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 1996011900170 19960119 00170 NE 1996 1 19 GMAL9501021 2 19960102 G 7323 116085025 GOVERNOR KAMAN K1200 K1200 05625F6 SW LYC T53 T5317A 41549 NE ENG OVERSPEED DEFECTIVE H GMAL O OTHER J WARNING INDICATION EX EXTERNAL LOAD 1 NM 09 132KA 410 A940004 PILOT REPORTED GOVERNOR DECAY FROM 104 PERCENT NR DOWN TO 97 PERCENT NR DURING HOVER. PROBLEM INTERMITTENT EVERY 3 TO 4 TURNS DURING LOGGING OPERATIONS. (X) 1 G 7 1 4F 4 U NT TR7BO E17EA 1996011900254 19960119 00254 GL 1996 1 19 HEEA966329 2 19960102 G 7250 23032345 COUPLING 23033185 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL 3RD STAGE STEP WEAR E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5007Y 453 CAT70022 45192 CAE860583 ENGINE REMOVED DUE TO TURBINE 3RD STAGE WHEEL REPLACEMENT. 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 1996022300681 19960223 00681 EA 1996 2 23 96ZZZX775 2 19960201 G 8530 7380685 PUSHROD LYC O235 O235L2C 41505 EA CYLINDER BALL SEPARATION D A K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 WP 11 L1840015 370 HOURS AFTER OVERHAUL, ENGINE VIBRATION WAS DETERMINED TO BE CAUSED BY BALL END SEPARATION FROM PN 73806-85 PUSHROD. PUSHROD WAS REPLACED AND ENGINE VIBRATION WAS BACK TO NORMAL. AD'S 80-25-02R2 AND 95-03-10 DO NOT PERTAIN TO THESE PUS HRODS. 3 O E223 1996022300685 19960223 00685 EA 1996 2 23 96ZZZX779 2 19960123 G 7322 13662 FLOAT BRACKET MA45 CESSNA 177 177 2073704 CE LYC O360 O360A1F6 41514 EA CARBURETOR BROKEN B S SL5R A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 NE 03 34102 500 75020609 17701642 L1573636A ENGINE LOST POWER IN CRUISE FLIGHT. AFTER SAFE LANDING AT NEARBY AIRPORT, REMOVED CARBURETOR AND DISASSEMBLED. FOUND FLOAT BRACKET BROKEN IN BEND RADIUS ALLOWING EXCESS FUEL TO ENTER CARBURETOR WHEN FLOAT VALVE COULD NOT SEAT. BEND RADI US OF FLOAT BRACKET APPEARED TO BE 90 DEGREES. SUBMITTER STATED LARGER BEND RADIUS MIGHT PREVENT UNUSUAL STRESSES IN TH E METAL REDUCING THE POSSIBILITY OF BREAKAGE. 1 H 7 1 3O 3 O NT A13CE E286 1996022300692 19960223 00692 EA 1996 2 23 96ZZZX786 2 19960201 G 8530 73806V PUSHROD LYC O235 O235L2C 41505 EA CYLINDER WRONG PART D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 11 L1610415 ENGINE WAS OVERHAULED BY FACTORY 2-20-95. DURING STC'D CONVERSION PRIOR TO INSTALLATION IN AIRCRAFT, ALL EIGHT PUSHRODS WERE FOUND TO BE P/N 73806 'V' PUSHRODS. SUBMITTER STATED AD 95-03-10 DOES NOT COVER THIS ENGINE (BUT SHOULD). FACTOR Y WAS NOTIFIED AND REPLACEMENT PUSHRODS INSTALLED. 3 O E223 1996022300704 19960223 00704 SO 1996 2 23 96ZZZX798 2 19960126 G 8540 63217H QUILL SHAFT CESSNA 421 421A 2076012 CE CONT O520 GTSIO520D 17032 SO LT ENG DRV GEAR FAILED B EKIR A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 WP 07 200CH 1320 481 421A0102 219168R LEFT ENGINE QUIT ON CLIMB-OUT. PROP FEATHERED AIRCRAFT, MADE SAFE LANDING. FOUND HOLE IN CASE UNDER INTERCOOLER FROM F AILED CONNECTING ROD. PROP TURNS FREELY. ENGINE NOT TORN DOWN AT THIS DATE. SUBMITTER SUSPECTS QUILL SHAFT FAILED ALL OWING ENGINE TO OVERSPEED. WILL SUBMIT FOLLOW-UP M OR D WHEN ENGINE IS TORN DOWN. 1 L 7 2 3O 3 O A7CE E7CE 1996022300719 19960223 00719 WP 1996 2 23 96ZZZX813 2 19960103 G 7250 31038393 ROTATING SEAL GARRTT TPE331 TPE33112UAR 01514 WP 1ST STAGE TURB FLANGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 7218 P70104 DURING INSPECTION FOR METAL CONTAMINATION, FOUND PART CRACKED AT SEALING FLANGE. THIS IS A CRITICAL LIFE-LIMITED COMPON ENT. LIFE-LIMIT IS 20,000 CYCLES. SUBMITTER STATED THIS IS THE 24TH MALFUNCTION/DEFECT REPORT SUBMITTED ON THIS PART B Y THIS REPAIR STATION. 4 T E4WE 1996030100220 19960301 00220 EU 1996 3 1 96ZZZX821 2 19960125 G 7230 BUSHING GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU HP COMPRESSOR SHIFTED B L GJQR O OTHER E VIBRATION/BUFFET DE DESCENT 1 NM 01 26WP 8630 1920 024 8576 ENGINE HAD INTERMTTENT HIGH VIBRATION READINGS. CREW REPORTED A BUZZ ON DESCENT AT 79 PERCENT HI PRESS ROTOR SPEED. IN -FLT VIB SURVEY SHOWED VIB PEAK OF 1.3 MILS CORRESPONDING TO HP ROTATIONAL FREQ AT THAT POWER SETTING. SECONDARY SMALLE R PEAK CORRESPONDING TO LP ROTOR NOTED. ENG DISASSEMBLED. SEVERAL 1ST STG HI PRESS COMPR BLADES WERE BOUND UP. ROTOR DISASSEMBLED, MTNG BUSHINGS FND BACKED OUT OF PIN HOLES. BUSHINGS SHOWED EVIDENCE OF CONTACT WITH ROTOR HUB. LOW PRESS COMPR BLADE PINS CONTAMINATED WITH DIRT & RUST. 1ST STAGE HAD HEAVIEST ACCUMULATION. 2 BRACKETS HOLD OUTER DUCT TO EN G BROKEN. BRACKETS NEAR MNT LOC FOR AFT VIB PICK-UP. LOCALIZED THERMAL DISTRESS TO NOZZLE GUIDE VANES & COMB CANS. 2 L 7 2 4F 4 F RT A12EA E2EU 1996030100470 19960301 00470 NE 1996 3 1 96ZZZX829 2 19960116 G 7250 BLADE CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE ENGINE HPT FAILURE B L DJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 120JP 550468 71331 ENGINE SOUNDED STRANGE AFTER START. TROUBLESHOT TO ENGINE INTERNAL. SENT OUT FOR OVERHAUL. FOUND 3 HT BLADES FAILED. 1 L 7 2 4F 4 F A22CE E1NE 1996030100483 19960301 00483 NE 1996 3 1 96ZZZX842 2 19960116 G 7230 310463301 ANTIROTATE RING CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE ENGINE FAILED B DJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 511AB 550299 70350 AFTER ENGINE START, ENGINE SOUNDED STRANGE (LIKE VACUUM CLEANER). TROUBLESHOT AND SUSPECTED INTERNAL DAMAGE. ENGINE RE MOVED AND SENT FOR OVERHAUL. FOUND THE ANTI-ROTATION RING HAD FAILED. 1 L 7 2 4F 4 F A22CE E1NE 1996030100487 19960301 00487 NE 1996 3 1 96ZZZX846 2 19960206 G 7210 7895922 TAB WASHER HAMSTD 775800 SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE GC49 GEARBOX CRACKED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 3903G 11548 340A0227 GEE785278 GEARBOX RETURNED TO HAMILTON STANDARD FOR FAILED BORESCOPE REPAIR. AT DISASSEMBLY OF THE DRIVE (BULL) GEAR, HAMILTON ST ANDARD DISCOVERED THE TABBED WASHER WAS CRACKED. THE CRACK IS ADJACENT TO A TAB AND EXTENDS THROUGH TO THE INSIDE DIAME TER TAB. THE DRIVE GEAR RETENTION NUT REQUIRED 1,600 FEET/POUNDS OF TORQUE TO REMOVE. THIS PART SUPERSEDED P/N 775796- 4. 2 L 7 2 4T 4 T RT A52EU E8NE6 1996030100489 19960301 00489 WP 1996 3 1 96ZZZX848 2 19960117 G 7250 8683793 STATOR GULSTM 690TP 690A 0141722 SW GARRTT TPE331 TPE3315 01514 WP HOT SECTION DEFECTIVE B L DJFR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 23 690HF 11298 P06541C DURING C/W WITH AD 95-16-08, FOUND HOT SECTION 3RD STATOR WAS IMPROPER DUE TO NOT BEING STAMPED OR SIGNED AND SERIAL NUM BER OF PART NOT ENTERED. 1 H 7 2 3T 4 T 2A4 E4WE 1996030100492 19960301 00492 SO 1996 3 1 96ZZZX851 2 19960117 G 8520 CRANKCASE CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO NR 3 CYLINDER CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 06 7560Q 421B0346 600641 UPON INSPECTION IAW AD 77-13-22 CRANKCASE CRACKS, CRACK FOUND AT NR 3 CYLINDER UPWARDS UNDER ENGINE DATA PLATE, LENGTH U NDETERMINED, BUT LEAKING OIL MAKES UNAIRWORTHY. ENGINE REMOVED FROM LEFT POSITION. ENT TT, 3,334.2 HOURS. ENG TSMOH, 916.3 HOURS. NOTE: RIGHT ENGINE HAS HEAVY CASE INSTALLED. 1 L 7 2 3O 3 O A7CE E7CE 1996030100494 19960301 00494 EA 1996 3 1 96ZZZX853 2 19960210 G 7414 66M21195 CLAMP NUT SLICK 4370 CESSNA 172 172N 2072434 CE LYC O360 O360A4M 41514 EA RT MAG ATTACH MISSING G K NONE O OTHER IN INSP/MAINT 1 GL 13 734FH 95040291 17268817 L2821736A RIGHT MAGNETO TOP ATTACHMENT MISSING. CLAMP, 66M21195. WASHER, STD-475. WASHER, STD-1727. NUT, STD-1410. RIGHT MAGN ETO INSTALLED 10-12-95. TOTAL TIME 168 HOURS. ACFT TT 4,328.5 HOURS. 1 H 7 1 3O 3 O NT 3A12 E286 1996030100497 19960301 00497 EA 1996 3 1 96ZZZX856 2 19960206 G 8520 CRANKSHAFT PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE PITTED B LK1R K NONE O OTHER IN INSP/MAINT 1 NE 01 4333C 1679 288416039 L1319839A DURING 100-HOUR ENGINE INSPECTION FOR AIRCRAFT ANNUAL INSPECTION, LYC SB 505A WAS C/W AND THE CRANKSHAFT FOUND PITTED IN THE AREA NOTED IN SB 505A. ENGINE WAS REMOVED AND REPLACED WITH A LYC FACTORY OVERHAULED. AFTER REMOVAL OF THE CRANKS HAFT PLUG, THE INTERIOR OF THE CRANKSHAFT WAS FOUND COMPLETELY PLUGGED WITH SLUDGE (1.25 POUNDS). GENERAL CONDITION AND RECORDS INDICATE A WELL MAINTAINED AIRCRAFT WITH MULTI-VISCOSITY OIL CHANGES AS REQUIRED. 1 L 7 1 3O 3 O 2A13 E274 1996030100531 19960301 00531 NE 1996 3 1 96ZZZX890 2 19960115 G 7210 310835601 SUN GEAR BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE POWER SECTION DEFECTIVE B MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 5YV 6668 21C611 UE05 114046 ALTHOUGH ALL INDICATIONS POINT TO AN ELECTRICAL DISCHARGE, THE POSSIBILITY OF A SUN GEAR FAILURE IS NOT BEING RULED OUT. THE NR 6 BEARING AND THE SUN GEAR WILL BE SHIPPED FOR FURTEHR INVESTIGATION. 2 L 7 2 4T 4 T RT A24CE E26NE 1996030800549 19960308 00549 SO 1996 3 8 96ZZZX938 2 19960130 G 7324 LINE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO NR 6 NOZ B-NUT BROKE H O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 SO 01 999CC 347570159 303156 FUEL LINE FROM FLOW DIVIDER TO NR 6 NOZZLE BROKE AT B-NUT NOZZLE AND SPRAYED RAW FUEL ON ENGINE. ENGINE ROUGH, BUT NOT SHUT DOWN AND LANDED OK WITH NO FIRE. VERY LUCKY! 1 L 7 2 3O 3 O A7SO E9CE 1996030800552 19960308 00552 EA 1996 3 8 96ZZZX941 2 19960220 G 8530 73806 PUSHROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 4 CYL EXH FAILED G A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SW 99 6110Q 15285135 L1545415 AIRCRAFT CRASHED AFTER TAKEOFF. POST-CRASH INSPECTION REVEALED NR 4 CYLINDER EXHAUST PUSHROD BROKEN AT VALVE END. NR 4 EXHAUST VALVE NOT IN OPERATION DUE TO BREAK OF PUSHROD. AD 80-25-02 AND AD 95-03-10 WERE ISSUED PERTAINING O-235 PUSHR ODS. TWO OTHER PUSHROD INCIDENTS WERE NOTED FROM CESSNA OWNER'S ORGANIZATION MAGAZINE, MARCH '96 ISSUE. SUBJECT PUSHRO D IAW OF AD 80-25-02 AND AD 95-03-10. 1 H 7 1 3O 3 O NT 3A19 E223 1996031500075 19960315 00075 GL 1996 3 15 96ZZZX1023 2 19960126 G 7230 6871534 CHIP PLUG HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL COMPRESSOR LEAKING B EOOR K NONE K FLUID LOSS IN INSP/MAINT 1 AL 03 5074R 1151D CAE832750 DURING REMOVAL OF COMPRESSOR, CHIP PLUG FOUND LEAKING PAST THE INSULATOR. REPLACED CHIP PLUG. 1 G 7 1 3U 3 U H3WE E4CE 1996031500076 19960315 00076 GL 1996 3 15 96ZZZX1024 2 19960220 G 7250 6890040 SHIELD 6898735 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL NR 1 TURB NOZZLE WARPED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 513 1151D CAE832750 DURING REPLACEMENT OF NR 1 TURBINE NOZZLE, THE NOZZLE SHIELD WAS FOUND WARPED OUT OF SHAPE. PART SENT IN FOR OVERHAUL. 1 G 7 1 3U 3 U H3WE E4CE 1996031500097 19960315 00097 GL 1996 3 15 96ZZZX994 2 19960209 G 7323 23007505 GOVERNOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE FAIL B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5059C 1499 86090389 S779 GOVERNOR SHAFT FAILED. REPLACED GOVERNOR. 1 G 7 2 3U 3 U H3EU E4CE 1996031500167 19960315 00167 NE 1996 3 15 96ZZZX1029 2 19960201 G 7260 430110701 BEARING BELL 222 222 1182122 SW LYC LTS101 LTS101650C3 41560 NE ACCY GEARBOX DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 EA 25 29KH 2554 79K027 47053 LE41123 ENGINE REMOVED FOR PT WHEEL REPLACEMENT. DURING DISASSEMBLY, SPUR GEAR PLAY FOUND EXCESSIVE. GEARBOX DISASSEMBLED AND SPUR GEAR ASSY REMOVED. THE NR 19 BEARING HAD BEEN SPINNING IN ITS BORE, WEARING AND ELONGATING BORE. SUBMITTER RECOMM ENDS PINNING OR SECURING BEARING OUTER RACE IN CASE. 1 G 7 2 3U 3 U H9SW E5NE 1996031500177 19960315 00177 GL 1996 3 15 96ZZZX1039 2 19960110 G 7323 SPLINE SHAFT HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL N2 GOVERNOR CAP DETACHED D P A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 13 8625F 1338 13605 470111D CAE830515 WHILE RETURNING TO BASE DURING FLIGHT, N2 RPM DROOPED. PILOT LANDED AIRCRAFT AND REPORTED MALFUNCTION TO THE MECHANIC. UPON INSPECTION OF GOVERNOR AND ATTACHING AIR LINES, THE DRIVE SPLINE RETAINING CAP WAS FOUND DETACHED AND SMALLER SHAF T FOUND PARTIALLY FAILED AND TWISTED. 1 G 7 1 3U 3 U H3WE E4CE 1996031500366 19960315 00366 SO 1996 3 15 96ZZZX1048 2 19960227 G 8530 642619F PISTON PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO NR 2 CYLINDER RINGS BROKEN H E A ENGINE SHUTDOWN UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 NM 09 83828 1540 348133089 315090 ENGINE LOST OIL PRESSURE DURING FLIGHT. PILOT SHUT DOWN ENGINE AND MADE UNEVENTFUL LANDING. LARGE AMOUNT OF OIL WAS FO UND UNDER THE ENGINE AND UNDER THE WING. COMPRESSION CHECK SHOWED ZERO COMPRESSION ON NR 2 CYLINDER. CYLINDER REMOVED AND DISCOVERED ALL RINGS BROKEN AND THE RING GLANDS SEVERELY BROKEN AND WORN. A SUBSTANTIAL AMOUNT OF ALUMINUM WAS FOUN D IN THE FILTER AND SCREEN. 1 L 7 2 3O 3 O A7SO E9CE 1996031500398 19960315 00398 GL 1996 3 15 96ZZZX1080 2 19960120 G 7323 369A795155 ROD END HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GOV/THROTTLE STIFF B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 4571V 4904870 DURING ANNUAL INSPECTION, THE ROD ENDS FROM THE GOVERNOR THROTTLE SHAFT TO THE BELLCRANK WERE FOUND EXTREMELY STIFF WITH SOME TEFLON RESIDUE COMING FROM THE ROD ENDS. REPLACED PARTS. 1 G 7 1 3U 3 U H3WE E4CE 1996031500632 19960315 00632 SO 1996 3 15 96ZZZX1083 2 19960217 G 8550 PUMP CESSNA 210 T210H 2073438 CE CONT O520 TSIO520R 17040 SO ENGINE OIL MISOVERHAULED D E ENGINE SHUTDOWN J W WARNING INDICATION INADEQUATE Q C IN INSP/MAINT 1 SW 13 65093 21061844 293717R ON THE 6TH RUN FOR GROUND ADJUSTMENTS, OIL PRESSURE DROPPED TO 30 THEN 10 PSI AND ENGINE SECURED. REPEATED ATTEMPTS TO PRIME OIL SYSTEM, COULD NOT GET OIL PRESSURE UP. PUMP WAS REMOVED AND INSPECTED WITH NO OBVIOUS DEFECTS. OIL PAN WAS R EMOVED AND PICK-UP TUBE INSPECTED WITH NO DEFECTS. ONLY DEFECT NOTED WAS THAT OIL PUMP WAS PROBABLY INCORRECTLY SILK TH READED ALLOWING AIR TO BE SUCKED INTO SYSTEM AROUND ORIFICE. AFTER REINSTALLATION OF COMPONENTS, NO FURTHER PROBLEMS EN COUNTERED AND ACFT FLOWN WITH NO PROBLEMS. 1 H 7 1 3O 3 O 3A21 E8CE 1996031500648 19960315 00648 EA 1996 3 15 96ZZZX1099 2 19960128 G 7322 MA3AU CARBURETOR CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA ENGINE DEFECTIVE G K NONE O OTHER IN INSP/MAINT 1 SW 11 757UK 4625 2552 CR0665 15280012 L1307415 INSPECTION FOUND CARBURETOR COMPOSITE FLOATS BLACK AND CARBONED. IN ADDITION, THROTTLE ARM WORN. TWO PIECE VENTURI WAS INSTALLED. 1 H 7 1 3O 3 O NT 3A19 E223 1996031500654 19960315 00654 SO 1996 3 15 96ZZZX1105 2 19960126 G 8520 649134 CRNAKSHAFT CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO NR 2 MAIN FAILED D A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 SW 03 4691E 975 325 B089312N 18503842 175052R CRANKSHAFT BROKE AFT OF NR 2 MAIN JOURNAL AT OIL TRANSFER TUBE. PARTS SET TO TCM FOR DETERMINATION OF FAILURE. CAUSE W AS DETERMINED TO BE LOW THROUGH-BOLT TORQUE WHICH, IN TURN, CAUSED BEARING TO SHIFT AND CRANKSHAFT TO VIBRATE. AIRCRAFT HAD DEPARTED NORMALLY, WHEN LEVELLING AND SETTING CRUISE CONDITION VIBRATION WAS NOTICED. WHEN AIRCRAFT TURNED TO RETU RN TO BASE, ENGINE FAILED. AIRCRAFT LANDED WITHOUT INCIDENT. (SEAPLANE). VAR TYPE CRANKSHAFT. CUT .010 INCH UNDER. 1 H 7 1 3O 3 O 3A24 E5CE 1996031500662 19960315 00662 EA 1996 3 15 96ZZZX1113 2 19960119 G 7414 1068256011 MAGNETO BENDIX PIPER PA28 PA28236 7102815 SO LYC O540 O540J3A5 41532 EA MAG MOUNT FLANGE FAILED H A A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 WP 05 2476Y E109008GR 288511016 RL2277540A BOTH MOUNTING FLANGES OF THE SINGLE DRIVE DUAL MAGNETO WERE BROKEN. MAGNETO BACKED OUT OF ENGINE GEAR DRIVE CAUSING ENG INE TO STOP. AIRCRAFT LANDED IN OCEAN. 1 L 7 1 3O 3 O 2A13 E295 1996031500665 19960315 00665 NE 1996 3 15 96ZZZX1116 2 19960207 G 7210 310709001 BEARING PWA 118 PW118A NE RGB NR 19 SPALLED B RA1R K NONE O OTHER IN INSP/MAINT 1 SW 05 8360 73C029 115608 INSPECTION FOUND REMOTE GEARBOX NR 19 BEARING SPALLED. 4 T E20NE 1996031500666 19960315 00666 NE 1996 3 15 96ZZZX1117 2 19960215 G 7210 310924401 BEARING PWA 118 PW118A NE RGB NR 15 SPALLED B RA1R K NONE O OTHER IN INSP/MAINT 1 SW 05 8486 RH475 121119 INSPECTION FOUND RGB NR 15 BEARING SPALLED. 4 T E20NE 1996031500667 19960315 00667 EU 1996 3 15 96ZZZX1118 2 19960215 G 7250 3053556220 BEARING CFMINT CFM56 CFM563B2 13802 EU HPT ROTOR DAMAGED B RA1R K NONE O OTHER IN INSP/MAINT 1 SW 05 RR10056 721339 ENGINE WAS REMOVED FROM SERVICE DUE TO IN-FLIGHT SHUT DOWN. DISASSEMBLY OF THE ENGINE REVEALED THE NR 4 BEARING AREA WI THIN THE HPT ROTOR REAR SHAFT AND LPT NR 4 BEARING ROTATING SEALS HAD HEAVY DAMAGE. FURTHER INVESTIGATION IS IN PROCESS AT AVIALL. 4 F E21EU 1996031500671 19960315 00671 SO 1996 3 15 96ZZZX1122 2 19960221 G 7414 S6LN25 MAGNETO BENDIX PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO MAGNETO COIL CLAMP BROKEN B APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 4490F 1489 B119325DR 747670339 COIL CLAMP FOUND BROKEN AT BEND RADIUS DURING MAGNETO 500-HOUR INSPECTION. NOTE: CLAMP HAD WHITE DYKEM MARK PER TCM MA NUAL PAGE 7-6, PARAGRAPH 7.2.G(D). 1 L 7 2 3O 3 O A7SO E9CE 1996031500672 19960315 00672 EA 1996 3 15 96ZZZX1123 2 19960223 G 7414 D6LN2230 MAGNETO BENDIX PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RETARD LEAD DEFECTIVE B APCR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 27343 317752163 RL727061A MAGNETO CAME INSTALLED ON FACTORY OVERHAULED ENGINE. WHEN CONNECTING IGNITION HARNESS, NOTED RETARD LEAD COULD BE PUSHE D ALL THE WAY INTO THE MAG WITHOUT TOUCHING CONTACT FINGER SPRING. REAR COVER REMOVED TO ADJUST FINGER AND RIGHT POINT SET FOUND LOOSE, AND FIVE DEGREE SPLIT BETWEEN LEFT AND RIGHT POINTS. INSTALLER MADE NECESSARY ADJUSTMENTS AND SECURED POINT ATTACHING SCREWS. 1 L 7 2 3O 3 O A20SO E14EA 1996032200002 19960322 00002 NE 1996 3 22 96ZZZX1129 2 19960222 G 7200 ENGINE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE7313B 01518 NE FWD FAN GRBOX OIL LOSS B MUCR E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION NR NOT REPORTED 1 GL 13 275GC 2316 6500162 87437 ENGINE EXHIBITED LOW OIL PRESSURE AND ENGINE WAS SHUT DOWN. AIRCRAFT MADE NORMAL LANDING ON SINGLE ENGINE. FOUND TWO Q UARTS OF OIL IN ENGINE. NORMAL CAPAPCITY (6 QUARTS). COULD NOT DUPLICATE ANY MALFUNCTIONS DURING TROUBLESHOOTING, BUT SUSPECT OIL SYSTEM PRESSURIZED FORCING OIL OUT BREATHER AS THE RESULT OF EITHER BREATHER PRESSURIZING VALVE STICKING OR UNSEATED CARBON SEAL. REPLACED NR 1 AND NR 3 CARBON SEAL AND BREATHER PRESSURIZING VALVE. 2 L 7 2 4F 4 F A9NM E6WE 1996032200008 19960322 00008 WP 1996 3 22 96ZZZX1135 2 19960207 G 7260 30702192 GEARSHAFT 30700934 BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315R 01518 WP TRANSFER GRBOX FAILED D A UNSCHED LANDING J Y WARNING INDICATION ENGINE STOPPAGE CR CRUISE 1 CE 05 1910H 5314 P4880 258023 P91118 AIRCRAFT WAS IN CRUISE FLIGHT AT 39,000 FEET WHEN MASTER WARNING FLASHER CAME ON AND WOULD NOT CANCEL. SEVERAL SECONDS LATER, RT N2 INDICATION DROPPED TO ZERO FOLLOWED BY SHUT DOWN OF RT ENGINE. AIRCRAFT LANDED SAFELY WITHOUT INCIDENT. C AUSE OF SHUT DOWN WAS FAILURE OF BEVEL GEAR ON VERTICAL GEARSHAFT, PN 3070219-2, INSIDE TRANSFER GEARBOX, PN 3070093-4. THERE IS NO REQUIREMENT TO DISASSEMBLE AND DETAIL INSPECT THE GEARBOX ON CIVILIAN AIRCRAFT. AN ANALYSIS OF THE FAILED GEAR IS BENG PERFORMED BY ALLIED SIGNAL. 2 L 7 2 4F 4 F RT A3EU E6WE 1996032200015 19960322 00015 NE 1996 3 22 96ZZZX1142 2 19960220 G 8520 CAMSHAFT DOUG DC3 DC3C 3021457 WP PWA R1830 R183092 52020 NE RT ENGINE FAILED E E ENGINE SHUTDOWN E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 11 59316 715 18986 BP462185 RIGHT ENGINE STARTED TO BACKFIRE AND RUN ROUGH. ENGINE WAS SHUT DOWN IN-FLIGHT AND PROP FEATHERED. UPON TROUBLESHOOTIN G, FOUND VALVES ON REAR CYLINDERS NOT ACTUATING. SUSPECT BROKEN CAM GEAR. ENGINE WAS REMOVED FOR REPAIR AND A SERVICEA BLE ENGINE WAS INSTALLED. 2 L 7 2 4R 4 R A669 5E4 1996032200128 19960322 00128 GL 1996 3 22 96ZZZX1167 2 19960101 G 7240 23056130 COMBUSTION LINER HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE BURNED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 1151D CAE832750 WHILE REMOVING TURBINE, THE COMBUSTION LINER WAS FOUND BURNED, WARPED, AND CRACKED. PART REPLACED. 1 G 7 1 3U 3 U H3WE E4CE 1996032200130 19960322 00130 GL 1996 3 22 96ZZZX1169 2 19960202 G 7261 6853301 SUMP HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL NR 6-7 BEARING WARPED B EOOR K NONE K FLUID LOSS IN INSP/MAINT 1 AL 03 5074R 1436 1151D CAE832750 DURING ANNUAL INSPECTION, NR 6 AND NR 7 BEARING SUMP ON THE TURBINE FOUND LEAKING AT THE MATING SURFACE. SUBSEQUENT INS PECTION REVEALED FLANGE WAS WARPED. 1 G 7 1 3U 3 U H3WE E4CE 1996032200131 19960322 00131 GL 1996 3 22 96ZZZX1170 2 19960211 G 7323 230574869 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 5074R 591 24657 1151D CAE832750 DURING RUN-UP, PILOT WAS ADJUSTING ENGINE 'BEEP' AND THE GOVERNOR HESITATED, BUT WHEN AN INCREASE WAS NOTED, IT JUMPED U P 3 PERCENT TO 4 PERCENT AND WAS NOT A SMOOTH TRANSITION. PART SENT IN FOR REPAIR. 1 G 7 1 3U 3 U H3WE E4CE 1996032200444 19960322 00444 EA 1996 3 22 96ZZZX1254 2 19960227 G 8530 60828 PISTON PIN PLUG CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA CYLINDER FAILED H K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 19 99263 25 17276424 L1141539A PISTON PIN PLUG, PN 60828, IS NOT CORRECT, BUT LOCATION IS CORRECT. ENGINE OVERHAULED 24.8 HRS AGO. COMPLAINT OF LOSS OF POWER. GROUND RUN SEEMED OK, NOTHING OBVIOUS. COMPRESSION TEST FOUND LOW COMPRESSION ON ONE CYLINDER. BORESCOPED A ND COULD SEE METAL FLAKES. UPON DISASSEMBLY OF CYLINDER, FOUND SMALL ALUMINUM BALL IN CHEWED UP PISTON. AREA FROM NR 2 RING DOWN TO TOP OF PISTON PIN, HOLE WORN AWAY. SECTION OF BOTTOM RING BROKE OFF. CYLINDER WALL IN THIS AREA DAMAGED. 1 H 7 1 3O 3 O NT 3A12 E274 1996032200457 19960322 00457 SO 1996 3 22 96ZZZX1267 2 19960228 G 8550 CH48109 OIL FILTER CHAMPION 641639 BEECH 58 58 1152740 CE CONT O550 IO550C SO LT/RT ENGINES MISINSTALLED B ERY2 K NONE O OTHER IN INSP/MAINT 1 SO 11 123ZM 22 TH1768 676924 DURING FIRST ROUTINE ENGINE OIL AND FILTER CHANGE, THE OIL FILTER WAS EXTREMELY DIFFICULT TO REMOVE FROM THE ADAPTER ASS Y. SUBMITTER SUSPECTS CAUSE FOR PROBLEM: NO LUBRICATION AT INSTALLATION AS ENGINE WAS READIED FOR SERVICE. SUGGEST FO LLOW RECOMMENDED PROCEDURE PER MFG. SAME PROBLEM ENCOUNTERED WITH RIGHT ENGINE. (RIGHT ENGINE SN 676926, SAME TOTAL TI ME). 1 L 7 2 3O 3 O 3A16 E3SO 1996032200469 19960322 00469 SO 1996 3 22 96ZZZX1279 2 19960215 G 7322 30764 FLOAT 103965121 CESSNA 182 182 2072702 CE CONT O470 O470L 17026 SO CARBURETOR DETACHED B KC2R O OTHER Y ENGINE STOPPAGE CR CRUISE 1 GL 03 4000457 ENGINE QUIT IN-FLIGHT ONCE AND ON THE GROUND ONCE. FOUND ONE PONTOON OF FLOAT ASSEMBLY HAD BROKEN OFF. DATE CODE STAMP ED IN FLOAT BRACKET IS 884. IT IS A FACTORY MANUFACTURED FLOAT; NOT A PMA. 1 H 7 1 3O 3 O NT 3A13 E273 1996032900226 19960329 00226 EA 1996 3 29 96ZZZX1341 2 19960227 G 7414 1051676 CAPACITOR BENDIX S6RN23 HILLER UH12 UH12B 4360110 WP FRNKLN 6AV335 6V335B 27020 EA RT MAG FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 07 4785C 7 430043 312 WHEN RT MAG SELECTED DURING ENGINE RUN-UP CHECK, ENGINE FAILED. OBSERVED EXCESSIVE SPARKING AND POINT WEAR (7 HRS SINCE NEW). ENGINE RAN NORMALLY AFTER REPLACEMENT OF CAPACITOR AND POINT ADJUSTMENT. SUSPECT MANUFACTURING DEFECT OF PMA CA PACITOR. 1 G 7 1 3O 3 O 6H2 E244 1996032900244 19960329 00244 NE 1996 3 29 96ZZZX1359 2 19960209 G 7230 BLADE RKWELL NA265 NA26560 7630106 CE PWA JT12 JT12A8 52042 NE COMPRESSOR RUB B JV2R K NONE O OTHER IN INSP/MAINT 1 CE 03 401MS 1210 30617 P673149NB DURING INSPECTION OF ENGINE, SN P673149NB, A CRACKED INLET GUIDE VANE PROMPTED REMOVAL OF INLET CASE FOR REPAIRS. WITH CASE REMOVED, A COMPRESSOR BLADE RUB, WHICH RESULTED IN DETERIORATION TO A STATOR, WAS NOTED AND REPORTED. AUTHORIZATIO N WAS RECEIVED FROM CUSTOMER TO DISASSEMBLE COMPRESSOR FOR FURTHER INVESTIGATION. UPON DISASSEMBLY OF COMPRESSOR, SEVER E CORROSION NOTED ON STEEL COMPONENTS. A CORROSION INSPECTION AND SUBSEQUENT COMPRESSOR OVERHAUL PER P&WA, SB 1508R16, WAS INITIATED. 2 L 7 2 4J 4 J RT A2WE 1E9 1996032900245 19960329 00245 NE 1996 3 29 96ZZZX1360 2 19960209 G 7250 566101 BLADE RKWELL NA265 NA26560 7630106 CE PWA JT12 JT12A8 52042 NE 1ST STG TURBINE OVERLAP B L JV2R K NONE O OTHER IN INSP/MAINT 1 CE 03 401MS 1210 30617 P673152NB DUE TO CORROSION DMG DISCOVERED ON RT ENG, CUSTOMER ELECTED TO DISASSEMBLE LT ENG FOR CORROSION INSP, & SUBSEQUENT COMPR OVERHAUL PER P&WA. UPON DISASSEMBLY OF COMPR, SEVERE CORROSION NOTED ON STEEL COMPONENTS. CORRRODED STEEL DISK REJECT ED. CUSTOMER ELECTED TO REPLACE LIFE LIMITED DISKS IN BOTH ENGS TO ALLOW ENGS TO CONTINUE IN SERV TO 3000 HRS TBO; THUS , PROMPTING TO ACCESS TURB AREA ON ENG, SN P673152NB, TO REPLACE LIFE LIMITED TURB DISKS. TURB BLADES REMOVED DUE TO RE PLACMENT OF LIFE LIMITED TURB DISK. NOTED 76 1ST STG TURB BLADES SHOWED SIGNS OF SHROUD OVERLAP, DISPLACED METAL & META L SEPARATION IN NOTCH SURFACE OF SHROUD. 14 TURB BLADES PREV INSTALLED IN NEW COND (TT: ZERO) & 2 WERE SERVICEABLE. 2 L 7 2 4J 4 J RT A2WE 1E9 1996032900348 19960329 00348 NE 1996 3 29 96ZZZX1377 2 19960210 G 7261 3008127 GEARSHAFT 3024287 PWA PT6 PT6A42 52043 NE OIL CAV PMP SHEARED D E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 GL 17 18260 2730 D618 PCE93133 PILOT REPORTED A LOW FUEL PRESSURE LIGHT FOLLOWED BY AN AUTOFEATHER ON LEFT ENGINE. PILOT SHUT DOWN ENGINE AND LANDED W ITHOUT INCIDENCE. UPON INVESTIGATION, NOTED THE OIL LEVEL LOW, THERE WAS OIL IN THE EXHAUST CASE, AND METAL PARTICLES A ND FLAKES PRESENT IN THE OIL FILTER. FURTHER INVESTIGATION SHOWED SCAVENGE PUMP SHAFT HAD SHEARED. ENGINE REMOVED FOR METAL IN OIL. 4 T E4EA 1996032900350 19960329 00350 EA 1996 3 29 96ZZZX1379 2 19960131 G 7250 SHROUD RING BEECH 200 B200 1152922 CE PWA PT6 PT6A41 52043 EA PT SECTION LUG MISSING B RX8R K NONE O OTHER IN INSP/MAINT 1 SO 15 203BS BB476 PCE85365 BINDING, WHEN PROPELLER WAS ROTATED, FOUND DURING MORNING PRE-FLIGHT. THE POWER SECTION WAS REMOVED AND SENT TO DALLGO AIRMOTIVE. D.A. FOUND A MISSING LOCATING LUG FROM THE PT SHROUD RING THAT WAS BINDING UP THE ROTATION OF THE POWER SECT ION. 1 L 7 2 4T 4 T A24CE E4EA 1996032900355 19960329 00355 NE 1996 3 29 96ZZZX1384 2 19960201 G 7532 34A39709 COVER A39710K PWA JT9 JT9* 52054 NE PRBC IMPROPER WELD B SF3R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 1151823 RECEIVED CECO P.R.B.C. FROM TOWER AIR INC., FOR ZERO TIME OVERHAUL 8-30-95. DISASSEMBLY AND INSPECTION OF COVER REVEALE D UNAUTHORIZED REWORK HAD BEEN PERFORMED (WELD). 4 F E20EA 1996040500402 19960405 00402 EA 1996 4 5 96ZZZX1467 2 19960301 G 8520 SL75060 ROD BOLT PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA NR 4 FAILED G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 16 8951N 3240753 L762248 NR 4 TOP ROD BOLT FAILED IN-FLIGHT. SEE AD NOTE 95-7-1 TW SMITH SENT LETTER TO SATISFY AD, THAT BOLT WAS NOT INSTALLED AT ENGINE OVERHAUL. TIME SINCE O/H WAS ABOUT 120 HRS. 1 L 7 1 3O 3 O A3SO 1E4 1996040500403 19960405 00403 SO 1996 4 5 96ZZZX1468 2 19960314 G 8530 653446A6 CYLINDER BEECH 58 58 1152740 CE CONT O520 IO520CB 17032 SO NR 2 CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 05 6650D 1531 TH1375 282375R FINDING STEEL CYLINDERS ARE CRACKING FROM THE FUEL INJECTOR BOSS ACROSS TO THE SPARK PLUG BOSS ON A REGULAR BASIS. SUBM ITTER REPORTS SOME CYLINDERS WITH AS LITTLE AS 600.0 TT CRACKED. SUBMITTER BELIEVES THERE MUST BE SOME TYPE OF MANUFACT URING PROBLEM. 1 L 7 2 3O 3 O 3A16 E5CE 1996040500411 19960405 00411 SO 1996 4 5 96ZZZX1476 2 19960225 G 7322 46512 VENTURI FACET MA35PA CESSNA 150 150 2071802 CE CONT O200 O200A 17020 SO CARBURETOR CASTING FLAW D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 11831 DE2216306R 15075658 INSPECTION OF A NEW PMA CARBURETOR VENTURI FOUND CASTING FLAWS. SUBMITTER STATES HAS SEEN THIS DEFECT FREQUENTLY. 1 H 7 1 3O 3 O NT 3A19 E252 1996040500624 19960405 00624 SO 1996 4 5 96ZZZX1501 2 19960219 G 8500 ENGINE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO LT ROUGHNESS I K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 NE 05 3249M 760 402C0296 290143R FLIGHT CREW NOTICED ROUGHNESS IN LEFT ENGINE. INSPECTED MAGS, COMPRESSION TESTED CYLINDERS, CHECKED SPARK PLUGS. ENGIN E WAS GROUND RUN. FLIGHT OK'D. NOTED NO PROBLEMS. RETURNED TO SERVICE. NOTED: MINUS 21 DEGREES FAHRENHEIT TEMPERATU RE. 1 L 7 2 3O 3 O A7CE E8CE 1996040500652 19960405 00652 SO 1996 4 5 96ZZZX1529 2 19960301 G 8530 CYLINDER CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO ENGINE HEAD SEPARATED D K NONE O OTHER NR NOT REPORTED 1 EA 23 5009J 1428 310R0730 266054R CYLINDER HEAD SEPARATED FROM BARREL. 1 L 7 2 3O 3 O 3A10 E5CE 1996040500657 19960405 00657 EA 1996 4 5 96ZZZX1534 2 19960322 G 7322 30766 FLOAT FACET MA3PA CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CARBURETOR CRACKED D A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SW 15 5366B 864 DM0922 15283849 CARBURETOR FLOAT FILLED WITH FUEL AND SANK IN-FLIGHT RESULTING IN ENGINE STOPPAGE AND FORCED LANDING. FLOAT WAS IN C/W AD 93-19-04. FLOAT CRACKED AND FILLED WITH FUEL. RECOMMEND RE-ENGINEERED FLOAT NOT PRONE TO CRACKING. 1 H 7 1 3O 3 O NT 3A19 E223 1996040500661 19960405 00661 SO 1996 4 5 96ZZZX1538 2 19960124 G 8520 MOUNT STUD CESSNA 340 340A 2076405 CE CONT O520 TSIO520N 17040 SO NR 4 CYLINDER BROKEN B EBVR K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 09 61JK 340A0333 509498 PILOT COMPLAINED RT ENGINE WAS ROUGH RUNNING. FOUND NR 1 CYLINDER HELD ON BY ONLY AFT TWO THROUGH-BOLTS. ALL OTHER MOU NT STUDS WERE BROKEN. REMOVED CYLINDER AND THROUGH-BOLTS. PENETRATE CHECK OF CASE MOUNTING AREA REVEALED TWO CRACKS (1 O'CLOCK AND 7 O'CLOCK) AT MOUNT STUD HOLES AND MAG PARTICLE OF THROUGH-BOLTS REVEALED ONE CRACKED. 1 L 7 2 3O 3 O 3A25 E8CE 1996040500668 19960405 00668 SO 1996 4 5 96ZZZX1545 2 19960305 G 8550 OIL FILTER CESSNA 180 180J 2072622 CE CONT O470 O470S 17026 SO CONNECTION WRONG PART B FE6R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 11 7824K 18052758 464271 DURING AN ANNUAL INSPECTION, NOTED A CHAMPION CH 48103 (.8125 INCH BY 16 INCH FEMALE THREAD) OIL FILTER WAS INSTALLED. T HE CORRECT OIL FILTER FOR THIS INSTALLATION SHOULD HAVE BEEN A CH-48110 (.75 INCH BY 16 INCH MALE THREAD). IT IS BELIEV ED THAT THE THREADED ADAPTER CAME OUT OF AN OIL FILTER (BRAND UNKNOWN) IN TIMES PAST (RECORDS SHOW CH 48103 FILTER INSTA LLED AT LEAST SINCE MARCH 1993) AND BECAME STUCK IN THE FEMALE THREADS OF THE OIL FILTER ADAPTER. PERSONNEL, AT THAT TI ME, OBTAINED A FILTER THAT FIT, ALBEIT POORLY. MAINTENANCE PERSONNEL, AFTER THAT TIME, REINSTALLED THE SAME PART NUMBER THAT WAS REMOVED. 1 H 7 1 3O 3 O 5A6 E273 1996040500669 19960405 00669 SO 1996 4 5 96ZZZX1546 2 19960305 G 8540 635050A4 ADAPTER CESSNA 182 182P 2075816 CE CONT O470 O470S 17026 SO STARTER FAILED B LX5R K NONE O OTHER IN INSP/MAINT 1 GL 19 841LL 1397 18263908 463648 WHEN STARTER WAS ENGAGED, THE PROPELLER MADE APPROXIMATELY ONE-EIGHTH REVOLUTION AND STOPPED. FURTHER ATTEMPTS WITH STA RTER WOULD NOT TURN PROPELLER. PROP WAS 'STIFF' TURNING IN DIRECTION OF NORMAL ROTATION. PROP COULD NOT BE TURNED AT A LL IN OPPOSITE DIRECTION. REMOVED STARTER ADAPTER FROM ENGINE AND PROP ROTATION FELT NORMAL IN BOTH DIRECTIONS. 1 H 7 1 3O 3 O NT TA13 E273 1996040500682 19960405 00682 SO 1996 4 5 96ZZZX1559 2 19960301 G 8520 115721 CRANKCASE CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO LT ENGINE CRACKED B L VA1R K NONE O OTHER IN INSP/MAINT 1 SW 19 12455 2080 677 1A688P 414A1207 800530 ENGINE CRANKCASE 1157-21 DEFECTIVE DUE TO CRACKS AFT OF NR 2 CYLINDER. ALSO, NR 2 AND NR 3 BEARING SADDLES HAVE CRACKS. CRANKCASE PN 643202 MODIFIED TO 1157-21 PER STC SE 3630SW. 1 L 7 2 3O 3 O A7CE E8CE 1996041200091 19960412 00091 NE 1996 4 12 96ZZZX1630 2 19960228 G 7321 7280774 SPIDER VALVE PWA JT8 JT8* 52044 NE FUEL CONTROL SEIZED B RD43 K NONE Y ENGINE STOPPAGE IN INSP/MAINT 1 SW 05 21J F9606 ENGINE SHUT DOWN IN TEST CELL DURING POST-RENTAL INSPECTION TEST. THE ENGINE WAS AT FULL POWER AT THE TIME OF SHUT DOWN . REMOVAL OF THE FUEL CONTROL SHOWED A SHEARED DRIVE SHAFT. REMOVAL OF THE HYDRAULIC HOUSING FROM THE LINKAGE HOUSING ON THE CONTROL SHOWED A SEIZED SPEED GOVERNOR PILOT VALVE IN THE SPIDER. THE CONTROL WAS RE-ASSEMBLED AND IS BEING ROUT ED TO AAR FOR INVESTIGATION. 4 F E2EA 1996041200096 19960412 00096 NE 1996 4 12 96ZZZX1635 2 19960209 G 7250 569551 VANE PWA JT12 JT12A8 52042 NE 1ST STG TURB PLATING PEEL B L IV2R K NONE O OTHER IN INSP/MAINT 1 SW 15 P637109NB REPORTED CAUSE FOR REMOVAL OF ENGINE FROM AIRCRAFT WAS TURBINE BLADE FAILURE. INVESTIGATION FINDINGS: ENGINE DISASSEMB LED AS NECESSARY AND REPAIRED DUE TO TURBINE BLADE FAILURE. DISCREPANCY NOTED DURING INSPECTION WAS PLATING PEELING OFF 23 EACH, PN 569551, FIRST STAGE TURBINE VANES WITH A TOTAL TIME OF 396.6 HRS, AND 10 EACH REWORKED (OVERHAULED) PN 5695 51 VANES WITH 396.6 HRS TSO (REF P & WA PN 435108 OVERHAUL MANUAL, PAGES 6-92, PARA 6-229). SUBJECT VANES WERE REPLACED . 4 J 1E9 1996041200496 19960412 00496 WP 1996 4 12 96ZZZM638 2 19960128 G 7260 3588941 BEARING SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP LT GEARBOX FAILED A PNSA E ENGINE SHUTDOWN Y ENGINE STOPPAGE CR CRUISE 1 AL 03 640PA 4729 AC759B P44691 DURING CRUISE FLIGHT, LEFT ENGINE FUEL CONTROL DRIVE GEARBOX BEARING FAILED. 2 L 7 2 4T 4 T RT A8SW E4WE 1996041200698 19960412 00698 EA 1996 4 12 96ZZZX1705 2 19960315 G 8500 ENGINE MOONEY M20 M20E 5870212 SW LYC O360 IO360A1A 41514 EA PWR SECTION SEIZED H A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SW 99 1940Y 247 L60951 AIRCRAFT WAS IN LEVEL FLIGHT AT 13,500 FEET, HAD COMPLETE ENGINE FAILURE AND SEIZED WITH NO PRIOR WARNING. DECLARED EME RGENCY. GLIDED 17.2 NM BACK TO AIRPORT, LANDED WITHOUT FURTHER INCIDENT. NO DAMAGE TO AIRCRAFT AND NO INJURIES. ENGIN E SCHEDULED TO BE REPLACED 3-28-96. 1 L 7 1 3O 3 O 2A3 1E10 1996041200702 19960412 00702 EA 1996 4 12 96ZZZX1709 2 19960303 G 8530 CYLINDER LYC O320 O320E2A 41508 EA SKIRT AREA DAMAGED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 100 DURING A TEAR DOWN OF AN ENGINE, FOUND CYLINDERS WERE VERY HARD TO MOVE. AFTER THEY WERE TAKEN OFF, NOTICED ENGRAVED ET CHING ON CYLINDER SKIRT WAS RAISED AND VERY MUCH HIGHER THAN THE SURROUNDING AREA. THE VIBRATING PENCIL WAS VERY SHARP AND SET TO CUT MAXIMUM. STONING THE EFFECTED AREA AND SMOOTHING THE CRANKCASE TO RELIEVE STRESS SOLVED THE PROBLEM. 3 O E274 1996041200703 19960412 00703 EA 1996 4 12 96ZZZX1710 2 19960214 G 7414 10382894 GEARTOOTH BENDIX DYRN2021 CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA LT MAGNETO BROKEN D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 21 1465E 343 5023753R 17271012 L122176T REMOVED MAGNETO DUE TO ROUGH ENGINE. FOUND A TOOTH BROKEN OFF OF LEFT DISTRIBUTOR GEAR. MAGNETO WAS ON A LYCOMING FACT ORY OVERHAUL. MAGNETO WAS OVERHAULED BY ELECTRO SYSTEMS, INC. 1 H 7 1 3O 3 O NT 3A12 E274 1996041200704 19960412 00704 SO 1996 4 12 96ZZZX1711 2 19960314 G 8530 VALVE PIPER PA28 PA28R200 7102811 SO CONT O360 IO360C 17025 SO NR 4 INT FAILED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 EA 27 32481 1526 28R7535061 L2220251A ON TAKEOFF, ENGINE BEGAN TO VIBRATE (AT FULL POWER SETTINGS). RETURNED TO AIRPORT. UPON INSPECTION, FOUND NR 4 INTAKE VALVE BROKEN IN HALF ON FACE AREA. NR 4 PISTON SEVERELY DAMAGED, COULD NOT LOCATE PARTS OF MISSING VALVE. SUSPECT INJE STED INTO ENGINE THOUGH NO METAL WAS FOUND IN OIL FILTER OR SUMP SCREEN. TT 1,526.0 HOURS ON ENGINE. 1 L 7 1 3O 3 O 2A13 E1CE 1996041200705 19960412 00705 EA 1996 4 12 96ZZZX1712 2 19960316 G 7414 M3525 COIL SLICK 4270 PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA RT MAGNETO OPEN D K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 NE 05 217LM 4270 21689 2821972 L2406227AC DURING RUN-UP, PILOT EXPERIENCED RT MAGNETO EXCESSIVE DROP. ON REMOVAL BY MAINTENANCE, ENGINE WOULD NOT RUN ON RT MAGNE TO. FOUND OPEN IN SECONDARY COIL WINDINGS. 1 L 7 1 3O 3 O 2A13 E274 1996041200719 19960412 00719 WP 1996 4 12 96ZZZX1726 2 19960103 G 7250 31038393 SEAL 31033155 GARRTT TPE331 TPE33112UHR WP TURB 1ST STAGE FLANGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 7217 1233151952 P70104 DURING INSPECTION FOR METAL CONTAMINATION, FOUND AIR SEAL CRACKED AT SEALING FLANGE. THIS IS A CRITICAL LIFE-LIMITED CO MPONENT. LIFE-LIMIT IS 20,000 CYCLES. SUBMITTER STATES THIS IS THE 24TH MALFUNCTION/DEFECT REPORT SUBMITTED ON THIS PA RT BY THIS REPAIR STATION. PART TOTAL CYCLES, 7,541. 4 T E4WE 1996041200720 19960412 00720 WP 1996 4 12 96ZZZX1727 2 19960212 G 7250 31038393 SEAL 31033155 GARRTT TPE331 TPE33112UHR WP TURB 1ST STAGE FLANGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 7318 1233151936 P70112 DURING SCHEDULED CAM INSPECTION, FOUND AIR SEAL CRACKED AT FLANGE. THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIFE-LIM IT IS 20,000 CYCLES. SUBMITTER SUGGESTS THIS IS THE 26TH MALFUNCTION/DEFECT REPORT ON THIS PART BY THIS FACILITY. PART TOTAL CYCLES, 7,435. 4 T E4WE 1996041200723 19960412 00723 WP 1996 4 12 96ZZZX1730 2 19960314 G 7250 31038393 SEAL 31033155 GARRTT TPE331 TPE33112UHR WP TURB 1ST STAGE FLANGE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 7144 1233151935 P70111C DURING SCHEDULED CAM INSPECTION, FOUND ROTATING AIR SEAL CRACKED AT FLANGE. THIS IS A CRITICAL LIFE-LIMITED COMPONENT. LIFE-LIMIT IS 20,000 CYCLES. SUBMITTER STATES THIS IS THE 29TH MALFUNCTION/DEFECT REPORT SUBMITTED BY THIS FACILITY ON THIS DISCREPANCY. PART TOTAL CYCLES, 7,125. 4 T E4WE 1996041800163 19960418 00163 EA 1996 4 18 96ZZZX1782 2 19960307 G 8520 LW19332S CONNECTING ROD PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA NR 1 CYLINDER FAILED G O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 CE 09 23NP 1903 318352007 L40668A CONNECTING ROD NR 1 CYLINDER FAILED AND CAME THROUGH THE CASE. THE ROD BEARING HAD NOT SPUN, THE ONLY ROD BOLT FOUND AP PEARED TO HAVE FAILED AFTER THE FACT. 1 L 7 2 3O 3 O A20SO E14EA 1996041800171 19960418 00171 EA 1996 4 18 96ZZZX1790 2 19960306 G 8530 LW11800 SPRING CESSNA 175 175 2072502 CE LYC O360 O360A1A 41514 EA NR 4 CYL EXH VLV BROKEN D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 27 9462B 400 55262 L1471536A ROUGH ENGINE OPERATION ABOVE 2,500 RPM'S. FOUND NR 4 CYLINDER OUTER EXHAUST VALVE SPRING BROKEN. 1 H 7 1 3O 3 O NT 3A17 E286 1996041800259 19960418 00259 GL 1996 4 18 96ZZZX1824 2 19960302 G 7210 23039793 SCAVENGE BODY 23035179 SKRSKY S76 S76 8143010 NE ALLSN 250C 250C30S 03013 GL SCAVENGE TUBE WORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 701AL 1833 760238 890772S UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY. VISUALLY INSPECTED, SHOWED WEAR AT SCAVENGE BODY SURFACE, AND IN TH E TUBE BONE. SCAVENGE TUBE WORN IN SCAVENGE BODY. SUSPECT CAUSE IS DUE TO IMPROPER FIT OR ALIGNMENT BRACKETS. 1 G 7 2 3U 3 U H1NE E1GL 1996041800267 19960418 00267 GL 1996 4 18 96ZZZX1832 2 19960320 G 7323 23057869 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 5074R 916 28419 1151D CAE832750 THIS IS THE SECOND TIME THIS UNIT HAS BEEN REMOVED FOR ERRATIC CONDITION. PILOT MUST MAKE CONSTANT ADJUSTMENTS TO THE G OVERNOR 'BEEP' WITH EVERY POWER CHANGE. 1 G 7 1 3U 3 U H3WE E4CE 1996042500306 19960425 00306 EU 1996 4 25 96ZZZX1953 2 19960325 G 7310 REGULATOR GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU ENG FUEL FLOW MALFUNCTIONED B UA9R K NONE O OTHER IN INSP/MAINT 1 EA 17 125JJ 906 B1669R 15 8674 ENGINE WAS INSPECTED FOR SUSPECTED OVERTEMPERATURE PER CREW REPORT. INSPECTION ACCOMPLISHED PER ROLLS ROYCE OVERHAUL MA NUAL. RESULTS SHOWED NO OVERTEMPERATURE EFFECTS. PRIOR TO DISASSEMBLY, NOTED THE P2 TOWER ON THE FUEL FLOW REGULATOR W AS LOOSE. THREE MOUNTING BOLTS HAD PULLED OUT OF THE HOUSING. THE P2 PORT WAS EXPOSED TO ATMOSPHERE, LOSS OF P2 SIGNAL WOULD EFFECT THE ENGINE'S ABILITY TO CORRECTLY METER FUEL. 2 L 7 2 4F 4 F RT A12EA E2EU 1996042500308 19960425 00308 SW 1996 4 25 96ZZZX1955 1 19960214 G 7332 99120332 SWITCH WIRE GULSTM 560 560 0141402 SW LYC O540 IGO540B1A 41532 EA LT BOOST PRESS CHAFED B EBVR K NONE J WARNING INDICATION NR NOT REPORTED 1 GL 09 60GL 1152 0187 AIRCRAFT WAS EXPERIENCING PERIODIC UNCOMMANDED LT BOOST PUMP OPERATION WITH LT BOOST PUMP AND LT FUEL LOW PRESSURE ANNUN CIATOR LIGHTS COMING ON. PROBLEM FOUND TO BE CAUSED BY THE LT ENGINE FUEL PRESSURE SWITCH WIRES HAD CHAFED THROUGH AGAI NST THE SHARP EDGE OF THE FUEL FLOW TRANSMITTER. SUBMITTER STATED WIRES SHOULD BE INSPECTED ON THESE AIRCRAFT FOR CHAFE DAMAGE, PROTECT AND REROUTE AS ABLE. 1 H 7 2 3O 3 O 6A1 1E11 1996042500314 19960425 00314 EA 1996 4 25 96ZZZX1961 2 19960301 G 7250 3027301 BLADE 3028821 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA CT WHEEL ERODED B CWBR K NONE O OTHER IN INSP/MAINT 1 GL 05 6739P 993 2F642 BB628 PCE81899 BORESCOPE INSPECTION FOUND EVIDENCE OF COATING LOSS FROM COMPRESSOR TURBINE BLADES. COATING WAS ERODED FROM LEADING EDG ES OF SOME BLADES. ENGINE WAS SPLIT AT 'C' FLANGE, HOT SECTION INSPECTED FURTHER. CT WHEEL REMOVED AND SHIPPED TO PRAT T AND WHITNEY FOR INSPECTION AND DETERMINATION OF CAUSE FOR COATING LOSS. CT BLADES WERE INSTALLED AT OVERHAUL IN SERVI CEABLE CONDITION. THESE BLADES WILL NOT BE REINSTALLED IN THIS ENGINE. 1 L 7 2 4T 4 T A24CE E4EA 1996042500398 19960425 00398 EA 1996 4 25 96ZZZX2020 2 19960401 G 7414 M3056 DISTRIBUTOR GEAR SLICK 6363 PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532 EA MAGNETO DAMAGED B WC7R K NONE O OTHER IN INSP/MAINT 1 GL 25 202SE 4622092 C908761A 'ENGINE WON'T START' - 766.8 HRS HOBBS. FOUND DISTRIBUTOR GEAR M3056 BURNED. FOUND THE MS20822 FITTING TO PRESSURIZE T HE MAGNETO HAD BEEN SCREWED INTO THE OUTER CASE AND BOTTOMED OUT AGAINST THE DISTRIBUTOR HEAD M3820. SUBMITTER SURMISES THE LACK OF PRESSURIZING AIR CAUSED ARCING THAT, IN TURN, BURNED THE NYLON DISTRIBUTOR GEAR M3056. REPLACED MAGNETO, T RIMMED FITTING MS20822 SO IT WOULD NOT COME IN CONTACT WITH DISTRIBUTOR HEAD. REF: 40-2350. 1 L 7 1 3O 3 O RT A25SO E14EA 1996042500406 19960425 00406 SO 1996 4 25 96ZZZX2028 2 19960326 G 8530 CYLINDER CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO ENGINE MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 11 9438M 1117 U20604546 248770R WHEN TRYING TO REMOVE CYLINDERS FOR A TOP OVERHAUL, FOUND TORQUES VERY HIGH TO ALMOST FINGER TIGHT ON CYLINDER STUDS AND THROUGH-BOLTS. THIS ENGINE HAS TORQUE PASTE STILL IN PLACE - ONE-HALF INCH DRIVE AIR WRENCH DID NOTHING - HAD TO CHISE L TWO NUTS OFF SO FAR - TWO CYLINDERS TO GO. SUBMITTER SUGGESTS QUALITY CONTROL SEVERELY LACKING ON THIS FACTORY REMANU FACTURED ENGINE. ENGINE WAS INSTALLED JUNE '89. NO PRIOR PROBLEMS. BROKE CYLINDER WRENCH ON NR 2 CYLINDER. 1 H 7 1 3O 3 O A4CE E8CE 1996042500715 19960425 00715 EA 1996 4 25 96ZZZX2063 2 19960327 G 7414 ES10382585 CONTACT ASSY BENDIX S1227 PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA MAGNETO LOOSE D K NONE O OTHER IN INSP/MAINT 1 EA 25 7693C 907002 28R7635113 L657751A DURING 100-HOUR INSPECTION AND C/W AD 78-9-7R3 (BENDIX IMPULSE COUPLING AND PIN INSP), THE MAIN CONTACT ASSY WAS FOUND L OOSE AND SURROUNDING AREA FROSTED. AGAIN, THE MOUNTING SCREWS WERE TIGHT, BUT THE MFG ASSY SCREW AND NUT WERE LOOSE CAU SING CONTACT HALVES TO DRIFT FROM ALIGNMENT. THE CONTACTS TOTAL TIME WAS UNKNOWN, BUT ESTIMATING BY THE LOOKS, THEY HAD NO MORE THAN 500 HOURS ON THEM. DATE FOUND WAS 3-22-96. 1 L 7 1 3O 3 O 2A13 1E10 1996042500716 19960425 00716 EA 1996 4 25 96ZZZX2064 2 19960327 G 7414 ES10382585 CONTACT ASSY BENDIX D2000 CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MAGNETO LOOSE D K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 EA 25 739NT 413 8324738 17270680 RL460276T ENGINE FAILED TO MAKE FULL STATIC RPM ON GROUND. UPON FURTHER INSPECTION, IT WAS DETERMINED TO BE A MAGNETO PROBLEM. U PON OPENING MAG COVER, BOTH SETS OF CONTACTS WERE FOUND TO BE LOOSE. THE CONTACT ASSY SCREW (NOT MOUNTING SCREWS) WERE DETERMINED TO BE LOOSE. CONTACT HALVES WERE MISALIGNED WITH ONE ANOTHER CAUSING EXCESSIVE FROSTING AROUND ENTIRE CONTAC T AREA AND ON DISTRIBUTOR CAP. 1 H 7 1 3O 3 O NT 3A12 E274 1996042500718 19960425 00718 SO 1996 4 25 96ZZZX2066 2 19960308 G 8520 633620 CRANKSHAFT CESSNA 340 340CESSNA 2076404 CE CONT O520 TSIO520J 17040 SO NR 3 MAIN BRG FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 EA 23 78S 6209 1140 10991 3400151 20818870J AFTER TAKEOFF WHILE IN LEVEL FLIGHT, THE PILOT EXPERIENCED A SUDDEN ENGINE SEIZURE ON THE RT ENGINE. AN UNEVENTFUL LAND ING WAS MADE. THE CRANK WAS FOUND BROKEN AT THE NR 3 MAIN BEARING SADDLE BETWEEN THE NR 4 AND NR 5 ROD THROW. THERE WA S CATASTROPHIC DAMAGE INSIDE AND OUTSIDE THE ENGINE TO CASES, CYLINDERS, AND COMPONENTS. THE NR 5 ROD WAS TORN LOOSE FR OM ITS THROW. LOGS SHOWED THE CRANK TO BE OF AIRMELT TYPE AND HAD BEEN GROUND .010 INCH UNDER AT LAST OVERHAUL 1,140 HR S AGO. CAUSE OF CRACK COULD NOT BE DETERMINED. ENGINE WAS A R.A.M. CONVERSION. 1 L 7 2 3O 3 O 3A25 E8CE 1996042500720 19960425 00720 SO 1996 4 25 96ZZZX2068 2 19960325 G 8540 SA539800M15 CLUTCH SPRING 641348A8 CONT O360 TSIO360EB 17025 SO STARTER FAILED B QX2R K NONE O OTHER IN INSP/MAINT 1 EA 11 1 311356 CLUTCH SPRING WOUND ITSELF AROUND STARTER SHAFT GEAR AND WOULD NOT ALLOW ENGINE TO START. 3 O E9CE 1996050200107 19960502 00107 EA 1996 5 2 96ZZZX2074 2 19960228 G 8530 LW13561 CYLINDER BEECH 60 B60 1153605 CE LYC O541 TIO541E1C4 41536 EA NR 4 EXH ROCKER FAILED B BKHR K NONE O OTHER IN INSP/MAINT 1 WP 01 294D 829 P451 RL98559 DURING ENGINE RUN-UP FOR TAKEOFF, ENGINE QUIT. INVESTIGATION BY BORESCOPE FOUND NR 4 CYLINDER EXHAUST VALVE NOT WORKING . REMOVED ROCKER BOSS AND FOUND EXHAUST VALVE ROCKER SHAFT INBOARD ROCKER BOSS CASTING AND COVER TAB FAILED. OUTBOARD CASTING OK. ALL OTHER CYLINDERS ROCKER CASTINGS OK. SUSPECT ROCKER RETAIN CLIP FAILED INITIALLY. 1 L 7 2 3O 3 O A12CE E10EA 1996050200115 19960502 00115 SO 1996 5 2 96ZZZX2082 2 19960403 G 8550 640726 TUBE ASSY CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO FUEL MANIFOLD FAILED C A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 SW 99 6867L 890 421C1087 R610188 DURING FLIGHT, OIL WAS NOTICED ON THE RIGHT NACELLE, THE AIRCRAFT LANDED SAFELY AND THE PROPELLER WAS FEATHERED. INVEST IGATION REVEALED TUBE ASSEMBLY FROM THE CRANKCASE TO THE FUEL MANIFOLD HAD BROKEN FROM THE SOLDER JOINT CLOSEST TO THE F UEL MANIFOLD. 1 L 7 2 3O 3 O A7CE E7CE 1996050200126 19960502 00126 NE 1996 5 2 96ZZZX2093 2 19960409 G 7530 8008311001L7 CONTROL CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE BLEED VALVE MALFUNCTIONED E A UNSCHED LANDING R M PARTIAL RPM/PWR LOSS OVER TEMP CL CLIMB 1 GL 07 312QS 740 5600312 500109 ON TAKEOFF, THE RIGHT ENGINE RPM ROLLED BACK 10 PERCENT AND THE I.T.T. INCREASED TO 700 DEGREES. AIRCRAFT RETURNED AND ENGINE WAS INSPECTED. NO PROBLEM WAS FOUND. AIRCRAFT WAS TEST FLOWN AND NR 2 ENGINE I.T.T. WAS 50 DEGREES HIGHER. FOU ND BLEED VALVE OPERATING ON GROUND WHEN NOT CALLED FOR. BLEED VALVE CONTROL AND BLEED VALVE ACTUATOR WERE REPLACED AND PROBLEM CORRECTED. 2 L 7 2 4F 4 F RT A22CE E25EA 1996050200127 19960502 00127 NE 1996 5 2 96ZZZX2094 2 19960409 G 7532 F008881L1 ACTUATOR CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE BLEED VALVE MALFUNCTIONED E A UNSCHED LANDING R M PARTIAL RPM/PWR LOSS OVER TEMP CL CLIMB 1 GL 07 312QS 740 F22028 5600312 500109 ON TAKEOFF, THE RIGHT ENGINE RPM ROLLED BACK 10 PERCENT AND THE I.T.T. INCREASED TO 700 DEGREES. AIRCRAFT RETURNED AND ENGINE WAS INSPECTED. NO PROBLEM WAS FOUND. AIRCRAFT WAS TEST FLOWN AND NR 2 ENGINE I.T.T. WAS 50 DEGREES HIGHER. FOU ND BLEED VALVE OPERATING ON GROUND WHEN NOT CALLED FOR. BLEED VALVE CONTROL AND BLEED VALVE ACTUATOR WERE REPLACED AND PROBLEM CORRECTED. 2 L 7 2 4F 4 F RT A22CE E25EA 1996050200272 19960502 00272 SO 1996 5 2 96ZZZX2150 2 19960320 G 8530 652954A1 CYLINDER CESSNA 206 U206A 2073316 CE CONT O520 IO520A 17032 SO CYLS 2,6,1,3,5 CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 4975U 778 U20605179 284679R NR 2, NR 6, NR 1, NR 3, AND NR 5 CYLINDERS WERE FOUND CRACKED AT INTAKE SEAT. 1 H 7 1 3O 3 O A4CE E5CE 1996050200273 19960502 00273 SO 1996 5 2 96ZZZX2151 2 19960301 G 8530 652954A1 CYLINDER CESSNA 206 U206 2073306 CE CONT O520 IO520A 17032 SO CYLS NR 4, 1 CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 4672U 540 U20605046 284695R NR 4 AND NR 1 CYLINDERS WERE FOUND CRACKED AT INTAKE SEAT. 1 H 7 1 3O 3 O A4CE E5CE 1996050200274 19960502 00274 SO 1996 5 2 96ZZZX2152 2 19960320 G 8530 652954A1 CYLINDER CESSNA 206 U206 2073306 CE CONT O520 IO520A 17032 SO CYLS NR 3, 2, 5 CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 244PL 760 4371 28468R NR 3, NR 2, AND NR 5 CYLINDERS WERE FOUND CRACKED AT INTAKE SEAT. 1 H 7 1 3O 3 O A4CE E5CE 1996050200283 19960502 00283 SO 1996 5 2 96ZZZX2161 2 19960401 G 7414 CONTACT POINTS SLICK 6320 CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO LT ENG LT MAG CORRODED B CRJR K NONE O OTHER IN INSP/MAINT 1 CE 01 135BG 92080002 414A0419 521195 JUST PRIOR TO AIRCRAFT BEING INDUCTED FOR 100-HOUR INSPECTION, PILOT INFORMED MAINTENANCE OF ROUGH RT MAG ON RT ENGINE. INVESTIGATION SHOWED SEVERE CORROSION ON POINTS, GEARS, CAPACITOR, AND BEARINGS. CHECK REMAINING 3 MAGNETOS AND FOUND IDENTICAL CONDITIONS OF SEVERE CORROSION. ALL FOUR MAGNETOS WERE CLEANED AND AFFECTED PARTS WERE REPLACED. PROBLEM BEL IEVED TO BE CAUSED BY PRESSURIZED AIR FROM TURBOS. 1 L 7 2 3O 3 O A7CE E8CE 1996050200284 19960502 00284 SO 1996 5 2 96ZZZX2162 2 19960401 G 7414 CONTACT POINTS SLICK 6320 CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO RT ENG LT MAG CORRODED B CRJR K NONE O OTHER IN INSP/MAINT 1 CE 01 135BG 93020037 414A0419 521195 JUST PRIOR TO AIRCRAFT BEING INDUCTED FOR 100-HOUR INSPECTION, PILOT INFORMED MAINTENANCE OF ROUGH RT MAG ON RT ENGINE. INVESTIGATION SHOWED SEVERE CORROSION ON POINTS, GEARS, CAPACITOR, AND BEARINGS. CHECK REMAINING 3 MAGNETOS AND FOUND IDENTICAL CONDITIONS OF SEVERE CORROSION. ALL FOUR MAGNETOS WERE CLEANED AND AFFECTED PARTS WERE REPLACED. PROBLEM BEL IEVED TO BE CAUSED BY PRESSURIZED AIR FROM TURBOS. 1 L 7 2 3O 3 O A7CE E8CE 1996050200285 19960502 00285 SO 1996 5 2 96ZZZX2163 2 19960401 G 7414 CONTACT POINTS SLICK 6320 CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO LT ENG RT MAG CORRODED B CRJR K NONE O OTHER IN INSP/MAINT 1 CE 01 135BG 92080010 414A0419 521195 JUST PRIOR TO AIRCRAFT BEING INDUCTED FOR 100-HOUR INSPECTION, PILOT INFORMED MAINTENANCE OF ROUGH RT MAG ON RT ENGINE. INVESTIGATION SHOWED SEVERE CORROSION ON POINTS, GEARS, CAPACITOR, AND BEARINGS. CHECK REMAINING 3 MAGNETOS AND FOUND IDENTICAL CONDITIONS OF SEVERE CORROSION. ALL FOUR MAGNETOS WERE CLEANED AND AFFECTED PARTS WERE REPLACED. PROBLEM BEL IEVED TO BE CAUSED BY PRESSURIZED AIR FROM TURBOS. 1 L 7 2 3O 3 O A7CE E8CE 1996050200286 19960502 00286 SO 1996 5 2 96ZZZX2164 2 19960401 G 7414 CONTACT POINTS SLICK 6320 CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO RT ENG RT MAG CORRODED B CRJR K NONE O OTHER IN INSP/MAINT 1 CE 01 135BG 93020044 414A0419 521195 JUST PRIOR TO AIRCRAFT BEING INDUCTED FOR 100-HOUR INSPECTION, PILOT INFORMED MAINTENANCE OF ROUGH RT MAG ON RT ENGINE. INVESTIGATION SHOWED SEVERE CORROSION ON POINTS, GEARS, CAPACITOR, AND BEARINGS. CHECK REMAINING 3 MAGNETOS AND FOUND IDENTICAL CONDITIONS OF SEVERE CORROSION. ALL FOUR MAGNETOS WERE CLEANED AND AFFECTED PARTS WERE REPLACED. PROBLEM BEL IEVED TO BE CAUSED BY PRESSURIZED AIR FROM TURBOS. 