FAILURE. BLADE TSN, 6529.8 - CSN 6988. 1 H 7 2 3T 4 T RT A10SW E4WE 1995032000066 19950320 00066 SO 1995 3 20 95ZZZX1148 2 19950112 G 8530 CYLINDERS BEECH 36 A36TC 1151603 CE CONT O520 TSIO520UB 17040 SO ROCKER SHAFT EXCESS WORN B CCAR K NONE O OTHER IN INSP/MAINT 1 EA 17 48PD 581 EA75 515609 FACTORY NEW CYLINDERS TT 581.4 HOURS. INSTALLED 2-1-91, LOW COMPRESSION ALL CYLINDERS. CYLINDERS ARE WORN BEYOND SERVI CEABLE LIMITS AND HAVE SEVERE RING WEAR. ROCKER SHAFTS ARE SEVERELLY WORN AND UNAIRWORTHY. 1 L 7 1 3O 3 O 3A15 E8CE 1995032000067 19950320 00067 SO 1995 3 20 95ZZZX1149 2 19950203 G 8520 CAMSHAFT CESSNA 402 402A 207590M CE CONT O520 TSIO520E 17040 SO GEAR END BROKEN G O OTHER Y ENGINE STOPPAGE CR CRUISE 1 GL 19 4584Q 71 402A0084 183466R IN-FLIGHT ENGINE SHUT DOWN. CHECKED PROBLEM AND FOUND NO MOVEMENT IN VALVE TRAIN, ETC., WHEN PROP MOVED. PULLED ENGINE AND SENT BACK TO OVERHAUL AGENCY. VERIFIED UPON DISASSEMBLY THAT CAMSHAFT WAS BROKEN NEAR GEAR END. 1 L 7 2 3O 3 O A7CE E8CE 1995032000077 19950320 00077 EA 1995 3 20 95ZZZX1159 2 19950220 G 7414 ES103910881 COIL ELECTROSYS 103493653 PIPER PA34 PA34200 7103405 SO LYC O360 LIO360C1E6 41515 EA MAGNETO CRACKED B QKKR K NONE O OTHER IN INSP/MAINT 1 CE 01 0110063 DURING INSPECTION PER CUSTOMER INSTRUCTIONS, COIL CRACK WAS NOTED. REMOVED AND TESTED COIL. FOUND HIGH VOLTAGE LEAK OU T FROM CRACK. SUSPECT CAUSE MAY BE FROM MANUFACTURE DATE STAMP IN INSULATION. CRACK LOCATION ABOUT 1 INCH FROM OUTPUT TAB. 1 L 7 2 3O 3 O A7SO 1E10 1995032000081 19950320 00081 EA 1995 3 20 95ZZZX1163 2 19950206 G 8540 71667 LOCK PLATE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C1B5 41532 EA IDLE GEAR FAILED D E A ENGINE SHUTDOWN UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SO 03 6792Y 274130 L526048 DURING PART 91 OPERATION, LEFT ENGINE QUIT RUNNING AND PILOT FEATHERED PROP AND LANDED AT AIRPORT. INSPECTION FOUND LOC K TAB FOR BOLT ON IDLE GEAR HAD BROKEN OFF AND BOLT BACKED OUT AND ENGINE JUMPED TIME AND QUIT. 1 L 7 2 3O 3 O 1A10 1E4 1995032000083 19950320 00083 SO 1995 3 20 95ZZZX1165 2 19950216 G 8540 643257 SHAFT GEAR 643259A5 CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO STARTER CLUTCH FAILED B QX2R K NONE O OTHER IN INSP/MAINT 1 EA 11 88604 429 421C0604 608427 DURING DISASSEMBLY OF THIS ENGINE, THE 'NEW STYLE' STARTER CLUTCH (REF: SB M92-10) GEAR TEETH WERE STARTING TO FAIL. A LSO, REF: CRITICAL SB 94-4. 1 L 7 2 3O 3 O A7CE E7CE 1995032000084 19950320 00084 SO 1995 3 20 95ZZZX1166 2 19950216 G 8540 643257 SHAFT GEAR 643259A5 CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO STARTER CLUTCH FAILED B QX2R K NONE O OTHER IN INSP/MAINT 1 EA 11 88604 429 421C0604 604981 DURING DISASSEMBLY OF THIS ENGINE, THE 'NEW STYLE' STARTER CLUTCH (REF: SB M92-10) GEAR GEETH WERE STARTING TO FAIL. A LSO, REF: CRITICAL SB 94-4. 1 L 7 2 3O 3 O A7CE E7CE 1995032000436 19950320 00436 EA 1995 3 20 95ZZZX1208 2 19950215 G 7322 2525033 REGULATOR BODY BENDIX RSA10 LYC O540 IO540* 41532 EA FUEL INJECT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 FOUND CRACK AT THE CENTERBODY BELLOWS OPENING WITH O.E.M.'S BRASS BELLOWS ALREADY INSTALLED. RECOMMENDATIONS - HAVE A B ETTER BELLOWS INSTALLING TOOL AND BIGGER BODY SUPPORT. 3 O 1E4 1995032000437 19950320 00437 EA 1995 3 20 95ZZZX1209 2 19950217 G 8520 CONNECT ROD PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA NR 1,2,3 CYLS FAILED D E A ENGINE SHUTDOWN UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CL CLIMB 1 EA 21 3581C 4998 606 318052091 L110068A AFTER TAKEOFF, RIGHT ENGINE BECAME VERY ROUGH. ENGINE WAS FEATHERED, AIRCRAFT RETURNED TO AIRPORT AND LANDED. INSPECTI ON FOUND CONNECTING ROD CAPS HAD SEPARATED FROM NR 1, NR 2, AND NR 3 RODS. CONNECTING ROD PENETRATED BOTH BOTTOM AND TO P OF ENGINE CASE. 1 L 7 2 3O 3 O A20SO E14EA 1995032000445 19950320 00445 1995 3 20 95ZZZX1217 1 19950221 G 7312 101050A1 VALVE ASSY CHNDLREVANS PWA JT9 JT9* 52054 NE FUEL DEICE MISOVERHAULED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 CLEAR SILICONE COMPOUND USED FOR POTTING IN SWITCH CAVITY INSTEAD OF SILASTIC 'E' RTV. REMOVED TO CONVERT TO 101050A1. WIRE ENDS LEFT SUSPENDED IN CLEAR SILICONE. ORIGINAL PART NUMBER AND PARTS LIST NUMBER CROSSED OUT ON NAMEPLATE AND NE W P/N VIBROPEENED IN INCORRECT LOCATION. UNIT WAS RECEIVED FROM FEDERAL EXPRESS FOR OVERHAUL. 4 F E20EA 1995032000449 19950320 00449 EA 1995 3 20 95ZZZX1221 2 19950123 G 8530 76038 VALVE COVER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA NR 4 CYL CRACKED D L K NONE K FLUID LOSS IN INSP/MAINT 1 SO 09 11AB 31P7300169 L77962 OPERATOR/OWNER COMPLAINED OF OIL LEAK ON LEFT ENG. REMOVED COWLING AND FOUND OIL AROUND 2-4-6 CYLINDER AREAS. WASHED D OWN ENGINE. RAN AND SHUT DOWN ENGINE, FOUND OIL SEEPING FROM AROUND NR 4 CYLINDER VALVE COVER/GASKET. WASHED AREA AND RAN ENGINE AGAIN. FOUND OIL LEAKING AT SURFACE OF VALVE COVER. REMOVED VALVE COVER, FOUND COVER, PN 76038, CRACKED WHE RE INTAKE ROCKER ARM HAD BEEN HITTING. 1 L 7 2 3O 3 O A8EA E19EA 1995032000738 19950320 00738 SO 1995 3 20 95ZZZX1253 2 19950301 G 8520 CRANKSHAFT BEECH 35 V35B 1151548 CE CONT O550 IO550B SO NR 3 CRANK CHEEK BROKEN G K NONE O OTHER IN INSP/MAINT 1 GL 13 1693W 1006 D9389 249112R ENGINE DISASSEMBLY REVEALED THE CRANKSHAFT HAD FAILED THROUGH THE NR 3 CRANK CHEEK. THE FRACTURE FACE WAS EXAMINED BY T HE TCM METALLURGIST WHO CONFORMED THE FAILURE WAS IN BENDING OVERLAOD. THE NR 1 AND NR 2 MAIN BEARINGS WERE HAMMERED OU T TO EXTRUDE THE BEARINGS. THE CRANKCASE PARTING SURFACE WAS SEVERELY FRETTED AT THE NR 2 MAIN BEARING SUPPORT. FRETTI NG WAS ALSO PRESENT, BUT TO A LESSER DEGREE, ON THE NR 1 AND NR 3 MAIN BEARING SUPPORTS. BEARING AND ALUMINUM DEBRIS WA S PRESENT IN THE OIL SUMP. 1 L 7 1 3O 3 O 3A15 E3SO 1995032000764 19950320 00764 EA 1995 3 20 95ZZZX1280 2 19950209 G 7414 M3525 COIL SLICK 4281 CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA LT MAG DEFECTIVE B OF1R A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 25 89414 2596 042090 15282737 L2230215 ENGINE LOST 125 RPM IN-FLIGHT, LANDED WITHOUT INCIDENT, MAG CHECK REVEALED LT MAGNETO DEAD. TROUBLESHOT AND FOUND NO DE FECTS IN MAG AFTER DISASSEMBLY. REPLACED COIL AND RAN UP AND OPS CHECKED OKAY. 1 H 7 1 3O 3 O NT 3A19 E223 1995032000774 19950320 00774 EA 1995 3 20 95ZZZX1290 2 19950302 G 7414 104001679 CAM ASSY BENDIX D4LN3000 LYC O360 IO360A3B6 41514 EA MAIN BODY CRACKED B TY5R K NONE O OTHER IN INSP/MAINT 1 NE 03 1353 MAGNETO WAS DISASSEMBLED FOR OVERHAUL. PREVIOUSLY, HAD NEW SNAP RING IMPULSE COUPLING INSTALLED. COUPLING CAM ASSY APP EARED TO BE IN GOOD CONDITION AND LOW TIME. CAM ASSY WAS INSPECTED IAW TCM MSB NR 645, SECT. I AND FOUND GOOD. THEN CA M WAS MAGNAFLUX INSPECTED IAW MIL-STD1949A AND FOUND 1 CRACK AT CORNER OF KEYWAY AND AT LEAST 7 OTHER LONGITUDINAL CRACK ED NEAR THE LARGE END OF CENTER TAPERED HOLE. DO NOT KNOW WHETHER COUPLING WAS INSTALLED IAW TCM SB NR 639. 3 O 1E10 1995032400065 19950324 00065 EA 1995 3 24 95ZZZX1309 2 19950216 G 7414 ES10357424 DIST BLOCK BENDIX S4LN200 MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA MAGNETO LOOSE BUSHING D P K NONE O OTHER IN INSP/MAINT 1 NM 05 3205F 971 409402 680002 RL274451A ON DISASSEMBLING THE MAG FOR INSPECTION, THE CENTER BRONZE BUSHING IN THE DISTRIBUTOR BLOCK WAS FOUND LOOSE IN THE PLAST IC MATERIAL OF THE BLOCK. THIS IS THE SECOND ELECTRO SYSTEMS DISTRIBUTOR BLOCK FOUND IN THIS CONDITION IN LAST MONTH, T HE OTHER BLOCK WAS P/N ES10-357426. 1 L 7 1 3O 3 O 2A3 1E10 1995032400070 19950324 00070 EA 1995 3 24 95ZZZX1314 2 19950130 G 7414 10507464 DISTRIBUTOR GEAR BENDIX S4LN204 ENSTRM F28 F28A 3300406 GL LYC O360 IO360C1A 41514 EA RT MAG TEETH FAILED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 13 9087 603 8017066 211 L1627651AC TEN MINUTES INTO A TOUR FLIGHT, ENGINE BECAME MOMENTARILY ROUGH. UPON RETURNING TO THE HELIPAD, A MAG CHECK REVEALED TH E RIGHT MAG WAS DEAD. UPON REMOVAL AND INSPECTION, FOUND MORE THAN HALF OF THE PLASTIC TEETH WERE MISSING (BROKEN OFF) OF THE LARGE DISTRIBUTOR GEAR. 1 G 7 1 3O 3 O H1CE 1E10 1995032400129 19950324 00129 GL 1995 3 24 HEEA954545 2 19950316 G 7250 6886407 WHEEL 6898735 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL 1ST STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 54197 1740 CAT40390 S805 CAE830763 ENGINE REMOVED DUE TO 1750 HOUR INSPECTION AND TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: SULFIDATION ON ALL 1ST STAGE WHEEL BLADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 2 3U 3 U H3EU E4CE 1995032400130 19950324 00130 GL 1995 3 24 HEEA954546 2 19950317 G 7320 40030043800 LINEAR ACTUATOR BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL ENGINE INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3116P 359 51530 BEEP MOTOR INOPERATIVE. 1 G 7 1 3U 3 U H2SW E1GL 1995032400268 19950324 00268 EA 1995 3 24 95ZZZX1334 2 19950308 G 7310 3022660 ACCUMULATOR SKRSKY S58T S58JT 8141807 NE PWA PT6T PT6T6 52045 EA FUEL LEAKING H JSYL K NONE K FLUID LOSS NR NOT REPORTED 1 NM 09 581SR 581539 CPPS72005 DURING POWER PLANT OPERATION, FUEL ACCUMULATOR STARTED TO LEAK FUEL FROM THE FRONT SEAM. ACCUMULATOR WAS REPLACED AT TH AT TIME. 2 G 7 2 4U 4 U 1H11 E22EA 1995032400406 19950324 00406 EA 1995 3 24 95ZZZX1363 2 19950228 G 8530 73806P PUSH ROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA ENGINE CYLNDER BROKEN D S K NONE O OTHER IN INSP/MAINT 1 GL 15 6145K 15285553 L232U415 FOUND 1 BROKEN AND 3 OTHERS CRACKED. ALL DAMAGE ON END OF THE TUBE NEAR INSERT OPPOSITE END OF TUBE WHERE PART NUMBER I S LOCATED. AD95-03-10 PERTAINS TO ASSEMBLY NR 73806 AND 'V' OR 'W' REVISION. PART TT UNKNOWN. 1 H 7 1 3O 3 O NT 3A19 E223 1995032400409 19950324 00409 EA 1995 3 24 95ZZZX1366 2 19950222 G 8550 LW13306 GASKET MOONEY M20 M20M 5870222 SW LYC O540 TIO540AF1A 41532 EA OIL SUMP PAN BROKEN B GN1R K NONE K FLUID LOSS IN INSP/MAINT 1 NE 01 1085W 232 270043 L912161A NEW MOONEY M20M AT 124.6, ENGINE OIL PAN GASKET LEAKING. REMOVED AND REPLACED WITH 06B2132C, REVISED PART NUMBER AND GA SKET. THE TURBO MOUNT IS LOCATED ON THE SIDE OF THE OIL PAN. BOTH GASKETS LEAKED AT THE LT REAR SIDE. BOTH LW-13306 G ASKETS WERE FOUND BROKEN AT THE SAME LOCATION. LYCOMING IS NOW USING THE OLD STYLE TIO-540 OIL PAN GASKET USED ON OTHER ENGINES. SEE FAA AC43-16 DATED 2-95. SUBMITTER RECOMMENDS SB FOR GASKET REPLACEMENTS. 1 L 7 1 30 3 O RT 2A3 E14EA 1995032400410 19950324 00410 NE 1995 3 24 95ZZZX1367 2 19950216 G 8510 96657 COUPLING DOUG DC3 DC3G102A 3021404 WP PWA R1830 R183094M1 52020 NE ENG FRONT SEC BROKEN D L A K NONE O OTHER IN INSP/MAINT 1 SW 99 13JA 945 4082 145873 REMOVED SN 145873 ENGINE DUE TO INCREASING AMOUNTS OF STEEL IN OIL SCREEN OVER A PERIOD OF 108 HRS. TSMOH WAS 2-1/2 YRS AND 945 HRS. TWO OIL ANALYSES DURING THAT TIME REPORTED ALL WEAR CHECKS NORMAL. UPON EXAMINING REMOVED ENGINE, FND PN 96657 COUPLING ASSY CRACKED COMPLETELY THROUGH. ALSO, AN APPROX 1 SQUARE INCH PIECE WAS BROKEN AWAY, BUT RETAINED IN P LACE BY CHANNEL DESIGN OF MATING PN 92991 COUPLING ASSY. ONLY REASON GEARS ARE TIMED IS SO MAGNETO TIMING CAN BE CHECKE D VIA A TIMING PIN THROUGH A SIGHTING HOLE IN NOSE CASE. NOTED GEAR NOT TIMED, BROKEN PIECE WAS THROUGH THE GROOVE OF T HE TOOTH WITH RIVET HOLE AND TIMING PIN (PN 93407) WAS NOT INSTALLED. 2 L 7 2 4R 4 R A618 5E4 1995032400411 19950324 00411 NE 1995 3 24 95ZZZX1368 2 19950216 G 8510 96657 COUPLING DOUG DC3 DC3G102A 3021404 WP PWA R1830 R183094M1 52020 NE ENG FRONT SEC BROKEN D L A K NONE O OTHER IN INSP/MAINT 1 SW 99 13JA 1064 4082 BP600184 ENGINE HAD BEEN SHOWING SMALL AMOUNTS OF STEEL IN THE OIL SCREEN FOR 138 HRS. TSMOH WAS 2-1/2 YRS AND 1064 HRS. DECIDE D TO REMOVE FRONT SECTION AGAIN PN 96657 COUPLING ASSEMBLY FOUND BROKEN. THIS TIME, NOT ALL THE WAY THROUGH, BUT .75 IN CH OF THE 1.50 INCH LONG TOOTH WITH THE RIVET HOLE WAS BROKEN LOOSE. AGAIN, HELD IN PLACE BY THE DESIGN OF CHANNEL SHAP ED PN 92991 MATING COUPLING ASSY. THE TIMING RIVET FROM PN 96657 COUPLING ASSY HAD ALSO BEEN REMOVED AND THE COUPLING R ANDOMLY INSTALLED. 2 L 7 2 4R 4 R A618 5E4 1995032400423 19950324 00423 WP 1995 3 24 95ZZZX1380 2 19950312 G 7321 8977807 FUEL CONTROL WOODWARD BAG JETSTM JETSTM3101 1500215 EU GARRTT TPE331 TPE33110UA 01514 WP RT ENGINE FAILED B UN7R A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SW 19 608JX 34 1945014 608 P42026 DURING REPOSITION FLIGHT FROM CIT TO BWI 20 MINUTES INTO FLIGHT, RT ENGINE STARTED BYPASSING FUEL, REDUCED POWER AND CON TINUED CLIMB. AT 19,000 FEET, NOTICED EGT AT 655. REDUCTION OF POWER DID NOT CHANGE EGT. POWER LEVER REDUCED TO FLIGH T IDLE, EGT WENT TO 650 DEGREES CENTIGRADE AT 80 PERCENT TORQUE. ON DESCENT BACK TO LIT, EGT AND POWER REDUCED ON ITS O WN (10,000 FEET EGT 600 DEGREES CENTIGRADE TORQUE 60 PERCENT) (2,000 FEET 400 DEGREES CENTIGRADE AND 6 PERCENT TORQUE). LANDED AT LIT WITHOUT INCIDENT. PILOTS SHUT RT ENGINE DOWN FOR TAXI. INSPECTED ENGINE FOR ANY EXTERNAL DEFECTS, NONE NOTED. REMOVED FUEL CONTROL FROM ENGINE FOR INSPECTION AT WOODWARD AND TO PERFORM SB TPE 331-73-0228 PER AD 94-26-07. 2 L 7 2 4T 4 T RT A21EU E4WE 1995033100143 19950331 00143 NE 1995 3 31 HEEA954346 2 19950214 G 7261 0292005220 OIL RETURN SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1 60030 NE TURBINE BLOCKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 350BZ 846 2653 FREE TURBINE OIL RETURN RESTRICTED. 1 G 7 1 3U 3 U H9EU E19EU 1995033100153 19950331 00153 GL 1995 3 31 HEEA954563 2 19950322 G 7250 6886407 WHEEL 6898735 BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL 4TH STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 2271V 1244 CAT32847F 3615 CAE835219 ENGINE REMOVED DUE TO CYCLED 1ST THROUGH 4TH STAGE WHEELS. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MILD SULFIDATION ON 50% OF TURBINE 1ST STAGE WHEELS BLADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 1 3U 3 U H2SW E4CE 1995033100182 19950331 00182 GL 1995 3 31 HEEA954594 2 19950323 G 7261 6854424 SHAFT SEAL BELL 230 230 1182149 SW ALLSN 250C 250C30 03013 GL START/GENERATOR LEAKING E HEEA K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 230UN 23009 LEAK AT STARTER GENERATOR SEAL. REPLACED WITH SERVICEABLE SEAL. 1 G 7 2 3U 3 U NC H9SW E1GL 1995033100197 19950331 00197 GL 1995 3 31 HEEA954611 2 19950323 G 7323 25246928 GOVERNOR BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL ENGINE DEFECTIVE E HEEA K NONE O OTHER TO TAKEOFF 1 SW 03 6160Z 7083 51610 ON TAKEOFF, N1, N2 AND ROTOR FLUCTUATIONS -- OVERTORQUE EXCEEDING 120%. REPLACED WITH SERVICEABLE GOVERNOR AND PERFORMED OVERTORQUE INSPECTION. 1 G 7 1 3U 3 U H2SW E1GL 1995033100221 19950331 00221 GL 1995 3 31 HEEA954635 2 19950324 G 7261 MS9372019 SEAL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL OIL NOZZLE "T" LEAKING E A HEEA O OTHER A K FLAME/FIRE FLUID LOSS NR NOT REPORTED 1 SW 03 27702 CAT70676 45300 PILOT REPORTED A FIRE IN ENGINE COMPARTMENT. THE FIRE FLASHED, THEN EXTINGUISHED. INVESTIGATION REVEALED OIL LEAK AT 6 & 7 OIL NOZZLE "T" FITTING. REPLACED SEAL ASSEMBLY AND RETURNED ENGINE TO SERVICE. 1 G 7 1 3U 3 U H2SW E1GL 1995033100223 19950331 00223 GL 1995 3 31 HEEA954637 2 19950324 G 7210 6893660 ENGINE ASSY BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL NR 1 CHIP LIGHT E HEEA K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 03 7136J 4876 S830 #1 ENGINE CHIP LIGHT CAME ON IN FLIGHT. (FOUND METAL ON THE LOWER PLUG) INSTALLED SERVICEABLE ENGINE AND RETURNED AIRCR AFT TO SERVICE. 1 G 7 2 3U 3 U H3EU E4CE 1995033100383 19950331 00383 EA 1995 3 31 95ZZZX1416 2 19950227 G 7314 LW15473 PUMP PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA ENGINE FUEL WASHER FAILED B A OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 802ND 2837002 L2528051A OIL QUICK DRAIN WOULD NOT SHUT OFF. FOUND 2 PARTS OF STEEL WASHER IN QUICK DRAIN. FOUND OTHER 2 PARTS OF WASHER IN PAN . WASHER IS FROM JUST BELOW LEVER SLOT OF PUMP WHERE IT SLIDES OVER PUMP VERTICAL PLUNGER SHAFT. THIS IS THE SECOND OC CURRENCE OF THIS FAILURE BY THIS OPERATOR (OTHER FAILED PUMP HAD 641 TSN). 1 L 7 1 3O 3 O 2A13 1E10 1995033100390 19950331 00390 EA 1995 3 31 95ZZZX1423 2 19950303 G 8530 65427 VALVE SPRING PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA OUTER WRONG PART D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 01 3975K 2823861 L2497427AC CUSTOMER REPORTED ENGINE 'BACKFIRING' INTERMITTENTLY AT HIGH IDLE. VALVE TRAIN PROBLEMS SUSPECTED & COLD CYLINDER TESTE R DISCLOSED NR 3 CYL SLIGHTLY COOL (COMPRESSION WAS EXCELLENT). CLOSER INSP DISCLOSED INCORRECT SPRINGS PN 65427 INSTAL LED INSTEAD OF LW-11800. NO RECORD OF MX ON THIS CYL SINCE O/H. PN 65427 SPRING HAS ABOUT 35 POUNDS LESS LOAD THAN COR RECT SPRING & IS USED IN O-235/O-290 SERIES ENGINES. VALVE & GUIDE WEAR WERE CHECKED & WITHIN LIMITS, BUT ENOUGH MUST H AVE CHANGED SINCE ENG HAS RUN 1620 HRS SMOH W/O COMPLAINT OF BACKFIRING. IN THIS CASE, 'WEAK' SPRINGS ALLOWED VALVES TO RESONATE OR BOUNCE IN A NARROW RPM RANGE (1200-1500 RPM) & RESULTED IN 'AFTERFIRING'. REPLACING SPRINGS CURED PROBLEM. 1 L 7 1 3O 3 O 2A13 E274 1995033100394 19950331 00394 SO 1995 3 31 95ZZZX1427 2 19950201 G 8530 CYLINDERS CESSNA 210 T210L 2073449 CE CONT O520 TSIO520R 17040 SO ENGINE WORN B BJ3R K NONE O OTHER IN INSP/MAINT 1 WP 15 210MG 21060838 506427 ENGINE RUN SMOH WITH MOBIL AV-1 ENGINE OIL. ENG STARTED SHOWING HIGH READINGS OF IRON, CHROMIUM, ALUMINUN ON OIL ANALYS IS. CYLS REMOVED FOR INSP. ALL OIL CONTROL RINGS FND STUCK W/LEAD BUILD-UP & ALL CYL WALLS FND WORN UP TO .014 INCH. E NG REMOVED FROM ACFT & DISASSEMBLED. FND VERY HIGH SLUDGE BUILD-UP IN ENG CAUSING PARTIAL BLOCKAGE OF MAIN OIL GALLEY. THIS CAUSED PREMATURE MAIN & CONNECTING ROD BRNG WEAR TO NEAR FAILURE. CRANKSHAFT ALSO FND SCORED AT PROP TRANSFER COL LAR AREA. CAM FOLLOWERS FND PITTED. ENG O/H 2-1/2 YEARS EARLIER W/ALL NEW CYLS, BRNGS, & CAMSHAFT FOLLOWERS INSTALLED. SUBMITTER STATED SEEING SIMILAR DAMAGE IN OTHER ENG RUN ON THIS OIL. RECOMMEND INSP OF ENG WITH THIS OIL. 1 H 7 1 3O 3 O 3A21 E8CE 1995033100396 19950331 00396 EA 1995 3 31 95ZZZX1429 2 19950224 G 7414 1068256013 HOUSING D6LN3000 PIPER PA32 PA32RT300 7103215 SO LYC O540 IO540K1G5 41532 EA CLAMP FLANGE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 16 6240C 250 A139406GB 32R7885022 ENGINE WAS LEAKING OIL. INVESTIGATION REVEALED CRACKED MAG HOUSING AT LOWER HOLD DOWN FLANGE. GASKET SURFACE WAS CLEAN , CLAMP BLOCKS WERE PROPERLY POSITIONED AND TORQUED. CRACKED OUT SECTION REVEALED LARGE AREAS OF AIR POCKETS IN CASTING . SUSPECT CRACK STARTED FROM PRESSED IN IMPULSE PINS AGGREVATED BY INTERNAL WEAKNESS DUE TO FLAWED CASTING. 1 L 7 1 3O 3 O A3SO 1E4 1995033100397 19950331 00397 EA 1995 3 31 95ZZZX1430 2 19950303 G 8520 SL78290 PLUNGER ASSY SUPAIRPART PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA TAPPET LOOSE D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SO 01 3975K 1620 2823861 L2497427AC DURING COURSE OF TROUBLESHOOTING A ROUGH RUNNING ENGINE, THE HYDRAULIC PLUNGER ASSEMBLIES WERE REMOVED FROM THE TAPPETS. THE 'STEMS' OF 7 OF THE 8 UNITS WERE LOOSE AND WOULD SPIN IN THE BODY OF THE PLUNGER ASSEMBLY. NO CLUE WAS FOUND TO I NDICATE WHAT MADE THE STEMS LOOSE. THAT PART OF THE UNIT RIDES ONLY IN OIL, ONLY NORMAL WEAR NOTED, AND ONLY IN THE NOR MAL PLACES. THIS DEFECT ALLOWED LIFTERS TO BLEED DOWN UNUSUALLY QUICKLY. PARTS WERE REPLACED AND DEFECTIVE LIFTERS RET URNED TO MANUFACTURER FOR FURTHER EVALUATION. 1 L 7 1 3O 3 O 2A13 E274 1995033100400 19950331 00400 SO 1995 3 31 95ZZZX1433 2 19950303 G 7414 S6LN21 MAGNETO BENDIX CESSNA 172 172 2072402 CE CONT O300 O300A 17022 SO ENGINE RT DEFECTIVE D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 SO 11 6110E 1586 2422862R 46210 159337AK AIRCRAFT LANDED ON ROAD 15 MINUTES AFTER TAKEOFF DUE TO ROUGH ENGINE AND NOT ABLE TO MAINTAIN ALTITUDE. AIRCRAFT HAS NO T RUN IN A LONG TIME. RAN AIRCRAFT ON GROUND 15 TO 20 MINUTES. MAGS CHECKED GOOD UP UNTIL THEN. STARTED GETTING REAL ROUGH, BOTH MAGS AND THEN WORSE. AIRCRAFT IN LICENSE - AD 94-01-03R1 NOT COMPLIED WITH ON MAG COILS AND ROTATING MAGNET S. 1 H 7 1 3O 3 O NT 3A12 E253 1995033100592 19950331 00592 SO 1995 3 31 95ZZZX1460 2 19950222 G 8530 538288 CYLINDER BEECH 33 F33A 1151425 CE CONT O520 IO520BA 17032 SO NR 1 GUIDE LOOSE D K NONE O OTHER IN INSP/MAINT 1 SW 07 1096W 70 CE436 569112 DURING A ROUTE INPSECTION, NR 1 CYLINDER DISPLAYED LOW COMPRESSION. FURTHER INVESTIGATION, AFTER REMOVAL OF CYLINDER, R EVEALED A LOOSE VALVE GUIDE IN THE CYLINDER HEAD. THIS ENGINE HAD BEEN OVERHAULED 70.0 HOURS PREVIOUS TO THE INSPECTION . CAUSE: INCORRECT TOLERANCES ON INSTALLATION. PREVENTION: INSPECTION OF GUIDES AFTER 100 HOURS OF OPERATION. 1 L 7 1 3O 3 O 3A15 E5CE 1995033100594 19950331 00594 EA 1995 3 31 95ZZZX1463 2 19950221 G 7322 30766 FLOAT FACET MA3A CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CARBURETOR FILLED B EBVR K NONE K FLUID LOSS IN INSP/MAINT 1 GL 09 6449M 2888 CR27388 15284733 NOTED FUEL DRIPPING FROM COWL. UNCOWLED AND FOUND FUEL LEAKING FROM CARBURETOR ENGINE RAN ROUGH AT LOW SPEEDS. PULLED CARBURETOR AND FOUND FLOAT FULL OF FUEL. REPLACED WITH NEW. HAD METAL FLOAT REPLACED 10-12-89 UNDER PRECISION SERVICE BULLETIN MSA-1. 1 H 7 1 3O 3 O NT 3A19 E223 1995033100596 19950331 00596 SO 1995 3 31 95ZZZX1465 2 19950321 G 8530 646255 PISTON CESSNA 172 172F 2072414 CE CONT O300 O300D 17022 SO NR 3 CYLINDER CRACKED C P K NONE O OTHER IN INSP/MAINT 1 SW 99 8677U 17252580 29549D4D PISTON CRACKED ON NR 3 CYL. TOTAL TIME SINCE O/H MAJOR, 48 HOURS. CRACK WAS FROM LOWER OIL RING GROOVE UPWARD APPROX 1 .5 INCHES. CYLINDER AND ALL COMPONENTS CHECK OUT GOOD. ALL SPECS CHECK GOOD. TELEDYNE CONTINENTAL INSPECTED AND STATE D THE FAILED PISTON WAS DUE TO BEING ASSEMBLED INCORRECTLY NOT MANUFACTURING. THIS DIAGNOSIS IS IN DISAGREEMENT BY THE A & P TECH., THE SAFETY OFFICER AND OWNER. 1 H 7 1 3O 3 O NT 3A12 E253 1995033100597 19950331 00597 SO 1995 3 31 95ZZZX1466 1 19950210 G 8120 TURBOCHARGER PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO LT TURBO MOUNT BOLTS MISSING B EBVR K NONE O OTHER IN INSP/MAINT 1 GL 09 4378S 1561 468508009 273622R DURING REPAIR OF PILOT COMPLAINT ON CHT SYSTEM, NOTED AND REPAIRED: LT TURBO MOUNT BOLTS MISSING. 1 L 7 1 3O 3 O A25SO E8CE 1995033100598 19950331 00598 SO 1995 3 31 95ZZZX1467 1 19950210 G 8120 TURBOCHARGER PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO RT TURBO MOUNT INCORRECT BOLTS B EBVR K NONE O OTHER IN INSP/MAINT 1 GL 09 4378S 1561 468508009 273622R DURING REPAIR OF PILOT COMPLAINT ON CHT SYSTEM, NOTED AND REPAIRED: INCORRECT MOUNT BOLTS IN RT TURBO. 1 L 7 1 3O 3 O A25SO E8CE 1995040700208 19950407 00208 SO 1995 4 7 95ZZZX1601 2 19950321 G 8520 CONNECT ROD PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360FB 17025 SO NR 3-4 FAILED G K NONE E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 WP 23 2443M 1328 28R7803128 THIS ENGINE, CONVERTED FROM A TSIO-360-GB, HAD NR 3 AND NR 4 CONNECTING RODS FAIL AT THE SAME TIME KNOCKING A HOLE IN TH E UPPER CASE AREA OF ABOUT 8 INCHES DIAMETER. TELEDYNE-CONTINENTAL SB M86-11 R1 PERTAINS TO THIS SUB JECT. 1 L 7 1 3O 3 O 2A13 E9CE 1995040700209 19950407 00209 EA 1995 4 7 95ZZZX1603 2 19950321 G 8520 CRANKCASE PIPER PA23 PA23250 7102308 SO LYC O540 O540B1B5 41532 EA LT ENGINE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 23 4529P 2500 2733 L110440 CRANKCASES FOUND CRACKED AND FRETTING AROUND MAIN BEARING SUPPORT STRUCTURE IN THE AREA OF THE CRACKED CRANKSHAFTS. 1 L 7 2 3O 3 O 1A10 E295 1995040700210 19950407 00210 EA 1995 4 7 95ZZZX1604 2 19950321 G 8520 CRANKCASE PIPER PA23 PA23250 7102308 SO LYC O540 O540B1B5 41532 EA RT ENGINE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 23 4529P 2500 2733 L128540 CRANKCASES FOUND CRACKED AND FRETTING AROUND MAIN BEARING SUPPORT STRUCTURE IN THE AREA OF THE CRACKED CRANKSHAFTS. 1 L 7 2 3O 3 O 1A10 E295 1995040700331 19950407 00331 NE 1995 4 7 HEEA954647 2 19950328 G 7323 25249994 GOVERNOR SHAFT BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE FREE TURBINE BINDING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3911L 33023 FREE TURBINE GOV THROTTLE SHAFT BINDING. 1 G 7 2 4U 4 U H4SW E22EA 1995040700613 19950407 00613 NE 1995 4 7 95ZZZX1682 2 19950303 G 7210 7895922 BOWED TAB WASHER 7758001 SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE GC 49 GEARCASE BROKEN B SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 16437 UDAC0185 GEE367286 GEARBOX WAS RETURNED FOR 'METAL CONTAMINATION'. AFTER TEAR DOWN OF GEARBOX, NOTICED TABS WERE BROKEN OFF TAB WASHER (IT EM 20A OF SEI 663) AND RETAINING NUT (ITEM 25 OF SEI 663) WAS BACKED OFF THREAD ON PROP SHAFT (ITEM 80 OF SEI 663). NOT E: NO OTHER DAMAGE SEEN. REF: CMM 72-11-02. 2 L 7 2 4T 4 T RT A52EU E8NE6 1995040700614 19950407 00614 EA 1995 4 7 95ZZZX1683 2 19950323 G 7230 COMPRESSOR BEECH 90 B90 1152912 CE PWA PT6 PT6A20 52043 EA FIRST STAGE FOD DAMAGE G A UNSCHED LANDING A J FLAME/FIRE WARNING INDICATION CR CRUISE 1 GL 05 939K 5092 1603 LJ349 PCE21635 MGY - EN ROUTE, RT ENGINE FUEL FLOW FLUCTUATED AND FLAMES WERE OBSERVED OUT OF EXHAUST. FLIGHT DIVERTED TO DAY WHERE IN SPECTION SHOWED FOD TO FIRST STAGE COMPRESSOR. ENGINE REMOVED FOR INSPECTION AND REPAIR FOLLOW-UP. 1 L 7 2 3T 3 T 3A20 E4EA 1995040700738 19950407 00738 EA 1995 4 7 95ZZZX1702 2 19950310 G 8530 SL74230 GUIDE LW12419 SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA LOWER PORTION CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 140ER 1529 DURING CYLINDER OVERHAUL, THE EXHAUST VALVE GUIDE WAS FOUND CRACKED IN THE LOWER PORTION. 1 L 7 1 3O 3 O NT AS1EU E274 1995040700739 19950407 00739 EA 1995 4 7 95ZZZX1703 2 19950310 G 8530 74230 GUIDE LW12416 SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA LOWER PORTION CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 140ER 1757 1529 DURING CYLINDER OVERHAUL, THE EXHAUST VALVE GUIDE WAS FOUND CRACKED IN THE LOWER PORTION. 1 L 7 1 3O 3 O NT AS1EU E274 1995040700740 19950407 00740 EA 1995 4 7 95ZZZX1704 2 19950310 G 8530 74230 GUIDE LW12419 SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA LOWER PORTION CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 117ER 1763 1509 DURING CYLINDER OVERHAUL, THE EXHAUST VALVE GUIDE WAS FOUND CRACKED IN THE LOWER PORTION. 1 L 7 1 3O 3 O NT AS1EU E274 1995040700741 19950407 00741 EA 1995 4 7 95ZZZX1705 2 19950308 G 8530 74230 GUIDE LW12416 SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA LOWER PORTION CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 137ER 1665 1527 DURING CYLINDER OVERHAUL, THE EXHAUST VALVE GUIDE WAS FOUND CRACKED IN THE LOWER PORTION. 1 L 7 1 3O 3 O NT AS1EU E274 1995040700742 19950407 00742 EA 1995 4 7 95ZZZX1706 2 19950310 G 8530 74230 GUIDE LW12416 SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA LOWER PART CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 130ER 1568 1511 DURING CYLINDER OVERHAUL, EXHAUST VALVE GUIDE WAS FOUND CRACKED IN THE LOWER PORTION. 1 L 7 1 3O 3 O NT AS1EU E274 1995040700746 19950407 00746 EA 1995 4 7 95ZZZX1710 2 19950308 G 7414 10400006 IDENT PLATE D4LN3000 MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA MAGNETO DAMAGED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 194ER 1500 J049108G 243255 ALUMINUM FOIL IDENTIFICATION PLATE FOUND TORN WHEN MAGNETO WAS RECEIVED FOR REPAIR. CORRECTIVE ACTION WAS TO INSTALL A NEW, PN 10-400006, IDENTIFICATION PLATE. IT IS EXPECTED THE NEW IDENTIFICATION PLATE WILL EXPERIENCE THE SAME CONDITION THAT LED TO DAMAGE OF THE PREVIOUSLY INSTALLED IDENTIFICATION PLATE. RECOMMEND A METAL DATA PLATE BE PERMANENTLY ATTAC HED TO MAGNETO. 1 L 7 1 3O 3 O 2A3 1E10 1995040700747 19950407 00747 GL 1995 4 7 95ZZZX1711 2 19950313 G 7261 23006661 BODY ALLSN 501D 501D13 03004 GL PUMP GEAR POCKET DEBONDED B WS2R K NONE O OTHER IN INSP/MAINT 1 WP 01 OIL PUMP REPAIR MATERIAL DEBONDING. APPROXIMATELY .50 SQUARE INCH OF MATERIAL HAS LIFTED AWAY FROM GEAR POCKET WALL. S URROUNDING MATERIAL SHOWS EVIDENCE OF GENERAL DEBONDING. BODY IDENTIFIED WITH 'IAR 7148'. 4 T E282 1995040700748 19950407 00748 NE 1995 4 7 95ZZZX1712 2 19950310 G 7314 2113045 HOUSING PWA JT9 JT9* 52054 NE PUMP GEAR POCKET DEBONDED B WS2R K NONE O OTHER IN INSP/MAINT 1 WP 01 FUEL PUMP DEBONDING OF GEAR POCKET REPAIR MATERIAL APPROXIMATELY 50 PERCENT OF REPAIR MATERIAL IS MISSING FROM GEAR POCK ET WALLS. REMAINDER IS FLAKING OFF. HOUSING IDENTIFIED WITH 'IAR 9931D'. 4 F E20EA 1995041400080 19950414 00080 GL 1995 4 14 HEEA954669 2 19950404 G 7230 23008090 GEARSHAFT 23005290 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL SPUR ADAPTER STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3122H 678 CAC90180 760233 CAE890176S ENGINE REMOVED DUE TO CYCLED 1ST AND 2ND STAGE WHEELS. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP W EAR BEYOND SPECS ON SPUR ADAPTER GEARSHAFT FWD AND AFT SPLINES AND STEP WEAR ON INTERNAL SPLINES OF SPLINE ADAPTER BEYON D SPECS. INSTALLED NEW SPUR ADAPTER GEARSHAFT AND SPLINE ADAPTER. SEE MMIR #4670 FOR SPLINE ADAPTER INFORMAITON. 1 G 7 2 3U 3 U H1NE E1GL 1995041400081 19950414 00081 GL 1995 4 14 HEEA954670 2 19950404 G 7230 230052711 SPLINE ADAPTER 23005290 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL COMPRESSOR WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3122H 678 CAC90180 760233 CAE890176S ENGINE REMOVED DUE TO CYCLED 1ST AND 2ND STAGE WHEELS. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP W EAR BEYOND SPECS ON SPUR ADAPTER GEARSHAFT FWD AND AFT SPLINES AND STEP WEAR ON INTERNAL SPLINES OF SPLINE ADAPTER BEYON D SPECS. INSTALLED NEW SPUR ADAPTER GEARSHAFT AND SPLINE ADAPTER. SEE MMIR #4669 FOR SPUR ADAPTER GEARSHAFT INFORMATI ON. 1 G 7 2 3U 3 U H1NE E1GL 1995041400082 19950414 00082 GL 1995 4 14 HEEA954671 2 19950404 G 7250 23032345 N1 COUPLING 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL TURBINE STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3122H 678 CAT90574 760233 CAE890176S ENGINE REMOVED DUE TO CYCLED 1ST AND 2ND STAGE WHEELS. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: FWD AND A FT SPLINE STEP WEAR BEYOND LIMITS ON N1 COUPLING. INSTALLED NEW COUPLING. 1 G 7 2 3U 3 U H1NE E1GL 1995041400084 19950414 00084 NE 1995 4 14 HEEA954673 2 19950404 G 7421 9560147770 IGNITOR SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1C 60030 NE ENG LT DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6095S 615 2777 DURING ROUTINE INSPECTION NOTED LH IGNITER DID NOT FIRE. 1 G 7 1 3U 3 U H9EU E19EU 1995041400101 19950414 00101 GL 1995 4 14 HEEA954692 2 19950406 G 7210 6876925 TUBE ASSY. 23001938 AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20B 03013 GL GR BOX DEFECTIVE E HEEA K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 57906 8674 CAG40092 5107 CAE840091 ENGINE WAS REMOVED DUE TO OIL LEAK AT AFT T/M BUSHING. UPON INSPECTION OF GEARBOX PARTS NOTED THE FOLLOWING: OIL TRANS FER TUBE FAILED DIMENSIONAL CHECK IN ACCORDANCE WITH CEB 1307. INSTALLED NEW TUBE ASSEMBLY. 1 G 7 2 3U 3 U H11EU E4CE 1995041400107 19950414 00107 GL 1995 4 14 HEEA954703 2 19950407 G 7210 23056128 GEARSHAFT 23001938 AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL ENG GR BOX SPALLED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5796T 361 CAG40449 5166 CAE840100 ENGINE REMOVED DUE TO MAIN ENGINE DRIVESHAFT FAILURE. UPON INSPECTION OF GEARBOX PARTS NOTED THE FOLLOWING: SPALLING O N GEAR TEETH OF BOTH GEARSHAFTS. INSTALLED NEW GEARSHAFT. SEE MMIR #4704 FOR OTHER GEARSHAFT INFORMATION. 1 G 7 2 3U 3 U H11EU E4CE 1995041400108 19950414 00108 GL 1995 4 14 HEEA954704 2 19950407 G 7210 6896437 GEARSHAFT 23001938 AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL ENG GR BOX SPALLED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5796T 361 CAG40449 5166 CAE840100 ENGINE REMOVED DUE TO MAIN ENGINE DRIVESHAFT FAILURE. UPON INSPECTION OF GEARBOX PARTS NOTED THE FOLLOWING: SPALLING O N GEARTEETH OF BOTH GEARSHAFTS. INSTALLED NEW GEARSHAFT. SEE MMIR #4703 FOR OTHER GEARSHAFT INFORMATION. 1 G 7 2 3U 3 U H11EU E4CE 1995041400387 19950414 00387 EA 1995 4 14 95ZZZX1733 2 19950303 G 7414 104001678 IMPULSE COUPLING BENDIX S6LN1227 PIPER PA25 PA25260 7102508 SO LYC O540 O540G1A5 41532 EA LT MAG WORN D K NONE O OTHER IN INSP/MAINT 1 CE 07 9785P 401 0127691 257556096 MAG INSPECTION FOUND FLYWEIGHT TO AXLE CLEARANCE BEYOND LIMITS. 1 L 7 1 3O 3 O 2A10 E295 1995041400390 19950414 00390 SO 1995 4 14 95ZZZX1736 2 19950213 G 8530 SA632932 PISTON CESSNA 182 182C 2072708 CE CONT O470 O470L 17026 SO NR 3 CYLINDER FAILED D K NONE O OTHER NR NOT REPORTED 1 CE 07 856ST 868 52465 80505964 PISTON WAS COMPLETELY DISINTEGRATING. ALL VALVES AND OTHER ENGINE PARTS COMPLETE AND ACCOUNTED FOR. SUSPECT CAUSE WAS METAL WAS TOO BRITTLE. PISTON PIN WAS IN ROD AND MOVING AROUND IN CYLINDER. 1 H 7 1 3O 3 O NT 3A13 E273 1995041400405 19950414 00405 EA 1995 4 14 95ZZZX1751 2 19950301 G 7200 ENGINE PWA PT6 PT6* 52043 EA MAINT PART HARD O-RING D K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 07 DURING MAINTENANCE ON A PT6 ENGINE, FOUND A NEW O-RING PN MS9388115 CAME OUT OF PACKAGING UNUSEABLE DUE TO VERY HARD CON DITION. O-RING PURCHASED FROM AVIALL ABOUT JUNE, 1994. 3 T E2NE 1995041400514 19950414 00514 EA 1995 4 14 95ZZZX1775 2 19950321 G 8530 SL134441 PIN LYC O540 IO540K1F5 41532 EA PISTON FAILED D S K NONE O OTHER IN INSP/MAINT 1 GL 07 178 L1572548A FOUND PISTON PIN BROKEN DURING ROUTINE TEAR DOWN FOR OVERHAUL. 3 O 1E4 1995041400520 19950414 00520 EA 1995 4 14 95ZZZX1781 2 19950329 G 8530 LW13870 CYLINDER LYC O540 O540F1B5 41532 EA NR 6 CYLINDER MISMANUFACTURED B YV3R K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 05 L2485640A CYLINDER NR 6 ON A NEW PRODUCTION ENGINE HAS THE CYLINDER HEAD ORIENTED 2 DEGREES CCW RELATIVE TO THE BASE AND THE OTHER CYLINDERS. THIS PUTS THE EXHAUST FLANGE SURFACE OUT OF ALIGNMENT WITH THE OTHER CYLINDERS AND THE PUSH ROD HOUSINGS AR E ASKEWED ACCORDINGLY. 3 O E295 1995041400529 19950414 00529 SO 1995 4 14 95ZZZX1790 2 19950224 G 7322 63255531 LEVER 632840A1 CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO THROTTLE BODY BROKEN D P A O OTHER R PARTIAL RPM/PWR LOSS DE DESCENT 1 CE 07 5313U 913 21064862 522546 THROTTLE CONTROL FAILED AFTER POWER REDUCTION FOR DESCENT INTO MEM. ENGINE POWER REMAINED AT APPROXIMATELY 24 INCHES M. P. AIRCRAFT SUCCESSFULLY LANDED WITH MIXTURE CONTROL. FOUND THROTTLE LEVER BROKEN AT BASE OF ARM AND REAR ALTERNATOR BELT BROKEN. CAUSE OF BREAKAGE UNDETERMINED, THROTTLE CONTROL ATTACHMENT AND ALTERNATOR BELT CONDITION WERE KNOWN TO BE CHECKED AT 50-HOUR INSPECTION JUST PRIOR TO INCIDENT AND FOUND SATISFACTORY. FORWARDED INFORMATION ON INCIDENT TO CESS NA AN TCM PRODUCT SAFETY. 1 H 7 1 3O 3 O 3A21 E8CE 1995041400537 19950414 00537 SO 1995 4 14 95ZZZX1798 2 19950325 G 8530 630626 BALANCE TUBE CESSNA 182 182 2072702 CE CONT O470 O470R 17026 SO CYL INTAKE DISCONNECTED B SH5R O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 NE 03 92680 18260308 238098H PILOT REPORTED ROUGH ENGINE IN-FLIGHT AND WOULD NOT IDLE ON GROUND. FOUND BALANCE TUBE ASSY DISCONNECTED FROM RT SIDE A ND BOTH ENDS BROKEN OFF. TACH TIME 8418.1. 1 H 7 1 3O 3 O NT 3A13 E273 1995041400538 19950414 00538 EA 1995 4 14 95ZZZX1799 2 19950325 G 8520 CYLINDER PIPER PA60 PA60602P 7106015 NM LYC O540 IO540S1A5 41532 EA RT ENG NR 4 BASE NUT FAILED D E A ENGINE SHUTDOWN UNSCHED LANDING J R WARNING INDICATION PARTIAL RPM/PWR LOSS CL CLIMB 1 WP 23 6902T 1893 350 608265046 ON TAKEOFF, RT ENGINE FIRE LIGHT, LOSS OF POWER. PILOT SHUT DOWN, RETURNED TO AIRPORT. FOUND NR 4 CYLINDER HELD ON BY ONE BASE NUT. EXAMINED CYLINDER/PISTON, FOUND NO DISCREPANCIES. SUSPECT NUTS OVER/UNDERTORQUED. 1 M 7 2 3O 3 O RT A17WE 1E4 1995041400541 19950414 00541 EA 1995 4 14 95ZZZX1802 2 19950330 G 8530 74230 GUIDE PIPER PA28 PA28161 7102803 SO LYC O320 O320D2A 41508 EA EXH VALVE CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 167ER 398 LW12419 2841183 DURING CYLINDER OVERHAUL, EXHAUST VALVE GUIDE FOUND CRACKED AT THE LOWER END OF THE GUIDE. THE CRACK WAS ORIENTED IN TH E SAME PLACE AS THE ROCKER ARM. 1 L 7 1 3O 3 O 2A13 E274 1995041400542 19950414 00542 1995 4 14 95ZZZX1803 1 19950216 G 7600 310047503 CONTROL ASSY PWA PT6 PT6A65B 52043 EA ENGINE DEFECTIVE B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 CONTROL ASSY DEFECTIVE. 4 T E4EA 1995041400543 19950414 00543 EA 1995 4 14 95ZZZX1804 2 19950216 G 7250 3029885 NUT PWA PT6 PT6A65B 52043 EA POWER SECT DAMAGED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 NEWLY OVERHAULED PART RECEIVED FROM TURBINE PARTS THAT HAS THREAD DAMAGE AND HEAVY CORROSION. RECEIVED UNDER P.O. NR 95 0207023. 4 T E4EA 1995042100097 19950421 00097 EA 1995 4 21 95ZZZX1811 2 19950119 G 7210 310164701 BEARING BEECH 1900 1900D 1154162 CE PWA PT6 PT6A65B 52043 EA NR 6 SPALLED B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 35YV 5412 64D513 UE35 114073 THE NR 6 BEARING WAS FOUND WITH SPALLING ON ONE INNER RACE HALF AND SEVERAL OF THE BEARING BALLS. SUBMITTER BELIEVES TH E SPALLING TO BE INTRODUCED BY THE STATIC PROBLEMS THAT ARE KNOWN TO BE ASSOCIATED WITH THE PROPELLER SYSTEM. 2 L 7 2 4T 4 T RT A24CE E4EA 1995042100100 19950421 00100 EA 1995 4 21 95ZZZX1814 2 19950102 G 7532 311271401 VALVE ASSY BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA GAS GEN FRETTED B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 76YV 5R106 UC76 32488 SUSPECT CAUSE OF FAILURE IS A FAULTY BLEED VALVE. THE DEFINITE CAUSE IS STILL UNDER INVESTIGATION. 2 L 7 2 4T 4 T RT A24CE E4EA 1995042100101 19950421 00101 EA 1995 4 21 95ZZZX1815 2 19950112 G 7230 310920901 BEARING BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA GAS GEN COMP FRACTURED B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 118YV 2353 FC12409 UC118 32027 THE PRELIMINARY INVESTIGATION IS INDICATING THE NR 1 BEARING FAILED. 2 L 7 2 4T 4 T RT A24CE E4EA 1995042100119 19950421 00119 1995 4 21 95ZZZX1833 1 19950315 G 6120 3031844 CASING ASSY PWA PT6 PT6A65B 52043 EA PROP CONTROL DENTED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 PART WAS RECEIVED FROM VENDOR (TURBINE PARTS) AND FOUND DENTED BEYOND SERVICEABLE LIMITS. 4 T E4EA 1995042100120 19950421 00120 EA 1995 4 21 95ZZZX1834 2 19950308 G 7260 3012124 HOUSING PWA PT6 PT6A65B 52043 EA ASSORY GEARBOX MISMANUFACTURED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 2390 PART RECEIVED FROM STOCK. WHEN HOUSING ASSEMBLED IN THE AGB, GEARS WOULD NOT ROTATE. FURTHER INVESTIGATION REVEALED TH E GEARS' PARTS WORKED PROPERLY WHEN INSTALLED IN ANOTHER HOUSING ASSY. 4 T E4EA 1995042100121 19950421 00121 EA 1995 4 21 95ZZZX1835 2 19950308 G 7260 3008360 DRIVE GEAR PWA PT6 PT6A65B 52043 EA ASSORY GEARBOX CORRODED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 RECEIVED PART FROM STOCK. PLASTIC BEAD FOUND PACKED INTO GEAR END OF SHAFT. INNER LUG FOUND CORRODED AND PITTED. 4 T E4EA 1995042100122 19950421 00122 EA 1995 4 21 95ZZZX1836 2 19950327 G 7532 310687301 PISTON PWA PT6 PT6A65B 52043 EA BLEED VALVE DAMAGED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 THE PISTON RECEIVED FROM PARTS ROOM AND FOUND DAMAGED. UNABLE TO INSTALL PISTON RINGS BECAUSE OF THE BENT RING GROOVE. 4 T E4EA 1995042100123 19950421 00123 EA 1995 4 21 95ZZZX1837 2 19950308 G 7210 310236001 RING GEAR PWA PT6 PT6A65B 52043 EA POWER SECTION TEETH NICKED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 44A697 PART RECEIVED FROM VENDOR WITH GEAR TEETH NICKED. RETURNED TO VENDOR AS UNACCEPTABLE. 4 T E4EA 1995042100124 19950421 00124 EA 1995 4 21 95ZZZX1838 2 19950308 G 7260 3008785 GEAR PWA PT6 PT6A65B 52043 EA ASSORY GEARBOX PITTED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 PART RECEIVED FROM VENDOR FOUND CORRODED AND PITTED. RETURN TO VENDOR AS UNACCEPTABLE FOR USE. 4 T E4EA 1995042100126 19950421 00126 EA 1995 4 21 95ZZZX1840 2 19950301 G 7210 310236001 RING GEAR PWA PT6 PT6A65B 52043 EA POWER SECTION DAMAGED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 36B504 RECEIVED PART FROM VENDOR THAT HAS DAMAGE ON GEAR TEETH. 4 T E4EA 1995042100127 19950421 00127 EA 1995 4 21 95ZZZX1841 2 19950222 G 7260 3017609 GEARSHAFT PWA PT6 PT6A65B 52043 EA STARTER DRIVE DAMAGED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 RECEIVING INSPECTION OF PART REVEALED DAMAGE TO SNAP-RING GROOVE, DRIVE AND SEAL END OF SHAFT AND GEAR FACE-PLATE. 4 T E4EA 1995042100128 19950421 00128 EA 1995 4 21 95ZZZX1842 2 19950327 G 7250 3043061 VANE RING PWA PT6 PT6A65B 52043 EA HOT SECTION DENTED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 7L779 THE VANE RING RECEIVED FROM THE PARTS ROOM AND FOUND DENTED AT THE OUTBOARD EXIT FLANGE. 4 T E4EA 1995042100133 19950421 00133 NE 1995 4 21 95ZZZX1847 2 19950317 G 7250 BLADE GE CJ610 CJ6106 30006 NE TURB 1ST STAGE BOWED B IY2R K NONE O OTHER IN INSP/MAINT 1 SW 15 251562A STAGE 1 TURBINE BLADES ARE BOWED OUT OF LIMITS. TIME ON THE BLADES IS UNKNOWN. THE BLADES ARE MARKED WITH 'BK' WHICH S HOULD IDENTIFY THE PART NUMBER. HOWEVER, 'BK' IS NOT RECOGNIZED BY GENERAL ELECTRIC. 4 J 1E16 1995042100134 19950421 00134 NE 1995 4 21 95ZZZX1848 2 19950317 G 7230 6002T57P05 BLUCKET 6028T47P01 GE CF700 CF7002D2 30010 NE FAN ROTOR CRACKED B IY2R K NONE O OTHER IN INSP/MAINT 1 SW 15 2945 7689FT 304572B DURING EDDY CURRENT INSPECTION OF THE FAN BLUCKETS REQUIRED AS PART OF THE HOT SECTION INSPECTION, FOUND ONE FAN BLUCKET WITH A MINUTE CRACK ON THE LEADING EDGE IN THE HOT SECTION PORTION OF THE BLUCKET. 4 F E7EA 1995042100486 19950421 00486 SO 1995 4 21 95ZZZX1878 2 19950328 G 8520 CRANKCASE CONT O520 TSIO520WB 17040 SO BEARING BORE DEFECTIVE B CYKR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 07 518882 IN COMPLYING WITH SB M92-09 DURING ASSEMBLY USING NEW 12-POINT NUT PN 652541 AND TORQUE OF 790-810 INCHES/POUNDS, ENGINE FAILED TO TURN WHEN FULL TORQUE WAS REACHED. UPON DISASSEMBLY, MAIN BEARING BORES WERE FOUND OUT OF ROUND. SUSPECT 'S OFT' CRANKCASE. 3 O E8CE 1995042100498 19950421 00498 EA 1995 4 21 95ZZZX1890 2 19950404 G 8530 AL16740 VALVE LYC O360 IO360C1C6 41514 EA ENGINE EXHAUST WORN B YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 160 RL1811351A ONE CYLINDER WAS REMOVED FOR LOW COMPRESSION. INSPECTION REVEALED THE EXHAUST VALVE BADLY WORN IN THE VALVE KEEPER AREA . STEM DIAMETER WAS WORN FROM .336 INCH TO ,280 INCH. THE OTHER 3 CYLINDERS WERE INSPECTED AND FOUND TO HAVE WORN VALV ES AS WELL. NO SIGNS OF IMPROPER ASSEMBLY WERE FOUND. THE VALVE HAS BEEN RETURNED TO AIRCRAFT TECHNOLOGY CORP. FOR ANA LYSIS. SUSPECT THE VALVES MAY NOT HAVE BEEN PROPERLY HARDENED. 3 O 1E10 1995042100510 19950421 00510 EA 1995 4 21 95ZZZX1899 2 19950405 G 7414 COIL SLICK 4271 CESSNA 177 177 2073704 CE LYC O320 O320E2D 41508 EA MAGNETO CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 11 29406 180 89080358 17700866 L2123927A THE MAGNETO COIL CRACKED CAUSING MAG TO FAIL. THIS REPORT IS IN CONJUNCTION WITH AN ADDITIONAL REPORT ON THE SAME AIRPL ANE AT THE SAME TIME A DUAL MAG FAILURE OCCURRED ON LANDING ROLL OUT. INSPECTIONS ON THE NAGNETOS DO NOT REQUIRE REMOVA L OF COIL TO SATISFY INPSECTION, BUT IT WOULD BE HIGHLY RECOMMENDABLE TO DO SO. SHOP HAS NOW FOUND 4 CRACKED SLICK COIL S. 1 H 7 1 3O 3 O NT A13CE E274 1995042100514 19950421 00514 SO 1995 4 21 95ZZZX1903 2 19950301 G 7322 NOZZLE FACET MA3SPA CESSNA 150 150J 2071820 CE CONT O200 O200A 17020 SO CARB DISCHARGE NOT COMPATIBLE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 61184 BE2420609 15020869 251274A48 ONE-PIECE VENTURI, NOT COMPATIBLE WITH ORIGINAL DISCHARGE NOZZLE. SHOULD BE MANDATORY TO CHANGE DISCHARGE NOZZLE AT THE TIME OF ONE-PIECE VENTURI IS INSTALLED. OLD NOZZLE NOT COMPATIBLE WITH NEW VENTURI. 1 H 7 1 3O 3 O 3A19 E252 1995042100522 19950421 00522 GL 1995 4 21 95ZZZX1912 2 19950130 G 7230 BLADE GOVT N22 N22S 3880103 WP ALLSN 250B 250B17 03012 GL COMPRESSOR SEPARATED D K NONE O OTHER IN INSP/MAINT 1 EA 27 6305U N22S160 CAE880492 AFTER REGULAR DAILY RUN AND COMPRESSOR RINSE, AIRCRAFT SHUT DOWN WITH NO PROBLEMS. FOUND AFTER SHUT DOWN, COMPRESSOR BL ADES (STATIONARY) HAD SEPARATED FROM CASE AND FROZE COMPRESSOR. 1 H 7 2 3T 3 T RT A7PC E10CE 1995042800197 19950428 00197 EA 1995 4 28 95ZZZX1974 2 19950328 G 8550 LW15550 GEROTOR PIPER PA23 PA23250 7102308 SO LYC O540 TIO540C1A 41532 EA TURBO SCAVANGE SEIZED H K NONE O OTHER IN INSP/MAINT 1 EA 05 54748 6 277554062 L364561A TURBO SCAVANGE PUMP FAILED. APPEARS THAT THE ROTOR CRACKED WHICH, IN TURN, SHEARED AN ANTI-ROTATION PIN IN THE PUMP HOU SING IN WHICH THE GEROTOR TURNS. THE HOUSINGS WERE DAMAGED BY THIS PUMP HOUSING SPINNING, THE TURBO WAS NOT SCAVANGED W ITH OIL LEADING TO THE LOSS OVERBOARD OF THE ENGINE OIL. 1 L 7 2 3O 3 O 1A10 E14EA 1995042800209 19950428 00209 NE 1995 4 28 95ZZZX1986 2 19950328 G 7320 800816 CASE PWA JT8 JT8D219 52053 NE 8TH STAGE STATOR CRACKED B P SQ5R K NONE O OTHER IN INSP/MAINT 1 NE 03 TF6682 718144 EIGHTH STAGE STATOR SUPPORT SHELF CRACKED. CRACK APPEARS TO HAVE STARTED AT A SLOT. CRACK CAUSED SOME LIBERATION OF MA TERIAL. FOR SUSPECT CAUSE SEE SB 6117. CASE WAS REMOVED AND IS IN THE PROCESS OF HAVING SB 6117 INCORPORATED. 4 F E9NE 1995042800214 19950428 00214 NE 1995 4 28 95ZZZX1991 2 19950309 G 7321 78360014068 EEC HAMSTD BOEING 757 757222 1384956 NM PWA 2037 PW2037 NE SOLDER JOINTS DEFECTIVE B OHER K NONE O OTHER IN INSP/MAINT 1 NE 03 560UA 16340 20370410 26660 EEC EXHIBITS FRACTURED SOLDER JOINTS: CHAN 'A' PROCESSOR BD. LOCATION U427, PIN NR 15 (UVPROM) BD ASSY 781336-9-068, S N 89011490. CHAN 'B' PROCESSOR BD. LOCATION U427, PIN NR 14 (UVPROM) BD ASSY 781338-9-068, SN 89012339. CAUSE OF FRAC TURING IS UNKNOWN AT THIS TIME. SUSPECT OXIDIZED CHIP LEADS. 2 L 7 2 4F 4 F RT A2NM E17NE 1995042800215 19950428 00215 WP 1995 4 28 95ZZZX1992 2 19950405 G 7250 31038391 SEAL 31070852 GARRTT TPE331 TPE33112UAR 01514 WP 1ST STAGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 6751 0233151120 P70059 DURING CAM INSPECTION, FOUND SEAL CRACKED 3 PLACES. SB 72-0840 AUTHORIZES INSTALLATION OF THIS PART TO PROVIDE INCREASE D PRESSURE AGAINST 1ST STAGE ROTOR. THIS INCREASED PRESSURE RESULTS IN CRACKING OF THE SEAL EDGE DIAMETER. SUGGEST ALL IED SIGNAL ENGINEERING REVIEW PART/INSTALLATION PROBLEM. CSN, 9,014. 4 T E4WE 1995042800216 19950428 00216 NE 1995 4 28 95ZZZX1993 2 19950317 G 7250 634E583P3 WHEEL GE CJ610 CJ6106 30006 NE TURB 1ST STAGE BOGUS PART B L IY2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 251562A THIS WHEEL WAS FOUND IN A COMMERICAL ENGINE. THE PART NUMBER IS NOT RECOGNIZED BY GENERAL ELECTRIC. 4 J 1E16 1995042800217 19950428 00217 EA 1995 4 28 95ZZZX1994 2 19950406 G 7310 3032090 LINE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA PRIMARY FUEL CRACKED D C D ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 SO 11 119CJ UC19 32250 PRIMARY ENGINE FUEL LINE CRACKED AT FERRULE REINFORCEMENT RESULTNG IN LOSS OF SUFFICIENT FUEL PRESSURE TO MAKE REQUIRED POWER. TAKEOFF WAS ABORTED. SUSPECT CAUSED BY FATIGUE FROM ENVIRONMENT. 2 L 7 2 4T 4 T RT A24CE E4EA 1995042800618 19950428 00618 SO 1995 4 28 95ZZZX2054 2 19950303 G 7414 10357586 DISTRIBUTOR GEAR S6RSC25P PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO RT MAG WQORN B LF1R O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 07 121RF 500 4608034 273695R OWNER COMPLAINED OF ROUGHNESS IN FLIGHT. MIXTURE CHANGE OR FUEL PUMP OPERATION WOULD NOT AFFECT ENGINE. PERFORMED MAG NETO CHECK ON GROUND. FOUND RT MAGNETO WOULD NOT KEEP ENGINE RUNNING. REMOVED RT MAGNETO AND FOUND 10 TEETH MISSING FR OM DISTRIBUTOR GEAR. POSSIBLY CAUSED AN ENGINE BACKFIRE. GEAR SEEMED TO BE IN GOOD SHAPE. ROTOR GEAR IS METAL IN THES E MAGNETOS WHICH COULD CONTRIBUTE TO THIS PROBLEM. RECOMMEND 100 HOUR INSPECTIONS FOR THESE MAGNETOS. 1 L 7 1 3O 3 O A25SO E8CE 1995042800699 19950428 00699 EA 1995 4 28 95ZZZX2067 2 19950408 G 7310 LW102980134 LINE PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA NR 3 CYL NOZ BROKEN D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AL 01 31606 1394 327840137 L1586248A DURING FLIGHT, ENGINE BEGAN RUNNING VERY ROUGH. THE PILOT LANDED AT NEAREST AIRPORT. UPON INSPECTION, FOUND LINE GOING FROM THE SPIDER TO THE NR 3 CYLINDER FUEL NOZZLE HAD BROKEN. THIS BREAK OCCURRED UNDER THE B-NUT NEXT TO THE BALL AT T HE END OF THE LINE WHERE IT CONNECTS TO THE FUEL NOZZLE. THE NUT WAS TIGHT AND CONNECTED PROPERLY. FUEL LINE REPLACED WITH NEW. 1 L 7 1 3O 3 O A3SO 1E4 1995042800707 19950428 00707 NE 1995 4 28 95ZZZX2075 2 19950403 G 7310 216365003 MANIFOLD 216362035 BAG BAE146 BAE146200A 1500266 EU LYC ALF502 ALF502R 41580 NE NR 5-6 NOZ PORT LEAKS D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 13 8997 1110 227P MANIFOLD HAS LEAK IN SCALLOP AREA BETWEEN 5TH AND 6TH NOZZLES. A SB WAS ISSUED, ALF502R73-8, REQUIRING A ONE FPI OF ALL MANIFOLDS WITH P/N ENDING IN DASH 09 THROUGH DASH 34. WHEN COMPLETED, MANIFOLDS ARE REIDENTIFIED AS DASH 35 OR DASH 36 . FPI FOR ALL MANIFOLDS HAS SINCE BEEN INCORPORATED INTO THE REPAIR MANUAL AND IS REQUIRED AT EACH OVERHAUL. SUBMITTER SUGGESTS SHORTER TIME BETWEEN OVERHAUL/REPAIR OR THAT THESE PARTS BE LIFE-LIMITED. 