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 20081028 CE 2008 10 28 2008FA0000713 1 20041013 G 2510 05140778 SEAT FRAME CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA COCKPIT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 20454 5822 17261300 DURING A ROUTINE 100 HOUR INSPECTION IT WAS DISCOVERED THAT THE PILOTS FULLY ADJUSTABLE SEAT FRAME WAS CRACKED IN SEVERA L PLACES. SOME AREAS WERE COVERED UP BY THE UPHOLSTERY WHICH IS GLUED TO THE FRAME IN THAT AREA. OTHER AREAS OF CONCERN WERE INCOMPLETE WELDS DONE AT THE FACTORY. (3) OUT OF (4) SUPPORT LEGS WERE CRACKED AT THE WELD AND AT THE ATTACHMENT P OINT TO THE BOTTOM SEAT ASSY. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2005042500009 20050425 00009 EA 2005 4 25 CA041222016 2 20041222 G 7421 REM38E SPARK PLUG CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ENGINE CRACKED W A UNSCHED LANDING E R J VIBRATION/BUFFET PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA L2751651A (CAN) NR 1 TOP SPARK PLUG INSULATOR FOUND BROKEN UNDER ELECTRODES. REPLACED NR 1 TOP SPARK PLUG, REMAINING PLUGS FOR LT MAGNETO CLEANED AND FUNCTION TESTED. GROUND RUN CARRIED OUT, LT MAGNETO OPERATION NORMAL. 1 H 7 1 3O 3 O NT 3A12 1E10 2004022500029 20040225 00029 WP 2004 2 25 54140A 2 20040119 G 7200 310166811 PLENUM JETAIR JETSTM JETSTM4101 1500501 EU GARRTT TPE331 TPE33110UG 01514 WP ENGINE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 FOUND CRACKED AT DRAIN. 2 L 7 2 4T 4 T RT A41NM E4WE 2004022700082 20040227 00082 SW 2004 2 27 2004FA0000142 1 20040123 G 5711 SPAR BBAVIA 7 7AC 2110102 SW CONT A75 A75* 17005 SO WINGS CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 07 83899 7AC2580 AD 200-25-02-R1, INSPECTION OF WING SPARS WAS SIGNED OFF AS COMPLIANCE WITH, ON 19 AUG O1 AS A NON-REOCCURRING INSP. DU RING ANNUAL INSPECTION IN JAN 04, BOTH MAIN SPARS WERE FOUND TO BE CRACKED AT THE ROOT END. 1 H 7 1 3O 3 O A759 E213 2004030100083 20040301 00083 CE 2004 3 1 2004FA0000190 1 20040211 G 5512 04121761 SKIN CESSNA 150 150B 2071806 CE CONT O200 O200A 17020 SO MCAULY 1A100 1A100* GL HORIZONTAL STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 09 1163Y 3548 15059563 30082A 36505 REMOVED HORIZONTAL STABILIZER FOR TAILCONE REPAIR. FOUND TWO 1.5 INCH CRACKS RADIATING FROM LOWER FORWARD CORNER OF TAI L CONE SKIN WHERE BOTTOM OF HORIZONTAL LEADING EDGE RESTS. CRACKS PROGRESSING TOWARDS FORWARD HORIZONTAL STABILIZER MOU NT BOLT HOLES. APPEARS INTERFERENCE FIT BETWEEN HORIZONTAL AND TAIL CONE WAS A CONTRIBUTING FACTOR. AREA HAD TO BE CLE ANED TO FIND CRACK DUE TO THE ACCUMULATION OF DEBRIS AND WEAR MATERIAL. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004030100084 20040301 00084 CE 2004 3 1 2004FA0000191 1 20040211 G 5512 04121761 SKIN CESSNA 150 150B 2071806 CE CONT O200 O200A 17020 SO MCAULY 1A100 1A100* GL ZONE 300 CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 09 1163Y 3548 15059563 30082A 36505 REMOVED HORIZONTAL STABILIZER FOR TAILCONE REPAIR. FOUND TWO 1.5 INCH CRACKS RADIATING FROM LOWER FORWARD CORNER OF TAI L CONE SKIN WHERE BOTTOM OF HORIZONTAL LEADING EDGE RESTS. CRACKS PROGRESSING TOWARDS FORWARD HORIZONTAL STABILIZER MOU NT BOLT HOLES. APPEARS INTERFERENCE FIT BETWEEN HORIZONTAL AND TAIL CONE WAS A CONTRIBUTING FACTOR. AREA HAD TO BE CLE ANED TO FIND CRACK DUE TO THE ACCUMULATION OF DEBRIS AND WEAR MATERIAL. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004030100114 20040301 00114 CE 2004 3 1 6604 1 20040212 G 5343 07436062 FITTING CESSNA 182 182P 2075816 CE CONT O470 O470* 17026 SO NLG BROKEN B C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 GL 11 7371Q 2737 18261011 ABORTED TAKEOFF AFTER LOUD NOISE HEARD ON TAKEOFF AND RUDDER KICKED FULL DEFLECTION. FOUND NOSE GEAR LOWER FITTING BROK EN IN TWO, INSPECT THIS FITTING CLOSELY AT ANNUAL. 1 H 7 1 3O 3 O NT TA13 E273 2004030100121 20040301 00121 CE 2004 3 1 2004FA0000182 1 20040204 G 2133 40117 CHECK VALVE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP CABIN PRESSURE CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 03 600JD 6500236 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSE MBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECKED AND AN IDENTICAL CHECK VALVE COND ITION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2 L 7 2 4F 4 F A9NM E6WE 2004030100127 20040301 00127 EA 2004 3 1 2004FA0000186 2 20040114 G 7414 4347 MAGNETO MOONEY M20 M20C 5870208 SW LYC O360 IO360A1A 41514 EA ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 05 6784V 665 700083 L1506136A ROUGH ENGINE ON RUNUP. MAGNETO REMOVED AND DISASSEMBLED. BEARING CAP ASSEMBLY NOT HELD STATIONARY IN FRAME. RETAINING SCREWS AND TABS WERE FOUND TIGHT BUT NOT TIGHT ON BEARING CAP. BEARINGS FOUND TO BE OK. BELIEVE THAT CAP ON HOUSING W AS MACHINED INCORRECTLY AND WAS NEVER TIGHT FROM DAY ONE. 1 L 7 1 3O 3 O 2A3 1E10 2004030300089 20040303 00089 CE 2004 3 3 2004FA0000199 1 20040202 G 8120 K1250860M105 INLET CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO TURBO EXH SYS MISMANUFACTURED B CVDR K NONE O OTHER IN INSP/MAINT 1 WP 17 111VF 21064005 2935795 UPON INSPECTION OF NEW PARTS DEFECTS WERE FOUND WITH THE TURBO INLET COMPONENT. DAMAGE WAS NOTED ON THE TURBOCHARGER MO UNTING FLANGE AND THE WELDING HAD VERY POOR PENETRATION. PART REJECTED AND SENT BACK TO O/H FACILITY. UPON RECEIVING P ARTS, FACILITY WAS NOT ABLE TO IDENTIFY IF PART WERE NEW OR REPAIRED DUE TO INSUFFICIENT PAPER WORK. W/O AND INVOICE IS ONE AND SAME FOR NEW PARTS AND OVERHAULED PARTS. 1 H 7 1 3O 3 O 3A21 E8CE 2004021700155 20040217 00155 SW 2004 2 17 2004FA0000148 1 20040109 G 7120 204060031015 FITTING BELL 205 205A1 1181414 SW LYC T53 T5313B 41549 NE ENGINE DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 4750R 30009 LEO7587 UPON OPENING PACKED FOR FITTING ASSEMBLY FOUND THREADS ON LONG SIDE OF FITTING PULLED LOOSE. PART REJECTED BEFORE INSTA LLATION. 1 G 7 1 4U 4 U H1SW E17EA 2004030300102 20040303 00102 CE 2004 3 3 YK1R062001 1 20040227 G 4920 GTCP36150W APU RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE7313R1H 29001 WP APU BAY FAILED B YK1R H E DEACTIVATE SYST/CIRCUITS ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 SW 11 653XP 11 11 258653 DURING TAXI, SMOKE RAPIDLY FILLED THE COCKPIT AND THE CABIN. EMERGENCY SHUTDOWN OF ALL SYSTEMS WAS PERFORMED, GROUND EM ERGENCY DECLARED AND AIRCRAFT EVACUATED. IT WAS FOUND DUE TO FAILURE IN THE APU, OIL ENTERED THE BLEED AIR DUCT WHICH C AUSED THE SMOKE. SYSTEM IS IN TROUBLESHOOTING/TEARDOWN PROCESS. 2 L 7 2 4F 4 F RT A3EU E6WE 2004030300185 20040303 00185 NM 2004 3 3 SROM200400002 1 20040220 G 5310 655495616 SHEAR TIE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND ELONGATED HOLE IN SHEAR TIE AT STA 500 BETWEEN STR 16R AND 17R, FORWARD UPPER HOLE. REM OVED DAMAGED SHEAR TIE. FABRICATED AND INSTALLED REPLACEMENT SHEAR TIE IAW B737 SRM 53-10-4. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030300191 20040303 00191 SO 2004 3 3 2004FA0000208 2 20040211 G 8530 AEC631397SN712B CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER AS RECEIVED. FOUND EXHAUST VALVE GUIDE INSIDE DIAMETER TO BE BELOW MINIMUM SPECIFICATIONS, AND VA LVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300192 20040303 00192 SO 2004 3 3 2004FA0000210 2 20040202 G 8530 AEC631397SN712B CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISMANUFACTURED D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE DID NOT MEET MINIMUM MFG. DIMENSI ONS, AND VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300196 20040303 00196 SO 2004 3 3 2004FA0000209 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISMANUFACTURED D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300197 20040303 00197 SO 2004 3 3 2004FA0000214 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300203 20040303 00203 SW 2004 3 3 2004FA0000216 1 20040217 G 3210 P1912506252M ROLL PIN MOONEY MOONEY M20 M20R 5870225 SW CONT O550 IO550G 17042 SO MCAULY 3A32C 3A32C418G GL LT MLG TUBE SHEARED C A UNSCHED LANDING J WARNING INDICATION DE DESCENT 1 GL 09 909WM 1923 182352 290152 679307 010286 SHEAR PINS ON LT MLG TUBE ASSEMBLY FAILED. AFT INSERT SEPARATED FROM TUBE ASSEMBLY. LT MAIN GEAR SUBSEQUENTLY REMAINE D UNSAFE AND RETRACTED UPON CONTACT WITH RUNWAY. RT MLG AND NOSE GEAR WERE IN THE DOWN AND LOCKED AT TIME OF LT MLG FAI LURE. 1 L 7 1 3O 3 O RT 2A3 E3SO 5 C P21EA 2004030400025 20040304 00025 WP 2004 3 4 2004FA0000219 1 20040113 G 6120 6873725012 O-RING AEROPRODTSXX CVAC 440 440 2422902 WP ALLSN 501D 501D13 03004 GL TRANSFER TUBE CUT B MV1R A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 EA 17 49 33437 603 R242 479 AT CRUISE FLIGHT NR 1 PROP EXPERIENCED RPM FLUCTUATIONS. AS A PRECAUTIONARY MEASURE, PROP WAS FEATHERED. PILOT LANDED UNEVENTFULLY. FOUND REGULATOR TO PROP, OIL TRANSFER TUBE, O-RING CUT. INSTALLED NEW O-RING. GROUND RUN FUNCTIONAL AND LEAK CHECKS GOOD. 2 L 7 2 4R 4 T 6A6 E282 2004030400028 20040304 00028 NM 2004 3 4 SROM200400003 1 20040223 G 5310 654652548 SHEAR TIE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND SHEAR TIE AT STA 380 BETWEEN STR 20R AND 21R HAS HOLES THAT ARE LARGER THEN SRM LIMITS. REMOVED DAMAGED SHEAR TIE, FABRICATED AND INSTALLED REPLACEMENT SHEAR TIE IAW B737 SRM 51-40-3. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400029 20040304 00029 NM 2004 3 4 SROM200400004 1 20040224 G 5340 6935352U14 STRINGER CLIP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 639, STR 4L. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED N EW CLIP IAW B737 SRM 51-30-2 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400031 20040304 00031 NM 2004 3 4 SROM200400006 1 20040223 G 5340 6935352U14 STRINGER CLIP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 616, STA 4L. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED N EW STRINGER CLIP IAW B737 SRM 51-30-2 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400041 20040304 00041 EA 2004 3 4 2004FA0000223 2 20040130 G 8520 LW16812 LIFTER CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE WORN B FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 73827 1033 17267703 L23476T DURING A ROUTINE OIL CHANGE, WHILE COMPLYING WITH AD. MINUTE METAL PARTICLES WERE FOUND IN THE OIL FILTER WHEN IT WAS C UT OPEN FOR INSPECTION. HYDRAULIC LIFTERS WERE REMOVED FOR A MORE DETAILED INSP. THE ONE CAM LOBE FOR NR 3 AND NR 4 CY LINDERS HAD PLATING SEVERELY WORN OFF THE TOP OF THE LOBE AND THE BASE OF THOSE TWO LIFTERS HAD SEVERE DAMAGE. THIS ENG INE GETS FREQUENT OIL CHANGES. THIS ENGINE HAS THE 76T MOD INSTALLED INFORMATION WAS FORWARDED TO CERTIFICATION OFFICE. THIS ENGINE HAS BEEN REMOVED AND SENT FOR OVERHAUL. (NE05200404276) 1 H 7 1 3O 3 O NT 3A12 E274 2004030400050 20040304 00050 SO 2004 3 4 2004FA0000226 2 20040210 G 7310 631526 DIAPHRAGM BEECH 35 M35 1151526 CE CONT O470 IO470C 17026 SO FUEL MANIFOLD CRACKED D ET9T O OTHER O OTHER NR NOT REPORTED 1 NM 07 762AA 3600 D6168 718869C FUEL DIAPHRAGM ON THE FUEL MANIFOLD VALVE SHOWED DETERIORATION DUE TO AGEING. FUEL LEAKED OUT OF THE AIR BLEED HOLE ON THE FUEL MANIFOLD VALVE, CAUSING ENGINE FUEL FLOW PROBLEMS. ADDITIONAL INSPECTIONS AFTER PROLONGED STORAGE. 1 L 7 1 3O 3 O 3A15 E273 2004030400072 20040304 00072 EU 2004 3 4 B30R20040226 1 20040219 G 5310 DOOR FRAME SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE FUSELAGE CRACKED B B3OR K NONE O OTHER IN INSP/MAINT 1 SW 03 5204Y 1359 100 3101 9571 DURING 100 HOUR INSPECTION DISCOVERED CO-PILOT DOOR POST CRACKED 14 INCHES LONG STARTING 8 INCHES ABOVE CABIN FLOOR, EXC EEDING THE LIMITS IN REPAIR MANUAL. REPAIRED CRACK IAW MM. REQUESTED FROM MFG. 1 G 7 1 3U 3 U H9EU E19EU 2004030400082 20040304 00082 GL 2004 3 4 2004FA0000236 1 20040206 G 1430 FASTENER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA LT AILERONS CHAFED B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 28 201023 DEFLECTION OF LT AILERON UP CAUSES IT TO RUB AGAINST AN EXPOSED RIVET. DEFLECTION OF RT AILERON UP CAUSES IT TO RUB AGA INST TWO EXPOSED RIVETS POSSIBLY HINDERING TRAVEL. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400087 20040304 00087 GL 2004 3 4 2004FA0000239 1 20040206 G 3250 BUNGEE CYLINDER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA NLG STEERING STIFF B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 201023 NOSE WHEEL STEERING BUNGEES ARE EXTREMELY STIFF, CAUSES THE RUDDER TO REQUIRE EXTREMELY HIGH RUDDER INPUTS IN FLIGHT. P ILOT CAN FEEL A BREAKOVER POINT. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400090 20040304 00090 2004 3 4 2004FA0000240 4 20040206 G 3454 INDICATOR AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA VOR SYSTEM INACCURATE B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 28 201023 NEWLY INSTALLED VORS INDICATORS 6-10 DEGREES DIFFERENCE. NAV 1 G430 W G5, NAV 2 BK W G5 KX 155. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400092 20040304 00092 GL 2004 3 4 2004FA0000241 1 20040206 G 5260 STEP AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA PAX DOOR LOOSE B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 201023 RT ENTRANCE STEP IS EXTREMELY LOOSE. (GL200305339) 1 L 7 1 3 O EXPA1L71 E223 2004030400093 20040304 00093 SO 2004 3 4 2004FA0000248 1 20040227 G 3230 67502000 RETAINER PIPER PA34 PA34200 7103405 SO LYC O360 IO360A1A 41514 EA RT MLG LOOSE D E H ENGINE SHUTDOWN DEACTIVATE SYST/CIRCUITS W INADEQUATE Q C LD LANDING 1 SO 05 15412 347350060 ON LANDING ROLL-OUT, RIGHT MLG COLLAPSED AFT AND CAME TO REST AGAINST AFT PORTION OF WHEEL WELL.RETAINING PIN HAD SLIPPE D OUT OF TRUNNION, ALLOWING GEAR TO COLLAPSE. THIS GEAR WAS PREVIOUSLY REMOVED FOR SPAR REPAIR. THE RETAINER BOLT WAS EI THER LEFT OUT OR WAS NOT INSTALLED CORRECTLY. OVER A PERIOD OF TIME, THE RETAINER SLID OUT OF THE TRUNNION. RECOMMEND P OST MAINTENANCE INSPECTIONS BE MORE COMPLETE. THIS INCIDENT, IF IT HAD HAPPENED 20 SECONDS EARLIER, WOULD HAVE CAUSED MA JOR STRUCTURAL DAMAGE AND POSSIBLY PERSONAL INJURY. 1 L 7 2 3O 3 O A7SO 1E10 2004030400095 20040304 00095 GL 2004 3 4 2004FA0000243 1 20040206 G 5320 BRACKET AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA CARB HEAT BROKEN B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 21 201023 CARB HEAT BRACKET BROKE LOOSE IN FLIGHT. 1 L 7 1 3 O EXPA1L71 E223 2004030400096 20040304 00096 2004 3 4 2004FA0000244 4 20040206 G 2300 AUDIO PANEL AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA COCKPIT INOPERATIVE B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 13 201023 STEREO INPUT INTO AIRCRAFT DOES NOT WORK. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400098 20040304 00098 CE 2004 3 4 8570000 1 20040227 G 2731 S3280 GEAR BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA ELEVATOR TRIM SLIPPED A JJBA K NONE O OTHER IN INSP/MAINT 1 EA 01 857CA 5662 UE403 WHILE CHECKING ELEVATOR TRIM FOR FCD BE2703 DISCOVERED ELEVATOR TAB DIAL MECHANISM MOUNT ASSY HAD SLIPPED CAUSING THE TR IM INDEX MARK CALIBRATION TO CHANGE. UPON FURTHER INSPECTION IT WAS DISCOVERED THAT THE SLIPPAGE WAS CAUSED BY A PRESSED ON GEAR IN THE ELEVATOR TAB DIAL MECHANISM MOUNT ASSY THAT HAD SLIPPED ON ITS SHAFT. 2 L 7 2 4T 3 T RT A24CE E2NE 2004030400105 20040304 00105 NM 2004 3 4 SROM200400008 1 20040225 G 5310 654654851 SHEAR TIE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND AT STA 747 SHEAR TIE CRACKED AT FASTNER HOLE BETWEEN STR 20L AND 21L. REMOVED DAMAGE, F ABRICATED AND INSTALLED REPAIR SHEAR TIE IAW SRM 53-10-4. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400106 20040304 00106 NM 2004 3 4 SROM200400009 1 20040225 G 5513 654577428 STRINGER BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 ELONGATED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND AFT CARGO PIT STRINGER 20L HAS SEVERAL ELONGATED FASTNER HOLES AND MULTIPLE CRACK INDICA TIONS AROUND HOLES STA 747 TO 887. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR STRINGER AND SPLICES IAW SRM 53-10-3 . 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400107 20040304 00107 NM 2004 3 4 SROM200400010 1 20040226 G 5340 69353521 STRINGER CLIP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND STRINGER TO FRAME CLIP CRACKED AT STA 495-500, STR 24R. REMOVED DAMAGED STRINGER CLIP, FABRICATED AND INSTALLED REPLACEMENT STRINGER CLIP IAW B737 SRM 51-20-1, 51-30-2. 2 L 7 2 4F 4 F RT A16WE E2EA 2004031500001 20040315 00001 NM 2004 3 15 AUS20040043 1 20040117 G 5210 723D1009 ACTUATOR BOEING 747 747438 NM RROYCE RB211 RB211524* NE PAX DOOR INTERMITTENT W O OTHER J WARNING INDICATION CR CRUISE 1 AU S 34991 (AUS) RT UPPER DECK DOOR FLIGHT LOCK ACTUATOR INTERMITTENT IN OPERATION. ACTUATOR INTERMITTENTLY UNLOCKS DOOR HANDLE. 2 L 7 4 4F 4 F RT A20WE E12EU 2004031500002 20040315 00002 CE 2004 3 15 CA040211007 1 20040122 G 5610 10138402524 WINDSHIELD BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) RT WINDSHIELD INNER LAYER CRACKED IN FLIGHT AT FLIGHT LEVEL 240. REPORTED OAT -45C. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004031500003 20040315 00003 EU 2004 3 15 CA040123006 1 20040105 G 2497 WIRE161 WIRE HARNESS BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 1 GENERATOR CHAFED W O OTHER J WARNING INDICATION AP APPROACH 1 CA 37287 37287 (CAN) DURING APPROACH WHEN ATTEMPTING TO START APU , LOST AC BUSS 1 AND ESSAC , NR 1 GENERATOR WOULD NOT RE-SET, AIRCRAF T LANDED NORMALLY. MAINTENANCE INSPECTION FOUND CHAFING OF THE 'B' PHASE (YELLOW STRIPE) NR 1 ENGINE GENERATOR WIRING CH AFED TO GROUND AT THE LT TOP FWD COWL (WIRING BUNDLE CONTAINING FEEDER CABLE AND GEN CONTROL WIRING), ALSO FOUND CHAFIN G OF THE NR 1 GENERATOR 'RED STRIPE' WIRING AT PYLON COVER. NOTE: PREVIOUS SIMILAR EVENT ON THIS AIRCRAFT HAD BEEN BLAM ED ON CONTAMINATION OF THE CONNECTOR (1XB-7R), PROBLEMS WERE SEVERAL DAYS APART. 2 H 7 4 4F 4 F A49EU E6NE 2004031500008 20040315 00008 2004 3 15 AUS20040046 4 20040122 G 3418 C809072 TRANSDUCER DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE STALL WARNING STICKING W O OTHER N FALSE WARNING TO TAKEOFF 1 AU S (AUS) RT STALL WARNING SYSTEM TRANSDUCER STICKING IN FORWARD POSITION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500009 20040315 00009 SW 2004 3 15 AUS20040047 1 20040130 G 5330 2722197002 DOUBLER SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE DOUBLER LOCATED AT RT EMERGENCY EXITS, BADLY CORRODED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004031500010 20040315 00010 NM 2004 3 15 AUS20040048 1 20040129 G 5310 65056131 DOOR FRAME BOEING 727 7272J4 1384006 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AFT CARGO DOOR CUTOUT FRAME LOCATED AT BS 1090 RIB BL28 CRACKED. CRACK LENGTH 8.255MM (0.325IN). 2 L 7 3 4F 4 F RT A3WE E2EA 2004031500012 20040315 00012 SW 2004 3 15 CA040211010 1 20040209 G 8012 REGULATOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 27214 (CAN) CREW WERE ON A TRAINING FLIGHT AND WENT THROUGH A SIMULATED ENGINE FAILURE. ENGINE WOULD NOT RESTART AFTER 3 ATTEM PTS. AIRCRAFT RETURNED TO BASE. MAINTENANCE FOUND THE START PRESSURE REGULATOR TO BE AT FAULT. PART WAS REPLACED AND AI RCRAFT RETURNED TO SERVICE AFTER SUCCESSFUL ENGINE STARTS IAW MM. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2004031500014 20040315 00014 CE 2004 3 15 CA040212001 1 20040204 G 5210 051300735 POST CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL CREW DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10532 (CAN) DURING 200 HR INSPECTION, CRACK NOTED AT LOWER DOOR HINGE IN LT FRONT DOORPOST. VISIBLE THROUGH ACCESS HOLE ON IN SIDE OF POST. CRACK APPEARS TO HAVE INITIATED DUE TO FLEXING CAUSED BY HINGE PULLING ON POST WHEN DOOR CLOSES. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004031500017 20040315 00017 CE 2004 3 15 CA040212005 1 20040206 G 5210 50430043619 CHANNEL BEECH BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL CABIN DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION OF THE DOOR HINGE FOR LOOSE RIVETS, A CRACK WAS DISCOVERED THAT PROPAGATED APPROXIMATELY .7500 T HE LENGTH OF THE DOOR CHANNEL. THE DOOR WAS REMOVED AND SENT TO AN APPROVED REPAIR STATION. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004031500022 20040315 00022 CE 2004 3 15 CA040126002 1 20040122 G 7160 1019100209 HINGE BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL INLET VANE WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAINTENANCE INSPECTION DISCOVERED LT ENGINE INLET VANE HINGE PIN WAS WORKING OUT OF THE HINGE AND CONTACTING THE I NNER COWL STRUCTURE. MFG ADVISES THE HINGE ENDS ARE CRIMPED TO PREVENT PIN MOVEMENT, HOWEVER ON THIS ASSY THE PIN APPE ARS TO HAVE WORN THROUGH THE CRIMP. HINGE ASSEMBLY REPLACED NEW. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004031500035 20040315 00035 EU 2004 3 15 CA040127002 1 20040126 G 3000 23053191 LEVER BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ANTI ICE ACT CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) PILOT REPORTED THAT THE INLET ANTI-ICE SYSTEM WAS UNSERVICEABLE. THE ANTI-ICE VALVE WOULD NOT TO CLOSE. THE CIRCUI T BREAKER FOR THE SYSTEM ALSO TRIPPED. UPON INSPECTION MAINTENANCE FOUND THAT THE ANTI-ICE LEVER WAS CRACKED AND ELONGAT ED WHERE IT ATTACHES TO THE ACTUATOR ALLOWING THE ANTI-ICE LEVER TO DISCONNECT FROM THE ACTUATOR. THE ACTUATOR WOULD RUN BUT NOT EXTEND OR RETRACT THE INLET ANTI-ICE VALVE. 1 G 7 2 3U 3 U H3EU E4CE 2004031500044 20040315 00044 EA 2004 3 15 CA040213010 1 20040210 G 2731 C2T41 JACKSCREW DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELEVATOR TRIM CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 12498 (CAN) MINOR CORROSION NOTED ON THE EXTERNAL SURFACE OF THE TRIM DRUM (CABLE GROOVES EXFOLIATING NEAR THE CABLE INDEX PIN ) ON REMOVAL OF THE TRIM DRUM SCREW ASSEMBLY THE MIDDLE PORTION OF THE JACK SCREW PN NR C2T41 WAS FOUND TO BE SEVERELY C ORRODED IN THE MID PORTION OF THE ACME THREAD. THIS PART OF THE JACKSCREW IS NOT VISIBLE DURING ROUTINE MAINTENANCE, AN D REQUIRES THE JACK TO BE DISASSEMBLED TO VERIFY ITS CONDITION. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500049 20040315 00049 EA 2004 3 15 CA040127006 1 20040127 G 2150 32156221 REGULATOR VALVE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE LT & RT PACK INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT AND RT PACK HI PRESS. MESSAGE ON T/O, CHECKLIST COMPLETED. LT PACK CAME BACK MOMENTARILY. BOTH PACKS U/S WITH H IGH PRESS. MSG. LT AND RT PRESSURE REGULATOR VALVES REPLACED, BOTH PACKS OPERATED AT T/O POWER, NO FAULT FOUND. CONS.SER V. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500054 20040315 00054 NM 2004 3 15 CA040127011 1 20040127 G 3230 273T41202 GEAR BOEING 767 7673Y0 NM PWA 4060 PW4060 52119 NE NLG LOCK INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN GEAR WAS LOWERED, NOSE DID NOT LOCK. CREW WAS ABLE TO EXTEND AND LOCK USING THE ALTERNATE METHOD, CONTINUING THE LANDING WITHOUT FURTHER INCIDENT. ACFT REMOVED FROM SERVICE FOR INVESTIGATION. 2 L 7 2 4F 4 F RT A1NM E24NE 2004031500063 20040315 00063 CE 2004 3 15 CA040216006 1 20040213 G 2510 05142132 LOCK CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL COCKPIT SEAT SHEARED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING THE PRE-FLT PHASE, THE PILOT ATTEMPTED TO ADJUST THE LT SEAT WHEN THE SEAT BACK DROPPED BACK BEYOND ITS NOR MAL RANGE OF ADJUSTMENT. IT WAS DETERMINED THEN THAT THE SEAT WAS NOT IN A SAFE CONDITION TO USE AND THE CREW MADE AN E NTRY IN THE LOGBOOK THUS GROUNDING THE AIRCRAFT. CLOSER EXAMINATION OF THE SEAT ADJUSTING MECHANISM BY THE MAINTENANCE PERSONNEL REVEALED THAT THE AFT ROD ATTACHMENT FOR THE LOCK CYLINDER HAD SHEARED WHERE THE ROD IS SECURED INTO THE END C AP. THE CRIMP REMAINED INTACT WHERE AS THE SHEAR OCCURRED JUST FORWARD OF THE CRIMP. DIRECTLY CAUSING THE SEAT ADJUSTME NT MECHANISM TO FAIL. A NEW REPLACEMENT PART ORDERED FROM THE MFG. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004031500065 20040315 00065 CE 2004 3 15 CA040217001 1 20040217 G 7120 265102215 MOUNT CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE THE ENGINE MOUNT RING (HORSE COLLAR) WAS FOUND CRACKED AT TWO OF THE FOUR CORNERS, INSI DE JOINT. DUE TO THIS BEING A KNOWN PROBLEM, AN ADDITIONAL TASK CARD TO CHECK FOR THIS CONDITION, INITIATED IN 1999, WA S ADDED TO OUR MAINTENANCE SCHEDULE EVERY 100 HOURS. AS A RESULT, WE HAVE DISCOVERED THE CONDITION ON 9 SEPARATE COLLAR S. THE COLLAR WAS REPLACED AND THE AIRCRAFT RELEASED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004031500067 20040315 00067 SO 2004 3 15 CA040127018 1 20040124 G 2820 465299 LINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FUEL SYSTEM LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) DURING START UP, PILOT NOTICED FUEL ODOR IN CABIN SHORTLY AFTER ENGINE START UP. MAINTENANCE WAS NOTIFIED AND AFTE R INSPECTION IT WAS NOTED A FINE MIST FROM RT FLEXIBLE FUEL PRESSURE LINE. HOSE WAS REPLACED WITH NO FURTHER PROBLEMS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500069 20040315 00069 SW 2004 3 15 CA040217002 1 20040211 G 5210 44P14 HOSE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL DOOR SEAL CRACKED W B EMER. DESCENT W INADEQUATE Q C CR CRUISE 1 CA (CAN) THE HOSE THAT SUPPLIES THE CABIN DOOR SEAL CRACKED, ALLOWING THE SEAL TO DEFLATE WHICH IN TURN ALLOWED THE CABIN OF THIS FREIGHTER TO DEPRESSURIZE AT 17000 FT. THE CREW DESCENDED TO A SAFE ALTITUDE AND COMPLETED THE FLIGHT. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004031500070 20040315 00070 CE 2004 3 15 CA040217003 1 20040217 G 3040 KRP3DH24 RELAY CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL WINDSHIELD BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING TROUBLESHOOTING OF THE WINDSHIELD HEAT AUTO FUNCTION, THE AUTO RELAY WAS FOUND TO BE INTERNALLY SHORTED AND HAD MELTED THE CLEAR CASE. THE RELAY WAS REPLACED AND THE AIRCRAFT RELEASED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004031500074 20040315 00074 NM 2004 3 15 CA040217008 1 20040213 G 2750 696670833 CONTROL CABLE BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE LT IB FLAP FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SCHEDULED MAINTENANCE, IT WAS OBSERVED THAT THE LT IB FLAP ASSY WAS DROOPING. UPON FURTHER INVESTIGATION, T HE CABLE ASSY WAS FOUND FRAYED AND BROKEN. A NEW CABLE ASSY WAS INSTALLED IAW MM 27-51-5 AND FUNCTIONED SERVICEABLE IAW MM 27-51-0. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004031500078 20040315 00078 SW 2004 3 15 CA040217009 1 20040210 G 2497 206075559005 CONNECTOR BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL LEAD GRD CONNECT BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BURNED CABLE CONNECTORS AT FUSELAGE GROUND CONNECTION. LOOSE/CORRODED CONNECTION. CABLE ASSEMBLY REPLACED. THIS MA Y HAVE CONTRIBUTED TO EARLIER PROBLEMS WITH RCR /VOLT.REG. (CABLE K5B8N AND K5D8N) 1 G 7 1 3U 3 U H2SW E4CE 2004031500088 20040315 00088 EA 2004 3 15 CA040218003 2 20040212 G 8530 LW12966 CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE DAMAGED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) OVERHAUL ENGINE WAS INSTALLED AT 7117.6. IN THE PROCESS OF DOING A 100 HOUR, FOUND NR 1 CYLINDER VERY LOW ON COMPR ESSION. REPLACED CYLINDER WITH OVERHAULED CYLINDER. CHECKED COMPRESSION AFTER INSTALLATION AND COMPRESSION WAS WHERE IT WAS SUPPOSED TO BE. GROUND RUN NO FAULTS FOUND. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500089 20040315 00089 SW 2004 3 15 CA040128001 1 20040128 G 6510 407340339107 BEARING RACE BELL 427 427 1182207 SW PWC PW207 PW207D NE T/R DRIVE MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) IT WAS BROUGHT TO OUR ATTENTION THAT A BEARING WAS DELIVERED TO A CUSTOMER AND FOUND WITHOUT THE REQUIRED 4 (.062 DIA.) LUBE HOLES. THE 4 LUBE HOLES TO BE LOCATED IN THE LUBRICATION GROOVES. 1 G 7 1 3U 3 U R00001RC E42NE 2004031500092 20040315 00092 NM 2004 3 15 CA040128004 1 20040127 G 7711 LINE BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE PT7 NR 1 ENGINE CHAFED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) NR 1 ENGINE EPR INDICATION ERRATIC. FOUND PT7 LINE CHAFED ON LT WING LEADING EDGE AT WBL 114.0. ELBOW AT END OF L INE CONNECTION FOUND CRACKED. BOTH CHAFED LINE AND ELBOW REPLACED. 2 L 7 2 4F 4 F A16WE E2EA 2004031500093 20040315 00093 EA 2004 3 15 CA040128005 2 20040109 G 7414 BEARING CONT 3200 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MAGNETO CONTAMINATED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA A0491056R (CAN) ON RETURN FLIGHT THE LT ENGINE STARTED TO RUN ROUGH. UPON LANDING THE PILOT DID A MAGNETO CHECK AND FOUND THAT THE MAGNETO DROP WAS EXCESSIVE. REMOVED MAGNETO WITH COVER OFF FOUND METAL IN BACK OF MAGNETO. INSTALLED OVERHAULED MAGNETO , GROUND RUN AIRCRAFT NO FAULTS FOUND. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500095 20040315 00095 NM 2004 3 15 CA040128007 1 20040126 G 3242 214664 BRAKE DISC DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE MLG BRAKE UNIT DEFORMED W K NONE O OTHER IN INSP/MAINT 1 CA 0092 (CAN) DURING REMOVAL OF THE BRAKE UNIT FROM THE AIRCRAFT, HALF OF THE BRAKE DISC DROPPED ONTO THE FLOOR. ONCE THE BRAKE UNIT WAS REMOVED FROM THE AIRCRAFT, THE REMAINING HALF OF THE DISC WAS RECOVERED FROM THE BRAKE UNIT. IT APPEARS TO BE S OME DEFORMITY OF THE DISC. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500099 20040315 00099 EA 2004 3 15 CA040218004 2 20040212 G 8530 LW12966 CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE INOPERATIVE W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) OVERHAUL ENGINE WAS INSTALLED AT 7117.6. IN THE PROCESS OF DOING A 100 HOUR FOUND NR 6 CYLINDER VERY LOW ON COMPRE SSION. REPLACED CYLINDER WITH OVERHAUL CYLINDER CHECKED COMPRESSION AFTER INSTALL, COMPRESSION WAS WHERE IT WAS SUPPOSED TO BE. GROUND RUN NO FAULTS FOUND. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500100 20040315 00100 EU 2004 3 15 CA040218005 1 20040218 G 7830 THRUST REVERSER AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE NR 1 ENGINE INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) SHORTLY AFTER T/O ROTATION ECAM ENG. NR 1 REV. UNLOCKED. NO BUFFET EXPERIENCED. JETTISONED FUEL AFTER ECAM AND RET URNED TO LAND, OVERWEIGHT 229,000, VERTICAL SPEED AT TOUCHDOWN ESTIMATED APPROX 300/FTM. THRUST REVERSER PLACED UNDER M EL 78-30-01. IAW REQUEST FROM MOC DFDR REMOVED FOR POSSIBLE INVESTIGATION. 2 L 7 4 4F 4 F RT A197 E37NE 2004031500101 20040315 00101 CE 2004 3 15 CA040218007 1 20040128 G 5610 5042006937 WINDSHIELD BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 CA (CAN) PILOTS FRONT WINDOW CRACKED ACROSS WINDOW ON OUTER PANE. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2004031500102 20040315 00102 GL 2004 3 15 CA040219001 1 20040216 G 7810 2078000107 EXHAUST STACK DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912 55555 EU HOFMAN HOV352 HOV352F NE CYLINDER HEAD BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE RT REAR EXHAUST STACK WAS FOUND TO BE COMPLETELY FRACTURED IN TWO AT THE BEND NEAR THE CYLINDER HEAD. THIS FAI LURE IS THE SECOND COMPLETE FRACTURE NOTED IN THE PAST WEEK. A THIRD EXHAUST STACK WAS FOUND CRACKED IN THE SAME LOCATIO N DURING THE PREVIOUS WEEK. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 5 C TP5BO 2004031500104 20040315 00104 NE 2004 3 15 CA040219003 2 20040218 G 7200 JT8D15A ENGINE BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE NR 1 FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 CA 685598 (CAN) UPON THE TRANSITIONING FROM CLIMB TO CRUISE, A LOUD BANG WAS HEARD AND SUBSEQUENT VIBRATION FELT THROUGHOUT THE AI RFRAME. ALL NR 1 ENGINE PARAMETERS IMMEDIATELY BEGAN TO DETERIORATE RAPIDLY. AT FL280, ENGINE FAILURE DRILL INITIATED A ND COMPLETED. ATC ADVISED OF ENGINE FAILURE. EMERGENCY DECLARED AND AIRCRAFT RETURNED. EMERGENCY CREW MET AIRCRAFT AN D AFTER INSPECTION OF ENGINE, AIRCRAFT WAS THEN TAXIED BACK TO RAMP AND SHUT DOWN. MORE TO FOLLOW AFTER INVESTIGATION. 2 L 7 3 4F 4 F A3WE E2EA 2004031500108 20040315 00108 EU 2004 3 15 CA040129006 1 20040119 G 6320 350A38101891 BEAM SNIAS 350 AS350B1 8680811 EU TMECA ARRIEL ARRIEL1D1 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIRCRAFT ON HELISKIING WHEN THIS OCCURRED. INSPECTED IAW AD96-156-071(B) R1 PART 1.1, EVERY 30 HOURS OR 150 CYCLES . THIS WAS BEING INSPECTED DUE TO THE CYCLES EVERY 2 OR 3 DAYS. THE CROSSBEAM WAS FOUND SMOKING IN THE REGION OF SUSPEC TED CRACK. THE AREA WAS CLEANED, INSPECTED AND FOUND TO BE SERVICEABLE. AFTER A NEXT DAY FLYING IT WAS INSPECTED AGAIN AND FOUND TO BE SMOKING AGAIN REMOVED FROM SERVICE TO BE NDT. SENT TO A NDT AMO AND CRACK WAS CONFIRMED. THE AD IS WOR KING. 1 G 7 1 3U 3 U H9EU E19EU 2004031500113 20040315 00113 2004 3 15 CA040102002 4 20040102 G 3417 9B810202 ADC BOEING 737 737200 1384453 NM PWA JT8 JT8D17 52049 NE COCKPIT INTERMITTENT W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) PRIOR TO DEPARTURE THE FLIGHT CREW A MACH AIRSPEED WARNING CLACKER INOPERATIVE ASSOCIATED WITH A FLAG ON THE MACH AIRSPEED INDICATOR. RECTIFICATION THE MACH AIRSPEED INDICATOR WAS REPLACED. HOWEVER THE SNAG RETURNED ON DECEMBER 29. T HE SYSTEM WAS PLACED ON MEL. THE MACH AIRSPEED INDICATOR WAS REPLACED AGAIN ON DECEMBER 31. HOWEVER THE FAULT RETURNED F OR A THIRD TIME ON JANUARY 2, 2004. 2 L 7 2 4F 4 F A16WE E2EA 2004031500117 20040315 00117 NM 2004 3 15 CA040130002 1 20040106 G 2422 054021 RESISTOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE INVERTER FAILED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA 1882S8 (CAN) COMPONENT RESPONSIBLE FOR INVERTER FAILURE WAS THE RESISTOR (R324) P/N 054021 DESCRIPTION: ON APPROACH, PRIMARY IN VERTER, SECONDARY INVERTER, AND AUX INVERTER, L26AC BUS, AND R26AC BUS CAUTION LIGHTS ILLUMINATED. AFTER AUX INVERTER S WITCHED OFF, PRIMARY, SECONDARY AND BOTH 26AC BUS LIGHTS WENT OUT. CREW BROKE OFF APPROACH AND AC RETURNED. COULD NOT F AULT ON GROUND. PRIMARY INVERTER VOLTAGE INDICATING 107V AND REPLACED. AUX INVERTER REPLACED FOR T/S. ALL RELATED CON NECTOR PLUGS AND CIRCUIT BREAKERS INSPECTED SVC. INVERTERS SENT OUT TO VENDOR AND RETURNED WITH S/N 1882-S8 S WO CONFIRM ING FAULT, AND NAMING THE RESISTOR AS THE CULPRIT COMPONENT P/N 054021. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500118 20040315 00118 NE 2004 3 15 CA040130003 2 20040126 G 7200 3020159 RETAINER CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE HOT SECTION WAS GIVEN A SCHEDULED HOT SECTION INSPECTION. FOUR CT SHROUD SEGMENTS HAD SHIFTED SLIGHTLY. THE RE TAINING RING HAD COME OUT OF THE GROOVE. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. PWA HAS ISSUED P/N 3110741-0 2 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42, 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETA INING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE R OBUST RETAINING RING TO BE USED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004031500120 20040315 00120 EU 2004 3 15 CA040130006 1 20040125 G 6230 11741904 SWASHPLATE BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE MAIN ROTOR WORN W O OTHER O OTHER CR CRUISE 1 CA (CAN) UPON RETURNING AFTER A TRIP THE PILOTS REPORTED A (HUMP) (VERTICAL VIBRATION) ON THE AIRCRAFT. A VISUAL INSPECTION WAS CARRIED OUT ON THE MAIN ROTOR HEAD, BLADES, PITCH LINKS, AND THE SWASHPLATE. CHECKING THE SWASHPLATE FOUND IT TO H AVE AN EXCESSIVE AMOUNT OF PLAY. 1 G 7 2 3U 3 U H13EU E5NE10 2004031500122 20040315 00122 SO 2004 3 15 CA040103001 1 20040102 G 5540 4004009 TORQUE TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL RUDDER CORRODED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) WHILE COMPLYING WITH AD 2003-24-07, FOUND SURFACE CORROSION OF RUDDER TORQUE TUBE (VISUAL INSPECTION OF RUDDER INT ERNAL STRUCTURE MFG SB NR 1105A. REMOVED TORQUE TUBE AND FOUND AREA TO BE INSPECTED IAW AD REPAIRABLE BUT FOUND THAT THE INTERNAL TORQUE TUBE CORROSION SEVERE AND METAL/OXIDE FALLING OFF TORQUE TUBE INTERNAL WALLS. (NOT MENTIONED BY AD). RU DDER ALUMINUM RIBS TO STEEL TORQUE TUBE CORROSION ALSO NOTED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500126 20040315 00126 SO 2004 3 15 CA040219006 1 20040218 G 3213 4041304 AXLE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG BROKEN W C D ABORTED TAKEOFF RETURN TO BLOCK D INFLIGHT SEPARATION TX TAXI/GRND HDL 1 CA 16094 (CAN) PILOT WAS TAXIING OUT FOR TAKEOFF WHEN THE AXLE BROKE. VIBRATION AND NOISE WAS HEARD. TAXIED BACK AND DISCOVERED T HE MAIN WHEEL HAD TILTED OVER AND WAS RUBBING ON THE FORK ASSEMBLY. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500128 20040315 00128 2004 3 15 CA040220002 4 20040211 G 3416 24929412 ALTIMETER BEECH 99 99 1154002 CE PWA PT6 PT6A36 52043 NE HARTZL HCB3T HCB3TN3 GL COCKPIT FAILED W A UNSCHED LANDING P NO WARNING INDICATION CR CRUISE 1 CA 1535 (CAN) CAPTAIN'S ALTIMETER ERROR OF APPROXIMATELY 1,000 FEET CHECKED OK PRIOR TO DEPARTURE. NOT SURE WHEN FAILURE OCCURRE D, BUT NOTICED ERROR AT LEVEL CRUISE. MAINTENANCE CONFIRMED NO STATIC SYSTEM LEAKS. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004022300108 20040223 00108 EU 2004 2 23 2004FA0000077 1 20040104 G 7697 30709341 WIRE HARNESS BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE7313R 01518 WP RT ENGINE DETERIORATED D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CE 03 120JC 6970 6970 NA0247 P80195C WHILE EN ROUTE, NOTED RT ENGINE COMPUTER AMBER WARNING LAMP BECAME ANNUNCIATED. ALSO NOTED, INDICATED LOSS OF POWER RT ENGINE. CONSULTED AND COMPLIED WITH EMERGENCY PROCEDURES WHICH INSTRUCTED TO SWITCH TO MANUAL CONTROL AND MONITOR ALL A PPLICABLE ENGINE PARAMETERS. IMMEDIATE NOTIFICATION TO ATC REQUESTS TO DIVERT TO DAL FOR INSPECTION AND REPAIRS. FOLLO WING TROUBLESHOOTING AND INSPECTION TO DETERMINE SOURCE OF DEFECT, IT WAS NOTED THAT THE RT ENGINE PT2 HARNESS WAS DEFEC TIVE. PARTS WERE REPLACED, ENGINE AND COMPUTER FUNCTIONS WERE TESTED, AND NO RECURRING DEFECTS WERE NOTED. 2 L 7 2 4F 4 F A3EU E6WE 2004022500032 20040225 00032 NM 2004 2 25 2004FA0000080 1 20040119 G 5711 SPAR UNIVAR 415 415C 0420302 NM CONT C85 C8512F 17008 SO MCAULY 1A90 1A90CF GL CENTER WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 05 93517 840 28872712 598 AD 2002-26-02 CORROSION INSPECTION: REMOVED BOTH WINGS AND BOTH FUEL TANKS. INSPECTED ENTIRE CENTER SECTION AND FOUND FO UR QUARTER SIZED AREAS OF LIGHT CORROSION ON FWD SIDE OF FRONT CENTER SECTION SPAR. CORROSION AREAS WERE SANDED WITH 240 GRIT SANDPAPER AND THE ENTIRE CENTER SECTION WAS CLEANED AND SPRAYED WITH CORROSION PREVENTIVE. CLEANED AND INSPECTED E XTERIOR OF BOTH GAS TANKS AND FOUND NO CORROSION. REPLACED ONE RIVET IN TOP EDGE OF RIGHT FRONT CENTER SECTION SPAR CAP WITH AN OVERSIZE RIVET. REINSTALLED BOTH WING PANELS AND BOTH FUEL TANKS. WORK PERFORMED IAW AC 43.13-1B, SB-31 REVISIO N 1, AC 43-4A AND PATIENCE. 1 L 7 1 3O 3 O A718 E233 5 N P842 2004022500041 20040225 00041 NM 2004 2 25 2004FA0000088 1 20040112 G 2720 ABC10800318 CONTROL CABLE AMBLP A150 A150 3850110 NM LYC O360 IO360A1A 41514 EA RUDDER FAILED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 154ZP 104 NICOPRESS FITTING FAILED ON THIS PARTICULAR CABLE. 1 B 7 2 3O 3 O 0 SOOOO2SE 1E10 2004022300077 20040223 00077 2004 2 23 2004FA0000033 4 20040105 G 2562 E01 ELT AVIAT A1 A1A 2210405 GL LYC O360 O360A1D 41514 EA CABIN CORRODED P K NONE O OTHER IN INSP/MAINT 1 AL 03 40HU 1315 OPERATIONAL TEST OF ELT ON PRE-FLIGHT AT THE REMOTE SWITCH SHOWED THE ELT WAS NOT WORKING. MANUALLY TURNED THE ELT ON A T THE UNIT, STILL NOT WORKING. REMOVED ELT AND OPENED UP THE UNIT TO DISCOVER CONDENSATION AND ELECTROLYSIS CORROSION H AD COMPLETELY RENDERED THE UNIT USELESS. THE O-RINGS APPEARED TO BE IN GOOD SHAPE. THE ELT HAD BEEN INSPECTED AND NEW BA TTERIES INSTALLED DURING THE 100 HR. INSPECTION ON 9/2003. TEMPERATURES OUTSIDE HAVE BEEN IN THE -30 DEG. F RANGE AND T HE PLANE HAD BEEN PUT INTO THE HANGAR TO WARM UP. 1 H 7 1 3O 3 O NC A22NM E286 2004022300092 20040223 00092 CE 2004 2 23 CM2R 1 20040108 G 7160 963800295 SEPARATOR BEECH 55 95C55 1152708 CE CONT O520 IO520C 17032 SO ENG AIR INTAKE OBSTRUCTED C K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 3367 TE146 810839R OLD ENGINE SEPARATOR WAS CRACKED. ORDERED NEW PART. INSPECTED NEW PART AND COULD NOT BLOW THROUGH IT. THE AIR OUTLET TUBE WAS BLOCKED INTERNALLY. NEW OUT OF BOX FAILURE. IF THIS UNIT WAS INSTALLED ON THE ENGINE IT WOULD HAVE PRESSURIZE D THE CASE AND LEAD TO POSSIBLE ENGINE FAILURE DUE TO ENGINE OIL LOSS. 1 L 7 2 3O 3 O 3A16 E5CE 2004022300124 20040223 00124 SO 2004 2 23 2004FA0000055 2 20040109 G 8520 AEC648029 PISTON CONT CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO NR 2 CYLINDER BROKEN C D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 WP 23 4810N 260 273185R 18267384 273185R REBARRELED CYL, ECI PISTONS. LOSS OF OIL PRESSURE, 260 STOH, 1043 SMOH. CAUSE, BROKEN NR 2 PISTON, PARTS BLOCKING OIL PICKUP SCREEN. POSSIBLE CAUSES. DEFECTIVE PISTON CASTING, DROPPED PISTON OR IMPROPERLY MACHINED NR 4 RING GROOVE, SQUA RE CUT BOTTOM OF GROOVE. 50 PERCENT OF BOTTOM SKIRT BROKE OFF PISTON. PISTON RING BROKE INTO ABOUT 20 PIECES. 1 H 7 1 3O 3 O NT 3A13 E273 2004022300126 20040223 00126 CE 2004 2 23 2004FA0000058 1 20040110 G 7921 TCM639171 OIL COOLER CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO ENGINE LOOSE C K NONE P NO WARNING INDICATION IN INSP/MAINT 1 WP 23 4810N 206 206 18267384 273185R 8/22/2002, OIL COOLER TCM 639171. TACH TIME NOT LOGGED. APPROX 830 SMOH. 12/1/2003 A MAJOR OIL LEAK DEVELOPED AROUND T HE OIL COOLER AND THE NR 5 CYL PUSH ROD TUBES. ISOLATED LEAK TO OIL COOLER GASKETS. 1036 SMOH. DURING REMOVAL OF OIL C OOLER BASE PLATE, IT WAS DETERMINED THAT THE ATTACHING BOLTS WERE IMPROPERLY TORQUED. NEW GASKETS WERE INSTALLED AND CO OLER ATTACHING BOLTS PROPERLY TORQUED. PROBLEM CAUSED BY IMPROPERLY TORQUED ATTACHING BOLTS. 1 H 7 1 3O 3 O NT 3A13 E273 2004022300130 20040223 00130 EA 2004 2 23 2004FA0000059 2 20040112 G 7324 2524321 FLOW DIVIDER BENDIX PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA HARTZL HCC2Y HCC2YK1 GL FUEL SYSTEM BYPASSING G O OTHER G R J MULTIPLE FAILURE PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 SO 07 4658J 4947 28R30553 L481751A 7666A2 FUEL FLOW DIVIDER, TEARDOWN AND TEST OF DIVIDER SHOWED UNIT WAS BY-PASSING FUEL , WHICH INTERRUPTED FLOW OF FUEL TO ENG UNDER HIGH POWER SETTINGS, LEADING TO INTERRUPTION OF ENG POWER AND/OR TOTAL LOSS OF ENG POWER. FURTHER TEAR DOWN, REVE ALED DIAPHRAGM WAS STIFF, AN INDICATION OF LONG TIME IN SERVICE. CONNECTING SCREW WHICH ATTACHES DIAPHRAGM TO SHAFT WAS LOSE, NOT TORQUED. ESTIMATED DIAPHRAM WAS MANUFACTURED IN 1967. AFTER TIGHTENING ATTACHMENT SCREW TO ITS PROPER TORQ UE, DIVIDER WAS TESTED AGAIN. AT 2.5 POUNDS OF FUEL PRESSURE APPLIED, NO INDICATION OF FUEL DIVIDER FLOWING UNTIL 3.750 0 POUNDS OF FUEL PRESS WAS APPLIED. 1 POUND OF PRESSURE DIFFERENCE FOR FUEL FLOW WAS DUE TO STIFFNESS OF DIAPHRAGM. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2004022500071 20040225 00071 EU 2004 2 25 2004FA0000097 1 20040109 G 3230 1090512431 SELECTOR VALVE AGUSTA A109 A109A2 0260120 EU ALLSN 250C 250C20 03013 GL MLG WORN D O OTHER O OTHER NR NOT REPORTED 1 NM 01 1PJ 7262 LANDING GEAR WOULD NOT EXTEND. FINALLY FORCE LANDING GEAR HANDLE DOWN GEAR EXTENDED AND LOCKED BUT STILL HAD TRANSITION LIGHT. PART FAILED PRIMARILY DUE TO AGE AND USE (WEAR). 1 G 7 2 3U 3 U H7EU E4CE 2004022500097 20040225 00097 2004 2 25 2004FA0000132 4 20040116 G 3424 303770 INDICATOR PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C 2D34C215 GL TURN COORDINATOR FAILED G O OTHER S AFFECT SYSTEMS NR NOT REPORTED 1 WP 17 8227V 236 28R8018085 62208651A 931655PC085 TURN COORDINATOR UNIT FAILED DURING IFR CONDITIONS. PROBLEM SEEMS TO BE INTERMITTENT BECAUSE AFTER LANDING, UNIT WORKED AND CONTINUED FOR DURATION OF FLIGHT (VFR) FROM FCH TO FYI (FAT). (WP17200402720) 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004030100049 20040301 00049 SO 2004 3 1 2004FA0000197 2 20040206 G 7414 641742 GEAR CONT O550 IO550B SO MAGNETO DRIVE GALLED B K NONE O OTHER IN INSP/MAINT 1 SO 09 500 500 684070 DURING ENGINE DISASSEMBLY FOR CYLINDER REPLACEMENT FOUND RT MAGNETO DRIVE GEAR DISCOLORED AND THRUST SURFACE GALLED. MA GNETO/ACCESSORY DRIVE ADAPTER BUSHING GALLED AND HEAT DAMAGED. 3 O E3SO 2004030100071 20040301 00071 SO 2004 3 1 2004FA0000171 1 20040122 G 5310 45467016017 RIB PIPER PA31 PA31310 7103103 SO LYC O540 TIO540* 41532 EA MLG WW CORRODED B C85R O OTHER O OTHER NR NOT REPORTED 1 NE 01 131PJ 5052 317912030 REPORTED OCCASIONAL GEAR CYCLING PROBLEM. INSPECTED LANDING GEAR AND FOUND RIBS (WHICH ARE IN THE LT AND RT MAIN GEAR W HEEL WELLS) TO BE SEVERELY CORRODED. MOUNTED ON THIS RIBS IS THE BRACKET FOR THE UPLOCK LATCH SWITCH. THERE WAS ENOUG H MOVEMENT IN THE RIBS THAT SWITCH CONTACT BECAME AN ISSUE. BOTH RIBS WERE REPLACED . SOME OF PROBLEMS MIGHT BE CORREC TED BY INSTALLING KIT, WHICH C/W AND CHANGED THE GEAR PUSH-PULL TUBES TO CABLES INSTEAD. THIS WAS ALSO DONE. REMOVED O LD PUSH-PULL TUBES, WHICH WERE CORRODED. (NE01200402913) 1 L 7 1 3O 3 O RT A20SO E14EA 2004030100076 20040301 00076 CE 2004 3 1 2004FA0000173 1 20040122 G 3260 DOWNLOCK SWITCH CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO MLG FAILED D O OTHER J WARNING INDICATION AP APPROACH 1 GL 17 356D 340A0745 LANDING GEAR WOULD NOT EXTEND, FOUND LANDING GEAR ACTUATOR DOWN LIMIT SWITCH STUCK IN GEAR DOWN POSITION. PERIODIC REPL ACEMENT OF SWITCH WOULD BE THE ONLY WAY TO PREVENT REOCURRENCE. THE SWITCH IS A SEALED UNIT AND CANNOT BE INSPECTED INT ERNALLY. (GL17200402312) 1 L 7 2 3O 3 O 3A25 E8CE 2004030100116 20040301 00116 EA 2004 3 1 2004FA0000178 2 20040109 G 8550 LW13792 SEAL AMRGEN AA1 AA1B 0631206 SO LYC O235 O235C2C 41505 EA ENGINE WORN G O OTHER K FLUID LOSS NR NOT REPORTED 1 EA 25 6291L 1446 AA1B0091 L1121615 FOUND CRANKSHAFT SEAL PUSHED FREE FROM ITS MOUNTING AREA. SEAL APPEARED DRY ROTTED AND INSTALLED WITH INSUFFICIENT SEA LANT. INSTALLED NEW SEAS IAW SRM. INSPECTED OIL SCREEN AND TOOK OIL SAMPLE. NO METAL FOUND SEAL SHOULD BE INSPECTED F OR PROPER MOUNTING EVERY 100 HOURS. 1 L 7 1 3O 3 O A11EA E223 2004030100122 20040301 00122 CE 2004 3 1 2004FA0000184 1 20040204 G 2133 40117 CHECK VALVE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP CABIN PRESSURE CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 03 900JD 4923 6500213 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSE MBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECKED AND AN IDENTICAL CHECK VALVE COND ITION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2 L 7 2 4F 4 F A9NM E6WE 2004030100123 20040301 00123 CE 2004 3 1 2004FA0000185 1 20040204 G 2133 40117 CHECK VALVE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP CABIN PRESSURE CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 03 900JD 4923 6500213 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSE MBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECK AND AN IDENTICAL CHECK VALVE CONDIT ION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2 L 7 2 4F 4 F A9NM E6WE 2004030100130 20040301 00130 CE 2004 3 1 041332 1 20040212 G 2823 CCA1550 DRAIN CESSNA CESSNA 172 172 2072402 CE CONT O300 O300* 17022 SO FUEL VALVE CRACKED B W2OR K NONE O OTHER IN INSP/MAINT 1 GL 09 6341E 46441 PILOT REPORT OF FUEL LEAK FROM SELECTOR. FOUND LEAKAGE PAST SHAFT SEAL. REMOVED SELECTOR VALVE FOR REPAIR. CCA-1550 DRAI N VALVE WAS INSTALLED IN BOTTOM OF SELECTOR VALVE. WHEN DRAIN VALVE WAS REMOVED, ORING RETAINING WASHER AT END OF DRAIN VALVE WAS OBSERVED TO BE CRACKED IN NUMEROUS PLACES AND IN IMMINENT DANGER OF FAILURE. HAD THE WASHER BROKEN OFF, AN UNC ONTROLLABLE LOSS OF FUEL THROUGH THE DRAIN VALVE WOULD HAVE OCCURRED. THE ONLY WAY TO PREVENT FUEL LEAKAGE WOULD HAVE BE EN TO SHUT OFF THE FUEL SELECTOR, WHICH RESULTS IN ENGINE STOPPAGE. 1 H 7 1 3O 3 O NT 3A12 E253 2004030300081 20040303 00081 CE 2004 3 3 2004FA0000198 1 20040204 G 7921 654585 OIL COOLER CESSNA 210 T210L 2073449 CE CONT O520 TSIO520* 17040 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 732HN 465 367 21061527 821036R LOWER OB FLANGE OF ENGINE OIL COOLER IS CRACKED AND LEAKING. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300093 20040303 00093 SO 2004 3 3 2004FA0000215 2 20040218 G 8530 655166 VALVE GUIDE CONT CONT O520 IO520D 17032 SO CYLINDER LOOSE C K NONE O OTHER IN INSP/MAINT 1 WP 07 109 109 Q226 293450 MFG CYLINDER (109.9HRS) DISASSEMBLED FOR REASONS NOT RELATED TO THIS REPORT. INTAKE VALVE GUIDE FOUND TO BE ONLY FINGER TIGHT, NO INTERFERENCE FIT. P005 FOUND STAMPED NEXT TO GUIDE. 3 O E5CE 2004030300184 20040303 00184 NM 2004 3 3 SROM200400001 1 20040217 G 3397 WIRE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE EMERGENCY LIGHT DAMAGED C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 736BP 6 23465 AFT LEFT EMERGENCY EXIT LIGHT UNDER FA JUMP SEAT INOPERATIVE. REPAIRED WIRE TO LIGHT ASSEMBLY. LIGHT OPS NORMAL WITH E MERGENCY LIGHTS TURNED ON. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030300188 20040303 00188 2004 3 3 21200004 4 20040221 G 2210 55X AUTOPILOT SYS CESSNA 210 T210L 2073449 CE CONT O520 TSIO520* 17040 SO COCKPIT DEFECTIVE C H DEACTIVATE SYST/CIRCUITS F FLT CONT AFFECTED CR CRUISE 1 NM 10 2084S 700 21061050 AIRCRAFT PORPOISES WHILE IN ALTITUDE HOLD MODE. DISABLE ALTITUDE HOLD MODE. MAINTENANCE CONFIRMS DEFECTIVE UNIT BY MAN UFACTURER. MANUFACTURER UNABLE TO SUPPLY REPLACEMENT PART. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300189 20040303 00189 SO 2004 3 3 2004FA0000205 2 20040210 G 8530 AEC631397SN712B CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE DID NOT MEET MINIMUM SIZE DIMENSIONS AN D VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300190 20040303 00190 SO 2004 3 3 2004FA0000207 2 20040203 G 8530 AEC631397SN712B CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY TISN 71.2BCA AS RECEIVED. FOUND VALVE SEAT MACHINING NOT CONCENTRIC AND EXHAUST VALVE SEAT DIAMETER CUT TO APPX. 1.847 INCH WHEN IT SHOULD BE APPX. 1.781 INCH ACCORDING TO PRINT DIMENSIONS IN OVERHAUL MANUAL. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300194 20040303 00194 SO 2004 3 3 2004FA0000212 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. PRE-SIZED GUIDES ARE USED ON THIS UNIT AND 5 OTHERS IN THIS BATCH INSPECTED. ALL UNAIRWORTHY. ALL BALL SIZED. ALL BELL MOUTHED. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300195 20040303 00195 SO 2004 3 3 2004FA0000213 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MFG. MINIMUM SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300202 20040303 00202 SO 2004 3 3 BHA03RS 2 20040223 G 8500 ENGINE CESSNA 340 340A 2076405 CE CONT O520 TSIO520NB 17040 SO MCAULY 3AF32C 3AF32C505 GL RIGHT DAMAGED E A UNSCHED LANDING F K FLT CONT AFFECTED FLUID LOSS CL CLIMB 1 NM 04 114BH 3094 1494 340A1230 503082 020379 DURING FLIGHT, RT ENGINE OIL PRESSURE GAGE INDICATED A SIGNIFICANT INCREASE IN PRESSURE. RT ENGINE DAMAGE OCCURRED. AIR CRAFT LANDED WITHOUT FURTHER INCIDENT. 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 2004030400021 20040304 00021 CE 2004 3 4 2004FA0000217 1 20040124 G 1430 NAS679A4 NUT BEECH 58 58 1152740 CE CONT O520 IO520* 17032 SO HORIZONTAL STAB CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 03 4423A 7200 TH28 NUTS ON SEVERAL HORIZONTAL STABILIZER REAR SPAR BOLTS WERE CRACKED OR BROKEN. NUT INSTALLED, NO NUTS HAD COME OFF AND B OLTS WERE NOT LOOSE IN SPAR. REPLACED NUTS AND NEW BOLTS WITH CURRENT HARDWARE. 