1 L 7 2 3O 3 O A7CE E8CE 1996050200298 19960502 00298 EA 1996 5 2 96ZZZX2176 2 19960328 G 8530 65007 RETAINER PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA INTAKE PUSHROD CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 WP 17 8172Q 500 288090263 L2803436A PUSHROD TUBE ON NR 2 CYLINDER INTAKE HAS A PERSISTENT OIL LEAK NEAR THE CRANKCASE. WHEN CHANGING THE PUSHROD TUBE SEAL THIS TIME, THE PUSHROD TUBE RETAINER WHICH IS PRESSED INTO THE CRANKCASE WAS FOUND CRACKED ABOUT ONE-FOURTH OF THE WAY A ROUND THE CIRCUMFERENCE. 1 L 7 1 3O 3 O 2A13 E286 1996050200300 19960502 00300 EA 1996 5 2 96ZZZX2178 2 19960412 G 7322 3472 VALVE SEAT MA45 CESSNA 182 182R 2072731 CE LYC O540 O540L3C5 41532 EA PUMP DISCHARGE WORN D K NONE O OTHER IN INSP/MAINT 1 CE 01 58JK 656 75030510 18268286 ENGINE RUNNING EXTREMELY RICH. FOUND PUMP DISCHARGE CHECK VALVE SEAT WORN OFF. 1 L 7 1 3O 3 O NT 3A13 E295 1996050200311 19960502 00311 EA 1996 5 2 96ZZZX2189 2 19960322 G 8520 75060 CONNECT ROD PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA NR 6, NR 1 ROD BOLT NOT MARKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 4053R 339 3240355 L794448 ENGINE DISASSEMBLED AND FOUND 3 BOLTS WITH NO HEAD MARKING. ONE EACH LOCATED ON NR 6 ROD. TWO EACH LOCATED ON NR 1 ROD . 1 L 7 1 3O 3 O A3SO 1E4 1996050200592 19960502 00592 GL 1996 5 2 96ZZZX2218 2 19960307 G 7210 6889326 BEARING SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL GEARBOX GALLED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 768AL MP02911 760031 890074S UPON DISASSEMBLY OF GEARBOX, CLEANED AND INSPECTED PARTS AS REQUIRED. FOUND EXCESSIVE GALLING ON PTO AFT, BEARING INNER RACE. EXCESSIVE GALLING, BEARING INNER RACE, POSSIBLY DUE TO BEARING CAGE OUT-OF-ROUND CAUSING TIGHT FIT BETWEEN INNER AND OUTER RACE AND BALLS. 1 G 7 2 3U 3 U H1NE E1GL 1996050900103 19960509 00103 NE 1996 5 9 96ZZZX2228 2 19960403 G 7240 4059T02601 RETAINER CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF343A 30015 NE NR 5 BEARING FAILED E S A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 GL 03 826JP 2656 5050 350353 PILOTS NOTICED ABNORMAL VIBRATION ON LT ENGINE OVER THE NORTH ATLANTIC. UNSCHEDULED LANDING. GE WAS CONTACTED AND ENGI NE WAS REPLACED. ON TEAR-DOWN, NR 5 BEARING RETAINER LOCK PIN FOUND TO HAVE BROKEN OFF ALLOWING BEARING TO SPIN IN ITS SEAT, SUBSEQUENTLY, DAMAGING MOST OF THE ROTATING COMPONENTS ATTACHED. THE PTO SHAFT WAS FOUND LOOSE IN THE ENGINE, AND MAY HAVE BEEN A CONTRIBUTING FACTOR DUE TO VIBRATION. THIS PTO CONDITION WAS FOUND ON THE AIRCRAFT'S OTHER ENGINE AT 3 75 TTSN. 2 L 7 2 4F 4 F RT A21EA E15NE 1996050900117 19960509 00117 NE 1996 5 9 96ZZZX2242 2 19960228 G 7321 EEC SMITHSIND LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE LT ENGINE MALFUNCTION C O OTHER J WARNING INDICATION CR CRUISE 1 SW 09 799SC 54 Y7545 067 PCE305250 AMBER AND WHITE COMPUTER LIGHTS CAME ON AND ITT INDICATION WAS LOST FOR THE LEFT ENGINE; OTHERWISE, OPERATION WAS NORMAL IN-FLIGHT. ENGINE WOULD NOT START ON GROUND. NO ITT INDICATION CAUSED THE FADER TO ABORT START ATTEMPTS. REPLACED E. E.C. OPERATION NORMAL. 2 L 7 2 4F 4 F RT A10CE E35NE 1996050900324 19960509 00324 SO 1996 5 9 96ZZZX2292 2 19960329 G 7414 10349271 COIL BENDIX S6RN1225 BEECH 55 95B55 1152706 CE CONT O470 IO470L 17026 SO MAGNETO CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 09 2023Z A224421 TC2171 465369 DURING ANNUAL INSPECTION, FOUND MAGNETO COIL CRACKED IN NUMEROUS PLACES. AD 94-01-03 R2 REQUIRES REPLACEMENT OF THESE C OILS, BUT THIS SERIAL NUMBER MAGENTO IS NOT COVERED BY THE AD (COIL IS AN OPAQUE AMBER COLOR AS REFERENCED IN TELEDYNE C ONTINENTAL IGNITION SYSTEMS SB MSB644). THERE ARE NO MAINTENANCE RECORD ENTRIES OF THESE COILS HAVING BEEN PREVIOUSLY R EPLACED. 1 L 7 2 3O 3 O 3A16 3E1 1996050900325 19960509 00325 SO 1996 5 9 96ZZZX2293 2 19960411 G 7414 104001664 IMPULSE CAM S6RN25 CESSNA 182 182B 2072706 CE CONT O470 O470L 17026 SO LT MAGNETO WORN D K NONE O OTHER IN INSP/MAINT 1 NM 11 7244E 596 K149104DR 52244 069744R UPON INSPECTION OF CAMS IN IMPULSE COUPLINGS FOR WEAR PER AD 78-09-07, FOUND ONE FLYWEIGHT AND RIVET WORN WELL BEYOND LI MITS. THIS IS NEW STYLE CAM WITH SNAP RING ASSEMBLY. FOR A TOTAL TIME OF ONLY 595 HOURS, FEEL THIS TO BE SIGNIFICANT W EAR AND WOULD ALSO QUESTION THE HARDNESS OF METAL. 1 H 7 1 3O 3 O NT 3A13 E273 1996050900326 19960509 00326 EA 1996 5 9 96ZZZX2294 2 19960317 G 8530 VALVE PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA NR 1 CYL INTAKE HEAD SEPARATED D O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 GL 15 8347C 1734 287690121 L2101336A ENGINE ROUGHNESS DURING FLIGHT FOUND BENT PUSHROD HOUSING AND PUSHROD. REMOVED CYLINDER AND FOUND VALVE HEAD SEPARATED FORM STEM INTAKE SIDE. 1 L 7 1 3O 3 O 2A13 E286 1996050900332 19960509 00332 NE 1996 5 9 96ZZZX2300 2 19960304 G 7210 7757571 BEARING 5074T6LG10 SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE GC 49 GEARCASE CRACKED B SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 202KD 1073 9376 340B202 GEAR CASE WAS RETURNED FOR OIL CONTAMINATION. UNIT WAS DISASSEMBLED AND AN EXAMINATION OF INTERNAL HARDWARE REVEALED A CRACKED INNER RACE ON THE PROPELLER SHAFT FORWARD ROLLER BEARING RACE. LEFT - TSI 4,239.5 HRS. CSI, 4,048. 2 L 7 2 4T 4 T RT A52EU E8NE 1996051600058 19960516 00058 GL 1996 5 16 96ZZZX2357 2 19960207 G 7210 23030994 SCAVENGE TUBE 23035178 BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL GEARBOX BRACKET BROKEN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 366AL 4181 51470 CAE895428 UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY, AND SCAVENGE TUBE. FOUND ALIGNMENT BRACKET ON SCAVENGE TUBE BROKEN. ALIGNMENT BRACKET AT LOWER END OF SCAVENGE TUBE WAS FOUND BROKEN AT WELD AREA. SUSPECT CAUSE IS DUE TO IMPROPER FIT O N ALIGNMENT BRACKETS. 1 G 7 1 3U 3 U H2SW E1GL 1996051600063 19960516 00063 GL 1996 5 16 96ZZZX2362 2 19960207 G 7261 23039793 SCAVENGE BODY 23035179 SKRSKY S76 S76 8143010 NE ALLSN 250C 250C30S 03013 GL GEARBOX WORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 769AL 2570 760048 CAE890253S UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY. VISUALLY INSPECTED, SHOWED WEAR AT SCAVENGE BODY AND SCAVENGE TUBE MATING SURFACE. SCAVENGE TUBE WORE INTO SCAVENGE BODY. SUSPECT CAUSE IS DUE TO IMPROPER FIT ON ALIGNMENT BRACKETS. 1 G 7 2 3U 3 U H1NE E1GL 1996051600257 19960516 00257 SO 1996 5 16 96ZZZX2389 2 19960319 G 8550 ENGINE CONT O470 O470R 17026 SO OIL SYSTEM FAILED D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 EA 03 987908RR ENGINE 235.3 SMOH, 7.6 HRS AFTER NR 4 CYLINDER REMOVED FOR REPAIR. PHILLIPS XC OIL BEING USED. AV BLEND PUT IN ENGINE AFTER CYLINDER WAS REPAIRED. IN-FLIGHT, OIL PRESSURE STARTED TO DECREASE. LANDING MADE OK. AT IDLE, OIL PRESSURE DROP PED TO ZERO PSI, TOTAL FLIGHT TIME, 7 MINUTES. OIL DRAINED, FOUND SLUDGE OF UNKNOWN SUBSTANCE, ABOUT 1-2 TABLESPOONS O F MATERIAL, BROWNISH COLOR, DRAINED OUT WITH OIL. OIL SCREEN WAS VERY CLEAN. NONE OF THIS MATERIAL IN SCREEN. 3 O E273 1996051600259 19960516 00259 GL 1996 5 16 96ZZZX2391 2 19960220 G 7261 ENGINE CESSNA 206 U206G 2073356 CE ALLSN 250C 250C20 03013 GL OIL SYSTEM CHIP LIGHT B LX5R K NONE J WARNING INDICATION NR NOT REPORTED 1 GL 19 891LL 829 U206G06937 CAE290031 RECEIVED OIL CHIP LIGHT INDICATION. PERFORMED REQUIRED MAINTENANCE PER ALLISON 250-C20S AND SOLOY/CESSNA MAINTENANCE AN D OVERHAUL MANUALS. RECEIVED SECOND CHIP LIGHT INDICATION 3.9 HRS TIS LATER. ENGINE REMOVED AND SENT OUT FOR INSPECTIO N/REPAIR PER ALLISON 250-C20S MAINTENANCE AND OVERHAUL MANUALS. 1 H 7 1 3O 3 U A4CE E4CE 1996051600267 19960516 00267 EA 1996 5 16 96ZZZX2399 2 19960225 G 8550 62817 FILTER SCREEN MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA ACCESSORY CASE SPLIT D K NONE O OTHER IN INSP/MAINT 1 EA 27 7821V 2805 RL1289236A DURING ANNUAL, OIL PRESSURE SCREEN WAS REMOVED AND CHECKED FOR METAL, ETC. AFTER SCREEN WAS CLEANED IN PARTS WASHER, IT WAS NOTED THE SOLDERED SEAM OF THE INNER FINE MESH SCREEN WAS SPLIT. ON CLOSER INSPECTION, THE OUTER SCREEN SHOWED APP ROXIMATELY FOUR STRANDS SEPARATED FROM THE SOLDER. THE AREA OF SEPARATION IS MIDWAY AND THE SCREEN LOOKS AS IF IT WAS S WOLLEN. SUSPECT AGE, HEAT CHANGES, AND DIFFERENTIAL OF PRESSURES ON THE INNER AND OUTER SIDES OF SCREEN FROM DIRT, GRIT , AND COLD THICK OIL WERE CAUSES. SUBMITTER STATED MORE FREQUENT AND THOROUGH CLEANING OF SCREEN OR REPLACMENT AT INTER VALS (500 HOURS OR 5 YEARS). 1 L 7 1 3O 3 O 2A3 E286 1996051600275 19960516 00275 SO 1996 5 16 96ZZZX2407 2 19960402 G 8530 646303 PISTON CESSNA 421 421C 2076016 CE CONT O520 GTSIO520N 17032 SO LT ENG NR 5 BURNED B ITWR K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 07 67934 900 421C1026 610051 AIRCRAFT LOST POWER ON NR 1 ENGINE. REMOVAL OF NR 5 CYLINDER REVEALED PISTON DOME EDGE BURNED AWAY FROM 6:00 POSITION T O 12:00 POSITION. AT 9:00 POSITION, PISTON DOME BURNED COMPLETELY THROUGH, APPROXIMATELY 1 INCH OF PISTON MATERIAL MISS ING FROM EDGE TOWARDS CENTER OF DOME. 1 L 7 2 3O 3 O A7CE E7CE 1996051600276 19960516 00276 SO 1996 5 16 96ZZZX2408 2 19960320 G 8530 CYLINDER CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO ROCKER BOSS CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 732DZ 1669 21061446 567326 FIVE OF SIX CYLINDERS HAVE CRACKS IN ROCKER BOSS AREA UP TO THE ROCKER SHAFT RETAINING BOLTS. TWO OF THESE FIVE HAVE CR ACKS ON INTAKE AND EXHAUST BOSSES. THIS ENGINE DOES NOT INCORPORATE LONG BOLTS AND SOLID SHAFTS. 1 H 7 1 3O 3 O 3A21 E5CE 1996051600278 19960516 00278 SO 1996 5 16 96ZZZX2410 2 19960307 G 8540 99101371 SHAFT CESSNA 421 421C 2076016 CE CONT O520 GTSIO520H 17032 SO RT ENG HYD SHEARED D K NONE O OTHER IN INSP/MAINT 1 GL 09 215MP 421C1231 FOUND DRIVE SHAFT ON AIR CONDITIONING, HYDRAULIC PUMP SHEARED. UPON REMOVAL, SYSTEM HYDRAULIC PUMP SHAFT SPLINES WERE F OUND WORN OUT AND RUSTED. SUBMITTER SUGGESTS SPLINES BE LUBED AT 200-HOUR INTERVALS TO PREVENT THIS PROBLEM FROM RECURR ING. 1 L 7 2 3O 3 O A7CE E7CE 1996051600280 19960516 00280 SO 1996 5 16 96ZZZX2412 2 19960320 G 8530 ENGINE CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO CYLINDER DEFECTIVE B EBVR K NONE O OTHER IN INSP/MAINT 1 GL 09 761TF 1975 21062499 PRE-PURCHASE INSPECTION OF AIRCRAFT REVEALED ENGINE COMPRESSION WELL BELOW ACCEPTABLE LIMITS, SEAT RAILS WERE WORN BEYON D LIMITS. ESTABLISHED BY AIRWORTHINESS DIRECTIVE. ELEVATOR TRIM TAB WITH HOLES CORRODED THROUGH THE TAB SKIN. AIRCRAF T WAS ANNUALLED THE FIRST WEEK OF MARCH, 1996, AND LESS THAN 2 HOURS AGO. 1 H 7 1 3O 3 O 3A21 E8CE 1996051600304 19960516 00304 EU 1996 5 16 96ZZZX2437 2 19960322 G 7314 996590 PUMP DIAMON DA20A1 DA20A1 05626UX GL ROTAX 912 ROTAX912 55555 EU ENGINE OIL LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 526SS 24 10085 FUEL PUMP STARTED LEAKING OIL AT SEAM WHERE DIAPHRAM WAS IN PUMP. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 1996051600534 19960516 00534 GL 1996 5 16 96ZZZX2482 2 19960425 G 7250 6899373 WHEEL ALLSN 250C 250C20B 03013 GL THIRD STAGE SHROUD CRACKED B YKER K NONE O OTHER IN INSP/MAINT 1 EA 17 HX58891 CAE820030 TURBINE WAS DISASSEMBLED AS PART OF ENGINE REPAIR FOR COMPRESSOR STALLS. FOUND THE SHROUD ON THE THIRD STAGE WHEEL CRAC KED ALL THE WAY THROUGH. 3 U E4CE 1996051600556 19960516 00556 SO 1996 5 16 96ZZZX2505 2 19960425 G 8530 653445A11 CYLINDER BEECH 58 58 1152740 CE CONT O520 IO520CB 17032 SO PLUG BOSS CRACKED I K NONE O OTHER IN INSP/MAINT 1 SW 07 3695V 1216 TH1183 282447R THE CONTINENTAL CYLINDER CRACKED WITH ONLY 1,216.4 HOURS ON IT. THE CRACK ORIGINATED AT THE SPARK PLUG BOSS AND WAS TRA VELLING TO THE FUEL INJECTION NOZZLE. THE COMPRESSION WAS STILL IN THE UPPER 60'S. SUBMITTER STATED THEY HAVE BEEN EXP ERIENCING ALOT OF THIS TYPE OF CRACKING AND BELIEVE IT TO BE A PROBLEM WITH THE MANUFACTURING PROCESS AT CONTINENTAL OR THEIR SUB-CONTRACTORS. 1 L 7 2 3O 3 O 3A16 E5CE 1996051600557 19960516 00557 SO 1996 5 16 96ZZZX2506 2 19960410 G 8530 CYLINDER CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO NR 1 CYL EXH RKR BOSS CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 27 9264U 1438 15078214 254467 DURING POST 100 HOUR OPERATIONAL RUN AND LEAK CHECK, NOTED A NOISE SIMILAR TO A 'BAFFLE RATTLE' BEING MADE. AFTER SHUT DOWN, NO LOOSE BAFFLES WERE FOUND. THE ROCKER BOX COVERS WERE REMOVED TO REPLACE THE GASKETS FOUND LEAKING. WHEN NR 1 COVER REMOVED, A SMALL 'HALF-MOON' SHAPED PIECE OF CASTING WAS FOUND. THE OUTER EXHAUST ROCKER SHAFT BOSS HAD BROKEN OF F THROUGH ITS DIAMETER PARALLEL WITH THE ROCKER ARM. AD 94-05-05 ADDRESSES THIS PROBLEM AT OVERHAUL. 1 H 7 1 3O 3 O 3A19 E252 1996051600561 19960516 00561 SO 1996 5 16 96ZZZX2510 2 19960423 G 8520 CRANKCASE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO RT NR 5 CYL CRACKED B APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 8407C 15133 1266 347670137 265901R SMALL CRACK FOUND IN RIGHT SIDE OF CRANKCASE NEXT TO THROUGH-BOLT JUST FORWARD OF CYLINDER NR 5. CONSIDERED NON-CRITICA L AREA PER SB M90-17. 1 L 7 2 3O 3 O A7SO E9CE 1996051600562 19960516 00562 EA 1996 5 16 96ZZZX2511 2 19960423 G 7414 M2637 POINTS SLICK 6393 LYC O540 IO540C4B5 41532 EA LT MAG DEFORMED D K NONE O OTHER IN INSP/MAINT 1 NE 05 392 94020017 RL1924648A AIRCRAFT WAS BEING RUN BEFORE FLIGHT. WHEN SHUTTING RIGHT MAG OFF ON LEFT ENGINE, ENGINE QUIT. CHECKED P-LEADS FOR GRO UNDING AND PROPER INSTALLATION. REMOVED MAG AND CHECKED COIL, POINT GAP AND REPLACED CONDENSER. UPON CHECKING E-GAP FO UND POINTS NOT CLOSING. REPLACED POINTS WHICH CORRECTED DISCREPANCY. SUSPECT CAUSE: INSPECTING POINTS WRONG. WHEN OP ENING POINTS TO INSPECT, BE CAREFUL NOT TO OPEN TOO FAR. 3 O 1E4 1996051600563 19960516 00563 SO 1996 5 16 96ZZZX2512 2 19960426 G 8520 653877 LIFTER CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO LIFTER FACE GALLED D K NONE O OTHER IN INSP/MAINT 1 NE 05 61368 433 18504159 282672R WHILE DOING TOP OVERHAUL, FOUND 3 HYDRAULIC LIFTERS PITTED AND GALLED. SUBMITTER RECOMMENDS CLOSER INSPECTION OF LIFTER S AT OVERHAUL. 1 H 7 1 3O 3 O 3A24 E5CE 1996051600566 19960516 00566 EA 1996 5 16 96ZZZX2515 2 19960413 G 7414 MAGNETO BENDIX 2000 MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA ENGINE MISINSTALLED H A UNSCHED LANDING Y W ENGINE STOPPAGE INADEQUATE Q C CL CLIMB 1 EA 17 4244H 240679 ENGINE FAILURE OCCURRED UPON REACHING 4,500 FEET. EMERGENCY LANDING AT AIRPORT WAS MADE. INVESTIGATION DETERMINED MAGN ETO HAD FALLEN OFF ENGINE. INSPECTION REVEALED MAGNETO HAD BEEN REMOVED 4 MONTHS EARLIER TO C/W AD 78-09-07RE. UPON RE INSTALLATION OF MAGNETO, A FLANGED TYPE GASKET P/N 62224 HAD BEEN USED INSTEAD OF PROPER ROUND GASKET, P/N CW12681. THI S ALLOWED GASKET MATERIAL TO BE COMPRESSED BETWEEN MAGNETO HOLD-DOWN CLAMPS AND ACCESSORY HOUSING RESULTING IN IMPROPER TORQUING AND SUBSEQUENT FAILURE. 1 L 7 1 3O 3 O 2A3 1E10 1996051600570 19960516 00570 SO 1996 5 16 96ZZZX2519 2 19960424 G 8520 CRANKSHAFT BBAVIA 7 7BCM 2110106 SW CONT C85 C858 17008 SO PROPELLER ATTACH FAILED G K NONE O OTHER NR NOT REPORTED 1 GL 09 46AC 120 7AC3382 PROPELLER SEPARATED FROM ENGINE DUE TO CRANKSHAFT FAILURE. INDICATION OF PREVIOUS CRACK AT AREA OF FRACTURE. 1 H 7 1 3O 3 O A759 E233 1996051600573 19960516 00573 GL 1996 5 16 96ZZZX2522 2 19960404 G 7250 23055438 2ND STG NOZZLE ALLSN 250C 250C30 03013 GL GP SEC DIAPHRAGM LOOSE B ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 X61606 UPON RECEIVING FROM ALLISON (NEW) 3-5-96, NOZZLE HAD A DIAPHRAGM MOVEMENT OF .005 INCH. ACCORDING TO CEB-72-3188, THE D IAPHRAGM SHOULD HAVE A RADIAL MOVEMENT OF .003 INCH MAXIMUM. THE NOZZLE WAS SENT BACK TO ADDISON FOR WARRANTY. TIGHTEN ED THE KEYS ON THE DIAPHRAGM INNER RING. 3 U E1GL 1996051600574 19960516 00574 GL 1996 5 16 96ZZZX2523 2 19960404 G 7250 23055438 2ND STG NOZZLE 23035128 ALLSN 250C 250C30 03013 GL GP SEC DIAPHRAGM LOOSE B ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 X61647 UPON RECEIVING FROM ALLISON (NEW) 3-5-96, NOZZLE HAD A DIAPHRAGM MOVEMENT OF .005 INCH. ACCORDING TO CEB-72-3188, THE D IAPHRAGM SHOULD HAVE A MAXIMUM MOVEMENT OF .003 INCH. THE NOZZLE WAS SENT BACK TO ALLISON FOR WARRANTY. TIGHTENED THE K EYS ON THE DIAPHRAGM INNER RING. 3 U E1GL 1996051600575 19960516 00575 GL 1996 5 16 96ZZZX2524 2 19960404 G 7250 23055438 2ND STG NOZZLE 2305128 ALLSN 250C 250C30 03013 GL GP SEC DIAPHRAGM LOOSE B ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 X61626 UPON RECEIVING FROM ALLISON (NEW) 3-8-96, NOZZLE HAD A DIAPHRAGM MOVEMENT OF .004 INCH. ACCORDING TO CEB-72-3188, THE D IAPHRAGM SHOULD HAVE A MAXIMUM MOVEMENT OF .003 INCH. THIS IS UNACCEPTABLE. THE NOZZLE WAS SENT BACK TO ALLISON FOR WA RRANTY. TIGHTENED THE KEYS ON THE DIAPHRAGM INNER RING. 3 U E1GL 1996052100004 19960521 00004 GL 1996 5 21 96ZZZX2367 2 19960319 G 7260 6859435 BEARING AGUSTA A109 A109A2 0260120 EU ALLSN 250C 250C20B 03013 GL GEARBOX FAILED B KUVR O OTHER J WARNING INDICATION NR NOT REPORTED 1 SO 19 8WH 266 7256 CAE832739 CHIP LIGHT ILLUMINATED IN-FLIGHT. SHORTLY THEREAFTER, ENGINE FAILED. MAINTENANCE FOUND THE BEARINGS ON EITHER END OF T HE FUEL CONTROL AND OIL PUMP SPUR GEARSHAFT FELL APART STOPPING FUEL CONTROL OPERATION. EXACT CAUSE UNKNOWN AT THIS TIM E. UNUSUAL BECAUSE SHAFT IS SUPPORTED ON BOTH ENDS. SUSPECT ONE BEARING FAILED ALLOWING SHAFT TO WOBBLE AND DESTROY SE COND BEARING. 1 G 7 2 3U 3 U H7EU E4CE 1996052100008 19960521 00008 EA 1996 5 21 96ZZZX2371 2 19960415 G 8530 CYLINDER PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA NR 3 FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 15 39609 2800 400 287890542 L2519936A NR 3 CYLINDER BARREL BROKEN. BARREL FAILED 75 PERCENT OF RADIUS ABOUT 2 INCHES DOWN FROM TOP OF CYLINDER BARREL. 1 L 7 1 3O 3 O 2A13 E286 1996052300222 19960523 00222 SO 1996 5 23 96ZZZX2555 2 19960228 G 8530 VALVE GUIDE CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO NR 1 CYLINDER LOOSE D K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SO 16 52727 390 18262801 462760 VALVE GUIDE LOOSENED IN CYLINDER HEAD ALLOWING CYLINDER TO MISFIRE. NOTE: DIFFICULT TO DIAGNOSE. COMPRESSION WAS 55/8 0 UNTIL SPRING ASSY WAS MOVED. SUBMITTER RECOMMENDS CHECKING SPRING ASSYS FOR SIDE PLAY WHEN VALVE COVERS REMOVED FOR A NY REASON. 1 H 7 1 3O 3 O NT TA13 E273 1996052300226 19960523 00226 EA 1996 5 23 96ZZZX2559 2 19960124 G 8520 SL72877 LIFTER BBAVIA 7 7KCAB 21101P3 CE LYC O320 IO320E2A 41508 EA FACE DAMAGED D K NONE O OTHER IN INSP/MAINT 1 WP 09 8643 84 35473 L495755A ANNUAL INSPECTION - LARGE AMOUNT OF METAL FRAGMENTS IN OIL PRESSURE AND OIL SUCTION SCREENS. CYLINDERS REMOVED, 7 LIFTE R BODIES NOT TURNING, ENGINE TEAR-DOWN REVEALED VERY LITTLE TAPER ON CAM LOBE TIPS EXCEPT NR 4 EXHAUST LUBE. IT HAD .00 1 INCH TAPER AND WAS TURNING. FURTHER INVESTIGATION REVEALED NR 3 CONNECTING ROD AND NR 3 ROD JOURNAL SCORED BADLY REND ERING CRANKSHAFT AND NR 3 ROD UNREPAIRABLE DUE TO LARGE FRAGMENT FROM NR 2 INTAKE LIFTER BODY PASSING THROUGH OIL SUCTIO N SCREEN AND BACK INTO OIL SYSTEM. 1 H 7 1 3O 3 O A759 1E12 1996052300333 19960523 00333 EA 1996 5 23 96ZZZX2579 2 19960402 G 7414 103493704 IMPULSE COUPLER PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1B5 41532 EA MAGNETO WORN D K NONE O OTHER IN INSP/MAINT 1 NE 01 3044K 327940025 960402 MAGNETO SQAWKED AS DEAD. REMOVED AND DISASSEMBLED MAGNETO, FOUND COIL TAB BENT UPWARD TO MAKE UP FOR THE ERODED CONDITI ON OF TAB. TAB HAD COME IN CONTACT WITH METAL AREA OF ROTOR. WORN THROUGH, GROUNDING MAG. IMPULSE COUPLING WORN SO BA DLY AS TO NARROWLY MISS CONTACT WITH STOP POSTS DURING ENGINE RUN MODE. IMPULSE COUPLING SPRING BROKEN. THIS MAGNETO H AS 250 HRS SINCE ENGINE OVERHAUL. WHILE SERVICING TIRES TO MOVE AIRCRAFT OUT OF HANGAR, NOTED MISSING SCREWS ON LEFT FU EL TANK. 1 L 7 1 3O 3 O A3SO 1E4 1996052300334 19960523 00334 SO 1996 5 23 96ZZZX2580 2 19960426 G 8530 CYLINDER CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO ROCKER SHAFT BOLTS FAILED B FCPR E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 NM 09 421CW 421C0137 292087R ENGINE WAS SHUT DOWN IN-FLIGHT BY PILOT. FOUND ROCKER SHAFT BOLTS BROKEN, AND BENT PUSH ROD. VALVES, GUIDES AND PISTON WERE INSPECTED. ALL PARTS FOUND IN GOOD CONDITION. REINSTALLED CYLINDER AND GROUND RUN. ALL FOUND GOOD. 1 L 7 2 3O 3 O A7CE E7CE 1996052300714 19960523 00714 GL 1996 5 23 96ZZZX2586 2 19960426 G 7313 6898735 TURBINE BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL NR 1 NOZZLE FAILED H A A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 SW 09 3187D 6260 3284 1326 CAE833935 DURING CRUISE FLIGHT, TORQUE YAW WAS EXPERIENCED ALONG WITH TOT RISES TO 890 DEGREES CELSIUS. TORQUE WAS REDUCED TO 60 PERCENT AND TOT STABILIZED TO 800 DEGREES CELSIUS. PILOT RETURNED TO OIL PLATFORM WHERE HE SAFELY LANDED. INSPECTION O F ENGINE REVEALED NR 1 NOZZLE (ON CONDITION PART) HAD FAILED. 1 G 7 1 3U 3 U H2SW E4CE 1996052300721 19960523 00721 NE 1996 5 23 96ZZZX2593 2 19960304 G 7250 0292507640 COVER SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE MODULE 3 CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SO 14 869AC 518 1695 652 ENGINE NOISE DURING START-UP AND SHUT-DOWN. REMOVED AND DISASSEMBLED MO5, 4, AND 3. FOUND COVER AND DEFLECTOR BROKEN A ND RUBBING ON MO4 TURBINE DISC. THIS IS 2ND TIME THIS ENGINE SERIAL NUMBER HAS HAD A COVER AND DEFLECTOR BROKEN. SUBMI TTER SUGGESTS A DIFFERENT STYLE COVER AND DEFLECTOR ABLE TO WITHSTAND ENGINE HEAT AND NORMAL VIBRATION LEVELS. 1 G 7 1 3U 3 U H9EU E19EU 1996052300723 19960523 00723 GL 1996 5 23 96ZZZX2595 2 19960424 G 7230 A23034784 GEARSHAFT RACE 6890550 BOLKMS 105 BO105C 5626005 EU ALLSN 250C 250C20B 03013 GL SPUR ADAPTER SPALLED H K NONE O OTHER IN INSP/MAINT 1 CE 03 205LF 489 010 S146 THE RACE OF THIS SPUR ADAPTER GEARSHAFT SUPPORTS THE TWO AND ONE-HALF BEARING. THE TWO AND ONE-HALF BEARING CAGE FAILED SPALLING THE RACE. THIS GEARSHAFT DRIVES THE TURBINE AND COMPRESSOR. THIS IS AN FAA PMA PART MFG BY SUPERIOR PARTS. 1 G 7 2 3U 3 U H3EU E4CE 1996052300725 19960523 00725 GL 1996 5 23 96ZZZX2597 2 19960307 G 7323 23007506 GOVERNOR BENDIX BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL INPUT LEVER CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 01 211WP 509 6740 3225 CAE833581 DURING A DAILY INSPECTION, MECHANIC FOUND GOVERNOR WITH .75 INCH CRACK AT AREA OF INPUT LEVER BUSHING. GOVERNOR WAS REM OVED AND REPLACED. THESE GOVERNORS HAVE A 2,000-HOUR OVERHAUL. ENGINE HAD BEEN OPERATING NORMALLY. 1 G 7 1 3U 3 U H2SW E4CE 1996052300726 19960523 00726 GL 1996 5 23 96ZZZX2598 2 19960410 G 7261 206075659001 TUBE ASSY BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL ENGINE OIL CHAFED B PN5R A UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 NM 03 617DE 6133 51138 895179 FREEWHEEL RETURN HOSE CHAFED THROUGH ENGINE OIL PRESSURE TUBE CAUSING OIL TO LEAK ONTO DECK. PRECAUTIONARY LANDING MADE , LINE REPLACED AND RETURNED AIRCRAFT TO SERVICE. 1 G 7 1 3U 3 U H2SW E1GL 1996052300734 19960523 00734 GL 1996 5 23 96ZZZX2606 2 19960315 G 7261 23057790 SEAL BELL 206 206B 1181511 SW ALLSN 250C 250C20J 03013 GL OIL JET LEAK D O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 SO 09 381 CAC42587 UPON LANDING FOR STUDENT CHANGE, SMOKE WAS SEEN COMING FROM ENGINE COMPARTMENT. REPLACED NR 6 AND NR 7 ENGINE OIL JET S EAL. 1 G 7 1 3U 3 U H2SW E4CE 1996052300735 19960523 00735 GL 1996 5 23 96ZZZX2607 2 19960424 G 7230 A23034787 BEARING 6894171 BOLKMS 105 BO105C 5626005 EU ALLSN 250C 250C20 03013 GL ENGINE GRBX FAILED D K NONE J WARNING INDICATION IN INSP/MAINT 1 CE 03 205LF 489 034 S146 831080 PART IS AN FAA PMA BEARING. BEARING CAGE CAME APART CAUSING 'CHIP' LIGHT. BEARING FAILURE ALSO CAUSED SPALLING OF THE INNER RACE ON SPUR ADAPTER GEARSHAFT. THIS GEARSHAFT COUPLES (DRIVES) TURBINE AND COMPRESSOR. 1 G 7 2 3U 3 U H3EU E4CE 1996052300743 19960523 00743 NE 1996 5 23 96ZZZX2615 2 19960402 G 7321 32448512 FUEL CONTROL CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE NR 1 ENGINE DEFECTIVE H L O OTHER J WARNING INDICATION CR CRUISE 1 GL 03 502T 3281 B29352 5600153 108317 FOLLOWING POWER REDUCTION FOR DESCENT, WHEN THROTTLE ADVANCED, NO ENGINE RESPONSE. SELECTED ANTI-ICE OFF AND ENGINE RES PONSE INCREASED TO NORMAL OPERATION. SERVICE CENTER REPLACED BOTH ENGINE FUEL CONTROLS. TEST FLIGHT, ENGINE OPERATED, NORMAL AT ALL ALTITUDES. 2 L 7 2 4F 4 F RT A22CE E25EA 1996052300744 19960523 00744 NE 1996 5 23 96ZZZX2616 2 19960402 G 7321 32448512 FUEL CONTROL CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE NR 2 ENGINE DEFECTIVE H L O OTHER J WARNING INDICATION CR CRUISE 1 GL 03 502T 3281 B29358 5600153 108316 FOLLOWING POWER REDUCTION FOR DESCENT, WHEN THROTTLE ADVANCED, NO ENGINE RESPONSE. SELECTED ANTI-ICE OFF AND ENGINE RES PONSE INCREASED TO NORMAL OPERATION. SERVICE CENTER REPLACED BOTH ENGINE FUEL CONTROLS. TEST FLIGHT, ENGINE OPERATED, NORMAL AT ALL ALTITUDES. 2 L 7 2 4F 4 F RT A22CE E25EA 1996053000011 19960530 00011 SO 1996 5 30 96ZZZX2648 2 19960514 G 8530 653445 CYLINDER BEECH 58 58 1152740 CE CONT O520 IO520CB 17032 SO PLUG BOSS CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 07 1847F 1019 TH1291 298505R THE CONTINENTAL STEEL CYLINDER CRACKED FROM THE SPARK PLUG BOSS TO THE AREA BEHIND THE FUEL NOZZLE. THE CYLINDER HAD A TOTAL TIME OF ONLY 1,019.0 HRS. THE CYLINDER STILL HELD GOOD COMPRESSION, BUT WITH A SOAP CHECK, THE AIR LEAK WAS EVIDE NT. SUBMITTER STATES HAVE BEEN HAVING A SERIOUS PROBLEM WITH CYLINDERS CRACKING IN THIS POSITION. BELIEVE THIS IS A SE RIOUS PROBLEM AND SHOULD BE INVESTIGATED FURTHER. 1 L 7 2 3O 3 O 3A16 E5CE 1996053000231 19960530 00231 NE 1996 5 30 96ZZZX2698 2 19960507 G 7261 2380 OIL BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE ENGINE METAL FOD H A K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 01 207R FL14 PCE95489 WHEN ADDING OIL TO ENGINE (EXXON 2380 LOT NR B652 11-29-95) NOTICED METAL CONTAMINATION IN STRAINER USED TO POUR OIL INT O ENGINE. INVESTIGATED OIL IN CAN, FOUND PARTICLES COULD BE PICKED UP BY A MAGNET. DRAINED AND FLUSHED ENGINE OIL SYST EM. INFORMED EXXON AND FAA. OIL SAMPLE SUPPLIED TO EXXON. 2 L 7 2 4T 4 T RT A24CE E4EA 1996053000233 19960530 00233 EA 1996 5 30 96ZZZX2700 2 19960430 G 7321 2528973 BEARING BENDIX DPF2 BEECH 90 B90 1152912 CE PWA PT6 PT6A20 52043 EA RT ENG FUEL CONT FAILED D O OTHER Y ENGINE STOPPAGE NR NOT REPORTED 1 WP 23 388MC 322 194208 LJ383 PCE22420 RIGHT ENGINE FLUCTUATIONS 2-3 SECONDS, 3 TIMES. AIRCRAFT YAW. FIFTEEN MINUTES LATER, FLUCTUATINS OCCURRED THEN FUEL FL OW WENT TO ZERO. ENGINE QUIT. RESTARTED ON GROUND, NO RESPONSE TO THROTTLE. DISASSEMBLED FUEL CONTROL, FOUND BUSHING ASSY BEARING FAILED. 1 L 7 2 3T 3 T 3A20 E4EA 1996053000296 19960530 00296 SO 1996 5 30 96ZZZX2762 2 19960513 G 7414 104001664 IMPULSE COUPLER BENDIX S6RN25 PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO MAGNETO CAM SPLIT B APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 5384F 1751 V149214DR 347770013 MAGNETO IMPULSE COUPLER CAM SPLIT IN HALF DURING RE-INSTALLATION ON MAGNETO DURING MAGNETO 500-HOUR INSPECTION AND IMPUL SE COUPLER AD 78-09-07R3. 1 L 7 2 3O 3 O A7SO E9CE 1996053000299 19960530 00299 SO 1996 5 30 96ZZZX2765 2 19960504 G 8530 PISTON PIN CESSNA 337 337C 2075712 CE CONT O360 IO360C 17025 SO NR 2 CYLINDER FAILED D O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 AL 03 2615S 312 3370915 501398C IT APPEARS THE PISTON PIN BROKE AND THE PISTON HIT THE CRANKSHAFT COUNTERWEIGHT WHICH BROKE A LARGE HOLE IN THE TOP OF T HE CRANKCASE. THE AIRCRAFT WAS ON A CROSS-COUNTRY FLIGHT AT NORMAL CRUISE. WHEN THE VIBRATION STARTED, THE PILOT REDUC ED POWER, BUT THE VIBRATION CONTINUED SO THE PROPELLER WAS FEATHERED AND FLIGHT CONTINUED WITH REAR ENGINE OPERATING. 1 H 7 2 3O 3 O A6CE E1CE 1996053000300 19960530 00300 SO 1996 5 30 96ZZZX2766 2 19960507 G 8540 539800 SPRING CLUTCH CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO RT START ADAPTER FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 13 4677N 26 414A0068 290873R TWENTY-SIX HOURS AFTER INSTALLING A TCM OVERHAULED ENGINE, STARTER ADAPTER FAILED. INSPECTION SHOWED THAT SPRING CLUTCH FAILED AND WAS UNCOILING INTO ENGINE ACC CASE. 1 L 7 2 3O 3 O A7CE E8CE 1996053000305 19960530 00305 CE 1996 5 30 96ZZZX2771 1 19960401 G 8120 641284 COUPLING BEECH 58 58P 1152744 CE CONT O520 TSIO520L 17040 SO TURBO EXHAUST CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 05 4269S TJ96 237270R CLAMP WAS FOUND CRACKED WHEN REMOVED FOR OTHER MAINTENANCE ON THE EXHAUST SYSTEM. SUBMITTER SUSPECTS CLAMP WAS OVERTORQ UED AT PRIOR INSTALLATION. FAILURE OF THIS CLAMP COULD ALLOW HOT EXHAUST GASES TO BE RELEASED IN THE ENGINE COMPARTMENT . SUBMITTER RECOMMENDS CLOSE INSPECTION OF ALL V-BAND STYLE CLAMPS DURING SCHEDULED MAINTENANCE INSPECTION. DEFECT WOU LD BE DETECTABLE WITHOUT REMOVAL. 1 L 7 2 3O 3 O A23CE E8CE 1996060600132 19960606 00132 EA 1996 6 6 96ZZZX2786 2 19960423 G 7414 67542 BEARING PIPER PA31 PA31310 7103103 SO LYC O540 TIO540A2B 41532 EA MAG DRIVE MISINSTALLED D L A UNSCHED LANDING Y W ENGINE STOPPAGE INADEQUATE Q C CR CRUISE 1 SO 16 107FC 31612 L807761 WHILE IN LEVEL FLIGHT, THE RIGHT ENGINE QUIT WITHOUT WARNING. UPON INVESTIGATION, DETERMINED THE DRIVE DOWEL PIN (STD-1 065) HAD BEEN SHEARED, AND THE LEFT IDLER GEAR (71668) HAD LOST A TOOTH AND JAMMED THE MAGNETO DRIVE GEAR (GEAR RETAINER ASSY LW-19102 OR LW 19096). WHEN THE LEFT MAGNETO (S6LN-1208) WAS REMOVED, THE MAGNETO HAD A BURNED APPEARANCE. UPON D ISASSEMBLY, FOUND THE ROTOR HAD CONTACTED THE POLE SHOES IN THE HOUSING. AFTER SENDING THE MAGNETO TO THE BENDIX FACTOR Y, DISCOVERED THE DRIVE GEAR HAD A SIDE LOAD PLACED ON IT CAUSING THIS TO OCCUR. 1 L 7 1 3O 3 O RT A20SO E14EA 1996060600166 19960606 00166 NE 1996 6 6 96ZZZX2799 2 19960301 G 7310 9550147560 ELECTROVALVE AEROSP SA365 SA365N1 8680668 EU TMECA ARRIEL ARRIEL1C 60030 NE NR 2 ENG START FAILED B KY1R K NONE O OTHER IN INSP/MAINT 1 EA 07 92MD 2906 3521 6311 5094 NR 2 ENGINE WOULD NOT HAVE T4 CLIMB UNTIL NG SHOWED 30 PERCENT, THEN RAPID RISE ONCE IGNITION OCCURRED. REPLACED START FUEL ELECTROVALVE. 1 G 7 2 3U 3 U H10EU E19EU 1996060600874 19960606 00874 EA 1996 6 6 96ZZZX2868 2 19960513 G 8530 VALVE SEAT PIPER PA31 PA31325 7103105 SO LYC O540 TIO540F2BD 41532 EA LT ENG NR 2 CYL DISLODGED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 25 62992 554 LW12967 317712013 L631961AC ON A SHORT FLIGHT, A ROUGHNESS DEVELOPED IN THE LEFT ENGINE. NO EMERGENCY ACTION WAS REQUIRED. AFTER PERFORMING A COMP RESSION CHECK, FOUND THE EXHAUST VALVE SEAT ON NR 2 CYLINDER HAD BECOME DISLODGED CAUSING THE EXHAUST VALVE TO REMAIN PA RTIALLY OPEN. THE CYLINDER (HEAD) IN THE AREA OF THE EXHAUST SEAT WAS DAMAGED BEYOND REPAIR, AND THE VALVE OR SEAT CAUS ED MINOR DAMAGE TO THE PISTON. NO CAUSE FOR THE SEAT BECOMING DISLODGED HAS BEEN DETERMINED. 1 L 7 2 3O 3 O A20SO E14EA 1996060600885 19960606 00885 SO 1996 6 6 96ZZZX2879 2 19960508 G 8530 CYLINDER CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO NR 1 CYLINDER HEAD SEPARATED B ETER E A ENGINE SHUTDOWN UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 SO 11 49TD 421C0025 241033R ON TAKEOFF, NR 1 CYLINDER SEPARATED AT THE HEAD CAUSING ENGINE POWER LOSS. PILOT SHUT DOWN LEFT ENGINE AND RETURNED TO AIRPORT. ENGINE AND CYLINDER HAD 757 HOURS SINCE OVERHAUL WITH .010 INCH OVERSIZED BARRELS. CYLINDER TOTAL TIME UNKNOW N. 1 L 7 2 3O 3 O A7CE E7CE 1996060600892 19960606 00892 EA 1996 6 6 96ZZZX2886 2 19960410 G 7322 8618 LOCKWIRE FACET MA4SPA PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA CARB MIX CONTROL FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 09 3567P 2200 CK815279 288016202 L1271039A CARBURETOR MIXTURE CONTROL DID NOT FUNCTION PROPERLY. UPON INSPECTION, PN 86-18 LOCKWIRE, FOUND FATIGUED, CRACKED IN HA LF, NOT ALLOWING FOR MIXTURE CONTROL SHAFT TO BE PROPERLY OPERATED. 1 L 7 1 3O 3 O 2A13 E274 1996060600893 19960606 00893 EA 1996 6 6 96ZZZX2887 2 19960501 G 8500 ENGINE SLNSBY T67 T67M260 8323006 EU LYC O540 AEIO540D4A5 41532 EA POWER PLANT FAILED D O OTHER Y ENGINE STOPPAGE AB AEROBATIC 1 SW 17 3193K 100 2233 L2559748A ENGINE STOPPED IN-FLIGHT AFTER POWER REDUCTION IN SPIN DURING POWER ON OF THE SPIN DEMONSTRATION SORTIE. ENGINE RESTART ED WITH START BUTTON. 1 L 7 1 3O 3 O NT A73EU 1E4 1996060600894 19960606 00894 EA 1996 6 6 96ZZZX2888 2 19960508 G 7414 M3525 COIL SLICK 4271 PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA LT MAGNETO FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 01 8089C 220 89100029 28769002 RL3247136A AFTER FLIGHT, ENGINE WOULD NOT START. BOTH MAGNETOS FOUND TO BE INOPERATIVE, NO SPARK. IT HAS BEEN FOUND THAT ONE MAG GOES INOP. ENGINE STARTS ON THE GOOD ONE, UNTIL IT FAILS. AFTER THE ENGINE RPM MEETS OR EXCEEDS 600 RPM, THESE COILS W ILL MAG CHECK OK. INSTALLED FACTORY NEW COILS, PN M3975. OPS SATISFACTORY. 1 L 7 1 3O 3 O 2A13 E286 1996060600905 19960606 00905 GL 1996 6 6 96ZZZX2899 2 19960513 G 7250 6892828 NOZZLE SHIELD 23031925 ALLSN 250C 250C30 03013 GL 1ST STAGE TURB CRACKED B YKER K NONE O OTHER IN INSP/MAINT 1 EA 17 CAT90284 CAE890278 DURING REPAIR OF THE TURBINE, NOTED THE DEFLECTOR ON THE FIRST STAGE NOZZLE SHIELD WAS BURNED. CLOSER EXAMINATION REVEA LED 2 CRACKS IN THE DOME DETAIL. THE DOME WAS CHECKED FOR PROPER MATERIAL PER DEB A-72-3208 AND WAS FOUND TO CONFORM. S USPECT THE CAUSE COULD BE A STREAKING FUEL NOZZLE. 3 U E1GL 1996060600910 19960606 00910 WP 1996 6 6 96ZZZX2904 2 19960315 G 7250 3587591 BEARING LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP ENG NR 4 FAILED B L MJ1R E ENGINE SHUTDOWN E J VIBRATION/BUFFET WARNING INDICATION DE DESCENT 1 EA 11 130F 2399 044 P74225 DURING DESCENT, FLT CREW OBSERVED FLUCTUATING FUEL FLOW ON RT ENG FOLLOWED BY VIBRATION AND NOISE. CREW REDUCED POWER S ETTING TO IDLE AND CONTINUED FLT. DURING FINAL APROACH, OIL PRESSURE BEGAN TO FLUCTUATE AND LOW OIL PRESSURE CAUTION LI GHT ILLUMINATED. PILOT COMMANDED A SHUT-DOWN AND LANDED ACFT WITHOUT FURTHER INCIDENCE. UNABLE TO ROTATE EITHER THE LP OR HP SPOOLS. EXAMINATION OF INLET AREA SHOWED NO EVIDENCE OF FOREIGN OBJECT INGESTION. METAL CONTAMINATION FND IN OI L TANK, XSFER GEARBOX AND OIL FILTER, FILTER BYPASS BUTTON WAS NOT OUT. UNABLE TO DISASSEMBLE OIL PUMP DUE TO INTERNAL DAMAGE. ENG IN-FLT SHUTDOWN CAUSED BY FAILURE OF NR 4 BEARING AND SUBSEQUENT INTERNAL DOMESTIC OBJECT DAMAGE TO ENGINE. 2 L 7 2 4F 4 F A10CE E6WE 1996061300217 19960613 00217 GL 1996 6 13 96ZZZX2935 2 19960510 G 7230 ROTOR ASSY HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL COMPRESSOR DEFECTIVE D K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 07 911FT 3888 1257 811036D CAE836410 POWER CHECK RESULTS - LOW POWER. COMPRESSOR ASSY REPLACED, DISCREPANCY CLEARED. (ALLISON MODEL 250 REPORT NR A 134718) . 1 G 7 1 3U 3 U H3WE E4CE 1996061300377 19960613 00377 GL 1996 6 13 96ZZZX2943 2 19960507 G 7200 ENGINE AGUSTA A109 A109C 0260118 EU ALLSN 250C 250C20 03013 GL NR 2 MAKING METAL D A K NONE J WARNING INDICATION NR NOT REPORTED 1 GL 03 97CH 337 7657 CAE295546 NR 2 ENGINE REMOVED DUE TO EXCESSIVE CHIP LIGHTS. THIS IS THE 3RD OCCURRENCE WITH THIS ENGINE. ENGINE TT, 336.5 HRS SI NCE NEW. 1 G 7 2 3U 3 U H7EU E4CE 1996061300386 19960613 00386 EA 1996 6 13 96ZZZX2952 2 19960501 G 8520 AL12186 NUT PIPER PA32 PA32301 7103207 SO LYC O540 IO540K1G5 41532 EA CON ROD BOLT MISMANUFACTURED H L K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 2586Y 328506007 L2254348A ASSEMBLING THIS ENGINE DURING NORMAL OVERHAUL, THE ROD BOLT NUT WAS TORQUED AND THE BOLT MEASURED FOR STRETCH LENGTH. T HE MICROMETER DID NOT SMOOTHLY SNUG UP. THE BOLT'S OUTBOARD EDGE MEASURED 2.255 INCHES AND INBOARD EDGE MEASURED, 2.259 INCHES. BELIEVING THE BOLT TO BE DEFECTIVE, IT WAS REMOVED. WHEN SPUN, THE NUT HAD A WOBBLE. INSPECTION FOUND THE TH READS OF THE NUT WERE NOT SQUARE WITH THE FACE AND THIS CAUSED THE BOLT TO BE BENT WHEN TORQUED. THE BOLT WAS STRAIGHT WHEN UNTORQUED. REPLACED BOTH THE NUT AND BOLT WITH NEW PARTS. 1 L 7 1 3O 3 O A3SO 1E4 1996061300394 19960613 00394 NE 1996 6 13 96ZZZX2960 2 19960514 G 8550 CYLINDER SCWZER G164 G164A 3952704 EA PWA R1340 R1340AN1 52016 NE NR 8 CRACKED H S MWRG A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 EA 17 6620Q 1693 10419 PILOT EXPERIENCED POPPING, MISFIRING, AND POWER LOSS DURING TAKEOFF. AN UNSUCCESSFUL OFF AIRPORT LANDING MADE. AIRCRAF T FLIPPED OVER AND WAS SUBSTANTIALLY DAMAGED. INSPECTION REVEALED NR 8 CYLINDER CRACKED BETWEEN SPARK PLUG BOSSES AND D OWN TO BARREL ON BACK SIDE OF CYLINDER. AIRCRAFT HAD BEEN OPERATED SEVERAL TIMES DURING AG OPERATIONS ON THIS DAY. SMO H: 930.0 HRS. 1 Q 7 1 3R 3 R 1A16 5E2 1996061300410 19960613 00410 EA 1996 6 13 96ZZZX2976 2 19960423 G 7322 105135 CARBURETOR ARM FACET PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA THROTTLE DETACHED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 3457Q 250 CK815086 287716157 L732439A CARBURETOR THROTTLE ARM CAME LOOSE FROM THROTTLE SHAFT DUE TO ATTACHMENT NUT LOOSENING OFF OF ARM. THE SUSPECT CAUSE OF THE NUT COMING LOOSE WAS IMPROPER INSTALLATION OF KOTTER KEY INTO NUT. 1 L 7 1 3O 3 O 2A13 E274 1996061300411 19960613 00411 SO 1996 6 13 96ZZZX2977 2 19960514 G 7414 1051324 SPRING 10400307 CESSNA 182 182C 2072708 CE CONT O470 O470R 17026 SO MAG IMPULSE COUP BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 01 8617T 7 52517 988558RR TWO NEW SNAP-RING COUPLINGS INSTALLED AT ANNUAL INSPECTION. SEVEN HOURS LATER BOTH COUPLING SPRINGS FAILED ON CONSECUTI VE ENGINE STARTS. SPRING FAILURES APPEAR TO BE IDENTICAL. COUPLINGS WERE BOUGHT AND INSTALLED AS ASSEMBLIES PREVENTING INSPECTION OF SPRINGS PRIOR TO INSTALLATION. 1 H 7 1 3O 3 O NT 3A13 E273 1996061300691 19960613 00691 SO 1996 6 13 96ZZZX2995 2 19960426 G 8530 625393 RETAINER PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO NR 6 CYL VALVE FRACTURED D K NONE O OTHER IN INSP/MAINT 1 EA 05 6908P 1350 468508062 528156 ON REMOVAL OF NR 6 CYLINDER DUE TO METAL FOUND IN OIL FILTER, FOUND PIECES IN ROCKER AREA. THIS WAS VERIFIED AS CONTAMI NANTS THROUGH T.C.M. NO SERVICE INFO ISSUED TO DATE ON AN ONGOING PROBLEM OF THIS PART. 1 L 7 1 3O 3 O A25SO E8CE 1996061300692 19960613 00692 CE 1996 6 13 96ZZZX2996 1 19960601 G 7920 HOSE BEECH 95 B95A 1153406 CE LYC O360 IO360B1A 41514 EA OIL COOLER CHAFE H A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 SW 99 10 GROUND PERSONNEL NOTED FUEL TYPE VAPORS TRAILING BEHIND TAXIING BEECH TRAVEL AIR. ACFT RETURNED TO AIRPORT. INVESTIGAT ION REVEALED VAPOR WAS, IN FACT, BURNING OIL FROM CHAFED THROUGH OIL LINES FROM COOLER. LINE WAS CHAFED AND BURNED THRO UGH BY UNSHIELDED EXHAUST. REPLACED OIL LINE WITH LONGER HOSE AND ADDED AN ADEL CLAMP, ROUTING HOSE FURTHER DOWN IN COW L. A NEW OIL HOSE HAD BEEN INSTALLED ONLY 10 HOURS PREVIOUSLY. 1 L 7 2 3O 3 O 3A16 1E10 1996061300693 19960613 00693 NE 1996 6 13 96ZZZX2997 2 19960517 G 8530 PISTON SCWZER G164 G164A 3952704 EA PWA R1340 R1340AN1 52016 NE NR 1 CYLINDER RING BROKE D A UNSCHED LANDING R K PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 EA 17 6565 1921 722 38065 FIRST OR SECOND COMPRESSION RING BROKE CAUSING RING LANDS TO WEAR BETWEEN FIRST AND SECOND RING LAND AND THROUGH PISTON HEAD. COMBUSTION HEAT BURNED HOLE LARGER DIRECTING PRESSURE TO ENGINE CASE. THIS PRESSURE BLEW THE ENGINE OIL OVERBOAR D. THIS RESULTED IN AN EMERGENCY LANDING. 1 Q 7 1 3R 3 R 1A16 5E2 1996061300694 19960613 00694 NE 1996 6 13 96ZZZX2998 2 19960528 G 7322 67019 MIXTURE CONTROL BENDIX P012H4 DOUG DC3 DC3A 3021433 WP PWA R1830 R1830* 52020 NE CARB AUTO MIX MALFUNCTION H O OTHER M E R OVER TEMP VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 17 32MS 844 5682114A 4978 CYLINDER HEAD TEMPERATURE RUNNING HIGHER THAN NORMAL AND ENGINE ERRATIC WHEN AUTO LEAN SELECTED AT CRUISE. AMC TIME IN SERVICE, 843.9 HRS. 2 L 7 2 4R 4 R A669 5E4 1996061300704 19960613 00704 EA 1996 6 13 96ZZZX3008 2 19960525 G 7314 41270175 FUEL PUMP PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA ENGINE FAILED H A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 SW 99 40933 327400025 L48648 PILOT REPORTED LOSS OF ENGINE POWER ON TAKEOFF AND ELECTED TO LAND ON GOLF COURSE. DURING INVESTIGATION, ENGINE WAS OPE RATED AND ENGINE DRIVEN FUEL PUMP FOUND INOPERATIVE. 1 L 7 1 3O 3 O A3SO E295 1996062000426 19960620 00426 WP 1996 6 20 96ZZZX3045 2 19960509 G 7260 8968042 GEARSHAFT 31017262 MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP FUEL PUMP SHEARED B IZ2R O OTHER Y ENGINE STOPPAGE NR NOT REPORTED 1 SW 15 175CA 4942 3P9426 736SA P36014 AIRCRAFT EXPERIENCED AN UNCOMMANDED ENGINE SHUT DOWN. ENGINE DISASSEMBLY REVEALED GEARSHAFT HAD SHEARED CAUSING FUEL PU MP TO STOP TURNING. REFERENCE: 1PC 72-01-16, SECTION 72-10-17, PAGE 2, ITEM 40. 1 H 7 2 3T 4 T RT A10SW E4WE 1996062000438 19960620 00438 SO 1996 6 20 96ZZZX3057 2 19960513 G 8550 643716 FILTER ADAPTER CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO WASTEGATE OIL WRONG CONN B L EVGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 33 2FOR U20606295 EXPERIENCED INCONSISTENT MANIFOLD PRESS & FUEL FLOWS. LOOKED AT SOURCE OF OIL TO WASTEGATE FROM OIL PUMP HSNG P/N 64371 6, & FND PORT USED SUPPLIED UNFILTERED OIL. OIL PUMP HSNG IS NEW P/N WHICH USES FULL FLOW OIL FILTER. NEW HSNG HAS, BE LOW FILTER BASE, A 2ND PORT THAT WILL PROVIDE FILTERED OIL. OLD P/N 632770 OIL PMP HSNG WHICH USES OTHER STYLE OF FILTE R (CESSNA SUPPLIED OIL FILTER ADAPTER P/N 1250922-4) HAS 1 PORT FOR FILTERED OIL SUPPLY TO W/G. PORT IS IN SAME LOCALE AS UNFILTERED PORT ON NEW P/N HSNG. PROBLEM DEVELOPED WHEN REPLACING ENG WITH OLD HSNG WITH ENG HAVING NEW. ASSUMED FI LTERED OIL WOULD COME OUT OF SAME LOCALE, PORT IS DIFFERENT INSIDE. PORT IS PLUGGED WITH ALLEN HEAD PLUG. 1 H 7 1 3O 3 O A4CE E8CE 1996062000756 19960620 00756 SO 1996 6 20 96ZZZX3072 2 19960528 G 7414 10357281H COIL PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO ENGINE RT MAG WIRE BROKEN D K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 05 42946 28R8331025 299532R INSTALLED NEW MAGNETO, WAS INOPERATIVE. TROUBLESHOOTING REVEALED THE COIL WIRE WAS BROKEN AT THE TERMINAL END. (INSULA TION WAS STILL INTACT). SUBMITTER STATED CAUSE WAS DUE TO THE TERMINAL END BEING CRIMPED TOO HARD RESULTING IN BROKEN W IRE. RECOMMEND MANUFACTURER BE INFORMED. 1 L 7 1 3O 3 O 2A13 E9CE 1996062000757 19960620 00757 SO 1996 6 20 96ZZZX3073 2 19960526 G 7414 107902018R MAGNETO PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO ENG RT MAG FAILED D K NONE O OTHER NR NOT REPORTED 1 CE 05 42946 59 28R8331025 299532R MAGNETO FAILED. DID NOT TROUBLESHOOT MAG DUE TO IT BEING UNDER WARRANTY. 1 L 7 1 3O 3 O 2A13 E9CE 1996062000758 19960620 00758 SO 1996 6 20 96ZZZX3074 2 19960528 G 7414 CONDENSER 107902018R PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO ENG LT MAG FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 05 42946 90 28R8331025 299532R INVESTIGATION FOR MAG PROBLEM FOUND CONDENSER HAD NO CONTINUITY. 1 L 7 1 3O 3 O 2A13 E9CE 1996062000759 19960620 00759 SO 1996 6 20 96ZZZX3075 2 19960528 G 7414 10357281H CONDENSER 107902018R PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO ENG RT MAG WIRE BROKEN D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 05 42946 59 28R8331025 299532R RT MAG INOPERATIVE. INSTALLED NEW MAG, SN 1069532DR. THIS NEW MAG WAS INOPERATIVE. TROUBLESHOOTING BOTH MAGS REVEALED ORIGINAL MAG HAD BAD CONSENSER AND THE NEW MAGNETO HAD A BAD COIL. BOTH NEW MAGNETOS HAD A BAD COIL. BOTH THE CONDENS ER AND COIL PROBLEMS RESULTED FROM THE TERMINAL ENDS BEING CRIMPED TOO HARD CAUSING THE WIRE TO FAIL. SUBMITTER RECOMME NDS THE MANUFACTURER BE INFORMED ON THIS PROBLEM. 1 L 7 1 3O 3 O 2A13 E9CE 1996062000765 19960620 00765 GL 1996 6 20 96ZZZX3081 2 19960515 G 7322 CARBURETOR AMTR SONERI SONERAI GL AMTRVW VOLKS VW1700VOLKS 99999 GL ENGINE BLOCKED VENT D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 CE 05 283SX 55 283 DURING TAKEOFF ENGINE HAD POWER LOSS. FUEL STARVATION DUE TO BLOCKED VENT SUSPECTED. SPARK PLUGS CONFIRM EXCESSIVE LEA N MIXTURE CAUSED POWER LOSS. 1 M 7 1 3O 3 O EXPA1M71 EXP3O 1996062000769 19960620 00769 EA 1996 6 20 96ZZZX3085 2 19960521 G 8550 STD1686 SCREEN PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA LT ENGINE DEFECTIVE B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 63ND 178 317852098 L697361A DURING SCHEDULED MAINTENANCE FOUND SCREW AND GASKET MATERIAL IN SUCTION SCREEN. REMOVED OIL SUMP/PAN, INSTALLED SCREW P ER LYCOMING INSTRUCTIONS. 1 L 7 2 3O 3 O A20SO E14EA 1996062700645 19960627 00645 EA 1996 6 27 96ZZZX3198 2 19960530 G 7414 10382896 GEAR ASSY PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RT MAG TEETH MISSING D K NONE O OTHER IN INSP/MAINT 1 AL 01 59829 1071 317652081 L521661A MAGNETO CHECK PRIOR TO TAKEOFF. ENGINE WOULD NOT RUN ON RT MAGNETO. INSPECTION OF MAGNETO FOUND 4 TEETH MISSING, RT SI DE DISTRIBUTOR GEAR ASSY. ALL TEETH ON RT AND LT GEAR ASSYS BADLY WORN AND CHIPPED. SUSPECT CAUSE, AGE, HEAT, AND LACK OF LUB ON DRIVE GEAR. CLOSER INSPECTION OF MAG GEARS ON INSPECTION. 1 L 7 2 3O 3 O A20SO E14EA 1996062700646 19960627 00646 EA 1996 6 27 96ZZZX3199 2 19960522 G 8530 PISTON PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA NR 3 CYLINDER RINGS WORN D K NONE O OTHER IN INSP/MAINT 1 AL 03 4170R 4065 141 3240502 L465848A LOWER SPARK PLUG FOWLED WITH OIL. REMOVED CYLINDER ASSY AND FOUND UPPER FACE OF RINGS KNIFE EDGED. REMOVED AND REPLACE D CYLINDER ASSY. 1 L 7 1 3O 3 O A3SO 1E4 1996062700652 19960627 00652 SO 1996 6 27 96ZZZX3205 2 19960514 G 7322 3232 FLOAT SHAFT FACET MA35PA CESSNA 150 150D 2071810 CE CONT O200 O200A 17020 SO CARBURETOR BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 13 6006T 3978 1493 15060706 2048879A DURING CARBURETOR TEAR DOWN, FLOAT SHAFT WAS FOUND WITH ONE END BROKEN, PUMP PLUNGER, PN 194-593, WAS ALSO FOUND DETERIO RATED, AS WELL AS THE BOWL BEING FULL OF TRASH. SUBMITTER STATED CARBURETORS, AS WELL AS ALL OTHER ACCESSORIES, SHOULD BE OVERHAULED OR HAVE A CLOSE INSPECTION EACH 500-800 HRS OF OPERATION. 1 H 7 1 3O 3 O 3A19 E252 1996062700654 19960627 00654 SO 1996 6 27 96ZZZX3207 2 19960529 G 8550 FILL TUBE CONT O360 TSIO360FB 17025 SO ENGINE OIL RUSTY D K NONE O OTHER IN INSP/MAINT 1 NE 03 2135 305857 THE INSIDE OF THE OIL FILLER TUBE AND OIL CAP WERE RUSTED TO THE POINT OF FLAKES OF RUST BEING KNOCKED OFF OF THE SURFAC E AND FALLING INTO THE CRANKCASE. SUBMITTER STATED THESE ASSEMBLIES SHOULD PROBABLY BE MADE OF STAINLESS STEEL. THEY A RE CADMIUM PLATED WHEN NEW, AND THAT DOESN'T SEEM TO PREVENT THE CORROSION. 3 O E9CE 1996062700658 19960627 00658 EA 1996 6 27 96ZZZX3211 2 19960515 G 8530 LW19281 CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA NR 4 CYL EXH CRACKED B KD4R K NONE K FLUID LOSS NR NOT REPORTED 1 SO 17 350MP 342 318152116 L606961A PILOT REPORTED OIL LEAK ON THE LT ENGINE FOLLOWING A FLIGHT OF APPROXIMATELY 1 HOUR. MAINTENANCE UNCOWLED ENGINE AND DI SCOVERED AN EXHAUST STUD FROM THE NR 4 CYLINDER HAD BACKED OUT OF EXHAUST FLANGE. STUD BOUNCED AGAINST THE PUSH ROD HOU SING WEARING A HOLE THROUGH IT APPROX THE SAME SIZE AS THE STUD DIAMETER CAUSING THE OIL LEAK. ENGINE WAS OPERATING NOR MALLY WITH THE EXCEPTION OF THE REPORTED OIL LEAK. AN INVESTIGATION REVEALED A CRACK EXTENDING FROM THE EXHAUST PORT TO STUD RETENTION AREA. CRACK RELIEVED TENSION ON THE STUD CAUSING IT TO BECOME DISLODGED. FURTHER INVESTIGATION REVEALE D 4 OF 6 CYLINDERS HAD CRACKS IN SAME GENERAL AREA. 1 L 7 2 3O 3 O A20SO E14EA 1996070300390 19960703 00390 SO 1996 7 3 96ZZZX3319 2 19960618 G 8530 653452A9 CYLINDER CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO NR 2 HEAD CRACKED B S APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 48SA 163 4040417 276408R FOUND NR 2 CYLINDER HEAD CRACKED AT LOWER SPARK PLUG HOLE. 1 L 7 2 3O 3 O A25CE E7CE 1996070300392 19960703 00392 EA 1996 7 3 96ZZZX3321 2 19960503 G 8550 FITTING GULSTM AA5 AA5B 3960105 SO LYC O360 O360A4K 41514 EA ACCESSORY CASE FAILED D A K NONE K FLUID LOSS NR NOT REPORTED 1 SW 15 28462 125 AA5B0626 L2208436A OIL PRESSURE FITTING AT ENGINE TO GAUGE HAD BRASS FITTING AND THEN 90 DEGREE RESTRICTIVE FITTING. APPEARS TO HAVE BEEN TOO CLOSE TO MOUNT. BRASS FITTING BROKE FLUSH AT ACCESSORY CASE AND OIL PUMPED OUT OF ENGINE. BRASS FITTING APPEARED T O BE INCORRECT PART NUMBER. 1 L 7 1 3O 3 O A16EA E286 1996070300394 19960703 00394 EA 1996 7 3 96ZZZX3323 2 19960618 G 8530 LW12993 CYLINDER MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA ROCKER BOX DRAIN CRACKED D S A K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 201RP A319521 240215 L1725451AC FOUR NEW LW-12993 CYLINDERS HAVE CRACKS AT THE ROCKER BOX DRAIN FITTING BOSS. THESE CRACKS OCCUR AT A CASTING FLAW. TH IS MAY BE CAUSED BY THE TAPERED THREAD OF THE MS-20823-6D ELBOW FITTING. 1 L 7 1 3O 3 O 2A3 1E10 1996070300395 19960703 00395 EA 1996 7 3 96ZZZX3324 2 19960618 G 8530 LW12993 CYLINDER MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA ROCKER BOX DRAIN CRACKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 201RP A300517 240215 L1725451AC FOUR NEW LW-12993 CYLINDERS HAVE CRACKS AT THE ROCKER BOX DRAIN FITTING BOSS. THESE CRACKS OCCUR AT A CASTING FLAW. TH IS MAY BE CAUSED BY THE TAPERED THREAD OF THE MS-20823-6D ELBOW FITTING. 1 L 7 1 3O 3 O 2A3 1E10 1996070300396 19960703 00396 EA 1996 7 3 96ZZZX3325 2 19960618 G 8530 LW12993 CYLINDER MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA ROCKER BOX DRAIN CRACKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 201RP A340519 240215 L1725451AC FOUR NEW LW-12993 CYLINDERS HAVE CRACKS AT THE ROCKER BOX DRAIN FITTING BOSS. THESE CRACKS OCCUR AT A CASTING FLAW. TH IS MAY BE CAUSED BY THE TAPERED THREAD OF THE MS-20823-6D ELBOW FITTING. 1 L 7 1 3O 3 O 2A3 1E10 1996070300397 19960703 00397 EA 1996 7 3 96ZZZX3326 2 19960618 G 8530 LW12993 CYLINDER MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA ROCKER BOX DRAIN CRACKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 201RP A167521 240215 L1725451AC FOUR NEW LW-12993 CYLINDERS HAVE CRACKS AT THE ROCKER BOX DRAIN FITTING BOSS. THESE CRACKS OCCUR AT A CASTING FLAW. TH IS MAY BE CAUSED BY THE TAPERED THREAD OF THE MS-20823-6D ELBOW FITTING. 1 L 7 1 3O 3 O 2A3 1E10 1996070300411 19960703 00411 EA 1996 7 3 96ZZZX3340 2 19960605 G 7414 P-LEAD PIPER PA24 PA24180 7102402 CE LYC O360 O360A1A 41514 EA LT MAGNETO DETERIORATED G K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 05 5984P 2222 241077 L143836 ENGINE INTERMITTENT, ROUGHNESS, WAS BELIEVED CAUSED BY LEFT MAGNETO P-LEAD SHORTING OUT AGAINST OUTSIDE SHIELDING. BOTH LT AND RT P-LEADS INTERNAL INSULATION HAD DETERIORATED TO POWDER. THIS CONTRIBUTED TO ACCIDENT. P-LEADS APPEARED TO B E ORIGINAL EQUIPMENT ON AIRCRAFT. 