2 H 7 4 4F 4 F RT A49EU E6NE 1995042800721 19950428 00721 GL 1995 4 28 95ZZZX2089 2 19950329 G 7321 953505120 SCREW BENDIX 23059790 BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL RETAINER PLATE FAILED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 358AL 1291 BR53561 51460 CAE895436 ON DAILY SERVICE CHECK, FOUND INBOARD SCREW WHICH SECURES BYPASS VALVE RETAINING PLATE TO THE FUEL CONTROL BODY WAS FOUN D WITH HEAD BROKEN OFF. CAUSE UNKNOWN. COMPLETE FUEL CONTROL WITH BROKEN SCREW WAS SENT TO ALLIED SIGNAL - BENDIX FOR EVALUATION. CEB'S 73-3061 REPLACEMENT OF THESE SCREWS AND LAPPING THE RETAINER PLATE HAS BEEN PREVIOUSLY COMPLIED WITH AS HAS CEB 78-A-3065 REPLACMENT OF RELIEF VALVE. 1 G 7 1 3U 3 U H2SW E1GL 1995050500126 19950505 00126 NE 1995 5 5 95ZZZX2098 2 19950407 G 7230 50H067 NUT PLATE PWA 4056 PW4056 NE STG 9-10 STATOR MISMANUFACTURED B TUVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 PURCHASED NUT PLATE ASSY HAS OVERALL LENGTH WHICH IS APROXIMATELY ONE INCH LONGER THAN A PN 50H067. IN ADDITION, NUT PA TTERN IS INCORRECT FOR PN 4000 9/10 STAGE COMPRESSOR STATOR. 4 F E24NE 1995050500139 19950505 00139 EA 1995 5 5 95ZZZX2111 2 19950410 G 8550 DRIVE COUPLING PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA ENG OIL SUMP BLOCK OIL GALLEY D K NONE O OTHER IN INSP/MAINT 1 NM 09 357DA 447995271 DURING COMPLETION OF AD 78-09-07 ON LT ENGINE AND WHILE INSTALLING LT MAG, RUBBER DRIVE COUPLING WAS DROPPED INTO ENGINE . WHEN SUMP DRAIN WAS REMOVED TO RETRIEVE COUPLING, TWO WERE FOUND NEAR THE QUICK DRAIN. ENGINE HAD A HISTORY OF LOW O IL PRESSURE ON OCCASIONS, BUT REASON HAD NOT BEEN FOUND. IT IS BELIEVED THE PREVIOUSLY LOST COUPLING WAS REASON FOR LOW OIL PRESSURES. 1 L 7 2 3O 3 O A19S0 E286 1995050500142 19950505 00142 CE 1995 5 5 95ZZZX2114 1 19950404 G 8120 4078109006 TURBOCHARGER GARRTT CESSNA 414 414 2075908 CE CONT O520 TSIO520BB 17040 SO RT ENGINE FAILED B EB1R E A ENGINE SHUTDOWN UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 13 99EF XI000097 414A0666 236935R AIRCRAFT EXPERIENCED LOSS OF POWER ON RIGHT ENGINE DURING FLIGHT. THE ENGINE WAS SHUT DOWN AND MADE AN EMERGENCY LANDIN G. INVESTIGATION REVEALED THE TURBOCHARGER UNIT HAD FAILED INTERNALLY. THE TURBOCHARGER WAS REPLACED AND ENGINE WAS GR OUND AND FLIGHT CHECKED SATISFACTORILY. 1 L 7 2 3O 3 O RT A7CE E8CE 1995050500146 19950505 00146 EA 1995 5 5 95ZZZX2118 2 19950412 G 8550 LW14888 SUMP ASSY PIPER PA44 PA44180 7104402 SO LYC O360 LO360E1A6 41514 EA INDUCTION DRAIN BOSS CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 05 3040A 447995093 L17672 DURING INSPECTION AT ENGINE OVERHAUL, BOTH INDUCTION DRAIN BOSSES ON OIL SUMPS WERE FOUND CRACKED. SUSPECT BOSSES CRACK ED FROM OVER TIGHTENING DRAIN VALVE ASSY, PN 24995-00. 1 L 7 2 3O 3 O A19S0 E286 1995050500231 19950505 00231 NE 1995 5 5 HEEA954876 2 19950425 G 7210 3024780 GEARBOX BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE COMBINING BOX MAKING METAL E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3911L 13832 33023 METAL IN OIL. 1 G 7 2 4U 4 U H4SW E22EA 1995050500244 19950505 00244 NE 1995 5 5 HEEA954889 2 19950425 G 7314 02527730007 FUEL PUMP BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE NR 1 ENG FAILED E HEEA O OTHER X ENGINE FLAMEOUT NR NOT REPORTED 1 SW 03 1079U 10278 31122 #1 ENGINE FLAMED OUT IN FLIGHT. FOUND FUEL PUMP DRIVE COUPLING FAILURE. MALE SPLINES ON DRIVE GEAR INSIDE PUMP WERE RO UNDED OFF. REPLACED FUEL PUMP AND RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 1995050500247 19950505 00247 GL 1995 5 5 HEEA954892 2 19950425 G 7250 6898911 WHEEL 23031925 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL 1ST STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1750 CAT90593 CAE890585 ENGINE REMOVED DUE TO TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: EXCESSIVE SULFIDATION AN D DELAMINATION ON ALL 1ST STAGE WHEEL BLADES CAUSING 10 EACH BLADE TIP FAILURES .062" CHORDALLY PROGRESSING .062"ACROSS TRAILING EDGE MAXIMUM. SCRAPPED 1ST STAGE WHEEL. 1 G 7 2 3U 3 U H1NE E1GL 1995050500314 19950505 00314 GL 1995 5 5 HEED9558 2 19950421 G 7320 222360703101 SOLENOID BELL 230 230 1182149 SW ALLSN 250C 250C30G2 03013 GL NR 1 ENG INOPERATIVE E HEED K NONE O OTHER IN INSP/MAINT 1 SW 03 236X 678 23015 NR 1 ENGINE FLIGHT IDLE SOLENOID INOPERATIVE. 1 G 7 2 3U 3 U NC H9SW E1GL 1995050500383 19950505 00383 SW 1995 5 5 95ZZZX2127 2 19950124 G 8530 RINGS CESSNA 195 195B 2073112 CE JACOBP R755 R755A2 35006 SW ENGINE EXCESS WORN D O OTHER A FLAME/FIRE IN INSP/MAINT 1 NM 08 2164C 16149 31151 DURING HOT ENGINE START, A CARBURETOR FIRE RESULTED. FIRE EXTINGUISHED USING DRY CHEM. ENGINE WASHED DOWN AND FLOWN. E XCESS OIL CONSUMPTION NOTED (1 GALLON PER HOUR). TEAR DOWN OF ENGINE REVEALED WORN PISTON RINGS AND GUMMED-UP INTAKE VA LVES PLUS GRIT IN OIL. SUBMITTER RECOMMENDS TO NOT USE DRY CHEMICAL ON ENGINE FIRES. 1 H 7 1 3R 3 R A790 TC237 1995050500403 19950505 00403 NE 1995 5 5 95ZZZX2147 1 19950324 G 7500 0301027300 P2 PIPE SKRSKY S76 S76A 8143006 NE TMECA ARRIEL ARRIEL1S 60030 NE FREE TURBINE CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 25 65MS 1503 760259 3516TEC DURING APPLICATION OF SB 292 75 0193, (TU 247 A), PN 9562810760 CLAMP WAS REMOVED. SERIOUS CORROSION WAS FOUND ON THE P 2 AIR PIPE WHERE THE CLAMP ATTACHES TO THE PIPE. THE PIPE SUPPLIES COMPRESSOR DISCHARGE AIR WHICH IS EXTERNALLY ROUTED TO THE FREE TURBINE BEARING LABYRINTH SEAL. FAILURE OF THIS TUBE WILL CAUSE AN ENGINE FAILURE, POSSIBLY CATASTROPHIC IN NATURE. THE SB INCORPORATES AN IMPROVED STAINLESS STEEL CLAMP WHICH SHOULD ELIMINATE THE CORROSION PROBLEM. THE PURPO SE FOR THE BULLETIN IS TO REDUCE MECHANICAL STRESSES AND INCREASE MECHANICAL RESISTANCE ON END OF THE PIPE, AS STATED BY THE MANUFACTURER. 1 G 7 2 3U 3 U H1NE E19EU 1995050500404 19950505 00404 GL 1995 5 5 95ZZZX2148 2 19950329 G 7323 23007506 GOVERNOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE MALFUNCTION B EOOR K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 AL 03 3115Y 24622 500716D CAE830750 PILOT COMPLAINED THE ENGINE DROOPED AT HIGH POWER. REMOVED AND REPLACED GOVERNOR, CURED THE PROBLEM. UNIT SENT IN FOR REPAIR ON ALLISON REPORT NR A 160111. 1 G 7 1 3U 3 U H3WE E4CE 1995050500410 19950505 00410 NE 1995 5 5 95ZZZX2154 2 19950124 G 7230 496706 DISK SKRSKY S64 S64A 8142504 NE PWA JFTD12 JFTD12A5A 52047 NE ENGINE PITTED D K NONE O OTHER IN INSP/MAINT 1 NM 09 1536 604 8V1080 496706 P AND W SB 1508, REQUIRES ALL ENGINES TO BE COMPLETELY DISASSEMBLED TO CONDUCT A CORROSION INSPECTION EVERY 7 YEARS. SE RIOUS CORROSION PITTING FOUND WHEN CONVERTING MILITARY T73-P-1 OR T73-P-700 ENGINES TO COML. USE. DISK FAILURE CAN OCCU R IF CORROSION INSPECTION NOT C/W. EXAMPLE SUBMITTED. 2 G 7 2 4U 4 U H1EA E15EA 1995050500412 19950505 00412 GL 1995 5 5 95ZZZX2156 2 19950315 G 7250 A6871505 BEARING C20B HILLER UH12 UH12E 4360122 WP ALLSN 250C 250C20B 03013 GL NR 5 FAILED B HDNR O OTHER J WARNING INDICATION NR NOT REPORTED 1 SW 03 114HA 265 CAT35461 HA3014 NR 5 BEARING FAILED AT THE BALLS RETAINER. CHIP LIGHT CAME ON IN-FLIGHT. NO CAUSE AT THE TIME. THIS PART IS A P.M.A. F.A.A. APPROVED. 1 G 7 1 3O 3 U 4H11 E4CE 1995050500422 19950505 00422 GL 1995 5 5 95ZZZX2166 2 19950417 G 7230 6890550 COMPRESSOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE STALLS B EOOR K NONE K FLUID LOSS IN INSP/MAINT 1 AL 03 3115Y 8437 2785 CAC31132 500116D CAE832750 COMPRESSOR STALLS WITH SMALL, BUT RAPID POWER CHANGES. UNIT SENT IN FOR REPAIR. 1 G 7 1 3U 3 U H3WE E4CE 1995050500425 19950505 00425 GL 1995 5 5 95ZZZX2169 2 19950407 G 7323 23007506 GOVERNOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 3115Y 711 500716D CAE830750 THE GOVERNOR WOULD NOT HOLD RPM WITH SLIGHT POWER CHANGES. THIS UNIT HAS BEEN SENT IN FOR REPAIR 2 TIMES BEFORE IN THE LAST 239.8 HOURS FOR THE SAME PROBLEM. SEE ALLISON 250 REPORT A160113. 1 G 7 1 3U 3 U H3WE E4CE 1995050500518 19950505 00518 EA 1995 5 5 95ZZZX2175 2 19950406 G 8530 CYLINDER DOUG DC3 DC3C 3021457 WP WRIGHT R1820 R182022 67020 EA ENG NR 1 CYL 6 FAILED H A E UNSCHED LANDING ENGINE SHUTDOWN E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 WP 13 99131 6128 1128 18949 73469 LEFT ENGINE RAN SLIGHTLY ROUGH AT CRUISE ALTITUDE (5,000 FEET). NOTED OIL LEAK AT NR 6 CYLINDER POSITION. FEATHERED LT ENGINE AND RETURNED TO HONOLULU. AFTER LANDING, FOUND NR 6 CYLINDER FAILURE. (METAL PARTICLES (ALUMINUM) FOUND IN OIL SCREEN. REMOVED ENGINE. NO RECOMMENDATIONS FOR THIS PROBLEM. 2 L 7 2 4R 4 R A669 TC154 1995050500519 19950505 00519 SO 1995 5 5 95ZZZX2176 2 19950414 G 8520 CYLINDER BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO CYLINDER BASE STUD SHEARED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 05 111AW 1637 TH841 561631 PILOT REPORTED OIL LEAK. UPON INSPECTION, 3 UPPER CYLINDER BASE STUDS FOUND SHEARED. REMOVED CYLINDER AND NOTICED CASE CRACKED AT LOWER RIGHT STUD. 1 L 7 2 3O 3 O 3A16 E5CE 1995050500525 19950505 00525 EA 1995 5 5 95ZZZX2182 2 19950224 G 8530 LW17540RW VALVE CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA NR 3 CYL EXH FAILED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 17 64373 1350 17265201 3794427A DURING FLIGHT, ENGINE STARTED RUNNING ROUGH, ENGINE FAILED ON LANDING. NR 3 CYLINDER VALVE EXHAUST FAILED. REPLACED/OV ERHAULED CYLINDER. AIRCRAFT RETURNED TO SERVICE. 1 H 7 1 3O 3 O NT 3A12 E274 1995050500526 19950505 00526 EA 1995 5 5 95ZZZX2183 2 19950412 G 8530 LW12416 CYLINDER PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA NR 2 CRACKED B LCPS K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SO 17 38897 2410 160 287716288 L780139A ENGINE ROUGH. FOUND NR 2 CYLINDERS CRACKED WHERE HEAD AND BARREL ATTACH. 1 L 7 1 3O 3 O 2A13 E274 1995050500529 19950505 00529 EA 1995 5 5 95ZZZX2186 2 19950411 G 8530 LW18289 CYLINDER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CYLINDER BARREL CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 AL 03 96082 52 15286004 L2498015 CRACK FOUND DURING AN INSPECTION TO FIND AN OIL LEAK. LOCATION OF CRACK IS AT THE BOTTOM PORTION OF CYLINDER BARREL, 3. 75 INCHES FROM BOTTOM OF FLANGE. THE CRACK IS APPROXIMATELY 2 INCHES LONG AND EXTENDS PARALLEL TO COOLING FINS. 1 H 7 1 3O 3 O NT 3A19 E223 1995050500531 19950505 00531 SO 1995 5 5 95ZZZX2188 2 19950413 G 8530 CYLINDER CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO CYL NR 5 CRACKED C E A ENGINE SHUTDOWN UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 GL 17 3748C 1030 402B606 183845R AFTER TAKEOFF, LEFT ENGINE STARTED VIBRATING. ENGINE WAS SHUT DOWN AND AIRCRAFT RETURNED TO THE AIRPORT. INSPECTION RE VEALED A CRACK IN THE NR 5 CYLINDER. SINCE OVERHAULED CYLINDERS HAVE HIGH TOTAL TIME, THEY ARE MORE LIKELY TO CRACK DUE TO AGE AND STRESS. RECOMMEND USING NEW CYLINDERS AT OVERHAUL TO REDUCE RECURRENCE OF THIS PROBLEM. 1 L 7 2 3O 3 O A7CE E8CE 1995050500532 19950505 00532 SO 1995 5 5 95ZZZX2189 2 19950310 G 7322 30764 FLOAT FACET MA45 CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO CARBURETOR FAILED D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 17 182HM 1077 C002042 18266720 467536 AFTER FINDING A 4 FOOT DIAMETER FUEL STAIN ON THE FLOOR AND FUEL DRIPPING FROM COWLING, INVESTIGATION DISCOVERED THE FLO AT RIGHT PONTOON SOLDER JOINT HAD BROKE ALLOWING THE PONTOON TO COME FREE FROM THE FLOAT LEVER AND HOLD THE NEEDLE OFF I TS SEAT. RECORDS INDICATE THAT AT ENGINE OVEHAUL, CARUBURETOR WAS OVERHAULED, BUT NO MENTION OF FLOAT REPLACEMENT. MAN UFACTURE DATE OF FLOAT: 4-84. 1 H 7 1 3O 3 O NT 3A13 E273 1995050500534 19950505 00534 EA 1995 5 5 95ZZZX2191 2 19950419 G 8530 SL10301AZP CYLINDER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA HEAD MISMANUFACTURED G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 17 48670 15283359 NEW SUPERIOR CYLINDERS WERE INSTALLED AT ROUTINE OVERHAUL. AT FIRST OIL CHANGE, SIGNIFICANT AMOUNTS OF ALUMINUM WERE FO UND IN THE OIL FILTER. AFTER 5 MORE FLIGHT HOURS, THE FILTER WAS AGAIN INSPECTED, MORE ALUMINUM WAS FOUND. THE ENGINE WAS DISASSEMBLED AND INSPECTED. IT WAS FOUND THE OUTER SPRINGS (VALVE) WERE RUBBING AGAINST THE SPRING POCKETS, REMOVIN G ALUMINUM FROM THE INSIDE OF THE HEAD CASTING. THIS CONDITION WAS FOUND IN SEVERAL OTHER ENGINES WITH SUPERIOR MILLENI UM O-235-L2C CYLINDERS. 1 H 7 1 3O 3 O NT 3A19 E223 1995050500535 19950505 00535 SO 1995 5 5 95ZZZX2192 2 19950404 G 7322 VENTURI FACET CESSNA 172 172 2072402 CE CONT O300 O300D 17022 SO CARBURETOR MISINSTALLED D K NONE E R W VIBRATION/BUFFET PARTIAL RPM/PWR LOSS INADEQUATE Q C IN INSP/MAINT 1 GL 09 1706F 100 17255101 34670D6D ON TWO SEPARATE AIRCRAFT WITH ENGINE ROUGHNESS, FOUND ONE PIECE VENTURI INSTALLED INCORRECTLY WITH THE NOTCH IN THE VENT URI NOT ALIGNED WITH THE NOZZLE. THIS MISALIGNMENT SEEMS TO CAUSE AN EXTREMELY RICH RUNNING ENGINE. THE MECHANICS ARE NOT OBSERVING THE ALIGNMENT AND ARE PROBABLY NOT USING THE OVERHAUL MANUAL. THIS PROBLEM COULD CAUSE ENGINE OPERATION/P OWER TO NOT BE ADEQUATE FOR SAFE OPERATION. 1 H 7 1 3O 3 O NT 3A12 E253 1995050500715 19950505 00715 NE 1995 5 5 95ZZZX2254 2 19950407 G 7250 50H067 NUTPLATE PWA 4056 PW4056 NE FLANGE STG 9-10 MISMFG B TUVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 PURCHASED NUTPLATE ASSY IDENTIFIED AS PN 50H069, WAS ONE OFFSET NUT WITH RELATION TO THE OTHERS. THIS CONFIGURATION IS CONSISTANT WITH PN 50H067. APPEARS NUTPLATE ASSY HAS BEEN MISIDENTIFIED. 4 F E24NE 1995050500721 19950505 00721 SO 1995 5 5 95ZZZX2260 2 19950323 G 8530 648044 PISTON CONT O520 TSIO520BE 17040 SO NR 1 THU NR 6 PIN BOSS CRACKED B DC2R K NONE O OTHER IN INSP/MAINT 1 SW 15 791 273705R UPON DISASSEMBLY OF ENGINE FOR PROP STRIKE INSPECTION AND TOP O/H, PISTONS FOUND CRACKED IN THE PIN BOSS AREA EXTENDING UP TO THE TOP INSIDE SURFACE (ONE SIDE ONLY). SUBMITTER UNSURE OF CAUSE. COULD BE MANUFACTURE DEFECT, DETONATION, MISU SE, ETC. 3 O E8CE 1995050500722 19950505 00722 SO 1995 5 5 95ZZZX2261 2 19950410 G 8550 538517 OIL PAN BEECH 55 D55 1152730 CE CONT O520 IO520C 17032 SO UNDER 2-4 CYLS CRACKED D O OTHER K FLUID LOSS CR CRUISE 1 SW 07 69RP 479 TE766 287258R DURING FLIGHT, PILOT NOTICED OIL STREAMING FROM RT COWLING. INSPECTION BY MAINTENANCE PERSONNEL REVEALED A 2 INCH CRACK IN THE OIL PAN AT LOWER RADIUS. SUSPECT FATIGUE, POOR STAMPING, DURING MANUFACTURING. 1 L 7 2 3O 3 O 3A16 E5CE 1995050500729 19950505 00729 1995 5 5 95ZZZX2269 1 19950419 G 7922 53E19600 VALVE LYC O540 AEIO540D4A5 41532 EA THERMO BYPASS NUT LOOSE G A K NONE O OTHER IN INSP/MAINT 1 WP 17 L2334348A BYPASS VALVE REMOVED TO COMPLY WITH LYCOMING SB 518A. THE NUT WAS FOUND LOOSE AND HALF-WAY UNSCREWED FROM THE THREADED SHAFT OF THE VALVE. IT WAS NOTED THE S/N OF VALVE WAS HIGHER THAN THE AFFECTED S/N'S LISTED IN SB. SUBMITTER RECOMMEND S INSPECTION PER SB OF ALL VALVES REGARDLESS OF S/N'S SB SHOULD BE AMENDED OR AN AD ISSUED. 3 O 1E4 1995051200001 19950512 00001 SO 1995 5 12 95ZZZX2270 2 19950429 G 8520 CRANKSHAFT CONT O520 IO520A 17032 SO ROD WEIGHTS OUT OF BALANCE B L YCTR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 11 1 112746 THE CONNECTING ROD WEIGHTS ON THE LARGE END FROM THE LIGHTEST TO THE HEAVIEST WAS 57 GRAMS. THIS ENGINE HAS NEVER BEEN INSTALLED IN AN AIRCRAFT. 3 O E5CE 1995051200162 19950512 00162 GL 1995 5 12 HEEA954914 2 19950504 G 7230 23008090 GEARSHAFT 23051643 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL SPUR ADAPTER STEP WEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5435V 821 CAC90511 760158 CAE890507S ENGINE REMOVED DUE TO COMPRESSOR 1750 HOUR INSPECTION AND TURBINE OVERHAUL. UPON INSPECTION OF COMPRESSOR PARTS NOTED T HE FOLLOWING: STEP WEAR BEYOND LIMITS ON SPUR ADAPTER GEARSHAFT FORWARD AND AFT SPLINES. INSTALLED NEW SPUR ADAPTER GEA RSHAFT. 1 G 7 2 3U 3 U H1NE E1GL 1995051200163 19950512 00163 GL 1995 5 12 HEEA954915 2 19950504 G 7250 23031494 LAB SEAL 23031925 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL NR 8 BEARING DEFECTIVE E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 CAT90593 CAE890585S RECEIVING INSPECTION OF NEW, NEVER INSTALLED #8 BEARING. LAB SEAL INDICATED EXCESSIVELY FLATTENED LAB SEAL. INSTALLED NEW LAB SEAL. 1 G 7 2 3U 3 U H1NE E1GL 1995051200164 19950512 00164 GL 1995 5 12 HEEA954916 2 19950504 G 7250 23031478 BEARING 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30P 03013 GL NR 8 BEARING DEFECTIVE E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 CAT95521 CAE900058 ENGINE REMOVED FOR MODIFICATION. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: PULLER GROOVE MISSING ON #8 BEA RING. INSTALLED NEW #8 BEARING. 1 G 7 2 3U 3 U H1NE E1GL 1995051200358 19950512 00358 WP 1995 5 12 95ZZZX2309 2 19950423 G 7200 ENGINE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE7313 01518 WP NR 1 FAILED B NV1R E ENGINE SHUTDOWN E B VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 GL 05 4350M 6352 142 P76568 DAY/EWR - IN-FLIGHT SHUT DOWN 4-23-95, ENGINE EXPERIENCED INTERMITTENT VIBRATION AND ODOR EMISSION INTO CABIN. ABNORMAL N1 AND ITT READINGS INCREASED VIBRATION, PROMPTED SHUT DOWN WHILE DESCENDING INTO EWR AT 6,000 FEET. THE NR 1 ENGINE O N THIS AIRCRAFT HAD FAILED PREVIOUSLY UNDER SIMILAR CIRCUMSTANCES AND TIMES. SAME BLOCK OF SERIAL NUMBERS. 2 L 7 3 4F 4 F A46EU E6WE 1995051200470 19950512 00470 SO 1995 5 12 95ZZZX2314 2 19950429 G 8530 629401 RING CONT O520 IO520A 17032 SO PISTON SCRAPER BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 11 112746 PISTON SCRAPER RING WAS BROKEN AT ASSEMBLY. PART OF THE BROKEN RING WAS IN THE OIL SUMP. 3 O E5CE 1995051200471 19950512 00471 SO 1995 5 12 95ZZZX2315 2 19950419 G 8520 SA530213 ROD BOLT CONT O200 O200A 17020 SO CON ROD MISMANUFACTURED B CT3R K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 17 INSPECTION OF CONNECTING ROD BOLTS REVEALED ONE SIDE OF THE BOLT HEAD WAS FLAT ON THE EDGE INSTEAD OF ROUND. SUBMITTER SUGGESTS IN VIEW OF ALL THE PROBLEMS INVOLVING SUPERIOR PARTS. THIS IS SUSPECT. 3 O E252 1995051200475 19950512 00475 1995 5 12 95ZZZX2319 1 19950419 G 7922 53E19600 VALVE LYC O540 AEIO540D4A5 41532 EA THERMO BYPASS CRIMP NUT LOOSE B CT3R K NONE O OTHER IN INSP/MAINT 1 WP 17 L2334348A BYPASS VALVE REMOVED TO COMPLY WITH LYCOMING SB 518A. THE NUT WAS FOUND LOOSE AND HALF-WAY UNSCREWED FROM THE THREADED SHAFT OF THE VALVE. IT WAS NOTED THE SERIAL NUMBER OF VALVE WAS HIGHER THAN THE AFFECTED SERIAL NUMBERS LISTED IN SB. R ECOMMEND INSPECTION PER SB OF ALL VALVES REGARDLESS OF SERIAL NUMBERS. SB SHOULD BE AMENDED OR AN AD ISSUED. 3 O 1E4 1995051200479 19950512 00479 SO 1995 5 12 95ZZZX2323 2 19950401 G 8520 646297 BRACKET BEECH 36 A36 1151604 CE CONT O550 IO550B SO CYLINDERS 2-4 BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 03 4759M E1300 249125R SEVENTH STUD, CYLINDERS 2 AND 4: BRACKET BROKEN IN HALVES. ONE ONE-HALF FOUND LYING NEXT TO KEEL, OTHER ONE-HALF MISSI NG. (ANNUAL 100-HOUR INSPECTION.) REPLACED BRACKET AND NUT, PN 646312. SUSPECT CAUSE: PROGRESSIVE CRACK LEADING TO U LTIMATE FAILURE. 1 L 7 1 3O 3 O 3A15 E3SO 1995051900094 19950519 00094 NE 1995 5 19 HEEA954941 2 19950510 G 7510 5044T08P05 VALVE BELL 214 214ST 1182106 SW GE CT7TS CT72A 30030 NE ENGINE AI CORROSION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 8045T 28101 GEE343061 ANTI ICE VALVE CORROSION. 2 G 7 2 4U 4 U H10SW E8NE 1995051900095 19950519 00095 NE 1995 5 19 HEEA954942 2 19950510 G 7313 5051T35G05 NOZZLE BELL 214 214ST 1182106 SW GE CT7TS CT72A 30030 NE ENG FUEL DEFECTIVE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 8045T 28101 GEE343006 FUEL NOZZLE DEFECTIVE. EXCESSIVE DROOLING AND SPITTING. SERIAL NUMBERS REMOVED PKHC4238 & PANO0613 & PKHA8102. 2 G 7 2 4U 4 U H10SW E8NE 1995051900463 19950519 00463 GL 1995 5 19 95ZZZX2367 2 19950421 G 7230 6890550 COMPRESSOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE STALLS B EOOR K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 AL 03 5074R 5623 2432 1151D CAE832750 COMPRESSOR STALLS WITH SLIGHT BUT RAPID POWER CHANGES. NOTE: THIS ENGINE WAS REMOVED FROM ANOTHER A/C WITH THESE SYMPT OMS AND ANOTHER ENGINE INSTALLED SO IT COULD START A JOB. THIS COMPRESSOR WAS INSTALLED FOR TROUBLESHOOTING WHEN THIS E NGINE WAS INSTALLED IN 5074R. *(PREVIOUS MDR FOR THE SAME PROBLEM WAS FILLED OUT ON THIS ENGINE WHEN IT WAS INSTALLED O N N3115Y). BOTH COMPRESSORS HAVE BEEN SENT IN FOR REPAIR. 1 G 7 1 3U 3 U H3WE E4CE 1995051900464 19950519 00464 GL 1995 5 19 95ZZZX2368 2 19950425 G 7323 23007506 GOVERNOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 4571V 478 4447 490487D CAE830976 'BEEP' RANGE IS ERRATIC. RPM JUMPS FROM POINT-TO-POINT DURING SMOOTH GOVERNOR TRIM MOTOR ACTUATION. UNIT SENT IN FOR R EPAIR ON ALLISON 250 REPORT NR A160118. 1 G 7 1 3U 3 U H3WE E4CE 1995051900465 19950519 00465 GL 1995 5 19 95ZZZX2369 2 19950430 G 7323 23007506 GOVERNOR 6887190 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 3115Y 917 17979 500716D CAE838348 PILOT COULD NOT MAKE SMOOTH 'BEEP' ADJUSTMENTS. REMOVED AND REPLACED UNIT. FELT A NOTCH IN THE ROTATION OF THE LEVER A RM. UNIT SENT TO BE REPAIRED ON ALLISON 250 REPORT A160119. 1 G 7 1 3U 3 U H3WE E4CE 1995051900473 19950519 00473 EA 1995 5 19 95ZZZX2377 2 19950427 G 7414 10357281H CAPACITOR BENDIX S4LN200 LYC O360 IO360A1A 41514 EA MAG SHORTING D S K NONE O OTHER IN INSP/MAINT 1 GL 15 INVESTIGATION FOR AN INTERMITTENT DEAD MAG FOUND SPRING STRAP TOUCHING HOUSING AS P-LEAD IS PUSHED INTO COVER. 3 O 1E10 1995051900474 19950519 00474 SO 1995 5 19 95ZZZX2378 2 19950424 G 8530 CYLINDER CESSNA 206 U206F 2073333 CE CONT O520 IO520A 17032 SO BASE MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 07 7144Q U20603075 553939 TOTAL TIME 1067.8 SMOH. TIME SINCE TOP OVERHAUL 125.0. DURING MAINTENANCE TO REPAIR BURNED VALVES UPON CYLINDER REMOVA L, FOUND CYLINDERS GLUED ON AT BASE. (IT TOOK OVER AN HOUR USING AIR PRESSURE AND PULLING AND PRYING TO REMOVE ONE CYLI NDER). IT SEEMS THAT A FOREIGN SUBSTANCE WAS APPLIED AROUND O-RING AT THE CYLINDER BASE. SUBMITTER BELIEVES THIS IS A CASE OF IMPROPER MATERIALS BEING USED. 1 H 7 1 3O 3 O A4CE E5CE 1995051900475 19950519 00475 SO 1995 5 19 95ZZZX2379 2 19950427 G 8520 633258 CRANKSHAFT BEECH 35 J35 1151522 CE CONT O470 IO470C 17026 SO FLANGE CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 8330D 1870 D5483 8777380R REMOVED PROPELLER TO REPLACE CRANKSHAFT SEAL. FOUND CRANKSHAFT FLANGE SEVERELY CORRODED. REMOVED ENGINE FROM SERVICE F OR CRANKSHAFT REPLACEMENT. ENGINE HAD BEEN OVERHAULED BY AN 'IA' JUST 75 HOURS AND 3 YEARS PREVIOUS TO THIS DISCOVERY. SUBMITTER BELIEVES CORROSION EXISTED AT THAT TIME. 1 L 7 1 3O 3 O 3A15 E273 1995051900484 19950519 00484 GL 1995 5 19 95ZZZX2389 2 19950427 G 8530 SA10203 CYLINDER CESSNA 150 150 2071802 CE AMTR CUSHMN O200 05645 GL NR 2 CYLINDER CRACKED H K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 6400T 500 17800 ENGINE HAD MINOR OIL LEAK FOR APPROXIMATELY 100 HOURS. IN ONE WEEK, OIL LEAK BECAME SEVERE. FOUND NR 2 CYLINDER BARREL CRACKED ABOUT 4 INCHES FORM BASE OF CYLINDER. CYLNDER HELD 74 POUNDS OF COMPRESSION. SUBMITTER IS OF THE OPINION THE CRACK WAS CAUSED FROM A MANUFACTURING DEFECT. 1 H 7 1 3O 3 O NT 3A19 EXPA3O 1995051900490 19950519 00490 SO 1995 5 19 95ZZZX2395 2 19950321 G 8530 632485 PUSH TUBE CONT O520 GTSIO520* 17032 SO SEAM CORRODED B C6YR K NONE O OTHER IN INSP/MAINT 1 SW 05 PUSH TUBE WAS SENT IN FOR REPLATING. AFTER CLEANING PUSH TUBE, CORROSION WAS FOUND IN SEAM PENTRATING THROUGH THE TUBE. PUSH TUBES SHOULD BE MADE FROM SEAMLESS TUBING. 3 O E7CE 1995051900682 19950519 00682 NE 1995 5 19 95ZZZX2404 2 19950417 G 7323 430128701 GOVERNOR 2860 SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A3 41560 NE POWER TURBINE FAILED D A A UNSCHED LANDING O OTHER CL CLIMB 1 WP 13 138EH 513 1403 LE434500E DURING FLIGHT, EXPERIENCED LOW SIDE GOVERNOR FAILURE (LOW POWER). THE PILOT JUST LIFTED OFF PAD NR 1, ACFT WAS ABOUT 4 FEET OFF DECK, PILOT MANAGED TO SET IT BACK DOWN WITHOUT ANY INCIDENT OR DAMAGE TO THE AIRCRAFT. PILOT TOOK ANOTHER SHI P AND THE SAME PASSENGERS AND COMPLETED THE TOUR. THE MECHANIC REMOVED P.T. GOV. TSO 513.6, AND INSTALLED SERVICEABLE ONE AND C/W OPERATIONAL AND A MAX TOPPING CHECK FLIGHT AND PASSED CHECK FLIGHT. 1 G 7 1 3U 3 U H9EU E5NE 1995051900684 19950519 00684 SO 1995 5 19 95ZZZX2406 2 19950403 G 8530 CYLINDER PIPER PA60 PA60601P 7106012 NM CONT O520 IO520* 17032 SO LT ENG NR 2 HEAD SEPARATION B VTMR A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 05 8244J 982 61P0648796 L1918148A CYLINDER HEAD SEPARATED FROM CYLINDER BARREL IN-FLIGHT. THE ENGINE KEPT RUNNING, PILOT REDUCED POWER AND LANDED ACFT WI TH NO OTHER DAMAGE TO ENGINE OR AIRCRAFT. THE CYLINDER, HEAD, AND PISTON ARE AT SHOP FOR INSPECTION. 1 M 7 2 3O 3 O RT A17WE E5CE 1995051900698 19950519 00698 EA 1995 5 19 95ZZZX2420 2 19950324 G 8550 4013383 BAFFLE PIPER PA32 PA32R301 7103218 SO LYC O540 IO540K1G5 41532 EA OIL SUMP FAILED B AMYR K NONE O OTHER IN INSP/MAINT 1 CE 05 923CN 466 3213076 L2523848A DURING REMOVAL OF OIL PAN TO CHANGE PAN GASKET, FOUND OIL SUMP BAFFLE COMING APART WHERE VERTICAL FINS ARE ATTACHED TO H ORIZONTAL PART, FOUND ALL RIVETS LOOSE, ONE RIVET HEAD COMPLETELY MISSING. 1 L 7 1 3O 3 O A3SO 1E4 1995051900701 19950519 00701 EA 1995 5 19 95ZZZX2423 2 19950425 G 8530 76220 THROUGH-BOLT MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA NR 1 CYLINDER FAILED D L K NONE O OTHER IN INSP/MAINT 1 NM 09 7112V 2763 1788 220047 L12C2451A SUBJECT NR 1 CYLINDER UPPER THROUGH-BOLT FOUND BROKEN DURING PRE-FLIGHT. DETECTED AS THE MAJOR REMAINING PORTION AND HO LD-DOWN NUT FOUND BACKED OUT OF POSITION AND LODGED AGAINST CYL FINS. INST NEW BOLT, SPACER, AND NUT. TORQUED PER LYCOM ING S.I. 10293. BOLT, THREADED END, BROKE OFF FLUSH WITH NUT'S SEATING SURFACE. INDICATIONS WERE A CRACK ABOUT 50 PERC ENT ACROSS THE DIAMETER HAD EXISTED FOR SOME TIME AND BOLT ULTIMATELY FAILED IN A TYPICAL TENSILE FACTURE. 1 L 7 1 3O 3 O 2A3 1E10 1995052600063 19950526 00063 EA 1995 5 26 95ZZZX2427 2 19950424 G 8530 78743 INTAKE PIPE MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA NR 3 CYLINDER CRACKED D L K NONE O OTHER IN INSP/MAINT 1 NE 05 7112V 1680 678 220047 L1262451A REPLACED PARTS RECEIVED BACK FROM OVERHAUL AGENCY FOLLOWING PROP STRIKE DISASSEMBLY INSPECTIONS INCLUDED A PN SL-10204J PISTON AND SUBJECT NR 3 CYL. INTAKE PIPE. PISTON EXHIBITED EARLY STAGES OF TYPICAL DETONATION DAMAGE ON THE HEAD, ADJAC ENT TO ITS O.D. AT THE 12 O'CLOCK POSITION AS INSTALLED. TPT 678 HRS. CAUSE APPARENTLY DUE TO EXCESSIVELY LEAN MIXTURE S RESULTING FROM AMBIENT AIR ENTERING SUBJECT CRACKED INTAKE PIPE ADJACENT TO ITS CYLINDER-MATING END. 1 L 7 1 3O 3 O 2A3 1E10 1995052600065 19950526 00065 EA 1995 5 26 95ZZZX2429 2 19950426 G 8530 LW12966 CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA NR 1 HOLED E A E UNSCHED LANDING ENGINE SHUTDOWN E K VIBRATION/BUFFET FLUID LOSS AP APPROACH 1 SO 17 684JJ 698 317952194 L486361A DURING AN APPROACH TO LANDING, PILOT REPORTED A VIBRATON IN THE LEFT ENGINE AND OIL LEAKING FROM COWLING. A PRECAUTIONA RY SHUT DOWN MADE AND PILOT MADE AN UNEVENTFUL LANDING. INSPECTION REVEALED A HOLE IN NR 1 CYLINDER UNDER THE INTAKE PU SH ROD HOUSING. THE HOLE ALLOWED EXHAUST GASES TO BURN A HOLE IN THE PUSH ROD HOUSING ALLOWING OIL LEAKAGE, AND THE PUS H ROD TO BREAK. SUBMITTER SUGGESTED PROBLEM MAY HAVE BEEN DUE TO A POOR WELD. 1 L 7 2 3O 3 O A20SO E14EA 1995052600067 19950526 00067 EA 1995 5 26 95ZZZX2431 2 19950322 G 8530 LW72198 PISTON BEECH 23 C23 1151242 CE LYC O360 O360A4K 41514 EA OIL RING DAMAGED D K NONE O OTHER IN INSP/MAINT 1 SO 13 9226S 2904 M1723 L2042136A PISTON PIN CAP DEVELOPED WEAR AND WORKED OUT LARGE HOLE INSIDE OF PISTON CAUSING FAILURE OF OIL RING AND LOSS OF COMPRES SION. CAP HAD WORN DOWN TO .25 INCH THICKNESS AND WORKED OUT HOLE REACHING PISTON OIL RING GROOVE. 1 L 7 1 3O 3 O A1CE E286 1995052600068 19950526 00068 EA 1995 5 26 95ZZZX2432 2 19950322 G 8530 LW75089 PIN PLUG BEECH 23 C23 1151242 CE LYC O360 O360A4K 41514 EA PISTON WORN D K NONE O OTHER IN INSP/MAINT 1 SO 13 9226S 2904 M1723 L2042136A PISTON PIN CAP DEVELOPED WEAR AND WORKED OUT LARGE HOLE INSIDE OF PISTON CAUSING FAILURE OF OIL RING AND LOSS OF COMPRES SION. CAP HAD WORN DOWN TO .25 INCH THICKNESS AND WORKED OUT HOLE REACHING PISTON OIL RING GROOVE. 1 L 7 1 3O 3 O A1CE E286 1995052600071 19950526 00071 SO 1995 5 26 95ZZZX2435 2 19950130 G 8530 SA631475 PISTON BEECH 35 V35 1151538 CE CONT O520 IO520BA 17032 SO NR 2 CYLINDER FAILED D K NONE O OTHER NR NOT REPORTED 1 SW 07 9516Q 382 D8064 569329 PISTON SKIRT FAILED AT LOWER RING LAND ON THRUST SIDE. DEBRIS EXTENSIVELY DAMAGED CRANKCASE, CRANKSHAFT, CAMSHAFT, RODS , ADJACENT PISTONS AND CYLINDERS. ALSO, THE ENTIRE OIL SYSTEM WAS CONTAMINATED. 1 L 7 1 3O 3 O 3A15 E5CE 1995052600072 19950526 00072 EA 1995 5 26 95ZZZX2436 2 19950430 G 8520 SL72877MJP TAPPET MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA CAM FAILED D K NONE O OTHER NR NOT REPORTED 1 CE 05 4145H 240648 L2305951A TAPPET BODIES BROKE AT THE TOP WHERE THEY RIDE ON THE CAM. PARTS OF TAPPETS THEN LODGED BETWEEN THE CAM AND CASE CAUSIN G A CRACK IN THE CASE, ALSO, DAMAGE TO PISTONS, RODS, CRANK, AND CAM, RESULTING ENGINE FAILURE. 1 L 7 1 3O 3 O 2A3 1E10 1995052600081 19950526 00081 WP 1995 5 26 95ZZZX2445 2 19950404 G 7250 31038393 SEAL 31033155 GARRTT TPE331 TPE33112UAR 01514 WP TURBINE CRACKED H K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 25 5283 1233152013 P70094C DURING INSPECTION FOR LOW POWER, FOUND PART CRACKED 12 PLACES UP TO APPROXIMATELY .5 INCH. SB 72-0840 AUTHORIZES INSTAL LATION OF THIS PART TO PROVIDE INCREASED SEAL PLATE TENSION AGAINST FIRST STAGE ROTOR. THIS INCREASED TENSION RESULTS I N CRACKING AT THE SEAL PLATE EDGE DIAMETER. CRACKING RESULTS IN AIR LEAK AND SUBSEQUENT POWER LOSS. SUGGEST ALLIED SIG NAL ENGINEERING REVIEW PART/INSTALLATION PROBLEM. 4 T E4WE 1995052600082 19950526 00082 WP 1995 5 26 95ZZZX2446 2 19950509 G 7250 31038391 SEAL 31070852 GARRTT TPE331 TPE33112UAR 01514 WP TURBINE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 8568 9233151435 P70017 DURING INSPECTION FOR COMPRESSOR DAMAGE, FOUND PART CRACKED 11 PLACES. SB 72-0840 AUTHORIZES INSTALLATION OF PN 3107085 -2 TO PROVIDE INCREASED SEAL PLATE TENSION AGAINST FIRST ROTOR ASSY. THIS PART WAS MODIFIED TO PN 3107085-2 BY INCORPOR ATING A SHIM BETWEEN THE AIR SEAL AND CURVIC COUPLING (NOTE: LIFE LIMITED PART LOG IDENTIFICATION WAS NOT UPDATED UPON MODIFICATION). INCREASED TENSION ON SEAL FLANGE RESULTS IN CRACKING AT FLANGE EDGE. SUGGEST ALLIED SIGNAL ENGINEERING REVIEW CAUSE/RESULT OF THIS DISCREPANCY. TIME SINCE MOD: 2130 HOURS, 2132 CYCLES. NOTE: THIS IS THE FIFTH ASSEMBLY F OUND CRACKED. CYCLES: 8915. 4 T E4WE 1995052600083 19950526 00083 WP 1995 5 26 95ZZZX2447 2 19950508 G 7250 8683793 STATOR 8940423 GARRTT TPE331 TPE3313U 01514 WP 3RD STAGE FAILURE B DSCR O OTHER T ENGINE CASE PENETRATION CR CRUISE 1 GL 25 1250 1013459365 P03209 ENGINE EXPERIENCED UNCONTAINED TURBINE SECTION FAILURE IN-FLIGHT. LOCATION OF PENETRATION THROUGH PENUM AND CONDITION O F REMAINING COMPONENTS INDICATE FAILURE OF THE 3RD STAGE ROTOR RESULTING FROM CONTACT OF ROTOR HUB WITH 3 INCH STATOR IN NER SHEET METAL SEAL SUPPORT. THIRD STATOR WAS DUE REPLACEMENT IN 8 CYCLES AS REQUIRED BY AD NOTE 92-26-08. CSO: 592 4 T E4WE 1995052600127 19950526 00127 GL 1995 5 26 HEEA955024 2 19950518 G 7421 CH34269 IGNITER PLUG BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 105WK 281 S812 TIP WORN AND CORRODED, NO IGNITION. 1 G 7 2 3U 3 U H3EU E4CE 1995052600224 19950526 00224 GL 1995 5 26 95ZZZX2472 2 19950307 G 7321 25400012V FUEL CONTROL BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL ENGINE DEFECTIVE B CZ4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 AL 01 133AL 323311 51133 PART WAS ZERO TSO, COULD NOT ADJUST START ADJUSTMENT FOR A COOL ENOUGH START EVEN AT LOWEST SETTINGS. 1 G 7 1 3U 3 U H2SW E1GL 1995060200099 19950602 00099 NE 1995 6 2 95ZZZX2524 2 19950421 G 7321 FUEL CONTROL SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A3 41560 NE BELLOWS AIR LEAKS D O OTHER J WARNING INDICATION AP APPROACH 1 WP 13 3608R 1312 1265 LE435560E DURING FINAL APPROACH, M/R RPM DROOPS. PILOT MADE SOFT LANDING ON THE RUNWAY. INSPECTED AND PNEUMATIC LEAK CHECK AND F OUND AIR LEAKS FROM GOVERNOR BELLOWS OF THE FUEL CONTROL UNIT. REMOVED AND REPLACED WITH SERVICEABLE FCU. PERFORMED RU N-UP LEAK CHECK AND NG TOPPING CHECK. ACFT RETURNED TO SERVICE. 1 G 7 1 3U 3 U H9EU E5NE 1995060200175 19950602 00175 EA 1995 6 2 95ZZZX2541 2 19950419 G 8530 SL74230P5 VALVE GUIDE LW12416 PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA EXHAUST CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 164ER 995 2841180 DURING CYLINDER REPAIR, THE EXHAUST GUIDE WAS FOUND CRACKED IN THE LOWER PORTION OF THE GUIDE. 1 L 7 1 3O 3 O 2A13 E274 1995060200176 19950602 00176 EA 1995 6 2 95ZZZX2542 2 19950419 G 8530 SL74230 VALVE GUIDE LW12416 PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA EXHAUST CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 167ER 1189 2841183 DURING CYLINDER REPAIR, THE EXHAUST GUIDE WAS FOUND CRACKED IN THE LOWER PORTION. 1 L 7 1 3O 3 O 2A13 E274 1995060200181 19950602 00181 SO 1995 6 2 95ZZZX2547 2 19950509 G 8530 643766 VALVE GUIDE CONT O520 IO520* 17032 SO INTAKE WORN D K NONE O OTHER IN INSP/MAINT 1 SW 11 807949R SIX EACH INTAKE VALVE GUIDES OUT OF NEW LIMITS, .0005 INCH (ONE-HALF THOUSANDTHS) AND TAPERED FROM TOP TO BOTTOM. 3 O E5CE 1995060200182 19950602 00182 SO 1995 6 2 95ZZZX2548 2 19950509 G 8530 643767 VALVE GUIDE CONT O520 IO520* 17032 SO EXHAUST WORN D K NONE O OTHER IN INSP/MAINT 1 SW 11 807949R SIX EACH EXHAUST VALVE GUIDES OUT OF NEW LIMITS, .0006 (SIX-TENTHS OF ONE THOUSANDTH). 3 O E5CE 1995060200183 19950602 00183 SO 1995 6 2 95ZZZX2549 2 19950509 G 8520 CRANKSHAFT CONT O520 IO520BA 17032 SO ROD JOURNAL WORN H K NONE O OTHER IN INSP/MAINT 1 SW 11 807040R THREE OF THE CONNECTING ROD JOURNALS AND TWO OF THE MAIN BEARING JOURNALS ARE OUT OF NEW LIMITS, .0002 (TWO-TENTHS OF ON E THOUSANDTH). 3 O E5CE 1995060200517 19950602 00517 WP 1995 6 2 95ZZZX2613 2 19950511 G 7261 8656645 GASKET CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP PROP PITCH LEAKS H K NONE K FLUID LOSS IN INSP/MAINT 1 WP 17 441JD 26 4410336 P77715 ENGINE OIL LEAK DETERMINED TO BE PROP PITCH CONTROL GASKET. INSTALLED THREE MORE NEW GASKETS WITH SAME OIL LEAK. GASKE TS HAVE THE WORD 'CANADA' MARKED ON THE EDGE OF THE TACH GENERATOR MOUNT FACE. GASKETS WERE INSTALLED PER GARRETT MM. 1 L 7 2 3T 4 T RT A28CE E4WE 1995060200530 19950602 00530 EA 1995 6 2 95ZZZX2627 2 19950504 G 8530 77160 VALVE GUIDE LW12427 AVIANW SKYHWK SKYHAWK 0900104 NM LYC O360 O360A4M 41514 EA EXHAUST WORN B NQ2R K NONE O OTHER IN INSP/MAINT 1 WP 05 3823R 207 17255323 L3387436A CYLINDER REMOVED DUE TO LOW COMPRESSION. FOUND .010 INCH WEAR IN EXHAUST GUIDE ALLOWING EXHAUST VALVE TO WEAR SEAT AND VALVE FACE. THIS WAS A FACTORY NEW ENGINE. VALVE GUIDE, PN 77160. VALVE, PN LW19001. 1 B 0 0 3 O A3NW E286 1995060200537 19950602 00537 1995 6 2 95ZZZX2634 1 19950508 G 7922 53E19600 VALVE LYC O360 AEIO360B4A 41514 EA THERMO BYPASS NUT LOOSE B CT3R K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 17 55733 L1654251A INSPECTION OF THERMOSTIC BYPASS VALVE. NUT WAS FOUND LOOSE. SERIAL NUMBER IS HIGHER THAN VALVES AFFECTED IN TEXTRON LY COMING SB 518B. 3 O 1E10 1995060900080 19950609 00080 EA 1995 6 9 95ZZZX2646 2 19950418 G 8500 ENGINE CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA OIL SYSTEM MAKING METAL H K NONE O OTHER IN INSP/MAINT 1 EA 07 62085 2283 17275209 L1162539A FILTER WAS OPENED DURING AN ANNUAL INSPECTION. A HIGH AMOUNT OF METAL WAS FOUND, MOSTLY ALUMINUM WITH SOME STEEL. AIRC RAFT WAS GROUNDED AND ENGINE SENT OUT TO OVERHAUL FACILITY FOR DISASSEMBLY. 1 H 7 1 3O 3 O NT 3A12 E274 1995060900081 19950609 00081 SO 1995 6 9 95ZZZX2647 2 19950426 G 7414 1056513 STOP PIN MOONEY M20 M20K 5870220 SW CONT O360 TSIO360GB 17025 SO LT MAG DISLOCATED D O OTHER J WARNING INDICATION CL CLIMB 1 EA 07 4086H 250462 309496 PILOT REPORTED LOW OIL PRESSURE AFTER TAKEOFF. AFTER TROUBLESHOOTING ACTUAL PRESSURE, FOUND WHAT WAS LATER TO BE DETERM INED TO BE THE STOP PIN FROM THE LEFT MAGNETO IN THE SUCTION SCREEN CAUSING LOW FLOW TO OIL PUMP. 1 L 7 1 3O 3 O 2A3 E9CE 1995060900091 19950609 00091 EA 1995 6 9 95ZZZX2657 2 19950421 G 8530 CYLINDER CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA CYLS 2-4 RINGS BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 99 3065E 4095 725 17271425 L405276 DURING 100-HOUR INSPECTION, COMPRESSION ON CYLINDERS 2 AND 4 LOW. REMOVED CYLINDERS. BROKEN AND MISSING PIECES OF RING . OIL SAMPLE SENT OUT. OVERHAUL FACILITY SAYS TAPPET DAMAGE. INSPECTED SAME AND FOUND NR 1 CYLINDER EXHAUST TAPPET WI TH HEAVY DAMAGE. ENGINE SENT OUT FOR REPAIR. 1 H 7 1 3O 3 O NT 3A12 E274 1995060900093 19950609 00093 SO 1995 6 9 95ZZZX2660 2 19950130 G 8520 629680M010 COLLAR CONT O520 IO520* 17032 SO CRANKSHAFT OIL OUT OF SPEC B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 OIL TRANSFER COLLAR IS OUT OF SPECIFICATIONS. THIS PART WOULD HAVE CAUSED AN ENGINE FAILURE. 3 O E5CE 1995060900094 19950609 00094 SO 1995 6 9 95ZZZX2661 2 19950407 G 8520 649141 CRANKSHAFT CONT O470 O470R 17026 SO MAIN BEARING WORN B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 189509 CRANKSHAFT MAIN BEARING JOURNALS OUT OF LIMITS .0005 INCH (ONE-HALF THOUSANDS.) CRANKSHAFT CONNECTING ROD JOURNALS OUT OF LIMITS .0002 INCH. (TWO-TENTHS OF A THOUSANDS.) 3 O E273 1995060900095 19950609 00095 SO 1995 6 9 95ZZZX2662 2 19950130 G 8530 629325 INTAKE PIPE CONT O520 IO520* 17032 SO CYLINDER CRACKED B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 INDUCTION PIPE CRACKED, APPROXIMATELY 1.50 INCHES LONG. 3 O E5CE 1995060900096 19950609 00096 SO 1995 6 9 95ZZZX2663 2 19950201 G 8530 CYLINDER BEECH 35 V35A 1151544 CE CONT O520 IO520BA 17032 SO NR 2 CRACKED B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 7624N 2147 521 D8854 1218568B CRACKED CYLINDER FROM EXHAUST PORT AROUND CYLINDER HEAD TO SPARK PLUG HOLE, THREE-FOURTHS SEPARATED FROM BARREL. 1 L 7 1 3O 3 O 3A15 E5CE 1995060900097 19950609 00097 SO 1995 6 9 95ZZZX2664 2 19950216 G 8520 CRANKSHAFT CONT O520 IO520BA 17032 SO ENGINE WORN B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 807023R ENGINE WAS CONTAMINATED WITH METAL. THE CRANKSHAFT HAD TO BE TURNED UNDERSIZE TO REPAIR. FACTORY TEST RUN TIME ONLY. 3 O E5CE 1995060900098 19950609 00098 SO 1995 6 9 95ZZZX2665 2 19950306 G 8530 646286 VALVE STEM CONT O520 IO520BB 17032 SO CYLINDER WORN B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 333 274831R FOUND 5 EXHAUST VALVE STEMS WORN ONE-FOURTH THE DIAMETER OF THE VALVE STEM. THESE WERE FOUND ON AN ENGINE TEAR DOWN FOR PROPELLER STRIKE. THESE VALVES WOULD EVENTUALLY HAVE CAUSED ENGINE FAILURE. 3 O E5CE 1995060900102 19950609 00102 SO 1995 6 9 95ZZZX2671 2 19950126 G 7414 M3525 COIL SLICK 88090670 BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MAG FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 13 358Y 825 TH1557 6763A7 NO HIGH TENSION RESISTANCE. SECOND COIL REPLACED ON AIRCRAFT. THIS COIL DATE CODE 91688. 1 L 7 2 3O 3 O 3A16 E5CE 1995060900105 19950609 00105 EA 1995 6 9 95ZZZX2674 2 19950223 G 7414 10103209 COIL BENDIX PIPER PA28 PA28180 7102808 SO LYC O360 O360A3A 41514 EA MAG CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 13 44156 A105928 7405224 THIS COIL WAS INSTALLED IN MAGNETO NOT COVERED BY AD 94-01-03 OR AD 94-01-03-R1. SUBMITTER SUGGESTS REMOVING PLASTIC FL AG ON DATA PLATE SIDE OF ALL SUSPECT MAGS AND LOOK WITH A PEN LIGHT FOR IMPROPER COILS. 1 L 7 1 3O 3 O 2A13 E286 1995060900113 19950609 00113 GL 1995 6 9 GCHA957 2 19950413 G 7230 23005250 COMPRESSOR BELL 206 206L1 1182107 SW ALLSN 250C 250C30P 03013 GL SCROLL CRACKED I GCHA K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 19 4227E 7600 45702 CAE890233 REMOVED COMPRESSOR DUE TO CRACKED COMPRESSOR SCROLL AND LOW POWER. REMOVED COMPRESSOR S/N CAC-90608, AND REPLACED I T WITH COMPRESSOR S/N CAC-90095. 1 G 7 1 3U 3 U H2SW E1GL 1995060900134 19950609 00134 GL 1995 6 9 HEEA955117 2 19950602 G 7250 23032345 COUPLING 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL ENG N1 STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1546K 826 CAT90437 760082 CAE890431S ENGINE REMOVED DUE TO TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIMITS ON N1 COUPLING FORWARD I.D. SPLINES. INSTALLED NEW N1 COUPLING. 1 G 7 2 3U 3 U H1NE E1GL 1995060900135 19950609 00135 GL 1995 6 9 HEEA955118 2 19950602 G 7250 23055438 NOZZLE 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL 2ND STAGE DEFECTIVE E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 2743E CAT90644 760155 CAE890476S RECEIVING INSPECTION OF NEW, NEVER INSTALLED 2ND STAGE NOZZLE INDICATES .009" RUNOUT IN BOTH TIP PATHS, DIAPHRAGM OFF C ENTER. NOTE: DAMAGE TO KEYS AND TANGS BY ADJUSTMENT PRIOR TO RECEIPT BY PHI. INSTALLED NEW 2ND STAGE NOZZLE. 1 G 7 2 3U 3 U H1NE E1GL 1995060900136 19950609 00136 GL 1995 6 9 HEEA955119 2 19950602 G 7250 6886407 WHEEL 6898735 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL 1ST STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 81832 1000 CAT25276 S828 CAE836418 ENGINE REMOVED DUE TO CYCLED OUT 1ST AND 2ND STAGE WHEELS. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MINOR SULFIDATION ON ALL 1ST STAGE WHEEL BLADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 2 3U 3 U H3EU E4CE 1995060900138 19950609 00138 GL 1995 6 9 HEEA955121 2 19950602 G 7250 6898782 WHEEL 6898735 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL 2ND STAGE BLADES FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 54191 30 CAT32744F S804 CAE836073 ENGINE REMOVED DUE TO ENGINE FAILURE ON RUN-UP. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: 100% OF 1ST STAG E WHEEL BLADE TIPS FAILED .450" OUTBOARD FROM HUB TO BLADE TIP LEADING EDGE DUE TO THERMAL FATIGUE CAUSED BY ENGINE OPER ATING IN AN OVERTEMPERATURE CONDITION AND 94% OF 2ND STAGE WHEEL BLADE TIPS FAILED .781" OUTBOARD FROM HUB TO BLADE TIP LEADING EDGE. SCRAPPED 1ST AND 2ND STAGE WHEELS. SEE MMIR #5120 FOR 2ND STAGE WHEEL INFORMATION. 1 G 7 2 3U 3 U H3EU E4CE 1995060900149 19950609 00149 GL 1995 6 9 HEEA955057 2 19950523 G 7250 23032345 COUPLING 23035128 BELL 206 206L1 1182107 SW ALLSN 250C 250C30P 03013 GL ENG N1 STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 2135V 683 CAT97841 45657 CAE895561 ENGINE REMOVED DUE TO TURBINE OVERHAUL AND COMPRESSOR 1750 HOUR INSPECTION. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIMITS ON N1 COUPLING I.D. SPLINES. INSTALLED NEW N1 COUPLING. 1 G 7 1 3U 3 U H2SW E1GL 1995060900152 19950609 00152 NE 1995 6 9 HEEA955060 2 19950523 G 7261 0292005220 ENGINE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1 60030 NE OIL SYS FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 60951 1294 2771 OIL BLOWING OUT EXHAUST AND OIL PSI FELL TO ZERO. 1 G 7 1 3U 3 U H9EU E19EU 1995060900162 19950609 00162 GL 1995 6 9 HEEA955071 2 19950524 G 7250 6886407 WHEEL 6898735 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL 1ST STAGE BLADES SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 54197 1691 CAT37782 S805 CAE802035F ENGINE REMOVED DUE TO TURBINE 1750 HOUR INSPECTION AND BURNT 1ST STAGE NOZZLE. UPON INSPECTION OF TURBINE PARTS NOTED T HE FOLLOWING: MINOR SULFIDATION ON ALL 1ST STAGE WHEEL BLADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 2 3U 3 U H3EU E4CE 1995060900163 19950609 00163 GL 1995 6 9 HEEA955072 2 19950524 G 7250 6895801 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 1ST STAGE BLADES SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 2758N 1373 CAT70546 45267 CAE860213 ENGINE REMOVED DUE TO TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: SULFIDATION ON ALL 1ST S TAGE WHEEL BLADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 1 3U 3 U H2SW E1GL 1995060900181 19950609 00181 GL 1995 6 9 HEEA955091 2 19950525 G 7230 23007208 DIFFUSER VANE 23033192 ALLSN 250C 250C28C 03013 GL ENGINE SEPARATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 CAC28048 CAE280047 ENGINE REMOVED DUE TO TURBINE OVERHAUL, COMPRESSOR N1 SHAFTING INSPECTION AND UPGRADE CEB'S. UPON INSPECTION OF COMPRES SOR PARTS NOTED THE FOLLOWING: TURNING VANE APPEARS TO BE SEPARATING FROM FORWARD AND AFT PLATES ON DIFFUSER VANE ASSY AND MATING SURFACES ARE DEFLECTED CAUSING LOW POWER DURING TEST CELL RUN. 3 U E1GL 1995060900255 19950609 00255 SO 1995 6 9 95ZZZX2683 1 19950503 G 8120 646434 CLAMP PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO LT TURBO EXH BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 23 424J 468408019 273511R ON 5-3-95 WHILE ENGINE WAS BEING CHECKED FOR UNRELATED MATTER, MECHANIC NOTED BROKEN CLAMP WHICH HOLDS EXHAUST TO LEFT T URBOCHARGER. IT APPEARED TO HAVE BEEN OVERTORQUED AS ENDS OF CLAMP WERE TOUCHING AND SAFETY WIRED IN THAT POSITION. ME CHANIC THEN REMOVED AND INSPECTED SIMILAR CLAMP ON RIGHT TURBO TO EXHAUST AND FOUND IT CRACKED ALSO. SUGGEST EARLY REPL ACEMENT. THESE APPEARED TO BE ORIGINAL EQUIPMENT. 1 L 7 1 3O 3 O A25SO E8CE 1995060900268 19950609 00268 EA 1995 6 9 95ZZZX2696 2 19950503 G 7414 ES10382585 CONTACT ASSY 1068255511 MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA CAM FOLLOWER WORN B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 189ER 396 B6208910C 24169814 MAGNETO WAS REMOVED FROM THE AIRCRAFT AFTER MAGNETO TIMING CHECK INDICATED MAGNETO INTERNAL TIMING WAS OFF BY 10 DEGREES . MAGNETO DISASSEMBLY INSPECTION REVEALED EXCESSIVE CAM FOLLOWER WEAR. CAM FOLLOWER ALSO APPEARED MELTED. CONTINUED O PERATION WOULD HAVE CAUSED MAGNETO TO BECOME INOPERATIVE. 1 L 7 1 3O 3 O 2A3 1E10 1995060900272 19950609 00272 1995 6 9 95ZZZX2700 1 19950502 G 7922 75944 VALVE LYC O360 IO360A1B6 41514 EA THERMO BYPASS CRIMP NUT LOOSE D K NONE O OTHER IN INSP/MAINT 1 EA 09 122198 REF LYC SB 518B. TWO OUT OF THREE NUTS HAVE BEEN LOOSE. ONE NUT WAS CRACKED. 3 O 1E10 1995060900273 19950609 00273 1995 6 9 95ZZZX2701 1 19950502 G 7922 75944 VALVE LYC O360 IO360A1B6 41514 EA THERMO BYPASS CRIMP NUT LOOSE D K NONE O OTHER IN INSP/MAINT 1 EA 09 41150 REF LYC SB 518B. TWO OUT OF THREE NUTS HAVE BEEN LOOSE. ONE NUT WAS CRACKED. 3 O 1E10 1995060900282 19950609 00282 SO 1995 6 9 95ZZZX2710 2 19950406 G 8530 PISTON CONT O520 TSIO520E 17040 SO NR 2 CYLINDER BURNED C K NONE O OTHER IN INSP/MAINT 1 NE 01 810 275313R FOUND CYLINDER NR 2 TOP SIDE PISTON BURNED, POSSIBLE DETONATION. SENT FOR EVALUATION AT TCM. 3 O E8CE 1995060900284 19950609 00284 EA 1995 6 9 95ZZZX2712 2 19950303 G 8530 69603 HOSE CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA INTAKE COUPLING DEFECTIVE D K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 13 9526H 17266201 L4349627A UPON INVESTIGATION OF LOWER THAN NORMAL POWER OUTPUT, FOUND INTAKE COUPLING HOSE INTERIOR (ALL 4) INTERNALLY REDUCING IN SIZE FROM 1.75 INCHES TO 1.25 INCHES. THIS IS A SUBSTANTIAL REDUCTION IN FLOW (NEARLY ONE-HALF VOLUME) FROM 3.06 SQUAR E INCH TO 1.56 SQUARE INCH. THE COUPLINGS APPEAR TO HAVE SUFFERED FROM HEAT DUE TO PROXIMITY OF HOT EXHAUST. POWER RES UMED NORMAL UPON REPLACEMENT OF NEW COUPLINGS. 1 H 7 1 3O 3 O NT 3A12 E274 1995060900285 19950609 00285 CE 1995 6 9 95ZZZX2713 1 19950303 G 8011 EBB75A BENDIX DRIVE PRESTOLITE MZ4222 CESSNA 172 172L 2072432 CE LYC O320 O320E2D 41508 EA STARTER FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 13 7809G 17259559 THE STARTER MOTOR TURNS, BUT THE BENDIX WILL NOT ENGAGE. POSSIBLE FAULTS: 1. WORN. 2. WRONG LUBRICANT - NOT SILICON E AS RECOMMENDED. 3. DIRT/OIL PREVENTING 'SLIDING' AS REQUIRED. 1 H 7 1 3O 3 O NT 3A12 E274 1995060900286 19950609 00286 SO 1995 6 9 95ZZZX2714 2 19950303 G 8530 24047 VALVE GUIDE CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO EXHAUST FAILED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 13 714AJ 1005 15079024 255534A48 ENGINE MAJOR OVERHAULED WITH CYLINDERS SUPPLIED BY AERO AVIATION. CYLINDERS WENT 100 HOURS AND VALVE GUIDES FAILED DUE TO IMPROPER INSTALLATION. THEY WERE INSTALLED SO LOOSE THAT FIRE WAS EATING AWAY AT THE OUTSIDE OF THE GUIDE WHERE IT I S SUPPOSED TO BE A PRESS FIT IN THE CYLINDER HEAD. SN 41593, SN 41591, SN 41595 HAD GUIDES INSTALLED BY A BETTER CYLIND ER HOUSE, THE ENGINE NOW HAS 450 HOURS SMOH, AND RUNS JUST FINE. 1 H 7 1 3O 3 O 3A19 E252 1995060900287 19950609 00287 SO 1995 6 9 95ZZZX2715 2 19950303 G 8550 1250922202 ADAPTER CESSNA 182 182E 2072712 CE CONT O470 O470* 17026 SO OIL FILTER DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 13 9390X 18253790 WHEN INSPECTING FILTER ADAPTER IAW SEB 93-1R1A, FOUND FRETTING OF THE MOUNTING THREADS. THIS RENDERED THE ADAPTER UNAIR WORTHY. ADAPTER REPLACED WITH NEW UNIT. 1 H 7 1 3O 3 O NT 3A13 E273 1995060900292 19950609 00292 SO 1995 6 9 95ZZZX2720 2 19950407 G 8530 CYLINDER CESSNA 340 340A 2076405 CE CONT O520 TSIO520N 17040 SO ENGINE DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 05 300JM 3527 432 340A0233 509401 AT OVERHAUL, 5 CYLINDERS WERE CERAMICHROME AND 1 WAS CHANNELCHROME. AT THE 100-HOUR INSPECTION. COMPRESSION WAS HIGH 60 'S ON THE CERAMICHROME, 77 ON THE CHANNELCHROME. A PRE-BUY INSPECTION WAS DONE 2 HOURS LATER AND THE COMPRESSION DROPPE D 20 POUNDS ON THE CERAMICHROME. THIS PROBLEM IS CONSISTENT ON CERAMICHROME CYLINDERS. 