1 L 7 2 3O 3 O 3A16 E5CE 2004030400030 20040304 00030 NM 2004 3 4 SROM200400005 1 20040223 G 5340 6935352U14 STRINGER CLIP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 639, STR 4R. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED N EW STRINGER CLIP IAW B737 SRM 51-30-2. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400034 20040304 00034 GL 2004 3 4 2004FA0000221 2 20040128 G 7323 252469211 GOVERNOR BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 SW 11 124AE 645 51591 CAE890804 SUSPECT HIGH END GOVERNOR FAILURE. OVERSPEED OF N2. (SW11200403763) 1 G 7 1 3U 3 U H2SW E1GL 2004030400047 20040304 00047 SO 2004 3 4 2004FA0000224 1 20040210 G 5542 63396802 SKIN PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA RUDDER CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 4166H 4759 4759 2843119 DURING PREFLIGHT, FLIGHT INSTRUCTOR FOUND THE RUDDER SKIN CRACKED. PROBABLE CAUSE AIR FLOW OVER THE SKIN. NO RECOMMEND ATIONS AT THIS TIME. 1 L 7 1 3O 3 O 2A13 E286 2004030400048 20040304 00048 CE 2004 3 4 2004002 1 20040220 G 8011 MHB6016 STARTER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ENGINE DISENGAGED D K NONE O OTHER TX TAXI/GRND HDL 1 WP 07 97811 17276232 L1550339A STARTER WAS INSTALLED AFTER ORIGINAL STARTER FAILED ON 2/11/2004 (SDR FILED) FOR A SHATTERED BENDIX DRIVE GEAR. ENGINE WAS SUCCESSFULLY STARTED TWICE AND RETURNED TO SERVICE. ON FIRST FLIGHT ATTEMPT AFTER STARTER WAS INSTALLED THE BENDIX DRIVE GEAR WOULD NOT ENGAGE THE ENGINE STARTER RING GEAR, THE STARTER MOTOR WOULD SPIN BUT THE GEAR WOULD NOT COME FORWA RD TO ENGAGE THE ENGINE GEAR. THIS UNIT HAD ZERO HOURS SINCE NEW. 1 H 7 1 3O 3 O NT 3A12 E274 2004030400055 20040304 00055 EU 2004 3 4 2004FA0000229 1 20040217 G 5330 DOPE FILM AVIAT S2B PITTSS2B 2210308 EU LYC O540 AEIO540D4A5 41532 EA SKIN FABRIC DELAMINATED C K NONE O OTHER IN INSP/MAINT 1 EA 17 79D 560 5260 ALL OF THE DOPE FILM DELAMINATED FROM THE CECONITE 102 FABRIC. AFTER SEVERAL PHONE CALLS, IT WAS DETERMINED THAT IMPROP ER APPLICATION METHOD WAS USED. THE RANDOLPH DOPE PROCESS REQUIRES THE USE OF RANDO PROOF PRIMER FOR THE FIRST TWO COAT S ON CECONITE FABRIC AND THE FIBERS OF THE FABRIC MUST BE COMPLETELY ENCAPSULATED. AFTER ADDITIONAL CALLS, IT WAS DETER MINED THAT THE FACTORY OMMITED THE RANDO PROOF PRIMER STEP AND FAILED TO ENCAPSULATE THE FABRIC FIBERS RESULTING IN THE DELAMINATION OF THE DOPE FILM. (EA17200405558) 1 Q 7 1 3O 3 O NC A8SO 1E4 2004030400071 20040304 00071 CE 2004 3 4 40188138 1 20040226 G 5520 556555026 BRACKET CESSNA 500 500CESSNA 2076602 CE PWA JT15 JT15D1 52060 NE BALANCE WEIGHT CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 09 26NS 7280 5000340 BALANCE WEIGHT ARM FOR ELEVATOR CONTROL SYSTEM IS CRACKED. 1 L 7 2 4F 4 F A22CE E1NE 2004030400085 20040304 00085 2004 3 4 2004FA0000237 4 20040206 G 6113 SPINNER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA PROPELLER CHAFED B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 201023 PROP SPINNER RUBS AGAINST COWL, INCH LONG AND GOING THOUGH FIBERGLASS COWL. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400088 20040304 00088 SO 2004 3 4 2004FA0000249 1 20040227 G 2810 63901038 HOSE PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA FUEL SYSTEM MISROUTED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 05 15143 28R7335027 LANDING GEAR (IN-TRANSIT) LIGHT CAME ON INTERMITTENTLY. DURING TROUBLESHOOTING, FOUND FUEL FEED LINE FROM ELECTRIC PUMP TO ENGINE DRIVEN PUMP MISROUTED. HOSE WAS BEING JAMMED BETWEEN NLG TIRE AND ENGINE MOUNT WHEN GEAR IS RETRACTED. THIS CAUSED NLG TO INCOMPLETELY RETRACT, CAUSING UP-LIMIT SWITCH TO BE INTERMITTENT. REROUTED HOSE AND RIGGED GEAR PER MM. O PS CK OK.ENGINE MOUNT HAD BEEN REMOVED FOR REPAIR. WHEN IT WAS REINSTALLED, THE PART WAS PROBABLY NOT PUT BACK ON CORREC TLY AND NOT FOUND DURING POST MAINTENANCE INSPECTION. THERE IS NO WAY THE GEAR RIG CHECK WAS GOOD AFTER REINSTALLATION O F MOUNT. 1 L 7 1 3O 3 O 2A13 1E10 2004030400094 20040304 00094 GL 2004 3 4 2004FA0000242 1 20040206 G 2810 FUEL TANK AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA LT WING LEAKING B KC5R O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 13 622AM 201023 WITH FULL FUEL TANKS AND THE AIRCRAFT ON THE GROUND AN AMOUNT OF FUEL (.5 GALLON +) WILL DRAIN FROM THE VENT OF THE LT F UEL TANK AFTER A FORWARD OR AFT MOVEMENT OF THE AIRCRAFT. (GL13200305339) 1 L 7 1 3 O EXPA1L71 E223 2004030400097 20040304 00097 GL 2004 3 4 2004FA0000245 1 20040206 G 1100 PLACARD AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA TRIM CNTRL WHEEL MISSING B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 13 201023 DOES NOT INDICATE TAKEOFF POSITION, PLACARD MISSING. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400108 20040304 00108 NM 2004 3 4 SROM200400011 1 20040226 G 5330 65479576 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 CORRODED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND AFT PIT STA 807 LOWER FORWARD CARGO CUTOUT HAS NON-CPCP CORROSION. REMOVED DAMAGE FABRI CATED AND INSTALLED REPAIR DOUBLER IAW 53-10-1, 51-40-3 AND 51-30-2. 2 L 7 2 4F 4 F RT A16WE E2EA 2004031500004 20040315 00004 SO 2004 3 15 CA040123008 1 20040120 G 1430 AN546 BOLT PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG CORRODED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA (CAN) THE AIRCRAFT WAS ON APPROACH WHEN THE CREW COULD NOT GET A DOWN AND LOCKED (GREEN) INDICATION ON THE RT MAIN GEAR. THE AIRCRAFT FLEW LOCALLY AND AFTER SEVERAL ATTEMPTS FLEW TO ANOTHER AIRPORT FOR A TOWER FLYBY AND LANDING. UPON TOUCH DOWN, THE RT MAIN GEAR LIGHT ILLUMINATED. MAINTENANCE FOUND THE RT MAIN DOWN LOCK TO BE SLIGHTLY STIFF. SOME MOISTURE AND SLIGHT CORROSION WAS NOTED ON THE PIVOT BOLT FOR THE RT DOWNLOCK AND THE BOLT WAS REPLACED. BOTH MAIN DOWN LOCKS WE RE REMOVED, CLEANED, INSPECTED, AND RE-LUBRICATED. SUBSEQUENT GEAR SWINGS WERE NORMAL AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500005 20040315 00005 NE 2004 3 15 CA040123009 2 20040119 G 7412 103815504C IGNITER BOX PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ENGINE IGNITION INOPERATIVE W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) THE PILOT MADE TWO ATTEMPTS TO START THE AIRCRAFT. THE ENGINE FAILED TO START AND THE PILOT NOTED THAT THE IGNITI ON LIGHT ON THE CAWS PANEL HAD NOT ILLUMINATED DURING EITHER ATTEMPT. THE CAWS PANEL LIGHTS WERE TESTED AND FOUND SERVI CEABLE. AFTER APPROX. 5 MINUTES A THIRD STARTING SEQUENCE WAS INITIATED AND SUCCESSFUL. THE AIRCRAFT RETURNED TO BASE W ITHOUT FURTHER INCIDENT. MAINTENANCE CARRIED STARTED THE AIRCRAFT WITH NO INDICATION OF ANY DEFECT. THE AIRCRAFT WAS S HUT DOWN, AND FURTHER INVESTIGATION REVEALED THAT THE IGNITION EXCITER BOX WAS NOT FIRING IAW THE ENGINE MFG REQUIREMENT S. A REPLACEMENT UNIT WAS INSTALLED, AND TESTED SERVICEABLE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004031500006 20040315 00006 CE 2004 3 15 AUS20040044 1 20040127 G 5740 35115050602 ATTACH FITTING BEECH 36 A36 1151604 CE CONT O520 IO520B 17032 SO MCAULY 2A36C 2A36C23 GL RT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT WING UPPER AFT ATTACHMENT FITTING CORRODED. MAXIMUM DEPTH OF CORROSION 1.27MM (0.050IN). FOUND DURING INSPECT ION IAW AD. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 2004031500007 20040315 00007 NM 2004 3 15 AUS20040045 1 20040123 G 5210 PIN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PAX DOOR OUT OF ADJUST W O OTHER J WARNING INDICATION CR CRUISE 1 AU S (AUS) L1 FORWARD ENTRY DOOR CRACKED OPEN IN FLIGHT WITH HANDLE MOVING APPROXIMATELY HALF WAY UP. INVESTIGATION FOUND T HE DOOR LOCK SENSOR LATCH PIN TO BE 0.762MM (0.030IN) OUT OF LIMITS. 2 L 7 2 4F 4 F RT A1NM E23EA 2004031500011 20040315 00011 CE 2004 3 15 CA040211008 1 20040122 G 5610 10138402523 WINDSHIELD BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SERVICING THE LT WINDSHIELD WAS FOUND CRACKED IN THE OUTER PLY. REPORTED OAT FOR THE PREVIOUS FLIGHT WAS -4 5C. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004031500013 20040315 00013 EU 2004 3 15 CA040211011 1 20040114 G 6220 350A31190703 STARFLEX SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA M4517 (CAN) ON A ROUTINE AIRFRAME INSPECTION, A CRACK WAS NOTED ON THE TRAILING EDGE OF THE STAR ARM. AFTER COMPLETING THE R EPAIR TO THE AREA IAW THE SRM, IT WAS FOUND TO STILL BE A MUCH DEEPER FLAW. THE STAR WAS SENT TO MFG FOR FURTHER INVEST IGATION. A NEW STARFLEX WAS INSTALLED. 1 G 7 1 3U 3 U H9EU E19EU 2004031500018 20040315 00018 GL 2004 3 15 CA040213001 1 20040209 G 7810 2078000103 EXHAUST STACK BOMBDR DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912 55555 EU HOFMAN HOV352 HOV352F NE CYLINDER HEAD FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE LT REAR EXHAUST STACK WAS FOUND COMPLETELY BROKEN AND SEPARATED AT THE BEND NEAR THE CYLINDER. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 5 C TP5BO 2004031500020 20040315 00020 SO 2004 3 15 CA040125001 1 20040122 G 2913 1213HBG310A PUMP PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL HYD SYSTEM FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) THE FAILURE OF PUMP WAS FOUND BY PILOT AFTER FLIGHT HYDRAULIC PUMP CHECK- PUMP FAILED THE TEST. TIME EXCEEDED 11 S ECONDS. PUMP REMOVED, INSPECTED - NO DAMAGE FOUND FAILED INTERNALLY. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500023 20040315 00023 NM 2004 3 15 CA040126003 1 20040114 G 2910 AN81510D COUPLING DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE PRESS MANIFOLD CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION DE DESCENT 1 CA (CAN) APPROXIMATELY 90 DME FROM LANDING AT THE TOP OF DESCENT THE CREW NOTICED THE NR 2 HYD CONTENTS DROPPING. AT APPRO X 12 DME THE NR 2 HYD CAUTION LIGHT ILLUMINATED. A PAN WAS CALLED AND QRH ACTIONS WERE CARRIED OUT. ENGINEERING INVEST IGATION REVEALED THAT THE NR 2 PRESSURE MANIFOLD INLET UNION HAD FRACTURED. THE UNION WAS REPLACED ALONG WITH THE HYD P UMP AND THE AIRCRAFT WAS RETURNED TO SERVICE. OPERATOR HAS BEEN INFORMED OF SYD 8-29-002, WHICH REPLACES THE ALUMINUM F ITTINGS WITH STAINLESS STEEL FITTINGS FOR THIS AREA. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500024 20040315 00024 EU 2004 3 15 CA040126004 1 20040126 G 3232 D3221401700062 UPLOCK AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE NLG DOOR INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NOSE LDG DOOR WOULD NOT CLOSE AFTER T/O. RECYCLED 3 TIMES (NO SUCCESS) DOOR CLOSED NORMALLY WITH GEAR DOWN. NLG DOOR UPLOCK REPLACED IAW AMM32-31-21-400-001, CONSIDERED SERVICEABLE. 2 L 7 2 4F 4 F RT A28NM E29NE 2004031500029 20040315 00029 CE 2004 3 15 CA040126005 1 20040126 G 2571 10112011613 FLANGE BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL BATTERY COVER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) INSPECTION REVEALED THE BATTERY COVER SUPPORT FLANGE (FWD) CRACKED WHERE IT ATTACHES TO THE VERTICAL SUPPORT ANGLE S. PART TO BE REPLACED NEW. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004031500030 20040315 00030 GL 2004 3 15 CA040213003 1 20040209 G 7810 2078000107 EXHAUST STACK BOMBDR DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912 55555 EU HOFMAN HOV352 HOV352F NE CYLINDER HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE RT REAR EXHAUST STACK WAS FOUND CRACKED APPROX .5000 WAY AROUND THE CIRCUMFERENCE AT THE BEND NEAR THE CYLIND ER. THIS CRACK WAS IN A SIMILAR LOCATION AS THE ONE THAT LEAD TO THE COMPLETE FAILURE OF THE LT REAR EXHAUST STACK. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 5 C TP5BO 2004031500032 20040315 00032 EU 2004 3 15 CA040126007 1 20040126 G 3250 Z4242170001 SPRING MORAVN 242 Z242L 5920207 EU LYC O360 AEIO360A1B6 41514 EA MUHBR MTV MTV3BC EU NLG STEERING BROKEN W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI A STUDENT PILOT NOTICED THAT THE AIRCRAFT WOULD NOT STEER PROPERLY. MAINTENANCE NOTICED THAT THE RT ST EERING SPRING WAS BROKEN. THIS HAS BEEN AN ON GOING PROBLEM WITH STUDENTS WHEN THEY TRY TO STEER THE AIRCRAFT WITHOUT GE TTING THE AIRCRAFT ROLLING FIRST ADDING STRESS TO THE SPRINGS. 1 L 7 1 3O 3 O NT A76EU 1E10 5 C USSR 2004031500033 20040315 00033 EA 2004 3 15 CA040126008 1 20040106 G 2720 272613 SWITCH CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE RUDDER TRIM FAILED W A UNSCHED LANDING F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) 30 MINS OUT, FL260 RUDDER TRIM FAILED, INADVERTENT AND SUDDEN DISPLACEMENT TO HALFWAY TO FULL NOSE LT. DECLARED EM ERGENCY, UNEVENTFUL LANDING. RUDDER TRIM FAILED. REMOVED AND REPLACED RUDDER TRIM SWITCH. OPS CHECKS REQUIRED WHEN PANE L REINSTALLED IAW27-12-10, REMOVED AILERON/RUDDER TRIM CONTROL PANEL, REINSTALLED TRIM CONTROL PANEL AND TESTED IAW AMM 27-12-00, CHECKS OK. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500034 20040315 00034 NM 2004 3 15 CA040127001 1 20040121 G 2720 682015 SWITCH BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU RUDDER TRIM INOPERATIVE W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) AFTER TAKE OFF, THE FLIGHT CREW REPORTED RUDDER TRIM INOPERATIVE. QRH PERFORMED. RETURNED TO DEPARTURE AIRPORT FO R LANDING WITHOUT FURTHER INCIDENT. MECHANIC RESET THE RUDDER TRIM CB THEN TESTED TRIM, NO MOVEMENT. RUDDER TRIM PANEL R EMOVED AND PANEL WAS (TAPPED) THEN RE-INSTALLED, THEN TRIM OPERATION WAS NORMAL. RUDDER TRIM SWITCH REPLACED AS PRECAUTI ON. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004031500038 20040315 00038 EA 2004 3 15 CA040213004 1 20040213 G 7830 MPN1267587 POWER UNIT CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE THRUST REVERSER INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) LT THRUST UNLOCKED IN CLIMB. QHR PARTIALLY CARRIED OUT LANDED (WOULD NOT STOW) FELT LIKE IT WAS NEVER DEPLOYED. AIRCRAFT CAME BACK FOR TROUBLESHOOTING AND REPAIR. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500040 20040315 00040 NE 2004 3 15 CA040213006 1 20040202 G 6210 6117020201067 SPAR SKRSKY SKRSKY S61 S61N 8142104 NE GE CT58 CT581402 30011 NE M/R BLADE CRACKED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 61M3314311 (CAN) MAIN ROTOR BLADE LEAK CHECKED AT BASE AND SPAR FOUND TO BE CRACKED. 2 G 7 2 4U 4 U 1H15 1E3 2004031500041 20040315 00041 EA 2004 3 15 CA040213007 1 20040210 G 2720 C2CF209 TORQUE TUBE DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE RUDDER PEDAL CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 12498 (CAN) RT RUDDER PEDAL TORQUE TUBE HAD AGGRESSIVE CORROSION BUILD UP ON THE EXTERIOR OF THE TORQUE TUBE IN THE VICINITY O F THE OIL COOLER. THIS IS A COMMON PROBLEM WITH FLOAT EQUIPPED AIRCRAFT OPERATING IN A SALT WATER ENVIRONMENT. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500042 20040315 00042 EA 2004 3 15 CA040213008 1 20040210 G 5552 C2T7A TORQUE TUBE DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELEVATOR WORN W K NONE O OTHER IN INSP/MAINT 1 CA 12498 (CAN) LOSS OF ELEVATOR CABLE TENSION REVEALED WORN ATTACH POINTS ON THE ELEVATOR TORQUE TUBE ASSEMBLY. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500045 20040315 00045 2004 3 15 CA040213011 4 20040210 G 2562 110324 ANTENNA ARTEX DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ELT ANTENNA FOUND BROKEN AT THE BASE OF THE ANTENNA MOUNTING FLANGE (EXTERNAL). 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500047 20040315 00047 NM 2004 3 15 CA040216001 1 20040216 G 2120 ODOR BOEING 767 76735H 1385208 NM GE CF6 CF680C2B6F 30025 NE COCKPIT DETECTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA (CAN) THE FLIGHT EXPERIENCED AN ACRID ODOR IN THE COCKPIT. AC DECLARED AN EMERGENCY LANDING AND CARRIED OUT THE QRH. AC SENT TO HANGAR FOR INVESTIGATION. 2 L 7 2 4F 4 F RT A1NM E13NE 2004031500048 20040315 00048 WP 2004 3 15 CA040216002 1 20040207 G 7933 56B17C SENSOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE OIL TEMP FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) RT ENGINE OIL TEMP EXCEEDED 160 DEGREES DURING CRUISE. AIRCRAFT DIVERTED. OIL TEMP SENSOR REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. ON THE NEXT DAY FEB. 8, 2004, AIRCRAFT DEPARTED AND SAME PROBLEM CAME BACK DURING CLIMB. AIR CRAFT LANDED. THE OIL TEMP SENSOR WAS REPLACED WITH THE SYSTEM DISPLAY PANEL P/N 201EDP1-1 S/N AD660/072. AIRCRAFT DISP ATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500050 20040315 00050 EA 2004 3 15 CA040127007 1 20040127 G 3250 STEERING SYS CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE NLG FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LOST NOSEWHEEL STEERING ON LANDING CLT. TRIED NUMEROUS RESETS WITH NO SUCCESS. TUG ARRIVED AND TOWED TO GATE. OUT OF SERVICE FOR INVESTGATION. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500059 20040315 00059 EA 2004 3 15 CA040127016 1 20040127 G 2613 OVERHEAT SENSOR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE LT ENGINE INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT 14TH DUCT MESSAGE ON EICAS AT 500 AGL (84 PERCENT N1) SHORTLY AFTER T/O, DUCT SHOWED RED BETWEEN COWL A/I AND W ING A/I VALVES ON ANTI-ICE STATUS PAGE. CREW RETURNED, LANDED 700 KGS OVERWEIGHT. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500060 20040315 00060 CE 2004 3 15 CA040216003 1 20040114 G 2731 26616151 ACTUATOR CESSNA 208 208B 2073701 CE PWA PT6 PT6A114 52043 NE MCAULY 3AF34C 3GFR34C703 GL ELEVATOR TRIM FAILED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT WITH AUTOPILOT ENGAGED, PILOT NOTED THAT AIRCRAFT WAS NOT HOLDING ALTITUDE. PILOT DISENGAGED AUTOPILOT AND AIRCRAFT PITCHED NOSE UP. ELECTRIC ELEVATOR TRIM SELECTED BUT NO TRIM MOVEMENT. ATTEMPTED MANUAL TRIM BU T TRIM WHEEL WOULD NOT MOVE, SPRING BACK. PILOT MAINTAINED CONTROL OF AIRCRAFT WITH ELEVATOR AND LANDED WITHOUT INCIDEN T. INITIAL INSPECTION UNABLE TO MOVE ELEVATOR TRIM. AIRCRAFT HANGARED FOR SHORT PERIOD AND TRIM OPERATION OKAY. ELEVA TOR TRIM CABLE/CHAIN CIRCUIT INSPECTED, NO DEFECTS. LT AND RT TRIM ACTUATOR DISASSEMBLED AND FOUND MOISTURE. ACTUATORS I NSPECTED AND LUBRICATED IAW MFG INSTRUCTIONS. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004031500061 20040315 00061 NM 2004 3 15 CA040216004 1 20040121 G 2910 APT7510004000SG TRANSDUCER DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYD SYSTEM LEAKING W L ABORTED APPROACH K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) DURING APPROACH TO AIRPORT THE HYDRAULIC ISOLATION VALVE LIGHT ILLUMINATED. THE CREW BROKE OFF THE APPROACH TO CHE CK LIGHT AND NOTED THE NR 1 HYDRAULIC CONTENTS LOW. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE PERSONNEL DISCOVERED A LEAK FROM THE NR 1 HYDRAULIC STANDBY PUMP PRESSURE TRANSDUCER. NEW TRANSDUCER INSTALLED, HYDRAULIC FLUID REPLENISHED A ND LEAK CHECKED OKAY. CLOSE INSPECTION OF THE TRANSDUCER FOUND A CRACK IN THE BODY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500064 20040315 00064 NE 2004 3 15 CA040216007 2 20040205 G 7220 3036723 RETAINER PWA 120 PW123D 52152 NE ENG BREATHER MISSING W A UNSCHED LANDING K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) ENGINE TSN 13318, TSO291, CSN 13305,AFTER TAKEOFF CONTROL TOWER NOTED FLUID LOSS/SMOKE FROM ENGINE AND INFORMED PI LOT. PILOT REDUCED POWER AND RETURNED TO DEPARTURE AIRPORT WHERE UNEVENTFUL LANDING WAS MADE. EXAMINATION OF THE ENGINE SHOWED BREATHER SHAFT PLUG AND RETAINING CIRCLIP TO BE MISSING. ENGINE REMOVED FOR TEARDOWN TO DETERMINE WHETHER CLIP FR ACTURED AND ENTERED AGB. OPERATOR IS CHECKING FLEET TO CONFIRM PRESENCE OF CIRCLIP AND PLUG IS PRESENT ON ALL ENGINES. S HOP HAS IMPLEMENTED DOUBLE WITNESS CHECK OF PLUG & CIRCLIP INSTALLATION. 4 T E20NE 2004031500066 20040315 00066 SW 2004 3 15 CA040127017 1 20040105 G 6310 269A54021 NUT HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA FREEWHEEL UNIT LOOSE W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) OIL LEAKING FROM FREEWHEEL WAS NOTED AT REFUELING STOP. NUT (WHICH IS ALSO SEAL RUNNER) WAS FOUND LOOSE. NUT WAS RETORQUED AND FLUSH OF FREEWHEEL PRODUCED NO DISCOLORATION OR PARTICLES. LEAK CHECK CARRIED OUT AND RETURNED TO SERVIC E. NOTE: THAT OIL ONLY LEAKED OUT AFTER SHUTDOWN (NO OIL SPRAY). THEREFORE, IN THIS INSTANCE, THE OIL WAS DYNAMICALLY HE LD IN, EVEN WITH THE LACK OF SEALING AT FRONT. 1 G 7 1 3O 3 O O 4H12 E286 2004031500068 20040315 00068 CE 2004 3 15 CA040127020 1 20040112 G 3340 055201913 RING CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL LANDING LIGHT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LANDING LIGHT ASSEMBLY MOUNTING RING (MADE OF ALUMINUM, RIVETED INTO COWLING NOSE BOWL) CRACKED THROUGH SEVERAL RI VET HOLES AND ANCHOR NUT HOLES. THESE RINGS ARE PRONE TO CRACKING, BUT THIS ONE HAS LASTED ONLY 20 MONTHS/1100 HOURS. MA TERIAL MAY BE TOO BRITTLE. OTHER FACTORS: FREQUENT LANDING LIGHT CHANGES, VIBRATION, POSSIBLE HEAT FROM LIGHTS, POSSIBLE OVER TIGHTENING OF SCREWS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004031500086 20040315 00086 2004 3 15 CA040218001 4 20040212 G 2216 40002928511 SERVO PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ELEVATOR TRIM INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) ELEVATOR TRIM SERVO WAS VERY NOISY REMOVED FOR REPAIR. LOANER INSTALLED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500087 20040315 00087 2004 3 15 CA040218002 4 20040212 G 2216 40002928511 SERVO PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ELEVATOR TRIM JAMMED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN TRIM WAS TESTED BY THE PILOT, THE TRIM SERVO JAMMED AND COULD NOT BE RELEASED. THE FLIGHT WAS CANCELLED. INST ALLED LOANER NEXT DAY AIRCRAFT SERVICEABLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500090 20040315 00090 EU 2004 3 15 CA040128002 1 20040128 G 3510 89151114 OXYGEN BOTTLE AIRBUS A330 A330* EU RROYCE RB211 RB211TRENT77 NE COCKPIT FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) RAMP CHECK CREW O2 WAS 1200 PSIG AFTER 3.5 HOURS WE HEARD A RUSHING AIR NOISE WAS F/O O2 MASK THIS NOISE WAS STOP BY PUSHING TEST BUTTON O2 WAS DOWN TO 72 PSIG (MUST HAVE BEEN SLOWLY LEAKING ALONG THEN FAILED. CREW O2 BOTTLE AND REG. REPLACED. F/O MASK TESTED AND RESET OK. 2 L 7 2 4F 4 F RT A46NM E39NE 2004031500103 20040315 00103 NE 2004 3 15 CA040219002 2 20040219 G 7200 ENGINE AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE NR 1 STALLED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) NR 1 ENGINE STALL IN CRUISE. DUE TO HISTORY MTC ADVISED RETURN FOR INVESTIGATION AND FURTHER T/S. DFDR PULLED. 2 L 7 2 4F 4 F RT A28NM E29NE 2004031500110 20040315 00110 SO 2004 3 15 CA040129008 1 20040122 G 3230 BRACKET PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL NLG BENT W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 14630 (CAN) ON TAKE OFF WHEN GEARS SELECTED UP PILOT FOUND GEARS INTERMITTED INDICATION. NOSE GEAR WON'T STAY UP LOCKED. TROUB LESHOT SNAG FOUND TUBE ASSEMBLY, NOSE LANDING GEAR IDLER LINK PN: 41770-00, UNSERVICEABLE. UPLOCK HOOK HOLDING BRACKET I S BENT AND WORN, AS RESULT UPLOCK HOOK MISALIGNED WITH UPLOCK ROLLER, PREVENTING NOSE GEAR FROM LOCKING UP. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500114 20040315 00114 2004 3 15 CA040130001 4 20040125 G 3417 C17053AC03 ADC BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU COCKPIT INOPERATIVE W O OTHER J WARNING INDICATION LD LANDING 1 CA (CAN) DURING LANDING ROLL OUT IAS MISMATCH MESSAGE APPEARED, NR 1 IAS WAS 30 KTS HIGHER THAN NR 2 IAS. AFTER PARKING AT THE ARRIVAL GATE, NR 1 IAS INDICTED 38 KTS AND TAS WAS SCROLLING. NR 2 IAS STEADY AT 30 KTS (NORMAL). MAINTENANCE PU RGED NR 1 PITOT/STATIC LINES THEN RECONNECTED. NR 1 IAS CONTINUED TO FLUCTUATE AT 38 KTS FOR SEVERAL MINUTES THEN DROPP ED TO 30 KTS AND BECAME STEADY. NR 1 ADU REPLACED. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004030300187 20040303 00187 2004 3 3 2004FA0000204 4 20040220 G 2210 ST566 AUTOPILOT SYS CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO HARTZL HCJ3Y PHCJ3YF1 GL COCKPIT MALFUNCTIONED C H DEACTIVATE SYST/CIRCUITS S AFFECT SYSTEMS CR CRUISE 1 WP 03 210MT 201 21064165 291649R FP235A ONCE ESTABLISHED IN CRUISE FLIGHT WITH ALTITUDE HOLD ENGAGED, THE S-TEC SYSTEM 55X AUTOPILOT FREQUENTLY BEGINS TO GENTLY PORPOISE IN PITCH. THIS GETS PROGRESSIVELY WORSE UNTIL THE AUTOPILOT CAUSES SERIOUS PITCH EXCURSIONS OF SEVERAL HUNDRE D FEET PER MINUTE UP AND DOWN. THE ONLY SOLUTION FOUND IS TO DISENGAGE THE ALTITUDE HOLD MODE AND SELECT VERTICAL SPEED EQUALS ZERO. THE OTHER MAJOR PROBLEM NOTICED WITH SYSTEM 55X IS THAT DURING THE APPROACH TO LANDING, THE AUTOPILOT WI LL PITCH DOWN ABRUPTLY WHEN THE FLAPS AND/OR GEAR ARE DEPLOYED. THIS CAN BE ALARMING, ESPECIALLY DURING AN INSTRUMENT A PPROACH IN INSTRUMENT METEOROLOGICAL CONDITIONS. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P36EA 2004030300193 20040303 00193 SO 2004 3 3 2004FA0000211 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISMANUFACTURED D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG SPECS., A ND VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030400046 20040304 00046 CE 2004 3 4 2004001 1 20040211 G 8000 MHB6016 STARTER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ENGINE FAILED D K NONE O OTHER TX TAXI/GRND HDL 1 WP 07 97811 163 136 17276232 L1550339A RECEIVED AN OVERHAULED ENGINE FROM MFG ON 5 DEC 2003 AND INSTALLED ON THE AIRCRAFT. STARTER BENDIX DRIVE GEAR SHATTERED AGAINST ENGINE RING GEAR ON A START ATTEMPT. 1 H 7 1 3O 3 O NT 3A12 E274 2004030400049 20040304 00049 SO 2004 3 4 2004FA0000225 1 20040206 G 2420 HOUSING PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA ALTERNATOR BROKEN B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 4130W 99 D071998 2843204 L2847836A DURING ROUTINE INSPECTION, LOWER FRONT ATTACHMENT EAR FOR ALTERNATOR WAS FOUND TO BE CRACKED THROUGH AND BROKEN. PROBAB LE CAUSE IS VIBRATION, POOR MFG OR MATERIAL FAILURE. NO RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 2A13 E286 2004030400070 20040304 00070 GL 2004 3 4 2004FA0000230 1 20040220 G 5550 2055300099 SLEEVE DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO RUDDER HINGE PIN LOOSE D K NONE O OTHER IN INSP/MAINT 1 NM 03 922AF C0179 THE SLEEVE ON THE RUDDER HINGE PIN CAME LOOSE FROM ITS LOCTITED POSITION ON THE PIN AND WORKED UP INTO THE CAVITY ABOVE THE BEARING ON THE FIN. RUDDER HAD CONSIDERABLE PLAY AT THE TOP. 1 L 7 1 3O 3 O NT TA4CH E7SO 2004030400080 20040304 00080 GL 2004 3 4 2004FA0000234 3 20040206 G 6110 C50462 PLATE CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA MCAULY 2D34C B2D34C218 GL PROP BULKHEAD CRACKED D W59R K NONE O OTHER IN INSP/MAINT 1 WP 07 35G 144 R18201785 776893 DURING AN INSPECTION, THE BULKHEAD MOUNTING PLATES WERE FOUND CRACKED AND BROKEN AROUND THE HOLES THROUGH WHICH THE PROP ELLER MOUNTING STUDS PASS. THIS CONDITION IS FOUND VERY OFTEN AND THE PLATES REALLY NEED TO BE REDESIGNED TO NOT CRACK AS EASILY AS THEY DO NOW. SHOULD THE CRACKS GO UNDETECTED, FAILURE OF THE SPINNER ASSEMBLY AND DAMAGE TO THE PROPELLER AND COWLING WILL RESULT. (WP07200403102) 1 H 7 1 3O 3 O RT 3A13 E295 5 C P7EA 2004030400081 20040304 00081 GL 2004 3 4 2004FA0000235 1 20040206 G 2700 STRUCTURE AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA STABILATOR CHAFED B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 28 201023 STABILATOR RUBS AGAINST FUSELAGE SCREW. .5 INCH GAP ON LT SIDE, .2500 INCH GAP ON RT SIDE. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400086 20040304 00086 GL 2004 3 4 2004FA0000238 1 20040206 G 5540 RUDDER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA VERTICAL STAB MISINSTALLED B KC5R O OTHER W INADEQUATE Q C NR NOT REPORTED 1 GL 13 622AM 201023 RUDDER CONTACTS FUSELAGE BEFORE REACHING STOPS. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400089 20040304 00089 SO 2004 3 4 2004FA0000246 1 20040227 G 3210 400885 BOLT PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA NLG DOWNLOCK MISSING D K NONE O OTHER IN INSP/MAINT 1 SO 05 15143 28R7335027 LANDING GEAR (IN-TRANSIT) LIGHT CAME ON INTERMITTENTLY. DURING TROUBLESHOOTING, FOUND NLG DOWNLOCK BOLT MISSING (GOES I N METAL BLOCK ON RT LOWER ENG MOUNT STRUCTURE). THIS IS THE BOLT THE DOWNLOCK HOOK ENGAGES IF THE NLG COLLAPSES. ORDERED REPLACEMENT BOLT AND INSTALLED IAW MM. RETRACTION CHECK OK. ENGINE MOUNT HAD BEEN REMOVED FOR REPAIR. WHEN IT WAS REIN STALLED, THE PART WAS PROBABLY NOT PUT BACK ON (UP LIMIT STOP BOLT WAS ALSO MISSING). THERE IS NO WAY THE GEAR RIG CHECK WAS GOOD AFTER REINSTALLATION OF MOUNT. RECOMMEND MAINTENANCE ACTIONS ON MAJOR ACFT SYSTEMS BE STRICTLY BY THE BOOK. L UCKILY THERE WAS NOT A HARD NOSE LANDING ON THIS ACFT WHILE THE BOLT WAS MISSING. 1 L 7 1 3O 3 O 2A13 1E10 2004030400111 20040304 00111 NM 2004 3 4 SROM200400015 1 20040226 G 5313 654577835 STRINGER BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 ELONGATED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND AFT CARGO PIT STRINGER 21R HAC ELONGATED HOLE STA 927. REMOVED DAMAGE, FABRICATED AND I NSTALLED REPAIR FILLER CHANNEL SRM 53-10-3. 2 L 7 2 4F 4 F RT A16WE E2EA 2004031500016 20040315 00016 EU 2004 3 15 CA040212004 1 20040203 G 6520 350A020005 GEARBOX SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE TAIL ROTOR MAKING METAL W K NONE J WARNING INDICATION IN INSP/MAINT 1 CA (CAN) T/R GEARBOX MAKING METAL. CHIPS DETECTED ON DETECTORS. REPLACED T/R GEARBOX. 1 G 7 1 3U 3 U NC H9EU E19EU 2004031500021 20040315 00021 EA 2004 3 15 CA040126001 1 20040126 G 3234 750006000 SELECTOR VALVE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE MLG DOOR INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) GEAR DISAGREE ON UP SELECTION AFTER T/O. NOISE IN FLT DECK CONFORMING NOSE GEAR NOT RETRACTED (INDICATED RED HAT CHING ON EICAS CHECK- LIST CARRIED OUT GEAR INDICATED 3 GREEN AIRCRAFT RETURNED TO AIRPORT. DOOR SELECTOR VALVE REPLACED IAW AMM 32-22-15-400-801. A/C SERVICEABLE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500028 20040315 00028 2004 3 15 CA040123004 4 20040114 G 3197 INSULATION PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ELECTRICAL WIRE CHAFED W O OTHER H ELECT. POWER LOSS-50 PC AP APPROACH 1 CA (CAN) DURING APPROACH FLIGHT ON MULTIPLE OCCASIONS THE PILOTS EHSI FAILED ON APPROACH , POWERED DOWN AND RE POWERED UNCO MMANDED. ON EACH OCCASION THE SYSTEM TESTED NORMAL AFTER LANDING AND DID NOT REOCCUR FOR DAYS. EACH COMPONENT IN THIS S YSTEM WAS REPLACED WITH A SERVICEABLE UNIT WITH NO CHANGE. DURING INSP OF THE A/C WIRING CHAFED WIRING WAS DISCOVERED UN DER THE COPILOTS SEAT IN THE OUTFLOW VALVE COMPARTMENT. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004031500031 20040315 00031 EA 2004 3 15 CA040126006 1 20040126 G 2740 9960023 SWITCH CNDAIR CL600 CL6002D24 1390016 EA GE CF34 CF343A1 30015 NE STAB TRIM DIRTY W A UNSCHED LANDING F H FLT CONT AFFECTED ELECT. POWER LOSS-50 PC CL CLIMB 1 CA (CAN) WENT TO DISCONNECT STAB CHANNEL 1, LOST BOTH STAB TRIM CHANNELS AND MACH TRIM. TRIED TO ENGAGE EITHER STAB CHANNE L WITHOUT SUCCESS. ACTIONED QUICK RESPONSE PROCEDURE AND RETURNED TO AIRPORT USING FLAPS 20 IAW QRH. GREATER THAN NORM AL FORCE ELEVATOR FORCE WAS REQUIRED DURING APPROACH. LANDED WITHOUT FURTHER INCIDENT. THE STAB TRIM DISCONNECT SWITCH WAS CLEANED AND SYSTEM RETESTED SERVICEABLE IAW FUNCTIONAL TEST PROCEDURE P601R4500 PARA 5.6.20, THEN A/C WAS RETURNED T O FLIGHT WITHOUT ANY FURTHER OCCURENCES. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500039 20040315 00039 EU 2004 3 15 CA040213005 1 20040213 G 7830 THRUST REVERSER AIRBUS A319 A319112 3930323 EU CFMINT CFM565 CFM565B6 13802 NE ENGINE SMOKE W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) AFTER LANDING AND EXITING THE RUNWAY, THE FLIGHT CREW WERE ADVISED BY THE FLIGHT ATTENDANT THAT THE CABIN HAD FILL ED WITH SMOKE. ATC CONTACTED AND EMERGENCY VEHICLE RESPONDED. THE SMOKE IN THE CABIN QUICKLY DISSIPATED AND ATC ADVIS ED. AFTER DISCUSSION WITH FLIGHT CREW SMOKE WAS INFACT INGESTED SMOKE FROM REVERSERS. THE CREW LEFT THE REVERSER WELL B ELOW 60KTS LIMIT. (NO FURTHER ACTION REQUIRED). 2 L 7 2 4F 4 F RT A28NM E37NE 2004031500043 20040315 00043 EA 2004 3 15 CA040213009 1 20040210 G 5552 C2TP11 HOUSING DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12498 (CAN) LOSS OF ELEVATOR CABLE TENSION REVEALED WORN BEARINGS IN THE C2TP15A HOUSINGS (2), ON REMOVAL OF THE LT HOUSING FO R BEARING REPLACEMENT A CORROSION ASSISTED CRACK WAS NOTED. FAILURE OF THE BEARING HOUSING WAS NOT EASILY DETECTABLE UNT IL THE HOUSING ASSEMBLY WAS REMOVED FOR BEARING REPLACEMENT. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500046 20040315 00046 EA 2004 3 15 CA040215001 1 20040208 G 5610 NP13932110 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE COCKPIT CRACKED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) TAKE OFF ABORTED AT APPROXIMATIVELY 80 KNOTS BECAUSE RT WINDSHIELD CRACKED. RT WINDSHIELD REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500051 20040315 00051 EA 2004 3 15 CA040127008 1 20040127 G 2120 ODOR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE CABIN DETECTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLIGHT CREW NOTICED AN ACRID ODOR IN THE COCKPIT. AFTER NOTING THE ACRID ODOR THE FLIGHT CREW OBSERVED A CIRCUIT BREAKER THAT HAD POPPED. THE ODOR SEEMED TO CLEAR AND THEN REOCURRED ASSOCIATED WITH A SOUND. THE FLT CREW ELECTED TO DEC. MAINTENANCE INVESTIGATION UNDER WAY. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500053 20040315 00053 CE 2004 3 15 CA040127010 1 20040121 G 5610 10138402521 WINDSHIELD BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL COCKPIT CRACKED W B EMER. DESCENT H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) IN CRUISE 28,000 FT, OAT-32, WINDSHIELD HEAT ON. HEARD A BANG - PILOT'S WINDSHIELD CRACKED. DESCENDED TO 12,500 FT , REDUCED AIRSPEED AND CABIN PRESSURE DIFFERENTIAL TO 4.0, RETURNED TO BASE. LANDED AIRCRAFT FROM RT SEAT. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004031500058 20040315 00058 EA 2004 3 15 CA040127015 1 20040127 G 5270 WARNING LIGHT CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE PAX DOOR FALSE ACTIVATION W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER DEPARTURE, CREW HAD DOOR WARNING INDICATION. CREW ELECTED TO RETURN, LANDED WITHOUT INCIDENT. OFF LINE FOR I NVESTIGATION. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500062 20040315 00062 EA 2004 3 15 CA040216005 2 20040110 G 8520 78030 CONNECTING ROD CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1A175 1A175ATM GL ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 CA L4427827A (CAN) ENGINE WAS CONTAMINATED. ABNORMAL WEAR WAS DETECTED ON FOUR CONNECTING RODS CAUSING METAL CONTAMINATION. DEMARCA TION WAS ALSO NOTED ON CRANKSHAFT. AFTER COMPLETING A THOROUGH INSP (MEASUREMENT OF INTERNAL BUSHINGS, A TORSION, PARALL ELISM, INSPECTION OF CONNECTING RODS, SIDE PLAY INSP OF CONNECTING RODS AND CRANKSHAFT), CONCLUDED THAT ALL MFG INSP REQ UIREMENTS WERE CARRIED OUT IN CONFORMITY WHEN IT WAS OVERHAULED. AC WAS IN OPERATION WITH 100 MINERAL OIL (SUMMER OIL) BECAUSE 80 MINERAL OIL (WINTER OIL) WAS NOT AVAILABLE. WE CONCLUDED THAT USE OF 100 MINERAL OIL IN VERY COLD STARTING C ONDITION CAUSED A LACK OF LUBRICATION IN THIS SPECIFIC AREA. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P857 2004072800202 20040728 00202 EA 2004 7 28 AUS20040383 2 20040503 G 8530 LW19339 SCREW CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE CRACKED W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S 591 (AUS) EXHAUST VALVE ROCKER ADJUSTMENT SCREW CRACKED ALLOWING LOCKNUT TO LOOSEN AND ADJUST VALVE CLEARANCE. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2004031500071 20040315 00071 EA 2004 3 15 CA040217005 2 20040210 G 8520 LW13521 BEARING ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA CONNECT ROD FAILED W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA L2549440A (CAN) NR 5 CONNECTING ROD BEARING FAILED. BEARING FACE MATERIAL WAS BREAKING AWAY FROM BEARING. METAL CONTAMINATION WA S NOTED DURING PREFLIGHT CHECK. CONNECTING ROD BEARING HAD LOST APPROXIMATELY 15 PERCENT OF TOTAL SURFACE AREA. BOTH TH E CRANKSHAFT AND IDLER GEAR HAD RECEIVED SIGNIFICANT DAMAGE TO THEIR TEETH. BOTH GEARS HAD TO BE REMOVED FROM SERVICE. 1 G 7 1 3O 3 O H11NM E295 2004031500084 20040315 00084 EU 2004 3 15 CA040217012 1 20040216 G 2435 23085024 STARTER GEN PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ENGINE INOPERATIVE W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING AN ENGINE START THE PILOT NOTED THERE WAS AN ABNORMAL NOISE GENERATING FROM THE ENGINE. THE NOISE WAS NOTIC EABLE AROUND 10 PERCENT GG SPEED AND DISAPPEARED AFTER STABLE RPM WAS REACHED AT 17 PERCENT GG SPEED. THE STARTER GENERA TOR WAS REPLACED AND THE NOISE HAS NOT REOCCURRED. NO FURTHER ACTION REQUIRED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004031500085 20040315 00085 WP 2004 3 15 CA040217013 2 20040211 G 7240 31016687 COMBUSTION LINER BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP MCAULY 4HFR34 4HFR34C652 NE LT ENGINE CRACKED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) THE LT ENGINE WOULD NOT PRODUCE RATED POWER, IN FACT IT ONLY WENT TO 80 PERCENT. THE CREW ABORTED THE TAKEOFF ROLL AND RETURNED TO THE HANGAR. ON INVESTIGATION, A CRACK WAS FOUND ON THE LOWER CENTER OF THE COMBUSTION CASE. THE CRACK GOES AROUND AN UNUSED PORT ON THE CASE. THIS APPEARS AT FIRST GLANCE TO BE VERY SIMILAR TO A PREVIOUS PROBLEM HAD WITH ANOTHER ENGINE OF THE SAME TYPE. ON THAT ONE IT TURNED OUT TO BE A FAILED SECOND STAGE COMPRESSOR IMPELLER THAT WAS CAUS ING DAMAGING VIBRATIONS. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C 3PNE 2004031500091 20040315 00091 NM 2004 3 15 CA040128003 1 20040123 G 3020 4100S02801 HEATER BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU AIR INTAKE BURNED W F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) AFTER OUR AIRCRAFT ARRIVED ON THE PARKING POSITION OUR TECHNICIAN REPORTED SMOKE AND FLAMES COMING OUT OF THE LT E NGINE COWLINGS AND AIR INTAKE SECTION. THE FIRE WAS EXTINGUISHED AND THE CAUSE WAS FOUND TO BE THAT THE AIR INTAKE HEATE R CAUGHT FIRE. THE AIR INTAKE WHICH WAS THE CAUSE, WAS A PRE MOD UNIT PN 4100S028-01. RELATED REFERENCE, SYD 84-30-02, APPLIES ADDITIONAL SEALANT TO PREVENT FLUID INGRESS TO HEATER CORE. PN 4100S028-03, POST MODSUM 4-113435 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004031500098 20040315 00098 EU 2004 3 15 CA040129001 1 20040129 G 2120 ODOR AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE COCKPIT DETECTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) STRONG ELECTRICAL ODOR FOR 2 MIN DURING DESCENT. WENT AWAY AFTER SHUTTING THE VTRS OFF. CIRCUIT BREAKER WAS PULLED FOR THE REMAINING OF THE FLIGHT, DUE UNABLE TO REACH ANYBODY TO INVESTIGATE IN FLIGHT. 2 L 7 2 4F 4 F RT A28NM E29NE 2004031500106 20040315 00106 EA 2004 3 15 CA040129002 1 20040129 G 7110 ACCOUSTIC LINER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE LT & RT ENGINE DAMAGED W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 CA (CAN) ON TAKEOFF, THRU 100KIAS N1 VIB. BOTH ENGINES 4.0 (RED),VIB. REDUCED AFTER APROX 5 MIN. FOUND ACCOUSTIC LINER DAMA GED. A/C REMOVED FROM SERVICE AND SENT TO HGR FOR REPAIR. (MORE INFO WILL FOLLOW). 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500116 20040315 00116 EA 2004 3 15 CA040219005 1 20040129 G 2701 C3CF3915 CONTROL COLUMN DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 14020 (CAN) CONTROL COLUMN FOUND CRACKED IN THREE LOCATIONS WHEN SB 3/39 CW. 1 H 7 1 3R 4 T A815 E4EA 6 C P15EA 2004031500119 20040315 00119 NM 2004 3 15 CA040130005 1 20040116 G 5610 17180003 WINDOW DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE COCKPIT CRACKED W B EMER. DESCENT D INFLIGHT SEPARATION CR CRUISE 1 CA 14921 (CAN) SHORT WHILE AFTER TAKEOFF AT 13:54 AT 23000 FEET PILOT NOTICED COCKPIT PORT SIDE WINDOW SHOWING SIGNS OF DISCOLORA TION. WHEN PILOT NOTICED DISCOLORATION SIDE WINDOW HEAT WAS SELECTED ON. SHORTLY AFTER HEAT WAS SELECTED ON, OUTER PAN E CRACKED FOLLOWED NOT LONG AFTER BY A PARTIAL SEPARATION OF OUTER PANE. SEPARATION PORTION OF WINDOW PANE STRUCK THE L T IB WING LEADING EDGE AND LT HORIZONTAL STABILIZER CAUSING SOME MINOR DAMAGE TO DEICER BOOTS. FOLLOWING THIS, AC RETUR NED TO DORVAL. MAINTENANCE REPLACED THE PORT COCKPIT SIDE WINDOW AND AC WAS RETURNED BACK TO SERVICE. RECORDS INDICATE T HIS TO BE THE ORIGINAL WINDOW. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500127 20040315 00127 EA 2004 3 15 CA040220001 2 20040219 G 8520 PISTON RING PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA HARTZL HCC2Y HCC2YR2 GL ENGINE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) CYLINDER NR 4 REMOVED DURING 100 HR INSPECTION DUE TO OIL CONTAMINATED SPARK PLUG. TOP COMPRESSION RING FOUND IN S EVERAL PIECES EMBEDDED INTO PISTON. ALL CYLINDERS REMOVED FROM BOTH ENGINES, 8 TOTAL AND 3 OTHER PISTONS FOUND WITH CRAC KED TOP COMPRESSION RINGS. NOTE THAT ALL OTHER CHECKS WHERE NORMAL, COMPRESSION TEST RESULTS ABOVE 70PSI. AFFECTED CYLI NDERS SENT TO OVERHAUL FACILITY FOR REPAIR/REPLACEMENT. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004031500129 20040315 00129 CE 2004 3 15 CA040220003 1 20040211 G 3234 404EN16 SWITCH BEECH 99 99 1154002 CE PWA PT6 PT6A36 52043 NE HARTZL HCB3T HCB3TN3 GL MLG SELECTOR CONTAMINATED W A UNSCHED LANDING O OTHER AP APPROACH 1 CA (CAN) LANDING GEAR FAILED TO EXTEND WHEN SELECTED. APPROXIMATELY 1-5 MINUTES GEAR EXTENDING WITH NO ADDITIONAL CREW ACTI ONS. AIRCRAFT RETURNED TO MAINTENANCE BASE. AIRCRAFT EXPOSED TO -30 DEGREES COLD SOAK FOR APPROXIMATELY 3 HOURS. AIRCRAF T PREVIOUS OPERATED IN WARM CLIMATES FOR 20 YEARS. MAINTENANCE FOUND VERY DIRTY AND (GUMMED) SWITCHES IN LANDING GEAR CO NTROL HANDLE. FIRST EXPOSURE TO COLD CONDITIONS SINCE IMPORT. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004031500131 20040315 00131 WP 2004 3 15 CA040220005 1 20040211 G 7711 LC80E1 TRANSMITTER DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE EPR FAILED W C ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 CA (CAN) TAKEOFF REJECTED DUE TO RT ENGINE EPR INDICATION INOPERATIVE. AIRCRAFT WAS DISPATCHED IAW MEL 77-1 FOR THE DAY. E PR TRANSMITTER REPLACED ON THE FOLLOWING DAY AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500132 20040315 00132 EA 2004 3 15 CA040104001 2 20040102 G 7320 252444076 FUEL CONTROL BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL LT ENGINE FAILED W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION DE DESCENT 1 CA PCE52113 (CAN) LT ENGINE HAD TO BE SHUT DOWN IN FLIGHT AS FCU THROTTLE ARM WOULD NOT RETURN TO IDLE. DUE TO WEEKEND AND PARTS ON ORDER WE WILL BE REMOVING FCU NEXT WEEK. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2004031500133 20040315 00133 CE 2004 3 15 CA040130007 1 20040106 G 2434 C6FF10555A HOUSING CESSNA 337 337G 2075730 CE CONT O360 IO360G 17025 SO MCAULY 2AF34C D2AF34C306 GL ALTERNATOR CRACKED W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA 9041135 (CAN) ON INSPECTION OF ALTERNATOR HOUSING 2 RIBS WERE FOUND CRACKED COMPLETELY THROUGH. THERE HAVE BEEN TWO OTHER SIMILA R ALTERNATORS FOUND WITH CRACKED RIBS. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2004031500136 20040315 00136 SW 2004 3 15 CA040130009 1 20040130 G 5412 CAP BELL BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE MAIN BEAM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NOT UNUSUAL FOR THE OLDER STYLE BEAM CAP TO CRACK. THIS IS A REGION THAT IS PART OF OUR INSPECTION PROGRAM. THER E IS A MORE EXTENSIVE INSPECTION AFTER 10,000 HOURS. 1 G 7 1 4U 4 U H4SW E22EA 2004031500137 20040315 00137 EU 2004 3 15 CA040131001 1 20040130 G 2913 704A33690004 DRIVE BELT SNIAS 350 AS350BA 8680817 EU LYC LTS101 LTS101600A3 41560 NE HYDRAULIC PUMP BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) THE BELT BROKE 2 MINUTES AFTER TAKE-OFF. OAT WAS -15C. THE AIRCRAFT MADE A NORMAL HYDRAULIC-OFF LANDING. NO UNC OMMANDED CONTROL MOVEMENT OCCURRED AT THE TIME OF THE INCIDENT. 1 G 7 1 3U 3 U NC H9EU E5NE 2004031500138 20040315 00138 GL 2004 3 15 CA040202001 3 20040211 G 6110 LW13792 SEAL PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL PROPELLER BLOWN W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA L175755A (CAN) PILOT NOTICED ENGINE SEEPING FROM LT ENGINE COWL, THEY WERE NEAR THE AIRPORT AND DECIDED TO SHUTDOWN LT ENGINE TO PREVENT ENGINE DAMAGE. IT WAS DETERMINED ON THE GROUND BY MAINTENANCE THAT THE LT PROP SEAL HAD BLOWN DUE TO A FROZEN BR EATHER. IT WAS DETERMINED THAT PROBLEM RESULTED FROM AN EXTREME DROP IN TEMPERATURE CAUSING ANY MOISTURE IN THE BREATHER FROM PREHEAT TO FREEZE. PROP SEAL WAS REPLACED AND TEST FLIGHT SUCCESSFUL. 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 2004031500141 20040315 00141 NM 2004 3 15 CA040105001 1 20040101 G 2435 51539008D GCU LUCAS DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE STARTER GEN FAILED W E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 31251 31251 1163 (CAN) DURING NR 1 ENGINE START AFTER PUSHBACK SMOKE WAS NOTED COMING OUT OF THE GEN EXHAUST DUCT ON THE NR 1 NACELLE. T HE PILOT IMMEDIATELY SHUT ENGINE DOWN AND DECLARED AN EMERGENCY, REQUESTED ERS RESPONCE. PASSENGERS WERE DEPLANED AND PI LOT NOTED THAT GENERATOR WAS STILL SPOOLING AFTER EVERYTHING WAS SHUT DOWN, MAINTENANCE WAS SUMMONED TO AC AND MAIN BATT ERY WAS DISCONNECTED AND GENERATOR STOPPED. AC WAS BROUGHT BACK TO HANGAR AND STARTER GEN, GCU AND MAIN BATTERY WERE RE PLACED AND AIRCRAFT RETURNED TO SERVICE AFTER ALL FUNCTION CHECKS WERE CARRIED OUT. COMPONENTS WILL BE SENT OUT FOR REPA IR AND INVESTIGATION AS TO WHY THE GEN DIDN'T DISENGAGE AFTER START UP WHICH CAUSED THE INCIDENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500149 20040315 00149 EA 2004 3 15 CA040220008 2 20040218 G 7510 909100999 HOSE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL ANTI ICE SYSTEM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT COWL ANTI ICE FLEX HOSE FOUND CRACKED DURING OPS 1 INSPECTION. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004031500150 20040315 00150 EA 2004 3 15 CA040220009 2 20040202 G 7220 109910029121 DUCT BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LOWER FORWARD COWL AIR INLET DUCT CRACKED. REPAIR TO BE ACCOMPLISHED IAW MFG FIELD REPAIR PROCEDURE. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004031500152 20040315 00152 EU 2004 3 15 CA040223001 1 20040221 G 2597 RDAV400111 WIRE AIRBUS 320 A320232 3930326 EU IAE V2527 V2527A5 NE VIDEO SYSTEM BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) WHILE TROUBLE SHOOTING THE NON-DEPLOYMENT OF A VIDEO MONITOR IT WAS FOUND THAT THE JUNCTION BOX FOR THIS MONITOR H AD FAILED. THE UNIT SMELLED OF BURNED ELECTRICAL MATTER. THERE WHERE SIGNS OF ARCING SHOWING ON THE OUTSIDE CASE. THE AS SOCIATED MONITOR DID NOT WORK AND DID NOT WORK WITH ANOTHER JUNCTION BOX. BOTH THE MONITOR AND JUNCTION BOX WERE REPLACE D AND FUNCTIONED SERVICEABLE. THE JUNCTION BOX WILL BE INVESTIGATED. 2 L 7 2 4F 4 F RT A28NM E40NE 2004031500158 20040315 00158 WP 2004 3 15 CA040202004 1 20040105 G 2133 39271411 OUTFLOW VALVE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE CABIN PRESSURE FAULTY W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) UNABLE TO PRESSURIZE THE AIRCRAFT. AIRCRAFT LANDED. MAINTENANCE FOUND RT PRSO VALVE P/N 392714-1-1 S/N 2653 IN FAU LT. VALVE REPLACED. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500159 20040315 00159 WP 2004 3 15 CA040202005 1 20040109 G 2133 39245431 REGULATOR VALVE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE CABIN PRESSURE FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) COULD NOT PRESSURIZE THE AIRCRAFT. AIRCRAFT LANDED BACK, FOLLOWING INVESTIGATION, MAINTENANCE FOUND IN FAULT THE L T PILOT PRESSURE REGULATING VALVE P/N 392454-3-1 S/N 6549 AND LT PRESSURE REGULATOR VALVE P/N 392714-1-1 S/N 4522. BOTH VALVES REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500160 20040315 00160 WP 2004 3 15 CA040202006 1 20040115 G 2910 B-NUT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE HYD LINE LOOSE W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) UPON ARRIVAL AT GATE WHEN APU AIR SELECTED 'ON', CABIN AND COCKPIT FILLED WITH BLUE SMOKE. CAUSED BY THE INGESTION OF HYDRAULIC OIL IN THE APU AIR INTAKE. SOURCE OF FLUID CAME FROM RT WHEEL WELL. MAINTENANCE FOUND 2 (B) NUTS LOOSE ON ONE HYDRAULIC LINE NEAR RT HYDRAULIC RESERVOIR. NUTS TIGHTENED AND SYSTEM CHECKED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500163 20040315 00163 CE 2004 3 15 CA040224001 1 20040218 G 7830 282D0007505 PRESSURE SWITCH EATON LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE HCU FALSE INDICATION W O OTHER L J NO TEST WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXIING AIRCRAFT, FLIGHT CREW INCREASE ENGINE POWER. ONE THRUST REVERSER LIGHT STAYS ON. AFTER TROUBLESHOOT ING, MAINTENANCE REPLACED HYDRAULIC CONTROL UNIT. THE PRESSURE SWITCH INSIDE THE HCU GIVES A FALSE INDICATION. AIRCRAFT RETURN TO SERVICE. 2 L 7 2 4F 4 F RT A10CE E35NE 2004031500169 20040315 00169 CE 2004 3 15 CA040202012 1 20040113 G 5410 5012000886 SPAR RAYTHN BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCD4N3 HCD4N3A GL NACELLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA LJ1305 (CAN) NACELLE OB WEB TO SPAR ATTACHMENT CHANNEL CRACKED IN BEND RADIUS ON LOWER END OF CHANNEL. THIS CONDITION EXISTED I N THE SAME AREA ON BOTH NACELLES. CRACKS ARE COMMON IN THESE AREAS ON HIGH CYCLE AIRPLANES. LATER SN AIRCRAFT COME FROM THE FACTORY WITH DOUBLERS ALREADY INSTALLED IN THESE AREAS. 1 L 7 2 3T 4 T RT 3A20 E4EA 5 C STC 2004031500173 20040315 00173 NM 2004 3 15 CA040202017 1 20040106 G 2422 116250 CONNECTOR DH103024600C DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE LOAD EQUALIZER FAILED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA 1814S8 (CAN) COMPONENT RESPONSIBLE FOR INVERTER FAILURE IS SOLDER CONNECTION ON LOAD EQUALIZER SUBASSEMBLY P/N 116250. ON APPRO ACH, PRIMARY INVERTER, SECONDARY INVERTER, AND AUX INVERTER, L26AC BUS, AND R26AC BUS CAUTION LIGHTS ILLUMINATED. AFTER AUX INVERTER SWITCHED OFF, PRIMARY, SECONDARY AND BOTH 26AC BUS LIGHTS WENT OUT. CREW BROKE OFF APPROACH AND AC RETURNED . COULD NOT FAULT ON GROUND. PRIMARY INVERTER VOLTAGE INDICATING 107V AND REPLACED. AUX INVERTER REPLACED FOR T/S. ALL R ELATED CONNECTOR PLUGS AND CIRCUIT BREAKERS INSPECTED SVC. INVERTERS SENT TO VENDOR AND RETURNED WITH S/N 1814-S8 CONFI RMING FAULT, AND NAMING SOLDER CONNECTION ON LOAD EQUALIZER SUBASSEMBLY AS CULPRIT COMPONENT P/N 116250. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500174 20040315 00174 CE 2004 3 15 CA040203001 1 20040130 G 3260 1EN18 DOWNLOCK SWITCH LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP RT MLG FALSE INDICATION W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) ON GEAR SELECT DOWN, INDICATED RT MAIN GEAR NOT DOWN AND LOCKED WITH 2 MAIN GEAR DOOR UNSAFE RED. LIGHT BULB TEST INDICATED THAT BULBS WERE OK. RECYCLED GEARS SELECTOR 3 TIMES WITH NO SUCCESS. HYDRAULIC PRESSURE WAS NORMAL. CONDUCTED EMERGENCY GEAR EXTENSION PROCEDURE BUT DID NOT OBTAIN NORMAL (DOWN AND LOCK) GREEN LIGHTS. TOWER CONFIRMED THAT THERE W AS NO LANDING LIGHT ON RT SIDE. EMERGENCY WAS DECLARED, LANDING WAS PERFORMED WITH NO FURTHER PROBLEMS, BESIDE (DOWN AN D LOCK) LIGHTS. RT DOWN AND LOCK SWITCH WAS REPLACED, GEAR SWINGS WERE C/O, AND THE SYSTEM WAS FOUND SERVICEABLE AND AIR CRAFT RELEASED TO SERVICE. 2 L 7 2 4F 4 F A10CE E6WE 2004031500175 20040315 00175 EA 2004 3 15 CA040225002 1 20040218 G 3340 2LA00691307 LIGHT CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT INOPERATIVE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) FLOODLIGHT CAUSED SMOKE IN THE FLT DECK. CB POPPED AND WHEN FLOOD LIGHT WAS TURNED OFF IT QUIT SMOKING. FLOOD LI GHT ASSEMBLY WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004031500177 20040315 00177 CE 2004 3 15 CA040225005 1 20040121 G 2710 051010513 CONTROL CABLE CESSNA 180 180C 2072608 CE CONT O470 O470K 17026 SO MCAULY 2A34C 2A34C203 GL AILERON FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CABLE FRAYED AT PULLEY AREA. WING ROOT PULLEY WAS NOT SEIZED. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004031500183 20040315 00183 EA 2004 3 15 CA040106008 1 20040106 G 2497 WIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE E/E COMP. FAILED W K NONE B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION IN INSP/MAINT 1 CA (CAN) AFTER LANDING, CAUTION MSG ESS TRU 1 ON EICAS A PUFF OF ELECTRICAL ODOR WAS DETECTED AT GATE FOUND A1 CB POPPED WO ULD NOT RESET. DUE TO THIS SITUATION THREE WIRES WERE CHANGED ALSO TR1 REPLACED AND J12 CONNECTOR REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031900013 20040319 00013 NM 2004 3 19 18069 1 20040303 G 5710 STRUCTURE LKHEED P2V P2V7 5260112 NM WRIGHT R3350 R3350* 67040 EA LT WING CRACKED F K NONE O OTHER IN INSP/MAINT 1 NM 04 139HP 9034 145906 THE CRACK/CORROSION IS LOCATED ON THE AFT VERTICAL SIDE OF STRINGER (HAT SECTION) NR 18. IT IS LOCATED IN THE LEFT HAND OUTER WING AT WING STATION 284. THE CRACK/CORROSION IS 1.25 INCH LONG AND RUNS SPAN WISE. THE CORROSION WAS REMOVED C OMPLETELY AT .024 OF GRIND OUT. THE CRACK IS STILL EVIDENT AND APPEARS TO GO ALL THE WAY THRU THE MATERIAL. THE MATERI AL THICKNESS OF THE HAT SECTION IS .120. 2 M 7 2 4R 4 R RT A1RM E272 2004032500028 20040325 00028 CE 2004 3 25 CA040203004 1 20040130 G 3230 MS24171D1 RELAY BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL MLG MOTOR FAILED W O OTHER O OTHER AP APPROACH 1 CA (CAN) LANDING GEAR FAILED TO EXTEND ON APPROACH. EMERGENCY EXTENSION WAS CARRIED OUT AND AIRCRAFT LANDED SAFELY. MAINTEN ANCE FOUND THAT THE LANDING GEAR MOTOR WAS NO LONGER RUNNING. THE LANDING GEAR RELAY WAS FOUND INTERNALLY DAMAGED WITH T HE CONTACTS STUCK IN THE CLOSED POSITION THUS PROVIDING CONTINUOUS POWER TO THE LANDING GEAR MOTOR. THIS CAUSED THE MOT OR TO FAIL. P/N OF RELAY MS24171D1 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004032500036 20040325 00036 CE 2004 3 25 CA040225011 1 20040224 G 2750 14601008 CONTROL CABLE CESSNA 337 337A 2075704 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C59 GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP CABLES REMOVED FOR INSPECTION DUE TO SERVICE DIFFICULTY ALERT AL-2003-05. LT AND RT OUTBOARD FLAP CABLES FOUN D TO BE FREYED AT THE INBOARD BELLCRANK, APPROXIMATELY 1 INCH FROM THE SWAGGED TERMINAL. BOTH CABLES ARE ORIGINAL CESSNA FLAP CABLES AND WERE REPLACED WITH NEW CESSNA FLAP CABLES. ALSO, THE RT, INBOARD FLAP CABLE WAS FREYED AT THE INBOARD B ELLCRANK, APPROXIMATELY 1 INCH FROM THE SWAGGED TERMINAL. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2004032500039 20040325 00039 EA 2004 3 25 CA040226003 1 20040224 G 2421 721428 IDG CNDAIR CL600 CL600* EA LYC ALF502 ALF502* 41580 EA LT ENGINE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) OIL NOTED LEAKING FROM LT ENGINE DRAIN MAST. INTEGRATED DRIVE GENERATOR REMOVED AND ACCESSORY DRIVE GARLOCK SEAL AND IDG SHAFT O-RING REPLACED. LEAK RETURNED AT DRAIN MAST TWO DAYS LATER. IDG WAS REMOVED AND INSPECTED. THE LEAK WA S DETERMINED TO ORIGINATE FROM THE INTEGRATED DRIVE GENERATOR CARBON SEAL. THIS IS AN ABNORMAL OCCURRENCE. IDG REPLACED WITH SERVICEABLE UNIT. 2 L 7 2 4F 4 F RT A21EA E6NE 2004032500043 20040325 00043 EA 2004 3 25 CA040108003 1 20040107 G 2497 BMS1360T01C03G0 WIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE ELECTRICAL INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE RE-INSTALLING CIRCUIT BREAKER PANEL THAT WAS ROBBED TO SERVICE AN OTHER AIRCRAFT THE MECHANIC NOTICE THREE P OWER CABLES WERE SHAVING ALONG THE STRUCTURE OF THE PANEL. (STRAINS WERE SHOWING) THOSE THREE WIRES WERE REPLACED, FOL LOWING THIS FINDING, A CAMPAIN WILL BE LAUNCHED DUE TO FIRE POTENTIAL. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032500046 20040325 00046 CE 2004 3 25 CA040108007 1 20040107 G 2820 VALVE CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE FUEL CROSSFEED INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING REFUELING, FBO LINE CREW FAILED TO CARRY OUT SINGLE POINT REFUELING PRE-CHECK. DURING FUELLING, ONLY LT TAN K WAS FILLED (RT REFUELING VALVE APPARENTLY FAILED IN THE CLOSED POSITION). BY THE TIME THE FLIGHT CREW NOTICED THE DIFF ICULTY A SIGNIFICANT FUEL IMBALANCE HAD BEEN CREATED, REQUIRING CROSSFEED FROM LT TO RT TANK. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004032500050 20040325 00050 NM 2004 3 25 CA040109004 1 20040109 G 2612 FIRE DETECTOR BOEING 727 72722C 138400F NM PWA JT8 JT8D7B 52053 NE ENGINE BAY MALFUNCTIONED W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) ON APPROACH, THE ENGINE FIRE WARNING BELL SOUNDED CONTINUOUSLY, THERE WERE NO ENGINE WARNING LIGHTS ON. ON THE GR OUND MAINTENANCE INSPECTED ALL ENGINES NO FAULTS WERE FOUND. MAINTENANCE WAS UNABLE TO DUPLICATE PROBLEM AGAIN ON THE GR OUND. THE FIRE DETECTION DETECTOR UNIT P/N 65-24920-3 WAS REPLACED . REMOVED AND INSPECTED AND CLEANED PIN/SOCKETS AN AL L THREE ENGINE FIRE DETECTION POWER OPERATING UNITS P/N 1011B-1. THE SYSTEM WAS TESTED WITH NO FAULTS. THE AIRCRAFT WAS RETURNED TO SERVICE AND OPERATED WITHOUT ANY FURTHER PROBLEMS. 2 L 7 3 4F 4 F A3WE E2EA 2004032500054 20040325 00054 CE 2004 3 25 CA040203009 1 20040116 G 3220 5042013497A FORK CESSNA CESSNA 340 340A 2076405 CE CONT O520 TSIO520N 17040 SO MCAULY 3AF32C 3AF32C93 GL NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK FOUND IN FORK CASTING ON LT SIDE OF TUBE BORE. DISASSEMBLY REVEALED FORK CRACKED COMPLETELY THROUGH LT SIDE OF BORE. 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 2004032500057 20040325 00057 GL 2004 3 25 CA040203013 1 20040123 G 7820 973670 MUFFLER DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912S3 EU HOFMAN HOV352 HOV352F NE ENGINE EXHAUST BROKEN W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) TAILPIPE NEARLY SNAPPED OFF FROM MUFFLER, INTERNAL BAFFLES LOOSE AND OBSTRUCTING EXHAUST OUTLET PART, CAUSING THE BACK PRESSURE TO RISE AND FAILURE OF TAILPIPE HAS OCCURRED. ENGINE POWER WAS ROBBED AND FORCED THE BUILD-UP OF BACK PRES SURE TO EXIT THE HOLE IT HAS CREATED. CORRECTION ACTION IS TO SEND MUFFLER TO AN AMO WHOM MAY REPAIR MUFFLER AND COMPLE TE TAP TESTS TO MUFFLER TO VERIFY THE STATUS OF INTERNAL BAFFLES, AT EVERY INSPECTION. 1 L 7 1 3O 3 O NT TA4CH E00051EN 5 C TP5BO 2004032500058 20040325 00058 SW 2004 3 25 CA040203014 1 20040128 G 6320 206040030101 BEARING RACE BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL M/R GEARBOX SPALLED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA BKW1417 (CAN) BEARING SPALLED AND CAUSED A CAUTION LIGHT TO COME ON. 1 G 7 1 3U 3 U H2SW E4CE 2004032500062 20040325 00062 EU 2004 3 25 CA040109006 1 20040107 G 2913 716988 PUMP BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE HYDRAULIC SYS LEAKING W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA 23682 23682 LF05559AC (CAN) IN FLIGHT SHUT DOWN OF NR 2 ENGINE DUE TO LOSS OF OIL PRESSURE AND QUANTITY. MAINTENANCE FOUND EVIDENCE OF HYD FLU ID MIGRATION INTERNALLY FROM HYDRAULIC PUMP TO THE PUMP SHAFT. SUSPECT THAT HYD FLUID CAUSED DETERIORATION OF THE PUMP S HAFT SEAL (O-RING) TO THE POINT THAT IT CAUSED THE ENGINE OIL TO BE LOST. PUMP REPLACED. NR 2 ENGINE ALSO BEING REPLACE D. 2 H 7 4 4F 4 F A49EU E6NE 2004031500130 20040315 00130 WP 2004 3 15 CA040220004 1 20040216 G 2410 902241 WHEEL PRESTOLITE ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA ALTERNATOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA F219612E (CAN) BROKEN ALTERNATOR FAN WHEEL. REPLACED WHEEL. 1 G 7 1 3O 3 O H11NM E295 2004031500134 20040315 00134 CE 2004 3 15 CA040220006 1 20040213 G 2820 05001183 LINE CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA MCAULY 1C172 1C172MTM GL FUEL SYSTEM CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FUEL LINE WAS FOUND CHAFED DURING 200 HR INSPECTION. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004031500135 20040315 00135 SO 2004 3 15 CA040130008 1 20040127 G 3220 67054003 TRUNNION PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA HARTZL HCC2Y HCC2YK1 GL NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK EMANATING FROM TOP OF WEB JUST RT OF CENTER STRUT HOUSING. NO REPORT OF HARD LANDING OR ABUSE. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2004031500140 20040315 00140 2004 3 15 CA040104002 4 20040101 G 8300 FLANGE BOEING 727 727231 1384079 NM PWA JT8 JT8D15A 52051 NE ACCESSORY GEARBO CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 6674486K (CAN) SCHEDULED MAINTENANCE WAS CARRIED OUT TO REPLACE THE FCU/FUEL PUMP QUAD RING. THE RUN OUT TORQUE INSPECTION WAS CA RRIED OUT AND THE CLEARANCE FAILED. DISASSEMBLY OF THE AREA DETERMINED THAT THE QUAD RING NUT ATTACHMENT FLANGE WAS CRAC KED. THE UNSERVICEABLE GEARBOX WAS REMOVED AND A SERVICEABLE UNIT WAS INSTALLED. NO FURTHER PROBLEM WAS FOUND. 2 L 7 3 4F 4 F A3WE E2EA 2004031500148 20040315 00148 CE 2004 3 15 CA040220007 1 20040218 G 2133 47061 VALVE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL ENERGENCY PRESS FAILED W B G EMER. DESCENT O2 MASK DEPLOYED D J INFLIGHT SEPARATION WARNING INDICATION CL CLIMB 1 CA (CAN) DURING THE CLIMB THE AIRCRAFT EMERGENCY PRESSURIZATION VALVE OPENED WITH OUT BEING SELECTED. THE CREW DEPRESSURIZE D THE AIRCRAFT AND RETURNED TO BASE. THE EMERGENCY PRESSURIZATION VALVE WAS REPLACED AND THE AIRCRAFT SYSTEMS FUNCTION C HECKED SERVICABLE 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004031500151 20040315 00151 CE 2004 3 15 CA040220010 1 20040202 G 5610 10138402523 WINDSCREEN BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIR CREW REPORTED THAT THE PILOTS WINDSCREEN WAS DISCOLOURED AT THE OB EDGES AND HAD A MILKY APPEARANCE. THE WINDS CREEN HAD PREVIOUSLY BEEN REPAIRED BY THE MFG. THE WINDSCREEN WAS REPLACED WITH A NEW UNIT AND THE DAMAGED UNIT WAS RETU RNED TO THE MFG FOR EVALUATION. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004031500153 20040315 00153 NM 2004 3 15 CA040223002 1 20040217 G 5610 56100165 WINDOW BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE COCKPIT CRACKED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) UPON ARRIVAL AT GATE THE CREW NOTICED F/O NR 4 EYEBROW WINDOW CRACKED. SUSPECT INTERNAL O/HEAT WINDSHIELD SYSTEM C HECKED SERVICEABLE NR 4 EYEBROW WINDOW REPLACED AIRCRAFT RETURNED TO SERVICE 2 L 7 2 4F 4 F A16WE E2EA 2004031500156 20040315 00156 EU 2004 3 15 CA040105008 1 20040103 G 3260 A23802105 SQUAT SWITCH AMD FALC20 FALCON20F5 2730105 EU GE CF700 CF7002D2 30010 NE NLG FROZEN W O OTHER N FALSE WARNING LD LANDING 1 CA (CAN) ON LANDING THE PIC COULD NOT ACTIVATE THE NORMAL BRAKES AND THE NOSE WHEEL STEERING. PIC USED NR 2 BRAKE SYSTEM AN D DIFFERENTIAL POWER TO CONTROL THE AC. SQUAT SWITCH WAS REMOVED, CLEANED AND RE-INSTALLED. NORMAL BRAKES AND NOSE WHEE L STEERING FUNCTION TESTED SERVICEABLE. AC RETURNED TO SERVICE. OPERATOR PLANS TO IMPLEMENT MONTHLY INSPECTION AND CLE ANING OF ALL LANDING GEAR SWITCHES OF MOISTURE. 2 L 7 2 4F 4 F RT A7EU E7EA 2004031500157 20040315 00157 NE 2004 3 15 CA040202003 2 20040102 G 7320 BELLCRANK DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE FUEL LEVER LACK OF LUBE W K NONE W E INADEQUATE Q C VIBRATION/BUFFET IN INSP/MAINT 1 CA (CAN) COULD NOT SHUT DOWN LT ENGINE WITH FUEL LEVER. HAD TO PULL FIRE HANDLE. ALSO RT ENGINE VERY DIFFICULT TO SHUT OFF. CABLE MECHANISM FOUND STIFF DUE TO VERY COLD WEATHER. FUSELAGE TO PYLON BELLCRANK LUBRICATED AND BOTH SYSTEMS SERVICEAB LE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500161 20040315 00161 NM 2004 3 15 CA040202010 1 20040202 G 7830 THRUST REVERSER BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE ENGINE INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER T/O CREW RECEIVED A FLAP WARNING AND T/O WARNING HORN. SIMILAR INCIDENT. THE FLIGHT RETURNED AND UPON LANDI NG, THE RT ENGINE QUIT. A/C REMOVED FROM SERVICE FOR INVESTIGATION. FLIGHT DATA RECORDER REMOVED FOR READOUT. CAPT CONTA CTED REGARDING ENGINE QUIT STATEMENT, THE ENGINE DID NOT QUIT, IT ROLLED BACK BELOW 60 KTS AFTER THRUST REVERSER STOWED NIL EGT, INCREASE NOTICED BY CREW. INCIDENT UNDER INVESTIGATION. 2 L 7 2 4F 4 F RT A1NM E3NE 2004031500162 20040315 00162 CE 2004 3 15 CA040202011 1 20040109 G 5260 10151417617 HANDLE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE AIRSTAIR DOOR FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 17475 (CAN) DURING TAKEOFF ROLL THE AIRSTAIR DOOR EXTERIOR HANDLE SEPARATED FROM THE DOOR. FURTHER INSPECTION FOUND IMPACT DAM AGE TO LT PROPELLER AND LT IB FLAP. APPROXIMATELY ONE INCH MISSING FROM TIP OF ONE PROPELLER BLADE AND DENT IN LOWER SKI N OF IB FLAP. HANDLE RECOVERED AND INSPECTED FOR CONDITION. RETAINER RING P/N MS16624-1075 MISSING ALLOWING HANDLE TO SE PARATE FROM DOOR. LSO FOUND PIN P/N MS9048-072 SHEARED. THIS PIN HOLDS SHAFT IN HANDLE. HANDLE ASSEMBLY REPLACED WITH NE W. PROPELLER ASSEMBLY REPLACED. SKIN REPAIR CARRIED OUT TO IB FLAP. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004031500164 20040315 00164 CE 2004 3 15 CA040224003 1 20040216 G 3240 RIVET CLEVELAND BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA MCAULY 4HFR34 4HFR34C652 NE BRAKE PAD RIVETS SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA 1544 (CAN) BRAKE ASSEMBLY S/N 1544 WAS FOUND WITH THE BRAKE PAD RIVETS SHEARED ALLOWING THE PADS TO BECOME DISLODGED, THIS IS THE SECOND TIME WE HAVE HAD WEAR PADS BEING DISLODGED FROM THE PRESSURE PLATE ASSEMBLY. THIS BRAKE ASSEMBLY WAS IN SER VICE FOR ONE YEAR SINCE NEW. NO TIMES AVAILABLE. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004031500165 20040315 00165 NE 2004 3 15 CA040106002 2 20040102 G 7200 ENGINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE NR 2 MAKING METAL W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA 872684 (CAN) CREW REPORTED APPROXIMATELY 30 MINUTES FROM DESTINATION, THAT NR 2 ENGINE OIL PRESSURE HAD DROPPED BELOW MINIMUM. CREW ELECTED TO PERFORM IN FLIGHT SHUT DOWN. CREW REQUESTED CFR AND LANDED WITHOUT INCIDENT. INSPECTION REVEALED NR 2 E NGINE 2 QTS LOW WITH NO SOURCE OF OIL LEAKS. AGB CHIP DETECTOR REVEALED SOME METAL DEBRIS. CHIP DETECTOR TROUBLESHOOTING KIT WAS INSTALLED AND SECOND INSPECTION OF THE CHIP DETECTOR REVEALED A SIGNIFICANT AMOUNT OF METAL. A BOROSCOPE INSPEC TION REVEALED THAT THE AXIS P GEAR WAS MISSING TEETH AND THAT THE AXIS B-B GEAR WAS HEAVILY WORN. LAB ANALYSIS OF THE RE MOVED DEBRIS CONFIRMED TO BE M50 MATERIAL. ENGINE WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500170 20040315 00170 2004 3 15 CA040225001 4 20040213 G 3497 MS2536175 CIRCUIT BREAKER CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE EDU INOPERATIVE W O OTHER O OTHER TO TAKEOFF 1 CA (CAN) DURING TAKE OFF ROLL (LESS THAN 20 KTS), THE CAPT'S PFD, MFD, NR 2 EDU AND NR 1 RTU WENT BLANK THAN CAME BACK ON. REPLACED 75 AMP. DC ESS FEED, CIRCUIT BREAKER IN LT DCPC. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004031500171 20040315 00171 EU 2004 3 15 CA040202015 1 20040130 G 6320 332A32323300 TIE ROD UROCOP SNIAS AS332 AS332L 8680809 EU TMECA MAKILA MAKILA1A 60040 EU M/R GEARBOX SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA M279 (CAN) ONE OF THE THREE BOLTS ATTACHING THE ENGINE TO THE MAIN GEARBOX WAS DISCOVERED SHEARED DURING A TURN AROUND CHECK. THE BOLT WAS SHEARED ABOUT MIDWAY IN THE THREADED PORTION OF THE BOLT. THE ENGINE WAS REMOVED AND AREA INSPECTED IAW WR ITTEN PROCEDURES. NO REASON FOR BOLT DAMAGE WAS DETERMINED. 2 G 7 2 4U 4 U H4EU E12NE 2004031500172 20040315 00172 EU 2004 3 15 CA040202016 1 20040202 G 3230 D172890 CONTROL CABLE BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315R 01518 WP MLG BINDING W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA (CAN) UPON FUNCTIONAL TEST OF LANDING GEAR RETRACTION, THE SECONDARY MECHANICAL NOSE GEAR INDICATOR WAS NOT INDICATING P ROPER EXTENSION (PROTRUSION OF CABLE END). PROBLEM TRACED TO BINDING CABLE. EXAMINATION OF DEFECTIVE PART (REMOVAL OF CABLE FROM METAL JACKET BY CUTTING) REVEALED BULGE AT SWAGED END CAUSING CABLE TO BIND WITHIN ITS JACKET. THIS ASSY IS T O BE LUBRICATED (HAND PACKED) EVERY 48 MONTHS IAW MFG RECOMMENDATIONS. HOWEVER THE LIMITED TRAVEL OF THE CABLE WOULD PRE -EMPT ANY LUBRICANT FROM REACHING THE SWAGED WIRE PORTION ON THE E-CABLE. ONLY THE METAL ROD END WOULD RECEIVE THE LUBRI CANT. 2 L 7 2 4F 4 F RT A3EU E6WE 2004031500186 20040315 00186 EA 2004 3 15 CA040106011 1 20040104 G 2710 CONTROL CABLE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE AILERON CONTAMINATED W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXING DURING FLT CONTROL CHECK FOUND AILERONS NOT RETURNING TO NEUTRAL. AFTER INVESTIGATION FOUND WHEEL WEL L CONTAMINATED WITH DIRT AND MOISTURE. AREA CLEANED AND LUBRICATED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032500026 20040325 00026 EA 2004 3 25 CA040224002 2 20040216 G 7261 OIL SYSTEM PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL RT ENGINE CONTAMINATED W O OTHER O OTHER LD LANDING 1 CA PCE51909 (CAN) PILOT REDUCED ENG POWER FOR LANDING AFTER FIRST FLIGHT OF DAY, RT ENGINE PRESSURE DECREASE WAS OBSERVED. TECH DIS COVERED LARGE QUANTITY OF CARBON IN ENGINE OIL FILTER. ENGINE WAS REMOVED AND SENT TO MFG FOR INVESTIGATION. ENGINE WA S DISSEMBLED AT THE (C FLANGE) FOR AN ITT PROBLEM. AFTER REASSEMBLY, ALL GROUND TESTS WERE PERFORMED AND AC WAS RETURNED TO SERVICE AND ENGINE OIL WAS ADDED. AN INTERNAL INVESTIGATION DETERMINED THAT CARBON DISCOVERED IN FILTER WAS MADE OF LITTLE BLACK STONES. FUNNEL THAT WAS USED TO ADD ENGINE OIL WAS LOCATED, INSPECTED AND CLEANED AND SAME LITTLE BLACK STO NES WERE DISCOVERED IN THE FUNNEL. WE WERE NOT ABLE TO DETERMINE THE ORIGIN OF THE LITTLE BLACK STONES. 1 L 7 2 3T 4 T A8EA E4EA 6 C P15EA 2004032500027 20040325 00027 SW 2004 3 25 CA040203003 1 20040202 G 2710 2771026001 CONTROL CHAIN SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE AILERON WORN W O OTHER F FLT CONT AFFECTED DE DESCENT 1 CA (CAN) DURING DECENT THE FLIGHT CREW NOTICED THE AILERONS BINDING AND VERY DIFFICULT TO MOVE. UPON SLOWING DOWN THE AIRC RAFT THE AILERON CONTROL RETURNED TO NORMAL. INVESTIGATION BY MAINTENANCE REVEALED THAT THE 27-71026-001 CONTROL CHAIN WAS SEIZED AND ALMOST WORN THROUGH ON A COUPLE OF CHAIN LINK SEGMENTS. IT APPEARS AS THOUGH DURING HIGH SPEED FLIGHT TH E AIR LOAD ON THE AILERONS CAUSED HIGHER TENSION LOADS ON THE CONTROL CABLES PUTTING MORE FORCE ON THE CHAIN WHICH THEN BECAME VERY DIFFICULT TO MOVE. THE CHAINS (27-71026-001) AND SPROCKETS (26-71010-3) ON BOTH CONTROL COLUMN WHEELS WERE R EPLACED AND THE AIRCRAFT RELEASED FOR FLIGHT. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2004032500029 20040325 00029 CE 2004 3 25 CA040203006 1 20040108 G 5610 10138402518 WINDSHIELD BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL COCKPIT BROKEN W B EMER. DESCENT H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) IN CRUISE RT WINDSHIELD HEAT ON, WINDOW SHATTERED, DESCENDED TO 12,000 FT, REDUCED AIR SPEED AND CABIN PRESSURE AN D RETURNED TO BASE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004032500035 20040325 00035 GL 2004 3 25 CA040107008 1 20040107 G 7921 654585 OIL COOLER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) OIL COOLER FOUND CRACKED ON OB FORWARD LOWER CORNER FLANGE WHERE THE BAFFLE IS ATTACHED. CRACK IS ABOUT 1 INCH LON G. THIS IS THE THIRD COOLER FOUND CRACKED ON THE TYPE OF INSTALLATION. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2004032500037 20040325 00037 CE 2004 3 25 CA040225014 1 20040224 G 2750 14601007 CONTROL CABLE CESSNA 337 337A 2075704 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C59 GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP CABLES REMOVED FOR INSPECTION, REFERENCE SD ALERT AL-2003-05 IB FLAP CABLE, RT SIDE, PART NR 1460100-7 FRAYED APPROX 50 PERCENT AT IB BELLCRANK. 1 INCH FROM SWAGGED TERMINAL. ALSO BOTH OB CABLES PN 1460100-8 FRAYED AT IB BELLCRAN K, APPROX. 1 INCH FROM SWAGGED TERMINAL. ALL CABLES ARE ORIGINAL FLAP CABLES AND HAVE BEEN REPLACED WITH NEW FLAP CABLES SUPPLIED BY MFG. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2004032500038 20040325 00038 EU 2004 3 25 CA040226002 1 20040217 G 6410 10531980 BLADE UROCOP BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20 03013 GL TAIL ROTOR PEELING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) TAIL ROTOR BLADES RECEIVED FROM MFG WITH THE PAINT REFINISHED AFTER REPAIR OR INSPECTION ARE PEELING OR SHREDDING TO THE BLADE BODY SURFACE BELOW. THIS IS OCCURRING USUALLY WITHIN THE FIRST 100 HOURS OF OPERATION. THE NEW REFINISHED PAINT SURFACE IS THICK ENOUGH TO PROTRUDE CONSIDERABLY ABOVE THE LEADING EDGE ABRASION STRIP CAUSING THE PAINT TO PEEL BACK ON THE SURFACE OF THE BLADE, CAUSING IMBALANCE, AND BLADE SURFACE TO BE SUSCEPTIBLE TO MOISTURE. THE PAINT REFINISH ING PROCESS APPEARS TO BE TOO THICK WITH NO TRANSITION POINT TO THE LEADING EDGE ABRASION STRIP. THIS IS AN ON GOING PRO BLEM INVOLVING NUMEROUS TAIL ROTOR BLADE SETS FOR THE PAST 18 MONTHS. 1 G 7 2 3U 3 U H3EU E4CE 2004032500040 20040325 00040 EA 2004 3 25 CA040226004 2 20040224 G 7322 G20102 FLOAT VALVE CNDAIR CL600 CL600* EA LYC ALF502 ALF502* 41580 EA CARBURETOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING GROUND RUN MAINTENANCE NOTED A RUMBLE FROM THE RT ENGINE AT HI IDLE AND BELOW. THE ECOLOGY TANK FLOAT VALV E WAS REMOVED AND THE FLOAT WAS FOUND TO BE CORRODED AND DETERIORATED PREVENTING PROPER VALVE OPERATION. THE VALVE WAS H ELD OPEN ALLOWING AIR TO BE DRAWN INTO THE INLET SIDE OF THE ENGINE DRIVEN FUEL PUMP CAUSING THE PUMP TO CAVITATE. ABOVE HIGH IDLE THE EJECTOR VALVE CLOSES THE SUCTION LINE PREVENTING FURTHER CAVITATION AND STOPPING THE RUMBLE. A NEW FLOAT VALVE WAS INSTALLED AND A SUBSEQUENT GROUND RUN CONFIRMED THE REPAIR. 2 L 7 2 4F 4 F RT A21EA E6NE 2004032500042 20040325 00042 EA 2004 3 25 CA040203007 1 20040122 G 2435 2007583 GROUND WIRE DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL STARTER GEN FAILED W F ACTIVATE FIRE EXT. B A SMOKE/FUMES/ODORS/SPARKS FLAME/FIRE TX TAXI/GRND HDL 1 CA (CAN) ON STARTING THE ENGINE THERE WAS ARCING AND SPARKS COMING FROM THE STARTER GROUND ATTACHMENT LOCATED UNDERNEATH TH E COCKPIT. THE SPARKS CAME FROM THE GROUNDING ATTACHMENT BOLT ANCHOR NUT RIVET. RECOMMEND A BETTER GROUNDING LOCATION AND ATTACHMENT. 1 H 7 1 3R 4 T A815 E4EA 6 C P15EA 2004032500049 20040325 00049 EA 2004 3 25 CA040109003 1 20040108 G 5270 600314703 ROLLER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE STRIKER GUIDE MISALIGNED W K NONE N FALSE WARNING IN INSP/MAINT 1 CA (CAN) AFTER TAKE OFF, DOOR LATCH CAUTION. 30 SEC LATER, PASSENGER DOOR. PRESSURE OK AND DOOR INDICATION PIN INSIDE WERE IN THE GREEN. REPLACED FORWARD STRIKER GUIDE ROLLER IAW FMR. SEAL LUB AND VENT HOLE ALIGN. ALL LATCH PINS & HANDLE LUB. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032500055 20040325 00055 CE 2004 3 25 CA040203010 1 20040126 G 5610 9031002P WINDSHIELD BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCB4T HCB4TN3 GL COCKPIT CRACKED W B EMER. DESCENT O OTHER CR CRUISE 1 CA (CAN) DURING CRUISE, PILOT HEARD SMALL CRACK SOUND THOUGHT HE DROPPED SOMETHING, WHILE LOOKING AROUND, NOTICED RT WINDSH IELD CRACK DESCENDED AND CARRIED ON. LANDED WITHOUT INCIDENT. 1 L 7 2 3T 4 T A14CE E4EA 6 C P40EA 2004032500056 20040325 00056 NE 2004 3 25 CA040203011 2 20040127 G 7322 91620 SHAFT BELL 204 204B 1181404 SW LYC T53 T5313B 41549 NE FUEL CONTROL WORN W O OTHER P NO WARNING INDICATION NR NOT REPORTED 1 CA 2ADS1203 (CAN) UPON SUSPECTING A PROBLEM WITH FUEL CONTROL UNIT. REMOVED FCU FROM THE ENGINE TO INSPECT THE SPLINES IAW MFG SBT53 13-107. FOUND THE INTERNAL SPLINES KNIFE EDGED AND VERY CLOSE TO TOTAL FAILURE OF THE FCU. THIS WOULD HAVE LEAD TO THE F AILURE AND SHUTDOWN OF THE ENGINE. THESE PARTS HAD 434 HOURS SINCE THEY WERE REPLACED WITH SERVICEABLE UNITS. SHAFTS P/N 9162076081. 1 G 7 1 4U 4 U H1SW E17EA 2004032500069 20040325 00069 NM 2004 3 25 CA040112001 1 20040109 G 5610 80260008 WINDSHIELD BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DURING A FLIGHT THE RT COCKPIT WINDSHIELD CRACKED, ZERO VISIBILITY AND AN EMERGENCY LANDING WAS CARRIED OUT. MAINT ENANCE TECH'S CHANGED WINDOW AND A/C RETURNED TO SERVICE. A/C JUST CAME OUT OF 'C' CHECK, IS MODSUM 4Q5300002 COMPLETED, WHICH REMOVES BOTH WINDSHIELDS FOR RE-SEALING. BELIEVE THAT THE WINDOW WAS DAMAGED DURING THE REMOVAL PROCESS. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004032500071 20040325 00071 NM 2004 3 25 CA040112003 1 20040109 G 3242 BRAKE PADS BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE MLG DAMAGED W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, CREW REPORTED THAT THERE WAS SOME DRAGGING FELT WHEN THE BRAKES WERE APPLIED. THE AIRCRAFT RETURNED T O THE BLOCKS. A DETAILED INSPECTION WAS CARRIED OUT AND NR 4 BRAKE WAS FOUND UNSERVICEABLE. THE BRAKE PADS WERE DAMAGED AND BROKEN. A SERVICEABLE BRAKE WAS INSTALLED IAW MM 32-41-31 AND CHECKED SERVICEABLE. THERE WAS NO PROBLEM DURING SUB SEQUENT FLIGHT. 2 L 7 3 4F 4 F RT A3WE E2EA 2004032500086 20040325 00086 CE 2004 3 25 CA040204005 1 20040121 G 2710 051010516 CONTROL CABLE CESSNA 180 180C 2072608 CE CONT O470 O470K 17026 SO MCAULY 2A34C 2A34C203 GL AILERON FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AILERON DIRECT CABLE LT AND RT FRAYED EACH IN 3 DIFFERENT PLACES AT PULLEYS, PULLEYS WERE NOT SEIZED, ROTATES FREE LY, ALSO FRAYED AILERON CARRY THROUGH CABLE P/N 0510105-113 AT PULLEY AREA. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004032500088 20040325 00088 EU 2004 3 25 CA040204009 1 20040128 G 5210 5521012219 PIN PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PAX DOOR HANDLE MISSING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PAX/CREW DOOR HANDLE LOCKING MECHANISM HARD TO OPERATE EXCEPT UPON ARRIVAL AT MAIN BASE. INSPECTING DOOR, FOUND P IN LOCK AND ITS SPRING FROM SAFETY LOCKING MECH TO BE MISSING. LOCKING MECH STOPS ACCIDENTAL OPERATION OF DOOR HANDLE IN SIDE AC. RELEASE LEVER IS INSTALLED ON INSIDE OF DOOR BELOW INNER HANDLE. CABLE CONNECTS IT TO A LOCKING PIN WHICH ENG AGES IN OUTER HANDLE IF PIN LOCK BREAKS OR IS FORCED OUT OF CRANK, COMPRESSION SPRING EJECTS ITSELF AND PIN LOCK AWAY FR OM AC AND THE DOOR CAN BE OPENED JUST BY ACTIVATING HANDLE. SUSPECT FORMATION OF ICE BETWEEN THE LOCKING PIN AND THE DO OR STRUCTURE TO RESTRAIN MOVEMENT OF PIN AND CAUSE A FAILURE OF LOCKING MECHANISM. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500090 20040325 00090 NE 2004 3 25 CA040112004 2 20040112 G 8500 ENGINE DOUG DC3 DC3C 3021457 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E50 NE RIGHT FAILED W E ENGINE SHUTDOWN J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB THE PILOT NOTICED THE RT ENGINE OIL TEMPERATURE WAS INCREASING SIGNIFICANTLY. THE ENGINE WAS SHUT DOW N AND FLIGHT CARRIED OUT WITHOUT INCIDENT. 2 L 7 2 4R 4 R A669 5E4 6 C P603 2004032500091 20040325 00091 SO 2004 3 25 CA040112005 1 20040111 G 3230 4204200 ARM PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER TAKE-OFF, CREW SELECTED LANDING GEAR UP. RT MAIN LANDING GEAR STILL INDICATED DOWN AND LOCKED AFTER RETRACTI ON. CREWS SELECTED GEAR DOWN AND ALL GEAR INDICATED DOWN AND LOCKED. AIRCRAFT RETURNED TO BASE WITH NO FURTHER FAULTS NO TED BY CREW. VISUAL INSPECTION OF LANDING GEAR SYSTEM CARRIED OUT. FOUND RT MAIN LANDING GEAR RETRACTION ARM P/N 42042-0 0 BROKEN. THIS PART ORIGINAL CRACK LOCATION NOT POSSIBLE TO BE INSPECTED OR FOUND WITH OUT COMPLETE DISMANTLE OF RETRACT ION SYSTEM. RETRACTION ACTUATOR ROD END P/N 762-554 ALSO DAMAGED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004032500093 20040325 00093 EU 2004 3 25 CA040113001 1 20040113 G 3234 210TS07Y01 SELECTOR AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE MLG MALFUNCTIONED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SELECTED GEAR DOWN AND NOTHING HAPPENED FOR AT LEAST A MINUTE, THEN WIGGLED HANDLE THEN THE GEAR CAME DOWN. NOTE: AC SENT TO HANGAR FOR TROUBLE/SHOOTING. 2 L 7 4 4F 4 F RT A197 E37NE 2004032500096 20040325 00096 NM 2004 3 25 CA040113004 1 20040113 G 5610 141T480150 WINDSHIELD BOEING 767 767333 1385301 NM PWA 4060 PW4060 52119 NE COCKPIT FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 36170 (CAN) WHILE IN FLT ENROUTE FROM YYZ TO TLV, R1 WINDSHIELD OUTER PANE SHATTERED. FLT CONTINUED WITHOUT FURTHER INCIDENT. MTCE POOLED A WINDOW AND CHANGED. 2 L 7 2 4F 4 F RT A1NM E24NE 2004032500098 20040325 00098 SW 2004 3 25 CA040113006 1 20040107 G 6710 AN17415 BOLT BELL BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA DAMPER ARM SHEARED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) HELISKI OPERATION. PILOT REPORTED BAD VIBRATION IN TURNS AND CONTROLLABILITY CONCERNS, ALSO IN TURNS. RETURNED TO BASE IMMEDIATELY. SHEARED BOLT FOUND WHERE MAIN ROTOR HYDRAULIC DAMPER CONTROL ARM ATTACHES TO STABILIZER BAR CONTROL TU BE ROD END. BOLT WAS CORRODED WITH EVIDENCE OF BEING LOOSE. ALSO BLACK ON NUT AND WASHER. NO OTHER DAMAGE FOUND. ATTACHM ENT HARDWARE REPLACED WITH NEW AND AIRCRAFT RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2004032500102 20040325 00102 CE 2004 3 25 CA040204012 1 20040114 G 3260 1CH25 DOWNLOCK SWITCH BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL NLG FROZEN W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) ON APPROACH THE PILOT SELECTED GEAR DOWN. THERE WAS NO NOSE GEAR INDICATION. AFTER CONFIRMING WITH THE TOWER THAT THE GEAR WAS DOWN, THE AIRCRAFT LANDED WITHOUT INCIDENT. THE DOWNLOCK SWITCH WAS FOUND DEFECTIVE AND SUBSEQUENTLY REPLAC ED. OAT WAS -25 TO -30 DEGREES CELSIUS. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2004032500106 20040325 00106 EA 2004 3 25 CA040205003 1 20040126 G 5610 601R330333 WINDOW CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA 14843 (CAN) DURING CRUISE, FLIGHTDECK LT SIDE WINDOW CRACKED. FLIGHT WAS DIVERTED WHERE THE WINDOW WAS REPLACED. THE CRACKED W INDOW HAD BEEN FITTED SINCE THE A/C WAS NEW. THERE IS NO PRE OR POST SB FOR SIDE WINDOWS. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032500120 20040325 00120 NM 2004 3 25 CA040113007 1 20040111 G 5755 65982962 HINGE BOEING 727 72725C 138400H NM PWA JT8 JT8D7B 52053 NE SPOILER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 61773 (CAN) DURING SERVICE CHECK, FOUR CRACKS WERE FOUND ON THE NR 7 GROUND SPOILER SUPPORT HINGE. HINGE REPLACED WITH NEW PA RT. ALL HINGES INSPECTED FOR CRACKS, NO FAULTS FOUND. 2 L 7 3 4F 4 F A3WE E2EA 2004032500125 20040325 00125 SW 2004 3 25 CA040206002 1 20040128 G 2810 206288017 SIGHT GLASS BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL RANGE EXTENDER CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) SIGHT GLASS ON FORWARD SIDE OF RANGE EXTENDER WAS FOUND TO BE THE CAUSE OF A SLOW FUEL LEAK. WHEN THE AIRCRAFT WAS FULL OF FUEL AND KEPT IN THE HANGAR OVER NIGHT A SMALL POOL OF FUEL WAS NOTICED ON THE FLOOR. A CRACK RUNNING ACROSS FROM TWO SCREWS WAS FOUND. A NEW SIGHT GLASS HAS BEEN ORDERED AND WILL BE INSTALLED WHEN RECEIVED. UPON FURTHER INSPECT ION OF AIRCRAFT, ANOTHER WITH THE SAME RANGE EXTENDER WAS FOUND TO HAVE THE SAME CRACK IN THE SAME LOCATION. 1 G 7 1 3U 3 U H2SW E4CE 2004032500127 20040325 00127 NM 2004 3 25 CA040113009 1 20040107 G 2910 82970009121 LINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYDRAULIC SYS LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH, CREW REPORTED NR 2 HYDRAULIC SYSTEM WENT LOW. NR 2 ISO VALVE LIGHT AND OB ROLL SPOILER CAUTION LIGH TS CAME ON, WHEN MAIN LANDING GEAR SELECTED DOWN. AFTER LANDING DOWN DOORS STAYED OPEN AND FLUID LEAKING FROM LT WHEEL WELL. MAINTENANCE FOUND HYDRAULIC LINE FOR NR 2 SYSTEM MLG UP PRESSURE TO BE LEAKING FROM PIN HOLES. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004032500137 20040325 00137 GL 2004 3 25 CA040114002 1 20040111 G 2752 SEAL DIAMON DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA (CAN) PILOT REPORTED FLAP STUCK IN LANDING POSITION, UPON INSPECTION IT WAS FOUND THAT THE SPLINED RUBBER SEAL PUSHED OU T OF POSITION ON FLAP ACTUATOR ROD ASSY. SPLINED RUBBER SEAL INTERFERED WITH FLAP POSITION MICRO SWITCHES. RE-INSTALLED SPLINED RUBBER SEAL WITH EPOXY AND ALLOWED TO CURE. FLAP SYSTEM FUNCTION TESTED, FLAP POSITION LIGHTS AND FLAPS SERVIC EABLE. IT APPEARED THAT THE SPLINES WERE USED TO KEEP THE SEAL IN PLACED BUT AS THERE IS LITTLE LUBRICATION REQUIRED ON THE FLAP ACTUATOR SHAFT, FRICTION OF THE SHAFT ON THE SEAL, PULLS THE SEAL OUT OF POSITION AND DRAGS IT ALONG WITH IT INTO THE SWITCHES. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004032500138 20040325 00138 CE 2004 3 25 CA040114004 1 20040107 G 7722 3031566 BUSS BAR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE UNSERVICEABLE W O OTHER P NO WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) PILOTS WERE CARRYING OUT AN ENGINE START ON THE RT ENGINE AND NOTICED THAT THERE WAS NO ITT INDICATION SO THE ENGI NE WAS SHUT DOWN. MAINTENANCE TROUBLESHOOTING DETERMINED THE ITT HARNESS WAS SERVICEABLE BUT THAT THE ENGINE INTERNAL B USSBAR HAD FAILED. THE ENGINE WAS SPLIT AT THE C FLANGE AND THE BUSS BAR WAS FOUND SEPARATED FROM THE TOP OF THE JUNCTIO N BLOCK. THE BUSS BAR P/N 3031566 WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004032500139 20040325 00139 2004 3 25 CA040114005 4 20040112 G 2297 BACC47DJ1DJ2 PIN ROSEMOUNT BOEING 757 757* NM RROYCE RB211 RB211535E437 54555 NE RELAY MISMANUFACTURED W A UNSCHED LANDING W INADEQUATE Q C CL CLIMB 1 CA A44369 (CAN) UPON ROTATION, TAT PROBE EICAS MESSAGE FOLLOWED BY AUTO THROTTLE DISCONNECT, AND ASSOCIATED WARNINGS. AIR TURN BA CK. TAT PROBE REPLACED. GROUND TEST GOOD. DEFECT RECURRED ON NEXT TAKEOFF.K143 AND K203 AIR/GND RELAYS REPLACED. TESTED GOOD IAW MM 30-33-00-501. NO FAULTS ON RETURN FLIGHT TO YVR. REVIEW OF THE RECORDS SHOWED 4 REPORTS SINCE 4TH DECEMBE R 2003. DUE TO THE INTERMITTENT NATURE OF THIS DEFECT, AS A PRECAUTIONARY MEASURE WIRING CHECKS WERE PERFORMED ON RETUR N TO YVR. A POOR CRIMP AT THE BASE OF RELAY K203 PIN B2 WAS FOUND. PIN REPLACED. 2 L 7 2 4F 4 F RT A2NM E12EU 2004032900073 20040329 00073 CE 2004 3 29 CA040209001 1 20040205 G 2121 903840311 BLOWER BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL AIR CONDITIONING SEIZED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) JUST AFTER LEVELING OUT PILOT NOTICED SMOKE IN THE COCKPIT/CABIN AREA. AIRCRAFT WENT TO 10000 FT, DEPRESSURIZED AN D ELECTRICAL POWER WAS REMOVED. POWER WAS RESTORED AND AIRCRAFT RETURNED TO BASE WITHOUT FURTHER INCIDENT. UPON INVESTI GATION IT WAS DETERMINED THAT THE VENTILATION BLOWER BEARING SEIZED AND CAUSED THE SMOKE. VENT BLOWER WAS REPLACED AND S YSTEM TESTED SERVICEABLE. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2004032900096 20040329 00096 NM 2004 3 29 CA040209003 1 20040205 G 3260 189915 TARGET BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE MLG MISINSTALLED W D RETURN TO BLOCK N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, THE RT MLG UNSAFE LIGHT ILLUMINATED AND GREEN SAFETY LIGHT WAS OUT. MAINTENANCE INSTALLED LANDING GEA R PINS AND THE AIRCRAFT TAXIED BACK TO THE RAMP. DURING INSPECTION OF THE PROXIMITY LANDING GEAR SWITCHES, IT WAS OBSER VED THE TARGETS WERE INSTALLED IMPROPERLY. THE TARGETS WERE RE-INSTALLED CORRECTLY IAW MM 32-41-91 AND 32-04-121. FUNCT ION CHECKED SERVICEABLE IAW MM 32-61-91. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004032500063 20040325 00063 NM 2004 3 25 CA040109007 1 20040109 G 5610 NP1579029 WINDOW DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON PREFLIGHT INSPECTION , FLT ENGINEER DISCOVERED OUTER PLY OF PILOT SIDE WINDOW WITH MULTIPLE CRACKS EXTENDING AR OUND THE CIRCUMFERENCE OF WINDOW ORIGINATING FROM LOWER FWD CORNER. NO OBVIOUS IMPACT DAMAGE FOUND ON INSPECTION. NO M. E.L. RELIEF. MANUFACTURER ADVISED TO CHANGE WINDOW BEFORE FURTHER FLIGHT. OVERNIGHT TEMP: -13C 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004032500068 20040325 00068 EU 2004 3 25 CA040110001 1 20040109 G 2997 9740926112 RELAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE OFF THE CREW SELECTED GEAR UP. THE HYDRAULIC CAWS LIGHT CAME ON AND THE GEAR WOULD NOT FULLY RETRACT. T HE GEAR WAS EXTENDED FULLY WITH THE HAND PUMP AND AN UNEVENTFUL LANDING CARRIED OUT. UPON INSPECTION BY MAINTENANCE, THE HYDRAULIC RELAY K601 WAS FOUND TO BE AT FAULT. THE RELAY WAS REPLACED, GEAR SWINGS CARRIED OUT AND THE AIRCRAFT RETURNE D TO SERVICE. THERE ARE SEVERAL OTHER INSTANCES INVOLVING FAILURE OF THESE RELAYS, WITH SIMILAR SNAG CIRCUMSTANCES. A SUGGESTION TO PLACE THESE COMPONENTS ON A HARD TIME INTERVAL IN LIEU OF, ON-CONDITION FOR OTHER OPERATORS WOULD BE BENEF ICIAL. WE ARE CURRENTLY RESEARCHING THE TIME BETWEEN FAILURE, AS THESE ARE NOT NORMALLY TIME TRACKED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500089 20040325 00089 EU 2004 3 25 CA040204010 1 20040130 G 2435 23085024 BEARING LUCAS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL STARTER GEN FAILED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA Y0253 (CAN) GEN NR 1 FAILED IN FLIGHT. UPON ARRIVAL, MAINTENANCE FOUND THE REAR BEARING OF THE STATER GENERATOR FAILED CAUSING THE COOLING FAN TO RUB ON THE CASE.CREATING VIBRATION. STARTER GENERATOR REPLACED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500092 20040325 00092 GL 2004 3 25 CA040112006 1 20040107 G 2752 SEAL DIAMON DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA (CAN) PILOT REPORTED FLAP STUCK IN LANDING POSITION, OVERSPED FLAPS 100 KTS FOR 5 MIN,FLAP INDICATOR U/S. UPON INSPECTI ON IT WAS FOUND THAT SPLINED RUBBER SEAL PUSHED OUT OF POSITION ON FLAP ACTUATOR ROD ASSY. SPLINED RUBBER SEAL INTERFERE D WITH FLAP POSITION SWITCHES. RE-INSTALLED SPLINED RUBBER SEAL WITH EPOXY AND ALLOWED TO CURE. FLAP SYSTEM FUNCTION TES TED, FLAP POSITION LIGHTS AND FLAPS SERVICEABLE. FLAPS INSPECTED FOR OVER SPEED DAMAGE NONE FOUND. AC RELEASED. IT APPE ARED THAT THE SPLINES WERE USED TO KEEP THE SEAL IN PLACED BUT AS THERE IS LITTLE LUBRICATION REQUIRED ON THE FLAP ACTUA TOR SHAFT, FRICTION OF THE SHAFT ON THE SEAL, PULLS THE SEAL OUT OF POSITION AND DRAGS IT ALONG INTO THE SWITCHES. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004032500094 20040325 00094 NM 2004 3 25 CA040113002 1 20040113 G 2824 MA20A10011 ACTUATOR BOEING 767 767209 1385127 NM PWA JT9 JT9D7R4D 52054 NE CROSSFEED VALVE FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) ON PRE-DESCENT CHECK WHEN FUEL CROSSFEED WAS CHECKED ON AND OFF, EICAS MESSAGE FUEL CROSSFEED AND VALVE LIGHT ON C ROSSFEED SWITCH REMAINED ILLUMINATED. ON GROUND RECYCLED CIRCUIT BREAKER NIL FIX. TAKEN OFF LINE FOR INVESTIGATION FLT CANCLED PART: ELECTRIC ACTUATOR REPLACED IAW AMM 28-22-12. 2 L 7 2 4F 4 F RT A1NM E3NE 2004032500097 20040325 00097 EU 2004 3 25 CA040113005 1 20040113 G 3230 D31AAB4431 SAFETY VALVE AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE MLG INOPERATIVE W O OTHER J WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH, GEAR DID NOT EXTEND NORMALLY ON FIRST ATTEMPT, SECOND ATTEMPT HAD SAME RESULT. CREW ELECTED TO CARRY OUT GO AROUND. LANDING GEAR CONTROL LEVER REPLACED AND TESTED IAW MM 32-31-11-400, MLG ISOLATION SAFETY VALVE (85GA) REP LACED IAW MM 32-31-17. MLG. EXTENDED AND RETRACTED SEVERAL TIMES IAW MM 32-31-00-710-801, CHKD. SERV. REMOVE UNI 32-30-0 482C1024AC 001 FISOS: NINSTALLUNI 32-30-0482 FTN 1341Q9 AC 001REMOVE UNI 32-30-0513 FTN 5Y25Z5 AC FI SOS: N INSTALL UNI 32-30-0513FTN 55656R AC. 2 L 7 4 4F 4 F RT A197 E37NE 2004032500101 20040325 00101 NE 2004 3 25 CA040204011 2 20040111 G 7200 ENGINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LEFT FAILED W A UNSCHED LANDING C F.O.D. CR CRUISE 1 CA (CAN) DURING CRUISE AT 31,000 FT, ENGINE SURGE FELT ON LT ENGINE (EPR REDUCED TO 1.67) WITH AN IMMEDIATE ODOR. SAME SURG E/ODOR WAS FELT A SECOND TIME APPROXIMATELY 45 MINUTES LATER. AIRCRAFT DIVERTED TO POP. MAINTENANCE FOUND FORWARD LAVATO RY LEAKING. LT ENGINE INSPECTED IAW MM 72-0-04 P.115 AND ENGINE RUN C/OUT TO 2-0 EPR AND NO FAULT FOUND. AIRCRAFT DISPAT CHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004032500104 20040325 00104 EA 2004 3 25 CA040205001 1 20040129 G 3310 LIGHT CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA (CAN) SMOKE AND SPARKS WERE COMING FROM THE FIRST OFFICER FLOOD LIGHT. MAINTENANCE ACTION WAS TO REPLACED THE FLOOD LIGH T ASSEMBLY AND TO RETORQUE THE SIDE WINDOW. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004032500121 20040325 00121 CE 2004 3 25 CA040205005 1 20040202 G 8011 PM2401H DRIVE ASSY LAMAR CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL STARTER JAMMED W E ENGINE SHUTDOWN O OTHER TX TAXI/GRND HDL 1 CA 85017317 (CAN) STARTER DRIVE ONCE ENGAGED DID NOT RETRACT JAMMED OUTWARD. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2004032500122 20040325 00122 EU 2004 3 25 CA040205006 1 20040203 G 7714 DISPLAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL EIS FAILED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT, THE UPPER PORTION OF THE ENGINE INDICATION SCREEN FAILED TQ, NG, & ITT. THE ALTERNATE SCREEN WAS SELECTED AND PERFORMED PROPERLY. THE EIS COMPUTER WAS REPLACED WITH A SERVICEABLE UNIT AND FUNCTION TREATED SERVICE ABLE. IT WAS NOTED A NORMAL ENGINE START COULD NOT BE ACCOMPLISHED AS THERE WAS NO ENGINE NG INFORMATION AVAILABLE TO T HE START COMPUTER TO SIGNAL IGNITION AND BOOST PUMPS. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500123 20040325 00123 NE 2004 3 25 CA040205007 2 20040122 G 7321 FUEL CONTROL CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE LT ENGINE INOPERATIVE W D RETURN TO BLOCK X J ENGINE FLAMEOUT WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXIING, LT ENG POWER LEVER WAS ADVANCED TO FACILITATE TURN. THRUST LEVER WAS ADVANCED, LT ENG SUFFERED A R OLL BACK AND FLAME-OUT. AC WAS TAXIED CLEAR OF RUNWAY, FAULT ANALYSIS RELIGHT ATTEMPTED WITH NO SUCCESS. RELIGHT WAS SU CCESSFUL. AC WAS THEN SHUT DOWN AND SURRENDERED TO MAINT FOR ACTION. EVENT FOLLOWED ACTION AND INSTALLATION OF SB 30253. FUEL LINE, ATTENUATOR ASSY AND FCU WERE REMOVED AND SENT TO MFG FOR ANALYSIS. DURING REMOVAL, A BLACK SUBSTANCE WAS DE TECTED. SUBSTANCE WAS SENT OFF FOR CHEMICAL ANALYSIS BY MFG. NR C 10420020 REGARDING SUBSTANCE. FUEL LINE, ATTENUATOR A SSY AND FCU WERE REPLACED, IAW SB 30253. AC WAS GROUND RUN AND TEST FLOWN SATISFACTORILY, RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004032500124 20040325 00124 NE 2004 3 25 CA040205008 2 20040122 G 7200 ENGINE CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE LEFT FLAMED OUT W D RETURN TO BLOCK X J ENGINE FLAMEOUT WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXIING AND TURNING ONTO THE RUNWAY, THE LT ENGINE POWER LEVER WAS ADVANCED TO FACILITATE THE TURN. AS THE T HRUST LEVER WAS ADVANCED, THE LT ENGINE SUFFERED A ROLL BACK AND FLAME-OUT. THE AIRCRAFT WAS TAXIED CLEAR OF THE RUNWAY AND A FAULT ANALYSIS RELIGHT ATTEMPTED WITH NO SUCCESS. THE AIRCRAFT WAS THEN TAXIED TO THE RAMP WHERE A FURTHER RELIGHT WAS ATTEMPTED. THE RELIGHT WAS SUCCESSFUL. THE AIRCRAFT WAS THEN SHUT DOWN AND SURRENDERED TO MAINTENANCE FOR ACTION. THE EVENT FOLLOWED ACTION AND INSTALLATION OF SERVICE BULLETIN 30253. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004032500126 20040325 00126 EU 2004 3 25 CA040113008 1 20040108 G 3310 2527 LAMP PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE HARTZL HCE5N HCE5N3 GL MAP LIGHT INOPERATIVE W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING CRUISE, COCKPIT ROOF MOUNTED MAP LIGHT FAILED, C/B ACTIVATED, CREW NOTICED A SLIGHT ODOR. DURING TROUBLESHO OTING THE ROOF PANEL WAS REMOVED AND IT WAS DISCOVERED THAT THE LAMP TERMINAL HAD BEEN IN CONTACT WITH AIRFRAME STRUCTUR E CAUSING THE RUBBER PROTECTIVE BOOT ON THE TERMINALS TO WEAR THROUGH AND GROUND ELECTRICAL SUPPLY. IT WAS ESTABLISHED THAT DURING COMPLETION AT A THIRD PARTY COMPLETION CENTER SPACER RINGS UNDER THE LAMP COLLAR HAD BEEN OMITTED. FLEET RE VIEW FOUND THAT SISTER AIRCRAFT WAS IN SAME CONDITION, BUT AN OTHER HAD SPACERS INSTALLED. SPACERS OBTAINED AND INSTALLE D ON AFFECTED AIRCRAFT. 1 H 7 2 3O 4 T RT A59EU E26NE 5 C PZONE 2004032500140 20040325 00140 SO 2004 3 25 CA040206003 1 20040204 G 2140 BLADE JANITROL B4050 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FAN CRACKED W O OTHER O OTHER CR CRUISE 1 CA (CAN) ONE OF FOUR BLADES SEPARATED FROM FAN AND MADE A SIGNIFICANT AMOUNT OF NOISE AND VIBRATION IN THE HEATER SUCH THAT THE PILOT SHUT THE HEATER DOWN IN FLT. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004032500141 20040325 00141 EU 2004 3 25 CA040206004 1 20040205 G 3110 9728132012 DISPLAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL CAWS FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING CRUISE THE CREW NOTICED SOME OF THE CAWS LIGHTS OUT. THE TEST BUTTON WAS USED TO DETERMINE IF THE BULBS WE RE AT FAULT. ONCE PRESSED THE CAWS PANEL AND MASTER CAUTION/WARNING ILLUMINATED FOLLOWED A SERIES OF FLICKERING LIGHTS A ND A ODOR OF BURNED WIRES, THE PANEL THEN GOING BLACK. THE BREAKERS WERE PULLED, THE ODOR DISAPPEARED AND AIRCRAFT CONTI NUED FLIGHT TO ITS MAIN MAINTENANCE BASE. NO PASSENGERS WERE ON BOARD THE AIRCRAFT. THE CAWS DISPLAY AND CAWS COMPUTER W ERE BOTH REPLACED AND THE AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER FAULTS. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500142 20040325 00142 EU 2004 3 25 CA040206005 1 20040202 G 2197 WIRE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HEATING SYSTEM BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ONE POWER WIRE FOR THE FOOT HEATER HEAT CONTROL HAD FALLEN ON TO THE BRAKE LINE THAT RUNS ALONG THE FIREWALL JUST AHEAD OF THE RUDDER PEDALS. AS A RESULT ARCING OCCURED AND BURNED A HOLE IN THE LINE. THE .2500 INCH ALUMINUM BRAKE LIN E WAS REPLACED, SYSTEM BLED AND THE WIRE WAS REPLACED AND SECURED BETTER TO THE BUNDLE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500154 20040325 00154 NE 2004 3 25 CA040205004 2 20040131 G 7200 ENGINE CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE NR 2 FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE OFF, 2000 ASL, NR 2 LOUD BANG FOLLOWED BY ENGINE STOPPAGE, MAYDAY DECLARED, ENGINE SECURED AND QRH DRIL LS ACTIONED. RADAR VECTORED SINGLE ENGINE APPROACH AND LANDING. FIRE SERVICE ESCORTED ON LANDING, PAX OFFLOADED ON STAND . THE ENGINE WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004032900051 20040329 00051 NE 2004 3 29 CA040208002 2 20040126 G 7320 FUEL CONTROL CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE RT ENGINE FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION LD LANDING 1 CA (CAN) JUST AFTER TOUCHDOWN THE RT FADEC CAUTION MESSAGE CAME ON FOLLOWED BY THE RT ENG FLAMEOUT CAUTION MESSAGE. MAINTEN ANCE STARTED AND OPERATED THE ENGINE THROUGH SEVERAL CYCLES WITHOUT DUPLICATION OF THE FLAMEOUT CONDITION. MAINTENANCE R EPLACED THE RT FADEC AND FUEL MANAGEMENT UNIT, THEN OPERATED THE ENGINE THROUGH SEVERAL MORE CYCLES INCLUDING HIGH POWER AND REVERSE WITH NO FLAMEOUT OCCURANCE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004032900052 20040329 00052 EA 2004 3 29 CA040208003 1 20040125 G 4930 38004883 APU CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE APU BAY LEAKING W K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 CA (CAN) FOR THE OVERNIGHT, THE FLIGHT CREW WERE ASKED TO LEAVE THE APU RUNNING TO PERMIT AIRCRAFT GROOMING. APPROXIMATELY ONE HOUR AFTER ARRIVAL, THE APU FIRE DETECTION SYSTEM PERFORMED AN AUTO SHUTDOWN AND APU FIRE BOTTLE WAS DEPLETED. GRO UND/AIRCRAFT PERSONNEL CONTACTED THE FIRE DEPARTMENT. THE APU WAS INSPECTED, AND EVIDENCE OF FUEL WAS OBSERVED, HOWEVER THE SOURCE OF THE APU FUEL LEAK COULD NOT BE ABSOLUTELY PIN-POINTED AND RESULTED IN THE APU'S REPLACEMENT. THE AIRCRAF T RETURNED TO SERVICE FOLLOWING THE APU REPLACEMENT. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032900059 20040329 00059 NM 2004 3 29 CA040115001 1 20040110 G 3230 54C546349 SOLENOID VALVE DHAV DHC8 DHC8103 1386005 NM PWA PW121 PW121 52124 NE HAMSTD 14SF 14SF7 NE MLG FAILED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) DURING TAKEOFF AND THE GEAR UP SELECTION THE AIRCRAFT EXPERIENCED A COMPLETE LOSS OF ALL FLUID FROM THE NR2 HYDRAU LIC SYSTEM. ALTERNATE LANDING GEAR EXTENSION PREFORMED AND AIRCRAFT RETURNED SAFELY TO BASE. FINDINGS, LT MLG SOLENOID SEQUENCE VALVE FAILED. SOLENOID SEPARATED FROM VALVE. TWO BOLTS OF FOUR, WHICH CONNECT SOLENOID HOUSING, HAD BROKEN. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004032900060 20040329 00060 NM 2004 3 29 CA040115003 1 20040112 G 4920 38007021 APU BOEING 737 73776N 13844CH NM CFMINT CFM567 CFM567B22 13802 NE APU BAY SMOKE W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) ON ARRIVAL TO THE GATE, GROUND POWER WAS PLUGGED IN, SMOKE IN THE FLIGHT DECK AND CABIN WHEN APU BLEED AIR AND PNE UMATICS SELECTED 'ON'. CAPTAIN THEN SELECTED APU ELECTRICAL 'ON' AND F/O CONTACTED GROUND CONTROL TO REQUEST CFR. SMOKE CLEARED AND MAINTENANCE WAS CALLED TO AIRCRAFT. SUSPECT DE-ICE FLUID IN THE APU INLET AS A RESULT OF DE-ICING OUT OF YO W. APU MEL'D AND GROUND CHECKED SERVICEABLE. ON NEXT RUN, APU MEL CLEARED FOLLOWING FLIGHT MONITORING AND MAINTENANCE P ERFORMANCE RUNS. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004032900072 20040329 00072 2004 3 29 CA040115005 4 20040101 G 2562 G SWITCH DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELT FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA 55130 (CAN) ELT HAS HAD A PREVIOUS HISTORY OF SELF ACTIVATIONS (1 PREVIOUS, ELT ACTIVATED WHILE THE AIRCRAFT WAS INACTIVE). E LT WAS RECERTIFIED AND ON INSTALLATION THE UNIT SELF ACTIVATED. REPAIR SHOP NOTED THAT THE G SWITCH ON THIS MODEL WAS V ERY SUSCEPTIBLE TO MOISTURE RELATED FAILURES. DUE TO AGE THERE ARE NO PARTS AVAILABLE FOR REPAIR, THE UNIT WILL BE SCRA PPED. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004032900095 20040329 00095 NM 2004 3 29 CA040209002 1 20040205 G 5610 57176249 WINDOW BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) DURING CLIMB, THE F/O OBSERVED THE R2 SLIDING WINDOW WAS CRACKED. THE DECISION WAS MADE TO RETURN TO BASE. THE AI RCRAFT LANDED WITHOUT INCIDENT. THE R2 WINDOW ASSY WAS REPLACED IAW MM 56-12-11 AND CHECKED SERVICEABLE. THE R2 WINDOW H EAT CONTROLLER AND TEMP SWITCH WERE CHANGED AS A PRECAUTION. FUNCTIONAL CHECK WAS CARRIED OUT SERVICEABLE IAW MM 30-41- 02. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F RT A3WE E2EA 2004032900099 20040329 00099 NM 2004 3 29 CA040209007 1 20040206 G 4900 23088002B STARTER GEN DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE APU BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA (CAN) APU FAILED TO START, TECHNICIANS FOUND STARTER / GENERATOR BURNED, THE ATTACHED WIRES AND CONNECTORS WERE ALSO FOU ND DAMAGED. OPERATOR ADVISED BY THEIR SPARES THAT THE STARTER GENERATOR, P/N 23088-002B SN Y0084 WAS REPAIRED BY THE VE NDOR ONCE ALREADY. THE GENERATOR WAS REPLACED YESTERDAY AND FAILED AFTER 2 FLIGHTS. THE APU WAS STARTED WITH BATTERY POW ER. DUTY CYCLE WAS OBSERVED. TIME SINCE REPAIR: 1.37 CYCLE SINCE REPAIR: 2. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004032900102 20040329 00102 EU 2004 3 29 CA040116001 1 20040116 G 5270 WARNING SYSTEM AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE CARGO DOOR INOPERATIVE W O OTHER N FALSE WARNING CL CLIMB 1 CA (CAN) IN CLIMB OUT OF 17T ECAM MSG DOOR AFT CARGO. PRESSURISATION NORMAL. MSG DISAPPEARED IN CRUISE 10 MIN. LATER. (SEE COMMENTS FOR TROUBLESHOOTING. FOR TROUBLESHOOTING, CARRY OUT TSM FAULT ISOLATION TASK NR 32-31-00-810-831 AND 32-31-00-8 10-833. SENSOR 34WV GAP WITHIN TOLERANCE. SENSOR 32WV RESISTANCE ONLY 11 OHMS BETWEEN PINS A AND B. (SHOULD BE 13) SEN SOR 32WV REPLACED IAW AMM 52-71-12. CHECKED SERVICEABLE. 2 L 7 2 4F 4 F RT A28NM E29NE 2004032900103 20040329 00103 EA 2004 3 29 CA040116003 1 20040116 G 2760 270007 PCU CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE SPOILERS INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) REPEAT OF L1411710 UPON RT ENG START WITH HYD PUMPS IN AUTO RT FLT SPOILER HAS UNCOMMANDED DEPLOYMENT TO 50 DEG SL OWLY AND THEN RETRACTS TO ZERO . SPOILERS DO NOT OPERATE DURING THIS OCCURANCE REGARDLESS OF FLT SPOILER LEVER POSN. UNT IL RT SPOILER REACHES 0 DEG SECU'S INTERROGATED AND BOTH, NR 1 AND NR 2 FAULT LOG SHOWS CODE 82 (THROTTLE SWITCH). THROT TLE QUADRANT REPLACED IAW MM., TASK 76-10-00-720-801, CUTOUT, NO FAULTS. ACFT. SERVICEABLE. TH. QUADRANT REMOVED: FTN N R X21X8B INSTALLED: FTN NR JW4J0A. 2 L 7 2 4F 4 F RT A21EA E15NE 2004033000119 20040330 00119 NE 2004 3 30 CA040116004 2 20040113 G 7230 COMPRESSOR WHEEL LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE ENGINE FRACTURED W E ENGINE SHUTDOWN E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) FOLLOWING UNEVENTFUL LANDING AND ROLL-OUT, CREW NOTED VIBRATION AND RISING ITT. ENGINE WAS SECURED. POST FLIGHT EX AMINATION SHOWED THAT ROTOR 1 OF THE HPC HAD .3333 OF ONE AIRFOIL MISSING. 2 L 7 2 4F 4 F RT A10CE E35NE 2004033000126 20040330 00126 CE 2004 3 30 CA040116006 1 20040116 G 3242 PIN CESSNA 180 180J 2072622 CE CONT O470 O470S 17026 SO MCAULY 2A34C 2A34C203 GL BRAKE LINKAGE WORN W K NONE O OTHER IN INSP/MAINT 1 CA 13232 (CAN) DURING GROUND HANDLING THE RT RUDDER PEDAL BRAKE ASSY SEEMED SLOPPY COMPARED TO THE LT UNIT. INVESTIGATION REVEAL ED THAT THE PIN THAT CONNECTS THE BRAKE PEDAL TO THE MASTER CYLINDER WAS ALMOST COMPLETELY WORN THROUGH, THIS IS A HOLLO W SHAFT PIN ASSY. WORN PARTS WERE REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004033000127 20040330 00127 NE 2004 3 30 CA040117001 1 20040115 G 6320 WARNING LIGHT SKRSKY S61 S61N 8142104 NE GE CT58 CT581402 30011 NE GEARBOX OIL ILLUMINATED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 24309 (CAN) AT 5500 FT VFR ENROUTE TO THE PLATFORM, JUST NEARING THE COASTLINE, THE MASTER CAUTION AND INTERMEDIATE GEARBOX CH IP LIGHT ILLUMINATED. 2 G 7 2 4U 4 U 1H15 1E3 2004033000130 20040330 00130 CE 2004 3 30 CA040119001 1 20040115 G 3260 404EN16 SWITCH LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP MLG FAULTY W A UNSCHED LANDING P NO WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE-OFF PILOT SELECTED THE GEAR HANDLE TO THE UP POSITION. THE GEAR WOULD NOT RETRACT. AIRCRAFT RETURN TO MAINTENANCE BASE. MAINTENANCE TECH FOUND RT TRUNNION SWITCH AT FAULT. SWITCH REPLACED AND LANDING GEAR SYSTEM SWUNG. AIRCRAFT RETURN TO SERVICE. 2 L 7 2 4F 4 F A10CE E6WE 2004033000131 20040330 00131 CE 2004 3 30 CA040119002 1 20040116 G 2121 11438002811 BLOWER BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE AFT VENT BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) DURING CLIMB, CREW NOTED AN ELECTRICAL ODOR AND TRACE OF SMOKE IN CABIN. AIRCRAFT RETURNED TO AIRPORT WITHOUT FUR THER INCIDENT. MAINT FOUND THE AFT VENT BLOWER HAD OVERHEATED DUE TO ONE OF THE BEARING RESISTING ROTATION. THE NORMAL TEMPERATURE FUSE THAT IS SUPPOSED TO BLOW, DISCONTINUING POWER TO THE UNIT DID NOT APPEAR TO OPEN PRIOR TO BOTH SPEED RE SISTORS BECOMING BADLY HEATED AND DISTORTED. THE RESISTORS AND TEMP FUSE ARE CONTAINED INSIDE A METAL CONTAINER MOUNTED ON THE SIDE OF THE BLOWER. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004033000145 20040330 00145 NM 2004 3 30 CA040119003 1 20040117 G 3810 24E507009G03 WATER HEATER AIRBUS A319 A319114 3930350 NM CFMINT CFM56 CFM565A1 NE LAVATORY FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) BURNING ELECTRICAL ODOR NOTICED IN LAVATORY D. WHEN ODOR BECAME STRONGER, FLIGHT DIVERTED, DECLARING AN EMERGENC Y, FOUND TO BE THE WATER HEATER AT FAULT HEATER DE-ACTIVATED, UNDER MEL. 2 L 7 2 4F 4 F RT A28NM E29NE 2004033000146 20040330 00146 WP 2004 3 30 CA040209010 1 20040203 G 2540 WASTE TANK DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LAVATORY LEAKING W O OTHER K FLUID LOSS DE DESCENT 1 CA (CAN) ON DESCENT, RT THROTTLE STUCK AT APPROXIMATELY 2 CM ABOVE IDLE POSITION. (UNABLE TO CONTROL POWER ON ENGINE) REGAI NED CONTROL OF THROTTLE AT 1000 FEET ABOVE GROUND. FUNCTIONED NORMAL FOR LANDING AND TAXI. MAINTENANCE FOUND ICE BUILD UPON RT ENGINE THROTTLE CABLE SYSTEM QUADRANT TO CROSS SHAFT. SYSTEM CLEANED AND CHECKED FREE FOR MOVEMENT. THE ICE BUIL D UP CAME FROM WATER LEAK FROM RT REAR LAVATORY. THE LAVATORY FAUCET WAS STUCK OPEN DURING FLIGHT AND OVERFILLED THE WA STE TANK. WATER OVERBOARD THE TANK ON THE TOILET FLOOR AND DRIPPED OVER THE ENGINE CONTROL. 2 L 7 2 4F 4 F RT A6WE E9NE 2004033000147 20040330 00147 EU 2004 3 30 CA040209011 1 20040209 G 3297 G21A24 WIRE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG INDICATOR BROKEN W O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) LT MLG GREEN INDICATION WAS INTERMITENTLY LOST. FAULT COULD BE DUPLICATED BY WIGGLING THE WIRES AT THE ACTUATOR P LUG. WIRE G21A24 FOUND BROKEN AT P055 CONNECTOR, REPAIRED, GROUND TESTS SATISFACTORY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004033000148 20040330 00148 NE 2004 3 30 CA040209012 2 20040127 G 7321 85634 SHAFT BELL 204 204B 1181404 SW LYC T53 T5313B 41549 NE FUEL CONTROL WORN W K NONE O OTHER IN INSP/MAINT 1 CA 2ADS1203 (CAN) FUEL CONTROL RECEIVED FROM CUSTOMER FOR INSPECTION FOLLOWING PREVIOUS RECORDS ABOUT PUMP FAILURE (WSDR 20040128006 ). FUEL CONTROL HAS TSO- 3195.3 AND WAS OPERATING ON EXTENSION TIME DUE TO A GOOD PERFORMANCES. IT WAS REMOVED FROM A/C FOR INSPECTION IAW SB. T5317A-1-107 (CECO SB.73-39). INSPECTION FOUND WORN EXCESSIVELY, WORN MAIN DRIVE INTERNAL SPLIN ES, SECONDARY LARGE SPLINE AND PRIMARY PUMP GEAR EXTERNAL SPLINE. THIS IS THIRD CASE OF PUMP-MAIN DRIVE SHAFT FAILURE IN VESTIGATED. WE HAVE REPORTED THIS CASE TO MANUFACTURER AND WE ARE WAITING FOR FUTHER GUIDANCE. 1 G 7 1 4U 4 U H1SW E17EA 2004033000150 20040330 00150 CE 2004 3 30 CA040210003 1 20040208 G 7120 265102215 RING CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE THE ENGINE MOUNT RING (HORSE COLLAR) WAS FOUND CRACKED AT TWO OF THE FOUR CORNERS, INSI DE JOINT. DUE TO THIS BEING A KNOWN PROBLEM, AN ADDITIONAL TASK CARD TO CHECK FOR THIS CONDITION, INITIATED IN 1999, WAS ADDED TO OUR MAINTENANCE SCHEDULE EVERY 100 HOURS. AS A RESULT, WE HAVE DISCOVERED THE CONDITION ON 8 SEPARATE COLLARS. THE COLLAR WAS REPLACED AND THE AIRCRAFT RELEASED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004033000151 20040330 00151 NE 2004 3 30 CA040119004 2 20040112 G 7200 ENGINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE NR 2 FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 CA 807608 (CAN) AIRCRAFT HAS RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. WHILE IN CRUISE, THE FLIGHT CREW FELT VIBRATI ON AND NR 2 ENGINE VIBRATION WAS FLUCTUATING BUT WAS WITHIN LIMITS. AFTER A FEW SECONDS, OIL PRESSURE DROPED TO ZERO. TH E CREW FOLLOWED THE QRH, AN EMERGENCY WAS DECLARED, NR 2 ENGINE WAS SHUT DOWN, AIRCRAFT DIVERTED AND LANDED WITHOUT FURT HER INCIDENT. ENGINE REMOVED AND REPLACED. AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004033000153 20040330 00153 WP 2004 3 30 CA040120002 1 20040119 G 6322 C1861 HUB ROBSIN ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA CONING FLANGE GALLED W K NONE O OTHER IN INSP/MAINT 1 CA LOT102A (CAN) OTHER PART AFFECTED LOWER BEARING C181-3 S/N 1328 UPON REMOVING FAN ASSY FOR ACCESS TO A DEFECTIVE ACTUATOR C051-1 , DAMAGE (FRETTING AND GALLING) WAS DISCOVERED ON BOTH MATING FLANGE OF FAN HUB C186-1 (PART OF D174-2 ASSY) AND LOWER B EARING C181-3. NO PREVIOUS SIGN OF MOVEMENT WERE NOTED PRIOR TO DISMANTLING FAN ASSY. FAN WAS NEVER REMOVED AFTER IT LEF T FACTORY. FAN HAD BEEN BALANCED ONCE SINCE NEW. FAN HAS BEEN SPLIT APART FOR INVESTIGATION AND A LARGE AMOUNT OF METAL PARTICLES WERE DISCOVERED BETWEEN BACK PLATE AND FAN AND ALSO SOME EXTENSIVE CORROSION BETWEEN SHIM C178-2 FLANGES, HUB MATING SURFACE AND FAN ITSELF. PART REMOVED AND RETURNED FOR REPAIR AND FURTHER INVESTIGATION. 1 G 7 1 3O 3 O H11NM E295 2004033000155 20040330 00155 NE 2004 3 30 CA040120005 2 20040120 G 7200 ENGINE BOEING 767 76735H 1385208 NM GE CF6 CF680C2B6F 30025 NE LEFT FLAMED OUT W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) ON TAXI OUT LT ENGINE FLAMED OUT, WITH OIL ODOR IN THE CABIN. RETURNED TO GATE, AIRCRAFT CHANGED, ENGINE REPLACED IAW 71-00-02 CONF. 2 L 7 2 4F 4 F RT A1NM E13NE 2004033000163 20040330 00163 EU 2004 3 30 AUS20040001 1 20040103 G 3231 5322112082 ROD PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG DOOR SHEARED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) LT NOSE LANDING GEAR DOOR OPERATING ROD BROKEN IN AREA LOCATEDADJACENT TO LOWER WITNESS HOLES. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004033000164 20040330 00164 GL 2004 3 30 AUS20040002 3 20040104 G 6111 CLIP MCAULY CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL PROPELLER BLADE SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S 1280 (AUS) PROPELLER BLADE ROOT CIRCLIP AND ASSOCIATED SHIMS SEPARATED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P47GL 2004033000165 20040330 00165 NE 2004 3 30 AUS20040003 3 20040106 G 6110 4HFR34C652 PROPELLER SWRNGN SWRNGN SA227 SA227* SW GARRTT TPE331 TPE3312U 01514 WP MCAULY 4HFR34 4HFR34C652 NE PROPELLER LIGHTNING STRIKE W O OTHER C F.O.D. CR CRUISE 1 AU S 944 DC873B (AUS) LIGHTNING STRIKE ON RT PROPELLER AND RT FUSELAGE ADJACENT TO SAS VANE. SAS CIRCUIT BREAKER POPPED. DAMAGE TO RT P ROPELLER AND RT FUSELAGE CONSISTENT WITH LIGHTNING STRIKE. 2 L 7 2 4T 3 T RT A5SW E3WE 6 C 3PNE 2004033000167 20040330 00167 EA 2004 3 30 AUS20040005 2 20040104 G 7322 NEEDLE PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA CARBURETOR STICKING W O OTHER E Y B VIBRATION/BUFFET ENGINE STOPPAGE SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S (AUS) FIRE IN ENGINE COWLS. SUSPECT CAUSED BY STICKING CARBURETOR NEEDLE AND SEAT CAUSING FLOODING OF ENGINE. EXCESS FUEL LEAKED INTO COWLS AND IGNITED. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004033000168 20040330 00168 NM 2004 3 30 CA040120009 1 20040120 G 5510 6524189 BLOCK BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE HORIZONTAL STAB WORN W K NONE O OTHER IN INSP/MAINT 1 CA 46421 (CAN) DURING C CHECK, ONE RUB BLOCK (P/N 69-31604-4) WAS FOUND LOOSE ON THE LOWER BEAM. AFTER REMOVAL OF THE BLOCK, IT W AS FOUND THAT THE LOWER BEAM WAS WORN OUT OF LIMIT AT THE PLACE WHERE THE RUB BLOCK WAS INSTALLED. THE LOWER BEAM HAS TO BE REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 2004033000170 20040330 00170 EA 2004 3 30 AUS20040007 2 20040108 G 7414 103827991 ROTOR BENDIX BEECH 76 76 1153005 CE LYC O360 LO360A1G6 41514 EA HARTZL HCM2Y HCM2YR GL MAGNETO FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S 274 9032476 (AUS) RT ENGINE MAGNETO ROTATING MAGNETIC SLIPPED ON SHAFT BY APPROXIMATELY 25 DEGREES. 1 L 7 2 3O 3 O A29CE 1E10 5 C P43GL 2004033000171 20040330 00171 NE 2004 3 30 AUS20040008 1 20040108 G 3230 2071235 BEARING RACE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LANDING GEAR INTERCONNECT ROD SPHERICAL BEARING INNER RACE CRACKED. FOUND DURING INSPECTION IAW AD/S-76/66 PT4. 1 G 7 2 3U 3 U NC H1NE E19EU 2004033000173 20040330 00173 NE 2004 3 30 AUS20040010 1 20040108 G 6210 7615009043050 CAP SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE MAIN ROTOR BLADE CRACKED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) MAIN ROTOR BLADE TIP CAP TOP SKIN CRACKED IN AREA ADJACENT TO THE ATTACHMENT DOUBLER. CRACK LENGTH 270MM (10.62IN) . TIP CAP HAD DISBONDED INTERNALLY FROM THE METAL DOUBLER ASSEMBLY AND THE KEVLAR SKIN HAD CRACKED AND DELAMINATED. 1 G 7 2 3U 3 U NC H1NE E19EU 2004033000174 20040330 00174 EU 2004 3 30 AUS20040011 1 20040110 G 5740 SD3230488XA ATTACH FITTING STBROS SD3 SD360 8100606 EU PWA PT6 PT6A67R 52043 NE HARTZL HCA6A HCA6A3 NE LT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING STRUT FORWARD LOWER STRUT TO STUB WING ATTACHMENT LUG CORRODED ON AFT FACE. DEPTH OF CORROSION 3.327MM (0. 131IN) WHICH IS APPROXIMATELY 13 PERCENT OF THE FITTING THICKNESS. FOUND DURING INSPECTION IAW AD/SD3-60/48 AMDT2. 2 H 7 2 4T 4 T A41EU E26NE 6 C P14NE 2004033000175 20040330 00175 NM 2004 3 30 AUS20040012 1 20040101 G 2742 4012373817 ACTUATOR DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE STABILIZER FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) YAW DAMPER LINEAR ACTUATOR FAULTY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004033000176 20040330 00176 EU 2004 3 30 AUS20040013 2 20040105 G 7200 CFM563C1 ENGINE BOEING 737 737376 NM CFMINT CFM56 CFM563C 13802 EU OVERHEATED W O OTHER M OVER TEMP NR NOT REPORTED 1 AU S 724786 (AUS) ENGINE EXCEEDED EGT LIMITS. EGT REACHED 938 DEGREES C. 2 L 7 2 4F 4 F RT A16WE E21EU 2004032900097 20040329 00097 SO 2004 3 29 CA040209004 1 20040205 G 6120 2489410 CONTROL CABLE PIPER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL PROP GOVERNOR BROKEN W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) AT ENGINE WARMING UP PILOT FOUND ( WHEN TRYING CHECK OF PROP GOVERNOR WORK) LT PROP CONTROL LEVER WENT LOOSE, PROP DID NOT FOLLOW SETTING ANY MORE. INSPECTION REVEALED LT PROP GOVERNOR CABLE PN:24894-10 BROKEN AND SEPARATED CABLE END FITTING AT GOVERNOR SIDE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004032900098 20040329 00098 WP 2004 3 29 CA040209005 1 20040208 G 6320 369D25100505 NOZZLE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL M/R GEARBOX MISSING W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) UNIT INSTALLED IN A/C AFTER REPLACEMENT OF CRACKED CASE BY CUSTOMER US REPAIR FACILITY. AFTER INITIAL TEST RUNS IT WAS REPORTED TO HAVE VERY LOW OIL PRESSURE, AFTER NUMEROUS HOURS OF TROUBLESHOOTING (PRESSURE PUMP, SWITCH, GAUGE REPLA CEMENT AND WIRING CHECKS), THE UNIT WAS REMOVED FROM A/C FOR FURTHER INSPECTION. THE T/R O/P PINION WAS REMOVED TO EXPOS E A LARGE PART OF THE PRESSURE PROBLEM AS THE I/P OIL NOZZLES WERE MISSING. WE HAVE DOCUMENTED THIS ON DIGITALLY WITH PI CTURES.WE AWAIT FURTHER INSTRUCTION. 1 G 7 1 3U 3 U H3WE E4CE 2004033000128 20040330 00128 EA 2004 3 30 CA040118001 1 20040107 G 3397 2LA006913 WIRE CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE FLOOD LIGHT BURNED W O OTHER A FLAME/FIRE AP APPROACH 1 CA (CAN) THE COPILOT REPORTED FWD FLOOD LIGHT WIRES CAUGHT FIRE. CAPTAIN REPORTED THAT FO PINCHED WIRE WITH FINGERS TO EXTI NGUISH FLAMES. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE FI FWD FLOOD LIGHT ASSEMBLY WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004033000152 20040330 00152 NM 2004 3 30 CA040120001 1 20040120 G 5610 141T480150 WINDSHIELD BOEING 767 767333 1385301 NM PWA 4060 PW4060 52119 NE COCKPIT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE IN FLIGHT, R1 WINDSHIELD OUTER PANE SHATTERED. (FL370) R1 WINDOW REPLACED IAW AMM 56-11-01 REMOVED: UNI 56- 10-0174 MPN: 141T4801-50 INSTALLED: UNI 56-10-0174 MPN: 141T4801-50 2 L 7 2 4F 4 F RT A1NM E24NE 2004033000154 20040330 00154 NE 2004 3 30 CA040120004 3 20040120 G 6114 52590 THRUST WASHER CNDAIR CL215 CL2151A10 1900320 EA PWA R1340 AWASP 52016 NE HAMSTD 43E 43E60 NE PROPELLER GALLED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PROPELLER REMOVED FOR AD 81-13-06R2, CF 83-16 CORROSION INSPECTION. EVIDENCE OF CORROSION WAS NOT FOUND BUT EXTENS IVE PITTING / GALLING WAS DISCOVERED ON A BEVELED THRUST WASHER P/N 52590 AND FLAT WASHER P/N 57525 AS IDENTIFIED IN HAM ILTON STANDARD BLADE OVERHAUL MANUAL NO. 130B, PAGE 424. PROPELLER TO BE SENT FOR REPAIR AND OVERHAUL ASSESSMENT. 2 H 7 2 4R 3 R RT A14EA ATC14 6 C P871 2004033000158 20040330 00158 NM 2004 3 30 CA040120008 1 20040120 G 5511 65174392 RIB BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 46421 (CAN) DURING C CHECK,THE INSPECTION OF THE HORIZONTAL STABILIZER, REVEALED A CRACK ON THE ELEVATOR HINGE SUPPORT RIB ON THE RT SIDE AT STATION 136.5. 2 L 7 3 4F 4 F A3WE E2EA 2004033000166 20040330 00166 2004 3 30 AUS20040004 4 20040104 G 2210 4051601937 CONTROL PANEL BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU AUTOPILOT SYSTEM FAILED W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S 90101410 (AUS) AUTOPILOT MODE CONTROL PANEL FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2004033000169 20040330 00169 CE 2004 3 30 AUS20040006 1 20040107 G 5341 BB148 WASHER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL LT & RT WING WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LT AND RT WING LOWER ATTACHMENT BOLT WASHERS INCORRECTLY FITTED. DAMAGE TO BATHTUB FITTING. PERSONNEL/MAINTENANC E ERROR. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004033000179 20040330 00179 NM 2004 3 30 CA040121001 1 20040119 G 7711 10607371 TRANSMITTER BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE ENGINE EPR FAILED W D RETURN TO BLOCK N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, IT WAS OBSERVED THAT THE NR 1 ENGINE EPR HAD NO INDICATION. THE AIRCRAFT WAS RETURNED TO THE RAMP. AFTER SOME TROUBLESHOOTING, MEL 77-01-01 WAS RAISED. THIS IS A 3 FLIGHT DAY, A CAT, MEL. THE AIRCRAFT WAS DISPATCHED. ON RETURN TO HOME BASE, THE EPR TRANSMITTER WAS REPLACED AND CHECKED SERVICEABLE AND NO FURTHER PROBLEM DURING SUBSEQUEN T FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004033000181 20040330 00181 CE 2004 3 30 CA040121004 1 20040104 G 5610 1013840252 WINDSHIELD BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL COCKPIT BROKEN W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) WINDOW SHATTERED IN CRUISE, INSIDE AND OUT SIDE PANE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004033000182 20040330 00182 EU 2004 3 30 CA040121005 1 20040121 G 3246 32200022 BEARING AIRBUS A321 A321211 3930370 EU IAE V2530 V2530A5 NE NLG WHEEL FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RT NOSE WHEEL SEPARATED FROM THE NLG SHOCK ABSORBER DURING TAXING IN, IT IS BELIEVED THAT THIS HAPPENED ON THE LAS T TURN TO THE GATE. THE AC HAS ACCUMULATED 4,747FH AND 1,813CY. A FAILURE OF THE NOSE LANDING GEAR WHEEL BEARING (TFU 32.41.12.006) IS SUSPECTED. 2 L 7 2 4F 4 F RT A28NM E40NE 2004033000183 20040330 00183 GL 2004 3 30 CA040122001 3 20040121 G 6114 D1657 CYLINDER PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PROPELLER HUB DEFECTIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PROPELLER CYLINDER FOUND DEFECTIVE. MANUFACTURE DEFECT IN THE C AREA MISSING MATERIAL. THIS HAS BEEN SEEN IN SEV ERAL OTHER CYLINDERS, MFG WAS CONTACTED ON ALL OF THE DEFECTIVE ASSEMBLIES. MFG INSPECTED AND ANALYZED THEM ALL AND HAS NOT PROVIDED ANY LIMITS FOR DAMAGES IN THE C AREA. ALL CYLINDERS HAVE BEEN WARRANTEED FOR REPLACEMENT. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004033000184 20040330 00184 CE 2004 3 30 CA040122002 1 20040121 G 2750 14601008 CONTROL CABLE CESSNA 337 T337G 2075726 CE CONT O360 TSIO360CB 17025 SO MCAULY 2AF34C D2AF34C303 GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION IT WAS DICOVERED THAT THESE CABLES (2EA. 1 LT AND 1 RT) WERE FRAYED WHERE THE CABLE BENDS AROUND THE FLAP CABLE QUADRANT LOCATED IN THE WING TRAILING EDGE. 1 H 7 2 3O 3 O A6CE E9CE 5 C P5EA 2004033000185 20040330 00185 CE 2004 3 30 CA040122003 1 20040121 G 2750 14601007 CONTROL CABLE CESSNA 337 T337G 2075726 CE CONT O360 TSIO360CB 17025 SO MCAULY 2AF34C D2AF34C303 GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION IT WAS DISCOVERED THAT THESE CABLES (2EA. 1 LEFT AND 1 RIGHT) WERE FRAYED WHERE THE CABLE BENDS AROUND THE FLAP CABLE QUADRANT LOCATED IN THE WING TRAILING EDGE. 1 H 7 2 3O 3 O A6CE E9CE 5 C P5EA 2004033000186 20040330 00186 NM 2004 3 30 AUS20040016 1 20040113 G 3230 161A661143 SPRING BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE MLG UPLOCK MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT MAIN LANDING GEAR AFT UPLOCK SPRING MISSING. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004040100160 20040401 00160 2004 4 1 2004FA0000255 4 20040105 G 3418 STALL WARNING DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO FROZEN B FE4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 102U 319 C0205 WE HAVE FOUND THAT THE STALL WARNING SYSTEM ON THIS TYPE OF AIRCRAFT IS PRONE TO FREEZE UP. MOISTURE IS INTRODUCED TO T HE SYSTEM THROUGH THE SENSORY HOLE IN THE LEFT WING. MOISTURE TRAVELS TO THE LOW POINT IN THE SYSTEM LOCATED IN THE AIR CRAFT BELLY AD FREEZES UP CAUSING THE STALL WARNING SYSTEM TO NOT FUNCTION. 1 L 7 1 3O 3 O NT TA4CH E7SO 2004040100164 20040401 00164 EA 2004 4 1 2004FA0000257 2 20040101 G 8550 LW13388 GASKET PIPER PA32 PA32R300 7103213 SO LYC O540 TIO540* 41532 EA OIL FILTER FAILED G O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 21 589Q 32R7780492 OIL FILTER CONVERTER PLATE GASKET (PN LW13388) PROTRUDED OUT OF THE PLATE CAUSING LOSS OF OIL AND SUBSEQUENT ENGINE SEIZ URE. RECOMMENDATION: CURRENT AD ALONG WIGH LYC SI CAN LEAD INTO MECHANIC TRAP. IF THE OIL FLITER CONVERTER PLATE KIT (PN LW-13904, THIS PROBLEM WOULD BE RESOLVED. (WP21200402668) 1 L 7 1 3O 3 O A3SO E14EA 2004040100169 20040401 00169 CE 2004 4 1 2004FA0000261 1 20040201 G 3243 988200104 MASTER CYLINDER CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA LT BRAKE INOPERATIVE B EHHR O OTHER O OTHER NR NOT REPORTED 1 EA 17 641SP 679 172S8049 PILOT REPORTED NO RESPONSE FROM LT BRAKE PEDAL, FOUND THAT BOTTOM LT BRAKE MASTER CYLINDER ATTACHMENT CLEVIS PIN MISSING . LOCATED CLEVIS PIN ON UPPERSIDE OF BELLY SKIN AND COTTER PIN. FOUND THAT COTTER PIN WAS BARELY BENT AND APPEARENTLY FELL OUT O F CLEVIS PIN HOLE THUS ALLOWING CLEVIS PIN TO FALL OUT OF BRAKE MASTER CYLINDER ATTACHMENT. 1 H 7 1 3O 3 O NT 3A12 1E10 2004040100170 20040401 00170 SW 2004 4 1 2004FA0000262 1 20040213 G 5753 190151 HINGE BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C1E 41514 EA HARTZL HCC2Y HCC2YR1 GL TE FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 01 5060M 32679 L2722636A CH24256 CONDUCTED ANNUAL INSPECTION ON AIRCRAFT. FOUND BOTH LEFT AND RIGHT WING FLAP CONTROL ROD ATTACH POINTS TO CONTROL SURFA CES TO BE CRACKED. SPECULATE DAMAGE MAY HAVE BEEN INDUCED BY WIND ACTION AND LACK OF USE OF CONTROL SURFACE LOCK. 1 H 7 1 3O 3 O A21CE E286 5 C P920 2004040100171 20040401 00171 EA 2004 4 1 2004FA0000263 2 20040213 G 7414 IMPULSE COUPLING CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MAGNETO CRACKED B NF1R O OTHER O OTHER NR NOT REPORTED 1 CE 07 9210H 1936 95120132 17266017 L4305327A ONE OF THE MAGNETO IMPULSE COUPLING PAWLS OR PAWL ATTACH RIVETS FAILED DURING TOUCH AND GO OPERATION. THE PAWL BROKE TH E MAGNETO MOUNTING CASTING AND DEPARTED THE AIRCRAFT. MAGNETO WAS HANGING FROM THE ACCESSORY HOUSING WITH THE HELP OF T HE IGNITION HARNESS. PILOT REPORTED ONLY A SLIGHT BACKFIRE DURING CLIMB OUT WITH A LITTLE LOSS OF POWER. MAGNETO HAD R ECEIVED A 500 HOUR INSPECTION 260 HOURS PRIOR TO FAILURE. IF FAILURE HAD OCCURRED DURING A LONG CROSS COUNTRY FLIGHT, T OTAL LOSS OF OIL MAY HAVE OCCURRED. (PILOT WOULD HAVE PROBABLY ADVANCED THROTTLE SLIGHTLY TO MAKE UP FOR ONE MAGNETO FA ILING AND DROPPING RPM SLIGHTLY). 1 H 7 1 3O 3 O NT 3A12 E274 2004040100172 20040401 00172 CE 2004 4 1 2004FA0000264 1 20040213 G 3244 TIRE CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA NLG OUT OF BALANCE D O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 SW 13 64107 17265023 PILOT REPORTED NOSE WHEEL SHIMMY AFTER TOUCH DOWN AND HIGH SPEED TAXI. INSPECTED NOSE GEAR AND NOTED SHIMMY DAMPENER AN D STEERING COLLAR BEARING A LITTLE MORE THAN NORMAL AXIAL MOVEMENT, TIRE STILL HAD 65 PERCENT TREAD AND SAW NO OBVIOUS TIRE DEFECTS. REMOVED NOSE STRUT TO INSPECT AND RESHIM STEERING COLLAR AND SERVICE/SHIM SHIMMY DAMPENER. WHEN THE NOSE STRUT LOWER FRONT HALF CLAMP WAS REMOVED, THE NOSE STRUT TUBE SPRUNG FORWARD .120 OUT OF ALIGNMENT WITH THE TOP STRUT M OUNT. FOUND NO DAMAGE TO AIRFRAME OR NO NOSE GEAR HISTORY. POSSIBLE LEAVING FACTORY LIKE THIS. INSPECTED AND RESHIMED NOSE GEAR ASSEMBLY AND LOWER STRUT CLAMP UP TO RELIEVE STRESS. MOUNTED NEW TIRE, DIFFERENT BRAND. NO SHIMMY DETECTED. 1 H 7 1 3O 3 O NT 3A12 E274 2004040100174 20040401 00174 EA 2004 4 1 2004FA0000265 2 20040129 G 7322 30768 FLOAT PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA CARBURETOR SATURATED B WIWR O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 07 923RS 75132505 447995196 RL70177T PILOTS REPORTED THAT UPON LANDING THE LEFT ENGINE DIED AND THAT FUEL WAS DRIPPING FROM THE COWLING. MAINTENANCE INSPECT ED LEFT ENGINE AND COULD NOT FIND FUEL LEAKAGE. AIRCRAFT WAS GROUND RUN AND OPERATIVE NORMALLY EXCEPT AT IDLE. AT IDLE AIRCRAFT RAN SMOOTHLY FOR ABOUT 15 TO 20 SECONDS AND THEN WOULD BEGIN TO DIE AS IF THE ENGINE WAS EXCESSIVELY RICH. MI XTURE WAS LEANED TO ICO AND ENGINE CONTINUED TO RUN AND THERE WAS FUEL DRIPPING FROM THE AIRBOX. CARBURETOR WAS REMOVED FROM THE AIRCRAFT AND THE TOP OPENED. THE FLOAT INSIDE THE CARBURETOR WAS FOUND TO BE HALF FILLED WITH FUEL. MFG TO M ONITOR PRODUCTION OF FLOATS. (WP07200410619) 1 L 7 2 3O 3 O A19S0 E286 2004040100175 20040401 00175 CE 2004 4 1 2004FA0000266 1 20040218 G 3260 12700344 SAFETY SWITCH CESSNA 337 337H 2075732 CE CONT O360 IO360GB 17025 SO MCAULY 2AF34C D2AF34C* GL NLG DAMAGED B LX5R A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 19 1244S 5920 33701892 236691R 780550 AFTER TAKE OFF PILOT WAS UNABLE TO RETRACT THE LANDING GEAR, THE GEAR DID SHOW DOWN AND LOCKED. THE PLANE LANDED WITHOU T INCIDENT. FOUND NOSE GEAR SAFETY SWITCH BAD INTERNALLY NOT ALLOWING NOSE GEAR TO RETRACT, (SENSING STILL ON GROUND). IT IS SUSPECTED THAT THIS WAS NORMAL WEAR OF SWITCH. THERE WAS NO EVIDENCE OF EXTERNAL DAMAGE. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2004040100176 20040401 00176 CE 2004 4 1 2004FA0000267 1 20040212 G 3297 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO MLG INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1565A CE1331 825800R PILOT REPORTED THAT LANDING GEAR WOULD NOT EXTEND. AFTER GEAR HANDLE CYCLED SIX TIMES GEAR CAME DOWN. UPON TROUBLESHOO TING OF THE LANDING GEAR SYSTEM FOUND LANDING GEAR DYNAMIC RELAY INTERMITTENT. NO RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 3A15 E5CE 2004040200001 20040402 00001 EU 2004 4 2 CA040210006 1 20040206 G 7334 8346 PRESSURE SWITCH SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R389 R3894123F25 NE FUEL SYSTEM LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA 367302 (CAN) DUE TO INTERNAL LEAKAGE OF DIFFERENTIAL PRESSURE SWITCH, A LOST OF FUEL WAS HAPPENING THRU THE OVERBOARD DRAIN WHI CH WAS CREATING A PRESSURE DROP IN FUEL PUMP SYSTEM, THE AUX PUMP WOULD THEN COME ON AND OFF THUS CREATING A SMALL FLUCT UATIONIN THE ENGINE PARAMETERS. AFTER INVESTIGATION AN IMPROVE SWITCH WAS MADE AVAILABLE THRU SB73-011 DUE TO IMPROVED R ELIABILITY. THE OLD PN 8346 CAN BE NOW IMPROVE BY USING PN 8346-001. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P30NE 2004040200002 20040402 00002 EA 2004 4 2 CA040211006 1 20040205 G 7921 853877 OIL COOLER DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA ENGINE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AIRCRAFT RETURNED FROM FLIGHT WITH AN EXCESSIVE OIL LEAK ON THE LT ENGINE COWLS. INVESTIGATION DISCOVERED A CRACK IN THE OIL COOLER VERNATHERM INLET/OUTLET HOUSING. THE OIL COOLER WAS REPLACED WITH AZERO TIME UNIT AND CHECKED SERVICEA BLE.THE OIL COOLER HAD BEEN INSTALLED 77.2 HOURS EARLIER AS PART OF A 3000 HOUR BENCH TEST REQUIREMENT. 1 H 7 2 3T 4 T RT A9EA E4EA 2004040200003 20040402 00003 CE 2004 4 2 CA040122004 1 20040108 G 5210 1295140791 BRACKET BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE PAX DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12505 (CAN) DURING GROUND HANDLING, CREW ATTEMPTED TO OPEN DOOR FROM INSIDE AND THE MAIN HANDLE UPON APPLYING PRESSURE, RELEAS ED WITHOUT ACTUATING DOOR CAMS. MAINTENANCE FOUND THAT THE MAIN DOOR ACTUATION BRACKETHAD BROKEN INTO TWO PIECES. THE BR ACKET WAS REPLACED AND THE AIRCRAFT CONTINUED OPERATIONS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004040500001 20040405 00001 EA 2004 4 5 CA040308009 1 20040304 G 3310 82510189S103 RHEOSTAT DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE COCKPIT LIGHT FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 28497 28497 (CAN) DURING MAINT WHEEL REPLACEMENT ON RAMP , FLIGHT CREW (ONLY PERSONNEL ONBOARD) NOTICED SMOKE IN THE COCKPIT (NO FIR E) . MAINTENANCE INSPECTION FOUND OVERHEAD READING LIGHT RHEOSTAT WAS SOURCE OF SMOKE. COCKPIT OVERHEAD PANEL ASSEMBLY WITH RHEOSTAT REPLACED. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004040500004 20040405 00004 EA 2004 4 5 CA040309002 1 20040304 G 6320 61352095012 COVER SKRSKY CARSON S61 S61LSKRSKY EA GE CT58 CT581401 30011 NE M/R GEARBOX CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 26356 A14994 (CAN) CRACK ON LOWER LT LEG OF MAIN GEARBOX REAR COVER DISCOVERED ON DAILY INSPECTION. 2 G 7 2 4U 4 U H8EA 1E3 2004040500005 20040405 00005 NE 2004 4 5 CA040309003 1 20040307 G 6320 FILTER SKRSKY 613520600046 SKRSKY S61 S61N 8142104 NE GE CT58 CT581401 30011 NE M/R GEARBOX INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION HO HOVERING 1 CA 18054 A141027 (CAN) MAIN GEAR BOX OIL PRESSURE DROPPED IN FLIGHT. AIRCRAFT RETURNED TO LANDING AREA AND SHUT DOWN. EXAMINATION OF MGB COARSE SCREEN FILTER REVEALED RESIN COATING FROM INSIDE OF MGB HAD FLAKED OFF. MGB REPLACED. 2 G 7 2 4U 4 U 1H15 1E3 2004040500006 20040405 00006 NM 2004 4 5 CA040309004 1 20040225 G 2742 6355B000103 MOTOR BOEING 737 73776N 13844CH NM CFMINT CFM567 CFM567B22 13802 NE STAB TRIM JAMMED W H DEACTIVATE SYST/CIRCUITS F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 CA (CAN) 2 HRS INTO FLT (STAB OUT OF TRIM) LIGHT ILLUMIN. NON-NORMAL CKLIST WAS COMPLETED, ELEC TRIM REMAINED INOP,TRIM C HANGES ACCOMPLISHED MANUALLY. MAINT CTRL WAS CONSULTED AND CB 6B AND 610 WERE PULLED AND RESET. (STAB OUT OF TRIM) LIGHT CONTINUED INTERMITTENT, PILOTS CONTINUED MANUALLY INPUT REQUIRED TRIM CHANGES. STAB BECAME COMPLETELY JAMMED NON-NORMAL CKLIST WAS COMPLETED. STAB REMAINED JAMMED FOLLOWING COMPLETION OF CKLIST, MAINT CTRL REQUESTED THAT CB 6B AND 610 BE PULLED AND LT OUT. MAN CTRL OF STAB WAS RESTORED AND A NON-NORMAL LANDING WAS COMPLETED, WITHOUT FURTHER INCIDENT. UPDAT E: MAR.09/04 - MFG HAS REQUESTED FLIGHT DATA RECORDED READOUT FROM SUBJECT FLIGHT AND RELATED TROUBLESHOOTING RESULTS. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004040500007 20040405 00007 NM 2004 4 5 CA040310001 1 20040306 G 4997 CONNECTOR GARRTT GTCP8511 BOEING 737 7372H4 138448C NM PWA JT8 JT8D9A 52048 NE APU BURNED W A E UNSCHED LANDING ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA P34583 (CAN) INDICATION OF APU FIRE AT 35,000 FT. AFTER DISCHARGING BOTTLE AND SHUTTING DOWN APU, RED WARNING LIGHT EXTINGUISHE D. CREW DIVERTED AND AC LANDED W/O INCIDENT. MAINT INSP FOR FIRE DAMAGE IAW SRM 51-4-10. FIRE CONTAINED BETWEEN BLKHD S TA.1156 AND APU EXHAUST BAFFLE. NO EVIDENCE OF BURNED PRIMER OR DISCOLORED METAL. APU EGT AND TAIL PIPE FIRE DETECTION WIRING HARNESS FOUND BURNED, TAIL PIPE FIRE. APU TUB REMOVED AND INSP, NO LEAKS AND NO INDICATION OF FIRE DAMAGE. MAINT SUSPECT CAUSED OFFIRE AT EGT CONNECTORS TO WIRE HARNESS, FOUND BURNED. POSSIBLE SHORT OCCURRED, DAMAGED WIRING HARNESS ES REPLACED AND APU FIRE DETECTION SYSTEM TESTED SERVICEABLE. APU FIRE BOTTLE REPLACED. AC RETURNED TO SERVICE. 2 L 7 2 4F 4 F A16WE E2EA 2004040500008 20040405 00008 EU 2004 4 5 CA040310002 1 20040308 G 2510 EQMFG200002901 SEAT BELT SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE COCKPIT INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SHOULDER HARNESS INERTIA REEL ON COPILOT'S SEAT WOULD NOT RETRACT AFTER FULL EXTENSION. THE PN SPECIFIED IN 9B AP PLIES TO THE 4 POINT HARNESS ON ENERGY ABSORBING STYLE OF SEAT. 1 G 7 1 3U 3 U H9EU E00054EN 2004040500010 20040405 00010 SW 2004 4 5 CA040310004 1 20040225 G 5313 206031314123 LONGERON BELL 206 206L1 1182107 SW ALLSN 250C 250C30P 03013 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SCHEDULED MAINTENANCE THE ENGINEER DETECTED THE ENGINE MOUNT TO BE LOOSE. FURTHER INVESTIGATION INDICATED A CRACKED LONGERON WITH THE ENGINE MOUNT IS ATTACHED. 1 G 7 1 3U 3 U H2SW E1GL 2004040500021 20040405 00021 EU 2004 4 5 CA040311007 1 20040311 G 3340 0320713406 LIGHT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL EXTERIOR FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) NAVIGATION LIGHT ASSEMBLY (TAIL) APPEARS TO HAVE PROBLEMS WITH THE TOP BULB BURNING OUT. THERE HAS BEEN 8 BULBS P/ N 972.87.87.184 REPLACED WITHIN 7 DAYS. THE COMPLETE ASSEMBLY HAS BEEN REPLACED ALONG WITH A ELECTRONIC SWITCH UNIT. THE SAME RESULTS. THE BULBS THEMSELVES ARE EXTREMELY HOT WITHIN A SORT TIME OF OPERATION.(SECONDS) THIS NAV LIGHT ASSEMBLY IS PART OF A KIT P/N 500.50.12.276 DUAL NAV LIGHT SYSTEM. MFG S/B 33-009 WAS USED FOR THE INSTALLATION OF THIS PRODUCT. IN SHORT, THE LIGHT IS UNRELIABLE. ON GOING TRIALS ARE CONTINUING TO FIND A SOLUTION. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004040500025 20040405 00025 CE 2004 4 5 CA040311011 1 20040227 G 5210 50430043619 CHANNEL BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION A CRACK WAS DISCOVERED ALONG THE TRAILING EDGE OF THE CABIN DOOR CHANNEL P/N 50430043619. THE CR ACK PROPAGATED APPROXIMATELY 6 IN, JUST ABOVE THE DOOR HINGE. THE DOOR WAS REMOVED AND SENT TO AN APPROVED OVERHAUL SHOP , REPAIRED AND REINSTALLED. AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004040500029 20040405 00029 GL 2004 4 5 CA040315001 2 20040309 G 7210 6850209 GEARBOX LKHEED 382 382G 526414U SO ALLSN 501D 501D22A 03006 GL HAMSTD 54H 54H60117 NE NR 2 REDUCTION CONTAMINATED W E ENGINE SHUTDOWN J WARNING INDICATION CL CLIMB 1 CA (CAN) AT TOP OF CLIMB ENROUTE, NR 2 RGB CHIP LIGHT OBSERVED. THE INDICATION WOULD NOT CLEAR, NR 2 ENGINE WAS SHUT DOWN. MAINTENANCE FOUND BOTH RGB CHIP PLUGS BRIDGED. NR 2 ENGINE WAS REPLACED FOR CONVENIENCE AND THE AIRCRAFT RETURNED TO S ERVICE. 2 H 7 4 4T 4 T A1SO E282 6 C P906 2004041300011 20040413 00011 CE 2004 4 13 CA040315008 1 20040302 G 2823 1013890253 SHUTOFF VALVE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL FUEL SYSTEM FAILED W O OTHER L NO TEST TX TAXI/GRND HDL 1 CA (CAN) DURING PRESTART CHECKS FLIGHT CREW COULD NOT EXTINGUISH (LOW FUEL PRESSURE) WARNING LIGHT. FLIGHT CANCELLED. INSPE CTION FOUND RT FUEL SHUT OFF VALVE HAD FAILED IN THE CLOSED POSITION. VALVE HAD BEEN RECENTLY OVERHAULED. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004041300012 20040413 00012 EU 2004 4 13 CA040315009 1 20040306 G 5330 SKIN BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 36314 (CAN) A PILOT IN THE PROCESS OF DOING HIS DAILY INSPECTION OF THE AIRCRAFT NOTICED A CRACK (2.5 INCHES) IN THE LT FORWAR D FUSELAGE SKIN JUST BELOW A LAP JOINT BETWEEN FRAMES 10 AND 11 NEAR THE WATER LINE. THE AIRCRAFT WAS REMOVED FOR SERVIC E, A SECTION OF SKIN IN THE AFFECTED AREA WAS REMOVED AND SENT FOR ANALYSIS, THE BREAK OCCURRED ON AN INSIDE RADIUS OF T HE SKIN THAT WAS CHEMICALLY MILLED. OUR SHEET METAL PEOPLE EXAMINED THE SPECIMEN THAT WAS REMOVED AND THEY FELT THAT TH E RADIUS OF THE CONTOUR WAS A BIT SHARP WHERE THE CRACK OCCURRED. THE AIRCRAFT WAS TEMPORARILY REPAIRED IAW BARA/AVR/66 81/04-DC INSTRUCTIONS FROM THE MANUFACTURER WITH A PERMANENT REPAIR DUE AT THE NEXT C-CHECK. 2 H 7 4 4F 4 F A49EU E6NE 2004041300013 20040413 00013 NM 2004 4 13 CA040315010 1 20040308 G 3250 65727628 COLLAR BOEING 727 727233 138408A NM PWA JT8 JT8D15 52051 NE NLG STEERING WORN W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA 12000 (CAN) THE TAKE-OFF WAS REJECTED AT 70KTS DUE TO NLG SHIMMEY. BOTH NLG WHEELS REPLACED AND STEERING COLLAR ADJUSTMENT CHE CKED. AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 3 4F 4 F RT A3WE E2EA 2004041300014 20040413 00014 CE 2004 4 13 CA040315011 1 20040308 G 7712 3012347 VALVE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE TORQUEMETER ERODED W O OTHER O OTHER DE DESCENT 1 CA PS0164 (CAN) FLIGHT CREW REPORTED OCCASIONAL PROBLEMS WITH TORQUE INDICATION DURING POWER REDUCTIONS. TORQUE INDICATION WOULD H ANG UP AT VARIOUS HIGH SETTINGS DESPITE POWER REDUCTIONS TO IDLE. FROM A PREVIOUS CASE OF THIS ON ANOTHER AIRCRAFT, THE POWER REDUCTION CASE WAS SPLIT WITH AN EXPECTATION THAT THE TORQUEMETER VALVE WAS PREMATURELY WORN, AND IT WAS. A PREV IOUS SUBMISSION UNDER AGL-0120 REFLECTS EXACTLY THE SAME PROBLEM, PRESENTATION AND FIX. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004041300015 20040413 00015 EU 2004 4 13 CA040315012 1 20040314 G 6730 AC67246 SERVO VALVE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE COLLECTIVE UNSERVICEABLE W C ABORTED TAKEOFF F FLT CONT AFFECTED TO TAKEOFF 1 CA (CAN) PILOT REPORTED THAT WHEN HE TRIED TO PULL THE COLLECTIVE UP, IT FELT VERY HEAVY. IT WAS NOTED DURING TROUBLESHO OTING THAT THE SPOOL VALVE WAS VERY DIFFICULT TO MOVE AND THEN IT WOULD ONLY MOVE A SMALL AMOUNT. A SERVICEABLE SERVO W AS INSTALLED AND CONTROLS CHECKED OUT NORMAL. 1 G 7 1 3U 3 U H9EU E19EU 2004041300019 20040413 00019 NM 2004 4 13 CA040316008 1 20040305 G 3010 85720014005 BOOT DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE LT LE DEICE DELAMINATED W C ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 CA 36874 36874 (CAN) CREW REJECTED TAKE-OFF AT ROTATION DUE TO STICK PUSHER SHAKE. AIRCRAFT WAS AT MORE THAN 80 KNOTS AT TIME OF REJEC TION. FLIGHT RETURNED TO GATE. BOTH STALL SYSTEMS CHECKED SERVICEABLE ON THE GROUND. FOUND THAT THE LT LE DEICE BOOT DE LAMINATING CAUSING THE STALL/STICK SHAKER TO ACTIVATE. THE LEADING EDGE WAS REPLACED AND THE AIRCRAFT BROUGHT BACK TO SE RVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004041300024 20040413 00024 NM 2004 4 13 CA040203012 1 20040203 G 2910 272T3100351 LINE BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE HYDRAULIC SYS RUPTURED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT HYDRAULIC QTY LOST ON T/O ROLL NO HYD FLUID REMAINING ASSOCIATED SYSTEM AFFECTED. FOUND LT HYDRAULIC RETURN LIN E RUPTURED. LINE REPLACED, PRESS/CASE FILTERS REPLACED. LEAK AND FUNCTION CHECK SERVICEABLE. 2 L 7 2 4F 4 F RT A1NM E3NE 2004041300025 20040413 00025 SW 2004 4 13 CA040318004 1 20040311 G 6420 AN5161A GREASE FITTING BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL TAIL ROTOR CLOGGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING 50 HOUR LUBRICATION INTERVAL. FITTINGS WOULD NOT PASS GREASE. FITTING REPLACED. 1 G 7 1 3U 3 U H2SW E4CE 2004041300028 20040413 00028 CE 2004 4 13 CA040319002 1 20040309 G 3020 1099100491 ANTI-ICE SYSTEM BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL RT ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIR INTAKE ANTI-ICE LIP WAS FOUND CRACKED AT THE WELDED ATTACH JOINTS AT BASE OF EXHAUST INLET/OUTLET TUBES. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004041300029 20040413 00029 GL 2004 4 13 CA040216008 1 20040213 G 2510 VISOR BOMBDR BD700 BD7001A10 1390006 GL RROYCE BR700 BR700710A220 09500 NE COCKPIT SEPARATED W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA (CAN) PILOT WAS MOVING HIS VISOR BACK FROM EXTREME RT SIDE OF VISOR RAIL TO LT, WHEN VISOR FELL OFF RAIL ONTO THROTTLE Q UADRANT. LT ENGINE RUN SWITCH ON QUADRANT WAS INADVERTENTLY MOVED TO OFF POSITION BY VISOR IMPACT AND ENGINE STARTED T O SHUT DOWN. PILOT DESCENDED TO FL410 TO KEEP SPEED UP, SELECTED ENGINE RUN SWITCH BACK TO RUN POSITION. SUCCESSFUL RE LIGHT OF ENGINE OCCURRED AND A/C WAS BROUGHT BACK TO FL450 AND TRIP CONTINUED WITHOUT FURTHER INCIDENT. MAINT CREW RAN ENGINES ON GROUND TO VERIFY THROTTLE QUADRANT AND ENGINE RUN SWITCHES FUNCTIONALITY OF ENGINE RUN SWITCH CONFIRMED. EN GINE GROUND RUNS PERFORMED BEFORE AIRCRAFT RETURNED TO SERVICE. NO FURTHER CONCERNS WERE IDENTIFIED. 2 L 7 2 4F 4 F RT T00003NY E00061EN 2004041300030 20040413 00030 NM 2004 4 13 CA040319006 1 20040317 G 2421 700842A CSD BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE AC GENERATOR FAILED W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC TO TAKEOFF 1 CA (CAN) DURING TAKEOFF, IT WAS OBSERVED THAT ELECTRICAL POWER WAS LOST WITH NR 3 GENERATOR. A REJECTED TAKE-OFF WAS CARRIE D OUT AND AIRCRAFT RETURNED TO THE GATE WITHOUT INCIDENT. NR 3 ENGINE CONSTANT SPEED DRIVE WAS DISCONNECTED AND SYSTEM W AS DEFERRED IAW MEL 24-01. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004041600033 20040416 00033 SO 2004 4 16 CA040322007 2 20040311 G 8530 631397 CYLINDER HEAD CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE SEPARATED W O OTHER E D B VIBRATION/BUFFET INFLIGHT SEPARATION SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA 195786R (CAN) IN FLIGHT SEPARATION OF CYL NR 3 HEAD. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2004041600034 20040416 00034 NM 2004 4 16 CA040322008 1 20040322 G 2520 25606801 SEAT BACK BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE CABIN BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE IN THE AIR, SEATBACK 17K BROKE AT HINGE CAUSING PAX WHO WAS SITTING IN SEAT TO HURT THEIR BACK. YYZ MTCE TO REPAIR DURING O/NIGHT.STUD PIVOT PIN REPLACED. 2 L 7 2 4F 4 F RT A1NM E3NE 2004041600035 20040416 00035 WP 2004 4 16 CA040323001 1 20040318 G 4900 CSD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE APU OVERSERVICED W A UNSCHED LANDING W M J INADEQUATE Q C OVER TEMP WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE FROM FLL, LT CSD OIL TEMP WENT HIGH. GENERATOR SWITCHED OFF. AIRCRAFT LANDED BACK TO FLL DUE TO APU NOT START. MAINTENANCE FOUND LT CSD OIL OVERFILLED. CSD RESERVICED IAW MM AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004033000125 20040330 00125 NM 2004 3 30 CA040116005 1 20040104 G 2910 DSC3461 LINE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE HYDRAULIC SYS RUPTURED W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) AFTER ENGINE START NR 2 HYD CAUTION LIGHT ILLUMINATED, NR 2 QUANTITY NOTED TO BE DECREASING. A/C SHUT DOWN. LARGE HYDRAULIC LEAK FROM NR 2 ENGINE NOTED. FOUND PRESSURE LINE P/N DSC346-1 RUPTURED IN THE FLEXIBLE SECTION. LINE REPLAC ED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004033000143 20040330 00143 GL 2004 3 30 CA040209009 2 20040209 G 7397 JG7039C2C33 WIRE HARNESS CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13H 03004 GL FUEL QTY CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING WINTER MAINTENANCE INSPECTION, WIRES WERE FOUND RUBBING AGAINST EACH OTHER AT A FUEL QUANTITY TRANSMITTER P ROBE IN THE LT WING AT APPRX WS 253.0. ONE WIRE HAD CHAFED ENOUGH TO EXPOSED THE BARE WIRE. ALL OTHER AREAS IN BOTH W INGS WERE INSPECTED AT THE FUEL QUANTITY PROBES WITH NO OTHER DAMAGE NOTED. 2 L 7 2 4R 4 T 6A6 E282 2004033000149 20040330 00149 EA 2004 3 30 CA040210001 1 20040209 G 3310 2LA00691307 LIGHT CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT INOPERATIVE W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) THE FLIGHT CREW REPORTED, ON POWER UP, SMOKE COMING FROM THE RT SIDE OF COCKPIT. ADDITIONAL INFORMATION IS THAT T HE SMOKE WAS COMING FROM AROUND THE FO WINDSHIELD/WINDOW POST. MAINTENANCE DEFERED THE FLIGHT DECK FLOOD LIGHTS IAW MEL 33-11-01, AND RETURNED THE AIRCRAFT TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004033000156 20040330 00156 EU 2004 3 30 CA040120006 1 20040120 G 5610 NP1752321 WINDSHIELD AIRBUS A330 A330* EU RROYCE RB211 RB211TRENT77 NE COCKPIT BROKEN W A UNSCHED LANDING O OTHER CL CLIMB 1 CA 14463 (CAN) AFTER TAKE OFF, CLIMBING THROUGH 10000 FT, THE CAPTS SLIDING WINDOW SHATERED. CREW ELECTED TO RETURN TO CDG AND L ANDED APPROX 35000 KG OVER MLW. CAPTS SIDE WINDOW CHANGED IAW 56-12-11. PARTS: SLIDE WINDOW MPN NR NP175232-1 INSTALLED. OUTER STRUCTURAL PANE WAS SHATERED ON CAPTS SLIDING WINDOW (NO) DAMAGED REPORTED ON STRUCTURE. 2 L 7 2 4F 4 F RT A46NM E39NE 2004033000157 20040330 00157 CE 2004 3 30 CA040120007 1 20040118 G 2435 M230881320 BRUSHES LUCAS BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE STARTER GEN WORN W K NONE O OTHER IN INSP/MAINT 1 CA 98048 (CAN) DURING FLEET WIDE INSPECTION OF PREMATURE BRUSH WEAR. THIS UNIT FOUND TO HAVE EXCESSIVE WEAR. 149.4 SINCE TBO.618 HRS OF BRUSH WEAR REMAINING. TBO 1500 HRS. VENDOR IN CONTACT WITH BRUSH MANUFACTURER. OTHER OPERATORS FINDING SIMILAR SDR ALERT WOULD SPEED RECTIFICATION PROCESS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004033000172 20040330 00172 CE 2004 3 30 AUS20040009 1 20040105 G 7120 26011895 SUPPORT CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE HARTZL H3B3M HCB3M GL ENGINE MOUNT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE SUPPORT HOUSING FOR AIR CONDITIONER DRIVE LEAKING OIL. INVESTIGATION FOUND THE SUPPORT HOUSING ALIGNMENT SP IGOT TO BE TOO LONG TO FIT INTO THE RECESS IN THE ENGINE MOUNT PAD. THESPIGOT BOTTOMS OUT ON THE SEAL CARRIER CAUSING A 0.33MM (0.013IN) GAP ON THE GASKET FLANGE. THE SPIGOT BOTTOMING ON THE PAD CAUSES EXCESSIVE WEAR ON THE DRIVE SHAFT SPLI NES PN 2601267-2 AND THE INTERNAL SPLINES ON THE DRIVE GEAR PNO 3100450-01. 1 H 7 1 3T 3 T A37CE E4EA 5 C P9NE 2004033000177 20040330 00177 NM 2004 3 30 AUS20040014 1 20040105 G 2781 189929 PROXIMITY SWITCH BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU SLATS FAULTY W O OTHER N FALSE WARNING CR CRUISE 1 AU S 196670 (AUS) NR 3 LEADING EDGE SLAT PROXIMITY SWITCH FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004033000178 20040330 00178 2004 3 30 AUS20040015 4 20040114 G 6113 05502636 SUPPORT MCAULY CESSNA 172 172H 2072424 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL SPINNER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 30 (AUS) PROPELLER SPINNER FORWARD SUPPORT CRACKED AROUND PROPELLER BOLT ATTACHMENT HOLES. SUPPORT HAD BEEN FITTED 30 HOU RS AGO DUE TO THE SAME PROBLEM WITH THE PREVIOUS SUPPORT. 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2004040100163 20040401 00163 SO 2004 4 1 2004FA0000256 1 20040116 G 5720 62371008 HINGE PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA IB RT AILERON WORN D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 EA 01 56264 28R7535212 RECEIVED 2 NEW HINGES FROM API WITH EXCESSIVE PLAY BETWEEN PIN AND HINGE HALFES. DATE CODES: 12/23/03 AND 01/16/04. H INGES ARE MADE BY AC MFG. 1 L 7 1 3O 3 O 2A13 1E10 2004040100166 20040401 00166 SO 2004 4 1 2004FA0000259 2 20040207 G 8530 SA10200A1 CYLINDER CESSNA 150 150F 2071814 CE CONT O200 O200A 17020 SO NR 4 BROKEN G O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 15 8745S 841 15062045 AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING A FORCED LANDING AFTER TOTAL LOSS OF ENGINE POWER. INVESTIGATION SHOWED THE C YLINDER HAD COMPLETELY SEPARATED IN THE MIDDLE WHILE IN FLIGHT, CAUSING THE TOTAL LOSS OF POWER. 1 H 7 1 3O 3 O 3A19 E252 2004040500003 20040405 00003 CE 2004 4 5 CA040309001 1 20040303 G 7603 1143890503 CONTROL CABLE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL POWER LEVER SEVERED W E D ENGINE SHUTDOWN RETURN TO BLOCK W E INADEQUATE Q C VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) AFTER LANDING AND SUBSEQUENT TAXI THE RT ENGINE SPOOLED UP AND DID NOT RESPOND TO POWER LEVER MOVEMENT. THE ENGINE WAS SHUT DOWN AND THE AIRCRAFT COMPLETED TAXI TO THE TERMINAL ON THE LT ENGINE. MAINTENANCE INVESTIGATED AND DISCOVERED THAT THE POWER LEVER CABLE HAD BEEN SEVERED BY THE PULLEY OF THE VAPOR CYCLE AIR CONDITIONING SYSTEM. THE CABLE HAD BEE N ROUTED TOO CLOSE TO THE PULLEY DURING AN ENGINE REMOVAL AND REINSTALLATION 64 HOURS PRIOR TO THE INCIDENT. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004040500014 20040405 00014 SO 2004 4 5 CA040310009 1 20040310 G 3230 WTC345 POWERPACK PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) WHEN THE PILOT SELECTED GEAR UP, ONE OF THE GEARS WAS NOT RETRACTING AND THE TRANSITION LIGHT REMAINED ILLUMINATED . AFTER SEVERAL ATTEMPTS THE GEAR RETRACTED AND EVERYTHING WAS NORMAL. THE POWER PACK WAS REPLACED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040500015 20040405 00015 NM 2004 4 5 CA040310010 1 20040309 G 5610 NP15790213 WINDOW DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE COCKPIT BROKEN W O OTHER O OTHER CL CLIMB 1 CA (CAN) AFTER TAKEOFF THROUGH 6000 FT. THE OUTER PANE OF THE CAPTAIN'S SIDE WINDOW SHATTERED. THERE WAS NO NOTICEABLE CHAN GE IN PRESSURIZATION. THE CAPTAIN DEPRESSURIZED THE AIRCRAFT AND THE FLIGHT RETURNED WITHOUT FURTHER INCIDENT. DETERMINE D TO BE OUTER PLY (NON-STRUCTURAL).WINDOW SPEED TAPED AND DETERMINED TO BE SAFE FOR FERRY. A/C FERRIED FOR REPAIRS. LOG PAGE 343040 AND 343041 EXPLAIN THE DEFECT AS DESCRIBED ABOVE, AND DESCRIBE THE RECTIFICATION DETAILS TO BE AS FOLLOWS: LT SIDE WINDOW REPLACED, AND TEMP CONTROLLER REPLACED. LT SIDE WINDOW P/N NP157902-13, S/N 00213H4459 TEMP CONTROLLER P/N SYLZ50970, S/N 724C REASON FOR FAILURE NOT YET DETERMINED. TEAR DOWN REPORTS TO FOLLOW. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004040500017 20040405 00017 NM 2004 4 5 CA040311002 1 20040208 G 6120 697073002 PITCH CONTROL BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NR 1 PROP INOPERATIVE W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 CA (CAN) AIRCRAFT EXPERIENCED NR 1 PROPELLER TO FEATHER PITCH JUST AFTER TAKEOFF POWER WAS SET ON. PIREP RATING POWER SET, NR 1 ENG TORQUE INDICATION IN TURNED RED AND PROPELLER RPM DECREASED TO 200RPM. CONDITION LEVER MOVED TO START/FEATHER THEN BACK TO MAX BUT NO HELP. TAKE OFF REJECTED. NR 1 PROP REMAINED FEATHERED DURING TAXI TO GATE. PP FAULTS CHECKED, NO FAULTS. EMU DOWNLOAD, NO PP EXCEEDENCE RECORDED. ENGINE RUN-UP CHECKS, COULD NOT DUPLICATE. CLEANED FADEC, PEC AND PCU CONNECTORS. REPLACED NR 1 PCU FOR TROUBLESHOOTING. AIRCRAFT RTS. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004040500019 20040405 00019 EU 2004 4 5 CA040311005 1 20040310 G 2822 9868411404 PUMP PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL FUEL BOOST INOPERATIVE W K NONE J WARNING INDICATION CR CRUISE 1 CA (CAN) WHILE IN CRUISE FLIGHT THE PILOT NOTED A 2 LED DIFFERENCE BETWEEN LT AND RT FUEL INDICATORS. A FEW MINUTES LATER T HE RT BOOST PUMP LT INDICATOR CAME ON. THE LT REMAIN ON FOR THE DURATION OF THE FLIGHT AND THE FUEL IMBALANCE REMAINED. ON THE GROUND THE FUEL BOOST PUMPS WERE TESTED MANUALLY. THE RT BOOST PUMP INDICATED NORMALLY BUT NO SOUND OF THE PUMP RUNNING WAS NOTED. THE FUEL PUMP WAS REPLACED AND THE SYSTEM TESTED SERVICEABLE. NO FURTHER ACTION WAS REQUIRED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004040500022 20040405 00022 NE 2004 4 5 CA040311008 2 20040308 G 7230 3040933 DISK PWA PT6 PT6A67B 52043 NE COMPRESSOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ENGINE WAS STRIPPED AS PART OF ROUTINE SCHEDULED OVERHAUL. VISUAL EXAMINATION OF HPC DISK 3 SHOWS CRACK IN RIM OF DISK. FURTHER INVESTIGATION IS UNDERWAY. 4 T E26NE 2004040500023 20040405 00023 WP 2004 4 5 CA040311009 1 20040310 G 3220 STRUT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NLG DEFLATED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB OUT, L/G SELECTED UP, NOSE GEAR UNSAFE LIGHT ON WITH ASSOCIATED BUFFERING & NOISE. AIRCRAFT LANDED. M AINTENANCE FOUND NOSE OLEO DEFLATED. NOSE STRUT SERVICED, GEAR RETRACTION CARRIED OUT AND AIRCRAFT DISPATCHED SERVICEABL E. 2 L 7 2 4F 4 F RT A6WE E9NE 2004040500027 20040405 00027 SO 2004 4 5 CA040312003 2 20040312 G 8530 C8512F CYLINDER HEAD CESSNA 120 120 2071402 CE CONT C85 C8512F 17008 SO MCAULY 1B90 1B90CM GL ENGINE MISALIGNED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) ENGINE WAS SENT TO ENGINE SHOP FOR PROP STRIKE INSPECTION. UPON REINSTALLATION OF NR 1 CYLINDER, IT WAS DISCOVERE D THAT THE BARREL AND HEAD WERE MISALIGNED BY APPROX. 5 DEGREES (UNIT WAS REPLACED). ENGINE SHOP ADVISES THIS IS A DEFE CT OCCURING DURING ORIGINAL ASSEMBLY AT THE FACTORY AND FURTHER ADVISE THAT THIS IS THE SECOND ONE THEY HAVE FOUND. 1 H 7 1 3O 3 O A768 E233 5 N P842 2004040500028 20040405 00028 NM 2004 4 5 CA040312004 1 20040311 G 3230 ACCESSORY UNIT BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE MLG FAULTY W L ABORTED APPROACH N FALSE WARNING LD LANDING 1 CA (CAN) DURING APPROACH AND LANDING GEAR HANDLE EXTENDED, IT WAS OBSERVED THAT THERE WAS AN UNSAFE LT LANDING GEAR LIGHT. IT WAS DECIDED THAT A MISSED APPROACH WOULD BE CARRIED OUT AND GO AROUND. EMERGENCY PROCEDURES WERE CARRIED OUT. TOWE R WAS NOTIFIED OF THE PROBLEM AND EMERGENCY EQUIPMENT WAS MADE READY. IT WAS CONFIRMED THE GEAR WAS DOWN AND LOCKED AND THE LANDING WAS PERFORMED WITHOUT INCIDENT. MTCE INSPECTED THE AIRCRAFT AND THE LANDING GEAR ACCESSORY UNIT WAS SWAPPED WITH ANOTHER AIRCRAFT FOR TROUBLESHOOTING. IT WAS CONFIRMED THAT THE L/G ACCESSORY UNIT WAS AT FAULT AND A SERVICEABLE UNIT WAS INSTALLED, ADJUSTED AND FUNCTIONED SERVICEABLE IAW MM 32-09-121. NO FAULT DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004040600002 20040406 00002 SO 2004 4 6 CA040315003 1 20040310 G 3245 650X10600X6 TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL NLG FLAT W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) A/C DEPARTED WITH 10KT WINDS AND BLOWING SNOW. A/C MADE ROUTINE TAKE OFF AND FLIGHT. AFTER LANDING, DURING TAXI ON RUNWAY, PILOT NOTICED A/C WAS PULLING TO ONE SIDE. PILOT TAXIED OFF RUNWAY AND PARKED. HE THEN VISUALLY INSPECTED LT MA IN TIRE AND SAW IT WAS FLAT. MAINT WAS DISPATCHED. MAINT REPLACED MAIN WHEEL AND INSTALLED NEW TUBE IN NOSE WHEEL. UPON INSP MAIN ASSY HAD A SHEARED VALVE STEM AND NOSE TUBE HAD A PIN HOLE IN IT. CAUSE OF SHEARED VALVE STEM IS BELIEVED T O HAVE BEEN FROZEN BRAKES. CAUSE OF PIN HOLE IN THE NOSE TUBE IS BELIEVED TO HAVE BEEN THE CHANGE IN TEMPERATURE BETWEE N AREA OF DEPARTURE AND AREA OF ARRIVAL CAUSING WHEEL PRESSURE TO HAVE GONE DOWN AND TUBE GETTING PINCHED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040600003 20040406 00003 CE 2004 4 6 CA040315004 1 20040311 G 2510 05130391 LIGHTER CESSNA 172 172N 2072434 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL COCKPIT SHORTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) SMOKE/ FUMES DETECTED IN COCKPIT DURING CRUISE FLT. CREW SURVEYED ELECTRICAL SYSTEM CONTROLS AND FOUND CIGAR LIGH TER TO BE HOT. REMOVED LIGHTER FROM DASH AND RETURNED TO BASE WITH NO FURTHER COMPLICATIONS. INSPECTION REVEALED COILS O F LIGHTER SHORTED CAUSING FUMES. MAINTENANCE DISCONNECTED POWER WIRE TO LIGHTER ASSEMBLY IAW AD 78-08-03. NOTE: THIS AD DOES NOT APPLY TO THIS A/C SN BUT CERTAINLY WAS AFFECTED IN THIS INSTANCE, SHIPS AFFECTED BY THIS SN SHOULD BE REVISITE D BY THE AD ISSUER. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004041300016 20040413 00016 SO 2004 4 13 CA040315014 2 20040312 G 8530 538684 BUSHING CIRRUS SR SR20 05628AJ GL CONT O360 IO360ES SO HARTZL HCJ2Y BHCJ2YF1 GL ENGINE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 357431 (CAN) DURING OIL CHANGE, NOTED A .5000 LONG X .1250 INCH WIDE ROUND PIECE OF WHAT APPEARS TO BE BUSHING MATERIAL STUCK O N THE OIL DRAIN PLUG S MAGNET. FOUND THE NR 5 CYLINDER CONNECTING ROD S PISTON PIN BUSHING HAD A MISSING PIECE WHICH MA TCHES THE PIECE FOUND ON THE OIL SUMP DRAIN PLUG. 1 L 7 1 3O 3 O NT A00009CH E1CE 5 C P37EA 2004041300017 20040413 00017 EU 2004 4 13 CA040316004 1 20040218 G 2435 03600923 BEARING LUCAS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL STARTER GEN WORN W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA 98103 (CAN) OPERATOR HEARD GRINDING NOISE DURING ENGINE START. NOISE WAS LOUDEST AT 10 PERCENT NG. ABORTED START AND INVESTI GATED. FOUND RADIAL PLAY AT FAN END OF ARMATURE. REPLACED STARTER GEN. SENT FAILED UNIT FOR REPAIRS. FOUND THE ADE B EARING HAD RADIAL PLAY, MEASURED .0045 INCH. INSPECTED FOR CORRECT ASSY AT PREV OVERHAUL, FOUND OK(BRG PART NR TOWARD A RMATURE). REMOVED BEARING. IT RATTLES, IS LOOSE, HAS CONSIDERABLE PLAY BOTH RADIALLY AND AXIALLY. IF LEFT IN SERVICE, THIS WOULD HAVE FAILED AND DESTROYED THE STARTER-GEN WITHIN AFEW HOURS. BEARINGS WERE REPLACED AND UNIT OVERHAULED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004041300018 20040413 00018 NM 2004 4 13 CA040316006 1 20040305 G 2897 W5200100718 WIRE BOEING 757 75728A 1384976 NM RROYCE RB211 RB211535E437 54555 NE PYLON CHAFED W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) RT SPAR FUEL SHUTOFF VALVE CB C1062 ACTIVATED DURING SHUTDOWN AFTER FLIGHT. CB WOULD NOT RESET, AND SPAR VALVE DIS AGREEMENT LIGHT ALSO ILLUMINATED. TROUBLESHOOTING REVEALED WIRE HAD CHAFING DAMAGE AT BULKHEAD LOCATED AT STATION PP ST N 208.40 VISIBLE BEHIND PANEL 313N5018. WIRE WAS REPAIRED IAW SWPM20-30-12. GIVEN THE PROBLEM IS IN THE FLAMMABLE ARE A OF THE NACELLES, IT IS SUGGESTED THAT THE COMPLETE WIRE BUNDLE CONTAINING WIRE W5200-1007-18 BE INSPECTED REPAIRED AN D PROTECTED AS REQUIRED BETWEEN CONNECTION POINTS AT D92292J AT BRACKET AN2285 TO THE VALVE CONNECTOR D2022 AT STN PP ST N 265.60AFTSN 7524:36 AFCSN 2509 2 L 7 2 4F 4 F RT A2NM E12EU 2004041300021 20040413 00021 CE 2004 4 13 CA040317004 1 20040311 G 5520 115610010125 SPLINE BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON INSPECTION FOUND THREE VISUAL CRACKS IN OB SECTION OF THE ELEVATOR TRAILING EDGE SPLINE, AS DESCRIBED IN OTHER SDR'S /SERVICE DIFFICULTY ADVISORY. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2004041300022 20040413 00022 EA 2004 4 13 CA040318001 2 20040309 G 7250 3032151 RING BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA ENGINE VANE BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE HOT END BORESCOPE INSPECTION, HOT END DISTRESS WAS NOTED. POWER SECTION REMOVED FROM AIRCRAFT, HOT END REMOVED. COMBUSTION CHAMBER CRACKED (MANY) ON NR 2 LOUVERED COOLING RING. SMALL DUCT BURNED/WARPED IN TWO AREAS (V ANES). VANE RING ASSEMBLY, SEVERE BURNING ON 1 VANE AT TRAILING EDGE APPROXIMATELY .5 SQUARE INCH MISSING. ADJACENT VA NE TRAILING EDGE CRACKED. VANE RIM BURNED AND CRACKED (3032151). HOUSING ASSEMBLY, CT SHROUD, ONE SEGMENT 3018503 WARPE D INWARD CAUSING CT BLADE CONTACT. BLADE LEADING EDGE AT TIP ROUNDED. DISK/BLADE ASSEMBLY, CONTACT WITH WARPED BLADE S HROUD SEGMENT. 1 G 7 1 4U 4 U H4SW E22EA 2004041300026 20040413 00026 WP 2004 4 13 CA040318005 1 20040315 G 5610 5887275505 WINDSHIELD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) CENTER WINDSHIELD CRACKED IN FLIGHT AND SPARK, CREW DECIDED TO TURNBACK. THE CENTER WINDSHIELD WAS REPLACED IAW TH E MM 56-10-01. THE WINDSHIELD ANTI-ICE AND ANTI-FOG SYSTEM WAS CHECKED SERVICEABLE IAW THE AMM. 2 L 7 2 4F 4 F RT A6WE E9NE 2004041300027 20040413 00027 EU 2004 4 13 CA040319001 1 20040312 G 2731 Z4244120000 CONTROL CABLE MORAVN 242 Z242L 5920207 EU LYC O360 AEIO360A1B6 41514 EA MUHBR MTV MTV9* EU ELEVATOR TRIM FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 100 HOUR INSPECTION, IT WAS NOTICED THAT THE AFT TRIM CABLE HAD A BROKEN STRAND FORWARD OF THE RT PULLEY NEAR THE TRIM DRUM. THROUGH EXPERIENCE IT WAS FOUND THAT CONDITION WOULD LEAD TO A TOTAL FAILURE OF THE CABLE IN THE NE AR FUTURE. THE CABLE WOULD FRAY SO MUCH THAT IT WOULD BIND UP IN THE DRUM ASSEMBLY RENDERING THE ELEVATOR TRIM SYSTEM I NOPERABLE. THIS SYSTEM IS CLOSELY INSPECTED EVERY 100 HOUR INSPECTION DUE TO SIMILAR FAILURES OF THIS CABLE. 1 L 7 1 3O 3 O NT A76EU 1E10 5 C P24NE 2004042100019 20040421 00019 GL 2004 4 21 CA040326001 3 20040323 G 6114 PROPELLER PIPER J3 J3L65 7100546 SO CONT A65 A658F 17003 SO MCAULY 1B90 1B90CM GL CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CUSTOMER REQUESTED REPITCH ONLY. ADVISED CUSTOMER TO OVERHAUL DUE TO VISUAL CORROSION ON PROP CORROSION REMOVED IA W MANUAL 730720. 1 H 7 1 3O 3 O A698 E205 5 N P842 2004042200124 20040422 00124 NE 2004 4 22 2004FA0000309 2 20040401 G 7250 557501 TURBINE WHEEL PWA JT8 JT8D7B 52053 NE ENGINE WORN B ZAVR O OTHER O OTHER NR NOT REPORTED 1 WP 07 7381 4723 649049 T-1 DISC RUB ON INNER TURBINE NOZZLE CASE SEAL. SEAL COMPLETELY RUBBED OFF. 4 F E2EA 2004042200125 20040422 00125 CE 2004 4 22 2004FA0000296 1 20040325 G 5523 1695240761 ROD BEECH 23 C23 1151242 CE LYC O360 O360* 41514 EA TRIM TAB CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 09 24652 M1430 DURING ANNUAL INSPECTION THE TRIM TAB ROD WAS FOUND TO HAVE RUST ON IT. WHILE CLEANING THE PART, A HOLE WAS FOUND AT TH E MID POINT OF THE ROD AND MOISTURE(WATER) WAS FOUND INSIDE. IT APPEARS THIS ROD IS RUSTING FORM THE INSIDE OUT. THIS UNIT SHOULD BE TAKEN APART, INSPECTED, CLEANED, PAINTED INSIDE AND OUT AND REASSEMBLED TO ASURE THE AIRCRAFT HAS A SERVI CEABLE PART. (GL092004040017) 1 L 7 1 3O 3 O A1CE E286 2004033000180 20040330 00180 CE 2004 3 30 CA040121003 1 20040119 G 2752 66000863 ACTUATOR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP TE FLAP CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING PRE-FLIGHT INSPECTION FLUID LOSS WAS NOTED. FLAP ACTUATOR WAS FOUND TO HAVE A CRACKED BODY. 2 L 7 2 4F 4 F A10CE E6WE 2004040500002 20040405 00002 SO 2004 4 5 CA040308010 1 20040221 G 2731 4420000 TRIM SYSTEM PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL ELEVATOR TRIM LACK OF LUBE W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) PILOT REPORTED ELEVATOR TRIM JAMMED FULL FORWARD AND COULD NOT TRIM NOSE UP. ELEVATOR TRIM JACK FOUND NOT LUBRICA TED. SHAFT LUBRICATED, SYSTEM FUNCTIONS NORMAL. FORWARD TRIM JACK SPOOL CHECKED OK. SPOOLING AROUND ELECTRIC ACTUATOR CKECKED OK. CABLE TENSION CHECKED OK. AFT TRIM TAB ACTUATOR FREE PLAY CHECKED WITHIN LIMITS IN MM. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040500009 20040405 00009 SO 2004 4 5 CA040310003 1 20040226 G 2435 MHB4016B STARTER GEN PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL LT ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) AIRCRAFT WAS AT AIRPORT. AFTER STARTING THE RT ENGINE, THE PILOT WENT TO START THE LT ENGINE, THE ENGINE WOULD NO T TURN OVER, FOUND THAT THE STARTER WAS TURNING OVER BUT THE BENDIX WOULD NOT TURN. CHANGED LT STARTER ENGINE STARTED. NO FAULTS FOUND. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040500011 20040405 00011 EA 2004 4 5 CA040310005 2 20040108 G 8520 CAMSHAFT PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL ENGINE WORN W O OTHER J WARNING INDICATION CR CRUISE 1 CA L52772T (CAN) CAMSHAFT LOBES AND LIFTERS WEARING PREMATURALLY. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004040500013 20040405 00013 CE 2004 4 5 CA040310008 1 20040218 G 1430 A251352 BOLT MCAULY CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROPELLER SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA K19086 (CAN) UPON APPLICATION OF 27 FT/LBS TO 2 OF THE MOUNTING BOLTS AT THE THREADS FAILED. BOLTS FORWARDED TO COMPANY FOR E VALUATION. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004040500016 20040405 00016 CE 2004 4 5 CA040311001 1 20040310 G 3260 JE6 SWITCH CESSNA 310 310L 2074230 CE CONT O470 IO470VO 17026 SO HARTZL HCJ3Y PHCJ3YF2 GL MLG BROKEN W O OTHER O OTHER AP APPROACH 1 CA (CAN) UPON APPROACH THE LANDING GEAR WAS SELECTED DOWN WITH NO GREEN LIGHT DOWN AND LOCKED INDICATION ON THE RT GEAR. T HE GEAR WAS CYCLED, THE MANUAL EXTENSION WAS PERFORMED ALL WITH THE SAME RESULT. THE AIRCRAFT LANDED UNEVENTFULLY AND U PON INVESTIGATION THE MICRO SWITCH ACTUATOR TAB WAS FOUND BROKEN AT THE ATTACHING BRACKET. THE ACUATOR WAS REPLACED AND THE GEAR WAS SWUNG NUMEROUS TIMES SERVICEABLE. 1 L 7 2 3O 3 O 3A10 3E1 5 C P36EA 2004040500018 20040405 00018 WP 2004 4 5 CA040311004 1 20040307 G 2910 7936907615 LINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE HYD SYSTEM CRACKED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) ON DEPARTURE LT HYD PRESSURE LIGHT ILLUMINATED IN FLIGHT WITH HYD PRESS. READING ZERO. AIRCRAFT LANDED. MAINTENAN CE FOUND LT EDP INOPERATIVE. LT EDP SWAPPED WITH RT EDP AND AIRCRAFT DISPATCHED IAW MEL 29-5.EDP P/N AS666411-L-5666 S /N MX134145-4M. THE LT HYDRAULIC QTY LOW LIGHT ILLUMINATED IN FLIGHT WITH QTY INDICATION OF 3 QTS WITH SYSTEM PRESSURIZE D. FOLLOWING INVESTIGATION BY MAINTENANCE, FOUND LT PIPE ASSY-FUSELAGE SECTION HYD SYSTEM PRESSURE P/N 7936907-615 CRAC KED AT FLARE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004040500020 20040405 00020 GL 2004 4 5 CA040311006 2 20040302 G 8550 23038229 SEPARATOR AROFAL OH58 OH58C 1181580 SW ALLSN 250C T63A720 03002 GL OIL/AIR SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA AE405314 (CAN) ON DISASSEMBLY OF THE GEARBOX ASSEMBLY, THE AIR OIL SEPARATOR GEAR SHAFT WAS FOUND SHEARED AT THE JUNCTION OF GEAR AND SHAFT. THE ENGINE WAS SENT TO THE SHOP FOR METAL CONTAMINATION. THE AIRCRAFT HAD PREVIOUSLY BEEN INVOLVED IN A WIR E STRIKE. THE ENGINE RAN FOR 5 MINUTES AFTER THE STRIKE BUT BOTH CHIP DETECTORS HAD A LOT OF METAL. 1 G 7 1 3U 3 U NC H22NM E4CE 2004040500024 20040405 00024 EA 2004 4 5 CA040311010 2 20040309 G 8520 LW16812 LIFTER PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC3Y HCC3YR2 NE LT ENGINE SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA L44377T (CAN) DURING A ROUTINE INSPECTION, METAL CONTAMINATION WAS DETECTED IN THE FULL FLOW OIL FILTER CARTRIDGE ELEMENT. THE L IFTER ASSEMBLIES WERE REMOVED NEXT TO DETERMINE THEIR CONDITION. THIS HAS BEEN A RECURRING PROBLEM ON THIS MODEL ENGINE. THE SURFACE OF THE LIFTERS HAD EVIDENCE OF SPALLING AND SURFACE CHIPS. THE ENGINE WAS SUBSEQUENTLY REMOVED FROM THE AIR CRAFT FOR INSPECTION BY THE OVERHAUL SHOP. A S IMILAR INSPECTION WAS CARRIED OUT ON THE RIGHT ENGINE, HOWEVER THERE WAS NO EVIDENCE OF DAMAGE DUE TO THE CONDITION DESCRIBED ABOVE. 1 L 7 2 3O 3 O A19S0 E286 5 C P25EA 2004040500026 20040405 00026 EA 2004 4 5 CA040312002 2 20040309 G 8530 CONNECTING ROD PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE CRACKED W E A ENGINE SHUTDOWN UNSCHED LANDING E B VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA L230368A (CAN) DURING CRUSE, THE CREW HEARD NOISES COMING FROM THE NR 2 ENGINE, SHORTLY AFTER THERE WAS A LOUD BANG AND VIBRATION . THE CREW NOTICED OIL AND SMOKE COMING FROM THE ENGINE COWL, THE PROP WAS FEATHERED AND ENGINE STOWED. THE OIL HIT THE TURBOCHARGER AND IGNITED CAUSING FIRE TO FLOW ALONG THE LOWER WING AND CAUSED DAMAGE TO THE LOWER SKIN AND GEAR DOOR. TH E LOWER FLAP SKIN ALSO SHOWED SIGNS OF HEAT DAMAGE. THE A/C LANDED WITH NO FURTHER PROBLEMS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040600001 20040406 00001 NM 2004 4 6 CA040315002 1 20040313 G 8011 97907021 START VALVE BOEING 727 727243 138408D NM PWA JT8 JT8D9A 52048 NE NR 1 ENGINE CRACKED W K NONE O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING DEPARTURE CREW WAS UNABLE TO START NR 1 ENGINE. MAINTENANCE CALLED TO PERFORM A MANUAL START. FOUND THE B OTTOM OF THE START VALVE CRACKED AT THE ADJUSTMENT SCREW. VALVE REPLACED AND A/C DEPARTED. 2 L 7 3 4F 4 F RT A3WE E2EA 2004041300008 20040413 00008 GL 2004 4 13 CA040311003 2 20040210 G 7261 6896451 TRANSFER TUBE ALLSN 250C 250C30P 03013 GL OIL SYSTEM MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) FERRULE UNDER B NUT OF SCAVENGE OIL LINE FROM NR 8 BEARING WAS WRONGLY MANUFACTURED, CAUSING PENDING FRACTURE OF F LANGE. HAS CAUSED 360 DEGREE LINE AROUND THE BASE OF THE FLANGE. TUBE REPLACED, A/C RETURNED TO SERVICE. OIL LOSS AT T HIS LOCATION WOULD HAVE CAUSED OIL STARVATION TO NR 8 BEARING RESULTING IN ENGINE FAILURE. 3 U E1GL 2004041300020 20040413 00020 NM 2004 4 13 CA040316009 1 20040229 G 2750 M390166105L RELAY DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE TE FLAP CONTROL FAILED W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH FLAPS FAILED TO LOWER WHEN SELECTED. AIRCRAFT DID A GO AROUND AND THE PERFORMED AN UNEVENTFUL FLAPLESS LANDING. MAINTENANCE NOTED THAT FLAP POWER CAUTION LIGHT NOT OPERATING WHEN FLAP LEVER SELECTED. TROUBLESHOOTING DISCOV ERED RELAYS AT 2752-K2 AND 2752-K3 HAD FAILED. RELAYS REPLACED AND FLAPS FUNCTION CHECKED SERVICEABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004041300023 20040413 00023 SW 2004 4 13 CA040318003 1 20040309 G 6510 2120406883 COUPLING BELL BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA DRIVESHAFT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA A20218 (CAN) DRIVESHAFT UNDERGOING SCHEDULED 600 HR/12 MONTH INSPECTION/LUBRICATION. COUPLING HAS EXCESSIVE CORROSION. PART R EPLACED. COUPLING P/N 212-040-688-3. 1 G 7 1 4U 4 U H4SW E22EA 2004041600032 20040416 00032 NM 2004 4 16 CA040322002 1 20040319 G 5210 693741810 ROLLER CAM BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE PAX DOOR SHEARED W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) ON CLIMB OUT, CREW HEARD A LOUD BANG AND FELT A CORRESPONDING PRESSURE BUMP. UPON RETURNING TO THE APRON, IT WAS D ISCOVERED THAT THE AFT UPPER GUIDE ROLLER ON THE MAIN ENTRANCE DOOR HAD SHEARED OFF. AFTER INSPECTING THE DOOR, THE CREW ELECTED TO CONTINUE THE FLIGHT UNPRESSURIZED. THE A/C RETURNED TO A MAINTENANCE FACILITY WHERE THE DOOR WAS REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 2004042200148 20040422 00148 CE 2004 4 22 2004FA0000298 1 20040315 G 5312 07126167 BULKHEAD CESSNA 182 182P 2075816 CE CONT O470 O470* 17026 SO AFT FUSELAGE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 05 20844 2890 18261251 DURING COMPLIANCE WITH AD72-07-09 REFERENCED BUKHEAD WAS FOUND CRACKED PART REPLACED WITH NEW. SUSPECT FAILURE OCCURRED DUE TO AGE. 1 H 7 1 3O 3 O NT TA13 E273 2004042200186 20040422 00186 EA 2004 4 22 2004FA0000290 2 20040315 G 7414 COIL PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2A GL MAGNETO INOPERATIVE C O OTHER O OTHER NR NOT REPORTED 1 AL 01 712MA G03JA028R 317405217 L55868A DJ8171A WEAK COIL, SUSPECT BREAK DOWN IN COIL. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004042300012 20040423 00012 SW 2004 4 23 2004FA0000271 1 20040219 G 6720 407340334101 BEARING BELL 407 407 1182206 SW ALLSN 250C 250C47B GL T/R CONTROL SEIZED D O OTHER O OTHER NR NOT REPORTED 1 WP 17 601MT 843 53428 BEARING SEIZED DURING TRAINING FLIGHT, RESULTING IN D/S FAILURE AND LOSS OF T/R CONTROL ALLOWING THE TAIL ROTOR BLADES T O STRIKE TAILBOOM. (WP17200403114) 1 G 7 1 3U 3 U O H2SW E1GL 2004042700007 20040427 00007 NE 2004 4 27 2004FA0000272 2 20040213 G 7310 0301007710 PIPE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE LT FUEL INJECTOR CRACKED D O OTHER K R J FLUID LOSS PARTIAL RPM/PWR LOSS WARNING INDICATION TX TAXI/GRND HDL 1 SW 15 448AE 704 3210 9639 DURING ENGINE START AFTER CHANGING THE START DRAIN VALVE, LT FUEL INJECTOR PIPE WAS SPRAYING FUEL AT INJECTOR FITTING. INSPECTION OF PIPE REVEALED A CACK AT THE TOP OF THE FLARE ON THE PIPE. CAUSE OF CRACK APPEARS TO BE FROM THE FLARE NOT BEING CENTERED ON THE LINE DURING MANUFACTURE. 1 G 7 1 3U 3 U H9EU E19EU 2004042700008 20040427 00008 CE 2004 4 27 2004FA0000274 1 20040217 G 3220 5082020517 DRAG BRACE BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA HARTZL HCE4A HCE4A3A NE NLG CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 03 842E UE336 THE LOWER BOLT WAS SEVERELY CORRODED IN PLACE REQUIRING IT TO BE DRIVEN OUT FOR REPLACEMENT. THIS BOLT, CENTER DRAG BRA CE ASSY PIVOT, IS LUBRICATED ON BOTH ENDS VIA THRU BOLT GREASE PROVISIONS. THE CENTER PORTION HAS NO PROVISION FOR GREA SE SINCE THIS AREA IS NON ROTATING. THERE IS NO REQUIREMENT TO REMOVE THIS BOLT UNTIL THE 5 YEAR OVERHAUL BY WHICH TIME THE BOLT AND DRAG BRACE HAVE CORRODED TO THE POINT OF REQUIRING REPLACEMENT. 2 L 7 2 4T 3 T RT A24CE E2NE 5 C P10NE 2004042700043 20040427 00043 EA 2004 4 27 2004FA0000278 2 20040223 G 8520 LW11750 CONNECTING ROD PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA ENGINE BROKEN G A UNSCHED LANDING R Y PARTIAL RPM/PWR LOSS ENGINE STOPPAGE CR CRUISE 1 GL 03 3370W 6526 1381 32216 L1034040 WHILE IN CRUISE FLIGHT, ENGINE STARTED TO RUN ROUGH, CATASTROPHIC ENGINE FAILURE OCCURED. PILOT MADE AN EMERGENCY LANDI NG, MINOR DAMAGE TO AIRCRAFT. INSPECTION OF FAILED ENGINE REVIELD A BROKEN NR 1, (ONE) CONNECTING ROD. 1 L 7 1 3O 3 O A3SO E295 2004042700047 20040427 00047 2004 4 27 2004FA0000140 4 20040128 G 6113 SPINNER AMTR RV4 RV4 GL LYC O320 O320E2C 41508 EA SNSNCH 70C 70CM6 EA PROPELLER MISINSTALLED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 227MJ 33609K PROPELLER DAMAGED BEYOND REPAIR DUE TO IMPROPER SPINNER INSTALLATION. 1 L 7 1 3O 3 O NC EXPA1L71 E274 5 N P28NE 2004042800029 20040428 00029 EA 2004 4 28 CA040317003 2 20040309 G 7200 ENGINE PWA PT6 PT6A27 52043 EA FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 11359 (CAN) ENG WAS REMOVED FROM WING, NOTED HIGHER THAN NORMAL OIL TEMP, OIL DISCOLORATION. UPON REMOVAL, EXH DUCT WAS MISSI NG SECT OF INNER DUCT EXPOSING PT SHAFT HSG TO EXH GASES. IT WAS FOUND THAT REAR SECTION OF EXH DUCT INNER SKI JUMP S ECTION, EXTENDING FWD FROM NR 3 BRG END ABOUT 5 INCHES HAD DISAPPEARED. SAME SECTION OF INSULATION BLANKET HAD ALSO DIS APPEARED. IMPACT MARKS IN ONE EXH PORT AREA, NO SIGNIFICANT DAMAGE TO PT DISK, BLADES INDICATING THAT EXH DUCT SKIN HA D FRACTURED INTO A LARGE NR OF SMALL PIECES. THERE WERE A NR OF CRACKS EMANATING FROM SURFACE CORROSION PITS IN AREAS A WAY FROM FRACTURE EDGES THAT EXTENDED ACROSS DUCT WALL. MATERIAL DEGRADATION WAS PRIMARY CAUSE, FAILURE OF THIS DUCT. 4 T E4EA 2004042900004 20040429 00004 NM 2004 4 29 AUS20040019 1 20040114 G 2910 AN81510D COUPLING DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE HYD MANIFOLD FRACTURED W O OTHER K FLUID LOSS DE DESCENT 1 AU S (AUS) NR 2 HYDRAULIC SYSTEM PRESSURE MANIFOLD INLET UNION FRACTURED. LOSS OF HYDRAULIC FLUID. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004042900005 20040429 00005 SO 2004 4 29 AUS20040020 1 20040115 G 5540 63502000 HINGE PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA MCAULY 1C160 1C160EGM GL RUDDER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER RUDDER HINGE BRACKET CONTAINED SEVERE CORROSION EXTENDING TO APPROXIMATELY 50 PERCENT OF THE DEPTH OF THE BR ACKET. 1 L 7 1 3O 3 O 2A13 E274 5 N P910 2004042900012 20040429 00012 EU 2004 4 29 AUS20040027 1 20040118 G 2120 UNKNOWN AIRBUS 330 A330300 EU GE CF6 CF680 30025 NE GALLEY FUMES W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) PLASTIC SMELLING FUMES IN REAR GALLEY. INVESTIGATION COULD FIND NO CAUSE FOR THE FUMES. 2 L 7 2 4F 4 F RT E13NE 2004042900013 20040429 00013 NM 2004 4 29 AUS20040028 1 20040118 G 5523 65C2638415A TRIM TAB BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU ELEVATOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR TAB FREE PLAY EXCEEDED MAXIMUM LIMIT OF 0.9144MM (0.036IN). FREE PLAY MEASURED 1.143MM (0.045IN). FOUND DURING INSPECTION IAW AD/B737/175 AND EI 737-55-12R5. 2 L 7 2 4F 4 F RT A16WE E21EU 2004042900018 20040429 00018 CE 2004 4 29 AUS20040033 1 20040120 G 3230 EVE4001 MOTOR BEECH 76 76 1153005 CE LYC O360 O360A1G6D EA HARTZL HCM2Y HCM2YR GL HYD PUMP FAULTY W O OTHER O OTHER LD LANDING 1 AU S 108 (AUS) LANDING GEAR HYDRAULIC PUMP ELECTRIC MOTOR FAULTY. INVESTIGATIONFOUND BROKEN WIRE IN THE MOTOR WINDINGS. 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2004042900021 20040429 00021 SO 2004 4 29 AUS20040036 1 20040120 G 3241 396512 VALVE EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14SF 14SF9 NE ANTISKID SYS FAULTY W O OTHER O OTHER LD LANDING 1 AU S (AUS) LT IB BRAKE ANTISKID VALVE SUSPECT FAULTY. BRAKE LOCKED ON LANDING CAUSING FAILURE OF BRAKE UNIT AND DEFLATION OF MAIN WHEEL TIRE. 2 L 7 2 4T 4 T RT A31SO E20NE 6 N P11NE 2004042900022 20040429 00022 CE 2004 4 29 AUS20040037 1 20040121 G 5744 58244659 BRACKET CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING OB AILERON ATTACHMENT BRACKET CRACKED. INVESTIGATION FOUND INDICATIONS OF SURFACE INTERGRANNULAR CORROSIO N AND CONFIRMATION OF A CRACK LOCATED APPROXIMATELY 3.175MM (0.125IN) BEHIND THE BEARING HOUSING. CRACK LENGTH APPROXIMA TELY 12.7MM (0.5IN). 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004042900023 20040429 00023 NM 2004 4 29 AUS20040038 1 20040122 G 2752 7341529001 ACTUATOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL TE FLAP FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TRAILING EDGE FLAP POWER DRIVE UNIT BYPASS VALVE ROTARY ACTUATOR FAULTY. INVESTIGATION FOUND THE ROTARY ACTUATOR PURPLE INDICATION ARM PIVOT RETAINING PIN ADRIFT AND CAUSING INTERFERENCE BETWEEN THE ACTUATOR DRIVE AND ACTUATOR HOUSIN G. 2 L 7 2 4F 4 F RT A1NM E23EA 2004042900024 20040429 00024 NM 2004 4 29 AUS20040039 1 20040123 G 7830 CF680C2 THRUST REVERSER BOEING 747 747438 NM GE CF6 CF680C2* GL ENGINE FAILED W O OTHER E VIBRATION/BUFFET LD LANDING 1 AU S (AUS) NR 3 AND NR 4 ENGINE THRUST REVERSERS FAILED TO OPERATE. SUSPECT CAUSED BY FROZEN LINE TO PILOT VALVE. LOCAL TEMP ERATURE WAS 15 DEGREES F (-9.5 DEGREES C). BOTH THRUST REVERSERS OPERATED SATISFACTORY FOLLOWING HEATING AND RECYCLING OF CIRCUIT BREAKER. NR 1 ENGINE THRUST REVERSER WAS ALREADY LOCKED OUT. 2 L 7 4 4F 4 F RT A20WE E23EA 2004042900025 20040429 00025 2004 4 29 AUS20040040 4 20040123 G 2215 6225734002 SERVO EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE AUTOPILOT FAULTY W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S 3902 (AUS) AUTOPILOT CAUSED AIRCRAFT TO PITCH UP ON APPROACH. INVESTIGATION FOUND ELEVATOR AUTOPILOT SERVO FAULTY. RT ENGIN E OVERTORQUED TO 134 PERCENT AND LT ENGINE OVERTORQUED TO 125 PERCENT DURING RECOVERY FROM AUTOPILOT MALFUNCTION. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2004042900026 20040429 00026 NM 2004 4 29 AUS20040041 1 20040124 G 2710 256T34304 GEARBOX BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AILERON CONTROL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 7860 (AUS) RT INBOARD AILERON ANGLE GEARBOX FAULTY. 2 L 7 2 4F 4 F RT A1NM E23EA 2004042900028 20040429 00028 NM 2004 4 29 2004FA0000330 1 20040303 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 15 902PD 399 106 0099990078 DURING ACCOMPLISHMENT OF AD 2002-10-05 INSP. (MAIN ROTOR UPPER HUB INSP.) FOUND (2) OUT OF (10) FLANGE BOLT HOLES WITH C RACKS AS DEPICTED IN MFG SERVICE BULLETIN 900-072. CRACKS RUN RADIALLY FROM BOLT HOLE INWARD TO FLANGE EDGE. PART TOTAL TIME WAS 399.65 HRS. UPPER HUB WAS FLOWN 106 HRS WITH MFG SERVICE BULLETIN 900-093 (INCREASED BOLT TORQUE) INCORPORATED. REMOVED AND REPLACED HUB WITH SERVICEABLE PART IAW MFG MM. 1 G 7 2 3U 3 U NC H19NM E42NE 2004042900037 20040429 00037 SW 2004 4 29 2004FA0000333 1 20040325 G 6220 2040121127 STRAP BELL BELL 204 UH1H 1181407 SW LYC T53 T53L13B 41549 NE M/R HEAD CRACKED B K NONE O OTHER IN INSP/MAINT 1 NM 04 667HP 4815 131 ARA0638 659952 22986B AIRCRAFT WAS EXPERIENCING VIBRATIONS DURING FLIGHT, MAINTENANCE WAS UNABLE TO REMOVE THE VIBRATION THROUGH TRACK AND BAL ANCE PROCEDURES. THE MAIN ROTOR ASSEMBLY WAS REMOVED FOR INSPECTION. DURING THE INSPECTION A TENSION-TORSION STRAP WAS F OUND CRACKED AT BOTH ENDS WHERE THE PINS HOLD THE STRAPS IN PLACE. UPON FURTHER INVESTIGATION IT WAS DISCOVERED THAT THE STRAPS INSTALLED WERE NOT THE PROPER STRAPS FOR THIS M/R HEAD CONFIGURATION. 1 G 7 1 4U 4 U EXPA1G71 E17EA 2004042900041 20040429 00041 NM 2004 4 29 SROM200400033 1 20040325 G 5330 65C80736834 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION C/W 069 LOG 4755642 REPLACE SKIN PANEL BS 908 - 1016 STR 20L TO 25L. REMOVED SKIN PANEL, RECE IVED AND INSTALLED NEW SKIN PANEL IAW MFG SRM 51-30-2. 2 L 7 2 4F 4 F RT A16WE E2EA 2004042900042 20040429 00042 NM 2004 4 29 SROM200400034 1 20040328 G 5330 DOUBLER BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION FOUND DENT AT STA 338 TO 344 JUST BELOW FWD AIRSTAIR DOOR CUTOUT BEYOND LIMITS IAW SRM 53-30-1 FIG 1 DETAIL 3. REF. SAD LOG 0176053 BEYOND LIMITS DUE TO CHANGES TO SRM INCLUDING PROXIMITY TO CUTOUTS AND SEAMS. RE MOVED DAMAGED DOUBLER, FABRICATED AND INSTALLED REPLACEMENT REPAIR DOUBLER IAW ASA EA 5310-02327 AND AAR 10300. 2 L 7 2 4F 4 F RT A16WE E2EA 2004042100018 20040421 00018 EA 2004 4 21 CA040325003 2 20040322 G 7314 69159 ADAPTER PIPER PA31 PA31300 7103104 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL ACC CASE BROKEN W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) OIL LOSS WAS NOTED BY PILOTS AS THE OIL PRESSURE DROPPED. INFLIGHT SHUTDOWN WAS INITIATED. ON LANDING, MAINTENANCE DISCOVERED THAT THE ENGINE DRIVEN FUEL PUMP DRIVE ADAPTER HAD BROKEN AND CAUSED THE LOSS OF OIL FROM THE ACCESSORY CASE . ALSO NOTED WAS THAT THE EDFP IDLER GEAR HAD BROKEN GEAR TEETH. P/N OF THE IDLER GEAR IS LW-10324. ENGINE HAS BEEN REMO VED AND SENT FOR REPAIR OR OVERHAUL. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004042200133 20040422 00133 EU 2004 4 22 2004FA0000280 1 20040226 G 6320 7052A3652038 PLUG UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE GEARBOX LOOSE D E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 SW 17 1240W 1240 PILOT STARTED ENGINE, COMPLETED CHECKLIST AND (BEEPS) IN HEADSET AND VISUAL WARNING ON CAUTION PANEL OF MAIN GEAR BOX (L OW OIL PRESSURE). SHUT DOWN ENGINE AND OPENED COWL, TRANSMISSION FILLED WAS COVERING BOTH ENGINE DECK AND TRANSMISSION DECK. DISCOVERED THAT THE BLANKING PLUG HAD COME LOOSE FROM TRANS INPUT FLANGE CAUSING LOSS OF TRANS FLUID. THIS (LOOS E BLANKING PLUG) ADDRESSED IN ALERT SB 63-003, WHEN THIS EVENT HAPPENS IT IS NOT JUST A SMALL LEAK WITH MINOR CONSEQUENC ES, BUT A MAJOR LEAK, EMPTYING THE TRANSMISSION WITHIN A SHORT PERIOD CAUSING A POWER REDUCTION IAW FLIGHT MANUAL, A RUN ON LANDING, OR POSSIBLE CRASH. 1 G 7 2 3U 3 U NC R0001RD E34NE 2004042300016 20040423 00016 SO 2004 4 23 2004FA0000277 2 20040224 G 8530 CYLINDER PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO ENGINE LEAKING B FFKR O OTHER O OTHER NR NOT REPORTED 1 SO 05 1063X 1058 394 347570198 807611R VALVE COVER GASKETS ON RT ENGINE WERE SEEPING. PROCEEDED TO CHANGE GASKETS ON NR 1 CYLINDER AND DISCOVERED THE LOCKING SAFETY FOR THE NUTS ON THE VALVE ROCKER ARM WERE NOT BENT TO SECURE THE NUT FROM BACKING OFF. INSPECTED ALL 6 CYLINDERS AND FOUND ALL SIX TO BE IN THE SAME CONDITION. CHECKED TORQUE ON THE NUTS AND BENT LOCK TANGS. NO FURTHER ACTION WAS REQUIRED. AFTER REVIEW OF ENGINE LOG BOOK, THIS ENGINE WAS DISASSEMBLED IN APRIL OF 2003 FOR A PROP STRIKE. SUSPECT TH IS TO BE AN ISOLATED INCIDENT. 1 L 7 2 3O 3 O A7SO E9CE 2004042700003 20040427 00003 WP 2004 4 27 2004FA0000269 1 20040214 G 7712 6510043 GAUGE HUGHES 369 369E 4470707 WP ALLSN 250C 250C20R2 GL TORQUE INACCURATE D A UNSCHED LANDING N FALSE WARNING NR NOT REPORTED 1 WP 05 1726B 2231 829 0551E PILOT REPORTED OPERATIONAL EXCEEDANCE DURING FLIGHT RETURNED AC TO HELIPORT. UPON FURTHER INSPECTION AND EVALUATION IT WAS DETERMINED THAT THE DIAMOND J. TORQUE GAUGE WAS READING APPROX 15 LBS. LOW. AT 60 KNOTS AIRSPEED TORQUE READING 26- 27 LBS. NORMAL READING 42 LBS. HOVERING BEFORE TAKEOFF, FIFTY POUND RANGE NORMAL IS 65 LBS. GROUNDED AIRCRAFT, REMOVAL INSTRUMENT AND TRANSDUCER SENT TO MANUFACTURE FOR TESTING AND EVALUATION. 1 G 7 1 3U 3 U H3WE E4CE 2004042700012 20040427 00012 SO 2004 4 27 2004FA0000276 1 20040224 G 2424 68804007 VOLT REGULATOR PIPER PA28 PA28181 7102807 SO LYC O360 O360C1F 41514 EA LT KICK PANEL FAILED B VJ3R O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 WP 07 4188T 1 2843124 ALTERNATOR INOPERATIVE LIGHT CAME ON DURING GROUND RUN UP. TROUBLESHOOT SYSTEM AND FOUND NO OUTPUT VOLTAGE TO THE FIELD WIRE. PROBABLE CAUSE REGULATOR FAILED INTERNALLY, NO RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 2A13 E286 2004042900006 20040429 00006 SO 2004 4 29 AUS20040021 1 20040115 G 7120 J961340 MOUNT PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA MCAULY 1C160 1C160EGM GL ENGINE LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT LOWER ENGINE MOUNT LOOSE. 1 L 7 1 3O 3 O 2A13 E274 5 N P910 2004042900016 20040429 00016 NM 2004 4 29 AUS20040031 1 20040120 G 2910 HOSE BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE HYD SYSTEM BURST W O OTHER K J FLUID LOSS WARNING INDICATION LD LANDING 1 AU S (AUS) LT MAIN LANDING GEAR DOWNLOCK ACTUATOR HYDRAULIC HOSE BURST. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A16WE E2GL 2004042900019 20040429 00019 NE 2004 4 29 AUS20040034 3 20040118 G 6114 8173891 SEAL HAMSTD DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE PROP HUB FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S MFG950719 (AUS) PROPELLER HUB NR 3 BLADE SEAL LEAKING DUE TO FRACTURE OF SEALSPRING IN THE AREA ADJACENT TO THE WELDMENT. NR 2 BL ADE SEAL WAS ALSO REPLACED AS A PRECAUTION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004042900020 20040429 00020 NM 2004 4 29 AUS20040035 1 20040121 G 2824 MA20A10011 ACTUATOR BOEING 737 737* NM GE CFM56 CFM567B24 NE FUEL TRANSFER STICKING W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) FUEL CROSSFEED VALVE ACTUATOR FAILED. CROSSFEED VALVE STUCK IN THE OPEN POSITION. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004042900036 20040429 00036 SO 2004 4 29 2004FA0000339 1 20040323 G 8120 60051004 HOUSING PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO TURBOCHARGER CRACKED C O OTHER O OTHER NR NOT REPORTED 1 WP 07 8177C 1119 CGR0706 28R8231065 REMOVED TURBO FOR OTHER WORK, INSPECTED HOUSING PN 600510-04 AND FOUND IT TO BE CRACKED AS SHOWN IN AD 82-27-03 FIGURE 2 , AD 82-27-03 DOES NOT APPLY TO THIS HOUSING NUMBER, RECOMMEND INSPECTING ALL TURBOS REGARDLESS OF AD. 1 L 7 1 3O 3 O 2A13 E9CE 2004042900097 20040429 00097 NM 2004 4 29 CA040122005 1 20040122 G 2997 W2900086 WIRE BOEING 767 767375 1385217 NM GE CF6 CF680C2B6F 30025 NE LT PYLON CHAFED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) FAULT: LT ENGINE HYD. ALT. CURRENT MOTOR DRIVEN PUMP (ACMP)POWER FEEDER WIRES FOUND CHAFFING AND ARCHING ON STRUT STRUCTURE. STRUC. DAMAGE WAS ALSO NOTED DUE TO ARCHING. 2 L 7 2 4F 4 F RT A1NM E13NE 2004042900098 20040429 00098 NM 2004 4 29 CA040122006 1 20040116 G 5630 WINDOW BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU AIRSTAIR DOOR CHAFED W F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, A PASSENGER NOTICED A SMALL AMOUNT OF SMOKE / FIRE COMING UP FROM THE FLOOR NEXT TO THE MAIN CABIN DO OR AND POINTED IT OUT TO THE FLIGHT ATTENDANT WHO IMMEDIATELY NOTIFIED THE PILOTS. THE FIRE WAS APPROXIMATELY 1 INCH HIG H AND WAS LOCATED AT THE MAIN CABIN DOOR HINGE ARM WHERE THE MAIN CABIN DOOR LIGHT WIRES COME OUT OF A CONDUIT. THE PILO T GOT THE FIRE EXTINGUISHER FROM THE COCKPIT AND PUT OUT THE FIRE. THE PILOT THEN ORDER TO THE PASSENGERS TO EXIT OUT TH E REAR AIRSTAIR DOOR. THE CIRCUIT BREAKER FOR THE AIRSTAIR DOOR LIGHTS DID NOT TRIP. MFG IS INVESTIGATING THE EVENT. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004042900100 20040429 00100 SW 2004 4 29 CA040123001 1 20040123 G 5744 250000281 WEB GULSTM 690TP 690 0141720 SW GARRTT TPE331 TPE3315251K NM HARTZL HCB3T HCB3TN5 GL LT IB HINGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON AILERON INSPECTION, CRACK WAS FOUND UNDER LT IB HINGE. CRACK IS AROUND LOWER OB HINGE MOUNTING HOLE. ONE CRAC K OUT OF FIVE AC CHECKED. 1 H 7 2 3T 4 T 2A4 E2WE 6 C P15EA 2004042900102 20040429 00102 2004 4 29 CA040123003 4 20040114 G 3197 WIRE HARNESS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL COCKPIT CHAFED W O OTHER O OTHER AP APPROACH 1 CA (CAN) DURING APPROACH FLIGHT ON MULTIPLE OCCASIONS THE PILOTS EHSI SCREEN WOULD POWER DOWN AND RESTART UNCOMMANDED. IN THE TROUBLESHOOTING PROCESS ALL REMOVABLE COMPONENTS WERE REPLACE WITH SERVICEABLE UNITS. A VISUAL INSPECTION OF THE A/ C WIRING BY THE AVIONICS SHOP REVEALED CHAFED WIRING UNDER THE PILOTS SEAT IN THE OUTFLOW VALVE COMPARTMENT. WIRING P/N REPAIRED 9C95A22, 9C94 A22, 9C3G20, 9C32A22, 3F14A22N,ITN5A24. CHAFE PROTECTION INSTALLED ON THIS BUNDLE TO PREVENT F UTURE SIMILAR HAPPENINGS. SYSTEM TESTED SERVICEABLE AND LOG ENTRIES MADE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004050300102 20040503 00102 NM 2004 5 3 2004FA0000322 1 20040413 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 0099990080 9000085 DURING ACCOMPLISHMENT OF AD2002-10-05 (MAIN ROTOR UPPER HUB INSP.) FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTED IN MFG SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300103 20040503 00103 NM 2004 5 3 2004FA0000323 1 20040413 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 0099990080 9000085 DURING ACCOMPLISHMENT OF AD2002-10-05 (MAINROTOR UPPER HUB INSP.) FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTED I N MFG SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300105 20040503 00105 CE 2004 5 3 2004FA0000312 1 20040108 G 5320 245000616 BUMPER BLOCK CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA RT NLG WW WORN B CMXR O OTHER O OTHER NR NOT REPORTED 1 CE 05 9084F 172RG0352 NG DOOR OB EDGE CAUGHT ON GEAR WELL BUMPERS AND PREVENTED NG DOORS FROM OPENING WHEN GEAR SELECTED DOWN. IT IS CAUSED B Y DOORS BEING RIGGED WITH TOO LITTLE CLEARANCE, BUMPERS WEAR THIN AND ALLOW GEAR DOORS TO RAISE ON TOP OF BUMPER AND WED GE DOORS. NOSE GEAR WOULD NOT EXTEND BECAUSE DOORS WERE WEDGED AND COULD NOT OPEN CAUSING A LANDING WITHOUT NOSE GEAR D EPLOYED, CAUSING DAMAGE TO THE PROPELLER AND NOSE GEAR DOORS. CLEARANCE IS .160 MAX AND .100 MIN BUMPER IS .375 IN WIDT H AND IF BUMPER WEARS THIN OR EVEN AWAY THEN THERE IS AN EDGE THAT DOOR CAN WEDGE ON. CHECK GEAR DOOR OB EDGES TO INSUR E SPOT WELDS ARE INTACT AND DOOR SKINS HAVE NOT SEPARATED ALLOWING ONE SKIN TO CATCH ON BUMPERS. 1 H 7 1 3O 3 O 3A17 E286 2004050300106 20040503 00106 NM 2004 5 3 2004FA0000324 1 20040421 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 0099990080 DURING ACCOMPLISHMENT OF AD 2002-10-05 (MAIN ROTOR UPPER HUB INSPECTION), FOUND (3) OUT OF (10) BOLT HOLES TO BE CRACKED AS DEPICTED IN MFG SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0HOURS. REMOVED AN D REPLACED UPPER HUB WITH NEW. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300123 20040503 00123 EA 2004 5 3 2004FA0000325 2 20040329 G 8530 PUSHROD ROBSIN R22 R22MARINER 7640115 NM LYC O360 O360J2A 41514 EA NR 2 CYLINDER BENT C A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 SW 03 203CP 2659M L3525336A NUMBER 2 CYLINDER EXHAUST VALVE STUCK AND BENT PUSHROD CAUSING ENGINE POWER LOSS. PILOT THEN EXECUTED A PRECAUTIONARY L ANDING. 1 G 7 1 3O 3 O H10WE E286 2004050300132 20040503 00132 CE 2004 5 3 2004FA0000344 1 20040312 G 5541 SPAR CESSNA 150 152 2071835 CE LYC O235 O235* 41505 EA RUDDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 17 68329 15282261 FOUND RUDDER SPAR CRACKED AT LIGHTENING HOLE JUST UNDER TOP RUDDER MOUNTING HINGE. 4 CRACKS WERE PRESENT, THE LONGEST W AS .5 INCH. RECOMMEND INSPECTION EVERY 100 HOURS, REPLACE WITH NEW SPAR MISSING LIGHTENING HOLE IF DEFECTIVE. 1 H 7 1 3O 3 O NT 3A19 E223 2004050300140 20040503 00140 NM 2004 5 3 SROM200400045 1 20040404 G 5315 65C3453711 FLOORBEAM BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION STA 651 FLOORBEAM, BL O REPAIR ANGLE HAS A FASTNER GIVING SHORTED ON P/N 65C34537-11 ANGLE. T RIMMED P/N 65C34537-11 ANGLE, FLAP PEENED, TREATED, PRIMED AND INSTALLED IAW ASA EA 5310-02318 AND AAR EA 10312. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300149 20040503 00149 EU 2004 5 3 2004FA0000350 1 20040405 G 3411 LINE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6* 52043 EA PITOT SYSTEM SEPARATED B O OTHER G J MULTIPLE FAILURE WARNING INDICATION CR CRUISE 1 SO 11 529PB 188 529 PILOT EXPERIENCED AN ALTITUDE PORPOISE WITH AUTOPILOT ENGAGED. AIRSPEED IND INDICATED THAT AIRSPEED WAS DECREASING, ALT HOUGH AIRSPEED REMAINED SAME. BOTH PITOT SYS WERE CHECKED, OK. RT STATIC SYS WAS CHECKED, FOUND TO BE OK. THE LT STATI C SYS WOULD NOT PRESSURIZE AT ALL. ISOLATED THE STATIC SYS LEAK TO FITTING AT AFT PRESSURE BULKHEAD (FRAME 36, STATION 380.7). STATIC LINE TUBING ON INSIDE OF PRESSURE BULKHEAD HAD PULLED OUT OF THE FITTING, IT HAD BEEN CUT TOO SHORT AT T HE FACTORY. WHEN THIS LINE PULLED OUT, IT EXPOSED THE PILOT SIDE STATIC SYS TO CABIN PRESSURE. MAKE THE STATIC LINES SL IGHTLY LONGER DURING THE MFG PROCESS, THUS PREVENTING THEM PULLING OUT OF THE FITTINGS AS THE AC STRETCHES. 1 L 7 1 3T 3 T RT A78EU E2NE 2004050300151 20040503 00151 SO 2004 5 3 3M57931704 1 20040317 G 2742 5913114 RESOLVER GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE STAB ACTUATOR INACCURATE B LD2R O OTHER J WARNING INDICATION CL CLIMB 1 GL 15 23M 2780 400 579 11261262 FLAP STAB MISCOMPARE CAS MESSAGE. STAB ACTUATOR HAS BAD RESOLVER. 2 L 7 2 4F 4 F RT A12EA E00057EN 2004050300152 20040503 00152 EU 2004 5 3 2004FA0000351 1 20040315 G 2823 SF2601314611 ROD MRCHTI SF260 SF260 8121206 EU LYC O540 O540* 41532 EA FUEL VALVE BROKEN G A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION AP APPROACH 1 GL 07 260MN 5342 121 PILOT WAS MOVING FUEL SELECTOR KNOB FROM WING TIP TANKS TO WING TANKS AND THE FUEL SELECTOR ROD BROKE AT THE FUEL SELECT OR VALVE WITH THE FUEL SELECTOR VALVE IN BETWEEN TANK POSITIONS. THE ENGINE STOPPED AND AN EMERGENCY LANDING WAS ACCOMP LISHED. INVESTIGATION REVEALED THE FUEL SELECTOR ROD BROKE WERE IT WAS DRILLED FOR THE TAPERED PIN, P/N AN385H40-7. INF O ON MFG'S PART BOOK AT PAGE 8-22-01, FIGURE 1. 1 L 7 1 3O 3 O A10EU E295 2004050300156 20040503 00156 NM 2004 5 3 SROM200400051 1 20040408 G 5330 654688259 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION DENT IN SKIN STA 1147.5, 8.5 INCHES ABOVE S5. A=2 INCHES Y=.056 A/Y=35.7, BUT DUE TO PROXIM ITY OF CUTOUT FOR HORIZONTAL FITTING IT IS BEYOND LIMITS IAW SRM 53-30-1, FIG 1 NOTE K AND DETAIL 111. COMPLIED WITH HF EC. NO DEFECTS NOTED, COMPLIED WITH IAW ASA EA 5330-01757 AND AAR EA 10285. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300162 20040503 00162 WP 2004 5 3 54148 2 20040119 G 7230 310166811 PLENUM GARRTT TPE331 TPE33110UG 01514 WP ENGINE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 FOUND CRACKED AT DRAIN BOSS. 4 T E4WE 2004050300163 20040503 00163 CE 2004 5 3 CA040318006 1 20040304 G 5330 1304300515 SKIN BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSP, SEVERAL LOOSE RIVETS IN FWD AREA OF PRESSURE VESSEL, 2 RIVET HEADS SHEARED OFF AT FS 201.775. AFTER REMOVING ELEC PANEL AND DUCTS UNDER CABIN FLOOR, CRACKS WERE DETECTED IN RADIUS OF RIB WHERE IT ATTACHES TO STINGER 16, 15L. STRIPPED PAINT OFF BELLY FROM FS 158 TO 201 TO FACILITATE CLOSER INSP 2 CRACKS WERE VISUALLY DETECTED IN SKIN AROUN D RIVET HOLES FOR STRINGERS 16. HAD EDDY CURRENT TESTING ON ENTIRE AREA WITH CRACKS FOUND AND NOTED IN BELLY SKIN AT FS 179.525 AT 1ST RIVET LT OF C/L , 1ST RIVET RT OF CENTER LINE AND 8TH RIVET RT OF CENTER LINE. EDDY CURRENT TESTING WAS CARRIED OUT ON RIB WITH CRACKS NOTED IN RADIUS ON OB SIDE OF STRINGER 15 LT AND BOTH SIDES OF STRINGER 16 (C/L). 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004050300165 20040503 00165 CE 2004 5 3 2004FA0000317 1 20040408 G 2497 WIRE CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA ALTERNATOR SHORTED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 65045 237 A155851 17275674 THE 3 WIRES COMING FROM THE STATOR ARE SHORTED OUT ON THE CASE. THIS IS THE 4TH ALTERNATOR OVERHAULED BY FACILITY WITH THE SAME FAILURE. ALL 4 ALTERNATORS HAD LESS THAN 390 HOURS SINCE OVERHAUL. THERE NEEDS TO BE MORE INSULLATION ON THE 3 WIRES. 1 H 7 1 3O 3 O NT 3A12 E274 2004050300169 20040503 00169 SO 2004 5 3 2004FA0000292 2 20040305 G 8530 24077 RETAINER CESSNA 172 172D 2072410 CE CONT O300 O300D 17022 SO CYLINDER FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 11 2650U 17250250 2513770R FOUND UPPER VALVE RETAINER ABOUT 09 PERCENT WORN THROUGH BY OUTER SPRING (PN 625958) BUT HAD NOT FAILED YET. PN 24077 U PPER VALVE SPRING RETAINER. 1 H 7 1 3O 3 O NT 3A12 E253 2004050300179 20040503 00179 SO 2004 5 3 2004FA0000355 2 20040427 G 8530 CYLINDER HEAD CESSNA 421 421B 2076014 CE CONT O520 GTSIO520C 17032 SO ENGINE CRACKED C O OTHER O OTHER NR NOT REPORTED 1 GL 09 5988M 421B0231 AIRCRAFT NDT SERVICE WAS CONTRACTED TO VERIFY CRACKS IN THE ENGINE CYLINDER HEADS BETWEEN THE SPARK PLUG AND FUEL INJECT OR MOUNTING BOSS. AN EDDY CURRENT EXAMINATION DETERMINED THAT ALL TWELVE CYLINDER HEADS WERE CRACKED. THE OPERATOR REPL ACED ALL TWELVE CYLINDER HEADS WITH FRESH OVERHAULED HEADS. AN EDDY CURRENT EXAMINATION DETERMINED THAT FIVE OF THE TWEL VE OVERHAULED HEADS WERE CRACKED IN THE SAME LOCATION. 1 L 7 2 3O 3 O A7CE E7CE 2004050300183 20040503 00183 NM 2004 5 3 2004FA0000332 1 20040413 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 0099990080 9000085 DURING ACCOMPLISHMENT OF AD2002-10-05 (MAINROTOR UPPER HUB INSP.) FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTED IN MFG SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300186 20040503 00186 GL 2004 5 3 2004FA0000357 1 20040307 G 3350 D4125609000 BATTERY PACK DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA INSTRUMENT PNL SHORTED D K NONE O OTHER IN INSP/MAINT 1 EA 09 338MA 207 40298 EMERGENCY BATTERY PACK SHORTED DUE TO SET SCREW FALLING THROUGH HOLE IN BOTTOM OF INSTRUMENT PANEL DIRECTLY ABOVE BATTER Y PACK TERMINALS. HOLE IS FOR WIRES FROM BATTERY PACK, HAS A RECESS IN AREA OF ELECTRICAL TERMINALS. WHEN SET SCREW FE LL THROUGH HOLE, LODGED BETWEEN TERMINAL CONNECTIONS IN RECESS, COMPLETELY DRAINING EMERGENCY BATTERY PACK. BATTERIES R EACHED HIGH ENOUGH TEMP DURING SHORT/DISCHARGE CYCLE THAT INDIVIDUAL BATTERY JACKETS WERE DEFORMED OR ACTUALLY MELTED, SOME OF BATTERY CASES SPLIT, SPILLING CONTENTS. ANYTHING THAT FALLS THROUGH THIS HOLE IN THE INSTRUMENT PANEL (INCLUDIN G WATER) WILL NATURALLY BE TRAPPED IN RECESS IN TOP OF EMERGENCY BATTERY PACK. 1 L 7 1 3O 3 O NT A47CE 1E10 2004050300190 20040503 00190 NM 2004 5 3 SROM200400037 1 20040401 G 5330 65C80736824 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 063 LOG 4755636 REPLACE SKIN PANEL BS 360 - 540 STR 19R - 25R. REMOVED AND REPLACED SKIN P ANEL IAW B737 SRM 51-30-2. SIN REPLACED TO ELIMINATE PREVIOUS REPAIRS FOR DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300192 20040503 00192 NM 2004 5 3 SROM200400039 1 20040401 G 5330 0072040404 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 065 LOG 4755638 REPLACE SKIN PANEL BS 727 - 908 STR 20R - 25R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300193 20040503 00193 NM 2004 5 3 SROM200400040 1 20040401 G 5330 65C80736850 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 066 LOG 4755639 REPLACED SKIN PANEL MFG 908 STR 20L TO 25L. REMOVED AND REPLACED SKIN IAW MFG SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300194 20040503 00194 NM 2004 5 3 SROM200400041 1 20040401 G 5330 65C36745116 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 067 LOG 4755640 REPLACE SKIN PANEL BS 908 - 1016 STR 20R - 25R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300195 20040503 00195 NM 2004 5 3 SROM200400042 1 20040401 G 5330 6545800Y135 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W LOG 4755645 REPLACE SKIN PANEL BS 178-259 STR 24R - BLO. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300196 20040503 00196 NM 2004 5 3 SROM200400043 1 20040331 G 5743 658276415 SUPPORT BEAM BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE MLG CORRODED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 4514 23466 DURING D CHECK INSPECTION LT MLG SUPPORT BEAM HAS CORROSION IN OB ATTACH HOLE IN BETWEEN BUSHINGS. REMOVED BUSHINGS AND CORROSION. INSPECTED AND INSTALLED REPLACEMENT BUSHINGS IAW MFG EA 5750-01939 AND EA 10537. MINOR REPAIR. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300208 20040503 00208 SO 2004 5 3 2004FA0000343 2 20040331 G 7414 10160844 BRUSHES S6RH1225 CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MAG DIST GEAR MISINSTALLED D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 SW 99 PKMAR F02HA216 U20606231 523210 UPON COMPLETING THE FIRST 500 HOUR INSPECTION ON THE MAGNETO, IT WAS DISCOVERED THAT THE CARBON BRUSH AND SPRING ASSY (P N 10160844) WERE NOT INSTALLED. THE BUSHING IN THE DISTRIBUTOR GEAR HAD BEEN MAKING CONTACT WITH THE TAB ON THE COIL SO THE MAGNETO APPEARED TO BE FUNCTIONING NORMALLY. ADDITIONALLY, THE WEDGES (PN 10349219) THAT SECURE THE COIL ASSEMBLY INTO THE CASE WERE OVER-DRIVEN, BENT AND MALFORMED SEVERELY BY THE INSTALLATION PROCESS WHEN MANUFACTURED. 1 H 7 1 3O 3 O A4CE E8CE 2004050300209 20040503 00209 EA 2004 5 3 2004FA0000305 2 20040407 G 8520 SL13521 ROD BEARING PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA NR 6 POSITION DELAMINATED B YYBR O OTHER O OTHER NR NOT REPORTED 1 GL 03 L1034040 ENGINE EXPERIENCED FAILURE OF CONNECTING ROD BOLT, PN 74644 OR DELAMINATION OF CONNECTING ROD BEARING, PN SL 13521 IN N R 6 CONNECTING ROD POSITION. NOT SURE WHICH CAUSED THE FAILURE OF THE ENGINE. A ROD BEARING HALF WAS FOUND IN THE SUMP , MANGLED BUT INTACT; ITS MATE HAD DISINTEGRATED AND WAS SCATTERED THROUGHOUT THE ENGINE. THE ROD BOLT IN QUESTION WAS MISSING THREADS, AND WAS BLUE IN COLOR FROM EXCESSIVE HEAT. THE ROD NUT AND BOLT HEAD WERE NOT FOUND IN THE ENGINE AND SUSPECTED THAT THEY EXITED THE CRANKCASE THROUGH THE HOLE CREATED BY THE CONNECTING ROD BEING THROWN OFF THE CRANKSHAFT . THE ENGINE DID NOT SHOW SIGNS OF OIL STARVATION OR PROBLEMS WITH ANY OF THE OTHER CONNECTING ROD BEARINGS OR BOLTS. 