1 L 7 1 3O 3 O NT 1A15 E286 1996070300413 19960703 00413 EA 1996 7 3 96ZZZX3342 2 19960424 G 8530 HELICOIL PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA NR 6 CYL PLUG CAME LOOSE D K NONE O OTHER IN INSP/MAINT 1 AL 03 4170R 3965 41 3240502 L465848A SPARK PLUG UPPER HELICOIL CAME LOOSE WITH SPARK PLUG. REMOVED CYLINDER ASSEMBLY AND REPLACED WITH OVERHAULED CYLINDER A SSY. 1 L 7 1 3O 3 O A3SO 1E4 1996070300414 19960703 00414 EA 1996 7 3 96ZZZX3343 2 19960617 G 8530 LW11633 CYLINDER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 3 CYL LOWER HELICOIL FAILED B CBCR A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 03 93069 1356 1285389 L1405315 LOWER SPARK PLUG HELICOIL BLEW OUT ON NR 3 CYLINDER RESULTING IN LOSS OF THAT CYLINDER COMRPESSION AND LOSS OF ENGINE PO WER. AIRCRAFT LANDED ON HIGHWAY WITHOUT INCIDENT. SUSPECT CAUSE: OVERTORQUE OR UNDERTORQUE OF SPARK PLUG ALLOWING PLU G TO MOVE IF UNDERTORQUED, OR PULLED THREADS IF OVERTORQUED. THIS ENGINE HAS STC SE792NW AND SA1008NW - HIGHER COMPRESS ION PISTONS AND WOULD AGGRAVATE THE SUGGESTED CAUSE. 1 H 7 1 3O 3 O NT 3A19 E223 1996070300429 19960703 00429 EA 1996 7 3 96ZZZX3358 2 19960426 G 7322 46A226 VENTURI MA45 CESSNA 172 172N 2072434 CE LYC O360 O360A4M 41514 EA CARBURETOR FRACTURED B S ZM3R K NONE O OTHER IN INSP/MAINT 1 WP 07 260ER 3991 1985 75034605 17270223 L3261636A DURING INSPECTION FOR OVERHAUL, VENTURI WAS FOUND BROKEN AT 3 SUPPORT LEGS AT CENTER OF THE VENTURI. 1 H 7 1 3O 3 O NT 3A12 E286 1996071000013 19960710 00013 SO 1996 7 10 96ZZZX3371 2 19960426 G 8550 ENGINE BEECH 36 A36 1151604 CE CONT O520 IO520BB 17032 SO OIL SYSTEM EXCESS SLUDGE B ZM3R K NONE O OTHER IN INSP/MAINT 1 WP 07 3869A 1760 E1853 2745064 ENGINE WAS DISASSEMBLED FOR MAJOR OVERHAUL. FOUND EXCESSIVE SLUDGE BUILD-UP IN CRANKSHAFT AND OIL SUMP. SLUDGE BUILD-U P IN OIL SUMP HAD IMPACTED ALL P/U TUBE SCREENS TO THE POINT OF 80 PERCENT RESTRICTION. THE OIL DRAIN IS FORWARD OF THE OIL P/U TUBE, SO WHEN NOSE OF AIRCRAFT IS UP WHEN DRAINING OIL, IT DOES NOT ALLOW PROPER DRAINAGE OF CONTAMINATION. SU GGEST LOWERING NOSE OF AIRCRAFT AND ALLOWING OIL TO DRAIN OVERNIGHT. 1 L 7 1 3O 3 O 3A15 E5CE 1996071000015 19960710 00015 SO 1996 7 10 96ZZZX3373 2 19960610 G 7414 ES10349276 CONDENSER ELECTROSYS BEECH 55 95B55 1152706 CE CONT O470 IO470L 17026 SO ENGINE MAGNETO DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 99DC TC1490 CS20158672L MAGNETOS OVERHAULED WITH NEW ELECTROSYSTEM CONDENSER, PN E510-349276, CODE NR 03108 AND NR 9544. MAGNETOS CHECKED ON TE ST STAND, OPERATED NORMALLY. MAGS INSTALLED AND TIMED TO ENGINE. DURING GROUND RUN, 3 MAGS CHECKED NORMAL. FOURTH MAG DEVELOPED A 1,000 RPM DROP. CHECKED MAG, FOUND BAD CONDENSER. REPLACED CONDENSER WITH NEW CONDENSER. GROUND RUN, SAM E PROBLEM DEVELOPED. REPLACED CONDENSER WITH A USED BENDIX CONDENSER. ENGINE RAN NORMAL. 1 L 7 2 3O 3 O 3A16 3E1 1996071000021 19960710 00021 EA 1996 7 10 96ZZZX3379 2 19960411 G 8530 CYLINDER PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA NR 2-6 CYLINDERS WORN D K NONE O OTHER IN INSP/MAINT 1 AL 03 9000N 148 3240883 L1338348A INSPECTION FOUND CYLINDER ASSEMBLIES WERE STEPPED AT TOP OF BORE. RINGS HAD KNIFE EDGE AT TOP FACE OF RING. 1 L 7 1 3O 3 O A3SO 1E4 1996071000036 19960710 00036 WP 1996 7 10 96ZZZX3394 2 19960604 G 7421 CH31815 IGNITER CHAMPION AMD FALC50 FALCON900 2700160 EU GARRTT TFE731 TFE7315BR WP ENGINE IGNITER FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 09 523AC 852 139 DURING ROUTINE MAINTENANCE, THE IGNITER FIRING TIP OF THE CENTER ELECTRODE WAS FOUND LOOSE. THE IGNITER IS AN EXTENDED LIFE IRIDIUM IGNITER. THIS WAS A NON-SERIALIZED IGNITER, BUT THE 'TST' INDICATES PREVIOUS SPECIAL TESTING FOR LOOSE CEN TER ELECTRODE WAS COMPLIED WITH BY CHAMPION, THE MANUFACTURER. 2 L 7 3 4F 4 F RT A46EU E6WE 1996071000288 19960710 00288 NE 1996 7 10 96ZZZX3411 2 19960503 G 7230 9136M89G19 ROTOR SPOOL GE CF6 CF650* 30018 NE HP COMP CRACKED G S K NONE O OTHER IN INSP/MAINT 1 EU 01 517842 DURING NDT INSPECTION, A CRACK WAS FOUND IN THE 3-9 HPC SPOOL. THE CRACK IS NOT IN THE AREA DESCRIBED IN THE AD ON SPOO LS. 4 F E23EA 1996071000294 19960710 00294 GL 1996 7 10 96ZZZX3417 2 19960424 G 7323 252466713 GOVERNOR BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE B EOPR O OTHER R PARTIAL RPM/PWR LOSS AP APPROACH 1 AL 01 493HL 26236 S809 GOVERNOR REQUIRED TO BE RETRIMMED FREQUENTLY, THEN ENGINE FELL TO IDLE ON DESCENT FOR FINAL. GOVERNOR WAS CLOSE TO OVER HAUL, 56.0 HOURS LEFT. REPLACED GOVERNOR. 1 G 7 2 3U 3 U NC H3EU E4CE 1996071800014 19960718 00014 EA 1996 7 18 96ZZZX3426 2 19960601 G 8520 SL13792 SEAL CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CRANKSHAFT LOOSE H K NONE O OTHER IN INSP/MAINT 1 SO 16 67658 15285305 1656615 OUTER CIRCUMFERENCE OF SEAL IS NOT A TIGHT FIT TO THE CRANKCASE. AFTER SEAL IS INSTALLED, SEAL IS ABLE TO ROTATE. NO S EALANT IS RECOMMENDED IN THE OVERHAUL OR SERVICE MANUALS, PN 13792 AND SL 13792 SEALS. 1 H 7 1 3O 3 O NT 3A19 E223 1996071800029 19960718 00029 SO 1996 7 18 96ZZZX3441 2 19960624 G 8530 648005CP RING CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO PISTON BROKEN E O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 25 33247 U20602692 553910 TEMPORARY POWER LOSS DURING CRUISE. SUSPECT CAUSE: BROKEN PISTON RING WHICH BECAME WEDGED BETWEEN PISTON AND CYLINDER WALL. REPLACED COMPLETE CYLINDER ASSY. 1 H 7 1 3O 3 O A4CE E5CE 1996071800030 19960718 00030 SO 1996 7 18 96ZZZX3442 2 19960212 G 8520 CRANKCASE BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO NR 1-2 CYLINDERS FAILED E A O OTHER O OTHER AP APPROACH 1 GL 25 4520S 1086 TH660 287021R DIPSTICK DEPARTED AIRCRAFT ON FINAL. MAINTENANCE UNCOWLED ENGINE TO PERFORM COMPRESSION TEST. ENGINE CRANKCASE HAD ERU PTED BETWEEN NR 1 AND NR 2 CYLINDER. BOTH MAGNETOS TORN FROM MOUNTING PADS NR 1 AND NR 2 CYLINDER ROD CAPS AND ROD BOLT S SHEARED FROM RODS AND 1 COUNTERWEIGHT DETACHED FROM CRANKSHAFT. SUSPECT CAUSE: COUNTERWEIGHT PIN FAILURE. ENGINE MA NUFACTURER NOTIFED AND REP TO EXAMINE ENGINE TEAR DOWN INSPECTION REQUESTED BY OWNER, OPERATOR, AND MAINTENANCE. 1 L 7 2 3O 3 O 3A16 E5CE 1996071800032 19960718 00032 SO 1996 7 18 96ZZZX3444 2 19960530 G 8520 643202 CRANKCASE CESSNA 340 340CESSNA 2076404 CE CONT O520 TSIO520J 17040 SO LT HALF CRACKED B S CTUR K NONE O OTHER IN INSP/MAINT 1 GL 21 123KK 809 3400251 509176 ENGINE CRANKCASE WAS FOUND CRACKED FROM THE CRANKCASE THROUGH-BOLT AT CYLINDER NR 2. THE CASE WAS REPLACED 4-9-95. THE ENGINE CURRENTLY HAS 1,257 HOURS TSO. 1 L 7 2 3O 3 O 3A25 E8CE 1996071800036 19960718 00036 SO 1996 7 18 96ZZZX3448 2 19960620 G 7322 182022111 SUPPORT CESSNA 182 182Q 2072732 CE CONT O520 IO520D 17032 SO THROTTLE BODY CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 11 182PG 58 18266379 293230R THIS AIRCRAFT IS MODIFIED PER STC SA00152W1 AND THE ITEM IS PART OF THE MODIFICATION. THIS SUPPORT WAS CRACKED TWO-THIR DS THE WAY THROUGH; AND, IF HAD BROKEN OFF, WOULD HAVE LET THE FUEL CONTROL UNIT SLIP DOWN AND CAUSE A VERY LEAN MIXTURE AND A POSSIBLE ENGINE CUT-OFF. THE SUPPORT COULD BE REMOVED COMPLETELY OR MADE OF STEEL. 1 H 7 1 3O 3 O NT 3A13 E5CE 1996071800108 19960718 00108 GL 1996 7 18 96ZZZX3486 2 19960531 G 7323 2523240 BEARING 23007505 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20 03013 GL FLYWEIGHTS FROZEN B A ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 107AL 1447 S772 DURING TEAR DOWN INVESTIGATION OF UNIT, FOUND 2523240 BEARINGS FROZEN CAUSING FLYWEIGHTS TO STICK. 1 G 7 2 3U 3 U H3EU E4CE 1996071800216 19960718 00216 NE 1996 7 18 96ZZZX3523 2 19960611 G 7230 COMPRESSOR RKWELL NA265 NA26540 6402608 CE PWA JT12 JT12A8 52042 NE ENGINE BINDING D K NONE O OTHER IN INSP/MAINT 1 SO 09 317NT 10605 322 282100 P637622NB COMPRESSOR VERY DIFFICULT TO ROTATE AND SPOOL DOWN VERY SHORT. INTERNAL BINDING COULD BE FELT WHEN ROTATING BY HAND. T HIS IS A MULTI-STAGE UNIT, SO VISUAL INSPECTION/DETECTION OF A PARTICULAR PARTS FAILURE IS VERY DIFFICULT. NO FOD NOTED AND NO DAMAGE OR DEFECTS NOTED IN TURBINE HOT SECTION. ALL IN-FLIGHT AND GROUND TEST PARAMETERS NORMAL. 2 L 7 2 4J 4 J A2WE 1E9 1996071800221 19960718 00221 EA 1996 7 18 96ZZZX3528 2 19960628 G 7414 M3525 COIL SLICK 4270 CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA RT MAG FAILED H O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 01 92595 200 89020072 17261591 ENGINE SUDDENLY BECAME ROUGH. MAG CHECK INDICATED TROUBLE WITH RIGHT MAG, FLIGHT CONTINUED ON SINGLE MAG. OPERATION - AT TERMINATION OF FLIGHT, MAGS RE-CHECKED. RT MAG DEAD; OPENING UP MAG REVEALED 'BEARING' GREASE IN MAG HOUSINGS. COIL APPEARED INTACT, BUT DID NOT CHECK OUT. FRONT BEARING HAD 'ROUGH SPOTS'. TOTAL TIME SINCE NEW, 200 HOURS. 1 H 7 1 3O 3 O NT 3A12 E274 1996071800222 19960718 00222 EA 1996 7 18 96ZZZX3529 2 19960619 G 8520 CRANKCASE PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA NR 2 CYLINDER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 EA 21 75340 1000 28R7635292 RL1019351A DURING 100-HOUR INSPECTION, THE CRANKCASE WAS FOUND CRACKED (2 INCHES). THIS WAS THE SAME CRACK THAT WAS FOUND 2 YEARS AGO WHEN THE ENGINE HAD 1,500 HOURS TSMO. THE CASE HALVES WERE REPLACED AND NOW 1,000 HOURS LATER, THE SIMILAR CRACK HA S RE-APPEARED. SUSPECT VIBRATION PROBLEM. 1 L 7 1 3O 3 O 2A13 1E10 1996071800228 19960718 00228 SW 1996 7 18 96ZZZX3535 1 19960702 G 8120 60051004 HOUSING ROTOMASTER 3AT6EE10J2 MOONEY M20 M20K 5870220 SW CONT O360 TSIO360GB 17025 SO TURBO CRACKED B A WTXR K NONE O OTHER IN INSP/MAINT 1 NM 07 123VW 222449 250447 309450 SUBMITTER RECOMMENDS THAT ROTO-MASTER TURBINE HOUSING P/N 600510-04 (TCM P/N 643931) BE ADDED TO ROTO-MASTER AD 82-27-03 . AD 82-27-03 STATES THIS INSPECTION MAY BE DISCONTINUED WITH THE INSTALLATION OF P/N 600510-04, BUT SUBMITTER HAS FOUN D THIS TURBINE HOUSING TO BE CRACKING IN THE SAME AREAS SHOWN IN FIGURE 2 OF AD 82-27-03. 1 L 7 1 3O 3 O 2A3 E9CE 1996071800229 19960718 00229 EA 1996 7 18 96ZZZX3536 2 19960702 G 8530 VALVE GULSTM AA5 AA5A 3960106 SO LYC O320 O320E2G 41508 EA NR 4 CYL INT BLOCKED OPEN D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 26390 1961 AA5A0557 L4583127A ON INITIAL RUN-UP AFTER INSTALLING ENGINE AFTER MAJOR OVERHAUL, ENGINE WAS RUN AROUND 5 MINUTES AT 1,000-1,200 RPM'S. E NGINE RPM WAS INCREASED TO 1,700 FOR MAG CHECK. THE ENGINE STARTED TO RUN EXTREMELY ROUGH. ENGINE WAS SHUT DOWN. COMP RESSION CHECK SHOWED ZERO COMPRESSION ON NR 4 CYLINDER. FURTHER INSPECTION WAS CONDUCTED AND AN OBJECT WAS FOUND LODGED BETWEEN THE VALVE GUIDE BOSS AND THE VALVE WHICH HELD IT OPEN. IT APPEARED TO BE A ROUND SAND CAST ROD OF ALUMINUM. 1 L 7 1 3O 3 O A16EA E274 1996071800428 19960718 00428 NE 1996 7 18 96ZZZX3561 2 19960506 G 8530 CYLINDER SCWZER G164 G164A 3952704 EA PWA R1340 R1340* 52016 NE NR 1 CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 23 48395 261 1628 21888 INSPECTION FOUND NR 1 CYLINDER CRACKED HORIZONTALLY THROUGH SPARK PLUG BUSHING ON FORWARD FACE. 1 Q 7 1 3R 3 R 1A16 5E2 1996071800433 19960718 00433 EA 1996 7 18 96ZZZX3566 2 19960313 G 7414 IMPULSE COUPLER SLICK 4371 CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA MAGNETO EXCESS WEAR D K NONE O OTHER IN INSP/MAINT 1 GL 09 79301 115 95090178 17258030 L2497227A DURING ROUTINE MAINTENANCE (COMPRESSION CHECK) ENGINE 'LOCKED UP.' UPON INVESTIGATION/EXAMINATION, IMPULSE COUPLER PAWL AND PAWL AXIS FOUND EXTREMELY WORN ALLOWING IMPULSE COUPLING TO JAM INTERMITTENTLY WITH NO WARNING. 1 H 7 1 3O 3 O NT 3A12 E274 1996071800745 19960718 00745 EU 1996 7 18 96ZZZX3632 2 19960507 G 7250 3013300650 SHAFT CFMINT CFM56 CFM563B2 13802 EU LPT ROTOR CRACKED B RD43 K NONE O OTHER IN INSP/MAINT 1 SW 05 28425 FN01136 721108 THE LPT SHAFT HAS 2 EACH CRACKS, ONE IS 5 AND ONE IS 7 INCHES LONG, ONE INCH APART STARTING APPROXIMATELY .50 INCH FROM THE AFT END OF THE SPLINES. INVESTIGATION IS IN PROGRESS BY CFMI. 4 F E21EU 1996071800746 19960718 00746 NE 1996 7 18 96ZZZX3633 2 19960607 G 7210 447245 BEARING PWA JT8 JT8D217A 52053 NE N2 GEARBOX FAILED B RD43 K NONE J WARNING INDICATION NR NOT REPORTED 1 SW 05 717374 ENGINE EXPERIENCED LOUD BANG AND EPR AND RPM WENT TO ZERO. ENGINE WAS REMOVED WITH INTERNAL AND EXTERNAL DAMAGE TO THE N2 GEARBOX. DISASSEMBLY OF THE GEARBOX REVEALED A FAILED BEARING. INVESTIGATION IS STILL UNDER WAY AT AVIALL. 4 F E9NE 1996072200002 19960722 00002 SO 1996 7 22 96ZZZX3551 2 19960628 G 7421 SPARK PLUG CHAMPION CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO ENGINE ELECTRODE LOOSE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 25 11174 18504435 282968R NEW SPARK PLUG HAS DEFECT, SIDE ELECTRODE LOOSE. 1 H 7 1 3O 3 O 3A24 E5CE 1996072500383 19960725 00383 SO 1996 7 25 96ZZZX3678 2 19960710 G 8530 530341 PISTON CESSNA 172 172E 2072412 CE CONT O300 O300D 17022 SO NR 1 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 05 3793S 925 17250993 28332D3D DURING SCHEDULED OIL CHANGE, OWNER REQUESTED A COMPRESSION CHECK BE DONE. NR 1 CYLINDER WAS LOW AT 28/80. FURTHER INVE STIGATION REVEALED THE FOLLOWING: PISTON CRACKED FROM SKIRT TO FACE AT 6:00 O'CLOCK POSITION. TOP COMPRESSION RING BRO KEN AND CYLINDER WALL SCORED. THIS ENGINE ONLY HAD 30 HOURS SINCE PREVIOUS COMPRESSION CHECK WHICH WAS WELL WITHIN TCM CRITERIA. SUBMITTER RECOMMENDS COMPRESSION CHECKS BE DONE ON THESE OLDER ENGINES ESPECIALLY IF TOTAL TIME IS UNKNOWN AN D TSMOH IS MID-POINT OR BEYOND. 1 H 7 1 3O 3 O NT 3A12 E253 1996072500388 19960725 00388 EA 1996 7 25 96ZZZX3683 2 19960601 G 8550 TUBE CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA OIL RUNBACK HOLE CHAFED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 16 69082 15282477 INSPECTION FOUND WIRING FOR ALTERNATOR MISROUTED, WORE HOLE IN OIL RUNBACK TUBE CAUSING OIL LEAK. 1 H 7 1 3O 3 O NT 3A19 E223 1996072500398 19960725 00398 EA 1996 7 25 96ZZZX3694 2 19960708 G 8520 CASE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA NR 2 CYL LT SIDE CRACKED B DPOD K NONE O OTHER IN INSP/MAINT 1 NM 07 739PJ 1431 17270694 L607576T LEFT CASE CRACKED BELOW NR 2 CYLINDER BASE. CRACK WAS ABOUT 2.5 INCHES LONG. 1 H 7 1 3O 3 O NT 3A12 E274 1996072500401 19960725 00401 EA 1996 7 25 96ZZZX3697 2 19960702 G 8530 434011 CYLINDER NAMER NA260 T28* GL WRIGHT R1820 R1820* 67020 EA FLANGE CRACKED D O OTHER B K SMOKE/FUMES/ODORS/SPARKS FLUID LOSS NR NOT REPORTED 1 SW 99 28YF 400 137799W ENGINE SHOWED EVIDENCE OF OIL LEAK. MECHANIC MUST HAVE THOUGHT HE HAD CURED PROBLEM. AIRCRAFT CLEARED FOR FLIGHT. NR 1 CYLINDER DEPARTED ENGINE SOME TIME AFTER PILOT NOTICED SMOKE IN COCKPIT. INSTRUMENTS SHOWED NORMAL READINGS. CYLINDE R HAD EVIDENCE OF OLD CRACK IN AREA OBSCURED BY COOLING FINS AND PROPELLER GOVERNOR. FOLLOWING MILITARY MAINTENANCE PRO GRAM, COULD (MIGHT) HAVE HELPED, BUT CYLINDER CRACKS OCCURRED IN MILITARY USE ALSO. 1 L 7 1 4R 4 R 1A18 5E10 1996072500404 19960725 00404 EA 1996 7 25 96ZZZX3700 2 19960625 G 7414 M3065 ROTOR SLICK 4347 BEECH 95 D95A 1153408 CE LYC O360 IO360B1B 41514 EA MAGNETO SHAFT FAILED D S K NONE O OTHER IN INSP/MAINT 1 WP 13 199Q 205 94120022 TD581 L655351A ENGINE NO START. TROUBLESHOOTING ISOLATED TO MAGNETO. OPENED MAGNETO HOUSING TO INSPECT. REMOVED DISTRIBUTOR BLOCK AN D GEAR ASSEMBLY. NOTICED ROTOR GEAR APPEARED DETACHED. REMOVED GEAR AND FOUND SHAFT HAD BROKEN AT AREA BELOW POINT CAM SLOT. SLOTTED PORTION OF SHAFT REMAINED IN ROTOR GEAR. BREAK AREA APPEARED TO HAVE HAD MATERIAL DEFECT/CORROSION FROM DISCOLORED DARK AREA. SUBMITTER STATED DUE TO LOW TIME, SUSPECT DEFECTIVE MATERIAL. 1 L 7 2 3O 3 O 3A16 1E10 1996072500406 19960725 00406 SO 1996 7 25 96ZZZX3702 2 19960703 G 8550 CH48108 FILTER CHAMPION BEECH 58 58P 1152744 CE CONT O520 TSIO520WB 17040 SO ENGINE OIL DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 05 6648K TJ204 248173R OIL FILTER CUT OPEN AT OIL CHANGE. NOTICED INSIDE GASKET WAS CUT AND SLIGHTLY MISALIGNED. CLOSER LOOK REVEALED METAL P ORTION WAS CUT APPROXIMATELY ONE INCH AND ONE INCH SLIVER ABOUT .0625 INCH THICK WAS STICKING INTO OIL OUTLET PATH. HAD THIS SLIVER COME LOOSE, IT WOULD HAVE GONE INTO THE ENGINE, POSSIBLY CAUSING A CATASTROPHIC FAILURE. RECOMMEND STICKIN G FINGER INTO NEW FILTERS PRIOR TO INSTALLING TO CHECK FOR DEFECTS. 1 L 7 2 3O 3 O A23CE E8CE 1996072500574 19960725 00574 GL 1996 7 25 96ZZZX3728 2 19960607 G 7200 ENGINE DOUG DC10 DC1030 3023501 WP GE CF6 CF66D 30020 GL NR 3 FIRE B ZUFY K NONE A FLAME/FIRE IN INSP/MAINT 1 EA 35 833LA 46937 DURING ENGINE START ON PUSH-BACK, NR 3 ENGINE SUFFERED A JET-PIPE FIRE AT MANCHESTER. FIRE EXTINGUISHED BY AIRPORT FIRE SERVICE. NO DAMAGE. AIRCRAFT HISTORY OF FUEL FLOW PROBLEMS. FIRE OCCURRED ON SECOND ATTEMPT TO START. NR 3 ENGINE, NR 2 FIRE BOTTLE USED, NO EFFECT. NR 1 FIRED. OK. FULL REPORT TO FOLLOW. 2 L 7 3 4F 4 F A22WE E23EA 1996072500577 19960725 00577 GL 1996 7 25 96ZZZX3731 2 19960110 G 7323 A1AA1 GOVERNOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL N2 GOVERNOR SHAFT SEPARATED D P K NONE O OTHER NR NOT REPORTED 1 WP 13 8625F 1338 327 13605 470111D CAE830515 ENGINE RPM DROOPED. REMOVED N2 GOVERNOR AND FOUND DRIVE SPLINE, SPRING AND WASHERS HAD FALLEN OFF. 1 G 7 1 3U 3 U H3WE E4CE 1996080200196 19960802 00196 SO 1996 8 2 96ZZZX3750 2 19960701 G 8550 15000793 NIPPLE CESSNA 337 T337C 2075714 CE CONT O360 TSIO360A 17025 SO ACCESSORY CASE FAILED B A DJ3R A E UNSCHED LANDING ENGINE SHUTDOWN K FLUID LOSS NR NOT REPORTED 1 WP 17 2522S 3370822 197111R THE RIGID PIPE NIPPLE THAT IS THREADED INTO ACCESSORY CASE BETWEEN MAGNETOS FAILED AT THE BOTTOM OF THE THREAD GROOVE FL USH WITH THE ACCESSORY CASE. THIS ALLOWED RETURN OIL FROM THE WASTEGATE CONTROLLERS TO GO OVERBOARD. THE PILOT SAW THE OIL PRESSURE DROPPING. SHUT DOWN ENGINE AND MADE A SAFE LANDING. THE PART INSTALLED IN FACTORY REBUILT ENGINE. ENGIN E TIME AT FAILURE 172 HOURS. FAILURE WAS CAUSED BY METAL FATIGUE AND CONCENTRATED STRESS OF A RIGID ARM PROTRUDING 8 IN CHES SUPPORTING A T-FITTING AND TWO HOSES. THIS IS A CESSNA PART ALTHOUGH IT CAME FROM CONTINENTAL ON THE ENGINE. 1 H 7 2 3O 3 O A6CE E9CE 1996080200203 19960802 00203 EA 1996 8 2 96ZZZX3757 2 19960318 G 7414 1016301010 MAGNETO S6L200 PIPER PA23 PA23250 7102308 SO LYC O540 TIO540C1A 41532 EA DRIVE FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 99 123CF 550 J229127EX 278054017 MAGNETO WAS FOUND WITH DRIVE NUT HAVING NO THREADS AND NO THREADS ON DRIVE. 1 L 7 2 3O 3 O 1A10 E14EA 1996080200209 19960802 00209 EA 1996 8 2 96ZZZX3763 2 19960705 G 8520 CRANKCASE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA RT CASE NR 1 CYL CRACKED B DPOD K NONE O OTHER IN INSP/MAINT 1 NM 07 181SP 299 17268171 RL101576 RIGHT CRANKCASE CRACKED BELOW NR 1 CYLINDER BASE. CRACK WAS APPROXIMATELY 6 INCHES LONG. CASE WAS NOT REPAIRABLE. 1 H 7 1 3O 3 O NT 3A12 E274 1996080200462 19960802 00462 SO 1996 8 2 96ZZZX3766 2 19960713 G 8530 627335D13B NOZZLE CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO FUEL INJ THREADS STRIPPED D K NONE O OTHER IN INSP/MAINT 1 SO 15 2013S 21060981 294685R WHEN REMOVING FUEL INJECTOR NOZZLE FOR CLEANING AT FIRST 91-HOUR TSMOH, FACTORY REMANUFACTURE, NOZZLE CAME OUT OF CYLIND ER HEAD WITH ALUMINUM, STRIPPED THREADS IN CLYINDER HEAD. 1 H 7 1 3O 3 O 3A21 E5CE 1996080200470 19960802 00470 SO 1996 8 2 96ZZZX3774 2 19960711 G 8530 635448CP CYLINDER CESSNA 207 T207A 2073614 CE CONT O520 TSIO520H 17040 SO NR 3 SEPARATED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 07 6308H 1018 20700476 506728 PILOT REPORTED ROUGH ENGINE AND LARGE RPM DROP ON MAG CHECK. INSPECTION FOUND NR 3 CYLINDER CRACKED. WHEN CYLINDER REM OVED, IT WAS DISCOVERED THE HEAD WAS COMPLETELY SEPARATED. BOTTOM SPARK PLUG WAS FOULED. 1 H 7 1 3O 3 O A16CE E8CE 1996080600001 19960806 00001 EU 1996 8 6 CA960103002 1 19960102 G 3320 S2806102 SOCKET BAG BAE146 BAE146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE SIDEWALL LIGHT BURNT W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA LF05465A (CAN)SMOKE COMING FROM SIDEWALL LIGHTING ROW 16 DEF. SOCKET FOR LIGHT BAR FOUND BURNED FROM ELECTRICAL ARCING. LAMP HOLD ER REPLACED. 2 H 7 4 4F 4 F RT A49EU E6NE 1996080800046 19960808 00046 SO 1996 8 8 96ZZZX3795 2 19960712 G 8530 653445 CYLINDER BEECH 58 58 1152740 CE CONT O520 IO520CB 17032 SO ENGINE CRACKED B LNCR K NONE O OTHER IN INSP/MAINT 1 SW 05 3695V 1315 TH1183 282448R ON INSPECTION, THE CYLINDER WAS FOUND TO HAVE A CRACK FROM THE SPARK PLUG BOSS TO THE FUEL NOZZLE. THE CRACK TRAVELS AL ONG THE CASTING MARK ON THE CYLINDER. THE CYLINDER WAS STILL HOLDING 78/80. SUBMITTER BELIEVES THAT THIS IS A MANUFACT URING PROBLEM. 1 L 7 2 3O 3 O 3A16 E5CE 1996080800048 19960808 00048 NE 1996 8 8 96ZZZX3797 2 19960719 G 7322 PD12FS CARBURETOR BENDIX DOUG DC3 DC3 3021401 WP PWA R1830 R183090D 52020 NE ENGINE MALFUNCTION D K NONE O OTHER IN INSP/MAINT 1 SW 17 32MS 740817A 4978 CP350411 ENGINE WILL NOT IDLE, DIES/RESTARTS OK. WILL NOT TAKE THROTTLE. WANTS TO BACKFIRE THROUGH CARBURETOR. REMOVED CARBURE TOR. REPLACED WITH OVERHAULED UNIT. 2 L 7 2 4R 4 R A669 5E4 1996080800059 19960808 00059 EA 1996 8 8 96ZZZX3808 2 19960510 G 8500 ENGINE SLNSBY T67 T67M260 8323006 EU LYC O540 AEIO540D4A5 41532 EA POWER SECTION STOPPAGE C O OTHER Y ENGINE STOPPAGE AB AEROBATIC 1 SW 17 3037C 2134 L2524848 ENGINE STOPPED DURING AEROBATIC MANEUVER. SUCCESSFUL RESTART AND RETURN TO BASE WITHOUT FURTHER INCIDENT. ALL INDICATI ONS NORMAL. PRELIMINARY ASSESSMENT IS THAT AIRCRAFT WAS PUT IN CONDITION KNOWN TO INDUCE ENGINE STOPPAGE. 1 L 7 1 3O 3 O NT A73EU 1E4 1996080800060 19960808 00060 EU 1996 8 8 96ZZZX3809 1 19960425 G 7931 SENDER SLNSBY T67 T67M260 8323006 EU LYC O540 AEIO540D4A5 41532 EA ENG OIL PRESS FAILED C A UNSCHED LANDING J WARNING INDICATION NR NOT REPORTED 1 SW 17 3037X 2137 L2557048A PILOT MADE AN EMERGENCY LANDING AT A SMALL AIRSTRIP. THE PILOT REPORTED LOW OIL PRESSURE AND RAISING OIL TEMPERATURE. A DOSS MAINTENANCE TEAM WAS SENT TO THE AIRSTRIP TO RECOVER THE AIRCRAFT. THE MAINTENANCE PERSONNEL REMOVED AND REPLACED THE OIL PRESSURE SENDING UNIT. GROUND RUN WAS ACCOMPLISHED, OPERATION CHECK GOOD. THE AIRCRAFT WAS FLOWN BACK TO HOND O AT APPROXIMATELY 1,500 HOURS, 25 APRIL 1996, WITH NO RETURN FLIGHT PROBLEMS. 1 L 7 1 3O 3 O NT A73EU 1E4 1996080800061 19960808 00061 EA 1996 8 8 96ZZZX3810 2 19960625 G 8500 ENGINE SLNSBY T67 T67M260 8323006 EU LYC O540 AEIO540D4A5 41532 EA POWERPLANT STOPPAGE C O OTHER Y ENGINE STOPPAGE AB AEROBATIC 1 SW 17 3192E 2227 L2257048A ENGINE STOPPED. DURING TRAFFIC PATTERN STALL MANEUVERS WITH THE ENGINE AT APPROXIMATELY IDLE. STARTER WAS ENGAGED FOR A SUCCESSFUL RESTART. DURING LANDING THE ENGINE STALLED AGAIN, NO RESTART WAS ATTEMPTED. AIRCRAFT LANDED WITHOUT INCID ENT. ALL OTHER INDICATIONS WERE NORMAL. NO KNOWN REASON AT THIS TIME. AIRCRAFT IMPOUND, PUT INTO DEPOT STATUS. DOSS AVIATION IS PERFORMING AN ENGINE STOPPAGE CHECK LIST. NO DISCREPANCIES FOUND AT THIS TIME. ENGINE AND AIRFRAME TIME IS 72.0 HOURS. 1 L 7 1 3O 3 O NT A73EU 1E4 1996080800064 19960808 00064 NE 1996 8 8 96ZZZX3813 2 19960610 G 8530 CYLINDER SCWZER G164 G164A 3952704 EA PWA R985 R985AN1 52008 NE NR 4 HEAD LEAKAGE D K NONE O OTHER IN INSP/MAINT 1 SO 01 5296 580 24011 OVER LAST 200 HOURS, CYLINDER HEAD SEPARATED ON 3 CYLINDERS IN FLIGHT OR ON TAKEOFF. THE 4TH CYLINDER HAD STAINS AND LE AKAGE AND REMOVED BEFORE FAILURES, BUT WAS NOT BETWEEN NR 2 AND NR 3 FIN PER AD 78-08-07. IT WAS LEAKING BETWEEN TOP ST EEL FIN AND NR 1 ALUMINUM FIN. NONE OF FAILED CYLINDERS SHOWED LEAKAGE PRIOR TO FAILURE. 1 Q 7 1 3R 3 R 1A16 5E1 1996080800074 19960808 00074 NE 1996 8 8 96ZZZX3823 2 19960408 G 7250 566004 TURBINE RKWELL NA265 NA26540 6402608 CE PWA JT12 JT12A8 52042 NE 2ND STAGE FAILED D E F A ENGINE SHUTDOWN ACTIVATE FIRE EXT. UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SO 09 307NT 1196 282072 P637801NB CLIMBING THROUGH 5,000 FEET, THE CREW HEARD AND FELT A LOUD REPORT FOLLOWED IMMEDIATELY BY THE LT ENGINE FIRE WARNING LI GHT. THE LT ENGINE SPEED ROLLED BACK TO APPROXIMATELY 12 PERCENT. PILOT SHUT ENGINE DOWN, DISCHARGED THE FIRE BOTTLE A ND MADE A SINGLE ENGINE LANDING. INSPECTION REVEALED NUMEROUS 1ST AND 2ND STAGE TURBINE BLADES MISSING AND EXTENSIVE DA MAGE TO 2ND STAGE DISK. 2 L 7 2 4J 4 J A2WE 1E9 1996080800734 19960808 00734 SO 1996 8 8 96ZZZX3869 2 19960717 G 8520 CRANKCASE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO LT ENG NR 5 CYL CRACKED B S APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 36319 347870318 265936R THE INSPECTION FOUND CRANKCASE HAS A SMALL .3750 INCH CRACK NEXT TO THE UPPER BOLT JUST FORWARD OF CYLINDER NR 5. THIS IS CONSIDERED A NON-CRITICAL AREA PER SB M90-17. 1 L 7 2 3O 3 O A7SO E9CE 1996080800740 19960808 00740 EA 1996 8 8 96ZZZX3875 2 19960723 G 8520 11F20022D3 CRANKCASE PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA NR 6 CYL STUDS FAILED B WC7R O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 25 585DT 493 318052117 L172868A PILOT REPORTED HEARING A 'BOOM' AND A DECREASE IN MANIFOLD PRESSURE DURING FLIGHT. UPON INSPECTION, NR 6 CYLINDER OF RI GHT ENGINE WAS FOUND TO BE AWAY FROM CRANKCASE PAD. FIVE OUT OF EIGHT CYLINDER HOLD-DOWN STUDS HAD BROKEN OFF. TWO THR OUGH STUDS, AND ONE SHORT STUD REMAINED TO HOLD CYLINDER ON. SUSPECT CAUSE, NOT TORQUED PROPERLY. 1,454.3 HOBBS. 1 L 7 2 3O 3 O A20SO E14EA 1996080800741 19960808 00741 EA 1996 8 8 96ZZZX3876 2 19960701 G 8530 EC75971 CYLINDER BEECH 23 C23 1151242 CE LYC O360 O360A4K 41514 EA NR 4 CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 05 63TW 1209 M1762 L2069136A INSPECTION FOUND NR 4 CYLINDER CRACKED FROM OUTSIDE RADIUS OF INTAKE VALVE TO OUTSIDE RADIUS OF EXHAUST VALVE. CYLINDER HEAD SPLIT OPEN BLOWING BOTTOM SPARK PLUG FROM CYLINDER. 1 L 7 1 3O 3 O A1CE E286 1996080800742 19960808 00742 EA 1996 8 8 96ZZZX3877 2 19960715 G 8530 SL13790A ROCKER SHAFT LYC O320 O320* 41508 EA ENGINE BENT B CYKR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 07 ROUTINE CHECK OF O320 SERIES ENGINE ROCKER SHAFTS FROM STOCK, FOUND P/N SL13790A, LOT NR 510924 DATED 4-30-96, 9 OUT OF 20 WERE FOUND BENT. 3 O E274 1996081500077 19960815 00077 NE 1996 8 15 96ZZZX3897 2 19960621 G 7310 991202426 HOSE CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE MOTIVE FLOW FUEL CHAFED B A CNQR K NONE O OTHER IN INSP/MAINT 1 CE 07 323QS 785 5600323 FOUND THE LEFT ENGINE THRUST REVERSER CONTROL LINKAGE HAD CUT INTO THE OUTER PROTECTIVE COVER OF THE MOTIVE FLOW FUEL HO SE. THE FUEL HOSE ASSY WAS REPLACED AND THE T/R CONTROL LINKAGE SAFETY WIRE REPOSITIONED TO PREVENT IT FROM CHAFING THE HOSE. 2 L 7 2 4F 4 F RT A22CE E25EA 1996081500086 19960815 00086 NE 1996 8 15 96ZZZX3906 2 19960710 G 7230 COMPRESSOR RKWELL NA265 NA26540 6402608 CE PWA JT12 JT12A8 52042 NE ENGINE BINDING D K NONE O OTHER IN INSP/MAINT 1 SO 09 309NT 11970 1398 28261 P638364NB COMPRESSOR VERY DIFFICULT TO ROTATE AND SPOOL DOWN VERY SHORT. INTERNAL BINDING COULD BE FELT WHEN ROTATING BY HAND. T HIS IS A MULTI-STAGE UNIT, SO VISUAL INSPECTION/DETECTION OF A PARTICULAR PART FAILURE IS VERY DIFFICULT. NO FOD NOTED AND NO DAMAGE OR DEFECTS NOTED IN TURBINE HOT SECTION. ALL IN-FLIGHT AND GROUND TEST PARAMETERS NORMAL. 2 L 7 2 4J 4 J A2WE 1E9 1996081500090 19960815 00090 EA 1996 8 15 96ZZZX3910 2 19960613 G 8530 LW16475 SPRING SEAT PIPER PA44 PA44180T 7104404 SO LYC O360 LTO360E1A6 41515 EA VALVE FAILED B PAIR O OTHER Y ENGINE STOPPAGE CR CRUISE 1 SO 05 8269T 229 448107022 RL00026674T THE OPERATOR INCURRED AN IN-FLIGHT FAILURE. INSPECTION REVEALED VALVE SEAT FAILED. SUBMITTER STATED THIS UNIT WAS NOT REPLACED DURING LAST OVERHAUL BECAUSE LYCOMING SB 447A FAILED TO LIST LTO-360-E1A6D AS AN EFFECTED ENGINE. SUBMITTER ST ATED AD 80-14-07 NEGLECTED TO ADDRESS THIS ENGINE MODEL POSSIBLY IN ERROR. 1 L 7 2 3O 3 O A19SO E26EA 1996081500091 19960815 00091 EA 1996 8 15 96ZZZX3911 2 19960717 G 7414 10357592 OIL SEAL S4LN200 HUGHES 269 TH55A 4471004 WP LYC O360 HIO360B1A 41514 EA MAG DRIVE END FAILED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 WP 07 331SD 450 00349 291105 L333351A DURING TRAINING FLIGHT, ENGINE ROUGHNESS 'FELT' IN-FLIGHT; FOUND MAGNETO POINTS SATURATED WITH OIL. REPLACED MAGNETO WI TH REBUILT UNIT. 1 G 7 1 3R 3 O 1E10 1996081500108 19960815 00108 EA 1996 8 15 96ZZZX3928 2 19960722 G 7421 REM37BY SPARK PLUG PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA NR 4 CYLINDER FOULED D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 09 2416B 50 3879A0052 L1758615 WHILE FLYING, PILOT EXPERIENCED PARTIAL LOSS OF ENGINE RPM AND MADE A PRECAUTIONARY LANDING IN A FIELD. UPON INVESTIGAT ION, FOUND THE BOTTOM SPARK PLUG IN NR 4 CYLINDER WAS NOT GAPPED PROPERLY. A PIECE OF CARBON GOT STUCK BETWEEN THE ELEC TRODES OF THE SPARK PLUG ALLOWING IT TO BECOME OIL FOULED. THERE WAS NO DAMAGE TO AIRCRAFT OR PERSONS. 1 L 7 1 3O 3 O A18SO E223 1996081500109 19960815 00109 EA 1996 8 15 96ZZZX3929 2 19960701 G 7322 105267 CARBURETOR CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA FINGER SCREEN BLOCKAGE D K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 05 3281R 15284363 L2106415 PARTIAL POWER LOSS. FINGER SCREEN WAS FOUND PARTIALLY FILLED WITH A LINT-LIKE SUBSTANCE TO THE POINT THAT FUEL FLOW WAS RESTRICTED. THE FUEL SYSTEM WAS CHECKED BY DRAINING FUEL FROM SUMPS, GASCOLATOR, FUEL LINE, CARBURETOR FLOAT BOWL. NO FURTHER CONTAMINATION WAS FOUND. GASCOLATOR WAS DISASSEBLED, AND SCREEN WAS FOUND TO BE CLEAN. THE GASOLATOR HAD FAIL ED TO TRAP CONTAMINATION. SYSTEM REASSEMBLED, AIRCRAFT GROUND RUN AND TEST FLOWN. OPERATION NORMAL, RETURNED TO SERVIC E. 1 H 7 1 3O 3 O NT 3A19 E223 1996081500112 19960815 00112 NE 1996 8 15 96ZZZX3932 2 19960722 G 8530 399354 CYLINDER SCWZER G164 G164A 3952704 EA PWA R985 R985AN14B 52008 NE NR 1 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 11 8605H 5000 1157 1432 13782 ENGINE INSPECTION FOUND NR 1 CYLINDER HEAD HAD CRACKED FROM FORWARD SPARK PLUG BOSS UP OVER CENTER OF CYLINDER HEAD AROU ND BELOW EXHAUST PORT, FORWARD AT CYLINDER HEAD/BARREL ATTACH AREA, BACK TO LOWER SIDE OF FORWARD SPARK PLUG BOSS. 1 Q 7 1 3R 3 R 1A16 5E1 1996081500239 19960815 00239 GL 1996 8 15 96ZZZX3944 2 19960729 G 7230 6898607 BEARING 6896028 BELL 206 206L 1181522 SW ALLSN 250C 250C28B 03013 GL NR 1 FAILED B KUVR O OTHER J WARNING INDICATION NR NOT REPORTED 1 SO 19 165BH 2509 R1747 45249 CAE860728 AIRCRAFT EXPERIENCED 3 CHIP LIGHTS WITHIN 50 HOURS. AIRCRAFT GROUNDED PER ALLISON MM. UPON INVESTIGATION FOUND NR 1 BE ARING CAGE BROKEN INTO PIECES AND BEARING FELL APART. SIMPLE MECHANICAL FAILURE THAT COULD HAVE CAUSED ENGINE FLAME-OUT . 1 G 7 1 3U 3 U H2SW E1GL 1996081500240 19960815 00240 EA 1996 8 15 96ZZZX3945 2 19960718 G 7260 330170501 HOUSING 330160203 SKRSKY S76 S76B 8143007 NE PWA PT6 PT6B36 52043 EA NR 1 ENG AGB DAMAGED B EGRR K NONE O OTHER IN INSP/MAINT 1 EA 17 22CP 999 760425 36207 AIRCRAFT TT: 999.1 HOURS. NR 1 ENGINE TT, 999.1 HOURS. DURING REPLACEMENT OF NR 1 HMU, FOUND CORROSION DAMAGE IN THE BORE ON THE HOUSING WHERE HMU IS INSTALLED. CORROSION DAMAGE WAS AT THE 6 O'CLOCK POSITION, AND RANGED FROM MINOR TO SO ME DEEP PITS UP TO .140 INCH DEEP. ENGINE IS BEING REMOVED AND SENT FOR EVALUATION AND REPAIR. 1 G 7 2 4U 4 U H1NE E4EA 1996081500742 19960815 00742 EA 1996 8 15 96ZZZX4007 2 19960719 G 8520 75154 STUD PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA NR 4 BEARING CORRODED B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 145ND 3197 796 2841226 RL1708539A DURING ENGINE TEAR DOWN FOLLOWING ACCIDENT, CRANKCASE HALF NUT ON NR 4 BEARING STUDS SEIZED RESULTING IN STUD BACKING OU T OF CRANKCASE. UPON REMOVAL, FOUND BOTH NR 4 BEARING CRANKCASE STUDS HEAVILY CORRODED/RUSTED. ALSO, HAD GLASS BEADS I N STUD RECEPTACLES. ENGINE WAS FACTORY OVERHAULED 11-18-94, INSTALLED 1-95. 1 L 7 1 3O 3 O 2A13 E274 1996081500748 19960815 00748 1996 8 15 96ZZZX4013 1 19960801 G 7810 62749 GASKET CONT A65 A658 17003 SO NR 2/3 CYL EXH MISMANUFACTURED D P K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 NEW EXHAUST GASKET IS MISMANUFACTURED .032 INCH LARGER THAN ORIGINAL. IT WILL FIT OK ON CYLINDERS 1 AND 4, BUT DUE TO C LEARANCE REQUIRED FOR FIT, IT IS TOO LARGE FOR CYLINDERS 2 AND 3. 3 O E205 1996081500750 19960815 00750 NE 1996 8 15 96ZZZX4015 2 19960730 G 7261 31B360801 PUMP LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE LT ENG OIL HOUSING CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 65BL 371 17A861 054 305218 EXCESSIVE OIL LEAK ON LEFT ENGINE. FOUND OIL PUMP HOUSING CRACKED AT UPPER LEFT BOLT HOLE AREA. SUBMITTER STATED THIS IS TURNING INTO A FLEET-WIDE CONCERN AS THIS CAN CAUSE AN ENGINE SHUTDOWN IN FLIGHT. OTHER OPERATORS HAVE EXPERIENCED T HIS SAME CRACK. AD RECOMMENDED. 2 L 7 2 4F 4 F RT A10CE E35NE 1996082200080 19960822 00080 NE 1996 8 22 96ZZZX4037 2 19960725 G 7250 805172 VANE PWA JT8 JT8D217A 52053 NE N1 TURBINE FAILED D E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 SW 05 709893 ENGINE WAS REMOVED FROM SERVICE DUE TO A LOUD BANG AND ENGINE EXPERIENCED AN IN-FLIGHT SHUT DOWN. DISASSEMBLY OF THE EN GINE REVEALED A SECOND STAGE VANE CLUSTER WAS MISSING AND THE REMAINDER OF THE N1 TURBINE HAD MASSIVE DAMAGE. THE CAUSE FOR THE FAILURE IS STILL UNDER INVESTIGATION. 4 F E9NE 1996082200404 19960822 00404 NE 1996 8 22 96ZZZM1243 2 19960717 G 7320 P3 LINE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE RT ENGINE LOOSE A AMWA A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 CE 07 182YV UE182 FLT 5627 - AFTER TAKEOFF RIGHT ENGINE ROLLED BACK TORQUE AND THEN STABILIZED AT ABOUT 1000 FT/LBS OF TORQUE, AIRCRAFT. R ETURNED TO FIELD AT MCI. MAINTENANCE TIGHTENED P3 LINE C/W FLIGHT TEST RETURNED AIRCRAFT TO SERVICE. (M) 2 L 7 2 4T 4 T RT A24CE E26NE 1996082900162 19960829 00162 EA 1996 8 29 96ZZZX4059 2 19960716 G 8520 72877 CAM FOLLOWER LYC O540 O540B2C5 41532 EA CYLS 1,3,5 BROKEN D P K NONE O OTHER IN INSP/MAINT 1 NM 07 1481540 CAM FOLLOWERS BROKEN ON NR 1 CYLINDER EXHAUST NR 3, EXHAUST AND INTAKE, NR 5 CYLINDER-INTAKE. REST OF CAM FOLLOWERS PIT TED OR SPALLED. NR 2 CYLINDER DROPPED THE EXHAUST VALVE. OIL SUMP REMOVED FOR INSPECTION AND CLEANING. FOUND PIECES O F CAM FOLLOWERS IN SUMP. ENGINE DISASSEMBLED FOR OVERHAUL. ALL SIX ROD CAPS DAMAGED. ALL PIECES RETAINED AND ARE AVAI LABLE FOR SCRUTINY. 3 O E295 1996082900175 19960829 00175 EA 1996 8 29 96ZZZX4072 2 19960517 G 8520 CRANKCASE PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA LT NR 2 CYL FWD CRACKED B DPOD K NONE O OTHER IN INSP/MAINT 1 NM 07 2141T 1058 28R7135144 L619151A LEFT CRANKCASE CRACKED BELOW NR 2 CYLINDER, FORWARD LOWER BASE STUD. CRACK WAS APPROXIMATELY 2 INCHES LONG. CASE WAS R EPAIRED. 1 L 7 1 3O 3 O 2A13 1E10 1996082900177 19960829 00177 CE 1996 8 29 96ZZZX4074 1 19960722 G 8120 CLAMP CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO TURBO FAILED G E A ENGINE SHUTDOWN UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 09 28SA 4040072 276238R CLAMP CAME LOOSE AND DUCT BETWEEN TURBO AND INTAKE THROAT LEAKED CAUSING ENGINE TO RUN ROUGH. PILOT CHOSE TO SHUT DOWN ENGINE IN-FLIGHT AND MADE SAFE SINGLE ENGINE LANDING. NEW CLAMP WAS INSTALLED AND TORQUED TO SPECS. 1 L 7 2 3O 3 O A25CE E7CE 1996082900179 19960829 00179 EA 1996 8 29 96ZZZX4076 2 19960701 G 7414 10682016 GEAR PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540S1AD 41532 EA MAGNETO FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 03 36201 529 32R7887027 L697961A MAGNETO DISTRIBUTOR GEAR FAILED. 1 L 7 1 3O 3 O A3SO E14EA 1996082900184 19960829 00184 EA 1996 8 29 96ZZZX4081 2 19960730 G 7414 10682016 GEARTOOTH D6LN3000 CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA MAGNETO FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 01 6339T E029002GR R18201986 RL2385940A DURING C/W AD 96-12-07, DISCOVERED DISTRIBUTOR GEAR MISSING A TOOTH, DID NOT AFFECT ENGINE OPS. REPLACED BOTH DISTRIBUT OR GEARS WITH NEW. REASON FOR FAILURE UNKNOWN, NO OTHER DEFECTS NOTED. 1 H 7 1 3O 3 O 3A13 E295 1996082900327 19960829 00327 GL 1996 8 29 HEEA967686 2 19960822 G 7230 23033439 DAMPER SEGMENT 23038126 ALLSN 250C 250C20B 03013 GL ENG COMP BELOW SPECS E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 CAC15233 CAE830070 RECEIVING INSPECTION REVEALED DAMPER SEGMENT LENGTH .0335 BELOW BLUE PRINT SPECS OF .542 - .544. REPLACED DISCREPANT PAR T WITH NO CHARGE REPLACEMENT RECEIVED FROM ALLISON. 3 U E4CE 1996082900335 19960829 00335 EA 1996 8 29 96ZZZX4142 2 19960418 G 8530 LW14115 CYLINDER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA NR 1 CYL SLEEVE CRACKED H K NONE K FLUID LOSS IN INSP/MAINT 1 GL 25 17PS 321 31P7630008 RL62362 HOBBS - 3,213.6 HOURS. OIL APPEARED AROUND NR 1 CYLINDER PUSH ROD TUBES. SEALS REPLACED, GROUND CHECK OPS GOOD. AFTER FLIGHT, OIL APPEARED AGAIN. REMOVED NR 1 CYLINDER, FOUND CYLINDER SLEEVE CRACKED APPROXIMATELY THREE-FOURTHS OF CIRCUM FERENCE. LOG REVEALED THIS TO BE THE 3RD CYLINDER ON NR 1 IN 4 YEARS. PISTON P/N LW 10545 SHOWED SIGNS OF BEING HOT. S USPECT OIL NOZZLE FOR PISTON COOLING INOPERATIVE. REPLACED NOZZLE, P/N 73772. REPLACED CYLINDER KIT, P/N 05K21116-3, A ND ASSOCIATED SEALS AND GASKETS. PISTON SKIRT WAS OIL COKED AND DISCOLORED. 1 L 7 2 3O 3 O A8EA E19EA 1996082900339 19960829 00339 EA 1996 8 29 96ZZZX4146 2 19960410 G 7420 P-LEAD PIPER PA32 PA32RT300 7103215 SO LYC O540 IO540K1G5 41532 EA FIREWALL SHORTING H K NONE O OTHER IN INSP/MAINT 1 GL 25 376AA 32R7885094 L1803048A TROUBLESHOOTING FOR INTERMITTENT INOPERATIVE CONDITION ON RT MAGNETO FOUND P-LEAD SHORTING WHERE IT EXITS THROUGH FIREWA LL. REPLACED P-LEADS AND INSTALLED PLASTIC SLEEVING. 1 L 7 1 3O 3 O A3SO 1E4 1996082900344 19960829 00344 SO 1996 8 29 96ZZZX4151 2 19960807 G 7310 6410321147 VALVE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO FUEL MANIFOLD LEAKING B APCR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 666HL 54 ED89606CK 347770235 809072R FUEL MANIFOLD VALVE HAS FUEL LEAKING FROM TOP OF UNIT. INCREASE TORQUE VALUE FOR SCREWS. 1 L 7 2 3O 3 O A7SO E9CE 1996082900349 19960829 00349 EA 1996 8 29 96ZZZX4156 2 19960728 G 7414 M3081 CONTACT POINTS SLICK 4373 CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MAGNETO SPRING DEFECT D K NONE O OTHER IN INSP/MAINT 1 SO 13 73785 239 94090132 17267677 AIRCRAFT LANDED AFTER CROSS-COUNTRY. WHEN THE PILOT ATTEMPTED TO DEPART, ENGINE WOULD NOT START. TROUBLESHOOTING DETER MINED THE POINTS IN THE LEFT MAGNETO WOULD NOT CLOSE COMPLETELY. GAP WAS WITHIN TOLERANCE. RETURN SPRING APPEARED TO B E BOWED, NOT SUPPLYING ENOUGH TENSION. INSTALLED NEW CONTACT KIT. 1 H 7 1 3O 3 O NT 3A12 E274 1996082900350 19960829 00350 SO 1996 8 29 96ZZZX4157 1 19960806 G 8120 3AT6EE10J2 TURBOCHARGER GARRTT PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO RT ENGINE LOCKED UP E K NONE P NO WARNING INDICATION IN INSP/MAINT 1 SW 11 98HD 1258 347870461 PILOT APPLIED POWER TO RIGHT ENGINE FOR PRE-FLIGHT CHECK. ENGINE WOULD ONLY TURN UP TO 26 INCHES MAN/PRESSURE. FOUND T URBO HAD LOCKED UP. INSTALLED OVERHAULED TURBO, ENGINE GROUND RAN, CHECKED NORMAL. AIRCRAFT TEST FLOWN, ALL CONDITIONS NORMAL. 1 L 7 2 3O 3 O A7SO E9CE 1996090500140 19960905 00140 EA 1996 9 5 96ZZZX4232 2 19960821 G 8520 LW17060 CRANKSHAFT PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA FLANGE CRACKED D S A UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 NE 03 84652 6047 288216062 L947639A THE AIRCRAFT COMPLETED AN UNSCHEUDLED ON AIRPORT EMERGENCY LANDING DUE TO OIL SPRAYING ON THE WINDSHIELD. THE CRANKSHAF T WAS FOUND CRACKED AT THE RADIUS BY THE PROPELLER FLANGE. (APPROXIMATELY 1.75 INCH VISIBLE.) 1 L 7 1 3O 3 O 2A13 E274 1996090500675 19960905 00675 EA 1996 9 5 96ZZZX4287 2 19960814 G 8530 LW11634 VALVE LW11633 PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA NR 1 CYL EXH FAILED G K NONE O OTHER IN INSP/MAINT 1 CE 05 33BA 200 511561 3879A0021 L1598715 EXHAUST VALVE FAILURE, 200 HOURS AFTER CYLINDER OVERHAUL. YELLOW TAG INDICATES CYLINDER WAS REBUILT USING SERVICEABLE P ARTS. REBUILDER WAS CONTACTED, BUT COULD NOT DETERMINE TOTAL NUMBER OF HOURS ON VALVE WHEN INSTALLED. LYC SB NR 301B ST ATES EXHAUST VALVES SHOULD NOT BE RE-USED UNLESS THEY HAVE BEEN RECENTLY INSTALLED AND MEET INSPECTION CRITERIA. 1 L 7 1 3O 3 O A18SO E223 1996090500680 19960905 00680 SO 1996 9 5 96ZZZX4292 2 19960201 G 8530 646100A1 CYLINDER CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO SPARK PLUG HOLE CRACKED B S APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 41SA 1449 4040023 276274R DURING A ROUTINE ENGINE COMPRESSION TEST, CYLINDER NR 1 SHOWED 10/80. A VISUAL INSPECTION CONFIRMED A CRACK EMANATING F ROM THE LOWER SPARK PLUG HOLE TO THE COOLING FINS, APPROXIMATELY 1.50 INCHES LONG. THIS IS A RECURRING ITEM, OPERATOR K NOWS OF AT LEAST 12 OCCURRENCES OVER THE LAST 2 YEARS. 1 L 7 2 3O 3 O A25CE E7CE 1996090500701 19960905 00701 EA 1996 9 5 96ZZZX4313 2 19960812 G 8550 CH48111 FILTER CHAMPION CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ENGINE OIL LEAKING D S K NONE K FLUID LOSS IN INSP/MAINT 1 GL 15 99604 63 F11F181 172766477 WHEN OIL FILTER WAS REMOVED, MECHANIC NOTICED THE CAN AREA OF THE FILTER TURNED, BUT THE ATTACH MOUNTING (CRIMPED FLANGE END BRACKET) STAYED STATIONARY. 1 H 7 1 3O 3 O NT 3A12 E274 1996091200048 19960912 00048 SO 1996 9 12 96ZZZX4316 2 19960731 G 7310 60100040234 HOSE CESSNA 206 U206F 2073333 CE CONT O520 TSIO520C 17040 SO FUEL SYSTEM LEAKING G K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 2316U U20602360 HOSE ASSY FAILED AFTER 2 YEARS AND LESS THAN 200 HOURS OF OPERATION. HOSE TSO: C531, MFG DATE A1094, LOT NR 06827. 1 H 7 1 3O 3 O A4CE E8CE 1996091200049 19960912 00049 SO 1996 9 12 96ZZZX4317 2 19960731 G 7310 60100040286 HOSE ASSY AEROQUIP CESSNA 206 U206F 2073333 CE CONT O520 TSIO520C 17040 SO FUEL SYSTEM LEAKING D L K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 2316U U20602360 HOSE ASSY FAILED AFTER 2 YEARS AND LESS THAN 200 HOURS OF OPERATION. HOSE IS TSO C53A, MFG DATE A1094, LOT NR 06827. 1 H 7 1 3O 3 O A4CE E8CE 1996091200055 19960912 00055 NE 1996 9 12 96ZZZX4323 2 19960701 G 7230 536210 LOCK PWA JT12 JT12A8 52042 NE 3RD STAGE DISK MISSING B JV2R K NONE O OTHER IN INSP/MAINT 1 CE 03 322 P637622NB INTERNAL BLADE RUBBING, BINDING, AND LOCKING UP. AN INDUCTION TEST RUN WAS PEFORMED ON 6-20-96. DURING THE TEST, VIBRA TION OF 3.8 MIL AT 75 PERCENT WAS NOTED. (3.2 MIL IS MAXIMUM ALLOWABLE). ENGINE WAS DISASSEMBLED AS NECESSARY TO ACCE SS COMPRESSOR ASSY. COMPRESSOR WAS DISASSEMBLED TO ELEVATE RUBBING CONDITION. P/N 536203, 3RD STAGE COMPRESSOR BLADE W AS FOUND LOOSE IN THE BLADE SLOT OF 3RD STAGE DISK. BLADE HAD MOVED AFT MAKING CONTACT WITH COMPRESSOR STATOR, P/N 3855 03, DAMAGING EVERY VANE. BLADE LOCK COULD NOT BE FOUND AND SUSPECT IT MAY HAVE FAILED AND EXITED ENGINE ALLOWING BLADE TO WORK LOOSE. NO OBVIOUS DAMAGE FROM LOCK WAS NOTED. CAUSE OF LOCK FAILURE IS UNKNOWN AT THIS TIME. ONE EACH P/N 536 4 J 1E9 1996091200063 19960912 00063 NE 1996 9 12 96ZZZX4331 2 19960808 G 7230 COMPRESSOR RKWELL NA265 NA26540 6402608 CE PWA JT12 JT12A8 52042 NE ENGINE BINDING D K NONE O OTHER IN INSP/MAINT 1 SO 09 302NT 5836 420 28281 P672953NB COMPRESSOR VERY DIFFICULT TO ROTATE, IINTERNAL BINDING COULD BE FELT WHEN ROTATING BY HAND WITH SHORT SPOOL DOWN TIME. N O FOD NOTED, NO DAMAGE OR VISUAL DEFECTS NOTED IN TURBINE HOT SECTION. ALL IN-FLIGHT AND GROUND TEST PARAMETERS NORMAL. ENGINE WAS REMOVED FROM SERVICE AND RETURNED TO SABERLINER FOR TEAR DOWN INSPECTION. 2 L 7 2 4J 4 J A2WE 1E9 1996091200068 19960912 00068 NE 1996 9 12 96ZZZX4336 2 19960719 G 7230 3021436 BYPASS DUCT MTSBSI MU300 MU300 5780602 CE PWA JT15 JT15D4 52112 NE LT ENGINE FAILED D A K NONE O OTHER IN INSP/MAINT 1 SO 03 83BG 452 A018SA PCE70623 A CRACK DEVELOPED AT THE FORWARD FLANGE OF THE AFT INNER BYPASS DUCT AT THE 6 O'CLOCK POSITION ALLOWING IT TO COME OUT O F THE MATING FLANGE AND ENTER THE AIR FLOW, THEREBY CAUSING A 3 INCH (APPROX) SECTION TO PEEL BACK AND CAUSE A 2 INCH (A PPROX) TEAR ALONG THE RADIUS OF THE BEND. THE PILOT NOTICED THE PIECE HANGING DOWN DURING PRE-FLIGHT INSPECTION AND ASS Y WAS REPLACED BEFORE FURTHER FLIGHT. 2 H 7 2 4F 4 F RT A14SW E1NE 1996091200074 19960912 00074 NE 1996 9 12 96ZZZX4342 2 19960711 G 7230 536211 LOCK PWA JT12 JT12A8 52042 NE 4TH STAGE DISK MISSING B L JV2R K NONE O OTHER IN INSP/MAINT 1 CE 03 1300 P672928NB METAL-TO-METAL CONTACT, BIND, BLADE RUB. INVESTIGATION FINDINGS: AN INDUCTION TEST RUN COULD NOT BE ACCOMPLISHED DUE T O RUBBING CONDITION. THE ENGINE AND COMRPESSOR ASSEMBLY WERE DISASSEMBLED TO IDENTIFY CAUSE OF DISCREPANCY. INVESTIGAT ION REVELAED THAT P/N 536204, FOURTH STAGE COMPRESSOR BLADE, WAS FOUND LOOSE IN THE BLADE SLOT OF THE FOURTH STAGE DISK. THE BLADE HAD MOVED AFT MAKING CONTACT WITH THE INNER SEAL AREA OF THE FOURTH STAGE COMPRESSOR STATOR, P/N 542274. P/ N 536211, BLADE LOCK, COULD NOT BE FOUND AND SUSPECT IT MAY HAVE FAILED AND LEFT THE ENGINE ALLOWING THE BLADE TO WORK L OOSE. NO OBVIOUS DAMAGE FROM THE LOCK WAS NOTED. 4 J 1E9 1996091200530 19960912 00530 SO 1996 9 12 96ZZZX4373 2 19960813 G 8530 635448CP CYLINDER CESSNA 188 A188B 2073005 CE CONT O520 IO520D 17032 SO NR 4 FAILED D A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 SW 17 9370R 450 5538AA620 18802262T 563670 NR 4 CYLINDER HEAD SEPARATED FROM BARREL CAUSING ENGINE FAILURE IN-FLIGHT RESULTING IN FORCED LANDING (I-35 SOUTH, SAN A NTONIO). R2 CYLINDER ASSY OPS CHECK OK. 1 L 7 1 3O 3 O A9CE E5CE 1996091200531 19960912 00531 CE 1996 9 12 96ZZZX4374 1 19960822 G 3710 3P194FA PUMP PESCO CESSNA 182 182J 2072722 CE CONT O470 O470N 17026 SO VACUUM SYSTEM DRIVE SHEARED D K NONE O OTHER NR NOT REPORTED 1 CE 07 2714F PE09124FDG 18256814 1319985R VACUUM PUMP DRIVESHAFT SHEARED AND SPLINES EXTREMELY WORN. IT STILL MADE VACUUM PRESSURE. SUBMITTER RECOMMENDS MORE FR EQUENT INSPECTIONS OF DRIVE SPLINE ASSY (NOTE: WET DRIVE VACUUM PUMP). 1 H 7 1 3O 3 O NT 3A13 E273 1996091200537 19960912 00537 NE 1996 9 12 96ZZZX4380 2 19960814 G 7313 231009801 NOZZLE 216362036 BAG BAE146 BAE146100A 1500260 EU LYC ALF502 ALF502R 41580 NE FUEL MANIFOLD CRACKED B S A PGLR K NONE O OTHER IN INSP/MAINT 1 SO 13 82F001 OVERTORQUED CONDITION RESULTING IN CRACKED FLANGE AREA. RECOMMEND USE OF PROPER TORQUE DURING INSTALLATION OF NOZZLE IN TO MANIFOLD ASSY. 2 H 7 4 4F 4 F RT A49EU E6NE 1996091200539 19960912 00539 EA 1996 9 12 96ZZZX4382 2 19960820 G 8530 CYLINDER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 2 CRACKED D C ABORTED TAKEOFF E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 NM 01 46758 15283101 L1612315 TAKEOFF ABORTED FOR LOSS OF POWER/ROUGH RUNNING ENGINE. POST-FLIGHT MAINTENANCE INSPECTION REVEALED 3 INCH HAIR LINE CR ACK RUNNING CIRCUMFERENTIALLY, BETWEEN NR 14 AND NR 15 FIN (COUNTING DOWN FROM TOP) OF NR 2 CYLINDER. SMALL BURN AREA O BSERVED ON NR 4 CYLINDER INTAKE PUSH ROD TUBE. REPLACED ENGINE. 1 H 7 1 3O 3 O NT 3A19 E223 1996091200540 19960912 00540 SO 1996 9 12 96ZZZX4383 2 19960801 G 8520 6436511 STUD PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO CYLINDER BASE STRETCH B P A YYBR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 03 2847J 28R7931221 24809612 ENGINE WAS BEING REPAIRED FOR SEVERAL BROKEN CYLINDERS, BASE STUDS, AND LOOSE NUTS. MECHANIC RECEIVED 36 BRAND NEW STUD S FROM THREE DIFFERENT VENDORS IN TCM PACKAGING. UPON TORQUING TO THE REQUIRED MINIMUM TORQUE VALVE, A TOTAL OF 12 STRE TCHED. THEY WERE ALL REMOVED. TWO WERE SUBMITTED TO TCM FOR ANALYSIS. 1 L 7 1 3O 3 O 2A13 E9CE 1996091200555 19960912 00555 EA 1996 9 12 96ZZZX4398 2 19960722 G 7414 103493576 IMPULSE CAM 1038255511 CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B 41514 EA MAGNETO WORN B K NONE O OTHER IN INSP/MAINT 1 SW 99 52073 426 177RG1161 L1696551A INSPECTED MAGNETO RIVETED CAM ASSY AND FOUND WORN BEYOND 'X' PLUS .014 INCH. SUBMITTER STATES THESE EARLY RIVETED UNITS SHOULD BE CHANGED OUT TO THE SNAP RING STYLE AT 500 HOURS. NEW STYLE FOR THIS APPLICATION IS 10-400167-9. 1 H 7 1 3O 3 O A20CE 1E10 1996091200556 19960912 00556 SO 1996 9 12 96ZZZX4399 2 19960725 G 8530 625393 SPRING RETAINER BEECH 58 58P 1152744 CE CONT O520 TSIO520U 17040 SO EXH VALVE NR 3 FAILED B QL5R K NONE O OTHER IN INSP/MAINT 1 NM 05 112Z 1336 TJ371 274153R WHILE CHANGING VALVE COVER GASKET ON NR 3 CYLINDER, MECHANIC FOUND TWO SMALL PIECES OF METAL IN VALVE COVER. INVESTIGAT ED AND DETERMINED PIECES CAME FROM THE EXHAUST VALVE INNER VALVE SPRING RETAINER TCM. PERFORMED HIDDEN DAMAGE INSPECTIO N. INSPECTED AND CHECKED OK. INSTALLED NEW SPRING RETAINER. ENGINE IS A TCM FACTORY REMANUFACTURED WITH 1,336 HOURS T SMOH. 1 L 7 2 3O 3 O A23CE E8CE 1996091200557 19960912 00557 EU 1996 9 12 96ZZZX4400 2 19960627 G 8530 PISTON AMTR 500 MINI500 13015HW GL ROTAX 582 ROTAX582 55555 EU SKIRT UNDERSIZE F L A K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 CE 05 500ZZ 0000 4655214 THE ENGINE BACKFIRED AND MOMENTARILY HAD A LOSS OF POWER. THE PISTONS WERE FOUND UNDERSIZED AT THE SKIRT END. THIS COU LD HAVE POSSIBLY BEEN CAUSED BY IMPROPER BREAK IN PROCEDURES. 1 G 7 1 3I 3 I NC EXPA1G71 EXPE3I 1996091200558 19960912 00558 EA 1996 9 12 96ZZZX4401 2 19960807 G 7414 1038255514 MAGNETO BEECH 76 76 1153005 CE LYC O360 IO360A1G6 41514 EA RT ENGINE SEPARATED D O OTHER Y ENGINE STOPPAGE TO TAKEOFF 1 WP 27 66291 ME224 MAGNETO SEPARATED FROM ENGINE ON TAKEOFF CAUSING ENGINE TO STOP. THIS IS A DUAL MAGNETO ON A SINGLE DRIVE. IT WAS DETE RMINED THE NUTS HAD LOOSENED AND ALLOWED MAG TO COME OFF. THERE IS NO TORQUE LISTED FOR THIS MAGNETO EXCEPT STANDARD TO RQUE. RECOMMEND THAT MAGNETO ATTACHMENTS BE CHECKED AT 50-HOUR INTERVALS. ALSO, MAG NEEDS TO BE CHECKED FOR NEW STYLE HOLD-DOWN BRACKETS. TIME SINCE LAST CHECK OF HOLD-DOWN NUTS WAS APPROXIMATELY 80 HOURS. 1 L 7 2 3O 3 O A29CE 1E10 1996091200559 19960912 00559 EA 1996 9 12 96ZZZX4402 2 19960729 G 8520 CRANKSHAFT BOEING 75 A75N1 1380134 CE WRIGHT R975 R975* 67012 EA HUB SOCKET SCREWS FAILED D A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 WP 27 68251 700 757976 78224 AFTER TAKEOFF, ENGINE STOPPED. AIRCRAFT CRASH LANDED IN A FIELD. AIRCRAFT DESTROYED BY POST-FIRE. INVESTIGATION FOUND CRANKSHAFT GEAR ASSEMBLY HUB SOCKET SCREWS SHEARED. P/N 401337. TSO: 700 HOURS. TT: UNKNOWN. 1 Q 7 1 3R 3 R A743 ATC21 1996091200564 19960912 00564 CE 1996 9 12 96ZZZX4407 1 19960805 G 2752 C3010020103 MOTOR CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO FLAP SHORTED D K NONE O OTHER NR NOT REPORTED 1 EA 07 7513G 4089 15074679 242709R FLAPS EXCEEDED THE LIMIT SWITCH, STOPS, AND BROKE THE DOWN-LIMIT SWITCH AND FUSE BLEW. PROBLEM WAS CAUSED BY FLAP MOTOR DEVELOPED AN INTERNAL SHORT WHICH PROVIDED THE GROUND NORMALLY WHICH IS PROVIDED THROUGH THE LIMIT SWITCH CIRCUIT. THI S MOTOR IS A REVERSING 12V DC MOTOR WHICH CHANGES POWER AND GROUND CIRCUIT THROUGH THE SWITCH AND LIMIT SWITCHES NORMALL Y. NO LOG ENTRY SHOWS MOTOR CHANGED PREVIOUSLY. 1 H 7 1 3O 3 O 3A19 E252 1996091200565 19960912 00565 SO 1996 9 12 96ZZZX4408 2 19960625 G 8550 CH48109 FILTER CHAMPION PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO ENGINE OIL BROKEN B JAVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 01 94MA 23 F11E111 468608056 273793R AFTER CUTTING OIL FILTER OPEN, THE MANUFACTURER'S ANTI-DRAIN BACK VALVE ROLLED EDGE WAS FOUND CRACKED APPROXIMATELY ONE- HALF WAY AROUND AND A PIECE, APPROXIMATELY 1 INCH LONG, HAD BROKEN OFF. BROKEN PIECES WERE FOUND AFTER OIL COOLER WAS R EMOVED AND BACK-FLUSHED. 