1 L 7 2 3O 3 O 3A25 E8CE 1995060900408 19950609 00408 EA 1995 6 9 95ZZZX2725 2 19950518 G 8530 RETAIN STUD CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA NR 4 CYL ROCKER BACKED OUT D A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 NE 03 734XC 1100 17269188 RL00595576T AFTER APPROXIMATELY 5 MINUTES IN CRUISE FLIGHT, THE PILOT REPORT A LOSS OF ENGINE POWER AND A SEVERE ROUGHNESS AND AN AI RPORT LANDING WAS MADE WITHOUT INCIDENT. INVESTIGATION REVEALED NR 4 CYLINDER INTAKE VALVE PUSH ROD AND SHROUD WERE BUR NED AND LEAKING OIL. THE EXHAUST VALVE RETAIN STUD FOR THE FULCRUM AND ROCKER ARM HAD BACKED OUT APPROXIMATELY 5 THREAD S; THUS, CREATING EXCESSIVE VALVE CLEARANCE. THE OTHER 3 CYLINDERS WERE INSPECTED AND THIS CONDITION OF THE ROCKER ASSY RETAIN STUD ALSO EXSISTED ON NR 2 CYLINDER. 1 H 7 1 3O 3 O NT 3A12 E274 1995060900410 19950609 00410 EA 1995 6 9 95ZZZX2727 2 19950517 G 8530 AL19001 VALVE LYC O320 O320D3G 41508 EA EXHAUST WORN B CYKR K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 07 336 L851039A ENGINE RAN ROUGH AT IDLE AND LOUD MECHANICAL NOISES WERE REPORTED. VISUAL INSPECTION OF ENGINE BEFORE DISASSEMBLY SHOWE D ZERO VALVE STEM TO ROCKER CLEARANCE. DISASSEMBLY OF CYLINDER SHOWED EXHAUST VALVE PN AL19001 WORN EXCESSIVELY IN THE RETAINER GROOVE. RECOMMEND REPLACEMENT OF EXHAUST VALVE. 3 O E274 1995060900411 19950609 00411 EA 1995 6 9 95ZZZX2728 2 19950517 G 8530 AL19001 VALVE LYC O320 O320E2D 41508 EA EXHAUST WORN B CYKR K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 07 296 L3354027A ENGINE RAN ROUGH AT IDLE AND LOUD MECHANICAL NOISES WERE REPORTED. VISUAL INSPECTION OF ENGINE BEFORE DISASSEMBLY SHOWE D ZERO VALVE STEM TO ROCKER CLEARANCE. DISASSEMBLY OF CYLINDER SHOWED EXHAUST VALVE PN AL19001 WORN EXCESSIVELY IN THE RETAINER GROOVE. RECOMMEND REPLACEMENT OF EXHAUST VALVE. 3 O E274 1995060900412 19950609 00412 SO 1995 6 9 95ZZZX2729 2 19950530 G 8550 0024100143 PAN BEECH 36 A36 1151604 CE CONT O520 TSIO520UB 17040 SO ENGINE CRACKED B HBKR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 11 8285C 268 E2810 HOLE HAD BROKEN OUT IN CENTER OF PAN. PAN IS FORMED FROM .032. NOTIFIED BEECH OF PROBLEM. INSTALLED A NEW PART. BEEC H INDICATED THEY MAY USE .061 MATERIAL SOMETIME IN THE FUTURE. 1 L 7 1 3O 3 O 3A15 E8CE 1995060900417 19950609 00417 EA 1995 6 9 95ZZZX2734 2 19950418 G 8530 CYLINDER PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA NR 4 FAILED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 NE 03 8115H 800 288016117 L941139A PILOT DECLARED AN EMERGENCY SHORTLY AFTER TAKEOFF DUE TO ROUGH RUNNING ENGINE. FOUND NR 4 CYLINDER HAD .50 INCH DIAMETE R PIECE OF ALUMINUM BURNED OUT NEAR EXHAUST VALVE SEAT. POSSIBLY CAUSED BY PRE-IGNITION OR DETONATION. APPROXIMATELY 3 00 HOURS PRIOR, ENGINE WAS CRACKING THE PORECELAIN IN THE SPARK PLUGS. MOST LIKELY HAPPENED DUE TO IMPROPER LEANING. 1 L 7 1 3O 3 O 2A13 E274 1995060900419 19950609 00419 EA 1995 6 9 95ZZZX2736 2 19950511 G 8550 61837 VALVE SLEEVE PIPER PA28 PA28180 7102808 SO LYC O360 O360A3A 41514 EA PRESS RELIEF VLV BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 11 7851W 4402 281870 L726636A FOUND LARGE ALUMINUM PARTS IN SUCTION SCREEN. THEY APPEARED BROKEN AND UNMARRED, I,E,; HAD NOT BEEN GROUND UP IN A GEAR TRAIN. FURTHER INVESTIGATION USING LYCOMING OVERHAUL MANUAL NR 60294-7, PAGE 7-2, IDENTIFIED POSS END ITEM, DISASSEMBL ED OIL PSI RELIEF VALVE PLUG AND FOUND SLEEVE (IT-16) MISSING 2 SIDES. UPON REMOVAL OF SLEEVE, WAS ABLE TO REASSEMBLY E NTIRE ITEM WITH PARTS FOUND IN SUCTION SCREEN. INSTALLED NEW ASSY AND RETURNED ENGINE TO SERVICE. 1 L 7 1 3O 3 O 2A13 E286 1995060900619 19950609 00619 GL 1995 6 9 95ZZZX2784 2 19950522 G 7230 23005250 COMPRESSOR BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL ENGINE CONTAMINATED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 343AL 10813 51372 DURING A COMPRESSOR CHANGE FOUND WHILE POSITIONING THE COMPRESSOR ON A WORK BENCH, A SMALL WHITE HARD BEAD ROLLED OUT OF THE SCROLL DISCHARGE TUBE. THE COMPRESSOR SCROLL WAS BORESCOPED TO CHECK FOR ANY MORE BEADS WHICH MAY HAVE BEEN LODGED IN THE SCROLL. NO FURTHER BEADS WERE NOTED. 1 G 7 1 3U 3 U H2SW E1GL 1995060900620 19950609 00620 GL 1995 6 9 95ZZZX2785 2 19950502 G 7260 6898642 GEARSHAFT BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL GEARBOX PITTED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 343AL 3053 51372 UPON DISASSEMBLY AND INSPECTION, FOUND AIR OIL GEARSHAFT PITTED. 1 G 7 1 3U 3 U H2SW E1GL 1995060900639 19950609 00639 GL 1995 6 9 95ZZZX2804 2 19950502 G 7240 23030911 COMBUSTION CASE 230335128 SKRSKY S76 S76 8143010 NE ALLSN 250C 250C30S 03013 GL ARMPIT CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 701AL 1750 28263 760238 THIS DEFECT WAS DISCOVERED AT 1750-HOUR OVERHAUL. OUTER COMBUSTION CASE WAS CRACKED IN ARMPIT UNDER THE SCREEN PATCH RE INFORCEMENT AND EXTENDED ON SEAM AND INTO THE SEAM PERPENDICULAR TO THE FLANGE AND PARALLEL TO THE FLANGE. A CRACK SUCH AS THIS MAY CAUSE POSSIBLE POWER LOSS IN ENGINE. NO REPAIR IS PERMITTED IN THIS AREA. OUTER COMBUSTION CASE IS SCRAPP ED. CAUSE UNKNOWN. 1 G 7 2 3U 3 U H1NE E1GL 1995060900829 19950609 00829 EA 1995 6 9 95ZZZX2839 2 19950505 G 7261 3004091 SCREEN BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA OIL SCAV PUMP BLOCKED B L ERY2 E ENGINE SHUTDOWN J K WARNING INDICATION FLUID LOSS CR CRUISE 1 SO 11 780RC 4949 1808 BB780 PCE81769 PILOT REPORTED LOSS OF OIL PRESSURE DURING FLIGHT. THE ENGINE WAS SHUT DOWN AND AN UNEVENTFUL LANDING MADE. OIL WAS LE AKING FROM THE COMPRESSOR INLET AND BLEED AIR VALVES. AFTER TROUBLESHOOTING, THE ACCESSORY GEARBOX WAS DISASSEMBLED AND THE INLET SCREEN FOR THE OIL SCAVAGE PUMP WAS BLOCKED WITH VARNISH COATING FROM INSIDE THE GEARBOX. ENGINE REMOVED AND SENT TO P AND W FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 1995061600063 19950616 00063 WP 1995 6 16 95ZZZX2851 2 19950510 G 7250 31038391 SEAL 31969752 GARRTT TPE331 TPE33112UA 01514 WP TURB ROTATE AIR CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 6977 9233151471 P70032 DURING INSPECTION FOR CAM, FOUND PART CRACKED 15 PLACES. SB 72-0840 AUTHORIZES INSTALLATION OF PN 3107085-2 TO PROVIDE INCREASED SEAL PLATE TENSION AGAINST THE FIRST STAGE ROTOR ASSEMBLY BY INCORPORATING A SHIM BETWEEN THE AIR SEAL AND CUR VIC COUPLING. INCREASED TENSION ON THE SEAL FLANGE RESULTS IN CRACKING AT THE SEAL PLATE FLANGE; 3714 CYCLES, 3735:28 H OURS IN SERVICE SINCE COMPLIANCE WITH SB 72-0840. 4 T E4WE 1995061600064 19950616 00064 NE 1995 6 16 95ZZZX2852 2 19950530 G 7314 025323150 PUMP PESCO CESSNA 425 425 2076018 CE PWA PT6 PT6A112 52043 NE LT ENG FUEL FAILED D K NONE K FLUID LOSS NR NOT REPORTED 1 SW 09 1BM 2092 4250042 PCE12091 FUEL PUMP ON LEFT ENGINE, SEAL LEAKED FUEL INTO FUEL CONTROL DRIVE, WASHING THE GREASE OUT OF THE DRIVE BEARING CAUSING BEARING FAILURE AND DRIVE COUPLING TO SHEAR. 1 L 7 2 3T 3 T RT A7CE E4EA 1995061600130 19950616 00130 EA 1995 6 16 95ZZZX2883 2 19950501 G 7322 46A227 VENTURI FACET MA45 PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA CARBURETOR CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 23 4315T R418863 327200016 L1061440 FOUND CORROSION IS OCCURRING BELOW THE SURFACE OF THE CASTING CAUSING THE SURFACE TO BUBBLE UP, CHANGING THE SHAPE OF TH E VENTURI. IF THIS PART IS PLATED, CAN THE PLATING BE ELIMINATED? 1 L 7 1 3O 3 O A3SO E295 1995061600133 19950616 00133 SO 1995 6 16 95ZZZX2886 2 19950519 G 8520 CRANKSHAFT BEECH 55 95B55 1152706 CE CONT O520 IO520E 17032 SO FLANGE CRACKED D A UNSCHED LANDING J K WARNING INDICATION FLUID LOSS NR NOT REPORTED 1 SO 09 3653A 600 TC1309 515599R EMERGENCY LANDING MADE DUE TO OIL LOSS AND PRESSURE LOSS. FOUND OIL LOSS AT APPROXIMATELY 1 QUART PER MINUTE AT 1,000 R PM. REMOVED PROPELLER AND FOUND FLANGE CRACKED 50 PERCENT AROUND CIRCUMFERENCE OF FLANGE. FAILURE OF CRANKSHAFT (LOSS OF PROPELLER) WAS VERY LIKELY TO HAPPEN AT ANY TIME. NOTE: THIS INSTALLATION IS A COLEMILL CONVERSION. VAR CRANKSHAFT NOT INSTALLED. 1 L 7 2 3O 3 O 3A16 E5CE 1995061600139 19950616 00139 SO 1995 6 16 95ZZZX2892 2 19950530 G 8520 633620 CRANKSHAFT CESSNA 340 340CESSNA 2076404 CE CONT O520 TSIO520J 17040 SO MAIN JOURNAL BROKE D E A ENGINE SHUTDOWN UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 EA 03 7632Q 6532 440 3400236 218750 ENGINE FAILURE - LEVEL AT 12,000 FEET MSL CRUISE POWER. RAPID REDUCTION IN RPM, M.A.P., AND O.P., THEN PUT IN FEATHER. UPON LANDING, MECHANIC DETERMINED THAT NR 1 AND NR 2 CYLINDERS PISTONS DO NOT MOVE WHEN CRANKSHAFT/PROPELLER IS ROTATED . ALTHOUGH THE ENGINE HAS YET TO BE DISASSEMBLED, IT CAN BE ASSUMED THE CRANKSHAFT IS PROBABLY BROKEN AT A REAR MAIN JO URNAL. 1 L 7 2 3O 3 O 3A25 E8CE 1995061600152 19950616 00152 SO 1995 6 16 95ZZZX2906 2 19950504 G 7310 635158S4S32 HOSE ASSY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO FUEL INJ LEAKING B A CGHR K NONE K FLUID LOSS IN INSP/MAINT 1 GL 03 8132N 404 CE1585 578743 PILOT REPORTS THE ENGINE COULD NOT BE LEANED AT ALTITUDE AND THAT IT WOULD NOT IDLE OR CONTINUE RUNNING AT SPEEDS BELOW 800 RPM. FOUND THE FLEXIBLE FUEL LINE LEAKING THROUGH THE BRAIDED EXTERIOR ALONG ITS ENTIRE LENGTH. THIS LINE SUPPLIES FUEL FROM THE FUEL INJECTOR TO THE FUEL FLOW TRANSMITTER HARD LINE. IT IS ROUTED BETWEEN NR 3 AND NR 5 CYLINDERS. 1 L 7 1 3O 3 O 3A15 E5CE 1995061600326 19950616 00326 NE 1995 6 16 95ZZZX2938 2 19950605 G 7321 FUEL CONTROL CESSNA 425 425 2076018 CE PWA PT6 PT6A112 52043 NE ROD ENDS REQ LUBE B EIPR O OTHER O OTHER DE DESCENT 1 WP 07 6773L 4250037 PCE12119 HOBBS 115.1. TT A/F 4861.2. ON DESCENT, LEFT ENGINE DID NOT RESPOND TO POWER REDUCTION. TROUBLESHOT, CLEANED, AND LUB RICATED F.C.U., ROD ENDS, AND LINKGAGE. OPS CHECK OKAY. FLIGHT CHECK OKAY. ENGINE T.S.O. 1369.7. 1 L 7 2 3T 3 T RT A7CE E4EA 1995061600328 19950616 00328 WP 1995 6 16 95ZZZX2940 2 19950605 G 7230 30720122 BLADE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE7313 01518 WP 2ND STAGE LP SEPARATED D O OTHER O OTHER CR CRUISE 1 GL 05 4350M 6299 142 76556 SECOND STAGE L.P. BLADE SEPARATED IN STRESS RUPTURE, 4712 CYCLES. OCCURRED ON 1-31-95 IN-FLIGHT. REF: SB TFE 731-72-3 556. 2 L 7 3 4F 4 F A46EU E6WE 1995061600329 19950616 00329 WP 1995 6 16 95ZZZX2941 2 19950605 G 7230 30720122 BLADE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE7313 01518 WP 2ND STAGE LP FAILED D K NONE O OTHER NR NOT REPORTED 1 GL 05 4350M 6352 142 76568 OCCURRENCE 4-26-95. SECOND STAGE L.P. BLADE FAILURE IN-FLIGHT TO EWR. REF: SB TFE731-72-3556 STRESS RUPTURE. 2 L 7 3 4F 4 F A46EU E6WE 1995061600338 19950616 00338 EA 1995 6 16 95ZZZX2950 2 19950503 G 7414 10382585 CONTACT ASSY D6LN3000 PIPER PA32 PA32RT300 7103215 SO LYC O540 IO540K1G5 41532 EA RT MAG TIP BROKEN B CQVR K NONE O OTHER IN INSP/MAINT 1 CE 01 36590 28 8325063 32R7885197 L1831648A PILOT NOTED A DEAD MAG IN THE RIGHT POSITION. INVESTIGATION REVEALED THE POINTS NOT OPENING. CONTACT ASSEMBLY HAS TIP BROKEN OFF. PART TOTAL TIME 30 HRS. TCM IGNITION SB 651 COVERS THIS, BUT IS NOT WELL KNOWN. RECOMMEND ALERT BE ISSUED . 1 L 7 1 3O 3 O A3SO 1E4 1995061600345 19950616 00345 SO 1995 6 16 95ZZZX2957 2 19950521 G 8500 ENGINE GULSTM 680 685 0141612 SW CONT O520 GTSIO520K 17032 SO NR 2 CYL FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 05 333HQ 12018 605129 ENG. LOST M.P. AND OIL PRESS. FOUND COMP. TURBO DAMAGE, NR 2 CYLINDER. PISTON NOT MOVING AND LIFTERS MISSING FROM HOUS INGS. THREE CYLINDERS FOUND VISIBLY CRACKED. OIL FOUND IN VAC. AND PRESS. PUMP LINES. 'LINES FOUND CON BACKWARDS ON V AC-PRESS. PUMP.' 71 HRS S.M.O.H. RECENT ANNUAL S.M.O.H. SUBMITTER SUGGESTS STRICTER CONTROL ON ENG. OVERHAULERS AND MA INT. SHOP. 1 H 7 2 3O 3 O 2A4 E7CE 1995061600347 19950616 00347 EA 1995 6 16 95ZZZX2959 2 19950514 G 7322 MA4SPA CARBURETOR FACET PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA VENTURI DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SO 05 1453T 200 287225521 L3182327A SINCE INSTALLING ONE-PIECE VENTURI, ENG. HAS PROGRESSIVELY RUN RICH - HAVE HAD CARB. APART ON 2 OCCASIONS TO CHECK FLOAT LEVEL, VENTURI, ACCELL. PUMP, AND NEEDLE AND SEAT FOR PERFORMANCE, MIXTURE HAS TO BE LEANED (1) KNOB. VIOLENT SHUDDER ON POWER REDUCTION UNLESS MIXTURE IS LEANED FIRST. SUSPECT CARB. NEEDS DIFFERENT DISCHARGE NOZZLE WITH THIS VENTURI. 1 L 7 1 3O 3 O 2A13 E274 1995061600354 19950616 00354 EA 1995 6 16 95ZZZX2966 2 19950606 G 8550 ENGINE CESSNA 210 P210N 2073454 CE LYC O540 TIO540V2AD 41532 EA OIL PAN OIL SLUDGE D K NONE O OTHER IN INSP/MAINT 1 SO 03 4994K 800 P21000392 L861661A DURING TEAR DOWN INSPECTION OF ENGINE AFTER PROP STRIKE, THICK OIL SLUDGE DEPOSITS WERE FOUND IN THE CRANKSHAFT AND THE OIL PAN. TWO ACCESSORY HOUSING GEARS HAD TO BE REPLACED DUE TO PITTING AND WEAR. RECORDS SHOW THE ENGINE HAD BEEN RUN USING MOBILE AV-1 OIL FROM 05-02-88 THROUGH 03-25-93 FOR A TOTAL OF 592.6 HOURS. THE SOLID FILM IN THE CRANKSHAFT AND O IL PAN MEASURED .1250 INCH THICK. 1 H 7 1 3O 3 O 3A21 E14EA 1995061600478 19950616 00478 SO 1995 6 16 95ZZZX3002 2 19950515 G 8520 ROD CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO ENGINE FAILED E EAVV A UNSCHED LANDING O OTHER NR NOT REPORTED 1 GL 09 36934 820 414A0486 276819R ENGINE CAME APART IN-FLIGHT. SUSPECT CONNECTING ROD OR COUNTERWEIGHT FAILURE. DATE 5-15-95. 1 L 7 2 3O 3 O A7CE E8CE 1995061600482 19950616 00482 EA 1995 6 16 95ZZZX3006 2 19950529 G 8520 149518 BEARING WRIGHT R1820 R182080 67020 EA MASTER ROD FAILED B EJ4R K NONE O OTHER IN INSP/MAINT 1 SW 11 473912 MASTER ROD BEARING FAILED AND SEIZED TO CRANKSHAFT ROD JOURNAL ON GROUND AFTER START-UP. LACK OF PROPER LUBRICATION. S USPECT CAUSED FROM NOT PROPERLY PRE-OILING DURING START-UP. SUBMITTER SUGGESTS THIS ENGINE IS EXTREMELY SENSITIVE TO OI L STARVATION AT START-UP, ESPECIALLY AFTER SITTING. 4 R E259 1995061600491 19950616 00491 NE 1995 6 16 95ZZZX3015 2 19950529 G 8530 116731 CYLINDER PWA R1830 R183092 52020 NE NR 12 FAILED B EJ4R O OTHER O OTHER NR NOT REPORTED 1 SW 11 480 56873 NR 12 CYLINDER SKIRT CRACKED AND BROKE OFF IN-FLIGHT AFTER CHAFING MOST OF ONE SIDE OF PISTON AWAY. 4 R 5E4 1995062300027 19950623 00027 GL 1995 6 23 95ZZZX3026 2 19950207 G 7320 23007827 VALVE BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL ENG INOPERATIVE C K NONE O OTHER IN INSP/MAINT 1 EU 01 732H 20 3457 51607 VALVE INOPERATIVE. 1 G 7 1 3U 3 U H2SW E1GL 1995062300028 19950623 00028 GL 1995 6 23 95ZZZX3027 2 19950128 G 7320 23007827 VALVE BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL ENG FAILED C K NONE O OTHER IN INSP/MAINT 1 EU 01 732H 1526 2395 51607 THE SOLENOID VALVE IS NOT WORKING. 1 G 7 1 3U 3 U H2SW E1GL 1995062300036 19950623 00036 SO 1995 6 23 95ZZZX3034 2 19950607 G 8550 12509222 ADAPTER ASSY BEECH 35 J35 1151522 CE CONT O470 IO470C 17026 SO OIL FILTER WORN G S A UNSCHED LANDING J K WARNING INDICATION FLUID LOSS CR CRUISE 1 EA 01 8378D 405 D5497 786273CR DURING CRUISE FLIGHT, THE ENGINE BEGAN TO LOSE OIL PRESSURE. THE PILOT DECLARED AN EMERGENCY AND LANDED IN A FIELD WITH MINIMAL DAMAGE. THE ENGINE HAD BEEN EQUIPPED WITH FULL FLOW OIL FILTER KIT INSTALLED UNDER STC 3262 WE. THE THREADS O N THE ADAPTER ASSEMBLY BECAME WORN AND THE ADAPTER WAS LOOSE WHERE IT FITS INTO THE ENGINE ACCESSORY CASE. THE OIL LEAK ED OUT AROUND THE ADAPTER AND THE ENGINE SEIZED. THE ADAPTER NUT ITEM NR 5 GETS TORQUED DOWN COMPRESSING A PACKING ITEM NR 6. IF THE NUT WERE UNDERTORQUED, THE WEIGHT OF THE FILTER PLUS THE LENGTH OF THE ADAPTER WOULD CREATE LEVERAGE TO V IBRATE AND WEAR OUT THE THREADS OF THE ADAPTER. THE THREADS OF THE ENGINE CASE WERE IN GOOD CONDITION. 1 L 7 1 3O 3 O 3A15 E273 1995062300040 19950623 00040 EA 1995 6 23 95ZZZX3038 2 19950606 G 7250 310250201 BLADE 3029312 BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA 1ST PT TIP MISSING B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 259AF 3729 UB55 32028 THE POWER SECTION WAS RECEIVED FROM ARIZONA AIRWAYS WITH 35 PERCENT OF A FIRST STAGE PT BLADE TIP PLATFORM MISSING. AFT ER THE PT BLADE AND DISK WERE DISASSEMBLED AND INSPECTED, A TOTAL OF (2) 1ST STAGE AND (11) 2ND STAGE BLADES WERE REPLAC ED. 2 L 7 2 4T 4 T RT A24CE E4EA 1995062300042 19950623 00042 NE 1995 6 23 95ZZZX3040 2 19950301 G 7210 310983901 SHAFT BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67 52043 NE PROP SHAFT GALLED B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 3YV 3970 4X271 UE3 114086 THE POWER SECTION WAS REPORTED AS HARD TO ROTATE. UPON DISASSEMBLY, FOUND PROP SHAFT AND SLEEVE WAS GALLED IN SUCH A WA Y THAT IT COULD NOT ROTATE FREELY. IT HAS BEEN DETERMINED THE GALLING OCCURRED DUE TO FUEL OIL HEATER CONTAMINATING THE OIL SYSTEM WITH FUEL. 2 L 7 2 4T 4 T RT A24CE E26NE 1995062300043 19950623 00043 NE 1995 6 23 95ZZZX3041 2 19950411 G 7250 311269601 BEARING BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67 52043 NE PWR TURB SPALLED B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 154ZV 21613 557 FC22643 UE154 32041 THE METAL OBSERVED IN THE POWER SECTION WAS BEING GENERATED BY THE NR 4 BEARING. THE CAUSE OF THE NR 4 BEARING SPALLING IS UNDER INVESTIGATION BY PRATT AND WHITNEY CANADA. 2 L 7 2 4T 4 T RT A24CE E26NE 1995062300044 19950623 00044 NE 1995 6 23 95ZZZX3042 2 19950221 G 7210 310835601 SUN GEAR PWA PT6 PT6A67 52043 NE POWER SECT TEETH MISSING B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 4756 UE004 114018 THE FIRST STAGE SUN GEAR WAS SPALLED AND SEVERAL GEAR WERE FOUND LIBERATED. INVESTIGATION IS LOOKING TOWARD ELECTROSTAT IC DISCHARGE DUE TO THE SPALLING AND PAST HISTORY OF THE ENGINE AND PROPELLER COMBINATION. 4 T E26NE 1995062300047 19950623 00047 NE 1995 6 23 95ZZZX3045 2 19950507 G 7230 3023401 BLADE PWA PT6T PT6T3B 52045 NE CT DISK MISMANUFACTURED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 PART WAS RECEIVED FROM PWC AND WAS FOUND INCOMPLETE RIVET SLOT NOT CHAMFERED ON LEADING EDGE SIDE. PART RETURNED TO PWC FOR CREDIT. 4 U E22EA 1995062300048 19950623 00048 EA 1995 6 23 95ZZZX3046 2 19950410 G 7250 310023601 SEAL RING PWA PT6 PT6A65B 52043 EA HOT SECT EXCESS GAP B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 PARTS RECEIVED FROM PRATT AND WHITNEY AND WERE FOUND TO HAVE AN EXCESSIVE GAP 1,000. 4 T E4EA 1995062300049 19950623 00049 EA 1995 6 23 95ZZZX3047 2 19950515 G 7313 3005305 WASHER KEY PWA PT6 PT6A65B 52043 EA GAS GENERATOR MISINSTALLED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 RECEIVED FUEL NOZZLE SET FROM STOCK AND ONE KEY WASHER WAS FOUND TO BE IMPROPERLY INSTALLED. SET RETURNED TO OVERHAUL F ACILITY REGIONAL AIRCRAFT SERVICES. 4 T E4EA 1995062300050 19950623 00050 NE 1995 6 23 95ZZZX3048 2 19950413 G 7210 3037767CL1 GEAR ASSY PWA PT6 PT6A67 52043 NE POWER SECT GALLED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 65C908 PART RECEIVED FROM STOCK AS NEW PART FROM PWC. PART SHOWS GAULING MARKS ON GEAR SIDEWALLS. PART RETURNED TO VENDOR. 4 T E26NE 1995062300051 19950623 00051 EA 1995 6 23 95ZZZX3049 2 19950417 G 7240 3035567 SEAL ASSY PWA PT6 PT6A65B 52043 EA HOT SECT MISIDENTIFIED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 50013 PART RECEIVED FROM STOCK AND WAS FOUND TO BE IMPROPERLY IDENTIFIED. PART IS A CL 5, BUT IS IDENTIFIED AS A CL 7. 4 T E4EA 1995062300327 19950623 00327 EA 1995 6 23 95ZZZX3085 2 19950511 G 7414 2G6394 MAGNETO BOSCH DOUG DC3 R4D8 3021474 WP WRIGHT R1820 R182080 67020 EA NR 2 ENGINE NR 1 DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 17 3906J 1200 43344 EXCESSIVE MAGNETO DROP ON RUN-UP. SUSPECT CAUSE INTERNAL MAG PROBLEM. DOUGLAS MANUAL RECOMMENDS NO FIELD WORK, JUST RE PLACE AND SEND FOR OVERHAUL. 2 L 7 2 4R 4 R 6A2 E259 1995062300333 19950623 00333 WP 1995 6 23 95ZZZX3091 2 19950314 G 7260 3070394 BRACKET ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE7313 01518 WP ASSORY GEARBOX BROKEN B A XEFR K NONE O OTHER IN INSP/MAINT 1 GL 31 420JM 5217 193 P77130 WHILE COWL OPENED FOR NON-RELATED MAINTENANCE, NOTED INBOARD ACCESSORY GEARBOX TO FAN SUPPORT STRUT HANGING LOOSE DUE TO BROKEN MOUNTING EARS ON GEARBOX STRUT ROD ATTACH BRACKET. WHILE REPLACING BRACKET AND ADJUSTING PER TFE 731-3 L.M.M. 7 2-60-01, NOTED SLIGHT PRELOAD ON BRACKET AND ROD-END BEARING OF SHAFT REQUIRED TO INSTALL LOWER BOLT. LOOSENING FIT BY EXPANDING LOWER ROD-END ONE-HALF TURN PRODUCED A MUCH BETTER FIT WITH NO PRELOAD. SUBMITTER SUSPECTS SLIGHT PRELOAD STR ESS OVER TIME CREATED FATIGUE. BELIEVE NEW PN 3070394-1 BRACKET MAY BE IMPROVED PART. 2 M 7 2 4F 4 F A2SW E6WE 1995062300641 19950623 00641 NE 1995 6 23 HEEA955179 2 19950613 G 7321 25491281 FUEL CONTROL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101650B1 41560 NE ENGINE DEFECTIVE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 217UC 2405 7152 ENGINE HOT STARTS. REPLACED WITH SERVICEABLE FUEL CONTROL AND RETURNED AIRCRAFT TO SERVICE. 1 G 7 2 3U 3 U H13EU E5NE 1995062300653 19950623 00653 GL 1995 6 23 HEEA955191 2 19950615 G 7250 6895801 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 1ST STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 50182 951 CAT70556 45242 CAE860771 ENGINE REMOVED DUE TO LOW POWER. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: SEVERLY SULFIDATED BLADE TIP ON #1 WHEEL CAUSING WHEEL AND NOZZLE CONTACT WITH TRAILING EDGE TIPS OF 8 EACH BLADES MISSING. SCRAPPED #1 WHEEL. 1 G 7 1 3U 3 U H2SW E1GL 1995063000005 19950630 00005 SO 1995 6 30 95ZZZX3130 2 19950516 G 7314 6493683AIR PUMP PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO RT ENG FUEL SEAL LEAK D O OTHER K FLUID LOSS CR CRUISE 1 GL 03 76PB 332 B119404BR 347970067 266445R ON 2-21-95, THE RIGHT ENGINE DEVELOPED A SURGE ON F.F. AND M.A.P. DURING CRUISE. AFTER TROUBLESHOOTING, DISCOVERED ANER OID SEAL HAD FAILED. THE PUMP WAS REPAIRED AND REINSTALLED (PART TT 257.5.) ON 5-16-95, THE SAME THING HAPPENED TO THE RIGHT ENGINE 62.6 HRS AFTER IT WAS REPAIRED. GENUINE T.C.M. PARTS WERE USED AND IT WAS REPAIRED BY A T.C.M. DEALER UND ER WARRANTY. NOTE: THE PUMPS T.B.O. IS 1800 HOURS. 1 L 7 2 3O 3 O A7SO E9CE 1995063000009 19950630 00009 SO 1995 6 30 95ZZZX3134 2 19950419 G 8520 CRANKCASE BEECH 55 95B55 1152706 CE CONT O470 IO470L 17026 SO NR 4 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 06 213CH 733 TC2298 272888R DURING INSPECTION, A .75 INCH CRACK WAS FOUND RADIATING UPWARD FROM THE AFT UPPER MOUNTING STUD FOR NR 4 CYLINDER. THE ENGINE HAD 732.9 HOURS SINCE BEING REBUILT BY THE FACTORY AND HAD BEEN IN SERVICE FOR 24 MONTHS. 1 L 7 2 3O 3 O 3A16 3E1 1995063000012 19950630 00012 EA 1995 6 30 95ZZZX3137 2 19950605 G 7414 M3637 CONTACT SLICK 4250R CESSNA 172 172N 2072434 CE LYC O360 O360A4A 41514 EA MAGNETO POINTS CLOSED D K NONE O OTHER IN INSP/MAINT 1 WP 25 734RA 68 1010138 17269044 L1032136F A MISS ON ONE MAG CAUSED REMOVAL AND EXAMINATION OF THE MAG. THE POINT GAP WAS CLOSED DOWN AND THE POINTS WERE OF A TYP E NOT SEEN IN THIS SERIES MAG BEFORE. SINCE THEY HAD BEEN INSTALLED A SHORT TIME BEFORE, A CALL TO THE INSTALLING AGENC Y WAS MADE. ACCORDING TO THEIR SLICK MANUAL, M3637 WAS CORRECT (1993). ACCORDING TO THE '94 (AND '89) MANUAL, M3081 WO ULD BE CORRECT. A CALL TO SLICK VERIFIED THE MISTAKE IN THE 1993 MANUAL. 1 H 7 1 3O 3 O NT 3A12 E286 1995063000015 19950630 00015 EA 1995 6 30 95ZZZX3140 2 19950512 G 7414 ES10382585 BREAKER POINT BENDIX 3FLN3000 MOONEY M20 M20C 5870208 SW LYC O360 IO360A3B6 41514 EA CAM FOLLOWER EXCESS WEAR B L A DYTR K NONE O OTHER IN INSP/MAINT 1 SO 15 6079Q 3 C090010G 3255 l2568151A DURING 100-HOUR PHASE INSPECTION, MAG WAS REPLACED WITH OVERHAULED UNIT. TWO AND ONE-HALF FLIGHT HOURS LATER, MAG FAILE D. FOUND CAM FOLLOWER ON BOTH BREAKER POINTS EXCESSIVELY WORN. MAG TIMING OUT OF LIMITS. SUBMITTER SUGGESTS MFG CHANG E FROM PHENOLIC TO PLASTIC CAM FOLLOWER MATERIAL TO BE THE CONTRIBUTING FACTOR. 1 L 7 1 3O 3 O 2A3 1E10 1995063000039 19950630 00039 NE 1995 6 30 95ZZZX3164 2 19950518 G 7200 ENGINE LEAR 23 23LEAR 5170102 CE GE CJ610 CJ6104 30006 NE LT ENGINE FLAME OUT C B EMER. DESCENT X ENGINE FLAMEOUT CL CLIMB 1 SO 17 154AG 6814 3490 23034 LEFT ENGINE FLAMED OUT AT 40,900 FEET CLIMBING THROUGH BAD WEATHER. PILOT REQUEST DESCENT TO 10,000 FEET AND NEAREST AI RPORT. AIRCRAFT ENGINE RE-LIGHT PROCEDURES FOLLOWED, ENGINE RE-STARTED AT 20,000 FEET, AND NORMAL LANDING AT NEAREST AI RPORT. ENGINE INSPECTED FOR DAMAGE, NONE NOTED. GROUND RUNS PERFORMED ALL NORMAL. AIRCRAFT RETURNED TO SERVICE. ATTR IBUTE CAUSE TO POOR WEATHER, HEAVY TURBULENCE AND RAINS. 1 L 7 2 4J 4 J A5CE 1E16 1995063000316 19950630 00316 EA 1995 6 30 95ZZZX3191 2 19950510 G 7414 10357584 DISTRIBUTOR GEAR S4LN20 PIPER PA28 PA28180 7102808 SO LYC O360 O360A3A 41514 EA MAGNETO LOOSE FINGER D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 EA 07 9521J 942448T 283739 ENGINE RAN ROUGH ON RIGHT MAG. DISASSEMBLED MAG AND FOUND TEETH ON DISTRIBUTOR GEAR MISSING AND LOOSE DISTRIBUTOR FINGE R ELECTRODE. LOOSE ELECTRODE PROBABLY HIT STATIONARY ELECTRODE CAUSING TEETH TO BREAK. 1 L 7 1 3O 3 O 2A13 E286 1995063000317 19950630 00317 SO 1995 6 30 95ZZZX3192 2 19950526 G 7314 6467661 PUMP BEECH 36 A36 1151604 CE CONT O550 IO550* SO ENG FUEL DEFECTIVE D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 25 8180N 198 E2606 281968R ENGINE RAN ROUGH AT ALTITUDE, AUTOMIX NOT WORKING. WOULD NOT AUTOLEAN. 1 L 7 1 3O 3 O 3A15 E3SO 1995063000318 19950630 00318 CE 1995 6 30 95ZZZX3194 1 19950531 G 7603 AN311 BOLT BEECH 33 F33A 1151425 CE CONT O520 IO520BA 17032 SO THROTTLE CONTROL BROKEN D A UNSCHED LANDING O OTHER CR CRUISE 1 GL 03 24184 CE765 569214 PILOT REPORTED NO THROTTLE CONTROL WHILE AT CRUISE POWER. AFTER LANDING, FOUND THROTTLE CONTROL DISCONNECTED FROM FUEL CONTROL ARM. BOLT WAS FOUND IN ENGINE COMPARTMENT BROKEN OFF AT THE COTTER PIN HOLE. 1 L 7 1 3O 3 O 3A15 E5CE 1995063000327 19950630 00327 1995 6 30 95ZZZX3203 1 19950519 G 7922 75944 VALVE LYC O360 O360* 41514 EA THERMO BYPASS CRIMP NUT LOOSE D K NONE O OTHER IN INSP/MAINT 1 GL 21 ON C/W LYC SB 518C BY CHECKING FOR LOOSE CRIMP NUTS, HAVE INSPECTED 6 AND FOUND 4 LOOSE NUTS. 3 O E286 1995063000337 19950630 00337 SO 1995 6 30 95ZZZX3213 2 19950615 G 8530 530658 BUSHING 632043 CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO PISTON PIN SPLIT B NT2R K NONE O OTHER IN INSP/MAINT 1 CE 07 525RG 903 421C0616 241062R FOUND NR 1 PISTON PIN ROD BUSHINGS CRACKED CIRCUMFERENCE WISE .3750 INCH AND SPLIT ABOUT .0312 INCH. FOUR OUT OF 6 BUSH INGS CRACKED. NR 2 CYLINDERS WERE REMOVED FOR LOW COMPRESSION AT ANNUAL. 1 L 7 2 3O 3 O A7CE E7CE 1995063000340 19950630 00340 EA 1995 6 30 95ZZZX3216 2 19950501 G 8530 RING PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA CYLINDER BROKEN D E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 NM 07 27354 153 317752180 L222568A ENGINE SHUT DOWN IN-FLIGHT DUE TO LOSS OF OIL PRESSURE. INVESTIGATION REVEALED BROKEN COMPRESSION RINGS ON 1 CYLINDER A ND SEVERELY WORN RINGS ON ANOTHER. THESE WERE NUCHROME CYLINDERS WITH 153.2 HOURS SINCE NEW. ENGINE OVERHAUL AGENCY IN DICATED THEY HAVE SEEN THIS PROBLEM BEFORE AND ATTRIBUTE ITS CAUSE TO AN EXCESSIVELY LEAN MIXTURE CREATING HIGH HEAD TEM PERATURES. ENGINE HAS BEEN REPAIRED. 1 L 7 2 3O 3 O A20SO E14EA 1995063000358 19950630 00358 NE 1995 6 30 95ZZZX3234 2 19950605 G 7532 2856201 BLEED VALVE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1 60030 NE ENGINE INOP D A A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 WP 13 269JM 1398 401 AIRCRAFT DEPARTED. ON ITS FIRST FLIGHT ABOUT 8:45, PILOT HEARD A BIG BANG COMING FROM THE ENGINE FOLLOWED BY POPPING SO UND AND LOSS OF POWER. THE PILOT WENT INTO EMERGENCY PROCEDURE. AS DECREASE OF POWER, ENGINE CAME BACK ON-LINE. THE P ILOT MANAGED TO SET THE ACFT DOWN ON A PRIVATE PROPERTY. MECHANICS WERE SENT OUT AND FOUND BLEED VALVE INOP. REPLACED THE VALVE AND C/W RUN-UP AND OPS CHECK AND FOUND ACFT AND ENGINE SERVICEABLE. 1 G 7 1 3U 3 U NC H9EU E19EU 1995063000377 19950630 00377 EA 1995 6 30 95ZZZX3239 2 19950518 G 8530 73806 PUSHROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CYLINDER TIP FAILED D K NONE O OTHER NR NOT REPORTED 1 SW 11 5241Q 15285088 L2241915 PUSHROD TIP SEPARATION. SECOND FAILURE ON THIS ENGINE. TOTAL TIME 6696. ENGINE TSMOH 366. REMOVED PN 73806. REPLACE D WITH NEW PUSHROD PN 73806, REV A. 1 H 7 1 3O 3 O NT 3A19 E223 1995063000383 19950630 00383 EA 1995 6 30 95ZZZX3245 2 19950609 G 8530 77998 HOUSING PIPER PA31 PA31310 7103103 SO LYC O540 TIO540A2C 41532 EA ENG INDUCT SYS BOLT DETACHED B BCBR K NONE O OTHER NR NOT REPORTED 1 EA 03 44RL 124 317401217 HOUSING FOR YEARS HAS BEEN INSTALLED WITH 4 EACH STD 1875 BOLTS AND THE TWO INTERNAL BOLTS WERE STD 1890 DRILLED HEADS F OR SAFETY WIRE, STD 1890 NOW IS CHANGED TO STD 1875 UNDRILLED AND INSTALLED WITH A PLAIN WASHER, AN960, AND MS535333 ST ARLOCK WASHER. ONE OF THE INSIDE BOLTS BACKED OUT AND WENT INTO NR 2 CYLINDER AND DESTROYED THE PISTON, CYLINDER HEAD, AND VALVES. 1 L 7 1 3O 3 O RT A20SO E14EA 1995063000384 19950630 00384 SO 1995 6 30 95ZZZX3246 2 19950612 G 8530 643766 GUIDE CONT O520 IO520* 17032 SO INTAKE OUT OF LIMITS B YCTR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 11 INSPECTION OF NEW PARTS FOUND 6 EACH INTAKE VALVE GUIDES DEFECTIVE OUT OF 6 EACH NEW TCM CYLINDERS. ALL GUIDES ARE OUT OF NEW LIMITS AND TAPERED FROM TOP TO BOTTOM. TOTAL OF 18 INTAKE GUIDES, PN 643766, REPORTED OUT OF LIMITS BY SUBMITTER . 3 O E5CE 1995063000385 19950630 00385 SO 1995 6 30 95ZZZX3247 2 19950612 G 8530 643767 GUIDE CONT O520 IO520* 17032 SO EXHAUST OUT OF LIMITS B YCTR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 11 SIX EACH EXHAUST VALVE GUIDES DEFECTIVE OUT OF 6 EACH NEW TCM CYLINDERS. ALL GUIDES ARE OUT OF NEW LIMITS AND TAPERED F ROM TOP TO BOTTOM. TOTAL OF 18 EXHAUST GUIDES, PN 643767, REPORTED OUT OF LIMITS BY SUBMITTER. 3 O E5CE 1995063000386 19950630 00386 NE 1995 6 30 95ZZZX3248 2 19950503 G 7323 3535196 DRIVE PIN WOODWARD 8061526 GE CFM56 CFM565A 13802 NE HMU MISMANUFACTURED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 79445 INVESTIGATI0N OF 2 FIELD REJECTS (DUE TO OVERSPEED GOV FAULT INDICATIONS). MFG FND CARBIDE WEAR PAD OF GOV DRIVE PIN AS SY IMPROPERLY POSITIONED WHEN BRAZED IN PLACE. INVESTIGATION FOCUSED UPON 1 MFG LOT. THESE CONDITIONS RESULT IN WEAR W HICH CAUSES A SHIFT IN OVERSPEED GOV SET POINT (IN REDUCED SPEED DIRECTION). THIS IS NOT BELIEVED TO BE A SAFETY CONCER N BECAUSE OF FAULT INDICATING LOGIC WHICH WILL PRECEDE ANY OPERATING PROBLEMS. WOODWARD & GEAE ARE COORDINATING ADVISAB ILITY OF SB TO INFORM FIELD OF CONDITION & RECOMMEND CHECK/REPLACE INTERVAL IN ORDER TO PREVENT POSSIBLE UNSCHEDULED REM OVAL. AFFECTED S/NS: WYG 79269-79270, WYG 79272-79290, WYG 79374-79382, WYG 79436-79443, WYG 79445, WYG 84161-84162. 4 F E29NE 1995063000396 19950630 00396 EA 1995 6 30 95ZZZX3258 2 19950602 G 7322 25244919 SERVO PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA FUEL INJ LT DEFECTIVE B BSYR K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 07 8090J 600576796118 L646648A LEFT ENGINE WILL NOT PRODUCE POWER. REMOVED AND REPLACED FUEL SERVO. OPS CHECKED GOOD. 1 M 7 2 3O 3 O RT A17WE 1E4 1995063000402 19950630 00402 SO 1995 6 30 95ZZZX3264 2 19950612 G 7314 6462121A5 FUEL PUMP CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO ENGINE DEFECTIVE D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 NE 05 4446C 536 C319410BR 18504338 293028R AIRCRAFT EXPERIENCED INTERMITTENT ROUGHNESS. FUEL PRESSURE CHECK SHOWED FLUCTUATING FUEL PRESSURE. REPLACED PUMP, ENGI NE RAN SMOOTH WITH NO FLUCTUATION OF FUEL PRESSURE. 1 H 7 1 3O 3 O 3A24 E5CE 1995063000403 19950630 00403 SO 1995 6 30 95ZZZX3265 2 19950607 G 8530 CYLINDER CESSNA 150 150 2071802 CE CONT O200 O200A 17020 SO NR 4 CYL ROCKER BOSS BROKEN D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 NE 05 66386 1283 150760101 31612A PILOT COMPLAINED OF ROUGH RUNNING ENGINE. UPON INVESTIGATION, FOUND NR 4 CYLINDER ROCKER SHAFT BOSSES (3 EACH) BROKEN O FF. CYLINDER HAD ONLY 1283 HOURS SINCE OVERHAUL. SEE AD 94-05-05. 1 H 7 1 3O 3 O NT 3A19 E252 1995063000596 19950630 00596 EA 1995 6 30 95ZZZX3270 2 19950612 G 8530 VALVE GUIDE PIPER PA32 PA32301T 7103209 SO LYC O540 TIO540S1AD 41532 EA EXHAUST EXCESS WEAR D K NONE O OTHER IN INSP/MAINT 1 EA 03 8317Y 873 328124005 L751761A C/W INSPECTION ITEM NR 9. REMOVAL OF ROCKER BOX COVERS EA400 HOURS AND FOUND EXCESSIVE EXHAUST DEPOSITS ON AND AROUND V ALVE SPRINGS. C/W LYC SB 388B. EXHAUST VALVE GUIDE WEAR TO BE VERY EXCESSIVE .050 INCH PLUS ON FIVE OF THE SIX CYLINDE RS, 837.00 HOURS SINCE NEW. SUBMITTER SUGGESTS VALVE FAILURE WAS IMMINENT WHICH COULD CAUSE TOTAL LOSS OF POWER. 1 L 7 1 3O 3 O A3SO E14EA 1995063000609 19950630 00609 SO 1995 6 30 95ZZZX3283 2 19950619 G 8530 534398 ROCKER ARM CESSNA 414 414 2075908 CE CONT O520 TSIO520J 17040 SO LT ENG CYLS WORN B MJ7R K NONE O OTHER IN INSP/MAINT 1 GL 05 13MN 1400 4140422 218655R ROCKER ARM BEARING WORN BEYOND LIMITS. SUSPECT DUE TO AGE AND OIL STARVATION TO THIS PART. 1 L 7 2 3O 3 O RT A7CE E8CE 1995070700025 19950707 00025 NE 1995 7 7 95ZZZX3312 2 19950614 G 8500 ENGINE DOUG DC3 DC3A 3021433 WP PWA R1830 R183090D 52020 NE NR 2 MAKING METAL C RPFB K NONE O OTHER NR NOT REPORTED 1 SW 17 32MS 1183 473 4978 CP350411 OIL TEMP HIGHER THAN NORMAL ON TRAINING FLIGHT. FOUND SMALL AMOUNT OF METAL IN OIL SCREEN. ENGINE REMOVED FOR REPAIR 6 -13-95. 2 L 7 2 4R 4 R A669 5E4 1995070700268 19950707 00268 EA 1995 7 7 95ZZZY0717 2 19950405 G 7200 ENGINE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA CONTROL SYS MALFUNCTION H CZ4R K NONE O OTHER IN INSP/MAINT 1 FS 01 24HL 30815 ENGINE HAD UNCONTROLLED ACCELERATION FROM IDLE. RPM OF NF REACHED 110% BEFORE MANUAL GOVERNOR WAS ENGAGED AND ENGINE SE CURED. INVESTIGATION REVEALED NO LOOSE LINES, NO LINES WITH ICE, AND AFCU DRIVESHAFT WAS SERVICABLE. ENGINE WAS REMOVED AND RETURNED TO PRATT & WHITNEY FOR EVALUATION AND REPAIR. 1 G 7 1 4U 4 U H4SW E22EA 1995070700273 19950707 00273 EU 1995 7 7 95ZZZY0722 1 19950405 G 7931 IPT70RT11000250G TRANSDUCER BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE ENG OIL DEFECTIVE H R7MA K NONE O OTHER IN INSP/MAINT 1 FS 01 202HN 183 7115 LE45071 PRESSURE TRANSDUCER UNIT CAUSES PRESSURE FLUCTUATION. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995070700275 19950707 00275 EU 1995 7 7 95ZZZY0725 1 19950405 G 7931 IPT70RT11000250G TRANSDUCER BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE ENG OIL DEFECTIVE H R7MA K NONE O OTHER IN INSP/MAINT 1 FS 01 911VU 101 7141 LE45582 #2 OIL PRESSURE GAUGE FLUCTUATES. REPLACED WITH NEW UNIT CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995070700282 19950707 00282 NE 1995 7 7 95ZZZY0759 2 19950426 G 7250 430136201 BEARING BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE ENGINE FAULTY H R7MA K NONE W INADEQUATE Q C IN INSP/MAINT 1 FS 01 7059N 66 7154 LE45518E THIS BEARING IS AFFECTED BY SB LT101-72-10-0151. ALLIED SIGNAL PARTS FACILITY FAILED TO ISOLATE AND DISCARD THIS BEARIN G. SUBSQUENTLY, ALLIED SIGNAL SHIPPED THE BEARING TO RMH. ALLIEDSIGNAL ADVISED RMH OF ERROR. THE AIRCRAFT WAS GROUNDE D AND THE ENGINE REMOVED. 1 G 7 2 3U 3 U H13EU E5NE10 1995070700340 19950707 00340 NE 1995 7 7 95ZZZY1001 2 19950510 G 7250 414129001 PT ROTOR BOLKMS 117 BK117A4 5626017 EU LYC LTS101 LTS101650B1 41560 NE ENGINE BLADE SHIFT H R7MA K NONE O OTHER IN INSP/MAINT 1 FS 01 127HH 1231 7060 LE45244E FAILED SERVICE BULLETIN LT 101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT. #12 +0.012". REPLACED WITH NEW UNIT(S), CORRECT ED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995070700341 19950707 00341 NE 1995 7 7 95ZZZY1002 2 19950510 G 7250 414129001 PT ROTOR BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE ENGINE BLADE SHIFT H R7MA K NONE O OTHER IN INSP/MAINT 1 FS 01 117MA 1076 7107 LE45155E FAILED SERVICE BULLETIN LT 101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT. #4-0.0145". REPLACED WITH NEW UNIT(S), CORRECTE D PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995070700342 19950707 00342 NE 1995 7 7 95ZZZY1003 2 19950510 G 7250 411105056 ROTOR ASSY BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE GAS PRODUCER DEFECTIVE H R7MA K NONE O OTHER IN INSP/MAINT 1 FS 01 7059N 1817 7154 LE45752 DUE SERVICE BULLETIN LT 101-72-10-0150. REQUIRES DISASSEMBLY AND INSPECTION OF ROTOR BROACH SLOTS FOR POSSIBLE CRACKS I N THE DISC/TENON AREA. LAB SEAL ENCLOSED WITH ROTOR. REPLACED WITH NEW UNIT(S), CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995070700343 19950707 00343 NE 1995 7 7 95ZZZY1004 2 19950510 G 7250 414129001 PT ROTOR BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE ENGINE BLADE SHIFT H R7MA K NONE O OTHER IN INSP/MAINT 1 FS 01 5188B 1776 7163 LE45518E FAILED SERVICE BULLETIN LT 101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT. REPLACED WITH NEW UNIT(S), CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995070700344 19950707 00344 NE 1995 7 7 95ZZZY1005 2 19950510 G 7250 414129001 PT ROTOR BOLKMS 117 BK117A4 5626017 EU LYC LTS101 LTS101650B1 41560 NE ENGINE BLADE SHIFT H R7MA K NONE O OTHER IN INSP/MAINT 1 FS 01 128HH 663 7036 LE45332 FAILED SERVICE BULLETIN LT 101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT. REPLACED WITH NEW UNIT(S), CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995070700345 19950707 00345 GL 1995 7 7 95ZZZY1458 2 19950612 G 7323 23007505 GOVENOR ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE H XH3R K NONE O OTHER IN INSP/MAINT 1 FS 01 NG SPLIT. FOUND GOV FAULTY 3 U E4CE 1995070700351 19950707 00351 NE 1995 7 7 EKGA9520836 2 19950505 G 7321 0164448080 FUEL CONTROL SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE DEFECTIVE E EKGA K NONE O OTHER IN INSP/MAINT 1 WP 07 123TV 2057 1682 4045 FCU WILL NOT PRODUCE MINIMUM ROTOR RPM. 1 G 7 1 3U 3 U H9EU E19EU 1995070700361 19950707 00361 NE 1995 7 7 RMXA9520533 2 19950326 G 7313 411101007 NOZZLE ASSY BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE GAS PRODUCER CRACKED E RMXA K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 05 117VU 578 7211 LE45528E UPON INSPECTION OF ENGINE ASSEMBLY FOR CAUSE OF LOW POWER (-86%) THE G.P. NOZZLE WAS FOUND TO HAVE A LARGE CIRCUMFERENTI AL CRACK ON THE INNER SHROUD TO VANE ASSY. WELD (81/2" CRACK) CIRCUMFERENCE OF INNER SHROUD IS APPROXIMATELY 19". REPLAC ED NOZZLE. 1 G 7 2 3U 3 U H13EU E5NE10 1995070700372 19950707 00372 GL 1995 7 7 RMXA9520553 2 19950326 G 7250 6895021 1ST NOZZLE ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE E RMXA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 DIAPHRAM IMPROPERLY INSTALLED, BOLT HOLES WOULD NOT LINE UP. 3 U E4CE 1995070700605 19950707 00605 EA 1995 7 7 95ZZZX3315 2 19950428 G 7414 MAGNETO BENDIX 6050880 BEECH B80 B80 1153010 CE LYC O540 IGSO540A1D 41532 EA LT ENG LT MAG POINTS GROUNDED D K NONE O OTHER IN INSP/MAINT 1 CE 05 65RW 2224 924 LD404 L256450 ON THE THIRD FLIGHT OF THE DAY, THE LEFT ENGINE FAILED TO START. THE CAP WAS REMOVED FROM THE MAG AND MOISTURE WAS FOUN D WHICH WAS GROUNDING THE VIBRATOR POINTS. MAG WAS DRYED OUT. OPS CHECK OK. 1 L 7 2 3O 3 O RT 3A20 1E7 1995070700618 19950707 00618 EA 1995 7 7 95ZZZX3328 2 19950406 G 7322 2539449 ADJUSTING NUT BENDIX 252427311 CESSNA 188 A188B 2073005 CE LYC O540 IO540K1G5 41532 EA SERVO BALL STEM MISSING B JK2R K NONE O OTHER IN INSP/MAINT 1 GL 07 4854R 31705 18802373T L1880848A INJECTOR ARRIVED WITH NO FUEL FLOW. UPON PUTTING IT ON FLOW BENCH USING NORMAL FLOW PROCEDURES, WAS UNABLE TO GET FUEL FLOW. REMOVED HEX BRASS NUT FROM REGULATOR. THE RETAINING AND FLOW ADJUSTING NUT WAS MISSING. RECOMMEND ALL FLOW BENC H OPERATORS SHOULD BE CAUTIONED ABOUT C/W SB RS-71, LOCTITE THE ADJUSTING NUT. 1 L 7 1 3O 3 O A9CE 1E4 1995070700619 19950707 00619 NE 1995 7 7 95ZZZX3329 2 19950502 G 7250 411105064 ROTOR LYC LTS101 LTS101650C3 41560 NE GP ROTOR BLADES CRACKED B E5RR K NONE O OTHER IN INSP/MAINT 1 SO 13 202 LE41115 DURING INSPECTION PER SB LT101-72-50-0150, SEVERAL BLADES FOUND TO HAVE INDICATION OF CRACKS DURING FPI. CRACKS WERE IN THE BLADE ROOT AREA. INVESTIGATION IS ON-GOING. 3 U E5NE 1995071400132 19950714 00132 GL 1995 7 14 95ZZZX3334 2 19950608 G 7321 23057344 FUEL CONTROL HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE MALFUNCTION B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5313Y 66 490496D CAE831718 AIRCRAFT HUNG-START AT 30 PERCENT - ALL SUBSEQUENT ADJUSTMENT HAD LITTLE OR NEGATIVE EFFECT ON THE FUEL SCHEDULING. REM OVED AND REPLACED UNIT AND AIRCRAFT STARTS NOW. UNIT SENT IN FOR OVERHAUL. 1 G 7 1 3U 3 U H3WE E4CE 1995071400133 19950714 00133 GL 1995 7 14 95ZZZX3335 2 19950515 G 7532 23005366 BLEED VALVE BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL ENGINE FAILED E A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SW 03 6610Y 1326 FF26510 51419 CAE895529 SHORTLY AFTER TAKEOFF, PILOT REPORTED ENGINE COMPRESSOR STALL. LANDED ON OFFSHORE PLATFORM WITHOUT INCIDENT. FOUND BLE ED VALVE STUCK IN OPEN POSITION. ALLISON 250-C30 IPC, CHAPTER 75, SECTION 10-00, FIGURE 5, ITEM 1J. 1 G 7 1 3U 3 U H2SW E1GL 1995071400134 19950714 00134 GL 1995 7 14 95ZZZX3336 2 19950512 G 7250 6876667 AIR TUBE BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20 03013 GL NR 1 ENGINE HOLE CHAFED E A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SW 03 54197 1663 CAT37782 S805 CAE802035F IN CRUISE FLIGHT, PILOT EXPERIENCED AN ENGINE TORQUE SPLIT, NR 1 ENGINE DROPPING OFF-LINE. LANDED ON OFFSHORE PLATFORM WITHOUT INCIDENT. FOUND HOLE CHAFED IN AIR TRANSFER TUBE, WITH ASSOCIATED CRACKS. ALLISON IPC, CHAPTERS 2-60, FIGURE 1 3, ITEM 24. 1 G 7 2 3U 3 U NC H3EU E4CE 1995071400135 19950714 00135 GL 1995 7 14 95ZZZX3337 2 19950531 G 7261 6895096 FILTER CAP 23035179 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL GEAR BOX OIL BROKEN E E A ENGINE SHUTDOWN UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 SW 03 1546K CAG90620 760082 CAE890616S ON 5-31-95 AT 1700, PILOT REPORTED NR 2 ENGINE LOW PRESSURE LIGHT ON. OIL PRESSURE LOW. SMELL OF OIL IN CABIN. SHUT D OWN ENGINE. SINGLE ENGINE LANDING MADE IN HOUMA. FOUND EAR ON ENGINE OIL FILTER CAP BROKEN, O-RING CUT. MINIMUM OIL P RESSURE BEFORE ENGINE SHUT DOWN, 50 PSI. S-76 IPC, FIGURE 9, SECTION 72-60-00, ITEM 4. 1 G 7 2 3U 3 U H1NE E1GL 1995071400170 19950714 00170 GL 1995 7 14 95ZZZX3373 2 19950525 G 7250 23035262 ROLLER BEARING 23051643 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL COMPRESSOR NR 1 FAILED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 708AL 1965 244 MP00558 760277 CAE890775S REPORTED LOUD GRINDING NOISE ON SHUT DOWN. COMPRESSOR WAS DISASSEMBLED DUE TO IMPELLER DRAGGING ON SHROUD AND FOUND NR 1 ROLLER BEARING HAD FAILED. UPON DISASSEMBLY, FOUND SEPARATE CAGE FOR ROLLERS BROKEN. APPROXIMATELY 80 DEGREES OF SEP ARATOR CAGE BROKEN OFF. FOUND 2 EACH ROLLERS AND PARTS FROM SEPARATOR CAGE LAYING ON TOP OF BEARING INSIDE OF NR 1 BEAR ING HOUSING. 1 G 7 2 3U 3 U H1NE E1GL 1995072800205 19950728 00205 EA 1995 7 28 95ZZZX3458 2 19950616 G 8520 CRANKCASE PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA NR 2-3 MAIN BOLTS LOOSE B EKIR O OTHER J WARNING INDICATION CR CRUISE 1 WP 07 252MA 2566 25 31P33 RL12762 ENGINE OVERHAULED 2-3-94. INSTALLED IN AIRCRAFT 4-1-94. AT 1,800 RPM CRUISE POWER, OIL PRESSURE AT 55 PSI, 190 DEGREES , OIL TEMPERATURE, WHICH IS ON THE TOP OF YELLOW ARC, BOTTOM OF GREEN ARC, AT HIGHER OIL TEMP, OIL PRESSURE WOULD DROP I NTO YELLOW ARC. REMOVED ENGINE TO DISASSEMBLE, FOUND SEVERAL CASE-THROUGH BOLTS NOT TORQUED. DISASSEMBLED, FOUND EVIDE NCE OF NR 2 AND NR 3 MAIN BEARINGS WORKING. MEASURED, FOUND WITHIN LIMITS. REASSEMBLED WITH NEW BEARINGS, OPS CHECKED GOOD, OIL PRESSURE 63 PSI AT 1,800 190 DEGREES. 1 L 7 2 3O 3 O A8EA E19EA 1995072800217 19950728 00217 CE 1995 7 28 95ZZZX3470 1 19950601 G 8120 4066105 TURBOCHARGER AIRESRCH CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO BEARINGS FAILED B BTSR A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 GL 23 5244A 357 TJR6449 21063324 517272 FOLLOWING DEPARTURE FROM AIRPORT WHILE IN A CRUISE CLIMB AT 8,500 FEET MSL, THE AIRCRAFT'S ENGINE LOST POWER, THEN SURGE D. AN IMMEDIATE RETURN TO AIRPORT WAS MADE AND ON THE DESCENT, THE ENGINE WAS INTERMITTENTLY SURGING. MANIFOLD PRESSUR E VARIATIONS FROM 18 INCHES UP TO 27 INCHES DURING POWER SURGES. PART OF THE TIME ENGINE WOULD RUN SMOOTHLY. LANDED WI THOUT INCIDENT WITH SURGING POWER OUTPUT. 1 H 7 1 3O 3 O 3A21 E8CE 1995072800221 19950728 00221 SO 1995 7 28 95ZZZX3474 2 19950620 G 8550 ADAPTER CESSNA 207 T207A 2073614 CE CONT O520 TSIO520M 17040 SO OIL PUMP THREAD DAMAGE D K NONE O OTHER IN INSP/MAINT 1 WP 07 9629M 1394 20700712 520424 DURING COMPLIANCE WITH SEB 92-1R1 (CESSNA). ADAPTER WAS REMOVED FROM PUMP HOUSING AND THREAD DAMAGE WAS EVIDENT. 3OX M AGNIFICATION OF DAMAGE APPEARED TO BE A MANUFACTURING DEFECT. NO DAMAGE DUE TO MISUSE IS SUSPECTED. SEB 93-1R1 IS TO C HECK THREAD DAMAGE DUE TO IMPROPER TORQUE AND SUBSEQUENT LOOSENESS. THIS CONDITION DID NOT EXIST AND SEB 93-1R1 DOES NO T APPLY TO THIS AIRCRAFT BY SERIAL NUMBER, HOWEVER, ENGINE AND PART IN QUESTION ARE SAME AS SERIAL NUMBER AIRCRAFT IN EF FECTIVITY CLAUSE. 1 H 7 1 3O 3 O A16CE E8CE 1995072800227 19950728 00227 EA 1995 7 28 95ZZZX3480 2 19950606 G 7322 CF2541803 DIAPHRAGM STEM BENDIX RSA10ED1 LYC O540 IO540K1A5 41532 EA FUEL SERVO FAILED B PB4R A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 SO 13 59361 ENGINE FAILURE CAUSING FORCED LANDING. FUEL DIAPHRAGM STEM FAILED (PN CF2541803). BROKE AT BALL SWAGE AREA INTERRUPTIN G FUEL FROM SERVO TO ENGINE. 3 O 1E4 1995072800235 19950728 00235 GL 1995 7 28 HEEA955222 2 19950626 G 7250 6895801 WHEEL 23031899 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 1ST STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5745S 1494 CAT70036 45491 CAE860022 ENGINE REMOVED DUE TO TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MINOR SULFIDATION ON ALL BLADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 1 3U 3 U H2SW E1GL 1995072800236 19950728 00236 GL 1995 7 28 HEEA955223 2 19950626 G 7250 23032280 WHEEL 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL 2ND STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1545K 1685 CAT95464 760047 CAE890643 ENGINE DISASSEMBLED DUE TO TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MINOR SULFIDATION O N OUTER TIP PATH AREAS OF ALL BLADES. SCRAPPED 2ND STAGE WHEEL. 1 G 7 2 3U 3 U H1NE E1GL 1995072800237 19950728 00237 GL 1995 7 28 HEEA955224 2 19950626 G 7250 6898911 WHEEL 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL 1ST STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1545K 1685 CAT95464 760047 CAE890643 ENGINE DISASSEMBLED DUE TO TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MINOR SULFIDATION O N ALL 1ST STAGE WHEEL BLADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 2 3U 3 U H1NE E1GL 1995072800291 19950728 00291 GL 1995 7 28 HEEA955283 2 19950629 G 7250 23038212 INTERNAL SUMP 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL ENG N2 SEAL DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5737T CAT70180 45454 CAE860136 ENGINE REMOVED DUE TO N2 SEIZURE. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: 50% OF GRAPHITE LIFTING IN INT ERNAL SUMP 9/12 SEAL, CAUSING N2 SEIZURE. 1 G 7 1 3U 3 U H2SW E1GL 1995072800348 19950728 00348 CE 1995 7 28 TEIL952 1 19950505 G 2910 124D0036SL0226 HOSE ASSY CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE RT HYD FAILED H TEIL K NONE K J FLUID LOSS WARNING INDICATION LD LANDING 1 SW 09 502T 2583 5600153 108316 DURING APPROACH AND LANDING AT SAT, AS LANDING GEAR WAS EXTENDED, HYDRAULIC LOW FLOW (RH) AND HYDRAULIC LOW LEVEL LIGHTS ILLUMINATED. INSPECTION ON THE GROUND AT SAT BY LOCAL MAINTENANCE PERSONNEL DETERMINED THE RH HYDRAULIC PUMP PRESSURE L INE HAD FAILED AND WAS LEAKING FLUID. REPLACEMENT LINE WAS ORDERED AND SHIPPED TO SAT MAINTENANCE PERSONNEL FROM CESSNA AIRCRAFT AT ICT. LINE WAS REPLACED, SYSTEMS SERVICED, AND GROUND RUNS ACCOMPLISHED. HYDRAULIC PRESSURE FILTERS WERE INSP ECTED FOR METAL CONTAMINATION AND NONE FOUND. SYSTEM BLED AND AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A22CE E25EA 1995072800349 19950728 00349 GL 1995 7 28 TEIL953 2 19950508 G 7323 10560590 LEVER ASSY BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL GOV DEFECTIVE H TEIL K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 09 GOVENOR ATTACH BEARING WILL NOT GO ON SLEEVE. MIC DIMENSION OF BEARING SHAFT 6.016 MM. NEW PART SECURED AND INSTALLED. N EW PART SHAFT DIMENSION 5.9 MM. 1 G 7 2 3U 3 U NC H3EU E4CE 1995072800352 19950728 00352 NE 1995 7 28 95ZZZX3488 2 19950626 G 7414 SF14LN3 MAGNETO BENDIX DOUG DC3 DC3 3021401 WP PWA R1830 R183092 52020 NE RT ENG RT MAG LOOSE D E ENGINE SHUTDOWN E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 11 24320 028394 20197 CP313794 RIGHT ENGINE STARTED RUNNING ROUGH IN-FLIGHT. ENGINE SHUT DOWN AND FEATHERED. FOUND RIGHT MAG HAS COME LOOSE. RE-TIME D AND TORQUED RIGHT MAG. OPS CHECKED SATISFACTORY. 