1 L 7 1 3O 3 O A3SO E295 2004050300220 20040503 00220 GL 2004 5 3 CA040222001 1 20040220 G 2752 SEAL DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) IT WAS FOUND THAT THE SPLINED RUBBER SEAL PUSHED OUT OF POSITION ON FLAP ACTUATOR ROD ASSY. ON THIS AIRCRAFT IT D ID NOT MAKE CONTACT WITH THE FLAP POSITION SWITCHES. THE COMPLETE ASSY WAS REMOVED AND SENT FOR INSPECTION. NEW ASSY IN STALLED. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004050300221 20040503 00221 EA 2004 5 3 CA040224004 2 20040217 G 7310 3011587 BEARING BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL FCU ROD END LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON INSPECTION, THE ROD ENDS WERE FOUND TO BE BADLY WORN ON THE ROD FROM THE START CONTROL TO FUEL CONTROL UNIT. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2004042300011 20040423 00011 SO 2004 4 23 2004FA0000270 1 20040205 G 2822 BEARING PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL BOOST PUMP WORN D O OTHER O OTHER NR NOT REPORTED 1 AL 03 200HM 2AV3 32R7680025 RL2471148A CH34707 CIRCUIT BREAKER POPPED DUE TO FUEL PUMP ELECTRICAL DRAW ON SYSTEM HIGH RESISTANCE. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2004042700073 20040427 00073 EU 2004 4 27 CA040224006 1 20040220 G 3260 WARNING LIGHT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL LT MLG ILLUMINATED W O OTHER N FALSE WARNING LD LANDING 1 CA (CAN) 3 GREEN ANNUNICATOR LIGHTS CAME AS WELL AS RED WARNING LIGHT ON LT MLG. AC DID FLY OVER TO CONFIRM LT MLG WAS DOW N. PILOT SELECTED 30 DEGREES OF FLAP TO SLOW AC DOWN. WHEN 30 DEGREES OF FLAP WAS REACHED, 3 RED WARNING LIGHTS FOR LT MLG CAME ON. AC LANDED WITHOUT INCIDENT. WHEN TAXING TO HANGAR, FLAPS WERE RETRACTED TO 15 DEGREES, 3 RED WARNING LIGHT S WENT OUT INDICATING LT MLG SYS WAS NORMAL. AC JACKED AND MLG CYCLED TO DUPLICATE PROBLEM. SYS OPERATED NORMAL. PINS OF CONNECTOR WERE SPRAYED WITH ELECTRICAL CONTACT CLEANER AND REINSTALLED ON TO ACTUATOR. OTHER WIRES IN SYS WERE INSPECTE D, LT MLG CYCLED SEVERAL TIMES AND NO DEFECTS FOUND. AC WAS RELEASED BACK TO SERVICE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004042800030 20040428 00030 NM 2004 4 28 CA040130004 1 20040107 G 2422 048503 TRANSISTOR PHOENIX DH103024600C DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE INVERTER SHORTED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA 2218S8 (CAN) COMPONENT RESPONSIBLE FOR INVERTER FAILURE WAS DRIVER TRANSISTOR WHICH SHORTED. ON APPROACH MSTR CAUTION LIGHT I LLUMINATED GPWS, PRIM INV, SEC INV, AUX INV, L626AC AND/OR R26AC BUSES, BOTH TCAS S AND IVSI S FLAGGED, LASTED 1-2 MIN. AND THEN RETURNED TO NORMAL. MSTR CAUTION COULD NOT BE RESET, CONTINUOUSLY FLASHING. INITIATED MISSED APPROACH AND DIV ERTED. FOUND SECONDARY INV. OUTPUT VOLTAGE LOW. REPLACED SEC. INV. REPLACED 400 HZ 115V/26V TRANSFMR T1. REPLACED 400H Z CNTRL BOX. REPLACED PRIMARY INV. OPERATION TEST OF AC400 HZ SYSTEM SERVICEABLE IAW MM. INVERTERS SENT OUT TO VENDOR AND RETURNED TO JAZZ WITH WO CONFIRMING FAULT, AND NAMING THE DIVER TRANSISTOR AS THE CULPRIT COMPONENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004042900003 20040429 00003 NE 2004 4 29 AUS20040018 2 20040112 G 7210 5074T51G10 GEARBOX SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE ENGINE UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PROPELLER GEARBOX BYPASS PIN ACTIVATED. FOUND DURING INSPECTION IAW AD/CT7/10 (SB CT7-72-0453). METAL CONTAMINAT ION OF CHIP DETECTOR ALSO PRESENT. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 2004042900008 20040429 00008 NM 2004 4 29 AUS20040023 1 20040108 G 3397 J1 CONNECTOR BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE OEU ARCED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S (AUS) OVERHEAD ELECTRONICS UNIT (OEU) 1-2-1 D7466 LOCATED AT DL2 HAD A DAMAGED J1 CONNECTOR. OVERHEATING OF UNIT CAUSED PLASTIC CONNECTOR TO MELT CAUSING SHORT CIRCUIT WITH ARCING AND SPARKING. 2 L 7 4 4F 4 F RT A20WE E30NE 2004042900010 20040429 00010 2004 4 29 AUS20040025 4 20040116 G 2210 AUTOPILOT SYS BOEING 737 737800* NM GE CFM56 CFM567B24 NE COCKPIT FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 AU S (AUS) NEITHER AUTOPILOT WOULD TRIM THE AIRCRAFT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004042900011 20040429 00011 EU 2004 4 29 AUS20040026 1 20040116 G 5270 WARNING LIGHT AIRBUS 330 A300* EU GE CF6 CF680 30025 NE CARGO DOOR ILLUMINATED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) FORWARD CARGO DOOR MESSAGE. LIMITED INFORMATION PROVIDED. 2 L 7 2 4F 4 F RT A26NM E13NE 2004042900095 20040429 00095 EA 2004 4 29 033104 2 20040324 G 7230 MS9714XX BOLT BEECH 90 C90 1152913 CE PWA PT6 PT6A20 52043 EA COMPRESSOR BACKED OUT B K NONE O OTHER IN INSP/MAINT 1 SO 17 30HF 370 LJ506 PCE22520 PILOT REPORTS (GRINDING) SOUND WHEN PROPELLER IS SPUN BY HAND. THE ENGINE WAS SPLIT AT THE (C) FLANGE WHERE DEBRIS WAS N OTED AT THE 6 O'CLOCK AREA BETWEEN THE COMPRESSOR TURBINE BLADES AND SHROUD SEGMENTS. AFTER REMOVAL OF THE CT DISK, IT W AS NOTED THAT FOUR BOLTS HOLDING THE INNER EXIT DUCT TO THE ENGINE WERE MISSING. THE DEBRIS WERE THE REMAINS OF THE FOUR BOLTS. SAFETY WIRE WAS NOT PRESENT IN THE REMAINING FOUR BOLTS. 370 HOURS SINCE ENGINE O/H. 1 L 7 2 3T 3 T 3A20 E4EA 2004042900096 20040429 00096 EA 2004 4 29 CA040113010 2 20040108 G 7414 10400554 SEAL PIPER PA12 PA12 7101202 SO LYC O320 O320C1A 41508 EA SNSNCH 74DM M74DM EA MAGNETO WORN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA BL6006441 (CAN) ENGINE OIL IN RT MAGNETO SEAL P/N 10-400554 LIP WORN FLAT. SLEEVE P/N 10-357078 APPEARS TO BE OF SINTERED IRON NO T STEEL AS SINTERED IRON AND SINTERED BRASS SLEEVES WERE OBSOLETED MANY YEARS AGO. FIVE NEW SLEEVES IN STOCK ALSO APPEAR TO BE SINTERED IRON. NOTE: SEAL IN LT HAND MAGNETO WAS NOT LEAKING BUT WAS WORN FLAT: DOES THE ENGINE OIL WEEP THRU T HE NEW SINTERED BUSHING SLEEVES? IS THERE TOO MUCH TENSION ON THE OIL SEAL GARTER SPRING CAUSING PREMATURE WEAR. OR I S THE SINTERED IRON THE CULPRIT CAUSING EARLY SEAL WEAR? 1 H 7 1 3O 3 O A780 E274 5 N P88614 2004050300137 20040503 00137 CE 2004 5 3 2004FA0000346 1 20040403 G 5320 20430129 RUB STRIP CESSNA CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA NLG DOOR ACT MISSING D K NONE O OTHER IN INSP/MAINT 1 CE 07 8828Y 100 177RG1289 DURING ANNUAL INSPECTION LANDING GEAR RETRACTION TEST WAS PERFORMED AND THE NOSE GEAR DOORS WOULD NOT FULLY CLOSE. INVES TIGATION FOUND THE TEFLON RUB STRIP ON THE NOSE LANDING GEAR DOOR ACTUATOR MISSING. 1 H 7 1 3O 3 O A20CE 1E10 2004050300139 20040503 00139 CE 2004 5 3 2004FA0000347 1 20040331 G 2434 646843 ALTERNATOR BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO ENGINE FAILED C A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CL CLIMB 1 SO 11 42RK 24 24 CE934 813981 OVERHAULED GEAR DRIVEN ALTERNATOR REPEATED FAILURE. ALTERNATOR P/N 646843 S/N D022878 WENT TO TWO TIMES FOR REPAIR OR OV ERHAUL AND FAILED VERY SOON AFTERWARDS EACH TIME. 25 HOURS FIRST TIME AND .5 HOURS SECOND TIME. FIRST TIME WO NR MW25590 SECOND TIME WO NR MW29610. 1 L 7 1 3O 3 O 3A15 E5CE 2004050300153 20040503 00153 CE 2004 5 3 BHA04RS 1 20040408 G 5341 50110241 ATTACH FITTING CESSNA 414 414A 2075907 CE CONT O520 TSIO520* 17040 SO RT WING CORRODED B K NONE O OTHER IN INSP/MAINT 1 NM 04 414PG 3914 414A0811 IN COMPLYING WITH SUPPLEMENTAL INSPECTION 57-10-20, FOUND THE RT WING LOWER SPAR ATTACH FITTING HAD SIGNIFICANT CORROSIO N IN SOME OF THE FITTING MOUNTING HOLES. THE FITTING WAS REPLACED. NO FURTHERDEFECTS WERE NOTED. 1 L 7 2 3O 3 O A7CE E8CE 2004050300158 20040503 00158 EA 2004 5 3 2004FA0000318 1 20040316 G 3520 STCSA8082NMD OXYGEN SYSTEM CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE PAX FAILED B TJ4R K NONE L NO TEST IN INSP/MAINT 1 GL 11 316FX 5387 DURING A 12 MONTH OXYGEN SYS OPERATIONAL TEST, FOUND NO OXYGEN FLOW TO LT SIDE CABIN MASKS (6 EA) LOCATED IN LT CABIN OV ERHEAD PASSENGER SERVICE UNIT. (PSU) 6 MASKS SUPPLY EMERGENCY OXYGEN FOR 4 LT CABIN SEATS. THERE WAS SUFFICIENT PRESSUR E IN THE SYSTEM FOR THE MASKS TO DEPLOY FROM THE DEPLOYMENT CONTAINERS LOCATED IN THE PSU, BUT WHEN THE MASK LANYARDS WE RE PULLED TO ENABLE OXYGEN FLOW TO THE MASKS THERE WAS NO FLOW OF OXYGEN TO THE MASKS. DISCOVERED THE OXYGEN SUPPLY HOS E (PN17341024) FOR THE LT SIDE OF THE CABIN WAS PINCHED BETWEEN THE OVERHEAD PSU AND THE INTERIOR SHELL PANEL DUE TO MIS ALIGNMENT OF THE HOSE PASS-THROUGH HOLES AT FS364. HOSE WAS REPLACED WITH NEW, AND PASS-THROUGH CLEARANCE PROVIDED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004050300166 20040503 00166 CE 2004 5 3 2004FA0000353 1 20040311 G 2720 22601145 TORQUE TUBE CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA ZONE 100 DETACHED D A UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 SO 09 736ZX 5075 R18200813 LT RUDDER BAR TORQUE TUBE ASSEMBLY, PN 2260114-5 FAILURE. FAILURE OCCURRED IN FLIGHT RESULTING IN LT SIDE PILOT'S TOTAL LOSS OF LT RUDDER AND STEERING CONTROL. NATURE OF FAILURE; LT OB RUDDER PEDAL SOCKET ON TORQUE TUBE BROKE AWAY FROM THE TORQUE TUBE. THERE IS NO OBVIOUS REASON WHY THIS MIGHT HAVE HAPPENED. THERE ARE NO BENT OR DAMAGED COMPONENTS WITHIN TH E SAME SYSTEM, AND THE STEEL TORQUE TUBE HAS ONLY VERY LIGHT INTERNAL CORROSION. 1 H 7 1 3O 3 O RT 3A13 E295 2004050300191 20040503 00191 NM 2004 5 3 SROM200400038 1 20040401 G 5330 65C3584336 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 064 LOG 4755637 REPLACE SKIN PANEL BS 727 - 968 STR 14R - 20R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS FOR DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300197 20040503 00197 NM 2004 5 3 SROM200400044 1 20040331 G 5330 6545775 BEAR STRAP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE BROKEN C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION BEAR STRAP HAS A HOLE BROKE FROM EDGE (NO E/D) STA 767, STR 18R. TRIMMED DAMAGE, FABRICATED A ND INSTALLED REPAIR FILLER IAW MFG EA. 5330-01764 AND MFG EA 10311. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300203 20040503 00203 CE 2004 5 3 2004FA0000284 1 20040303 G 3230 0541153 U BOLT CESSNA 172 172F 2072414 CE CONT O300 O300* 17022 SO LT GEAR LEG SHEARED D O OTHER O OTHER NR NOT REPORTED 1 NE 05 5705R 3600 17253359 FOUND U BOLT ON LT MAIN GEAR SHEARED IN THREAD AREA UNDER NUT. PROBABLY NUT WAS OVERTORQUED. 1 H 7 1 3O 3 O NT 3A12 E253 2004050300222 20040503 00222 NM 2004 5 3 CA040224005 1 20040224 G 3220 65462154 TORQUE LINK BOEING 737 7372T2 1384491 NM PWA JT8 JT8D17 52049 NE NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 33572 (CAN) DURING THE SCHEDULED NOSE LANDING GEAR SEAL CHANGE AT THE C CHECK, A CRACK WAS DISCOVERED AT THE LOWER TORQUE LINK ATTACHMENT LUG. THE FINDING RESULTED IN THE TORQUE LINK BEING REPLACED. NOTE A FLEET CAMPAIGN HAS BEEN ISSUED TO VISU ALLY INSPECT ALL TORQUE LINKS ON FLEET. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300230 20040503 00230 NM 2004 5 3 CA040225012 1 20040225 G 2710 550030017 ACTUATOR BOEING 767 767375 1385217 NM GE CF6 CF680C2B6F 30025 NE RT AILERON STUCK W K NONE O OTHER IN INSP/MAINT 1 CA 66125 (CAN) EICAS MESAGE AILERON LOCKOUT, FOUND RT AILERON LOCK OUT ACTUATOR STUCK IN THE EXTEND POSITION, ACTUATOR REPLACED. 2 L 7 2 4F 4 F RT A1NM E13NE 2004050300240 20040503 00240 EA 2004 5 3 CA040226001 1 20040221 G 2497 VOLT REGULATOR DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL ELECTRICAL FAILED W A UNSCHED LANDING B G H SMOKE/FUMES/ODORS/SPARKS MULTIPLE FAILURE ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) AFTER DEPARTURE, THE AIRCRAFT SUFFERED A COMPLETE ELECTRICAL FAILURE. THE CREW NOTICED A BURNING ODOR. THE AIRCRAF T RETURNED WITHOUT FURTHER INCIDENT. UPON INVESTIGATION IT SEEMS LIKE A VOLTAGE SURGE OCCURRED, BOTH GPS ACU'S, BOTH COM M'S, RCR, DME, NR 1 NAV, NR 1 VOLTAGE REGULATOR ARE ALL UNSERVICEABLE AFTER THE EVENT. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2004050300243 20040503 00243 WP 2004 5 3 CA040227001 2 20040224 G 7200 TPE33110UA ENGINE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE RIGHT MAKING METAL W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 22198 P54043 (CAN) ONCE AT LEVEL FLIGHT THE RT ENGINE OIL PRESSURE WAS NOTICE TO BE AT THE LOWER END OF THE GREEN ARC 70 PSI, THE OIL PRESSURE WAS MONITORED UNTIL IT DROPPED TO 65 PSI AND THE CREW ELECTED TO RETURN. THE PRESSURE REMAINED STABLE AT 65 PS I, UNTIL TOUCHDOWN WHERE THE OIL PRESSURE DROPPED TO ZERO. THE ENGINE WAS SECURED AND THE LANDING COMPLETED WITHOUT FURT HER INCIDENT. A SUBSEQUENT INSPECTION REVEALED EXCESSIVE METAL IN THE OIL FILTER, THE LT ENGINE WAS REMOVED FOR REPAIR. FOLLOWUP INFORMATION WILL BE ADDED ONCE TEAR DOWN AND ANALYSIS IS COMPLETE. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2004050300251 20040503 00251 CE 2004 5 3 CA040228001 1 20040227 G 2720 AN2311 CLEVIS BOLT CESSNA 206 206CESSNA 2073302 CE CONT O520 IO520F 17032 SO MCAULY 2A34C D2A34C58 GL RUDDER BELCRANK WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RUDDER CABLE CLEVIS BOLTS INSPECTED DURING ROUTINE INSPECTION FOUND TO BE WORN APPROX. 30 PERCENT THROUGH THE BOLT . NEW CLEVIS BOLTS PART NUMBER AN23-11 INSTALLED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P3EA 2004050300264 20040503 00264 EU 2004 5 3 CA040301003 1 20040224 G 2420 5243212137 DRIVE SHAFT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL GENERATOR SHEARED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) ON RETURN FLIGHT, THE FLIGHT CREW HAD A GEN 2 FAILURE SO DECREASED ELECTRICAL LOAD AND CONTINUED TO MAINTENANCE BA SE. MAINTENANCE REMOVED THE GEN 2 AND INSPECTED IT FOR ANY FAULTS. A REPLACEMENT GENERATOR WAS BEING INSTALLED WHEN IT WAS NOTICED THAT THE DRIVE PULLEY WAS LOOSE AND DID NOT SEEM TO BE CONNECTED TO THE ENGINE. THE HOUSING WAS REMOVED AND THE DRIVE SHAFT WAS FOUND TO BE SHEARED, NO OTHER DAMAGE WAS NOTICED. A NEW SHAFT, BEARINGS AND GASKET WERE INSTALLED. SYSTEM WAS GROUND TESTED SERVICEABLE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004050300276 20040503 00276 CE 2004 5 3 CA040301006 1 20040225 G 7810 17540071 TUBE CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL EXHAUST CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HAIRLINE CRACK IN TUBING, AROUND APPROXIMATELY .25 OF THE CIRCUMFERENCE, IMMEDIATELY BELOW WELDED FLANGE. CRACK WA S ON IB SIDE OF FLANGE AND NOT READILY VISIBLE. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004050300278 20040503 00278 NE 2004 5 3 CA040302001 3 20040223 G 6114 73030SOCN817388 SEAL HAMSTD DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE BLADE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 20030512 (CAN) EXCESSIVE OIL LEAK FROM RT PROP, NR 3 BLADE. BLADES NR 1, 3, 4 REMOVED, BLADE SEALS AND SPRING ASSEMBLIES INSPECT ED. ON INSP ONE SEAL WAS FOUND TO BE BADLY SPLIT WITH A DISTORTED SPRING. OTHER 2 BLADE SEALS SPRING ASSEMBLIES WERE BRO KEN AND SHOWING SIGNS OF DISTORTION. ALL 3 BLADE SEAL AND SPRING ASSEMBLIES WERE REPLACED WITH NEW. LEAK CHECK CARRIED OUT, NIL LEAKS. NR 2 BLADE SEAL AND SPRING ASSEMBLY PREVIOUSLY REPLACED DUE TO OIL LEAK, SPRING WAS FOUND TO BE BROKEN DURING REPLACEMENT. LT PROP INSPECTED AS PRECAUTIONARY MEASURE, NR 1, 4 BLADES CHECKED SERVICEABLE, NR 2, 3 BLADE SEALS FOUND TO BE DAMAGED DUE TO INCORRECT SPRINGS FITTED. NEW SEALS AND SPRING ASSEMBLIES FITTED, NO DEFECTS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050400002 20040504 00002 EA 2004 5 4 CA040302002 2 20040221 G 7230 BLADE DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL COMPRESSOR SEPARATED W E A ENGINE SHUTDOWN UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) ON 2ND FLIGHT OF THE DAY, A SUDDEN PARTIAL POWER LOSS OCCURRED ON NR 1 ENGINE, A STRONG SMELL ACCOMPANIED THE POWE R LOSS. ENGINE NR 1 WAS SUBSEQUENTLY SHUT DOWN. THE AIRCRAFT COMPLETED AN UNEVENTFUL UNSCHEDULED LANDING. UPON SUBSEQU ENT INSPECTION IT WAS FOUND THAT ENGINE SUFFERED SEVERE DAMAGE TO THE COMPRESSOR SECTION RESULTING FROM THE LOSS OF A BL ADE FORM THE FIRST STAGE COMPRESSOR. THE BLADE WAS FOUND STUCK IN THE INLET SCREEN AND ALL THE FIRST STAGE BLADES SUFFE RED SEVERE DAMAGE. THE ENGINE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2004050400003 20040504 00003 WP 2004 5 4 CA040302003 1 20040131 G 2435 150SG117Q STARTER GEN HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE BURNED W B EMER. DESCENT H A D ELECT. POWER LOSS-50 PC FLAME/FIRE INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) WHILE IN FLIGHT PILOT NOTICED NR BEGIN TO DROP. HE INITIATED AN AUTOROTATION, HEARD A LOUD BANG, AND THE RPM CAME BACK UP. UPON LANDING FLAMES AND SMOKE WERE NOTICED IN THE ENGINE BAY. PILOT EXTINGUISHED FIRE AND DETERMINED IT WAS THE STARTER GENERATOR. IT APPPEARS THE BEARINGS SEIZED WHICH WAS BRINGING DOWN THE ENGINE RPM UNTIL THE SG SHAFT SHEARED. 1 G 7 1 3U 3 U H3WE E4CE 2004050400009 20040504 00009 EA 2004 5 4 CA040302007 1 20040221 G 3897 4E32644 DRAIN MAST CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE WATER SYS SHORTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FWD GALLEY WATER SYSTEM PUMP WAS NOT OPERATING. TROUBLESHOOTING REVEALED THAT A WIRE BEHIND THE GALLEY WAS AT FAUL T, NO COMMAND WAS BEING SENT TO THE PUMP. MAINT REMOVED THE GALLEY AND FOUNDTHE WIRING FROM THE PORTABLE WATER SYSTEM C ONTROLLER TO BE DAMAGED FROM OVERHEATING, SPECIFICALLY WIRES GBG7044W-22 & GBG7044B-22 TO THE DRAIN HEATERS FROM A177P3 PINS 20 AND 21. THIS OVERHEATING HAD ALSO AFFECTED ADJACENT WIRES OVER A CONSIDERABLE LENGTH, REQUIRING REPLACEMENT OF E NTIRE WIRING BUNDLE FROM THE PWS CONTROLLER, HARNESS PN SH670-59071-001. THIS HARNESS INCLUDES THE WIRING FROM PLUGS A17 7P1, A177P2, A177P3 AND A177P4. A SHORT WAS FOUND IN THE HEATING CIRCUIT OF DRAIN MAST ASSY HR02 (P/N 4E3264-4 ) 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004050400012 20040504 00012 CE 2004 5 4 CA040303002 1 20040226 G 2435 PLUG PWA LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE GEAR SHAFT DISLODGED W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) EN-ROUTE, THE CREW OBSERVED A LOSS OF OIL PRESSURE. THE ENGINE WAS SECURED AND AN UNEVENTFUL LANDING WAS MADE. EXA MINATION OF THE ENGINE REVEALED THAT A PLUG IN THE STARTER GEAR SHAFT ASSEMBLY WAS DISLODGED, SUCH THAT PRESSURE OIL COU LD ESCAPE THE ENGINE. FURTHER EXAMINATION SHOWED THAT THE PLUG HAD NOT BEEN ADEQUATELY SWAGED INTO THE BORE OF THE GEAR SHAFT. OTHER OPERATORS WHO HAVE GEAR SHAFTS FROM THE SAME PROCESS BATCH OF GEAR SHAFTS HAVE BEEN ADVISED AND THEIR GEAR SHAFTS ARE BEING RE-INSPECTED TO CONFIRM ADEQUATE SWAGING OF THE PLUG. 2 L 7 2 4F 4 F RT A10CE E35NE 2004050400013 20040504 00013 CE 2004 5 4 CA040303003 1 20040221 G 3010 571531025 TUBE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP BLEED AIR CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 10921 10921 (CAN) DURING FLIGHT THE CREW NOTICE AN INTERMITENT WING O/H WARNING. MAINTENANCE WAS CONTACTED AND THE AIRCRAFT INSPECTE D. INSPECTION REVEALED A CRACK IN BLEED AIR TUBE PN 5715310-25. THE TUBE WAS REPLACE. THERE WAS NO RESULTING DAMAGE FROM THE BLEED AIR LEAK. 1 L 7 2 3T 4 T RT A28CE E4WE 2004050400014 20040504 00014 CE 2004 5 4 CA040303004 1 20040302 G 5310 GUSSET BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL WINDOW POST UNBONDED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE REMOVING A BROKEN CO-PILOT WINDSHIELD IT WAS NOTED CHAFFING ON THE WINDSHEILD FRAME. INTERIOR TRIM THAT IS ATTACHED TO THE CENTER PILLAR HAD BECOME UNATTACHED AND FALLEN DOWN INTO CONTACT WITH THE WINDSHEILD PILLAR GUSSET. MF G WAS IMMEDIATELY CONTACTED AND A REPAIR SCHEME FORWARDED TO ALLOW THE AIRCRAFT TO RETURN TO SERVICE. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2004050400015 20040504 00015 NM 2004 5 4 CA040303005 1 20040302 G 3242 BRAKE BOEING 757 75728A 1384976 NM RROYCE RB211 RB211535E437 54555 NE MLG CONTAMINATED W K NONE B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) NR 5 BRAKE SMOKING ON ARRIVAL. A/C HAS JUST RETURNED FROM PAINT, IT IS SUSPECTED THAT EXCESS FLUID HAD COLLECTED O N THE SURROUNDING AREA OF NR 5 BRAKE. BRAKE AND WHEEL AREA THOROUGHLY CLEANED. 2 L 7 2 4F 4 F RT A2NM E12EU 2004050400016 20040504 00016 EU 2004 5 4 CA040304001 1 20040227 G 2910 PILOT VALVE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FORE, AFT SERVO SEIZED W O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 CA DE013 (CAN) IN ORDER TO COMPLY WITH AIRWORHTINESS DIRECTIVE CF-2003-002R1, THE FLIGHT CONTROL RODS WERE DISCONNECTED AND THE P ILOT VALVE WAS FOUND TO BE SEIZED ON THE FORE AND AFT SERVO. 1 G 7 1 3U 3 U NC H9EU E19EU 2004050400017 20040504 00017 EU 2004 5 4 CA040304003 1 20040225 G 6730 704A34635019 O-RING DUNLOP SNIAS 350 AS350BA 8680817 EU LYC LTS101 LTS101600A3 41560 NE CHECK VALVE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HAD A HARD OVER CYCLIC PROBLEM WITH AN ENGINE, THE AIRCRAFT WAS EQUIPPED WITH MFG SERVOS. HAD THIS PROBLEM AT 30 D EGREES C TO -15 DEGREES C (OUTSIDE TEMPERATURE), NO DIFFERENCE. BOLT LATERAL SERVOS WAS DUE FOR OVERHAUL, SEND SERVOS FO R OVERHAUL AND REINSTALLED THESE SERVOS AFTER OVERHAUL, NOTHING CHANGED. REPLACED THE VALVE FILTER BLOCK AND NOTHING CHA NGE. REPLACED THE LT INPUT CHECK VALVE AT THE SERVO AND HAD A GAIN OF 60 PERCENT. REPLACED THE RT INPUT CHECK VALVE AT T HE SERVO AND HAD A GAIN OF 100 PERCENT, NO MORE FEED BACK. FOUND THE O-RING INSIDE OF THE CHECK VALVE (FLAT). 1 G 7 1 3U 3 U NC H9EU E5NE 2004050400018 20040504 00018 EU 2004 5 4 CA040304004 1 20040225 G 2913 704A33690004 BELT AEROSP SNIAS 350 AS350BA 8680817 EU LYC LTS101 LTS101600A3 41560 NE HYD PUMP UNBONDED W B A EMER. DESCENT UNSCHED LANDING F Z FLT CONT AFFECTED SIGNIFICANT FAILURE REPORT CR CRUISE 1 CA (CAN) WHILE IN FLIGHT THE PILOT EXPERIENCE A LOST OF HYDRAULIC POWER AND EMERGENCY LANDED ON A NEAR BY LEAKE WITH NO DAM AGE TO AIRCRAFT. AFTER INSPECTION THE HYDRAULIC BELT HAS BEEN FOUND SECTIONED AT THE GLUED JOINT. 1 G 7 1 3U 3 U NC H9EU E5NE 2004050500044 20040505 00044 SO 2004 5 5 2004FA0000321 2 20040323 G 8530 654959A1 CYLINDER CESSNA 182 182D 2072710 CE CONT O470 O470* 17026 SO ENGINE DAMAGED B UGZR K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 AL 03 8924X 18253324 COULD NOT GET ENGINE TO RUN PROPERLY. COMPRESSION GOOD ON NR 6, FINALLY DETERMINED NR 6 WAS NOT OPERATING PROPERLY. RE MOVED CYLINDER, SENT FOR OVERHAUL. FOUND HOLE IN EXHAUST VALVE PORT. (VOID IN THE CYLINDER CASTING) CYLINDER REJECTED AND RETURNED WITH LETTER. 1 H 7 1 3O 3 O NT 3A13 E273 2004042200181 20040422 00181 2004 4 22 2004FA0000300 4 20040308 G 2210 BRIDAL CABLE CESSNA 172 172S 2072439 CE LYC O360 IO360B1E 41514 EA ROLL SERVO WORN B EHHR O OTHER O OTHER NR NOT REPORTED 1 EA 17 642SP 462 172S8050 ROLL SERVO BRIDLE CABLE WAS IMPROPERLY INSTALLED. TOP PORTION OF CABLE WAS WRAPPED AROUND PRIMARY AILERON CABLE, CAUSIN G BRIDLE CABLE TO CHAFE AGAINST A PULLEY FLANGE. INSTALLATION OF CABLE ASSEMBLY OCCURRED AT THE FACTORY AND HAS NOT BEE N REPLACED SINCE AIRCRAFT WAS MANUFACTURED. REPAIRED BY REMOVING BRIDLE CABLE AND INSTALLING CABLE CORRECTLY. (EA17200 405907) 1 H 7 1 3O 3 O NT 3A12 1E10 2004042700011 20040427 00011 SO 2004 4 27 2004FA0000275 1 20040227 G 3240 D2113 BRAKE ASSY PIPER J3 J3C65 7100510 SO CONT A65 A65* 17003 SO RT MLG BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 15 25WF 5671 AFTER DISASSEMBLY OF THE RT WHEEL AND BRAKE COMPONENTS FOR INSPECTION, ONE OF SIX BRAKE BLOCK (NR B27-59-D) WAS FOUND TO BE BROKEN, AND ONE OF SIX SPRING RETAINERS (NR R21-35) WAS FOUND TO BE BROKEN, AND LOOSE. THIS CLIP (RETAINER) MAY HAV E JAMMED UNDER A BRAKE BLOCK AND CAUSED THE RT WHEEL TO DRAG EXCESSIVELY ENOUGH TO CAUSE LOSS OF CONTROL DURING THE LAND ING ROLLOUT. ACTUAL TIME OF SERVICE FOR COMPONENTS ARE UNKNOWN. 1 H 7 1 3O 3 O A691 E205 2004042900007 20040429 00007 NM 2004 4 29 AUS20040022 1 20040106 G 2621 EXTINGUISHER BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE LAVATORY MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CS41B TOILET WASTE DISPOSAL SYSTEM BUILT IN FIRE EXTINGUISHER MISSING. 2 L 7 4 4F 4 F RT A20WE E30NE 2004042900009 20040429 00009 NM 2004 4 29 AUS20040024 1 20040118 G 3244 275Q221 TIRE BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE MLG SEPARATED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 AU S (AUS) LT NOSE WHEEL TIRE TREAD SEPARATED. TCAS ANTENNA COVER RIPPED OFF AND FOUND ON RUNWAY. DAMAGE CAUSED TO NLG AIR/ GROUND SENSOR, BRACKETRY AND WIRING CONDUIT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004042900014 20040429 00014 WP 2004 4 29 AUS20040029 2 20040119 G 7210 PLANETARY GEAR ISRAEL 1125 ASTRASPX 4500205 EU GARRTT TFE731 TFE7314R 01518 WP ENGINE VIBRATES W O OTHER E F VIBRATION/BUFFET FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) RT ENGINE VIBRATION. INVESTIGATION FOUND THE VIBRATION CAME FROM THE PLANETARY GEARSET. 2 L 7 2 4F 4 F RT A16NM E6WE 2004042900015 20040429 00015 2004 4 29 AUS20040030 4 20040103 G 3418 C809072 TRANSDUCER DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE STALL WARNING FAILED W C ABORTED TAKEOFF F J FLT CONT AFFECTED WARNING INDICATION TO TAKEOFF 1 AU S (AUS) STALL WARNING VANE FAILED DUE TO FAULTY TRANSDUCER. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004042900027 20040429 00027 NM 2004 4 29 AUS20040042 1 20040122 G 2781 SENSOR BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE LE SLATS OUT OF ADJUST W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 AU S (AUS) LEADING EDGE FLAP NR 2 EXTEND SENSOR OUT OF ADJUSTMENT. 2 L 7 2 4F 4 F RT A16WE E2GL 2004050300143 20040503 00143 CE 2004 5 3 040604 1 20040406 G 1430 MS9714XX BOLT BEECH 90 C90 1152913 CE PWA PT6 PT6A20 52043 EA ENGINE DAMAGED B K NONE O OTHER IN INSP/MAINT 1 SO 17 30HF LJ506 PCE22543 THE ENGINE WAS SPLIT AT THE (C) FLANGE. AFTER REMOVAL OF THE C.T. DISC, IT WAS NOTED THAT 2 BOLTS HOLDING THE INNER EXI T DUCT TO THE ENGINE HAD SHEARED OFF AND WERE LODGED IN THE AREA, WITH THE REMAINDER OF THE BOLT SHANKS LEFT IN THE BOLT HOLES. DAMAGE WAS NOTED ON THE C.T. DISC. SAFETY WIRE WAS PRESENT IN ALL THE BOLTS INCLUDING THE SHEARED BOLT HEADS. 1 L 7 2 3T 3 T 3A20 E4EA 2004050300144 20040503 00144 CE 2004 5 3 2004FA0000348 1 20040318 G 3230 3A0500002 CYLINDER CESSNA 185 A185F 2072821 CE CONT O520 IO520* 17032 SO MLG LEAKING G O OTHER O OTHER NR NOT REPORTED 1 NM 01 185TH 18503456 LEAKING CYLINDER CAUSED GEAR NOT TO LOCK, GEAR COLLAPSED DURING TAXI. 1 H 7 1 3O 3 O 3A24 E5CE 2004050300145 20040503 00145 EA 2004 5 3 2004FA0000329 2 20040329 G 8530 PUSHROD ROBSIN R22 R22MARINER 7640115 NM LYC O360 O360J2A 41514 EA ENGINE BENT C A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 03 203CP 2659M L3525336A NR 2 CYLINDER EXHAUST VALVE STUCK AND BENT PUSHROD CAUSING ENGINE POWER LOSS. PILOT THEN EXECUTED A PRECAUTIONARY LANDI NG. 1 G 7 1 3O 3 O H10WE E286 2004050300147 20040503 00147 SO 2004 5 3 2004FA0000349 1 20040401 G 8097 A02855688499 SWITCH PIPER PA46 PA46500TP 7104622 SO PWA PT6 PT6A42 52043 NE AUTO START SYS SHORTED D K NONE O OTHER IN INSP/MAINT 1 EA 07 77Y 531 4697035 AUTO START SYSTEM WOULD NOT DISENGAGE AUTOMATICALLY AT 56 PERCENT NG. FOUND ELECTRONIC CONTROL MODULE 1012 (P/N 688-499) INTERNALLY SHORTED CAUSING POWER TO CONSTANTLY FLOW REGARDLESS OF COMMANDS. 1 L 7 1 3O 4 T RT A25SO E4EA 2004050300154 20040503 00154 2004 5 3 2004FA0000352 4 20040312 G 2210 55X AUTOPILOT SYS CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA COCKPIT INOPERATIVE C O OTHER O OTHER AP APPROACH 1 GL 19 738QV 300 10 R18200955 IN APR AND NAV MODE, AUTOPILOT WILL NOT PROPERLY INTERCEPT AND TRACK LOCALIZER AND/OR VOR SIGNAL. AUTOPILOT WILL SCALLOP ACROSS COURSE. AUTOPILOT HAS BEEN SENT IN FOR EVALUATION. WE HAVE EVALUATED OUR PN-101 HSI TO DETERMINE IF THEY ARE TH E SOURCE. AFTER EVALUATIONS THE AUTOPILOT IS SOURCE OF THE PROBLEM. ALSO, WHEN FLAPS AND GEAR ARE EXTENDED ON APPROACH, AUTOPILOT WILL PITCH UP AND DOWN WILDLY. THIS PROBLEM HAS PERSISTED SINCE INSTALLATION AND ON-SITE EVALUATION. AWARE O F SEVERAL OTHER AIRCRAFT THAT HAVE THIS PROBLEM. AUTOPILOT NEEDS TO BE FULLY RE-EVALUATED BY THE FAA AND MANUFACTURER. 1 H 7 1 3O 3 O 3A13 E295 2004050300155 20040503 00155 NM 2004 5 3 SROM200400050 1 20040318 G 5330 6545775 BEAR STRAP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION, BEAR STRAP HAS A HOLE BROKEN FROM EDGE (NO E/D) AT STA 767 AND STR 18R. REMOVED DAMAGE, FAB RICATED AND INSTALLED REPAIR FILLER IAW ASA EA 5330-01764 AND AAR EA 10311. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300178 20040503 00178 CE 2004 5 3 2004FA0000354 1 20040427 G 2750 99141873 CONTROLLER CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP TE FLAP DEFECTIVE B O OTHER O OTHER NR NOT REPORTED 1 GL 11 934H 6500172 FLAP CONTROLLER FAILED TO INDICATE PROPERLY ON SYSTEM TEST. 2 L 7 2 4F 4 F A9NM E6WE 2004050300189 20040503 00189 NM 2004 5 3 SROM200400036 1 20040401 G 5330 0072040410 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 062 LOG 4753635 REPLACE SKIN PANEL BS 360 - 540 STR 14R - 19R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300252 20040503 00252 SO 2004 5 3 CA040301001 1 20040219 G 2497 W23X1A1G20 CIRCUIT BREAKER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) CIRCUIT BREAKER SENT FOR EVALUATION. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004050300270 20040503 00270 NM 2004 5 3 CA040301004 1 20040215 G 2150 7786832 HEAT EXCHANGER DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE CABIN AIR CRACKED W O OTHER O OTHER CR CRUISE 1 CA 15073 (CAN) PILOT REPORTED UNABLE TO CONTROL CABIN ALTITUDE AT LOWER POWER SETTINGS. AFTER ARRIVAL MAINTENANCE FOUND FORWARD HEAT EXCHANGE CRACKED/SPLIT OPEN. UNIT REPLACED AND AIRCRAFT RETURNED TO SERVICE. NOTE: THIS HEAT EXCHANGER HAD BEEN RE PAIRED FOR (CRACK ALONG INSIDE WELD OF PRIMARY INLET HEADER) IN MAY OF 2002. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050300275 20040503 00275 EU 2004 5 3 CA040301005 1 20040216 G 5302 350A2310534451 SUPPORT SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE TAIL BOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A CRACK WAS DISCOVERED IN MAY ON THE NR 5 HANGER BEARING SUPPORT. THIS PART WAS REPLACED IN THE FIELD USING ALL TH E APPROPIATE TOOLING. SOMETIME LATER THE PILOT COMPLAINED OF A HIGH FREQ VIBRATION. THE SHAFT WAS REBALANCED TO .2 IPS. AGAIN ABOUT 20 HOURS LATER THE PILOT COMPLAINED OF A HIGH FREQ, AGAIN IT WAS DETERMINED THE SHAFT WAS OUT OF BALANACE. FURTHER INVESTIGATION DETERMINED THE HANGER SUPPORT WAS AGAIN CRACKED. 1 G 7 1 3U 3 U H9EU E19EU 2004050400006 20040504 00006 2004 5 4 CA040302004 4 20040214 G 5301 143232 CABLE 143232 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL HOOK END FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT HAD UNCOMMANDED LOAD RELEASE. INVESTIGATION DETERMINED THAT A FRAYED MANUAL RELEASE CABLE HAD CAUSED THIS PR OBLEM. IT WAS BADLY FRAYED WHERE THE CABLE WENT INTO THE CARGO HOOK. 1 G 7 1 3U 3 U H3WE E4CE 2004050400008 20040504 00008 SW 2004 5 4 CA040302006 1 20040224 G 2822 2C271 PUMP BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUEL BOOST DESTROYED W E F ENGINE SHUTDOWN ACTIVATE FIRE EXT. A FLAME/FIRE NR NOT REPORTED 1 CA (CAN) DURING GROUND RUN FOR MAINTENANCE ACTIVITY STROBING OF TAIL ROTOR ASSEMBLY AN EXPLOSING AND SUBSEQUENT FIRE OCCURR ED IN THE FUEL CELL ASSEMBLY AND AFT PASSENGER COMPARTMEN. AIRCRAFT WAS ON ITS FOURTH START OF THE DAY FOR TAIL ROTOR B ALANCING CHECK, FIRE EXTINGUISHED. AIRCRAFT SUFFERED SERIOUS STRUCTUREAL DAMAGE. MINOR GROUND MAINTENANCE PERSONNEL INJ URY. 1 G 7 1 3U 3 U H2SW E4CE 2004050500094 20040505 00094 EA 2004 5 5 2004FA0000360 2 20040420 G 8550 73772 COOLING JET PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA CRANKCASE MISSING B NX42 K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 703ER 2079 2844057 L3013951A UPON DISASSEMBLY FOR ITS FIRST OVERHAUL, THE TECH FOUND TAPERED PIPE PLUGS WERE INSTALLED IN CRANKCASE INSTEAD OF THE RE QUIRED PISTON COOLING JETS. PISTONS AND CYLINDERS SHOWED SIGNS OF OVERHEATING ALTHOUGH NO MALFUNCTION OCCURRED. ENGINE RECORDS INDICATE THE ENGINE WAS BUILT FACTORY NEW, INSTALLED ON AC AND HAS HAD NO HISTORY OF CYLINDER REMOVAL OR REPLAC EMENT. 1 L 7 1 3O 3 O 2A13 1E10 2004050600009 20040506 00009 2004 5 6 CA040316007 4 20040304 G 2310 064101700 COUPLER DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL HF AMPLIFIER BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA P2193 (CAN) HF SYS FAILED, SMOKE AND BURN SMELL CAME FROM HF PWR AMP/COUPLER. UNIT WAS REMOVED AND SENT FOR INSP. FOUND THAT HARDWARE ATTACHING COVER ON CONNECTOR J9524 TO FACEPLATE OF UNIT HAD CONTACTED PRINTED CIRCUIT BD AND SHORTED +28 VDC S UPPLY TO GROUND. ELEC TRACE MELTED AND OPENED CIRCUIT TO UNIT. PC BOARD WAS REPAIRED, TRACE REPLACED. UPON TESTING IT WAS FOUND THAT COUPLER WOULD NOT TUNE AT ALL. TROUBLESHOOTING DISCLOSED, VSWR SENSOR WAS NOT OPERATING PROPERLY. IT WAS DISCOVERED CNTRL BOARD HAD AN OBSOLETE MICROPROCESSOR. MOST OF BOARDS ARE OBSLETE. WIRING ON AC FOR HF SYS WAS TESTED IA W WIRING MANUAL AND NO FAULT WAS FOUND. REPLACEMENT HF PWR AMP/COUPLER WAS INSTALLED, SYSTEM TESTED, OK. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2004050600019 20040506 00019 SO 2004 5 6 2004FA0000361 2 20040429 G 8530 CYLINDER GULSTM 680 685 0141612 SW CONT O520 GTSIO520K 17032 SO NR 3 DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 SO 09 414C 12021 NR 3 CYLINDER ON LT ENGINE HOLD DOWN STUDS BROKE OFF ON UPPER FWD AND LOWER FWD. ONLY ONE NUT WAS TIGHT ENOUGH TO USE A WRENCH. THE OTHER NUTS WERE LOOSE. AFTER CYLINDER REMOVAL A PIECE OF THE CASE HALF CAME OFF WITH THE CYLINDER APPROX. 6 INCHES ACROSS ALONG THE TOP OF THE CYLINDER. EXHAUST PIPE FOR THE NR3 CYLINDER BROKE OFF AT THE FLANGE. 1 H 7 2 3O 3 O 2A4 E7CE 2004050600025 20040506 00025 CE 2004 5 6 2004FA0000307 1 20040409 G 2497 103003 WIRE CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA ALTERNATOR SHORTED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 54589 383 17275007 THE 3 WIRES COMING FROM THE STATOR WERE SHORTED OUT ON THE CASE, THIS IS THE 4TH ALTERNATOR OVERHAULED WITH THE SAME FAI LURE. WITH LESS THAN 390.0 HOURS SINCE OVERHAUL. WIRES NOT INSULATED PROPERLY. 1 H 7 1 3O 3 O NT 3A12 E274 2004050600035 20040506 00035 CE 2004 5 6 SO1450 1 20040322 G 2710 05232182 ROD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA AILERONS BENT C C ABORTED TAKEOFF F FLT CONT AFFECTED TX TAXI/GRND HDL 1 SO 05 7275G 1898 20 17280788 L2848551A DURING PREFLIGHT, PILOT FOUND LT AILERON CONTROL ROD BENT AT AILERON SURFACE. AIRCRAFT GROUNDED AND TAKEN TO MAINTENANCE . REMOVED LT AILERON CONTROL ROD AND FOUND IT TO BE BENT APPROXIMATELY 25 DEGREES JUST AFT OF AFT ROD END BEARING. REPLA CED WITH NEW ROD. 1 H 7 1 3O 3 O NT 3A12 1E10 2004050600039 20040506 00039 EA 2004 5 6 2004FA0000364 2 20040315 G 7320 FUEL CONTROL PIPER PA18 PA18 7101802 SO LYC O320 O320* 41508 EA ENGINE MISMARKED D K NONE O OTHER IN INSP/MAINT 1 EA 23 AS MANUFACTURED, THE FUEL VALVE SELECTOR HANDLE CONSISTS OF A SMALL POINTER AND A SILVER HANDLE OPPOSITE OF EACH OTHER O N THE LT INTERIOR WALL BY THE FRONT SEAT. OPPOSITE BOTH FUEL VALVE SELECTIONS OF (LT) AND (RT) IS AN (OFF) POSITION. T HE POINTER IS OFTEN PAINTED THE SAME COLOR AS THE BACKGROUND COLOR OF THE INTERIOR, USUALLY DARK RED. THIS LEADS TO THE POSSIBILITY OF SOMEONE INADVERTENTLY USING THE SILVER HANDLE TO MAKE THE VALVE SELECTION INSTEAD OF THE POINTER, PERHAP S TURNING THE VALVE (OFF) INSTEAD OF SELECTING A FUEL TANK. THE POINTER SHOULD BE PAINTED A DISTINCTIVE COLOR AND PERHA PS THE VALVE SELECTOR SHOULD BE PLACARDED: (USE POINTER NOT SILVER HANDLE TO MAKE VALVE SELECTION). 1 H 7 1 3O 3 O 1A2 E274 2004050600046 20040506 00046 GL 2004 5 6 2004FA0000334 1 20040303 G 1410 HOSE AMTR VORTEX VORTEX 05603FA GL ROTAX 582 ROTAX582 55555 EU VACUUM SYSTEM IMPROPER PART G C ABORTED TAKEOFF Y ENGINE STOPPAGE TO TAKEOFF 1 WP 25 96XV 12 5437430 THE VACUUM LINE GOING TO THE FUEL PNEUMATIC PUMP HAD AN IRREGULAR PART INSTALLED. THE MM REQUIRES A HARD, NON-COLLAPSIBL E, FUEL RESISTANT LINE. THE LINE INSTALLED WAS FLEXIBLE/COLLAPSABLE AND HAD A 45 DEGREE KINK ON THE VACUUM SIDE. THIS MA Y LEAD TO LESS VACUUM TO THE FUEL PUMP LOWERING THE CAPABILITY OF THE PUMP. RECOMMEND FOLLOW THE MFG PROCEDURES WHEN INS TALLING THE ENGINE. 1 G 7 1 3I 3 I NT EXPA1G71 EXPE3I 2004050600062 20040506 00062 CE 2004 5 6 2004FA0000295 1 20040127 G 2842 58380019 SENSOR BEECH 55 E55 1152732 CE CONT O520 IO520* 17032 SO FUEL TANK FAULTY D O OTHER O OTHER NR NOT REPORTED 1 NM 08 4000W TE1004 FLOAT DOES NOT BRING ARM TO FULL UP STOP WHEN SUBMERGED. IT WILL COME UP TO APPROX .7500 TO .8750 OF ITS TRAVEL. TAPPI NG ON THE HOUSING WILL EVENTUALLY BRING IT TO THE UP STOP. THIS, IAW MFG, DOES NOT MEET THEIR SPECIFICATIONS. THE FLOA T APPEARS TO NOT HAVE ENOUGH BUOYANCY. FOUR (4) OF THESE TRANSMITTERS WERE TRIED, WITH NO FAVORABLE RESULTS. 1 L 7 2 3O 3 O 3A16 E5CE 2004050600068 20040506 00068 2004 5 6 2004FA0000297 4 20040206 G 3418 DETECTOR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO STALL WARNING INOPERATIVE D O OTHER N FALSE WARNING NR NOT REPORTED 1 GL 27 421ZM 421C1058 THIS NEWLY OVERHAULED DETECTOR WAS INSTALLED AND OPS CHECKED AFTER A COUPLE OF CHECKS THE STALL HORN WILL STAY ON. RETU RNED UNIT FOR ANOTHER O/HED DETECTOR. THIS ABOUT SECOND AIRCRAFT I WENT THROUGH THIS WITH (ORDERING DETECTORS UNTIL I G ET ONE THAT WORKED. NEED BETTER QC). 1 L 7 2 3O 3 O A7CE E7CE 2004050600070 20040506 00070 SO 2004 5 6 2004FA0000370 2 20040426 G 8530 AEC626820ST2J CYLINDER CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO NR 1 SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 SO 09 97660 18267161 466461 NR 1 CYLINDER HEAD SEPARATED FROM CYLINDER BASE IN FLIGHT. (SO09200406841) 1 H 7 1 3O 3 O NT 3A13 E273 2004050600076 20040506 00076 CE 2004 5 6 2004FA0000306 1 20040409 G 2720 S100343A BEARING CESSNA 182 182S 2072701 CE LYC O540 IO540* 41532 EA RUDDER BAR MISSING D K NONE O OTHER IN INSP/MAINT 1 WP 15 182TA 18280062 DURING THE ANNUAL INSPECTION, IT WAS DETERMINED THAT THE BEARING FOR THE CO-PILOT RT RUDDER BAR TO BRAKE BELLCRANK WAS M ISSING. THE FACTORY TORQUE SEAL ON THE ATTACHING HARDWARE WAS UNDISTURBED. 1 H 7 1 3O 3 O NT 3A13 1E4 2004050600078 20040506 00078 CE 2004 5 6 2004FA0000291 1 20040318 G 5312 05530315 FIREWALL CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL FUSELAGE CRACKED C O OTHER O OTHER NR NOT REPORTED 1 SO 13 98528 500 17280605 L769436A R1152 LOWER FIREWALL NUMEROUS CRACKS IN LOWER LEFT SIDE ZONE, 124, RADIATING FROM LOWER BATTERY MOUNT AND COWL MOUNT BRACKETS. THIS IS THE THIRD FIREWALL THAT DEVELOPED CRACKS IN THE SAME AREA. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004050600080 20040506 00080 SO 2004 5 6 2004FA0000293 2 20040305 G 8530 RETAINER CESSNA 172 172D 2072410 CE CONT O300 O300D 17022 SO ENGINE WORN D O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 08 2650U 17250250 2513770R FOUND PN 24077, UPPER VALVE SPRING RETAINER WORN OUT ALLOWING VALVE SPRING TO BYPASS IT. CAUSED LOSS OF STATIC RPM AND SOME ROUGHNESS OCCASIONALLY. 1 H 7 1 3O 3 O NT 3A12 E253 2004050700001 20040507 00001 SO 2004 5 7 BHA05RS 2 20040423 G 8530 TISN712BCA221 CYLINDER HEAD CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO ENGINE SEPARATED B A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 NM 04 414PG 204 414A0811 514461 DURING POWER REDUCTION FROM TAKE-OFF POWER TO CLIMB POWER, A (POP) WAS HEARD AND ONE OF THE ENGINES BEGAN RUNNING ROUGH. THERE WAS NO INSTRUMENT/GAGE INDICATION AS TO WHICH ENGINE. AIRCRAFT LANDED WITH OUT INCIDENT. POST FLIGHT EXAMINATION FOUND NR 1 ENGINE, NR 6 CYLINDER HEAD HAD SEPARATED. 1 L 7 2 3O 3 O A7CE E8CE 2004050700002 20040507 00002 EA 2004 5 7 2004FA0000315 2 20040313 G 8520 PISTON PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C 2D34C215 GL NR 3 CYLINDER MELTED D O OTHER O OTHER NR NOT REPORTED 1 EA 03 8364N 7226 1760 28R8118060 L1544651A 805737 NR 3 PISTON/ CYLINDER MELTED. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004050700022 20040507 00022 CE 2004 5 7 CA040304007 1 20040303 G 7602 5038901027 CONTROL CABLE BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL MIXTURE CONTROL BROKEN W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT THE PILOT NOTICED THAT THE RT MIXTURE WAS NOT RESPONDING TO CONTROL MOVEMENT. THE AIRCRAFT RE TURNED TO BASE UNEVENTFULLY AND UPON MAINTENANCE INSPECTION FOUND THE ENGINE SIDE OF THE CABLE HAD BROKEN AT THE ROD END WHERE THE CABLE SHEATH WAS SWAGED ONTO THE CABLE. THE CABLE IS BEING REPLACED. THE TOTAL TIME ON THIS CABLE ASSY WAS 4. 6 TSN. 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P920 2004050700023 20040507 00023 NM 2004 5 7 CA040304008 1 20040227 G 6120 3034384 LINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE P3 SENSE OUT OF POSITION W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 CA (CAN) THE SHOP ENGINEER WAS TAKING STOCK OF ENGINE WHEN HE NOTICED THAT THE PCU CONTROL ROD (CONDITION) P/N 87620097-023 ,POWER PLANT BUILD IPC REF 71-00-02 FIG 10ITEM 2 WAS CONTACTING THE P3 AIR PRESSURE SENSING LINE P/N 3034384 (PW) IPC 72 -01-30 FIG 1 ITEM 10 BEFORE CONTACTING THE HMU STOP AT MAX SETTING.THIS OCCURS WHEN THE HMU IS REPLACED AND THE T FITTIN G P/N MS9196-04 IS NOT POSITIONED PROPERLY AND OVERLOOKED WHEN RIGGING IS DONE.THE OFFENDING PART IPC REF 72-01-40 FIG 1 ITEM 120 WAS REPOSITIONED SO A GAP BETWEEN THE SENSE LINE AND THE CONTROL ROD WAS SUFFICIENT FOR FULL AND NORMAL MOVEME NT OF THE HMU CONTROL ROD. THE MECHANISM WAS FUNCTIONED WITH NO REOCCURRENCE OF THE PROBLEM ON THE ENGINE IN QUESTION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050700024 20040507 00024 NE 2004 5 7 CA040304009 3 20040304 G 6114 69494R124 SEAL HAMSTD LKHEED 382 382G 526414U SO ALLSN 501D 501D22A 03006 GL HAMSTD 54H 54H60117 NE PUMP HOUSING DISLODGED W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 233452 (CAN) DEPARTING ,THE CREW OBSERVED A LOW PROPELLER FLUID INDICATION ON NR 2. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT RE TURNED TO POINT OF DEPARTURE. MAINTENANCE FOUND THE PACKING FOR THE PRESSURE SUMP FILLER PORT DISLODGED. PACKING REPOSIT IONED, FLUID LEVEL SERVICED, AIRCRAFT GROUND CHECKED SERVICEABLE. 2 H 7 4 4T 4 T A1SO E282 6 C P906 2004050700026 20040507 00026 EU 2004 5 7 CA040304011 1 20040303 G 2910 69596 MAXARET BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP ROTOL R333 R333482F12 GL HYD SYSTEM BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER A FLIGHT THE AIRCRAFT WAS BEING PULLED INTO THE HANGAR. AN AME WAS WALKING PAST THE AIRCRAFT AND NOTICED TH E LT ANTI-SKID COVER WAS MISSING THE THREE RIVETS ON THE CASE. ON REMOVAL OF THE COVER THE COMPOSITE BLOCKS DESIGNED TO HOLD THE DRIVE PORTION OF THE MAXARET AND THE DRIVING HEAD WERE FOUND BROKEN. THE MAXARET APPEARS TO HAVE SEIZED CAUSI NG THE DAMAGE. THIS UNIT HAS NO LIFE OR OVERHAUL LIMITS. THE ONLY SCHEDULED INSPECTION OF THE UNIT IS WHEN IT IS INSTA LLED. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2004050700027 20040507 00027 EA 2004 5 7 CA040210004 1 20040210 G 3220 LANDING GEAR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE NOSE INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) UNABLE TO RETRACT NLG ON GEAR UP SELECTION. 2 L 7 2 4F 4 F RT A21EA E15NE 2004050700031 20040507 00031 SW 2004 5 7 2004FA0000308 1 20040413 G 6220 206010450113 SWASHPLATE BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL MAIN ROTOR INCORRECT D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 WP 01 383SH 12050 51073 RECEIVED SWASHPLATE ASSY FROM VENDOR OVERHAUL SHOP. DURING INSTALLATION FOUND LEVER (PN 206-010-467-001) WAS INSTALLE D UP-SIDE-DOWN. ALSO FOUND SHIMS (PN 206-010-463-005) WERE NET STACKED EVENLY. PROBABLE CAUSE: WORKMANSHIP AND QA PROB LEM. 1 G 7 1 3U 3 U H2SW E1GL 2004050700034 20040507 00034 WP 2004 5 7 CA040305001 1 20040304 G 5240 HOOK CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13D 03004 GL SERVICE DOOR DISENGAGED W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) ON CLIMB OUT, CREW EXPERIENCED CABIN DEPRESSURIZATION AND ILLUMINATION OF (REAR SERVICE DOOR UNLOCKED) LIGHT. UPON RETURN TO THE RAMP, MAINTENANCE PERSONEL DISCOVERED ONE OF THE FOUR HOOKS THAT HOLD THE DOOR CLOSED WAS NOT PROPERLY EN GAGED IN IT'S YOKE. AFTER INSPECTING THE DOOR AND CYCLING SEVERAL TIMES, THE DOOR WAS CLOSED AND THE A/C WAS PRESSURIZED ON THE GROUND. THE AIRCRAFT WAS THEN RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2004050700037 20040507 00037 EA 2004 5 7 CA040305004 1 20040304 G 3310 RV4NBYSD502A RHEOSTAT BOMBDR DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE CAPT DIMMER BURNED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 28503 (CAN) DURING PRE-FLIGHT CHECKS ON THE RAMP, THERE WAS A BURNING ODOR IN THE COCKPIT AND SMOKE WAS OBSERVED COMING OFF TH E CAPTAIN'S SIDE OVERHEAD CEILING PANEL IN THE COCKPIT. AIRCRAFT POWER WAS SHUT DOWN. MAINTENANCE INVESTIGATION REVEALE D A BURNED RHEOSTAT ON THE DIMMER CONTROL FOR THE CAPTAIN'S OVERHEAD LIGHT. THE PANEL ASSY WAS REPLACED WITH NO FURTHER FAULTS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050700038 20040507 00038 NM 2004 5 7 CA040305005 1 20040303 G 5755 85711503001 BRACKET AEROSP DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE ROLL SPOILER UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 36304 095 (CAN) ROLL SPOILER MOUNTING BRACKET P/N 85710559-001. THE AIRCRAFT WAS IN THE PAINT SHOP BEING PREPPED FOR PAINT AND THE CLEANERS THAT WERE CLEANING THE AREA IN AND AROUND THE RT OB ROLL SPOILER ACTUATOR ON THE REAR SPAR NOTICED A LARGE CRA CK IN THE MOUNTING BRACKET. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050700040 20040507 00040 SO 2004 5 7 CA040308008 1 20040303 G 5540 4004009 TORQUE TUBE PIPER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL RUDDER ASSY CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 20210 315435 (CAN) DURING INSPECTION IAW AD 2003-24-07 RUDDER FOUND TORQUE TUBE CORRODED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004050700045 20040507 00045 NE 2004 5 7 CA040306003 2 20040227 G 7320 FADEC CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT LIGHTNING STRIKE W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION AP APPROACH 1 CA (CAN) DURING APPROACH, WITH FLAPS 20, GEAR UP, WING AND COWL ANTI-ICE ON, CONTINUOUS IGNITION ON AC HIT BY A SEVERE LIGH TNING STRIKE. WITHIN 10 SECONDS, ENGINE 2 FLAMED OUT WITH N1 AROUND 20 PERCENT. AROUND 10 SECONDS AFTER, FADEC AUTO RE LIGHT SUCCESSFULLY CARRIED OUT. WITHIN THAT TIME FRAME MESSAGES RT ENG DEGRADED, RT ENG BLEED AND STALL FAIL APPEARED. QRH APPLIED, ALL ENGINES PARAMETERS NORMAL. AC LANDED WITHOUT FURTHER INCIDENT. ON GROUND, LIGHTNING STRIKE CONFIRMED WITH SEVERAL IMPACT ON FUSELAGE. ENGINE RUNS SUCCESSFULLY CARRIED OUT TO CONFIRM GOOD OPERATION OF ENGINE AND FADEC.R FADEC AND DFDR. REMOVED FROM AC FOR ANALYSIS. STRUCTURAL DAMAGES REPAIRED AND AC RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004050700047 20040507 00047 CE 2004 5 7 CA040308001 1 20040218 G 1430 A251352 BOLT CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROPELLER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSTALLATION OF THE PROPELLER, WHEN TIGHTENING THE BOLTS TO THE SPECIFIC TORQUE OF 25-30 POUNDS FOOT. ONE OF THE BOLTS BROKE AT APPROXIMATELY 27 POUNDS FOOT. THE BOLT BROKE AT THE BASE OF THE THREADS NEAR THE START OF THE GRI P. A SECOND BOLT WAS TIGHTENED USING A DIFFERENT TORQUE WRENCH AND IT ALSO BROKE AT THE BASE OF THE THREADS AND AT APPRO XIMATELY THE SAME TORQUE VALUE. THE TORQUE WRENCHES HAD BEEN CERTIFIED APPROXIMATELY ONE WEEK PRIOR. THE PROPELLER AND BOLTS HAD BEEN OVERHAULED AT A PROPELLER OVERHAUL SHOP AND WERE BEING REINSTALLED ON THE AIRCRAFT. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004050700048 20040507 00048 EU 2004 5 7 CA040308002 1 20040224 G 2913 704A33690008 BELT SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE HYDRAULIC PUMP STRETCHED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE INSPECTING THE HYDRAULIC DRIVE BELT IAW 63.00.00.601 PARA 4 FOR PROPER TENSION IT WAS FOUND TO BE LOOSE. AT TEMPTS WERE MADE TO TENSION THE BELT IAW 63.00.00.401 PARA 4.2.3. WE WERE UNABLE TO GET THE REQUIRED TENSION DUE TO NO MORE MOTION OF THE TENSIONING BRACKET. MET 63.00.00.601 PARA 4.1 STATES THAT IF YOU CANT ACHIEVE REQUIRED TENSION REPL ACE THE BELT WHICH OCCURRED. THIS IS THE LATEST BELT PT NR 704A33690008 POLY V 597K4 WHICH HAS A PUBLISHED LIFE IAW M SR OF 1500 HOURS. THIS BELT FAILED INSPECTION AT 371. HOURS. DISCUSSIONS WITH MFG INDICATED THAT A LOWER TIGHTENING TEN SION IS IN THE WORKS SO THE BELT WOULD NOT BE RUNNING AS TIGHT. 1 G 7 1 3U 3 U H9EU E19EU 2004050700050 20040507 00050 EA 2004 5 7 CA040308005 1 20040308 G 5297 840534 SWITCH CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE SERVICE DOOR INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SERVICE DOOR EXTERIOR HANDLE WAS OUT AFTER LANDING WITH NO CAUTION OR INDICATIONS. SWITCH REPLACED. DOOR RIGGED IA W AMM. 2 L 7 2 4F 4 F RT A21EA E15NE 2004050700051 20040507 00051 CE 2004 5 7 CA040308007 1 20040302 G 3230 GEARBOX BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA MCAULY 4HFR34 4HFR34C652 NE MLG INOPERATIVE W O OTHER O OTHER CL CLIMB 1 CA 405880 (CAN) DURING FLIGHT THE LANDING GEAR TOOK LONGER THAN NORMAL TO RETRACT. COULD NOT DUPLICATE THE PROBLEM IN THE HANGAR E VEN WHEN SWINGING THE GEAR WITH EXTRA LOADS. SUSPECTED THAT THE CLUTCH WAS SLIPPING DURING RETRACTION WITH THE INCREASE D LOADS DURING FLIGHT. THE LANDING GEAR GEARBOX WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE WITH OUT FURTHER I NCIDENT. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004050700053 20040507 00053 CE 2004 5 7 CA040210008 1 20040206 G 3260 1003810061 DOWNLOCK SWITCH BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE MLG DEFECTIVE W O OTHER N FALSE WARNING AP APPROACH 1 CA 12293 (CAN) ON APPROACH TO HIGH LEVEL WHEN GEAR WAS EXTENDED THE GREEN NOSE GEAR DOWN LIGHT DID NOT ILLUMINATE. THE RED IN TR ANSIT LIGHT HAD EXTINGUISHED. AIRCRAFT LANDED UNEVENTFULLY AND WAS INSPECTED AND DEEMED SAFE FOR SPECIAL FLIGHT PERMIT WITH NO PAX. MAINTENACE FOUND THE NOSE GEAR DOWNLOCK SWITCH TO BE DEFECTIVE. IT WAS REPLACED AND GEAR SWINGS SHOWED NO FURTHER PROBLEMS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004050700054 20040507 00054 NE 2004 5 7 CA040211001 2 20040131 G 7322 2100140007 GEARBOX CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE RT THROTTLE INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) RT ENGINE WOULD NOT SHUTDOWN AT GATE WITH THRUST LEVER AT SHUT OFF POSITION. MAINTENANCE REPLACED THE RT THROTTLE CONTROL GEARBOX ASSY AND RT MAIN FUEL CONTROL UNIT. AIRCRAFT RETURNED TO SERVICE. PARTS REPLACED: THROTTLE CONT GEAR BOX ASSY, P/N: 2100140-007, S/N: 601, MAIN FUEL CONT, P/N: 6078T55P09, S/N: WYG85422, 2 L 7 2 4F 4 F RT A21EA E15NE 2004050700055 20040507 00055 EA 2004 5 7 CA040211002 1 20040203 G 5610 NP1393219 WINDOW CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT SIDE BROKEN W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) CAPTAIN SIDE WINDOW SHATTERED IN CRUISE AT FL370. AN UNEVENTFUL LANDING FOLLOWED. THE SIDE WINDOW WAS REPLACED A ND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004050700057 20040507 00057 WP 2004 5 7 CA040211004 1 20040210 G 6310 369F55101 DRIVE SHAFT HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL MAIN ROTOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A SCHEDULED INSPECTION THE MAIN ROTOR DRIVESHAFT WAS REMOVED AND INSPECTED. THE DRIVE SPLINES SHOWED EVIDE NCE OF CORROSION UNDER THE COATING ON THE SPLINES. ALL SPLINES SHOWED BLACK FLAKES OF THE COATING COMING OFF AND YOU CO ULD SEE CORROSION UNDER THE COATING. 