1 L 7 1 3O 3 O A25SO E8CE 1996091200582 19960912 00582 SO 1996 9 12 96ZZZX4425 2 19960801 G 7414 10400309 IMPULSE COUPLER BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO ENGINE MAG CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 255EM TC1552 WHILE C/W AD 78-09-07R3, AN IMPULSE COUPLER WAS FOUND TO NEED REPLACEMENT. A NEW PART WAS INSTALLED ON MAG. WHILE TIGH TENING NUT ON COUPLER TO 240 INCH/POUNDS, THE COUPLER CRACKED WHERE IT SLIDES ON THE TAPERED SHAFT. SUBMITTER FOUND THA T IMPULSE COUPLERS THAT ARE CHECKED ARE ONLY LASTING FOR ONE CYCLE (500 HOURS) OF AD INSPECTION, WHERE IN THE PAST, AN I MPULSE COUPLER WOULD OFTEN LAST FOR 1,000 HOURS OR MORE. SUBMITTER SUSPECTS THE MATERIAL USED FOR NEW UNITS IS NOT AS G OOD A MATERIAL AS WAS USED IN THE PAST. 1 L 7 2 3O 3 O RT 3A16 3E1 1996091200850 19960912 00850 EU 1996 9 12 CA960123027 2 19960102 G 7200 ENGINE RROYCE SPEY SPEY55515P 54521 EU TAIL PIPE MAKING METAL W E ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 CA 9796 (CAN)VIBRATIONS FELT AT FL250. POWER REDUCED FROM 94 PERCENT TO 91 PERCENT & VIBRATIONS INCREASED. ENGINE WAS SHUTDOWN & FLIGHT DIVERTED. POST FLIGHT INSPECTION FOUND METAL IN TAILPIPE & DAMAGE TO BOTH THE LP & HP SYSTEMS. FURTHER DETAILS W ILL FOLLOW ENGINE TEARDOWN. 4 F E2EU 1996091900001 19960919 00001 EA 1996 9 19 96ZZZX4371 2 19960824 G 8530 CYLINDER PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA SPARK PLUG HOLE CRACKED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 16 30230 287990088 L2558336A CYLINDER CRACKED FROM TOP SPARK PLUG HOLE AROUND SIDE TO BOTTOM SPARK PLUG HOLE. AIRCRAFT LANDED SAFELY WITHOUT FURTHER PROBLEMS (LOSS OF RPM). ENGINE TT, 2,601.4 HOURS. TSMOH: 607.7 HOURS. SUBMITTER STATED THIS IS THE THIRD CRACKED CY LINDER ON THIS AIRCRAFT SINCE OVERHAUL. 1 L 7 1 3O 3 O 2A13 E286 1996091900006 19960919 00006 EA 1996 9 19 AU960002 2 19960102 G 8520 74309 BEARING LYC O540 TIO540J2BD 41532 EA NR 4 CON ROD FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S L462561A (AUS) ENGINE NO4 CONNECTING ROD BEARING FAILED IN AREA OF RELIEF FOR CONNECTING ROD BOLT SHANK 3 O E14EA 1996091900007 19960919 00007 EU 1996 9 19 AU960003 1 19960103 G 7160 352002034 HOSE BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA ENG AIR INT COLLAPSED W O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S L2549448A (AUS) LH ENGINE INDUCTION HOSE BETWEEN ALTERNATE AIR BOX AND FUEL CONTROL COLLAPSED - SUSPECT CAUSED BY FAULTY BATCH OF SCAT HOSES 1 H 7 2 3O 3 O A17EU 1E4 1996091900014 19960919 00014 EU 1996 9 19 AU960010 1 19960103 G 7110 7271110505 COWLING SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ENGINE COWL SYS DAMAGED W K NONE E D VIBRATION/BUFFET INFLIGHT SEPARATION CL CLIMB 1 AU S 367303K (AUS) LH ENGINE INBOARD COWL UNLATCHED - PROPELLER SLIPSTREAM HAD DISTORTED THE COWL CRACKING SEVERAL INTERNAL STIFFENE R FRAMES -SUSPECT LATCHES LEFT UNLOCKED FOLLOWING ENGINE SERVICING - PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4T 4 T RT A52EU E8NE6 1996091900024 19960919 00024 EA 1996 9 19 AU960021 2 19960109 G 8550 NOZZLE PIPER PA36 PA36285 7103610 SO LYC O720 IO720A1B 41546 EA ENGINE OIL SYS FAILED W K NONE O OTHER CR CRUISE 1 AU S L12775AA (AUS) ENGINE OIL SYSTEM CONTAMINATED BY METAL - NO3 CYLINDER OIL SQUIRT NOZZLE MISSING - THE NOZZLE BALL WAS FOUND IN TH E CRANKCASE ANDTHE REMAINDER OF THE NOZZLE WAS FOUND IN THE SUMP FOLLOWING REMOVAL - INVESTIGATION FOUND THAT THE NOZZL E HAD BEEN CRUSHED BETWEEN THE CONNECTING ROD CAP AND THE CRANKCASE AND DESTROYED - SUSPECT THE NOZZLE WAS UNDERTORQUED DURING ASSEMBLY 1 L 7 1 3O 3 O A10SO 1E15 1996091900031 19960919 00031 EU 1996 9 19 AU960028 1 19960112 G 7160 352002034 HOSE BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA ENG AIR INT RT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH ENGINE INDUCTION HOSE COLLAPSED IN MID SECTION - INNER WIRE SEPARATED FROM OUTER WALL 1 H 7 2 3O 3 O A17EU 1E4 1996091900032 19960919 00032 EU 1996 9 19 AU960029 1 19960112 G 7160 352002034 HOSE BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA ENG AIR INT LT FAILED W K NONE O E R OTHER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 AU S (AUS) LH ENGINE INDUCTION HOSE COLLAPSED 1 H 7 2 3O 3 O A17EU 1E4 1996091900033 19960919 00033 EU 1996 9 19 AU960030 1 19960112 G 7160 352002034 HOSE BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA ENG AIR INT RT FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH ENGINE INDUCTION HOSE BETWEEN AIR FILTER AND FUEL SERVO UNIT INTERNAL WIRE DISPLACED 1 H 7 2 3O 3 O A17EU 1E4 1996091900038 19960919 00038 EA 1996 9 19 AU960035 2 19960111 G 7414 M3485 BEARING SLICK 4371 LYC O360 O360A4K 41514 EA ENG MAG LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 92020112 L2674136A (AUS) MAGNETO DISTRIBUTOR END BEARING LOOSE AND SPINNING IN HOUSING - MAGNETO FILLED WITH BLACK DUST 3 O E286 1996091900039 19960919 00039 EU 1996 9 19 AU960036 2 19960101 G 7200 MAKILA1A ENGINE TMECA MAKILA1A SNIAS AS332 AS332L 8680809 EU TMECA MAKILA MAKILA1A 60040 EU ENGINE (TURBINE OVER TEMP W K E NONE ENGINE SHUTDOWN M OVER TEMP NR NOT REPORTED 1 AU S 877 241 241 (AUS) ENGINE OVERTEMPED ON START - EGT WAS BELOW 900 DEGREES C FOR 38 SECONDS - EGT LIMITS ON START 810 DEGREES C TO 90 0 DEGREES C FOR 2 SECONDS - SUSPECT START FOLLOWED ABORTED START WHICH LEFT A SUBSTANTIAL AMOUNT OF FUEL IN THE ENGINE 2 G 7 2 4U 4 U H4EU E12NE 1996091900040 19960919 00040 EU 1996 9 19 AU960037 1 19960116 G 7160 352002034 HOSE BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA ENG AIR INT RT FAILED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S (AUS) LH ENGINE INDUCTION AIR HOSE BETWEEN AIR BOX AND FUEL CONTROL COLLAPSED - RH ENGINE INDUCTION HOSE INSPECTED AND WAS FOUND TOBE ALSO CLOSE TO FAILURE - NUMEROUS OTHER FAILURES RECORDED IN FLEET 1 H 7 2 3O 3 O A17EU 1E4 1996091900041 19960919 00041 CE 1996 9 19 AU960038 1 19960112 G 2434 BRUSH ALTERNATOR CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA GENERATOR-ALT WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 1850 L330176 (AUS) ALTERNATOR BRUSHES WORN EXCESSIVELY - PIGTAIL JUNCTION WORN INTO SLIP RING 1 H 7 1 3O 3 O NT 3A12 E274 1996091900042 19960919 00042 CE 1996 9 19 AU960039 1 19960112 G 5320 DOOR POST CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA FS 65.3 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1850 (AUS) AFT DOOR POST ASSEMBLY CRACKED IN AREA OF INNER RELIEF AT FS 65.3 TOWARDS OUTBOARD LANDING GEAR HOUSING FASTENERS 1 H 7 1 3O 3 O NT 3A12 E274 1996091900049 19960919 00049 EA 1996 9 19 AU960047 2 19960111 G 7230 BLADE PWA PT6 PT6A34 52043 EA T ENG CMPRSR/FAN FOD W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 40582 (AUS) ENGINE GAS GENERATOR 1ST STAGE COMPRESSOR BLADES (15OFF) CONTAIND FOD TO THE LEADING EDGES - INVESTIGATION FOUND T HAT THE 1ST STAGECOMPRESSOR SPACER RUBBED ON THE STATOR AND CRACKED CIRCUMFERENTIALLY LIBERATING A PIECE OF MATERIAL APP ROXIMATELY 12.7MM (0.5IN) WIDE AND 76.2MM (3IN) LONG WHICH WAS INGESTED THROUGH THE COMPRESSOR - DAMAGE TO THE TRAILING EDGES OF THE 1ST STAGE STATOR BLADES - EVIDENCE OF FURTHER DAMAGE DOWNSTREAM - ONE COMPRESSOR BLADE HAD FORE AND AFT MOV EMENT OF APPROXIMATELY5.08MM TO 7.62MM (0.2IN TO 0.3IN) 4 T E4EA 1996091900052 19960919 00052 CE 1996 9 19 AU960050 1 19960112 G 7603 CABLE BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO THROTTLE BROKEN W K NONE O OTHER DE DESCENT 1 AU S 272978R (AUS) THROTTLE INNER CABLE BROKE APPROXIMATELY 25MM (1IN) FROM SLIDING SLEEVE INSIDE FLEXIBLE PART OF CABLE ON THE ENGIN E SIDE - CABLE HAD A VERY MINOR KINK NEAR THE ATTACHMENT BRACKET - SUSPECT INCORRECT INSTALLATION - PERSONNEL/MAINTENAN CE ERROR 1 L 7 2 3O 3 O RT 3A16 3E1 1996091900055 19960919 00055 EU 1996 9 19 AU960120 1 19960205 G 3220 115C5201 FORK GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA NOSE GEAR SYS DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR FORK DELAMINATED - AIRCRAFT NLG HAD BEEN BOGGED IN SAND - SEE MDR 96/0093 AND MDR 96/0121 FOR FU RTHER INFORMATION 1 L 7 1 3O 3 O NT A57EU E286 1996091900056 19960919 00056 EU 1996 9 19 AU960121 1 19960202 G 3220 115C5201 FORK GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA NOSE GEAR SYS CRACKED W K NONE O OTHER LD LANDING 1 AU S 82032C2 (AUS) NOSE LANDING GEAR FORK CRACKED AND DELAMINATED - FOUND DURING INSPECTION FOLLOWING REPORTED HEAVY LANDING - SEE M DR 96/0093 ANDMDR 96/0120 FOR FURTHER INFORMATION 1 L 7 1 3O 3 O NT A57EU E286 1996091900069 19960919 00069 EU 1996 9 19 AU960662 1 19960521 G 2842 TRANSMITTER GROB G115 G115C 1660303 EU LYC O360 O360F1A6 41514 EA FUEL INDICATION FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH FUEL TRANSMITTER FLOATS DETERIORATED 1 L 7 1 3O 3 O NT A57EU E286 1996091900073 19960919 00073 EA 1996 9 19 AU960670 2 19960523 G 7310 HOSE LYC O360 O360A1F6 41514 EA ENG FUEL DIST SY FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE PRIMER HOSE FAULTY - END FITTINGS CAN BE PULLED AWAY FROM HOSE 3 O E286 1996091900079 19960919 00079 SO 1996 9 19 AU960679 2 19960520 G 8520 63026143 BEARING CONT COUNTERWGHT CONT O360 IO360HB 17025 SO RT ENG CTRWT WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 353395 (AUS) CRANKSHAFT COUNTERWEIGHT ROLLER BEARING PNO 630261-43 INCORRECT PART - CORRECT PART NUMBER FITTED SHOULD HAVE BEE N PNO 630261-44 - COUNTERWEIGHT RETAINING WASHER WORN INTO COUNTERWEIGHT - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 3 O E1CE 1996091900252 19960919 00252 SO 1996 9 19 96ZZZX4623 2 19960801 G 7322 39077 NEEDLE VALVE BENDIX NAS3A1 CESSNA 140 140 2071602 CE CONT C90 C9012F 17009 SO FLOAT CHAMBER SWELLED UP G C D ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 NM 06 CARBURETOR FLOAT CHAMBER NEEDLE VALVE TIP SWELLED UP, PROBABLY DUE TO 100 LL OR AUTOGAS. ENGINE FALTERED AT HIGH POWER SETTINGS. TAKEOFF ABORTED. 1 H 7 1 3O 3 O NC A768 E252 1996091900303 19960919 00303 GL 1996 9 19 HEEA967779 2 19960904 G 7250 23008054 NOZZLE ALLSN 250C 250C28 03013 GL NR 1 OUT OF SPECS E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: MEASUREMENT ON #1 NOZZLE DIMENSION (A) .019 BELOW CEB72-2103R-6 SPECS, (B) .005 BELOW BL UEPRINT SPECS, (C) .012 BELOW BLUEPRINT SPECS. 3 U E1GL 1996091900308 19960919 00308 GL 1996 9 19 HEEA967786 2 19960906 G 7230 23056634 GEAR 23033193 ALLSN 250C 250C30P 03013 GL SPUR ADAPTER DEFECTIVE E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 CAC91370 CAE895336 RECEIVING INSPECTION REVEALED: SERIAL NUMBER ON SPUR GEAR DOES NOT MATCH NUMBER ON BOX. REPLACED DISCREPANT PART. 3 U E1GL 1996091900551 19960919 00551 CE 1996 9 19 CA960126034 1 19960112 G 2730 05130631 BRACKET CESSNA 05130631 CESSNA 172 172F 2072414 CE CONT O300 O300D 17022 SO ELEV BELLCRANK CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 5948 29320D4D (CAN)AT THE ANNUAL INSPECTION OF THIS AIRCRAFT THE FORWARD ELEVATOR BELLCRANK SUPPORT BRACKET WAS FOUND CRACKED. THE LOC ATION IS AT THE LEFT FORWARD ATTACHMENT ANGLE UNDER THE CABIN FLOOR AFT OF THE FUEL S ELECTOR. THE TOP BAR SUPPORTING TH E BELLCRANK CENTRE BOLT WAS ALSO FOUND BROKEN. THE PART WAS NOT REPAIRABLE AND THEREFORE WAS REPLACED WITH NEW P/N 05130 63-1. SUBMITTER NOTES THAT THE REPLACEMENT PART WAS FOUND TO BE MORE ROBUST THAN THE ORIGINAL. 1 H 7 1 3O 3 O NT 3A12 E253 1996091900592 19960919 00592 GL 1996 9 19 96ZZZX4704 2 19960322 G 7210 23035178 GEARBOX BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL MOUNT PAD CORRODED D K NONE O OTHER IN INSP/MAINT 1 EU 01 722H 3546 CAG95568 51452 PITTED CORROSION ON RT GEARBOX BOSS OCCURRED DURING NORMAL OPERATION. FOUND DURING ROUTINE INSPECTION. RECOMMENDED SUP PLIER CHECK MATERIALS FOR DEFECTS. SIMILAR PROBLEM FOUND ON THREE GEARBOXES. 1 G 7 1 3U 3 U H2SW E1GL 1996091900604 19960919 00604 WP 1996 9 19 96ZZZX4717 2 19960821 G 7250 30733543 AIR SEAL 30727262 GARRTT TFE731 TFE73122B 01518 WP TRANSITION DUCT DEFECTIVE B L IY2R K NONE O OTHER IN INSP/MAINT 1 SW 15 4225 463 1013453990 P74146 DURING AN UNSCHEDULED MAINTENANCE EVENT, FOUND AN P/N 3073354-3, AIR SEAL WAS INSTALLED IN THE TRANSITION DUCT, P/N 3072 726-2, S/N 1-01345-3990. SB TFE731-72-3577, REV ZERO, ADDRESSES THIS SUBJECT. 4 F E6WE 1996091900616 19960919 00616 SO 1996 9 19 96ZZZX4729 2 19960819 G 7310 HOSE CESSNA 210 210E 2073416 CE CONT O520 IO520A 17032 SO ENGINE FUEL DETERIORATED G K NONE O OTHER IN INSP/MAINT 1 WP 23 4931U 21058631 1108644A FUEL HOSES NON-OPERATONAL FOR 3 YEARS ALLOWING NON-PRESSURE SIDE OF FUEL HOSES TO DRY OUT AND INSIDE OF HOSE TO DETERIOR ATE. SMALL PIECES OF RUBBER HOSE BROKE OFF AND CLOGGED FUEL LINES IN FUEL INJECTION SYSTEM. 1 H 7 1 3O 3 O 3A21 E5CE 1996091900927 19960919 00927 SO 1996 9 19 96ZZZX4742 2 19960806 G 8530 ROCKER BOSS CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO NR 3 CYL EXH FAILED D K NONE E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 AL 01 105AK 40400833 243227R ROCKER BOSS FAILED (CRACKED) ON EXHAUST SIDE ON CYLINDER NR 3. ROCKER SHAFT PUNCHED THROUGH VALVE COVER. INSPECTED MAG NETO DRIVE COUPLING PER SB M90-11, FOUND OK. 1 L 7 2 3O 3 O A25CE E7CE 1996091900936 19960919 00936 EA 1996 9 19 96ZZZX4751 2 19960821 G 8520 AS16507A01 CAMSHAFT PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA LT ENGINE BROKE D K NONE O OTHER IN INSP/MAINT 1 SO 15 2110F 1897 WB1122M182 447995152 L45377T ENGINE WAS REMOVED FOR CAM FAILURE AT 299.20 TSMOH. A RE-GROUND CAM WAS INSTALLED BY CRS. AT 2,195.50 TSMOH, ENGINE W AS REMOVED FOR OVERHAUL AND DISASSEMBLY REVEALED CAM HAD BROKEN IN 2 PIECES WHERE THE PROP GOVERNOR GEAR P/N LW-15274 IS INSTALLED AND CRACKED WHERE THE WOODRUFF KEY P/N STD-96 IS INSTALLED TO SECURE THE PROP GOVERNOR DRIVE GEAR. THE ORIGI NAL PART NUMBER FOR THIS CAM BEFORE IT WAS RE-GROUND AND INSTALLED BY THE CRS WAS AS16508. NOTE: THIS ENGINE NEVER GAV E AN INDICATION OF FAILURE/METAL IN OIL. 1 L 7 2 3O 3 O A19S0 E286 1996092600122 19960926 00122 EA 1996 9 26 96ZZZX4785 2 19960705 G 7414 1051324 SPRING CESSNA 172 172 2072402 CE LYC O320 O320H2AD 41508 EA IMPULSE COUPLING BROKEN D L K NONE O OTHER IN INSP/MAINT 1 EA 21 75814 578 17267971 CHECKED IGNITION TIMING. FOUND APROXIMATELY 90 DEGREES OFF. REMOVED MAGNETO, FOUND IMPULSE COUPLING SPRING BROKEN. CH ECKED I-C PER AD 78-09-07R3/AD 96-12-0-7 AND FOUND SATISFACTORY. REVIEWED MAG O/H DATE FAXED BY INS. ADJ. FOUND I-C S PRING, INSP AND REUSED, CONTRARY TO MANUFACTURER'S DATA TO "REPLACE AT EACH DIS ASSEMBLY WITH NEW PARTS." 1 H 7 1 3O 3 O NT 3A12 E274 1996092600140 19960926 00140 SO 1996 9 26 96ZZZX4803 2 19960910 G 7414 1015828Y MAGNET BENDIX SFS4RNR CONT A75 A75* 17005 SO ENGINE MAG SHAFT FAILED H A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 07 80998 MAGNETO FAILED IN-FLIGHT. MAGNET, P/N 10-15828Y, SHAFT FAILED. BROKE IN TWO PIECES AT THE INNER WOODRUFF KEY SLOT AT T HE OUTER EDGE OF THE SLOT. THIS FAILURE WAS INSIDE THE MAGNETO SO THE GEAR AND OUTWARD END OF THE SHAFT CONTINUED TO RO TATE. THE ENGINE CONTINUED RUNNING UNTIL A SUCCESSFUL LANDING WAS MADE. THE MAGNETO DRIVE GEAR TILTED PARTIALLY GRINDI NG ALUMINUM FROM THE ACCESSORY CASE CONTAMINATING THE OIL AND RESULTING IN SUBSEQUENT ENGINE OVERHAUL. THERE IS NO EVID ENCE OF A LOCK-UP OF THE MAGNETO CAUSING THE SHAFT TO SHEAR THE WAY IT DID. THE BEARINGS WERE VERY ROUGH, BUT INTACT. M AGNETO MAINTENANCE HISTORY IS UNKNOWN AND TOTAL TIME IS UNKNOWN. THE MAGNETO WAS USED ON A HOMEBUILT. ENGINE, CONTINE 3 O E213 1996092600145 19960926 00145 EA 1996 9 26 96ZZZX4808 2 19960528 G 8530 05K21120 CYLINDER PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA NRS 1/2-3/4 WORN D K NONE O OTHER IN INSP/MAINT 1 NM 09 377LC 4544 689 28R7918120 L277151A COMPRESSION CHECK INDICATES ALL 4 CYLINDERS NOT SERVICEABLE DUE TO LOW COMPRESSION. TSO: 689 HOURS. TT: 4,544 HOURS. 1 L 7 1 3O 3 O 2A13 1E10 1996092600150 19960926 00150 SO 1996 9 26 96ZZZX4813 2 19960514 G 7322 30764 FLOAT ASSY FACET MA45 CESSNA 182 182A 2072704 CE CONT O470 O470L 17026 SO CARBURETOR DETACHED B YECR K NONE O OTHER IN INSP/MAINT 1 NM 09 88MA 850 3997983 34691 CARBURETOR WAS REMOVED AT ANNUAL INSPECTION FOR EXCESSIVE WEAR ON THROTTLE SHAFT. UPON DISASSEMBLY, ONE OF THE FLOATS W AS FOUND BROKEN FROM THE ACTUATING ARM. IT WAS NOT RUPTURED OR WORN THROUGH. FLOAT WAS DATE CODED 4-84. SUSPECT A ROU GH RUNNING ENGINE AND/OR A BAD SOLDER POINT ON THE FLOAT TO BRACKET. NOTE: THE ENGINE WAS 'OVERHAULED' 77 HOURS AGO. T HE CARBURETOR WAS NOT. 1 H 7 1 3O 3 O NT 3A13 E273 1996092600152 19960926 00152 EA 1996 9 26 96ZZZX4815 2 19960720 G 7230 3108301 CT BLADE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA GAS GEN FAILED A A MASR E ENGINE SHUTDOWN O OTHER CR CRUISE 1 SW 07 156YV 3059 UC156 32460GG AN IN-FLIGHT SHUT DOWN OF THE RIGHT ENGINE DUE TO THE FAILURE OF THE HOT SECTION CT BLADE. AT THE ENGINE TEAR DOWN, NOT ED ONE CT BLADE HAD LIBERATED AT THE ROOT AND ALL THE OTHER CT BLADES WERE SEVERELY DAMAGED DUE TO THE CONTACT WITH THE LIBERATED BLADE. THE CT BLADE REMAINING ROOT SECTION WAS SENT TO PRATT AND WHITNEY FOR FURTHER INVESTIGATION 2 L 7 2 4T 4 T RT A24CE E4EA 1996092600153 19960926 00153 EA 1996 9 26 96ZZZX4816 2 19960507 G 7210 310076701 SUN GEAR BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA POWER SECTION FAILED A A MASR E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 SW 01 157YV 13550 13550 55C036 UC157 32512PS AN IN-FLIGHT SHUT DOWN OF THE LT ENGINE DUE TO THE FAILURE OF THE POWER SECTION. AT THE ENGINE TEAR DOWN, THE INVESTIGA TION REVEALED THE 1ST STAGE SUN GEAR HAD FAILED AND IS BEING CONSIDERED THE CAUSE OF THE SHUT DOWN. 2 L 7 2 4T 4 T RT A24CE E4EA 1996092600156 19960926 00156 EA 1996 9 26 96ZZZX4819 2 19960801 G 8530 VALVE PIPER PA28 PA28161 7102803 SO LYC O320 O320E3D 41508 EA ENGINE EXHAUST FAILED B BXPR A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 EA 09 32490 1709 287515169 L3989027A ENGINE LOST POWER ON TAKEOFF. PILOT ABLE TO MAINTAIN ALTITUDE AND RETURN TO AIRPORT. VALVE APPEARS TO BE P/N 75068 WH ICH IS PRONE TO BREAKAGE WHEN USING FUEL HIGHER THAN 80/87 (REF: LYCOMING SB 404). ANY VALVES STILL IN SERVICE SHOULD BE REPLACED. 1 L 7 1 3O 3 O 2A13 E274 1996092600162 19960926 00162 EA 1996 9 26 96ZZZX4825 2 19960504 G 7414 1068255511 MAGNETO D4KB3999 MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA DIST BLOCK DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SO 11 91307 K20882G 243201 L2556651A INSPECTED MAG IAW 500-HOUR INSPECTION AT 1,057 HRS TTSN AND FOUND DISTRIBUTOR BLOCK DRIVEN GEAR BEARING BROKEN LOOSE FRO M BLOCK (BROWN BLOCK). REPLACED WITH 10-682054 BLOCK. ENGINE STILL HAD ACCEPTABLE MAG DROP. APPROXIMATELY 500 HRS SINC E LAST 500-HOUR COMPLYING INSPECTION. NO 500-HOUR INSPECTION LISTED FOR MAGNETO IN LOG BOOKS. 1 L 7 1 3O 3 O 2A3 1E10 1996092600166 19960926 00166 GL 1996 9 26 96ZZZX4829 2 19960202 G 7250 6877736 LABYRINTH SEAL 6898735 ALLSN 250C 250C20B 03013 GL GP TURBINE FRACTURED B YKER K NONE O OTHER IN INSP/MAINT 1 EA 17 TURBINE WAS REMOVED DUE TO RUB. UPON DISASSEMBLY, FOUND THE GP STATOR SEAL HAD FRACTURED AT THE FORWARD END OF THE BEAR ING BORE. THIS TURBINE HAD THE NEW NR 8 BEARING AND RETAINING PLATE INCORPORATED PER CEB 1326. CAUSE OF FAILURE UNKNOW N. 3 U E4CE 1996092600216 19960926 00216 GL 1996 9 26 96ZZZX4838 2 19960729 G 7412 6899093 EXCITER BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE IGNITION FAILED B JSNR K NONE O OTHER IN INSP/MAINT 1 NM 09 204PC 648 S895 836679 START CIRCUIT BREAKER OPENED 1-2 SECONDS AFTER START INITIATED. TROUBLESHOT AND FOUND HIGH TENSION SIDE OF IGNITION EXC ITER SHORTED OUT. REPLACED EXCITER. THIS AIRCRAFT HAS CONTINUOUS IGNITION SYSTEM WHICH MUST BE OPERATED WHEN FLYING IN FALLING SNOW. THIS SYSTEM OPERATES APPROXIMATELY 25 OF LAST 30 FLIGHT HOURS. PERHAPS TOO MUCH FOR EXCITER UNIT. AIRC RAFT SHOULD INCORPORATE AUTO-RELIGHT INSTEAD. 1 G 7 2 3U 3 U H3EU E4CE 1996092600219 19960926 00219 GL 1996 9 26 96ZZZX4841 2 19960725 G 7230 6871259 TIE BOLT 6890550 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL COMP ROTOR UNDERSIZE B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 107AL 59038 S772 821484 DISCOVERED DEFECT DURING TOLERANCE INSPECTION. THE TIE BOLT SHOULDER UNDER SIZE BY .002 INCH, .440 INCH, BPS .4420 INCH TO .4425 INCH. 1 G 7 2 3U 3 U H3EU E4CE 1996092600227 19960926 00227 GL 1996 9 26 96ZZZX4849 2 19960719 G 7261 23030994 SCAVENGE TUBE 23035179 SKRSKY S76 S76 8143010 NE ALLSN 250C 250C30S 03013 GL GEARBOX BRACKET BROKEN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 702AL 4117 760243 CAE890588S UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY AND SCAVENGE TUBE. FOUND ALIGNMENT BRACKET ON SCAVENGE BROKEN. 1 G 7 2 3U 3 U H1NE E1GL 1996092600253 19960926 00253 GL 1996 9 26 96ZZZX4868 2 19960910 G 7323 23057869 GOVERNOR BELL 206 206B 1181511 SW ALLSN 250C 250C20J 03013 GL ENGINE MALFUNCTION D O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NE 05 221GP 863 BR40733 4309 CAE270674 ENGINE RPM BLEEDS OFF. UNABLE TO ADJUST, DROOPS IN-FLIGHT. REPLACED GOVERNOR. 1 G 7 1 3U 3 U H2SW E4CE 1996092600261 19960926 00261 EA 1996 9 26 96ZZZX4876 2 19960904 G 7230 ENGINE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA RT ENG COMP FAILED H O OTHER Y ENGINE STOPPAGE CR CRUISE 1 WP 07 200FV BB299 80637 WHILE IN-FLIGHT, THE RIGHT PROPELLER STOPPED TURNING SUDDENLY. INITIAL INSPECTION REVEALED A FAILURE OF THE COMPRESSOR SECTION OF THE RIGHT ENGINE CAUSING COMPLETE STOPPAGE. ENGINE WAS REMOVED AND SENT TO PRATT AND WHITNEY, CANADA, FOR EV ALUATION. 1 L 7 2 4T 4 T A24CE E4EA 1996100300419 19961003 00419 EA 1996 10 3 96ZZZX4930 2 19960909 G 8530 LW11775 PIN PLUG PIPER PA28 PA28* SO LYC O360 IO360C1C 41514 EA ENGINE CYLINDERS FAILED B PB2R K NONE O OTHER IN INSP/MAINT 1 GL 23 450 CYLINDER REMOVED FROM ENGINE DUE TO ALUMINUM IN OIL SCREEN. FOUND PIN PLUG SHAVED COMPLETELY OFF ON NR 3 CYLINDER ALLOW ING PIN TO RUB AGAINST CYLINDER WALL. THESE TYPES OF PIN PLUGS ARE A LOOSE FIT UNLIKE SUPERIOR AIR PARTS, INC., STYLE A ND WERE INSTALLED WITH CORRECT LYCOMING PART NUMBER AND FIT. REMAINING PIN PLUGS SHAVED ALSO. 1 L 7 1 3O 3 O 2A13 1E10 1996100300421 19961003 00421 NE 1996 10 3 96ZZZX4932 2 19960911 G 8520 AT90114 CRANKSHAFT PWA R1340 R1340AN1 52016 NE AFT CNTRWEIGHT CRACKED B A EJ4R K NONE O OTHER IN INSP/MAINT 1 SW 11 1800 900 RE56 18171 ENGINE RECEIVED FOR OVERHAUL DUE TO CRACK IN REAR COUNTERWEIGHT. UPON INSPECTION, FOUND THE REAR COUNTERWEIGHT CRACKED IN THE 4-1/2 ORDER FLYWEIGHT LINER AREA OF CRANKSHAFT. THIS SAME CRANKSHAFT WAS FOUND CRACKED IN THE SAME AREA AT THE PR EVIOUS OVERHAUL, 900 HOURS. AT THAT TIME, CRANKSHAFT WAS RETURNED TO AIR TRACTOR TO HAVE SNOW ENGINEERING CO. SL NR 134 C/W. AD NOTE 96-15-02 DID NOT APPLY TO THIS CRANKSHAFT AS IT ALREADY HAD THE LATE PART NUMBERED COUNTERWEIGHTS INSTALL ED (AT 90133-1 AND AT 90134-1). 3 R 5E2 1996100300422 19961003 00422 EA 1996 10 3 96ZZZX4933 2 19960224 G 8520 LW17676 CRANKSHAFT BNORM BN2 BN2 1520202 EU LYC O540 O540E4C5 41532 EA FRONT MAIN CORROSION PITS B P YECR K NONE O OTHER IN INSP/MAINT 1 NM 09 XCDUT L2223640A ENGINE DISASSEMBLED AT O/H, CRANKSHAFT INSPECTED. FRONT MAIN ID FND WITH NUMEROUS CORROSION PITS, APPROX 2.0 INCHES AFT OF FRONT EDGE OF FLANGE PILOT. CRANK ASSY LW 17676, SN V721 (CRANK AND BUSHING SUBASSY LW17622) HAS ALWAYS OPERATED WI TH CONSTANT-SPEED PROP AND IS NOT INCLUDED BY MDL OR DESIGN IN INSP REQUIREMENTS OF LYC SB 505A. THIS REPAIR STATION I NSPECTS ALL CRANKS FOR INTERNAL CORROSION REGARDLESS OF MDLS AND THIS IS 2ND CONSTANT-SPEED PROP CRANK SUBMITTER HAS SEE N IN PAST MONTH WITH SERIOUS INTERNAL CORROSION. CRANKSHAFT SUGGESTS ENVIRONMENT AND OPERATION ARE KEY FACTORS IN AFFEC TING CORROSION AS WELL AS CONSTANT-SPEED/FIXED PITCH APPLICATION. SUBJECT ACFT OPERATED IN MEXICO AND HAWAII. 1 H 7 2 3O 3 O A17EU E295 1996100300438 19961003 00438 EA 1996 10 3 96ZZZX4949 2 19960806 G 8530 75413 PISTON CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA CYLINDERS WRONG PART B PB2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 52219 250 17274443 L1227539A CUSTOMER COMPLAINED OF LOW STATIC RPM AND SLUGGISH PERFORMANACE OF AIRCRAFT. THIS CORRESPONDED WITH APPROXIMATE TIME OF A TOP OVERHAUL. PROPELLER AND TACHOMETER WERE CHECKED AND WITHIN SPECIFICATIONS. LOG BOOK ENTRIES STATING WORK DONE W AS VERY VAGUE AND NO PARTS LIST PROVIDED. ONE CYLINDER WAS REMOVED TO EXAMINE INTERNAL ENGINE CONDITION AND PARTS INSTA LLED. LOW COMPRESSION (150 HP) PISTON P/N LW75413 WERE INSTALLED INSTEAD OF HIGH COMPRESSION (160 HP) PISTON PN 75089. 1 H 7 1 3O 3 O NT 3A12 E274 1996100300447 19961003 00447 SO 1996 10 3 96ZZZX4958 2 19960705 G 8520 631716 CRANKSHAFT CESSNA 210 T210M 2073451 CE CONT O520 TSIO520H 17040 SO PROPELLER FLANGE FAILED B MW2R K NONE O OTHER NR NOT REPORTED 1 GL 17 7398M 21062018 506302 PROPELLER AND CRANKSHAFT PROPELLER FLANGE SEPARATED FROM ENGINE. 1 H 7 1 3O 3 O 3A21 E8CE 1996100300698 19961003 00698 EA 1996 10 3 96ZZZX4988 2 19960911 G 7414 ES1068291012 MAGNETO D6LN3200 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MOUNT FLANGE CHAFED D S K NONE O OTHER IN INSP/MAINT 1 NE 05 3587P 112 5032447 318052120 RL263261A LEFT ENGINE WITH LESS THAN 100 HOURS SINCE OVERHAUL HAD NAGGING SMALL LEAK AT MAGNETO, WAS THOUGHT TO BE IMPROPER INSTAL LATION, MAG GASKET GETTING DAMAGED. UPON FURTHER INVESTIGATION, FOUND MOUNTING FLANGE WORN AT SPOT WHERE CLAMP GOES. O RDERED NEW BENDIX SHELL PN 10-682001-1, AND FOUND FLANGE TO BE MUCH THICKER. ALSO, BEFORE MAG WAS REMOVED, IT SHOWED SI GNS OF BEING LOOSE. ALSO, FOUND ONE OTHER MAG OF SAME TYPE STARTING TO WEAR AT SAME SPOT PN ES10-382910-12. 1 L 7 2 3O 3 O A20SO E14EA 1996100300699 19961003 00699 EA 1996 10 3 96ZZZX4989 2 19960911 G 7414 ES10398291012 MAGNETO D6LN3200 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MOUNT FLANGE CHAFED D K NONE O OTHER IN INSP/MAINT 1 NE 05 3587P 112 R011355010 318052120 RL263261A LEFT ENGINE WITH LESS THAN 100 HOURS SINCE OVERHAUL HAD NAGGING SMALL LEAK AT MAGNETO, WAS THOUGHT TO BE IMPROPER INSTAL LATION, MAG GASKET GETTING DAMAGED. UPON FURTHER INVESTIGATION, FOUND MOUNTING FLANGE WORN AT SPOT WHERE CLAMP GOES. O RDERED NEW BENDIX SHELL PN 10-682001-1, AND FOUND FLANGE TO BE MUCH THICKER. ALSO, BEFORE MAG WAS REMOVED, IT SHOWED SI GNS OF BEING LOOSE. ALSO, FOUND ONE OTHER MAG OF SAME TYPE STARTING TO WEAR AT SAME SPOT PN ES10-382910-12. 1 L 7 2 3O 3 O A20SO E14EA 1996100300815 19961003 00815 NE 1996 10 3 AU960055 2 19960121 G 7260 GEAR BAG BAE146 BAE146100A 1500260 EU LYC ALF502 ALF502R3A 41580 NE T ENG AUX DRIVE SEPARATED W K E NONE ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 AU S LF050235 (AUS) NO3 ENGINE ACCESSORY GEARBOX INPUT BEVEL GEAR SEPARATED FROM THE MOUNTING FLANGE IN THE CASE - THE SLIMSERTS AND B OLTS WERE STILL ATTACHED TO THE GEAR AND BEARING HOUSING - METAL CONTAMINATION OFENGINE OIL SYSTEM 2 H 7 4 4F 4 F RT A49EU E6NE 1996100300816 19961003 00816 NE 1996 10 3 AU960056 2 19960120 G 7200 ENGINE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE ENGINE SYS BIRD STRIKE W K NONE E C VIBRATION/BUFFET F.O.D. TO TAKEOFF 1 AU S (AUS) DURING TAKEOFF THE AIRCRAFT HIT A FLOCK OF GALAHS - ALL ENGINE PARAMETERS REMAINED NORMAL FOLLOWING INGESTION - NO 1 ENGINE REQUIRED MAINTENANCE AND NO3 ENGINE WAS REMOVED FOR RECTIFICATION DUE TO MINOR DAMAGE - SEE MDR 96/0176 FOR ADD ITIONAL INFORMATION 2 H 7 4 4F 4 F A49EU E6NE 1996101000099 19961010 00099 SO 1996 10 10 96ZZZX4999 2 19960911 G 8530 646678 SEAL PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360KB 17025 SO INT VALVE STEM FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 17 64TP 129 3447003 320270 DURING AN ANNUAL INSPECTION, THE ENGINE OIL SUCTION SCREEN WAS FOUND TO CONTAIN A SPRING AND FRAGMENTS OF A RUBBER COMPO UND. TELEDYNE CONTINENTAL SB CSB 95-4 PERTAINS TO THIS SUBJECT, BUT IS NOT SUBJECT TO MODELS AFFECTED BY SERIAL NUMBER. THE SB WAS C/W ON BOTH ENGINES, AND EACH SEAL WAS FOUND DEFECTIVE IN EACH ENGINE. SUGGEST REVISING SERIAL NUMBER APPL ICABILITY OF SB. 1 L 7 2 3O 3 O A7SO E9CE 1996101000106 19961010 00106 SO 1996 10 10 96ZZZX5007 2 19960918 G 7322 643085 BRACKET CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO THROTTLE BODY SEPARATED D S K NONE O OTHER IN INSP/MAINT 1 SW 99 9489M 157 21062081 294714R THROTTLE BODY SUPPORT BRACKET FOUND SEPARATED AT ANNUAL INSPECTION. TIS: 156.5 HOURS, SEPARATED AT SPOT WELDS. 1 H 7 1 3O 3 O 3A21 E5CE 1996101000122 19961010 00122 EA 1996 10 10 96ZZZX5023 2 19960820 G 8530 PISTON PIPER PA14 PA14 7101402 SO LYC O290 O290D 41506 EA NR 3 CYLINDER FAILED D P A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 NM 11 5196H 2286 14493 188521 DURING FLIGHT, THE PILOT REPORTED HEARING A SLIGHT KNOCKING IN THE ENGINE AND NOTED A 20 PSI DROP IN OIL PRESSURE. A PR ECAUTIONARY LANDING WAS MADE WITHOUT INCIDENT. COMPRESSION CHECK REVEALED NR 3 CYLINDER LOW AT 50/80. CYLINDER REMOVAL REVEALED NR 3 PISTON SKIRT BROKE WITH 2 INCH BY 3 INCH PIECE LOCATED IN OIL SUMP OF ENGINE. 1 H 7 1 3O 3 O A797 E229 1996101000189 19961010 00189 EA 1996 10 10 96ZZZX5038 2 19960618 G 8540 76327 DRIVE GEAR BELL 47 47G5 1181032 SW LYC O435 VO435B1A 41516 EA ACCY DRIVE BOLTS SHEARED H K NONE O OTHER IN INSP/MAINT 1 GL 27 1449W 530 7931 2345331 GEAR AND SHAFT ASSEMBLY IS A TWO-PART GEAR HELD TOGETHER BY SIX .25 INCH BOLTS AND THREE .25 INCH PILOT PINS. IT APPEAR S THE SIX .25 INCH BOLTS WERE NOT PROPERLY TORQUED AT OVERHAUL AND THEY SHEARED OFF AT 529.6 HOURS SMOH. 1 G 7 1 3O 3 O 2H3 E279 1996101000194 19961010 00194 NE 1996 10 10 96ZZZX5043 2 19960912 G 7250 834401 BLADE PWA JT8 JT8D9A 52048 NE N2 TURBO T1 FAILURE B SQ5R K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 NE 03 P674220 ENGINE EXHIBITED HIGH VIBRATION IN SERVICE. DISASSEMBLY INSPECTION REVEALED T-2 BLADE FAILURE AND CONSEQUENTIAL DAMAGE TO THE 2ND, 3RD, AND 4TH AIRFOILS. THE CAUSE OF FAILURE IS UNDER INVESTIGATION. 4 F E2EA 1996101000195 19961010 00195 NE 1996 10 10 96ZZZX5044 2 19960912 G 7240 628748001 T-DUCT PWA JT8 JT8D9A 52048 NE COMB CHAMBER FAILURE B SQ5R K NONE O OTHER IN INSP/MAINT 1 NE 03 P674220 DISASSEMBLY INSPECTION OF ENGINE AFTER HPT BLADE FAILURE REVEALED FAILURE OF THE COMBUSTION CHAMBER SUPPORT/INNER C.C. C ASE ATTACHMENT FINGERS. SUSPECT CAUSE OF FAILURE WAS RELATED TO SHORT TERM OPERATION OF MALFUNCTIONING ENGINE AFTER HPT BLADE FAILURE. 4 F E2EA 1996101000197 19961010 00197 NE 1996 10 10 96ZZZX5046 2 19960902 G 7250 3115154 NOZZLE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE PT HOUSING OIL PLUGGED A A MASR K NONE O OTHER IN INSP/MAINT 1 SW 01 35YV 9267 1156 UE35 114031 AT DISASSEMBLY, THE NR 3 BEARING WAS FOUND COMPLETELY DESTROYED. IT APPEARS TO BE OIL STARVATION DUE TO THE NR 3 AND NR 4 BEARING OIL NOZZLE BEING PLUGGED. WHEN THE NOZZLE WAS FLOW CHECKED, IT REVEALED 3 OF THE 4 OIL PORTS WERE PLUGGED. T HE BLOCKAGE APPEARS TO BE CARBON BUILD-UP INSIDE THE NOZZLE. THE OIL NOZZLE WAS SENT TO PRATT AND WHITNEY FOR INVESTIGA TION ALONG WITH THE FAILED NR 3 BEARING REMAINS. 2 L 7 2 4T 4 T RT A24CE E26NE 1996101000200 19961010 00200 NE 1996 10 10 96ZZZX5049 2 19960913 G 8530 CYLINDER DOUG DC3 DC3C 3021457 WP PWA R1830 R183092 52020 NE RT ENG NR 2 CRACKED E E A ENGINE SHUTDOWN UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 11 59316 950 18986 359283 RIGHT ENGINE STARTED TO RUN ROUGH AND BACKFIRE IN-FLIGHT. ENGINE SHUT DOWN AND AN UNEVENTFUL LANDING WAS MADE. INVESTI GATION FOUND NR 2 CYLINDER CRACKED. CYLINDER WAS REMOVED AND REPLACED WITH A YELLOW TAGGED UNIT. ENGINE GROUND RAN, CH ECKED SATISFACTORY. AIRCRAFT RETURNED TO SERVICE. SUSPECT FATIGUE AS CAUSE OF CRACK. 2 L 7 2 4R 4 R A669 5E4 1996101000203 19961010 00203 NE 1996 10 10 96ZZZX5052 2 19960820 G 7250 ENGINE PWA JT8 JT8D219 52053 NE TURBINE FAILURE B RH2R E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 SO 19 11588 725447 IN-FLIGHT SHUTDOWN AND ENGINE WAS REMOVED FROM AIRCRAFT DUE TO TURBINE FAILURE. 1ST, 2ND, 3RD, AND 4TH TURBINE BLADES A ND 2ND, 3RD, AND 4TH NOZZLE GUIDE VANES SUSTAINED EXTENSIVE DAMAGE. EXACT CAUSE HAS NOT BEEN DETERMINED AT THIS TIME. I T IS SUSPECTED THE 2ND NGV'S MADE CONTACT WITH THE T-2 BLADES CAUSING FAILURE. SB'S 5830, 5840, AND 5891 HAD BEEN PREVI OUSLY C/W AND ASB 5782 WAS CURRENT. 4 F E9NE 1996101000318 19961010 00318 CE 1996 10 10 AU960063 1 19960122 G 7820 075016189 MUFFLER CESSNA 185 185B 2072806 CE CONT O470 IO470F 17026 SO ENG NOISE SUPPRS CRACKED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 76735 (AUS) ENGINE MUFFLER TO OVERBOARD PIPE WELDED JOINT CRACKED - SCORCHINGOF LOWER COWL IN AREA OF CRACK - A NEW EXHAUST MU FFLER HAD BEENFITTED AT THE LAST PERIODIC INSPECTION 8 HOURS PREVIOUS - SUSPECT PIPE CONTACTED COWL IN AREA OF CUTOUT - PERSONNEL/MAINTENANCEERROR 1 H 7 1 3O 3 O 3A24 3E1 1996101000326 19961010 00326 EA 1996 10 10 AU960072 2 19960122 G 8530 SL134441 PIN BEECH 76 76 1153005 CE LYC O360 O360A1G 41514 EA ENG NR 1 CYL FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S 372 L54171A (AUS) ENGINE NO1 PISTON PIN FRACTURED IN CENTRE CAUSING PISTON PIN BOSSTO BREAK EVENLY ON BOTH SIDES OF PISTON - DURING THE 100 HOURLYINSPECTION THE OIL PRESSURE FILTER WAS FOUND TO CONTAIN LARGE AMOUNTS OF STEEL AND ALLOY AND THE ENGINE W AS STRIPPED - DAMAGETO TAPPET BODIES, CAMSHAFT, CONNECTING RODS, CRANKCASE AND CYLINDER SKIRTS - MEF INVESTIGATION FOUND THAT FAILURE WAS CAUSEDBY FATIGUE ORIGINATING FROM CORROSION PITTING ON THE SURFACE OF THE PISTON PIN 1 L 7 2 3O 3 O A29CE E286 1996101000328 19961010 00328 NE 1996 10 10 AU960074 2 19960116 G 7230 SEAL BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 2 BEARING LEAKING W K NONE B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S LF05896A (AUS) NO3 ENGINE NO2 BEARING PACK SEAL FLATTENED AND LEAKING 2 H 7 4 4F 4 F A49EU E6NE 1996101000329 19961010 00329 CE 1996 10 10 AU960075 1 19960119 G 2730 040010730 CONTROL CABLE 040010728 CESSNA 150 A150L 2071828 CE CONT O200 O200A 17020 SO ELEVATOR CONTROL CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 0 (AUS) ELEVATOR REAR TRIM CABLES PN 0400107-28 AND PN 0400107-30 SEVERELY RUSTED AND FRAYED - 75% OF STRANDS BROKEN - PR OBLEM SHOULD HAVE BEEN FOUND DURING PERIODIC INSPECTIONS - PERSONEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O 3A19 E252 1996101000342 19961010 00342 SO 1996 10 10 AU960089 2 19960112 G 8540 537721 BEARING CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY R ENGINE REAR SE DISINTEGRATED W K NONE O OTHER IN INSP/MAINT 1 AU S 276338R (AUS) CRANKCASE STARTER ADAPTER GEAR SHAFT NEEDLE BEARING DISINTEGRATED- CRANKCASE DAMAGED - OTHER COMPONENTS DAMAGED WE RE OIL PUMP HOUSING, IMPELLERS, ENGINE BEARINGS, STARTER ADAPTER KIT SHAFT PNO EQ6642 AND CRANKSHAFT GEAR - METAL CONTAM INATION OF OILSYSTEM - ENGINE HAD BEEN MODIFIED AND COMPLIED WITH AD/CON/71 1 L 7 2 3O 3 O A25CE E7CE 1996101000343 19961010 00343 CE 1996 10 10 AU960090 1 19960122 G 7921 635996 OIL COOLER CONT IO520M CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY AC,ENG OIL DIST LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 786 565768 LH565768 (AUS) ENGINE OIL COOLER CORE LEAKING - LOSS OF 5 QUARTS OF OIL 1 L 7 2 3O 3 O 3A10 E5CE 1996101000344 19961010 00344 NE 1996 10 10 AU960092 2 19960123 G 7260 BEARING DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE T ENG AUX DRIVE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S PCE120282 (AUS) LH ENGINE ACCESSORY DRIVE SHAFT UPPER BEARING FAILED 2 H 7 2 4T 4 T RT A13NM E20NE 1996101000346 19961010 00346 GL 1996 10 10 AU960094 3 19960123 G 6111 FC84756 BLADE HARTZL BHCC2YF2 BEECH 55 E55 1152732 CE CONT O520 IO520C 17032 SO HARTZL HCC2Y BHCC2YF2 GL PROPELLER ASSY S DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S 80 AN694 AN694 (AUS) BOTH PROPELLER BLADES BENT AND TWISTED - NO IMPACT DAMAGE VISIBLE- SUSPECT DAMAGE CAUSED BY MISUSE OF BLADE BATS 1 L 7 2 3O 3 O 3A16 E5CE 5 C P920 1996101000349 19961010 00349 WP 1996 10 10 AU960097 2 19960109 G 7261 300143619AA1150C FILTER GULSTM 690TP 690A 0141722 SW GARRTT TPE331 TPE3315 01514 WP T ENGINE OIL SYS DISINTEGRATED W K NONE O OTHER IN INSP/MAINT 1 AU S P0684M (AUS) LH ENGINE OIL FILTER ELEMENT DISINTEGRATING - METAL FROM FILTER ELEMENT CASING CONTAMINATED ENGINE OIL SYSTEM 1 H 7 2 3T 4 T 2A4 E4WE 1996101000353 19961010 00353 EU 1996 10 10 AU960101 2 19960128 G 7321 8063210 FCU CFMINT CFM56 CFM563C 13802 EU ENG,FUEL CONTROL FAULTY W K NONE R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S WYG76817 856531 (AUS) NO1 ENGINE FUEL CONTROL UNIT FAULTY - INVESTIGATION FOUND WEAR INTHE CDP PILOT BUSHING, NEEDLE BEARINGS AND BUSHIN G AND CDP LEVER ASSEMBLY 4 F E21EU 1996101000354 19961010 00354 EA 1996 10 10 AU960102 2 19960119 G 7322 60260 BUSHING FACET MA45PA CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY ENG,FUEL CONTROL WORN W K NONE O OTHER IN INSP/MAINT 1 AU S CK817203 (AUS) CARBURETTOR THROTTLE SHAFT PNO 13-1521 AND BUSHINGS PNO 60-260 HAD EXCESSIVE CLEARANCE DUE TO WEAR IN THE BUSHINGS WHICH WERE WORN THROUGH CAUSING WEAR IN THE BODY OF THE CARBURETTOR AS WELL - ACCELERATOR PUMP LEVER PNO 155-226 AND CO NNECTING ROD PNO17-372 WERE ALSO EXCESSIVELY WORN - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O NT 3A12 E274 1996101000356 19961010 00356 EU 1996 10 10 AU960105 1 19960129 G 2821 GASCOLATOR BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA HARTZL ENG,FUEL DIST SY LEAKING W K NONE K FLUID LOSS TO TAKEOFF 1 AU S (AUS) RH ENGINE GASCOLATOR LOOSE DUE TO RETAINER ARM MOVING AND ALLOWING BOWL TO MOVE SIDEWAYS - FUEL LEAKING FROM GASC OLATOR -SUSPECT CAUSED BY OVERTORQUEING OF THE RETAINER ARM CAUSING DISTORTION OF THE ARM 1 H 7 2 3O 3 O A17EU 1E4 1996101000358 19961010 00358 NE 1996 10 10 AU960108 2 19960120 G 7321 F4305ANSSN06 FCU LYC ALF502 ALF502R5 41580 NE ENG,FUEL CONTROL FAULTY W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S F4305ANSS LF05589A (AUS) NO1 ENGINE FUEL CONTROL UNIT FAULTY 4 F E6NE 1996101000360 19961010 00360 NE 1996 10 10 AU960110 2 19960120 G 7261 AL366 PUMP BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE TURBINE ENGINE O FAILED W K NONE K FLUID LOSS DE DESCENT 1 AU S AL366 LF05582A (AUS) NO3 ENGINE DRIVEN OIL PUMP FAILED DUE TO GEAR WEAR AND EROSION OFTHE HOUSING GEAR POCKETS - ALUMINIUM METAL CONTAM INATION OF OILFILTER 2 H 7 4 4F 4 F A49EU E6NE 1996101000375 19961010 00375 WP 1996 10 10 96ZZZX5067 2 19960901 G 7310 300297719 MANIFOLD AMD FALC20 FALCON200 2730150 EU GARRTT ATF3 ATF36A4 29002 WP LT ENGINE CRACKED B GQRR K NONE O OTHER IN INSP/MAINT 1 SW 05 200WY P426C P21122 509 FUEL MANIFOLD SHROUD WAS FOUND CRACKED. REPLACED WITH SERVICEABLE UNIT. UNKNOWN IF FUEL WAS LEAKING FROM MANIFOLD. AF TT: 3,358 HOURS. LE TT: 3,653 HOURS. TC LE: 2,655. 2 L 7 2 4F 4 F RT A7EU E7WE 1996101000376 19961010 00376 WP 1996 10 10 96ZZZX5068 2 19960901 G 7240 300174517 LINER AMD FALC20 FALCON200 2730150 EU GARRTT ATF3 ATF36A4 29002 WP COMB LINER CRACKED B GQRR K NONE O OTHER IN INSP/MAINT 1 SW 05 200WY 509 P21122 DURING ROUTINE 600 HOUR INSPECTION, DISCOVERED SEVERAL COMBUSTION LINER CRACKS OUTSIDE OF MM LIMITATIONS. REMOVED AND R EPLACED LINER. AFTT: 3,358 HOURS. LE TT: 3,653 HOURS. TC: 2,655. 2 L 7 2 4F 4 F RT A7EU E7WE 1996101000377 19961010 00377 WP 1996 10 10 96ZZZX5069 2 19960901 G 7250 30031522 MID FRAME AMD FALC20 FALCON200 2730150 EU GARRTT ATF3 ATF36A4 29002 WP LT ENGINE CERAMIC FLAKING B GQRR K NONE O OTHER IN INSP/MAINT 1 SW 05 200WY 5P3930 509 P21122 BLADE TIP SEALING CERAMIC FLAKED OFF 30 TO 40 PERCENT OF AREA. NO DETECTABLE RESULTING DISCREPANCY. DISCOVERED DURING SCHEDULED 600 HOUR INSPECTION BORESCOPE INSPECTION. NEW INNER MID-FRAME ASSY INSTALLED TO CORRECT PROBLEM. AFTT: 3,35 8 HOURS. LE TT: 3,653 HOURS. TC: 2,655. 2 L 7 2 4F 4 F RT A7EU E7WE 1996101000387 19961010 00387 NE 1996 10 10 96ZZZX5079 2 19960827 G 7210 7757582 BEARING HAMSTD 7757582 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GC 49 GEARCASE SPALLED B S A K NONE O OTHER IN INSP/MAINT 1 SW 99 11502 8137 GEE785540 DISASSEMBLY OF GEARCASE REVEALED THE AFT ROLLER BEARING ASSEMBLY SHOWED HEAVY SPALLING OF ALL BEARING COMPONENTS (775758 -2) (ITEM 10, FIG 7, AND ITEM 110, FIG 8 IPL). 2 L 7 2 4T 4 T RT A52EU E8NE 1996101000388 19961010 00388 NE 1996 10 10 96ZZZX5080 2 19960916 G 7210 7757651 ROLLER BEARING HAMSTD 7758001 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GC 49 GEARCASE CAGE BROKEN A A SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 13095 5237 GEE367358 DISASSEMBLY OF GEARCASE REVEALED THE FORWARD INPUT ROLLER BEARING CAGE WAS BROKEN (775765-1, FIG 5, ITEM 180 OF 72-11-02 PARTS LIST). ALSO,THE INPUT PINION GEAR HAS STARTED TO HAVE SEVERE TOOTH BREAK DOWN (775755-3, FIG 3, ITEM 1558). BOT H IDLER GEARS ALSO HAD TOOTH WEAR. LT IDLER SN 1C6411358A (775753-5, FIG 8-40B). RT IDLER SN 1C64411268A (775754-5, FI G 8-75B).` 2 L 7 2 4T 4 T RT A52EU E8NE 1996101000416 19961010 00416 SW 1996 10 10 CA960131014 1 19960123 G 6510 2060403389 HANGER ASSEMBLY BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL LUG AREA WORN W K NONE O OTHER IN INSP/MAINT 1 CA CAE802381 (CAN)WHEN CARRYING OUT ASB 206-95-86 REV.B, INSPECTION OF TAIL ROTOR DRIVESHAFT HANGER ASSEMBLY AND SPRING. A VISIBLE WE AR STEP IN THE FILLET RADIUS OF THE HANGER LUG WAS FOUND. 1 G 7 1 3U 3 U H2SW E4CE 1996101000422 19961010 00422 NM 1996 10 10 CA960202007 1 19960126 G 2435 03600923 BEARING LUCAS 23088002A DHAV DHC8 DHC8* NM PWA 120 PW120 NE GEN DRIVE END FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 1021 1284 120896 (CAN)DRIVE END BEARING FAILED ON STARTER GENERATOR. 2 H 7 2 4T 4 T RT A13NM E20NE 1996101000423 19961010 00423 EU 1996 10 10 CA960202008 1 19960122 G 8200 2220FG TANK UNIT BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU MENTHENOL INTERMITTENT W K NONE O OTHER IN INSP/MAINT 1 CA 14902 (CAN)WATER MENTHENOL TANK DOES NOT INDICATE CONTENTS OF TANK IN THE 20-27 RANGE. 2 L 7 2 3T 4 T A24EU A196 1996101000433 19961010 00433 1996 10 10 CA960202019 4 19960119 G 2360 211SC1 STATIC WICK CHELTON EMB 120 EMB120RT SO PWA 118 PW118 NE HAMSTD 14RF 14RF9 NE WINGS & ELEV CORRODED W K NONE O OTHER DE DESCENT 1 CA PCE115667 880130 (CAN)ON DESCENT IN LIGHT RAIN, AIRCRAFT HAD RADIO RECEPTION FAILURE, BUT COMMUNICATION TRANSMISSION WAS NORMAL. 8 STATIC WICKS HAD TO BE REPLACED. 2 ON EACH WING AND 2 ON EACH ELEVATOR. RESISTANCE CHECKS T O BE INCREASED TO 1200 HOURS FROM 4000. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 1996101000469 19961010 00469 EA 1996 10 10 96ZZZX5112 2 19960920 G 8520 LIFTER PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA CYL NR 4 LOBE FAILED B CB1R K NONE O OTHER IN INSP/MAINT 1 GL 05 43125 2243 287415430 L3796827A LIFTER FAILED AT NR 4 CYLINDER CAM LOBE. LOBE DAMAGED AND PEENED ON CAMSHAFT. CRANKSHAFT PILOT END, BENT OVER LIMITS. FLANGE ON CRANKSHAFT OUT OF LIMITS ON RUN-OUT. FINDINGS RESULT OF ENGINE, TIME EXPIRED INSPECTION. 1 L 7 1 3O 3 O 2A13 E274 1996101000472 19961010 00472 EA 1996 10 10 96ZZZX5115 2 19960903 G 7310 S1236C30420 HOSE CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA FLOW DIVIDER DEFECTIVE D A A UNSCHED LANDING J K WARNING INDICATION FLUID LOSS CL CLIMB 1 EA 07 520 299 177RG1164 PILOT REPORTED A TOTAL DROP IN FUEL PRESSURE DURING CLIMB-OUT LANDING WITHOUT INCIDENT. UPON INSPECTION, FOUND FUEL PRE SSURE HOSE FROM FIREWALL TO FLOW DIVIDER LEAKING PROFUSELY WHERE THE RE-USABLE SOCKET THREADS TO HOSE. THIS HOSE WAS PU RCHASED FROM CESSNA ON 8-93 AND INSTALLED. THE METAL IDENTIFICATION BAND HAD AN ASSEMBLY DATE OF 4-85. RECOMMEND CESSN A REVIEW THEIR POLICY ON SHELF LIFE OF HOSES WHICH AT PRESENT IS CONTRARY TO THE HOSE MANUFACTURER. SUBMITTER STATED THI S SITUATION COULD HAVE BEEN CATASTROPHIC. 1 H 7 1 3O 3 O A20CE 1E10 1996101000850 19961010 00850 EA 1996 10 10 96ZZZX5130 2 19960828 G 7310 LW120980100 LINE PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540S1AD 41532 EA NR 3 FUEL INJ FAILED D L K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 21 39603 1767 32R7887119 1554961A AIRCRAFT OPERATOR REPORTED ROUGH RUNNING ENGINE. OWNER REMOVED TOP COWL AND FOUND NR 3 FUEL INJECTION LINE COMPLETELY B ROKEN OFF AT AND JUST BEHIND WHERE NUT AND FITTING ARE WELDED TO LINE. FURTHER INSPECTION REVEALED NR 4 CYLINDER OIL RE TURN TUBE CHAFED THROUGH BY FUEL INJECTION LINE AT THIS AREA (VIBRATING). OIL RETURN LINE AND FUEL INJECTION LINE BOTH REPLACED WITH NEW PARTS. FUEL INJECTION T-FITTING ON 2ND, 4TH, AND 6TH BANK OF CYLINDERS WAS FOUND LOOSE AT THIS TIME A ND RESECURED. 1 L 7 1 3O 3 O A3SO E14EA 1996101000861 19961010 00861 NE 1996 10 10 96ZZZX5141 2 19960923 G 7240 97861798P02 SCREW GE CFM56 CFM563B1 13802 NE COMBUSTION SECT FAILED B L LY2R C D ABORTED TAKEOFF RETURN TO BLOCK J WARNING INDICATION TO TAKEOFF 1 CE 07 10390 724982 ABORTED TAKEOFF DUE TO HIGH EGT. INVESIGATION FOUND DAMAGE TO HPTR BLADES. FOUND COMBUSTION SECTION SCREWS HAD BEEN RE USED AND FAILED. MANUAL CALLS FOR CENTER PUNCHING SCREW LEAKS TO AID IN REMOVAL OF THE SCREW. MANUAL CALLS FOR SCREWS TO BE DISCARDED AFTER REMOVAL. IN THIS CASE TWO SCREWS WERE REINSTALLED. 4 F E2GL 1996101000881 19961010 00881 NE 1996 10 10 96ZZZX5161 2 19960925 G 7320 CONTROL CABLE SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ANTICIPATOR BINDING D O OTHER O OTHER AP APPROACH 1 SO 17 54EW 1936 949 ON FINAL APPROACH, COLLECTIVE WAS LOWERED TO START A DESCENT, ROTOR RPM OBSERVED HIGHER THAN NORMAL. THE COLLECTIVE WAS RAISED TO RESTORE ROTOR RPM TO NORMAL, BUT NO CHANGE WAS OBSERVED. PER THE MANUFACTURER'S FLIGHT MANUAL, THE FUEL FLOW CONTROL LEVER WAS USED TO SLOW RPM. THIS RESULTED IN AN OPPOSITE PROBLEM IN SLOWING THE RPM TOO MUCH. UPON LANDING, A IRCRAFT WAS GROUNDED UNTIL MAINTENANCE COULD LOOK AT THE AIRCRAFT, THEY DISCOVERED THE CABLE THAT ATTACHES TO THE FFC WA S BINDING, AND REPLACED THE CABLE. 