2 L 7 2 4R 4 R A669 5E4 1995072800356 19950728 00356 SO 1995 7 28 95ZZZX3492 1 19950618 G 8120 07A19870 BRACKET PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532 EA LT TURBOMOUNT BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 19 61FL 1110 4622037 L897161A LEFT TURBOMOUNT BRACKET BROKE AT SUMP ATTACH POINT. THIS BRACKET SUPPORTS THE TURBOCHARGER. 1 L 7 1 3O 3 O RT A25SO E14EA 1995072800358 19950728 00358 EA 1995 7 28 95ZZZX3494 2 19950628 G 8530 15F1995736 PUSH ROD LYC O360 IO360A3B6 41514 EA ENGINE CORRODED B IBIR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 27 RECEIVED 3 EACH PUSH ROD ASSEMBLIES FROM DISTRIBUTOR. PUSH ROD ASSEMBLY HAS EXCESSIVE WEATHERING CORROSION AND PITTING ON THE OUTER SURFACE ON THE RODS. REFERENCED TO THE VENDOR FOR INSPECTION AND DISPATCH. ROD ASSEMBLIES WERE NOT PRESER VED IN ANY TYPE OF ANTI-CORROSION PACKING. 3 O 1E10 1995072800368 19950728 00368 SO 1995 7 28 95ZZZX3504 2 19950524 G 8530 630046 PISTON PIN BEECH 58 58 1152740 CE CONT O550 IO550C SO NR 5 CYLINDER FRACTURED D S K NONE O OTHER IN INSP/MAINT 1 EA 01 91WM 1314 TH1396 676056H WHEN REMOVING NR 2 AND NR 5 CYLINDERS TO CORRECT LOW COMPRESSION (LEAKING PAST RINGS), BOTH PISTON PINS WERE FOUND BROKE N IN TWO. 1 L 7 2 3O 3 O 3A16 E3SO 1995072800372 19950728 00372 SO 1995 7 28 95ZZZX3508 2 19950711 G 8530 SA6291171 ROTOR COIL CONT O470 O470* 17026 SO NR 6 CYL EXH FAILED B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 34 462596 SUPERIOR AIR PARTS VALVE ROTOR FAILED. NR 6 CYLINDER EXHAUST VALVE POSITION CAUSING ENGINE METAL CONTAMINATION. 3 O E273 1995072800373 19950728 00373 SO 1995 7 28 95ZZZX3509 2 19950711 G 8530 SA6291171 ROTOR COIL CONT O470 O470* 17026 SO NR 2 CYL EXH FAILED B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 34 462596 SUPERIOR AIR PARTS VALVE ROTOR FAILED. NR 2 CYLINDER EXHAUST VALVE POSITION CAUSING ENGINE METAL CONTAMINATION. 3 O E273 1995072800374 19950728 00374 EA 1995 7 28 95ZZZX3510 2 19950612 G 7310 6390107 HOSE ASSY PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA ENGINE CARB BROKE D K NONE O OTHER IN INSP/MAINT 1 GL 09 43224 3207 287425346 AT ANNUAL, NOTED ENGINE HOSES DATED 1974. UPON REMOVAL OF FUEL PRESSURE LINE FOR REPLACEMENT, FLEX HOSE BROKE NEAR SOCK ET. HOSE WAS VERY BRITTLE AND INNER LINER WAS CRACKED. SUBMITTER RECOMMENDED AD TO ESTABLISH LIFE LIMIT ON FLEXIBLE HO SES AT 5 YEARS OR ENGINE OVERHAUL, WHICHEVER COMES FIRST. 1 L 7 1 3O 3 O 2A13 E274 1995072800380 19950728 00380 SO 1995 7 28 95ZZZX3516 2 19950711 G 8530 SA6291171 ROTOR COIL CONT O520 IO520BA 17032 SO NR 3 CYL EXH BROKEN B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 560 232563R SUPERIOR AIR PARTS VALVE ROTOR FAILED. NR 3 CYLINDER EXHAUST VALVE POSITION CAUSING ENGINE METAL CONTAMINATION. 3 O E5CE 1995072800381 19950728 00381 SO 1995 7 28 95ZZZX3517 2 19950711 G 8530 SA6291171 ROTOR COIL CONT O470 O470* 17026 SO NR 3 CYL EXH FAILED B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 34 462596 SUPERIOR AIR PARTS VALVE ROTOR FAILED. NR 3 CYLINDER EXHAUST VALVE POSITION CAUSING ENGINE METAL CONTAMINATION. 3 O E273 1995072800382 19950728 00382 SO 1995 7 28 95ZZZX3518 2 19950711 G 8530 SA6291171 ROTOR COIL CONT O520 IO520BA 17032 SO NR 5 CYL EXH BROKEN B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 560 232563R SUPERIOR AIR PARTS VALVE ROTOR FAILED. NR 5 CYLINDER EXHAUST VALVE POSITION CAUSING ENGINE METAL CONTAMINATION. 3 O E5CE 1995072800390 19950728 00390 SO 1995 7 28 95ZZZX3526 2 19950524 G 8550 CH48108 OIL FILTER BEECH 58 58 1152740 CE CONT O550 IO550C SO SEAL DEFECTIVE D S K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 01 91WM 65 F11D301 TH1396 676056H RUBBER SEAL FOUND PROTRUDING FROM CENTER HOLE WHEN FILTER WAS REMOVED: 1 L 7 2 3O 3 O 3A16 E3SO 1995072800392 19950728 00392 EA 1995 7 28 95ZZZX3528 2 19950705 G 7322 PUMP BENDIX PIPER PA24 PA24260 7102406 SO LYC O540 IO540D4A5 41532 EA INJ PUMP DAUBER FOD D K NONE O OTHER IN INSP/MAINT 1 SO 11 9155P 244641 ON 100-HOUR INSPECTION, DISCOVERED LARGE MUDDAUBERS' NESTS IN THE INLET TO THE FUEL INJECTION PUMP. THIS WEBCO KIT WAS INSTALLED IN RESPONSE TO AN AD NOTE FOR AN ALTERNATE ENGINE INLET AIR SOURCE. (CARBURETOR HEAT BOX TYPE DEVICE). THIS AREA IS AFTER THE AIR INTAKE FILTER AND CANNOT BE DISCOVERED ON PRE-FLIGHT. 1 L 7 1 3O 3 O 1A15 1E4 1995080400001 19950804 00001 GL 1995 8 4 HEEA955336 2 19950710 G 7320 1564T1005 SERVOMOTOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENG CONTROL TRIPS BREAKER E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3071K 1395 S859 POPS CIRCUIT BREAKER. INSPECTED BY ACCESSORY OVERHAUL SHOP AND FOUND MOTOR HAS INTERMITTENT OPERATION. 1 G 7 2 3U 3 U H3EU E4CE 1995080400125 19950804 00125 NE 1995 8 4 EGRA95101 2 19950612 G 7412 9580113800 GENERATOR ARRIEL1C2 AEROSP SA365 AS365N2 8680815 EU TMECA ARRIEL ARRIEL1C 60030 NE ENGINE INOP E EGRA K NONE O OTHER IN INSP/MAINT 1 EA 17 272NE 281 12105 6435 HE GENERATOR INOPERATIVE . REPLACED 1 G 7 2 3U 3 U RT H10EU E19EU 1995080400150 19950804 00150 GL 1995 8 4 EGRA9524 2 19950410 G 7321 25490922 FUEL CONTROL 250C30P BELL 206 206L 1181522 SW ALLSN 250C 250C20B 03013 GL ENGINE MALFUNCTION E EGRA O OTHER O OTHER TO TAKEOFF 1 EA 17 209PD 277 895752 52075 FUEL CONTROL REQUIRES INTERNAL ADJUSTMENT TO START DERICH AND ACCEL. FUEL CONTROL SENT TO AIRWORK FOR REPAIR. UNIT REPAI RED BY AIRWORK UNDER WORK ORDER # V04689. UNIT RETURNED TO KEYSTONE AND PERFORMED OPERATIONAL CHECKS. OP CHECKED GOOD. 1 G 7 1 3U 3 U H2SW E4CE 1995080400179 19950804 00179 NE 1995 8 4 EGRA9557 2 19950427 G 7421 CH34016 IGNITER PLUG BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE ENGINE DEFECTIVE E EGRA K NONE O OTHER IN INSP/MAINT 1 EA 17 116MB 2163 7095 ENGINE IGNITER PLUG INOPERATIVE. 1 G 7 2 3U 3 U H13EU E5NE 1995080400246 19950804 00246 GL 1995 8 4 HEEA955378 2 19950720 G 7532 23053176 BLEED VALVE AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL ENGINE DEFECTIVE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 5793Y 6481 5141 #1 ENGINE COMPRESSOR SURGES WITH THROTTLE APPLICATION. REPLACED BLEED VALVE AND RETURNED TO SERVICE. 1 G 7 2 3U 3 U H11EU E4CE 1995080400461 19950804 00461 GL 1995 8 4 HEEA955405 2 19950724 G 7250 6895801 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 1ST STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 406EH 877 CAT70498 45183 CAE860655 ENGINE REMOVED DUE TO LOW POWER. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MINOR SULFIDATION ON ALL BLADES . SCRAPPED 1ST STAGE WHEEL. 1 G 7 1 3U 3 U H2SW E1GL 1995080400462 19950804 00462 GL 1995 8 4 HEEA955406 2 19950724 G 7250 6886407 WHEEL 6898735 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL 1ST STAGE SULFIDATION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3071K 1055 CAT33837 S859 CAE836510 ENGINE REMOVED DUE TO 1ST STAGE WHEEL RETIREMENT DUE. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MINOR SULF IDATION ON ALL BLADES. SCRAPPED 1ST STAGE WHEEL. 1 G 7 2 3U 3 U H3EU E4CE 1995080400515 19950804 00515 GL 1995 8 4 HEEA955480 2 19950728 G 7210 6876925A TUBE ASSY 23001938 AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL GEAR BOX MAKING METAL E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5793Y 7930 CAG40058 5141 CAE840058 ENGINE REMOVED DUE TO METAL IN OIL. UPON INSPECTION OF GEARBOX PARTS NOTED THE FOLLOWING: BELOW CEB1307 REQUIREMENTS O N TUBE ASSEMBLY. INSTALLED NEW TUBE ASSY. PART RETURNED TO ALLISON FOR CEB1307. REFERENCE: AFA#24405A (PART IS OUT O F CALENDAR DATE AND TIME LIMITS) 1 G 7 2 3U 3 U H11EU E4CE 1995080400518 19950804 00518 GL 1995 8 4 HEEA955483 2 19950728 G 7250 23004223 WHEEL 23031899 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 2ND STAGE MIS MFG E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 5745S CAT70036 45491 CAE860022 UPON INSPECTION OF NEW NEVER INSTALLED #2 WHEEL NOTED THE FOLLOWING: RECEIVED OVERMACHINED PER O/H SPECS ON #2 WHEEL SP LINES. INSTALLED NEW #2 WHEEL. 1 G 7 1 3U 3 U H2SW E1GL 1995080400525 19950804 00525 SO 1995 8 4 95ZZZX3572 2 19950711 G 7414 6220 MAGNETO SLICK PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO LT SIDE LEAD BROKEN B LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 888HL 535 89030035 468508081 273621R OWNER COMPLAINED OF A 'DEAD' LT MAGNETO. CHECKED TIMING AND FOUND POINTS OPENING PROPERLY. REMOVED MAGNETO AND DISASSE MBLED. FOUND INSIDE OF MAGNETO CORRODED AND COIL GROUND LEAD BROKEN. SUSPECT LEAD BROKE DUE TO THE CORROSION. SLICK S B1-88 REFERS TO INSPECTING MAGNETOS EVERY 100 HRS FOR MOISTURE CONTAMINATION. THIS WAS DONE ON THIS AIRCRAFT WITHIN 130 HRS. THIS IS A VERY IMPORTANT BULLETIN BASED ON THE FACT THAT THESE MAGNETOS ARE PRESSURIZED AND WILL TEND TO HOLD MOI STURE. SUBMITTER RECOMMENDS MAKING THIS A MANDATORY INSPECTION. 1 L 7 1 3O 3 O A25SO E8CE 1995080400532 19950804 00532 NE 1995 8 4 95ZZZX3579 2 19950530 G 7200 ENGINE LEAR 24 24D 5170311 CE GE CJ610 CJ6106 30006 NE NR 1 FLAME-OUT D O OTHER X ENGINE FLAMEOUT CR CRUISE 1 GL 25 888FA 9078 4483 257 251357A AT CRUISE ALTITUDE OF 45,000 FEET, ABOUT 1.5 HOURS INTO FLIGHT, BOTH ENGINES FLAMED OUT AT EXACTLY THE SAME TIME. THE F IRST INDICATION WAS A SLIGHT BUMP, THEN THE RPM GAUGES STARTED ERODING FROM 95 PERCENT. THE CREW WAS ABLE TO EXECUTE A RE-LIGHT ON BOTH ENGINES AT 25,000 FEET. BOTH ENGINES WERE CHECKED FOR FOD DAMAGE. FUEL FILTERS WERE CHECKED. P AND D VALVES WERE LOOKED AT. NO REASON FOR FLAME-OUT WAS FOUND AT THIS TIME. 2 L 7 2 4J 4 J A10CE 1E16 1995080400533 19950804 00533 NE 1995 8 4 95ZZZX3580 2 19950530 G 7200 ENGINE LEAR 24 24D 5170311 CE GE CJ610 CJ6106 30006 NE NR 2 FLAME-OUT D O OTHER X ENGINE FLAMEOUT CR CRUISE 1 GL 25 888FA 9122 4483 257 251358A AT CRUISE ALTITUDE OF 45,000 FEET, ABOUT 1.5 HOURS INTO FLIGHT, BOTH ENGINES FLAMED OUT AT EXACTLY THE SAME TIME. THE F IRST INDICATION WAS A SLIGHT BUMP, THEN THE RPM GAUGES STARTED ERODING FROM 95 PERCENT. THE CREW WAS ABLE TO EXECUTE A RE-LIGHT ON BOTH ENGINES AT 25,000 FEET. BOTH ENGINES WERE CHECKED FOR FOD DAMAGE. FUEL FILTERS WERE CHECKED. P AND D VALVES WERE LOOKED AT. NO REASON FOR FLAME-OUT WAS FOUND AT THIS TIME. 2 L 7 2 4J 4 J A10CE 1E16 1995080400543 19950804 00543 WP 1995 8 4 95ZZZX3592 2 19950621 G 7310 YA001295 LINE BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE7313 01518 WP RT ENGINE DAMAGED B WLCR K NONE O OTHER IN INSP/MAINT 1 WP 01 34RE 257022 LINE ASSEMBLY FOUND KINKED AT LOWER END. THIS PART IS AN ENGINE MAIN FUEL SUPPLY LINE (FLEXIBLE). THIS LINE MUST BE DI SCONNECTED IN ORDER TO ALLOW CERTAIN DEFUELING OPERATIONS. CARE MUST BE EXERCISED WHEN DISCONNECTING THE LOWER FITTING; OTHERWISE, KINKING WILL OCCUR RESULTING IN DIMINISHED FUEL SUPPLY TO THE ENGINE. SUBMITTER SUGGESTS MECHANICS SHOULD B E ADVISED TO USE MORE CARE WHEN DISTURBING THIS LINE ASSEMBLY. ACFT TT 3,223 HOURS. 2 L 7 2 4F 4 F A3EU E6WE 1995080400552 19950804 00552 EU 1995 8 4 95ZZZX3602 2 19950621 G 7310 YA001295 LINE HWKSLY DH125 HS125600A 4230158 EU RROYCE VIPER VIPER60122 54551 EU RT ENGINE KINKED B WLCR K NONE O OTHER IN INSP/MAINT 1 WP 01 777SA 7742 256015 LINE ASSEMBLY FOUND KINKED AT LOWER END. THIS PART IS AN ENGINE MAIN FUEL LINE (FLEXIBLE). THIS LINE MUST BE DISCONNEC TED IN ORDER TO ALLOW CERTAIN DEFUELING OPERATIONS. CARE MUST BE EXERCISED WHEN DISCONNECTING THE LOWER FITTING; OTHERW ISE, KINKING WILL OCCUR RESULTING IN DIMINISHED FUEL SUPPLY TO THE ENGINE. SUBMITTER SUGGESTS MECHANICS SHOULD BE ADIVS ED TO USE MORE CARE WHENEVER THIS LINE ASSEMBLY IS DISTURBED. ACFT TT 2,952 HRS. 2 L 7 2 4J 4 J A3EU E15EU 1995080400611 19950804 00611 GL 1995 8 4 95ZZZX3609 2 19950629 G 7310 219216 FILTER CESSNA 525 525 2076601 CE WILINT FJ44 FJ44 66000 GL LT ENGINE WARN LIGHT B IW1R L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 EA 25 94MZ 33 5250094 1206 LEFT FUEL FILTER BYPASS INDICATOR LIGHT ILLUMINATED (ANNUNCIATING PENDING FILTER BYPASS) DURING 'GO-AROUND'. AIRCRAFT L ANDED WITHOUT PROBLEMS. LEFT ENGINE FUEL FILTER ELEMENT WAS REPLACED. NO OBVIOUS FAULTS NOTED. RIGHT ENGINE FILTER EL EMENT WAS ALSO REPLACED. IT, TOO, HAD NO OBVIOUS FAULTS. 1 L 7 2 4F 4 F RT A1WI E3GL 1995080400612 19950804 00612 SO 1995 8 4 95ZZZX3610 2 19950710 G 7310 641032148 VALVE CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO ENGINE FUEL GASKET FAILED D O OTHER K FLUID LOSS NR NOT REPORTED 1 SO 17 2FOR 4040628 276446R NEWLY INSTALLED OVERHAULED ENGINE AFTER 20 HOURS OF FLYING TIME. FUEL DISTRIBUTION VALVE ON TOP OF ENGINE HAD A BLOWN G ASKET WHICH SPRAYED RAW FUEL ALL OVER THE ENGINE WHILE IN FLIGHT. ENGINE OVERHAULED BY TELEDYNE CONTINENTAL MOTORS. 1 L 7 2 3O 3 O A25CE E7CE 1995080400624 19950804 00624 EA 1995 8 4 95ZZZX3622 2 19950703 G 7310 60100040544 HOSE CESSNA 172 R172K 2072431 CE LYC O320 O320E2D 41508 EA ENGINE FUEL LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 09 3315V R1722248 FUEL HOSE RUNS ACROSS THE TOP OF THE ENGINE. WHEN PRESSURE CHECKED, IT LEAKED ALONG THE ENTIRE LENGTH. TAG ON HOSE HAS THE FOLLOWING DATA: PAW 601000-4-0544. PT10-89. A4Q89. 1000 PSI. RUBBER. 00624. TSO - 053A. SEE AEROQUIP SBAA13 5 - THESE HOSES ARE STILL OUT THERE. 1 H 7 1 3O 3 O 3A17 E274 1995080400632 19950804 00632 NE 1995 8 4 95ZZZX3630 2 19950607 G 7260 208312604 LOCK PIN 208325023 SEMCO CLNGER CHALLENGER 8070802 NM LYC ALF502 ALF502L2 41580 NE ASSORY DR GR BOX FAILED B L SH5R K NONE O OTHER IN INSP/MAINT 1 NE 03 733CF 1486 82G004 1041 LF03089S OIL ANALYSIS, FINDING AN INCREASE IN METAL CONTAMINATION, INVESTIGATION REVEALED THE ACCESSORY DRIVE GEARBOX DRIVESHAFT LOCK ASSY POST SB ALF502L 72-0175, HAD DROPPED DOWN ONTO THE STARTER DRIVESHAFT MACHINING AWAY AT THE DRIVESHAFT WHICH C AUSED THE REPLACEMENT OF THE FOLLOWING COMPONENTS: ACCESSORY DRIVE GEARBOX MODULE, FUEL/OIL HEAT EXCHANGER, THE ENGINE DRIVEN OIL PUMP ASSY AND THE NR 12 BEARING. SUSPECT CAUSED BY FAILURE OF THE DRIVESHAFT LOCK PIN (PN 2-083-126-04). RE COMMEND ASAP (ESPECIALLY IF NOT ON ACTIVE OIL ANALYSIS PROGRAM) TO REMOVE ACCESSORY DRIVE GEARBOX DRIVESHAFT LOCK ASSY A ND INSPECT DRIVESHAFT LOCK PIN (PN 2-083-126-04) FOR BEING ANYTHING LESS THAN STRAIGHT WITH EVENLY CUT ENDS. 1 B 0 0 4 F A13SO E6NE 1995080400634 19950804 00634 GL 1995 8 4 95ZZZX3632 2 19950701 G 7250 WHEEL ALLSN 250C 250C20 03013 GL TURBINE SHAFT MISMFG B UP9R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 07 FACTORY NEW WHEEL SPLINED ADAPTER SHAFT PILOT MEASURES 0.566 INCH WHICH IS APPROXIMATELY 0.010 INCH LARGER THAN MAXIMUM. WHEEL RETURNED TO ALLISON. 3 U E4CE 1995080400641 19950804 00641 NE 1995 8 4 95ZZZX3639 2 19950525 G 7414 SB9RU3 MAGNETO BOSCH AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340* 52016 NE RT ENGINE SHORTED D K NONE Y ENGINE STOPPAGE NR NOT REPORTED 1 SW 11 36552 900 3010299 MAGNETO COVER ON RIGHT MAGNETO VIBRATED SCREWS LOOSE CAUSING COVER TO GROUND COIL KILLING MAGNETO WHICH CAUSED ENGINE FA ILURE. 1 L 7 1 3R 3 R A9SW 5E2 1995080400652 19950804 00652 EA 1995 8 4 95ZZZX3650 2 19950613 G 7414 K3823 DISTRIBUTOR SLICK 6250 PIPER PA32 PA32* SO LYC O540 IO540K1G5 41532 EA MAG BLOCK DESTROYED B BF1R K NONE O OTHER IN INSP/MAINT 1 EA 05 30 DISMANTLED MAG FOUND DISTRIBUTOR OR BEARING BLOCK DESTROYED BY ARCING FROM DEFECTIVE COIL. 1 L 7 1 3O 3 O A3SO 1E4 1995080400655 19950804 00655 SO 1995 8 4 95ZZZX3653 2 19950703 G 8530 CYLINDER CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO LT ENG NR 3 CRACKED B APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 41SA 1298 4040023 276274R LEFT ENGINE NR 3 CYLINDER CRACKED AT BOTH SPARKPLUG HOLES. SUBMITTER KNOWS OF MANY EXAMPLES OF IDENTICAL FAILURES THROU GHOUT FLEET AIRCRAFT. 1 L 7 2 3O 3 O A25CE E7CE 1995080400656 19950804 00656 EA 1995 8 4 95ZZZX3654 2 19950712 G 7322 HA6 CARBURETOR VALVE CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA CONTROL ARM SEIZED D K NONE O OTHER IN INSP/MAINT 1 NM 01 5210V 20 172RG0471 L2854136A PILOT REPORTED THROTTLE WOULD NOT MOVE FROM IDLE AFTER START. REMOVED CARBURETOR, FOUND CONTROL ARM SEIZED. REPLACED C ARBURETOR UNDER WARRANTY. SENT CARBURETOR TO PRECISION AIRMOTIVE FOR WARRANTY/PROBLEM INSPECTION. 1 H 7 1 3O 3 O 3A17 E286 1995080400744 19950804 00744 SO 1995 8 4 95ZZZX3657 2 19950627 G 8530 CYLINDER CESSNA 310 310P 2074238 CE CONT O470 IO470VO 17026 SO RT ENG NR 4 EXITED D A E UNSCHED LANDING ENGINE SHUTDOWN E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 WP 25 5819M 8 310P00119 1487209V THE AIRCRAFT MADE AN EMERGENCY LANDING WITH THE RIGHT ENGINE FEATHERED. THE COPILOT HAD NOTED NR 4 CYLINDER EXIT THROUG H THE SIDE COWLING IN A DOWNWARD DIRECTION. THE CONNECTING ROD WAS STILL ON THE CRANK, BENT SLIGHTLY AFT AND THE PISTON PIN BOSS WAS ELONGATED. ALL HOLD-DOWNS WERE BROKEN OFF. 1 L 7 2 3O 3 O 3A10 3E1 1995080400745 19950804 00745 EA 1995 8 4 95ZZZX3658 2 19950705 G 8530 73806 PUSHROD BEECH 77 77 1153007 CE LYC O235 O235L2C 41505 EA ENGINE FAILED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 17 38025 1491 TH1208 L2167815 PUSHROD FAILED AND WAS NOT MARKED WITH THE PROPER P/N PER THE A.O. 80-25-02 LYCOMING ADVISED THAT THE PROPER PUSHRODS WE RE INSTALLED DURING ORIGINAL ASSEMBLY. ALL PUSHRODS REMOVED AND INSPECTED. ALL FOUND TO HAVE THE WRONG P/N. NO RECORD S OF THE PUSHRODS BEING REPLACED. 1 L 7 1 3O 3 O A30CE E223 1995080400749 19950804 00749 EA 1995 8 4 95ZZZX3662 2 19950706 G 8530 CYLINDER PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA NR 4 WORN G K NONE O OTHER IN INSP/MAINT 1 EA 01 67WA 5724 1247 287125267 L2935627A NR 4 CYLINDER FOUND TO HAVE CHOKE BORE OUT OF TOLERANCE. SUSPECT CAUSE FOUND TO BE 2 INCH SCAT HOSE COLLAPSED BLOCKING OFF COOLING AIR. 1 L 7 1 3O 3 O 2A13 E274 1995080400752 19950804 00752 EA 1995 8 4 95ZZZX3665 2 19950626 G 7322 CONTROL BOLT CESSNA 177 177 2073704 CE LYC O320 O320D2A 41508 EA THROTTLE DETACHED D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 WP 23 3420T 3934 17700720 L2095127AC AT ABOUT 700 FEET ALTITUDE AFTER DEPARTURE, ENGINE WENT TO IDLE. AFTER A SUCCESSFUL OFF AIRPORT LANDING WAS MADE, BOLT AND HARDWARE CONNECTING THROTTLE CONTROL TO CARBURETOR WERE FOUND MISSING. INSTALLED NEW BOLT, NUT, SPACER, AND WASHERS . AIRCRAFT TOWED TO A ROAD AND WITH CHP PERMISSION, RETURNED TO AIRPORT. SUBMITTER STATED BOLT AND CASTELLATED NUT HAD PROBABLY BEEN OVERTORQUED. MAYBE MANY TIMES IN PAST. SUBMITTER SUGGESTS REPLACING AT OVERHAUL AND DO NOT OVERTORQUE. 1 H 7 1 3O 3 O NT A13CE E274 1995080400761 19950804 00761 SO 1995 8 4 95ZZZX3674 2 19950716 G 8520 CRANKCASE BEECH 55 E55 1152732 CE CONT O520 IO520C 17032 SO ENGINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 91WC 3016 300 TE909 231829R AIRCRAFT HAS SEVERAL OIL LEAKS ON RT ENGINE FINALLY RESULTING IN CRACKED CASE. SUSPECT THAT WHEN TEAR DOWN IS DONE, CRA NK HAS COUNTERWEIGHT PROBLEM. THIS IS THE THIRD ENGINE THIS YEAR TO REJECT DUE TO CRANK PROBLEMS. SUBMITTER STATED MAY BE ENGINE OVERHAUL SHOULD REQUIRE CLOSER CRANK OVERHAUL INSPECTION FOR BUSHING REPLACMENT, 300 TSO. 1 L 7 2 3O 3 O 3A16 E5CE 1995080400762 19950804 00762 SO 1995 8 4 95ZZZX3675 2 19950705 G 8520 CRANKCASE BEECH 55 95B55 1152706 CE CONT O470 IO470L 17026 SO NR 6 CYL THRU BOLT SEPARATED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 96NL TC721 297553R DURING A SCHEDULED INSPECTION, THE LOWER FORWARD CRANKCASE THROUGH-BOLT ON NR 6 CYLINDER WAS FOUND COMPLETELY SEPARATED. FURTHER INSPECTION FOUND THE BOLT IMPROPERLY INSTALLED. THE BOLT FAILED IN THE O-RING GROOVE LOCATED IN THE MIDDLE PO RTION OF THE BOLT. THIS ENGINE WAS A FACTORY REMANUFACTURE WITH 77.2 HRS SINCE INSTALLED ON THIS AIRCRAFT, P/N 64193198 1. 1 L 7 2 3O 3 O 3A16 3E1 1995080400767 19950804 00767 EA 1995 8 4 95ZZZX3680 2 19950619 G 7322 105135 CARBURETOR JET FACET MA4SPA CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE BLOCKED D L K NONE O OTHER IN INSP/MAINT 1 SO 06 5415J 1248 CT610931 17273785 TEAR DOWN OF CARBURETOR TO IDENTIFY REASON FOR FAILURE. MAIN JET ASSEMBLY WAS FOUND PARTIALLY BLOCKED. BLOCKAGE REMOVE D USING A .040 INCH PIECE OF SAFETY WIRE PASSED THROUGH THE OUTLET END OF THE MAIN JET ASSEMBLY. 1 H 7 1 3O 3 O NT 3A12 E274 1995081100117 19950811 00117 WP 1995 8 11 95ZZZX3727 2 19950630 G 7260 30753562 ADAPTER SPLINE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP RT ENGINE STRIPPED B GMCR K NONE O OTHER IN INSP/MAINT 1 GL 23 5111 440 6507011 102124 RIGHT ENGINE WOULD NOT ROTATE WHEN STARTER BUTTON ENGAGED. FOUND OUTER SPLINES ON ADAPTER STRIPPED. LEFT ENGINE SPLINE ADAPTER ALSO WORN EXCESSIVELY. MFG RECOMMENDS INSPECTION AT 2,100 HOUR INTERVALS. OPERATOR CONTROL NR 95-003. 2 L 7 2 4F 4 F A9NM E6WE 1995081100119 19950811 00119 WP 1995 8 11 95ZZZX3729 2 19950201 G 7210 30730371 WASHER GARRTT TFE731 TFE7312 01518 WP PLANETARY GEAR CRACKED B AN3D K NONE O OTHER IN INSP/MAINT 1 WP 05 DURING DETAILED INSPECTION OF PLANETARY ASSEMBLY, PN 3073037-1/2, WASHERS HAVE BEEN FOUND CRACKED ON SEVERAL TFE 731-2/3 ENGINES. CURRENT MAINTENANCE MANUALS DO NOT REQUIRE REMOVING THIS BEARING CAGE TO ACCOMPLISH INSPECTION OF GEAR ASSEMB LY. SEE LIGHT MM 72-02-41, PAGE 224C, AND MM 72-72-02, SECTION 2 INSPECTION. APPROXIMATELY 30 OF THESE WASHERS HAVE BE EN FOUND CRACKED IN THE LAST 6 MONTHS. ALL HAVE BEEN SENT TO THE MANUFACTURER. PART TOTAL TIMES 3747.0 TO 6938.0. 4 F E6WE 1995081100120 19950811 00120 EA 1995 8 11 95ZZZX3730 2 19950714 G 7532 310334601 DIAPHRAM 310092205 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA BLEED VALVE RUPTURED B LX5R K NONE O OTHER NR NOT REPORTED 1 GL 19 971LL 9B540 BB572 PCE81368 DIAPHRAM RUPTURED RENDERING BLEED VALVE INOPERATIVE. 1 L 7 2 4T 4 T A24CE E4EA 1995081100133 19950811 00133 GL 1995 8 11 95ZZZX3743 2 19950710 G 7250 68993737 WHEEL HX66921 BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL 3RD STAGE CRACKED B SZTR K NONE O OTHER IN INSP/MAINT 1 WP 07 206WP 2773 CAT34702 2752 CAE830842 ENGINE WOULD NOT MAKE POWER. FOUND 3RD STAGE WHEEL CRACKED. 1 G 7 1 3U 3 U H2SW E4CE 1995081100134 19950811 00134 GL 1995 8 11 95ZZZX3744 2 19950414 G 7250 A6871505 BEARING BOLKMS 105 BO105C 5626005 EU ALLSN 250C 250C20B 03013 GL TURBINE NR 5 FAILED B HDNR K NONE O OTHER IN INSP/MAINT 1 SW 03 105SJ 153 077 S104 CAT23301 NR 5 BEARING BALL RETAINER FLAKING OFF. THE BEARING MANUFACTURED BY SUPERIOR TURBINE. 1 G 7 2 3U 3 U H3EU E4CE 1995081100139 19950811 00139 EA 1995 8 11 95ZZZX3749 2 19950707 G 8540 72230 IDLER SHAFT HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA ENG REAR CASE STUDS BROKE D A K NONE O OTHER IN INSP/MAINT 1 GL 09 8377F 1120 480680 L836851A STUDS, .3125 INCH, IN REAR OF CRANKCASE THAT HOLDS IDLER GEAR SHAFT BROKE WHICH LET THE IDLER GEAR GET BETWEEN CRANK AND CAMSHAFT WHICH CAME LOOSE AND WAS VERY NEAR FAILURE. ENGINE HAD 1,120 HOURS TOTAL SINCE NEW. THE STUDS IN THE REAR OF THE CASE SHOULD BE .3750 INCH STUDS. HAVE HAD THIS SAME THING HAPPEN ON ANOTHER ENGINE OF SAME MAKE AND MODEL WITH 1,1 02 HOURS SINCE MOH AND TOTAL TIME OF 3,200 HOURS. 1 G 7 1 3O 3 O 4H12 1E10 1995081100140 19950811 00140 GL 1995 8 11 95ZZZX3750 2 19950703 G 7200 ENGINE BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL FUEL FILTER FLAME OUT H A O OTHER X ENGINE FLAMEOUT HO HOVERING 1 GL 23 321JW 10309 3446 820486 ENGINE FLAMED OUT IN HOVER. EXPERIENCED SUCCESSFUL RESTART ON FIRST ATTEMPT. TWO MINUTES RUN AT 100 PERCENT N2 WITH BO OST PUMPS OFF - CHECKED OKAY. SHUT DOWN ENGINE. BLED SYSTEM, FOUND AIR IN ENGINE MOUNTED FUEL FILTER HOUSING. RAN ENG INE, SHUT DOWN, BLED FILTER AGAIN - NO AIR FOUND. AIRCRAFT RETURNED TO SERVICE. NOTE: AIRCRAFT WAS JUST RETURNED TO S ERVICE AFTER APPROXIMATELY 5 WEEKS IN PAINT SHOP ABOUT TEN HOURS BEFORE FLAMEOUT. 1 G 7 1 3U 3 U H2SW E4CE 1995081100143 19950811 00143 GL 1995 8 11 95ZZZX3753 2 19950622 G 7240 23056130 BURNER LINER BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL COMB CAN MISINSTALLED B A SNCD K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 455H 958 3453 CAE833825 WHEN BURNER CAN LINER WAS ASSEMBLED, THE LOWER SKIRT WAS TURNED 90 DEGREES WHICH MISPLACED TWO LARGE COOLING HOLES. THI S CAUSED THE ENGINE TO START SLOW (60 SECONDS), HANG AT 42 PERCENT, AND HAVE A DELAYED LIGHT OFF. THE PROBLEM ONLY SHOW ED UP AFTER ABOUT 500 HOURS IN USE. 1 G 7 1 3U 3 U H2SW E4CE 1995081100241 19950811 00241 NE 1995 8 11 F6LM9581 2 19950227 G 7421 956013490 HE IGNITER SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1 60030 NE ENGINE DEFECTIVE H F6LM K NONE O OTHER IN INSP/MAINT 1 SO 19 6095T 744 2671 9241 IGNITER WOULD NOT FIRE, TESTED ON OTHER BOX STILL INOP. REPLACED HE IGNITER, OPS CHECKED OKAY 1 G 7 1 3U 3 U H9EU E19EU 1995081100289 19950811 00289 GL 1995 8 11 HEEA955519 2 19950802 G 7321 252494410 FUEL CONTROL BELL 206 206L 1181522 SW ALLSN 250C 250C28B 03013 GL ENGINE DEFECTIVE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 7074W 8748 52033 FUEL CONTROL BY-PASS COVER RETENTION SCREW HEAD BROKEN (SHEARED) 1 G 7 1 3U 3 U H2SW E1GL 1995081100400 19950811 00400 SO 1995 8 11 95ZZZX3791 2 19950710 G 8530 630046 PISTON PIN CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO NR 3 CYLINDER BROKEN B APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 41S 1298 4040023 276274R PISTON REMOVED ALONG WITH CYLINDER NR 3 DUE TO CYLINDER HEAD CRACKS. WHEN INSPECTING PISTON, FOUND PIN PLUG (NON-REMOVA BLE, FORGED-IN TYPE) TO BE BROKEN IN MIDDLE WITH ONE END LOOSE. SUBMITTER STATES, OBSERVED THIS TWICE BEFORE ON SIMILAR ENGINES. 1 L 7 2 3O 3 O A25CE E7CE 1995081100408 19950811 00408 EA 1995 8 11 95ZZZX3799 2 19950621 G 7414 HOUSING BENDIX S4LN1209 BEECH 23 B19 1151215 CE LYC O320 O320E2C 41508 EA RT MAGNETO CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 21 24582 7195 1550 243050 MB540 L1803127A DURING ANNUAL INSPECTION, THE RIGHT MAGNETO HOUSING WAS FOUND CRACKED IN SEVERAL PLACES. CRACKED ON BOTH SIDES OF THE M AGNETO DOWN NEAR THE DRIVE END. 1 L 7 1 3O 3 O A1CE E274 1995081100499 19950811 00499 EA 1995 8 11 95ZZZX3860 2 19950717 G 8530 60401 ROCKER SHAFT CESSNA 177 177 2073704 CE LYC O320 O320E2D 41508 EA NR 3 CYL EXH CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 11 2942X 1417 17700542 L2027927A DURING THE CHANGING OF THE PUSHROD HOUSING TUBE SEALS WHICH INVOLVES REMOVING THE ROCKER BOXES, FOUND THE VALVE ROCKER S HAFT ON THE EXHAUST SIDE OF CYLINDER NR 3 CRACKED ABOUT ONE-HALF THE WAY AROUND AND .25 INCH FROM THE END. 1 H 7 1 3O 3 O NT A13CE E274 1995081100598 19950811 00598 GL 1995 8 11 95ZZZX3922 2 19950727 G 7230 6887121 VENT TUBE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL COMP ASSY DETACHED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 3115Y 500716D CAE830348 ENGINE DIFFUSER VENT ORIFICE TUBE WOULD NOT STAY IN PLACE. INSPECTION FOUND END OF THE TUBE THAT SLIPS INTO THE VENT BO SS WAS DEFORMED. INSTALLED NEW TUBE. 1 G 7 1 3U 3 U H3WE E4CE 1995081100640 19950811 00640 WP 1995 8 11 95ZZZX3940 2 19950717 G 7310 31016081 TUBE ASSY BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP RT ENG FWD RT CHAFED D E ENGINE SHUTDOWN B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 GL 03 178NC BE17 P27035 FAILURE OCCURRED IN-FLIGHT, PILOT NOTICED HIGH FUEL FLOW AND SMOKE. ENGINE SHUT DOWN IN-FLIGHT. FOUND ADEL CLAMP WORN THROUGH TUBE ASSY. ADDED EXTRA ADEL CLAMPS TO AFT END OF TUBE ASSY TO PREVENT MOVEMENT. 1 L 7 2 4T 4 T A14CE E2WE 1995081100916 19950811 00916 SO 1995 8 11 95ZZZX3987 2 19950723 G 8520 649134SP CRANKSHAFT CESSNA 188 T188C 2073012 CE CONT O520 TSIO520T 17040 SO NR 2-3 CYLS BROKE D A UNSCHED LANDING O OTHER CR CRUISE 1 SO 09 2158J 442 B099417 T18803395T 511683 NEW V.A.R. CRANKSHAFT BROKE BETWEEN NR 2 AND NR 3 CYLINDERS. THIS CRANKSHAFT HAD A TOTAL TIME OF 442 HOURS SINCE NEW. FAILURE WAS IN-FLIGHT AND PILOT MADE SAFE LANDING WITH NO DAMAGE TO AIRCRAFT OR PROPERTY. THIS APPEARS TO BE A DEFECTI VE CRANKSHAFT. 1 L 7 1 3O 3 O A9CE E8CE 1995081800056 19950818 00056 SO 1995 8 18 95ZZZX3998 2 19950701 G 8550 CH48109 FILTER CHAMPION CESSNA 207 T207A 2073614 CE CONT O520 TSIO520M 17040 SO ENG OIL SYSTEM GASKET DISPLACED D P A K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 803AN 50 20700570 283222R OIL FILTER INTERNAL GASKET WAS OUT OF PLACE AND COVERING INLET PASSAGE OF FILLER BODY. APPEARS TO BE MANUFACTURE DEFECT . SUBMITTER ADVISES A CLOSER INSPECTION OF OIL FILTER PRIOR TO INSTALLATION TO INSURE GASKET IS NOT BLOCKING INLET HOLE . 1 H 7 1 3O 3 O A16CE E8CE 1995081800070 19950818 00070 EA 1995 8 18 95ZZZX4012 2 19950801 G 8520 LW18837 CAMSHAFT CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA ENGINE WEAR G K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 01 13599 1200 17262390 CAMSHAFT WAS PURCHASED FROM AIR SUPPORT INTERNATIONAL, INC. CAMSHAFT WAS OVERHAULED AT AIRCRAFT SPECIALTIES SERVICES FA A REPAIR STATION DD2R764K. CAMSHAFT SHOWED SIGNS OF PREMATURE WEAR. SUBMITTED BY EXECUTIVE FLYERS 141 SCHOOL LP8S302Q. 1 H 7 1 3O 3 O NT 3A12 E274 1995081800071 19950818 00071 EA 1995 8 18 95ZZZX4013 2 19950801 G 8520 LW18837 CAMSHAFT PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE WEAR G K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 01 2180E 532 287916165 CAMSHAFT PURCHASED FORM AIR SUPPORT INTERNATIONAL, INC. CAMSHAFT WAS OVERHAULED AT AIRCRAFT SPECIALTIES SERVICES, FAA R EPAIR STATION DD2R764K. CAMSHAFT SHOWED SIGNS OF PREMATURE WEAR. SUBMITTED BY EXECUTIVE FLYERS 141 SCHOOL LP8S302Q. 1 L 7 1 3O 3 O 2A13 E274 1995081800075 19950818 00075 EA 1995 8 18 95ZZZX4017 2 19950801 G 8520 LW18837 CAMSHAFT CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA ENGINE WEAR G K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 01 61992 666 17264943 CAMSHAFT WAS PURCHASED FROM AIR SUPPORT INTERNATIONAL, INC. CAMSHAFT WAS OVERHAULED AT AIRCRAFT SPECIALTIES SERVICES, F AA REPAIR STATION DD2R764K. CAMSHAFT SHOWED SIGNS OF PREMATURE WEAR. SUBMITTED BY EXECUTIVE FLYERS 141 SCHOOL LP8S302Q . 1 H 7 1 3O 3 O NT 3A12 E274 1995081800077 19950818 00077 SO 1995 8 18 95ZZZX4019 2 19950714 G 8530 629404 VALVE CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO NR 3 CYL EXH BINDING D K NONE O OTHER IN INSP/MAINT 1 EA 13 6836G 229 15072336 681947A INSPECTION REVEALED VALVE STEM TIGHT IN GUIDE DUE TO EXCESSIVE CARBON BUILD-UP. AFTER CLEAN-UP OF GUIDE, THE CLEARANCE WAS MEASURED AND DETERMINED TO BE IN LIMITS. CAUSE OF CARBON BUILD-UP, POSSIBLE RICH CARBURETOR. INSPECTION OF 3 REMAI NING CYLINDERS ON ENGINE REVEALED NO PROBLEMS. ENGINE TT 4,082.0. TSM O/H, 979 HOURS. 1 H 7 1 3O 3 O 3A19 E252 1995081800079 19950818 00079 EA 1995 8 18 95ZZZX4021 2 19950312 G 7314 02532330003 FUEL PUMP PESCO STBROS SD3 SD330 8100602 EU PWA PT6 PT6A45R 52043 EA LEFT ENGINE STRIPPED D A A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 GL 13 336MV 392 8519 SH3018 84070 DURING CRUISE AND LEVEL FLIGHT ON 3-12-94, ENGINE SHUT DOWN. CREW TRIED SEVERAL ATTEMPTS AT RESTART WITH NO SUCCESS. F EATHERED ENGINE AND LANDED AT NEAREST AIRPORT. MAINTENANCE FOUND FUEL PUMP DRIVE SPLINES STRIPPED. REPLACED FUEL PUMP WITH OVERHAULED UNIT IAW MM 73-11-02. UNIT SENT BACK TO OVERHAUL SHOP FOR TEAR-DOWN REPORT. 2 H 7 2 4T 4 T A41EU E4EA 1995081800082 19950818 00082 EA 1995 8 18 95ZZZX4024 2 19950726 G 8530 69602 TUBE ENSTRM F28 F28C 3300407 GL LYC O360 HIO360E1AD 41514 EA ENG INDUCTION DETACHED H A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 WP 27 5689T 2085 85 4742 HELICOPTER DEPARTED SCK AIRPORT AND MADE A FORCED LANDING IN A FIELD. INVESTIGATION FOUND AN INDUCTION TUBE HAD COME LO OSE. RECOMMEND DURING OVERHAUL, ALL TUBES BE RE-SWAGED. 1 G 7 1 3O 3 O H1CE 1E10 1995081800088 19950818 00088 EA 1995 8 18 95ZZZX4030 2 19950605 G 7250 310209404 GAS GENERATOR PWA PT6 PT6A65B 52043 EA GAS GEN CASE DAMAGED B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 PART RECEIVED FROM EDM IN OVERHAULED CONDITION. WHEN GAS GENERATOR CASE WAS ASSEMBLED AND RUN ON THE TEST CELL FOR EVAL UATION, ENGINE RAN HOT AND TOO FAST. ALL CORRECTIVE ACTIONS FAILED TO CORRECT THE PROBLEM. THE GAS GENERATOR CASE WAS REPLACED AND THE ASSEMBLED ENGINE RAN WELL WITHIN LIMITS. SUSPECT HIDDEN CRACKS OR DAMAGE TO THE CASE AND SAID CASE HAS BEEN SENT TO PWC FOR EVALUATION. 4 T E4EA 1995081800089 19950818 00089 EA 1995 8 18 95ZZZX4031 2 19950621 G 7260 3040026 HOUSING PWA PT6 PT6A65B 52043 EA GAS GEN AGB BORE OVERSIZE B MAXR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 13 PWC95M376 THE HOUSING WAS RECEIVED FROM PWC AFTER THEY REPAIRED THE HOUSING AND REINSPECTED ALL BEARING BORES. THE BEARING BORES WERE MEASURED BY DTS INSPECTION DEPARTMENT AND FOUND OUT OF TOLERANCE. (OVERSIZED). PART RETURNED TO PWC FOR REWORK AND /OR REPAIR. 4 T E4EA 1995081800090 19950818 00090 EA 1995 8 18 95ZZZX4032 2 19950725 G 7320 311454801 LEVER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA FCU ACTUATOR JAMS D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 13 2883 BB144 PCE80042 LEFT POWER LEVER WOULD INTERMITTENTLY STOP BEFORE FULL TRAVEL IN QUADRANT, LIMITING ENGINE SPEED TO APPROXIMATELY 80 PER CENT N1. ENGINE WAS NEWLY OVERHAULED, AND FCU LEVER, PN 311458-01, WAS INSTALLED DURING C/W SB 3304. FCU LEVER FOUND J AMMING ON PROPELLER REVERSE CONTROL FOLLOWING LEVER. REINSTALLED ORIGINAL FCU LEVER, PN 3010454, NO FURTHER PROBLEMS NO TED. THIS PROBLEM IS ADDRESSED BY SB 3310, WHICH INSTALLS LEVER, PN 3119355-01. 1 L 7 2 4T 4 T A24CE E4EA 1995081800095 19950818 00095 GL 1995 8 18 95ZZZX4037 2 19950802 G 7250 6898735 TURBINE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE LOCKED-UP B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 4282X 6472 2957 180253D CAE833827 N2 LOCKED UP. UNIT SENT IN FOR SAME PROBLEM 356.7 HOURS AGO. REMOVED SN CAT 33968 AND SENT TO BE REPAIRED ON ALLISON R EPORT NR A160209. 1 G 7 1 3U 3 U H3WE E4CE 1995081800097 19950818 00097 GL 1995 8 18 95ZZZX4039 2 19950622 G 7260 GEARBOX AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL NR 1 ENGINE FAILED E A UNSCHED LANDING J X WARNING INDICATION ENGINE FLAMEOUT CR CRUISE 1 SW 03 5774M 11516 5009 CAE840464 INBOUND FOR OFFSHORE PLATFORM, PILOT REPORTED NR 1 ENGINE CHIP LIGHT ILLUMINATED, AIRCRAFT YAWED, ENGINE FLAMED OUT. LA NDED AT ONSHORE WITHOUT INCIDENT. INVESTIGATION REVEALED BOTH ENGINE ACCESSORY GEARBOX CHIP PLUGS COVERED WITH METAL. N 1 DOES NOT TURN FREELY. ENGINE TSO, 3,199:55. 1 G 7 2 3U 3 U H11EU E4CE 1995081800583 19950818 00583 SO 1995 8 18 95ZZZX4060 2 19950615 G 7320 RSA7AD1 SERVO BENDIX BEECH 58 58P 1152744 CE CONT O520 TSIO520WB 17040 SO FUEL SERVO DIAPHRAGM TORN D L O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 SO 01 3807T 2480 494 56467 TJ332 L518458 DURING CRUISE, RT MAG INTERMITTENT. AT 14,000 FEET ALTITUDE, FUEL VENTING OUT OF LT ENGINE INBOARD UPPER COWL VENT. FO UND FUEL SERVO DIAPHRAGM TORN ALLOWING FUEL INTO AIR SIDE. FUEL VENTED OUT MAG FILTER AND INTO MAG CAUSING MISFIRE. 1 L 7 2 3O 3 O A23CE E8CE 1995081800585 19950818 00585 NE 1995 8 18 95ZZZX4062 2 19950719 G 7321 1037642 SCREW WOODWARD 8061858 GE CF6 CF680C2A5 NE FUEL CONTROL BROKEN B L UU2R K NONE O OTHER IN INSP/MAINT 1 GL 03 WOODWARD HAS RECENTLY FOUND SEVERAL INSTANCES OF BROKEN SCREWS WHILE DIS-ASSEMBLING FUEL CONTROLS. THERE WAS NO FUNCTIO NAL PROBLEM AS A RESULT OF THIS FAILURE. FURTHER INVESTIGATION HAS SHOWN THE BROKEN SCREWS ARE HARDER THAN THAT WHICH I S ALLOWED PER THE ENGINEERING DRAWING. INSPECTION OF SEVERAL PARTS HAS LED TO THE CONCLUSION THE BROKEN PARTS ARE ALL F ROM THE SAME MANUFACTURING LOT AND NOT PROPERLY HEAT TREATED. INSPECTION RECORDS INDICATE THE LOT WAS PROCESSED PROPERL Y, AND CONFORMED TO DRAWING REQUIREMENTS SO SEARCH FOR ROOT CAUSE IS FOCUSING ON POSSIBLE MIX-UP DUE TO LOOK-ALIKE PARTS OR POSSIBILITY SOME PORTION OF LOT MAY HAVE MISSED THAT OPERATION. 4 F E13NE 1995081800588 19950818 00588 NE 1995 8 18 95ZZZX4065 2 19950719 G 7321 1037642 SCREW WOODWARD 8061886 GE CF6 CF680C2A5 NE FUEL CONTROL BROKEN B L UU2R K NONE O OTHER IN INSP/MAINT 1 GL 03 WOODWARD HAS RECENTLY FOUND SEVERAL INSTANCES OF BROKEN SCREWS WHILE DIS-ASSEMBLING FUEL CONTROLS. THERE WAS NO FUNCTIO NAL PROBLEM AS A RESULT OF THIS FAILURE. FURTHER INVESTIGATION HAS SHOWN THE BROKEN SCREWS ARE HARDER THAN THAT WHICH I S ALLOWED PER THE ENGINEERING DRAWING. INSPECTION OF SEVERAL PARTS HAS LED TO THE CONCLUSION THE BROKEN PARTS ARE ALL F ROM THE SAME MANUFACTURING LOT AND NOT PROPERLY HEAT TREATED. INSPECTION RECORDS INDICATE THE LOT WAS PROCESSED PROPERL Y, AND CONFORMED TO DRAWING REQUIREMENTS SO SEARCH FOR ROOT CAUSE IS FOCUSING ON POSSIBLE MIX-UP DUE TO LOOK-ALIKE PARTS OR POSSIBILITY SOME PORTION OF LOT MAY HAVE MISSED THAT OPERATION. 4 F E13NE 1995081800589 19950818 00589 NE 1995 8 18 95ZZZX4066 2 19950719 G 7321 1037642 SCREW WOODWARD 8061888 GE CF6 CF680C2A5 NE FUEL CONTROL BROKEN B L UU2R K NONE O OTHER IN INSP/MAINT 1 GL 03 WOODWARD HAS RECENTLY FOUND SEVERAL INSTANCES OF BROKEN SCREWS WHILE DIS-ASSEMBLING FUEL CONTROLS. THERE WAS NO FUNCTIO NAL PROBLEM AS A RESULT OF THIS FAILURE. FURTHER INVESTIGATION HAS SHOWN THE BROKEN SCREWS ARE HARDER THAN THAT WHICH I S ALLOWED PER THE ENGINEERING DRAWING. INSPECTION OF SEVERAL PARTS HAS LED TO THE CONCLUSION THE BROKEN PARTS ARE ALL F ROM THE SAME MANUFACTURING LOT AND NOT PROPERLY HEAT TREATED. INSPECTION RECORDS INDICATE THE LOT WAS PROCESSED PROPERL Y, AND CONFORMED TO DRAWING REQUIREMENTS SO SEARCH FOR ROOT CAUSE IS FOCUSING ON POSSIBLE MIX-UP DUE TO LOOK-ALIKE PARTS OR POSSIBILITY SOME PORTION OF LOT MAY HAVE MISSED THAT OPERATION. 4 F E13NE 1995081800590 19950818 00590 NE 1995 8 18 95ZZZX4067 2 19950719 G 7321 1037642 SCREW WOODWARD 8061889 GE CF6 CF680C2A5 NE FUEL CONTROL BROKEN B L UU2R K NONE O OTHER IN INSP/MAINT 1 GL 03 WOODWARD HAS RECENTLY FOUND SEVERAL INSTANCES OF BROKEN SCREWS WHILE DIS-ASSEMBLING FUEL CONTROLS. THERE WAS NO FUNCTIO NAL PROBLEM AS A RESULT OF THIS FAILURE. FURTHER INVESTIGATION HAS SHOWN THE BROKEN SCREWS ARE HARDER THAN THAT WHICH I S ALLOWED PER THE ENGINEERING DRAWING. INSPECTION OF SEVERAL PARTS HAS LED TO THE CONCLUSION THE BROKEN PARTS ARE ALL F ROM THE SAME MANUFACTURING LOT AND NOT PROPERLY HEAT TREATED. INSPECTION RECORDS INDICATE THE LOT WAS PROCESSED PROPERL Y, AND CONFORMED TO DRAWING REQUIREMENTS SO SEARCH FOR ROOT CAUSE IS FOCUSING ON POSSIBLE MIX-UP DUE TO LOOK-ALIKE PARTS OR POSSIBILITY SOME PORTION OF LOT MAY HAVE MISSED THAT OPERATION. 4 F E13NE 1995081800591 19950818 00591 NE 1995 8 18 95ZZZX4068 2 19950719 G 7321 1037642 SCREW WOODWARD 8061893 GE CF6 CF680C2A5 NE FUEL CONTROL BROKEN B L UU2R K NONE O OTHER IN INSP/MAINT 1 GL 03 WOODWARD HAS RECENTLY FOUND SEVERAL INSTANCES OF BROKEN SCREWS WHILE DIS-ASSEMBLING FUEL CONTROLS. THERE WAS NO FUNCTIO NAL PROBLEM AS A RESULT OF THIS FAILURE. FURTHER INVESTIGATION HAS SHOWN THE BROKEN SCREWS ARE HARDER THAN THAT WHICH I S ALLOWED PER THE ENGINEERING DRAWING. INSPECTION OF SEVERAL PARTS HAS LED TO THE CONCLUSION THE BROKEN PARTS ARE ALL F ROM THE SAME MANUFACTURING LOT AND NOT PROPERLY HEAT TREATED. INSPECTION RECORDS INDICATE THE LOT WAS PROCESSED PROPERL Y, AND CONFORMED TO DRAWING REQUIREMENTS SO SEARCH FOR ROOT CAUSE IS FOCUSING ON POSSIBLE MIX-UP DUE TO LOOK-ALIKE PARTS OR POSSIBILITY SOME PORTION OF LOT MAY HAVE MISSED THAT OPERATION. 4 F E13NE 1995081800592 19950818 00592 NE 1995 8 18 95ZZZX4069 2 19950719 G 7321 1037642 SCREW WOODWARD 8061896 GE CF6 CF680C2A5 NE FUEL CONTROL BROKEN B L UU2R K NONE O OTHER IN INSP/MAINT 1 GL 03 WOODWARD HAS RECENTLY FOUND SEVERAL INSTANCES OF BROKEN SCREWS WHILE DIS-ASSEMBLING FUEL CONTROLS. THERE WAS NO FUNCTIO NAL PROBLEM AS A RESULT OF THIS FAILURE. FURTHER INVESTIGATION HAS SHOWN THE BROKEN SCREWS ARE HARDER THAN THAT WHICH I S ALLOWED PER THE ENGINEERING DRAWING. INSPECTION OF SEVERAL PARTS HAS LED TO THE CONCLUSION THE BROKEN PARTS ARE ALL F ROM THE SAME MANUFACTURING LOT AND NOT PROPERLY HEAT TREATED. INSPECTION RECORDS INDICATE THE LOT WAS PROCESSED PROPERL Y, AND CONFORMED TO DRAWING REQUIREMENTS SO SEARCH FOR ROOT CAUSE IS FOCUSING ON POSSIBLE MIX-UP DUE TO LOOK-ALIKE PARTS OR POSSIBILITY SOME PORTION OF LOT MAY HAVE MISSED THAT OPERATION. 4 F E13NE 1995081800593 19950818 00593 NE 1995 8 18 95ZZZX4070 2 19950719 G 7321 1037642 SCREW WOODWARD 8061526 GE CFM56 CFM565A 13802 NE FUEL CONTROL BROKEN B L UU2R K NONE O OTHER IN INSP/MAINT 1 GL 03 WOODWARD HAS RECENTLY FOUND SEVERAL INSTANCES OF BROKEN SCREWS WHILE DIS-ASSEMBLING FUEL CONTROLS. THERE WAS NO FUNCTIO NAL PROBLEM AS A RESULT OF THIS FAILURE. FURTHER INVESTIGATION HAS SHOWN THE BROKEN SCREWS ARE HARDER THAN THAT WHICH I S ALLOWED PER THE ENGINEERING DRAWING. INSPECTION OF SEVERAL PARTS HAS LED TO THE CONCLUSION THE BROKEN PARTS ARE ALL F ROM THE SAME MANUFACTURING LOT AND NOT PROPERLY HEAT TREATED. INSPECTION RECORDS INDICATE THE LOT WAS PROCESSED PROPERL Y, AND CONFORMED TO DRAWING REQUIREMENTS SO SEARCH FOR ROOT CAUSE IS FOCUSING ON POSSIBLE MIX-UP DUE TO LOOK-ALIKE PARTS OR POSSIBILITY SOME PORTION OF LOT MAY HAVE MISSED THAT OPERATION. 4 F E29NE 1995081800695 19950818 00695 GL 1995 8 18 95ZZZX4087 2 19950609 G 7210 A6887772 BEARING 6894171 BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL GEARBOX GALLED B ALGR K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 03 209AL 132 032 1044 8800956BA DISASSEMBLED GEARBOX DUE TO 'ENGINE CHIP LIGHT'. DISCOVERED THE P.T.O. ROLLER BEARING TO BE 'GALLING ROLLERS'. CAUSE U NKNOWN. 1 G 7 1 3U 3 U H2SW E4CE 1995082500225 19950825 00225 EA 1995 8 25 95ZZZX4181 2 19950803 G 8530 7380685 PUSHROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CYL NR 3 MUSHROOMED D K NONE O OTHER IN INSP/MAINT 1 EA 01 757UR 15280018 L2016515 CYLINDER NR 3 REMOVED FOR LOW COMPRESSION, FOUND EXCESSIVE CLEARANCE BETWEEN EXHAUST VALVE AND ROCKER ARM CAUSED BY PUSH ROD THAT HAD MUSHROOMED UNDER BALL END. 1 H 7 1 3O 3 O NT 3A19 E223 1995082500232 19950825 00232 SO 1995 8 25 95ZZZX4188 2 19950804 G 8520 632857 BEARING PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360KB 17025 SO REAR MAIN BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 11 83747 1174 348133074 268263R INSPECTION OF OIL FILTER ELEMENT DURING ROUTINE OIL CHANGE AND LARGE AMOUNT OF ALUMINUM SHAVINGS AND MINOR AMOUNT OF STE EL (MAGNETIC) PARTICLES WERE FOUND. ENGINE WAS REMOVED FROM AIRCRAFT AND DISASSEMBLED. FOUND REAR INTERMEDIATE MAIN BE ARING HAD BROKEN INTO ABOUT 6-8 PIECES, BUT WAS BEING HELD IN PLACE BY CASE WEB AND BEARING JOURNAL. THE BEARING PIECES HAD SHIFTED ENOUGH TO SPIN IN WEB AND PRODUCE THE SHAVINGS OF ALUMINUM FOUND IN THE FILTER. IT WAS NOTED DURING DISASS EMBLY THAT TORQUE ON THROUGH-BOLT NUTS AT THIS WEB SEEMED LOW. ENGINE WAS OVERHAULED WITH BOTH CASE AND CRANKSHAFT BEIN G RETURNED TO SERVICE AFTER REPAIR. 1 L 7 2 3O 3 O A7SO E9CE 1995082500572 19950825 00572 SO 1995 8 25 95ZZZX4262 2 19950518 G 8520 CAMSHAFT CESSNA 207 207 2073602 CE CONT O520 IO520F 17032 SO CYL 3-4 LOBE FAILED D K NONE O OTHER IN INSP/MAINT 1 AL 03 1704U 486 472013 20700304 286372R FAILURE OF CAMSHAFT AT NR 3 AND NR 4 INTAKE LOBE. DESTROYED LIFTER BODIES, METAL IN ENGINE, ETC. TIME SINCE OVERHAUL 4 86.1 HOURS. 1 H 7 1 3O 3 O A16CE E5CE 1995082500573 19950825 00573 SO 1995 8 25 95ZZZX4263 2 19950517 G 8530 RING CESSNA 207 207 2073602 CE CONT O520 IO520F 17032 SO NR 2 CYLINDER BROKEN D K NONE O OTHER IN INSP/MAINT 1 AL 03 707FY 598 20700063 286190R OIL ANALYSIS SHOWING ALUMINUM HIGH. THEN IRON, NICKEL, CHROME. COMPRESSION GOOD, UNTIL TIME ON ENGINE OVER 600 HOURS A ND COMPRESSION DROPPED TO 60/80 ON NR 2 CYLINDER. PULLED CYLINDER, FOUND BROKEN RING TOP COMPRESSION. 1 H 7 1 3O 3 O A16CE E5CE 1995082500576 19950825 00576 EA 1995 8 25 95ZZZX4266 2 19950627 G 8530 SL74230 GUIDE SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA EXHAUST VALVE CRACKED B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 138ER 971 1528 DURING CYLINDER REPAIR, THE EXHAUST VALVE GUIDE WAS FOUND CRACKED AT BOTH THE TOP AND BOTTOM PORTIONS OF THE GUIDE. THE CRACKS WERE NOT CONNECTED. 1 L 7 1 3O 3 O NT AS1EU E274 1995082500577 19950825 00577 EA 1995 8 25 95ZZZX4267 2 19950627 G 8530 74230 GUIDE SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA CYLINDER EXHAUST BROKEN B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 177ER 1376 1353 DURING CYLINDER REPAIR, A RECTANGULAR SECTION OF THE EXHAUST VALVE GUIDE THAT MEASURED APPROXIMATELY .3125 INCH X .25 IN CH WAS FOUND MISSING FROM THE LOWER PORTION OF THE GUIDE. 1 L 7 1 3O 3 O NT AS1EU E274 1995082500578 19950825 00578 EA 1995 8 25 95ZZZX4268 2 19950627 G 8530 SL74230 GUIDE LW12416 SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA CYLINDER EXHAUST BROKEN B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 245ER 722 1350 DURING CYLINDER REPAIR, A HALF-MOON SHAPED SECTION OF THE EXHAUST VALVE GUIDE THAT MEASURED APPROXIMATELY .3125 INCH X . 25 INCH WAS FOUND MISSING FROM THE LOWER PORTION OF THE GUIDE. 1 L 7 1 3O 3 O NT AS1EU E274 1995082500579 19950825 00579 EA 1995 8 25 95ZZZX4269 2 19950606 G 7414 ES10382585 CONTACT ASSY D4LN3000 MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA MAGNETO WORN B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 193ER 997 497 B208905G 243243 WHEN MAGNETO WAS UNDERGOING PRELIMINARY INSPECTION, THE CONTACT ASSEMBLY WAS FOUND PITTED AND THE CAM FOLLOWER WAS EXCES SIVELY WORN. SOME CAM FOLLOWER MATERIAL HAD TRANSFERRED TO THE OUTER FELT OF THE CONTACT ASSEMBLY. A THIN DARK COATING WAS FOUND ON THE MAGNETO CAM. CAUSE IS SUSPECTED TO BE CAM FOLLOWER WEAR. CAM FOLLOWER WEAR RESULTS IN DECREASING CON TACT CLEARANCE AND MAY LEAD TO MAGNETO FAILURE. 1 L 7 1 3O 3 O 2A3 1E10 1995082500581 19950825 00581 SO 1995 8 25 95ZZZX4271 2 19950727 G 7322 GASKET FACET MA5SPA CESSNA 175 175 2072502 CE CONT O300 GO300A 17022 SO CARBURETOR WRONG PART G K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 15 6618E 56118 61919A FOLLOWING ENGINE OVERHAUL, CARBURETOR WAS RE-INSTALLED TO OIL SUMP USING O-RING SUPPLIED IN KIT NR 627372-A1, PAGE 25 OF GO-300 PARTS MANUAL, FORM X30020. CARBURETOR INSTALLED PER G0-300 PARTS MANUAL, FIGURE 5, WHICH CALLS FOR AN O-RING. N O O-RING GROOVE EXISTED. G0-300 OVERHAUL MANUAL, SECTION 12-11 CALLS OUT GASKET OR O-RING DEPENDING ON PART NUMBER. OI L PUMP INSTALLED. INDUCTION SYSTEM SHOWN IN FIGURE 8. 1 H 7 1 3O 3 O NT 3A17 E298 1995082500589 19950825 00589 GL 1995 8 25 95ZZZX4279 2 19950805 G 7323 23007505 GOVERNOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE ERRATIC B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 4282X 424 28419 180253D CAE833827 GOVERNOR IS ERRATIC WITH ANY POWER CHANGE. UNIT REMOVED AND SENT IN FOR REPAIR ON ALLISON 250 REPORT NR A151615. 1 G 7 1 3U 3 U H3WE E4CE 1995082500598 19950825 00598 NE 1995 8 25 95ZZZX4288 2 19950801 G 7530 451077 SENSE LINE BOEING 727 72722 1384002 NM PWA JT8 JT8D7B 52053 NE NR 3 ENGINE BROKEN D O OTHER J WARNING INDICATION CR CRUISE 1 SW 99 400RG 19149 P648871 DURING CRUISE, NR 3 ENGINE'S FUEL FLOW AND EGT BEGAN TO CLIMB WITH LOWER RPM'S AT SAME THROTTLE SETTING AS NR 1 AND NR 2 ENGINES. OK, PRESSURE GOOD, NO VIBRATION NOTED. REDUCED POWER TO IDLE FOR ABOUT 1.50 HOURS, INBOUND TO EWR. FOUND 13 TH STAGE AIR PRESSURE SENSE LINE BROKEN AT 13TH STAGE SADDLE DUCT. LINE BROKE AT FERRULE TO TUBE WELD JUNCTION, SUSPECT CAUSE - VIBRATION. 2 L 7 3 4F 4 F A3WE E2EA 1995082500616 19950825 00616 SO 1995 8 25 95ZZZX4306 2 19950721 G 8550 9696001111 LINE BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO PROP GOVERNOR FAILED B EKGR K NONE K FLUID LOSS NR NOT REPORTED 1 WP 07 365C 3299 TH346 PILOT REPORTED OIL LOSS FROM RIGHT ENGINE COMPARTMENT. INSPECTION REVEALED THE METAL LINE CONNECTED TO THE PROPELLER GO VERNOR HAD SEPARATED JUST BELOW THE FLARE. A NEW LINE WAS INSTALLED. REASON FOR FAILURE IS UNKNOWN. 1 L 7 2 3O 3 O 3A16 E5CE 1995082500620 19950825 00620 EU 1995 8 25 95ZZZX4310 2 19950727 G 8530 935730 GEAR AMTR CH701 CH701 0564900 GL ROTAX 582 ROTAX582 55555 EU ROTARY VALVE TEETH SHEARED G O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 CE 03 701ZA 414 73001 4016584 ROTARY VALVE GEAR OIL SUMP FASTENER BROKE AND SUMP FELL TO A LOWER LEVEL THAN THE CRANKSHAFT. LACK OF LUBRICATION FROM SUMP CAUSED BRASS ROTARY VALVE GEAR TO SHEAR OFF ITS TEETH. RESULT WAS THE ROTARY VALVE SLIPPED AND BECAME OUT OF TIME WITH ENGINE; THUS, ROUGHNESS AND POWER LOSS OCCURRED. 1 H 7 1 3O 3 I NT EXPA1H71 EXPE3I 1995090100342 19950901 00342 SO 1995 9 1 95ZZZX4349 2 19950815 G 7414 M3525 COIL SLICK 4201REVE TCRAFT 19 F19 9230703 GL CONT O200 O200A 17020 SO MAGNETO OPEN H K NONE O OTHER IN INSP/MAINT 1 AL 01 3682T 145 89060087 F089 255713 INSPECTION FOUND M3121 DISTRIBUTOR BLOCK AND ROTOR CONTACTS BURNED. M3525 COIL FAILED - OPEN AND HAD A CRACK IN SIDE. 1 H 7 1 3O 3 O 1A9 E252 1995090100343 19950901 00343 EA 1995 9 1 95ZZZX4350 2 19950731 G 8520 71105ASR218 LIFTER PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA NR 2 CYL EXH BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 15 2412K 1071 3879A0621 L1874815 DURING ANNUAL INSPECTION, NR 2 CYLINDER WAS REMOVED DUE TO LOW COMPRESSION. WHEN CYLINDER WAS REMOVED, THE CUP PORTION OF THE EXHAUST SOLID LIFTER FELL TO THE FLOOR. THE CUP SECTION OF THE LIFTER HAD BROKEN COMPLETELY OFF. ALL LIFTERS HA D BEEN REPLACED DURING PREVIOUS ENGINE OVERHAUL. 