1 G 7 1 3U 3 U H3WE E4CE 2004051000039 20040510 00039 2004 5 10 2004FA0000320 4 20040415 G 8300 GEAR MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA ACCESSORY G/B WORN D O OTHER O OTHER NR NOT REPORTED 1 NM 02 78940 1974 1635236A REMOVED OIL PUMP TO CHECK ON TYPE OF GEARS, FOUND SINTERED IRON IMPELLERS. REPLACED WITH HARDEN GEAR KIT. 1 L 7 1 3O 3 O 2A3 E286 2004050300157 20040503 00157 CE 2004 5 3 2004FA0000313 1 20040108 G 5280 24130832 DOOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA NOSE GEAR OUT OF RIG B CMXR O OTHER O OTHER NR NOT REPORTED 1 CE 05 9084F 172RG0352 NOSE GEAR OB EDGE CAUGHT ON GEAR WELL BUMPERS AND PREVENTED NG DOORS FROM OPENING WHEN GEAR SELECTED DOWN. IT IS CAUSED BY DOORS BEING RIGGED WITH TOO LITTLE CLEARANCE, BUMPER WEAR THIN AND ALLOW GEAR DOORS TO RAISE ON TOP OF BUMPER AND WE DGE DOORS. NOSE GEAR WOULD NOT EXTEND BECAUSE DOORS WERE WEDGED AND COULD NOT OPEN CAUSING A LANDING WITHOUT NOSE GEAR DEPLOYED, CAUSING DAMAGE TO THE PROPELLER AND NOSE GEAR DOORS. CLEARANCE IS .160 MAX AND .100 MIN. BUMPER IS .375 IN W IDTH AND IF BUMPER WEARS THIN OR EVEN AWAY THEN THERE IS AN EDGE THAT DOOR CAN WEDGE ON. CHECK GEAR DOOR OB EDGES TO IN SURE SPOT WELDS ARE INTACT AND DOOR SKINS HAVE NOT SEPARATED ALLOWING ONE SKIN TO CATCH ON BUMPERS. 1 H 7 1 3O 3 O 3A17 E286 2004050300160 20040503 00160 SO 2004 5 3 LU4R349M 1 20040316 G 6120 B24521 CYLINDER PIPER PA23 PA23250 7102308 SO LYC O540 IO540* 41532 EA HARTZL HCE2Y HCE2YR2 GL PROPELLER DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 SO 15 BP9634 CYLINDER (PN B-2452-1) SEPARATED FROM PROPELLER ON GROUND RUN. INSPECTION SHOWED THREAD DAMAGE OF CYLINDER. AFTER DISCUS SION WITH MFG, THE LIKELY CAUSE IS DIE TO HIGH PRESSURE FROM GOVERNOR, USUALLY CAUSED BY STICKING PRESSURE RELIEF VALVE. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 2004050300161 20040503 00161 NM 2004 5 3 2004FA0000331 1 20040413 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 102 0099990080 DURING ACCOMPLISHMENT OF AD 2002-10-05 (MAIN ROTOR UPPER HUB INSP.) FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTE D IN SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300182 20040503 00182 CE 2004 5 3 MAFPAPUA 1 20040322 G 2810 S2020 DRAIN CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL FUEL SUMP FAILED D O OTHER O OTHER NR NOT REPORTED 1 WP 23 PK-MA U20606231 532210 781860 WHILE INSTALLING THE WING FUEL TANK SUMP DRAIN AT THE MFG RECOMMENDED TORQUE VALUE OF 90 IN-LBS, THE DRAIN ITSELF FAILED , SEPARATING AT THE DRILLED HOLES JUST ABOVE THE FITTING HEAD. 1 H 7 1 3O 3 O A4CE E8CE 5 C P47GL 2004050300232 20040503 00232 SW 2004 5 3 CA040225013 1 20040218 G 2140 BEARING BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL HEATER FAILED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING FLIGHT PILOT COULD SMELL SOMETHING ABNORMAL, HE LOOKED AT CB PANEL AND NOTICED HELICRAFT HEATER CB SWITCH H AD TRIPPED. HE THEN TURNED OFF BLEED AIR TO PREVENT HEAT DAMAGE, ONCE BLOWER WAS REMOVED IT WAS DETERMINED THAT THE BEAR INGS HAD FAILED. 1 G 7 1 3U 3 U H2SW E4CE 2004050300245 20040503 00245 GL 2004 5 3 CA040114003 2 20040105 G 7323 8575472 LOCK GEAR ALLSN 501D 501D13 03004 GL SSC DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SPEED SENSITIVE CONTROL (SSC) RECEIVED FROM CHANNEL EXPRESS AS A TYPE-CERTIFICATED COMPONENT. STANDARD AERO LIMIT ED (SAL) ASSUMED OWNERSHIP OF SSC, AND PLACED UNIT INTO SAL REPAIRABLE STOCK. SSC RECENTLY REMOVED FROM SAL STOCK TO BE OVERHAULED AND INSTALLED ON A 501-D13 ENGINE. TECHNICIAN NOTED P/N 8575472, A NON TYPE-CERTIFICATED MILITARY COMPONENT , WAS EMBODIED IN THE SSC. 4 T E282 2004050300277 20040503 00277 EA 2004 5 3 CA040301007 2 20040229 G 7210 3021467 BEARING PWA BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA REUX GEARBOX DISINTEGRATED W A UNSCHED LANDING J WARNING INDICATION AP APPROACH 1 CA (CAN) VISUAL INSPECTION REVEALED BEARING RETAINING FAILURE. APRROXIMATELY ONE QUARTER OF RETAINER MISSING. WILL SEND TO PWC FOR EXAMINATION. 1 G 7 1 4U 4 U H4SW E22EA 2004050400007 20040504 00007 2004 5 4 CA040302005 4 20040225 G 5301 143232 CABLE 143232 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL HOOK END FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT HAD UNCOMMANDED LOAD RELEASE. INVESTIGATION REVEALED THAT THE MANUAL RELEASE CABLE HAD FRAYED WHERE THE CABL E GOES INTO THE CARGO HOOK. THIS CAUSED THE HOOK TO RELEASE. THIS IS A ONBOARD SYSTEMS KEEPERLESS HOOK. 1 G 7 1 3U 3 U H3WE E4CE 2004050400011 20040504 00011 WP 2004 5 4 CA040303001 2 20040302 G 7230 3072163 BLADE GARRTT LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP FAN ROTOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 970322900732 (CAN) A MECHANIC WAS CARRYING OUT A SERVICE CHECK AND HE NOTICED FOD IN THE RT ENGINE INTAKE. UPON INSPECTION OF THE IN TAKE, FOUND A PIECE OF BLADE RUB STRIP MISSING, REAR ACOUSTIC LINER DAMAGE AND TWO DAMAGED FAN BY PASS STATOR BLADES. ON E FAN BLADE DAMPENER WAS ALSO MISSING. ENGINE REPLACED. 2 L 7 2 4F 4 F A10CE E6WE 2004050500155 20040505 00155 SO 2004 5 5 2004FA0000340 2 20040331 G 8530 631996 ROCKER CESSNA 172 R172K 2072431 CE CONT O360 IO360KB 17025 SO ENGINE BROKEN B H00R O OTHER O OTHER NR NOT REPORTED 1 EA 21 736DU R1722452 288641 FOUND HOLE IN ROCKER COVER CAUSED BY ROCKER ARM ON EXHAUST SIDE. FOUND FWD STUD ASSY BROKEN OFF FLUSH WITH CYLINDER HEA D. STUD (PN 401852). ROCKER RETAINER (PN 631996) WAS BROKEN AND HALF MISSING (GONE OUT OF HOLE IN COVER) IB STUD HOLD DOWN NUT WAS 4 TO 5 THREADS FROM COMING OFF. SUSPECT NUTS WERE NOT PROPERLY TORQUED. 1 H 7 1 3O 3 O 3A17 E1CE 2004050600028 20040506 00028 CE 2004 5 6 206040204 1 20040402 G 7820 12502505 MUFFLER CESSNA 206 206CESSNA 2073302 CE CONT O520 IO520* 17032 SO ENGINE BULGED B JBZR K NONE O OTHER IN INSP/MAINT 1 WP 27 5224U 2060224 WHILE PERFORMING A ROUTINE PREFLIGHT INSPECTION, MECHANIC LOOKED UP TAILPIPES OF EXHAUST SYSTEM AND NOTICED SILENCER CON E HAD EXTENDED TO POSITION THAT WAS JUST SHORT OF CLOSING OFF EXHAUST PATH. THIS CONDITION OCCURRED OVER A PERIOD OF LE SS THAN 50 HOURS WHEN SAME MECHANIC HAD PERFORMED SAME VISUAL INSPECTION AND NOTED NO UNUSUAL CONDITIONS. 1 H 7 1 3O 3 O A4CE E5CE 2004050600029 20040506 00029 CE 2004 5 6 2004FA0000363 1 20040413 G 5210 551123514 HINGE CESSNA CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE CABIN DOOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 25 92B 6678 5500471 WHEN PILOT OPENED CABIN DOOR, A GUST OF WIND CAUGHT DOOR AND SLAMMED IT INTO STOP. PILOT REPORTED A LOUD (POP) AND PAINT FELL FROM DOOR HINGE. INSPECTION REVEALED LOWER LEG OF DOOR HINGE HAD BROKEN. DISASSEMBLY REVEALED EVIDENCE OF A PRE EXISTING SUBSURFACE CRACK IN CASTING, 3 INCH AFT OF HINGE BEARING. A SURFACE CRACK 1INCH LONG 1.5 INCH AFT OF HINGE BEAR ING WAS HIDDEN BY HEAVY PAINT COATING. THESE CRACKS WOULD NOT BE VISIBLE WITHOUT PAINT REMOVAL. RECOMMEND PAINT BE REMO VED AND CAST PORTION OF HINGE INSPECTED UNDER MAGNIFICATION AT 500 HR INTERVALS. 1 L 7 2 4F 4 F A22CE E1NE 2004050600047 20040506 00047 CE 2004 5 6 2004FA0000311 1 20040108 G 5280 245000615 BUMPER BLOCK CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA LT NLG DOOR WORN B CMXR O OTHER O OTHER NR NOT REPORTED 1 CE 05 9084F 172RG0352 NG DOOR OB EDGE CAUGHT ON GEAR WELL BUMPERS AND PREVENTED NG DOORS FROM OPENING WHEN GEAR SELECTED DOWN. IT IS CAUSED B Y DOORS BEING RIGGED WITH TOO LITTLE CLEARANCE, BUMPERS WEAR THIN AND ALLOW GEAR DOORS TO RAISE ON TOP OF BUMPER AND WED GE DOORS. NOSE GEAR WOULD NOT EXTEND BECAUSE DOORS WERE WEDGED AND COULD NOT OPEN CAUSING A LANDING WITHOUT NOSE GEAR D EPLOYED, CAUSING DAMAGE TO THE PROPELLER AND NOSE GEAR DOORS. CLEARANCE IS .160 MAX AND .100 MIN. BUMPER IS .375 IN WI DTH AND IF BUMPER WEARS THIN OR EVEN AWAY THEN THERE IS AN EDGE THAT DOOR CAN WEDGE ON. CHECK GEAR DOOR OB EDGES TO INS URE SPOT WELDS ARE INTACT AND DOOR SKINS HAVE NOT SEPARATED ALLOWING ONE SKIN TO CATCH ON BUMPERS. 1 H 7 1 3O 3 O 3A17 E286 2004050600057 20040506 00057 EA 2004 5 6 2004FA0000289 2 20040301 G 7324 2526388 DIAPHRAGM LYC O540 IO540* 41532 EA FUEL DIVIDER IMPROPER B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 MATERIAL TOO THIN OR TOO SOFT. WHEN TORQUING RETAINING SCREW MATERIAL SQUEEZES OUT WITH NR 5 TORQUE. FUEL FLOW DIVIDER , BENDIX. 3 O 1E4 2004050600061 20040506 00061 EA 2004 5 6 2004F00085 2 20040227 G 7310 LW120980100 TUBE BEECH 36 36BEECH 1151602 CE LYC O540 TIO540J2BD 41532 EA FUEL SYSTEM BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 07 7886L E10 1719461A THIS IS THE TUBE THAT ATTACHES FROM THE FLOW DIVIDER TO THE INJECTOR. THE TUBE BROKE AT THE WELD ON THE END ATTACHED TO T THE FLOW DIVIDER. THE LACK OF SUPPORT CLAMPS ON THE LINE MAY HAVE CAUSED THE LINE TO VIBRATE AND BREAK. 1 L 7 1 3O 3 O 3A15 E14EA 2004050600075 20040506 00075 CE 2004 5 6 2004FA0000316 1 20040408 G 2434 DOFF10300BR WIRE CESSNA 210 210M 2073450 CE CONT O520 IO520* 17032 SO ALTERNATOR SHORTED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 761SP 21062483 THE 3 WIRES COMING FROM THE STATOR ARE SHORTED OUT ON THE CASE. THIS IS 4TH ALTERNATOR OVERHAUL BY FACILITY WITH THE SA ME FAILURE, ALL 4 ALTERNATORS HAD LESS THAN 390 HOURS SINCE OVERHAUL. THERE NEED TO BE MORE INSULATION ON THE 3 WIRES. 1 H 7 1 3O 3 O 3A21 E5CE 2004050700021 20040507 00021 NE 2004 5 7 CA040304005 2 20040303 G 7321 4147T70P02 FCU CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE ENGINE MALFUNCTIONED W A UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 CA GEE950069 (CAN) DURING TEST FLIGHT PROCEDURES, AFTER DOING RELIGHT OF LT ENGINE, THERE WAS NO THROTTLE REPONSE ON THE LT ENGINE. THE CREW DECLARED AN EMERGENCY AND CARRIED OUT A SINGLE ENGINE LANDING WITHOUT FURTHER INCIDENT. UPON RETURN, ALL ENGIN E RIGGING WAS VERIFIED ( STATIC AND DYNAMIC ) WITHOUT ANY FINDINGS. EVERYTHING WAS NORMAL. THEN, A/C WAS TAKEN OUT TO RUN ENGINE AND PROBLEM WAS CONFIRMED, THEN FAULT ISOLATION LED TO THE FUEL CONTROL UNIT SINCE MOTIVE FLOW WAS PRESENT. THE FUEL CONTROL UNIT WAS REPLACED AND A/C RAN SERVICEABLE. IT HAS SINCE RETURNED TO FLIGHT WITHOUT FURTHER OCCURENCES. 2 L 7 2 4F 4 F RT A21EA E15NE 2004050700058 20040507 00058 CE 2004 5 7 CA040211005 1 20040123 G 5610 101384025 WINDSHIELD BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT FAILED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DEFECT REPORTED AS, RT OUTER WINDSHIELD SHATTERED IN FLIGHT. AIRCRAFT WAS ENROUTE AT FL250 WHEN THE WINDSHIELD S HATTERED WITH NO PRIOR INDICATIONS AND NO WINDSHIELD HEAT SELECTED, OAT WAS 41C. THE AIRCRAFT DIVERTED TO HOME BASE. UPON INSPECTION IT WAS DISCOVERED THAT THE INNER PANE HAD SHATTERED AND WINDSHIELD REPLACED WITH SUPERCEDED P/N 101-3840 25-24 IAW THE STRESS FREE INSTALLATION KIT INSTRUCTIONS. SCREWS TORQUED FOLLOWING SEALANT CURE TIME. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004051000034 20040510 00034 SO 2004 5 10 2004FA0000371 1 20040423 G 3245 TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA TIRE BLEW OUT G O OTHER O OTHER LD LANDING 1 EA 17 102WM 250 318152112 NOSE TIRE BLEW ON LANDING. NO CAUSE COULD BE DETERMINED BY MAINT. THEY SUSPECTED LOW TIRE PRESSURE. TUBE VALVE SHEARE D OFF. 1 L 7 2 3O 3 O A20SO E14EA 2004051200027 20040512 00027 CE 2004 5 12 FBFQA1 1 20040507 G 3610 621456120 BELLOWS CESSNA 650 650 2076802 CE GARRTT TFE731 TFE7313 01518 WP PRECOOLER CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 09 534H 8587 6500196 P87512 UPON INSPECTION AND PRESSURIZATION CHECKS THE WYE PIPE BELLOWS WAS FOUND TO BE CRACKED. 2 L 7 2 4F 4 F A9NM E6WE 2004051200029 20040512 00029 SO 2004 5 12 2004FA0000376 1 20040504 G 3220 400873 BOLT PIPER PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL ZONE 700 SHEARED B A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SO 15 708ER 1692 35 2844067 L3023651A 011204 DURING FLIGHT, THE PILOT REPORTED THAT THE GEAR UNSAFE LIGHT WAS ILLUMINATED DURING GEAR RETRACTION. THE GEAR WAS EXTEND ED AND 3 GREEN LIGHTS WERE OBSERVED. DURING THE SUBSEQUENT INSPECTION, THE BOLT IDENTIFIED BELOW WAS FOUND SHEARED AND T HE PORTION OF THE BOLT WITH THE HEX ON IT WAS NOT FOUND. THE THREADED PORTION, WITH THE NUT AND WASHER STILL ATTACHED, W AS FOUND TO BE THE ONLY ATTACHING ITEM CONNECTING THE ACTUATOR ROD END TO THE OVER CENTER DEVICE. NO OTHER DAMAGE WAS FO UND AND THE HARDWARE WAS REPLACED WITH NEW. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004051300019 20040513 00019 CE 2004 5 13 2004FA0000379 1 20040415 G 2720 CONTROL CABLE CESSNA 182 182R 2072731 CE CONT O470 O470* 17026 SO RUDDER FRAYED B OACR O OTHER O OTHER NR NOT REPORTED 1 NE 05 9873E 2357 18268459 WHILE INSTALLING THE BATTERY AFTER SERVING, IT WAS NOTICED THAT THE FORWARD RT RUDDER CABLE WAS FRAYED IN TWO SPOTS. IT WAS DETERMINED THAT, AT SOMETIME, DURING BATTERY REMOVAL OR REINSTALLATION THE RUDDER CABLE ARCED ON BOTH POSITIVE AND NEGATIVE POSTS. THE FORWARD SPOT WAS ARCED THROUGH MORE THAN HALF THE DIAMETER OF THE CABLE. AFTER REMOVING THE CABLE IT WAS NOTICED THAT ONLY TWO STRANDS OF THE CABLE HELD IT TOGETHER. THE CABLE WAS REPLACED WITH FACTORY NEW. THE BATTE RY REMOVAL AND REINSTALLATION ON THIS MODEL AC REQUIRES GOING THROUGH A PANEL IN THE AFT SIDE FUSELAGE. 1 L 7 1 3O 3 O NT 3A13 E273 2004051300024 20040513 00024 SO 2004 5 13 2004FA0000385 2 20040426 G 8530 AEC626820ST2J CYLINDER HEAD CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO MCAULY 2A34C C2A34C204 GL ENGINE SEPARATED D A UNSCHED LANDING B E K SMOKE/FUMES/ODORS/SPARKS VIBRATION/BUFFET FLUID LOSS CL CLIMB 1 SO 09 97660 404 18267161 466461 804513 NR 1 CYLINDER HEAD SEPARATED FROM CYLINDER BASE IN FLT. MAY NEED TO BE ADDED TO AD 2004-08-10. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2004051300026 20040513 00026 SO 2004 5 13 2004FA0000387 2 20040507 G 7313 TITAN ADAPTER CESSNA 310 310Q 2074242 CE CONT O470 IO470VO 17026 SO FUEL NOZZLE BACKED OUT D K NONE O OTHER IN INSP/MAINT 1 SO 15 3310D 45 310Q0630 2 FUEL INJECTION NOZZLE ADAPTERS BACKED OUT WITH FUEL NOZZLES. 1 L 7 2 3O 3 O 3A10 3E1 2004051300038 20040513 00038 SO 2004 5 13 T0438 1 20040504 G 1100 DATA PLATE PIPER PA32 PA32R301T 7103220 SO LYC O540 TIO540* 41532 EA ENGINE DEPARTED B K NONE D INFLIGHT SEPARATION IN INSP/MAINT 1 SW 05 424PW 197 197 3257186 RL900561A ENGINE DATA PLATE RIVETS ARE BECOMING LOOSE CAUSING THE DATA PLATE TO SEPARATE FROM ENGINE. WE ARE SEEING THIS ON SEVERA L ENGINES. 1 L 7 1 3O 3 O A3SO E14EA 2004051400024 20040514 00024 GL 2004 5 14 2004FA0000377 2 20040510 G 8500 BEARING AMTR VANS RV8A 05608J0 GL AMTR CHEVY6 CHEVYV6 GL ENGINE SEIZED G A UNSCHED LANDING G MULTIPLE FAILURE CL CLIMB 1 SW 13 82LS 5 81013 THIS WAS SECOND FLIGHT ON THE AIRCRAFT, AIRCRAFT DEPARTED, AND UPON CLIMB OUT ENGINE EXPERIENCED HIGH OIL TEMPERATURE AN D REDUCED RPM, PILOT RETURNED TO RUNWAY AND LANDED SHORT OF RUNWAY THRESHOLD. EXAMINATION OF ENGINE BY THE PILOT REVEALE D THAT MAIN BEARINGS AND ROD BEARING CLEARANCES WERE TOO TIGHT AND ENGINE PARTIALLY SEIZED. ENGINE INSTALLED IN THIS EXP ERIMENTAL AIRCRAFT IS CONVERTED FOR AIRCRAFT USE. TOTAL RUN TIME ON ENGINE IS APPROXIMATELY FIVE HOURS. 1 L 7 1 3O 3 V NC EXPA1L71 EXPE3V 2004051400071 20040514 00071 EA 2004 5 14 2004FA0000394 2 20040414 G 7320 70210301 SERVO CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL FUEL SYSTEM INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 WP 27 665SP 1 172S8069 L1699851A S4101 ENGINE HAD VERY ROUGH AND RICH IDLE, COULD NOT ADJUST IDLE MIXTURE IAW AD. FUEL SERVO WAS INSTALLED ON A FRESH O/H ENGI NE AND FUEL SERVO WAS ALSO FRESH FROM O/H. ENGINE WAS OPERATED AND LEAK CHECKED. AFTER .2 HOURS OF ENGINE OPERATION. FUEL SERVO BECOME ROUGH AND RICH. IDLER MIXTURE COULD NOT BE ADJUSTED. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2004051400095 20040514 00095 SO 2004 5 14 2004FA0000398 1 20040317 G 5720 STRAP MICCO 145A MAC145A 5660000 SO LYC O540 IO540T4B5 41532 EA WING CRACKED D LM8S O OTHER O OTHER NR NOT REPORTED 1 NM 07 969WC 188 260010 DURING AN ANNUAL INSPECTION THE BUTT WELDS IN THE LOWER MAIN SPAR REINFORCEMENT STRAP, APPROX 3.25 INCHES IB FROM EACH E ND OF THE REINFORCEMENT STRAP, DO NOT HAVE PROPER PENETRATION AND ARE CRACKED THRU THE WELD. MFG WAS CONTACTED AND REPA IR INSTRUCTIONS WERE PROVIDED. THE WELDS WERE PROPERLY PREPARED AND REWELDED IAW THE MFG INSTRUCTIONS BY A CERTIFIED WE LDING REPAIRMAN. 1 L 7 1 3O 3 O RC 1E4 2004051400096 20040514 00096 SO 2004 5 14 2004FA0000399 1 20040317 G 5720 STRAP MICCO 145A MAC145A 5660000 SO LYC O540 IO540* 41532 EA WING CRACKED D LM8S O OTHER O OTHER NR NOT REPORTED 1 NM 07 969WC 260010 L2797148A DURING AN ANNUAL INSPECTION THE BUTT WELDS IN THE LOWER MAIN SPAR REINFORCEMENT STRAP. APPROX 6.50 INCHES IB FROM EACH E ND OF THE REINFORCEMENT STRAP. DO NOT HAVE PROPER PENETRATION AND ARE CRACKED THRU THE WELD. MFG WAS CONTACTED AND REP AIR INSTRUCTIONS WERE PROVIDED. THE WELDS WERE PROPERLY PREPARED AND REWELDED IAW MFG. 1 L 7 1 3O 3 O RC 1E4 2004051400112 20040514 00112 2004 5 14 705050704 4 20040504 G 3414 26465933 INDICATOR ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE7313 01518 WP AIRSPEED ERRATIC E C ABORTED TAKEOFF M OVER TEMP TO TAKEOFF 1 SO 35 705AC 870 870 209 AIRCRAFT ABORTED TAKEOFF DUE TO A AIRSPEED INDICATION ANOMALY. BRAKES EXPERIENCED AN OVERHEAT. 2 M 7 2 4F 4 F A2SW E6WE 2004051400125 20040514 00125 CE 2004 5 14 2004F00104 1 20040322 G 2701 100524119 CONTROL COLUMN BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE COCKPIT INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 GL 23 552TP 1753 FL281 PK301 DURING A PHASE INSPECTION A SQUEAK WAS NOTED DURING MOVEMENT OF FLIGHT CONTROL COLUMN. INVESTIGATION REVEALED. LOOSE R IVETS BETWEEN THE CONTROL T COLUMN AND BEARING PLATES AT THE POINT WHERE THE CONTROL COLUMN ATTACHES TO THE AIR FRAME AN D PIVOTS. MFG ISSUED SB. AC WAS INSPECTED AT THAT TIME AND FOUND AIRWORTHY. THIS PROBLEM OCCURRED 12 HOURS AFTER COMP LETION OF SB. WOULD SUGGEST MFG THIS ITEM TO ALL PHASE INSP. 2 L 7 2 4T 4 T RT A24CE E4EA 2004050300224 20040503 00224 NE 2004 5 3 CA040225004 2 20040225 G 7200 ENGINE AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE NR 1 STALLED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) REPEAT NR 1 ENG STALL. (MORE INFO WILL FOLLOW) 2 L 7 2 4F 4 F RT A28NM E29NE 2004050300226 20040503 00226 EU 2004 5 3 2004F00101 1 20040310 G 3340 017601 HOUSING SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1 60030 NE SPOT LIGHT CRACKED B O OTHER O OTHER NR NOT REPORTED 1 WP 23 232LA 502 3356 CRACKED AT DRIVE FLANGE WELD. POSSIBLE CAUSE- AERODYNAMIC AND MECHANICAL FORCES AT DRIVE FLANGE. RECOMMENDATION-USE OF STRONGER BASE MATERIAL AND STRICTER CONTROL OF WELDING PROCESS. 1 G 7 1 3U 3 U H9EU E19EU 2004050300242 20040503 00242 WP 2004 5 3 CA040226006 2 20040224 G 7200 TPE33110UA ENGINE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE RIGHT MAKING METAL W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 22198 P54043 (CAN) ONCE AT LEVEL FLIGHT THE RT ENGINE OIL PRESSURE WAS NOTICE TO BE AT THE LOWER END OF THE GREEN ARC 70 PSI, THE OIL PRESSURE WAS MONITORED UNTIL IT DROPPED TO 65 PSI AND THE CREW ELECTED TO RETURN. THE PRESSURE REMAINED STABLE AT 65 PS I, UNTIL TOUCHDOWN WHERE THE OIL PRESSURE DROPPED TO ZERO. THE ENGINE WAS SECURED AND THE LANDING COMPLETED WITHOUT FURT HER INCIDENT. A SUBSEQUENT INSPECTION REVEALED EXCESSIVE METAL IN THE OIL FILTER, THE LT ENGINE WAS REMOVED FOR REPAIR. FOLLOWUP INFORMATION WILL BE ADDED ONCE TEAR DOWN AND ANALYSIS IS COMPLETE. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2004050300248 20040503 00248 NE 2004 5 3 CA040227003 2 20040206 G 7322 PD12H4 CARBURETOR DOUG DC3 DC3C 3021457 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E50 NE ENGINE OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 CA CP356035 (CAN) AIRCRAFT LANDED AND THROTTLES RETURNED TO IDLE, THE NR 2 ENGINE LOADED UP AS IF IT WAS EXCESSIVELY RICH AND THE EN GINE STOPPED. IT WAS IN TAXI PHASE SO THE AIRCRAFT ROLLED TO PARKING POSITION. MAINTENANCE FOUND THAT THE IDLE MIXTURE W AS EXCESSIVELY RICH AND WOULD NOT RESPOND TO ADJUSTMENT CARBURETOR WAS REPLACED AND THE AIRCRAFT RELEASE FOR RETURN TO S ERVICE. CARBURETOR WITH ONLY 3.8 HOURS TSO, WAS SENT FOR WARRANTY AND REPORT OF DEFECT. 2 L 7 2 4R 4 R A669 5E4 6 C P603 2004050600079 20040506 00079 SO 2004 5 6 2004FA0000369 2 20040429 G 8520 SA627246 MAIN BEARING CESSNA 150 150E 2071812 CE CONT O200 O200* 17020 SO ENGINE SEPARATED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2586J 2385 15061086 605994A AFT THRUST FACES OF BOTH FRONT MAIN BEARING HALVES WERE SEPARATED FROM BEARING. THIS IS A ONE PIECE STYLE THRUST/MAIN B EARING. PROBLEM FOUND DURING OVERHAUL, NO INDICATIONS OF FAILURE NOTED BEFORE DISASSEMBLY. NO DAMAGE TO CASE OR CRANKS HAFT. 1 H 7 1 3O 3 O 3A19 E252 2004050700016 20040507 00016 WP 2004 5 7 CA040202007 1 20040116 G 2752 59370525001 ACTUATOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE RT FLAP LEAKING W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) AFTER TAKEOFF, CABIN AND COCKPIT FILLED WITH BLUE SMOKE SMELLED LIKE SKYDROL. APU HAS INGESTED SKYDROL FROM LEAK R T WHEEL WELL. AIRCRAFT LANDED BACK. THE USE OF APU HAS BEEN CANCELLED IAW MEL. WATER SEPARATORS AND COALESER BAGS CLEANE D AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004050700032 20040507 00032 NE 2004 5 7 CA040202014 2 20040106 G 7250 PT6A112 ENGINE PWA PT6 PT6A112 52043 NE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 12519 (CAN) ENG WAS INVOLVED IN A PROP STRIKE INCIDENT, AC PULLED OFF THE RUNWAY AND NLG STRUCK A STUMP, FORCE OF THIS IMPACT COLLAPSED LANDING GEAR, BOTH PROPS STRUCK THE GROUND. IT WAS CLEAR TO IDENTIFY THAT ENG SUFFERED FROM PROP STRIKE. E XHAUST DUCT WAS SEVERELY TWISTED, DISTORTED AND ASSOCIATED IT WERE 2 BENT OIL TRANSFER TUBES. THIS TWISTED CONDITION OF EXHAUST DUCT ALSO CAUSED PT DISK ASSEMBLY, SEALS TO SEVERELY RUB AGAINST THE PT SHROUD RING KNIFE-EDGES AND THE PTV RING INTERSTAGE BAFFLE, PROP SHAFT WAS NOT TURNING PRIOR TO DISASSEMBLY. EXHAUST DUCT OUTER SKIN SEC MOVED OFF CENTER DURIN G IMPACT, WHICH CAUSED THESE COMPONENTS TO DISPLACE, RUB AND SEIZE. ENGINE WILL BE RESTORED TO A SERVICEABLE CONDITION. 3 T E4EA 2004050700035 20040507 00035 NM 2004 5 7 CA040305002 1 20040304 G 3260 PROXIMITY SENSOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE NLG DISCONNECTED W O OTHER N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER TAKEOFF, CREW SELECTED LANDING GEAR UP, AFTER SELECTION OF LANDING GEAR UP THE CREW HAD AN UNSAFE NOSE GEAR INDICATION, AND PROCEEDED TO SELECT LANDING GEAR DOWN WHEN SELECTION DOWN WAS COMPLETED THE NOSE GEAR INDICATION REMAINE D NOSE UNSAFE, BUT ALTERNATE NOSE DOWN AND SAFE WAS GREEN (POSITIVE DOWN) CREW DECLARED EMERGENCY LANDING, LANDED SAFELY . MAINTENANCE FOUND BROKEN WIRE AT NOSE LANDING GEAR DRAG STRUT PROXIMITY SENSOR, WIRES WERE REPAIRED, GEAR SWING CARRI ED OUT AND AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004051000042 20040510 00042 CE 2004 5 10 0423JKW 1 20040424 G 2742 2A9200H ACTUATOR LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP HORIZONTAL STAB INOPERATIVE C O OTHER J WARNING INDICATION NR NOT REPORTED 1 CE 09 45HF 258 172 121 CREW REPORTED (PRIMARY TRIM FAULT) WHITE EICAS MESSAGE, WHICH CHANGED TO (PRIMARY AND SECONDARY TRIM FAIL EICAS) AMBER M ESSAGE ON APPROACH TO LANDING. HORIZONTAL STAB SYSTEM LOCKED OUT ALL MOVEMENT FOR REMAINDER OF THE FLIGHT. CREW RESET SYSTEM POST LANDING, ALL FAULTS CLEARED, AND THE SYSTEM RETURNED TO NORMAL OPERATION. NO FAULTS REOCCURED ON NEXT FLIGH T TO HOME STATION. REMOVED ACTURATOR PN662740100-007 SN H0053, INSTALLED ACTUATOR PN 662740100-007 SN H0113. (MFG PN 2A 9200H). COMPLIED WITH AD. (CE09200403217) 2 L 7 2 4F 4 F RT T00008WI E6WE 2004051000043 20040510 00043 SO 2004 5 10 2004FA0000287 1 20040219 G 2701 20965 CONTROL WHEEL PIPER PA30 PA30 7103002 SO LYC O320 IO320* 41508 EA PILOT CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 35 752CF 5839 30592 A CRACK WAS FOUND IN THE CO-PILOT CONTROL WHEEL WHEN IT WAS REMOVED. THE BOTTOM OF THE WHEEL FROM FRONT TO REAR THROUGH THE PIN HOLE. THIS CRACK IS NOT VISABLE FROM THE OUTSIDE. 1 L 7 2 3O 3 O A1EA 1E12 2004051200023 20040512 00023 SO 2004 5 12 2004FA0000374 1 20040511 G 5341 6676200 ATTACH FITTING PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL FUSELAGE LOOSE B K NONE O OTHER IN INSP/MAINT 1 SO 15 703ER 2155 2844057 L2983151A 010001 DURING A ROUTINE INSPECTION, THE LT AFT WING ATTACHMENT FITTING WAS FOUND TO HAVE A LOOSE ATTACHING BOLT. THIS PROBLEM H AS BEEN TYPICAL ON A FLEET OF 6 AIRCRAFT OF THIS MODEL. THE PARTS IN QUESTION ARE: P/N-401-187 BOLT (AN5-7A), P/N-66762- 00 (PLATE-AFT SPAR) AND P/N-62448-02 (FITTING-LWR LT FUSELAGE). ONLY THE LT SIDE FITTING HAS BEEN FOUND LOOSE ON ANY OF THESE AIRCRAFT. THE MANUFACTURER HAS BEEN ADVISED OF THIS PROBLEM AND HAS INSPECTED THE SUBJECT AIRCRAFT. THE ONLY PREVE NTIVE MAINTENANCE AT THIS TIME IS REPETITIVE TORQUING OF THE BOLT, VERY OFTEN. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004051300025 20040513 00025 CE 2004 5 13 AMCR200400001 1 20040407 G 1420 MS3106E10SL3S CONNECTOR CESSNA 525 525A 2076615 CE WILINT FJ44 FJ44 66000 GL STROBE BURNED B AMCR K NONE O OTHER IN INSP/MAINT 1 GL 09 179DV 13 20122 525A0172 LT WINGTIP STROBE ASSEMBLY WAS INSTALLED 13 HOURS PRIOR IAW SB525A-33-02. WHEN STROBE FAILURE WAS NOTED, FOUND CONNECTOR SEVERELY BURNED, WITH ONE PIN COMPLETELY BURNED AWAY (ON POWER SUPPLY SIDE). POWER SUPPLY FAILED ALSO (MFG:FLIGHT COMPO NENTS AG). CHANGED POWER SUPPLY AND STROBE UNIT. 1 L 7 1 4F 4 F RT A1WI E3GL 2004051400067 20040514 00067 SO 2004 5 14 2004FA0000400 1 20040317 G 5740 ATTACH BRACKET MICCO 145A MAC145A 5660000 SO LYC O540 IO540T4B5 41532 EA HARTZL HCC3Y HCC3YR GL LT WING CRACKED D LM8S O OTHER O OTHER NR NOT REPORTED 1 NM 07 969WC 260010 L2797148A DY4978B DURING AN ANNUAL INSPECTION THE WELD JOINT THAT ATTACHES THE UPPER WING SKIN ATTACH BRACKET TO THE UPPER MAIN WING SPAR CENTER SECTION JUST ABOVE THE UPPER LT WING ATTACHMENT FITTING WAS CRACKED. MANUFACTURER WAS CONTACTED AND REPAIR INSTR UCTIONS WERE PROVIDED. THE LT WING WAS REMOVED FOR ACCESS. THE LT WING WELD AREA WAS PROPERLY PREPARED AND REWELDED IA W MM. 1 L 7 1 3O 3 O RC 1E4 5 C P25EA 2004052500031 20040525 00031 CE 2004 5 25 2004FA0000408 1 20040430 G 2110 45AS63019009 SHUTOFF VALVE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE AIR CONDITIONER INOPERATIVE B E81R C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 GL 03 453CW RK53 PILOT REPORTED EMERGENCY PRESSURIZATION SYSTEM CAME ON DURING TAKEOFF WITH AIR CONDITIONING FAIL ANNUNCIATOR LIGHT ILLUM INATED. TROUBLESHOT SYS IAW MM21-00-00. FOUND RT PRESSURE REGULATING/SHUT-OFF VALVE (PRSOV) HAD FAILED, ALLOWING FULL BLEED AIR VOLUME THROUGH AT ALL THROTTLE SETTINGS. REPLACED PRSOV WITH OVERHAULED VALVE IAW MM21-10-00. ENVIRONMENTAL SYS OPERATIONAL CHECKS NORMAL ON GROUND RUN-UP. MAINTENANCE RECORDS UNAVAILABLE. 2 H 7 2 4F 4 F RT A16SW E25EA 2004052600055 20040526 00055 NE 2004 5 26 00141 2 20040524 G 7200 ENGINE LEAR 24 24F 5170317 CE GE CJ610 CJ6106 30006 NE LEFT FLAMED OUT E HAEA O OTHER X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 SW 05 444TW 15995 10363 24F348 241C050A AIRCRAFT ENCOUNTERED TURBULENCE AT FL390K. LT ENGINE FLAMED OUT. ENGINE RELIGHT NORMAL. 2 L 7 2 4J 4 J A10CE 1E16 2004052600056 20040526 00056 WP 2004 5 26 2004FA0000409 2 20040524 G 7250 8687466 GASKET GARRTT TPE331 TPE33110 01514 WP PLENUM FAILED B O OTHER O OTHER NR NOT REPORTED 1 GL 25 P36043C PLENUM FUEL NOZZLE BOSS BLANK-OFF COVER GASKET PN 868746-6 (BLEW OUT) ON 5 OF 5 BOSSES. GASKET FAILURE ALLOWS HOT COMPR ESSOR GAS LEAKING. GASKETS WERE ALL REPLACED AND ENGINE WAS TEST RUN. 3 OF 5 NEW GASKETS (BLEW OUT) DURING TEST RUN. 4 T E4WE 2004052600068 20040526 00068 WP 2004 5 26 2004FA0000410 2 20040524 G 7250 8687466 GASKET GARRTT TPE331 TPE33110 01514 WP PLENUM FAILED B O OTHER O OTHER NR NOT REPORTED 1 GL 25 P36043C PLENUM FUEL NOZZLE BOSS BLANK-OFF COVER GASKET PN 868746-6 (BLEW OUT) ON 5 OF 5 BOSSES. GASKET FAILURE ALLOWS HOT COMPR ESSOR GAS LEAKING. GASKETS WERE ALL REPLACED AND ENGINE WAS TEST RUN. 3 OF 5 NEW GASKETS (BLEW OUT) DURING TEST RUN. 4 T E4WE 2004052600126 20040526 00126 CE 2004 5 26 2004FA0000413 1 20040506 G 7921 53E22144 VALVE CESSNA 150 150J 2071820 CE LYC O720 IO720A1B 41546 EA OIL COOLER INOPERATIVE D O OTHER J WARNING INDICATION NR NOT REPORTED 1 GL 15 50786 12 15069552 RL146754A PILOT REPORTED HIGH OIL TEMPERATURE 220-225 DEGREES, REMOVED VALVE AND TESTED SIDE BY SIDE WITH NEW VALVE, OLD VALVE DID NOT CLOSE AT THE SAME RATE AS NEW VALVE, INSTALLED NEW VALVE AND OIL TEMP DECREASED TOO. 1 H 7 1 3O 3 O 3A19 1E15 2004052600130 20040526 00130 SO 2004 5 26 2004FA0000414 1 20040514 G 2197 WIRE PIPER PA23 PA23250 7102308 SO LYC O540 IO540* 41532 EA FAN BURNED C D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 SO 15 661SC 5694 010316 278054052 COCKPIT BEGAN TO FILL WITH SMOKE WHILE TAXIING FOR TAKE-OFF. AIRCRAFT WAS SHUTDOWN AND UPON INSPECTION FOUND AVIONIOCS FAN TO BE BURNT ON CORNER WHERE WIRES ENTER FAN ASSEMBLY. THE DATE STAMPED ON FAN IS NOV. 1979. SUSPECT THE AGE AND TI ME IN SERVICE WOULD BE THE CAUSE OF DEFECT. THESE ELECTRICAL PARTS SHOULD BE INSPECTED CLOSELY FOR ANY SIGNS OF MELTING OR DISCOLORED PLASTIC. 1 L 7 2 3O 3 O 1A10 1E4 2004052700078 20040527 00078 SW 2004 5 27 2004FA0000423 1 20040325 G 6220 K910005007 PIN KAMAN K1200 K1200 05625F6 SW LYC T53 T5317A 41549 NE LT ROTOR HUB UNSERVICEABLE D O OTHER O OTHER NR NOT REPORTED 1 SO 15 358KA 269 A940029 THE LEADING EDGE OF THE LT SIDE TEETER PIN WAS DAMAGED (MUSHROOMED). FURTHER INSPECTION SHOWED THAT THE HEAD SIDE OF TH E INSIDE DIAMETER OF THE LINER THAT THE TEETER PIN SITS IN IS ALSO DAMAGED. THE LINER IS DEFORMED AND PROTRUDES IN AN I RREGULAR MANNER ON THE LEADING EDGE. THE TEETER PIN SHOWS CROSS-CORNER WEAR. THE TEETER THRUST WASHER ON THE HEAD SIDE WAS ALSO MISSING. THERE WAS RESIDUE OF THE COATING ON THE ID OF THE LINER. THE DAMAGES EXCEED THE INSPECT LIMITS ON T HE TEETER PIN NON-CRITICAL AREA IAW THE CRITERIA ON THE ROTOR HUB ASSY INSP. RESIDUE WAS FOUND ON THE HEAD SIDE OF THE RIGHT TEETER PIN. PLAY GREATER THAN .015 ON THE TEETER PIN ALLOWABLE PLAY LIMITS WAS ALSO NOTED. 1 G 7 1 4F 4 U NT TR7BO E17EA 2004050600074 20040506 00074 CE 2004 5 6 2004FA0000314 1 20040108 G 5280 24130831 DOOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA NLG OUT OF RIG B CMXR O OTHER O OTHER LD LANDING 1 CE 05 9084F 172RG0352 NG DOOR OB EDGE CAUGHT ON GEAR WELL BUMPERS AND PREVENTED NG DOORS FROM OPENING WHEN GEAR SELECTED DOWN. IT IS CAUSED BY DOORS BEING RIGGED WITH TOO LITTLE CLEARANCE, BUMPERS WEAR THIN AND ALLOW GEAR DOORS TO RAISE ON TOP OF BUMPER AND WE DGE DOORS. NOSE GEAR WOULD NOT EXTEND BECAUSE DOORS WERE WEDGED AND COULD NOT OPEN CAUSING A LANDING WITHOUT NOSE GEAR DEPLOYED, CAUSING DAMAGE TO THE PROPELLER AND NOSE GEAR DOORS. CLEARANCE IS .160 MAX AND .100 MIN. BUMPER IS .375 IN W IDTH AND IF BUMPER WEARS THIN OR EVEN AWAY THEN THERE IS AN EDGE THAT DOOR CAN WEDGE ON. CHECK GEAR DOOR OB EDGES TO IN SURE SPOT WELDS ARE INTACT AND DOOR SKINS HAVE NOT SEPARATED ALLOWING ONE SKIN TO CATCH ON BUMPERS. 1 H 7 1 3O 3 O 3A17 E286 2004050700025 20040507 00025 NE 2004 5 7 CA040202013 2 20040106 G 7200 ENGINE PWA PT6 PT6A112 52043 NE ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 12566 (CAN) ENGINE WAS INVOLVED IN A PROP STRIKE INCIDENT WHEN AIRPLANE PULLED OFF RUNWAY AND NLG STRUCK A STUMP, FORCE OF THI S IMPACT COLLAPSED THE LANDING GEAR AND BOTH PROPELLERS STRUCK THE GROUND. IT WAS CLEAR TO IDENTIFY THAT ENGINE HAD SUF FERED FROM A PROPELLER STRIKE. EXHAUST DUCT TWISTED CONDITION ALSO CAUSED POWER TURBINE DISK ASSEMBLY AND SEALS TO SEVER ELY RUB AGAINST THE PT SHROUD RING KNIFE-EDGES AND PTV RING INTERSTAGE BAFFEL, THIS IS ALSO REASON WHY PROPELLER SHAFT W AS NOT TURNING PRIOR TO DISASSEMBLY. DUCT OUTER SKIN SECTION MOVED OFF CENTER DURING IMPACT, WHICH CAUSED THESE COMPONEN TS TO RUB AND SEIZE. ENGINE WILL BE RESTORED TO A SERVICEABLE CONDITION THROUGH A COMPLETE OVERHAUL. 3 T E4EA 2004050700044 20040507 00044 SW 2004 5 7 CA040203005 1 20040122 G 6320 3023724 TUBE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA GEARBOX CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10894 (CAN) DURING THE SCHEDULED INSPECTION CARRIED OUT THE BASE, THE AME NOTICED THAT THE TUBE P/N 3023724 WAS CRACKED BEHIND THE B-NUT AREA. THE CRACKED TUBE WAS REMOVED AND REPLACED. 1 G 7 1 4U 4 U H4SW E22EA 2004050700049 20040507 00049 GL 2004 5 7 CA040308003 1 20040301 G 2752 SEAL DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING A 50 HR INSPECTION, IT WAS FOUND THAT THE SPLINED SEAL PUSHED OUT OF POSITION ON FLAP ACTUATOR ROD ASSY. O N THIS AIRCRAFT IT DID NOT MAKE CONTACT WITH THE FLAP POSITION SWITCHES. THE COMPLETE ASSY HAD BEEN REPLACED ONLY 26.3 HRS PREVIOUSLY DUE TO AN UNRELATED PROBLEM. MFG SUGGESTED WE CLEAN THE AREA WITH ALCOHOL AND RE-GLUE THE SEAL USING LOC TITE 409 ADHESIVE. THIS HAS BEEN CARRIED OUT AND AIRCRAFT RETURNED TO SERVICE. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004050700056 20040507 00056 SO 2004 5 7 CA040211003 1 20040210 G 3245 0923440 TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL RT MLG FAILED W O OTHER O OTHER LD LANDING 1 CA (CAN) ON LANDING , THE PILOT NOTICED A SLIGHT PULL TO THE RT. WHEN THE PILOT SLOWED THE AIRCRAFT, THE PULL GOT STRONGER FOLLOWED BY FLOPPING SOUND. THE PILOT STOPPED AND SHUT DOWN ON THE RUNWAY. ON INVESTIGATION OF THE TIRE AND TUBE, A S MALL .1250 INCH SLIT WAS FOUND IN THE TUBE. NOTHING SHARP WAS FOUND IN THE TIRE. SUSPECT THAT THE TUBE HAD A SLIGHT F OLD ON INSTALLATION AND COLD WEATHER OR RUBBING CREATED A HOLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004051000033 20040510 00033 EU 2004 5 10 CA040129004 1 20040127 G 2600 3473641 HEAD KIDDE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FIRE EXTINGUISH CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA 10152EL (CAN) THIS DUAL OUTLET CARGO BAY EXTINGUISHER WAS RECEIVED FOR OVERHAUL AFTER HAVING BEEN DISCHARGED THROUGH ONE OUTLET. UPON REMOVAL OF THE DISCHARGE HEAD FROM THE FIRED OUTLET, A SIGNIFICANT AMOUNT OF AN UNIDENTIFIED COARSLY CRYSTALLINE C ONTAMINANT WAS FOUND INSIDE THE DISCHARGE HEAD. THE MAJORITY OF THE CONTAMINANT WAS PACKED INTO THE UPPER PART OF THE DI SCHARGE HEAD, BETWEEN THE INSIDE SURFACES OF THE HEAD AND THE DEBRIS SCREEN. SOME OF THE CONTAMINANT HAD ALSO FALLEN INT O THE INTERIOR OF THE EXTINGUISHER THROUGH THE FIRED OUTLET.THE CONTAMINANT APPEARS TO BE CORROSIVE, BECAUSE SIGNIFICANT CORROSION WAS FOUND ON THE DISCHARGE HEAD RETAINING NUT, AND TO A LESSER DEGREE ON THE INSIDE SURFACES OF THE DISCHARGE 2 H 7 4 4F 4 F A49EU E6NE 2004051000040 20040510 00040 EA 2004 5 10 2004FA0000303 2 20040402 G 7314 200F5003 PUMP PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA FUEL SYSTEM LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 05 350PC 318152006 DURING ENGINE 100 HOUR INSPECTION AND SERVICE FOUND THAT THE ENGINE DRIVEN FUEL PUMP LEAKING FUEL FROM THE REGULATOR HOU SING. (SO05200407947) 1 L 7 2 3O 3 O A20SO E14EA 2004051400092 20040514 00092 SO 2004 5 14 2004FA0000397 2 20040501 G 7414 10400316 IMPULSE COUPLING CESSNA 337 T337G 2075726 CE CONT O360 TSIO360CB 17025 SO MAGNETO BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 13 8AH 36 P3370030 824766 PILOT REPORTED REAR ENGINE WAS HARD TO START. AFTER TROUBLESHOOTING, THE LT MAGNETO WAS REMOVED. UPON INSPECTION THE I MPULSE COUPLING WOULD NOT ROTATE IN THE CORRECT DIRECTION. THE MECH WAS NOT SURE IF WRONG IMPULSE COUPLING OR SPRING TU RN BACKWARD. DUE TO ONLY 36 HRS AND 1 YR 10 MO. SINCE ENGINE WAS REBUILT BY MFG. MFG INSPECTED IMPULSE COUPLING AND DI SCOVERED IMPULSE SPRING BROKEN. 1 H 7 2 3O 3 O A6CE E9CE 2004051400100 20040514 00100 CE 2004 5 14 2004FA0000395 1 20040318 G 2820 RSA5AD1 SERVO CESSNA 172 172S 2072439 CE LYC O320 IO320* 41508 EA MCAULY 1A170 1A170E GL FUEL SYSTEM INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 WP 27 974SP 2195 172S8178 L2893651A TB007 FUEL MIXTURE CONTROL ARM WILL NOT ROTATE TO (IDLE CUT-OFF) POSITION. 1 H 7 1 3O 3 O NT 3A12 1E12 5 N P857 2004052400055 20040524 00055 SO 2004 5 24 2004FA0000407 2 20040520 G 7322 45A10396512 CARBURETOR CESSNA 180 180 2072602 CE CONT O470 O470* 17026 SO ENGINE WORN D O OTHER O OTHER NR NOT REPORTED 1 NM 03 180C 4000 32312 CARBURETOR STICKING AT FULL THROTTLE DUE TO WEAR OF THE FULL THROTTLE STOP. IT WAS ACTUALLY GOING PAST FULL THROTTLE. THE PUMP LEVER ASSEMBLY WOULD TURN PAST THE AIR METERING PIN AND HANG UP THE THROTTLE SHAFT IN WIDE OPEN POSITION. 1 H 7 1 3O 3 O NC 5A6 E273 2004052500029 20040525 00029 GL 2004 5 25 W592004F00000 3 20040127 G 6110 C4513 SPACER CESSNA 150 A150L 2071828 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROPELLER CRACKED B W59R O OTHER O OTHER NR NOT REPORTED 1 WP 07 9903G G13417 A1500456 G13417 PROPELLER SPACER WAS FOUND CRACKED FROM DOWEL PIN HOLES. ONE CRACK PROGRESSED COMPLETELY THROUGH SPACEER, THE SECOND WA S 90 PERCENT THROUGH SPACER. PROPELLER DOWEL PIN HOLES ARE ELONGATED AND OVERSIZE, PROPELLER WAS BENT SEVERELY AT ONE T IME AND IMPROPERY REPAIRED. ANGLES WERE WELL OUT OF SPEC, SOME AS MUCH AS 1 DEGREE. PROPELLER WAS OUT OF BALANCE TRACK AND ANGLES. SUSPECT SEVERE VIBRATION FROM PROPELLER OR PREVIOUS IMPACT DAMAGE CAUSED SPACER TO CRACK. PROPELLER AND S PACER ARE SCRAP. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004052600129 20040526 00129 CE 2004 5 26 2004FA0000417 1 20040504 G 5511 053200196 SPAR CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA HORIZONTAL STAB DAMAGED B LC1R K NONE O OTHER IN INSP/MAINT 1 EA 07 24787 172S8804 WHILE PERFORMING THE INSPECTIONS REQUIRED BY MFG SB04-55-01, FOUND THE RT SIDE HOLE IN THE HORIZONTAL STABILIZER AFT SPA R ELONGATED. THIS ELONGATION OPENED THE HOLE APPROX. .040 TO .050 INCHES IN THE 5 O`CLOCK DIRECTION (VIEWING THE HOLE F ROM THE ACCESS IN THE TIO STABILIZER SKIN, LOOKING AFT). ELONGATION DID NOT APPEAR TO EXTEND INTO THE PN 0531006-113 HO RSESHOE FITTING ON THE VERTICAL STABILIZER OR INTO THE PN 05121595 AFT BULKHEAD. ADDITIONALLY, THE BOLT DID NOT APPEAR TO BE WORN. IAW MFG TECH SUPPORT, HOLE WILL BE ENLARGED TO NEXT BOLT SIZE AND APPROPRIATE SIZE BOLT WILL BE INSTALLED. CONDITION SB IS INSPECTING FOR WAS NOT FOUND. 1 H 7 1 3O 3 O NT 3A12 1E10 2004051200016 20040512 00016 SO 2004 5 12 2004FA0000373 2 20040506 G 7310 6561511A5M MANIFOLD DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA ENGINE FUEL MALFUNCTIONED C A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION AP APPROACH 1 NM 03 491 C0208 806463 AF0823 ENGINE DIED ON DOWNWIND. PILOT LANDED SAFELY. ENGINE STARTED ON GROUND, BUT WAS IDLING AT 750 HAS BEEN SET AT 900. ALSO, HAD NO MIXTURE RISE. DURING SETUP FOR FUEL PRESSURE TESTS THE LINE FROM THE THROTTLE BODY TO THE FUEL MANIFOLD HAD RESI DUAL PRESSURE. THE FUEL MANIFOLD WAS CHANGED AND ENGINE BEHAVED NORMALLY. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004051200026 20040512 00026 SO 2004 5 12 2004FA0000375 1 20040504 G 1430 400873 BOLT PIPER PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL NLG SHEARED B A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SO 15 708ER 1692 35 2844067 L3023651A 011204 DURING FLIGHT, THE PILOT REPORTED THAT THE GEAR UNSAFE LIGHT WAS ILLUMINATED DURING GEAR RETRACTION. THE GEAR WAS EXTEND ED AND 3 GREEN LIGHTS WERE OBSERVED. DURING THE SUBSEQUENT INSPECTION, THE BOLT IDENTIFIED BELOW WAS FOUND SHEARED AND T HE PORTION OF THE BOLT WITH THE HEX ON IT WAS NOT FOUND. THE THREADED PORTION, WITH THE NUT AND WASHER STILL ATTACHED, W AS FOUND TO BE THE ONLY ATTACHING ITEM CONNECTING THE ACTUATOR ROD END TO THE OVER CENTER DEVICE. NO OTHER DAMAGE WAS FO UND AND THE HARDWARE WAS REPLACED WITH NEW. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004051200092 20040512 00092 EA 2004 5 12 040505 2 20040504 G 8530 68795 ROCKER COVER LYC HELIO H295 H295 4300802 CE LYC O480 GO480G1D6 41527 EA ENGINE WORN B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 62JA 370 1443 ROCKER BOX, PN 68795 WAS WORN BY THE VALVE ROCKER SHAFT UNTIL THE SHAFT CUT THROUGH THE SHAFT RETAINER WHICH IS SPOT WEL DED TO THE VALVE COVER. THREE OF SIX COVERS WERE SEVERELY WORN. A FOURTH COVER'S BRACKET WAS WORN THROUGH AND THE RESU LTING SLUG OF METAL (ROCKER SHAFT WAS WORKING LIKE A WAD CUTTER) WAS FOUND LYING IN THE VALVE ROCKER BOX. REPLACED FOUR VALVE COVERS WITH SERVICEABLE PARTS. 1 H 7 1 3O 3 O 1A8 E275 2004051300022 20040513 00022 EA 2004 5 13 2004FA0000383 2 20040329 G 8500 IO360L2A ENGINE CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MAKING METAL D K NONE O OTHER IN INSP/MAINT 1 WP 07 52531 776 172S9172 L3045551A DURING A PHASE INSPECTION, SOME METAL WAS FOUND IN THE FILTER, TOOK OIL SAMPLE FROM OIL COOLER, REMOVED SUCTION SCREEN, MORE METAL WAS FOUND, SENT FILTER AND OIL TO LAB FOR ANALYSIS, SENT METAL FROM SCREEN, WAS ADVISED THAT THE SCREEN MATE RIAL WAS FROM BEARINGS, REMOVED ENGINE FROM SERVICE. THIS IS THE 2ND ENGINE FROM THIS AREA WITH THIS PROBLEM. THIS AIRC RAFT HAS BEEN ON A PHASE INSPECTION PROGRAM SINCE NEW, WITH OIL CHANGES EVERY 50 HRS. 1 H 7 1 3O 3 O NT 3A12 1E10 2004051300034 20040513 00034 SW 2004 5 13 2004FA0000389 1 20040417 G 7810 6414185 EXHAUST DUCT GULSTM 680 685 0141612 SW CONT O520 GTSIO520K 17032 SO NR 3 CYLINDER BROKEN B A UNSCHED LANDING A FLAME/FIRE CR CRUISE 1 SO 35 414C 12021 226116 IB EXHAUST ON LT ENGINE BROKE AT THE WELD BELOW NR 3 CYLINDER. BURNED HOLE IN LOWER ENGINE COWLING. BURNED WIRE BUNDLE O N THE FIREWALL AFT OF NR 1 CYLINDER. SCORCHED FIRE SLEEVE ON THREE FUEL HOSES. 1 H 7 2 3O 3 O 2A4 E7CE 2004051400094 20040514 00094 SO 2004 5 14 2004FA0000396 1 20040413 G 3340 6041H202 RELAY PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360* 17025 SO STROBE LIGHT INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 SO 13 312AJ 3449188 DURING A RAIN STORM FLIGHT PERSONNEL REPORTED TO RAMP 66 MAINTENANCE DEPT THAT AC. WINGS AND TAIL STROBE LIGHTS CAME ON . MAINT MECH CHECKED BATTERY SWITCH. SWITCH WAS TURNED OFF. DURING TROUBLESHOOT AFT COMPARTMENT FLOORING WAS REMOVED BEHIND PASSENGER SEATS. WATER WAS STANDING 2 INCHES IN BELLY OF AC. BATTERY RELAY WAS STANDING IN WATER. AFTER REMOVI NG, WATER WAS FOUND INSIDE OF THE RELAY. RELAY HAD LARGE PITTING HOLE AND SHOWED SIGNS OF ARCING. 1 L 7 2 3O 3 O A7SO E9CE 2004051400116 20040514 00116 CE 2004 5 14 2004FA0000402 1 20040310 G 2752 1015210161R ACTUATOR BEECH 200 A200 1152921 CE PWA PT6 PT6A41 52043 EA TE FLAPS SEPARATED D D RETURN TO BLOCK F J FLT CONT AFFECTED WARNING INDICATION TX TAXI/GRND HDL 1 WP 23 200ET 3753 BC73 CREW RETRACTED FLAPS, FLAPS STOPPED .5000 WAY UP. SPLIT FLAP SAFETY CIRCUIT STOPPED FLAP RETRACTION. REVEALED THAT LT IB FLAP ACTUATOR HAD FAILED. 90 DEGREE DRIVE (P/N 50-380153-3) HAD COMPLETELY SEPARATED FROM MAIN BODY (SCREW DRIVE) OF ACTUATOR. FAILURE WAS CAUSED BY LOCKING PIN IN 90 DEG. DRIVE WHICH HAD NOT BEEN PROPERLY ENGAGED INTO GROOVE IN MAIN B ODY AT LAST O/H. WEAR EVIDENCE SHOWS, PIN WAS IMPROPERLY ENGAGED IN MAIN BODY, DID NOT ENGAGE GROOVE APPROPRIATELY. GR OOVE AND PIN WORE UNTIL IT ALLOWED THE 90 DEGREE DRIVE TO DISENGAGE FROM MAIN BODY, 3352 LANDINGS AND 3753 HOURS SINCE A CTUATOR ASSY WAS LAST OVERHAULED. THERE IS NO PRESCRIBED OVERHAUL TIME OR CYCLE LIMIT REQUIREMENT FOR THIS ACTUATOR. 1 L 7 2 4T 4 T A24CE E4EA 2004051900111 20040519 00111 CE 2004 5 19 2004FA0000386 1 20040405 G 7810 22540122 EXHAUST STACK CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA ENGINE FRACTURED C B A EMER. DESCENT UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 09 738QV 1200 1200 R18200955 DURING CRUISE FLT AT 7,500 FT. VFR, AIRCRAFT WOULD NOT MAINTAIN 25 INCHES MP. MP DROPPED TO 23 INCHES AFTER APPROX. 15 M IN. MP DROPPED ABRUPTLY TO 18.5 INCHES MP MADE EMERGENCY DESCENT & UNSCHEDULING LANDING AT VNX WITHIN 3 MINUTES OF POWER LOSS. UPON EXAMINATION, FOUND EXHAUST STACK ASSY COMPLETELY FRACTURED, FULL CIRCUMFERANCE OF PIPE AROUND BASE OF FLANGE . ADDITIONALLY, FOUND COMPLETE CIRCUMFERAL FRACTURE OF CROSSOVER AT THE WYE INTERSECTION DOWNSTREAM OF WASTEGATE. ADDITI ONAL HEAT DAMAGE TO EGT PROBE AND WIRING, & LANDING LIGHT & WIRING. DUE TO THE DESIGN OF THIS SYSTEM, & AFTER READING N TSB REPORT CHI02LA218. RECOMMEND AN AD BE ISSUED. 1 H 7 1 3O 3 O 3A13 E295 2004052500028 20040525 00028 SW 2004 5 25 2004F00121 1 20040326 G 3230 71404 LEG ASSY BBAVIA 7 7GCBC 1220601 SW LYC O320 O320A2B 41508 EA SNSNCH 74D 74DM EA MLG BROKEN G O OTHER O OTHER NR NOT REPORTED 1 NM 05 31276 40772 UPON LANDING, GEAR RT MLG, BROKE FLUSH AT FUSELAGE. AIRCRAFT HAD SADDLE BLOCKS INSTALLED BY STC437SWP. THE LANDING GEA R BREAK, SHOW SIGNS OF INTERGRANULAR CORROSION. 1 H 7 1 3O 3 O NC A759 E274 5 N P88614 2004060100009 20040601 00009 SO 2004 6 1 2004FA0000422 1 20040301 G 7120 5501111501 MOUNT AMRGEN AA5 AA5B 3960105 SO LYC O360 O360* 41514 EA ENGINE CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 23 74608 4700 AA5B0282 DURING ANNUAL INSP, A CRACK WAS NOTED IN THE LOWER HORIZONTAL CROSSPIECE OF THE ENGINE MOUNT. THE CRACK IS APPROX .5000 INCH AWAY FROM THE PILOT SIDE END OF THIS TUBE, NEAR THE WELD THAT ATTACHES THIS TUBE TO THE DIAGONAL TUBE THAT ATTACHE S TO THE FIREWALL LOWER PILOT SIDE SUPPORT BRACKET. THIS SAME CRACK LOCATION HAS BEEN SEEN IN SEVERAL AIRCRAFT. APPEAR S TO BE A POINT OF HIGH VIBRATION INDUCED STRESS, AS THERE IS LITTLE LOAD ON THE PART DURING OPERATION. 1 L 7 1 3O 3 O A16EA E286 2004060900138 20040609 00138 SO 2004 6 9 AUS20040254 2 20040401 G 7322 25765407 SERVO CONT PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360RB SO MCAULY 3AF32C 3AF32C* GL FUEL CONTROL CONTAMINATED W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S 70470306 (AUS) RT ENGINE FCU REGULATOR AIR SECTION CONTAMINATED WITH OIL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2004060900139 20040609 00139 CE 2004 6 9 AUS20040255 2 20040322 G 7322 25765407 SERVO CONT PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL FUEL CONTROL LEAKING W O OTHER E VIBRATION/BUFFET LD LANDING 1 AU S 70470304 (AUS) ENGINE FCU SERVO STEM SEAL LEAKING FUEL. FURTHER INVESTIGATION FOUND THAT THERE WERE MANY SMALL PARTS OF BLUE RUBB ER THROUGH OUT THE UNIT. THESE RUBBER PARTS HAD COME FROM A POSSIBLE DAMAGED O RING SEAL DURING ASSEMBLY. ON TOTAL STRIP OF THE UNIT NONE OF THE O RINGS SHOWED SIGNS OF DAMAGE INDICATING THAT THE DAMAGED ORING MAY HAVE BEEN CHANGED BUT THE RUBBER NOT REMOVED. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2004060900140 20040609 00140 EU 2004 6 9 AUS20040256 1 20040325 G 2510 959300111 SEAT PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PILOTS SEAT BACKREST ASSEMBLY CRACKED IN TWO PLACES. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004060900141 20040609 00141 CE 2004 6 9 AUS20040257 1 20040407 G 1420 MS20470AD3 RIVET CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE SKIN RIVET HEADS CORRODED AND MISSING. RIVETS ARE LOCATED IN THE AREA UNDER THE BELLY OF THE AIRCRAFT AN D ATTACH THE MAIN LANDING GEAR CASTINGS PNO 0741627-1 AND PNO 0741627-2 TO THE FUSELAGE BELLY SKIN. 1 H 7 1 3O 3 O NT TA13 E273 5 C P3EA 2004060900143 20040609 00143 EU 2004 6 9 AUS20040259 1 20040404 G 4920 38004545 APU AIRBUS A330 A330* EU GE CF6 CF680 30025 NE APU BAY FAILED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 AU S 3723 (AUS) APU FAILED TO START DURING TAXI. 2 L 7 2 4F 4 F RT A46NM E13NE 2004061000001 20040610 00001 CE 2004 6 10 AUS20040262 1 20040408 G 8011 D112530 GEAR LYC CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL ENGINE STARTER DISINTEGRATED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S D112530 (AUS) STARTER BENDIX DRIVE GEAR DISINTEGRATED ON START. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2004061000007 20040610 00007 NE 2004 6 10 AUS20040268 2 20040411 G 7200 ENGINE DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE RIGHT OVERTORQUED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) RT ENGINE OVERTORQUED TO 155 PERCENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061000008 20040610 00008 NM 2004 6 10 AUS20040269 1 20040407 G 2421 761574B IDG BOEING 737 737* NM GE CFM56 CFM567B24 NE AC GENERATOR FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 AU S (AUS) NR 2 ENGINE INTEGRATED DRIVE GENERATOR (IDG) PRESSURE RELIEF REGULATING VALVE RETAINING COVER SCREW SHEARED. COVE R, POPPET VALVE AND SPRING SEPARATED FROM IDG RESULTING IN LOSS OF OIL INTO FAN COWL. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000009 20040610 00009 EU 2004 6 10 AUS20040270 1 20040408 G 2434 5243212137 DRIVE SHAFT PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL DC GENERATOR SHEARED W O OTHER H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 AU S (AUS) NR 2 GENERATOR DRIVESHAFT SHEARED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000010 20040610 00010 2004 6 10 AUS20040271 4 20040414 G 2215 065005656 SERVO PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL AUTOPILOT SYS FAULTY W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S (AUS) AUTOPILOT ROLL SERVO FAULTY. INVESTIGATION FOUND THAT THE SCREWS HOLDING THE CLUTCH HAD LOOSENED ALLOWING THE CLU TCH TO REMAIN ENGAGED WHEN THE AUTOPILOT WAS DISENGAGED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000011 20040610 00011 WP 2004 6 10 AUS20040272 2 20040416 G 7210 GEAR BAG JETSTM JETSTM3201 1500217 EU GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C653 NE RT ENGINE FAILED W O OTHER E VIBRATION/BUFFET DE DESCENT 1 AU S (AUS) RT ENGINE SUFFERED AN UNCONTAINED GEARBOX FAILURE. DEBRIS FROM THE FAILED GEAR IMPACTED ON THE RT SIDE OF THE AIRC RAFT CABIN. 2 L 7 2 4T 4 T RT A56EU E4WE 6 C 3PNE 2004061000014 20040610 00014 NM 2004 6 10 AUS20040275 1 20040415 G 2810 FUEL TANK BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE LT WING LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LT WING FUEL TANK LEAKING INTO DRY BAY AT WBL 616.75 LOWER AFT CORNER. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000016 20040610 00016 WP 2004 6 10 AUS20040277 1 20040420 G 6310 A1902 DRIVE BELT ROBSIN R22 R22ALPHA 7640104 WP LYC O320 O320B2C 41508 EA ENGINE/XMSN DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED AND WORN. 1 G 7 1 3O 3 O H10WE E274 2004061000018 20040610 00018 EU 2004 6 10 AUS20040279 1 20040405 G 7110 SKIN BAC 146 AVRO146RJ70A 1500095 EU LYC LF507 LF5071F NE ENGINE COWLING CHAFED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE REAR COWLING SKIN CHAFING IN AREA LOCATED JUST BENEATH THE REAR ATTACHMENT/HINGE POINT. CHAFING EVIDENT ON ALL EIGHT REAR COWLING DOORS. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000025 20040610 00025 NM 2004 6 10 AUS20040282 1 20040416 G 3242 26123121 BRAKE BOEING 737 737* NM GE CFM56 CFM567B24 NE RT MLG WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT OB BRAKE WORN BEYOND LIMITS. BRAKE SEIZED ON WHEEL. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000026 20040610 00026 NM 2004 6 10 AUS20040283 1 20040402 G 2750 FLAP BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU TRAILING EDGE FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 AU S (AUS) AIRCRAFT HAD AN ASSYMETRIC FLAP INDICATION DURING SELECTION. THE AIRCRAFT HAS HAD A TOTAL OF FOUR SIMILAR OCCURRE NCES DURING A TWO WEEK PERIOD. INVESTIGATION IS CONTINUING. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061000031 20040610 00031 NM 2004 6 10 AUS20040285 1 20040417 G 2611 473054 SMOKE DETECTOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE CARGO BAY FAULTY W O OTHER N FALSE WARNING CR CRUISE 1 AU S (AUS) BAGGAGE COMPARTMENT SMOKE DETECTOR UNIT FAULTY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061000032 20040610 00032 NM 2004 6 10 AUS20040286 1 20040408 G 2820 GASCOLATOR ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA FUEL SYS CONTAMINATED W O OTHER E Y VIBRATION/BUFFET ENGINE STOPPAGE LD LANDING 1 AU S (AUS) ENGINE FAILED. INVESTIGATION FOUND WATER AND RUST IN THE AIRCRAFT FUEL FILTER GASCOLATOR AND CARBURETOR. 1 G 7 1 3O 3 O H10WE E274 2004061000035 20040610 00035 SW 2004 6 10 AUS20040289 1 20040416 G 6710 B542DD BEARING BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL MAIN ROTOR LACK OF LUBE W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) COLLECTIVE JACKSHAFT SUPPORT BEARING FAULTY. INVESTIGATION FOUND THAT THE BEARING LUBRICANT HAD DRIED OUT. 1 G 7 1 3U 3 U H2SW E4CE 2004061000042 20040610 00042 NM 2004 6 10 AUS20040296 1 20040418 G 1430 BACB30US16K47 BOLT BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL FUSELAGE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT AND RT VERTICAL FIN FORWARD ATTACHMENT BOLTS FAILED TORQUE TEST. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061000043 20040610 00043 NM 2004 6 10 AUS20040297 1 20040420 G 5220 H2052K3833 LATCH BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL EMERGENCY EXITS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S PH0225 (AUS) LT OFFWING SLIDE DOOR NR 3 LATCH GUIDE PIN, BUSH AND SPRING MISSING. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061000044 20040610 00044 NE 2004 6 10 AUS20040298 1 20040318 G 2720 ROD END CONAER LA4 LA4200 5110310 NE LYC O360 IO360A1B 41514 EA HARTZL HCC2Y HCC2YK1 GL RUDDER CONTROL FAILED W O OTHER F FLT CONT AFFECTED LD LANDING 1 AU S 40 (AUS) RUDDER CONTROL ROD BALL JOINT SEIZED AND ROD END FAILED. THE SEIZED BALL JOINT ALLOWED THE CONTROL ROD END TO BEND UP AND DOWN DURING RUDDER APPLICATIONS UNTIL FINAL FAILURE. 1 H 7 1 3O 3 O 1A13 1E10 5 C P920 2004061000045 20040610 00045 EU 2004 6 10 AUS20040300 1 20040428 G 2730 D19202001 BRACKET FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ELEVATOR CONTROL MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LT ELEVATOR CONTROL ROD LOCK BRACKET INCORRECTLY INSTALLED AND FOULING ON LT ELEVATOR ROD CAUSING RESTRICTION IN E LEVATOR MOVEMENT. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT E25NE 2004061000046 20040610 00046 EU 2004 6 10 AUS20040301 1 20040428 G 5310 DOOR FRAME FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SERVICE DOOR FRAME CONTAINED LEVEL 3 CORROSION LOCATED AT THE BOTTOM FORWARD CORNER. 2 L 7 2 4F 4 F RT E25NE 2004061000047 20040610 00047 EU 2004 6 10 AUS20040302 1 20040424 G 3242 1090300 PAD CLEVELAND PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL BRAKE SEPARATED W O OTHER O OTHER TX TAXI/GRND HDL 1 AU S 2050 1200 (AUS) BRAKE ASSEMBLY WEAR PAD SEPARATED FROM BRAKE DISC ROTOR AND DAMAGED FOUR MORE PADS CAUSING THE BRAKE UNIT TO LOCK UP. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000049 20040610 00049 SW 2004 6 10 AUS20040304 1 20040310 G 3411 STATIC PORT SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE PITOT/STATIC SYS BLOCKED W O OTHER W INADEQUATE Q C CL CLIMB 1 AU S (AUS) PITOT/STATIC INSTRUMENTS FAILED TO OPERATE FOLLOWING TAKEOFF. INVESTIGATION FOUND CLEAR PLASTIC TAPE OVER AFT STAT IC VENT PORTS. TAPE HAD BEEN LEFT ON FOLLOWING PITOT/STATIC CHECK. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061000050 20040610 00050 NE 2004 6 10 AUS20040305 2 20040429 G 7261 OIL SYSTEM BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE ENGINE FAILED W O OTHER E K J VIBRATION/BUFFET FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) ENGINE SHUTDOWN DUE TO LOW OIL PRESSURE WARNING AND ZERO OIL QUANTITY. INVESTIGATION CONFIRMED ENGINE OIL TANK CON TENTS EMPTY BUT COULD NOT FIND ANY SOURCE OF LEAKAGE. ENGINE WAS REMOVED DUE TO FAILING WINDMILL CRITERIA. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000051 20040610 00051 CE 2004 6 10 AUS20040306 1 20040428 G 5511 053200199 RIB CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILIZER RIB CRACKED AROUND CIRCUMFERENCE OF AFT ATTACHMENT HOLES. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004061000052 20040610 00052 WP 2004 6 10 AUS20040307 1 20040422 G 1430 STD1419 BOLT ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA ENGINE MISSING W O OTHER K B J FLUID LOSS SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 AU S (AUS) CRANKCASE BOLT MISSING. OIL LEAKING FROM CRANKCASE. ENGINE HAD JUST BEEN FITTED AND AIRCRAFT WAS ON TEST FLIGHT. PERSONNEL/MAINTENANCE ERROR. 1 G 7 1 3O 3 O H11NM E295 2004061000055 20040610 00055 EU 2004 6 10 AUS20040309 1 20040420 G 2910 SA7670006131 HOSE BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE DRAG CONTROL ACT RUPTURED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) ROLL SPOILER ACTUATOR PRESSURE HOSE RUPTURED. LOSS OF YELLOW HYDRAULIC SYSTEM FLUID. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000056 20040610 00056 CE 2004 6 10 AUS20040310 1 20040414 G 3610 12945085021 MANIFOLD LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP PNEUMATIC DIST CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 AU S (AUS) LT ENGINE HP SERVO PRESSURE SUPPLY TUBE TO MANIFOLD WELDED JOINT CRACKED. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004061000057 20040610 00057 2004 6 10 AUS20040311 4 20040429 G 2210 FCS80 AUTOPILOT SYS SWRNGN SA227 SA227AT 8780610 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL COCKPIT FAULTY W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) AUTOPILOT FAULTY. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C P61GL 2004061000058 20040610 00058 NM 2004 6 10 AUS20040312 1 20040427 G 1430 BOLT BOEING 737 737376 NM GE CFM56 CFM56* 13802 NE PAX SEAT SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PASSENGER SEAT SUPPORT BEAM TO AISLE SIDE LEG STRUCTURE BOLTS SEPARATED AND FOUND UNDER SEAT 12 DEF. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000059 20040610 00059 NM 2004 6 10 AUS20040313 1 20040426 G 7830 BRAKE ASSY GE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL THRUST REVERSER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE THRUST REVERSER LT AND RT ELECTROMECHANICAL BRAKES FAILED SYSTEM TORQUE CHECK. FOUND DURING INSPECTION IAW AD/B767/182 AND AD/B767/83. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061000060 20040610 00060 NM 2004 6 10 AUS20040314 1 20040415 G 1420 MS3470L1412P CONNECTOR LUCAS DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE AC GENERATOR FAILED W O OTHER H ELECT. POWER LOSS-50 PC CL CLIMB 1 AU S 5966 Y10007 (AUS) NR 2 AC GENERATOR FAILED. REPLACED IAW MANUFACTURERS MM. INVESTIGATION FOUND PHASE IMBALANCE PROTECTION CIRCUITRY WIRE CHAFED INSIDE GENERATOR UNIT. CONNECTOR CONTAMINATED WITH OIL. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004060100006 20040601 00006 SO 2004 6 1 2004FA0000419 2 20040406 G 8530 655474 CYLINDER CONT O520 GTSIO520* 17032 SO ENGINE CRACKED B VA1R K NONE O OTHER NR NOT REPORTED 1 SW 19 RAM AIRCRAFT HAS FOUND NUMEROUS CYLINDERS WITH LOW HOURS CRACKED IN AN AREA EXTENDING FROM FUEL INJECTOR BOSS AREA TO TH E SPARK PLUG HOLE. IN THIS AREA IS A MACHINED AREA WITHOUT SUFFICIENT RADIUS. SUGGEST RADIUS OF THIS AREA TO PREVENT C RACKING. 3 O E7CE 2004060100008 20040601 00008 CE 2004 6 1 2004FA0000421 1 20040421 G 3610 99144022 PRECOOLER CESSNA 525 525 2076601 CE WILINT FJ44 FJ441A GL RT PYLON SPLIT D K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 CE 01 195ME 4395 5250110 PILOTS NOTICED SLIGHT TEMP RISE IN RT ENGINE, AND AN UNUSUAL VIBRATION ALL ENGINE INDICATIONS IN NORMAL RANGES POSTFLIGH T WALK AROUND NOTICED A SPLIT IN THE PRESSURIZATION (BLEED AIR) PRE-COOLER IN THE RT PYLON. PAINT DISCOLORATION WAS NOT ED NO DAMAGE TO ADJACENT STRUCTURES. NO EVIDENCE OF IMPACT DAMAGE. IT SHOULD BE NOTED THAT THIS PRE-COOLER IS UP-STREA M OF THE BLEED AIR SHUT OFF VALVES. INCLUDE INSPECTION AT PRE-POST FLIGHT. 1 L 7 2 4F 4 F RT A1WI E3GL 2004060100148 20040601 00148 EU 2004 6 1 20040209 1 20040526 G 3251 CA248003 SELECTOR VALVE CASA C212 C212CC 2410204 EU GARRTT TPE331 TPE33110R 0517 WP HARTZL HCB4M HCB4M GL NLG FAILED M K NONE O OTHER LD LANDING 1 WP 28 00177 336 DURING LANDING ROLL-OUT AC VEERED LT. PC WAS STILL ON FLT CNTRLS (CONTROL YOKE, POWER LEVERS, AND RUDDERS) WITH FULL RT RUDDER INPUT AND PWR LEVERS IN FULL REVERSE. PC WAS APPLYING BRAKES. GO-AROUND WAS NOT AN OPTION AS THERE WAS NOT ENOU GH RUNWAY, NOR TIME TO SPOOL UP ENG. GLANCED AT TILLER WHEEL AND IT INDICATED NOSE WHEEL WAS CENTERED. AC DEPARTED RUNWA Y, AND AFTER GOING OVER A SMALL RISE, STOPPED IN SAND BETWEEN RUNWAY AND PARALLEL TAXIWAY. WHEN INSPECTED NOSE-WHEEL ST EERING SYS, FOUND HYD FLUID AROUND STEERING SEL VALVE, INDICATING INTERNAL FAILURE. REPLACED STEERING SEL VALVE. AC WAS TEST-FLOWN AND RELEASED FOR FLIGHT. TEARDOWN REVEALED CENTERING SPRING TENSION WAS LESS THAN SPECIFIED BY CMM 30-50-02. 2 H 7 2 4T 4 T A43EU E4WE 6 C P56GL 2004060900136 20040609 00136 CE 2004 6 9 AUS20040252 1 20040331 G 2720 1015242653 PUSHROD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE RUDDER CONTROL CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER PUSHROD CONTAMINATED WITH WATER CAUSING CORROSION OF THE INTERNAL BORE. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004060900137 20040609 00137 EU 2004 6 9 AUS20040253 1 20040316 G 5311 FRAME BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME 29 RHS CRACKED FROM RIVET IN AREA LOCATED ABOVE STRINGER NR 13. 2 H 7 4 4F 4 F A49EU E6NE 2004060900144 20040609 00144 NM 2004 6 9 AUS20040260 1 20040405 G 5210 STOP BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE PAX DOOR FAULTY W O OTHER O OTHER CL CLIMB 1 AU S (AUS) FOLLOWING LOUD CRACKING NOISES IN FLIGHT AN INSPECTION OF THE DOOR AND DOOR CUTOUT AREA WAS CARRIED OUT. I NVESTIG ATION FOUND THE DOOR STOPS HEAVILY WORN AND DRY. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000002 20040610 00002 NE 2004 6 10 AUS20040263 1 20040414 G 2612 7630607902103 FIRE DETECTOR SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE NR 2 ENGINE FAULTY W O OTHER E B N VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS FALSE WARNING CR CRUISE 1 AU S (AUS) NR 2 ENGINE FLAME DETECTOR FAULTY. 1 G 7 2 3U 3 U NC H1NE E19EU 2004061000003 20040610 00003 EA 2004 6 10 AUS20040264 2 20040406 G 7322 70274603 SERVO LYC CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA FUEL CONTROL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 70274603 (AUS) FUEL CONTROL UNIT AIR CHAMBER CONTAMINATED WITH FUEL. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004061000004 20040610 00004 CE 2004 6 10 AUS20040265 1 20040411 G 2434 10300B ALTERNATOR CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL DC SYSTEM FAILED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 260 (AUS) ALTERNATOR FAILED IN FLIGHT. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004061000006 20040610 00006 EA 2004 6 10 AUS20040267 2 20040326 G 7313 252405411 INJECTOR PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YR2 GL FUEL SYSTEM CONTAMINATED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S 1184 (AUS) RT ENGINE FUEL INJECTORS CONTAMINATED BY SMALL FERROUS (RUST) PARTICLES. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000021 20040610 00021 EU 2004 6 10 AUS20040281 1 20040317 G 5343 HC537L0002006 DIAPHRAGM BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE MLG ACT MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR ACTUATOR MOUNTING BOSS DIAPHRAGM CRACKED. FOUND DURING INSPECTION IAW AD/BAE146/71. 2 H 7 4 4F 4 F A49EU E6NE 2004061000027 20040610 00027 NE 2004 6 10 AUS20040284 2 20040319 G 7220 311467901 CASE BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60 52043 NE HARTZL HCB4M HCB4MP3 GL RT ENGINE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE AIR INLET CASE CORRODED. 2 L 7 2 4T 4 T A24CE E4EA 6 C P56GL 2004061000039 20040610 00039 NM 2004 6 10 AUS20040293 1 20040416 G 2731 6355B000103 MOTOR BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE ELEVATOR TAB FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 AU S (AUS) STABILIZER ELECTRIC TRIM MOTOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000081 20040610 00081 NE 2004 6 10 AUS20040053 2 20040128 G 7261 4074T58P09 O-RING SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R375 R3754123F21 NE ENGINE OIL LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S 853 (AUS) LT ENGINE POWER TURBINE (C) SUMP COVER O-RING SEAL LEAKING. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P17NE 2004061000108 20040610 00108 GL 2004 6 10 AUS20040055 2 20040128 G 7200 695686 ENGINE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RIGHT FAILED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 6242 (AUS) RT ENGINE FAILED TO START. FURTHER INVESTIGATION FOUND N2 SHAFT NOT BEING DRIVEN BY N2 GEARBOX. INVESTIGATION IS CONTINUING. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061000110 20040610 00110 CE 2004 6 10 AUS20040058 1 20040202 G 5554 10164001417 HINGE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL RUDDER TAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER CENTER HINGE CONTAINED EXFOLIATION CORROSION IN THE HINGE BRACKET WEB. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004061000112 20040610 00112 2004 6 10 AUS20040060 4 20040203 G 3416 5035P ALTIMETER REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ALTIMETER FITTED TO AIRCRAFT WITH INCORRECT ALTITUDE RANGE. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004061000115 20040610 00115 EA 2004 6 10 AUS20040063 2 20040128 G 8530 EXHAUST VALVE NEWZE FU24 FU24954 6280102 WP LYC O720 IO720A1B 41546 EA HARTZL HCC3Y HCC3YR GL ENGINE STICKING W O OTHER E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 AU S 1367 (AUS) NR 2 CYLINDER REAR PUSHROD COVER BENT AND LEAKING OIL. SUSPECT CAUSED BY STICKING EXHAUST VALVE. 1 L 7 1 3O 3 O A9PC 1E15 5 C P25EA 2004061000116 20040610 00116 CE 2004 6 10 AUS20040064 1 20040203 G 1420 606171 CONNECTOR BEECH 76 76 1153005 CE LYC O360 O360A1G 41514 EA HARTZL HCM2Y HCM2YR GL ENGINE CONTAMINATED W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S (AUS) RT ENGINE INSTRUMENT CLUSTER CONNECTOR CONTAMINATED. 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2004061000119 20040610 00119 EU 2004 6 10 AUS20040067 1 20040202 G 3710 687751710 HOSE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1G6 41514 EA HARTZL HCC2Y HCC2YK2 GL VACUUM DIST DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) VACUUM HOSE KINKED. DISTORTION WAS LOCATED ON FRAME F AT THE TOP FRONT LT DOOR FRAME AND WAS CAUSED BY THE BEND RA DIUS BEING TOO SMALL AFTER PASSING OVER THE FRAME. PERSONNEL/MAINTENANCE ERROR. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000124 20040610 00124 2004 6 10 AUS20040072 4 20040104 G 2565 BATTERY BOEING 767 767* NM RROYCE RB211 RB211524* NE ESCAPE SLIDE DISCHARGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 3R DOOR ESCAPE SLIDE EMERGENCY LIGHTING FAILED TO ILLUMINATE. INVESTIGATION FOUND THE BATTERY FLAT. 2 L 7 2 4F 4 F RT A1NM E12EU 2004061000125 20040610 00125 CE 2004 6 10 AUS20040073 1 20040210 G 5753 052390114 ARM CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL TE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLAP SUPPORT ARM TO FLAP SUPPORT ARM RIB RIVETS MISSING DUE TO CORROSION. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004061000126 20040610 00126 CE 2004 6 10 AUS20040074 1 20040105 G 8011 DRIVE GEAR CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE STARTER STRIPPED W K NONE O OTHER IN INSP/MAINT 1 AU S 154 (AUS) ENGINE STARTER MOTOR DRIVE GEAR TEETH STRIPPED. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004061000127 20040610 00127 EA 2004 6 10 AUS20040075 2 20040205 G 7322 105267 CARBURETOR CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL FUEL CONTROL FAULTY W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S 62 (AUS) CARBURETOR FAULTY. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004061000128 20040610 00128 CE 2004 6 10 AUS20040076 1 20040211 G 5711 SPAR CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL LT WING DEBONDED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING SPAR WEB DISBONDED IN AREA LOCATED AT CWS 57. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004061000129 20040610 00129 CE 2004 6 10 AUS20040077 1 20040205 G 2497 WIRE HARNESS CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL DC POWER DISTRIB BURNED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WIRING LOOM CHAFED AND BURNED BY ELEVATOR COUNTERWEIGHT. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 2004061000130 20040610 00130 CE 2004 6 10 AUS20040078 1 20040211 G 3210 12411171 LANDING GEAR CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL MAINS COLLAPSED W O OTHER O OTHER TX TAXI/GRND HDL 1 AU S (AUS) LT MAIN LANDING GEAR LEG COLLAPSED. THE LEG WAS A NEWLY FITTED ITEM AND FAILED 530MM (20.8IN) FROM THE IB TIP OF THE LEG. AIRCRAFT TAILPLANE, ELEVATOR, WINGTIP AND POD DAMAGED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 2004061000131 20040610 00131 NM 2004 6 10 AUS20040080 1 20040206 G 2910 HYDRAULIC SYSTEM BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE HYDRAULIC SYSTEM LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) HYDRAULIC SYSTEM LEAKING. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000132 20040610 00132 EA 2004 6 10 AUS20040081 2 20040210 G 7322 MA4SPA CARBURETOR LYC PIPER PA28 PA28151 7102805 SO LYC O320 O320D3G 41508 EA SNSNCH 74DM M74DM EA FUEL CONTROL ICED W O OTHER E Y VIBRATION/BUFFET ENGINE STOPPAGE LD LANDING 1 AU S DC2950 (AUS) ENGINE FAILED DURING LANDING. SUSPECT CAUSED BY CARBURETOR ICING. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004061000134 20040610 00134 SO 2004 6 10 AUS20040083 1 20040204 G 2710 3866003 FITTING PIPER PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL AILERON CONTROL LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S NA (AUS) LT AND RT AILERON CONTROL ROD ATTACHMENT FITTINGS, LOOSE. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004061000149 20040610 00149 EU 2004 6 10 AUS20040088 1 20040211 G 3242 1597400 ROTOR CLEVELAND PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL BRAKE BROKEN W O OTHER O OTHER TX TAXI/GRND HDL 1 AU S 1229 (AUS) RT BRAKE ROTOR BROKEN INTO TWO PIECES WITH ONE PIECE LODGING BETWEEN THE BRAKE ASSEMBLY AND WHEEL. ON DISASSEMBLY IT WAS NOTED THAT THE ROTOR HAD BEEN BROKEN FOR SOME TIME. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000153 20040610 00153 EU 2004 6 10 AUS20040091 1 20040209 G 3246 5006227 WHEEL SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE NLG VIBRATES W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S (AUS) NOSE LANDING GEAR WHEELS VIBRATING. INVESTIGATION COULD FIND NO OBVIOUS DEFECTS BUT REPLACED THE NOSE WHEELS AND SERVICED THE SHIMMY DAMPER. THE AIRCRAFT WAS THEN RETURNED TO SERVICE WITH NO FURTHER DEFECTS REPORTED. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 2004061000155 20040610 00155 CE 2004 6 10 AUS20040093 1 20040205 G 3230 CIRCUIT BREAKER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL MLG TRIPPED W O OTHER J WARNING INDICATION DE DESCENT 1 AU S (AUS) RT MAIN LANDING GEAR WOULD NOT EXTEND. CIRCUIT BREAKER (60AMP)FOUND TRIPPED. CB RESET AND RETRACTION TESTS CARRI ED OUT WITH NO REOCCURANCE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004061000158 20040610 00158 CE 2004 6 10 AUS20040096 1 20040206 G 5311 FRAME BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME LOCATED AT RF 265-760 CRACKED IN AREA ADJACENT TO FLOORBEAM. FOUND DURING INSPECTION IAW AD/BEECH 200/65. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061000160 20040610 00160 NM 2004 6 10 AUS20040098 1 20040210 G 2730 BEARING BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE ELEVATOR CONTROL SEIZED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 AU S (AUS) ELEVATOR CONTROL CENTERING UNIT MOUNT BEARING SEIZED. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000178 20040610 00178 NE 2004 6 10 AUS20040101 2 20040216 G 7230 3035569 IMPELLER EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE ENG COMPRESSOR DAMAGED W O OTHER E B VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S (AUS) LT ENGINE LP IMPELLER BADLY DAMAGED. FURTHER INSPECTION ALSO FOUND SEVERE DAMAGE TO THE HP IMPELLER AS WELL AS TH E GAS GENERATOR CASE AND THE LP DIFFUSER CASE. A DENT WAS ALSO FOUND IN THE COMBUSTION CHAMBER OUTER LINER. SUSPECT CA USED BY FOD. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2004061000179 20040610 00179 NE 2004 6 10 AUS20040102 2 20040211 G 7250 3053094CL SHROUD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE TURBINE SECTION DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE TURBINE SHROUD AND BLADES DAMAGED. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004061000181 20040610 00181 SO 2004 6 10 AUS20040104 1 20040205 G 3222 35123002 FORK PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA NLG CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR FORK CONTAINED INTERGRANNULAR CORROSION IN ATTACHMENT AREA. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004061000184 20040610 00184 SW 2004 6 10 AUS20040105 1 20040122 G 5711 129579 SPAR BBAVIA 7 7EC 2110120 SW LYC O235 O235C1 41505 EA AMTR C8289 C8289 GL RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT WING FRONT AND REAR SPARS CRACKED. CRACKS APPEAR TO ALIGN WITH THE ATTACHMENT FITTING BOLT HOLES. SPARS ARE CO NSTRUCTED FROM TIMBER. FOUND DURING INSPECTION IAW AD/CHA/23 AMDT4. 1 H 7 1 3O 3 O A759 E223 5 N EXPP5N 2004061000186 20040610 00186 SW 2004 6 10 AUS20040107 1 20040102 G 5302 SKIN BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TAILBOOM CRACKED IN LOWER SKIN TO UPPER SKIN ATTACHMENT RIVET LINE LOCATED ON AFT RT SIDE. 1 G 7 1 3U 3 U H2SW E4CE 2004061000187 20040610 00187 EU 2004 6 10 AUS20040109 1 20040213 G 2910 1379305A155 HOSE BAG JETSTM JETSTM3201 1500217 EU GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C653 NE HYD SYSTEM FAILED W O OTHER K F FLUID LOSS FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) RT MAIN LANDING GEAR UPLOCK FLEXIBLE HOSE FAILED. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4T 4 T RT A56EU E4WE 6 C 3PNE 2004061000189 20040610 00189 NM 2004 6 10 AUS20040111 1 20040213 G 5270 SWITCH BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE DOOR WARNING SYS OUT OF ADJUST W O OTHER N FALSE WARNING NR NOT REPORTED 1 AU S (AUS) MAIN CARGO DOOR NR 1 AND NR 7 LATCH INDICATOR MICROSWITCHES OUT OF ADJUSTMENT. 2 L 7 3 4F 4 F RT A3WE E2EA 2004061000191 20040610 00191 EU 2004 6 10 AUS20040112 1 20040215 G 2120 ODOR AIRBUS A330 A330* EU GE CF6 CF680 30025 NE CABIN DETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S (AUS) ELECTRICAL ODOR IN CABIN IN AREA OF SEAT 48JK. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A46NM E13NE 2004061000192 20040610 00192 EU 2004 6 10 AUS20040113 1 20040219 G 6730 SC5072 SERVO SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1D NE TAIL ROTOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 200 (AUS) TAIL ROTOR SERVO FAULTY. INVESTIGATION FOUND ALTHOUGH FULL TAIL ROTOR PEDAL CONTROL WAS AVAILABLE, THE ACTUATOR G AVE LIMITED OUTPUT. 1 G 7 1 3U 3 U H9EU E19EU 2004061000193 20040610 00193 CE 2004 6 10 AUS20040114 1 20040213 G 8011 D083645 GEAR LYC CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE STARTER BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S D083645 (AUS) STARTER MOTOR BENDIX DRIVE GEAR DISINTEGRATED. ENGINE RING GEAR TEETH DAMAGED. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004061000209 20040610 00209 NM 2004 6 10 AUS20040119 1 20040224 G 6310 A1902 DRIVE BELT ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA ENGINE/XMSN DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED. 1 G 7 1 3O 3 O H10WE E274 2004061000216 20040610 00216 SW 2004 6 10 AUS20040124 1 20040224 G 2752 2736053001 ACTUATOR SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE TE FLAPS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING TRAILING EDGE FLAP ACTUATOR HOUSING CRACKED AND LEAKING FROM A HAIRLINE FRACTURE AT THE END OF THE HOUSING . 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061000220 20040610 00220 NM 2004 6 10 AUS20040127 1 20040224 G 2120 61B600051155 BLANKET BOEING 747 747338 NM RROYCE RB211 RB211524D419 54555 NE AIR DISTRIBUTION DETERIORATED W K NONE B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) APU DUCT INSULATION BLANKET BURNED AND IN POOR CONDITION. 2 L 7 2 4F 4 F RT A20WE E12EU 2004061000225 20040610 00225 CE 2004 6 10 AUS20040128 1 20040224 G 3260 SWITCH CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL MLG OUT OF ADJUST W O OTHER N FALSE WARNING CL CLIMB 1 AU S (AUS) LT MAIN LANDING GEAR UPLOCK SWITCH OUT OF ADJUSTMENT. MICROSWITCH WAS SWITCHING OFF LOADING VALVE BUT NOT THE IN TRANSIT LIGHT. INVESTIGATION FOUND SOME WEAR IN THE SWITCH WHICH AFFECTED ADJUSTMENT. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004061000226 20040610 00226 EU 2004 6 10 AUS20040129 1 20040226 G 1430 HC554H0074000 BOLT BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE RUDDER STRUCTURE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER FIXED HINGE BOLT CRACKED UNDER BOLT HEAD. BOLT IS LOCATED AT VERTICAL STABILISER RIB 5. CRACK LENGTH 2.2 86MM (0.090IN). FOUND DURING NDT INSPECTION. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000229 20040610 00229 CE 2004 6 10 AUS20040131 1 20040225 G 2910 4529101060001 PIPE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP HYDRAULIC SYSTEM FRACTURED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) HYDRAULIC PRESSURE LINE LOCATED IN RT ENGINE PYLON AREA FRACTURED AND LEAKING IN AREA OF RINGLOK SWAGE ON UPPER EN D OF THE LINE. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004061000239 20040610 00239 EU 2004 6 10 AUS20040133 1 20040206 G 5711 SPAR CAP PARTEN P68 P68B 6780104 EU LYC O360 IO360A1G6 41514 EA HARTZL HCC2Y HCC2YK2 GL LT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) REAR WING SPAR BOTTOM SPAR CAP CRACKED IN AREA OF LT SIDE WING ATTACHMENT. CRACK LENGTH 6MM (0.236IN). FOUND DURIN G EDDY CURRENT INSPECTION. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000240 20040610 00240 CE 2004 6 10 AUS20040134 1 20040114 G 3230 50450107 TORQUE TUBE CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO MCAULY 3AF32C 3AF32C87 GL MLG BROKEN W O OTHER O OTHER LD LANDING 1 AU S (AUS) LT MAIN LANDING GEAR TORQUE TUBE BROKEN. 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 2004061000243 20040610 00243 EA 2004 6 10 AUS20040136 2 20040227 G 7322 252434710 FUEL CONTROL HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA ENGINE FAULTY W O OTHER E Y VIBRATION/BUFFET ENGINE STOPPAGE DE DESCENT 1 AU S 272 (AUS) ENGINE FUEL CONTROL UNIT FAULTY. INVESTIGATION FOUND PRESSURE ON THE MIXTURE ARM CHANGED THE FUEL FLOW RATE CAUSI NG THE ENGINE TO STOP. 1 G 7 1 3O 3 O 4H12 1E10 2004061400002 20040614 00002 SO 2004 6 14 AUS20040138 1 20040222 G 5313 LONGERON PIPER PA18 PA18150 7101828 SO LYC O320 O320A2B 41508 EA SNSNCH 74DM M74DM EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER LT LONGERON TUBE CRACKED IN AREA BETWEEN FORWARD WELD OF LT REAR STABILIZER SUPPORT AND FORWARD WELD OF CROS S BRACE TUBE. 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 2004061400003 20040614 00003 NE 2004 6 14 AUS20040139 3 20040223 G 6111 8173881 SEAL HAMSTD DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE PROPELLER BLADE UNSERVICEABLE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 20030212 (AUS) RT PROPELLER NR 3 BLADE SEAL BADLY SPLIT AND SPRING DISTORTED. NR 1 AND NR 4 BLADE SEALS BROKEN WITH SIGNS OF DIS TORTION. SEALS WERE FOUND TO HAVE INCORRECT SPRINGS FITTED. LT PROPELLER NR 2 AND NR 3 BLADE SEALS ALSO DAMAGED DUE TO F IT OF INCORRECT SPRINGS. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061400008 20040614 00008 2004 6 14 AUS20040144 4 20040219 G 6122 8210263 GOVERNOR MCAULY SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE PROPELLER FAILED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 813 (AUS) LT ENGINE PROPELLER GOVERNOR FAILED. WORKSHOP INVESTIGATION AND DISASSEMBLY OF THE GOVERNOR FOUND A NUMBER OF FAU LTS WITH THE UNIT, HOWEVER THE MAIN FAILURE MODE WAS DUE TO THE FLYWEIGHT HEAD ASSEMBLY MISSING ALL TRIGGER TEETH, CAUSE D BY CONTACT WITH THE MONOPOLE DURING ROTATION OF THE FLYWEIGHT HEAD. THE MONOPOLE HAD RECENTLY BEEN ADJUSTED AS A FAUL T FINDING ACTION FOR THE EGT FLUCTUATIONS. IT IS BELIEVED THAT THIS ADJUSTMENT CAUSED THE REDUCTION IN SETUP GAP BETWEE N THE MONOPOLE AND THE FLYWEIGHT TEETH. ALL OTHER DAMAGE TO THE GOVERNOR FOUND DURING DISSASSEMBLY WAS SUBSEQUENT AND D UE TO THE INITIAL DAMAGE. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061400009 20040614 00009 CE 2004 6 14 AUS20040145 1 20040223 G 3230 131378252CL LINK BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL NLG MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) NOSE WHEEL RETRACTION CHAIN CONNECTING LINK INCORRECTLY FITTED. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061400010 20040614 00010 WP 2004 6 14 AUS20040146 1 20040301 G 1430 AN626 BOLT 245109 FLTCHR 24 FU24AAIRPTS 3530204 WP LYC O720 IO720A1B 41546 EA HARTZL HCC3Y HCC3YR GL MLG FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) RT MAIN LANDING GEAR TOP TORQUE LINK BOLT FAILED. 1 L 7 1 3O 3 O 4A12 1E15 5 C P25EA 2004061400013 20040614 00013 CE 2004 6 14 AUS20040150 1 20040218 G 2612 473275 FIRE DETECTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL LT ENGINE FAULTY W O OTHER N FALSE WARNING CL CLIMB 1 AU S 1527 (AUS) LT ENGINE FORWARD UPPER FIRE DETECTOR SUSPECT FAULTY. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061400014 20040614 00014 EU 2004 6 14 AUS20040152 1 20040302 G 3610 JR28930A DUCT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE PNEUMATIC SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 BLEED AIR SYSTEM BIFURCATED DUCT CRACKED IN AREA OF SUPPORT ATTACHING BRACKET ADJACENT TO THE PRSOV. CRACK LE NGTH APPROXIMATELY 25MM (0.984IN). 2 L 7 2 4F 4 F RT E25NE 2004061400017 20040614 00017 SW 2004 6 14 AUS20040155 1 20040303 G 7921 8538100 OIL COOLER BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE ENGINE LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S (AUS) ENGINE/TRANSMISSION OIL COOLER INTERNAL LEAK. THE LEAK ALLOWED TRANSMISSION OIL TO ENTER THE COMBINING GEARBOX OIL SYSTEM UNDERPRESSURE AND OVERFILL THE COMBINING GEARBOX WHICH THEN VENTED THROUGH THE BREATHER. 1 G 7 2 4U 4 U H4SW E22EA 2004061400021 20040614 00021 NM 2004 6 14 AUS20040160 1 20040228 G 3412 102LA2AG PROBE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL OUTSIDE AIR TEMP FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S 3458 (AUS) TAT PROBE FAILED. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400022 20040614 00022 EA 2004 6 14 AUS20040161 2 20040228 G 8530 LW12416 CYLINDER GULSTM STC STCAA5 LYC O320 O320E2G 41508 EA MCAULY 1C172 1C172* GL ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 1001 L4190629A (AUS) NR 1 CYCLINDER WORN. PISTON, RING, & BARREL CLEARANCES EXCESSIVE. 1 L 7 1 3O 3 O A16EA E274 5 N P910 2004061400023 20040614 00023 2004 6 14 AUS20040162 4 20040209 G 3416 AW2835AB06 ALTIMETER BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE COCKPIT OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CABIN ALTIMETER OUT OF CALIBRATION. FOUND DURING INSPECTION IAW AD/INST/9. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400026 20040614 00026 CE 2004 6 14 AUS20040165 1 20040306 G 7931 1013890235 TRANSDUCER BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL ENG OIL PRESS UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE OIL PRESSURE TRANSDUCER FAULTY. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004061400029 20040614 00029 CE 2004 6 14 AUS20040168 1 20040309 G 5320 12131842 TUNNEL WALL CESSNA 210 210R 2073458 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT SIDE NOSE LANDING GEAR TUNNEL WALL CRACKED IN AREA NEAR RT NOSE LANDING GEAR TORQUE TUBE STIFFENER PN 1213801-2 . FURTHER INVESTIGATION OF THE STRUCTURE FOUND CRACKS IN THE LT AND RT NOSE GEAR TUNNEL WALLS LOCATED AT THE LOWER END OF THE FORWARD ENGINE SHOCK MOUNT ASSEMBLY CHANNEL. CRACKS WERE ALSO FOUND IN THE STIFFENERS PN 1213195-1 AND PN 1213195 -2). AREA HAD BEEN MODIFIED IAW STC NO SA00796AT. 1 H 7 1 3O 3 O RT 3A21 E5CE 5 C P47GL 2004061400034 20040614 00034 NM 2004 6 14 AUS20040174 1 20040309 G 3231 4000894E BELLCRANK PIPER PA60 PA60601P 7106012 NM LYC O540 IO540S1A5 41532 EA HARTZL HCC3Y HCC3YR2 NE RT MLG DOOR BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S R133819 (AUS) RT MAIN LANDING GEAR DOOR BELLCRANK LUG BROKEN. 1 M 7 2 3O 3 O RT A17WE 1E4 5 C P25EA 2004061400035 20040614 00035 EU 2004 6 14 AUS20040175 1 20040311 G 3260 5EN16 SWITCH BAG JETSTM JETSTM3201 1500217 EU GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C653 NE MLG FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) NOSE LANDING GEAR SQUAT SWITCH FAULTY. INVESTIGATION FOUND THE CONTACTS HAD HIGH RESISTANCE. 2 L 7 2 4T 4 T RT A56EU E4WE 6 C 3PNE 2004061400037 20040614 00037 2004 6 14 AUS20040177 4 20040308 G 3461 1714970501 FMC BOEING 737 737800* NM GE CFM56 CFM567B24 NE FLT MANAGEMENT FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) DUEL FLIGHT MANAGEMENT COMPUTER (FMC) FAILURE. INVESTIGATION FOUND THAT BOTH FMCS EXPERIENCED A RESTART DUE TO AN UNHANDLED SOFTWARE EXCEPTION (SOFTWARE PROGRAM ERROR). 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400040 20040614 00040 EA 2004 6 14 AUS20040180 2 20040315 G 7414 6089188 IMPULSE COUPLING SLICK PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA AMTR C8289 C8289 GL MAGNETO LOOSE W O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 AU S 6089188 (AUS) LT MAGNETO IMPULSE COUPLING LOOSE ON SHAFT. FURTHER INVESTIGATION FOUND THE IMPULSE COUPLING LOCATION KEY SHEARED . 1 L 7 1 3O 3 O 2A13 E274 5 N EXPP5N 2004061400041 20040614 00041 NM 2004 6 14 AUS20040182 1 20040309 G 5210 PIN BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE PAX DOOR SEPARATED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) L2 OUTER DOOR HANDLE MOVED TO VERTICAL POSITION AFTER DEPARTURE. DURING INVESTIGATION, THE WHOLE HANDLE AND SHAFT ASSEMBLY CAME AWAY FROM THE DOOR. A LOOSE CASTELLATED NUT AND SHIMS WERE FOUND IN THE HOUSING ASSEMBLY. FURTHER INVES TIGATION FOUND A DEFORMED SPLIT PIN IN THE BOTTOM OF THE DOOR STRUCTURE. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061400042 20040614 00042 CE 2004 6 14 AUS20040183 1 20040308 G 2910 572700223 PIPE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL HYDRAULIC SYS CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 AU S (AUS) HYDRAULIC PIPE CRACKED AND LEAKING. LOSS OF HYDRAULIC FLUID. PIPE IS LOCATED IN RT WING LEADING EDGE. INVESTIGAT ION FOUND TOOLING MARKS ON THE PIPE IN THE AREA OF THE PIPE BEND. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004061400044 20040614 00044 SW 2004 6 14 AUS20040185 1 20040314 G 6220 471401341 CLAMP BELL 47 47G5A 1181034 SW LYC O435 VO435B1A 41516 EA MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN ROTOR STABILIZER BAR CLAMP CRACKED. 1 G 7 1 3O 3 O 2H3 E279 2004061400045 20040614 00045 EU 2004 6 14 AUS20040186 1 20040311 G 3260 213NW447AB SWITCH STBROS SD3 SD360 8100606 EU PWA PT6 PT6A67R 52043 NE HARTZL HCA6A HCA6A3 NE MLG FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) NOSE LANDING GEAR DOWNLOCK SWITCH FAULTY. 2 H 7 2 4T 4 T A41EU E26NE 6 C P14NE 2004061400046 20040614 00046 NE 2004 6 14 AUS20040187 2 20040315 G 7200 CFM567B26 ENGINE BOEING 737 737* NM GE CFM56 CFM567B24 NE NR 1 CONTAMINATED W K NONE J WARNING INDICATION IN INSP/MAINT 1 AU S (AUS) NR 1 ENGINE GEARBOX CHIP DETECTOR CONTAMINATED. INVESTIGATION SUSPECTS THAT DEBRIS IS M50 BEARING MATERIAL. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400048 20040614 00048 EA 2004 6 14 AUS20040189 3 20040312 G 6111 72CK056 BLADE PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 788 (AUS) PROPELLER BLADES CONTAINED SEVERE INTERGRANNULAR CORROSION. 1 L 7 1 3O 3 O A18SO E223 5 N P9045 2004061400050 20040614 00050 2004 6 14 AUS20040191 4 20040225 G 3497 WIRE CESSNA 402 402B 207590P CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C93 GL ATC TRANSPONDER FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TRANSPONDER WIRING SUSPECT FAULTY. TRANSPONDER AND GPS WIRING PARALLEL WHICH CAN CAUSE INACCURATE ALTITUDE READING S. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2004061400060 20040614 00060 NM 2004 6 14 AUS20040193 1 20040123 G 2121 6066223 FAN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AIR DISTRIBUTION FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 24556 1072073 (AUS) CABIN RECIRCULATING FAN FAULTY. SMOKE AND FUMES IN COCKPIT ANDCABIN. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400062 20040614 00062 NM 2004 6 14 AUS20040194 1 20040303 G 2121 7322591E FAN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AIR DISTRIBUTION FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 9138 (AUS) FORWARD EQUIPMENT COOLING FAN SEIZED. FUMES IN COCKPIT. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400066 20040614 00066 NE 2004 6 14 AUS20040196 2 20040211 G 7297 6068T54P01 WIRE HARNESS SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R354 R3544123F13 NE RT ENGINE FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) RT ENGINE W4 (YELLOW) WIRING HARNESS FAULTY. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 2004061400071 20040614 00071 2004 6 14 AUS20040199 4 20040319 G 2213 4051601935 PANEL BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FLT CONTROLLER FAULTY W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) AUTOPILOT MODE CONTROL PANEL FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061400074 20040614 00074 NM 2004 6 14 AUS20040201 1 20040309 G 2750 CONTROL SYSTEM BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL TE FLAPS FAULTY W O OTHER F FLT CONT AFFECTED AP APPROACH 1 AU S (AUS) FLAPS FAILED TO MOVE FROM 20 TO 30. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400076 20040614 00076 SO 2004 6 14 AUS20040202 1 20040316 G 5711 67069003 SPAR PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA HARTZL HCC2Y HCC2YK1 GL WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING SPAR CORRODED. FOUND FOLLOWING REMOVAL OF FUEL TANK FOR STRUCTURAL DEFECT REPAIR. CORROSION WAS SEVERE ENOUGH TO HAVE COMPROMISED STRUCTURAL INTEGRITY. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2004061400078 20040614 00078 EU 2004 6 14 AUS20040203 1 20040305 G 3222 RING PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL NLG WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 1542 (AUS) NOSE LANDING GEAR OVEREXTENDED. INVESTIGATION FOUND THE OLEO GUIDE RING WORN AND DAMAGED ALLOWING THE RETAINING P INS TO MIGRATE OUT DISCONNECTING THE GUIDE TUBE FROM THE NOSE FORK. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061400080 20040614 00080 NM 2004 6 14 AUS20040205 1 20040311 G 5311 65B0175424 FRAME BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME PN 65B01754-24 AND FRAME DOUBLER PN 65B26275-34 CRACKED. INVESTIGATION FOUND CRACKING WAS DUE TO TH E USE OF A SPLICE PLATE OF THE INCORRECT MATERIAL AS STATED IN BSB 747-53-2483. 2 L 7 4 4F 4 F RT A20WE E30NE 2004061400083 20040614 00083 SW 2004 6 14 AUS20040208 1 20040318 G 3260 SWITCH SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE MLG STICKING W O OTHER N FALSE WARNING CL CLIMB 1 AU S (AUS) RT MAIN LANDING GEAR MICROSWITCH STICKING. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061400084 20040614 00084 NE 2004 6 14 AUS20040209 3 20040309 G 6114 660714259 HUB SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE PROPELLER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 7004 (AUS) LT PROPELLER HUB CRACKED IN ATTACHMENT BOLT HOLE. FOUND DURING NDT INSPECTION IAW AD/PR/33. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 2004061400086 20040614 00086 NM 2004 6 14 AUS20040210 1 20040318 G 2912 271T00424 FILTER BOEING 767 767* NM RROYCE RB211 RB211524* NE HYDRAULIC SYS FAILED W O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 AU S (AUS) NR 1 HYDRAULIC SYSTEM FILTER MODULE PRESSURE FILTER BOWL SHEARED OFF. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A1NM E12EU 2004061400087 20040614 00087 NM 2004 6 14 AUS20040211 1 20040319 G 1430 AN3167R NUT BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE TE FLAPS MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT IB FLAP CARRIAGE DEAD WEIGHT ROLLER NUT AND LOCK WASHER MISSING. BOLT WAS STARTING TO MIGRATE FROM POSITION. SU SPECT CAUSED BY FAILURE OF LOCK WASHER TAB. 2 L 7 3 4F 4 F RT A3WE E2EA 2004061400089 20040614 00089 CE 2004 6 14 AUS20040213 1 20040312 G 2824 10138901157 VALVE BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE FUEL TRANSFER FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) DEFECT REPORT NR WAS CREATED IN LIEU OF DATA BEING ATTACHED TO MDR 04/0176. CANCELLED, DATED 25TH MARCH 2004. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004061400090 20040614 00090 EU 2004 6 14 AUS20040214 1 20040320 G 6123 3012534 CLAMP REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL PROPELLER FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) LT ENGINE PROPELLER REVERSING LEVER CABLE CLAMP BOLT FAILED ALLOWING PROPELLER REVERSING PY LEVER TO DISCONNECT FR OM PUSH/PULL CABLE. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004061400093 20040614 00093 EA 2004 6 14 AUS20040216 2 20040323 G 7421 URHB32E SPARK PLUG PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SPARK PLUG CRACKED IN AREA BETWEEN HEXAGONAL BODY AND FLANGE AT UPPER THREADED AREA. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004061400095 20040614 00095 CE 2004 6 14 AUS20040218 1 20040322 G 8011 85073009 GEAR LAMAR CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA ENGINE STARTER BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S 85073009 (AUS) STARTER MOTOR BENDIX DRIVE GEAR DISINTEGRATED. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004060900142 20040609 00142 NM 2004 6 9 AUS20040258 1 20040407 G 3610 8021709 VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PNEUMATIC SYS FAULTY W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 AU S 5669 940627 (AUS) LT ENGINE PRESSURE REGULATING VALVE (PRV) FAULTY. 2 L 7 2 4F 4 F RT A1NM E23EA 2004060900145 20040609 00145 CE 2004 6 9 AUS20040261 1 20040408 G 3230 AS119E10C000 HOSE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP MLG RUPTURED W O OTHER K FLUID LOSS CL CLIMB 1 AU S (AUS) NOSE LANDING GEAR RETRACTION SYSTEM HYDRAULIC HOSE RUPTURED. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004061000005 20040610 00005 SW 2004 6 10 AUS20040266 1 20040410 G 2150 434422123 SWITCH SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C663 NE CABIN COOLING FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LEADING EDGE DUCT THERMAL SWITCH FAULTY. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061000015 20040610 00015 EA 2004 6 10 AUS20040276 2 20040416 G 7313 252405411 INJECTOR PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YR2 GL RT ENGINE FAULTY W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 AU S 37 (AUS) RT ENGINE FUEL INJECTOR FLOW ERRATIC. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000017 20040610 00017 EA 2004 6 10 AUS20040278 2 20040420 G 7414 E02HA23B DISTRIBUTOR BLK CONT ROBSIN R22 R22BETA 7640110 NM LYC O360 HO360* 41514 EA MAGNETO LOOSE W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S E02HA23B (AUS) LT MAGNETO DISTRIBUTOR BLOCK LOOSE IN HOUSING. 1 G 7 1 3O 3 O H10WE E286 2004061000020 20040610 00020 2004 6 10 AUS20040280 4 20040419 G 2350 M1035AAABJLB2 PANEL SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL AUDIO FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 41 (AUS) COPILOTS AUDIO PANEL FAULTY. SMOKE AND ODOR IN COCKPIT. SMOKE AND ODOR DISSIPATED WHEN CIRCUIT BREAKER POPPED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004061000036 20040610 00036 NM 2004 6 10 AUS20040290 1 20040416 G 5753 65C344836 SPINDLE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU TE FLAPS FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT OB MID FLAP CARRIAGE SPINDLE SUSPECT CRACKED. FOUND DURING ULTRASONIC INSPECTION IAW EI 737-57-72R2. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061000148 20040610 00148 EU 2004 6 10 AUS20040087 1 20040205 G 6123 1310176 VALVE SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R354 R3544123F13 NE PROP FEATHERING FAULTY W C ABORTED TAKEOFF E J VIBRATION/BUFFET WARNING INDICATION TO TAKEOFF 1 AU S (AUS) RT ENGINE PROPELLER FEATHER SOLENOID VALVE FAULTY. VALVE WAS SLOWLY BLEEDING PCU PRESSURE. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 2004061000152 20040610 00152 CE 2004 6 10 AUS20040090 1 20040102 G 8011 643109 SPRING CONT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL ENGINE STARTER BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) ENGINE STARTER ADAPTER CLUTCH SPRING TANG BROKEN OFF CAUSING SPRING TO SLIP ON GEAR. BROKEN PIECE OF SPRING FOUN D IN BASE OF STARTER ADAPTER. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 2004061000156 20040610 00156 2004 6 10 AUS20040094 4 20040210 G 6122 661001002 GOVERNOR SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R354 R3544123F13 NE PROPELLER FAULTY W O OTHER J WARNING INDICATION NR NOT REPORTED 1 AU S (AUS) RT PROPELLER OVERSPEED GOVERNOR HAD AN INTERMITTENT FAULT. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 2004061000159 20040610 00159 NM 2004 6 10 AUS20040097 1 20040209 G 2761 65448517 ACTUATOR BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE DRAG CONTROL CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) NR 4 GROUND SPOILER OB ACTUATOR BODY CRACKED AND LEAKING IN AREA NEXT TO RETRACT FITTING. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000227 20040610 00227 NE 2004 6 10 AUS20040130 1 20040225 G 7170 0174078010 DRAIN VALVE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE ENGINE LEAKING W O OTHER K FLUID LOSS LD LANDING 1 AU S (AUS) ENGINE START DRAIN VALVE LEAKING DUE TO ORING SEAL FAILURE. 1 G 7 2 3U 3 U NC H1NE E19EU 2004061400001 20040614 00001 2004 6 14 AUS20040137 4 20040229 G 2215 065001501 SERVO REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL AUTOPILOT SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AUTOPILOT ROLL SERVO CAPSTAN FOUND IN PIECES ON AIRCRAFT FLOOR. SIX FASTENEING SCREWS FOUND IN CLOSE PROXIMITY TO THE SERVO MOUNT. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004061400006 20040614 00006 EA 2004 6 14 AUS20040142 2 20040302 G 7414 10400553 BEARING CONT SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL MAGNETO FAILED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 AU S B259305G (AUS) MAGNETO DRIVE SHAFT OUTER BEARING COMPLETELY DESTROYED. BEARING HAD BEEN RUNNING DRY FOR SOME TIME. SUSPECT MAGN ETO ASSEMBLED WITHOUT GREASE IN THE BEARING. PERSONNEL/MAINTENANCE ERROR. 1 L 7 1 3O 3 O RT A51EU E286 5 C P920 2004061400015 20040614 00015 NM 2004 6 14 AUS20040153 1 20040302 G 1430 26084383 RIVET HONEYWELL BOEING 717 717200 1383700 NM RROYCE BR700 BR700715A130 NE BRAKE FAILED W O OTHER O OTHER LD LANDING 1 AU S B0367 (AUS) RT MAIN LANDING GEAR NR 3 BRAKE ASSEMBLY BRAKE PADS LOCATED BETWEEN NR 2 AND NR 3 ROTORS HAD SEPARATED AND JAMMED THE BRAKE UNIT. INVESTIGATION FOUND PAD SEPARATION WAS DUE TO RIVET FAILURE. 2 L 7 2 4F 4 F TR A6WE E00061EN 2004061400018 20040614 00018 SO 2004 6 14 AUS20040156 1 20040220 G 2810 FUEL TANK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL RT ENGINE CONTAMINATED W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) RT ENGINE MISFIRING IN FLIGHT. INVESTIGATION FOUND CONTAMINATION IN THE LT FUEL TANK. A HAIR LIKE FIBER WAS FOUN D IN THE FUEL FILTERS AND INJECTOR NOZZLES. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004061400019 20040614 00019 NM 2004 6 14 AUS20040157 1 20040305 G 2910 O-RING BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE HYDRAULIC SYS FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) HYDRAULIC SYSTEM A PRESSURE MODULE SUPPLY LINE O-RING SEAL FAILED. LOSS OF HYDRAULIC FLUID. 2 L 7 3 4F 4 F RT A3WE E2EA 2004061400024 20040614 00024 2004 6 14 AUS20040163 4 20040209 G 3416 WL102AM53 ALTIMETER BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STANDBY ALTIMETER/AIRSPEED INDICATOR FAULTY. BENCH TESTING FOUNDTHE LIGHTING UNSERVICEABLE, EXCESSIVE FRICTION AND THE STOP AND JUMP TEST OUTSIDE LIMITS. FOUND DURING INSPECTION IAW AD/INST/9 AND BENCH TEST IAW CMM 34-10-61 REV9. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400027 20040614 00027 GL 2004 6 14 AUS20040166 2 20040308 G 7261 AN8334J FITTING BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL ENG OIL PRESS SEPARATED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S CAG30074BA (AUS) ENGINE TURBINE OIL PRESSURE FITTING PN AN833-4J SEPARATED FROM GEARBOX COVER PN 6898569 ALLOWING ENGINE OIL TO BE PUMPED OVERBOARD. SUSPECT CAUSED BY B NUT VIBRATING LOOSE ALLOWING THE FITTING TO FRET IN THE COVER. REDUCED OIL FLOW ( AND COOLING) TO THE TURBINE DAMAGED THE TURBINE BEARINGS. BEARING DEBRIS COLLECTED ON THE FORWARD CHIP PLUG. 1 G 7 1 3U 3 U H2SW E4CE 2004061400028 20040614 00028 EU 2004 6 14 AUS20040167 1 20040225 G 6123 30048000011 AUTOFEATHER SYS FOKKER F27 F27MK50 EU PWA PWA120 PW125B NE ROTOL R352 R3526123F1 GL PROPELLER FAULTY W O OTHER J WARNING INDICATION NR NOT REPORTED 1 AU S (AUS) AUTOFEATHER UNIT SUSPECT FAULTY. INVESTIGATION COULD FIND NO FAULTS BUT THE LT AND RT AUTOFEATHER UNIT PLUGS WERE CLEANED AND FUNCTIONAL TESTS CARRIED OUT. 2 H 7 2 4T 4 T RT A817 E20NE 6 C P16NG 2004061400030 20040614 00030 CE 2004 6 14 AUS20040169 1 20040309 G 5320 12131842 TUNNEL WALL CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT SIDE