1 G 7 1 3U 3 U H9EU E19EU 1996101700157 19961017 00157 CE 1996 10 17 AU960117 1 19960129 G 7922 75944 NUT LYC VERNATHERM CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA AC ENG OIL DIST LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 471 (AUS) ENGINE THERMOSTATIC OIL COOLER BYPASS VALVE (VERNATHERM) NUT LOOSE - FOUND DURING INSPECTION IAW AD/LYC/78 1 H 7 1 3O 3 O NT 3A19 E223 1996101700162 19961017 00162 CE 1996 10 17 AU960127 1 19960103 G 5330 221300011 SKIN CESSNA 22130005 CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA EXT PLATES/SKIN CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AIRCRAFT SKIN CORRODED UNDER SOUND INSULATION COMPOUND - LOWER LHFORWARD BELLY SKIN ALSO CORRODED - SKIN PNO 22130 00-11, PNO2213000-5 AND PNO 2213000-6 - FOUND DURING INSPECTION IAW AD/C180/75 1 H 7 1 3O 3 O RT 3A13 E295 1996101700163 19961017 00163 WP 1996 10 17 AU960128 2 19960126 G 7230 31011607 SEAL GARRTT TPE331 TPE33110U 01514 WP T ENG CMPRSR/FAN LEAKING W K NONE O J OTHER WARNING INDICATION CR CRUISE 1 AU S 1816 (AUS) RH ENGINE COMPRESSOR SEAL LEAKING 4 T E4WE 1996101700167 19961017 00167 EU 1996 10 17 AU960139 1 19960201 G 7110 365A24100503 COWLING 36010A AEROSP SA365 SA365C 8680667 EU TMECA ARRIEL ARRIEL1A 60030 NE NAC PYLON FAIRNG DAMAGED W K NONE D INFLIGHT SEPARATION CR CRUISE 1 AU S (AUS) TRANSMISSION RH COWLING FORWARD LATCH ASSEMBLY PNO 360-10A LOCKING PIN SHEARED ALLOWING FORWARD EDGE OF COWL TO LI FT ANDEVENTUALLY SEPARATE FROM AIRCRAFT 1 G 7 2 3U 3 U H10EU E19EU 1996101700168 19961017 00168 EU 1996 10 17 AU960140 2 19960111 G 8520 BEARING RROYCE GIPSY GIPSY30* 20005 EU R ENGINE POWER S FAILED W K NONE O OTHER CL CLIMB 1 AU S 1289 66850 (AUS) LH ENGINE OIL FILTER METAL CONTAMINATION - SUSPECT FAILED MAIN BEARING 3 I E294 1996101700169 19961017 00169 EA 1996 10 17 AU960145 2 19960209 G 8520 75060 BOLT LYC CONROD PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA R ENGINE POWER S UNAPPROVED PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S L1080840 (AUS) NO2 CYLINDER CONNECTING ROD PNO 74502 BOLT INCORRECT PART - BOLT PNO 75060/1 FITTED - CORRECT PNO 74644 - INCORREC T BOLT IS LONGERTHAN THE CORRECT ONE - IPC IS UNCLEAR ON CORRECT PART NUMBER BOLTTO BE FITTED - UNAPPROVED PART - PERSON NEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 1A10 1E4 1996101700170 19961017 00170 SO 1996 10 17 AU960146 1 19960131 G 3210 78717O2 STUD PIPER ARROW PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA MAIN GEAR SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 3840 (AUS) RH MAIN LANDING GEAR SIDE BRACE STUD CRACKED IN AREA UNDER SHOULDER - FOUND DURING INSPECTION IAW AD/PA28/91 1 L 7 1 3O 3 O 2A13 1E10 1996101700171 19961017 00171 EA 1996 10 17 AU960147 2 19960126 G 7310 D2310 GASKET ROMEC FUELPUMP GULSTM 680 680FLP 0141610 SW LYC O720 IO720B1B 41546 EA ENG,FUEL DIST SY LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S D2310 L75754 (AUS) ENGINE DRIVEN FUEL PUMP RELIEF VALVE GASKET LEAKING 1 H 7 2 3O 3 O 2A4 1E15 1996101700176 19961017 00176 GL 1996 10 17 AU960152 2 19960202 G 7230 6871443 BLADE ALLSN 250C18B BELL 47 47G3B1 1181028 SW ALLSN 250C 250C18 03011 GL T ENG CMPRSR/FAN FAILED W O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 1030 CAC22003B 800621B (AUS) COMPRESSOR NO2/3 ROTOR ASSEMBLY BLADE FAILED - BLADES EXITED THROUGH BOTH COMPRESSOR CASE HALVES - FURTHER DAMAGE TO TURBINESECTION DUE TO FOD AND OVERTEMPERATURE - AIRCRAFT IS A SOLOY TURBINE ENGINE MODIFICATION ALLISON 250C18B POWER ED BELL 47G3B1 1 G 7 1 3O 3 U 2H3 E4CE 1996101700177 19961017 00177 GL 1996 10 17 AU960153 3 19960207 G 6111 787699 BLADE MCAULY 3AF32C87N CESSNA 310 310R 2074245 CE CONT O520 TSIO520M 17040 SO MCAULY 3AF32C 3AF32C87 GL PROPELLER ASSY S LOOSE W K NONE E VIBRATION/BUFFET TO TAKEOFF 1 AU S 271 787699 787699 (AUS) PROPELLER BLADE LOOSE - BLADE COULD BE ROTATED ABOUT 50.8MM (2IN)FROM FINE PITCH TO FEATHER - INVESTIGATION FOUND BLADE ACTUATING PIN FAILURE IN AREA ABOVE THREAD - MENTION WAS ALSO MADE OF FINDING FLAKES OF CHROME PLATING AND EVIDEN CE OF SCUFFING 1 L 7 2 3O 3 O 3A10 E8CE 5 C P22EA 1996101700180 19961017 00180 SO 1996 10 17 AU960157 2 19960131 G 8520 CRANKCASE BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL R ENGINE POWER S CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1665 565559 (AUS) CRANKCASE CRACKED IN AREA OF NO4 CYLINDER - CRACK RADIATES FORWARD FROM THE FORWARD OIL FILTER STUD - CRACK LENGTH 135MM(5.314IN) - AIRCRAFT IS USED FOR TRAINING PURPOSES 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1996101700181 19961017 00181 SO 1996 10 17 AU960158 1 19960205 G 7170 PIPE PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA ENG FLUID DRAIN/ INCORRECT FIT W K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 AU S L2006651A (AUS) ENGINE INTAKE FUEL DRAIN LINE INCORRECTLY FITTED - LINE WAS DOUBLED UP INTO A KINK PREVENTING FUEL FROM DRAINING - FUELLEAKED INSIDE COWLING - PERSONNEL/MAINTENANCE ERROR 1 L 7 1 3O 3 O 2A13 1E10 1996101700185 19961017 00185 EA 1996 10 17 AU960164 2 19960205 G 7421 RME38E SPARK PLUG CHAMPION REM38E PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA ENG,IGNITN DISTR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S IO360CIC6 (AUS) SPARK PLUGS (6OFF) FAULTY - CENTRE ELECTRODE WAS BEYOND LIMITS FOR RECONDITIONING - NO1 CYLINDER TOP SPARK PLUG HA D TWO COPPERWASHERS FITTED - NO1 CYLINDER LOWER SPARK PLUG HAD CORE LEAKAGE -ENGINE HAD COMPLETED ONLY 38 HOURS SINCE OV ERHAUL -PERSONNEL/MAINTENANCE ERROR 1 L 7 1 3O 3 O 2A13 1E10 1996101700188 19961017 00188 GL 1996 10 17 AU960167 3 19960123 G 6111 FC84756 BLADE HARTZL HCC2YF2CHUF BEECH 55 E55 1152732 CE CONT O520 IO520C 17032 SO HARTZL HCC2Y HCC2YF2 GL PROPELLER ASSY S DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 80 AN694 AN694 (AUS) PROPELLER BLADE CONTAINED TOOLING MARK DAMAGE IN BALANCE CAVITY -SUSPECT CAUSED DURING REMOVAL OF BALANCE LEAD - B LADE SNO C49080 1 L 7 2 3O 3 O 3A16 E5CE 5 C P920 1996101700190 19961017 00190 NE 1996 10 17 AU960170 2 19960202 G 7230 701509 DISC BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE T ENG CMPRSR/FAN CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S P76768 687560 (AUS) ENGINE 9TH STAGE HIGH PRESSURE COMPRESSOR DISC CONTAINED CORROSION PITTING IN THE BLADE SLOT PRESSURE FACES AND BL ADE SLOTSIDES IN EXCESS OF LIMITS - FOUND DURING INSPECTION IAW PWA SB 6038 AND AD/JT8D/29 - ENGINE HAD BEEN FITTED TO A LOW UTILISATIONAIRCRAFT 2 L 7 3 4F 4 F RT A3WE E2EA 1996101700193 19961017 00193 SO 1996 10 17 AU960174 1 19960127 G 7922 NUT LYC VERNATHERM PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA AC,ENG OIL DIST LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S L566061A (AUS) ENGINE THERMOSTATIC OIL COOLER BYPASS VALVE (VERNATHERM) NUT LOOSE - FOUND DURING INSPECTION IAW AD/LYC/78 1 L 7 2 3O 3 O A20SO E14EA 1996101700194 19961017 00194 NE 1996 10 17 AU960175 2 19960122 G 7260 86A002 GEAR LYC ALF502R3A BAC 146 146100A 1500260 EU LYC ALF502 ALF502R3A 41580 NE T ENG AUX DRIVE SEPARATED W K NONE E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 AU S (AUS) ENGINE ACCESSORY GEARBOX INPUT BEVEL GEAR SEPARATED FROM MOUNTINGFLANGE - BOLTS WERE STILL ATTACHED TO THE GEAR AN D BEARING HOUSING - FOUND WHEN ENGINE STRIPPED FOLLOWING OIL PRESSURE LOSS - SUSPECT CAUSED BY INSUFFICIENT BACKLASH BET WEEN THE SPIRAL INPUT GEAR AND THE BEVEL GEAR DURING INSTALLATION 2 H 7 4 4F 4 F RT A49EU E6NE 1996101700195 19961017 00195 NE 1996 10 17 AU960176 2 19960121 G 7250 HOT SECTION BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE T ENG TURBINE SE DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S LF05869A (AUS) ENGINE HOT SECTION DETERIORATED BEYOND LIMITS - FOUND DURING STRIP INSPECTION FOLLOWING BIRDSTRIKE 2 H 7 4 4F 4 F A49EU E6NE 1996101700200 19961017 00200 EA 1996 10 17 AU960182 2 19960123 G 8540 67542 BEARING PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1G5 41532 EA R ENGINE REAR SE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S L1914048A (AUS) LH MAGNETO DRIVE BEARING LOCATED IN THE ENGINE ACCESSORY HOUSING FAILED - METAL CONTAMINATION OF OIL SYSTEM 1 L 7 1 3O 3 O A3SO 1E4 1996101700201 19961017 00201 WP 1996 10 17 AU960183 1 19960125 G 7620 3141665 CABLE LKHEED 1049 C121C 5262118 WP WRIGHT R3350 R3350* 67040 EA EMER SHUTDOWN SY BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO3 ENGINE EMERGENCY SHUTOFF CABLE FAILED - SUSPECT CABLE FAILED AT A POINT WITHIN A PULLEY BLOCK WHERE THE CABLE HAD BEEN DAMAGED- NO CORROSION OR WEAR WAS EVIDENT 2 L 7 4 4R 4 R 6A5 E272 1996101700202 19961017 00202 SW 1996 10 17 AU960184 1 19960215 G 6510 WASHER BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL T/R DRIVE SHAFT UNAPPROVED PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 820269 (AUS) TAIL ROTOR DRIVE TRAIN AFT SHORT SHAFT TO LONG TAIL ROTOR DRIVE SHAFT DISC ASSEMBLY FITTED WITH INCORRECT TYPE FL AT WASHERSINSTEAD OF WITH CORRECT TYPE BEVELLED WASHERS AS REQUIRED BY THE MAINTENANCE MANUAL - UNAPPROVED PART - PERSON NEL/MAINTENANCE ERROR 1 G 7 1 3U 3 U H2SW E4CE 1996101700203 19961017 00203 CE 1996 10 17 AU960185 1 19960220 G 5510 1236232 BRACKET CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL HORZ STAB SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILISER REAR CENTRE SPAR REINFORCEMENT BRACKET CRACKED IN AREA OF LOWER LH FLANGE - INITIAL POINT OF CRACKAPPEARS TO BE AT THE BOLT HOLE WITH SECONDARY CRACKING IN BRACKETRADIUS - SUSPECT CAUSED BY PUSHING DOWN ON STABIL ISER DURING GROUND HANDLING 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1996101700206 19961017 00206 NE 1996 10 17 AU960188 2 19960214 G 7261 235237790 CHIP DETECTOR TMECA ARRIEL1S1 SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE T ENGINE OIL SYS SHORT CIRCUIT W K NONE J WARNING INDICATION TO TAKEOFF 1 AU S 15515 15515 (AUS) NO2 ENGINE FREE TURBINE CHIP DETECTOR HAD INTERNAL SHORT CIRCUIT 1 G 7 2 3U 3 U NC H1NE E19EU 1996101700208 19961017 00208 SW 1996 10 17 AU960190 1 19960202 G 6120 4GBU80M GOVERNOR GULSTM G73 G73 3951802 SW PWA R1340 R1340AN1 52016 NE HAMSTD 23D 23D40 NE PROP CNTRL SYS FAULTY W K NONE O OTHER CR CRUISE 1 AU S 291735 ZP10966 210267 (AUS) RH ENGINE PROPELLER GOVERNOR TRANSFER VALVE FAULTY - VALVE ALLOWED FEATHER PUMP PRESSURE TO PARTIALLY BYPASS PREVE NTING UNFEATHERING OF PROPELLER 1 H 7 2 3R 3 R A783 5E2 6 C P719 1996101700209 19961017 00209 WP 1996 10 17 AU960191 1 19960215 G 6510 369A5518601 DRIVE SHAFT HUGHES 369 369HS 4470728 WP ALLSN 250C 250C18 03011 GL T/R DRIVE SHAFT SHEARED W O OTHER F FLT CONT AFFECTED TO TAKEOFF 1 AU S (AUS) TAIL ROTOR DRIVE SHAFT SHEARED APPROXIMATELY 457.2MM (18IN) FROM THE FORWARD END - SEVERAL LONGITUDINAL CRACKS WER E EVIDENT IN THEAREA OF THE FAILURE WHEN VIEWED UNDER X10 MAGNIFICATION 1 G 7 1 3U 3 U H3WE E4CE 1996101700210 19961017 00210 WP 1996 10 17 AU960192 1 19960215 G 5530 369A2129 HOUSING HUGHES 369 369HS 4470728 WP ALLSN 250C 250C18 03011 GL ATTACH FITTING S CORRODED W O OTHER F E FLT CONT AFFECTED VIBRATION/BUFFET TO TAKEOFF 1 AU S (AUS) STABILIZER STRUT DAMPER SHAFT PULLED FROM FITTING DURING HEAVY VIBRATION FOLLOWING TAIL ROTOR DRIVE SHAFT FAILURE (MDR 96/0191) - FITTING EXHIBITED SIGNS OF SEVERE INTERGRANNULAR CORROSION - AIRCRAFT OPERATES IN A SALT LADEN ENVIRONME NT 1 G 7 1 3U 3 U H3WE E4CE 1996101700211 19961017 00211 CE 1996 10 17 AU960193 1 19960215 G 2432 CB24380E BATTERY CESSNA 208 208 2073702 CE PWA PT6 PT6A114 52043 NE BATTERY/CHARGER LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) BATTERY LEAKING ACID IN AREA AROUND POSITIVE TERMINAL SEAL - SUSPECT MANUFACTURING FAULT 1 H 7 1 3T 3 T NT A37CE E4EA 1996101700212 19961017 00212 NE 1996 10 17 AU960194 1 19960219 G 6730 SS275761024 BOLT SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE R-CRAFT SERVO SY WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD MAIN ROTOR SERVO LOWER MOUNT BOLT BADLY WORN - WORN BOLT AND REMAINING TWO SERVO BOLTS WERE ALSO FOUND TO BE INCORRECTLYINSTALLED 1 G 7 2 3U 3 U NC H1NE E19EU 1996101700219 19961017 00219 NM 1996 10 17 AU960201 1 19960206 G 2910 82970010149 PIPE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE MAIN HYD SYS HOLED W K NONE K FLUID LOSS LD LANDING 1 AU S (AUS) ALUMINIUM ALLOY HYDRAULIC PRESSURE PIPE LOCATED BETWEN THE ENGINE DRIVEN PUMP AND THE PRESSURE MANIFOLD HOLED DUE TO RUBBING ONSTRUCTURE IN AREA OF NACELLE ABOVE THE JET PIPE - LOSS OF NO2 SYSTEM HYDRAULIC FLUID 2 H 7 2 4T 4 T RT A13NM E20NE 1996101700220 19961017 00220 CE 1996 10 17 AU960202 1 19960221 G 5312 BULKHEAD CESSNA 182 182M 2072728 CE CONT O470 O470R 17026 SO MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH SIDE FORWARD DOORPOST BULKHEAD CRACKED - FOUND DURING INSPECTION IAW AD/C180/75 AMDT1 1 H 7 1 3O 3 O NT 3A13 E273 1996101700221 19961017 00221 CE 1996 10 17 AU960203 1 19960219 G 5312 07136084 BULKHEAD CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MCAULY MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STRUT ATTACHMENT BULKHEAD CRACKED ON LH SIDE - CRACK STARTS AT BEND RELIEF NOTCH AND GOES UNDER THE STRUT ATTACHME NT FITTING -CRACK LENGTH APPROXIMATELY 9.525MM (0.375IN) 1 H 7 1 3O 3 O RT 3A13 E295 1996101700225 19961017 00225 SO 1996 10 17 AU960208 2 19960219 G 7310 633958 SEAL 628556 CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO ENG,FUEL DIST SY UNAPPROVED PART W K NONE E VIBRATION/BUFFET CL CLIMB 1 AU S 514615 (AUS) RH ENGINE FUEL NOZZLE SEALS PNO 633958-3 AND WASHERS PNO 640612 DETERIORATED AND IN POOR CONDITION - ON TWO NOZZL ES THE 'O' RING PNO 630979-9 HAD BEEN SUBSTITUTED BY AN UNKNOWN BLACK RUBBER 'O' RING WHICH HAD HARDENED TO A BRITTLE CO NDITION - TWO NOZZLES WEREPARTLY BLOCKED BY RUBBER DEPOSITS - UNAPPROVED PART 1 L 7 2 3O 3 O A7CE E8CE 1996101700232 19961017 00232 EU 1996 10 17 AU960217 2 19960216 G 7250 3053556220 BEARING CFMINT CFM56 CFM563C1 13802 EU TURBINE SECTION FAILED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 725278 (AUS) NO1 ENGINE VIBRATION AT APPROXIMATELY 70% N1 - CREW ADVISED OF 4-5 LARGE ILLUMINATIONS FROM LEFT WING AREA - ENGIN E REDUCED TOIDLE WHERE OPERATION APPEARED NORMAL - SUSPECT NO4 BEARING FAILURE 4 F E21EU 1996101700235 19961017 00235 SO 1996 10 17 AU960220 1 19960221 G 7110 COWLING EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE ENGINE COWL SYS BIRD STRIKE W K NONE C F.O.D. TO TAKEOFF 1 AU S (AUS) RH ENGINE UPPER INTAKE COWL DAMAGED BY BIRDSTRIKE 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 1996101700236 19961017 00236 CE 1996 10 17 AU960221 1 19960226 G 5510 123262Y1 BRACKET CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO HORZ STAB SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILIZER AFT LH MOUNTING REINFORCING BRACKET CRACKED ALONG BEND RADIUS ADJACENT TO LOWER OUTBOARD BOL T - CRACK LENGTH 25MM (0.98IN) 1 H 7 1 3O 3 O 3A21 E5CE 1996101700244 19961017 00244 GL 1996 10 17 AU960229 3 19960221 G 6110 A3205 SCREW BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO HARTZL HCJ3Y PHCJ3YF2 GL PROPELLER ASSY S LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S ED1641 (AUS) PROPELLER SCREW LOOSE AND CONTACTING LOW PITCH STOP CAUSING PROPELLER TO FEATHER ON SHUTDOWN 1 L 7 2 3O 3 O 3A16 E5CE 5 C P36EA 1996101700245 19961017 00245 1996 10 17 AU960230 4 19960222 G 6113 SUPPORT BEECH 35 M35 1151526 CE CONT O470 IO470C 17026 SO MCAULY 2A36C 2A36C23 GL PROPELLER ASSY S FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 742410 (AUS) PROPELLER SPINNER SUPPORT FAILED - SPINNER BULKHEAD CRACKED - THIS IS THE SECOND SIMILAR OCCURRENCE ON THIS AIRCR AFT (LAST TIMEIN AUGUST 1992) - SUSPECT CAUSED COMBINATION OF OUT OF BALANCE PROPELLER AND LOSS OF PRELOAD DUE TO EXCESS IVE HOURS BETWEEN INSPECTIONS 1 L 7 1 3O 3 O 3A15 E273 5 C P880 1996101700275 19961017 00275 NE 1996 10 17 96ZZZX5181 2 19960329 G 7230 536210 TABLOCK SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A4A 52047 NE 3RD STAGE DISK MISSING B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 154AC 575 64037 672566 TABLOCK MISSING AT POST-FLT INSP ON 3-29-96. LAST O/H PERFORMED BY EAC ON 3-23-95. WHEN INSP COMP THRU INLET, CONTACT OF 3RD STG BLD NOTED ON FACE OF 4TH STG STATOR NEAR CENTERLINE OF ENG (ROOT END OF BLD). BLD MOVED AFT CONTACTING FRONT OF STATOR DUE TO TABLOCK FAILURE. ERICKSON ALSO DOCUMENTED DIMENSIONAL VARIANCES FND ON TABLOCKS SUPPLIED BY TP&M, SE NT A PIECE OF FRACTURED TABLOCK TO P&W FOR LAB ANALYSIS. WHEN CORRECTIVE ACTION WAS NOT FORTHCOMING FROM P&W, REMAINING PIECE OF TABLOCK SENT TO OUTSIDE LAB FOR METALLURGICAL ANALYSIS. RESULTS SHOWED MICRO CRACKING ON EDGES OF TABLOCKS WH ICH ARE A MFG DEFECT. 2 G 7 2 4U 4 U H4EA E15EA 1996101700509 19961017 00509 NE 1996 10 17 96ZZZX5190 2 19960625 G 7230 536210 TABLOCK SKRSKY S64 S64F NE PWA JFTD12 JFTD12A5A 52047 NE 3RD STAGE DISK MISSING B L JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 178AC 423 64097 677799 TABLOCK FOUND MISSING AT POST-FLIGHT INSPECTION ON 6-25-96. THE LAST OVERHAUL WAS PERFORMED BY SABRELINER. WHEN INSPEC TING THE COMPRESSOR THROUGH THE INLET, CONTACT OF 3RD STAGE BLADE NOTED ON FACE OF 4TH STAGE STATOR NEAR CENTERLINE OF E NGINE (ROOT END OF BLADE). THE BLADE MOVED AFT CONTACTING FRONT OF STATOR DUE TO TABLOCK FAILURE. THIS IS THE 7TH OCCU RRENCE OF TABLOCK FAILURE NOTED BY ERICKSON SINCE 1994. ALL PROBLEMS HAVE BEEN REPORTED TO THE MANUFACTURER. 2 G 7 2 4U 4 U H6EA E15EA 1996101700510 19961017 00510 NE 1996 10 17 96ZZZX5191 2 19960426 G 7230 536210 TABLOCK SKRSKY S64 S64F NE PWA JFTD12 JFTD12A5A 52047 NE 3RD STAGE DISK MISSING B L JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 178AC 581 64097 677770 TABLOCK FOUND MISSING AT PRE-FLIGHT INSPECTION CONDUCTED ON 4-26-96. THE LAST OVERHAUL PERFORMED BY EAC ON 8-4-94. WHE N INSPECTING THE COMPRESSOR THROUGH THE INLET, CONTACT OF 3RD STAGE BLADE WAS NOTED ON FACE OF 4TH STAGE STATOR NEAR CEN TERLINE OF ENGINE (ROOT END OF BLADE). THE BLADE MOVED AFT CONTACTING FRONT OF STATOR DUE TO TABLOCK FAILURE. THIS IS THE 6TH OCCURRENCE OF TABLOCK FAILURE NOTED BY ERICKSON SINCE 1994. ALL PROBLEMS HAVE BEEN REPORTED TO THE MANUFACTURER . 2 G 7 2 4U 4 U H6EA E15EA 1996101700861 19961017 00861 EA 1996 10 17 96ZZZX5208 2 19960903 G 7322 MA45 CARBURETOR PRECISION LYC O360 O360A4A 41514 EA BOWL DRAIN LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 100 K33508 FOUND LEAK IN BOWL DRAIN WHEN REBUILT CARBURETOR INSTALLED. REMOVED DRAIN, RESEAL. 3 O E286 1996101700865 19961017 00865 CE 1996 10 17 96ZZZX5212 1 19960901 G 8120 4066109025 TURBOCHARGER CESSNA 402 402CESSNA 207590K CE CONT O520 TSIO520E 17040 SO NR 1 ENGINE FAILED D A UNSCHED LANDING D R INFLIGHT SEPARATION PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 19 82TA 454 SHR1829 4020156 22356872E WHILE IN-FLIGHT, NR 1 TURBOCHARGER FAILED. THE AIRCRAFT LANDED WITHOUT DAMAGE. UPON INSPECTION BY MAINTENANCE, DISCOVE RED TURBO MAIN SHAFT HAD BROKEN AND WHEEL ON THE EXHAUST SIDE WAS MISSING. IT APPEARS TO HAVE GONE OUT THE OVERBOARD ST ACK. THE OTHER WHEEL WAS STILL IN THE TURBO. CAUSE: UNKNOWN. 1 L 7 2 3O 3 O A7CE E8CE 1996101700879 19961017 00879 EA 1996 10 17 96ZZZX5226 2 19960926 G 8530 74541 VALVE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA NR 3 CYL EXH STEM FAILED G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 09 737FP 1855 17269385 L220576 PRECAUTIONARY LANDING MADE DUE TO POWER LOSS AND FLUCTUATING OIL PRESSURE. ENGINE WOULD MAINTAIN 1,800 RPM, AT FULL THR OTTLE. NR 3 CYLINDER EXHAUST VALVE FAILED JUST ABOVE HEAD/STEM RADIUS. SECONDARY CYLINDER AND PISTON DAMAGE REMNENTS O F VALVE FOUND IN MUFFLER. STEM REMAINED FROZEN IN VALVE GUIDE. RECOMMENDATIONS: LYC SI 1425. SL L197. 1 H 7 1 3O 3 O NT 3A12 E274 1996101700897 19961017 00897 EA 1996 10 17 96ZZZX5243 2 19960629 G 8520 LW13809 CRANKCASE AMTR ACROSP ACROSPORT GL LYC O360 IO360B1F 41514 EA OIL SUMP BROKEN D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 09 4362D 1346 780 L619836C NOTED OIL LEAK ON LT SIDE OF OIL SUMP. FOUND THE CRANKCASE HAD MISSING PIECES AT LT REAR OIL SUMP MOUNTING STUD. ENGI NE WAS CONVERTED TO IO-360 APPROXIMATELY 100 HOURS PREVIOUSLY. A NEW OIL SUMP WAS INSTALLED AT THAT TIME. SUSPECT OIL SUMP TO CASE BOLTS WERE OVERTORQUED CAUSING A CRACK AND EVENTAULLY VIBRATION CAUSED PIECE TO DEPART CASE. 1 Q 7 1 3O 3 O NC EXPA1Q71 1E10 1996102200002 19961022 00002 CE 1996 10 22 AU960209 1 19960211 G 7603 AN35A BOLT CESSNA 150 A150M 2071831 CE CONT O200 O200A 17020 SO POWER CONTROL SY MISSING W K NONE O OTHER LD LANDING 1 AU S 205388 (AUS) BOLT ATTACHING THROTTLE CABLE TO CARBURETTOR ARM MISSING CAUSING LOSS OF ENGINE CONTROL AND FORCED LANDING 1 H 7 1 3O 3 O 3A19 E252 1996102300004 19961023 00004 SO 1996 10 23 96ZZZX5000 2 19960911 G 8530 646678 SEAL PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360KB 17025 SO INT VALVE STEM FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 17 64TP 129 3447003 319279 DURING AN ANNUAL INSPECTION, THE ENGINE OIL SUCTION SCREEN WAS FOUND TO CONTAIN A SPRING AND FRAGMENTS OF A RUBBER COMPO UND. TELEDYNE CONTINENTAL SB CSB 95-4 PERTAINS TO THIS SUBJECT, BUT IS NOT SUBJECT TO MODELS AFFECTED BY SERIAL NUMBER. THE SB WAS C/W ON BOTH ENGINES, AND EACH SEAL WAS FOUND DEFECTIVE IN EACH ENGINE. SUGGEST REVISING SERIAL NUMBER APPL ICABILITY OF SB. 1 L 7 2 3O 3 O A7SO E9CE 1996102300007 19961023 00007 NE 1996 10 23 CA960202026 2 19960125 G 7310 "O" RING PACKING PWA PW120 PW126A NE FUEL MANIFOLD DAMAGED W E ENGINE SHUTDOWN A FLAME/FIRE CL CLIMB 1 CA 4578 458 124535 (CAN)DURING A LANDING ROLL THERE WAS A FIRE ON #1 ENGINE. POST FLIGHT THE FIRE WAS CONFIRMED TO ORIGINATE FROM A DAMAGED FUEL MANIFOLD PACKING THAT WAS REPLACED THE PREVIOUS DAY AFTER A FUEL LEAK WAS DETEC TED. 4 T E2ONE 1996102300008 19961023 00008 NE 1996 10 23 AU960111 2 19960130 G 7250 COUPLING 9272M76G02 GE CF6 CF680A 30025 NE T ENG TURBINE SE FAILED W K NONE K FLUID LOSS CL CLIMB 1 AU S 580187 (AUS) NO2 ENGINE CONTAINED A MASSIVE OIL LEAK IN THE INTAKE AREA - INSPECTION OF THE OIL SCAVENGE PUMP FOUND THE PUMP CO NTAMINATEDWITH BRAIDED SEAL MATERIAL - HP TURBINE COUPLING NUT PRESSURE TUBE RUPTURED AT THE TUBE TO AFT FLANGE WELDED JOINT - A CIRCUMFERENTIAL CRACK OF APPROXIMATELY 228.6MM (9IN) WAS FOUND WITH TWO PIECES OF THE TUBE APPROXIMATELY 19.0 5MM BY 19.05MM (0.75IN BY 0.75IN) AND 63.5MM BY 12.7MM (2.5IN BY 0.5IN) MISSING - THIS ALLOWED HIGH TEMPERATURE AND PRES SURE COMPRESSOR DISCHARGEAIR TO ESCAPE INTO THE COOLING AIR CAVITY OF THE HPC AND HPT ROTORS AND THEN CHANNELED FORWARD TO THE NO3 AIR/OIL SEAL CAUSINGTHE SEAL TO FAIL 4 F E13NE 1996102300009 19961023 00009 NM 1996 10 23 AU960131 2 19960122 G 7210 31030351 BEARING GARRTT TORQUESENSOR GULSTM 690TP 690A 0141722 SW GARRTT TPE331 TPE3315251K NM ENGINE REDUCTION FAILED W K NONE E R J VIBRATION/BUFFET PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 AU S P8240 P06269C (AUS) RH ENGINE TORQUE SENSOR BEARING FAILED - METAL CONTAMINATION OF OIL SYSTEM - INVESTIGATION FOUND THAT THE CHIP DE TECTOR WIRING WAS CROSSED AT THE FIREWALL PREVENTING OPERATION OF THE CHIP DETECTOR LIGHT 1 H 7 2 3T 4 T 2A4 E2WE 1996102300015 19961023 00015 NM 1996 10 23 AU960210 1 19960115 G 5410 311T31021 PIN BOEING 767 767277 NM GE CF6 CF680A 30025 NE NAC-PYL M-FRAME CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ENGINE PYLON MID SPAR FITTING FUSE PIN CRACKED ON INNER BORE APPROXIMATELY 23MM (0.90IN) IN FROM THE HEAD OF T HE PIN - CRACK LENGTH APPROXIMATELY 12MM (0.47IN) - FOUND DURING EDDY CURRENT INSPECTION IAW B76-54-40-4D - CRACK CONFIR MED BY MAGNETICPARTICLE INSPECTION 2 L 7 2 4F 4 F RT A1NM E13NE 1996102400020 19961024 00020 SO 1996 10 24 96ZZZX5263 2 19960927 G 7414 10357426 DISTRIBUTOR BLOC S6RN25 PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO MAG OVERHEAT B SMTR K NONE M OVER TEMP IN INSP/MAINT 1 EA 17 91284 1 A233618 347970111 306764 DISTRIBUTOR BLOCK AND DISTRIBUTOR GEAR HAD EXCESSIVE HEAT BUILD-UP AND MELTING OF GEAR POSSIBLY DUE TO LACK OF SUFFICIEN T CLEARANCE DURING MANUFACTURE OR IMPROPER OIL IMPREGNATION DURING MANUFACTURE. 1 L 7 2 3O 3 O A7SO E9CE 1996102400095 19961024 00095 EA 1996 10 24 96ZZZX5287 2 19960127 G 7314 LW15473 PUMP PIPER PA34 PA34200 7103405 SO LYC O360 IO360C1E6 41514 EA ENGINE FUEL PORT BLOCKED G O OTHER Y ENGINE STOPPAGE NR NOT REPORTED 1 EA 13 2FOR 7 7 347350236 L1054451A AN AUSTRALIAN BASED PA-34 PILOT REPORTED ENGINE FAILURE DUE TO FUEL STARVATION. CAUSE WAS A RUBBER WASHER BLOCKING THE FUEL OUTLET PORT OF A NEW TEXTRON FUEL PUMP. TEXTRON SB 525 ADDRESSES THE PROBLEM. NO AIRWORTHINESS DIRECTIVE HAS BEEN ISSUED TO DATE. SUBMITTER STATED THERE ARE 4 KNOWN FAILURES FROM SAME CAUSE. NOTE: SAME PROBLEM AS MOONEY M20J IN OC T '96 ALERTS. 1 L 7 2 3O 3 O A7SO 1E10 1996102400097 19961024 00097 SO 1996 10 24 96ZZZX5289 2 19961001 G 7414 107902010 IMPULSE COUPLING S6RN2510 CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO RT MAGNETO SPRING BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 02 2700X 125 I059114DR 18051500 1311175R5 FOUND IMPULSE COUPLING, SPRING BROKEN DUE TO CORROSION. 1 H 7 1 3O 3 O 5A6 E273 1996102400098 19961024 00098 SO 1996 10 24 96ZZZX5290 2 19961001 G 7414 107902010 IMPULSE COUPLING S6RN2510 CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO LT MAGNETO SPRING BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 02 2700X 125 H089109DR 18051500 1311175R5 FOUND IMPULSE COUPLING, SPRING BROKEN DUE TO CORROSION. 1 H 7 1 3O 3 O 5A6 E273 1996102400100 19961024 00100 EA 1996 10 24 96ZZZX5292 2 19960814 G 7314 LW154731095 PUMP PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1G5 41532 EA ENGINE FUEL PORT BLOCKED G O OTHER Y ENGINE STOPPAGE NR NOT REPORTED 1 EA 13 29145 30 327940128 L1932048A PILOT REPORTED ENGINE FAILURE DUE TO FUEL STARVATION. CAUSE WAS A RUBBER WASHER BLOCKING THE FUEL OUTLET PORT OF A NEW TEXTRON FUEL PUMP. TEXTRON SB 525 ADDRESSES THE PROBLEM. NO AIRWORTHINESS DIRECTIVE HAS BEEN ISSUED TO DATE. SUBMITTE R STATED THERE ARE 4 KNOWN FAILURES FROM SAME CAUSE. NOTE: SAME PROBLEM AS MOONEY M20J IN OCT '96 ALERTS. 1 L 7 1 3O 3 O A3SO 1E4 1996102400105 19961024 00105 CE 1996 10 24 96ZZZX5297 1 19960912 G 8120 TURBOCHARGER CESSNA 401 401 207590C CE CONT O520 TSIO520E 17040 SO WASTEGATE FAILED D O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 19 401LF 40180018 PILOT COMPLAINED OF LOOSING POWER IN BOTH ENGINES ALTHOUGH NOT SIMULTANEOUSLY. DURING GROUND RUN BOTH WASTEGATES WERE F OUND STUCK IN THE OPEN POSITION. AFTER LUBRICATING WASTEGATE SHAFTS AND MOVING THEM BY HAND, SUBSEQUENT GROUND RUNS SHO WED NORMAL OPERATION. FAILURE INITIALLY OCCURRED EN ROUTE AT 19,000 FEET. MOUSE MILK WAS USED TO LUBE. RECOMMEND REGU LAR LUBRICATION. 1 L 7 2 3O 3 O A7CE E8CE 1996102400109 19961024 00109 CE 1996 10 24 96ZZZX5301 1 19960621 G 7810 15550142 CLAMP CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA EXHAUST SYSTEM CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 09 5249P 5047 15284901 L1451415 DURING INSPECTION, FOUND SIX EXHAUST CLAMP HALVES CRACKED. SUBMITTER SUSPECTS HIGH TOTAL TIME AND CORROSION OF EXHAUST PARTS. 1 H 7 1 3O 3 O NT 3A19 E223 1996102400111 19961024 00111 SO 1996 10 24 96ZZZX5303 2 19960910 G 8530 642410CN CYLINDER CESSNA 182 182M 2072728 CE CONT O470 O470R 17026 SO INT RKR SHAFT OUT OF SPEC D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 71136 28 18259509 1949268R CYLINDER CLASS 68-1 RECEIVED WITH INTAKE ROCKER SHAFT END-PLAY IN EXCESS OF (SIDE CLEARANCE). .040 INCH RECEIVED FROM EC SW, 8-13-96. 1 H 7 1 3O 3 O NT 3A13 E273 1996102400112 19961024 00112 EA 1996 10 24 96ZZZX5304 2 19960501 G 7314 LW15473 PUMP PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA ENGINE FUEL PORT BLOCKED G A O OTHER Y ENGINE STOPPAGE NR NOT REPORTED 1 EA 13 7567J 12 28R30946 L556251 PILOT REPORTED ENGINE FAILURE DUE TO FUEL STARVATION. CAUSE WAS A RUBBER WASHER BLOCKING FUEL OUTLET PORT OF A NEW TEXT RON FUEL PUMP. TEXTRON SB 525 ADDRESSES THE PROBLEM. NO AIRWORTHINESS DIRECTIVE HAS BEEN ISSUED TO DATE. SUBMITTER ST ATES THERE ARE 4 KNOWN FAILURES FROM SAME CAUSE. NOTE: SAME PROBLEM AS MOONEY M20J IN OCT '96 ALERTS. 1 L 7 1 3O 3 O 2A13 1E10 1996102400120 19961024 00120 EA 1996 10 24 96ZZZX5312 2 19960927 G 7414 MAGNETO CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA CAM FOLLOWER EXCESS WEAR D L O OTHER R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 SO 08 4696G 27 H019606GR 17273322 RL18276T AFTER INSTALLING A FACTORY REBUILT 3000 SERIES, MAGNETO AIRCRAFT WAS PLACED BACK ON RENTAL STATUS ON 9-27-96, A FLIGHT I NSTRUCTOR NOTICED TAKEOFF POWER WAS DOWN BY APPROXIMATELY 200 RPM AT FULL THROTTLE. MAINTENANCE INVESTIGATION REVEALED BOTH SETS OF MAGNETO POINTS HAD CLOSED TO APPROXIMATELY .005 INCH TO .006 INCH. CAM FOLLOWERS ON BOTH POINTS SHOWED AN ABNORMAL AMOUNT OF WEAR AND THE CAM SURFACE APPEARED ROUGH AND GRAINEY. ANOTHER REBUILT MAGNETO WAS SUPPLIED BY TCM WHI CH HAD AN EVEN ROUGHER CAM. BOTH MAGNETOS WERE RETURNED. 1 H 7 1 3O 3 O NT 3A12 E274 1996102400364 19961024 00364 NE 1996 10 24 96ZZZX5313 2 19960126 G 7230 536210 TABLOCK SKRSKY S64 S64F NE PWA JFTD12 JFTD12A5A 52047 NE THIRD STAGE DISK MISSING B L JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 159AC 1100 64084 677815 TABLOCK FOUND MISSING AT HIDDEN DAMAGE INSPECTION CONDUCTED ON COMPRESSOR BEING PROCESSED INTO THE REPAIR STATION ON 1-2 6-96. THE LAST OVERHAUL WAS PERFORMED BY EAC ON 8-4-94. WHEN INSPECTING THE COMPRESSOR THROUGH THE INLET, CONTACT OF 3 RD STAGE BLADE NOTED ON FACE OF 4TH STAGE STATOR NEAR CENTERLINE OF ENGINE (ROOT END OF BLADE). THE BLADE MOVED AFT CON TACTING FRONT OF STATOR DUE TO TABLOCK FAILURE. THIS IS THE 4TH OCCURRENCE OF TABLOCK FAILURE NOTED BY ERICKSON SINCE 1 994. ALL PROBLEMS HAVE BEEN REPORTED TO THE MANUFACTURER. 2 G 7 2 4U 4 U H6EA E15EA 1996102400743 19961024 00743 WP 1996 10 24 96ZZZX5320 2 19960928 G 7313 8687521 NOZZLE GARRTT TPE331 TPE331* 01514 WP ENG FUEL THREADS CRACKED B IUMR K NONE O OTHER IN INSP/MAINT 1 SW 11 DEFECT - CRACKS IN THE NOZZLE THREADS. THESE ARE VERY NOTICEABLE UPON ASSEMBLY WHEN BEING TORQUED, THEY TWIST OFF. THE SE TIPS COULD HAVE SEVERAL THOUSAND HOURS AND PREVIOUSLY OVERTORQUED. A LOT OF ENGINE DAMAGE CAN BE DONE IF THESE SEPAR ATE IN-FLIGHT. SUBMITTER RECOMMENDATION: CLOSE INSPECTION OF THREAD AREA AFTER CLEANING, BEFORE ASSEMBLY. NOTE: OTHE R ACCESSORY SHOPS ARE ALSO FINDING THIS PROBLEM WITH CRACKING. 3 T E2WE 1996102400745 19961024 00745 NE 1996 10 24 96ZZZX5322 2 19960802 G 7313 814358 NOZZLE PWA JT8 JT8D217 52053 NE FUEL NOZZLE NUT DETACHED D K NONE O OTHER IN INSP/MAINT 1 GL 09 5195 THE FUEL NOZZLE AS RECEIVED CONDITION FOR OVERHAUL TO CMM73-13-02 BY FST REPAIR STATION - IUR 948M WITH THE NUT COMPLET ELY DETACHED FROM THE NOZZLE ASSY. THE NUT HAD LOOSENED AND MANY AREAS OF THE NUT, NOZZLE, AND SUPPORT SHOW AREAS OF SE VERE WEAR. SOME OF THESE AREAS ARE OVER FUEL PASSAGES, INTERNAL TO THE NOZZLE ASSY, AD 94-14-16 WAS C/W IN '95. P AND W SB 6240 WAS ISSUED SUBSEQUENT TO THE LAST OVERHAUL. 4 F E9NE 1996102400765 19961024 00765 SO 1996 10 24 96ZZZX5341 2 19960907 G 8530 646657A2 CYLINDER CESSNA 210 P210N 2073454 CE CONT O520 TSIO520P 17040 SO NR 5 HEAD SEPARATED G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 03 44C P21000311 513319 DURING CRUISE ENGINE BECAME ROUGH RUNNING. EMERGENCY LANDING WAS MADE. INVESTIGATION REVEALED HEAD SEPARATION OF CYLIN DER. 1 H 7 1 3O 3 O 3A21 E8CE 1996103000007 19961030 00007 GL 1996 10 30 HEEA968220 2 19961011 G 7230 23039791 SPLINE ADAPTER ALLSN 250C 250C20 03013 GL ENGINE BELOW LIMITS E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: MEASURED .0034 BELOW MINIMUM LIMITS OF .8994 ON COUPLING'S EXTERNAL SPLINES. SERIAL NUMB ER 65243 AND S/N 65246 9-17-96 AND SERIAL NUMBER 64938 3 U E4CE 1996110100033 19961101 00033 CE 1996 11 1 CA960311022 1 19960301 G 3242 16404700 BRAKE DISC CLEVELAND 4074A CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO BOLT HOLES CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 713 520066 (CAN)WHILE CARRYING OUT AN INSPECTION ON A FLOAT AIRCRAFT, WHEEL REMOVED. AXLE REMOVED TO SERVICE BEARINGS AND REPLACE B RAKE DISC AND THEN FOUND CRACKS ALONG THE BOLT HOLES. ALL THREE HOLE WERE FOUND CRACK ED. 1 H 7 1 3O 3 O A4CE E8CE 1996110100177 19961101 00177 CE 1996 11 1 AU960274 1 19960313 G 5312 12121273 DOUBLER CESSNA BULKHEAD CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) REAR BULKHEAD RH TAILPLANE ATTACHMENT BRACKET DOUBLER CRACKED THROUGH - FURTHER INSPECTION FOUND REAR BULKHEAD CR ACKED IN THESAME AREA 1 H 7 1 3O 3 O A4CE E5CE 1996110100178 19961101 00178 GL 1996 11 1 AU960275 2 19960103 G 7250 TURBINE ALLSN SERIES11 ALLSN 250C 250C20 03013 GL T ENG TURBINE SE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S CAT34207 (AUS) ENGINE GAS PRODUCER TURBINE ASSEMBLY FAULTY - TURBINE ASSEMBLY HAD NIL HOURS SINCE OVERHAUL - GP SUPPORT MOUNTING FLANGE BENT - DURING DISMANTLING TO CHANGE THE SUPPORT THE FOLLOWING DEFECTIVE ITEMS WERE FOUND :-1. 1ST STAGE NGV PNO 6 895021 - CRACKED AND VALVE DAMAGED 2. 1ST STAGE NGV HEAT SHIELD PNO 6890040 - CRACKED AND WARPED3. POSITION PLUGS (2OFF) PNO 6845899 - WORN 4. NO8 SUMP PNO 6845632 - EXCESSIVELY DENTED PERSONNEL/MAINTENANCE ERROR 3 U E4CE 1996110100181 19961101 00181 CE 1996 11 1 AU960280 1 19960314 G 5412 12534096 BULKHEAD CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FIREWALL AND RH BULKHEAD CRACKED IN AREA OF EXHAUST MOUNT ATTACHMENT - AIRCRAFT IS USED AS A FLOAT PLANE 1 H 7 1 3O 3 O A4CE E5CE 1996110100182 19961101 00182 CE 1996 11 1 AU960281 1 19960314 G 5412 12534095 BULKHEAD CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FIREWALL AND LH BULKHEAD CRACKED AT EXHAUST MOUNT ATTACHMENT - AIRCRAFT IS USED AS A FLOAT PLANE 1 H 7 1 3O 3 O A4CE E5CE 1996110100184 19961101 00184 CE 1996 11 1 AU960283 1 19960314 G 2730 12346506 TORQUE TUBE CESSNA ELEVATOR CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO ELEVATOR STRUCT LOOSE RIVETS W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH ELEVATOR ASSEMBLY TORQUE TUBE PNO 1234650-6 TO ELEVATOR ATTACHMENT RIVETS LOOSE AND WORKING - AIRCRAFT IS OPERA TED AS AFLOAT PLANE 1 H 7 1 3O 3 O A4CE E5CE 1996110100189 19961101 00189 GL 1996 11 1 AU960288 3 19960314 G 6110 B15921 SPRING HARTZL HCC2YK2CUF PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL PROPELLER ASSY S WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 1350 AU5509 AU5509 (AUS) PROPELLER RETAINER SPRING INCORRECT PART - EARLY MODEL SPRING PNOB1594 IN LATE MODEL SPRING RETAINER PNO B1592-1 - UNAPPROVED PART- PERSONNEL/MAINTENANCE ERROR 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1996110100190 19961101 00190 CE 1996 11 1 AU960289 1 19960312 G 6120 DCF290D2BT3 CSU MCAULY DCF290D2BT3 CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C505 GL PROP CNTRL SYS CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 1510 762113 248434R 950621 (AUS) PROPELLER CSU END CAP CRACKED AND LEAKING - THE CRACK COMMENCED AT THE FULL FINE CONTROL STOPS AND RADIATED AROUN D THE CENTRECOLLAR AND WAS HIDDEN BY THE CONTROL ARM RETURN SPRING - THE END CAP IS MANUFACTURED FROM A BRITTLE PLASTIC TYPE MATERIAL 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1996110100191 19961101 00191 CE 1996 11 1 AU960290 1 19960312 G 8120 47090813 VALVE GARRTT 47090813 CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO TURBO SUPERCHRGR LEAKING W K NONE E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 AU S RHR0102 290447R (AUS) WASTEGATE VALVE LEAKING OIL - OIL WAS DUMPED OVERBOARD VIA THE WASTEGATE VALVE DRAIN TUBE 1 L 7 2 3O 3 O A7CE E8CE 1996110100193 19961101 00193 CE 1996 11 1 AU960292 1 19960203 G 3210 BUSHING CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY MAIN GEAR SYS SEPARATED W K NONE O OTHER LD LANDING 1 AU S (AUS) LANDING GEAR PIVOT TORQUE LINK ATTACHMENT BOLT PULLED THE BUSH THROUGH THE CENTRE OF THE TORQUE LINK ALLOWING THE WHEEL ASSEMBLYTO TURN 90 DEGREES TO THE FORWARD DIRECTION OF THE AIRCRAFT - CAUSED BY WHEEL SHIMMY - SUSPECT A NON STAN DARD BUSH WAS FITTED APPROXIMATELY 4 YEARS PREVIOUS WITH A DIAMETER CLOSE TO THAT OF THE BOLT HEAD - FRETTING IN SERVIC E EVENTUALLY ALLOWED THE BOLTTO PULL THROUGH - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 3A10 E5CE 1996110100197 19961101 00197 SO 1996 11 1 AU960297 2 19960213 G 8520 652541 NUT CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO R ENGINE POWER S CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 570318 (AUS) ENGINE CYLINDER HOLD DOWN NUT CRACKED 1 H 7 1 3O 3 O 3A21 E5CE 1996110100198 19961101 00198 EA 1996 11 1 AU960298 2 19960316 G 8530 SL14995 RETAINER CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA R ENGINE CYL SEC CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L2817336A (AUS) ENGINE PUSH ROD TUBE RETAINERS (4OFF) CRACKED - RETAINERS WERE SHIPPED WITH GASKET SET PNO SL 75439-1 1 H 7 1 3O 3 O 3A17 E286 1996110100199 19961101 00199 EA 1996 11 1 AU960299 2 19960315 G 8530 L201552 PISTON LYC VO435A1F BELL 47 47G3B1 1181028 SW LYC O435 VO435A1F 41516 EA R ENGINE CYL SEC WORN W K NONE O E R OTHER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 AU S 117 L201552 L201552 (AUS) ALL SIX CYLINDERS FOUND TO HAVE EXCESSIVE WEAR TO PISTONS, RINGS AND VALVE TRAIN INCONSISTANT WITH TIME SINCE OVER HAUL - SUSPECTCAUSED BY UNREPORTED ENGINE OVERSPEED 1 G 7 1 3O 3 O 2H3 E279 1996110100200 19961101 00200 CE 1996 11 1 AU960300 1 19960215 G 3233 12810012 ACTUATOR CESSNA RHLGACTUATOR CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO LG EXT-RETRACT S CRACKED W K NONE O OTHER CL CLIMB 1 AU S 7316 (AUS) RH MAIN LANDING GEAR ACTUATOR CRACKED ALLOWING DRIVE GEAR TO DISENGAGE FROM DRIVEN GEAR 1 H 7 1 3O 3 O 3A21 E5CE 1996110100205 19961101 00205 EA 1996 11 1 AU960305 2 19960201 G 7320 3008787 ROD END EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL POWER CONTROL SY STIFF W K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 57092 (AUS) ENGINE FUEL CONTROL UNIT CONTROL ROD CONNECTOR ROD END STIFF 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1996110100206 19961101 00206 GL 1996 11 1 AU960306 3 19960319 G 6110 C3475 BLADE NUT MCAULY 3AF32C87 CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL PROPELLER ASSY S FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 366 791363 791363 (AUS) PROPELLER BLADE NUTS HAD NOT BEEN REWORKED IAW THE MANUAL - PROPELLER HAS BEEN MODIFIED TO AN OIL FILLED MODEL AT WHICH TIME THE 'O' RING GROOVES ARE SUPPOSED TO BE MACHINED OUT - PERSNNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1996110100209 19961101 00209 EA 1996 11 1 AU960309 2 19960213 G 7310 LW120980210 PIPE PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1G5 41532 EA ENG,FUEL DIST SY CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 764 L1607348A (AUS) FUEL INJECTION LINES ON NO2, NO3, NO5 AND NO6 CYLINDERS CRACKED IN AREA OF SOLDER LINE JOINT TO THE FLANGE - FOUN D DURINGINSPECTION IAW AD/LYC/90 1 L 7 1 3O 3 O A3SO 1E4 1996110100213 19961101 00213 CE 1996 11 1 AU960313 1 19960131 G 5720 PLATE 00243001811 BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL CENTRE WING SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING CENTRE SECTION FORWARD SPAR WEB PLATE LOCATED AT RH UPPER WING ATTACHMENT AREA CRACKED 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1996110100214 19961101 00214 CE 1996 11 1 AU960314 1 19960223 G 3260 13771 SWITCH CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO LG POSITION IND FAULTY W K NONE O P OTHER NO WARNING INDICATION DE DESCENT 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK MICROSWITCH FAULTY - NLG MICROSWITCH SUSPECT FAULTY 1 H 7 1 3O 3 O 3A21 E5CE 1996110100216 19961101 00216 SO 1996 11 1 AU960316 2 19960229 G 8520 CRANKCASE CONT GTSIO520M CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO R ENGINE POWER S CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 276412R (AUS) LH ENGINE CRANKCASE CRACKED - CRACK STARTED ABOVE AND FORWARD OF NO5 CYLINDER AND EXTENDED DOWNWARDS TO THE ALTERN ATOR ATTACHMENT PAD - VISIBLE CRACK LENGTH 110MM (4.33IN) 1 L 7 2 3O 3 O A25CE E7CE 1996110100217 19961101 00217 SO 1996 11 1 AU960317 2 19960310 G 7414 104001667 SPRING BENDIX 103493505 BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO LT ENG MAG BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 4719 1263468C (AUS) LH ENGINE LH MAGNETO IMPULSE COUPLING SPRING BROKEN - ENGINE HAD NOT OPERATED FOR APPROXIMATELY 8 MONTHS WHILE AIR CRAFT WAS WAITING FOR FITMENT OF THE RH ENGINE - ENGINE WAS GROUND RUN ON AWEEKLY BASIS - SUSPECT CORROSION AS CAUSE OF FAILURE 1 L 7 2 3O 3 O 3A16 E5CE 1996110100224 19961101 00224 EA 1996 11 1 AU960324 2 19960209 G 7240 PCE56614 CASE PWA PT6A34 EMB 110 EMB110P2 3260124 SO PWA PT6 PT6A34 52043 EA TURBINE ENGINE C CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1211 PCE56614 PCE56614STB (AUS) RH ENGINE GAS GENERATOR CASE CRACKED IN AREA AROUND THE UPPER ENGINE LORD MOUNT BRACKET ATTACHMENT RUNNING ALONG THE INNER EDGEOF THE WELD BEAD - CRACK LENGTH 25.4MM (1IN) 1 L 7 2 4T 4 T A21SO E4EA 1996110100230 19961101 00230 EA 1996 11 1 AU960331 2 19960317 G 7322 MA3PA CARBURETTOR FACET MA3PA CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA ENG FUEL CONTROL CONTAMINATED W K NONE E Y VIBRATION/BUFFET ENGINE STOPPAGE CL CLIMB 1 AU S DT0269 L2303015 (AUS) CARBURETTOR MIXTURE/CUTOFF VALVE CONTAMINATED BY TWO LUMPS OF BROWN PARTICLES APPROXIMATELY 3MM (0.118IN) IN DIAM ETER -INVESTIGATION FOUND CORROSION IN THE CARBURETTOR AND FUEL FILTER ASSEMBLIES AND THE PARTICLES INDICATE THAT THEY A RE THE RESULT OFCORROSION OR WEAR 1 H 7 1 3O 3 O 3A19 E223 1996110100231 19961101 00231 NE 1996 11 1 AU960332 2 19960226 G 7320 PROBE BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE ENG,FUEL CONTROL BLOCKED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 687513 (AUS) NO1 ENGINE PT2 PROBE BLOCKED WITH INSECT REMAINS 2 L 7 3 4F 4 F RT A3WE E2EA 1996110100232 19961101 00232 EU 1996 11 1 AU960333 1 19960321 G 4900 PANEL BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) APU CENTRAL FIRE BOX PANEL CRACKED IN THREE PLACES - FOUND DURING INSPECTION IAW AD/BAE146/53 AMDT1 2 H 7 4 4F 4 F A49EU E6NE 1996110100235 19961101 00235 SO 1996 11 1 AU960336 2 19960313 G 8520 1265879C CRANKCASE CONT IO520C BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO R ENGINE POWER S CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 544 1265879C 126879C (AUS) CRANKCASE CRACKED FROM NO6 CYLINDER TOP REAR STUD - FURTHER INVESTIGATION FOUND CRANKCASE WAS CRACKED IN FOUR ARE AS -CRACKING CAUSED BY THERMAL STRESS DUE TO POWER AND TEMPERATURE LOADS IMPOSED DURING FLIGHT TRAINING 1 L 7 2 3O 3 O 3A16 E5CE 1996110100371 19961101 00371 SO 1996 11 1 96ZZZX5404 2 19961009 G 8520 643207 CRANKCASE CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO NR 2 MAIN CRACKED H K NONE O OTHER IN INSP/MAINT 1 WP 17 37U 1379 414A0010 276971R AFTER REMOVAL OF CYLINDER NR 4 DUE TO A LEAKING EXHAUST VALVE, A 4 INCH CRACK WAS FOUND STARTING AT THE NR 2 MAIN JOURNA L. THIS CRACK STARTED AT THE BEARING SURFACE AND PROGRESSED TO THE INSIDE OF THE CASE BETWEEN CYLINDERS NR 2 AND 4. NO EVIDENCE OF A CRACK WAS FOUND ON THE OUTSIDE OF THE CASE. SUBMITTER STATED THIS IS THE 3RD CRACK FOUND IN THIS AREA ON 3 DIFFERENT ENGINES. 1 L 7 2 3O 3 O A7CE E8CE 1996110100376 19961101 00376 EA 1996 11 1 96ZZZX5409 2 19961006 G 8520 LW11750 CONNECT ROD PIPER PA23 PA23250 7102308 SO LYC O540 IO540J4A5 41532 EA NR 6 CYL FAILED D K NONE O OTHER NR NOT REPORTED 1 NM 03 6730Y 991 274062 L647748 ROD FOR CYLINDER NR 6 FAILED AT CRANKSHAFT END. UNABLE TO TELL IF ROD OR ROD BOLTS FAILED BECAUSE OF DAMAGE. 1 L 7 2 3O 3 O 1A10 1E4 1996110100381 19961101 00381 NE 1996 11 1 96ZZZX5414 2 19960906 G 7322 2523973 SPOOL BEARING BENDIX 430124803 LYC LTS101 LTS101750B2 41560 NE FUEL CONTROL NOT LUBED B A ESER K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 86010299 USCG FUEL CONTROL RECEIVED FROM BENDIX WEST COAST AS ZERO HOURS TSO REQUIRED UPGRADE IAW GT 264 AND GT 279. IN THE PROC ESS OF DISASSEMBLY DISCOVERED THE BLUE GREASE RESERVOIR IN THE SPOOL BEARING CAP HAD NEVER BEEN FILLED. THIS CONDITION HAS BEEN CITIED IN THE PAST AS BEING A CAUSE OF SPOOL BEARING FAILURE. 3 U E5NE 1996110100434 19961101 00434 EA 1996 11 1 AU960343 2 19960130 G 7414 S6LN1227 MAGNETO BENDIX S6LN1227 BNORM BN2MK3 BN2AMK3 1520203 EU LYC O540 O540E4C5 41532 EA HARTZL ENG IGNITION FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S A110031 (AUS) MAGNETO CAPACITOR LEAKING - CONTACT GAP LESS THAN 0.304MM (0.012IN) 1 H 7 3 3O 3 O A29EU E295 1996110100435 19961101 00435 SO 1996 11 1 AU960344 2 19960228 G 8530 SA643767P5 VALVE GUIDE CESSNA 303 T303 2073820 CE CONT O520 TSIO520AE 17040 SO R ENGINE CYLINDE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 161 246053 (AUS) NO2, NO4 AND NO6 CYLINDER EXHAUST VALVE GUIDES WORN BEYOND LIMITS 1 L 7 2 3O 3 O A34CE E8CE 1996110100436 19961101 00436 EA 1996 11 1 AU960345 2 19960130 G 7414 IO349371 COUPLING BENDIX S6LN1227 BNORM BN2MK3 BN2AMK3 1520203 EU LYC O540 O540E4C5 41532 EA ENG IGNITION WORN W K NONE O OTHER IN INSP/MAINT 1 AU S A275228 (AUS) MAGNETO IMPULSE COUPLING WORN IN EXCESS OF 0.3556MM (0.014IN) - INTERNAL TIMING GEAR OUT ONE TOOTH - FOUND DURING INSPECTION IAW AD/ELECT/27 AMDT6 1 H 7 3 3O 3 O A29EU E295 1996110100437 19961101 00437 EA 1996 11 1 AU960346 2 19960130 G 7414 S6LN1227 MAGNETO BENDIX S6LN1227 BNORM BN2MK3 BN2AMK3 1520203 EU LYC O540 O540E4C5 41532 EA ENG IGNITION OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S A94453 (AUS) MAGNETO CONTACT GAP LESS THAN 0.3048MM (0.012IN) - INTERNAL TIMING GEAR OUT BY ONE TOOTH 1 H 7 3 3O 3 O A29EU E295 1996110100438 19961101 00438 CE 1996 11 1 AU960347 1 19960318 G 7603 12504012 BRACKET CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO THROTTLE CONTROL BROKEN W K NONE O OTHER DE DESCENT 1 AU S (AUS) THROTTLE CONTROL CABLE ATTACHMENT BRACKET BROKEN ALLOWING INNER AND OUTER CABLES TO MOVE TOGETHER - BRACKET WAS M ANUFACTURED FROM0.8128MM (0.032IN) ALCLAD 1 H 7 1 3O 3 O A4CE E5CE 1996110100439 19961101 00439 CE 1996 11 1 AU960348 1 19960314 G 3411 LINE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA PITOT SYS SEPARATED W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) PITOT SYSTEM PRESSURE LINE SEPARATED FROM CONNECTION TO HOURMETER AIRSPEED SWITCH - SUSPECT LINE DISCONNECTED DURI NG REFITMENT OF TACH INDICATOR DURING AD/INST/9 CALIBRATION CHECK WHICH WAS CARRIED OUT FOLLOWING PITOT/STATIC CALIBRATI ON CHECK 1 H 7 1 3O 3 O NT 3A12 E274 1996110100443 19961101 00443 CE 1996 11 1 AU960352 1 19960318 G 2610 WIRE AMPLFIER BEECH 99 C99 1154006 CE PWA PT6 PT6A36 52043 NE FIRE DETECTION S SHORTED W K NONE N FALSE WARNING IN INSP/MAINT 1 AU S (AUS) RH ENGINE FIRE DETECTOR CONTROL AMPLIFIER SUSPECT FAULTY - FURTHER INVESTIGATION FOUND A SHORT CIRCUIT IN THE WIRE BETWEENTHE AMPLIFIER AND THE 'T' HANDLE 1 L 7 2 3T 4 T A14CE E4EA 1996110100444 19961101 00444 WP 1996 11 1 AU960353 1 19960225 G 6220 5143711 HUB HILLER HEAD HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 189 1959 (AUS) MAIN ROTOR HUB CRACKED - FOUND DURING INSPECTION IAW AD/HIL12/22A 1 G 7 1 3O 3 O 4H11 E304 1996110100446 19961101 00446 NM 1996 11 1 AU960356 1 19960317 G 2435 300SGL127Q GENERATOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE STARTER-GEN FAULTY W K NONE H ELECT. POWER LOSS-50 PC CL CLIMB 1 AU S 5 1116XL (AUS) ENGINE STARTER/GENERATOR FAULTY - INSPECTION FOUND EXTENSIVE INTERNAL ARCING AND HEAT DAMAGE 2 H 7 2 4T 4 T RT A13NM E20NE 1996110100447 19961101 00447 NE 1996 11 1 AU960357 2 19960319 G 7320 3035381 PIPE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE ENG,FUEL CONTROL BROKEN W K NONE E VIBRATION/BUFFET DE DESCENT 1 AU S 120201 (AUS) NO2 ENGINE P3 SENSE LINE FROM COMPRESSOR TO HMU FRACTURED AT HMU 'T' FITTING - VIBRATION FROM FAILED RH STARTER/GE NERATOR MAY HAVECONTRIBUTED TO FAILURE (MDR 96/0356) 2 H 7 2 4T 4 T RT A13NM E20NE 1996110100451 19961101 00451 SO 1996 11 1 AU960363 1 19960325 G 6120 B24914S ROD PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL PROPELLER ASSY S FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S CH2018 (AUS) PROPELLER PITCH CHANGE ROD SUSPECT FAULTY - DIMENSION FROM REAR PISTON SHOULDER TO FRONT RETAINER GROOVE AS ADVIS ED BY HARTZELLPROPELLERS IS 10.960INCHES (278.384MM) - MEASUREMENTS ON AFFECTED ROD WAS 10.85INCHES (275.59MM) RESULTING IN OVER COMPRESSION OF FEATHER SPRINGS CAUSING SLOW UNFEATHERING OPERATION 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 1996110100452 19961101 00452 CE 1996 11 1 AU960365 1 19960306 G 3245 TUBE GOODYEAR FLIGHTCUSTOM BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO LT MLG DEFLATED W K NONE O OTHER LD LANDING 1 AU S (AUS) LH MAIN LANDING GEAR TYRE DEFLATED DURING LANDING ROLL - INVESTIGATION COULD FIND NO FAULT WITH THE TYRE BUT THE T UBE CONTAINED A SMALL TEAR SUSPECT CAUSED FOLLOWING DEFLATION AS TYREWAS BADLY DAMAGED DURING LANDING ROLL WHILE FLAT 1 L 7 2 3O 3 O 3A16 E5CE 1996110100453 19961101 00453 CE 1996 11 1 AU960366 1 19960308 G 2710 500000896 CONTROL CABLE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO AILERON CONTROL FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH FORWARD AILERON CONTROL CABLE CONTAINED NUMEROUS BROKEN WIRES OVER A 100MM (4IN) LENGTH AT THE PULLEY LOCATED A T THE FIREWALLAREA AT FS 100.00 1 L 7 2 3O 3 O A7CE E8CE 1996110100456 19961101 00456 EA 1996 11 1 AU960369 2 19960130 G 8530 L70155 CYLINDER LYC IO320B1A PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA LT ENG CYL SEC OVER TEMP W K NONE O OTHER IN INSP/MAINT 1 AU S 1365 L70155 L70155 (AUS) LH ENGINE INTERNAL COMPONENTS EXHIBITED SIGNS OF OVERHEATING - STEEL ITEMS BLUED - ENGINE CYLINDER BORES GLAZED - SUSPECT CAUSEDBY GROUND RUNNING AT HIGH POWER SETTINGS DURING FAULT FINDING OF THE ELECTRICAL POWER SUPPLY SYSTEM - SEE MDR 96/0368 FOR SIMILAR DEFECT ON RH ENGINE 1 L 7 2 3O 3 O A1EA 1E12 1996110100457 19961101 00457 NM 1996 11 1 AU960370 1 19960301 G 6310 A1882 CLUTCH ROBSIN FREEWHEEL ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA ENG/TRANS CPLNG DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 0274 (AUS) ENGINE TO TRANSMISSION SPRAG CLUTCH ASSEMBLY DAMAGED - WEAR EVIDENT ON CLUTCH SHAFT, CLUTCH HOUSING AND SPRAG ROL LERS -SUSPECT CLUTCH SLIPPAGE CONTRIBUTED TO THE FAILURE OF THE FORWARDFLEX PLATE 1 G 7 1 3O 3 O H10WE E274 1996110100458 19961101 00458 NM 1996 11 1 AU960371 1 19960228 G 6310 A9471 FLEX PLATE ROBSIN A9471 ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA ENG/TRANS CPLNG FAILED W K NONE O OTHER TO TAKEOFF 1 AU S 1946 (AUS) CLUTCH TO TRANSMISSION FLEX PLATE FAILED AT ALL FOUR ATTACHMENT POINTS - TWO LOOSE BOLTS WERE FOUND ON THE FORWAR D YOKE ON THE TRANSMISSION - FLEX PLATE WAS A PRE 'F' MODEL 1 G 7 1 3O 3 O H10WE E274 1996110100464 19961101 00464 SO 1996 11 1 AU960378 2 19960324 G 7314 PUMP CESSNA 206 P206C 2073312 CE CONT O520 IO520A 17032 SO ENG,FUEL DIST SY FAULTY W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S (AUS) ENGINE LOST POWER - FOLLOWING FITMENT OF A NEW FUEL PUMP THE LOW POWER WAS STILL EVIDENT - ANOTHER FUEL PUMP WAS F ITTED AND THE POWER LOSS RETURNED AFTER A SHORT PERIOD OF OPERATION - A THIRD FUEL PUMP RECTIFIED THE POWER LOSS - INVE STIGATION OF THE FIRST REPLACEMENT PUMP WHICH WAS A NIL TSO ITEM WHICH HAD BEEN ON THE SHELF FOR APPROXIMATELY THREE YE ARS REVEALED EVIDENCE OF INTERNAL CORROSION ON THE WORKING SURFACES - INVESTIGATION OF THE OTHER PUMP REVEALED DEBRIS IN THE VAPOUR RETURN 1 H 7 1 3O 3 O A4CE E5CE 1996110100465 19961101 00465 NM 1996 11 1 AU960379 1 19960222 G 5720 5711098007 PANEL DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE CENTRE WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CENTRE WING INNER ACCESS PANEL EXCESSIVELY CORRODED ON THE INNER BONDED EDGE DOUBLER 2 H 7 2 4T 4 T RT A13NM E20NE 1996110100468 19961101 00468 SW 1996 11 1 AU960384 1 19960321 G 3211 S2735011055M SUPPORT SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE3313UW 01514 WP MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH MAIN LANDING GEAR OUTBOARD UPPER DRAG BRACE SUPPORT STRUCTURE CRACKED - PART NUMBERS OF CRACKED COMPONENTS:- 1. HAT SECTION PNO S27-35011-055M - CRACKED 2. T DOUBLER PNO S27-35011-23M - CRACKED3. DOUBLER PNO S27-35011-017M - CRAC KED 4. DOUBLER PNO S27-35011-074M - WORN DRAG BRACE BUSHING ATTACHMENT HOLES 2 L 7 2 4T 4 T RT A8SW E4WE 1996110100473 19961101 00473 CE 1996 11 1 AU960389 1 19960115 G 5320 05121871 DOOR POST 05121872 CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH DOOR POST CRACKED FROM RELIEF RADIUS AT FLOOR LEVEL TO HIGH SHEAR FASTENER HOLE ON LH POST AND EXTENDING APPROXIMATELY7.937MM (0.3125IN) PAST HIGH SHEAR FASTENER HOLE ON RH POST - MAXIMUM CRACK LENGTH OF 31.75MM (1.25IN) EX TENDING OUTBOARD FROM RELIEF RADIUS 1 H 7 1 3O 3 O NT 3A12 E274 1996110100530 19961101 00530 SO 1996 11 1 96ZZZX5422 2 19961017 G 8520 CRANKCASE ARONCA 15 15AC 0191202 EA CONT O300 O300* 17022 SO ENGINE FAILURE G O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 AL 03 1132H 15AC145 PUSH ROD FAILURE RESULTED IN ENGINE STOPPING AND SUBSEQUENT CRANKCASE FAILURE. (ROD THROUGH CASE.) SUBMITTER SUSPECTS OIL PUMP FAILURE, ENGINE OVERHEAT. 1 H 7 1 3O 3 O A802 E253 1996110100532 19961101 00532 EA 1996 11 1 96ZZZX5424 2 19961017 G 8530 73806 PUSH ROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 1 CYL EXH CHAFED D K NONE O OTHER IN INSP/MAINT 1 NE 01 25813 6000 15280797 L1416215 UNDER NORMAL OPERATING CONDITIONS, REMOVED NR 1 CYLINDER EXHAUST SIDE PUSH ROD AND NOTICED SHINEY CHAFE MARK. THE CAUSE IS UNKNOWN. THERE WAS NO DENT IN THE PUSH ROD TUBE. SUBMITTER STATED THIS IS THE THIRD OCCURRENCE ON THE O-235 ENGINE AT THE NR 1 CYLINDER LOCATION. 1 H 7 1 3O 3 O NT 3A19 E223 1996110100931 19961101 00931 SO 1996 11 1 96ZZZX5448 2 19961008 G 8520 CRANKSHAFT PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360FB 17025 SO NR 2 CON ROD BROKEN B CR1R A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 25 99TM 28R7703073 248145R ENGINE LOST POWER IN-FLIGHT. ACFT ABLE TO LAND AND TAXIED IN UNDER ITS OWN POWER. ENG INSP REVEALED PROP COULD BE MOVE D 15 TO 20 DEGREES WITHOUT RESISTANCE. WITH PLUGS REMOVED, FND THE FRONT 4 PISTONS WOULD MOVE IN THAT 15 TO 20 DEGREES, BUT NR 1 AND NR 2 CYL PISTON WOULD NOT. REMOVED TIMING PLUG AND FND CRANKSHAFT HAD A ROCKING MOTION WHILE MOVING PROP IN THAT FREE-PLAY AREA. THE ENGINE NOT TORN DOWN AT TIME OF REPORT, BUT IT APPEARS THE CRANKSHAFT BROKE JUST FWD OF WHE RE THE NR 2 CONNECTING ROD ATTACHES. 1 L 7 1 3O 3 O 2A13 E9CE 1996110100932 19961101 00932 GL 1996 11 1 96ZZZX5449 2 19960923 G 7250 6892832 NOZZLE SHIELD ALLSN 250C 250C30P 03013 GL 3RD STAGE ELONGATED HOLES B YKER K NONE O OTHER IN INSP/MAINT 1 EA 17 CAE895208 UPON DISASSEMBLY OF THE TURBINE FOR REPLACEMENT OF THE FIRST STAGE NOZZLE, FOUND FRETTING WEAR ON THE SHEATHS OF THE TOT HARNESS PROBES, AND ELONGATED HOLES IN THE THIRD STAGE NOZZLE SHIELD WHERE THE PROBES PASS THROUGH. TOT HARNESS REQUIR ED REPLACEMENT. 3 U E1GL 1996110100933 19961101 00933 1996 11 1 96ZZZX5450 1 19960923 G 7722 6893072 HARNESS ALLSN 250C 250C30P 03013 GL ENG TOT PROBE FRETTED B YKER K NONE O OTHER IN INSP/MAINT 1 EA 17 FF4311E CAE895208 UPON DISASSEMBLY OF THE TURBINE FOR REPLACEMENT OF THE FIRST STAGE NOZZLE, FOUND FRETTING WEAR ON THE SHEATHS OF THE TOT HARNESS PROBES, AND ELONGATED HOLES IN THE THIRD STAGE NOZZLE SHIELD WHERE THE PROBES PASS THROUGH. TOT HARNESS REQUIR ED REPLACEMENT. 