1 L 7 1 3O 3 O A18SO E223 1995090100348 19950901 00348 EA 1995 9 1 95ZZZX4355 2 19950728 G 8530 SL134441 PISTON PIN PIPER PA60 PA60601P 7106012 NM LYC O540 LTIO540J2BD 41533 EA NR 3 CYLINDER BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 17 36BW 243 61P0232033 L227168A DISASSEMBLING ENGINE FOR SEALING OIL LEAKS. WHEN NR 3 PISTON PIN WAS PUSHED OUT IT WAS FOUND BROKEN IN HALF RIGHT IN TH E MIDDLE OF THE CONNECTING ROD BUSHING. FOUND LIGHT (0.002 INCH - 0.003 INCH DEEP) SCORING IN CONNECTING ROD BUSHING. A PPARENTLY, THE PIN HAD NOT BEEN BROKEN FOR LONG. REMAINDER OF CYLINDER ASSY APPEARED NORMAL. NO SIGNIFICANT DIFFERENCE FROM OTHER 5. PLAN TO SUBMIT PIN TO U. OF T. METALLURGY LAB FOR ANALYSIS. APPEARS TO BE METAL DEFECT. 1 M 7 2 3O 3 O RT A17WE E14EA 1995090100354 19950901 00354 EA 1995 9 1 95ZZZX4361 2 19950712 G 7210 310074701 SHAFT PWA PT6 PT6A65B 52043 EA PROP MISMATCH SET B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 PART WAS RECEIVED FROM THE VENDOR. THE PROP SHAFT AND SLEEVE HAVE TO BE A MATCHED SET, SAME S/N. THE SLEEVE HAS A S/N OF A1351. THE SHAFT IS S/N 5F780. THEREFORE, THIS IS NOT A MATCHED SET. 4 T E4EA 1995090100371 19950901 00371 NE 1995 9 1 95ZZZX4378 2 19950730 G 8530 PISTON GRUMAN SA16 HU16 3950405 EA PWA R1830 R1830* 52020 NE RT ENG NR 9 CYL DAMAGED D E ENGINE SHUTDOWN J E WARNING INDICATION VIBRATION/BUFFET CR CRUISE 1 WP 28 7025J 110 131910 AT 6,500 MSL-10 MI E OF DSM, RT ENGINE CHIP DETECTOR LIGHT CAME ON WITH ENGINE VIBRATION. FEATHERED RT ENGINE, PRECAUTI ONARY. LANDING NORMAL. FOUND VALVE AND PISTON DAMAGE NR 9 CYLINDER. REPLACED CYLINDER, RECHECKED BOTH ENGINES FOR VAL VE CLEARANCE, CHANGED OIL. 2 H 7 2 4R 4 R EXPA2H72 5E4 1995090100377 19950901 00377 SO 1995 9 1 95ZZZX4384 2 19950817 G 8500 ENGINE CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO CYLINDER DEFECTIVE D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NE 03 300SQ 817 414A0416 800543 ENGINE HAS HIGH OIL CONSUMPTION, HIGH COOLENT PRESSURE, ROUGH RUNNING, LOW MANIFOLD PRESSURES. SUSPECT POSSIBLE CRACKED CYLINDER(S). 1 L 7 2 3O 3 O A7CE E8CE 1995090100383 19950901 00383 EA 1995 9 1 95ZZZX4390 2 19950726 G 8520 LW12596 ROD BOLT BEECH 80 65B80 1152812 CE LYC O540 IGSO540A1A 41532 EA NR 6 ROD BROKEN D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 CE 05 265RW 122 LD381 LL317830 ROD BOLT BROKE SUDDENLY WITH NO WARNING. ENGINE WAS RUNNING SMOOTH UNTIL ROD BROKE. 1 L 7 2 3O 3 O 3A20 1E7 1995090100385 19950901 00385 SO 1995 9 1 95ZZZX4392 2 19950801 G 8520 649895 CRANKCASE CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO NR 4 CYL PAD CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 07 53SA 7712 469 402B0597 20650271E DURING A ROUTINE INSPECTION, THE LEFT ENGINE CRANKCASE WAS FOUND CRACKED AT THE NR 4 CYLINDER MOUNTING PAD. AD 77-13-22 DOES NOT APPLY TO THIS CRANKCASE DUE TO MARKINGS. SUSPECT FATIGUE, WEAK DESIGN. SUBMITTER SUGGESTS INSPECTING AREA CL OSELY AT 100-HOUR INTERVALS. INVESTIGATE ALL OIL LEAKS IMMEDIATELY ON CONTINENTAL CRANKCASES. 1 L 7 2 3O 3 O A7CE E8CE 1995090100386 19950901 00386 SO 1995 9 1 95ZZZX4393 2 19950811 G 8530 6291171 ROTOR CONT O520 IO520* 17032 SO EXH VALVE DEFECTIVE B YCTR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 11 FOUND EXHAUST VALVE ROTOR CAP WILL NOT ROTATE. THIS VALVE ROTOR WAS OUT OF A CYLINDER VALVE ASSY. 3 O E5CE 1995090100388 19950901 00388 SO 1995 9 1 95ZZZX4395 2 19950701 G 8520 629340 ROD BOLT CONT O470 O470U 17026 SO NR 5 CYLINDER BROKE G K NONE O OTHER NR NOT REPORTED 1 SW 17 1300 1300 HOURS SINCE FACTORY OVERHAUL, ENGINE NR 5 CYLINDER CONNECTING ROD BOLT BROKE IN TWO PIECES. 3 O E273 1995090800132 19950908 00132 EA 1995 9 8 95ZZZX4428 2 19950810 G 8530 73806 PUSH ROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 1 CYL INT DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 03 6141Q 15285164 L2242115 ENGINE LOW STATIC. FOUND PUSH ROD WITH BOTH ENDS LOOSE AND TUBE MUSHROOMED. REPLACED PUSH ROD. INSPECTED ALL OTHER FO R PROPER ADJUSTMENT - OK. 1 H 7 1 3O 3 O NT 3A19 E223 1995090800136 19950908 00136 SO 1995 9 8 95ZZZX4432 2 19950801 G 8530 SA63624210 VALVE GUIDE 639272CD CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO NR 6 CYL EXH LOOSE D K NONE O OTHER IN INSP/MAINT 1 AL 01 735ER 300 A0916 U20604909 15961270F INSPECTION FOUND EXHAUST VALVE GUIDE EXCESSIVELY LOOSE IN CYLINDER. 1 H 7 1 3O 3 O A4CE E5CE 1995090800159 19950908 00159 WP 1995 9 8 95ZZZX4452 2 19950522 G 7320 625501038 LINE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE7313 01518 WP LT ENG P2T2 CRACKED B CWQR K NONE R PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 05 370TG 6500070 87317L THE CREW INDICATED THE LEFT ENGINE WOULD NOT MAKE POWER AT CRUISE ALTITUDE. UPON INVESTIGATION, FOUND THE P2T2 SENSE LI NE WAS CRACKED AT THE PROBE. SUBMITTER RECOMMENDS THE LINE BE REPLACED WITH A SUITABLE FLEXIBLE LINE. THIS WILL ELIMIN ATE THE POSSIBILITY OF CRACKING DUE TO VIBRATION. 2 L 7 2 4F 4 F A9NM E6WE 1995090800192 19950908 00192 EA 1995 9 8 95ZZZX4485 2 19950624 G 8510 IDLER SHAFT PIPER PA32 PA32301 7103207 SO LYC O540 IO540K1G5 41532 EA PROP GOVERNOR SCREW MISSING H L A K NONE O OTHER IN INSP/MAINT 1 GL 17 801MT 1818 328306030 L2170548A WHILE PERFORMING A ROUTINE OIL CHANGE ON A PIPER PA32301, A 10-32 SET SCREW WAS FOUND IN THE OIL SUMP SUCTION SCREEN. T HE SCREW HAD OBVIOUSLY BEEN SMASHED AND WAS IN TWO PIECES. INVESTIGATION FOUND THE ONLY 10-32 SET SCREW IN THE IO-540 S ERIES ENGINES WAS USED TO HOLD THE PROP GOVERNOR IDLER GEAR SHAFT IN THE FRONT OF THE CASE. AFTER REMOVING THE PROPELLE R AND THE EXTERIOR CAP, PLACED A MAGNET ON THE IDLER SHAFT AND WAS ABLE TO NEARLY PULL IT OUT OF THE CASE. NOT KNOWING THE EXTENT OF DAMAGE INTERNALLY AND SINCE THE ENGINE WAS NEAR OVERHAUL TIME, THE OWNER OPTED TO REPLACE THE ENGINE WITH A FACTORY OVERHAULED ENGINE. 1 L 7 1 3O 3 O A3SO 1E4 1995091500003 19950915 00003 NE 1995 9 15 95ZZZX4489 2 19950727 G 8530 399356 CYLINDER SCWZER G164 G164A 3952704 EA PWA R1340 R1340AN1 52016 NE NR 4 FAILED G A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 SW 11 6636Q 1694 P356716 CYLINDER HEAD HAD CRACKED ON THE EXHAUST ROCKER BOX ASSEMBLY AREA CAUSING ENGINE TO QUIT AND AIRCRAFT CRASHED. 1 Q 7 1 3R 3 R 1A16 5E2 1995091500006 19950915 00006 SO 1995 9 15 95ZZZX4492 2 19950720 G 8530 CYLINDER CONT O470 O470U 17026 SO EXHAUST SEAT FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 01 467573 CYLINDER CRACKED TWO PLACES BETWEEN SPARK PLUG AND EXHAUST SEAT. EXHAUST SEAT CRACKED. CYLINDER CRACKED ALSO, THREE-QU ARTERS AROUND. SUBMITTER RECOMMENDS CYLINDER TT SHOULD BE TRACKED AND CYLINDERS BE RETIRED AFTER 3 ENGINE T.B.O.'S. TH IS IS A RECURRING PROBLEM WITH SECOND-RUN CYLINDERS. DO NOT SEE WITH FIRST-RUN CYLINDERS. 3 O E273 1995091500235 19950915 00235 GL 1995 9 15 HEEA955575 2 19950808 G 7320 6890586 TUBE ASSY BELL 230 230 1182149 SW ALLSN 250C 250C30 03013 GL NR 2 ENG N1 CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 230UN 672 23009 CAE898201 #2 ENGINE N1 NOT ADVANCING WITH THROTTLE INPUT. UPON TROUBLESHOOTING NOTED THE FOLLOWING: CRACKED TUBE ASSY APPROXIMAT ELY 270 DEGREES AROUND FERRULE MATING SURFACE AT GOVERNOR END. SCRAPPED TUBE ASSEMBLY AND INSTALLED NEW TUBE ASSY. 1 G 7 2 3U 3 U NC H9SW E1GL 1995091500237 19950915 00237 GL 1995 9 15 EKGA9520837 2 19950505 G 7261 6854424 SHAFT SEAL BELL 230 230 1182149 SW ALLSN 250C 250C30P 03013 GL STARTER DRIVE LEAKING E EKGA K NONE K FLUID LOSS IN INSP/MAINT 1 WP 07 303PS 291 23016 898237 STARTER DRIVE SEAL IS LEAKING. 1 G 7 2 3U 3 U NC H9SW E1GL 1995091500257 19950915 00257 SO 1995 9 15 95ZZZX4506 2 19950821 G 8530 PUSH ROD BEECH 55 95B55B CE CONT O470 IO470L 17026 SO EXHAUST VALVE BROKEN D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 09 527T TC576 OIL LEAK TRACED TO BROKEN ROCKER BOSS AND ROCKER COVER. EXHAUST PUSH ROD BROKEN AND BENT. ENGINE MAY HAVE BEEN STARTED WITH STUCK EXHAUST VALVE SOME TIME IN PAST AND BENT PUSH ROD. PUSH ROD AND TUBE SHOWED SIGNS OF LONG TERM WEAR PRIOR T O BREAKING. 1 L 7 2 3O 3 O 3A16 3E1 1995091500262 19950915 00262 SO 1995 9 15 95ZZZX4511 2 19950801 G 8520 642720 BEARING CONT O520 TSIO520R 17040 SO CRANK MAIN WORN G K NONE O OTHER IN INSP/MAINT 1 WP 07 190 269786R ENGINE DISASSEMBLED AT 190 HRS TSO FOR INSP DUE TO PROP STRIKE. UNUSUAL WEAR ON ROD BEARINGS AND MAIN BEARINGS WAS OBSE RVED. THE ROD BEARING WEAR WAS FOUND ONLY ON THE ROD-SIDE BEARINGS WHILE THE CAP-SIDE BEARINGS APPEAR NORMAL. ALL THE WORN BEARINGS SHOW HEAT STRESS DAMAGE. THE HEAT DAMAGE AND UNUSUAL WEAR ARE VERY ABNORMAL CONSIDERING THE LOW TIME IN S ERVICE SINCE NEW (190 HRS). IDENTICAL SITUATION HAS OCCURRED 4 TIMES IN LAST 4 MONTHS ON 520 MODEL ENGINES OF SIMILAR L OW TSO. ONE SIMILARITY OF ALL THE ENGINES IS, ALL USED AEROSHELL 15W-50 MULTIGRADE SYNTHETIC OIL. 3 O E8CE 1995091500277 19950915 00277 SO 1995 9 15 95ZZZX4526 2 19950829 G 8530 652112 ROTO COIL CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO CYLINDERS 3-5 MAKING METAL D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 61423 1358 18504180 282785R WHEN REPLACING ROCKER COVER GASKETS BECAUSE OF OIL LEAKS, FOUND STEEL SLIVERS IN BOTTOM OF COVERS ON NR 3 AND NR 5 CYLIN DERS. SENT SLIVERS TO CONTINENTAL TO BE ANALYZED. WAS INSTRUCTED BY CONTINENTAL TO REPLACE ALL ROTO COILS IN BOTH CYLI NDERS. NO METAL FOUND IN OIL FILTER. 1 H 7 1 3O 3 O 3A24 E5CE 1995091500278 19950915 00278 SO 1995 9 15 95ZZZX4527 2 19950815 G 7310 641502 FITTING BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO FUEL PUMP FAULTY B KD4R A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SO 17 26UR 1321 CE1274 578399 AFTER A NORMAL RUN-UP, ACFT LOST POWER ON TAKEOFF AT APPROX 300 FEET AGL. PILOT SWITCHED FUEL TANKS AND ADJUSTED MIXTUR E CONTROL WITH NO RESULTS. A SAFE EMERGENCY LANDING WAS MADE ON THE DOWN-WIND RUNWAY. ENGINE WAS SHUT OFF AND ACFT TOW ED TO MAINTENANCE HANGAR. INVESTIGATION REVEALED THE MAIN FUEL LINE FROM ENGINE DRIVEN FUEL PUMP TO CONTROL ASSY HAD BA CKED OFF AT FUEL PUMP SIDE. FURTHER INVESTIGATION REVEALED THE THREADS ON THE 90-DEGREE ELBOW FITTING AT THE FUEL PUMP WERE SHARP AND SHOWED SIGNS OF WEAR. THE FITTING REPLACED WITH NEW UNIT. FUEL SYSTEM PRESSURE TESTED WITH NO LEAKS NOT ED. ACFT REASSEMBLED AND RETURNED TO SERVICE. 1 L 7 1 3O 3 O 3A15 E5CE 1995091500279 19950915 00279 SO 1995 9 15 95ZZZX4528 2 19950828 G 8530 SHAFT SUPPORT CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO EXH ROCKER ARM BROKEN D S K NONE O OTHER IN INSP/MAINT 1 WP 23 21997 3854 411 15074599 250401 DURING A SCHEDULED INSPECTION, (ACFT HAD SAT FOR ABOUT 6 MONTHS), THE COMPRESSION TEST WAS PERFORMED. NR 1 CYLINDER WAS BLOWING-BY FROM EXHAUST VALVE. TO STAKE THE VALVE, THE ROCKER BOX COVER WAS REMOVED. A BROKEN PIECE OF ROCKER ARM SHA FT SUPPORT WAS FOUND INSIDE OF ROCKER BOX COVER. IT CAME OFF OF EXHAUST SIDE. 1 H 7 1 3O 3 O 3A19 E252 1995091500288 19950915 00288 GL 1995 9 15 95ZZZX4537 2 19950812 G 7210 A23034787 BEARING ALLSN 250C 250C20 03013 GL GEARBOX MAKING METAL B UP9R K NONE O OTHER IN INSP/MAINT 1 NM 07 2745 083 CAB832926 GEARBOX 2 1/2 BEARING STARTING TO MAKE METAL. ROLLERS STARTING TO GALL. 3 U E4CE 1995091500289 19950915 00289 GL 1995 9 15 95ZZZX4538 2 19950817 G 7250 23001967 TURBINE WHEEL ALLSN 250C 250C20 03013 GL NR 3 SHROUD CRACKED B UP9R K NONE O OTHER IN INSP/MAINT 1 NM 07 2745 HX73658 CKE832926 TURBINE NR 3 WHEEL SHROUD CRACKED THROUGH. 3 U E4CE 1995091500290 19950915 00290 GL 1995 9 15 95ZZZX4539 2 19950813 G 7230 23031922 GEARSHAFT ALLSN 250C 250C20 03013 GL SPUR ADAPTER STEP WEAR B UP9R K NONE O OTHER IN INSP/MAINT 1 NM 07 2745 TH83938 CAE832926 SPUR ADAPTER GEARSHAFT SPLINES ON TURBINE END STEPPED. 3 U E4CE 1995091500291 19950915 00291 GL 1995 9 15 95ZZZX4540 2 19950812 G 7210 A6887772 BEARING ALLSN 250C 250C20 03013 GL GEARBOX PTO SPALLED B UP9R K NONE O OTHER IN INSP/MAINT 1 NM 07 2745 044 CAE832926 PTO BEARING STARTING TO SPALL AND MOVE METAL. 3 U E4CE 1995091500293 19950915 00293 EU 1995 9 15 95ZZZX4542 2 19950730 G 7314 7086002 PUMP BOEING 737 737* NM CFMINT CFM56 CFM563B2 13802 EU LT ENG HP FUEL LEAKING B GJPY K NONE K FLUID LOSS IN INSP/MAINT 1 WP 33 20127 WHEN STARTING LT ENGINE, HIGH PRESSURE FUEL PUMP LEAKED FUEL. REPLACED THE FUEL PUMP PER MM73-11-01. ADJUSTED AND RAN ENGINE PER TEST 6, ALL PARAMETERS WERE OKAY. 2 L 7 2 4F 4 F RT A16WE E21EU 1995091500297 19950915 00297 WP 1995 9 15 95ZZZX4546 2 19950815 G 7314 8973902 PUMP AYRES S2 S2RRESTD 0970101 SO GARRTT TPE331 TPE3311 01514 WP ENGINE FUEL DEFECTIVE C K NONE O OTHER IN INSP/MAINT 1 WP 07 8034V 2400 2453R P91136 PILOT REPORTED OIL CONSUMPTION AT APPROXIMATELY 1 QUART PER HOUR. NO OIL FOUND AT THE FORWARD OR REAR CARBON SEALS. OI L WAS DISCOVERED INSIDE THE FUEL PUMP BY A FUEL SAMPLE ANALYSIS FROM THE FUEL PUMP FILTER BOWL. ON ENGINES INCORPORATIN G SB 72-0104 (WET SPLINE FUEL PUMP DRIVE), THE OIL CAN PASS THROUGH A SMALL ORIFICE IN THE FUEL PUMP IMPELLER SHAFT WHIC H IS PACKED WITH A SPECIAL GREASE. ONCE THE GREASE IS WASHED AWAY, THE ENGINE FUEL PUMP DRAWS IN OIL INTO THE FUEL FLOW . THE PROBLEM WAS REPAIRED BY GARRETT WITH A PLUG INSTALLED IN THE IMPELLER SHAFT. SUBMITTER STATES SECOND INCIDENT FO UND IN 5 MONTHS. 1 L 7 1 3R 3 T A4SW E3WE 1995091500399 19950915 00399 SO 1995 9 15 95ZZZX4564 2 19950819 G 8550 1002 OIL TUBE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO ENGINE EXTENDER CRACKED D K NONE K FLUID LOSS NR NOT REPORTED 1 AL 03 4975U 2000 U2065179 284679R THE EXTENDER CRACKED AT BOTTOM FLANGE AND THE TUBE FELL OFF THE ENGINE CAUSING OIL TO COME OUT OF ENGINE. SUBMITTER SUG GESTS LARGER WELDS WOULD HELP HOLD IT TOGETHER BETTER. 1 H 7 1 3O 3 O A4CE E5CE 1995091500405 19950915 00405 CE 1995 9 15 95ZZZX4570 1 19950725 G 7920 3608D0504 HOSE CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA ENGINE OIL FAILED D A UNSCHED LANDING Y K ENGINE STOPPAGE FLUID LOSS NR NOT REPORTED 1 EA 21 4702R 1067 S1167 R18200605 12418440A OIL COOLER TO ENGINE HOSE RUPTURED APPROXIMATELY 6 INCHES FROM FITTING. SUSPECT SOME KIND OF ACID PENETRATED THE HOSE I N ONE SPOT APPROXIMATELY 3 INCHES TO 3.50 INCHES AND DETERIORATED THE METAL AWAY. HOSE LINING FAILED ON A REAL HOT DAY AND PUMPED ALL THE OIL OVERBOARD CAUSING ENGINE TO SEIZE. 1 H 7 1 3O 3 O RT 3A13 E295 1995091500416 19950915 00416 NE 1995 9 15 95ZZZX4581 2 19950710 G 7322 INLET SCREEN AYRES S2 S2RR1340NORM 0970210 SO PWA R1340 R1340AN1 52016 NE CARBURETOR CLOGGED G A KOIG A UNSCHED LANDING Y ENGINE STOPPAGE AG AGRICULTURE 1 SW 11 8972Q 1642R AIRCRAFT EXPERIENCED LOSS OF ENGINE POWER DURING AERIAL APPLICATION. AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING A FORCED LANDING. INVESTIGATION REVEALED PARTICLES OF RUBBER ON CARBURETOR FUEL INLET SCREEN AND CARBURETOR BOWL CONTAINED WATE R AND RUST CONTAMINATES. SUBMITTER RECOMMENDS 137 FAR OPERATORS CHECK FUEL SUPPLY FOR CONTAMINATION AND FUEL HOSES FOR SERVICE ABILITY. FUEL SCREENS AND FUEL BOWL SHOULD BE THOROUGHLY INSPECTED DURING 100-HOUR AND ANNUAL INSPECTION. 1 L 7 1 3R 3 R A3SW 5E2 1995091500417 19950915 00417 EA 1995 9 15 95ZZZX4582 1 19950809 G 8110 12768 BEARING SCWZER G164 G164B 3952802 EA PWA R985 R985AN14B 52008 NE SUPERCHARGER FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 CE 09 6771Q 496 28013 18437 ENGINE EXPERIENCED TOTAL LOSS OF POWER SHORTLY AFTER TAKEOFF. AIRCRAFT CRASHED. NO INJURY TO PIC, AIRCRAFT INCURRED SU BSTANTIAL DAMAGE. SUBSEQUENT INSPECTION DISCLOSED THE FAILURE OF THE THREE SUPERCHARGER IMPELLER SUPPORT BEARINGS, PN 1 2768. TWENTY-NINE DAMAGED ROLLERS RETRIEVED FROM BLOWER SUPPORT BEARING CAVITY. ENGINE TT: 7,245.5 HOURS. ENGINE T.S .O.: 495.5 HOURS. 1 Q 7 1 3R 3 R 1A16 5E1 1995091500418 19950915 00418 1995 9 15 95ZZZX4583 1 19950821 G 7922 75944 VALVE LYC O320 O320E2D 41508 EA THERMO BYPASS CRIMP NUT LOOSE D K NONE O OTHER IN INSP/MAINT 1 NM 03 891 L2974527A WHILE COMPLYING WITH LYCOMING SB NR 518C DURING 100-HOUR INSPECTION, FOUND THERMOSTATIC OIL BYPASS VALVE HAD LOOSE CRIMP NUT, ACCOMPLISHED REPAIR IAW LYCOMING SERVICE INSTRUCTION NR 1423 AND REINSTALLED. 3 O E274 1995091500419 19950915 00419 EA 1995 9 15 95ZZZX4584 2 19950731 G 8530 LW190001 VALVE PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA ENGINE FAILED D K NONE O OTHER NR NOT REPORTED 1 CE 03 95207 1311 2825842 L2544527A VALVE STEM CRACKED JUST BELOW HEAD OF VALVE. THE HEAD OF THE VALVE FALLING INTO THE CYLINDER CAUSED MAJOR DAMAGE TO THA T CYLINDER. SUBMITTER SUGGESTS DETONATION MAY HAVE BEEN A FACTOR. NOTE: AUTO FUEL WAS BEING USED. 1 L 7 1 3O 3 O 2A13 E274 1995091500421 19950915 00421 SW 1995 9 15 95ZZZX4586 1 19950817 G 8120 60051004 HOUSING ROTOMASTER 646396 MOONEY M20 M20K 5870220 SW CONT O360 TSIO360GB 17025 SO TURBOCHARGER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 5659L 555 010902 250762 309812 WHILE COMPLYING WITH AD 82-27-03 IAW ROTO MASTER SERVICE LETTER 27A, RAY JAY SERVICE LETTER 21, FOUND TURBO HOUSING CRAC KED BEYOND ALLOWABLE LIMITS. THIS SCROLL IS THE NEW TYPE TURBINE HOUSING. 1 L 7 1 3O 3 O 2A3 E9CE 1995091500426 19950915 00426 EA 1995 9 15 95ZZZX4591 2 19950815 G 7322 CARBURETOR TUBE FACET MA4SPA CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ACCEL PUMP LOOSE D A UNSCHED LANDING O OTHER NR NOT REPORTED 1 NM 01 54635 1715 CK49853 17275018 RL1496639A RPM COULD NOT BE REDUCED BELOW 2,000 RPM IN-FLIGHT, NECESSITATING POWER-OFF LANDING. INSPECTION REVEALED THE CARBURETOR ACCELERATOR PUMP DISCHARGE TUBE HAD COME LOOSE AND LODGED IN THE THROTTLE VALVE PREVENTING FULL CLOSURE OF THROTTLE. T HE OVERHAUL MANUAL SPECIFIES THE TUBE IS HELD IN PLACE WITH LOCTITE ONLY. SUBMITTER RECOMMENDS REDESIGN SO THE TUBE IS MECHANICALLY HELD IN PLACE OR ELSE A REGULAR INSPECTION INTERVAL TO DETERMINE IF THE TUBE IS LOOSE. ENGINE TT: 3,882 H OURS. ENGINE TSOH: 1,714 HOURS. 1 H 7 1 3O 3 O NT 3A12 E274 1995091500428 19950915 00428 CE 1995 9 15 95ZZZX4593 2 19950818 G 8530 SA632310S GASKET MOONEY M20 M20K 5870220 SW CONT O360 TSIO360MB 17025 CE ROCKER COVER SCREWS LOOSE H K NONE O OTHER IN INSP/MAINT 1 NM 01 52202 16 251204 AFTER TALKING TO ANOTHER MECHANIC WHO HAD SIMILAR PROBLEM (LOOSE ROCKER COVER SCREWS), CHECKED SUBJECT AIRCRAFT AND FOUN D LIKE CONDITION. DUE TO SILICONE GASKETS BEING INSTALLED, FOUND SCREWS WOULD LOOSEN OVER TIME. RE-INSTALLED SCREWS US ING LOCKTITE TO PREVENT RECURRENCE. SUBMITTER STATED IT SHOULD BE NOTED THESE GASKETS DID NOT COME WITH SPECIAL INSTALL ATION INSTRUCTIONS TO THIS EFFECT. IF CONDITION IS ALLOWED TO EXIST, COVER SEPARATION AND OIL LOSS COULD RESULT. 1 L 7 1 3O 3 O 2A3 E9CE 1995091500429 19950915 00429 SW 1995 9 15 95ZZZX4594 2 19950829 G 8500 ENGINE CESSNA 195 195 2073102 CE JACOBP R755 R755B2 35007 SW POWER SECTION FAILED H A UNSCHED LANDING K B E FLUID LOSS SMOKE/FUMES/ODORS/SPARKS VIBRATION/BUFFET NR NOT REPORTED 1 SW 01 9368A 7447 11465 PILOT REPORTED SUDDEN SEVERE VIBRATION APPROXIMATELY 20 MINUTES INTO FLIGHT FOLLOWED WITHIN 1-2 MINUTES BY COMPLETE LOSS OF OIL PRESSURE TO ZERO. APPROXIMATELY 6 MINUTES TO LANDING WITH RISE IN OIL TEMP OFF SCALE, INCREASED VIBRATION, BURN ING ODOR AND PROGRESSIVE POWER LOSS. HAD NORMAL RECENT FLIGHTS, NORMAL START, RUN-UP, AND INITIAL FLIGHT BEFORE PROBLEM STARTED. BRIEF INSPECTION AFTER LANDING DID NOT IDENTIFY PROBLEM, ALTHOUGH THERE WAS A LARGE AMOUNT OF OIL ALONG BELLY AND SOME ON PROP. MECHANICS CURRENTLY WORKING TO ASCERTAIN PROBLEM. 1 H 7 1 3R 3 R NC A790 TC237 1995091500432 19950915 00432 SO 1995 9 15 95ZZZX4597 2 19950905 G 8530 653426A4 CYLINDER CESSNA 175 175A 2072504 CE CONT O300 GO300* 17022 SO NR 2 CYLINDER GUIDE WORN D K NONE O OTHER IN INSP/MAINT 1 NM 08 6821E 84 56321 14017 VALVE GUIDE WORN EXCESSIVELY. WOULD NOT PASS COMPRESSION CHECK. OWNER STATED HE WAS NOT USING AUTO FUEL. VALVE GUIDE WAS REPLACED. 1 H 7 1 3O 3 O 3A17 E298 1995091500696 19950915 00696 SO 1995 9 15 95ZZZX4599 2 19950818 G 7414 6220 MAGNETO SLICK CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENG LT MAG FAILED H O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 17 37AA 348 91030039 21062989 ENGINE BECAME ROUGH IN-FLIGHT. FOUND WOULD RUN BETTER ON RT MAG ONLY. INVESTIGATION FOUND WHEN LEFT MAG REMOVED. IT W AS DESTROYED BY AN INTERNAL FIRE. SUSPECT OIL LEAK INTO PRESSURED MAG AND IGNITED. 1 H 7 1 3O 3 O 3A21 E8CE 1995091500699 19950915 00699 NE 1995 9 15 95ZZZX4602 2 19950823 G 7250 3028601 BLADE 3023411 CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE HP TURBINE DAMAGED E K NONE O OTHER IN INSP/MAINT 1 GL 25 84EA 1869 5M028 5500484 71375 DURING PHASE 25/HOT SECTION INSPECTION, ALL 71 HIGH TURBINE BLADES WERE FOUND NICKED, DENTED AND BROKEN BY IMPACT DAMAGE FROM DEFLECTOR - RING FAILURE. NUMEROUS BLADES WERE MISSING FORWARD ONE-QUARTER OF OUTBOARD LEADING EDGE. NO COCKPIT INDICATION WAS NOTED AS TIP CLEARANCES FOR REMAINDER OF BLADE WAS STILL IN TOLERANCE. ALL BLADES WERE REPLACED WITH NEW . 1 L 7 2 4F 4 F A22CE E1NE 1995091500700 19950915 00700 NE 1995 9 15 95ZZZX4603 2 19950823 G 7250 3131060C212 SHROUD SEGMENT 3031461 CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE HP TURBINE GOUGED E K NONE O OTHER IN INSP/MAINT 1 GL 25 84EA 1869 PWC9001700 5500484 71375 DURING PHASE 25/HOT SECTION INSPECTION, ALL HIGH PRESSURE TURBINE SHROUD SEGMENT WIRE FOUND GOUGED. DAMAGE WAS CAUSED B Y FAILURE OF DEFLECTOR RING AND RESULTING HIGH TURBINE BLADE DAMAGE. ALL SHROUD SEGMENTS WERE REPLACED. 1 L 7 2 4F 4 F A22CE E1NE 1995091500701 19950915 00701 NE 1995 9 15 95ZZZX4604 2 19950823 G 7250 3022202 BLADE 3022722 CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE LP TURBINE DAMAGED E K NONE O OTHER IN INSP/MAINT 1 GL 25 84EA 5736 1869 6M040 5500484 71375 DURING PHASE 25/HOT SECTON INSPECTION, IMPACT DAMAGE WAS FOUND ON 2ND STAGE LOW TURBINE. THIS WAS CAUSED BY FAILURE OF DEFLECTOR RING. UNIT WAS SENT TO P & WC, DISASSEMBLED, BLENDED AND REASSEMBLED. NO COCKPIT INDICATIONS OF DAMAGE WERE NOTED PRIOR TO HOT SECTION INSPECTION. 1 L 7 2 4F 4 F A22CE E1NE 1995091500702 19950915 00702 WP 1995 9 15 95ZZZX4605 2 19950712 G 7250 31038393 SEAL PLATE 31033155 GARRTT TPE331 TPE33112UAR 01514 WP TURB 1ST STAGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 5829 1233151925 P70110C DURING SCHEDULED INSPECTION, FOUND SEAL PLATE CRACKED 5 PLACES. SB 72-0840 AUTHORIZES INSTALLATION OF THIS PART TO PROV IDE INCREASED SEAL PLATE TENSION AGAINST FIRST STAGE ROTOR ASSEMBLY. INCREASED TENSION ON THE SEAL FLANGE RESULTS IN CR ACKING AT THE SEAL PLATE FLANGE EDGE. NO SIGNS OF ABNORMAL/OVERTEMP OPERATION. SUBMITTER SUGGESTS ENGINEERING REVIEW C AUSE/EFFECT. NOTE: THIS IS A CRITICAL LIFE-LIMITED COMPONENT WITH LIMIT OF 20,000 CYCLES. THIS IS THE 7TH SEAL FOUND CRACKED. CSN: 5,865. 4 T E4WE 1995091500703 19950915 00703 WP 1995 9 15 95ZZZX4606 2 19950721 G 7250 31038393 SEAL PLATE 31033155 GARRTT TPE331 TPE33112UAR 01514 WP TURB 1ST STAGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 5952 1233151955 P70106C DURING INSPECTION/REPAIR FOR LOW POWER, FOUND SEAL PLATE CRACKED. SB 72-0840 AUTHORIZES INSTALLATION OF THIS PART TO IN CREASE SEAL PLATE TENISON AGAINST FIRST STAGE ROTOR ASSEMBLY. INCREASED TENSION OF THE SEAL FLANGE RESULTS IN CRACKING AT THE EDGE PROPOGATING RADIALLY INWARD. SUBMITTER SUGGESTS ENGINEERING REVIEW CAUSE/EFFECT. NOTE: THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIFE LIMIT IS 20,000 CYCLES. THIS IS THE EIGHTH SEAL FOUND CRACKED. TOTAL CYCLES, 7,221. 4 T E4WE 1995091500704 19950915 00704 WP 1995 9 15 95ZZZX4607 2 19950821 G 7250 31038939 SEAL PLATE 31033155 GARRTT TPE331 TPE33112UAR 01514 WP TURB 1ST STAGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 6135 1233151943 P70105C DURING INSPECTION/REPAIR FOR LOW POWER, FOUND SEAL PLATE CRACKED. SB 72-0840 AUTHORIZES INSTALLATION OF THIS PART TO IN CREASE SEAL PLATE TENSION AGAINST FIRST STAGE ROTOR ASSEMBLY. INCREASED TENSION ON THE SEAL FLANGE RESULTS IN CRACKING AT THE EDGE PROPOGATING RADIALLY INWARD. SUBMITTER SUGGESTS ALLIED SIGNAL ENGINEERING REVIEW CAUSE/EFFECT. NOTE: THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIMIT IS 20,000 CYCLES. THIS IS THE 9TH SEAL PLATE FOUND CRACKED. TOTAL CYCLE S, 7,427. 4 T E4WE 1995092200060 19950922 00060 EU 1995 9 22 HEEA955670 1 19950831 G 7332 10593910 SWITCH BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL NR 2 ENG PRESS MALFUNCTION E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 91070 S145 #2 ENGINE DIFFERENTIAL PRESSURE SWITCH WOULD NOT FUNCTION CHECK AS PER BO-105 M & O CHAPTER 62 PAGE 43 PARA. 62-39 ITEM #2. REPLACED DIFFERENTIAL PRESSURE SWITCH. 1 G 7 2 3U 3 U H3EU E4CE 1995092200068 19950922 00068 GL 1995 9 22 HEEA955678 2 19950831 G 7300 230060714101 BELLCRANK BELL 230 230 1182149 SW ALLSN 250C 250C30 03013 GL ENGINE WORN E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 230UN 2347 23009 WORN BEARING AND STIFF (BEARING HAD FROZE UP) 1 G 7 2 3U 3 U NC H9SW E1GL 1995092200172 19950922 00172 NE 1995 9 22 95ZZZX5025 2 19950901 G 8510 408119904 GEAR 408136005 LYC LTS101 LTS101650B1 41560 NE OUTPUT CHROME DEFECT D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 87D037 CHROME PLATING ON PN 4-081-199-04 BEARING JOURNAL WAS FOUND TO HAVE AN AIR POCKET IN CHROME APPROXIMTELY .1250 INCH FROM END OF PART. DISCONTINUITY WAS ON A NON-FUNCTIONAL SURFACE AND PART WAS SALVAGED BY REMOVING ALL CHROME IN THIS AREA. THIS IS NOT THE FIRST INSTANCE OF PROBLEMS RANGING FROM LEAKING MASKING TO AIR POCKETS IN CHROME FROM THIS VENDOR. 3 U E5NE 1995092200175 19950922 00175 SO 1995 9 22 95ZZZX5028 2 19950903 G 7414 10357586 DISTRIBUTOR GEAR BENDIX 101630601 CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MAGNETO TEETH MISSING E P K NONE O OTHER IN INSP/MAINT 1 NE 05 3249M 359 A148802ER 402C0296 266997R ENGINE HAD SLIGHT ROUGHNESS AND TIMING JUMP TO THE TIME OF FAILURE. FOUND DISTRIBUTOR GEAR TEETH MISSING. RECOMMEND SH IMS BE CHECKED FOR GEAR FREEDOM AND UNIT BE REPLACED AT ONE-HALF OF SPECIFIC T.B.O. OF MAGNETO. 1 L 7 2 3O 3 O A7CE E8CE 1995092200181 19950922 00181 SO 1995 9 22 95ZZZX5034 2 19950831 G 8530 646743 PISTON PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO NR 2 CYLINDER ERODED B LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 9249N 296 3448048 320200 OWNER REPORTED AN INCREASE IN OIL CONSUMPTION ON A SQUAK FOR ANNUAL INSPECTION. ENGINE APPEARED TO OPERATE NORMALLY ON RUN-UP. COMPRESSION CHECK REVEALED NR 2 CYLINDER AT 25 PSI. LEAKING PART RINGS. REMOVED CYLINDER AND FOUND NR 1 PISTO N CROWN DAMAGE. FIFTY PERCENT OF EDGE SEEMED TO BE MELTED AWAY AND FIRST RING FLANGE BROKEN. SUSPECT MATERIAL DEFECT. 1 L 7 2 3O 3 O A7SO E9CE 1995092200472 19950922 00472 GL 1995 9 22 95ZZZX5086 2 19950425 G 7320 222360703101 SOLENOID BELL 230 230 1182149 SW ALLSN 250C 250C30 03013 GL ENGINE DEFECTIVE B SL3R K NONE O OTHER IN INSP/MAINT 1 NE 01 230TX 327 651 23014 SOLENOID DEFECTIVE. NEW SOLENOID INSTALLED. 1 G 7 2 3U 3 U NC H9SW E1GL 1995092200556 19950922 00556 SO 1995 9 22 95ZZZX5104 2 19950801 G 8530 SA629690 PISTON PIN PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360F 17025 SO NR 2 CYLINDER BROKEN D K NONE O OTHER NR NOT REPORTED 1 NM 03 327LP 122 28R7803275 281050R NR 2 CYLINDER PISTON PIN FAILED AT MIDSECTION (BROKEN IN HALF). SUBSEQUENT FAILURE OF NR 2 PISTON AND METAL CONTAMINATE D SUPERIOR AIR PARTS SUPPLIED PISTON PIN WITH A SHIP DATE OF 11-8-94. CAUSE UNKNOWN. 1 L 7 1 3O 3 O 2A13 E9CE 1995092200558 19950922 00558 1995 9 22 95ZZZX5106 1 19950817 G 7922 SL53E19600 VALVE LYC O360 O360A4A 41514 EA THERMO BYPASS DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 L1256836A TO COMPLY WITH SB 518C. A NEW THERMOSTATIC BYPASS VALVE WAS INSTALLED. DURING RUN-UP TEST, THE NEW VALVE FAILED TO CON TROL OIL TEMPERATURE. THE VALVE WAS RETURNED TO VENDOR AND ANOTHER NEW ONE WAS INSTALLED AND FUNCTIONED SATISFACTORY. 3 O E286 1995092200559 19950922 00559 SO 1995 9 22 95ZZZX5107 2 19950830 G 8530 21479 VALVE BBAVIA 7 7AC 2110102 SW CONT C85 C8512 17008 SO NR 3 CYL EXH BROKEN G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 09 82560 2246 7AC1197 23693612 EMERGENCY LANDING MADE AFTER EXHAUST VALVE HEAD SEPARATED. THIS ENGINE HAD 732 HRS SINCE 'TOP' OVERHAUL AND 2,246 HOURS SINCE NEW. THIS IS THE 446-HOUR PAST MANUFACTURER'S RECOMMENDED TIME. 1 H 7 1 3O 3 O A759 E233 1995092200563 19950922 00563 EA 1995 9 22 95ZZZX5111 2 19950613 G 8530 GASKET CESSNA 172 172 2072402 CE LYC O360 O360A4M 41514 EA NR 1 PUSHROD LEAKING B BJFR K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 6338F 521 17273195 L2944236A ON 100-HOUR ENGINE INSPECTION, NR 1 CYLINDER WAS FOUND TO HAVE A LEAKING PUSHROD GASKET. UPON REMOVING ROCKER COVER TO REPLACE PUSHROD GASKET, THE SHROUD TUBE SPRING WAS FOUND BROKEN. UPON RESEARCH, FOUND THIS ENGINE WAS NOT EFFECTED BY L YCOMING SB 519, DUE TO ENGINE OVERHAUL DATE. 1 H 7 1 3O 3 O NT 3A12 E286 1995092200568 19950922 00568 EA 1995 9 22 95ZZZX5116 2 19950801 G 7414 BEARING PIPER PA25 PA25235 7102504 SO LYC O540 O540G1A5 41532 EA MAG DRIVE FAILED D K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 13 8566L 520 254990 MAG DROP 400 RPM, BUT SMOOTH. FOUND MAGNETO DRIVE BEARING FAILURE, RETARDING TIMING. BALLS OF BEARING COMING OUT OF BE ARING CAGE AND EATING UP THE REAR OF CASE AND THEN AFTER MAKING SPACE AVAILABLE, FELL INTO THE ENGINE TIMING GEARS. 1 L 7 1 3O 3 O 2A10 E295 1995092200579 19950922 00579 EA 1995 9 22 95ZZZX5127 2 19950816 G 8530 PIPE GULSTM AA1 AA1A 0630710 SO LYC O235 O235L2C 41505 EA NR 3 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 23 10FA AA1A0337 DURING ANNUAL INSPECTION, FOUND FUEL STAINS AT NR 3 CYLINDER. REMOVED NR 3 CYLINDER INTAKE PIPE AND FOUND PIPE FLANGE C RACKED ONE-THIRD AROUND TOP. THIS MAY BE CRACKED BY IMPROPER SEAT OR AGE. NEW PIPE INSTALLED THAT HAD A THICKER FLANGE . TOTAL TIME, 1,806.6 HOURS. 1 L 7 1 3O 3 O A11EA E223 1995092200589 19950922 00589 SO 1995 9 22 95ZZZX5137 2 19950831 G 8530 6291171 ROTOR CONT O520 IO520* 17032 SO EXHAUST VALVE DEFECTIVE B YCTR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 11 EXHAUST VALVE ROTOR CAP WILL NOT ROTATE. THIS VALVE ROTOR WAS OUT OF A CYLINDER VALVE ASSEMBLY. 3 O E5CE 1995092200590 19950922 00590 SO 1995 9 22 95ZZZX5138 2 19950820 G 7414 6220 MAGNETO SLICK CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE BURNED D K NONE M OVER TEMP NR NOT REPORTED 1 SW 15 37AA 348 91030039 21062989 269610R MAGNETO LOOKED LIKE NEW FROM OUTSIDE. WHEN REMOVED ALL COMPONENTS INSIDE WERE BURNED UP. NO ROTOR AND ONLY 3 TOWERS OF DISTRIBUTOR WERE LEFT. MAGNETO WAS BURNED UP VERY FAST AND VERY HOT. DESTROYED HALF OF THE HARNESS CONNECTION (PLATE) . 1 H 7 1 3O 3 O 3A21 E8CE 1995092900353 19950929 00353 GL 1995 9 29 95ZZZX5213 2 19950808 G 7250 A6871505 BEARING BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL TURB NR 5 MAKING METAL B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 105NC 95 790 BEARING WAS PURCHASED AS PMA PART FROM SUPERIOR TURBINE. AN INFORMATION LETTER FROM SUPERIOR DATED MAY 1, 1995, RECOMME NDED INSPECTION OF BEARING AND FILTER FOR METAL FLAKES. THIRTEEN PIECES FOUND IN FILTER, ONE WAS 'TRIANGULAR 2 X 4MM', SINCE TWO SB HAVE BEEN ISSUED FROM SUPERIOR, ONE FOR NR 5 AND ONE FOR NR 8 BEARINGS. 1 G 7 2 3U 3 U NC H3EU E4CE 1995092900361 19950929 00361 SO 1995 9 29 95ZZZX5221 2 19950905 G 8530 653426A4 CYLINDER CESSNA 175 175A 2072504 CE CONT O300 GO300C 17022 SO NR 4 GUIDE WORN D K NONE O OTHER IN INSP/MAINT 1 NM 08 6821E 84 56321 14017 VALVE GUIDE WORN EXCESSIVELY. WOULD NOT PASS COMPRESSION CHECK. OWNER STATED HE WAS NOT USING AUTO FUEL. VALVE GUIDE WAS REPLACED. 1 H 7 1 3O 3 O 3A17 E298 1995092900365 19950929 00365 EA 1995 9 29 95ZZZX5225 2 19950801 G 8540 BOLT LYC O540 IO540K1G5 41532 EA CRANK GEAR NOT MARKED B H5LR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 05 L1640348P ORDER NEW CRANKSHAFT AND GEAR/CAMSHAFT ATTACHING BOLT. BOLT INSPECTED AND NO HEAD ID MARKINGS IAW AD 91-14-22 TITLED TO PREVENT LOOSENING OR FAILURE AT CRANKSHAFT GEAR RETAINING BOLT. 3 O 1E4 1995092900367 19950929 00367 SO 1995 9 29 95ZZZX5227 2 19950824 G 8520 CRANKCASE CESSNA 340 340A 2076405 CE CONT O520 TSIO520NB 17040 SO NR 4 CYL PAD CRACKED B NT2R K NONE K FLUID LOSS IN INSP/MAINT 1 CE 07 340P 803 340A0507 276960R FOUND CRANKCASE CRACKED AT NR 4 CYLINDER PAD. CRACK IS CLEAR THROUGH CYLINDER PAD BOSS AND PROTRUDES DOWNWARDS ABOUT 5 INCHES TOWARD THE OIL FILLER MOUNTING HOLE. LEAKS OIL. ENGINE REPLACED. 1 L 7 2 3O 3 O 3A25 E8CE 1995092900370 19950929 00370 SO 1995 9 29 95ZZZX5230 2 19950828 G 7414 4370 MAGNETO SLICK BBAVIA 7 7KCAB 21101P3 CE CONT O360 IO360E 17025 SO ENGINE FAILED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 01 57678 94010167 41774 L512755A ENGINE INTERMITTENTLY RUNNING ROUGH. MAGNETOS BOTH HAD 1,786 HOURS SINCE INSTALLATION. SABOTAGE PAINT APPLIED BY MANUF ACTURER WAS NOT DISTURBED INDICATING NO 500-HOUR INSPECTIONS HAD BEEN PERFORMED. INSPECTION SHOWED TRACES OF 'CROSS-FIR ING' IN DISTRIBUTOR AREAS OF BOTH MAGNETOS. SUBMITTER RECOMMENDS INSPECTIONS WHEN DUE WILL FIND SMALL PROBLEMS PREVENTI NG PREMATURE REPLACEMENT. 1 H 7 1 3O 3 O A759 E1CE 1995092900374 19950929 00374 CE 1995 9 29 95ZZZX5234 2 19950906 G 8530 646678 GUIDE SEAL MOONEY M20 M20K 5870220 SW CONT O360 TSIO360MB 17025 CE NR 5-6 CYLS DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 CE 03 52RJ 6 251070 317071 AFTER COMPLAINCE WITH TELEDYNE CONTINENTAL SB CSB-95-4 REGARDING IMPROPERLY INSTALLED INTAKE VALVE GUIDE SEALS, FOUND 2 OF 6 DEFECTIVE SEALS ON ENGINE NOTED. TWO FWD CYLINDERS NR 5 AND NR 6 HAD BROKEN SEALS. REMOVED AND REPLACED ALL INTAK E VALVE GUIDE SEALS ON THIS ENGINE IAW TELEDYNE CONTINENTAL SB CSB-95-4. SUBMITTER RECOMMENDS ALL SEALS IN QUESTION INS PECTED IAW THIS SB, BE REPLACED FOR ASSURANCE. 1 L 7 1 3O 3 O 2A3 E9CE 1995092900375 19950929 00375 EA 1995 9 29 95ZZZX5235 2 19950811 G 7261 3004116 SPACER COVER PWA PT6 PT6* 52043 EA SCAVENGE PUMP SCORED B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 PWC95M666 THE SCAVENGE PUMP SPACER COVER WAS SENT TO PW & C FOR OVERHAUL. PART WAS RETURNED TO D.T.S. AFTER THEY OVERHAULED AND I NSPECTED PART. THE RETURNED PART HAS DEEP SCORING ON THE GEAR SURFACE AREA AND HAS NOT BEEN RECOATED PROPERLY. PART WI LL BE RETURNED TO OVERHAUL FACILITY FOR REPAIR. 3 T E2NE 1995092900382 19950929 00382 EU 1995 9 29 95ZZZX5243 2 19950707 G 7250 9514M71P04 SHAFT CFMINT CFM56 CFM563B2 13802 EU HPT ROTOR FAILED B R3AR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 05 15859 D21448 725345 ENGINE WAS REMOVED FROM SERVICE DUE TO VIBRATION. DISASSEMBLY OF THE ENGINE REVEALED A SECTION OF THE HPT REAR SHAFT HA D LIBERATED CAUSING EXTENSIVE DAMAGE WITHIN THE HPT AND LPT MAJOR MODULES. FAILURE INVESTIGATION IS BEING CONDUCTED. 4 F E21EU 1995092900385 19950929 00385 NE 1995 9 29 95ZZZX5246 2 19950817 G 7323 230305204 CONTROLLER CNDAIR CL600 CL6001A11 1900302 EA LYC ALF502 ALF502L 41580 NE ENGINE OVERSPEED FAILED B JO1R K NONE O OTHER IN INSP/MAINT 1 EA 25 91UC 1445 3009 1051 LF03101 WHILE PERFORMING AN OVERSPEED SHUT-DOWN CHECK ON RIGHT ENGINE, THE ENGINE FAILED TO SHUT DOWN WHEN OVERSPEED TEST SWITCH WAS THROWN. THE PROBLEM WAS TRACED TO THE OVERSPEED CONTROLLER. THE UNIT WAS REPLACED AND OPS CHECKED NORMAL. 2 L 7 2 4F 4 F RT A21EA E6NE 1995092900386 19950929 00386 NE 1995 9 29 95ZZZX5247 2 19950817 G 7261 230328701 OIL LINE CNDAIR CL600 CL6001A11 1900302 EA LYC ALF502 ALF502L 41580 NE LT ENG PYLON CHAFED B JO1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 25 90UC 4397 1023 LF03059 DURING A 100-HOUR PYLON INSPECTION, THE OIL FILTER TO NR 12 STRUT OIL LINE ASSEMBLY WAS FOUND CHAFING AGAINST THE 4 BOLT HEADS THAT SECURE THE APRON FRAME SUPPORT TO THE ENGINE. ONE CHAFE HAD BEGUN TO SEEP. THE OIL LINE IS FLATTENED OUT I N THIS AREA TO PROVIDE CLEARANCE. THE NEW LINE, WHEN INSTALLED, FIT WITH PLENTY OF CLEARANCE. 2 L 7 2 4F 4 F RT A21EA E6NE 1995092900402 19950929 00402 NE 1995 9 29 HEEA955717 2 19950912 G 7200 0292005220 ENGINE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE POWER SECT MAKING METAL E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6095S 908 2777 ENGINE MAKING METAL. 1 G 7 1 3U 3 U H9EU E19EU 1995092900406 19950929 00406 NE 1995 9 29 HEEA955721 2 19950912 G 7210 3024780 GEARBOX BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE COMBINING GR BOX MAKING METAL E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 2148K 11909 36001 COMBINING GEARBOX HAS METAL IN OIL. 1 G 7 2 4U 4 U H4SW E22EA 1995092900407 19950929 00407 NE 1995 9 29 HEEA955722 2 19950912 G 7200 3017600 ENGINE BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE POWER SECT FAILED E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 102PH 10531 30899 ENGINE FAILURE. 1 G 7 1 4U 4 U H4SW E22EA 1995092900413 19950929 00413 NE 1995 9 29 HEEA955728 2 19950912 G 7320 6038T62P24 HMU BELL 214 214ST 1182106 SW GE CT7TS CT72A 30030 NE ENGINE MALFUNCTION E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 3897N 28106 NO FUEL DURING START. 2 G 7 2 4U 4 U H10SW E8NE 1995092900428 19950929 00428 NE 1995 9 29 HEEA955743 2 19950913 G 7240 414302017 HOUSING BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101650B1 41560 NE GP SHROUD MIS MFG E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 GP SHROUD PILOT WAS MACHINED BELOW SPECS. 1 G 7 2 3U 3 U H13EU E5NE 1995092900496 19950929 00496 GL 1995 9 29 HEEA955801 2 19950921 G 7321 252473830 FUEL CONTROL BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL ENGINE LEAKS E HEEA K NONE K FLUID LOSS NR NOT REPORTED 1 SW 03 2249Z 9574 45753 FUEL LEAKS FROM BY-PASS VALVE RETENTION PLATE. REPLACED WITH SERVICEABLE FUEL CONTROL. 1 G 7 1 3U 3 U H2SW E1GL 1995092900497 19950929 00497 GL 1995 9 29 HEEA955802 2 19950921 G 7323 252467710 GOVERNOR BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL ENGINE DEFECTIVE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 10778 10801 45391 GOVERNOR LEVER STIFF. REPLACED WITH SERVICEABLE GOVERNOR. 1 G 7 1 3U 3 U H2SW E1GL 1995092900503 19950929 00503 NE 1995 9 29 95ZZZX5259 2 19950121 G 7250 430144801 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 117MA 109 0791973 7107 LE45155E NR 3 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900504 19950929 00504 NE 1995 9 29 95ZZZX5260 2 19950121 G 7230 430135702 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 117MA 109 019 7107 LE45155E NR 2 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNITS(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900505 19950929 00505 NE 1995 9 29 95ZZZX5261 2 19950121 G 7261 430101501 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE GOV/FCU/STARTER LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 117MA 109 7107 LE45155E ACCESSORY DRIVE SEALS LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900506 19950929 00506 NE 1995 9 29 95ZZZX5262 2 19950121 G 7261 430101201 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE ALTERNATOR LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 117MA 109 7107 LE45155E ALTERNATOR FORWARD SEAL LEAKING BEYOND SERVICEABLE LIMITS REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900507 19950929 00507 NE 1995 9 29 95ZZZX5263 2 19950121 G 7261 230307203 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE CSD LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 117MA 109 7107 LE45155E CSD LIP SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900508 19950929 00508 NE 1995 9 29 95ZZZX5264 2 19950121 G 7250 410106701 SEAL RING BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE FIRST TURBINE WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 117MA 274 7107 LE45155E FIRST TURBINE SHROUD SEAL RING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900513 19950929 00513 NE 1995 9 29 95ZZZX5269 2 19950518 G 7250 410106701 SEAL RING BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE 1ST TURB SHROUD WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 420MB 677 7077 LE45382E FIRST TURBINE SHROUD SEAL RING WORN BEYOND SERVICEABLE LIMITS. 1 G 7 2 3U 3 U H13EU E5NE 1995092900514 19950929 00514 NE 1995 9 29 95ZZZX5270 2 19950519 G 7250 430144801 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 424MB 62 0492445 7082 LE45078 NR 3 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNITS(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900515 19950929 00515 NE 1995 9 29 95ZZZX5271 2 19950519 G 7230 430135703 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 424MB 62 320 7082 LE45078 NR 2 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900521 19950929 00521 NE 1995 9 29 95ZZZX5277 2 19950420 G 7261 230307203 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE CSD LIP LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 527SF 350 7111 LE45306E CSD DRIVE LIP SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900522 19950929 00522 NE 1995 9 29 95ZZZX5278 2 19950420 G 7261 430101201 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE ALTERNATOR FWD LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 527SF 371 7111 LE45306E ALTERNATOR FORWARD SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WTIH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900535 19950929 00535 WP 1995 9 29 95ZZZX5291 2 19950303 G 7310 39423041 SOLENOID VALVE MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP FUEL SOV FAILED B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 454MA 6589 1535SA P36357C SOLENOID VALVE NO RESPONSE WHEN POWERED. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 H 7 2 3T 4 T RT A10SW E4WE 1995092900540 19950929 00540 NE 1995 9 29 95ZZZX5296 2 19950328 G 7250 410106701 SEAL RING BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE FIRST TURBINE WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 5194C 304 7169 LE45522E FIRST TURBINE SHROUD SEAL RING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNIT(S CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995092900544 19950929 00544 NE 1995 9 29 95ZZZX5300 2 19950509 G 7250 410106701 SEAL RING BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE 1ST TURB SHROUD WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 528SF 609 7104 LE45295E FIRST TURBINE SHROUD SEAL RING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995092900548 19950929 00548 NE 1995 9 29 95ZZZX5304 2 19950317 G 7250 430144801 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 7060G 290 05920411 7173 LE45988 NR 3 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995092900551 19950929 00551 NE 1995 9 29 95ZZZX5307 2 19950425 G 7230 430135703 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 71703 561 751 7227 LE45755E NR 2 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995092900552 19950929 00552 NE 1995 9 29 95ZZZX5308 2 19950425 G 7250 430144801 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 71703 561 84940454 7227 LE45755E NR 3 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995092900554 19950929 00554 NE 1995 9 29 95ZZZX5310 2 19950324 G 7230 430135703 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 911VU 591 723 7141 LE45540E NR 2 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995092900555 19950929 00555 NE 1995 9 29 95ZZZX5311 2 19950324 G 7250 430144801 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 911VU 591 35783 7141 LE45540E NR 3 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995092900558 19950929 00558 NE 1995 9 29 95ZZZX5314 2 19950828 G 7250 569551 GUIDE VANE RKWELL NA265 NA26560 7630106 CE PWA JT12 JT12A8 52042 NE 1ST STAGE BURNED B L A K NONE O OTHER IN INSP/MAINT 1 SW 99 8NR 1227 306141 P638049NB ENGINE RECEIVED FOR CORR & HOT SECT INSP PER SB 1508. ENG OPERATED TO 1,227 HRS TIME SINCE LAST HOT SECT INSP. ENG SUF FERED LOSS OF 3 EA NOZZLE GUIDE VANES COMPLETELY BURNED IN HALF ALLOWING INNER SHROUD HALVES TO ENTER GAS PATH & DAMAGE TURB. FAILURE RESULTED IN DOMESTIC OBJECT DAMAGE OF ALL 92 EA 1ST STAGE & 46 EA 2ND STAGE TURB BLADES. P & W SB 1508, REV NR 16, OUTLINES RECOMMENDED 1,500 HR HOT SECT INSP INTERVAL. FAILURE IS PARTICULAR TO JT12A-8 ENG PARTICULAR TO NA2 6540 (DASH 8 CONFIGURED) & ALL 60 MDL ACFT. SUBMITTER STATES HAVE EXPERIENCED 30-40 ENG OVER LAST 6 YRS THAT SUFFERED N OZZLE GUIDE VANE FAILURES & SUBSEQUENT TURB BLADE IMPACT DAMAGE FROM NOZZLE GUIDE VANE MATL RELEASED INTO TURB GAS PATH. 2 L 7 2 4J 4 J RT A2WE 1E9 1995100600010 19951006 00010 NE 1995 10 6 95ZZZX5366 2 19950509 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE LT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 528SF 1807 1089 SC04224 7104 LE45295E FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 15, MINUS 0.009 INCH. REPLACED WITH NEW UNITS(S) CORRECTED P ROBLEM. PART TOTAL CYCLES, 4296.4. 1 G 7 2 3U 3 U H13EU E5NE 1995100600011 19951006 00011 NE 1995 10 6 95ZZZX5367 2 19950712 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE LT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 428MB 1597 508 SC20597 7088 LE45154 FAILED SB LT5101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 4, MINUS 0.011 INCH. REPLACED WITH NEW UNIT(S) CORRECTED PR OBLEM. PART TOTAL CYCLES 3925.7. 1 G 7 2 3U 3 U H13EU E5NE 1995100600012 19951006 00012 NE 1995 10 6 95ZZZX5368 2 19950621 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE RT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 420MB 786 218 SC13879 7077 LE45244E FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 5, MINUS 0.017 INCH, NR 8, MINUS 0.011 INCH, NR 9, MINUS 0.00 9 INCH, NR 12, MINUS 0.010 INCH. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. PART TOTAL CYCLES, 2920.6. 1 G 7 2 3U 3 U H13EU E5NE 1995100600016 19951006 00016 NE 1995 10 6 95ZZZX5372 2 19950829 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE RT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 5188B 709 SC47941 7163 LE45757E FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 1, PLUS 0.010 INCH, NR 26, PLUS 0.012 INCH. REPLACED WITH US ED UNIT, CORRECTED PROBLEM. PART TOTAL CYCLES, 1136.9 1 G 7 2 3U 3 U H13EU E5NE10 1995100600018 19951006 00018 NE 1995 10 6 95ZZZX5374 2 19950420 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE LT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 527SF 1457 371 SC12211 7111 LE45306E FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 15, PLUS 0.013 INCH. REPLACED WITH NEW UNIT(S) CORRECTED PRO BLEM. PART TOTAL CYCLES, 3477.8. 1 G 7 2 3U 3 U H13EU E5NE 1995100600019 19951006 00019 NE 1995 10 6 95ZZZX5375 2 19950425 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE RT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 71703 561 SC12095 7227 LE45755E FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 11, PLUS 0.014 INCH. PART TOTAL CYCLES 1304.9. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600020 19951006 00020 NE 1995 10 6 95ZZZX5376 2 19950228 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE RT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 420MB 1752 880 SC17237 7077 LE45282 FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 7, PLUS 0.011 INCH, NR 12, PLUS 0.018 INCH, NR 17, PLUS 0.010 INCH, NR 18, PLUS 0.010 INCH. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. PART TOTAL CYCLES, 5811.3. 1 G 7 2 3U 3 U H13EU E5NE 1995100600021 19951006 00021 NE 1995 10 6 95ZZZX5377 2 19950518 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE LT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 420MB 2111 938 SC12532 7077 LE45382E FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 5, PLUS 0.012 INCH, NR 26, PLUS 0.009 INCH. REPLACED WITH NE W UNIT(S) CORRECTED PROBLEM. PART TOTAL CYCLES, 5788.1. 1 G 7 2 3U 3 U H13EU E5NE 1995100600026 19951006 00026 NE 1995 10 6 95ZZZX5382 2 19950622 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE LT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 7059N 1273 SC04098 7154 LE45987E FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 22, MINUS 0.018 INCH, NR 20, MINUS 0.010 INCH. PART TOTAL CY CLES, 2747.2. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600027 19951006 00027 NE 1995 10 6 95ZZZX5383 2 19950717 G 7250 414129001 ROTOR ASSY BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE RT ENG TURB BLADE SHIFT B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 7059N 2356 SC12802 7154 LE45754 FAILED SB LT101-72-10-0153. EXCESSIVE IBPT BLADE SHIFT NR 12, PLUS 0.012 INCH. REPLACED WITH REPAIRED UNIT, CORRECTED PROBLEM. PART TOTAL CYCLES, 5344.3. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600310 19951006 00310 NE 1995 10 6 95ZZZX5480 2 19950121 G 7250 411100720 SHROUD BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE GP BLADE TIP RUB B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 117MA 109 1A29 7107 LE45155E GAS PRODUCER SHROUD HAS EXCESSIVE GP BLADE TIP RUB. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995100600320 19951006 00320 NE 1995 10 6 95ZZZX5490 2 19950509 G 7230 430135703 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 528SF 354 386 7104 LE45295E NR 2 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995100600325 19951006 00325 GL 1995 10 6 95ZZZX5495 2 19950512 G 7250 6898764 SEAL BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL OIL BELLOWS LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 911BH 110 685 CAT37299 OIL BELLOW SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U NC H3EU E4CE 1995100600326 19951006 00326 GL 1995 10 6 95ZZZX5496 2 19950310 G 7250 A23007202 BEARING BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL NR 6 MAIN SPALLED B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 911BH 53 123 685 CAT24854 NR 6 MAIN BEARING SPALLING. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U NC H3EU E4CE 1995100600327 19951006 00327 NE 1995 10 6 95ZZZX5497 2 19950324 G 7250 414144001 BEARING BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE ENGINE PITTED B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 911VU 831 K575 7141 LE45540E BEARING OUTER RACE HAS EXCESSIVE PITTING. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600329 19951006 00329 NE 1995 10 6 95ZZZX5499 2 19950705 G 7250 0292507660 BEARING SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE SCAVENGE LINE LEAKS B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 94LG 262 1 541 2728 9334 REAR BEARING LEAKS AT THE SCAVENGE LINE BOSS. REPLACED BRONZE CRUSH SEAL TWICE WITH NO SUCCESS. IT WAS FOUND THE REAR BEARING HAD A SMALL NICK WHICH PREVENTED THE CRUSH SEAL FROM SEATING PROPERLY. SUSPECT SOMEONE NICKED THE REAR BEARING WHILE CLEANING COKE FROM MODULE 4. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 1 3U 3 U H9EU E19EU 1995100600507 19951006 00507 EA 1995 10 6 95ZZZX5525 2 19950908 G 8530 71973 GASKET BEECH 60 B60 1153605 CE LYC O541 TIO541E1C4 41536 EA INTAKE FAILED B FC6R K NONE O OTHER IN INSP/MAINT 1 NM 11 234RD 10 P566 INTAKE TO CYLINDER GASKET FAILED NEAR BOLT HOLE AFTER 10 HOURS FLIGHT. SURFACE PLATE TEST REVEALED NO ABNORMALITIES IN SEALING SURFACE. GASKET SHOWED DEFINITE IMPRESSION FROM INTAKE TUBE - SEATED 360 DEGREES. GASKET SUPPLIER SUGGESTS A S OFT SPOT ON THE GASKET WHICH FAILED. 1 L 7 2 3O 3 O A12CE E10EA 1995100600510 19951006 00510 EA 1995 10 6 95ZZZX5528 2 19950912 G 8530 LW12416 CYLINDER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA HEAD ATTACH BARREL CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 13 55404 718 17275175 RL1533239A CYLINDER BARREL CRACKED AT BASE OF THE 4TH COOLING FIN AWAY FROM CYLINDER HEAD ATTACH AREA. THIS IS SECOND CYLINDER TO FAIL IN THIS MANNER ON THIS SAME ENGINE SINCE OVERHAUL WITH NEW LYCOMING CYLINDERS. 1 H 7 1 3O 3 O NT 3A12 E274 1995100600515 19951006 00515 WP 1995 10 6 95ZZZX5533 2 19950825 G 7250 30747553 BLADE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP NR 3 LPT SHROUD MISSING B GMCR K NONE O OTHER IN INSP/MAINT 1 GL 23 5112 1526 6507012 102125 ONE BLADE TIP SHROUD FOUND MISSING DURING POST-FLIGHT ON NR 3 LOW PRESSURE TURBINE. 2 L 7 2 4F 4 F A9NM E6WE 1995100600520 19951006 00520 NE 1995 10 6 95ZZZX5538 2 19950822 G 7250 0292377110 SWIRL PLATE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE RT ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 25 399KK 424 4739B 760421 15059 DURING 150-HOUR ENGINE INSPECTION, BORESCOPING RT ENGINE REVEALED CRACK ON SWIRL PLATE AND PIECES MISSING. DAMAGE BEYON D LIMITS. REMOVED ENGINE, INSTALLED LOANER ENGINE. INSPECTION AT TEAR DOWN REVEALED NO OTHER DAMAGE. NEW TYPE SWIRL P LATE TO BE INSTALLED AT MANUFACTURER OF ENGINE. 1 G 7 2 3U 3 U NC H1NE E19EU 1995100600521 19951006 00521 GL 1995 10 6 95ZZZX5539 2 19950814 G 7321 23056935 FUEL CONTROL BENDIX HILLER UH12 UH12E 4360122 WP ALLSN 250C 250C20B 03013 GL ENGINE MALFUNCTION B PN5R K NONE O OTHER IN INSP/MAINT 1 NM 03 603RA 170 335937 1527 831594 FUEL CONTROL WILL NOT RESPOND PROPERLY TO ADJUSTMENTS FOR START TEMPS. START TEMPS GO EITHER HOT OR COLD IN AN ERRATIC MANNER. RETURNED CONTROL FOR BENCH CHECK. 1 G 7 1 3O 3 U 4H11 E4CE 1995100600534 19951006 00534 NE 1995 10 6 95ZZZX5551 2 19950713 G 7260 430124102 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE FCU GOV START LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 10UM 116 7231 LE45807E ACCESSORY SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600535 19951006 00535 NE 1995 10 6 95ZZZX5552 2 19950121 G 7230 411100212 NUT BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE COMPRESSOR WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 117MA 109 7107 LE45155E NUT WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1995100600544 19951006 00544 NE 1995 10 6 95ZZZX5561 2 19950312 G 7250 411105064 ROTARY ASSY BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE GAS PRODUCER DISC DAMAGE B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 424MB 814 4395 7082 LE45313 DISC HAS EXCESSIVE DAMAGE (WARPED CAUSING LOOSE BLADES) RESULTING FROM LAB SEAL ELEMENT RUBBING INTO DISC KNIFE EDGES. T HIS LAB SEAL HAS FEWER WELD POINTS AS COMPARED TO THE MORE RECENT SEAL DESIGN. THE LAB SEAL WAS INSTALLED NEW AS A PART OF SB 126 UPGRADE. HERE ARE THE VIBRATION RESULTS OF THE ENGINE TEST CELL RUN AT THE TIME THE ROTOR WAS INSTALLED NEW. DYNR = 0.16, GB-R = 0.21, AD-A = 0.26, PT-R = 0.15. PART TOTAL CYCLES, 1299.4. 1 G 7 2 3U 3 U H13EU E5NE 1995100600556 19951006 00556 NE 1995 10 6 95ZZZX5573 2 19950622 G 7230 430135703 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 7059N 250 781 7154 LE45987E NR 2 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600557 19951006 00557 NE 1995 10 6 95ZZZX5574 2 19950622 G 7250 410106701 SEAL RING BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE 1ST TURB SHROUD WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 7059N 250 7154 LE45987E SEAL RING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600559 19951006 00559 NE 1995 10 6 95ZZZX5576 2 19950516 G 7250 430144801 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 7060G 544 05920414 7173 LE45583 NR 3 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT FROM T05K KIT CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600560 19951006 00560 NE 1995 10 6 95ZZZX5577 2 19950516 G 7230 430135703 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 7060G 544 144 7173 LE45583 NR 2 BEARING SEAL WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995100600561 19951006 00561 NE 1995 10 6 95ZZZX5578 2 19950516 G 7250 410106701 SEAL RING BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE 1ST TURB SHROUD WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 7060G 544 7173 LE45583 SEAL RING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE10 1995101300137 19951013 00137 GL 1995 10 13 HEEA955827 2 19951004 G 7230 23008090 GEARSHAFT 23051643 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL SPUR ADAPTER STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 31219 663 CAC90152 760230 CAE890432S ENGINE REMOVED DUE TO CRACKED SCROLL. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIMITS ON SPUR ADAPTER GEARSHAFT FORWARD & AFT SPLINES. NEW PART INSTALLED. 1 G 7 2 3U 3 U H1NE E1GL 1995101300138 19951013 00138 GL 1995 10 13 HEEA955828 2 19951004 G 7230 23056634 GEARSHAFT 23051643 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL SPUR ADAPTER STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 911MJ 810 CAC90484 760231 CAE890499S ENGINE REMOVED DUE TO CRACKED SCROLL. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIMITS ON SPUR ADAPTER GEARSHAFT FWD & AFT SPLINES. NEW PART INSTALLED. 1 G 7 2 3U 3 U H1NE E1GL 1995101300139 19951013 00139 GL 1995 10 13 HEEA955829 2 19951004 G 7230 23008090 GEARSHAFT 23051643 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL SPUR ADAPTER STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1545K 840 CAC90527 760047 CAE890639S ENGINE REMOVED DUE TO 1750 HOUR INSPECTION. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIMITS ON SPUR ADAPTER GEARSHAFT AFT SPLINES. NEW PART INSTALLED. 1 G 7 2 3U 3 U H1NE E1GL 1995101300175 19951013 00175 SO 1995 10 13 95ZZZX5598 2 19950816 G 8520 642360 CRANKCASE CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO NR 5 CYLINDER CRACKED D P K NONE O OTHER IN INSP/MAINT 1 NM 09 6994B 3034 461 21062868 512941 CRACK IN THE CRANKCASE ON THE FORWARD LOWER PORTION OF NR 5 CYLINDER, RUNNING THROUGH THE LOWER FORWARD CYLINDER MOUNTIN G STUD. 1 H 7 1 3O 3 O 3A21 E8CE 1995101300180 19951013 00180 EA 1995 10 13 95ZZZX5603 2 19950906 G 7414 ES10682014 DISTRIBUTOR GEAR LW385124115 CESSNA 172 172 2072402 CE LYC O320 O320H2AD 41508 EA DUAL MAG RT TEETH FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 03 6583D 157 5030663 17272876 L29976T FOUND RIGHT DISTRIBUTOR GEAR WITH 21 OF 53 TEETH MISSING. HELICAL SPRING MISSING FROM NR 1 TOWER (RIGHT SIDE) OF THE DI STRIBUTOR BLOCK. EVIDENCE OF HEAVY ARCING INSIDE NR 1 TOWER BECAUSE OF MISSING SPRING. THIS DUAL MAGNETO IS AN ELECTRO SYSTEM, INC., OVERHAUL. 1 H 7 1 3O 3 O NT 3A12 E274 1995101300182 19951013 00182 EA 1995 10 13 95ZZZX5605 2 19950925 G 8530 LW12039 VALVE BEECH 23 A2324 1151226 CE LYC O360 IO360A2B 41514 EA NR 4 CYL EXH DEFECTIVE D P K NONE O OTHER IN INSP/MAINT 1 GL 09 232W 825 MA7 L211951A DURING ANNUAL INSPECTION, FOUND LOW COMPRESSION IN NR 4 CYLINDER, INSPECTED INSIDE CYLINDER WITH BORESCOPE AND FOUND EXH AUST VALVE WITH PIECES MISSING. VALVE SEAT WAS UNDAMAGED, NO OTHER DEFECTS IN CYLINDER WERE FOUND. 1 L 7 1 3O 3 O A1CE 1E10 1995101300191 19951013 00191 EA 1995 10 13 95ZZZX5614 2 19950911 G 7261 3201104 JUNCTION BOX SKRSKY S76 S76B 8143007 NE PWA PT6 PT6B36 52043 EA NR 2 CHIP DET DEFECTIVE D K NONE N FALSE WARNING NR NOT REPORTED 1 EA 17 22CP 760425 PCE36041 NR 2 ENGINE 'CHIP' LIGHT ILLUMINATED, WOULD NOT CLEAR BY CYCLING NR 2 CHIP CIRCUIT BREAKER. INSPECTED BOTH AGB AND RGB CHIP PLUGS FOR METAL PARTICLES - BOTH WERE CLEAN (NO METAL PARTICLES ATTACHED). REINSTALLED CHIP PLUGS, LIGHT STILL ILL UMINATED. REMOVED AND REPLACED POWER MODULE JUNCTION BOX (ZAPPER BOX). SYSTEM FUNCTIONED NORMALLY. 1 G 7 2 4U 4 U H1NE E4EA 1995101300192 19951013 00192 NE 1995 10 13 95ZZZX5615 2 19950830 G 7230 3032145 IMPELLER VANE CESSNA 501 501 2076603 CE PWA JT15 JT15D1 52060 NE ENGINE CRACKED B OG5R O OTHER R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 GL 21 83ND 4733 1285 5010178 77202 DURING TAKEOFF ROLL, ENGINE MADE WHAT PILOT DESCRIBED AS COMPRESSOR STALLS. ENGINE DISASSEMBLED BY P & W. INVESTIGATIO N FOUND A LARGE PORTION OF ONE VANE (APPROXIMATELY 1.75 SQUARE INCH) WAS FRACTURED FROM THE INDUCER AREA OF THE IMPELLER . NO OTHER EVIDENCE OF FOD DAMAGE FOUND ON OTHER BLADES. ENGINE SUSTAINED HEAVY DAMAGE TO GAS GENERATOR, HIGH TURBINE, SEGMENTS, LOW TURBINE, ETC. (ENGINE TO BE OVERHAULED). 1 L 7 2 4F 4 F A27CE E1NE 1995101300193 19951013 00193 WP 1995 10 13 95ZZZX5616 2 19950901 G 7210 8968051 GEAR MTSBSI MU2 MU2B20 5780407 SW GARRTT TPE331 TPE3311 01514 WP FWD GEARBOX FAILED G O OTHER O OTHER CL CLIMB 1 SW 15 500PS 5747 224 P92297 ENGINE FAILED AFTER TAKEOFF. TEAR DOWN REVEALED SPUR GEAR IN FORWARD GEARBOX HAD FAILED CAUSING SECONDARY DAMAGE TO OTH ER GEARS. GEAR SENT TO ALLIED SIGNAL FOR EVALUATION. 1 H 7 2 3T 3 T A2PC E3WE 1995101300195 19951013 00195 SO 1995 10 13 95ZZZX5618 2 19950831 G 8530 6291171 ROTOR CAP CONT O520 IO520* 17032 SO EXHAUST VALVE DEFECTIVE B YCTR K NONE O OTHER IN INSP/MAINT 1 SW 11 EXHAUST VALVE ROTOR CAP WILL NOT ROTATE. THIS VALVE ROTOR WAS OUT OF CYLINDER VALVE ASSEMBLY. 3 O E5CE 1995101300207 19951013 00207 EA 1995 10 13 95ZZZX5630 2 19950910 G 8530 61247 ROCKER COVER BEECH 77 77 1153007 CE LYC O235 O235L2C 41505 EA ENGINE CYLS RUSTED D K NONE O OTHER IN INSP/MAINT 1 GL 11 6754W 1286 WA99 L2082115 WHILE PERFORMING AN ANNUAL INSPECTION THE ROCKER COVERS WERE FOUND EXTREMELY RUSTY ON THE INSIDE. OWNER ADVISED HE HAD LEFT THE ENGINE HEATER PLUGGED IN ALL WINTER. SUBMITTER SUSPECTS CONDENSATION FORMED ON COVERS DUE TO COOL TEMPS OUTSI DE ENGINE AND THAT COUPLED WITH LACK OF WINTER FLYING KEPT OIL FILM TO A MINIMUM. SUGGEST ENGINE HEATERS ONLY BE USED P RIOR TO A FLIGHT TO WARM ENGINE AND NEVER LEAVE THEM PLUGGED IN FOR EXTENDED TIME. TWENTY-THREE HOURS SINCE LAST 12-MON TH INSPECTION. 1 L 7 1 3O 3 O A30CE E223 1995101300213 19951013 00213 SO 1995 10 13 95ZZZX5636 2 19950908 G 8530 639702 CYLINDER CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO NR 2 CYLINDER ROCKER BROKE D O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 11 19111 6116168Q3 15074176 21346671A A LOSS OF 500 RPM IN-FLIGHT PROMPTED A NORMAL LANDING AT AIRPORT. FURTHER INVESTIGATION REVEALED NR 2 CYLINDER INOPERAT IVE. CLOSER DISASSEMBLY REVEALED THE COMPLETE ROCKER ARM ASSY WAS BROKEN LOOSE. ROCKER ARM BOSSES WERE ALL BROKEN OFF HALF WAY UP THEIR HEIGHT. AD 94-04-05 C/W 235.2 HRS PRIOR AT 6-1-94. 1 H 7 1 3O 3 O 3A19 E252 1995101300216 19951013 00216 SO 1995 10 13 95ZZZX5639 2 19950821 G 8520 641931981 THROUGH-BOLT CONT O470 IO470N 17026 SO ENGINE BROKE B S JZYR K NONE O OTHER IN INSP/MAINT 1 NM 09 NEW THROUGH-BOLT BROKE AFTER TORQUED TO 67 FEET/POUND. BROKE AT O-RING GROOVE IN CENTER OF BOLT. SUBMITTER SUSPECTS PO SSIBLE HYDROGEN EMBRITTLEMENT FROM PLATING. 3 O 3E1 1995101300219 19951013 00219 SO 1995 10 13 95ZZZX5642 2 19950616 G 8530 633821 TUBE CESSNA 319 319 2074402 SO CONT O470 O470* 17026 SO INTAKE DISLOCATED D E A ENGINE SHUTDOWN UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 99 36880 608 457115J DURING WILDLIFE SURVEY, ENGINE BECAME ROUGH AND WAS SHUT DOWN. AIRCRAFT LANDED ON RIVER LEVEE. CARBURETOR TO MANIFOLD TUBE HAD BECOME DISLODGED. REPLACED TUBE, ENGINE FUNCTIONED NORMALLY. THIS AIRCRAFT FUEL SYSTEM IS GRAVITY FLOW AND IS PLACARDED TO TURN ON ELECTRIC FUEL PUMP FOR MANEUVERING. SUSPECT BACKFIRE DUE TO DISRUPTED FUEL FLOW CAUSED TUBE TO BE COME DISLODGED. 1 H 7 1 3O 3 O NC E273 1995101300225 19951013 00225 EA 1995 10 13 95ZZZX5648 2 19950729 G 8530 RING PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA NR 1-3 CYLS BROKEN D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 25 8351W 1600 288116176 L949439A PILOT MADE EMERGENCY LANDING DUE TO POWER LOST. FOUND NR 1, NR 3 BOTTOM SPARK PLUGS OIL FOULED. REMOVED THE CYLINDERS AND FOUND BROKEN COMPRESSION RINGS. TSO NR 1 CYLINDER, 1600 HRS. TSO NR 3 CYLINDER, 777 HRS. 1 L 7 1 3O 3 O 2A13 E274 1995101300228 19951013 00228 NE 1995 10 13 95ZZZX5651 2 19950922 G 8530 366249 CYLINDER PWA R1340 R1340AN1 52016 NE ROCKER HOUSING FAILED H P A K NONE O OTHER IN INSP/MAINT 1 SW 15 SUBMITTER REPORTS THAT ONE OPERATOR OF A PRATT & WHITNEY R-1340 ENGINE HAS HAD AT LEAST 4 CYLINDERS BREAK AT SAME LOCATI ON. HE REPORTS THE EXHAUST ROCKER SHAFT HOUSING AREA OF THE CYLINDERS HAVE EITHER CRACKED OR BROKE IN TWO. TWO RADIAL ENGINE OVERHAUL FACILITIES STATE THAT THEY REJECT AT LEAST 3 PERCENT OF THE CYLINDERS FOR ROCKER FAILURE. THEY FEEL MAI NTENANCE PERSONS IN THE FIELD ARE OVERTIGHTENING THE ROCKER SHAFT NUTS WHEN A SLIGHT SEEPAGE IS DETECTED. THEY ADVISE R ECOMMENDED TORQUE NEVER SHOULD BE EXCEEDED. ONCE A SEEPAGE IS DETECTED, REPLACMENT OF OIL SEALS IS REQUIRED TO STOP THE LEAK. 3 R 5E2 1995101300230 19951013 00230 NE 1995 10 13 95ZZZX5653 2 19950915 G 7261 785543 PRESSURE TUBE PWA JT9 JT9* 52054 NE NR 4 BEARING MISREPAIRED H A K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 27 THREE DIAMETERS OF TUBE ASSY ARE PLASMA COATED. ASSY IN QUESTION WAS RETURNED AS UNREPAIRABLE DUE TO EXCESSIVE PLASMA C OATING THICKNESS. REPAIR CAUSE FOR THE REMOVAL OF EXISTING PLASMA AND RE-APPLICATION. ORIGINAL OR REPAIRED AREAS WERE SHOWING AT LEAST TWICE THE ALLOWABLE THICKNESS. THIS CONDITION COULD CAUSE THE COATING TO BREAK AWAY FROM PARENT METAL AND CAUSE A PROBLEM. 4 F E20EA 1995101300231 19951013 00231 NE 1995 10 13 95ZZZX5654 2 19950922 G 7250 786822A TURBINE DISK PWA JT8 JT8D17R 52049 NE 2ND STAGE FIR TREE FAILURE D A K NONE O OTHER IN INSP/MAINT 1 NE 03 18729 N92357 700823 DURING DEBLADING OF THE SECOND STAGE TURBINE DISK, 3 FIR TREES FELL OFF WHEN THE BLADES WERE REMOVED. OVERHAUL MANUAL P ROCEDURES WERE FOLLOWED AND WERE NOT A CONTRIBUTING CAUSE TO THE DAMAGE. THE CRACKS ON THE FIR TREES APPEAR TO BE OLD D UE TO SOOT DEPOSITS. THE OEM (PRATT & WHITNEY) NOTIFIED ON 9-21-95. GAS TURBINE COMPANY CONTROL ORDER IS 11730E. 4 F E2EA 1995101300361 19951013 00361 GL 1995 10 13 95ZZZX5716 2 19950825 G 7200 23053301 ENGINE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL POWER SECTION FLAME-OUT D A A UNSCHED LANDING X R ENGINE FLAMEOUT PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 09 34698 355 4324 296031 HELICOPTER EXPERIENCED 3 ENGINE FLAME-OUTS WITHIN APPROXIMATELY 5 MINUTES. THE AUTO RE-IGNITION STARTED THE ENGINE IN-F LIGHT EACH TIME. NORMAL LANDING WAS ACCOMPLISHED. A COMPLETE INSPECTION OF THE FUEL SYSTEMS, CONTROL SYSTEMS, FUEL FIL TERS, AIR FILTERS, FUEL NOZZLE, FUEL CONTROL, GOVERNOR, FUEL PUMPS, FUEL VENTS. GROUND RAN AND TEST FLOWN FOR 4 HOURS W ITH NO MALFUNCTIONS. COULD NOT FIND A CAUSE FOR THE FLAME-OUTS. 1 G 7 1 3U 3 U H2SW E4CE 1995101300480 19951013 00480 NE 1995 10 13 CHI1478 2 19950808 G 7210 M2001517 SWITCH BOEING 234 234 1385049 EA LYC AL5512 AL5512 41581 NE NR 1 ENGINE BROKEN B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 239CH 33043 MJ006 PILOTS REPORTED INTERMITTENT NR 1 ENGINE TRANSMISSION HOT LIGHT. DURING TROUBLESHOOTING, FOUND M2001-517 TEMP SWITCH BR OKE IN HALF AND WIRES PULLED OUT AT CANNON PLUG. REPLACED TEMP SWITCH AND CANNON PLUG. CHECKED GOOD. CAUSE UNKNOWN. S UBMITTER SUGGESTS POSSIBLE VIBRATION OR STRUCK DURING MAINTENANCE. (X) 2 G 7 2 4U 4 U H9EA E4NE 1995102000077 19951020 00077 EA 1995 10 20 95ZZZX5743 2 19950927 G 7310 LW120980210 LINE PIPER PA24 PA24250 7102404 SO LYC O540 IO540* 41532 EA INJECTOR B-NUT BROKEN D S K NONE O OTHER IN INSP/MAINT 1 SO 11 10 INSPECTION FOUND INJECTOR FITTING BROKEN. 1 L 7 1 3O 3 O 1A15 1E4 1995102000080 19951020 00080 SO 1995 10 20 95ZZZX5746 2 19950926 G 8530 639615 ROCKER ARM CESSNA 150 150H 2071818 CE CONT O200 O200A 17020 SO EXHAUST ROCKER FAILED B KO2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 01 50231 2678 15069153 690208A THE EXHAUST VALVE WAS NOT STUCK IN THE GUIDE. THE BUSHING HAD BEEN CHANGED IN THE ARM AT SOME TIME (OIL HOLE IS NOT LIN ED UP WITH OIL HOLE IN THE ARM). MAYBE THE BUSHING WAS TOO TIGHT OF A FIT. 1 H 7 1 3O 3 O 3A19 E252 1995102000087 19951020 00087 EA 1995 10 20 95ZZZX5753 2 19950627 G 8520 CRANKSHAFT GULSTM 680 680FL 0141608 SW LYC O540 IGSO540B1A 41532 EA NR 6 JOURNAL FAILED E E A ENGINE SHUTDOWN UNSCHED LANDING Y K ENGINE STOPPAGE FLUID LOSS CR CRUISE 1 SW 99 114MN 1553107 L34250 WHILE IN CRUISE FLIGHT, THE RIGHT ENGINE QUIT. THE PROP CONTINUED TO WINDMILL. THE PILOT FEATHERED THE PROP AND SECURE D RIGHT ENGINE. AN EMERGENCY LANDING WAS COMPLETED. THE ENGINE WAS INSPECTED. THE CRANKCASE WAS CRACKED AND DISTORTED AROUND NR 6 CYLINDER. CRANKSHAFT FAILED AT NR 6 JOURNAL. NR 6 ROD BROKEN AT BASE AND AFT OF PISTON PIN. CRANKSHAFT T T UNKNOWN. ENGINE TT, 3,828.2 HOURS. 1 H 7 2 3O 3 O 2A4 1E7 1995102000088 19951020 00088 SO 1995 10 20 95ZZZX5754 2 19950901 G 8530 SA539988 VALVE CESSNA 182 182 2072702 CE CONT O470 O470R 17026 SO INTAKE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 230 191187R CYLINDER FAILED COMP. TEST. INTAKE VALVE LEAK. DEFECTIVE INTAKE VALVE HAD ONE-FOURTH OF FACE BURNED AND PITTED, AND A SMALL CRACK ACROSS THE FACE. INTAKE VALVE MADE BY SUPERIOR AIR PARTS. 1 H 7 1 3O 3 O NT 3A13 E273 1995102000089 19951020 00089 SO 1995 10 20 95ZZZX5755 1 19950811 G 8120 LW14463 DRAIN TANK PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540S1AD 41532 EA TURBO CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 03 9244C 2056 32R1887004 L510061A TURBO DRAIN TANK FOUND CRACKED 1.50 INCHES LONG AND OIL LEAKING OUT. CRACK WAS AT BASE OF WELD WHERE MOUNT TUBE IS WELD ED TO TANK. SHEET METAL WALL JUST AHEAD OF TANK WAS WORN THROUGH EDGE OF TANK WHICH HAD BEEN RIDING ON IT. SUBMITTER R ECOMMENDS INSPECTING AIRCRAFT FOR BENDING LOAD ON TANK AND CAUSING TANK METAL TO FATIGUE AND CRACK. IF WEAR IS FOUND ON SHEET METAL, CUT OUT ROUND AREA AND PUT ON A CURVED PATCH. 1 L 7 1 3O 3 O A3SO E14EA 1995102000091 19951020 00091 EA 1995 10 20 95ZZZX5757 2 19950824 G 8530 LW14995 RETAIN SPRING PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA NR 2 CYL TUBE BROKEN B OG5R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 21 852ND 4495006 L2456936A INSPECTED OVERHAULED ENGINE (FACTORY OVERHAUL) PER SB 519 DURING SCHEDULED ENGINE CHANGE. FOUND NR 2 CYLINDER SHROUD SP RING BROKEN. SPRING FOUND BEFORE ENGINE RUN-UP. INSTALLED NEW PART. 1 L 7 2 3O 3 O A19S0 E286 1995102000093 19951020 00093 EA 1995 10 20 95ZZZX5759 2 19950921 G 8520 LW11026 CRANKCASE MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA RT HALF CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 639MA 2703 1997 LW745436A 2893 L745436A RIGHT CRANKCASE HALF FROM PARTING SURFACE LOWER NR 3 BOLT HOLE HAS 1 EACH .25 INCH CRACK FROM BOLT HOLE TO PARTING SURFA CE, AND 1 EACH 1.850 INCH CRACK FROM BOLT HOLE INTO CASE WEBBING. SUBMITTER CANNOT DETERMINE THE CAUSE OF CRACK. NOTE: THE PROPELLER GOVERNOR OIL LINE AND THE GENERATOR HAD TO BE REMOVED BEFORE THE CRACK AREA WAS VISIBLE. 1 L 7 1 3O 3 O 2A3 E286 1995102000099 19951020 00099 SO 1995 10 20 95ZZZX5765 2 19950814 G 8530 SA6323105 GASKET PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360FB 17025 SO NR 3 CYL ROCKER FAILED D O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 01 38182 3 28R7703186 305238H REPLACED ROCKER BOX COVER GASKETS WITH NEW SUPERIOR SILICON GASKET. USED ALL NORMAL PROCEDURES FOR INSTALLATION. COVER S CAME OFF IN-FLIGHT CAUSING ENGINE OIL LOSS. AFTER FURTHER INVESTIGATION, SUPERIOR FOUND A SL NR P1B-93007, THAT SAYS TO USE LOCTITE ON SCREW THREADS FOR THIS GASKET ONLY. SUBMITTER FEELS GASKET IS DEFECTIVE AND A FATALLY DANGEROUS PRODU CT. NO PAPERWORK WITH GASKET SAYING TO USE LOCTITE. ENGINE REQUIRES OVERHAUL. 1 L 7 1 3O 3 O 2A13 E9CE 1995102000102 19951020 00102 WP 1995 10 20 95ZZZX5768 2 19950918 G 7261 30748831 OIL TUBE BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315R 01518 WP NR 6 BEARING CRACKED D E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 GL 15 95AE 2578 NA0447 P91455 DURING STABLE CRUISE, A DROP OF OIL PRESSURE INDICATED ON MASTER WARN PANEL LED TO AN ENGINE SHUT DOWN (RT) AFTER POWER BACK ELECTION AND CONTINUED DROP OF PRESSURE ON GAUGE. INSPECTION REVEALED A CRACKED OIL TUBE PROVIDING PRESSURE TO ENG INE NR 6 BEARING. CRACK OCCURRED AT FERRULE ELBOW EXITING SHROUD. SENT BOTH ENGINE LINES (NR 1 AND NR 2 ENGINES) TO AL LIED SIGNAL FOR EVALUATION. NEW LINES INSTALLED. 2 L 7 2 4F 4 F RT A3EU E6WE 1995102000107 19951020 00107 EA 1995 10 20 95ZZZX5773 2 19950905 G 8520 LW75061 ROD BOLT LYC O360 O360A1A 41514 EA CON ROD WRONG PART D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 23 IT IS NOT UNCOMMON TO FIND THE LONGER LW 75061 ROD BOLTS THAT ARE CALLED OUT IN THE LATEST O-360 TEXTRON LYCOMING PARTS BOOK MIS-MATCHED WITH THE CONNECTING RODS. THE EARLIER RODS, SUCH AS THE 74502 ROD, REQUIRE A SHORTER CONNECTING ROD BO LT (LW 74644). UNFORTUNATELY, DUE TO THE NECKED-DOWN DESIGN OF THE SHANK OF THE BOLT, THE 40 FEET/POUND TORQUE VALUE CA N BE ACHIEVED WITH EITHER BOLT; BUT, WITH THE WRONG BOLT WHICH IS LONGER, ONLY ABOUT 80 PERCENT OF THE THREADS IN THE CO NNECTING ROD NUT ARE MAKING CONTACT WITH THE BOLT THREADS. 3 O E286 1995102000110 19951020 00110 EA 1995 10 20 BIER950022 2 19950925 G 8530 74541 VALVE GULSTM AA5 AA5B 3960105 SO LYC O360 O360A4K 41514 EA NR 1 CYL EXH BROKEN B BIER K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 EA 21 28805 600 AA5B0824 62494336A PILOT REPORTED ROUGH RUNNING ENGINE. COMPRESSION CHECK REVEALED 0/80 ON NR 1 CYLINDER. FURTHER INSPECTION REVEALED EXH AUST VALVE BROKEN - HALF HEAD MISSING. REPLACED CYLINDER/PISTON ASSEMBLY WITH REBUILT UNIT. (X) 1 L 7 1 3O 3 O A16EA E286 1995102000112 19951020 00112 NE 1995 10 20 CHI1477 2 19950821 G 7210 M2001517 SWITCH BOEING 234 234 1385049 EA LYC AL5512 AL5512 41581 NE NR 1 ENGINE BROKE B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 2FOR 89438 MJ003 DURING REMOVAL OF ENGINE SCREEN AND NOSE BOX COWL, NOTICED NR 1 ENGINE TRANSMISSION TEMP SWITCH WAS HANGING BY THE CANNO N PLUG WHERE IT HAD BROKEN IN HALF AT THE WELDED SEAM. NO SIGN OF LEAKAGE. CAUSE UNKNOWN. (X) 2 G 7 2 4U 4 U H9EA E4NE 1995102000131 19951020 00131 NE 1995 10 20 HEEA955884 2 19951013 G 7250 3017600 ENGINE BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE POWER SECT FAULTY E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 22347 3871 36005 HIGH N1, 1% TO 2% HIGH ON POWER CHECK. 1 G 7 2 4U 4 U H4SW E22EA 1995102000135 19951020 00135 NE 1995 10 20 HEEA955890 2 19951013 G 7250 3017600 ENGINE BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE POWER SECT FAULTY E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 2261D 13799 33076 HIGH ITT AT POWER CHECK. 1 G 7 2 4U 4 U H4SW E22EA 1995102000183 19951020 00183 EA 1995 10 20 95ZZZX5820 2 19950727 G 7310 25244508 INJECTOR BENDIX PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA MIXTURE STOP SCREW MISSING D S K NONE O OTHER IN INSP/MAINT 1 EA 25 75139 853 43621 28R7635269 L881951A PILOT COMPLAINT OF A/C NOT STARTING. FOUND MIXTURE STOP SCREW MISSING ALLOWING MIX. CONTROL ARM TO GO BEYOND FULL RICH BACK TO I.C.O. MIXTURE CONTROL STRIKES SAFETY WIRE ON STOP CAUSING IT TO BREAK. RECOMMEND DIFFERENT METHOD OF SAFETYIN G. 1 L 7 1 3O 3 O 2A13 1E10 1995102000185 19951020 00185 EA 1995 10 20 95ZZZX5822 2 19950919 G 8530 CYLINDER PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA NR 6 CRACKED D S K NONE K FLUID LOSS IN INSP/MAINT 1 GL 13 2471M 980 CP31039 277954065 THE PILOT REPORTED LOW EGT ON THE LEFT ENGINE. A VISUAL INSPECTION OF NR 6 CYLINDER WHERE THE EGT PROBE IS LOCATED REVE ALED A CRACK AT THE LOWER SPARK PLUG HOLE. AFTER REMOVING THE CYLINDER, FOUND THE CRACK WENT FROM SPARK PLUG HOLE TO SP ARK PLUG HOLE WITH MISSING METAL AROUND THE EXHAUST VALVE. 1 L 7 2 3O 3 O 1A10 1E4 1995102000429 19951020 00429 WP 1995 10 20 95ZZZX5843 2 19950907 G 7250 3103893 SEAL 31033155 GARRTT TPE331 TPE33112UAR 01514 WP TURB 1ST STAGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 3556 1233151957 P70129 DURING SCHEDULED INSPECTION, FOUND SEAL CRACKED AT FLANGE. SB 72-0840 AUTHORIZES INSTALLATION OF THIS PART TO PROVIDE I NCREASED TENSION AGAINST THE FIRST STAGE ROTOR. THIS INCREASED TENSION RESULTS IN CRACKING AT THE SEAL FLANGE. THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIFE LIMIT - 20,000 CYCLES. SUBMITTER STATES THIS IS THE 13TH SEAL FOUND CRACKED. PART TOTAL CYCLES, 3,550. 4 T E4WE 1995102000430 19951020 00430 WP 1995 10 20 95ZZZX5844 2 19950918 G 7250 31038391 SEAL 31035152 GARRTT TPE331 TPE33112UAR 01514 WP TURB 1ST STAGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 9724 9233151477 P70023C DURING SCHEDULED INSPECTION, FOUND SEAL FLANGE CRACKED. SB 72-0840 AUTHORIZES INSTALLATION OF THIS PART WITH A SHIM TO INCREASE TENSION AGAINST 1ST STAGE ROTOR. INCREASE TENSION CAUSES CRACKING AT THE SEAL FLANGE. THIS IS A CRITICAL LIFE -LIMITED COMPONENT. LIFE LIMIT IS 20,000 CYCLES. SUBMITTER STATES THIS IS THE 15TH CRACKED SEAL PLATE REPORTED BY THIS FACILITY. SUGGEST ALLIED SIGNAL DETERMINE/CORRECT CAUSE. PART TOTAL CYCLES, 9,933. 4 T E4WE 1995102700024 19951027 00024 GL 1995 10 27 95ZZZX5912 2 19950910 G 7250 A6871505 BEARING BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL NR 5 MAKING METAL B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 07 105NC 96 104 790 CAE836124 INSPECTED AIRFRAME SCAVENGE OIL FILTER PER SUPERIOR TURBINE INFORMATION BULLETIN NR 95-IB001 (SB T95-SB001). FOUND 13 S ILVER FLAKES IN FILTER BOWL. NO ABNORMAL INDICATIONS OR CHIP LIGHTS. REPLACED WTIH NEW SERVICEABLE BEARING. SUPERIOR TURBINE OFFERED EXCELLENT SERVICE WHEN ADVISED OF FINDINGS. 1 G 7 2 3U 3 U NC H3EU E4CE 1995102700455 19951027 00455 NE 1995 10 27 HEEA955912 2 19951020 G 7261 17425000080 FILTER HOUSING BOLKMS 117 BK117A4 5626017 EU LYC LTS101 LTS101650B1 41560 NE ENG OIL DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 230H 7136 BY PASS BUTTON WON'T STAY RESET. RECEIVED INSTALLED ON AIRCRAFT. 1 G 7 2 3U 3 U H13EU E5NE 1995102700458 19951027 00458 NE 1995 10 27 HEED95353 1 19950922 G 7400 9550147560 START ELECTRODE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE ENGINE DEFECTIVE E HEED K NONE O OTHER IN INSP/MAINT 1 SW 03 89H 167 760406 15014 ENGINE WILL NOT START. REPLACE UNIT 1 G 7 2 3U 3 U NC H1NE E19EU 1995102700462 19951027 00462 NE 1995 10 27 HEED95357 2 19951002 G 7261 0292005250 SEAL SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE LABYRINTH LEAKING E HEED K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 89H 184 760406 REAR LABYRINTH SEAL LEAKING HIGH OIL USEAGE. ENGINE SMOKING. REPLACE ENGINE ASSEMBLY 1 G 7 2 3U 3 U NC H1NE E19EU 1995102700463 19951027 00463 NE 1995 10 27 HEED95358 2 19951003 G 7261 0292005250 SEAL SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE MODULE 5 LEAK E HEED K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 89H 2999 760406 ENGINE HAD BAD OIL LEAK AT MODULE 5 AFTER SEAL REPLACEMENT ON VIBRATION CHECK AT REAR BEARING HAD HIGH VIBRATION OF 35 MM AND GOT ENGINE CHIPLITES, FOUND METAL ON MODULE 5 PLUG AND ON OTHER CHIP PLUGS AND IN FILTER. NONE 1 G 7 2 3U 3 U NC H1NE E19EU 1995110200008 19951102 00008 GL 1995 11 2 HEEA954913 2 19950504 G 7230 23008090 GEARSHAFT 23051643 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL SPUR ADAPTER STEP WEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 31219 681 CAC90703 760230 CAE890555S ENGINE REMOVED DUE TO TURBINE OVERHAUL AND COMPRESSOR N1 SHAFTING INSPECTION. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIMITS ON SPUR ADAPTER GEARSHAFT FORWARD AND AFT SPLINES. INSTALLED NEW SPUR ADAPTER G EARSHAFT. 1 G 7 2 3U 3 U H1NE E1GL 1995110200013 19951102 00013 NE 1995 11 2 HEEA955090 2 19950525 G 7300 0164248800 FUEL CONTROL SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE ENGINE DEFECTIVE E HEEA A UNSCHED LANDING R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 SW 03 6097Z 572 2820 9353 ROTOR DROOPED ON TAKEOFF ABOVE 80% TORQUE AND SLOW TO RESPOND DURING LET DOWN. 1 G 7 1 3U 3 U H9EU E19EU 1995110600021 19951106 00021 SO 1995 11 6 95ZZZX5925 2 19950921 G 7414 10160844 DISTRIBUTOR CONT O520 IO520* 17032 SO MAG BRUSH LOOSE H K NONE O OTHER IN INSP/MAINT 1 EA 05 100 MAG INOPERATIVE. FOUND DISTRIBUTOR SHAFT BLUE. OPENED MAG AND FOUND DISTRIBUTOR BRUSH LOOSE IN MAG CASE. FOUND DISTRI BUTOR GEAR HUB AND COIL FINGER DAMAGED BY ARCING. BRUSH EITHER FELL OUT OR WAS INSTALLED IMPROPERLY. MAG RAN SEVERAL H OURS USING BRUSH SPRING TO COMPLETE CIRCUIT. 3 O E5CE 1995110600023 19951106 00023 NE 1995 11 6 95ZZZX5927 2 19950920 G 8530 399356 CYLINDER AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE NR 4 HEAD BROKE G A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 SO 11 2362D 16 3010404 22167 CYLINDER HEAD BROKE AT EXHAUST VALVE ROCKER SHAFT ATTACHMENT PREVENTING THE ROCKER ARM FROM OPENING THE EXHAUST VALVE. T HE ENGINE SUBSEQUENTLY QUIT AND THE AIRCRAFT CRASHED IN A FIELD. 1 L 7 1 3R 3 R A9SW 5E2 1995110600028 19951106 00028 SO 1995 11 6 95ZZZX5932 2 19950922 G 8530 GUIDE CESSNA 172 172 2072402 CE CONT O300 O300A 17022 SO EXHAUST VALVE EXCESS WEAR H K NONE O OTHER IN INSP/MAINT 1 GL 27 6079A 28679 1599708A NEW CYLINDERS FOR ENGINE ONLY LASTED FOR 85 HOURS WHEN EXHAUST GUIDES EXHIBITED EXCESS WEAR. 1 H 7 1 3O 3 O NT 3A12 E253 1995110600030 19951106 00030 SO 1995 11 6 95ZZZX5934 2 19950826 G 8550 641734 FILTER ADAPTER 641801 CESSNA 172 R172K 2072431 CE CONT O360 IO360K 17025 SO CRANKCASE COVER THREADS STRIPPED G O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 25 1439V 2184 616 R1722191 230344R OIL FITLER ADAPTER SEPARATED FROM ENGINE AT CRANKCASE COVER MOUNTING BOSS ALLOWING OIL SUPPLY TO BE EXHAUSTED. INVESTIG ATION REVEALED 80 PERCENT OF THE MOUNTING THREADS CONTAINED IN THIS BOSS WERE STRIPPED. HIGH TEMP RTV WAS FOUND ON THES E THREADS AS WELL AS THE THREADS OF THE OIL FILTER ADAPTER. THE TCM OVERHAUL MANUAL DOES NOT CALL FOR SEALER IN THIS AR EA. 1 H 7 1 3O 3 O 3A17 E1CE 1995110600031 19951106 00031 SO 1995 11 6 95ZZZX5935 1 19950923 G 8120 4078009003 TURBOCHARGER GARRTT PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA SEAL OIL LOSS B EKIR O OTHER K J FLUID LOSS WARNING INDICATION AP APPROACH 1 WP 07 110SK 139 XK019256 31P7630006 L13362 ENGINE LOST OIL PRESSURE ON APPROACH TO AIRPORT. UPON INSPECTION ON THE GROUND, FOUND NO OIL IN ENGINE. OIL ON TURBO C ENTER HOUSING AND OVERBOARD EXHAUST STACK. FOUND NO OTHER EVIDENCE OF LEAKAGE. PRESSURE TESTED ALL OIL LINES AND HOSES , FOUND NO OTHER LEAKS. SUSPECT LOSE OF TURBO SEAL. 1 L 7 2 3O 3 O A8EA E19EA 1995110600035 19951106 00035 EA 1995 11 6 95ZZZX5939 2 19951005 G 8530 LW19001 VALVE GULSTM AA5 AA5A 3960106 SO LYC O320 O320E2G 41508 EA NR 3 CYL EXHAUST FAILED D K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 05 9671U AA5A0037 L4300227A PILOT REPORTED POWER LOSS OF MAX RPM 1600. INSPECTED POWERPLANT, FOUND NR 3 CYLINDER HAD NO COMPRESSION. PULLED CYLIN DER, FOUND EXHAUST VALVE BROKEN. TOP OF PISTON AND CYLINDER HEAD DAMAGED BADLY. SUSPECT VALVE FATIGUE AS CAUSE OF FAIL URE. 1 L 7 1 3O 3 O A16EA E274 1995110600036 19951106 00036 CE 1995 11 6 95ZZZX5940 1 19950907 G 2701 05131661 CONTROL WHEEL 05131822 CESSNA 172 172D 2072410 CE CONT O300 O300D 17022 SO PILOT BROKE G A UNSCHED LANDING O OTHER AP APPROACH 1 SW 11 2519U 1670 17250119 27720D2D AFTER 40 MINUTES OF CRUISE FLIGHT TO 3,000 FEET MSL, THE ENGINE LOST POWER. ABOUT 80 FEET ABOVE THE GROUND, ON SHORT FI NAL TO A HAY FIELD, THE CONTROL WHEEL BROKE. THE PILOT GRABBED THE CONTROL WHEEL TUBE AND STARTED TO FLARE FOR LANDING WHEN THE AIRCAFT STRUCT THE GROUND IN A NOSE-LOW ATTITUDE. CAUSE OF POWER LOSS AND CONTROL WHEEL BREAKAGE STILL UNDER I NVESTIGATION. 1 H 7 1 3O 3 O NT 3A12 E253 1995110600037 19951106 00037 SO 1995 11 6 95ZZZX5941 2 19950907 G 8500 ENGINE CESSNA 172 172D 2072410 CE CONT O300 O300D 17022 SO POWER SECTION FAILED G A UNSCHED LANDING O OTHER CR CRUISE 1 SW 11 2519U 1670 17250119 27720D2D AFTER 40 MINUTES OF CRUISE FLIGHT TO 3,000 FEET MSL, THE ENGINE LOST POWER. ABOUT 80 FEET ABOVE THE GROUND, ON SHORT FI NAL TO A HAY FIELD, THE CONTROL WHEEL BROKE. THE PILOT GRABBED THE CONTROL WHEEL TUBE AND STARTED TO FLARE FOR LANDING WHEN THE AIRCAFT STRUCT THE GROUND IN A NOSE-LOW ATTITUDE. CAUSE OF POWER LOSS AND CONTROL WHEEL BREAKAGE STILL UNDER I NVESTIGATION. 1 H 7 1 3O 3 O NT 3A12 E253 1995110600041 19951106 00041 SO 1995 11 6 95ZZZX5945 2 19950510 G 8530 RINGS BEECH 58 58P 1152744 CE CONT O520 TSIO520WB 17040 SO CYLS 2,4,6 SEIZED B VIBR K NONE O OTHER IN INSP/MAINT 1 SO 13 6685D 602 TJ241 274203R THE OPERATOR REPORTED EXCESSIVE OIL CONSUMPTION. COMPRESSION ON CYLINDERS 2, 4, AND 6 WAS BELOW MINIMUMS WITH BLOWBY BY PISTON RINGS. DISASSEMBLY REVEALED THE RINGS ON ALL THREE PISTIONS WERE SEIZED DUE TO CARBON BUILD-UP. THE ENGINE HAS BEEN SERVICED WITH AEROSHELL 15W50 OIL SINCE COMPLETING NORMAL BREAKING. SUBMITTER STATED THIS SAME CONDITION HAS BEEN NOTED ON OTHER CONTINENTAL ENGINES USING AEROSHELL 15W50. 1 L 7 2 3O 3 O A23CE E8CE 1995110600042 19951106 00042 SO 1995 11 6 95ZZZX5946 2 19950925 G 8520 530184A2 CONNECTING ROD CESSNA 170 170B 2072306 CE CONT C145 C1452 17012 SO NR 6 CYLINDER BROKEN D K NONE O OTHER NR NOT REPORTED 1 GL 03 2209D 3600 20361 6241D12 NR 6 CONNECTING ROD FRACTURED APPROXIMATELY 2 INCHES BELOW PISTON SKIRT. BREAK SHOWED EVIDENCE OF PROGRESSION OVER TIME . FINAL FRACTURE WAS APPROXIMATELY ONE-HALF THE DIAMETER OF THE ROD WITH SOME MINOR CORROSION EVIDENT ALONG THE BEGINNI NG OF THE CRACK. AREA OF BREAK WAS CONSISTENT WITH A STRESS RELATED BUILD-UP CAUSED BY NICKING THE ROD THROUGH POOR MAI NTENANCE HANDLING DURING OVERHAULS. ENGINE HAD TWO MAJORS AND A TOP OVERHAUL LOGGED. MAGNAFLUXED AT LAST OVERHAUL. 1 H 7 1 3O 3 O A799 E253 1995110600052 19951106 00052 GL 1995 11 6 HEEA955926 2 19951027 G 7230 23009591 BEARING HOUSING 23033193 BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL ENG NR 1 CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 8588X 1426 CAC91088 51486 CAE895185 ENGINE REMOVED DUE TO TURBINE OVERHAUL AND COMPRESSOR 1750 HOUR INSPECTION. UPON DISASSEMBLY OF #1 BEARING AREA DUE TO OIL LEAK NOTED THE FOLLOWING: #1 BEARING FAILURE. FOUND 75% OF SEPERATOR CRACKED AFT OF CENTERING TAB; WITH BREAK OUT OF 40%FWD RING. SCRAPPED #1 BEARING. SEE MMIR#5925 FOR #1 BEARING. 1 G 7 1 3U 3 U H2SW E1GL 1995110600053 19951106 00053 GL 1995 11 6 HEEA955927 2 19951027 G 7230 6898607 BEARING 6890550 BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL NR 1 FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3181Y 2817 CAC33622 3772 CAE836332 ENGINE REMOVED DUE TO #1 BEARING FAILURE. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: #1 BEARING SEPARATO R BROKEN INTO MANY PIECES, INNER AND OUTER RACE SPALLED, BEARING BALLS SCORED AND FLATTENED. SECONDARY DAMAGE - MUTE R UB ON 1STSTAGE WHEELS, CARBON SEAL MATING SURFACE GROOVED ON 1ST STAGE WHEEL STUB SHAFT, CASE HALF VANES EXHIBIT EXCESSI VE CONTACT WITH WHEEL MUTES AND PLASTIC GROOVED, CRACKED AND MISSING, IMPELLER CONTACT WITH FRONT DIFFUSER, REAR DIFFUSE R MAJOR AND MINORSEALS GROOVED. SCRAPPED #1 BEARING. 1 G 7 1 3U 3 U H2SW E4CE 1995110600057 19951106 00057 SO 1995 11 6 95ZZZX5949 1 19950929 G 8120 60051004B HOUSING ROTOMASTER 3AT6EE10J2 PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360FB 17025 SO TURBO EXHAUST CRACKED B K NONE O OTHER IN INSP/MAINT 1 EA 13 8088D 940 212901 287921043 248060R DURING COMPLIANCE WITH AD 82-27-03 AND AFTER REMOVING THE EXHAUST HOUSING OF THE TURBOCHARGER, A CRACK, APPROXIMATELY .7 5 INCH LONG, WAS NOTED IN THE WEB AREA NEAR THE INLET. PARAGRAPH J OF THE AD STATES THE 200-HOUR REPETITIVE INSPECTION REQUIREMENT IS RELIEVED IF THIS PART NUMBER IS INSTALLED. CRACKS OF THIS NATURE ARE ALLOWABLE IN THE OTHER CASTINGS OF EARLIER MANUFACTURE. SINCE NO DATA WAS AVAILABLE ON THIS P/N, IT WAS REPLACED. 1 L 7 1 3O 3 O 2A13 E9CE 1995110600088 19951106 00088 EU 1995 11 6 95ZZZX5980 2 19950907 G 8530 850710 OIL SEAL AMTR FLTSTR FLIGHTSTAR 05644KB GL ROTAX 582 ROTAX582 55555 EU ROTARY VALVE LEAKING D K NONE O OTHER NR NOT REPORTED 1 SO 09 93FS 86 093 4317143 AFTER TOTAL ENGINE FAILURE WITH NO WARNING, ROTARY VALVE SHAFT WAS FOUND DEFECTIVE. ROTARY VALVE SPLINES WERE FOUND MEL TED OFF. FAILURE WAS FOUND TO BE DUE TO ROTARY VALVE OIL BEING DILUTED BY WATER. WATER WAS FOUND IN ROTARY VALVE OIL T ANK. SEAL HAD FAILED. INSPECTED THREE OTHER AIRCRAFT AND FOUND SAME PROBLEM. SUBMITTER STATED THIS IS AN EXPERIMENTAL AIRCRAFT, BUT A PROBLEM NEEDS TO BE ADDRESSED. 1 H 7 1 3I 3 I EXPA1H71 EXPE3I 1995110600268 19951106 00268 EA 1995 11 6 95ZZZX5982 2 19951004 G 8530 CYLINDER PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA LT ENG NR 4 SEPARATED D K NONE O OTHER NR NOT REPORTED 1 GL 05 6892R 600887816125 L1888448A LEFT ENGINE NR 4 CYLINDER SEPARATED FROM ENGINE. CAUSE UNKNOWN AT THIS TIME. REMOVED AND REPLACED ENGINE, PROPELLER, A ND ACCESSORIES. 1 M 7 2 3O 3 O RT A17WE 1E4 1995110600270 19951106 00270 SW 1995 11 6 95ZZZX5984 2 19950829 G 8500 ENGINE CESSNA 195 195 2073102 CE JACOBP R755 R755B1 35007 SW POWERPLANT FAILED D A UNSCHED LANDING E B R VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 01 9368A 7447 11465 ON FIRST FLIGHT AFTER MAINTENANCE (STARTER REPLACEMENT) ON 8-29-95, 25 MINUTES INTO FLIGHT, HAD SUDDEN ONSET OF ENGINE V IBRATION. HEADED TOWARD AIRPORT. WITHIN 1 MINUTE HAD COMPLETE LOSS OF OIL PRESSURE. OVER NEXT FEW MINUTES, HAD OIL TE MP PAST RED LINE AND OFF SCALE, OIL PRESSURE REMAINED ZERO, VIBRATION WORSENED, HAD PARTIAL POWER LOSS, AND BURNING ODOR . WAS ABLE TO RETURN AND LAND WITH PARTIAL POWER (ABOUT 10-12 INCHES MP). NO DAMAGE TO AIRFRAME. SUBSEQUENT INSPECTIO N FOUND MECHANICAL PROBLEMS RELATED TO THE RECENT MAINTENANCE. 1 H 7 1 3R 3 R NC A790 TC237 1995110600271 19951106 00271 SO 1995 11 6 95ZZZX5985 2 19950616 G 8530 639272 CYLINDER CESSNA 185 A185E 2072818 CE CONT O520 IO520D 17032 SO NR 5 FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 07 1997U 300 18501766 175979R DURING AN INSPECTION OF THE ENGINE, THE NR 5 CYLINDER WAS FOUND CRACKED BETWEEN THE TOP SPARK PLUG HOLE AND INJECTOR NOZ ZLE HOLE. INVESTIGATION REVEALED THE MAGNETO TO ENGINE TIMING WAS 10 DEGREES ADVANCED. AFTER THE NR 5 CYLINDER WAS REM OVED, THE PISTON, PISTON PIN, AND CONNECTING ROD WERE FOUND TO SHOW SIGNS OF EXCESSIVE HEAT. THE NR 2 CYLINDER WAS THEN PULLED AS A PRECAUTIONARY MEASURE AND WHILE THE CYLINDER WAS NOT CRACKED, THE PISTON, PISTON PIN, AND CONNECTING ROD WE RE ALL FOUND HEAT-DAMAGED. THE ENGINE WAS THEN REMOVED FROM SERVICE AND THE OVERHAUL FACILITY CONTACTED REGARDING THIS DISCREPANCY. REFERENCE SB M84-8 AND SB M94-8. 1 H 7 1 3O 3 O 3A24 E5CE 1995110600272 19951106 00272 EA 1995 11 6 95ZZZX5986 2 19950921 G 8530 FLANGE LYC O320 O320* 41508 EA INTAKE PIPE WARPED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 05 ORDERED NEW INTAKE FLANGES FROM FACTORY. FOUND WARPED. THIS CONDITION COULD LEAD TO BURNED VALVES AND POWER LOSS. 3 O E274 1995110600274 19951106 00274 SO 1995 11 6 95ZZZX5988 2 19950301 G 8550 632970 OIL PUMP CESSNA 340 340A 2076405 CE CONT O520 TSIO520N 17040 SO ENGINE SEAL FAILED D O OTHER K W FLUID LOSS INADEQUATE Q C NR NOT REPORTED 1 GL 07 808TW 85 34A0304 R508512 IN-FLIGHT, OIL PUMP CASE SEAL FAILURE. SILK THREAD DISPLACED FROM PARTING FLANGE. INSPECTIONS REVEALED WARP AT PARTING FLANGE. SILICONE USED BY OVERHAUL FACILITY TO SEAL FLANGE. THIS SHOP SUGGESTS FOLLOWING TCM DIRECTIVES FOR SEALER IN THIS AREA. SILICON SHOULD 'NOT' BE USED. 1 L 7 2 3O 3 O 3A25 E8CE 1995110600294 19951106 00294 SO 1995 11 6 95ZZZX6008 1 19950925 G 8120 LW18822 INTERCOOLER PIPER PA31 PA31P350 7103111 SO LYC O540 LTIO540V2AD 41533 EA LT SUPPORT BRCKT CRACKED B FGQR K NONE O OTHER IN INSP/MAINT 1 SO 01 50RN 153 31P8414013 RL269968A INSPECTION FOUND A CRACK INITIATED IN THE RADIUS OF A MACHINED AREA FOR THE LT SUPPORT BRACKET, AND PROPOGATED FORE AND AFT. THIS IS THE SECOND FAILURE FOUND OF THIS TYPE ON THE MOJAVE INTERCOOLERS. CURRENTLY, THERE ARE NO NEW PARTS AVAIL ABLE AND NO REPAIR DATA AVAILABLE. 1 L 7 2 3O 3 O RT A8EA E14EA 1995110600295 19951106 00295 EA 1995 11 6 95ZZZX6009 2 19951005 G 8530 73806P PUSH ROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 1-4 EXHAUST DAMAGED D K NONE K FLUID LOSS IN INSP/MAINT 1 NE 03 4648L 15284205 L2282415 DURING A 100-HOUR INSPECTION, A SMALL DENT IN NR 1 AND NR 4 EXHAUST PUSH ROD SHROUDS WAS DETECTED. THEY SEEMED TO BE LE AKING OIL. A FURTHER INSPECTION OF THE PUSH RODS REVEALED A VERY DEEP GROOVE OR CHANNEL WORN INTO THEM WHERE THE DENT I N THE SHROUD WAS LOCATED. REPLACED ALL PUSH RODS IN NR 1 AND NR 4 CYLINDERS ALONG WITH THE RESPECTIVE SHROUDS. SUSPECT NR 1 EXHAUST PUSH ROD HAD DAMAGE CAUSED BY A ROCK KICKED UP BY THE PROPELLER. 1 H 7 1 3O 3 O NT 3A19 E223 1995110600599 19951106 00599 EA 1995 11 6 95ZZZX6015 2 19950808 G 8550 LW11252 OIL PUMP PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA ENGINE SEIZED D A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 SO 15 61367 317552088 L104468A AIRCRAFT ON CLIMB-OUT AT 4,500 FEET OIL PUMP SEIZED AND SEVERAL ACCESSORY GEARS SHEARED INCLUDING CRANK GEAR CAUSING ENG INE TO FAIL. AIRCRAFT LANDED, SINGLE ENGINE. TIME ON ENGINE, 1,139 HOURS SINCE MAJOR OVERAHUL. 1 L 7 2 3O 3 O A20SO E14EA 1995110600623 19951106 00623 NE 1995 11 6 95ZZZX6039 2 19950914 G 7313 NOZZLE LEAR 25 25 5170506 CE GE CJ610 CJ6106 30006 NE 1ST STAGE DEFECTIVE D O OTHER Y ENGINE STOPPAGE CR CRUISE 1 GL 07 121EL 010 251382 RT ENGINE FLAMED OUT AT 42,000 FEET. DISASSEMBLED ENGINE, SENT FIRST STAGE NOZZLE OUT FOR RE-WORK, REASSEMBLED ENGINE. TEST FLIGHT OK. 2 L 7 2 4J 4 J A10CE 1E16 1995110600626 19951106 00626 NE 1995 11 6 95ZZZX6042 2 19951003 G 7240 3008822 RIVET CESSNA 500 500CESSNA 2076602 CE PWA JT15 JT15D1 52060 NE LEFT ENGINE SHEARED B SI6R K NONE O OTHER IN INSP/MAINT 1 SW 17 88GJ 4222 5000155 76332 DURING A HOT SECTION INSPECTION, RIVETS IN THE SUPPORT RING THAT HOLD THE DEFLECTOR SEGMENTS WERE FOUND MISSING. PIECES OF THE MISSING RIVETS WERE FOUND THROUGHOUT THE AFT END OF THE ENGINE. THE HIGH PRESSURE TURBINE BLADE TIPS WERE FOUND DAMAGED DUE TO THE RIVETS. ALL 71 BLADES WERE REPLACED ON THE HIGH PRESSURE TURBINE DISC ASSEMBLY DUE TO THE DAMAGE IN FLICTED BY THE RIVETS. 1 L 7 2 4F 4 F A22CE E1NE 1995111300002 19951113 00002 NE 1995 11 13 95ZZZX6051 2 19951002 G 8530 CYLINDER DOUG DC3 DC3C 3021457 WP PWA R1830 R183092 52020 NE NR 4 HEAD SEPARATED E O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 11 59316 743 18986 BP429393 LEFT ENGINE STARTED TO RUN ROUGH IN-FLIGHT. UPON TROUBLESHOOTING, FOUND CYLINDER NR 4 HEAD HAD SEPARATED FROM THE BARRE L. CYLINDER WAS REPLACED WITH AN OVERHAULED UNIT. 2 L 7 2 4R 4 R A669 5E4 1995111300003 19951113 00003 SW 1995 11 13 95ZZZX6052 1 19951012 G 7922 75944 VALVE MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA THERMO BYPASS LOOSE CRIMP NUT B WIZR K NONE O OTHER IN INSP/MAINT 1 WP 25 68KH 680074 L1231736A DURING INSPECTION OF THERMOSTATIC BYPASS VALVE PER LYC SB518C, THE RETAINING NUT WAS FOUND LOOSE AND THE SPRING PRESSURE WAS NOTICEABLY LESS THAN OTHER VALVES PREVIOUSLY INSPECTED. ENGINE TSMOH, 320.0 HOURS. 1 L 7 1 3O 3 O 2A3 E286 1995111300004 19951113 00004 SO 1995 11 13 95ZZZX6053 2 19951017 G 8520 CRANKCASE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO RIGHT SIDE CRACKED D A K NONE O OTHER IN INSP/MAINT 1 NM 01 6834C 1540 421C0476 241181R INSPECTION FOUND CRACK IN CRANKCASE STARTING AT TOP CASE FLANGE BOLT DOWN UNDER ENGINE DATA PLATE, THEN DOWN BETWEEN NR 3 AND NR 5 CYLINDERS. CRACK IS 8 INCHES LONG. LEFT ENGINE HAD A CRACK SAME AREA 96 HOURS AGO. 1 L 7 2 3O 3 O A7CE E7CE 1995111300017 19951113 00017 NE 1995 11 13 95ZZZX6066 2 19950922 G 7414 SB9RU3 MAGNETO BOSCH DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE LT MAG GEAR FLATED B NZBR C D ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AL 05 2738G 444 BB2769 1511 JP210889 PILOT REPORTED PARTIAL LOSS OF POWER ON TAKEOFF. TROUBLESHOT TO LEFT MAGNETO, STRIPPED DISTRIBUTOR GEAR. REPLACED LEFT MAGNETO WITH OVERHAULED UNIT. GROUND RUN AND OPERATIONAL CHECK GOOD. 1 H 7 1 3R 3 R A806 5E1 1995111300186 19951113 00186 EA 1995 11 13 95ZZZX6141 2 19950425 G 8520 76220 THROUGH-BOLT MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA NR 1 CYLINDER BROKEN D K NONE O OTHER IN INSP/MAINT 1 NE 05 7112V 2763 1788 220047 L12C245A SUBJECT NR 1 CYLINDER UPPER THROUGH-BOLT FOUND BROKEN DURING PREFLIGHT. DETECTED AS THE MAJOR REMAINING PORTION AND HOL D-DOWN NUT FOUND BACKED OUT OF POSITION AND LODGED AGAINST CYL FINS. INSTALLED NEW BOLT, SPACER, AND NUT. TORQUED PER LYC SERVICE LETTER 1029C. BOLT THREADED END BROKE OFF FLUSH WITH NUT'S SEATING SURFACE. INDICATIONS WERE A CRACK ABOVE 50 PERCENT ACROSS DIAMETER HAD EXISTED FOR SOME TIME & BOLT ULTIMATELY FAILED IN A TYPICAL TENSILE FRACTURE. MISSING S PACER HAD MIGRATED THROUGH CABIN HEATER SCAT TUBING & FOUND LODGED IN MUFFLER OPENING. NUT WITH SHEARED OFF END WAS LOD GED BETWEEN NR 2 AND NR 4 ROCKER BOXES. ENGINE HAD BEEN ASSEMBLED 27 HRS PREVIOUSLY. 1 L 7 1 3O 3 O 2A3 1E10 1995111300187 19951113 00187 EA 1995 11 13 95ZZZX6142 2 19950424 G 8530 78743 PIPE MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA NR 3 CYLINDER CRACKED D L K NONE O OTHER IN INSP/MAINT 1 NE 05 7112V 1680 678 220047 L1262451A REPLACED PARTS RECEIVED BACK FROM OVERHAUL AGENCY FOLLOWING PROP STRIKE DISASSEMBLY INSPECTIONS, INCLUDED A PN SL-1024J PISTON AND SUBJECT NR 3 CYL INTAKE PIPE. PISTON EXHIBITED EARLY STAGES OF TYPICAL DETONATION DAMAGE ON THE HEAD, ADJACE NT TO ITS O.D., AT THE 12 O'CLOCK POSITION AS INSTALLED. TPT 678 HRS. CAUSE APPARENTLY DUE TO EXCESSIVELY LEAN MIXTURE S RESULTING FROM AMBIENT AIR ENTERING SUBJECT CRACKED INTAKE PIPE AND ADJ TO ITS CYL MATING END. CRACK WAS IN THE PIPE' S ATTACHMENT FLARE RADIUS, WAS CLEARLY VISIBLE, & EXTENDED AROUND APPROX 40 PERCENT OF THE PIPE'S DIAMETER. CYL HAD BEE N REPLACED 67 HRS PREVIOUSLY. 1 L 7 1 3O 3 O 2A3 1E10 1995111300188 19951113 00188 EA 1995 11 13 95ZZZX6143 2 19950424 G 8550 75167 OIL LINE MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA PROP GOVERNOR CHAFED D L K NONE O OTHER IN INSP/MAINT 1 NE 05 7112V 678 220047 L1262451A INSPECTION FOLLOWING ENGINE REMOVAL REVEALED EXTREME CHAFING/WEAR DAMAGE TO PROP GOVERNOR EXTERNAL OIL LINE AT GOV END A PPROX 5 INCHES AWAY FROM B-NUT ATTACH. DAMAGED AREA APPROX .25 INCH BY .50 INCH & WEAR WAS NEARLY THROUGH TUBE WALL THI CKNESS. OIL LOSS WAS IMMINENT. AD NOTE 90-04-06 WAS ACCOMPLISHED 678 HRS PREVIOUSLY. ACFT HAD BEEN ANNUALED 5 TIMES S INCE. THE AD LYC REQUIRED CLAMPING WAS PRESENT AND INTACT. ENG MOUNT TUBE WAS SIMILIARY DAMAGED, REQUIRING WELD REPAIR . EXTREME WEAR PRESENT INDICATES PARTS HAD BEEN IN CONSTANT CONTACT AS OPPOSED TO START-UP/SHUT-DOWN MOTION. 1 L 7 1 3O 3 O 2A3 1E10 1995111300197 19951113 00197 SO 1995 11 13 95ZZZX6152 2 19951002 G 8530 PISTON CESSNA 172 172F 2072414 CE CONT O300 O300C 17022 SO NR 1 CYLINDER BROKEN H K NONE O OTHER IN INSP/MAINT 1 WP 13 8636U 177 17252538 31849D40 LOW COMPRESSION ON NR 1 CYLINDER (80/60) FOUND DURING ANNUAL INSPECTION. DISCOVERED OIL RING MISSING AND PISTON SKIRT B ROKEN OFF. SUBMITTER SUSPECTS CAUSED BY IMPROPER CYLINDER INSTALLATION METHODS. 