3 U E1GL 1996110100981 19961101 00981 GL 1996 11 1 AU960405 2 19960327 G 7320 CONNECTOR 206062721103 BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL ENG,FUEL CONTROL HIGH RESISTANCE W K NONE O OTHER LD LANDING 1 AU S (AUS) GOVERNOR LINEAR ACTUATOR (PNO 206062721103) EARTH TERMINAL CRIMP HAD HIGH RESISTANCE PREVENTING ACTUATOR FROM WORK ING DURINGLANDING 1 G 7 1 3U 3 U H2SW E1GL 1996110100986 19961101 00986 SO 1996 11 1 AU960410 2 19960322 G 8530 646680 CYLINDER CONT O470U CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO R ENGINE CYL SEC WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 230 466437 (AUS) CYLINDER AND PISTON FITTED TO NO3 POSITION WERE INCORRECT PARTS -INCORRECT CYLINDER PNO 646680 HAD A SHORT REACH S PARK PLUG - CORRECT PNO 653444 CYLINDER HAS A LONG REACH SPARK PLUG AND PISTON PNO 648029 WITH STEEL INSERT - DIFFERENC E IN PISTON WEIGHTS WAS 315 GRAMS - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PART 1 H 7 1 3O 3 O NT 3A13 E273 1996110100989 19961101 00989 EA 1996 11 1 AU960413 2 19960226 G 7314 RA8987 GASKET ROMEC FUELPUMP PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA ENG,FUEL DIST SY FAILED W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S 209 D2499 L108268A (AUS) RH ENGINE DRIVEN FUEL PUMP GASKET RUPTURED AND LEAKING FUEL - AD/FSM/25 HAD BEEN CARRIED OUT 25.2 HOURS PREVIOUSL Y 1 L 7 2 3O 3 O A20SO E14EA 1996110100993 19961101 00993 EU 1996 11 1 AU960418 1 19960401 G 7714 408106008 GEAR LYC LTS101750B1 BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE ENG PWR IND SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S LE45818E LE45818E (AUS) ENGINE NG SPEED PICKUP GEAR PLATE RIVETS LOOSE 1 G 7 2 3U 3 U H13EU E5NE10 1996110700110 19961107 00110 SO 1996 11 7 96ZZZX5470 2 19960910 G 8530 501867 LOCK TAB PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360F 17025 SO RKR SHAFT BOLT FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 03 CYLINDERS WERE SENT OUT FOR CHROMING AND OVERHAUL. CYLINDERS WERE RECEIVED BACK READY TO INSTALL. NEW SUPERIOR AIR PAR TS ROCKER ARM SHAFT BOLT LOCK TABS WERE INSTALLED. UPON BENDING TANGS OVER BOLT HEADS, ALL TANGS EITHER CRACKED OR BROK E OFF COMPLETELY. SUBMITTER STATES, APPARENTLY, A STOCK METAL WAS TEMPERED WRONG AND WAS TOO BRITTLE. CONTINENTAL LOCK TABS WERE INSTALLED AND OPERATED FINE. 1 L 7 1 3O 3 O 2A13 E9CE 1996110700122 19961107 00122 SO 1996 11 7 96ZZZX5483 2 19961022 G 7310 111F4174S HOSE STRATOFLEX CESSNA 188 T188C 2073012 CE CONT O520 TSIO520T 17040 SO FUEL MANIFOLD LEAKING G A A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 GL 07 3619J T18803655T THE ENGINE LOST POWER, AN EMERGENCY LANDING ACCOMPLISHED WITH SMOKE COMING FROM THE ENGINE. AN EXAMINATION OF THE ENGIN E FOUND THE FUEL HOSE BETWEEN THE THROTTLE AND CONTROL ASSY AND THE FUEL MANIFOLD LEAKING AT A 20 PSI CHECK. THE BAND O N THE HOSE INDICATED A 1Q8R DATE. 1 L 7 1 3O 3 O A9CE E8CE 1996110700124 19961107 00124 EA 1996 11 7 96ZZZX5485 2 19961015 G 8550 78619 PUMP PIPER PA28 PA28235 7102810 SO LYC O540 O540B4B5 41532 EA ENG OIL FAILED B PB2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 4232T 1700 287210005 L1475740 DURING OVERHAUL DISASSEMBLY OF OIL PUMP, DISCOVERED WOODRUFF KEY DRIVE SHAFT AND SINTERED IRON GEARS. AD 75-08-09 REQUI RES REMOVAL OF THIS STYLE, BUT THIS SERIAL NUMBER IS OUTSIDE OF THOSE SPECIFIED BY LYCOMING. AD 81-18-04 CALLS FOR REPL ACEMENT AT 2,000 HRS OR AT ACCY CASE DISASSEMBLY FOR SINTERED IRON OIL PUMP IMPELLERS. CURRENT AD 96-09-10 DOES SPECIFI CY THIS ENGINE AS HAVING SINTERED IRON, BUT THIS STYLE OF DRIVE SHOULD HAVE BEEN REPLACED PER 75-08-09. 1 L 7 1 3O 3 O 2A13 E295 1996110700138 19961107 00138 EA 1996 11 7 96ZZZX5498 2 19961016 G 8530 ENGINE CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA PIN BUSHING MAKING METAL D K NONE O OTHER IN INSP/MAINT 1 SW 03 93772 2403 800 15285549 L231015 DURING OIL CHANGE, REMOVED AND CUT OPEN OIL FILTER, FOUND COMPLETELY CONTAMINATED WITH NONFERROUS MATERIAL. APPEARED TO BE ALUMINUM. LYCOMING NOTIFIED, INFORMED OUR SHOP THAT MATERIAL PROBABLY WAS PISTON WRIST PIN OUTER BUSHINGS. AIRCRAF T GROUNDED, WAITING ON REPLACEMENT ENGINE. NOTE: CONDITION DID NOT DEGRADE-PREVIOUS OIL CHANGE (50 HRS) DID NOT SHOW M ATERIAL OF ANY SORT. LYC SB 525 AND SB 527 A AND B ARE SIMILAR. (FACTORY REBUILT/OVERHAULED ENGINE.) 1 H 7 1 3O 3 O NT 3A19 E223 1996110700139 19961107 00139 SW 1996 11 7 AU960435 1 19960328 G 6310 B121892 BEARING 0476206831 BELL 47 47G3B 1181026 SW LYC O435 TVO435D1A 41516 EA ENG/TRANS CPLNG UNDERSIZE W K NONE O OTHER IN INSP/MAINT 1 AU S 300 B121892 (AUS) MAIN ROTOR FREE WHEEL UNIT BEARING ROLLERS UNDERSIZE - SEE MDR 96/0433 FOR ADDITIONAL INFORMATION 1 G 7 1 3O 3 O 2H3 1E13 1996110700140 19961107 00140 SW 1996 11 7 AU960437 1 19960402 G 3246 16210 WHEEL AIRPTS A A9A 0144204 SW LYC O540 O540B2B5 41532 EA LG WHEEL/BRAKE S BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN WHEEL FLANGE FAILED AND BROKE AWAY DURING TYRE INFLATION - DYE PENETRANT CHECK HAD FOUND NO INDICATION OF CR ACKING - PIECEOF FLANGE BROKEN AWAY WAS APPROXIMATELY 100MM (4IN) - SUSPECT A CRACK APPROXIMATELY 76.2MM (3IN) LONG HAD EXISTED FOR SOME TIMEPRIOR TO FAILURE AS OXIDATION OF THE CENTRE SECTION OF THE BROKENFLANGE PORTION WAS PRESENT 1 L 7 1 3O 3 O A4WE E295 1996110700141 19961107 00141 SO 1996 11 7 AU960438 1 19960326 G 2740 62701047 CONTROL CABLE PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA HORIZ STAB SYS FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STABILATOR TRIM CABLE FRAYED AROUND TURN BARREL AT THE AIRCRAFT TAIL - THE CABLE WAS FRAYED FOR APPROXIMATELY A Q UARTER OF THE CABLE DIAMETER 1 L 7 1 3O 3 O 2A13 E274 1996110700144 19961107 00144 NE 1996 11 7 AU960441 3 19960228 G 6110 70096 BEARING AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 23D 23D40 NE PROPELLER ASSY S BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S N216907 (AUS) PROPELLER BLADE THRUST ROLLER BEARING PNO 70096 BROKEN INTO FIVE PIECES - THE OTHER BEARING WAS CRACKED, CORRODED AND HAD PIECESMISSING FROM THE ROLLER - INVESTIGATION FOUND MOISTURE HAD CAUSEDTHE BEARING TO RUST WHICH LED TO THE EVEN TUAL BEARING FAILURE -AIRCRAFT HAS A LOW UTILISATION RATE AND HAD BEEN ORIGINALLY FITTED TO AN OTTER SEAPLANE IN CANADA BEFORE BEING PURCHASED BYTHE PRESENT OWNER 1 L 7 1 3R 3 R A9SW 5E2 6 C P719 1996110700149 19961107 00149 SO 1996 11 7 AU960447 2 19960315 G 8520 649163 CRANKCASE CESSNA 150 A150M 2071831 CE CONT O200 O200A 17020 SO R ENGINE POWER S DEFECTIVE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 772 25471450 25471450 (AUS) DURING RECIFICATION FOR A LEAKING PUSHROD TUBE AND REPLACEMENT OF NO1 CYLINDER, A LOWER CRANKCASE THROUGH STUD PUL LED OUT - THE CRANK CASE WAS SPLIT AND IT WAS THEN FOUND THE FRONT BEARING HOUSING WAS 0.0010IN OUT OF ROUND AND THE MID DLE HOUSING WAS +0.0005IN ON ONE SIDE AND -0.005IN ON THE OTHER - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O 3A19 E252 1996110700151 19961107 00151 SO 1996 11 7 AU960450 2 19960324 G 7310 627346 DIAPHRAGM CONT MANIFOLDVALV BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO ENG,FUEL DIST SY LEAKING W K NONE E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 AU S 1448 I158114C 571950 (AUS) FUEL MANIFOLD VALVE DIAPHRAGM LEAKING AT THE SHAFT ASSEMBLY 1 L 7 1 3O 3 O 3A15 E5CE 1996110700154 19961107 00154 SO 1996 11 7 AU960453 1 19960404 G 5741 9010443 BOLT GULSTM AA5 AA5A 3960106 SO LYC O320 O320E2G 41508 EA ATTACH FITTING S CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING SHOULDER BOLTS (2OFF) CRACKED - FOUND DURING MAGNETIC PARTICLE INSPECTION (MPI) 1 L 7 1 3O 3 O A16EA E274 1996110700158 19961107 00158 NE 1996 11 7 AU960458 2 19960407 G 7250 TURBINE BLADE PWA 4056 PW4056 NE TURBINE SECTION FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S P724208 (AUS) NO1 ENGINE FIRST STAGE HPT MISSING APPROXIMATELY HALF A BLADE - FOUND DURING BORESCOPE INSPECTION 4 F E24NE 1996110700164 19961107 00164 WP 1996 11 7 AU960464 1 19960208 G 6230 269A530511 DRIVE SHAFT HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA M/R MAST/SWASHPL RUSTED W K NONE O OTHER IN INSP/MAINT 1 AU S 618270 (AUS) MAIN ROTOR DRIVE SHAFT (MAST) BORE BADLY RUSTED 1 G 7 1 3O 3 O 4H12 1E10 1996110700165 19961107 00165 SW 1996 11 7 AU960465 1 19960314 G 8010 H2211 SWITCH SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ENGINE CRANKING FAULTY W A K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ENGINE BEGAN TO ROTATE RAPIDLY WHEN AIRCRAFT BATTERY SWITCHES SELECTED ON - SUSPECT INTERNAL SHORT ACROSS THE S TARTER SWITCH CONTACTS CAUSED CONTACTS TO STICK 2 L 7 2 4T 4 T RT A8SW E4WE 1996110700167 19961107 00167 1996 11 7 AU960467 4 19960404 G 2312 RADIO SYSTEM BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA VHF COMMUNICATIO FAULTY W K NONE O OTHER CL CLIMB 1 AU S (AUS) RADIO SYSTEM JAMMED IN TRANSMIT MODE ON THREE OCCASIONS - ON LANDING, AFTER EACH FAILURE THE SYSTEM OPERATED NOR MALLY 1 L 7 2 4T 4 T A24CE E4EA 1996110700171 19961107 00171 SO 1996 11 7 AU960471 1 19960411 G 5753 6232002 RIB 2232002 PIPER PA28 PA28235 7102810 SO LYC O540 O540B4B5 41532 EA WING TE SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING FLAP HAS EXTENSIVE CORROSION BETWEEN THE STEEL ATTACHMENT BRACKETS AND THE INTERNAL NOSE RIBS - ALL RIBS H AD PARTED FROM THE ATTACHMENT BRACKETS - THE TRAILING SKIN RIB SITUATED UNDER AND ON THE OUTER END OF THE STRENGTHENED W ALKWAY PORTION OF THE FLAP HAD CORRODED AWAY TO VIRTUALLY NOTHING - AIRCRAFT IS OF 1963VINTAGE WITH ONLY 2100 HOURS TTIS - NO CORROSION PROTECTION WAS APPLIED DURING MANUFACTURE 1 L 7 1 3O 3 O 2A13 E295 1996110700172 19961107 00172 SO 1996 11 7 AU960472 1 19960411 G 5753 6232000 RIB PIPER PA28 PA28235 7102810 SO LYC O540 O540B4B5 41532 EA HARTZL HCC2Y HCC2YK1 GL WING TE SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WING FLAP HAS EXTENSIVE CORROSION MAINLY BETWEEN THE STEEL ATTACHMENT BRACKETS AND INTERNAL NOSE RIBS - ALL OF WHICH HADDEPARTED FROM THEIR ATTACHING SURFACES DUE TO THE CORROSION - SEEMDR 96/0471 FOR FURTHER INFORMATION 1 L 7 1 3O 3 O 2A13 E295 5 C P920 1996110700176 19961107 00176 CE 1996 11 7 AU960476 1 19960410 G 5312 BULKHEAD CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD DOOR POST BULKHEAD CRACKED ON BOTH SIDES - FOUND DURING INSPECTION IAW AD/C180/75 AMDT 1 1 H 7 1 3O 3 O RT 3A13 E295 1996110700178 19961107 00178 SO 1996 11 7 AU960479 2 19960325 G 8520 642396 CRANKSHAFT CONT IO520M CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO R ENGINE POWER S BROKEN W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S 565246 565246 (AUS) ENGINE CRANKSHAFT BROKEN AT NO9 CHEEK 1 L 7 2 3O 3 O 3A10 E5CE 1996110700179 19961107 00179 CE 1996 11 7 AU960480 1 19960415 G 5711 35410217 SPAR BEECH 35 V35A 1151544 CE CONT O520 IO520B 17032 SO MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRONT SPAR CARRY THROUGH SECTION CRACKED AT BOTH OUTBOARD SIDES 1 L 7 1 3O 3 O 3A15 E5CE 1996110700180 19961107 00180 CE 1996 11 7 AU960481 1 19960212 G 5711 3511006178 SPAR CAP BEECH 35 V35 1151538 CE CONT O520 IO520B 17032 SO OUTER WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING LOWER SPAR CAP CORRODED 1 L 7 1 3O 3 O 3A15 E5CE 1996110700181 19961107 00181 CE 1996 11 7 AU960482 1 19960415 G 2820 F123660156 HOSE F123660144 CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA FUEL DISTRBUTION LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) FUEL HOSE LEAKING BETWEEN FITTING AND HOSE - FOUND DURING INSPECTION IAW AD/HOSE/3 AMDT5 1 H 7 1 3O 3 O RT 3A13 E295 1996110700185 19961107 00185 CE 1996 11 7 AU960488 1 19960418 G 2810 CAP CESSNA 182 182H 2072718 CE CONT O470 O470R 17026 SO FUEL STORAGE SYS LEAKING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUEL TANK CAPS LEAKING - REPLACED BY TYPE PNO SK182-8513 - FOUND DURING INSPECTION IAW AD/CESSNA180/70 AMDT 1 1 H 7 1 3O 3 O NT 3A13 E273 1996110700274 19961107 00274 GL 1996 11 7 96ZZZX5502 2 19960705 G 7240 23031260 COMBUSTION CASE BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL ARM PIT CRACKED B EOPR K NONE O OTHER IN INSP/MAINT 1 AL 01 493HL S809 ENGINE COMBUSTION CASE CRACKED AT 'ARMPIT' THROUGH WIRE MESH REINFORCEMENT. ENGINE SHOWED A CONTINUING TREND OF LOW POW ER. REPLACED CASE. 1 G 7 2 3U 3 U NC H3EU E4CE 1996110700275 19961107 00275 GL 1996 11 7 96ZZZX5503 2 19961001 G 7230 6870992 CAN 6890550 BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL COMPRESSOR CRACKED B EOPR K NONE O OTHER IN INSP/MAINT 1 AL 01 493HL 4917 41732 S809 TURBINE 'CAN' PN 6870992 WAS FOUND CRACKED TWO TIMES IN APPROXIMATELY 100 HOURS. VIBRATION ANALYSIS SHOWED HIGH VIBRATI ON LEVELS, .8IPS AT 48,000 RPM (N-1 SPEED) ON THE COMPRESSOR. REPLACED COMPRESSOR AND HAVE HAD NO MORE CRACKING. NOTE: TURBINE VIBRATION LEVEL NORMAL. REPLACED COMPRESSOR FOR REPAIR. 1 G 7 2 3U 3 U NC H3EU E4CE 1996110700312 19961107 00312 GL 1996 11 7 96ZZZX5539 2 19960909 G 7250 23032264 NOZZLE 23035128 SKRSKY S76 S76 8143010 NE ALLSN 250C 250C30S 03013 GL OUTER BAND/WEB CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 702AL 4667 1448 X59426 760243 CAE890287S UPON MAJOR REPAIR OF TURBINE, FOUND WEB OF OUTER BAND SEEMS TO HAVE BEEN MACHINED BELOW SPECS AND REPLATED. THIS CAUSED A WEAK SPOT IN FLANGE OF NOZZLE THAT CRACKED AND WENT INTO BOTH BLADE TIP PATHS. NOZZLE IS TO BE SCRAPPED. ASSURE THA T PARENT METAL IS MACHINED BELOW SPECS. 1 G 7 2 3U 3 U H1NE E1GL 1996110700470 19961107 00470 GL 1996 11 7 96ZZZX5548 2 19961009 G 7230 23050833 MODULE AGUSTA A109 A109C 0260118 EU ALLSN 250C 250C20 03013 GL AXIAL COMP FOD DAMAGE H K NONE O OTHER IN INSP/MAINT 1 EU 01 109TW 683 15299 7650 CAE295180 DURING A ROUTINE 100-HOUR INSPECTION, FOD DAMAGE FOUND TO RT ENGINE AXIAL COMPRESSOR ROTORS AND STATOR VANES. UNABLE TO ESTABLISH EXACT SOURCE OF FOD. OPERATOR TO REVIEW CURRENTLY USED LANDING SITES. 1 G 7 2 3U 3 U H7EU E4CE 1996110700478 19961107 00478 SO 1996 11 7 96ZZZX5556 2 19961025 G 8530 631521 SPRING CESSNA 402 402B 207590P CE CONT O520 TSIO520EB 17040 SO INT VALVE BROKEN D L K NONE O OTHER IN INSP/MAINT 1 GL 23 33NC 402B0825 271359R DURING A ROUTINE COMP CHECK, NR 6 CYL WAS NOTED TO HAVE LOW COMP. THE ROCKER COVER WAS REMOVED TO STACK VALVE. AT THAT POINT, IT WAS NOTED THAT THE INT VALVE SPRING WAS BROKEN. THE ADJACENT ROCKER WAS THEN REMOVED AND ANOTHER SPRING WAS FOUND TO BE BROKEN AS WELL. AT THIS POINT, THE REMAINING COVERS WERE REMOVED AND SPRINGS WERE FOUND TO BE BROKEN ON ALL REMAINING CYLINDERS. 1 L 7 2 3O 3 O A7CE E8CE 1996110700481 19961107 00481 SO 1996 11 7 96ZZZX5559 2 19961022 G 8530 653446A11 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO NR 2 BROKEN D A UNSCHED LANDING O OTHER CL CLIMB 1 NM 11 4856U 1470 21064825 517396 AFTER DEPARTURE, THE PILOT RETURNED AND LANDED DUE TO AN UNUSUAL NOISE FROM THE ENGINE. HE STATED THAT HE BELIEVED THE EXHAUST SYSTEM HAD PROBABLY BROKEN. UPON INVESTIGATION OF THE ENGINE, DISCOVERED THE NR 2 CYL HAD CRACKED 3/4 OF THE WA Y AROUND THE CIRCUMFERENCE OF THE COMBUSTION CHAMBER. COMBUSTION PRESSURE AND EXH GAS BURNED A HOLE THROUGH THE COOLING FINS OF THE NR 4 CYL. COMBUSTION GAS EXITING THE BROKEN CYL WAS DIRECTED ON TO THE STAINLESS STEEL FUEL INJECTION NOZZ LE LINE. CONTINUED FLIGHT AND WOULD MOST PROBABLY HAVE RESULTED IN AN ENGINE FIRE. 1 H 7 1 3O 3 O 3A21 E8CE 1996110700482 19961107 00482 SO 1996 11 7 96ZZZX5560 2 19961004 G 7313 633723019A INJECTOR CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO NR 3 CYLINDER MISDRILLED B S EVCR K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 03 915DW 846 421B0914 634835R WHILE PERFORMING REPAIR IN ADJACENT AREA, FUEL STAINS WERE NOTED AT NR 3 CYLINDER INJECTOR WHERE IT THREADS INTO CYLINDE R HEAD. WHILE REMOVING THE INJECTOR, IT BROKE OFF AT THREADS. FURTHER INSP OF INJECTOR REVEALED THE ORIFICE IN THE OUTL ET OF THE INJECTOR IS DRILLED OFF-CENTER. SUBMITTER STATED FAILURE OF INJECTOR IN THIS AREA IS POTENTIALLY CATASTROPHIC DUE TO RAW FUEL LEAKING OVER THE TOP OF THE ENGINE. INJECTORS SHOULD BE INSP CLOSELY WHEN CLEANED OR AFTER RECEIVING FR OM OVERHAUL FACILITY. 1 L 7 2 3O 3 O A7CE E7CE 1996111300011 19961113 00011 WP 1996 11 13 AU960327 2 19960311 G 7240 8697281 PLENUM GARRTT TPE3311151A MTSBSI MU2 MU2B30 5780410 SW GARRTT TPE331 TPE33111U 01514 WP T ENG BURNER SEC CRACKED W K NONE E B VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S P90181 P90181 (AUS) RH ENGINE PLENUM CHAMBER CRACKED AROUND DRAIN FITTING TAKEOFF FLANGE - CRACK LENGTH 50.8MM (2IN) - RH ENGINE BLEE D AIR TUBECHAFED AND LEAKING - PERSONNEL/MAINTENANCE ERROR 1 H 7 2 3T 4 T A2PC E4WE 1996111300015 19961113 00015 NE 1996 11 13 AU960354 2 19960306 G 7240 13146 LINER RROYCE RB211524G2 RROYCE RB211 RB211524G19 NE TURBINE ENGINE C FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 13146 13146 (AUS) ENGINE COMBUSTION LINER HEAD BREAKING UP IN AREA BETWEEN NO2 AND NO5 BLEED STRUTS - FOUND DURING BORESCOPE INSPECT ION IAW AD/RB211/19 AMDT1 (ROLLS ROYCE SB RB211-72-B482) 4 F E30NE 1996111300019 19961113 00019 NM 1996 11 13 AU960417 1 19960323 G 2920 6510 SWITCH BOEING 767 76733A NM PWA 4056 PW4056 NE AUX HYD SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 6510 (AUS) RAM AIR TURBINE (RAT) AIRSPEED SWITCH FAULTY - SUSPECT FAULTY DIODE - RAT FAILED TO AUTODEPLOY 2 L 7 2 RT 4 F RT A1NM E24NE 1996111400003 19961114 00003 CE 1996 11 14 AU960491 1 19960416 G 5720 316321 FITTING 316322 BBAVIA 8 8KCAB 2110612 CE LYC O320 AEIO320E2B 41508 EA OUTER WING SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) BOTH FORWARD WING STRUT FITTINGS PNO 3-1362-1 AND PNO 3-1632-2 CRACKED - ALL FOUR FORWARD AND REAR FITTING PIECES CRACKED - FOUND DURING DYE PENETRANT INSPECTION 1 H 7 1 3O 3 O A21CE 1E12 1996111400011 19961114 00011 SO 1996 11 14 AU960499 1 19960411 G 8011 ESEBB75A DRIVE UNIT PRESTOLITE NO1724206 PIPER PA30 PA30 7103002 SO LYC O320 IO320C1A 41508 EA ENGINE CRANKING MALFUNCTIONED W K NONE O OTHER NR NOT REPORTED 1 AU S IF000589 (AUS) ENGINE STARTER MOTOR DRIVE LOCKED IN THE ENGAGED POSITION 1 L 7 2 3O 3 O A1EA 1E12 1996111400012 19961114 00012 EU 1996 11 14 AU960500 1 19960416 G 7170 0174078010 DRAIN VALVE SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENG FLUID DRAIN/ INCORRECT ASSY W K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 AU S 0174078010 585 (AUS) ENGINE STARTER DRAIN VALVE LEAKING FUEL AT BODY SPLIT LINE - CAUSED BY INCORRECT ASSEMBLY AT OVERHAUL - PERSONNEL/ MAINTENANCE ERROR 1 G 7 1 3U 3 U H9EU E19EU 1996111400013 19961114 00013 EU 1996 11 14 AU960501 1 19960310 G 5340 FITTING SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA ATTACH FITTING S DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH FRONT WING ATTACHMENT FITTING AT FUSELAGE DAMAGED - FUSELAGE PANELS LH AND RH SIDE ABOVE MAIN SPARS DISTORTED 1 L 7 1 30 3 O NT A51EU E286 1996111400016 19961114 00016 CE 1996 11 14 AU960505 1 19960419 G 5720 3163212 FITTING 316322 BBAVIA 8 8KCAB 2110612 CE LYC O360 AEIO360H1A 41514 EA OUTER WING SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 75295LAND (AUS) WING STRUT FITTINGS (4OFF) PNO 3-1632-1 AND PNO 3-1632-2 CRACKED IN THE CORNER OF THE RECTANGULAR HOLLOW SECTIONS - FOUND DURINGINSPECTION IAW AD/CHA/25 AND SL408 - AIRCRAFT HAS ONLY 103 HOURS TIME SINCE NEW WITH 20 HOURS OF AEROBATIC TIME 1 H 7 1 3O 3 O A21CE 1E10 1996111400020 19961114 00020 WP 1996 11 14 AU960509 2 19960315 G 7210 GEAR GARRTT TPE331 TPE33110U 01514 WP ENGINE REDUCTION PITTED W K NONE C F.O.D. CL CLIMB 1 AU S P42106 (AUS) ENGINE SUFFERED A LIGHTNING STRIKE - DOME REMOVED AND GEARING FOUND TO BE PITTED 4 T E4WE 1996111400021 19961114 00021 NE 1996 11 14 AU960510 2 19960415 G 7261 OIL SYSTEM PWA PWA120 PW125B NE TURBINE ENGINE O CONTAM-METAL W K NONE O OTHER IN INSP/MAINT 1 AU S TM124027 (AUS) ENGINE OIL FILTER CONTAMINATED WITH METAL 4 T E20NE 1996111400024 19961114 00024 EU 1996 11 14 AU960513 1 19960411 G 5610 NF20216402 WINDSHIELD BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FLT CMPT WINDOW DELAMINATED W K NONE O OTHER CR CRUISE 1 AU S 235789 (AUS) RH `B' WINDSCREEN OUTER PANE DELAMINATED AND A LARGE SECTION SEPARATED 2 H 7 4 4F 4 F A49EU E6NE 1996111400026 19961114 00026 SO 1996 11 14 AU960516 1 19960412 G 2740 26701111 CONTROL CABLE PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA HORIZ STAB SYS BROKEN W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) HORIZONTAL STABILISER TRIM CABLE BROKEN IN AREA WHERE CABLE PASSES THROUGH THE SERVO TRIM PULLEYS AND CAPSTAN 1 L 7 1 3O 3 O 2A13 1E10 1996111400027 19961114 00027 EU 1996 11 14 AU960517 2 19960307 G 7310 9375M18G01 MANIFOLD CFMINT CFM56 CFM563C1 13802 EU ENG,FUEL DIST SY CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 721762 (AUS) ENGINE FUEL MANIFOLD 'Y' TUBE CRACKED - CRACK LENGTH 19.05MM (0.75IN) - FOUND DURING FLUORESCENT PENETRANT INSPECT ION 4 F E21EU 1996111400030 19961114 00030 EU 1996 11 14 AU960520 1 19960406 G 4990 O-RING GTCP36150M BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE APU OIL SYS FAILED W K NONE B K SMOKE/FUMES/ODORS/SPARKS FLUID LOSS TO TAKEOFF 1 AU S P210UC (AUS) APU ENGINE OIL SYSTEM QUANTITY LOW - SMOKE OBSERVED FROM EXHAUST - GENERATOR DRIVE CARBON SEAL LEAKING - MAIN CAUS E OF OIL LOSS ISCONSIDERED TO BE A FAILED `O' RING SEAL ON THE OIL FILLER/DIPSTICK 2 H 7 4 4F 4 F RT A49EU E6NE 1996111400034 19961114 00034 EU 1996 11 14 AU960525 1 19960422 G 5713 STRINGER PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA OUTER WING SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING STRINGERS CRACKED FROM RIVET HOLES - ALL CRACKS WERE LESS THAN 12.7MM (0.5IN) IN LENGTH - FOUND DUR ING INSPECTIONIAW AD/P68/42 1 H 7 2 3O 3 O A31EU 1E10 1996111400035 19961114 00035 SW 1996 11 14 AU960526 1 19960313 G 5710 WING MOONEY M20 M20E 5870212 SW LYC O360 IO360A1A 41514 EA CENTRE WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING CENTRE SECTION SEVERELY CORRODED - THE FOLLOWING ITEMS NEEDED REPAIR: 1.PNO 210022-091 - WING RIB INBOARD FU SELAGE ATTACHMENT - LH 2. PNO 210022-901 - WING RIB INBOARD FUSELAGE ATTACHMENT - RH 3.PNO 210029-4 - WING RIB INBOARD UNDERCARRIAGE BAY 4. PNO 210104-000 - HINGE ARM FLAP INBOARD5.PNO 210105-501 - HINGE ARM FLAP OUTBOARD 6. PNO 210059- 007 - FITTING WING ATTACHMENT REAR SPAR - LH7.PNO 210059-007 - FITTING WING ATTACHMENT REAR SPAR - RH 8. PNO 210011-00 0 - SPLICE PLATE SPAR CAP UPPER 9.PNO 210010-000 - SPLICE PLATE SPAR CAP LOWER 10. PNO 210054-505 - STUB SPAR ASSEMBLY11 . PNO 210000-111 - STRINGER SPAR WEB 12. PNO 210000-112 - STRINGER SPAR WEB 13. PNO 210020-007 - WEB REAR SPAR 1 L 7 1 3O 3 O 2A3 1E10 1996111400036 19961114 00036 SO 1996 11 14 AU960527 1 19960406 G 3010 36E966A REGULATOR EMB 120 EMB120 3260201 SO PWA 118 PW118A NE ICE-RAIN PROTECT LEAKING W K NONE J WARNING INDICATION CR CRUISE 1 AU S RF1812 (AUS) RH DE-ICE SYSTEM PRESSURE REGULATOR LEAKING AIR 2 L 7 2 4T 4 T RT A31SO E20NE 1996111400038 19961114 00038 SO 1996 11 14 AU960529 1 19960428 G 8120 LW127996S116 HOSE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA TURBO SUPERCHRGR DETERIORATED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S (AUS) ENGINE LOST POWER DUE TO FAILURE OF HOSE BETWEEN AIRBOX PNO LW-12799-6S116 AND DIFFERENTIAL CONTROLLER - STRATOFL EX 193.4HOSE HAD DETERIORATED DUE TO HEAT FROM ADJACENT TURBOCHARGER 1 L 7 2 3O 3 O A20SO E14EA 1996111400039 19961114 00039 SO 1996 11 14 AU960530 1 19960320 G 5753 FLAP PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA WING TE SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING FLAPS CORRODED IN AREA BETWEEN STEEL HINGE FITTINGS AND NOSERIBS AND SPARS 1 L 7 1 3O 3 O A3SO 1E4 1996111400040 19961114 00040 SO 1996 11 14 AU960531 1 19960320 G 5711 62054 SPAR PIPER PA32 PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA OUTER WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING REAR SPARS CORRODED IN AREA BENEATH STEEL FITTINGS AS REFERRED TO IN AD/PA28/40 AND AD/PA32/27 - THE CORROSIO N WAS ONLYFOUND FOLLOWING REMOVAL OF THE FITTINGS 1 L 7 1 3O 3 O A3SO 1E4 1996111400045 19961114 00045 CE 1996 11 14 AU960536 1 19960419 G 3260 1CH1066 SWITCH WESTERNHYD NLGACTUATOR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO LG EXT-RETRACT S FAULTY W K NONE O P OTHER NO WARNING INDICATION LD LANDING 1 AU S 1409 (AUS) NOSE LANDING GEAR DOWNLOCK SWITCH FAULTY 1 L 7 2 3O 3 O A7CE E7CE 1996111400048 19961114 00048 CE 1996 11 14 AU960539 1 19960330 G 5720 50110231 FITTING CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO OUTER WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH STUB WING ATTACHMENT FITTING CONTAINED EXFOLIATION CORROSION - FURTHER CORROSION FOUND FOLLOWING REMOVAL OF TH E FITTING 1 L 7 2 3O 3 O A7CE E8CE 1996111400049 19961114 00049 CE 1996 11 14 AU960540 1 19960417 G 2510 SEAT BELT CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO FLIGHT COMPARTME WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) SEAT BELTS USED AUTOMOTIVE HARDWARE WITH NON MIL-SPEC WEBBING - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O NT TA13 E273 1996111400280 19961114 00280 EU 1996 11 14 CA960412017 1 19960402 G 5320 15S53572604204 STRAP AEROSP AEROSP ATR42 ATR42300 8680920 EU PWA 120 PW120 NE LH MLG WELL CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 17306 (CAN)DURING AIRCRAFT BLOCK CHECK THE STRAP USED TO REINFORCE THE MAIN LANDING GEAR WHEEL WELL WAS FOUND CRACKED. THIS ON E ON THE LEFT SIDE. OPERATOR NOTES THAT THEY HAVE SSEN THIS BEFORE. 2 H 7 2 4T 4 T RT A53EU E20NE 1996111400292 19961114 00292 EA 1996 11 14 CA960415008 2 19960411 G 7414 1051324 IMPULSE SPRING BENDIX D4LN2021 CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA DUAL MAG BROKEN W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 CA 2295 758 3437 L13680 (CAN)ON CLIMBOUT, ENGINE RPM DROPPED TO IDLE. EXAMINATION REVEALED THE DUAL MAGNETO IMPULSE SPRING BROKEN. AWD 78-09-07 NOT COMPLIED WITH. 1 H 7 1 3O 3 O A20CE 1E10 1996111400302 19961114 00302 GL 1996 11 14 96ZZZX5588 2 19961025 G 7320 23033400 FILTER ELEMENT BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL FCU PC FILTER CRACKED H K NONE O OTHER IN INSP/MAINT 1 NM 11 937S 3271 51258 CAE895318 FILTER ELEMENT CRACKED WHERE END CAP IS ATTACHED TO ELEMENT. SOME PIN HOLES AND CORROSION AROUND FILTER TO END CAP BOND . ELEMENT MAY HAVE BEEN FROM ENGINE OPERATED IN SALT LADEN ATMOSPHERE AND INSTALLED WHEN ENGINE WAS TORN DOWN FOR INSPE CTION BY OUTSIDE VENDOR. RECOMMEND INSP WITH 10X MAGNIFYING GLASS EACH INSP INTERVAL. 1 G 7 1 3U 3 U H2SW E1GL 1996111400306 19961114 00306 EA 1996 11 14 96ZZZX5592 2 19961025 G 7310 883410000600094 HOSE DEUTSCH CESSNA 177 177 2073704 CE LYC O360 O360A1F6 41514 EA PUMP TO CARB LEAK H K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 19974 30 17702617 NOTICED FUEL STAIN ON STEEL BRAID HOSE. REMOVED AND TESTED. FOUND SEEP HOLE. NOTIFIED SUPPLIER AND SENT FOR FACTORY I NSPECTION. (SEEP WAS DETECTABLE WITH SHOP AIR AND SOAPY WATER.) 1 H 7 1 3O 3 O NT A13CE E286 1996111400485 19961114 00485 GL 1996 11 14 96ZZZX5609 2 19960930 G 7321 23057344 FCU HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FAILED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 440 329147 1151D CAE832750 FCU CAUSED DELAYED LIGHT-OFF WHEN AT AMBIENT TEMP. UNITS REPLACED, STARTS NORMAL. 1 G 7 1 3U 3 U H3WE E4CE 1996111400487 19961114 00487 GL 1996 11 14 96ZZZX5611 2 19960930 G 7323 23057869 GOVERNOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE ERRATIC B EOOR K NONE O OTHER NR NOT REPORTED 1 AL 03 5074R 1100 27963 1151D CAE832750 PILOT COMPLAINED OF ERRATIC OPERATION AND CONSTANT BEEP ADJUSTMENT. UNIT IS 344.6 HOURS SINCE REPAIR. THIS IS ANOTHER OF NUMEROUS GOVERNOR PROBLEMS. 1 G 7 1 3U 3 U H3WE E4CE 1996111400621 19961114 00621 NE 1996 11 14 CA960418016 2 19960325 G 7250 214112605 SCREW LYC 214105720 LYC ALF502 ALF502R5 41580 NE HEAT SHIELD LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA A457 (CAN)ON REMOVAL OF THE 4TH ROTOR, A SCREW WAS FOUND LOOSE AND PROTRUDING APPROXIMATELY 3/16 INCH FROM THE REAR HEAT SHIE LD WITH ASSOCIATED DAMAGE IN THE AREA OF THE BLADE ROOTS. RIVET HEADS WORN DOWN AND L IGHTLY RUBBING ON ROTOR DISC. MANU FACTURER SUGGESTED A REVISED TORQUE VALUE FOR THE SCREW. 4 F E6NE 1996111400622 19961114 00622 SO 1996 11 14 CA960418201 2 19960402 G 8540 MOUNTING PAD CONT CESSNA 310 T310R 2074246 CE CONT O520 TSIO520BB 17040 SO ALTERNATOR PAD MISMACHINED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 674 236988R (CAN)MOUNTING HOLE AND PAD FOR ALTERNATOR MACHINED APPROXIMATELY .080 INCH TOO FAR FORWARD CAUSING ALTERNATOR DRIVE GEAR NOT MESHING PROPERLY. 1 L 7 2 3O 3 O 3A10 E8CE 1996112100164 19961121 00164 GL 1996 11 21 CA960424018 3 19960423 G 6110 BU10602 PISTON SEAL HARTZL DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL PROP LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 1159 BU10602 PCE42076 BU10602 (CAN)SLIGHT OIL TRACE AFT OF PROP SPINNER . PISTON SEAL REPLACED 1 H 7 2 3T 4 T A9EA E4EA 6 C P15EA 1996112100173 19961121 00173 WP 1996 11 21 CA960429001 2 19960411 G 8530 35175 MOUNTING BOLT DHAV GM10103 DHAV DHC1 DHC1B2 2801736 GL DHAVXX GIPSY GIPSYMAJOR1 20004 WP VALVE RKR BOX LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA 254 DHC120 (CAN)PILOT FOUND #3 ROCKER BOX LOOSE AND TWO NUTS INSIDE LOWER COWLING. MAINTENANCE FOUND #3 ROCKER BOX MOUNTING BOLTS H AD BACKED OFF AND FALLEN INTO BOX COVER. ALSO, THE MOUNTING BOLTS ON ALL THREE REMAINING ROCKER BOXES HAD LOST THEIR TOR QUE LEADING TO BELIEVE THAT INCORRECT TORQUE WAS APPLIED AT LAST OVERHAUL 15 YEAR PREVIOUS. 1 L 7 1 3O 3 I EXPA1L71 A8EU 1996112100179 19961121 00179 NE 1996 11 21 CA960429009 2 19960411 G 7250 123022 TURBINE CASE PWA PW123 DHAV DHC8 DHC8301 NM PWA PW120 PW123 NE NR 2 ENG PUNCTURED W A A E UNSCHED LANDING ENGINE SHUTDOWN E A T VIBRATION/BUFFET FLAME/FIRE ENGINE CASE PENETRATION CL CLIMB 1 CA 5857 123022 123022 (CAN)AFTER TAKEOFF, VIBRATION FROM #2 ENGINE FOLLOWED BY ENGINE FIRE. AFM PROCEDURES CARRIED OUT, BOTH BOTTLES DISCHARG ED. FIRE EXTINGUISHED BUT LATER REIGNITED AFTER LANDING, AIRPORT FIRE CREW EXTINGUISHED FIRE. A LARGE QUANTITY OF RESID UAL OIL NOTED IN THE NACELLE AREA WHICH COULD BE THE SOURCE OF SECOND FIRE. HOLE IN THE FRONT OF THE TURBINE SUPPORT CAS E AT THE 8 O'CLOCK POSITION WITH BLADE AND SHROUD SEGMENT DEBRIS IN THE NACELLE. 2 H 7 2 4T 4 T RT A13NM E20NE 1996112100188 19961121 00188 SO 1996 11 21 CA960502049 2 19960415 G 8530 PISTON PIN CESSNA 337 337G 2075730 CE CONT O360 IO360G 17025 SO MCAULY 2AF34C D2AF34C306 GL REAR ENG FRACTURED W A E UNSCHED LANDING ENGINE SHUTDOWN J R WARNING INDICATION PARTIAL RPM/PWR LOSS CL CLIMB 1 CA 130 352477 793546 (CAN) CLIMBING THROUGH 5,200 FEET, REAR ENGINE RPM STARTED FLUCTUATING 200-300 RPM. OIL PRESSURE DROPPED TO ZERO, ENGINE FEATHERED. ENGINE TEARDOWN REVEALED BROKEN PISTON PIN. SUPERIOR AIR PART. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 1996112100196 19961121 00196 1996 11 21 CA960507003 4 19960208 G 3422 6225812001 FLUX VALVE COLLINS 6225812001 BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA COMPASS SYS OIL SOAKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 7111 PCE25675 (CAN)AIRCRAFT COMPASS SYSTEM REPORTED UNRELIABLE. EXAMINATION OF COMPASS COMPONENTS AND WIRING REVEALED THAT THE FLUX VA LVE WAS SATURATED WITH INSTRUMENT OIL. COLLINS CONFIRMED THAT THE LOSS OF OIL COULD R ESULT IN FAILURE OF THE COMPONENT. FLUX VALVE REPLACED. 1 L 7 2 3T 4 T RT 3A20 E4EA 1996112700010 19961127 00010 EA 1996 11 27 CA960509201 2 19960425 G 7320 76772 HOSE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA #3 & #1 CYLINDER DETERIORATED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA 489 L673261A (CAN)PILOT REPORTED ROUGH RUNNING ENGINE ACCOMPANIED BY BLACK EXHAUST. PIECES OF INJECTOR AIR BLEED HOSE FOUND INSIDE TH E NOZZLE ASSEMBLES. 1 L 7 2 3O 3 O A20SO E14EA 1996112700014 19961127 00014 NE 1996 11 27 CA960513001 2 19960408 G 7250 120111 TURBINE DISC PWA PW120A DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE FIRTREE FRACTURED W A A UNSCHED LANDING X M ENGINE FLAMEOUT OVER TEMP CL CLIMB 1 CA 3683 120111 120111 (CAN)DURING CLIMB, LOUD BANG FOLLOWED BY HIGH ITT ABOVE 950 DEGREES AND ENGINE FLAME OUT MOLTEN DEBRIS IN THE EXHAUST W ITH ALL THREE #6/7 OIL TUBES FRACTURED ENGINE TEARDOWN HAS REVEALED FRACTURE OF TWO LP TURBINE DISC FIRTREE WITH RELEA SE OF THREE LPT BLADES. THE DISC/BLADE ASSEMBLY TO BE RETURNED TO P&WC FOR INVESTIGATION. 2 H 7 2 4T 4 T RT A13NM E20NE 1996112700015 19961127 00015 NE 1996 11 27 CA960513002 2 19960403 G 7250 TURBINE DISC DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE FIRTREE FRACTURED W A A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 CA 9988 5395 120050 (CAN)CLIMBING THROUGH 2,800 FEET, A LOUD SOUND WAS HEARD FROM PORT ENGINE. THE ENGINE WAS SECURED AND RETURNED TO BASE. DISASSEMBLY AT P&WC REVEALED ON LPT DISC FIRTREE HAD FRACTURED BELOW THE FIRST SERRAT ION AND RELEASED TWO BLADES. 2 H 7 2 4T 4 T RT A13NM E20NE 1996112700016 19961127 00016 NE 1996 11 27 CA960513003 2 19960319 G 7310 FUEL LINE MAIN DHAV DHC8 DHC8102 2809003 NM PWA PW121 PW121 52124 NE FLOW DIVIDER LOOSE W A UNSCHED LANDING Y K ENGINE STOPPAGE FLUID LOSS TO TAKEOFF 1 CA 11162 6155 120312 (CAN)ON TAKEOFF, THE ENGINE SPOOLED DOWN AND THE AIRCRAFT RETURNED TO THE GATE. POST FLIGHT INSPECTION FOUND FUEL SPILL ON THE COWLINGS. THE NUT FROM THE MAIN FUEL LINE TO THE FLOW DIVIDER HAD LOOSENED. 2 H 7 2 4T 4 T RT A13NM E20NE 1996112700018 19961127 00018 EA 1996 11 27 CA960513005 2 19960403 G 7250 BLADE BEECH 200 B200 1152922 CE PWA PT6 PT6A41 52043 EA COMP TURBINE FRACTURED W A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 4629 1742 81501 (CAN)ENGINE SHUTDOWN FOLLOWING AN INCREASE IN ITT. AS THE POWER LEVER WAS BEING RETARDED, DRBRIS WAS SEEN TO BE COMING F ROM THE EXHAUST. INITIAL REPORT INDICATE THIS TO BE A COMPRESSOR TURBINE BLADE FRACTU RE. 1 L 7 2 4T 4 T A24CE E4EA 1996112700045 19961127 00045 NE 1996 11 27 CA960521002 2 19960511 G 7313 FUEL NOZZLES PWA PWA120 PW125B NE NR 1 ENG LEAKING SEAL W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 8123 125093 (CAN)PRIOR TO DEPARTURE, FUEL LEAKAGE WAS DETECTED FROM FUEL NOZZLES ON #1 ENGINE. TWO FUEL NOZZLES AND THE FLOW DIVIDER REPLACED. AFTER NEXT FLIGHT, FUEL WAS AGAIN LEAKING. ONE MORE FUEL NOZZLE REPLACED. 4 T E20NE 1996112700046 19961127 00046 NE 1996 11 27 CA960521003 2 19960515 G 7261 TRANSFER TUBE DHAV DHC8 DHC8101 2809002 NM PWA 120 PW120A NE #6 & #7 BEARINGS FRACTURED W A A E UNSCHED LANDING ENGINE SHUTDOWN K FLUID LOSS CR CRUISE 1 CA 17989 13194 120399 (CAN)IN CRUISE AT 9K, #1 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED. ENGINE SHUT DOWN. INSPECTION REVEALED THE OIL TRANSF ER TUBE FEEDING THE #6 & #7 BEARINGS WAS FRACTURED. A TEMPORARY OIL LINE WAS FITTED A ND A DRY MOTORING RUN WAS ATTEMPTE D PRODUCING LOUD NOISE FROM THE ENGINE. FURTHER INSPECTION SHOWED LARGE QUANTITY OF METAL ON THE CHIP DETECTOR. 2 H 7 2 4T 4 T RT A13NM E20NE 1996112700049 19961127 00049 NE 1996 11 27 CA960521006 2 19960510 G 7230 COMPRESSOR PWA PT6 PT6A60A 52043 NE NR 1 ENG DAMAGED W A E UNSCHED LANDING ENGINE SHUTDOWN R B PARTIAL RPM/PWR LOSS SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 CA 1805 95083 (CAN)DURING DESCENT, LARGE TORQUE FLUCTUATIONS ON #1 ENGINE ACCOMPANIED BY FLAMES FROM THE EXHAUST AND SMOKE IN THE CABI N. ENGINE SECURED AND LANDED OK. LARGE AMOUNT OF OIL IN THE EXHAUST AREA AND SIGNIFIC ANT DAMAGE IN THE COMPRESSOR AREA. 4 T E4EA 1996112700051 19961127 00051 EA 1996 11 27 CA960521008 2 19960509 G 7250 GAS GENERATOR BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA NR 2 ENG SEIZED W A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 13571 6197 32481 (CAN)IN CRUISE, #2 ENGINE STOPPED SUDDENLY WITH NO WARNING OF UNUSUAL ENGINE PARAMETERS. RETURNED TO ALBUQUERQUE WITHOUT INCIDENT. INSPECTION REVEALED THE GAS GENERATOR SECTION SEIZED AND METAL CONTAMINATI ON OF THE OIL FILTER. THE POWER TU RBINE ROTATES FREELY. 2 L 7 2 4T 4 T RT A24CE E4EA 1996112700052 19961127 00052 CE 1996 11 27 CA960521009 1 19960508 G 7810 EXHAUST DUCT BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA NR 1 ENG CRACKED W A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 13550 6296 32512 (CAN)DURING CRUISE, A LOUD BANG WAS HEARD AND THE #1 ENGINE AUTOFEATHERED. ENGINE SECURED AND LANDED OK. A 6 INCH CRACK FOUND IN THE BIFURCATED EXHAUST DUCT AT THE 9 O'CLOCK POSITION. 2 L 7 2 4T 4 T RT A24CE E4EA 1996112700053 19961127 00053 NE 1996 11 27 CA960521010 2 19960509 G 7250 BLADE PWA PWA PT6 PT6A25 52043 NE POWER TURBINE FRACTURED W A E UNSCHED LANDING ENGINE SHUTDOWN Y ENGINE STOPPAGE AB AEROBATIC 1 CA 5199 48076 (CAN)FOLLOWING A STALL EXERCISE DURING FLIGHT TRAINING, ON POWER APPLICATION, THERE WAS AN EXPLOSION FROM THE ENGINE. EN GINE WAS SECURED AND A LANDING MADE. AFTER ENGINE SPLIT AT THE "C" FLANGE, A FRACTURE D POWER TURBINE BLADE WAS EVIDENT. 3 T E4EA 1996112700074 19961127 00074 1996 11 27 CA960524014 4 19960516 G 3416 40416410020 DIAPHRAGM 1122343 DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA ALTIMETER DEFECTIVE W K NONE I FLT. ATTITUDE INST. TX TAXI/GRND HDL 1 CA EGH2390 PCE42076 (CAN) DURING TAXI AND GROUND OPERATION THE ALTIMETER WOULD SHOW A DISCREPANCY TO AIRPORT ALTITUDE. INSTRUMENT REPLACED A ND SHOP CHECK FOUND FAULT WITH THE DIAPHRAGM. 1 H 7 2 3T 4 T A9EA E4EA 1996112700086 19961127 00086 EA 1996 11 27 CA960527005 2 19960517 G 7414 10391586 DISTRIBUTOR BLOC BENDIX 103492901 PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA ENG MAG WORN BUSHING W K NONE O OTHER IN INSP/MAINT 1 CA 13 1015567 L313361A (CAN)DISTRIBUTOR BUSHING WORN AT A VERY RAPID RATE UNTIL DISTRIBUTOR GEAR ARM BEGAN INTERFERING AGAINST DISTRIBUTOR BLOC K CONTACTS. 1 L 7 2 3O 3 O A20SO E14EA 1996112700087 19961127 00087 SW 1996 11 27 CA960527006 1 19960415 G 5711 SPAR BBAVIA 7 7BCM 2110106 SW CONT C85 C8512F 17008 SO REAR SPAR ROOT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 102725R (CAN)ON INSPECTION THE REAR SPAR WAS FOUND FAILED (CRACKED) AT THE RIGHT HAND REAR SPAR ROOT END BISCUIT. IT WAS NOTED T O HAVE FAILED ACROSS THE TOP AT THE SECTION OF THE SPAR THAT IS MILLED OUT TO ACCOMMODATE THE BISCUIT DOUBLERS. SUBMITTE R STATES THAT THE AIRCRAFT WAS BUILT IN 1947 AND THAT THE SPAR APPEARS TO BE ORIGINAL. 1 H 7 1 3O 3 O A759 E233 1996112700250 19961127 00250 SO 1996 11 27 96ZZZX5628 2 19961028 G 8530 653453 VALVE SEAT CONT O520 GTSIO520* 17032 SO INT VALVE MISINSTALLED B VA1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 19 613067 CYLINDER INTAKE SEAT NOT SEATED INTO MACHINED PORTION OF CYLINDER HEAD ALL THE WAY IN. UPON INSTALLATION AT FACTORY, NO T TAPPED IN COMPLETELY OR SEATED TO MACHINED HOLE. SUBMITTER STATES ALWAYS INSPECT NEW CYLINDERS FOR CORRECT SEATING OF VALVE SEAT INTO CYLINDERS. 3 O E7CE 1996112700251 19961127 00251 SO 1996 11 27 96ZZZX5629 2 19961028 G 8530 653445 VALVE SEAT CONT O520 TSIO520* 17040 SO EXH VALVE MISINSTALLED B VA1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 19 519648 CYLINDER EXHAUST SEAT NOT SEATED INTO MACHINED PORTION OF CYLINDER HEAD ALL THE WAY IN. SUSPECT CAUSE: UPON INSTALLATI ON AT FACTORY, SEATS ARE NOT TAPPED IN, BUT DROPPED IN ASSUMING INSTALLED. SUBMITTER STATED ALWAYS INSPECT NEW CYLINDER S FOR GOOD SEATING OF SEAT INTO CYLINDER. 3 O E8CE 1996112700272 19961127 00272 EA 1996 11 27 96ZZZX5650 2 19961029 G 8530 LW12416 VALVE CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA NR 3 CYL EXH STUCK H K NONE E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 SO 17 52276 5091 602 17274476 L1376139A NR 3 CYLINDER EXHAUST VALVE STUCK, AND BENT PUSH ROD AND PUSH ROD HOUSING. THIS CAUSED ROUGH ENGINE AND AN OIL LEAK. C YLINDER WAS REPLACED WITH OVERHAULED UNIT. 1 H 7 1 3O 3 O NT 3A12 E274 1996112700281 19961127 00281 SO 1996 11 27 96ZZZX5659 2 19961101 G 8550 646253 ADAPTER ASSY CESSNA 172 R172K 2072431 CE CONT O360 IO360KB 17025 SO OIL FILTER WORN B S G9NR K NONE O OTHER IN INSP/MAINT 1 EA 07 758RV 365 R1723308 288547R BYPASS PLUG CAME OUT OF HOUSING. FOUND WORN PLUG AND DAMAGED HOUSING. PLUG IS STAKED IN IF BYPASS VALVE IS NOT USED. F OUND METAL IN OIL FILTER AT PREVIOUS OIL CHANGE 10 HRS PRIOR AND AT THIS OIL CHANGE. SUBMITTER STATED MFG NEEDS BETTER WAY TO SECURE PLUG. 1 H 7 1 3O 3 O 3A17 E1CE 1996112700520 19961127 00520 SO 1996 11 27 96ZZZX5713 2 19961030 G 7314 6493682 PUMP PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO ENG FUEL FAILED B APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 8407C 443 K139506BR 347670137 265901R ENGINE DRIVEN FUEL PUMP DEVELOPED EXCESSIVE OUTPUT. (HIGH PRESSURE) FOUND FUEL IN DECK REFERENCE LINE, INDICATING INTER NAL LEAKAGE. 1 L 7 2 3O 3 O A7SO E9CE 1996112700529 19961127 00529 SO 1996 11 27 96ZZZX5722 2 19961107 G 8530 653426A13 CYLINDER CESSNA 172 172 2072402 CE CONT O300 O300A 17022 SO EXH GUIDE EXCESS WEAR D L K NONE O OTHER IN INSP/MAINT 1 SW 99 14 THIS FACILITY INSTALLED SIX CYL ASSEMBLIES PREASSEMBLED BY TCM ON AN O300A ENGINE (CESSNA 172). ENGINE WAS OPERATED ON 80/87 AVIATION FUEL AND AEROSHELL 80 MINERAL OIL. AFTER 14 HOURS TOTAL TIME IN SERVICE (TWO MONTHS ELAPSED TIME) LOW CO MPRESSION WAS EXPERIENCED ON THREE CYLINDERS. FURTHER EXAMINATION REVEALED EXHAUST GUIDES WORN BEYOND LIMITS IN ALL SIX CYLINDERS. .007L TO APPROXIMATELY .014L AT THE COMBUSTION END. 1 H 7 1 3O 3 O NT 3A12 E253 1996112700535 19961127 00535 EA 1996 11 27 96ZZZX5728 2 19961025 G 7414 10382585 CONTACT POINTS ELECTROSYS LW685124 MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA MAG FAILED D A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CE 05 1163Z 2361 3012013 241285 L1412151A ENGINE QUIT DURING ROUTINE FLIGHT. REMOVED MAGNETO AFTER FORCED LANDING. FOUND CONTACT POINTS PITTED AN CAM FOLLOWERS WORN OUT TO THE POINT THAT THEY WOULD NO LONGER OPEN THE CONTACTS. SUBMITTER STATED MAGNETOS SHOULD BE INSPECTED ON 500 -HOUR INTERVALS AND POINTS SHOULD BE REPLACED ON CONDITION DURING THESE INSPECTIONS. THE POINTS IN THIS MAG HAD A T.I.S . OF 2361.0 HRS. 1 L 7 1 3O 3 O 2A3 1E10 1996112700540 19961127 00540 NE 1996 11 27 96ZZZX5733 2 19961011 G 7250 775404 BLADE PWA JT8 JT8D217A 52053 NE TURBINE T4 FAILED H K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 05 708485 ENGINE WAS REMOVED FROM SERVICE DUE TO LOST POWER, LOW SPEED AND TURBINE DAMAGE. THE ENGINE WAS DISASSEMBLED TO DETERMI NE CAUSE OF THE TURBINE DAMAGE. ONE T4 BLADE HAD FRACTURED IN HIGH CYCLE FATIGUE CAUSING MASSIVE TURBINE DAMAGE. THE F AILURE IS STILL UNDER INVESTIGATION AT GREENWICH, TX. 4 F E9NE 1996112700546 19961127 00546 NE 1996 11 27 96ZZZX5739 2 19961017 G 7320 5225742 VALVE WOODWARD 8061531 GE CFM56 CFM565A 13802 NE HMU MISMANUFACTURED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 03 1119 WOODWARD HMU WAS RECENTLY RETURNED FROM SINGAPORE AIRLINES DUE TO A REPORTED COMPLAINT OF 'HP FUEL VALVE DID NOT OPEN DU RING ENG START'. THE SUBSEQUENT INVESTIGATION REVEALED THAT THE FUNCTIONAL OBSERVATION WAS THE RESULT OF AN IMPROPERLY MACHINED PART. P/N 5225-742 FEATURES A THRUST BEARING DIAMETER WHICH EXTENDS TO AN ADJACENT SHOULDER (RELIEF GROOVE). T HE SHOULDER POSITIONS THE BEARING AND WITHSTANDS THE OPERATING THRUST LOADS. IN THE CASE OF THE IMPROPERLY MACHINED PAR T, THE BEARING DIAMETER WAS THE PROPER SIZE BUT DID NOT FULLY EXTEND INTO A GRINDING RELIEF GROOVE. 4 F E29NE 1996120500022 19961205 00022 SW 1996 12 5 96ZZZX5769 1 19960823 G 7331 912042T38D METER BELL 222 222 1182122 SW LYC LTS101 LTS101750C1 41560 NE FUEL FLOW MALFUNCTION B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911LW 78 1252 47520 FUEL FLOW METER WILL NOT COMPLETE SELF-TEST. FAILED AFTER ONLY 77.8 HRS INSTALLED. 1 G 7 2 3U 3 U H9SW E5NE 1996120500224 19961205 00224 GL 1996 12 5 HEEA968536 2 19961121 G 7230 6851574 SCROLL ASSY ALLSN 250C 250C20B 03013 GL ENGINE MIS REPAIRED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: REPAIR TO SCROLL ASSEMBLY ANTI-ICE PORT NOT FULLY WELDED AS MARKED AND DIMENSION FROM AN TI-ICE PORT TO SPLIT LINE MEASURES .080 ABOVE BLUE PRINT SPECS (2.225) 3 U E4CE 1996120500320 19961205 00320 SO 1996 12 5 96ZZZX5803 2 19961018 G 8550 538937 TUBE BEECH 35 K35 1151524 CE CONT O470 IO470C 17026 SO OIL SUMP BROKEN D S K NONE O OTHER IN INSP/MAINT 1 GL 19 192AA 4306 D5964 716589C DISASSEMBLING ENG FOR OVERHAUL FOUND THE OIL SUCTION TUBE WAS BROKEN IN 2 PLACES. TUBE WAS BROKE OFF FROM SCREEN AND ON E OF THE ATTACHING ANGLES WAS BROKEN BY BOLT HOLE. TT ENG 4306.44. SMOH 1448.84. 1 L 7 1 3O 3 O 3A15 E273 1996120500324 19961205 00324 EA 1996 12 5 96ZZZX5807 2 19961024 G 7310 60100030092 HOSE CESSNA 177 177B 2073708 CE LYC O360 O360A1F6 41514 EA ENG FUEL LEAKING B BXSR K NONE K FLUID LOSS IN INSP/MAINT 1 EA 09 34933 17702099 PILOT REPORTED A FUEL LEAK FROM THE ENGINE COMPARTMENT. FOUND THE FUEL PRESSURE HOSE LEAKING. THIS PROBLEM HAS BEEN AD DRESSED BY AEROQUIP SB AA135. THIS HOSE WAS DATED 2Q86. ALTERNATE P/N FROM CESSNA: S1236-3-0092. 1 H 7 1 3O 3 O A13CE E286 1996120500325 19961205 00325 EA 1996 12 5 96ZZZX5808 2 19961004 G 7414 M3215 CARBON BRUSH SLICK 6393 PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA ENG MAG EXCESS WORN D K NONE O OTHER IN INSP/MAINT 1 EA 05 415CC 336 91110003 273908 RL1063248 OWNER REPORTED EXCESSVIE MAG DROP INTERMITTENTLY RIGHT ENG LEFT MAG. NOTICED EXCESSIVE CARBON DUST AROUND MAG VENT. PUL LED MAG AND OPENED UP EVERYTHING COATED WITH CARBON DUST. SUBMITTER STATED BRUSH WORN TOO QUICKLY. MANUFACTURE BRUSH F ROM HARDER SUBSTANCE. 1 L 7 2 3O 3 O 1A10 1E4 1996120500326 19961205 00326 SO 1996 12 5 96ZZZX5809 2 19961106 G 7310 646425 LINE PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO NR 5 CYL INJ BROKE G K NONE O OTHER IN INSP/MAINT 1 GL 19 4323D 3475 1884 468408018 528375 NR 5 CYLINDER FUEL INJECTOR LINE BROKE. SUBMITTER RECOMMENDS DIFFERENT TYPE CLAMPING SYSTEM BE USED ON THESE FUEL INJEC TION LINES. CURRENT SYSTEM ALLOWS FOR ALOT OF VIBRATION. 1 L 7 1 3O 3 O A25SO E8CE 1996120500336 19961205 00336 SO 1996 12 5 96ZZZX5819 2 19961105 G 8530 630046 PISTON PIN PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO NR 4 CYL BROKEN G K NONE O OTHER IN INSP/MAINT 1 GL 19 9133G 808 4608111 528427 REMOVED NR 4 CYLINDER FOR MAINTENANCE FOUND PISTON PIN INTERNAL PIN BROKEN. INSTALLED NEW P/N 630046 PIN ASSY WITH EXCH ANGE CYLINDER ASSY. 1 L 7 1 3O 3 O A25SO E8CE 1996120500345 19961205 00345 GL 1996 12 5 96ZZZX5828 2 19960925 G 7200 ENGINE CESSNA 525 525 2076601 CE WILINT FJ44 FJ44 66000 GL M50 BEARING MAKING METAL B MUCR K NONE O OTHER IN INSP/MAINT 1 GL 13 525FS 5250026 1022 ROUTINE OIL ANALYSIS REVEALED SMALL SHINY PLATELETS OF M-50 BEARING MATERIAL. ENGINE MANUFACTURER ADVISES ENGINE IS TO BE REMOVED FOR TEAR DOWN EVALUATION. 1 L 7 2 4F 4 F RT A1WI E3GL 1996120500355 19961205 00355 EA 1996 12 5 96ZZZX5838 2 19961111 G 8520 78290 PLUNGER ASSY PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA NR 1 CYL EXH LIFTER BROKEN B P3NR O OTHER K FLUID LOSS NR NOT REPORTED 1 EA 13 27236 1097 317752111 L249268A PILOT NOTICED OIL COMING FROM COWLING. INVESTIGATION REVEALED NR 1 CYLINDER EXHAUST VALVE TRAIN FAILURE, PUSH ROD BENT, AND HYDRAULIC LIFTER BROKEN. CAUSE UNKNOWN. EXHAUST VALVE TO GUIDE CLEARANCE OKAY. 1 L 7 2 3O 3 O A20SO E14EA 1996120500356 19961205 00356 GL 1996 12 5 96ZZZX5839 2 19961113 G 7210 6705924 OIL PLUG 6854702 CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL COMP DRV ASSY DETACHED G K NONE O OTHER IN INSP/MAINT 1 EA 25 49 866 479 501422 AS PART OF TROUBLESHOOTING FOR AN ENGINE OIL QUANTITY PROBLEM, OIL PLUG, WAS FOUND MISSING FROM THE ENGINE DRIVEN COMPRE SSOR DRIVE ASSEMBLY. ALLISON P/N 6854702. OIL PLUG WAS RETRIEVED FROM THE REDUCTION GEARBOX LOW POINT DRAIN. OIL PLUG IS PRESS-FIT INTO DRIVE ASSEMBLY SHAFT AT MANUFACTURE, AND SEPARATED FROM SHAFT FOR UNKOWN REASONS. REDUCTION GEARBOX SPLIT, INSPECTED, REPAIRED AND RETURNED TO SERVICE. ENGINE TSO 865.8. 2 L 7 2 4R 4 T 6A6 E282 1996120500360 19961205 00360 EA 1996 12 5 CA960529007 1 19960524 G 2422 MS250242 RELAY DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA #1 INVERTER INTERMITTENT W K NONE J WARNING INDICATION NR NOT REPORTED 1 CA PCE42076 (CAN) #1 INVERTER INDICATED A FAILURE UNTIL THE SELECTOR SWITCH WAS CYCLED AND THE PROBLEM CLEARED. MAINTENANCE CHANGED THE INVERTER SELECTOR RELAY. 1 H 7 2 3T 4 T A9EA E4EA 1996120500366 19961205 00366 CE 1996 12 5 CA960530002 1 19960401 G 2434 PU1605 FAN PRESTOLITE ALE8105A BEECH 23 A2319 1151212 CE LYC O320 O320E2C 41508 EA SNSNCH 74DM M74DM EA ALTERNATOR BROKEN W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA 1878 L1759327A K3029 (CAN)PILOT HEARD LOUD BANG FOLLOWED BY AMMETER SHOWING DISCHARGE. ALTERNATOR SEPARATED FROM ENGINE. HOUSING MOUNTING LUG S BROKEN OFF BY VIBRATION DUE TO IMBALANCE FOLLOWING A PORTION OF THE FAN BREAKING OF F. 1 L 7 1 3O 3 O A1CE E274 5 N P88614 1996120500367 19961205 00367 EA 1996 12 5 CA960604002 2 19960517 G 7414 9050365 BEARING CAP ASSY SLICK 4250 PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA MAG ROTOR SHAFT FAILED W D RETURN TO BLOCK E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA 9050365 L2739436A (CAN)ENGINE ROUGH ON RUN UP. MAGNETO SEPARATED FROM ENGINE AND HANGING FROM HARNESS. MAGNETO SEIZED AND MOUNTING FLANGE FRACTURED. ROTOR SHAFT SEIZED DUE TO BEARING FAILURE ENSUING FROM OUTER RACE OF BEARING SPINNING WITHIN THE BEARING CAP ASSEMBLY. BEARING CAP ASSEMBLY LACKED THE "J" MARKING SEPCIFIED IN SB 2-88A ALTHOUGH THIS MAGNETO FALLS INTO THE SERIAL NUMBER RANGE FOR THE SB. 1 L 7 1 3O 3 O 2A13 E286 1996120500368 19961205 00368 SO 1996 12 5 CA960604003 2 19960524 G 8530 CYLINDER CESSNA 337 337G 2075730 CE CONT O360 IO360G 17025 SO MCAULY 2AF34C D2AF34C306 GL ENGINE NOT FIRING W E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS CR CRUISE 1 CA 155 352839 793546 (CAN)IN CRUISE AT 9.5K, ENGINE RAN ROUGH AND BACKFIRED, SHUTDOWN. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 1996120500386 19961205 00386 SO 1996 12 5 CA960606004 2 19960517 G 8530 VALVE GUIDE CONT CESSNA 182 182 2072702 CE CONT O470 O470L 17026 SO MCAULY 2A34C 2A34C50 GL EXHAUST VALVE LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA 513 693105LR 731568 (CAN)ON 100 HOUR INSPECTION, LOW COMPRESSION IN CYLINDER. EXHAUST VALVE GUIDE LOOSE IN CYLINDER HEAD. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1996120500390 19961205 00390 SW 1996 12 5 CA960610004 1 19960520 G 7120 162301 RUBBER BUSHING LORD BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA ENG MOUNT DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 CA 474 L1967536A (CAN)ON ANNUAL INSPECTION, THE LOWER RIGHT ENGINE MOUNT RUBBER BUSHING FOUND SEVERELY DETERIORATED. THIS MOUNT IS DIRECT LY BELOW THE OIL FILLER TUBE AND IS SUSCEPTIBLE TO OIL SPILLAGE. 1 H 7 1 3O 3 O A21CE E286 1996121000001 19961210 00001 NE 1996 12 10 CA960507010 2 19960409 G 7261 LA153 PUMP LYC 218324001 CNDAIR CL600 CL600* EA LYC ALF502 ALF502L2 41580 NE PIN HOLE IN CASE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA LA153 LF030363S (CAN)OIL FOUND IN COWLING AND ON GROUND . OIL PUMP HAD A PINHOLE IN THE CASING, VERIFIED BY EDDY CURRENT INSPECTION 2 L 7 2 4F 4 F RT A21EA E6NE 1996121000002 19961210 00002 1996 12 10 CA960513006 1 19960321 G 7712 TRANSDUCER PWA PT6 PT6A6 52043 EA ENG TORQUE FAILED W C D ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 CA 1681 103172 (CAN)ON TAKEOFF, TORQUE INDICATION DECAYED THROUGH 60 PSI FROM 68 PSI. POWER REDUCTION WAS ALSO AUDIBLE. THE ELECTRONIC LIMITER UNIT WARNING LIGHT ILLUMINATED AND THE CREW ISOLATED THE ELECTRONIC LIMITER S YSTEM. POST EVENT DOWNLOAD OF THE ELU REVEALED A FAULT CODE RELATING TO TORQUE PRESSURE. TORQUE TRANSDUCER REPLACED. 3 T E4EA 1996121200069 19961212 00069 GL 1996 12 12 96ZZZX5874 2 19961017 G 7250 68777362 STATOR SEAL ALLSN 250B 250B17 03012 GL GAS PROD AFT CRACKED B YKER K NONE O OTHER IN INSP/MAINT 1 EA 17 CAE870101 DURING PARTIAL DISASSEMBLY OF TURBINE TO REPLACE THE FIRST STAGE NOZZLE, FOUND CRACKS IN BEARING BORE AREA OF SEAL. UPO N REMOVAL OF SEAL, NOTICED FRETTING ON OUTER DIAMETER. SUSPECT IMPROPER FIT OF SEAL IN SUPPORT. 3 T E10CE 1996121200070 19961212 00070 EA 1996 12 12 96ZZZX5875 2 19961113 G 8540 75288 DRIVE ASSY CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA ASSORY CASE DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 19956 17260886 L3181427A WHILE C/W AD 960910C, IT WAS DISCOVERED AD 75-8-9R3 HAD NOT BEEN C/W. (REQUIRED REPLACEMENT OF DRIVE ASSY 75288 WITH DR IVE ASSY PN 61174) A CHECK OF AD 75-8-9R3 AND RELATED SB. ENG S/N WAS NOT LISTED. AD APPLICABLE TO S/N 33229-27A TO 41 054-27A. NO RECORD OF ENG OVH OR ANY MAINT ON OIL PUMP GEARS. ENG TOTAL TIME 625. 1 H 7 1 3O 3 O NT 3A12 E274 1996121200071 19961212 00071 EA 1996 12 12 96ZZZX5876 2 19961112 G 8550 06B21326 GASKET 06B21326 CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA OIL SUMP DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 EA 07 3626C 431 R18200284 L1983640A OIL SUMP GASKET DETERIORATED AND TURNED TO MUSH LIKE SUBSTANCE CAUSIING GASKET INGESTION AND LOSS OF GASKET SEAL AT OIL PICK UP GALLEY CAUSING LOW OIL PRESSURE. OIL PUMP CAVITATED AND SUCKED AIR INSTEAD OF OIL. 1 H 7 1 3O 3 O RT 3A13 E295 1996121200082 19961212 00082 GL 1996 12 12 96ZZZX5887 2 19961001 G 7260 6854424 SEAL 6886442 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL START/GEN MT PAD FAILED D A UNSCHED LANDING J K WARNING INDICATION FLUID LOSS CR CRUISE 1 WP 09 268ST 2 AG35540 470122D CAE830599 DURING NORMAL CRUISE FLIGHT, PILOT NOTICED A LOW TORQUE PRESSURE INDICATION, FURTHER EXAMINATION OF ENGINE INSTRUMENTS R EVEALED ENGINE OIL PRESSURE STEADILY DROPPING. PILOT PROCEEDED TO IMMEDIATELY LAND HELICOPTER. AFTER AIRCRAFT WAS SHUT DOWN PILOT FOUND OIL LEAK IN ENGINE AREA AT THE ENGINE GEARBOX STARTER GENERATOR MOUNT PAD. WHEN STARTER GENERATOR WAS REMOVED, THE P/N 6854424 SEAL WAS LAYING ON THE STARTER GENERATOR SPLINED SHAFT. FURTHER INVESTIGATION OF THE FAILED S EAL REVEALED THAT THE OUTER DIAMETER OF SEAL WAS SMALLER THAN THREE OTHER SAME P/N SEALS INCLUDING ANOTHER PREVIOUSLY IN STALLED SEAL. SEAL TOTAL TIME WAS 1.5 HOURS. 1 G 7 1 3U 3 U H3WE E4CE 1996121200084 19961212 00084 SO 1996 12 12 96ZZZX5889 2 19961125 G 8530 539467 PISTON PIN CONT O470 IO470D 17026 SO ENG CYL MISMFG D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 BOUGHT 6 EACH 539467 PISTON PINS. 4 OF THEM WERE WAY TOO LONG. 2 OF THEM WERE CORRECT. RETURNED AND FOUND OUT ALL OF THEM IN STOCK THAT WERE LONG HAD HG CODE ON THE BOX. THE ONES WITH DG AND JG CODES WERE THE CORRECT LENGTH. 3 O 3E1 1996121200085 19961212 00085 CE 1996 12 12 96ZZZX5890 1 19961101 G 5510 07321014 REINFORCEMENT 12320008 CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO HORIZ STAB CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 NE 01 9F 4283 18502855 282576R AT 50 HR INSP, NOTICED REINFORCEMENT CRACKED AT BOTTOM FLANGE WHERE HINGE BOLTS TO STABILIZER. INSTALLED NEW REINFORCEM ENT FROM CESSNA. SUBMITTER STATED HINGE BOLTS WERE NOT LOOSE, SO CRACK MUST HAVE OCCURRED DUE TO FATIGUE. 1 H 7 1 3O 3 O 3A24 E5CE 1996121200094 19961212 00094 SO 1996 12 12 96ZZZX5899 2 19961120 G 8530 625432A2 CYLINDER BEECH 45 D45 1152012 CE CONT O470 O4704 17026 SO NR 4 RKR BOSS CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 07 111JH 237 BG392 116049 INSP FOUND ALL FOUR ROCKER BOSSES CRACKED OFF CYLINDER. 1 L 7 1 3O 3 O 5A3 E269 1996121200096 19961212 00096 EA 1996 12 12 96ZZZX5901 2 19961119 G 8520 75359 DOWEL 75670 PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA CRANKSHAFT LOOSE B EKIR K NONE O OTHER IN INSP/MAINT 1 WP 07 18MC 3235 99 31P7300143 2L48862 FOUND DOWEL FOR CRANKSHAFT SPLINE BUSHING IN SUMP AT OIL SCREEN. UPON TEAR DOWN FOUND ONLY 1 OF 3 DOWELS STILL IN CRANK SHAFT. BUSHING WAS STARTING TO TWIST IN BETWEEN CRANKSHAFT AND SPLINE BUSHING. NO OTHER INDICATION OF PROBLEMS. ENGIN E RAN GOOD, FILTER WAS CLEAR. 1 L 7 2 3O 3 O A8EA E19EA 1996121200211 19961212 00211 NE 1996 12 12 CA960612026 2 19960118 G 7210 310703301 BEARING AEROSP ATR42 ATR42* 8680900 EU PWA 120 PW120 NE RGB NR 15 BRG SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 10431 121018 (CAN)METAL ON THE RGB CHIP DETECTOR. #15 BEARING SPALLED SEVERELY. SMALL AMOUNT OF RESIDUAL MAGNETISM DETECTED ON PROPEL LER SHAFT AND #18 AND #19 BEARING RACES. 2 H 7 2 4T 4 T RT A53EU E20NE 1996121200212 19961212 00212 NE 1996 12 12 CA960612027 2 19960118 G 7210 310120201 BEARING EMB 120 EMB120 3260201 SO PWA 118 PW118A NE RGB NR 14 BRG SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 11758 115521 (CAN)METAL ON RGB CHIP DETECTOR. #14 BEARING OUTER RACE SPALLED, ROLLERS FLAKING AND CAGE CRACKED. 2 L 7 2 4T 4 T RT A31SO E20NE 1996121200213 19961212 00213 NE 1996 12 12 CA960612028 2 19960130 G 7210 310406201 BEARING AEROSP ATR42 ATR42* 8680900 EU PWA PW121 PW121 52124 NE RGB NR 18 BRG SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 12880 1125 120460 (CAN)METAL ON THE RGB CHIP DETECTOR. #18 BEARING BALLS SPALLED. ELECTRICAL PITTING FOUND ON #15 AND #19 BEARINGS ON IDLE R DRIVE, THEREFORE THE SPALLING ON THE #18 BEARING IS LIKELY DUE TO ELECTRICAL DISCHA RGE FROM AN EXTERNAL AIRCRAFT SOUR CE. 2 H 7 2 4T 4 T RT A53EU E20NE 1996121200216 19961212 00216 NE 1996 12 12 CA960612031 2 19960108 G 7230 311362301 BEARING EMB 120 EMB120 3260201 SO PWA 118 PW118 NE NR 5 BRG CAGE FRACTURED W A K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 CA 13630 2994 115309 (CAN)ENGINE REPORTED MAKING "GRUMBLING" NOISES. METAL CONTAMINATION OF THE OIL FILTER AND METAL FLAKES ON THE TURBOMACH INE CHIP DETECTOR. #5 BEARING FAILED DUE TO FAILURE OF ONE SEPARATOR OF THE BEARING CA GE ALLOWING ONE ROLLER TO MOVE O UT OF POSITION AND SKIDDING OF THAT ROLLER. NO OBVIOUS REASON FOR THE CAGE FAILURE. THIS BEARING HAD BEEN REPLACED 299 4 HOURS PREVIOUS FOLLOWING A HP STUBSHAFT BOLT FAILURE. 2 L 7 2 4T 4 T RT A31SO E20NE 1996121200244 19961212 00244 NE 1996 12 12 CA960614015 2 19960401 G 7210 310924401 BEARING PWA AEROSP ATR42 ATR42* 8680900 EU PWA 120 PW120 NE RGB NR 15 BR SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 14134 5708 120661 120661 (CAN)REDUCTION GEAR BOX REPORTED MAKING METAL. #15 BEARING HAD SEVERE SPALLING ON THE ROLLERS AND OUTER RACE. 2 H 7 2 4T 4 T RT A53EU E20NE 1996121200245 19961212 00245 NE 1996 12 12 CA960614016 2 19960404 G 7210 310703301 BEARING PWA AEROSP ATR42 ATR42* 8680900 EU PWA PW121 PW121 52124 NE RGB NR 15 BRG SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 6812 121140 121140 (CAN)METAL ON THE REDUCTION GEAR BOX CHIP DETECTOR. #15 BEARING INNER RACE SPALLED. ELECTRICAL DISCHARGE PITTING ON #15 ROLLERS AND #18 BEARING LIKELY FROM STRAY ELECTRICAL DISCHARGE FROM SOME AIRCRAFT COM PONENT. 2 H 7 2 4T 4 T RT A53EU E20NE 1996121200246 19961212 00246 NE 1996 12 12 CA960614017 2 19960409 G 7210 310119101 BEARING PWA DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE RGB NR 10 BRG SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 17032 120417 120417 (CAN)REDUCTION GEAR BOX MAKING METAL. LEFT HAND #10 BEARING, ONE BALL SPALLED. REMAINING OIL IN THE GEARBOX WAS VERY DIR TY AND FOUND TO CONTAIN HIGH LEVELS OF PHOSPHORUS AND VANADIUM. SEVERAL OTHER BEARING S HAD PITS AND DISCOLORATION SIMIL AR TO CORROSION THAT MAY BE RELATED TO THE CONTAMINATED OIL. 2 H 7 2 4T 4 T RT A13NM E20NE 1996121200248 19961212 00248 NE 1996 12 12 CA960614019 2 19960530 G 7210 310709001 BEARING PWA EMB 120 EMB120 3260201 SO PWA 118 PW118 NE RGB NR 19 BRG CRACKED W A K NONE O OTHER IN INSP/MAINT 1 CA 14724 8138 115151 115151 (CAN)REDUCTION GEAR BOX CONTAMINATED WITH METAL. #19 BEARING INNER RACE CRACKED. 2 L 7 2 4T 4 T RT A31SO E20NE 1996121200249 19961212 00249 NE 1996 12 12 CA960614020 2 19960205 G 7210 310703301 BEARING PWA DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE RGB NR 15 BRG SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 9266 121064 121064 (CAN)REDUCTION GEARBOX METAL CONTAMINATION. #15 BEARING HAD A LARGE SPALL OVER 60 DEGREES OF THE OUTER RACE. SEVERAL STE EL COMPONENTS WERE HEAVILY MAGNETISED AND #18 AND #19 BEARINGS SHOWING SIGNS OF ELECT RICAL PITTING LEADING TO BELIEVE T HAT LIGHTNING STRIKE IS LIKELY THE CAUSE OF THE BEARING FAILURE. 2 H 7 2 4T 4 T RT A13NM E20NE 1996121200250 19961212 00250 NE 1996 12 12 CA960614021 2 19960308 G 7210 310924401 BEARING PWA AEROSP ATR42 ATR42* 8680900 EU PWA 120 PW120 NE RGB NR 15 BRG SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 7573 121172 121172 (CAN)REDUCTION GEARBOX METAL CONTAMINATION. #15 BEARING SUFFERED A MAJOR FAILURE WITH SPALLING ON THE ROLLERS AND THE OU TER RACE. NOTE: ENGINE LOGS INDICATE THAT M50 BEARING MATERIAL PLATELETS WERE DISCOVE RED IN THE RGB 2 MONTHS BEFORE THI S FAILURE BUT NO FURTHER METAL WAS FOUND IN A SAMPLE TAKEN 10 DAYS LATER. 2 H 7 2 4T 4 T RT A53EU E20NE 1996121200251 19961212 00251 NE 1996 12 12 CA960614022 2 19960319 G 7250 MS969611 BOLTS EMB 120 EMB120 3260201 SO PWA 118 PW118 NE INTERSTAGE FLANG BROKEN W A K NONE O OTHER IN INSP/MAINT 1 CA 13584 115244 (CAN)BOLT FOUND LODGED IN POWER TURBINE BLADE ON ROUTINE BORESCOPE INSPECTION. 2 BROKEN BOLTS ON THE INTERSTAGE CASE FLA NGE. SEVERE CORROSION AT ALL BOLT POSITIONS OF THE INTERSTAGE CASE REAR FLANGE. THIS ENGINE WAS PRE SB 21175. 2 L 7 2 4T 4 T RT A31SO E20NE 1996121200252 19961212 00252 NE 1996 12 12 CA960614023 2 19960403 G 7230 311267601 CUP WASHER EMB 120 EMB120 3260201 SO PWA 118 PW118 NE #4 BEARNING UNIT WRONG PART W A K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 13693 115440 (CAN)OPERATOR REPORTED THE ENGINE MAKING A GROWLING NOISE. #4 BEARING FAILED DUE TO THE INSTALLATION OF THE WRONG PART N UMBER RETAINING NUT CUP WASHER. THE CUP WASHER INSTALLED, P/N 3112676-01 IS NOT APPLI CABLE TO THE PW118 AND IS TOO LARG E TO LOCK PROPERLY ON THE IMPELLER ASSEMBLY. 2 L 7 2 4T 4 T RT A31SO E20NE 1996121200253 19961212 00253 NE 1996 12 12 CA960614024 2 19960605 G 7210 311192701 BEARING PWA EMB 120 EMB120 3260201 SO PWA 118 PW118 NE RGB NR 8 BRG SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 13400 3480 115307 115307 (CAN)REPORTED METAL ON THE CHIP DETECTOR. NOS.8, 9 & 15 BEARINGS SPALLED WITH #8 SHOWING THE MOST DAMAGE. THE CAGE OF #8 BEARING WAS BROKEN IN 2 PLACES AND HAD SECTIONS MISSING, SEVERAL ROLLERS WERE SEVERELY WORN. #15 BEARING HAD ELECTRICAL DISCHARGE PITTING WHICH APPEARS DUE TO LIGHTNING STRIKE. 2 L 7 2 4T 4 T RT A31SO E20NE 1996121200261 19961212 00261 SO 1996 12 12 CA960619031 2 19960610 G 8520 633976 COUNTERWEIGHT PL CONT MOONEY M20 M20K 5870220 SW CONT O360 IO360G 17025 SO CRANKSHAFT BROKEN W A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA 875 A574M2 309568 (CAN) THE ENGINE DEVELOPED A SLIGHT VIBRATION INFLIGHT. THE ENGINE OIL PRESSURE & VACUUM SUCTION DROPPED TO ZERO. THE ST ANDBY VACUUM RESTORED SUCTION. THE ENGINE OPERATING TEMPERATURE INCREASED BUT STAYED IN THE GREEN. THE MANIFOLD PRESSURE WAS NORMAL. POST FLIGHT INSPECTION REVEALED THAT A CRANKSHAFT COUNTERWEIGHT PIN RETAINER PLATE HAD FAILED ALLOWING THE PIN TO FALL INTO THE CRANKCASE, THE LOOSE PIN FRACTURED AN INTAKE VALVE PUSH ROD CREATING A REDUCTION IN OIL PRESSURE. T HE VACUUM PUMP SHAFT SHEAR BUSHING ALSO FAILED. NO OBVIOUS CAUSE FOR THE RETAINER PLATE WAS DETERMINED. 1 L 7 1 3O 3 O 2A3 E1CE 1996121200276 19961212 00276 NE 1996 12 12 CA960620029 2 19960605 G 7260 310137101 BEARING EMB 120 EMB120 3260201 SO PWA 118 PW118 NE FUEL PUMP DRIVE SPALLED W A K NONE O OTHER IN INSP/MAINT 1 CA 18800 9823 115070 (CAN) ENGINE METAL CONTAMINATION. FUEL PUMP DRIVE BEARING HEAVILY SPALLED. 2 L 7 2 4T 4 T RT A31SO E20NE 1996121200298 19961212 00298 EA 1996 12 12 CA960703013 1 19960528 G 5312 C2FS533 BULKHEAD DHAV DHAV DHC2 DHC2MK3 2800107 EA PWA PT6 PT6A27 52043 EA AFT FS 228 CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 11071 PCE42145 (CAN) AFT FULL BULKHEAD AT STA. 228 FOUND CRACKED ON BOTH LEFT AND RIGHT SIDES WHERE RUDDER CONTROL RODS PASS THROUGH TH E BULKHEAD. CRACKS RADIATE FROM HOLES 3/32" TO 1/2" TOWARDS THE VERTICAL STAB ATTACHMENT. TWO OTHER AIRCRAFT WERE FOUND WITH SAME CRACKS. 1 H 7 1 3T 4 T A806 E4EA 1996121200319 19961212 00319 NE 1996 12 12 CA960708007 2 19960626 G 7210 310709001 BEARING PWA PWA 118 PW118 NE RGB NR 19 BRG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 115256 (CAN) THE REDUCTION GEARBOX (RGB) WAS SENT FOR INVESTIGATION AND REPAIR BECAUSE THE RGB WAS MAKING METAL. THE CAUSE OF T HE RGB MAKING METAL WAS AN AXIAL CRACK ON THE INNER RACE OF THE #19 BEARING AND THE SPALLING OF THE #18 BEARING INNER RI NG PLAIN HALF. 4 T E20NE 1996121200343 19961212 00343 EA 1996 12 12 CA960722001 2 19960711 G 8530 VALVE SEAT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA #6 CYLINDER DISLODGED W K NONE O OTHER TX TAXI/GRND HDL 1 CA 660 L1449868A (CAN) AFTER LANDING THE PILOT NOTICED THE NR 2 ENGINE WAS RUNNING ROUGH AT IDLE. INVESTIGATION FOUND THERE WAS NO COMPRE SSION ON #6 CYLINDER. AFTER THE CYLINDER WAS REMOVED IT WAS REVEALED THE EXHAUST VALVE SEAT WAS DISLODGED FROM THE CYLIN DER AND HOLDING THE VALVE PARTLY OPEN. 1 L 7 2 3O 3 O A20SO E14EA 1996121200350 19961212 00350 SO 1996 12 12 96ZZZX5946 2 19961119 G 7310 646432 PRIMER LINE PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO TOP OF ENG CRACKED D A K NONE O OTHER IN INSP/MAINT 1 EA 07 4323B 468408009 AIRCRAFT ENGINE HARD TO START AND RUNNING LEAN WITH HIGH TIT READING WHEN FLYING. INSPECTED ENGINE AND FOUND CLAMP P/N 24609 (CONTINENTAL) WAS BROKEN THROUGH AND PRIMER VALVE WAS MOVING AROUND UNSUPPORTED. THIS CAUSED THE PRIMER LINE TO W ORK-HARDEN AND AT THE B-NUT CONNECTION. SUBMITTER STATED THIS CAN CAUSE ENGINE FIRE AT A HOT START CONDITION. 1 L 7 1 3O 3 O A25SO E8CE 1996121200351 19961212 00351 SO 1996 12 12 96ZZZX5947 2 19961120 G 8540 GEAR SHAFT CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO LT START ADAPTER WORN D K NONE O OTHER IN INSP/MAINT 1 SW 03 511LC 310 421B0423 1881017A STARTER ADAPTER SHAFT GEAR WAS REMOVED FOR INSPECTION AND FOUND TO BE WORN BEYOND ACCEPTABLE LIMITS IAW CSB94-4A. 1 L 7 2 3O 3 O A7CE E7CE 1996121200357 19961212 00357 EA 1996 12 12 96ZZZX5953 2 19961111 G 8530 SL134441 PISTON PIN CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA NR 3 CYL BROKEN B PP4R K NONE O OTHER IN INSP/MAINT 1 SO 05 65665 1055 17275810 L1336139A NR 3 CYL HAS BROKEN PISTON PIN. SUSPECT CAUSE - MANUFACTURER'S DEFECT. 1 H 7 1 3O 3 O NT 3A12 E274 1996121200358 19961212 00358 EA 1996 12 12 96ZZZX5954 2 19961023 G 8550 RJ10251 PUMP PIPER PA60 PA60700P 7106023 NM LYC O540 LTIO540U2A 41533 EA OIL SCAV WASHER WORN D K NONE O OTHER IN INSP/MAINT 1 GL 17 6905A 3268 608423001 L271568A IN C/W AEROSTAR SB600-131 INSPECTION OF TURBO OIL SCAVENGE PUMP, FOUND WASHER UNDER RETAINING RING OF SCAVENGE PUMP EMP ELLER WORN AWAY LEAVING RING TO FLOAT IN COUPLING AREA. SUBMITTER STATED THIS CONDITION APPARENTLY SHOULD NOT HAPPEN IF PROPER GARLOCK SEAL IS INSTALLED IN ENGINE ADAPTER WHICH, ON THIS PARTICULAR APPLICATION, THE PROPER SEAL IS INSTALLED. PART TOTAL TIME 784.1 HRS. 1 M 7 2 3O 3 O RT A17WE E14EA 1996121200359 19961212 00359 SO 1996 12 12 96ZZZX5955 2 19961107 G 8540 GEAR SHAFT CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO LT START ADAPTER WORN D K NONE O OTHER IN INSP/MAINT 1 SW 03 707DM 550 421B0145 218419R STARTER ON THE RIGHT ENGINE BEGAN TO WORK INTERMITTENTLY. THE PILOT SAID THE STARTER HAD BEEN TURNING SLOW AND MAKING N OISE. WHEN THE STARTER WAS REMOVED AND TESTED, IT WORKED FINE. THE STARTER ADAPTER SHAFT GEAR WAS REMOVED AND FOUND TO BE WORN BEYOND ACCEPTABLE LIMITS, IT ALSO DAMAGED THE REST OF THE ENGINE. 1 L 7 2 3O 3 O A7CE E7CE 1996121200360 19961212 00360 SO 1996 12 12 96ZZZX5956 2 19961112 G 8530 653446 VALVE CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO NR 1 CYL EXH LEAKAGE B FE6R K NONE O OTHER IN INSP/MAINT 1 NM 11 717CM 40 U20604988 230184R ENGINE HAS 40.0 HRS SINCE MAJOR OVERHAUL AT WHICH TIME NEW TCM CYLINDERS WERE INSTALLED. COMPRESSION CHECK SHOWS NR 1 C YLINDER AT 40/80 LEAKING THROUGH EXHAUST VALVE AND CYLINDERS NR 2, 3, 5, AND 6 TO BE AT 70/80 WITH SLIGHT EXHAUST VALVE LEAKAGE. BORESCOPE INSPECTION SHOWS NR 1 CYLINDER TO HAVE A VERY NARROW EXHAUST VALVE SEAT WITH LIGHT CONTACT. COMPRES SION READINGS ON THE ABOVE CYLINDERS ARE OUTSIDE THE LIMITS SPECIFIED IN TCM SB M84-15, DATED DEC 21, 1984. 1 H 7 1 3O 3 O A4CE E8CE 1996121200375 19961212 00375 NE 1996 12 12 96ZZZX5972 2 19961120 G 7200 ENGINE AEROSP 601 SN601 8680661 EU PWA JT15 JT15D4 52112 NE RT ENG FAILED G A O OTHER O OTHER CR CRUISE 1 GL 05 200MT 2040 606 40 PCE70080 PILOT EXPERIENCED SUDDEN RT ENGINE FAILURE AT 27,000 FEET ALTITUDE WITH NO WARNING OR PREVIOUS INDICATIONS. PRELIMINARY INSPECTION BY CREW AFTER LANDING DISCLOSED DAMAGED PARTS COMING OUT ENGINE TAIL SECTION. 2 L 7 2 4F 4 F A37EU E1NE 1996121200505 19961212 00505 NE 1996 12 12 CA960212038 2 19960207 G 7250 BLADE PWA 120 PW120A NE LP TURBINE FRACTURED W K NONE B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA 120057 (CAN) IN CRUISE, THE WASHROOM SMOKE DETECTOR ALARM SOUNDED AND A SLIGHT ODOUR OF OIL IN THE CABIN WAS NOTICED. POST FLIG HT INSPECTION REVEALED A VIBRATION IN THE CONTROLS DURING ENGINE START. UPON ENGINE REMOVAL, TWO LP TURBINE BLADES WERE FOUND TO BE FRACTURED AT MID-SPAN. 4 T E20NE 1996121200533 19961212 00533 CE 1996 12 12 CA960418010 1 19960305 G 7603 5052456849 CONTROL LEVER BEECH 5052456849 BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA AT PEDESTAL GROOVED W K NONE O OTHER IN INSP/MAINT 1 CA 12050 PCE52489 (CAN) WHILE INSPECTING OF THE THROTTLE LEVER PEDESTAL A GROOVE WAS FOUND TO HAVE BEEN WORN BY RUBBING THE CATCH PLATE. S IMILAR CONDITION FOUND ON BOTH THE RIGHT AND LEFT CONTROL LEVERS. SUBMITTER STATES THAT BEECH NOW MAKES THE PLATES OF A SOFTER MATERIAL AND RECOMMENDS INSPECTING THIS AREA CLOSELY. 1 L 7 2 3T 4 T A14CE E4EA 1996121200535 19961212 00535 CE 1996 12 12 CA960424021 1 19960409 G 3231 ART5CR ROD END C3500A CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO MCAULY 2A34C D2A34C58 GL NLG BROKEN W K NONE J WARNING INDICATION CR CRUISE 1 CA 1132 564221 763171 (CAN) BOW WHEEL FAILED TO RETRACT, FOUND ROD END HAD BEEN BROKEN NEXT TO THE CENTRE BALL ALLOWING THE ROD END TO PULL AW AY FROM THE BALL END. SUSPECT INCORRECT RIGGING DUE TO THE 1/4 INCH DISTANCE OF THE ROD END FROM THE GEAR WITH THE GEAR MANUALLY RETRACTED UP AND THE ACTUATOR IS FULLY RETRACTED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P3EA 1996121200536 19961212 00536 SO 1996 12 12 CA960424022 1 19960326 G 3211 2082900 STUD PIPER PIPER PA24 PA24250 7102404 SO LYC O540 O540A1A 41532 EA MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 3155 L392640 (CAN) INSPECTION OF STUDS AS PER AWD 95-20-07 REVEALED FINE LINEAR CRACK INDICATIONS AT THE RADIUS UNDER THE BOLT HEAD. THE BOLTS WERE REJECTED. 1 L 7 1 3O 3 O 1A15 E295 1996121200537 19961212 00537 CE 1996 12 12 CA960424023 1 19960330 G 5312 BULKHEAD CESSNA 210 210G 2073430 CE CONT O520 IO520A 17032 SO MCAULY 3A32C D3A32C88 GL STA 230.1 CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1106394A 72066 (CAN) DURING A 100 HOUR ANNUAL INSPECTION A CRACK WAS FOUND ON THE AFT BULKHEAD AT STA. 230.1. THE BULKHEAD IS AN ATTACH FOR THE VERTICAL FIN. THE CRACK IS LOCATED ON THE RIGHT HAND SIDE FROM THE CUT OUT FOR THE RUDDER CABLES AND MIGRATES T OWARD THE LOWER RIGHT HAND BOLT. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 1996121200541 19961212 00541 SO 1996 12 12 CA960429008 1 19960404 G 3213 78033 TORQUE LINKS PIPER 78033 PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA SNSNCH 74DM M74DM EA MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 3031 L2232127A K13495 (CAN) TORQUE LINKS INSPECTED AS PER AWD AND FOUND CRACKED IN THE LOCATION SHOWN IN THE SERVICE MANUAL. CRACKS WERE DYE P ENETRANT CHECKED BUT SUBMITTER STATES THAT THE CRACKS WERE VISIBLE WITH A 10X MAGNIFYING GLASS. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1996121200655 19961212 00655 CE 1996 12 12 96ZZZX6002 1 19961122 G 8011 641500 CLUTCH ASSY CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO STARTER FAILED D L K NONE O OTHER IN INSP/MAINT 1 NE 03 21968 15074576 250816A48 ENGINE WAS INSTALLED IN TEST CELL AFTER OVERHAUL AND RUN FOR OVER 1 HR WITH AT LEAST 4 STARTS. CUSTOMER THEN INSTALLED ON AIRCRAFT, STARTED IT TO TAXI, PILOT SAID IT SEEMED ROUGH. ENGINE WAS SHUT DOWN. VISUAL CHECKS REVEALED NOTHING. TI MING WAS OK. HARNESS WAS ROUTED CORRECTLY. PILOT AGAIN ATTEMPTED TO START ENGINE. AFTER SEVERAL REVOLUTIONS PROP STOP PED AND HE SAID IT BRACKED UP BUT STARTER MOTOR CONTINUED TO TURN FREELY NOW WITHOUT TURNING CRANKSHAFT. STARTER WAS RE MOVED AND CLUTCH WAS FOUND WITH THE PILOT CENTER SHAFT BROKEN OFF AND ALL GEAR TEETH BROKEN OFF AND THE GEAR BODY SPLIT AT FRONT BUSHING HOLE LOCATION. 1 H 7 1 3O 3 O 3A19 E252 1996121200657 19961212 00657 EA 1996 12 12 96ZZZX6004 2 19961015 G 7414 M3056 DISTRIBUTOR GEAR SLICK 631 MOONEY M20 M20M 5870222 SW LYC O540 TIO540AF1A 41532 EA LT MAG DETERIORATED C K NONE O OTHER IN INSP/MAINT 1 SO 15 530JP 631 92080001 270114 L928361A INVESTIGATION FOR DETERIORATED LT MAG FOUND LEFT MAG WAS (PRESSURIZED) FROM SAME 'T' FITTING AS RIGHT MAG BUT HAS MORE H EAT. LEFT MAG HAS B AND D TACHOMETER PICK UP WITH LARGER ORIFICE WHICH ALLOWS ALMOST TWICE THE AIRFLOW ALLOWING MORE HE AT INTO MAG. SUBMITTER STATED SLICK REPORTED OVER 1 YR AGO THEY WERE AWARE OF PROBLEM AND IT WOULD BE CORRECTED. THIS IS THE 2ND TIME HAVE HAD THIS PROBLEM WHICH IS SHARED BY MANY MOONEY OWNERS. 1 L 7 1 30 3 O RT 2A3 E14EA 1996121200658 19961212 00658 SO 1996 12 12 96ZZZX6005 2 19961115 G 7414 10349237 GEAR TOOTH 103493505 CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO RT MAG BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 07 6506G 1330 653290R 21064406 269905R DURING INSP OF MAG FOR POINT WEAR AND CONDITION, A TOOTH WAS FOUND BROKEN FROM THE DIST GEAR. A NEW GEAR, CONDENSOR, AN D POINT WAS INSTALLED. THE MAG WAS RUN ON A TEST BENCH WITH NORMAL OPERATION. A POSSIBLE FLAW IN MATERIAL OR A GEAR HO LDING TOOL NOT BEING USED PROPERLY IS SUSPECT CAUSE OF THIS DEFECT. SUBMITTER STATED IF YOU USE A HOLDING TOOL, PAY CLO SE ATTENTION NOT TO TWIST THE MAG. ON REINSTALLATION! 1 H 7 1 3O 3 O 3A21 E8CE 1996121200661 19961212 00661 SO 1996 12 12 96ZZZX6008 2 19961111 G 8520 646778 CONNECT ROD CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO ENG FAILED G O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 WP 17 732LR 1633 21061601 512467 ENGINE OPERATED 233 HOURS OVER MFG RECOMMENDED OVERHAUL TIME OF 1400 HRS. REF SB NR M91-8, 10JULY91. CONNECTING ROD FA ILED IN NORMAL CRUISE AT 8,000 FEET ALTITUDE. ENGINE HAD A 100 HR INSPECTION WITHIN PREVIOUS 25 HRS OF OPERATION. COMP RESSION REPORTED 72/80 ALL CYLINDERS. NOTE: ENGINE HAD A PROP STRIKE IN EARLY LIFE. 1 H 7 1 3O 3 O 3A21 E8CE 1996121200672 19961212 00672 EA 1996 12 12 96ZZZX6020 2 19961120 G 8530 PISTON PIPER PA60 PA60601P 7106012 NM LYC O540 IO540S1A5 41532 EA NR 2 CYL HOLE IN SIDE D E A ENGINE SHUTDOWN UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 NE 03 771LB 61P059979632 L2086348A DURING TEST FLIGHT, A LARGE STREAM OF OIL, FROM OIL DOOR OF RIGHT ENGINE WAS NOTICED. SUBSEQUENTLY, ENGINE SHUT DOWN WA S PERFORMED AND AN UNEVENTFUL LANDING WAS MADE. TROUBLESHOOTING REVEALED A DIME SIZE HOLE IN NR 2 CYLINDER PISTON AND S IGNS OF SEVER DETONATION. CAUSE UNKNOWN. ENGINE WAS REMOVED FOR REPAIR/OVERHAUL. 1 M 7 2 3O 3 O RT A17WE 1E4 1996121900101 19961219 00101 NE 1996 12 19 AU960543 2 19960308 G 7261 SEAL SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE T ENGINE OIL SYS LEAKING W K NONE O OTHER IN INSP/MAINT 1 AU S 785597 (AUS) LH ENGINE INTERNAL OIL LEAK DUE TO CARBON BUILDUP IN THE MIDFRAME ASSEMBLY - NO1 CARBON SEAL WORN 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1996121900103 19961219 00103 NE 1996 12 19 AU960545 2 19960318 G 7230 DAMPER SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE T ENG CMPRSR/FAN BROKEN W K NONE E J VIBRATION/BUFFET WARNING INDICATION NR NOT REPORTED 1 AU S 785592 (AUS) RH ENGINE NO3 BEARING LOCKNUT INERTIA DAMPER BROKEN - METAL CONTAMINATION OF ENGINE OIL SYSTEM 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1996121900104 19961219 00104 NE 1996 12 19 AU960546 2 19960415 G 7261 CHIP DETECTOR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE T ENGINE OIL SYS CONTAM-METAL W K NONE E J VIBRATION/BUFFET WARNING INDICATION LD LANDING 1 AU S 785604 (AUS) RH ENGINE OIL SYSTEM CHIP DETECTOR CONTAMINATED WITH METAL 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1996121900106 19961219 00106 SO 1996 12 19 AU960548 1 19960218 G 2434 12872 BEARING PRESTOLITE ALTERNATOR PIPER PA32 PA32R301 7103218 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC2Y HCC2YK1 GL AC GENERATOR-ALT FAILED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 12872 (AUS) ALTERNATOR REAR BEARING FAILED - BRUSHES WORN OUT 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 1996121900107 19961219 00107 NM 1996 12 19 AU960549 1 19960429 G 7931 APT761000100D TRANSMITTER DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE ENG OIL IND SYS FAULTY W K NONE E K VIBRATION/BUFFET FLUID LOSS NR NOT REPORTED 1 AU S (AUS) RH ENGINE OIL PRESSURE TRANSMITTER FAULTY 2 H 7 2 4T 4 T RT A13NM E20NE 1996121900109 19961219 00109 SO 1996 12 19 AU960551 1 19960328 G 3230 67748003 VALVE PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C 2D34C215 GL LG EXT-RETRACT S LEAKING W K NONE K FLUID LOSS NR NOT REPORTED 1 AU S (AUS) LANDING GEAR EMERGENCY EXTENSION VALVE LEAKING DUE TO FAULTY 'O' RING SEALS 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 1996121900110 19961219 00110 EA 1996 12 19 AU960552 2 19960329 G 8520 LW72877 TAPPET LYC CAMSHAFT PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA HARTZL HCC2Y HCC2YK1 GL R ENGINE POWER S SPALLED W K NONE O OTHER IN INSP/MAINT 1 AU S L1097351A (AUS) NO1 AND NO2 CYLINDER TAPPET BODIES PNO LW72877 SPALLED - CAMSHAFT PNO LW18840 FORWARD LOBE WORN 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 1996121900111 19961219 00111 SO 1996 12 19 AU960553 1 19960430 G 5712 RIB PIPER PA25 PA25150 7102503 SO LYC O320 O320A2B 41508 EA MCAULY 1A170 1A170GM GL OUTER WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING RIBS AND STIFFENERS CONTAINED SEVERE EXFOLIATION CORROSION AND CRACKING OF INBOARD TRAILING EDGE A SSEMBLIES PNO 61217-000 AND PNO 61217-001 - CORROSION ALSO FOUND IN NUMEROUS WING WALK RIBS PNO 61224-000 - WING SKINS P NO 61158-010, PNO 61158-011, PNO 61329-000 AND PNO 61329-001 - RH WING INTERNAL STRUT PNO 61101-000 CONTAINED SEVERE CO RROSION IN AREA WHERE THE REAR SPAR ATTACHMENT FITTING IS RIVETTED TO THE STRUT - AIRCRAFT WAS CONSTRUCTED IN 1959 AND I S USED FOR AGRICULTURAL SPRAYING 1 H 7 1 3O 3 O EXPA1H71 E274 5 N P857 1996121900112 19961219 00112 EU 1996 12 19 AU960554 1 19960221 G 7712 CTOT SYSTEM SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE POWER CONTROL SY INOPERATIVE W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 785465785 DRG143990DA (AUS) LH ENGINE CTOT (CONSTANT TORQUE ON TAKE-OFF SYSTEM) INOPERATIVE DUE TO INTERMITTENT ELECTRICAL PROBLEM 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 1996121900113 19961219 00113 CE 1996 12 19 AU960555 1 19960420 G 3230 9880710116530004 SWITCH CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL LG EXT-RETRACT S FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LANDING GEAR MOTOR PRESSURE SWITCH WIRE BROKEN AT SOLDERED JOINT - FAILURE WAS COVERED BY HEAT SHRINK MAKING IT DI FFICULT TODETECT 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1996121900115 19961219 00115 EU 1996 12 19 AU960557 1 19960415 G 3211 NB40075 BRACKET RHMLG BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL MAIN GEAR SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH MAIN LANDING GEAR BRACKET CRACKED AND BROKEN 1 H 7 2 3O 3 O A17EU E295 5 C P920 1996121900118 19961219 00118 WP 1996 12 19 AU960560 2 19960426 G 7260 310183616 HOUSING GARRTT TPE33110UA SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL T ENG AUX DRIVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 2870 P54299 P54299 (AUS) ENGINE ACCESSORY HOUSING CRACKED IN GUSSET CASTING ADJACENT TO THE RH ENGINE MOUNTING PAD - CRACK LENGTH 25.4MM (1 IN) 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 1996121900119 19961219 00119 SW 1996 12 19 AU960561 1 19960131 G 5340 RIVET MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL ATTACH FITTING S SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILISER RH ATTACHMENT BRACKET RIVETS (8OFF) SHEARED 1 L 7 1 3O 3 O 2A3 1E10 5 C P920 1996121900120 19961219 00120 1996 12 19 AU960562 4 19960425 G 3140 6226190204 COMPUTER EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE CENTRAL COMPUTER FAULTY W K NONE O J OTHER WARNING INDICATION CR CRUISE 1 AU S 2084 (AUS) NO2 AHRS COMPUTER FAULTY - BENCH CHECK COULD FIND NO FAULTS 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 1996121900121 19961219 00121 SO 1996 12 19 AU960563 1 19960420 G 3230 2060500005 ACTUATOR EMB 120 EMB120 3260201 SO PWA 118 PW118A NE LG EXT-RETRACT S OUT OF ADJUST W K NONE O OTHER CL CLIMB 1 AU S 344 (AUS) NOSE LANDING GEAR ACTUATOR OUT OF ADJUSTMENT 2 L 7 2 4T 4 T RT A31SO E20NE 1996121900122 19961219 00122 SO 1996 12 19 AU960564 1 19960501 G 3211 9529902 SIDE BRACE PIPER PA34 PA34200 7103405 SO LYC O360 IO360C1E6 41514 EA HARTZL HCC2Y HCC2YK2 GL MAIN GEAR SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH MAIN LANDING GEAR SIDE BRACE STUDS CRACKED IN RADIUS - FOUND DURING MAGNETIC PARTICLE INSPECTION IAW AD/ PA34/46 1 L 7 2 3O 3 O A7SO 1E10 5 C P920 1996121900125 19961219 00125 EU 1996 12 19 AU960567 1 19960327 G 5320 TB1021029165 STIFFENER SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK2 GL MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE STIFFENER LH CRACKED IN AREA OF TORQUE TUBE SUPPORT REAR ANCHOR NUT HOLE - FOUND DURING INSPECTION IAW SO CATA 10-77-53 1 L 7 1 30 3 O NT A51EU E286 5 C P920 1996121900128 19961219 00128 NM 1996 12 19 AU960570 1 19960316 G 3213 19335LH193 TRUNNION BOEING 767 767277 NM GE CF6 CF680A 30025 NE MAIN GEAR SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 19335LH (AUS) LH AND RH MAIN LANDING GEAR OUTER CYLINDER AFT TRUNNIONS CONTAINED UNACCEPTABLE CORROSION DURING ULTRASONIC AND ED DY CURRENT INSPECTIONS IAW ER B76-32-10-24 - RH OUTER CYLINDER CORRODED IN AREA OF JOURNAL CHAMFER AT THE 2 O'CLOCK POS ITION -LH TRUNNION CORRODED IN AREA OF INBOARD CROSS BOLT HOLE AT THE 6 O'CLOCK POSITION - SUSPECT CAUSED BY CRACKING OF THE FILLET SEAL ALLOWING MOISTURE INGRESS 2 L 7 2 4F 4 F RT A1NM E13NE 1996121900129 19961219 00129 GL 1996 12 19 AU960571 2 19960401 G 7320 6876376 PIPE GOVT N22 N22B 3880102 WP ALLSN 250B 250B17B 03010 GL HARTZL HCA3V HCA3VF7 GL ENG,FUEL CONTROL CRACKED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S 880049 DS95 (AUS) COMPRESSOR SCROLL TO PC FILTER INLET PIPE CRACKED ACROSS FLARE AND PARTIALLY BLOCKED WITH CARBON 1 H 7 2 3T 3 T A7PC E10CE 5 C P6EA 1996121900137 19961219 00137 GL 1996 12 19 AU960579 3 19960502 G 6110 692935 O-RING MCAULY 3AF32C75LW BEECH 55 D55 1152730 CE CONT O520 IO520C 17032 SO MCAULY 3AF32C 3AF32C75 GL PROPELLER ASSY S WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 692935 692935 (AUS) PROPELLER BLADE RETENTION NUT 'O' RINGS WERE THE INCORRECT TYPE CAUSING EXCESSIVE BINDING ON FERRULE - PERSONNEL/ MAINTENANCE ERROR - UNAPPROVED PART 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1996121900138 19961219 00138 EA 1996 12 19 AU960580 2 19960417 G 8520 LW1883785 CAMSHAFT LYC O320B2C ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA R ENGINE POWER S WRONG PART W K NONE E R W VIBRATION/BUFFET PARTIAL RPM/PWR LOSS INADEQUATE Q C NR NOT REPORTED 1 AU S 198 RL1220239A RL1220239A (AUS) CAMSHAFT SUSPECT FAULTY - COMPARISON WITH A NEW ITEM FOUND THAT THE CAM PROFILE WAS DIFFERENT - INVESTIGATION FOU ND THAT THE CAMSHAFT WAS MARKED IN SMALL LETTERS WITH THE PNO LW18837-85 BUT WAS ALSO MARKED WITH THE PNO 76097 WHICH IS THE PART NUMBER FOR INSTALLATION IN FIXED WING APPLICATIONS - THERE IS ALSO EVIDENCE THAT THE CAMSHAFT HAS BEEN REGROUN D - UNAPPROVED PART -PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O H10WE E274 1996121900139 19961219 00139 CE 1996 12 19 AU960581 1 19960417 G 7603 AH37A BOLT NUT CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO MCAULY 3FF32 3FF32C501 GL POWER CONTROL SY SEPARATED W K NONE E VIBRATION/BUFFET DE DESCENT 1 AU S 604164 (AUS) ENGINE THROTTLE CONTROL UNIT ARM PNO 5055002-1 ATTACHMENT NUT PNOMS21044N3 AND BOLT PNO AH37A SEPARATED FROM ARM A ND WERE FOUND ONTHE FLOOR OF THE ENGINE BAY - THE NUT WAS OF THE METAL LOCK TYPE AND INVESTIGATION FOUND THAT IT COULD B E SPUN ONTO THE BOLT BY HAND - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O A7CE E7CE 5 C P45GL 1996121900140 19961219 00140 EU 1996 12 19 AU960582 1 19960429 G 5755 A16053410 HINGE FOKKER F28 F28MK1000 4990808 EU RROYCE SPEY SPEY55515 54521 EU WING SPOILER SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S SH47 (AUS) RH WING OUTBOARD LIFT DUMPER NO5 PANEL INBOARD HINGE LUG CRACKED 2 L 7 2 4F 4 F RT A20EU E2EU 1996121900141 19961219 00141 1996 12 19 AU960583 1 19960421 G 7160 365A54103301 AIR INTAKE TMECA ARRIEL ARRIEL1A 60030 NE ACFT,ENG AIR INT SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S 275 (AUS) ENGINE INTAKE FLANGE LOWER PORTION BROKE AWAY AND ENTERED THE ENGINE CAUSING DAMAGE TO THE COMPRESSOR 3 U E19EU 1996121900142 19961219 00142 SO 1996 12 19 AU960584 2 19960425 G 8530 648045 PISTON CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO R ENGINE CYLINDE DAMAGED W K NONE R E PARTIAL RPM/PWR LOSS VIBRATION/BUFFET CL CLIMB 1 AU S 1005 552607 (AUS) NO2 CYLINDER PISTON SEVERELY ERODED AND HOLED IN THE AREA OF THE OIL RING GROOVE - METAL CONTAMINATION OF OIL SYST EM - NO4CRANKSHAFT BEARING ALSO TURNED 1 H 7 1 3O 3 O A4CE E5CE 1996121900143 19961219 00143 CE 1996 12 19 AU960585 1 19960424 G 7603 1005241771 LEVER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL POWER CONTROL SY BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH FUEL CONTROL LEVER FAILED IN AN AREA LEVEL WITH THE PEDESTAL QUADRANT - LEVER EXHIBITED ADVANCED WEAR IN AREA OF FAILURE -FURTHER INVESTIGATION SHOWED SIMILAR WEAR IN THE RH LEVER - SUSPECT LEVER HAD BEEN BENT AND RESTRAIGHTENED AT ONE TIME WHICH CAUSED CRACKING AND EVENTUAL FAILURE 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1996121900146 19961219 00146 CE 1996 12 19 AU960588 1 19960320 G 5720 NAS15237M BOLT BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO HARTZL HCJ3Y PHCJ3YF2 GL OUTER WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING BOLTS CORRODED DUE TO COVERING OF BARIUM CHROMATE 1 L 7 2 3O 3 O 3A16 E5CE 5 C P36EA 1996121900147 19961219 00147 CE 1996 12 19 AU960589 1 19960401 G 5711 SPAR CESSNA 182 182N 2072730 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL OUTER WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WING CONTAINED SEVERE EXFOLIATION CORROSION IN THE UPPER FORWARD SPAR EXTRUSIONS, EXFOLIATION CORROSION AND CR ACKING IN THE MAIN SPAR AND CORROSION IN THE INNER SPAR WEB - CORROSION APPEARS TO HAVE BEEN PREVIOUSLY TREATED WITH LP S TYPE COMPOUND 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1996121900148 19961219 00148 EA 1996 12 19 AU960590 2 19960430 G 7261 CHIP DETECTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL TURBINE ENGINE O CONTAMINATED W K NONE J WARNING INDICATION CL CLIMB 1 AU S 80713 (AUS) LH ENGINE CHIP DETECTOR ILLUMINATED - INSPECTION FOUND A VERY FINE METALLIC HAIR ACROSS THE PROBES - AFTER CLEANI NG AND REINSTALLING IAW PRATT AND WHITNEY MAINTENANCE MANUAL THE AIRCRAFT WAS OPERATED FOR 15 FLIGHT HOURS AND THE CHIP DETECTORREINSPECTED WITH NO CONTAMINATION EVIDENT 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1996121900149 19961219 00149 CE 1996 12 19 AU960591 1 19960509 G 2612 302158 FIRE DETECTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL FIRE DETECT SYS CONTAM-WATER W K NONE F N FLT CONT AFFECTED FALSE WARNING TO TAKEOFF 1 AU S (AUS) RH ENGINE FIRE DETECTOR ACTIVATED DUE TO MOISTURE ON THE SENSORS - FIRE BOTTLE DISCHARGED 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1996121900150 19961219 00150 EU 1996 12 19 AU960592 1 19960507 G 3260 A204D14 SCREW ROTOL 200921732 STBROS SD3 SD360 8100606 EU PWA PT6 PT6A65R 52043 EA HARTZL HCB5M HCB5MP3 GL LG POSITION IND LOOSE W K NONE N FALSE WARNING CR CRUISE 1 AU S (AUS) NOSE LANDING GEAR ABUTTMENT PLATE OUT OF ADJUSTMENT 2 H 7 2 4T 4 T A41EU E4EA 6 C P44GL 1996121900151 19961219 00151 NM 1996 12 19 AU960593 1 19960422 G 3260 INDICATION SYS DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE LG POSITION IND FAULTY W K NONE N FALSE WARNING DE DESCENT 1 AU S (AUS) NOSE LANDING GEAR INDICATION SYSTEM FAULTY - EXTENSIVE INVESTIGATION COULD FIND NO FAULT WITH THE SYSTEM 2 H 7 2 4T 4 T RT A13NM E20NE 1996121900152 19961219 00152 NM 1996 12 19 AU960594 1 19960402 G 7710 ENGINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE ENG PWR IND SYS FLUCTUATES W K NONE E VIBRATION/BUFFET TO TAKEOFF 1 AU S (AUS) RH ENGINE EXPERIENCED TORQUE FLUCTUATIONS - EXTENSIVE INVESTIGATION COULD FIND NO FAULTS 2 H 7 2 4T 4 T RT A13NM E20NE 1996121900154 19961219 00154 EA 1996 12 19 AU960597 2 19960507 G 8530 VALVE GUIDE LYC O320 O320D1A 41508 EA R ENGINE CYLINDE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S L1620439A (AUS) ENGINE CYLINDER EXHAUST VALVE GUIDES (3OFF) EXCESSIVELY WORN - VALVE GUIDES WERE WITHIN SERVICE LIMITS BUT WOULD N OT LAST TO THENEXT TOP END OVERHAUL 3 O E274 1996121900155 19961219 00155 WP 1996 12 19 AU960598 2 19960501 G 7210 31039401 SUPPORT GARRTT TPE331 FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE REDUCTION FAULTY W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S P70144 P70144 (AUS) ENGINE TORQUE RING SUPPORT ASSEMBLY FAULTY 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1996121900157 19961219 00157 SO 1996 12 19 AU960600 1 19960406 G 3220 6708403 TRUNNION PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA NOSE-TAIL GEAR S DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR DRAG BRACE ATTACHMENT TRUNNION DAMAGED - ALLOY CASTING APPEARS TO BE CRYSTALLISED AT THE DRAG BR ACE ATTACHMENTPOINT - SUSPECT CAUSED BY LOCALISED HEATING TO REMOVE/REPLACE BUSHES - PERSONNEL/MAINTENANCE ERROR - UNAP PROVED PROCEDURE 1 L 7 2 3O 3 O A19S0 E286 1996121900164 19961219 00164 SO 1996 12 19 AU960607 1 19960429 G 3211 20829000 STUD PIPER PA24 PA24250 7102404 SO LYC O540 O540A1D5 41532 EA MCAULY 2D36C 2D36C28 GL MAIN GEAR SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN LANDING GEAR SIDE BRACE STUD CRACKED - FOUND DURING MAGNETIC PARTICLE INSPECTION IAW AD/PA24/44 1 L 7 1 3O 3 O 1A15 E295 5 C P901 1996121900165 19961219 00165 CE 1996 12 19 AU960608 1 19960426 G 3260 INDICATOR BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL LG POSITION IND BROKEN WIRE W K NONE O P OTHER NO WARNING INDICATION DE DESCENT 1 AU S (AUS) RH MAIN LANDING GEAR INDICATOR LAMP WIRE BROKEN 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1996121900166 19961219 00166 SO 1996 12 19 AU960612 1 19960501 G 3230 4198300 HOOK PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2 GL LG EXT-RETRACT S SEIZED W K NONE O P OTHER NO WARNING INDICATION LD LANDING 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK HOOK STIFF ON PIVOT BOLT PNO AN5-46- AIRCRAFT OPERATES FROM UNPREPARED STRIPS IN A S ALT LADEN ENVIRONMENT WITH HIGH HUMIDITY 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1996121900170 19961219 00170 SO 1996 12 19 AU960620 2 19960510 G 8530 PISTON RING CESSNA 182 182E 2072712 CE CONT O470 O470R 17026 SO HARTZL HCC2Y BHCC2YF1 GL R ENGINE CYLINDE WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 987337R (AUS) INCORRECT PISTON RING SETS FITTED TO ALL PISTONS - PNO 632932 PISTONS FITTED WHICH SHOULD HAVE RECTANGULAR TOP RI NGS AS PER SB M91-4 - PISTONS WERE FITTED WITH TAPERED RINGS - DAMAGE TO PISTONS AND MINOR SCORING TO CYLINDERS - VALVE SEATS APPEAR TO BEINCORRECTLY CUT - 3 PISTON PINS HAVE LOOSE PLUGS - NO1 CYLINDER HAS VERY DEEP SCORING FROM PREVIOUS H ONING - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O NT 3A13 E273 5 C P920 1996121900175 19961219 00175 CE 1996 12 19 AU960625 1 19960502 G 3260 404EN16 SWITCH BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE LG POSITION IND FAILED W K NONE N FALSE WARNING CL CLIMB 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK MICROSWITCH INTERNAL FAILURE 1 L 7 2 4T 4 T A24CE E4EA 1996121900176 19961219 00176 CE 1996 12 19 AU960627 1 19960502 G 2121 1013841001 BLOWER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL AIR DISTRIBUTION FAULTY W K NONE B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S 1100ECH (AUS) AIRCONDITIONING SYSTEM FORWARD EVAPORATOR VENT BLOWER FAN FAULTY - SUSPECT BURNT OUT CIRCUIT 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1996121900177 19961219 00177 CE 1996 12 19 AU960629 1 19960503 G 2120 5055434 VALVE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL AIR DISTRIBUTION FAULTY W K NONE O OTHER CL CLIMB 1 AU S 1619 (AUS) RH BLEED AIR BYPASS VALVE FAULTY - INVESTIGATION FOUND VALVE BUTTERFLY DAMAGED DUE TO A LOOSE SECURING SCREW ALLOW ING THE PLATE TO ROTATE OUT OF ALIGNMENT WITH THE VALVE BORE 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1996121900178 19961219 00178 CE 1996 12 19 AU960630 1 19960502 G 2610 DETECTOR BEECH 99 C99 1154006 CE PWA PT6 PT6A36 52043 NE HARTZL HCB3T HCB3TN3 GL FIRE DETECTION S CONTAM-WATER W K NONE F B N FLT CONT AFFECTED SMOKE/FUMES/ODORS/SPARKS FALSE WARNING DE DESCENT 1 AU S (AUS) LH ENGINE FIRE DETECTION SYSTEM CONTAMINATED WITH WATER WHEN FLYING THROUGH HEAVY RAIN - FALSE FIRE WARNING CAUSED ENGINE TOBE SHUT DOWN AND FIRE BOTTLE OPERATED 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 1996121900182 19961219 00182 GL 1996 12 19 AU960634 2 19960504 G 7261 890274 CHIP DETECTOR ALLSN 250C30S SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30 03013 GL TURBINE ENGINE O CONTAM-METAL W K NONE J WARNING INDICATION CR CRUISE 1 AU S 890274 890274 (AUS) ENGINE CHIP DETECTOR CONTAINED A FINE SLIVER OF METAL - CHIP DETECTOR WAS CLEANED AND AN ENGINE SERVICEABILITY CHE CK WASPERFORMED - NO FURTHER CONTAMINATION WAS FOUND AND AIRCRAFT RETURNED TO SERVICE 1 G 7 2 3U 3 U H1NE E1GL 1996121900183 19961219 00183 EU 1996 12 19 AU960635 1 19960418 G 5730 SKIN BNORM BN2MK3 BN2AMK3 1520203 EU LYC O540 O540E4C5 41532 EA HARTZL HCE2Y HCE2YK2 GL OUTER WING SYS DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) RH WING INTERIOR SKIN DAMAGED IN AREA ADJACENT TO REAR WING ATTACHMENT DUE TO ANGLE GRINDER DIGGING INTO AND THRO UGH INTERIORSKIN - FOUND DURING INSPECTION IAW AD/BNT/17-2 - PERSONNEL/MAINTENANCE ERROR 1 H 7 3 3O 3 O A29EU E295 5 C P9EA 1996121900184 19961219 00184 SO 1996 12 19 AU960636 1 19960322 G 2810 FUEL TANK PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8S5 EA FUEL STORAGE SYS EMPTY W K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 AU S (AUS) ENGINE SURGED DUE TO LACK OF FUEL 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 1996121900185 19961219 00185 SO 1996 12 19 AU960637 1 19960515 G 3230 1217222123 HOSE EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL LG EXT-RETRACT S RUPTURED W K NONE K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK HOSE RUPTURED - LOSS OF HYDRAULIC FLUID 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1996121900187 19961219 00187 SO 1996 12 19 AU960639 1 19960515 G 2910 MS287785 SEAL EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL MAIN HYD SYS DISTORTED W K NONE O OTHER CL CLIMB 1 AU S (AUS) RH MAIN LANDING GEAR DOOR DROPPED INTO AIRFLOW - INVESTIGATION FOUND PRESSURE SIDE HYDRAULIC SERVICE COUPLING LEAK ING UNDER PRESSURE DUE TO FLATTENED 'O' RING SEAL 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1996121900188 19961219 00188 EA 1996 12 19 AU960640 2 19960302 G 8530 LW12966 VALVE SEAT LYC TIO540J2BD PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL R ENGINE CYLINDE SEPARATED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 1298 L810361A L810361A (AUS) NO1 CYLINDER VALVE SEAT SEPARATED - NO2 CYLINDER PISTON RING LANDWORN 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1996121900192 19961219 00192 NE 1996 12 19 AU960644 2 19960503 G 7260 3087 SEAL TMECA NO1MODULE SKRSKY S76 S76A 8143006 NE TMECA ARRIEL ARRIEL1S 60030 NE TURBINE ENG. ACC LEAKING W K NONE O K OTHER FLUID LOSS CR CRUISE 1 AU S 827 3087 3527 (AUS) NO2 ENGINE NO1 MODULE AIR/OIL SUPERIOR DRIVE CARBON SEAL SUSPECT LEAKING - FACTORY STRIP INSPECTION COULD FIND NO REAL PROBLEMS BUT COMMENTED THAT THE ACCESSORY GEARBOX BREATHER PIPE MAY HAVE BEEN POSITIONED TOO FAR FORWARD CAUSING H IGH OIL CONSUMPTION 1 G 7 2 3U 3 U H1NE E19EU 1996121900193 19961219 00193 SO 1996 12 19 AU960645 1 19960518 G 7120 7197204 BRACKET PIPER PA42 PA42 7104202 SO PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE MOUNTING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ENGINE UPPER OUTBOARD ENGINE MOUNT TO FIREWALL ATTACHMENT BRACKET CRACKED THROUGH VERTICAL FACE FROM TOP WELD L INE EXTENDING DOWN BETWEEN RIVET HOLES - CRACK LENGTH 9MM (0.35IN) 1 L 7 2 4T 4 T A23SO E4EA 6 C P15EA 1996121900194 19961219 00194 NM 1996 12 19 AU960646 1 19960304 G 7720 11046 PROBE BOEING 737 737377 NM CFMINT CFM56 CFM563B2 13802 EU ENG TEMP IND SYS BROKEN W K NONE E VIBRATION/BUFFET CL CLIMB 1 AU S 11046 (AUS) NO2 ENGINE THERMOCOUPLE 'G' PROBE HAD APPROXIMATELY 3/4 OF ITS LENGTH BROKEN OFF - TGT HARNESS LOWER SECTION FAILE D RESISTANCECHECKS 2 L 7 2 4F 4 F RT A16WE E21EU 1996121900282 19961219 00282 EA 1996 12 19 96ZZZX6082 2 19961122 G 8530 71894 VALVE SEAT PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA NR 5 CYL EXH LOOSE B EKIR K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 07 252MA 31P33 L52162 ENGINE RUN-UP AND ROUGH. CHECKED COMPRESSION, FOUND NR 5 CYLINDER 0/80. REMOVED CYLINDER, FOUND EXHAUST VALVE SEAT LOO SE IN HEAD FOLLOWING VALVE DURING VALVE MOVEMENT. 1 L 7 2 3O 3 O A8EA E19EA 1996121900289 19961219 00289 EA 1996 12 19 96ZZZX6089 2 19961109 G 8530 73806 PUSH ROD PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA NR 1 CYL INT BENT D P A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 15 38PT 3616 3878A0042 L1533715 PILOT NOTED A SUDDEN ROUGHNESS IN THE ENGINE FOLLOWED BY A 200-300 RPM LOSS. MADE A SAFE EMERGENCY LANDING. DISPATCHED A MECHANIC TO DETERMINE CAUSE. THE INTAKE PUSHROD AND TUBE WERE SEVERELY BENT. THE LOWER SPARK PLUG WAS BADLY LEAD FO ULED. SUSPECT CAUSE WAS DETERMINED TO BE EITHER DETONATION OR THE INTAKE VALVE STICKING MOMENTARILY. THE ENGINE WAS RE MOVED FOR OVERHAUL. 1 L 7 1 3O 3 O A18SO E223 1996121900300 19961219 00300 SO 1996 12 19 96ZZZX6100 2 19961121 G 7322 63357310 FUEL CONTROL CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO RT ENG MIX DEFECTIVE B APCR O OTHER R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 NM 01 48SA 706 G119402AR 4040417 276387R PILOT REPORTED ENGINE STUMBLE ON TAKEOFF AND AT CLIMB POWER SETTING. EXTENSIVE TROUBLESHOOTING FOUND LOOSE BUSHING AT R IGHT ENGINE. MIXTURE CONTROL SHAFT INSTALLED USED SERVICEABLE FUEL CONTROL ASSY. TEST FLOWN OK. 1 L 7 2 3O 3 O A25CE E7CE 1996121900302 19961219 00302 SO 1996 12 19 96ZZZX6102 2 19961202 G 7310 6343264 MANIFOLD CESSNA 340 340CESSNA 2076404 CE CONT O520 TSIO520NB 17040 SO ENG FUEL CLOGGED B AM2R K NONE O OTHER IN INSP/MAINT 1 SW 15 69520 20 A167532C 3400353 311659 FUEL MANIFOLD WAS ONLY ABLE TO SUPPLY FUEL TO 3 OF THE ENGINES CYLINDER. THREE OF THE FUEL LINES WERE CLOGGED. THE MAN IFOLD HAD LESS THAN 20 HRS SINCE OVERHAUL. 1 L 7 2 3O 3 O 3A25 E8CE 1996121900756 19961219 00756 NE 1996 12 19 96ZZZX6122 2 19961211 G 7270 5757513501 DUCT DOUG DC8 DC862 3021970 WP PWA JT3D JT3D7 52039 NE FAN BYPASS FAILED B UMXR K NONE O OTHER NR NOT REPORTED 1 SO 19 1808E 130 46105 FAILURE OF DUCT, P/N 5757513-501, CAUSED BY COMPRESSOR STALL/SURGE. REPORT ON FILE AT REPAIR STATION UMXR629L. 2 L 7 4 4F 4 F 4A25 1E8 1996121900760 19961219 00760 NE 1996 12 19 96ZZZX6126 2 19961111 G 7230 793015 DISC BOEING 747 747136 1384883 NM PWA JT9 JT9D7 52054 NE STAGE 15 HPC CRACKED H S K NONE O OTHER IN INSP/MAINT 1 SW 99 79240 B85733 685824 DISC HAS .1875 INCH LONG CIRCUMFERENTIAL CRACK IN FRONT SNAP DIAMETER (I.E. IN AN UNUSUAL LOCATION NOT PREDICTED BY ASB 4908). PART CYCLES, 9,092. 2 L 7 4 4F 4 F A20WE E20EA 1996121900761 19961219 00761 NE 1996 12 19 96ZZZX6127 2 19961013 G 7510 7958591503 DUCT 13277503 DOUG MD88 MD88 3023688 NM PWA JT8 JT8D219 52053 NE NR 2 ENG AI B NUT LOOSE H A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SW 99 12FQ 15021 49766 718244 AFTER TAKEOFF, PILOT REPORTED NR 2 ENGINE OVERHEAT LIGHTS CAME ON ONE AFTER THE OTHER. AIRCRAFT LEVELED OFF. NR 2 THRO TTLE RETARDED AND OVERHEAT CONDITION DISAPPEARED. AIRCRAFT RETURNED TO DEPARTING AIRPORT AND NORMAL LANDING PERFORMED. INSPECTION REVEALED THAT NOSE COWL ANTI-ICE DUCT'S FORWARD ATTACH B-NUT DESINTEGRATED CAUSING 13TH STAGE BLEED AIR TO H EAT UP THE 'A' AND 'B' LOOPS. MDC S/N 3061 NOT C/W AT THE TIME OF INCIDENT. 2 L 7 2 4F 4 F RT A6WE E9NE 1996121900764 19961219 00764 EU 1996 12 19 96ZZZX6129 1 19961116 G 3234 LANDING GEAR BAC 146 AVRO146RJ100 1500096 EU LYC LF507 LF5071F NE MLG LACK OF LUBE W ANCF A UNSCHED LANDING O OTHER CL CLIMB 1 SO 23 504MM E3221 LF07320 AFTER TAKEOFF, LANDING GEAR LEVER DIDN'T COME UP AND SPOILER LIGHT ON MWS CAME ON. RETURNED TO AIRPORT. LUBRICATED LAN DING GEAR LEVER MECHANISM. CHECKED SPOILER AND FOUND NORMAL. 2 H 7 4 4F 4 F RT A49EU E6NE 1996121900765 19961219 00765 NE 1996 12 19 96ZZZX6130 2 19961117 G 7200 ENGINE BAC 146 AVRO146RJ100 1500096 EU LYC LF507 LF5071F NE NR 2 VIBRATION W ANCF C D ABORTED TAKEOFF RETURN TO BLOCK E J VIBRATION/BUFFET WARNING INDICATION TO TAKEOFF 1 SO 23 508MM E3247 LF73062 DURING TAKEOFF ROLL, ENGINE VIBRATION WARNING LIGHT CAME ON. ENGINE NR 2 REACHED 2.2. TAKEOFF WAS REJECTED. ENGINE NR 2 WAS CHANGED. TEST WAS PERFORMED ACCORDING TO AMM 72-00-00. 2 H 7 4 4F 4 F RT A49EU E6NE 1996121900766 19961219 00766 NE 1996 12 19 96ZZZX6131 2 19961110 G 7200 ENGINE BAC 146 AVRO146RJ100 1500096 EU LYC LF507 LF5071F NE NR 3 BIRD STRIKE W ANCF K NONE C F.O.D. IN INSP/MAINT 1 SO 23 508MM 4014 222 E3247 LF07320 PERFORMING WALK-AROUND IN SAN JOSE, A BIRD WAS FOUND INGESTED IN ENG NR 3. ACCOMPLISHED ENGINE BORESCOPIC INSPECTION DU E TO BIRD STRIKE, NO DAMAGE FOUND ON THE ENGINE. ENGINE RUN-UP. ALL PARAMETERS WITHIN LIMITS. 2 H 7 4 4F 4 F RT A49EU E6NE 1996121900789 19961219 00789 CE 1996 12 19 CA960509202 1 19960308 G 5712 RIBS BEECH 95 95 1153402 CE LYC O360 O360A1A 41514 EA WS 94.864 BENT W K NONE O OTHER IN INSP/MAINT 1 CA L2413536A (CAN) RIGHT WING RIBS AT W.S. 94.864, 108.281 AND 122.500 FOUND BENT AND BUCKLED UNDER THE UPPER WING SKIN. POSSIBLY CAU SED BY OVERPRESSURE OF FUEL IN AUXILIARY TANK (THERMAL EXPANSION ). 