1 H 7 1 3O 3 O NT 3A12 E253 1995111300208 19951113 00208 EA 1995 11 13 95ZZZX6163 2 19951010 G 8530 CYLINDER CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA NR 4 CRACKED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 03 6105V 172RG0580 L2878136A ENGINE BECAME ROUGH DURING FLIGHT. UPON LANDING AND INSPECTION, IT WAS DETERMINED THAT CYLINDER NR 4 WOULD NOT PASS CYL INDER LEAKAGE TEST. AFTER FURTHER INSPECTION, CYLINDER WAS FOUND TO BE CRACKED ONE-HALF WAY AROUND CIRCUMFERENCE BETWEE N FINS AT JUNCTION OF HEAD-TO-BARREL. CYLINDER WAS REPLACED AND ENGINE WAS RETURNED TO SERVICE. CYLINDER WAS BORED .01 0 INCH. ENGINE TT, 2,344.8 HRS. ENG SMOH, 319.8 HRS. 1 H 7 1 3O 3 O 3A17 E286 1995111300424 19951113 00424 EA 1995 11 13 95ZZZX6182 2 19950912 G 7414 CONTACT POINTS BENDIX S6LN20 PIPER PA25 PA25235 7102504 SO LYC O540 O540G1A5 41532 EA LT MAG FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 13 8566L 254990 CONTACT POINTS' SOFT PLASTIC THAT RIDES THE CAM WORE DOWN UNTIL THERE WAS NO CONTACT POINT OPENING (MAG FAILURE). THE R OTATING MAGNET CONTINUED TO MAKE ELECTRIC ENERGY, SENDING IT TO THE CAPACITOR, OVERLOADING THE CAPACITOR, CAUSING IT TO BURN ITSELF OUT. THIS HAPPENED TO BOTH MAGS 1-21 HRS SMOH AND 1-23 HRS. ALL PARTS WERE TCM, NEW MFG, PURCHASED AUG, 19 95. 1 L 7 1 3O 3 O 2A10 E295 1995111300439 19951113 00439 GL 1995 11 13 95ZZZX6197 2 19951019 G 7313 6890917 NOZZLE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FUEL DEFECTIVE B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 3115Y 1016 2843 500716D CAE830348 PILOT COMPLAINED OF POWER/N2 FLUCTUATING WITH COLLECTIVE INPUT. SUBSEQUENT INSPECTION REVEALED THE FUEL NOZZLE WAS AT F AULT. REMOVED AND REPLACED NOZZLE AND PROBLEM WAS CURED. NOZZLE SENT IN FOR REWORK. 1 G 7 1 3U 3 U H3WE E4CE 1995111300440 19951113 00440 GL 1995 11 13 95ZZZX6198 2 19951005 G 7240 6870992K COMBUSTION CASE BELL 206 206L 1181522 SW ALLSN 250C 250C20B 03013 GL ENGINE CRACKED B S LX5R K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 19 781LL 1318 31292 45079 CAE835862 INVESTIGATION FOR LOSS OF POWER AND HIGH T.O.T., FOUND COMBUSTION CASE CRACKED. 1 G 7 1 3U 3 U H2SW E4CE 1995111700131 19951117 00131 NE 1995 11 17 95ZZZX6211 2 19950926 G 7321 0164348670 FCU E2 BOLKMS BK117 BK117C1 5626025 EU TMECA ARRIEL ARRIEL1 60030 NE ANTICIPATOR DEFECTIVE D O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 03 911TG 1378 C555B 7506 18019 IN CRUISE FLIGHT, 60 PERCENT TORQUE WHEN ENGINE IS BEEPED TO 100 PERCENT, N2 TORQUE DROPS OFF 40 PERCENT, AND N1 DROPS O FF 10-15 PERCENT. SEEMS TO OPERATE NORMALLY WHEN N2 IS AT 98-99 PERCENT. 1 G 7 2 3U 3 U NC H13EU E19EU 1995111700171 19951117 00171 GL 1995 11 17 HEEA955933 2 19951031 G 7230 23051099 DIFFUSER COVER 23051643 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL COMPRESSOR AIR LEAK E HEEA K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 03 31217 2444 CAC91772 760229 CAE890786S ENGNE REMOVED DUE TO LOW POWER AND TURBINE OVERHAUL. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: AIR LEAK AT SPLIT LINE OF DIFFUSER COVER PLATE DUE TO EXCESSIVE DOUBLER WELDS. NOTE: REPLACED PART AND CURED PROBLEM. INSTALL ED NEW DIFFUSER COVER PLATE. 1 G 7 2 3U 3 U H1NE E1GL 1995111700624 19951117 00624 SW 1995 11 17 95ZZZX6243 1 19950922 G 6310 289052017 SEAL 2060402703 BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL FREEWHEEL LEAKING B A KUVR K NONE K FLUID LOSS IN INSP/MAINT 1 SO 19 167BH 99 BMB10321 1961 CAE831086 INSTALLED NEW SEAL AFTER INSPECTION OF UNIT. STARTED LEAKING OIL AFTER VERY LITTLE TIME IN SERVICE. SUBMITTER STATED B ELL SEEMS TO HAVE CHANGED MANUFACTURERS. SEAL IS GARLOCK TYPE, BUT BLACK INSTEAD OF USUAL ORANGE COLOR. APPEARS TO BE OF DIFFERENT MATERIAL, HARDER THAN PREVIOUS STYLE. 1 G 7 1 3U 3 U H2SW E4CE 1995111700626 19951117 00626 NE 1995 11 17 95ZZZX6245 2 19950731 G 7322 76081 DRIVE SHAFT 106500A2 KAMAN K1200 K1200 05625F6 SW LYC T53 T5317A 41549 NE FUEL CONTROL DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 NE 03 692 9ADS1682 TA-7 FUEL CONTROL, TIP SEAL PUMP EQUIPPED, WAS FOUND TO HAVE WORN SPLINES. PUMP SECONDARY FUEL FLOW REDUCED TO ZERO PPH . PRIMARY PUMP FLOW REMAINED FULLY FUNCTIONAL. DRIVE SHAFT AND MATING PUMP GEAR SET WERE REPLACED WHILE CONTROL WAS RE TURNED REPAIRED. 1 G 7 1 4F 4 U NT TR7BO E17EA 1995111700628 19951117 00628 NE 1995 11 17 95ZZZX6247 2 19951023 G 7200 ENGINE CNDAIR CL601 CL6013A 8070802 EA GE CF34 CF343A 30015 NE RT POSITION VIBRATION C O OTHER E VIBRATION/BUFFET TO TAKEOFF 1 EA 25 399SW 3482 482 5009 350246RH NR 2 ENGINE ON TAKEOFF EXPERIENCED HIGH VIBRATION LIGHT AND READING OF 2.1. PERFORMED ENGINE RUN WITH ANTI-ICE SELECTED AND VIBES AT 1.8. PERFORMED BORESCOE OF RT ENGINE. NO ABNORMALTIES. NOTIFIED GE PER MM 72-00-00, PAGE 517, WITHIN OP S LIMITS. AS PRECAUTIONARY, DELIVERED AIRCRAFT TO GE FOR INSPECTION. FOUND PARTIAL FLAKING OF COATING FROM COMB GEAR. INSTALLED LOANER ENGINE. OPS NORMAL. 2 L 7 2 4F 4 F RT A21EA E15NE 1995112400246 19951124 00246 EA 1995 11 24 95ZZZX6302 2 19951017 G 8530 SL73806 PUSHROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 1 CYL INTAKE LOOSE B EBVR K NONE O OTHER IN INSP/MAINT 1 GL 09 6449M 1112 15284733 L217711 DURING ROUTINE INSPECTION, A VALVE GUIDE CLEARANCE CHECK WAS DONE. THE NR 1 CYLINDER INTAKE PUSHROD WAS FOUND TO HAVE T HE STEM LOOSE. IT COULD EASILY BE REMOVED BY HAND. THIS PART IS NORMALLY A PRESS-FIT AND IS NOT REMOVABLE. REPLACED W ITH NEW. 1 H 7 1 3O 3 O NT 3A19 E223 1995112400247 19951124 00247 SO 1995 11 24 95ZZZX6303 2 19950925 G 8540 643259A2 ADAPTER ASSY CESSNA 421 421C 2076016 CE CONT O520 GTSIO520N 17032 SO STARTER FAILED B PAIR K NONE O OTHER IN INSP/MAINT 1 SO 05 2683Y 506 421C1218 277061R THE OPERATOR INCURRED A STARTER ADAPTER FAILURE THAT CONTAMINATED THE ENGINE. DISASSEMBLY OF THE ENGINE REVEALED THAT B EARING, PN 537721, HAD FAILED FIRST CAUSING THE STARTER ADAPTER TO BIND AS IT ROTATED WHICH CAUSED IT TO FAIL. THE ADAP TER HAD BEEN REMOVED AND REINSTALLED PRIOR TO THIS FAILURE TO C/W SB. DURING INSTALLATION OF THE STARTER ADAPTER, THE B EARING WAS PROBABLY DAMAGED CAUSING THE CHAIN OF EVENTS TO OCCUR. 1 L 7 2 3O 3 O A7CE E7CE 1995112400262 19951124 00262 NE 1995 11 24 95ZZZX6318 2 19951027 G 7210 7757591 BEARING HAMSTD GC49 SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE PROP SHAFT SPALLED B SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 587MA 11298 371 9129 340B166 GEAR CASE RETURNED FROM FIELD DUE TO 'MAKING METAL'. DISASSEMBLY REVEALED THE BALL BEARING, PN 775759-1, ON THE MAIN PRO PELLER SHAFT HAD FAILED. REFERENCE CMM 72-11-02. 2 L 7 2 4T 4 T RT A52EU E8NE 1995112400263 19951124 00263 NE 1995 11 24 95ZZZX6319 2 19951027 G 7210 7895781 TAB WASHER HAMSTD GC49 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GEAR CASE FAILED B SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 7552 6747 UDA60542 GEE785360 GEAR CASE WAS RECEIVED DUE TO IDLER GEAR SHIFTED FORWARD WHICH RESULTED IN WEARING A HOLE THROUGH THE FORWARD GEAR CASE HOUSING. DISASSEMBLY REVEALED THE RIGHT IDLER GEAR NUT, PN 775770-1, HAD COME OFF THE RT IDLER GEAR, PN 775754-5. THE TABS ON THE TAB WASHER HAD FAILED ALLOWING THE NUT TO COME OFF THE IDLER GEAR. REFERENCE CMM 72-11-02. 2 L 7 2 4T 4 T RT A52EU E8NE 1995112400267 19951124 00267 GL 1995 11 24 95ZZZX6323 2 19951103 G 7230 6877410 CASE HALF HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL COMPRESSOR CRACKED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 4571V 559 13287 490487D CAE830976 INSPECTED CASE HALVES AT ANNUAL, FOUND PLASTIC CRACKED BEYOND LIMITS WITH SOME MATERIAL MISSING. 1 G 7 1 3U 3 U H3WE E4CE 1995112400269 19951124 00269 GL 1995 11 24 95ZZZX6325 2 19951024 G 7200 ENGINE BELL 206 206B 1181511 SW ALLSN 250C 250C20J 03013 GL POWER SECTION MAKING METAL B DFUR A UNSCHED LANDING J WARNING INDICATION NR NOT REPORTED 1 SO 09 67773 72 5205 CAE272716 PILOT REPORTED ENGINE CHIP LIGHT. PRECAUTIONARY LANDING COMPLETED OK. EVALUATION OF ENGINE REVEALED EXCESSIVE METAL IN SCREEN AND CHIP PLUG. 1 G 7 1 3U 3 U H2SW E4CE 1995112400282 19951124 00282 NE 1995 11 24 HEEA956049 2 19951115 G 7200 0292005220 ENGINE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE FUEL CONTROL MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6095S 1215 2777 DURING ENGINE START, WHEN THE START BUTTON IS PRESSED AND FFC LEVER WAS ADVANCED, NORMAL IGNITION AND ACCELERATION WOULD OCCUR UNTIL REACHING 25 TO 30% NG. AT THAT TIME ACCELERATION WOULD ALMOST STOP. THE ENGINE WOULD NOT ACCELERATE UNLES S THE T4 WAS KEPT AT THE TOP OF THE GREEN ARC. EVEN THEN ACCELERATION TO 40% WAS VERY SLOW. WHEN ENGINE WAS COLD, ACCE LERATION TO 40% WOULD TAKE 45 TO 65 SEC. WHEN ENGINE WAS WARM ACCELERATION TO 40% TOOK 35 TO 40 SEC. 1 G 7 1 3U 3 U H9EU E19EU 1995112400283 19951124 00283 NE 1995 11 24 HEEA956050 2 19951115 G 7200 0292005220 ENGINE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE CHIP PLUG MAKING METAL E HEEA K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 03 6097Z 1089 2820 ENGINE CHIP LIGHT. FOUND TINY AMOUNT FERROUS SHINY FUZZ ON LOWER CHIP PLUG. FILTER HAD SMALLER AMOUNT OF SAME TYPE OF FUZZ. CLEANED AND COMPLIED WITH 30 MINUTE PENALTY RUN. ON REAR BEARING ELEC. PLUG FOUND TINY FERROUS SPECKS (ABOUT 15 EA)REINSTALLED ALL CHIP PLUGS. COMPLIED WITH ANOTHER 30 MINUE PENALTY RUN. REAR BEARING CHIP PLUG HAD 10 FERROUS SPECK S AND THE OTHER 4 DETECTORS HAD 2-5 EACH SPECKS. 1 G 7 1 3U 3 U H9EU E19EU 1995112400293 19951124 00293 EA 1995 11 24 95ZZZX6331 2 19950915 G 7230 310830101 BLADE 3031811 PWA PT6 PT6A65B 52043 EA CT DISK MISMANUFACTURED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 FIFTY-NINE EACH CT BLADES RECEIVED FROM PWC. INSPECTION OF BLADES REVEALED 1 EACH BLADE MISSING THE CHAMFER ON THE TRAI LING EDGE OF RIVET SLOT. BLADE RETURNED TO PWC FOR CREDIT. 4 T E4EA 1995112400295 19951124 00295 NE 1995 11 24 95ZZZX6333 2 19951012 G 7210 310709001 BEARING PWA 118 PW118 NE RED GEARBOX SPALLED D K NONE O OTHER IN INSP/MAINT 1 SW 05 17940 1317 RGB115071 THE REDUCTION GEARBOX HAD REPORTED METAL IN OIL. REDUCTION GEARBOX WAS REMOVED FROM SERVICE AND SENT TO AVIALL FOR OVER HAUL. CAUSE OF MIO WAS SPALLED NR 19 BEARING. 4 T E20NE 1995112400297 19951124 00297 EA 1995 11 24 95ZZZX6335 2 19951020 G 8520 77416 PLUG HUGHES 269 269C 4470504 WP LYC O360 HIO360C1A 41514 EA CRANKSHAFT MISSING B HIAR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 27 61463 0003 L3448336A LOWER PULLEY (CRANK) PLUG MISSING. STANDARD OIL PLUG INSTALLED IN ENGINE. LYCOMING P/N 77416 SHOULD BE INSTALLED IN EN GINES ON 269 SERIES HELICOPTERS PER LYCOMING SI 1180B. INSTALLED SCHWEIZER PLUG, PN 269A5513. 1 G 7 1 3O 3 O 4H12 1E10 1995112400300 19951124 00300 EA 1995 11 24 95ZZZX6338 2 19951020 G 8520 77416 PLUG HUGHES 269 269C 4470504 WP LYC O360 HIO360C1A 41514 EA CRANKSHAFT MISSING B HIAR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 27 61416 0006 L3448536A LOWER PULLEY (CRANK) PLUG MISSING. STANDARD OIL PLUG INSTALLED IN ENGINE. LYCOMING P/N 77416 SHOULD BE INSTALLED IN EN GINES ON 269 SERIES HELICOPTERS PER LYCOMING SI 1180B. INSTALLED SCHWEIZER PLUG, PN 269A5513. 1 G 7 1 3O 3 O 4H12 1E10 1995112400301 19951124 00301 EA 1995 11 24 95ZZZX6339 2 19951020 G 8520 77416 PLUG HUGHES 269 269C 4470504 WP LYC O360 HIO360C1A 41514 EA CRANKSHAFT MISSING B HIAR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 27 61447 0007 L3448736A LOWER PULLEY (CRANK) PLUG MISSING. STANDARD OIL PLUG INSTALLED IN ENGINE. LYCOMING P/N 77416 SHOULD BE INSTALLED IN EN GINES ON 269 SERIES HELICOPTERS PER LYCOMING SI 1180B. INSTALLED SCHWEIZER PLUG, PN 269A5513. 1 G 7 1 3O 3 O 4H12 1E10 1995112400302 19951124 00302 EA 1995 11 24 95ZZZX6340 2 19951020 G 8520 77416 PLUG HUGHES 269 269C 4470504 WP LYC O360 HIO360C1A 41514 EA CRANKSHAFT MISSING B HIAR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 27 61458 0008 L3447736A LOWER PULLEY (CRANK) PLUG MISSING. STANDARD OIL PLUG INSTALLED IN ENGINE. LYCOMING P/N 77416 SHOULD BE INSTALLED IN EN GINES ON 269 SERIES HELICOPTERS PER LYCOMING SI 1180B. INSTALLED SCHWEIZER PLUG, PN 269A5513. 1 G 7 1 3O 3 O 4H12 1E10 1995120100047 19951201 00047 NE 1995 12 1 95ZZZX6347 2 19950804 G 7323 25249994 GOVERNOR BENDIX BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE NR 1 ENGINE FAILED A HEEA A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 SW 03 5736J 7897 1742 A61467 31140 CPPS63158 AIRCRAFT DEPARTED FOR OFFSHORE. OUTBOARD NR 1 ENGINE EXPERIENCED A LOW SIDE GOVERNOR FAILURE. RETURNED AND LANDED WITH OUT INCIDENT. REPLACED GOVERNOR ASSY. PT6 IPC, CHAPTER 72-10-30, FIGURE 1, ITEM 20C. 1 G 7 1 4U 4 U H4SW E22EA 1995120100061 19951201 00061 WP 1995 12 1 95ZZZX6361 2 19951023 G 7230 3073330 SEAL/RING LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP HP COMPRESSOR LEAKING A ROSA A UNSCHED LANDING B K SMOKE/FUMES/ODORS/SPARKS FLUID LOSS CL CLIMB 1 SW 01 135DE 1466 667 P89726 ABQ - AIRCRAFT EXPERIENCED SMOKE IN CABIN IMMEDIATELY AFTER TAKEOFF. FLIGHT CREW FOLLOWED EMERGENCY PROCEDURES AND LAND ED WITHOUT INCIDENT. BORESCOPE INSPECTION OF RIGHT ENGINE REVEALED 4/5 BEARING SEALS LEAKING OIL INTO COMPRESSOR SECTIO N. RIGHT ENGINE WAS REMOVED FROM SERVICE. NOTE: THIS IS A FOLLOW-UP REPORT SUBMITTED 10-23-95. 2 L 7 2 4F 4 F A10CE E6WE 1995120100181 19951201 00181 SO 1995 12 1 95ZZZX6379 2 19951024 G 7414 1035716520S COIL 105136539 CESSNA 172 172G 2072420 CE CONT O300 O300D 17022 SO ENG LT MAG OPEN H K NONE O OTHER NR NOT REPORTED 1 NM 09 6070R 80 K059203D 17253739 O25651R LEFT MAGNETO FAILURE DUE TO OPEN IN SECONDARY WINDING OF THE COIL. 1 H 7 1 3O 3 O NT 3A12 E253 1995120100182 19951201 00182 EA 1995 12 1 95ZZZX6380 2 19951024 G 7414 10391088 COIL 103493652 PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA ENG LT MAG FAILURE D K NONE O OTHER NR NOT REPORTED 1 NM 09 2086T 51 A08997 28R7135030 L760051A LEFT MAGNETO FAILURE DUE TO COIL FAILURE (SECONDARY WINDINGS OPEN). 1 L 7 1 3O 3 O 2A13 1E10 1995120100183 19951201 00183 SO 1995 12 1 95ZZZX6381 2 19951017 G 8530 632585 PISTON CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO LT/RT ENGINE WRONG PART D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 3380Q 328 421B0264 600218 FOUND 11 OUT OF 12 CYLINDERS WITH THIS P/N PISTON WHICH IS NOT APPROVED FOR USE IN GTSIO520 ENGINES. PISTONS WERE SENT FROM ECI AS PART OF A GTSIO-520 CYLINDER ASSY. P/N 632585 CYLINDER IS DOMED WITH NO STEEL INSERT FOR THE TOP RING GROOV E. THE CORRECT PISTON FOR THE GTSIO520 ENGINE IS FLAT WITH A STEEL INSERT. ONE PISTON WAS CORRECT ON LT ENGINE, BUT TH IS WOULD CAUSE AN OUT OF BALANCE CONDITION. 1 L 7 2 3O 3 O A7CE E7CE 1995120100185 19951201 00185 SO 1995 12 1 95ZZZX6383 2 19951017 G 8530 642344RB CYLINDER CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO CYLS 1,2,6 CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 11 3380Q 328 421B0264 600218 FOUND THREE CYLINDERS CRACKED BETWEEN THE SPARK PLUG AND INJECTOR HOLES. SUBMITTER STATED CRACKS MAY BE CAUSED BY OVERT ORQUING THE INJECTOR NOZZLES OR POSSIBLY EXCESSIVE VIBRATION. 1 L 7 2 3O 3 O A7CE E7CE 1995120100192 19951201 00192 EA 1995 12 1 95ZZZX6390 2 19951026 G 7414 1068291013 MAGNETO LYC O540 TIO540* 41532 EA RETARD GAP MISOVERHAULED D K NONE O OTHER IN INSP/MAINT 1 SO 01 L149409GR RECEIVED ZERO TIME REBUILT MAG FROM TCM. RETARD POINTS WERE SET TO BOOK SPECS OF 11 DEGREES, BUT RETARD POINTS GAP WAS .004 INCH. BOOK SPEC IS .016 PLUS OR MINUS .004 INCH. THIS MAG BUILT UNDER WORK ORDER NR 862174-2, AND MAINTENANCE REL EASE IS DATED 12-14-94. 3 O E14EA 1995120100194 19951201 00194 SO 1995 12 1 95ZZZX6392 2 19951013 G 8540 635050 STARTER DRIVE CONT O470 O470L 17026 SO ENGINE HOUSING BROKEN D K NONE O OTHER IN INSP/MAINT 1 AL 03 220 691041LR STARTER DRIVE HOUSING CRACKED. SUBMITTER SUSPECTS BACKFIRING DURING STARTING. 3 O E273 1995120100302 19951201 00302 EA 1995 12 1 95ZZZX6402 2 19951023 G 8530 L12215 CYLINDER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA LT ENG NR 5 EXH BOSS BROKEN B EKIR K NONE O OTHER IN INSP/MAINT 1 WP 07 26556 326 31P7400184 L13962 NR 5 CYLINDER ON LT ENGINE INBOARD EXHAUST ROCKER SHAFT ARM BOSS BROKE OFF CYLINDER. NO EVIDENCE OF PREVIOUS CRACK. NO INDICATION OF VALVE CONTACTING PISTON. SUSPECT CASTING DEFECT AT MANUFACTURER. 1 L 7 2 3O 3 O A8EA E19EA 1995120100307 19951201 00307 EA 1995 12 1 95ZZZX6408 2 19950811 G 7414 D4RN2000 MAGNETO BENDIX BEECH 76 76 1153005 CE LYC O360 LIO360A1G6 41515 EA ENGINE DEFECTIVE B VT3R K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 09 6013X 360 4071459 ME113 RL57871A REMOVED MAGNETO DURING INSPECTION OF ROUGH ENGINE. FOUND BOTH CONTACT POINTS WORN, BOTH COILS CRACKED AT CENTER POST, L EFT DISTRIBUTOR ARCED, IMPROPER LUBRICATION OF BEARINGS CAUSING GREASE TO BE SLUNG OUT, CAM LOBES HAVE VERY ROUGH FINISH . 1 L 7 2 3O 3 O A29CE 1E10 1995120100308 19951201 00308 SO 1995 12 1 95ZZZX6409 2 19951101 G 7414 6320 MAGNETO PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO LT/RT MAG CORRODED B DECR K NONE O OTHER IN INSP/MAINT 1 GL 19 511PJ 144 4608029 528437 REMOVED MAGS AND OPENED UP FOR CORROSION INSPECTION PER OWNER'S REQUEST. BOTH MAGS WERE FULL OF CORROSION OF ALL METAL SURFACES. MAGS WERE INSTALLED NEW 11/94 FOR SAME REASON. FILTERS CHANGED REGULARLY. 1 L 7 1 3O 3 O A25SO E8CE 1995120100309 19951201 00309 EA 1995 12 1 95ZZZX6410 2 19950928 G 8530 73806P PUSHROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 4 CYL INTAKE CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 07 45905 1974 15282942 L2321515 ANNUAL INSPECTION FOUND NR 4 INTAKE PUSHROD TO HAVE .75 INCH CRACK AT ROCKER ARM END. REFERENCE AD 80-25-02R2, AD 95-03 -10, LYCOMING SB 453 AND LYCOMING SI 2388A. PART TOTAL TIME, 1,973.6 HOURS. 1 H 7 1 3O 3 O NT 3A19 E223 1995120100311 19951201 00311 CE 1995 12 1 95ZZZX6412 1 19951003 G 8120 4708369018 CONTROLLER CESSNA 414 414 2075908 CE CONT O520 TSIO520NB 17040 SO LT ENG WASTEGATE OIL LEAK B SJ7R K NONE K FLUID LOSS IN INSP/MAINT 1 SO 01 28901 329 XI009705 4140353 290758R WASTEGATE CONTROLLER OIL LEAKING FROM CENTER PISTON. 1 L 7 2 3O 3 O RT A7CE E8CE 1995120100315 19951201 00315 SO 1995 12 1 95ZZZX6416 2 19951101 G 8520 6524201048 THROUGH BOLT PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO NR 2,3 CYLS BASE BROKEN B DECR K NONE K FLUID LOSS IN INSP/MAINT 1 GL 19 2900D 347970341 307745 CRANKCASE 'THROUGH' BOLTS, UPPER AND LOWER FOR NR 2 AND NR 3 CYLINDERS, BROKEN AT CYLINDER BASE NUTS. LOCATED AFTER REP ORTED OIL LEAK. ENGINE TT 3,816.90 HOURS. TSMOH, 535.63 HOURS. 1 L 7 2 3O 3 O A7SO E9CE 1995120800132 19951208 00132 EA 1995 12 8 95ZZZX6465 2 19951001 G 7321 DPF2 FUEL CONTROL BENDIX PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA FCU TO PUMP SHAFT BROKEN B DDNR E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 GL 27 29CA A7784 317T78120076 AIRCRAFT WAS CRUISING AT 20,000 FEET AND PILOT NOTICED ITT, NG, AND FUEL FLOW RISE DRAMATICALLY. TRIED TO PULL POWER BA CK, BUT HAD NO CONTROL OVER ENGINE WITH POWER LEVER. ENGINE WAS SHUT DOWN IN-FLIGHT. FOUND FCU TO FUEL PUMP INTERCONNE CT SHAFT BROKEN. FUEL CONTROL UNIT SHAFT WAS SEIZED. 1 L 7 2 3T 4 T A8EA E4EA 1995120800163 19951208 00163 GL 1995 12 8 95ZZZX6497 2 19950601 G 7261 6876925 OIL TUBE BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 2907T S577 CAE834920 OIL TUBE FAILED INSPECTION REQUIRED BY CEB1307. REMOVED AND REPLACED. 1 G 7 2 3U 3 U H3EU E4CE 1995120800165 19951208 00165 NE 1995 12 8 95ZZZX6499 2 19951006 G 7412 9580113800 H. E. GENERATOR AEROSP SA365 SA365N1 8680668 EU TMECA ARRIEL ARRIEL1C 60030 NE ENGINE IGN DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 365SC 333 6656 6298 5028 INTERMITTENT OPERATION OF H.E. GENERATOR. 1 G 7 2 3U 3 U H10EU E19EU 1995120800255 19951208 00255 GL 1995 12 8 HEEA956080 2 19951121 G 7230 6890502 BLADE 6890550 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL 3RD STAGE FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 7062X 1358 CAC41432 S793 CAE836134 ENGINE REMOVED DUE TO #1 BEARING OIL LEAK AND 3RD STAGE COMPRESSOR BLADE FAILURE. UPON INSPECTION OF COMPRESSOR PARTS N OTED THE FOLLOWING: ONE EACH BLADE BROKEN OFF ON 3RD STAGE WHEEL. SECONDARY DAMAGE -- 4TH STAGE WHEEL P/N 6876654, S/N ER58760SCRAPPED DUE TO F.O.D. -- 5TH STAGE WHEEL P/N 6876655, S/N KR42186 SCRAPPED DUE TO F.O.D.-- CASE HALF ASSY P/N 6877410, S/N 16779 SENT FOR REPAIR DUE TO F.O.D. NOTE: FRONT SUPPORT P/N 6890530 S/N 39066 SCRAPPED DUE TO LEA KING DURINGPRESSURE CHECK. PARTS SCRAPPED. 1 G 7 2 3U 3 U H3EU E4CE 1995120800311 19951208 00311 GL 1995 12 8 HEEA956137 2 19951122 G 7510 1092T1002W SERVOMOTOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ANTI ICE STICKS E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 6607K S841 STICKING ANTI-ICE ACTUATOR. 1 G 7 2 3U 3 U H3EU E4CE 1995120800327 19951208 00327 GL 1995 12 8 HEEA956156 2 19951129 G 7230 23056634 GEARSHAFT 23051643 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL SPUR ADAPTER STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5128 644 CAC90014 760181 CAE890014S ENGINE REMOVED DUE TO CYCLED OUT WHEELS. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIM ITS ON SPUR ADAPTER GEARSHAFT FORWARD AND AFT SPLINES. NEW PART INSTALLED. 1 G 7 2 3U 3 U H1NE E1GL 1995120800328 19951208 00328 GL 1995 12 8 HEEA956157 2 19951129 G 7230 23056634 GEARSHAFT 23033193 BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL SPUR ADAPTER STEPWEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 8592X 816 CAC90959 51508 CAE890638 ENGINE REMOVED DUE TO TURBINE OVERHAUL AND COMPRESSOR 1750 HOUR INSPECTION. UPON INSPECTION OF COMPRESSOR PARTS NOTED T HE FOLLOWING: STEP WEAR BEYOND LIMITS ON SPUR ADAPTER GEARSHAFT FORWARD AND AFT SPLINES. NEW PART INSTALLED. 1 G 7 1 3U 3 U H2SW E1GL 1995120800329 19951208 00329 GL 1995 12 8 HEEA956158 2 19951129 G 7260 23053968 SEAL 23053960 ALLSN 250C 250C30G2 03013 GL GEARBOX OIL LEAK E HEEA K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 1204 CAG98241 CAE898241 ENGINE REPAIRED DUE TO OIL LEAK AND 300 HOUR INSPECTION. UPON INSPECTION OF GEARBOX PARTS NOTED THE FOLLOWING: 1) OIL LEAKING FROM PTO MAG SEAL 2) EXCESSIVE WEAR ON SPACER. SEE MMIR #6159 FOR SPACER INFORMATION. 3 U E1GL 1995120800330 19951208 00330 GL 1995 12 8 HEEA956159 2 19951129 G 7260 23059575 SPACER 23053960 ALLSN 250C 250C30G2 03013 GL GEARBOX WORN E HEEA K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 1204 CAG98241 CAE898241 ENGINE REPAIRED DUE TO OIL LEAK AND 300 HOUR INSPECTION. UPON INSPECTION OF GEARBOX PARTS NOTED THE FOLLOWING: 1) OIL LEAKING FROM PTO MAG SEAL 2) EXCESSIVE WEAR ON SPACER. 3 U E1GL 1995120800331 19951208 00331 GL 1995 12 8 HEEA956160 2 19951129 G 7250 23001977 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 3RD STAGE BLADE DAMAGE E A HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 21240 558 CAT70404 45647 CAE860702 ENGINE REMOVED DUE TO LOUD GRINDING NOISE, HIGH PITCH SQUEAL ACCOMPANIED BY TORQUE FLUCTUATIONS. UPON INSPECTION OF TUR BINE PARTS NOTED THE FOLLOWING: RIM BREAKOUT OF 1 1/2" AND 1/4" OF TWO EACH BLADES ON 3RD STAGE WHEEL. SUSPECT CAUSE O F FAILURE TO BE A STRESS CRACK ORIGINATING ON THE LEADING EDGE SIDE OF BREAKOUT IN REFERENCE TO DIRECTION OF ROTATION, O N THE TRAILING EDGE OF RIM SHROUD AND PROGRESSED APPROXIMATELY 1/2 OF CHORDAL LENGTH UNTIL OVERLOAD. SECONDARY DAMAGE - P.T.SECTION EXHIBITS EXCESSIVE KNIFE AND SEAL CONTACT AND BEARING AREA DAMAGE. 1 G 7 1 3U 3 U H2SW E1GL 1995120800332 19951208 00332 GL 1995 12 8 HEEA956161 2 19951129 G 7250 23001977 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 3RD STAGE DAMAGED E A HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 27702 636 CAT70741 45300 CAE860520 ENGINE REMOVED DUE TO LOUD ROAR AND WHINE FOLLOWED BY ENGINE CHIP LIGHT. UPON INSPECTION OF TURBINE PARTS NOTED THE FOL LOWING: RIM BREAKOUT OF 1 3/4" AND 1/4" OF THREE EACH BLADES ON 3RD STAGE WHEEL. SUSPECT CAUSE OF FAILURE TO BE A STRE SS CRACK ORIGINATING ON THE LEADING EDGE SIDE OF BREAKOUT IN REFERENCE TO DIRECTION OF ROTATION, ON THE TRAILING EDGE OF RIM SHROUD AND PROGRESSED APPROXIMATELY 1/2 OF CHORDAL LENGTH UNTIL OVERLOAD. SECONDARY DAMAGE - P.T. SECTION EXHIBITS EXCESSIVE F.O.D., KNIFE AND SEAL CONTACT AND BEARING AREA DAMAGE. 1 G 7 1 3U 3 U H2SW E1GL 1995120800396 19951208 00396 SO 1995 12 8 95ZZZX6536 2 19951114 G 8520 639200 CRANKSHAFT CONT O360 TSIO360CB 17025 SO FLANGE CRACKED D L K NONE O OTHER IN INSP/MAINT 1 EA 21 6LH R236024R ENGINE WAS WINDMILLING DURING A GEAR-UP LANDING (10-11-95) AT ROCKY MOUNTAIN AIRCARE. REPAIRED BELLY AND HAD PROP OVERH AULED AT H & H. REINSTALLED PROPELLER WITH A DIAL INDICATOR RUN-OUT CHK ONLY, WAS RETURNED TO SERVICE AS AIRWORTHY. DU RING THE INSPECTION, THE CRANKSHAFT WAS FOUND CRACKED IN THE RADIUS IMMEDIATELY BEHIND THE PROP FLANGE. SEVERAL CRACKS RUNNING AROUND THE RADIUS EDGE GO APPROXIMATELY 80 PERCENT AROUND THE SHAFT. UPON DISASSEMBLY OF THE ENGINE, THE CRANKC ASE WAS ALSO FOUND CRACKED IN THE FRONT MAIN BEARING SADDLE. 3 O E9CE 1995120800405 19951208 00405 EA 1995 12 8 95ZZZX6545 2 19951026 G 8520 LW18372 CRANKCASE PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ALT MOUNT BOSS CRACKED B OG5R K NONE K FLUID LOSS IN INSP/MAINT 1 GL 21 118ND 3845 650 2841136 L1596139A DURING ENGINE INSPECTION, TECHNICIAN TRACED OIL LEAK TO A CRANKCASE CRACK IN THE AREA OF THE ALTERNATOR MOUNT BOSS. CRA CK IS IN THIS AREA OF RIGHT CRANKCASE HALF LESS THAN .25 INCH FORWARD OF SECOND CRANKCASE BOLT HOLE (FROM FRONT OF ENGIN E). NEW ENGINE BEING INSTALLED. 1 L 7 1 3O 3 O 2A13 E274 1995120800406 19951208 00406 EA 1995 12 8 95ZZZX6546 2 19951021 G 8530 LW19001 VALVE PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA NR 3 CYL EXHAUST BROKEN G A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 CE 05 6932W 1589 2821290 L1587427A ENGINE - NR 3 EXHAUST VALVE BROKE (STEM INTACT) CAUSING ENGINE FAILURE AND RESULTNG IN EMERGENCY LANDING/ACCIDENT. ANNUA L INSPECTION ACCOMPLISHED OCTOBER 6, 1995. HAD NOT FLOWN FROM 6-26-91 THROUGH 6-26-95. FOUR YEARS OF INACTIVE FLIGHT T IME. 1 L 7 1 3O 3 O 2A13 E274 1995120800407 19951208 00407 SO 1995 12 8 95ZZZX6548 2 19951113 G 8530 648044 PISTON CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO NR 4 FAILED D A UNSCHED LANDING J WARNING INDICATION NR NOT REPORTED 1 WP 07 6591M 1651 21061980 522628 LOST OIL PRESSURE AND MADE FORCE LANDING, NO DAMAGE TO AIRCRAFT, PILOT OR PASSENGERS. FOUND PISTON FAILED. 1 H 7 1 3O 3 O 3A21 E8CE 1995120800410 19951208 00410 SO 1995 12 8 95ZZZX6551 2 19951107 G 8530 ROCKER SHAFT BEECH 36 A36 1151604 CE CONT O520 IO520BB 17032 SO NR 2 CYL BOLT SHEARED D K NONE O OTHER IN INSP/MAINT 1 WP 07 3853Z E1836 573570 NR 2 CYLINDER VALVE COVER REMOVED FROM PUSHROD TUBE SEAL REPLACEMENT. FOUND FORWARD ROCKER SHAFT THROUGH-BOLT IN 3 PIEC ES. BOLT SHEARED FLUSH IN CYL HEAD, ALSO, INSIDE ROCKER SHAFT. APPROX .3125 INCH HOLE IN FWD SHAFT HOLDER WAS FND ENLA RGED TO .50 INCH. ENG TIME SINCE TOP OVERHAUL, 450 HRS AT WHICH TIME TAPERED ROCKER SHAFTS WERE INSTALLED PER TCM SB. E NG TT, 2,000 PLUS HRS. CUSTOMER STATED OIL ANALYSIS SHOWED HIGH ALUM AND FERROUS MATERIALS. SUSPECT OVERTORQUING TO BE CAUSE OF PROBLEM. REPLACED CYL WITH RE-WORKED CYL. ALSO, INSPECTED REMAINING CYLINDERS, NO DEFECTS NOTED. 1 L 7 1 3O 3 O 3A15 E5CE 1995120800411 19951208 00411 EA 1995 12 8 95ZZZX6552 2 19951101 G 8530 77160S GUIDE MOONEY M20 M20M 5870222 SW LYC O540 TIO540AF1A 41532 EA NR 3 EXH VALVE EXCESS WEAR D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 99 505RD 281 270143 L937061A PILOT EXPERIENCED ROUGH ENGINE ON RUN-UP. PERFORMED COMPRESSION TEST AND FOUND CYLINDER NR 3 HAD ZERO COMPRESSION. UPO N REMOVAL OF CYLINDER, FOUND EXHAUST VALVE MISSING APPROX ONE-THIRD OF FACE AREA. FURTHER INSP REVEALED EXCESSIVE WEAR OF GUIDE. OTHER FIVE CYLINDERS HAD EXCESSIVE GUIDE WEAR ALSO. LYCOMING SB NR SB503 ISSUED IN 1992 CALLS FOR REPLACEMEN T OF EXHAUST GUIDES WITH NEW P/N LW-19001 FOR ENGINE S/N'S THROUGH L-9293-61A. AFFECTED CYLINDERS FALL OUTSIDE OF THIS S/N RANGE. 1 L 7 1 30 3 O RT 2A3 E14EA 1995120800414 19951208 00414 EA 1995 12 8 95ZZZX6555 2 19951115 G 8520 CRANKCASE PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA NR 1 CYLINDER CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 05 29296 2778 551 287990447 L2865836A DISCOVERED A 3 INCH LONG CRACK IN ENGINE CASE BELOW NR 1 CYLINDER WHILE INVESTIGATING AN OIL LEAK. 1 L 7 1 3O 3 O 2A13 E286 1995120800416 19951208 00416 SO 1995 12 8 95ZZZX6557 2 19950616 G 8540 628760 INDICATOR 635050A4 CESSNA 185 A185E 2072818 CE CONT O520 IO520D 17032 SO ENG TIMING PLATE DEFECTIVE D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 07 1997U 300 18501766 175979R WHILE CHECKING MAGNETO TO ENGINE TIMING, DISCOVERED WHEN THE TIMING MARK ON THE ALTERNATOR DRIVE SHEAVE, P/N 635165, WAS LINED UP WITH THE TIMING MARKS ON THE ENGINE TIMING INDICATOR PLATE, THE CRANKSHAFT POSITION WAS 10 DEGREES ADVANCED OF THE POSITION INDICATED. THESE TIMING MARKS WERE USED TO SET IGNITION TIMING AND THE TIMING WAS FOUND 10 DEGREES ADVANC ED FROM ITS NORMAL 22 DEGREE POSITION, RESULTING IN AN UNAIRWORTHY CONDITION. TCM SB M84-8 ADDRESSES THIS PROBLEM BY RE QUIRING THE INDICATOR PLATE TO BE REMOVED AND THE TIMING PROCEDURE IN SB M94-8 USED INSTEAD. 1 H 7 1 3O 3 O 3A24 E5CE 1995120800425 19951208 00425 SO 1995 12 8 95ZZZX6566 2 19951122 G 7414 0703200MJ3A FILTER CESSNA 310 310P 2074238 CE CONT O470 IO470VO 17026 SO MAG P-LEAD DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 NM 08 55DP 310P0038 FOUND MAGNETO FILTER DEFECTIVE WHEN SUBJECT TO MAGNETO P-LEAD VOLTAGE OR HIGH TENSION LEAD TESTER VOLTAGE. REGULAR OHM CHECK DID NOT PICK UP DEFECT. ENGINE WOULD RUN INTERMITTENTLY BAD ON THIS MAGNETO. THIS IS AN AFTER-MARKET PART INSTAL LED IN LINE WITH P-LEADS TO REDUCE MAGNETO P-LEAD VOLTAGE INTERFERENCE. 1 L 7 2 3O 3 O 3A10 3E1 1995120800429 19951208 00429 EA 1995 12 8 95ZZZX6570 2 19951018 G 8530 CYLINDER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 2 CRACKED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 03 757BG 4744 1358 15279605 RL1524115 LOSS OF POWER AND ENGINE ROUGHNESS WAS REPORTED. UPON INSPECTION, CYLINDER NR 2 WAS FOUND TO HAVE LOW COMPRESSION. FUR THER INSPECTION LED TO FINDING A CRACK APPROXIMATELY ONE-HALF WAY AROUND THE CIRCUMFERENCE OF THE CYLINDER BETWEEN THE F INS AT THE JUNCTION OF THE HEAD AND BARREL. CYLINDER WAS REPLACED AND ENGINE WAS RETURNED TO SERVICE. CYLINDER WAS BOR ED .010 INCH. 1 H 7 1 3O 3 O NT 3A19 E223 1995120800434 19951208 00434 EA 1995 12 8 95ZZZX6575 2 19950925 G 7322 MA4SPA CARBURETOR TUBE CESSNA 172 172 2072402 CE LYC O320 O320E2D 41508 EA ACCEL DISCHARGE MISSING D K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 15 12805 2125 BL2010704 17262275 L3514627A PILOT SAID THE ENGINE HAD A LOSS OF POWER AND IT WAS HARD TO START. ENGINE WAS REMOVED FOR OVERHAUL WITH 2125 TSO. WHE N THE CARBURETOR WAS REMOVED, IT WAS NOTICED THE ACCELERATOR DISCHARGE TUBE WAS MISSING. SUBMITTER SUSPECTED REASON FOR LOSS OF TUBE WAS CARBURETOR FIRE. 1 H 7 1 3O 3 O NT 3A12 E274 1995120800438 19951208 00438 NE 1995 12 8 95ZZZX6579 2 19951117 G 7510 37B201215P10 HOSE LEAR 25 25D 5170514 CE GE CJ610 CJ6108 30006 NE LT NAC AI TUBE FAILED D K NONE O OTHER LD LANDING 1 SW 15 1U 4798 371 E311328A PILOT STATED LT NACELLE ANTI-ICE INOP AND TRIPPING CIRCUIT BREAKER ON LANDING. AFTER REMOVAL OF TOP COWLING, FOUND HOSE CONNECTING ANTI-ICE TUBE AND ANTI-ICE TEE TUBE WAS TORN IN HALF CAUSING EXPELLED BLEED AIR TO DISCONNECT ANTI-ICE VALVE POWER WIRE FROM CANNON PLUG AND GROUND TO ENGINE. ALSO, ANTI-ICE TUBE WAS CRACKED AT FLANGE TO ANTI-ICE VALVE. 2 L 7 2 4J 4 J A10CE 1E16 1995120800452 19951208 00452 NE 1995 12 8 95ZZZX6593 2 19951009 G 7250 430136201 BEARING BELL 222 222U 1182140 SW LYC LTS101 LTS101650B1 41560 NE TURBINE NR 2 CRACKED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 6992 609 31482 47521 LE47231 UPON DISASSEMBLY OF POWER SECTION FOR REPAIR, NR 2 INNER BEARING WAS FOUND TO HAVE 11 OF 20 CAGE SEPARATORS CRACKED ON F ORWARD SIDE OF AFT 'WINGS'. OHI WO NR 96-894. INSTALLED SERVICEABLE BEARING. 1 G 7 2 3U 3 U H9SW E5NE 1995120800577 19951208 00577 EA 1995 12 8 95ZZZX6609 2 19951016 G 8530 LW11633 CYLINDER CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA NR 4 HEAD CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 19 4973B 50 15283733 INSTALLED CERMICHROME OHL CYLINDERS AT OVERHAUL. AT 50 SMOH, DETECTED A LEAK IN THE NR 4 CYLINDER-HEAD-BARRREL JUNCTION . UPON REMOVAL, OBSERVED A 11 INCH CIRCUMFERENTIAL CRACK 1 INCH FROM THE TOP OF THE BARREL AT THE 6:00 POSITION. 1 H 7 1 3O 3 O 3A19 E223 1995120800579 19951208 00579 SO 1995 12 8 95ZZZX6611 2 19951116 G 8530 VALVE BEECH 36 A36 1151604 CE CONT O550 IO550B SO NR 6 CYLINDER BURNED D O OTHER E R J VIBRATION/BUFFET PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 SW 15 36CL 740 E1980 281855R PILOT REPORTED LOSS OF RPM, ENGINE ROUGHNESS IN CRUISE FLIGHT, CONFIRMED BY EXTREMELY HOT INDICATION ON AIRCRAFT EGT SCA NNER. NR 6 CYLINDER POSITION, FOUND NR 6 CYLINDER EXHAUST VALVE BURNED THROUGH, SEAT DETERIORATED BEYOND LIMITS. REMOV ED NR 4 CYLINDER TO FACILITATE REMOVAL OF NR 6 CYLINDER. FOUND EXHAUST GUIDE WORN BEYOND LIMITS ON NR 4 CYLINDER. INST ALLED NEW FACTORY SUPPLIED CYLINDER NR 6 POSITION AND REWORKED AND INSTALLED NEW GUIDE NR 4 CYLINDER. ENGINE TEST RUN A ND FLOWN. 1 L 7 1 3O 3 O 3A15 E3SO 1995120800580 19951208 00580 EA 1995 12 8 95ZZZX6612 2 19951114 G 7414 D6LN3000 MAGNETO PIPER PA32 PA32RT300 7103215 SO LYC O540 IO540K1G5 41532 EA BASE FLANGE DEFECTIVE E K NONE K FLUID LOSS IN INSP/MAINT 1 EA 05 3421W 400 32R7885276 'ACCESSORY CASE OIL LEAK'. A FACTORY LYCOMING ENGINE HAD A PERSISTENT SLIGHT OIL SEEP AT THE MAGNETO BASE. AFTER REMOV AL, IT WAS FOUND TO HAVE A FLAW IN THE APPARENT CASTING. A LOW SPOT IN THE GASKET AREA ALLOWED OIL TO SEEP BY. PART WA S REPLACED FOR THIS REASON AS WELL AS FLANGE/CLAMP WEAR. 1 L 7 1 3O 3 O A3SO 1E4 1995120800581 19951208 00581 EA 1995 12 8 95ZZZX6613 2 19951113 G 8550 60746 PUMP CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA ENGINE OIL FAILED D A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 NM 09 21329 17263931 L3919527A ENGINE LOST OIL PRESSURE ON DEPARTURE AND RETURNED TO THE AIRPORT. NO INCIDENT OCCURRED. ENGINE WOULD NOT MAKE FULL RP M. PROPELLER STOPPED WHEN POWER REDUCED TO IDLE. SUBMITTER STATED ENGINE WAS OPERATED MOST OF ITS LIFE WITHOUT AN OIL FILTER. RECOMMEND MANDATORY FILTER INSTALLATIONS FOR PROPER ENGINE LIFE. FOUND BROKEN OIL PUMP GEAR, SHEARED PUMP DRIV E, LOST OIL PRESSURE. SPUN ROD BEARINGS. ENGINE TSMOH, 1,970 HOURS. 1 H 7 1 3O 3 O NT 3A12 E274 1995120800582 19951208 00582 CE 1995 12 8 95ZZZX6614 1 19951101 G 7922 53E19600 VALVE CESSNA 172 172F 2072414 CE LYC O360 O360* 41514 EA THERMO BYPASS DEFECTIVE B PB2R K NONE O OTHER IN INSP/MAINT 1 GL 23 5700R 17253350 L1395036A DURING OVERHAUL, THERMOSTATIC BYPASS WAS INSPECTED. IN ADDITION TO CRIMP NUT BEING LOOSE, SNAP RING THAT HOLDS BODY OFF VALVE WAS FOUND TO HAVE EXCESSIVE PLAY. DISSASSEMBLY SHOWED SNAP RING WORN APPROXIMATELY 50 PERCENT AND BRASS PORTION OF PLUNGER THAT IT SEATS ON IS BROKEN. 1 H 7 1 3O 3 O NT 3A12 E286 1995120800585 19951208 00585 EA 1995 12 8 95ZZZX6617 2 19951023 G 8520 CONNECT ROD PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA NR 4 CYLINDER BOLT FAILED G QFGS O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 SW 15 7471J 28R30824 553251A NR 4 CONNECTING ROD CAP CAME OFF. ENGINE FAILED. ENGINE TEAR DOWN REVEALED THAT ONE NUT CAME OFF OF ONE CONNECTING ROD BOLT AND THE OTHER CONNECTING ROD BOLT BROKE. IT WAS ALSO NOTED THAT ONE CONNECTING ROD BOLT WAS MISSING FROM THE NR 2 CONNECTING ROD. THAT NUT WAS FOUND IN SUMP IN SEVERAL PIECES. THE BOLT WAS NOT FOUND. ENGINE TIMES WERE 1,800 HOURS SMOH, 1,000 HOURS STOH. 1 L 7 1 3O 3 O 2A13 1E10 1995120800590 19951208 00590 GL 1995 12 8 95ZZZX6622 2 19951122 G 7250 6898735 TURBINE CAT36372 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL NR 2 NOZZLE CRACKED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 4571V 3776 520 490487D CAE830976 WHILE CHANGING NR 1 NOZZLE, IT WAS DISCOVERED THE NR 2 NOZZLE WAS CRACKED. UNIT WAS SENT IN FOR REPAIR. 1 G 7 1 3U 3 U H3WE E4CE 1995121500244 19951215 00244 SO 1995 12 15 95ZZZX6681 2 19951116 G 8520 633403 CONNECT ROD CESSNA 207 207 2073602 CE CONT O520 IO520F 17032 SO NR 2 CYLINDER FAILED D O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 NM 01 9641M 1116 20700714 291167R NR 2 CONNECTING ROD FAILED. THIS FAILURE CAUSED A HOLE IN CRANKCASE AND OIL BEING SPRAYED EVERYWHERE. 1 H 7 1 3O 3 O A16CE E5CE 1995121500299 19951215 00299 NE 1995 12 15 HEEA956205 2 19951207 G 7210 3024780 GEARBOX BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE COMB GR BOX OIL LEAK E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 22347 15026 36005 OIL TRANSFER FROM #1 ENGINE TO GEARBOX. 1 G 7 2 4U 4 U H4SW E22EA 1995121500454 19951215 00454 SO 1995 12 15 95ZZZX6745 2 19951019 G 8530 SA534610 SEAL BEECH 35 V35A 1151544 CE CONT O470 IO470* 17026 SO NT 5 CYL SHROUD LEAKS B HI1R K NONE K FLUID LOSS IN INSP/MAINT 1 NE 05 168M 5 D8762 SHORTLY AFTER REPLACING A REPAIRED NR 5 CYLINDER, OIL LEAKS DEVELOPED AROUND OUTBOARD ENDS OF SHROUD TUBES. COMPARISON TO ORIGINAL TCM PARTS SHOWED REPLACEMENT SEAL TO BE LARGER IN OUTSIDE DIAMETER CAUSING SEAL NOT TO PROPERLY FIT IN MACHI NED RECESS CAUSING LEAKS. 1 L 7 1 3O 3 O 3A15 E1CE 1995121500468 19951215 00468 EA 1995 12 15 95ZZZX6759 2 19951010 G 7414 M3525 COIL SLICK 4732 CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA LT MAG OPEN D K NONE O OTHER IN INSP/MAINT 1 NM 09 49191 920 91090065 5281184 L1366615 LEFT MAG INOP ON RUN-UP. REMOVED MAGNETO AND DISASSEMBLED. ELECTRICALLY CHECKED COIL AND FOUND OPEN CIRCUIT. REPLACED COIL WITH SERVICEABLE COIL AND OPS CHECK OK. DATE CODE ON FAILED COIL: 9/16/91. 1 H 7 1 3O 3 O NT 3A19 E223 1995121500472 19951215 00472 EA 1995 12 15 95ZZZX6763 2 19951030 G 7310 LW120982194 INJECTOR LINE GULSTM 680 680FL 0141608 SW LYC O720 IO720B1B 41546 EA NR 3 CYL CHAFED D K NONE O OTHER IN INSP/MAINT 1 SW 01 1414S 298 1642122 RL165654A REF TEXTRON SB 342B ISSUED 10-22-93, PAGE 32. CLAMP NR 47, CYL NR 3, RT ENG, FOUND INJECTOR LINE AND IGNITION LEAD BOTH DEEPLY SCORED UNDER CLAMP. SUSPECT CAUSE, INEFFECTIVE CLAMPING ACTION OF CLAMP, PN 71829, WHEN USED WITH SLEEVE TO CLA MP LEAD AND INJECTOR LINE TOGETHER. RECOMMEND USING CLAMP, CW16266-25-13, TO CLAMP INJECTOR LINE BY ITSELF AT ORIGINAL PLACE, AND USE CLAMP, LW16266-25-25, TO CLAMP LEAD TO ADJOINING SCREWS. 1 H 7 2 3O 3 O 2A4 1E15 1995121500473 19951215 00473 SO 1995 12 15 95ZZZX6764 2 19950929 G 8540 642383 SEAL BEECH 36 A36 1151604 CE CONT O520 IO520BB 17032 SO STARTER ADAPTER LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 13 17782 1000 E1024 THE GARLOCK SEAL OR LIPPED SEAL ON THE AIR CONDITIONER PULLEY SHAFT WHICH STICKS OUT THE AFT SIDE OF THE STARTER ADAPTER (THE SHAFT WITH THE CASTELATTED NUT AND COTTER PIN ON THE AFT FORWARD OF IT), WAS LEAKING OIL. HARD TO LOCATE LEAK AT THIS SEAL AS IT LOOKS DRY ALL THE TIME. HAVE FOUND MANY IO520 AND IO550'S LEAKING AT THIS SEAL. SEAL REPLACEMENT STOPS THE LEAK. 1 L 7 1 3O 3 O 3A15 E5CE 1995121500476 19951215 00476 EA 1995 12 15 95ZZZX6767 2 19951031 G 8530 LW12215 CYLINDER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA EXH ROCKER BOSS BROKEN B EKIR K NONE O OTHER NR NOT REPORTED 1 WP 07 26556 327 31P7400184 L13962 EXHAUST VALVE INBOARD ROCKER ARM SHAFT BOSS BROKEN OFF CYLINDER ASSY. ROCKER ARM AND SHAFT LIFTED UP CRACKING CYLINDER ON OUTBOARD SIDE WHERE SHAFT PASSES THROUGH CYLINDER. SUBMITTER SUSPECTED DEFECTIVE CASTING AS THERE IS NO EVIDENCE OF PREVIOUS CRACK. 1 L 7 2 3O 3 O A8EA E19EA 1995121500478 19951215 00478 EA 1995 12 15 95ZZZX6769 2 19951121 G 8530 SL10301A20 CYLINDER BEECH 77 77 1153007 CE LYC O235 O235L2C 41505 EA NR 1,2,3,4, CYLS GLAZED B MGOR K NONE O OTHER IN INSP/MAINT 1 CE 09 18152 101 WA286 L2234915 ENGINE INSTALLED WITH NEW MILLENNIUM CYLINDERS DURING MAJOR OVERHAUL. COMPRESSION CHECKS AFTER 100.5 HOURS REVEALED NR 1 - 52 PSI, NR 2 - 64 PSI, NR 3 - 52 PSI, NR 4 - 72 PSI. ALL CYLINDERS REMOVED FOR REHONING AND PISTONS RE-RINGED. SU BMITTER RECOMMENDS REVISED RUN-IN PROCEDURES AND OPERATING PROCEDURES DURING FIRST 50 HOURS. ENGINE TT, 4051.8 HOURS. 1 L 7 1 3O 3 O A30CE E223 1995121500480 19951215 00480 SO 1995 12 15 95ZZZX6771 2 19951110 G 7414 6320 MAGNETO SLICK CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO RT MAGNETO CORRODED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 CE 01 6086C 961 92080045 21063798 517711 PILOT EXPERIRENCED ROUGH RUNNING ENGINE AFTER DEPARTING AIRPORT. PILOT RETURNED TO AIRPORT AND HAD MAGNETOS CHECKED. B OTH MAGNETOS WERE SEVERELY CORRODED INSIDE. ONE MAGNETO WAS DEAD. PILOT ELECTED TO REPLACE BOTH MAGNETOS WITH NEW UNIT S. THIS IS THREE MAGNETOS IN TWO MONTHS. SUBMITTER SUGGESTS PROBLEM IS CAUSED BY TURBOCHARGER PRESSURIZING AIR AND MOI STURE. 1 H 7 1 3O 3 O 3A21 E8CE 1995121500481 19951215 00481 SO 1995 12 15 95ZZZX6772 2 19951110 G 7414 6320 MAGNETO SLICK CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO LT MAGNETO CORRODED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 CE 01 6086C 961 91050026 21063798 517711 PILOT EXPERIRENCED ROUGH RUNNING ENGINE AFTER DEPARTING AIRPORT. PILOT RETURNED TO AIRPORT AND HAD MAGNETOS CHECKED. B OTH MAGNETOS WERE SEVERELY CORRODED INSIDE. ONE MAGNETO WAS DEAD. PILOT ELECTED TO REPLACE BOTH MAGNETOS WITH NEW UNIT S. THIS IS THREE MAGNETOS IN TWO MONTHS. SUBMITTER SUGGESTS PROBLEM IS CAUSED BY TURBOCHARGER PRESSURIZING AIR AND MOI STURE. 1 H 7 1 3O 3 O 3A21 E8CE 1995121500482 19951215 00482 SO 1995 12 15 95ZZZX6773 2 19951101 G 8500 653812 CRANKSHAFT CESSNA 140 140 2071602 CE CONT C90 C9012F 17009 SO NR 1,2 JOURNAL BROKE D P K NONE O OTHER NR NOT REPORTED 1 SO 01 720CU 130 9307 27862712 CRANKSHAFT BROKE BETWEEN FIRST AND SECOND ROD THROW. TOTAL TIME SINCE NEW, 129.8 HOURS. 1 H 7 1 3O 3 O NC A768 E252 1995121500485 19951215 00485 EA 1995 12 15 95ZZZX6776 2 19951114 G 8530 SL32000WA21P CYLINDER ASSY PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA ENGINE CORRODED G L A K NONE O OTHER IN INSP/MAINT 1 SO 16 6323W 70 2820379 L1499527A INSPECTION FOUND CYLINDER ASSY WITH EXCESS RUST AND CORROSION AFTER 70 HOURS TT IN SERVICE. SUBMITTER STATES RUST IS DU E TO A NEW PROCESS CALLED 'MILLENNIUM CYLINDER' IN ADDITION TO IMPROPER PAINTED OR UNPAINTED CYLINDER ASSY. 1 L 7 1 3O 3 O 2A13 E274 1995121500487 19951215 00487 EA 1995 12 15 95ZZZX6778 2 19950905 G 7322 103007 VENTURI FACET MA45 STOLAM RC3 RC3 3080203 NM FRNKLN 6A8215 6A8215B9F 27030 EA ENGINE CARB LOOSE G K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 WP 23 6769K 1600 1059 23459 PILOT COMPLAINT, ENGINE RUNNING VERY RICH. DISASSEMBLED CARBURETOR, FOUND FLOAT LEVEL TOO HIGH AND TWO-PIECE VENTURI IN STALLED. TWO OF THE THREE LEG CLIPS WERE MISSING AND VENTURI WAS LOOSE. SUBMITTER STATED AD 63-22-03 IS NOT CLEAR. DOE S NOT INCLUDE THESE SERIES ENGINES WHICH IT SHOULD. MARVEL-SCHEBLER BULLETIN A4-63 STATES ALL MA4-5 CARBURETORS. SUBMI TTER STATED AD 63-22-03 SHOULD HAVE ALL ENGINE REFERENCES DELETED AND JUST SAY ALL MA4-5 CARBS. THIS IS A SAFETY OF FLI GHT ITEM. 1 H 7 1 3O 3 O RC A769 E242 1995121800001 19951218 00001 SO 1995 12 18 95ZZZX6547 2 19951113 G 7414 6320 MAGNETO SLICK CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO ENGINE COIL FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 07 6591M 558 92020065 21061980 522628 MAG FAILURE TRACED TO BAD COIL. 1 H 7 1 3O 3 O 3A21 E8CE 1995122200368 19951222 00368 GL 1995 12 22 HEEA956220 2 19951211 G 7320 222360703101 SOLENOID BELL 230 230 1182149 SW ALLSN 250C 250C30 03013 GL IDLE STOP DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 230UN 2654 23009 INTERMITTENT IDLE STOP. 1 G 7 2 3U 3 U NC H9SW E1GL 1995122200373 19951222 00373 GL 1995 12 22 HEEA956230 2 19951212 G 7250 23001977 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 3RD STAGE BLADE CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5017G 552 CAT28005 45228 CAE860290 ENGINE REMOVED DUE TO 3RD STAGE TURBINE WHEEL INSPECTION. 3RD STAGE WHEEL RETURNED TO ALLISON FOR INSPECTION PER LETTER C1245F-RMG-1195. ZYGLO INSPECTION REVEALED SIX EACH CRACKS ON L/E OF BLADES 1/8" FROM SHROUD 3/16" LONG. INSTALLED SER VICEABLE 3RD STAGE WHEEL. RETURNED TO ALLISON ON RO#0635. APPLICATION FOR CREDIT ACCOMPLISHED ON AFA# 24437A. 1 G 7 1 3U 3 U H2SW E1GL 1995122200374 19951222 00374 GL 1995 12 22 HEEA956231 2 19951212 G 7250 23001977 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 3RD STAGE CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5007Y 453 CAT70022 45192 CAE860583 ENGINE REMOVED DUE TO 3RD STAGE TURBINE WHEEL INSPECTION. 3RD STAGE WHEEL RETURNED TO ALLISON FOR INSPECTION PER LETTER C1245F-RMG-1195. ZYGLO INSPECTION REVEALED ONE EACH INDICATION ON L/E 15/16" FROM HUB. INSTALLED SERVICEABLE 3RD STAGE WHEEL. 1 G 7 1 3U 3 U H2SW E1GL 1995122200375 19951222 00375 GL 1995 12 22 HEEA956232 2 19951212 G 7250 23001977 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 3RD STAGE BLADE CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3905B 250 CAT70502 45598 CAE860771 ENGINE REMOVED DUE TO 3RD STAGE TURBINE WHEEL INSPECTION. 3RD STAGE WHEEL RETURNED TO ALLISON FOR INSPECTION PER LETTER C1245F-RMG-1195. ZYGLO INSPECTION REVEALED ONE EACH BLADE CRACKED 3/32" FROM HUB L/E 3/16" LONG, AND ONE EACH BLADECRA CKED 1/8" FROM SHROUD L/E 3/16" LONG. INSTALLED SERVICEABLE 3RD STAGE WHEEL. 1 G 7 1 3U 3 U H2SW E1GL 1995122200376 19951222 00376 GL 1995 12 22 HEEA956233 2 19951212 G 7250 23001977 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 3RD STAGE BLADE CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5745S 311 CAT70467 45491 CAE860136 ENGINE REMOVED DUE TO 3RD STAGE TURBINE WHEEL INSPECTION. 3RD STAGE WHEEL RETURNED TO ALLISON FOR INSPECTION PER LETTER C1245F-RMG-1195. ZYGLO INSPECTION REVEALED FOUR EACH BLADES CRACKED 3/16" LONG, 1/16" FROM SHROUD ON L/E. INSTALLED SERVICEABLE 3RD STAGE WHEEL. 1 G 7 1 3U 3 U H2SW E1GL 1995122200402 19951222 00402 EA 1995 12 22 95ZZZX6804 2 19951117 G 7322 105235HA6 CARBURETOR CESSNA 182 R182 2072734 CE LYC O540 O540L3C5 41532 EA FLOAT SHAFT WORN D K NONE K FLUID LOSS IN INSP/MAINT 1 CE 01 DG0229 FUEL STARTED RUNNING FROM CARBURETOR AIR INTAKE 'EXCESSIVE'. REMOVED CARBURETOR, FOUND FLOAT SHAFT WORN EXCESSIVELY AND SHAFT BACKED OUT. 1 H 7 1 3O 3 O RT 3A13 E295 1995122200403 19951222 00403 SO 1995 12 22 95ZZZX6805 2 19951107 G 8530 641916 CYLINDER CESSNA 172 172 2072402 CE CONT O300 O300D 17022 SO ROCKER BOSS ROCKER BROKE D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 11 3864L 17254033 33771D5D THIS CYLINDER WAS NOT WITHIN THE DIMENSIONAL SPECS REQUIRED IN AD 94-05-05, BUT WAS NOT REQUIRED TO BE INSPECTED UNTIL O VERHAUL. THE ROCKER BOSSES BROKE IN-FLIGHT, BUT A SAFE-ON-AIRPORT LANDING WAS MADE. SUBMITTER RECOMMENDS THAT AD 94-05 -05 BE CHANGED TO REQUIRE AT LEAST A DIMENSIONAL CHECK OF THE ROCKER BOSS THICKNESS AT NEXT ANNUAL INSPECTION. 1 H 7 1 3O 3 O NT 3A12 E253 1995122200404 19951222 00404 EA 1995 12 22 95ZZZX6806 2 19950905 G 7414 10382585 POINTS BENDIX BL68255514 CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MAGNETO FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 09 737HK 297 3012041 17269428 INSPECTED MAG, FOUND POINTS NOT LUBRICATED AND PLASTIC PUSH ARMS WORN OFF. POINTS WOULD NOT OPEN AND BOTH LEFT AND RIGH T SIDES OF MAG WERE NOT OPERATIONAL. 1 H 7 1 3O 3 O NT 3A12 E274 1995122200410 19951222 00410 SO 1995 12 22 95ZZZX6812 2 19951117 G 8540 640808 GEAR 642085A2 CESSNA 402 402A 207590M CE CONT O520 TSIO520E 17040 SO START ADAPTER FAILED C K NONE O OTHER IN INSP/MAINT 1 WP 13 7816Q 1254 4020116 165122 OIL PUMP GEAR BROKE AND CRACKED THE BODY ASSEMBLY OF THE SCAVENGE PUMP, P/N 640766. REPLACED STARTER ADAPTER WITH A REB UILT, P/N 642085A2. 1 L 7 2 3O 3 O A7CE E8CE 1995122200418 19951222 00418 SO 1995 12 22 95ZZZX6820 2 19950926 G 7414 10357592 OIL SEAL BENDIX S6RN201 CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO LT MAGNETO LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 09 5199G 433 K159402ER 402B0573 DURING A 100-HOUR INSPECTION, OIL WAS FOUND IN THE LT MAGNETO ON THE RT ENGINE. THE OIL SEAL WAS REPLACED AND THE MAGNE TO WAS PUT BACK INTO SERVICE. 433.1 HOURS SINCE FACTORY OVERHAUL. 1 L 7 2 3O 3 O A7CE E8CE 1995122200434 19951222 00434 EA 1995 12 22 95ZZZX6836 2 19951030 G 7230 3036551 VANE RING SKRSKY S76 S76B 8143007 NE PWA PT6 PT6B36 52043 EA COMPRESSOR TURB CRACKED B CW1R K NONE O OTHER IN INSP/MAINT 1 EA 25 780P 2024 5D496 760359 36130 INSPECTION FOUND CRACKS IN COMPRESSOR TURBINE VANE RING WHICH CAUSE INACCURATE POWER ASSURANCE READINGS. 