1 L 7 2 3O 3 O 3A16 E286 1996121900794 19961219 00794 CE 1996 12 19 CA960515004 1 19960507 G 3411 20186 STATIC SENSOR NARCO AR850 CESSNA 210 2105 2073404 CE CONT O470 IO470S 17026 SO MCAULY 2A34C D2A34C58 GL HOUSING ASSEMBLY LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 20186 1090767SR 950428 (CAN) PIEZO STATIC SENSOR HOUSING LEAKING IN EXCESS OF LIMITS 1 H 7 1 3O 3 O 3A21 3E1 5 C P3EA 1996121900795 19961219 00795 SO 1996 12 19 CA960515005 1 19960326 G 3411 12644 STATIC SENSOR NARCO AR850 PIPER PA31T PA31T2 7103127 SO PWA PT6 PT6A135 52043 NE HOUSING ASSEMBLY LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 12644 PCE92402 (CAN) PIEZO STATIC SENSOR HOUSING LEAKING IN EXCESS OF LIMITS 1 L 7 2 3T 4 T RT A8EA E4EA 1996121900808 19961219 00808 NM 1996 12 19 CA960527103 1 19960518 G 5751 SKIN STINSON UNIVAR 108 1083 9230408 NM CONT O470 O470R 17026 SO MCAULY 2A36C 2A36C29 GL AIL BAL WGHT ATT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2510 514656R 63447 (CAN) CRACKS 1/4 INCH LONG RADIATING FROM 3 HOLES FOR THE ATTACHMENT OF THE STEEL BALANCE WEIGHT ON THE OUTBOARD LEADING EDGE OF RIGHT HAND AILERON. 1 H 7 1 3O 3 O A767 E273 5 C P880 1996121900809 19961219 00809 SO 1996 12 19 CA960528103 1 19960506 G 2740 69623004 TUBE PIPER PIPER PA28 PA28160 7102806 SO LYC O320 O320B2B 41508 EA STAB WEIGHT END DEFECTIVE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA L476739 (CAN) PREPARING THE TUBE FOR INSTALLATION, THERE WAS A BLOB OF PAINT IN THE AREA OF MOUNTING OF THE WEIGHT. ON REMOVING THE BLOB OF PAINT, A FOLD IN THE METAL AND A 3 INCH LONGITUDINAL CRACK IN THE TUBE WAS REVEALED. MATERIAL DEFECT. POOR Q UALITY CONTROL. 1 L 7 1 3O 3 O 2A13 E274 1996121900817 19961219 00817 SO 1996 12 19 CA960604001 1 19960512 G 3230 2128600 MOTOR BOSCH M072218A PIPER PA24 PA24 7102402 SO LYC O360 O360A1D 41514 EA GEAR EXTEND BURNT W O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 CA 2824 36461 L363136 (CAN) LANDING GEAR REFUSED TO EXTEND AND LOCK. EMERGENCY EXTEND SUCCESSFUL. ELECTRICAL MOTOR BURNT OUT. 1 L 7 1 3O 3 O 1A15 E286 1996121900827 19961219 00827 SO 1996 12 19 CA960610001 1 19960516 G 5412 5048 FIREWALL MAULE M4210C MAULE M4 M4210C 5460112 SO CONT O360 IO360A 17025 SO MCAULY 2A34C D2A34C67 GL R/H CORNER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1070C 10557 681071 (CAN) DURING AN ENGINE CHANGE, FIREWALL WAS FOUND TO BE CORRODED EXCESSIVELY. FIREWALL WAS REPLACED AS PER MAINTENANCE M ANUAL. SUBMITTER NOTES THAT THE MATERIAL OF THE FIREWALL IS GALVANIZED STEEL. 1 H 7 1 3O 3 O 3A23 E1CE 5 C P3EA 1996121900839 19961219 00839 CE 1996 12 19 CA960612018 1 19960606 G 2913 OAS29401 HYDPOWER PACK OZONE OAS29401 CESSNA 210 210E 2073416 CE CONT O520 IO520A 17032 SO MCAULY 2A34C E2A34C73 GL HYD SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA 296 112324R 726919 (CAN) THE HYDRAULIC RESERVOIR WAS FOUND TO BE CONTAMINATED WITH A FILM OF SLUDGE. FURTHER INVESTIGATION FOUND TEFLON TAP E ON THE VARIOUS FITTINGS AND TEFLON CONTAMINATION THROUGHOUT THE UNIT. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1996121900842 19961219 00842 CE 1996 12 19 CA960614007 1 19960606 G 2620 RETAINING CLIP RAYTHN 1015700215 BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA FIRE EXT SWITCH FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 2290 PCE25648 (CAN) ON INSPECITON OF THE ENGINE FIRE EXTINGUISHER ELECTRICAL SYSTEM, IT WAS NOTED THAT THE FIRE EXTINGUISHER MICROSWIT CH ON THE PANEL ACTIVATING BUTTON HAD COME OFF THE HOLDING CLIP RENDERING THE BUTTON INOPERATIVE. THE SWITCH MANUFACTURE R - RAYTHEON - INDICATES A REPLACEMENT SWITCH IS BEING PRODUCED. 1 L 7 2 3T 4 T RT 3A20 E4EA 1996122600006 19961226 00006 EA 1996 12 26 96ZZZX6140 2 19961205 G 8510 75562 GEAR TOOTH PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA PROP SHAFT BROKEN B EKIR K NONE O OTHER IN INSP/MAINT 1 WP 07 18MC 4117 50 246 31P7300143 L38662 ENGINE SOUNDED ROUGH ON SHUT DOWN. FOUND EXCESSIVE PLAY IN PROPELLER. DRAINED OIL, PULLED SUCTION SCREEN, FOUND PIECE OF TOOTH IN SCREEN. ENGINE TORN DOWN, FOUND BROKEN TEETH ON PROP SHAFT DRIVE GEAR, ALSO, DRIVE GEAR DAMAGED. SUBMITTER SUSPECTS PREVIOUS CRACK CAUSED TOOTH TO BREAK OFF. 1 L 7 2 3O 3 O A8EA E19EA 1996122600007 19961226 00007 EA 1996 12 26 96ZZZX6141 2 19961212 G 7322 15B395 RETAIN SCREW FACET HA6 GULSTM AA5 AA5B 3960105 SO LYC O360 O360A4K 41514 EA MIX CONTROL LOOSE D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 07 28794 1014 CH101834 AA5B0819 L249536A PILOT REPORTED ENIGNE HAD STARTED RUNNING ROUGH AND EGT AT PEAK WITH MIXTURE FULL RICH. INVESTIGATION REVEALED MIXTURE CONTROL VALVE END PLAY OF APPROX .0625 INCH. PRECISION AIRMOTIVE SB MSA-6 HAD NOT BEEN C/W. RETENTION SCREW P/N 15-B3 95 WAS FOUND TO HAVE PIN SEPARATED FROM END AND FLOATING IN HOLE. PIN AND SCREW APPEAR TO HAVE BEEN WELDED IN MANUFACTU RE AND SEPARATED AT WELD. INSTALLATION OF RETENTION KIT PER MSA-6 RETURNED NORMAL OPERATION. 1 L 7 1 3O 3 O A16EA E286 1996122600406 19961226 00406 EA 1996 12 26 96ZZZX6155 2 19961120 G 7322 25244919 INJECTOR SERVO BENDIX RSA10ED1 PIPER PA60 PA60601P 7106012 NM LYC O540 IO540S1A5 41532 EA ENGINE FAILED D K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 NE 03 3646N 1768 63 64435 61P085881634 L2051648A INJECTOR SERVO 'SHUT DOWN' DURING ACTUAL FUEL FLOW TEST', ALLOWING ONLY A DRIBBLE OF FUEL THROUGH WITH FULL THROTTLE AND FULL MIXTURE AND FUEL PUMP ON. HAD THIS HAPPENED IN-FLIGHT, ENGINE WOULD HAVE STOPPED. 1 M 7 2 3O 3 O RT A17WE 1E4 1996122600407 19961226 00407 EA 1996 12 26 96ZZZX6156 2 19961101 G 7322 VALVE TANG FACET HA6 CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA FUEL CUT OFF WORN B S ATZR K NONE O OTHER IN INSP/MAINT 1 CE 09 5099U 4986 1015 DL0414 172RG0223 L2782536A TANG OF FUEL CUT OFF VALVE ASSY WORE DEEPLY INTO FULL RICH STOP AREA ALLOWING APPROX ONE-QUARTER TURN MORE THAN NORMAL. ENGINE WENT EXTREMELY LEAN. TAKEOFF ABORTED. 1 H 7 1 3O 3 O 3A17 E286 1996122600411 19961226 00411 EA 1996 12 26 JZBR13659 2 19961108 G 8520 CRANKCASE PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA NR 1 CYL BROKEN B JZBR K NONE K FLUID LOSS NR NOT REPORTED 1 EA 25 6896B 1540 600919816126 L2121748A ENGINE LOST MOST OF ITS OIL DUE TO A HOLE IN THE TOP OF THE CRANKCASE ABOVE THE CAMSHAFT LOBE FOR NR 1 CYLINDER. SUSPEC T CAMSHAFT FOLLOWER FAILURE WHICH WEDGED ITSELF BETWEEN THE CASE AND CAMSHAFT CAUSING CASE FAILURE. (X) 1 M 7 2 3O 3 O RT A17WE 1E4 1996122600527 19961226 00527 WP 1996 12 26 96ZZZX6174 2 19961211 G 7210 3072178 GEAR ASSY LEAR 35 31A 5170531 CE GARRTT TFE731 TFE7312 01518 WP RT ENG PLANETARY DAMAGED E L A O OTHER O OTHER DE DESCENT 1 CE 07 112FX 347 347 116 P99348 DURING DESCENT INTO ICT, PILOT REPORTED UNUSUAL NOISE FROM RT ENGINE. AFTER LANDING AND SHUT DOWN, ROTATION OF FAN BY L EAR JET MECHANIC CONFIRMED NOISE. INSP FOUND A BAYONET FROM A STUD IN THE TEETH OF THE FAN SUPPORT RING GEAR FOR GEARBO X. INSPECTION FOUND THE STUD THAT WAS MISSING THE BAYONET, THE STUD WAS REPLACED AND NO OTHER DAMAGE WAS NOTED. 2 L 7 2 4F 4 F RT A10CE E6WE 1996122600551 19961226 00551 CE 1996 12 26 CA960620026 1 19960513 G 7910 AS9413117 O-RING LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP L/H OIL CAP CUT W A E UNSCHED LANDING ENGINE SHUTDOWN K FLUID LOSS CR CRUISE 1 CA 2010 2010 P89737 (CAN) 'O' RING P/N AS9413-117 WAS DAMAGED WHEN OIL CAP WAS INSTALLED. CONDITION CAUSED OIL TO LEAK FROM ENGINE IN FLIGHT AND DUE TO LOW OIL PRESSURE, AN IN-FLIGHT SHUTDOWN WAS CARRIED OUT. AIRCRAFT LANDED WITH NO FURTHER INCIDENT. 'O' RING WAS REPLACED AND ENGINE SERVICED WITH OIL AND RETURNED TO SERVICE. 2 L 7 2 4F 4 F A10CE E6WE 1996122600556 19961226 00556 SO 1996 12 26 CA960625012 1 19960521 G 2701 62839000 SPROCKET PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA CONTROL YOKE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 3977 L3284927A (CAN) ON ANNUAL INSPECTION, FOUND CONTROL YOKE SPROCKET CRACKED AT WELD. STOP PIN LOOSE BUT STILL IN PLACE. 1 L 7 1 3O 3 O 2A13 E274 1996122600572 19961226 00572 NM 1996 12 26 CA960703033 1 19960613 G 2923 AO293 SEAL 65W01025 BOEING 720 720023B 1383841 NM PWA JT3D JT3D3B 52039 NE AUX PUMP BLOWN W K NONE K FLUID LOSS TX TAXI/GRND HDL 1 CA AO293 645267 (CAN) AFTER LANDING THE F E NOTICED AN ACCUMULATION OF HYDRAULIC FLUID IN AREA OF L/H WHEEL. FUNCTION CHECK CARRIED OUT AND FLUID WAS LEAKING FROM BETWEEN HEAD AND MAIN BODY OF AUXILIARY PUMP WHICH WAS REPLACED 2 L 7 4 4F 4 F 4A28 1E8 1996122600577 19961226 00577 NE 1996 12 26 CA960709001 2 19960626 G 7260 4002T00G09 DRIVE SPLINE SKRSKY S61 S61N 8142104 NE GE CT58 CT581101 30011 NE STARTER DRIVE DAMAGED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING AN ATTEMPTED START, THE STARTER MOTOR WOULD NOT ENGAGE. ON REMOVING STARTER, ENGINE SIDE OF ENGAGE DRIVE BE CAME UNATTACHED. 2 G 7 2 4U 4 U 1H15 1E3 1996122600579 19961226 00579 GL 1996 12 26 CA960711002 2 19960702 G 7250 6898663 TURBINE BLADES SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL 3 AND 4 STAGE DAMAGED W A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA (CAN) A #2 ENGINE ICP CHECK WAS BEING CONDUCTED WHEN #1 ENGINE WAS OBSERVED STARTING TO DECELERATE ACCOMPANIED BY A FUEL PRESSURE CAUTION LIGHT. WHILE TROUBLESHOOTING #1 ENGINE PROBLEM ENG FAILED. UPON SHUT DOWN AND INVESTIGATION, A POWER T URBINE FAILURE WAS OBSERVED. 1 G 7 2 3U 3 U H1NE E1GL 1996122600583 19961226 00583 SW 1996 12 26 CA960711011 1 19960618 G 5551 22123 BRACKET BLANCA 22123 BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA MID LWR BRACKET CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2797 4374 L188836A (CAN) CRACKS FROUND IN LEFT AND RIGHT ARM OF THE LOWER AFT STAB BRACKET. THIS PART HAS BEEN FOUND CRACKED BEFORE AND REP AIRED BY WELDING. THESE LATEST CRACKS WERE FOUND THROUGH OR NEXT TO THE PREVIOUS REPAIRS. WELD REPAIRS WERE ONCE AGAIN C ARRIED OUT. 1 H 7 1 3O 3 O A21CE E286 1996122600585 19961226 00585 CE 1996 12 26 CA960711015 1 19960606 G 2620 RETAINING CLIP RAYTHN 1015700215 BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA FIRE EXT SWITCH FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 2295 PCE25637 (CAN) ON INSPECTION OF THE ENGINE FIRE EXTINGUISHER ELECTRICAL SYSTEM, IT WAS NOTED THAT THE FIRE EXTINGUISHER MICROSWIT CH ON THE PANEL ACTIVATING BUTTON HAD COME OFF THE HOLDING CLIP, RENDERING THE BUTTON INOPERATIVE. THE SWITCH MANUFACTUR ER - RAYTHEON - INDICATES THAT A REPLACEMENT SWITCH IS BEING PRODUCED. 1 L 7 2 3T 4 T RT 3A20 E4EA 1996122600587 19961226 00587 SO 1996 12 26 CA960711201 1 19960618 G 2435 603871 FLANGE AUXILEC 8013C PIPER PA31T PA31T2 7103127 SO PWA PT6 PT6A135 52043 NE START/GEN BROKEN LEGS W K NONE O OTHER IN INSP/MAINT 1 CA 954 PCE92560 (CAN) THE STARTER/GENERATOR QUICK ATTACH-DETACH FLANGE WAS FOUND TO HAVE BROKEN LEGS DURING AN INSPECTION. THE PILOT NOT ED A DIFFERENT NOISE WHILE STARTING THE AIRCRAFT. 1 L 7 2 3T 4 T RT A8EA E4EA 1996122600617 19961226 00617 SW 1996 12 26 CA960722008 1 19960711 G 2730 31072 CONTROL CABLE 31072 BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2A 41514 EA ELEV AFT PULLY FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA L1868036A (CAN) ON INSPECTION THE ELEVATOR CABLE WAS FOUND FRAYED WHERE IT PASSES OVER THE UPPER REAR PULLEY. 1 H 7 1 3O 3 O A21CE E286 1997010200026 19970102 00026 NE 1997 1 2 AU960626 2 19960507 G 8550 827 SEAL PWA DOUG DC4 C54E 3021530 WP PWA R2000 2SD13G 52021 NE HAMSTD 23E 23E50 NE R ENGINE INT OIL FAILED W K NONE E K VIBRATION/BUFFET FLUID LOSS CL CLIMB 1 AU S P107816 P107816 (AUS) NO4 ENGINE OIL SYSTEM NOSE SCAVENGE SYSTEM PIPE UNION SEAL FAILED- LOSS OF ENGINE OIL 2 L 7 4 4R 4 R A762 E230 6 C P603 1997010200027 19970102 00027 NE 1997 1 2 AU960628 2 19960503 G 7414 SF14RN MAGNETO DOUG DC4 C54E 3021530 WP PWA R2000 R2000* 52023 NE HAMSTD 23E 23E50 NE NR 3&4 ENG CONTAM-WATER W K NONE E VIBRATION/BUFFET TX TAXI/GRND HDL 1 AU S P108363P107 (AUS) NO3 AND NO4 ENGINE MAGNETOS CONTAMINATED WITH MOISTURE 2 L 7 4 4R 4 R A762 5E5 6 C P603 1997010200029 19970102 00029 EU 1997 1 2 AU960648 1 19960513 G 4990 SP3967464 BEARING SUNDSTRANDEM 4500506 BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE APU OIL SYS INCORRECT FIT W A K NONE E B VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S SP3967464 (AUS) APU OIL COOLER FAN THRUST BEARING FAILED DUE TO INCORRECT FITMENT(FITTED BACK TO FRONT) - METAL CONTAMINATION OF A PU OIL COOLER MATRIX, OIL FILTERS (2OFF) AND CHIP DETECTOR 2 H 7 4 4F 4 F A49EU E6NE 1997010200031 19970102 00031 CE 1997 1 2 AU960652 1 19960510 G 5712 RIB CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL OUTER WING SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH MAIN LANDING GEAR WHEEL WELL WING RIBS AND SKINS CRACKED 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1997010200032 19970102 00032 CE 1997 1 2 AU960653 1 19960510 G 5711 512203112 SPAR CAP CESSNA RHSPARCAP CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL OUTER WING SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING SPAR CAPS PNO 5122031-1 (LH) AND PNO 512203-2 (RH)CORRODED IN AREA OF NACELLE FUEL TANKS - WING SKI NS AND CHANNELS ALSO CORRODED 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1997010200033 19970102 00033 WP 1997 1 2 AU960655 1 19960515 G 5530 TAILPLANE GOVT N22 N22B 3880102 WP ALLSN 250B 250B17B 03010 GL HARTZL HCA3V HCA3VF7 GL VERT STAB STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH SECTIONS OF TAILPLANE CRACKED IN EIGHT PLACES - MOST CRACKING WAS FOUND TO ORIGINATE FROM RIVETS IN RIBS AND INTERCOSTAL ANGLES - TWO CRACKS WERE ALSO FOUND IN THE SKIN - NUMEROUS RIVETS WORKING - FOUND DURING INSPECTION IA W NMD-55-34 1 H 7 2 3T 3 T A7PC E10CE 5 C P6EA 1997010200035 19970102 00035 SO 1997 1 2 AU960657 1 19960517 G 5320 ANGLE PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCE2Y HCE2YR2 GL NLG WELL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR WHEEL WELL LH AND RH LOWER ANGLES CRACKED IN AREA WHERE NLG DRAG BRACE PIVOT BRACKET ATTACHES AN D TO WHICH THENOSE GEAR DOOR HINGES ATTACH 1 L 7 2 3O 3 O A19S0 E286 5 C P9EA 1997010200038 19970102 00038 EU 1997 1 2 AU960661 1 19960515 G 3220 FORK GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL NOSE-TAIL GEAR S DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR FORK ASSEMBLY DELAMINATING IN AREA OF RADIUS 1 L 7 1 3O 3 O NT A57EU E286 5 C P27EA 1997010200039 19970102 00039 NM 1997 1 2 AU960663 1 19960517 G 5710 WING DHAV DHC8 DHC8103 1386005 NM PWA PW121 PW121 52124 NE WING LE SYS BIRD STRIKE W K NONE C F.O.D. DE DESCENT 1 AU S (AUS) AIRCRAFT SUFFERED A BIRDSTRIKE BY A LARGE WEDGETAIL EAGLE - THE EAGLE GLANCED OFF THE LH WINDSCREEN AND STRUCK TH E LH WING LEADING EDGE BETWEEN THE FUSELAGE AND THE ENGINE JUST INBOARD OF THE PROPELLER ARC CAUSING SEVERE DAMAGE TO TH E LEADING EDGESTRUCTURE, ELECTRICAL WIRING AND PLUMBING BETWEEN STN YW57.20 ANDYW42.00 - MAJOR DAMAGE ALSO OCCURRED TO T HE FRONT SPAR AND LOWER WING SKIN IN THE SAME AREA INCLUDING SEPARATION OF THE LOWER SPARBOOM FROM THE MACHINED WEB AND BUCKLING OF THE LOWER SKIN 2 H 7 2 4T 4 T RT A13NM E20NE 1997010200040 19970102 00040 CE 1997 1 2 AU960664 1 19960507 G 3231 ARB4EDUS ROD END CESSNA CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C87 GL LG EXT-RETRACT S FAILED W K NONE O OTHER CL CLIMB 1 AU S 402C0049 (AUS) LH MAIN LANDING GEAR DOOR LINK ASSEMBLY INBOARD RODEND FAILED IN THE AREA OF THE NUT 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1997010200042 19970102 00042 EA 1997 1 2 AU960669 2 19960518 G 7322 75029611 BRACKET LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL ENG,FUEL CONTROL FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S 75029611 L3406836A (AUS) CARBURETTOR FLOAT PIVOT PIN BRACKET FRACTURED - CARBURETTOR FLOODING 3 O E286 5 C P27EA 1997010200045 19970102 00045 EU 1997 1 2 AU960678 1 19960518 G 7930 230384601 PROCESSOR LYC BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE ENG OIL IND SYS FAULTY W K NONE E K VIBRATION/BUFFET FLUID LOSS TX TAXI/GRND HDL 1 AU S LF05863A (AUS) NO2 ENGINE DUAL LOW OIL PRESSURE PROCESSOR FAULTY - CAUSES INTERFERENCE WITH MASTER WARNING SYSTEM - LYCOMING MODI FICATION79-2-0013D HAD BEEN CARRIED OUT 2 H 7 4 4F 4 F A49EU E6NE 1997010200046 19970102 00046 SO 1997 1 2 AU960680 1 19960516 G 3230 O-RING EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL LG EXT-RETRACT S FAILED W K NONE O OTHER CL CLIMB 1 AU S (AUS) LANDING GEAR HYDRAULC SYSTEM PRESSURE REDUCER VALVE 'O' RING SEAL FAILED 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997010200048 19970102 00048 SW 1997 1 2 AU960683 1 19960209 G 5340 51700367165 BRACKET 51700367165 GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA HARTZL HCA3V HCA3VK2 GL ATTACH FITTING S CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WING ROOT BRACKETS PNO 5170036-5-165 AND PNO 5170036-7-165 CRACKED - FOUND DURING INSPECTION IAW AD/AC/93 1 H 7 2 3O 3 O 6A1 1E4 5 C P6EA 1997010200049 19970102 00049 CE 1997 1 2 AU960684 1 19960503 G 2434 A103214 BEARING PRESTOLITE CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL AC GENERATOR-ALT FAILED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 1368 A103214 (AUS) RH ENGINE ALTERNATOR BEARINGS DESTROYED - DRIVE AND DRIVEN GEARS DAMAGED - METAL CONTAMINATION OF OIL SYSTEM 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1997010200052 19970102 00052 NE 1997 1 2 AU960688 2 19960108 G 7250 AS3218173 RING PWA PWA PT6 PT6A42 52043 NE TURBINE SECTION MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S 4405 94202 94202 (AUS) ENGINE POWER TURBINE DISC NO3 BEARING COVER PNO 3103204-01 MOVED REARWARDS CONTACTING THE 2ND STAGE POWER TURBINE DISC RIM PNO3029313 - SUSPECT RETAINING RING PNO AS3218-173 NOT FITTED AT LAST ASSEMBLY - PERSONNEL/MAINTENANCE ERROR 4 T E4EA 1997010200054 19970102 00054 1997 1 2 AU960696 1 19960513 G 7830 SLIDER CFMINT CFM56 CFM563C 13802 EU T ENG THRUST REV SEPARATED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) ENGINE THRUST REVERSER NO2 OUTBOARD REVERSER HALF LOWER SLIDER SEPARATED FROM THE SLIDER TRACK - TRANSLATING COWL HAD BEEN RECENTLY REMOVED TO CARRY OUT A LOWER BLOCKER DOOR HINGE REPLACEMENT - PERSONEL/MAINTENANCE ERROR 4 F E21EU 1997010200056 19970102 00056 EU 1997 1 2 AU960698 1 19960503 G 5750 68160351 PLATE PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL WING TE SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLAP SYSTEM HINGE PLATES BADLY CORRODED IN AREA OF PIVOT BOLT HOLES - UPPER ATTACHMENT BEARING SEIZED DUE TO LACK OF LUBRICATION 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200057 19970102 00057 EU 1997 1 2 AU960699 1 19960503 G 7120 J961340 MOUNT PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA ENGINE MOUNTING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ENGINE TOP OUTBOARD LORD MOUNT PLATE CONTAINED EXFOLIATION CORROSION - PLATE WAS ALSO SEPARATED FROM THE RUBBE R MOUNT ASSEMBLY 1 H 7 2 3O 3 O A31EU 1E10 1997010200058 19970102 00058 EU 1997 1 2 AU960700 1 19960412 G 3230 SA7670006123 HOSE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE LG EXT-RETRACT S FAILED W K NONE K FLUID LOSS CR CRUISE 1 AU S (AUS) RH MAIN LANDING GEAR ACTUATOR DOWN LINE FLEXIBLE HOSE BURST IN AREA JUST BELOW 90 DEGREE UNION WHERE HOSE ATTACHES TO MANIFOLD -LOSS OF GREEN SYSTEM HYDRAULIC FLUID 2 H 7 4 4F 4 F A49EU E6NE 1997010200059 19970102 00059 EU 1997 1 2 AU960701 1 19960503 G 7120 J961340 MOUNT PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL ENGINE MOUNTING DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE MOUNT RUBBERS DETERIORATED 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200060 19970102 00060 EU 1997 1 2 AU960703 1 19960503 G 5540 68340451 BRACKET PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL RUDDER STRUCT SY CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER HINGE BRACKET CONTAINED EXFOLIATION CORROSION IN THE AREA BETWEEN THE HINGE UPPER FORK LUGS - CORROSION ALS O IN THE AREA OFTHE PIVOT BOLT HOLE - PIVOT BUSH SEIZED DUE TO LACK OF LUBRICATION - THE HINGE FITTING FAILED THROUGH TH E PIVOT BOLTHOLE WHEN ATTEMPTING TO REMOVE THE BOLT 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200061 19970102 00061 1997 1 2 AU960704 4 19960517 G 3452 AT150 TRANSPONDER PIPER PA32 PA32260 7103206 SO LYC O540 O540E4A5 41532 EA HARTZL HCC2Y HCC2YK1 GL DEPDNT POSN DATA FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 25256 (AUS) TRANSPONDER FAILED TO OPERATE DUE TO A FAULTY CAVITY BAND PASS FILTER IN THE RECEIVER 1 L 7 1 3O 3 O A3SO E295 5 C P920 1997010200063 19970102 00063 EU 1997 1 2 AU960706 1 19960503 G 3242 16424A BRAKE DISC PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL LG WHEEL/BRAKE S CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH BRAKE DISCS CORRODED THROUGH IN AREA OF WELD 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200064 19970102 00064 NM 1997 1 2 AU960707 1 19960127 G 5720 CHORD BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE WING LE SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING LEADING EDGE RIB 'T' AT STN 269.298 CORRODED ON THE BOTTOM FLANGE - FURTHER INVESTIGATION FOUND A SECTION OF THE CHORD APPROXIMATELY 152.4MM (6IN) FROM THE WING FRONT SPAR AND APPROXIMATELY 50.8MM (2IN) IN LENGTH COMPLETELY C ORRODED AWAY 2 L 7 3 4F 4 F RT A3WE E2EA 1997010200065 19970102 00065 EA 1997 1 2 AU960708 2 19960503 G 8540 GEAR PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL R ENGINE REAR SE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ENGINE STARTER RING GEAR WORN - BENDIX DRIVE GEAR ON STARTER MOTOR ALSO WORN - ENGINE HAD DIFFICULTY IN CRANKI NG 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200066 19970102 00066 EU 1997 1 2 AU960709 1 19960503 G 2434 ALTERNATOR PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL AC GENERATOR-ALT FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LH ENGINE DRIVEN ALTERNATOR FAULTY - ALTERNATOR HOUSING LOOSE DUETO LOOSE RETAINING BOLTS AND A WORN ALTERNATOR AT TACHMENT HOUSING- THE REPLACEMENT ALTERNATOR WAS SUPPLIED WITHOUT TAGS AND ON INSPECTION WAS FOUND TO BE INCORRECTLY AS SEMBLED AND THE ATTACHMENT HOLE IN THE HOUSING HAD BEEN ILLEGALY REWORKED - SUSPECT BY AN AUTOMOTIVE REPAIRER - PERSONN EL/MAINTENANCE ERROR -UNAPPROVED PART 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200067 19970102 00067 EU 1997 1 2 AU960710 1 19960503 G 7110 COWLING PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL ENGINE COWL SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH ENGINE TOP COWLS BADLY CORRODED AND CRACKED - LH ENGINEOIL DIPSTICK ACCESS DOOR TORN AND ALMOST SEPARATE D 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200070 19970102 00070 EA 1997 1 2 AU960713 2 19960503 G 8500 ENGINE LYC PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL ENGINE (RECIPROC INCORRECT DATA W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH ENGINE DATA PLATES CONTAINED DIFFERENT TIMING DATA - BOTH ENGINES ARE IDENTICAL TYPES - ONE DATA PLATE S TATES 20DEGREES WHILE THE OTHER STATES 25 DEGREES 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200073 19970102 00073 EU 1997 1 2 AU960716 1 19960503 G 5712 RIB PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL OUTER WING SYS INCORRECT MOD W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) RH WING RIB LOCATED IN ENGINE BAY ILLEGALLY MODIFIED - A HOLE HAD BEEN DRILLED THROUGH THE RIB STAINLESS STEEL FIR E BARRIER TO FACILITATE PUSHROD REMOVAL - THE HOLE WAS LEFT UNCOVERED ALLOWINGA POSSIBLE ENGINE FIRE TO PENETRATE TO THE FIBREGLASS LEADINGEDGE AREA CONTAINING FUEL PLUMBING - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED MODIFICATION 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200074 19970102 00074 EU 1997 1 2 AU960717 1 19960503 G 6120 75167 PIPE PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL PROP CNTRL SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PROPELLER CONSTANT SPEED UNIT (CSU) RIGID PIPE, STEEL 'B' NUTS AND SLEEVE BADLY CORRODED/RUSTED 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200075 19970102 00075 EA 1997 1 2 AU960718 2 19960503 G 7314 AC6441271 PUMP PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL ENG,FUEL DIST SY LOOSE SCREWS W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH ENGINE DRIVEN FUEL PUMP COVER SCREWS LOOSE 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200079 19970102 00079 NM 1997 1 2 AU960722 1 19960111 G 5330 SKIN BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE EXT PLATES/SKIN CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AIRCRAFT LOWER SKIN CORRODED AND SPLIT IN THE AREA OF THE LH RAM AIR INTAKE BETWEEN STRINGERS 27LH AND 28LH AT FRA ME AT STN 700 - AREA OF CORROSION APPROXIMATELY 50.8MM BY 76.2MM (2IN BY 3IN) - INVESTIGATION FOUND THAT THE EXFOLIATIO N CORROSION WAS CAUSED BY A SALT WATER SPILL ORIGINATING FROM THE CARGO 2 L 7 3 4F 4 F RT A3WE E2EA 1997010200082 19970102 00082 SO 1997 1 2 AU960725 2 19960524 G 8530 646657 CYLINDER CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY D3A34 D3A34C403 GL R ENGINE CYLINDE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 780 552106 (AUS) ENGINE CYLINDER CRACKED FROM SPARK PLUG HOLE 1 H 7 1 3O 3 O 3A24 E5CE 5 C P47GL 1997010200083 19970102 00083 SO 1997 1 2 AU960726 2 19960317 G 8550 SPRING CONT CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO MCAULY 3AF32C 3AF32C87 GL R ENGINE INT OIL WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 275442R 275442R (AUS) ENGINE OIL PRESSURE RELIEF VALVE SPRING WAS AN INCORRECT PART - FOUND DURING POST INSTALLATION GROUND RUN - ENGIN E WAS A FACTORY REMANUFACTURED ENGINE - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PART 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1997010200084 19970102 00084 1997 1 2 AU960727 1 19960528 G 7820 MUFFLER LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL ENG NOISE SUPPRS FAILED W K NONE E VIBRATION/BUFFET LD LANDING 1 AU S (AUS) RH EXHAUST MUFFLER ASSEMBLY FAILED AT FORWARD END IN AREA OF INLET PIPE TO END PLATE WELDED JOINT 3 O E286 5 C P27EA 1997010200088 19970102 00088 NM 1997 1 2 AU960731 1 19960513 G 7910 3006084 CAP DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE AC,ENG OIL TANK DAMAGED W K NONE E K J VIBRATION/BUFFET FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S 120032 (AUS) ENGINE OIL FILLER CAP LUG BROKEN - LOSS OF APPROXIMATELY THREE LITRES OF OIL 2 H 7 2 4T 4 T RT A13NM E20NE 1997010200090 19970102 00090 NM 1997 1 2 AU960733 1 19960516 G 3244 319K281 TYRE 314353 DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE LG WHEEL/BRAKE S LEAKING W K NONE O OTHER IN INSP/MAINT 1 AU S 1926 (AUS) RH MAIN LANDING GEAR INBOARD TYRE LEAKING EXCESSIVELY THROUGH SIDEWALL PLY VENTS - TYRE WENT COMPLETELY FLAT 2 H 7 2 4T 4 T RT A13NM E20NE 1997010200091 19970102 00091 1997 1 2 AU960734 1 19960529 G 7160 115C6662 AIR BOX LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL ACFT,ENG AIR INT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CARBURETTOR AIR BOX CRACKED FROM BEND RELIEF HOLES 3 O E286 5 C P27EA 1997010200092 19970102 00092 1997 1 2 AU960735 4 19960530 G 3452 TR661A TRANSPONDER PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA DEPDNT POSN DATA FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 5024 (AUS) TRANSPONDER NOT WORKING - INVESTIGATION FOUND OFF/ON/MODEC/TEST SELECTOR ON FRONT FACE NOT CONNECTED TO SWITCH WA FER ON PCB DUETO OVERLOAD FAILURE OF THE SWITCH SHAFT 1 L 7 1 3O 3 O 2A13 E274 1997010200093 19970102 00093 SO 1997 1 2 AU960736 2 19960529 G 8520 CRANKCASE CESSNA 182 182K 2072724 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL R ENGINE POWER S CRACKED W K NONE E K VIBRATION/BUFFET FLUID LOSS NR NOT REPORTED 1 AU S 191100 (AUS) CRANKCASE CRACKED IN AREA OF NO1 BEARING - CRACK ALSO IN CRANKCASE TOP FLANGE AT 7TH HOLE FROM THE FRONT - NO1 BEA RINGSPINNING AND BREAKING UP - FRETTING OF CRANKCASE MATING FACES INDICATES EXCESSIVE MOVEMENT POSSIBLY DUE TO INSUFFIC IENT THROUGHBOLT TENSION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997010200101 19970102 00101 NE 1997 1 2 AU960744 2 19960509 G 7240 LINER RROYCE RB211 RB211524G19 NE TURBINE ENGINE C DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 13059 (AUS) NO1 ENGINE COMBUSTION LINER HEAD DAMAGE EXCEEDED MAINTENANCE MANUAL LIMITS - FOUND DURING BOROSCOPE INSPECTION IAW AD/RB211/19AMDT1 AND ROLLS ROYCE SERVICE BULLETIN RB211-72-B482 4 F E30NE 1997010200102 19970102 00102 SO 1997 1 2 AU960745 1 19960514 G 7931 APT79100080D TRANSMITTER EMB 120 EMB120 3260201 SO PWA 118 PW118A NE ENG OIL IND SYS FLUCTUATES W K NONE O OTHER CL CLIMB 1 AU S 338612179 (AUS) RH ENGINE OIL PRESSURE TRANSMITTER FLUCTUATING 2 L 7 2 4T 4 T RT A31SO E20NE 1997010200103 19970102 00103 WP 1997 1 2 AU960746 1 19960526 G 6220 362093 CONTROL ROTOR HILLER HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10068 (AUS) MAIN ROTOR HEAD CONTROL ROTOR CRACKED AT SPAR END THROUGH THE FIRST BOLT HOLE FOR APPROXIMATELY 50% OF CIRCUMFERE NCE - FOUND DURING INSPECTION IAW AD/HIL12/17 AMDT4 1 G 7 1 3O 3 O 4H11 E304 1997010200105 19970102 00105 WP 1997 1 2 AU960748 1 19960402 G 6220 5143711 ROTOR HUB HILLER HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 773 10452 (AUS) MAIN ROTOR HUB CRACKED IN AREA OF THREADED CUFF AND TRUNNION BOLTHOLE EXTENDING DOWN THE INNER HUB SURFACE - CRACK LENGTH APPROXIMATELY 6.35MM (0.25IN) - FOUND DURING INSPECTION IAW AD/HIL12/22A 1 G 7 1 3O 3 O 4H11 E304 1997010200109 19970102 00109 EU 1997 1 2 AU960752 1 19960517 G 5713 STRINGER PARTEN P68B PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL OUTER WING SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING UPPER SKIN STRINGERS CRACKED - UPPER WING SKIN ALSO CRACKED - FOUND DURING INSPECTION IAW AD/P68/42 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997010200110 19970102 00110 SW 1997 1 2 AU960753 1 19960314 G 3230 790270505 CYLINDER GULSTM 500 500S 0141107 SW LYC O540 IO540K1A5 41532 EA HARTZL HCA3V HCA3VK2 GL LG EXT-RETRACT S DAMAGED W K NONE O OTHER LD LANDING 1 AU S (AUS) NOSE LANDING GEAR RETRACTION CYLINDER SHAFT BENT - NOSE LANDING GEAR COLLAPSED DURING LANDING ROLL - SUSPECT SHAF T PREVIOUSLY BENT BY TOWING INCIDENT OR HEAVY LANDING 1 H 7 2 3O 3 O 6A1 1E4 5 C P6EA 1997010200111 19970102 00111 EU 1997 1 2 AU960754 1 19960425 G 2150 8182833ANSN TURBINE NORMALAIR BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE CABIN COOLING SY SEIZED W A K NONE O OTHER CL CLIMB 1 AU S 10814 8182833AN (AUS) RIVET ATTACHING BAFFLE TO PLENUM/TORUS FAILED AND WAS INGESTED BYTHE RH AIRCONDITIONING PACK COOLING TURBINE CAUSI NG IT TO SEIZE -INVESTIGATION FOUND THAT THE PLENUM/TORUS BAFFLE ASSEMBLY PNO 1344D710 CAME LOOSE DUE TO THE FAILURE OF THE ATTACHMENT RIVETS AND HAD CUT THROUGH THE PLENUM/TORUS OUTER SKIN ALLOWING THE RIVET HEADS TO ENTER AND DAMAGE THE TURBINE - THE MUFF INLET PIPEWAS ALSO FOUND TO BE CRACKED DUE TO THE SEVERE VIBRATION 2 H 7 4 4F 4 F RT A49EU E6NE 1997010200112 19970102 00112 SW 1997 1 2 AU960755 1 19960603 G 3240 2785004079 PIPE FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE LG WHEEL/BRAKE S CHAFED THRU W K NONE O OTHER LD LANDING 1 AU S (AUS) LH BRAKE SYSTEM HYDRAULIC PIPE CHAFED THROUGH BY ELEVATOR CONTROL CABLE - LOSS OF HYDRAULIC FLUID - SUSPECT PIPE D AMAGED DURING AIRCRAFT ASSEMBLY CAUSING IT TO COME IN CONTACT WITH THE ELEVATOR CABLE 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1997010200117 19970102 00117 SO 1997 1 2 AU960762 1 19960528 G 5751 86399803 RIB PIPER 8656219 PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL WING AIL/ELV SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 448195001 (AUS) AILERON RIBS PNO 86399-803 AND PNO 86399-003 CRACKED 1 L 7 2 3O 3 O A19S0 E286 5 C P920 1997010200224 19970102 00224 SO 1997 1 2 CA960724403 2 19960726 G 8520 40644 MAIN BEARING TMPSON NAVION NAVIONA 6150104 SW CONT E225 E2254 17015 SO CRANKCASE SEIZED W K NONE O OTHER IN INSP/MAINT 1 CA 770 30025D34 (CAN) CRANKCASE ASSEMBLY RECEIVED FOR INSPECTION AFTER REPORTS OF HIGH OIL TEMPERATURE, LOW OIL PRESSURE AND STIFFNESS O F PROP ROTATION. CRANKCASE DISMANTLED, CLEANED AND INSPECTED. INSPECTION FOUND THE #5 MAIN BEARING SEIZED. FAILURE TYPIC AL OF OIL STARVATION, FURTHER INSPECTION REVEALED A LARGE AMOUNT OF RUBBER DEBRIS IN THE SUCTION TUBE, CHOKING THE SUCTI ON SCREEN. CRANKCASE OVERHAULED. 1 L 7 1 3O 3 O A782 E267 1997010200257 19970102 00257 EA 1997 1 2 CA960801016 1 19960720 G 7500 BELLOWS C6VE10081C DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA RT ENG BLEED FAILED W H DEACTIVATE SYST/CIRCUITS O OTHER TX TAXI/GRND HDL 1 CA 25844 PCE42076 (CAN) DURING TAKEOFF CHECKS IT WAS NOTED THERE WAS NO CHANGE IN RIGHT HAND ENGINE INDICATION WHEN BLEED AIR WAS SELECTED ON. MAINTENANCE FOUND THE BLEED AIR LINE HAD FAILED AT THE EXPANSION BELLOWS ALLOWING BLEED AIR TO ESCAPE AT ALL TIMES. 1 H 7 2 3T 4 T A9EA E4EA 1997010200273 19970102 00273 NE 1997 1 2 CA960808013 2 19960731 G 7250 MS969611 BOLT PWA PW121 PW121 52124 NE INTERSTAGE CASE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 12457 120870 (CAN) THE ENGINE WAS UNDERGOING ROUTINE INSPECTION AND WAS OBSERVED TO HAVE SUSTAINED CONSIDERABLE POWER TURBINE DAMAGE. DISASSEMBLY FOUND THE ENGINE HAD SUFFERED A FRACTURE OF ONE INTERSTAGE CASE BOLT, WHICH RELEASED THE BOLT HEAD WHICH WA S SUBSEQUENTLY INGESTED BY THE POWER TURBINE CAUSING EXTENSIVE SECONDARY DAMAGE. THE INTERSTAGE CASE REAR FLANGE WAS COR RODED IN THE LOCATION THAT THE BOLT FAILED, WITH THE CORROSION PRODUCTS INCREASING THE LOCAL FLANGE THICKNESS CONSIDERAB LY, RESULTING IN BOLT STRETCH AND FAILURE. 4 T E20NE 1997010200274 19970102 00274 NE 1997 1 2 CA960808014 2 19960729 G 7210 310924401 BEARING PWA 119 PW119B NE RGB NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 5095 116023 (CAN) THE REDUCTION GEARBOX (RGB) WAS FOUND TO HAVE METAL CONTAMINATION. DISASSEMBLY OF THE RGB REVEALED THE SOURCE OF T HE METAL CONTAMINATION WAS THE #15 BEARING WHICH HAD SPALLED BADLY ON THE INNER RACE, AROUND APPROXIMATELY 90 PERCENT OF THE CIRCUMFERENCE. SECONDARY DAMAGE FROM THE CONTAMINATS WAS RESTRICTED TO THREE OTHER SECOND STAGE BEARINGS. 4 T E20NE 1997010200303 19970102 00303 1997 1 2 CA960826104 1 19960710 G 6310 3024680 CLUTCH ASSEMBLY PWA 3024780 PWA PT6T PT6T6 52045 EA #2 ENGINE SIDE DISENGAGED W A UNSCHED LANDING O OTHER EX EXTERNAL LOAD 1 CA 1857 CPGB1591 CPPS72009 (CAN) THE HELICOPTER WAS LIFTING A LOAD, WHEN THE FREEWHEEL CLUTCH INSIDE THE COMBINING GEARBOX DECOUPLED OR DISENGAGED ON THE #2 ENGINE SIDE. THE #2 ENGINE WENT TO FLIGHT IDLE. THE PILOT RELEASED THE LOAD AND LANDED AS SOON AS POSSIBLE. THE COMBINING GEARBOX WAS REMOVED AND SHIPPED TO A REPAIR STATION. 4 U E22EA 1997010200459 19970102 00459 NM 1997 1 2 AU960764 1 19960520 G 5530 220000 HINGE 220018201 PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA VERT STAB STRUCT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FIN HINGE ASSEMBLIES CORRODED 1 M 7 2 3O 3 O RT A17WE 1E4 1997010200460 19970102 00460 NM 1997 1 2 AU960765 1 19960506 G 5330 SKIN BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE EXT PLATES-SKIN CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) REAR FUSELAGE LOWER SKIN CONTAINED EXFOLIATION CORROSION AT FUSELAGE STATION 1050 AND BENEATH STRINGER 27 - DURIN G PROBING INSPECTION SKIN BROKE AWAY LEAVING A 12.7MM (0.5IN) HOLE - SUSPECT CAUSED BY SALT WATER SPILLAGE 2 L 7 3 4F 4 F RT A3WE E2EA 1997010200461 19970102 00461 NE 1997 1 2 AU960766 2 19960519 G 7230 FAN BLADE BOEING 737 737377 NM GE CFM56 CFM563B1 13802 NE TURBINE ENGINE C BIRD STRIKE W K NONE E C VIBRATION/BUFFET F.O.D. TO TAKEOFF 1 AU S 721553 (AUS) NO2 ENGINE SUFFERED A BIRD STRIKE CAUSING SEVERE FAN BLADE DAMAGE - ONE FAN BLADE FRAGMENT EXITED FORWARD OF THE E NGINE AND PENETRATED THE NOSE AND FAN COWLS 2 L 7 2 4F 4 F RT A16WE E2GL 1997010200464 19970102 00464 EA 1997 1 2 AU960769 2 19960501 G 8520 LW11036S CRANKCASE GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA R ENGINE POWER S CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 503 L632748C (AUS) ENGINE CRANKCASE CRACKED IN AREA OF NO2 CYLINDER FORWARD UPPER HOLD DOWN STUD HOLE - CRACK LENGTH 31.75MM (1.25IN) 1 H 7 2 3O 3 O 6A1 1E4 1997010200465 19970102 00465 SO 1997 1 2 AU960770 1 19960218 G 5610 8660804 WINDOW 8660217 PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL FLT CMPT WINDOW BROKEN W K NONE D INFLIGHT SEPARATION CR CRUISE 1 AU S (AUS) PILOTS PERSPEX SIDE WINDOW FAILED AND PARTS SEPARATED FROM AIRCRAFT DUE TO CRAZING - WINDOW IS PART OF THE EMERGEN CY EXIT DOOR ASSEMBLY 1 L 7 2 3O 3 O A19S0 E286 5 C P920 1997010200470 19970102 00470 CE 1997 1 2 AU960775 1 19960607 G 2430 WIRE CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL AC GENERATOR-ALT DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S 280208R D3A34C4048 (AUS) ALTERNATOR BATTERY WIRE DETERIORATED INTERNALLY - WIRE FRACTURED AND ARCING 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997010200473 19970102 00473 SW 1997 1 2 AU960778 1 19960606 G 6220 206011113103 TRUNNION BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S GDLM122299 833095 (AUS) MAIN ROTOR HUB TRUNNION CRACKED IN RADIUS - FAILURE ANALYSIS GROUP COULD FIND NO EVIDENCE OF CRACKING USING BOTH F LUORESCENTDYE PENETRANT AND MAGNETIC PARTICLE INSPECTION TECHNIQUES - THERE WAS EVIDENCE OF REWORK BY POLISHING - PART RETURNED TO BELLHELICOPTER FOR FURTHER INVESTIGATION 1 G 7 1 3U 3 U H2SW E4CE 1997010200474 19970102 00474 EA 1997 1 2 AU960779 2 19960530 G 7414 M3548 ROTOR SLICK 4370 PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA ELEC PWR SUPPLY FAILED W K NONE E VIBRATION/BUFFET TO TAKEOFF 1 AU S 238 95100288 L1185439A (AUS) MAGNETO ROTOR FAILED AT THE BASE OF THE CAM RECESS 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1997010200475 19970102 00475 CE 1997 1 2 AU960780 1 19960603 G 2612 303267 AMPLIFIER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL FIRE DETECTION S FAULTY W K NONE O N OTHER FALSE WARNING CL CLIMB 1 AU S (AUS) RH ENGINE FIRE WARNING SYSTEM FIRE CONTROL AMPLIFIER FAULTY 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997010200476 19970102 00476 CE 1997 1 2 AU960781 1 19960601 G 2612 302158 FIRE DETECTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL FIRE DETECTION S FAULTY W K NONE N FALSE WARNING CR CRUISE 1 AU S (AUS) RH ENGINE FORWARD UPPER DETECTOR FAULTY 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997010200478 19970102 00478 CE 1997 1 2 AU960783 1 19960513 G 5340 0512122 BLOCK CESSNA CESSNA 172 172D 2072410 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL ATTACH FITTING S CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CENTRE WING SPAR BEARING BLOCK CONTAINS SEVERE INTERGRANNULAR EXFOLIATION CORROSION 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 1997010200479 19970102 00479 CE 1997 1 2 AU960784 1 19960422 G 3230 583800901 MOTOR BEECH 58 58 1152740 CE CONT O520 IO520F 17032 SO LG EXT-RETRACT S FAULTY W K NONE O OTHER CL CLIMB 1 AU S 3976 (AUS) LANDING GEAR ELECTRIC MOTOR ARMATURE SEGMENT FAULTY 1 L 7 2 3O 3 O 3A16 E5CE 1997010200482 19970102 00482 GL 1997 1 2 AU960787 3 19960516 G 6110 A163570 SCREW MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA MCAULY 2D34C B2D34C214 GL PROPELLER ASSY S FAILED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 832220 (AUS) PROPELLER CYLINDER RETAINING SCREWS (3OFF14) BROKEN - OTHER SCREWS (9OFF14) LOOSE - SUSPECT INSUFFICIENT TORQUE O N SCREWS AT LAST INSTALLATION - SOME FRETTING DAMAGE TO GASKET 1 L 7 1 3O 3 O 2A3 1E10 5 C P7EA 1997010200483 19970102 00483 CE 1997 1 2 AU960788 1 19960304 G 2913 105932E POWER PACK CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MCAULY 2D34C B2D34C207 GL LG EXT-RETRACT S FAULTY W K NONE O OTHER LD LANDING 1 AU S 105932E (AUS) HYDRAULIC POWER PACK ELECTRIC MOTOR RUNNING SLOW - SLOW TO BUILD UP HYDRAULIC PRESSURE 1 H 7 1 3O 3 O A20CE 1E10 5 C P7EA 1997010200484 19970102 00484 SO 1997 1 2 AU960789 1 19960530 G 3411 FITTING PIPER PA28 PA28180 7102808 SO LYC O360 O360A3A 41514 EA SNSNCH 76E M76EMMS EA ENVIRONMENT DATA WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) AIRSPEED INDICATOR PITOT LINE FITTING AND PIPE INCORRECT AUTOMOTIVE PARTS - PERSONNEL/MAINTENANCE ERROR - UNAPPROV ED PART - FOUND DURING PITOT SYSTEM LEAK CHECK IAW AD/INST/8 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA4 1997010200485 19970102 00485 SO 1997 1 2 AU960790 1 19960530 G 2820 PIPE PIPER PA28 PA28180 7102808 SO LYC O360 O360A3A 41514 EA SNSNCH 76E M76EMMS EA FUEL DISTRBUTION DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) FUEL SUPPLY PIPE BETWEEN FUEL SHUTOFF AND FIREWALL BULKHEAD FITTING KINKED FROM HAND BENDING - PIPE IS MALLEABLE COPPER FITTED DURING MODIFICATION FOR USE OF MOGAS IAW FAA STC SA2660CE,SE2563CE AND SE2587CE - PERSONNEL/MAINTENANCE ER ROR 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA4 1997010200489 19970102 00489 EU 1997 1 2 AU960796 1 19960510 G 5610 92274H8274ANS WINDSHIELD BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FLT CMPT WINDOW FAILED W K NONE O OTHER LD LANDING 1 AU S 92274H8274 (AUS) LH `B' WINDSCREEN ARCED AT TOP LEFT HAND CORNER AND THEN THE OUTER GLASS PLY SHATTERED - SUSPECT FAILURE WAS HEAT RELATED 2 H 7 4 4F 4 F A49EU E6NE 1997010200490 19970102 00490 EA 1997 1 2 AU960797 2 19960606 G 8520 LW17760 CRANKSHAFT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL R ENGINE POWER S FAILED W K NONE Y ENGINE STOPPAGE TO TAKEOFF 1 AU S L720561A (AUS) ENGINE CRANKSHAFT FAILED THROUGH WEBS OF NO1 AND NO2 BIG END JOURNALS - NO1 AND NO2 CYLINDERS AND CONNECTING RODS DAMAGED 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997010200491 19970102 00491 EU 1997 1 2 AU960798 1 19960429 G 5610 NP1701022 WINDSHIELD BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FLT CMPT WINDOW FAILED W K NONE O OTHER CL CLIMB 1 AU S 90218H3813A (AUS) RH `B' WINDSCREEN OUTER GLASS PLY SHATTERED - SUSPECT CAUSED BY ARCING 2 H 7 4 4F 4 F A49EU E6NE 1997010200492 19970102 00492 SO 1997 1 2 AU960799 1 19960607 G 7602 24894007 CABLE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE2Y HCE2YK2 GL POWER CONTROL SY BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH ENGINE MIXTURE CONTROL INNER CABLE BROKEN APPROXIMATELY 10MM (0.39IN) FROM SWAGING TO CABLE CONTROL ROD AT THE ENGINE END 1 L 7 2 3O 3 O A20SO E14EA 5 C P9EA 1997010200496 19970102 00496 SO 1997 1 2 AU960803 1 19960605 G 5520 317912110 ELEVATOR PIPER PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2 GL ELEVATOR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 317912110 (AUS) LH AND RH ELEVATORS CRACKED - FOUND DURING RADIOGRAPHIC INSPECTION IAW AD/PA31/126 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997010200497 19970102 00497 NE 1997 1 2 AU960804 2 19960604 G 7412 3038137 EXCITER DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE ELEC PWR SUPPLY FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 2406 120122 (AUS) ENGINE IGNITION EXCITER BOX FAULTY 2 H 7 2 4T 4 T RT A13NM E20NE 1997010200498 19970102 00498 1997 1 2 AU960805 1 19960323 G 7930 230376303 HARNESS LYC ALF502 ALF502R5 41580 NE ENG OIL IND SYS DAMAGED W K NONE O K OTHER FLUID LOSS CR CRUISE 1 AU S LF05506A (AUS) NO1 ENGINE OIL INDICATION SYSTEM HARNESS DAMAGED AND SHORT CIRCUITING ON PYLON DRAIN PIPE ON FRONT RH COWLING 4 F E6NE 1997010200500 19970102 00500 SO 1997 1 2 AU960808 2 19960528 G 8530 646460 EXHAUST VALVE CONT PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO HARTZL HCC2Y BHCC2YF2 GL R ENGINE CYLINDE FAILED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S 237339R AN444913 (AUS) LH ENGINE NO5 CYLINDER EXHAUST VALVE FAILED - SUSPECT CAUSED BY EXCESSIVE LEANING OF ENGINE 1 L 7 2 3O 3 O A7SO E9CE 5 C P920 1997010200501 19970102 00501 SO 1997 1 2 AU960809 1 19960503 G 5310 TUBE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YK2 GL MAIN FRAME SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE STEP TUBE CRACKED - AIRCRAFT HAS BEEN MODIFIED IAW SB672AND AD/PA28/81 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 1997010200503 19970102 00503 SW 1997 1 2 AU960812 1 19960522 G 7810 4606AC CLAMP BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL T ENG CONE-PIPE FAILED W K NONE O OTHER LD LANDING 1 AU S CAE830380 (AUS) ENGINE EXHAUST CLAMP FAILED IN RIVETTED AREA DUE TO CORROSION FROM EXHAUST GASSES 1 G 7 1 3U 3 U H2SW E4CE 1997010200505 19970102 00505 CE 1997 1 2 AU960814 1 19960301 G 5720 HINGE BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL OUTER WING SYS WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING LOWER FORWARD SPAR TO LEADING EDGE `D' SECTION HINGE AND HINGE PINS WORN - MAXIMUM AMOUNT OF WEAR IS LOCATED BETWEEN WING ROOT TO JUST OUTBOARD OF ENGINE 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1997010200506 19970102 00506 CE 1997 1 2 AU960815 1 19960301 G 5540 NIAS5054J BEARING BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL RUDDER STRUCT SY CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER BEARINGS (2OFF) CORRODED INTERNALLY - AIRCRAFT OPERATES IN A SALT LADEN ENVIRONMENT - SUSPECT BEARINGS ORIG INAL FITMENT 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1997010200509 19970102 00509 SO 1997 1 2 AU960818 1 19960607 G 3230 14595 ACTUATOR EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL LG EXT-RETRACT S FAULTY W K NONE O N OTHER FALSE WARNING CR CRUISE 1 AU S 1454 (AUS) LH MAIN LANDING GEAR DOWNLOCK ACTUATOR FAULTY - MICROSWITCH STRIKER NOT ACTIVATING MICROSWITCH 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997010200512 19970102 00512 SW 1997 1 2 AU960821 1 19960514 G 2910 79024681 PIPE GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA HARTZL HCA3V HCA3VK2 GL MAIN HYD SYS CORRODED W K NONE K FLUID LOSS DE DESCENT 1 AU S (AUS) HYDRAULIC PIPE LOCATED IN WING ROOT AREA CONTAINED A PINHOLE LEAK DUE TO CORROSION ON THE OUTER RADIUS OF THE 90 D EGREE BEND 1 H 7 2 3O 3 O 6A1 1E4 5 C P6EA 1997010200514 19970102 00514 SW 1997 1 2 AU960823 1 19960412 G 6230 0471301101 BEARING BELL 47 47G3B 1181026 SW LYC O435 TVO435D1A 41516 EA M/R MAST/SWASHPL FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 1166 047130114 (AUS) MAIN ROTOR MAST BEARING FAILED - SUSPECT CAUSED BY HEAVY LANDING - METAL CONTAMINATION OF OIL SYSTEM 1 G 7 1 3O 3 O 2H3 1E13 1997010200515 19970102 00515 CE 1997 1 2 AU960824 1 19960607 G 3250 24670031 BUNGEE CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL ACFT STEERING SY BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AIRCRAFT STEERING SYSTEM BUNGEE JACK SCREW BROKEN DUE TO A WORN HOUSING - SYSTEM HAD BEEN MODIFIED IAW AD/CESSNA1 70/45 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 1997010200516 19970102 00516 EA 1997 1 2 AU960825 2 19960607 G 8520 CRANKSHAFT LYC PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL R ENGINE POWER S BROKEN W K NONE E VIBRATION/BUFFET TO TAKEOFF 1 AU S L720561A (AUS) ENGINE CRANKSHAFT BROKEN - CRANKCASE BROKEN - CAMSHAFT DAMAGED - NO1 AND NO2 CYLINDERS DAMAGED - CONNECTING RODS B ENT - SEE MDR 96/0797 FOR FURTHER INFORMATION 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997010200517 19970102 00517 NM 1997 1 2 AU960826 1 19960513 G 7910 3006084 CAP DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE AC,ENG OIL TANK DAMAGED W K NONE O K OTHER FLUID LOSS CL CLIMB 1 AU S 120032 (AUS) RH ENGINE OIL FILLER CAP DAMAGED - ONE LOCKING LUG BROKEN OFF - APPROXIMATELY 3 LITRES OF OIL LOST - DUPLICATE OF MDR 96/0731 2 H 7 2 4T 4 T RT A13NM E20NE 1997010200518 19970102 00518 NM 1997 1 2 AU960827 1 19960529 G 2750 745583A CONTROL CABLE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE FLAP SYS FAILED W A K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLAP CABLE SWAGED END FITTING SEPARATED FROM CABLE OUTER SHEATH -INNER CABLE DAMAGED - FOUND DURING INSPECTION IAW AD/DHC8/8 2 H 7 2 4T 4 T RT A13NM E20NE 1997010200521 19970102 00521 SW 1997 1 2 AU960830 1 19960614 G 2520 2790567033 SEAT SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP PASSENGER COMPAR BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PASSENGER SEAT BACK BROKEN 2 L 7 2 4T 4 T RT A8SW E4WE 1997010200523 19970102 00523 SW 1997 1 2 AU960832 1 19960605 G 7810 PIPE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP T ENG CONE-PIPE CRACKED W K NONE F B J FLT CONT AFFECTED SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION NR NOT REPORTED 1 AU S (AUS) ENGINE EXHAUST SYSTEM SHORT PIPE CRACKED - HOT EXHAUST GASSES ACTIVATED FIRE WARNING SYSTEM AND FIRE BOTTLE WAS D ISCHARGED 2 L 7 2 4T 4 T RT A8SW E4WE 1997010200524 19970102 00524 SW 1997 1 2 AU960833 1 19960607 G 7712 27191587 INDICATOR 6112104 SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ENG PWR IND SYS FLUCTUATES W K NONE O OTHER TO TAKEOFF 1 AU S PORT77102 (AUS) LH ENGINE TORQUE INDICATOR FLUCTUATING 2 L 7 2 4T 4 T RT A8SW E4WE 1997010200525 19970102 00525 GL 1997 1 2 AU960835 2 19960606 G 7240 6899081 LINER SNIAS 350 AS350B 8680801 EU ALLSN 250C 250C30 03013 GL TURBINE ENGINE C FAILED W K NONE O OTHER NR NOT REPORTED 1 AU S 941 CAT890502 (AUS) ENGINE COMBUSTION ASSEMBLY AIR SURROUND TO COMBUSTION LINER ATTACHMENT SADDLES (3OFF) FAILED AT WELDS - SADDLES W ERE INGESTEDTHROUGH THE ENGINE 1 G 7 1 3U 3 U H9EU E1GL 1997010200644 19970102 00644 CE 1997 1 2 97ZZZX6192 1 19961127 G 7500 635404767 TUBE CESSNA 525 525 2076601 CE WILINT FJ44 FJ44 66000 GL RT ENG BLEED BROKEN D K NONE O OTHER IN INSP/MAINT 1 CE 07 229CJ 361 5250129 1268 PILOT REPORTED RT ENG ITT PROBLEMS. INSP FOUND RT ENG OUTB BLEED AIR TUBE BROKEN IN FLEX TUBE AREA. REPLACED TUBE, OPS CHECK OK. 1 L 7 2 4F 4 F RT A1WI E3GL 1997010800003 19970108 00003 NE 1997 1 8 AU960761 2 19960509 G 8530 166313 PISTON PWA R2000 DOUG DC4 C54E 3021530 WP PWA R2000 R2000* 52023 NE HAMSTD 23E 23E50 NE R ENGINE CYLINDE BURNT W K NONE E K VIBRATION/BUFFET FLUID LOSS CL CLIMB 1 AU S 889 P107816 P107816 (AUS) NO4 ENGINE NO 10 CYLINDER PISTON BURNT - ENGINE OIL VENTING OVERBOARD 2 L 7 4 4R 4 R A762 5E5 6 C P603 1997010800011 19970108 00011 EU 1997 1 8 AU960763 1 19960529 G 7712 97521206 TRANSMITTER PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67 52043 NE ENG PWR IND SYS FAULTY W K NONE O OTHER CR CRUISE 1 AU S (AUS) ENGINE TORQUE PRESSURE TRANSMITTER INTERNAL FAILURE 1 L 7 1 3T 4 T RT A78EU E26NE 1997010800012 19970108 00012 SO 1997 1 8 AU960834 2 19960601 G 7322 2523047 NEEDLE NA53A1 CESSNA 140 140 2071602 CE CONT C90 C90* 17009 SO ENG,FUEL CONTROL DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CARBURETTOR FLOAT NEEDLE RUBBER TIP HARDENED AND DEFORMED - OBSOLETE PART 1 H 7 1 3O 3 O NC A768 E252 1997010900094 19970109 00094 EA 1997 1 9 97ZZZX1 2 19961021 G 7420 M6083 HARNESS SLICK 6351 AMTR 540 EDGE540 056020M GL LYC O540 IO540* 41532 EA TERMINAL CAP NU DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 NM 11 42GP 130 95060063 ALTHOUGH THIS PROBLEM OCCURRED ON AN EXPERIMENTAL ACROBATIC AIRCRAFT, IT IS BELIEVED IT COULD OCCUR ON ANY NEW ENGINE AP PLICATION. THE SPARK PLUG NUT IS SEIZED TO THE DRIVE FERRULE MAKING REMOVAL FROM THE SPARK PLUG IMPOSSIBLE WITHOUT HOLD ING THE DRIVE FERRULE. IT APPEARS THE SPARK PLUG NUT IS PLATED TOO HEAVILY RESULTING IN GALLING OF THE NUT TO THE DRIVE FERRULE. THE PLATING ALSO FORMS SLIVERS OF METAL WHICH DROP INTO THE SPARK PLUG CERAMIC. AFTER REMOVAL, THE DRIVE FER RULE IS COATED WITH AN ANTI-SEIZE COMPOUND. SUBSEQUENT OPERATION NORMAL. 1 M 7 1 3O 3 O NC EXPA1M71 1E4 1997010900103 19970109 00103 SO 1997 1 9 97ZZZX10 2 19961105 G 8530 641066 O-RING 649358A2 BEECH 36 36BEECH 1151602 CE CONT O550 IO550B SO CYL BASES MISSING D K NONE W INADEQUA