1 G 7 2 4U 4 U H1NE E4EA 1995122200546 19951222 00546 GL 1995 12 22 95ZZZX6873 2 19951120 G 7250 23001977 WHEEL 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL TURB 3RD STAGE RIM BREAK OUT G L A K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 03 27702 12073 635 HX91198 45300 CAE860520 LOUD ROAR AND WHINE FOLLOWED BY ENGINE CHIP LIGHT. TEAR DOWN INSPECTION REVEALED 3RD STAGE WHEEL EXHIBITED RIM BREAK OU T OF 1.75 INCH AND .25 INCH OF 3 EACH BLADES. SUSPECT CAUSE OF FAILURE TO BE A STRESS CRACK ORIGINATING ON THE LEADING E DGE SIDE OF BREAK OUT IN REFERENCE TO DIRECTION OF ROTATION, ON THE TRAILING EDGE OF RIM SHROUD AND PROGRESSED APPROXIMA TELY ONE-HALF OF CHORDAL LENGTH UNTIL OVERLOAD. POWER TURBINE SECTION EXHIBITS EXCESSIVE KNIFE AND SEAL CONTACT, FOD, A ND BEARING AREA DAMAGE. TOTAL CYCLES, 1,140. 1 G 7 1 3U 3 U H2SW E1GL 1995122200556 19951222 00556 GL 1995 12 22 95ZZZX6883 2 19951109 G 7240 23038218 1ST STAGE NOZZLE 6898735 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL HOT SECTION CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 2785R 1635 ER220597 S642 CAE270093 DURING PRE-FLIGHT OF AIRCRAFT, FOUND BURNED AND CRACKED AIRFOIL VANES AND CRACKS IN OUTER BAND. PART IS SCRAPPED. 1 G 7 2 3U 3 U H3EU E4CE 1995122200558 19951222 00558 GL 1995 12 22 95ZZZX6885 2 19951109 G 7250 23008054 1ST NOZZLE 23031899 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL G.P. SECTION ERODED VALVE B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 27554 2929 1444 MK194600AL1 45246 CAE860443 UPON DISASSEMBLY OF TURBINE, INSPECTION OF PARTS FOR LOWER POWER FOUND BURNED AND ERODED VANE L.E. AND T.E. 1 G 7 1 3U 3 U H2SW E1GL 1995122200559 19951222 00559 GL 1995 12 22 95ZZZX6886 2 19951110 G 7250 23031866 NR 2 NOZZLE 23031899 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL G.P. SECTION ERODED VANE B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 27554 2926 1444 X49954AL1 45246 CAE860443 UPON DISASSEMBLY OF TURBINE, INSPECTION OF PARTS FOR LOW POWER FOUND BURNED AND ERODED VANE L.E. AND T.E. 1 G 7 1 3U 3 U H2SW E1GL 1995122200563 19951222 00563 GL 1995 12 22 95ZZZX6890 2 19951109 G 7323 2526146 SPOOL BUSHING 252466712 AEROSP AS355 AS355F 8680806 EU ALLSN 250C 250C20 03013 GL DRIVE SHAFT WORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 5787E 1288 27192 5058 DURING TEAR DOWN, FOUND GOVERNOR HAD WORN SPOOL BUSHING. CAUSES POSSIBLE ENGINE VIBRATION. 1 G 7 2 3U 3 U H11EU E4CE 1995122200567 19951222 00567 GL 1995 12 22 95ZZZX6894 2 19951114 G 7210 6898785 PTO GEAR 23035179 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL GEARBOX CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 709AL 2850 CG56557 760278 CAE890465S 4-24-95 - RECEIVED GEARBOX FROM A/C N709AL-PTN WITH PTO GEAR CRACKED. CONDITION - FOUND PTO GEAR CRACKED AT FWD END ABO VE SPLINED AREA. SUSPECT OVERTORQUE ON OUTPUT SHAFT. 1 G 7 2 3U 3 U H1NE E1GL 1995122200568 19951222 00568 GL 1995 12 22 95ZZZX6895 2 19951114 G 7250 23055438 NR 2 NOZZLE 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL G.P. SECTION CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 708AL 4566 1514 X57635AL2 760277 CAE890101S AIRCRAFT POWER CHECK PROBLEM. FOUND CRACKED OUTERBAND AND BURNED VANE L.E. AND T.E. 1 G 7 2 3U 3 U H1NE E1GL 1995122900068 19951229 00068 EA 1995 12 29 95ZZZX6928 2 19950915 G 7414 10382681 CAPACITOR D6LN3000 CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA LT MAG FAULTY B DF1R K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 EA 17 6562S 163 B249501G R18201691 L2232240A ENGINE EXPERIENCED EXTREME ROUGHNESS AND HIGH RPM DROP ON LEFT POSITION OF 1800 RPM MAG CHECK. NR 4 AND NR 5 CYLINDERS WENT COLD ON G.E.M. FOR 3 SUCCESSIVE CHECKS. PLUGS AND WIRES CHECKED OK TO BOTH CYLINDERS. MAG WAS REMOVED AND INSPECT ED WITH NO OBVIOUS DEFECTS NOTED. INSTALLED NEW TCM MAGNETO AND CAPACITORS AND RAN UP, OPERATIONALLY CHECKED OK. FURTH ER DISASSEMBLY OF REMOVED MAGNETO REVEALED NO COIL, ROTOR, POINT, OR DISTRIBUTOR BLOCK DEFECTS, BUT ONE CAPACITOR WILL I NTERMITTENTLY CHECK ABNORMALLY LOW MICROFARAD READINGS. 1 H 7 1 3O 3 O RT 3A13 E295 1995122900074 19951229 00074 GL 1995 12 29 95ZZZX6934 2 19951124 G 7250 23056130 COMBUSTION LINER HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL TURB 1ST STAGE CRACKED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 4571V 520 278175 490487D CAE830976 FOUND CRACKS IN THE 1ST SECTION CONE BEYOND LIMITS. RETURNED LINER FOR OVERHAUL ON ALLISON 250, REPORT 159678. 1 G 7 1 3U 3 U H3WE E4CE 1995122900075 19951229 00075 GL 1995 12 29 95ZZZX6935 2 19951124 G 7250 6890040 SHIELD HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL NR 1 NOZZLE WARPED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 4571V 520 984276 490487D CAE830976 DURING REPLACEMENT OF NR 1 NOZZLE, THE NR 1 NOZZLE SHIELD WAS FOUND WARPED. SENT IN FOR REPAIR ON ALLISON 250 REPORT NR A159679. 1 G 7 1 3U 3 U H3WE E4CE 1995122900264 19951229 00264 NE 1995 12 29 HEED95400 1 19951121 G 7170 0174078010 DRAIN VALVE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S1 60030 NE ENG START DEFECTIVE E HEED K NONE O OTHER IN INSP/MAINT 1 SW 03 276X 18 760405 15094 ENGINE NOT STARTING. REPLACED START DRAIN VALVE UNIT. 1 G 7 2 3U 3 U NC H1NE E19EU 1995122900268 19951229 00268 EA 1995 12 29 95ZZZX7008 2 19951201 G 8530 7380685 PUSH ROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 01 6379M 1100 15284701 L1703215 FOUND BALL END IN PUSH ROD LOOSE AND PUSH ROD TUBE CRACKED ABOUT .75 INCH ON SAME END. 1 H 7 1 3O 3 O NT 3A19 E223 1995122900276 19951229 00276 EA 1995 12 29 95ZZZX7016 2 19951121 G 8530 VALVE PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA NR 3 CYL EXH SEPARATED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 09 47451 2405 287890076 L2369036A NR 3 CYLINDER EXHAUST VALVE SEPARATED THE STEM FROM THE HEAD. AIRCRAFT WAS FORCED TO LAND. ENGINE HAD GOOD HISTORY OF MAINTENANCE. THE ENGINE WAS NEW IN 1977. SUBMITTER SUGGESTS THE INDUSTRY SHOULD BE REQUIRED TO REMOVE THE EXHAUST SYST EM AND INSPECT VALVES FOR CORROSION IN A CALENDER TIME FRAME. 1 L 7 1 3O 3 O 2A13 E286 1995122900285 19951229 00285 WP 1995 12 29 95ZZZX7025 2 19950310 G 7200 ENGINE MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP LT ENGINE DAMAGED D E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 NM 11 479MA 5697 1883 1553SA P36379 AIRCRAFT LEVEL FLIGHT 17,000 FEET NORMAL TORQUE FOR BOTH ENGINES. TEMPS NORMAL, FUEL FLOW NORMAL. LEFT ENGINE WENT TO ZERO TORQUE, FLUCTUATED SOME. EGT REMAINED BELOW RED LINE, FUEL FLOW WAS STILL NORMAL. OIL PRESSURE NORMAL. PILOT USE D EMERGENCY CUT-OFF, FEATHERED PROP. ENGINE CAME TO A QUICKER THAN NORMAL STOP. AIRCRAFT LANDED AT SLC WITH NO PROBLEM . EXTREME HOT SECTION DAMAGE FROM EXTERNAL VIEW. NOT DISASSEMBLED AT THIS TIME. 1 H 7 2 3T 4 T RT A10SW E4WE 1995122900331 19951229 00331 GL 1995 12 29 95ZZZX6971 2 19950512 G 7250 6898764 SEAL BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL OIL BELLOWS LEAKING B R7MA K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 301LG 480 5065 CAT24238 OIL BELLOWS SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U NC H3EU E4CE 1995122900332 19951229 00332 GL 1995 12 29 95ZZZX6972 2 19950512 G 7250 6898764 SEAL BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL OIL BELLOWS LEAKING B R7MA K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 301LG 355 5065 CAE40356 OIL BELLOWS SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM. 1 G 7 2 3U 3 U NC H3EU E4CE 1995122900333 19951229 00333 GL 1995 12 29 95ZZZX6973 2 19950801 G 7250 A6871505 BEARING SUPAIRPART BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL NR 5 MAIN MAKING METAL B R7MA K NONE O OTHER IN INSP/MAINT 1 NM 11 105NC 96 104 790 CAT37299 C/W SUPERIOR AIR PARTS SB T95-SB001. FOUND 13 METAL FLAKES IN FACET FILTER BOWL. TURBINE ASSY CAT37299. REPLACED WITH ALLISON MANUFACTURED BEARING. 1 G 7 2 3U 3 U NC H3EU E4CE 1996010500025 19960105 00025 NE 1996 1 5 95ZZZX7060 2 19951207 G 7250 797957 SEAL RING PWA JT9 JT9D7 52054 NE NR 3 BEARING FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 99 1171 662836 DURING TEAR DOWN OF ENGINE TO INVESTIGATE THE CAUSE OF HIGH OIL CONSUMPTION, THE NR 3 BEARING SEAL RING WAS FOUND LIBERA TED FROM ITS SUPPORT (DUCT) ASSY, PN 75663U. ALL 30 RIVETS, PN AN123320, HAD FAILED UNDER MANUFACTURED HEAD. INVESTIGA TION INTO CAUSES OF FAILURE ONGOING. 4 F E20EA 1996010500258 19960105 00258 EA 1996 1 5 96ZZZX1 2 19951013 G 7210 3100767 SUN GEAR BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA PT HOUSING FRACTURED B MASR E ENGINE SHUTDOWN J WARNING INDICATION NR NOT REPORTED 1 SW 01 118YV 4384 55C037 UC118 32532 AN IN-FLIGHT SHUT DOWN OF THE LT ENGINE DUE TO THE FAILURE OF THE POWER SECTION. AT THE TEAR DOWN, THE INVESTIGATION RE VEALED THE NR 1 SUN GEAR AS BEING THE MODE OF FAILURE. 2 L 7 2 4T 4 T RT A24CE E4EA 1996010500271 19960105 00271 NE 1996 1 5 96ZZZX21 2 19951114 G 7230 766933 CASE BOEING 727 727172C 1384058 NM PWA JT8 JT8D7B 52053 NE LP COMPRESSOR FRACTURED B L RRXR K NONE O OTHER IN INSP/MAINT 1 GL 11 527PC 45420 UAL3388 19665 ON DISASSEMBLY OF ENGINE, FOUND THE LP COMPRESOR HAD SUFFERED A 360 DEGREE FRACTURE OF FORWARD FLANGE OF INTERMEDIATE CA SE (WHERE IT IS BOLTED TO THE REAR OF THE 3-4 STATOR). ON EXAMINATION OF CASE. IT WAS EVIDENT IT HAD BEEN PARTIALLY CRA CKED FOR SOME TIME BEFORE FINALLY FAILING AND FRACTURING COMPLETELY THROUGH 360 DEGREES. THIS TOTAL FAILURE OF THE FRON T FLANGE CAUSED THE LP COMPRESSOR ASSY LOSS OF LOCATION, THE LP COMPRESSOR MOVING FORWARD CAUSNG HEAVY RUBS TO ALL STAGE S OF LP COMPRESSOR BLADE TIPS, STAGE 3 THROUGH STAGE 6. CYCLES, 35,247. 2 L 7 3 4F 4 F A3WE E2EA 1996010500276 19960105 00276 NE 1996 1 5 96ZZZX26 2 19951201 G 7250 825601 DISC BOEING 747 747* NM PWA JT9 JT9D7 52054 NE HPT STAGE 1 CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 34540 662325 HPT INSPECTION FOUND ON THE FORWARD OUTSIDE DIAMETER OF THE DISC IN THE RADIUSED PORTION, OVER AN 0.5 INCH WIDE BAND FOR 360 DEGREES, MULTIPLE CIRCUMFERENTIAL CRACKING CAUSED BY COALESCED CORROSION PITS APPROXIMATELY 0.007 INCH DEEP. CYCLE S, 10,324. 2 L 7 4 4F 4 F RT A20WE E20EA 1996010500278 19960105 00278 NE 1996 1 5 96ZZZX28 2 19951213 G 7250 311269202 BEARING BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE NR 4 SPALLED D K NONE O OTHER IN INSP/MAINT 1 CE 01 887T BB1233 PCE93939 DURING PRE-FLIGHT WHILE TURNING RIGHT PROPELLER, HEARD AN UNUSUAL NOISE COMING FROM POWER SECTION. INSPECTED CHIP DETEC TOR AND MAIN OIL SCREEN AND FOUND SMALL QUANTITIES OF METAL. REMOVED POWER SECTION FOR REPAIR. FOUND NR 4 BEARING RACE STARTING TO SPALL. CAUSED BY METAL FATIGUE. REINSTALLED POWER SECTION AFTER REPAIR. FLUSHED OIL SYSTEM PER P & W MM. ENGINE WAS RETURNED TO SERVICE IAW P & W MM, PROCEDURES, AND P & W TECH REP RECOMMENDATIONS. ENGINE TT, 4,618.1 HOURS . ENGINE TSO, 1,569.3 HOURS. 1 L 7 2 4T 4 T A24CE E4EA 1996010500280 19960105 00280 EA 1996 1 5 96ZZZX3 2 19950615 G 7230 3032208 BEARING BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA COMP NR 1 FRACTURED B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 119YV 76 FC27221 UC119 32026 THERE ARE TWO AREAS THAT ARE BEING TAKEN UNDER INVESTIGATION WITH THIS ENGINE. A MATERIAL FAILURE OF THE NR 1 BEARING A ND A BAD STARTER GENERATOR. 2 L 7 2 4T 4 T RT A24CE E4EA 1996010500282 19960105 00282 EA 1996 1 5 96ZZZX4 2 19950714 G 7250 3035228 NOZZLE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA GAS GENERATOR BURNED VANE B A MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 160AM 449 1197 UC160 32544 LEFT ENGINE ITT ROSE ABOVE LIMITS MOMENTARILY. WHEN THE ENGINE WAS SEPARATED FROM THE POWER SECTION, DISCOVERED THE CT VANE RING HAD A SECTION COMPLETELY BURNED THROUGH. THE INVESTIGATION IS LOOKING AT THE FUEL NOZZLES AS A POSSIBLE CAUSE . THE FUEL NOZZLES ARE CHANGED OUT AT 480.0 HOURS 2 L 7 2 4T 4 T RT A24CE E4EA 1996010500283 19960105 00283 NE 1996 1 5 96ZZZX5 2 19951020 G 7250 3023683 SEAL 3037312 PWA PT6 PT6A67D NE DISK 1ST STAGE FAILED B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 6527 58A981 114091 WHEN DTS RECEIVED THE POWER SECTION FROM MOUNTAIN WEST, IT WOULD NOT ROTATE FREELY. AT THE TIME OF DISASSEMBLY, SEVERAL PIECES OF NON-FUROUS METAL FELL OUT OF THE EXHAUST DUCT. IT WAS NOTED AFTER THE METAL FELL OUT, THE POWER SECTION ROTA TED FREELY. 4 T E26NE 1996010500295 19960105 00295 NE 1996 1 5 HEED95406 2 19951127 G 7230 0292015310 ENGINE ASSY SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE COMPRESSOR FOD E HEED K NONE O OTHER IN INSP/MAINT 1 SW 03 276X 3020 760405 COMPRESSOR FOD. REPLACED UNIT 1 G 7 2 3U 3 U NC H1NE E19EU 1996010500304 19960105 00304 GL 1996 1 5 HEED95417 2 19951213 G 7210 0292108170 SEAL RING SKRSKY S76 S76C 8143008 NE ALLSN 250C 250C30S 03013 GL NR 1 ENG LEAKING E HEED K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 476X 14 760436 15529 FRONT SEAL ON POWER SHAFT LEAKING ON #1 ENGINE . REPLACED UNIT. 1 G 7 2 3U 3 U NC H1NE E1GL 1996010500403 19960105 00403 EA 1996 1 5 96ZZZX45 2 19951207 G 8520 CRANKSHAFT UNIVAR 108 1083 9230408 NM FRNKLN 6A4165 6A4165B3 27025 EA STARTER GEAR BROKE D P K NONE O OTHER NR NOT REPORTED 1 SW 99 6817M 2515 648 1084817 32543 CRANKSHAFT BROKE AT KEYWAY WHERE STARTER GEAR MOUNTS ON SHAFT. 1 H 7 1 3O 3 O A767 E238 1996010500406 19960105 00406 EA 1996 1 5 96ZZZX48 2 19951204 G 7322 46F10 VENTURI FACET MA4SPA CESSNA 172 172K 2072430 CE LYC O320 O320E2C 41508 EA CARBURETOR DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 CE 03 7362G 100 17259062 C/W AD 93-18-03 BY REMOVING TWO-PIECE VENTURI AND INSTALLING CONSOLIDATED FUEL SYSTEM'S ONE-PIECE VENTURI. THEREAFTER, PILOT REPORTED CRUISE FLIGHT FUEL BURN INCREASED FROM 7 GPH TO 9 GPH. INSPECTION OF CARBURETOR AND VENTURI DISCLOSED NO DISCREPANCIES, BUT AS A PRECAUTION, A NEW 46-F10 ONE-PIECE VENTURI WAS INSTALLED AND FUEL CONSUMPTION HAS SINCE RETURNE D TO NORMAL. 1 H 7 1 3O 3 O NT 3A12 E274 1996010500407 19960105 00407 EA 1996 1 5 96ZZZX49 2 19951107 G 8530 VALVE GULSTM AA5 AA5A 3960106 SO LYC O320 O320E2G 41508 EA ENG INTAKE LEAKING D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 NE 01 97520 57 AA5A0152 L4647827A AIRCRAFT WAS TAKING OFF, NOT GENERATING FULL POWER. NOTICED SLIGHT VIBRATION. RETURNED TO AIRPORT. VIBRATION INCREASE D AS AIRCRAFT EXECUTED EMERGENCY LANDING AT AIRPORT. PERFORMED COMPRESSION CHECK, FOUND TO BE 20/80. REMOVED CYLINDER. 1 L 7 1 3O 3 O A16EA E274 1996010500413 19960105 00413 NE 1996 1 5 96ZZZX55 2 19951026 G 7260 311196801 GEAR PWA 118 PW118 NE TOWER SHAFT SHEARED D E ENGINE SHUTDOWN J WARNING INDICATION NR NOT REPORTED 1 SW 05 45C307 PCE115298 ENGINE HAD AN IFSD. TEAR DOWN OF ENGINE REVEALED THE TOWER SHAFT GEAR WAS SHEARED NEAR THE TOP OF THE GEAR. INVESTIGAT ION AS TO ROOT CAUSE OF FAILURE IS ON-GOING. 4 T E20NE 1996010500419 19960105 00419 SO 1996 1 5 96ZZZX61 2 19951206 G 7414 105136539 MAGNETO S6LN21 CESSNA 172 172C 2072408 CE CONT O300 O300C 17022 SO FRONT HOUSING BEARING LOOSE H K NONE O OTHER IN INSP/MAINT 1 WP 07 1851Y 448 I299206DR 17249451 TIME SINCE MAGNETO FACTORY REBUILT, 448.4 HOURS. DURING INSPECTION (500-HOURS), DISCOVERED FRONT BEARING RACE WAS LOOSE IN FRONT HOUSING. NOT APPARENT UNTIL WIPED GREASE OFF TO REPLACE WITH NEW GREASE. SUSPECT CAUSE: MAXIMUM TOLERANCE F IT WHEN ASSEMBLED AT FACTORY REBUILD. 1 H 7 1 3O 3 O NT 3A12 E253 1996010500420 19960105 00420 SO 1996 1 5 96ZZZX62 2 19951204 G 7314 64621216 PUMP BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO ENGINE FUEL SHAFT SHEARED D O OTHER Y ENGINE STOPPAGE CL CLIMB 1 WP 07 5587K 2340 620 H139202BR CE1392 285675R ENGINE DRIVEN FUEL PUMP FAILED ON CLIMB AT 400 FEET AGL. 1 L 7 1 3O 3 O 3A15 E5CE 1996010500421 19960105 00421 EA 1996 1 5 96ZZZX63 2 19951121 G 8520 CRANKCASE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RT FORWARD CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NM 09 59919 6 317552038 A CRACK DEVELOPED 6 HOURS AFTER MAJOR OVERHAUL FROM LYCOMING. THE CRACK WAS 2.5 INCHES TO 3 INCHES LONG. SUBMITTER BEL IEVES THE CRACK MUST HAVE BEEN THERE WHEN IT LEFT THE FACTORY. THIS ENGINE WAS A FACTORY REMANUFACTURE. 1 L 7 2 3O 3 O A20SO E14EA 1996010500422 19960105 00422 GL 1996 1 5 96ZZZX64 1 19951111 G 7410 IGNITION SYSTEM AMTR SONERI SONERAI2 GL AMTRVW VOLKS VW2200VOLKS GL ENGINE FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 WP 17 912BS 184 1189L AT 1,500 MSL, BOTH IGNITION SOURCES FAILED TO PRODUCE HIGH VOLTAGE TO THE SPARK PLUGS RESULTING IN THE REDUCTION OF ENGI NE POWER AND THE ENGINE STOPPED ROTATION. THE AIRCRAFT CRASHED IN AN OPEN FIELD WITH MINOR DAMAGE. BOTH COILS' NEGATIV E TERMINALS EXHIBIT WIRES CONNECTED TOGETHER AT A SINGLE POLE SWITCH ATTACHED TO THE ELECTRONIC TACHOMETER THAT HAD AN I NTERNAL GROUND FAULT THAT CAUSED THE COILS TO OVERHEAT, AND INTERNALLY FAIL TO PRODUCE HIGH VOLTAGE IGNITION TO THE SPAR K PLUGS. 1 M 7 1 3O 3 O EXPA1M71 EXP3O 1996010500423 19960105 00423 GL 1996 1 5 96ZZZX65 1 19951111 G 7714 TACHOMETER AMTR SONERI SONERAI2 GL AMTRVW VOLKS VW2200VOLKS GL ENGINE SHORTED G A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 WP 17 912BS 184 1189L AT 1,500 MSL, BOTH IGNITION SOURCES FAILED TO PRODUCE HIGH VOLTAGE TO THE SPARK PLUGS RESULTING IN THE REDUCTION OF ENGI NE POWER AND THE ENGINE STOPPED ROTATION. THE AIRCRAFT CRASHED IN AN OPEN FIELD WITH MINOR DAMAGE. BOTH COILS' NEGATIV E TERMINALS EXHIBIT WIRES CONNECTED TOGETHER AT A SINGLE POLE SWITCH ATTACHED TO THE ELECTRONIC TACHOMETER THAT HAD AN I NTERNAL GROUND FAULT THAT CAUSED THE COILS TO OVERHEAT, AND INTERNALLY FAIL TO PRODUCE HIGH VOLTAGE IGNITION TO THE SPAR K PLUGS. 1 M 7 1 3O 3 O EXPA1M71 EXP3O 1996010500424 19960105 00424 SO 1996 1 5 MCA12BMV 2 19951027 G 7310 64103211A8 VALVE PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO FUEL MANIFOLD LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 23 8412B 98 11239506CR 28R8131164 299536R FUEL MANIFOLD VALVE FOUND LEAKING AROUND VALVE DIAPHRAGM. REASON FOR LEAK UNKNOWN. ENGINE AND COMPONENTS REBUILT BY TC M 5-12-95. (X) 1 L 7 1 3O 3 O 2A13 E9CE 1996010500581 19960105 00581 SO 1996 1 5 96ZZZX71 2 19951201 G 8550 QUICK DRAIN CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO ENGINE OIL FAILED C K NONE K FLUID LOSS NR NOT REPORTED 1 WP 11 66172 15075893 252929 COMPONENTS FELL OUT OF THE OIL QUICK-DRAIN. SUBMITTER SUGGESTS RE-DESIGN SO IT CANNOT HAPPEN AGAIN. 1 H 7 1 3O 3 O 3A19 E252 1996010500584 19960105 00584 EA 1996 1 5 96ZZZX74 2 19951212 G 8510 LW14021 SHAFT CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA PROP IDLER GEAR MISSING H O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 07 9099C 3297 1218 R18200398 L2012540A THE CESSNA R182 LANDED AND TAXIED ONTO THE PARKING RAMP. THE AIRCRAFT WAS COVERED WITH ENGINE OIL. VISUAL INSPECTION R EVEALED A HOLE IN THE LOWER FRONT NOSE COWLING, A DAMAGED PROPELLER BLADE AND BENT CYLINDER FINS ON NR 1 CYLINDER. AFTE R FURTHER INVESTIGATION, THE PROPELLER GOVERNOR IDLER GEAR SHAFT, PN LW-14021, AND PLUG, PN LW-13896, WERE DISCOVERED MI SSING. THE PLUG THREADS WERE STRIPED AND IT APPEARED THE SET SCREW, PN AN565B1032H5, WAS NEVER ENGAGED IN THE PROP GOVE RNOR SHAFT. 1 H 7 1 3O 3 O RT 3A13 E295 1996010500585 19960105 00585 EA 1996 1 5 96ZZZX75 2 19951212 G 8510 LW13896 PLUG CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA PROP GOV DRV MISSING H O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 07 9099C 3297 1218 R18200398 L2012540A THE CESSNA R182 LANDED AND TAXIED ONTO THE PARKING RAMP. THE AIRCRAFT WAS COVERED WITH ENGINE OIL. VISUAL INSPECTION R EVEALED A HOLE IN THE LOWER FRONT NOSE COWLING, A DAMAGED PROPELLER BLADE AND BENT CYLINDER FINS ON NR 1 CYLINDER. AFTE R FURTHER INVESTIGATION, THE PROPELLER GOVERNOR IDLER GEAR SHAFT, PN LW-14021, AND PLUG, PN LW-13896, WERE DISCOVERED MI SSING. THE PLUG THREADS WERE STRIPED AND IT APPEARED THE SET SCREW, PN AN565B1032H5, WAS NEVER ENGAGED IN THE PROP GOVE RNOR SHAFT. 1 H 7 1 3O 3 O RT 3A13 E295 1996010500586 19960105 00586 SO 1996 1 5 96ZZZX76 2 19951128 G 8520 24878 BOLTS CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO CASE HALF DETACHED B ESER K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 747JB 215 414A1006 L800588 UPON REMOVAL OF THE OIL SUMP TO REPLACE A LEAKING GASKET, FOUND 2 CASE HALF BOLTS AND ASSOCIATED HARDWARE (NUTS AND WASH ERS) HAD COME OUT AND WERE LAYING IN THE SUMP. INSPECTION OF THE CASE HALF BOLT HOLES SHOWED NO SIGN OF FORGING ON THES E 2 BOLTS. IT IS THEORIZED THEY WERE INSTALLED BY HAND DURING ENGINE ASSEMBLY, BUT FAILED TO BE TORQUED. THUS, THEY LO OSENED AND FELL INTO THE SUMP. 1 L 7 2 3O 3 O A7CE E8CE 1996010500595 19960105 00595 SO 1996 1 5 96ZZZX85 2 19951123 G 8520 632941F CONNECTING ROD CESSNA 185 A185E 2072818 CE CONT O520 IO520D 17032 SO NR 6 PISTON BROKE G K NONE O OTHER NR NOT REPORTED 1 SO 17 8H 1851172 17406870D12 ENGINE'S NR 6 ROD BROKE. PISTON PIN BOSS WAS GONE. 1 H 7 1 3O 3 O 3A24 E5CE 1996010500609 19960105 00609 GL 1996 1 5 96ZZZX99 2 19950915 G 7323 56075042 CONTROL CABLE BELL 47 47G5 1181032 SW ALLSN 250C 250C18B 03011 GL N2 GOVERNOR FAILED B EOOR K NONE W INADEQUATE Q C IN INSP/MAINT 1 AL 03 2251W 7965 CAE800447B N2 GOVERNOR CONTROL CABLE END FAILED WHILE BEING INSTALLED ON HELICOPTER. THREADED END BROKE OFF DURING INITIAL ADJUSTM ENT ON GROUND. THIS CABLE END IS A 1/4-28 THREADED FITTING THAT IS SWAGED ONTO A .1875 INCH CABLE SHANK. THE THREADS H AD BEEN CUT TOO FAR DOWN UNTIL THEY MET THE END OF THE BORE THAT IS SWAGED ONTO CABLE SHANK LEAVING VERY LITTLE MATERIAL . SUBMITTER STATED PROPERLY MANUFACTURED THREADED ENDS HAVE APPROXIMATELY .125 INCH BETWEEN END OF THREADS AND END OF S WAGE BORE. 1 G 7 1 3O 3 U 2H3 E4CE 1996010500612 19960105 00612 GL 1996 1 5 96ZZZX106 2 19951114 G 7230 23005667 PC TUBE ASSY BELL 206 206L4 1182110 SW ALLSN 250C 250C30P 03013 GL COMP SCROLL B-NUT BURRED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 176AL 16 52146 CAE895824 DURING REMOVAL OF LINE TO C/W ENGINE POWER RECOVERY WASH. NOTICED THE B-NUT WAS HARD TO TURN WHEN REMOVING THE LINE. B -NUT THREADS BURRED. 1 G 7 1 3U 3 U NC H2SW E1GL 1996011000001 19960110 00001 SO 1996 1 10 95ZZZX6407 2 19951016 G 8530 653421 GUIDE PIPER J3 PA11 7101102 SO CONT C90 C9012F 17009 SO NR 2,4 CYLS EXH EXCESS WORN D K NONE O OTHER IN INSP/MAINT 1 GL 27 4565M 98 1168 4103688 OWNER REPORTED EXCESSIVE BLOW-BY. COMPRESSION CHECK NR 2 - 52/80 AND NR 4 - 50/80. EXHAUST VALVES LEAKING. PISTONS HE AVY WITH CARBON BUILD-UP. EXHAUST GUIDES WORN BEYOND TCM LIMITS. SUBMITTER STATES THIS IS 4 OUT 10 CYLINDERS INSTALLED , ALL WITH LESS THAN 100 HOURS SINCE NEW. 1 H 7 1 3O 3 O A691 E252 1996011200245 19960112 00245 EA 1996 1 12 96ZZZX174 2 19950905 G 7310 LW120980210 TUBE PIPER PA24 PA24250 7102404 SO LYC O540 IO540C1B5 41532 EA FUEL INJECTOR CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 09 7969P 1394 243206 L35948 DURING C/W LYCOMING AD 93-02-05, FOUND ALL 6 FUEL INJECTOR LINES CRACKED AT SOLDER JOINT AND LEAKING FUEL. SUBMITTER NO TED THAT ON PREVIOUS ANNUAL INSPECTION FORMS, A NOTATION WAS MADE THAT LINES WERE LEAKING, BUT DEFERRED. THE LEAKING LI NES POSED A SERIOUS FIRE HAZARD AND SHOULD NOT HAVE BEEN DEFERRED. INSTALLED NEW LINES AND CLAMPED PER LYC SB 342A. 1 L 7 1 3O 3 O 1A15 1E4 1996011200247 19960112 00247 EA 1996 1 12 96ZZZX176 2 19951031 G 7414 M3525 COIL SLICK 4270 CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA ENG RT MAG DEFECTIVE D K NONE Y ENGINE STOPPAGE IN INSP/MAINT 1 GL 09 19992 582 89050304 17260917 L4057227A DURING RUN-UP, RT MAG DROP WAS EXCESSIVE OR ENGINE WOULD STOP. MAGNETO WAS DISASSEMBLED AND POINTS AND CONDENSOR REPLAC ED DUE TO WORN CONDITION. COIL WAS TESTED AND THE SECONDARY WAS FOUND TO HAVE APPROXIMATELY 5 MILLION OHMS RESISTANCE. THE SPEC IS 13,000-20,500 OHMS. UPON REMOVAL OF COIL, ALSO NOTED LAMINATIONS HAD STARTED TO SEPARATE. SUBMITTER RECOM MENDS ADHERENCE TO SLICK MANUAL WHICH REQUIRED 500-HOUR INSPECTIONS. THERE WAS NO PREVIOUS WORK ON MAGS NOTED IN LOG BO OK. 1 H 7 1 3O 3 O NT 3A12 E274 1996011200248 19960112 00248 SO 1996 1 12 96ZZZX177 2 19951026 G 7414 1076304 COIL BENDIX 105136027 PIPER J3 J3C65 7100510 SO CONT A65 A658 17003 SO RT MAGNETO CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 09 87873 782939 15491 4626268 WHILE DETERMINING C/W TELEDYNE AD 94-01-03R2, FOUND RIGHT MAGNETO TO HAVE AN UNAIRWORTHY COIL. UPON REMOVAL, COIL WAS F OUND CRACKED IN TWO PLACES ORIGINATING FROM THE CORE ON THE GROUND LEAD END. LOG ENTRY OF 2-20-88 INDICATES THIS MAGNET O COIL WAS CHANGED TO THE 'NEW STYLE', BUT DID NOT GIVE A PART NUMBER. 1 H 7 1 3O 3 O A691 E205 1996011200249 19960112 00249 SO 1996 1 12 96ZZZX178 2 19951130 G 8540 643257 SHAFT TOOTH 635050 CESSNA 421 421A 2076012 CE CONT O520 GTSIO520D 17032 SO STARTER ADAPTER BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 15 2219Q 3658 932 421A0019 1884908D PILOT REPORTED LOWER OIL PRESSURE, RT ENGINE. TROUBLESHOT TO BROKEN TOOTH ON STARTER ADAPTER SHAFT AND FAILED BEARING I N CRANKCASE. BEARING SUPPORT WAS OVERSIZED, FILLING ENGINE OIL SYSTEM WITH METAL. NO PREVIOUS INDICATION OF C/W TCM CS B NR 94-4 COULD BE FOUND. 1 L 7 2 3O 3 O A7CE E7CE 1996011200250 19960112 00250 SO 1996 1 12 96ZZZX179 2 19951130 G 8540 537721 BEARING 635050 CESSNA 421 421A 2076012 CE CONT O520 GTSIO520D 17032 SO STARTER ADAPTER FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 15 2219Q 3658 932 421A0019 1884908D PILOT REPORTED LOWER OIL PRESSURE, RT ENGINE. TROUBLESHOT TO BROKEN TOOTH ON STARTER ADAPTER SHAFT AND FAILED BEARING I N CRANKCASE. BEARING SUPPORT WAS OVERSIZED, FILLING ENGINE OIL SYSTEM WITH METAL. NO PREVIOUS INDICATION OF C/W TCM CS B NR 94-4 COULD BE FOUND. 1 L 7 2 3O 3 O A7CE E7CE 1996011200251 19960112 00251 SO 1996 1 12 96ZZZX180 2 19951208 G 8530 649177 VALVE GUIDE CESSNA 182 182A 2072704 CE CONT O470 O470R 17026 SO EXHAUST VALVE WORN D K NONE O OTHER IN INSP/MAINT 1 NM 11 3774D 766 34474 321243R FOUND CYLINDER COMPRESSION AT 40/80. REMOVED CYLINDER AND FOUND EXHAUST VALVE GUIDE WORN OVER LIMITS. EXHAUST VALVE IN GUIDE CLEARANCE AS MEASURED IS 0.016 INCH. SERVICEABLE LIMITS ARE 0.006 INCH. 1 H 7 1 3O 3 O NT 3A13 E273 1996011200556 19960112 00556 EA 1996 1 12 96ZZZX195 2 19951221 G 7322 R5A5AD1 SERVO INJECTOR BBAVIA 8 8KCAB 2110612 CE LYC O320 AEIO320E1B 41508 EA DIAPHRAGM SEAL FAILED G A UNSCHED LANDING E R Y VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ENGINE STOPPAGE CR CRUISE 1 SO 11 53870 1600 11665131 22576 L538355A WHILE IN LEVEL FLIGHT AT AN ALTITUDE OF 4,500 FEET MSL, ENGINE DEVELOPED A ROUGH RUNNING CONDITION AND THEN QUIT. UPON INSPECTION OF SERVO INJECTOR, FOUND A SEAL IN THE DIAPHRAGM HOUSING HAD BECOME DEFECTIVE. 1 H 7 1 3O 3 O A21CE 1E12 1996011200559 19960112 00559 SO 1996 1 12 96ZZZX198 2 19951122 G 7322 6397172 FUEL CONTROL CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO THROTTLE ARM BUSHING WORN B CL4R K NONE O OTHER IN INSP/MAINT 1 AL 03 9987N 779 18504379 175762R STEEL BUSHING HAS WORN AWAY ABOUT 90 PERCENT OF THE THROTTLE ARM. THE BOLT WAS CORRECTLY INSTALLED AND PROPERLY TORQUED . THIS AREA HAS BEEN SUBJECT TO CLOSE INSPECTION AT EACH 100-HOUR INSPECTION SINCE EARLIER REPORTS OF SIMILAR PROBLEMS (CESSNA SEB 95-15), A.C. 43-16. SUBMITTER SUGGESTS THIS DAMAGE APPARENTLY PROGRESSED RAPIDLY SINCE THE LAST 100-HOUR IN SPECTION. 1 H 7 1 3O 3 O 3A24 E5CE 1996011200565 19960112 00565 GL 1996 1 12 96ZZZX204 2 19951217 G 7323 252466714 GOVERNOR BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL TURBINE DEFECTIVE D K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 09 1082N 508 25884 2945 CAE830561 GOVERNOR DROOPED TO 98 PERCENT N2 AND DID NOT RECOVER. N2 CONTINUED TO DROP WITHOUT RECOVERY. GOVERNOR ARM FELT STIFF. SENT IN FOR WARRANTY REPAIR. THE FOLLOWING ITEMS WERE REPLACED INSIDE GOVERNOR. PN 2520501, BEARING. PN 2523240, BE ARING. PN 2525170, BUSHING. PN 2539034, WEIGHT. THIS GOVERNOR HAS A 2,000-HOUR OVERHAUL. 1 G 7 1 3U 3 U H2SW E4CE 1996011900163 19960119 00163 EA 1996 1 19 96ZZZX264 2 19951214 G 8500 ENGINE PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA INDUCTION LOST POWER D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 07 6896B 600919816126 L2124748A DURING FLIGHT, RT ENGINE LOSING POWER, LANDED. ENGINE CHECKED, NO PROBLEMS NOTED. SUSPECT INDUCTION PARTIALLY PLUGGED WITH SNOW. 1 M 7 2 3O 3 O RT A17WE 1E4 1996011900169 19960119 00169 GL 1996 1 19 96ZZZX270 2 19950718 G 7230 6871484 DIFFUSER 6890550 BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL SCROLL ASSY CRACKED D S K NONE O OTHER IN INSP/MAINT 1 EA 21 2150K 4540 857 37682 3462 CAE834209 COMPRESSOR WAS FOUND CRACKED CAUSING HIGH TOT. COMPRESSOR IS OUT OF BALANCE AND ALSO NR 1 BEARING OIL SEAL WAS LEAKING. 1 G 7 1 3U 3 U H2SW E4CE 1996011900252 19960119 00252 NE 1996 1 19 96ZZZX277 2 19951220 G 7321 FUEL CONTROL CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE LT/RT ENGINE REQUIRED ADJUST D A D RETURN TO BLOCK X ENGINE FLAMEOUT TX TAXI/GRND HDL 1 CE 03 953F 2702 5600005 108007 PILOT STARTED AIRCRAFT AND BEGAN TO TAXI FOR TAKEOFF, LEFT ENGINE FLAMES OUT. SHORTLY THEREAFTER, RIGHT ENGINE FLAMED OU T WHILE RETURNING TO RAMP. CHECK MINIMUM FUEL FLOW SETTINGS. FOUND LOW, RESET PER SB 7458R1. OPERATION CHECKED GOOD. SUBMITTER STATED MINIMUM FUEL FLOW SETTINGS ARE A KNOWN PROBLEM ON THIS MODEL ENGINE. 2 L 7 2 4F 4 F RT A22CE E25EA 1996012600425 19960126 00425 EA 1996 1 26 96ZZZX349 2 19951204 G 8520 71105ASR177 TAPPET CESSNA 150 152 2071835 CE LYC O235 O235L2A 41505 EA NR 4 CYLINDER DEFECTIVE H K NONE O OTHER IN INSP/MAINT 1 NM 01 24883 1770 15280430 L1987815 ENGINE EXPERIENCED INTERMITTENT MISS. WHILE TROUBLESHOOTING, DISCOVERED NR 4 CYLINDER ROCKER TO VALVE CLEARANCE COULD N OT BE SET PROPERLY. ENGINE TORN DOWN AND FOUND TWO TAPPETS DEFECTIVE. SOCKET END WAS LOOSE AND TURNED FREELY IN END OF BODY. CAUSED EXCESSIVE WEAR ON SOCKET TO THE POINT THAT VALVE ADJUSTMENT NOT ATTAINABLE. TWO OF THE EIGHT HAD THIS CO NDITION. BOTH ON NR 4 CYLINDER. 1 H 7 1 3O 3 O NT 3A19 E223 1996012600426 19960126 00426 EA 1996 1 26 96ZZZX350 2 19951215 G 7313 LW18265 INJECTOR PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA CYL INTAKE PORT NOZZLE CLOGGED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 NE 01 53995 1 28R7918258 L2000151A THE ENGINE HAD BEEN INSTALLED AFTER OVERHAUL. OVERHAULER DID RUN-UP AND REPORTED THAT ENGINE WAS SATISFACTORY. COMPLET ED THE INSTALLATION WITH NEW MOUNT, VIBRATION ISOLATORS, AND COMPLETE HOSE KIT. TEST RAN ON THE GROUND FOR .7 HOUR WHIC H GAVE SATISFACTORY RESULTS. APPROXIMATELY 10 SECONDS INTO FIRST FLIGHT, VIBRATION WAS ENCOUNTERED. FLOW CHECKED NOZZL ES, ONE WAS CLOGGED. CALLED OVERHAULER ABOUT PROBLEM AND RECEIVED NEW NOZZLE. OPERATION SINCE THEN HAS BEEN SATISFACTO RY. 1 L 7 1 3O 3 O 2A13 1E10 1996012600440 19960126 00440 SO 1996 1 26 96ZZZX364 1 19951204 G 8120 LW318444 BOLT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA TURBO MOUNT LOOSE B APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 3582X 1300 318052105 BOLTS THAT SECURE TURBO MOUNT TRUSS TO ENGINE MOUNT PYLONS CONTINUALLY WORK LOOSE. NUTS CHATTER ON THREADS AND WEAR TO A POINT WHERE RE-TORQUING IS NOT POSSIBLE. MAIN PROBLEM IS STEEL BOSS ON TURBO MOUNT EATING INTO ALUMINUM MOUNT PYLON. SUBMITTER SUGGESTS SHOULDERED STEEL BUSHING BE PRESS-FIT INTO ALUMINUM ENGINE MOUNT PYLON TO BEAR STRAPS OF TURBO MOUNT . ALSO, SUGGEST FINE THREAD BOLTS RATHER THAN COARSE TO HELP PREVENT TORQUE LOSS WITH MINOR SHIFTING OF KEYED, CASTELLA TED NUT. 1 L 7 2 3O 3 O A20SO E14EA 1996012600447 19960126 00447 EA 1996 1 26 96ZZZX371 2 19951222 G 8550 LINE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA OIL RETURN LOOSE D O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 EA 23 738UD 980 17270240 L829076T PILOT REPORTED SMOKE IN COCKPIT AFTER APPLYING CABIN HEAT. REMOVED COWLING AND INSPECTED MUFFLER ASSEMBLY. SMALL OIL S TAIN ON MUFFLER SHROWD. FOUND OIL RETURN LINES WERE SLIGHTLY 'WET' WITH OIL. TIGHTENED OIL RETURN LINE CLAMPS. WASHED DOWN ENGINE AND MUFFLER SHROWD. MADE A LOG BOOK ENTRY, AND RETURNED TO SERVICE. 1 H 7 1 3O 3 O NT 3A12 E274 1996012600448 19960126 00448 EA 1996 1 26 96ZZZX372 2 19951227 G 8510 71328 RING GEAR PIPER PA24 PA24250 7102404 SO LYC O540 O540A1C5 41532 EA STARTER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 13 5252P 3288 24284 L161440 DURING ANNUAL INSPECTION, STARTER RING GEAR SUPPORT ASSEMBLY WAS FOUND CRACKED BETWEEN 2 BOLT HOLES, 1 INCH LONG. THIS CAN BE INSPECTED ONLY IF PROPELLER IS REMOVED. SUBMITTER SUGGESTS THIS AREA BE INSPECTED AT LEAST EVERY 1,000 HOURS. 1 L 7 1 3O 3 O 1A15 E295 1996012600453 19960126 00453 NE 1996 1 26 96ZZZX377 2 19951213 G 7250 694702 SUPPORT ASSY 589741 PWA JT9 JT9* 52054 NE NR 3 BEARING FAILED H K NONE O OTHER IN INSP/MAINT 1 GL 11 X685710 BRITISH AIRWAYS EXPERIENCED AN ENGINE CONDITION SHOWING HIGH OIL CONSUMPTION ON ONE OF THEIR ENGINES. AN INVESTIGATION LED TO A COMPONENT ASSEMBLY FAILURE LOCATED IN THE NR 3 BEARING COMPARTMENT. SUBMITTER RECOMMENDATIONS: COMPLY WITH PR ATT AND WHITNEY'S SB NR 3985. 4 F E20EA 1996012600458 19960126 00458 SO 1996 1 26 96ZZZX382 2 19951015 G 8530 GUIDE CONT O300 O300A 17022 SO EXHAUST VALVE WORN D L A K NONE O OTHER IN INSP/MAINT 1 SW 15 INSTALLED 6 NEW SUPERIOR MILLENIUM CYLINDERS. THREE CYLINDERS LOST COMPRESSION WITHIN 24 HOURS. PULLED ALL 6 CYLINDERS . ALL 6 EXHAUST GUIDES WORN BEYOND SERVICE LIMITS. THESE WERE THEIR 'POWER PACKS'. PRE-ASSEMBLED WITH NEW VALVES, SPR INGS, PISTONS, ETC. 3 O E253 1996012600459 19960126 00459 SO 1996 1 26 96ZZZX383 2 19951015 G 8530 643767 GUIDE CONT O520 TSIO520H 17040 SO VALVES WORN D A K NONE O OTHER IN INSP/MAINT 1 SW 15 120 INSTALLED 6 CERMICHROME CYLINDER REBUILT UNITS WITH 643767 GUIDES. 120 SMOA. COMPRESSION LEAK ON TWO CYLINDERS. PULLE D ALL 6 AND RETURNED UNITS TO ECI. THEY DIAGNOSED AS JUST WORN OUT. THEY REPAIRED SAME AND SUGGESTED FULL FLOW LIFTERS AND DRILLED ROCKERS TO 'HELP ALLEVIATE FUTURE PROBLEMS'. 3 O E8CE 1996012600460 19960126 00460 SO 1996 1 26 96ZZZX384 2 19951015 G 8530 GUIDE CONT O200 O200A 17020 SO EXHAUST VALVE WORN D A K NONE O OTHER IN INSP/MAINT 1 SW 15 300 ONE YEAR AGO INSTALLED 4 NEW TCM POWER PACKS. DROPPED COMPRESSION ON ONE EXHAUST VALVE AFTER 300 HOURS. WORN GUIDE WAS AT FAULT. 3 O E252 1996012600461 19960126 00461 SO 1996 1 26 96ZZZX385 2 19951015 G 8530 GUIDE CONT O470 IO470K 17026 SO VALVE WORN D A K NONE O OTHER IN INSP/MAINT 1 SW 15 110 INSTALLED 6 RECONDITIONED CHROME UNITS BY DIVCO. AFTER 110 HOURS, LOST COMPRESSION IN TWO CYLINDER GUIDES WORN BEYOND L IMITS. 3 O 3E1 1996012600462 19960126 00462 SO 1996 1 26 96ZZZX386 2 19951015 G 8530 GUIDE CONT C85 C85* 17008 SO VALVE WORN D A K NONE O OTHER IN INSP/MAINT 1 SW 15 24 INSTALLED 4 NEW TCM POWER PACKS. AFTER 24 HOURS, LOST COMPRESSION ON TWO CYLINDERS. VALVE GUIDES OUT OF LIMITS. 3 O E233 1996020200083 19960202 00083 NE 1996 2 2 96ZZZX450 2 19951206 G 7310 1742510 FILTER BELL 222 222U 1182140 SW LYC LTS101 LTS101750C1 41560 NE ENGINE METAL CONTAM B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 6992 47521 LE47020 FILTER WAS INSTALLED IN FILTER BOWL WHEN ADDING OIL (OHI MECHANIC SAW METAL INSIDE). 1 G 7 2 3U 3 U H9SW E5NE 1996020200276 19960202 00276 1996 2 2 96ZZZX463 1 19951227 G 2434 ALU8421LS ALTERNATOR ELECTROSYS LYC O540 TIO540J2BD 41532 EA DRIVE SHAFT PULLEY BACKWARDS B APCR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 5112140 ALTERNATOR PULLEY INSTALLED BACKWARDS ON SHAFT. THIS WAS A NEWLY OVERHAULED UNIT RECEIVED FROM OVERHAULER. 3 O E14EA 1996020200291 19960202 00291 EA 1996 2 2 96ZZZX478 2 19951130 G 8530 7380685 PUSH ROD PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA NR 4 CYL INTAKE DAMAGED D L K NONE O OTHER IN INSP/MAINT 1 NE 01 9171A 590 3882A0119 L1533115 THE PUSH ROD METAL INSERT ON THE VALVE END BECAME LOOSE. THIS ALLOWED THE INSERT TO POUND AGAINST THE METAL TUBE, CURLI NG THE METAL OVER, UNDER THE INSERT TO THE OUTSIDE. 1 L 7 1 3O 3 O A18SO E223 1996020200294 19960202 00294 SO 1996 2 2 96ZZZX481 2 19951019 G 8530 ROCKER CESSNA 150 150 2071802 CE CONT O200 O200A 17020 SO NR 2 CYLINDER BOSS FAILED G P A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 NM 01 3481J 15066181 00304 PILOT OWNER DEPARTED HOME AIRPORT FOR ROUTINE SCENIC FLIGHT. AFTER ABOUT 20 MINUTES INTO CROSS-COUNTRY FLIGHT, ENGINE S TARTED RUNNING ROUGH, CARBURETOR HEAT HAD NO EFFECT. RETURN HOME WITH PARTIAL POWER. INSPECTION OF NR 2 CYLINDER ROCKE R REVEALED ALL FOUR BOSSES BROKEN OFF REQUIRING REPLACEMENT OF CYLINDER. SUBMITTER SUGGESTS FATIGUE MOST LIKELY CAUSE O F FAILURE. TOTAL TIME ON CYLINDER-ENGINE, 2,100 HOURS SMOH. RECOMMEND DYE PENETRANT CHECK EVERY 500 HOURS. 1 H 7 1 3O 3 O NT 3A19 E252 1996020200300 19960202 00300 WP 1996 2 2 96ZZZX487 2 19951207 G 7250 31038391 SEAL GARRTT TPE331 TPE33112UAR 01514 WP 1ST STAGE TURB CRACKED B A DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 10508 9233151457 P70018 DURING SCHEDULED HOT SECTION INSPECTION, FOUND SEAL CRACKED AT SEALING FLANGE. THIS IS A CRITICAL LIFE LIMITED COMPONEN T. LIFE LIMIT IS 20,000 CYCLES. SUBMITTER SUGGESTS ALLIED SIGNAL ENGINEERING DETERMINE/CORRECT CAUSE OF CRACKING. NUM EROUS MALFUNCTION/DEFECT REPORTS SUBMITTED ON THIS TOPIC BY THIS REPAIR STATION ALONE. CYCLES SINCE NEW, 10,865. 4 T E4WE 1996020200308 19960202 00308 NE 1996 2 2 96ZZZX495 2 19950806 G 7260 9699M27P01 COVER PLATE BOEING 747 7472D3B 1384805 NM GE CF6 CF650E2 30018 NE NR 2 GEARBOX SEAL LEAK B A CISY E A ENGINE SHUTDOWN UNSCHED LANDING K FLUID LOSS CL CLIMB 1 EA 31 505MC 21251 LUX - AIRCRAFT DEPARTED, DURING CLIMB THE NR 2 ENGINE'S OIL QUANTITY DROPPED AND WAS SHUT DOWN. AIRCRAFT RETURNED TO LU X AND LANDED SAFELY. OIL SERVICED AND ENGINE MOTORED - NO LEAK, IDLE CHECK - NO LEAK, POWER LEVEL ADVANCED AND LEAK APP EARED AT THE GEARBOX MANUAL CRANK PAD. FOUND WASHER INSTALLED BEHIND CRANK PAD. WASHER REMOVED AND SEAL REPLACED, ENGI NE RUN AND LEAK CHECK ACCOMPLISHED. AIRCRAFT RETURNED TO SERVICE. NOTE: THE GEARBOX MANUAL CRANK PAD WAS REMOVED FOR MAINTENANCE, SEAL REPLACED, NO LEAKS NOTED BY MOTORING. BOEING MM 72-00, PAGES 201-203, NO LEAK CHECK INDICATED, ESPECI ALLY ADVANCED. 2 L 7 4 4F 4 F RT A20WE E23EA 1996020200511 19960202 00511 NE 1996 2 2 96ZZZX500 2 19951212 G 7321 0164448330 FUEL CONTROL SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE DEFECTIVE B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 11 151AC 1372 1 434B 1173 4019 FUEL CONTROL FAILED TO MEET FLIGHT MANUAL AND MM NR RPM GUIDE LINES. AT FLAT PITCH AND DURING FLIGHT, RPM WAS TOO HIGH. REPLACED WITH REPAIRED UNIT, CORRECTED PROBLEM. 1 G 7 1 3U 3 U H9EU E19EU 1996020200515 19960202 00515 NE 1996 2 2 96ZZZX504 2 19950719 G 7250 430144801 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 417BK 637 05920370 7143 LE45509EF SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 4,312.8. 1 G 7 2 3U 3 U H13EU E5NE10 1996020200516 19960202 00516 NE 1996 2 2 96ZZZX505 2 19950312 G 7230 430124202 BEARING BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE COMPRESSOR NR 1 WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 11 424MB 814 2951 7082 LE45313 BEARING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 7,314.4 1 G 7 2 3U 3 U H13EU E5NE 1996020200517 19960202 00517 NE 1996 2 2 96ZZZX506 2 19950312 G 7250 430144801 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 424MB 814 1190731 7082 LE45313 SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 7,314.4. 1 G 7 2 3U 3 U H13EU E5NE 1996020200518 19960202 00518 NE 1996 2 2 96ZZZX507 2 19950818 G 7250 430124202 BEARING BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE TURBINE NR 3 WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 11 420MB 313 41472 7077 LE45244E BEARING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 8,721.5. 1 G 7 2 3U 3 U H13EU E5NE 1996020200525 19960202 00525 NE 1996 2 2 96ZZZX515 2 19950829 G 7250 430144801 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 5188B 708 0492446 7163 LE45757E SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 5,938.0. 1 G 7 2 3U 3 U H13EU E5NE10 1996020200526 19960202 00526 NE 1996 2 2 96ZZZX516 2 19950829 G 7230 430135702 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 5188B 708 338 7163 LE45757E SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 5,938.0. 1 G 7 2 3U 3 U H13EU E5NE10 1996020200527 19960202 00527 NE 1996 2 2 96ZZZX517 2 19950613 G 7250 430144801 SEAL BOLKMS 117 BK117A3 5626015 EU LYC LTS101 LTS101650B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 527SF 490 7111 LE45273E SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 6,224.8. 1 G 7 2 3U 3 U H13EU E5NE 1996020200531 19960202 00531 NE 1996 2 2 96ZZZX521 2 19950923 G 7230 430135703 SEAL BOLKMS 117 BK117A4 5626017 EU LYC LTS101 LTS101650B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 586BH 97 741 7129 LE45344E SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 7,698.4. 1 G 7 2 3U 3 U H13EU E5NE 1996020200533 19960202 00533 NE 1996 2 2 96ZZZX523 2 19951220 G 7321 0164248800 FUEL CONTROL SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE ENGINE DEFECTIVE B DYRR K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 NM 11 6099P 442 B236B 2818 9365 OCCASIONAL SMOKE AND FUEL SMELL EMITTING FROM HEATER OUTLET. REPLACED WITH NEW FCU, CORRECTED PROBLEM. 1 G 7 1 3U 3 U H9EU E19EU 1996020200535 19960202 00535 NE 1996 2 2 96ZZZX525 2 19950717 G 7250 411101007 NOZZLE ASSY BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE GAS PRODUCER CRACKED B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 11 7059N 1189 D159 7154 LE45754EF NOZZLE ASSY CRACKED AND BURNED BEYOND SERVICEABLE LIMITS. UNIT IS NOT REPAIRABLE. REPLACED WITH REPAIRED UNIT, CORRECT ED PROBLEM. ENGINE TOTAL CYCLES, 3,790.3. 1 G 7 2 3U 3 U H13EU E5NE10 1996020200536 19960202 00536 NE 1996 2 2 96ZZZX526 2 19950822 G 7250 430144801 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 7060G 621 0492489 7173 LE45552EF SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 4,063.2. 1 G 7 2 3U 3 U H13EU E5NE10 1996020200537 19960202 00537 NE 1996 2 2 96ZZZX527 2 19950825 G 7250 430144801 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 3 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 71703 794 1190802 7227 LE45514EF SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 4,927.3. 1 G 7 2 3U 3 U H13EU E5NE10 1996020200538 19960202 00538 NE 1996 2 2 96ZZZX528 2 19950825 G 7230 430135703 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 11 71703 794 479 7227 LE45514EF SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 4,927.3. 1 G 7 2 3U 3 U H13EU E5NE10 1996020200540 19960202 00540 NE 1996 2 2 96ZZZX530 2 19950825 G 7250 410106701 SEAL RING BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE 1ST TURB SHROUD WORN B DYRR K NONE O OTHER IN INSP/MAINT 1 NM 11 71703 794 7227 LE45514EF SEAL RING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 4,927.3. 1 G 7 2 3U 3 U H13EU E5NE10 1996020200542 19960202 00542 NE 1996 2 2 96ZZZX532 2 19950908 G 7230 430135703 SEAL BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE NR 2 BEARING LEAKING B DYRR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 911VU 976 446 7141 LE45582EF SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. ENGINE TOTAL CYCLES, 4,870.4. 1 G 7 2 3U 3 U H13EU E5NE10 1996020900295 19960209 00295 SO 1996 2 9 96ZZZX585 2 19951130 G 8530 653452 CYLINDER CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO LT ENG NR 4 INT CRACKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 17 37167 100 4040129 276434R DURING 100-HOUR INSPECTION OF ENGINE, A FACTORY REMANUFACTURE WITH 100 HOURS ON IT, A CRACK OR CASTING FLAW WAS DISCOVER ED NEAR THE INTAKE FLANGE AREA, APPROXIMATELY .75 INCH DOWN FROM THE INTAKE FLANGE TOWARDS THE FIN AREA WHERE THE FINS M EET THE INTAKE PORT ON CYLINDER NR 4 OF LEFT ENGINE. 1 L 7 2 3O 3 O A25CE E7CE 1996020900630 19960209 00630 NE 1996 2 9 96ZZZX614 2 19951213 G 7250 414129001 ROTOR BELL 222 222B 1182124 SW LYC LTS101 LTS101750C1 41560 NE PT ROTOR BLADE SHIFT H K NONE O OTHER IN INSP/MAINT 1 WP 17 911RA 40 47150 LE47228 POWER TURBINE ROTOR INSPECTION, SB LT101-72-50-0153, COMPLIED WITH EARLY DUE TO ANNUAL INSPECTION FOUND UNSERVICEABLE. T IME SINCE INSTALLATION 40.3 HOURS. CYCLES, 65. 1 G 7 2 3U 3 U H9SW E5NE 1996022300008 19960223 00008 EA 1996 2 23 96ZZZX715 2 19950725 G 7414 M3485 BEARING CAP SLICK 4271 GULSTM AA5 AA5B 3960105 SO LYC O360 O360A4K 41514 EA MAG ROTOR WORN D K NONE O OTHER IN INSP/MAINT 1 WP 05 74608 91040066 AA5B0282 3295236A PART NR M-3485 HAS A STEEL BEARING PRESSED INTO AN ALUMINUM BEARING CAP. IT PROVIDES SUPPORT TO THE ROTOR. DURING ROUT INE 500-HOUR INSPECTION (500 TTSN), A BLACK POWDER-LIKE SUBSTANCE WAS SEEN THROUGHOUT THE MAG. FOUND STEEL BEARING WAS MOVING INSIDE THE BEARING CAP, ABRADING ALUMINUM PARTICLES AWAY TO CONTAMINATE THE MAG. SUSPECT EXCESSIVE CLEARANCE AT OPERATING TEMP. SUBMITTER RECOMMENDS: 1) TIGHTER PRESS FIT BETWEEN BEARING AND CAP, OR, 2) FLUSH SET SCREWS AROUND E XTERIOR SIDES OF CAP TO HOLD BEARING IN PLACE, OR, 3) MAKE ALUMINUM CAP OF STEEL TO AVOID DIFFERENT EXPANSION RATES. 1 L 7 1 3O 3 O A16EA E286 1996022300010 19960223 00010 SO 1996 2 23 96ZZZX717 2 19950905 G 8530 653426 CYLINDER CESSNA 175 175A 2072504 CE CONT O300 GO300* 17022 SO NR 1 CYLINDER GUIDE WORN D K NONE O OTHER IN INSP/MAINT 1 EA 27 6821E 84 56321 VALVE GUIDE WORN EXCESSIVELY AND WOULD NOT PASS COMPRESSION CHECK. OPERATOR STATED ENGINE NEVER WAS OVERTEMPED AND WAS NOT USING AUTO FUEL. VALVE GUIDE WAS REPLACED. 1 H 7 1 3O 3 O 3A17 E298 1996022300016 19960223 00016 NE 1996 2 23 96ZZZX723 2 19951208 G 7210 310703301 BEARING PWA 118 PW118 NE RGB NR 15 SPALLED B R3AR K NONE O OTHER IN INSP/MAINT 1 SW 05 3023 FC16572 121346 SPALLED INNER RACE ON RGB NR 15 BEARING. 4 T E20NE 1996022300017 19960223 00017 NE 1996 2 23 96ZZZX724 2 19951210 G 7210 310703301 BEARING PWA 118 PW118 NE RGB NR 15 SPALLED B R3AR K NONE O OTHER IN INSP/MAINT 1 SW 05 5190 FC8779 115066 INNER BEARING OUTER RACE SPALLED. ENGINE REMOVED FROM SERVICE FOR REMOTE GEARBOX MIO. 4 T E20NE 1996022300018 19960223 00018 NE 1996 2 23 96ZZZX725 2 19951205 G 7210 310703301 BEARING PWA 120 PW120A NE RGB NR 15 SPALLED B R3AR K NONE O OTHER IN INSP/MAINT 1 SW 05 6453 68D271 121102 SPALLED OUTER RACE NR 15 BEARING OF RGB. 4 T E20NE 1996022300122 19960223 00122 GL 1996 2 23 96ZZZX738 2 19951229 G 7210 23038182 GEARBOX HOUSING 23035155 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL TACK GEN. PAD UNBONDING B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 1084Y 7348 859 HL23371 45433 CAE860485 UPON DISASSEMBLY AND INSPECTION OF THE GEARBOX PARTS, HOUSING INSPECTION FOUND BRONZE LIFTING FROM TACK GEN. PAD. POSSI BLE CAUSE FOR BRONZE PLATING UNBONDING IS DUE TO SURFACE CORROSION ON HOUSING AND OIL ACCUMULATION UNDER BRONZE DEBONDS PLATING. 1 G 7 1 3U 3 U H2SW E1GL 1996022300127 19960223 00127 GL 1996 2 23 96ZZZX743 2 19950929 G 7210 23035139 HOUSING 23035139 BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL GEARBOX UNBONDED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 346AL 3893 HL36745 51378 CAE895538 UPON DISASSEMBLY OF THE ENGINE, FOUND BRONZE PLATING UNBONDING AT COMP. BORE. ALSO, FOUND T/M HELICOIL DAMAGED. THE CA USE FOR BRONZE PLATING UNBONDING IS DUE TO THE SURFACE CORROSION ON HOUSING AND OIL ACCUMULATION. THE CAUSE FOR T/M HEL ICOIL DAMAGE IS DUE TO METAL FATIGUE IN THE OIL PORTS. 1 G 7 1 3U 3 U H2SW E1GL 1996022300386 19960223 00386 NE 1996 2 23 96ZZZX750 2 19951214 G 7250 569551 VANE RKWELL NA265 NA26540 6402608 CE PWA JT12 JT12* 52042 NE 1ST STAGE TURB DEBONDING B S JV2R K NONE O OTHER IN INSP/MAINT 1 CE 03 306NT 917 28230 P638155 UNDER NORMAL OPERATING CONDITIONS, THE PROTECTIVE COATING IS DEBONDING FROM THE SURFACE (LEADING EDGE) OF NEW VANES. DE FECT WAS FOUND BY BORESCOPING THE ENGINE. 2 L 7 2 4J 4 J A2WE 1E9 1996022300399 19960223 00399 NE 1996 2 23 96ZZZX763 2 19951214 G 7250 569551 VANE RKWELL NA265 NA26540 6402608 CE PWA JT12 JT12* 52042 NE 1ST STG TURBINE DEBONDED B JV2R K NONE O OTHER IN INSP/MAINT 1 CE 03 309NT 397 28261 P637109 UNDER NORMAL OPERATING CONDITIONS, THE PROTECTIVE COATING IS DEBONDING FROM THE SURFACE OF NEW VANES. DEFECT WAS FOUND BY BORESCOPING THE ENGINE. 2 L 7 2 4J 4 J A2WE 1E9 1996030100221 19960301 00221 SO 1996 3 1 96ZZZX822 2 19951201 G 7314 634053 VAPOR SEPARATOR 64621216 BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO FUEL PUMP FOD JAMMED PUMP B L WTXR A UNSCHED LANDING O OTHER CL CLIMB 1 NM 11 5587K 1720 620 H139202BR CE1392 285675R CUSTOMER REPORTED ENG DRIVEN FUEL PUMP FAILED AT 600 FEET AGL AFTER T/O. PILOT ACTIVATED ELEC PUMP AND SAFELY LANDED AI RPLANE. PUMP SENT TO THIS FACILITY FOR DISASSEMBLY AND INSP. WHEN PUMP DISASSEMBLED, 2 SMALL FLAKES OF ALUM FOUND JAMM ED IN VANES OF PUMP. THIS CAUSED PUMP TO SEIZE AND DRIVE COUPLING TO SHEAR. VAPOR SEPARATOR OF PUMP FND TO BE SOURCE O F ALUM. A SHARP MACHINED EDGE INSIDE HOUSING OF SEPARATOR HAD LOST MATERIAL INTO VANES OF PUMP. CASTING OF VAPOR SEPAR ATOR MAY HAVE BEEN POOR QUALITY THAT ALLOWED THIS TO HAPPEN. A POSSIBLE MEASURE TO PREVENT THIS SITUATION FROM OCCURRIN G WOULD BE TO ROUND THE SHARP EDGE IN VAPOR SEPARATOR DURING OVERHAUL. 1 L 7 1 3O 3 O 3A15 E5CE 1996030100480 19960301 00480 NE 1996 3 1 96ZZZX839 2 19951123 G 7250 3037313 PT DISK BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE 2ND STAGE BLADE FAILURE B MASR K NONE